EPA/600/R-16/059 I October 2016
www.epa.gov/homeland-security-research
United States
Environmental Protection
Agency
oEPA
Progress Report: Transportable
Gasifier for On-Farm Disposal of
Animal Mortalities
Office of Research and Development
Homeland Security Research Program

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
EPA/600/R-16/059
October 2016
Progress Report: Transportable Gasifier for On-Farm Disposal of Animal Mortalities
U.S. Environmental Protection Agency
Office of Research and Development
National Homeland Security Research Center
Decontamination and Consequence Management Division
Research Triangle Park, NC 27711

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Notice
The U.S. Environmental Protection Agency (EPA), through its Office of Research and Development's
(ORD's) National Homeland Security Research Center (NHSRC), funded and managed the research
described here through Interagency Agreement HSHQPM-ll-X-00340 with The Department of
Homeland Security and Contract Number EP-C-09-027 with ARCADIS US. It has been subjected to the
Agency's administrative review and approved for publication. The views expressed in this report are
those of the authors and do not necessarily reflect the views or policies of the Agency. Mention of trade
names or commercial products does not constitute endorsement or recommendation for use.
Questions concerning this document or its application should be addressed to:
Paul Lemieux
National Homeland Security Research Center
Office of Research and Development
U.S. Environmental Protection Agency
Mail Code E343-06
Research Triangle Park, NC 27711
919-541-0962

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Table of Contents
Table of Contents	i
List of Figures	ii
Executive Summary	iii
Acronyms and Abbreviations	iv
Acknowledgments	v
1.Introduction	1
1.1.	Gasifier Prototype Description	1
1.2.	Discussion of Previous Design Deficiencies	4
2.Implemented Design Modifications	5
2.1.	Burners	5
2.2.	Feed System	5
2.3.	Internal Material Transport System	7
2.4.	Supervisory Control and Data Acquisition (SCADA) System	7
3.Description	of Testing	9
3.1.	Test Objectives and Results	9
3.2.	General Observations	11
4.Recommendation	s	12
5.Conclusion	s	14
6.Reference	s	15
Appendices	16

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
List of Figures
Figure 1. Gasifier Concept Schematic	2
Figure 2. Front View of Gasifier and Diesel Generator	3
Figure 3. Opposing Side View of Gasifier	3
Figure 4. LP Burners and Exhaust Stack	5
Figure 5. Pre-Breaker and Finer	6
Figure 6. Accumulator Bin	6
Figure 7. Feed Augers	7
Figure 8. Gasifier Chamber Showing Drag Chains and Ash Auger	7

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Executive Summary
A prototype transportable gasifier intended to process 25 tons per day of animal mortalities (scalable to
200 tons per day) was built as part of an interagency effort involving several federal agencies as well as
the State of North Carolina. This effort is intended to demonstrate the feasibility of gasification for
contaminated carcass disposal and to identify technical challenges and improvements that will simplify,
improve, and enhance the gasifier system as a mobile response tool. Past testing of the prototype
demonstrated partial success, in that the transportability and rapid deployment requirements were met,
however, the throughput of animal carcasses was approximately 1/3 of the intended design capacity.
Significant modifications were made to various gasifier components, including the burner system, feed
system, control system, power distribution, and ash handling system in order to increase its operating
capacity to the rated design throughput. A series of tests were performed in September 2015 to
evaluate the effectiveness of the design modifications at increasing the system's throughput, as well as
to demonstrate the unit's ability to operate around the clock for an extended period of time. These
tests, once again, were partially successful, with the new burner system, feed system, control system,
and power distribution systems all functioning in an acceptable manner. However, the ash removal
system and the system to move material across the bed failed during the tests due to material issues.
The test and evaluation showed that improved alloys would be needed in some of the parts to achieve
the desired results. This report summarizes the results of the test and lessons learned from the
modifications.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Acronyms and Abbreviations
APHIS
Animal and Plant Health Inspection Service (USDA)
BGP
Brookes Gasification Process
DoD
U.S. Department of Defense
EPA
U.S. Environmental Protection Agency
LP
Liquified Propane
NHSRC
National Homeland Security Research Center (EPA)
ORD
Office of Research and Development (EPA)
PAC
Programmable Automation Controllers
PC
Personal Computer
PCC
Primary Combustion Chamber
RTP
Research Triangle Park, NC
SCADA
Supervisory Control and Data Acquisition
see
Secondary Combustion Chamber
TSWG
Technical Support Working Group (DoD)
USDA
U.S. Department of Agriculture
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Acknowledgments
The authors would like to acknowledge the contributions of Lori Miller (USDA/APHIS), Michelle Colby
(DHS S&T), Jim Howard (independent consultant), and Shannon Serre (EPA/CMAD) in the preparation of
the testing protocols and performance of the testing. The authors would also like to acknowledge the
contributions of ARCADIS, Ag Protein, Rendeq, and Joe Moore and Company to this effort.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
1. Introduction
The U.S. Department of Defense (DoD) Technical Support Working Group (TSWG), in collaboration with
the U.S. Environmental Protection Agency (EPA) and the U.S. Department of Agriculture's Animal and
Plant Health Inspection Service (USDA/APHIS), built a transportable gasifier with the goal of processing
large quantities of animal carcasses and plant materials resulting from agricultural emergency events.
This unit may also be useful for other homeland security-related events involving contamination with
biological agents as an on-site treatment/disposal process. This gasifier converts biomass material into
an inert ash (although the ash may have to meet state disposal requirements) and a combustible
synthesis gas that is burned in a secondary combustion chamber (1).
Performance testing on the prototype unit using a mixture of poultry and swine carcasses was
performed in 2008 to evaluate the unit's potential throughput and environmental impact in terms of
both air emissions and ash characteristics. The complete data set from the source emissions testing can
be found in a published EPA report (2) and further analysis can be found in additional symposium papers
(3-6). A second shorter performance test was conducted in 2010, mainly to evaluate material
throughput issues. Based on shortcomings that were observed in those two tests, additional design
modifications were made to the unit specifically to overcome the throughput limitations and
operational difficulties. This report discusses the modifications made since the second test and the
results of a test and evaluation exercise performed in 2015.
1.1. Gasifier Prototype Description
The BGP-D1000 gasifier (BGP, Inc., Toronto, Canada) was designed to process 25 tons per day of feed
material, using a series of chambers, each with different fuel/air stoichiometry. Two independent
primary combustion chambers (PCCs), operating sub-stoichiometrically under natural draft, feed hot
combustible vapors into two independent secondary combustion chambers (SCCs), thus achieving a
quasi-steady-state operating mode. The PCCs serve to create the oxygen deficient atmosphere to gasify
the carcasses. Heat from the SCCs provides the PCC hearth with thermal energy, and the SCCs provide
for destruction of any combustible gases leaving the PCCs. The majority of the insulating refractory in
the gasifier is composed of lightweight insulating wool refractory to minimize weight. Only the hearth
and the load-bearing refractory components are composed of conventional firebrick and castable
refractory. The thermal inertia of the hearth prevents significant PCC temperature loss when materials
of high water content are charged onto the hearth. The unit operates on natural draft without requiring
an induced draft fan. The commercial implementation of this design concept would allow manifolding
up to eight gasifier units together with a pre-breaker and finer to achieve larger capacities, up to
approximately 200 tons per day, which is comparable to other large capacity fixed-site incineration
facilities (although this has not been demonstrated). The pre-breaker and finer are used to grind the
animal carcasses into a size capable of being pumped to the feed distribution system and deposited
onto the hearths. The pre-breaker is loaded using a "skid steer" or telehandler-type front end loader
with a nominal bucket capacity between 500 and 600 lb. The gasifier is designed to operate 24 hours per
day for an extended period of time before any maintenance shutdowns would be required, provided
that the liquefied propane (LP) fuel tanks (for the burners) and the diesel fuel tank (for the generator)
are refilled. Figure 1 gives a graphic depiction of the gasifier design concept.
Major components of the gasifier system include a pre-breaker (to reduce the size of the animal carcass
to approximately 1.5 in), finer (to further reduce the size of the material to approximately 0.75 in),
accumulator (to hold feed material until it is fed into the gasifier), transfer auger and pump (to move the
ground animal carcass material to the accumulator), variable speed feed augers, carbon steel drag chain
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
conveyors in each gasifier PCC (to spread the material on the hearth and to move it down the hearth),
carbon steel ash auger (to move the ash to a bin for disposal), and exhaust stack. The gasifier control
system is operated by two programmable automation controllers (PACs) connected to a personal
computer (PC)-based Supervisory Control and Data Acquisition (SCADA) system.
The prototype gasifier was originally designed to be completely transportable. However, as the recent
design modifications were introduced, in an effort to have a successful proof-of-concept of the main
design changes, some of the transportability was sacrificed in an effort to reduce costs. These design
modifications can be altered to be completely transportable once the proof-of-concept tests have been
completed successfully.
LP Burner
Stack
Hearth
Feed
Finer
Pre-Breaker
Accumulator Bin
Figure 1. Gasifier Concept Schematic
The gasifier unit is equipped with a telescoping stack (34-inch diameter and approximately 12 feet high)
projecting above the gasifier. A 34-inch diameter dilution air inlet at the base of the stack allows for
control of the natural draft that draws the air through the PCCs and draws the combustion gases
through the SCCs.
Two burners (2.15 MM BTU/h/630 kW), each capable of firing 20 gal/h of LP gas, are mounted in the
duct between the PCC and SCC (i.e., one burner on each side). These burners provide initial heat to
make the hearth hot enough to initiate gasification in the PCCs. The burners also provide process control
to maintain predetermined temperatures in the SCCs based on a user-defined set point. The burners are
fed from three 1,000 gallon LP fuel tanks mounted adjacent to the unit.
The gasifier unit is designed with a reservoir at the back end of the PCC to collect ash from the hearths.
Once a substantial amount of ash accumulates, an ash removal auger continuously removes the ash to
metal bins outside the gasifier. The ash removal process is manually actuated to initiate the motor, then
runs continuously as the material on the hearths is gasified.
Photographs of the gasifier are shown in Figures 2 and 3.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Figure 2. Front View of Gasifier and Diesel Generator
Figure 3. Opposing Side View of Gasifier
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
1.2. Discussion of Previous Design Deficiencies
Many aspects of the 2008 and 2010 performance testing satisfactorily met the required criteria for
acceptance of the technology. Some of the successfully achieved requirements included:
•	Transportability over primary and secondary roads;
•	Ability to begin operations within 24 hours of arriving on site;
•	Operation of the burner system; and
•	Operation of the material feed system.
However a number of design deficiencies were not overcome during either the initial performance test
in 2008 or the follow-on tests in 2010. These design and/or operational deficiencies included:
•	The feed system was not able to handle equine or bovine carcasses due to feed hopper size and cost
considerations when selecting the animal carcass maceration equipment when the prototype was
built (this was an intentional design choice);
•	The ash removal auger system failed during the 2008 performance test, although it was repaired for
the 2010 performance test, also failed in the 2010 performance test. During the previous tests, the
operating time was insufficient to provide enough ash to test the ash removal auger system;
•	The material feed system introduced an amount of material into the gasifier equal to the amount of
material fed into the macerator, making it difficult to control the distribution of mass onto the
gasifier hearth;
•	The oil-fired burners initially provided with the prototype (a design decision made to minimize the
need for multiple types of fuel to be delivered in the field) offered poor flexibility regarding the
range minimum and maximum fuel feed rates (turndown ratio) and difficult ignition. The oil-fired
burners could not be replaced while the unit was hot;
•	The electrical system of the gasifier was not effectively shielded from heat, resulting in damage to
some of the wiring;
•	A significant amount of manual labor was required both on the ground and on the top of the gasifier
to feed a batch of material into the gasifier. The manual labor requirement not only complicated the
feeding procedures but also made all-weather operation of the gasifier somewhat problematic due
to the need for personnel to be on top of the unit potentially during inclement weather;
•	No automated system for distributing the feed materials on the hearth was available;
•	No automated system for pushing the combusted material back to the ash removal section of the
gasifier was available; and
•	No automated method was provided for controlling the throughput speed or volume of mass fed
into the system.
These design deficiencies were noted and a new project was initiated to modify the existing
configuration. These changes are discussed in the next section.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
2. Implemented Design Modifications
Initial observations from the 2008 and 2010 performance tests highlighted potential system
modifications needed for the prototype unit to meet the defined set of operational requirements that
were specified. These proposed modifications were documented in a paper at the 2012 Carcass
Management Symposium (5). These planned modifications were implemented, and proof-of-concept
testing was conducted in September 2015.
2.1. Burners
The oil-fired burner system was replaced with LP gas-fired burners (2.15 MM BTU/h) to improve the
ability to control the temperature in the gasifier, offer improved turndown ratios (ability to operate at
very low and very high firing rates), simplify the burner electronics, and allow for hot-swapping of
burners in the case of a burner failure (increasing the reliability of the unit). The burners are Eclipse
Ratiomatic 5 burners (Eclipse, Rockford, IL). Although use of LP will necessitate delivery of diesel fuel for
the generator and LP fuel for the burners, delivery of two fuels to the site is not expected to
unnecessarily complicate operational logistics and will increase the reliability of the unit. The burners
are shown in Figure 4.
*
(
ft1—
Burners
v V V' I ^nHBS 9T

Figure 4. LP Burners and Exhaust Stack
2.2. Feed System
The feed system was modified with a pre-breaker (Reitz PB-24, Hoexter, Germany) to allow for
processing of larger animals, including bovine and equine carcasses. This will increase the ability of the
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
unit to process a wider variety of animal carcasses. A finer (Weiller 1109, Whitewater, Wl) was added to
further reduce the size of the mass particles (nominally 0.75 inch diameter) to improve the efficiency
and throughput of the system. The pre-breaker is shown in Figure 5. The material feed system was also
modified to provide for more precise control over how much material is fed into each region of each
hearth upon each feed event. Following the addition of the pre-breaker and finer, an accumulator bin
(Rendeq, Burlington, NC) was installed. Material is pumped into the accumulator bin (about 3,500 lb
capacity) after size reduction in the pre-breaker and finer, then the material is augered into the ports in
the tops of the gasifier. This greatly improves the feed rate control of the unit. The accumulator bin is
shown in Figure 6, and the material feed augers are shown in Figure 7.
y.*Yn
Figure 5. Pre-Breaker and Finer
Figure 6. Accumulator Bin
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
Figure 7. Feed Augers
2.3. Internal Material Transport System
Significant modifications converted the gasifier from a semi-batch feed system to a continuous feed
system to minimize operational fluctuations that previously occurred due to intermittent feeding
operations and to enable steady-state operation at a higher throughput rate. The hearth was modified
with a set of drag chains (Rendeq, Burlington, NC) to improve material distribution across the hearth and
to allow for continuous movement of the material across the hearth until it eventually reaches the ash
removal reservoir. The drag chains and ash auger are shown in Figure 8.
Figure 8. Gasifier Chamber Showing Drag Chains and Ash Auger
2.4. Supervisory Control and Data Acquisition (SCADA) System
The supervisory control and data acquisition (SCADA) system provides the human-machine interface
(HMI) with the gasifier temperature, burner control, and feed control systems. In addition to providing
the HMI, the SCADA system also electronically logs the system temperatures with timestamps for later
retrieval and analysis. Alarm handling and recording is also built into the HMI package of the SCADA
system.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
The gasifier control system is operated by two programmable automation controllers (PACs) connected
to the personal computer (PC)-based SCADA system. One is installed in the power distribution panel,
and the other is in the main control panel. The power panel PAC is primarily responsible for controlling
the pre-breaker, finer, and feed system components. A second PAC is installed in the main control panel.
This PAC interfaces with the two burner management systems (BMSs) and also monitors the many
thermocouples installed in the system. The two PACs are connected to the SCADA computer (Opto 22,
Temecula, CA) by way of an Ethernet switch installed in the main control panel.
The following tests were performed in September, 2015:
•	A throughput performance test to evaluate maximum material throughput and to identify
appropriate operating regimes. These tests intended to determine the unit's nominal operating
capacity for the second set of tests; and
•	A long-term operation test where the unit is operated at its nominal operating capacity for 72
continuous hours.
Documentation of the operation of the gasifier, estimates of fuel usage and thermal efficiency, and
development of training materials for operator and maintenance personnel were an additional goal of
the 2015 tests.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
3. Description of Testing
The unit began initial heating on September 10, 2015, with feeding of swine initiated on September 14,
2015.
3.1. Test Objectives and Results
•	Objective 1: Repair the components of the gasifier prototype which were damaged and deteriorated
as a result of and since the 2010 test.
Accomplished. Known areas of damage were the failure and seizure of the Ash Conveyor and the
new Drag Chain on Side 1 and possibly on Side 2.
•	Objective 2: Replace the oil-fired burners and associated equipment with gas-fired burners.
Accomplished. New gas burners permitted better operation and control than oil burners and
provided sufficient heat for the current design of the unit. There was some difficulty in
dependability during the initial ignition, but much of this difficulty was caused by long periods
between firings. Moisture and oxidation may have influenced the efficiency of the flame control
system. The SCADA system provided significant benefit over the previous burner control system.
Two spare burners were stored with the gasifier system.
•	Objective 3: Modify the feeding system to accurately distribute desired quantities of macerated
material onto specifically targeted locations within the gasifier.
Substantially accomplished. The prebreaker, transfer screw, pump, finer, accumulator bin, bin
screws, feed screws and feed valves (gates) operated well except for some balkiness of the feed
valve limit switches due to corrosion from moisture infiltration of the whisker housing. Additional
weather-proofing of the feed valve limit switches could serve to minimize potential corrosion. The
SCADA made the operation of the feed system extremely user friendly.
The height of the feed chute required the construction of a platform that allowed dumping of the
carcass material, but with some difficulty. Large carcasses loaded horizontally were subject to
bridging in the hopper. Plans to have a higher lift capacity were not accomplished because of time
and funding limitations. ATelehandler with a grapple bucket and a quick release hook would be a
solution for loading large animals such as cattle and horses. One steer was loaded vertically using a
heavy duty forklift during the initial testing of the prebreaker in Burlington at Rendeq Inc., and it was
ground without difficulty. Weighing the loader empty and loaded to track the mass being fed into
the gasifier was burdensome. Either a full size scale or load cell on the loader would greatly simplify
this process.
As part of 2015 upgrades, an innovative feed component was installed in the gasifier primary
chambers. The feed component consisted of a motor-driven drag chain assembly to transport the
carcass material deposited on the hearth along the hearth at a speed that would permit gasification
and then deposit the resulting ash at the ash auger for transport to the ash discharge chute. The
drag chain operation was fully controllable in both speed and direction from the SCADA system. The
drag chain units were approximately 43 inches wide and moved approximately 19 feet along the
hearth, discharging approximately 4 feet from the ash auger, which is 9" in diameter and mounted
about 3 inches above the hearth. The metals in the conveyor and frame were carbon steel and
tested to approximately 750 °C. The actual operating temperatures were almost double the
temperature for which the chain systems were designed. Despite repeated efforts by Rendeq Inc.
the drag chains and their components were not able to withstand the heat. The graphite bearings
failed, the rails warped, the sprocket welds failed, and the pins came out of the chain links.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
The ash auger that had malfunctioned in the previous tests warped from the heat, the bearings
failed, and the flight seized in the refractory openings between primary chambers.
Special high temperature materials such as cast iron or Inconel are needed for the feed and ash
discharge systems. The systems themselves need to be redesigned and better coordinated, possibly
using screw augers and carbon or ceramic sleeves. Additionally, the initial feed location of the
carcass material should be moved to a point beyond the end of the hearth to allow for maximum
residence time of the material on the hearth.
•	Objective 4: Modify the macerator system to handle larger animals (e.g., bovine carcasses).
Accomplished, but not demonstrated. The capability to handle larger carcasses was implemented
with the PB-24 prebreaker, transfer screw, screw pump, finer, and accumulator as discussed
previously, but the capability was not demonstrated during the 2015 test because a high lift loader
was not rented for the activity and no bovine or equine carcasses were obtained due to time,
contract, and funding constraints. The unit performed effectively using swine carcasses.
•	Objective 5: Develop training materials for operational personnel.
Accomplished, but not evaluated. Documentation related to operation of the gasifier system was
prepared, but third party training and evaluation did not occur due to time, contract, and funding
constraints. Actual operating personnel for the activities related to the gasifier system were
intimately involved in the design, construction, and debugging of the system, so the documentation
is believed to be complete and accurate, although not confirmed.
•	Objective 6: Evaluate and modify controls for the macerator and gasifier to assure that the system
can be operated properly and safely in all weather conditions.
Accomplished. The SCADA internet-based electronic monitoring and control system provided
outstanding capability to control, monitor, evaluate, and analyze the performance of the gasifier
system, including remote control. Some period of operational familiarization is necessary for
operation. A qualified SCADA programmer is required to debug, modify, or update the SCADA
system.
•	Objective 7: Conduct sufficient test runs to properly adjust the system, manage limitations, train
sufficient personnel to safely and reliably operate it in the field, and to assure performance at the
highest throughput possible.
•	Attempted but not accomplished. The test and evaluation period was compressed and restricted
due to contract, funding, and schedule constraints. The tests did confirm that the Gasifier System
was operational, but the capabilities were limited by its current configuration. The tests revealed
the inadequacy of carbon steel and low grade stainless steel to withstand the high operating
temperatures required for prion destruction. In addition, the tests revealed that the transport
system components required closer design tolerances to operate effectively. Another result was
that the primary chamber temperature dropped by over 200 °C when carcass material was fed on
the >450 °C hearth, while the secondary chamber remained at >850 °C. When the primary chamber
temperature returned to about 325 "C+/-2C, the carcass material on the hearth flashed and the
primary chamber temperature climbed steeply to over 1083 °C, exceeding the maximum set points
for the primary chambers, causing both burners to shut down. This shutdown had no influence on
the fire in the primary chamber, where the temperature remained above 1000 °C until the mass was
consumed. Closing the vent ports had limited influence on quenching this uncontrolled heating. This
uncontrolled heating resulted in the thermal damage to the ash auger and drag chains and bearings.
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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
These problems may be able to be resolved by having higher temperature materials for the hearth
transport system.
Objective 8: Carry out a three-day Proof of Concept test at the highest throughput safely possible.
Not Accomplished. The gasifier system components within the primary chamber failed due to the
high operating temperatures encountered once the carcass feed was initiated. See Objective 3
above
Objective 9: Clean and prepare the system for relocation.
Accomplished. The unit was cleaned with crushed ice, disassembled, manually cleared, and pressure
washed. All components were documented, packaged and transported by truck to a storage location
at the EPA facility in Research Triangle Park, NC.
Objective 10: Evaluate and document the system, its operation, its performance, its maintenance,
and any modifications or improvements
Accomplished. This report completes this objective.
2. General Observations
General
The upgrades since 2010 provided significant improvement in the understanding, design,
fabrication, operation, disassembly, capabilities, and challenges of mobile gasification technology.
Things as simple as repairs by individuals who do not understand the operation of the system,
influence of government shutdown and contract changes, and uncontrolled temperature spikes
significantly influenced the system performance.
Foundation and Containment-
The upgrades required that a substantial concrete foundation was needed to support the feed
system weight and to anchor the structural steel necessary to construct the feed system. Part of this
need was caused due to budgetary constraints placing the proof-of-concept tests at a higher priority
than having all components be transportable. For an operational unit, some sort of structure that
would be operable in the universe of potential emergency sites would be needed. In addition,
environmental containment was needed for the carcass materials and related runoff. Based on
these needs, a 100 foot long x 30 foot wide x 7 inch thick concrete pad with a 30' x 30' containment
area adjoining the end of one side was constructed to meet all the equipment mounting and carcass
containment needs. Gravel was distributed along one end and both sides of the pad to provide
access and support loaded vehicles in all weather. These site preparations proved to be extremely
beneficial during all phases of the construction and testing, especially during severe weather
periods.
Generator
The 250 kW, 230/460 V, three-phase diesel generator is capable of powering the continuous
operation of the upgraded gasifier system as long as loads were added so that the starting current
loads drop back to baseline. The generator must be run periodically and maintained in accordance
with manufacturer's recommendations to prevent major repair costs.
Material and System Compatibility
Improved component materials are needed for better thermal resistance, strength, machinability,
dependability, cost and availability so that the carcass material can be moved through the gasifier

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Early Phase Waste Staging for Wide Area Radiological Releases Operational Guidelines and Recommendations
chamber at a rate that accomplishes the desired thermal destruction, whether that is 100 °C for
Avian Influenza-contaminated birds or 1000 °Cfor prion-contaminated cattle or deer.
•	Transportability
The gasifier was originally intended to arrive at an affected premises within 24 hours of request and
be ready to process materials 24 hours after that. The current system requires at least 120 hours to
set up if an adequate concrete pad and traffic pattern is available. To meet the 24-hour objective, all
major gasifier components would require dedicated trailers with jacks to be connected, erected, and
operated in a manner similar to a mobile asphalt plant which can be erected in 24 hours or less.
4. Recommendations
The transportable gasifier prototype has been significantly improved since its inception a decade ago,
but it requires additional improvements in order to be fully functional. The US has a continuing need for
such a system, as evidenced by the 2015 HPAI outbreak, which was the largest animal disease outbreak
in US history. It is recommended that the following actions be taken in order to leverage the
investments to-date, and provide the needed capability to agricultural health emergency responders.
Recommendation 1: Partner with institutions, technology developers, emergency responders, and
industry to improve this prototype to full functionality for production of units which can be maintained
for deployment when needed.
Recommendation 2: Repair and reassemble the current gasifier system hardware for response to
disease outbreaks such as Avian Influenza, Swine Flu, Exotic New Castle Disease, and similar diseases
which can be destroyed with temperatures of 100 °C(7).
Recommendation 3: Make system improvements to reach higher temperatures for prion-infected
carcasses, such as:
•	A single hearth (10 feet wide by 3 feet high) with numerous channels (~13) for high temperature 9"
screw augers feeding ground material (3/4" diameter) from a feed location outside the hearth, the
full length of a longer hearth (at least 30 feet) to a ash discharge auger in a lower trench to a
discharge chute.
•	Select materials compatible with the high temperatures and materials being processed. Design
temperatures for all internal components should be able to operate continuously at 800 °C.
•	Permit mounting of screw auger bearing or graphite sleeves outside of the high temperature
chamber.
•	Control the air draft into the chamber into which the carcass materials is transported to minimize
the turbulence and open flame production.
•	Relocate the carcass feed to a point outside the end of the hearth to permit maximum residency
time on the hearth.
•	Install V-shaped lanes along the surface of the hearth, spaced to allow the installation and operation
of high temperature 9-inch or 10-inch screw augers to move the carcass the length of the hearth.
•	Install a similar V-shaped structure at the rear of the hearth to facilitate the operation of a high
temperature 9-inch ash auger transporting the material to the ash discharge chute.
•	Select either extremely high temperature bearings or graphite sleeves to permit unrestricted
operation of the auger shafts, which will be controlled by the SCADA system. Ensure transportation,
erection, assembly, operation and maintenance of the system components have maximum
simplicity, flexibility, and efficiency.
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Recommendation 4: Erect the gasifier under a suitable shelter with due consideration for process flow,
vehicular access, operation, serviceability, and safety to minimize moisture problems for controls,
motors, burners and refractory.
Recommendation 5: Ensure adequate trained personnel are available to assure safe and reliable system
operation, even for the current system design.
Recommendation 6: Maintain, service, operate, and inspect gasifier and its components regularly so the
prototype will be functional if additional improvements are initiated. This includes:
•	Running the diesel generator at least monthly and treat the fuel to avoid separation, condensation,
and gumming.
•	Putting a load on the generator at least once a year to assure no loss of field. Rotate the motors to
reduce the likelihood of corrosion. If they are stored outside they should be appropriately covered
with plastic or other protective material. Secure all switch covers and seal the holes in the back of
panels. Cover connector receptacles to prevent insect nesting. Protect cables and hoses from sun
exposure and vermin such as mice and squirrels.
•	Treat cabinets and storage containers with suitable vermin traps or poison. Keep the control
computer up to date as far as operating system, security, and software updates and charge the
battery regularly. Protect hardware components and structural steel from rust and corrosion as well
as scrap hunters. Properly store project documentation and media to prevent degradation from
moisture or vermin damage.
Recommendation 7: If there is benefit from future use of the current gasifier system or its components
then the sooner action is taken the more benefit may be gained. Long term storage of the unit has in the
past resulted in loss of components, moisture absorption, corrosion, component failure, contamination,
and expensive repairs. Changes in technology will render many parts of the system out of date or
impractical.
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5. Conclusions
A prototype transportable gasifier, intended to thermally process contaminated animal carcasses, was
constructed and tested, with some design requirements met and others not met.
A series of design modifications were completed, and testing was performed to address the
effectiveness of the modified prototype so that this technology can be included in the toolbox of
available technologies for mass disposal of animal mortalities.
These design modifications culminated in a series of tests to assess maximum throughput capacity,
which was less than the target. Although a 72-hour long term operational test was also planned, it was
not conducted due to inadequate characteristics of metals used in some gasifier components.
The throughput test was partially successful. Some design features worked as planned; others were
somewhat less successful. A summary of the more successful and less successful aspects of the tests
follows:
•	LP gas-fired burners were easy to light and reliably adjusted their firing rate as temperatures in the
primary and secondary chambers changed;
•	The modified feed system using the pre-breaker, finer, and accumulation tank worked much better
than the previously installed macerator system; it allowed consistent feed to be fired into the
primary chamber;
•	The modified control system enables automatic control of the gasifier without requiring any manual
actuation of control valves; this will provide a significant improvement in all-weather operation; and
•	The internal material transport system to move the burning material and ash across the hearth and
to remove the ash from the inside of the gasifier failed due to inadequate materials of construction.
The design itself appears to be functional for the purposes it was designed, but due to transient
temperature fluctuations inside the gasifier, and non-uniform temperature distribution within the
primary chambers, the temperatures that the components were exposed to were much higher than
the design limits of the components. It is recommended that a high temperature alloy such as
Hastelloy be used for these components.
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6. References
1.	BGP Inc. Engineering Report: Initial Shakedown And Testing Of Mobile Gasifier Prototype; DoD
Contract Number: W91CRB-06-C-0007. 2008.
2.	Lemieux P. Emissions Test Report: Source Sampling for Transportable Gasifier for Animal
Carcasses and Contaminated Plant Material. RTP, NC: 2008 August. Report No.: EPA/600/R-08/127.
3.	Lemieux P, Brookes D, Howard J, McKinney J. Transportable Gasifier for Animal Carcasses:
Emission Test Results. Proceedings of the International Symposium on Management of Animal
Carcasses, Tissue and Related Byproducts; July 21-23; Davis, CA2009.
4.	Lemieux P. Gasification of Catastrophic Losses. Proceedings of the 2010 National Poultry Waste
Management Symposium; October 26-28; Greensboro, NC2010.
5.	Lemieux P, Serre S, Hall B, Sharpe B, Howard J. Transportable Gasifier for On-Farm Disposal of
Animal Mortalities: Status Update. 4th International Animal By-Products Symposium; May 21-24;
Dearborn, MI2012.
6.	Lemieux P, Serre S, Hall B, Sharpe B, Howard J. Transportable Gasifier for On-Farm Disposal of
Animal Mortalities: Status Update. 5th International Symposium on Managing Animal Mortality,
Products, By Products and Associated Health Risk; September 28-October 1; Lancaster, PA2015.
7.	Kansas State University. Carcass Disposal: A Comprehensive Review 2004 [cited 2013 May 29],
Available from: http://hdl.handle.net/2097/662.
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Appendices
APPENDIX A: Miscellaneous Operating Procedure: Operation of Transportable Gasifier
APPENDIX B: Transportable Gasifier Control Electrical Schematics
APPENDIX C: Grinding, Transfer, Accumulation and Feed (GTAF) System Manuals
APPENDIX D: Continuous Monitoring Data from September 2015 Performance Test
APPENDIX E: Manufacturer's Documentation
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APPENDIX A: Miscellaneous Operating Procedure for the
Transportable Gasifier for Animal Carcasses

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Appendix A
Miscellaneous Operating Procedure for
the Transportable Gasifier for Animal
Carcasses
Prepared for
U.S. Environmental Protection Agency
National Homeland Security Research Center
Decontamination and Consequence Management Division
Research Triangle Park, NC 27711
Prepared by
ARCADIS
4915 Prospectus Dr., Suite F
Durham, NC 27713

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Miscellaneous Operating Procedure for the
Transportable Gasifier for Animal Carcasses
Prepared by:		Date: _
Reviewed by:		Date:
Approved by:		Date:_
Prepared for
U.S. Environmental Protection Agency
National Homeland Security Research Center
Decontamination and Consequence Management Division
Research Triangle Park, NC 27711

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Table of Contents
Section	Page
I.0	SCOPE AND APPLICATION	5
2.0	SUMMARY OF METHOD	5
3.0	DEFINITIONS/ACRONYMS	13
4.0	CAUTIONS	13
5.0	APPARATUS AND MATERIALS	14
6.0	SYSTEM SETUP	14
7.0	METHOD CALIBRATION	22
8.0	SYSTEM OPERATION	23
9.0	SAMPLE COLLECTION, PRESERVATION, AND STORAGE	41
10.0	SAMPLE ANALYSIS PROCEDURE	42
II.0	DATA ANALYSIS AND CALCULATIONS	42
12.0	COMPUTER HARDWARE AND SOFTWARE	42
13.0	DATA AND RECORDS MANAGEMENT	42
14.0	QUALITY ASSURANCE	42
15.0	PERIODIC MAINTENANCE	42
16.0	TROUBLESHOOTING	43
17.0	REFERENCES	44
List of Figures
Figure 1.	Front View of Gasifier and Diesel Generator	6
Figure 2.	Opposing Side View of Gasifier	6
Figure 3.	Rear View of Gasifier	7
Figure 4.	Pre-Breaker and Screw	7
Figure 5.	FeedPump	8
Figure 6.	Finer	8
Figure 7.	Accumulator	9
Figure 8.	Bin Screws	9
Figure 9.	Screw with Opposing Flights to Gate Valves	10
Figure 10.	Gate Valve to Gasifier	10
Figure 11.	Gasifier Chamber showing Drag Chain and Ash Auger	11
Figure 12. LP Burners and Exhaust Stack	12
Figure 13. Generator Docking Station	15
Figure 14. Connect Battery in Preparation for Starting Generator	15

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Figure 15. Alarm and Run Buttons on Generator Control Panel	16
Figure 16a. Outside of Power Distribution Panel	17
Figure 16b. Inside of Power Distribution Panel	17
Figure 17. Power Switch on front of Power Distribution Panel	18
Figure 18. UPS Control Panel	18
Figure 19. EPA Gasifier Control Panel, outside (a) and inside (b)	19
Figure 20. Power Switch on EPA Gasifier Control Panel	20
Figure 21. Gas Line Solenoid Valve Reset	22
Figure 22. Home Screen	25
Figure 23. Burner Screen	28
Figure 24. Temperature Screen	30
Figure 25. Motor Control Screen	33
Figure 26. Alarm Screen	35
Figure 27. Calibration Screen	39

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1.0 SCOPE AND APPLICATION
This standard operating procedure (SOP) describes the operation of the Transportable Gasifier for Animal
Carcasses (gasifier) modified for the U.S. Environmental Protection Agency's (EPA) National Homeland
Security Research Center's (NHSRC) Decontamination and Consequence Management Division (DCMD). In
April 2013, ARCADIS was awarded a contract to make repairs and modifications to the gasification system
as part of a comprehensive response strategy to effectively mitigate animal health emergencies (i.e.,
high-consequence foreign animal diseases) and maintain continuity of business to the maximum extent
practicable. The focus of this project was confined to the accomplishment of a minimum throughput of 25
tons of carcass material per day over a three day period and the identification of challenges,
opportunities, and advances that relate to the technology. This response strategy must incorporate plans
and technologies for rapid depopulation, decontamination, and disposal of affected animals. This
technology could be used as a disposal option for animal carcasses following a disease outbreak.
Major components of the gasifier system include a pre-breaker, finer, accumulator, feed augers, drag
chain conveyors in each gasifier chamber, ash auger, exhaust stack, and multiple pumps. Liquefied
petroleum (LP) gas burners are used to heat the chambers and a diesel fueled generator is used to power
the remainder of the system components and control system. The gasifier control system is operated by
two programmable automation controllers (PACs) connected to a personal computer (PC)-based
Supervisory Control and Data Acquisition (SCADA) system.
This SOP references instrument identification defined in the Transportable Gasifier Control electrical
schematics. A copy of these electrical schematics can be found in Appendix B.
2.0 SUMMARY OF METHOD
The gasifier currently resides in Rose Hill, NC and is shown in Figures 1, 2 and 3. The blue diesel generator
can be seen beside the gasifier.

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Figure 1. Front View of Gasifier and Diesel Generator
Figure 2. Opposing Side View of Gasifier
it was determined that a larger macerator or grinder would be necessary to effectively and efficiently
grind the larger bovine and equine carcasses that may be processed in the future. This was accomplished
by the incorporation of a pre-breaker (Figure 4) and associated infrastructure and transporting systems.
The screw, seen on the far right of Figure 4, moves material to the feed pump (Figure 5) which transports
the material to a finer (Figure 6). The finer further reduces the size of the ground animal parts to < %" size
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Figure 3. Rear View of Gasifier
Screw
Figure 4. Pre-Breaker and Screw

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Figures. FeedPump
Figure 6. Finer
The reduced animal parts are dispensed from the finer, through an extrusion plate with holes, and into an
accumulator (Figure 7), which serves as an intermittent holding bin for the gasifier feed stock.

