Coolant Delivery System for Creep-Feed Grinding - Mechanical ...

Dalhousie University MECH 4010 – Design Project I – Fall Term Report 

Dalhousie University 

Mechanical Engineering Department 

MECH 4010 – Design Project I 

Coolant Delivery System for Creep-Feed Grinding 

Fall Term Report 

Team 10 

Brian Murphy 

David Pottle 

Andrew Rockwell 

Kyle Ryan 

December 4, 2006


Table of Contents 

List of Tables ......................................................................................................................iii 

List of Figures ....................................................................................................................iii 

Abstract...............................................................................................................................iv 

1.0 Introduction ...................................................................................................................1 

1.1 Background Information...............................................................................................2 

1.1.1 Grinding..............................................................................................................................2 

1.1.2 Grinding Wheels.................................................................................................................2 

1.1.3 Grinding Fluids ...................................................................................................................3 

1.1.4 Analysis of the Grinding Process .......................................................................................3 

1.1.5 Temperatures at the Work Surface ....................................................................................4 

1.1.6 Grinding Operations and Grinding Machines .....................................................................5 

1.1.6.1 Surface Grinding .........................................................................................................................5 

1.1.6.2 Creep Feed Grinding ..................................................................................................................5 

1.2 Previous Research of Coolant Delivery at Dalhousie ..................................................6 

2.0 Design Requirements ...................................................................................................8 

3.0 Design Options..............................................................................................................9 

4.0 Selected Design...........................................................................................................12 

4.1 Pump and Motor Options...........................................................................................12 

4.1.1 Pump Selection ................................................................................................................12 

4.1.2 Drive Selection .................................................................................................................13 

4.2 Detailed Final Design Specifications..........................................................................14 

5.0 Project Status ..............................................................................................................17 

6.0 Cost Analysis...............................................................................................................18 

7.0 Conclusions.................................................................................................................19 

8.0 References...................................................................................................................21 

APPENDIX A – Calculations .............................................................................................22 

APPENDIX B – Pump-Motor Curves ................................................................................24 

APPENDIX C – Equipment Specifications.......................................................................27 

APPENDIX D – Budget ......................................................................................................18 

i


APPENDIX E – Quotes ......................................................................................................51 

APPENDIX F – Winter Term Gantt Chart .........................................................................56 

APPENDIX G – Detail Drawings .......................................................................................58 

ii


List of Tables 

Table 1.1 – Hardness values of abrasive materials used in grinding wheels ................3 

Table 4.1 – Pump Selection Chart....................................................................................13 

List of Figures 

Figure 1.1 – Blohm Planomat 408 Creep-Feed Grinder....................................................1 

Figure 1.2 – The geometry of surface grinding.................................................................4 

Figure 1.3 – Comparison of (a) conventional surface grinding and (b) creep feed 

grinding................................................................................................................................6 

Figure 3.1 – System Schematic # 1..................................................................................10 

Figure 3.2 – System Schematic # 2..................................................................................11 

Figure 4.1 – Final Design Schematic ...............................................................................16 

Figure 4.2 – Final Design Layout .....................................................................................16 

iii


Abstract 

The following report summarizes the basic facts, the proposed design, and the detailed 

engineering drawings for the upgrade to the coolant delivery system on the Blohm Planomat 408 

CNC grinding machine at Dalhousie University. The creep feed grinding machine is the 

property of the Dalhousie Grinding Research Group. The report will explain how the coolant 

delivery system was designed, how it will be installed, and how the upgrades will benefit the 

Dalhousie Grinding Research Group. 

The coolant delivery system will use two pumps and two motors to supply the coolant to the two 

desired locations during grinding. The pumps were sized to obtain the pressures and flow rates 

required for exit velocities to be greater than the tangential velocity of the wheel. The motors for 

the pumps were sized so as to meet the power requirements of this high pressure system. Two 

speed controllers are to be installed so that research students are able to experiment with a wide 

variety of flow rates. 

The report will also outline the amount of progress that has been completed up to this point. The 

main progress of the report has been talking to local distributors for pumps and motors and 

selecting components. The main components of the system have been selected, such as the 

pumps, motors, and the variable speed controllers. These components have also been ordered, 

for an early January installation. 

The frame for the pumps and motors has been completely designed and a list of materials has 

been produced. This list of materials will be used to order the materials so the frame can be 

constructed over the Christmas break. With the frame being constructed over the Christmas 

break; the pumps, motors, and variable speed controllers will be installed in early January. 

iv


1.0 Introduction 

The Blohm Planomat 408 Computer Numerical Control (CNC) grinding machine in the CNC lab 

at Dalhousie University is to be upgraded so that it can used for creep-feed profile grinding using 

cubic boron nitride (CBN) grinding wheels. 

The tangential velocity of a CBN grinding wheel is typically 45 – 60 m/s as compared to the 25 – 

35 m/s for conventional aluminum oxide grinding wheels. A key component of this upgrade is 

the coolant delivery and wheel cleaning system. The current system is not capable of delivering 

coolant to the wheel with sufficient profile coverage or velocity. Therefore, we need to design, 

install, and test an upgraded coolant system. 

Figure 1.1 – Blohm Planomat 408 Creep-Feed Grinder 

Courtesy: Mechanical Engineering Department - Dalhousie University - Grinding Research Group


1.1 Background Information 

1.1.1 Grinding 

Grinding is a material removal process using abrasive particles bonded in the shape of a disk. 

These disks are called grinding wheels, which are precisely balanced to rotate at very high 

speeds. 

Grinding can be likened to the milling process, but there are significant differences between the 

two. The first key difference in the two processes is the abrasive grains in the grinding wheel are 

much smaller and more numerous than the number of teeth on the milling cutter. Also, the 

cutting speeds in grinding are much higher. The abrasive particles in grinding wheels are 

randomly oriented and possess very large negative rake angles. Finally, a grinding wheel is self 

sharpening. As the abrasive particles become dull or break off, new particles are exposed. 

Abrasive processes are important in industry and technologically for three main reasons. 

Abrasive processes can be used on a wide range of materials, ranging from soft metals to 

hardened steels, and even on some nonmetallic materials such as ceramics and silicon. Some of 

the higher end abrasive processes can be used to produce extremely fine surface finishes, to 

0.025 μm (1 μ-in). Finally, certain abrasive processes can hold extremely close tolerances. 

[Groover, 2004] 

1.1.2 Grinding Wheels 

There are many different types of grinding wheels that are used in the industry. The first wheel 

to be discussed will be the Aluminum Oxide wheel (Al2O3). Al2O3 wheels are the most common 

type of grinding wheels. They are mainly used to grind steels, other ferrous metals, and high 

strength alloys. Another type of wheel used is Silicon Carbide (SiC). SiC grinding wheels are 

slightly harder than Al2O3 wheels, but are not as tough. SiC wheels are generally used to grind 

ductile metals such as aluminum, brass, and stainless steels, as well as some brittle materials 

such as cast iron and ceramics. Cubic Boron Nitride (cBN) wheels are the second hardest known 

to man. These cBN wheels are used for grinding much harder materials such as hardened tool 

steels, and aerospace alloys. The final type of grinding wheel material most commonly used is 

2


Diamond. Diamond grinding wheels are produced naturally or synthetically. Diamond grinding 

wheels are used on hard, abrasive materials such as ceramics, cemented carbides, and glass. 

Table 1.1 – Hardness values of abrasive materials used in grinding wheels 

Abrasive Material Knoop Hardness 

Aluminum Oxide 2100 

Silicon Carbide 2500 

Cubic Boron Nitride 5000 

Diamond (artificial) 7000 


1.1.3 Grinding Fluids 

Proper application of cutting fluids reduces thermal effects in the work piece and high work 

surface temperatures. Cutting fluids are called grinding fluids when used in the grinding process. 

The main purposes of grinding fluids in grinding are reducing friction and removing heat from 

the process. Additionally, the grinding fluid is used to wash away pieces of metal chips and 

wheel particles. 

Types of grinding fluids include grinding oils and emulsified oils. Grinding oils are derived 

from petroleum and other sources. These products seem to be very attractive due to the large 

friction in the grinding process. However, grinding oils pose hazards in terms of fires and 

operator health, and their cost is quite high compared to emulsified oils. Additionally, grinding 

oils have a low capacity to carry away heat when compared with water based fluids. Therefore, 

mixtures of oils in water are most commonly used as grinding fluids. These types of oil-water 

mixtures are usually mixed with higher concentrations than emulsified oils used as conventional 

cutting fluids. This way, the friction reduction mechanism is emphasized. 


1.1.4 Analysis of the Grinding Process 

The cutting in the grinding process is characterized by very high speeds, and very small cut size. 

The peripheral speed of the grinding wheel is determined by the rotational speed of the grinding 

wheel. 

3


v = πDN 

where v = the surface speed of the wheel (m/s, ft/min, etc.); N = spindle speed (rev/min); D = 

wheel diameter (m, ft, etc.). 

The depth of the cut, d, is called the infeed. The infeed is the distance the wheel is below the 

original work surface. As the grinding process proceeds, the grinding wheel is fed laterally 

across the surface of the work piece. The movement of the wheel refers to the crossfeed, and it 

determines the width of the grinding path, w. The width of the cut multiplied by the depth of the 

cut determines the cross-sectional area of the cut. Most grinding processes, the work piece 

moves past the wheel at a certain speed vm. The material removal rate (MRR) of the grinding 

process can be determined by 


1.1.5 Temperatures at the Work Surface 

MRR = vm 

wd 

Figure 1.2 – The geometry of surface grinding 

Due to the high rake angles and the plowing and rubbing of the abrasive particles against the 

work surface, high temperatures and friction are common in the grinding process. The heat 

generated in the grinding process is transferred to the work piece, unlike in conventional 

machining operations where most of the heat generated is removed by the chips. The transfer of 

heat to the work piece results in higher work surface temperatures. High surface temperatures 

4


cause several damaging effects, which primarily include surface burn and cracking. Burn marks 

appear right away as discoloration on the surface. These burn marks are an immediate sign of 

metallurgical damage beneath the surface. An extreme case of thermal damage is the sight of 

cracks. The cracks in grinding appear perpendicular to the rotation of the grinding wheel. 

A second harmful effect of high temperatures is softening of the work piece. Many grinding 

operations are performed on heat treated parts to obtain high strength and hardness. The high 

temperatures of grinding can cause some parts to lose some of their strength. The final effect 

that temperatures can have on the work piece is through residual stresses, which decrease the 

fatigue strength of the part. 


1.1.6 Grinding Operations and Grinding Machines 

1.1.6.1 Surface Grinding 

Surface grinding is usually used to grind plain flat surfaces. The process can be performed by 

using either the periphery or the flat face of the grinding wheel. The work piece is usually held 

in a horizontal orientation; peripheral grinding is performed by rotating the grinding wheel about 

a horizontal axis. Face grinding is performed by rotating the grinding wheel about a vertical 

axis. In both cases, the relative motion of the work piece is done by reciprocating the work piece 

across the wheel or by rotating it. 

1.1.6.2 Creep Feed Grinding 

Creep feed grinding was developed around 1958. Creep feed grinding is performed at very large 

cut depths and very low feed rates. The comparison between conventional surface grinding and 

creep feed grinding is illustrated in Figure 1.3. 

5


Figure 1.3 – Comparison of (a) conventional surface grinding and (b) creep feed grinding 


Depth of cuts in creep feed grinding are generally 1,000 to 10,000 times greater than in 

conventional surface grinding. The feed rates of creep feed grinding are typically reduced by the 

same proportion. However, the material removal rate and productivity are increased in creep 

feed grinding because the grinding wheel is continuously moving. This contrasts with 

conventional grinding in which the reciprocating motion of the work piece results in significant 

lost time during each stroke. 

The introduction of creep feed grinding machines has spurred interest in the process. The 

features of creep feed grinding include high static and dynamic stability, highly accurate slides 

with reduced tendency to stick-slip, increased spindle power (two or three times the power of 

conventional grinding machines), consistent table speeds for low feeds, high-pressure grinding 

fluid delivery systems, and dressing systems capable of dressing the grinding wheels during the 

process. Typical advantages of creep feed grinding include high material removal rates, 

improved accuracy for formed surfaces, and reduced temperatures at the work surface. 


