Schenk

BELT WEIGHER
616
MULTIBELT Belt Weighers

Installation and Operating Instructions
we make processes work

BV-H2190 GB
617
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Copyright 2005
SCHENCK PROCESS GmbH
Measuring and Process Technologies
Landwehrstrae 55, D-64293 Darmstadt
http://www.schenck-process.com
All rights reserved. Any reproduction of manual, regardless of method, without prior permission by
SCHENCK PROCESS GmbH in writing, even by excerpt, is prohibited.
Subject to change without prior notice.
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MULTIBELT Belt Weighers Installation and Operating Instructions

SCHENCK PROCESS GmbH, Darmstadt
618
Contents
1 General Information ......................................................................... 1

1.1 Hints for Delivery...................................................................................................... 1
1.2 Information on Documentation................................................................................. 1
2 Belt Weighers Overview................................................................... 3

2.1 Single-idler Belt Weighers ....................................................................................... 4
2.1.1 BEM type........................................................................................................... 4
2.1.2 BEP type ........................................................................................................... 5
2.1.3 BED type ........................................................................................................... 6
2.2 Multi-idler Belt Weighers.......................................................................................... 6
2.2.1 BMP type........................................................................................................... 7
2.2.1.1 BMP2 type .................................................................................................. 8
2.2.1.2 2BMP type .................................................................................................. 8
3 Planning-in Hints (The 10 Rules)..................................................... 9

3.1 General Information ................................................................................................. 9
3.1.1 Hints for Movable Conveyors .......................................................................... 10
3.2 The 10 Rules.......................................................................................................... 10
3.2.1 Overview ......................................................................................................... 10
3.2.2 The Rules in Detail .......................................................................................... 11
4 Single-idler Belt Weigher BEM ...................................................... 22

4.1 Installation Instructions .......................................................................................... 22
4.1.1 Items Supplied................................................................................................. 22
4.1.2 Installation Prerequisites ................................................................................. 22
4.1.3 Displacing Measuring Modules ....................................................................... 23
4.1.4 Installation ....................................................................................................... 24
4.1.4.1 Prerequisites............................................................................................. 24
4.1.4.2 Mounting Measuring Modules .................................................................. 25
4.1.4.3 Mounting Carrying Idler Sets.................................................................... 27
4.1.4.4 Cabling ..................................................................................................... 28
4.1.5 Aligning............................................................................................................ 28
4.1.6 Acquiring Effective Platform Length ................................................................ 30
4.2 Operating Instructions............................................................................................ 31
4.2.1 Maintaining Belt Weigher ................................................................................ 31
4.2.1.1 Maintaining ............................................................................................... 32
4.2.1.2 Inspecting ................................................................................................. 32
4.2.1.2.1 Ensuring Proper Alignment of Carrying Idler Sets............................. 32
4.2.1.2.2 Checking Leaf Spring Parallel Guidance ........................................... 33
4.2.1.2.3 Checking Load Cell Signal................................................................. 34
4.2.1.2.4 Checking Load Cell............................................................................ 34
4.2.1.3 Repairing Belt Weigher............................................................................. 35
5 Single-idler Belt Weigher BEP....................................................... 37

5.1 Installation Instructions .......................................................................................... 37
5.1.1 Items Supplied................................................................................................. 37
5.1.2 Installation Prerequisites ................................................................................. 38
5.1.3 Installation ....................................................................................................... 38
5.1.3.1 Prerequisites:............................................................................................ 39
5.1.3.2 Mounting Weighed Idler Set ..................................................................... 41
5.1.3.3 Mounting Carrying Idler Sets.................................................................... 43
5.1.3.4 Aligning..................................................................................................... 44
5.1.3.5 Acquiring Effective Platform Length ......................................................... 46
5.1.4 Cabling ............................................................................................................ 46
5.2 Operating Instructions............................................................................................ 47
5.2.1 Maintaining ...................................................................................................... 47
5.2.2 Inspecting and Repairing ................................................................................ 47
5.2.2.1 Replacing Load Cell ................................................................................. 48
5.2.2.2 Replacing Leaf Springs ............................................................................ 49

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Contents
6 Single-idler Belt Weigher BED....................................................... 50

6.1 Installation Instructions ...........................................................................................50
6.1.1 Items Supplied .................................................................................................50
6.1.2 Installation Prerequisites..................................................................................50
6.1.3 Installation........................................................................................................51
6.1.3.1 Prerequisites .............................................................................................51
6.1.3.2 Mounting Belt Weigher on Belt Stringers ..................................................54
6.1.3.2.1 Mounting Load Cells...........................................................................55
6.1.3.3 Mounting Carrying Idler Sets.....................................................................56
6.1.3.4 Aligning Carrying Idler Sets.......................................................................57
6.1.3.5 Aligning Weighed Idler Set........................................................................58
6.1.3.6 Acquiring Effective Platform Length..........................................................60
6.1.4 Cabling .............................................................................................................60
6.2 Operating Instructions ............................................................................................61
6.2.1 Maintaining.......................................................................................................61
6.2.2 Inspecting and Repairing .................................................................................62
6.2.2.1 Replacing Load Cell ..................................................................................62
6.2.2.2 Replacing Leaf Springs .............................................................................63
7 Multi-idler Belt Weigher BMP......................................................... 64

7.1 Installation Instructions ...........................................................................................64
7.1.1 Items Supplied .................................................................................................64
7.1.2 Installation Prerequisites..................................................................................64
7.1.3 Installation........................................................................................................65
7.1.3.1 Prerequisites: ............................................................................................65
7.1.3.2 Mounting Weighed Idler Set(s)..................................................................67
7.1.3.3 Mounting Carrying Idler Sets.....................................................................71
7.1.3.4 Aligning......................................................................................................71
7.1.3.5 Acquiring Effective Platform Length..........................................................73
7.1.4 Cabling .............................................................................................................74
7.2 Operating Instructions ............................................................................................75
7.2.1 Maintaining.......................................................................................................75
7.2.2 Inspecting and Repairing .................................................................................76
7.2.2.1 Replacing Load Cell ..................................................................................76
7.2.2.2 Replacing Leaf Springs .............................................................................77
8 Speed Transducer (Option) ........................................................... 78

8.1 FGA20-RSLE Type.................................................................................................78
8.1.1 Installation Instructions ....................................................................................78
8.1.1.1 Installing Speed Transducer .....................................................................78
8.1.1.1.1 Further Installation Instructions ..........................................................79
8.1.1.2 Cabling ......................................................................................................79
8.1.2 Operating Instructions......................................................................................80
8.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers .......................................80
8.1.2.2 Maintenance..............................................................................................80
8.1.2.3 Inspection and Repair ...............................................................................81
8.2 FGA24A Type.........................................................................................................81
8.2.1 Installation Suggestions ...................................................................................81
8.2.1.1 Suitability ...................................................................................................82
8.2.1.2 Mounting Pole Wheel ................................................................................83
8.2.1.3 Mounting Proximity Switch ........................................................................83
9 Test Weight Suspension (Option) ................................................. 84

9.1 BEP, BMP Types....................................................................................................85
9.1.2 Installation and Setting Instructions .................................................................85
9.2 BED Type ...............................................................................................................86
9.2.2 Operating and Setting Instructions ..................................................................87
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General Information
1 General Information
1.1 Hints for Delivery
Inspection of incoming goods
Carefully inspect packaging for any damage during transit.
If damage is discovered, contact your carrier immediately and file a claim

for damages.
Check items supplied for completeness. For information on items supplied,

please refer to the individual 'Items Supplied" items of Chapters 4 to 7.
Storage hints
Check to see whether the admissible limit temperatures of - 25 oC or + 55 oC can
possibly be exceeded:
If no, store the items supplied in their genuine packaging in dry and clean
rooms whose relative humidity does not exceed 75%.
If yes, remove load cell, (optional) speed transducer and terminal box, and
store the electronic components in rooms meeting the above requirements.
Additionally observe the

'Guideline for Storage and Handling of Components and Machines
Supplied'
(BV-R2000 AA).
1.2 Information on Documentation

This manual includes any information required for installation and operation of our
belt weighers:
Single-idler belt weighers:
BEM, BEP and BED types
Multi-idler belt weighers
BMP, 2BMP and BMP2 types
For general information on the belt weighers described in the present manual,
please refer to the 'Belt Weighers Overview' chapter.
Application
Construction
Operating Principle
Accuracy

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General Information
The information is complete with significant technical data on every belt weigher type:
Operating principle
Dimensions
Load cell type
Possible belt widths
Feed rates
Accuracies
Optimal planning-in is essential for obtaining the specified data and ensuring proper
functioning of your belt weigher.
Before mounting, please read the
'Planning-in Hints (The 10 Rules)' item.
To every belt weigher type, a main chapter is dedicated comprising the following
information:
Installation Instructions
Operating and Setting Instructions
Identify your belt weigher type and refer to the relevant chapter.
If your belt weigher is equipped with optional devices, the variants of the particular
type as well as the relevant Installation and Operating Instructions are referenced
accordingly:
Speed measurement system:
See chapter
'Speed Transducer (Option)'
Test weight system::
See chapter
'Test Weight Receptors (Option)'
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Belt Weighers Overview
2 Belt Weighers Overview

Belt weighers are components designed for installation in user's belt conveyor
systems. The systems are designed and documented so that the user can perform
installation and commissioning single-handedly. However, advanced mechanical skills
and utmost care are required to provide the proper environment for the belt weighers.
Proper mounting is an important consideration for system accuracy.
Therefore, we recommend to have commissioning and inspections
performed by a SCHENCK engineer.
Application
Used for continuous acquisition of feed rates and totalized amounts, the belt weighers
are designed for installation in continuously operating belt conveyor systems. There is
a broad range of applications:
Throughput and consumption measurement in production plants
Balancing of amounts fed in and out
Reporting of load limits
Batching in load-out stations
Legal-for-trade weighing
Prefeeder control
The rugged design of the system ensures a high degree of operating safety and
availability.
Construction
A standard belt weigher comprises:
Weighing modules or weighing platform for accommodation of user's idler sets
Overload protected load cell(s) with a high degree of protection
Cable junction box for connection of sensors
Fixing elements for the installation
For speed measurement, various speed transducers (e.g. frequency generators with
friction wheel) are available as options.
Operating Principle
Belt weighers are designed to acquire continuous material flows of varying strengths.
Load cells acquire the weight of the load on a certain belt section, and a speed
transducer measures the belt speed (up to approx. 6 m/s). The product of the two
measured variables results in the current feed rate. Totalization of feed rate results in
the material amount fed.
If belt speed acquisition is omitted (belt load measuring system), a constant speed
value must be transferred to the weighing electronics in form of a parameter.
However, this procedure has the potential to adversely affect weighing accuracy.

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Accuracy
The stated accuracies assume that the belt weigher is mounted in suitable belt
conveyor systems and that the weighed idler set is installed and calibrated in
accordance with our installation and calibration instructions.
For accuracy data, please refer to the following documention:

BV-D2105 AA 'Definition of Belt Weigher System Accuracy'
2.1 Single-idler Belt Weighers
Easy integration into user's belt stringers with no need to interrupt the
construction
Belt tension forces absorbed by leaf spring parallel guidances
Suitable for handling feed rates up to 15,000 t/hr
Accuracies of up to 0.5 %
2.1.1 BEM type

Type: Fixation by welding
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Belt weigher of modular design, suitable for DIN

belt widths from 400 to 1400 mm
(exceptionally, up to 2000 mm)
Easy installation
2 lateral weighed idler sets
Components independent of belt width
Load cell: PWS type (platform load cell)
Feed rates up to approx. 4,000 t/hr
Accuracy 1 % of nominal feed rate

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2.1.2 BEP type
Belt weigher with weighing platform, suitable for

DIN belt widths from 400 to 1400 mm
Weighed idler set inside belt stringers
Insensitive to crosswise belt stringers
instabilities caused by centrally displaced crossmember
Load cell:
o PWS type (platform load cell)
o RT.. types (ring-torsion load cells)
Accuracy 0.5 % of nominal feed rate
Acuracy 1 % of actual feed rate
Legal-for-trade variants also available

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2.1.3 BED type

The BED type comprises two weighing sections.

2 weighed idler sets inside belt stringers
instabilities caused by centrally displaced crossmember
Load cell:
o VBB type (shear beam)
Accuracy 0.5 % of nominal feed rate
Accuracy 1 % of actual feed rate
2.2 Multi-idler Belt Weighers
Easy integration into user's belt stringers with no need to interrupt the
construction
Belt tension forces absorbed by leaf spring parallel guidances
Suitable for handling feed rates up to 15,000 t/hr
Accuracies of up to 0.25 %
Legal-for-trade variants also available
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2.2.1 BMP type

The design of the BMP series is similar to that of the BEP series. The weighing
platform is designed to accommodate two carrying idler sets.
Belt weigher with weighing platform suitable for

Weighed idler set inside belt stringers
instabilities: extended weigh span
Load cell:
o VBB type (shear beam)
Acuracy 0.25 % of nominal feed rate
Accuracy 0.5 % of actual feed rate

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2.2.1.1 BMP2 type

For higher belt widths (to increase the feed
rate), two BMP weighed idler sets are
arranged side by side.
Dimensions of weighed idler sets identical with
those of the BMP type
For feed rate, see BMP.
For accuracy, see BMP.
2.2.1.2 2BMP type
Belt weigher with weighing platform, suitable for DIN belt widths from 500 to
1400 mm
To extend the weigh span (and increase accuracy), two BMP weighed idler
sets are arranged in a row.
Dimensions of weighed idler sets identical with those of the BMP type
Accuracy 0.25 % of actual feed rate
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Planning-in Hints (The 10 Rules)
3 Planning-in Hints (The 10 Rules)

3.1 General Information
The specified accuracies assume that your belt weigher is regularly and carefully
maintained and calibrated in accordance with the instructions and planning-in hints
supplied.
Carefully plan the integration of the weighed idler set into your belt
conveyor system using the 10 rules. This is an important consideration
for obtaining the specified measuring accuracy.
General Information
The stricter these rules are followed, the lower is the risk of adversely affecting
functioning and measuring accuracy of your belt weigher.
To achieve highest accuracies (related to actual value), rules 4, 5, and 9 are of
special import. The weighed idler sets themselves are designed stable and rigid.
The installation, calibration and commissioning instructions for the individual weigher
types detail installation and alignment.
To be observed
With legal-for-trade belt weighers, additionally observe the applicable

regulations of the Verification Ordinance.
Never change belt stringers when using belt conveyors to DIN 22107.
The accuracy of belt weighers without speed transducer (v-measurement)

varies as a function of belt speed.
Verify accuracy by check measurements under load. Ensure that the check
amount is at least 10% of the hourly amount fed at nominal feed rate (Inom)
over at least one belt circuit.
Ensure that the location of your belt weigher is fully accessible to installation
work.
Particularly observe the relation

'Feed rate measuring accuracy' 'number of carrying idlers in the
weigher influential zone'
o
Accuracies related to nominal value require the presence of 2

carrying idlers approach and retreat of weighed idler set.
Accuracies related to actual value require the presence of 3

carrying idlers approach and retreat of weighed idler set.
Depending on type of weigher, the weighed idler set is equipped with one or multiple
carrying idler sets.

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3.1.1 Hints for Movable Conveyors

Movable conveyors (mobile systems, crushers1) are normally of light-weight design.
The lacking stiffness has the potential to cause additional issues (vibrations).
Here, the constancy of the slope is an important consideration for accuracy. With
stationary conveyors, the influence resulting from the slope is considered upon
calibration.
If the belt slope is changed with mobile conveyors (e.g. on vehicles) or in adjustable
conveyors (e.g. booms), there are two possibilities:
Angle measurement and correction of measured value via cosine pendulum

(option)
Calibration at mean slope and specification of accuracy at maximum

adjustment angle.
Ensure constant power supply.
3.2 The 10 Rules

3.2.1 Overview
No. Meaning
1
2
3
4
5
6
7
Install belt weigher in a straight belt section (horizontal or rising).

Ensure that the ascending or descending slope of the belt conveyor (angle of
inclination) is selected so that relative movements of the material are excluded.
Install belt weigher with sufficient distance from prefeeder, so that the material
flow is settled and no relative material movements can occur.
Ensure that the minimum distance of belt weigher from the belt pulley in a
troughed belt is given.
Depth and shape of troughing are important considerations for accuracy.
Ensure that the belt is fully troughed in the weigher influential zone.
Accurately align idler sets in the weigher influential zone.
Sets with offset idlers (viewed from above) have the potential to adversely
affect measuring accuracy.
8 Ensure that the belt stringers are mounted on a solid and level base.
9 Provide gravity take-up.
Safeguard your system against wind, weather, extreme temperature variations
10 and
vibrations.
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3.2.2 The Rules in Detail

Please note:
For simplicity reasons, the measuring station in the following sketches
consists of one idler station only ("single-idler belt weigher"). All statements
anologously apply to multi-idler belt weighers that feature a measuring
station composed of multiple idler stations.
Install belt weigher in a straight belt section

(horizontal or rising).
Rule 1:
Ensure that the unloaded conveyor belt also fully rests on all carrying idlers,
i.e.
o
in weigher influential zone
and, if possible, in two further sets approach and retreat of weigher

influential zone.
Garlands are not suitable.
The figures below show belt conveyor systems with typical belt weigher locations. The
circled numbers refer to a valuation scale (1= preferred to 7=unfavourable) used to
judge the influence of location on accuracy.

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Horizontal belt conveyor
Rising belt conveyor
Belt conveyor with curved belt
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Rule 2:
Ensure that the ascending or descending slope of the belt conveyor

(angle of inclination) is selected so that relative movements of the
material are excluded.
If conveyors are designed for adjustable slope, any change fully enters into
measurement as error (see 'Hints for Movable Conveyors' item).
Caution! Relative movements may occur:
o
with fines and uniformly shaped materials

('grain size' max. 100 mm)
with high belt speeds
right downstream of feed units
upon loading gaps.

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Rule 3:
Install belt weigher with sufficient distance from prefeeder, so that

the material flow is settled and no relative material movements can
occur.
Ensure that the complete weigher influential zone is outside the prefeeder
area.
The required distance is influenced by

o
belt speed
belt inclination
type of material infeed, and
material properties.
(*) Make sure the minimum distance corresponds to the belt travel per
second, however, to minimum 2 m.
Arrange skirt boards in weigh span so that the weighing accuracy is not
affected.
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Rule 4:
Ensure that the minimum distance of belt weigher from the belt
pulley in a troughed belt is given.
Rule 5:
Depth and shape of troughing are important considerations for

accuracy.
A flat belt (small belt troughing angle ) increases the measuring accuracy.
A V-shaped belt (*) is unfavourable.
(*) Deep or V-shaped belts are suitable only if more approximate measurement will
suffice.

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Ensure that the belt always rests on the carrying idlers of the sets. This is best
achieved by
o
small troughing
flexible belt.
Provide for high belt load.
Ensure correct belt tracking and avoid off-centre load that could lead to belt
slip and inaccurate weighing results.
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Rule 6:
Ensure that the belt is fully troughed in the weigher influential zone.
Avoid the use of belt conveyors whose pulleys are arranged higher than the
carrying idlers. If need be, increase distance between pulley and weigher
influential zone.

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Rule 7:
Accurately align idler sets in the weigher influential zone.

Sets with offset idlers (viewed from above) have the potential to
adversely affect measuring accuracy.
Arrange carrying idlers in the weigher influential zone elevated by 3 to 5 mm.
Secure aligned carrying idler sets against displacement and lowering.
Mean the carrying idlers' out-of-round tolerance during alignment.
Maximum admissible out-of-round tolerance = 0.2 mm; identify location of

mean out-of-round tolerance on idler shell on either side.
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Ensure that the spindles of the weighed and limiting idlers are perfectly level
viewed from above.
(also applies to V-shaped belts)
Weighed and limiting idler sets with offset spindles do not produce any exact
weigh span.

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Rule 8:
Ensure that the belt stringers are mounted on a solid and level base.
Ensure that the belt stringers impact points in the weigher influential zone are
welded.
Select belt stringers and support so that the carrying idler alignment is
secured (see Rule 6). If need be, reinforce or shim belt stringers accordingly.
Wire-rope-suspended belt conveyors are unsuitable for the installation of belt

weighers.
Avoid vibrations in the weigher influential zone.
Always install belt tracking idlers for correction of belt run outside the weigher
influential zone.
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Rule 9:
Provide gravity take-up.
The potential measuring error increases along with varying belt tension.
Rule 10:
Safeguard your system against wind, weather, extreme temperature

variations and vibrations.
Wind falsifies the measurement.
Direct insolation can excessively raise load cell temperature.
Moisture, ice and snow give rise to material build-ups and cause misalignment
in the weigher influential zone.
One-sided insolation of belt weigher has the potential to cause twisting and
temperature drifts.
Protect foundation from strong vibrations.

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Single-idler Belt Weigher BEM
4 Single-idler Belt Weigher BEM

Type: Fixation by welding
4.1 Installation Instructions

4.1.1 Items Supplied
Documentation
Manual
BV-H2190
Dimensioned
drawing
BEM drawing no. F008 401
Guideline
'Guideline for Storage and Handling of Components and

Machines Supplied' (BV-R2000 AA)
Mechanical Equipment
Qty Type Name
Comments
1 pc.
Measuring module with clamping plate
R.H. type
1 pc.
Measuring module with clamping plate
L.H. type
1 pc.
Speed transducer (*)

with friction wheel and rocker
Optional
1 pc.
Terminal box
for summation of load cell, transducer and weighing
electronics cables
1 set
Compression screws
Short
1 set
Compression screws
Long
1 set
Shims
for alignment of carrying idler sets in weigher influential
zone
(*) See 'Speed Transducer (Option)' item.
Limiting blocks
Thick shims
Shims
4.1.2 Installation Prerequisites

SAFETY HINT:
Ensure work protection at this device by using it as originally intended only, in
accordance with supply specification, and having it installed by skilled
technicians.
Plan arrangement of weighed idler set in belt conveyor in accordance with

the 10 RULES. The latter ensure that the measuring accuracy will be
obtained. See 'Planning-in Hints (The 10 Rules)' item.
The belt weigher is suitable for integration into belt conveyors in accordance
with DIN 22107 with 400-1400 mm belt widths, without any modification of belt
stringers.
After adjustment of belt stringers, the belt weigher can also be integrated into
other types of conveyor.
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4.1.3 Displacing Measuring Modules

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4.1.4 Installation
4.1.4.1 Prerequisites
Determine belt weigher location using the 10 RULES.

Make sure all checklist criteria have been kept:
Catchword
Rules
Location in conveyor
1 2 3 4 5 10
Stability
78
Belt tension
Requirements of carrying idler sets 4 5 6

(profile, out-of-round tolerance)
If the belt has already been applied, release tension, if need be, and lift off
from carrying idlers in the weigher influential zone using appropriate lifting
tackle. Raise belt so far that you can plug the measuring modules onto the
belt stringers at the proper time.
Further prerequisites:
o
If necessary, ready additional supports for use on belt stringers and in

measuring module area (see "Displacing Belt Weigher Measuring
Modules' item).
Optional: use hole pattern if the speed transducer is to be bolted in

place (instead of being welded on).
Debur ties of carrying idler sets in support points.
For alignment of carrying idler sets in the weigher influential zone as well as
for later alignment and fixing of sets, use the parts of the shim set supplied.
Mount hoist used to be able to raise belt in mounting area.
Remove the carrying idler seat to be used for weighed idler set.
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4.1.4.2 Mounting Measuring Modules
Lift both measuring modules with proper sides onto belt stringers in the
provided displacement point. (Transit weight per measuring module = approx.
20 kg).
Align both measuring modules square to belt stringers.
To perform welding work, and in order to protect the load cell,

connect the minus pole direct to the point of welding.
Attach measuring modules to belt stringers using the clamping plates, and
align vertically using the compression bolts.
Use the short or the long compression bolt sets, as the steel channel of the
belt conveyor may be situated.
Shift carrying idler set on measuring module brackets.

Make sure they are mounted square to belt stringers.
Evenly set measures H to 3 to 5 mm. This is the space between carrying idler
set bottom edge and belt stringers top edge.
Measure H serves as reference for the alignment of the two carrying
idler sets approach and retreat of weighed idler set.

0536
BV-H2190 GB
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645
Use the compression bolts to carefully adjust the brackets for two-sided
support on the tie of the carrying idler set over the entire surface.
When adjusting brackets for measure H, carefully tighten the

compression/tension bolts.
Secure all nuts using counter nuts.
Mount transit restraints in depicted location to save them for later use.
To secure clamping, weld measuring modules in place in the area of the

non-painted surfaces of the module base plates.
BV-H2190 GB
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646
4.1.4.3 Mounting Carrying Idler Sets
Arrange carrying idlers in the weigher influential zone elevated by 3 to 5 mm.
Place prepared carrying idler sets (troughing profile, out-of-round tolerance)

on belt stringers using the shims supplied.
Align all idler sets in the weigher influential zone (also consider the adjacent
non-elevated carrying idler sets):
Ensure squareness to belt stringers.
Align sets relative to one another.
Observe preset double idler spacing between the carrying idler sets
adjacent to the weighed idler set.
VERY IMPORTANT: Make sure the two carrying idler sets adjacent to
the weighed idler set are parallel.
Provisionally bolt carrying idler sets onto belt stringers.

0536
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647
4.1.4.4 Cabling
Mount cable junction box on clamping plate of relevant measuring module on

the selected side. Use the provided mounting holes.
For cable junction, please refer to the instructions given in Weighing

Electronics manual.
Also observe the following:
o
Lead cables of load cells and (optional) speed transducer to cable

junction box (terminal box) in the protected areas of the belt stringers.
ATTENTION: Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
Never shorten ready-to-connect cable ends; if need be, arrange in

loops.
Pay heed to the local regulations.
Check to see that the cable connector of the (optional) speed

transducer does not affect the positive contact of the friction wheel
with the return belt.
4.1.5 Aligning
Align the carrying idler sets arranged in the weigher influential zone elevated
by 3 to 5 mm for max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1 and 2 and from the
weighed idler set.
Tension six (*) 5-mm steel wires.
Insert first idler in one of carrying idler sets 2, and align as described
below.
Align one idler after the other terminating with the idlers of the
weighed idler set.
Align every idler side with meaned out-of-round tolerance (mark on idler shell
turned towards the steel wires) by adjusting the spindle seat of the idler in the
carrying idler set on the particular idler side.
o
To lower, refile idler side,
To raise, shim idler side, e.g. by deposit welding with subsequent

refiling.
BV-H2190 GB
- 28 -
0536

648
(*) Flat belt conveyors can be aligned with 2 steel wires only.
Upon alignment, ensure that

o
carrying idler sets adjacent to the weighed idler set are parallel
all carrying idler sets are square to belt stringers in the weigher
influential zone
idler spacing = 2 x L 5 mm.
Affix carrying idler sets to belt stringers by welding shims and limiting blocks
in place.

0536
BV-H2190 GB
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649
Before removing the steel wires, check bolted connections for tight fit, and recheck idler alignment.
Ensure that belt stringers and measuring module areas affected by welding
and other work are well protected from corrosion.
4.1.6 Acquiring Effective Platform Length

When installation is complete, acquire the effective platform length.
Measure spindle spacings a1 and a2 on
either side of your belt conveyor and
calculate effective platform length 'Ing' as
mean value:
Enter acquired value with proper unit into

the weighing electronics as shown in the
Electrical Equipment manual.
BV-H2190 GB
- 30 -
0536

650
4.2 Operating Instructions

The measuring modules are designed on the principle of leaf spring parallel guidance.
Attached to the belt stringers, the modules support the base profile with load cell and
the leaf spring parallel guidance.
The leaf spring parallel guidance, in turn, supports the weighing profile transmitting the
measured load from the bracket of the carrying idler set onto the load cell without lever
ratio.
An overload protection with deflection for measurement S protects the load cell from
overload peaks (S = deflection for measurement from load cell to overload protection).
4.2.1 Maintaining Belt Weigher

SAFETY HINT:
Before performing maintenance, inspection and/or repair work, remove and
lock out power to the belt weigher.

0536
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4.2.1.1 Maintaining
Regularly remove material build-ups in the earmarked area between

(1) tie of weighed idler set and hood of measuring modules
(2) tie of weighed idler set and belt stringers.
Material build-ups in the earmarked areas can cause shunt forces to

occur which adversely affects belt weigher accuracy.
Do not remove build-ups recurring in other areas of the weighed idler set
because of the associated change in tare.
Measuring modules need not be maintained.
4.2.1.2 Inspecting
Inspect belt weigher each time your conveyor system is inspected.
4.2.1.2.1 Ensuring Proper Alignment of Carrying Idler Sets

(See also the "Alignment" paragraph of the 'Installation" item.)
Raise conveyor belt in weigher influential zone.
Align carrying idler sets arranged in weigher influential zone elevated by 3 to 5

mm to max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1 and 2 and from weighed
idler set.
Exchange all idlers featuring an out-of-round tolerance over 0.2 mm.
Remove materials build-ups from all idlers.
below.
weighed idler set.
BV-H2190 GB
- 32 -
0536

652
o
To lower, refile idler side,

refiling.
Keep the carrying idlers in the weigher influential zone free from build-ups.
4.2.1.2.2 Checking Leaf Spring Parallel Guidance

The leaf spring thickness is adjusted to
the rated capacities of the load cells
used:
Rated capacity
Leaf spring thickness
60 kg
100 kg
150 kg
1 mm
300 kg
2 mm
In perfect condition, both leaf springs must be totally plane. The upper leaf spring is
loaded by tensile forces; the lower, by compressive forces.
Damage to leaf springs with buckling of the lower leaf springs can occur only upon
measuring modules overload. In this case, the weighed idler set is no longer square to
conveyor belt.

0536
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653
4.2.1.2.3 Checking Load Cell Signal
Ensure that check is performed by a skilled measuring and control

engineer !
Ensure that the weighing electronics is ready to operate and the
conveyor cut off.
Check load cell measured load

signal (totals output signal of both
load cells) in the load range
between preload and preload +
belt load using commercial
weights.
(For load cell rated capacity [kg]
and characteristic value [mV/V],
see load cell type plate.)
Display load cell signal of preload.
Stagger commercial weights on
weighed idler set, at best with
conveyor belt removed.
Record load diagram as shown on
the left.
The measuring points connecting
line should result in a straight line.
If you note bigger deviations from straight line, follow these steps.
4.2.1.2.4 Checking Load Cell
To begin with, stagger commercial weights on one side of the belt weigher.
Record load diagram.
Repeat on other side of belt weigher.
Result: the measuring module featuring a big deviation from the straight line
requires further checking.
Repeat the above steps with load cell connecting lines disconnected.
Any damaged measuring module should now be clearly identified.
NOTE:
Errors in measurement can also be caused by torsional forces in belt stringers
transferred to the measuring modules via the weighed idler set. For reliable diagnosis,
remove the weighed idler set.
Remove counter nuts and nuts of tension bolt.

ATTENTION: Mark side position to ensure proper reassembly.
Check individual measuring modules by suspension of test weights, and a

damaged measuring module, if any, can be clearly identified.
Normally, a damaged measuring module cannot be repaired at site since devices and
gauges are required for reassembly. Therefore, mount new measuring module as
described below.
BV-H2190 GB
- 34 -
0536

654
4.2.1.3 Repairing Belt Weigher
Replace damaged measuring

module.
Remove load cell cable.
Unscrew the 3 fixing bolts of
the base profile and remove
measuring module from
module base plate.
Mount new measuring
module as supplied.
Any new measuring module comes with a transit restraint protecting the load cell.
Carefully lift weighing profile and remove load cell transit restraint from the side.
Carefully lower weighing profile to prevent it from hitting the contact plate of the
measured load application.
Make sure the weighed idler set easily centers in bores when being plugged into the
weighing profiles on both sides.

0536
BV-H2190 GB
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655
Carefully run load cell cable and ensure protection to IP 65 of cable junction box.
Align idler sets as described at the 'Ensuring Proper Alignment of Carrying Idler Sets'
item.
BV-H2190 GB
- 36 -
0536

656
Single-idler Belt Weigher BEP
5 Single-idler Belt Weigher BEP

Documentation
Manual
BV-H2190
Dimensioned
drawing
BEP drawing no. D607 522
Guideline

Machines Supplied'
(BV-R2000 AA)
Qty Type Name
1 pc.
Comments
Weighed idler set
2 pcs. Cross-member
1 pc.

1 pc.
Terminal box
for summation of load cell, transducer and
weighing electronics cables
1 pc.
Load cell
PWS type (platform load cell) or
VBB type (shear beam) or
RT.. type (ring-torsion load cell)
1 set
Test weight receptors (**), comprising

2 telescopic tubes
1 tubular cross-member
2 test weights
1 set
Shims
for alignment of carrying idler sets in
weigher influential zone
(*) see 'Speed Transducer (Option)' item
(**) see 'Test Weight Receptors (Option)' item
Optional
Optional
For suspension of test weights
Limiting blocks
Thick shims
Shims

0536
BV-H2190 GB
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657

SAFETY HINT:
technicians.

with DIN 22107 with 400-1400 mm belt widths, without any modification of belt
stringers.
5.1.3 Installation
Modify belt stringers as shown in the relevant dimensioned drawing.
Displace weighed idler set using two cross-beams to DIN 1026.
BV-H2190 GB
- 38 -
0536

658
5.1.3.1 Prerequisites:

Catchword
Rules
1 2 3 4 5 10
Stability
78
Belt tension

If the belt has already been applied, raise by at least 500 mm in the weigher
influential zone using appropriate lifting tackle, so that you can insert the belt
weigher from the side and align it at the proper time.
Make sure the profiles of the carrying idler sets are identically shaped, so as
to provide the prerequisites specified at the 'Aligning' item.
Place carrying idler sets on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning' item.
ATTENTION! Identify the locations so as to protect carrying idler sets and
idlers from being confused when being mounted as described at the 'Mounting
Carrying Idler Sets' item.
Shim carrying idler sets using the elements of the shim set supplied. Arrange
the carrying idler sets in the weigher influential zones elevated by 3 to 5 mm
as described at the 'Mounting Carrying Idler Sets' item .

0536
BV-H2190 GB
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659
Recess the ends of the tie of the weighed idler set.
To secure carrying idler alignment:

o
Secure foundation against settlement.
Anchor stringer supports in foundation.
Provide reinforced belt stringers or additional supports, if required.
Weld belt stringers impact points all around.
Remove return belt cover plates in the weigher influential zone, or
remove return belt cover plates in weighed idler set area, and disengage them
in carrying idler set support points.
BV-H2190 GB
- 40 -
0536

660
5.1.3.2 Mounting Weighed Idler Set

To insert load cell (PWS, VBB or RT..) in weighed idler set:
Remove transit restraint from weighed idler set.
Carefully raise weighing yoke by approx. 5 mm and shim.
Remove dummy plate.
Insert load cell (PWS, VBB or RT..) complete with pre-mounted mount.
NOTE: The design of load transducers PWS and VBB differs from that of the
load cell RT. The operational overall height and the load transmission
elements are identical to the load cell RT. Fastening is done in the same spot
with a bolt M8 and a spring washer.

0536
BV-H2190 GB
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661
PWS and VBB types only:
Ensure that no shunt forces occur between weighing yoke

and load cell; this would falsify the weighing result.
To do so, turn load cell so (angle W) that the screw heads cannot
come into contact with the weighing yoke. Angle W is of no import
for the weighing result.
Carefully center load cell (PWS, VBB or RT..) relative to the load button, and
bolt in place.
Never grease load buttons of weighing yoke and load cell but clean
using a soft cloth.
Carefully lower weighing yoke.

To perform welding work, and in order to protect the load cell,
connect the minus pole direct to the point of welding.
To install weighed idler set, loosely bolt set to cross-members and place onto
belt stringers with correct side in direction of travel.
BV-H2190 GB
- 42 -
0536

662
Align weighed idler set square to belt stringers as specified in dimensioned

drawing and bolt:
Weighed idler set to cross-members, and
Cross-members to belt stringers.
Arrange carrying idler sets in weigher influential zone elevated by 3 to 5 mm.

onto the premade shims on belt stringers.
Place weighed idler set on its height-adjustable receptors and protect from
overbalancing.
Align all idler sets in the weigher influential zone (also consider the adjacent
non-elevated carrying idler sets):
o
VERY IMPORTANT: Make sure the two limiting idler sets adjacent to

0536
BV-H2190 GB
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663
5.1.3.4 Aligning
Align the carrying idler sets arranged in the weigher influential zone elevated
by 3 to 5 mm for max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1 and 2 and from the
weighed idler set.
Tension six (*) 0.5 mm steel wires.
below.
weighed idler set.
o
To lower, refile idler side.

refiling.
BV-H2190 GB
- 44 -
0536

664

o
influential zone
Affix carrying idler sets to belt stringers by welding shims and limiting blocks
in place.
Affix weighed idler set by welding it to its receptors.

0536
BV-H2190 GB
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665
5.1.3.5 Acquiring Effective Platform Length

When installation is complete, acquire the effective platform length.
Measure spindle spacings a1 and a2 on
either side of your belt conveyor and
calculate effective platform length 'Ing' as
mean value:

5.1.4 Cabling
For details, please refer to the instructions given in Weighing Electronics

manual, and observe the following additional hints:
Lead cables of load cells and (optional) speed transducer to cable junction
box mounted in a safe location.
o
Load cell = 5 m
Transducer = 6 m
Never shorten ready-to-connect cable ends; if need be, arrange in loops.
Connect (optional) speed transducer as shown the in circuit diagrams

supplied.
Attach cables to stationary parts of construction directly approach and retreat

of connectors using sleeves. In-between, run cables in ducts or use sleeves.
Check to see that the cable connector of the (optional) speed transducer does
not affect the positive contact of the friction wheel with the return belt.
BV-H2190 GB
- 46 -
0536

666

The weighed idler set is designed on the principle of leaf spring parallel guidance.
Bolted to the two cross-members in three points, a rigid support frame serves for
accommodation of the load cell and the leaf spring parallel guidance used to restrain
the weighing yoke. Mounted on the load cell, the weighing yoke supports the weighed
idler set.
The SCHENCK load cell is hermetically sealed and service-free.
For type, please see load cell type plate and Belt Weigher Spec Sheet.
Explosion Protection
If the belt weigher operates in hazardous areas, Zones 1, 2 or 11 as
specified by DIN 57165, or VDE 0165, the load cell is protected to EEx
ibIIC T6.
5.2.1 Maintaining
If the weighing accuracy gives rise to doubt, first check the carrying idler sets for
proper alignment:
Tension six 0.5-mm steel wires over the cleaned carrying idlers.
Align individual carrying idlers as described at the 'Aligning' item.
Replace idlers featuring an out-of-round tolerance > 0.2 mm.
Keep carrying idlers in the weighing influential zone free from build-ups.
5.2.2 Inspecting and Repairing
Proceed as described at the 'Maintaining' item.

0536
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667
5.2.2.1 Replacing Load Cell

(if required)
Disconnect load cell cable in terminal box and remove from fixing points.
Raise weighing yoke by approx. 5 mm and shim.
Unscrew fixing bolt from load cell mount and remove from weighed idler set
from the side.
Handle new load cell as described in the attached brochure.
If need be, also replace load button before installing the new load cell.
Introduce load cell complete with pre-installed mount.

(With PWS types: observe the 'Mounting Weighed Idler Set' item.)
Carefully center load cell relative to load button, and bolt in place.
If need be, align weighed idler set relative to the carrying idler sets in the
weigher influential zone as described at the 'Aligning' item.
Run and affix load cell cable.
BV-H2190 GB
- 48 -
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668
5.2.2.2 Replacing Leaf Springs

(if required)
Always replace all 4 leaf springs.
Ensure that the connecting surfaces of the parts to be bolted are metallically
clean and deburred.
Before tightening bolts in steps, align weighing yoke
centrically to the load cell load button
vertically to the load cell load button
axis-parallel to the weighed idler set support frame.
Align weighed idler set relative to the carrying idler sets in the weigher
influential zone as described at the 'Aligning' item.
ATTENTION!
Check effective platform length.
If necessary, correct value in weighing electronics.

0536
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669
Single-idler Belt Weigher BED
6 Single-idler Belt Weigher BED

Documentation
Manual
BV-H2190
Dimensioned
drawing
BED drawing no. D608 600
Guideline

Machines Supplied'
(BV-R2000 AA)
Qty Type Name
Comments
2 pcs. Weighing section

2 pcs. Cross-member
1 pc.

1 pc.
Terminal box
Optional
2 pcs. Load cell

RT.. type (ring torsion load cell) or
VBB type (shear beam)
2 pcs. Test weight receptor (**)
Optional
1 set
Limiting blocks
Thick shims
Shims
Shims
(*) see 'Speed Transducer (Option)' item
(**) see 'Test Weight Receptors (Option)' item

SAFETY HINT:
technicians.

BV-H2190 GB
- 50 -
0536

670
with DIN 22107 with 1600-2000 mm belt widths, without any modification of
belt stringers.
6.1.3 Installation
Modify belt stringers as shown in the relevant dimensioned drawing.
Displace weighed idler set using two cross-beams to DIN 1026.
6.1.3.1 Prerequisites

Catchword
Rules
1 2 3 4 5 10
Stability
78
Belt tension

weigher from the side and align it at the proper time.
to provide the prerequisites given at the 'Aligning Carrying Idler Sets' item.
Place carrying idler set on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning Carrying Idler Sets' item.

0536
BV-H2190 GB
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671

BV-H2190 GB
- 52 -
0536

672

o
in weighed idler set support points.

0536
BV-H2190 GB
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673
6.1.3.2 Mounting Belt Weigher on Belt Stringers
Install the two identical cross-members with distance 'A' = approx. 1080 mm in
the provided location on belt weigher and protect from overbalancing.
Lift weighing sections and place between cross-members with correct sides in
direction of travel.
Bolt loosely to cross-members, and
adjust in height using the set screws so that the four holes are flush
with the cross-member bottom edge.
Remove cross-member fixations to be able to bolt cross-members to the

weighing modules. (Unscrew again upon belt weigher alignment as described
at the "Aligning Carrying Idler Sets' item).
BV-H2190 GB
- 54 -
0536

674
6.1.3.2.1 Mounting Load Cells

Insert load cells in weighing sections.
Cut transit restraint straps and remove the dummy plates replacing the load
cells in the weighing sections.
Lift compression bolts using a hex socket head spanner s = 6 mm so far that
you can insert the load cells from below complete with pre-assembled mounts.
Never grease load cell load buttons and compression bolt. Clean
using a soft cloth.
Carefully bolt load cells in place using the central fixing bolts secured with
spring washers.
Place a ruler along the leaf spring and set surfaces A and B to 0.5 mm
difference in height (compression bolt resting in place) using the compression
bolts on both weighing sections.
Immediately secure each compression bolt using a counter nut (SW 24).
NOTE: The design of force transducers PWS and VBB differs from that of the

0536
BV-H2190 GB
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675
To perform welding work, and in order to protect the load cell, connect
the minus pole direct to the point of welding.
Align belt weigher accurate and square to belt stringers, and bolt crossmembers to belt stringers.
Arrange carrying idler sets in weigher influential zone elevated by 3 to 5 mm.

on the premade shims on belt stringers.
overbalancing.
BV-H2190 GB
- 56 -
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676
Align all idler sets in the influential zone (also consider the adjacent nonelevated carrying idler sets):
o
6.1.3.4 Aligning Carrying Idler Sets
Align the carrying idler sets arranged in the influential zone elevated by 3 to 5
mm to max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1 and 2, however, not from
the weighed idler set.
below.
Align one idler after the other, terminating the procedure without the
idlers of the weighed idler set.
o

refiling.

0536
BV-H2190 GB
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677
6.1.3.5 Aligning Weighed Idler Set
Lightly unscrew bolted connections between cross-member and weighing

sections and cross-member and belt stringers and remove the fixation
between weighed idler set and receptors. Now you can level weighing
sections and thus the weighed idler set relative to the tensioned steel wires
with finger-tip control so as to be free from tension.
BV-H2190 GB
- 58 -
0536

678
To do so, use the set screws on weighing sections.

ATTENTION!
o
Ensure that the transversal and longitudinal axes of the weighing

sections have the same level. Check to see that the 4 alignment holes
are in the same position relative to the cross-members.
Also ensure that the tie of the weighed idler set rests on the two
weighed idler receptors over their entire width.
Provide a 'spy' ( = 0.2 mm thick).
To ensure proper alignment, re-check all bolted connections for tight fit, and
set screws for the rpesence of counter nuts.
Align weighed idler set as described at the 'Aligning Carrying Idler Sets' item.
Ensure that
o
influential zone
Affix carrying idler sets to belt stringers by welding limiting blocks and shims
in place.
Attach the weighed idler set by four approx. 30 mm welds at the corners of
both weighed idler sets.

0536
BV-H2190 GB
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679

When installation is complete, acquire the effective platform length 'lng'.
Measure spindle spacings on either side of
your belt conveyor and calculate as mean
value:

6.1.4 Cabling

o
Load cell = 5 m
Transducer = 6 m
Connect (optional) speed transducer as shown the in the circuit diagrams

supplied.

BV-H2190 GB
- 60 -
0536

680

The belt weigher is designed on the principle of leaf spring parallel guidance.
Two weighing sections each equipped with a load cell measure the load exerted from
the weighed idler set direct.
The support frame of every weighing section accommodates the load cell and the leaf
spring parallel guidance used to restrain the weighed idler receptors.
The SCHENCK load cells of the RT.. type are hermetically sealed and service-free.
For exact type, see load cell type plate or Belt Weigher Spec Sheet.
6.2.1 Maintaining
proper alignment:
Raise conveyor belt in weigher influential zone by approx. 500 mm.
Align individual carrying idlers as described at the 'Aligning Carrying Idler

Sets' item.

0536
BV-H2190 GB
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681
Keep carrying idlers in the weigher influential zone free from build-ups.

(if required)
Unscrew fixing bolt from load cell mount.
Raise weighed idler receptors by approx. 5 mm, secure in this position, and
remove load cell from weighing section from below.
BV-H2190 GB
- 62 -
0536

682
In case of doubt, also replace the compression bolt before mounting the new
load cell.
ATTENTION! Before replacing the compression bolt, always
o
adjust weighed idler set in height as described at the 'Mounting Load

Cells' item
align weighed idler set as described at the 'Aligning Carrying Idler

Sets' item.
Introduce load cell complete with pre-installed mount and bolt in place using
fixing bolt and spring washer.
Carefully lower weighed idler set.
influential zone as described at the 'Aligning Carrying Idler Sets' item.

(if required)
Always replace all 4 leaf springs.
clean and deburred.
Before tightening bolts in steps, align the weighed idler receptors of both
weighing sections relative to the weighed idler set:
centrically
vertically to the load cell load button.
influential zone as described at the 'Aligning Carrying Idler Sets' item.

0536
BV-H2190 GB
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683
Multi-idler Belt Weigher BMP
7 Multi-idler Belt Weigher BMP

Documentation
Manual
BV-H2190
Dimensioned
drawing
Type BMP drawing no. 676 300

Type 2BMP drawing no. 677 954
Type BMP2 drawing no. 677 700
Guideline

Machines Supplied' (BV-R2000 AA)
Qty Type Name
1 pc.
Comments
Weighed idler set
(*)
2 pcs. Side part
(*)
2 pcs. Weighed idler receptor
(*)
2 pcs. Cross-member
(*)
1 set
Screws
1 pc.

1 pc.
Terminal box
1 pc.
Load cell
RT.. type (ring-torsion load cell) or
VBB type (shear beam)
2 pcs. Test weight receptors (***)

(telescopic tubes)
Optional
Optional
1 set
Limiting blocks
Shims
Thick shims
Shims
(*) pre-assembled in double number when two weighed idler sets are installed
(**) see 'Speed Transducer (Option)' item
(***) see 'Test Weight Receptors (Option)' item

SAFETY HINT:
technicians.
BV-H2190 GB
- 64 -
0536

684

with DIN 22107.
7.1.3 Installation
Install one or two weighed idler set(s), as the belt width may be.
Check against dimensioned drawing to see if belt stringers must be modified.
Thoroughly follow the given installation instructions in order to ensure the belt
weigher's measuring accuracy. This is of special importance if your belt
weigher is going to be stamped.
7.1.3.1 Prerequisites:

Catchword
Rules
1 2 3 4 5 10
Stability
78
Belt tension

weigher from the side and align at the proper time.
to provide the prerequisites given at the 'Aligning' item.
Place carrying idler set on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning' item.

0536
BV-H2190 GB
- 65 -
685

o
BV-H2190 GB
- 66 -
0536

686
in weighed idler set support points.
7.1.3.2 Mounting Weighed Idler Set(s)

First mount load cell(s).
Remove transit restraint angle (painted red), twist and bolt in place.
Turn in compression bolt (SW 17) with counter nut (SW 24) until the fitting
dimension of load cell with mount is approximately reached.

0536
BV-H2190 GB
- 67 -
687
Carefully raise weighing yoke against leaf spring force by max. 5 mm to be

able to insert the load cell with pre-assembled mount. Center fixing bolts and
spring washer relative to compression bolt and bolt in place. Carefully lower
weighing yoke.
Place a ruler along one of the leaf springs and set surfaces A and B to 0.5
mm difference in height (compression bolt resting in place) using the
compression bolt.
Secure compression bolt using a counter nut.

NOTE: The design of force transducers PWS and VBB differs from that of the
To perform welding work, and in order to protect the load cell, connect
the minus pole direct to the point of welding.
BV-H2190 GB
- 68 -
0536

688
Assemble weighed idler set; first bolt loosely outside the belt stringers.
Belt weigher with one weighed idler set
Belt weighers with two weighed idler sets normally come pre-assembled and
aligned.

0536
BV-H2190 GB
- 69 -
689
Detail of 'A':
Mount weighed idler set(s) on belt stringers with correct side in direction of travel.
Belt weighers with one weighed idler set, first loosely bolted.
Align weighed idler set(s) as shown in dimensioned drawing and bolt the 4
screw heads in place on belt stringers.
Place rulers in measuring positions [1] and [2].
Level surfaces C-D, and E-F relative to each other using set screws (4) and
(5), however, without twisting the weighed idler set(s), i.e. ensure that
distance 'H' is almost the same in the 4 corner points.
If only one weighed idler set is installed, additionally tighted bolts (1), (2) and
(3). If necessary, mean the difference in height between surfaces C-D, or E-F,
within the hole pattern of bolts (1) and (2) and set distance 'H' anew.
BV-H2190 GB
- 70 -
0536

690
Arrange carrying idler sets in weighing influential zone elevated by 3 to 5 mm.

on the premade shims on belt stringers.
overbalancing.
Align all idler sets in the influential zone (also consider the adjacent nonelevated carrying idler sets):
Observe preset triple idler spacing between the carrying idler sets
7.1.3.4 Aligning
Align the weighed and carrying idler sets arranged in the weigher influential
zone elevated by 3 to 5 mm to max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1 and 2.
Set weighed idler set with nuts (4) and (5) to distance H + X, roughly
aligning the weighed idler set relative to carrying idler sets 3.

0536
BV-H2190 GB
- 71 -
691
Remove idlers from weighed idler sets.
below.
Align idlers one after the other, terminating with the idlers of the
weighed idler set.
o

refiling.
BV-H2190 GB
- 72 -
0536

692

o
all carrying idler sets in the weigher influential zone are square to belt
stringers
Affix carrying idler sets to belt stringers by welding limiting blocks and shims in
place.
Attach the weighed idler set by welding it to the weighed idler receptors.

When installation is complete, acquire the effective platform length 'lng'.
Measure spindle spacings on either side of your belt conveyor and compute as mean
values:
a = (spindle spacing side a1 + side a2) / 2 =
__________
b = (spindle spacing side b1 + side b2) / 2 =
__________
c = (spindle spacing side c1 + side c2) / 2 =
__________

0536
BV-H2190 GB
- 73 -
693
Effective platform length:
Enter acquired value with proper

unit into the weighing electronics
as shown in the Electrical
Equipment manual.
7.1.4 Cabling

o
Load cell = 5 m
Transducer = 6 m
Connect (optional) speed transducer as shown the in the circuit diagrams

supplied.

BV-H2190 GB
- 74 -
0536

694

Depending on belt width, one or two weighed idler set(s) are available. The weighed
idler set(s) are designed on the principle of leaf spring parallel guidance.
Bolted to the two cross-members in three points, a rigid support frame serves for
accommodation of load cell and leaf spring parallel guidance used to restrain the
weighing yoke. Mounted on the load cell, the weighing yoke supports the weighed
idler set.
The SCHENCK load cells of the RT.. type are hermetically sealed and service-free.
For exact type designation, see load cell type plate or Belt Weigher Spec Sheet.
Explosion Protection
If the belt weigher operates in hazardous areas, Zones 1, 2 or 11 as
specified by DIN 57165, or VDE 0165, the load cell is protected to EEx
ibIIC T6.
7.2.1 Maintaining
proper alignment:
Align individual carrying idlers as described at the 'Aligning' item.
Keep carrying idlers in the weighing influential zone free from build-ups.

0536
BV-H2190 GB
- 75 -
695

(if required)
Unscrew fixing bolt of load cell mount.
Raise weighing yoke by approx. 5 mm, secure in this position, and remove
load cell from weighed idler set from below.
In case of doubt, also replace the compression bolt before mounting the new
load cell.
ATTENTION! Before replacing the compression bolt:
o
Adjust weighing yoke in height as described at the 'Mounting Weighed

Idler Set' item.
Align weighed idler sets as described at the 'Aligning' item.
Introduce load cell complete with pre-installed mount, carefully center load cell
relative to compression bolt, and bolt in place.
If need be, align weighed idler set relative to the carrying idler sets in the
weigher influential zone as described at the 'Aligning' item.
BV-H2190 GB
- 76 -
0536

696

(if required)
Always replace all 4, or 8, leaf springs.
clean and deburred.
Before tightening bolts in steps, align weighing yoke
centrically to the load cell load button
vertically to the load cell load button
axis parallel to the weighed idler set support frame.
influential zone as described at the 'Aligning' item.
ATTENTION!
Check effective platform length.
If necessary, correct value in weighing electronics.

0536
BV-H2190 GB
- 77 -
697
Speed Transducer (Option)
8 Speed Transducer (Option)

8.1 FGA20-RSLE Type
8.1.1 Installation Instructions
SAFETY HINTS:
Ensure work protection at this device by having it installed by skilled
technicians and using it as originally intended only, in accordance with
supply specification, and by operating it in accordance with the
suggestions to follow.
Ensure that the rocker joint cannot detach from belt stringers and
damage your belt weigher.
8.1.1.1 Installing Speed Transducer

The speed transducer of the FGA 20-RSLE type equipped with friction wheel and
rocker is designed to acquire the belt speed at the inside of the return belt.
BV-H2190 GB
- 78 -
0536

698
Mount speed transducer on weighed idler set direct or max. 5 m away.
Avoid vibration of the return belt in speed transducer area. Arrange return idler
towards transducer in return belt direction of travel as shown in sketch.
Ensure 1 mm maximum out-of-round tolerance of return idler.
Remove build-ups from return idler and/or avoid build-ups, e.g. by using
rubber-coated idlers.
To avoid slip between friction wheel and belt, keep belt interior clean using
appropriate devices, so as to avoid errors in measurement.
8.1.1.1.1 Further Installation Instructions
Carefully align speed transducer with friction wheel relative to belt run. Slip
causes wear of the running ring.
Securely bolt speed transducer with joint to the provided location on weighed
idler set or belt stringers or weld in place; ensure that rocker joint does not
detach from belt stringers and damage your belt conveyor.
To ensure positive contact of friction wheel on return belt, check to see that
o
loops of sensor cable in rocker spindle area are sufficiently long
rocker joint freely moves
friction wheel is perfectly level with return belt.
8.1.1.2 Cabling
Connect cables as described in the Weighing Electronics manual and observe

the following additional hints:
Run load cell and speed transducer cables to terminal box supplied using
cable ducts. Mount terminal box in a safe location.
ATTENTION!
Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
o
Never shorten ready-to-connect cable ends; if need be, arrange in

loops.
Pay heed to the local regulations.

Check to see that the speed transducer cable does not affect
the positive contact of friction wheel and return belt and
does not interfere with the rocker spindle.

0536
BV-H2190 GB
- 79 -
699
8.1.2 Operating Instructions

Rolling on the interior of the return belt, the webs of the friction wheel dampen an
inductive proximity switch, thus causing the latter to output a pulse frequency
proportional to belt speed.
The number of pulses per belt meter is the speed characteristic vs-K used to
acquire the belt weigher's feed rate.
Enter this value into the weighing electronics in form of a parameter; for details, see
Weighing Electronics manual.
8.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers
The counter pulses of the second switch are

offset with respect to those of the first switch
by measure 'O'. The weighing electronics
continuously compares counter results and
reports error when a deviation is detected. T
is the pulse interval.
8.1.2.2 Maintenance
Ensure free movement of the rocker joint; if necessary, dismount and clean.
Check friction wheel rubber ring for wear, and replace if necessary.
Ensure positive contact with return belt.
BV-H2190 GB
- 80 -
0536

700
8.1.2.3 Inspection and Repair
Measure 'X':
Mild steel variant (galvanized)
= 2 ... 3 mm
Stainless steel variant
= 1 ... 1.5 mm
The friction wheel is mounted in sealed grooved ball bearings lubricated for
life. If you note bearing damage, replace speed transducer.
When replacing proximity switch, ensure proper switching distance.
When running sensor cable, observe the instructions given at the 'Installation
Instructions' item.
8.2 FGA24A Type

8.2.1 Installation Suggestions
SAFETY HINT:
Ensure work protection at this device by having it installed by skilled
technicians and using it as originally intended only, in accordance with supply
specification, and by operating it in accordance with the suggestions to follow.
The speed transducer of the FGA 24 A type is designed for measuring the belt speed
on the belt conveyor tail pulley.

0536
BV-H2190 GB
- 81 -
701
8.2.1.1 Suitability
Make sure the

following prerequisite
is given:
DTr =
Pulley diameter in [m]
tbelt =
Belt thickness in [m]
fmin =
Smallest frequency the weighing electronics can measure (

0.04 Hz with INTECONT and DISOCONT,
10% safety allowance for running message, etc. included)
24 =
Number of pulses per pole wheel / belt pulley revolution
Related to the pulley diameters below and assuming 10 mm belt thickness, the
following minimum belt speeds Vbelt result:
Belt conveyor
DTr
Vbelt
[m]
[m/s]
Comments
0.200 0.250 0.315 0.400 0.500 0.630
as per DIN
22101
0.15 0.19 0.23 0.30 0.37 0.46
determines
calibration
vs-characteristic [I/m] 36.38 29.38 23.51 18.63 14.98 11.94
accuracy
(*)
(*) Having been computed with 10 mm assumed belt thickness, the vs-characteristics
in table can only serve as mean values .
BV-H2190 GB
- 82 -
0536

702
Decisive for feed rate determination

is the vs-characteristic (number of
pulses per belt meter) to be
computed using the formula on the
right, to be then entered into the
weighing electronics.
8.2.1.2 Mounting Pole Wheel

Best mount pole wheel on webs in the belt pulley protected area. Weld or bolt in place.
The pole wheel is equipped with a centre hole d=8mm serving for adjustment to the
required diameter. Ensure min. 20 mm distance from pulley bottom in order to prevent
the pulse quality from being affected.
8.2.1.3 Mounting Proximity Switch

Mount proximity switch on belt stringers using the mounting angle. The provided hole
pattern allows for universal arrangement; two possibilities are depicted in the figure.
Arrange switch centrally to pole wheel windows. Protect the switch cables from
mechanical damage by using cable ducts.

0536
BV-H2190 GB
- 83 -
703
Test Weight Suspension (Option)
9 Test Weight Suspension (Option)

The weighed idler sets of the BEP, BED and BMP types are prepared for manual
suspension of test weights.
The test weight suspension lets you simulate the belt weigher's operating points with
the use of test weights in place of a material load.
ATTENTION
Ensure that test weights are accurate to 1.
Check to see that the weight value display of every single weight is easy-toread.
Ensure that number and assignment of single weights are clearly identified.
Remove test weights after test weighing.
Select test weights in the range of 50 % to 80 % of belt load.
Check to see that no material is present in weighed idler set area.
Maintenance
The test weight suspension is free from maintenance and requires no special
inspection.
Before every test operation, remove lumpy material possibly jammed between
weighing sections. Do not remove overaged build-ups from belt weigher
components; this would only cause taring errors.
BV-H2190 GB
- 84 -
0536

704
9.1 BEP, BMP Types

Turn out threaded pins on either side of weigher, so that the telecopic tubes
can be pushed in.
Twist telecopic tubes, turn threaded pins into guide grooves and counter.
In pushed-in state, the telecopic tubes rest inside the belt stringers; in pulledout state, the test weights can be suspended.
9.1.2 Installation and Setting Instructions
G= total of suspended test weights

0536
BV-H2190 GB
- 85 -
705
Operating Principle
The test weight suspension lets you simulate the belt weigher's operating points
without material load on belt.
Pull out telescopic tubes from both sides of the weighed idler set and suspend
the test weights supplied (or commercial units) in equal shares.
Remove test weights when test weighing is complete.
Push in telecopic tubes.
9.2 BED Type

The test weight equipment consists of two weld-on pieces and a number of test
weights.
To assemble, expertly weld the weld-on pieces to the faces of the weighed idler set tie
on either side as depicted above.
Consider the following:
Weld the weld-on pieces in place best before aligning the weighed idler set.
The welding heat can cause deformation and deteriorate the accuracy of
alignment so that realignment is required.
BV-H2190 GB
- 86 -
0536

706
9.2.2 Operating and Setting Instructions

The test weight equipment consists of
two weld-on pieces welded to the weighed idler set as described above, and
a number of test weights supplied upon request or readied by the user.
The test weights suspended on either side in equal shares = G/2 let you simulate the
belt weigher's measuring points without belt load.
Concerning the testing accuracy, please always heed the instructions given in the
Weighing Electronics manual and
never remove overaged build-ups from belt weighers components because of

the change in tare.