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Accumulator
Figure?. Accumulator
The fully ground material is then conveyed by two bin screws that are mounted within the bottom of the
accumulator (Figure 8). At approximately the midpoint of the bin screws, the pipe diameter is decreased
slightly to force a full capacity pipe. Temperature elements (thermocouples) monitor the temperature at
these locations for possible flashback from the gasifier chambers.
Temperature
Elements
Full Capacity
Pipe
Figures. Bin Screws

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The bin screws terminate in a box that has a screw with opposing flights (Figure 9), so that material is fed
into the gate valve for each opposing chamber (Figure 10).
Figure 9. Screw with Opposing Flights to Gate Valves
Gate valve
motor
Figure 10. Gate Valve to Gasifier
The two gate valves allow material to drop into each gasifier chamber (Figure 11). A drag chain conveyor
travelling approximately 1 foot/20 minutes in each primary chamber is used to distribute the feed
material across the hearth. The hearth of each primary chamber is heated from below by a 2.15 MM

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Btu/hr vertical down-fired LP gas burner (Figure 12). The ash auger conveys the remaining ash and bone
out of the chamber as it accumulates.
Figure 11. Gasifier Chamber showing Drag Chain and Ash Auger

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S
Secondary blower
(unused)
Figure 12. LP Burners and Exhaust Stack
2,1 SCADA System Operation
The Supervisory Control and Data Acquisition (SCADA) system provides the human-machine interface
(HMI) with the gasifier's temperature, calibration, burner control, and feed control systems. As well as
providing the HMI, the SCADA system logs to disk the system temperatures with timestamps for later
retrieval and analysis. Alarm handling and recording is also built into the HMI package of the SCADA
system.
The gasifier system uses two programmable automation controllers (PACs). One is installed in the power
distribution panel and the other is in the main control panel. The power panel PAC is primarily responsible
for controlling the pre-breaker, finer, and feed system components. A second PAC is installed in the main
control panel. This PAC interfaces with the two burner management systems (BMS) and also monitors the
many thermocouples installed in the system. The two PACs are connected to the SCADA computer by way
of an Ethernet switch installed in the main control panel.

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3.0 DEFINITIONS/ACRONYMS
°C	Degrees Celsius
°F	Degrees Fahrenheit
BMS	Burner Management System
CMC	Combination Motor Controller
CR	Control Relay
CSV	Comma Separated Values
DCMD	Decontamination and Consequence Management Division
EPA	Environmental Protection Agency
HMI	Human-machine interface
LP	Liquefied petroleum
mA	Milliamps
MC	Motor Controller
NHSRC	National Homeland Security Research Center
O&M	Operations and Maintenance
PAC	Programmable Automation Controller
PC	Personal Computer
PID	Proportional Integral Derivative
QA	Quality Assurance
SC	Speed Controlled (Variable Frequency Drive [VFD])
SCADA	Supervisory Control and Data Acquisition
SOP	Standard Operating Procedure
SS	Soft Starter
TE	Temperature Element (Thermocouple or Resistance Temperature Detector)
TIC	Temperature Indicating Controller
UPS	Uninterruptible Power Supply
4.0 CAUTIONS
4.1
LP and diesel fuel

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4.2	Moving parts (blowers, pre-breaker, pumps, shafts, pulleys, etc.)
4.3	Electrical hazards (control panels, blowers, pumps, generator connections, etc.)
4.4	Slip/trip/fall hazards accessing generator, electrical panels, mezzanine, and machinery
4.5	Heat hazards from gasifier high temperatures at stack, gasifier surfaces, and mezzanine
level surfaces and equipment
5.0 APPARATUS AND MATERIALS
5.1	Apparatus
Gasifier and associated grinding and feed system.
Portable 250 kVA, 277/480 volt, 3 phase diesel generator with patch panel.
Dell SCADA laptop computer.
Custom ARCADIS control and power distribution panels with Opto 22 process control hardware.
Opto 22 PAC Project software suite for control logic programming and SCADA configuration.
5.2	Supplies
The SCADA system is virtually maintenance free. For maintenance of the control system
hardware, check the Gasifier Control System Operations and Maintenance (O&M) Manual for
additional information.
6.0 SYSTEM SETUP
6.1 Start the generator.
1.	Check that sufficient diesel fuel is available for planned operations. Insert a dip stick
through the fill cap located on the inside of the first door, on the left side from the rear
of the generator. The generator holds approximately 300 gallons of fuel.
2.	Connect, and secure by turning % turn, the flexible cables from the generator to the docking
station (Figure 13) on the back of the power distribution panel.

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Figure 13. Generator Docking Station
3. Turn the key on the battery isolation switch to connect the battery to the generator so
that it can be started (Figure 14). This will start an alarm on the generator control
panel.
Figure 14. Connect Battery in Preparation for Starting Generator
4. Turn off the alarm by pressing the alarm silence button, then press the green RUN
button to start the generator (Figure 15). Additional generator operating and

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maintenance information can be found in the Caterpillar Operation and Maintenance
Manual (Reference 3).
Alarm
button
re 15. Alarm and Run Buttons on Generator Control Panel
Switch power to systems.
1. Turn main disconnect switch located at the top right of the power distribution panel
ON (Figures 16a and 16b) by pushing it upward. This panel provides power for all of
the gasifier electric panels and accessories. See drawing number E-2.3 for
identification of all hardware.

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Main
disconnect
switch
Figure 16a. Outside of Power Distribution Panei

mm iim it
Figure 16b. Inside of Power Distribution Panel
2. Turn POWER switch on leftside of left front door ON (Figure 17). This turns on
power to the control hardware located in the power distribution panel and the white
power light should light up as well as other indicator lights on the left door panel.

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POWER
switch
Figure 17. Power Switch on front of Power Distribution Panel
3. Open door on EPA Gasifier Control System panel and turn the UPS ON (Figure 18;
location in panel shown in Figure 19). Close the door. The control hardware is
powered by the UPS and wilf not come on if the UPS is not enabled. The main
control panel interfaces with the Blower Management System (BMS), thermocouples,
combustion air, and blower motor starters. See drawing number E-3.1 (Appendix B)
for identification of hardware inside the main control panel.
Smart-UPS
Figure 18. UPS Controi Panel

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4.	Close cabinet door and turn disconnect switch on main control panel ON (shown in
Figure 19).
5.	Turn power switch on front door of control panel ON (Figure 20). White indicator light
should light up indicating that panel is energized. This switches power to the control
hardware.
6.	To enable remote connection/operation, connect extension cord and CAT 5 cable to
receptacle and connector location on left side of front door of Control Panel. Place
wireless internet receiver in a water resistant container at a safe location and as high
as possible on the mezzanine level.
Disconnect
Switch
Power
Switch
EPA Gasifier
Main Control
Panel
Figure 19. EPA Gasifier Control Panel, outside (a) and inside (b)

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EPA GASIFIER
CONTROL SYSTEM
Figure 20. Power Switch on EPA Gasifier Control Panel
6.3	Enable field devices.
Confirm all local motor disconnects are in the up or ON position.
6.4	Complete startup through SCADA system PAC interface.
1. Connect all computer accessories and Ethernet cable, then power up computer.
2 Set large monitor as the primary display in Windows.
3. Click on Start and select PAC Display which will open to the Home Screen (see
Figure 22). Using mouse, drag and drop this window from the laptop to the large
screen monitor. The following navigation buttons are located across the bottom of the
screen. Their function is detailed in Section 8,
a)	Go To Feed Sys Screen (under development)
b)	Go To Burner Screen (see Figure 23)
c)	Go To Temperature Screen (see Figure 24)
d)	Go To Motor Ctrl Screen (see Figure 25)
e)	Go To Alarm Screen (see Figure 26)
f)	Go To Calibration Screen (see Figure 27)

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4.	Go to the Motor Ctrl screen (Figure 25). Click the Forward Drag Chain buttons at
callout C located under the tags labeled SC-211 and SC-212 for gasifier sides 1 and
2, respectively. The buttons will change from displaying OFF to a filled green FW
status, and the Running lights should also illuminate at callout E for SC-211 and SC-
212. Click the Forward buttons once more to stop the drag chains.
The motors can be reversed by employing the same procedure by using the Reverse
buttons at callout D under tags SC-211 and SC-212.
5.	Motor speed can be changed by entering a percentage of full speed in the Freq SP
Opto box at callout G. These motors will not go below 11 Hz out of a possible 60 Hz.
6.	Before starting the burners, make sure the LP gas supply is on and a sufficient
quantity is available in the tanks for planned operations.
7.	DO NOT ADJUST THE SMALL VALVE TO THE PILOT. The flame rod will lose sight
of the pilot flame if it is too rich.
8.	Go to the Alarm Screen (Figure 26) and verify that there are no active alarms. Reset
any alarms present by selecting the Reset button at callout E.
9.	Go to the Burner Screen (Figure 23) and "enable" the burners by clicking on the
buttons next to Burner 1 and Burner 2 at callouts N and R, respectively. This will
start the flame safety sequence including a purge time, pilot trial for ignition time, and
enabling of the main gas valves if successful. Yellow flames will start flashing on the
screen when a flame is present and temperatures will start rising.
If a burner doesn't start after the trial for ignition period or the flame goes out for any
reason, a BMS Alarm will be indicated at callout P of Figure 23. To attempt a restart,
"disable" the burner by clicking the button at callout N. Wait a few seconds and
enable the burner again as described at the start of Step 9.
If a burner fails to light repeatedly, it may be necessary to manually reset the solenoid
valves on the gas lines by firmly pushing the indicator light on the front of the
solenoid (Figure 21).

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Indicator
Light
Figure 21. Gas Line Solenoid Valve Reset
10.	To control the gasifier to a specified temperature, enter a target set point at callout D
of Figure 23. It is recommended to ramp up the temperatures slowly to confirm the
operation of the temperature control system before advancing to the final target.
Confirm the Proportional Integral Derivative (PID) loops are in "auto" mode. They
can be toggled between "man" (manual) and "auto" using the button at callout F.
11.	While the unit is warming up, walk around the gasifier and look for hotspots on the
skin and confirm the proper operation of the other devices in the system. The area
around the burners can get quite hot. A glowing red area would indicate an
insulation failure.
METHOD CALIBRATION
The environmental sensors in the gasifier system include the following:
•	Eighteen thermocouples (plus six spare inputs) shown in Figure 24.
•	Two level switches (bindicators) shown at callout K in Figure 25,
Sensors should be routinely calibrated by a capable metrology laboratory or other reference standard.
The SCADA system applies linear correction curves to the raw transmitter inputs. The corrected values are
used for display and calculations, and the results are logged for later retrieval and analysis. See Section
8.6 for additional information on the calibration procedure.

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SYSTEM OPERATION
The SCADA system provides the main interface with the gasifier control system. The graphical interface
allows the user to enter set points, review historical data, view alarm conditions, and interface with the
process control hardware. There are seven screens:
1.	Home Screen
2.	Feed System Screen (under development and not addressed in this SOP)
3.	Burner Screen
4.	Temperature Screen
5.	Motor Control Screen
6.	Alarm Screen
7.	Calibration Screen
The graphs shown on many of the PAC Display screens display historical data for review by the operator
and provide a quick check for anomalies. The display characteristics of the graph can be changed using the
icons located below the graph's window. The active variable can be chosen using the drop-down arrow
below the graph. By clicking on the magnifying glass, the y-scale for the active variable can be changed.
Historical data that has been shifted off the real-time graph can be displayed by clicking the folder icon
and selecting the appropriate day. The arrows can then be used to page through time. To return to real
time, simply click the clock icon. Additional information about the graphing features and options can be
found in Opto 22's PAC Display Manual (Reference 1).
The operation of the system will be described screen-by-screen starting with the Home Screen.
For each screen, the user interface will be described, as well as general information about the
physical devices that are manipulated in the control strategy as they relate to the screen. Note
that any number or "button" with a yellow outline represents a user-settable number or condition. Yellow
outlined buttons are also used to enable devices and for navigation between the screens.
8.1 Home Screen
The Home Screen is shown in Figure 22. The Home Screen allows quick access to all of the
screens as well as providing a graphic of the system flow and instrumentation. From this screen,
the operator can navigate to any of the other screens using the buttons identified by callouts A
through E.

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Callout
Screen
A
Burner
B
Temperature
C
Motor Control
D
Alarm
E
Calibration
The Power Monitor Reset buttons, identified by callout F in Figure 22, are used to latch a relay
inside the control panel. This relay opens if there is a failure in the power supplied to the control
panel. The opening of this relay alerts the operator (see Alarm Screen, Figure 26) and control
system that a power failure has occurred. If the Power Monitor light is green, nothing needs to
be done. If it is flashing red, then the relay has opened and should be reset by selecting the
"Reset" button. Note that this relay will not unlatch when the power switch on the panel is
cycled. A Power Monitor light flashing red does not necessarily mean that there is presently no
power to the control panel, but that a power failure has occurred since the last "reset". If the
Power Monitor light does not go to green after selecting "reset", then the outage is still in effect.
The status of the relay can be observed by looking at the indicator status on control relay CR-1
inside the main control panel.

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U.S. ENVIRONMENTAL PROTECTION AGENCY - GASIFIER CONTROL SYSTEM
Primary Chamber #1
Secondary Chamber *1
Primary Chamber #2
Goto
Cabbratrof
Figure 22. Home Screen

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Burner Screen
The Burner Screen shown in Figure 23 allows the operator to "enable" the burners and to control
and monitor the burners and temperature set points in each gasifier chamber.
The buttons located at callout A are used to enable the burners for each chamber.
Burners 1 and 2 can also be "enabled" by clicking on the buttons at callouts N and R,
respectively. This will start the flame safety sequence including a purge time and pilot
trial for ignition time, and will then enable the main gas valves if the pilot was successful.
Yellow flames will start flashing on the screen when a flame is present and temperatures
will start rising. If a burner doesn't start after the trial for ignition period or the flame goes
out for any reason, a BMS Alarm will be indicated at callout P. Callout O indicates when
the burner combustion air blower has been enabled; callout Q is clicked to toggle the
secondary air blower and is typically not used. Note: Callout Q should be disabled and
the disconnects at the secondary air blowers locked out because they have been blocked
with refractory material.
Callouts L and M on the Burner Screen can be used to toggle the drag chains on and off. Drag chain
control can also be accessed through the Motor Ctrl screen (Figure 25) where the speed and
direction of the chain can be modified.
The buttons located at callout B indicate the thermocouple providing the PV Input for
each chamber. Each chamber has two control thermocouple choices: one in the primary
chamber (TE-212 and TE-222 for chambers #1 and #2, respectively), and one located at
the end of the secondary chamber under each hearth (TE-213 and TE-223 for chambers
#1 and #2, respectively). Clicking on the buttons at callout B will toggle between the two
options. Due to the indirect heating of the chamber area, it was found that controlling to
the secondary temperature was more responsive and provided a much more responsive
feedback control loop. This condition may change once carcass material is introduced
into the primary chambers.
Callout C shows the current process variables, while the target set points are shown at
and can be adjusted at callout D. The button at callout F allows the operator to switch the
PID calculation to manual. In manual mode, the output value does not automatically
adjust, and the operator can manually control the burner output by entering a percent
output value at callout E.

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The P, I, and D parameters located at callout G are involved in the PID calculation. The
PID algorithm adjusts the PID Output value to align the process variable with the target
set point. Adjusting these parameters (P, I and D) will "tune" the PID loop and can be
used to reduce the response time or increase the stability of the process. Typically these
values should not be changed. If the operator wishes to change these values, they
should record the current values for later reference in the event that the loop becomes
unstable.
"Max dOut" at callout H will set an upper limit on the allowable output change by the PID
calculation. The "Input Low Clamp" and "Input High Clamp" at callout I are basic limits on the input
values (temperatures) feeding into the PID algorithm. "Output Hi Clamp" at callout J will limit the
maximum output of the burner. For example, it may be advantageous to limit the "Output Hi
Clamp" of the burner to 85 percent to prevent overheating. "Scan Time" at callout K determines
how often the PID algorithm is run in seconds. None of these tuning parameters will typically need
to be modified unless there are significant physical changes to the system.

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£il* ¥#*
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4/50/2015
Figure 23. Burner Screen

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Temperature Screen
The temperature screen is shown in Figure 24. This screen shows all of the measured
temperatures in the gasifier as well as a graphic of their general location. The bin screw
temperatures are also shown on this screen. These are used to monitor for flashback into the
feed screws and shut the system down if the temperatures exceed certain values.

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V.; r .r	&»«:- C	Oft* PAC Zh.f'^- 				">
ierature Screen
Primary Chamber #1
Secondary Chamber #1
Secondary Chamber ft2
Figure 24. Temperature Screen

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Motor Control Screen
The Motor Control Screen is shown in Figure 25. This screen allows the operator to
control all of the motors in the system and view the operational status of the motor
controllers. It also allows the operator to reset motor controller faults, open and close the
feed valves, and shows the status of the bindicator level switches.
In the top left of the screen are the six speed controllers (variable frequency drives)
identified by the tags to the left of callout A. The motors can be controlled from the
computer interface or manually from the front of the power panel. The system defaults to
computer control, however each motor can be switched to manual control by toggling the
button to the left of callout B. This switches between "Modbus" and "Teminal" mode. In
"Modbus" mode, the motor is controlled by the power distribution PAC via the RS-485
Modbus network. In the "Terminal" mode, the motor is controlled by the screw terminals
on the variable frequency drive that are connected to switches mounted on the front of
the power distribution panel.
Forward and reverse operation of each motor is allowed by toggling the buttons at
callouts C and D. The motor should be toggled off before reversing the direction. The
status of the drive is shown to the left of callout E. When the drive status is filled solid
green, the drive is ready. When the drive is running in either the forward or reverse
direction, the running indicator to the left of callout F is filled green. Faults are indicated
to the left of callout G by a flashing red button. The frequency set point in percent is
entered at the left of callout H. 100% corresponds to the maximum speed or frequency of
60 Hz. Note that the minimum drive speed is 11 Hz or approximately 18% of full speed.
Operational details are provided to the left of callout I, including the frequency set point,
actual frequency, motor current, and the last fault code stored in the drive. Drive faults
can usually be reset by pressing the "reset faults" button to the left of callout J. If the fault
does not clear, note the drive fault code and refer to the appropriate drive manual.
Below the speed controllers are the controls for the soft starters SS-101 and SS-104.
The soft starters are used to ramp the speed up on the pre-breaker and finer. The
motors can be switched on using the buttons to the right of callout K. They can also be
used to reverse the speed of each motor using the button to the left of callout L. The
motor should be switched off prior to reversing direction. There are several status
buttons to the left of callout M that indicate the operational status of the soft starter. The
"Ready to switch on" and "Switched on" follow nomenclature in the starter manual and
need to be filled green prior to enabling the motor. A problem with the starter is shown by

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a flashing red button to the left of callout N. The motor current is displayed to the left of
callout O. Starter faults can often be reset using the buttons to the left of callout P. If the
fault does not clear, check the circuit breaker in the power panel, note the fault displayed
on the front of the soft starter, and refer to the starter manual as needed.
The feed screw, ash auger, and the two combustion air blowers have basic on/off control.
The feed screw and combustion air blowers are controlled with combination motor
controllers and can be switched on and off using the buttons to the left of callout Q. The
ash auger is a very small motor controlled by a relay (2-CR).
Slide gate valves 1 and 2 are controlled with reversing combination motor controllers.
When the "open" button is selected at callout R, the motor runs until the open limit switch
is triggered. Similarly, when the "closed" button is selected (callout S), the motor runs
until the closed limit switch is triggered. The "stop" button at callout T will stop the motor,
but it has little use since the valves open and close nearly instantaneously after pressing
the open or close button. Both accumulator bin screws and the feed screw will be
stopped if either slide gate valve is closed.
Also displayed on this screen at callout U is the status of the bindicators located in the
accumulator hopper. If the "high" switch is met, the pump will be stopped to prevent
overfilling the accumulator hopper. Similarly, the pump and pump feed screw will be
started if the "low" switch is not met indicating a close to empty condition.

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Figure 25. Motor Control Screen

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Alarm Screen
The Alarm Screen is shown in Figure 26. This screen typically displays some of the most
important process variables as well as any alarm conditions that may be present. The
area above callout A displays the current process variable. If this is a controlled variable,
the set point is displayed in the area above callout B. In the case of the gasifier
temperature control system, these set points may correspond to primary or secondary
chamber temperatures. See Section 8.2 describing the burner operation and
temperature control for additional information on switching the control set points from the
primary to the secondary chamber. The low and high alarm limits can be entered above
callouts C and D, respectively. If an alarm condition is detected, the condition at the time
of alarm will be stored in red under the "Trap" column. The alarm and the trapped
conditions are cleared by pressing the "Reset" button at callout E.
While not shown explicitly on this screen, the power monitor alarm is configured and will
be displayed in the alarm log above callout F. Alarms stored in the alarm log can be
acknowledged using the "Acknowledge" and "Acknowledge All" buttons at callout G.
Additional information on the operation of the alarm display log can be found in Opto 22's
PAC Display Manual (Reference 1).

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V.; r .r	&»«:- C	Oft* PAC Zh.f'^- 				">
ol System - Alarm Screen
Figure 26. Alarm Screen

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Calibration Screen
The Calibration Screen is shown in Figure 27. This screen displays calibration data for
the thermocouples used in the system. The area above callout A displays the "raw" signal
received by the main control panel. This may be a voltage, milliamps (mA), or an un-
calibrated variable. In the area above callouts B and C, the operator can enter linear
corrections (scale and offset values, y = mx + b) for each sensor. The values displayed
on all of the other SCADA screens and the values logged to primary data file are the
"calibrated" values shown above callout D after the application of the linear correction
factors. A capable metrology lab or certified reference device can assist in determining
these values.
The button on the right of the screen at callout E labeled "Enable (or Disable) Calibration
Log" will enable the recording of the "raw" values from the sensors. With the calibration
log enabled, the raw data is collected every 5 seconds to a data file located in "C:\Data".
This data can be compared to the reference measurements using a linear regression
procedure to calculate correction factors that will map the raw values into calibrated
engineering units.
The calibration factors can then be entered on the calibration screen, but these values
will be replaced with the default values the next time the control strategy is downloaded
to the PAC. Any values that have been entered on this screen will revert back to those
stored in the "C:\Gasifier Opto\PAC ControlWlain Control\lnit.txt" file. For this reason, it is
good practice to update the "lnit.txt" file as soon as new calibration data is available.
ARCADIS staff in the EPA metrology laboratory are familiar with this file and can assist in
modifying it with the appropriate values. Instead of entering the scale and offset
manually on the screen, it is typically easier and more accurate to download the PAC
Control program and let the values be updated directly from the "lnit.txt" file. See the PAC
Control User Guide (Reference 2) for additional information on downloading strategies.
The contents of the "lnit.txt" file are similar to the following text containing scale and offset
values for all of the sensors:
\ ""DOWNLOAD_COMPRESSION_OFF
1.0 1	}TE_Scale TABLE!
1.0 2	}TE_Scale TABLE!
1.0 3	}TE_Scale TABLE!
1.0 4	}TE_Scale TABLE!

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1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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0
5
}TE Scale TABLE!
0
6
}TE Scale TABLE!
0
7
}TE Scale TABLE!
0
8
}TE Scale TABLE!
0
9
}TE Scale TABLE!
0
10
}TE Scale TABLE!
0
11
}TE Scale TABLE!
0
12
}TE Scale TABLE!
0
13
}TE Scale TABLE!
0
14
}TE Scale TABLE!
0
15
}TE Scale TABLE!
0
16
}TE Scale TABLE!
0
17
}TE Scale TABLE!
0
18
}TE Scale TABLE!
0
19
}TE Scale TABLE!
0
20
}TE Scale TABLE!
0
21
}TE Scale TABLE!
0
22
}TE Scale TABLE!
0
1
}TE Offset TABLE!
0
2
}TE Offset TABLE!
0
3
}TE Offset TABLE!
0
4
}TE Offset TABLE!
0
5
}TE Offset TABLE!
0
6
}TE Offset TABLE!
0
7
}TE Offset TABLE!
0
8
}TE Offset TABLE!
0
9
}TE Offset TABLE!
0
10
}TE Offset TABLE
0
11
}TE Offset TABLE
0
12
}TE Offset TABLE
0
13
}TE Offset TABLE
0
14
}TE Offset TABLE
0
15
}TE Offset TABLE
0
16
}TE Offset TABLE
0
17
}TE Offset TABLE
0
18
}TE Offset TABLE
0
19
}TE Offset TABLE
0
20
}TE Offset TABLE
0
21
}TE Offset TABLE

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0.0 22 }TE_Offset TABLE!
0.0 23 }TE_Offset TABLE!
0.0 24 }TE_Offset TABLE!
1000.0 1 }Alm_Limits_Hi TABLE!
1000.0 2 }Alm_Limits_Hi TABLE!
816.0 3 }Alm_Limits_Hi TABLE!
816.0 4 }Alm_Limits_Hi TABLE!
193.0 5 }Alm_Limits_Hi TABLE!
850.0 6 }Alm_Limits_Hi TABLE!
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0.0 1	}Alm_Limits_Lo TABLE!
0.0 2	}Alm_Limits_Lo TABLE!
0.0 3	}Alm_Limits_Lo TABLE!
0.0 4	}Alm_Limits_Lo TABLE!
0.0 5	}Alm_Limits_Lo TABLE!
140.0	6 }Alm_Limits_Lo TABLE!

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||g PAC CXsfrfj* Mwt ltac- CA&fHfcpOlWAWC	*

Gasifier Control System - Calibration Screen
Scute Offset deq C
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Figure 27. Calibration Screen

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Log Files
The operator interface (PAC Display) creates four historical data files. The variables and the
recording frequency for each are described in this section.
Primary Historical Data Log -10 second samples (C:\Data\date.h06)
The primary historical data log contains the current operating conditions of the gasifier system
vs. time. The values recorded are after the application of the scale and offset calibration factors.
The following parameters are recorded in the primary data log every 10 seconds:
•	Date
•	Time
•	TE_lll_Surge_Bin_Screw (C) temperature
•	TE_112_Surge_Bin_Screw (C) temperature
•	TE_211_Primary_Chamber (C) temperature
•	TE_212_Primary_Chamber (C) temperature
•	TE_213_Secondary_Chamber (C) temperature
•	TE_214_Secondary_Chamber (C) temperature
•	TE_215_Downstream_of_Burner (C) temperature
•	TE_216_Drag_Chain_Drive_Box (C) temperature
•	TE_221_Primary_Chamber (C) temperature
•	TE_222_Primary_ChambeR (C) temperature
•	TE_223_Secondary_Chamber (C) temperature
•	TE_224_Secondary_Chamber (C) temperature
•	TE_225_Downstream_of_Burner (C) temperature
•	TE_226_Drag_Chain_Drive_Box (C) temperature
•	TE_231_Ash_Auger (C) temperature
•	TE_232_Ash_Auger_Exit (C) temperature
•	TE_233_Stack (C) temperature
•	TE_241_Ambient (C) temperature
Sample:
Date,Time,TE 111 Surge Bin Screw (C),TE 112 Surge Bin Screw
(C),TE 211 Primary Chamber (C),TE 212 Primary Chamber
(C),TE 213 Secondary Chamber (C),TE 214 Secondary Chamber

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(C),TE 215 Downstream of Burner (C),TE 216 Drag Chain Drive Box
(C),TE 221 Primary Chamber (C),TE 222 Primary ChambeR
(C),TE 223 Secondary Chamber (C),TE 224 Secondary Chamber
(C),TE 225 Downstream of Burner (C),TE 226 Drag Chain Drive Box
(C),TE_231_Ash_Auger (C),TE_232_Ash_Auger_Exit (C),TE_233_Stack
(C),TE_241_Ambient (C)
2015/03/02,11:59:32,13.152,13.327,7.638,7.115,6.316,6.466,6.366,7
.713,7.414,7.015,6.166,5.992,5.842,7.339,6.466,8.786,6.491,11.830
2015/03/02,11:59:42,13.2 02,13.377,7.63 8,7.040,6.341,6.341,6.316,7
.663,7.414,7.164,5.967,5.942,6.017,7.439,6.491,8.811,6.616,11.980
2015/03/02,11:59:52,13.277,13.4 02,7.63 8,7.115,6.191,6.241,6.341,7
.688,7.489,7.214,6.042,6.017,5.992,7.489,6.491,8.811,6.541,11.830
2015/03/02,12:00:02,13.177,13.377,7.564,7.189,6.366,6.441,6.266,7
.688,7.514,7.164,6.216,6.042,5.942,7.439,6.391,8.786,6.516,11.855
The refresh time is currently set at 10 seconds for the primary log. This can be changed within
the PAC Display Configurator program: Configure/Historic Data Log/Primary/Modify/Refresh
Time/ and then select a new time.
Calibration Historical Data Log - 5-second samples (C:\Data\date.h05)
The calibration data log is only enabled during calibration periods to record the raw values of
temperature and mA. This data log writes values every 5 seconds to provide additional data for
averaging prior to the calibration regression calculations. The parameters recorded and the
format are the same as for the primary log.
Alarm Log (C:\Data\Alarms\date.alm)
The alarm log provides a time stamped text record of all alarm events.
Sample:
10:28:56,2014/12/08,Power Monitor,FALSE,In Alarm,0,Power Failure
12:15:16,2014/12/08,Power Monitor,FALSE,In Alarm,0,Power Failure
SAMPLE COLLECTION, PRESERVATION, AND STORAGE
There are no sampling events associated with this SOP.

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10.0 SAMPLE ANALYSIS PROCEDURE
There are no sample analyses associated with this SOP.
11.0 DATA ANALYSIS AND CALCULATIONS
The data is logged to comma separated values (CSV) files as described in Section 8.14 and are stored in
"C:\Data". A new file is started daily with the naming convention: RDYYMMDD.H06. The files can be easily
imported into a spreadsheet or other program for data reduction or statistical analysis.
12.0 COMPUTER HARDWARE AND SOFTWARE
The SCADA computer is connected to the main control panel through an Ethernet switch located in the
control panel. A custom "Project" has been configured within Opto 22's PAC Display Configurator and
runs with Opto 22's PAC Display Runtime. This "Project" is the basis of the SCADA system. A custom
"Strategy" has been configured with Opto 22's PAC Control program that runs on the PAC located inside
the main control panel and the one located inside the power distribution panel. These processors
communicate with all of the field devices, maintain interlocks, and control all of the PID loops. See
References 1 and 2 for additional information the Opto 22 software.
13.0 DATA AND RECORDS MANAGEMENT
The logged environmental data files are stored on the hard drive of the SCADA computer in "C:\Data".
Backups of the data and the Opto 22 configuration files in the "C:\Gasifier Opto" folder should be
performed at least every 6 months. Descriptions of test plan experiments should be recorded in
laboratory notebooks.
14.0 QUALITY ASSURANCE
Environmental sensors (temperature, humidity, pressure, differential pressure, and flow) should be
calibrated at least once a year.
15.0 PERIODIC MAINTENANCE
The SCADA system requires very little maintenance other than data backup and associated instrument
calibration. UPS batteries should be replaced every 3 to 5 years.

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Beginning of every test: Verify that all temperature, humidity, differential pressure, and absolute
pressure transmitters are displaying reasonable values. With the system off for an extended period of
time, all temperature sensors should indicate readings close to ambient temperatures. Perform daily
instrument calibrations required by the quality assurance (QA) plan.
Monthly: Perform monthly instrument calibrations and QA checks required by the QA plan. Confirm
proper operation of the flame safety system and associated sensors, valves, and interlocks. Refer to the
maintenance section of the gasifier O&M Manual for control system hardware maintenance schedules.
This manual contains reference manuals for all of the component systems.
Yearly: Refer to the maintenance section of the gasifier O&M Manual for control system hardware
maintenance schedules. This manual contains reference manuals for all of the component systems. The
Grinding, Transfer, Accumulation, and Feed (GTAF) System Manual can be seen in Appendix C.
16.0 TROUBLESHOOTING
If normal troubleshooting procedures, including those listed in the equipment manuals of the ARCADIS
gasifier O&M Manual do not solve the problem, call the gasifier control system integrator:
ARCADIS U.S., Inc.
4915 Prospectus Drive
Durham, NC 27713
919-544-4535
Rendeq Inc
1813 Frank Holt Drive
Burlington, NC 27215
336-226-1100
Eclipse, Inc.
5959 Shallowford Road
Chattanooga, TN 37421
423-643-2180
Joe Moore & Company
1431 Gavin Street
Raleigh, NC 27608
919-832-1665
Jim Howard

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6117 Riverside Drive
Wake Forest, NC 27587
919-306-0409
17.0 REFERENCES
1.	PAC Display User's Guide, Form 1702-110720—July 2011, Opto 22, Temecula, CA 92590-
3614.
2.	PAC Control User's Guide, Form 1700-110720—July 2011, Opto 22, Temecula, CA 92590-
3614.
3. Operation and Maintenance Manual, C9 Generator Set, March 2006, Caterpillar, Mossville, IL
61552-0610.

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APPENDIX B: Gasifier Schematics

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U.S. Environmental Protection Agency
Transportable Gasifier Control System
Research Triangle Park, NC
For U.S. Environmental Protection Agency
109 T.W. Alexander Drive, RTP, North Carolina 27711
Phone: (919)541-3817 Fax: (919)541-XXXX
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INDEX OF DRAWINGS
Cover Sheet
ARCADIS Drawings
E-1.1 Trailer Front Deck Layout
E-1.2 Control Panel Riser Diagram
E-1.3 Control Panel Riser Diagram
E-2.1	Power Panel Front Layout
E-2.2	Power Panel Rear Layout
E-2.3	Power Panel Internal Layout
E-2.4	480 VAC Distribution Schematic
E-2.5	480 VAC Distribution Schematic
E-2.6	Power Panel Ctrls Schematic
E-2.7	Power Panel Ctrls Schematic
E-2.8	Power Panel Ctrls Schematic
E-2.9	Power Panel Ctrls Schematic
E-2.10	Power Pnl Pushbutton Layout
E-3.1	Control Panel Layout
E-3.2	Control Panel Power Distribution
E-3.3	Control Panel Power Distribution
E-3.4	Control Panel Schematic
E-3.5	Control Panel Schematic
E-3.6	Control Panel Schematic
E-4.1	Burner Panel Layout
E-4.2	BMS Controls Schematic
& ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F
Durham, North Carolina 27713
Tel: 919-544-4535 Fax: 919-544-5690

-------
i |
"d" c
£ D
FZ
a: -c
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REV. ISSUED DATE DESCRIPTION
PROJECT TITLE
LIGHT
SUPPORT
TRANSFORMER
TRA
PANELBOARD
"A"
SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
TRAILER FRONT DECK LAYOUT
TRAILER FRONT
DECK PLAN VIEW
PROJECT MANAGER
B. HALL
DEPARTMENT MANAGER
LEAD DESIGN PROF.
CHECKED BY
TASK/PHASE NUMBER
00001
DRAWN BY
R. SHARPE
PROJECT NUMBER
DRAWING NUMBER
RN990274.0021
© 2014 ARCADIS U.S., Inc.
1 =16
EXISTING HANDRAIL
AND LIMITS OF-
TRAILER FRONT DECK
-11'-
_jm_
GENERATOR
DOCKING
STATION
POWER DISTRIBUTION
PANEL

-------
NOTES
1.	MULTI-CONDUCTOR CABLE INFORMATION
BELDEN 8760 18 AWG, TSP, NOM. OD = 0.222"
BELDEN 9534 24 AWG, 4 CONDUCTOR NOM. OD = 0.184"
BELDEN 9536 24 AWG, 6 CONDUCTOR NOM. OD = 0,209"
BELDEN 9540 24 AWG, 10 CONDUCTOR NOM. OD = 0.244"
STEREN 300-783, 24 AWG SOLID, CAT5E UTP, OD = 0.212"
2.	USE TYPE KX THERMOCOUPLE EXTENSION WIRE, 20 GA SOLID, UL
LISTED TYPE PLTC, OD «0.137x0.204".
3.	ALL LOW VOLTAGE (^24 VDC) WIRING iS SUPPLIED FROM UL LISTED
CLASS 2 POWER SUPPLIES.
4.	ADJUST WIRE AND CONDUIT SIZES TO MEET AMPACITY AND CONDUIT
FILL REQUIREMENTS FOR LOADS AND OPERATING CONDITIONS.
5.	-
6. -
i »
5 I
- g
ZJ
CONTROL
PANEL
(CP)
%"C, 7# 1 4, & 1 #14(G)
%>"C, 1 TSP
%"C, 7# 1 4, & 1 #14(G)
%>"C, 1 TSP
BMS #1
CONTROL
PANEL
BMS #2
CONTROL
PANEL
%"C, 12#1 4, & 1 #14(G)
%"C, 7# 14, & 1 #14(G)
ECLIPSE
RATIOMATIC
BURNER #1
AREA
PROPANE
VALVE TRAIN
JUNCTION
BOX #1
5/4"C, 10#14, & 1 $14(G)
1/2"C, 2# 14, & 1 $14(G)
h"C, 1#14, & 1 #14(G)
%"C, 2# 14, & 1 $14(G)
-| E-STOP h
%"C, 2#14, & 1 #14(G)
1/2"C, 1 HIGH TENSION
ye, i tsp
%"C, 12#1 4, & 1 #14(G)
¦jj"c, 7# 14, & 1 #14(G)
ECLIPSE
RATIOMATIC
BURNER #2
AREA
PROPANE
VALVE TRAIN
JUNCTION
BOX #2
5/4"C, 10#14, & 1 $14(G)
1/2"C, 2# 14, & 1 #14(G)
%"C, 1 #1 4, & 1 #14(G)
%"C, 2# 14, & 1 $14(G)
-| E-STOP h
£"C, 2#14, & 1 #14(G)
1/2"C, 1 HIGH TENSION
JS"C, 1 TSP
© 2014 ARCADIS U.S., Inc.
j		1 SIEMENS REVERSING
"I	 ZUZ	1 ACTUATOR
H SV-2.02 | AIR FLOW PRESSURE SWITCH
\
> 120 VAC
H FLAME ROD~| FLAME ROD
H E-STOP #T"l REMOTE E-STOPS
H IGNITER | SPARK PLUG
H FCV-101 I SIEMENS REVERSING ACTUATOR
HIGH
TENSION
24 VDC
OR LESS
j		1 SIEMENS REVERSING
"I	 ZUZ	1 ACTUATOR
H SV-2.02 | AIR FLOW PRESSURE SWITCH
\
> 120 VAC
H FLAME ROD~| FLAME ROD
H E-STOP #T"l REMOTE E-STOPS
H IGNITER | SPARK PLUG
H FCV-101 I SIEMENS REVERSING ACTUATOR
HIGH
TENSION
24 VDC
OR LESS
1 3/5/14
ISSUED FOR
REVIEW
REV. ISSUED DATE DESCRIPTION
fr ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durham, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.arcadis-UB.cQni
PROJECT TITLE


£
PRCfl*-

%
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SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
RISER DIAGRAM
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-1.2

-------
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THERMO-
COUPLE
J-BOX
1J£"C. 2Q#20KX
CONTROL
PANEL
(CP)
%"C, 5# 14, & 1# 14(G)
%"C, 5# 14, & 1# 14(G)
2"C, 76#14, & 1 §14(G)
BURNER #1
	&RE4	
BURNER #2
	&RE£	
FEED AREA
>
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© 2014 ARCADIS U.S., Inc.
%"C. 1#20KX
yC, 1#20KX
yC, 1#20KX
yc, 1#20KX
%"C. 1#20KX
yc, 1#20KX
yc, 1#20KX
yc, 1#20KX
yc, 1#20KX
%"C. 1#20KX
yc, 1#20KX
yc, 1#20KX
yc, 1#20KX
yc, 1#20KX
%"C. 1#20KX
yC, 1#20KX
yc, 1#20KX
yc, 1#20KX
yc, 1#20KX
%"C. 1#20KX
TE—111	I SIDE 1 SURGE BIN SCREW	\
TE-112	I SIDE 2 SURGE BIN SCREW
TE—211	I SIDE 1 PRIMARY CHAMBER
TE—212	I SIDE 1 PRIMARY CHAMBER
TE—213	I SIDE 1 SECONDARY CHAMBER
TE—214	I SIDE 1 SECONDARY CHAMBER
TE—215	I SIDE 1 DOWNSTREAM OF BURNER
TE—216	I SIDE 1 DRAG CHAIN BOX
TE—221	I SIDE 2 PRIMARY CHAMBER
TE—222	I SIDE 2 PRIMARY CHAMBER
TE—223	I SIDE 2 SECONDARY CHAMBER
TE—224	I SIDE 2 SECONDARY CHAMBER
TE—225	I SIDE 2 DOWNSTREAM OF BURNER
TE—226	I SIDE 2 DRAG CHAIN BOX
TE—231	I ASH AUGER
TE—232	I ASH AUGER EXIT
TE—233	I STACK
TE—241	I AMBIENT
TE—XXX	] SPARE
TE—XXX	] SPARE	/
>
24 VDC
OR LESS
1/2"C, 3#14, & 1 #14(G)
\
1/2"C, 2#14, & 1 #14(G)
1/2"C, 3#14, & 1 #14(G)
1/2"C, 2#14, & 1 #14(G)
M—101	I	BURNER #1 BLOWER MOTOR
M-111	I	SECONDARY AIR BLOWER #1
M-102	I	BURNER §2 BLOWER MOTOR
M-112	I	SECONDARY AIR BLOWER #2
k 120/208
/ VAC
1/2"C, 2#14, & 1#14(G)
M-213
ASH AUGER MOTOR
/
1 3/5/14
ISSUED FOR
REVIEW
REV. ISSUED BATE DESCRIPTION
fr ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durham, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.arcadis-UB.cQni
PROJECT TITLE


£
PRCfl^
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%
UJ
0
SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
RISER DIAGRAM
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-1.3

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NOTES
1.	DIMENSIONS SHOWN ARE FOR REFERENCE PURPOSES ONLY.
2.	TERMINAL BLOCKS AND WIREWAY SHOULD BE ARRANGED TO FACILITATE FIELD CONNECTIONS.
3.
6.
7.
COMPONENTS SHOWN ARE TO SCALE. DEVIATIONS FROM THE GENERAL ARRANGEMENT SHOWN
HERE ARE SUBJECT TO APPROVAL BY ARCADIS.
TERMINAL BLOCKS FOR HIGH VOLTAGE (>100 VAC) FIELD WIRING MUST BE LARGE ENOUGH TO
ACCEPT #14 AWG.
PANDUIT (WIREWAY) AS SHOWN IN DRAWING MAY PASS OVER INTERNAL PANEL MOUNTING
STUDS/NUTS. CUT HOLE IN BACK OF PANDUIT TO ALLOW CLEARANCE.
UL 508 LISTING AND LABELING IS REQUIRED FOR THIS PANEL ASSEMBLY.