Fundamentals of Modern Manufacturing 

1.2 Previous Research of Coolant Delivery at Dalhousie 

In recent years a significant amount of research has been done by the Dalhousie Grinding 

Research Group to attempt to optimize the coolant deliver for creep feed grinding. The findings 

of this research constitute the motivation for this design project. This research is summarized in 

the following paragraphs. 

6


Former Masters candidate Joachim Steffen upgraded the coolant system on the Blohm Planomat 

to produce a coherent jet. The fan-like spray of the stock coolant nozzle was replaced with a 

precise jet of 0.5 degree coherency 1 . A high pressure wheel cleaning system was also 

implemented, using coolant sprayed perpendicular to the wheel to remove debris from the wheel 

surface. The coherent jet system resulted in an increase in the achievable MRR of up to 60% 

over the stock nozzle system. The wheel cleaning system nearly eliminated the problem of 

premature wheel breakdown. 

Later tests were performed by Masters candidate Rishad Irani, in which he implemented a high 

pressure jet system in place of Steffen’s coherent jet system. This resulted in further increases in 

the achievable MRR which were found to be an additional 40% over the improvement of the 

coherent jet system. 

Therefore, based on these research findings it was determined that a high pressure coherent jet 

system running in conjunction with a high pressure wheel cleaning system would have potential 

to produce further improvements. For this reason it is believed that a system incorporating these 

characteristics would be useful in attempting to optimize the coolant delivery for creep feed 

grinding. 

[Irani, 2006] 

[Steffen, 2004] 

1 Degree of coherency = (Diameter of jet at nozzle exit) / (Diameter of jet at six inches from nozzle exit) 

7


2.0 Design Requirements 

The design criteria and performance goals of the project are as follows: 

• The size and geometry of the coolant system are to fit the existing grinding machine. 

• The coolant system will be easy to adjust, operate and maintain 

• One prototype will be produced 

• A set of operating instructions will be developed 

• All piping must be designed to handle operating pressures and secured to prevent any risk 

of injury. All safety features of the grinding machine will be retained. 

• The coolant delivery system must be robust, to handle potential daily use of the grinding 

machine. 

• The coolant system is required to handle several years of use with regular preventative 

maintenance 

• The coolant system will be made of quality materials, while keeping cost in 

consideration. The materials will be selected to suit their functional requirements in the 

system. 

• The project budget is $10,000. 

• The coolant system will be adaptable to flat and profile grinding. 

• The coolant will provide coverage of the entire cutting profile. 

• The amount of coolant will be minimized while still providing adequate cooling and 

lubrication. 

• The wheel cleaning system will be upgraded and integrated into the new design 

• Pressure and flow meters will be installed at various locations in the system. 

• The device will be built and testing will begin prior to March 21, 2007. 

8


3.0 Design Options 

After receiving the design requirements, it was required to develop a system that would meet or 

exceed these requirements. Brainstorming was performed and various ideas for the system were 

developed. The following section will describe two separate designs that were considered during 

the brainstorming sessions, but were found to be unsuitable designs and therefore, they were not 

selected for this application. This will be followed by a detailed description of the chosen and 

final design. 

The first considered design was a system with a single pump and motor that would provide the 

coolant to both the cleaning and coolant side of the grinding machine by dividing the flow. This 

design was one of the initial ideas and it was considered due to its simplicity. It was initially 

thought that it would be easiest to have one pump and one motor, similar to the current system, 

but to provide greater flow and pressure. The new pump would provide flow through one line 

which would be split into two separate lines using a valve or flow divider. The line providing the 

coolant to the coolant/lubrication side of the system would use the majority of the flow while the 

line providing the coolant to the cleaning side would only require a small flow. The motor for 

this design would be similar to the existing motor, which is a three-phase electric AC motor but 

would require a greater horsepower rating required by the pump to achieve the desired pressures 

and flow rates. The pump would be one that could provide a maximum of 1000 psi and have a 

flow rate of 15 US gallons per minute (gpm), which as mentioned above would be divided such 

that the coolant/lubrication side would receive approximately 13 gpm and the wash side would 

receive approximately 2 gpm. This system would be as shown in Figure 3.1. 

9


Wash Side 

Figure 3.1 – System Schematic # 1 

The second design that was considered was a system with multiple small rotary vane pumps that 

would have to be mounted in series to achieve the desired pressures. This design was considered 

because it was found that rotary vane pumps are reliable and inexpensive. They are also very 

small in size; therefore, having numerous pumps was assumed to not be a problem for space 

requirements. This design would consist of one motor driving two separate pump systems to 

provide the coolant to the coolant/lubrication side and the wash side separately. The motor 

would again be a three-phase electric AC motor with a horsepower rating to meet the 

requirements of the pumps. Each rotary vane pump would be capable of providing a pressure of 

up to 250 psi and a flow rate of up to 11 gpm. The pumps would have to be placed in series to 

achieve the desired system pressure of 1000 psi. Therefore, with the 250 psi maximum provided 

by each pump, a minimum of four pumps would be required to achieve the 1000 psi for each 

side. The pumps would provide a flow rate of approximately 11 gpm for the coolant/lubrication 

side and approximately 2 gpm for the wash side. A series of pulleys would also be required to 

drive all of the pumps with the one motor. The system is shown in Figure 3.2. 

10 

Coolant Side


Figure 3.2 – System Schematic # 2 

11 

Wash Side Coolant Side


4.0 Selected Design 

The design that has been decided on involves the use of two triplex plunger pumps driven by 

twin 10 Hp electric motors. These pumps will provide highly pressurized flow to two locations 

on the grinding wheel for both wheel lubrication and cleaning purposes. 

4.1 Pump and Motor Options 

4.1.1 Pump Selection 

To determine the required pressures and flow rates of the pumps a series of calculations were 

performed and can be seen in Appendix A. From these calculations it was found that the 

required pressure for the coolant/lubrication side of the system was a maximum of approximately 

1200 psi, and a flow rate of approximately 10 US gallons per minute (gpm). For the wash side 

of the system it was found that a maximum pressure of approximately 3000 psi was required, and 

a maximum flow rate of approximately 5 gpm. In order to achieve these desired pressures and 

flow rates, various pump types were considered for the system. The pumps that were considered 

were: sliding vane (rotary vane) pumps, rotary screw pumps, gear pumps, centrifugal pumps, 

and piston/plunger pumps. The advantages and disadvantages of each pump type were compared 

and the plunger pump was selected as the chosen pump type for this project. A selection chart 

for the pumps can be seen in Table 4.1. 

12


Table 4.1 – Pump Selection Chart 

Pumps 

Pressures 

(psi) 

Flow Rates 

(gal/min) 

Fluid 

Compatibility 

Sliding Vane 100 – 250 1 to 10 water based ~ $400 

Rotary Screw 

low to high 

pressures 

1 to 100 oil > $2000 

Gear Pumps > 1500 1 – 10 oil ~ $200 

Centrifugal < 500 10 – 60 oil & water > $1000 

Piston / Plunger 100 to 5000 1 - 20 oil & water 

4.1.2 Drive Selection 

13 

Cost Selection 

$400 - 

$2000 

-4 pumps required on 

coolant side. 

-12 pumps required on 

wash side. 

-Expensive for system 

specifications. 

-Not suitable for water 

based fluids. 

-Not suitable for water 

based fluids. 

-Too expensive for 

desired pressures. 

-Required rotation in 

excess of 17,000 rpm. 

-Able to obtain 

desired flow rates and 

pressures. 

-Flow rates can be 

changed by changing 

the speed of the 

motor. 

The drive selection was based on the selected pumps. To achieve the desired pressures and flow 

rates with the pumps, the motor would have to output a certain amount of power. It was found 

that to deliver the maximum of 1200 psi with a maximum flow rate of 10 gpm for the coolant 

side, that a 10 hp motor would be required. And to deliver the 3000 psi with a maximum flow 

rate of 5 gpm, that a similar 10 hp motor would also be required. This facilitated the selection, as 

the two motors would be identical. Also, to verify that the motors could deliver enough torque to 

drive each pump, torque vs. speed curves were obtained and created for the motor and pump. 

These curves can be found in Appendix B and it can be seen that the two motor curves had 

torques greater than those of the pumps at the given operating points. It was found that only a 

600-volt power line was available in the lab and therefore, the two motors would have to be 575 

volt.


In order to obtain a variety of flow rates, a variable speed AC controller would be used with each 

motor. This would be a simple controller as it was found that variable speed controllers were 

quite costly. The controller would have a simple potentiometer for user input. This would vary 

the speeds of the motors which in turn varies the flow rates of the pumps. Specifications for this 

controller can be found in Appendix C. 

4.2 Detailed Final Design Specifications 

A Giant P420 (see Appendix C) triplex plunger pump has been selected to supply coolant to the 

grinding zone in order to provide lubrication and cooling. This pump is capable of providing the 

fluid at a rate of approximately 10 gpm at pressures up to 1200 psi. The delivery line from this 

pump will enter the grinding machine and attach to a long straight section of pipe located prior 

the nozzle. This long straight section of pipe should maximize the possibility of achieving fully 

developed flow conditions which are desirable when attempting to attain a coherent jet. 

Turbulence will be minimized in the line by using flexible hosing to eliminate sharp corners, and 

any in-line components will be installed early in the system where possible in order to allow the 

fluid to settle out afterward. The nozzle for this system is likely going to be made out of 

aluminum, and it will be designed to attempt to create a coherent jet that will provide fluid to the 

entire working profile of the grinding wheel. 

The wash system will utilize a Giant P310 (see Appendix C) triplex plunger pump, which will 

provide coolant fluid to clean the surface of the grinding wheel. This pump is capable of 

providing coolant at approximately 5 gpm at pressures of around 3000 psi. This high pressure 

should be capable of removing a significant amount of debris from the surface of the wheel, thus 

reducing wheel wear. The delivery line from this pump will enter the grinding machine and 

introduce fluid perpendicular to the surface of the wheel through a small nozzle, which will 

provide the high pressure spray across the entire working profile of the wheel. 

The two parts of the coolant delivery system will be powered by twin 575 volt, 3-phase AC 

motors, manufactured by Reliance. These motors were chosen in order to be compatible with 

existing 600 volt lines in the lab with minimal electrical work. Each motor provides 10 

horsepower, as is required to achieve the desired pressures with the two selected pumps. Both 

14


motors are totally enclosed and fan-cooled in order to protect them from damage in the event of a 

leak at the pump. These motors will be attached to variable speed controllers which, by varying 

the frequency of input voltage, can be used to adjust the speed of the motors, and thus the flow 

rates in the two systems. Power will be transferred from these motors to the pumps via a dual V- 

belt and pulley arrangement. 

There will be many additional components installed on both the wash-side and the coolant and 

lubrication-side delivery lines. Both lines will be equipped with safety valves immediately 

following the pump outlet. These valves are specified to release pressure before the system 

reaches a critical limit. Pressure unloader valves will be used on each line to throttle off and 

adjust pressures as desired. Any fluid lost through the unloader would travel through the 

attached discharge line and back into the coolant tank. Pressure gages and flow meters are also 

incorporated at several points in this final design in order to give clear visual readings of these 

variables. 

A frame has been designed in order to house the pumps and motors. It is to be constructed out of 

welded 1” box-section steel tubing. Vibration mounts have been incorporated in order to isolate 

any vibration of the pumps and motors from the floor and other laboratory equipment. A steel 

mesh safety cage will enclose the entire frame in order to protect lab occupants from moving 

parts, while still allowing air circulation to cool these powered components. Noise insulation 

may be added to this frame if determined to be necessary during initial testing. 

15


Hose 

Unloade 

Speed Controller 

Flow Meter 

Safety Valve 

Wash Nozzle 

Wash Pump 

Coolant Nozzle 

Pressure Gage Settling Pipe 

Motor 

Coolant Pump 

Figure 4.1 – Final Design Schematic 

Figure 4.2 – Final Design Layout 

16 

Safety 

Valve 

Unloade 

Flow Meter 

Hose


5.0 Project Status 

As the first semester comes to a close, this design project seems to be at a good stage for 

completion on schedule next semester. 

At this point, the desired major system parameters have been determined and major design 

components specified. Many of these components; including pumps, motors, speed controllers, 

drive components and valves, have been ordered from local industrial supplier Kinecor, and 

should arrive mid-December. 

The frame design is complete and the materials will be purchased by mid December to allow for 

construction over the Christmas break. 