0536
BV-H2190 GB
- 87 -
707
Appendix
2BMP type 8
Acquiring Effective Platform Length 30, 46, 60, 73
Aligning 28, 44, 71
Aligning Carrying Idler Sets 57
Aligning Weighed Idler Set 58
BED type 6
BED Type 86
Belt Weighers Overview 3
BEM type 4
BEP type 5
BEP, BMP Types 85
BMP type 7
BMP2 type 8
Cabling 28, 46, 60, 74, 79
Checking Leaf Spring Parallel Guidance 33
Checking Load Cell 34
Checking Load Cell Signal 34
Displacing Measuring Modules 23
Ensuring Proper Alignment of Carrying Idler Sets 32
FGA 20-RSlE for Legal-for-trade Belt Weighers 80
FGA20-RSLE Type 78
FGA24A Type 81
Further Installation Instructions 79
General Information 1, 9
Hints for Delivery 1
Hints for Movable Conveyors 10
Information on Documentation 1
Inspecting 32
Inspecting and Repairing 47, 62, 76
Inspection and Repair 81
Inspection of incoming goods 1
Installation 24, 38, 51, 65
Installation and Setting Instructions 85
Installation Instructions 22, 37, 50, 64, 78, 85, 86
Installation Prerequisites 22, 38, 50, 64
Installation Suggestions 81
Installing Speed Transducer 78
Items Supplied 22, 37, 50, 64
Maintaining 32, 47, 61, 75
Maintaining Belt Weigher 31
Maintenance 80
Mounting Belt Weigher on Belt Stringers 54
Mounting Carrying Idler Sets 27, 43, 56, 71
Mounting Load Cells 55
Mounting Measuring Modules 25
Mounting Pole Wheel 83
Mounting Proximity Switch 83
Mounting Weighed Idler Set 41
Mounting Weighed Idler Set(s) 67
Multi-idler Belt Weigher BMP 64
Multi-idler Belt Weighers 6
Operating and Setting Instructions 87
Operating Instructions 31, 47, 61, 75, 80
Overview 10
Planning-in Hints (The 10 Rules) 9
Prerequisites 24, 51
Prerequisites: 39, 65
Repairing Belt Weigher 35
Replacing Leaf Springs 49, 63, 77
Replacing Load Cell 48, 62, 76
Single-idler Belt Weigher BED 50
Single-idler Belt Weigher BEM 22
Single-idler Belt Weigher BEP 37
Single-idler Belt Weighers 4
Speed Transducer (Option) 78
Storage hints 1
BV-H2190 GB
- 88 -
0536

708
Appendix
Suitability 82
Test Weight Suspension (Option) 84
The 10 Rules 10
The Rules in Detail 11

0536
BV-H2190 GB
- 89 -
709
Measuring and Process Technologies

D-64273 Darmstadt
Phone:
+49 (0) 6151-32 10 28
Fax:
+49 (0) 6151-32 11 72
E-Mail:
www.schenck-process.net
The
Group
710
SINGLE-POINT LOAD CELL, PWS TYPE

Type plate, sticker
SER = Load cell serial number
Emax =
Rated load
10 kg
30 kg
60 kg
100 kg
150 kg
300 kg
10kg
30kg
60kg
100kg
150kg
300kg
10kg
30kg
60kg
100kg
150kg
300kg
# 500 kg
# 700 kg
Part =
Material No.:
D725443.01
D725443.02
D725443.03
D725443.04
D725443.05
D725443.06
D725443.11
D725443.12
D725443.13
D725443.14
D725443.15
D725443.16
D725443.21
D725443.22
D725443.23
D725443.24
D725443.25
D725443.26
3360.119
3360.120
"A"
"B"
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
8,5
10,4
10,4
(mm)
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M8
M10
M10
Nominal sensitivity
Combined error
Compensated temp. range
Sensitivity temperature
coefficient
Zero signal temperature
coefficient
Creep over 20 min.
Zero signal tolerance
Variability, VDE 2637
Service temperature range
Storage temperature range
Max. excitation voltage
Input resistance
Output resistance
Isolation resistance
Limit load rel. to rated load
Breaking load / rated load
Corner load error at 50% rated load
# Corner load error at 50% rated load
"C"
Torque
Full range
to travel
ATEX
Category
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
30,73
36,50
36,50
32 Nm
32 Nm
32 Nm
32 Nm
39 Nm
39 Nm
32 Nm
32 Nm
32 Nm
32 Nm
39 Nm
39 Nm
32 Nm
32 Nm
32 Nm
32 Nm
39 Nm
39 Nm
79 Nm
79 NM
0,30 mm
0,35 mm
0,35 mm
0,45 mm
0,45 mm
0,50 mm
0,30 mm
0,35 mm
0,35 mm
0,45 mm
0,45 mm
0,50 mm
0,30 mm
0,35 mm
0,35 mm
0,45 mm
0,45 mm
0,50 mm
0,50 mm
0,50 mm
2G/D
2G/D
2G/D
2G/D
2G/D
2G/D
3G/D
3G/D
3G/D
3G/D
3G/D
3G/D
-
2 0,002
mV/V
0,03
%
-10 bis +40 C
(*)
0,045
%/10K
(*)
0,045
0,03
2,0
0,01
-30 bis +70
-50 bis +85
15
min 350
350 3
>5000
150
300
0,05
0,5
%/10K (*)
%
(*)
%
(*)
%
(*)
C
C
V
M
%
%
%/100mm
%/100mm
(*) Error related to rated load

BV-D2214GB
711
Arrow-head on front side = Measuring force direction

Electrical Cable: 6 Conductor + Shield, 5m long
Cable Colour Code:
Input Voltage -Input Voltage +
Measuring signal -Measuring signal +
Sensor conductor -Sensor conductor +
Shield
Green
Black
White
Red
Orange
Blue
Yellow Conductor, isolated over its entire length
The connecting cable shield is not connected to the measuring body. Therefore, load cell grounding has to be
provided for, e.g. via the connecting structure.
PWS load cells in rated capacity range 10 300 kg are also available as legal-for-trade variants with the following
additional characteristics:
Max. number of increments n = 3000 (C3)
Min. utilization Bamin = 42% (with 3000d)
Min. load cell increment value V
min L / C =
E max
7143
Example: PWS 100kg

Min. utilization Bamin = 42 kg
Min. increment value
V min L / C =
100kg
= 14 g (theoret.megnitude )
7143
i.e., the weighing electronics increment value is the next possible increment = 20g.
Measuring and Process Systems

D-64273 Darmstadt
Telefon: +49 (0) 61 51-32 17 58
Fax:
+49 (0) 61 51-32 36 32
E-Mail: sales.process@schenck.net
www.schenck-process.de
BV-D2214GB 0417. We reserve the right to discontinue or change specifications or designs at any time without notice or obligation.
Dimensions
712
INTECONT PLUS
Operating Instructions
DE
GB
FR
IT
ES
NL
RU
CS
Bedienungshinweise
Operating instructions
Instructions de service
Istruzioni per luso
Instrucciones de uso
Bedieningsinstructie

Vaga za traku
Bandwaage
Belt Weigher
Bascule Intgratice
Bilancia per nastro
Bscula de cinta
Bandweger
K
Uputstva za upravljanje
BV-H 2007AA
713
Contacts, Copyright
Sales:
Tel.:
Fax:
Email:
+49 (0)6151 32 - 10 28
+49 (0) 6151-32 11 72
Service:
24h Emergency Hotline:
+49 (0) 172 - 650 17 00 Discontinuous Weighing Technology

+49 (0) 171 - 255 11 95 Continuous Weighing Technology
service.process@schenck.net
Email:
Business Segments:
Service Tel.:
Service Fax:

Service Tel.:
Service Fax:
Vibrating Machines
Service Tel.:
Service Fax:

Service Tel.:
Service Fax:

Service Tel.:
Service Fax:
+49 (0) 61 51 32 - 26 23
+49 (0) 61 51 32 - 32 70
Bvh.process@schenck.net
+49 (0) 61 51 32 - 25 72
+49 (0) 61 51 32 - 20 72
+49 (0) 61 51 32 - 3525

+49 (0) 61 51 32 - 30 96
+49 (0) 61 51 32 - 24 48
+49 (0) 61 51 32 - 13 69
+49 (0) 61 51 32 - 17 58
+49 (0) 61 51 32 - 36 32
Copyright 2004
Landwehrstrae 55
D-64293 Darmstadt http://www.schenck-process.com
Alle Rechte vorbehalten. Jegliche Vervielfltigung dieser Dokumentation, gleich nach welchem Verfahren, ist
ohne vorherige schriftliche Genehmigung durch die SCHENCK PROCESS GmbH, auch auszugsweise,
untersagt. nderungen ohne vorherige Ankndigung bleiben vorbehalten.
All rights reserved. Any reproduction of this manual, regardless of method, without prior permission by
SCHENCK PROCESS GmbH in writing, even by excerpt, is prohibited. Subject to change without prior notice.
Tous droits rservs. Toute reproduction de cette documentation, mme partielle, et par quelque procd que ce
soit, sans lautorisation pralable crite de SCHENCK PROCESS GmbH, est strictement interdite. Sous rserve
de modification sans avis pralable.
714
VBW
ENGLISH
O
--
gB START/STOP
U SCROLL
T
Z1 = 1500 kg
I = 100 kg/h
if preselected
Select lower display line and functions
(1) Counters Z2, Z3
(4) Belt load Q
(2) Feed rate I
(5) Belt speed v
(3) Feed rate Ir in %
RESET
Reset counter(s)
(1) Enter number of desired counter (1 or 2).
(2) Use ENTER key
to acknowledge
(3) Use ESCAPE key
to abort input
(4) Use DELETE key
to delete faulty digits
FUNCTION
Call function distributor and event messages

(1) SCROLL keys let you select desired function
If an event is available, Display Event function is preselected
(2) ENTER key lets you activate function
(3) SCROLL keys let you view available event messages one after the other
(4) ESCAPE key lets you return to normal displays
DELETE
Acknowledge event messages, delete inputs
ESCAPE
Abort function and return to normal displays
ENTER
Acknowledge input
start functions, e.g. Display Events (see FUNCTION)
DATA
Prepare input, e.g. parameters
O
N
f
P
INTECONT PLUS Operating Instructions BV-H2007AA / 0502

SCHENCK PROCESS
715
VBW
Reserved for users notes
BV-H2007AA / 0502
INTECONT PLUS Operating Instructions

SCHENCK PROCESS
716
717

D-64293 Darmstadt
Phone: +49 (0) 6151-32 10 28
Fax:
+49 (0) 6151-32 11 72
E-Mail: sales.process@schenck.net
www.schenck-process.com
The
Group
718
INTECONT PLUS Belt Weigher

Operating Manual
BV-H 2214GB
719
Contacts, Copyright
Sales:
Tel.:
Email:
+49 (0)6151 32 - 10 28
Service:
24h emergency hotline:
Email:
+49 (0) 172 - 650 17 00

+49 (0) 171 - 255 11 95 (belt weighers, weighfeeders)
Business Segments & Services:

Heavy Industry
Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 26 23
+49 (0) 61 51 32 - 32 70
Light Industry
Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 25 72
+49 (0) 61 51 32 - 20 72
Mining (Vibratory Machines)

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 35 25
+49 (0) 61 51 32 - 30 96

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 24 48
+49 (0) 61 51 32 - 13 69
Components & Spares

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 17 58
+49 (0) 61 51 32 - 36 32
Copyright 2005
MEASURING AND PROCESS TECHNOLOGIES
Landwehrstrasse 55, D-64293 Darmstadt
http://www.schenck-process.net
All rights reserved. Any reproduction of this manual, regardless of method, without prior permission by
SCHENCK PROCESS GmbH in writing, even by excerpt, is prohibited.
Subject to change without prior notice.
720
INTECONT PLUS
VBW
Contents
1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power ON 4
Signal Lamps 4
Normal Displays 5
Control In Normal Mode 5
Event Messages 6
Function Distributor 8
Display Test and Version Number 8
Batching Mode 9
Visual Make-up 11
Keyboard Mode 11
Activate/Deactivate EasyServe 12
Prefeeder 12
Printing 12
Zero Setting 16
Read Parameters 17
3 Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7
Setting Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Function Distributor 33
Calibrating Functions 34
Belt Circuit LB 34
Tare TW 35
Weight Check CW 36
Set Time 38
Simulation Mode 38
8 Service Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.
Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Preselect Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Enter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Parameters Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10 Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
System Messages S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electrics E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Calibration C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Maximum H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Minimum L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Batching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Signal Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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11 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Transmission to third parties and reproduction of

this documentation are not permitted. SCHENCK
PROCESS GmbH reserves all rights of ownership
and copyrights.
Technische
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CONTENTS
BV-H2214 GB I - 1
721
VBW
INTECONT PLUS
How To Operate Your INTECONT 83

Mechanical Prerequisites 84
Electrical Prerequisites 84
Enter Parameters 85
Functional Check 86
Calibration 87
Check Using Check Weight 87
Check Belt Speed 88
Check Using Material 88
Automatic Zero Setting 89
Belt Run Monitoring 89
Belt Influence Compensation BIC 90
Control for Point of Discharge CPD 90
Cosine Pendulum 91
Test Plug 91
12 Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Batching Without Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Batching With Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Data Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Base Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Weighing Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1. Effective Platform Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2. Check Weight QPRF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3. Conveyor Belt Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Printer Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
13 Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replacing INTECONT PLUS FIP > INTECONT PLUS VEG. . . . . . . . . . . . . . . . . . . . . . 111
This manual applies to software version:

Edition
VBW 20600-05
: 0539
0539
CONTENTS
BV-H2214 GB
I-2
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and copyrights.
722
INTECONT PLUS
1
VBW
Overview
What Is The INTECONT:
Display:
INTECONT PLUS is designed as measuring and

evaluation system for
5 x 7 - dot matrix with 6 mm character height
Belt Weighers
Solids Flow Meters
Mass Flow Meters
Mass Flow Feeders
Weighfeeders
Loss-in-weight Feeders
Upper display left

: running message
right : delivery rate in kg or t
Lower display left
: event messages
right : selectable
feed rate, belt speed
etc.
Three system versions are available:
Display can be changed over to American units.
1. Without option card (standard)
LEDs:
2. With option card VFE 610V for additional

input/outputs and printer
2 green and 3 red LEDs

Green LEDs
: Ready
Red LEDs
: Error or limit value
messages
3. With option card for fieldbus

VSS021V : Modbus/S5
VPB 020V: Profibus
VCB020V: DeviceNet
VET020V: MODBUS/TCP
VET022V: ETHERNET/IP
This manual applies to belt weighers using the fully
equipped INTECONT variant.
For Further Reading:

Fieldbus manual
BVH2220
SS-RK512 (3964R)
FH 458
Modbus (Comp)
FH 525
O
E1
Keyboard:
Flexible membranes with tactile touch
gB
TU
i
G FUNC
O DEL
Start/stop measurement
Preselect lower display
Select functions
Reset counter
Call function distributor and
event texts
Acknowledge event messages
Delete input
Z1 = 1 2 0 0 0 kg
I = 1 0 0 0 kg/h
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Overview
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VBW
N ESC
f ENT
P DAT
B9
KL
INTECONT PLUS
The basic diagram shows all inputs and outputs.
Abort function
Start function
Acknowledge input
Prepare input
Enter parameters
Enter sign and decimal point
Some Definitions:
I
= Feed rate
in kg/hr or t/hr
Material amount discharged from belt
per unit time
= Delivery rate
in kg or t
Material amount fed out = feed rate x feed time
= Belt speed
Z1 = 1500 kg
I=
100 kg/h
in m/s
Q = Belt load
in kg/m
Material weight on one belt meter
Measuring Principle:
Belt load Q and speed V are continuously measured
and multiplied.
The result is feed rate I used to determine delivery
rate.
L/C
Load cell for acquisition of belt load Q
Speed transducer
Belt circuit sensor for automatic belt

influence compensation BIC
(non-standard)
Measurement techniques:
24 V
Power supply
Precision AC voltage amplifier with continuous

correction of zero point and range
Speed transducer
Highly resolving analog-to-digital converter

The integrated method is designed to efficiently
suppress line voltage interferences.
Load cell
I
Q
V
in kg/hr
in kg/m
in m/s
16-bit microcontroller
Unlimited
storage
of
counter
configuration and calibration data.
ANALOG=
Analog output selectable for feed rate,

belt load, belt speed
SERIAL =
Serial interfaces for printer and host

computer
MIN
Relay output for limit value monitoring

Open = MIN value exceeded down
readings,
=
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INTECONT PLUS
MAX
Relay output for limit value monitoring

Open = MAX value exceeded up
Feed rate, belt load, or belt speed, can be
monitoring separately for excess of MIN
and MAX values.
FAULT
Relay output for alarms

Open = Alarm
FULL
Relay output for full feed in batching

mode
Closed = full feed
DRIBBLE =
Relay output for dribble feed

Closed = dribble feed
MOTOR =
Control output for belt drive

Closed = ON
PREF.
Control output for prefeeder

Closed = On
RELEASE
=
Release signal for totalization

H = Release
ON/OFF =
Start scale and totalization.

High = ON
OFF
Stop
Low = STOP
VBW
COUNTER= Pulse output for connection of external

totalizing counter
For simple measuring tasks, with constant belt speed,

speed transducer D can be omitted.
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Overview
BV-H2214 GB 3
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2
INTECONT PLUS
Control
Power ON
Signal Lamps
During power failure

Counter readings
Counter pulses not yet output
Preselected normal displays
Service values, e.g. ON-time
E1
remain stored for an endless period of time.

The internal clock continues running for approx. 5
days.
After power-on, display and lamps are automatically
tested before version number of system is displayed
for some seconds to be then replaced by the normal
displays.
E1
a
b
X
Z1 = 2 5 0 0 kg
I =
0
kg/h
Z1 = 2 5 0 0 kg
I =
0
kg/h
(green) POWER OK
lights if all power supplies are OK.
(green) CPU OK
lights if microprocessor is ready to
operate.
(red)
ALARM
flashes if an Alarm event is
available.
In addition, an event code appears
in lower display line.
MIN
(red)
MIN LIMIT VALUE

lights if feed rate limit value is
exceeded down.
MAX
(red)
MAX LIMIT VALUE

lights if feed rate limit value is
exceeded up.
Message E1
reports power failure and can be defined as ALARM or
WARNING.
ALARM:
Red lamp
and message E1 are
flashing.
To start scale, first acknowledge
message.
WARNING:
Signal lamp
remains dark,
message E1 does not flash.

Start/stop scale automatically or in
manual. No acknowledgement is
required.
READY:
The two green signal lamps must be lit, and no Alarm
message available.
Lets you acknowledge event

message.
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INTECONT PLUS
VBW
Normal Displays
Upper Display
Left
Rotating point as running message.

Scale has started, totalized amount
and feed rate are acquired.
In stop state of scale (point stands
still) only belt load and belt speed are
measured.
Totalizing counter Z1
Right
Lower Display
Left
Right
TU
O
Control In Normal Mode
Event message, alphanumerically

coded, e.g. E1 for power failure.
Selectable display
Select display
Start totalization
Prerequisite : External release signal
available (selectable)
START source (B06)
set to OP or Keyboard
Mode active.
Feature : Rotating point in left field
of upper display
B
i
Stop totalization
Feature : Point stands still
Belt load and belt speed continue
being measured.
Z1 = 50 000 kg
Z2 = 60 0 kg/h
Counter Z2
Counter Z3
Feed rate
Feed rate
Belt load
Belt load
Belt speed
Batching displays
Z2 = 6000 kg
Z3 = 1000 kg
I = 1000 kg/hr
Ir = 50.00 %
1)
Q = 10.000 kg/m
Qr = 50.0%
2)
V = 0.0500m/s
Zb, ZI, Zd, Nb
3)
f
N
TU
O
G
N
Reset totalizing counters.

Enter number of desired counter
(1 or 2).
Counter no. : _
Counter 3 cannot be reset. In case of
overflow, counting resumes from 0.
Acknowledge input.
Correct faulty input or accidental use
of DELETE key.
Select lower display
(see Normal Display).
Acknowledge event messages.
Call further functions, e.g. display
event messages, calibration.
Exit function distributor.
1) related to nominal feed rate

2) related to nominal belt load
3) see Batching Mode.
Display formats and units of counters Z1, Z2, Z3 and I

can be selected separately.
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INTECONT PLUS
Acknowledgement:
If cause of fault is still present,
underscores are faded out.
Event Messages
Definitions
WARNING 2
Display permanent, not

underscored
All important scale functions are internally monitored,

and faults are reported by event message.
For troubleshooting details, see Event Messages
item.
E1
IGNORE
Power Failure
Group code (e.g. E) and number (e.g. 1) appear in left

field of lower display.
In addition, an explanatory text can be called up.
Operation
The events are organized into 4 classes. The

assignment between event and class can be selected
using relevant parameter.
n
No event monitoring, save

MIN/MAX messages via contact
outputs and signal lamps.
If several events occur at the same time, the most

significant event is displayed first.
Priority: Alarm, Warning 1, Warning 2
Z1 = 2500 kg
I =
0 kg/h
Message E1
Acknowledgement:
None
ALARM
Acknowledge events of ALARM and

WARNING 1 classes after
elimination of fault. If several events
are available, acknowledge one
after the other.
Display is underscored and

flashes.
Red signal lamp
X flashes.
Totalization stops, scale is

inoperable.
Start:
If cause of Alarm has been
removed and error message
acknowledged.
Display event texts:
G
TU
f
Call function distributor.

Scroll Show Event function into
lower display field.
Select function.
Acknowledgement:
If cause of Alarm has not been
removed, flashing stops but
message is still on display.
n
WARNING 1
Display permanent and

underscored Totalization goes on.
0539
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728
INTECONT PLUS
VBW
Minimum L
L1 I < MIN
L2 Load < MIN
L3 v < MIN
L4 L/C Input < MIN
1. Event S 2 = O 0 7
No Release
Feed Rate
Belt Speed
L/C
Load Cell
Display shows
event name
event code
and a note
e.g. No Release
e.g. S2
e.g. Parameter O07.
* Fault on device or cabling
The note informs the operator of relevant parameter.
TU
N
Let you view various events.

Return to normal displays.
Contact Outputs
General Alarm
MIN/MAX Outputs
List of Events
The events are listed in accordance with display
priority.
0539
System messages
S1
S2
S3
S4
Electrics
E1 Power Failure
E2 Namur Error Tacho*
E3 Namur Error Sensor*
Material flow
B1 Out of Tolerance
B4 BATCH Actual Value MAX
Calibration C
C1
C2
C3
C4
C5
C7
C8
C9
L/C Input *
Tacho Input *
Belt Skew
Belt Drift
Tare Correction > MAX
ZERO Time
Slip Error
Tare Diff > MAX
Maximum H
H1
H2
H3
H4
I > MAX
Load > MAX
v > MAX
L/C Input > MAX
available until acknowledged

independent of event class,
active also in IGNORE class.
Limit values are reported as long
as event is available and only
with active scale.
Memory Error
No Release*
Scale Maintenance ON
Maintenance Interval
Electrics
S7 Simulation active
S9 Host Communication

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BV-H2214 GB 7
729
VBW
INTECONT PLUS
Function Distributor
= If batching mode is selected, you can access

additional functions in main distributor.
Abort Batch
Deselect Batch
Batch Number
Print Batch
Make-up
Next = Belt Empty
The function distributor lets you call further functions,

or dialogs.
G
f
N

If no event is available, display shows
function selected last.
Start function.
S
= Calibrating functions protected by password.

Prompt is output after call of function.
= If an event is available
= Iif activated via parameter
Return to normal display and/or

abort function.
Function
Display Events
Moving through function distributor has no effect on

weighing functions.
Display Test and Version Number
TU Scroll through function distributor
Lets you check displays and signal lamps.

Display Events
E
Test Display
START/STOP Prefeeder Z
Service Values
Batch Number
B
Print Counter Readings
>0< Zero Set
START/STOP Keyboard Mode
Activate/Deactivate EasyServe
Programming
Calibrating Functions
S
Read Parameters
Enter Parameters
S
Load Default Parameters S
Print Parameters
Status Report
Tare
S
START/STOP Simulation
Check Weight
S
Imp/Belt Circuit
S
Set Time
S
G
TU
f
Call display test.

1. Display elements flash
rhythmically.
2. Version number is displayed for
apr. 3 s.
Test terminates automatically.
INTECONT PLUS
VBW 20600-00 2482
Example:
VBW
20600-00
: Belt Weigher
: Version number
Programming and calibrating functions lead to further

menus you can move through using cursor keys.
Control
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INTECONT PLUS
Batching Mode
VBW
Select Batching Mode
Selection of batching mode enables batching,
however, no batch is started yet.
Additional Displays
Prerequisite:
G
TU
f
Z1 = 2500 kg
ZI = 400 kg
Scale OFF
Scroll Select Batch into display
field.
Select function.
Upper display :
If batching mode is selected, a

totals sign is displayed left of
running message.
System prompts for input of batch setpoint.

If batch is selected from external PC, setpoint input is
omitted.
Lower display :
Use cursor keys to scroll 4

additional values into display field.
Enter Setpoint
1. Zb = Batch setpoint
2. ZI = Batch actual value
Amount already
discharged
3. Zd = Batch residual value
Amount not yet
discharged
Zd = Zb - ZI
Setpoint prompt is output automatically upon selection

or can be started in manual when batch is complete
(scale OFF).
If batching mode is deselected or a batch is running,
no input is possible.
When presetting batch setpoint via fieldbus
(Parameter I09 Batch Source = FB), no input is
possible either. This also applies to the input of batch
number and make-up setpoint.
P
19
Prepare setpoint input.

Enter setpoint in kg or t
Max. 9 digits including decimal
point.
The unit is that of counter 1.
4. Nb = Consecutive batch
number
Use Batch Number
function to set initial value.
.
Before a batch starts, ZI and Zd indicate the amounts

fed out during previous batch.
If you deselect batching mode (Deselect Batch function), displays are disabled but enabled again upon
next selection.
The display format corresponds to the format of
counter 1.
f
N
O
Setpoint Batch
Zb = . . . . . . kg
Acknowledge input.
Abort input, old setpoint remains
stored.
Delete faulty digits.
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INTECONT PLUS
Start and Abort
g
B
Make-up
Start batch, process starts.

Display ZI moves from 0 towards
setpoint
Display Zd moves from setpoint
towards 0.
Display ZI
Batch actual setpoint resumes from

achieved value.
Abort batch.
Display Zd
Batch residual value remains

unchanged.
Batching continues upon next start

command.
Display Zbn
Make-up setpoint
Display Zdn
Batch residual value of make-up

amount
Zdn = Zbn - make-up amount
already fed.
Deselect Batch
Lets you deselect batching mode, i.e. mode is removed
from active functions available.
Totals sign disappears from upper display, batching
values ZI, Zd, Zb and Nb are no longer available, but
remain stored.
Prerequisites :
GT
f
Lets you add a selected amount of material to a batch

aborted or complete.
Prerequisites : Running batch complete, scale OFF.
No batch printout.
Batch complete, or aborted using

Abort Batch function; scale OFF.
Call function distributor,
select Deselect Batch function,
and acknowledge.
You can scroll all displays into lower display field

using cursor keys.
Zdn and Zbn are available only until start of next
batch.
GT
f
Use Select Batch function to reactivate batching

mode.
Old values ZI, Zd, Zb and Nb can be viewed again.
Abort Batch
gB
This function lets you abort a running batch, i.e.

batching immediately stops.
Batching mode remains selected.
New batch starts upon next start command, old batch
is not resumed.
Use Make-up function to complete old batch.
GT
f
Call function distributor and select

Make-up function.
Acknowledge.
System prompts for input of
make-up setpoint Zbn in kg or t.
The units is that of Counter 1.
Until start of make-up, setpoint Zbn
can be changed.
Start or abort make-up
If make-up batch is complete, normal batch starts

upon next start command.
For new make-up, call function again.
Abort Batch function also aborts make-up
operations.

Abort Batch function.
Acknowledge.
You can also abort batch using the P02 contact.

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INTECONT PLUS
VBW
Batch Number Nb
Visual Make-up
Select a number incrementing by 1 after start of every

new batch.
The consecutive number is printed in batch report and
indicated in lower display line.
Belonging to previous batch, make-up operations are
not counted.
GT
f
f
N

Batch Number function.
Acknowledge.
Prompt Nb = -
is output.
Acquire input.
Abort input.
Old number remains stored.
Current number can be changed also while a batch is

running.
Next = Belt Empty
A batch report can be printed only if batch is complete

(setpoint reached).
If an unspecified amount is to be batched using the
START/STOP keys, the results can be printed using a
little trick:
1. Call Select Batch function.
2. Enter very high batch setpoint,
e.g. 999999999 kg.
3. Scroll batch actual value ZI into lower display field.
4. Start scale.
5. If desired amount ZI is reached, stop scale.
6. Call Abort Batch function.
7. Start printing
(see Print Batch).
Make-up can be performed only before print

command. To start next batch, resume from item 4.
One-off changeover to clearance mode.

Next batch is controlled via prefeeder. When batch is
complete, conveyor belt still performs approx. 1/2 belt
circuit.
Prerequisites
GT
f
g
: Scale OFF,
batch complete,
prefeeder control present and
active.
Batching mode without clearance.
Next - Belt Empty function.
Acknowledge.
Start batch.
Keyboard Mode
This function lets you place the selected control
source for
Start/Stop
on the INTECONT keyboard. If you deselect Keyboard
Mode, the old source is active again. When changing
over from external source (e.g. serial) to keyboard, the
Start/Stop status remains stored; vice versa, the
external signal is active.
GT

Start Keyboard Mode or Stop
Keyboard Mode functions.
Display feature:
You will know Keyboard Mode by the rectangle in the
upper left display field.
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BV-H2214 GB 11
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VBW
INTECONT PLUS
Activate/Deactivate EasyServe
This function lets you control your INTECONT using
the EasyServe PC service tool.
GT

Activate EasyServe function.
Enter communication parameters using Block R.

Note:
Upon power failure, the current

status is stored, i.e. the Activate
EasyServe function needs not be
reselected.
Connection to PC can also be made using a 9-pole

SUB-D connector on X4 (RS 232 only) or a Phoenix
connector on X5 (RS232, RS422 or RS485).
See also Wiring Diagram in chapter DETAILS.
Prefeeder
The Start/Stop Prefeeder function lets you activate or
deactivate prefeeder. Select Start, and INTECONT
will control your prefeeder. In Stop state, material flow
is interrupted and scale can be tared.
Prerequisites :
GT
f
Control
BV-H2214 GB
External prefeeder present and

controlled by INTECONT.
Activate function using parameter
N 01.
Printing
The printing functions are available only if the option
card is present.
Print Batch
The batch report can be printed:
1. using Print Batch function
2. automatically after each complete batch
(Parameter J02 = YES).
Start of printing disables the Make-up function for the
current batch.
Prerequisites : Batch complete, scale OFF.
Print format : Order of sequence, line and column
divisions can be selected at will
(Parameter Block J).
GT
N

Print Batch function.
Start function.
Abort printing.
Batch Nummer 40
20.11.02
Batch Setpoint
Batch Actual Val.
Totalizer 1
Totalizer 2
Zero Set beforer
16:49:41
0.150 t
0.150 t
0.806t
806.47 kg
19 min.
Events
E1
Power Failure O01

Start Prefeeder or Stop Prefeeder
function.
Start control signal.
12
Technische
Redaktion BVED
Batch Number: Consecutive number of batch

20.11.02:
Date and time
Batch Setpoint: Preset batch amount
Batch Actual Val.: Amount batched (actual value)
Totalizer 1:
Totalizing counter 1
Totalizer 2:
Zero Set before: Feeder run time after last taring or
zeroing operation (see Service
Values)
Events
: available during printing

and copyrights.
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Print Counter Readings (FMZ), Quantity Report
Print Events
This report is identical with the batch report, however,

the numerical values are identified as sub-totals by
the # symbol.
Parameter J03 lets you select/deselect printout of

event messages.
There are 3 options:
If no batching mode is selected, batch number, batch

setpoint and batch actual value are not printed. This
type of report figures as Quantity Report.
Batch actual value
etc.
[kg]
# 998 #
1. No printout (NO)
2. Print events (error)
3. Print events and counter readings (YES)
(see Printer Counter Readings)
Call:
20.11.02 11:45:21 L2 W1
20.11.02 11:59:01 L2 W1
1) Use Print Counter Readings function.

Unlike the Print Batch function, printing is
possible during running batch.
2) Printed automatically upon every event printout
(Parameter J03 = YES)
Print Parameters
Print complete parameter list with current values.
Inputs differing from default values are identified by *.
The list is complete with all possible event messages
and the current hardware assignment.
PARAMETER PRINTOUT
L2
W1
Load > MAX

Load < MIN
:
:
:
:
Event code
Error class, e.g. WARNING 1
Event has occurred
Cause removed, event acknowledged, if
required.
Load<MIN: Explanation
Event is displayed on INTECONT as long as

available.
INTECONT PLUS VBW 20600-01 2482
For more information, see Event Messages item.

20.11.02
16:59:51
BLOCK A
01 Language
02 Units
Dialog Behaviour
ENGLISH
SI
BLOCK B Rated Data

01 Feed Rate Unit kg/h
02 Nominal Feed Rate * 1,000 t/h
etc.
0539
GT
f
N

Print Parameters function.
Start function.
Abort printing at any time.

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VBW
INTECONT PLUS
Print Zero Setting Results

The result of the automatic zero setting function can
be printed automatically after every belt circuit.
Prerequisite:Parameter H 01 = YES (Auto Zero Active)
Parameter H09 = YES
Tare correction is the total of all zero point changes;
total tare additionally includes the basic tare.
Values correspond to same-name parameters
D 03/05.
Print Zero Setting Results

Total Tare [kg/m]
50,23
Tare Correction T [kg/m] 1,56
STATUS REPORT INTECONT PLUS

25.11.02 13:37:12
Software
: VBW 20600-01 2482
Hardware version
:1
Option card version
:1
Station address
:1
------------------------------Latest Report of: 25.11.02 12:13:13
------------ ------------------SPC values:
Zero Set before
Voltage ON-time
Feeder ON-time
Latest password entry of
Latest matkor change
: 4086 min
: 68 h
: 68 h
: 22.11.02 17:02:12
: 15.11.02 15:02:34
K05 SPC Time

K06 SPC Filter
Feed rate
Mean value Imitt
Variance
Belt load Q MAX
Time Q MIN
Totalizer 3
Belt skew
Belt Drift
:1h
: 1.00 h
Latest taring results (max. 5) T

22.11.02
16:04:05
21.11.02
16:11:22
21.11.02
16:10:53
22.11.02
16:05:22
22.11.02
16:04:43
Status Report
The status report can be printed at any time.
Reported are previous events, calibration results, and
SPC measurement values, e.g. feed rate variance.
SPC = Statistic Process Control
: 0.15 %
: 0.09 %
:0%
:0%
: 510 t
: 0.00 %
: 0.00 cm
in % of Qnenn
: 12.99 %
: 30.75 %
: 33.40 %
: 12.99 %
: 12.99 %
Test weight check of

16.06.03 16:23:17
25.11.02 09:06:28
Set/Act
0.9643
N05 BIC Active
NO
Events since power on
1
*
1
*
1
*
H03 v> MAX

C07 Set Time To Zero
E01 Power Failure
For individual data, see Service Values item.
GT
f
N

Status Report function.
Start function.
Abort printing at any time.
Zero Set before:

Zero point corrected by taring
manual/automatic zero setting.
program
or
Voltage ON-time:
Total voltage ON-time.
Feeder ON-time:
Total ON-time of conveyor belt and INTECONT.
Last password entry on:
Date of last password input for start of a service function
or parameter change.
Latest matkor change:
The matkor parameter lets you change feed rate and
totalization range.
SPC time:
Measuring time for SPC values Qmax and TQ < MIN.
Control
BV-H2214 GB
14
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SPC filter:
Filter time for SPC values mean value and variance
Mean value Imitt:
Feed rate mean value exponentially filtered using the
SPC filter time related to nominal feed rate.
Feed Rate Diagram

Printed automatically after status report, the feed rate
diagram shows the current feed rate value in percent
of nominal feed rate. The report period is determined
by Parameter K 05 SPC Time .
Variance:
Feed rate variance related to the square of nominal feed
rate.
Belt load QMAX:
Maximum belt load during last few hours limited by SPC
time related to nominal belt load.
Time Q < MIN:
Total time during which belt load was below Qmin
(Parameter F 05), evaluated over the past few hours
(SPC time).
Last taring results (max. 5):
Results (total tare) of last 5 zero point or tare corrections,
related to nominal belt load.
Test weight check on :
Date and time of last check using check weight,
performed using Weight Check CW setting program.
BIC active:
indicates
whether
automatic
compensation is active, or not.
belt
Feed Rate in Percent Pnenn

0
- 6h
- 5h
- 4h
20
40
60
80
100 120
5,000 t/h
10,000 t/h
20,000 t/h
*
*
- 3h
- 2h
- 1h
- 0h
140 %
*
*
*
>
40,000 t/h
50,000 t/h
50,000 t/h
The actual diagram resolution is higher than shown in

sample.
Feed rate
50 dots for nominal feed rate
Time
: 32 dots for time K 05
Units
: t/h, h
Initialisation : upon power-up and change of
Parameter K 05.
Symbol >
: Feed rate exceeds 140 %
influence
Events report:
lists number and type of events occurred after last
printout.
If no report has been printed yet, counting starts from
time of power-up.
Counter 3:
Belt skew:
indicates change in belt length in % of total belt length
(Parameter D06).
Belt drift:
indicates belt drift in cm.
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INTECONT PLUS
Zero Setting
The zero setting program is designed to acquire the belt

weighers zero point error over one or multiple integer
belt circuits.
In normal mode, value is used to correct current
measuring result.
If no automatic mode is selected, use program in regular
intervals.
During zero setting, totalizing counters stop counting.
Prerequisite:1. Conveyor belt totally unloaded.
If necessary, abort program.
User Start Prefeeder function, if
available.
2. Belt running,
indicated automatically.
3. No batch active; batching mode can
remain active.
Call:
G
TU
f
Program complete:
0.
Dev.
Tarkor
Upper display:
Lower display:
70.2 %
1.12 %
Deviation of zero point from

previous zero setting operation in %
of nominal belt load.
Dev = + : error increased
Dev = - : error decreased.
Deviation of zero point from basic
tare in % of nominal belt load.
Taring program corrects basic tare
during calibration.
Acquire result, or view for information and reject.
f
N
Acquire result.
Scale zero point is corrected.
Abort program.
Result is rejected.
Call Zero Setting function and start.

If belt is not running, program aborts
and requests START.
Restart prefeeder.
Event messages:
1- C7
Program running:
Zero setting time elapsed.

Deselect message, if not desired.
2- Value
0.
>0<
Tarkor
70.2 %
1.12 %
3.
Upper display:
Lower display:
Residual run time in % of total run

time.
Zero point error in %, related to
nominal belt load.
Abort program at any time.
Excessive
Zeroing range exceeded; clean
scale and retare, if necessary.
Note:
The function setting to zero can also be
started via the digital input P05. The
program is started by a positive flank of the
contact. The result is automatically accepted
if it is within the admissible zero setting limit
(5% of the nominal belt load). An
ackowledgement of the result is not
necessary. The calibration program can only
be aborted in its active phase.
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INTECONT PLUS
VBW
Read Parameters
Parameters are defined as variable characteristics or
data used to match INTECONT to the particular
application.
Parameter input is protected by password (see Enter
Parameters).
The Read Parameters function lets you view all
parameters without jeopardizing the operating
reliability.
The parameters are organized into function blocks A ,
B,... and consecutively numbered within a block.
GTf
Tf
Scroll Programming function into

display field and acknowledge.
Select Read Parameters
sub-function.
Display shows title of first parameter block.
Dialog Behaviour
Block: A
TU
fT
Scroll through parameter blocks

A, B,...
Scroll through parameters within a
block.
Nominal Feed Rate

B02 1000.0 kg/h
N
N
Return to blocks.
For more information, see Enter Parameters.

0539

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Control
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INTECONT PLUS
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Control
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18
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INTECONT PLUS
3
VBW
Control Overview
O Z1 = 1500 kg
-- I = 100 kg/h
gB
U SCROLL
T
i RESET
G
O
N
f
P
FUNCTION
Start/Stop
if preselected
Select lower display line and functions.

(1) Counters Z2, Z3
(4) Belt load Q
(2) Feed rate I
(5) Belt speed v
(3) Feed rate Ir in %
Reset counter(s)
(1) Enter number of desired counter (1 or 2).
(2) Use ENT key
to acknowledge.
(3) Use ESCAPE key
to abort input.
(4) Use DELETE key
to delete faulty digits.
Call function distributor and event messages
(1) SCROLL keys let you select desired function.
If an event is available, Display Event function is preselected.
(2) ENTER key lets you activate function.
(3) SCROLL keys let you view available event messages one after the other.
(4) ESCAPE key lets you return to normal displays.
DELETE
Acknowledge event messages, delete inputs.
ESCAPE
Abort function and return to normal displays.
ENTER
Acknowledge input, e.g. setpoint,

start functions, e.g. Display Events (see FUNCTION).
DATA
Prepare input, e.g. parameters.
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Control Overview
BV-H2214 GB 19
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Control Overview
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4
VBW
Operating Principle
A belt weigher is designed to continuously weigh the

material amount transported on a conveyor belt.
Belt Load:
The material is guided to a weighing platform
arranged under the belt and limited by 2 carrying
idlers. Via one or multiple weighed idlers, the platform
load excerts a force on load cell (L/C).
The deflection for measurement is 0.2 mm. The
weighed idlers are connected with the frame structure,
e.g. with the use of a leaf spring parallel system.
Belt Speed:
A further measure for feed rate is belt speed v,
acquired with the use of speed transducer D and
translated into a corresponding pulse frequency.
If belt load is constant and more approximate
accuracy will suffice, speed measurement can be
omitted.
Feed Rate:
INTECONT normalizes physical units kg/m and m/s.
Multiplication of the two values results in feed rate I.
I
v
Q
QB
Leff
in kg/s
in m/s
in kg/m
in kg
in m
I in kg/h:
Proportional to platform load, the load cell output
voltage is amplified and transferred to the INTECONT
microprocessor with the use of an analog-to-digital
converter.
The white triangle indicates the load distribution on a
single-idler platform scale. Only half of the materials
weight force is applied to the weighed idler.
I
in kg/h
As to the rest,
see above.
Automatic Belt Influence Compensation (BIC):
The translation of load ratio into platform length has

become accepted usage in weighing technology.
Leff = effective platform
length
Lg = total platform length
For weighing platforms equipped with multiple
weighed idlers, factor 1/2 is different.
Belt load in kg/m is thus:
QB = total load on
weighing platform.
Not even the best of conveyor belts is perfectly even;

particulary in welding points, the belt will be heavier
and stiffer. The figure above shows the relations over
one belt circuit in exaggerated fashion.
0539

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Operating Principle
BV-H2214 GB 21
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INTECONT PLUS
Therefore, a high accuracy can normally be ensured

only over entire belt circuits, i.e. over the mean value.
INTECONT is able to acquire and correct this
influence with the use of a belt circuit sensor and a
metal belt mark.
This considerably increases the scales short-term
accuracy.
To enable variations to be considered during
operation, the belt influence is continuously
measured. The compensation adaptively follows up,
also if material is fed.
Measurement at the point of discharge (CPD):
0
Start batch and conveyor belt.
Abort batch
or
resume at any time.
Reduce belt speed, change over to dribble feed.
Stop conveyor belt.
For constructional reasons, the weighing platform is

not directly located at the point of material discharge.
Therefore, if belt load varies, the feed rate measuring
result does not exactly correspond to the current feed
rate at the point of discharge.
A special speed-dependent delay elements shifts the
measurement to the discharge point.
To do so, no special load transducers are required;
however, the additional use of the automatic belt
influence compensation is reasonable.
Drive stops, batch setpoint is reached.
Start batch and conveyor belt.

Open prefeeder.
Batching:
Stop belt, if necessary; cut off belt and prefeeder

drive.
In batching mode, a preselected material amount is

fed. When batch setpoint is reached, batching stops.
Batching can be controlled via conveyor belt drive or
material prefeeder.
Resume batching.
Changeover to dribble feed is possible, but not

always reasonable.
Control via belt drive:
Stop prefeeder if precalculated distance to

setpoint is reached.
In this mode, the conveyor belt is still fully loaded after

complete batch.
Batch complete.
Conveyor belt continues running for approx. 1/2
belt circuit.
Control via prefeeder:

Batch complete, conveyor belt is empty.
0539
Operating Principle
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INTECONT PLUS
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Dribble feed and cut-off point are self-optimizing, i.e.

they are automatically corrected after every batch.
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Operating Principle
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INTECONT PLUS
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Operating Principle
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INTECONT PLUS
5.
VBW
Technical Data
Panel-mounting unit: VEG 20600/20610

Front panel:
96 x 288 mm
Panel cut-outs
: 88 x 282, wall thickness
max. 10 mm
Mounting depth : min. 225 mm
(including 50 mm for
connectors)
Protected to
: IP 20, front to IP 65
Material
: plastic grey to RAL 7022
Display
: fluorescent, 2 lines of 20
characters, 6 mm high
Keyboard
: flexible membranes with
tactile touch
Signal lamps
: LEDs, 2 x green, 3 x red
Power supply
: 24 V(DC) 50 % -25%,
max. 1 A,
no fuse, pole-reversal
protective circuit
Ext. power supply : 90...264V/ 50HZ...60HZ
Surface-mounting unit: with panel mounting unit

VEG 20...
Wall-mounting housing
Measuring
systems
Feeding
systems
Protected to
Material
Voltage supply
Extension
: width x height x depth

500x600x300mm
: IP 65
: steel sheet, 1.5 mm, grey
: 90...264V/50Hz...60Hz
: Feed unit controller
Environment
Temperature
Humidity
Interference
immunity
Interference
suppression
Z1 = 2500 kg
I = 0 kg/h
: width x height x depth

410x330x236mm
Housing safety
EC recommendations
: -25 C ... +45 C,

tested to -40C
: Class F (DIN 40 040) *
: to IEC 801
: to VDE 871, EN 55 011
: to IEC 348
: CE label
* Tropical version (class R) upon request

n
Storage temperature
-40 C ... +60 C
Connectors
Plug/screw connectors (Phoenix Combicon),
non-confusible
Control outputs
Number
Base board
Option card
Load
0539

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Technische
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:
:
:
:
8 N/O relay contacts

3
5
max. 230 V(AC)
8 A resistive load, 1 A
inductive
Technical Data
BV-H2214 GB 25
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INTECONT PLUS
If error message CPU Not OK is output, all contacts

open.
n
:
:
:
:
5
3
2
24 V(DC) +/-30 %, 5 mA,
galvanically isolated
Control inputs (NAMUR)

Number
Type
: 2
: NAMUR (DIN 19234),
short-circuit and cable
breakage monitoring
n
Analog output
Number
Base card
Option card
Current
Raise
Load
Reference
2
1
1
raise ...20 mA impressed
0... <20 mA
max. 500 ohms
0 V by user,
galvanically isolated
: 12 bits +/- 1 d
Data format
Isolation
Connectors
Character map
n
If error message CPU Not OK is output, output

signal turn 0 mA.
Analog input
Number
Current
Raise
Load
Reference
:
:
:
:
:
1
raise ...20 mA impressed
0... 20 mA
500 ohms
0 V internal,
galvanically non isolated
: 10 bits +/- 1/2 d
: <0.4% over entire
temperature range
Resolution
Acuracy
: max. 10 Hz
: selectable 50...1000 ms
: 24 V, max. 100 mA
optionally active low or active
high,
galvanically isolated,
short-circuit-proof, limited to
apr. 350 mA,
negative amounts are stored
internally and must be
compensated by positive
amounts before new pulse is
output.
This ensures integral
accuracy also with minimal
belt load.
Serial printer interface

Number
Type
:
:
:
:
:
:
:
Resolution
External totalizing pulse counter

Frequency
Pulse length
Output
Control
Number
Base card
Option card
Type
: 1 (option card)
: RS 232 (V24), max. 38400
baud
: 8 data bits, 1 stop bit, no
parity
: galvanically non-isolated
: Phoenix MSTB, contat
spacing 3.5 mm, max.
1.5 mm2
: ISO-Latin-1 (ISO-8859-1)
Load cell connection

Voltage supply
: +/- 6 V AC (+/-3 %)
(apr. 66 Hz
short-circuit-proof
Measuring cycle : 100ms
Resolution
: 24 Bit
Load
: R (load cell) = min. 80 ohms
Cable length
: max. 30 % voltage drop,
max. 500 m
Measuring range : -20mV....+50mV
with VLW:
-1.6mV...min. 32mV
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Technical Data
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VBW
Serial interface for service PC

Number
Type
Data format
Isolation
Connectors
: 1
: RS232; RS422 or RS 485
max. 19200 baud
: 8 data bits, 1 stop bit, odd
parity changeable to even or
no
: galvanically non-isolated
: Phoenix MSTB, contact
spacing 3.5 mm, max. 1.5
mm2 or 9-pole D-Sub HD20
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Technical Data
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Technical Data
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INTECONT PLUS
6.
VBW
Characteristics
Power failure
Scale data, calibration values, counter readings
and pulses pending remain stored after power
failure for an unlimited period of time. The internal
clock continues running for approx. 5 days.
Dialog language
for error messages, operation, and service
programs.
Select:
VOLTAGE
OK (green)
PROCESSOR OK (green)
ALARM
(red)
MIN
(red) MIN feed rate value
MAX
(red) MAX feed rate value
n
Events and faults are displayed in form of an

alphanumeric code. Call clear text of consecutive
events via keyboard.
Events are organized into Alarms and Warnings,
with and without acknowledgement. Alarms stop
scale; warnings dont.
All alarms are additionally reported via relay
output.
DEUTSCH
ENGLISH
FRANCAIS
ESPANOL
ITALIANO
NON-SI units:
kg ,
t ,
m ,
kg/h
t/h
cm
lb ,
t ,
f ,
lb/h
t/h
inch
Start/Stop totalizing counter

Select using Parameter B06.
Displays
Upper display:
Lower display:
0539
Totalizing counters 2 and 3
Feed rate absolute
Feed rate relative
Belt speed
Belt load absolute
Belt load relative
Batch data
Operating philosophy
Operator prompting through multi-level menus.
Important configuration and calibration functions
are protected by password.
(see Parameter List)
Event messages
Units (selectable)
SI units
Signal lamps (top down)
Belt speed
For simple applications, speed measurement can
be omitted.
Zero setting
Zero setting can be performed
1- manually via keyboard
2- automatically, if belt is empty.
The maximum admissible zero setting elevation is

monitored.
Select for lower display using cursor keys.

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Characteristics
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VBW
n
INTECONT PLUS
n
Taring
Designed to zero the basic tare load, the taring
program on principle has the same function as the
zero setting program. However, tare elevation is
not monitored, and the call is protected by
password.
2 separately selectable limit values for monitoring

of signal lamps and relay outputs.
Any event can be reported by message.
MIN/MAX for
(1) Feed rate
(2) Belt load
(3) Belt speed
Automatic belt influence compensation (BIC)

Using an additional belt circuit sensor and a metal
belt mark, the dynamic zero point influence of the
conveyor belt can be compensated during
operation (with and without material).
Switching threshold, relay outputs and event class

can be defined individually for all 6 possibilities.
n
This considerably increases the belt weighers

short-term accuracy.
n
Define individually for feed rate, belt load and belt

speed.
n
(1) Voltage ON-time

(2) Scale ON-time
Belt drift display
(3) Zero setting required

n
Batching mode
(2) With clearance of conveyor belt.

Controlled is the material prefeeder.
Cut-off point and start of dribble feed can be
adapted automatically in either case.
Statistic Process Control (SPC)

Mean values, variances, maximum value storage,
zero settings tables, etc. are available in form of
service values.
(1) Without clearance of conveyor belt.

Controlled is the belt drive motor.
Maintenance hints
Display event on screen.
For prerequisites, see BIC.

n
Display filter
Measurement at the point of discharge (CPD)

A special speed-dependent delay element shifts
the point of measurement to the material
discharge point where the material amount
discharged is acquired.
MIN/MAX messages and outputs
Adaptions
The electrical system needs not be redesigned,
adapted, etc.
Zero drop out

Used to suppress totalization upon measurements
around zero, for counter to stop while belt is being
unloaded.
Deselect function, if not desired.
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Characteristics
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n
VBW
n
Calibration
Calibration as such is not necessary.
All you have to do is enter some constructional
data on load cells, speed transducer, belt
inclination, etc. INTECONT uses these data to
compute all requisite display normalizations.
Check, or recalibration, can be effected in two
ways:
a) Using material
Enter check result into INTECONT, and
measuring result will be corrected.
b) Using check weight
A special check program lets you check
normalization, or if certain technical data are
not exactly known (lever ratio, belt inclination,
etc.), correct them.
Digital Outputs
Number
Name
Default Value
Q04
Q05
Q01
Q02
Q03
Q11
Q12
N15
N16
N17
Q06
Q07
Q08
Q09
Q10
DO I-MIN
DO I-MAX
DO ALARM
DO START Feeder
DO START Scale
DO Full Feed
DO Dribble Feed
DO Belt Skew
DO Belt Drift
DO Belt Slip
DO Q-MIN
DO Q-MAX
DO v-MIN
DO v-MAX
DO Batch Active
DO4
DO2
DO3
DO1
In subsequent operation, this program can be

used to detect mechanical changes, e.g. platform
distorsion after settling of foundation.
n
Digital inputs
Number
Name
Default Value
P03
P01
B06
P02
N04
B03
P04
P05
N18
DI Ackn. Events
Release
START Source
DI Abort Batch
Sensor Source
Tacho Source
DI Start
DI Zero Set
Freeze BIC
DI1
DI3
(OP)
DI6
DI7
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Characteristics
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INTECONT PLUS
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Characteristics
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7
VBW
Setting Programs
Function Distributor
The function distributor lets you access all setting

programs.
Programming and Calibrating functions lead to further

menus you can move through using cursor keys.
B=

If no event is available, function selected last
is displayed.
f
N
Abort Batch
Deselect Batch
Batch Number
Print Batch
Make-up
Next = W/Belt Empty
Start function.
Return to normal displays, or
abort function.
F u n ctions
Displa y Result s
If batching mode is selected, additional

functions can be accessed in main distributor.
S=
Calibrating functions protected by password.

Prompt is output after call of function only
E=
An event is available.
Z=
Activated via parameter.
Moving through function distributor has no effect on

weighing functions.
TU
Move through function distributor.
Display Results
E
Display Check
START/STOP Feeder Z
Service Values
Batch Number
B
Print Counter Readings
>0< Zero Set
START/STOP Keyboard Mode
START/STOP EasyServe
Programming
Calibration Functions
S
Read Parameters
Enter Parameters
Load Default Par.
Print Parameters
Print Status Report
0539
S
S
START/STOP Simulation
Tare
S
Weight Check
S
Imp/Belt Circuit
S
Set Time
S

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Setting Programs
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INTECONT PLUS
There are 3 setting programs designed to ease initial

calibration and recalibration.
(1)
Pulses/Belt Circuit
LB
(2)
Taring
TW
(3)
Weight Check
CW
Upon initial calibration, perform functions in the above
order of sequence.
All functions can be reached using the CALIBRATION
function and are protected from unauthorized use by
password.
During program run until acknowledgement
(1) no totalization takes place
(2) analog outputs are set to offset values
(3) no event messages are suppressed
(4) all BIC functions are cut off.
The operating sequence is the same with all
programs.
G
TUf
B7f

Scroll CALIBRATION FUNCTIONS
into lower display field and
acknowledge.
Enter password 07734.
Display shows a setting program, e.g. TW: Tare.
Call setting program LB: IMP/BELT only

(1) upon initial calibration
(2) after mounting new belt or considerably varying
belt tension
(3) after having changed parameter B 04
Charact.Val. vs or B 05 Nominal Speed (in case
of scales with and without speed measurement).
Program acquires the number of speed transducer
pulses for one belt circuit and uses the number of
pulses as belt circuit code for the following programs:
(a) Manual or automatic zero setting
(b) Taring
TW
(c) Weight Check
CW
Upon initial calibration, first call setting program LB.
This also applies to scales without speed
measurement.
Prerequisites : (1) Before calling program, measure
time of one belt circuit with
maximum possible accuracy and
enter into Parameter C 02.
(2) Deselect batching mode.
(3) Ensure conveyor belt is running.
Sequence:
Gf
TU
f
N
S5 TW. Tare
f
N
Belt Circuit LB
Start setting program.

For approx. 2 min., Calibration menu can be
recalled without password input.
Function distributor, calibrating

functions, password
(see Calibrating Functions)
Scroll LB: Imp/Belt
into lower display field.
Start.
Abort at any time.
Setting programs do not control belt drive and

prefeeder.
If any condition is not met, setting program aborts
and a corresponding message is output.
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Setting Programs
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INTECONT PLUS
Program running:
>.
LB :
5.6 s
1500 Imp
VBW
Error message : If sensor is improperly recognized
(sensor pulses measured do not
correspond to parameter setting),
message Sensor Error is output
and setting program aborts. For
troubleshooting, see
Commissioning/Belt Run
Monitoring item.
Upper display : residual run time in seconds

Lower display : added speed transducer pulses
Program complete:
>.
LB: v
0.095 m/s
451251 I/B
Upper display : belt speed mean value over total run

time
Lower display : Pulses/belt circuit total
f
N
Accept result and enter into

Parameter D 06.
Reject result.
The sequence is the same if no speed measurement

is provided.
Special Messages:
(1)
START if belt is not running
(2)
ABORTED
Tare TW
The taring program acquires the belt weighers zero
point error over one or multiple integer belt circuits
and uses value to correct current measuring result in
normal mode.
On principle, taring program is identical with zero setting program.
Tare
: acquire basic tare (weight of
mechanical system, conveyor belt,
etc.) upon commissioning, service
and maintenance.
Set to zero
: acquire zero point deviation during

operation, e.g. contamination.
Unlike the zero setting program, the correction

amount of the taring program is unlimited.
After taring, the admissible correction amount of the
zeroing program relates to the new reference value.
Prerequisites : (1) Conveyor belt totally unloaded.
Control prefeeder using the
START/STOP Feeder function.
(2) Clean mechanical scale system in
weighing area.
Normal deposits immediately
recurring during operation need
not be removed.
(3) Deselect batching mode.
(4) Ensure conveyor belt is running.
Corresponding hint is output
automatically.
Attention!
0539
If a belt circuit sensor is present (N03 = YES),

program sequence slightly differs.
Running
message
: E-PROG active (lower display)
Complete
message
: ... - I/B
value flickers upon every belt circuit.
Operation
: as described above

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Sequence:
Gf
TU

functions, password
(see Calibrating Functions)
Scroll TW: Tare
function into lower display field.
Technische
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Setting Programs
BV-H2214 GB 35
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VBW
f
N
INTECONT PLUS
(2)
If deviation (dev) exceeds 20%, check scale for

mechanical faults, e.g. jammed material
particles.
(3)
If BIC is active (M05 = YES), BIC tare vectors

are initialized along with taring program.
Start function.
Abort function at any time.
Program running:
Weight Check CW
>.
TW:
Tare
9 0. 2 %
5 2. 3 5
Upper display : residual run time in % of total run time

Lower display : continuously meaned tare in % of
nominal belt load
Program complete:
>. Dev.
Tare
This program lets you check the INTECONT

measuring range.
Load weighing platform with a known check weight
and acquire platform load mean value over one or
multiple integer belt circuits.
INTECONT compares the result with defined setpoint
and displays value. Automatic correction does not
take place.
Prerequisites : (1) Tare or zero set
(2) Enter check weight into Parameter
C 08.
Select check weight between
30...100 % of nominal platform
load Q0.
2.45 %
53.20
Q0
q0
= q0 * Leff
= nominal belt load
Parameter D 01
= eff. platform length
Parameter C 05
Leff
(3) Apply check weight in proper

location.
(4) Select batching mode.
(5) Start conveyor belt.
Corresponding hint is output
automatically.
Upper display : deviation of tare value from previous

taring result
in % of nominal belt load
dev = + : tare has increased
dev = - : tare has decreased
Lower display : mean value of total tare
in % of nominal belt load
f
N
Accept taring result and enter into

Parameter D 04.
Set tare correction (D05) to zero.
Sequence:
Gf
Reject result, i.e. scale is not tared.
Special Messages:
(1)
START if belt is not running
(2)
ABORTED
Note:
(1)
Related to nominal belt load, tare value can
exceed 100%.
Setting Programs
BV-H2214 GB
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TU
f
N

functions, password
(see Calibrating Functions).
Scroll CW: Weight Check
function into lower display field.
Start function.
Abort function at any time.

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Program running:
>.
CW:
Set / Act
Evaluating Result:
Error < 1 %
: KOR = 0.99...1.01
Scale OK, no further action required.
51,4 %
0,9842
Upper display : residual run time in % of total run time

Lower display : continuously meaned SET/ACT
measuring result
Program complete:
>.
VBW
CW: 1200,34 kg
COR 0,99915
Error < 5 %
: KOR = 0.95...1.05
Enter KOR value into Parameter D
02.
This make good sense only if
parameter has not yet considered
result of check using material.
Error > 5 %
: KOR < 0.95, or KOR > 1.05

Multi-percent deviations suggest
faulty data input (e.g. belt incination,
lever arms not exactly known), and/or
mechanical faults (misalignment,
distorsions).
Check does not consider Parameter D 02 Range

Correction, so that check program will indicate
same error quotient KOR after check.
Upper display : Fictitious material amount fed over

run time *.
Lower display : mean value KOR of SET/ACT over
total run time
fN
Exit program.
Since result is not
AUTOMATICALLY ACQUIRED,
both keys are equivalent.
Special Messages:
(1)
START
if belt is not running
(2)
ABORTED (irrelevant)
Lets you check scale zero point without check

weight.
Display format: xxxxxxx,yy kg
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Setting Programs
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INTECONT PLUS
Set Time
Unlike the other programs, date and time can be

changed in START and STOP states of scale and
read off under SERVICE VALUES.
Gf
TU
f
N
033
f
O
Function distributor, Calibrating

functions, password
(see Calibrating Functions).
Scroll Set Time function into lower
display field.
Call menu.
Simulation Mode
The Simulation Mode lets you check all scale
functions without material at the time of
commissioning.
During simulation, scale is cannot operate in normal
mode.
Gf
Function distributor, Calibration

functions, password (see
Calibration Functions).
TU
f
Scroll START Simulation into lower

display field.
Start program.
Abort at any time.

Year, e.g. 03
Enter month, day, hour, minute,
second.
Acknowledge every input.
As soon as seconds are
acknowledged, new date is stored,
and complete date is briefly
displayed.
Display
Event message S7
In upper line, the = symbol
flashes.
Function can be cut off in the same way (STOP

Simulation).
Features:
Delete digit entered last
After power failure, time remains stored for min. 5

days.
1.
All operating functions can be performed.
2.
Feed rate actual value is set to nominal rate.
3.
Belt load and speed measurement are active.
4, All control inputs/outputs operate as usually.
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Setting Programs
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INTECONT PLUS
8
VBW
Service Values
The Service table includes detailed system

information.
Call does not affect weighing functions.
GT
f
TU
N
6)
Input switching condition

I+ : DI = 1 1 1 1 1 + 0
1" = contact closed
0" = contact open
Call SERVICE VALUES function and

activate.
Inputs 4 + 5 on option card

N = no option card
Move through service values.

Inputs 6 + 7 designed as Namur inputs
(belt sensor, tacho)
+ short circuit; - cable breakage;

1" = sensor covered; 0" = sensor free
Displays:
7)
1)
VBW 20600-01 2482
Version number
2)
HW = 1
Hardware version
3)
Option card:
0
1
(not available)
(available)
EL = 22 h
Voltage ON-time
Monitored: Parameter K 01, Message S4
8)
ED : >0 = 95 min
Scale ON-time after last taring, or last manual or
automatic zero set.
O Z1 =
1500100 kg
Opt..Card : 1
Prerequisite
Monitored
9)
4)
Date and time
5)
Relay outputs switching condition

I + DO = 1 1 1 0 0 0 0 0
1" = contact closed
0" = contact open
Outputs 4-8 on option card
N = no option card
: Totalization ON, conveyor belt

may be stopped.
: Parameter H 07, Message C7
ED = 19 h
Scale and conveyor belt ON-times
Prerequisite
Monitored
: Totalization ON
: Parameter K 03, Message S3
10) Tacho = 96.6 Hz

Speed transducer input frequency
Select frequency between 0.4...3000 Hz.
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Service Values
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INTECONT PLUS
11) aw = 30.988 %
17) Belt Drift tr = 0.12 cm
Load on load cells related to total of load cells

rated capacity.
If value exceeds 100 %, load cells are
overloaded.
From 110 % onward, message H4 :
The arrows indicate the direction of drift.
L/C Input > MAX is output.

12) vap = 0.883168 mV/V
Unnormalized load cell amplifier output value
delayed for point of material discharge (CPD
active).
13) bic = 2.34001 mV/V
Prerequisite:
Monitored :
see Slip
Parameters N09-N12, messages
C3 and C4
18) Pulses of sensor area Imp.S. = 386

with active BIC (Belt Influence Compensation)
Measured pulses of sensor area. If belt sensor is

properly located, the following result is expected:
Imp.S. = 0.5 * sensor length * 0.01 * charact. value vs
14) L/C = 1.383257 mV/V

(Gross).
Acquired before belt influence compensation and
delay for point of discharge.
Prerequisite: see Slip

19) Mean value Imitt = 22.27 %
Feed rate mean value related to nominal feed
rate
Filter
Prerequisite
Initialization
15) R_L/C = 300 ohms

Load cell resistance value
: Exponential, Parameter K 06
: Totalization ON, V > Vmin
: Zero at power ON
20) Variance var = 0.02 %
16) Slip s = 0.25 %

Variation in belt length in % of total belt length
(Parameter D 06).
Prerequisite:
Monitored
Belt sensor active (N03), sensor

area on conveyor belt (N04).
: Parameter N13, message C8
Feed rate variance related to nominal feed rate

square.
Filter
Prerequisite
Initialization
: Exponential, Parameter K 06
: Zero at power ON
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Service Values
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INTECONT PLUS
The variance indicates belt load instability.
Higher values suggest poor discharge behaviour
of material.
VBW
25) AO2 = 10.00 mA
Analog output 2 output current
(on option card)
21) Max. belt load QMAX = 57 %
26) ZE = 53
Maximum belt load during preselected SPC time
related to nominal belt load.
Time
Evaluation
Prerequisite
Initialization
Max. display
:
:
:
:
:
SPC time, Parameter K 05

SPC time continuously floating
Totalization ON, V > Vmin
Zero at power ON
255 %
Pulses output across pulse output of external

totalizing counter, counted from command Reset
Counter 1
27) ZO = 1
Pulses pending.
If value constantly exceeds zero, pulse frequency
surpasses 10 Hz.
Increase smallest display digit of Counter 1
(Parameter B 07).
22) No load percentage TQ < MIN = 23 %

Total time during which belt load is below Qmin
(F 05), related to SPC time, Parameter K 05
Evaluation
Prerequisite
Initialization
: SPC time continuously floating

: with Q = Qmin at power ON
28) AI = 12.54 mA
Analog input input current
29) CS = 10851
Check sum of scale software
30) CS_b = 10851
Check sum recomputed in cycles. If value
CS_b differs from CS, a serious fault is
present. Contact the Schenck Service.
31
23) Last taring T (date) 23.51 %

Date and total tare related to nominal belt load
Prerequisites : Correct zero point using taring
program or manual/automatic
zero setting function.
Manual changes of correction
parameters are not recorded.
Displayed are the 5 last taring or zeroing
operations.
BIC-N = 27
Counter reading indicating how often BIC sensor
has been recognized
32. BIC-E = 5
Counter reading indicating faulty BIC circuits not
entered into tare vectors
33. ES-Version = 11
Current EasyServe Version
24) AO1 = 4.15 mA

Analog output 1 output current
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Service Values
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INTECONT PLUS
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Service Values
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9.
VBW
Parameterization
General Information
Parameters are variable characteristics or data used
to match the INTECONT to the application.
Display units and format
Limit values
Nominal and calibration data, etc.
Some parameters can be selected in accordance with
the requirements (e.g. display formats), others have to
be taken from Spec Sheets supplied.
During parameter input, all functions are maintained.
However, during operation, only parameters with no
influence on measurement, e.g. display filter, should
be changed.
Default Parameters:
All parameter are preset with default values. These
are proven suggestions and can normally be used as
defined.
The default values can be loaded using sub-function
Load Default Parameters.
There are two types of parameter:

Selection parameters
Let you select from various
options, e.g.
WARNING, ALARM.
Numeric parameters
Enter numeric value, e.g.

nominal feed rate.
Call Parameter Menu
G
TUf
TUf
Bf

Scroll PROGRAMMING function
into lower display field and
acknowledge.
Select ENTER PAR. function.
Enter password 07734.
Display shows title of first parameter block.
Identification
Dialog Behaviour
Block: A
The parameters are organized into function blocks A,

B, ... and, within a block, described by
name
number 1, 2, 3 ..
and
value.
Values differing from default are identified by a *
before the block letter.

For approx. 2 minutes, parameter
menu can be recalled without
password input.
Nominal Feed Rate

B02 1000.0 kg/h
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Parameterization
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INTECONT PLUS
Preselect Parameters
Enter Parameters
P
TU
Rated Data
Block: B
46
B9
1. Block letter
TU
f
Move through blocks A, B ..., up and

down.
Block letter flashes.
Select block.
Parameter selected last is
displayed.
f
O
N
Prepare input.
Selection parameters:
Value flashes.
Scroll desired value into lower
display field.
Go to the left (4) or to the right (6),
see Hardware Configuration.
Numeric parameters:
Feature - - - - - - - - - - - - - - - Enter value using keypad.
Acknowledge input.
Next parameter is displayed.
Delete digits.
Abort input.
OFF key 0 is active always; ON key I, only after

completed parameter input.
2. Parameter number
Nominal Feed Rate

B02 10000.0 kg/h
TU
f
NN
Move through parameter numbers

within a block.
Parameter number flashes.
Move through parameter numbers
independent of block (UP only).
Return to block titles.

Return to normal mode.
0539
Parameterization
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INTECONT PLUS
Load Default Parameter
Hardware Configuration
When parameterizing the hardware used, the source
determines whether unit, channel and level must be
indicated, or not. The table below will assist you in
selecting the hardware configuration:
Source
Unit
Channel
VBW
Level
FB
Lets you load the default settings.

Function is protected by password and YES/NO
prompt.
Attention!
All variable parameters and calibration values are
reset.
G Call
PROGRAMMING function and
DEFAULT PARAMETERS.
B1 YES
=1
f Acknowledge
NO
=0
selection.
OP
v
-
Power Failure
DI
I+
DI1-DI7
HI, LO
DO
I+
DO1-DO8
HI, LO
AI
I+
Parameters remain stored for an unlimited period of

time.
As you can see, with Fieldbus [FB", Control Unit

(OP), Speed (v) and Not Assigned (-)] no additional
information is required.
Digital Inputs (DI) and Digital Outputs (DO) require
unit, channel and level to be indicated.
With Analog Input (AI), the unit is firmly set to I+.
Sample:
Parameter B06 START Source determines from
where the scale is started.
Description
Source
B06 START Source
OP
Alternatives
FB, DI, v
On standard, the scale is started from INTECONT

keyboard (OP).
Alternatively, fieldbus, digital input (DI) or speed (v)
can be selected. If DI is the desired source,
additionally indicate channel and level (see Hardware
Configuration table); the unit is firmly set to I+.
0539
4
6
Keys 4 (go to the left) and 6 (go to

the right), let you shift between
source, channel and level.

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Parameterization
BV-H2214 GB 45
767
VBW
INTECONT PLUS
Block F
Parameters Overview
This list applies to software: VBW 20600-05
Block A
A 01 Language
A 02 Units
Block B
B 01
B 02
B 03
B 04
B 05
B 06
B 07
B 08
B 09
B 10
Feed Rate Unit

Nominal Feed Rate
Tacho Source
vs Charact. Value
Nominal Speed
START Source
FMZ1 Unit
FMZ1 Pulse Dur.
FMZ2 Unit
FMZ3 Unit
Block C
Dialog Behaviour
ENGLISH
SI
Rated Data
- t/h
400,0000 t/h
DI I+, DI7 HI
50.26 I/m
1,0000 m/s
OP
t
0 ms
t
t
F 01
F 02
F 03
F 04
F 05
F 06
F 07
F 08
F 09
F 10
F 11
F 12
Value for I-MIN

Event Class I-MIN
Value for I-MAX
Event Class I-MAX
Value for Q-MIN
Event Class Q-MIN
Value for Q-MAX
Event Class Q-MAX
Value for V-MIN
Event Class V-MIN
Value for V-MAX
Event Class V-MAX
Belt Circuit No.

