AJAX® Engine-Compressor Package Service Manual Contract# 10754
Engine
Model DPC-2802LE
Serial Number 85486
Compressor
Model 23” YK1111MB 13” YK11F
Contents Section 1 – Supplementary Documentation Section 2 – Package Drawings Section 3 – Engine Section 4 – Fuel System Section 5 – Cooling System Section 6 – Cooler Section 7 – Compressor Section 8 – Process Gas Equipment Section 9 – Control Panel and Instrumentation Section 10 – Lubrication System Section 11 – IGTB RPM Control
Engine-Compressor Package Service Manual
Serial number 14787 14824
Section 1 – Supplementary Documentation Vendor
Bulletin No.
Warranty......................................................................... Ajax Mathematical Conversion Tables ................................... Ajax Lube Oil & Low Temp Starting Recommendations .................................................... Ajax
ES 1006
Trimming for Sour Gas Applications............................... Ajax
ES 25
Installation of Sheave and Flywheel ............................... Ajax
ESS-F-961
Flywheel Installation and Ignition Timing........................ Ajax
ESS-F-963
Jet Cell Operation and Maintenance............................... Ajax
ESS-L-981
Jet Cell System Installation..............................................Ajax
ESS-L-983
General PM Schedule .................................................... Ajax
TIB 020326
Component Wear Limits................................................. Ajax
TIB 020718
% Load vs Engine Coolant Temperature........................ Ajax
TIB 030910
Hydraulic Fuel Injection System Purging........................ Ajax
TIB 031104
Lubrication Rates ........................................................... Ajax
TIB 040910
Installation Design for Permanent Packages.................. Ajax
TIB 061115
Engine Operating with Fuel Containing H2S................... Ajax
TIB 050610
Torque Tables for Ajax Fasteners....................................Ajax
TIB 061212
Engine-Compressor Package Service Manual
WARRANTY Warranties To Original Purchaser (Non-Transferable).
a) "Material and Workmanship Warranty": The Seller warrants to the Purchaser that the Equipment of Seller's own manufacture to be supplied hereunder will be complete in all its parts, and, for the *Warranty Period - The warranty period shall extend for 12 months from date of start-up, but shall not exceed 18 months from date of shipment from factory. Warranty Period specified will be free from defects in material or workmanship caused by the Seller and arising under normal and proper operating conditions; and that such Equipment will be delivered free from any lawful security interest or other lien or encumbrance known to the Seller, except security interests or other liens or encumbrances arising hereunder. The obligation of the Seller and the Purchaser's sole and exclusive remedy hereunder shall be limited at the Seller's option: 1)
To replacement or repair of any Equipment or parts thereof which are returned to the Seller's works within the Warranty Period, transportation charges prepaid.
2)
Should the Equipment or parts thereof be determined by the Seller to be so defective, however, as to preclude the remedying of warranty defects by replacement or repair, the Purchaser's sole and exclusive remedy shall then be a refund of the purchase price, less a reasonable charge for any utilization of the Equipment by Purchaser.
3)
Nothwithstanding the foregoing, the Seller shall have no obligation as a result of improper storage, installation, repairs or modifications not made by the Seller, or as a result of removal, improper use, or misapplication of the Equipment after it has been delivered to the Purchaser.
4)
Purchaser shall pay freight charges in connection with the return or replacement of the defective Equipment or parts.
b)
"Performance Warranty": The Seller warrants that the Equipment of its own manufacture, when shipped and/or installed, will operate within any performance characteristics which are expressly specified herein as a performance guarantee. Any performance characteristics indicated herein which are not expressly stated as guarantees are expected, "but not guaranteed". When factory testing is conducted for measuring any performance guarantee of the Equipment purchased, then certified test results verifying any such guarantees shall be considered both by the Purchaser and the Seller as conclusive. The Purchaser may have a representative present when such factory tests are conducted,
if requested at the time an order is placed. Should Purchaser desire to conduct a field performance test to verify any performance guarantee, such test must be conducted by Purchaser, at his expense, within thirty (30) days from the date of initial start-up of the Equipment, and in accordance with the appropriate ASME Power Test Code, except as otherwise agreed in writing by Seller. Seller shall be entitled to have a representative or representatives present to witness such test and Purchaser shall reimburse Seller for the time and expense of such representatives at the Seller's service rates then in effect at the time of the test. Purchaser shall give Seller fifteen (15) days written notice prior to the date Purchaser intends to commence such test. If the field performance test is not conducted within the aforesaid period all performance guarantees shall be deemed to have been met. In the event any Equipment performance guarantee which is to be verified by the field performance test is not successfully demonstrated within thirty (30) days from the commencement of such test, the obligation of the Seller and the Purchaser's sole and exclusive remedy hereunder shall be that set forth in paragraph (a) above. c)
"OSHA" Warranty": The Seller warrants for installations within the United States that Equipment of its own manufacture, when shipped, will be in compliance with the Occupational Safety and Health Act, and any and all amendments thereto and regulations promulgated thereunder that may be in effect as of the date of the Seller's quotation insofar as said law and regulations may pertain to the physical characteristics of the Equipment "provided however", the Seller does not warrant such compliance with respect to the circumstances of use of said Equipment and "provided further", the Seller makes no warranty with respect to the noise level of said Equipment, when put into operation, since such noise levels will be influenced by and dependent upon the environment into which the Equipment may be placed. The Seller's obligation and the Purchaser's sole remedy with respect to this warranty shall be providing notice of any such non-compliance is given within one year from the date of delivery of said Equipment to Purchaser, to repair or replace any part of said Equipment that is proven to Seller's satisfaction not to have been in compliance with the Act as amended and regulations thereto in effect as of the date of quotation or, if it be determined by Seller that the Equipment or parts thereof cannot be repaired or replaced in such a manner as to put the Equipment in compliance, Purchaser's sole and exclusive remedy shall then be a refund of the purchase price less a reasonable charge for any utilization of the Equipment by Purchaser. Purchaser shall pay freight charges in connection with the return or replacement of any Equipment or parts that are found not to be in compliance.
Notwithstanding the foregoing, the Seller shall have no obligation under this warranty as a result of installation, repairs or modifications not made by the Seller, or as a result of removal, improper use, improper operation, or misapplication of the Equipment after it has been delivered to the Purchaser. d)
"Warranty As To Equipment Not Made By The Seller": Equipment parts and accessories made by other manufacturers and supplied hereunder by the Seller are warranted only to the extent of the original manufacturer's warranty to the Seller.
e)
"EXCEPT AS SET FORTH HEREIN, AND EXCEPT AS TO TITLE IT IS EXPRESSLY AGREED": "THAT THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY, NOT OTHER WARRANTY, EXPRESS, IMPLIED, OR STATUTORY, NOR ANY AFFIRMATION OF FACT, OR PROMISE BY THE SELLER WITH REFERENCE TO THE EQUIPMENT OR PARTS THEREOF, OR OTHERWISE, WHICH EXTENDS BEYOND THE DESCRIPTION OF THE EQUIPMENT AS SET FORTH HEREIN, AND (2) THAT THE PURCHASER ACKNOWLEDGES THAT IT IS PURCHASING THE EQUIPMENT SOLELY ON THE BASIS OF THE COMMITMENTS OF THE SELLER EXPRESSLY SET FORTH HEREIN".
DAMAGES. "IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES, NOR FOR LOSS OF ANTICIPATED PROFITS NOR FOR LOSS OF USE OF ANY EQUIPMENT, INSTALLATION SYSTEM, OPERATION OR SERVICE INTO WHICH THE GOODS OR PARTS MAY BE PUT, OR WITH RESPECT TO WHICH ANY SERVICES MAY BE PERFORMED BY SELLER". "THIS LIMITATION ON SELLER'S LIABILITY SHALL APPLY TO ANY LIABILITY FOR DEFAULT UNDER OR IN CONNECTION WITH THE GOODS, PARTS OF UNIT SALES OR SERVICESDELIVERED HEREUNDER, WHETHER BASED ON WARRANTY, FAILURE OF OR DELAY IN DELIVERY OR OTHERWISE". "ANY ACTION FOR BREACH OF CONTRACT HEREUNDER MUST BE COMMENCED WITHIN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED".
TDI TURBOTWINTM Engine Air Starters
MATHEMATICAL CONVERSION TABLE UNITS
TO CONVERT
INTO
P R E S S U R E
Bars Kilograms/Sq. Centimeter Kilopascals PSIG PSIG PSIG
PSIG PSIG PSIG Bars Kilograms/Sq Centimeter (Kg/cm) Kilopascals (Kpa)
14.5 14.22 0.145 0.069 0.070 6.895
V O L U M E
Liters Gallons Gallons Cubic Centimeters Cubic Inches Cubic Inches Cubic Feet Cubic Inches
Cubic Inches (in3) Cubic Inches (in3) Cubic Feet (ft3) 3 Cubic Inches (in ) Liters (L) Gallons (Gal) Gallons (Gal) Cubic Centimeters (cm3)
61.023 232.56 0.135 0.061 0.0164 0.0043 7.413 16.39
T O R Q U E
Newton Meters Kilogram Meters Foot Pounds Foot Pounds Kilogram Meters
Foot Pounds (Ft-lb) Foot Pounds (Ft-lb) Newton Meters (N-m) Kilogram Meters (K-gm) Newton Meters (K-gm)
0.7376 7.233 1.356 0.1383 9.807
F L O W
Standard Cubic Feet per Minute Cubic Meters/Hr Standard Cubic Feet per Minute
Cubic Meters/Hr (m/h)
1.70 0.588 0.0750
Horsepower Horsepower Kilowatts
Kilowatts (KW) Ft-lbsp/Second Horsepower (HP)
P O W E R
Standard Cubic Feet per Minute (SCFM)
Pounds per Minute (Lb/Min.)
MULTIPLY BY
0.746 550.0 1.340
AN03-147 9/97
TDI TURBOTWINTM Engine Air Starters
MATHEMATICAL CONVERSION TABLE UNITS
TO CONVERT
INTO
P R E S S U R E
Bars Kilograms/Sq. Centimeter Kilopascals PSIG PSIG PSIG
PSIG PSIG PSIG Bars Kilograms/Sq Centimeter (Kg/cm) Kilopascals (Kpa)
14.5 14.22 0.145 0.069 0.070 6.895
V O L U M E
Liters Gallons Gallons Cubic Centimeters Cubic Inches Cubic Inches Cubic Feet Cubic Inches
Cubic Inches (in3) Cubic Inches (in3) Cubic Feet (ft3) 3 Cubic Inches (in ) Liters (L) Gallons (Gal) Gallons (Gal) Cubic Centimeters (cm3)
61.023 232.56 0.135 0.061 0.0164 0.0043 7.413 16.39
T O R Q U E
Newton Meters Kilogram Meters Foot Pounds Foot Pounds Kilogram Meters
Foot Pounds (Ft-lb) Foot Pounds (Ft-lb) Newton Meters (N-m) Kilogram Meters (K-gm) Newton Meters (K-gm)
0.7376 7.233 1.356 0.1383 9.807
F L O W
Standard Cubic Feet per Minute Cubic Meters/Hr Standard Cubic Feet per Minute
Cubic Meters/Hr (m/h)
1.70 0.588 0.0750
Horsepower Horsepower Kilowatts
Kilowatts (KW) Ft-lbsp/Second Horsepower (HP)
P O W E R
Standard Cubic Feet per Minute (SCFM)
Pounds per Minute (Lb/Min.)
MULTIPLY BY
0.746 550.0 1.340
AN03-147 9/97
!
" #
!" # $%&'()*)$+, - + + # #
.# / +, +# , + #+ # + # # # 0
1 .# /# - # +# , 2# + # # ### ##+ $ $%&'()*)$.+ # ## - +, -+# / #
-+ # 1 +,
+, -+# # +# # - # # ## - # #+ % #+ -# + 3 , ' 4 # # 2 5 2# ,*,.+ # ## -/ # # + # 6# # -#
4 +, -+# # # #- + # + +#
+## -+ # - # - 2 (-# 0
Flywheel Hardened Washer
Collar Inner Ring Crankshaft
Locking Screw
7 2 # # 8 , #+, -+# 6 + - # #
# + # 2# ,*,+ ## # # + + # # % ## - ++, - + #
9 : - #6 # + - +, -+# -# . # ; # ++# / # # ++, # + #++, 6 + . #+
6 + / 2 # # # 6# +# # #6 + - - #6 2 0
1 +, , # +# # #
- + - - #6 . / < + = # - - +# + +, # > 2 (-# # # + % # > + +, +# - # +, $ - +# - 6 + # + +, # > # +
.005" T.I.R.
.020" T.I.R. Flywheel
Shaft
'# # +, -+# # % ++# # 6 # # # - - + #
! !! !
# # + # # < + +# # #
: # + 2# ,*, 1 % + # $ - % #+ # - - 2
# # +
ESS-F-963 Title: Keyless Flywheel Installation And Timing
Engineering Sales & Service Bulletin Ajax-Superior Oklahoma City, OK 73129
Engines/ Compressors ESS-F-963
Keyless Flywheel Installation and Ignition Timing This procedure applies to all Ajax models 2200 and 2800 series Ajax engines. It covers the installation of the keyless ringfeder locking device fitted on flywheels on 2200 and 2800 series engines. The procedure explains the method used to find top dead center (TDC) and proper ignition timing of the engine.
Installation 1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.
! Caution Firmly secure the flywheel to prevent it from falling over. 2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not, lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent. 3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel. 4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN
Figure 1 Flywheel Hardened Washer
Collar Inner Ring Crankshaft
Locking Screw
5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both for assembly. 6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between .001”-.003”. Do not over-lubricate.
Note Step 6 should only be performed during initial engine assembly. Do not lubricate on field units. 7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the Page 1 of 4
Released: 6/8/99
ESS-F-963 Title: Keyless Flywheel Installation And Timing
flywheel and the end of the crankshaft are even.
Note Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat and possibly gall the surface of the crankshaft. 8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to the crankshaft. 9. Remove the crosshead side access door from power cylinder one. 10. Set the timing pointer on the ignition bracket, allowing 1/8” clearance from the flywheel. Adjust the pointer until it is located in the middle of vertical slot on the bracket.
Finding TDC and Timing Degree Marks 11. Place a 4” bar or equivalent between the end of the crosshead and the pack flange. Bar the engine over clockwise until the bar stops against the packing. Hold the flywheel in this position, keeping the crosshead against the bar. 12. Mark the flywheel on the outer diameter (O.D.) with an ink marker at the pointer location. This is “Temporary Mark #1”. 13. Remove the tension on the bar in the crosshead and remove. 14. Rotate the engine clockwise until is has passed TDC far enough to re-insert the bar. 15. Reinsert the bar and rotate the engine counter-clockwise until the bar stops the crosshead against the packing. Hold the flywheel in this position. 16. Mark the flywheel on the O.D. with an ink marker at the pointer location. This is “Temporary Mark #2”. 17. Release the tension from the bar and remove. Rotate the engine to allow access to both of the temporary marks. 18. Measure the distance between the marks. Divide the distance by two and, using an ink marker, create a third mark equidistant between the two marks. This will be “Temporary Mark #T”. Mark T represents the Top Dead Center (TDC) of the crankshaft.
Note You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then marks #2 and T. These distances should be equal. 19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200 and 2800 engines use a 48” diameter flywheel. This means that:
3° = 1ÿ” Flywheel O.D. distance 9° = 3¾” Flywheel O.D. distance 11° = 4-5/8” Flywheel O.D. distance 20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3°, 9° or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel. 21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crankshaft in the general range of normal ignition timing. 22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be installed between the sheave and end cover. See Figure 2. This picture shows the method of locking the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field installation. 23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that Page 2 of 4
Released: 6/8/99
ESS-F-963 Title: Keyless Flywheel Installation And Timing
the scribed line located on the end of the crankshaft is positioned below horizontal. See Figure 3. 24. Loosen the ringfeder bolts to free up the flywheel on the crankshaft.
Figure 2
Figure 3
End of Crankshaft Horizontal
Power Cylinder Side
DC #1 T
Page 3 of 4
Released: 6/8/99
ESS-F-963 Title: Keyless Flywheel Installation And Timing
Engineering Sales & Service Bulletin Ajax-Superior Oklahoma City, OK 73129
Engines/ Compressors ESS-F-963
Setting Timing Of the Flywheel 25. Ensure that the ignition pickup coils are in the proper holes:
3° - Top Holes 9° - Two Holes From The Bottom 11° - Bottom Holes
26. Rotate the flywheel on the crankshaft, without moving the crankshaft itself, until the recessed magnet is centered over the number 1 pickup coil. This is the “A” pickup coil or the one closest to the power end. 27. While keeping the magnet aligned, re-tighten the ringfeder to the flywheel. Now place a permanent timing mark on the flywheel and mark it either 3°, 9°, 11° accordingly. 28. Permanently mark the TDC location and then erase all of the temporary marks made on the flywheel. 29. Remove all crankshaft locking devices and find TDC as in the above procedures to verify that the TDC position and the ignition timing mark have been correctly located relative to the magnet position. 30. When certain that the permanent marks are correct, tighten and torque all flywheel bolts. 31. Match mark the flywheel coincident with the scribe line on the end of the crankshaft using a chisel. Stamp a “1” next to this mark. 32. Stamp the engine serial numbers on the crankshaft and hub of the flywheel. 33. Chisel mark a line on the OD of the flywheel at TDC. Metal stamp a “0” next to this mark. 34. Chisel mark a line at either the 3°, 9°, or 11° (depending on model) on the OD of the flywheel. Metal stamp the correct timing value next to this mark. 35. It may be necessary after engine start-up to readjust the timing pointer. The pickup coil should be centered over the cylinder #1 recessed magnet when the pointer is pointing at the timing mark.
2804 (DPC-800) Engines Only These engines do not use flywheel magnets and pickup coils. When finished with Step 20 above go directly to Step 29.The magneto should be adjusted via the slotted holes on the mounting flange until the cylinder #1 is aligned with the flywheel timing marks.
Page 4 of 4
Released: 6/8/99
ESS-L-981 AJAX LOW EMISSIONS ENGINES
ESS-L-981 Date: July 13,1998 Supercedes ESS-L-921 AJAX LOW EMISSIONS ENGINES AJAX JET CELL OPERATION AND MAINTENANCE ABSTRACT The jet cell concept is required for low emission or emission reduction engines. The highenergy torch issuing from the pre-chamber allows the main chamber to be operated with a leaner mixture and consistently ignited, as compared to a conventional spark plug ignition of a lean mixture. Also, the jet cell is applied to units to improve combustion stability and improve fuel consumption when operating at variable speeds and reduced torque. This paper describes the jet cell operation and general maintenance procedures relating to AJAX Low Emissions Two-Cycle Engines. JET CELL OPERATION The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head. The nozzle end is designed with a specific volume and has a communicating angled exit orifice. A spark plug for ignition and a fuel admission check valve complete the necessary operational components. Pilot fuel headers supply fuel to each admission check valve. The supply to the header is taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with an additional regulator. The ignitor fuel pressure is thus regulated manually according to site conditions. For one cycle of operation, as the piston comes up on compression, the pressure within the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When 1
Revised 07/98
ESS-L-981 AJAX LOW EMISSIONS ENGINES
the pressure within the cylinder becomes greater than the fuel pressure, then the pilot check valves close. The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this energy release forces the burning mixture to exit through the nozzle orifice across the top of the piston in the main combustion chamber, igniting the main combustible charge. IGNITION TIMING In standard spark ignited engines, the spark plugs ignite the charge and a progressive flame front occurs within the combustion chamber. Due to the time required for this flame propagation, the ignition timing is approximately 9°-12° before top dead center (BTDC). With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fuel/air mixture within the main combustion chamber. The mixture is ignited uniformly by this higher energy source, which promotes faster burning. For this reason, the ignition timing is set at 3° BTDC. For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs 7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day (24 hrs), and 30 days of operation would equal 19,008,000 times. MAINTENANCE The jet cell, when installed into the cylinder head, has a round Armco iron gasket which acts as a fire seal; a graphoil seal employed as a bottom water seal, and an ‘O’ ring as the top water seal. The unit is held in place with a two-bolt flange and torqued to 70 ft-lbs. If a cell is removed from the head, it is important that the access hole for the cell is clean and free of any scale build-up. New gaskets and seals should be installed and the unit properly torqued. A locating dowel is used to assure proper orientation of the exit orifice of the cell in relation to the main combustion chamber. SPARK PLUGS Cooling of the spark plug is accomplished primarily through the spark plug gasket seating surface and the threads. These areas within the cell have thin metal sections and are surrounded with engine coolant. In service, the center and ground electrodes will deteriorate, which increases the spark plug gap. Erratic firing will occur once the gap increases 0.005”-0.010” from the original setting and the plugs should be replaced. 2
Revised 07/98
ESS-L-981 AJAX LOW EMISSIONS ENGINES
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to 0.018″ was used. The main chamber spark plug utilized the Champion W-18 (BM-1022). Current production models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022) spark plug is used with an initial gap of 0.020″. This allows use of the same spark plug for both the main chamber and igniter. The current production jet cell (YK-8209-C-1) identified with a ‘3/4’ stamped on the top face. IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage may occur to igniter and/or spark plug threads as the result of thread depth and thread reach respectively. The secondary ignition wiring and associated components should always be in good condition. FUEL ADMISSION CHECK VALVES The primary check valve (P/N YK-8338-A) is most important in the operation of the jet cell. As noted previously, the number of cyclic operations relates to the unit’s speed, with fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and being shut off the cylinder pressure increases. The check valve also withstands the high pressure within the cell at time of ignition. Present production check valves use a ceramic ball with tool steel enclosure and seat. Ajax continues to improve the life and operation of the valves with ongoing research and development programs. From the primary check valve, the fuel gas enters the cell through drilled communication holes. Due to fuel entrapment, incomplete combustion can occur in these passages, which tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to the check valve’s operation, but in other cases it can be severe. If this build-up becomes heavy, erratic operation of the check valves will occur and they should be removed, cleaned and tested. Whenever the spark plugs are replaced, it would be appropriate to remove and clean the check valves. Some end users have a spare set of check valves which are installed at this time, and the removed set is cleaned for reinstallation at a later date. An orifice (P/N K-8050) is installed on the inlet side of the primary check valve to allow pilot fuel pressures to be comparable to main fuel pressure. The orifice resembles a 1/8″ toe nipple. Ensure this is an orifice by visual inspection, noting a small 0.038″ internal hole. Clean when servicing the primary check valve. Connected directly upstream of the orifice is a secondary check valve (P/N BM-21064). This is utilized only as a backup to the primary check valve. 3
Revised 07/98
ESS-L-981 AJAX LOW EMISSIONS ENGINES
A jet cell-equipped engine does require some additional maintenance over a standard combustion engine. This additional maintenance is offset by gains in combustion stability, lower emissions and improved fuel economy.
4
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
ESS-L-983 Date: July 14, 1998 Supercedes ESS-L-923 AJAX LOW EMISSIONS RETROFIT CONVERSIONS 13-1/4″″ & 15″″ BORES SUPPLEMENT ASSEMBLY PROCEDURE
The new AJAX Low Emissions (LE) Engine utilizes a squish design combustion chamber that includes a jet cell (ignitor cell). The assembly procedure is basically the same as on a standard engine, with the following additions and changes in gas valve timing, ignition timing and power piston position. 1. PISTON & HEAD INSTALLATION: A) The piston used on the LE engine does not incorporate notches or tapped holes in the crown for installation as compared to the standard combustion engine. It is recommended that a rod wrench (or strap wrench) be used to install or remove the power piston. B) Screw piston into crosshead until approximately three (3) threads are left showing. Do not tighten rod nut at this time. C) Install cylinder head (with gasket) and torque to 600 ft-lbs. D) Using solder, set piston-to-head striking clearance at 0.110″ (± 0.010″). This is measured at the 6:00 position by inserting solder through the gas injection hole down towards bottom of head. Roll piston forward (rotate crankshaft in CW direction) past TDC, thus crushing solder. Using a micrometer or dial calipers, measure thickness of crushed solder. Adjust piston position accordingly, to obtain proper striking clearance. Refer to Figure 1.
1
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
Figure 1. Measuring Proper Piston-To-Head Distance
E) Once clearance is set, torque rod nut and check clearance again. Piston has a tendency to turn out slightly when tightening nut. 2. GAS CAM TIMING: Refer to ESS-T-911 as a basis for fuel injection timing. The following changes must be made when converting an engine to LE application. A) The flywheel and gear shield must be removed in order to remove layshaft and reset cam timing. B) Cam timing is retarded from the standard 13° ABDC beginning of injection to 37° ABDC. DO NOT GO BEYOND 37° ABDC! If gears do not line up with cams at 37° ABDC, go back towards BDC (i.e. 35° ABDC). Beginning of injection is 37° 2
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
ABDC on all LE engines but the method of setting the timing is different on DPC-800s & DPC-2804s. C) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2) cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders. #2 & #4 cylinders run off the other cam. Refer to Figure 2.
Figure 2. Control Box And Cams
#1 power cylinder gas cam timing is referenced off #3 bank on the control box. The crankshaft should be rotated in a clockwise direction to 26° ABDC #1 power cylinder. DO NOT GO BEYOND 26° ABDC! If gears do not line up with cams at 26° ABDC, go back towards BDC (i.e. 24° ABDC). The crankshaft is positioned at 26° ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is due to the way the cam is installed on the layshaft. The result will be injection beginning at 37° ABDC. Refer to FIG 3. The cam can now be set using the method illustrated in ESS-T-911. D) Once the preceding is complete, the layshaft gear should be installed and reindexed. 3. IGNITION TIMING: Ignition timing is changed on all LE engines to 3° BTDC. New mag pickup brackets are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate the timing change. 3
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator must be removed and re-indexed to 3° BTDC (refer to the standard DPC-800/DPC2804 Operation & Maintenance Manual for procedure).
Figure 3. Alignment Of Crankshaft
4. IGNITOR ASSEMBLY INSTALLATION: Refer to FIG 4 A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in the LE power head. This ensures proper direction of ignitor exit orifice. It is very important that they are lined up properly! Misalignment will result in severe piston crown damage. It should be noted that when ignitor is torqued into head, the roll pin will not completely set into slot. This is only an alignment reference. B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small amount of grease to hold gasket in place when installing ignitor into the head. Insure O-ring is installed on ignitor at this time also. C) Install water seal (P/N 2-013-129-002) into head.
4
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
Figure 4. Ignitor Assembly
D) Install ignitor into head being very careful not to damage water seal. This may take some hand fitting of seal. Torque down in progressive 5 ft-lb increments to 70 ft-lbs. 5. SPARK PLUGS: On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to 0.018″ was used. The main chamber spark plug utilized the Champion W-18 (BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020″. This allows use of the same spark plug for both the main chamber and igniter. The current production jet cell (YK-8209-C-1) is identified with a ‘3/4’ stamped on the top face. IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage may occur to ignitor and/or spark plug threads as the result of thread depth and thread reach, respectively.
5
Revised 07/98
ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE
6. GAS INJECTION VALVES: The gas injection valve used in the LE power end is of the same basic design as the one used in the standard combustion assembly but the valve housing and plunger housing are not interchangeable. The gas injection valve assembly on the LE engine has a longer valve body housing and a shorter plunger housing to accommodate the profile of the power head. 7. MISCELLANEOUS: In addition to the preceding requirements, engines that are converted to the LE design must have: A) Dry-type, low restriction intake system B) Ring gear start system on 15″ bore engines C) 3/8″ hydraulic supply lines on gas injection system D) Exhaust line adjustment to compensate for length of insertion pipe in muffler If you have any questions or problems pertaining to an LE retrofit conversion, contact your local AJAX-SUPERIOR representative.
6
Revised 07/98
Technical Information Bulletin # 020718 r2 August 24, 2004
Subject: Ajax Component Wear Limits all 15” Bore x 16” Stroke (Includes DPC-180, -360, -600, -800, & 2800 Series models) all 13¼” Bore x 16” Stroke (Includes DPC-115, -140, -230, -280, & 2200 Series models) The following component dimensional specifications and wear limits should be used as a guide for preventative maintenance programs for Ajax equipment. Problems can be detected early before failures occur. These specifications are based on data gathered from a broad range of Ajax installations covering many decades of operating experience. Specific unit performance and maintenance requirements may vary based on application conditions and preventative maintenance practices.
Engine End Data Item
As New Limits
15” Cylinder Bore
14.997- 15.001
15” Piston Skirt Diameter
14.968 – 14.970
Max. Acceptable Up to 15.013, Max .002 TIR Down to 14.961
15” Piston-to-Cylinder Clearance
.027 - .033
Up to .045
15” Piston Ring 1 & 2 Side Clearance
.010 - .0125
Up to .015
15” Piston Ring 3 & 4 Side Clearance
.008 - .0105
Up to .013
15” Piston Ring End Gap
.115 - .135
13¼” Cylinder Bore
13.247 – 13.251
13¼” Piston Skirt Diameter
13.220 – 13.222
Up to .145 Up to 13.263, Max .002 TIR Down to 13.213
13¼” Piston-to-Cylinder Clearance
.025 - .031
Up to .045
13¼” Piston Ring 1 & 2 Side Clr.
.010 - .0125
Up to .015
13¼” Piston Ring 3 & 4 Side Clr.
.008 - .0105
Up to .013
13¼” Piston Ring End Gap
.100 - .126
Up to .145
Piston Rod
2.497 – 2.500
Down to 2.495
Crosshead Guide
12.000 – 12.002
Up to 12.004
Crosshead O.D.
11.987 – 11.989
Down to 11.985
Crosshead-To-Guide Clearance .009 - .013 Up to .016 *Note: determine the minimum clearance by passing the thickest feeler gauge possible over the top of the crosshead to project out the opposite side. Then slide the gauge along the entire length of the crosshead-to-guide fit.
Engine End Data (continued) Item
r2>
As New Limits
Max. Acceptable
Conn Rod Pin Bushing I.D.
5.5044 – 5.5069
Up to 5.509
Conn Rod Side Clearance
.010 - .026
Crosshead Pin O.D.
5.4995 – 5.5000
Crosshead-to-Pin Clearance
.0044 - .0074
Conn Rod Bearing Bore
7.503 – 7.505
Crank Pin O.D.
7.499 – 7.500
Crank Pin-to-Bearing I.D. Clearance
.0044 - .006
Up to .029 Down to 5.4985 Max .001 TIR Up to .0085 Up to 7.507 Max .001 TIR Down to 7.4975 Max .0015 TIR Up to .0075
Main Brg. Journal O.D.
8.374 – 8.375
Main Bearing I.D.
8.3796 – 8.3816
Main Journal-to-Bearing I.D.
.0046 - .0076
Down to 8.3725 Up to 8.3831 Max .002 TIR Up to .0091
Main Bearing Thrust,
.010 - .020
Up to .022
Layshaft Bearing Bore
1.502 - 1.503
Up to 1.504
Layshaft O.D. Layshaft O.D.-to-Bearing Bore Clearance Center Main Bearing I.D. on Twins
1.498 - 1.500
Down to 1.497
.002 - .005
Up to .007
7.754 - 7.756
Up to 7.757
7.749 - 7.750
Down to 7.748
.004 - .007
Up to .0084
DPC-600, DPC-800, DPC-2803, DPC-2804 only
Crankshaft Journal on Twins Center Main-to-Journal Clearance on Twins
Compressor End Data Item As New Limits Max. Acceptable Cylinder Bore ** ** Piston Rings & Riders ** ** Piston-to-Cylinder Clearance ** ** ** contact the Technical Support department at Ajax Piston Rod, 2½" 2.497 – 2.500 2.495 Piston Rod, 2¼ " 2.249 – 2.250 2.2455 Crosshead Guide 11.999 - 12.001 Up to 12.008 Crosshead O.D. 11.984 - 11.986 Down to 11.982 Crosshead-To-Guide Clr.* .011 - .015 Up to .018 *Note: determine the minimum clearance by passing the thickest feeler gauge possible over the top of the crosshead to project out the opposite side. Then slide the gauge along the entire length of the crosshead-to-guide fit. Connecting Rod Pin Bushing I.D. 4.5035 - 4.5062 Up to 4.507 Crosshead Pin O.D. 4.4995 - 4.500 Down to 5.4985 Pin Bushing-to-Pin Clearance .0044 - .006 Up to .0066 Connecting Rod Bearing I.D. 7.503 - 7.505 Up to 7.506 Crank Pin O.D. 7.499 - 7.500 Down to 7.498 Crank Pin-to-Rod Bearing Clearance .0042 - .0066 Up to .008
Technical Information Bulletin # 031104 November 4, 2003 Subject: Hydraulic Fuel Injection System a) Potential Fire Hazard b) Purging Procedure c) Recommended System Modifications A potential fire hazard exists on Ajax engines with hydraulic fuel injection: 1) An incorrect purging procedure can allow hydraulic fluid to contact a hot exhaust pipe and ignite. Use the following procedure: Hydraulic System Purging Procedure:
1. 2. 3. 4. 5. 6. 7. 8.
Shut the engine off. Pressurize the hydraulic reservoir to 15-20 psig. Open the flow control valve (at control box) for the gas injection valve line to be purged. Connect a 10”-12” length of clear plastic 3/8” hose to the bleed valve. Slowly open the bleed valve while directing purged fluid and bubbles into a clean container for reclamation. After the fluid runs without bubbles, close the bleed valve. Close the flow control valve at the control box. Check the reservoir’s fluid level. Be certain to depressurize the reservoir before replenishing the fluid. Note Use Ajax® hydraulic fluid p/n YAE-2150-2. Do not use other fluids.
2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot exhaust pipe and ignite . As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas injection valve assembly is mishandled during servicing.
Traditional bleed valve location for purging of the hydraulic injection system.
Figure 1
As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve minimizes damage potential, and permits more efficient purging of the hydraulic system.
Relocated bleed valve for improved purging of the hydraulic injection system.
Bend tubing to 45º for optimum fluid flow and vibration resistance
Clear plastic 3/8” hose temporarily connected for purging the system.
Figure 2
Convert to the current design by replacing the injection valve’s cap with the current design. A parts kit for the conversion is available, or individual pieces can be specified. See the appropriate table below for a kit P/N or the individual P/Ns. See Figure 2 for a typical installation of the current design. “Top Purge Conversion Kit” (one per Gas Injection Valve) p/n: SPEC 7456-S (steel valve & fittings) Item 1 2 3 4 5 6 7 8
Description Valve Cap Bleed Valve 3/8 Tube x ¼ NPT Reducer, ¼ NPT(F) x 1/2 NPT(M) ¼ Tube Nut & Ferrules 3/8 Tube Nut & Ferrules ¼ Tubing, 316SS 3/8 Tubing, 316SS
p/n: SPEC 7456-SS (ss valve & fittings)
P/N A-2565-F-4 BM-10936 BM-11573-S-6-4
Qty 1 1 1
Item 1 2 3
BM-21147-S-4-2
1
4
BM-21163-S-4 BM-21163-S-6 BM-21071-2-035 BM-21071-3-035
1 1 4’ 4’
5 6 7 8
Description Valve Cap Bleed Valve 3/8 Tube x ¼ NPT Reducer, ¼ NPT(F) x 1/2 NPT(M) ¼ Tube Nut & Ferrules 3/8 Tube Nut & Ferrules ¼ Tubing, 316SS 3/8 Tubing, 316SS
P/N A-2565-F-4 BM-16580-2 BM-11573-SS-6-4
Qty 1 1 1
BM-21147-SS-4-2
1
BM-21163-SS-4 BM-21163-SS-6 BM-21071-2-035 BM-21071-3-035
1 1 4’ 4’
Technical Information Bulletin # 040910 September 10, 2004 Subject: Lubrication Rates for DPC-2200 and DPC-2800 series engine-compressors Use of divider valve designs provides a simple, reliable and predictable approach to engine cylinder and compressor cylinder lubrication. Simplicity is enhanced by use of a lubrication monitor that senses divider valve operation, and displays pints/day of lube oil consumption based on RPM and a divider valve assembly’s displacement volume. The following rates for engine cylinders are based on the use of dry gas, and lube oil per Ajax engineering standard ES-1006. HP listings are at standard conditions of 100ºF and <1500’ elevation. Load Condition
RPM
Lube Rate Pints/Day
Load Condition
DPC-2201 & LE
RPM
Lube Rate Pints/Day
DPC-2803
74 HP
440
2.9*
317 HP
440
12.7 *
76 HP
300
2.6
324 HP
300
10.8
111 HP
440
3.7
475 HP
440
15.8
101 HP
300
3.4
432 HP
300
14.4
148 HP
440
4.9
634 HP
440
21.1
DPC-2202 & LE
DPC-2803LE
148 HP
440
5.9 *
300 HP
440
12 *
151 HP
300
5
307 HP
300
10.2
222 HP
440
7.4
450 HP
440
15
202 HP
300
6.7
409 HP
300
13.6
296 HP
440
9.9
600 HP
440
20
DPC-2801 & LE
DPC-2804
96 HP
440
3.8 *
422 HP
440
16.9 *
98 HP
300
3.3
432 HP
300
14.4
144 HP
440
4.8
634 HP
440
21.1
131 HP
300
4.3
576 HP
300
19.1
192 HP
440
6.4
845 HP
440
28.2
DPC-2802 & LE
DPC-2804LE
192 HP
440
7.7 *
400 HP
440
16.0 *
196 HP
300
6.5
409 HP
300
13.6
288 HP
440
9.6
600 HP
440
20.0
262 HP
300
8.7
545 HP
300
18.1
384 HP 440 12.8 800 HP 440 * This rate is for initial break in running. It is calculated at 1 pint/25 HP.
26.7
Engine lubrication rates for normal operations are based on 1 pint/30 HP.