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OPENED	OPENED
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PUSHBUTTON ARRANGEMENT
US EPA
GASIFIER POWER
DISTRIBUTION

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116 4315
4055
3R RAINHOOD
^PFANNENBERG
PF-RH 40000
TYP. OF 2
© 2014 ARCADIS U.S., Inc.
1 2/27/14
ISSUED FOR
REVIEW
REV. ISSUED BOTE DESCRIPTION
& ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durtiom, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.orcadi8-us.coni
PROJECT TITLE


£
PRO^

%
UJ
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SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
POWER PANEL FRONT LAYOUT
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-2.1

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WATERTIGHT TWIST-LOCK
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SC-111
SC-112
CMC—121
CMC—121
SC-211
CMC-123
FEED SCREW
BIN SCREW
BIN SCREW
GATE VALVE
GATE VALVE
DRAG CHAIN
DRIVE
DRIVE
SC-211 SC-102
DRAG CHAIN PB SCREW
2	DRIVE
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WATERTIGHT TWIST-LOCK
"RECEPTACLE
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REV. ISSUED DATE DESCRIPTION
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PROJECT TITLE

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LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-2.2

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INTERIOR PANEL LAYOUT
CUTOUTS FOR FEEDER
FROM DOCKING STATION
ADD PLASTIC EDGE TRIM
TO ALL CUT EDGES
PRIMARY FEEDER
ROUTING
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PANEL
EXTERIOR
LIMITS
© 2014 ARCADIS U.S., Inc.
1 2/27/14
ISSUED FOR
REVIEW
REV. ISSUED BOTE DESCRIPTION
& ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durtiom, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.orcadi8-us.coni
PROJECT TITLE
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UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
POWER PANEL INTERNAL LAYOUT
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-2.3

-------
(Vs)
©
.	GROUNDING
V*-r>T ELECTRODE
CONDUCTOR
#1/0
—	
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OPERATION)
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CONDUCTOR
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in lu2b 12FU nr

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CONTINUED ON
DRAWING E—2.5
	3# 14
;3D
;3S)
PB-24
100 HP
124 A © 480 VAC
FINER
100 HP
124 A © 480 VAC
M -v SCREW DRIVE (EXISTING)
Vl02y 7-5 HP
v J 17 A 9 480 VAC
PUMP DRIVE (EXISTING)
30 HP
42 A ® 480 VAC
SURGE BIN SCREW DRIVE
5 HP
11.5 A 8 480 VAC
SURGE BIN SCREW DRIVE
5 HP
11.5 A © 480 VAC
VALVE ACTUATOR MOTOR
1 HP
2.1 A © 480 VAC
VALVE ACTUATOR MOTOR
1 HP
2.1 A @ 480 VAC
FEED SCREW
3 HP
4.8 A © 480 VAC
FUS
E SPECIFICATIONS
TAG
AMPS
CLASS
TYPE
MODEL
F—1
10
J
TIME-DELAY
BUSSMANN LPJ-10SP
F—11
20
J
DRIVE FUSE
BUSSMANN DF'J—20
F—12
20
J
DRIVE FUSE
BUSSMANN DFJ—20
F—21
20
J
DRIVE FUSE
BUSSMANN DFJ—20
F—22
20
J
DRIVE FUSE
BUSSMANN DFJ—20
F—15
25
J
TIME-DELAY
BUSSMANN LPJ-25SP
© 2014 ARCADIS U.S., Inc.
CIRCUIT BREAKER SPECIFICATIONS
TAG
AMPS
POLES
SC RATING
MODEL
CB—1
200
3
35kA
SQUARE D JGL36200
CB—2
30
3
18kA
SQUARE D FAL34030*
CB—3
100
3
18kA
SQUARE D FAL34100*
CB—4
200
3
35kA
SQUARE D JGL36200
CB—11
600
3
35kA
SQUARE D MGL36600
CB-12
175
3
35kA
SQUARE D JGL36175




~EXISTING - PROVIDED




BY ARCADIS, INSTALLED




BY FABRICATOR
f7\ 320 kW RENTAL GENERATOR SET WITH 4/0 PARALLELED
CONDUCTORS AND CAM LOCK LEADS
/7\ 2x3#4/0 & 2x#4/0 GROUND (90"C TYPE W CABLE WITH
\=/ CAM-STYLE ENDS)
EXISTING 22.5 kW CATERPILLAR C9 GENERATOR SET WITH BUILT IN
/Vk 400 AMP 35 kAIC CIRCUIT BREAKER. INSTALL TRYSTAR 400 AMP
W GLAND PLATE GLD-ALS-4004-FSS-F WITH PLASTIC FLIP COVERS
FOR CAM-LOCK CABLE CONNECTIONS.
/TV 3#4/0 & 1#4/0 GROUND (90*C TYPE W CABLE WITH CAM-STYLE
W ENDS)
600 AMP 48OV/30/4—WIRE WALL MOUNT TRYSTAR GENERATOR
(H) DOCKING STATION. TWO SETS OF MALE CAM-LOCKS PER PHASE.
^ LOAD LUGS ARE RATED FOR (2) #4-600 MCM CABLES.
PANDUIT 18—PORT UNIVERSAL GROUND BAR MODULE
/-\ UGB2/0—414—18 MOUNTED WITH TWO BONDING STAND-OFFS
W UGB—3—SO AND ADDITIONAL CLMAR2/0—14—Q CONNECTOR FOR
PARALLELED 2/0 GROUND CONDUCTORS.
SQUARE D POWERPACT M-FRAME 600 AMP MOLDED CASE CIRCUIT
(7) BREAKER MGL36600. STANDARD LUG CONFIGURATION: (3) 3/0
AWG-500 kcmil PER LUG.
POWERPACT J-FRAME THERMAL-MAGNETIC CIRCUIT BREAKER
<8> JGL36175. STANDARD LUG CONFIGURATION: (1) 4-4/0 AWG AL
OR CU.
CB—1 AND CB—4 ARE SQUARE D POWERPACT J-FRAME
(9) THERMAL-MAGNETIC CIRCUIT BREAKERS JGL362.00. STANDARD LUG
^ CONFIGURATION: (1) 3/0 AWG-350 kcmii AL OR CU,
BUSSMANN ENCLOSED POWER DISTRIBUTION BLOCKS MODEL
PDBFS377 (3 RQD). GANG TOGETHER WITH ACCESSORY PART
2A1279 INTERLOCKING DOVETAIL (2 RQD).
LINE SIDE: 300KCMIL TO 4 AWG
LOAD SIDE: 4 TO 14 AWG
/-jv NEMA 3R XFMR TRA 15kVA 480-208Y/120V 30, 4W 150' C RISE.
'x'^ SQUARE D EE15T3H WITH WS363 WEATHERSHIELD OR EQUAL.
HUBBELL HBL2730SW WATERTIGHT TWIST-LOCK RECEPTACLE
V-y TYP. OF 3
SCHNEIDER ELECTRIC ATS48C14Y SOFT START WITH LC2D115G6
/-}. REVERSING CONTACTOR. FORWARD AND REVERSE CONTACTORS
SHALL BE BE FITTED WITH SCHNEIDER ELECTRIC LADN02 FRONT
MOUNTED AUXILLARY CONTACT BLOCKS (2 NC CONTACTS).
/TA HUBBELL HBL2430SW WATERTIGHT TWIST-LOCK RECEPTACLE
V-? TYP. OF 3
_ SCHNEIDER ELECTRIC COMBINATION REVERSING MOTOR CONTROLLER.
<15) LU2B 12FU STARTER BASE WITH LUCA 05FU CONTROL UNIT AND
LINE PHASE BARRIER LU9SP0.
_ SCHNEIDER ELECTRIC COMBINATION MOTOR CONTROLLER. LUB 12
(16) STARTER BASE WITH LUCA 12FU CONTROL UNIT AND LINE PHASE
BARRIER LU9SP0.
1 3/17/14
ISSUED FOR
REVIEW
REV. ISSUED DATE DESCRIPTION
(P ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durham, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.arcadi8-us.coni
PROJECT TITLE


£
PRO^
jm
UJ
CD
T
SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
480 VAC DISTRIBUTION SCHEMATIC
PROJECT MANAGER
DEPARTMENT MANAGER
B. HALL

LEAD DESIGN PROF.
CHECKED BY
TASK/PHASE NUMBER
DRAWN BY
00001
R. SHARPE
PROJECT NUMBER
DRAWING NUMBER
RN990274.0021
E-2.4

-------
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CONTINUED FROM
DRAWING E—2.4
-3#8
-3#8
-3#S




*-3#12 & 1 #12(G)




L1 I SC-211 LH
IJ SCHNEIDER UL
H ATV71HU40N4 PT
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ATV71HU40N4 Pra
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3#10 & 1 #10(G)

V
#6
GND
I	I
DD
3#6, 1 #6(N) & 1#8(G)
DRAG CHAIN DRIVE
5 HP
11.5 A © 480 VAC
DRAG CHAIN DRIVE
5 HP
11.5 A © 480 VAC
PANELBOARD "A"
18 A © 208 VAC
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PANELBOARD
"A"

VOLTAGE: 208/120V, 30, 4W





MOUNTING: SURFACE MOUNTED
BUS RATING: 60 AMP MCB





MIN AIC: 10,000 AMPS SYM. RMS
CIRCUIT DESCRIPTION
CIRC.
BKR.
CIRC.
NO.
PH. A
LOAD
PH. B
LOAD
PH. C
LOAD
CIRC.
NO.
CIRC.
BKR.
CIRCUIT DESCRIPTION
MAIN BREAKER
60A
1
-



40A
GASIFIER CONTROL PANEL
3#6, #6 N, #8 GROUND - 1" C
3P

3300


2
3P
3#8, #8 N, #10 GROUND - 3/4" C


3

-








3600

4




5


-








2100
6


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6.	UL 508 LISTING AND LABELING IS REQUIRED FOR THIS PANEL ASSEMBLY.
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1 3/5/14
ISSUED FOR
REVIEW
REV. ISSUED DATE DESCRIPTION
fr ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durham, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.arcadis-UB.coni
PROJECT TITLE


£
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SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
CONTROLS SCHEMATIC
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-3.5
-------
Acad Version : R19.1s (LMS Tech) Date\Time : Mon, 22 Jun 2015 — 11:43am	Current Plotsyle : ByColor
User Name : bsharpe	Path\Name : G:\Active Projects\Environmental Monitoring & Engineering\2013 Projfceb8^ATa^2B_5cfeifier\Controls\Controls.dwg
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BASED ON UL485E - EQUIPMENT WIRING TERMINALS.
SLOT LENGTH OF SCREW
TIGHTENING TORQUE, POUND-INCHES (Nxrn)
SLOT WIDTH OF SCREW,
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SLOT WIDTH OF SCREW,
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INCH
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7 (0.79)
7 (0.79)
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6 (0.68)
7 (0.79)
10 (1.1)
12 (1.4)
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(6.4)
7 (0.79)
9 (1.0)
10 (1.1)
12 (1.4)
9/32
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15 (1.7)
ABOVE 9/32
(7.1)


16 (1.8)
20 (2.3)
A FOR SLOT LENGTHS OP INTERMEDIATE VALUES, SELECT TORQUES PERTAINING TO THE NEXT SHORTER SLOT
LENGTH. SLOT LENGTHS ARE MEASURED AT THE BOTTOM OF THE SLOT.
B TERMINALS HAVING DAMPING SCREWS WITH MULTIPLE TIGHTENING MEANS; FOR EXAMPLE, A HEXAGONAL
HEAD SCREW, ARE TO BE TESTED USING BOTH VALUES OF TORQUE.
C SLOT WIDTH IS THE NORMAL DESIGN VALUE.
NOTES
1.	ALL SOLA POWER SUPPLIES SPECIFIED ARE UL 508 LISTED AND CLASS 2 APPROVED. PANEL BUILDER SHOULD
ADD INPUT FUSES IF REQUIRED BY UL508. NOTE THAT INTERNAL INPUT FUSING IS SUPPLIED WITH UNIT - SEE
SOLA MANUAL ALL SUPPLIES ARE DIN-RAIL MOUNTABLE FROM FACTORY.
2.	ASSEMBLED PANEL SHALL BE UL508 LABELED.
3.	CONTROL RELAYS 1CR-6CR ARE OMRON MK2PNSAC120 OCTAL BASE RELAY WITH PUSH-TO-TEST FEATURE AND
INDICATION LAMP OR EQUAL,
4.	POWER RELAYS 1PR-2PR CORRESPOND TO OMRON G7L-1A-BJ-CB-AC100/120. USE DIN RAIL MOUNTING
ADAPTER OMRON P7LF-D AND P7LF-C COVER, INSTALL ROXBURGH XEB1201 SURGE SUPPRESSOR PARALLEL
TO COIL.
5.	CONNECT OPTO 22 CONTROLLER AND PANEL ACCESS PORT TO ETHERNET SWITCH USING PATCH CABLES.
6.	PROVIDE DIN RAIL TYPE TERMINAL BLOCKS AS NECESSARY FOR POWER DISTRIBUTION AND FUSING. PROVIDE
UNUSED TERMINAL BLOCKS TO SUPPORT THE ADDITION OF ONE FUTURE 120 VAC POWER SUPPLY.
7. LEGEND
INTERNAL WIRING
	FIELD WIRING
8.	ALL FIELD WIRING AND INSTRUMENTS BY ARCADIS. ALL OPTO 22 HARDWARE AND UPS (1) WILL BE PROVIDED
BY ARCADIS AND INSTALLED BY PANEL CONTRACTOR. ALL OTHER HARDWARE (INCLUDING POWER SUPPLIES,
ETHERNET SWITCH, AND WIRELESS RADIO) SHALL BE PROVIDED AND INSTALLED BY PANEL CONTRACTOR.
9.	ANT3 WILL BE CONNECTED TO EXTERNAL FIELD MOUNTED ANTENNA. THIS WILL BE FIELD WIRING.
10. CONNECT HIGH DENSITY DIGITAL OUTPUT MODULES SNAP—ODC—32—SNK TO BREAKOUT RACKS SNAP-ODC-HDB USING
SNAP—HD—3F6 HEADER CABLE (PROVIDED BY ARCADIS, INSTALLED BY FABRICATOR). RELAYS 20CR THROUGH 38 CR ARE
ALLEN-BRADLEY 700-HLT1U24, USE 700-TBJ20B BLUE JUMPER LINK TO CONNECT COMMON TERMINALS OF RELAYS.
USE END BARRIER 700-HN177 BETWEEN GROUPS OF 8 RELAYS. USER MARKER CARD 1492-MC6X10 FOR LABELING.
MOUNT RELAYS WITH COIL CONNECTIONS UP.
11. PFANNENBERG NORMALLY OPEN TEMPERATURE CONTROL SWITCH FLZ530
PANEL.
17121000010. MOUNT AT OR NEAR TOP OF
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NOTES
1.	dimensions shown are for reference purposes only.
2.	terminal blocks and wireway should be arranged to facilitate field connections,
ANALOG INPUT AND OUTPUT SIGNALS WILL BE ATTACHED DIRECTLY TO THE I/O MODULES.
3.	COMPONENTS SHOWN ARE TO SCALE. DEVIATIONS FROM THE GENERAL ARRANGEMENT SHOWN
HERE ARE SUBJECT TO APPROVAL BY ARCADIS.
4.	TERMINAL BLOCKS FOR HIGH VOLTAGE (>100 VAC) FIELD WIRING MUST BE LARGE ENOUGH TO
ACCEPT #14 AWG.
5.	PANDUIT (WIREWAY) AS SHOWN IN DRAWING MAY PASS OVER INTERNAL PANEL MOUNTING
STUDS/NUTS. CUT HOLE IN BACK OF PANDUIT TO ALLOW CLEARANCE.
6.	UL 508 LISTING AND LABELING IS REQUIRED FOR THIS PANEL ASSEMBLY.
7.	USE 7.5 mm HIGH DIN RAIL FOR ALL RAIL MOUNTED COMPONENTS. (DO NOT USE ELEVATED
RAIL.)
8.	VERI—FLAME AND IGNITION TRANSFORMER WILL BE PROVIDED BY ARCADIS AND INSTALLED BY
PANEL FABRICATOR.
oo
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Tj	EPA GASIFIER
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TYPE 4 ENCLOSURE WITH
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FILTER FAN
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11622154055
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24"
© 2014 ARCADIS U.S., Inc.
1 "=8"
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PANEL EXTERIOR
LIMITS
17X21 INTERNAL
PANEL
PANEL EXTERIOR
LIMITS
17X21 INTERNAL
PANEL
1 2/27/14
ISSUED FOR
REVIEW
REV. ISSUED BOTE DESCRIPTION
& ARCADIS
ARCADIS U.S., Inc.
4915 Prospectus Dr., Suite F Durtiom, NC
27713 Tel: 919-544-4535 Fax:
919-544-5690
www.orcadi8-us.coni
PROJECT TITLE
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SHEET TITLE
UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY
TRANSPORTABLE GASIFIER
BURNER PANEL LAYOUT
PROJECT MANAGER
B. HALL
LEAD DESIGN PROF.
TASK/PHASE NUMBER
00001
PROJECT NUMBER
RN990274.0021
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
R. SHARPE
DRAWING NUMBER
E-4,1
-------
Acad Version : R19.1s (LMS Tech) Date\Time : Mon, 22 Jun 2015 — 11:43am	Current Plotsyle : ByColor
User Name : bsharpe	Path\Name : G:\Active Projects\Environmental Monitoring & Engineering\2013 Projfceb8^ATate-20_dd&ifier\Controls\Controls.dwg
_ FROM MAIN CONTROL _
PANEL DRAWING E-3.3
I B11 | | B12 h
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RATIOMATIC BURNER #1
I QOM I	^LOW I MQ
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AUXILIARY SWITCH
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V	LOW FIRE? | 15 | -
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SAFETY SHUTOFF
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LOW GAS
PRESSURE SWITCH
HIGH GAS
PRESSURE SWITCH
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CUT RED JUMPER BETWEEN
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AUXILIARY SWITCH m
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AUXILIARY SWITCH m
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AUTOMATIC | LR I
LOW FIRE [j ^
HIGH FIRE mil
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-------
APPENDIX D: ARCADIS Design Drawings
-------
27-0'
T]OPEN)
(OPEN)
(OPEN)
14" 7YP.
(OPEI
(OPEN)
(OPEN)
THIS FORMAT FOR ALL
BOTTOM SEGMENTS
(NO OPENINGS)
30" 7YP.
(OPEN)
SQ.
SIDE ELEVATION
NOTES:
1)	SCALE: 1/4" = 1'
2)	WELDS JOINING STRUCTURAL TO
BE CONTINUOUS.
3)	PLATE TO STRUCTURAL WELDS
TO BE STITCHED (2"&2")
ITEM
NOTES & SPECS.


1
2"x4"x.12" M.S. RECT. TUBE
2
2"x2"x3/16" M.S. ANGLE
3
2"x4"x3/16" M.S. FLAT BAR
4
10 GA. 304 S.S I.
5
4"x4"x3/16" S.S. < UNDER HEARTH
(OPEN)
40"
42"
31'
. A ) rn
11 -5
> A >
VIEW ON A

11-5"
6"
(OPEN)
(OPEN)
4"
75"
11-2
FRONT VIEW
© 2012 ARCADtS G&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED STEEL SHELL
DETAILS, DWG. NO. 276-D
DRAWN BY D. BROOKS DATED
AUG. 16, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C—1869
PROJECT TITLE
SHEET TITLE
Steel Shell Details 276-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-3
-------
I
8
ii
si
&
II
II
I
1
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ii
ii
NOTES:
1) SCALE: 1/4" = 1'
A
A
10—6
6
26-8"
I I I I I r
I I I I I
46"
H
I f i I
^ (
-\
I ( 1 I

I ( 1 I
20"

I ( 1 I
L
40'

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I f i I

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~1
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I I I I I

[	

j
A
J
PLAN VIEW
'J

26"
OPENING FOR ASH
REMOVAL AUGER 12 1/2"
12"
10-9"
ELEV. VIEW ON A-A

-ALTERNATE CONSTRUCTION;
USE © THROUGH THE
SEC. CH. OUTSIDE WALL IN
CONJUNCTION WITH ©
ITEM
NOTES St SPECS.


1
2600' F CER. MODULES (SERPENTIN) 10 LF/FT3
2
2600' F INS. FIRE BRICK
3
HEARTH MTL. 3000* F CASTABLE
4
1400* F INS. BOARD
5
COLUMNAR PIERS 2600* F MW CAST.
6
DOOR POST 2800' F CASTABLE
7
4"x4"x3/8" S.S. <
4?5
1»
TF
ELEV. VIEW C-C
54 3/4




ELEV. VIEW ON B-B
© 2012 ARCADtS 6&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED STEEL SHELL
REFRACTORY DETAILS, DWG. NO.
277-D DRAWN BY D. BROOKS
DATED AUG. 28, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C—1869
PROJECT TITLE
SHEET TITLE
Steel Shell Refractory Details
277-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-4
-------
TRANS DUCT
2 REQ'D
SEC. AIR FAN INLET
BURNER INLET
FLANGE 'A'
MATCHING FLANG 'A1
WELED TO SHELL
4 HOLES (INCL.
CORNERS) 5/8"0
EQUAL-SPACED
FOR UNC BOLTS
38 1/2
PLAN VIEW
SIDE VIEW
6 HOLES (INCL CORNERS)
5/8*0 EQUAL-SPACED
41 1/2"
34"
59 1/2"
3»
4
X-SECT. VIEW ON A-A
60
50
r
i
12" TYP.
_L_
5/8"0 HOLES-
FOR 1/2" UNC
MNTG. BOLTS
/
FLANGE 'A'
4 REQ'D
P.C. AIR VALVE INLET
O
1
MAIN DOOR
2 REQ'D
MIDDLE DOOR LATCH
1 REQ'D
~SCALE:
1 1/2' = 1"
DRILL 1 l/8"0 WELD
1" UNC NUT.
(ONE ONLY, IN CTR.)
DRILL 2 HOLES
7/8*0 FOR
MOUNTING
10-^"
GUSSETS lu2
BOTH SIDES
SIDE DOOR
LATCHES
2 REQ'D
ii"
3"

78"
NOTES:
1)	SCALE: 1/2' = 1"
2)	WELDS JOINING STRUCTURAL TO
BE CONTINUOUS.
3)	PLATE TO STRUCTURAL WELDS
TO BE STITCHED (2"&2").
5-7"
X-SECT. VIEW ON B-B
FRONT PLATE
ONE LEFT HAND - ONE RIGHT HAND
ITEM
NOTES & SPECS.


1
1 1/2"x1 1/2"x3/16" M.S. ANGLE
2
2"x2"x1/4" M.S. ANGLE
3
3"x4"x1/4" M.S. ANGLE
4
10 GA. 304 S.S. ft.
5
2"x1/4" M.S. FLAT BAR
6
4"x1/2" M.S. FLAT BAR
7
1"x1/4" M.S. FLAT BAR
8
1" UNC NUT
© 2012 ARCADtS G&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED DOORS,
TRANS-DUCT, FRONT PLATES.
DWG. NO. 278-D DRAWN BY D.
BROOKS DATED SEPT. 1, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C-1869
PROJECT TITLE
SHEET TITLE
Doors, Transition Duct Front
Plates 278-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-5
-------
8
ii
si
&
II
II
I
1
n
ii
ii
37 1/2"0
THREADED STUDS FOR
LOCKING TOP SECT.
ONCE ELEVATED
34 1/2 0
34 O.D.
CUT OUT FOR
STACK CONNECTION
HOLES TO MATCH
STUDS ON BASE
SECTION
BOTTOM FULLY
COVERED
38 I.D.
34 1/2 0
SEE NOTE 2
REMOVABLE
DAMPER
SLEEVE
REMOVABLE BOTTOM FLANGE
NOTCHED TO CLEAR ANGLE
V-WHEEL RAILS
ITEM
NOTES & SPECS.


1
1/4" ALUM. SHEET
2
5/8" ALUM. PLATE
3
1"x1"x3/16" ALUM. ANGLE
4
1 /4"x2" ALUM. FLAT BAR
a
FIXED STACK
CONNECT. SLEEVE
REMOVABLE STACK
CONNECT. SLEEVE
NOTES:
1)	SCALE: 1/2" = 1'
2)	RIGIDIZE OUTER SECTION WITH
FLAT BAR STIFFENERS TO SUIT
© 2012 ARCADtS G&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED TELESCOPING
STACK SYSTEM, DWG. NO.
279-D DRAWN BY D. BROOKS
DATED SEPT. 9, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C—1869
PROJECT TITLE
SHEET TITLE
Telescoping Stack 279-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-6
-------
1FS (FUSE)
120v/30A


1CR-1
QW-9
TO B
A
2CR
2CR
-1
<;w-7
SW-4
2TR-1
<;w-5
3CR-1
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3CR-1
6CR-2
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3CR-1
1CR-2
1TR-1

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3TR-1
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{W1>
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P.C. TEMP.
R> oi
	00
T/C (K)
V
CYCLE TIMER
SEC. AIR FAN 1
SEC. AIR FAN 2
PURGE TIMER
DROP VLV. FAN 1
DROP VLV. FAN 2
PURGE COMPLETE
DROP VLV. 1
DROP VLV. 2
GATE VLV. 1
GATE VLV. 2
LOAD TIMER
LOAD START
LOAD STOP
v
S.C. TEMP. CONTROL
4CR-1
CHfcO
TIC—1
BELOW S.P
4CR-2
5CR-1
BURNER RELAY
7CR-1
BURNER 2 RELAY
o
7CR-2
CYCLE IN PROGRESS
RELOAD
1TR-2
NOTES:
1)	RELAY (CR) SHOWN UNPOWERED.
2)	¦ INDICATES POINTS ON TERM. STRIP.
3)	T/C INDICATES THERMOCOUPLE.
&C. TEMP. M P.C. TEMP.
PWR.
0
©
(SI
0
E
COUPlfTE
©
BNR1 BNR2 S. AIR 1 S. MR 2
D. VLV. FANS	PURGE
® ©
DROP VLVS.
$
©
0
GATE VLVS.
$
©
7CR 16CRI SCR 4CR
12TRI 3CR 12CRI 1CR
| TERWNAL STRIP |
PANEL FACE
INTERNAL LAYOUT
© 2012 ARCADtS 6&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED ELECTRICAL
SCHEMATIC, DWG. NO. 281-D
DRAWN BY D. BROOKS DATED
OCT. 7, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C—1869
PROJECT TITLE
SHEET TITLE
Electrical Diagram 281-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-7
-------
I
I
II
$6
II
II
NOTES:
1) SCALE: 1/4" = 1'
PARTS EOR MTG. ON TOP OE UNIT TO BE
LIFTED INTO PLACE USING SCISSORS LIFTS &
ROLLER BEDS.
EST. PAYLOAD ON TRAILER IS 60,000 LBS.
2)
3)
TELESCOPING STACK
FULLY EXTENDED
BURNERS
SEC. AIR FANS
TELESCOPING STACK
(RETRACTED) DWG. 279-D
c
I FUEL
" TANK/
* X
STORAGE FOR
GENERATOR
CONTROL PANELS
& MISC.
X ; DESIGN CHANGE
TO RIDGED
TT
PLAN VIEW
STACK
J
RRP-nmnn kfy skftch
MAIN DOORS
~NOT TO SCALE
TRANS DUCT
DROP VALVE
FRONT
PLATE
SIDE VIEW
FRONT VIEW
TRANS DUCTS [
DWG. 278-D I
11
COUNTERWEIGHT
SYSTEM FOR VERTICAL
LIFTING DOORS-
ZEBREX DROP
VALVE DWG. DV-10
BGP-D100 MAIN
SHELL DWGS.
276-D, 277-D
TYPICAL LOWBOY TRAILER
SIDE ELEVATION VIEW
n
Ji
~UPPER PHANTOM LINES SHOW PARTS
TO BE MOUNTED UPON ARRIVAL AT SITE.
-DOOR LATCHES DWG.
278-D
MAIN DOORS &
FRONT PLATES
DWG. 278-D
STORAGE FOR
ARTICULATING CONVEYOR
& MISC. PARTS
1
(159" TRAVELING HEIGHT
© 2012 ARCADtS G&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED BASIC
ARRANGEMENT, DWG. NO.
282-D DRAWN BY D. BROOKS
DATED SEPT. 12, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C-1869
PROJECT TITLE
SHEET TITLE
Basic Arrangement 282-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-8
-------
I
si
&
II
II
n
Ji
LEGEND
o
a
FROM MACERATOR PUMP
TELESCOPING STACK
DWG. 279-D
REFRACTORY LINED STEEL SHELL
DWG'S 276-D, 277-D & 278-D
STACK EXHAUST
COMBINED IN ONE ENCLOSURE
GASIFIER CONTROLS
LOADING CONTROLS
LOADING GATE VALVE
SEC. AIR FAN «
PRIMARY CHAMBER #1
T/C-K	^\FUME
/-ASH REMOVAL
/ AUGER®
VERTICAL LIFTING
MAIN DOOR
SECONDARY CHAMBER #1
SECONDARY CHAMBER #2
SLIP-SLEEVE
LOADING
CONVEYOR
ASH REMOVAL
AUGER	/ / FUME
HOPPER
THERMOCOUPLE (T/C)
TYPE K
PRIMARY CHAMBER #2
LOADING GATE VALVE Up
LOADING CONTROLS
ITEM ON PRIMARY MATERIALS LIST
CONTROL MOTOR
CONTROL SIGNAL FOR BURNERS
CONTROL SIGNAL FOR LOADING VALVES
NOTES:
1) NOT TO SCALE
CONVEYOR
+ DESIGNED TO SHIFT
SIDE TO SIDE
GASIFIER CONTROLS
COMBINED IN ONE ENCLOSURE
FROM MACERATOR PUMP
© 2012 ARCADtS G&M, INC.
NOTES:
ORIGINAL DRAWING BY DRB
TECH. TITLED PROCESS AND
INSTRUMENTATION DIAGRAM,
DWG. NO. 283-D DRAWN BY D.
BROOKS DATED NOV. 6, 2006.
REV. ISSUED DATE DESCRIPTION
ft ARCADIS
ARCADIS G&M of North Carolina, Inc.
801 Corporate Center Drive, Suite 300
Raleigh, NC 27607
Tel: 919-854-1282 Fax: 919-854-5448
www.arcadis-us.com
License Number C—1869
PROJECT TITLE
SHEET TITLE
Process and Instrumentation
Diagram 283-D
PROJECT MANAGER
LEAD DESIGN PROF.
TASK/PHASE NUMBER
PROJECT NUMBER
DEPARTMENT MANAGER
CHECKED BY
DRAWN BY
A. LYNCH
DRAWING NUMBER
2-9
-------
APPENDIX E: RENDEQ Design Drawings
-------
320
65
30
66










2
4 [
r








i











' '
1
i r
2
L
2 :