Belt Circuit Time
L/C Charac. Value
L/C Rated Cap.
Eff. Platf. Length
Lever Ratio
Angle a
Check Weight
Block D
D 01
D 02
D 03
D 04
D 05
D 06
Nominal Belt Load

Span Correction
Total Tare
Basic Tare N
Tare Correction T
Belt Circuit Char
Block E
E 01
E 02
E 03
E 04
E 05
E 06
Elevation AO1
Elevation AO1
Limit Value AO1
Source AO2
Elevation AO2
Limit Value AO2
Parameterization
BV-H2214 GB
46
5,0 %I
WARNING 2
120,0 %I
WARNING 2
20,0 %Q
WARNING 2
120,0 %Q
WARNING 2
5,0 %V
WARNING 2
120,0 %V
WARNING 2
Block G
Filter Setting
G 01
G 02
G 03
G 04
G 05
G 06
3,0 s
3,0 s
3,0 s
3,0 s
1,0 s
3,0 s
I Display
I Analog Output
Q Display
V Display
L/C Filter
Afterfl. Time
Calibrating Data
Block H
C 01
C 02
C 03
C 04
C 05
C 06
C 07
C 08
Limit Values
1.00
30.0 s
2,8500 mV/V
220,000 kg
1,000 m
1,0000
0.0 degrees
50,000 kg
Calibrat. Results
111,11 kg/m
1,0000
0,00 kg/m
0,00 kg/m
0,00 kg/m
1000 000 I/B
Analog Output
I
4,00 mA
20,00 mA
Q
4.00 mA
20.00 mA
Technische
Redaktion BVED
H 01
H 02
H 03
H 04
H 05
H 06
H 07
H 08
H 09
H 10
H 11
H 12
AUTO Zero Active

Limit Value Diff.
Mean Limit Value
Zero Set Limit
Tare Corr. > MAX
Zero Set Time
Time Elapsed
Print Result
ZDO Active
ZDO Limit
Zero Set Diff.
Tare Diff. >MAX
AUTO Zero Set

NO
0,50 %Q
1,00 %Q
5,00 %Q
WARNING 1
4h
IGNORE
NO
NO
1,00 %Q
5,0 %
WARNING 2
Block I
Batch Mode
I 01
I 02
I 03
I 04
I 05
I 06
I 07
I 08
I 09
100,000 kg
0,000 kg
1,0
1,0 %
1,0 %
WARNING 1
NO
IGNORE
OP
Batch Dribble FD
Batch End
Adaption Fact.
Batch Tolerance +
Batch Tolerance Out of Tolerance
Belt Empty
Batch > Setp.
Batch Source

and copyrights.
0539
768
INTECONT PLUS
Block J
J 01
J 02
J 03
J 04
J 05
J 06
J 07
J 08
J 09
J 10
J 11
J 12
J 13
J 14
J 15
J 16
J 17
J 18
J 19
J 20
J 21
J 22
Baud Rate
AUTO Print
Print Subtotal
Reset Print FMZ 1
Reset Print FMZ 2
Print Page Length
Batch Setp.Line
Batch Setp.Col.
Batch Act.Line
Batch Act.Col.
FMZ 1 Line
FMZ 1 Column
FMZ 2 Line
FMZ 2 Column
Date/Time Line
Date/Time Column
Event Line
Event Column
Set Line to Zero
Set Column to Zero
Line Number
Column Number
Block K
K 01
K 02
K 03
K 04
K 05
K 06
Maintenance Elec.
Event Maint. EL.
Maint. STR-Meter
Event Maint. Run.
SPC Time
SPC Filter
Block L
0539
L 01
L 02
L 03
L 04
L 05
L 06
L 07
L 08
L 09
L 10
L 11
L 12
L 13
L 14
L 15
L 16
L 17
L 18
Protocol Type
Host Timeout
Comm.-Error Host
Address
Resolution
Word Sequence
Physics
Baud Rate
Format Data
FLOAT Format
Physics
Baud Rate
Format Data
Address
FLOAT Format
Configuration
Address
Baud Rate

and copyrights.
Printer Setting
9600
NO
Error
NO
NO
72 lines
6
8
7
8
8
8
9
8
4
8
12
8
10
8
3
8
Maintenance Int.
3000 hours
WARNING 1
3000 hours
WARNING 1
8 hrs
1,00 hour
Comm. Fieldbus
NO
10s
IGNORE
1
4096
I:hrd/L:sdd
RS 485
9600
8-E-1
SIEMENS-KG
RS 422
9600
8-E-1
16
I/hr/L:hr
FIXED-1
16
125k
VBW
L 19
L 20
L 21
L 22
L 23
L 24
L 25
L 26
L 27
L 28
L 29
L 30
L 31
L 32
L 33
L 34
L 35
L 36
L 37
L 38
Configuration
Byte Sequence
Word Sequence
WEB coding
DHCP
IP-Address 1
IP Address 2
IP-Address 3
IP-Address 4
Net Mask 1
Net Mask 2
Net Mask 3
Net Mask 4
Gateway 1
Gateway 2
Gateway 3
Gateway 4
Byte sequence
Word sequence
Configuration
Block M
M 01
M 02
M 03
M 04
M 05
Feeder Active
Setting Time
Feed Distance
Motor STOP aft. ST
Change-over FF/DF
Block N
FIXED-1
Low-High
I:hr/L:hr
XML
NO
192
168
240
1
255
255
255
0
192
168
240
0
High-Low
I:std/L:std
FIXED 1
Feeder Control
NO
0,0 s
0,00 m
NO
YES
Scale Monitoring
N 01 CPD Active
N 02 Platf.Dis.Length
N 03 Belt Sensor Active
N 04 Source Sensor
N 05 BIC Active
N 06 Sensor Length
N 07 Sensor Width
N 08 Sensor Offset
N 09 Belt Drift
N 10 Belt Drift Event
N 11 Belt Skew
N 12 Belt Skew Event
N 13 Slip Limit
N 14 Slip Event
N 15 DO Belt Drift
N 16 DO Belt Skew
N 17 DO Slip
N 18 Freeze BIC
NO
0,00 %LB
NO
DI6
NO
8.20cm
12.00 cm
0.00 cm
3.00 cm
W1 (C04)
4.00cm
A (C03)
2.00 %LB
W1 (C08)
Technische
Redaktion BVED
Parameterization
BV-H2214 GB 47
769
VBW
Block O
O 01
O 02
O 03
O 04
O 05
O 06
O 07
O 08
O 09
O10
Power Failure
Memory Error
Tacho Input
Namur Err. Tacho
Namur Err Belt
L/C Input
No Release
L/C Input > MAX
L/C Input < MIN
Simualtion Active
Block P
P 01
P 02
P 03
P 04
P 05
Release
Stop Batch
Ackn. Events
DI Start
DI Setting to zero
Block Q
Q 01 DO Alarm
Q 02 DO Prefeeder ON
Q 03 DO Feeder ON
Q 04 DO I-MIN
Q 05 DO I-MAX
Q 06 DO Q-MIN
Q 07 DO Q-MAX
Q 08 DO v-MIN
Q 09 v-MAX
Q 10 DO Batch Active
Q 11 DO Full Feed
Q 12 DO Dribble Feed
Block R
R 01
R 02
R 03
R 04
R 05
R 06
Station Address
Physics
EasyServe Baudr.
Format Data
Connection
MODBUS Idle Time
INTECONT PLUS
Events
A (E01)
A (S01)
A (C02)
A (E02)
W1 (E03)
A (C01)
W1 (S02)
A (H04)
A (L04)
W2 (S07)
Digital Inputs
DI I+ DI 3 HI
DI I+DI1 HI
Digital Outputs
DO I+ D03 LO
DO I+ D01 HI
DO I+ DO4 LO
DO I+ DO2 LO
Comm. EasyServe
1
RS 232
19200
8-0-1
serial
4ms
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770
INTECONT PLUS
VBW
Block A :
Dialog Behaviour
A 02 Units
A 01 Language
Range:
DEUTSCH
Default: DEUTSCH
ENGLISH*
AMERICAN ENG*
FRANCAIS
ESPANOL
ITALIANO
Selection applies to all displays, error messages and

parameters.
* identical
Range:
B 01 Feed Rate Unit

Range:
---------.---.---.-----------.- - -. - - -.- - -
t/h
t/h
t/h
t/h
kg/h
kg/h
kg/h
kg/h
American Units
SI Units
Conversion
lb
t
f
inch
kg
t
m
cm
1 lb = 0.453593 kg
1 t = 0.907185 t = 2000 lb
1 f = 0.3048 m
1 inch = 2.54 cm
also applicable to compound units, e.g. kg/hr
Rated Data
B 03 Tacho Source
Default: - - - - - - t/h
Determine feed rate display format.
B 02 Nominal Feed Rate

Range:
Default: SI
Convert displays and parameter inputs from SI units

into American units.
Block B :
SI
NON-SI
0,0020...99999,9 t/h Default: 400,0000 t/h
Reference for limit values and service displays
Range:
DI
Default: DI I+ DI7 HI
Select - to stop belt speed measurement.

Computation uses nominal speed B 05.
B 04 vs Charact. Val.
Range:
10,00...100 000,0 I/m
Default:
50,26 I/m
Number of speed transducer pulses per belt meter.

Product B 04 * B 05 must range between 0.5...2500
Hz of speed input.
Special case:B 03 = NO
Do not change characteristic value vs; this
would change the run time of your setting
programs.
0539

and copyrights.
Technische
Redaktion BVED
Parameterization
BV-H2214 GB 49
771
VBW
INTECONT PLUS
B 05 Nominal Speed
Range:
0,0100...10,000 m/s Default: 1,0000 m/s
Limit value reference.

If BIC or CPD (Parameter Block N) are used, value
should be accurate to some percent.
If scales operate without speed measurement, B 05
determines the accuracy.
B 06 START Source
Range:
OP
FB
DI
v
Default: OP
Note:
If you select v, no batching is possible.
To start/stop totalization, there is no single solution:

OP : from INTECONT keyboard
FB : via fieldbus interface
DI
: using digital input. Default value is DI2. You
can also use any other free digital input.
Digital input operates edge-controlled, i.e. if
scale fails after Alarm, remove START signal
and re-apply.
v
: If you select belt speed v, totalization starts at
v>v-min (Parameter F09) and stops at
v<v-min.
Dialog function Keyboard Mode lets you change

over from selected source to keyboard, and vice
versa.
Note
G06 defines the totalizing counters tracking time.
If Parameter P01 Release is set to - -", no release is
required.
0539
Parameterization
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INTECONT PLUS
B 07 FMZ 1 Unit
Range:
------- t
-----.- t
----.-- t
---.--- t
- - - - - - t *10
----t *100
- - - - - - - kg
- - - - - . - kg
- - - - . - - kg
- - - . - - - kg
VBW
B 09 FMZ 2 Unit
Default: - - - - - - - t
same as B08, however, for Counter 2
B 10 FMZ 3 Unit
same as B08, however, for Counter 3
Lets you determine the display format for Counter 1,

all batch values and pulse weighting.
If no external counter is present, set Parameter B08 to
0.
B 08 FMZ 1 Pulse Dur.

Range:
0....1000 ms
Default: 0 ms
Lets you determine output pulse length of external

totalizing counter. Pulse weighting corresponds to the
smallest display digit of Counter 1
(Parameter B07).
B08 < 10 ms : Pulse output is disabled.
All pulses not yet output still are
deleted.
At nominal feed rate the output frequency is:
PNENN
= nominal feed rate in kg/h or t/h
Zmin
= smallest display digit of Counter 1

(B 07) in kg or t
Select Zmin (B07) so that f does not exceed

10 Hz.
In addition, pulse duration B08 must be smaller than
1/f.
0539

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Technische
Redaktion BVED
Parameterization
BV-H2214 GB 51
773
VBW
INTECONT PLUS
Block C : Calibrating Data
C 01 Belt Circuit No.

Range:
1...100
C 06 Lever Ratio
Default: 1,00
lets you determine the run time of the Zero Setting,

Taring and Weight Check setting programs.
Range:
0,0100...2,0000
Default: 1,0000
Lever ratio of force transducing weighed idler of

platform and load cell.
Does not apply to AUTO Zero Set.
Q = platform load
F = load on load cell
C 02 Belt Circuit Time

Range:
1,0...9999,0 s
Default: 30,0 s
lets you determine the measuring time for the

Imp/Belt Circuit calibration program.
Normally, the time is selected for one belt circuit.
With weighing modules with leaf spring parallel

guidance, lever ratio is always 1.
C 07 Angle a
Range:
Angle of longitudinal scale axis if load cell is mounted

vertical to belt.
C 03 L/C Charac. Value

Range:
0,01...9,9999 mV/V Default: 2,8500 mV/V
indicates the load cell characteristic value

(transmission factor).
C 08 Check Weight
Range:
0,5000...
220 000.0 kg
0,001...22000,0 kg Default: 50,000 kg
Weight of material on load cell simulated by check

weight
C 04 L/C Rated Cap.

Range:
0,0...60,00 degrees Default: 0,00 degrees
Default: 220,000 kg
indicates the total of load cell rated capacities.

Pivots are considered as load cells.
C 05 Eff. Platf. Length

Range:
0,1000...50,000 m
Default: 1,000 m
indicates effective length of weighing platform.

0539
Parameterization
BV-H2214 GB
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Redaktion BVED

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774
INTECONT PLUS
Block D :
D 01 Nominal Belt Load
No input possible
Default: 111,11 kg/m
computed from nominal data B 02 and B 05
VBW
Calibrat. Results
D 05 Tare Correction T
No input required
max. +- 1000 kg/m
Default: 0,00 kg/m
Result of manual or automatic zero setting program

used as reference value for limit values and zero
setting program.
After every taring operation, D 05 is set to 0.
D 02 Span Correction
Range:
0,5000...2,0000
Default: 1,0000
proportionally influences measurement of belt load q.

q(corrected) = q(measured) D 02
used to correct measuring system through check with
material.
D 03 Total Tare
No input possible
Default: 0,00 kg/m
Total tare = basic tare + tare correction
D 06 Belt Circuit Char

No input required
max. 9E6
Default: 1000000 I/U
Result of basic calibration program Imp/Belt Circuit.

Determines cycle of setting programs.
Divided by Parameter B 04 (vs Charact.Val.), belt
length in m results.
D 04 Basic Tare N
No input required
max. 10000 kg/m
Default: 0,00 kg/m
Result of taring program.
Attention!
When entering Parameters D 02 ... D 05 in manual, start
with D 02.
0539

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Technische
Redaktion BVED
Parameterization
BV-H2214 GB 53
775
VBW
INTECONT PLUS
Block E :
E 01 Source AO 1
Range:
I (feed rate)
Q (belt load)
V (belt speed)
Analog Output
E 04 Source AO 2
Default: I
Range:
I (feed rate)
Q (belt load)
V (belt speed)
Default: Q
One of these values can be output in analog fashion.
One of these values can be output in analog fashion.
Filters: Parameters G 02, G 04, G 05
Filters: Parametesr G 02, G 04, G 05
E 02 Elevation AO 1
Range:
0,00...20,00 mA
E 05 Elevation AO 2
Default: 4,00 mA
Output current with E 01 set to 0.

The smallest value is limited to E 02, also in stop state
of scale.
E 03 Limit Value AO 1
Range:
Range:
0,00...20,00 mA
Default: 4,00 mA
Output current with E04 set to 0.

The smallest value is limited to E 05, also in stop state
of scale.
E 06 Limit Value AO 2
0,00...1000,00 mA Default: 20,00 mA
Range:
0,00...1000,00 mA Default: 20,00 mA
Output current with E 01 set to 100 % (nominal value).
Output current with E04 set to 100 % (nominal value).
Range of output current is limited to 0...20 mA.
Current output range is limited to 0...20 mA by the

hardware.
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Parameterization
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INTECONT PLUS
VBW
Block F :
If measurement values exceed their MIN/MAX limits, a
corresponding event message is output (L1... L3,
H1... H3).
Limit Values
F 06 Event Class Q-MIN
Range:
Monitoring starts 10 s after start up.
F 01 Value for I-MIN

Range:
-10...200,0 % I
WARNING 2
WARNING 1
IGNORE
ALARM
L2
Default:
WARNING 2
F 07 Value for Q-MAX

Default: 5,0 % I
Range:
Reference: Nominal Feed Rate B 02.
-10...200,0 % Q
Default: 120,0 % Q
Reference: Nominal Belt Load D 01
F 02 Event Class I-MIN

Range:
WARNING 2
WARNING 1
IGNORE
ALARM
L1
Default:
WARNING 2
Range:
F 03 Value for I-MAX

Range:
-10...200,0 % I
Default: 120,0 % I
F 04 Event Class I-MAX

WARNING 2
WARNING 1
IGNORE
ALARM
-10...200.0 % Q
Default:
WARNING 2
Range:
-10...200,0 % V
Default: 5.0 % V
Reference: Nominal Speed B 05
H1
Default:
WARNING 2
F 10 Event Class V-MIN

Range:
F 05 Value for Q-MIN

Range:
WARNING 2
WARNING 1
IGNORE
ALARM
WARNING 2
WARNING 1
IGNORE
ALARM
L3
Default:
WARNING 2
F 11 Value for V-MAX

Default: 20,0 % Q
Range:
-10...200,0 % V
Default: 120,0 % V
Reference: Nominal Speed B 05
F 12 Event Class V-MAX

Range:
0539

and copyrights.
H2
F 09 Value for V-MIN
Reference: Nominal Feed Rate B 02.
Range:
F 08 Event Class Q-MAX
WARNING 2
WARNING 1
IGNORE
ALARM
Technische
Redaktion BVED
H3
Default:
WARNING 2
Parameterization
BV-H2214 GB 55
777
VBW
INTECONT PLUS
Block G :
I = feed rate
V = belt speed
Q = belt load
G 01 I Display
Range:
0.0...600.0 s
G 04 V Display
Default: 3.0 s
Feed rate display
0.0...600.0 s
Default: 3.0 s
Default: 3.0 s
Range:
1.0...600.0s
Default: 1.0 s
Holds for all functions and displays depending on belt

load.
G 03 Q Display
0.0...600.0 s
0.0...600.0 s
G 05 L/C Filter
Feed rate analog output
Range:
Range:
Belt speed display
G 02 I Analog output
Range:
Filters
G 06 Afterfl. Time
Default: 3.0 s
Belt load display
Range:
0.0...2000.0 s
Default: 3.0 s
Determines the time totalization goes on after turn-off

of feeder.
All filters are of the 1st order type

(exponential), i.e. after abrupt
change of signal, approx. 2/3
of the limit value are reached
after the set time.
Longer times stabilize display
but reduce update rate.
0539
Parameterization
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778
INTECONT PLUS
Block H :
H 01 AUTO Zero Active
Range:
NO
YES
Default: NO
For more information,
see Calibration item.

Lets you select the automatic zero setting function
used to correct zero point on empty conveyor belt
after every belt circuit.
Prerequisites:
v > vmin
No setting program
No parameter input
0.00...10.00 %Q
AUTO Zero Set

H 04 Zero Set Limit
Range:

Maximum admissible totals value of all manual and
automatic zero setting operations. Correction is not
acquired.
H 05 Tare Corr. > MAX

Range:
WARNING 1
ALARM
C5
Default: WARNING 1
H 06 Zero Set Time

Range:
H 03 Mean Limit Value

0.00...10.00 %Q
Default: 5.00 %Q
Default: 0.50 %Q
First prerequisite for automatic zero setting.

Defines the uniformity of mean belt load between two
consecutive belt circuits.
Range:
0.00...100.00 %Q
Automatic zero setting has exceeded Zero Set Limit

H04. Value is not acquired.
H 02 Limit Value Diff.

Range:
VBW
Default: 1.00 %Q
1...999 h
Default: 4 h
Lets you know that no manual or automatic zero

setting nor taring has been performed during the set
time.
Message C 7: Set Time To Zero

Second prerequisite for automatic zero setting.
Defines the maximum admissible belt load mean value
over 2 consecutive belt circuits.
H 07 Time Elapsed
Range:
IGNORE
WARNING 1
WARNING 2
C7
Default: IGNORE
Zeit
: H 06
0539

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Technische
Redaktion BVED
Parameterization
BV-H2214 GB 57
779
VBW
INTECONT PLUS
H 08 Print Result
Range:
NO
YES
H 11 Zero Set Diff.

Range:
Default: NO
Print zero setting result after every belt circuit.
0.00...100.00 %F
Default: 5.0 %F

Indicates the difference between two consecutive
manual or automatic zero setting operations.
Excess is reported by message C9.
Result autom. zero setting

Total Tare [kg/m]
50,23
(D 03)
Tare [kg/m] 1,56

(D 05)
H 12 Tare Diff. > MAX

Range:
H 09 ZDO Active
Range:
NO
YES
WARNING 2
WARNING1
IGNORE
ALARM
C9
Default: WARNING 2
Default: NO
Activates Zero Drop Out function (see H 10).

Manual or automatic zero setting has exceeded
difference H 11.
Correction is acquired save in case of ALARM
messages.
H 10 ZDO Limit
Range:
0.0...10.00 %Q
Default: 1.00 %Q

If ZDO function is active and belt load exceeds the
defined limit, feed rate measurement and totalization
are suppressed.
No symbol appears on display.
0539
Parameterization
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780
INTECONT PLUS
VBW
Block I :
The sequence of the available batch modes is
detailed in Chapter Details.
Make sure start source B 06 is not set to v.
I 01
Range:
Batch Dribble FD
0.00...220 000 kg
Range:
I 03
Range:
Adaption Fact.
0.0...1.0
Default: 1.0
Pre-cut-off amount I 02 is adapted automatically, so

that the system better suits the situation upon next
batch.
Value is corrected by the batch error * I 03.
Default: 100 000 kg
If batch setpoint is reached Batch Setpoint I 01-I 02",

full feed output Q11 is reset; dribble feed output Q12
activated.
These signals can be used, e.g. to reduce belt speed
or prefeeder output.
I 02
Batch Mode
I 03
I 03
= 0:
= 1:
no adaption
full adaption
Intermediate values cause a filtered adaption,

preferred in the case of plants with non-exact
repeatability.
Batch End
0.00...220 000 kg
Default: 0.000 kg
If batch setpoint minus pre-cut-off amount I 02 is

reached, batch is complete.
Drive, or prefeeder, stops.
I 04
Range:
Batch Tolerance +
0.0...100.0 %
Default: 1.0 %
Reference: Batch Setpoint

Defines the value admissible for excess of batch
setpoint.
I 05
Range:
Batch Tolerance 0.0...100.0 %
Default: 1.0 %
Reference: Batch Setpoint

Defines the value for shortfall of batch setpoint.
I 02 makes allowance for possible afterflow.
I 06
Range:
Out of Tolerance
WARNING 1
WARNING2
ALARM
IGNORE
B1
Default: WARNING 1
Event message B1 reports excess of limit values I 04

or I 05.
0539

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Technische
Redaktion BVED
Parameterization
BV-H2214 GB 59
781
VBW
I 07
Range:
INTECONT PLUS
Belt Empty
NO
YES
Default: NO
NO
: Batching without belt clearance.

Stop of conveyor belt aborts batch.
YES
: Batching with belt clearance.

Stop of prefeeder aborts batch.
(Prefeeder Active M 01 = YES)
I 08
Range:
Batch > Setp.

IGNORE
WARNING1
WARNING 2
ALARM
B4
Default: IGNORE
Batch actual value exceeds setpoint by tolerance I 04.

Message B4 is output.
After acknowledgement (also ALARM messages),
monitoring of current batch cuts off.
I 09
Range:
Batch Source
OP
FB
Default: OP
OP
: Batch setpoint, batch number and make-up

setpoint are preset from the INTECONT
keyboard.
FB
: Above values are set via fieldbus interface.
0539
Parameterization
BV-H2214 GB
60
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782
INTECONT PLUS
VBW
Block J :
Printer Setting
J 01 Baud rate
Range:
2400
4800
9600
19200
38400
Default: 9600
30.09.97 11:45:21L2 W1 Load < MIN
30.09.97 11:59:01L2 W1 Load < MIN
Event report
Baud rate for transmission to printer.
Print Batch
Batch number
30.06.03
Batch Setpoint
Batch Actual Val.
Totalizer 1
Totalizer 2
Zero Set before
J 03 Print Subtotal
12
11:45:10
1000 kg
998 kg
1200 kg
90000 kg
75 min
Range:
Error
YES
NO
Default: Error
Error
: Each event is printed automatically as soon

as available.
YES
: See above, however, including totalizing

counter (FMZ) sub-totals.
NO
: No printout
Events
Printing is effected in batching and normal modes.

Save parameter J 03, all parameters are valid for batch
and counter reports.
J 02 AUTO PRINT
Range:
NO
YES
Default: NO
NO
: Batch report can be printed only using the

control menu.
YES
: Batch report is printed automatically when

batch is complete.
Special case:
If a value is set to line 0 and column 0, it does not
appear in report.
J 04 Reset Print FMZ 1

Range:
NO
YES
Default: NO
YES
: Reset counter 1 upon start of next batch

provided that batch report has been
printed.
1)
NO
: Counter 1 can be reset only using the

control function.
0539
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Parameterization
BV-H2214 GB 61
783
VBW
INTECONT PLUS
J 05 Reset Print FMZ 2

Range:
NO
YES
J 12 FMZ 1 Column
Default: NO
Range:
0...127
Default: 8
J 13 FMZ 2 Line
See J 04, however, for counter 2.
Range:
J 06 Print Page Length

Range:
9...127 lines
0...117
Default: 9
J 14 FMZ 2 Column
Default: 72 lines
Range:
0...127
Default: 8
The page must be minimum 4 times longer than the

number of data to be printed.
The line spacing is always 1/6 inch.
J 15 Date/Time Line
Change of parameter automatically initializes printer.
Range:
J 07 Batch Setp. Line

Range:
0...117
0...127
Default: 6
0...117
Default: 8
0...127
Default: 7
0...117
Default: 8
Range:
0...17
Default: 12
Range:
0...127
Default: 8
J 19 Set Line to Zero

Default: 8
J 11 FMZ 1 Line
Range:
0...127
J 18 Event Column
J 10 Batch Act. Col.

Range:
Range:
J 17 Event Line
J 09 Batch Act. Line

Range:
Default: 4
J 16 Date/Time Col.
J 08 Batch Setp. Col.

Range:
0...117
Range:
0...117
ED:>0
Default: 10
J 20 Set Column to Zero

Default: : 8
Range:
0...127
ED:>0
Default: 8
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INTECONT PLUS
J 21 Line Number
Range:
0...117
VBW
Nb
Default: 3
Range:
Block K :
K 01 Maintenance Elec.
Range:
0...10000 h
J 22 Column Number
0...127
Nb
Default: 8
Maintenance Int.
When the set interval has elapsed, message S3 is
output.
Default: 3000 h
Message: S4 (K 02)
Alerts you on maintenance work to be effected after a

certain voltage ON-time.
K 02 Event Maint. EL
Range:
WARNING 1
WARNING 2
IGNORE
K 05 SPC Time
S4
Range:
Default:
WARNING 1
K 06 SPC Filter
Range:
K 03 Maint. STR-Meter
0...10000 h
Default: 8 h
Acquisition interval for service values, e.g. empty belt.

SPC = Statistical Process Control
The total of voltage ON-times exceeds the time

defined by K 01.
When the set interval has elapsed, message S4 is
output.
Range:
1...24 h
Default: 3000 h
Message: S3 (K 04)
0.00...24.00 h
Default: 1.00 h
Exponential first-order filter for service values, e.g.

mean value and feed rate variance.
Alerts you of maintenance work to be effected after a

certain conveyor belt run time.
K 04 Event Maint. Run.

Range:
WARNING 1
WARNING 2
IGNORE
S3
Default: WARNING 1
The total of conveyor belt run times exceeds the time

defined by K 03.
0539

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Parameterization
BV-H2214 GB 63
785
VBW
INTECONT PLUS
Block L :
L 01 Protocol Type
Range:
NO
MODBUS COMP.
S5-BCC COMP.
MODBUS
PROFIBUS DP
DEVICENET
MODBUS/TCP
ETHERNET/IP
L 05 Resolution
Default: NO
Range:
1...32767
Default: 4096
Resolution of data for nominal value in Modbus

protocol (integer format).
L 06 Word Sequence
Possible protocol variants. Every protocol type

requires an optional interface card to be present.
COMP identifies the compatible types.
Range:
I: std/L:std
I: swp/L: std
I: std/L: swp
I: swp/L: swp
Default: I: std/L: std
Determines the word sequence within a data double

word in the Modbus protocol.
I stands for IEEE-754 values (floating point values)
L stands for 4-byte integer values
std does not swap the word sequence; swp does.
L 02 TIMEOUT Host
Range: 0...600s
Comm. Fieldbus
Default: 10s
If timeout value exceeds 0, a host system message is

expected to arrive during the set time.
L 03 Comm. Error Host

Range:
S9
IGNORE
Default: IGNORE
W1 (WARNING 1)
W2 (WARNING 2)
A (Alarm)
L 07 Physics
Range:
RS232
RS 422
RS 485
Default: RS 485
Lets you set the Modbus interface physics.

If no message is received during the time set by
parameter L02, event message S9 Data Link Host is
output.
L 08 Baud Rate
L 04 Address
Range:
1...254
Range:
Default: 1
Slave address for Modbus protocol
2400
4800
9600
19200
38400
Default: 9600
Modbus baud rate
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L 09 Format Data
Range:
8-E-1
8-0-1
8-N-2
VBW
L 14 Address
Default: 8-E-1
Range:
0...126
Default: 16
Profibus DP slave address
Modbus data format (data bits, parity, stop bits).
L 15 FLOAT Format
L 10 FLOAT-FORMAT
Range:
SIEMENS-KG
IEEE
Range:
SIEMENS-KG
IEEE
Default: IEEE
Default: SIEMENS-KG
Determines the representation of the floating point
values for the Profibus DP protocol.
Determines the S5 protocol used for representation of

floating point values.
L 16 Configuration
L 11 Physics
Range:
RS 232
RS 422
Range:
Default: RS 422
Lets you set the interface physics for the S5 protocol.
L 12 Baud Rate
Range:
2400
4800
9600
19200
38400
FIXED-1
FIXED-2
NO-PARA-ID
PARA-ID
Default: FIXED-1
Determines structure and size of the process image

(Profibus DP).
L 17 Address
Default: 9600
Range:
0...63
Default: 16
DeviceNet slave address
Baud rate for S5 protocol
L 18 Baud Rate
Range:
L 13 Format Data
Range:
8-E-1
8-0-1
8-N-2
125k
250k
500k
Default: 125k
Default: 8-E-1
DeviceNet baud rates
S5 data format (data bits, parity, stop bits)
0539

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L 19 Configuration
Range:
FIXED-1
FIXED-2
NO-PARA-ID
PARA-ID
L 24 IP-Address 1
Default: FIXED-1
Range: 0-255
Default: 192
Lets you enter IP address in manual
Determines structure and size of the process image

(DeviceNet).
L 25 IP-Address 2
Range: 0-255
Default: 168
L 20 Byte Sequence
Range:
LOW-High
High-LOW
Default: LOW-High
L 26 IP-Address 3
Determines the byte sequence within a data word
Range: 0-255
Default: 240
L 21 Word Sequence
Range:
I: std/L:std
I: swp/L: std
I: std/L: swp
I: swp/L: swp
Default: I: std/L: std
Range: 0-255
Default: 1
Determines the word sequence within a data double

word in the DeviceNet protocol.
I stands for IEEE-754 values (floating point values)
L stands for 4-byte integer values
std does not swap the word sequence; swp does.
L 28 Net Mask 1
Range: 0-255
Default: 255
Determines subnet mask
L 22 WEB Coding
Range: HTML, XML
L 27 IP-Address 4
Default: XML
Defines type of web page coding. If XML is selected,

stylesheet determines data representation in browser.
L 29 Net Mask 2
L 23 DHCP
Range: NO
Range: 0-255
Default: NO
Default: 255
Determines how IP address shall be preset

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L 30 Net Mask 3
Range: 0-255
VBW
L 36 Byte sequence
Default: 255
Range:
High-Low
Low-High
Default: High-Low
Swaps user data word in byte sequence
L 31 Net Mask 4
Range: 0-255
Default: 0
Range:
L 32 Gateway 1
Range: 0-255
L 37 Word sequence
Default: 192
Determines standard gateway address
Range: 0-255
Default: 168
Default:
I: std/L: std
Determines word sequence during transmission of

measurement values in IEEE-/LONG format. Also
swaps analog preset values.
L 38 Configuration
Range:
L 33 Gateway 2
I: std/L:std
I: swp/L: std
I: std/L: swp
I: swp/L: swp
FIXED1,
FIXED2,
NO_PARA_ID.
PARA_ID
Default: FIXED 1
Not used with MODBUS/TCP
L 34 Gateway 3
Range: 0-255
Default: 240
L 35 Gateway 4
Range: 0-255
Default: 0
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Block M :
M 01 Feeder Active
Range:
YES
NO
M 04 Motor STOP aft. ST

Range:
: The START/STOP Prefeeder dialog function

is active. In turned-on state, the prefeeder is
controlled through the scale-specific
sequence.
NO
: Dialog function is faded out.

Control output is always set to STOP
Prefeeder.
M 02 Setting Time
0.0...1000.0 s
NO
: After cut-off or batch complete command,

belt continues running for the time specified
by Parameter M02.
YES
: Conveyor belt immediately stops.
Parameter is active only if Batch Mode has been

preselected.
Normally, belt immediately stops.
M 05 Change-over FF/DF
Range:
M 03 Feed Distance
0.00...10000.00 m
Default: NO
Default: 0.0 s
Setting time of material prefeeder
Range:
NO
YES
Default: NO
YES
Range:
Feeder Control
Default: 0.00 m
Material path from prefeeder to end of weighbridge.

Input is required only if Full Feed / Dribble Feed
control via prefeeder is desired.
YES
NO
Default: YES
I 07 = YES
Belt clearance.
M 05 ineffective.
I 07 = NO
No belt clearance.
Parameter M 05 lets you select Full
Feed / Dribble Feed control via
conveyor belt (NO), or prefeeder
(YES).
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INTECONT PLUS
VBW
Block N :
Scale Monitoring
N 01 CPD Active
Range:
NO
YES
N 04 Source Sensor
Range:
Default: NO
Starts speed-controlled delay element used to shift

belt load measurement to the point of material
discharge.
Prerequisites:
Default: DI (DI6)
Digital input for belt sensor. Can be checked using the

relevant service value.
Only DI6 can be used. If you select alternative -, BIC
and belt monitoring functions cannot be used.
Speed meter must be present and

active. No belt circuit sensor is
required.
N 05 BIC Active
N 02 Platf.Dis.Length
Range:
Range:
DI
0.00...50.00 %LB
Default: 0.00 %LB
NO
YES
Default: NO
Input required only with CPD active

Length from mid platform to material discharge point
in % of total belt length LB.
The resolution is approx. 200.
Lets you start adaptive belt influence compensation

BIC.
To initialize BIC:
The dynamical tare portion is cleared upon power-up
or after changes to a parameter of the following list:
N 03 Belt Sensor Active

Range:
NO
YES
Default: NO
Parameter N 05 BIC Active
Parameter B 04 vs Charact. Val.
Parameter D 06 Belt Circuit Char
Brief instructions:
Belt sensor and sensor area on conveyor belt are
designed to acquire belt slip and belt drift, and
synchronize the adaptive belt influence compensation
BIC.
1. N03 = YES, enter N 06... N 08.

2. Start setting program LB: IMP/Belt.
3. Activate BIC (N05 = YES).
4. Tare.
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Parameterization
BV-H2214 GB 69
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INTECONT PLUS
Action:
N 06 Sensor Length
Range:
0.01....400.00 cm
Default: 8.20 cm
Length of sensor area in direction of belt travel.

See also Service value Imp.S..
Clean head and tail pulleys.
2.
Align belt.
Monitoring system can fail, too. So watch service

values of belt circuit sensor and remove fault, if any.
N 11 Belt Skew
N 07 Sensor Width
Range: 0.01...400.00 cm
1.
Default: 12.00 cm
Range: 0.01...400.00 cm
Default: 4.00 cm
Limit value for admissible belt skew. If exceeded,

event message C3 Belt Skew is output and digital
output N16 DO Belt Skew is set.
Width of sensor area
N 08 Sensor Offset
Range:
400.00....400.00 cm Default: 0.00 cm
The offset lets you correct the zero point of the belt
run monitoring result.
However, the maximum display range is limited.
Therefore bigger corrections should be effected by
sensor shifting (see Commissioning chapter).
N 12 Belt Skew Event

Range:
WARNING 1
WARNING 2
Ignore
Alarm
C3
Default: Alarm (C03)
Conveyor belt is too far off-centre. Feeder is no longer

operable.
New display = old display - offset
Action:
See Belt Drift event.
N 09 Belt Drift
Range:
0.01...400.00 cm
Default: 3.00 cm
Limit value for admissible belt drift. If exceeded, event

message C4 Belt Drift is output and digital output
N15 DO Slip Event is set.
N 10 Belt Drift Event

Range:
WARNING 1
WARNING 2
Ignore
Alarm
C4
Default: WARNING 1
(C04)
N 13 Slip Limit
Range:
0.00...10.00 %LB
Default: 2.00 %LB
Admissible variance of belt length in % of total belt

length.
Limit value exceeded, event message C8 Slip Error
is output and digital output N17 DO Slip is set.
Cause of event:
Belt leaves specified tolerance range.
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INTECONT PLUS
N 14 Slip Event
Range:
WARNING 1
WARNING 2
IGNORE
ALARM
VBW
C8
Default: WARNING 1
(C08)
Admissible limit value (N13) is exceeded.
N 15 Do Belt Drift
Range:
DO
__
Default: __
Digital output used to report belt drift.
N 16 DO Belt Skew
Range:
DO
__
Default: __
Digital output used to indicate belt skew event.
N17 DO Slip
Range:
DO
__
Default: __
Digital output used to indicate belt slip event.
M 18 Freeze BIC
Range:
DI
__
Default:
If digital input is set, current BIC values are frozen.

This helps to protect acquired values from falsification
upon heavily varying belt loads.
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Parameterization
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Block O:
O 01 Power Failure
Range:
ALARM
WARNING 1
WARNING 2
IGNORE
Events
E1
Default: ALARM
O 02 Memory Error
O 05 Namur Err Belt

Range:
S1
WARNING 1
ALARM
IGNORE
E3
Default: WARNING 1
Short-circuit or breakage of belt circuit sensor cable

(BIC).
Prerequisite: N 03 = YES
ALARM (S01)
No changes possible.
Feeder is no longer operable.
O 03 Tacho Input
Range:
ALARM
WARNING 1
WARNING 2
C2
Default: ALARM
O 06 L/C Input
Range:
Input frequency exceeds 2700 Hz.

Monitoring starts 10 s after power-up.
Prerequisite: B 03 = YES
O 04 Namur Err. Tacho

Range:
ALARM
WARNING 1
WARNING 2
IGNORE
E2
Default: ALARM
ALARM
WARNING 1
WARNING 2
C1
Default: ALARM
1.
Load cell cable not (or improperly) connected.
2.
Analog-to-digital converter of measuring amplifier

is in saturation (see Service Value wz_roh).
3.
Supply voltage has fallen below 19V.
Fault must be available for min. 3 s.
O 07 No Release
Cable breakage or short-circuit.
Range:
Prerequisite: B 03 = YES
Namur errors reset internal speed value to 0.
Frequency display (service value) is still active.
WARNING 1
WARNING 2
IGNORE
S2
Default: WARNING 1
RELEASE input signal pending.

Special case:
IGNORE always releases feeder.
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INTECONT PLUS
O 08 L/C Input > MAX
Range:
ALARM
WARNING 1
WARNING 2
VBW
H4
Default: ALARM
Load on load cell exceeds 110 % of the total of load

cell rated capacities (C 04).
Full scale: approx. 115 % with CSD load cells.
O 09 L/C Input < MIN

Range:
ALARM
WARNING 1
WARNING 2
L4
Default: ALARM
Load on load cells is smaller than 3 % of the total of

load cell rated capacities.
O 10 Simulation Active
Range:
WARNING 1
WARNING 2
ALARM
IGNORE
S7
Default:
WARNING 2
Simulation mode started
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Parameterization
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Block P:
P 01 Release
Range:
DI
Digital Inputs
P 05 DI Setting to zero
Default: DI (DI1)
Determine digital input for feeder release.

Setting - means that no release is required.
Default is DI1, however, any other free digital input
can be used as well.
Range:
DI
__
Default:
The function setting to zero can also be started via the

digital input. The program is started by a positive flank
of the contact. The result is automatically accepted if it
is within the admissible zero setting limit (5% of the
nominal belt load). An ackowledgement of the result is
not necessary. The calibration program can only be
aborted in its active phase.
P 02 DI Stop Batch
Range:
DI
Default: DI (DI3)
Digital input signal used to abort a running batch.
P 03 Ackn. Events
Range:
DI
Default: DI (DI1)
Digital input used to acknowledge event messages.

Level acts statically and should not be permanently
available (permanent acknowledgement).
P 04 DI Start
Range:
DI
__
Default:
If OP has been selected for start source, digital input

DI Start can be configured and used to start feeder
using a start pulse (key). Feeder is stopped by a pulse
output across digital input Release.
This configuration is possible parallel to the
START/STOP keys on INTECONT keyboard.
Parameterization
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Block Q:
Q 01 DO Alarm
Range:
DO
VBW
Digital Outputs
Q 05 DO I-MAX
Default: DO I+DO3 LO
Digital output used to report general alarm.
Range:
DO
Default: DO (DO2)
Digital output signal used to indicate that maximum

feed rate (F03) is exceeded up.
Contact output is independent of event class (F04).
Q 02 DO Prefeeder ON
Range:
DO
Default: DO (DO4)
Digital output used to START/STOP prefeeder.
DO
Range:
DO
Default:
Digital output signal used to indicate that minimum

belt load (F05) is exceeded down.
Q 03 DO Feeder ON
Range:
Q 06 DO Q-MIN
Default: DO (DO5)
Digital output signal used to indicate START/STOP

state of scale.
Q 07 DO Q-MAX
Range:
This very output can also be used to START/STOP

drive.
DO
Default:

belt load (F07) is exceeded up.
Q 04 DO I-MIN
Range:
DO
Default: Do (DO1)

feed rate (F01) is exceeded down. Contact output is
independent of event class (F02).
Q 08 DO v-MIN
Range:
DO
Default:

belt speed (F09) is exceeded down.
Contact output is independent of set event class
(F10).
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Q 09 DO v-MAX
Range:
DO
Default:

belt speed (F11) is exceeded up.
Contact output is independent of set event class
(F12).
Q 10 DO Batch Active
Range:
DO
Default:
Digital output signal reporting that a batch is active.

Signal becomes active upon start of batch and is
deactivated when batch is complete. Signal remains
available after abort of batch.
Q 11 DO Full Feed
Range:
DO
Default: DO (DO6)
Full feed signal is available from start of batch until

batch amount Value for I-MIN (F01)- Batch Dribble
FD (I02) is reached. Batching continues in dribble
feed.
Q 12 DO Dribble Feed
Range:
DO
Default: DO (DO7)
Dribble feed signal is output after the full feed phase

(see Q11).
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Block R:
R 01 Station Address
Range:
1...254
VBW
Comm. EasyServe
R 04 Format Data
Default: 1
Station address and baud rate of feeder and

EasyServe must be identical.
The relevant setting (including communication
interface) can be searched using EasyServe (menu:
Tools/Options/Communication).
The station address is specially designed for plants
using a service bus. If the latter is not available,
select 1.
Connection to PC can also be made using a 9-pole
SUB-D connector on X4 (RS 232 only) or a Phoenix
connector on X5 (RS232, RS422 or RS485).
See also Wiring Diagram in chapter DETAILS.
Range:
8-0-1
8-E-1
8-N-2
Default: 8-0-1
EasyServe always uses an 11-bit character frame.

For example:
8-0-1 means:
1 start bit, 8 data bits, odd parity, 1 stop bit
(N = No parity, E = Even Parity)
R 05 Connection
Range:
R 02 Physics
Range:
RS 232
RS 422
RS 485
Default: RS 232
Determines the physics of the data transmission

protocol.
R 03 EasyServe Baudr.
Range:
9600
19200
Default: 19200
Serial
SERIAL+TCP
Default: Serial
If MODBUS/TCP (Ethernet) has been selected for

fieldbus, communication between feeder and
EasyServe can also take place via Ethernet.
To do so, set Connection parameter to SERIAL-TCP.
R 06 MODBUS Idle Time

Range: 2...20ms
Default: 4 ms
For Modbus driver, single character timeout (idle time)

for end recognition can be adjusted using this
parameter (see BVH2220).
Baud rate
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10
Event Messages
System Messages S
S1 :
VBW
S9 :
Memory Error
Program and parameter memories are
checked in cycles. If an error is found, cal is
inoperable in most cases.
Action
: Contact the SCHENCK
Service.
Parameter:
O02
S2 :
No Release
External RELEASE signal pending.
Scale cannot start.
Parameter
: O 07
Electrics E
E1 :
S3 :
Power failed or cut off.

Feed rate possibly not recorded during this
time.
Action
: Acknowledge message.
Parameter
: O 01
E2 :
Maintenance Int. Elec
Namur Err Tacho

Short circuit or breakage in speed transducer
cable. Scale no longer operable.
Action
: Check speed transducer cable.
Deselect speed measurement
for a short time using
Parameter B 03 .
Parameter
: O 04
The INTECONT power supply has been

switched on for a preset period of time.
Perform requisite service work, if necessary.
Acknowledgement of message does not
influence time intervals.
Parameters : K 01, K 02
E3 :
S7 :
Power Failure
Maint. STR Meter

Total ON-time of conveyor belt and
measurement is exceeded.
Perform requisite service work, if necessary.
Acknowledgement of message does not
influence time intervals.
Parameters : K 03, K 04
S4 :
Data Link Host

Serial communication interrupted for longer
than timeout.
Action
: Check cable connections.
Parameter
: L 03
Namur Err Belt
Simulation Active
Operating in Simulation mode, scale is not
prepared for normal operation.
The Simulation mode lets you test all scale
functions without material at the time of
commissioning.
Action
: Deselect Simulation function.
Parameter
: N1
Short circuit or breakage in belt circuit sensor

cable.
Action
: Check sensor cable.
Parameter
: O 05
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Event Messages
BV-H2214 GB 79
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C7 :
Calibration C
C1 :
L/C Input
During preset time, no taring nor manual or

automatic zero setting has taken place.
Action
: Tare or set to zero,
acknowledge message.
Parameters : H 06, H 07
Load cell cable broken, not or improperly

connected. Supply voltage too low.
Action
: Check cabling.
If OK, check load cell amplifier.
Parameter
: O 06
C8 :
C2 :
Conveyor belt length inadmissibly changed.

Error is acquired only using additional belt
circuit sensor.
Action
: Check belt tension; if
necessary, correct.
Check sensor for proper
measuring distance.
Parameters : N13, N14
C9 :
Tare Diff > MAX
Belt Skew
Conveyor belt runs too far off centre. Scale is
no longer operable.
Action:
See C4
Parameters: N11, N12
C4 :
Slip Error
Tacho Input
Speed transducer output frequency exceeds
3000 Hz, most probably due to subsequent
change of belt speed (e.g. gearbox).
Action
: Check speed transducer for
proper dimensioning.
If necessary, measure pulse
frequency using oscillograph.
Parameter
: O 03
C3 :
Set Time To Zero
Automatic or manual zero setting has detected

excessive zero point deviation.
Correction takes place only if no Alarm is
available.
Action
: Acknowledge message, clean
scale; if need be, retare.
Parameters : H 01, H 11, H 12
Belt Drift
Belt has left defined tolerance zone.
Action:
1) Clean head and tail pulleys.
2) Align belt.
Parameters: N09, N10
C5 :
Tare Corr. > MAX

Automatic zero setting has exceeded specified
limit. No correction takes place.
Action
: Clean scale; if need be, retare.
Parameter
: H 01, H 04, H 05
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Event Messages
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INTECONT PLUS
VBW
Maximum H
Minimum L
H1 :
L1 :
I > MAX
Current feed rate exceeds set limit value.
Action
: Normally none, unless
message H4 is available or
system-specific limits have to
be observed.
Parameters : F 03, F 04
H2 :
Load > MAX
Current feed rate has fallen below set limit

value. Error in measurement possibly out of
tolerance.
Action
: System specific unless L4 is
additionally available
L2 :
Current belt load exceeds set limit value.

Action
: Normally none, unless
message H4 is available or
system-specific limits have to
be observed.
v > MAX
L4 :
L/C Input > MAX
Weighing system overloaded. Errors in
measurement possible.
Action
: Check material infeed; belt
load is too big.
Parameter
: O 08
V < MIN
Current belt speed has fallen below set limit
value.
Action
: Check to see if belt is running.
Current belt load exceeds set limit value.

Action
: System specific unless C2 is
additionally available.
H4 :
Load < MIN

Current belt load has fallen below set limit
value.
Action
: See L1
L3 :
H3 :
I < MIN
L/C Input < MIN

Weighing system underloaded. Errors in
measurement possible.
Action
: Check mechanical weighing
system, weighed idler
alignment and load cell cable.
Parameter
: O 09
0539

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Event Messages
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INTECONT PLUS
Batching
Signal Lamps
B1 :
Out of Tolerance
Batch not completed with specified accuracy.
Tolerance
: Parameters I 04, 05
Event
: Parameter I 06
Cause
: Automatic adaption started
(Parameter I 03) ?
Material infeed or belt drive
faulty ?
B4
b
X
MAX Batch Act. Value
(green) POWER OK
LED not lit:
1. No power supply
2. Device defective
3. All other functions OK, LED
probably defective. Call display
test.
(green) CPU OK
Display pending or flashing,
processor system is faulty. Scale is
inoperable.
(red)
Current batch actual value exceeds preset

tolerance.
Limit value : Parameters I 04, I 08
ALARM
flashes if an Alarm message is
available.
Display additionally shows event
code.
Action
MIN
(red)
(red)
event
MIN LIMIT VALUE

lit if feed rate limit value is exceeded
down.
Action
MAX
: See relevant
code.
: See L1: I<MIN
MAX LIMIT VALUE

lit if feed rate limit value is exceeded
up.
Action
: See H1: I>MAX.
No power supply:
Upon short circuit on the secondary side of the power
supply, internal overload protection responds.
Disconnect power supply for approx. 1 minute, and its
is ready to operate again.
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Event Messages
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INTECONT PLUS
11
VBW
Commissioning
How To Operate Your INTECONT
1. Event E2 = O04
Namur Err. Tacho
There is no way out.

Who wants to put the INTECONT into service has to
work himself through the Operation and Service
Manuals.
To make learning easier, the INTECONT can be
operated without mechanical equipment, load cells
and speed transducer.
Although no feed rate is displayed, all operating
functions can be performed.
1. Connect power supply and turn on (Chapter
DETAILS).
2. The upper two green LEDs report Ready to
Operate, the red LED in the middle flashes and
reports Alarm E1.
T
U
Operate cursors to view available

events.
1. Namur Err. Tacho
E2
Speed transducer not connected, or
cabling faulty.
2. L/C Input C1
Load cell not connected, or
cabling error.
3. L/C Input >MIN
L4
4. No release
S2
No external RELEASE signal.
E1
Z=
I=
0t
0 kg/h
Upper display : Totalizing Counter Z1

Lower Display : Event Message E1
Power Failure Feed Rate I
Acknowledge Message E1 with key

ACK.
Display shows Event Message E2
which reports that no speed transducer
is connected.
3. Except Scale ON and Set to Zero, all functions

described in the Operating Manual can be
performed, e.g. display of event messages.
G
f
4. If you wish to turn off the flashing signal lamp or try

the setting programs, change some parameters as
shown in Parameterization chapter.
(a) Parameter O04
to
WARNING 1 E2
(b) Parameter O06
to
WARNING 1 C1
(c) Parameter O09
to
WARNING1
L4
(d) Parameter O07
to
IGNORE
S2
(e) Parameter B 03
to
-Deselect belt speed measurement with Parameter B
03. Weigher can then operate without tacho generator.
Use residual parameters to change the event class of
the 4 message types.
5. Set Release contact (Parameter P01).
6. Start INTECONT, all setting programs are
available.
First call LB program as described in Chapter 6
Start function Display Events.

and acquire result using the
f key.
7. To simulate belt load, see Test Plug item.

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Mechanical Prerequisites
Mount mechanical equipment in accordance with the

instructions given in separate manual. Check weighed
and carrying idlers in the weigher influential zone for
correct alignment and out-of-round.
Out-of-round
The out-of-round error of idlers in the weigher
influential zone must not exceed 0.4 mm.
Securement
After alignment, secure idler sets against
displacement.
Mark idlers and sets to avoid mistakes during
maintenance.
Influences
Influential zone
All weighed idlers and three carrying idlers upstream
and downstream of weighing station.
Alignment
Incorrect alignment entails a zero point error which is

normally compensated during calibration.
However, changes in belt tension increase the error
size.
For this reason, ensure correct alignment and
constant belt tension for accurate weighing.
Maintenance
Raise idlers in the influential zone to approx. 3...5 mm

above remaining idlers. Align then against one
another to a height difference below 0.4 mm.
If idlers are dismounted for maintenance work to be

effected, make sure that they are remounted in their
former locations.
Electrical Prerequisites
Run and connect cables as described in Chapter
DETAILS.
Depending on idler set equipment, idlers have to be

aligned in various points.
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VBW
Enter Parameters
All important rated and calibration data are shown in
the supplied Spec Sheet.
In addition, see hints given below. We recommend to
read through all parameters and to select the best
possible setting.
Parameter Block A
Dialog language and display unit.
Parameter values are automatically converted if the
unit is changed.
Parameter Block B
Characteristic value vs B 04 is important for
calibration. Adjust units to nominal feed rate. To
ensure stable display, resolution of feed rate display
(B 01) should not exceed 4...5 decimals.
Display format of totalizing counters should not
exceed 6...7 digits. The decimal point is one digit.
Determine belt inclination by using spirit level and

measuring element. Repeat measurement with spirit
level turned and calculate mean value of height h.
Example:
Nominal feed rate
10 t/h
Unit B 07
-.- t
Max. Wert
999.999 t
Angle C 07:
a = tan (h/l)
Angles < 20 degr.:
a = 55 h/l
Parameter Block D
Max. counter run time =
Calibration results need not be entered.

During initial calibration, range correction D 02 should
be set to 1.
Check to see if, with rated data entered, load cell
rated capacity is not exceeded.
Then counter is reset.

If an external totalizing counter is connected, output
frequency must not exceed 10 Hz (see Parameters B
07, 08 and Service Displays Z0 and ZE).
Parameter Block C
Ensure correct input of calibration and evaluation data
as shown in relevant Spec Sheet. Measure effective
belt length and inclination at site.
For definition of belt length, see Chapter DETAILS.
0539
Enter belt inclination only if load cells are arranged

right-angled to belt. If load cells are mounted
vertically, the effective angle is 0. For definition of
check weight, see Data Flow Diagrams in Chapter
DETAILS.

and copyrights.
F = q * L * H * cos(a)
q
L
H
a
F
=
=
=
=
=
nominal belt load

eff. platform length
lever ration
angle
force on load cell
D 01
C 05
C 06
C 07
in kg
in kg/m
in m
in degr.
F should be the total of load cell rated capacities C

04. If not, load cells are too small for the requested
nominal feed rate.
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Parameter Block F
Functional Check
Select limit values and their event classes in

accordance with application requirements.
Parameter Block G
Adjust display filters, if required. Normally, the default
values can be used.
Parameter Block H
See Automatic Zero Setting. Maintain default values
for the time being. Do not start automatic zero setting
before calibration is effected.
Parameter Block K
For calibration, the maintenance parameters are
irrelevant. The default values are useful suggestions.
Parameter Block N
Measuring at discharge point (CPD) should normally be
activated (N 01, N 02). For automatic belt influence
compensation (BIC) and belt drift display, a special belt
circuit sensor and a metal sensor area on belt are
required. If these are not available, set Parameter N 03
to NO. Disconnect BIC during initial commissioning.
Parameter Block O
The event classes are selected for a standard scale. If
messages O 04, O 06 and O 07 have been modified
for training, reset to default.
1. Start weigher and conveyor belt.

Starting depends on selected start source B 06 .
Acknowledge Message E1.
2. As running display, a rotating point appears in top
left display field.
If not, Parameter Vmin (F 09) is set too high or
START key has not been operated.
3. Interpret event messages, if any, as shown in
Chapter 10 and remedy fault.
4. Call Service messages.
(a) Tachometer
If measurement is ON (B 03 = DI7), speed
transducer output frequency must be below
3000 Hz. Compare value with Spec Sheet. If
frequency heavily varies at constant belt
speed, there is too much space between
speed transducer NAMUR sensor and
gearing. See also Check of Belt Speed.
(b) wz
The unnormalized output value of load cell
amplifier must not exceed 2.85mV/V, not even
with nominal platform load. Value changes
with varying load on platform (e.g. check
weight).
Value excessive:
Load cell overloaded

Tare balance weight, if any, improperly set
Value negative:
Load cell improperly connected

Tare balance weight, if any, improperly set
(c) aw
Load on load cell in percent related to the total
of load cell rated capacities.
Interpret as under Item b). At nominal belt
load, aw should not exceed 100%.
5. If all else fails, see Test Plug item.

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808
INTECONT PLUS
Calibration
Calibration as such is not required. After input of rated
and calibration data, scale is calibrated.
VBW
Check Using Check Weight
Check with check weight is useful because
1. Mechanical or electrical faults may be given
Simply call:
1. Setting program Belt Circuit LB determining the
basis of one belt circuit for zeroing and taring
programs
2. Calibration data may be uncertain, e.g. lever

ratio not exactly known, inclination hard to
measure
3. Incorrect data may have been entered.
2. Taring program TW
The check weight should range between 30 %...100

% of nominal platform load and be exactly known.
3. Zero setting program for training. Zero point error

should be small after taring.
1. Enter effective check weight as Parameter C 08.

If weighing modules with leaf spring parallel
guidance are used, the check weight corresponds
to the actual value. In other cases, see Spec Sheet
or calculate check weight in accordance with
Chapter DETAILS / Data Flow Diagrams. For
effective check weight, belt inclination is irrelevant.
Always observe the above order of sequence.

For first program, measure exact time of one belt
circuit and enter value into Parameter C 02. For
operation and message interpretation, see Chapter 3.
Two further checks should be effected:
1. Check using check weight
2. Check of belt speed
2. Call program Weight Check CW,

as shown in Chapter Setting Programs.
For evaluation of results, see operating sequence description.
Possible causes of faults:

Distorsion of platform, insufficient alignment,
interferences on load cell cable.
In case of suspicion, repeat check with another
weight.
If something goes wrong:
our service department is always prepared to help.
Maybe only some small error or maloperation is the
cause of trouble. Check individual operations one
by one. Normally, the issue can be eliminated.
Unlinearity is mostly due to above faults; linear errors,

to incorrect data.
0539

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INTECONT PLUS
Check Belt Speed
The speed transducer frequency generator can be

driven by
1. Friction wheel in the lower belt run
2. Drive motor shaft.
In the first case, the entered characteristic value vs
(Parameter B 04) depends on the exact friction wheel
diameter; in the second, on the belt wrap factor.
Hence, check speed measurement for accuracy.
1. Acquire belt speed with stop watch and tape
measure.
To be on the safe side, conduct various
measurements and calculate mean value.
2. Read INTECONT speed display over the same
period of time.
3. Compare both values with one another and, if
necessary, correct characteristic value vs B 04.
Check Using Material

Checks or calibrations with check weights cannot
reproduce the actual circumstances to perfection.
Highly accurate weighing results can be achieved only
by various measurements with material and
subsequent correction.
For correction, use Parameter D 02.
Observe the following items:
1. Make sure the route from platform to material
collecting point is clean.
2. Ensure that material diverters, if any, do not divert
any material.
3. If feed screws or air slides are used between
platform and collecting point, feeding starts approx.
30 min. before check measurement so that normal
build-ups are given.
4. Set dedustings to a minimum.
5. Ensure that hoppers or vehicles used for transport
of material to a legal-for-trade weigher are cleaned
and weighed before every filling operation (tare).
Example:
old
new
Vg
Va
=
=
=
=
old parameter value

new parameter value
measured speed
read off speed
Old value of Parameter D 02 = 1

Within 15 min. a material amount of MW = 4.9 t is fed.
Difference in counter reading MA read on INTECONT
is 5.0 t.
This method is also applicable with unknown

characteristic values.
If characteristic value vs is known and deviations are
excessive, the space between sensor (Namur
transducer) and gearing is too big. Check by switching
ammeter into sensor circuit.
= 1 x 4.9 = 0.98
5.0
Enter computed value into Parameter D 02 .
Tooth over sensor:

else:
i= 0.1...1.65 mA
i = 1.65...8 mA
Neither level should exceed limit value 1.65 mA.
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810
INTECONT PLUS
Automatic Zero Setting
Activate the automatic zero setting function only in
clearly defined cases, e.g. if some belt circuits are run
with no load.
Parameter H 01 =
=
JA
NO
Automatic active
Automatic not active
Automatic system is active both in turned-on and

turned-off state of scale, if belt speed exceeds Vmin.
VBW
Belt Run Monitoring
INTECONT comes with belt a belt run monitoring
function designed to detect belt drift and belt slip.
Activate monitoring using Parameter N03 Belt Sensor
Active.
The belt run monitoring functions can be used only if a
belt circuit sensor (Namur transducer) and
a triangle metal sensor area on belt area
available (see Fig. Below). If not,
Parameters N03 Belt Sensor Active and
N05 BIC Active must be set to NO.
Z1 = 2500 kg
I = 0 kg/h
Measuring result of one belt circuit is continuously

compared to previous result.
If Belt Empty is identified, zero point is automatically
corrected.
Set continuous plausibility check with Parameters H
02 and H 03. For normal conveyor belts, default
values can be used, however, a check is
recommended.
1. Deactivate automatic
H 01 = NO.
2. Call zero setting program via function distributor
various times and acquire result.
3. Note final results Dev. (upper display) as of second
run.
4. The
.
highest value of Item 3 is the smallest value
for Parameter H 02.
Enter double to triple value, but min. 0.1 %.
5. Parameter H04 monitors the total of all zeroing
operations. Enter value, e.g. 2...4 times higher
than H 02.
6. Activate Automatic using Parameter H 01.
Fig.: Belt Run Monitoring

To activate belt run monitoring:
1. Set Parameter N03 Belt Sensor Active to YES.
2. Enter sensor length L into Parameter N06 Sensor
Length (s. Belt Run Monitoring figure).
3. Enter sensor width B into Parameter N07 Sensor
Width (s. Belt Run Monitoring figure).
4. Set Parameter N08 Sensor Offset to 0.
5. Call calibrating function LB: IMP/Belt.
6. Acquire result after min. 2 belt circuits.
7. Adjust sensor.
Note: Service value Imp.S indicates the number
of pulses measured for the covered sensor. If the
belt sensor is located exactly in mid sensor area,
the following value results:
Imp.S. = 0.5 * L (N06) * 0.01 * vs_Charact. Val.
(B04)
Example: N06 = 8.40 cm and
B04 = 1000 I/m result in Imp.S. = 42
0539

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INTECONT PLUS
Note: Monitor service value Belt Drift Tr indicating

the deviation of mid sensor and thus of belt from
sensor position in cm.
Example: Belt drift = 0.20 cm: Parameter N08
Sensor Offset = - 0.20 cm indicates belt slip 0.00 cm.
8. If necessary, determine event classes of belt slip
and drift messages (Parameters N09...N17).
Note: Normally, the default values can be used in
actual practice.
Control for Point of Discharge CPD

Upon measurement at the point of discharge, the
measuring point of the weighing platform is shifted to
the point of material discharge using a delay element.
The amount discharged is measured direct.
Note: If CPD is active, Automatic Belt Influence
Compensation BIC should be started as well.
Prerequisites:
Length ratio from mid platform to material discharge

point and total conveyor belt length is known.
Length ratio in percent is entered into Parameter

N02 Platf.Dis.Length.
9. Check messages.
Note: To check, adapt Parameter N08
SensorOffset accordingly and remember to reset
value to default.
To start CPD, set Parameter N01 CPD Active to

YES .
Belt Influence Compensation BIC

The automatic Belt Influence Compensation BIC is
designed to monitor and correct the belt influence. As
is with belt run monitoring, a sensor and a sensor area
are required. To commission BIC, first start belt run
monitoring.
Note: Perform initial commissioning without active
BIC.
Features
After start of the belt influence compensation, the
influence of the conveyor belt on measurement will be
compensated after approx. 10 belt circuits.
Prerequisites:
Belt run monitoring commissioned
Belt run monitoring started.
To start BIC, set Parameter N05 BIC Active to YES

.
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812
INTECONT PLUS
VBW
If items 4 and 5 cannot be performed, use
pendulum position and Rv in turn.
Cosine Pendulum
Belt weighers with variable belt inclination are equipped
with a so-called cosine pendulum which compensates
the impact of inclination on measuring result.
7. Tare scale, best in horizontal position.

8. Calibrate range using check weight and Parameter
D 02. Use setting program CW.
The pendulum is switched into the load cell (L/C)

supply voltage.
L/C
RD
Rp
Rw
Angle
C 07
1 x CSD
2 x CSD
1 x HBM
4000
2000
350
3000
1500
300
727
363
123
+/- 30
0.73
0.73
0.64
Test Plug
Almost any possible error in operation is reported by

event message. For interpretation, see Chapter 10.
RD = load cell input resistance in ohms
Rp = pendulum potentiometer resistance in ohms
Rw = calibrated resistance of Rv in ohms
1. Switch plug as shown in drawing.
1. Position pendulum near weighbridge and align

using spirit level.
2. Withdraw load cell connector X7 and replace by

test plug.
2. Param.:
At the indicated resistance values, the following

service values result:
Angle a
Lever
Tare
Tare
Do not tare scale.
(C 08)
(C 07)
(D 04)
(D 05)
=
=
=
=
0
table value
0
0
3. Use Rv to preset RW with highest possible

accuracy.
4. Bring weigher into two opposite positions,
e.g.
degr. Apply check weight, if necessary.
5. Set belt load displays to same value by correcting
the pendulum case zero point position.
0539
Check INTECONT for proper operation by using a

simple test plug. This helps to see whether the fault is
with load cel, or cabling and electrical equipment.
1. wz
apr.1.1mV/V
2. Load cell
utilization aw
apr. 55 % (C 03 =2mV/V)
apr. 39% (C03 =2.85mV/V)
If wz is in specified range, measuring amplifier

properly operates.
Note:
The test plug ordering number is V037426.B01.
6. Use potentiometer rv to vary range until until

minimum dependence of belt inclination is
reached.

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INTECONT PLUS
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INTECONT PLUS
12
VBW
Details
Start / Stop
Start / stop states exclusively refer to belt drive,
prefeeder and feed rate measurement.
Belt load and belt speed are acquired in either case.
Display with START Rotating point in upper display
:
field.
Rotation speed is approximately
proportional to feed rate, but
never zero.
Display with STOP
3. START/STOP with belt speed higher, or smaller,

than set limit value Vmin (v).
System prompts for input of unmeaned value
measured for speed V.
Point stands still after completion

:
of measurement.
After effective stop command, totalization is cut off as

soon as set afterflow time Tnach has elapsed.
STOP commands have highest priority.
Four different control modes can be configured (see
also Parameter B06).
1. START/STOP using digital input.
The default value is DI2. However, you can use any
other free digital input as well.
The digital input operates edge-controlled, i.e. If
scale cuts off after Alarm, START signal must be
removed and applied again.
4. START/STOP via fieldbus interface (FB).

Serial START/STOP commands acts in the same
ways as the corresponding keys.
The Select Keyboard Mode function lets you shift the
Start/Stop commands onto keyboard.
Return to Deselect Keyboard Mode function using
Parameter B06.
2. START/STOP using keyboard (OP)
0539
Start :
START key if no Alarm is

available and release signal
has been output.
Stop:
Stop key, Alarm, or No

Release.

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BV-H2214 GB 93
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INTECONT PLUS
Note
1) Selection v does not allow for batching.
2) Digital input Release P01 can be cut off (setting
- -), and scale is released always.
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INTECONT PLUS
VBW
Batching Without Clearance

If batch is complete, belt drive is cut-off. Feeding by
full feed/dribble feed can be controlled via belt speed
or prefeeder (dashed line).
It is recommended to activate delay for material
discharge (O 01 = YES).
Select keyboard as START source
(B 06 = DE + T).
For details, see OPERATION chapter.
Parameter Schedule:
B 06
START source
OP
G 06
Belt tracking time Tn
apr. 3 s
Feed rate determination tracking time after

belt cut-off.
Enables afterflowing material to be acquired.
N 01
CPD Active
YES
Delay for point of discharge

I 01
Batch Dribble Feed
kg
Change-over point from full feed to dribble

feed, e.g. by belt speed reduction. Enter
deviation from cut-off point I 02 (see Figure).
I 02
Batch Cut-Off Point
I 03 = 0 : No adaptation
I 03 = 1 : Full adaption
kg
Intermediate values lead to filtered

adaptation.
Belt drive cut-off point. To be set to slightly

below setpoint to enable afterflowing material
to be acquired.
Suggestion: I 03 = 0.6
I 03
Suggestion:
Mean dribble feed feed rate in kg/h divided by
3600.
I 04...
For monitoring, see Parameter List.
Correction Factor
I 07
Empty Belt
0.6
Dribble feed changeover and cut-off points

are automatically adapted upon completion of
batch for system to be better matched to
actual conditions until the time of next
batching operation.
Prerequisite for batching mode.

M 01
Feeder Active
NO
YES
0539

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NO
: Feeder control output is always

LOW. Full feed/dribble feed
changeover must be controlled via
belt drive. Function Next W/Belt
Empty is not possible.
: Prerequisite for feeder control via
batch mode and for function
START/STOP Feeder.
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VBW
M 02
INTECONT PLUS
Setting Time
sec
From 0 to nominal feed rate (see Sequence

and Parameter M 04).
M 03
Feed Distance
Material path from feeder to end of weighing

platform.
If CPD is active (N 01 = YES) the length from
platform center to point of discharge (N 02)
has to be added.
M 05 = NO
No entry required.
M 04
Motor STOP Aft. ST
YES/NO
Use M 04 to determine whether belt tracking

is desired after completion of batch or after
cut-off.
With slow feeders, tracking helps to avoid
excess feed.
Prerequisite: M 01 = YES
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INTECONT PLUS
M 05
Change-over FF/DF
Adaption:
NO
YES
After every completed batch, system uses the missing

amount to compute a correction value for cut-off point
A (I 02). Dribble feed changeover point is
automatically corrected.
Change-over via belt drive

: Change-over via feeder
(signals dashed in diagram)
Sequence:
0
Start batch through START command.

Belt drive, prefeeder, totalization (counters)
start operating.
Abort batch through STOP command.
To avoid excess feed, belt drive continues
running for time TZ after feeder cut-off
(Parameters M 01, M 02, M 04).
Restart batch through START command.

feed FM = SET - A - F is reached. Signals
Full Feed and Dribble Feed change levels.
A and F are the pre-act cut-off points
(Parameters I 01 und I 02).
Cut-off point HM = SET - A

is reached and batch is complete.
Belt drive cuts off.
So as to avoid excess feed, prefeeder shuts
down as soon as differential amount M (TZ) is
reached (M 04 = NO).
M(TZ) = I * TZ/3600
I
TZ
6.
VBW
= Current feed rate filtered through

display filter G 01
= Parameter M 02
Belt tracking and end of material flow.

If Parameters H and V are correctly set,
setpoint has now been reached. If not, see
Item Adaptation.
feed, if prefeeder is used for feed control
(Parameter N 05 = YES).
Pre-act cut-off point FMS is estimated on the
basis of the mean belt load.
Error = SETPOINT - amount fed

The new cut-off point for the next batch is computed
from the error and an evaluation factor.
F(new) = F(0ld) + FAK * Error

F
=Batch cut-off point
I 02
FAK
=Adaption factor
I 03
(see Parameter)
Errors smaller than the smallest display digit are not

corrected.
Release Signal:
Pending release signal acts as STOP command.
Alarm:
Batch is interrupted (motor and prefeeder cut off
immediately). Remedy fault, acknowledge error
message and restart..
Power DOWN:
Batch mode is cut off. Counter readings and values of
amounts fed remain stored for an unlimited period of
time. Resume batching with Preselect Batch
function.
Abort Batch function:
Abort batch. Control signal behaviour is the same as
after STOP command.
FMS = VM - L * Q - M(TZ)
Q
L
= Belt load displayed (Filter G 04)

= Material path (M 03)
M(TZ)= See Item 4
0539

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BV-H2214 GB 97
819
VBW
INTECONT PLUS
Batching With Clearance
When batch is complete, prefeeder cuts off; belt drive,

after approx. another half belt circuit. Conveyor belt is
empty. Delay for point of discharge should be
activated
(N 01 = YES).
Select keyboard for START source (B 06 = DE + T).
Function Next W/Belt Empty automatically activates
clearance mode. For details, see OPERATION
chapter.
The smallest possible actual batch amount
corresponds to the load on belt from weighing platform
to point of feed.
Parameter Schedule:
B 06
START source
OP
G 06
Belt tracking time Tn
ca. 3 s
Tracking time of feed rate acquisition after

belt cut-off.
N 01
CPD Active
YES
Delay for point of discharge
0539
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820
INTECONT PLUS
I 01
Batch Dribble Feed
VBW
kg
Sequence:
0
Start batch through START command. Belt

drive, feeder and totalizing counters start
operating.
Abort batch through STOP command.