Design of the nozzle for the coolant and lubrication side of the system has already begun, and the 

design will be refined throughout December. A final design with a preliminary nozzle opening 

should be complete and ready for manufacturing in January. Further refinements to the nozzle 

opening to achieve improved profile coverage may occur throughout January and February 

depending on time requirements and test results. Design of the nozzle for the wash side will also 

take place throughout December. 

Design of the mounting components for both nozzles is also underway and should be completed 

in December or early January. 

17


6.0 Cost Analysis 

In order to stay within our budget of $10,000, many suppliers were contacted and many quotes 

were received for the major components of the system. It was found that the prices varied quite 

a bit from supplier to supplier. Extensive research was also performed to find the best 

components suitable for our system. Once this was done, the suppliers were contacted and the 

researched components were mentioned. This resulted in a system that was well within our 

budget and would have quality components that would be durable and reliable. The budget can 

be seen in Appendix D, along with the final quote from the chosen supplier in Appendix E. 

It can be seen that after purchasing the major components, a good portion of the budget remains 

for unforeseen circumstances along with materials for our design of several nozzles and any 

required structural components. 

18


7.0 Conclusions 

As a result of our efforts this fall term, we are very confident that our design will work and that 

our requirements will be met. Below is a summary of requirements that are already on their way 

to being met: 

• Current engineering drawings show that the coolant system is going to fit the existing 

grinding machine. 

• Hydraulic hose has been priced, and is rated for pressures high enough for a safety factor 

of 1.6 

• Most coolant system components have been priced. Major equipment (i.e. pumps, motors 

and speed controllers) have been ordered. They are high quality, cost effective 

components. 

• Total estimated cost is currently about $7000, leaving $3000 in the budget for future 

possible upgrades and unforeseen costs. 

• Speed controllers have been ordered to enable flowrate adjustments. This will allow 

experimental research to determine optimal operating parameters and minimize the 

amount of coolant used in the grinding process. 

• Pressure gages have been priced and flow meters are currently being investigated. 

• The attached Gantt Chart shows that the winter schedule has a start-up milestone in early 

March, to enable testing to begin prior to March 21, 2007. 

The Gantt Chart for the Winter Term can be found in Appendix F. Some major parts of our 

project that are to be progressed during the winter term are as follows: 

• Nozzle Design. 

• Fabrication of pump & motor frame. 

• Procurement of remaining system components. 

19


• Coolant system layout - design finalization and installation. 

• System testing and optimization. 

20


8.0 References 

Groover, Mikell P. 2004. Fundamentals of Modern Manufacturing (Hoboken, NJ: John Wiley & 

Sons, Inc.). Chapter 25. 

Irani, Rishad A. 2006. Dual Cutting Fluid Application in the Grinding Process (Halifax, NS: 

Dalhousie University). 

Steffen, Joachim K. 2004. Application of a Coherent Jet Coolant System in Creep-Feed Grinding 

of Inconel 718 (Halifax, NS: Dalhousie University). 

21


APPENDIX A – Calculations 

22

Pressure Calculations: 

⎛ P 

⎜ + 

⎝ ρg 

2 

V ⎞ ⎛ P 

+ z 

g ⎟ = ⎜ 

2 ⎠ ⎝ ρg 

1 

2 

V ⎞ 

+ + z 

g ⎟ 

2 ⎠ 

2 

− h 

pump 

+ h 

2 1000 2 

P = V = × 60 = 1800kPa 

≈ 260 psi 

2 2 

ρ 

2 1000 2 

P = V = × 130 = 8450kPa 

≈ 1200 psi 

2 2 

ρ 

Pressure Loss Calculations: 

2 

2 

⎛ P V ⎞ ⎛ P V ⎞ 

⎜ + α + z 

z + h f 

g g ⎟ = ⎜ + α + 

g g ⎟ 

⎝ ρ 2 ⎠ ⎝ ρ 2 ⎠ 

1 

Vd 

Re = 

ν 

⎟ 2 ⎛ L V ⎞ 

ΔP 

= ρ gh = ⎜ 

f ρg 

f 

⎝ D 2g 

⎠ 

Q = VA 

V 

= 

Q 

A 

−5 

10 × 6. 

309× 

10 

= 

= 2. 

2135m 

/ s 

2 

× 0. 

01905 

( π / 4) 

Vd 2. 

2135× 

0. 

01905 

Re = = 

≈ 42000 

−6 

ν 1. 

005× 

10 

ε 0. 

046 

ε = 0 . 046mm 

→ = = 

d 19. 

05 

f = 0. 

053 from Moody Chart 

0. 

0024 

2 

friction 

α = 1. 

0 for turbulent flow 

TURBULENT FLOW 

2 

⎛ 10 2. 

2135 ⎞ 

Δ P = 1000× 

9. 

81× 

⎜ 

⎜0. 

053× 

× ≈ 6. 

8kPa 

≈ 1psi 

0. 

01905 2 9. 

81 ⎟ 

⎝ 

× ⎠ 

2 

V ⎛ L ⎞ 

ΔP = ρ g ⎜ f + ∑ K ⎟ 

2g 

⎝ D ⎠ 

Say K = 20 (tees, fittings, etc.) 

2 

2. 

2135 ⎛ 10 ⎞ 

Δ 

P = 1000 × × ⎜0. 

053× 

+ 20⎟ 

≈ 117kPa 

≈ 17 psi 

2 ⎝ 0. 

01905 ⎠


APPENDIX B – Pump-Motor Curves 

24

Torque (lb*ft) 

80 

70 

60 

50 

40 

30 

20 

10 

0 

Wash Pump Curve 

0 200 400 600 800 1000 1200 1400 1600 1800 2000 

Angular Velocity (rpm) 

Motor 1000 psi 1500 psi 2000 psi 3000 psi 3500 psi

Torque (lb*ft) 

80 

70 

60 

50 

40 

30 

20 

10 

0 

Coolant Pump Curve 

0 200 400 600 800 1000 1200 1400 1600 1800 2000 

Angular Velocity (rpm) 

Motor 1000 psi 1500 psi 2200 psi 2500 psi 3000 psi


APPENDIX C – Equipment Specifications 

27

Series 

P300 

Updated 5/03 

Triplex Ceramic 

Plunger Pump 

Operating Instructions/ 

Repair and Service 

Manual 

For Models: 

P313 

P314 

P316 

P317 

P318 

P319 

P340 

Contents: 

Installation Instructions: page 2 

Pump Specifications: pages 3-7, 10 

Exploded View: page 8 

Parts List: page 9 

Kits/Torque Specifications: page 11 

Pump Mounting Selection 

Guide: page 11 

Trouble Shooting: page 12 

Recommended Spare 


Repair Instructions: pages 13-14 

Dimensions/Warranty Info: back page

P316 HORSEPOWER REQUIREMENTS 

RPM GPM 1000 

PSI 

1500 

PSI 

2000 

PSI 

2500 

PSI 

3000 

PSI 

3500 

PSI* 

745 2.0 1.4 2.1 2.8 3.4 4.1 4.8 

1025 2.7 1.9 2.8 3.8 4.7 5.7 6.6 

1340 3.6 2.5 3.7 5.0 6.2 7.4 8.7 

1450 3.9 2.7 4.0 5.4 6.7 8.0 9.4 

1750 4.7 3.2 4.9 6.5 8.1 9.7 

*Intermittent duty 

Specifications 

Model P316 

U.S. (Metric) 

1450 RPM 

Ratings (Continuous) ...................................... 3.9 GPM @ 3000 PSI ...... (14.8 LPM @ 200 bar) 

Ratings (Intermittent) ..................................... 3.9 GPM @ 3500 PSI ...... (14.8 LPM @ 240 bar) 

1750 RPM 

Ratings (Continuous) ...................................... 4.7 GPM @ 2500 PSI ...... (17.8 LPM @ 175 bar) 

Ratings (Intermittent) ..................................... 4.7 GPM @ 3000 PSI ...... (17.8 LPM @ 200 bar) 

Inlet Pressure .................................................. 140 PSI............................. (10 bar) 

Stroke.............................................................. 0.55”................................. 14.1mm 

Plunger Diameter ............................................ 0.71”................................. 18mm 

Temperature of Pumped Fluids ...................... Up to 160 o F ..................... (71 o C) 

Inlet Ports................................................................................................... (2) 1/2" BSP 

Discharge Ports .......................................................................................... (2) 3/8" BSP 

Shaft Rotation ............................................................................................ Top of pulley towards manifold 

Crankshaft Diameter .................................................................................. 24mm 

Key Width.................................................................................................. 8mm 

Shaft Mounting .......................................................................................... Either side 2 

Weight ............................................................. 16 lbs. ............................... (7.26 kg) 

Crankcase Oil Capacity .................................. 14.2 fl.oz. ......................... (0.42 liters) 

Extended Crankcase Oil Capacity .................. 17 fl. oz. ........................... (0.5 liters) 

NPSHR (@ 1450 RPM) ............................................................................ 19.0 ft of water - 5.8 mW 

Consult the factory for special requirements that must be met if the pump is 

to operate beyond one or more of the limits specified above. 

4 

HORSEPOWER RATINGS: 

The rating shown are the power 

requirements for the pump. Gas 

engine power outputs must be 

approximately twice the pump 

power requirements shown above. 

We recommend a 1.15 service factor 

be specified when selecting an 

electric motor as the power source. 

To compute specific pump horse 

power requirements, use the 

following formula: 

HP = (GPM X PSI) / 1450 

SPECIAL NOTE: 

The theoretical gallons per revolution 

(gal/rev) is 0.00268. 

To find specific outputs at various RPM, 

use the formula: GPM = 0.00268 x RPM

Exploded View - P300 Series 

8 

+ Not present in P340 Pumps

P300 SERIES PARTS LIST 

A = P313 B = P314 C = P316 D = P317 E = P318 F = P340 G = P319 

ITEM PART NO. DESCRIPTION QTY. 

1 08326 Crankcase 1 

2 06773 Dipstick Assembly 1 

3 08410B Crankcase Cover, Short 1 

3 08410-LG Crankcase Cover, Extended 1 

3A 07190 Oil Drain Plug 1 

3B 13262 Gasket for Plug 1 

4 08328 O-Ring 1 

5 06273 Oil Drain Plug 1 

5A 08192 Gasket 1 

6 07188 Screw, Short Cover 4 

6A 01176-2 Spring Washer 4 

6B 01196 Screw, Long Cover 4 

7 08303 Bearing Cover I (A, B, G) 1 

7 08303 Bearing Cover I (C, D, E, F) 2 

8 08330 Bearing Cover II (A, B, G) 1 

8 08491 Sight Glass (C, D, E, F) 1 

9 07193 O-Ring 1 

10 07225 Screw with Lock Washer 8 

11 08331 Radial Shaft Seal 1 

12 01086 Ball Bearing (A, C, D, E, G) 2 

12 01086 Ball Bearing (B, F) 1 

12A 07760 Roller Bearing (B, F) 1 

13 08332 Crankshaft (A, B, C, F) 1 

13 08478 Crankshaft (D) 1 

13 08340 Crankshaft (E) 1 

13 06508 Crankshaft (G) 1 

14 06207 Straight Key 1 

15 08333 Connecting Rod 3 

16 08413 Plunger Assembly Complete, 

12mm (A,B) 3 


18mm (C, D, G) 3 


20mm (E) 3 

16 06540 Plunger Assembly, 16mm (F) 3 

16A 08367 Plunger Base (C, D, E, F, G) 3 

16B 08455 Plunger Pipe (C, D, G) 3 

16B 08449 Plunger Pipe (E) 3 

16B 06541 Plunger Pipe (F) 3 

16C 08456 Tension Screw (C, D, F, G) 3 

16C 08450 Inner Hex Screw (E) 3 

16D 07676 Copper Washer (C, D, F, G) 3 

16D 08451 Copper Washer (E) 3 

17 06542 Wrist Pin 3 

17A 22723 Clip Ring 6 

ITEM PART NO. DESCRIPTION QTY. 