16 3
L
4
r





i i
i i
~-i i
i







---i i
i i
i i
i
rn rn rn f






1	r
i i
















i













i




		«n		
1
SCREW OUT
-------

233 5/16 [19'—5 1/4"]
622 1/2 [51'-10 1/2"] TRAILER-
226 3/8 [18 —10 1/4 ] PLATFORM
ACCESS PLATFORM
TRAILER
PREBREAKER NLET
PUMP
FEED SCREW
7 1/2 HP
E
FEED SCREW 9
3 HP MOTOR
TEMPERATURE
PROBES
167 5/16 [13'—11 1/4"]-
FINER 14
100 HP
PLATFORM
SURGE BIN
(2) 5 HP
SET UP GEARING 6-8 RPM,
BUT WILL NEED YOUR VDF
TO TAKE IT TO 1 1/2 RPM
CONTROLS GATES,
TYPE K THERMAL COUPLER
THMK—C12—03
PLAN VIEW
BINDICATOR DIAPHRAM
MODEL A UDA2182
(RAW BIN)
FEED PIPE
KNIFE GATE
VALVES
OPEN, NO TOP, 8 FT WIDE
GOING INTO CHAMBER
PLATFORM •
OUTLINE
SAME ELECTRICAL
SET UP AS OTHER
GRINDER
WE WILL GEAR TO 6-8 FPM,
BUT WILL NEED YOUR VDF
TO TAKE IT TO 2 FPM
CHAIN DRAG
(2) 5 HP
PUMP
30 HP
324 [27']
T.C.
HAS TWO GEARMOTORS 1 HP WITH
2 EACH LIMIT SWITCHES, TYPE
MODEL 9007C54J SQUARE D
T.C.
T.C.
3
O
T.C.
o
T.C.
158 [13'—2"]
GROUND
SHOULD HAVE VDF
SHOULD HAVE VDF
ELEVATION
THERMOWELLS IN SAME LOCATION
ON OPPOSITE SIDE OF GASIFIER
DIMENSIONS AND LOCATIONS WILL VARY SLIGHTLY AT FINAL ASSEMBLY
THIS PRINT IS THE PROPERTY OF RENDEQ
INC., TO BE RETURNED UPON REQUEST.
NOT TO BE COPIED, REPRODUCED, LOANED
OR OTHERWISE DISPOSED OF DIRECTLY OR
INDIRECTLY. IT CONTAINS CONFIDENTIAL
PROPRIETARY INFORMATION TO BE USED
FOR REFERENCE ONLY. NO OTHER USAGE
UNLESS AUTHORIZED IN WRITING.
NO
DATE
2/14
REVISION
ADDED ELECTRICAL NOTES
APPR
TOLERANCES (EXCEPT AS NOTED)
DECIMALS
FRACTIONS
ANGLES
REF:
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
Fax: (336)-270-5357
E-mail: rendeq@bellsouth.net or chip@rendeq .com
Web Site: www.rendeq.com	
PROJECT:
PB24 RAW GRINDER
THERMOWELL LOCATIONS
CUSTOMER: ARCADIS
LOCATION:
SCALE NONE
DRAWN
PROJECT NO.
13-409
DATE
SHEET 1 OF 1
DRAWING NO.
OUST
REV.
0
-------
PARTIAL
END view































o

~	1	E
i











1

1







1

1






I
g	i	E






















PLAN VIEW
GROUND
ELEVATION
-------
235 13/16
19'—7 3/4"]
129 13/16 [10'—9 3/4"]
/
•FEED SCREW
7 1/2 HP

--Us



r-\—\—\
¦167 5/16 [13-11 1/4"]-
622 1/2 [51-10 1 /2 ] TRAILER
226 3/8 [18 —10 1/4 ] PLATFORM
ACCESS PLATFORM
TRAILER
FEED SCREW 9
3 HP MOTOR
FINER 14
100 HP
•PREBREAKER INLET
PUMP
•SURGE BIN
(2) 5 HP
SET UP GEARING 6-8 RPM,
¦PLATFORM BUT WILL NEED YOUR VDF
TO TAKE IT TO 1 1/2 RPM
PLAN VIEW
• TEMPERATURE
PROBES
CONTROLS GATES,
TYPE K THERMAL COUPLER
THMK-C12-03
FNE GRNDER
RAW B N
BINDICATOR DIAPHRAM
MODEL A UDA2182
(RAW BIN)
324 [27"]
KNIFE GATE
VALVES
FEED PIPE
HAS TWO GEARMOTORS 1 HP WITH
2 EACH LIMIT SWITCHES, TYPE
MODEL 9007C54J SQUARE D
294 1/2 [24 -6 1/21
OPEN, NO TOP, 8 FT WIDE
GOING INTO CHAMBER
PLATFORM
OUTLNE
WE WILL GEAR TO 6-8 FPM
BUT WILL NEED YOUR VDF
TO TAKE IT TO 2 FPM
RENDEQ PB-24
100 HP
176 [14 —8 J
CHAIN DRAG
(2) 5 HP
158 [13"-2"]
SAME ELECTRICAL
SET UP AS OTHER
GRINDER
PUMP
30 HP
80 1/4 [6 -8 1/4 J
GROUND
GROUND
236 1/4 [19-8 1/4"]
PARTIAL
END VIEW
SHOULD HAVE VDF
SHOULD HAVE VDF
ELEVATION
THERMOWELLS IN SAME LOCATION
ON OPPOSITE SIDE OF GASIFIER
DIMENSIONS AND LOCATIONS WILL VARY SLIGHTLY AT FINAL ASSEMBLY
THIS PRINT IS THE PROPERTY OF RENDEQ
INC., TO BE RETURNED UPON REQUEST.
NOT TO BE COPIED, REPRODUCED, LOANED
OR OTHERWISE DISPOSED OF DIRECTLY OR
INDIRECTLY. IT CONTAINS CONFIDENTIAL
PROPRIETARY INFORMATION TO BE USED
FOR REFERENCE ONLY. NO OTHER USAGE
UNLESS AUTHORIZED IN WRITING.
NO
DATE
2/14
REVISION
ADDED ELECTRICAL NOTES
APPR
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
Fax: (336)-270-5357
E-mail: rendeq@bellsouth.net or chip@rendeq .com
Web Site: www.rendeq.com	
PROJECT:
PB24 RAW GRINDER
CUSTOMER: ARCADIS
LOCATION:
TOLERANCES (EXCEPT AS NOTED)
DECIMALS
FRACTIONS
ANGLES
SCALE NONE
DRAWN
REF:
PROJECT NO.
13-409
DATE
SHEET 1 OF 1
DRAWING NO. REV.
CUST	1
-------
49 3/8
INSIDE
9 13/16
r
5 5/16
59 1/2 INSIDE
A
A
3 SPACES AT
14 = 42
B
B
24 13/16
INSIDE
C
M (q) (q

o) (o) ll(o)~fo
c
SECTION OE
EXISTING COVER
CHAIN DRAG
END COVERS
FABRICATE ONE AS SHOWN;
ONE OPPOSITE
26
INSIDE
R6 15/16
REF
06
9 13/16
THIS AREA NOT
TANGENT
12 7/8
R2
¦A <
9 13/16
5 7/8
24 13/16
INSIDE
SECTION A-A
SECTION B-B
CLEARANCE FOR
CHAIN DRAG
n 4
3
3
— 55 1/2	
59 1/2 INSIDE
4 REF
SECTION C-C
THIS PRINT IS THE PROPERTY OF RENDEQ
INC., TO BE RETURNED UPON REQUEST.
NOT TO BE COPIED, REPRODUCED, LOANED
OR OTHERWISE DISPOSED OF DIRECTLY OR
INDIRECTLY. IT CONTAINS CONFIDENTIAL
PROPRIETARY INFORMATION TO BE USED
FOR REFERENCE ONLY. NO OTHER USAGE
UNLESS AUTHORIZED IN WRITING.
NO DATE
REVISION
APPR
REN D ECDI nc
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
Fax: (336)-270-5357
E-mail: rendeq@bellsouth.net or chip@rendeq.com
Web Site: www.rendeq.com	
PROJECT:
PROPOSED REFRACTORY
GASIFIER END DOORS
CUSTOMER:
LOCATION:
TOLERANCES (EXCEPT AS NOTED)
DECIMALS
FRACTIONS
ANGLES
SCALE -
DRAWN
REF:
PROJECT NO.
13-409
DATE
SHEET 1 OF 1
DRAWING NO.
REV.
2
-------
TRAILER
OUTLINE
GASSIFIER
COVERED PLATFORM
HOPPER
GRINDER
EXISTING
r
L.
EXISTING
1
J
TRAILER
OUTLINE
RENDEQlnc;
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
•sj-
CM
I
00
CL
CC

PUMP

1 1 1 1


BOBCAT
1 1 1 1
-------
TRAILER
OUTLINE
GASSIFIER
EXISTING
r
L.
COVERED PLATFORM
HOPPER
EXISTING
CM
I
OQ
CL

GRINDER
1
J
TRAILER
OUTLINE
V J
PUMP

1 1 1 1


BOBCAT
1 1 1 1
REMDEQlt^
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
Fax: (336)-270-5357
E-mail: rendeq@bellsouth.net or chip(a)rendeq.com
Web Site: www.rendeq.com
-------
OPERATIONAL FLOW
RENDEQ
PB-24 GRINDER
SCREW
CONVEYOR
FNER
GRINDER
SURGE BIN
GASSIFIER
PUMP
DUMPSTER
-------
OPERATIONAL FLOW
RENDEQ
PB-24 GRINDER
SCREW
CONVEYOR
PUMP
REN FINER
14 GRINDER
SURGE BIN
GASSIFIER
DUMPSTER
-------
0
-------
I I I I I I I I I I I I I I I I I I I I ITT

I I I I I I I TTT
-SEE SLAT DETAIL
-INLET
I	
	I
H

n
i	
	i
IA I I I I I I I I I I I I V I I I I I I I I I I I I I I I I I
ii i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i r
ii i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i r
	I TTT
i i i i
i i i i
i i i i
i i i i
SECOND SLAT
THIRD SLAT
SLAT DETAIL
PLAN VIEW
L
OUTLET
SIDE ELEVATION
VIEW A-A
THIS PRINT IS THE PROPERTY OF RENDEQ
INC., TO BE RETURNED UPON REQUEST.
NOT TO BE COPIED, REPRODUCED, LOANED
OR OTHERWISE DISPOSED OF DIRECTLY OR
INDIRECTLY. IT CONTAINS CONFIDENTIAL
PROPRIETARY INFORMATION TO BE USED
FOR REFERENCE ONLY. NO OTHER USAGE
UNLESS AUTHORIZED IN WRITING.
NO DATE
REVISION
TOLERANCES (EXCEPT AS NOTED)
DECIMALS
FRACTIONS
ANGLES	
REF:

1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
Fax: (336)-270-5357
_WebSite^www£CTd^xo^_
PROJECT:
GASSIFER
DRAG CONCEPT
CUSTOMER: EPA
LOCATION:
SCALE NONE
DRAWN
PROJECT NO.
DATE 1/9/14
SHEET 1 OF 1
DRAWING NO.
13409—C
REV.
0
-------
RENDEQ
PB-24 GRINDER
REN EINER
14 GRINDER
SURGE BIN
GASSIEIER
DUMPSTER
-------
FINE GRINDER
RAW BIN
294 1/2 [24'—6 1
OPEN
236 1/4 [19'—8 1/4"]
RENDEQ PB-24
100 HP
176 [14'—8"]
104 1/2 [8'-8 1/2"]
80 1/4 [6'-8 1/4"]
GROUND
PARTIAL
END VIEW
-------
eevtcvABLe
Sou-re o JOIMT
PROPOSED J^cw£
LOCATION
-------
APPENDIX C: Gasifier Grinding, Transfer, Accumulation, and
Feed (GTAF) System Manuals
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
-------
797 7/8 [66'—5 3/4"]
ACCESS PLATFORM
TRAILER
n
	H
PREBREAKER INLET
235 13/16 [19'—7 3/4"]
PUMP
FEED SCREW
7 1/2 HP
	H
FEED SCREW 9
3 HP MOTOR
RAW BIN
(2) 5 HP
PLATFORM
FINER 14
100 HP
PLAN VIEW
FINE GRINDER
RAW BIN
324 [27']
KNIFE GATE
VALVES
FEED PIPE
O
294 1/2 [24'—6 1/2"]
OPEN
236 1/4 [19'—8 1/4"]
RENDEQ PB-24
100 HP
176 [14'—8"]
CHAIN DRAG
(2) 5 HP
158 [13'—2"]
PUMP -
30 HP
80 1/4 [6'-8 1/4"]
PARTIAL
END VIEW
ELEVATION
DIMENSIONS AND LOCATIONS WILL VARY SLIGHTLY AT FINAL ASSEMBLY
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
Table of Contents
Supporting
Section	Unit	Information
1	Pre-breaker	Page
Reitz PB 24
2	Secondary Grinder Page
Weiller 1109
3	Raw/Surge Bin	Page
4	Inlet Screw	Page
5	Drag Chain	Page
6	Misc.	Page
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
Section 1
Pre-breaker
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
PRE-BREAKER
Item
Qty
Part Numbers/ Description
Prebreaker
i
Reitz PB 24
1813 Frank Holt Drive Burlington NC 27215 336-226-1100
rendeq.com
-------
Standard Double, Triple and
Quadruple Reduction Units
MOTOREDUCERS
SPEED REDUCERS
Series F
323-130
i tvi> c-
G vi- - 1-V7:
f'AG:
1
INTRODUCTION
STANDARD DRIVES — This literature applies to ail standard
Series F gear drives (FZ, FXZ, FC, FCL & FCX) with ratings, speeds,
ratios and dimensions as catalogued in current Falk bulletins. Refer
to the Factory for ail specials and modifications.
HOW TO ORDER Give complete data shown on reducer
nameplate. Also, give Reference Numbers and name of parts
required. — Drawings and Reference Numbers are representative
of all sizes and the actual parts may not agree in exact detail for
each unit. Complete nameplate data and parts Reference Numbers
will assure receipt of correct parts.
The numerical designation stamped on the nameplate completely
identifies all parts used in the reducer. All units with exactly the same
nameplate markings have interchangeable rotating elements.
PINION-SHAFT-BEARING ASSEMBLIES — With today's production
procedures Falk can normally furnish a total rotating assembly more
economically than a customer can if he purchases individual parts,
disassembles the old parts, and reassembles using some new and
some old parts. Falk replacement assemblies also reduce down time
and always consist of all new parts.
Pinion-shaft assemblies such as Reference Number 2 include the
pinion, shaft, bearings, locknut and spacers, keys, dowels, Nilos rings,
etc., as required. Gears, such as 2P4, 3P4, and 4P4 ARE NOT in-
cluded and must be ordered separately if required. If gears 2P4,
3P4, or 4P4 are ordered without the shaft on which they are mounted,
also order a new locknut. Bearings are mounted on the shafts, except
when a gear (as 2P4) must precede the bearing during reducer
assembly; bearings are then shipped loose in their original packages.
F !
Note that some elements cannot be removed in the tielcr^Eecause
of the high interference fit between parts. The parts, in effect, be-
come integral or non-removable and, in turn, make some bearings
on high speed and intermediate shafts non-removable. See service
manual for details. AH low speed pinion and gear shaft bearings
are removable and the assemblies may be purchased with or without
the bearings.
SHIM-GASKETS — When shaft seals are ordered, shim-gasket(s)
for the seal cage(s) are furnished with the seals. When replacing
internal rotating elements, order Seals and Shim-Gasket Kit Ref.
No. 100. The Kit consists of a complete set of shims and gaskets for
the unit.
BACKSTOPS — When internal backstops are replaced, also replace
the low speed pinion shaft. New shim-gaskets are furnished with the
internal backstop package. Return external *20 and #60 backstops
to the Factory for servicing; replace the high speed shaft if damaged
during backstop removal. Refer to Service Manual 143-911 for
replacing bearings in external backstops or price new replacement
7^20 and =60 external backstops from the gear drive price list.
FASTENERS — Fasteners and dowels are sold in sets for a specific
item, i.e. (4) for an end cover, (8) for a L.S. flange, (1 6) for a housing
cover, etc. Fasteners describes cap screws, bolts, studs and nuts, and
lockwashers as required.
RATIO CHANGE — Refer complete information to the Factory.
MOTOR BRACKETS — Refer complete information to the Factory.
SHAFT COUPLINGS — Refer to coupling parts guide and price list.
Ref. No.
Part Description

ROTATING ELEMENTS
1 thru 5
Refer to Page 4
10
Fan, Cooling
11
Fan Guard

OIL SEALS
14
Seal, All H.S.S.
15
Seal, L.S.S. — Horiz.
16
Seal (2>, L.S.S.-Vert.
17
Seal, H.S.S.— Vert. Inner

(for 80, 90 & 100FX2)

CAGES, COVERS, & MISC.
20
Dipstick & Plug
21
Cage, Seal — H.S.
22
Cage, Seal — L.S.S. Horiz.
23
Cage, Seal — L.S.S. Vert.
27
Cover, Int. — 1st
28
Cover, Int. — 1st S 2nd
29
Cover, Pinion — L.S. Horiz.
32
Cover, Backstop — Internal
33
Cage, Backstop — Internal

r Backstop — Internal, Incl. Ref. No. 91
34 .
(for 60-90F)

Backstop — External, Sizes 20 & 60

^ (for 100-130F)
35
Sleeve, L.S.S. — Seal
36
¦'0" Ring (for Ref. No. 35)
Ref. No.
Part Description
37
Foot, R.H. — Near Side "l Identical for
38
Foot, L.H. — Far Side J* Sizes 60-100
39
Pan, Oil
41
Spacer, Bearing — L.S. Pinion

(for 9QF & 60-90FX)
42
Spacer, Bearing — 1st Int.

(for 60-90F4)
44
Cage, Seal — H.S. Inner

(for 80-100FX2)
45
Cage, Bearing — H.S.

(for F2 & FX2)
46
Deflector, Oil — F2
47
Spacer, Bearing — Int.

(for 60-90F3 & F4)
48
Standpipe, Oil — Vert.
49
Vent, Air —Vert.
50
Cover, Pinion — L.S. Vert.

(for 90 & 1Q0FX)
53
Plate, Thrust (for 100-130F)

FASTENER & DOWEL SETS
59
For Ref. No. 21
60
For Ref. No. 22
61
For Ref. No. 23
64
For Ref. No. 27
65
For Ref. No. 28
66
For Ref. No. 29
67
For Ref. No. 50
68
For Ref. No. 32 & 33
Ref. No.
Part Description
69
For Ref. No. 37 & 38
70
For Ref. No. 39
73
For Ref. No. 110
74
For Ref. No. 112
78
For Ref. No. 44
79
For Ref. No. 46
80
For Ref. No. 53

SHIM-GASKETS (See Ref. No. 100)
87
For Ref. No. 21
88
For Ref. No. 22
89
For Ref. No. 23
91
For Ref. No. 29, 32 & 33
92
For Ref. No. 50 (for 90 & 100FX..
94
For Ref. No. 113
97
For Ref. No. 27
98
For Ref. No. 28
100
SHIM-GASKET KITS

60-130F Includes

Ref. Nos. 87, 88, 91, 94, 97, 98

60-100FX Includes

Ref. Nos. 87, 89, 92, 94, 97, 98

HOUSING COMPONENTS CFurnished

only as assemblies.)
110
Head, H.S.
112
Plate, Bearing — L.S.
113
Housing, Helical
-------
I REFER TO PAGE 1 FOR INSTRUCTIONS
PARTS DESCRIPTIONS 
-------
42 9? 27

80
53
4? 98 28 65
73
45 { 70F ONLY)
QUAD. REDUCTION
H.S. ENDS
80
53
53
SIZES 100-130 F
73
TRIPLE REDUCTION
H.S. ENDS
74
L
46
8? 14
79
EX
70
45
59
DOUBLE REDUCTION
H.S. ENDS
73
39
PARTS GUIDE 3 2 3-130 .3
-------
Typical Assembly
Ref. No.
_ . _ ... f See notes below
Part Description fof WB an(j W0B

B m i
f 2P4
..+*S 3P4 OR
I L4P4
[ j
1
U.S. Pinion & Shaft —WB
f i - 'i
2P4' I L
: ^ 3P4
L.J
2P3
2P4
Int. Pinion & Shaft — WB
(1st Int. for F4, Quad, Red.)
Locknut — for 2P4
Gear, US, — Mates with Ref, No. 1 for F4, Quad. Red.
j=5f J
"f't >13P4
r*^4p4
3
3P3
3P4
Int. Pinion & Shaft — WB
(1st int. for F3, Triple Red.;
(2nd int. for F4, Quad. Red,.
Locknut — For 3P4
Gear — Mates with
Ref. No. 1 for F3, Triple Red.
Ref. No. 2 for F4, Quad. Red.
4 PI
y
4,'4P
5. 5P
4P2
j 4P5
I J EE3 i
4P4'Y^j |
4P3
4
4P
4P1
4P2
4P3
4P4
4P5
WB 1
J> L.S. Pinion & Shaft
WOB 1
J
Bearing — Outer
Bearing — Inner
Locknut — For 4P4
Gear, H.S. — Mates with
Ref. No. 1 for F2, Double Red.
Ref. No. 3 for F3, Triple Red. and F4, Quad. Red.
Spacer — For 100FX & 100-130F Only
5.5P. t——:
/ ^Piis

5
5P
5P1
5P2
WB 1
> L.S, Helical Gear & Shaft
WOB J
Bearing — Outer
Bearing — Inner
!>P
X
5PI 7 fj£|
*5P2
WB = With bearings land locknut if required), but without gears 2P4, 3P4 or 4P4.
WOB ~ Without bearings, without gears 2P4f 3P4 or 4P4, (but with lockout if required).
^"~*Refer to Page 1 for !
f complete instructions j
4* PARTS GUIDE 323-1 30
-------
Seal Part Numbers	MOTOREDUCERS	323-11Q
and Dimensions	SPEED REDUCERS
o&*&s& 9 1
FALK PART NUMBERS

Number of Reductions
H.S. Shaft
Falk Seal Part No.
L.S. Shaft — Falk Seal Part Number
UNIT
SIZE
Concentric
Right Angle
Types
Types
Types FOB and FZB
Shaft Units
Shaft Units
All Type F Units
FC and FZ
FCX and FZX
Extension
Inner
20
2
3
3
4
912743
912743
912853
912853
912775
912775
912748
912748
912676
912676
30
2
3
4
3
4
5
912743
912746
912743
912749
912749
912749
912859
912859
912859
912753
912753
912753
912860
912860
912860
40
2
3
4
3
4
5
912746
912746
912743
912775
912775
912775
912756
912756
912756
912754
912754
912754
912861
912861
912861
50
2
3
4
3
4
5
912749
912749
912743
912781
912781
912781
912790
912790
912790
912757
912757
912757
912546
912546
912546
60
2
3
4
3
4
5
912845
912849
912746
912757
912757
912757
912741
912741
912741
912758
912758
912758
912857
912857
912857
70
2
3
4
3
4
5
912680
912749
912746
912759
912759
912759
912760
912760
912760
912741
912741
912741
912832
912832
912832
80
2
3
4
3
4
5
912680
912845
912849
912741
912741
912741
912791
912791
912791
912760
912760
912760
912816
912816
912816
90
2
3
4
3
4
5
912680
912845
912849
912850
912850
912850
912762
912762
912762
912761
912761
912761
912834
912834
912834
100
2
3
4
3
4
5
912757
912775
912775
912761
912761
912761
912763
912763
912763
912762
912762
912762
912856
912856
912856
110
2
3
4

912758
912775
912775
912787
912787
912787



120
2
3
4

912759
912778
912753
912762
912762
912762



130
2
3
4

912741
912778
912753
912763
912763
912763



SEAL PART NUMBERS AND DIMENSIONS
Falk
Manufacturers' Part No.*
Basic Dimensions—Inches
Part
Chicago

Shaft
Outside

Number
Rawhide
National
Dia
Dia
Width*
912546
CRWH 47394
455138
4.750
5.756
.562
912676
CRWH 27368
457316
2.750
3.756
.500
912680
CRWA 25075
476273
2.500
3.628
.375
912741
CRWA 34887
477437
3.500
4.505
.375
912743
CRWA 11124
471652
1.125
1.628
.250
912746
CRWA 13650
471192
1.375
2.129
.312
912748
CRWA 16118

1.625
2.441
.312
912749
CRWA 17285
471504
1.750
2.441
.312
912753
CRWA 19993
472397
2.000
3.005
.312
912754
CRWA 22441
472636
2.250
3.256
.375
912756
CRWA 26124

2.625
3.355
.375
912757

417316
2.750
3.756
.375
912758
CRWA 29907
475995
3.000
4.008
.375
912759
CRWA 32395
476470
3.250
4.254
.375
912760
CRWA 39923

4.000
5.004
.375
912761
CRWA 44960

4.500
5.506
.375
912762
CRWA 49985
476865
5.000
6.256
.500
912763
CRWA 54960

5.500
6.756
.500
Falk
Manufacturers' Part No.*
Basic Dimensions—Inches
Part
Chicago

Shaft
Outside

Number
Rawhide
National
Dia
Dia
Width*
912775

470898
2.125
2.879
.375
912778
CRWA 22354
471272
2.250
3.005
.375
912781
CRWA 26238
475458
2.625
3.628
.375
912787
CRWHA 47395
415138
4.750
5.756
.500
912790
CRWA 31139
476404
3.125
4 008
.375
912791
CRWA 42419

4.250
5.256
.375
912816
CRWH 70016
455517
7.000
8.009
750
912832
CRWH 64994
455294
6.500
7.508
.562
912834
CRWH 78738
455121
7.875
9.383
.750
912845
CRWA 19832
472492
2.000
2.754
312
912849
CRWA 16062
473230
1.625
2.256
.375
912850
CRWA 40077

4.000
5.631
.375
912853
CRWA 14939
470625
1.500
2.254
.312
912856
HDSI 590408

8.750
10.008
.625
912857
CRWH 52488
455645
5250
6.507
.625
912859

470565
2.375
3.130
.375
912860

455389
3.625
4.504
.468
912861
CRWH" 42426
455195
4.250
5256
468
* Subject to substitution of equivalent seals without notice.
$ The seal width listed may be slightly narrower than shown.
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
Section 2
Secondary Grinder
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.cont
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
SECONDARY GRINDER
Item
Qty
Part Numbers/ Description
Secondary
Grinder
i
Weiller 1109 Grinder
1813 Frank Holt Drive Burlington NC 27215 336-226-1100
rendeq.com
-------
Service Instructions and
Parts List for:
'a.



1398-5

1398-5HA

1992-5HA

I


I98-5HB

^6* 1992-5HB
Fig. 1 1398,1992 Gearboxes.
MODEL DIFFERENCES
The main difference between the models -5, -5HA
and -5HB is the main shaft. Refer to parts list on page
5 for specific differences. Service instructions are
identical for all models.
mKUU w I
Shut off and lock out power to the
machine before performing service. All
safety guards must be installed when
operating.
GENERAL
Gear ratios are as follows:
1398-5
7.53
1
I39S-5HA
7.53
1
1398 -5 HB
7.53
1
1992-5HA
4.84
1
1992-5HB
4.84
1
SPECIAL INSTRUCTIONS
After a "run-in"period of 40 hours, drain the oil from
gearbox. ^ Refill with five quarts of fresh
AGMA-4EP Gear Oil oi equivalent. Run reducer
without load for 15 minutes. Drain and refill. Clean
magnetic drain plug each time the plug is removed.
INSPECTION
Periodically remove the oil plug and check level and
condition of oil. If no oil flows from plug hole, this
indicates a need to add oil. Dirty or murky oil would
indicate a worn main shaft seal. If excessive oil
Gearbox Mortei.
1398-5, 1398-5HA, 1398-5HE
1992-5HA, 1992-5HE
changes are required to keep oil clean, the main se
should be replaced.
AT THIS POINT, POWER TO
MACHINE SHOULD BE
LOCKED OUT
Remove inspection cover to check condition of ge;
set and to refill box with oil. Check breather, locate
on the cover, for _ blockage which could caus
pressure build-up in the gearbox and may caus
unnecessary leakage past oil seals.
LUBRICATION
Oil level should be maintained at upper oil plug.
Change oil every 6 months or if inspection indicate
that it is contaminated. Add oil through tin
inspection cover opening.
Use oil specification AGMA-4EP Gear Oil o;
equivalent. A complete refill requires five quarts.
OUTER SEAL LUBRICATION
Lubricate this seal DAILY or at least every 8 hours 01
operation through the fitting on top of the gearbox
flange. Refer to your specific Safety, Installation,
Operation and Maintenance Manual for installation
and removal.
MAIN SHAFT WEAR COLLAR
REPLACEMENT
See GEARBOX DISASSEMBLY.
PINION SHAFT OIL SEAL REPLACEMENT
1. Remove belt guard cover, drive belts and pulleys
from both gearbox pinion shaft and motor.
Remove belt guard body.
Remove seal carrier (5) from gearbox and
remove seal (6) from carrier.
Clean all old sealant from the mating surfaces of
carrier and from seal bore.
Apply a small amount of Permatex** (or
equivalent) sealing compound to outer diameter
of seal and to carrier mating surface.
• fc
¦p	_
Food Processing Systems
2.
3.
4.
5.
AAM-120 Revised Nov, 1997
1
-------
6,	Press seal into carrier with lip facing inward
(toward the gearbox).
7.	Place a strip of masking tape over key way of
pinion shaft to protect seal lip from being cut
8.	Carefully install carrier and seal assembly.
Secure carrier with four cap screws.
9,	Replace gearbox pulley, all belts and belt guard at
this time.
GEARBOX DISASSEMBLY
1.	Remove pilot bearing cover (4) and pinion shaft
end cap (7).
2.	Remove seal carrier (5).
4.	Pry housing halves apart and lift off top housing.
5.	Remove both tapered dowel pins (3) by tapping
up from the bottom.
6.	Remove lock nut and tabbed lock washer (10
11).
7.	Remove lock wire (16) and loosen two set screws
(15) at least three turns.
8.	Remove pinion shaft and bearing assembly.
9.	Lift entire bull gear/main shaft/bearing assembly
from lower housing.
10.	Remove pilot bearing (12). A press or puller may
be required.
3. Remove eight cap screws (29) which attach top 11. Remove snap ring (13).
half of housing to bottom half.
34,35 6
34,35 7
I t 2 Guarbox Cross-Section (Top View).
AAM-120 Revised Nov, 1997
2
-------
12.	Press main shaft from bull gear. It may be
necessary to heat the hub of bull gear, especially
if the gearbox has been operated for a long period
of time under severe operating conditions,
13.	Remove spacer (18) from main shaft.
14.	Remove bearing cup and bearing cone (19, 20).
15.	Remove wear collar (22),
16.	Remove pinion shaft bearings (8) from pinion
shaft.
INNER SEAL REPLACEMENT (Main Shaft)
1.	With hopper and adapter plate removed, use a
hooded tool to pull inner seal and seal adapter
ring from gearbox.
2.	Clean cavity and use a sealant coating on outer
rim of new seal. Press new seal into seal adapter
ring before tapping [jack in place. Lip of seal
must face inward (Fig. 2). Install flush with
gearbox face,
CLEANING AND INSPECTION OF PARTS
CAUTION: Do not spray high pressure water or
steam directly against outer or inner seal. Water may
be forced past the seal(s) and into gearbox.
Clean all parts, including inside of housing halves,
thoroughly with a U.S. FX A. approved solvent.
Check for damage or excessively worn gear teeth and
bearings. If bearing condition is doubtful, replace
them. DO NOT RE-USE PITTED BEARINGS.
Always replace all seals and wear collar (22) during
major overhaul of gearbox.
NOTE: If one side of gear teeth on bull gear are
badly worn, the gear can be turned around so the
unused side of the teeth can be used. In this case, a
new pinion gear must be installed. Replace gears if
any teeth are broken.
Check and clean out breather pipe opening.
Remove, clean and re-install magnetic drain plug.
GEARBOX RE-ASSEMBLY
Make sure all parts are thoroughly cleaned before
re-assembling.
1. Prepare the main shaft/bull gear/bearing
assembly as follows:
a. Preheat wear collar (22) to 200°~250° F be-
fore installing. Install tight against shoulder
of main shaft (Fig. 2).
CAUTION: Overheating wear collar will damat
chrome plating.
b.	Install bearing cone (20) tight against we
collar.
c.	Install bearing cup (19).
d.	Install main shaft spacer (18) tight agair
cone.
e.	Install key (1 7) in shaft against collar, makii
sure it is "bottomed" in the key slot. 1I\
PORTANT: Make sure set screws do ii
protrude through inside of gear key way. Ri
move them to make sure.
f.	It may be necessary to lieat the gear hi)
evenly to about 250°-300° F before installin
main shaft, A press may be required.
g.	When installing main shaft, make sure tli
square key does not slip out of position.
h.	Press bull gear tight against spacer col la
Thread set screws in place and lighten.
i.	IMPORTANT: Tighten set screws (15) an
install lock wire (16). FINAL PRE-LOAI
MUST BE DONE AFTER INSTALLINC
TOP HOUSING HALF.
j. Install snap ring (13), making sure it is com
	 plefeiy "bottomed" in the groove.
k. Install pilot bearing (12),
1. Install tabbed washer and lock nut (11, 10;
loosely (to be torqued later).
m. Lift entire assembly into lower housing, posi-
tioning outer bearing races. Check for proper
seating.
n. Tighten lock nut (10) to temporarily pre-po-
sition all parts and remove any slack between
bearing outer races and housing shoulders.
Loosen lock nut to remove all pre-load.
2.	Install two pinion bearings (8) onto each end of
pinion gear shaft and install this assembly as
shown In Fig. 3.
3.	Temporarily install pinion end cap (7) with two
screws. This will assure proper position of the
front bearing.
4.	Temporarily install seal carrier (5) to properly
position rear pinion bearing. Remove seal carrier
and pinion end cap.
5.	Apply Permatex** (or equivalent) sealing
compound oil mating surface of lower housing.
CAUTION: Do not use silicone type sealing
AAM-120 Revised Nov, 1997
3
-------
compound in this area, as oil passages to
bearings could be plugged causing premature
gearbox failure.
6.	With a hoist, lift upper housing half and place on
lower housing.
7.	Install dowel pins (3) but do not hammer in yet.
This will properly align upper and lower housing
halves.
8.	Install main shaft seal and seal carrier flush with
face of gearbox. (Too far in will close oil
passage).
9.	Secure housing halves with nine cap screws and
hex nuts (29, 30). Torque down evenly to 90 ft.
lbs.
10.	Tap dowel pins in with hammer. One rap each.
11.	Install pinion end cap (7).
12.	Install oil seal and seal carrier (6,5). See PINION
SHAFT OIL SEAL REPLACEMENT on page 2.
13.	Pre-load main shaft thrust bearing as follows:
a.	Torque lock nut (10) to 80 ft. lbs., then loosen
completely and re-torque to 10-15 ft. lbs.
b.	Secure lock nut by bending a tab of the lock
washer (21) into slot in lock nut.
CAUTION: FAILURE TO SECURE LOCK NUT
WITH LOCK WASHER WILL RESULT IN
ULTIMATE GEARBOX DAMAGE.
34. Apply silicone* type sealing compound to pilot
bearing cover (4) and install with cap screws.
GEARBOX OILER ASSEMBLY
After gearbox is completely assembled, screw in
two lubricator studs on each side of gearbox upper
housing half (total of four) as shown in Fig. 3.
Coat stud and inner face of nut with an oil-proof
sealant. Screw in stud until it comes in contact
with bull genr, then loosen one half turn. Tighten
nut against housing. Make sure slot in stud is
VERTICAL.
FINAL INSPECTION, LUBRICATION AND
ASSEMBLY
1.	ADD OIL. See LUBRICATION on page 1.
2.	Apply silicone* type sealing compound to
inspection cover mating surfaces. Install
inspection cover (1).
3.	Re-check tightness of all bolts and nuts.
"'SILICONE TYPE SEALING COMPOUND (or
equivalent): Silicone type sealing compound should
be used in this location to assure a more permanent
seal.
**PERMATEX SEALING COMPOUND (or
equivalent): Permatex type sealing compound
should be used at these locations rather than silicone
to prevent plugging of "bearing oil passages" and
allow easier disassembly when rebuilding is
required.
AAM-120 Revised Nov, 1997
4
-------
WEILER® GEARBOX MODELS:
1398-5,1398-5HA, 1398-5HB
1992-5HA, 1992-5HB
31,32,33
11 12 13,14 ?5 43
&
1398-511A
1992-5HA
H 34 48 35
•J	1398-5HB
.1992-5IIB
47 46
39,40,41
1398-511A & J 992-511A
1398-5HB & 1992-5HB
Fig, 3 1398-5, 1398-5HA, 1398-5HB,'l992^5HA,1992-5HB Gearbox Exploded"View. '
MODEL	1398	& 1992 GEARBOX ASSEMBLY
	 cruniox moj)EL_ _
1398-> _ 		~
]398-5IIA with113-1392 Adapter Plate
wjj.-242H AdapterJ'Litc (1675 Tilted)
1398-aHB with 113-2103 Adapter Plate (167."> Vertical)
1398-5H13 with 113-0899 Adapter Hate
1992-5I1A with 113-1392 Adapter Plate _
with 113-2 128 Adaptei Plate (1675 '1 lited)
J"2-5118 v,ith 113-2U)3_Adaptei Plate (16 75 Vertical)
_lJ392-5HB_wUh 113-0899 Adapter Plate
1398 5 (ieaihox is discontinued hut paits aie available Can betoiiveiteJto -5HA"or""-S[nT
WITH ADAPTER PLATE
11± 2_4i*
114-2460
Ij 4-'24ftl_
U4 -2445
114^-244
114-2463
114-7462
114 2444
WITHOUT \DAPTER PLATK
_H4 ni":
n i-i lis
JJ4- fl 16
114- U16
n i-fin
n 4 -11j 7
114 1117
~114 Ill7
AAM-120 Revised Nov, 1997
5
-------
WEILER® GEARBOX MODELS:
1398-5,1398-5HA, 1398-5HB
1992-5HA, 1992-5HB
ITEM
1398-5
014-1124
114-1329
10
12
13
14
15
18
17
18
19
20
21
22
23
24
26
27
28
29
30
31
32
114-1331
024-1332*
114-1330
022-1342*
026-1373
010-1344*
010-1345*
022-1346*
010-1347*
026-1396
114-1381
114-1397*
114-1350*
022-1351*
022- 1352*
NOTE_~ _
114-1388*
024-1386*
114-1387
014-1077
114-1328
114-5046
010-1269
114-2096 "
010-2686
010-2687
33
34
35
36
37
38
39
40
41
42
43
44
45
4eL
47
48
49_'
so"
51
kT
53_
54
55
56
S7~
58
59
60
6	1	
NOTI< ~
010-2688
010-2689
010-1048
024-1152*
118-3127*"
113-1392N
014-1J20
m-jrojr
010-1118
_0J0-fl64
014 1057
014-1058
1398-SUA
PART NUMBERS
1992-5HA
014-1124
114-1329
114-1331
024-1332*
114-1379
022-1342*
026-1373
010-1344*
010-1345*
022-1346*
010-1347*
026-1396
114-1361
114-1384*
114-1385*
022-1351*
022-1352*
114-1301*
114-1388*
024-1386*
024-1394*
114-1387
014-1077
114-1328
114-5046
010-1269
114-2096
010-2686
010-2687
010-2688
010-2689
010-1048
024-1152*
118-3127*
113-1392N
_oto_-m7
m-_l320_
010 1?04
014-1120
114-1035
010-1118
010-11b4
01 1-1057
014J068
010 115/
1398-51 ID
014-1124
114-1329
114-1331
024-1332*
114-1379
014-1124
114-1329
114-1399
024-1403*
022-1342*
026-1373
010-1344*
010-1345*
022-1346*
010-1347*
026-1396
114-1361
114-1384*
114-1385*
022-1351*
022-1352*
114-0898*
114-1388*
024-1386*
024-1394*
114-1387
014-1077
114-1328
114-5046
010-1269
114-2096
010-2686
010-2687
010-2688
010-2689
010-1048
024-1152*
118-3127*
113-0899N
114-1379
022-1381*
026-1372
010-1344*
010-1345*
022-1346*
010-1347*
026-1383
114-1361
114-1384*
114-1385*
022-1351*
022-1352*
114-1391*
114-1388*
024-1386*
024-1394*
114-1387
014-1077
114-2374
114-5046
010-1269
114-2096
010-2686
010-2687
010-2688
010-2689
010-1048
024-1152*
118-3127*
113-1392N
11u-2428N
113-2103N
014-1120
114-1035
J 1_£ 1 26
010-1204
114-1139_
0i 0"io88
114 t39C_
114 1085
J14-1139_
"010-1088
1j4-Ktee
114-1085"
010-1118
010-1164"
014-1057"
_014-j058~
°-10-JJ57_
114-1326
010 -1204
010-1103
"010-1184"
014-1120
114-1035
010-1118
010-1164
014-1057"
"014-1058""
"010-1157"
"114-1326
1992-5HB
014-1124
114-1329
114-1399"
024-1403*
114-1379
022-1381*
026-1372
010-1344*
010-1345*
022-1346*
010-1347*
026-1383
114-1361
114-1384*
114-1385*
022-1351*
022-1352*
114-0898*
114-1388*
024-1386*
024-1394*
114-1387
014-1077
114-2374
114-5046
010-1269
114-2096
010-2686
010-2687
010-2688
010-2689
010-1048
024-1152*
118-3127*
113-0899N
113-2428N
113-2103N
014-1120
114-1035
010-1118
010-1164
010-1204
13-0900N
207 '
010
010-1220
010-1160
010-1091
114-1139
_010 1088
114-1395 "
114-1085
113-0901 SS_
1 W8 5 UtMibox repair kits da awilabk with m.nn bhatt only i
014-1057
014"-1058
010-1157
1]4-1326"_
"010-1204"
o_iq_ii°3
0J£-Jj[84_
m-0900N
_010-1207
_oio:j2?° _
"o"10-1 160
010-1091
113-0901SS
DESCRIPTION
PIN, DOWEL, #8x4-1/2"
COVER, PILOT BEARING
CARRIER, SEAL
SEAL, OIL, PINION
END CAP, PINION
BEARING, PINION
GEAR, PINION, 13 TOOTH
GEAR, PINION, 19 TOOTH
LOCK NUT
WASHER, TABBED LOCK
BEARING, PILOT
SNAP RING
GEAR, BULL, 98 TOOTH
GEAR, BULL, 92 TOOTH
SET SCREW, 5/8"-11 x 1-1/2"
KEY, 7/8" SQ, x 5" (1398-5 Key: 3/4" x 7/8")
SPACER, MAIN SHAFT
CUP, BEARING
CONE, BEARING
MAIN SHAFT
WEAR COLLAR
SEAL, OIL, INNER
SEAL, OIL, OUTER
RING, SEAL ADAPTER
LIFTING EYE, 5/8"-11
KEY, 1/2" SQ. X 6"
KEY, 5/8" SQ, X 6"
HOUSING ASSY, UPPER & LOWER
FITTING, LUBE, 1/4" NPT
STUD, LUBRICATION
BOLT, HEX, 5/8-18 x 8"
BOLT, HEX, 5/8-18 x 9-1/2"
BOLT, HEX, 5/8-18 x 11"
NUT, HEX, 5/8-18
BOLT, HEX, 1/2-13 x 1-1/4"
GASKET, ADAPTER TO GEARBOX
WRENCH, G.BOX MAIN SHFT (Not Shown)
ADAPTER PLATE, Standard (HA SPLINE)
ADAPTER PLATE, Standard (HB SPLINE)
ADAPTER PLATE, Standard (HB SPLINE TILTED)
ADAPTER PLATE, Standard (HB SPLINE VERT)
VENT, BREATHER
LOCKWIRE	"
CAP SCREW, 3/8-16X 1"
LOCK WASHER, 3/8"
PLUG, OIL DRAIN, 1/2-NPT
QTY
12
PLUG, OIL LEVEL CHECK
LOCK WASHER, 1/2"
COVER, INSPECTION
NUT, HXJ5/8-JJ_
GAP SCREW, Jl-
FLATWASHER,
1/4-12X6-1/2"
1-1/4"
WASHER, THICK	
NUT HEX 1-1/4-12
NUTJAMj 1/4-12"
S?UD, 3/4-10X3" ^
LOCK WASHER, 7/8"
CAP SCREW, 7/8-9
LOCK, CAP SCREW
STUD, 3/4-10X2-1/2"
SPACER
ml Will be tomerud to 1398 SUA 4Parts Included in Gearbox Ktpair Kit
GKARIiOX M()I)ftI,
W/MAIN SHAFT "
W/O MAIN'SIIAFT ~
[ GEARBOX MODFI
ni>8-5HA
114-2470
114-247f
r "1992-MIA
1 W8 *511H
114-2467
114 2466
1992- 51 Hi
W/ MAIN SHAFT
114-2469
114 2 16 1
W/O MAIN SHAFT"
114-2468
114-2465
AAM-120 Revised Nov, 1997
6
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Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
Section 3
Raw/Surge Bin
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
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Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
RAW/SURGE BIN
Item
Qty
Part Numbers/ Description
Bearings
2
Dodge 023113
Level Switches
2
Model: AB-R
Chain
~20ft.
80 Single Riveted Roller Chain
Motors
2
(l~)Baldor M2280T, (1~) Leeson
Gearboxes
2
Conedrive H054204-2 40:1 Ratio
Sprockets
3
(1) Dodge 100619 (1) Dodge 100595
(l)Martin 80BTB70
Shafts
2
3in Machined
Bushings
2
Dodge 117134
Thermocouples
2
TypeK
1813 Frank Holt Drive Burlington NC 27215 336-226-1100
rendeq.com
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262 3/8 APP
72 INSIDE
SCREW 12 DIA
54
INSIDE
SCREW 9 DIA
—— 34 1/2 —
DRIVE
GUARD
60 3/4
DRIVE GUARD NOT
SHOWN IN THIS VIEW
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Instruction Manual for Dodge Type E Bearings
These instructions must be read thoroughly before installation or operation.
WARNING; To ensure the drive is not unexpectedly started,
turn off and lock-out or tag power source before proceeding.
Failure to observe these precautions could result in bodily
injury.
INSTALLATION:
1.	Clean shaft and bore of bearing. Lubricate with light oil or anti
seize compound.
2.	Slip bearing in position.
3.	Bolt bearing to support, using shims where necessary to
align bearing.
4.	Tighten setscrews to the torque values shown on Table 1.
5.	The effort required to turn the shaft should be the same before
and after bolting bearing to the support.
Table 1 - Set Screw Torque Table
Shaft Size
(inches)
Set Screw Size
Tightening Torque
1-3/16-1-11/16
5/16-18
165 in—lbs
1-3/4-2-1/2
3/8-16
290 in—lbs
2-11/16 -3-1/2
1/2-13
620 in—lbs
315/16 -5
5/8-11
1325 in—lbs
5-7/16 -6
3/4 -10
2150 in—lbs
6-7/16 -7
7/8 -9
5130 in—lbs
Shaft Size
(mm)
Set Screw Size
Tightening Torque
35-4Qmm
m
17.8 NM
45-65mm
M10
35 NM
70-75mm
M12
57 NM
80-90mm
M12
57 NM
100-125mm
M16
126 NM
Lubrication Guidelines
This bearing is factory lubricated with a lithium or lithium complex
base grease which is suitable for most applications. However, extra
protection is necessary if the bearing is subjected to excessive
moisture, dust, corrosive vapor or other harsh environments. In
these cases, the bearing should contain as much grease as speed
will permit (a full bearing with consequent slight leakage through
the seal is the best protection against contaminant entry).
For relubrication, select a grease that is compatible with a lithium
or lithium complex grease. The following table is a general guide
for normal operating conditions. However, some situations may
require a change in lubricating periods as dictated by experience,
WARNING; Because of the possible danger to person(s) or
property from accidents which may result from the improper
use of products, it is important that correct procedures be
followed: Products must be used in accordance with the
engineering information specified in the catalog. Proper
installation, maintenance and operation procedures must be
observed. The instructions in the instruction manuals must
be followed. Inspections should be made as necessary to
assure safe operation under prevailing conditions. Proper
guards and other suitable safety devices or procedures as
may be desirable or as may be specified in safety codes
should be provided, and are neither provided by Baldor
Electric Company nor are the responsibility of Baldor Electric
Company. This unit and its associated equipment must be
installed, adjusted and maintained by qualified personnel
who are familiar with the construction and operation of all
equipment in the system and the potential hazards involved.
When risk to persons or property may be involved, a fail
safe device must be an integral part of the driven equipment
beyond the speed reducer output shaft.
Generally, a lower quantity of grease at frequent intervals is more
effective than a greater quantity at extended lubrication intervals.
Lubrication Guide (in weeks)
Read Preceding Paragraphs Before Establishing Lubrication Schedule
Hours
1 to
251 to
501 to
751 to
1001
1501
2001
2501
Run per
250
500
750
1000
to
to
to
to
Day
RPM
RPM
RPM
RPM
1500
2000
2500
3000