To avoid excess feed, belt drive continues
running for time TZ after prefeeder cut-off
(Parameters M 02, M 04).
Feeder cut-off point.
Restart batch through START command.
Suggestion: Initial value 0
Changeover point to dribble feed is reached.

Full feed and dribble feed signals change
level.

feed, e.g. through reduction of feed rate.
Enter deviation from cut-off point I 02 (see
Diagram). Normally not used in clearance
mode.
I 02
Batch Cut-Off Point
I 03...
See Without Clearance
I 07
Belt Empty
kg
YES
FM = AM - F
Prerequisite for clearance mode

M 01
Feeder Active
AM
F
YES
Prerequisite for clearance mode
M 02
Setting Time
4
sec
Feed Distance
A
Mg
Material path from feeder to end of weighing

platform.
If CPD is active (N 01 = YES) the length from
platform center to point of discharge (N 02)
has to be added.
M 04
Motor STOP Aft. ST
M 05
Change-Over FF/DF
Parameter has no effect.
YES/NO
= Parameter I 02, Cut-Off Point

= Estimated load on belt between
weighing platform and prefeeder.
Mg = L * Q + I * TZ/3600
I
TZ
Q
YES/NO
Use M 04 to determine whether belt tracking

is desired after completion of batch or after
cut-off.
With slow feeders, tracking helps to avoid
excess feed (see Sequence and Diagram).
Cut-off point AM is reached, feeder cuts off.

Belt drive continues running for time Tab to
enable belt to be unloaded.
AM = SOLL - A - Mg
From 0 to nominal feed rate (see Sequence

and Parameter M 04).
M 03
= Cut-off point, see Item 4

= Parameter I 01, Dribble Feed
= Current feed rate filtered through

display filter G 01.
= Parameter M 02.
= Current belt load filtered through
display filter G 04
Tab = TZ + time for another half belt circuit

With N 04 = NO, TZ is doubled.
5.
Batching amount reached.
Cut-off command routed between Item 4 and 5 totally

aborts batch.
For Adaption, Release, etc.:
See Batching Without Clearance.
0539

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Details
BV-H2214 GB 99
821
VBW
INTECONT PLUS
Data Flow Diagram
Fig.: Measurement
Note:
Parameters:
In normal INTECONT operation, data flow diagrams

need not be known.
In special cases, they can be used to trace internal
normalizations, particulary important for (theoretical)
precalibration.
Io
Nominal Feed Rate
B 02
in t/h
Io is reference value for limit values and

service display. Io has no effects on
calibration.
Qo = in kg/m
Vo = in m/s
Io = in t/h
0539
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822
INTECONT PLUS
VBW
L
Effective Platform Length
C 06
in m
Acquire accurate length and enter.

VS
Speed Transducer Characteristic

Value
B 04
in I/m
VS determines speed measurement

normalization, thus being relevant for
weighing accuracy.
Fo
Load Cell Rated Capacity
C 04
in kg
Total of load cell rated capacities. Pivots are

considered as load cells.
Fo = (N +M) * NNENN
NENN = load cell rated capacity
N
= number of load cells
M
= number of pivots
Fo determines weigher accuracy.
E
Load Cell Characteristic Value

in mV
C 04
The transmission coefficient is an important

value for calibration.
Ua
Ue
Fig.: Displays, limit values, analog input
Qo
Nominal Belt Load
D 01
CSD load cells

HBM load cells
in kg/m
Computed by INTECONT, Qo is reference

value for limit values and displays.
Vo
Nominal Speed
B 05 in m/s
Reference value for limit values, only relevant

for calibration of weighers
0539
1.
2.
E = 2.85 mV/V
E = 2.00 mV/V
With some types, E is not calibrated. For

value, see type plate.
Nominal platform load QB = Qo L

L = effective platform length
= Load cell output voltage in mV

= Load cell input voltage in V
=
5 V (10 V)
= Load on load cell
Lever Ratio
C 06
The lever ratio is decisive for calibration

accuracy. However, it must not enter into
check weight computation.
operating without speed measurement or

using adaptive belt influence compensation
BIC is used.

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101
823
VBW
INTECONT PLUS
Belt load results from platform data and belt inclination.
F
QB
LWB
= Force applied to load cell

= Platform load
= See Figure.
in kg
in kg
With platforms with leaf spring parallel

guidance H = 1.
Belt Inclination
C08 in degr
Enter belt inclination if load cells are mounted

right-angled to belt. With vertically mounted
load cells, degree is always 0
QPRF Effective Check Weight
C 08 in kg
Fo=
Total of load cell

rated capacities
in kg
E=
Load cell characteristic value in m/mV
GK=
Device constant
This weight serves for check of theoretical

calibration.
As effective check weight, enter platform load
simulated by check weight.
For check weight factor f, see Spec Sheet.
a=
= Load cell input voltage

Angle
in V
in degr
Belt speed is computed from speed transducer output

frequency.
QPRF = f * Check Weight
KOR
Ue
Range Correction
D 02
D 02 is primarily used to calibrate results of a

material check. This parameter exclusively
acts on belt load measuring branch.
Analog Output:
The product from Q and V is feed rate I.

I = Q * V * 3600s/f in kg/h
For tare parameters to be accurately calibrated, range
correction takes place before taring. If range
normalization QN is modified (Parameters KOR, Fo,
etc.), tare parameters are automatically converted so
that zero point is maintained.
ANH << = 1 >> = 20mA

X = I, V or Q (see Fig. Analog Output)
Operating Principle - Summary
Load cell output voltage Va is amplified and converted
into digital value d.
As transmission factor A0 of AD converter and load
cell data are known to INTECONT, load on load cell
can be computed from the output voltage.
Details
BV-H2214 GB
102
Technische
Redaktion BVED
Weighers without Speed Measurement:

For setting program LB, a frequency of V0 * VS is
internally generated. If one of the two parameters is
changed, call LB program again. Only then all other
setting programs will run over integer belt circuits.
0539

and copyrights.
824
INTECONT PLUS
VBW
Connection Diagram
Base Card
0539

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BV-H2214 GB
Details
103
825
VBW
INTECONT PLUS
0539
Details
BV-H2214 GB
104
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and copyrights.
826
INTECONT PLUS
VBW
Option Card
0539

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BV-H2214 GB
Details
105
827
VBW
INTECONT PLUS
n
Namur Inputs
8 mA
=
1.65...8 mA =
0.1...1.65 mA=
0,1 mA
=
Cable Fastening
Short circuit
Level 0
Level 1 (sensor covered)
Cable breakage
Option Card:
The option card is attached to the INTECONT cover.
Signal exchange with base card is via a pluggable flat
cable connector.
If pulled off, system behaves as if no option card was
present and only the operating functions and
parameters of the base card can be used.
Cabling Hints
n
All cables are led to the device from the rear

(front-of-panel mounting housing) or from below
(flush mounting housing) and connected with
special connectors. Connectors cannot be
confused.
The INTECONT is isolated from the mounting

surface by its plastic housing.
The rear earthing connector is internally connected
with the electronics zero potential.
The protective ground used requires to be hum- and
transient-free.
The power supply zero potential (0V ext.) is not
connected to the earthing connector. In general, no
earthing is required.
Ensure that no leakage currents are conducted over

cable shields. Therefore shields are applied to one
side of INTECONT. The load cell housing is not
connected with shields.
Shields of data cables to host computer are
connected to ground on either side.
The consumers connected to the relay and pulse

outputs require to be radioshielded, e.g. by
suppressor diodes or RC elements.
Analog outputs
Long cables, particularly to frequency transducers,
can interact on analog outputs. We suggest to use
an isolating amplifier.
Make sure the space between power and

measuring cables, if run in parallel, is 0.30 m.
If this is not possible lay measuring cable in steel
conduit. The same holds if the measuring cable is
laid over free stretches or close to powerful
transmitters (e.g. broadcasting stations).
Details
BV-H2214 GB
106
Technische
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In the rear wall of the INTECONT, under each

connector, several slots are provided. The
upper slot pair is reserved for the cable clamp
which presses the shielded cable against the
rear wall. The shield needs not be separately
connected. The lower cut-out serves for
accommodation of a pull relief, e.g. by cable
binders.
Attention!
Connectors to base card require to be plugged-in
with screwed connections up; connectors to option
card, with screwed connections down.
n
Intecont rear view: Connectors
0539

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828
INTECONT PLUS
VBW
Weighing Platforms
1. Effective Platform Length
Multi-Idler Platform
The effective platform length is an important value for

calibration. Determined by platform design, it can
normally be taken from Spec Sheet. However, we
recommend to remeasure length and to enter the
exact value into parameter.
The hatched areas shows the distribution of load on
platform.
n
Single-Idler Platform
Buckled Platform
e.g. BMK type
The platform consists of two sections. In its center,
force is applied to load cell. Instead of weighed
idlers, a two-sectional weighing table can also be
used.
e.g. BEZ, BED types

Platform load is applied to load cell via a weighed
idler. This can be done by using a lever system or,
with no levers, by leaf spring parallel guidance.
Buckled Platform
Single-Idler
Platform
n
e.g. BMP, BMC types
Various weighed idler are connected to form a
mechanical unit.
0539

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BV-H2214 GB
Details
107
829
VBW
n
INTECONT PLUS
One-sided mounting of total belt
2. Check Weight QPRF

Simulating a certain belt load, the check weight is
used for control of weighing system. It can act on
weighing platform direct or via lever system.
The weight to be entered into INTECONT is not the
actual weight, but the weight acting on platform.
Effective check weight QPRF is the platform load in
kg simulated by the check weight
Single-Idler Platform
a) Parallel Leaf Spring Mounting
Theoretically, the check weight can be applied
to any point of the mechanical platform
equipment. Applied weight QP is active always.
One-sided
mounting
QPRF = OP
b)
Joint Mounting (e.g. Universal Spring Joint):
Lg = Length up to mid hillside
tan(a)
Angle a= 0
Angle a = neg
: K
:K
=
=
0,018 a
0
neg
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830
INTECONT PLUS
n
VBW
3. Conveyor Belt Inclination
a) Total platform mounted on load cells:

In certain cases, the inclination of conveyor belt has to
be entered into parameter. Decisive is the load cell
mounting position.
QPRF = QP
b)
Joint Mounting
a) Right-angled to conveyor belt
See Single-Idler Platform

n
Enter angle a into parameter. Load cell is loaded

with N = Q * cos a.
Buckled Platform
QPRF = QP
Normally, check weight acts on center.
One-sided mounting of total belt
QPRF = QP
LPG
LWZ
b) Vertical to conveyor belt
With inclined belts, consider extension, or shortening,

of calibration lever, if any, in accordance with
single-idler platform.
Enter 0 as angle a. Load cells are loaded with full

force Q.
Chain Calibration Weight:

If a chain curtain is placed over the platform area, the
total weight of chains in weighing area is the effective
check weight.
QPRF = n * Lg * s
N=
Number of chains
Lg=
Overall belt length
in m
s=
Chain weight per m
in kg/m
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Details
109
831
VBW
INTECONT PLUS
Printer Connectivity
Interface
Character map:
Cable
: Serial (see Chapter Technical

Data).
ISO-Latin-1 (ISO-8859-1)
: The connection diagram holds
for EPSON and CITIZEN
printers.
Switch
1-1
1-2
1-3
1-4
1-5...8
2-1...6
:
:
:
:
:
:
OFF
8-bit message
OFF
No parity bit
ON, OFF Even/odd
OFF
Positive edge
OFF, ON, OFF, OFF
9600 baud
ON, ON, OFF, OFF, OFF, OFF
(default)
Use Parameter J 01 to set baud rate to 9600. On the

right side of printer, there are two additional DIP
switches. Diagram view corresponds to top of printer.
Fig. EPSON Printer

Switch
1-1
1-2
1-3
1-4
1-5
1-6...8
2-1
2-2
2-3
2-4
Fig.: Printer Cable
:
:
:
:
:
:
:
:
:
:
OFF
Character spacing 10 CPI
OFF
Zero with no backslash
ON
Graphics character set
OFF
Auto hyphenation activated
ON
Normal print speed
ON, ON, ON
USA
ON
Page length 12 inch
OFF
No cut sheet
OFF
Jump over perforation
OFF
No auto line feed
Information on switch position can be printed by using

the printer self-test function. (Press line feed key while
starting printer).
CITIZEN Printer: 120D
Fig. EPSON Interface
EPSON Printer: LX 850
Fig. Serial Interface
The interface board is equipped with 2 DIP switches

used for selection of serial message base data.
0539
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832
INTECONT PLUS
VBW
13 Replacement Instructions
Replacing INTECONT PLUS FIP > INTECONT PLUS VEG
INTECONT PLUS, type VEG, is equipped with added functions for INTECONT PLUS, type FIP. Logical
inputs/outputs can now be assigned to hardware at will. Please also check all connectors with relevant
parameter assignment.
When using our convenient replacement set (ordering no. V036910.B01), hardware is adapted by plugging.
The EasyServe setting program supplied enables easy assignment and transfer of all software parameters.
FIP base card connection diagram
FIP option card connection diagram

0539

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Technische
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Replacement Instructions
BV-H2214 GB 111
833
VBW
INTECONT PLUS
The FIP base and option cards connection diagrams

indicate for every digital input and output the relevant
INTECONT VEG parameter numbers used for
distribution on physical signals.
The tables below compares the connector
assignments of FIP and VEG for all physical signals.
Digital Outputs
FIP
X1
X1
X1
X6
X6
X6
X6
X6
1,2
3,4
5,6
1,2
3,4
5,6
7,8
9,10
Physical Signal
VEG
DA1
DA2
DA3
DA4
DA5
DA6
DA7
DA8
X1
X1
X1
X8
X8
X8
X8
X8
1,2
3,4
5,6
1,2
3,4
5,6
7,8
9,10
X3
X9
X9
X3
X5
X3
1,2
1,2
3,4
5,6
1,2
3,4
FIP
X5
X5
X5
X5
X5
X5
Physical Signal
VEG
DE1
DE2
DE3
DE4
DE5
Sensor = (DE6)
V1 (Tacho 1) = DE7
V2 (Tacho2)
X3
X3
X6
X9
X9
X3
X7
-
1,2
3,4
6,7
1,2
3,4
5,6
1,2
3
4
5
6
7
8
9,10
OUT1
REF1
IN2
IN1
REF2
OUT2
X7
X7
X7
X7
X7
X7
3
4
6
5
7
8
Power Supply
FIP
1
2
3
4
Physical Signal
VEG
0V ext
24V ext
ext. 0V supply
ext. 24V supply
X2
X2
X2
X2
Physical Signal
VEG
Screen
TX
RX
X10
X10
X10
Physical Signal
VEG
24V
Open collector
Open emitter
0V
X6
X6
X6
X6
1
2
3
4
Printer
FIP
X8
X8
X8
1
2
3
FIP
X9
-
VEG
1
2
3
Pulse Output
Analog Inputs/Outputs
FIP
Physical Signal
Attention:
Signals IN1 and IN2 are swapped between FIP and
VEG. (VEG is compatible to DISOCONT).
X2
X2
X2
X2
Digital Inputs
FIP
Load Cell
Physical Signal
VEG
A01
A02
X6
X9
4,5
5,6
AI
X6
1,2,3
X9
X9
X9
X9
5
6
7
8
8
9
10
11
With VEG, fieldbus is connected via separate fieldbus

cards (FIP: Connector X7). See Fieldbus Manual
BVH2220.
0539
BV-H2214 GB
112
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and copyrights.
834
INTECONT PLUS
VBW
Connector Size
FIP
X1
X2
X3
X5
X6
X7
X8
X9
Phoenix contact spacing 5mm : 6 pins

Phoenix contact spacing 5mm : 8 or 10 pins
SUB-D: 9 pins
SUB-D: 9 pins
VEG
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10

Phoenix contact spacing 3.5mm : 6 pins
SUB-D: 9 pins
0539

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BV-H2214 GB 113
835
VBW
INTECONT PLUS
0539
BV-H2214 GB
114
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and copyrights.
836
837
MEASURING AND PROCESS TECHNOLOGIES

D-64273 Darmstadt
Phone:
+49 (0) 6151-32 10 28
Fax:
+49 (0) 6151-32 11 72
E-Mail:
www.schenck-process.net
The
Group
838
Spec Sheet FLB679S

Edit
Print
Excel
Customer
TAIM-TFG
Order no.
Serial number, mechanics
Serial number, options
Serial number, hopper
Serial number, electrics
P4810
FLB679S
Designer, CPE mechanical

Designer, CPE electrical
Tester mechanical
Tester electrical
Last modifed by
Text
TECHNICAL DATA SHEET
BELTWEIGHER EXTENDED
TYPE OF CONTROLLER
TYPE OF CONTROLLER SOFTWARE
English
MACHINE DATA
BELT LENGTH (+- 3%)
BELT CIRCUIT NO: CALIBRATION
BELT CIRCUIT TIME AT PNOM
SENSOR LENGTH
SENSOR WIDTH
LOAD CELL TYPE (L/C TYPE)
L/C RATED CAPACITY (L/C TOTAL)
L/C CHARACTERISTIC VALUE
LENGTH OF LEVER PLATFORM L LP
LENGHT OF LEVER L/C L LC
LEVER RATIO R1
(C07, RATIO R1=L LP : L LC)
BELT INCLINATION
Load last
Code word
CSD code word
G7.052-BS
Master Spec Sheet type
VBW0600
Date
Date
Date
Date
Date
Parameter
Value
Unit
INTECONT PLUS
VBW 20600
GENERAL DATA
SCALE TYPE
DIMENSIONAL DRAWING
DOCUMENTATION ELEC. EQUIP.
FEED MATERIAL
BULK DENSITIY GAMMA
GRAIN SIZE
HUMIDITY (MOISTURE)
MATERIAL TEMPERATURE
FLOW PROPERTIES
OTHER CHARACTERISTICS
RATING DATA (NOMINAL VALUES)
NOMINAL FEED RATE PNOM
EFFECTIV PLATFORM LENGTH
NOMINAL SPEED AT PNOM
FREQUENCY SPEED TRANSDUCER AT PNOM
PULLEY DIAMETER
MATERIAL OUTLET AREA
MATERIAL BED DEPTH
LOAD ON PLATFORM AT PNOM
PRELOAD
Auslegen
BEM14
F 008 401
t/m3
mm
%
C
B02
C05
B05
1600000
1,2
2,09
70,028
255,183
106
kg/h
m
m/s
Hz
m
m2
m
kg
kg
m
C01
C02
N06
N07
1
s
cm
cm
C04
C03
PWS 300
600
2
C06
1,0
C07
kg
mV/V
mm
mm
grd
839
(LC IN RIGHT ANGLE TO THE BELT)

SPEED TRANSDUCER TYPE
SPEED TRANSDUCER CHARACT. VALUE VS
TEST WEIGHT UNIT
LENGTH LEVER TEST WEIGHT L TW
TEST WEIGHT (NO. OF STROKES) N1
F=SIMUL. PLATFORMLOAD/KG TESTWEIGHT
EFFECTIV CHECKW.= F X CHECKW. Q
B04
Imp/m
mm
kg/kg
kg
C08
ELECTRICAL EQUIPMENT, DATA

SUPPLY VOLTAGE
CHARGEABLE NEUTRAL W. REQUIRED ?
MAINS FREQUENCY
POWER CONSUMPTION
MAX. EXT. FUSE
OPTIONAL FUNCTIONS
BELT INFLUENCE COMPENSATION BIC
DELAY FOR THE HEAD PULLEY
BELT LENGTH PLATFORM-HEAD PULLEY
FGA20 RSLE
33,51
V
NO
Hz
kVA
A
N05
N01
N02
NO
NO
% LB
840
841
842
843
844
845
846
847
848
849
DE
Richtlinien zur Lagerung und Handhabung der gelieferten Teile und Maschinen
GB
Guideline for Storage and Handling of Components and Machines Supplied
FR
Directives pour le stockage et la manutention des fournitures de pices et de machines.
NL
Richtlijnen voor de opslag en behandeling van geleverde componenten en installaties
IT
Direttive per limmagazzinamento e la manipolazione di componenti e macchine fornite
ES
Directrices para el almacenamiento y la manipulacin de las piezas y mquinas suministradas
PT
Diretrizes para Armazenamento e Manuseio de Componentes e Mquinas Fornecidos
SE
Bestmmelser om frvaring och hantering av de levererade delarna och maskinerna
PL
Wytyczne dla skadowania oraz postpowania z dostarczonymi czciami oraz urzdzeniami
RU
RO
Directive pentru depozitarea i manipularea pieselor i mainilor livrate
BV-R2000AA
850
851
Contacts, Copyright
Sales:
Tel.:
E-Mail:
+49 (0)6151 32 - 10 28
Service:
24h Emergency hotline:
+49 (0) 172 - 650 17 00 Discontinuous Weighing Technology

+49 (0) 171 - 255 11 95 Continuous Weighing Technology
E-Mail:
Business Segments:
Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 26 23
+49 (0) 61 51 32 - 32 70

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 25 72
+49 (0) 61 51 32 - 20 72
Vibrating Machines
Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 10 75
+49 (0) 61 51 32 - 30 96

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 24 48
+49 (0) 61 51 32 - 13 69

Service Tel.:
Service Fax:
E-Mail:
+49 (0) 61 51 32 - 17 58
+49 (0) 61 51 32 - 36 32
Copyright 2004
Landwehrstrae 55,
D-64293 Darmstadthttp://www.schenck-process.com
Alle Rechte vorbehalten. Jegliche Vervielfltigung dieser Dokumentation, gleich nach welchem Verfahren, ist ohne vorherige schriftliche
Genehmigung durch die SCHENCK PROCESS GmbH, auch auszugsweise, untersagt. nderungen ohne vorherige Ankndigung bleiben
vorbehalten.
All rights reserved. Any reproduction of manual, regardless of method, without prior permission bySCHENCK PROCESS GmbH in writing, even
by excerpt, is prohibited. Subject to change without prior notice.
Tous droits rservs. Toute reproduction de cette documentation, mme partielle, et par quelque procd que ce soit, sans lautorisation
pralable crite de SCHENCK PROCESS GmbH, est strictement interdite. Sous rserve de modification sans avis pralable.
852
853
Richtlinie zur Lagerung ..., Guideline for Storage ...

Directives pour le stockage ...Richtlijnen voor de ...
Equipment supplied by Schenck is, as a matter

of principle, intended for immediate installation or
erection. However, if between the time of delivery
to site and the time of installation and/or erection
intermediate storage becomes necessary,
customer shall so notify Schenck, and unless
Schenck determines otherwise, customer shall in
this case adhere to the following instructions.
The possibility of storage on site depends on the
type of packing selected. If storage on site is not
be possible, Schenck will notify the customer
accordingly.
1.
Goods Inwards Inspection
1.1
Check packages as soon as received for complete count and

apparent damage.
1.2
If package is damaged, file a claim with carrier, call in the appropriate damage assessing agent, and notify Schenck immediately and comprehensively of the damage. Do not take any
other measures for the time being (save in case of imminent
danger) until discussed and agreed with Schenck. Schencks
liability in any such case depends upon Contractual arrangements.
1.3
If package has been opened by Customs authorities, reclose

package immediately, or repack equipment in accordance
with Schenck standards. Schenck will give relevant details
upon request. Pay particular attention to the functionality of
all corrosion preventive means (intactness of foil wrapping,
especially air-tightness; presence of rust-preventive paint
coat, and effects of desiccating agents, etc.).
2.
Transport, Storage and Retrieval

Operations
2.1
For in-plant transport, storage and retrieval, use the transport

aids provided for this purpose (e.g. eyes), and follow appropriate Schenck instructions.
2.2
Take precautionary measures to ensure shock- and vibration-sensitive equipment is handled gently (especially, measuring instruments and weighing equipment). Shocks and
vibrations in handling and storage are by all means to be avoided.
3.6
Protect equipment from ionizing radiation (X rays, radio activity, etc.) as well as microvave radiation and magnetic
fields. The same limit values apply as for the protection of
personnel.
3.7
Maximum storage life of equipment in original packing is six

months from delivery ex Schenck works. Storage time does
not extend the warranty period granted by Schenck.
3.8
Check packing for damage at regular intervals, at least once a

month. Verification after six months of storage from date of
shipping ex works shall comprise opening of the outside packing, checking of the interior packing (air-tightness of foil)
and functionality of desiccating agents, and the possible taking of conservation measures (see 4.5). After this verification, and after taking the necessary measures, including
restoration of the air-tightness of foil, reclose the outer packing so as to restore the original state.
If damage to packing or equipment is discovered, call in the
appropriate damage assessing agent for assessing the actual
damage. Make available to him all required portions of the
packing material and goods plus documents, especially shipping documents., and give all data necessary for the assessment. Schenck shall be liable only for damage which
according to the assessment is demonstrably and incontestably due to improper packing or has occurred in transit to the
agreed point and/or before the date of transfer of risk of loss.
Schenck shall not be liable for damage occurring during or on
the occasion of inspection activities described or any measures taken by the customer.
The inspection intervals may have to be reduced depending
on local conditions. On the other hand, after the inspection
described and taking the necessary measures (replacement of
foil, desiccating agents, etc., and conservation measures),
another six-month storage period may follow; hence a total
period of 12 months storage from date of shipment ex works
is permissible.
3.9
After completion of the maximum permissible storage period (3.7 and 3.8), further conservation measures may become
necessary. If so, the measures to be taken will have to be discussed with Schenck. Without such agreement, any contractual warranty becomes null and void, should it still have been
in effect.
3.10
Before unpacking the equipment for installation or errection,

or taking the measures described in 3.8 and 4.5., store the packages in the unopenend state for a minimum of 24 hours in
the room where unpacking is to take place.
4.
Special Instructions for Storage and

Handling
4.1
Electrical/Electronic Components, Assemblies, Equipment

Store in air conditioned location,
4.2
Data Carriers (Floppy disks, hard disks, magtapes)

Place all data carriers in protective wrapper (original packing) as soon as removed from drive. Do not kink, fold, or
place under load. Keep floppy disks standing upright in protective box. Protect data carriers from magnetic fields (e.g.
line transformer) and ferromagnetic material. Strong magnetic fields may destroy data stored on data carriers, and heat
and sun radiation will harm data carriers.
4.3
Mechanical Parts/Components
Keep packages containing such items in an enclosed space.
Symbols painted onto package are to be noted.

2.3
Interconnecting cables are no handles! If they are used as

handles, damage will be inevitable. Cables supplied by
Schenck are properly manufactured and tested. Schenck accepts no liability for damage or loss caused by improper
handling.
3.
Storage
3.1
Store all goods in original packing, except those repacked

under 1.3 or 3.8.
3.2
Store on a plane surface and in upright position. Crates are

marked accordingly.
3.3
Permissible stacking pressure is:
Cartons: 0.2 t/m2

Wooden crates: 2.0 t/m2
3.4
Store equipment so as to be protected from rain, dew, condensate, other kinds of moisture, and corrosion-promoting
atmosphere. Permissible storage temperature is -5...+45 C.
Avoid greater changes. Maximum permissible relative humidity is 70% at all temperatures.
3.5
Ensure sufficient protection from infestation by vermins, taking due account of local conditions.
BVR 2000 AA/0408
854
Richtlinie zur Lagerung ..., Guideline for Storage ...

Directives pour le stockage ...Richtlijnen voor de ...
4.3.1
Conveyor Rubber Belts and OtherRubber Items

After the time period according to 3.7 has expired, the following conservation measures are required:
4.3.2
In the event customer gains new information about the state

of the art in storage, or if such new information becomes generally known, customer shall have an obligation to act in accordance therewith or, as applicable, to fulfil whichever
requirements are stricter.
5.3
If damage occurs and customer cannot prove that these Instructions have been adhered to, customer shall lose the Contractual right to claim compensation for any damage or loss
demonstrably or apparently due to his failure to adhere to these Instructions.
5.4
The extent of Schencks liability for any damage or loss shall

be governed exclusively by the Contractual arrangements.
Under no circumstances shall Schenck be liable for damage
or loss not occurring to the delivered equipment itself.
Release tension of rubber belts.

Treat rubber belts with glycerol.
Store in cool, dry place, protected from incident light.
Protect rubber items from ozone effects.
Conveyor Idlers
After the time period according to 3.7 has expired, rotate idlers by hand, in order to counteract segregation of lubricants
and, thus, resination. Check protective, coating of idlers,
especially on turned idler shells. Touch up if necessary.
4.3.3
Bright Parts
After the time period according to 3.7 has expired, check protective coating of all bright parts. Touch up if necessary, or
renew, using, for instance, Tectyle 506.
4.3.4
Gearboxes
are normally supplied conserved. After the time period according to 3.7 has expired, do flush with a conservation
agent, ENSIS 20 (Shell), for example.
4.4
Steel Structures
Steel sructures may be stored in a space that is merely roofed
over if conditions according to 3.4, first sentence, are met.
Store in elevated location to ensure protection from ground
moisture.
4.5
Hazardous Goods
Keep hazardous goods strictly apart from other goods. Store
in accordance with legal regulations.
4.6
Vibration Exciters
are internally preserved and packed in crates. In case of
long-time storage, corrosion protection has to be renewed.
Please heed instructions in technical documentation.
4.7
Compression Springs
are to be untensioned. To do so, proceed as follows: Measure
distances between spring supports top and bottom. Cut two
steel channels per spring position to 30 mm longer than distance measured. Lower machine on the channels, thereby releasing spring tension.
5.
Validity and Effectiveness
5.1
The storage instructions above apply generally for all

Schenck deliveries in accordance with the first paragraph of
these Instructions. Furthermore, data sheets and/or technical
information, instructions, etc., provided in or with sales proposals, order confirmations, or other correspondence, arevalid.
5.2
The foregoing limitation of liability shall not apply in case of

intent or gross negligence. However, where intent or gross
negligence on the part of non-executive personnel of
Schenck is involved, Schenck accepts liability only if the employee in question has violated an essential obligation under
the Contract. Furthermore, the aforesaid limitation shall not
apply in cases where a defect in the delivery item causes bodily injury or damage to privately used property and where
liability for such injury or damage is incurred by virtue of the
Product Liability Act. Neither shall it apply in case of deficiency in expressly warranted features or properties, where it
has been the purpose of such warranty to save the customer
harmless from loss or damage occurring not to the delivery
item itself. For losses which are purely economic, e.g., loss of
production, decrease in output, or loss of profit, the level of
compensation shall be limited with due regard to the general
bona fide principles, for instance when the amount of loss is
out of all proportion to the price of delivery.
6.
Applicable Law; Place of Jurisdiction;

Miscella neous
6.1
With respect to the relationship established between Schenck

and customer by the formation of the Contract, there shall apply exclusively the laws, orders and regulations in force in
the Federal Republic of Germany, with the exception of the
United Nations Convention on Contracts for the International Sale of Goods.
6.2
For all suits arising out of controversies over Contractual

matters, customer consents to the jurisdiction of the Darmstadt courts. Schenck reserves the right, however, to bring action in any other court where jurisdiction over customer may
be obtained.
6.3
The data supplied to Schenck will be processed and stored on

a computerized basis. Information supplied relating to persons is protected against misuse in conformity with German
data privacy legislation.
BVR 2000 AA/0408
855
OLEO BUFFER
856
Manuals 2006
Issued 26/04/06
Index
Introduction
Page 2-3
Routine Attention
Page 4-5
Extension Checks
Page 6
Air Inflation and Checking
Page 7-8
Inflation Tools
Page 9
Dismantling
Page 10-11
Re-Assembly
Page 12-14
Spares
Page 15
Special Tools
Page 16
Special Features
Page 17
Appendices A and B
Pages 18-19
Assembly Drawing - 4M
Page 20
Assembly Drawing - 4G
Page 21
Installation Drawing and Data
Page 22-23
Plunger Assembly Drawing and Parts List
Page 24-25
Cylinder Assembly Drawing and Parts List
Page 22-24
Head/Bellows Assembly Drawing and Parts Page 28-29

List
Metering Pin Assembly Drawing and Parts Page 30
List
Buffer Coding
Page 31
Safety and Environmental addendum
Page 32-34
Note: Please refer to important information

in the Safety and Environmental Addendum
on Pages 32-34
Type 4 service manual
1
857
Manuals 2006
Issued 26/04/06
Introduction
The OLEO buffer is essentially an oil dashpot and the sectional illustration shows
its simple yet robust construction. Under impact, the plunger is forced into the
cylinder displacing the oil through the orifice into the plunger, moving the
separator piston towards the buffer head and compressing the air to a higher
pressure. The compressed air acting through the separator piston on to the oil
forms the recoil spring to re-extend the buffer plunger.
When the plunger is moved in slowly the oil passes through the orifice at a slow
velocity with little pressure drop so that the resistance to closure is controlled
mainly by the compression of air. This gives a ''soft'' buffer to cushion low speed
impacts gently.
However, when the plunger is forced in rapidly, the oil displaced by the plunger
has to pass through the orifice at very high velocity which automatically raises
the pressure in the oil compression chamber thus providing the resistance to
buffer closure required to cushion the impact. By absorbing the impact energy as
evenly as possible throughout the plunger travel, buffer forces can be kept to a
minimum and this very desirable feature is accomplished in the OLEO buffer by
the tapered metering pin which progressively reduces the orifice area during
buffer closure. The contour of the taper is precisely calculated to provide the best
possible protection to travelling cranes etc., whether lightly or heavily loaded and
no matter what the impact speed may be, the impact is always hydraulically
cushioned throughout the buffer travel.
The 'OLEO buffer therefore possesses the unique ability of changing its
characteristics according to the needs and therefore keep buffer forces to a
minimum under all impact conditions In addition, most of the impact energy is
transformed into heat in the oil and thus absorbed within the buffer and even the
low recoil force is partially damped out

2
858
Manuals 2006
Issued 26/04/06
Introduction
Metering Pin
Cylinder
Air Chamber
Oil
Chamber
Orifice
Separator
Plunger

3
859
Manuals 2006
Issued 26/04/06
Routine attention
The OLEO buffer may be considered to be a sealed unit, and requires no
scheduled attention in the form of topping up with air or oil in the field
The buffer service life for normal duty, such as cranes, is expected to be in the
order of ten years or more. Where the utilisation is above the norm, i.e. frequent
impacts per hour, it should be understood that a periodic check be made to
ensure there is no serious loss in performance, resulting in damage. However, in
order to achieve the best service life, whatever the duty, it is beneficial to give
certain routine attention when the opportunity arises, for instance during plant
shutdown time.
The amount of attention required largely depend upon the working conditions in
which the buffer is operating. Where conditions are exceptionally dirty and the
buffers may become entirely covered with waste material such as metal scale or
coal dust, it is beneficial to brush away all external material and to wipe clean
whenever possible.
Where buffers are operating in adverse environments, e.g. North Sea Platforms
and Dockside installations, particles from the salt laden atmosphere can be
deposited on the buffer and in time cause corrosion of the plunger. In such
environments it is recommended the plungers are frequently cleaned to remove
any corrosive deposits and then coated with a film of mineral oil. In some
environments it is likely that bellows have been fitted to protect the chromium
plated plunger. These should be removed at service intervals and the plunger
wiped clean to reduce the adhesion of abrasives which can be drawn into the
buffer, when refitting bellows having a rotating adapter adjacent to the buffer
head -it should be lubricated

4
860
Manuals 2006
Issued 26/04/06
Routine attention
CHECK
ACTION (if faulty)
(a) The extension of the plunger when
Proceed with Service Maintenance.
free, to be checked against dimensions
Alternatively, return buffer to Maker s
given on page 6
Works for attention
(b) The bolts attaching the buffer to the

structure or vehicle are fully tight
Retighten bolts.
(c) The Allen screw securing the buffer

head should be checked for lightness
Retighten screws with Socket Wrench to
they may have become loosened by
50 1b.ft.torque loading (68 Nm)
intensive impact brows.

5
861
Manuals 2006
Issued 26/04/06
Extension checks
4GBZ ***
4GFZ ***
4GCP ***
117MM
108MM
4ABZ 145 **
4AFZ 145 **
4ACP 145 **
139MM
130MM

6
862
Manuals 2006
Issued 26/04/06
Air inflation and checking

INTRODUCTION
The compressed air in the OLEO buffer is contained within the Plunger at the
Buffer Head end.
The Air Plug is situated in the centre of the Buffer Head in the Type 4G unit.
However, in the Type 4A and the Type 9 unit, it is situated in the centre of the
End Plug behind the Buffer Head, which has to be removed in order to gain
access by removing the head retaining socket screws. Air plugs are protected by
screw-in Dust Caps or Rubber Plugs.
TO CHECK AIR PRESSURE (Refer pages 24-25)
1. Using a broad bladed screwdriver, unscrew the Dust Cap and wipe out any dirt
in the recess
2. Smear the rubber seal on the stem of the Checking Adaptor (OPT 2A) with oil,
and push into the recess and oscillate until the square head of the Air Plug
has been engaged (DO NOT UNSCREW THE AIR PLUG AT THIS STAGE).
3. Screw up the centre spindle so that the threaded end protruding through the
Checking Adaptor engages the thread in the Air Plug, and tighten slightly to
retain the Checking Adaptor in position.
4. Using the Air Checking Adaptor as a box spanner, unscrew the Air Plug very
slightly so that the air in the buffer is connected to the Air Checking Adaptor,
and record the pressure.

7
863
Manuals 2006
Issued 26/04/06
Air inflation and checking

TO RELEASE AIR PRESSURE
Proceed as instructed previously but in this case unscrew the Air Plug half a turn
to release all the air. Alternatively, use Box Spanner OPT. 1.
TO INFLATE AIR CHAMBER

First connect the Air Pump (OPT.3) . Alternatively. a nitrogen bottle fitted with a
reducing valve set at between 25-35 Bar to the Checking Adaptor at the end of
the hexagonal extension in place of the blanking plug and follow instructions up
to Stage 4, but in this case unscrew the Air Plug half a turn.
Inflate until the required pressure (see table below) is reached Any excess
pressure may be released by unscrewing the knurled knob on top of the Adaptor
slightly. Now tighten the Air Plug securely, using the Adaptor as a spanner.
Remove the Air Checking Adaptor by first fully unscrewing the knurled knob to
disconnect from the Air Plug, after which the Adapter can be pulled out. Replace
dust cap.
INFLATION PRESSURE TABLE (UNLESS OTHERWISE SPECIFIED)
METERING PIN CODE
PRESSURE
5 BAR
7 BAR
7 BAR
5 AND UPWARDS TO 16
10 BAR

8
864
Manuals 2006
Issued 26/04/06
Inflation tools
OPT. 1. AIR PLUG BOX SPANNER
This is basically a standard 3/8 inch sq. box spanner with the outside reduced to
.62 inch diameter to enter the recess in the buffer head and the tommy bar
limited to 4 inches long to prevent over straining.
OPT. 2A AIR INFLATING AND CHECKING ADAPTOR
This is designed for both initial inflating of the buffer assembly, and for
subsequent checking of the air pressure, and is supplied complete with a 300
p.s.i. Pressure gauge. The air plug housed in a recess in the buffer head centre
has a inch square head and the centre of the air plug is tapped inch B. S. F.
thread. Part of the Inflation Adaptor is in the form of a box spanner to fit over the
square head of the air plug and it has a screwed spindle position against the air
pressure. The outside of the box spanner portion of the adapter carries a rubber
"O" seal to prevent leakage of air.
In use, the head of the air plug and adapter is first fitted over the centre spindle
lightly tightened to retain it in position The adapter is then used as a spanner to
open the air plug about half a turn either for inflating or checking the air pressure
The air plug should always be retighten securely before removing the adapter,
unless all a pressure has been released from the buffer. The initial unscrewing of
the centre spindle, less than a quarter of a turn, acts as an air release if it is
desired to drop the air pressure
OPT 1

9
OPT 2A
865
Manuals 2006
Issued 26/04/06
Dismantling
Although cleanliness is not of major importance during dismantling, it is desirable
to remove as much dirt as possible from the outside of the buffer prior to
dismantling.
TYPE 4G and 4A BUFFERS (Refer to pages 24-25 and 30)
WARNING. Before dismantling THE AIR PRESSURE MUST BE RELEASED as
instructed in Pages 7-8. Remove protective bellows, if fitted.
To drain out the oil.
Stand the buffer with metering pin Nut (2) uppermost. Unscrew the Nut
completely and remove. With the buffer compressed, screw Extension Rod into
end of Metering Pin (1) and remove 'O' Seal (9). Now push in Pin to release oil.
To Separate Plunger and Cylinder.
Stand the buffer with head upwards. Lift out Plunger. During extraction the
reduced neck of the Plunger passes inside the Bearing (16) and Scraper Ring
(14) (metal type). Otherwise, as soon as the neck appears, remove Scraper Ring
(14) rubber type) from its groove. Should the ring become jammed, cut it away.
When the Bearing (16) springs inwards and is free, fully withdraw the Plunger,
keeping it centralised as much as possible. Ensure Bearing extracts evenly,
otherwise push Plunger back in and repeat. Replace Nut (2) to retain Pin.
To remove Seals and Bearings
Stand Plunger on its head. Spring off Piston Ring (19) and Bearings (14) and
18).Cut off Sealing Ring (17) and Backing Rubber (7).Spring off Support Ring

10
866
Manuals 2006
Issued 26/04/06
Dismantling
(6) by opening up its gap. Similarly, remove Scraper Ring (14) (metal type)
(Also, if fitted, unscrew Drive Screw from groove in Cylinder -scrap).
4A Units Only
This unit may be further stripped to give access to the Separator Piston and
Metering Pin. Proceed as follows:
Gently tap End Plug (3) downwards into Plunger far enough to allow Circlip (2)
removal. Fit Lifting Bar to screwed holes in End Plug and lift out. Remove 'O'
Seal (4) and scrap. Now place Plunger on its side and push out the Separator
(15) by means of the Extension Rod screwed into the Metering Pin.
4. The following parts removed to be considered as scrap:
Item 17 Seal Ring OP 2009
Item 18 Bearing OP 2013C
Item 5 Separator Seal OP 2241
Item 7 Backing Rubber OP 2010
Item 9 O Seal OP 2017
Item 14 Scraper Ring OP 2852
Item 4 O Seal OP 2012
Item 16 Bearing OP 2039
All other components to be wiped clean in preparation for re-assembly. Particular

attention should be given to the Plunger grooves. These should be free from
damage and any accumulation of dirt should be carefully be cleaned out.

11
867
Manuals 2006
Issued 26/04/06
Re-assembly - 4G and 4A
Attention: Careful handling and cleanliness of components during
assembly is important. Thoroughly clean all components prior to assembly.
Always rinse rubber seals and rings in clean buffer oil before fitting.
TYPE 4G BUFFER (Refer pages 24-25)
Plunger Assembly Fitting of seals and Bearings
Stand Plunger on its head. Commence with the scraper ring (14) by fitting it over
the Plunger and placing it mid-way along its chrome portion, with the scraper
edge downwards. Spring Support Ring (6) apart sufficiently to place temporarily
around the neck portion below its groove.
Take the Nylon Seal Ring (17) checking that there is no damage to the sharp
leading edge and with heel downwards, fit it into its groove. Now place the
Support Ring (6) into the same groove, after which they should be free to rotate.
Carefully stretch the Backing Rubber (7) over the plunger and fit it into its groove
under the lip of the Nylon Seal. Work it all around to give an even snug fit. Next
spring the Piston Ring (19) into its groove and check that it may rotate freely.
Finally spring the Plunger Bearing (18) into its recess and place the cylinder
bearing (16) over the neck of the Plunger.
Fitting the Plunger into the Cylinder Assembly.
Stand the Cylinder with the open end upwards its bore with buffer oil from the
cylinder Bearing recess downwards.

12
868
Manuals 2006
Issued 26/04/06
With Nut removed and the Metering pin hanging loosely downwards, carefully
lower the Plunger Assembly into Cylinder, ensuring that the Piston Ring and Seal
Ring do not catch the edge of the grooves in the mouth of the Cylinder. The
Cylinder bearing (16) automatically locates into the recess by reason of the
tapered bore. Always keep the Plunger square in the Cylinder and never rotate
the Plunger but only gently rock it to assist location. Now fit Scraper Ring into its
groove in the mouth of the cylinder by fitting heel of ring into the groove at one
position and run the rest in by means of a thin steel rule. Finally, push the
plunger right down to the bottom of the cylinder so that the Metering Pin
protrudes through the hole in the base. Do NOT use excessive force. Screw on
NUT loosely to prevent Pin dropping back into the buffer.
5A Type 4A Only
If the Buffer Head and End Plug have been removed for Separator Metering Pin
attention, proceed with assembly as follows :
Fitting of Metering Pin and Separator into Plunger Assembly
Enter Metering Pin into the mouth of the Plunger with thread end first. Secure
loosely with nut to retain. Take Separator and check that its Seal is correctly
position in its groove. Now enter the Separator into the mouth of the Plunger with
its flat crown inwards. Push the Separator into the plunger bore until the top of
the skirt is about 2 inches from the mouth of the Plunger. At this stage pour about
5 cc`s of buffer oil into the well of the Separator
Now fit End Plug complete with its Seal into the mouth of the Plunger, ensuring
that the four tapped holes are uppermost. Push the End Plug down into the
Plunger bore so that its top end is just below the rimmed bore in the Plunger.

13
869
Manuals 2006
Issued 26/04/06
Now fit Internal Circlip into its groove. Fit Lifting Bar by two socket screws into the
End Plug and pull back End Plug against Circlip.
To Fill with Oil
Stand buffer on its head. Screw the Rod into the end of the Metering Pin.
Remove the Nut. Lower the Metering Pin until it contacts the Separator. To
ensure that the Separator is fully home, slide the Tube over the Rod and tap
firmly down.
Fill with buffer oil (Texaco Cappella MS32/Batoyle Rhesus 32 or equivalent)
through the Metering Pin hole until it just overflows (Capacity 1.63 Lt. approx.)
Rock the Buffer slightly to release any air and top up as necessary.
To Secure the Metering Pin
Raise the Pin and fit 'O' Seal (9) in the undercut below the thread Screw on the
Nut two or three turns and remove Rod. Tighten up Nut using a Ring Spanner
and hammer up tight (340 Am approx.).
Inflation
The buffer should now be inflated with air or nitrogen as instructed on Page 7-8

14
870
Manuals 2006
Issued 26/04/06
Spares
The following kits of parts cover all that is necessary to rehabilitate the OLEO
Industrial Buffer as instructed. Mainly, this provides for replacement of all seals
and bearings, some of which because of wear, have caused the buffer to
become defective.
Item
Part Number
Description
17
OP 2009
Seal Ring
Backing Rubber
OP 2010
Support Ring
OP 2011
18
Plunger Bearing
OP 2013
O Seal
OP 2017
19
Piston Ring
OP 2020
12
Air Plug
OP 2025
16
Cylinder Bearing
OP 2039
Nut
OP2042
10
Screw
OP 2524
11
Rubber Washer
OP 2525

15
871
Manuals 2006
Issued 26/04/06
Special tools
The following Tools are required for the dismantling and assembly of the Oleo
units.
OPT. 1 Special Spanner

OPT 2A Air Injection Adaptor
OPT 3. Hand pump (optional)
+ OPT 26 Seal Lead
+ OPT 30 Extension Lead
+ OPT 35 Drift
+ OPT 125Lifting Bar
+ OPT 126Tube
+ These tools may easily be made in any workshop (Drawings will be provided
upon request)
STANDARD TOOLS
The most essential is:
Ring Spanner 1.30" A/F for Metering Pin Nut Socket Wrench 5/16" A/F for Head
Attachment Screws

16
872
Manuals 2006
Issued 26/04/06
Special features
Type 4SBZ-145-**
Type 4LBZ-145-**
Type 4SFZ-145-**
Type 4LFZ-145-**
These buffers are fitted with Safety Chains a mandatory requirement for North
America.
The Safety Chain is attached at one end to the Buffer Head and at the other end
to the Mounting Bracket.
Changes to the parts list:
Ref
Part Number
Description
4SBZ 4SFZ
4LBZ
44
OP 2752
Mounting Bracket
45
OP 2719
Mounting Bracket
46
OP2713
Safety Chain Assy
47
OP 2713F
Safety Chain
4LFZ
1
1
1
Type 4LBZ-145-**
Type 4LFZ-145-**
Type 4SBZ-145-**
Type 4SFZ-145-**
To remove Safety Chain

Remove the Buffer Head then unscrew the eyebolt from the Mounting Bracket.
To fit the Safety Chain firstly screw eyebolt to Mounting Bracket, then fit Buffer
Head to Plunger, rotate Plunger if necessary to obtain alignment of holes in
Buffer Head and End Plug.

17
873
Manuals 2006
Issued 26/04/06
Appendix a - Type 4G and

4M
A new Cylinder Part No. 1-10117-1 and two new Front Mounting Brackets Part
number 1-10139-1 have been introduced to standardise the Cylinder for all types
of the 4G and 4A Buffers.
Cylinder Part No. 1-10117-1 replaces OP 2526 (M) Front Mounted Cylinder and
OP 2037G Back Mounted Cylinder.
Mounting Bracket 1-10119-1 replaces OP 2514Z Mounting Bracket 1-10139-1
replaces OP 2719
SERVICING INSTRUCTIONS
During servicing, Front Mounting Brackets OP 2514Z and OP 2719 can be
replaced with 1-10119-1 or 1-10139-1 respectively, using Loctite Grade 648 in
the approved manner to fix the Bracket in position on the existing Cylinder OP
2526 (M).
Replacement of the Cylinder OP 2526 (M) with Cylinder Part No. 1-10117-1
necessitates including fitting matching Front Mounting Bracket 1-10119-1 or 110139-1 as the Cylinders are not interchangeable for Front Mounting applications

18
874
Manuals 2006
Issued 26/04/06
Appendix b - Type 4G and

4M
Industrial Type 4 A(M) -Metric Buffer Head Attachment
As part of our product rationalisation, metric buffer head attachment is now a
standard feature, thus completing the change from 3/8 UNF to M10. The parts
affected are:
Buffer Head diameter 145 - OP 2518,
Now becomes: Buffer Head diameter 145 - 1-11168-1
End Plug - OP 2517
Now becomes: End Plug - 1-11081-1
Cap Screw - OP 2373
Now becomes: Cap Screw M10x40 - OP 3021
New Part
Buffer Head diameter 145, with tapping for eyebolt & chain assembly, part No.
1-11169-1
Effective from May 1984 and serial No.16898
Service instructions
The End Plug is not interchangeable with the previous part, OP 2517, however
the nerd Buffer Head, 1-11168-1 (and 1-11169-1) can be used with 3/8 UNF
screws if a heavy gauge washer is fitted under the head of the Cap Screw OP
2373. Use new part numbers when ordering spares and replacements.

19
875
876
Issued 26/04/06
CYLINDER ASSEMBLY
HEAD ASSEMBLY
METERING PIN ASSEMBLY
ITEM 2
ITEM 4
ITEM 4

20
PLUNGER ASSEMBLY
Assembly drawing - 4M series
ITEM 1
Manuals 2006
877
Issued 26/04/06
CYLINDER ASSEMBLY
HEAD ASSEMBLY
METERING PIN ASSEMBLY
ITEM 2
ITEM 4
ITEM 4

21
PLUNGER ASSEMBLY
Assembly drawing - 4G series
ITEM 1
Manuals 2006
878
Manuals 2006

22
Installation drawing
Issued 26/04/06
879
and
280
280
330
330
330
Z 11A
Z 11B
Z 130
Z13A
Z 13B
12.1
12.1
12.1
12.1
6.5
Dim R
Issued 26/04/06
314
314
280
280
Flat
YES
YES
holes
Mtg.
120
13
41
49
280
330
91
KJ
Capacity

23
Max Force kN
Min Force kN
39
156
61
53
51
50.3
75
67
65
64.3
Square
Mounting
Front Rear
1000
KN
Dynamic Force
Maximum
72
64
62
61.3
Rear
Rect.
330 Head C/W Flat as above -5Kg
38.3
Capsule
bellows and wire
Weight Kg (Complete) excluding
140
Head
Installation data
Slow Closure/Static Compression - 10 bar inflation
146
Z 575
code
head
Head
3rd letter
Manuals 2006
880
Manuals 2006

24
Plunger assembly drawing
Issued 26/04/06
Manuals 2006
Issued 26/04/06
Plunger assembly parts

list
ITEM NUMBER
ITEM
PART NUMBER
Plunger
1-02516-1 or 1-13817-1
or 1-02036-1 or OP
2781
Circlip
OP 2519
End Plug
1-11170-1
O Ring (End Plug)
OP 2012
Separator Seal
OP 2241
Support Ring
OP 2011
Backing Rubber
1-14087-1
O Ring (Orifice Plate)
1-10507-1
O Ring
1-10507-1
10
Screw Air Plug
OP 2524
11
Rubber Washer
OP 2525
12
Air Plug
OP 2025
13
Bearing - Separator
OP 2808
14
Scraper
OP 2852
15
Separator
1-02006-1
16
Bearing - Cylinder
1-10331-1
17
Seal Ring
OP 2009
18
Bearing - Plunger
OP 2013D
19
Piston Ring
OP 2020
20
Circlip
OP 2298
21
Orifice Plate
OP 2297
Note: Part numbers in italics denote a composite drawing number.

Please contact Oleo for details

25
881
882
Manuals 2006

26
Identification
Label
Screw
Eyebolt
4
5
6
ITEM
Cylinder
Abutment
Segment
Bracket
ITEM NUMBER
1
2
Cylinder assembly drawing
Issued 26/04/06
OP 2103
OP 2881
OP 2176Z OR
1-10119-1
OP 3069
PART NUMBER
1-10117-1
1-14134-1
Manuals 2006
Issued 26/04/06
Head/bellows assembly
drawing

27
883
Manuals 2006
Issued 26/04/06
Head/bellows parts list
ITEM NUMBER
ITEM
PART NUMBER
Buffer head
1-11325-2
Socket Head Cap Screw
OP 3021
Shackle
1-14236-1
Anchor Block
1-14264-1
Nut
1-14114-1
Bolt
1-10450-1
Ferrule
1-14265-1
Wire Rope
1-14266-1
Flexible Bellows
7-10976-1
Assembly
10
Hose Clip
1-11155-1


28
884
Manuals 2006
Issued 26/04/06
Metering Pin Assembly
ITEM NUMBER
ITEM
PART NUMBER
Metering Pin
1-13831-1
Nut
OP 2042


29
885
886

30
Capsule - c/w
abutment segments
Back mounted
(rect.)
Back mounted (sq.)
+ eye bolt
Back mounted
(rect.) + eye bolt
N
L
Capsule
Front mounted
Standard plate &

high temp seals
Marine plate &
standard seals
Marine plate & high
temp. seals
Buffer head c/w

bellows
Buffer head c/w
shackle & anchor
Buffer head c/w wire
(front mtg.)
Buffer head c/w wire
(back mtg.)
Head c/w bellows +
wire (front mtg.)
Head c/w bellows +
wire (back mtg.)
Buffer head only
Back mounted (SQ)
HEAD PART NO.
ITEM 3
Standard plate &

standard seals
THIRD
LETTER
OF ENG.
CODE
ITEM 2
Composite drg 7 11825-1
SECOND
LETTER
OF ENG.
CODE
CYLINDER
ASSEMBLY
Composite drg. 712760 -1
ITEM 1
Type 4 buffer code
Issued 26/04/06
PLUNGER
ASSEMBLY
Composite drg. 712785 -1
FIRST
LETTER
OF ENG.
CODE
Manuals 2006
See sales order for

metering pin
reference
METERING PIN
ASSY.
Composite drg 7 10095 -1
ITEM 4
Manuals 2006
Issued 26/04/06
Safety and Environmental

addendum
SAFETY
The buffer assembly is a self-contained energy absorbtion device and
contains nitrogen and oil under pressure. In the event that the buffer piston
fails to re-extend, care needs to be taken and do not stand in line with the
piston return path.
Faulty buffers may exhibit one or more of the following characteristics:
Failure to re-coil (re-extend)
Leaking oil
Damaged piston (plunger)
It is strongly recommended that a faulty buffer not continue to be used. To
ensure safety, it is essential that the dismantling of an Oleo hydraulic buffer
should only be undertaken by competent and approved service personnel
working in conjunction with the dismantling and safety instructions in the
applicable Oleo service manual. Please contact Oleo Technical staff or your
local agent if further guidance or advice is required.
All tools and drawings are supplied expressly for use in conjunction with
appropriate Service manuals for the buffer being dismantled.
It is most
important that all safety procedures are strictly adhered to. Oleo International
Ltd. takes no responsibility for the misuse of these tools or their use by
unauthorised persons.
Care must be taken when lifting and handling the buffers to ensure that the
operation is planned and that the load is both stable and safe. Buffers contain
mineral oil and care must be taken to protect skin from prolonged contact.

31
887
Manuals 2006
Issued 26/04/06

addendum
ENVIRONMENTAL
Oleo International Ltd is aware of the potential environmental impact of its
operation and products. This concern continues beyond the supply to the end
user through service and to the end of life of the product and it constituent
parts.
Steel Components
Steel should be treated as recyclable scrap.
Capsule Fluid
Fluids should be regarded as special waste and should be presented to a
local licensed carrier.
Rubber and Plastic Components
These components may be disposed of as general waste.
Packaging materials
Please recycle when possible

32
888
Manuals 2006
Issued 26/04/06

addendum
If more information is required on Oleos Environmental Policy please contact
The Quality Manager at the following address:
Llalco Fluid Technology, S.L.

C/ Natalia de Silva, 3A
Madrid 28027
Spain
Telfono: (+34) 91 742 30 57

Fax: (+34) 91 320 45 78
E-mail: llalco@llalco.com
OLEO INTERNATIONAL IS ACCREDITED TO ISO 14001

33
889
ELECTROMECHANICAL
FEEDERS
890
Setting up and maintenance

instructions
Electromechanical
feeders
ATTENTION
Before proceeding to the setting up, it is necessary to read this

instruction manual.
The machine herewith identified is clearly specified with its

denomination and its serial number.
For any further inquiry regarding this machine, it is necessary to
indicate both references.
The Product Validation is included in a separated file.

We kindly ask you to dully fill it and fax it to us to the (+34) 943 692 667.
www.urbar.com
891
Electromechanic feeders or conveyors

Setting up / Maintenance
CONTENT
Page
EC Directives.......................................................................................................................... 3
Safety ....................................................................................................................................... 3
Storage procedures............................................................................................................... 4
General matters ..................................................................................................................... 5
Technical data ........................................................................................................................ 6
Installation
Suspended machines ............................................................................................................ 7
Supported machines ............................................................................................................. 9
Setting up under a hopper
Open trays ............................................................................................................................10
Trays closed or over tightened..........................................................................................13
Electric installation ...............................................................................................................16
Driving unbalanced motors consumption ........................................................................19
Setting up ..............................................................................................................................20
Tightening torque ................................................................................................................21
Flow regulation
Unbalanced motors connected to the mains ....................................................................23
Unbalanced motors connected through a frequency changer......................................24
Unbalanced motors centrifugal force regulation ............................................................27
Unbalanced motors greasing recommendations ............................................................28
Unbalanced motors noise level..........................................................................................30
Preventive maintenance......................................................................................................31
Recommended spare parts ................................................................................................31
Fault tracing guide ...............................................................................................................32
Spare parts
Suspensions ..........................................................................................................................34
JR Suspension .......................................................................................................................35
RG Suspension .....................................................................................................................36
2 RG Suspension ..................................................................................................................37
RGV Suspension...................................................................................................................38
Supporting spring ................................................................................................................39
Novibra mounting Type M..................................................................................................40
Evidgom mounting ..............................................................................................................41
Driving unbalanced motors ................................................................................................42
www.urbar.com
-2892

EC DIRECTIVES
In compliance with the 98/37/CE directive, regarding machinery safety,
the URBAR vibrating equipment is supplied with a data plate, where all
the information required by these directives is included.
SAFETY
The safety of the screen during installation, operation and maintenance
is of vital importance. Personal injuries and mishaps or damage to the
screen can only be avoided with the use of suitable material and
appropriate procedures. Accidents can be avoided by the individual
worker using foresight and common sense as tools.
In order to optimise safety, URBAR Ingenieros recommend the following major lines:
!
!
!
!
!
!
!
!
!
!
!
During installation, operation and maintenance of the screen, always

consult the company drawings and manuals of URBAR Ingenieros.
Do not use URBAR equipment for any use other than that for which it
is designed. If in any doubt, contact the manufacturer.
Do not start up the machine until its base is perfectly anchored.
The equipment has to be fully checked in case there are any loose
screws or the like.
The equipment must not be started up without having installed the
safety fittings (protection gear, covers, fairings, vibration detectors).
Do not walk, sit or lean on the feeder or the conveyor.
No maintenance work should be carried out neither on springs,
driving motors nor any part of the machine until it is totally stopped
and with no electric current applied.
The personnel in charge of operating the screen have to be
provided with the necessary dress (clothing, glasses, etc.).
The emergency stop and safety devices of the equipment have to be
within the reach of the operators.
Do not allow dirt to build up, nor the accumulation of tools, pieces
that are not suitable or any other element that could obstruct the
vibrating of the screen.
Periodically check the state of the electric cables and that they are
securely fastened.
www.urbar.com
-3893

STORAGE PROCEDURES
When URBAR machines have to be stored for some time, the following considerations
have to be taken into account.
Avoid situating them out of doors, in order to avoid water, wind, snow or
dust to damage one of the parts.
Care has to be taken with the ground

or floor on which it rests, since drains
or other types of facility can also lead
to deterioration of the machine.
Some parts are shipped dismantled (suspensions), in separated boxes.

They must not be storage out of doors.
The storage temperature must be

between 30C and + 70C.
This storage temperature must not be
mixed up with the working
temperature.
The machine has to be manipulated

carefully when storage and the
operations previous to the definitive
installation.
The driving unbalanced motors are supplied with a plastic protection in

the stuffing boxes, in order to avoid the water to get inside. It is highly
recommended to keep that protection up to the final connection.
www.urbar.com
-4894

GENERAL MATTERS
Driving unbalanced motors
The driving unbalanced motors are IP66.
It is convenient to avoid the dust accumulation..
If the driving unbalanced motors are standard, they cannot be installed in

explosive ambient.
The working temperature, for the standard driving unbalanced motors,

under normal functioning is: -15C ~ +50C.
Electromechanical feeders and conveyors

Usually, the flows are indicated in cubic meters. Nevertheless, that
measure can vary, as it depends on the product to be handled, on its
density, on its size, on its moisture For instance, a gravel with a size 5-25
mm flows much better than another one with a size 90-200 mm.
The flows are obtained with dry gravel, size 6-10 mm, bulk density 1.6 t/m3
and a standard tray inclined 10.
Dusty products do not behave correctly face to the vibrations.

Instead, granulated products do not show any problem.
If a product gets sticked to the tray, the feeder capacity is reduced.

This circumstance has then to be avoided.
www.urbar.com
-5895

INSTALLATION
Suspended feeders and conveyors
The suspended types have to be installed

taking in account that the suspensions are
totally verticals, so that the rod does not
knock on the spring support, avoiding
unnecessary noises and wearing.
In order to install correctly the suspensions, it is necessary to follow the indications

given in the drawing:
1: Tightener
2: Chain
3: Suspension
4: Suspension chain
The first chain link must be fixed to the suspension. The suspension is
attached to the tray. The chain (not included in the scope of the supply)
is then suspended through the tightener or any other chosen element.
The disposal herewith indicated must be observed. Eventually, the
chain can be placed between the tray and the suspension.
www.urbar.com
-6896

Following the General Disposals, regarding the security with the

machines, the vibrating feeders are equipped with anchorages in order
to guarantee the necessary stability, if a suspension broke happened.
If the machine is suspended, a flexible wire has to be set, between the
machine and the hopper or the structure, to assure it if a fall happened.
The minimum diameter for the wire is:
- 5 mm for the machines with a weight lighter than 700 kg
- 8 mm for the machines with a weight heavier than 700 kg
Security wire
Do not make any welding in the structures with the unbalanced motors
connected. The welding could cause injuries to the stators.
www.urbar.com
-7897

Installation for supported feeders and conveyors

The machines to be installed supported to a structure are equipped with
mountings or springs. The machine lies on those isolating elements.
If the feeder is to be supported, at a certain height, a flexible wire has to

be set, between the machine and the hopper or the structure, to assure
it if a fall happened.
The minimum diameter for the wire is:
- 5 mm for the machines with a weight lighter than 700 kg
- 8 mm for the machines with a weight heavier than 700 kg
Do not make any welding in the structures with the unbalanced motors
connected. The welding could cause injuries to the stators.
www.urbar.com
-8898

INSTALLATION UNDER A HOPPER

Open feeders or conveyors under a hopper.
In order to make the feeder work correctly, the material-loading column,

inside the silo, needs not to gravitate on the feeder tray.
The silo outlet has to stand the efforts due to the product charge. If the
product lies directly on the tray, the flow would be reduced.
If, by any means, the silo outlet can not be built following the indicated
drawing, please contact URBAR, in order to design a special silo outlet
to solve your specific problem.
YES
www.urbar.com
NO
NO
-9899

When charging the hopper, the direct falls of big blocks might cause
injuries to the vibrating feeder or conveyor.
To protect them, it is necessary to:
- Install hopper outlets to reduce the knocks
- Keep a certain quantity of product, on the tray.
YES
YES
NO
The hopper outlet walls have to be parallel to the feeder sides.
The distance between the bottom

of the feeder and the hopper
outlet must grow, from the rear to
the front part (2 angle).
The distance between the static
parts and the dynamic parts must
be larger than 40 mm.
Excessive charges, sizes too bigs
or a wrong hopper could cause a
non wanted displacement in the
feeder.
www.urbar.com
- 10 900

Installation under a hopper for open feeders
When installing feeders or hoppers extractors, the hopper outlet height

controls the product cope, in the tray.
The maximum flow is obtained when, the machine being stopped, the
product reaches the nearest to the tray outlet.
If, by any means, the silo outlet can not be built following the indicated
drawing, please contact URBAR, in order to design a special silo outlet
to solve your specific problem.
www.urbar.com
- 11 901

Installation under a hopper for closed elements

Tube diameter > 400 mm
The hopper outlet has to be equipped with an elbow, to avoid that the
charge gravitates on the feeder tray.
YES
NO
The disposal on the right can eventually be made with diameters larger
than 400 mm if the product to be handled shows a low density.
www.urbar.com
- 12 902

Tube diameter 400 mm

The hopper outlet can be made directly to the feeder or the conveyor,
when the tube diameter is smaller than 400 mm.
YES
www.urbar.com
YES
- 13 903

The hopper bevelling outlet must reach up to the bottom of the tray, to
avoid the charges on the rear part of the machine.
YES
NO
The bevelling height determines the product flow cope.
The flexible unions between the hopper and the pan need to be
equipped with a bellow, allowing the free movement for the vibrating
feeder or conveyor.
YES
NO
The distance between the static and the dynamic parts must be bigger
than 40 mm.
www.urbar.com
- 14 904

ELECTRIC CONNECTION
The vibrators must be connected to the electric mains following the
electric drawing and taking into account rated voltage and frequency.
www.urbar.com
- 15 905

The voltage at wich the unbalanced motors are clearly specified in the
technical file and in the motors themselves.
Usually, and unless otherwise indicated, the vibrators are supplied ready
to be connected at the maximum voltage connection, that is to say, in star.
The electric wire must be H07-RNF, three-phases and Herat, adapted to

the consumption, following the unbalanced motors, as indicated.
The earth wire (green-yellow) must always be connected.
The electric wire works under vibrations. In order to avoid any

breakdowns, ther must be no contact with vibrating elemen
Wire minimum section and diameter to be used for the connection.
Tipe
REX-A
REX-B
REX-C
REX-D
REX-E
REX-F
ext.
4-8 mm
4-8 mm
6-12 mm
6-12 mm
10-15 mm
10-15 mm
S min.
1 mm2
1 mm2
2,5 mm2
2,5 mm2
4 mm2
4 mm2
www.urbar.com
- 16 906

Current levels under normal operating conditions must not be higher than
those shown in the data plate.
Check vibrator consumption regularly.
Always protect each vibrator individually using a break component and

delayed magneto-thermal switches adequate to consumption, to avoid
the dsiconnexion when starting. The starting will be posiibly longer with
lower temperatures..
www.urbar.com
- 17 907

When working with two vibrators in tandem, any thermal triggering of

one of them must also stop the second one.
If there is any overload, it must be reduced as follows checking and

tightening the fixing screws (following the chapter TIGHTENING
TORQUE) as it is a fundamental concept, for the right motor functionning
Rated consumption, in A, for the driving unbalanced motors

Type
230V
400V
REX-A
8/30
0.7
0.4
REX-A
16/30
0.7
0.4
REX-A
20/30
0.7
0.4
REX-A
24/30
0.7
0.4
REX-A
28/30
0.7
0.4
REX-B
35/30
0.9
0.6
REX-B
60/30
1.0
0.6
REX-C 90/30
2.4
1.4
REX-C 140/30
2.7
1.5
REX-C 165/30
2.7
1.5
www.urbar.com
Type
REX-A
7/15
REX- A 12/15
REX B 30/15
REX-B 40/15
REX-C 60/15
REX-C 90/15
REX-C 110/15
REX-C 140/15
REX-D 170/15
REX-D 250/15
REX-E 350/15
REX-E 500/15
REX-F 750/15
230V
400V
0.5
0.6
1.4
1.4
2.1
2.2
2.2
2.4
5.2
5.4
9.5
11.0
13.9
0.3
0.4
0.8
0.8
1.1
1.3
1.3
1.4
3.1
3.2
6.0
6.6
8.0
Type
230V
400V
REX-C 40/10
2.4
1.4
REX-C 55/10
2.5
1.4
REX-C 74/10
2.6
1.5
REX-D 110/10
5.0
2.9
REX-D 160/10
6.0
3.5
REX-D 210/10
6.7
4.0
REX-E 280/10
10.0
6.2
REX-E 380/10
11.0
6.6
REX-E 500/10
11.8
6.8
REX-F 750/10
15.0
8.5
- 18 908

SETTING UP
The electric external vibrators drive the vibrating machine and work
thanks to the unbalanced weights turning. The weights turn inside the
vibrator. The truning zone is limited by the caps.
Before starting up the vibrators, check that the caps and covers have
been correctly set.
As the vibrators are supposed to work in tandem, it is essential, for the
right functioning that each vibrator rotates in the opposite direction one to
the other.
Therefore the vibrators turning direction must be checked.
YES
NO
To do so, remove provisionally one cap to check the turning direction,

and exchange two phases if it needs to be corrected.
Assemble the caps and cover, once turning direction has been checked.
Before starting up the vibrator, check that the caps and covers have been
correctly set.
www.urbar.com
- 19 909

DRIVING UNBALANCED MOTORS TIGHTENING TORQUE

The correct vibrators tighten is extremely important. If the tightening is
not correctly made the vibrators will be destroyed in a short time and
some failures might occur in the equipment.
The screws have to be tightened again, a few minutes after the starting
up, repeating the operation until assuring that tightening torque is the
correct.
Recommended tightening torques depending on the driving unbalanced

motor
Type
Thread
Metric
REX-A
REX-B
REX-C
REX-D
REX-E
REX-F
Normal
Normal
Fine pitch
Fine pitch
Fine pitch
Fine pitch
M 14
M 14
M 20
M 20
M 24
M 24
To fix the unbalanced

motors, it is mandatory to
use special steel screws
(Q = 8.8, DIN 267).
www.urbar.com
Tightening torque
daN.m
14
14
47
47
79
79
It is advisable to check the

tightening torque fairly
frequently, following the
above data.
- 20 910

Tightening elements characteristics
REX-A
REX-B
REX-C
REX-D
REX-E
REX-F
Bolt
Screw
Washer
Self blocking
Normal screw thread
DIN 982.8
Self blocking
Fine srew thread
DIN 985.8
Self blocking
Fine srew thread
DIN 985.8
M14 Q = 8.8
Normal screw thread
DIN 931
DIN 125
M20 Q = 8.8
Fine srew thread
DIN 125
M24 Q = 8.8
Fine srew thread
Special URBAR
DIN CK-45
UNE F 1140
If by any means, the unbalanced motors have to dismounted from the

feeder or the conveyor structure, it is important to set up the bolts,
washers and screws, in their original position, as shown in the following
drawings:
REX-A / REX-B / REX-C / REX-D
1. Self blocking bolt.