18 07770 O-Ring (C, D, E, F, G) 3 

19 08356-0010 Oil Seal 3 

20 08414 Seal Case (A, B) 3 

20 08458 Seal Case (C, D, G) 3 

20 08357 Seal Case (E) 3 

20 06543 Seal Case (F) 3 

21 07234 O-Ring (A, B) 3 

21 07780 O-Ring (C, D, E, F, G) 3 

22 12027 O-Ring 3 

23 07391 Grooved Seal Ring (A, B) 3 

23 08477 V-Sleeve (C, D, G) 3 

23 08358 Grooved Seal (E), Black 6 

23 07767 Grooved Seal (F) 3 

23A 08598 Grooved Seal (A, B) 3 

23A 08087 Grooved Seal (C, D, G), Brown 3 

23A 08359 Spacer (E) 3 

23A 06315 Grooved Seal (F) 3 

24 07392 Pressure Ring (A, B) 3 

24 07904 Pressure Ring (C, D, G) 6 

24 08346 Pressure Ring (E) 3 

24 07768 Pressure Ring (F) 3 

25 08417 Weep Return Ring (A, B) 3 

25 08337 Weep Return Ring (C, D, G) 3 

25 08361 Weep Return Ring (E) 3 

25 06544 Weep Return Ring (F) 3 

26 06556 Valve Casing (A, B) 1 

26 06349* Valve Casing (C, D, G) 1 

26 06413* Valve Casing (E) 1 

26 06545 Valve Casing (F) 1 

27 07849 Valve Seat 6 

28 07491 Valve Plate 6 

29 07906 Valve Spring 6 

30 07907 Valve Spring Retainer 6 

31 07853 O-Ring 6 

32 06350* Valve Plug (C, D, E, G) 6 

32 06546 Valve Plug (A, B, F) 6 

32X 07946 Valve Assembly, Complete 6 

33 07913 O-Ring 6 

34 08363 Hex Head Cap Screw 6 

36 13338 Plug, 3/8" BSP l 

36A 08486 Copper Crush Washer, 3/8” 1 

37 07109 Plug, 1/2" BSP 1 

37A 07661 Seal 1 

*For P316/P317 pumps manufacturerd prior to 5/98, Item 26=08459 & Item 32=07928;for P318 pumps manufacture 

prior to 5/98, Item 26=08362 & Item 32=07928 

9

PUMP SYSTEM MALFUNCTION 

MALFUNCTION CAUSE REMEDY 

The Pressure and/ Worn packing seals Replace packing seals 

or the Delivery Broken valve spring Replace spring 

Drops Belt slippage Tighten or Replace belt 

Worn or Damaged nozzle Replace nozzle 

Fouled discharge valve Clean valve assembly 

Fouled inlet strainer Clean strainer 

Worn or Damaged hose Repair/Replace hose 

Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts 

Cavitation Check suction lines on inlet of 

pump for restrictions 

Unloader Check for proper operation 

Water in crankcase High humidity Reduce oil change interval 

Worn seals Replace seals 

Noisy Operation Worn bearings Replace bearings, Refill crankcase 

oil with recommended lubricant 

Cavitation Check inlet lines for restrictions 

and/or proper sizing 

Rough/Pulsating Worn packing Replace packing 

Operation with Inlet restriction Check system for stoppage, air 

Pressure Drop leaks, correctly sized inlet 

plumbing to pump 

Accumulator pressure Recharge/Replace accumulator 

Unloader Check for proper operation 

Cavitation Check inlet lines for restrictions 

and/or proper size 

Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Flow 

Rated, Pressure Rate of Pump 

Drop at Gun 

Excessive Worn plungers Replace plungers 

Leakage Worn packing/seals Adjust or Replace packing seals 

Excessive vacuum Reduce suction vacuum 

Cracked plungers Replace plungers 

Inlet pressure too high Reduce inlet pressure 

High Crankcase Wrong Grade of oil Giant oil is recommended 

Temperature Improper amount of oil in crankcase Adjust oil level to proper amount 

Preventative Maintenance Check-List & Recommended Spare Parts List 

Check Daily Weekly 50hrs Every Every Every 

500 hrs 1500 hrs 3000 hrs 

Oil Level/Quality X 

Oil Leaks X 

Water Leaks X 

Belts, Pulley X 

Plumbing X 

Recommended Spare Parts 

Oil Change (1 Quart) p/n 1153 X X 

Seal Spare Parts (1 kit/pump) X 

(See page 11 for kit list) 

Oil Seal Kit (1 kit/pump) X 

(See page 11 for kit lit) 

Valve Spare Parts (1 kit/pump) X 

(See page 11 for kit list) 

12

P300 SERIES DIMENSIONS - INCHES (mm) 

GIANT INDUSTRIES LIMITED WARRANTY 

Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from 

defects in workmanship and material as follows: 

1. For portable pressure washers and self-serve car wash applications, the discharge 

manifolds will never fail, period. If they ever fail, we will replace them free of charge. 

Our other pump parts, used in portable pressure washers and in car wash applications, 

are warranted for five years from the date of shipment for all pumps used in NON- 

SALINE, clean water applications. 

2. One (1) year from the date of shipment for all other Giant industrial and consumer 

pumps. 

3. Six (6) months from the date of shipment for all rebuilt pumps. 

4. Ninety (90) days from the date of shipment for all Giant accessories. 

This warranty is limited to repair or replacement of pumps and accessories of which 

the manufacturer’s evaluation shows were defective at the time of shipment by the manufacturer. 

The following items are NOT covered or will void the warranty: 

1. Defects caused by negligence or fault of the buyer or third party. 

2. Normal wear and tear to standard wear parts. 

3. Use of repair parts other than those manufactured or authorized by Giant. 

4. Improper use of the product as a component part. 

5. Changes or modifications made by the customer or third party. 

6. The operation of pumps and or accessories exceeding the specifications set forth 

in the Operations Manuals provided by Giant Industries, Inc. 

Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those 

products returned freight prepaid to Giant Industries which are deemed to be defective due to 

workmanship or failure of material. A Returned Goods Authorization (R.G.A.) number and completed 

warranty evaluation form is required prior to the return to Giant Industries of all products under 

warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A. number. 

Repair or replacement of defective products as provided is the sole and exclusive remedy provided 

hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, 

OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR 

INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT. 

THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR 

REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR- 

RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH 

WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER. 

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607 

PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com 

© Copyright 2003 Giant Industries, Inc. 

5/03 P300.PM6

Series 

P400A 

Updated 1/05 

Triplex Ceramic 

Plunger Pump 

Operating Instructions/ 

Repair and Service 

Manual 

For Models: 

P420 

P422 

P423 

P425 

P430 

P440 

P450 

P455 

Contents: 

Installation Instructions: page 2 

Pump Specifications: pages 3-9 

Parts List/Torque Specs: page 10 

Exploded View/Kits: page 11 

Repair Instructions: pages 12-13 

Trouble Shooting Chart: page 14 

Recommended Spare 


Dimensions: page 15 

Warranty Information back page

NOTES: 

Consult the factory for special requirements that must be met if the pump is 

to operate beyond one or more of the limits specified above. 

In order to drive the pump from the side opposite the present shaft 

extension, simply remove the valve casing from the crankcase and 

rotate the pumps 180 degrees to the desired position. Be certain to 

rotate the seal case (item #20) as well, so that the weep holes are 

down at the six o'clock position. Exchange the oil fill and the oil 

drain plugs, also. Refer to the repair instructions as necessary for 

the proper assembly sequence. 

SPECIAL NOTE: 

The theoretical gallons per revolution 

(gal/rev) is 0.0069. 

To find specific outputs at various RPM, 

use the formula: GPM = 0.0069 x RPM 

Specifications 

Model P422 

U.S. (Metric) 

Volume ........................................................... Up to 10.7 GPM ....... (37.85 LPM) 

Discharge Pressure Continuous ...................... Up to 2200 PSI ......... (151.6 bar) 

Discharge Pressure Intermittent ..................... Up to 3000 PSI ......... (206.8 bar) 

Inlet Pressure .................................................. -4.35 to 145 PSI ....... (-.3 to 10 bar) 

Stroke.............................................................. 0.945”....................... (24mm) 

RPM ................................................................................................... Up to 1450 RPM 

Plunger Diameter ............................................ 0.866”....................... (22mm) 

Temperature of Pumped Fluids ...................... Up to 160 o F ............. (71 o C) 

Inlet Ports........................................................................................... (2) 1" NPT 

Discharge Ports.................................................................................. (2) 3/4" NPT 

Shaft Rotation ................................................. Top of pulley towards manifold 

Crankshaft Diameter ....................................... 1.102”....................... (28mm) 

Key Width ...................................................... 315”.......................... (8mm) 

Shaft Mounting .................................................................................. Either side 1 

Weight ............................................................ 36 lbs. 11oz .............. (16.64 kg) 

CrankcaseCapacity ......................................... 30 fl.oz. .................... (0.89 liters) 

Volumetric Efficiency @ 1450.......................................................... (0.95) 

Mechanical Efficiency @ 1450 ......................................................... (0.83) 

P422 HORSEPOWER REQUIREMENTS 

RPM GPM 1000 PSI 1500 PSI 2200 PSI 2500 PSI 3000 PSI 

900 6.2 4.3 6.4 9.3 10.7 12.8 

1050 7.2 5.0 7.4 10.8 12.4 14.9 

1160 8.0 5.5 8.3 12.1 13.8 16.6 

1300 8.9 6.1 9.2 13.4 15.3 18.4 

1450 10.0 6.9 10.3 15.1 17.2 20.7 

*Intermitent duty only* 

4 

HORSEPOWER RATINGS: 

The rating shown are the power 

requirements for the pump. Gas 

engine power outputs must be 

approximately twice the pump 

power requirements shown above. 

We recommend a 1.15 service factor 

be specified when selecting an 

electric motor as the power source. 

To compute specific pump horse 

power requirements, use the 

following formula: 

HP = (GPM X PSI) / 1450

ITEM PART DESCRIPTION QTY. 

1 08377 Crankcase 1 

2 08378 Oil Fill Plug with Gasket 1 

3 06479 Crankcase cover 1 

3A 07186 Oil Sight Glass w/ Gasket 1 

4 08380 O-Ring 1 

5 07606 Oil Drain Plug 1 

5A 07182 Gasket for Oil Drain Plug 1 

5B 08092 Plug with Gasket 1 

6 01010 Screw 4 

6A 01011 Spring Washer 4 

7 08471 Bearing Cover Open 1 

8 08472 Bearing Cover Closed 1 

8A 06245 Shim 1 

8B 06330 Shim (May not be present) 1 

9 01016 O-Ring 2 

10 07114 Screw with Washer 8 

11 07459 Radial Shaft Seal 1 

12 08473 Bearing 1 

12A 08474 Bearing 1 

13 08475 Crankshaft (A,B,C) 1 

13 08482 Crankshaft (D,E,F,G,H) 1 

14 08091 Fitting Key 1 

15 08390 Connecting Rod Assembly 3 

15A 07311 Screw with Washer 6 

16 06622 Plunger Assy., 18mm (C,F) 3 

16 08391 Plunger Assy., 25mm, (A, H) 

For items 16A-16H 3 

16 06246 Plunger Assy., 22mm, (B,G) 


16 06622 Plunger Assy., 18mm, (F) 


16 08383 Plunger Assy.,18mm (C,D,E) 


16A 08384 Plunger Base 3 

16B 08398 Plunger Pipe, 25mm (A, H) 3 

16B 06247 Plunger Pipe, 22mm (B,G) 3 

16B 08397 Plunger Pipe, 18mm (C,D,E,F) 3 

16C 07256 Centering Sleeve 3 

16D 08399 Tensioning Screwing 3 

16E 07023 O-Ring 3 

16F 07203 Backup Ring 3 

16G 07258 Copper Washer (A,B,C,D,E,G,H) 3 

16G 07676 Copper Washer (F) 3 

16H 06431 Oil Scraper 3 

17 06790 Crosshead Pin 3 

19 08366 Oil Seal 3 

20 06771 Seal Case (A, H) 3 

20 06770 Seal Case (B,G) 3 

P400A SERIES PARTS LIST 

A=P420 B= P422 C=P430 D=P440 E=P450 F=P455 G=P423 H=P425 

P400A SERIES TORQUE SPECIFICATIONS 

Position Item# Description U.S Metric 

15A 07311 Screw with Washer 216 in.-lbs. 24.4 N-M 

16D 08399 Tensioning Screw 240 in.-lbs. 27.1 N-M 

32 08373 Plug (P420, P422, P423, P425) 125 ft.-lbs. 169.4 N-M 

32 06624 Plug (P455) 125 ft.-lbs. 169.4 N-M 

32 08406 Plug (P430, P440, P450) 110 ft.-lbs. 149.1 N-M 

34 08396/08484 Cap Screw 35 ft.-lbs. 47.5 N-M 

10 

ITEM PART DESCRIPTION QTY. 