RPM
RPM
RPM
RPM
8
12
12
10
7
5
4
3
2
16
12
7
5
4
2
2
2
1
24
10
5
3
2
1
1
1
1
Lubrication recommendations are intended for standard products
applied in general operating conditions. For modified products,
high temperature environments and other anomalous applications,
contact product engineering at 864.284.5700.
Storage or Special Shutdown
If exposed to wet or dusty conditions or to corrosive vapors, extra
protection is necessary. Add grease until it shows at the seals;
rotate the bearing to distribute grease; cover the bearing. After
storage or idle period, add a little fresh grease before running.
High Speed Operation
In thehigherspeed ranges too much grease will cause overheating.
The amount of grease that the bearing will take for a particular high
speed application can be determined only by experience — see
"Operating Temperature" below. If excess grease in the bearing
caused overheating, it will be necessary to remove grease fitting
to permit excess grease to escape. The bearing has been greased
at the factory and is ready to run. When establishing a relubrication
schedule, note that a small amount of grease at frequent intervals
is preferable to a large amount at infrequent intervals.
Operation in Presence of Dust, Water or
Corrosive Vapors
Under these conditions the bearing should contain as much
grease as speed will permit, since a full bearing with consequent
slight leakage is the best protection against entrance of foreign
material. In the higher speed ranges too much grease will cause
overheating — see "High Speed Operation." In the lower speed
ranges it is advisable to add extra grease to a new bearing before
putting into operation. Bearings should be greased as often as
necessary (daily if required) to maintain a slight leakage at the
seals. For extreme conditions or dust and/or moisture consider
adding a supplemental sealing system with the E-TECT seal kits.
See catalog for details.
Average Operation
This bearing has been greased at the factory and is ready to run.
The table above is a general guide for relubrication. However,
certain conditions may require a change of lubricating periods
as dictated by experience. See "High Speed Operation" and
"Operating in Presence of Dust, Water, or Corrosive Vapors."
BALDOR • DO^GE
1
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Operating Temperature
Abnormal bearing temperature may indicate faulty lubrication.
Normal temperature may range from "cool to warm to the touch"
up to a point "too hot to touch for more than a few seconds,"
depending on bearing size and speed, and surrounding conditions.
Unusually high temperature accompanied by excessive leakage
of grease indicates too much grease. High temperature with no
grease showing at the seals, particularly if the bearing seems
noisy, usually indicates too little grease. Normal temperature and
a slight showing of grease at the seals indicate proper lubrication.
Kind of Grease
Many ordinary cup greases will disintegrate at speeds
far below those at which DODGE bearings will operate
successfully if proper grease is used, dodge bearings have
been factory lubricated with an NLGI #2 lithium complex base
grease. Relubricate with Lithium complex-base grease or a grease
which is compatible with original lubricant and suitable for roller
bearing service. In unusual or doubtful cases the recommendation
of a reputable grease manufacturer should be secured.
E-TECT SEAL KIT: Added Protection for
Extremely Wet and Dirty Environments
A V-ring seal is added to the standard "R" seal system. The V-ring
is held in place by the locking collar. The V-ring has face rubbing
contact with the steel "R" seal carrier. The resulting system
puts a flinger collar, V-ring seal, clearance seal, lip seal and two
grease dams between the rollers and the outside environment.
All components are designed for optimum sealing and purging
action.
Type K, DOUBLE-INTERLOCK, TAF
and E-XTRA E-TECT Seal Kits
Shaft Size
Kit Part*
Inches
Number
1-3/16 to 1-1/4
037650
1-3/8 to 1-7/16
037651
1-1/2 to 1-11/16
037652
1-3/4 to 2
037653
2-3/16
037654
2-1/4 to 2-1/2
037655
2-11/16 to 3
037656
3-3/16 to 3-1/2
037657
3-5/16 to 4
037658
4-7/16 to 4-1/2
037659
4-15/16 to 5
037660
5-7/16 to 6
037673**
6-7/16 to 7
037674**
* Kit includes one collar, special set screws and seal.
** Kit for 5-7/16 to 7" consists of a modified V-ring seal only.
For Type K bearings, E-TECT Seal may be used on collar side only.
For Double-Interlock, TAF and E-XTRA, two kits are required (one for each collar)
SPECIAL COLLAR (6)
, V-RING SEAL (5)
BORE OF BEARING
"CONE (7)
E-TECT SEAL -1-3/16 through 5"
¦STANDARD COLLAR (1)
r-V-RING SEAL (5)
O.D. OF BEARING
CONE (4)
E-TECT SEAL - 5-7/16 through 7"
Special Operating Conditions
Refer acid, chemical, extreme or other special operating
conditions to Baldor Electric, Dodge Product Support, Greenville,
SC (864-284-5700).
© Baldor Electric Company
MN3012 (Replaces 499791,
and 499792, 499793)
A MEMBER OF THE ABB GROUP
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1)479.646.4711, Fax (1) 479.648.5792, International Fax (1)479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
All Rights Reserved. Printed in USA.
8/12 TCP 10,000
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mm
Bin-Dicator®
Installation & Operation Manual
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<
Bin-Dicator®
Installation & Operation Manual
com
I.	HANDLING & STORAGE	1
Inspection and Handling
Disposal and Recycling
Storage
II.	GENERAL SAFETY	2
Authorized Personnel
Use
Misuse
III.	PRODUCT DESCRIPTION	3
Function
Features
Bantam Bin-Dicator
Auto Bin-Dicator
Model 'A'
Technical Specifications
Approvals
IV.	MECHANICAL INSTALLATION	5
Mounting
Figure 1: General Component Layout
Figure 2: Mercury Switch Component Layout
V.	ELECTRICAL INSTALLATION	9
General Safety
Disconnect Requirements
Wiring
VI.	MAINTENANCE	11
Preventive
Recommended Spare Parts
VII.	DIMENSIONAL DRAWINGS	13
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SAFETY SYMBOLS
WARNING:
IDEK '< NDiTIC i" ' PPOCED^	\1 DT FOLLOWED, COULD
RESlili iN iOl' !' i ! . r !3K OF ELECTRIC. •' iOCK.
IDEM M H , < NDiTIONS Of-' H" OCEC!;> '* \ VHICH SF NOT FOLLOWED, COULD
RES'.- , i«r ¦ H ! IOL .> i. Mf CI > ^ I '• .«• '"«!" ; , «L f >UIPMENT.
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Installation & Operation Manual
I. HANDLING AND STORAGE
SAVE THESE INSTRUCTIONS
INSPECTION AND HANDLING
Do not dispose of the carton or packing materials.
Each package should be inspected upon receipt for damage that may have occurred due to mishandling during
shipping. If the unit is received damaged, notify the carrier or the factory for instructions. Failure to do so may
void your warranty. If you have any problems or questions, consult Customer Support at 1-800-778-9242.
DISPOSAL AND RECYCLING
This product can be recycled by specialized companies and must not be disposed of in a municipal collection
site. If you do not have the means to dispose of properly, please contact for return and disposal instructions or
options.
If the device is not scheduled for immediate installation following delivery, the following steps should be
observed:
1.	Following inspection, repackage the unit into its original packaging.
2.	Select a clean dry site, free of vibration, shock and impact hazards.
3.	If storage will be extended longer than 30 days, the unit must be stored at temperatures between
32° and 104° F (0° to 40° C) in non-condensing atmosphere with humidity less than 85%.
CAUTION: DO NOT STORE A NON-POWERED UNIT OUTDOORS FOR A PROLONGED PERIOD.
STORAGE
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II. GENERAL SAFETY
www.bindicator.com
AUTHORIZED PERSONNEL
All instructions described in the document must be performed by authorized and qualified service personnel
only. Before installing the unit, please read these instructions and familiarize yourself with the requirements and
functions of the device. The required personal protective equipment must always be worn when servicing this
device.
USE
The device is solely intended for use as described in this manual. Reliable operation is ensured only if the
instrument is used according to the specifications described in this document. For safety and warranty
reasons, use of accessory equipment not recommended by the manufacturer or modification of this device is
explicitly forbidden. All servicing of this equipment must be performed by qualified service personnel only. This
device should be mounted in locations where it will not be subject to tampering by unauthorized personnel.
MISUSE
Improper use or installation of this device may cause the following:
•	Personal injury or harm
•	Application specific hazards such as vessel overfill
•	Damage to the device or system
If any questions or problems arise during installation of this equipment, please contact Customer Support at
800-778-9242.
2
LAA180313 Rev. B
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-"rf^-fir' n" I'Ufrri
www.bindicator.com
III. PRODUCT DESCRIPTION
FUNCTION
Bin-Dicator® diaphragm-type level controls were the original electromechanical point level switches and the
first to enjoy general usage in the industry. Bin-Dicator controls eliminate bin overflow, empty bins, clogged
conveyors, choked elevators and the resulting damage and waste.
The Bin-Dicator control is a pressure actuated switch for use with free flowing bulk materials at atmospheric
pressures. Actuation of the switch is the result of pressure exerted by the bulk material against the diaphragm
assembly. De-actuation or switch release is a result of the bulk material clearing away from the diaphragm.
FEATURES
Bantam Bin-Dicator
•	5%" diameter
•	2 diaphragm material options
•	Light duty
•	8" diameter
•	Cast aluminum housing
•	Neoprene or SS diaphragm material
•	Medium duty
•	10%" diameter
•	Explosion proof model avail.
•	7 diaphragm material options
•	Heavy duty
Auto-Bin-Dicator
Model 'A'
LAA180313 Rev. B
3
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www.bindicator.com
TECHNICAL SPECIFICATIONS
FUNCTIONAL
Switch
Standard 185° F
(85° C)
Model-A
SPDT: 15 amp resistive @ 250 VAC
Auto-Bin-Dicator
Standard SPDT Snap Action Switch (Dry Rated): 15 amp resistive @ 125, 250 or 480 VAC;
Pilot duty 375 VA, 125 VAC or 750 VA, 250 VAC
Bantam
SPDT: 20 amp resistive @ 250 VAC
Optional Switches
Ratings
250° F (121 ° C), 800° F (427° C)
Explosion Proof
Model-A and Auto-Bin-Dicator
Temperature
1.0 of calibrated span (combined linearity, hysteresis, stability) between 0° and 150° F
32° F to185° F (0° to 85° C) standard, Auto and Bantam
Frame
Polyester-coated aluminum casting
Cover
Polyester-coated aluminum casting (Auto and Bantam)
Standard durable ABS white plastic (Model "A")
Construction
Weather-proof or explosion-proof (Auto)
Diaphragms
Neoprene, Stainless Steel (Auto), Aluminum (Bantam), Steel galvanized back plate; Steel polyester washer (Model "A")
Gasket
Rubber (Bantam), Fiber (Model "A")
Mounting
Can be mounted on underslopes up to 45 degree (Bantam & Model "A")
Shipping Weight
Aluminum 8 lbs (Auto & Bantam), Aluminum 10 lbs (Model "A")
Pollution Degree
2
Installation Category
II
Altitude
6,526 ft (2000 m)
DIAPHRAGM MATERIAL	MAX. TEMP	PRODUCT WT. Cu./Ft. APPLICATION REMARKS
Neoprene Rubber (light)
170° F (77° C)
10-40
Highest sensitivity, abrasion resistant
Neoprene Rubber (medium)
170° F (77° C)
30-100
Strong, resists abrasion, low temperatures
Neoprene Rubber (heavy)
170° F (77° C)
100-350
Strong, resists abrasion, low temperatures
Canvas
200° F (93° C)
10-60
Powders only
Fiberglass
1000° F (538° C)
25-100
Very high temp-see switch temperatures
T-302 SS
800° F (427° C)
30 Min.
Auto-Bin-Dicator® only
Silicone Rubber (heavy)
450° F (232° C)
50-150
Extreme low to medium-high temperature
Teflon® Coated Fiberglass (heavy)
400° F (204° C)
50-150
Corrosion resistant, medium-high temperatures
Note: For high temperature applications, special switches may be required in addition to proper diaphragm selection. Please consult factory.
APPROVALS - CONSULT FACTORY FOR SPECIFIC MODEL LISTING
General Purpose: UL, CSA
Hazardous Location:
UL: Class 1, Groups C & D, Class II, Groups E, F, G
4
LAA180313 Rev. B
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www.bindicator.com
\ \il * - ' lm\± .HMh i ' 'fON
I WARNING: REMOVE POWER FROM THE UNIT BEFORE INSTALLING, REMOVING, OR MAKING
JA ADJUSTMENTS.
BANTAM
GUIDELINES
• Should be located at a point where the material will normally reach and actuate the diaphragm, and
when receding, will completely clear the diaphragm.
• Mounting location should be out of the direct flow of material into the vessel.
MOUNTING
/|\ CAUTION: FOR ALL ANGLES OF MOUNTING, LINE C-D MUST BE IN A VERTICAL PLANE AND
/ ' \ LINE A-B MUST BE HORIZONTAL.
1.	Lay out 4 and 5 1/s in. (10 and 13 cm) concentric circles at point where the Bantam Bin-Dicator device is
to be mounted.
2.	Cut out the 4 in. (10 cm) circle and drill four %2 in. holes on the 5 1/s in. (13 cm) circle.
3.	Insert gasket between vessel wall and face of the unit.
4.	Fasten to vessel wall with 1A" mounting bolts.
5.	Check operation of lever system and switch; make field adjustments as necessary.
6.	Connect conduit and make wiring connections.
7.	Replace cover.
4Smr
LAA180313 Rev. B
5
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-"rf^-fir' n" I'Ufrri
www.bindicator.com
FIELD ADJUSTMENT
1.	Check for binding at the pivot points. If binding is occurring, it is likely due to improper mounting. Check
to be sure the lever alarm is in a vertical plane and that the mechanism operates freely.
2.	Adjust the counterweight. For reliable operation of the counterweight must be sufficient to return the
diaphragm to normal position when the material completely clears the diaphragm. To adjust the
counterweight, loosen the nuts holding the segments in place. Move the weight toward the lever arm to
decrease the counterweight. To increase the counterweight, move the weight away from the lever arm.
Be sure to lock the counterweight at the desired position.
3.	Check switch sensitivity. Switch may be adjusted for more sensitive operation by loosening the top
machine screw holding the switch in place and shifting the position of the switch to obtain the desired
sensitivity. When making this adjustment, be sure the switch returns to normal when the level plate is
slowly lowered by hand.
AUTO-BIN-DICATOR
GUIDELINES
•	High Level Mounting: unit should be mounted low enough on the vessel wall, so that material will
normally cover the diaphragm and provide sufficient head of material before the high level signal is
required.
•	Low Level Mounting: unit should be mounted high enough on the vessel wall, so that material in its
normal flow will cover the diaphragm and provide sufficient head of material before the low level signal is
required.
•	Mounting location should be out of the direct flow of material into the vessel.
MOUNTING
6-9/32" (7mm) HOLES ON
7 7/16" (189mrn) BOLT CIRCLE
DIAPHRAGM
8" O.D.
(203mm)
'3/4"
CONDUIT
CONNECTION
1.	Mark two concentric circles on the vessel wall at the point where the unit is to be mounted. One circle
should be 6 7/s in. (17 cm) in diameter, the second 77/ie in. (19 cm) in diameter.
2.	Cut out the 6 T/a in. (17 cm) circle.
3.	Lay out six (6) equally spaced holes on the 7 Vie in. (19 cm) circle.
4.	Drill or tap 1A in. for bolts or cap screws.
6
LAA180313 Rev. B
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www.bindicator.com
5.	Insert the gasket between the vessel wall and the flange of the unit with the conduit entry facing downward.
6.	Fasten the unit to the vessel wall with 1A in. bolts or cap screws.
7.	Connect conduit and make wiring connections at switch terminals.
8.	Screw cover to housing securely to prevent damage or moisture.
9.	Check switch operation by manually depressing diaphragm and releasing. The switch should now
respond to the pressure.
IV;'.'"r ;• ^ndard or with Mer*.t;iv 'smU I/
GUIDELINES
•	Should be located at a point where the material in its normal flow will reach and move the diaphragm,
and when receding, will completely clear the diaphragm.
•	Mounting location should be out of the direct flow of material into the vessel.
•	If the material is of lighter density or if the unit is to be mounted on the under-slope, the counterweight
must be reduced to provide sensitive operation of the unit.
•	If the material is of heavier density or if the unit is mounted on the under-slope, the counterweight must
be increased to return the diaphragm to normal as the material clears the diaphragm.
MOUNTING
/j\ CAUTION: WHEN MOUNTING LINE C-D MUST BE ON A VERTICAL PLANE AND LINE A-B MUST
/ • \ BE HORIZONTAL.
]
1.	Mark two concentric circles on the vessel wall at the point where the unit is to be mounted. One circle
should be 8 in. (20 cm) in diameter, the second 9% in. (24 cm) in diameter.
2.	Cut out the 8 in. (20 cm) circle.
3.	Lay out six (6) equally spaced holes on the 9% in. (24 cm) circle.
4.	Drill or tap 1A in. bolts or cap screws.
5.	Insert the gasket between the vessel wall and the flange of the unit with the conduit facing down.
6.	Fasten the unit to the vessel wall with 1A in. bolts or cap screws.
LAA180313 Rev. B
7
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www.bindicator.com
7.	Check operation of lever system and switch; make field adjustments as necessary.
8.	Connect conduit and make wiring connections.
9.	Replace cover.
FIELD ADJUSTMENT
1.	Check for binding at the pivot points. If binding is occurring, it is likely due to improper mounting. Check
to be sure the lever alarm is in a vertical plane and that the mechanism operates freely.
2.	Adjust the counterweight. For reliable operation of the counterweight must be sufficient to return the
diaphragm to normal position when the material completely clears the diaphragm. To adjust the
counterweight, loosen the nuts holding the segments in place. Ad or remove counterweight washers to adjust.
3.	Check switch sensitivity. Switch may be adjusted for more sensitive operation by loosening the top
machine screw holding the switch in place and shifting the position of the switch to obtain the desired
sensitivity. When making this adjustment, be sure the switch returns to normal when the level plate is
slowly lowered by hand.
Figure 1. General Component Layout	Figure 2. Mercury Switch Component Layout
Lever Plate
¦Counterweight
•Mecury Switch
Pivot Points
Lever Plate
Counter Weight
Level Actuator
Micro Switch
8
LAA180313 Rev. B
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www.bindicator.com
V. ELECTRICAL INSTALLATION
/j\ WARNING: VERY HIGH VOLTAGE IS PRESENT. REMOVE POWER FROM THE UNIT BEFORE
/ ' \ INSTALLING, REMOVING, OR MAKING ADJUSTMENTS
GENERAL SAFETY
When using electrical equipment, you should always follow basic safety precautions, including the following:
•	The installation and wiring of this product must comply with all national, federal, state, municipal, and
local codes that apply.
•	Properly ground the enclosure to an adequate earth ground.
•	Do not modify any factory wiring. Connections should only be made to the terminals described in this section.
•	All connections to the unit must use conductors with an insulation rating of 300V minimum, rated for
221 ° F (105° C), a minimum flammability rating of VW-1, and be of appropriate gauge for the voltage and
current required (see specifications).
•	Do not allow moisture to enter the electronics enclosure. Conduit should slope downward from the unit
housing. Install drip loops and seal conduit with silicone rubber product.
DISCONNECT REQUIREMENTS FOR PERMANENTLY INSTALLED EQUIPMENT
A dedicated disconnecting device (circuit breaker) must be provided for the proper installation of the unit. If
independent circuits are used for power input and outputs, individual disconnects are required.
Disconnects must meet the following requirements:
•	Located in close proximity to the device
•	Easily accessible to the operator
•	Appropriately marked as the disconnect for the device and associated circuit
•	Sized appropriately to the requirements of the protected circuit (See specifications)
PROTECTIVE EARTH GROUND
To eliminate shock hazards in the unlikely event of an internal insulation breakdown, the unit is provided with a
"protective earth" ( (3=) ) lead which must be connected to earth ground. In addition, the input power ground
lead must be connected to the "protective earth" ( (3=) ) terminal provided. Wire sizes must be selected such
that it can safely carry the sum total of all circuits' maximum amperage.
WIRING
Common	
Normally Open (NO)	
Normally Closed (NC)	
LAA180313 Rev. B
9
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www.bindicator.com
VI. MAINTENANCE
PREVENTIVE MAINTENANCE
Semi-annual or annual inspection of the diaphragm, vent and switch circuit is recommended.
RECOMMENDED SPARE PARTS
BANTAM BIN-DICATOR
LAB110700
A-BB-3
Lever Arm Assembly
LAB121360
BB-2
Cover
LAB121410
BB-6
Aluminum Diaphragm Retaining Washer
LAB121420
BB-6A
Stainless Steel Diaphragm Retaining Washer
LAB121430
BB-9
Neoprene Diaphragm
LAB121510
BB-9H
Teflon®-Coated Neoprene Diaphragm
LAB121530
BB-15
Diaphragm Back Plate
LAB121580
BB-5
Brass Pivot Rod
LAB122138
BB-3
Brass Lever Arm
LAB130940
BB-7
Rubber Mounting Gasket
LAB130950
BB-7A
Rubber Cover Gasket
LAB130960
BB-8
Counterweight Segment, Lead, 1 oz
LAB130970

Micro Switch, 185° F (85° C), Marked BA-2RV-191-A2
LAB130980

Micro Switch, 250° F (121° C)
AUTO-BIN-DICATOR
LAD110750
A-D-8A
Switch Assembly w/ Bracket, Cam, and Barriers; 185° F (85 C)
LAD110751
A-D-8B
Switch Assembly w/ Bracket, Cam, and Barriers; 250 F (121 C)
LAD110752
A-D-8C
00 Switch Assembly w/ Bracket, Cam, and Barriers; 800 F (427 C)
LAD121590
AB-4
Diaphragm Back Plate
LAD121600
AB-5
Aluminum Diaphragm Retaining Washer
LAD121610
AB-6
Stainless Steel Diaphragm
LAD121620
AB-6A
Neoprene Diaphragm
LAD122004
AB-5SS
Stainless Steel Diaphragm Retaining Washer
LAD131030
AB-8
Perimeter Springs (Behind Diaphragm Back Plate)
LAD131040
D-8A
Micro Switch Marked BA-2RB35-A2, 185° F (85° C)
LAD131050
D-8B
Micro Switch, 250° F (121° C)
LAD131060
D-8C
Micro Switch, 800° F (427° C)
LAD131090
AB-10
Mounting Gasket
LAG110800
G-6E
Cam Assembly
LAG121700
G-3
Cover
LAG121760
G-7A
Push Rod
10
LAA180313 Rev. B
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www.bindicator.com
MODEL A
LAA110550
A-115-A
Canvas Diaphragm Assembly
LAA110560
A-11
Fiberglass Diaphragm Assembly, 0.010 in. (0.254 mm)
LAA110570
A-115-C
Light Neoprene Diaphragm Assembly, 0.013 in. (0.330 mm)
LAA110580
A-115-D
Medium Neoprene Diaphragm Assembly, 0.025 in. (0.635 mm)
LAA110590
A-115-E
Heavy Neoprene Diaphragm Assembly
LAA110610
A-115-G
Heavy Silicone Diaphragm Assembly
LAA110630
A-115-J
Heavy Teflon®-Coated Fiberglass Diaphragm Assembly
LAA110670
A-AA18
(2) 119-A Switches Mounted in Brackets
LAA110790
A-116A
Mercury Switch (G-10Z) and Mounting Clip
LAA120980
AA-5A
Lever Plate (Micro/Mercury Switch)
LAA120990
AA-5B
Lever Plate (Micro Switch) Model, Underslope Mounting
LAA121010
AA-9A
Cover for Explosionproof Model A Bin-Dicator
LAA121040
AA-10
Steel Diaphragm Retaining Washer
LAA121050
AA-10A
Stainless Steel Diaphragm Retaining Washer
LAA121090
AA-13B
Single/Double Micro Switch Bracket, Aluminum (2 Required)
LAA121110
AA-13D
High Temperature Micro Switch Bracket (1 Required)
LAA121130
AA-14
Steel Diaphragm Back Plate
LAA122120
AA-2
Brass Pivot Rod
LAA122121
AA-3
Brass Diaphragm Push Rod
LAA130591
AA-9
General Purpose Cover, Plastic, Model A
LAA130592

General Purpose Cover, Minion®, Model A
LAA130730
AA-7
Counterweight Segment, Lead, 1 oz
LAA130770
AA-11
Cover Mounting Gasket
LAA130780
AA-11
Klinger Mounting Gasket for High Temperature Switch
LAA130800
117
Mercury Switch (G-10Z) Mounting Clip
LAA130810
118
2-Pole Terminal Block
LAA130820
119-A
Micro Switch, 185° F (85° C)
LAA130830
119-B
Micro Switch, 250° F (121° C)
LAA130840
119-C
00 Micro Switch, 800° F (427° C)
LAA130850
122-A
0 EX-AR Explosionproof Micro Switch, SP/DT, 185° F (85° C)
LAA130860
122-B
0 EX-DAR Explosionproof Micro Switch, DP/DT, 185° F (85° C)
LUA030820
4107
Brass External Cap Nut for AA-3 Brass Rod
LUA030830
4107A
Stainless Steel External Cap Nut for AA-3 Brass Rod
LAA180313 Rev. B
11
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VI. DIMENSIONAL DRAWINGS
Bantam Bin-Dicator
5 0 D
k I 46mm) nQ2mm>
k	; DIAPHRAGM
4-9/32" i 7mm) HO. FS ON
¦>	(130mm) BOLT CIRC
LE
LLVKL
DOLLED AND
W-£J FOR
5/4" CONDUIT
SIN WALL-
•- -ADjU-JIAfcSLl
\GOJMTFRWEICHT
_X
X	
°1- , V
jr~ -- -=^