2. Washer.
3. Structure.
4. Screw.
REX-E / REX-F
1. Self blocking bolt.

2. Washer.
3. Special washer M 24.
4. Structure.
5. Screw.
The unbalanced motors are normally fixed on plates welded in the

perimeter. These weldings have to be checked regularly.
www.urbar.com
- 21 911

FLOW REGULATION
The flow varies depending on the centrifugal force supplied by the
unbalanced motors.
a. Unbalanced motors connected directly to the mains.
The flow in the electromechanic machines is fixed. It can be modified

when the machine is stopped (unless the connection is made through a
frequency changer, see next page).
If the flow has to be modified, in an electromechanic feeder or conveyour,
not equipped with a frequency changer, it is necessary to change the
unbalanced weights position, when stopped, as explained in the following
lines.
Nevertheless, it is necessary to note that the machine is supplied with the
unbalanced motors adjusted in order to obtain the requested performances.
Then, if the centrifugal force is modified, the functioning will be different.
Unbalanced motors centrifugal force adjusting procedure
The REX unbalanced motors are disegned for a continuous service a the
100% of their maximum centrifugal force.
The modification in the weights position when the machine is stopped- must
be done exactly the same in both sides of each vibrator.
Do not manipulate, nor dismount the unbalanced motor withour

disconnecting it from the mains. If necessary, take out fuses or any ofther
element, in order to avoid any unwanted connection. When turning, the
weights can produce physical injuries, if the caps are not in their position.
Loose the caps. Release the screws which tighten the weights, in the end of
the axle. Change the weights positions, following the data included in the
following data, taking care that new positions are exactly the same at both
sides of the each vibtators. Tighten the caps.
For the REX-A unbalanced motor, the weights have to be substituted by
washers.
www.urbar.com
- 22 912

FLOW REGULATION
b. Unbalanced motors connected through a frequency changer
The frequency changer modifies the unbalanced motors speed,
affecting to the supplied centrifugal force, proportionnaly to the square
of the unbalanced motors turning frequency.
Both driving unbalanced motors have to be connected to the same
frequency changer.
Minimum intensity necessary for the frequency
depending on the driving unbalanced motors
Driven by two
unbalanced motors
at 3000 r.min -1
REX-A
8/30
REX-A
16/30
REX-A
20/30
REX-A
24/30
REX-A
28/30
REX-B
35/30
REX-B
60/30
REX-C 90/30
REX-C 140/30
REX-C 165/30
at 1500 r.min -1
7/15
REX-A
12/15
REX-A
30/15
REX-B
REX-B
40/15
REX-B
60/15
REX-C 90/15
REX-C 110/15
REX-C 140/15
REX-D 170/15
REX-D 250/15
REX-E 350/15
REX-E 500/15
REX-F 750/15
www.urbar.com
changer,
Required intensity for the changer (A)

at 230V
at 400V
1,8
1,8
1,8
1,8
1,8
2,3
2,6
6,2
7,0
7,0
1,0
1,0
1,0
1,0
1,0
1,6
1,6
3,6
3,9
3,9
1,3
1,6
3,6
3,6
5,5
5,7
5,7
6,2
13,5
14,0
24,7
28,6
36,1
0,8
1,0
2,1
2,1
2,9
3,4
3,4
3,6
8,1
8,3
15,6
17,2
20,8
- 23 913

Minimum intensity necessary for the frequency

depending on the driving unbalanced motors
Driven by two
unbalanced motors
at 1000 r.min -1
REX-C 40/10
REX-C 55/10
REX-C 74/10
REX-D 110/10
REX-D 160/10
REX-D 210/10
REX-E 280/10
REX-E 380/10
REX-E 500/10
REX-F 750/10
changer,
Required intensity for the changer (A)

at 230V
at 400V
6,2
6,5
6,8
13,0
15,6
17,4
26,0
28,6
30,7
39,0
3,6
3,6
3,9
7,5
9,1
10,4
16,1
17,2
17,7
22,1
As a general rule, the frequency changer must stand a consumption

equivalent to 130% of the driving unbalanced motors consumption.
To adjust the requested flow, it is recommended to adjust first the

maximum requested flow, without modifying the mains
frequency, thus without using the frequency changer.
The adjustment has to be done, first, as if there was not any possibility to
use the frequency chager, adjusting the unbalanced weights (see
previous page). That centrifugal force must be the maximum centrifugal
force in use.
Once the first adjustment has been done, the frequency changer can be
used in order to modify the unbalanced motors turning speed. To do so,
the following matters have to be considered:
Never overpass the mains frequency. If the unbalanced motors

work Ander a frequency higher than the mains frequency, the bearings
would be quickcly dammaged and on the other hand, the unbalanced
motors or the tray could get broken, due to internal tensions.
www.urbar.com
- 24 914

The refence values to consider as low functioning limits for the two
unbalanced motors to synchronize are:
- 25 Hz for unbalanced motors with nominal speed 1500 r.min-1.
- 30 Hz for unbalanced motors with nominal speed 1000 r.min-1.
These values have to be considered as reference values and as such
values, they can be different from one machine to the other depending
on the tray structure strength, on the unbalanced motor type, on the
unbalanced weight regulation.
It is recommended to make a test, in order to check the real low limit.
Once the low limit has been checked, its value has to be introduced in
the frequency chager programmation, so it cannot be underpassed,
assuring that the unbalanced motors always work sinchronized.
The high limit value (mains frequency) must be also introduced in the
programmation.
A simple way to check that the unbalanced motors work synchronized is
to check the feeder side walls do not vibrate transversally.
Tray side walls
Finally it is very important that the frequency changer is programmated

with a null ascent acceleration, for the unbalanced motors work at the
100% of the fixed frequency value, since the very first moment.
When checking the frequency changer outlet voltages, True RMS

voltimeters have to be used.
www.urbar.com
- 25 915

CENTRIFUGAL FORCE REGULATION TABLE

Position
1000 rpm at 50 Hz
1500 rpm at 50 Hz
3000 rpm at 50 Hz
Type
REX B
35/30
3,5
3,3
3,0
2,2
REX B
60/30
6,0
4,0
3,0
1,0
REX C
90/30
9,0
7,0
5,0
3,0
REX C
140/30
14,0
12,0
10,0
7,5
REX C
165/30
16,5
14,0
11,0
8,0
REX B
30/15
3,0
2,5
1,5
0,8
REX B
40/15
4,0
2,8
1,9
1,0
REX C
60/15
6,0
5,0
4,0
3,0
REX C
90/15
9,0
8,0
7,0
5,0
3,0
REX C
110/15
11,0
10,0
9,0
6,5
4,0
REX C
140/15
14,0
12,0
10,0
6,0
REX D
170/15
17,0
14,0
12,0
10,0
8,0
6,0
REX D
250/15
25,0
22,5
20,0
17,5
15,0
12,5
10,0
REX E
350/15
35,0
30,0
25,0
20,0
15,0
REX E
500/15
50,0
45,0
40,0
35,0
REX F
750/15
75,0
67,5
60,0
52,5
REX C
40/10
4,0
3,2
2,3
1,4
REX C
55/10
5,5
5,0
4,0
26,5
REX C
74/10
7,4
6,5
5,0
3,5
REX D
110/10
11,0
10,0
8,0
7,0
5,5
3,5
REX D
160/10
16,0
14,0
12,0
10,0
8,0
6,0
REX D
210/10
21,0
18,0
15,0
12,0
9,0
6,0
REX E
280/10
28,0
25,0
21,0
16,0
REX E
380/10
38,0
35,0
30,0
25,0
REX E
500/10
50,0
45,0
40,0
35,0
REX F
750/10
75,0
67,5
60,0
52,5
Centrifugal force in kN
REX-A unbalanced motors

The REX-A unbalanced weigths cannot be adjusted but extracted. Those
unbalanced weigths can be subustitued by yoke sleeves, always the
same quantity on each side and on each unbalanced motor, to reduce the
centrifugal force. Each couple of unbalanced weights represent a 0,4 kN
force on unbalanced motors turning at 3000 r.min-1 and 0,1 kN on the
types turning at 1500 r.min-1.
www.urbar.com
- 26 916

DRIVING VIBRATORS GREASING RECOMMENDATIONS

For the vibrators bearings lubrication it is recommended to use the
KLBER LUBRICATION grease, due to the working conditions, such as
high charges, dust, humidity, high centrifugal force.
Depending on the unbalanced motors centrifugal force, there are two
KLBER grease types recommended:
STABURAGS NBU- 4
Centrifugal force < 15 kN
STABURAGS NBU-12
Centrifugal force 15 kN
These greases are made to withstand long operating periods, his thermal
stability is high and its behaviour face to the vibrations has been
checked.
Those two grease technical data are the following:
Working temperature
Speed factor:
Dynamic viscosity:
Welding charge VKA (DIN 51350)
Oil separation (DIN 51817)
STABURAGS NBU 4 STABURAGS NBU 12

-35C +150C
-35C +150C
500 000 n.dm
350 000 n.dm
6 000 mPa.s
10 000 mPa.s
> 3000 N
< 2%
On disassembly, if the grease still is in good condition, replenish using

new grease, if it is observed that the grease has been there for a long
time, clean thoroughly and apply new grease, filling the roller voids.
Always use the same lubricating grease.
Should there not be KLBER grease available, it is IMPORTANT to clean the bearings
properly and then use any other grease with the following characteristics:
Thickener: Barium complex soap
Drop point: 220C
Base oil: ISO-68 - 68 mineral oil
Rested penetration: 245-275
Consistency: Between 2 and 3
The bearings for the REX-A unbalanced motors are sealed. Thus, they
have to be replaced in case of problem.
The type of lubricating grease to be used varies according to the
centrifugal force and the vibration frequency of the vibrator.
www.urbar.com
- 27 - vibrator
917

The STABURAGS NBU 4 grease must be used for lubricating the following
unbalanced motor bearings:
Unbalanced motor
Bearing
REX B
REX B
REX C
REX C
REX C
35/30
60/30
90/30
140/30
165/30
NJ-2203
NJ-2203
NJ- 305
NJ-2305
NJ-2205
Lubrication interval
h
2500
2500
2500
2500
2500
Grease
gr
4
4
6
6
6
REX B
REX B
REX C
REX C
REX C
REX C
30/15
40/15
60/15
90/15
110/15
140/15
NJ-2203
NJ-2203
NJ- 305
NJ- 305
NJ-2305
NJ-2305
2500
2500
2500
2500
2500
2500
4
4
6
6
6
6
REX C
REX C
REX C
40/10
55/10
74/10
NJ-2305
NJ-2305
NJ-2305
2500
2500
2500
6
6
6
The STABURAGS NBU 12 grease must be used with the following unbalanced motors.
Unbalanced motor
Bearing
Lubrication interval
h
Grease
gr
REX D
REX D
REX E
REX E
REX F
170/15
250/15
350/15
500/15
750/15
NJ-2308
NJ-2308
NJ-2311
NJ-2313
NJ-2316
1000
1000
1000
800
800
8
8
8
10
12
REX D
REX D
REX D
REX E
REX E
REX E
REX F
110/10
160/10
210/10
280/10
380/10
500/10
750/10
NJ-2308
NJ-2308
NJ-2308
NJ-2311
NJ-2311
NJ-2313
NJ-2316
1000
1000
1000
1000
1000
800
800
8
8
8
8
8
10
12
The indicated intervals are referred to 8 hours per day work and an ambient
temperature up to 20C.
The greasing frequency could be incresed up to a 100%, if the temperatura reaches
45C.
www.urbar.com
- 28 918

UNBALANCED MOTORS NOISE LEVEL

The equivalent average continuous acoustic pressure level given off by
the REX vibrators (without considering the product being handled) is
lower than 70 dB (A) at a distance of one meter, except for the models
REX-E 350/15 and REX-F 500/15 which level does not, under any
circumstances, rise above 85 dB (A).
Unbalanced motor powers and weights

Type
P. Weight
kW
kg
REX-A
8/30
0,14
3,9
REX-A
16/30
0,14
4,1
REX-A
20/30
0,14
4,2
REX-A
24/30
0,14
4,3
REX-A
28/30
0,14
4,5
REX-B
35/30
0,24
15,2
REX-B
60/30
0,28
16,1
REX-C
90/30
0,90
25,3
REX-C 140/30
0,92
29,0
REX-C 165/30
0,92
31,0
www.urbar.com
Type
REX-A
7/15
REX- A 12/15
REX B 30/15
REX-B 40/15
REX-C 60/15
REX-C 90/15
REX-C 110/15
REX-C 140/15
REX-D 170/15
REX-D 250/15
REX-E 350/15
REX-E 500/15
REX-F 750/15
P. Weight
kW
kg
6,1
0,13
6,3
0,15
0,32 17,8
0,32 19,6
0,55 29,5
0,56 32,5
0,57 34,0
0,59 35,0
1,78 80,0
1,85 90,0
2,55 150,0
2,75 170,0
4,45 245,0
Type
P.
kW
Weight
kg
REX-C 40/10
0,41
35,0
REX-C 55/10
0,42
38,0
REX-C 74/10
0,45
40,0
REX-D 110/10
1,30
92,0
REX-D 160/10
1,75
101,0
REX-D 210/10
1,95
110,0
REX-E 280/10
3,42
175,0
REX-E 380/10
3,50
188,0
REX-E 500/10
3,59
220,0
REX-F 750/10
5,20
285,0
- 29 919

PREVENTIVE MAINTENANCE
Revisions
Periodically, the main elements have to be checked: electric wires,
security wires, springs or mountings, supports, tray
Thus, installation general conditions are appropriated.
Product
Check that the product to be dosed still reacts correctly to vibration.
Check that it does not get sticked to the tray.
Hopper
Check that there is no product between the tray and the static parts. If
there was some product in that zone, the vibration amplitude could be
limited and the flow could then be reduced.
Unbalanced motors
Check the tightening torque.
Check that the unbalanced motors consumption do not overpass the
value indicated in the data plate and in the Technical Data Sheet..
RECOMMENDED SPARE PARTS

As a general rule, the recommended spare parts for commissioning and
for a 2 year functioning are:
- 1 unbalanced motor.
- 2 suspensions o supports.
www.urbar.com
- 30 920

FAULT TRACING GUIDE

The unbalanced motor must not be dismounted, without a previous
disconnection from the mains. Do not hesitate in taking of fuses or other
elements to avoid any unwanted connexion.
When turning, the unbalanced weights can provoque physical injuries if

the cpas are not correctly set up.
Fault
Cause
Action
Insuficient
Flow
Faulty installation
Followi the instructions Setting up

under a hopper
Make the necessary modifications.
The tray knocks against any

static part.
Prodcut between the tray and
the static parts
Both unbalanced motors are
turning in the same way.
The
machines
works but
too noisely
Clean up the zone.

Change two phases in one of the
vibrators.
The unbalanced motors are

connected to a wrong voltage.
Faulty isolation.
Check that the frequency and the

voltage are adequate.
Suspensions are the other way
around or not totally vertical.
Some spring or suspension is
broken.
Supporting structure is too
Reinforce the structure where the
weak.
feeder is installed.
Faulty tray: Worn out, broken or Reinforce it or change it..
its configuration has been
modificated.
Wrong tightening torque
Tight the unbalanced motors
screws.
Unbalanced motor bearings
Change the bearings.
www.urbar.com
- 31 921

Fault
Cause
Action
Broken
suspension
The product gravitates too much Modify the outlet hopper, following
on the feeder tray.
the instructions.
Suspensions not vertically
installed.
Worn out.
Frequency changer wrongly
adjusted.
- Ascent acceleration too slow
Install the suspensions vertically.
The problem is located in the

bearings.
Change the bearings.
Change the suspension.
The ascent acceleration has to be

nul.
- Resonance problem in the
Increase the driving unbalanced
structures.
motors frequency.
Unbalanced Tightening torque too low
Retighten the screws.
motor
Tray broken.
Repair or change the tray.
consumption The unbalanced motor is
Repair the unbalanced motor
too high
working only with two phases.
connections
The functioning frequency is too Reprogramate the frequency
high, because of a faulty
changer.
programation for the frequency
changer.
The
Connection problem.
Change the vibrator, while the
unbalanced The motor is working under two broken one is repaired, checking
motor stator phases, due to an accident.
the new tightening torque.
burns out
The vibrator tightening torque is Protect the electric installation
in each motor.
too low,
The tray is broken and the
Repair or modify the tray and
motor consumption rises up.
replace the vibrator.
The motor
Works but
too noisely
Always use original spare parts. Otherwise, the machine functioning

cannot be guaranteed.
www.urbar.com
- 32 922

SPARE PARTS
SUSPENSIONS
The suspensions depend on the feeder dimensions and weight.
The suspensions installed on the feeder are clearly specified in the Technical Data
Sheet.
Most of the suspended feeders are hanged through JR or RG so called suspensions.
As an example, in the table below, we indicate the suspensions installed for standard
feeders.
It has to be mentioned that, sometimes, in order to obtain a better adjustment, the
spring wire diameter can be different in the rear part than in the front part.
ARBS Series
Type
ARBS 40/80
ARBS 50/90
ARBS 50/90
ARBS 60/105
ARBS 70/120
ARBS 80/135
ARBS 90/150
ARBS 90/150
Driven by 2
REX-B
REX-B
REX-C
REX-C
REX-C
REX-C
REX-D
REX-D
40/15
40/15
90/15
90/15
90/15
140/15
140/15
250/15
Suspension
Wire diamter
JR
JR
JR
JR
RG
RG
RG
RG
8 mm
8 mm
8 mm
10 mm
12 mm
14 mm
14 mm
14 mm
Suspension
Wire diamter
RG
RG
RG
RG
RG
RG
14 mm
14 mm
14 mm
14 mm
14-16 mm
14-16 mm
RBS Series
Type
RBS
RBS
RBS
RBS
RBS
RBS
100/165
100/165
110/180
110/180
120/195
120/195
www.urbar.com
Driven by 2
REX-C
REX-D
REX-C
REX-D
REX-C
REX-D
140/15
250/15
140/15
250/15
140/15
250/15
- 33 923

JR Suspension
Figure
Code
Denomination
1 79 05 00 1
1 79 05 00 2
JR Suspension
Spring wire 8 mm
Spring wire 10 mm
4
-
1
2
3
4
2 79 05 04 1
2 79 05 03 3
2 98 19 35 6
2 79 05 07 4
Eyebolt
Fork
Spring support
Upper support washer
1
1
1
1
1
1
1
1
"
4 5 94 41 67 1
5 5 94 41 67 0
Spring
8 mm
10 mm
1
-
5 79 05 06 9
5 79 05 05 1
5 73 30 24 3
5 50 75 06 3
Staple
Rubber
Bolt M12
Washer grower 12
1
1
6
5
1
1
6
5
6
7
8
9
Quantity
8
10
" The spring wire diameter (5) is indicated in the Data Sheet
www.urbar.com
- 34 924

RG Suspension
Figure
Code
Denomination
"
1 79 00 00 2
1 79 00 00 3
1 79 00 00 4
1 79 00 00 5
RG Suspension
Spring wire 12 mm
Spring wire 14 mm
Spring wire 16 mm
Spring wire 18 mm
4
-
4
-
4
-
1
2
2 79 05 04 1
2 79 05 03 3
Fork
Spring support
1
1
1
1
1
1
1
1
"
159426485
259426484
359426483
459426482
Spring
12 mm
14 mm
16 mm
18 mm
1
-
1
-
1
-
5 79 00 03 7
5 73 30 24 3
5 50 75 06 3
5 79 00 04 1
Link
Bolt M12 hexagonal
Washer 12
Rubber 12 x 290
2
8
4
1
2
8
4
1
2
8
4
1
2
8
4
1
4
5
6
7
12
Quantity
14 16
18
" The spring wire diameter (3) is indicated in the Data Sheet.
www.urbar.com
- 35 925

2 RG Suspension
Figure
Code
Denomination
"
1 79 01 00 7
1 79 01 00 8
1 79 01 00 9
1 79 01 01 0
2 RG Suspension
Spring wire 12 mm
Spring wire 14 mm
Spring wire 16 mm
Spring wire 18 mm
4
-
4
-
4
-
2 79 01 01 6
Suspension triangle
5 79 01 02 7
Fork - shackle
"
159426485
259426484
359426483
459426482
Spring
12
14
16
18
2
-
2
-
2
-
2 79 00 02 6
5 73 30 24 3
5 50 75 06 3
5 79 00 04 5
5 79 00 03 7
Spring support
bolt M12 hexagonal
Washer grower 12
Rubber 12x290
Link
4
8
8
8
2
4
8
8
8
2
4
8
8
8
2
4
8
8
8
2
4
5
6
7
8
12
Quantity
14 16
18
www.urbar.com
- 36 926

RGV Suspension
Figure
Code
Denomination
14
Quantity
16 18
20
"
1 79 02 00 7
1 79 02 00 8
1 79 02 00 9
1 79 02 0 10
RGV Suspension
Spring wire 14 mm
Spring wire 16 mm
Spring wire 18 mm
Spring wire 20 mm
4
-
4
-
4
-
1
2
3
4
5 44 53 13 9
5 52 03 04 6
2 79 02 02 2
2 79 02 01 4
Bolt 8G M-16
Washer Grower M-16
Spring support
16 mm Fork
1
1
2
2
1
1
2
2
1
1
2
2
1
1
2
2
"
259426484
359426483
459426482
559426481
Spring
14 mm
16 mm
18 mm
20 mm
1
-
1
-
1
-
www.urbar.com
- 37 927

MOUNTING SUPPORTS
The ARBA and RBA series are designed to be installed supported and not suspended,
on a structure. In this case, springs or mountings are used to isolate the vibrations.
The mounting or spring type is indicated in the Data Sheet.
Spring support
"
Spring
42648
"
Spring
44167
"
Spring
85149
159426485
12 mm
459441671
8 mm
259851491
10 mm
259426484
14 mm
559441670
10 mm
359851490
12 mm
359426483
16 mm
659441679
12 mm
459851499
14 mm
459426482
18 mm
759441678
14 mm
559851498
16 mm
" The type and the quantity are indicated in the Data Sheet.
www.urbar.com
- 38 928

Novibra M type mounting

El antivibrante Novibra Tipo M es ideal para la
amortiguacin multidireccional de frecuencias bajas
de interferencia.
Est especialmente diseado para obtener una gran
elasticidad y una buena deflexin con pequeas
cargas.
Novibra M Type. Dimensions and references.
The type and the quatinties are indicated in the Data Sheet.
www.urbar.com
- 39 929

Evidgom mounting
The Evidgom mounting suits perfectly to absorb
low frequency vibrations.
It is specially designed in order to obtain a high
elasticity and a good deflexion with mdium
charles.
Dimensions in diameters.
Referencia
5810 7669
5810 7681
5810 7699
5810 7731
5810 7756
A
85
95
108
140
155
B
70
90
90
120
150
C
M16
M16
M16
M16
M16
C3
30
30
34
35
30
W
60
60
70
70
90
T
M8
M8
M10
M10
M14
P
8
8
10
10
14
Low plate dimensions
Mounting
reference
5810 7669
5810 7681
5810 7699
5810 7731
5810 7756
Plate
reference
5337 5671
5337 5671
5337 5689
5337 5689
5337 5697
Fig.
a
a
a
a
b
D
mm
124/128
124/128
178/182
178/182
170
E
mm
10.2
10.2
10.2
10.2
10.5
F
mm
158
158
214
214
200
G
mm
110
110
150
150
-
H
mm
5
5
6
6
8
The type and the quantinties are indicated in the data sheet.
www.urbar.com
- 40 930

Driving unbalanced motors
The electromechanic machines are driven by two unbalanced motors,

belonging to the REX series:
REX-A; REX-B; REX-C; REX-D; REX-E or REX-F.
The driving unbalanced motors are indicated in the Data Sheet.
The spare parts list for the unbalanced motors is sent in a separate
document.
www.urbar.com
- 41 931
932
Before installing
the vibrator,
read carefully
these instructions.
Electric external vibrators

REX Serie
Installation and maintenance
Instructions
CE DIRECTIVES
In compliance with the 98/37/CE directive, regarding machinery safety, the REX vibrators are supplied
with a data plate, where all the information required by these directives is included.
INSTALLATION
External Electric Vibrators can be installed in any position, as far as they are properly fixed. It is
essential that the structure is correctly anchored for the vibrator to work properly. The surface on which
the vibrator is mounted must be completely smooth and clean. The structure to be vibrated has to be
rigid. When the installation is effected a flexible section of electric cable must always be left available to
connect the vibrator.
FIXING
To secure the vibrator it is necessary to use bolts, special steel (Q=8.8 DIN 267) self locking nuts and
safety washers. Urbar may optionally supply proper fixing devices.
Once the bolts are tightened up to the proper torque, the vibrator must be started up for a few minutes,
and then retightened to obtain the convenient torque.
TIGHTENING TORQUE
Type
daN.m
Type
daN.m
Type
daN.m
REX-A
REX-B
13
REX-C
REX-D
REX-11 AR
38
REX-E
REX-F
REX-21 AR
66
It is advisable to repeat this operation fairl frequently, checking that the tightening torque is correct.
Isolate the mechanical vibration with mounting or springs.
The weldings on the surface of the vibrator fixation have to be regularly checked.
933
Rex electric external vibrators

Installation and maintenance Instructions
ELECTRICAL INSTALLATION - CONNECTIONS
The vibrator must be connected to the electric mains, taking into account both, rated voltage and
frequency.
Unless otherwise indicated, the vibrators are supplied ready for maximum voltage connection, that is to
say, in star.
An electric lead appropriate to the power rating must be chosen.
Current levels under normal operating conditions must not be higher than those shown in the data plate.
Check vibrator consumption regularly.
If there is any overload, it must be reduced as follows:
Check and tighten the setscrews.
Strengthen the structure with plates or sections, thereby obtaining a more rigid unit.
Regulate the centrifugal force.
Always connect the earth cable and protect each vibrator individually using a magneto-thermal switch
adequate to consumption.
When working with two vibrators in tandem, any thermal triggering of one of them must also stop the
second one.
START UP
Before starting up the vibrator, check that the machine has been fitted with its caps and covers.
If the vibrators are supposed to work in tandem (screen, vibrating table ...) each vibrator must rotate in
the opposite direction one to the other. They must therefore be checked to ensure their turning
direction.
Remove provisionally one cap to check the turning direction, and exchange two phases if it needs to be
corrected.
Assemble the caps and cover, once turning direction has been checked.
OPERATION
The REX vibrators work through the rotation of unbalanced masses.
The turning area of these masses is contained inside the vibrator and is limited by the caps.
These machines must not be started up without the caps and covers fitted.
The caps may only be disassembled to check the direction of rotation and to regulate centrifugal force.
Once these operations have been carried out, replace and fix again the caps before restarting.
CENTRIFUGAL FORCE REGULATION
Loosen the nuts. Remove the caps.
Loosen the screws securing the masses at the ends of the shaft.
Change the position of the masses, as per the table, taking care that the new positions are identical, on
both sides of the vibrator.
Secure the masses again.
In the case of REX-A, change the masses for bushings, at both sides.
The rings are not supplied with the vibrator, but any commercial ring can be used.
Replace the caps, tighten as required.
Do not handle nor disassemble the vibrator without unplugging it first from the electric mains.
Do not hesitate to remove fuses or other elements to avoid accidental electric power connection.
When turning, the masses may cause physical damage if the caps are not properly fitted.
934

GENERAL BREAKDOWNS
Should the stator get burnt in a vibrator, this may be due to:
A connection problem, it may be down to two phases due to a broken cable or any other accidental
cause.
The vibrator may have loosened off, causing a greater level of consumption and eventual burn off.
The consumption rate does also increase if the vibrating part cracks.
None of this will happen if the electrical connection is properly protected in each vibrator.
On the other hand, if the vibrator works with difficulty, or it is noisy, there might be a problem with the
bearings.
LUBRICATION AND MAINTENANCE
The bearings for the REX-A vibrators are sealed. Thus, they have to be replaced in case of problem.
The type of lubricating grease to be used varies according to the centrifugal force and the vibration
frequency of the vibrator.
Three different types are established, where the KLBER grease is recommended:
- STABURAGS NBU-4:
- STABURAGS NBU-12:
- ISOFLEX LDS-18:
Centrifugal force lower than 15 kN

Speed lower (or equal) than 3000 rpm
Centrifugal force equal or higher than 15 kN
Speed lower (or equal) than 3000 rpm
Speed higher than 3000 rpm
Any centrifugal force.
These greases are made to withstand long operating periods.

On disassembly, if the grease still is in good condition, replenish using new grease, if it is observed that
the grease has been there for a long time, clean thoroughly and apply new grease, filling the roller
voids. Always use the same lubricating grease.
Should there not be KLBER grease available, it is IMPORTANT to clean the bearings properly and then
use any other grease with the following characteristics:
For low speed vibrators up to
3000rpm
For high speed vibrators 6000rpm
Thickener
Barium complex soap
Lithium soap
Base oil
ISO-68 - 68 mineral oil
ISO-15 - synthetic oil
Between 2 and 3
220C
190C
245-275
265-295
Consistency
Drop point
Rested penetration
VERY IMPORTANT
Always use the original factory parts; otherwise the vibrator can not be guaranted.
The protection level of the shell is IP66.
Avoid working underwater whenever possible, as well as excessive dust accumulation.
Do not place the standard vibrator in dangerous atmospheres.
The standard operating temperature range is: -15C ~ +50C.
935

VIBRATOR NOISE LEVEL
The equivalent average continuous acoustic pressure level given off by the REX vibrators is lower than
70 dB (A) at a distance of one meter, except for the models belonging to the range AR which level does
not, under any circumstances, rise above 85 dB (A).
Power
kW
Mass
kg
REX-A 8/30
140
3,9
REX-A 16/30
140
REX-A 20/30
140
REX-A 24/30
140
Type
Type
Power
kW
Mass
kg
REX-A 7/15
130
6,1
4,1
REX-A 12/15
150
4,2
REX-B 30/15
320
4,3
REX-B 40/15
320
Type
Power
kW
Mass
kg
REX-C 40/10
410
35,0
6,3
REX-C 55/10
420
38,0
17,8
REX-C 74/10
450
40,0
19,6
REX-D 110/10
1300
92,0
REX-A 28/30
140
4,5
REX-C 60/15
550
29,5
REX-D 160/10
1750
101,0
REX-B 35/30
240
15,2
REX-C 90/15
560
32,5
REX-D 210/10
1950
110,0
REX-B 60/30
280
16,1
REX-C 110/15
570
34,0
REX-E 280/10
3420
175,0
REX-C 90/30
900
25,3
REXC 140/15
590
35,0
REX-E 380/10
3500
188,0
REX-C 140/30
920
29,0
REX-D 170/15
1780
80,0
REX-E 500/01
3580
220,0
REX-C 165/30
920
31,0
REX-D 250/15
1850
90,0
REX-F 750/10
5200
285,0
REX-E 350/15
2550
150,0
REX-11 60/30 AR
550
12,0
REX-E 500/15
2750
170,0
REX-22 120/60 AR
710
23,0
REX-21 90/30 AR
890
24,5
REX-F 750/15
4450
245,0
REX-21 120/90 AR
830
23,0
CONCRETE PREFABRICATES
Vibrators with speeds of 3,000 and 6,000 rpm are normally applied, with a centrifugal force not higher
than 12 kN per unit, depending of the concrete, the form and the piece.
Their placement depends on the specific shape of each moulding, concrete type, steel reinforcement
type, etc. It also requires specific analysis of each case, before building the formwork.
Quick fixing or sliding devices are also used to aid this type of fabrication.
To improve the external aspect of prefabricates we may also supply dual speed vibrators, with two
different torque settings, operated by static frequency regulators, thus achieving better results.
OTHER APPLICATIONS
The vibrators are applied in couples, joining them rigidly and making them turn in opposite directions,
thus achieving unidirectional vibration.
The weldings of the vibrating system have to checked periodically.
The choice for the vibrators depends on the application.
Vibrators at 3000 rpm are used for compacting.
When transporting, screening or elevating vibrators at 1000 or 1500 rpm are installed.
Ctra. Villabona-Asteasu, km 3
Apartado 247
Tel. (+34) 943 691 500
Fax (+34) 943 692 667
E-20159 Asteasu
www.urbar.com
export@urbar.com
REX / 5
2002.03
936
Electromechanical vibrant equipments
Electric vibrators REX-D
REX-D 170/15
REX-D 250/15
55592026
55595016
REX-D 210/10
Description
Support
Stator
REX-D 160/10
Code
25592015
REX-D 110/10 SA
Ref.
REX-D 110/10
Part List
1
-
1
-
1
-
1
-
1
-
1
-
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
-
2
-
2
-
2
-
2
-
1
-
1
-
1
-
1
-
1
-
1
2
2
2
8
8
8
1
2
2
2
8
8
8
1
2
2
2
8
8
8
1
2
2
2
8
8
8
2
2
2
8
8
8
1
1
2
2
2
8
8
8
2
2
9
1
1
2
2
9
1
1
2
2
9
1
1
2
2
9
1
1
2
2
9
1
1
2
2
9
1
1
Rotor shaft
55592034
55595020
4
5
6
7
25592042
55069058
25592056
Support disk
Bearing
Cover
Fix part
25590010
25591013
25592064
25594016
25595034
8
Free part A
25590024
25591027
25592092
25594020
25595045
10
11
12
13
14
15
16
17
18
19
20
Free part B
25590038
25591032
25592072
25594034
25595054
55077085
55202048
25010117
55075063
59923524
55067128
25592080
25595068
55592117
56800204
25110180
55110191
Screw
Washer
Washer
Washer
Screw
Allen screw
Cover
O-Ring
Washer
Cover
Cover joint
937
Electromechanical vibrant equipments
Electric vibrators REX-D
REX-D 170/15
REX-D 250/15
Pin
REX-D 210/10
55590046
55591044
55592091
55594048
55595078
54404223
Description
Washer
Bushing
Connecting plate
Screw
Nut
Puente
Terminal
Terminal
Screwed bar
Bar
Screw
Washer
Oiler
Washer
Steel bar
Stuffing box
Joint
Washer
Washer
Nut
Name plate
REX-D 160/10
42
Code
56810419
25136060
55110233
55136089
56820533
55110241
56862303
59916452
55116297
25010133
54000070
55078059
55110282
25117136
55063135
55623102
55623110
55640155
55063317
55136071
REX-D 110/10 SA
Ref.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
REX-D 110/10
Part List
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
8
1
1
2
9
3
9
1
1
2
12
4
2
9
2
1
1
1
1
1
1
4
1
4
1
4
1
4
1
4
1
4
938
BOOM LUFFING HYDRAULIC

SYSTEM
939
VICKERS
APPLICATION:
HYDRAULIC POWER UNIT
CUSTOMER:
TAIM TFG
OFFER:
HT 05/0322A
(BOOM LUFFING)
DATE:
CENTRAL:
Avda.de la Industria s/n
33409 Avils (Asturias)
Tel:
98 552 57 57
Fax:
98 556 74 72
2006
DELEGACIN CENTRO-SUR:
Avda. del Sistema Solar, 13
Nave 14
28830 San Fernando de
Henares - Madrid
Tel:
91 383 88 75
Fax:
91 766 73 97
DELEGACIN BARCELONA:
Pol. Ind. Centro de Viladecans
C/La Forja, 37
08840 Viladecans (Barcelona)
Tel:
93 647 22 60
Fax:
93 637 75 10
DELEGACIN GALICIA:
Av. De la Hispanidad 57 A
1 planta- Ofic. 4
36203 Vigo
Tel/Fax: 98 647 39 12
Mvil:
61 025 89 34
940
05/0322A
INDEX
1. STARTING UP MANUAL, DECLARATION OF
CONFORMITY
2. PARTS LIST
3. DRAWINGS
4. CERTIFICATES
5. CATALOGUE ELEMENTS
6. HYDRAULIC HINTS & TROUBLE SHOOTING
GUIDE
HIDRASA-HIDRAVICK S.A.
941
05/0322A
STARTING UP MANUAL, DECLARATION OF

CONFORMITY
942
INDEX
SETTING UP:............................................................................................... 2
1.1
LIFTING THE MACHINE: ....................................................................... 2
1.2
POSITIONING THE MACHINE: ............................................................. 2
1.3
FILLING THE TANK: .............................................................................. 2
1.4
START UP:............................................................................................. 2
OPERATING:............................................................................................... 2
2.1
INTRODUCTION: ................................................................................... 2
MAINTENANCE:.......................................................................................... 3
CE APPROVAL CERTIFICATE ................................................................5
Pgina 1
943
The present hydraulic power unit with reference HT 05/0322A has been manufactured in
accordance with the European directives in force. However, if it is used incorrectly, it may
become a danger risk.
Any damage resulting from incorrect use is not covered by the manufacturer.
Authorised repairs and modifications are specified in the present manual, for the remainder of
operations not covered in the present manual, please contact the manufacturer.
1
1.1
SETTING UP:
LIFTING THE MACHINE:
There are 4 lugs on top of the tank for positioning the unit on site. This may be placed in
position using a loading bridge and slings in good condition that are able to support the weight
of the machine.
1.2
POSITIONING THE MACHINE:
If the floor where the machine is to be placed is not horizontal and/or may be subject to
vibrations other than those generated by the machine itself, this must be bolted to the floor at
each of the drill holes with which the tank supports are fitted. If the floor is secure, fastening with
bolts is not necessary but is recommendable. It is not recommendable for the machine to be
placed on carpeted floors or similar, as the cleaning of oil spills on these floors is very difficult.
The recommendations for oil cleaning given in this manual are exclusively for tiled, or similar,
non-permeable floors.
1.3
FILLING THE TANK:
The tank is to be filled exclusively with oil (the manufacturer recommends ISO VG46 oil). The
instructions for carrying out this operation are established in the section Filling the tank.
1.4
START- UP:
Connect the machine to the mains and press the start button and then the stop button
immediately, checking that the direction of rotation of the motor is precisely that indicated on the
casing. If the direction of rotation is incorrect, change the connections of the two terminals and
carry out the same check until the motor turns adequately. The machine may now be used
normally.
2
2.1
OPERATING:
INTRODUCTION:
This machine is not adequate for work in an explosive environment. The minimum protection
coefficient of the machine is IP55, which means that it may be exposed to splashing by water in
all directions, but does not support immersion.
Pgina 2
944
Before delivery, the machine has been regulated so that the operating parameters are the
correct ones, and therefore there is no need for the user to carry out any kind of adjustment. In
order to carry out adjustments in the machine, or to adjust it in the case of its becoming
misaligned, please contact the manufacturer at the nearest address to you (see the cover of the
present manual).
In no case should the user manipulate the pump compensator.

The manufacturer is not responsible for any damage that may arise as a consequence of
incorrect use of the machine.
MAINTENANCE:
-
Before dismantling: The manufacturer authorises the user to substitute those elements
of the machine that are listed below as long as the instructions are followed. Before
proceeding with dismantling, it is necessary to check via the installed pressure gauge
that there is no pressure in the circuit, making sure that the pressure gauge valve is
open. Likewise, the mains supply must be turned off.
Re-filling the tank: Unscrew the top-up cap and make sure that the drain valve is closed.
Proceed to pour in oil through the top-up neck carefully, since the filter of this neck does
not permit very fast filling. Foreign objects must not be introduced into the top-up neck
nor must the filter be broken with the aim of filling the tank with oil more rapidly. While
the tank is being filled, the visual level must be monitored so that the oil introduced is
within the indicators of maximum and minimum levels. If oil is spilled, see the section
Cleaning of oil spills. A level nearer to the maximum than to the minimum is
recommended.
Cleaning oil spills: The cleaning recommendations given here are exclusively for
cleaning tiled floors, or similar, which are not permeable. If oil is spilt onto the floor, all
the spills are to be covered with abundant sawdust. After waiting some fifteen minutes
for the sawdust to absorb all the oil, this is then to be removed with a broom.
Draining the tank: Place a container under the drain valve of the tank that will hold all
the oil that there is. Unscrew the top-up cap (the filter need not be removed) so that air
may enter the tank, and open the drain valve until the tank drains completely. If the
container is not low enough to fit under the valve, the machine may be lifted using a
loading bridge (see the section Lifting the machine). The use of several containers is
also valid, but the drain valve must be closed before changing containers.
Pgina 3
945
Top-up cap, return filter, pressure gauge and pressure gauge valve: In order to remove
these elements, there is no need to drain the tank, but the use of containers is
recommended to avoid oil spillage.
To remove the pressure gauge or the pressure gauge valve, an adjustable wrench must
be used to loosen the nuts. Once the nuts have been loosened, the pressure gauge is
to be unscrewed by hand. The pressure gauge valve cannot be removed without
removing the pressure gauge.
To remove the return filter, the bolts that fasten this to the tank must be removed.
To remove the top-up neck filter, the metal cap has to be unscrewed and then the
screws that fasten the plug to the tank have to be removed.
Drain valve, visual level, electric element, suction filter: To remove these elements, the
tank must first be drained (see the section Draining the tank).
Once the tank is drained, an adjustable wrench must be used to remove the drain valve,
by unscrewing it.
To remove the visual level or the electrical element, the bolts that fasten said elements
to the tank must be removed.
To remove the suction filter, which is inside the tank, it is necessary to remove the
circular lid of the tank after draining the tank. To do so, all the fastening bolts of said lid
are to be undone and the lid removed. To carry out the operation more securely, the
use of flashlights is recommended so as to be able to see clearly inside the tank. The
suction filter is dismounted by unscrewing it by hand (if it is too tight, an adjustable
wrench may be used). After substituting the suction filter, the tank has to be closed up
once again, making sure that no foreign object has been left inside the tank (wrenches,
bolts, flashlights, etc.). The drain valve is then closed and the circular lid of the tank
replaced, making sure that the rubber seal of this lid is correctly positioned. The
fastening bolts of the lid are to be tightened by firmly tightening the diametrically
opposed bolts first, and then the rest. Then proceed to re-filling the tank in the way
indicated in the section Re-filling the tank.
To carry out other manipulations not specified in the present manual, please contact the
manufacturer at the nearest address to you (see the cover of the present manual).
The manufacturer does not accept responsibility for the carrying out on the part of the user
of manoeuvres not specified in the present manual.
Pgina 4
946
947
05/0322A
PARTS
LIST
948
PART LIST
AVILES
HA-LMC-N
HA-PG-02
REV.:1
ANEXO IV
TAIM TFG
Customer
Offer
05/0322A
Ed.:0
05/0322A
Installation
Description
Drawing
HYDRAULIC POWERT UNIT

N. Customer 200506531
Quantity
1
Deliver
12-jun-06
OTH n
PREPARED BY
FDO:
REVISED BY
FDO:
Conrado Escrig Torres
Antonio Estevez Dueas
05/0322A
AVILES
DENOMINATION
REFERENCE
CODE
QUANTITY
POS
TANK 600 LIT
DRAWING 050322AES_00_00
HOUSING TANK
DRAWING 050322AES_00_00
1,1
RECEVOIR COVER
RD 475-V 449-6
1,2
LEVEL INDICATOR
LM 127 1T M10
AIR FILTER
TP1,02601
RETURN FILTER
UCMF 300 H N F(R1 1/2"G)+ UCF B
ELECTRIC MOTOR
30KW 1500 RPM 400V 50HZ B3/B5-CLIENTE
BELLHOUSING
RV400/204/200
COUPLING
SPIDEX A48/60,55H7+A48F+ZK48 Zahnkranz 92Shore A
PISTN PUMP
PVQ40 B2R SE1F 20 C21 12
BLOCK
S/PLANO 040340BL_00_01 (CON DR)
PROPORTIONAL VALVE
KTG4V 5 2B50N Z M U H7 30
565331
10
02-326010
11
870252
12
566490
13
POWER PLUGS FOR PROPORTIONAEHH AMP 702 D 20

DIRECTIONAL CONTROL VALVE 220V
DG4V 3 0C M U D6 60
DIFFERENTIAL PRESSURE SENSING VAL DPS2
10 F F 0 80
02-341949
PRESSURE HOSE
SMS-20-M-1 METRO
14
MANOMETER
D63 0-250 BAR R1/4"GAS PANEL
15
BLOCK
DRAWING 040340BL_01_02
16
PRESSURE SEQUENCE VALVE
PSV2 10 S 0 24
565583
17
RELIEF VALVE
RV2 10 S 0 35/
566212
18,1_18.2
RELIEF VALVE
RV2 10 S 0 50/
565565
18,3_18.4
GAUGE ISOLATOR
UC.1555
20
ELECTRIC LEVELS
RLG1-RF3-S2 (1000) ( N.A. )
21
MANOMETER
D63 0-250 BAR R1/4"GAS VERT.
22
PRESSURE HOSE
SMS-20-M-1 METRO-MATERIAL SUELTO
23
GAUGE OUTLET
686205 R1/4"GAS
24
GATE VALVE
GE2 R1/2"GAS
25
ELECTRICAL BOX + WIRING
DRAWING 040340EL_00_00
26
Pgina 1 de 2
949
PART LIST
AVILES
HA-LMC-N
HA-PG-02
REV.:1
ANEXO IV
TAIM TFG
Customer
Offer
05/0322A
Ed.:0
05/0322A
Installation
Description
Drawing

Quantity
1
Deliver
12-jun-06
OTH n
PREPARED BY
FDO:
REVISED BY
FDO:
05/0322A
AVILES
DENOMINATION
REFERENCE
CODE
QUANTITY
POS
1 1/2"
27
GATE VALVE
PASO TOTAL IDEAL
GAUGE OUTLET
686205 R1/4"GAS
28
CYLINDER
320/200/1400( S/PLANO 050322AMO_01_00 )
29
DIRECTIONAL CONTROL VALVE 230V CA
SV13 10 C 0 240AGH
30
SILENT BLOCK
REF:3356 DIAM80
FIXING BOLT KIT
(4)M-6x40 DIN-912 CAL.12.9
TAGS
25x15
HYDRAULIC OIL
EN BIDONES ( CENTRAL + CILINDROS )
INOX PIPE
PARA INTERCONEXION DE ELEMENTOS EN CENTRAL
02-182560
4
BKDG01633M
TOTAL
69
Pgina 2 de 2
950
05/0322A
DRAWINGS
951
952
953
954
955
05/0322A
CERTIFICATES
956
957
958
959
Messrs
HIDRASA HIDRAVICK SA
Trav. de la Industria, 10
Spain
Object: ISO Standard conformity declaration
We declare that GKN Uni Cardan filters are manufactured in accordance with the following ISO standards:
ISO 2941 Hydraulic fluid power -- Filter elements -- Verification of collapse/burst resistance
ISO 2942 Hydraulic fluid power -- Filter elements -- Verification of fabrication integrity
and determination of the first bubble point.
ISO 2943 Hydraulic fluid power -- Filter elements -- Verification of material compatibility with fluids (type HH, HM, HR, HV, HG according with ISO 6743/4)
ISO 3723 Hydraulic fluid power -- Filter elements -- Method for end load test
ISO 3724 Hydraulic fluid power -- Filter elements -- Verification of flow fatigue characteristics
ISO 3968 Hydraulic fluid power -- Filters -- Evaluation of differential pressure versus
flow characteristics
ISO 16889 Hydraulic fluid power filters -- Multi-pass method for evaluating filtration
performance of a filter element
Best Regards
Uni Cardan Italia S.p.A.
Michele Bogni
Product Manager Hydraulics
960
05/0322A
CATALOGUE ELEMENTS
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05/0322A
HYDRAULIC HINTS & TROUBLE SHOOTING GUIDE
1056
General Hydraulic Hints

Good Assembly
Practices
Most important cleanliness.
All openings in the reservoir should be
sealed after cleaning.
No grinding or welding operations
should be done in the area where
hydraulic components are being
installed.
All cylinder, valve, pump and hose
connections should be sealed and/or
capped until just prior to use.
Mineral spirits should be kept in safety
containers.
Air hoses can be used to clean fittings
and other system components. However,
the air supply must be filtered and dry to
prevent contamination of the parts.
Examine pipe fittings and hose
assemblies prior to use to be certain that
burrs, dirt and/or scale are not present.
All pipe and tubing ends should be
reamed to prevent restriction and
turbulent flow.
Do not use Teflon tape on straight
thread connections.
When installing pumps or motors,
always align coupling halves as closely
as possible, within 0.007 inch.
When using flexible couplings, follow the
manufacturers recommendations or
allow 1/32 to 1/16 inch clearance
between the coupling halves.
Do not drive couplings on pump or
motor shafts. They should be a slip fit,
or shrunk on using hot oil.
Always use a dry spray-on lubricant on
splines when installing. This prevents
wear and adds to the life of the splines.
When using double universal joint
couplings, the shafts must be parallel
and the yokes must be in line.
When installing V-belt pulleys on pumps
or motors, line up both pulleys as closely
as possible. Always install the pulleys with
a minimum amount of overhang as close
to the pump or motor face as possible.
This increases bearing service life.
Pipes
Tubing Dos And Donts
Iron and steel pipes were the first kinds

of plumbing used to conduct fluid
between system components. At
present, pipe is the least expensive way
to go when assembling a system.
Seamless steel pipe is recommended
for use in hydraulic systems with the
pipe interior free of rust, scale and dirt.
Dont take heavy cuts on thin wall tubing

with a tubing cutter. Use light cuts to
prevent deformation of the tube end. If
the tube end is out or round, a greater
possibility of a poor connection exists.
Early classifications of pipe wall

thicknesses were: standard, extra heavy
and double extra heavy.
Today, pipes are classified by schedule
number as specified by the American
National Standards Institute (ANSI). The
schedule numbers vary from 10 through
160. The larger the number, the heavier
the wall thickness. The outer pipe
diameter stays the same for a given pipe
size, while the inside opening becomes
smaller as schedule number increases.
A comparison of early classifications
versus the ANSI classification follows:
Standard
Schedule 40
Extra Heavy Schedule 80
The double extra heavy classification
does not compare with a schedule
number. However, the inside diameter of
a double extra heavy pipe is
approximately one half that of a schedule
160 pipe.
In many cases, flanges are welded to
the pipe ends and gaskets or O rings
are used to seal the connections.
Various pipe fittings are used to route
the piping to and from each system
component. These fittings can be
threaded or welded in place as the need
arises. Threaded connections are used
in low pressure applications and welded
connections are used if high pressure,
high temperature, or a severe
mechanical load exists.
Ream tubing only for removal of burrs.

DO NOT over ream tubing as it can
weaken the connection.
Do not allow chips to accumulate in the
tubing. They can be difficult to remove
after bending.
Follow the manufacturers
recommendations on the use of flaring
tools. Dont overtighten the feed screw
handle on a compression type flaring tool.
Improper use of a tool can cause washout
and/or splitting of the flare connection.
Bend tubing instead of cutting and using
a fitting. This reduces pressure drop and
minimizes system losses. The minimum
radius of a tubing bend should be at
least three times the inside diameter of
the tube. Larger bends are preferred.
Sketch the optimum tubing route before
beginning the bending process. Be sure
to use tubing with the proper temper to
prevent wrinkles and flattened bends.
Most flares are made by hand or power
tools that swage the tube end over a
split die. The standard flare angle is 37
degrees from the centerline. For best
results, heavy wall tubing should be cut,
deburred, and flared and bent using
power equipment.
For information on sealing technology, or
how to prevent leakage of hydraulic fluid,
refer to Leakage Control in this catalog.
All piping should be secured with

clamps to prevent vibration and
excessive stress due to the weight of
the fluid. Do not weld the clamps to the
pipe as it may weaken the pipe and
cause a stress crack.
1057
Troubleshooting Guide & Maintenance Hints

General
The troubleshooting charts and
maintenance hints that follow are of a
general system nature but should
provide an intuitive feeling for a specific
system. More general information is
covered in the following paragraphs.
Effect and probable cause charts
appear on the following pages.
System Design
There is, of course, little point in
discussing the design of a system which
has been operating satisfactorily for a
period of time. However, a seemingly
uncomplicated procedure such as
relocating a system or changing a
component part can cause problems.
Because of this, the following points
should be considered:
1. Each component in the system must
be compatible with and form an
integral part of the system. For
example, an inadequate size filter on
the inlet of a pump can cause
cavitation and subsequent damage to
the pump.
2. All lines must be of proper size and
free of restrictive bends. An
undersized or restricted line results in
a pressure drop in the line itself.
3. Some components must be mounted
in a specific position with respect to
other components or the lines. The
housing of an in-line pump, for
example, must remain filled with fluid
to provide lubrication.
4. The inclusion of adequate test points
for pressure readings, although not
essential for operation, will expedite
troubleshooting.
Knowing the System

Probably the greatest aid to
troubleshooting is the confidence of
knowing the system. The construction and
operating characteristics of each one
should be understood. For example,
knowing that a solenoid controlled
directional valve can be manually actuated
will save considerable time in isolating a
defective solenoid. Some additional
practices which will increase your ability
and also the useful life of the system
follow:
1. Know the capabilities of the system.

Each component in the system has a
maximum rated speed, torque or
pressure. Loading the system beyond
the specifications simply increases
the possibility of failure.
2. Know the correct operating pressures.
Always set and check pressures with a
gauge. How else can you know if the
operating pressure is above the
maximum rating of the components?
The question may arise as to what the
correct operating pressure is. If it isnt
correctly specified on the hydraulic
schematic, the following rule should be
applied:
The correct operating pressure is the
lowest pressure which will allow
adequate performance of the system
function and still remain below the
maximum rating of the components
and machine.
1. Excessive heat means trouble. A

misaligned coupling places an
excessive load on bearings and can
be readily identified by the heat
generated. A warmer than normal
tank return line on a relief valve
indicates operation at relief valve
setting. Hydraulic fluids which have a
low viscosity will increase the internal
leakage of components resulting in a
heat rise. Cavitation and slippage in a
pump will also generate heat.
2. Excessive noise means wear,
misalignment, cavitation or air in the
fluid. Contaminated fluid can cause a
relief valve to stick and chatter. These
noises may be the result of dirty filters,
or fluid, high fluid viscosity, excessive
drive speed, low reservoir level, loose
intake lines or worn couplings.
Maintenance
Once the correct pressures have been

established, note them on the hydraulic
schematic for future reference.
Three simple maintenance procedures

have the greatest effect on hydraulic
system performance, efficiency and life.
3. Know the proper signal levels,

feedback levels, and dither and gain
settings in servo control systems. If
they arent specified, check them
when the system is functioning
correctly and mark them on the
1. Maintaining a clean sufficient quantity

of hydraulic fluid of the proper type
and viscosity.
Developing Systematic
Procedures
Analyze the system and develop a
logical sequence for setting valves,
mechanical stops, interlocks and
electrical controls. Tracing of flow paths
can often be accomplished by listening
for flow in the lines or feeling them for
warmth. Develop a cause and effect
troubleshooting guide similar to the
charts appearing on the following pages.
The initial time spent on such a project
could save hours of system down-time.
Recognizing Trouble
Indications
2. Changing filters and cleaning

strainers.
3. Keeping all connections tight, but not
to the point of distortion, so that air is
excluded from the system.
Guidelines
The following charts are arranged in five
main categories. The heading of each
one is an effect which indicates a
malfunction in the system. For example,
if a pump is exceptionally noisy, refer to
Chart 1 titled Excessive Noise. The
noisy pump appears in Column A under
the main heading. In Column A there are
four probable causes for a noisy pump.
The causes are sequenced according to
the likelihood of happening or the ease
of checking it. The first cause is
cavitation and the remedy is a. If the
first cause does not exist, check for
cause number 2, etc.
The ability to recognize trouble

indications in a specific system is
usually acquired with experience.
However, a few general trouble
indications can be discussed.
1058

Chart 1
EXCESSIVE NOISE
1.
PUMP NOISY
MOTOR NOISY
RELIEF VALVE NOISY
Cavitation
Remedy: a
1.
Coupling misaligned
Remedy: c
1.
Setting too low or too

close to another valve
setting
Remedy: d
2.
Air in fluid
Remedy: b
3.
Coupling Misaligned
Remedy: c
4.
Pump worn or
damaged
2.
Motor or coupling
worn or damaged
2.
Worn poppet and seat

Remedy: e
Remedy: b
Remedy: e
Remedies:
a. Any or all of the following:
Replace dirty filters; wash strainers in
solvent compatible with system fluid;
clean clogged inlet line; clean or
replace reservoir breather vent;
change system fluid; change to
proper pump drive motor speed;
overhaul or replace supercharge
pump; fluid may be too cold.
b. Any or all of the following:

Tighten leaking connections; fill
reservoir to proper level (with rare
exception all return lines should be
below fluid level in reservoir); bleed
air from system; replace pump shaft
seal (and shaft if worn at seal
journal).
c. Align unit and check condition of

seals, bearings and coupling.
d. Install pressure gauge and adjust to
correct pressure.
e. Overhaul or replace.
1059

Chart 2
EXCESSIVE HEAT
PUMP HEATED
MOTOR HEATED
RELIEF VALVE HEATED
FLUID HEATED
1.
Remedy: See column D
1. Fluid heated
1. Fluid heated
1. System pressure too

high
Remedy: d
2. Cavitation
Remedy: a
2.
Relief or unloading
valve set too high
2.
Valve setting incorrect

Remedy: d
Remedy: d
3. Air in fluid
Remedy: b
3. Excessive load
Remedy: c
4. Relief or unloading
valve set too high
4. Worn or damaged
motor
Remedy: d
2.
Unloading valve set

too high
Remedy: d
3. Worn or damaged valve

Remedy: e
3. Fluid dirty or low supply

Remedy: f
4. Incorrect fluid
viscosity
Remedy: e
Remedy: f
5. Excessive load
5. Faulty fluid cooling

system
Remedy: c
Remedy: g
6. Worn or damaged
pump
6. Worn pump, valve, motor,

cylinder or other
component
Remedy: e
Remedy: e
Remedies:
Replace dirty filters; clean clogged
inlet line; clean or replace reservoir
breather vent; change system fluid;
change to proper pump drive motor
speed; overhaul or replace
supercharge pump.
journal).

seals and bearings; locate and
correct mechanical binding; check for
work load in excess of circuit design.
g. Clean cooler and/or cooler strainer;

replace cooler control valve; repair or
replace cooler.

correct pressure (keep at least 125
PSI difference between valve
settings).
f. Change filters and also system fluid if
improper viscosity; fill reservoir to
proper level.
1060
Chart 3
INCORRECT FLOW
NO FLOW
LOW FLOW
EXCESSIVE FLOW
1. Pump not receiving fluid

Remedy: a
1.
Flow control set too low

Remedy: d
1. Flow control set too high

Remedy: d
2.
2.
Relief or unloading
valve set too low
2.
Pump drive motor not

operating
Remedy: e
3.
Pump to drive coupling

sheared
Remedy: d
3.
Remedy: c
4. Pump drive motor turning
in wrong direction
Remedy: e
Flow by-passing thru

partially open valve
External leak in system

Remedy: b
5.
Remedy: f
6.
Entire flow passing

over relief valve
8.
Improperly assembled
pump
Remedy: h
4.
Improper size pump

used for replacement
Yoke actuating device

inoperative (variable
displacement pumps)
Remedy: e
6.
Remedy: d
7. Damaged pump
Remedy: c
RPM of pump drive

motor incorrect
Remedy: h
Remedy: g
5. Directional control set in
wrong position
3.
Remedy: e or f
4.

displacement pumps)
RPM of pump drive

motor incorrect
Remedy: h
7.
Worn pump, valve,

motor, cylinder or
other component
Remedy: e
Remedy: e
Remedies:
breather vent; fill reservoir to proper
level; overhaul or replace
supercharge pump.
c. Check for damaged pump or pump

drive; replace and align coupling.
d. Adjust.
f. Check position of manually operated

controls; check electrical circuit on
solenoid operated controls; repair or
replace pilot pressure pump.
g. Reverse rotation.
h. Replace with correct unit.
b. Tighten leaking connections.
1061
Chart 4
INCORRECT PRESSURE
NO PRESSURE
LOW PRESSURE
ERRATIC PRESSURE
EXCESSIVE
PRESSURE
1. No flow
Remedy: See Chart 3,
column A
1. Air in fluid
Remedy: b
1. Pressure relief path

exists
column A and B
1. Pressure reducing,
relief or unloading
valve misadjusted
Remedy: d
2.
2.
Pressure reducing valve

set too low
2.
Worn relief valve

Remedy: e

displacement pumps)
Remedy: e
Remedy: d
3. Pressure reducing
valve damaged
3. Contamination in fluid
Remedy: a
Remedy: e
relief or unloading
valve worn or damaged
Remedy: e
4. Damaged pump, motor

or cylinder
4. Accumulator defective
or has lost charge
Remedy: e
Remedy: c
5. Worn pump, motor or
cylinder
Remedy: e
Remedies:
a. Replace dirty filters and system fluid.
b. Tighten leaking connections (fill
reservoir to proper level and bleed air
from system).
1062
Chart 5
FAULTY OPERATION
NO MOVEMENT
SLOW MOVEMENT
ERRATIC MOVEMENT
EXCESSIVE SPEED
OR MOVEMENT
1. No flow or pressure
Remedy: See Chart III
1. Low flow
Remedy: See Chart 3
1. Erratic pressure
Remedy: See Chart IV
1. Excessive flow
Remedy: See Chart 3
2.
2.
2.
2.
Limit or sequence
device (mechanical,
electrical or hydraulic)
inoperative or
misadjusted
Fluid viscosity too high

Remedy: a
Air in fluid
Remedy: See Chart I
Feedback transducer
malfunctioning
Remedy: e
Remedy: e
3. Mechanical bind
Remedy: b
3. Insufficient control
pressure for valves
3. No lubrication of
machine ways or
linkage
Remedy: See Chart 4
3. Misadjusted or
malfunctioning servo
amplifier
Remedy: See Chart 4

4. No command signal
to servo amplifier
Remedy: f
5. Inoperative or misadjusted servo amplifier
Remedy: c
6. Inoperative servo valve
Remedy: c
4. No lubrication of machine
ways or linkage
4. Erratic command signal
Remedy: c
4. Over-riding work load
Remedy: f
Remedy: h
Remedy: g
5. Misadjusted or malfunctioning servo amplifier
Remedy: c
Remedy: c
6. Malfunctioning feedback
transducer
6. Sticking servo valve

Remedy: c
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: d
Remedy: e
8. Worn or damaged
cylinder or motor
Remedy: e
Remedies:
a. Fluid may be too cold or should be
changed to clean fluid of correct
viscosity.
c. Adjust, repair or replace.

d. Clean and adjust or replace; check
condition of system fluid and filters.
f. Repair command console or

interconnecting wires.
g. Lubricate.
b. Locate bind and repair.

h. Adjust, repair or replace

counterbalance valve.
1063
Quiet Hydraulics
Today, buyers are demanding quiet
machines because of their concern
about meeting industrys noise limits.
Vickers is helping to meet this demand
by supplying quiet hydraulic
components. Sound levels of some
pumps today, for example, are fifty
percent lower than the same model
pumps of a few years ago.
Sound Advice
Producing quiet, hydraulically-actuated
machines requires more than just the
use of quiet components.
Meeting the stringent sound-level
specifications of todays industrial hydraulic
systems and machines takes careful
engineering. The pump should be
considered first. It not only produces sound
directly but generates vibrations and fluid
pulsations. These react with other machine
parts which produce more sound.
Pump Selection
Pumps generate more acoustic energy
per unit of hydraulic power by running at
high speed rather than at low. For this
reason, a pump should operate at 1200
RPM whenever sound is critical. Below
3000 PSI, the trade-off between pressure
and pump size for a given drive power
has little effect on noise, so you are free
to select any combination of these factors
that otherwise meet your needs.
Mechanical Isolation
To meet lower sound level limits, the
pump should be mechanically isolated
from the rest of the machine using
anti-vibration mountings. This also
requires that all connections to the
pumps be made with flexible hose.
Flexible hose will often reduce noise even
where anti-vibration mountings are not
used. It prevents vibrations from reaching
other lines and components to keep them
from becoming sound sources. In long
lengths, this hose is, itself, a good sound
generator so only short lengths should be
used. For long runs, use solid pipes with
short hoses at the ends. All long lines must
be supported every meter or so, preferably
with clamps providing vibration damping.
Lines must not contact panels that are
good sounding boards. Where they pass
through such panels, allow sufficient
clearance to prevent direct contact; never
use bulkhead fittings in such cases.
Acoustic Isolation
Reservoirs
The greatest sound level reductions are

attained with the pump acoustically as
well as mechanically isolated. This
requires that the pump be completely
enclosed in a non-porous shell weighing
at least 10 kg per square meter of
surface. No openings can be tolerated
and all joints must be sealed with
resilient gaskets or moldings.
Reservoirs provide the means for

releasing entrained bubbles. These
can come from sources other than the
pump inlet and are usually present in
the fluid returning to the reservoir. It is
important to note that low reservoir
temperatures reduce the rate of
bubble escape and may result in
incomplete release. As pointed out
earlier, high temperatures promote
bubble formation. The best balance
between these two alternatives is
achieved by maintaining the
temperature of oil leaving the
reservoir in the range of 120 to
150F and the temperature of
water-based fluids between 100 and
120F.
Grommets of rubber or other soft

material should be used to close
openings around piping and to prevent
mechanical contact between the
enclosure and piping. It must be
emphasized that while mechanical
isolation by itself can reduce noise,
acoustic isolation can only be effective
when used in combination with
mechanical isolation.
Fluids
The condition of the fluid being pumped
is also important in controlling sound.
Fluid viscosity, temperature and
vacuum by themselves have no effect
on sound levels. It is important to
control them, however, to prevent the
formation of entrained air or vapor
bubbles that can double sound levels,
and reduce pump life.
A simple reservoir has to be large

to effect complete bubble release.
By providing baffles to guide the fluid
through a circuitous path and by
locating return and pump inlet lines
as far apart as possible, a reservoir
holding between two to three minutes
of maximum pump flow can be
adequate.
A combination of high fluid

temperature and inlet vacuum
generates what are called cavitation
bubbles. However, at low
temperatures, a high viscosity fluid in
a very long suction line can also
produce sufficient vacuum to cause
cavitation. Important methods of
suppressing bubble formation include:
Using short runs or large diameter
inlet lines; keeping the reservoir
elevation close to or above that of the
pump; using low pressure-drop inlet
filters that signal when they are
producing high vacuums and need
changing; and, providing adequate
fluid controls. These are all good
hydraulic practices that become
increasingly important where you
must achieve low sound levels.
10
1064
Contamination Control
Contaminant in hydraulic systems is
now recognized as the most frequent
cause of malfunction or failure of
hydraulic equipment. Dependent on the
nature, size and/or amount of
contaminant, it can cause:
Reduced component service life.
Control of Contamination
The following table prescribes
preventative measures relative to the
different common types and causes of
contamination. For additional information,
request Vickers Guide to Systemic
Contamination Control, catalog 561.
Machine malfunction, particularly

when operating near maximum
capacity.
Risk of frequent breakdowns under
the same conditions.
Production rates below schedule.
High product scrap rates and quality
faults.
Nature of Contaminant
Contaminant can be either particle
contaminant or the product(s) of fluid
degradation.
Particle contaminant can be metal,
rubber, plastic, dirt, dust, fibre, sand,
paint, etc.; several types may be present
at any time. It can enter the fluid at any
time after the fresh clean fluid has been
produced by the fluid manufacturer.
There is usually little likelihood that fresh
fluid became contaminated during the
refining and blending processes.
Fluid degradation results in:
Oxidation and/or the formation of
gummy deposits and sludge from the
combined effects of high
temperatures, air, water and particle
contaminant. These can increase
viscosity, cause gummy deposits to
coat moving parts, clog orifices and
small passages, thus impairing
smooth mechanical movements and
form sludge.
Unstable emulsions of poor lubricity
formed when water accidently
emulsifies with oil. These impair smooth
movements and promote wear.
Aeration or air bubbles in the fluid,
particularly at low pressures. In
excess, they cause noise in pumps
and valves leading to erratic or
spongy machine movements,
premature wear and failure.
Preventive Measures
For Storage Drums:
Store in cool, dry location.
Ensure that closures fully seal in the fluid.
Wipe away any dirt and moisture from around the
closure before loosening and emptying.
Use a portable filtration and transfer unit for
emptying and refilling.
For Storage Tanks:
Install in cool, dry location.
Ensure that all covers and stop valves effectively
seal in the fluid.
Keep filling lines clean; cap ends when not in use.
Use a portable filtration unit for filling and emptying.
For Hydraulic Systems:
Provide fluid filter(s) in location(s) that assure the
required protection.
The ideal steady-state flow conditions through an
off-line filter make this a must for most applications.
Whenever possible, use filters having element
condition indicators.
Vented systems must be fitted with an air breather
appropriate to the environment(s) in which the
machine is to be operated and the requirements of
the system.
Fit strainers to pump inlet lines if there is risk of
large contaminant particles (i.e. string, rag, screws,
etc.) entering the lines.
Prevent air entering the system, particularly through
pump inlet lines. Ensure air-tight joints in any
sub-atmospheric zone or pump inlet lines. Also
make sure that those lines and all return and drain
lines terminate below the minimum fluid level in the
reservoir; pump inlet lines should be sufficiently
below to prevent air entering through a vortex at
low fluid levels.
Design for, and maintain, fluid temperatures at
optimum levels for the application. Apply coolers if
necessary.
Locate or screen hydraulic systems away from high
temperature sources (e.g. furnaces).
Assemble system in clean conditions using clean
practices.
Pre-clean pipes and reservoir immediately before
installation. Cap any ends that cannot immediately
be connected to mating components (e.g. between
shifts).
11
Fluid degradation by:

Solid
High Water Air
Contam. Temp.