The following rates for compressor cylinders are based on the use of clean and dry gas, and lube oil per Ajax engineering standard ES-1006. Rates listed are based on MWP and maximum bore size and include the rod packing’s requirements. Refer to the O & M manual for other conditions. NOTE: to attain the total lube rate for a compressor unit, add the lube rates for the individual cylinders. Cylinder Model
MWP (PSIG)
Bore (Inches)
YKCBA
1500
7.25
2.4
1.8
YKCD
1800
5.00-5.75
2.2
1.7
YKDC
1350
6.50-8.00
2.4
1.8
YK11EA
900
9.00-10.50
2.7
1.9
YK11F
600
11.00-13.00
2.9
2.1
YK11G
400 400
14.00 15.00
3.0 3.2
2.1 2.2
YK11HA
400
16.00-17.00
3.5
2.4
YK11J
275
18.00
3.6
2.5
YK11K
250
20.00
3.9
2.7
YK11MA
200
22.00-23.00
4.3
3.0
YK11R
100
28.00
5.0
3.4
3000
3.00-3.50
2.3
1.9
3000 3000
4.00-4.75 5.00-5.75
2.5 2.6
2.0 2.1
5500 5500
3.00-3.50 4.00-4.50
3.1 3.3
2.7 2.8
YK11S
YK11T
Total Lube Rate- Pints/Day @ 440 RPM - @ 300 RPM
Individual cylinder and rod packing assembly lubrication rates are based on the following formula: (0.0000314 x Cylinder Bore x Stroke x RPM) + (0.000333 x Discharge Pressure) + 0.75 Example: YK11G, 14” bore, 11” stroke, @ 440 RPM, 400 psig (0.0000314 x 14 x 11 x 440) = 2.13 (0.000333 x 400) = 0.13 0.75 = 0.75 3.00 pints/day The lube monitor’s rate display is calculated by using the divider valve assembly’s cycle signal, and a BLOCK TOTAL of the assembly. The assembly’s BLOCK TOTAL is determined by adding the “sizing number” for each element within the assembly. Refer to the following table for the sizing number for a particular SMX element: DropSa Element Sizing Number SMX-08 5 SMX-12 8 SMX-16 10 SMX-25 15 SMX-35 20 SMX-40 25 SMX-50 30 Assure that the correct values are used for the engine’s divider valve assembly, and the compressor cylinder’s divider valve assembly. (Metering element designation (the SMX number) is stamped on each element’s nameplate.)
Installation Design for Permanent Ajax Compressor Packages
When designing the engine-compressor installation, several factors should be taken into consideration which can affect the overall performance of the installation: •
An adequate foundation must be provided to assure a stationary mounting base for the enginecompressor skid and any accessory equipment not mounted on the skid. If the unit is installed inside a building or adjacent to other machinery, sufficient space must be allowed around the unit to facilitate maintenance and service work (refer to the unit’s foundation drawing).
•
Avoid arrangements that allow hot air from the muffler or cooler to flow to the air inlet of the cooler or air cleaner.
•
It is recommended that the engine-compressor skid and accessories be placed on grouting on the foundation to ensure full, even bearing support under the equipment. Grouting is poured after the equipment has been properly set and aligned on the foundation. For a grouted installation, the foundation top surface should have a rough surface (not trowelled) to ensure an optimal grout-to-cement bond.
•
Air cleaners may be located outside the building to avoid heat generated by the unit; however, direction of prevailing winds should be considered in their location.
•
Installation of units inside buildings should be designed to allow for the passage of hot air from the coolers to the outside through adequate natural ventilation or through ducting to the outside of the building. Unitized vertical discharge coolers may frequently be installed outside the building to ease the disposal of heated air.
•
The exhaust system must be properly designed for the operating conditions of the enginecompressor, both for proper scavenging of the power cylinders, and for correct dissipation of exhaust heat.
•
The instrument panel should be placed in a location convenient for the operator.
NOTICE: The size and construction of the foundation must be selected to suit the soil conditions at the unit location. In designing the foundation, the static and dynamic loads must both be considered. The unbalanced forces and couples of each engine-compressor unit are available, on request, from the service branch or factory. In well compacted, high load capacity soils, (6 tons/ft2 minimum) the minimum dimensions shown on the appropriate foundation drawing supplied should be adequate for a reinforced concrete foundation (refer to the unit’s foundation drawing).
! "# The foundation design must include anchor bolts to secure the engine-compressor unit. Anchor bolts must be located to achieve precise alignment with the skid’s anchor bolt holes (refer to the unit foundation drawing). Use sufficiently long anchor bolts to ensure deep placement and adequate length above the foundation (account for full thread engagement of nuts and space required for grouting). Preferred practice is to set anchor bolts while pouring concrete for the foundation. A common practice is to use canister-style anchor bolts to afford position adjustment capability. Here, the anchor bolt is centered inside a piece of 2” to 2-1/2” pipe and positioned so the top of the pipe is flush with the top of the completed foundation. The open pipe end should be blocked to keep foundation concrete out. This approach is illustrated in Figure 1.
%
&
'
If the foundation has already been poured, then anchor bolts may be set by first drilling holes in the foundation and then placing and grouting the anchor bolts in. Sulphuring, a means to dissolve concrete, may also be used to create anchor bolt holes. In soils having a low load support capacity, a wider and longer foundation or one which angles out at the bottom should be used to distribute the load over a larger area on the bottom face of the foundation. NOTICE: In general, it is poor practice to economize on the amount of concrete used on the engine compressor unit foundation. If the soil load bearing capacity is questionable, it is highly recommended that a soil analysis be made prior to designing or pouring the foundation. If unsuitable soil is encountered, the foundation design must be changed to accommodate the soil.
$
Allow foundation concrete to cure for at least 28 days before installing an engine-compressor package. Using ASTM guidelines, a concrete physical properties test may be performed to ensure that sufficient curing has occurred. Any concrete-related problems that may exist, such as low tensile or compressive strength, may be detected at this time. If the concrete is ready for enginecompressor installation and grouting, then proceed with foundation surface preparation. In order to achieve optimal grout-to-concrete bonding, prepare surfaces for grouting by chipping away all laitance, oil-soaked concrete, and damaged concrete until 50% aggregate is exposed (the foundation contractor may have already prepared the foundation in this manner). A chipping hammer or 15-pound chipping gun (with chisel point) may be used for chipping. NOTICE: Avoid heavy chipping guns as they may create micro fractures within the foundation. Rebar wickets or dowels may be used to provide additional mechanical locks between grout and concrete. These may be set by drilling into the foundation and inserting the wickets or dowels. Locate the wickets/dowels away from foundation anchor bolts. Exposed length above the foundation surface should be limited to ≈60% of the grout thickness (1-1/2” maximum for 2-1/2” grout thickness). Determine whether or not grout expansion joints are required. Foam strips or other suitable (compressible, temporary) material may be used. Strips may be secured to the foundation with glue; apply wax to exposed surfaces to allow easy removal after the grout has cured. If a crane is to be used to place the engine-compressor unit, then expansion joints may be installed in advance. If jacks and rollers are used, then expansion joints should be added prior to lowering the unit. Set leveling planes in level position on the foundation under the leveling screw locations. Clean all residual paint, oil, grease, and dirt from foundation surfaces that will come into contact with grout. For final cleaning, use the grout manufacturer’s recommended solvent using clean solution and clean cloth for the last wash. Lacquer thinner may be substituted if necessary; however, mineral spirits cannot be used for this purpose. If cement-based grout is to be used then pre-soak the foundation with water to help ensure that foundation concrete does not draw water away from the grout after placement. If epoxy resin grout is to be used, then use compressed air to blow away all dust and debris and dry all moist foundation surfaces. NOTICE: Grout may adhere to levelling screws, tools, forms or other items which have not been protected with paste type wax. The end result is a properly prepared foundation ready for setting the engine-compressor package.
(
%
)
*
%
+
! "# It is recommended that the skid bottom in contact with grout be free from all paint, grease, primer, or other material that could inhibit grout bonding. A light film of rust is usually acceptable. Use evaporative solvent to wipe down all skid surfaces to be bonded to grout.
The engine-compressor skid is normally set directly upon the foundation block. Where overhead space and/or crane capacity permit, the unit may be lifted using brackets or lifting lugs (provided) and placed over the foundation anchor bolts. Lifting cables must be provided with spreaders so that the lifting cables will remain parallel to the vertical center-line of the unit. If overhead lifting capacity is not available, then jacks and rollers (cribbing) may be used to move the unit into place over the foundation anchor bolts. Lower the engine-compressor unit to its final elevation. Allow 2” nominal clearance between the foundation and skid (1-3/4” minimum, 2-1/2” maximum). This clearance is recommended to allow sufficient room for placing grout to all necessary locations beneath the skid. Use leveling screws to make final skid elevation adjustments such that all mounting pads are at the prescribed elevation.
Make certain that the unit is set level, accurately aligned with the cooler, aligned with any other offskid accessories, and adequately supported so that all bearing surfaces on the bottom of the skid have full contact to avoid deflections in the bed or skid
Perform web deflection measurements on the engine to check crankshaft alignment. Use these measurements to fine-tune the engine-compressor elevation using the leveling screws. For longterm engine performance it is essential that web deflections are held within specification (see Ajax-Superior Engineering Standard ES-4025: Crankshaft Web Deflections for Three- and FourCylinder Ajax Engines). Install belts on cooler drive and check alignment. Accurate alignment is essential to ensure acceptable drive component service life and to eliminate detrimental loads and vibrations. The drive alignment is checked by drawing a string taut between adjacent faces of the two sheaves (pulleys), lined up to intersect the two hubs. When the drive is properly aligned, the string will barely touch the face of each sheave at the points where the string crosses the sheave rims (see Figure 2 below).
%
, %
-
(
) %
.
Primary Sheave
Critical Alignment Point
Secondary Sheave Line Bring Line toward the Critical Alignment Point to establish Secondary Sheave alignment
Line Attachment
%
$&
/
%
(
After properly positioning the engine-compressor unit, then finish up by taping off or pastewaxing all leveling screw threads so screws can be removed after the grout has cured.
Grout should have the following characteristics: •
A consistency that allows for proper placement
•
High bonding strength
•
High dimensional stability
•
Strength to transmit static and dynamic forces from unit to foundation
Grout may be either of the conventional (cement based) type or of the epoxy resin type. Each type has advantages and disadvantages: Working Time: Check the grout specifications. Working time may vary from as little as 15-20 minutes to over 1 hour. Select a product that will allow adequate mixing, handling, and placing time. Working Temperature: Check the grout specifications. Manufacturers often recommend that foundation, equipment, and grout materials attain equilibrium temperature on the order of 70°F before mixing and pouring. If possible, avoid grouting at temperatures below 50°F, although grouts for use at such temperatures are available. Note, however, that temperature can affect grout working time. Flowability: Most grout manufacturers will claim that their products are “flowable,” but this is a relative term. Grout viscosity should not be too low (runny, not stackable) or too high (not pourable). Grout flowability may be increased by reducing the amount of aggregate used. Consult with the grout manufacturer’s technical representative if questions arise here.
*
! "# Compressive Strength and Curing Time: Epoxy-resin grouts, although more costly, provide greater compressive strength and cure much more quickly than do cement-based grouts. Long-Term Performance: Properly mixed, installed, and cured cement-based grouts have very good long-term dimensional stability but may degrade structurally (cracking) under continual, excessive vibration input. Epoxy-resin grouts have better long-term structural integrity but, being viscoelastic materials, are subject to creep that is heightened by elevated temperatures. Tables 1 and 2 provide examples of cement-based grout and epoxy resin grout respectively.
0
&,
-
*
*
1
2
'
/ %
Unisorb V-1® Non-Shrink Grout Five Star® Products’ High Strength Grout
$& , *
,
3
*
2
1
2
11,800
28
10,000 - 14,000
28
8,400
28
Philadelphia Resins Chockfast® ITWPRC 100 Non-Shrink
0
1
%
1
2
'
/ %
1
% 2
1
2
L&M Construction Chemicals’ Epogrout 758
13,200
7
Tristar Masterflow® 648CP
15,900
3
Ceilcote® 848 Grout
8,000
3-10
Epoxy resin type grouting materials may present certain health hazards. The grout manufacturer’s handling instructions should be strictly followed.
Affirm that the selected grout will meet the installation load requirement, the working temperature condition, and the working time requirement. Grouts such as those listed in Tables 1 and 2 have sufficient compressive load strength to support typical AJAX engine-compressor and cooler packages.
*
Table 3 provides compressive load estimates for 2801-, 2802-, 2803-, and 2804-based units. Skid footprint is the skid base area that will be in direct contact with the grout. The cooler load is computed separate from the engine-compressor load for 2803- and 2804-based units.
NOTICE: The estimates in Tables 1,2, and 3 are for reference purposes only! Be aware that total package weight is dependent on the number and size of compressor cylinders, and the number of compression stages and associated pressure vessels. If needed, grout manufacturer representatives can help in the grout selection process.
0
+& *
/
! " 7
%
%
6 1 0 82
6
3 5 2
,
1 9
9
8*
) %
* :1
/ ;1 2
$2
2801
31,000
26.3
8.6
2802
57,300-67,300
43.3
9.2-10.8
2803
70,000
35.2
13.8
2804
85,000
66.4
8.9
†: Minimum footprint comprised of primary longitudinal skid members only. ‡: Compressive Strength (Pressure) = Unit Weight / Skid Footprint Area.
All grout should be mixed according to manufacturer’s instructions and recommendations. All longitudinal skid members must be grouted. Major load-bearing lateral skid members should also be grouted. Grout the skid base using procedures suitable to the application or unit involved. The final grout level should be approximately up to the skid flange thickness. Care must be taken to provide adequate forms to retain grout. Remove any excess grout before it has been completely set.
After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all levelling screws.
NOTICE: This is essential to insure that the unit is being supported only by the grout, not by the screws. Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment. Remove temporary expansion joint materials and fill expansion joints with joint compound.
*
%
4
Table 1: Torque Table for Critical Ajax Fasteners ! "# $
&
"'( %
"$ % )
%
Frame and Crankshaft: End covers/bearing supports
Bolts
1
150
Front end bearing support
Bolts
1&2
25
Center main bearing
Bolts
2
95
Center main bearing cap
Bolts
2
250 - 265
Stud nuts
1
520 - 600
Flywheel ringfeder
Bolts
All
185
Drive shaft ringfeder
Bolts
All
185
Main bearing cap
Studs
3&4
250
Main bearing cap
Stud nuts
3&4
360
Tie bars to frame
Bolts
3&4
260
Top Center for crosshead guide
Bolts
3
100
Power cylinder to frame
Bolts
All
490
Connecting rod caps
Bolts
All, P & C
650 - 700
Allen Bolts
All
38
Studs
15 Bore
220 -250
Crankshaft counterweight
Power cylinder side cover plate Cylinder Head: Head to cylinder
* +, Table 1: Torque Table for Critical Ajax Fasteners ! "# $
&
"'( %
"$ % )
%
Head to cylinder
Stud nuts
15 Bore
600
Head to cylinder
Studs
13-1/4 Bore
8-1/8 height
Head to cylinder
Stud nuts
13-1/4 Bore
490
Precambrian hold down flange
Bolts
All LE
70
Pilot fuel check valve clamp
Bolts
All LE
15
Spark plugs
Plugs
All
60
Indicator cock
Valve
All
70
1
Control Box and Layshaft Control box to frame
Stud nuts
1
95
Control box to frame
Stud nuts
2,3, & 4
160
Support bracket on crank end of layshaft
Bolts
All
45
Cover on crank side of control box
Bolts
All
10 -12
Caps for hydraulic power plungers
Bolts
All
11
Cover on top of control box
Bolts
All
25
Gears in control box
Set Screws
All
25
Cams in control box
Set Screws
All
25
Ajax governor drive gear
Nut
All
0.003 - 0.006 clearance
Woodward gov. drive gear
Nut
All
7 - 15 (line up with pin)
Crosshead and Piston Rod:
Table 1: Torque Table for Critical Ajax Fasteners ! "# $
&
"'( %
"$ % )
%
Compressor guide to frame
Stud nuts
All, C
280 - 300
Rod packing ass’y to x-head guide
Bolts
All
38
Nut
All, P & C
3200
Set screws
All
55
Nuts
All
50
Piston rod to crosshead Crosshead set screws Crosshead jam nuts
Note #1: Key to “Type of Unit” Abbreviations 1 = 2201 & 2801 2 = 2202 & 2802 3 = 2803 4 = 2804 C = Compressor P = Power Side
Note #2: Torques are based on the use of Lubriplate Table 2: General Torque Table for Fasteners ) 2 $
. / ' )0
& "'( %3 45
& "'( % 3 45
1
#8
32
2
2.5
#8
36
2
2.5
#10
24
3
3.7
#10
32
3
3.7
1/4”
20 28
5 6
6 7.5
-
* +, Table 2: General Torque Table for Fasteners ) 2 $
. / ' )0
& "'( %3 45
& "'( % 3 45
1
5/16”
18 24
10 11
12 13
3/8”
16 24
17 18
20 21
7/16”
14 20
28 30
34 36
1/2”
13 20
43 50
53 60
9/16”
12 18
62 71
75 85
5/8”
11 18
85 100
103 120
3/4”
10 16
155 190
190 225
7/8”
9 14
250 280
310 340
1”
8 12 14
340 385 400
415 460 475
1-1/8”
7 8 12
450 475 525
550 575 625
1-1/4”
7 8 12
660 690 760
795 830 895
1-3/8”
6 8 12
870 940 1000
1020 1090 1150
1-1/2”
6 8 12
1150 1220 1310
1370 1440 1530
1-5/8”
6 8 12
1430 1510 1610
1690 1770 1870
6
Table 2: General Torque Table for Fasteners ) 2 $
. / ' )0
1-3/4”
& "'( %3 45
& "'( % 3 45
1 8 10 12
1920 1990 2050
2260 2330 2400
•
Torque values are for Grade 5 fasteners.
•
Values are Based on the use of Lubriplate.
•
For torques less than 10 lb-ft, a lb-in torque wrench should be used to improve accuracy (multiply the torques in this table by 12 to get lb-in).
7
Section 2 – Package Drawings Vendor
Bulletin No.
General Arrangement..........................................Ajax
02-00-T05E-397
P&ID....................................................................Ajax
02-00-T00A-307
Foundation(unit)..................................................Ajax
02-00-T050-363
Foundation(cooler)..............................................Ajax
02-00-T050-362
Engine-Compressor Package Service Manual
Section 3 – Engine Operation and Maintenance Manual – Integral Engine-Compressors .......................... Ajax Frame and Engine Crossheads ..................... 0102-000 Crankshaft and Flywheel................................ 0202-000 Power Connecting Rod .................................. 0300-000 15” Power Cylinder......................................... 0500-200 Fuel Distribution System ................................ 0802-002-01 Gas Injection Valve................................................... YAE-5100 Ignitor......................................................................... YK-8209-C-2
Control Box and Layshaft ............................... 0902-000 Air Intake Manifold...........................................GD-0043 Cooling System .............................................. 1102-200 Divider Block Lubrication System................... 1202-000-03 Integrated Governor Throttle Body................. 1302-000-04 Lubricator Drive Assembly ......................................... YAE-5581 Alternator Drive Assembly .......................................... YAE-1561-E
Compressor Crossheads and Guides ............ 1402-000 Compressor Connecting Rod ......................... 1512-000 Shielded Ignition System................................ 1802-000-06 Altronic III Service Manual................................... Altronic
AIII SM 12-96
Altronic III Installation .......................................... Altronic
AIII II 04-92
Ignition Coil, 591-010-S....................................... Altronic
Engine-Compressor Package Service Manual
591-010-S
Frame with Counterweights and Solid Pin on Throw # 1 Crosshead Assembly Drawing 0102-000 Ref # 1 2 3 4 5 * * * * 6 7 8 C D E F G H K L M 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26
Desscription Bed Compressor Nameplate Screw Drive Support Bearing Support Bearing Support Bearing Cap Bearing Nut Castle Bolt Support Bearing Washer Plain Packing Engine Rod Scraper Ring Set Plate Cup Adapter Cup Bolt Wire Bolt Slinger Ring Retaining Plug Pipe Plug Pipe Plug Pipe Cover Rect Bolt Hex Head Cover Square Breather Support Bearing Shield Gasket Flat Rect Gasket Flat Rd Gasket Flat Rect Baffle Washer Plain Gasket Flat Rd
P/N
Qty K-6000-J 1 ea BM-10003-M-1 1 ea BM-1386-A 8 ea K-6015-C 1 ea YAE-5549-3 1 ea A-3320 1 ea A-3321-1 1 ea BM-11916-1614 4 ea P-5455-2 4 ea A-2581-F-1 1 ea A-573 6 ea YAE-5014-A 2 ea A-3649 1 ea BM-1328-L-1 1 ea A-3666 1 ea A-3667 1 ea A-3665-A 1 ea A-3668-A 1 ea K-7021-D-5 3 ea XAISI 1010 WR 15GA 2 ft BM-11900-C-0616-20 3 ea A-1264-A-1 2 ea Q-6316-A 1 ea BM-11953-06 4 ea BM-11958-08 2 ea BM-11953-04 4 ea A-1944-A-1 1 ea BM-11900-0813-08 8 ea K-6013-F 2 ea BM-776-F 2 ea K-6018-B 1 ea A-2579-E 1 ea A-4522 1 ea A-4521-A 1 ea A-2233 1 ea K-6243 2 ea A-4675 8 ea A-2227-A 2 ea
Ref # 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 * * *
Desscription
Gasket Gasket Flat Rd Gasket Bolt Hex Head Bolt Hex Head Bolt Hex Head Bolt Hex Head Bolt Hex Head Bolt Hex Head Stud Nut Plain Hex Bearing Journal Shim Laminated Shim Solid Pin Cotter Crosshead Power Rod Solid Pin Crosshead CounterweightCrosshead Bolt Hex Head Washer Plain
P/N
A-2253-B A-2235-A K-6241 BM-11900-C-0420-06 BM-11900-C-0813-08 BM-11900-0813-10 K-7021-28 K-7021-B-9 BM-11900-1409-18 K-8095-0813-16 BM-11904-0813 A-3310-A A-3326-D A-3326-D-1 BM-11925-05-07 A-1220-K A-1222-D K-6343-L-1 BM-11900-0813-18 BM-11918-10-N
Qty 2 ea 2 ea 2 ea 8 ea 10 ea 41 ea 6 ea 8 ea 12 ea 16 ea 18 ea 1 ea 2 ea 2 ea 4 ea 2 ea 1 ea 2 ea 8 ea 8 ea
NOTE: components are not shown; see SK-9059-R for the counterweighting components used on throw # 1.
45 46 47 48 49 50 51 52 53 55 56 57 58 59 60
Plate Screw Screw Screw Nut Flange Gasket Plug Bolt Wire Bracket Bolt Pin Stud Decal
A-4629 2 ea BM-11921-1210-32-CP 2 ea BM-11921-1210-20-DP 2 ea BM-11921-1210-20-CP 2 ea BM-11910-A-1210 6 ea K-8010-B 2 ea K-8011-A 2 ea BM-11953-02 1 ea BM-11900-1409-16 8 ea XAISI 1010 WR 15GA 14 ft K-7257-K 1 ea Hex Head BM-11900-1409-22 4 ea Dowel T-278-A 2 ea Double End 913-942-013 2 ea Hyd System BM-21164 1 ea Set Set Set Jam Orifice Flat Rd Pipe Hex Head
Frame with Counterweights and Solid Pin on Throw #1 Crosshead Assembly Drawing 0102-000
020205
Power Connecting Rod Assembly # 0300-000 Ref # Description 1 Conn Rod Power B Bearing C Pin D Wire E Dip F Bushing G Screw H Screw J Pin
P/N C600-3-1A A-2894-E-2 BM-16475-6-8 XAISI 1010 WR 15GA A-2933 A-1223-3 BM-11090 K-6650 BM-11548-24-64
Qty 2 ea 1 ea 1 ea 3 ft 2 ea 1 ea 1 ea 2 ea 2 ea
Ref #
Power Connecting Rod Assembly # 0300-000
Description
P/N
Qty
022002
15" Power Cylinder, LE Cylinmder Head, Piston-Rod, and Mixing Valve Assembly # 0500-200 Ref # 1 3 4 A 6 7 9 10 11 13 14 15 17 18 19 * * 20 21 22 23 24 A B C D E F G
Description Cylinder, 15" Power Stud Valve Indicator Gasket Head, LE Power Gasket Head Screw Twelve Pt Washer Finished Plug Pipe Lockwasher Split Stud Tap End Nut Plain Hex Nut Gasket, Cyl-to-Frame Piston/Rod Engine Piston Rod Ring Piston Nut Piston Rod Gasket, Cyl-to-Exh Pipe Capscrew Hex Head Valve Mixing Valve Plate Stop Stop Spring Bolt Seat Pin
P/N K-7201-E K-8093-1608-32 BM-16556 A-3794 A-4502-N A-4513-C-1 K-8142 BM-11808 BM-11953-04 SF-115-2-036 1-04F-001-108-106 1-08F-005-108 BM-11904-1608 A-474-B YAE-7516-B-2 A-4506-A XTGSDI0208-041062 A-4711-A A-1278-B A-4514 BM-11900-1409-16 YAE-7510-B-1 A-2693-F A-4512 A-4512-1 M-1485 BM-11900-C-0420-08 A-4527-2 01RP121600
Qty 2 ea 8 ea 2 ea 1 ea 2 ea 2 ea 16 ea 28 ea 2 ea 28 ea 28 ea 28 ea 8 ea 2 ea 2 ea 1 ea 1 ea 8 ea 2 ea 2 ea 24 ea 2 ea 10 ea 2 ea 2 ea 20 ea 10 ea 1 ea 20 ea
Ref #
Description
15" Power Cylinder, LE Cylinder Head, Piston-Rod, and Mixing Valve Assembly # 0500-200
P/N
Qty
010307
DPC-2802 Divider Block with Proximity Switch Lubrication System Assembly # 1202-000-03 Ref # Description 1 Lubricator (ref 5.33:1 ratio) A Pump, " B Pump, ¼" C Rupture Disc 1750 psi D Rupture Disc 2950 psi E Check Valve Assembly 2 Bracket 3 Capscrew 4 Capscrew 5 Bracket 6 Bolt Hex Head 7 Capscrew Hex Head 8 Washer Plain 9 Nut Plain Hex 10 Tubing Stainless 11 Bracket Angle 12 Capscrew Hex Head 13 Valve Divider E Filter Assembly F Filter Element 10 Micron G Switch Proximity H Valve Check J Cycle Indicator 14 Bolt Hex Head 15 Nut Plain Hex 16 Lockwasher Split 17 Connector Tubing 18 Elbow Tubing 19 Valve Check 20 Elbow Tubing 21 Capscrew Hex Head 22 Union Tubing
P/N BM-21087-C-2 BM-21136-1 BM-21137-1 BM-21138-17 BM-21138-29 BM-21171 K-8016-A BM-11900-0616-10 BM-11900-0616-18 K-8016-B BM-11900-0813-16 BM-11901-0820-06 BM-11918-10-N BM-11904-0813 BM-21071-2-035 K-7193-17-A BM-11900-0813-08 BM-11083-W-2 BM-21135 BM-21135-A BM-21133 BM-21171-1 BM-21134 BM-11900-0420-16 BM-11904-0420 BM-11782-A-04 BM-11610-S-4-2 BM-11573-S-4-4 BM-10885-F-1 BM-11573-S-4-2 BM-11900-0813-08 BM-11623-S-4-4
Qty 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 2 ea 1 ea 2 ea 2 ea 6 ea 2 ea 40 ft 1 ea 4 ea 1 ea 1 ea 1 ea 1 ea 6 ea 1 ea 2 ea 5 ea 5 ea 6 ea 1 ea 6 ea 2 ea 3 ea 1 ea
Ref # 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 42 43
Description Tubing Stainless Connector Tubing Union Tubing Elbow Tubing Gasket Flat Oval Capscrew Hex Head Trough Clamp Tubing Clamp Tubing Screw Machine Gasket Clamp Tubing Clamp Tubing Clamp Tubing Nut Hex Capscrew Hex Head Lockwasher Split
DPC-2802 Divider Block with Proximity Switch Lubrication System Assembly # 1202-000-03
P/N BM-21071-1-3-035 BM-11610-S-6-4 BM-11623-S-6-6 BM-11573-S-6-4 A-2117 BM-11900-0616-10 A-2115 T-112 T-110-A BM-11929-2520-04 A-3175 2516 0402 2516 0403 2516 0404 BM--11468-0420 BM-11900-0420-20 BM-11782-A-06
Qty 3 ft 1 ea 1 ea 1 ea 1 ea 2 ea 1 ea 2 ea 2 ea 6 ea 1 ea 3 ea 3 ea 2 ea 12 ea 1 ea 2 ea
032807
Integrated Governor Throttle Body (Mechanical Assembly) 1302-000-04 Ref # 1 2* 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 34 37* 38
Description IGTB Governor, 30mm, 24VDC Cable & J-box Assembly O-ring Outlet Flange Inlet Flange SHCS #10-24 x 5 UNC Lock Washer, #10 Support Bracket HHCS, -11 UNC x 3¼ Flat Washer, " PCC Fuel Filter Bracket Lock Washer, " HHCS, -16 UNC x 1 Needle Valve Gauge, 0-30 PSIG Hex Head Plug, ¼" NPT Male Tubing Elbow, ¼" Flexible Hose, 1" Flexible Hose, 1½" Pipe Nipple, 1½" x 4"L Street Elbow, 45º, 1" NPT Alternator Drive Assy, 5.33:1 Drive Assembly Gasket Drive Gear, 5.33:1 System Set Screw Stud, -16 UNC x 2¼"L Flat Washer, " Lock Washer, " Hex Nut, -16 UNC V1 Alternator, 24VDC HHCS, -16 UNC x 1¼"L Battery Pack Lubricator Drive Assy, 5.33:1
P/N BM-21152-30 YAE-5583 BM-21146 K-8256-A K-8256-C BM-11473-0324-40 BM-11782-A-03 K-8256-B BM-11900-1011-26 BM-11918-12-N K-7889-1 BM-11782-A-06 BM-11900-0616-08 2549 0057 2015 3312 BM-11950-02 BM-11573-S-4-4 K-8263-A-24 K-8262-A-30 BM-11932-12-09 BM-11969-08 YAE-1561-E K-6258-C A-4658-A BM-11095-A K-8095-0616-18 BM-11918-08-W BM-11782-A-06 BM-11904-0616 BM-21156 BM-11900-0616-10 BM-21158 YAE-5581
Qty 1 ea 1 ea 2 ea 1 ea 1 ea 4 ea 4 ea 1 ea 2 ea 2 ea 1 ea 2 ea 8 ea 2 ea 2 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 4 ea 8 ea 6 ea 4 ea 1 ea 2 ea 1 ea 1 ea
Ref # 40 41* 42 43 44 45 46 47 48 49 50 51 52 53 54
Description Magnetic Pick Up, -18 x 3" Mag P/U Cable Assembly Mag P/U Bracket O-ring, Alternator Flange Plate Gasket Flat Oval Trough Gasket Flat Oval Stud Nut Plain Hex Bolt Hex Head Elbow Tube Compn Bolt Hex head Tubing Welded Union Tube Compn
P/N 2049 1291 3850 0033 8025 9400 BM-16348-F-236 A-1944-A-2 A-2233 A-2115 A-2117 K-8095-0813-16 BM-11904-0813 BM-11900-0616-10 BM-11573-S-6-4 BM-11900-0813-10 BM-21071-3-035 1 BM-11623-S-6-6
Qty 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 2 ea 2 ea 2 ea 5 ea 3 ea 1 ea
Note: refer to Manual's section 11 for additional information about the IGTB system. *shipped separately
Integrated Governor Throttle Body (Mechanical Assembly) 1302-000-04
091205
Section 4 – Fuel / Start System Vendor Fuel Filter Drawing .............................................. Ajax
Bulletin No. TP 00-22-T05A-002
Instrument Gas Pressure Regulator, 67CFR-225........... Fisher
Form 5469
Differential Pressure Gauge, 120-AA-00-00-30 .............. Mid-West
IM 120/05
Drain Trap, 22-LD ........................................................... Armstrong
LD-39
Level Controller, L1200NDVO, O & M ............................ Murphy
00-02-0175
Dump Valve, DVU-150, O & M........................................ Murphy
00-02-0483
Fuel / Start Gas Piping Drawing.......................... Ajax
TP 02-22-T010-331
Starter Relief Valve...............................................Ajax
00-22-T010-307
Starter / Relief Valve Vent Header....................... Ajax
02-48-T010-388
Regulator, Main Fuel, Type 627, O&M ........................... Fisher
5252
Fuel Shutdown Valve, M5081-C-LS................................ Murphy
M-7980
Mercer Relief Valve 8100 Series O & M.......................... Mercer Mercer Relief Valve 9100 Series O & M.......................... Mercer Regulator, PCC Fuel Pressure, Type 64 Operation and Maintenance........................................ Fisher
1245
Shutoff Valve, PCC Fuel, Type 119 Operation and Maintenance........................................ Fisher
5204
Starter Motor, BM-11679-Q-1, 90 PSIG, IOM ................ TDI
T1-702
Starter Motor Service Manual ......................................... TDI
T1-701
Performance Curve, T121-B, Natural Gas...................... TDI
AN00-639 8/00
Engine-Compressor Package Service Manual
Flange Fastener Tightening Torques The vessel’s closing flange gasket p/n is 3050 0160.
Thread Size Torque, Lbs-ft 3/4”-10
190
Notes: 1. The threads and nut faces must be lubricated to attain the correct clamping force. Use only crankcase oil or Lubriplate.
At 12-14 psid, replace the filter element.
2. Use a criss-cross star pattern to tighten the bolts in sequence.
Set the instrument gas pressure regulator at 30-50 psig.
Replacement element p/n is 6321 9734. The element’s retaining cap should be tightened to 5-10 lbs-ft only.
3. The torque should be applied in a minimum of three increments.
Warning
Fuel Inlet
All repair and resetting of safety relief valves should be performed by a National Board certified valve repair shop holding a “VR”stamp.
Fuel Outlet
Front View
Connect to the liquid drain system
Rear View
Manual Drain Valve
Fuel Filter Assembly TP 00-22-T05A-002 r2
Fuel Filter Assembly TP 00-22-T05A-002 r2 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Description
P/N
Ball Valve, ½" NPT 2549 2094 Bushing, ½" x ¼" NPT 2527 0402 Bushing, ¾" x ½" NPT 2527 0604 Bushing, ¾" x ¼" NPT 2527 0602 Bushing, 2" x 1" NPT 2527 2010 Differential Pressure Gauge, 0-30 psid 2015 0116 Drain Trap, 22-LD 2051 0102 Male Tubing Elbow, ½" Tube x ½" NPT 2507 4204 Male Tubing Elbow, ¼"Tube x ¼" NPT 2507 4202 Male Tubing Elbow, ¼"Tube x " NPT 2507 4201 Male Tubing Elbow, ¾"Tube x ¾" NPT 2507 4606 Pressure Regulator, Instrument Gas 2040 0063 Gauge Glass Valve Set 2015 3169 Level Controller, L1200NDVO 2005 9124 Male Connector, ½" Tube x ½" NPT 2507 1404 Male Connector, ¼" Tube x ¼" NPT 2507 1202 Male Connector, ¾" Tube x ¾" NPT 2507 1606 Male Connector, 1" Tube x 1" NPT 2507 1808 Relief Valve, 1" x 1" 155 psig 63ME2M2FVAC0155 Dump Valve, DVU 150 2003 6222 Needle Valve, ¼" 2549 0028 Pipe Nipple, Close, Sch 80, ½" NPT 2539 4404 Pipe Nipple, Close, Sch 80, ¼" NPT 2539 4200 Pipe Nipple, Close, ½" NPT x 3 LG 2539 4414 Pipe Plug, Hex Head, 2" NPT 2541 6020 Pressure Gauge, 0-60 psig 2015 0220 Red Line Gauge Glass 2015 0158 Tee Tube, ½" 2545 4004 Tee Tube, ½" 2507 6504 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504
Qty
Item
1 2 1 1 1 1 1 2 6 2 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 11" 8" 25" 32" 46" 20"
36 37 38 39
Fuel Filter Assembly TP 00-22-T05A-002 r2
Description
P/N
Qty
Tubing, 316SS, ¼" x 0.035 Wall Tubing, 316SS, ¼" x 0.035 Wall Tubing, 316SS, ¾" x 0.049 Wall Tubing, 316SS, 1" x 0.049 Wall
5551 3504 5551 3504 5551 4912 5551 4916
18" 16" 9" 47"
Filter Element Flange Gasket
6321 9734 3050 0160
1 1
120804
67C Series
Instruction Manual Form 5469 May 2006
67C Series Instrument Supply Regulators
TYPE 67CF FILTER REGULATOR WITH OPTIONAL GAUGE
TYPE 67C OR67CR REGULATOR
Figure t Typical 6 7C Series Regulators
Introduction
The Types 67C and 67CS are the standard instrument supply regulatorswithout a filter or internal relief.
Scope of Manual
The Types 67CF and 67CFS are equipped with a filter for removing particles from the supply gas.
This manual provides instructions and parts lists for 67C Series instrument supply regulators. Instructions and parts lists for other equipment mentioned in this instruction manual, as well as for other 67 Series regulators, are found in separate manuals.
Product Descriptions The 67C Series direct-operated regulators are typically used to provide constantly controlled, reduced pressures to pneumatic and electropneumatic controllers and other instruments. They are suitable for most air or gas applications. Other applications include providing reduced pressures to air chucks, air jets, and spray guns.
The Types 67CR and 67CSR have an internal relief valve with a soft seat for reliable shutoff with no discernible leakage. The Types 67CFR and 67CFSR have a filter and internal relief valve with a soft seat for reliable shutoff with no discernible leakage.
Specifications Some general 67C Series ratings and other specifications are given on page 2. A label on the spring case gives the control spring range for a given regulator as it comes from the factory.
EMERSONL
Process Management
® Mid-West Instrument
BULLETIN NO. IM120/05 (Supersedes IM120/03)
®
Model 120 Series “Filter Minder” Installation and Operating Instructions
INSPECTION Before installation check the nameplate on each instrument against the receiving paperwork and the intended application for correct part number, materials of construction, working pressure, dial range, etc. If equipped with switches, check electrical rating, type of enclosure, etc. Inspect for shipping damage and, if damaged, report it immediately. NOTE - Before attempting repairs contact your local Mid-West Representative or our factor y. Failure to do so will void any warranty. PRODUCT DESCRIPTION ®
The Model 120 Series "Filter Minder" is a rugged, medium-range differential pressure instrument available as a switch, a gauge, or both. See "Part Numbering System". (Fig. 4) for available options. Differential pressure is sensed by the movement of a floating piston magnet against a calibrated spring. The magnetically coupled gauge pointer outside the pressure housing follows the movement of the piston magnet and indicates differential pressure on the dial scale. When equipped with switches, a contact is made or broken by the magnetic field of the piston magnet. See Bulletin ELECIM120/latest for gauges with switches. The unit provides full over-range protection to the rated working pressure of the housing in either direction.