~3 ~V8"—
(98rrm)
Auto-Bin-Dicator
"ft-9/3^' ("mm) HuLES ON
/ "
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BALDOR • RELIANCE tu
Integral Horsepower
AC Induction Motors
ODP, WPI Enclosures
TENV, TEAO, TEFC Enclosure
Explosion Proof
8/12
Installation & Operating Manual
MN408
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Table of Contents
Section 1
General Information		1-1
Overview		1-1
Limited Warranty		1-1
Safety Notice 		1-1
Receiving 		1-2
Handling		1-2
Storage		1-3
Removal From Storage		1-4
Equipment Marking for IEC Certified Product		1-5
EMC Compliance Statement for European Union		1-5
Section 2
Installation & Operation		2-1
Overview		2-1
Location		2-1
Mounting Location		2-1
Frame Mounting Holes		2-2
Alignment		2-2
Doweling & Bolting		2-2
Guarding		2-3
Power Connection		2-3
Grounding 		2-3
Conduit Box		2-3
AC Power		2-4
Rotation 		2-4
Connection Diagrams		2-5
Initial Lubrication		2-7
First Time Start Up 		2-7
Coupled Start Up		2-8
Jogging and Repeated Starts		2-8
Hazardous Locations 		2-8
Selection		2-8
Protection Concepts		2-8
Repair of Motors used in Hazardous Locations		2-10
Section 3
Maintenance & Troubleshooting		3-1
General Inspection		3-1
Relubrication & Bearings 		3-1
Relubrication Intervals		3-2
Relubrication Procedure		3-4
Shaker Duty Motors only		3-4
Troubleshooting Chart 		3-5
Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY		3-6
MN408	i
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Section 1
General Information
Overview	This manual contains general procedures that apply to Baldor Motor products. Be sure to read and understand
the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform
maintenance procedures until you understand the Warning and Caution statements.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
Important: This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question about a
procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor distributor for
more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
•	NEMA Publication MG-2, Safety Standard for Construction and guide for Selection, Installation and Use of
Electric Motors and Generators.
•	IEC34-1 Electrical and IEC72-1 Mechanical specifications
•	ANSI C51.5, the National Electrical Code (NEC) and local codes and practices.
Limited Warranty
www.baldor.com/support/warranty_standard.asp
Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt installation, operation and maintenance of electrical equipment. Be sure
that you are completely familiar with NEMA publication MG-2, safety standards for construction and
guide for selection, installation and use of electric motors and generators, the National Electrical Code
and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or
fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this
equipment.
WARNING: Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING: Disconnect all electrical power from the motor windings and accessory devices before disassembly of
the motor. Electrical shock can cause serious or fatal injury.
WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you
ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal
injury. National Electrical Code and Local codes must be carefully followed.
WARNING: Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to
reduce harmful effects to your hearing.
WARNING: Surface temperatures of motor enclosures may reach temperatures which can cause discomfort or
injury to personnel accidentally coming into contact with hot surfaces. When installing, protection
should be provided by the user to protect against accidental contact with hot surfaces. Failure to
observe this precaution could result in bodily injury.
WARNING: This equipment may be connected to other machinery that has rotating parts or parts that are driven by
this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt
to install operate or maintain this equipment.
WARNING: Do not by-pass or disable protective devices or safety guards. Safety features are designed to prevent
damage to personnel or equipment. These devices can only provide protection if they remain operative.
WARNING: Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to
personnel or equipment.
WARNING: Be sure the load is properly coupled to the motor shaft before applying power. The shaft key must be
fully captive by the load device. Improper coupling can cause harm to personnel or equipment if the
load decouples from the shaft during operation.
WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if these
motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING: Thermostat contacts automatically reset when the motor has slightly cooled down. To prevent injury or
damage, the control circuit should be designed so that automatic starting of the motor is not possible
when the thermostat resets.
WARNING: Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
WARNING: Pacemaker danger - Magnetic and electromagnetic fields in the vicinity of current carrying carrying
conductors and permanent magnet motors can result result in a serious health hazard to persons
with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from the area
surrounding a permanent magnet motor.
WARNING: Before performing any motor maintenance procedure, be sure that the equipment connected to the
motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the load from
the motor shaft before maintenance is performed. Unexpected mechanical rotation of the motor parts
can cause injury or motor damage.
Continued on next page.
MN408
General Information 1 -1
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Safety Notice Continued
WARNING: Do not use non UL/CSA listed explosion proof motors in the presence of flammable or combustible
vapors or dust. These motors are not designed for atmospheric conditions that require explosion proof
operation.
WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the UL label on the
nameplate along with CSA listed logo. Specific service conditions for these motors are defined in NFPA
70 (NEC) Article 500.
WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions, should be permanently guarded to prevent accidental contact by personnel. Accidental
contact with body parts or clothing can cause serious or fatal injury.
Caution:	To prevent premature equipment failure or damage, only qualified maintenance personnel should
perform maintenance.
Caution:	Do not over tension belts. Excess tension may damage the motor or driven equipment.
Caution:	Do not over-lubricate motor as this may cause premature bearing failure.
Caution:	Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is
adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other driven
equipment) from the motor shaft before lifting the motor.
Caution:	If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction should
not exceed a 20 ° angle from the shank of the eye bolt or lifting lug. Excessive lifting angles can cause
damage.
Caution:	To prevent equipment damage, be sure that the electrical service is not capable of delivering more than
the maximum motor rated amps listed on the rating plate.
Caution:	If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure
in NEMA MG1 and MG2 standards to avoid equipment damage.
Caution:	The space heaters are designed to operate at or below the maximum surface temperature stated on the
nameplate. If the marked ambient and/or voltage are exceeded this maximum surface temperature can
be exceeded and can damage the motor windings. If applied in a division 2 or zone 2 environment this
excessive temperature may cause ignition of hazardous materials.
Caution:	Shaker Duty motors must be properly lubricated prior to Start Up to prevent damage. See Section 3.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor distributor or an Authorized Baldor Service Center.
Receiving Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. When you
receive your motor, there are several things you should do immediately.
1.	Observe the condition of the shipping container and report any damage immediately to the commercial
carrier that delivered your motor.
2.	Verify that the part number of the motor you received is the same as the part number listed on your
purchase order.
Handling	The motor should be lifted using the lifting lugs or eye bolts provided.
Caution:	Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is
adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other driven
equipment) from the motor shaft before lifting the motor.
1.	Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift only
the motor. Never lift the motor by the motor shaft or the hood of a WPII motor.
2.	To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.
(Room temperature is the temperature of the room in which it will be installed). The packing provides
insulation from temperature changes during transportation.
3.	When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into holes on
top of the cooling hood. These lugs are to be used for hood removal only. A spreader bar should be used
to lift the motor by the cast lifting lugs located on the motor frame.
4.	If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc., it may
not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling around the
mounting base. The entire assembly can be lifted as an assembly for installation. Do not lift the assembly
using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to lift motor only. If the load is
unbalanced (as with couplings or additional attachments) additional slings or other means must be used
to prevent tipping. In any event, the load must be secure before lifting. If the load is unbalanced (as with
couplings or additional attachments) additional slings or other means must be used to prevent tipping. In
any event, the load must be secure before lifting.
1 -2 General Information
MN408
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Storage	Storage requirements for motors and generators that will not be placed in service for at least six months from
date of shipment.
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does not
experience regular usage while being exposed to normally humid atmospheric conditions is likely to develop
rust in the bearings or rust particles from surrounding surfaces may contaminate the bearings. The electrical
insulation may absorb an excessive amount of moisture leading to the motor winding failure.
A wooden crate "shell" should be constructed to secure the motor during storage. This is similar to an export
box but the sides & top must be secured to the wooden base with lag bolts (not nailed as export boxes are) to
allow opening and reclosing many times without damage to the "shell".
Minimum resistance of motor winding insulation is 5 Meg ohms or the calculated minimum, which ever is
greater. Minimum resistance is calculated as follows: Rm = kV + 1
where: (Rm is minimum resistance to ground in Meg-Ohms and kV is rated nameplate
voltage defined as Kilo-Volts.)
Example: For a 480VAC rated motor Rm =1.48 meg-ohms (use 5 M Q).
For a 4160VAC rated motor Rm = 5.16 meg-ohms.
Preparation for Storage
1.	Some motors have a shipping brace attached to the shaft to prevent damage during transportation.
The shipping brace, if provided, must be removed and stored for future use. The brace must be reinstalled
to hold the shaft firmly in place against the bearing before the motor is moved.
2.	Store in a clean, dry, protected warehouse where control is maintained as follows:
a.	Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from
brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used.
b.	Storage temperatures of 10 °C (50 °F) to 49 °C (120 °F) must be maintained.
c.	Relative humidity must not exceed 60%.
d.	Motor space heaters (when present) are to be connected and energized whenever there is a possibility
that the storage ambient conditions will reach the dew point. Space heaters are optional.
Note: Remove motor from containers when heaters are energized, reprotect if necessary.
3.	Measure and record the resistance of the winding insulation (dielectric withstand) every 30 days of storage.
a.	If motor insulation resistance decreases below the minimum resistance, contact your Baldor District
office.
b.	Place new desiccant inside the vapor bag and re-seal by taping it closed.
c.	If a zipper-closing type bag is used instead of the heat-sealed type bag, zip the bag closed instead
of taping it. Be sure to place new desiccant inside bag after each monthly inspection.
d.	Place the shell over the motor and secure with lag bolts.
4.	Where motors are mounted to machinery, the mounting must be such that the drains and breathers are
fully operable and are at the lowest point of the motor. Vertical motors must be stored in the vertical
position. Storage environment must be maintained as stated in step 2.
5.	Motors with anti-friction bearings are to be greased at the time of going into extended storage with
periodic service as follows:
a.	Motors marked "Do Not Lubricate" on the nameplate do not need to be greased before or during
storage.
b.	Ball and roller bearing (anti-friction) motor shafts are to be rotated manually every 3 months and
greased every 6 months in accordance with the Maintenance section of this manual.
c.	Sleeve bearing (oil lube) motors are drained of oil prior to shipment. The oil reservoirs must be refilled
to the indicated level with the specified lubricant, (see Maintenance). The shaft should be rotated
monthly by hand at least 10 to 15 revolutions to distribute oil to bearing surfaces.
d.	"Provisions for oil mist lubrication" - These motors are packed with grease. Storage procedures are
the same as paragraph 5b.
e.	"Oil Mist Lubricated" - These bearings are protected for temporary storage by a corrosion inhibitor.
If stored for greater than 3 months or outdoor storage is anticipated, connected to the oil mist
system while in storage. If this is not possible, add the amount of grease indicated under "Standard
Condition" in Section 3, then rotate the shaft 15 times by hand.
MN408
General Information 1 -3
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6.	All breather drains are to be fully operable while in storage (drain plugs removed). The motors must be
stored so that the drain is at the lowest point. All breathers and automatic "T" drains must be operable to
allow breathing and draining at points other than through the bearings around the shaft. Vertical motors
should be stored in a safe stable vertical position.
7.	Coat all external machined surfaces with a rust preventing material.
An acceptable product for this purpose is Exxon Rust Ban # 392.
8.	Carbon brushes should be lifted and held in place in the holders, above the commutator, by the brush
holder fingers. The commutator should be wrapped with a suitable material such as cardboard paper as a
mechanical protection against damage.
Non-Regreaseable Motors
Non-regreasable motors with "Do Not Lubricate" on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types
Before storage, the following procedure must be performed.
1.	Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket prior
to lubricating the motor.
2.	The motor with regreasable bearing must be greased as instructed in Section 3 of this manual.
3.	Replace the grease drain plug after greasing.
4.	The motor shaft must be rotated a minimum of 15 times after greasing.
5.	Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months (see Section 3) to each bearing.
6.	Bearings are to be greased at the time of removal from storage.
Removal From Storage
1.	Remove all packing material.
2.	Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into service. If
resistance is low, contact your Baldor District office.
3.	Regrease the bearings as instructed in Section 3 of this manual.
4.	Reinstall the original shipping brace if motor is to be moved. This will hold the shaft firmly against the
bearing and prevent damage during movement.
1 -4 General Information
MN408
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Equipment Marking for IEC Certified Product
I EC certified products have special markings that identify the protection concept and environment
requirements. An example is shown in Figure 1-1.
Figure 1-1 IEC Certified Product Markings
Temperature Class
Gas Group (IIC)
Ex Protection Concept (ExnA)
Ambient Range
MOTOR
ExnA IIC	Gc Tamb
II 3 G IP	 (
C to	?C
ATEX Specific
Marking of
Explosion Protection
;CEx
BY BALDOR ELECTRIC FORT SMITH, AR 72901
European Conformity Mark
ATEX Equipment Group and Category (113)
Type of Atmosphere: G-Gas, D-Dust (G)
Place of Manufacture
Specific Conditions of Use:
If the motor certificate number is followed by the symbol "X", this indicates that the motor has specific
conditions of use which are indicated on the certificate. It is necessary to review the product certification
certificate in conjunction with this instruction manual.
Operation On Frequency Converters:
If the motor is evaluated for operation with an adjustable speed drive, the type of converter (for example PWM
for Pulse Width Modulated) and safe speed ranges (for example 0- 120Hz) will be specified in the certification
documents or on motor nameplates. It is necessary to consult the adjustable speed drive
manual for proper set up. lECEx Certificates are available online at www.iecex.com
Unit Conversions
Inches to Millimeters
Inches x 25.4 = mm
Millimeters to Inches
mm x .03937 = Inches
Horsepower to Kilowatts
Hp x .746 = Kw
Kilowatts to Horsepower
Kwx 1.341 = Hp
Pounds to Kilograms
Lbs x .454 = Kg
Kilograms to Pounds
Kg x 2.205 = Lbs
EMC Compliance Statement for European Union
The motors described in this instruction manual are designed to comply 2004/108/EC . These motors are
commercial in design and not intended for residential use. When used with converters, please consult
converter manufacturers literature regarding recommendations on cable types, cable shielding, cable shielding
termination, connection recommendations and any filters which may be recommended for EMC compliance.
For additional information, consult Baldor MN1383.
MN408
General Information 1 -5
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Section 2
Installation & Operation
Overview	Installation should conform to the National Electrical Code as well as local codes and practices. When other
devices are coupled to the motor shaft, be sure to install protective devices to prevent future accidents.
Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These protect against
accidental contact with moving parts. Machinery that is accessible to personnel should provide further
protection in the form of guard rails, screening, warning signs etc.
Location	It is important that motors be installed in locations that are compatible with motor enclosure and ambient
conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced operating
life of the motor.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.
1.	Open Drip-Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry, well
ventilated and non-corrosive.
2.	Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in
outdoor locations.
Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with high corrosion
or excessive moisture conditions. These motors should not be placed into an environment where there is the
presence of flammable or combustible vapors, dust or any combustible material, unless specifically designed
for this type of service. IEEE841 motors are suitable for application in Class I Division 2 and Class I Zone 2
areas on sine wave power in accordance with the applicable codes and standards.
Hazardous Locations are those where there is a risk of ignition or explosion due to the presence of
combustible gases, vapors, dust, fibers, or flyings. Facilities requiring special equipment for hazardous
locations are typically classified in accordance with local requirements. In the US market, guidance is provided
by the National Electric Code.
EMC Compliance Statement for European Union
The motors described in this instruction manual are designed to comply 2004/108/EC . These motors are
commercial in design and not intended for residential use.
Mounting Location
The motor should be installed in a location compatible with the motor enclosure and specific ambient. To allow
adequate air flow, the following clearances must be maintained between the motor and any obstruction:
Table 2-1 Enclosure Clearance
TEFC / TENV (IC0141 ) Enclosures
Fan Cover Air Intake
180 - 210T Frame 1" (25mm)
Fan Cover Air Intake
250 - 449T Frame 4" (100mm)

IEC 112 - 132 1" (25mm)

IEC 160 - 280 4" (100mm)
Exhaust
Envelope equal to the P Dimension on the motor
dimension sheet
OPEN/Protected Enclosures
Bracket Intake
Same as TEFC
Frame Exhaust
Exhaust out the sides envelope
A minimum of the P dimension plus 2" (50mm)
Exhaust out the end same as intake.
The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may cause
vibration, misalignment and bearing damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
When installation is complete and accurate alignment of the motor and load is accomplished, the base should
be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center for
further information.
MN428
Installation & Operation 2-1
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Frame Mounting Holes
Some motors have standardized frames containing 6 or 8 mounting holes. 6 hole frames are not suitable for
field reversal of mounting from F-1 to F-2, etc. Figure 2-1 indicates the proper mounting holes to use.
For short frame designations 182, 213,
254, 284, 324, 364, 404, 444 (NEMA)
Figure 2-1 6 & 8 Hole Motor Frame Mounting
Top View
Allows F-1 to F-2 Conversion on 8 hole
frames.
Not present on 6 hole frames.
Not used on 8 hole frames.
Shaft
For long frame designations 184,215,
256, 286, 326, 365, 405, 445 (NEMA)
(IEC) 112M, 132M, 160L, 200L, 225M,
250M, 280M
Caution:
Alignment
Caution:
Always use these holes, closer to the
shaft 112S, 132S, 160M, 180M,
200M, 225S, 250S, 280S, (IEC)
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is
adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other driven
equipment) from the motor shaft before lifting the motor.
In the case of assemblies on a common base, any lifting means provided on the motor should not be used
to lift the assembly and base but, rather, the assembly should be lifted by a sling around the base or by other
lifting means provided on the base. Assure lifting in the direction intended in the design of the lifting means.
Likewise, precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or
shock forces.
Accurate alignment of the motor with the driven equipment is extremely important. The pulley, sprocket,
or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible. It is
recommended to heat the pulley, sprocket, or gear before installing on the motor shaft. Forcibly driving a unit
on the motor shaft will damage the bearings.
1.	Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for more
information. Mechanical vibration and roughness during operation may indicate poor alignment. Use dial
indicators to check alignment. The space between coupling hubs should be maintained as recommended
by the coupling manufacturer.
2.	End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The standard
motor bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause
failure.
3.	Pulley Ratio
The best practice is to not exceed an 8:1 pulley ratio.
Do not over tension belts. Excess tension may damage the motor or driven equipment.
4.	Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt
tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage may
occur during starting.
Doweling & Bolting
After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation.
This will maintain the correct motor position should motor removal be required.
(Baldor*Reliance motors are designed for doweling.)
1.	Drill dowel holes in diagonally opposite motor feet in the locations provided.
2.	Drill corresponding holes in the foundation.
3.	Ream all holes.
4.	Install proper fitting dowels.
5.	Mounting bolts must be carefully tightened to prevent changes in alignment.
2-2 Installation & Operation
MN428
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Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure.
Flanged nuts or bolts may be used as an alternative to washers.
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key ways or
set screws. Some satisfactory methods of guarding are:
1.	Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2.	Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate guarding
during normal service.
Power Connection
Motor and control wiring, overload protection, disconnects, accessories and grounding should conform to the
National Electrical Code and local codes and practices.
For ExnA hazardous location motors, it is a specific condition of use that all terminations in a conduit box
be fully insulated. Fully insulated and lugged terminations must be bolted and provided with lock washer to
prevent rotation. Flying leads must be insulated with two full wraps of electrical grade insulating tape or heat
shrink tubing.
Grounding In the USA consult the National Electrical Code, Article 430 for information on grounding of motors and
generators, and Article 250 for general information on grounding. In making the ground connection, the
installer should make certain that there is a solid and permanent metallic connection between the ground point,
the motor or generator terminal housing, and the motor or generator frame. In non-USA locations consult the
appropriate national or local code applicable.
Motors with resilient cushion rings usually must be provided with a bonding conductor across the resilient
member. Some motors are supplied with the bonding conductor on the concealed side of the cushion ring to
protect the bond from damage. Motors with bonded cushion rings should usually be grounded at the time of
installation in accordance with the above recommendations for making ground connections. When motors
with bonded cushion rings are used in multimotor installations employing group fusing or group protection,
the bonding of the cushion ring should be checked to determine that it is adequate for the rating of the branch
circuit over current protective device being used.
There are applications where grounding the exterior parts of a motor or generator may result in greater hazard
by increasing the possibility of a person in the area simultaneously contacting ground and some other nearby
live electrical parts of other ungrounded electrical equipment. In portable equipment it is difficult to be sure that
a positive ground connection is maintained as the equipment is moved, and providing a grounding conductor
may lead to a false sense of security.
Select a motor starter and over current protection suitable for this motor and its application. Consult motor
starter application data as well as the National Electric Code and/or other applicable local codes.
For motors installed in compliance with IEC requirements, the following minimum cross sectional area of the
protective conductors should be used:
Crosssectional area of phase
conductors, S
Minimum crosssectional area of the
corresponding protective conductor, SD
mm2
mm2
S< 16
S
16 < S < 35
16
S> 35
0,5 S
Equipotential bonding connection shall made using a conductor with a cross-sectional area of at least 4 mm2.
Conduit Box For ease of making connections, an oversize conduit box is provided. Most conduit boxes can be rotated
360 ° in 90 ° increments. Auxiliary conduit boxes are provided on some motors for accessories such as space
heaters, RTD's etc.
WARNING:
Guarding
MN428
Installation & Operation 2-3
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AC Power Motors with flying lead construction must be properly terminated and insulated.
Connect the motor leads as shown on the connection diagram located on the name plate or inside the cover
on the conduit box. Be sure the following guidelines are met:
1.	AC power is within +10% of rated voltage with rated frequency. (See motor name plate for ratings).
OR
2.	AC power is within +5% of rated frequency with rated voltage.
OR
3.	A combined variation in voltage and frequency of +10% (sum of absolute values) of rated values, provided
the frequency variation does not exceed +5% of rated frequency.
Performance within these voltage and frequency variations are shown in Figure 2-3.
Figure 2-2 Accessory Connections
HEATERS
One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).
THERMISTORS
TD2
Three thermistors are installed in windings and tied in series.
Leads are labeled TD1 &TD2.
WINDING RTDS
RED ' RED 1 WHITE
Winding RTDs are installed in windings (2) per phase.
Each set of leads is labeled 1TD1,1TD2,1TD3,2TD1,2TD2,2TD3 etc.
BEARING RTD
RED 1 1 RED 1 WHITE
*	One bearing RTD is installed in Drive endplate (PUEP), leads
are labeled RTDDE.
*	One bearing RTD is installed in Opposite Drive endplate (FREP), leads
are labeled RTDODE.
*	Note RTD may have 2-Red/1-White leads; or 2-White/1-Red Lead.
Rotation
All three phase motors are reversible. To reverse the direction of rotation, disconnect and lock out power
and interchange any two of the three line leads for three phase motors. For single phase motors, check the
connection diagram to determine if the motor is reversible and follow the connection instructions for lead
numbers to be interchanged. Not all single phase motors are reversible.
Adjustable Frequency Power Inverters used to supply adjustable frequency power to induction motors produce
wave forms with lower order harmonics with voltage spikes superimposed. Turn-to-turn, phase-to-phase,
and ground insulation of stator windings are subject to the resulting dielectric stresses. Suitable precautions
should be taken in the design of these drive systems to minimize the magnitude of these voltage spikes.
Consult the drive instructions for maximum acceptable motor lead lengths, and proper grounding.
Note: Main power leads for CE Marked Motors may be marked U,V,W - for standard configurations,
please consult connection diagrams.
Caution:	The space heaters are designed to operate at or below the maximum surface temperature stated on the
nameplate. If the marked ambient and/or voltage are exceeded this maximum surface temperature can
be exceeded and can damage the motor windings. If applied in a division 2 or zone 2 environment this
excessive temperature may cause ignition of hazardous materials.
2-4 Installation & Operation
MN428
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Connection Diagrams
AC Motor Connection Diagram
IEC VERSUS NEMA LEAD MARKING
EXAMPLE COMPARISONS OF IEC AND NEMA LEADING MARKINGS FOR COMMON
CONNECTION TYPES ARE SHOWN BELOW.
SINGLE PHASE MOTORS
SINGLE VOLTAGE NON REVERSIBLE
U1(T1)
U2(T4)
DUAL VOLTAGE REVERSIBLE
U1(T1)
SINGLE VOLTAGE REVERSIBLE
U1(T1)
Z1CT8)
Z2(T5)
MAIN
WINDING
AUXILIARY
WINDING
U2(T4)
Z1(T8)
MAIN
WINDING
U2(T2)
U3(T3)
Z2(T5)
AUXILIARY
WINDING
U4(T4)
AC Motor Connection Diagram
DELTA-WYE CONNECT
U1(T1)
U2(T4)
W2CT6) V2CT5)
W1CT3)	V1(T2)
WYE-DELTA CONNECT
DUAL VOLTAGE-HIGH TO LOW VOLTAGE RATIO 1.73:1
W2CT6) U2(T4) V2CT5)
W2(T6) U2(T4) V2(T5)
p
p
p
U1
V1
W1
(T1) j.
I (T2) r
(T3)
U1
(T1)
V1	W1
(T2) (T3)
LINE 2 LINE 3
LOW VOLTS
LINE 1 LINE 2 LINE 3
HIGH VOLTS
WYE START-DELTA RUN
SINGLE VOLTAGE
W2fT6)
U1(T1)
W2CT6) U2CT4) V2CT5)
W2(T6) U2(T4) V2(T5)
W1(T3)
V2(T5)
U2(T4)
V1(T2)
p
p

U1
V1
W1
CTD s.
!> (T2) c
(T3)
LINE 2 LINE 3
RUN
U1
V1
W1
(T1)
Z
(T2)
Z
(T3)
Z
/
LINE 1
/
LINE 2
/
LINES

START

AC Motor Connection Diagram
THREE PHASE
FOR SINGLE WINDING 3 PHASE MOTORS, LEAD MARKINGS CAN BE DIRECTLY TRANSLATED
BETWEEN IEC AND NEMA DESIGNATIONS. FOR THESE MOTORS, THE LEAD MARKINGS ARE
EQUIVALENT AS FOLLOWS:
U1=T1	U2=T4
V1=T2 V2=T5
W1=T3 W2=T6
U5=T7
V5=T8
W5=T9
U6=T10
V6=T11
W6=T12
EXAMPLES OF COMMON CONNECTIONS ARE GIVEN BELOW.
THREE LEADS
WYE CONNECT
U1 (T1)
WIRING DIAGRAM
U1 (T1) V1(T2) W1(T3)
W1{T3)
V1 (T2)
DELTA CONNECT
U1(T1)
LINE 1 LINE 2
WIRING DIAGRAM
U1(T1) V1(T2) W1(T3)
LINE 1 LINE 2 LINE 3
W1(T3)
V1(T2)
AC Motor Connection Diagram
NINE LEADS
DUAL VOLTAGE-HIGH TO LOW VOLTAGE RATIO 2:1
WYE CONNECT
U2(T4)
U3(T7)
W3(T9)
v3(T8l
W2{T6)
V2{T5)
U2{T4) V2(T5) W2fT6)
WIRING DIAGRAM
U2(T4)
U3(T7) V3fT8) W3fT9)
W1
(T3)
UNE2 LINE 3
LOW VOLTS
V2(T5) W2fT6)
U3(T7)
V3(T8)
W3(T9)
U1
V1
W1
CTD


/
LINE 1
/
LINE 2
/
UNE3
DELTA CONNECT
U1(T1)
^U2(T4) ^V2{T5) ^W2(TB)
xW3CT9)
U3(T7)
LINE 1
WIRING DIAGRAM
U2(T4)
W1(T3) V3(T8) V2(T5) V1CT2)
UNE2 LINE 3
LOW VOLTS
V2(T5) W2(T6)
U3CT7)
V3(T8)
W3(T9)
U1
V1
W1
CT1)
(T2)
(T3)
/
LINE 1
/
LINE 2
/
UNE3
MN428
Installation & Operation 2-5
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Connection Diagrams Continued
AC Motor Connection Diagram
TWELVE LEADS
DUAL VOLTAGE WYE START - DELTA - RUN
HIGH VOLTS
U1(T1)
U3CT7)
U4(T10)
W4(T12),
U2(T4)
v V4(T11)
U4(T10) V4(T11) W4(T12)
U2
CT4)
V2
CT5)
W3(T9)
W2fT6) /
W1 (T3)
, V3(T0)
\V2(T5)
V1 (T2)
U3 I V3 I	W3
07) ° (T8)	(T9)
U1	V1	W1
7° (T1) ^ (T2) ^ (T3)
LINE 1 LINE 2
RUN
LINE 3
U4(T10) V4(T11) W4{T12)
O	0	o
U2CT4) V2(T5) W2CT6)
U3(T7)
V3(T8)
W3(T9)
U1
V1
W1
(T1)
Z
(T2)
Z
(T3)
z
/
LINE 1
/
LINE 2
/
LINE 3
W4(T12) , . U1(T1)
W3(T9)
W2(T6)
W1(T3)
U2(T4)
U3CT7)
U4(T10)
U4(T10) V4(T11)
W4(T12)
IU2(T4)
I V2(T5)
JW2(T6)
U3CT7)\
sV3fT8)\
W3CT9)
l U1
V1
W1
p (T1)
p 0"2)
i(T3)
V4 	V3 V2	V1
(T11)	(TB) (T5)	(T2)
LINE 2
RUN
U4(T10) V4(T11) W4(T12)
U2(T4) V2fT5) W2CT6)
U3(T7) V3CT8) W3fT9)
U1
(T1)
LINE 1 LINE 2 LINE 3
START

o
V1
W1
(T2)
(T3) J
AC Motor Connection Diagram
SINGLE WINDING
CONSTANT HP.
TWO WINDING
/•
N

(T6)2W (T4)2U (T5)ZV
(TB)2W (T4)2U fT5)2V

(T1)1U fT2)1V (T3)1W
ffri) f?T2) fCT3)

f f r
|*1U l*1V l*1W

L1 L2 L3
L1 L2 L3

I LOW SPEED
HIGHSPEED )

2U (T11) 2V (T12) 2W(T13)
2U fT11) 2V (T12) 2W(T13)
r"Vi) r^*n"2) r^cra)
iul^» ivl^iw
DC Motor Connection Diagram
(+)
WIRING DIAGRAM TYPE T MOTOR
4 POLES	, .	4INTERPOLES
(+)
A1(A1) A2(B2) S1(D1) S2(D2)	A1(A1) A2(B2) S1(D1) S2(D2)
COUNTERCLOCKWISE ROTATION	CLOCKWISE ROTATION
ROTATION - FACING COMMUTATOR END
COMPARISON OF IEC AND NEMA LEAD MARKINGS
FOR DIRECT CURRENT MOTORS
A1--A1
A2—B2
51--D1
52--D2
AC Motor Connection Diagram
SINGLE WINDING MULTI-SPEEDS CONSTANT TORQUE
(T4) 2U
2V (T5)
1W (T3)
-------
Figure 2-3 Typical Motor Performance VS Voltage Variations
a>
o
c
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10.	After 1 hour of operation, disconnect power and connect the load to the motor shaft.
Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.
11.	If motor is totally enclosed fan-cooled or non-ventilated it is recommended that condensation drain plugs,
if present, be removed. These are located in the lower portion of the end-shields. Totally enclosed fan-
cooled "XT" motors are normally equipped with automatic drains which may be left in place as received.
Coupled Start Up
This procedure assumes a coupled start up. Also, that the first time start up procedure was successful.
1.	Check the coupling and ensure that all guards and protective devices are installed.
2.	Check that the coupling is properly aligned and not binding.
3.	The first coupled start up should be with no load. Apply power and verify that the load is not transmitting
excessive vibration back to the motor though the coupling or the foundation.
Vibration should be at an acceptable level.
4.	Run for approximately 1 hour with the driven equipment in an unloaded condition.
The equipment can now be loaded and operated within specified limits. Do not exceed the name plate ratings
for amperes for steady continuous loads.
Jogging and Repeated Starts
Repeated starts and/or jogs of induction motors generally reduce the life of the motor winding insulation.
A much greater amount of heat is produced by each acceleration or jog than by the same motor under full
load. If it is necessary to repeatedly start or jog the motor, it is advisable to check the application with your
local Baldor distributor or Baldor Service Center.
Heating - Duty rating and maximum ambient temperature are stated on the motor name plate.
Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor
distributor or Baldor Service Center.
Hazardous Locations
Hazardous locations are those where there is a risk of ignition or explosion due to the presence of combustible
gases, vapors, dust, fibers or flyings.
Selection Facilities requiring special equipment for hazardous locations are typically classified in accordance with
local requirements. In the US market, guidance is provided by the National Electric Code. In international
hazardous location areas, guidance for gas / vapor / mist classification is given in IEC60079-14, or for dust in
IEC61241 —14. This classification process lets the installer know what equipment is suitable for installation in
that environment, and identifies what the maximum safe temperature or temperature class is required.
It is the customer or users responsibility to determine the area classification and select proper equipment.
Areas are classified with respect to risk and exposure to the hazard. In the US market, areas are typically
classified as follows Class, Division, Group and Temperature Class. In some newer installations in the US and
in most international markets, areas are classified in Zones.
Protection Concepts
Class I Division 1 / Zone 1 [Equipment Group I (mining) or II (surface), Equipment Protection Level (EPL)
Gb, Mb]
Baldor offers a range of motors suitable for installation in a Division 1 or Zone 1 environment.
These motors are known as explosion proof or flameproof.
Motors that are explosion proof or flameproof use specially machined flameproof joints between the end bell or
bracket and the frame, as well as along the rotating shaft and at connection box covers and entries.
The fit of these flameproof joints are designed to contain the combustion or quench the flame of an explosive
gas atmosphere prior to it exiting the motor. These flameproof joints have lengths and widths selected and
tested based on the gas group present in the atmosphere. Baldor*Reliance motors are typically designed to
meet Class I (Division 1) Group C and D (explosion proof) or Ex d MB (flameproof).
An application note regarding equipment applied in accordance with the US National Electric Code (NFPA
70-2008) - according to Article 500.8(C) Marking, sub clause (2) in the fine print note, it is noted that
Equipment not marked to indicate a division is suitable for both Division 1 and Division 2 locations.
These motors are not gas tight. To the contrary, this protection concept assumes that due to the normal
heating and cooling cycle of motor operation that any gas present will be drawn into the motor. Since
flameproof or explosion proof motors are designed to contain the combustion and extinguish any flame
transmission, for this protection concept, only external surface temperatures are of concern. Thermal limiting
devices such as thermostats, thermistors or RTDs may be provided on these motors to limit the external
surface temperature during overload conditions.
2-8 Installation & Operation
MN428
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If thermostats are provided as a condition of certification, it is the installer's responsibility to make sure that
these devices are properly connected to a suitable switching device. The ATEX directive requires that motor
shutdown on thermal trip be accomplished without an intermediate software command. Where intermediate
circuitry is involved the circuit shall fall within the scope of a safety, controlling and regulating device as defined
in article 1(2) of European Directive 94/9/EC, and shall be covered by an appropriate EC Type Examination
Certificate.
Flameproof motors, internationally referred to as Ex d use a protection concept similar to that used in Class
I Division 1 motors, with minor differences in the flameproof joints and cable entry designs. Flameproof and
explosion proof motors are both type tested. Representative motors are connected to a reference gas and
ignited in laboratory conditions to verify that the flame is not transmitted outside the motor enclosure and to
determine the maximum internal pressure encountered.
Explosion proof and Flame proof motors shipped without a conduit box require use of a certified box of
suitable dimensions and that is appropriate for the classification. Openings in connection boxes must be
closed with suitably certified and dimensioned device.
Class I Division 2 / Zone 2 Ex nA, [Equipment Protection Level (EPL) Gc ]
This protection concept relies on having no sources of ignition present such as arcing parts or hot surfaces.
For this protection concept, internal temperatures as well as external temperatures are considered. In many
cases, the internal temperatures are higher than the external temperatures and therefore become the limiting
factor in determination of temperature code designation. In these applications, it is very important to use a
motor that has been evaluated thermally for use with an inverter or converter, if variable speed operation is
desired. Thermostats used for Class I Division 2 and Ex nA motors are used to protect the motor only. For
motors using flying lead construction, it is important to use connection lugs and insulate with heat shrink
tubing or a double wrap of insulation grade electrical tape to avoid the risk of spark or ignition.
Class II Division 1 / Zone 21 [Equipment Group III, Equipment Protection Level (EPL) Db ]
This area classification is one where the risk of ignitable concentrations of dust is present at all or some of the
time. The protection concepts used for Class II Division 1 is similar to flamepath, except with additional dust
exclusion paths designed for the rotating shaft. In the international designations, this concept is referred to as
dust ignition proof or Ex tD. External surface temperature remains the limiting factor. Thermal limiting devices
such as thermostats, thermistors or RTDs may be provided on these motors to limit the external surface
temperature during overload conditions. If thermostats are provided as a condition of certification, it is the
installer's responsibility to make sure that these devices are properly connected to a suitable switching device.
Note: In the North American area classification system, Class III exists for fibers and flyings.
In the IEC designation, both dusts and flyings are absorbed into Group III.
Class II Division 2 / Zone 22 [Equipment Group III, Equipment Protection Level (EPL) Dc ]
This area classification is one where the risk of exposure to ignitable concentrations of dust are not likely
to occur under normal operating conditions and relies heavily on the housekeeping practices within the
installation.
Sine Wave Power Operation for Division 1 or 2 and Zone 1 or 2 and Zone 21 or 22 Hazardous Location.
These motors are designed to operate at or below the maximum surface temperature (or T-Code) stated
on the nameplate. Failure to operate the motor properly can cause this maximum surface temperature to
be exceeded. If applied in a Division 1 or 2 / Zone 1 or 2 and Zone 21 or 22 environment, this excessive
temperature may cause ignition of hazardous materials. Operating the motor at any of the following
conditions can cause the marked surface temperature to be exceeded.
1.	Motor load exceeding service factor nameplate value
2.	Ambient temperatures above nameplate value
3.	Voltages above or below nameplate value
4.	Unbalanced voltages
5.	Loss of proper ventilation
6.	Altitude above 3300 feet / 1000 meters
7.	Severe duty cycles of repeated starts
8.	Motor stall
9.	Motor reversing
10.	Single phase operation of polyphase equipment
11.	Variable frequency operation
MN428
Installation & Operation 2-9
-------
Variable Frequency Power Operation for Division 1 or 2 and Zone 1 or 2 and Zone 21 or 22
Hazardous Location (motors with maximum surface temperature listed on the nameplate).
Only motors with nameplates marked for use on inverter (variable frequency) power, and labeled for specific
hazardous areas may be used in those hazardous areas on inverter power. The motor is designed to operate
at or below the maximum surface temperature (or T-Code) stated on the nameplate.
Failure to operate the motor properly can cause this maximum surface temperature to be exceeded.
If applied in a Division 1 or 2 / Zone 1 or 2 and Zone 21 or 22 environment, this excessive temperature may
cause ignition of hazardous materials. Operating the motor at any of the following conditions can cause the
marked surface temperature to be exceeded.
1.	Motor load exceeding service factor nameplate value
2.	Ambient temperature above nameplate value
3.	Voltage (at each operating frequency) above or below rated nameplate value
4.	Unbalanced voltages
5.	Loss of proper ventilation
6.	Operation outside of the nameplate speed / frequency range
7.	Altitudes above 3300 feet / 1000 meters
8.	Single phase operation of polyphase equipment
9.	Unstable current wave forms
10.	Lower than name plate minimum carrier frequency
Thermal Limiting
Thermal limiting devices are temperature sensing control components installed inside the motor to limit
the internal temperature of the motor frame by interrupting the circuit of the holding coil of the magnetic
switch or contactor. They are required for most Division 1 and Zone 1 applications. For Division 2 or Zone
2 applications, motors should be selected that preclude running temperatures from exceeding the ignition
temperatures for the designated hazardous material. In Division 2 or Zone 2 classified locations, thermal
limiting devices should only be used for winding protection and not considered for limiting all internal motor
temperatures to specific ignition temperatures.
Equipotential Bonding and Shaft Current Reduction
Larger motors (ie WP construction) may require proper bonding between motor enclosures and covers to
avoid the risk of stray currents during start up. Fastening methods and bonding straps must not be modified.
Bearing currents can exist in some motors for both line-fed and inverter-fed applications. Larger line-fed
motors may require at least one insulated bearing to prevent a flow of current through the bearings. Do not
defeat such insulation whether the motor is line-fed or inverter-fed applications. Inverter-fed motors may
require additional bearing insulation or even a shaft brush. Do not defeat such features. When the motor and
the coupled load are not on a common conductive baseplate, it may also be necessary to electrically bond
together the stationary parts of the motor and the coupled equipment.
Repair of Motors used in Hazardous Locations
Repair of hazardous certified motors requires additional information, skill, and care. It is the customer's
responsibility to select service shops with proper qualifications to repair hazardous location motors. Contact
the manufacture for additional repair details. Use only original manufacturer's parts.
Repair of Explosion Proof or Flame Proof Motors Class I Division 1 and Zone 1
In the North American market, recertification programs are offered by Underwriters Laboratories and Canadian
Standards Association which allow authorized service shops to mark the rebuilt motors as certified. In the
international markets using IEC based requirements, repair should be undertaken only after consulting
IEC60079-19 Explosive Atmospheres-Part 19 Equipment repair, overhaul and reclamation. If use of a certified
repair facility is desired, consult the IECEX Repair Scheme at http://www.iecex.com/service_facilities.htm
Explosion proof and flameproof motors achieve their safety based on the mechanical construction -
flameproof joints and bearing clearance, and the electrical design including any thermal limiting devices. If it is
necessary to repair a flameproof or explosion proof motor, it is critical that the mechanical flameproof joints be
maintained. Consult Baldor Electric Company for flameproof joint construction details.
Use only Baldor*Reliance supplied parts. Baldor does not recommend reclamation of parts.
Since this protection method also relies on temperature being maintained, make sure that any rewinding uses
the original electrical designs, including any thermal protection that may be present.
2-10 Installation & Operation
MN428
-------
Repair of Dust Ignition Proof Motors - Class II Division 1 and 2, Zone 21 and 22.
For Dust Ignition Proof, proper sealing is required. Do not modify the motor construction to add any additional
opening, and ensure that proper sealing is maintained in the connection box and at the shaft seal. Since this
protection method also relies on temperature being maintained, make sure that any rewinding uses the original
electrical designs, including any thermal protection that may be present
Repair of Class I Division 2 and Zone 2 motors
For Division 2 and Zone 2, the internal and external temperatures are of concern. Since this protection method
also relies on temperature being maintained, make sure that any rewinding uses the original electrical designs,
including any thermal protection that may be present. Use only Baldor replacement thermostats, if provided.
MN428
Installation & Operation 2-11
-------
Section 3
Maintenance & Troubleshooting
WARNING: UL and EX Listed motors must only be serviced by UL or EX Approved Authorized Baldor Service
Centers if these motors are to be returned to a hazardous and/or explosive atmosphere.
General Inspection
Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3 months,
whichever occurs first. Keep the motor clean and the ventilation openings clear. The following steps should be
performed at each inspection:
WARNING: Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
1.	Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease,
water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor
is not properly ventilated, overheating can occur and cause early motor failure.
2.	Perform a dielectric with stand test periodically to ensure that the integrity of the winding insulation has
been maintained. Record the readings. Immediately investigate any significant decrease in insulation
resistance.
3.	Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings
Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability of a grease (over
time) depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates
and the severity of the operating conditions. Good results can be obtained if the following recommendations
are used in your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Baldor motors are pregreased, normally with
Polyrex EM (Exxon Mobil) or as stated on the nameplate.
Do not mix greases unless compatibility has been checked and verified.
Ball Bearing Motors
Operating Temperature -25 °C (-15 °F) to 50 °C (120 °F)
EXXON	POLYREX EM (Standard on Baldor motors)
EXXON	UNIREX N2
EXXON	BEACON 325
CHEVRON OIL	SRI NO. 2 (Compatible with Polyrex EM )
CHEVRON OIL	BLACK PEARL
TEXACO, INC.	PREMIUM RB
TEXACO, INC.	POLYSTAR
AMOCO	RYKON# 2
PENNZOIL	PENNZLUBE EM-2
DARMEX	DARMEX 707
DARMEX	DARMEX 711
PETRO-CANADA	PEERLESS LLG
SHELL OIL	DOLIUM BRB
Minimum Starting Temperature -60 °C (-76 °F)
SHELL OIL CO. AEROSHELL 7 (Standard on Baldor motors)
MOBIL	MOBIL 28
MOBIL	MOBILITH SHC 100 (Low Temperature - Arctic Duty)
Roller Bearing Motors
Operating Temperature -25 °C (-15 °F) to 50 °C (120 °F)
TEXACO, INC. PREMIUM RB
MOBIL	MOBILITH SHC 220 (Standard on Baldor motors)
CHEVRON OIL BLACK PEARL
MN408
Maintenance & Troubleshooting 3-1
-------
Relubrication Intervals
Recommended relubrication intervals are shown in Table 3-1. It is important to realize that the recommended
intervals of Table 3-2 are based on average use.
Refer to additional information contained in Tables 3-2, 3-3 and 3-4.
Table 3-1 Relubrication Intervals *
NEMA/
(IEC) Frame Size
Rated Speed - RPM
10000
6000
3600
1800
1200
900
Up to 210 incl. (132)
**
2700 Hrs.
5500 Hrs.
12000 Hrs.
18000 Hrs.
22000 Hrs.
Over 210 to 280 incl. (180)