20 06443 Seal Case (C,D,E,F) 3 

20A 06772 Gear Seal Adapter 3 

21 07266 O-Ring 3 

22 08059 O-Ring 3 

23 12254 V-Sleeve, 25mm (A,H) 

23 06249 V-Sleeve with Support Ring, 3 

22mm (B,G) 

23 08477 V-Sleeve, 18mm (C,D,E,F) 6 

23A 06251 Spacer Ring (B,G) 3 

23B 12255 Weep Seal (A,H) 3 

23B 13390 Weep Seal with Support Ring (B,G) 3 

24 08376 Pressure Ring (A,H) 6 

24 06252 Pressure Ring (B,G) 3 

24 07929 Pressure Ring (C,D,E,F) 3 

25 08394 Weep Return Ring (A,H) 3 

25 06254 Weep Return Ring (B,G) 3 

25 08402 Weep Return Ring (C,D,E,F) 3 

26 08395 Manifold (A,H) - Brass 1 

26 06255 Manifold (B,G) - Brass 1 

26 08409 Manifold (C) - Brass 1 

26 08403 Manifold (D) - Bronze 1 

26 08470 Aluminum Bronze (E) 1 

26 06623 Manifold (F) 1 

27A 08408 Valve Assy. (A,B,G,H) 6 

27A 06810 Valve Assy. (C,D,E,F) 6 

27 08370 Valve Seat (A,B,G,H) 6 

27 08404 Valve Seat (C,D,E,F) 6 

28 06791 Valve Plate (A,B,G,H) 6 

28 06809 Valve Plate (C,D,E,F) 6 

29 06377 Valve Spring (A,B,G,H) 6 

29 07906 Valve Spring (C,D,E,F) 6 

30 08372 Valve Spring Retainer (A,B,G,H) 6 

30 07907 Valve Spring Retainer (C,D,E,F) 6 

31 07212 O-Ring (A,B,G,H) 6 

31 07770 O-Ring (C,D,E,F) 6 

32 08373 Plug (A,B,G,H) 6 

32 06624 Plug (F) 6 

32 08406 Plug (C,D,E) 6 

33 07214 O-Ring (A,B,G,H) 6 

33 06487 O-Ring (F) 6 

33 07489 O-Ring (C,D,E) 6 

34 08396 Cap Screw (A,B,C,D,E,G,H) 8 

34 08484 Cap Screw (F) 8 

36 12250 Plug, 1/2" BSP (E,F Only) 2 

36A 06272 O-Ring (E,F Only) 2 

37 07703 Plug, G 3/4" (C,D Only) 1 

37A 07704 Copper Gasket (C,D Only) 1

Exploded View - P400A Series 

P420 ONLY 

Plunger Packing Kits 

P420, P425 # 09140 

Item Part # Description Qty 

21 07266 O-Ring 3 

22 08059 O-Ring 3 

23 12254 V-Sleeve 3 

23B 12255 Weep Seal 3 

24 08376 Pressure Ring 6 

P422, P423 # 09295 


21 07266 O-Ring 3 

22 08059 O-Ring 3 

23 06249 V-Sleeve with Support Ring 3 

23B 13390 Weep Seal 3 


P430, P440, P450, P455 # 09141 


21 07266 O-Ring 3 

22 08059 O-Ring 3 

23 08477 V-Sleeve 6 


P400A SERIES REPAIR KITS 

11 

* 

* 

(P422 & 423 ONLY) 

* P422 & P423 ONLY 

** This is item 37 for P430, P440 only 

+ This is item 37A for P430, P440 only 

Valve Assembly Kits 

P420, P422, P423, P425 # 09143 

Item Part # Description Qty. 

27A 08408 Valve Assembly, Complete 6 

33 07214 O-Ring 6 

P430, P440, P450, P455 # 09142 


27A 06810 Valve Assembly, Complete 6 

33 06487 O-Ring (P455 only) 6 

33 07489 O-Ring (except P455) 6 

Oil Seal Kit 

P400 Series # 09306 


19 08366 Oil Seal 3 

Optional Viton Seal Kit 

P430, P440, P450, P455 # 09456 


23 07902-0010 V-Sleeve 6 

w/support ring, Viton 

24 07904 Pressure Ring 6

P400A SERIES DIMENSIONS - Inches (mm) 

15

GIANT INDUSTRIES LIMITED WARRANTY 

Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from 

defects in workmanship and material as follows: 

1. For portable pressure washers and self-service car wash applications, the discharge 

manifolds will never fail, period. If they ever fail, we will replace them free of charge. 

Our other pump parts, used in portable pressure washers and in car wash applications, 

are warranted for five years from the date of shipment for all pumps used in NON- 

SALINE, clean water applications. 

2. One (1) year from the date of shipment for all other Giant industrial and consumer 

pumps. 

3. Six (6) months from the date of shipment for all rebuilt pumps. 

4. Ninety (90) days from the date of shipment for all Giant accessories. 

This warranty is limited to repair or replacement of pumps and accessories of which the manufacturer’s 

evaluation shows were defective at the time of shipment by the manufacturer. The following items 

are NOT covered or will void the warranty: 

1. Defects caused by negligence or fault of the buyer or third party. 

2. Normal wear and tear to standard wear parts. 

3. Use of repair parts other than those manufactured or authorized by Giant. 

4. Improper use of the product as a component part. 

5. Changes or modifications made by the customer or third party. 

6. The operation of pumps and or accessories exceeding the specifications set forth 

in the Operations Manuals provided by Giant Industries, Inc. 

Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those 

products returned freight prepaid to Giant Industries which are deemed to be defective due to 

workmanship or failure of material. A Returned Goods Authorization (R.G.A.) number and completed 

warranty evaluation form is required prior to the return to Giant Industries of all products under 

warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A. number. 

Repair or replacement of defective products as provided is the sole and exclusive remedy provided 

hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, 

OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR 

INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT. 

THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR 

REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR- 

RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH 

WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER. 

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607 

PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com 

© Copyright 2001 Giant Industries, Inc. 1/05 P400.PM6

575 Volt Motors 

575V Standard Motors - Sabre / Calibre / XE 

Totally Enclosed - IP44 

Electrical Characteristics 

Phase: 3 Duty Cycle: Continuous 

Frequency: 60 Hz Insulation: Class F 

Ambient: 40° C Temp. Rise: Class B 

Service Factor: 1.15 

Application Information: 

Designed for all general purpose industrial applications in a dusty, dirty 

and/or humid environment. Enclosed motors reduce the exchange of air 

between the inside and the outside of the motor. 

Key Information 

Construction Features 

48 - 140T Frames 

Materials: Steel frame, conduit box, and fan shroud; cast aluminum end shields. 

Shaded ratings have cast iron frames and end shields: steel conduit box 

and fan shroud. 

Conduit Box: Oversized, top mounted with F1 & F2 lead outlets 

Bearing Type: Double shielded ball bearings 

Bearing Protection: Permanently lubricated with moisture resistant grease 

Shaft Material: High strength carbon steel 

Nameplate Material: Adhesive Mylar. Shaded ratings - Stainless Steel 

Drain Type & Location: Weep hole in both end shields 

Additional Features: XE motors with a (♦) are inverter duty 575 volt and below. 

Motor insulation is rated 1800 volts on 575 volt motors per NEMA MG1 

part 31.40.4.2 

180T- 449T 

Frames 

Materials: Calibre: Cast iron frame and endshields , steel conduit box and fan shroud 

(180-280) . Cast iron fan shroud and conduit box (320-440) 

XE: Cast Iron frame and end shields; steel fan shroud and conduit box 

Conduit Box: F1 location, diagonally split, rotatable in 90 degree increments 

Bearing Type: Permanently lubricated, single shielded ball bearings (180T-210T frames); 

re-greasable, ball bearings with PLS (250T-449T frames). 

Bearing Protection: Shaft slinger on drive end 

Shaft Material: High strength carbon steel 

Nameplate Material: Stainless steel 

Drain Type & Location: Weep holes in both end shields 

Additional Features: Calibre and XE motors with a (♦) are inverter duty 575 volt and below. 

Motor insulation is rated 1800 volts on 575 volt motors per NEMA MG1 

part 31.40.4.2 

For additional product information, go to www.reliance.com 

Definitions: 

Sabre = Steel frame Motors that meet or exceed EPAct Efficiency 

levels 

Calibre = Cast Iron frame Motors that meet or exceed EPAct 

Efficiency levels 

XE = Premium Efficient motors that meet or exceed NEMA Premium 

efficiency levels 

Warranty (From Date Of Manufacture / From Date Of Installation): 

Standard/ Sabre/Calibre(24 / 12), XE (36 / 24) 

Nameplate Agency Approvals: 

CE, CSA, UL (UR) 

M-97 

Explosion Proof Washdown Duty Single Phase Brake Motor 575 Volt IEC

575 Volt Motors 

575V Standard Motors - Sabre / Calibre / XE 

Totally Enclosed - IP44 

Foot Mounted 1/3 - 350 HP con’t 

HP 

Synch 

RPM 

Voltage Frame Enclosure Product 

Efficiency 

Standard 

Model 

Number 

List 

Price 

Price 

Symbol 

“C” 

Dim. 

Eff. @ 

Full Load 

Notes 

Approx. 

Wt. (lb) 

3600 575 215T TEFC CALIBRE EPAct ♦ P21G4923 c $875 RTT20 19.43 89.5 7,9 185 

3600 575 215T TEFC CALIBRE EPAct ♦ P21G4503 875 RTT20 19.25 89.5 185 

3600 575 215T TEFC XE NEMA Prem ♦ P21G3821 1,265 RXE20 19.25 91 180 

1800 575 215T TEFC CALIBRE EPAct ♦ P21G4921 c 784 RTT20 19.43 89.5 7,9 185 

10 1800 575 215T TEFC CALIBRE EPAct ♦ P21G4553 784 RTT20 19.25 89.5 185 

1800 575 L215T TEFC XE NEMA Prem ♦ P21G3823 1,131 RXE20 20.12 91.7 180 

1200 575 256T TEFC CALIBRE EPAct ♦ P25G4921 c 1,716 RTT20 25.1 89.5 7,9 315 

1200 575 256T TEFC CALIBRE EPAct ♦ P25G4653 1,716 RTT20 24.56 89.5 315 




3600 575 254T TEFC XE NEMA Prem ♦ P25G413 2,012 RXE20 24.56 91.7 280 

1800 575 254T TEFC CALIBRE EPAct ♦ P25G4922 c 1,176 RTT20 23.4 91 7,9 280 

15 1800 575 254T TEFC CALIBRE EPAct ♦ P25G4552 1,176 RTT20 24.56 91 280 









20 1800 575 256T TEFC CALIBRE EPAct ♦ P25G4553 1,443 RTT20 24.56 91 315 





3600 575 284TS TEFC CALIBRE EPAct ♦ P28G4922 c 1,864 RTT20 25.53 91 7,9 380 

3600 575 284TS TEFC CALIBRE EPAct ♦ P28G4504 1,864 RTT20 26.06 91 380 

3600 575 284TS TEFC XE NEMA Prem ♦ P28G403 2,716 RXE20 26.06 93 378 


25 1800 575 284T TEFC CALIBRE EPAct ♦ P28G4552 1,777 RTT20 27.44 92.4 380 





3600 575 286TS TEFC CALIBRE EPAct ♦ P28G4923 c 2,229 RTT20 27.03 91 7,9 415 

3600 575 286TS TEFC CALIBRE EPAct ♦ P28G4505 2,229 RTT20 26.06 91 415 

3600 575 286TS TEFC XE NEMA Prem ♦ P28G404 3,123 RXE20 26.06 93 413 


30 1800 575 286T TEFC CALIBRE EPAct ♦ P28G4553 2,110 RTT20 27.44 92.4 415 





3600 575 324TS TEFC CALIBRE EPAct ♦ P32G4922 c 2,786 RTT20 26.32 91.7 7,9 490 

3600 575 324TS TEFC XE NEMA Prem ♦ P32G403 3,763 RXE20 28.94 94.1 487 

3600 575 324TS TEFC CALIBRE EPAct ♦ P32G4504 2,786 RTT20 28.94 91.7 586 


40 1800 575 324T TEFC XE NEMA Prem ♦ P32G3381 3,729 RXE20 30.44 94.1 490 

1800 575 324T TEFC CALIBRE EPAct ♦ P32G4552 2,760 RTT20 33.44 93 580 



1200 575 364T TEFC CALIBRE EPAct ♦ P36G4654 4,841 RTT20 33.44 93 800 

♦ - Inverter Duty. See page M-273 

Cast Iron Frame 

CC049A – “EPAct” and “NEMA Prem” model numbers without suffixes 

CC019A – model numbers with suffix 

For additional product information, go to www.reliance.com 

M-99 

Explosion Proof Washdown Duty Single Phase Brake Motor 575 Volt IEC

xt 

REL. 