The precise piston/bore fit allows minimal leakage from high to low sides. This leakage is only 5 to 15 SCFH air at ambient conditions and a pressure differential of 100 PSID. INSTALLATION ® Model 120 Series "Filter Minder" is calibrated and tested prior to shipment and is ready for immediate installation. Use of the following installation procedures should eliminate potential damage and provide optimum trouble-free operation. 1. CONNECTIONS 1/4” FNPT are provided as standard but check paperwork for connections ordered. There are two connections on the housing identified as “hi” and “lo” for high pressure and low pressure (Fig. 2). Be sure these get plumbed to the proper connections on your system. Improper connection will not damage the instrument, but it will not function properly. Flexible tubing is recommended to minimize the effect of any vibration that may exist. 2. INSTRUMENT LOCATION On liquid service the instrument should be mounted below the process connections to facilitate selfbleeding. On gas service it should be located above the process connections to promote self-draining. If the process contains particulates, a “pigtail” loop or drop leg (manometer “U-tube” configuration) in the tubing will minimize the possibility of it migrating into the instrument.
3. PANEL MOUNTING Gauges with 2-1/2” dials can only be mounted through the rear of the panel. Make the proper panel cutout as indicated in (Fig.1). Remove the (4) bezel screws. Insert the gauge front through the rear of the panel and reinstall the bezel screws through the front of the panel and into the gauge bezel. Tighten the screws securely, alternating in a diagonal pattern. Gauges with 3-1/2" dial should be mounted from the front of the panel. Contact factory for mounting information and dimensional data. Gauges with 4-1/2" dial should be mounted from the front of the panel. Make the cutout as indicated in (Fig. 1). Insert the (4) panel mounting studs, finger tight, into the metal inserts located in the rear of the bezel. Insert the gauge through the panel, aligning the panel mounting studs with the holes in the panel. Install the (4) #8-32 nuts onto the studs and tighten securely.
TROUBLE SHOOTING 1. Gaug e does not indicate differential. A. Check for proper hook up, high to “hi” and low to “lo”. B. Make certain block valves are open and, if using a 3-valve manifold, that the equalizer (balance) valve is closed. C. If A & B check out correctly, loosen or disconnect the high pressure line to determine if there is pressure to the instrument. D. If there is pressure to the instrument, check to determine that there is differential across the unit being monitored. If so, contact the factory for assistance and/or an “RGA” (return goods authorization) number to return the instrument for repair or replacement.
4. PIPE MOUNTING An optional pipe mounting kit is available for mounting the gauge to a 2” vertical or horizontal pipe (Fig. 3).
Model 120 2-1/2 Inch Dial (Std.)
Model 120 4-1/2 Inch Dial (Opt'l)
(Fig. 1)
Supplementar y 120 Dimensional/Mounting Data
(Fig. 2)
(Fig. 3) NOTES: 1. Drawings show standard gaug e nominal dimensions. (not to scale) 2. Dimensions shown in parentheses are in millimeters. 3. Manufacturer reserves the right to chang e specifications without prior notice .
STANDARD MODEL SPECIFICATIONS 120-AA-00-OO 6000 P.S.I.G. Working Pressure Aluminum Body, Stainless Steel Piston, Ceramic Magnets, Buna N Seals, 2-1/2" Engineering Plastic Case with Shatter-Resistant Lens. 1/4" FNPT Back Connections. Accuracy +3-2-3% Full Scale (Ascending). 2
0
–
–
–
–
➅ ➀ ➁
MATERIAL A. M. N. S. Z.
➂
➃
Aluminum Body, S.S. Piston (Standard) Monel Body (See 120 ABM) (5000 P.S.I.G. working pressure) Aluminum Bronze Body (See 120 ABM) (5000 P.S.I.G. working pressure) 316 S.S. Body & S.S. Piston (Standard) SPECIAL (Uncoded Options)
DIAL TYPE A. B. C. D. E. F. G. H. T. Z.
2-1/2” Round Uni-Directional Engrd. Plastic Housing Assy. (Standard) 2-1/2” Round Bi-Directional Engrd. Plastic Housing Assy. 4-1/2” Round Uni-Directional Engrd. Plastic Housing Assy. 4-1/2” Round Bi-Directional Engrd. Plastic Housing Assy. 3-1/2” Round Uni-Directional Anod. Aluminum Housing Assy. 3-1/2” Round Bi-Directional Anod. Aluminum Housing Assy. 4-1/2” Round Uni-Directional Anod. Aluminum Housing Assy. 4-1/2” Round Bi-Directional Anod. Aluminum Housing Assy. Non-Indicating Differential Pressure Switch Only (Select Appropriate Electrical Option) Special (Uncoded Options)
OPTIONS (Up to four options) O. A. B. C. D. F. L. M. T. U. V. W. X. Z.
BASIC MODEL NUMBER
➆
ELECTRICAL CONFIGURATIONS (NOTE: All options O. A. B. C. D. E. F. G. H. J. K. L. M. Z.
SEALS 0. Buna N (Standard) 1. Viton® 2. Neoprene 4. Teflon® 5. Ethylene Propylene 6. Perfluoroelastomer 9. Special (Uncoded Options) *Viton® is a Registered Trademark of DuPont Dow Elastomers. **Teflon® is a Registered Trademark of DuPont.
(1) (2) (3)
➄
None (Standard) Reversed High/Low Process Connections DIN2353 12-S (12mm) Steel Tube Fittings (2) Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options A & B Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options L & M Pipe Mounting Kit (Carbon Steel) (Not available w/C, D, E or F Electrical Switch Options) Liquid Fill (Not available w/follower pointer) (Not available with 3-1/2" dial) Maximum Indicator Follower Pointer Oxygen Cleaning S.S. Tag Mounted w/S.S. Wire S.S. Tag Mounted w/S.S. Screws Wall Mounting Kit Individual Gauge Packaging Special (Uncoded Options)
marked, except E, F, J & K)
None One (1) Switch in STD. Enclosure with Grommet Wire Seal Two (2) Switches in STD. Enclosures with Grommet Wire Seal One (1) Switch in STD. Enclosure with 1/4” FNPT Electrical Connection NEMA 4X Two (2) Switches in STD. Enclosures with 1/4” FNPT Electrical Connection NEMA 4X One (1) Switch in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3) Two (2) Switches in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3) One (1) Switch & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections) Two (2) Switches & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections) One (1) Switch in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2) Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2) One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11) Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11) Special (Uncoded Options)
– (Up to three options)
1
➆➇
PART NUMBERING SYSTEM
Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G. Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G. 5000 PSIG Working Pressure.
CONNECTIONS (NOTE: Models 120M and 120N available only with end connections) 0. 2. 6. 7. 8. 9.
1/4" FNPT Back Connections (Standard) 1/4" FNPT End Connections 7/16" - 20 Str. Thd. O-Ring Port (Back Connections) 1/2" FNPT Stainless Steel Adaptors 1/2" FNPT Monel Adaptors Special (Uncoded Options)
➇
ELECTRICAL SPECIFICATIONS (For Resistive Loads) A. E. F. G. H. Z. (4)
S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%) S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%) S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed) (Switch adjustable range of 25-95%) S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4) S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%) Special (Uncoded Options) Available with Electrical Configurations B, D, F, H, K and M only.
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS. NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)
(Fig. 4)
NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE. ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY.
Manufacturer reserves the right to change specifications without prior notice. PROOF PRESSURE: 12,000 PSI for models 120-A and 120-S. 10,000 PSI for models 120-M and 120-N. TEMPERATURE LIMITS: -40°F(-40°C) to +200°F (+93°C) - These limits are based on the entire instrument being saturated to these temperatures. System (process) temperatures may exceed these limitations with proper installation. Contact our customer service representative for details. STANDARDS: All Model 120 Series differential pressure gauges either conform to and/or are designed to the requirements of the following standards: ASME B1.20.1 ASME B40.100 CSA-C22.2 No. 14.25 and 30 EN-61010-1
NACE MR0175 NEMA Std. No. 250 SAE J514 UL Std. No. 50,508 and 1203
R E P R E S E N T E D B Y:
® Mid-West Instrument 6500 Dobry Dr. ■ Sterling Heights, MI 48314 U.S.A. (586) 254-6500 ■ FAX (586) 254-6509 E-mail:
[email protected] Website: www.midwestinstrument.com Printed in U.S.A.
A
Free Floating Guided Lever Drain Traps For Loads to 9,500 lblhr(4.309 kglhr) ...Pressures to 570 psig (39 bar)
hms-
Armstrong's stainless steel, free-floating guided lever drain traps use the same bodies, caps, lever mechanisms, valves and seats of Armstrong inverted bucket steam taps that have been proven in years of service. Elliptical floats and high leverage make it possible to open large orifices to provide adequate capacity for drain tap size and weight.
The hemispherical valve, seat and leverage of the 11-LD, 22-LD and 13-LD stainless steel traps are identical in design, materials and workmanship to those for saturated steam service up to 570 psig (39 bar) with the exception of the addition of a guidepost to assure a positive, leaktight valve closing under all conditions.
List of Materials
For a fully detailed certified drawing, refel to list below: 11-LD CD #I066 I b L D and 22-LD CD #I086
I
I
Model Valve& NO.
11~LD 22.~0 13-LD
Seat
I
Leverage Svstern
I I loa at
Stainless Steel
Body & Cap
I
Sealed
Stainless Steel. 304L
Gasket
I
-
For intomatianon special materials, consull the Armstrang Application
Figure LO-34. No. 11-LD. 22-LD and 13-LD stainless steel guided lever liquid drain trap with sealed, tamperproof construction.
Physical Data
NOD: Vessel aes pn press~remay exceeo lloatcollapre pressure n some carer Pce rile 01 vent conne?on s sme as mar 01 P ?I anc a l e : c0nPe:I 01s
",T115mm1o.net
"ha sde caqnecnoi
All dimensions and weights are appmximafe. Use ceriffledprlnf lor exact dlmenrlons. Deslgn and malerlals are SubIect to change without notice.
LO-39
Armstrong Steam and Condensate Group. 816 Maple St.. P.O.Box 408. Three Rivers. MI 49093 -USA Phone: (269) 273-1415 Fax: (269)278-6555 w.armrtrong-intl.com
00-02-0175 Revised 03-06 Section 15
Installation for L1100, L1200, L1200N Series Liquid Level Switches and DVU150, DVU175, and DVU2105/2115/2120 Series Dump Valves.
Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting. GENERAL INFORMATION **
Description Series L1100 and L1200 Liquid Level Switches are float activated to operate an electrical SPDT snap switch (optional DPDT on some models) for alarm or shutdown of an engine or electric motor. They screw directly into the wall of the vessel. Series L1200 can also be used with a weld collar or external float chamber.
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions. OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment. ✔ BE SURE all pressure HAS BEEN REMOVED from the vessel before opening any pressure connections.
Specifications
L1100
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump valves or similar devices. This model screws directly into the vessel or can be mounted via an external float chamber. It cannot be used with weld collar 15050375. Model variations include a dump valve operator with or without a filter/pressure regulator and indicating pressure gauge. NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and L1200NDVOR series carry Canadian Registration Number OF1476.2. Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a pneumatic input signal to cause an orifice to open or close allowing liquid condensate to be drained from a pressure vessel. A pop up button indicates valve open/closed. Stainless steel versions available. L1111
L1200
L1200N
L1200NDVO
L1200NDVOR
Body • Standard: Electroless Nickel plated steel • Optional: 316 Stainless Steel†
✗A ✗A
✗A ✗A
✗B ✗B
✗B ✗B
✗B ✗B
✗B ✗B
Pressure Rating • 15 psi (103 kPa) [1.03 bar] Polyethylene Float • 1500 psi (10.3 MPa) [103.42 bar] Stainless Float • 2000 psi (13.8 MPa) [138 bar] BUOYGLAS™ Float
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Temperature Rating • Standard: -20/175°F (-29/79°C) • Standard: -20/300°F (-29/149°C) • Optional: -20/400°F (-29/204°C)*
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Electrical • Standard SPDT: 5 A @ 125/480 VAC (see p. 3 for full ratings) • Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings)
✗ ✗
✗ ✗
✗ ✗
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
Specific Gravity • Standard: 0.5 with BUOYGLAS™ float • Optional: 0.65 with 304 Stainless Steel† • Standard 0.73 Polyethylene Float
O-Rings: Viton Valve: Two-way snap-action vent type • 1/8 in. (3 mm) orifice w/Viton “A” seat • 1/8 NPT inlet; 1/4 NPT vent • 30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure Dump Valve Operator: Operates Murphy DV Series dump valves or similar. 1/8 NPT inlet, outlet & vent. Pressure Regulator/Filter and Murphy 20BPG: 0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. Maximum input 300 psi (2.07 MPa) [20.68 bar]. 1/8 NPT in/out. Operation: H=For high level, L=For low level
✗
H
L
H
H
H
†Meets NACE standard MR-01-75 for direct exposure to H S service. *Not available with DPDT snap-switch. A =1-1/2 NPT B =2 NPT 2 **Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility. Installation 00-02-0175 page 1 of 6
H
DIMENSIONS L1200N, L1200NDVO and L1200NDVOR with Dump Valve Operator, Pressure Regulator and Gage
L1100 and L1200 11 in. (279 mm)
Pressure Regulator with 20BPG Pressure Gage
3-1/2 in. (89 mm)
2-3/16 in. (56 mm)
New Dump Valve Operator Assembly p/n 15010216
See Note 2
1/2 NPT
See Note 1 3-5/8 in. (92 mm)
Note 1: L1100: 1-1/2 NPT L1200: 2 NPT Note 2: 1-9/16 (40 mm) SF option: L1100: 1-1/2 (38 mm) L1200: 1-3/4 (44 mm)
1/8 NPT Old Round Dump Valve Operator Assembly p/n 15000940
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
1/8 NPT INLET
3-5/8 in. (92 mm)
5 in. (127 mm.) minimum clearance is required for float movement.
3/4 Hex (See Note)
2-3/16 in. (56 mm)
1/4 NPT VENT
1-9/16 in. (40 mm) SF option= 1-3/4 in. (44 mm)
2" 11-1/2 NPT
3-1/2 in. (89 mm) SF= 3-3/4 in. (95 mm) 11 in. (279 mm) SF option= 11-1/4 in. (286 mm) Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111 11-5/16 in. (287 mm) 3-53/64 in. (97 mm)
2-3/16 in. (56 mm)
DVU150, DVU175, DVU2105/2115/2120 Series Dump Valves
A
See Note
1/2 NPT
1-1/2 NPT 3-5/8 in. (92 mm)
Note: 1-9/16 (40 mm)
Pressure Inlet Port 1/8 in.-27 NPT
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
Manual Valve Operator
B
Vent Weep Hole Union
Valve Open/Closed Indicator Button
Electrical installation to be done by qualified person according to the NEC.
F Drain
C
Connection
D
E
shown G (dimension for reference only)
Plug Seal Model
A
B
C
D
E
F
G
DVU2120 DVU2115 DVU2105 DVU175 DVU150
7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191)
8.0 (203) 8.0 (203) 8.0 (203) 6.75 (171) 6.75 (171)
2.75 (70) 2.75 (70) 2.75 (70) 2.06 (52) 2.06 (52)
1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25)
2-11.5 NPT 2-11.5 NPT 2-11.5 NPT 1-11.5 NPT 1-11.5 NPT
1-11.5 NPT 1-11.5 NPT 1-11.5 NPT 3/4”-14 NPT 1/2”-14 NPT
1.03 1.03 1.03 1.03 1.03
NOTE: Dimensions are in inches and (millimeters)
Installation 00-02-0175 page 2 of 6
REPLACING AND INSTALLING THE DVOA ASSEMBLY
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR. Replacing and Installing the DVOA Assembly For Models L1200NDVO & L1200NDVOR
NOTE: Clean, dry instrument quality gas should be used. Use of filters will improve service life and reliability.
Tools Needed: Strap or pipe wrench; 3/4” Hex wrench; 9/16” hex wrench; needle nose pliers; tubing cutters and benders and the appropriate tools for the fittings. 1.
Block off and bleed the instrument gas pressure supply to the L1200NDVO. 2. Remove the tubing between the L1200NDVO and the separator dump valve, and remove the supply gas tubing (regulator [-R] if used). 3. Remove the L1200NDVO from the vessel (optional). 4. If the L1200N was removed from the vessel, mount it in a suitable vise on a work bench (if possible). 5. Using the proper tools, disconnect the Inlet, Outlet and Exhaust fittings from the existing DVO (see fig. 1). You will re-connect these to the new DVOA in a later step. NOTE: The following steps must be done with the DVO in the upright position (on top of the L1200N). 6. Remove the L1200N cover (this will aid with the alignment of the new DVOA Valve Bushing). The use of a strap wrench or a pipe wrench may be needed. 7. Insert the new Valve Bushing through the new DVOA (see fig. 2). The markings on top of the DVOA must be facing up. This will be needed in step 9. 8. With a 3/4” hex wrench loosen the existing DVO, valve stem, and static seal (see fig. 3). Once the assembly is loosened, VERY CAREFULLY use needle nose pliers to hold the Valve Seat Assembly in place. Remove the existing DVO making sure the Valve Seat Assembly inside the L1200NDVO is aligned and straight (see fig. 4).
Old DVO
Outlet (opposite side)
Inlet
Exhaust
Figure 1
Figure 2
New DVOA
Figure 3
CAUTION: MAKE SURE the Valve Seat Assembly inside the L1200N remains in place after removing the DVO. Holding the Seat Assembly up with the needle nose pliers inside the L1200NDVO body, place the tip of the new DVOA valve bushing through the spring and into the hole in the center of the valve seat, and tighten the valve bushing. The Valve Seat Assembly should be able to move freely up and down after the bushing has been tighten. The DVO red button must face away from the vessel. 10.With the new DVOA aligned over the hex on the L1200NDVO body, tighten the Valve Bushing using the 9/16” hex wrench. You may need to hold the DVOA while tightening the Valve Bushing to keep it from rotating (see fig. 5). 11.If the L1200N is in the vise, operate the float and inspect for smooth and proper operation of the Valve Seat Assembly. 12.Replace the L1200NDVO cover (see fig. 6). 13.Using the appropriate tools re-install the Inlet, the Outlet and the Exhaust fittings to the new DVOA (see fig. 5). 14 If the L1200N was removed from the vessel re-install it at this time. 15.Modify existing or install new tubing to connect the Inlet, the Outlet and Exhaust fittings.
Valve Bushing
Valve Seat Assembly
9.
Outlet
Figure 4
Inlet
Installation 00-02-0175 page 3 of 6
Exhaust
New DVOA
Figure 5
L1200N Cover
Figure 6
PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N
Direct Installation into the Wall of the Pressure Vessel 1. Determine that the float travel is not obstructed by the coupling in Tank the vessel wall, internal Wall baffles, etc. Do NOT use more than one arm extension P/N 15050395. Explosion proof 2. BE SURE that the float Level conduit seal Switch and extension are tight where required. and that the lock washer is in place. 3. Before installing the level switch a suitable pipe thread sealant is recommended. Screw the unit directly into the threaded connection in the wall of the pressure vessel. 4. Be sure that the electrical connection is positioned at the bottom. For L1200N the 1/8 NPT pneumatic connection should be on top (the 1/4 NPT vent connection should be on the bottom). See “Pneumatic models” section for further instructions for the L1200N. 5. Make the electrical wiring connections according to appropriate wiring diagrams for the alarm or shutdown system to be used. The electrical connection is 1/2-14 NPT. Electrical wiring and conduit should be installed by qualified personnel according to the NEC. 6. BE SURE all electrical connections are insulated and the cover is fully installed before reconnecting electrical power. 7. BE SURE all pressure connections are tight before pressurizing the system. Installation with a Weld Collar Tank Wall 1. The weld collar, P/N Weld Collar 15050375, must be welded into the wall of the pressure vessel according to code standards and good welding practices. L1200 2. Follow above instructions for installation directly into Explosion proof the wall of the pressure conduit seal vessel. where required. 3. NOTE: Weld collar 15050375 can be used ONLY with model L1200. It cannot be used with L1200N. Installation Using External Float Chamber 15051098
positioned away from the tank wall. 2. A tee is typically installed at the bottom of the lower 1 inch pipe riser to allow draining of the float chamber for servicing or replacement. NOTE: A typical installation Float with Blocking and Bleed valves is Chamber Tank shown at right. Block Valves 3. Install the L1200 or L1200N Level in the 2 NPT connection Switch of Tee the float chamber. Bleed BE SURE float travel Valve is not restricted and that the Explosion proof float is tight onto conduit seal where required. the float shaft. 4. To complete installation and wiring, follow the instructions for mounting directly into wall of the vessel and for wiring. Pneumatic Models 1. All pneumatic models operate on the vent Filter/Regulator Tank principle. The New Dump Valve Operator Assembly pneumatic signal Pneumatic p/n 15010216 Signal source MUST BE CLEAN AND DRY. The input pneumatic MURPHYGAGE® signal must be regulated between 30 L1200N and 70 psi (207-483 kPa) [2.07-4.83 bar]. If produced gas is used as the signal source, it should be taken after gas passes through the final scrubber. A suitable filter must be positioned before the L1200NDVO to prevent liquids and/or particulates from entering the dump valve operator. NOTE: Check filter periodically for wear and tear and elements that hamper the flow of the pneumatic signal. 2. All pressure connections must be tight and maintained tight so as not to leak air/gas. 3. Valve seat adjustment can be made if air/gas begins to leak. Care should be taken when adjusting as only slight movement is necessary to stop the leakage; excessive force will bind the
Hex Socket Set Screw • loosen for adjustment • tighten after adjustment
L1200N
CAUTION: USE “NON SPARKING TOOLING”. 1. Install the float chamber 15051098 on the outside wall of the pressure vessel using 1 NPT piping. Position the 2 NPT threaded connection at the height where you want the level switch to operate. The 2 NPT threaded connection must be
Hex Adjustment Nut • turn left until air seepage stops • Caution: only slight adjustment is needed—too much will lock up mechanism
Installation 00-02-0175 page 4 of 6
Trip Cam (float down) • should be in this position • non-adjustable
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation As condensate rises in the scrubber, the float on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber. Once the pressure enters the pilot chamber it forces the diaphragm and valve stem forward thus opening the valve seat (valve open/closed indicator button pops out) and releasing condensate through the valve stem and out the drain. As the condensate level drops, the L1200NDVOR pneumatic valve closes to shut off the pressure to the dump valve causing it to close. If for any reason the condensate continues to rise beyond normal dump levels, model L1200 operates the alarm and/or shuts down the equipment. The L1200NDVOR Filter/Regulator and the MURPHYGAGE® help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.
Typical/Scrubber/Separators VESSEL Minimum control pressure 30 psi (207 kPa) [2.07 bar]
Rising Level Shutdown L1200 (with snap-switch)
Explosion proof conduit seal required for Class I. Div 1, not required for intrinsically safe or non-incendive circuits like FWM TTD.
Rising Level Trips DVO
Electrical Conduit
L1200NDVOR Dump Valve Operator Union
Air Supply Maximum 300 psi (2.07 MPa) [20.70 bar]
Filter/Regulator with MURPHYGAGE®
Minimum control pressure 30 psi (207 kPa) [2.07 bar]
DVU Series Dump Valve Union Condensate Line (Out) Manual Drain Valve
REPLACEMENT PARTS
ELECTRICAL INFORMATION DPDT (Snap Switch) SPDT (Snap Switch) Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Switch Rating: 5 A @ 125-250- 480 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 2A @ 6-30 VDC Resistive 1A @ 6-30 VDC Inductive
Green Grd. Connection
Black N.O.
White COM.
Red N.C. Blue N.C.
Yellow COM.
Orange N.C.
Switch Rating: 10 A @ 125-250 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 10 A @ 6-24 VDC Inductive/Resistive
Order by part number designation. L1100/L1200* 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200 15000937: Stainless Steel float for L1100 15000124: SPDT snap switch assembly 15010213: L1100 counter balance assembly 15010214: L1200 counter balance assembly L1200N 15050420: Cam spring return 15050421: Cam 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200N 15050453: Valve stem 15010189: Counter balance assembly L1200NDVO and L1200NDVOR 55050621: Regulator only 05706499: 20BPG-D-75 Pressure MURPHYGAGE® 0-75 psi (517 kPa) [5.17 bar] 15010216: DVOA assembly (New rectangular style) 15000940: DVO assembly (Old round style) *To maintain hazardous location listings, all other repairs must be made by the factory.
Installation 00-02-0175 page 5 of 6
ACCESSORIES
Order by part number designation.
55050617: DVU150/DVU175 Adapter Bushing
15050375: Weld Collar
Material: 2-1/2 Hex bar stock C.R.S 2-1/16 in (52 mm) 1-1/16 in (27 mm)
2 NPT
2-1/2 in (64 mm)
2-7/8 in (73 mm) 3-5/8 in. (92 mm)
1 NPT
4-1/2 in (114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
2 NPT
15051098: External Float Chamber 3 in. (76 mm)
1-11.5 NPT (2 places)
2-11.5 NPT 10.5 in. (266 mm)
3 in. (76 mm)
1/2-20 UNF-2B (4 places) 7.55 in. (192 mm)
3.5 in. (89 mm)
Material: Cast Steel, WCB
7.01 in. (179 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
15000892: Float Shaft Extension 10-32 UNF
10-32 UNF 3/8 in (10 mm) 1-3/8 in (35 mm)
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
www.fwmurphy.com 918.317.4100 Email:
[email protected]
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0175 page 6 of 6
00-02-0483 Revised 03-06 Section 15
Installation and Operation Manual for DVU Series Dump Valves Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120
Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes. GENERAL INFORMATION
Fig. 2 Dimensions (all models)
WARNING
A Pressure Inlet Port 1/8 in.-27 NPT
Manual Valve Operator
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
Description The DVU Series models are pneumatically controlled dump valves. The valves open and close automatically by pneumatic control from a Murphy L1200NDVOR or similar level controller and dump valve operator. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi (207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] vessel pressure (depending on the model). A key benefit of this design is a hex union that provides the ability to replace the seat without removing the valve from piping.
Fig. 1 Control Pressure vs. Working Pressure Control Pressure (PSIG)
C
Connection
D
E
shown G (dimension for reference only)
Plug Seal
Model
A
B
C
D
E
F
G
DVU2120 DVU2115 DVU2105 DVU175 DVU150
7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191)
8.0 (203) 8.0 (203) 8.0 (203) 6.75 (171) 6.75 (171)
2.75 (70) 2.75 (70) 2.75 (70) 2.06 (52) 2.06 (52)
1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25)
2-11.5 NPT 2-11.5 NPT 2-11.5 NPT 1-11.5 NPT 1-11.5 NPT
1-11.5 NPT 1-11.5 NPT 1-11.5 NPT 3/4”-14 NPT 1/2”-14 NPT
1.03 1.03 1.03 1.03 1.03
NOTE: Dimensions are in inches and (millimeters)
DVU2120
DVU2115
60
Specifications
50 40
Valve Open/Closed Indicator Button
F Drain
Minimum Actuation Pressure 70
B
Vent Weep Hole Union
DVU150/175
DVU2105
30 20 10 0
500
1000
2000
1500
Vessel Pressure (PSIG)
Model DVU2120 DVU2115 DVU2105 DVU175 DVU150
Inlet 2 NPT 2 NPT 2 NPT 1 NPT 1 NPT
Outlet 1 NPT 1 NPT 1 NPT 3/4 NPT 1/2 NPT
Trim Size 0.436 in. (11 mm) 0.576 in. (15 mm) 0.859 in. (22 mm) 0.359 in. (9 mm) 0.359 in. (9 mm)
Operating Temperature: -30 to 250°F (-34.4 to +121°C) Valve Operating Pressure: Refer to chart, Fig 1. Maximum Process Pressure: DVU2120: 2000 psi (13.8 MPa) [138 bar]. DVU2115: 1500 psi (10.3 MPa) [103 bar]. DVU2105: 500 psi (3.44 MPa) [34 bar]. DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar]. Flow Characteristics: See chart, page 4 (DVU150/175 models only). Body Material: Electroless Nickel Plated 12L14 Carbon Steel Internal Wetted Parts: Plug Seal: 90 Durometer Urethane. Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.). Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.). Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
Installation 00-02-0483 page 1 of 4
TYPICAL INSTALLATION ON GAS COMPRESSORS
Fig. 3 Scrubber/Separators Basic Operation As condensate rises in the scrubber, the float on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber. Once the pressure enters the pilot chamber it forces the diaphragm and valve stem forward thus opening the valve seat (valve open/closed indicator button pops out) and releasing condensate through the valve stem and out the drain. As the condensate level drops, the L1200NDVOR pneumatic valve closes to shut off the pressure to the dump valve causing it to close. If for any reason the condensate continues to rise beyond normal dump levels, model L1200 operates the alarm and/or shuts down the equipment. The L1200NDVOR Filter/Regulator and the MURPHYGAGE® help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.
NOTE: Always use clean, dry, instrument quality gas.
The Murphy Gas Compressor Scrubber Level System (SLS) The system provides for liquid control in gas scrubber applications, by dumping liquids to drain and protecting compressors with a high liquid level switch. Wetted metal parts are made to survive constant use in corrosive environments. See Bulletin: SLS-04005B for more details.
High Level Shutdown Switch Stainless steel float actuated level switches to alarm and/or shutdown the equipment. L1200: 2” NPT pipe connection; Rated 2000 psi (13.7MPa) [137bar]; Class I, Division 1. SPDT snap-switch standard. DPDT Optional. All Stainless Steel available.
Filter/Regulator & MURPHYGAGE®
Control Panel
“Instrument Quality Air/Gas Supply”
Pneumatic Level Control Float actuated level snap-acting switch controls pneumatic pressure to open and close dump valve.
Pneumatic Dump Valves See DVU-01069B
L1200NDVOR: Dump Valve Operator,
for more details. Two piece union design with manual valve operator allows soft plug and hard seat to be replaced without disassembling outlet piping or scrubber pipe connection. Diaphragm actuated valves operate on 30-70 psi (207-483 kPa; 2-5 bar).
pressure regulator, and pressure indicating MURPHYGAGE.®
DUMP VALVE INSTALLATION
DVU Series Installation Upper Assembly (removable)
CAUTION: ALWAYS USE “NON-SPARKING TOOLS” WHEN GAS IS KNOWN TO BE PRESENT.
Valve Union
Fig. 4 Typical Dump Valve Installation
Maintenance Bolt Valve Indicator Vessel Wall
The following describes the “Direct Mounting” method to the tank wall. 1. Install the valve so the drain connection is on the bottom. Use pipe thread sealant on all the connections. 2. Be sure the unit is screwed tight and does not leak. 3. Install the piping for the pneumatic input signal into the 1/8 NPT threaded connection of the pressure inlet port (on top of the diaphragm housing of the DVU). 6. Install a union between the DVU drain connection and the condensate out line. Use pipe thread sealant on all the connections.
Pneumatic Input Signal
Weep Hole Drain Connection Union Condensate Out 2-Way (Manual Drain) Shutoff Valve
Installation 00-02-0483 page 2 of 4
REPAIR PROCEDURE
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSIBLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED.
Suggested Tools (Sizes listed are wrench openings. Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, flat edge screwdriver with 1/4” blade width, can also be used .) Model
Valve Body
Union Nut
Plug Seal Hex
Stem Nut
3” 3” 3” 2-1/4”
3” 3” 3” 2-1/4”
7/8” 1” 1-1/4” 3/4”
1/2” 1/2” 1/2” 3/8”
DVU2120 DVU2115 DVU2105 DVU150/DVU175
Replacing the Plug and Seat 1. Close the pressure block valves (suction & discharge valves) on the inlet and outlet of the skid. Lock them closed if possible. 2. Open the blowdown valve to remove pressure from the unit. Lock the blowdown valve open if possible. 3. After taking all possible precautions to insure there is no pressure in the vessel. (If the condensate line is pressurized, it must also be blocked and locked.) Open the manual drain valve so it bleeds into the vessel so it can also be bled down. Disconnect the pneumatic input signal connection after insuring it also has been de-pressurized. 4. Using a back-up wrench on the valve body, with a quick "breaking" action loosen the union nut on the valve. There is a "weep" hole in the nut. If at any time while loosening and taking off the nut pressure is escaping through the "weep" hole, immediately stop loosening the nut. Retighten the nut and check the preceding procedures to ensure the pressure is bled off the vessel. Never remove the assembly if pressure is coming through the weep hole. See Figure 4 on page 2. 5. With the upper assembly removed from the vessel the plug and/or seat can be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of the diaphragm cover. Spin the nut up against the head of the bolt. Tighten the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN.
Fig. 5 Plug
Seat
Stem
Stem Packing
O-Ring Seals Against Outlet
Washer(s)*
Stem Nut
O-Ring
Crush Washer Seal
Seat butts into here
*Number of washers varies depending on the model from 1 to 3.
Fig. 6
Seal Washer Pressure Inlet
Maintenance Bolt 1/2" Nut
Diaphragm
Backup Plate
1-1/8" or 1" round nut
Stem
Spring
Diaphragm Housing
Diaphragm Assembly
6. Using a back-up wrench on the plug, remove the stem nut on the shaft under the plug. Once the stem nut is broken loose, the 9/16” head maintenance bolt and top assembly will keep the stem from turning. The plug turns freely on the stem once loose. The plug and seat can now be removed. All soft seals should be replaced. Refer to kit part numbers under service parts on page 4.
Replacing the Diaphragm 6A. If the diaphragm is to be replaced, all preceding steps have to be done. Additionally, do the following: 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm spring to relax, and the stem to retract. Make alignment marks on the top and bottom halves of the diaphragm assembly for alignment during re-assembly. 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing together. 6D. Using a straight edge screwdriver, gently separate the 2 halves of the diaphragm housing, and remove the top, or outside portion. 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex or 1” round nut on the bottom of the diaphragm assembly to be accessible to a wrench and not have the spring interfere. If it is desired to replace the packing, pull the stem all the way out. The packing can be easily removed using a small screwdriver to pry the packing out. The new packing can be simply pressed in, making sure the orientation of the packing installed is the same as the orientation of the packing removed. The packing is wider toward the plug end. You will have to use the seat to hold the packing in place when re-inserting the stem. 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a wrench to loosen and remove the 1/2" nut on top of the diaphragm. The diaphragm can now be removed and replaced. 6G. With the new diaphragm in place and the 1/2" nut tightened, place the assembly, diaphragm down on a clean, smooth sturdy surface. 6H. Have the seat, plug, washers and stem nut handy (if any of these parts are to be replaced, use the old parts for this procedure). Press down evenly and smoothly on the bottom of the diaphragm assembly to cause stem to come up. Place the seat and plug in place. Then push the bottom of the diaphragm assembly down far enough to install the washers and stem nut on the stem. Tighten the stem nut enough to hold against the diaphragm spring. 6J. Align the diaphragm holes to the bolt holes (bottom half of the housing). Install the upper diaphragm housing using the alignment marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the bolts evenly going from one bolt then 180° around to the next bolt, then either 120°or 240° around to the next bolt and so forth until all 8 bolts are evenly tight. 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem out until the 9/16"bolt stops – DO NOT OVERTIGHTEN. 6L. Remove the stem nut holding the plug. (If old parts were used, prepare to install the new parts now.)
7. Install the seat and plug. Place the O-ring on the stem, followed by the washer and stem nut. 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one turn past the point where it is no longer in contact with the stem. Tighten the 9/16" jam nut holding the 9/16” head maintenance bolt. 9. Replace the crush washer and the O-ring hidden by the union nut. NOTE: If pressure or fluid comes out the weep hole of the union nut, either the O-ring under the union nut is leaking, or the packing could be leaking through the internal weep hole above that O-ring. 10. The assembly is ready to be re-installed. Check for relative position of the pneumatic input signal connections before tightening the union nut.
Installation 00-02-0483 page 3 of 4
PRESSURE VS. FLOW CHART
Pressure vs. Flow for DVU150 and DVU175 models only
Fig. 7 250 250
200 200
Pressure (psid)
150 150
100 100
50 50
0
0
5
10
15
20
25
30
35
40
45
Flow (gpm)
SERVICE PARTS
Part No.
Typical Diaphragm Repair Kit includes: Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate (1 or 2 pcs.), Packing, “O” Ring, Stem, Seal Washer for Maintenance Bolt.
Description
DVU2120 55-00-0237 55-00-0236
Seal Kit (includes plug) Diaphragm Kit
The DVU Series Valve is included in the following Scrubber Levels Systems.
DVU2115 55-00-0241 55-00-0240
Seal Kit (includes plug) Diaphragm Kit
(Includes L1200, L1200NDVOR, and DVU valve) SLS2120: Includes DVU2120 valve SLS2115: Includes DVU2115 valve SLS2105: Includes DVU2105 valve SLS175: Includes DVU175 valve SLS150: Includes DVU150 valve -LR: Less Regulator option
DVU2105 55-00-0245 55-00-0244
Seal Kit (includes plug) Diaphragm Kit
DVU175 55-00-0230 55-00-0231
Seal Kit (includes plug) Diaphragm Kit
DVU150 55-00-0230 55-00-0231
Seal Kit (includes plug) Diaphragm Kit
Warranty
Typical Seal Kit includes: Nut, Washer (1 to 3), “O” Ring, Plug and Seal, Seat, Crush Washer.
www.fwmurphy.com 918.317.4100 Email:
[email protected]
A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0483 page 4 of 4
Warning All repair and resetting of safety relief valves should be performed by a National Board certified valve repair shop holding a “VR”stamp. See engine assemblies for details Service the PCC fuel filter every 800 hours.
Tubing Fitting, Item 43, with 0.030" orifice supplies positive head pressure to hydraulic system.
Starter motor Ajax p/n BM-11679-Q-1. Maximum inlet pressure = 90 psig. Pinion-to-ring gear backlash = 0.020” to 0.030”
Starter Pinion
1 ” travel (ref.)
Ring Gear Flywheel Adjust main fuel pressure regulator to 15 psig (typically).
0.06” minimum ” minimum engagement
(Ajax p/n 2040 6430) (Fisher Type 627)
Starter Motor Gas Supply Maximum pressure = 90 psig Approximate maximum flow rate = 2028 scfm (values based on typical natural gas properties)
Adjust PCC fuel shut off relay valve (item 57) to actuate at 5 psig. (Fisher Type 119) Adjust PCC fuel (LE) pressure regulator (item 58) to 13-14 psig (typically). (Fisher 64 Series)
!