1065
Preventive Measures
Remove protective caps only just before connecting
mating components.
Use a portable filtration and transfer unit to fill the
reservoir system.
Flush new systems, and those that have undergone
major repairs, before starting up. Temporarily
remove actuators and replace with flushing
manifolds or valves. Servo valves and similar high
precision units should also be replaced with
flushing manifolds or valves for flushing operations.
Make sure that actuators are clean internally before
connecting to the system.
Make sure that air breathers and reservoir covers
are at all times properly installed and tightly
secured.
Stop any leakage of water into the system from
coolers or other sources. Make a leak-tight repair.
By planned maintenance, ensure that clean filter
elements are applied (or metallic elements cleaned
when appropriate) when indicators or visual
inspection shows this to be necessary.
Take fluid samples periodically and analyze to
determine whether effects of particle contaminant,
heat, water and air indicate need for more control of
those factors or replacement of the fluid.
Whenever the reservoir is emptied, clean it out
thoroughly and remove all residual contaminant. If
necessary, restore protective paint or other finishes.
On completion, cap all openings unless the system
is to be refilled immediately.

Solid
High Water Air
Contam. Temp.

12
1066
Hints On Maintenance Of Hydraulic Fluid In The System

Hydraulic Fluid Changes
Good maintenance procedures make it
mandatory to keep the hydraulic fluid
clean. A daily, weekly or monthly log
should be kept on the hydraulic fluid
condition.
No hard and fast rules can be
established for changing the fluid
because of the great variety of operating
conditions. However, we do know that
when filter elements are replaced
frequently, service life of a system
increases. Periodic testing of the fluid by
the supplier is recommended to confirm
suitability for continued use and to
establish the correct fluid and filter
element replacement interval.
Some of the considerations affecting
hydraulic fluid are: operating
temperature, type of service,
contamination levels, filtration, and the
chemical composition of the fluid.
Fluid Recommendations
The basic recommendations for fluid
are stipulated in the Hydraulic Fluid and
Temperature Recommendations for
Industrial Machinery in this catalog.
The fluids recommended give the
assurance of adequate wear protection
and excellent chemical stability under
the most adverse operating conditions.
finer) can be used. It is important that

fluid be clean and free of all substances
which will cause improper operation.
Fluid Contamination
Causes and Effects
Contamination
A contaminated system can be the result
of several factors; system design
inadequate, poor maintenance of the
system, poor housekeeping of the system
and adverse operating conditions.
System Design Inadequate
Effects of Contamination
Reservoirs which cannot be cleaned.

Breathers that permit abrasives
inherent in the atmosphere to enter
the system.
Poor cylinder packing design (no
wiper to clean dirt from the piston
rod).
Improper piston rod design (piston
rods with poor wear characteristic).
Improper valving (anticavitation
checks omitted from cylinder circuits
with rapid drop characteristics).
Failure to provide adequate filtration.
Poor Maintenance of the System
On mobile applications, the viscosity

grade of the fluid should be changed in
spring and autumn as is done with
automotive engines. Hydrostatic
transmissions and control mechanisms
may require a different viscosity fluid.
Fluid requirements are normally
outlined in the original equipment
manufacturers operation and
maintenance manuals.
Draining The System
Poor Housekeeping of the

System
Systems which have accumulated

deposits that were not removed during
draining must be flushed with a light
viscosity fluid. The fluid should contain
a rust inhibitor to protect metal surfaces
against rust formation after draining.
When hydraulic fluid is added to
replenish the system, it should be
pumped through a 25 micron filter. If
such a filter is not available, a funnel
with a fine wire screen (200 mesh or
Adverse Operating Conditions

From experience, we have found that
machines used in a very dusty
atmosphere and in windy areas require
special components. For example,
heavy duty breathers, chrome plated
piston rods, plus frequent changes of
the filter cartridges are also required.
Improper and unclean practices when

adding fluid to the system.
Failure to clean breathers.
Failure to change pitted cylinder rods
and worn cylinder packings.
Failure to use good cleanliness
practices when changing system
components.
Failure to change filter cartridges
and/or filter at proper intervals.
Failure to purge debris from the
system after a pump failure.
The system should be started and fluid

heated before draining. This will lower
the time it takes to drain the system and
allow impurities suspended in the fluid
to be removed. It is desirable to remove
all fluid from the system. Bleeding of
the fluid at the lowest point in the
system will help in most cases.
Preparation of pipes, tubes and fittings

in this catalog should be referred to and
followed. This will lower the possibility
of premature failure due to
contamination of the system.
Surgical cleanliness is not required,

however, ordinary clean practices
during assembly will pay off in
increased service life of the equipment.
Excessive and improper use of pipe
thread sealer on lines and gaskets in
the system can cause pump failures.
This is especially true when a type of
sealer is used that hardens.
Contamination affects all types of

hydraulic equipment adversely.
Precision high tolerance parts are very
susceptible to the effects of
contamination. Dirty fluid causes wear
which accelerates leakage and the
development of heat in a system. Heat
lowers the lubricity of a hydraulic fluid
and causes additional wear.
If a hydraulic pump or motor should fail,
the system becomes contaminated.
Remove the unit for repair. The
reservoir must be drained, flushed, and
cleaned. All hoses, lines, cylinders and
valves should be inspected for wear
and particles of the unit that failed.
Flush all components of the complete
system to remove metallic particles.
Replace filter elements. Dispose of the
fluid removed from the system and fill
the reservoir with clean hydraulic fluid.
Install a new or rebuilt unit and start-up
the system. Allow the system to run for
a period of time to verify normal
operation. Filter elements should be
changed after 40 or 50 hours of
operation. This guarantees that the
system is essentially clean and free of
any residue of the failed unit.
A very good reference catalog on
contamination is available titled Vickers
Guide to Systemic Contamination
Control. This catalog describes types
and sources for contamination, effects
of types and sizes of particles,
specifying contamination levels,
selecting a filter, locating a filter, design
steps and worked examples of fluid
sampling analysis. Order catalog 561
from your local Vickers representative.
Another source of contamination is

fittings, hoses and lines which are
received from a vendor uncapped. The
use of brazed or welded fittings, and
unpickled steel plating can also
contribute to the contamination.
13
1067
Aeration
Aeration
Causes
The following are candidates for the
formation of air in a system.
Leaking inlet lines.
Control valve O rings leaking.
Shaft seal leakage.
Leaking cylinder packings caused
by cavitating cylinders.
Turbulence or sloshing in the
reservoir.
Vortexing fluid in the reservoir
Release of air suspended within
the fluid.
Effects
Aeration can be in many forms; large
bubbles, foam or in various degrees of
suspension. It usually causes pump noise
(cavitation). Small bubbles cause extreme
and rapid ring wear, with corresponding
vane tip wear. Larger bubbles cause vanes
to collapse and pound. This pounding
effect develops rippling in the ring and the
ring will have a dull appearance. This is
more apparent on straight vane rings
which are hardened cast iron. With
extreme aeration cases, the wear is so
rapid that a ring and vanes can be
destroyed within an hour. In many cases, a
large step will be worn in the ring contour
at the pressure quadrant. When the step
reaches a depth where the vane extends
and locks, the vane and/or ring will break.
Also, the shaft can break where it enters
the rotor if the torque is great enough.
Cures
Leaking Inlet Lines
Pipe threaded fittings can be porous.
Use an approved type of pipe thread
sealer on all pipe threads.
If the pump inlet flange surface is
rough, scored or mutilated, air leakage
past the O ring seal can result.
With any of the above defects, air can
be pulled into the system.
Control Valve O Rings Leaking

O rings are used to seal against port
leakage in many control valves. These
seals can be checked by applying heavy
grease around the part to be checked. If
the noise stops, the trouble has been
located and repair can be initiated.
On systems which have been operating
at excessive high temperatures, the O
rings can harden and take a set. If this
occurs, air leakage can result. This is
true not only in a pump, but also in the
rest of the components of the system.
Another factor enhancing air leakage is
the actual fluid composition. Fluids which
have a high sulphur content tend to

accelerate O ring hardness. This is one
of the principle reasons for keeping
system operating temperatures down.
Normal operating temperature of a
system is 90 degrees above ambient.
When operating temperatures are in
excess of this value, trouble may result.
Maximum operating temperatures should
be checked at the pump outlet port.
Reservoir must be deep enough to

prevent aeration.
Shaft Seal Leakage
One of the best ways of curing a

vortex problem is to place an
anti-cavitation plate over the outlet of
the reservoir. This is a common piece
of sheet metal at lease 1/8 inch thick
set over and above the outlet opening.
This plate will allow flow into the outlet
from a horizontal direction and
effectively extends and enlarges the
reservoir opening. This prevents the
vortex condition from developing.
Most vane pumps are internally drained.

The shaft seal cavity is connected to the
pump inlet. Excessively high inlet
vacuums can cause air leakage at the
shaft seal. The maximum vacuum
measured at the pump inlet should not
exceed five inches of mercury.
Shaft misalignment can increase the
probability of air leakage past the shaft
seal. Universal jointed couplings or
splined couplings can cause seal
leakage if not properly aligned. Straight
(direct) coupling should never be used.
The use of the wrong type of tools can
cause distortion or mutilation of a shaft
seal at installation. The outer diameter of
the shaft should be lightly polished before
installation to remove any burrs or
roughness in the area of the shaft seal.
Shaft seals must be made of the correct
material for a given application. A material
that is not compatible with system fluid can
deteriorate and result in a leakage
problem.
Leaking Cylinder Packings

Caused By Cavitating Cylinders
On applications where a rapid raise and
lower cycle is experienced, air can enter
the system through a cylinder rod seal.
Vacuums in excess of 20 inches of
mercury have been recorded in systems
without anti-cavitation check valves. This is
enough to force dirt particles past the shaft
seal into the system with the air. An
anti-cavitation check will allow flow from
the reservoir to enter the rod area of the
cylinder during a vacuum condition from
developing. This will lower the possibility of
fluid contamination through the rod seal of
a working cylinder.
Turbulence or Sloshing in the

Reservoir
Vortexing Fluid in the Reservoir

If the fluid level in the reservoir is low
and the inlet demand is great, a vortex
condition can develop which pulls air
into the pump inlet. In a hydraulic
system, vortexing is normally the result
of low fluid or poor reservoir design.
Release of Air Suspended in Fluid

There is considerable air suspended in
cold hydraulic fluid. As the fluid warms,
air is released into the system. A
reduction of fluid pressure will also
release air out of suspension. A simple
relief valve poppet can create an orifice
that increases velocity of the fluid and
lowers its pressure. The reduced
pressure condition releases air out of
suspension into the system. Relief valves
should be returned below the fluid level
of the reservoir as far from the reservoir
outlet as possible. This allows time for
the air released by the relief valve to be
removed before leaving the reservoir and
entering the inlet area of the pump.
In some cases, special return line
configurations are needed, or air bleed
valves used, to remove air from the
system.
A special baffle made of 60 mesh screen
can be installed into the reservoir. This
baffle should be positioned at a 30 angle
in the reservoir so that inlet oil is above the
screen and outlet oil is below the screen.
The top of the screen should be below the
reservoir fluid level far enough to prevent
surface foam from coming in contact with
the screen. Surface foam can penetrate
through the screen into the outlet area.
The screen baffle will eliminate all
bubbles except the very small ones
from the fluid if designed properly.
Return lines, if improperly located,

can cause turbulence and aeration. A
Plexiglass window should be placed
in the prototype reservoir to study flow
conditions. Return lines emptying
above the fluid level cause bubbles to
form in the system. Return lines
should always be terminated below
the fluid level. Vehicle movement can
cause sloshing within the reservoir.
14
1068
Leakage Control
Cost Of Leakage
Concern for safety at work and the
rapidly increasing cost of oil makes
industry sensitive to leakage.
Leakage creates safety hazards,
wastes costly oil, increases machine
down-time, decreases production
rates, generates product spoilage and
increases replacement parts
inventory. The cost of effective
leakage control is minor when
compared to the long term costs of
leakage.
Leak-Free Design
Hydraulic systems do not need to leak.
Todays designer must create a more
leak resistant system, where static
seal leakage should not occur and
dynamic seal leakage will be
controlled. Before presenting some
design practices proved effective in
stopping leaks, we should consider the
sources of most leaks.
Cause Of Leaks
Almost all hydraulic system leaks
occurring after extended service result
from three conditions:
Loosening of fittings and connectors
by shock and vibration
Wear of dynamic seals and mating
parts especially in hydraulic cylinders
Deterioration of the elastomer
because of elevated fluid
temperatures or an incompatibility with
the hydraulic fluid
Combatting Shock And

Vibration
Many things can be done to minimize
leakage from loose fittings and
connectors subject to shock and
vibration:
1. Support all pipe lines with damped
mountings to absorb both shock and
vibration.
2. Reduce shock with low-shock valves
or accumulators.
3. Use pressure controls with low
override and strategically placed to
protect all parts of the system.
4. Use a minimum number of fittings and

connectors. Use welded joints
wherever practical.
5. Use parallel thread connectors, tees
and elbows in place of tapered pipe
threads.
6. Use manifolds instead of individual
lines wherever possible.
7. Specify proper bolt and plug torques
for expected peak pressures to
prevent surface separation and static
seal nibbling.
8. Stress good workmanship to avoid
poorly assembled fittings and
connectors.
Reducing Dynamic Seal

Wear
Most dynamic seals are well designed
and will provide long, relatively
leak-free service if given reasonable
chance. Four things a designer can do
to extend the life of dynamic seals are:
1. Eliminate side loads on cylinder rod
and drive shaft seals.
2. Protect cylinder rods from abrasive
dirt with scrapers, shields or rubber
gaiters.
3. Provide the requisite filtration and
easily cleaned reservoirs to prevent
dirt build-up in the oil.
4. Keep cylinder rod and shaft speeds
as low as possible.
Requirements For
Static Seals
A static seal retains fluid between rigid,
stationary surfaces. The seal must be
compressed as with a gasket or
deformed as with an O ring, to flow
into the microcrevices in the mating
surface and also raise the seals
internal stress level higher than the
pressure to be sealed. When parts are
not rigid enough or bolt preload is not
high enough, the mating surfaces will
separate under the action of fluid
pressure, creating clearances of
enlarging those that might exist
because the sealing surfaces were not
initially flat enough. With movement of
mating surfaces, the static seal
becomes a dynamic seal. Rough
surfaces will wear the seal and
changing clearances nibble seal edges.
15
Mounting Plates
When valve packages or subplates are
bolted to mounting plates, the condition
of the plate is important to obtain a
satisfactory initial seal and prevent
extrusion and wear. Requirements are:
Flat mounting surfaces
Good sealing surface finish -64
micro-inches with no radial scratches
High enough bolt preload to prevent
surface separation.
Preventing Seal
Deterioration
Premature deterioration of the seal can
result from other factors. A primary
factor is excessive fluid temperature. A
good guide is that seal life is halved by
every 20 F. rise. The cure: Incorporate
sufficient heat exchangers to keep fluid
temperatures below 150 F.
Another factor may be compatibility of
the fluid with the seal material where
special fluids are used. If a doubt arises,
contact your Vickers representative. The
following brief review of seal materials
may be helpful.
Nitrile (Buna N) is the most widely used
and best all around elastomer for
petroleum (mineral) oils, fuel and
fire-resistant fluids with the exception
of phosphate esters.
Fluoroelastomer (Viton or Fluorel)
costs more than Nitrile, can be used
instead of Nitrile but has the added
advantage of longer life when fluid
temperatures consistently run above
150 F. It can be used with phosphate
ester fluids (except Skydrol).
Polyurethane shows extrusion and
abrasion resistance superior to Nitrile
in petroleum oils, fuel and silicate
esters, but deteriorates if
contaminated with hot water.
Refer to Stop Leaks bulletin 394 for
more comprehensive coverage of
leakage control.
1069
Hydraulic Fluid And Temperature

Recommendations For Industrial Machinery
Unit Type
Viscosity
Anti-wear Characteristicts
Inline Piston
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)
Running: 13-54 cSt (70-250 SUS)
At Start Up: 220 cSt (1000 SUS) Max.
Antiwear type
y hydraulic
y
oils such as:
Angle Piston
Vane (Except MHT)
Gear
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)

MHT (High Torque/
Low Speed
Vane Motors
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)
automotive crankcase oils having API

letter designations SE, SF, SG, or
SH per SAE J183
cSt: Centistokes
SUS:Saybolt Universal Seconds
Adhere to the oil recommendations for MHT

units rather than the pumps involved.
Viscosity Grades are the standard viscosity

grades listed in ASTM D-2422 titled Viscosity
System for Industrial Fluid Lubricants, but any
intermediate viscosity is acceptable.
Selection Of Viscosity Grades

Use the following tabulation to
determine the temperature extremes
between which the viscosity grades
can be used to remain within Vickers
startup and running viscosity range
recommendations.
The SAE 10W grades fall between

the 32 cSt (150 SUS) and 46 cSt
(215 SUS) grades and the SAE
2020W approximates the 68 cSt
(315 SUS) grade.
Viscosity
Grade
40C (104F)
Start Up
860 cSt
(4000 SUS)
Start Up
220 cSt
(1000 SUS)
Start Up
110 cSt
(500 SUS)
Running
54 cSt
(250 SUS) Max.
Running
13 cSt
(70 SUS) Min.
32 cSt (150 SUS)

46 cSt (215 SUS)
68 cSt (315 SUS)
12C (11F)
6C (22F)
0C (32F)
6C (42F)
12C (54F)
19C (66F)
14C (58F)
22C (72F)
29C (84F)
27C (80F)
34C (94F)
42C (108F)
62C (143F)
71C (159F)
81C (177F)
General Data
Oil in hydraulic systems performs the
dual function of lubrication and
transmission of power. It constitutes a
vital factor in a hydraulic system, and
careful selection should be made with
the assistance of a reputable supplier.
Proper selection of oil assures
satisfactory life and operation of the
system components with particular
emphasis on hydraulic pumps and
motors. Generally, oil selected for use
with pumps and motors are acceptable
for use with valves. Critical servo
valves may need special consideration.
Some of the factors especially important

in the selection of oil for use in an
industrial hydraulic system are:
Two specific types of oil meet the

requirements of modern industrial
hydraulic systems:
1. The oil must contain the necessary

additives to ensure high antiwear
characteristics. Not all hydraulic oils
contain these in sufficient amounts.
1. Antiwear type industrial hydraulic oils.

A new generation of industrial
hydraulic oils containing adequate
quantities of antiwear compound is
recommended by VIckers for general
hydraulic service.
2. The oil must have proper viscosity to

maintain adequate sealing and
lubricating quality at the expected
operating temperature of the
hydraulic system.
3. The oil must have rust and oxidation
inhibitors for satisfactory system
operation.
16
1070

These oils are generally developed
and evaluated on the basis of pump
wear tests such as the Vickers
35VQ25A and ASTM D-2882. These
oils offer superior protection against
pump and motor wear and the
advantage of long service life. In
addition, they provide good
demulsibility as well as protection
against rust.
2. Automotive type crankcase oils
having API letter designation SE,
SF, SG, SH, per SAE J183.
The above classes of oils in the
10W and 20-20W SAE viscosity
ranges are for severe hydraulic
service where there is little or no
water present. The only adverse
effect is that the detergent
additive tends to hold water in a
tight emulsion and prevents
separation of water, even on long
time standing.
Automotive type crankcase oils
generally exhibit poorer shear stability
which could result in some loss of
viscosity during their service life.
More shear stable multiple viscosity
industrial grade hydraulic fluids will
provide improved viscosity control.
Over the years, Vickers hydraulic oil
recommendations have been based on
oils that: (1) provide adequate wear
protection, (2) have proper viscosity, and
(3) are sufficiently stable to withstand the
chemical, thermal and mechanical stresses
of severe hydraulic service. There are
automotive crankcase oils that are outside
of the API SE, SF, SG and SH classes
that meet the above basis of
recommendation.
With these oils, it is highly desirable to
have acceptable data from pump wear
tests (35VQ25A and ASTM-D-2882). In
exceptional cases where the requirements
of speed, pressure, temperature and
ambient conditions exceed the
recommendations for industrial machinery,
please refer to the oil recommendations.
These fluids must also pass the Vickers
35VQ25 pump test.
Viscosity
Viscosity is the measure of the fluids
resistance to flow. The selection of a
hydraulic oil of specific viscosity range
must be based on the needs of the
system, limitations of critical components,
or proper performance of specific types of
units. Vickers recommends that certain
maximum and minimum viscosity ranges

of the oil at start-up and during running be
maintained. (See chart) Very high
viscosities at start-up temperatures can
cause noise and cavitational damage to
pumps. Continuous operation at
moderately high viscosities will tend to hold
air in suspension in the oil as well as
generate higher operating temperatures.
This can cause noise and early failure of
pumps, motors and erosion of valves. Low
viscosities result in decreased system
efficiency and impairment of dynamic
lubrication which causes wear.
Choose the proper oil viscosity for your
particular system so that over the entire
temperature range encountered, the
start-up viscosity and the running
viscosity range shown in the chart is
met. This is important, and assurance
should be obtained from your oil
supplier that the viscosity of the oil being
used will not be less than the minimum
recommended at maximum oil
temperature encountered.
A number of antiwear hydraulic oils
containing polymeric thickeners (V.I.
improvers) are available and are used for
low temperature application. The
temporary and permanent viscosity loss of
some of these oils at operating
temperature may adversely affect the life
and performance of components. Be
certain you know the extent of loss of
viscosity (shear stability) of polymer
containing oils under hydraulic service
before using them so that you do not
operate below the recommended minimum
viscosity. The selection of an oil with good
shear stability, is recommended for low
temperature applications.
Temperature
To obtain optimum service life from
both the oil and the hydraulic system,
operate between 49C (120F) and
54C (130F). The maximum oil
temperature normally recommended
is 66C (150F).
Cleanliness
Thorough precautions should always be
observed to ensure that the hydraulic
system is clean.
1. Clean (flush) entire system to remove
paint, metal chips, welding shot, lint,
etc.
2. Filter each change of oil to prevent
introduction of contaminant into the
system.
3. Provide continuous oil filtration to
remove sludge and products of wear
and corrosion generated during the
life of the system.
4. Provide continuous protection of
system from entry of airborne
contamination by proper filtration of
air through breathers.
5. During usage, proper oil filling of
reservoir and servicing of filters,
breathers, reservoirs, etc. cannot be
over emphasized.
Sound Level
Noise can be an indication of system
problems. Fluid selection and the
condition of that fluid in service will
affect the noise levels of your systems.
Some of the major factors affecting the
fluid conditions that cause the loudest
noises in a hydraulic system are:
1. Very high viscosities at start-up
temperatures can cause pump noises
due to cavitation.
2. Running with moderately high
viscosity fluid will impede the release
of entrained air. The fluid will not be
completely purged of such air in the
time it remains in the reservoir before
recycling through the system.
MHT motors are permitted to operate at

higher temperatures, but this is
permissible by meeting special
application requirements. For this
service, oils should have antiwear
characteristics required to pass pump
test on page 20. Pumps can be
approved to operate MHT motors at
these higher temperatures. Contact your
Vickers representative for
recommendations.
17
1071
3. Aerated fluid can be caused by

ingestion of air through the pipe joints
of inlet lines, high velocity discharge
lines, cylinder rod packings, or by
fluid discharging above the fluid level
in the reservoir. Air in the fluid will
cause abnormal noise and wear in
your system.
4. Contamination fluids can cause
excessive wear of internal pump
parts which may result in increased
sound levels.
5. Systems using water based fluids
are susceptible to noise created by
vaporization of the fluid if excessive
vacuums and temperatures are
encountered.
Fire Resistant Fluids

Hydraulic systems using fire resistant
fluids require special engineering
considerations. For applications using
fire resistant fluids, consult Vickers
Guide to Alternative Fluids, Bulletin
579, for the specific component being
used or contact your local Vickers
representative for assistance.
Proper design, operation and
maintenance of fluid power systems is
of paramount importance to obtain the
optimum performance of fire resistant
fluids such as synthetics, water glycol
and water-in-oil emulsion types.
Additionally, you should consult your fluid
supplier for specific fluid maintenance
and application data on their fluid.
Water Based Fluids
Water-Glycol Fluids
General Data
Water-glycol fire-resistant fluids are

typically water and diethylene glycol
mixtures. They have approximately 40%
water content.
To assure an effective emulsion or

solution, the water should not have
excessive hardness or have an acid
nature, and it should be distilled or
deionized with less than 300 parts per
million hardness.
Hard water containing excessive mineral
content, such as calcium and iron, may
cause deposits in the hydraulic system
or result in additive separation or
emulsion breaking.
Oil-In-Water Fluids
Oil-in-water fluids are emulsions of oil
and water. When preparing these
mixtures, the soluble oil should always
be added to the water while maintaining
good fluid agitation. The water should
never be added to the soluble oil. Do not
mix soluble oil brands.
Filters
Proper maintenance of water containing
fluids requires periodic testing for pH, oil
and water concentrations. The pH
should be maintained at 8.0-9.5 in
accordance with the suppliers
recommendation. If the pH number
exceeds these limits, discard the fluid.
Always use a premixed fluid to replenish
the system. The recommended storage
or operating temperature range of water
containing fluids is 4C (39F) to 49C
(120F), unless otherwise specified by
the fluid supplier.
Types Of Water Based

Fluids
Invert Emulsions
Invert emulsions are inverted
water-in-oil emulsions consisting of a
continuous oil phase surrounding finely
divided water droplets that are uniformly
dispersed throughout the mixture.
18
Many Vickers standard indicating type

inlet filters and return line filters are
approved with water-based fluid types.
A reduction of predicted life of hydraulic
components should be expected when
using water-based fluid types.
Synthetic Fluid Type

Phosphate Ester
Phosphate ester type fluids are
manufactured from chemically produced
esters. These types of fluids require
fluorocarbon seals. Consult your fluid
supplier for the types of seals which are
compatible.
Environmental Hydraulic Oil

If you have equipment that operates in
environmentally sensitive areas, you may
consider use of more environmentally
aware fluids. These fluids perform well in
our hydraulic systems but may require
extra caution in order not to exceed their
performance capabilities.
1072

Recommendations For Mobile Hydraulic Systems
The oil in a hydraulic system serves as
the power transmission medium. It is
also the systems lubricant and coolant.
The selection of proper oil is a
requirement for satisfactory system
performance and life.
In most cases, use of these
recommendations will lead to selection of
a suitable oil. However, due to the
complex nature of oil formulation, the
variety of oils available and peculiarities of
individual hydraulic applications, there will
be rare instances where an oil selected
on the basis of these recommendations
may yield unsatisfactory results. Vickers
cannot be responsible for such
exceptions. In this respect, the customer
is encouraged to consult his Vickers
representative or a reputable oil company
when selecting an oil.
Important Factors In
Selecting An Oil
Additives
Hydraulic fluids contain a number of
additive agents which materially improve
various characteristics of oil for
hydraulic systems. These additives are
selected to reduce wear, increase
chemical stability, inhibit corrosion and
depress the pour point.
Antiwear
index. The viscosity index of hydraulic

system oil should not be less than 90.
Multiple viscosity oils, such as SAE
10W-30, incorporate additives to improve
viscosity index (polymer thickened). These
oils should have a minimum viscosity index
of 120. Oils of this type generally exhibit
both a temporary and permanent decrease
in viscosity due to oil shear encountered in
the operating hydraulic system. The actual
viscosity can, therefore, be far less in the
operating hydraulic system than what is
shown in normal oil data. Accordingly,
when such oils are selected, it is
necessary to use those with high shear
stability to insure that viscosity remains
within recommended limits while in service.
Chemical Stability
Oxidation and thermal stability are
essential characteristics of oils for mobile
hydraulic systems. The combination of
base stocks and additives should be
stable during the expected lifetime of the
oil when exposed to the environment of
these systems.
Suitable Types Of Oil

Crankcase Oil
Oil having an API letter designation SE,
SF, SG or SH per SAE J183. Note that
one oil may meet one or more of these
designations.
Antiwear Hydraulic Oil

These oils are produced by all major oil
suppliers and should consist of good
quality base stocks compounded with
antiwear, antioxidation, antifoam and
antirust additives. These may be
petroleum, vegetable or synthetic base oil.
Due to the large number of different
antiwear hydraulic oils, it is impossible
for Vickers to test its products with all of
the available fluids. Because of this, an
evaluation procedure was developed for
fluid suppliers to establish the suitability
of their products for use in Vickers
components. Refer to Pump Test
Procedure For Evaluation Of Antiwear
Hydraulic Fluids For Mobile Systems,
page 20, for details of the 35VQ25 test
procedure. It is the responsibility of your
oil supplier to assure that their fluids
meet Vickers requirements.

environmentally sensitive areas, you
may consider use of more
envionmentally aware fluids. These
fluids perform well in our hydraulic
systems but may require extra caution in
order not to exceed their performance
capabilities. For further clarification,
refer to Vickers Guide to Alternative
Fluids, Bulletin 579.
Other Oils
Pump performance and reliability are

directly affected by the antiwear additive
formulation contained in the oil. Oils
providing a high level of antiwear
protection are recommended for
optimum performance and long life.
Certain other types of petroleum oil are

suitable if they meet the following
provisions:
1. Contain the type and content of
antiwear additives found in the above
designated crankcase and antiwear
hydraulic oils, and have passed the
pump tests.
Viscosity
resistance to flow. The oil selected must
have proper viscosity to maintain an
adequate lubricating film at system
operating temperature.
2. Have sufficient chemical stability for

mobile hydraulic system service.
3. Meet the viscosity requirements
shown in the following tables.
In addition to dynamic lubricating

properties, oil must have sufficient body
to provide an adequate sealing effect
between working parts of pumps, valves,
clylinders and motors, but not enough to
cause pump cavitation or sluggish valve
action. Optimum operating viscosity of
the oil should be between 16 cSt (80
SUS) and 40 cSt (180 SUS).
Viscosity Index reflects the way viscosity
changes with temperature. The smaller the
viscosity change, the higher the viscosity
19
1073
Oil Viscosity Recommendations

Crankcase Oils
Antiwear Hydraulic Oils
Hydraulic System
Operating Temperature Range1
SAE Viscosity
Designation
Hydraulic System
23C to 54C
(10F to 130F)
5W, 5W-20,
5W-30
21C to 60C
(5F to 140F)
22
18C to 83C
(0F to 180F)
10W
15C to 77C
(5F to 170F)
32
18C to 99C
(0F to 210F)
10W-30,
10W-40
9C to 88C
(15F to 190F)
46
10C to 99C
(50F to 210F)
20-20W
1C to 99C
(30F to 210F)
68
ISO Viscosity
Grade
1 Temperatures
shown are cold (ambient) start-up to maximum operating. During cold start-up,
avoid high-speed operation of hydraulic components until the system is warmed up to provide
adequate lubrication.
20
1074
Pump Test Procedure For Evaluation Of

Antiwear Fluids For Mobile Systems
Test Pump
35VQ25A-11*20 (Cartridge Kit P/N
413421)
Test Conditions
Speed:
Outlet Pressure:
Inlet Pressure:
Inlet Temperature:
2350-2400 rpm
205-210 bar gage
(2975-3025 psig)
0-.15 bar gage
(0-2 psig) with
flooded inlet
90-96C
(195-205F)
Operating Mode
Steady-state pressure at above rated
conditions for 50 hours. Terminate test if
flow degradation exceeds 7.5 L/min
(2 gpm) prior to the completion of the
50-hour test. Such terminations are not
considered to be failures since this flow
degradation can be due to causes other
than excessive wear, such as erosion on
the side plates resulting from insufficient
inlet pressure.
Initial Fluid Condition

Water Content:
.075% maximum
Contamination Level: ISO Code
18/16/14 or better
particle count.
Alternatively, 30
mg/liter maximum
gravimetric contamination (using
filter membrane
of 0.8 micrometer
porosity).
Pump Break-In
Procedure
1. Increase pump speed to test level
and apply 70 bar gage (1000 psig)
outlet pressure. When inlet
temperature of approximately 50C
(125F) is achieved, maintain it for
elapsed time of 1/2 hour at pressure.
2. Increase pressure to 140 bar gage
(2000 psig). When inlet temperature
of approximately 80C (175F) is
achieved, maintain it for elapsed time
of 1/2 hour at pressure.
3. Increase pressure to 205-210 bar

gage (2975-3025 psig). When
temperature stabilizes at 90-96C
(195-205F), record operating
parameters, including flow. Terminate
test if flow is below 136 L/min (36
gpm) after five hours of operation.
With production tolerances, low flow
sometimes occurs while pumping
light fluids. This condition tends to
increase the wear rate.
Test Circuit
1
10
2 Line Size
9
Test Duration
Continue operation of the unit for 50
hours total (including break-in time),
periodically monitoring operation
parameters.
Number Of Cartridges
Evaluation requires a minimum of three
pump cartridges. The fluid should not be
changed during the total 150-hour test
period.
Description of Components
1. Reservoir (50 gallons minimum;
elevated above pump centerline to
provide gravity feed)
2. Temperature gage or thermocouple
Accept/Reject Guidelines
3. Inlet pressure gage
1. Total weight loss of all vanes from

individual cartridge tested should be
less than 15 mg (not including
intravanes).
4. Pump: 35VQ25A-11*20 (cartridge kit

P/N 413421)
2. Weight loss of ring from individual

cartridge tested should be less than
75 mg.
6. Outlet pressure gage
3. Regardless of weight loss

measurements, the pump parts,
especially the rings, should not have
evidence of unusual wear or stress in
contact areas. There may be
instances when unsatisfactory
performance is indicated even though
the weight loss is low; for example,
galling or excessive burning would
not show as excessive weight loss
but would be unacceptable.
8. Filter (10 micrometer nominal)
5. Electric motor (125 HP)
7. Pressure relief valve
9. Cooler
10. Flow meter
When any one cartridge out of three

fails for any reason, two more
cartridges should be tested. In this case,
four of the five tested cartridges must
meet the above accept/reject guidelines.
This procedure is offered only as a fluid
screening method. Successful
completion of this test does not
constitute endorsement or approval of
fluids by Vickers.
21
1075
Acceptable Rings
Unacceptable Rings
22
1076
Oil Flow Velocity In Tubing

Oil Flow Capacity Of
Tubing
Figures in the chart are USgpm flow
capacities of tubing, and were
calculated from the formula:
GPM = V
A B .3208,
in which V = velocity of flow in feet per
second, and A is inside square inch
area of tube.
Figures in Body of Chart are USgpm Flows

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
1/2
.035
.042
.049
.058
.065
.072
.083
.905
.847
.791
.722
.670
.620
.546
1.81
1.63
1.58
1.44
1.34
1.24
1.09
4.52
4.23
3.95
3.61
3.35
3.10
2.73
6.79
6.35
5.93
5.41
5.03
4.65
4.09
9.05
6.47
7.91
7.22
6.70
6.20
5.46
13.6
12.7
11.9
10.8
10.1
9.30
8.16
5/8
.035
.042
.049
.058
.065
.072
.083
.095
1.51
1.43
1.36
1.27
1.20
1.13
1.03
.926
3.01
2.85
2.72
2.54
2.40
2.26
2.06
1.85
7.54
7.16
6.80
6.34
6.00
5.66
5.16
4.63
11.3
10.7
10.2
9.51
9.00
8.49
7.73
6.95
15.1
14.3
13.6
12.7
12.0
11.3
10.3
9.26
22.6
21.4
20.4
19.0
18.0
17.0
15.5
13.9
3/4
.049
.058
.065
.072
.083
.095
.109
2.08
1.97
1.88
1.75
1.67
1.53
1.39
4.17
3.93
3.76
3.51
3.34
3.07
2.77
10.4
14.8
14.1
13.2
12.5
11.5
10.4
15.6
9.84
9.41
8.77
8.35
7.67
6.93
20.8
19.7
18.8
17.5
16.7
15.3
13.9
31.2
29.6
28.2
26.4
25.0
23.0
20.8
7/8
.049
.058
.065
.072
.083
.095
.109
2.95
2.82
2.72
2.62
2.46
2.30
2.11
5.91
5.64
5.43
5.23
4.92
4.60
4.22
14.8
14.1
13.6
13.1
12.3
11.5
10.6
22.2
21.1
20.4
19.6
18.5
17.2
15.8
29.5
28.2
27.2
26.2
24.6
23.0
21.1
44.3
42.3
40.7
39.2
36.9
34.4
31.7
1
.049
.058
.065
.072
.083
.095
.109
.120
3.98
3.82
3.70
3.59
3.40
3.21
3.00
2.83
7.96
7.65
7.41
7.17
6.81
6.42
6.00
5.65
19.9
19.1
18.5
17.9
17.0
16.1
15.0
14.1
29.9
28.7
27.8
26.9
25.5
24.1
22.4
21.2
39.8
38.2
37.0
35.9
34.0
32.1
29.9
28.3
59.7
57.4
55.6
53.8
51.1
48.2
44.9
42.4
23
15
Ft/Sec
20
Ft/Sec
30
Ft/Sec
1077
Pipe Sizes And Pressure Ratings

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
15
Ft/Sec
20
Ft/Sec
1-1/4
.049
.058
.065
.072
.083
.095
.109
.120
6.50
6.29
6.14
6.00
5.75
5.50
5.21
5.00
13.0
12.6
12.3
12.0
11.5
11.0
10.4
10.0
32.5
31.5
30.7
30.0
28.8
27.5
26.1
25.0
48.7
47.2
46.0
44.9
43.1
41.2
39.1
37.4
64.9
62.9
61.4
59.9
57.5
55.0
52.1
50.0
1-1/2
.065
.072
.083
.095
.109
.120
9.19
9.00
8.71
8.40
8.04
7.77
18.4
18.0
17.4
16.8
16.1
15.5
45.9
45.0
43.5
42.0
40.2
38.8
68.9
67.5
65.3
63.0
60.3
58.3
91.9
90.0
87.1
84.0
80.4
77.7
1-3/4
.065
.072
.083
.095
.109
.120
.134
12.8
12.6
12.3
11.9
11.5
11.2
10.7
25.7
25.2
24.6
23.8
23.0
22.3
21.5
64.2
63.1
61.4
59.6
57.4
55.8
53.7
96.3
94.7
92.1
89.3
86.1
83.7
80.6
2
.065
.072
.083
.095
.109
.120
.134
17.1
16.9
16.5
16.0
15.5
15.2
14.7
34.2
33.7
32.9
32.1
31.1
30.3
29.4
85.6
84.3
82.3
80.2
77.7
75.8
73.4
128
126
123
120
117
114
110
30
Ft/Sec
97.4
94.4
92.1
89.8
86.3
82.5
78.2
74.9
138
135
131
126
121
117
128
126
123
119
115
112
107
193
189
184
179
172
167
161
171
169
165
160
155
152
147
257
253
247
240
233
227
220

Nominal
Pipe
Size
in.
Outside
Diameter
of Pipe
in.
Number
of
Thre d
Threads
Per Inch
1/8
0.405
27
1/4
3/8
1/2
3/4
0.540
0.675
0.840
1.050
1
1-1/4
1-1/2
2
2-1/2
3
Length
of
Effective
Threads
in.
Schedule 40
(Standard)
Schedule 80
(Extra Heavy)
Schedule 160
Double
Extra Heavy
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
0.26
18
18
14
14
0.40
0.41
0.53
0.55
.364
.493
.622
.824
16,000
13,500
13,200
11,000
.302
.423
.546
.742
22,000
19,000
17,500
15,000
.466
.614
21,000
21,000
.252
.434
35,000
30,000
1.315
1.660
1.900
11-1/2
11-1/2
11-1/2
0.68
0.71
0.72
1.049
1.380
1.610
10,000
8,400
7,600
.957
1.278
1.500
13,600
11,500
10,500
.815
1.160
1.338
19,000
15,000
14,800
.599
.896
1.100
27,000
23,000
21,000
2.375
2.875
3.500
11-1/2
8
8
0.76
1.14
1.20
2.067
2.469
3.068
6,500
7,000
6,100
1.939
2.323
2.900
9,100
9,600
8,500
1.689
2.125
2.624
14,500
13,000
12,500
1.503
1.771
19,000
18,000
24
1078
Preparation Of Pipes, Tubes, And Fittings

Before Installation In A Hydraulic System
General Requirements
When installing the various iron and
steel pipes, tubes, and fittings of a
hydraulic system, it is necessary that
they be absolutely clean, free from
scale, and all kinds of foreign matter.
To attain this end, the following steps
should be taken:
Tubing, pipes and fittings should be
brushed with boiler tube wire brush
or cleaned with commercial pipe
cleaning apparatus. The inside edge
of tubing and pipe should be reamed
after cutting to remove burrs. Also
remove burrs from outside edge.
Short pieces of pipe and tubing and
steel fittings should be sandblasted
to remove rust and scale.
Sandblasting is a sure and efficient
method for short straight pieces and
fittings. Sandblasting should not be
used however, if there is the
slightest possibility that particles of
sand will remain in blind holes or
pockets in the work after flushing.
In the case of longer pieces of pipe or
short pieces bent to complex shapes
where is is not practical to sandblast, the
parts should be pickled in a suitable
solution until all rust and scale is
removed. Preparation for pickling
requires thorough degreasing in a
recommended vapor degreasing solvent.
Neutralize pickling solution.
Rinse parts and prepare for storage.
Tubing must not be welded, brazed,
or silver soldered after assembly as
proper cleaning is impossible in
such cases. It must be accurately
bent and fitted so that it will not be
necessary to spring it into place.
If flange connections are used,
flanges must fit squarely on the
mounting faces and be secured with
screws of the correct length. Screws
or stud-nuts must be drawn up
evenly to avoid distortion in the
valve or pump body.
Be sure that all openings into the
hydraulic system are properly
covered to keep out dirt and metal
slivers when work such as drilling,
tapping, welding, or brazing is being
done on or near the unit.
Threaded fittings should be

inspected to prevent metal slivers
from the threads getting into the
hydraulic system.
Before filling the system with
hydraulic oil, be sure that the
hydraulic fluid is as specified and
that it is clean. DO NOT use cloth
strainers or fluid that has been
stored in contaminated containers.
Use at least a No. 120 mesh screen
when filling the reservoir. Use of a
Vickers clean cart, porta filtering
and transfer unit, is recommended.
Operate the system for a short time
to eliminate air in the lines. Add
hydraulic fluid if necessary.
Rinse parts in hot water

Place in tank No. 3. The solution in
this tank should contain antirust
compounds as recommended by the
manufacturer. Usually the parts being
treated should be left to dry with
antirust solution remaining on them.
If pieces are stored for any period of
time, ends of the pipes should be
plugged to prevent the entrance of
foreign matter. Do not use rags or
waste as they will deposit lint on the
inside of the tube or pipe.
Immediately before using pipes,
tubes and fittings should be
thoroughly flushed with suitable
degreasing solution.
Safety precautions. Dangerous

chemicals are used in the cleaning
and pickling operations to be
described. They should be kept only
in the proper containers and
handled with extreme care.
Pickling Process
Thoroughly degrease parts in
degreaser, using a recommended
vapor degreasing solvent.
Tank No. 1 Solution. Use a
commercially available derusting
compound in solution as
recommended by the manufacturer.
The solution should not be used at a
temperature exceeding that
recommended by the manufacturer,
otherwise the inhibitor will
evaporate and leave a straight acid
solution. The length of time the part
will be immersed in this solution will
depend upon the temperature of the
solution and the amount of rust or
scale which must be removed. The
operator must use good judgement
on this point.
After pickling, rinse parts in cold
running water and immerse in tank
No. 2. The solution in this tank
should be a neutralizer mixed with
water in a proportion recommended
by the manufacturer. This solution
should be used at recommended
temperatures and the parts should
remain immersed in the solution for
the period of time recommended by
the manufacturer.
25
1079
ISO/ANSI Basic Symbols

For Fluid Power Equipment And Systems
Lines
Pumps
Line, Working
(Main)
Hydraulic Pump
Fixed
Displacement
Line, Pilot
(For Control)
Heater
Line, Liquid Drain

Variable
Displacement
Hydraulic
Flow, Direction of
Pneumatic
Cooler
Motors and Cylinders

Lines Crossing
or
Temperature
Controller
Hydraulic
Fixed
Displacement
Lines Joining
Filter, Strainer
Line With Fixed

Restriction
Variable
Displacement
Line, Flexible
Station, Testing,
Measurement or
Power Take-Off
Variable Component
(run arrow through
symbol at 45
Pressure Switch
Cylinder, Single
Acting
Cylinder, Double
Acting
Pressure Indicator
Single End Rod

Temperature
Indicator
Double End Rod
Pressure Compensated Units (arrow

parallel to short side
of symbol)
Adjustable
Cushion
Advance Only
Component
Enclosure
Differential
Piston
Miscellaneous Units
Temperature Cause
or Effect
Electric Motor
Vented
Reservoir
Pressurized
Line, To Reservoir
Above Fluid Level
Accumulator, Spring
Loaded
Methods of Operation
Spring
Manual
Below Fluid Level

Vented Manifold
Direction of Shaft
Rotation (assume
arrow on near side
of shaft
Accumulator, Gas
Charged
26
Push Button
1080
Pedal or Treadle
Flow Control,
Adjustable
(temperature and
pressure
compensated
Mechanical
Two Position
Two Connection
Detent
Two Position
Three Connection
Pressure
Compensated
Two Position
Four Connection
Push-Pull Lever
Solenoid, Single
Winding
Servo Control

Pilot Pressure
Remote Supply
Internal Supply
Valves
Check
OnOff
(manual shut-off)
Pressure Relief
Pressure Reducing
Flow Control,
Adjustable
Non-Compensated
Definition Of Functions
Function
Definition
Intensified Pressure
Pressure in
excess of supply
pressure which is
induced by a
booster or
intensifier.
Supply Pressure
Power-actuating
fluid.
Charging Pressure
Pump-inlet
pressure that is
higher than
atmospheric
pressure.
Three Position
Four Connection
Reduced Pressure
Auxiliary pressure
which is lower
than supply
pressure.
Two Position
In Transition
Pilot Pressure
Control-actuating
pressure.
Metered Flow
Fluid at controlled
flow rate, other
than pump
delivery.
Exhaust
Return of power
and control fluid
to reservoir.
Intake
Sub-atmospheric
pressure, usually
on intake side of
pump.
Drain
Return of leakage
fluid to reservoir.
Inactive
Fluid which is
within the circuit,
but which does
not serve a
functional
purpose during
the phase being
represented.
Valves Capable Of
Infinite Positioning
(horizontal bars
indicate infinite
positioning ability)
Note
Additional symbols are shown in
Vickers Circuitool booklet available for
a nominal charge. Ask for circuitool
template kit 352.
Color Code For Fluid

Power Schematic
Drawings
Function
Color
Intensified Pressure . .
Supply . . . . . . . . . . . . . .
Charging Pressure . . .
Reduced Pressure . . . .
Pilot Pressure . . . . . . . .
Metered Flow . . . . . . . .
Exhaust . . . . . . . . . . . . .
Intake . . . . . . . . . . . . . . .
Drain . . . . . . . . . . . . . . .
Inactive . . . . . . . . . . . . .
Black
Red
Intermittent Red
Intermittent Red
Intermittent Red
Yellow
Blue
Green
Green
Blank
27
1081
Conversion Factors
To convert
Into
Into
Multiply by
To convert
Unit
Symbol
Unit
Symbol
Divide by
Factor
Atmospheres
Atm
bar
bar
1.013250
BTU/hour
Btu/h
kilowatts
kW
0.293071 103
cubic centimeters
cm3
liters
0.001
cubic centimeters
cm3
milliliters
ml
1.0
cubic feet
ft3
cubic meters
m3
0.0283168
cubic feet
ft3
liters
28.3161
cubic inches
in3
cubic centimeters
cm3
16.3871
cubic inches
in3
liters
0.0163866
degrees (angle)
radians
rad
0.0174533
Fahrenheit
F
Celsius
C
C=5 (F32) / 9
feet
ft
meters
0.3048
feet of water
ft H2O
bar
bar
0.0298907
cubic centimeters
cm3
28.413
29.5735
fluid ounces, UK
UK fl oz
fluid ounces, US
US fl oz
cubic centimeters
cm3
foot pounds f
ft lbf
joules
1.35582
foot pounds/minute
ft lbf/min
watts
81.3492
gallons, UK
UK gal
liters
4.54596
gallons, US
US gal
liters
3.78531
horsepower
hp
kilowatts
kW
0.7457
inches of mercury
in Hg
millibar
mbar
33.8639
inches of water
in H2O
millibar
mbar
2.49089
inches
in
centimeters
cm
2.54
inches
in
millimeters
mm
2.54
kilogram force
kgf
newtons
9.80665
kilogram f. meter
kgf m
newton meters
Nm
9.80665
kilogram f. /sq. centimeter
kgf/cm2
bar
bar
0.980665
kilopascals
kPa
bar
bar
0.01
kiloponds
kp
newtons
9.80665
kilopond meters
kp m
newton meters
Nm
9.80665
kiloponds/square centimeter
kp/cm3
bar
bar
0.980665
kilowatts
kW
0.735499
metric horsepower
microinches
in
microns
0.0254
millimeters of mercury
mm Hg
millibar
mbar
1.33322
millimeters of water
mm H2O
millibar
mbar
0.09806
newtons/square centimeter
N/cm2
bar
bar
0.1
newtons/square meter
N/m2
bar
bar
105
28
1082
Conversion Factors
To convert
Into
Unit
pascals (newtons/sq meter)
pints, UK
pints, US
pounds (mass)
pounds/cubic foot
pounds/cubic inch
pounds force
pounds f feet
pounds f inches
pounds f/square inch
revolutions/minute
square feet
square inches
square inches
Symbol
Pa
UK pt
US liq pt
lb
lb/ft3
lb/in3
lbf
lbf ft
lbf in
lbf/in2
r/min
ft2
in2
in2
Into
Multiply by
To convert
Divide by
Unit
bar
liters
liters
kilograms
kilograms/cubic meter
kilograms/cubic centimeter
newtons
newton meters
newton meters
bar
radians/second
square meters
square meters
square centimeters
Symbol
bar
l
l
kg
kg/m3
kg/cm3
N
Nm
Nm
bar
rad/s
m2
m2
cm2
Factor
105
0.568245
0.473163
0.4536
16.0185
0.0276799
4.44822
1.35582
0.112985
0.06894
0.104720
0.092903
6.4516 10-4
6.4516
Hydraulic Formulas
Horsepower:
GPM PSI
1714
Horsepower =
Torque:
CU IN./REV. PSI
2
HP 63025
RPM
Torque (lb. in.) =

Torque (lb. in.) =
Flow:
Flow (gpm) =
CU IN./REV. RPM
231
Overall Efficiency:
Overall efficiency =
Output HP 100
Input HP
Volumetric Efficiency:
Volumetric
Output GPM 100
efficiency =
Theoretical GPM
(pump)
Volumetric
efficiency = Theoretical GPM 100
Input GPM
(motor)
Conversion Factors:
Pressure (PSI) = feet head 0.433

specific gravity.
1 hp = 33,000 ft. lbs. per minute

1 hp = 42.4 btu per minute
1 hp = 0.746 kwhr (kilowatt hours)
Specific gravity of oil is approximately 0.85.
1 U.S. gallon = 231 cubic inches.

Pipe volume varies as the square of the
diameter; volume in gallons = 0.0034 D2L
Thermal expansion of oil is

approximately 1 cu.in. per 1 gal. per
10F rise in temperature.
where: D = inside diameter of pipe in

inches
L = length in inches
Velocity in feet per second =
0.408 flow (gpm)
D2
inches
Atmospheric pressure at sea level =
14.7 PSI
Atmospheric pressure decreases
approximately 0.41 PSI for each one
thousand feet of elevation up to
23,000 feet
29
1083
CONTROL CABIN HYDRAULIC

SYSTEM
1084
VICKERS
APPLICATION:
CUSTOMER:
OFFER:
TAIM TFG
HT 05/0322B
(CABIN LEVELLING)
DATE:
CENTRAL:
Tel:
98 552 57 57
Fax:
98 556 74 72
2006
Avda. de Burgos, 42- Local 3
28036 Madrid
Tel:
91 383 88 75
Fax:
91 766 73 97
C/La Forja, 37
Tel:
93 637 66 44
Fax:
93 637 75 10
DELEGACIN GALICIA:
1 planta- Ofic. 4
36203 Vigo
Tel/Fax: 98 647 39 12
Mvil:
61 025 89 34
1085
05/0322B
INDEX
CONFORMITY
2. PARTS LIST
3. DRAWINGS
4. CERTIFICATES
GUIDE
1086
05/0322B

CONFORMITY
1087
INDEX
SETTING UP:............................................................................................... 2
1.1
1.2
1.3
FILLING THE TANK: .............................................................................. 2
1.4
START UP:............................................................................................. 2
OPERATING:............................................................................................... 2
2.1
INTRODUCTION: ................................................................................... 2
MAINTENANCE:.......................................................................................... 3
Pgina 1
1088
The present hydraulic power unit with reference HT 05/0322B has been manufactured in
1
1.1
SETTING UP:
of the machine.
1.2
1.3
FILLING THE TANK:
1.4
START- UP:
normally.
2
2.1
OPERATING:
INTRODUCTION:
Pgina 2
1089
present manual).

MAINTENANCE:
-
recommended.
Pgina 3
1090
by unscrewing it.
Pgina 4
1091
1092
05/0322B
PARTS
LIST
1093
PART LIST
AVILES
HA-LMC-N
HA-PG-02
REV.:0
ANEXO IV
05/0322B
Ed.:0
Customer
TAIM T.F.G.
Installation
Description
Drawing
S.HCO.EQ.CAB. ROTOPALA 120,RR-1

S.HCO.EQ.CAB. ROTOPALA 120,RR-1
6,570,295-00
Quantity
1
Deliver
12-jun-06
OTH n
PREPARED BY
FDO:
REVISED BY
FDO:
Offer
05/0322
05/0322B
AVILES
DENOMINATION
REFERENCE
CODE
QUANTITY
POS
HARD PUMP
BM_2P_20 + DEPOSITO 5 L
GAUGE VALVE
FT290
MANOMETER
10
HYDRAULIC CYLINDER
DE-80-40/470
11
GATE VALVE
GE2 R1/4"GAS
12
PIPE
40 MTS TUBERIA 12X1,5 + RACORES INOX
40
PRESSURE HOSE
L12 DE 6M
PRESSURE HOSE
L12 DE 1,8M
TOTAL
50
Pgina 1 de 1
1094
05/0322B
DRAWINGS
1095
1096
1097
05/0322B
CERTIFICATES
1098
1099
1100
1101
Messrs
Spain
Best Regards
Michele Bogni
1102
05/0322B
CATALOGUE ELEMENTS
1103
1104
1105
1106
TECHNICAL DATA
MODEL : G
MANOMETER STUFFED WITH GLYCERIN
Description: manometer stuffed with glycerine, mounted in stainless steel box

watertight AISI 304 and with brass internal parts.
Applications: particularly indicated for installations with vibrations and sudden and
repeated pressure changes.
CHARACTERISTICS.
GRADATION
DIAMETERS
- Diameters: 63 and 100
63
100
0-0,6 bar
- Box and ring: In stainless steel AISI 304 watertight,

Ring type bayonet in diameter 100.
MANOMETERES
0-1 bar
0-1,6 bar
0-2,5 bar
0-4 bar
0,6 bar
- Connection: In brass in Gas for diameter 63 and
0-10 bar
1/2 Gas for diameter 100.
0-16 bar
0-25 bar
0-40 bar
0-60 bar
black numbers.
0-100 bar
- Needle: In aluminium balanced, with brass centre.
0-250 bar
0-315 bar
0-400 bar
0-600 bar
- Overpressure:25% from final scale value till 60 bar.
0-100 bar
15 % from final scale value from 100 to600 bar.
- Racord Tube: In brass-Zinnbrass/CuSn8 (For

1.000 bar tube in stainless steel AISI 316).
- Mechanism: In brass
- Sphere: In aluminium painted in white and with
- Glass: Methacrylate.
- Accuracy: +/-1,6% from final scale value.
MANO VACUUM GAUGE
10 % from final scale value for more than 600 bar.
-1+0,6 bar
-1+1,5 bar
-1+3 bar
- Service Temperature: -10 + 60 C
-1+5 bar
- Protection Index: IP-55
-1+9 bar
-1+15 bar
-1+24 bar
-76/0 cmHg
-760/0 mmHg
-1/0 bar
VACUUM GAUGE
- To define a manometer: Diameter, reference,

model, thread and graduation.
1107
Vertical Thread
Posterior Thread
Frontal view
Frontal View
Vertical Thread
Posterior Thread
Vertical thread
Posterior Edge
Posterior Thread
Frontal Edge
Frontal View
Frontal View
Posterior Thread
With flange
Vertical Thread
Posterior edge
Posterior Thread
Frontal Edge
OPTIONS
Silicone stuffed
NPT Thread (1/4 para 63 y 1/2 para 100
Thread in Gas and 3/8 Gas

Other Graduations (psi, Kpa, Mpa, Kg/cm, etc)
Glass
Logo in the sphere
Without glycerine charge
Posterior Thread
With Flange
63
100
1108
1109
1110
1111
05/0322B
1112
Vickers
General Product Support
Hydraulic Hints &

Trouble Shooting Guide
Revised 8/96
694
1113
General Hydraulic Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Troubleshooting Guide & Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chart 1 Excessive Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chart 2 Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chart 3 Incorrect Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chart 4 Incorrect Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chart 5 Faulty Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quiet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Contamination Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hints on Maintenance of Hydraulic Fluid in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Leakage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Fluid and Temperature Recommendations for Industrial Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Fluid and Temperature Recommendations for Mobile Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Viscosity Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump Test Procedure for Evaluation of Antiwear Fluids for Mobile Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil Flow Velocity in Tubing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pipe Sizes and Pressure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Preparation of Pipes, Tubes and Fittings Before Installation in a Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ISO/ANSI Basic Symbols for Fluid Power Equipment and Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1114

Good Assembly
Practices
installed.
containers.
turbulent flow.
thread connections.
Pipes



Standard
Schedule 40
160 pipe.

after bending.
power equipment.

1115

General
System Design
the pump.
troubleshooting.
Knowing the System

follow:

applied:
and machine.

Maintenance




and viscosity.
Procedures
Recognizing Trouble
Indications

strainers.
Guidelines

1116

Chart 1
EXCESSIVE NOISE
1.
PUMP NOISY
MOTOR NOISY
RELIEF VALVE NOISY
Cavitation
Remedy: a
1.
Coupling misaligned
Remedy: c
1.

setting
Remedy: d
2.
Air in fluid
Remedy: b
3.
Coupling Misaligned
Remedy: c
4.
Pump worn or
damaged
2.
Motor or coupling
worn or damaged
2.

Remedy: e
Remedy: b
Remedy: e
Remedies:

journal).

correct pressure.
1117

Chart 2
EXCESSIVE HEAT
PUMP HEATED
MOTOR HEATED
RELIEF VALVE HEATED
FLUID HEATED
1.
1. Fluid heated
1. Fluid heated

high
Remedy: d
2. Cavitation
Remedy: a
2.
Relief or unloading
valve set too high
2.

Remedy: d
Remedy: d
3. Air in fluid
Remedy: b
3. Excessive load
Remedy: c
valve set too high
4. Worn or damaged
motor
Remedy: d
2.
Unloading valve set

too high
Remedy: d

Remedy: e

Remedy: f
4. Incorrect fluid
viscosity
Remedy: e
Remedy: f
5. Excessive load

system
Remedy: c
Remedy: g
6. Worn or damaged
pump

cylinder or other
component
Remedy: e
Remedy: e
Remedies:
supercharge pump.
journal).


replace cooler.

settings).
proper level.
1118
Chart 3
INCORRECT FLOW
NO FLOW
LOW FLOW
EXCESSIVE FLOW

Remedy: a
1.

Remedy: d

Remedy: d
2.
2.
Relief or unloading
valve set too low
2.

operating
Remedy: e
3.

sheared
Remedy: d
3.
Remedy: c
in wrong direction
Remedy: e


Remedy: b
5.
Remedy: f
6.
Entire flow passing

over relief valve
8.
pump
Remedy: h
4.
Improper size pump


displacement pumps)
Remedy: e
6.
Remedy: d
7. Damaged pump
Remedy: c
RPM of pump drive

motor incorrect
Remedy: h
Remedy: g
wrong position
3.
Remedy: e or f
4.

displacement pumps)
RPM of pump drive

motor incorrect
Remedy: h
7.
Worn pump, valve,

motor, cylinder or
other component
Remedy: e
Remedy: e
Remedies:
supercharge pump.

d. Adjust.

1119
Chart 4
INCORRECT PRESSURE
NO PRESSURE
LOW PRESSURE
ERRATIC PRESSURE
EXCESSIVE
PRESSURE
1. No flow
column A
1. Air in fluid
Remedy: b

exists
column A and B
relief or unloading
valve misadjusted
Remedy: d
2.
2.

set too low
2.
Worn relief valve

Remedy: e

displacement pumps)
Remedy: e
Remedy: d
valve damaged
Remedy: a
Remedy: e
relief or unloading
Remedy: e

or cylinder
or has lost charge
Remedy: e
Remedy: c
cylinder
Remedy: e
Remedies:
from system).
1120
Chart 5
FAULTY OPERATION
NO MOVEMENT
SLOW MOVEMENT
ERRATIC MOVEMENT
EXCESSIVE SPEED
OR MOVEMENT
1. Low flow
Remedy: See Chart 3
1. Erratic pressure
1. Excessive flow
Remedy: See Chart 3
2.
2.
2.
2.
Limit or sequence
device (mechanical,
inoperative or
misadjusted

Remedy: a
Air in fluid
Remedy: See Chart I
Feedback transducer
malfunctioning
Remedy: e
Remedy: e
3. Mechanical bind
Remedy: b
pressure for valves
machine ways or
linkage
Remedy: See Chart 4
3. Misadjusted or
amplifier
Remedy: See Chart 4

to servo amplifier
Remedy: f
Remedy: c
Remedy: c
ways or linkage
Remedy: c
Remedy: f
Remedy: h
Remedy: g
Remedy: c
Remedy: c
transducer

Remedy: c
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: d
Remedy: e
8. Worn or damaged
cylinder or motor
Remedy: e
Remedies:
viscosity.


g. Lubricate.


1121
Quiet Hydraulics
Sound Advice
Pump Selection
Acoustic Isolation
Reservoirs


120F.

Fluids

adequate.

10
1122

capacity.
faults.
degradation.
form sludge.
Preventive Measures
For Storage Drums:
For Storage Tanks:
seal in the fluid.
the system.
low fluid levels.
necessary.
practices.
shifts).
11

Solid
High Water Air
Contam. Temp.

1123
Preventive Measures
mating components.
reservoir system.
secured.

Solid
High Water Air
Contam. Temp.

12
1124

condition.

Fluid Contamination
Causes and Effects
Contamination

the system.
rod).

Draining The System

System



components.





13
1125
Aeration
Aeration
Causes
Shaft seal leakage.
reservoir.
the fluid.
Effects
Cures
Leaking Inlet Lines



prevent aeration.
Shaft Seal Leakage


problem.

a working cylinder.

Reservoir


system.

14
1126
Leakage Control
Cost Of Leakage
leakage.
Leak-Free Design
Cause Of Leaks
the hydraulic fluid

Vibration
vibration:
vibration.
or accumulators.

wherever practical.
threads.
seal nibbling.
connectors.

Wear
gaiters.
as low as possible.
Requirements For
Static Seals
15
Mounting Plates
surface separation.
Preventing Seal
Deterioration
may be helpful.
leakage control.
1127

Unit Type
Viscosity
Inline Piston
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)
Antiwear type
y hydraulic
y
oils such as:
Angle Piston
Vane (Except MHT)
Gear
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)

MHT (High Torque/
Low Speed
Vane Motors
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)

SH per SAE J183
cSt: Centistokes



recommendations.

(315 SUS) grade.
Viscosity
Grade
40C (104F)
Start Up
860 cSt
(4000 SUS)
Start Up
220 cSt
(1000 SUS)
Start Up
110 cSt
(500 SUS)
Running
54 cSt
(250 SUS) Max.
Running
13 cSt
(70 SUS) Min.
32 cSt (150 SUS)

46 cSt (215 SUS)
68 cSt (315 SUS)
12C (11F)
6C (22F)
0C (32F)
6C (42F)
12C (54F)
19C (66F)
14C (58F)
22C (72F)
29C (84F)
27C (80F)
34C (94F)
42C (108F)
62C (143F)
71C (159F)
81C (177F)
General Data


hydraulic systems:


hydraulic service.

hydraulic system.
operation.
16
1128

against rust.
time standing.
recommendation.
35VQ25 pump test.
Viscosity

Temperature
is 66C (150F).
Cleanliness
system is clean.
etc.
system.
life of the system.
over emphasized.
Sound Level
due to cavitation.

recommendations.
17
1129

your system.
sound levels.
encountered.

Water Based Fluids
Water-Glycol Fluids
General Data

water content.

million hardness.
emulsion breaking.
Oil-In-Water Fluids
Filters
the fluid supplier.

Fluids
Invert Emulsions
18


Phosphate Ester
compatible.

1130

Selecting An Oil
Additives
Antiwear

Chemical Stability
these systems.

Crankcase Oil
designations.


Other Oils


provisions:
pump tests.
Viscosity


19
1131

Crankcase Oils
Hydraulic System
SAE Viscosity
Designation
Hydraulic System
23C to 54C
(10F to 130F)
5W, 5W-20,
5W-30
21C to 60C
(5F to 140F)
22
18C to 83C
(0F to 180F)
10W
15C to 77C
(5F to 170F)
32
18C to 99C
(0F to 210F)
10W-30,
10W-40
9C to 88C
(15F to 190F)
46
10C to 99C
(50F to 210F)
20-20W
1C to 99C
(30F to 210F)
68
ISO Viscosity
Grade
1 Temperatures
20
1132

Test Pump
413421)
Test Conditions
Speed:
Outlet Pressure:
Inlet Pressure:
Inlet Temperature:
2350-2400 rpm
205-210 bar gage
(2975-3025 psig)
0-.15 bar gage
(0-2 psig) with
flooded inlet
90-96C
(195-205F)
Operating Mode
inlet pressure.

Water Content:
.075% maximum
18/16/14 or better
particle count.
Alternatively, 30
mg/liter maximum
filter membrane
of 0.8 micrometer
porosity).
Pump Break-In
Procedure

Test Circuit
1
10
2 Line Size
9
Test Duration
parameters.
period.

intravanes).

P/N 413421)

75 mg.

9. Cooler
10. Flow meter

fluids by Vickers.
21
1133
Acceptable Rings
Unacceptable Rings
22
1134

Tubing
GPM = V
A B .3208,
area of tube.