**
3600 Hrs.
9500 Hrs.
15000 Hrs.
18000 Hrs.
Over 280 to 360 incl. (225)

**
* 2200 Hrs.
7400 Hrs.
12000 Hrs.
15000 Hrs.
Over 360 to 449 incl. (315)

**
*2200 Hrs.
3500 Hrs.
7400 Hrs.
10500 Hrs.
Relubrication intervals are for ball bearings.
For vertically mounted motors and roller bearings, divide the relubrication interval by 2.
For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication
recommendations.
Table 3-2 Service Conditions
Severity of Service
Hours per day of
Operation
Ambient Temperature
Maximum
Atmospheric Contamination
Standard
40 °C
Clean, Little Corrosion
Severe
16 Plus
50 °C
Moderate dirt, Corrosion
Extreme
16 Plus
>50 °C* or Class H Insulation
Severe dirt, Abrasive dust, Corrosion,
Heavy Shock or Vibration
Low Temperature
<-29 °C
special high temperature grease is recommended (Uow uorning L)U44j. Note that Uow uorning L)U44
grease does not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.
Special low temperature grease is recommended (Aeroshell 7).
Table 3-3 Relubrication Interval Multiplier
Severity of Service
Multiplier
Standard
1.0
Severe
0.5
Extreme
0.1
Low Temperature
1.0
Some motor designs use different bearings on each motor end. This is normally indicated on the motor
nameplate. In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication
results, only use the appropriate amount of grease for each bearing size (not the same for both).
3-2 Maintenances Troubleshooting
MN408
-------
Table 3-4 Bearings Sizes and Types
Frame Size
NEMA (IEC)
Bearing Description (These are the "Large" bearings (Shaft End) in each frame size)
Bearing
Weight of Grease to
add * oz (Grams)
Volume of grease to be added
in3
teaspoon
56 to 140 (90)
6203
0.08 (2.4)
0.15
0.5
140 (90)
6205
0.15 (3.9)
0.2
0.8
180 (100-112)
6206
0.19 (5.0)
0.3
1.0
210 (132)
6307
0.30 (8.4)
0.6
2.0
250 (160)
6309
0.47 (12.5)
0.7
2.5
280 (180)
6311
0.61 (17)
1.2
3.9
320 (200)
6312
0.76 (20.1)
1.2
4.0
360 (225)
6313
0.81 (23)
1.5
5.2
400 (250)
6316
1.25 (33)
2.0
6.6
440 (280)
6318
1.52(40)
2.5
8.2
440 (280)
6319
2.12 (60)
4.1
13.4
5000 to 5800(315-355)
6328
4.70 (130)
9.2
30.0
5000 to 5800(315-355)
NU328
4.70 (130)
9.2
30.0
360 to 449 (225-280)
NU319
2.12 (60)
4.1
13.4
AC Induction Servo
76 Frame 180 (112)
6207
0.22 (6.1)
0.44
1.4
77 Frame 210 (132)
6210
0.32 (9.0)
0.64
2.1
80 Frame 250(160)
6213
0.49 (14.0)
0.99
3.3
*	Weight in grams = .005 DB of grease to be added
Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the next larger
size bearing.
Caution:	To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty
environment, contact your Baldor distributor or an authorized Baldor Service Center for additional
information.
Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease
already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the
recommended type is to be used.
Caution:	Do not over-lubricate motor as this may cause premature bearing failure.
With Grease Outlet Plug
1.	With the motor stopped, clean all grease fittings with a clean cloth.
2.	Remove grease outlet plug.
Caution:	Over-lubricating can cause excessive bearing temperatures, premature lubrication breakdown and
bearing failure.
3.	Add the recommended amount of grease.
4.	Operate the motor for 15 minutes with grease plug removed. This allows excess grease to purge.
5.	Re-install grease outlet plug.
MN408
Maintenance & Troubleshooting 3-3
-------
Without Grease Provisions
Note: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL7CSA listed
explosion proof motor to maintain it's UL7CSA listing.
1.	Disassemble the motor.
2.	Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3 full of
grease and outboard bearing cavity should be about 1/2 full of grease.)
3.	Assemble the motor.
Sample Relubrication Determination
Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of 43 °C
and the atmosphere is moderately corrosive.
1.	Table 3-2 list 9500 hours for standard conditions.
2.	Table 3-3 classifies severity of service as "Severe".
3.	Table 3-5 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.
Shaker Duty Motors only
Caution:	Shaker Duty motors must be properly lubricated prior to Start Up to prevent damage. See Table 3-6.
Lubrication should be performed before Start Up and at regular maintenance intervals.
Follow these recommendations to ensure proper lubrication.
Recommended Lubricant
For ambient temperatures between -15 °F to 120 °F the following lubricants are recommended:
Mobil PolyrexEM, Texaco Premium RB, Exxon Unirex N-2.
Do not mix greases unless compatibility has been checked and verified.
Table 3-5 Lubrication Volume

Volume in Cubic Inches
NEMA Frame Size
Normal Duty
Severe Duty
Extreme Duty

Start Up
Relub
Start Up
Relub
Start Up
Relub
184TY
1.4
0.5
1.4
0.5
2.7
0.5
215TY
1.6
0.5
1.6
0.5
4.5
1
256TY
7
1


11
2
286TY
9
1


15
3
Lubrication Frequency
Normal Duty 8 hours per day (16 hours per day in a clean environment). Lubricate every 2 months.
Severe Duty 16 hours per day or more in a dirty environment (corrosive atmosphere, chemical fumes, acids,
alkalies or extreme high humidity). Lubricate every month or 700 hours of operation.
Extreme Duty operation in extremely dirty or dusty environments and high ambient temperatures exceeding
104 °F (40 °C). Lubricate twice a month or 350 hours of operation.
Lubrication Procedure
1.	Locate the grease inlet and outlet. Clean the areas.
2.	Remove the plug(s) and install a grease fitting in the inlet if grease fitting is not already installed.
3.	Add the recommended amount of lubricant.
4.	Run the motor for two hours with the outlet plug removed.
5.	Install outlet plug.
Note: To loosen hardened grease it may be necessary to insert a rod or wire into the grease inlet and outlet
holes.
3-4 Maintenances Troubleshooting
MN408
-------
Table 3-6 Troubleshooting Chart
Symptom
Possible Causes
Possible Solutions
Motor will not start
Usually caused by line trouble, such as,
single phasing at the starter.
Check source of power. Check overloads, fuses,
controls, etc.
Excessive humming
High Voltage.
Eccentric air gap.
Check input line connections.
Have motor serviced at local Baldor service center.
Motor Over Heating
Overload. Compare actual amps
(measured) with nameplate rating.
Locate and remove source of excessive friction in motor
or load.
Reduce load or replace with motor of greater capacity.
Single Phasing.
Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Improper ventilation.
Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build-up on motor. Clean motor.
Unbalanced voltage.
Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Rotor rubbing on stator.
Check air gap clearance and bearings.
Tighten "Thru Bolts".
Over voltage or under voltage.
Check input voltage at each phase to motor.
Open stator winding.
Check stator resistance at all three phases for balance.
Grounded winding.
Perform dielectric test and repair as required.
Improper connections.
Inspect all electrical connections for proper termination,
clearance, mechanical strength and electrical continuity.
Refer to motor lead connection diagram.
Bearing Over Heating
Misalignment.
Check and align motor and driven equipment.
Excessive belt tension.
Reduce belt tension to proper point for load.
Excessive end thrust.
Reduce the end thrust from driven machine.
Excessive grease in bearing.
Remove grease until cavity is approximately 3/4 filled.
Insufficient grease in bearing.
Add grease until cavity is approximately 3/4 filled.
Dirt in bearing.
Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Vibration
Misalignment.
Check and align motor and driven equipment.
Rubbing between rotating parts and
stationary parts.
Isolate and eliminate cause of rubbing.
Rotor out of balance.
Have rotor balance checked are repaired at your Baldor
Service Center.
Resonance.
Tune system or contact your Baldor Service Center for
assistance.
Noise
Foreign material in air gap or ventilation
openings.
Remove rotor and foreign material. Reinstall rotor. Check
insulation integrity. Clean ventilation openings.
Growling or whining
Bad bearing.
Replace bearing. Clean all grease from cavity and new
bearing. Repack with correct grease until cavity is
approximately 3/4 filled.
MN408
Maintenance & Troubleshooting 3-5
-------
Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY
Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B
(80 °C) temperature rise at rated load and are built with a Class H winding insulation system. Based on this
low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be used as a
starting point. Some motors with 1.0 service factor have Class F temperature rise.
The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding RTD
alarm and trip settings should be selected based on these tables unless otherwise specified for specific
applications.
If the driven load is found to operate well below the initial temperature settings under normal conditions, the
alarm and trip settings may be reduced so that an abnormal machine load will be identified.
The temperature limits are based on the installation of the winding RTDs imbedded in the winding as specified
by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball or roller bearings
or in direct contact with the sleeve bearing shell.
Table 3-7 Winding RTDs - Temperature Limit In °C (40 °C Maximum Ambient)
Motor Load
(Typical Design)
Class B Temp Rise
< 80 °C
Class F Temp Rise
< 105°C
Class H Temp Rise
< 125°C
Alarm
Trip
Alarm
Trip
Alarm
Trip
< Rated Load
130
140
155
165
175
185
Rated Load to1.15S.F.
140
150
160
165
180
185
Note: • Winding RTDs are factory production installed, not from Mod-Express.
When Class H temperatures are used, consider bearing temperatures and relubrication requirements.
Table 3-8 Bearing RTDs - Temperature Limit In oC (40 °C Maximum Ambient)
Bearing Type Oil or
Grease
Anti-Friction
Sleeve
Alarm
Trip
Alarm
Trip
Standard*
95
100
85
95
High Temperature**
110
115
105
110
Notes: * Bearing temperature limits are for standard design motors operating at Class B temperature rise.
** High temperature lubricants include some special synthetic oils and greases.
Greases that may be substituted that are compatible with Polyrex EM (but considered as "standard" lubricants
include the following:
-	Texaco Polystar	- Rykon Premium #2	- Chevron SRI #2
-	Mobilith SHC-100 - Pennzoil Pennzlube EM-2	- Chevron Black Pearl
-	Darmex 707	- Darmex 711	- Petro-Canada Peerless LLG
See the motor nameplate for replacement grease or oil recommendation.
Contact Baldor application engineering for special lubricants or further clarifications.
3-6 Maintenances Troubleshooting
MN408
-------
r" * 1?
"B\r ±.06
NAME PLATE
5.00
FULL DEPTH
f
+0,05
8.25 (254T) -q.qq
4,25 x.09
+0.05
10.00 (256T)—0.00
in ah 4- no
-.38 SQ X 2=88 KEY
HAFT RJNQER
0125 NPT
CONDUIT HOLE
CONDENSATE DRAIN
8.50 x.09


If
s

2.49

5.00
5.00
12.49
NOTE: 258T HAS 8 MTG. HOLES, USING
BOTH 254T AND 25ST "2F" LOCATIONS.
01 REDRAWN TO CURRENT CAD ST/
THIS ORAMNG M DESMN AND DETAL IS OUR PROPERTY ANO MUST NOT BE USED EXCEPT
M CONNECTION WITH OUR WORK ALL RIGHTS OF DESGN ANO MVENDCN ARE RESERVED
THIS IS AN ELECTROHCALLY GENERATED DOCUMENT - DO NOT SCALE THS PRINT
TOLERANCES UNLESS
OTHERWISE
DEC INCHES METRIC
±.1
±.03
±.78
±.006 j ±.127
±M05T±xnzf
FRACTIONS [±1/M
j.	.
drawn orz mm/m
APPR.
R.F.P.
SCALE
REF.
FMF
OUTLINE - 250 FRAME
TEFC - RIGID, NEW CON-BOX
REV. DRAWING NO.
-------
; ELECTRIC MOTORS, GEARMOTORS AND DRIVES
Product Features
Catalog No 6151355,22 Mode! C254T8FB5A A
Product type AC MOTOR Stock Stock
Description ..5HP..900.254T.TEFC.230/460V.3PH.60HZ.CONT.40C..RIGID	
Information shown is for current motor's design
Volts 208-230
F.L. Amps 15.9-14,4
S„ F Amps 16,2
Volts 460
F.L. Amps 7.2
S F Amps 8.1
Volts
F.L. Amps
S„ F Amps
RPIWI 900
HP 5
KW 3,7
Frame 254T
Max Amb 40
Insul Class F
Ef'f 100% 88,3
UL Y-(LEESGN UL REC)
CC Number CCQ05A
Load Type
Hertz 60
Duty CONTINUOUS
Serv. Factor 1.15
Design B
Protection NOT
Eft 75%
CSA Yes
CE Yes
Inverter Type
TYPE TF
Phase 3
Code J
Therm.Prot.
PF 70
Bearing OPE 6308
Bearing PE 6309
Speed Range NONE
Motor Wt. 188 LB
Nameplate 080307
Assembly
Cust Part No
Packaging B
Carton Labe!
Iris
Enclosure TEFC
Mounting RIGID
Shaft Dia.
Outline 16953860
Paint STANDARD
Lubrication POLYREX EM
Rotation REV
Ext. Diao, 004172.01
Ext. Diag2
Winding T12908001
GROUP: 3
Test Card
Form Factor
Torque
SB Code
Resistance
Connection
RMS Amps
Pea it
PeaitffDegC
Const Torque Speed
Range
Rework Status
Rework. TYPE

Hazardous Loc NONE
Explosion Proof
Class
Class
Temp Op Code
GROUP:
GROUP:
Brake Motors
FORCE
VDC
ADC
Braise Coil OHMs @25 C
-------

Torque UOII1
LB-IFT

Inertia (WK»)

3.307


Torque
30,5{IFuII Load)
100(Break Down)

63(Pull Up)
63.1 (Locked Rotor)

CURRENT (amps)
7.2(Full Load)
0(Break Down)

0(Pull Up)
45(Locked Rotor)

Efficiency (»/„)
OflFuII Load)
88,lC75°/o Load)

86,7(50o/o Load)
73,9(25* Load)

IPoweirlFactoir
(Full Load)

66,9C75°/o Load)

54,6(50o/o Load)
34.7(25% Load)
Load Curve Data @60
Hz, 460 Volts,
5 Hi




Load
A imps
KW
RPM
.lie
EIFIF
IPIF
Rise By Resiis Frame Rise
0,0
4,12
0,406
898
0,0
0,0
20,3
0,0
0,25
4,43
1.219
894
8,67
79,9
34,7
0,0
0,5
5.1
2,256
888
16,57
86,7
54,6
0,0
0,75
6,0
3.24
881
23.98
88.1
66,9
0,0
1.0
7.18
4,261
873
31,39
88,3
70,0
29.1
1.25
8,58
5,401
866
39,57
88.1
79,0
0,0
1.5
10.1
6,53
857
47,5
86,8
81.0
0,0
SOURCE: CALCULATED GROUP: 3
-------
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-------
SPECIFICATION
DO{
j lor 1 Pitch Single Strand Chain
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-------
Product Detail
(3020) SPK ROLLER TB
80BTB70
A taper bushed sprocket is a sprocket where a tapered bushing is bolted into
the taper bore that is machined in the sprocket. When installed this bushing is
compressed onto the shaft providing a tight grip. Taper bushed sprockets have
a tapered bushing bolted into a taper bore with hex head set screws instead of
bolts.
Material
Chain Number
Chain Pitch
Number of Chain Rows
Number of Teeth
Outside Diameter
Pitch Diameter
Single Strand Tooth Thickness
Hardened Teeth
Hub Configuration
Hub Outside Diameter
Steel
Hub Recessed For Chain
Clearance
80	; Bore Type
1.000 in.	' Bushing Part Number
1	; Bushing Min Bore Size
70	: Bushing Max Bore Size
22.867 in.	Individually Packaged
22.289 in.	\ Storage Dimension Length
0.575 in.	j Storage Dimension Width
No	¦ Storage Dimension Height
B	i Weight
5.250 in.
No
Bushed TB
3020
0.938 in.
3.000 in.
No
22.867 in.
22.867 in.
2.000 in.
52.35 lbs.
-------
TAPER-LOCK® Bushings
These instructions must be read thoroughly before installation or operation.
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out
or tag power source before proceeding. Failure to observe these precautions could
result in bodily injury.
INSTALLATION:
1006 to 3030 3535 to 6050 3535 to 6050 120100
O Insert Screws to Install • Insert Screws to Remove
1.	Clean shaft, bore of bushing, outside of bushing and hub bore of all oil, paint and
dirt. File away burrs.
2.	Insert bushing into hub. Match the hole pattern, not threaded holes (each
complete hole will be threaded on one side only).
3.	"LIGHTLY" oil setscrews and thread into those half-threaded holes indicated by O
on above diagram.
CAUTION: Do not lubricate the bushing taper, bushing bore, hub taper or the
shaft. Doing so could result in breakage of the product.
4.	Position assembly onto shaft allowing for the small axial movement which will
occur during lightening procedure.
5.	Alternately torque setscrews to recommended torque setting in chart below.
CAUTION: Do not use worn hex key wrenches. Doing so may result in a loose
assembly or may damage screws.
6.	To increase gripping force, lightly hammer face of bushing using drift or sleeve. (Do
not hit bushing directly with hammer.)
7.	Re-torque screws after hammering.
CAUTION: Where bushing is used with lubricated products such as chain,
gear or grid couplings be sure to seal all pathways (where lubrication could
leak) with RTV or similar material.
8.	Recheck screw torques after initial run-in, and periodically thereafter. Repeat steps
5, 6 and 7 if loose.
WARNING: Because of the possible danger to person(s) or property from accidents which may result
from the improper use of products, it is important that correct procedures be followed: Products must
be used in accordance with the engineering information specified in the catalog. Proper installation,
maintenance and operation procedures must be observed. The instructions in the instruction manuals
must be followed. Inspections should be made as necessary to assure safe operation under prevailing
conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as
may be specified in safety codes should be provided, and are neither provided by Baldor Electric nor
are the responsibility of Baldor Electric. This unit and its associated equipment must be installed,
adjusted and maintained by qualified personnel who are familiar with the construction and operation
of all equipment in the system and the potential hazards involved. When risk to persons or property
may be involved, a holding device must be an integral part of the driven equipment beyond the speed
reducer output shaft.
DO0
-------
TO REMOVE:
1.	Remove all screws.
2.	Insert screws in holes indicated by • on drawing. Loosen bushing by alternately
tightening screws.
NOTE: If two bushings are used on the same component and shaft, fully tighten
one bushing before working on another. When installing bushing in sintered steel
product (sheave,coupling, etc.) follow torque recommendation shown on product
hub if present.
Recommended Installation Wrench Torque
Bushing No.
Lb.-In.
Nm
1008
55
6,2
1108
55
6,2
1210
175
19,9
1215
175
19,9
1310
175
19,9
1610
175
19,9
1615
175
19,9
2012
280
31,8
2517
430
48,8
2525
430
48,8
3020
800
90,8
3030
800
90,8
3525
1000
114
3535
1000
114
4030
1700
193
4040
1700
193
4535
2450
278
4545
2450
278
5040
3100
352
5050
3100
352
6050
7820
888
7060
7820
888
8065
7820
888
10085
13700
1556
12010
13700
1556
NOTE: When using TAPER-LOCK bushings with conveyor pulleys, refer to the
DODGE Instruction Manual for TAPER-LOCK, H.E., and QD Conveyor Pulley
Bushings.
World Headquarters
RO. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1)479.646.4711, Fax (1)479.648.5792, International Fax (1)479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1)864.281.2433
www.baldor.com
© Baldor Electric Company	All Rights Reserved. Printed in USA.
MN4044 (Replaces 499737)	2/11 TCP 25,000
-------
Thermocouple Probes with
Connection Head
Overview
THMJ & K - CXX-01 & 04	• All temperature sensors are pre-built stock items
•	Probe
-	Type j or K thermocouple elements to meet many
temperature sensing applications
-1h" diameter, 316 SS or Inconel Alloy 600 sealed
sheath to protect against harsh environments
-	Magnesium Oxide (MgO) insulation provides
vibration dampening and protection against
thermal shock
-	Bendableto adapt to installation requirements
-	6", 12" or 18" proble length
•	Connection Head
-	Cast aluminum NEMA tX, IP66 screw cover head with
captive gasket
• One turn cover removal & installation eliminates
cross threading and saves time
-	3/4" NPT conduit opening with internal stop to
prevent overtightening and installation damage
-	Gripping ribs on cover edge
-	Stainless steel cover chain
•	Wiring
-	Ceramicterminal base
-	Brass terminals with stainless steel screws eliminate
the need to wrap connections around screws
-	Elevated terminal block for easy wire
termination
•	Made in the USA
THMJ & K - CXX-02
THMJ & K - CXX-02 use
ProSense Compression
Fittings for Mounting
Thermocouple Probes with Connnection Head Types J and K
Part Number
Pcs/Pkg
Wt(lb)
Price
Type
Probe Diameter
(O.D.j
Probe Length
Probe Material
Temperature
Sensing Range
Mounting
THMJ-C06-01


<—>
J

6"

0 to 720°G
(32 to 1330°F)

THMJ-C12-01


<—>
J

12"


THMJ-C18-01


<—>
J

18"

Integral 1/2" x 1/2" NPT
THMK-C06-01


<—>
K

a*

0 to 927°G
(32 to 1700°F)
Hex Nipple, 316SS
THMK-C12-01


<—>
K

12


THMK-C18-01


<—>
K

18"
316 stainless steel

THMJ-C06-02


<—>
J

6"
0 to 720°C
(32 to 1330°F)

THMJ-C12-02
1
1.3
<—>
J
1/4"
12"

ProSense compression
fitting (see accessories -
purchased separately)
THMJ-C18-02


<—>
J

18"

THMK-C06-02


<—>
K

6"

0 to 927°C
(32 to 1700" F)
THMK-C12-02


<—>
K

12"

THMK-C18-02


<—>
K

18"


THMK-C06-04


<—>
K

6"







0 to 1149°C
(32 to 2100°F)
Integral 1/2" x 1/2" NPT
Hex NiDDle, 31SSS
THMK-C12-04


<—>
K

12"
Inconel Alloy 600
THMK-C18-04


<—>
K

18"



Note: Check the chemical compatibility of the sensor's wetted parts with the medium to be measured.
Not designed for use in a thermowelL Use spring-loaded probe when installing in a thermowell.	
-------
Thermocouple and RTD
Temperature Range
Thermocouple Temperature Range
THMK-C06-04

THMK-C12-04
THMK-C18-04
32 to 2100°F (0 to 1149°C)
THMK-H06L01-03

THMK-H12L01-03
THMK-H18L01-03
THMK-T06L06-03
32 to 2100°F (0 to 1149°C)
lead wire transition rated to
204°C (400°F)
THMK-T12L06-03
THMK-T18L06-03
TTD25C-20-0300F-H
0 to 300°F (-17.8 to 148.9°C)
TTD25N-20-0300F-H
THMJ-A01L04-01
32 to 900°F (0 to 482°C)
THMJ-A01L06-01
THMJ-AOILIO-OI
THMJ-A01L10-02
THMJ-B01L06-01
THMJ-B01L06-02
THMJ-B02L06-01
THMJ-B02L06-02
THMJ-D08L04-01
THMJ-D08L06-01
THMJ-D08L10-01
THMJ-D08L10-02
THMK-A01L04-01
THMK-A01L06-01
THMK-A01L10-01
THMK-A01L10-02
THMK-B01L06-01
THMK-B01L06-02
THMK-D08L04-01
THMK-D08L06-01
THMK-D08L10-01
THMK-D08L10-02
THMJ-T06L06-01
32 to 970°F (Oto 521''CI lead
wire transition rated to 400 °F
(204 °C)
THMJ-T12L06-01
THMJ-T18L06-01
THMJ-P06-01
32 to 970°F (0 to 521 °C), plug
rated to 400 °F (204 C)
THMJ-P12-01
THMJ-P18-01
THMJ-C04-03
32 to 1330°F (0 to 720°C)
THMJ-C04R-03
THMJ-C06-01
THMJ-C06-02
THMJ-C06-03
THMJ-C06R-03
THMJ-C12-01
THMJ-C12-02
THMJ-C12-03
THMJ-C12R-03
THMJ-C18-01
THMJ-C18-02
Thermocouple Temperature Range
THMJ- T06L 06-02
32 to 1330°F (0 to 720°C)
lead wire transition rated to
400 °F (204 °C)
THMJ-T12L06-02
THMJ-T18L06-02
THMJ-P06-02
32 to 1330°F (0 to 720°C)
plug rated to 400 °F (204 °C)
THMJ-P12-02
THMJ-P18-02
THMK-C04-03
32 to 1700°F (0 to 927°C)
THMK-C04R-03
THMK-C06-01
THMK-C06-02
THMK-C06-03
THMK-C06R-03
THMK-C12-01
THMK-C12-02
THMK-C12-03
THMK-C12R-03
THMK-C18-01
THMK-C18-02
THMK-H04L01-02
THMK-H06L01-01
THMK-H06L01-02
THMK-H12L01-01
THMK-H12L01-02
THMK-H18L01-01
THMK-T06L06-01
32 to 1700°F (0 to 927°C)
lead wire transition rated to
400 °F (204 °C)
THMK-T06L06-02
THMK-T12L06-01
THMK-T12L06-02
THMK-T18L06-01
THMK-T18L06-02
THMK-P06-01
32 to 1700°F (0 to 927°C)
plug rated to 400 °F (204 °C)
THMK-P06-02
THMK-P12-01
THMK-P12-02
THMK-P18-01
THMK-P18-02
THMK-B02L06-01
32° to 900°F (0° to 482°C)
THMK-B02L06-02
THMT-P06-01
-328 to 700°F (-200 to
371 °C) plug ratecf to 400 °F
(204 °C)
THMT-P12-01
THMT-P18-01
THMT-T06L06-01
-328 to 700°F (-200 to
371 °C), lead wire transition
rated to 400 °F (204 °C)
THMT-T12L06-01
THMT-T18L06-01
TTD25C-20-0100C-H
32 to 212°F (Oto 100°C)
TTD25N-20-0100C-H
TSD25N-0P-0284-H
-4 to 284°F (-20 to 140°C)
TSD25N-AP-0284-H
RTD Temperature Range
RTD1-R01-01
40 to 185°F (-40 to 85°C)
RTD1-S04-01
-58 to 572°F (-50 to 300°C)
RTD1-S04-02
RTD1-S04-03
RTD1-S04-04
RTD1-B01L06-01
RTD1-B02L06-01
RTD1-C04-03
RTD1-C04R-03
RTD1-C06-01
RTD1-C06-03
RTD1-C06R-03
RTD1-C12-01
RTD1-C12-02
RTD1-C12-03
RTD1-C12R-03
RTD1-C18-01
RTD1-C18-02
RTD1-H04L01-02
RTD1-H06L01-01
RTD1-H06L01-02
RTD1-H12L01-01
RTD1-H12L01-02
RTD1-H18L01-01
RTD1-P06-01
-58 to 572°F (-50 to 300°C)
Plug rated to 400°F (204°C)
RTD1-P12-01
RTD1-P18-01
RTD1-D08L10-01
-58 to 572°F (-50 to 300°C),
lead wire transition rated to
400°F (204°C)
RTD1-T06L06-01
RTD1-T12L06-01
RTD1-T18L06-01
J, K, & T Thermocouple Color Code
J
White
+

Red
-
K
Yellow
+
Red
-
T
Blue
+
1
Red
-
THMJ-H04L01-02
THMJ-H06L01-01
THMJ-H06L01-02
THMJ-H12L01-01
THMJ-H12L01-02
THMJ-H18L01-01
-------
Super Pack Seal
&

5?
%-
fS-
E B

With Super Pack Sea!
u
A
Pari

L
E
H Bolts
Weight
Shaft
Number

(-B)
(-R)
(-B)
(-R)









-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
Section 4
Inlet Screw
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
INLET SCREW
Item
Qty
Part Numbers/ Description
Chain
—7ft.
100 Single Riveted Roller Chain
Motors
3
(l)Baldor VWDM3546 (1) Baldor VM3546
(1) Baldor CWDM3615T
Gearboxes
3
(1) Conedrive 20:1 Ratio (2) 90 Degree
Gearboxes
Sprockets
2
fl} Dodge 100637 (T)Martin 100BT353020
Bushings
1
Dodge F4B-L10-200, 033213
Coupling &
Spider
set
(2) L-100 1-1/8" Bore Coupling (1) Spider L-
100
Limit Switches
4
Square D 9007C54J
1813 Frank Holt Drive Burlington NC 27215 336-226-1100
rendeq.com
-------
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-------
Instruction Manual
DODGE® SOLIDLUBE Bearings
700, 1000 and 800 Series
These instructions must be read thoroughly before installation or operation.
INSTALLATION and OPERATION:
Solid Film Lubrication:
Solid film lubricating bearing material will
transfer a film or coating of lubricant to
the shaft as the shaft rotates. This film or
coating prevents metal to metal contact
between the shaft and bearing material, as
the shaft actually rides upon the lubricant
and not upon the bearing itself. Because it
is a solid, the lubricant will not squeeze out
when the shaft is not rotating, The bearing
will not need additional lubrication since
the solid lubricant is impregnated into
the bushing material and is transferred
or "worn" onto the rotating shaft at a rate
determined by the rubbing speed of one
material to the other and the imposed
load. Since this is a "wear type" bushing,
wear will be experienced under normal
operating conditions.
NOTE; SOLIDLUBE bearings are
not designed for rotating housing
applications.
WARNING: Because of the possible
danger to person(s) or property from
accidents which may result from the
improper use of products, it is important
that correct procedures be followed:
Products must be used inaccordance with
the engineering information specified
in the catalog. Proper installation,
maintenance and operation procedures
must be observed. The instructions in the
instruction manuals must be followed.
Inspections should be made as necessary
to assure safe operation under prevailing
conditions. Proper guards and other
suitable safety devices or procedures as
may be desirable or as may be specified
in safety codes should be provided, and
are neither provided by Baldor Electric
Company nor are the responsibility
of Baldor Electric Company. This unit
and its associated equipment must be
installed, adjusted and maintained by
qualified personnel who are familiar
with the construction and operation
of all equipment in the system and the
potential hazards involved. When risk to
persons or property may be involved, a
fail safe device must be an integral part of
the driven equipment beyond the speed
reducer output shaft.	1
Installation:
Shaft preparation: The bearing journal
should not be exposed to grease, oils or
dirt to insure good life of the bearing. NO
OIL OR GREASE SHOULD BE USED
ON THE BUSHING OR SHAFT WHEN
ASSEMBLING THIS BEARING. The
shaft should be clean and free of burrs
and nicks. The shaft should be held to
a minimum amount of taper and as little
eccentricity as possible so a uniformly
distributed rubbing surface can be
maintained. For best results, the shaft
finish should be held to 10 to 20 micro-
inches (0.25 to 0.50 micro-meters) and
hardness should be 35 Rockwell "C" or
higher. Shaft tolerance should be +0.000/-
0.002.inches	(+0.000/-0.051 millimeters)
for commercial steel shafting,
NOTE: The SOLIDLUBE bearing has a
high coefficient of friction which can
result in stalling when many bearings
run off the same drive system. Please
contact Baldor Electric Company for
further information.
Installation of LT, LTB and LM
Pillow Block Assembly:
NOTE: The 1000 Series bushings may
have a white film in the bore which
should be wiped off with a clean cloth
before assembly.
1.	Slide the assembled pillow block on
the shaft,
2.	Align the pillow block on the shaft
and tighten the hold-down bolts. Shim
the pillow block base, if necessary.
NOTE: Inner unit assemblies are
installed properly at the factory. For
added service, the bearing inner unit
may be rotated 180° while on the shaft
to utilize a new bearing surface.
CAUTION: Units should not be rotated
180° with the stop-pin in place as this
may restrict self-aligning capabilities.
HALDOL • DG<3)GE"
-------
Installation of MM Pillow Block
Assemblies:
1.	Loosen the cap bolts being careful not
to lose housing shims.
2.	Slide the assembled pillow block on
the shaft and position for mounting.
3.	Insert hold-down bolts but do not
tighten.
4.	Align the bearing with the shaft using
shims when necessary and tighten
hold-down bolts.
5.	Rotate shaft to allow the inner unit to
align itself in the outer housing and
tighten the bearing cap bolts.
NOTE: Inner unit assemblies are
installed properly at the factory. For
added service, the bearing inner unit
may be rotated 180° while on the shaft
to utilize a new bearing surface.
CAUTION: Units should not be rotated
180° with the stop-pin in place as this
may restrict self-aligning capabilities.
Thrust Loads:
Shaft locating collars may be used for
slight amounts of thrust loads only. Total
collar to bearing clearance should be .010
to .020 inches or .005 to .010 inches per
collar.
Running In:
To improve life expectancy from this type
of bearing, a brief run-in or break-in can be
performed. This may not be possible, but
to obtain optimal service, it is advisable to
break in this type of bearing. The break-
in should be run with a bearing mounted
on its mating shaft, as in service, with all
possible loading removed. The break-
in period will build up the solid film of
lubricant on the shaft to reduce potential
start-up damage to the bushing.
Shaft Corrosion:
When commercial steel shafting is
exposed to corrosive media, the shaft will
oxidize, (rust), pit, etc. The SOLIDLUBE
bushing is chemically inert but a rusty
shaft will grow into the SOLIDLUBE
bushing, thus eliminating clearances and
restricting movement. Corrective action
is to use corrosive resistant shafting
such as stainless steel and/or to provide
for regularly scheduled movement of the
shaft.
Special Operating Conditions:
Consult Baldor Electric Company, Dodge
Engineering, Greenville, SC for application
assistance, acid, chemical, extreme or
other special conditions.
*3049-07 12*
A MEMBER OF THE ABB GROUP
RO. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1)479.646.4711, Fax (1)479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company	All Rights Reserved. Printed in USA.
MN3049 (Replaces 499954 & 499964)	07/12 TCP 25,000
-------
Instruction
Bulletin
Boletin de
instrucciones
Directives
d'utilisation

65013-309-03
Rev. 01, 12/2012
Limit Switches—Class 9007 Type C Replaces /Reemplaza/Remplace 65013-309-03 08/2001
Interruptores de Ifmite—clase 9007 tipo C	^p.i
Interrupteurs de position—classe 9007 type C	®v!M *"
Retain for future use. / Conservar para uso futuro. / A conserver pour usage ulterieur.
C€
~ DANGER/PELIGRO/DANGER
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
Turn off all power supplying this
equipment before working on it.
Failure to follow these
instructions will result in death
or serious injury.
PELIGRO DE DESCARGA ELECTRICA,
EXPLOSION O ARCO ELECTRICO
Desenergice el equipo antes de realizar
cualquier trabajo en el.
Si no se siguen estas instrucciones
provocara lesiones graves o incluso la
muerte.
RISQUE D'ELECTROCUTION,
D'EXPLOSION OU D'ARC ELECTRIQUE
Coupez I'alimentation de cet appareil
avant d'y travailler.
Le non-respect de ces instructions
provoquera la mort ou des blessures
graves.
Head / Cabeza / T§te
Switch Top /
Parte superior
del interruptor /
Dessus de I'interrupteur
Base
Receptacle /
Recepteculo de la base /
Prise de la base
Figure /Figura/ Figure 1