"# " # !$
2802LE Starter/Fuel Gas Piping TP 02-22-T010-331-90
2802LE Starter/Fuel Gas Piping TP 02-22-T010-331-90 Item
Description
P/N
Qty
Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Tubing ¼" x 0.035 Wall Tubing ¼" x 0.035 Wall Angle, 2" x 2" x ¼" x 28" Lg. Ball Valve, ½"NPT, 2000# Ball Valve, 1"NPT Ball Valve, 2" Spring Bushing, ½"NPT x ¼"NPT, 3000# Bushing, ¾"NPT x ½"NPT, 3000# Bushing, 1½"NPT x 1" NPT, 3000# Bushing, 1"NPT x ½"NPT, 3000# Bushing, 1"NPT x ¼"NPT, 3000# Bushing, 2"NPT x 1"NPT, 3000# Elbow, 1"NPT, 2000# Elbow, 1"NPT, 3000# Elbow, 2"NPT, 2000# Elbow, Male Tubing, ½" Tube x ½"NPT Elbow, Male Tubing, ¼" Tube x ¼" NPT Flat Bar, ½"NPT x 2" x 6" L Gauge, 0-30 psig Male Connector, ½" Tube x ½" NPT Male Connector, ¼"Tube x ¼"NPT Male Connector, 1" Tube x 1" NPT Mercer Relief Valve, 1" In x 1" Out Needle Valve, ¼", 6000# Close Nipple, ¼"NPT, Sch 80 Close Nipple, 2"NPT, Sch 80 Nipple, ½"NPT x 2" L, Sch 80 Nipple, ½"NPT x 3"L, Sch 80 Nipple, 1"NPT x 2½L, Sch 80 Nipple, 1"NPT x 6"L, Sch 80 Nipple, 1"NPT x 8"L, Sch 80 Nipple, 2"NPT x 8"L, Sch 80 Pipe 1", Sch 40 Pipe 1", Sch 40 Pipe 2", Sch 80
5551 3504 5551 3504 7004 2020 2549 2004 2549 2006 2549 2012 2527 0402 2527 0604 2527 1410 2527 1004 2527 1002 2527 2010 2535 3010 2535 4010 2535 3020 2507 4204 2507 4202 7040 0420 2015 3312 2507 1404 2507 1202 2507 1808 63ME2M2FVA0080 2549 0057 2539 4200 2539 4909 2539 4408 2539 4414 2539 4610 2539 4626 2539 4628 2539 4928 4053 0102 4053 0102 4053 0205
55" 73" 1 1 1 1 1 2 1 1 1 3 1 1 2 3 2 1 2 1 1 2 1 2 1 1 1 2 4 2 1 1 13" 12" 27"
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Description Pipe 2", Sch 80 Pipe 2", Sch 80 Pipe 2", Sch 80 Pipe 2", Sch 80 Plug, Hex Head, 2"NPT, 3000# Fuel Shutdown Valve, 2"NPT Street Elbow, 1½"NPT, 3000# ¼" Male Tubing Conn. w/0.030" Orifice Tee, ½"NPT, 2000# Tee, ¼"NPT, 2000# Tee, 1"NPT, 2000# Tee, 2"NPT, 2000# Tee Reducing Union, ½" x ¼" Tubing ½" x 0.035 Wall Tubing ½" x 0.049 Wall Tubing 1" x 0.049 Wall U-Bolt, 1" U-Bolt, 2" Union, 1"NPT 3000# Union, 2"NPT 3000# Unitstrut, 3" L Valve, PCC Fuel Shut Off Relay Regulator, PCC Fuel Pressure
2802LE Starter/Fuel Gas Piping TP 02-22-T010-331-90
P/N 4053 0205 4053 0205 4053 0205 4053 0205 2541 6020 2090 2521 2535 8014 2507 1325 2545 4004 2545 4002 2545 4010 2545 4020 2507 6205 5551 3508 5551 4908 5551 4916 1590 0100 1590 0103 2547 5010 2547 5020 7020 2558 BM-16089-K 2-04V-034-003
Qty 11" 15" 23" 58" 2 1 1 1 1 1 3 2 1 15" 48" 14" 1 3 1 2 2 1 1
M2582, M5081, and M5180 Series Electromechanical and Pneumatic, Fuel Gas Shutoff Valves Installation and Operation Instructions
M-7980N Revised 11-02 Section 55 (00-02-0206)
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install the unit and make sure installation conforms with NEC and local codes. GENERAL INFORMATION
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
Model M5081 Approved*
M2582 and M5081Series Tripping Power From Engine Ignition System or Battery (Models available for magneto, CD ignition or 12/24 V battery) These fuel shut-off valves are semi-automatic devices for shutdown of natural gas fueled engines. The standard valve opens by manual operation of the reset handle. A latch in the upper body of the valve will set and hold the valve open. At this point no electric power is used. The electromagnetic coil is de-energized, the snap-switch(es) is SET. If a SWICHGAGE® contact closes, a circuit is completed from power through the snap-switch and coil. Now energized, the electromagnet trips the latch, (latch can be tripped manually), the valve closes, and the snap-switch resets. Power switches from the coil circuit to your choice of an open line, an electrical ground, or an alarm. After tripping, the vent seal opens, and on the M50 models, the open/close indicator (green button) retracts to indicate that the valve is closed. Valve body is sandcast aluminum. Optional cast steel for M5081 models. M2582-P and M5180-P MURPHY-NUMATIC™ Pneumatic Version for Pressure The M2582-P and M5180 pneumatically controlled valves can operate from pressure, and are designed to open and close automatically or semiautomatically (the supply can be air, oil or gas). NOTE: If using oil as a pressure source, use a lightweight oil. These valves will open on rising control pressure and close on decreasing control pressure. M2582-P and M5180-P automatically open at 2 psi (14 kPa) [0.14 bar] and fully open at 3 psi (21 kPa) [0.21 bar]. All models include a built-in lever to aid in opening the valve manually. The M2582-P can be manually opened against inlet pressure of 80 psi (552 kPa) [5.52 bar]. The M5180-P valve can be opened against inlet pressure of 100 psi (689 kPa) [6.89 bar]. Standard models include an escape vent for gas trapped forward in the line after shut-off.
M5081FS Normally Energized Circuit The M5081FS is manually opened, electrically latched open and tripped by interrupting the coil power circuit.
Magnetic Switch Adapter
As ignition systems wear from usage, their power output becomes less and less. Ignition may not have the capacity to reliably trip the Fuel Valve. Therefore, the use of a Magnetic Switch Adapter for CD ignition systems is recommended. The Magnetic Switch Adapter is a device that stores energy from the CD ignition to trip the Fuel Valve. Three models are available: 65700053 (was 65020126): For use with negative ground ignitions up to 240 VDC. 65700054 (was 65020127): For use with positive ground ignitions up to 450 VDC. 65700055 (was 65020155): For use with negative ground ignitions up to 450 VDC.
100 ohm, 2 watt Resistor
For Capacitor Discharge Ignitions that are specified to be grounded when the valve closes, and a Magnetic Switch Adapter is in use. The resistor must be connected in the system to prevent damage to the snap-switches in the fuel shut-off valve (see typical wiring diagrams).
Diode Package
The Murphy diode package (65010065) is designed to allow the fuel shutoff valve to be used with dual Magneto Ignition systems. NOTE: All aluminum versions of the M5081 Series Fuel Valve carry Canadian Registartion Number OC1476.2. * M5081 model is CSA approved for Class I, Division 1, Groups C and D. See Specifications on page 12.
Installation M-7980N page 1 of 12
VALVE CUT-OUT
FLOW CHARACTERISTICS
Understanding the Basic Operation of the Fuel Shut-off Valve M2582 Series 4 oz . (0. 11 k g.) 10 o 5 ps z. (0 ig (3 .28 k 4 kP g.) 10 p a) [ 0.34 sig (69 bar] kPa ) [0 20 .69 psi bar g (1 ] 38 kPa ) [1 30 .38 psi bar g (2 ] 07 kPa ) [2 .07 bar ]
10.0 [254.0]
Inches water column (∆p) drop across valve. Millimeters water column in brackets [ ].
9.0 [228.6] 8.0 [203.2] 7.0 [177.8] 6.0 [152.4]
The valve below is shown in the run (open) position. Pressure is equalized, seat (B) is open, allowing the fuel to flow. When valve is in the tripped position (closed), seat closes (C). The vent (D) opens to relieve trapped downstream fuel to vent to a non-hazardous area. TYPICAL MODEL (M5081) SHOWN
5.0 [127.0]
Terminal Block is within this case.
4.0 [101.6] 3.0 [76.2]
F
2.0 [50.8] 1.0 [25.4]
0
E
250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 [7.08] [14.16] [21.24] [28.32] [35.40] [42.48] [4956] [56.64] [63.72] [70.80] [77.88] [84.96]
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
G B
C
A D Vent to relieve trapped fuel outside the hazardous area. 10 oz 4o . (. z. 28 (.1 kg 1k .) g.)
Inches water column (∆p) drop across valve. Millimeters water column in brackets [ ].
M5081 and M5180 Series
3.0 [76.2]
2.0 [50.8]
ar] 9b ) [.6 a P k bar] (69 sig [1.38 10 p 38 kPa) 1 bar] sig ( 2.07 20 p Pa) [ k 7 0 ig (2 30 ps
1.0 [25.4]
0
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 [14.16] [28.32] [42.48] [56.64] [70.80] [84.96] [99.12] [113.28] [127.44] [141.60]
H Pipe Plug (remove to install vent tube).
A. Main Stem B. Pressure Disc/seal (in run/open) C. Pressure Disc/seal (in trip/closed) D. Vent Seal Gland E. Reset Knob (latches valve open) F. Manual Trip Knob (not available for M5081FS) G. Indicator Button (out with valve open) H. Pipe Plug
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
NOTE: If the vent-after-tripping feature is not used, remove O-ring (D), to avoid condensation accumulation that can hamper trip action. Be sure to replace Pipe Plug (H) and to clean vent periodically.
Installation M-7980N page 2 of 12
DIMENSIONS CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M2582
M2582-P 1/2 NPT Conduit Connection
Reset Knob
1/4 in. (6 mm) tube connection; control pressure 3 psi (21 kPa) [0.21 bar] minimum, 75 psi (517 kPa) [5.17 bar] maximum.
Latch Arm (see NOTE)
Manual Trip Knob 1 NPT (2 places)
Breather/Vent 1/16 in. (2 mm) 1 NPT (2 places)
1/4 NPT Vent and Plug
6-9/16 in. (167 mm)
1/4 NPT Vent and Plug
7-5/16 in. (186 mm)
3-3/32 in. (79 mm) 5-1/2 in. (140 mm)
3-3/32 in. (79 mm) 5-1/2 in. (140 mm)
NOTE: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch)
M5180-P Latch Arm (see NOTE 2)
Breather Vent (see NOTE 1)
6-1/8 in. (156 mm)
10-7/16 in. (265 mm) 1/4 in. (6 mm) connection; control pressure 3 psi (21 kPa) [0.21 bar] minimum, 80 psi (552 kPa) [5.52 bar] maximum (see NOTE 1)
2 NPT (2 places)
4-3/8 in. (111 mm)
Vent and Plug 1/2 NPT 4-1/4 in. (108 mm)
9-3/8 in. (238 mm)
NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control. NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch).
65700053
Magnetic Switch Adapters 65700054 (was 65020127); 65700055 (was 65020155)
(was 65020126);
2-5/16 in. (59 mm) 1-15/32 in. (37 mm) Panel Mount screws 10-24 N.C. x 5/16 in. (8 mm) long
3/8 in. (10 mm)
2-5/8 in. (67 mm)
1-23/32 in. (44 mm)
31/32 in. (25 mm) 15/32 in. (12 mm)
GND ALT1
Terminal screws 8-32 N.C. x 1/4 in. (6 mm) long Installation M-7980N page 3 of 12
ALT2
SW
2-7/16 in. (62 mm)
DIMENSIONS continued CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M5081 and M5081FS Manual Trip Knob (M5081 only)
Reset Knob
Inlet Breather
1/2 NPT Conduit Connection (2 plcs.)
1-3/8 in. (35 mm)
10-5/16 in. (262 mm) 3-7/16 in. (87 mm)
Indicator Button
2 NPT (2 places)
Vent and Plug 1/2 NPT
4-1/16 in. (103 mm)
3 in. (76 mm) 9-3/8 in. (238 mm)
7-3/4 in. (197 mm)
M5081-3 Steel Flanged Option
45° 3-5/8 in. (92 mm) dia.
2 in. (51 mm) dia. 2 places 150# RF (raised face) pipe flange 14-25/64 to 14-29/64 in. (366/367 mm)
Installation M-7980N page 4 of 12
3/4 in. (19 mm) dia. (4 places) each end equally spaced on a 15/32 in. (121 mm) b.c. (bolt circle)
INSTALLATION WARNING: STOP THE ENGINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION. BEGIN THE INSTALLATION BY SECURING AREA OF ANY HAZARDOUS CONDITIONS. SHUTOFF THE FUEL GAS SUPPLY. FOR HAZARDOUS APPLICATIONS REFER TO NATIONAL ELECTRICAL CODE SPECIFICATIONS.
Connecting the Fuel Shut-off Valve
Figure 1 1. Before connecting the unit, apply pipe dope to plumbing male threads Physical Location and Plumbing (typical) that will be inserted into the valve. Do not apply pipe dope to the valve. 2. Make sure that the arrow on the side of the valve indicates the correct Fuel Shut-off Valve direction of the flow. 3. Fuel shut-off valves can be installed in all three planes. However, Master Regulator Bypass Fuel mounting the valve horizontally (with vent pointing down) is (High pressure) Regulator Filter Carburetor recommended. Do not install valve with top down. (Refer to Figure 1.) 4. Hold valve in position, (use a tool on valve wrench flats) and tighten plumbing into inlet and outlet ends. (Refer to dimensions on pages 3-4.) Wrench Flats
CAUTION: DO NOT TWIST THE VALVE BODY HOUSING.
5. To mount flanged models, follow the appropriate installation codes and ordinances for the application. (For dimensions see page 4.) 6. A vent line (to allow gas trapped forward between fuel valve and the carburetor to escape) should be attached to the vent connection at the bottom of the valve housing. Remove the plug and install the line. (Refer to Figure 1.)
FUEL FLOW
Remove plug and attach vent line. Route to non-hazardous area.
Figure 2 Pull the lever up, and press the latch down into ridge with thumb.
Connecting Pneumatic Models M2582-P and M5180-P 1. Repeat the steps above (1 thru 5), and observe the necessary cautions. 2. A lever/arm (handle) and a cocking latch are provided to allow manual opening of the valve. The thumb-operated latch can be locked in place to hold the lever/arm latched. The cocking latch will be released when pilot pressure reaches 2.5 psi (17 kPa) [0.17 bar]). M2582-P and M5180-P automatically open at 2 psi (14 kPa) [0.14 bar], and fully open at 3 psi (21 kPa) [0.21 bar]. See Specifications, page 12 for maximum control pressure.
Level Arm (Handle) Control Pressure Connection
CAUTION: BE SURE PNEUMATIC SOURCE RELEASES THE MECHANICAL LATCH WHEN RUNNING.
3. If vacuum control is desired, swap the Control Pressure connection fitting and the Breather Vent fitting on your M5180-P model (see Fig. 2).
Installation M-7980N page 5 of 12
Thumb-operated Cocking Latch Breather Vent
WIRING INFORMATION WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582 Internal Wiring
Wiring shown in normal mode of operation (seat open). The 20 AWG (0.75 mm2) wire is color coded to the coil: For CD ignitions: White and Orange For Magneto ignitions: White and Green For Battery: White and Blue Conduit Installation Install a 1/2 NPT conduit from the M2582 conduit connection to the power source. See M2582 Dimensions (page 3) for location. For wiring the M2582 fuel valve to Solid-State TATTLETALE® annunciators, refer to pages 9, 10, and 11.
M5081 Internal Wiring
Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2) wire is color coded to the coil: For CD Ignitions: White and Orange For Magneto Ignitions: White and Green For Battery: White and Blue
Internal Wiring for M2582 Optional Resistor (Note)
White Black
NOTE: For grounding the ignition (CD models only) through the fuel valve snap-switch, use a Magnetic Switch Adapter (see Magnetic Switch Adapter, below) and install a 100 ohm; 2 watt resistor (included on page 11).
M5081 Internal Wiring
Valve Coil
Red
Ground
Disconnect Switches Ignition 1 Ignition 2
Conduit Installation Install a 1/2 NPT conduit from the M5081 conduit connection to the power source. Refer to Dimensions (on page 4) for location. Ground
For typical wiring of the M5081 models refer to pages 7 and 8. For wiring the M5081 fuel valves to Solid-State TATTLETALE annunciators, refer to pages 9, 10, and 11.
®
M2582-C-LS Wiring White
Orange
White
Orange
FV+ (IGN)
FV+ (IGN)
For typical Wiring refer to page 8. For wiring the M5081FS to MARK IV 12/24 refer to page 10.
Valve Coil (Note)
8 7 6
5
4
3 2 1
Jumper
Optional Resistor (See Note)
FV–
M5081FS Internal Wiring
Switch 2
Jumper
M5081-C-LS Wiring
FV–
Ground
10 9
NOTE: For grounding the ignition (CD models only) through the fuel valve snap-switches, use a Magnetic Switch Adapter, see Magnetic Switch Adapter, below and the “TO CLOSE THE FUEL VALVE and GROUND THE IGNITION” attachment, and install a 100 ohm; 2 watt resistor (included with your attachment).
Magnetic Switch Adapters for Use with Capacitor Discharge Ignitions Connect the Magnetic Switch Adapter between the fuel Valve terminal 1 and the CD Ignition. See wiring diagrams (pages 7 and 11).
Switch 1
65700053 (was 65020126): For use with negative ground ignitions up to 240 VDC.
+
65700054 (was 65020127): For use with positive ground ignitions up to 450 VDC. 10 9
8 7 6
5
4
65700055 (was 65020155): For use with negative ground ignitions up to 450 VDC.
3 2 1
GND
ALT 1
IN4007
ALT 2
SW
Negative ground Magnetic Switch Adapter shown
NOTE: Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2) wire is red color for both options: 12 VDC and 24 VDC. Installation M-7980N page 6 of 12
TYPICAL WIRING for M5081-C (CD IGNITION MODELS)
M5081-C CD Ignition Models GND ALT1 ALT2 SW
Terminal Block
10 9
8 7 6
5
Magnetic Switch Adapter
4
3 2 1
Additional CD ignition
CD ignition
Ground
Jumpers 100 ohm, 2 watt Resistor (Notes 3 and 4)
Start-run timer
MS2100
6 1
2
3
MS2100
4 5
6 1
2
3
4 5
To additional TATTLETALE® NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single CD Ignition Systems) Remove the factory-installed jumper on terminals 6-5. Do NOT ground terminal 6. NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual CD Ignition Systems) Remove the jumper on terminals 6-5. Connect second ignition to Magnetic Switch Adapter terminal ALT2. NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single CD Ignition Systems) Remove the jumper on terminals 6-5. Connect a 100 ohm, 2 watt resistor between valve terminals 1-2. Ground terminal 6. NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual CD Ignition Systems) Remove the jumper on terminals 6-5. Connect a 100 ohm, 2 watt resistor between valve terminals 1-2. Ground terminal 6. Connect second ignition to Magnetic Switch Adapter terminal ALT2.
TYPICAL WIRING for M5081-B (BATTERY IGNITION MODELS)
M5081-B Battery Models
+ -DC Power source
Terminal Block
10 9
8 7 6
5
4
3 2 1
Ground Jumpers
*
MS2110
Diode *forIN4005 flyback protection
MS2110
Start-run timer 6 1
2
3
4 5
Installation M-7980N page 7 of 12
6 1
2
3
4 5
To additional TATTLETALE®
TYPICAL WIRING for M5081-A (MAGNETO IGNITION MODELS)
M5081-A Magneto Ignition Models Terminal Block
10 9
8 7 6
5
4
3 2 1
Magneto
Ground 65010065 Diode Package (See Notes 2/4)
Additional Magneto
Jumpers
MS2120
Start-run timer
6 1
2
3
MS2120
4 5
6 1
2
3
4 5
To additional TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single Magneto Systems) Remove the factory-installed jumper on terminals 6-5. Do NOT ground terminal 5. NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual Magneto Systems) Remove the factory-installed jumpers on terminals 6-5 and 9-8. Add 65010065 diode package as shown. Do NOT ground terminals. NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single Magneto Systems) The factory-installed jumpers (6-5 and 9-8) must be in place. Add ground wire to terminal 5. NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual Magneto Systems) Remove the jumper on terminals 9-8. Add 65010065 diode package as shown. Add ground wire to terminal 5.
TYPICAL WIRING for M5081FS (NORMALLY ENERGIZED MODELS)
M5081FS 12 or 24 VDC Models Terminal Block
10 9
8 7 6
Ground
MS2110
6 1
2
3
Ground
5
4
3 2 1 + -DC Power source
* MS2110
4 5
*
6 1
2
3
4 5
* Start-run timer
Installation M-7980N page 8 of 12
Diode * forIN4005 flyback protection
TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582-C to LCDT-PS-CD (R)-P (positive ground)
M5081-C to LCDT-PS-CD (R)-P (positive ground)
LCDT-PS-CD (R)-P M2582 Fuel Valve
+
–
White
IGN 1
10 9
GND
Black Red
jumper
NO
+
3 2 1
–
IGN 1
jumper
FV(-)
Relay Contacts
Relay Contacts
*
NO C NC
* FV(-) FET output rated: 0.5 A @ 250 VDC max.
Ground
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
M2582-C to LCDT-PS-CD-N (negative ground)
M5081-C to LCDT-PS-CD-N (negative ground)
LCDT-PS-CD-N
Red
4
FV
C
Black
5
GND
NC
White
8 7 6
FV(+) FV(-)
M2582 Fuel Valve
LCDT-PS-CD (R)-P Terminal block
M5081 Terminal block
–
IGN 1
10 9
FV(+) FV(-)
LCDT-PS-CD-N Terminal block
M5081 Terminal block
+
8 7 6
5
4
3 2 1
–
+
IGN 1 FV(+)
*
FV(-)
GND
jumper
NO
jumper
Relay Contacts
C NC
*
GND
Relay Contacts
NO C NC
* FV(-) FET output rated: 0.5 A @ 250 VDC max.
Ground
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
* Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
M2582-C to MARK IV-N (negative ground)
M5081-C to MARK IV-N (negative ground) M5081 Terminal block
M2582 Fuel Valve +
White
–
10 9
8 7 6
5
4
3 2 1
jumper
Ground
jumper
GRD F/VF/V+ IGN 1
Red
MARK IV-N terminal block
* MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
Installation M-7980N page 9 of 12
GRD F/VF/V+ IGN 1
Black
MARK IV-N * terminal block
TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M5081FS to MARK IV-12/24
M5081-B to MARK IV-12/24 M5081-B
M5081FS Terminal Block
8 7 6
5
4
3 2 1
10 9
Diode * forIN4005 flyback protection
8 7 6
jumper
M5081FS Terminal Block
5
4
1
3 2 1
1
12/24 S/D FV ALM GRD
MARK III has FET outputs rated: 0.5 A @ 250 V max. Auxiliary Relays must be hermetically-sealed, third party certified for use in Class I, Division 2, Gps. C & D areas.
*– *–
K2
+ +
* +
K2
K2 K1
+ -DC Power source
MARK IV-12/24 terminal block
MARK IV has FET outputs rated: 0.5 A @ 250 VDC max. Remove shunt jumper E2 for ignition ground time delay.
1
*–
M5081 Terminal block 10 9
8 7 6
5
4
†† Alarm Relay K1
+
Power Supply
–
3 2 1
Ignition
jumper
2
Auxiliary Relay
K1
–
K1
M5081-C to MARK III-N
+ -12/24 VDC Power source
MARK III-12/24 terminal block
* IN4005 Diode for flyback protection 2
jumper
* for flyback protection
*
1
3 2 1
IN4005 Diode
MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
8 7 6
4
+ -DC Power source
M5081FS to MARK III-12/24
10 9
5
K1 and K2: External Relay(s)
*
12/24V SD F/V GRD
*
1
1
GRD F/V S/D 12/24V
10 9
MARK IV-12/24 terminal block
2
Auxiliary or Shutdown Relay
IGN 90-250 Vdc +FV -FV ALM GRD
jumper
* IN4005 Diode for flyback protection
† MARK III-N
† MARK III has FET outputs rated:
terminal block
0.5 A @ 250 V max.
†† Alarm Relay must be
hermetically-sealed, third party certified for use in Class I, Division 2, Gps. C & D areas.
M2582-C to TTDJ-IGN-(T)
M5081-C to TTDJ-IGN-(T) M5081 Terminal block 10 9
8 7 6
jumper
5
jumper
4
M2582 Fuel Valve
3 2 1 IGN NA GRD FV+ FVALR NA NA
Installation M-7980N page 10 of 12
White Black
Red
–
+ IGN NA GRD FV+ FVALR NA NA
–
*
+
TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators continued WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NONHAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
(B) M2582-B to TTDJ-DC-(T)
(A) M5081-B to TTDJ-DC-(T)
10 9
8 7 6
jumper
1
5
4
To 12 or 24 VDC power supply
To 12 or 24 VDC power supply
M5081 Terminal block
M2582 Fuel Valve
3 2 1
*
jumper
K2
1
Black
SD 10-32VDC GRD NA FV ALR MPU GRD
K1
1
* 1N4005 diode for flyback protection.
TTDJ-DC-(T) to Relays Connections Shown for Use with Diagrams (A), (B), (C), and (D) on this page.
+
10 9
8 7 6
5
K1 and K2 are hermetically Sealed auxiliary relays, third party certified for use in Class I, Div. 2, Gps. C & D areas.
4
3 2 1
SD 10-32VDC GRD NA FV ALR MPU GRD
*
SD 10-32VDC GRD NA FV ALR MPU GRD
–
* 1
To 12 or 24 VDC power supply
–
1
K2
K1
K1 and K2 are hermetically Sealed auxiliary relays, third party certified for use in Class I, Div. 2, Gps. C & D areas.
M5081FS Terminal Block
*
12-24 VDC Power supply
1
M5081FS to TTDJ-DC-(T)
1
K1
K2
Red
K1 and K2 are hermetically Sealed auxiliary relays, third party certified for use in Class I, Div. 2, Gps. C & D areas.
IGNITION RELAY +
SD 10-32VDC GRD NA FV ALR MPU GRD
White
* 1N4005 diode for flyback protection.
* 1N4005 diode for flyback protection.
(C) M2582-C w/Magnetic
(D) M5081-C w/Magnetic
Switch Adaptor to CD Ignition Magnetic Switch Adapter
Switch Adaptor to CD Ignition
GND ALT1 ALT2 SW
M2582 Fuel Valve
+
White
K2
Black
1
10 9
8 7 6
5
4
3 2 1 +
– –
jumper Red
1
GND ALT1 ALT2 SW
M5081 Terminal block
jumper
K2 1
K2 is hermetically sealed auxiliary relay, third party certified for use in Class I, Div. 2, Gps. C & D areas.
1
K2 is hermetically sealed auxiliary relay, third party certified for use in Class I, Div. 2, Gps. C & D areas.
Installation M-7980N page 11 of 12
Magnetic Switch Adapter
SPECIFICATIONS Valve Body: Sandcast aluminum, painted red (corrosion resistance); Optional cast steel available for M5081 and M5081FS models only. Valve Seat: Buna-N Maximum Valve Inlet Pressure: • M2582/M2582-P: 80 psi (552 kPa) [5.52 bar] • M5081/M5081FS/ M5180-P: 100 psi (689 kPa) [6.89] Maximum Control Pressure (Pneumatic Models): • M2582-P: 75 psi (517 kPa) [5.17 bar] • M5180-P: 80 psi (552 kPa) [5.52 bar] Snap-switch: M2582: One SPDT, 5 A @ 480 VAC M5081, and M5081FS: Two SPDT, 5 A @ 480 VAC Wiring: M2582: Wire leads; M5081, and M5081FS: Terminal blocks NOTE: All aluminum versions of the M5081 Series Fuel Valve carry Canadian Registartion Number OC1476.2. SERVICE PARTS Coil Assembly Battery CD Ignition Magneto Ignition
Coil Rating: Intermittent duty; coil type must match power source; • CD ignition coil resistance: 72 Ω CD ignition primary voltage: 1.38 to 3.8 A • M5081FS: Energized to Run (continuous-duty coil) coil resistance: 12 V model: 33 Ω; 24 V model: 136 Ω • Magneto ignition coil resistance: 0.5 Ω Magneto primary voltage: 1 to 5 A • Battery coil resistance : 7 Ω 12 or 24 VDC: 1.2 to 2.4 A Laboratory Approval: CSA listed for Class I, Groups C and D Hazardous Locations. 5 amps maximum; intermittent duty; models M5081 and M5081-CD engine ignition powered, and model M5081-B, 12 or 24 VAC or VDC; switch contacts rated 5 A @ 480 VAC maximum. Maximum pressure 100 psi (689 kPa) [6.89 bar].
M2582
M5081
M5081FS
M2582-P
M5180-P
55000128 55000129 55000094
55000126 55000127 55000080
----------------------------------
----------------------------------
----------------------------------
M5081FS Coil Assembly 12 VDC 24 VDC Latch Block Assembly Latch block assembly Latch block switch and coil assembly Latch block switch and mounting bracket assembly
-----------------------
-----------------------
55000158 55000159
-----------------------
------------
55000095 -----------------------
55000074 -----------55000118
----------------------55000196
----------------------------------
----------------------------------
Handle and Latch Kit Handle and latch kit Handle kit
-----------55000096
55000102 ------------
55000102 ------------
5500148 ------------
55000154 ------------
Manual DIsconnect Assembly
55000097
55000137
---------------
---------------
---------------
Snap Switch Assembly
55000098
55000072
55000160
---------------
---------------
------------
Close/Open Indicator Assembly
------------
55000138
55000138
---------------
---------------
Stem and Seat Kit
55000093
55000075
55000135
55000147
55000135 55000155
Top Works Complete Valve Less Body and Vent
55000146
55000131
55000161
55000150
Vent Bushing Assembly
55000143
55000132
55000132
55000143
55000132
55000184
55000153
Diaphragm Assembly
------------
------------
------------
Pilot Diaphragm
------------
------------
------------
00007908
55050420
Diode Package for Dual Magneto Ignitions
------------
65010065
------------
------------
------------
Magnetic Switch Adapter for CD Ignitions Single/Dual ign. – negative ground up to 240 VDC
65700053
65700053
------------
------------
------------
Single/Dual ign. – positive ground up to 450 VDC
65700054
65700054
------------
------------
Single/Dual ign. – negative ground up to 450 VDC
65700055
65700055
------------
------------
-----------------------
Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product. Details are available on request and are packed with each unit.
FWMurphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA (918) 317-4100 fax (918) 317-4266 e-mail
[email protected] www.fwmurphy.com
CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA (281) 342-0297 fax (281) 341-6006 e-mail
[email protected] MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52-444-8206264 fax +52-444-8206336 Villahermosa Office +52-993-3162117 e-mail
[email protected] www.murphymex.com.mx
FRANK W. MURPHY, LTD. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail
[email protected] www.fwmurphy.co.uk
MACQUARRIE CORPORATION 1620 Hume Highway Campbellfield, Vic 3061; Australia +61 3 9358-5555 fax +61 3 9358-5558 e-mail
[email protected]
Installation M-7980N page 12 of 12
D
E
RE
MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA GI STER (661) 272-4700 fax (661) 947-7570 e-mail
[email protected] www.murphyswitch.com In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. Printed in U.S.A.
0966106
Type 119
Instruction Manual
Fisher Controls
Type 119 Control Valve
R
June 1990
Form 5204
Introduction Scope of Manual This instruction manual provides installation, spring adjustment, maintenance, and parts information for the Type 119 control valve.
Description The Type 119 control valve (figure 1) is used for on-off or throttling control of noncorrosive or mildly corrosive liquids and gases. It is designed to meet the low-pressure liquid and gas application requirements in many varied industries. As loading pressure is applied to the Type 119 control valve diaphragm, the disk holder is pulled off the orifice. As loading pressure is reduced, the opposing spring force moves the disk holder toward the closed position, resulting in spring-close action should a loss of supply pressure occur.
W3735-1
Figure 1. Type 119 Control Valve
Specifications Table 1 lists specifications for the Type 119 control valve. Some of the specifications for a given control valve as it originally comes from the factory are stamped on a nameplate (figure 2) located on the spring case flange.
the service conditions do not exceed the limits shown in table 1. The leak-off and spring case vents must be kept open. To avoid danger of fire or explosion from venting of flammable or otherwise hazardous fluid into a closed or poorly vented location, pipe the vents to a well-ventilated location, away from any buildings or windows so as not to create a further hazard.
WARNING To avoid personal injury or property damage caused by controlled process fluid or bursting of pressure-retaining parts, be certain eFisher Controls International, Inc. 1982, 1990; All Rights Reserved
2. The control valve can be installed in any position, but the normal orientation is with the actuator portion vertical above the body. If installing the control valve at an outside location, point the spring case and bonnet vents in the downward direction to protect them from moisture or foreign materials.
D100261X012
1. Before installing the valve, be sure the valve body and associated equipment are free of damage and foreign material.
Installation
R
Type 119 Table 1. Specifications Maximum Inlet Pressure(1) 150 psig (10.3 bar) Spring Ranges
Material Temperature Capabilities(1) With Nitrile Elastomers: -20 to 170_F (-29 to 77_C) With Fluoroelastomers: 0 to 250_F (-18 to 121_C) Note: Not for use with hot water or ammonia. Flow Direction Up through the seat ring
See table 2 Maximum Control Pressure to Diaphragm 150 psig (10.3 bar) Maximum Pressure Drop(1) 150 psi (10.3 bar) for all port diameters
Spring Case Vent and Bonnet Leak-Off Connection 1/4-inch NPT female Approximate Weight 6 lb (2.7 kg)
1. The pressure and temperature limitations in this manual, and any applicable code limitation, should not be exceeded.
Table 2. Spring Selection SPRING RANGE Psig
Bar
3-15 5-20 5-35 30-60
0.2-1.0 0.3-1.4 0.3-2.4 2.1-4.1
SPRING PART NUMBER 1D8923 27022 1D7515 27022 1D6659 27022 1D7455 27142
SPRING COLOR CODE Red Cadmium Blue Green
1E5427-F
Material Code AI/N SST/N SST/V
Orifice Seat Disk Material Aluminum/Nitrile Stainless steel/Nitrile Stainless steel/Fluoroelastomer
Spring Adjustment
Figure 2. Type 119 Nameplate
The control valve spring has been selected to meet the pressure condition requirements of the application as specified on the order. This pressure condition is stamped on the actuator nameplate.
3. Install the valve using accepted piping practices. Make sure that the valve is oriented so that flow through the body will match the flow direction arrow on the body.
The spring has a fixed pressure span over which loading pressure will stroke the valve. Adjustment of the spring compression shifts the span so that more or less loading pressure is required to start travel. Since the span does not change, there will be a corresponding increase or decrease in the pressure requirements at the end of the valve stroke.
4. If continuous operation is required during maintenance and inspection, install a three-valve bypass around the control valve. 5. Connect the control pressure line to the 1/4-inch NPT connection in the valve body bonnet marked PILOT.
2
If the control valve has been disassembled or pressure conditions have changed, the spring may need adjustment to make the valve travel coincide with the diaphragm pressure range. Make the adjustment in the following manner. Key numbers refer to figure 3.
Type 119 1. Loosen the locknut (key 13) on the spring case. 2. Turn the adjusting screw (key 12) clockwise to compress the spring (key 16) or counterclockwise to decrease spring compression. Increased spring compression results in increased loading pressure necessary to start travel. Decreased spring compression results in less loading pressure required to start travel. 3. After adjustment, tighten the locknut. Note that the spring can be identified by the color code. Depending on how much conditions are changed, it may be necessary to install a new spring, using appropriate steps in the Maintenance section. After changing the spring, adjust the valve using the above steps in this section, and indicate the new spring range on the nameplate.
7/8-inch socket wrench, and replace it with a new seat ring of the proper size. 4. Remove the bonnet O-ring (key 11), and inspect it for wear and damage. 5. Unscrew and remove the spring case cap screws (key 14). Remove the spring case, upper spring seat, and spring (keys 2, 17 and 16). Do not lose the nameplate (key 20) when removing the spring case. 6. Pull the hair pin clip (key 6) from the stem and remove the disk holder assembly (key 4). 7. Pull the diaphragm/stem assembly (key 5) out of the bonnet (key 9), and inspect for damage or deterioration. If necessary, replace the entire diaphragm assembly. 8. Without removing the O-rings and bushing spacers (keys 8 and 7) inspect their inside diameter surfaces for damage or deterioration.
Maintenance Valve parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance depends on the severity of the service conditions.
WARNING To avoid personal injury or property damage caused by sudden release of pressure or uncontrolled process fluid, isolate the control valve from the pressure system, and release all pressure from the valve body and actuator before performing maintenance operations. The following describes the procedure for complete disassembly and assembly of the actuator-valve body combination. When inspection or repairs are required, disassemble only those parts necessary to accomplish the job. Key numbers refer to figure 3.
Disassembly 1. Isolate the control valve from all pressure, and release pressure from the valve body and actuator. Loosen the locknut (key 13), and remove all spring compression from the control valve by turning the adjusting screw (key 12) out of the spring case. 2. Remove the two bonnet cap screws (key 15, not shown) that secure the bonnet to the body, and lift the spring case, bonnet, and trim assembly from the body. 3. Examine the seating edge of the orifice (key 3). If it is nicked or rough, unscrew it from the body with a thinwall 1. Trademark of Never-Seez Corp. 2. Trademark of Tretolite Div. of Petrolite Corp.
Note The following step should be performed only when there is an indication of O-ring or bushing spacer failure. 9. Remove the internal retaining rings, stem wipers, Orings, and bushing spacers (keys 10, 19, 8 and 7). Inspect these parts for wear or deterioration, and replace if necessary.
Assembly This procedure assumes that the control valve has been completely disassembled. If the control valve has been only partially disassembled, start these instructions at the appropriate step. 1. If the orifice (key 3) was removed during disassembly, lubricate the threads with Never-Seez(1) lubricant (key 21) or equivalent, and screw it into the valve body using a thinwall 7/8-inch socket wrench. 2. Lubricate the bushing spacers, O-rings, stem wipers, and internal retaining rings (keys 7, 8, 19 and 10) with Dow Corning(2) No. 111 silicon-base lubricant (key 22) or equivalent, and install as shown in figure 3. 3. Carefully slide the diaphragm assembly (key 5) into and through the O-rings and bushing cavity. Turn the diaphragm assembly to line up the diaphragm holes with the bonnet holes. 4. Slide the disk holder assembly (key 4) all the way into the stem. Connect the disk holder assembly with the hair pin clip (key 6). 5. Coat the bonnet O-ring (key 11) with Dow Corning No. 111 lubricant (key 22) or equivalent. Install the O-ring in the recessed notch in the bonnet (key 9). 3
R
Type 119 6. Mount the bonnet (key 9) on the valve body (key 1), insert two cap screws (key 15, not shown), and tighten to 7 foot-pounds (9 newton-meters).