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
1/2
.035
.042
.049
.058
.065
.072
.083
.905
.847
.791
.722
.670
.620
.546
1.81
1.63
1.58
1.44
1.34
1.24
1.09
4.52
4.23
3.95
3.61
3.35
3.10
2.73
6.79
6.35
5.93
5.41
5.03
4.65
4.09
9.05
6.47
7.91
7.22
6.70
6.20
5.46
13.6
12.7
11.9
10.8
10.1
9.30
8.16
5/8
.035
.042
.049
.058
.065
.072
.083
.095
1.51
1.43
1.36
1.27
1.20
1.13
1.03
.926
3.01
2.85
2.72
2.54
2.40
2.26
2.06
1.85
7.54
7.16
6.80
6.34
6.00
5.66
5.16
4.63
11.3
10.7
10.2
9.51
9.00
8.49
7.73
6.95
15.1
14.3
13.6
12.7
12.0
11.3
10.3
9.26
22.6
21.4
20.4
19.0
18.0
17.0
15.5
13.9
3/4
.049
.058
.065
.072
.083
.095
.109
2.08
1.97
1.88
1.75
1.67
1.53
1.39
4.17
3.93
3.76
3.51
3.34
3.07
2.77
10.4
14.8
14.1
13.2
12.5
11.5
10.4
15.6
9.84
9.41
8.77
8.35
7.67
6.93
20.8
19.7
18.8
17.5
16.7
15.3
13.9
31.2
29.6
28.2
26.4
25.0
23.0
20.8
7/8
.049
.058
.065
.072
.083
.095
.109
2.95
2.82
2.72
2.62
2.46
2.30
2.11
5.91
5.64
5.43
5.23
4.92
4.60
4.22
14.8
14.1
13.6
13.1
12.3
11.5
10.6
22.2
21.1
20.4
19.6
18.5
17.2
15.8
29.5
28.2
27.2
26.2
24.6
23.0
21.1
44.3
42.3
40.7
39.2
36.9
34.4
31.7
1
.049
.058
.065
.072
.083
.095
.109
.120
3.98
3.82
3.70
3.59
3.40
3.21
3.00
2.83
7.96
7.65
7.41
7.17
6.81
6.42
6.00
5.65
19.9
19.1
18.5
17.9
17.0
16.1
15.0
14.1
29.9
28.7
27.8
26.9
25.5
24.1
22.4
21.2
39.8
38.2
37.0
35.9
34.0
32.1
29.9
28.3
59.7
57.4
55.6
53.8
51.1
48.2
44.9
42.4
23
15
Ft/Sec
20
Ft/Sec
30
Ft/Sec
1135

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
15
Ft/Sec
20
Ft/Sec
1-1/4
.049
.058
.065
.072
.083
.095
.109
.120
6.50
6.29
6.14
6.00
5.75
5.50
5.21
5.00
13.0
12.6
12.3
12.0
11.5
11.0
10.4
10.0
32.5
31.5
30.7
30.0
28.8
27.5
26.1
25.0
48.7
47.2
46.0
44.9
43.1
41.2
39.1
37.4
64.9
62.9
61.4
59.9
57.5
55.0
52.1
50.0
1-1/2
.065
.072
.083
.095
.109
.120
9.19
9.00
8.71
8.40
8.04
7.77
18.4
18.0
17.4
16.8
16.1
15.5
45.9
45.0
43.5
42.0
40.2
38.8
68.9
67.5
65.3
63.0
60.3
58.3
91.9
90.0
87.1
84.0
80.4
77.7
1-3/4
.065
.072
.083
.095
.109
.120
.134
12.8
12.6
12.3
11.9
11.5
11.2
10.7
25.7
25.2
24.6
23.8
23.0
22.3
21.5
64.2
63.1
61.4
59.6
57.4
55.8
53.7
96.3
94.7
92.1
89.3
86.1
83.7
80.6
2
.065
.072
.083
.095
.109
.120
.134
17.1
16.9
16.5
16.0
15.5
15.2
14.7
34.2
33.7
32.9
32.1
31.1
30.3
29.4
85.6
84.3
82.3
80.2
77.7
75.8
73.4
128
126
123
120
117
114
110
30
Ft/Sec
97.4
94.4
92.1
89.8
86.3
82.5
78.2
74.9
138
135
131
126
121
117
128
126
123
119
115
112
107
193
189
184
179
172
167
161
171
169
165
160
155
152
147
257
253
247
240
233
227
220

Nominal
Pipe
Size
in.
Outside
Diameter
of Pipe
in.
Number
of
Thre d
Threads
Per Inch
1/8
0.405
27
1/4
3/8
1/2
3/4
0.540
0.675
0.840
1.050
1
1-1/4
1-1/2
2
2-1/2
3
Length
of
Effective
Threads
in.
Schedule 40
(Standard)
Schedule 80
(Extra Heavy)
Schedule 160
Double
Extra Heavy
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
0.26
18
18
14
14
0.40
0.41
0.53
0.55
.364
.493
.622
.824
16,000
13,500
13,200
11,000
.302
.423
.546
.742
22,000
19,000
17,500
15,000
.466
.614
21,000
21,000
.252
.434
35,000
30,000
1.315
1.660
1.900
11-1/2
11-1/2
11-1/2
0.68
0.71
0.72
1.049
1.380
1.610
10,000
8,400
7,600
.957
1.278
1.500
13,600
11,500
10,500
.815
1.160
1.338
19,000
15,000
14,800
.599
.896
1.100
27,000
23,000
21,000
2.375
2.875
3.500
11-1/2
8
8
0.76
1.14
1.20
2.067
2.469
3.068
6,500
7,000
6,100
1.939
2.323
2.900
9,100
9,600
8,500
1.689
2.125
2.624
14,500
13,000
12,500
1.503
1.771
19,000
18,000
24
1136

should be taken:
valve or pump body.

hydraulic system.


Pickling Process
on this point.
the manufacturer.
25
1137

Lines
Pumps
Line, Working
(Main)
Hydraulic Pump
Fixed
Displacement
Line, Pilot
(For Control)
Heater
Line, Liquid Drain

Variable
Displacement
Hydraulic
Flow, Direction of
Pneumatic
Cooler

Lines Crossing
or
Temperature
Controller
Hydraulic
Fixed
Displacement
Lines Joining
Filter, Strainer
Line With Fixed

Restriction
Variable
Displacement
Line, Flexible
Station, Testing,
Measurement or
Power Take-Off
Variable Component
(run arrow through
symbol at 45
Pressure Switch
Cylinder, Single
Acting
Cylinder, Double
Acting
Pressure Indicator
Single End Rod

Temperature
Indicator
Double End Rod

of symbol)
Adjustable
Cushion
Advance Only
Component
Enclosure
Differential
Piston
Miscellaneous Units
Temperature Cause
or Effect
Electric Motor
Vented
Reservoir
Pressurized
Line, To Reservoir
Above Fluid Level
Accumulator, Spring
Loaded
Spring
Manual
Below Fluid Level

Vented Manifold
Direction of Shaft
Rotation (assume
arrow on near side
of shaft
Accumulator, Gas
Charged
26
Push Button
1138
Pedal or Treadle
Flow Control,
Adjustable
(temperature and
pressure
compensated
Mechanical
Two Position
Two Connection
Detent
Two Position
Three Connection
Pressure
Compensated
Two Position
Four Connection
Push-Pull Lever
Solenoid, Single
Winding
Servo Control

Pilot Pressure
Remote Supply
Internal Supply
Valves
Check
OnOff
(manual shut-off)
Pressure Relief
Pressure Reducing
Flow Control,
Adjustable
Non-Compensated
Function
Definition
Pressure in
excess of supply
pressure which is
induced by a
booster or
intensifier.
Supply Pressure
Power-actuating
fluid.
Charging Pressure
Pump-inlet
pressure that is
higher than
atmospheric
pressure.
Three Position
Four Connection
Reduced Pressure
Auxiliary pressure
which is lower
than supply
pressure.
Two Position
In Transition
Pilot Pressure
Control-actuating
pressure.
Metered Flow
Fluid at controlled
flow rate, other
than pump
delivery.
Exhaust
Return of power
and control fluid
to reservoir.
Intake
Sub-atmospheric
pressure, usually
on intake side of
pump.
Drain
Return of leakage
fluid to reservoir.
Inactive
Fluid which is
within the circuit,
but which does
not serve a
functional
purpose during
the phase being
represented.
Valves Capable Of
(horizontal bars
indicate infinite
Note
template kit 352.

Power Schematic
Drawings
Function
Color
Supply . . . . . . . . . . . . . .
Metered Flow . . . . . . . .
Exhaust . . . . . . . . . . . . .
Intake . . . . . . . . . . . . . . .
Drain . . . . . . . . . . . . . . .
Inactive . . . . . . . . . . . . .
Black
Red
Intermittent Red
Intermittent Red
Intermittent Red
Yellow
Blue
Green
Green
Blank
27
1139
Conversion Factors
To convert
Into
Into
Multiply by
To convert
Unit
Symbol
Unit
Symbol
Divide by
Factor
Atmospheres
Atm
bar
bar
1.013250
BTU/hour
Btu/h
kilowatts
kW
0.293071 103
cubic centimeters
cm3
liters
0.001
cubic centimeters
cm3
milliliters
ml
1.0
cubic feet
ft3
cubic meters
m3
0.0283168
cubic feet
ft3
liters
28.3161
cubic inches
in3
cubic centimeters
cm3
16.3871
cubic inches
in3
liters
0.0163866
degrees (angle)
radians
rad
0.0174533
Fahrenheit
F
Celsius
C
C=5 (F32) / 9
feet
ft
meters
0.3048
feet of water
ft H2O
bar
bar
0.0298907
cubic centimeters
cm3
28.413
29.5735
fluid ounces, UK
UK fl oz
fluid ounces, US
US fl oz
cubic centimeters
cm3
foot pounds f
ft lbf
joules
1.35582
foot pounds/minute
ft lbf/min
watts
81.3492
gallons, UK
UK gal
liters
4.54596
gallons, US
US gal
liters
3.78531
horsepower
hp
kilowatts
kW
0.7457
inches of mercury
in Hg
millibar
mbar
33.8639
inches of water
in H2O
millibar
mbar
2.49089
inches
in
centimeters
cm
2.54
inches
in
millimeters
mm
2.54
kilogram force
kgf
newtons
9.80665
kilogram f. meter
kgf m
newton meters
Nm
9.80665
kgf/cm2
bar
bar
0.980665
kilopascals
kPa
bar
bar
0.01
kiloponds
kp
newtons
9.80665
kilopond meters
kp m
newton meters
Nm
9.80665
kp/cm3
bar
bar
0.980665
kilowatts
kW
0.735499
metric horsepower
microinches
in
microns
0.0254
mm Hg
millibar
mbar
1.33322
mm H2O
millibar
mbar
0.09806
N/cm2
bar
bar
0.1
N/m2
bar
bar
105
28
1140
Conversion Factors
To convert
Into
Unit
pints, UK
pints, US
pounds (mass)
pounds/cubic foot
pounds/cubic inch
pounds force
pounds f feet
pounds f inches
revolutions/minute
square feet
square inches
square inches
Symbol
Pa
UK pt
US liq pt
lb
lb/ft3
lb/in3
lbf
lbf ft
lbf in
lbf/in2
r/min
ft2
in2
in2
Into
Multiply by
To convert
Divide by
Unit
bar
liters
liters
kilograms
newtons
newton meters
newton meters
bar
radians/second
square meters
square meters
square centimeters
Symbol
bar
l
l
kg
kg/m3
kg/cm3
N
Nm
Nm
bar
rad/s
m2
m2
cm2
Factor
105
0.568245
0.473163
0.4536
16.0185
0.0276799
4.44822
1.35582
0.112985
0.06894
0.104720
0.092903
6.4516 10-4
6.4516
Hydraulic Formulas
Horsepower:
GPM PSI
1714
Horsepower =
Torque:
CU IN./REV. PSI
2
HP 63025
RPM
Torque (lb. in.) =

Torque (lb. in.) =
Flow:
Flow (gpm) =
CU IN./REV. RPM
231
Overall Efficiency:
Output HP 100
Input HP
Volumetric
Output GPM 100
efficiency =
Theoretical GPM
(pump)
Volumetric
Input GPM
(motor)
Conversion Factors:

specific gravity.




inches
0.408 flow (gpm)
D2
inches
14.7 PSI
23,000 feet
29
1141
CONVEYOR TAKE-UP
HYDRAULIC SYSTEM
1142
VICKERS
APPLICATION:
CUSTOMER:
TAIM TFG
OFFER:
HT 05/0322C
(CONVEYOR TAKE-UP)
DATE:
CENTRAL:
Tel:
98 552 57 57
Fax:
98 556 74 72
2006
Avda. de Burgos, 42- Local 3
28036 Madrid
Tel:
91 383 88 75
Fax:
91 766 73 97
C/La Forja, 37
Tel:
93 637 66 44
Fax:
93 637 75 10
DELEGACIN GALICIA:
1 planta- Ofic. 4
36203 Vigo
Tel/Fax: 98 647 39 12
Mvil:
61 025 89 34
1143
05/0322C
INDEX
CONFORMITY
2. PARTS LIST
3. CERTIFICATES
GUIDE
1144
05/0322C

CONFORMITY
1145
INDEX
SETTING UP:............................................................................................... 2
1.1
1.2
1.3
FILLING THE TANK: .............................................................................. 2
1.4
START UP:............................................................................................. 2
OPERATING:............................................................................................... 2
2.1
INTRODUCTION: ................................................................................... 2
MAINTENANCE:.......................................................................................... 3
Pgina 1
1146
The present hydraulic power unit with reference HT 05/0322C has been manufactured in
1
1.1
SETTING UP:
of the machine.
1.2
1.3
FILLING THE TANK:
1.4
START- UP:
normally.
2
2.1
OPERATING:
INTRODUCTION:
Pgina 2
1147
present manual).

MAINTENANCE:
-
recommended.
Pgina 3
1148
by unscrewing it.
Pgina 4
1149
1150
05/0322C
PARTS
LIST
1151
PART LIST
AVILES
ANEXO IV
TAIM TFG
Customer
HA-LMC-N
HA-PG-02
REV.:0
Offer
05/0322C
Ed.:0
05/0322
Installation
Desription
Drawing
CONVEYOR TAKE UP
Quanty
2
Deliver
OTH n
PREPARED BY
FDO:
REVISED BY
FDO:
05/0322C
AVILES
DENOMINATION
REFERENCE
CODE
QUANTITY
POS
HARD PUMP
PMT 25 RV
TANK 5 LIT
TNK5
LEVEL INDICATOR
LM 76 1T M10
GAUGE VALVE
FT290
MANOMETER
HYDRAULIC CYLINDER
100/56/100 S/PLANO 050322CMO_00_00
GAUGE OUTLET
686205 R1/4"GAS
GATE VALVE
GE2 R1/4"GAS
PRESSURE HOSE
L=4800 PTE
PRESSURE HOSE
L=2400 PTE
10
TOTAL
17
Pgina 1 de 1
1152
05/0322C
CERTIFICATES
1153
1154
1155
1156
Messrs
Spain
Best Regards
Michele Bogni
1157
05/0322C
CATALOGUE ELEMENTS
1158
Pompe manuali
Hand pumps
y
O/ 2
PMP
BSPP 3/8
x
max 170
38
Optional
15
15
P
112
Leva di
scarico
Unloading
lever
Optional
Pompe a mano 12/25/45 cm3 per montaggio sul serbatoio.

Corpo in ghisa verniciato, stelo in acciaio cromato. Leva di scarico
Leva di azionamento L=600 mm.
A richiesta: soffietto di protezione stelo, valvola di massima pressione
12/25/45 cm3 hand pumps for mounting on reservoir.
Painted cast-iron body, chromed steel rod. Unloading lever,
L=600 mm operation lever. On request: rod rubber protection, relief valve
P
118
O
/ 38
220
68
PMT
O2
BSPP 3/8
38
2
38
1
x
max 170
Optional
Optional
1
Optional
P
112
O
/ 38
Corpo in ghisa verniciato, stelo in acciaio cromato.

Deviatore 4 vie 3 posizioni con valvole di blocco doppio effetto.
Leva di azionamento L=600 mm.
A richiesta: soffietto di protezione stelo, valvola di massima pressione
12/25/45 cm3 hand pumps for mounting on reservoir.
Painted cast-iron body, chromed steel rod. 4 ways, 3 positions diverter
with double acting check valve.
L=600 mm operation lever. On request: rod rubber protection, relief valve
68
P
118
42
Sforzo (daN) esercitato allestremit della leva

Effort (daN) operating on the end of the lever
Caratteristiche tecniche
Features
Pressione max di esercizio

Max working pressure
Cilindrata
Displacement
Deviatore
Diver ter Pompe a mano 12/25/45 cm3 per montaggio sul serbatoio.
Peso
Weight
Kg
45 cm3
Cilindrata
Displacement
45
80
25
60
380 bar
350 bar
280 bar
12 cm
3
25 cm
daN
100
4,2
12
40
Senza soffietto
Without rod protection
12 cm
65
35
25 cm
85
25
75
35
45 cm
20
0
Codice di ordinazione
Ordering code
**
12
25
Cilindrata
Displacement
250
150
100
PMT
PMP
50
200
350
300
bar
400
Con soffietto
With rod protection
Cilindrata
Displacement
*
A richiesta
Optionals
Soffietto
Rubber protection
Valvola di max.
Relief valve
P
RV
12 cm
45
55
25 cm
75
35
75
35
45 cm
45
1159
Serbatoi in acciaio
Steel reservoirs
TNK
Verniciatura RAL9005 antiolio - nero

RAL9005 black oil proof painting
Features
15
Codice
Code
Peso
Weight
Kg
1
2
3
5
7
10
120
180
247
200
269
376
150
150
150
175
175
175
100
100
100
175
175
175
120
120
120
195
195
195
2,0
2,2
2,5
4,5
5,4
6,8
O
/ 8.5
TNK1
TNK2
TNK3
TNK5
TNK7
TNK10
50
90
Capacit
Capacity
50
M8-N.4
19
C
D
Foratura da eseguire sul piano del serbatoio per il fissaggio delle pompe
Drilling to be carried out on the tank for the pump fixing
50
45
Serbatoi in alluminio
Aluminium reservoirs
15
TNA
154
110
130
Codice
Code
Capacit
Capacity
TNA1
Peso
Weight
Kg
1,0
M8
180
15
19
Tappo sfiato
BSPP
Breather cap
O
/ 10.5
173
90
46
Tappo livello olio

Oil level
Optional
17
125
95
82
Features
O
/ 11-N.4 Fori - Holes
96
50
150
Tappo sfiato
BSPP
Breather cap
123
TNA2
TNA3
TNA5
Peso
Capacit H Weight
Capacity mm
Kg
25
2
1,5
70
3
1,6
180
5
1,8
168
35
23
164
204
Tappo
Cap
95
Codice
Code
119
Features
164
Guarnizione
Gasket
M8
50
70
164
56
1160
SP
INDICADORES OPTICOS DE NIVEL - SERIE LM

DESCRIPCION:
Montado en el exterior del deposito, permiten la
lectrua directa del nivel del fluido que contienen.
Diponibles tambien con termostato para leer la
temperatura (escala de 30 C a 80 C)
CARACTERISTICAS TECNICAS:
Cuerpo: Glass-filled nylon
Tornilleria: En acero
Juntas: Buna (viton si se solicitan)
Prexion maxima: 1 bar
Temperatura de trabajo: -30 C a + 90 C
Par de apriete de perno de tornillo: 10 Nm
Dimensiones (mm) y pesos (Kg)
1161
1162
1163
TECHNICAL DATA
MODEL : G
MANOMETER STUFFED WITH GLYCERIN
Description: manometer stuffed with glycerine, mounted in stainless steel box

watertight AISI 304 and with brass internal parts.
Applications: particularly indicated for installations with vibrations and sudden and
repeated pressure changes.
CHARACTERISTICS.
GRADATION
DIAMETERS
- Diameters: 63 and 100
63
100
0-0,6 bar
- Box and ring: In stainless steel AISI 304 watertight,

Ring type bayonet in diameter 100.
MANOMETERES
0-1 bar
0-1,6 bar
0-2,5 bar
0-4 bar
0,6 bar
- Connection: In brass in Gas for diameter 63 and
0-10 bar
1/2 Gas for diameter 100.
0-16 bar
0-25 bar
0-40 bar
0-60 bar
black numbers.
0-100 bar
- Needle: In aluminium balanced, with brass centre.
0-250 bar
0-315 bar
0-400 bar
0-600 bar
- Overpressure:25% from final scale value till 60 bar.
0-100 bar
15 % from final scale value from 100 to600 bar.
- Racord Tube: In brass-Zinnbrass/CuSn8 (For

1.000 bar tube in stainless steel AISI 316).
- Mechanism: In brass
- Sphere: In aluminium painted in white and with
- Glass: Methacrylate.
- Accuracy: +/-1,6% from final scale value.
MANO VACUUM GAUGE
10 % from final scale value for more than 600 bar.
-1+0,6 bar
-1+1,5 bar
-1+3 bar
- Service Temperature: -10 + 60 C
-1+5 bar
- Protection Index: IP-55
-1+9 bar
-1+15 bar
-1+24 bar
-76/0 cmHg
-760/0 mmHg
-1/0 bar
VACUUM GAUGE
- To define a manometer: Diameter, reference,

model, thread and graduation.
1164
Vertical Thread
Posterior Thread
Frontal view
Frontal View
Vertical Thread
Posterior Thread
Vertical thread
Posterior Edge
Posterior Thread
Frontal Edge
Frontal View
Frontal View
Posterior Thread
With flange
Vertical Thread
Posterior edge
Posterior Thread
Frontal Edge
OPTIONS
Silicone stuffed
NPT Thread (1/4 para 63 y 1/2 para 100
Thread in Gas and 3/8 Gas

Other Graduations (psi, Kpa, Mpa, Kg/cm, etc)
Glass
Logo in the sphere
Without glycerine charge
Posterior Thread
With Flange
63
100
1165
Test 20
Typ SMK
Connection Thread M 16 x 2
Fast coupling for:

Monitoring and control of pressure
Venting
Sampling in high, low and vacuum systems
Advantages:
Test hose
with swivel nut
Coupling at system pressure level

Leakproof connection before ball valve is open
Simple connection to measuring,
control and switching devices
Self locking metal guard cap
Working pressure:
Max. working pressure 630 bar
For SMK style G, K and S the recommended working
pressure of fitting manufacturer has to be applied
Joining under pressure up to 400 bar max.
Materials:
Test coupling
Metal parts: Steel, Stainless Steel on request

Ball: Stainless Steel
Seals:
P = NBR (Temperature range 20 C to + 90 C)
V = FPM (Temperature range 20 C to + 200 C)
E = EPDM Ethylene Propylene (for Break Fluid)
Temperature range 40 C to + 150 C
Hose: Polyamide (Temperature range -35 C . . . 100 C
max.)
Media:
Protective cap
Suitable for hydraulic oils and other mineral oil based fluids
(Please pay attention to the sealing materials used !)
For use in conjunction with other liquid media please
consult STAUFF
The complete STAUFF-TEST-20 -Type-SMK range is

available with hexagonal protection cap made of steel or
plastic protection cap
1166
Test 20
Typ SMK
Connection Thread M 16 x 2
Test coupling with protective cap SMK

Order No.
Thread
G
SW
Seal
NBR
FPM
37
17
SMK 20 M 8 x 1 PA
SMK 20 M 8 x 1 VA
O-Ring Type A
M 10 x 1
37
17
SMK 20 M 10 x 1 PA
SMK 20 M 10 x 1 VA
O-Ring Type A
M 12 x 1,5
37
17
SMK 20 M 12 x 1,5 PC SMK 20 M 12 x 1,5 VC O-Ring Type C
M 14 x 1,5
37
19
SMK 20 M 14 x 1,5 PB SMK 20 M 14 x 1,5 VB Metal joint Type B
M 16 x 1,5
37
22
SMK 20 M 16 x 1,5 PB SMK 20 M 16 x 1,5 VB Metal joint Type B
G /8
39
17
SMK 20 G 1/8 PC
SMK 20 G 1/8 VC
O-Ring Type C
G 1/4
37
19
SMK 20 G 1/4 PB
SMK 20 G 1/4 VB
Metal joint Type B
G 1/4
37
19
SMK 20 G 1/4 PC
SMK 20 G 1/4 VC
O-Ring Type C
G /8
37
22
SMK 20 G /8 PB
SMK 20 G /8 VB
Metal joint Type B
R /8 taper
37
17
SMK 20 R /8 K-PD
SMK 20 R /8 K-VD
Taper Type D
R 1/4 taper
36
17
SMK 20 R 1/4 K-PD
SMK 20 R 1/4 K-VD
Taper Type D
/8 NPT
36
17
SMK 20 1/8 NPT-PD
SMK 20 1/8 NPT-VD
Taper Type D
/4 NPT
35
17
SMK 20 /4 NPT-PD
SMK 20 /4 NPT-VD
Taper Type D
/16 24 UNF
38
17
SMK 20 /16 UNF-PE
SMK 20 /16 UNF-VE
O-Ring Type E
/16 20 UNF
38
17
SMK 20 7/16 UNF-PE
SMK 20 7/16 UNF-VE
O-Ring Type E
/2 20 UNF
38
17
SMK 20 1/2 UNF-PE
SMK 20 1/2 UNF-VE
O-Ring Type E
/16 18 UNF
37
19
SMK 20 /16 UNF-PE
SMK 20 /16 UNF-VE
O-Ring Type E
M8 x 1
M 16
SW
17
10
Other port connections and seals on request.
Port connections and seals

Type C
Type D
90
90
90
d1
t1
M8 x 1
9,5 + 0,1
11
M 10 x 1
11,5 + 0,1
12
t2
d1
t1
15,5 M 14 x 1,5
20
12
16,5 M 16 x 1,5
22
G 1/4
G 3/8
t2
d1
t1
18,5 1,5 M 12 x 1,5
18
12
12
18,5 1,5
G 1/8
15
19
12
18,5 1,5
G 1/4
19
23
12
18,5 2,0
t2
t1
t2
t1
t2
t2
t1
t1
G
12
d1
G
1,6
a
G
a
d1
G
t2
G
Type E
d2
d1
G
t1
t2
30
0,5
2,5
d1
Type B
Type A
d1
d2
/16 24 UNF
9,1
17
10,0 12,0 1,9
/16 20 UNF 12,4
21
11,5 14,0 2,4
/2 20 UNF 14,0
23
11,5 14,0 2,4
/16 18 UNF 15,6
25
12,7 15,5 2,5
t1
t2
18,5 1,5
R /8 taper
5,5
9,5
13,0 1,0
R 1/4 taper
8,5
13,5
12
18,5 1,5
6,9,0
11,6
16,4
/8 NPT
/4 NPT
10,0
t1
t2
1167
1168
1169
1170
05/0322C
1171
Vickers
General Product Support
Hydraulic Hints &

Trouble Shooting Guide
Revised 8/96
694
1172
General Hydraulic Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Troubleshooting Guide & Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chart 1 Excessive Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chart 2 Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chart 3 Incorrect Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chart 4 Incorrect Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chart 5 Faulty Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quiet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Contamination Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hints on Maintenance of Hydraulic Fluid in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Leakage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Fluid and Temperature Recommendations for Industrial Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Fluid and Temperature Recommendations for Mobile Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Viscosity Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump Test Procedure for Evaluation of Antiwear Fluids for Mobile Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil Flow Velocity in Tubing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pipe Sizes and Pressure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Preparation of Pipes, Tubes and Fittings Before Installation in a Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ISO/ANSI Basic Symbols for Fluid Power Equipment and Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1173

Good Assembly
Practices
installed.
containers.
turbulent flow.
thread connections.
Pipes



Standard
Schedule 40
160 pipe.

after bending.
power equipment.

1174

General
System Design
the pump.
troubleshooting.
Knowing the System

follow:

applied:
and machine.

Maintenance




and viscosity.
Procedures
Recognizing Trouble
Indications

strainers.
Guidelines

1175

Chart 1
EXCESSIVE NOISE
1.
PUMP NOISY
MOTOR NOISY
RELIEF VALVE NOISY
Cavitation
Remedy: a
1.
Coupling misaligned
Remedy: c
1.

setting
Remedy: d
2.
Air in fluid
Remedy: b
3.
Coupling Misaligned
Remedy: c
4.
Pump worn or
damaged
2.
Motor or coupling
worn or damaged
2.

Remedy: e
Remedy: b
Remedy: e
Remedies:

journal).

correct pressure.
1176

Chart 2
EXCESSIVE HEAT
PUMP HEATED
MOTOR HEATED
RELIEF VALVE HEATED
FLUID HEATED
1.
1. Fluid heated
1. Fluid heated

high
Remedy: d
2. Cavitation
Remedy: a
2.
Relief or unloading
valve set too high
2.

Remedy: d
Remedy: d
3. Air in fluid
Remedy: b
3. Excessive load
Remedy: c
valve set too high
4. Worn or damaged
motor
Remedy: d
2.
Unloading valve set

too high
Remedy: d

Remedy: e

Remedy: f
4. Incorrect fluid
viscosity
Remedy: e
Remedy: f
5. Excessive load

system
Remedy: c
Remedy: g
6. Worn or damaged
pump

cylinder or other
component
Remedy: e
Remedy: e
Remedies:
supercharge pump.
journal).


replace cooler.

settings).
proper level.
1177
Chart 3
INCORRECT FLOW
NO FLOW
LOW FLOW
EXCESSIVE FLOW

Remedy: a
1.

Remedy: d

Remedy: d
2.
2.
Relief or unloading
valve set too low
2.

operating
Remedy: e
3.

sheared
Remedy: d
3.
Remedy: c
in wrong direction
Remedy: e


Remedy: b
5.
Remedy: f
6.
Entire flow passing

over relief valve
8.
pump
Remedy: h
4.
Improper size pump


displacement pumps)
Remedy: e
6.
Remedy: d
7. Damaged pump
Remedy: c
RPM of pump drive

motor incorrect
Remedy: h
Remedy: g
wrong position
3.
Remedy: e or f
4.

displacement pumps)
RPM of pump drive

motor incorrect
Remedy: h
7.
Worn pump, valve,

motor, cylinder or
other component
Remedy: e
Remedy: e
Remedies:
supercharge pump.

d. Adjust.

1178
Chart 4
INCORRECT PRESSURE
NO PRESSURE
LOW PRESSURE
ERRATIC PRESSURE
EXCESSIVE
PRESSURE
1. No flow
column A
1. Air in fluid
Remedy: b

exists
column A and B
relief or unloading
valve misadjusted
Remedy: d
2.
2.

set too low
2.
Worn relief valve

Remedy: e

displacement pumps)
Remedy: e
Remedy: d
valve damaged
Remedy: a
Remedy: e
relief or unloading
Remedy: e

or cylinder
or has lost charge
Remedy: e
Remedy: c
cylinder
Remedy: e
Remedies:
from system).
1179
Chart 5
FAULTY OPERATION
NO MOVEMENT
SLOW MOVEMENT
ERRATIC MOVEMENT
EXCESSIVE SPEED
OR MOVEMENT
1. Low flow
Remedy: See Chart 3
1. Erratic pressure
1. Excessive flow
Remedy: See Chart 3
2.
2.
2.
2.
Limit or sequence
device (mechanical,
inoperative or
misadjusted

Remedy: a
Air in fluid
Remedy: See Chart I
Feedback transducer
malfunctioning
Remedy: e
Remedy: e
3. Mechanical bind
Remedy: b
pressure for valves
machine ways or
linkage
Remedy: See Chart 4
3. Misadjusted or
amplifier
Remedy: See Chart 4

to servo amplifier
Remedy: f
Remedy: c
Remedy: c
ways or linkage
Remedy: c
Remedy: f
Remedy: h
Remedy: g
Remedy: c
Remedy: c
transducer

Remedy: c
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: e
7. Worn or damaged
cylinder or motor
Remedy: d
Remedy: e
8. Worn or damaged
cylinder or motor
Remedy: e
Remedies:
viscosity.


g. Lubricate.


1180
Quiet Hydraulics
Sound Advice
Pump Selection
Acoustic Isolation
Reservoirs


120F.

Fluids

adequate.

10
1181

capacity.
faults.
degradation.
form sludge.
Preventive Measures
For Storage Drums:
For Storage Tanks:
seal in the fluid.
the system.
low fluid levels.
necessary.
practices.
shifts).
11

Solid
High Water Air
Contam. Temp.

1182
Preventive Measures
mating components.
reservoir system.
secured.

Solid
High Water Air
Contam. Temp.

12
1183

condition.

Fluid Contamination
Causes and Effects
Contamination

the system.
rod).

Draining The System

System



components.





13
1184
Aeration
Aeration
Causes
Shaft seal leakage.
reservoir.
the fluid.
Effects
Cures
Leaking Inlet Lines



prevent aeration.
Shaft Seal Leakage


problem.

a working cylinder.

Reservoir


system.

14
1185
Leakage Control
Cost Of Leakage
leakage.
Leak-Free Design
Cause Of Leaks
the hydraulic fluid

Vibration
vibration:
vibration.
or accumulators.

wherever practical.
threads.
seal nibbling.
connectors.

Wear
gaiters.
as low as possible.
Requirements For
Static Seals
15
Mounting Plates
surface separation.
Preventing Seal
Deterioration
may be helpful.
leakage control.
1186

Unit Type
Viscosity
Inline Piston
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)
Antiwear type
y hydraulic
y
oils such as:
Angle Piston
Vane (Except MHT)
Gear
(Pumps & Motors)
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)

MHT (High Torque/
Low Speed
Vane Motors
Viscosity
Grades: 32-68 cSt (150-315 SUS) @ 40C. (104F)

SH per SAE J183
cSt: Centistokes



recommendations.

(315 SUS) grade.
Viscosity
Grade
40C (104F)
Start Up
860 cSt
(4000 SUS)
Start Up
220 cSt
(1000 SUS)
Start Up
110 cSt
(500 SUS)
Running
54 cSt
(250 SUS) Max.
Running
13 cSt
(70 SUS) Min.
32 cSt (150 SUS)

46 cSt (215 SUS)
68 cSt (315 SUS)
12C (11F)
6C (22F)
0C (32F)
6C (42F)
12C (54F)
19C (66F)
14C (58F)
22C (72F)
29C (84F)
27C (80F)
34C (94F)
42C (108F)
62C (143F)
71C (159F)
81C (177F)
General Data


hydraulic systems:


hydraulic service.

hydraulic system.
operation.
16
1187

against rust.
time standing.
recommendation.
35VQ25 pump test.
Viscosity

Temperature
is 66C (150F).
Cleanliness
system is clean.
etc.
system.
life of the system.
over emphasized.
Sound Level
due to cavitation.

recommendations.
17
1188

your system.
sound levels.
encountered.

Water Based Fluids
Water-Glycol Fluids
General Data

water content.

million hardness.
emulsion breaking.
Oil-In-Water Fluids
Filters
the fluid supplier.

Fluids
Invert Emulsions
18


Phosphate Ester
compatible.

1189

Selecting An Oil
Additives
Antiwear

Chemical Stability
these systems.

Crankcase Oil
designations.


Other Oils


provisions:
pump tests.
Viscosity


19
1190

Crankcase Oils
Hydraulic System
SAE Viscosity
Designation
Hydraulic System
23C to 54C
(10F to 130F)
5W, 5W-20,
5W-30
21C to 60C
(5F to 140F)
22
18C to 83C
(0F to 180F)
10W
15C to 77C
(5F to 170F)
32
18C to 99C
(0F to 210F)
10W-30,
10W-40
9C to 88C
(15F to 190F)
46
10C to 99C
(50F to 210F)
20-20W
1C to 99C
(30F to 210F)
68
ISO Viscosity
Grade
1 Temperatures
20
1191

Test Pump
413421)
Test Conditions
Speed:
Outlet Pressure:
Inlet Pressure:
Inlet Temperature:
2350-2400 rpm
205-210 bar gage
(2975-3025 psig)
0-.15 bar gage
(0-2 psig) with
flooded inlet
90-96C
(195-205F)
Operating Mode
inlet pressure.

Water Content:
.075% maximum
18/16/14 or better
particle count.
Alternatively, 30
mg/liter maximum
filter membrane
of 0.8 micrometer
porosity).
Pump Break-In
Procedure

Test Circuit
1
10
2 Line Size
9
Test Duration
parameters.
period.

intravanes).

P/N 413421)

75 mg.

9. Cooler
10. Flow meter

fluids by Vickers.
21
1192
Acceptable Rings
Unacceptable Rings
22
1193

Tubing
GPM = V
A B .3208,
area of tube.

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
1/2
.035
.042
.049
.058
.065
.072
.083
.905
.847
.791
.722
.670
.620
.546
1.81
1.63
1.58
1.44
1.34
1.24
1.09
4.52
4.23
3.95
3.61
3.35
3.10
2.73
6.79
6.35
5.93
5.41
5.03
4.65
4.09
9.05
6.47
7.91
7.22
6.70
6.20
5.46
13.6
12.7
11.9
10.8
10.1
9.30
8.16
5/8
.035
.042
.049
.058
.065
.072
.083
.095
1.51
1.43
1.36
1.27
1.20
1.13
1.03
.926
3.01
2.85
2.72
2.54
2.40
2.26
2.06
1.85
7.54
7.16
6.80
6.34
6.00
5.66
5.16
4.63
11.3
10.7
10.2
9.51
9.00
8.49
7.73
6.95
15.1
14.3
13.6
12.7
12.0
11.3
10.3
9.26
22.6
21.4
20.4
19.0
18.0
17.0
15.5
13.9
3/4
.049
.058
.065
.072
.083
.095
.109
2.08
1.97
1.88
1.75
1.67
1.53
1.39
4.17
3.93
3.76
3.51
3.34
3.07
2.77
10.4
14.8
14.1
13.2
12.5
11.5
10.4
15.6
9.84
9.41
8.77
8.35
7.67
6.93
20.8
19.7
18.8
17.5
16.7
15.3
13.9
31.2
29.6
28.2
26.4
25.0
23.0
20.8
7/8
.049
.058
.065
.072
.083
.095
.109
2.95
2.82
2.72
2.62
2.46
2.30
2.11
5.91
5.64
5.43
5.23
4.92
4.60
4.22
14.8
14.1
13.6
13.1
12.3
11.5
10.6
22.2
21.1
20.4
19.6
18.5
17.2
15.8
29.5
28.2
27.2
26.2
24.6
23.0
21.1
44.3
42.3
40.7
39.2
36.9
34.4
31.7
1
.049
.058
.065
.072
.083
.095
.109
.120
3.98
3.82
3.70
3.59
3.40
3.21
3.00
2.83
7.96
7.65
7.41
7.17
6.81
6.42
6.00
5.65
19.9
19.1
18.5
17.9
17.0
16.1
15.0
14.1
29.9
28.7
27.8
26.9
25.5
24.1
22.4
21.2
39.8
38.2
37.0
35.9
34.0
32.1
29.9
28.3
59.7
57.4
55.6
53.8
51.1
48.2
44.9
42.4
23
15
Ft/Sec
20
Ft/Sec
30
Ft/Sec
1194

Tube
O.D.
Wall
Thick.
2
Ft/Sec
4
Ft/Sec
10
Ft/Sec
15
Ft/Sec
20
Ft/Sec
1-1/4
.049
.058
.065
.072
.083
.095
.109
.120
6.50
6.29
6.14
6.00
5.75
5.50
5.21
5.00
13.0
12.6
12.3
12.0
11.5
11.0
10.4
10.0
32.5
31.5
30.7
30.0
28.8
27.5
26.1
25.0
48.7
47.2
46.0
44.9
43.1
41.2
39.1
37.4
64.9
62.9
61.4
59.9
57.5
55.0
52.1
50.0
1-1/2
.065
.072
.083
.095
.109
.120
9.19
9.00
8.71
8.40
8.04
7.77
18.4
18.0
17.4
16.8
16.1
15.5
45.9
45.0
43.5
42.0
40.2
38.8
68.9
67.5
65.3
63.0
60.3
58.3
91.9
90.0
87.1
84.0
80.4
77.7
1-3/4
.065
.072
.083
.095
.109
.120
.134
12.8
12.6
12.3
11.9
11.5
11.2
10.7
25.7
25.2
24.6
23.8
23.0
22.3
21.5
64.2
63.1
61.4
59.6
57.4
55.8
53.7
96.3
94.7
92.1
89.3
86.1
83.7
80.6
2
.065
.072
.083
.095
.109
.120
.134
17.1
16.9
16.5
16.0
15.5
15.2
14.7
34.2
33.7
32.9
32.1
31.1
30.3
29.4
85.6
84.3
82.3
80.2
77.7
75.8
73.4
128
126
123
120
117
114
110
30
Ft/Sec
97.4
94.4
92.1
89.8
86.3
82.5
78.2
74.9
138
135
131
126
121
117
128
126
123
119
115
112
107
193
189
184
179
172
167
161
171
169
165
160
155
152
147
257
253
247
240
233
227
220

Nominal
Pipe
Size
in.
Outside
Diameter
of Pipe
in.
Number
of
Thre d
Threads
Per Inch
1/8
0.405
27
1/4
3/8
1/2
3/4
0.540
0.675
0.840
1.050
1
1-1/4
1-1/2
2
2-1/2
3
Length
of
Effective
Threads
in.
Schedule 40
(Standard)
Schedule 80
(Extra Heavy)
Schedule 160
Double
Extra Heavy
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
Pipe
ID-in.
Burst
Pres.
PSI
0.26
18
18
14
14
0.40
0.41
0.53
0.55
.364
.493
.622
.824
16,000
13,500
13,200
11,000
.302
.423
.546
.742
22,000
19,000
17,500
15,000
.466
.614
21,000
21,000
.252
.434
35,000
30,000
1.315
1.660
1.900
11-1/2
11-1/2
11-1/2
0.68
0.71
0.72
1.049
1.380
1.610
10,000
8,400
7,600
.957
1.278
1.500
13,600
11,500
10,500
.815
1.160
1.338
19,000
15,000
14,800
.599
.896
1.100
27,000
23,000
21,000
2.375
2.875
3.500
11-1/2
8
8
0.76
1.14
1.20
2.067
2.469
3.068
6,500
7,000
6,100
1.939
2.323
2.900
9,100
9,600
8,500
1.689
2.125
2.624
14,500
13,000
12,500
1.503
1.771
19,000
18,000
24
1195

should be taken:
valve or pump body.

hydraulic system.


Pickling Process
on this point.
the manufacturer.
25
1196

Lines
Pumps
Line, Working
(Main)
Hydraulic Pump
Fixed
Displacement
Line, Pilot
(For Control)
Heater
Line, Liquid Drain

Variable
Displacement
Hydraulic
Flow, Direction of
Pneumatic
Cooler

Lines Crossing
or
Temperature
Controller
Hydraulic
Fixed
Displacement
Lines Joining
Filter, Strainer
Line With Fixed

Restriction
Variable
Displacement
Line, Flexible
Station, Testing,
Measurement or
Power Take-Off
Variable Component
(run arrow through
symbol at 45
Pressure Switch
Cylinder, Single
Acting
Cylinder, Double
Acting
Pressure Indicator
Single End Rod

Temperature
Indicator
Double End Rod

of symbol)
Adjustable
Cushion
Advance Only
Component
Enclosure
Differential
Piston
Miscellaneous Units
Temperature Cause
or Effect
Electric Motor
Vented
Reservoir
Pressurized
Line, To Reservoir
Above Fluid Level
Accumulator, Spring
Loaded
Spring
Manual
Below Fluid Level

Vented Manifold
Direction of Shaft
Rotation (assume
arrow on near side
of shaft
Accumulator, Gas
Charged
26
Push Button
1197
Pedal or Treadle
Flow Control,
Adjustable
(temperature and
pressure
compensated
Mechanical
Two Position
Two Connection
Detent
Two Position
Three Connection
Pressure
Compensated
Two Position
Four Connection
Push-Pull Lever
Solenoid, Single
Winding
Servo Control

Pilot Pressure
Remote Supply
Internal Supply
Valves
Check
OnOff
(manual shut-off)
Pressure Relief
Pressure Reducing
Flow Control,
Adjustable
Non-Compensated
Function
Definition
Pressure in
excess of supply
pressure which is
induced by a
booster or
intensifier.
Supply Pressure
Power-actuating
fluid.
Charging Pressure
Pump-inlet
pressure that is
higher than
atmospheric
pressure.
Three Position
Four Connection
Reduced Pressure
Auxiliary pressure
which is lower
than supply
pressure.
Two Position
In Transition
Pilot Pressure
Control-actuating
pressure.
Metered Flow
Fluid at controlled
flow rate, other
than pump
delivery.
Exhaust
Return of power
and control fluid
to reservoir.
Intake
Sub-atmospheric
pressure, usually
on intake side of
pump.
Drain
Return of leakage
fluid to reservoir.
Inactive
Fluid which is
within the circuit,
but which does
not serve a
functional
purpose during
the phase being
represented.
Valves Capable Of
(horizontal bars
indicate infinite
Note
template kit 352.

Power Schematic
Drawings
Function
Color
Supply . . . . . . . . . . . . . .
Metered Flow . . . . . . . .
Exhaust . . . . . . . . . . . . .
Intake . . . . . . . . . . . . . . .
Drain . . . . . . . . . . . . . . .
Inactive . . . . . . . . . . . . .
Black
Red
Intermittent Red
Intermittent Red
Intermittent Red
Yellow
Blue
Green
Green
Blank
27
1198
Conversion Factors
To convert
Into
Into
Multiply by
To convert
Unit
Symbol
Unit
Symbol
Divide by
Factor
Atmospheres
Atm
bar
bar
1.013250
BTU/hour
Btu/h
kilowatts
kW
0.293071 103
cubic centimeters
cm3
liters
0.001
cubic centimeters
cm3
milliliters
ml
1.0
cubic feet
ft3
cubic meters
m3
0.0283168
cubic feet
ft3
liters
28.3161
cubic inches
in3
cubic centimeters
cm3
16.3871
cubic inches
in3
liters
0.0163866
degrees (angle)
radians
rad
0.0174533
Fahrenheit
F
Celsius
C
C=5 (F32) / 9
feet
ft
meters
0.3048
feet of water
ft H2O
bar
bar
0.0298907
cubic centimeters
cm3
28.413
29.5735
fluid ounces, UK
UK fl oz
fluid ounces, US
US fl oz
cubic centimeters
cm3
foot pounds f
ft lbf
joules
1.35582
foot pounds/minute
ft lbf/min
watts
81.3492
gallons, UK
UK gal
liters
4.54596
gallons, US
US gal
liters
3.78531
horsepower
hp
kilowatts
kW
0.7457
inches of mercury
in Hg
millibar
mbar
33.8639
inches of water
in H2O
millibar
mbar
2.49089
inches
in
centimeters
cm
2.54
inches
in
millimeters
mm
2.54
kilogram force
kgf
newtons
9.80665
kilogram f. meter
kgf m
newton meters
Nm
9.80665
kgf/cm2
bar
bar
0.980665
kilopascals
kPa
bar
bar
0.01
kiloponds
kp
newtons
9.80665
kilopond meters
kp m
newton meters
Nm
9.80665
kp/cm3
bar
bar
0.980665
kilowatts
kW
0.735499
metric horsepower
microinches
in
microns
0.0254
mm Hg
millibar
mbar
1.33322
mm H2O
millibar
mbar
0.09806
N/cm2
bar
bar
0.1
N/m2
bar
bar
105
28
1199
Conversion Factors
To convert
Into
Unit
pints, UK
pints, US
pounds (mass)
pounds/cubic foot
pounds/cubic inch
pounds force
pounds f feet
pounds f inches
revolutions/minute
square feet
square inches
square inches
Symbol
Pa
UK pt
US liq pt
lb
lb/ft3
lb/in3
lbf
lbf ft
lbf in
lbf/in2
r/min
ft2
in2
in2
Into
Multiply by
To convert
Divide by
Unit
bar
liters
liters
kilograms
newtons
newton meters
newton meters
bar
radians/second
square meters
square meters
square centimeters
Symbol
bar
l
l
kg
kg/m3
kg/cm3
N
Nm
Nm
bar
rad/s
m2
m2
cm2
Factor
105
0.568245
0.473163
0.4536
16.0185
0.0276799
4.44822
1.35582
0.112985
0.06894
0.104720
0.092903
6.4516 10-4
6.4516
Hydraulic Formulas
Horsepower:
GPM PSI
1714
Horsepower =
Torque:
CU IN./REV. PSI
2
HP 63025
RPM
Torque (lb. in.) =

Torque (lb. in.) =
Flow:
Flow (gpm) =
CU IN./REV. RPM
231
Overall Efficiency:
Output HP 100
Input HP
Volumetric
Output GPM 100
efficiency =
Theoretical GPM
(pump)
Volumetric
Input GPM
(motor)
Conversion Factors:

specific gravity.




inches
0.408 flow (gpm)
D2
inches
14.7 PSI
23,000 feet
29
1200
GAMA HYDROLUBRIC HM
DESCRIPTION
APPLICATION
HYDROLUBRIC HM oils are manufactured with paraphinic

mineral oils and prevent rust, antioxidant, antifoam and
antiwear additives.
HYDROLUBRIC HM oils have been specially formulated to

satisfy the severe use in hydraulic pumps (high pressure).
HOW TO USE
HYDROLUBRIC HM SERIES are recommended in

equipment where following standards are required:
Before use it, we recommended to clean the machine with

GUM SOLVENT GSC.
ISO 6743/4 HM Category

DIN 51524. Parte II HLP Type
AFNOR NFE 48603/48602
CINCINNATI MACHINE P-68, P-69 y P- 70
DENISON HF-2, HF- 0
VICKERS M- 2950 S ( 35VQ25)
PACKAGING
HYDROLUBRIC HM SERIES is supplied in drums of 50 Lt,
185 Kg and semi-bulks of 850 Kg.
TYPICAL PHYSICAL PROPETIERS

ENSAYO
10
15
22
32
46
68
100
METHOD
Color
Amber
Amber
Amber
Amber
Amber
Amber
Amber
HI-102
Specific Gravity
150C
0,850
g/cm3
0,860
g/cm3
0,865
g/cm3
0,870
g/cm3
0,875
g/cm3
0,880
g/cm3
0,885
g/cm3
ASTM D-1298
Viscosity 400C
10 cSt
15 cSt
22 cSt
32 cSt
46 cSt
68 cSt
100 cSt
ASTM D-445
1,7 cSt
3,7 cSt
4,7 cSt
5,6 cSt
6,8 cSt
9,7 cSt
10 cSt
ASTM D-445
CONCENTRATE PRODUCT
Viscosity 100 C
Flash Point
Viscosity In Dex
>145 C
>160 C
>185 C
>185 C
>185 C
>200 C
>200 C
ASTM D-92
>95
>95
>95
>95
>95
>95
>95
ASTM D-2270
HI = Houghton Ibrica test
1201
La informacin contenida en esta Noticia Tcnica es, en lo que respecta a nuestros conocimientos, correcta. Dado que el uso final del producto est fuera de nuestra
supervisin, no nos hacemos responsables de su empleo indebido. Los valores aqu presentes son datos promedios y cualquier diferencia es debida al margen de
especificacin propio del proceso de fabricacin.
HOUGHTON IBERICA, S.A.

P.I. Can Salvatella - Avda. Arraona, 73-79
08210 Barber del Valls BARCELONA
Tel. +34 93 718 85 00
Fax +34 93 718 93 00
info@houghton-ib.com
HI
DRAWINGS AND BILL OF

MATERIAL
1202
1203
Consortiums Item Code
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M5-G7-052-317
GGP-CIC-T-M5-G7-052-318
GGP-CIC-T-M2-G7-045-001
GGP-CIC-T-M5-G7-052-287
GGP-CIC-T-M4-G7-052-008
Main Item: GGP-CIC-T-M1-G7-052-001r03

1
GGP-CIC-T-M4-G7-052-007
Item
Project: GOL-E-GOHAR
TAIM-TFG S.A.
1204
657077000
616076100
616076600
515011700
616077300
657085900
657074000r03
TAIMs Item Code

STACKER RECLAIMER G7.052 GENERAL ASSEMBLY
ELEVATOR CONVEYOR ASSEMBLY
TRIPPER G7.051 ASSEMBLY
RAILWAY
PLATFORM STRUCTURE CONVEYOR TRANSFER
SAFETY & LIGHTING ELEMENTS
STACKER RECLAIMER G7.052 GENERAL ARRANGEMENT
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
1
Quantity
482831,00
39056,00
27079,00
90647,00
16820,00
710,00
Unit Weight
[Kg]
TOTAL:
TOTAL NET WEIGHT: 657143,00 Kg
LOCAL
LOCAL-TAIM
LOCAL-TAIM
LOCAL-TAIM
LOCAL-TAIM
LOCAL-TAIM
Nr.
Supplier
Unit
Sheet:
1205
2
3
4
5
6
7
8
9
10
11
GGP-CIC-T-M5-G7-052-251
GGP-CIC-T-M5-G7-052-251
GGP-CIC-T-M5-G7-052-251
GGP-CIC-T-M5-G7-052-250
GGP-CIC-T-M2-G7-052-004
GGP-CIC-T-M2-G7-052-002
GGP-CIC-T-M5-G7-052-275
GGP-CIC-T-M2-G7-052-002

1
GGP-CIC-T-M5-G7-052-274
Item
TAIM-TFG S.A.
1206
STACKER RECLAIMER G7.052-RAILWAY

HYDRAULIC END BUFFER
HYDRAULIC END BUFFER
ANCHORING BOLT M36-4
RAILWAY UIC-60
FASTENER GANTREX 41/125/BR
RAILWAY & CONVEYOR SLEEPER
RAILWAY SLEEPER W/ PLATE
RAILWAY SLEEPER WO/ PLATE
L-BEAM
PIT FOR VOLTAGE FEED
RAIL SUPPORT PLATE
TAIMs Item
Code
515011700r03
515012710
515012720
657082910
018004006000
606006367200
515012510
515012520
515012530
515012600
515012300
657082930
Description
BILL OF MATERIAL
12000
Length
[mm.]
Width
[mm.]
2
4
48
81
3220
161
161
1280
161
1
1602
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM/LOCAL
TAIM/LOCAL
Nr.
Supplier
Unit
Sheet:
90647 Kg
335
310
9
724
0,67
0
0
0
77
350
9
Unit Weight
[Kg]
1207
1208
2
3
4
5
6
GGP-CIC-T-M5-G7-052-243
GGP-CIC-T-M5-G7-052-243
GGP-CIC-T-M5-G7-052-243
GGP-CIC-T-M5-G7-052-243
Main Item: GGP-CIC-T-M2-G7-045-004

1
GGP-CIC-T-M5-G7-052-243
Item
TAIM-TFG S.A.
515012401
515012402
515012403
515012404
515012405
TRADE
515012300r01
TAIMs Item Code

UPPER FRAME
COVER 1300*1015
SUPPORT L=900
LADDER H=1910
GRATING FLOOR 30*30/30*3 457*457
BOLT HILTI HSA-M10*90
PIT FOR VOLTAGE FEED
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
8
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
350,00 Kg
203
85
37
15
6
Unit Weight
[Kg]
1209
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Main Item:
1
Item
Project:
TAIMs Item Code
5.150.127.10
5.150.127.11
C01574737011
TRADE
TRADE
GGP-CIC-T-M5-G7-052-274
GGP-CIC-T-M5-G7-052-270
GOL-E-GOHAR
TAIM-TFG S.A.
1210
Quantity
TOTAL:
TOTAL NET WEIGHT:
2
LOCAL
TAIM
LOCAL
LOCAL
Nr.
Supplier
Unit
1
1
4
4
Width
[mm.]
HYDRAULIC BUFFER ASSEMBLY
Length
[mm.]
Sheet:
BUFFER SUPPORT WITH LUG

HYDRAULIC BUFFER OLEO MFZ-140-15
SCREW M24x60 DIN933 QUALITY 8.8 Zn
SPRING WASHER 24 DIN127 Zn
Description
BILL OF MATERIAL
335,00 Kg
285
50
Total Weight
[Kg]
1211
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Main Item:
1
Item
Project:
TAIMs Item Code
5.150.127.20
5.150.127.21
C01574737011
TRADE
TRADE
GGP-CIC-T-M5-G7-052-275
GGP-CIC-T-M5-G7-052-270
GOL-E-GOHAR
TAIM-TFG S.A.
1212
Quantity
TOTAL:
TOTAL NET WEIGHT:
4
LOCAL
TAIM
LOCAL
LOCAL
Nr.
Supplier
Unit
1
1
4
4
Width
[mm.]
HYDRAULIC BUFFER ASSEMBLY
Length
[mm.]
Sheet:
BUFFER SUPPORT
HYDRAULIC BUFFER OLEO MFZ-140-15
SCREW M24x60 DIN933 QUALITY 8.8 Zn
Description
BILL OF MATERIAL
310,00 Kg
260
50
Total Weight
[Kg]
1213
2
3
4
5
6
7
8
9
10
11
12
GGP-CIC-T-M5-G7-052-306
GGP-CIC-T-M5-G7-052-241
GGP-CIC-T-M5-G7-052-148
GGP-CIC-T-M4-G7-052-308
GGP-CIC-T-M5-G7-052-292
GGP-CIC-T-M5-G7-052-284
GGP-CIC-T-M5-G7-052-320
GGP-CIC-T-M5-G7-052-283
GGP-CIC-T-M5-G7-052-287
GGP-CIC-T-M4-G7-052-005
Main Item GGP-CIC-T-M4-G7-052-007r02

1
GGP-CIC-T-M4-G7-052-256
Item
TAIM-TFG S.A.
1214
657086400
657086000
657077100
657086500
476024700
657075800
616076000
657074700
657077200
657077300
657074600
657077000r02
TAIMs Item Code
POSTER ASSEMBLY
LOAD TABLE
BUCKETWHEEL ASSEMBLY
BALANCING SYSTEM
TRAVELLING MECHANISM
BASEFRAME STRUCTURE
ELECTRIC EQUIPMENT PLATFORM
SLEW FRAME
BOOM ASSEMBLY
DISCHARGE CHUTES
MAST & COUNTERWEIGHT
STACKER RECLAIMER G7.052 GENERAL ASSEMBLY
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
2
1
1
1
1
1
1
1
1
1
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
TAIM/LOCAL
TAIM/LOCAL
TAIM/LOCAL
LOCAL
LOCAL
TAIM/LOCAL
TAIM/LOCAL
TAIM/LOCAL
TAIM/LOCAL
TAIM
Nr.
Supplier
Unit
Sheet:
483601 Kg
46
8475
17358
110000
35830
53230
28500
59520
86766
3720
80110
Unit Weight
[Kg]
1215
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30

1
Item
TAIM-TFG S.A.
1216
TRAVELLING MECHANISM
PRIMERY COMPENSATION BEAM
SECONDARY COMPENSATION BEAM
UPPER JOINT SUPPORT
2 WHEEL 630 BOGIE ASSEMBLY
2 WHEEL 630 BOGIE ASSEMBLY W/STOP END
2 WHEEL 630 BOGIE ASSEMBLY W/STOP END
2 WHEEL 630 BOGIE ASS. W/STOP END & ARM
2 WHEEL 630 BOGIE ASS. W/STOP END & ARM
2 WHEEL 630 BOGIE ASS. W/ENCODER
HEAD PIN 90 x 467
HEAD PIN 140 x 642
HEAD PIN 170 x 862
FIXATION WASHER 110 x 6
SCREW DIN 933 12x30 5.6 ZN
SPRING WASHER DIN 127 12 ZN
TYPE R PIN 2 ZN
HANDLE PIN D.12x125
PIN D.80
GREASING SYSTEM
SECONDARY COMPENSATION BEAM
6.570.602.00
6.570.785.90
6.570.609.00
6.570.793.00
6.570.783.00
6.570.781.91
6.570.794.00
6.570.781.90
6.570.782.90
6.570.782.91
6.570.765.00
6.570.784.00
0.178.091.14
0.178.091.15
0.178.091.16
0.110.001.42
0.110.001.63
0.110.001.75
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
0.684.012.02
0.178.041.18
C01574737009
6.570.785.91
Description
476024700 r01
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
4
2
4
2
2
1
2
1
1
1
1
1
12
4
4
12
4
4
24
8
8
24
8
8
2
2
2
4
2
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
35193 Kg
0,1
7
10
2125
840
2125
655
1590
1525
1675
1590
1675
1810
1810
1525
1525
23
77
153
0,6
2,4
4,1
Unit Weight
[Kg]
1217
Date:31/01/07[09:16]LISTADOESTRUCTURAMANTENIMENTOPage
TAIM-TFG S.A.Conversion.
Project : 74737
Status : Active
PLANTA DE PELETIZACIN 4Mt/AO

: C202525
Manufactured Item
: 000657079300
JOINT BALANCE BEAM 2 WHEELS
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
10
13
14
15
17
26
27
28
29
30
31
32
33
34
35
36
37
000657056500
000657056600
000657057390
000657053100
000657050900
000476803800
C01874737031
000422849300
683601500035
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120508015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
278702504512
C01874737027
Net weight:
630 DRIVE WHEEL ASSEMBLY

630 IDLER WHEEL ASSEMBLY
BALANCE BEAM 2 WHEELS 630
RAIL CLEANER SUPPORT
RAIL CLEANER
GEARBOX CV IV-200 H0 I-138.2
MOTOR_TRAVEL_DRIVE 7,5Kw
FIXING PLATE
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SPLIT PIN D94 5x 40 ZN
WASHER D125 25 140HV ZN
SPRING WASHER D127 12 ZN
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 80 8.8 ZN
HEXAG. NUT D934 M20 8 ZN
SCREW D931 24x100 8.8 ZN
FIXING WASHER D.120x8
SCREW D933 12x 40 5.6 ZN
INNER RING 25/ 34x 12
D.200 PULLEY BRAKE SYSTEM
GOL-E-GOHAR IRON ORE COMPANY
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,003
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1591,000
1218
1219
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078300
Description
L.
Pos. Item
1
2
3
4
5
6
8
9
10
14
15
23
24
25
26
27
28
29
30
31
32
34
000657056500
000657056600
000657057390
C00174737047
000476803800
C01874737031
000422849300
683601500035
278702504512
281512000005
282025000005
260218505015
281518000005
260120508015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
C01874737027
Net weight:

630/800/120 WEDGE BRAKE
FIXING PLATE
45 15 RUBBER PLATE
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 80 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,003
1,000
12,000
1,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
Un.
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1525,600
1220
1221
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078191
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
10
11
14
15
16
18
27
28
29
30
31
32
33
34
35
36
37
40
000657056500
000657056600
000657057391
000657053100
000657050900
000476803800
C01874737031
000422849300
683601500035
278702504512
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120509015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
000657086720
C01874737027
Net weight:

RAIL CLEANER
FIXING PLATE
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 90 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
BALANCE BEAM WITH BUFFER
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,003
1,000
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1672,905
1222
1223
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657079400
Description
L.
Pos. Item
1
2
3
4
5
6
7
8
10
13
14
15
17
26
27
28
29
30
31
32
33
34
35
37
000657056500
000657056600
000657057391
000657053100
000657050900
000476803800
C01874737031
278702504512
683601500035
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120508015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
C01874737027
Net weight:

RAIL CLEANER
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 80 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
0,003
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1590,000
1224
1225
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078190
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
10
11
14
15
16
18
27
28
29
30
31
32
33
34
35
36
37
40
000657056500
000657056600
000657057390
000657053100
000657050900
000476803800
C01874737031
000422849300
683601500035
278702504512
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120509015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
000657086720
C01874737027
Net weight:

RAIL CLEANER
FIXING PLATE
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 90 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
BALANCE BEAM WITH BUFFER
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,003
1,000
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1672,905
1226
1227
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078290
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
10
14
15
16
18
27
28
29
30
31
32
33
34
35
36
37
40
000657056500
000657056600
000657057391
000657053100
000657050900
000476803800
C01874737031
278702504512
683601500035
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120509015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
000657086710
C01874737027
Net weight:

RAIL CLEANER
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 90 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
BUFFER BALANCE BEAM
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
0,003
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1807,749
1228
1229
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078291
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
10
11
14
15
16
18
27
28
29
30
31
32
33
34
35
36
37
40
000657056500
000657056600
000657057390
000657053100
000657050900
000476803800
C01874737031
000422849300
683601500035
278702504512
305125555014
300605004005
282025000005
281512000005
260218505015
281518000005
260120509015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
000657086710
C01874737027
Net weight:

RAIL CLEANER
FIXING PLATE
45 15 RUBBER PLATE
BOLT B25 h11/5,5x550 F-1140
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 90 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
BUFFER BALANCE BEAM
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,003
1,000
1,000
2,000
3,000
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
1807,905
1230
1231
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657076500
Description
L.
Pos. Item
1
2
3
4
5
6
8
9
14
23
24
25
26
27
28
29
30
31
32
33
34
000657056500
000657076600
000657057391
C00174737047
000476803800
C01874737031
278702504512
683601500035
281512000005
260218505015
281518000005
260120508015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
282025000005
C01874737027
Net weight:

630 IDLER WHEEL WITH ENCODER
45 15 RUBBER PLATE
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 80 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
0,003
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
1525,000
1232
1233
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657078400
Description
L.
Pos. Item
1
2
3
4
5
6
8
9
14
23
24
25
26
27
28
29
30
31
32
33
34
000657056500
000657056600
000657057391
C00174737047
000476803800
C01874737031
278702504512
683601500035
281512000005
260218505015
281518000005
260120508015
281520000005
266620500015
260124610015
281524000005
266624600015
000011000147
260212304005
282025000005
C01874737027
Net weight:

45 15 RUBBER PLATE
SCREW D933 18x 50 8.8 ZN
SCREW D931 20x 80 8.8 ZN
SCREW D931 24x100 8.8 ZN
SCREW D933 12x 40 5.6 ZN
W.
50
NoUn
50
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
0,003
12,000
16,000
16,000
6,000
6,000
6,000
1,000
1,000
1,000
1,000
12,000
1,000
1,000
Un.
un
un
un
un
un
un
un
m2
un
un
un
un
un
un
un
un
un
un
un
un
un
1525,000
1234
1235
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000476803800
Description
L.
Pos. Item
1
2
3
4
5
6
7
8
9
12
13
14
15
16
17
21
22
23
24
26
27
30
31
34
35
36
37
38
39
41
43
44
45
46
47
49
52
56
57
58
59
61
62
63
64
65
66
90
95
000416815800
000140105700
000414904000
000415104600
000423301600
000414609500
000413000902
000413201603
000140315700
000417315400
000084503850
000084504253
000084336752
000417317400
000417407800
000010911003
278706007012
000410289100
278704004517
493635508089
493603008000
214001008000
215001008000
053000800700
053001400900
053001801100
053002501400
380003047010
380012050310
210031309000
210022212020
210006024000
210022209020
210003308000
210022206020
484062504400
499802129240
260208102005
260210203005
260212303505
281508000005
281510000005
281512000005
483501516000
278704505008
493603004000
499801320140
942201000100
359004505500
Net weight:
HOUSING G. CV-IV200 H0 i=138,2

GEAR GROUP i=39/14
AXIS PINION M-3,5 Z-16
AXIS PINION M-4,5 Z-17
HOLLOW AXIS
AXIS PINION M-2 Z-19
TEETHED WHEEL M-3,5 Z-63
TEETHED WHEEL M-4,5 Z-69
TEETHED WHEEL M-2 Z-59
CLOSING CAP CA 90
CLOSING CAP CL 100
CLOSING CAP CL 110 XY-64
CLOSING CAP RN 180 / 123
CLOSING CAP RN 62 / 32
INSPECTION CAP
INNER RING 45 / 60 x 6
SEPARATION RING
MAGNETIC PLUG TMA 1/2" BSP
STEEL EXAG PLUG 1/2" BSP
LOCK NUT DIN 981 KM 8
LOCK WASHER DIN 5406 MB 8
BRIGHT KEY DIN 6880 8 x 7
SEAL TYPE A 30x 47x 7 E NBR
SEAL TYPE A 120x150x12 E NBR
BEARING 31309
BEARING
22212 E
BEARING
6024
BEARING
22209 E
BEARING 3308 A
BEARING
22206 E
PLUG 1/4"BSP UC-SAB-1563-40
METAL RUBBER SEAL 21 x29x2
SCREW D933 8x 20 5.6 ZN
SCREW D933 10x 30 5.6 ZN
SCREW D933 12x 35 5.6 ZN
LEVEL VIEWER VR-103 1" BSP
INT. BUSHING 45/ 55 x 8
STEEL EXAG PLUG 1/4" BSP
METAL RUBBER SEAL 13.5x20x1.5
OIL CEPSA HP-320
GEARBOX FEATURE "I" 9.070.414
W.
40
24
50
85
NoUn
1
1
1
1
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
2,000
2,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
1,000
0,040
0,024
0,050
0,085
1,000
2,000
2,000
2,000
2,000
1,000
1,000
2,000
1,000
2,000
8,000
20,000
8,000
8,000
20,000
8,000
1,000
1,000
1,000
2,000
18,000
1,000
Un.
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
m
m
m
m
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
l
un
303,000
1236
1237
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657056500
Pos. Item
1
2
3
4
5
6
7
8
9
10
000657058600
000657056800
210022224020
219022224005
000657056900
000657057000
000657057200
490104410000
053003602000
053002501400
Net weight:
Description
D. 630 WHEEL
DRIVE WHEEL SHAFT
BEARING 22224 E
22224 AV NILOS RING
BEARING SUPPORT
BEARING SUPPORT
INNER RING 125/152x11,5
OILER TECALEMIT M10-1
L.
150
65
W.
NoUn
1
2
Quantity
1,000
1,000
2,000
2,000
1,000
1,000
1,000
2,000
0,150
0,130
Un.
un
un
un
un
un
un
un
un
m
m
411,490
1238
1239
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657056600
Pos. Item
1
2
3
4
5
6
7
000657058600
000657057100
210022224020
219022224005
000657057000
000657057200
490104410000
Net weight:
Description
D. 630 WHEEL
IDLER WHEEL SHAFT
BEARING 22224 E
22224 AV NILOS RING
BEARING SUPPORT
L.
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
1,000
2,000
Un.
un
un
un
un
un
un
un
382,910
1240
1241
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657076600
630 IDLER WHEEL WITH ENCODER
Description
L.
Pos. Item
1
2
3
4
5
6
7
8
9
10
000657058600
000657076700
210022224020
219022224005
000657057000
000657076800
000657057200
490104410000
000657076900
300105002400
Net weight:
D. 630 WHEEL
IDLER WHEEL SHAFT
BEARING 22224 E
22224 AV NILOS RING
BEARING SUPPORT
BEARING SUPPORT
10 ENCODER SHAFT
STRAIGHT PIN D1481 5x 24
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
1,000
1,000
1,000
2,000
1,000
1,000
Un.
un
un
un
un
un
un
un
un
un
un
382,930
1242
1243
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
GGP-CIC-T-M5-G7-052-280