S.O. 

AMPS DUTY 

215T 10 P 3/60 1750 575 

9.76 CONT 40/F 1.15 B G FCEM 

E/S ROTOR 

FRAME HP TYPE 

AMB C/ 

INSUL. 

544998 418425-43FE --- --- 2.12 

0 2.8 1800 9.13 0 

2.50 3.6 1789 60.0 86.8 

5.01 5.2 1777 79.6 90.5 

7.50 7.3 1764 84.7 90.6 

10.0 9.8 1749 85.8 89.5 

12.5 12.5 1732 85.6 87.8 

TORQUE 

LB.-FT. 

0 192 57.6 59.3 

0 192 57.6 59.3 

1500 253 76.0 36.0 

1749 100 30.0 9.8 

AMPERES SHOWN FOR 575. VOLT CONNECTION. IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE, THE 

AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE 

S.F. 

TEST 

S.O. 

PERFORMANCE 

LOAD HP AMPERES RPM 

NO LOAD 

1/4 

2/4 

3/4 

4/4 

5/4 

LOCKED ROTOR 

PULL UP 

BREAKDOWN 

FULL LOAD 

REMARKS: 

Rockwell 

Automation 

SPEED TORQUE 

RPM 

TYPICAL DATA 

E-MASTER MOTOR - NEMA NOM. EFF. 89.5% 

DR. BY 

CK. BY 

APP. BY 

DATE 

PHASE/ 

HERTZ 

NEMA 

DESIGN 

TORQUE 

% FULL LOAD 

TEST 

DATE 

A-C MOTOR 

RPM VOLTS 

CODE 

LETTER 

% 

POWER FACTOR 

ENCL. 

STATOR RES.@25 C 

OHMS (BETWEEN LINES) 

% 

EFFICIENCY 

AMPERES 

P.B. GREENE 

W.L. SMITH 

W.L. SMITH PERFORMANCE E02263-A-A002 

11/03/98 ISSUE DATE 11/03/98 

DATA 

Printed on 10/22/04 16:57 @ rgg

xt 

RPM 1750 S.F. 1.15 ROTOR 418425-43FE 

215T VOLTS 575 NEMA DESIGN B TEST S.O. TYPICAL DATA 

10 AMPS 9.76 CODE LETTER G TEST DATE --- 

P DUTY CONT ENCLOSURE FCEM STATOR RES.@ 25 C 2.12 

3/60 AMB C/INSUL 40/F E/S 544998 

REL S.O. 

FRAME 

HP 

TYPE 

PHASE/HERTZ 

1720 1730 1740 1750 1760 1770 1780 1790 1800 

SPEED IN RPM (4) 

0 20 40 60 80 100 120 

TORQUE IN LB. FT. (2) 

0 20 40 60 80 100 

P.F.(2) & EFF.(3) IN % 

0 20 40 60 80 100 120 

AMPS AT 575 VOLTS (1) 

0 2 4 6 8 10 12 14 16 

AMPS AT 575 VOLTS (1) 

AMPERES SHOWN FOR 575 VOLT CONNECTION, IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE, THE 

AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE. 

Rockwell 

Automation 

4 

2 

3 

E-MASTER MOTOR - NEMA NOM. EFF. 89.5% 

0 200 400 600 800 1000 1200 1400 1600 1800 

SPEED IN RPM,(FLT = 30.0 LB. FT.) 

DR. BY 

CK. BY 

APP. BY 

DATE 

P.B. GREENE 

W.L. SMITH 

W.L. SMITH 

11/03/98 

FL 

Printed on 10/22/04 16:57 @ rgg 

A-C MOTOR 

PERFORMANCE 

CURVES 

2 

1 

OHMS (BETWEEN LINES) 

0 2 4 6 8 10 12 14 16 18 20 22 

HORSEPOWER 

1 

E02263-A-A002 

ISSUE DATE 

11/03/98

GS2 Series - Introduction 

Overview 

The GS2 series of AC drives offers all of the 

features of our GS1 drive plus dynamic 

braking, PID and a removable keypad. 

The drive can be configured using the builtin 

digital keypad or with the standard 

RS-232/RS-485 serial communications 

port. The standard keypad allows you to 

configure the drive, set the speed, start and 

stop the drive, command forward and 

reverse direction of motor shaft, and 

monitor specific parameters during operation. 

Each GS2 features one analog and 

six programmable digital inputs, and one 

analog and two programmable relay 

outputs. 

12–22 

Drives/Motors/Motion 

GS2 Series Drives 

Motor Rating 

Hp 

kW 

.25 

0.2 

.5 

0.4 

1 

0.75 

2 

1.5 

3 

2.2 

5 

3.7 

7.5 

5.5 

10 

7.5 

Single Phase 115 Volt Class ✔ ✔ ✔ 

Single/Three Phase 230 Volt Class ✔ ✔ ✔ ✔ 

Three Phase 230 Volt Class ✔ ✔ ✔ 

Three Phase 460 Volt Class ✔ ✔ ✔ ✔ ✔ ✔ 

Three Phase 575 Volt Class ✔ ✔ ✔ ✔ ✔ ✔ 

Features 

Simple Volts/Hertz control 

Sinusoidal Pulse Width Modulation (PWM) 

1-12 kHz carrier frequency 

IGBT technology 

Starting torque: 125% at 0.5 Hz/150% at 5 Hz 

150% rated current for one minute 

Electronic overload protection 

Stall prevention 

Adjustable accel and decel ramps 

S-curve settings for acceleration and 

deceleration 

Automatic torque compensation 

Automatic slip compensation 

Dynamic braking circuit 

DC braking 

Three skip frequencies 

Trip history 

Programmable jog speed 

Integral PID control 

Removable keypad with speed potentiometer 

Programmable analog input 

Programmable analog output 

Six programmable digital inputs 

Two programmable relay outputs 

RS-232/485 Modbus communications up to 

38.4 Kbps. 

Optional Ethernet communications 

UL/CE listed 

GS2 series part numbering system 

GS2- 4 7P5 

Applicable Motor Capacity 

0P2: 0.25HP 0P5: 0.5HP 

1P0: 1.0HP 2P0: 2.0HP 

3P0: 3.0HP 5P0: 5.0HP 

7P5: 7.5HP 010: 10HP 

Input Voltage 

1: 100-120VAC 

2: 200-240VAC 

4: 380-480VAC 

5: 500-600VAC 

Series Name 

Accessories 

AC line reactors 

EMI filters 

RF filters 

Braking resistors 

Fuse kits and replacement fuses 

Ethernet interface 

Replacement keypads 

Keypad cables in 1, 3, and 5 meter lengths 

Four and eight-port serial communication 

breakout boards 

KEPDirect I/O Server 

GSoft drive configuration software 

Detailed descriptions and specifications for the 

accessories are available in the “GS/DURAPULSE 

Accessories” section. 

Typical Applications 

Conveyors 

Fans 

Pumps 

Compressors 

HVAC 

Material handling 

Mixing 

Shop tools 

1-800-633-0405

GS2 Series Specifications 

12–26 


575V CLASS GS2 SERIES 

Model GS2-51P0 GS2-52P0 GS2-53P0 GS2-55P0 GS2-57P5 GS2-5010 

Price 

Motor Rating 

HP 1hp 2hp 3hp 5hp 7.5hp 10hp 

kW 0.75kW 1.5kW 2.2kW 3.7kW 5.5kW 7.5kW 

Rated Output Capacity (kVA) 1.7 3.0 4.2 6.6 9.9 12.2 

Rated Input Voltage Three-phase: 500 to 600 VAC -15/+10%, 50/60 Hz 5% 

Rated Output Voltage Corresponds to input voltage 

Rated Input Current (A) 2.4 4.2 5.9 7.0 10.5 12.9 

Rated Output Current (A) 1.7 3.0 4.2 6.6 9.9 12.2 

DC Braking Frequency 60-0 Hz, 0-100% rated current, Start Time 0.0-5.0 seconds, Stop Time 0.0-25.0 seconds 

Protective Structure Protected chassis IP20 

Ambient Operating Temperature -10°C to 50°C (14°F to122°F) -10°C to 40°C(14°F to 104°F) 

Storage Temperature -20°C to 60°C (-4°F to 140°F) during short term transportation period 

Humidity 20 to 90% Humidity (no condensation) 

Vibration 9.8 m/s 2 (1G) at less than 10Hz, 5.9 m/s 2 (0.6G)10 to 60 Hz 

Location Altitude 1,000m or less, Keep from corrosive gases liquids or dust 

Watt Loss @ 100% I (W) 30 58 83 132 191 211 

Weight: (lb) 3.3 3.3 4.4 7.0 7.0 7.3 

Dimensions* (HxWxD) mm (in) 151.0 x 100.0 x 140.5. (5.94 x 3.94 x 5.53) 220.0 x 125.0 x 189.5 (8.66 x 4.92 x 7.46) 

Accessories 

Line Reactor GS-51P0-LR GS-52P0-LR GS-42P0-LR GS-43P0-LR GS-47P5-LR 

Braking Resistor GS-42P0-BR 

GS-42P0-BR x (2) 

in parallel 

EMI Filter not available 

Fuse Block (Edison 3-pole part #) BC6033PQ or CHCC3D or CHCC3DI 

Replacement Fuses (Edison Fuse part #) 

HCLR6 

(10 fuses per pack) 

HCLR10 


HCLR15 


Spare Keypad, GS2 Series Microdrive GS2-KPD 

Keypad Cable, GS2 Series, 1 meter GS-CBL2-1L 



Ethernet Communications Module for GS Series 

Drives (DIN rail mounted) 

GS-EDRV 

Four port RS-485 multi-drop terminaton board GS-RS485-4 

Eight port RS-485 multi-drop terminaton board GS-RS485-8 

Software GSoft / KEPDDiirreecctt 

OPC Server KEPDDiirreecctt 

*Note: Height dimension does not include external ground terminal, which adds 10 to 15 mm. Refer to dimensional drawings for details. 

HCLR20 


GS-4010-BR x (2) 

in series 

HCLR30 


1-800-633-0405

GS2 Series — General Specifications 

Control Characteristics 

www.automationdirect.com/drives 

General Specifications 

Control System Sinusoidal Pulse Width Modulation, carrier frequency 1kHz - 12kHz 

Output Frequency Resolution 0.1 Hz 

Overload Capacity 150% of rated current for 1 minute 

Torque Characteristics Includes auto-torque boost, auto-slip compensation, starting torque 125% @ 0.5Hz/150% @ 5.0Hz 

Braking Torque 20% without dynamic braking, 125% with optional braking resistor-braking transistor built in. 