Key
Part Kits Kits include keys 4, 5, 6, 8, 10, 11, and 19. For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5 mm) inch orifices w/aluminum disk holder nitrile diaphragm, and nitrile disk & O-rings For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices w/aluminum disk holder, nitrile diaphragm and nitrile disk & O-rings For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5 mm) inch orifices w/stainless steel disk holder, nitrile diaphragm and nitrile disk & O-rings For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices w/stainless steel disk holder, nitrile diaphragm and nitrile disk & O-rings For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5 mm) inch orifices w/stainless steel disk holder and fluoroelastomer diaphragm, disk, & O-rings and stainless steel disk holder For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices w/stainless steel disk holder and fluoroelastomer diaphragm, disk & O-rings
7. Put the spring (key 16) on the diaphragm assembly (key 5), and place the upper spring seat (key 17) in the end of the spring. 8. Lubricate the point and threads of the adjusting screw (key 12) with Never Seez lubricant (key 21) or equivalent. 9. Position the spring case (key 2) and nameplate (key 20) on the diaphragm assembly (key 5). Insert the cap screws (key 14). 10. Tighten all cap screws until finger tight. Then, following a crisscross pattern, tighten each cap screw. 11. Connect the control piping to the control connection in the bonnet. 12. Adjust the spring by following the procedures in the Spring Adjustment section, and remark the nameplate if necessary.
When contacting your Fisher sales office or sales representative for technical assistance or ordering replacement parts, include the type number and all other pertinent information stamped on the nameplate attached to the spring case.
Parts List Key
Part Number
Note In this parts list, parts marked NACE are intended for corrosion-resistant service as detailed in the National Association of Corrosion Engineers (NACE) standard MR-01-75.
4
1
2
Description
Part Number
R119X 000A12
R119X 000A22
R119X 00SN12
R119X 00SN22
R119X 00SV12
R119X 00SV22
NACE Construction For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), 5/16 (7.9 mm), and 3/8 (9.5 mm) inch orifices w/aluminum disk holder, fluoroelastomer diaphragm, disk and O-rings R119X N0SV32 For 1/2 (12.7 mm) and 9/16 (14.3 mm) inch orifices w/aluminum disk holder, fluoroelastomer diaphragm, disk and O-rings R119X N0SV42
Parts Ordering
When ordering replacement parts, also be sure to include the 11-character part number for each part required from the following parts list.
Description
3*
Valve Body Cast iron 3/4-inch 1-inch 1-1/4-inch Steel 3/4-inch 1-inch Spring Case Aluminum Orifice Aluminum 1/8-inch (3.2 mm) diameter 3/16-inch (4.8 mm) diameter 1/4-inch (6.4 mm) diameter 5/16-inch (7.9 mm) diameter 3/8-inch (9.5 mm) diameter 1/2-inch (12.7 mm) diameter 9/16-inch (14.3 mm) diameter Stainless steel 1/8-inch (3.2 mm) diameter 3/16-inch (4.8 mm) diameter 1/4-inch (6.4 mm) diameter 5/16-inch (7.9 mm) diameter 3/8-inch (9.5 mm) diameter 1/2-inch (12.7 mm) diameter 9/16-inch (14.3 mm) diameter
*Recommended spare parts
1E9871 19012 1E9873 19012 1E9875 19012 1E9871 X0012 1E9873 X0012 2P9015 08012
1A9367 09012 009912 09012 0B0420 09012 0B0421 09012 0B0422 09012 1A9288 09012 1E9852 09022 1A9367 35032 009912 35032 0B0420 35032 0B0421 35032 0B0422 35032 1A9288 35032 1C4252 35032
Type 119 Key 4*
5*
6
7
Description
Part Number
Disk Holder Aluminum/nitrile 1/2 and 9/16-inch Stainless steel/nitrile 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), 5/16 (7.9 mm) & 3/8 (9.5 mm) inch orifices 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices Stainless steel/fluoroelastomer 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm) 5/16 (7.9 mm) & 3/8 (9.5 mm) inch orifices 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices Nace MR-01-75, aluminum/fluoroelastomer 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm) 5/16 (7.9 mm) & 3/8 (9.5 mm) inch orifices 1/2 (12.7 mm) & 9/16 (14.3 mm) inch orifices Diaphragm/Stem Assembly(1) Aluminum/nitrile Stainless steel/nitrile Stainless steel/fluoroelastomer Nace MR-01-75, Aluminum/fluoroelastomer Hair Pin Clip(1) All except NACE NACE MR-01-75 Bushing Spacer, Delrin 500(2) (2 req’d)
Key 8*
Assembly(1)
1C4248 000B2
1A8328 000A2
9 10
1C4248 000A2 11* 1A8328 000M2
Description O-Ring(1) (2 req’d) Nitrile Fluoroelastomer (high-temperature, corrosion) Nace MR-01-75, fluoroelastomer Bonnet, aluminum Internal Retaining Ring(1) (2 req’d) Nitrile & fluoroelastomer Nace MR-01-75, fluoroelastomer
1D6671 25072 27A5516 X012 18A7024 X012 1E5427 11992
15
1C4248 X0182
16
Cap Screw, zinc plated steel (2 req’d) (not shown) Actuator Spring, zinc plated steel
17 18 19 20
Upper Spring Seat, zinc plated steel Type Y602-12 Vent (not shown) Stem Wiper(1), TFE (2 req’d) Nameplate, aluminum
21
Never-Seez Lubricant, 1 gal (3.81 L) can (not furnished with valve) Dow Corning 111 Lubricant, 10 lb (4.53 kg) can (not furnished with valve) Vent Screen, stainless steel (not shown) Nace Tag Tag Wire
23 24 25
18A7020 X022 18A7020 X032
1B7877 24052 See table 2
1A8328 X0122
22
18A7019 X022 18A7019 X022 48A7025 X012
13A5559 X012 1D9954 48702 1A3537 24122 1A3917 24052
12 13 14
19A0347 X012 19A0347 X022 18A7021 X012
18A7019 X012
Bonnet O-Ring(1) Nitrile Fluoroelastomer (high-temperature, corrosion) & Nace MR-01-75 Adjusting Screw, zinc plated steel Locknut, zinc plated steel Cap Screw, zinc plated steel (8 req’d)
1C4248 X0052
17A8080 X032 17A8080 X022 17A8080 X012 19A0348 X022
Part Number
1K5949 06562
1M5239 06992 1M5283 06992 0L0783 43062 19A6034 X012 1U7581 X0022
*Recommended spare part. 1. Included in repair kit. 2. Trademark of DuPont Co.
5
R
Type 119
V APPLY LUB/SEALANT 37A8078-C
Figure 3.Type 119 Control Valve
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness
R
6
Fisher Controls
or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.
For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France
Sao Paulo 05424 Brazil Singapore 2158 Printed in U.S.A.
Publication T1-702, Rev. 1 Dated: January 22, 2001
INSTALLATION AND OPERATING MANUAL
MODELS: T100-B, T100-D, T100-F, T100-P
TURBOTWIN Engine Air Starters
AN 95-414
From Tech Development Inc 6800 Poe Ave. ·Dayton OH 45414 Tel: (937) 898-9600 ·Fax: (937) 898-8431
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
TABLE OF CONTENTS SECTION
SUBJECT
PAGE
1.0 1.1 1.2 1.3
GENERAL INFORMATION DESCRIPTION PRODUCT IDENTIFICATION PERFORMANCE
2 2 2 3
2.0 2.1
ORIENTATION OF THE STARTER GENERAL
3 3
3.0 3.1 3.2 3.3 3.4 3.5 3.6
INSTALLING THE STARTER SUPPLY LINE INSTALLATION NLET PRESSURE PORT EXHAUST PIPING NATURAL GAS INSTALLATION PIPING SYSTEM BACKLASH
3 3 4 4 4 4 5
4.0 4.1 4.2
STARTER OPERATION BASIC OPERATION AUTOMATED START PANEL
5 6 6
5.0
PREVENTIVE MAINTENANCE
6
6.0
TROUBLE SHOOTING GUIDE
7
7.0
TURBOTWIN WARRANTY
8
LIST OF FIGURES 1. TURBOTWIN PART NUMBER LISTING 2. MODEL T112B/T121B INSTALLATION DRAWING 3. MODEL T106F/T112F INSTALLATION DRAWING 4. MODEL T112D/T121D INSTALLATION DRAWING 5. MODEL T112D/T121D INSTALLATION DRAWING
Publication T1-702, Rev 1 Issued January 22, 2001
(STD MESH)
1
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
1.0 GENERAL INFORMATION This manual provides instructions for the installation and operation of the TDI T100 TURBOTWIN Starters (Series: B,D,F,P). If there are questions not answered in this manual, please contact your TDI TURBOTWIN distributor or dealer for assistance. The T100 TURBOTWIN models are turbine driven starters with an inertially engaged starter drive. Depending on the starter model and engine installation, the TURBOTWIN starters have applications ranging from 1200 CID (20 Liters) on diesel engines and up to 15000 CID (250 Liters) on gas engines. The TURBOTWIN models are suited to operate within a wide range of inlet pressures and ambient temperatures. The engine size and parasitic loading will determine the exact minimum pressure that will assure reliable starting. The T100 TURBOTWIN starters are designed for operation with compressed air or natural gas; materials used are compatible with “sour” natural gas and marine environments. Small amounts of foreign matter or liquid in the air stream will not adversely affect TURBOTWIN starters. As with all other TDI starters, no lubrication is required in the air supply. Please review the rest of this manual before installing the T100 TURBOTWIN series air starter. WARNINGS, CAUTIONS AND NOTES Certain types of information are highlighted in this manual for your attention: WARNING - used where injury to personnel or damage to the equipment is likely. CAUTION - used where there is the possibility of damage to the equipment. NOTE - used to point out special interest information. NOTE Throughout this manual, the term “air” is used to designate the starter drive medium. Unless other wise stated, air “ means either compressed air or natural gas. 1.1 DESCRIPTION All models feature three basic subassemblies: a unique two stage turbine motor section, a planetary gearbox section and an inertia drive assembly. The two stage motor section features greater stall torque than a single stage turbine plus aerodynamic speed control. Page 2
This aerodynamic speed control helps protect the TURBOTWIN starter from damage caused by starter motor over speed. The T100 TURBOTWINS employ a 7.5:1 or 9:1 ratio planetary gearbox. This low gear ratio allows the turbine motor to spin at low speeds for long bearing life. At a typical 3000 rpm pinion speed, the turbine is cruising at a low 22500 rpm (7.5:1 ratio). Reliability and part commonality are designed into all TURBOTWINS. A simple and reliable inertia drive delivers the torque to the pinion. The pinion is thrown out to engage the engine's ring gear by the turbine motor's acceleration. Lighter weight rotating parts used in the TURBOTWIN provide low inertia and even "softer" engagement. In the event of overpressure, the friction clutch used in every TURBOTWIN protects ring gear teeth from static torque overloads. In addition, an inertia engaged starter eliminates the need for complex pre-engagement control plumbing...and is easier to install and maintain than pre-engaged type starters. Compressed air or natural gas is used to power T100 TURBOTWIN air starters through the inlet port. The air or gas is expanded through the first nozzle or stators. The high velocity gas impinges on the first stage rotor to yield torque to the gearbox. The gas is further expanded through the second stage stators, which impart additional torque to the second stage rotor. 1.2 PRODUCT IDENTIFICATION The starter nameplate which is attached to the turbine housing contains the following information: model number, serial number, part number, direction of rotation and the maximum rated operating pressure. The directions of rotation are either right hand or left hand rotation as shown in Figure 1. Right Hand rotation is defined as clockwise rotation as viewed from the pinion end of the starter, and Left Hand rotation is counter clockwise rotation viewed from the pinion end of the starter. The maximum operating pressure is also stamped on the nameplate. This pressure is measured at the check port on the starter inlet with the starter in operation. CAUTION Exceeding the maximum pressure shown on the nameplate may result in drive failure, damage to the starter, or damage to the engine. The housing proof pressure is 600 psig and is also shown on the nameplate. This means the turbine housing will not burst when subjected to a static pressure of 600 psig. Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
WARNING If a fuel (pulse) lubricator has previously been installed in the system, disconnect and plug the line to eliminate spraying diesel fuel on the engine. The starter should be installed with the inlet in a position between horizontal and straight down. Any condensation will be restricted to the air lines and not in the starter. WARNING Do not operate this starter unless it is properly connected to an engine. 3.1 SUPPLY LINE INSTALLATION
Figure 1. Direction of Rotation viewed from Pinion End. 1.3 PERFORMANCE Graphs of the performance curves feature pinion torque versus pinion speed (rpm) at constant drive air pressures and shaft horsepower versus pinion speed at constant drive air pressures. Pinion speed is shown on the horizontal axis. The pinion torque is shown along the left edge vertical axis. The shaft horsepower is shown along the right edge vertical axis. Air consumption rates are given for the various drive pressure lines. These performance curves feature air as the drive gas and have open exhaust (standard exhaust guard) which have no back pressure.
2.0 ORIENTATION OF THE STARTER 2.1 GENERAL If the factory orientation of the starter’s pinion housing assembly in relation to the inlet port does not fit your engine installation, these components can easily be re-oriented. All TURBOTWINS have the capability to rotate the inlet port relative to the drive opening for the optimum inlet port location. The number of different positions is 6 to 12 depending on model.
3.0 INSTALLING THE STARTER A turbine air starter does not require lubrication in the supply air. Therefore, if a vane type starter motor is being replaced, TDI recommends that all lubrication devices and lines removed to minimize flow restrictions.
Publication T1-702, Rev 1 Issued January 22, 2001
WARNING Be sure to either bleed the pressurized air reservoir and/or safety the system such as closing all valves prior to installing starter supply line. The T100 TURBOTWIN series air starters come standard with a 2" NPT female pipe thread for the inlet connection port. The supply line consists of the line from the air source, a pressure regulator (when necessary), a manual or relay valve, and the connection to the starter inlet. Hard piping may be used, but a section of flexible tubing should be installed at the starter to prevent leaks due to engine vibration. Care must be taken to ensure that all inlet supply line piping is no less than 1.5" and all components used are capable of passing the required air flow. NOTE Valves with a Cv of 40 or higher are recommended. If the supply line must be longer than 20 feet, the inlet supply line piping should be increased to 2" in diameter to ensure proper performance by your TURBOTWIN. Because turbine starters such as the T100 TURBOTWIN series are sensitive to flow restrictions, care must be taken to use uniform hose or tubing and fittings for connection of the supply line. Tees, elbows and line length must be kept to a minimum. TDI recommends that hose or flex couplings are installed to eliminate possible leakage caused by strain on the supply line. Normally, an air strainer is not required. However, in dirty environments use of a #40 mesh Y-strainer is recommended. The T100 TURBOTWIN series is highly tolerant of dirt in the air line, however, starter life can be increased with the use of an air strainer.
3
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
A pressure regulator is required when the air supply pressure is great enough to exceed the starter operating pressure (at the inlet port) and/or the maximum torque. A manual ball valve may be used to admit drive air/gas to the starter. The manual valve should be located in a safe position away from the engine.
installed at the pressure check port and electrical lines routed to a digital display at the operator's station. This pressure port is invaluable in diagnosing air starter and/or installation problems. 3.3 EXHAUST PIPING
A preferred valve is pilot-operated, which can be pneumatically or electrically actuated. The valve should be located close to or even on the starter inlet for best performance. Pneumatic or electrical control lines may be routed virtually anywhere for the customer's preferred operating station. This type of valve actuates from a fully closed to a fully open position very rapidly. TDI offers a variety of relay valves such as P/N RLVA-25683-001-2-01, which is a 1-1/2" port, pneumatically actuated valve.
The turbine exhaust may be plumbed away from the starter area. All starters using natural gas must be piped according to industry codes and local regulations.
The supply line should be dry-fitted for proper alignment /location prior to final assembly. All pipe threaded joints should be sealed with Loctite Pipe Thread Sealant (TDI P/N 9-94085) or equivalent for leak tight joints prior to final assembly. Be sure to tighten all joints to proper torque after final assembly.
Exhaust piping should be routed downward to help prevent any accumulation of condensation in the starter motor.
CAUTION In cold weather climates, care should be taken while designing your installation to prevent condensation from developing in the starter system. In systems with a regulator valve or relay valve, there is the possibility of freeze-ups.
Exhaust piping should be routed downward to help prevent any accumulation of condensate in the starter motor.
A tee connection with a quick disconnect can be added to the inlet. This will allow an external air source to be used to accomplish a “blow start” if the system freezes. Once the engine has been started, the other system components may be thawed. CAUTION On new installations, it is strongly recommended to blow out the supply line with air to remove possible dirt and welding slag prior to final connection to the TURBOTWIN starter. Be sure to secure the free end of the supply line prior to blowing out the line. 3.2 INLET PRESSURE PORT A 1/4" NPT port is located on the air inlet. This port may be used to check the supply pressure at the starter when the starter is operating. Remove the 1/4" NPT pipe plug and save for later use. Install a 1/4" minimum size tubing to the port. Route the tubing away from the starter to a safe location away from the engine. Install a pressure gauge on the tubing. This pressure monitoring line/gauge may be permanently installed. Use Loctite Pipe Thread Sealant or equivalent. Alternately, a pressure transducer may be Page 4
The performance of a turbine starter will be decreased because of back pressure when smaller than recommended exhaust piping is installed. If back pressure hampers starter performance, compensation can be made by increasing the supply pressure. Consult your TDI distributor for advice.
If the overhung section of the starter is not otherwise supported, TDI recommends supporting the exhaust piping with a suitable bracket(s).
3.4 NATURAL GAS INSTALLATION The installation of the starter using natural gas is similar to the air installation except all fittings, piping, valves and regulators must be compatible with natural gas. Proper control of natural gas is a major consideration when used in the starter system. All starters using natural gas must pipe the exhaust according to industry codes and local regulations. There is a natural gas vent port in the turbine housing that is plugged for compressed air use. This vent is used to remove any natural gas that could leak past the primary turbine shaft seal. Remove this 3/8"NPT plug and install a line to carry gas away from the starter area. WARNING Do not connect the turbine housing vent line to the turbine exhaust line. Exhaust gas can pressurize the housing. 3.5 PIPING SYSTEM Only type approved metallic hose assemblies are approved in permanently pressurized compressed air lines of starters. Non-metallic hose assemblies are allowed only in case the piping system will be emptied after the starting procedure. Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
Pipe unions must be type approved by GL. Downstream of the pressure regulator a pressure relief valve is to be provided. 3.6 BACKLASH Backlash is the "free play" between the mesh of two gears. Figure 15 shows the backlash between two gears. Maintaining the proper gear backlash setting allows the gears to mesh smoothly. Proper backlash and alignment allows smooth engagement/disengagement of the pinion gear and loads the tooth face surfaces evenly producing longer gear life. The correct backlash setting for 6/8 diametral pitch gearing used on larger engines is as follows: Minimum backlash Maximum backlash
.015 inch .025 inch
To check the backlash, the pinion will need to be rolled out onto the end of the drive prior to starter installation. This can be accomplished by using a hex drive wrench to rotate the turbine end of the starter while holding the pinion from rotating. The pinion will simply walk to the end of the shaft. An access hole to reach the turbine screw is provided in the turbine exhaust guard. The starter must then be installed on the engine. Checking backlash can be accomplished using a dial indicator or a simple blade-type feeler gauge. Because ring gears are not usually perfectly round, it is necessary to
DEVELOPMENT INC
mounting bolts. Torque the three 5/8" screws to 100 lb-ft.
4.0 STARTER OPERATION Prior to operation, check that all connections are tight and free from leaks. Check the 1/4" NPT pipe plug or a pressure gauge/transducer that may be connected to the pressure port on the starter inlet. WARNING Do not operate the TDI TURBOTWIN starter with air pressure greater than the pressure rating on the nameplate. This pressure is measured at the starter inlet while the starter is running. The maximum operating pressure limit is the inlet pressure measured at the starter’s inlet pressure check port. In order to check the starter, a 1/4"NPT pipe tap connection is provided in the inlet housing to attach a pressure gauge/transducer). The maximum pressure assumes an open exhaust (standard turbine exhaust guard). The standard exhaust guard causes no back pressure. The static non-flowing supply pressure will always be higher than the operating (dynamic) pressure. The maximum pressure limit (proof pressure) that the TDI TURBOTWIN starter housings may be subjected to is 600 PSIG (42 BAR). System pressure that exceeds the maximum operating limit must use a pressure reducing device to ensure that the operating pressure limit to the TDI TURBOTWIN starter is maintained. System static pressure that exceeds the 600 PSIG (42 BAR) limit must, in addition to pressure reducer devices incorporate a pressure relief valve set below 600 PSIG (42 BAR) in the supply air line.
Figure 2. Checking Backlash
NOTE For maximum life of the starter pinion and for the protection of the engine ring gear, limit the operating pressure to that necessary to start the engine at its most difficult starting conditions.
check backlash at several (six or more) points around the circumference of the ring gear. Average the highs and lows to allow a setting that is in the range cited above.
All appropriate local pressure codes and pressure limitations on other system components must be adhered to and supersede the guidelines given in this manual.
Setting the correct backlash may involve "shimming" and/or moving the starter bracket(s). An adjustable starter bracket design will simplify this procedure. Always re-check the backlash after a ring gear replacement.
Consult your TDI distributor if you have exhaust plumbing that creates back pressure and reduces starter performance. You may be able to increase the supply pressure to restore the lost power. Follow the engine manufacturer’s instructions for starting the engine.
Liberally grease the starter’s drive teeth with chassis lube and then mount the TURBOTWIN starter on the engine. Tighten all mounting hardware as appropriate. Make sure to use Loctite Threadlocker #290 or equivalent on the starter Publication T1-702, Rev 1 Issued January 22, 2001
4.1 BASIC OPERATION 5
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC speed.
The basic operation of the starter is as follows: Pressurized air or natural is admitted to the starter by opening of the manual or relay valve. The air expands through the turbine, which produces shaft rotation and torque. The acceleration of the drive assembly causes the pinion to advance and engage the ring gear of the engine. The starter motor torque causes the engine to accelerate. This acceleration causes the pinion to be disengaged from the ring gear. The fuel and ignition systems now fire the engine. Closing the relay valve stops the starter. The operator may decrease starter life by the continual operation of the starter after the engine has started. Upon a successful engine start, turn the air off to the starter immediately. Minimizing the time the starter is operating unloaded (i.e. the engine is running) will maximize starter life. If a start is aborted, a restart may be attempted after the engine and the starter has come to rest. CAUTION Do not engage the starter while the engine is running. The drive air pressure is the primary starter control parameter. It is important, especially on new installations, to measure this pressure during several engine starts. The secondary parameter is the starter pinion speed. This speed is usually measured by knowledge of the engine starting speed and the starter cranking ratio. The cranking ratio is the number of ring gear teeth divided by the number of pinion teeth. The starter pinion speed is then found by multiplying the engine speed by the cranking ratio. The pinion speed is usually 2000-3500 rpm at typical engine starting speed. 4.2 AUTOMATED START PANEL The starter drive pressure measured at the starter inlet must be set. As noted above, for maximum life of the starter pinion and for the protection of the engine ring gear, limit the operating pressure to that necessary to start the engine at its most difficult starting conditions. The speed control parameter will then need to be set. Engine starting speed along with the cranking ratio number can be used to determine starter pinion speed. The pinion speed is usually 2000-3500 rpm for a typical engine starting speed. Once the start sequence has begun, the air is admitted to the starter. The starter begins to accelerate the engine. Once the firing speed of the engine is reached, the automated start panel may deliver fuel to the engine. The engine will begin to accelerate under its own power. The starter should be dropped out of the sequence at a rpm higher than the firing speed, but less than the engine idle Page 6
The automated start panel should monitor engine speed to determine air on and air off. Do not simply use time as a control parameter. Avoiding excessive operation of the starter after the engine is firing will maximize the starter life.
5.0 PREVENTIVE MAINTENANCE The TDI TURBOTWIN starters provide distinct advantages of size and efficiency as compared to electric motor, vanetype or other turbine-type starters. It is important to properly install the starter to receive full benefit of these advantages. Repair technicians or service organizations without turbine starter experience should not attempt to repair this machine until they receive factory approved training from TDI, or its representatives. Proper operation and repair of your TDI TURBOTWIN starter will assure continued reliable and superior performance for many years. 5.1 Every Six (6) Months Perform the following procedures at six(6) months intervals if the normal cranking cycle is 0 - 10 seconds. 5.1.1 Check the amount and condition of grease in the planetary gearbox. If gearbox requires re-greasing, only use TDI grease. Approximately one (1) pint of grease is needed to repack the gearbox. 5.1.2 Check the turbine bearing and carrier output bearings for freedom of rotation without excessive play between races. If bearings are damaged, replace them with genuine TDI parts. Refer to TDI Service Manual for part numbers. 5.1.3 Place a small amount of chassis lube on the starter’s pinion teeth. 5.2 Every Three (3) Months Follow the six (6) month procedures if there is severe starter loading or extended duration crank cycles. Also perform these procedures every three (3) months when starter is used for motoring the engine for maintenance or valve adjustments. Motoring Crank Cycle: 10 -60 seconds Extended Crank Cycle: 60 seconds or longer starter, use only genuine TDI replacement parts. The component part numbers are found in the Illustrated Parts Breakdown. Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
6.0 TROUBLESHOOTING CHART TROUBLE
PROBABLE CAUSE
SOLUTION
1. Starter does not A. Relay valve not fully open. run; small air flow from B. Nozzle blockage. exhaust.
A. Repair or replace relay valve.
2. Starter does not run; normal air flow from exhaust.
A. Broken turbine rotor.
A. Replace all damaged parts.
B. Broken gear train.
B. Repair or replace geartrain.
C. Damaged starter drive.
C. Repair or replace starter drive.
A. Inlet air pressure too low.
A. Increase air pressure in 10 PSIG (0.6 BAR) increments; DO NOT EXCEED OPERATING LIMIT.
B. Inlet supply piping too small.
B. Supply piping must be a minimum of 1.5" diameter.
C. Pressure regulator orifice too small.
C. Increase orifice size or replace pressure regulator
D. Inlet supply line valve (ball, gate, relay, plug) too small.
D. Install larger valve.
E. In line lubricator installed in supply line.
E. Remove lubricator.
F. Y-Strainer in supply line clogged.
F. Clean strainer.
G. Excessive back pressure; exhaust restricted.
G. Clean exhaust piping or increase size to at least the minimum diameter recommended.
H. Damaged turbine nozzle.
H. Replace turbine nozzle.
I. Broken started drive.
I. Repair or replace starter drive.
J. Wrong rotation starter.
J. Replace with starter or proper rotation.
K. Wrong size starter.
K. Check the Application Guide for the correct starter.
A. Inlet air pressure too high.
A. Decrease air pressure in 10 PSIG (0.6 BAR) increments. OR If there is a manual shut-off valve in the supply line, partially close it. OR Install a restriction orifice in the inlet supply line.
B. Wrong size starter.
B. Check the Application Guide for the correct starter.
3. Reduced Starter output power.
4. Engine cranks too quickly.
Publication T1-702, Rev 1 Issued January 22, 2001
B. Remove blockage or obstruction from nozzles.
7
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
7.0 WARRANTY TDI TURBOTWIN ENGINE STARTER WARRANTY Tech Development Inc. (TDI) warrants to the original user of the TDI TurboTwin™ Model T30 Series air starters to be free from defects in material and workmanship for a period of one year from date of purchase by such user. The warranty period shall begin on the actual delivery date to the original user or twelve (12) months from the date of shipment from TDI, whichever comes first. The conditions of this warranty are: a) TDI is notified within this period by return of such product to TDI or its authorized distributor or dealer, transportation prepaid by user; b) such product has been installed according to TDI’s specifications; c) such product has not been misused, abused or improperly maintained by user; d) the defect is not the result of normal wear and tear; and e) such starter product has not been repaired with parts not manufactured or authorized by TDI, and TDI installation and repair procedures as outlined in the appropriate manual were properly followed. Tech Development Inc. shall, at its option, either repair or replace, without charge, any such starter product found by TDI’s examination to be defective, or by mutual agreement, refund the user’s purchase price in exchange for such starter product. Repairs or replacements are warranted for the remainder of the original warranty period. Tech Development Inc. makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. This warranty constitutes the entire obligation of Tech Development Inc. relating to the sale and use of such product, and TDI’s maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TDI be liable for incidental, indirect, consequential or special damages of any nature arising from the sale or use of such engine starter product.
Page 8
Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
Publication T1-702, Rev 1 Issued January 22, 2001
DEVELOPMENT INC
9
TDI TURBOTWIN FROM TECH
Page 10
DEVELOPMENT INC
Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
Publication T1-702, Rev 1 Issued January 22, 2001
DEVELOPMENT INC
11
TDI TURBOTWIN FROM TECH
Page 12
DEVELOPMENT INC
Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
Publication T1-702, Rev 1 Issued January 22, 2001
DEVELOPMENT INC
13
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
T112-B / T112-D Performance Curve 12 Nozzles, Compressed Air, 7.5:1 RATIO
TORQUE Nm LB.FT
POWER HP KW 100 74.6
476 350 150 psig
408 300
Inlet Pressure SCFM Nm3/h 150 psig 1360 2312 120 psig 1090 1853 90 psig 860 1462 60 psig 610 1037
Maximum Torque Transmitted by Drive
120 psig 340 250 90 psig
60 44.8
60 psig
40 29.8
272 200
204 150
80 59.6
136 100 20 14.9 68 50
0
5
340
250
204
150
100
60
30
35
40
45
50
55
POWER HP KW
Maximum Torque Transmitted by Drive
Inlet Pressure SCFM 90 psig 1560 60 psig 1070 30 psig 620
Nm3/h 2652 2140 1054
74.6
80
59.6
60
44.8
40
29.8
20
14.9
0
0
ps ig
30 psi g
50
0
0
Page 14
25
100
300
200
68
20
350
272
136
15
21 Nozzles, Compressed Air, 7.5:1 RATIO
90 psig 408
10
T121-B / T121-D Performance Curve
TORQUE Nm LB.FT 476
0
0
0
500
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Publication T1-702, Rev 1 Issued January 22, 2001
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
T106-F Performance Curve
TORQUE Nm LB. FT
POWER HP KW
6 Nozzles, Compressed Air, 7.5:1 RATIO
238 175
50 37.2 150 psig
204 150 12
0p
170 125 90
136 100
102 75
Inlet Pressure SCFM Nm3/h 150 psig 680 1156 120 psig 550 935 90 psig 430 731 60 psig 310 527
Maximum Torque Transmitted by Drive sig
30 22.4
ps ig
60 p
40 29.8
20 14.9
sig
68 50 10 7.5 34 25
0
0
0
500
T112-F Performance Curve
TORQUE Nm LB.FT 238 175
POWER HP KW
12 Nozzles, Compressed Air, 7.5:1 RATIO 90 psig
Maximum Torque Transmitted by Drive
204 150 60
170 125
ps
0
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Inlet Pressure SCFM Nm3/h 90 psig 860 1462 60 psig 610 1037 30 psig 370 629
45 33.5
ig
136 100
30 22.4
102 75
30
ps i g
68 50
15 11.2
34 25
0 0 Publication T1-702, Rev 1 Issued January 22, 2001
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0 5500
0
15
TDI TURBOTWIN FROM TECH
DEVELOPMENT INC
9 Nozzles, Compressed Air, 9.0:1 RATIO
408 300
15 0
340 250 272
12 0p
200
ps ig
DRIVE TORQUE LIMIT
Page 16
60 p s
50
0
80 59.6 SCFM 1050 850 670 460
Nm3/h 1785 1445 1139 782
60 44.8
40 29.8
136 100
0
Inlet Pressure 150 psig 120 psig 90 psig 60 psig
sig
90 psi g
204 150
68
POWER HP KW
T109-P Performance Curve
TORQUE Nm LB.FT 476 350
500
20 14.9
ig
0 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
0
Publication T1-702, Rev 1 Issued January 22, 2001
Publication T1-701, Edition 1 Dated: December 1998
SERVICE MANUAL
T100 Series (T112B/T121B,
T112D/T121D, T106F/T112F, T109P/T115P)
TURBOTWIN ENGINE AIR STARTERS
From Tech Development Inc 6800 Poe Ave. ·Dayton OH 45414 Tel: (937) 898-9600 ·Fax: (937) 898-8431
TDI TURBOTWINÔ FROM
TABLE OF CONTENTS Section 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Subject
Introduction……………………………. Description of Basic Groups…………. Disassembly………………………… … Cleaning and Inspection…………… … Assembly………………………………. Parts List……………………………. … Accessories…………………………….
LIST OF ILLUSTRATIONS Page
Figure
1 4 8 12 15 21 30
23 24 25 26 27 28 29 30 31 32 33
LIST OF TABLES Table No. 1 2 3 4 5
Title
T100 Series Service Tool Kits……….. Cleaning Materials & Compounds.. … Parts Inspection Check Req………. … Parts Wear Limits………………….. … Materials for Assembly………………..
TECH DEVELOPMENT, INC.
Page
Title
Page
Pressing Bearing onto Shaft………….. 18 Installing Shaft into Gearbox Hsg…….. 18 Tightening Retainer Nut……………….. 19 Woodruff Key Installation……………… 19 Tightening Retainer Nut (T106F)…….. 20 Drive Hsg. Installation (T106F)………. 20 Illustrated Parts Breakdown (B)……… 25 Illustrated Parts Breakdown (P)……… 26 Illustrated Parts Breakdown (D)……… 27 Illustrated Parts Breakdown (D)……… 28 Illustrated Parts Breakdown (F)……… 29
8 12 13 14 15
LIST OF ILLUSTRATIONS Figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Title
Page
TDI Turbotwin Nameplate……………. 2 T30 Series Part Number Coding…….. 3 Turbine Housing Assembly…………… 4 Gearbox Housing Assembly (B/P)…… 5 Gearbox Housing Assembly (F)……… 5 Gearbox Housing Assembly (D/Std) … 6 Gearbox Housing Assembly (D/Lg). … 6 Bendix Drive Assembly………………. 7 Bendix Drive Removal………………… 8 Bendix Drive Removal (F)……………. 9 Gearbox Retainer Nut Removal……… 9 Pressing Out Carrier Shaft……………. 10 Turbine Rotor Removal………………... 10 Turbine Shaft Removal….…………….. 11 Nozzle 2 Removal……………………… 11 Gear Teeth Wear Allowance………….. 14 Pressing Front Turbine Bearing………. 15 Pressing Spacer onto Bearing…………15 Installation of Turbine Shaft……………16 Installing the Aft Seal into Nozzle 1…...16 Pressing Aft Bearing onto Shaft……… 17 Planet Gear Carrier Shaft Assembly…. 17 Publication T1-701 Issued Dec 11, 1998
Page: i
TDI TURBOTWINÔ FROM
SECTION 1.0 INTRODUCTION 1.1 GENERAL INFORMATION This manual provides information for servicing, disassembly, and reassembly of the TDI Turbotwin T100 series air starters. If there are questions not answered by this manual, please contact your local TDI distributor or dealer for assistance. Illustrations and exploded views are provided to aid in disassembly and reassembly. The TDI Turbotwin T100 series of engine starters are specially designed for starting today’s automated, lowemission engines. The Turbotwin uses aerodynamic speed control, eliminating the need for a mechanical automatic trip valve (ATV) to control starter motor speed. The Turbotwin T100 series air starters are suited to operate within a wide range of inlet pressures and ambient temperatures. These starters are designed for operation with either compressed air or natural gas. The robust turbine motor design in the Turbotwin T100 series starters has no rubbing parts, and is therefore tolerant of hard and liquid contamination in the supply gas with almost no adverse affects. The motor is well adapted to running on “sour” natural gas. As with all TDI air starter products, there are no rubbing parts so there is no lubrication required. This eliminates failures due to lubricator problems, the expense of installing and maintaining the system, and the messy and hazardous oil film around the starter exhaust. The starter is factory grease packed for the life of the starter so it requires no maintenance. NOTE Throughout this manual, the term “air” is used to donate the starter drive medium. Unless otherwise stated, “air” means compressed air or natural gas. Please review the rest of this manual before attempting to provide service to the TDI Turbotwin T100 series starters.
1.2 WARNINGS, CAUTIONS, & NOTES Throughout this manual, certain types of information will be highlighted for your attention: WARNING - used where injury to personnel or damage to equipment is likely. Publication T1-701 Issued Dec 11, 1998
TECH DEVELOPMENT, INC.
CAUTION - used where there is the possibility of damage to equipment. NOTE - use to point out special interest information.
1.3 DESCRIPTION OF OPERATION The Turbotwin T100 series starters are powered by a pair of axial flow turbines coupled to a simple planetary gear reduction set. The T100 series starters incorporate an inertia bendix drive coupled to the starter gearbox drive train to provide a means of disengaging the pinion from the engine’s ring gear. The high horsepower of the turbine air motor combined with the planetary gear speed reducer results in a very efficient and compact unit. The Turbotwin T100 series starters can be used over a wide range of drive pressures from 30 psig (2 BAR) to 150 psig (10 BAR) and are suitable for operation on either air or natural gas. The Turbotwin T106F & T112F weighs approximately 47 pounds (21 KG) and each is capable of delivering over 44 HP (33 kW) of cranking power at their maximum pressure of either 150 psig (10 BAR) or 90 psig (6 BAR) respectively. The Turbotwin T112B & T121B weighs approximately 55 pounds (25 KG) and each is capable of delivering over 80 HP (60 kW) of cranking power at their maximum pressure of either 150 psig (10 BAR) or 90 psig (6 BAR) respectively. The Turbotwin T112D &T121D weighs approximately 70 pounds (32 KG) and each is capable of delivering over 80 HP (60 kW) of cranking power at their maximum pressure of either 150 psig (10 BAR) or 90 psig (6 BAR) respectively. The Turbotwin T109P & T115P weighs approximately 59 pounds (27 KG) and is capable of delivering over 60 HP (41 kW) of cranking power at their maximum pressure of either 150 psig (10 BAR) or 90 psig (6 BAR) respectively.