1
Item
TAIM-TFG S.A.
1244
657076110
657076210
657076220
657076310
657076320
657084900
657078001
657078002
657078003
657085700
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
657075800r00
TAIMs Item Code

CENTRAL FRAME
OUTER FRAME #1
OUTER FRAME #3
OUTER FRAME #2
OUTER FRAME #4
CABLE CHAIN TRAY
SLIDING FLOOR PLATE #1
ACCESSES
SCREW D7991 12x20 8,8 zn
SCREW D6914 20x95 10,9 S/REC
SCREW D6914 24x95 10,9 S/REC
NUT D6915 M-20 10 S/REC.
NUT D6915 M-24 10 S/REC.
FLAT WASHER D6916 21 S/REC.
FLAT WASHER D6916 25 S/REC.
BASEFRAME STRUCTURE ASSEMBLY
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
1
9
1
10
1
70
216
448
216
448
432
896
Quantity
17000
7000
7193
8174
8174
260
2,1
2
0,5
5400
Unit Weight
[Kg]
TOTAL:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
1245
616080210
616080220
502093010
502093015
502093020
502093025
502093030
502093040
502093050
502093060
502093070
502093080
502093090
616077602
616077701
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
GGP-CIC-T-M5-G7-052-098
GGP-CIC-T-M5-G7-052-098
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-200
GGP-CIC-T-M5-G7-052-061
GGP-CIC-T-M5-G7-052-062
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
UPPER GRATING
LOWER GRATING
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
PLATFORM HANDRAIL
BOLT
PLATE
SCREW D933 12x40 5,6 Zn
SCREW D931 12x80 8.8 ZN
SCREW D931 20x100 8.8 ZN
NUT D934 M-12 8 ZN
NUT D934 M-20 8 ZN
SCREW D6914 20x80 10,9
NUT D6915 M20 10
FLAT WASHER D6916 21
CONTROL REEL
PLATFORM STRUCTURE
ELECTRIC ROOM
DRIVE HEAD PLATFORM
POWER REEL
C01874737006
GGP-CIC-T-M5-G7-052-089
ELECTRIC EQUIPMENT PLATFORM ASSEMBLY
616077100
475010200
616079600
C01874737004
Description
BILL OF MATERIAL
616076000 r02
TAIMs Item Code
2
3
4

1
GGP-CIC-T-M5-G7-052-093
Item
TAIM-TFG S.A.
1246
Length
[mm.]
Width
[mm.]
1
1
5
1
1
1
1
1
1
1
1
1
1
2
2
4
8
8
8
8
12
8
24
24
48
1
1
1
1
Quantity
525
2328
32
17
23
12
16
32
17
19
18
44
43
16
1
530
17760
4700
1471
755
Unit Weight
[Kg]
TOTAL:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
TAIM
LOCAL
TAIM
Nr.
Supplier
Unit
Sheet:
1247
1
2
3
4
5
6
7
8
9
10
11
12
13
50
51
52
53
54
55
56
57
58
59
GGP-CIC-T-M5-G7-052-097
GGP-CIC-T-M4-G7-052-003
GGP-CIC-T-M4-G7-052-001
GGP-CIC-T-M4-G7-052-004
GGP-CIC-T-M5-G7-052-302
GGP-CIC-T-M5-G7-052-321
Item
TAIM-TFG S.A.
1248
6.570.749.00
6.570.834.00
9.070.463.00
0.110.001.70
6.570.820.00
6.570.821.00
6.570.751.00
6.570.750.90
6.570.750.91
6.570.748.00
6.570.836.00
6.160.801.00
0.681.001.16
6.570.747.00 r00
TAIMs Item Code

ASSEMBLY OF ACCESSES TO SLEW FRAME
BOOM LUFFING HYDRAULIC SYSTEM
SLEW RING GREASING SYSTEM
RETAINING PLATE
SHAFT 180/160 x 363
BUSH 160/180 x 88
ASSEMBLY OF SLEW MECHANISM
BOOM SUPPORT STRUCTURE
BOOM SUPPORT STRUCTURE
ASSEMBLY OF SLEW FRAME STRUCTURE
ANTI -CYCLONIC ANCHORAGE SYSTEM
CABLE CHAIN ARM
RETAINING PLATE
SCREW M24x110 DIN6914 QUALITY 10,9 BLACK
FLAT WASHER 25 DIN6916 BLACK
HEX. NUT M24 DIN6915 QUALITY 10 BLACK
SCREW M16x45 DIN933 QUALITY 8,8 Zn
HEX. NUT M16 DIN934 QUALITY 8 Zn
ASSEMBLY OF SLEW FRAME
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
Nr.
Unit
1
1
1
4
4
4
1
1
1
1
2
1
4
75
150
75
4
4
8
4
4
4
4
Quantity
1720
4865
70
2
63
4
11910
2566
2566
35260
106
11
0,1
Unit Weight
[Kg]
TOTAL:
TRADE
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
LOCAL
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM/LOCAL
TAIM/LOCAL
TAIM/LOCAL
Supplier
Sheet:
1249
1250
1
2
3
4
5
6
7
8
9
10
11
Item
TAIM-TFG S.A.
1251
C01574737010
6.570.855.01
6.570.855.02
9.070.463.00 r00
TAIMs Item Code

PUMP SUPPORT
SUPPORT FOR PRIMING PINION
FLAT WASHER 13 DIN125 Zn
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
Nr.
Unit
1
3
3
6
6
6
6
6
6
6
6
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
TAIM-TFG
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Supplier
Sheet:
100,00 Kg
36
1
10
Unit Weight
[Kg]
1252
2
3
4
10
11
12
13
14
15
16
17
18
19

1
GGP-CIC-T-M4-G7-052-002
Item
TAIM-TFG S.A.
1253
657080500
C0074737001
657042000
908067000
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
657075100 r00
TAIMs Item Code

SLEW DRIVE UNIT
SLEW RING
RUBBER FIXATION PLATE
RUBBER CURTAIN
SCREW D931 20x80 12,9 Zn
SCREW D931 24x250 12,9 Zn
SCREW D931 24x270 12,9 Zn
NUT D934 M-20 10 ZN
NUT D934 M-24 12 ZN
FLAT WASHER D6916 21 S/REC
NUT D934 M-12 5 ZN
FLAT WASHER D125 13 ZN
ASSEMBLY OF SLEW MECHANISM
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
3
1
9
4
38
95
95
38
190
76
380
44
44
44
Quantity
1
1
2425
4250
5
26
Unit Weight
[Kg]
TOTAL:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
1254
10
11
12
13
14
15
16
17
18
21
22
23
24
25

9
Item
TAIM-TFG S.A.
1255
SLEW DRIVE UNIT

HOUSING SLEEVE
HOUSING AXLE
HOUSING BEARING COVER
HOUSING PINION
PINION COVER
TYPE "A" RETAINER 165*200*15 NBR
BEARING 24132 K
TYPE "A" RETAINER 160*190*15 NBR
CIRCLIP D471 E-160
SCREW D912 14x150 12,9 zn
SCREW D912 10x25 8,8 zn
SCREW D7991 14x30 8,8 zn
BOOM SLEWING GEARBOX
SLEWING MOTOR 7,5 Kw 1000 rpm
657080600
657080800
657054100
657081000
657054200
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
C00174737049
C01874737032
Description
657080500r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
1
1
1
1
35
8
3
35
1
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
2425,00 Kg
1291
350
8
153
3
0,2
20,5
0,1
0,1
0,1
0,1
0,1
0,1
500
91
Unit Weight
[Kg]
1256
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
19
23
24
25
30
31
32
33

1
Item
TAIM-TFG S.A.
1257
ASSEMBLY OF SLEW FRAME

LEFT SIDE FRAME
RIGHT SIDE FRAME
WINDOW COVER
JOINT PLATE L=1200
JOINT PLATE L=1300
JOINT PLATE L=200
JOINT PLATE L=700
JOINT PLATE L=100
JOINT PLATE L=1680
JOINT PLATE L=1100
JOINT PLATE L=1330
JOINT PLATE L=1200
JOINT PLATE L=1200
JOINT PLATE L=140
SCREW D6914 24x95 10,9 S/REC
NUT D6915 M-24 10 S/REC
SCREW D933 12x40 5,6 Zn
NUT D934 M-12 5 ZN
FLOOR BEAM #1
FLOOR BEAM #2
FLOOR BEAM #3
FLOOR BEAM #4
657075601
657075602
657075700
657035801
657035802
657035803
657035804
657035805
657035806
657035807
657035808
657035809
657035810
657035811
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
657081201
657081202
657081301
657081302
Description
657074800 r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
2
4
1
2
3
3
1
4
1
2
2
2
380
380
760
32
32
24
1
1
1
1
Quantity
52
52
38
38
17000
16530
19
75
82
13
44
6
106
69
84
46
45
5
Unit Weight
[Kg]
TOTAL:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
1258
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657083600
ANCHORAGE MECHANISM ASSEMBLY
Description
L.
Pos. Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
000657083620
C00074737039
C00074737040
032005000011
032005000011
051014002005
282021000005
266630700015
300604003200
300106004000
053000800700
260216406005
281516000005
266616400005
Net weight:
ANCHORAGE BEAM
HANDLEBAR
SCREWED PIN
SQUARE DIN 178 F-1110 50
SQUARE DIN 178 F-1110 50
ROLLED FLAT S275JR 140 x 20
SPLIT PIN 4x 32
STRAIGHT PIN D1481 6x 40
SCREW D933 16x 60 5.6 ZN
W.
NoUn
128
140
140
1
1
2
25
Quantity
1,000
1,000
1,000
0,128
0,140
0,280
2,000
1,000
1,000
1,000
0,025
8,000
8,000
8,000
Un.
un
un
un
m
m
m
un
un
un
un
m
un
un
un
106,000
1259
1260
657077200r00
GGP-CIC-T-M5-G7-052-283
GGP-CIC-T-M4-G7-052-045
GGP-CIC-T-M5-G7-052-149
GGP-CIC-T-M5-G7-052-051
GGP-CIC-T-M5-G7-052-170
GGP-CIC-T-M5-G7-052-277
GGP-CIC-T-M5-G7-052-100
GGP-CIC-T-M5-G7-052-273
Main Item
1
2
3
4
5
6
7
657077500
217701200
657077600
657083300
657049500
657077700
657077900
TAIMs Item Code
Item
TAIM-TFG S.A.
1261
BOOM ASSEMBLY
BOOM STRUCTURE
BOOM BELT CONVEYOR
ACCESSES & WALKWAYS
ANTICOLISSION ELEMENTS
KNUCKLE JOINT
CONTROL CABIN
HYDRAULIC BALANCING SYSTEM
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
2
1
1
Quantity
58750
19996
3475
110
250
3900
35
Unit Weight
[Kg]
TOTAL:
TAIM/LOCAL
TAIM/LOCAL
TAIM/LOCAL
LOCAL
LOCAL
TAIM/LOCAL
TAIM/LOCAL
Nr.
Supplier
Unit
Sheet:
1262
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M5-G7-052-033
GGP-CIC-T-M5-G7-052-033
GGP-CIC-T-M5-G7-052-033
GGP-CIC-T-M5-G7-052-011
GGP-CIC-T-M5-G7-052-012
GGP-CIC-T-M5-G7-052-013
GGP-CIC-T-M5-G7-052-046
GGP-CIC-T-M5-G7-052-030

1
GGP-CIC-T-M5-G7-052-010
Item
TAIM-TFG S.A.
1263
657079500
657079600
657079700
657079800
657077800
657079680
657079900
657080001
657080002
657080003
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
657077500r01
TAIMs Item Code

BOOM STRUCTURE
FRONT FRAME
INTERMEDIATE FRAME
JOINT FRONT FRAME
REAR FRAME
BOOM JOINT
BRACING ANGLE
TORQUE ARM
JOINT PLATE
JOINT PLATE
JOINT PLATE
SCREW D6914 24x80 10,9 S/REC
NUT D6915 M24 10 S/REC
NUT D934 M20 8 ZN
SCREW D933 20x60 8.8 ZN
SCREW D6914 20x75 10,9 S/REC
NUT D6915 M20 10 S/REC
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
2
4
1
8
8
16
416
832
416
24
24
24
32
16
16
Quantity
15028
7244
7796,0
26335
225
77
298
55
52
22
Unit Weight
[Kg]
TOTAL:
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
1264
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
GGP-CIC-T-M5-G7-052-152
GGP-CIC-T-M4-0-000-048
GGP-CIC-T-M5-G7-052-076
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-075
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-071
GGP-CIC-T-M5-G7-052-121
GGP-CIC-T-M5-G7-052-122
GGP-CIC-T-M5-G7-052-123
GGP-CIC-T-M5-G7-052-120
GGP-CIC-T-M5-G7-052-153
GGP-CIC-T-M5-G7-052-118
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-124
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-072
GGP-CIC-T-M5-G7-052-115
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079

1
GGP-CIC-T-M5-G7-052-150
Item
TAIM-TFG S.A.
1265
657082600
657082700
270381708
657084200
657084101
657084102
657084103
657084104
657084105
657084106
657084107
657084108
657084601
657084602
657084603
657084604
657084605
657084606
289041101
289041102
289041103
289038100
657083100
289041700
657084507
657084508
289041600
657084505
657084506
573303600
289041800
657084503
657084504
217701200r00
TAIMs Item Code

DRIVE HEAD ASSEMBLY
TAKE-UP STATION ASSEMBLY
AUXILIARY PULLEY 500x1600
CONVEYOR FRAME
CONVEYOR BEAMS FRAME L= 6440
DECK PLATES L 720
DECK PLATES L 860
DECK PLATES L 878
DECK PLATES L 878
DECK PLATES L 860
DECK PLATES L 860
VAR. ANGLE 3/8 B-1400 BRNG-05 IDLER SUPPORT FRAME
BELT WINDTH 1400/30 BRNG-05 IDLER SUPPORT FRAME
BELT WINDTH 1400 BELT SCALE ASSEMBLY
IDLER SUPPOR FRAME B-1400 / 0
GUARDS
PLATES
GUARDS
PLATES
SELF-ALIGNEMENT IDLER SUPPORT
RETURN SELF-ALIGNEMENT IDLER ASSEMBLY B-1400
GUARDS
PLATES
Length
[mm.]
ST. RECLAIMER G7.052 BOOM BELT CONVEYOR ASSEMBLY
Description
BILL OF MATERIAL
Width
[mm.]
1
1
1
12
1
1
3
3
1
1
1
1
2
2
2
4
1
1
4
4
4
36
1
2
4
8
9
18
36
2
2
2
8
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM-LOCAL
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM-LOCAL
Nr.
Supplier
Unit
Sheet:
5978
3758
694
29
103
103
96
96
96
96
101
101
31
37
38
38
37
37
45
48
50
37
60
39
1
0,2
41
2
0,4
12
85
4
0,4
Unit Weight
[Kg]
1/3
53
54
55
56
57
58
59
60
61
62
63
64
65
66
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
GGP-CIC-T-M5-G7-052-078
GGP-CIC-T-M5-G7-052-078
GGP-CIC-T-M5-G7-052-077
GGP-CIC-T-M5-G7-052-077
GGP-CIC-T-M5-G7-052-077
GGP-CIC-T-M5-G7-052-154
GGP-CIC-T-M5-G7-052-064
GGP-CIC-T-M5-G7-052-063
GGP-CIC-T-M5-G7-052-073
GGP-CIC-T-M5-G7-052-173
GGP-CIC-T-M5-G7-052-074
Main Item GGP-CIC-T-M5-G7-052-149

34
Item
TAIM-TFG S.A.
1266
304
TOTAL:
TOTAL NET WEIGHT:
LOCAL
NUT D-934 M12 5 ZN
TRADE
36
105
3
24
2
4
1
1
4
3
4
2
8
44
40
8
2
1
104 m
Quantity
280
16
16
48
66
96
16
16
4
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
LOCAL
LOCAL
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
TOTAL:
Width
[mm.]
SCREW D-933 M12x35 5.6 ZN

SCREW D-931 M16x110 5.6 ZN
SCREW D-933 M24x110 5.6 ZN
IMPACT IDLER 133x530 BRNG-6305

STANDARD CARRYING IDLER 133-530 BRNG-6205
SPECIAL CARRYING IDLER 133-530 BRNG-6205
RETURN IDLER 159x800 BRNG-6205
CENTER ROLLER 70x120 BRNG-6204
SKIRTBOARD ASSEMBLY
SKIRTBOARD ASSEMBLY
DIAGONAL CLEANING SUPPORT
DIAGONAL CLEANING
SCRAPPER SUPPORT
SCRAPPER B-1400
WINDGUARD SUPPORT
WINDGUARD SUPPORT
WINDGUARD PLATES L= 1460
EMERGENCY SWITCH ROPE ASSEMBLY
BELT WIDTH 1400 EP-500/4 6+2 GRADE X
Length
[mm.]
Description
Sheet:
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
286890900
286890800
573303700
657085800
573303800
C00074737029
657084402
657084401
657084301
657084302
657084303
217701250
TRADE
217701200r00
TAIMs Item Code
BILL OF MATERIAL
11
10
10
18
30
1
444
370
1
19
2
54
6
6
6
6
3
45
1905,50
Unit Weight
[Kg]
2/3
81
82
83
68
69
70
71
72
73
74
75
76
77
78
79
80

67
Item
TAIM-TFG S.A.
1267
LOCAL
TAIM
LOCAL
TAIM
LOCAL
FLAT WASHER D-125 25 ZN

WEDGE WASHER D-434 18 ZN
TRADE
TRADE
128
4
12
154
296
20
210
32
4
20
210
32
4
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
LOCAL
TAIM
LOCAL
LOCAL
TAIM

ZN
ZN
ZN
ZN
ZN
TRADE
TRADE
TRADE
12
12
16
20
24
TAIM
LOCAL
LOCAL
TAIM
SPRING WASHER D-127

SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
ZN
ZN
ZN
ZN
Nr.
Supplier
Unit
TRADE
TRADE
TRADE
TRADE
TRADE
5
5
5
5
Width
[mm.]
NUT D-934 M12

NUT D-934 M16
NUT D-934 M20
NUT D-934 M24
Length
[mm.]
Description
TRADE
TRADE
TRADE
TRADE
217701200r00
TAIMs Item Code
BILL OF MATERIAL
20597,50 Kg
Unit Weight
[Kg]
3/3
1268
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M4-0-000-084
GGP-CIC-T-M5-G7-052-151
GGP-CIC-T-M4-0-000-040
GGP-CIC-T-M5-G7-052-080
GGP-CIC-T-M5-G7-052-081
GGP-CIC-T-M5-G7-052-081
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-079
GGP-CIC-T-M5-G7-052-082
GGP-CIC-T-M5-G7-052-083
GGP-CIC-T-M5-G7-052-081
Main Item GGP-CIC-T-M5-G7-052-150

1
GGP-CIC-T-M5-G7-052-084
Item
TAIM-TFG S.A.
1269
12
16
20
30
ZN
ZN
ZN
ZN
16
16
4
20
18
16
6
4
16
2
16
4
2
4
1
1
1
1
1
1
1
2
2
2
2
2
1
2
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
SPRING WASHER D-127

SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
TRADE
TRADE
TRADE
TRADE
ZN
ZN
ZN
ZN
LOCAL
LOCAL
LOCAL
LOCAL
5
5
5
5
NUT D-934 M12

NUT D-934 M16
NUT D-934 M20
NUT D-934 M30
TRADE
TRADE
TRADE
TRADE
657083200
270256602
217701212
270381505
657084000
657083901
657083902
657084501
657084502
657084509
657084510
657083800
657083700
657083903
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit

SCREW D-933 M16x45 5.6 N
SCREW D-933 M20x100 5.6 ZN
SCREW D-931 M30x130 5.6 ZN
Width
[mm.]
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
Length
[mm.]
LOCAL
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
DRIVE HEAD ASSEMBLY
Description
CONVEYOR FRAME
DRIVE PULEY 660
DRIVE UNIT 75 KW
DRIVE PULEY 315
DETECTOR SUPPORT
REACTION LEVER
REACTION LEVER
GUARD
PLATE
GUARD
PLATE
CHUTE SUPPORT
CHUTE
BOLT 28 X 175
657082600r00
TAIMs Item Code
BILL OF MATERIAL
1250
1120
2625
349
0,3
27
12
1,3
0,2
1,7
0,4
75
436
0,8
Unit Weight
[Kg]
1/2
1270
34
35
36
37

33
Item
TAIM-TFG S.A.
LOCAL
SPLT PIN D-94 6,3x45 ZN
TRADE
4
4
4
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
DRIVE HEAD ASSEMBLY
Width
[mm.]

Length
[mm.]
TRADE
TRADE
TRADE
Description
657082600r00
TAIMs Item Code
BILL OF MATERIAL
5977,92 Kg
Unit Weight
[Kg]
2/2
1271
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270256602
Pos. Item
1
2
3
4
5
6
7
8
11
000290022702
000289779009
272714019000
217001052860
210022228080
212003128000
216025015000
217001052810
942401000100
Net weight:
DRIVE PULLEY AB/RC B-1400 660
Description
DRIVE PULLEY SHELL B-1400 660
DRIVE SHAFT B1400 125140168
TOLLOK TLK-451 de 140 x 190
SUPPORT SN-528 ECAUCHO DK - E
BEARING 22228 EK
ADAPTER DIN 5415 H 3128
GUIDE RING FR 250/15
SUPPORT SN-528 ECAUCHO PS - E
GREASE LUBREX MOLY M-2
L.
W.
NoUn
Quantity
1,000
1,000
2,000
1,000
2,000
2,000
2,000
1,000
7,000
Un.
un
un
un
un
un
un
un
un
kg
1120,000
1272
1273
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381505
TAMBOR AUX. CL-RC 315 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
9
11
000290018203
000289778310
272910014500
217001051860
210022218080
212000318000
216016012500
022003000011
942401000100
Net weight:
IDLER PULLEY SHELL 315 B-1400

AUXILIARY SHAFT B-1400
BEARING 22218 EK
GUIDE RING FR 160/12,5
ROUND DIN 668 F-1110 30
W.
50
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
0,100
2,150
Un.
un
un
un
un
un
un
un
m
kg
348,770
1274
1275

1
Item
TAIM-TFG S.A.
1276
ASSEMBLY OF DRIVING UNIT 75 KW

GEARBOX 75 KW
MOTOR 75 KW
C00174737038
C01874737028
Description
217701212r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
2625,00 Kg
2000,00
625,00
Unit Weight
[Kg]
1277
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
GGP-CIC-T-M4-0-000-049
GGP-CIC-T-M4-0-000-048
GGP-CIC-T-M4-0-000-095

1
Item
TAIM-TFG S.A.
1278
ZN
ZN
ZN
ZN
ZN
ZN
ZN
4
42
2
12
4
4
6
4
8
32
2
2
12
4
4
1
4
1
1
1
2
1
1
2
1
1
1
1
2
2
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
NUT D-934 M10

NUT D-934 M12
NUT D-934 M16
NUT D-934 M18
NUT D-934 M20
NUT D-934 M24
NUT D-934 M42
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
5
5
5
5
5
5
5
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
SCREW D-931 M10x40

SCREW D-931 M12x35
SCREW D-933 M12x40
SCREW D-933 M12x70
SCREW D-933 M16x90
SCREW D-931 M18x70
SCREW D-933 M20x80
SCREW D-931 M24x90
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
5.6 ZN
5.6 ZN
5.6 ZN
5.6 N
5.6 ZN
5.6 ZN
5.6 ZN
5.6 ZN
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
TAKE UP STATION ASSEMBLY
Width
[mm.]
TAKE-UP FRAME
TAKE-UP PULLEY GUIDE
TAKE-UP AUXILIARY PULLEY 520x1600 LAGGERED
AUXILIARY PULLEY 504x1600 LAGGERED
TAKE-UP SCREW
SUPPORT BEAM
TAKE -UP HIDRAULYC ELEMENTS
GUARD
GUARD
GUARD
GUARD
GUARD
GUARD
BOLT 40 h11/9.0 x 150 F-1140
Length
[mm.]
657084801
657084802
270381709
270381708
270381506
032000398
657084803
C01574737005
657085001
657085002
657085003
657085004
657085005
657085006
305140915014
Description
657082700r00
TAIMs Item Code
BILL OF MATERIAL
1435
30
861
694
349
17
106
81
5
4,5
4,5
13
13
16
1,4
Unit Weight
[Kg]
1/2
35
36
37
38
39
40
41
42
43
44

34
Item
TAIM-TFG S.A.
1279
TAIM
SPLT PIN D-94 8x63 ZN
TRADE
4
4
10
4
40
18
4
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit

ZN
ZN
ZN
ZN
ZN
Width
[mm.]
TRADE
TRADE
TRADE
10
12
18
20
30
Length
[mm.]
SPRING WASHER D-127

SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
TAKE UP STATION ASSEMBLY
Description
TRADE
TRADE
TRADE
TRADE
TRADE
657082700r00
TAIMs Item Code
BILL OF MATERIAL
3757,72 Kg
Unit Weight
[Kg]
2/2
1280
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381709
TAMBOR AUX. AB-RC 520 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
11
000290018405
000289778311
272913018000
000078908002
000078908001
265208104015
490101210000
942401000100
Net weight:
AUX. SHELL AB-CR 520 B-1400

AUXILIARY SHAFTY B-1400
BEARING SUPPORT 110 DK-FREE
BEARING SUPPORT 110 DK-FIX
SET SCREW D914 8x 40 8.8 ZN
OILER HIDR. M10-1
W.
NoUn
Quantity
1,000
1,000
2,000
1,000
1,000
2,000
2,000
5,000
Un.
un
un
un
un
un
un
un
kg
861,000
1281
1282
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381708
TAMBOR AUX. AB-LS 500 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
11
000290018402
000289778311
272913018000
217001052460
210022224080
212003124000
216021514000
942401000100
Net weight:
VIROLA AUX. AB-LS 504 B-1400

AUXILIARY SHAFTY B-1400
BEARING 22224 EK
GUIDE RING FR 215 / 14
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
5,000
Un.
un
un
un
un
un
un
un
kg
694,000
1283
1284
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381506
TAMBOR AUX. CL-RC 315 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
11
000290018203
000289778310
272910014500
217001051860
210022218080
212000318000
216016012500
942401000100
Net weight:

BEARING 22218 EK
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
2,150
Un.
un
un
un
un
un
un
un
kg
348,770
1285
1286
2
3
4
5
6
7
8
9
10
11
12
13
14
GGP-CIC-T-M5-G7-052-167
GGP-CIC-T-M5-G7-052-104
GGP-CIC-T-M5-G7-052-104
GGP-CIC-T-M5-G7-052-104

1
GGP-CIC-T-M5-G7-052-104
Item
TAIM-TFG S.A.
1287
TRADE
TRADE
TRADE
TRADE
657085301
657085302
657085303
657085304
TRADE
TRADE
065100321
TRADE
TRADE
657083300r00
TAIMs Item Code

NUT D-934 M8 5 ZN
SPRING WASHER D-127 8 ZN
SUPPORT
SUPPORT
SUPPORT
SUPPORT
TENSOR 5/16"
SPRING
ROPE SUPPORT
ROPE CLAMP 5 3/16" GALVANIZED
PULL ROPE 6X7+1 2/4 PVC D-3055 80m.
BOOM ANTICOLISSION ELEMENTS ASSEMBLY
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
8
8
8
8
2
2
6
18
4
4
4
16
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
109,92 Kg
2,3
11
8
2,5
2,7
0,3
0,1
1,1
Unit Weight
[Kg]
1288
1289
2
3
4
5
6
7
8
9
10
11

1
Item
TAIM-TFG S.A.
BOOM KNUCKLE JOINT

RADIAL SPHERICAL BEARING
RADIAL BEARING SHAFT
DISTANCER RING
LOCKING RING
EXT. RING
JOINT PLATE
RETAINING PLATE
OIL SEAL A 200x230x15 N NBR
BOLT DIN-933 20x60 8,8 ZN
OILER
PIN DIN-913 16x35 8.8 ZN
211018010540
657049600
657049700
657049800
278326010060
011002206
418306703
380020030500
TRADE
490101210000
TRADE
Description
657049500r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
2
1
1
2
2
4
1
16
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
LOCAL
TAIM
LOCAL
Nr.
Supplier
Unit
Sheet:
250,00 Kg
19
180
21
6,5
7,4
7,2
0,1
0,2
Unit Weight
[Kg]
1290
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
GGP-CIC-T-M5-G7-052-282
GGP-CIC-T-M5-G7-052-099

31
GGP-CIC-T-M5-G7-052-099
Item
TAIM-TFG S.A.
1291
CONTROL CABIN ASSEMBLY

ACCESS TREAD 30/30x2 240 x 500
ACCESS TREAD 30/30x2 240 x 700
BOLT D933 12x30 8,8 ZN
BOLT D933 12x40 8,8 ZN
BOLT D933 12x50 8,8 ZN
NUT D934 M-12 8 ZN
FLAT WASHER D125 13 140 HV Zn
WEDGE WASHER D434 U-14 ZN
PIN 32 * L=134
FLAT WASHER D125 34 140 HV Zn
SPLIT PIN D94 6,3*50 Zn
657084701
657084703
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
017805534
TRADE
TRADE
Description
657077700r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
8
13
102
146
2
244
250
4
4
2
4
4
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
3900,00 Kg
5
7
Unit Weight
[Kg]
1292
1293
2
3
4
5
6
7
GGP-CIC-T-M5-G7-045-282

1
Item
TAIM-TFG S.A.
HYDRAULIC BALANCING SYSTEM FOR CONTROL CABIN

HYDRAULIC BALANCING SYSTEM ELEMENTS
PIN 32 * L=134
FLAT WASHER D125 34 140 HV ZN
SPLIT PIN DIN 94 6,3 * L=50 ZN
SCREW D933 10x30 5,6 Zn
NUT D934 M-10 5 ZN
C01574737004
017805534
TRADE
TRADE
TRADE
TRADE
TRADE
Description
657077900r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
4
8
8
4
4
4
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
29
0,8
35,00 Kg
Unit Weight
[Kg]
1294
6.570.773.00
6.570.773.01
6.570.773.02
6.570.773.03
6.570.773.04
6.570.773.05
6.570.773.06
6.570.773.07
6.570.773.08
0.927.001.18
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
GGP-CIC-T-M5-G7-052-287
GGP-CIC-T-M5-G7-052-225
GGP-CIC-T-M5-G7-052-209
GGP-CIC-T-M5-G7-052-226
GGP-CIC-T-M5-G7-052-174
GGP-CIC-T-M5-G7-052-172
GGP-CIC-T-M5-G7-052-171
GGP-CIC-T-M5-G7-052-171
GGP-CIC-T-M5-G7-052-171
GGP-CIC-T-M5-G7-052-169
Main Item:
1
2
3
4
5
6
7
8
9
50
51
52
53
54
55
56
57
58
59
60
61
TAIMs Item Code
Item
TAIM-TFG S.A.
1295
UPPER CHUTE
REMOVABLE STONE BOX
LOWER CHUTE
UPPER CHUTE
FINES CHUTE
LEVEL SWITCH SUPPORT
CHUTE RUBBER CLOSING
FIXATION PLATE
INSPECTION WINDOW 300 x 400
SCREW M10x25 DIN933 QUALIY 5.6 Zn
SPRING WASHER 10 DIN 127 Zn
HEX NUT M12 DIN 934 QUALITY 5.6 Zn
SQUARE BEVELED WASHER 18, Zn, DIN-434
HEX NUT M16 DIN 934 QUALITY 5.6 Zn
ASSEMBLY DISCHARGE CHUTES ON SLEW FRAME
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
2
1
1
2
5
5
10
13
23
46
46
20
25
45
15
45
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
3720,00 Kg
1045
430
1745
386
39
1
13
5
17
Total Weight
[Kg]
1296
2
3
4
5
6
7
8
9
10
12
13
14
15
17
18
19
20
21
22
23
26
27
28
29
30
31
32
33
34
35
36
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-008
GGP-CIC-T-M5-G7-052-004
GGP-CIC-T-M5-G7-052-004
GGP-CIC-T-M5-G7-052-014
GGP-CIC-T-M5-G7-052-005
GGP-CIC-T-M5-G7-052-006
GGP-CIC-T-M5-G7-052-006
GGP-CIC-T-M5-G7-052-015
GGP-CIC-T-M5-G7-052-016
GGP-CIC-T-M5-G7-052-002
GGP-CIC-T-M5-G7-052-003
GGP-CIC-T-M5-G7-052-009
GGP-CIC-T-M5-G7-052-009
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001
GGP-CIC-T-M5-G7-052-001

1
GGP-CIC-T-M5-G7-052-007
Item
TAIM-TFG S.A.
1297
657074200
657074500
657074401
657074402
657074403
657074100
657074301
657074302
657075900
657076000
657078700
657078600
657076410
657076420
657080902
657080906
657080901
657080905
657080903
657080904
657080907
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
657080909
657080908
TRADE
TRADE
TRADE
657074600 r01
TAIMs Item Code
MAST BRACING
COUNTERWEIGHT STAY
REAR MAST STRUCTURE
REAR MAST STRUCTURE
BRACING
COUNTERWEIGHT STRUCTURE
FRONT MAST STRUCTURE
FRONT MAST STRUCTURE
BRACING
BRACING
COMPENSATION CAM
JOINT PIECE
CABLE STAY L=35340 (BUCKETWHEEL SIDE)
CABLE STAY L=35340 (CONVEYOR SIDE)
BOLT 220
RETAINING PLATE 240
BOLT 250
RETAINING PLATE 280
BOLT 150
BOLT 150
RETAINING PLATE 180
SCREW M24x3x60 5.6 ZN DIN931
SPRING WASHER 24 ZN DIN127
SPRING WASHER 16 ZN DIN127
NUT M16x2 8 ZN DIN934
BOLT 250
BOLT 150
SCREW M24x3x90 10.9 DIN6914
FLAT WASHER 25 DIN6916
NUT M24x3 10 DIN6915
ASSEMBLY OF MAST AND COUNTERWEIGHT STRUCTURE
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
2
1
1
4
1
1
1
2
2
2
2
2
2
2
4
4
6
2
2
4
18
18
8
72
64
64
2
2
68
68
68
Quantity
278
175
3578
8962
5850
5850
536
28204
3822
3822
313
554
266
215
969
969
180
5
198
7
71
37
3
Unit Weight
[Kg]
TOTAL:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
1298
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M5-G7-052-119
GGP-CIC-T-M5-G7-052-216
GGP-CIC-T-M5-G7-052-224
GGP-CIC-T-M5-G7-052-237
GGP-CIC-T-M5-G7-052-242
GGP-CIC-T-M5-G7-052-242
GGP-CIC-T-M5-G7-052-215

1
Item
TAIM-TFG S.A.
1299
LOAD TABLE ASSEMBLY

LOAD TABLE SUPPORT
LOAD TABLE SUPPORT
CHUTE SUPPORT BEAM
DEFLECTOR SUPPORT BEAM
UPPER CHUTE
LOWER CHUTE
DEFLECTOR CHUTE
LOAD TABLE BEAM
LOAD TABLE BEAM
SKIRTBOARD ASSEMBLY
VIBRATING FEEDER
CARRYING IDLER SUPPORT
IMPACT IDLER 133x530, BRNG-6305
CARRYING IDLER 133x530, BRNG-6205
SCREW D933 12x40 5,6 Zn
SCREW D933 16x50 8,8 ZN
SCREW D933 16x60 8,8 ZN
SCREW D933 16x90 8,8 ZN
SCREW D933 20x60 5,6 Zn
SCREW D6914 20x75 10,9
NUT D934 M-12 5 ZN
NUT D934 M-16 8 ZN
NUT D934 M-20 5 ZN
NUT D6915 M-20 10
657086110
657086120
657086130
657086140
657086210
657086220
657086230
657086310
657086320
286893000
C00074737038
289041500
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
Description
657086000r00
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
1
1
1
1
1
1
1
16
30
18
52
44
4
8
36
72
52
72
36
72
32
144
52
72
36
32
56
14
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
8475,00 Kg
865
865
110
184
520
1300
435
163
163
850
2100
26
10
10
Unit Weight
[Kg]
1300
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
GGP-CIC-T-M5-G7-052-197
GGP-CIC-T-M5-G7-052-055
GGP-CIC-T-M5-G7-052-058
GGP-CIC-T-M5-G7-052-056
GGP-CIC-T-M5-G7-052-057

1
Item
TAIM-TFG S.A.
1301
657085600
657077400
107005100
657079100
657079200
573298800
573298900
657070000
657035700
068100146
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
573304800
657077100r01
TAIMs Item Code

SHAFT AND WHEEL ASSEMBLY
BUCKET 525 Ltr.
B.W. DRIVE UNIT
B.W. DEFLECTOR
B.W. GUIDE PLATE
B.W. DEFLECTOR SUPPORT
GUIDE PLATE SUPPORT
HEAD PIN
TORQUE ARM PIN
LOCKING PLATE 40x10x140
SPLIT PIN D94 10x90 ZN
SCREW D933 16x55 8,8 ZN
SCREW D933 20x55 8,8 ZN
SCREW D6914 30x160 10,9
SCREW D6914 36x200 10,9
NUT D934 M-16 8 ZN
NUT D934 M-20 8 ZN
NUT D6915 M-30 10
NUT D6915 M-36 10
ROTATION SPEED CONTROL SUPPORT
BUCKETWHEEL ASSEMBLY
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
8
1
1
1
1
1
16
1
2
16
83
16
4
4
79
16
4
4
16
16
83
16
8
8
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
17358 Kg
3,5
6.526
362
5.494
1.177
710
515
26
1
2
0,4
Unit Weight
[Kg]
1302
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000657085600
Pos. Item
1
2
3
4
5
6
7
8
9
10
11
12
13
000657078800
000657078900
000657079000
217008316410
217008314805
212003148000
212003164000
210023148060
210023164060
271535007100
260527609020
267427600020
282128000000
Net weight:
FRAME AND SHAFT ASSEMBLY
Description
*
*
*
*
*
*
*
*
*
*
*
*
*
BUCKET-WHEEL FRAME
BUCKET-WHEEL SHAFT
BUCKET-WHEEL HUB
BEARING SUPPORT SD3164 TSBF
BEARING SUPPORT SD3148 TSAL
ADAPTER DIN 5415 OH 3148 H
FIXING SLEEVE OH 3164 H
BEARING 23148 K
BEARING 23164 K
SCREW D6914 27x 90 10.9
HEXAG. NUT D6915 M27 10
L.
W.
NoUn
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
16,000
16,000
32,000
Un.
un
un
un
un
un
un
un
un
un
un
un
un
un
6526,420
1303
1304
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000107005100
Pos. Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
000657080400
000067700622
000502091900
278708007080
278708507089
C01874737029
C00174737052
C00174737048
685095912060
260208102505
260212303005
260124612015
260630734030
266608100005
266612300005
266624600005
266630700030
282008400005
282031000005
281508000005
281512000005
281524000005
283024000005
942201103200
942201000100
Net weight:
RODETE DRIVE GROUP
Description
DRIVE GROUP SUPPORT
700x700 "U" TYPE PROTECTION
DRIVE GROUP HAND RAIL
INT. BUSHING 80/ 94 x 80
INNER RING 85/ 99 x 89
MOTOR_132Kw_BUCKET WHEEL
HYDR. COUP. TRANSFLUID 21CKCG
BUCKET WHEEL GEARBOX
DAMPER 100x140x120 MN-60
SCREW D933 8x 25 5.6 ZN
SCREW D933 12x 30 5.6 ZN
SCREW D931 24x120 8.8 ZN
SCREW D912 30x340 12,9
HEXAG. NUT D934 M 8 5 ZN
HEXAG. NUT D934 M30 12
WASHER D125 8.4 140HV ZN
TAPER WASHER D434 U-24 ZN
HYDRAULIC OIL CEPSA HM-32
OIL CEPSA HP-320
L.
W.
NoUn
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
4,000
2,000
4,000
36,000
4,000
2,000
4,000
36,000
4,000
72,000
4,000
2,000
4,000
4,000
19,000
205,000
Un.
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
un
l
l
5699,000
1305
1306
1307
6.160.773.00r01
6.160.774.00
6.160.775.00
6.160.789.00
C00074737037
GGP-CIC-T-M4-G7-052-006r01
GGP-CIC-T-M5-G7-052-252
GGP-CIC-T-M5-G7-052-278
GGP-CIC-T-M5-G7-052-279
Main Item:
1
2
3
4
50
51
52
TAIMs Item Code
Item
TAIM-TFG S.A.
1308
ASSEMBLY OF PLATFORM STRUCTURE

ASSEMBLY OF ACCESSES TO PLATFORM STRUCTURE
ASSEMBLY OF DISCHARGE CHUTES
VIBRATING FEEDER
SCREW M20x65 DIN6914 QUALITY 10,9 BLACK
FLAT WASHER 21 DIN6916 BLACK
HEX. NUT M20 DIN6915 QUALITY 10 BLACK
PLATFORM STRUCTURE CONVEYOR TRANSFER
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
25
50
25
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
16820 Kg
10775
3400
1991,5
650
Unit Weight
[Kg]
1309
GGP-CIC-T-M5-G7-052-319
GGP-CIC-T-M5-G7-052-257
GGP-CIC-T-M5-G7-052-313
GGP-CIC-T-M5-G7-052-314
GGP-CIC-T-M5-G7-052-285
GGP-CIC-T-M5-G7-052-318r01
Main Item
1
2
3
4
5
6
7
8
9
10
11
Item
TAIM-TFG S.A.
1310
TRADE
TRADE
TRADE
616075900
471819600
616081300
616076622
616081400

NUT D-934 M16 5 ZN
ASSEEMBLY OF STRUCTURE
BOGIE DRIVEN WHEEL D-630 ASSEMBLY
ACCESS ASSEMBLY
TRIPPER BELT CONVEYOR ASSEMBLY
PULLEY FOR BELT LIFTING LIMITATION
TAIMs Item
Description
Code
616076600r01 TRIPPER G7.051 ASSEMBLY
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
6
6
6
1
10
1
1
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL-TAIM
LOCAL-TAIM
LOCAL
TAIM
LOCAL
Nr.
Supplier
Unit
Sheet:
27079 Kg
12525
621
3178
4876
287
Unit Weight
[Kg]
1311
2
3
4
5
6
7
8
9
50
51
52
53
54
55
56
57
58
59
60
61
62
Main Item:
1
Item
Project:
TAIMs Item Code
Description
BILL OF MATERIAL
GGP-CIC-T-M5-G7-052-179
GGP-CIC-T-M5-G7-052-180
GGP-CIC-T-M5-G7-052-181
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-059
GGP-CIC-T-M5-G7-052-061
GGP-CIC-T-M5-G7-052-062
6.160.798.00
6.160.799.00
6.160.800.00
6.160.784.10
6.160.784.20
6.160.784.30
6.160.770.00
6.160.776.03
6.160.777.02
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
UPPER SUPPORT BEAMS

INTERMEDIATE SUPPORT BEAMS
LOWER SUPPORT BEAMS
JOINT PLATES
JOINT PLATES
JOINT PLATES
GANTRY
BOLT
PLATE
SCREW D6914 24x80 10,9
SCREW D6914 24x95 10,9
SCREW D6914 24x75 10,9
SCREW D6914 20x60 10,9
SCREW D6914 16x55 10,9
SCREW D933 10x35 8,8 Zn
NUT D6915 M24 10
NUT D6915 M20 10
NUT D6915 M16 10
GGP-CIC-T-M5-G7-052-319rev00 6.160.759.00rev00 ASSEMBLY OF STRUCTURE OF TRIPPER CONVEYOR
GOL-E-GOHAR
TAIM-TFG S.A.
1312
Length
[mm.]
Width
[mm.]
1
1
1
8
8
16
1
4
4
130
10
25
90
45
10
165
330
90
180
45
90
10
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
12525,00
0,05
0,07
4.508,0
3.768,0
2.941,0
25,0
21,0
8,0
657,0
5,0
0,8
0,43
0,45
0,41
0,21
0,13
0,03
0,16
Unit Weight
[Kg]
1313
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000471819600
BALANCE BEAM ASS. DRIVE WHEEL
Description
L.
Pos. Item
1
2
3
4
5
6
7
000657056600
000474711700
000068004808
260218505015
281518000005
281514000005
266614400005
Net weight:

IDLER WHEEL CHASSIS
RAIL CLEANER PLAQUE
SCREW D933 18x 50 8.8 ZN
W.
NoUn
Quantity
1,000
1,000
2,000
8,000
8,000
4,000
4,000
Un.
un
un
un
un
un
un
un
621,370
1314
1315
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
GGP-CIC-T-M5-G7-052-315
GGP-CIC-T-M4-0-000-043
GGP-CIC-T-M5-G7-052-122
GGP-CIC-T-M5-G7-052-120
GGP-CIC-T-M5-G7-052-119
GGP-CIC-T-M5-G7-052-117
GGP-CIC-T-M5-G7-052-116
GGP-CIC-T-M5-G7-052-316
GGP-CIC-T-M5-G7-052-115

1
GGP-CIC-T-M4-0-000-052
Item
TAIM-TFG S.A.
1316
12
16
24
30
ZN
ZN
ZN
ZN
6
92
8
4
10
92
8
4
6
30
62
8
4
1
2
1
29
5
1
1
2
1
105
4
1
2
1
1
Quantity
Sheet:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
SPRING WASHER D-127

SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
TRADE
TRADE
TRADE
TRADE
ZN
ZN
ZN
ZN
LOCAL
LOCAL
LOCAL
LOCAL
5
5
5
5
NUT D-934 M12

NUT D-934 M16
NUT D-934 M24
NUT D-934 M30
TRADE
TRADE
TRADE
TRADE
270381806
270381608
289041102
289038100
289041500
289042101
289042102
616081600
289041800
TRADE
TRADE
TRADE
TRADE
C00074737028
616076650
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit

SCREW D-931 M16x100 5.6 ZN
SCREW D-931 M24x120 5.6 ZN
SCREW D-931 M30x160 5.6 ZN
Width
[mm.]
TRADE
TRADE
TRADE
TRADE
TRADE
Length
[mm.]
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
Description
SELF-ALIGNEMENT IDLER SUPPORT
RETURN SELF-ALIGNEMENT IDLER ASSEMBLY B-1400
SCRAPPER B-1400
616076622
TAIMs Item Code
BILL OF MATERIAL
977
583
48
37
26
38
40
31
85
10
18
30
1,3
54
8
Unit Weight
[Kg]
1/2
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66

34
Item
TAIM-TFG S.A.
1317
ZN
ZN
ZN
ZN
TRADE
13
17
25
31
FLAT WASHER D-125

FLAT WASHER D-125
FLAT WASHER D-125
FLAT WASHER D-125
Description
TRADE
TRADE
TRADE
TRADE
616076622
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
6
84
8
4
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
4876 Kg
Unit Weight
[Kg]
2/2
1318
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381806
TAMBOR AUX. AB-LS 630 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
11
000290018503
000289778312
272914019000
217001052860
210022228080
212003128000
216025015000
942401000100
Net weight:
PULLEY SHELL AB-LS 630 B-1400

BEARING 22228 EK
GUIDE RING FR 250/15
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
7,000
Un.
un
un
un
un
un
un
un
kg
975,000
1319
1320
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270381608
TAMBOR AUX. AB-RC 420 B-1400
Description
L.
Pos. Item
1
2
3
4
5
6
7
11
000290018306
000289778311
272913018000
217001052460
210022224080
212003124000
216021514000
942401000100
Net weight:

BEARING 22224 EK
GUIDE RING FR 215 / 14
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
5,000
Un.
un
un
un
un
un
un
un
kg
582,880
1321
1322
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
GGP-CIC-T-M5-G7-052-210

1
GGP-CIC-T-M5-G7-052-189
Item
TAIM-TFG S.A.
1323
LOCAL
LOCAL
LOCAL
LOCAL

TRADE
TRADE
TRADE
TRADE
8
4
12
4
12
4
12
4
2
22
4
4
1
32
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
NUT D-934 M8 5 ZN
NUT D-934 M12 5 ZN
TRADE
TRADE
616080620
065100317
TRADE
TRADE
TRADE
TRADE
LOCAL
LOCAL
Nr.
Supplier
Unit

Width
[mm.]
TRADE
TRADE
Length
[mm.]
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TRIPPER G7.051 - EMERGENCY SWITCH ROPE ASSEMBLY
Description
SWITCH SUPPORT
ROPE SUPPORT
TENSOR 5/16"
SPRING
PULL ROPE 6X7+1 2/4 PVC D-3055 67m.
ROPE CLAMP 5 3/16" GALVANIZED
616076650r00
TAIMs Item Code
BILL OF MATERIAL
7,75 Kg
2,40
1,76
1,20
0,40
1,94
0,05
Total Weight
[Kg]
1324
616076100r01
616076200
616076300
216907100
616080400
907047800
GGP-CIC-T-M5-G7-052-317r01
GGP-CIC-T-M5-G7-052-312
GGP-CIC-T-M5-G7-052-307
GGP-CIC-T-M5-G7-052-206
GGP-CIC-T-M5-G7-052-288
Main Item
1
2
3
4
5
TAIMs Item Code
Item
TAIM-TFG S.A.
1325
ASSEEMBLY OF STRUCTURE
ACCESS ASSEMBLY
BELT CONVEYOR ASSEMBLY
ASSY. OF DISCHARGE CHUTE
POSTER ASSEMBLY
ELEVATOR CONVEYOR ASSEMBLY
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
1
2
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
TAIM
LOCAL-TAIM
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
39056 Kg
22950
5029
10186
870
10
Unit Weight
[Kg]
1326
TAIMs Item Code
Description
BILL OF MATERIAL
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
50
51
52
53
54
55
56
57
58
59
GGP-CIC-T-M5-G7-052-095
GGP-CIC-T-M5-G7-052-096
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-193
GGP-CIC-T-M5-G7-052-085
GGP-CIC-T-M5-G7-052-086
GGP-CIC-T-M5-G7-052-086
GGP-CIC-T-M5-G7-052-086
GGP-CIC-T-M5-G7-052-087
GGP-CIC-T-M5-G7-052-087
GGP-CIC-T-M5-G7-052-087
GGP-CIC-T-M5-G7-052-087
GGP-CIC-T-M5-G7-052-054
GGP-CIC-T-M5-G7-052-053
GGP-CIC-T-M5-G7-052-052
GGP-CIC-T-M5-G7-052-061
GGP-CIC-T-M5-G7-052-062
GGP-CIC-T-M5-G7-052-061
GGP-CIC-T-M5-G7-052-062
GGP-CIC-T-M5-G7-052-194
616077900
616078000
616078410
616078420
616078430
616077210
616077220
616077230
616077240
616077250
616077260
616077270
616077280
616076800
616076700
616076400
616077601
616077701
616077603
616077702
616078300
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
INTERMEDIATE SUPPORT BEAMS

UPPER SUPPORT BEAMS
JOINT PLATES
JOINT PLATES
JOINT PLATES
SUPPORT BEAM
SUPPORT BEAM
SUPPORT BEAM
SUPPORT BEAM
BRACING BEAM
BRACING BEAM
BRACING BEAM
BRACING BEAM
GANTRY
GANTRY
GANTRY
BOLT
PLATE
BOLT
PLATE
STAIRS SUPPORT
SCREW D6914 24x80 10,9
SCREW D6914 20x60 10,9
SCREW D6914 20x75 10,9
SCREW D6914 16x50 10,9
SCREW D933 12x35 8,8 Zn
SCREW D933 10x35 8,8 Zn
NUT D6915 M24 10
NUT D6915 M20 10
Main Item: GGP-CIC-T-M5-G7-052-312rev01 6.160.762.00rev01 ASSEMBLY OF STRUCTURE OF ELEVATOR CONVEYOR

1
GGP-CIC-T-M5-G7-052-094
616077800
LOWER SUPPORT BEAMS
Item
TAIM-TFG S.A.
1327
Length
[mm.]
Width
[mm.]
1
1
1
8
8
16
1
1
1
1
1
1
1
1
1
1
1
2
2
8
8
1
135
100
30
35
5
20
255
510
143
285
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
0,07
4.223,0
5.047,0
4.742,0
25,0
21,0
8,0
2.215,0
550,0
670,0
14,0
348,0
416,0
270,0
245,0
710,0
546,0
1.790,0
9,0
1,2
5,0
0,8
404,0
0,43
0,21
0,26
0,12
0,04
0,03
0,16
Unit Weight
[Kg]
TAIMs Item Code
Description
BILL OF MATERIAL
61
62
63
64
65
TRADE
TRADE
TRADE
TRADE
TRADE

SCREW D6914 24x75 10,9
SCREW D6914 20x80 10,9
Main Item: GGP-CIC-T-M5-G7-052-312rev01 6.160.762.00rev01 ASSEMBLY OF STRUCTURE OF ELEVATOR CONVEYOR

60
TRADE
NUT D6915 M16 10
Item
TAIM-TFG S.A.
1328
Length
[mm.]
Width
[mm.]
13
120
20
70
35
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
22.950 Kg
0,41
0,27
0,05
Unit Weight
[Kg]
1329
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Main Item:
1
Item
Project:
GGP-CIC-T-M5-G7-052-195
GGP-CIC-T-M5-G7-052-195
GGP-CIC-T-M5-G7-052-196
GGP-CIC-T-M5-G7-052-289
GGP-CIC-T-M5-G7-052-208
GGP-CIC-T-M5-G7-052-192
GGP-CIC-T-M5-G7-052-191
GGP-CIC-T-M5-G7-052-183
GGP-CIC-T-M5-G7-052-191
GGP-CIC-T-M5-G7-052-183
GGP-CIC-T-M5-G7-052-185
GGP-CIC-T-M5-G7-052-207
GGP-CIC-T-M4-0-000-024
GGP-CIC-T-M4-0-000-019
GGP-CIC-T-M4-0-000-015
GGP-CIC-T-M5-G7-052-190
GGP-CIC-T-M5-G7-052-182
GGP-CIC-T-M5-G7-052-182
GGP-CIC-T-M5-G7-052-182
GGP-CIC-T-M5-G7-052-111
GGP-CIC-T-M5-G7-052-112
GGP-CIC-T-M5-G7-052-113
GGP-CIC-T-M5-G7-052-110
GGP-CIC-T-M5-G7-052-125
GGP-CIC-T-M5-G7-052-106
GGP-CIC-T-M5-G7-052-109
GGP-CIC-T-M5-G7-052-107
GGP-CIC-T-M5-G7-052-206r01
GOL-E-GOHAR
TAIM-TFG S.A.
1330
616076500
270380516
270380417
270380322
616078800
616080530
616080520
616080510
289041201
289041202
289041203
078062330
289041402
289042700
289042200
289042300
TRADE
TRADE
TRADE
TRADE
TRADE
2866891700
C00074737016
616078210
616078220
616078100
616081500
616907150
616078500
616078730
616078610
616078720
616078660
DRIVE HEAD AND TAKE-UP STATION ASSY

BEND PULLEY SUPPORT
DECK PLATES L 1040
DECK PLATES L 1060
DECK PLATES L 660
CARRYNG SELF-ALIGNEMENT IDLER BELT WIDTH 1000 BRNG-04
RETURN IDLER SUPPORT BELT WIDTH 1000-0 BRNG-04
RETURN SELF-ALIGNEMENT IDLER BELT WIDTH 1000 BRNG-04
IMPACT IDLER 133x380 BRNG-6205
BELT WIDTH 1000 EP-500/4 6+2 GRADE X
SKIRTBOARD ASSEMBLY
SCRAPPER B-1000
SUPPORT BEAMS
SUPPORT BEAMS
WEAR PLATES
DETECTOR SUPPORT
TAIL PULEY GUARD
DECK PLATE SUPPORT
DECK PLATE
DECK PLATE SUPPORT
DECK PLATE
TAIMs Item
Description
Code
216907100r01 BELT CONVEYOR ASSENBLY
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
2
4
1
1
1
2
2
2
36
1
1
12
1
18
114
13
4
110 m.
1
1
1
1
1
1
1
1
2
1
8
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
TAIM
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
3658
480
335
212
12
35
35
23
25
25
26
19
24
67
16
56
8
7
19
1,3
1430
327
40
63
60
343
0,3
12
27
0,4
103
0,6
44
Unit Weight
[Kg]
1/2
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
GGP-CIC-T-M5-G7-052-183
GGP-CIC-T-M5-G7-052-183
GGP-CIC-T-M5-G7-052-183
GGP-CIC-T-M5-G7-052-183

34
GGP-CIC-T-M5-G7-052-191
Item
TAIM-TFG S.A.
1331
125
14
4
8
4
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL

TRADE
TRADE
TRADE
TRADE
TRADE
TOTAL:
TOTAL NET WEIGHT:
220
38
50
4
LOCAL
LOCAL
LOCAL
LOCAL
ZN
ZN
ZN
ZN
SPRING WASHER D-127

SPRING WASHER D-127
SPRING WASHER D-127
SPRING WASHER D-127
TRADE
TRADE
TRADE
TRADE
12
16
20
24
225
38
50
4
LOCAL
LOCAL
LOCAL
LOCAL
ZN
ZN
ZN
ZN
NUT D-934 M12

NUT D-934 M16
NUT D-934 M20
NUT D-934 M24
TRADE
TRADE
TRADE
TRADE
5
5
5
5
40
85
90
20
18
38
8
4
4
616078720
616078630
616078620
616078650
616078640
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
12
1
1
4
1
Quantity

SCREW D-931 M20x100 5.6 ZN
SCREW D-931 M24x110 5.6 ZN
Nr.
Supplier
Unit
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
Width
[mm.]
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Length
[mm.]
Sheet:
DECK PLATE SUPPORT

DECK PLATE
DECK PLATE
DECK PLATE
DECK PLATE
TAIMs Item
Description
Code
216907100r01 BELT CONVEYOR ASSEMBLY
BILL OF MATERIAL
10186 Kg
1,3
62
53
45
39
Unit Weight
[Kg]
2/2
1332
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M5-G7-052-276
GGP-CIC-T-M4-0-000-079
GGP-CIC-T-M4-0-000-018

1
Item
TAIM-TFG S.A.
1333
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
NUT D-934 M10

NUT D-934 M12
NUT D-934 M16
NUT D-934 M18
NUT D-934 M24
NUT D-934 M30
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
4
16
4
16
8
12
4
6
4
16
8
12
4
1
2
1
1
1
2
2
1
1
1
2
2
1
1
Quantity
Sheet:
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM

SCREW D-931 M24x120 5.6 ZN
TRADE
TRADE
TRADE
TRADE
TRADE
ZN
ZN
ZN
ZN
ZN
ZN
TAIM
TAIM
BOLT 28 h11/7.0 x 175 F-1140

BOLT 40 h11/9.0 x 150 F-1140
305128717514
305140915014
5
5
5
5
5
5
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
TAIM
Nr.
Supplier
Unit
Width
[mm.]
TAKE-UP FRAME
DRIVE PULLEY ASSEMBLY 530x1500 LAGGERED
TAKE-UP PULLEY GUIDE
TAKE -UP SCREW
TAKE -UP HIDRAULYC ELEMENTS
SUPPORT BEAM
V CLEANING ASSEMBLY
GUARD
GUARD
DRIVE UNIT 37 KW
REACTION LEVER
Length
[mm.]
616080301
270255310
270380416
616080302
032000384
C01574737005
616080303
299016504
616080701
616080702
216907112
616080800
Description
616076500r01
TAIMs Item Code
BILL OF MATERIAL
0,8
1,4
1022
566
390
50
11
81
83
20
8
10
1310
13
Unit Weight
[Kg]
1/2
34
35
36
37
38
39
40
41
42
43
TOTAL:
TOTAL NET WEIGHT:
2
4
TAIM
TAIM
SPLT PIN D-94 6,3x45 ZN

SPLT PIN D-94 8x63 ZN
TRADE
TRADE
ZN
ZN
ZN
ZN
4
4
8
4
13
25
31
41
TAIM
TAIM
TAIM
TAIM
8
12
4
Quantity
FLAT WASHER D-125

FLAT WASHER D-125
FLAT WASHER D-125
FLAT WASHER D-125
Nr.
Supplier
Unit
TRADE
TRADE
TRADE
TRADE
Width
[mm.]
TAIM
TAIM
Length
[mm.]
Sheet:

616076500r01
GGP-CIC-T-M5-G7-052-207r01
Main Item
33
Description
BILL OF MATERIAL
TRADE
TRADE
TRADE
TAIMs Item Code
Item
TAIM-TFG S.A.
1334
3658 Kg
Unit Weight
[Kg]
2/2
1335
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270255310
Pos. Item
1
2
3
4
5
6
7
8
11
000290021401
000289778834
272711015500
217001052260
210022222080
212000322000
216020013500
217001052210
942401000100
Net weight:
DRIVE PULLEY B-1000 530
Description
DRIVE PULLEY SHELL B-1000 530
DRIVE SHAFT B1000 100110138
BEARING 22222 EK
SUPPORT SN-522 ECAUCHO PS - E
L.
W.
NoUn
Quantity
1,000
1,000
2,000
1,000
2,000
2,000
2,000
1,000
4,250
Un.
un
un
un
un
un
un
un
un
kg
566,000
1336
1337
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270380416
Pos. Item
1
2
3
4
5
6
7
11
000290017106
000289778130
272910014500
000078908202
000078908201
265208103515
490101210000
942401000100
Net weight:
AUXILIARY PULLEY RC 420 B1000
Description
AUX. SHELL CL-RC 420 B-1000
EJE AUX. B-1000 80 100 118
BEARING SUPPORT DK-FREE
BEARING SUPPORT DK-FIX
PITON D914
8x 35 8.8 ZN
OILER HIDR. M10-1
L.
W.
NoUn
Quantity
1,000
1,000
2,000
1,000
1,000
2,000
2,000
2,150
Un.
un
un
un
un
un
un
un
kg
390,000
1338
1339

1
Item
TAIM-TFG S.A.
1340
C00174737034
C01874737030
2169071120r00
TAIMs Item Code

GEARBOX 37 KW
MOTOR 37 KW
ASSEMBLY OF DRIVING UNIT 37 KW
Description
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
Quantity
TOTAL:
TOTAL NET WEIGHT:
TAIM
TAIM
Nr.
Supplier
Unit
Sheet:
1310,00 Kg
1000,00
310,00
Unit Weight
[Kg]
1341
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270380516
Pos. Item
1
2
3
4
5
6
7
11
000290017213
000289778118
272912016500
217001052260
210022222080
212000322000
216020013500
942401000100
Net weight:
AUXILIARY PULLEY LS 500 B1000
Description
AUX. SHELL CL-LS 500 B-1000
BEARING 22224 EK
L.
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
4,250
Un.
un
un
un
un
un
un
un
kg
480,000
1342
1343
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270380417
Pos. Item
1
2
3
4
5
6
7
9
11
000290017110
000289778130
272910014500
217001051860
210022218080
212000318000
216016012500
022003000011
942401000100
Net weight:
AUXILIARY PULLEY LS 400 B1000
Description
AUX. SHELL CL-LS 400 B-1000
BEARING 22218 EK
ROUND DIN 668 F-1110 30
L.
W.
50
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
0,100
2,150
Un.
un
un
un
un
un
un
un
m
kg
334,506
1344
1345
Project : 74737
Status : Active

: C202525
Manufactured Item
: 000270380322
Pos. Item
1
2
3
4
5
6
7
11
000290017318
000289778129
272909013000
217001051660
210022216080
212000316000
216014012500
942401000100
Net weight:
AUXILIARY PULLEY RC 315 B1000
Description
AUX. SHELL CL-RC 315 B-1000
SOPORTE SN-516 ECAUCHO DK - E
BEARING 22216 EK
L.
W.
NoUn
Quantity
1,000
1,000
2,000
2,000
2,000
2,000
2,000
1,400
Un.
un
un
un
un
un
un
un
kg
212,000
1346
1347
1348
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GGP-CIC-T-M5-G7-052-294
GGP-CIC-T-M5-G7-052-298
GGP-CIC-T-M5-G7-052-303
GGP-CIC-T-M5-G7-052-247
GGP-CIC-T-M5-G7-052-248
GGP-CIC-T-M5-G7-052-249
GGP-CIC-T-M5-G7-052-249
GGP-CIC-T-M5-G7-052-300
GGP-CIC-T-M5-G7-052-304

1
GGP-CIC-T-M5-G7-052-299
Item
TAIM-TFG S.A.
1349
SAFETY & LIGHTNING ELEMENTS

ASS. OF TRAVELLING LIMIT SWITCHES
BOOM LUFFING ENCODER
SLEW FRAME SWITCHES
ULTRASONIC SENSOR SUPPORT
VERTICAL LUMINARY SUPPORT
VERTICAL LUMINARY SUPPORT
LUMINARY SUPPORT
LUMINARY SUPPORT
LEVEL PROBE
LUMINARY CLAMP
SCREW D933 8x30 5.6 ZN
FLAT WASHER D125 8,4 ZN
CHEESE HEAD SCREW D84 4x25 5.6 ZN
NUT D934 M4 5 ZN
FLAT WASHER D125 4,3 ZN
657086600
657086900
657087100
573303208
573305601
573305602
573305801
573305802
573306400
604055500
TRADE
TRADE
TRADE
TRADE
TRADE
TRADE
Description
657085900
TAIMs Item Code
BILL OF MATERIAL
Length
[mm.]
Width
[mm.]
1
1
1
2
5
2
6
18
1
125
75
75
75
25
25
25
Quantity
TOTAL:
TOTAL NET WEIGHT:
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
Nr.
Supplier
Unit
Sheet:
710,00 Kg
90
16
65
1,5
7,5
9,5
17
15
20
0,7
Unit Weight
[Kg]

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BELT WEIGHER

MULTIBELT Belt Weighers

we make processes work

24h Emergency hotline:

+49 (0) 172 - 650 17 00

Light Duty Weighing & Feeding

Transport & Logistics

Components & Spare Parts

MULTIBELT Belt Weighers Installation and Operating Instructions

1 General Information ......................................................................... 1

2 Belt Weighers Overview................................................................... 3

3 Planning-in Hints (The 10 Rules)..................................................... 9

4 Single-idler Belt Weigher BEM ...................................................... 22

5 Single-idler Belt Weigher BEP....................................................... 37

MULTIBELT Belt Weighers Installation and Operating Instructions

6 Single-idler Belt Weigher BED....................................................... 50

7 Multi-idler Belt Weigher BMP......................................................... 64

8 Speed Transducer (Option) ........................................................... 78

9 Test Weight Suspension (Option) ................................................. 84

MULTIBELT Belt Weighers Installation and Operating Instructions

Carefully inspect packaging for any damage during transit.

If damage is discovered, contact your carrier immediately and file a claim

Check items supplied for completeness. For information on items supplied,

Additionally observe the

1.2 Information on Documentation

BEM, BEP and BED types

Multi-idler belt weighers

BMP, 2BMP and BMP2 types

MULTIBELT Belt Weighers Installation and Operating Instructions

Load cell type

Possible belt widths

Operating and Setting Instructions

Test weight system::

MULTIBELT Belt Weighers Installation and Operating Instructions

Belt Weighers Overview

2 Belt Weighers Overview

Throughput and consumption measurement in production plants

Balancing of amounts fed in and out

Reporting of load limits

Batching in load-out stations

Weighing modules or weighing platform for accommodation of user's idler sets

Overload protected load cell(s) with a high degree of protection

Cable junction box for connection of sensors

Fixing elements for the installation

MULTIBELT Belt Weighers Installation and Operating Instructions

Belt Weighers Overview

For accuracy data, please refer to the following documention:

2.1 Single-idler Belt Weighers

Belt tension forces absorbed by leaf spring parallel guidances

Suitable for handling feed rates up to 15,000 t/hr

2.1.1 BEM type

Belt weigher of modular design, suitable for DIN

MULTIBELT Belt Weighers Installation and Operating Instructions

Belt Weighers Overview

2.1.2 BEP type

Belt weigher with weighing platform, suitable for

MULTIBELT Belt Weighers Installation and Operating Instructions

Belt Weighers Overview

2.1.3 BED type

Belt weigher with weighing platform, suitable for

2.2 Multi-idler Belt Weighers

Belt tension forces absorbed by leaf spring parallel guidances

Suitable for handling feed rates up to 15,000 t/hr

Legal-for-trade variants also available