DC Braking Operation frequency 60-0Hz, 0-100% rated current. Start time 0.0-5.0 seconds. Stop time 0.0-0 25.0 seconds 

Acceleration/Deceleration Time 0.1 to 600 seconds (linear or non-linear acceleration/deceleration), second acceleration/deceleration available 

Voltage/Frequency Pattern 

V/F pattern adjustable. Settings available for Constant Torque - low and high starting torque, 

Variable Torque - low and high starting torque, and user configured 

Stall Prevention Level 

Operation Specifications 

20 to 200% or rated current 

Inputs 

Outputs 

Frequency 

Setting 

Operation 

Setting 

Input 

Terminals 

Output 

Terminals 

Keypad Setting by or buttons or potentiometer 

External Signal 

Potentiometer - 3k to 5k/2W, 0 to 10VDC (input impedance 10k), 0 to 20mA / 4 to 20 mA (input impedance 250), 

Multi-speed inputs 1 to 3, Serial Communication RS232 and RS485 (Modbus RTU) 

Keypad Setting by , buttons 

External Signal Forward/Stop, Reverse/Stop (run/stop, fwd/rev), 3-wire control, Serial Communication RS232 and RS485 (Modbus RTU) 

Digital 

Analog 

Digital 

6 user-programmable: FWD/STOP, REV/STOP, RUN/STOP, REV/FWD, Run momentary (N.O.), STOP momentary (N.C.), 

External Fault (N.O./N.C.), External Reset, Multi-Speed Bit (1-3), Jog, External Base Block (N.O./N.C.), 

Second Accel/Decel Time, Speed Hold, Increase Speed, Decrease Speed, Reset Speed to Zero, PID Disable (N.O.), 

PID Disable (N.C.), Input Disable 

1 user-configurable, 0 to 10VDC (input impedance 10k ) or 0 to 20mA / 4 to 20mA (input impedance 250 ), 10 bit 

resolution Frequency setpoint or PID process variable PV 

2 user-programmable; Inverter Running, Inverter Fault, At Speed, Zero Speed, Above Desired Frequency, Below Desired 

Frequency, At Maximum Speed, Over Torque Detected, Above Desired Current, Below Desired Current, 

PID Deviation Alarm 

Analog 1 user-programmable: 0 to 10VDC (max load 2mA), 8 bit resolution frequency, current, process variable PV 

Automatic voltage regulation, voltage/frequency characteristics selection, non-linear acceleration/deceleration, upper and 

Operating Functions 

lower frequency limiters, 7-stage speed operation, adjustable carrier frequency (1 to 12 kHz), PID control, skip frequencies, 

analog gain & bias adjustment, jog, electronic thermal relay, automatic torque boost, trip history, software protection 

Electronic Thermal, Overload Relay, Auto Restart after Fault, Momentary Power Loss, Reverse Operation Inhibit, Auto 

Voltage Regulation, Over-Voltage Trip Prevention, Auto Adjustable Accel/Decel, Over-Torque Detection Mode, 

Protective Functions 

Over-Torque Detection Level, Over-Torque Detection Time, Over-Current Stall Prevention during Acceleration, 

Over-Current Stall Prevention during Operation 

Operator Devices 8-key, 4-digit, 7-segment LED, 14 status LEDs, potentiometer 

Operator 

Interface 

Environment 

Options 

Programming Parameter values for setup and review, fault codes 

Status Display 

Actual Operating Frequency, RPM, Scaled Frequency, Amps, % Load, Output Voltage, DC Bus Voltage, 

Process Variable, Set-point Frequency 

Key Functions RUN, STOP/RESET, FWD/REV, PROGRAM, DISPLAY, , , ENTER 

Enclosure Rating Protected chassis, IP20 

Ambient Temperature 

-10° to 50°C (14°F to 122°F) 

-10° to 40°C (14°F to 104°F) For models 7.5Hp (5.5kW) and higher 

Storage Temperature -20° to 60 °C (-4°F to 140°F) - during short-term transportation period 

Ambient Humidity 20 to 90% RH (non-condensing) 

Vibration 9.8 m/s2(1G), less than 10Hz,. 5.9 m/s2 (0.6G) 10 to 60 Hz 

Installation Location Altitude 1000m or lower above sea level, keep from corrosive gas, liquid and dust 

Noise filter, input AC reactor, output AC reactor, cable for remote operator, programming software (GSOFT), 

Dynamic braking resistor, input fuses, ethernet interface (GS-EDRV), EMI filters 


12–27 

PLC 

Overview 

DL05/06 

PLC 

DL105 

PLC 

DL205 

PLC 

DL305 

PLC 

DL405 

PLC 

Field I/O 

Software 

C-more 

HMIs 

Other HMI 

AC Drives 

Motors 

Steppers/ 

Servos 

Motor 

Controls 

Proximity 

Sensors 

Photo 

Sensors 

Limit 

Switches 

Encoders 

Pushbuttons/ 

Lights 

Process 

Relays/ 

Timers 

Comm. 

TB’s & 

Wiring 

Power 

Enclosures 

Appendix 

Part Index

GS2 Specifications — Dimensions 

GS2-10P2, GS2-10P5, GS2-11P0; GS2-20P5, GS2-21P0, GS2-22P0; 

GS2-41P0, GS2-42P0, GS2-43P0; GS2-51P0, GS2-52P0, GS2-53P0 

GS2-23P0, GS2-25P0, GS2-27P5; 

GS2-45P0, GS2-47P5, GS2-4010; GS2-55P0, GS2-57P5, GS2-5010 

www.automationdirect.com/drives Drives/Motors/Motion 12–31 

PLC 

Overview 

DL05/06 

PLC 

DL105 

PLC 

DL205 

PLC 

DL305 

PLC 

DL405 

PLC 

Field I/O 

Software 

C-more 

HMIs 

Other HMI 

AC Drives 

Motors 

Steppers/ 

Servos 

Motor 

Controls 

Proximity 

Sensors 

Photo 

Sensors 

Limit 

Switches 

Encoders 

Pushbuttons/ 

Lights 

Process 

Relays/ 

Timers 

Comm. 

TB’s & 

Wiring 

Power 

Enclosures 

Appendix 

Part Index


APPENDIX D – Budget 

48

Budget 

Date: 11/17/2006 

To: Dr. Allen 

Cc: Dr. Warkentin, Dr. Bauer 

From: Brian Murphy, David Pottle, Andrew Rockwell, Kyle Ryan 

RE: Budget – Team 10 

The following is the budget for Team 10’s design project: 

Expenses 

• Supplies 

o Coolant Pump $ 1650 

o Wash Pump $ 450 

o 460 V 10 hp Motor $ 380 

o 575 V 10 hp Motor $ 380 

o 460 V Speed Controller $ 950 

o Bushings & Sheaves $ 150 

o V Belts $ 50 

o Mounting Frame $ 215 

o Hydraulic Hose $ 130 

o Suction Hose $ 40 

o Hydraulic Fittings $ 320 

o Valve $ 100 

o Unloaders $ 85 

o Pressure Gages $ 30 

o Pressure Relief Valves $ 50 

o Filtration System $ 600 

Sub-Total $ 5580 

Grand Total $ 6360 

11/17/2006 1

Budget 

• Departmental Technician Time 

o Angus MacPherson – Machine Shop 

Nozzle Manufacturing ~ 30 hours 

o Albert Murphy – Welding 

Mounting Frame Fabrication ~ 15 hours 

Income 

• Dalhousie Grinding Research Group 

o $10,000 budget 

Supervisor: Dr. Peter Allen 

________________________ 

11/17/2006 2


APPENDIX E – Quotes 

51

SUCCURSALE/BRANCH: 

COMM. 

ORDER 

quoteD 04/06 

DALHOU 

QUANTITÉ / QUANTITY 

À SUIVRE 

BACKORDER 

EXPÉDIÉ 

SHIPPED 

CODE 

INSTRUCTIONS 

TRANS. ENTRÉE 

FREIGHT IN 

NO D'ITEM ET DESCRIPTION 

ITEM CODE AND DESCRIPTION 

TRANS.SORTIE 

FREIGHT OUT 

U/M 

MULT. 

NUMÉRO DE SOUMISSION 

QUOTE NUMBER 

VENDU À: DALHOUSIE UNIVERSITY 31 EXPÉDIÉ À: DALHOUSIE UNIVERSITY 31 

SOLD TO: ARTS ADMIN BLDG SHIP TO: MECHANICAL ENGINEERING 

FINANCIAL SERV ROOM MORRIS STREET 

HALIFAX NS B3H 4H6 HALIFAX NS B3H 4H6 

***QUOTATION******QUOTATION******QUOTATION******QUOTATION******QUOTATION*** 


QUOTE NUMBER 

VENDEUR 

SALESPERSON 

DATE DE SOUMISSION 

QUOTE DATE 

REÇU PAR 

TAKEN BY 

NUMÉRO DE RÉFÉRENCE DU CLIENT 

CUSTOMER REFERENCE NUMBER 

DATE 

B - EN SOUFRANCE 

BACK ORDERED 

C - CONSIDÉRÉ COMPLET 

CONSIDER COMPLETE 

D - ENVOI DIRECT / DIRECT SHIP 

F - QTÉ MIN. PAR PAQUET 

MIN. PACKAGE SIZE 

CODE 

100 WRIGHT AVE 

SUITE 7 & 8 

31002872-0000-31 3109 11/22/06 3158 404-9725 11/22/06 

L - LPU 

P - RAMASSÉ / PICKED 

* TVP / PST 

# TVH / HST 

+TVP ET TPS / PST AND GST 

* Un nom commercial détenu par Wajax, associée commanditée Holdco inc., 

en sa qualité de fiduciaire de Fiducie Wajax commanditée, 

associée commanditée de Kinecor, société en commandite 

* A trade name of Wajax GP Holdco Inc., held in its capacity as Trustee 

of Wajax GP Trust, General Partner of Kinecor LP 

ATTN: BRIAN/ANDREW 

SOUMISSION / QUOTE 

31002872-0000-31 

EXP. 

FRT. 

B 

PRIX UNITAIRE 

UNIT PRICE 

SOUS TOTAL / SUB TOTAL 

DIVERS / MISC. 

TELE. CHARGE 

TRANS / FREIGHT 

T.P.S. / G.S.T. 

T.V.P. / P.S.T. 

PAIEM. REÇU / PAY REC'D. 

PAGE NO. 

1 

PRIX TOTAL 

EXTENSION 

2 P21G4553 REL EA 381.11 762.22 

10HP 1800 215T TEFC-EM 57 

P21G4553 

31- 

1 2B54 MAS EA 24.60 24.60 

P422 GIANT PUMP DR. SHEAVE 

31-1-9C 

1 SDS1 3/8 MAS EA 7.34 7.34 

P422 PUMP DRIVE BUSHING 

31-1-8D 

1 2B68 MAS EA 30.12 30.12 

P422 PUMP DRIVEN SHEAVE 

31-1-9C 

1 SDS28MM MAS EA 7.34 7.34 

P422 PUMP DRIVEN BUSHING 

31- 

CONTINUED


COMM. 

ORDER 

quoteD 04/06 

DALHOU 


À SUIVRE 

BACKORDER 

EXPÉDIÉ 

SHIPPED 

CODE 

INSTRUCTIONS 


FREIGHT IN 



TRANS.SORTIE 

FREIGHT OUT 

U/M 

MULT. 


QUOTE NUMBER 







QUOTE NUMBER 

VENDEUR 

SALESPERSON 


QUOTE DATE 

REÇU PAR 

TAKEN BY 



DATE 


BACK ORDERED 






CODE 


SUITE 7 & 8 

31002872-0000-31 3109 11/22/06 3158 404-9725 11/22/06 

L - LPU 


* TVP / PST 

# TVH / HST 








31002872-0000-31 

EXP. 

FRT. 

B 

PRIX UNITAIRE 

UNIT PRICE 



TELE. CHARGE 


T.P.S. / G.S.T. 

T.V.P. / P.S.T. 


PAGE NO. 

2 

PRIX TOTAL 

EXTENSION 

1 2B54 MAS EA 24.60 24.60 

P316 GIANT PUMP DR. SHEAVE 

31-1-9C 

1 SK28MM MAS EA 11.37 11.37 

P316 PUMP DRIVEN BUSHING 

31- 

1 2B52 MAS EA 23.76 23.76 

P316 PUMP DRIVE SHEAVE 

31-1-9C 

1 SDS1 3/8 MAS EA 7.34 7.34 

P316 PUMP DRIVE BUSHING 

31-1-8D 

1 *P422 GIANT PUMP EA 1638.89 1638.89 

10.0 GPM @ 2200/3000 PSI 

1450 RPM 

1 *P316 GIANT PUMP EA 433.33 433.33 

4.7 GPM @ 2500/3000 PSI 

1860 RPM 

CONTINUED


COMM. 

ORDER 

quoteD 04/06 

DALHOU 


À SUIVRE 

BACKORDER 

EXPÉDIÉ 

SHIPPED 

CODE 

INSTRUCTIONS 


FREIGHT IN 



TRANS.SORTIE 

FREIGHT OUT 

U/M 

MULT. 