1.4 INSTALLATION AND SERVICE It is important to properly install and operate the TDI Turbotwin T100 series starters to receive the full benefits of the turbine drive advantages. It must be installed in accordance with the instructions provided by Tech Development, Inc. (TDI).
Page 1
TDI TURBOTWINÔ FROM
WARNING Failure to properly install the starter or failure to operate it according to instructions provided byTDI may result in damage to the starter or engine, or cause personal injury. DO NOT OPERATE THIS STARTER UNLESS IT IS PROPERLY ATTACHED TO AN ENGINE. Repair technicians or service organizations without turbine starter experience should not attempt to repair this starter until they receive factory approved training from TDI, or its representatives. Proper operation and repair of your TDI Turbotwin will assure continuous reliability and superior performance for many years.
NOTE You should always have the starter’s Part Number, Serial Number, Operating Pressure, and Direction of Rotation information before calling your TDI distributor or dealer.
TDI TURBOSTARTä ENGINE AIR STARTERS FROM TECH DEVELOPMENT, INC. BARBER-COLEMAN - a Siebe Company 6800 POE AVE., DAYTON, OH 45414 MODEL NO. SERIAL NO.
T112-B
1.5 NAMEPLATE INFORMATION The nameplate, located on the turbine housing, provides important information regarding the construction of your T100 series starters, refer to Figure 1. The part number coding explanation, refer to Figure 2, can help you when talking to your distributor.
TECH DEVELOPMENT INC.
9609-124
PART NUMBER T112-60001-B1R CW (RH) X
CCW (LH) AIR or NAT. GAS USAGE
MAX PRESS. 150 PSIG MAESURED AT INLET WHILE OPERATING PROOF PRESSURE OF HOUSING IS 600 PSIG
WARNING:DO NOT OPERATE UNLOADED OR WITHOUT TURBINE GUARD OR EXHAUST FITTING U.S PATENT 4509896
Figure 1. TDI Turbotwin Nameplate
Page 2
Publication T1-701 Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
Figure 2. Part Number Coding
Publication T1-701 Issued Dec 11, 1998
Page 3
TDI TURBOTWINÔ FROM
SECTION 2.0 DESCRIPTION OF BASIC GROUPS 2.1 GENERAL The TDI Turbotwin T100 Series air starters are lightweight, compact units driven by a dual stage turbine type air motor. The starter is composed of three basic assembly groups: Turbine Housing Assembly; Gearbox Housing Assembly; and Bendix Drive Assembly.
TECH DEVELOPMENT INC.
2.2 TURBINE HOUSING ASSEMBLY The Turbine housing assembly, refer to figure 3, consists of a stage one (15) and a stage two (6) turbine wheel mounted on sungear shaft (33) . The front bearing (10) is secured by a retainer plate (32). The aft bearing is preloaded by wavy spring (12). The ring gear (29) is heat shrunk into the front of the turbine housing (26) and secured by a setscrew (25).
Figure 3. Turbine Housing Assembly
Page 4
Publication T1-701 Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
2.3 GEARBOX HOUSING ASSEMBLY The gearbox housing assembly, refer to figures 4, consist of a planet gear carrier and output shaft (35), three planet gears (37), needle bearings (38), spacers (36), and bearing pins (39).
TECH DEVELOPMENT, INC.
The carrier shaft is mounted on two ball bearings (41) in the gearbox housing (58). The retainer nut (48) secures the carrier shaft in the gearbox housing. The front bearing (41) is secured by a retainer plate (46). The back bearing is preloaded by use of a spring washer (42).
Figure 4. Gearbox Housing Assembly (T112B/T121B/T109P/T115P)
Figure 5. Gearbox/Bendix Assembly (T106F/T112F) Publication T1-701 Issued Dec 11, 1998
Page 5
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
Figure 6. Gearbox Assembly (T112D/T121D STD MESH)
Figure 7. Gearbox Assembly (T112D/T121D LONG MESH)
Page 6
Publication T1-701 Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
2.4 BENDIX DRIVE ASSEMBLY The Bendix drive assembly, refer to figure 8, consists of an inertial engagement drive or “bendix” (57) and drive housing (61). The bendix is mounted to the output shaft with two keys and a retaining set screw (53).
TECH DEVELOPMENT, INC.
The other end of the drive unit is mounted into a needle bearing (54), which is installed in the nose of the drive housing.
Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)
Publication T1-701 Issued Dec 11, 1998
Page 7
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
SECTION 3.0 DISASSEMBLY 3.1 GENERAL Always mark adjacent parts on the starter housing; Nozzle 2/ Containment Ring (13), Turbine Housing (26), Gearbox Housing (58), and Bendix Drive Housing (61) so these parts can be located in the same relative position when the starter is reassembled. Do not disassemble the starter any further than necessary to replace a worn or damaged part Always have a complete set of seals and o-rings on hand before starting any overall of a Turbotwin T100 series starter. Never use old seals or o-rings. The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T100 series starters. The best results can be expected when these tools are used, however the use of other tools are acceptable. TOOL DESCRIPTION TDI/PN Spanner wrench 52-20134 Spanner wrench 52-21345 Shaft Removal Tool 2-26945 Stage 2 Rotor Puller Tool 52-20076 Carrier Shaft Holding Tool 52-20202 Tool, Bearing Pressing 52-20143 Tool, Bearing/Seal 2-26943 Table 1. T100 Series Service Tools
Remove the needle bearing (62), if necessary, by simply tapping out the “welch” plug from the front of the drive housing and press bearing out.
3.3 DRIVE HOUSING (T112D/T121D) 3.3.1 Removal of Drive Housing Remove the six screws (22). Mark position of bendix pinion opening relative to gearbox housing for reference during reassembly. Pull drive housing (49) from gearbox housing (44). If drive housing is too tight, tap it with a mallet to loosen. 3.3.2 Removal of Bendix Drive In loaded spring area of drive (57) remove retaining ring (51) from set screw (53) slot. Remove set screw using a flat head screwdriver, Figure 9, and pull the bendix assembly from the starter carrier shaft. Remove spring (52). This spring fits loosely between the bendix assembly and carrier shaft. Remove the needle bearing (62), if necessary, by simply tapping out the “welch” plug from the front of the drive housing and press bearing out.
3.2 DRIVE HOUSING (T112B,T121B,T109P,T115P) 3.2.1 Removal of Drive Housing Mark position of bendix pinion opening relative to gearbox housing for reference during reassembly. Remove the six bolts (60) and lock nuts (59). Pull drive housing (61) from gearbox housing (58). If drive housing is too tight, tap it with a mallet to loosen. 3.2.2 Removal of Bendix Drive In loaded spring area of drive (57) remove retaining ring (51) from set screw (53) slot. Remove set screw using a flat head screwdriver, Figure 9 and pull the bendix assembly from the starter carrier shaft. Remove spring (52). This spring fits loosely between the bendix assembly and carrier shaft. Page 8
Figure 9. Bendix Drive Removal
Publication T1-701 Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
3.4 DRIVE/GEARBOX HOUSING (T106F/T112F) 3.4.1 Removal of Drive Housing Mark position of bendix pinion opening relative to turbine housing (26) for reference during reassembly. Per Figure 10, remove the six screws (27). Pull drive housing (69) from turbine housing. If drive housing is too tight, tap it with a mallet to loosen.
TECH DEVELOPMENT, INC.
Remove bearing (65) from shaft by pressing shaft while supporting inner race of bearing. Remove bearing retainer plate (64). 3.4.3 Planet Gear Disassembly Remove snap ring (34) from planet shaft (39) using snap ring pliers and push shaft through holes in assembly. Slide the planet gear (37) out from the carrier shaft and remove the two nylon spacer (36). Unless the needle roller bearings 38) are damaged, do not remove. If removal is necessary, simply press bearing out.
Figure 10. Bendix Drive Removal (T106F/T112F) 3.4.2 Removal of Bendix Drive Remove four screws (31). Pull carrier shaft assembly (63) from drive housing (69). The bendix (68) will remain in the drive housing. With snap ring tool, remove snap ring (66) and bendix drive (68)from drive housing.
Figure 11. Gearbox Retainer Nut Removal
3.5 GEARBOX HOUSING (T112B/T121B,T112D/T121D,T109P/T115P) * The drive housing removal procedure should be performed before performing this procedure.
If it is necessary to remove needle bearing (70) from drive housing, simply press bearing out.
3.5.1 Removal of Gearbox Housing
Mount the carrier shaft assembly on the TDI holding tool P/N 52-20202 placing the three holes on the gearbox over the dow pins. Refer to Figure11.
Remove the six screws (27) and lift the gearbox assembly from the turbine assembly. If the gearbox assembly is too tight, tap it with a mallet to loosen).
Place TDI tool P/N 52-21345 (Spanner Wrench) over shaft and into slots of retainer nut (67). Hold down carrier shaft and remove nut.
3.5.2 Gearbox Disassembly
Publication T1-701 Issued Dec 11, 1998
Mount the gearbox on the TDI holding tool P/N 5220202 placing the three holes on the gearbox over the dow pins. Refer to Figure 11. Page 9
TDI TURBOTWINÔ FROM
Remove woodruff keys (40) from shaft by tapping them with a chisel and hammer With screwdriver remove tang of lockwasher (47) from slot of retainer nut (48). Place TDI tool P/N 52-20134 (Spanner Wrench) over shaft and into slots of retainer nut. Hold gearbox down and remove nut. In most cases the gearbox housing (58, D-44) can be removed from the carrier shaft (35) by holding shaft down and pulling directly up on housing. If this is not the case, press carrier shaft from housing per Figure 12.
TECH DEVELOPMENT INC.
Slide the planet gear (37) out from the carrier shaft and remove the two nylon spacer (36). Unless the needle roller bearings 38) are damaged, do not remove. If removal is necessary, simply press bearing out.
3.6 TURBINE HOUSING 3.6.1 Stage 2 Rotor Removal Remove the six screws (27) that connect the gearbox assembly to the turbine housing and separate the two assemblies. Remove the four screws (18) and the clamping plate (32). Turn the turbine to the (exhaust) end up and remove the six screws (1), screen support ring (2), and the screen (3). For the T109P, remove six screws (74) and Exhaust Cover Housing (75). Hold the stage 2 rotor (6) and remove the turbine screw (4) and washer (5). Install the rotor puller tool P/N 52-20076 and remove the stage 2 rotor per Figure 13. Remove the woodruff key (7) using a hammer and chisel.
Figure 12. Pressing Out Carrier Shaft The aft bearing (41), spring washer (42), and bearing spacer (43) will come out with the shaft. Remove aft bearing (41) from shaft by pressing shaft while supporting bearing. If the aft bearing (41) is retained in the gearbox housing when the carrier shaft is removed, apply pressure through housing to the bearing to remove it. It will be necessary to elevate the housing with a brace to remove the bearing completely. Remove the six screws (18) and retainer plate (46). The front bearing may then be removed by lightly tapping. 3.5.3 Planet Gear Disassembly Remove snap ring (34) from planet shaft (39) and push shaft through holes in assembly. Page 10 701
Figure 13. Turbine Rotor Removal Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
3.6 Turbine Shaft Removal Using the shaft removal tool P/N 2-26945 per figure 14, press on the turbine shaft (33) while supporting the turbine housing. Press the shaft assembly (33) through the aft bearing (10) and continue pressing until the shaft assembly is completely out of the housing (26). Remove the woodruff key (16), seal spacer (8), bearing spacer (30), and bearing (10) from the shaft. The bearing can be removed from the shaft by pressing the shaft through the bearing. Note that if T100 is the original design (SN: 9501-239 to9611-191), the bearing will be pressed inside a spacer.
TECH DEVELOPMENT, INC.
Separate the stage 2 nozzle assembly (13) from the turbine assembly (26) by firmly holding the turbine assembly, while tapping nozzle 2 with a mallet. If nozzle 2 is too tight, it can be removed by installing two threaded screws into nozzle 2 and using them as jacks to separate nozzle 2 from the turbine assembly. Refer to Figure 15. Rotate the stage 1 rotor if necessary to allow the jacks to travel through the large holes in the rotor. The jacks will damage the stage 1 rotor if pressure is applied to them while removing nozzle 2. The stage 1 rotor (15) may now be removed. Remove the four screws (18) and nozzle 1 (19) from the turbine assembly. It may be necessary to tap the screws with a hammer and chisel to loosen. On the stage 2 nozzle (13), remove the seal spacer (8) from the forward side of the nozzle. Place the stage 2 nozzle on the exhaust end. Press through the lip seal nd onto the bearing until it, including the 2 lip seal and seal spacer disengages from the nozzle. Turn the nozzle over and press on the lip seal to remove.
Figure 14. Turbine Shaft Removal
Figure 15. Nozzle 2 Removal
Publication T1-701 Issued Dec 11, 1998
Page 11
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
SECTION 4.0 CLEANING and INSPECTION
Clean aluminum parts using the solutions per Table 2; soak for 5 minutes. Remove parts, rinse in hot water, and dry thoroughly.
4.1 CLEANING
Clean corroded steel parts with a commercially approved stripper.
Degrease all metal parts, except bearings, using a commercially approved solvent. Refer to Table 2. NOTE Never wash bendix assembly or bearings in cleaning solvents. It is recommended that the bearings be replaced with new parts.
Clean corroded aluminum parts by cleaning as stated above and then immerse the parts in chromic-nitricphosphoric acid pickle solution per Table 2. Rinse in hot water and dry thoroughly.
MATERIAL or COMPOUND Degreasing Solvent (Trichloroethylene) (O-T-634) Acetone Aluminum Cleaning Solution
MANUFACTURER Commercially Available Commercially Available Diversey Corp., 212 W. Monroe, Chicago, IL 60606 Dissolve 5 oz of Diversey 808 per gallon of water at 155°- 165°F. Steel Cleaner - Rust & Corrosion Oakite Products Corp., 50 Valley Rd., Berkeley Heights, NJ 07992 Mix 3-5 lb. of Oakite rust Stripper per gallon of water; use at 160°- 180°F. Chromic-Nitric-Phosphoric Acid Pickle Solution Mix 8lb. of chromic acid, 1.9 gal. of phosphoric acid, 1.5 gal. of nitric acid with enough water to make a total of 10 gal. of solution. WARNING Follow all instructions provided with the MSDS sheets on the materials and compounds listed above. Table 2. Cleaning Materials and Compounds
4.2 INSPECTION Use Table 3 as a guide to check for acceptable condition of the parts listed. Check all threaded parts for galled, crossed stripped, or broken threads. Check all parts for cracks, corrosion, distortion, scoring, or general damage.
Page 12 701
Check all bearing bores for wear and scoring. Bearing bores shall be free of scoring lines, not to exceed 0.005² width and 0.005² depth. Check gear teeth and turbine housing ring gear for wear. In general, visually check for spalling, fretting, surface flaking, chipping, splitting, and corrosion. If wear is apparent, check the gear teeth dimensions in accordance with Table 4. Nicks and dents that cannot be felt with a .020 inch radius scribe are acceptable.
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
Part Description Bendix Drive Housing Planet Gear
Check For Worn, loose, or missing parts Cracks and breakage Cracked, chipped, or galled teeth. Wear must not exceed limits per Table 4.
Carrier Shaft
Cracks, scoring or raised metal in planet shaft holes and keyways. Integrity of knurl connection.
Planet Pins
Wear grooves or flat spots
Washers Gearbox Housing Sungear / Turbine Shaft
Wear created grooves Cracks and Breakage Cracks, scoring, wear created grooves, chipped or broken gear- teeth, galling or scoring on bearing surface of shaft. Raised metal on the keyway. Parallelism of end surfaces Cracks and breakage
Spacers Turbine Housing
Ring Gear Seal Assembly Seal Spacer Needle Bearings Ball bearings Containment Ring/ Nozzle Turbine Rotors
Cracks, wear, chipped, or broken gear teeth. Wear grooves or scratched surfaces on carbon ring. Wear Grooves Freedom of needle rollers Freedom of rotation without excessive play between races Corrosion, erosion, cracks and broken nozzle edges. Corrosion, erosion, and broken edges.
cracks
TECH DEVELOPMENT, INC.
Requirements (Defective Parts Must Be Replaced) Defective unit to be replaced. Use figure 5 as a guideline for acceptable pinion wear. Cracks are not acceptable Wear must not exceed limits per table 4. There shall be no evidence of excessive wear. Deformation of metal smearing in planet pin holes & keyways not acceptable. Scoring on bearing diameter not to exceed .005² depth. Wear must not exceed limits per Table 4. Wear grooves in flat spots not permitted. Wear must not exceed limits per Table 4. Wear must not exceed limits per Table 4. Cracks and breakage not acceptable.
Wear must not exceed limits per Table 4. Ends must be parallel within 0.0005². Cracks and breakage are not acceptable. Minor surface damage is permitted if function is not impaired. Wear must not exceed limits per Table 4. Wear is not permitted. No wear permitted. Replace bearings Replace bearings Cracks and breakage are not acceptable. Minor surface damage is permitted if function is not impaired. Minor tip rub is permitted if function is not impaired.
Tip wear; bore and key way Wear is not permitted. wear Table 3. Parts Inspection Check Requirements
Publication T1-701 Issued Dec 11, 1998
Page 13
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
PART DESCRIPTION LIMIT, Inches Ring gear / Turbine Housing Internal measurement between two .084² diameter 5.0890 max. pins. Sun Gear / Turbine Shaft 0.6690 min Bearing diameter External measurement over two .096 diameter pins. 0.952 min 7.5:1 0.808 min 9:1 0.670 min 11.4:1 Planet Gear External measurement over two .0864² diameter pins. 2.3067 min 7.5:1 2.3699 min 9:1 2.4359 min 11.4:1 Carrier Shaft 1.1800 min Bearing Diameter 0.8750 max Planet Pin Bore Planet Pins 0.873 min Bearing Diameter Thrust Washer .055 min Thickness Table 4. Parts Wear Limits
Figure 16. Gear Teeth Wear Allowances
Page 14 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
SECTION 5.0 ASSEMBLY 5.1 GENERAL The tools listed in Table 1 are suggested for use by technicians servicing the T100 Series starters. The best results can be expected when the proper tools are used, however, use of other tools is acceptable. CAUTION Replace all screws , O-rings, lip seals, and bearings when the T100 Series starter is reassembled. These parts are included in the overhaul kits shown in Section 6.0 NOTE Always press the inner race of a ball bearing when installing a bearing on a shaft. Always press the outer race of a ball bearing when installing into a housing.
Figure 17. Pressing Front Turbine Bearing
Refer to Section 6.0, for a list of kits and components, which are available to aid in rebuilding T100 Series starters. Lubricate all O-rings with petroleum jelly or Parker-ORing Lube before assembly. Refer to Table 5 for a list of materials to be use during assembly. MATERIALS SOURCE Petroleum Jelly Commercially Available Parker-O-Ring Lube Commercially Available Loctite RC290 Commercially Available Grease, gearbox TDI P/N 9-94121-001 Table 5. Materials for Assembly CAUTION The screws that secure the Containment Ring/ Stage 2 Nozzle must have a drop of Loctite RC290 applied to the threads before being used. Figure 18. Pressing Spacer onto Bearing
5.2 TURBINE HOUSING 5.2.1 Turbine Shaft Installation Press the bearing (10) onto the shaft (33) until seated. Support the shaft and press on the inner race only with press tool P/N 2-26943 per Figure 17. Note that if
Publication T1-701 Issued Dec 11, 1998
T100 is the original design (SN: 9501-239 to 9611-191), press the spacer (31) onto the outer race of the bearing (10) per Figure 18 by supporting the bearing outer race, and then press the bearing/spacer (10, 31) onto the shaft. Press the bearing/shaft assembly, keyway end first, into bearing housing of the turbine housing. Use press tool P/N 2-26943 if required per Figure 19. Do not press on the end of the shaft because the load could damage the balls of the bearing. Page 15
TDI TURBOTWINÔ FROM
Install bearing retainer plate (32) and secure with four screws (18). Torque screws to 30 in-lbs.
TECH DEVELOPMENT INC.
Install nozzle 1 onto the turbine housing (26). Orient the nozzles facing the air inlet (23). Install four screws (18) to secure the nozzle. Do not tighten the screws at this time. 5.2.3 Rotor 1 Installation Install the woodruff key (large key) (16) for stage 1 rotor into the shaft (33). Install the stage 1 rotor (15), while supporting sun gear end of shaft, onto the turbine shaft by aligning the slot in the rotor with the woodruff key and hand press the rotor until firmly seated. Use press tool P/N 2-26943 if required. Visually inspect that the key was not pushed out during assembly. Note that the direction of rotation was oriented properly. This turbine rotor can be installed backwards.
Figure 19. Installation of Turbine Shaft Place turbine housing front surface (sungear end) on flat surface. Install long bearing space (30) over shaft. Install the seal spacer (8) onto the shaft. Note the small end of the spacer faces the long bearing spacer. Install the O-ring (21) into the aft face of the turbine housing (26).
Temporarily install Nozzle 2 on the turbine housing. Tighten the four screws that secure nozzle 1 (18) to 30 in-lb. The four screws can be accessed via the holes in nozzle 2 and the first stage turbine rotor. Remove Nozzle 2 when the four screws are tight. 5.2.3 Nozzle 2 Installation Press the lip seal (9) into the forward side of nozzle 2 with seal lip facing up. Use press tool P/N 2-26943. Install the O-ring (11) into the bearing bore of nozzle 2 (13). DO NOT LUBRICATE THIS O-RING.
5.2.2 Nozzle 1 Installation
Install O-ring (14) onto the outer diameter of nozzle 2.
Press the aft seal (17) into nozzle 1 (19) using press tool P/N 2-26943 per Figure 20 with the lips facing up.
Install nozzle 2 (13) onto the turbine housing (26). The three flats of nozzle 2 are always oriented opposite the turbine housing air inlet (SN 9505-213 to 9611-191). Install the seal spacer (8) onto the shaft with the small end facing the aft bearing (10). Install the wavy spring washer (12) into the bearing bore of the stage 2 nozzle. Support the sun gear end of the shaft. Press the aft bearing (10) onto the shaft by pressing onto the inner and outer race simultaneously. Use press tool per Figure 21. Press until bearing is seated.
Figure 20. Installing the aft seal into Nozzle 1
Page 16 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
5.2.5 Air Inlet Installation Place (23).
the O-ring (24) into the groove on the air inlet
Install the 2² NPT air inlet flange (23) and secure with six screws (22). Tighten the six screws to 170 in-lb. Mark the number of stage 1 nozzles (usually 6, 12,or 21) onto the O.D. of the unit for identification of the unit prior to name plate installation.
5.3 GEARBOX HOUSING (T112B/T121B, T112D/T121D, T109P/T115P) 5.3.1 Planetary Gear Carrier Reassembly If disassembled, press needle bearing (38) into planet gears (37). The planet gears are not identified by part number, therefore, dimensionally check if correct gears are being used. Use table 4 for over the wire measurements. With a thrust washer (36) on each side of gear, slide gear into carrier shaft slots (35), and align with pin holes.
Figure 21. Pressing Aft Bearing onto Shaft
Lightly slide plant shafts into aligned holes, making sure snap ring groove on end of pins goes in first per Figure 22.
Install the seal spacer (8) with the small end facing the aft bearing (10). Press the lip seal (9) into the stage 2 nozzle using press tool P/N 2-26943 with lip seal facing up. Install the stage 2 woodruff key (7) into the shaft (33). 5.2.4 Stage 2 Rotor Installation Install the stage 2 rotor (6) onto the shaft. Use press tool P/N 2-26943 if required. Visually inspect that the key was not pushed out during assembly. Note that the direction of rotation was oriented properly. This turbine can be installed backwards. Install the rotor washer (5) and secure with screws (4). Tighten screw to 100 in-lb.
Figure 22. Planet Gear Carrier Shaft Assembly
Install the exhaust screen (3) and back plate (2). Secure with six screws (1). Tighten the screws to 80 inlb.
Publication T1-701 Issued Dec 11, 1998
Page 17
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
NOTE Make sure that anti-rotation pins on shafts are properly located in retaining slots of carrier shaft (35). Install snap ring (34) with a snap ring tool. 5.3.2 Gearbox Reassembly Press the bearing (41) into the forward side of the gearbox housing (58, D-44). Pressing force should be on the outer race only. Install retainer plate (46) and secure with six screws (18). Press rear bearing (41) onto carrier shaft (35) using TDI Tool P/N 52-20143 per Figure 23. Pressing force should be on the inner race of bearing. Install spring washer (42) and bearing spacer (43) onto shaft and locate against bearing.
Figure 23. Pressing Rear Bearing onto Carrier Shaft
Position carrier shaft assembly (35,41,42,43) into bearing bore of the gearbox housing (58). Lift up on housing and slide shaft down. If shaft will not slide into bearing bore, press housing per Figure 24 until bearing is seated (41). Place gearbox assembly on TDI Tool P/N 2-20202 per Figure 25. Install lockwasher (47) and then retainer nut (48). Torque to 600-800 in-lb. Tang lockwasher into retainer nut slot. Place O-ring (14) onto outer diameter of assembly.
gearbox
Thoroughly grease planet gears, ring gear and sun gear using the grease specified in Table 5 and pack the center of the gears with grease. 5.3.3 Gearbox to Turbine Housing Assembly Rotate carrier shaft (35) slightly, and at the same time, align gearbox into the front of turbine housing (26). Install six screws and torque 90-120 in-lbs.
Figure 24. Installing Carrier Shaft into Gearbox Housing
Page 18 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
5.5.
TECH DEVELOPMENT, INC.
DRIVE/GEARBOX HOUSING (T106F/T112F)
5.5.1 Planetary Gear Carrier Reassembly If disassembled, press needle bearing (38) into planet gears (37). The planet gears are not identified by part number, therefore, dimensionally check if correct gears are being used. Use table 4 for over the wire measurements. With a thrust washer (36) on each side of gear, slide gear into carrier shaft slots (63), and align with pin holes. Lightly slide plant shafts (39) into aligned holes, making sure snap ring groove on end of pins goes in first.
Figure 25. Tightening Retainer Nut
NOTE Make sure anti-rotation pins on shafts are properly located in the retaining slots of the carrier shafts (63). 5.5.2 Planetary Carrier Bearing Installation
5.4 DRIVE HOUSING (T112B/T121B, T112D/T121D, T109P/T115P)
Install bearing retainer plate (64) over carrier shaft (63)
5.4.1
Press bearing (65) onto shaft making sure pressing force is on inner race of bearing only.
Bendix Drive Installation
Install two woodruff keys (40). properly installed per Figure 26.
Ensure keys are
Position bendix assembly (57) on shaft with retainer set screw (53) removed. Install spring ( 52) between bendix cavity and end of output shaft. Slide bendix over shaft until set screw hole aligns with set screw hole in shaft.
Place carrier shaft assembly onto TDI Tool P/N 5220202, see Figure 27. Thread retainer nut (67) onto shaft (63). Hold carrier assembly down and torque nut to 600-800 lb.-in. with spanner wrench, TDI Tool P/N 52-21345.
Install set screw and tighten firmly. Slip retainer (51) ring into set screw slot. 5.4.2 Bendix Drive Housing Installation If disassembled, press needle bearing (62, P-80) into drive housing (61) until flush with bottom surface. Mount drive housing over bendix drive, and align holes for desired bendix opening orientation with starter inlet connection. Torque bolts and nuts to 90-120 in-lbs. Figure 26. Woodruff Key Installation
Publication T1-701 Issued Dec 11, 1998
Page 19
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
Figure 28. Gearbox/Drive Housing Installation (T106F/T112F) Figure 27. Tightening Retainer Nut (T106F, T112F) 5.5.3 Bendix Drive Installation Install bendix drive (68) into drive housing (69), aligning bendix shaft into front needle bearing (70). With snap ring tool, install snap ring (66)into drive housing (69). Align carrier shaft assembly (63) into bendix drive and push assembly until seated against snap ring (66) per Figure 28. Install six screws (27) and torque 90 to 120 lb.-in.
Page 20 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
SECTION 6.0 PARTS LIST The components illustrated and/or described in this section are for the Turbotwin T100 series air starters. When rebuilding a T100 series starter, it is recommended to purchase, and completely install the appropriate service kit(s).
Key No.
Description
Part Number
1
Screw (6)
11F- 25020-072
2
Screen Support Ring
2-20831
3
Screen
2-26148
4
Screw
19F- 25028-012
5
Washer
9-93047
6
Rotor 2
2-26604
7
Woodruff Key
9-90211-006
8
Seal Spacer (3)
9
B
D
F
ü
ü
ü
ü
ü
ü
ü
9-93083-001
ü
ü
ü
ü
Seal, Lip (2)
2-26719
ü
ü
ü
ü
10
Bearing (2)
9-91224
ü
ü
ü
ü
11
O-ring (2)
9-90001-027
ü
ü
ü
ü
12
Wave Spring Washer
9-90439
ü
ü
ü
ü
13i
Nozzle 2/Containment Ring R.H.
2-27333-00R
13ii
Nozzle 2/Containment Ring L.H.
2-27333-00L
14
O-ring
9-90001-050
ü
ü
ü
ü
15
Rotor 1
2-26603
16
Woodruff Key
9-90211-009
17
Lip Seal
2-22376
ü
ü
ü
ü
18
Screw (14)
14F-19024-008
ü
ü
ü
ü
19i
Nozzle 1, R.H. 21 Noz
2-26718-21R
19ii
Nozzle 1, L.H. 21 Noz
2-26718-21L
19iii
Nozzle 1, R.H. 12 Noz
2-26718-12R
19iv
Nozzle 1, L.H. 12 Noz
2-26718-12L
Publication T1-701 Issued Dec 11, 1998
P
Page 21
TDI TURBOTWINÔ FROM
Page 22 701
Key Number
Description
Part Number
19v
Nozzle 1, R.H. 6 Noz
2-26718-06R
19vi
Nozzle 1, L.H. 6 Noz
2-26718-06L
20
Pipe Plug
9-93556-004
21
O-ring
9-90001-034
22
Screw (6) or (12 for T112D/T121D std)
14F-31218-016
23
Inlet Flange
1-18967
24
O-ring
9-90001-037
25
Set Screw (See Note 1)
52F-50013-016
26
Turbine Housing (See Note 1)
2-27045
27
Screw (6)
14F-25020-016
28
Pipe Plug
9-93501-004
29
Ring Gear (See Note 1)
1-18780
30
Bearing Spacer
9-93091-001
31
Screw (4)
14F-25020-008
32
Clamping Plate
2-26750
33
Turbine Shaft
2-26554
34
Retainer Ring (3)
9-92001-001
35
Planet Gear Carrier Shaft
2P-20156-006
36
Washer (6)
9-93004
37
Planet Gear (3)
1-19441
38
Needle Roller Bearing (3)
9-91004-001
39
Planet Shaft (3)
2P-20182
40
Woodruff Key (2)
9-90211-019
41
Bearing (2)
9-91351
TECH DEVELOPMENT INC. B
D
F
P
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
Key
Description
Part Number
42
Wave Spring Washer
9-90402-025
43
Bearing Spacer
9-93007
44
Gearbox Housing
2-22226
45
Screw (6)
14F-25020-028
46
Retainer Plate
1-18817
47
Lockwasher
9-93061-007
48
Retainer Nut
9-92127-007
49
Drive Housing
2-22301
50i
Inertia Drive Assembly, R.H.
2-22795
50ii
Inertia Drive Assembly, L.H.
2-22796
51
Retaining Ring
Included with item 50 or 57
52
Spring
Included with item 50 or 57
53
Set Screw
Included with item 50 or 57
54
Needle Bearing
9-91393
55
Adapter Plate
2-22794
56
Screw
14F-31218-020
57i
Inertia Drive Assembly, R.H.
1-18828
57ii
Inertia Drive Assembly, L.H.
1-19083
58
Gearbox Housing
1-18810
59
Lock Nut (6)
9-92107-015
ü
60
Screw (6)
11F-31218-024
ü
61
Drive Housing
1-18822
62
Needle Bearing
9-91005
63
Carrier Shaft
3P-20858-006
64
Retainer Plate
2-20855
65
Bearing
9-91356
Publication T1-701 Issued Dec 11, 1998
B
D
F
P
ü
ü
ü
ü
ü
ü
Page 23
TDI TURBOTWINÔ FROM
Key
Description
Part Number
66
Snap Ring
9-92001-006
67
Lock Nut
9-92105-008
68i
Inertia Drive Assembly, R.H.
2-22147
68ii
Inertia Drive Assembly, L.H.
2-22148
69
Drive Housing
2-20826
70
Needle Bearing
9-91380
71
Washer, Flat
9-93018-011
72
Nut, Hex
9-92108-003
73
Cover, Plate
2-20192
74
Screw (6)
11F-25020-072
75
Housing, Exhaust Cover
2-27069
76
Spring, Compression
9-90408-016
77
Post
2-27223
78
Drive Housing
2-25617
79
Screw (12)
11F-31218-024
ü
80
Needle Bearing
9-91423
ü
Model B D F P
Page 24 701
TECH DEVELOPMENT INC.
Overhaul Kit for S/N’s before: 9611-191 T10B-27618 T10D-27619 T10F-27617 T10P-27620
B
D
F
P
ü
ü
Overhaul Kit for S/N’s after: 9611-192 T10B-27634 T10D-27635 T10F-27633 T10P-27636
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
Figure 29. Illustrated Parts Breakdown (T112B/T121B)
Publication T1-701 Issued Dec 11, 1998
Page 25
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
Figure 30. Illustrated Parts Breakdown (T109P/T115P) Page 26 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
Figure 31. Illustrated Parts Breakdown (T112D/T121D, Standard Mesh) Publication T1-701 Issued Dec 11, 1998
Page 27
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
Figure 32. Illustrated Parts Breakdown (T112D/T121D, Long Mesh) Page 28 701
Publication T1Issued Dec 11, 1998
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT, INC.
Figure 33. Illustrated Parts Breakdown (T106F/T112F) Publication T1-701 Issued Dec 11, 1998
Page 29
TDI TURBOTWINÔ FROM
TECH DEVELOPMENT INC.
SECTION 7.0 ACCESSORIES SIZE
PART NUMBER
RELAY VALVES 1½" STAINLESS STEEL (AMOT) 52-93505 2" STAINLESS STEEL (AMOT) 52-93505-100 1½" 316 SST MANUALLY OPERATED 2" 316 SST MANUALLY OPERATED 1¼" NPT; BUNA N 1½" NPT; BUNA N 1¼" NPT; VITON 1½" NPT; VITON 12VDC; 1¼"; BUNA N 12VDC; 1½"; BUNA N
52-93508-300
RLVA-25683-001-1 RLVA-25683-001-1-01 RLVA-25683-001-2 RLVA-25683-001-2-01 RLVA-25683-012-1 RLVA-25683-012-1-01
12VDC; 1¼"; VITON
RLVA-25683-012-2
12VDC; 1½"; VITON 24VDC; 1¼"; BUNA N 24VDC; 1½"; BUNA N
RLVA-25683-012-2-01 RLVA-25683-024-1 RLVA-25683-024-1-01
24VDC; 1¼"; VITON
RLVA-25683-024-2
24VDC; 1½"; VITON 110VDC; 1½"; VITON 120VAC; 1½"; VITON
RLVA-25683-024-2-01 RLVA-25683-110-2-01 RLVA-25683-120-2-01
SIZE
PART NUMBER
GAUGES REAR CENTER MOUNT U-CLAMP REAR CENTER MOUNT BOTTOM MOUNT
52-21982 52-21982-100 52-21982-200
52-93508-400
PRESSURE REGULATORS 2" GAS 300 52-93552 2" GAS 125 52-93553 1½" AIR; MAX 1200 SCFM 52-20724-100 2" AIR; MAX 1600 SCFM 52-20724-200
EXHAUST 3" ELBOW KIT ECP KIT MUFFLER KIT (21 NOZ) MUFFLER KIT (6/12 NOZ) 3" NPT ADAPTER KIT FEMALE 4" NPT ADAPTER KIT FEMALE 4" STRAIGHT PIPE KIT 3" ELBOW KIT EXHAUST ELBOW W/ 3" PIPE WELD FLANGE EXHAUST ELBOW W/OUT WELD FLANGE
T100-27015 T100-27068 T100-27074 T100-27075 T100-27651 T100-27652 T100-27791 T100-27900 T100-28182-001 T100-28182-002
CONTROL & SOLENOID VALVES 1/8" NPT STR CONROL VALVE 52-93504 1/4", 24 VDC, CONDUIT 52-21981 1/4", 12 VDC, GROMMET 52-21981-002 1/4", 120 VAC, CONDUIT 52-93506-100 1/4", 120 VAC, GROMMET 52-93506-200 1/4", 24 VDC, CONDUIT 52-93506-300 1/4", 24 VDC, GROMMET 52-93506-400 1/4" 72 VDC 52-93506-500
Y-STRAINERS 1½" CARBON STEEL BODY, #40 52-93549-100 MESH, SST SCREEN 2" CARBON STEEL BODY, #40 52-93549-200 MESH, SST SCREEN 1½" CAST IRON BODY, #40 52-93550-100 MESH, SST SCREEN 2" CAST IRON BODY, #40 MESH, 52-93550-200 SST SCREEN
Page 30 701
Publication T1Issued Dec 11, 1998
Model: T I 21-B, T I 21-D Performance Curve 21 Nozzles, Natural Gas, 7.5:l Ratio
TORQUE N~ ~b.ft
I
-
0
Inlet Pressure 90 psig
90 psig
500
POWER HP KW
SCFM Nm31h 2028 3448 1391 2365 806 1370 Y~ -
1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 6,500
Output Speed, rpm
Section 5 – Cooling System Vendor
Bulletin No.
Coolant System Drawing................................................ Ajax
TP 02-04-T010-307
Compressor Cylinder Coolant System ........................... Ajax
02-04-T020-300
Water Pump and Mounting............................................. Ajax
TP 02-04-T03A-001
F1 820 AM Pump, Illustrated Parts List (8” Impeller) ............... Ajax Pump Maintenance Bulletin........................................................ Peerless
4845749
Pump Lubrication Guide ............................................................. Peerless
4852918
Thermostatic Control Valve Bulletin ........................................... FPE Butterfly Valve, 2”, O&M Bulletin ................................................ DEMCO
Engine-Compressor Package Service Manual
TC 1512
Note The pump’s bearings must be lubricated. Inject grease once per month as follows: 3.0 ounces in the inboard bearing 4.7 ounces in the outboard bearing Belt Tensioning Procedure 1. Loosen the 4 bolts clamping the pump’s frame to item 7. 2. Assure correct alignment of the pump sheave to the engine sheave for minimum wear. 3. Tighten the 4 bolts clamping the pump’s frame to item 7. DO NOT OVERTIGHTEN the belt. It will cause premature bearing wear or failure. Pump drive belt is not shown. Belt p/n is 1020 2131.