Guide/Gufa/
Guide
Figure / Figura / Figure 2
Access Hole/
Agujero de acceso/
Trou d'acc£s
Roller Plunger/
Pulsador con
roldana/
Poussoir &
Plunger Guide/ galet
Gufa del pulsador/
Guide de poussoir
Figure / Figura / Figure 3
Grip Springs with Pliers Here /
Agarre los resortes con ^
unas pinzas aquf/	,
Saisir les ressorts	fp
avec la pince ici	Lbf
Wrench Flats / •
Partes planas
para Have /
Parties plates
pour cl6
Figure / Figura / Figure 4
For complete application data, see
product data bulletin SM444R1.
Para obtener los datos de aplicacion
completos, consulte el boletin de
datos del producto no. SM444R1.
Pour des donnees completes
d'application, voir la fiche technique
n° SM444R1.
CONVERSION OF HEADS
Head Rotation—All Types
All heads can be rotated to one of
four positions, 90° apart. See
Figure 1.
1.	Loosen the four head mounting
screws.
2.	Rotate the head to the desired
position and tighten the screws.
Mode of Operation—
Lever Types A, B, and N
The mode of operation converts
easily to clockwise (CW),
counterclockwise (CCW), or both
(CW/CCW). See Figure 2.
1.	Loosen the four head mounting
screws and remove the head.
2.	Pull up on the guide and position
it so that the arrow points to the
desired letters: CW, CCW, or
CW/CCW.
CONVERSION DE LAS CABEZAS
Giro de la cabeza—todos los tipos
Todas las cabezas se pueden girar a una
de las cuatro posiciones, 90° separadas.
Vea la figura 1.
1.	Afloje los cuatro tornillos de montaje de
la cabeza.
2.	Gire la cabeza a la posicion deseada y
apriete los tornillos.
Modo de funcionamiento—
palanca tipos A, B y N
El modo de funcionamiento se puede
convertir facilmente en el sentido de las
manecillas del reloj (CW) o en sentido
contrario a las manecillas del reloj (CCW),
o ambos (CW/CCW). Vea la figura 2
1.	Afloje los cuatro tornillos de montaje de
la cabeza y retire esta ultima.
2.	Jale la guia hacia arriba y coloquela de
tal manera que la flecha senale las
letras deseadas: CW, CCW o CW/CCW.
CONVERSION DES TETES
Rotation des tetes—Tous les types
Toutes les tetes peuvent etre tournees a
I'une des quatre positions a 90 0 d'intervalle.
Voir la figure 1.
1.	Desserrer les quatre vis de montage de
la tete.
2.	Faire tourner la tete a la position desiree
et serrer les vis.
Mode de fonctionnement—
levier de types A, B et N
Le mode de fonctionnement peut facilement
etre converti en mode sens horaire (CW),
anti-horaire (CCW) ou aux deux
(CW/CCW). Voir la figure 2.
1.	Desserrer les quatre vis de montage de
la tete et enlever la tete.
2.	Tirersurle guide etle placerde sorte que
la fleche soit orientee vers les lettres
desirees : CW, CCW ou CW/CCW.
SQUARE ~
by Schneider Elect i
-------
Limit Switches—Class 9007 Type C
Interruptores de Ifmite—clase 9007 tipo C
Interrupteurs de position—classe 9007 type C
65013-309-03
Rev. 01, 12/2012
3.	Push the guide back down into
the slots.
4.	Reassemble the head in the
desired position.
NOTE: CWor CCW refers to the
operation.
Side Plunger Roller Operation—
Type F
The switch comes with the roller in
the vertical position. It can be
rotated 90° to a horizontal position.
See Figure 3.
1.	Loosen the four head mounting
screws and remove the head.
2.	Depress and hold in the roller
plunger.
3.	Insert the blade of a flat-head
screwdriver through the access
hole in the plunger guide to hold
the white nylon cam inside the
head. Pull out the roller plunger.
4.	Rotate the roller plunger 90° and
remove the screwdriver blade.
5.	Make sure the guide pin in the
plunger is seated in the slot of the
nylon cam and reassemble the
head in the desired position.
INSTALLATION
1.	When assembling or replacing
the switch top assembly
(Figure 1), be sure that the
gasket surface is clean and in
position. Tighten the switch's top
fastening screws to 20-30 Ib-in
(2.26-3.39 N*m), to ensure
proper sealing and electrical
integrity.
2.	When assembling or replacing
heads (Figure 1), always tighten
the head fastening screws to 20-
30 Ib-in (2.26-3.39 N*m), to
ensure proper operation and
adequate sealing.
3.	When connecting the conduit to
the base receptacle (Figure 1),
use tight fittings and apply a
sealing compound to the threads
for best sealing.
NOTE: On devices with
maintained contact heads, the
wiring diagram on the nameplate
and the base casting reflects the
contact status when the shaft is
in the CCW position (Type C
heads) or Reset position (Type H
heads).
3.	Empuje la guia en las ranuras.
4.	Vuelva a ensamblar la cabeza en la
posicion deseada.
NOTA: CW o CCW se refieren
al funcionamiento.
Funcionamiento del pulsador con
roldana lateral—tipo F
El interruptor esta provisto con una roldana
en posicion vertical. La roldana se puede
girar 90° en la posicion horizontal. Vea la
figura 3.
1.	Afloje los cuatro tornillos de montaje de
la cabeza y retire esta ultima.
2.	Baje el pulsador con roldana y
sostengalo en esa posicion.
3.	Inserte la punta plana de un desarmador
por el agujero de acceso en la guia del
pulsador para sostener la leva de nylon
bianco dentro de la cabeza y jale el
pulsador con roldana hacia afuera.
4.	Gire el pulsador con roldana 90° y retire
la punta del desarmador.
5.	Asegurese de que la espiga de la guia en
el pulsador este biencolocadaen laranura
de la leva de nylon y vuelva a ensamblar la
cabeza en la posicion deseada.
INSTALACION
1.	Cuando instale o reemplace el ensamble
de la parte superior del interruptor
(figura 1), asegurese de que este limpia la
superficie del empaque y que se
encuentre en su posicion. Apriete los
tornillos de sujecion de la parte superior
del interruptor en 2.26-3.39 N*m (20-30
Ibs-pulg), para asegurar un cierre
hermetico adecuado y la integridad
electrica.
2.	Cuando instale o reemplace las cabezas
(figura 1), siempre apriete los tornillos de
sujecion de la cabeza en 2.26-3.39 N*m
(20-30 Ibs-pulg), para asegurar un
funcionamiento correcto y el cierre
hermetico adecuado.
3.	Cuando realice las conexiones del tubo
conduit en el receptaculo de la base
(figura 1), apriete los adaptadores y
aplique un compuesto de cierre
hermetico a las roscas para obtener
mejores cierres.
NOTA: En los dispositivos con cabezas
de contacto sostenido, el diagrama de
cableado en la placa de identification y la
pieza fundida de la base reflejan el
estado del contacto cuando el eje se
encuentra en la posicion CCW (cabezas
tipo C) o en la posicion de
restablecimiento (cabezas tipo H).
3.	Enfoncer le guide dans les fentes.
4.	Reassembler la tete dans la position
desiree.
REMARQUE: CWou CCWse referent
au fonctionnement.
Fonctionnement du poussoir a galet
lateral—type F
L'interrupteur est fourni avec le galet en
position verticale. Le galet peut etre tourne
de 90 0 a la position horizontale. Voir la
figure 3.
1.	Desserrer les quatre vis de montage de
la tete et enlever la tete.
2.	Appuyer sur le poussoir a galet et le
maintenir enfonce.
3.	Introduire la lame d'un tournevis plat
dans le trou d'acces du guide de
poussoir pour retenir la came de nylon
blanc a I'interieur de la tete et faire sortir
le poussoir a galet en le tirant.
4.	Faire tourner le poussoir a galet de 90 0
et enlever la lame du tournevis.
5.	S'assurer que la goupille de guide du
poussoir est installee dans la fente de la
came de nylon et reassembler la tete
dans la position desiree.
INSTALLATION
1.	Lors de I'assemblage ou du
remplacement de I'ensemble de dessus
de l'interrupteur (figure 1), s'assurer
que la surface du joint est propre et
dans la bonne position. Serrer les vis
d'attache du dessus de l'interrupteur a
un couple entre 2.26 et 3.39 N*m (20 et
30 Ibs-po), pour assurer la bonne
etancheite et I'integrite electrique.
2.	Lors de I'assemblage ou du
remplacement des tetes (figure 1),
toujours serrer les vis d'attache de la
tete a un couple entre 2.26 et 3.39 N*m
(20 et 30 Ibs-po), pour assurer le bon
fonctionnement et la bonne etancheite.
3.	Lors de Installation du conduit de la
prise de base (figure 1), bien serrer les
adaptateurs et utiliser un produit
d'etancheite sur les filetages pour
assurer une meilleure etancheite.
REMARQUE : Sur les appareils avec
des tetes a contact maintenu, le
schema de cablage sur la plaque
signaletique et le moulage de base
indique I'etat du contact lorsque I'arbre
est dans la position anti-horaire (tetes
de type C) ou dans la position de
reinitialisation (tetes de type H).
) 1992-2012 Schneider Electric All Rights Reserved / Reservados todos los derechos / Tous droits reserves
-------
CAM Design Data / Datos de diserio de la leva / Donnees de conception de la CAME
Leading Edge / Borde anterior / Bord anterieur
Make these angles approximately the same, 45° recommended
Haga que los angulos sean aproximadamente del mismo tamano, se recomiendan 45°
Ces angles doivent etre approximativement les m§mes, 45 0 est recommande
Recommended overtravel: 5° min. to 15° max.
Use additional overtravel available for setup
and emergency only
Sobrerecorrido
recomendado:
mfn. 5°; m^x. 15°
Use el sobrerecorrido
adicional disponible
s6lo para la instalacitfn
y emergencias.
Surcourse recommandee:
min. 5 °; max. 15 0
Utiliser la surcourse
supplemental disponible
pour ('installation et en cas
d'urgence uniquement.
0.72
18.29
T
0.75
19,05
i
/ pulg / po
mm
Trailing Edge / Borde posterior / Bord arriere
Top of roller should not be
less than 0.25 in. (6.35
mm) below end of cam.
La parte superior
de la roldana
no debera estar
6,35 mm (0,25 pulg)
debajo del extremo
de la leva.
Le dessus du galet
ne doit pas etre
situe & moins de
6,35 mm (0,25 po) sous
I'extremite de la came.
60 0
MAX.
Reversing Cam
Leva reversible
Came reversible
80°
MAX.
Non-reversing Cam
Leva no reversible
Came non reversible
Lever arm initial position
Posicitfn inicial del brazo de la palanca
Position initiale du bras du levier
Came
Do not allow lever arm to snap back.
No permita que el brazo de la palanca
vuelva a la posicitfn inicial.
Ne pas permettre au bras du levier de
revenir en place brusquement.
~ Do not contact roller within the shaded area / No permite que la roldana tenga contacto con el area sombreada / Ne pas entrer en contact avec le galet dans la zone ombree
High Speed Cams (90 FPM or more), see SM444R1. / Levas de alta velocidad (0,46 MPS o mSs), vea SM444R1. / Cames grande Vitesse (90 pi/m ou plus), voir SM444R1.
Figure / Figura / Figure 5 : Lever Type / Tipo palanca / Type du levier
Top Roller Plunger /Pulsador de roldana superior / Poussoir a galet superieur
These points must NOT be lower than the top of the roller.
Estos puntos NO deber^n estar m^s bajos que la parte superior de la roldana.
Ces points ne doivent PAS etre plus bas que la partie superieure du galet
Initial Position
Posicitfn inicial
Position initiale
55.63
1.985
50.42
Recommended Cam angle,
leading and trailing edges: 10° to 25°
Angulo recomendado de la leva,
bordes anterior y posterior: 10° a 25°
Angle recommande de came,
bords anterieur et arriere de 10 0 & 250
in. / pulg / po
mm
Side Roller Plunger / Pulsador con roldana lateral / Poussoir a galet lateral
These points must NOT be
lower than the top of the roller.
Estos puntos NO deber^n
estar m^s bajos que la parte
superior de la roldana.
Ces points ne doivent PAS
etre plus bas que la partie
superieure du galet
19.05
45 • MAX.p
Recommended Cam angle,
leading and trailing edges 10° to 25°
Angulo recomendado de la leva,
bordes anterior y posterior: 10° a 25°
Angle recommande de came,
bords anterieur et arriere de 10 0 & 25 0
45 0 MAX-
in. / pulg / po
mm
Figure / Figura / Figure 6 : Roller Plunger Type / Tipo pulsador con roldana / Type de poussoir a galet
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Limit Switches—Class 9007 Type C
Interruptores de limite—clase 9007 tipo C
Interrupteurs de position—classe 9007 type C
65013-309-03
Rev. 01, 12/2012
Varilla oscilante
Wobble Stick
When changing or installing wobble
stick extensions on Types J, K, KC,
or JKC (Figure 4), use a 1/4 in.
open-end wrench to prevent the
shaft from turning. Grip the
extension spring with pliers and
turn CCW to remove or CW to
install. The extensions are
interchangeable.
Replacement Parts
Heads, switch top assemblies, and
base receptacles are available as
replacement parts. To order, specify
the Type number marked on the
individual component, or refer to the
Digest.
•	Type C limit switches, when fully
assembled, are designed to be
operationally interchangeable
with Type B limit switches.
However, individual components
(heads, switch tops, and base
receptacles) are not
interchangeable with the Type B
components.
•	On Type C limit switch plunger
devices, the cam track dimension
is the same as on the Type B
non-plug-in devices, but 0.22 in.
(5.6 mm) less than on the Type B
plug-in devices. If this creates a
problem, a 9007 CT10 adapter
plate is available.
•	Types C68, C068, CT68, T5, and
T10 neutral position limit switch
components are not
interchangeable with any other
Type C limit switch components
including Types C64, C064,
CT64, and BW.
•	Type CO plug-in units are UL
Listed only when used with
9007 CT base receptacles.
•	Class 9007 Type C limit switches
comply with IEC 60957.5.1,
SC 8.3.4 when protected with a
Bussmann CC KTK-R-10 fuse.
Cuando se cambian o instalan extensiones
de varilla oscilante en los tipos J, K, KC, o
JKC (figura 4), utilice una Have espanola
de 1/4 pulg para evitar que gire el eje.
Agarre el resorte de la extension con unas
pinzas y gire hacia CCW para retirar la
extension o gire hacia CW para instalarla.
Las extensiones son intercambiables.
Las cabezas, los ensambles de la parte
superior del interruptory los receptaculos
de la base se pueden obtener como piezas
de repuesto. Para solicitarlos, especifique
el numero de tipo del componente
individual o consulte el Compendiado.
•	Los interruptores de limite tipo C,
cuando estan completamente
instalados, han sido disenados para ser
funcionalmente intercambiables con los
interruptores de limite tipo B. Sin
embargo, los componentes individuales
(cabezas, partes superiores del
interruptory receptaculos de la base) no
se pueden intecambiar con los
componentes del interruptor tipo B.
•	La medida de la trayectoria de la leva de
los dispositivos del pulsador del
interruptor de limite tipo C es la misma
que para los dispositivos no enchufables
tipo B, pero 5,6 mm (0,22 pulg) menor
que la de los dispositivos enchufables
tipo B. Si esto le crea problemas, se
encuentra disponible una placa
adaptadora 9007 CT10.
•	Los componentes de los interruptores
de limite de posicion neutra tipos C68,
C068, CT68, T5 y T10 no son
intercambiables con ningun otro
componente de los interruptores de
limite tipo C incluyendo los tipos C64,
C064, CT64y BW.
•	Las unidades enchufables tipo CO estan
registrados por UL solamente cuando se
utilizan con los receptaculos de base
clase 9007 CT.
•	Los interruptores de limite clase 9007
tipo C cumplen con el requisito
IEC 60957.5.1, SC 8.3.4 cuando estan
protegidos con un fusible Bussmann
CC KTK-R-10.
Tige a ressort
Lors du changement ou de Installation de
rallonges de tige a ressort sur les types J,
K, KC, ou JKC (figure 4), utiliser une cle
plate de 1/4 po pour empecher I'arbre de
tourner. Saisir le ressort de la rallonge
avec des pinces et tourner dans le sens
anti-horaire pour demonter ou tourner
dans le sens horaire pour installer. Les
rallonges sont interchangeables.
Pieces de rechange
Les tetes, les assemblages de la partie
superieure de I'interrupteur et les receptacles
de base peuvent etre obtenus comme pieces
de rechange. Pour les commander, specifier
le numero de type inscrit sur le composant
individuel ou se reporter au Digest.
•	Les interrupteurs de position de type C,
lorsqu'ils sont completement assembles,
sont congus pour etre fonctionnellement
interchangeables avec les interrupteurs de
position de type B. Toutefois, les
composants individuels (tetes, parties
superieures de I'interrupteur et receptacles
de base) ne sont pas interchangeables
avec les composants de type B.
•	La dimension du trajet de la came des
appareils de poussoir pour interrupteurs
de position de type C est la meme que
celle des appareils de type B non
enfichables; mais 5,6 mm (0,22 po) de
moins que celle des appareils de type B
enfichables. Si cela cause un probleme,
une plaque intermediate 9007 CT10 est
disponible.
•	Les composants de I'interrupteur de
position a position neutre de type C68,
C068, CT68, T5 et T10 ne sont
interchangeables avec aucun autre
composant d'interrupteur de position de
type C, incluant les types C64, C064,
CT64 et BW.
•	Les unites enfichables de type CO sont
listees UL seulement lorsqu'elles sont
utilisees avec les receptacles de base
classe 9007 CT.
•	Les interrupteurs de position classe
9007 type C sont conformes avec
IEC 60957.5.1, SC 8.3.4 lorsqu'ils sont
proteges par un fusible Bussmann
CC KTK-R-10.
Piezas de repuesto
Electrical equipment should be installed,
operated, serviced, and maintained only by
qualified personnel. No responsibility is assumed
by Schneider Electric for any consequences
arising out of the use of this material.
Schneider Electric USA, Inc.
8001 Knightdale Blvd.
Knightdale, NC 27545
1-888-778-2733
www.schneider-electric.us
Solamente el personal especializado debera instalar,
hacer funcionar y prestar servicios de mantenimiento al
equipo electrico. Schneider Electric no asume
responsabilidad alguna por las consecuencias
emergentes de la utilization de este material.
Importado en Mexico por:
Schneider Electric Mexico, S.A. de C.V.
Calz. J. Rojo Gomez 1121-A
Col. Gpe. del Moral 09300 Mexico, D.F.
Tel. 55-5804-5000
www.schneider-electric.com.mx
Seul un personnel qualifie doit effectuer 1'installation,
I'utilisation, I'entretien et la maintenance du materiel
electrique. Schneider Electric n'assume aucune
responsabilite des consequences eventuelles
decoulant de I'utilisation de cette documentation.
Schneider Electric Canada, Inc.
5985 McLaughlin Road
Mississauga, ON L5R 1B8 Canada
Tel:1-800-565-6699
www.schneider-electric.ca
h 1992-2012 Schneider Electric All Rights Reserved / Reservados todos los derechos /Tous droits reserves
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC.
GTAF System
Section 5
Drag Chain
1813 Frank Holt Drive Burlington NC 27215 336-226-1100 rendeq.com
-------
Equipment, Service & Engineering
for the Animal Protein & Recycling Industries
RENDEQ, INC. GTAF System
DRAG CHAIN SYSTEM
Item
Qty
Part Numbers/ Description
Chain
~ 168ft.
runs at 42ft. each
Motors
2
(1 Baldo CWDM3615T, (l)Leeson
C184T17FK14D
Gearboxes
2
Conedrive U0-7600C-AL, U0-7700-AL
Sprockets
8
Custom Built
Bearings
4
Dodge P2B-LT10-200
Take-Up Frames
4
(2 Dodge 038211 (2 Custom Built
Take-Up Bearings
4
(2 Dodge 125363 (2 Dodge 125362
Drive Chain
~20ft.
120RIV
Drive Gears
2
B1216
Driven Gears
2
120BTL16H Taper Bus 1-1/2" Pitch
1 T eeth
Belts
4
3VX375
Bushings
4
(2 2" Bore (2) 1-1/8" Bor
Sheaves
2
Dodge 112194
1813 Frank Holt Drivt Burlington NC 27215 336-226-1100 rtndtq.com
-------
263 1/2 APP
A
INLET
CAPPED OFF
i. " ;
4'.
OUTLET
A
248 3/8 APP
53
43
12 3/8
d *
HOC


3a

nor

VIEW A-A
SEE SLAT
DETAIL

j'

p ¦
4
* 4

THIRD SLAT
SECOND SLAT

FIRST SLAT
SLAT DETAIL
SLATS SPACED 32"
TO 40" APART
REN D EQ1 ffiH
1813 Frank S. Holt Dr., Burlington, NC 27215
Phone: (336) 226-1100 or (336) 376-9004
E-mail: rendeq@bellsouth.net or chip@rendeq.com
Web Site: www.rendeq.com
SUBJECT.
CHAIN DRAG SYSTEM
FOR GASIFIER
-------
Washdown
Dirty Products

-------
*P A Til
Washdown Motors
The standard in the food and pharmaceutical processing industries for more
than 15 years, the Baldor Washdown Duty motors recently raised the bar once
again with more features to improve reliability. A new exterior paint process
makes the finish coat five times more resistant to corrosion and chipping.
Exxon Polyrex® EM grease provides improve lubrication life, provides greater
shear stability and superior resistance to washout, rust and corrosion.
Distinctive blue colored drain plugs make them easy to recognize; new shape
makes themeasy to remove.
Ilr

(
Performance Data: TEFC - Totally Enclosed Fan Cooled, TENV - Totally
Enclosed Non-Ventilated, 230/460 Volts, Three Phase, 1/2 through 20 Hp
Hp
kW
RPM
Frame
Catalog
No.
Amps @ High V
Full
Load
Torque
Lb. Ft.
Efficiency
f %
Power Factor %
Bearings
Volt
Code
"C"
Dim.
Conn.
Diag.
No.
Full
Load
Locked
Rotor
1/2
3/4
Full
Load
1/2
3/4
Full
Load
DE
ODE
Rigid base
0.5
0.37
1725
56
WDM3538 1
0.8
6.25
1.5
72.4
76.2
75.5
64
76
83
6205
6203
E1
11.07
CD0005
0.75
0.56
1725
56
WDM3542 1
1.1
8.5
2.3
77.9
79.9
80.0
55
71
81
6205
6203
E1
11.07
CD0005
1
0.75
1725
143T
WDM3546T 1
1.6
11.3
3.0
75.4
79.3
81.5
58
71
74
6205
6203
E
12.12
CD0005
1.5
1.1
1725
145T
WDM3554T 1
2.1
18.3
4.5
78.0
81.7
82.5
65
72
82
6205
6203
E
13.00
CD0005
2
1.5
1740
145T
WDM3558T ~
2.8
21.6
6.0
83.6
85.2
84.0
61
74
81
6205
6203
E
14.08
CD0005
3
2.2
1750
182T
WDM3611T ~
4.1
32.4
8.9
86.1
85.1
87.5
59
71
78
6206
6205
E
16.54
CD0005
5
3.7
1750
184T
WDM3615T ~
7.1
53.6
12.0
87.0
88.2
87.5
57
69
75
6206
6205
E
16.54
CD0005
7.5
5.6
1760
213T
WDM3710T ~
9.8
65.2
22.3
88.6
89.8
89.5
63
74
80
6307
6206
E
17.89
CD0005
10
7.5
1760
215T
WDM3714T ~
14.2
91.2
29.9
89.2
90.2
89.5
63
74
80
6307
6206
E
19.04
CD0005
C-face with base
0.5
0.37
3450
56C
CWDM3537 1
0.9
6.0
0.75
59.6
66.9
70.0
62
72
76
6205
6203
E
11.07
CD0005
0.5
0.37
1725
56C
CWDM3538 1
0.8
6.25
1.5
72.4
76.2
75.5
64
76
83
6205
6203
E1
11.07
CD0005
0.5
0.37
1140
56C
CWDM3539 1
1.0
5.6
2.3
71.5
76.4
77.0
44
57
66
6205
6203
E1
12.07
CD0005
0.75
0.56
3450
56C
CWDM3541 1
1.1
8.1
1.14
74.4
78.7
80.0
63
73
80
6205
6203
E1
11.07
CD0005
0.75
0.56
1725
56C
CWDM3542 1
1.1
8.50
2.3
77.9
79.9
80.0
55
71
81
6205
6203
E1
11.07
CD0005
0.75
0.56
1140
56C
CWDM3543 1
1.3
15.1
3.5
74.5
78.0
78.5
50
63
70
6205
6203
E
12.94
CD0005
1
0.75
3450
56C
CWDM3545 1
1.3
8.9
1.5
80.5
83.1
82.5
69
82
88
6205
6203
F
11.07
CD0005
1
0.75
1725
56C
CWDM3546 1
1.6
11.3
3.0
75.4
79.3
81.5
58
71
74
6205
6203
E
12.07
CD0005
1
0.75
1725
143TC
CWDM3546T1
1.6
11.3
3.0
75.4
79.3
81.5
58
71
74
6205
6203
E
12.13
CD0005
1
0.75
1140
56C
CWDM3556 ~
1.7
8.0
4.5
71.1
74.1
75.5
47
58
69
6205
6203
E
13.24
CD0005
1.5
1.1
3450
56C
CWDM3550 ~
2.3
16.0
2.3
66.7
72.7
75.5
59
71
76
6205
6203
F
12.24
CD0005
1.5
1.1
1725
145TC
CWDM3554T ~
2.1
18.3
4.5
78.0
81.7
82.5
65
72
82
6205
6203
E
13.00
CD0005
1.5
1.1
1140
56C
CWDM3557 ~
2.5
10.6
7.0
77.1
78.4
75.5
54
67
68
6205
6203
F
13.24
CD0005
2
1.5
3450
56HCY
CWDM3555 ~
2.7
17.5
3.0
78.2
80.3
78.5
80
87
93
6205
6203
E
13.24
CD0005
2
1.5
3450
145TC
CWDM3555T ~
2.6
24.3
3.0
81.2
83.8
84.0
73
80
88
6205
6203
E
13.30
CD0005
2
1.5
1740
145TC
CWDM3558T ~
2.8
21.6
6.0
83.6
85.1
84.0
64
74
81
6205
6203
E
14.17
CD0005
3
2.2
3460
145TC
CWDM3559T ~
3.7
37.5
4.5
82.8
85.1
85.5
78
86
89
6205
6203
E
14.17
CD0005
3
2.2
1750
182TC
CWDM3611T ~
4.1
32.4
8.9
86.1
87.8
87.5
59
71
78
6206
6205
E
16.54
CD0005
5
3.7
3450
184TC
CWDM3613T ~
6.0
56.0
7.6
87.8
88.4
87.5
83
89
92
6206
6205
E
16.54
CD0005
5
3.7
1750
184TC
CWDM3615T ~
7.1
53.6
12.0
87.0
88.3
87.5
57
69
75
6206
6205
E
16.54
CD0005
7.5
5.6
3450
213TC
CWDM3709T ~
8.7
94.0
11.3
88.4
89.3
88.5
84
91
93
6207
6205
E
18.54
CD0005
7.5
5.6
1760
213TC
CWDM3710T ~
9.8
65.2
22.2
88.6
89.8
89.5
63
74
80
6307
6206
E
18.65
CD0005
10
7.4
3500
215TC
CWDM3711T ~
11.5
84.0
15.0
90.6
90.8
89.5
83
88
91
6307
6206
E
18.65
CD0005
10
7.4
1760
215TC
CWDM3714T ~
13.0
91.2
29.9
89.2
90.2
89.5
63
74
80
6307
6206
E
19.78
CD0005
15
11.1
3450
254TC
CWDM23994T ~
17.0
152
22.6
91.6
91.9
90.2
85
90
91
6309
6206
E
21.94
CD0005
15
11.1
3450
215TC
CWDM3713T ~
17.0
152
22.6
91.6
91.9
90.2
85
90
91
6307
6206
E
21.26
CD0005
15
11.1
1760
254TC
CWDM23933T ~
17.3
115
42.6
90.3
91.5
91
71
81
89
6309
6208
E1
23.57
CD0005
20
15
3525
256TC
CWDM41906T ~
22.7
188
30.0
89.7
91.1
91
81
88
90
6309
6208
E1
23.57
CD0180
20
15
1760
256TC
CWDM23934T ~
23.0
164
60.0
91.0
91.9
91.7
85
84
89
6309
6208
E1
23.57
CD0005
NOTE: Volt Code: E = 208-230/460V 60Hz; E1 = 230/460V 60Hz, usable at 208V;
F = 230/460V 60 Hz; H = 575V, 60Hz.
See page 38 for Connection Diagrams. Efficiencies shown are nominal.
Data subject to change without notice. Contact Baldor for certified data.
I = TENV Enclosure - See
~ = TEFC Enclosure - See
page
page
26 for dimensions.
26 for dimensions.
www.baldor.com
-------
*P A Til
Dimension Drawings
Washdown Inverter and Vector Motors
THRU SHAFT
ENCODER-H
I
BB-H
H
HOLES
h-AH-
A

KEY
BD
AK
— 2F-
-2F—
•BA
3
SLINGER
OR SEAL
4 HOLES
TAP BF
AJ DIA.
AA
LEAD HOLE
(NPT)
U—E -I* E—I
NEMA
Frame
Thru Shaft
Encoder
2F
AH
AB
BA
U
BD
AK
AJ
BF
TAP
AA
BB
143TC
145TC
2.78
3.50
2.75
4.00
5.00
0.34
2.12
6.81
5.73
2.75
0.875
6.63
6.51
4.50
5.88
3/8-16
0.50
0.12
182TC
2.78
4.50
3.75
184TC
4.50
5.50
0.41
2.62
8.44
6.87
3.50
1.125
8.50
7.25
1/2-13
0.75
0.25
213TC
2.78
5.25
4.25
215TC
5.50
7.00
0.41
3.12
10.03
8.05
4.25
1.375
9.56
9.04
8.50
7.25
1/2-13
0.75
0.25
254TC
256TC
1.79*
6.25
5.00
8.25
10.00
0.53
3.75
12.00
9.72
4.75
1.625
11.69
9.44
8.50
7.25
1/2-13
1.25
0.25
NOTE: * 2.29 for Vector Motor.
Washdown Inverter
TENV Enclosure
TEFC Enclosure
AH—
BB—
LEAD HOLE
HOLES
4 HOLES
HOLES
TAP B.F.
AJ D A. B.C
-KEY
NEMA
Frame
D
E
2F
H
AH
O
AB
BA
U
P
BD
AK
AJ
BF
TAP
AA
BB
56C
3.50
2.44
3.00
0.34
2.06
6.81
5.73
2.75
0.625
6.62
6.50
4.50
5.88
3/8-16
0.50
0.12
143TC
145TC
3.50
2.75
4.00
5.00
0.38
2.12
6.81
5.73
2.75
0.875
6.62
6.50
4.50
5.88
3/8-16
0.50
0.12
182TC
184TC
4.50
3.75
4.50
5.50
0.41
2.62
9.00
6.56
3.5
1.125
8.50
8.86
8.50
7.25
1/2-13
0.75
0.25
213TC
215TC
5.25
4.25
5.50
7.00
0.41
3.12
10.03
7.46
4.25
1.375
10.18
9.04
8.50
7.25
1/2-13
0.75
0.25
NOTE: Dimension for reference only. Contact a Baldor District Office or www.baldor.com for the detailed dimension drawing for your specific catalog number.
www.baldor.com
-------

Dimension Drawings
Washdown Single Phase
2.06
0.12
KEY
6.50
4.50
0.625
-3.00—" -2.75-
HOLES "
0.34 DIA.
Catalog No. starting with "C" = C-face with base.
Catalog No. starting with "V" = C-face, no base.
Washdown Feather Picker
6.62
TOP
OF NP
5.25
4.13
6.81
3.50
-2.75-
>-3.25-
6.50—
!.75-
LEAD HOLE
0.50 NPT -
-.19 KEY
1.38 LONG
7.19
DIA.
|— 4.00
—5.00-
—5.94-
!.25-
6 HOLES
.34 DIA.
NOTE: Dimension for reference only. Contact a Baldor District Office or www.baldor.com for the detailed dimension drawing for your specific catalog number.
LEAD HOLE
HOLES
3/8-16 BF
5.88 DIA.
5.55 ref.
www.baldor.com
-------
*P A Til
Dimension Drawings
Washdown Super-E
-a




<§>	f- Key
Ua
BA
Holes
AA
Lead Hole
X
Washdown Super-E Brake Motor
/"Key o
H /
Holes-'
AA
Lead Hole
Washdown Baldor SmartMotor®
NEMA 143TC through 215TC
¦o o
C01
2F —'BA
¦ V -*
- BB
L
Lu

«	 P 	*¦

"* WB *
" ,n	
M


mmm,
45°

Dimension
Model
2F
D
E
O
P
U
V
AH
AJ
AK
BA
BB
BD
BF
C01
C02
C03
C04
LB
WB
56C
3.00
3.50
2.44
10.36
7.18
0.6250
1.93
2.06
5.88
4.50
2.75
0.13
6.51
.38-16
4.03
1.38
5.48
7.307
8.73
6.03
143TC
4.00
3.50
2.75
10.35
7.20
0.8750
2.26
2.13
5.88
4.50
2.75
0.13
6.51
.38-16
4.03
1.38
5.48
7.307
8.71
6.03
145TC
5.00
3.50
2.75
10.35
7.20
0.8750
2.26
2.13
5.88
4.50
2.75
0.13
6.51
.38-16
4.03
1.38
5.48
7.307
8.71
6.03
182TC
4.50
4.50
3.75
11.92
8.86
1.125
2.75
2.87
7.25
8.50
3.50
0.25
8.86
.50-13
3.96
1.38
5.58
9.72
11.26
7.12





















184TC
5.50
4.50
3.75
11.92
8.86
1.125
2.75
2.87
7.25
8.50
3.50
0.25
8.86
.50-13
5.46
1.38
5.58
9.72
11.26
7.12
213TC
5.50
5.25
4.25
13.69
10.62
1.375
3.37
3.37
7.25
8.50
4.25
0.25
9.04
.50-13
4.79
1.91
7.11
10.58
11.75
8.27
215TC
7.00
5.25
4.25
13.69
10.62
1.375
3.37
3.37
7.25
8.50
4.25
0.25
9.04
.50-13
4.74
1.91
7.11
10.58
11.75
8.27
NOTE: Dimension for reference only. Contact a Baldor District Office or www.baldor.com for the detailed dimension drawing for your specific catalog number.
www.baldor.com
-------

Dimension Drawings
Washdown NEMA 56 through 256TC
TENV Enclosure	Base Mount	TEFC Enclosure
AB
KEY
AA
LEAD HOLE
(NPT)
2F
BA
2F
HOLES
KEY
FP
2F
2F
HOLES
TENV Enclosure C-face with or without Base TEFC Enclosure
4 HOLES
TAP B.F.
AJ DIA. B.C.
AA
LEAD HOLE
(NPT)
HOLES
HOLES
Catalog No. starting with "C" = C-face with base.
Catalog No. starting with "V" = C-face, no base.
NEMA
Frame
A
B
D
E
2F
H
N
0
P
U
V
AA
AB
AH
AJ
BF
TAP
AK
BA
BB
BD
56
6.50
4.50
3.50
2.44
3.00
0.34
2.44
6.81
6.62
0.625
1.88
0.50
5.22
-
-
3/8-16
-
2.75
-
-
56C
6.50
4.50
3.50
2.44
3.00
0.34
-
6.81
6.62
0.625
1.88
0.50
5.22
2.06
5.88
3/8-16
4.50
2.75
0.12
6.50
143T
6.50
5.94
3.50
2.75
4.00
0.34
2.50
6.81
6.62
0.875
2.25
0.50
5.22
-
-
3/8-16
-
2.25
-
-
143TC
6.50
5.94
3.50
2.75
4.00
0.34
-
6.81
6.62
0.875
2.25
0.50
5.22
2.12
5.88
3/8-16
4.50
2.75
0.12
6.50
145T
6.50
5.94
3.50
2.75
5.00
0.34
2.50
6.81
6.62
0.875
2.25
0.50
5.22
-
-
3/8-16
-
2.25
-
-
145TC
6.50
5.94
3.50
2.75
5.00
0.34
-
6.81
6.62
0.875
2.25
0.50
5.22
2.12
5.88
3/8-16
4.50
2.75
0.12
6.50
182T
8.63
6.50
4.50
3.75
4.50
0.41
3.56
8.44
7.88
1.125
2.75
0.75
5.97
-
-
1/2-13
-
2.75
-
-
182TC
8.63
6.50
4.50
3.75
4.50
0.41
-
8.44
7.88
1.125
2.75
0.75
5.97
2.62
7.25
1/2-13
8.50
3.50
0.25
8.89
184T
8.63
6.50
4.50
3.75
5.50
0.41
3.56
8.44
7.88
1.125
2.75
0.75
5.97
-
-
1/2-13
-
2.75
-
-
184TC
8.63
6.50
4.50
3.75
5.50
0.41
-
8.44
7.88
1.125
2.75
0.75
5.97
2.62
7.25
1/2-13
8.50
3.50
0.25
8.89
213T
9.50
8.00
5.25
4.25
5.50
0.41
3.88
10.03
9.56
1.375
3.37
0.75
7.46
-
-
1/2-13
-
3.50
-
-
213TC
9.50
8.00
5.25
4.25
5.50
0.41
-
10.03
9.56
1.375
3.37
0.75
7.46
3.12
7.25
1/2-13
8.50
4.50
0.25
9.04
215T
9.50
8.00
5.25
4.25
7.00
0.41
3.88
10.03
9.56
1.375
3.37
0.75
7.46
-
-
1/2-13
-
3.50
-
-
215TC
9.50
8.00
5.25
4.25
7.00
0.41
-
10.03
9.56
1.375
3.37
0.75
7.46
3.12
7.25
1/2-13
8.50
4.50
0.25
9.04
254TC
11.25
9.50
6.25
5.00
8.25
0.53
-
12.00
11.50
1.625
4.00
1.25
8.99
3.75
7.25
1/2-13
8.50
4.75
0.25
9.44
256TC
11.25
11.25
6.25
5.00
10.00
0.53
-
12.00
11.50
1.625
4.00
1.25
8.99
3.75
7.25
1/2-13
8.50
4.75
0.25
9.44
NOTE: Dimension for reference only. Contact a Baldor District Office or www.baldor.com for the detailed dimension drawing for your specific catalog number.
www.baldor.com
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*P A Til
Dimension Drawings Series 5 Micro Inverters
1 Hp
T
n
F

y
x
POWER O
60 STATUS O
70
20 i
10 NgCj/*~90
0	100
% SPEED
ST0P[O]
REVERSE MANUAL STOP
AC MOTOR
— WASHDOWN DUTY DRIVE-
X
=/
ST
ITH OPTIONAL AUTO/MANUAL AND FORWAR
ING SCRE : / "
h*	

—~


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2 thru 5 Hp
m
A
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&
H