QUOTE NUMBER 







QUOTE NUMBER 

VENDEUR 

SALESPERSON 


QUOTE DATE 

REÇU PAR 

TAKEN BY 



DATE 


BACK ORDERED 






CODE 


SUITE 7 & 8 

31002872-0000-31 3109 11/22/06 3158 404-9725 11/22/06 

L - LPU 


* TVP / PST 

# TVH / HST 








31002872-0000-31 

EXP. 

FRT. 

B 

PRIX UNITAIRE 

UNIT PRICE 



TELE. CHARGE 


T.P.S. / G.S.T. 

T.V.P. / P.S.T. 


PAGE NO. 

3 

PRIX TOTAL 

EXTENSION 

1 *22760 APM HYD EA 83.28 83.28 

8GPM @ 3000 PSI UNLOADER 

PANEL MOUNT 

1 *22912A HYD EA 141.67 141.67 

13 GPM @ 2400 PSI UNLOADER 

1 *22531A HYD EA 11.06 11.06 

POP-OFF VALVE 2400 PSI 

1 *22532A HYD EA 11.06 11.06 

POP-OFF VALVE 3600 PSI 

4 B64 GY EA 8.09 32.36 

*SAMPLE PRICING FOR BELTS 

BASED ON MAX. 25" CD 

2 FOR EACH DRIVE* 

31-1-10F 

3,250.34 

455.05 

0.00 

0.00 

TOTAL AMOUNT DUE 

3,705.39

350 CARLINGVIEW DRIVE 

TORONTO ON,M9W-5G6 

TEL : (416) 248-0176 

FAX : (416) 248-2735 

If there are any problems with this transmission, please contact your representative. 

LIGHTING 

ELECTRICAL SUPPLIES 

CONTROLS & AUTOMATION 

LIGHTING CONSULTANT 

DATE OF QUOTE DATE REQUIRED CUSTUMER REFERENCE NUMBER CONTACT : 

BILLING ADDRESS: 

CUST. NO. QUOTED BY SHIP VIA OUR G.S.T. NO. 

LINE QTY CAT NO../ DESCRIPTION DELIVERY PRICE DISCOUNT TOTAL 

PAYMENT TERMS: 

FABRICATION 

QUOTATION 

QUOTATION NO: 19043 

07/11/06 08/11/06 QUOTE GS2 BRIAN 

CASH SALES ACCOUNT 

(PATTI BRAMMER) 

ON 

NET 30 DAYS 

SHIPPING ADDRESS: 

DALHOUSY UNIVERSITY 

(BRIAN) 

HALIFAX ON 

XXXXXX 

997751 / -1 PATTI BRAMMAR PPD & CHRG 

THIS QUOTATION IS SUBJECT TO FEI TERMS AND CONDITIONS. QUOTED 

PRICES ARE SUBJECT TO ACCEPTANCE WITHIN 30 DAYS FROM DATE OF 

QUOTATION UNLESS OTHERWISE INDICATED. 

FOR MORE INFORMATION CONSULT WITH YOUR REPRESENTATIVE 

P.S.T. NO. 

TOTAL 

PAGE 

QUOTATION 

1 

TEL: (902) 404-9725 

FAX: (902) 000-0000 

C - O - D 

1 1 GS2-5010 KOYO N/A 945.010/E NET 945.01$ 

GS2 10 HP AC DRIVE 575V 

DELIVERY: 7-10 DAYS 

SUB-TOTAL TRANSPORT+SERVICE 8.95$ 

SUB-TOTAL MATERIAL 945.01$ 

GST 6.00 57.24$ 

PST 8.00 76.32$ 

1087.52$ 

Taxes included.


APPENDIX F – Winter Term Gantt Chart 

56

ID Task Name Duration Start Finish Predecessors ec '06 07 Jan '07 14 Jan '07 21 Jan '07 28 Jan '07 04 Feb '07 11 Feb '07 18 Feb '07 25 Feb '07 04 Mar '07 11 Mar '07 18 Mar '07 25 Mar '07 01 Apr '07 

T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F 

1 Build Report #2 8 days Wed 03/01/07 Fri 12/01/07 

2 Equipment Arrival 6 days Wed 03/01/07 Wed 10/01/07 

3 Frame Construction 10 days Thu 11/01/07 Wed 24/01/07 2 

4 Installation 24 days Thu 25/01/07 Tue 27/02/07 

5 Pumps 12 days Thu 25/01/07 Fri 09/02/07 3 

6 Motors 12 days Thu 25/01/07 Fri 09/02/07 3 

7 Hose, Fittings 10 days Mon 12/02/07 Fri 23/02/07 5 

8 Electrical Hook-up 2 days Mon 19/02/07 Tue 20/02/07 6,12 

9 Nozzle 5 days Mon 12/02/07 Fri 16/02/07 11 

10 Plumbing 2 days Mon 26/02/07 Tue 27/02/07 7,5 

11 Nozzle machining 20 days Mon 15/01/07 Fri 09/02/07 1 

12 Electrical Modifications 25 days Mon 15/01/07 Fri 16/02/07 1 

13 System Check 3 days Wed 28/02/07 Fri 02/03/07 4 

14 Start up 0 days Fri 02/03/07 Fri 02/03/07 13 

15 Experiments 10 days Mon 05/03/07 Fri 16/03/07 

16 Testing 5 days Mon 05/03/07 Fri 09/03/07 14 

17 Optimization 5 days Mon 12/03/07 Fri 16/03/07 16 

18 Completion/Inspection 3 days Mon 19/03/07 Wed 21/03/07 17 

19 Inspection 0 days Wed 21/03/07 Wed 21/03/07 18 

20 Fix, More Tests 5 days Thu 22/03/07 Wed 28/03/07 18 

21 Reporting 13 days Mon 19/03/07 Wed 04/04/07 

22 Report / Presentation 10 days Thu 22/03/07 Wed 04/04/07 18 

23 Test Summary 5 days Mon 19/03/07 Fri 23/03/07 15 

24 Operating Procedure 5 days Mon 19/03/07 Fri 23/03/07 15 

Project: Gantt Chart - Winter Term 

Date: Sun 03/12/06 

Task 

Split 

Progress 

Milestone 

Summary 

Project Summary 

Page 1 

External Tasks 

External Milestone 

Deadline 

02/03 

21/03


APPENDIX G – Detail Drawings 

58

D 

C 

B 

A 

1 

8 7 6 5 4 3 2 1 

8 

10 

7 

2 

9 

6 

7 

12 

13 

5 

4 

11 

6 

4 

8 

3 

ITEM NO. PART NUMBER DESCRIPTION QTY. 

1 P21G4903 575 Volt AC Motor 1 

2 P21G4903 575 Volt AC Motor 1 

3 10gpmpump 10 gpm Plunger Pump 1 

4 5gpmpump 5 gpm Plunger Pump 1 

5 coolant sheave Pump Sheave 1 

6 wash sheave Pump Sheave 1 

7 motor sheave Motor Sheave 2 

8 New Frame Welded Tubing 1 

9 mesh plate side Safety Mesh Plate 2 

10 mesh plate front_back Safety Mesh Plate 4 

11 mesh plate top Safety Mesh Plate 1 

12 vibration mount Vibration Mounts 7 

13 new belt V-belt 2 

14 new belt 2 V-belt 2 

UNLESS OTHERWISE SPECIFIED: 

DIMENSIONS ARE IN INCHES 

TOLERANCES: 

FRACTIONAL 

ANGULAR: MACH BEND 

TWO PLACE DECIMAL 

THREE PLACE DECIMAL 

INTERPRET GEOMETRIC 

Q.A. 

PROPRIETARY AND CONFIDENTIAL 

THE INFORMATION CONTAINED IN THIS 

DRAWING IS THE SOLE PROPERTY OF 

. ANY 

REPRODUCTION IN PART OR AS A WHOLE 

WITHOUT THE WRITTEN PERMISSION OF 

IS 

NEXT ASSY USED ON 

TOLERANCING PER: 

MATERIAL 

FINISH 

COMMENTS: 

SIZE 

B 

PROHIBITED. 

APPLICATION 

DO NOT SCALE DRAWING 

14 

5 

3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

NAME 

DATE 

2 

TITLE: 

DWG. NO. 

Mount Frame 

SCALE: 1:20 WEIGHT: 

1 

REV 

1 

SHEET 1 OF 1 

D 

C 

B 

A

2.79 

5.31 

12.50 




. ANY 



IS 

PROHIBITED. 

5 

17.20 4.13 

8.50 

TYP. 

NEXT ASSY 

47.00 

APPLICATION 

4 

13.50 

USED ON 

TYP. 



TOLERANCES: 

FRACTIONAL 






MATERIAL 

FINISH 

8.50 


3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

1"X1"X1/8" SQUARE TUBING 

COMMENTS: 

29.00 

NAME DATE 

2 

TITLE: 

SIZE 

A 

DWG. NO. 

Bottom 1 

SHEET 1 OF 1 


1 

REV




. ANY 



IS 

PROHIBITED. 

5 

47.00 

NEXT ASSY 

APPLICATION 

4 

USED ON 

TYP. 

23.50 



TOLERANCES: 

FRACTIONAL 






MATERIAL 

FINISH 


3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

COMMENTS: 

29.00 


NAME DATE 

2 

TITLE: 

SIZE DWG. NO. 

A Top 

REV 

SCALE: 1:20 WEIGHT: SHEET 1 OF 1 

1


14.00 



. ANY 



IS 

PROHIBITED. 

5 

NEXT ASSY 

APPLICATION 

4 

USED ON 




TOLERANCES: 

FRACTIONAL 






MATERIAL 

FINISH 


3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

COMMENTS: 

NAME DATE 

2 

TITLE: 

SIZE DWG. NO. 

REV 

A Upright 


1




. ANY 



IS 

PROHIBITED. 

5 

NEXT ASSY 

APPLICATION 

4 

USED ON 



TOLERANCES: 

FRACTIONAL 






MATERIAL 

FINISH 


3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

COMMENTS: 

NAME DATE 

2 

TITLE: 

TYP. 

TYP. 

SIZE DWG. NO. 

REV 

A Frame 


1

73.00 


5 

TYP. 



. ANY 



IS 

PROHIBITED. 

70.10 


NEXT ASSY 

APPLICATION 

4 

USED ON 



TOLERANCES: 

FRACTIONAL 






MATERIAL 

FINISH 


3 

DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

COMMENTS: 

NAME DATE 

2 

TITLE: 

SIZE 

A 

DWG. NO. 

Hose Line SHEET 1 OF 1 


1 

REV

2 

15 

24.50 

37° 

A A 

64 

SECTION A-A 

SCALE 1 : 1 

34 




. ANY 



IS 


PROHIBITED. 

APPLICATION 

6 x 6.50 THRU 

on PCD 48 

DIMENSIONS ARE IN mm 

TOLERANCES: 

FRACTIONAL 




MATERIAL 

FINISH 

6061 T6 Al 

-- 


DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

NAME DATE 

COMMENTS: Drawing not yet complete 

Isometric View 

Scale 1:1 

25.40 

6 x 14 5 TYP 

Dalhousie - Team #10 

Coolant Nozzle 

SIZE DWG. NO. 

A 

SCALE:1:2 

WEIGHT: 

SHEET 1 OF 1 

REV.

60 

1.50 THRU 

11.13 

1/4 NPT 

37° 

13 

80 




. ANY 



IS 


PROHIBITED. 

APPLICATION 

SECTION C-C 

SCALE 1 : 1 

24 

C C 

60 

DIMENSIONS ARE IN mm 

TOLERANCES: 

FRACTIONAL 




MATERIAL 

FINISH 

25.40 (1") 

34.50 

6061 T6 Alu 

-- 


DRAWN 

CHECKED 

ENG APPR. 

MFG APPR. 

Q.A. 

COMMENTS: 

Isometric View 

Scale 1:2 

6 x M6 15 TYP 

on PCD 48 

1-1/4-12 UNF 30 

NAME DATE 

Dalhousie Team #10 

SCALE:1:2 

Nozzle Block 

SIZE DWG. NO. 

A 

WEIGHT: 

SHEET 1 OF 1 

REV.

Coolant Delivery System for Creep-Feed Grinding - Mechanical ...

Create successful ePaper yourself

Delete template?

Save as template?