4. Check the tension after the first 24 hours of initial operation, and retension if necessary. Tighten the belt by turning the two adjusting screws (item 5) an equal amount of CW turns.
Coolant Pump & Mounting Assembly TP 02-04-T03A-001
Coolant Pump & Mounting Assembly TP 02-04-T03A-001 Item
Description
P/N
Qty
1 2 3 4 5 6 7 8
Belt, 5V Sheave, 2 Groove 5V x 5½" SDS Pump, Peerless Bushing, SDS 1 " Dia., ¼" x 1¾" Key Set Screw, ½" x 6" C.P. Angle 2 x 2 x ¼ x 7½ Lg. Pump Mounting Bracket Pump Retaining Bracket
1020 2131 4536 2550 5027 2825 5240 0611 6833 1209 7004 2020 802-0403-01002 802-0403-01003
1 1 1 1 2 2 1 2
Note: Some items illustrated are not used in all assemblies. Refer to the BOM for items used for the specific Ajax assembly.
Peerless Pump Model F1-820AM for Ajax DPC-2802 Series
Peerless F1-820AM Pump for Ajax P/N 5027 2825 Item
Description
Material
P/N
1
Casing
Cast Iron
order by S/N
2
Impeller, Trimmed to 8" Diameter
Bronze
V1735B-449
6
Shaft
Steel
2681134-492
7
Casing Ring
Bronze
284006-186 2691519-199092
13
not used, see #65 & #81
14
Shaft Sleeve
Bronze
16
Inboard Bearing
Steel Assembly
1100750-000
17
not used, see #65 & #81
17B
not used, see #65 & #82
17C
not used, see #65 & #83
17D
not used, see #65 & #84
18
Outboard Bearing
Steel Assembly
266935-000
19
Bearing Frame
Cast Iron
order by S/N
Bearing Lock Nut Impeller Washer Impeller Cap Screw
Steel Steel Nylon/18-8 Stainless Steel
2681602-056 2698080-079 2698078-641
32
Impeller Key
Steel
V2343A-064
40
Deflector
Rubber
2675921-118
46
Coupling Key
Steel
49
Outboard Bearing Grease Retainer
Rubber/Steel Assembly
2681122-000
51
Inboard, Bearing Grease Retainer
Rubber/Steel Assembly
2681123-000
65
Mechanical Seal Seat
Ni-Resist
268716501-000
71
Adapter
Cast Iron
order by S/N
22 24A 26
73A
Casing Gasket
Fiber
80
Mechanical Seal Rotary
Steel (Metal & Spring)
119
Shaft Sleeve "O" Ring
Viton
V2377A5
V1774A-122 268716501-000 2691534-199
Page 1 of 12
Installation, Operation and Maintenance Manual
DEMCO® Resilient Seated Butterfly Valve
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Page 2 of 12
Publication TC1512
Published May 2000
DEMCO® is a trademark of Cooper Cameron Corporation ©Cooper Cameron Corporation, Cooper Cameron Valves Division, 2000. All rights reserved.
Publication TC1512
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Page 3 of 12
Table of Contents
Bill of Materials ................................................ 4 Scope .............................................................. 6 Nameplate Information .................................... 6 Storage .............................................................. 6 Installation ........................................................ 7 Disc to Pipe Clearance ................................ 8 Flange Bolts ................................................ 8 Procedure .................................................... 9 Operation .......................................................... 9 Trouble Shooting ............................................ 10
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Page 4 of 12
Bill of Materials
Figure 1 - Demco 2" thru 12" Resilient Seated Butterfly Valve
Demco 2" thru ITEM 1. 2. 3. 4. 6. 7. 14. 22. 23. 24.
12" Parts List REQ'D 1 1 1 1 1 2 1 1 * 2
DESCRIPTION Body Seat Disc Upper Stem Lower Stem Spring Pin Retainer Top O-Ring Stem O-Ring Bearing
* 4 Req'd for throttling valves only.
Publication TC1512
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Page 5 of 12
Figure 2 - Demco 14" thru 36" Resilient Seated Butterfly Valve
Demco 14" thru ITEM 1. 2. 3. 4. 6. 7. 14. 23. 24. 25.
36" Parts List REQ'D
DESCRIPTION
1 1 1 1 1 2 1 * 2 1
Body Seat Disc Upper Stem Lower Stem Spring Pin Retainer** Stem O-Ring Upper bearing Lower bearing
* 4 Req'd for throttling valves only. ** 24" 36" Spacer
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Page 6 of 12
Scope Demco resilient seated butterfly valves are an economical alternative to ball, gate or plug valves in many applications. They are light weight quarter turn devices with few parts. They are designed for bubble tight sealing up to rated
pressure and are capable of throttling service. They are easily adapted to automatic actuators. The Demco butterfly valve is available in flangeless wafer design or single flange tapped lug configuration.
Nameplate Information 4
3
2
1
Figure 3 - Demco Resilient Seated Butterfly Valve Nameplate. 5
ITEM 1 2 3 4 5 6
6
STAMP Product ID Number Product Description Body Material Disc Material Seat Material Stem Material
Storage Demco butterfly valves are shipped in the partial open position to minimize permanent deformation of the resilient seat. The disc edge is contained within the flange faces of the valve to prevent damage to the sealing area (Figure 4). Caution: Valves with fail open or closed actuators are shipped with the disc in the fail position, and extra care should be given to prevent damage to the disc edges. Valves should be stored in a clean dry area away from extremes of heat. The resilient seat surfaces should be protected from sunlight and physical abuse. Figure 4
Publication TC1512
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Page 7 of 12
Installation Direction Demco butterfly valves are bi-directional and will operate in any position. Normally the valve is installed with the upper stem pointing upward (Figure 5). Elevated valves with gear operators and chainwheels should be installed with the upper stem pointing down (Figure 6) so the open-closed indicator is visible from the ground and the chain does not drag on the pipe. End-of-Line Service Demco tapped lug butterfly valves are suitable for liquid service end-of-line applications with downstream piping removed (Figure 7). Only weld neck or socket weld flanges can be used for this service. Since the upstream pressure is excluded between the flange and the seat face by the exclusive Demco flange seal, there is no effective force to slide the seat downstream.
Figure 5
Caution: The valve must not be opened or closed with the downstream piping removed as the seat might be shifted breaking the flange seal and allowing pressure to slide the seat downstream. Gaskets Flange gaskets are not required nor recommended for use with positive shut-off Demco butterfly valves. An integral flange seal is molded into the edge of the rubber seat eliminating the need for flange gaskets. Throttling Valves, only, utilize an o-ring stem seal that must be assisted with flange gaskets for a proper seal.
Figure 6
Flanges Steel Class 150 ANSI (or MSS SP-44) weld neck, slipon, threaded and socket weld as well as stub end type C flanges are suitable for use with 2 thru 24 Demco butterfly valves. 30 and 36 Demco butterfly valves fit between ANSI 125 flanges (or MSS SP-44). Other flange types may be applicable also, but should be thoroughly checked to assure proper seal makeup. Plastic flanges are subject to damage at installation by over-tightening the bolting and may deflect or cup resulting in flange leaks. Figure 7
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Page 8 of 12
Disc to Pipe Clearance Before beginning installation, disc/pipe clearance should be checked to avoid the possibility of scraping the disc edge on the pipe ID and damaging the sealing surface. Minimum pipe ID requirements are given in Table 1. Valve Disc Swing Opens into: Size Clearance Std Pipe Sch 40 Sch 80
2" 2-1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36"
PIPE I.D. DISC CHORD
Figure 8
1.467" 2.144" 2.743" 3.601" 4.582" 5.624 7.428" 9.382" 11.35" 12.86" 14.72" 16.61" 18.53" 22.57" 28.67" 34.70"
x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x
x x x x x x x x x
Table 1 - Disc Clearance
WAFER BODY
Flange Bolts Recommended bolt and stud lengths for installation in ANSI flanges are provided in Table 2. MSS flanges require longer bolts.
STUDS & HEX NUTS
A
Valve Size 2" 2-1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36"
Bolt Size
Wafer Body Stud Screw Qty Length Length "A"(in.) "B"(in.)
5/8"-11 4 5/8"-11 4 5/8"-11 4 5/8"-11 8 3/4"-10 8 3/4"-10 8 3/4"-10 8 7/8"-9 12 7/8"-9 12 1"-8 12 1"-8 16 1-1/8"-7 16 1-1/8"-7 20 1-1/4"-7 20 1-1/4"-7 24 (8) 1-1/2"-6 28 (16)
5" 5-1/2" 5-1/2" 5-3/4" 6-1/2" 6-1/2" 7" 7-1/2" 8-1/4" 8-1/4" 10" 10-1/2" 11-3/4" 12-1/2" 13-1/2" 16"
(4") (4")
Table 2 - Flange Bolt Size
Lug Body Screw Qty. Length "B"(in.) 8 8 8 16 16 16 16 24 24 24 32 32 40 40 56 64
1-1/2" 1-1/2" 1-1/2" 1-3/4" 1-3/4" 2" 2-1/4" 2-1/4" 2-1/2" 2-1/2" 3-1/4" 3-1/2" 4" 4" 4" 4"
Figure 9
B
Figure 10
Publication TC1512
Flanges -
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Page 9 of 12
Procedure The following procedure applies to new installation between standard ANSI pipe flanges. When replacing a valve from an existing installation, clean flange faces and check for excessive corrosion or other damage to the sealing face of the flange.
wafer body is equal to the inside of the bolt circle of the flanges, so the valves are selfcentering.) Install the remaining flange bolts. 3. Lug bodies have tapped holes coinciding with those in the flanges. They should be positioned between the flanges and the capscrews inserted through the flange holes into the threaded lug holes. 1. Remove the valve from any packaging mate4. Tighten all bolts or capscrews in a crossover or rial. Close the valve disc so that it is contained star pattern to assure even sealing. Tighten within the flange faces. It is not necessary to sufficiently to assure metal-to-metal contact fully close the valve; the disc must be conbetween the flange face and the metal buttertained within the confines of the valve body fly valve body. No further tightening is reso it will slip between the mating flanges quired. without contact with the flanges. 5. Carefully check disc clearance by placing the 2. When installing wafer valves, install the lower valve in the full open position. Any binding or flange bolts without tightening. Position the scraping should be investigated and corrections valve between the flanges, within the pocket made. formed by the flange bolts. (The OD of the
Operation Demco butterfly valves should never be operated without a handle or other means of controlling the disc. Caution: Failure to restrain the disc under flow conditions can result in the disc slamming closed and possible damaged or broken parts. 2 thru 12 Demco butterfly valves have flats on the upper stem. 14 and larger valves have a single square key. Stem flats or the square key indicate valve position. When they are in line with the flow stream, the valve is open. When perpendicular, the valve is closed. Manually operated Demco butterfly valves operate from fully open to fully closed by a 90° turn of the handle. The handle is marked with a flow arrow. When this arrow is in line with the pipe axis, the valve is
Figure 11 Valve shown open
open (Figure 11). When perpendicular to the pipe, the valve is closed (Figure 12). Worm gear operated Worn gear operators are recommended for valves larger than 6 inches. Clockwise rotation of the handwheel closes the butterfly valve. Counterclockwise rotation opens the valve. Gear operators are always mounted with the input shaft perpendicular to the pipe axis for handwheel clearance. Each operator has an arrow on the top of the gear, which indicates the OPEN CLOSED position of the valve (Figure 13). Automated valves Butterfly valves with their quarter turn operation are easily adapted to automatic actuators for remote operation. To prevent water hammer, actuators should close the valve slower than 6 to 8 seconds, open-to-close. Rapid closure causes water hammer which can break or otherwise damage valve parts.
Figure 12 Valve shown closed
Figure 13 Valve with gear operator
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Page 10 of 12
Troubleshooting Trouble
Probable Cause
Remedy
The seat and/or disc is worn or damaged.
Replace worn parts.*
Foreign matter is present between seat and disc.
Operate several times to wipe clean.
Operator stops are not set properly.
Adjust stops to proper setting.
Build up of solids or roughness is on edge of disc.
Operate several times to wipe clean or disassemble valve and clean disc edge.*
Operator is not installed properly.
Reistall operator in proper alignment with valve stem.
Disc hits on side of pipe.
Check for proper pipe clearance.
Seat is damaged or worn.
Replace Seat.*
Disc is bent.
Replace disc, stems and seat as required.*
Flange seal is leaking.
Correct flange seal leak to prevent fluid from migrating behind seat and out stem.
Handle or actuator does not provide proper restraint.
Restrain disc with handle or actuator.
Line flow too great.
Choose larger valve or slow down flow.
Flange seal surface on seat is damaged.
Replace seat.*
Flange surfaces are damaged or corroded.
Clean, repair or replace flanges.
Flange bore is too large.
Replace with proper flanges.
Clockwise rotation of Gear Operator handwheel opens valve. Open-Shut indicators do not coincide wth valve disc position.
Gear operator has been rotated 90o on valve top. Hand-wheel shaft aligns with pipe (should be perpendicular).
Rotate gear operator 90o on valve top to put input shaft perpendicular with pipe axis.
Automatic actuator slams valve shut or open.
Speed control valves missing or not adjusted.
Hard, soft or cracked seat damage is present.
Heat or chemical damage to seat.
The valve will not seal properly.
The valve is hard to operate.
The valve will not open.
The valve is leaking around stem.
The valve closes with line flow.
Flange leaks.
Install and/or adjust speed control valves.
Replace elastomer seat with compatible material and/or correct offending fluid conditions.
*Contact your CCV representative for repair manual Publication TC1512
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Page 11 of 12
NOTES
DEMCO Resilient Seated Butterfly Valve Installation, Operation and Maintenance Manual
Publication TC1512
Headquarters Cooper Cameron Valves 16500 South Main Street, Missouri City, TX 77489-1300 Phone: 281-499-8511, 800-323-9160, Fax: 281-499-6965 Manufacturing Cooper Cameron Valves Demco Products P.O. Box 94700 Oklahoma City, OK 73143 Phone: 405-631-1321, Fax: 405-631-0420 http://www.ccvalve.com
DEMCO® is a trademark of Cooper Cameron Corporation c Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 5-00 / TC1512
Section 6 – Cooler Vendor
Bulletin No.
E72-9 Cooler Drawing ..................................................ACE
07366-C
Cooler Spec Sheet .........................................................ACE
7249PW
Cooler Spare Parts List ..................................................ACE
E72-9
Cooler Start Up Procedures.................................................ACE Cooler Operation and Maintenance Instructions .................ACE Bearing Lubrication Schedule Fan O&M Bulletin................................................................Crowley
Engine-Compressor Package Service Manual
8
7
6"
6
5
4
3
2
1
3"
n7/8"
6"
SECTION A-A
D
D
3"
(4 PLACES)
1 1/2"
1 1/2"
84 1/4" 82" 74 1/4" 125 1/2"
59" 42 7/8"
SEE CL BELOW 29" 67"
19 7/8"
5 1/2"
19 7/8"
LOUVER
3
2
1
1" NPT
1" NPT
C
85" ADD 2" LOUVERS OPEN
C
74 3/4"
91"
ACCESS DOOR (N.S.)
24 5/16"
36 7/16"
56 3/4" 56 1/4"
NC
A
A 78"
76" B
B
END ELEVATION
SIDE ELEVATION
RPM= 636 HP= 12.5 PER FAN BLADE ANGLE= 32
UNIT: 0736601 − 02 TAG: CT. 10753 − 54 JOB: 07366
SEE CL BELOW - THESE DIMENSION (S) ARE SYMETRICAL ABOUT THE CENTER OF COOLER. FLAG
NOTES 1. WEIGHT: 7239 POUNDS 2. FINISH: ACE std prep. w/ one coat QL-5505 primer A 3. FAN DRIVEN BY V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR
SERVICE
CL
LOUVERS
DESIGN PRESSURE
DESIGN TEMPERATURE
NOZZLES IN (1)2−150RF
(1)2−150RF
N/A
18.375
N/A
150 PSI
350 Deg F/−20 Deg F
NOZZLES OUT
OTHER NOZZLE
NC
1
EJW
112.75
2
IC
113.75
AUTO
215 PSI
350 Deg F/−20 Deg F
(1)6−150RF
(1)6−150RF
N/A
18.875
3
AC
113.75
AUTO
350 PSI
350 Deg F/−20 Deg F
(1)6−300RF
(1)6−300RF
N/A
18.875
AIR COOLED EXCHANGERS, LLC SCALE: 1:1 (FIT TO PLOT) DATE: 10/18/2007
BY
DATE
REV−1
DB
10/25/07
REV 2
KG 11−08−07
7
6
5
4
3
2
DESCRIPTION SHOW MISSING NOZZLE
AID DHB
CHECKED BY:
CUSTOMER: CAMERON COMPRESSION
4. ASME CODE ON IC,AC,
8
DRAWN BY:
ACE MODEL E72−9
P.O: CK’D DHB
A
4501415535
DRAWING NUMBER REV
07366
MOVE NOZ ON EJW PER SALES KG
1
−C
2
AIR COOLED EXCHANGERS, INC. P.O. BOX 577 - BROKEN ARROW, OKLAHOMA 74013 Ph (918) 251-7477 Fax (918) 258-1833 E-MAIL:
[email protected]
COOLER PERFORMANCE SPECIFICATION CUSTOMER REFERENCE MODEL
CAMERON COMPRESSION QT. 07126 - Purneftagas E72-9
PROPOSAL NUMBER DATE PAGE
7249PW 10/12/2007 1
PERFORMANCE OF ONE UNIT EJW IC AC
SERVICE FLOW FLUID TEMPERATURE IN, F TEMPERATURE OUT, F INLET PRESSURE, PSIG PRESSURE DROP, PSI DUTY, BTU/HOUR CORRECTED MTD BARE TUBE RATE FOULING BARE SURFACE, SQ. FT. TOTAL SURFACE SQ. FT.
121.5GPM 50%GLY 165.0 150.0 5.4 801200 34.1 207.4 0.00050 113 2710
3.01MMSCFD .947 162.8 130.0 41.9 1.9 148245 33.7 56.8 0.00200 77 1848
3.01MMSCFD .947 191.0 120.0 80.0 2.3 326450 35.4 61.7 0.00200 149 3572
CONSTRUCTION NO. SECTIONS NO. TUBES/SECTION LENGTH NO. ROWS NO. PASSES COUNTERFLOW TUBE O.D. AND BWG TUBE MATERIAL DESIGN PRESSURE, PSI DESIGN TEMPERATURE, F NOZZLES-INLET NOZZLES-OUTLET HEADER TYPE HEADER MATERIAL ASME CODE STAMP GROOVED TUBE SHEET CORROSION ALLOWANCE PLUGS, TYPE PLUGS, MATERIAL TURBULATORS ACCELERATORS LOUVERS STRESS RELIEVE NDE ADDITIONAL CODES CANADIAN REGISTRATION ADDITIONAL COUPLINGS BYPASS NOZZLE FINS
1 66 9.0 4 3
1 45 9.0 6 1
1 87 9.0 6 2
.75X16BWG SA214(WLD) 150 350/-20 2-150RF 2-150RF RECT TUBE STEEL
.75X16BWG SA214(WLD) 215 350/-20 6-150RF 6-150RF BOX W/PLUGS SA-516-70 YES
.75X16BWG SA214(WLD) 350 350/-20 6-300RF 6-300RF BOX W/PLUGS SA-516-70 YES
TAPER STEEL
TAPER SA-105
TAPER SA-105
NO
AUTO NO 100% X-RAY
AUTO NO 100% X-RAY
YES
1 ALUMINUM
1 ALUMINUM
ALUMINUM
AIR DATA INLET AIR, F OUTLET AIR, F
100.0 131.1
ELEVATION, FT. TOTAL SCFM
1500 37861
MECHANICALEQUIPMENT 1 12.5 637 72 NO FANS HP/FAN RPM DIA FAN CROWLEY 9WL FAN MATERIAL ALUM NUMBER OF BLADES 5 PITCH 32 DEGREES V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR FORCED DRAFT TYPE 7239 WIDTH 6.9 LENGTH 10.4 HEIGHT 7.1 EST SHIPPING WEIGHT ACCESSORIES FINISH ACE std prep. w/ one coat QL-5505 primer
Parts List
Air Cooled Exchangers, LLC 1201 S. 9th Street Broken Arrow, Oklahoma 74012 Phone: 918-251-7477 Fax: 918-251-7482
Customer: CAMERON COMPRESSION ACE Serial Number(s): 0
Cooler Model: E72-9 Fan Make & Model
1
6
Fan Shaft ###
5
Dia.
##
32
Blades
LEFT HAND
CROWLEY 72/5-10/32/PAG/9WL/SK/1.4375/AR
STD
Bore with
34.9
1.4375 Dia.
deg. Pitch at
4.25 in Keyway Fan end
Long with
## 0
0
Dia.
Long with
2
1.4375 in REXNORD MODEL ZA-2107
Idler Bearing
0
0
Electric Motor
###
15 TEFC
1500
HP Enclosure
Keyway one end
380
RPM
254T
Frame Size
WITH
$295.00
PRICE EACH
$0.00
PRICE EACH
$249.00
PRICE EACH
$0.00
SlideBase
0
$2,006.00
6 in Keyway other end
3
Volt
636
Fan RPM:
PRICE EACH
Idler Shaft Fan Bearing
5/6 RAD PRICE EACH
Keyway
Phase
50
0
PRICE EACH
$1,149.00
Motor Sheave
1
0
O.D.
2-5V5.2Type
0
Groove
0 Bore
PRICE EACH
$0.00
Fan Sheave
1
0
O.D.
2-5V11 Type
0
Groove
0 Bore
PRICE EACH
$0.00
V-Belts
$0.00
0
5VX780
PRICE EACH
0
0
0
PRICE EACH
0
0
0
PRICE EACH
LOUVER FOR IC
0
108 IN X 16.75 IN ALUMINUM AUTO WITH JOHNSON 3153-5 AIR MOTOR AND KIMRAY T12 T.C.
PRICE EACH
$0.00
LOUVER FOR AC
0
108 IN X 30.75 IN ALUMINUM AUTO WITH JOHNSON 3153-5 AIR MOTOR AND KIMRAY T12 T.C.
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0
0
0
PRICE EACH
$0.00
0 0 0 0
FAN, SHAFT, BEARINGS & V-BELTS ARE RECOMMENDED SPARE PARTS. ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE. ALL INQUIRiES AND ORDERS MUST BE ACCOMPANIED BY COOLER SERIAL NUMBER.
Cycle
AIR COOLED HEAT EXCHANGER SUGGESTED START UP PROCEDURE
Before any start up procedure is begun, a thorough inspection of the Air Cooled Exchanger should be made. 1.)
Be sure all bolted connections are properly tightened.
2.)
After tube bundle and piping hydrotest, remove hydrotest connections. Be sure tube bundle is properly drained, and if required, dried. Connect process piping and any auxiliary connections.
3.)
Inspect all process connection, as well as, vent drain, temperature and pressure, or any other auxiliary connections to be sure they are plugged or connected properly.
4.)
Check mechanical equipment before starting process through the tube bundle(s). a.)
Thoroughly check the plenum and fan drive area to be sure all tools and construction materials are removed.
b.)
Rotate the fan by hand and check fan tip clearance and alignment of belts and sheaves.
c.)
Check belt tension.
d.)
Check all fan drive bolts to be sure they are properly tightened. This includes bearing bolts, fan and sheave bushing bolts, set screws, motor bolts and fan blades attachment bolts.
e.)
If air operated auto-variable pitch fans are used, check for proper pitch with the air off. Fans may go to either minimum or maximum pitch at air failure. Check specifications for requirements. If fan pitch is not satisfactory, set pitch per manufacturer's instructions (see Operation and Maintenance Instructions). If fan pitch is satisfactory, cycle fan through it's range, using plant air and an air regulator. Page 1
5.)
f.)
If air operated louvers are provided, it is advisable to disconnect the air motor linkage and cycle the louvers by hand to assure there is no binding or obstruction of the louvers blades. If binding occurs, check to be sure louver frames are square. Attaching bolts may have to be loosened and frames shifted to ease binding. If louvers operate smoothly, reconnect air motor. Cycle the air motor, using plant air and an air regulator.
g.)
If manually adjusted pitch fans are provided, check fan pitch and re-pitch per manufacturer's instructions if required.
h.)
If manual operated louvers are provided, check for binding of the blades, as in instruction (f). Operate louvers to be sure there is no linkage obstruction or binding.
i.)
Remove condensate drain plugs, if provided, in electric motors and other electrical components to drain any condensation that might have occurred during storage. If space heaters are furnished in electric motors, louver actuators, controls, etc., activate the space heaters and allow approximately 24 hours before starting equipment.
j.)
After all the applicable steps previously stated are completed, the mechanical equipment may be cycled.
k.)
Be sure all personnel and equipment are away from the fan and fan drive area. For safety reasons, equipment guards should be installed. Activate the drive motor and let it reach speed. Check for vibration and excessive noise. If vibration or excessive noise occurs, immediately shut motor down, and check for loose connections or insufficient clearance between moving parts. If the system is running smoothly, replace any guards removed and move to the next drive and repeat above steps.
Start the process through the tube bundle(s). Open the inlet valves slowly and let the process "Warm" the bundles slowly. This will allow the components of the tube bundle to expand at the same rate and lessen the thermal shock.
Page 2
OPERATING AND MAINTENANCE INSTRUCTIONS FOR ACE COOLERS IMPORTANT Before start up, check set screws and bolts in the fan assembly and set screws in locking collars of all bearings and sheaves. These items should be checked again several days after start up. FAN & DRIVE Although the fan and drive are inspected before shipment, clearance between the fan blades and the fan ring and guard, and alignment of the fan shaft should be checked to assure that rough handling during shipment has not loosened bearing mounting bolts or caused misalignment. V-belt drives should be adjusted until tight enough to prevent excessive belt slippage. The belt is generally tight enough when it can be twisted one-quarter of a turn with the thumb and fore-finger. LUBRICATION Bearings should be greased in accordance with normal maintenance practice. Over-lubrication is the most common cause of bearing failure. In general, about one cubic inch of grease in each bearing every 2 to 3 months is adequate. The operating temperature of the bearing may indicate how much lubrication is required. Normal temperature may range from “cool to warm to 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 slight showing of grease at the seals indicates proper lubrication. Page 1
TUBE CLEANING Operating conditions sometimes cause an accumulation of dirt on the outside fin surface. This can be removed by directing compressed air, or a greaseless solvent followed by a water spray through the fins in a direction opposite the normal air flow. The inside of the tubes will require periodic inspection and cleaning as necessary. Removal of access plugs allows visual inspection, and if necessary, the use of mechanical tube cleaners. PLUG LEAKS Should tapered plugs develop leaks, additional tightening is normally all that is required. Thread dope may be used if tightening alone is not sufficient. If shoulder type plugs develop leaks, the gaskets should be replaced. Tapered plugs that are removed for the tube inspection or cleaning should be replaced in the same hole. TUBE LEAKS Tube leaks can be of two types: (1) leaks in the tubewall itself (usually corrosion) and (2) leaks in the tube to tubesheet joint. In the first case, it is usually most practical to plug both ends of the tube with the resulting loss in heat transfer surface. When so many tubes have been plugged that performance is affected, retubing will be necessary. If leaks develop in the tube to tubesheet joints, rerolling of the tube will be required. Care must be used in selection of the proper tube expander for the size and BWG of the tube being used. As with all rolled tube joints, over-rolling must be avoided. GENERAL If it is ever necessary to contact our plant for service or replacement parts, it is essential that our serial number or other identifying data be obtained from the metal nameplate attached to the cooler. This is the only way to positively identify the correct parts that may be required.
Page 2
Multi-Wing Z Series Fans Blade Pitch Angle Setting Instructions Before You Begin: To maintain balance of fan: • Mark the hub castings across a joint, so the fan hub can be reassembled in the same orientation. • Mark the location of any balancing weight. Balancing weight will be on the outer bolt circle, in the form of washers, and/or longer bolts, or an additional balancing nut. • Number the blades and blade sockets, so that they are replaced into their original position. If possible, note the location of the pitch setting pin in the blade socket when disassembling the fan, and whether pin is located in the Hub or Retainer half of the fan (see step 7 for detailed definition). Step 1 – Determine Blade Type: “1Z”, “2Z”, “4Z”, “5Z”, or “6Z” If the blade has a sickle shape, then look for 1Z or 2Z molded on the blade. If the blade is wider at the tip than at the base near the hub, then you have a 6Z. Otherwise, look for 4Z or 5Z markings on blade which are in one of two places: Look on cone section at base of blade (visible when fan is assembled), or Look inside the bottom of the socket (blade must be removed from hub). Alternatively, measure the width of the blade at the widest portion at base of blade: 4Z blade is approximately 4-1/2 inches, 5Z blade is approximately 5-1/4 inches. Step 2 – Determine Rotation Code: “L” or “R” R rotation rotates clockwise facing air discharge, L rotation is counterclockwise facing air discharge. The 1Z and 2Z blade profiles have an arrow showing rotation molded into the blade on inlet side. The 6Z is universal and can be used as an R or L rotation, depending on how pitch angle is set. For 4Z and 5Z blades, the rotation code is molded into the blade, either on the cone section at base of blade, or inside bottom of the socket. Examples of rotation for 4Z blades as viewed from end of socket are below, and 5Z is similar. R, or clockwise
L, or counterclockwise
P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021 Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com
44
Multi-Wing America - Z Series Pitch Setting Instructions - Page 2 of 4
Step 3 – Determine Boss location code: “A” or “B” The boss is the center section of the hub through which the fan is mounted to the shaft, and typically contains either setscrews or a center-tapered hole where the bushing inserts. Select boss location A or B: A is the boss on air inlet, including A, AR, and AS configurations. B is the boss on air discharge, including B, BR, and BS. See examples in drawing below. For flange mounted (engine) fans, use boss location A for blower fans, and boss location B for suction fans.
Step 4 – Find Blade Pitch Angle:
20, 25, 27.5, 30, 32.5, 35, 37.5, 40, 45, or 50
The blade pitch angle can be found several ways: First, by knowledge of the Multi-Wing fan part number. The pitch angle precedes the blade material code in the part number. For example, the pitch angle is 30 degrees in this part number: 36/9-9/30/PPG/5ZR/ SH 1-3/8 /AS Second, by careful disassembly with this method: • • • •
Disassemble fan on flat surface, and note in which groove the pin is located. See number code in picture to the right. Using pictures in step 7 on next page, determine if the pin was in the hub (HUB) or retainer side (RET) of fan. Using table in step 6 below, find the possible blade pitch. Using table in step 5 below, select your blade angle based on whether your pin was in the HUB or RET.
Third, by calling a sales engineer at Multi-Wing America for assistance in selecting a blade pitch angle for your application.
P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021 Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com
Multi-Wing America - Z Series Pitch Setting Instructions - Page 3 of 4
44
Step 5 – Determine Hub/Retainer Code: “HUB” or “RET” Find “HUB” or “RET” in chart below: Type
Rotation
Boss Pos.
1Z,2Z,4Z 1Z,2Z,4Z 5Z 5Z 6Z 6Z 6Z 6Z
R or L R or L R or L R or L R R L L
A B A B A B A B
Blade Pitch Angle 32.5° 35° 37.5°
20°
25°
27.5°
30°
40°
45°
RET
RET
-
RET
RET
HUB
HUB
HUB
HUB
50° -
HUB
HUB
-
HUB
HUB
RET
RET
RET
RET
-
-
RET
-
RET
RET
RET
HUB
HUB
HUB
HUB
-
HUB
-
HUB
HUB
HUB
RET
RET
RET
RET
RET
RET
HUB
RET
HUB
RET
-
-
-
-
HUB
HUB
RET
HUB
RET
HUB
-
-
-
-
HUB
HUB
RET
HUB
RET
HUB
-
-
-
-
RET
RET
HUB
RET
HUB
RET
-
-
-
-
37.5° 3 2 4 1 -
40° 2 3 3 2 -
45° 1 4 2 3 -
50° 1 4 -
Step 6 – Determine Groove Number: 1 or 2 or 3 or 4 Find the groove number in chart below: Type
Rotation
1Z,2Z,4Z 1Z,2Z,4Z 5Z 5Z 6Z 6Z
R L R L R L
Blade Pitch Angle 20° 4 1 1 1
25° 3 2 4 1 2 2
27.5° 1 4
30° 2 3 3 2 3 3
32.5° 1 4 2 3 2 3
35° 4 1 1 4 4 4
Step 7 – Final Assembly Definition of HUB and RET for purposes of these instructions: For 2-piece hubset like below:
Top half is the HUB, and bottom half is the RET or retainer ring.
P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021 Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com
Multi-Wing America - Z Series Pitch Setting Instructions - Page 4 of 4
44
Step 7 – Final Assembly continued For 3-piece hubset as below:
Top two pieces together are considered the HUB, and bottom piece is considered the RET or retainer ring. Using the HUB or RET code found in Step 5: If code is HUB, place the hub down on work surface first (one or two pieces, depending on above). If code is RET, place one retainer ring only down on the work surface first. A weighted coffee can could be used to elevate the fan from the work surface. Using the Groove Number found in Step 6: Using picture to right, place the locking pin in the groove number that you found in Step 6 above. Finally, Insert Blades: •
Place the blade over the pin in the hub/retainer blade socket, so that the pin also fits into the appropriate pitch angle groove in the blade. See example picture to the right. For 6Z fans, use the pitch angle groove in the blade marked with your rotation (R or L) and pitch angle. Example: L35 is “L” rotation and 35degree pitch angle.
•
Repeat for all blades.
•
Assemble hubset together, aligning the match marks you made.
•
Replace any balancing weight to its original position.
•
To finish, tighten the bolts in a cross pattern to 5 to 6 foot-pounds of torque. P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021 Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com
Z pitch setting Rev 1 1/25/05
INSTRUCTIONS FOR BLADE PITCH ADJUSTMENT FOR THE LARGE SERIES MULTI-WING W BLADES 1) NOTE ORIGINAL POSITION OF RETAINING PLATES, CENTER BOSS AND ALL HARDWARE INCLUDING ADDITIONAL HARDWARE USED FOR BALANCING 2) REMOVE ALL THE BOLTS AND NUTS. 3) DETERMINE BLADE ROTATION – ON THE CONCAVE SIDE OF THE BLADE IS A BLADE MARKING SHOWING 6WR, 6WL, 7WL, 7WR, OR 9WR. THE “L” AND “R” DENOTE THE ROTATION OF THE BLADE. 4) REPLACE THE PITCH INSERT IN THE BLADE ROOT WITH AN INSERT OF THE DESIRED PITCH. PITCH IS DETERMINED BY COUNTING DIAL MARKS ON THE INSERT FROM THE SIDE OF APPROPRIATE BLADE ROTATION FOUND IN STEP 3. EACH LARGE MARK REPRESENTS 5 DEGREES. THE ENDS OF THE INSERT ARE 20 AND 50 DEGREES ACCORDINGLY.
5) REPLACE BLADES TO THEIR ORIGINAL LOCATION. 6) REPLACE ALL NUTS, BOLTS, AND WASHERS ON THE FAN HUB. 7) REPLACE RETAINING PLATES AND CENTER BOSS TO ORIGINAL LOCATION. 7) TIGHTEN NUTS AND BOLTS TO: 14 FOOT POUNDS OF TORQUE (REV. 9/7/05)
Multi-Wing America A Crowley Company
P.O. Box 425 15030 Berkshire Industrial Pk. Burton, Ohio 44021
[email protected] www.multi-wing.net
Ph. 440 834 9400 Fax 440 834 0449 Toll free 800 311 8465
ISO 9001 QEC-15013 SAI Global
FANs 268.1, 1628.3 Product Bulletin D-3153 Issue Date 0596
D-3153 Pneumatic Actuator
The D-3153 Pneumatic Actuator is a multipurpose positioning device used primarily for operating ventilating dampers in response to the output signals of a pneumatic controller or electro-pneumatic transducer. The D-3153 can be used with dampers up to a maximum area of 16 square feet for proportional volume control and 25 square feet for two position actuation provided that the torque requirements are compatible with the specific application. The D-3153 is UL component recognized for use on UL classified 555/555S smoke and combination fire/smoke dampers which have been tested and approved to a degradation temperature of 250°F (121°C). Figure 1: D-3153
Features and Benefits ❑ All-aluminum Housing
Lightweight, non-combustible
❑ Telescoping Linkage
Fast, flexible installation
❑ Long Life and Reliable
Over a million now in service
❑ 2-way Swivel Head
Ensures full power delivery
❑ Agency Recognized
UL Recognized component for fire and smoke applications to 250°F (121°C)
© 1996 Johnson Controls, Inc. Code No. LIT-2681054P
1
A pplication
I nstallation
When used with proportional control, the damper size is limited to 16 square feet maximum. As a 2-position control, damper size is limited to 25 square feet.
Two standard mounting packages are available with the D-3153 pneumatic piston actuator. The models with universal mounting bracket assemblies provide all of the parts and instructions required for applying the actuator to Johnson Controls D-1300 damper applications: duct (wall) mounting or frame mounting-either normally open or normally closed.
Three nominal spring ranges are available: 3-7 psi (D-3153-7), 5-10 psi (D-3153-3 and -6), and 8-13 psi (D-3153-1, 2, 4, 5, and 18). The control air pressure for normal HVAC operation is 0-20 psig. The minimum control pressure for safety damper functions is 20 psig with the maximum pressure of 30 psig. When used for both proportional and safety applications, a separate air signal should be provided to override normal HVAC operation and cause safety damper functions. The D-3153 incorporates several internal and external features that add functional flexibility. A 2-way swivel connection on the actuator cylinder head provides non-binding movement. All actuators have a telescoping piston rod for easy linkage of the damper for attachment points up to 8-3/4 inches (222 mm) away from the face of the actuator. A swivel ball joint and slotted crank arm connector are furnished on all actuators for optional methods of linkage to the damper. The UL component recognized D-3153 actuator with universal and auxiliary mounting brackets are specifically designed for use with Johnson Controls safety dampers up to 250°F (121°C).
peration O Air pressure from a pneumatic controller is applied to the diaphragm of the actuator, which moves the piston against the forces of the internal spring and the load. The external load force shifts the operating range from the nominal spring range. The piston will move to a position where the applied force and the spring plus external forces are in equilibrium. However, with a pilot positioner added, the piston will move to a position proportional to the control signal regardless of the load.
The auxiliary mounting bracket assembly facilitates applying the D-3153 actuator to allied equipment manufacturer’s products, and non-Johnson Controls installations for actuator conversions. These assemblies are furnished with a crank arm linkage and pedestal style bracket. Two positions are provided on the pivot post for attaching the actuator to the mounting bracket so that force can be more directly applied to linkage points that are neither perpendicular nor parallel to the actuator mounting plane. A stop screw kit is available for special applications to limit the power stroke of the actuator when required. A 4 foot (122 cm) linkage rod is also available for special applications to reach extended linkage when required. Where precision sequential operation is desired, or additional positioning power is necessary, a D-9502 positioner should be used. Up to four more D-3153 actuators may be slaved from one pilot for coupled dampers. A D-9502 kit is also available to enable 2-stage actuator control for providing minimum outdoor air during occupation (refer to D-9502 literature). Refer to the appropriate D-3153 Installation Bulletin for more details.
R epair Information Field repairs must not be made. For a replacement D-3153 body, contact the nearest Johnson Controls representative.
Table 1: Force Values at 20 psig (140 kPa) Supply Spring Range psig (kPa)
Stroke
Force lb (Newton)
Torque Output for 90° Rotation
8 to 13
Power
105 (467)
158 in·lb (18 N·m)
(56 to 91)
Return
120 (534)
180 in·lb (20 N·m)
5 to 10
Power
150 (667)
225 in·lb (25 N·m)
(35 to 70)
Return
75 (334)
113 in·lb (13 N·m)
3 to 7
Power
195 (867)
293 in·lb (33 N·m)
(21 to 49)
Return
45 (200)
68 in·lb (8 N·m)
2 D-3153 Pneumatic Actuator Product Bulletin
D imensions P isto n R o d E xten sion S et S crew S wiv e l B a ll Jo int M axim u m T ele sco p ing 6-1/2 (1 65 )
Crankarm
2 -1 /4 (5 7)
5-1 /4 (1 3 3)
7 -2 3/3 2 (19 6 ) 1 1-5 /8 (2 9 5)
Figure 2: D-3153, inches (mm)
D -9502 P ositioner
8-7 /8 (2 2 5)
6- 9/1 6 (167 )
15-7/16 (39 2 )
6-9/32 (16 0)
Figure 3: D-3153 with Universal Mounting Bracket, inches (mm) D -95 0 2 P o sitio ne r
7 -7 /8 (20 0 )
P ositio n B 3 -2 5/3 2 (96 ) 5-9/1 6 (1 41 )
P iv o t P o st A u xilia ry M o un ting B ra cket 1 1-5/8 (2 95 )
4 (1 0 2)
P ositio n A 2-15 /16 (7 5 )
Figure 4: D-3153 with Auxiliary Mounting Bracket, inches (mm)
Table 2: Ordering Information Nominal Spring Range
With Universal Mounting Bracket
With Auxiliary Mounting Bracket
Body Only
8-13
D-3153-2
D-3153-5
D-3153-6003
8-13 w/D-9502
D-3153-1
D-3153-4
-
-
D-3153-18
-
5-10
D-3153-3
D-3153-6
D-3153-6002
3-7
-
D-3153-7
D-3153-6001
0-3 and 9-13 w/2-stage Pilot
D-3153 Pneumatic Actuator Product Bulletin 3
Table 3: Accessories Description
Shipping Weight lb (Kg)
Code Number
Rubber Boot Kit
0.2 (0.09)
D-3073-100
Ball Joint weather resistant
0.3 (0.11)
D-3073-604
Blade Arm Kit
1.0 (0.45)
D-9999-100
Crank Arm 1/2 inch adjustable to 2-3/4 inch radius
0.5 (0.23)
D-3153-101
Crank Arm 3/8 inch adjustable to 2-3/4 inch radius
0.5 (0.23)
D-3153-108
Crank Arm 7/16 inch adjustable to 2-3/4 inch radius
0.5 (0.23)
D-3153-109
Linkage Rod 4 ft. (122 cm)
2.0 (0.91)
D-3153-102
Linkage Rod replacement
1.0 (0.45)
D-3153-103
Stop Screw Kit, 1/4 - 24 x 3 inches
0.5 (0.23)
D-3153-104
Proportional Pilot Positioner Kit
2.0 (0.91)
D-9502-8
Ball Joint
0.5 (0.23)
D-9999-104
Pivot Post, 5 per kit
0.5 (0.23)
D-3153-110
E-rings for Pivot Post, 10 per kit
0.5 (0.23)
D-3153-111
Mounting Nuts for Pivot Post, 10 per kit
0.5 (0.23)
D-3153-112
Universal Mounting Bracket
3.5 (1.13)
D-3153-105
Auxiliary Mounting Bracket
1.0 (0.45)
D-3153-106
2.0 (0.91) 2-stage Positioner Kit Note: Positioner kit includes: positioner, mounting plate, spring, and mounting hardware.
D-9502-9
Specifications Product Stroke Control Air Pressure
Air Connections Ambient Operating Conditions Effective Diaphragm Area Materials Dimensions (H x W x D)
D-3153 Pneumatic Actuators 3 inches (76 mm) 0-20 psig for HVAC 20 psig (137 kPa) minimum for safety damper functions 30 psig (205 kPa) maximum w/o pilot 1/8 inch NPT straight barbed fitting for 5/32 or 1/4 inch O.D. polytubing (furnished) compression fitting for 1/4 inch O.D. copper tubing (optional) -20 to 150°F (-29 to 66°C) 15 inch2 (97 cm2) Body - Die-cast Aluminum, Diaphragm - Synthetic elastomer See Figures 2 through 4.
Shipping Weight, lb (Kg)
D-3153-1 11.5 (5.2) D-3153-3 10.0 (4.5) D-3153-5 8.5 (3.9) D-3153-7 8.5 (3.9) D-3153-2 10.0 (4.5) D-3153-4 10.5 (4.8) D-3153-6 8.5 (3.9) D-3153-18 10.5 (4.8)
Agency Listing
UL Recognized component to 250°F (121°C) with compression fitting for copper tubing File No. R15581 D-3153-42 and D-3153-43 ULC Listed
For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.
Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53201
4 D-3153 Pneumatic Actuator Product Bulletin
Printed in U.S.A.
Section 7 – Compressor Vendor
Bulletin No.
Performance Request Form ........................................... Ajax Performance Runs ......................................................... Ajax Illustrated Parts List, 23” Cylinder .................................. Ajax
MB-0000
Illustrated Parts List, 13” Cylinder .................................. Ajax
F-0000
Rod Packing Manual .................................................................... C.L.Cook
Engine-Compressor Package Service Manual
TBP 97U
NOTICE:
Cameron – Ajax ® furnishes compressor design performance to assist you in compressor operation. If operating conditions change beyond the ranges shown, new performance conditions can be obtained by supplying your Cooper Compression Sales Representative with the information on the accompanying form. Alternately, our sizing software, eAjax ™, is available for your use without charge. It is Windows® based, and user-friendly. If you have access to the World Wide Web, go to www.aciservicesinc.com/ajax to download a current version of the software.
WARNING!
Improper setting of variable volume pockets, fixed volume pockets, valve unloaders, improperly de-activated ends, or other unloading devices can result in dangerous operation and possible damage and/or injury to equipment or personnel. Operating this unit without clearance and unloading information can result in failure due to overloading, excessive rod loads or high temperature.
Fill out and return to:
Cameron Compression Systems- Ajax Application Engineering 2101 Southeast 18th Street Oklahoma City, OK 73129-8351 Or Fax: 405-672-8103
Package Contract Number: Engine Model & S/N: Compressor Cylinder Model & S/N: Compressor Cylinder Model & S/N: Compressor Cylinder Model & S/N: Site Elevation (Feet): Max. Ambient Temperature (Deg. F): Suction Gas Temperature (Deg. F): Gas Specific Gravity: Gas “N” Value: Design Suction Pressure (PSIG): Anticipated Suction Pressure Range (PSIG): Design Discharge Pressure (PSIG): Alternate Discharge Pressure (PSIG): In addition to the above data a complete gas analysis should be supplied. Return address for performance: _______________________
Cameron Compression Systems, Ajax Division
eAjax Performance Software
DATE: Friday, June 01, 2007 TIME: 11:17:57 AM
Version = 02.05.02
QUOTE: MODEL: DPC-2802LE
2-Throws
CYLINDER ON THROW #1: YK11MA [23] (HE equipped with a manual VVP.) {Poppet Valves} CYLINDER ON THROW #2: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves} ARRANGEMENT: Two Double Acting Cylinders, One Cylinder per Stage. Elevation (m): Ambient Temperature (°C): Gas Gravity: Gas Compress. Used: KW Available for Compression:
199.9 Barometric Pressure (Bars): 37.8 Gas to be Compressed: 1.3370 Ratio of Specific Heats: Redlich-Kwong Rated Speed (RPM): 287.8 Non-lube Factor:
0.989 User Entered Gas Analysis 1.1440 440 1.00
Standard Conditions: Base Pressure of 1.0101 Bars and Base Temperature of 15.56°C. Suction and Discharge Pressures are considered measured at the skid edge. Run ID#-->> 1 ============================================================================================ Stage : Throw: 1 : 1 2 : 2 Speed (RPM): 440 440 Active HEs : CEs: 1 : 1 1 : 1 * Cyl. Bore Diameter (mm):0.05/84.20 0.03/30.20 Stroke (mm): 279.40 279.40 Max Gas RL-Cmpress (Kg): 7216 4170 Max Gas RL-Tension (Kg): 7124 3851 Max Net RL-Cmpress (Kg): 4695 4241 Max Net RL-Tension (Kg): 4236 3412 Min Rod Reversal (°): Passed Passed Rod Diameter (mm): 63.50 63.50 * HE Fixed Clearance (%): 10.80 12.60 * HE Set Clearance (%): 10.80 12.60 * HE's VVP Setting (mm): 0.00 0.00 * CE Clearance (%): 10.80 11.60 * FC Clearance (%): 10.80 12.11 Z-Suction: 0.9860 0.9695 Z-Discharge: 0.9693 0.9484 Minimum HE VE Suct. (%): 76.0 83.3 Minimum CE VE Suct. (%): 76.0 84.4 Suction Press. (bar): 0.1 2.6 Discharge Press. (bar): 2.7 7.0 Suction Temp. (°C): 10.0 54.4 Discharge Temp. (°C): 56.3 89.8 Cooler Temp. (°C): 54.4 48.9 Compression Ratio: 3.33 2.26 Load Per Stage (KW): 142.9 110.5 Load Per Unit (KW): 253.4 253.4 Per Unit Flow (KW/MMscmd): 3214.06 3215.05 Flow (MMscmd): 0.08 0.08 User Notes: Run#1 Run#1 Cooler (bar): 1.06=6% 2.31=11% VVP Throw#1 (mm): 0.00 VVP Throw#2 (mm): 0.00 ============================================================================================ PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION. Underlined items indicate corresponding Run ID# details a non-valid operating condition! Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%. Page 1 of 1
23" YK11MB Compressor Cylinder Assembly MB-0000 Ref # 1 2 3 * * * * 4 5 6 7 8 9 10 A B 11 12 13 SA SB SC SD SE SF SG 14 DA DB DC DD DE DF DG 21
Description Body Head Piston/Rod Piston Half Piston Half Stud Nut Ring Rider Ring Seal Rod Collar Nut Packing Packing Ring Gasket Cover Cage Valve Seat Guard Poppet Spring Screw Pin Spring Valve Seat Guard Poppet Spring Screw Pin Spring Gasket
Compr Cyl Compr Rear Compressor
Self Lock Compr Seg O Ring Compr Pstn Thrust Self Lock Compr Rod Set Wire Compr Vlv Valve Poppet Suct
Wire
Belleville Poppet Dis
Wire
Belleville Wire
P/N K-6955-B-1 K-6957-A-1 YK11M-2302-3 K-6966 K-6966-1 K-6967 BM-16428-E-1011 BM-17042-14 BM-17011-B-34 BM-16348-F-393 K-6598-L K-7074-C K-4799-F BM-16154-H BM-16012-D BM-16689-7 7-065636-001 K-6937-B VPP971-026 SPP9710&01 GPP9710&01 VPX-118&01 VXPS-005&01 1-02F-017-016-012 1-10F-001-008-003 VPX-065&1 VPP971-027 SPP9711&01 GPP9711&01 VPX-118&01 VXPS-005&01 1-02F-017-016-014 1-10F-001-008-003 VPX-065&1 BM-15777-G-6
Qty 1 ea 1 ea 1 ea 1 ea 1 ea 6 ea 12 ea 2 ea 2 ea 2 ea 1 ea 2 ea 1 ea 1 ea 5 ea 1 ea 12 ea 12 ea 6 ea 1 ea 1 ea 28 ea 28 ea 2 ea 2 ea 2 ea 6 ea 1 ea 1 ea 28 ea 28 ea 2 ea 2 ea 2 ea 16 ea
Ref # 22 23 25 26 27 28 29 31 33 34 35 36 38 39 42 43 45 48 49 50 51 52 53 61 62 63 75 76 77 78 79 80 81 82 83
23"YK11MB Compressor Cylinder Assembly MB-0000
Description Gasket Stud Stud Stud Screw Nut Nut Nut Connector Valve Elbow Tubing Plug Nut Bushing Nameplate Tack Bushing Valve Connector Tubing Tee Nipple Stud Nut Gasket Guide Fitting Screw Bar Handwheel Key Nut Screw Seal
Flat
Set Plain Hex Plain Hex Tube Compn Check Tube Compn Stainless Pipe Piston Rod Pipe Redn Metal Pipe Redn Needle Tube Compn Stainless Pipe Thded Pipe
Flat Rd Grease Drive
Square Plain Hex Socket Hd
P/N BM-17047-30 K-8093-1409-32 K-8098-2 K-8093-A-1808-42 BM-16485-1 06HN1400PC BM-19067-A-1409 BM-19067-1808 BM-11610-SS-4-2 BM-11580 BM-16310-A 04TU070240 BM-11950-04 A-1278-B BM-11942-02-01-S BM-10003-N-1 907-004-001 BM-11942-04-02-S BM-17025-N BM-11610-SS-6-4 06TU040240 BM-11961-02 BM-11934-02-05 K-8094-1409-35 BM-19067-A-1409 K-6293-B K-6455-A BM-10046 BM-1386-A K-6456-1 K-6960 K-6457-A BM-11917-2408 BM-11473-1608-28 BM-16741-A
Qty 12 ea 72 ea 14 ea 32 ea 6 ea 72 ea 14 ea 32 ea 4 ea 3 ea 2 ea 1 ea 5 ea 1 ea 1 ea 1 ea 4 ea 1 ea 2 ea 2 ea 2 ea 1 ea 1 ea 4 ea 4 ea 1 ea 1 ea 1 ea 2 ea 1 ea 1 ea 1 ea 1 ea 10 ea 1 ea
010407
23" YK11MB Compressor Cylinder Assembly MB-0000 Ref # 84 85 86 * * 87 88 89 90 91 92
Description Plate Aluminum Head Compressor Piston/Rod Adj Clear Piston Compressor Rod Compr Piston Ring Compn Seal O Ring Adapter Stud Nut Gasket Flat Rd
P/N BM-16417-A K-6956 YK11M-2307 K-7134 K-6426-C BM-16247-278 BM-16348-F-278 K-6698 K-8093-2007-44 06HN2000PC BM-19016-Z
Qty 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 2 ea 1 ea 8 ea 8 ea 1 ea
Ref #
Description
P/N
Qty
Not shown: cylinder-to-guide gasket p/n: K-6293-B
23"YK11MB Compressor Cylinder Assembly MB-0000
010407
13" YK11F Compressor Cylinder with Poppet Valves Assembly # F-0000 Ref # 1 2 3 4 5 6 7 8 9 10 11 A B 12 13 14 15 16 SA SB SC SD SF SE
18 19 20 21 26 27 28 29 30 31
Description Body, 13" Cylinder Head Crank End Piston Compressor Collar Piston Ring Piston Rider Ring Piston Plug Clearance Cage Valve Rod Piston Nut Self Locking Packing Rod Packing Ring Gasket Wire O Ring Head-to-Cyl Connector Tubing Tubing Stainless Gasket Valve-to-Body Valve Suction Seat Guard Poppet Spring Pin Screw Gasket, Valve Cap-to-Body Valve Cap Stud Valve Cap Nut Plain Hex Stud Cyl-to-Head Nut O Ring Cyl-to-Head Gasket, Clr Plug-to-Body Plug Pipe Flange, Clearance Plug
P/N K-6791-D K-6957-C-1 YK11F-1302-2 K-7074 BM-17042-3 BM-17011-B-54 K-6348-V-3 K-7783-B K-6598-E K-4799-F BM-16154-K BM-16011-K BM-16689-7 BM-16348-F-383 BM-11610-SS-4-2 04TU040240 BM-17047-14 VHP771-004 SHP7710&1 GHP7710&7 VPX-119&01 VPS-017&6 CSA-152-1-008-003 1-02F-015-024-012 BM-15777-G-9 K-6790-A K-8093-1409-33 06HN1400PC K-8093-2007-44 06HN2000PC BM-16348-F-224 BM-19016-F BM-11950-04 K-6433-D-6
Qty 1 ea 1 ea 1 ea 2 ea 2 ea 1 ea 2 ea 8 ea 1 ea 1 ea 1 ea 5 ea 1 ea 2 ea 4 ea 1 ft 8 ea 4 ea 1 ea 1 ea 19 ea 19 ea 2 ea 2 ea 8 ea 8 ea 32 ea 32 ea 16 ea 16 ea 8 ea 2 ea 3 ea 2 ea
Ref # 32 33 34 35 36 37 38 DA DB DC DD DF DE
39 41 42 43 45 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Description Stud Clr Plug Flange Nut Plain Hex Gasket, Water Jacket Cover, Water Jacket Capscrew Hex Head Plug Pipe Valve Discharge Seat Guard Poppet Spring Pin Screw Set Screw Valve Cage Stud, Packing Case-to-Head Nut Piston Rod Nut Tack Metal Plug Pipe Valve Check Elbow Tubing Gasket, JW In/Out Cover Cover, JW In/Out Capscrew Hex Head Bushing Pipe Nameplate Identification Nameplate Danger Stud, CE Head-to-Guide Nut Valve Needle Connector Tubing Tubing Stainless Tee Pipe Nipple Pipe
13" YK11F Compressor Cylinder with Poppet Valves Asssembly # F-0000
P/N K-8093-1011-26 06HN1000PC K-6769 K-6768 BM-11900-0813-07 BM-11950-01 VHP771-003 SHP7711&2 GHP7711&1 VPX-119&01 VPS-017&6 CSA-152-1-008-003 1-02F-015-024-013 BM-16485-2 K-8094-1409-35 A-1278-B BM-19067-A-1409 907-004-001 BM-11958-10 BM-11580 BM-16310-A K-7844 K-7845 BM-11900-0813-10 BM-11942-02-01-S BM-10003-N 914-175-001 K-8098-2 BM-19067-A-1409 BM-17025-N BM-11610-SS-6-4 06TU040240 BM-11961-02 BM-11934-02-05
Qty 16 ea 16 ea 2 ea 2 ea 20 ea 1 ea 4 ea 1 ea 1 ea 19 ea 19 ea 2 ea 2 ea 4 ea 4 ea 1 ea 4 ea 8 ea 2 ea 2 ea 1 ea 4 ea 4 ea 24 ea 1 ea 1 ea 1 ea 14 ea 14 ea 2 ea 2 ea 2 ft 1 ea 1 ea
021804
13" YK11F Compressor Cylinder with Poppet Valves Assembly # F-0000 Description P/N Bushing Pipe Redn BM-11942-04-02-S not shown Gasket, Cylinder-to-Guide K-6293-B 75 Guide VVP K-6455-1 76 Fitting, VVP Grease BM-10046 77 Screw Drive BM-1386-A 78 Bar Locking K-6456-1 79 Handwheel VVP K-6429-B 80 Key Square K-6457 81 Nut 06HN1600PC 82 Screw Socket Hd BM-11473-1608-28 83 Seal VVP Sten BM-16741-A 84 Scale VVP BM-16417 85 Head Cylinder K-6689 86 Piston/Rod VVP YKPC-1307 * Piston Compressor K-7133 * Rod Piston CompressorK-6426-B 87 Ring VVP Piston BM-16247-275 88 O Ring VVP Piston BM-16348-F-275 89 Adapter, VVP Guide-to-Head K-6677 90 Stud, Adaptor-to-Head K-8093-1807-42 91 Nut 06HN1800PC 92 Gasket, Adaptor-to-Head BM-19016-Y Ref # 68
Qty 1 ea 1 ea 1 ea 1 ea 2 ea 1 ea 1 ea 1 ea 1 ea 10 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 2 ea 1 ea 8 ea 8 ea 1 ea
Ref #
13" YK11F Compressor Cylinder with Poppet Valves Asssembly # F-0000
Description
P/N
Qty
021804
Section 8 – Process Gas Equipment Vendor Process Control Tubing Schematic ................................ Ajax
Bulletin No. 02-18-T020-353
Murphy L1200N DVO Liquid Level Controller Installation and Operation Manual........................................... Murphy
Dump Valve Assembly ................................................... Ajax
00-02-0175
TP 00-06-T01A-001
Murphy DVU-175 Dump Valve O & M........................................ Murphy
Vent Header Piping......................................................... Ajax
02-48-T010-388
Relief Valves and Fittings.................................................Ajax
02-17-T020-393
Mercer Relief Valve, 9100, O & M................................................Mercer
Blowcase Piping...............................................................Ajax Norriseal 3023 Control Valve, O & M...........................................Norriseal
Blowdown Piping..............................................................Ajax Morin Actuator O & M...................................................................Morin
Bypass Piping ................................................................ Ajax
00-06-T010-320 OM 704004M
02-47-T010-324 OMI 0802
02-50-T010-356
Ball Valve, WKM, 310F O & M.....................................................Ajax
Gauge Glass Assembly...................................................Ajax
00-06-T02A-001
Liquid Level Gauge Glass, Model RA-16.....................................Inferno
F1-4
Gauge Valves, Model 15A............................................................Inferno
M031196
Gauge Valves...............................................................................Inferno
A031231 & A031226
Auto Blowdown ESD Schematic......................................Ajax Norriseal Piston Check Valve.......................................................Norriseal
Engine-Compressor Package Service Manual
00-18-T020-351 707000M
00-02-0175 Revised 03-06 Section 15
Installation for L1100, L1200, L1200N Series Liquid Level Switches and DVU150, DVU175, and DVU2105/2115/2120 Series Dump Valves.
Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting. GENERAL INFORMATION **
Description Series L1100 and L1200 Liquid Level Switches are float activated to operate an electrical SPDT snap switch (optional DPDT on some models) for alarm or shutdown of an engine or electric motor. They screw directly into the wall of the vessel. Series L1200 can also be used with a weld collar or external float chamber.
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions. OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment. ✔ BE SURE all pressure HAS BEEN REMOVED from the vessel before opening any pressure connections.
Specifications
L1100
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump valves or similar devices. This model screws directly into the vessel or can be mounted via an external float chamber. It cannot be used with weld collar 15050375. Model variations include a dump valve operator with or without a filter/pressure regulator and indicating pressure gauge. NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and L1200NDVOR series carry Canadian Registration Number OF1476.2. Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a pneumatic input signal to cause an orifice to open or close allowing liquid condensate to be drained from a pressure vessel. A pop up button indicates valve open/closed. Stainless steel versions available. L1111
L1200
L1200N
L1200NDVO
L1200NDVOR
Body • Standard: Electroless Nickel plated steel • Optional: 316 Stainless Steel†
✗A ✗A
✗A ✗A
✗B ✗B
✗B ✗B
✗B ✗B
✗B ✗B
Pressure Rating • 15 psi (103 kPa) [1.03 bar] Polyethylene Float • 1500 psi (10.3 MPa) [103.42 bar] Stainless Float • 2000 psi (13.8 MPa) [138 bar] BUOYGLAS™ Float
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Temperature Rating • Standard: -20/175°F (-29/79°C) • Standard: -20/300°F (-29/149°C) • Optional: -20/400°F (-29/204°C)*
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Electrical • Standard SPDT: 5 A @ 125/480 VAC (see p. 3 for full ratings) • Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings)
✗ ✗
✗ ✗
✗ ✗
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
Specific Gravity • Standard: 0.5 with BUOYGLAS™ float • Optional: 0.65 with 304 Stainless Steel† • Standard 0.73 Polyethylene Float
O-Rings: Viton Valve: Two-way snap-action vent type • 1/8 in. (3 mm) orifice w/Viton “A” seat • 1/8 NPT inlet; 1/4 NPT vent • 30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure Dump Valve Operator: Operates Murphy DV Series dump valves or similar. 1/8 NPT inlet, outlet & vent. Pressure Regulator/Filter and Murphy 20BPG: 0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. Maximum input 300 psi (2.07 MPa) [20.68 bar]. 1/8 NPT in/out. Operation: H=For high level, L=For low level
✗
H
L
H
H
H
†Meets NACE standard MR-01-75 for direct exposure to H S service. *Not available with DPDT snap-switch. A =1-1/2 NPT B =2 NPT 2 **Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility. Installation 00-02-0175 page 1 of 6
H
DIMENSIONS L1200N, L1200NDVO and L1200NDVOR with Dump Valve Operator, Pressure Regulator and Gage
L1100 and L1200 11 in. (279 mm)
Pressure Regulator with 20BPG Pressure Gage
3-1/2 in. (89 mm)
2-3/16 in. (56 mm)
New Dump Valve Operator Assembly p/n 15010216
See Note 2
1/2 NPT
See Note 1 3-5/8 in. (92 mm)
Note 1: L1100: 1-1/2 NPT L1200: 2 NPT Note 2: 1-9/16 (40 mm) SF option: L1100: 1-1/2 (38 mm) L1200: 1-3/4 (44 mm)
1/8 NPT Old Round Dump Valve Operator Assembly p/n 15000940
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
1/8 NPT INLET
3-5/8 in. (92 mm)
5 in. (127 mm.) minimum clearance is required for float movement.
3/4 Hex (See Note)
2-3/16 in. (56 mm)
1/4 NPT VENT
1-9/16 in. (40 mm) SF option= 1-3/4 in. (44 mm)
2" 11-1/2 NPT
3-1/2 in. (89 mm) SF= 3-3/4 in. (95 mm) 11 in. (279 mm) SF option= 11-1/4 in. (286 mm) Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111 11-5/16 in. (287 mm) 3-53/64 in. (97 mm)
2-3/16 in. (56 mm)
DVU150, DVU175, DVU2105/2115/2120 Series Dump Valves
A
See Note
1/2 NPT
1-1/2 NPT 3-5/8 in. (92 mm)
Note: 1-9/16 (40 mm)
Pressure Inlet Port 1/8 in.-27 NPT
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
Manual Valve Operator
B
Vent Weep Hole Union
Valve Open/Closed Indicator Button
Electrical installation to be done by qualified person according to the NEC.
F Drain
C
Connection
D
E
shown G (dimension for reference only)
Plug Seal Model
A
B
C
D
E
F
G
DVU2120 DVU2115 DVU2105 DVU175 DVU150
7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191)
8.0 (203) 8.0 (203) 8.0 (203) 6.75 (171) 6.75 (171)
2.75 (70) 2.75 (70) 2.75 (70) 2.06 (52) 2.06 (52)
1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25)
2-11.5 NPT 2-11.5 NPT 2-11.5 NPT 1-11.5 NPT 1-11.5 NPT
1-11.5 NPT 1-11.5 NPT 1-11.5 NPT 3/4”-14 NPT 1/2”-14 NPT
1.03 1.03 1.03 1.03 1.03
NOTE: Dimensions are in inches and (millimeters)
Installation 00-02-0175 page 2 of 6
REPLACING AND INSTALLING THE DVOA ASSEMBLY
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR. Replacing and Installing the DVOA Assembly For Models L1200NDVO & L1200NDVOR
NOTE: Clean, dry instrument quality gas should be used. Use of filters will improve service life and reliability.
Tools Needed: Strap or pipe wrench; 3/4” Hex wrench; 9/16” hex wrench; needle nose pliers; tubing cutters and benders and the appropriate tools for the fittings. 1.
Block off and bleed the instrument gas pressure supply to the L1200NDVO. 2. Remove the tubing between the L1200NDVO and the separator dump valve, and remove the supply gas tubing (regulator [-R] if used). 3. Remove the L1200NDVO from the vessel (optional). 4. If the L1200N was removed from the vessel, mount it in a suitable vise on a work bench (if possible). 5. Using the proper tools, disconnect the Inlet, Outlet and Exhaust fittings from the existing DVO (see fig. 1). You will re-connect these to the new DVOA in a later step. NOTE: The following steps must be done with the DVO in the upright position (on top of the L1200N). 6. Remove the L1200N cover (this will aid with the alignment of the new DVOA Valve Bushing). The use of a strap wrench or a pipe wrench may be needed. 7. Insert the new Valve Bushing through the new DVOA (see fig. 2). The markings on top of the DVOA must be facing up. This will be needed in step 9. 8. With a 3/4” hex wrench loosen the existing DVO, valve stem, and static seal (see fig. 3). Once the assembly is loosened, VERY CAREFULLY use needle nose pliers to hold the Valve Seat Assembly in place. Remove the existing DVO making sure the Valve Seat Assembly inside the L1200NDVO is aligned and straight (see fig. 4).
Old DVO
Outlet (opposite side)
Inlet
Exhaust
Figure 1
Figure 2
New DVOA
Figure 3
CAUTION: MAKE SURE the Valve Seat Assembly inside the L1200N remains in place after removing the DVO. Holding the Seat Assembly up with the needle nose pliers inside the L1200NDVO body, place the tip of the new DVOA valve bushing through the spring and into the hole in the center of the valve seat, and tighten the valve bushing. The Valve Seat Assembly should be able to move freely up and down after the bushing has been tighten. The DVO red button must face away from the vessel. 10.With the new DVOA aligned over the hex on the L1200NDVO body, tighten the Valve Bushing using the 9/16” hex wrench. You may need to hold the DVOA while tightening the Valve Bushing to keep it from rotating (see fig. 5). 11.If the L1200N is in the vise, operate the float and inspect for smooth and proper operation of the Valve Seat Assembly. 12.Replace the L1200NDVO cover (see fig. 6). 13.Using the appropriate tools re-install the Inlet, the Outlet and the Exhaust fittings to the new DVOA (see fig. 5). 14 If the L1200N was removed from the vessel re-install it at this time. 15.Modify existing or install new tubing to connect the Inlet, the Outlet and Exhaust fittings.
Valve Bushing
Valve Seat Assembly
9.
Outlet
Figure 4
Inlet
Installation 00-02-0175 page 3 of 6
Exhaust
New DVOA
Figure 5
L1200N Cover
Figure 6
PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N
Direct Installation into the Wall of the Pressure Vessel 1. Determine that the float travel is not obstructed by the coupling in Tank the vessel wall, internal Wall baffles, etc. Do NOT use more than one arm extension P/N 15050395. Explosion proof 2. BE SURE that the float Level conduit seal Switch and extension are tight where required. and that the lock washer is in place. 3. Before installing the level switch a suitable pipe thread sealant is recommended. Screw the unit directly into the threaded connection in the wall of the pressure vessel. 4. Be sure that the electrical connection is positioned at the bottom. For L1200N the 1/8 NPT pneumatic connection should be on top (the 1/4 NPT vent connection should be on the bottom). See “Pneumatic models” section for further instructions for the L1200N. 5. Make the electrical wiring connections according to appropriate wiring diagrams for the alarm or shutdown system to be used. The electrical connection is 1/2-14 NPT. Electrical wiring and conduit should be installed by qualified personnel according to the NEC. 6. BE SURE all electrical connections are insulated and the cover is fully installed before reconnecting electrical power. 7. BE SURE all pressure connections are tight before pressurizing the system. Installation with a Weld Collar Tank Wall 1. The weld collar, P/N Weld Collar 15050375, must be welded into the wall of the pressure vessel according to code standards and good welding practices. L1200 2. Follow above instructions for installation directly into Explosion proof the wall of the pressure conduit seal vessel. where required. 3. NOTE: Weld collar 15050375 can be used ONLY with model L1200. It cannot be used with L1200N. Installation Using External Float Chamber 15051098
positioned away from the tank wall. 2. A tee is typically installed at the bottom of the lower 1 inch pipe riser to allow draining of the float chamber for servicing or replacement. NOTE: A typical installation Float with Blocking and Bleed valves is Chamber Tank shown at right. Block Valves 3. Install the L1200 or L1200N Level in the 2 NPT connection Switch of Tee the float chamber. Bleed BE SURE float travel Valve is not restricted and that the Explosion proof float is tight onto conduit seal where required. the float shaft. 4. To complete installation and wiring, follow the instructions for mounting directly into wall of the vessel and for wiring. Pneumatic Models 1. All pneumatic models operate on the vent Filter/Regulator Tank principle. The New Dump Valve Operator Assembly pneumatic signal Pneumatic p/n 15010216 Signal source MUST BE CLEAN AND DRY. The input pneumatic MURPHYGAGE® signal must be regulated between 30 L1200N and 70 psi (207-483 kPa) [2.07-4.83 bar]. If produced gas is used as the signal source, it should be taken after gas passes through the final scrubber. A suitable filter must be positioned before the L1200NDVO to prevent liquids and/or particulates from entering the dump valve operator. NOTE: Check filter periodically for wear and tear and elements that hamper the flow of the pneumatic signal. 2. All pressure connections must be tight and maintained tight so as not to leak air/gas. 3. Valve seat adjustment can be made if air/gas begins to leak. Care should be taken when adjusting as only slight movement is necessary to stop the leakage; excessive force will bind the
Hex Socket Set Screw • loosen for adjustment • tighten after adjustment
L1200N
CAUTION: USE “NON SPARKING TOOLING”. 1. Install the float chamber 15051098 on the outside wall of the pressure vessel using 1 NPT piping. Position the 2 NPT threaded connection at the height where you want the level switch to operate. The 2 NPT threaded connection must be
Hex Adjustment Nut • turn left until air seepage stops • Caution: only slight adjustment is needed—too much will lock up mechanism
Installation 00-02-0175 page 4 of 6
Trip Cam (float down) • should be in this position • non-adjustable
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation As condensate rises in the scrubber, the float on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber. Once the pressure enters the pilot chamber it forces the diaphragm and valve stem forward thus opening the valve seat (valve open/closed indicator button pops out) and releasing condensate through the valve stem and out the drain. As the condensate level drops, the L1200NDVOR pneumatic valve closes to shut off the pressure to the dump valve causing it to close. If for any reason the condensate continues to rise beyond normal dump levels, model L1200 operates the alarm and/or shuts down the equipment. The L1200NDVOR Filter/Regulator and the MURPHYGAGE® help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.
Typical/Scrubber/Separators VESSEL Minimum control pressure 30 psi (207 kPa) [2.07 bar]
Rising Level Shutdown L1200 (with snap-switch)
Explosion proof conduit seal required for Class I. Div 1, not required for intrinsically safe or non-incendive circuits like FWM TTD.
Rising Level Trips DVO
Electrical Conduit
L1200NDVOR Dump Valve Operator Union
Air Supply Maximum 300 psi (2.07 MPa) [20.70 bar]
Filter/Regulator with MURPHYGAGE®
Minimum control pressure 30 psi (207 kPa) [2.07 bar]
DVU Series Dump Valve Union Condensate Line (Out) Manual Drain Valve
REPLACEMENT PARTS
ELECTRICAL INFORMATION DPDT (Snap Switch) SPDT (Snap Switch) Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Switch Rating: 5 A @ 125-250- 480 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 2A @ 6-30 VDC Resistive 1A @ 6-30 VDC Inductive
Green Grd. Connection
Black N.O.
White COM.
Red N.C. Blue N.C.
Yellow COM.
Orange N.C.
Switch Rating: 10 A @ 125-250 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 10 A @ 6-24 VDC Inductive/Resistive
Order by part number designation. L1100/L1200* 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200 15000937: Stainless Steel float for L1100 15000124: SPDT snap switch assembly 15010213: L1100 counter balance assembly 15010214: L1200 counter balance assembly L1200N 15050420: Cam spring return 15050421: Cam 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200N 15050453: Valve stem 15010189: Counter balance assembly L1200NDVO and L1200NDVOR 55050621: Regulator only 05706499: 20BPG-D-75 Pressure MURPHYGAGE® 0-75 psi (517 kPa) [5.17 bar] 15010216: DVOA assembly (New rectangular style) 15000940: DVO assembly (Old round style) *To maintain hazardous location listings, all other repairs must be made by the factory.
Installation 00-02-0175 page 5 of 6
ACCESSORIES
Order by part number designation.
55050617: DVU150/DVU175 Adapter Bushing
15050375: Weld Collar
Material: 2-1/2 Hex bar stock C.R.S 2-1/16 in (52 mm) 1-1/16 in (27 mm)
2 NPT
2-1/2 in (64 mm)
2-7/8 in (73 mm) 3-5/8 in. (92 mm)
1 NPT
4-1/2 in (114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
2 NPT
15051098: External Float Chamber 3 in. (76 mm)
1-11.5 NPT (2 places)
2-11.5 NPT 10.5 in. (266 mm)
3 in. (76 mm)
1/2-20 UNF-2B (4 places) 7.55 in. (192 mm)
3.5 in. (89 mm)
Material: Cast Steel, WCB
7.01 in. (179 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
15000892: Float Shaft Extension 10-32 UNF
10-32 UNF 3/8 in (10 mm) 1-3/8 in (35 mm)
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
www.fwmurphy.com 918.317.4100 Email:
[email protected]
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0175 page 6 of 6
Set the control signal pressure at 45 psig.
NOTE If pressure or fluid comes out the weep hole of the union nut, either the o-ring under the union nut is leaking, or the packing could be leaking through the internal weep hole above that o-ring.
Dump valve operating temperature is -30ºF to 250ºF. Dump valve maximum process pressure is 1800 psi. Refer to the manufacturer’s bulletin for details.
Murphy DVU175 Dump Valve Assembly TP 00-06-T01A-001 Rev 2
Murphy DVU175 Dump Valve Assembly TP 00-06-T01A-001 Rev 2 Item 1 2 3 4 5 6 7
Description Dump Valve, Murphy 1" NPT x ¾" NPT Male Connector, ¾" Tube x ¾" NPT Bushing, 1" x ¾" NPT, 3000# Pipe Nipple, 1" NPT x 2"L, Sch 160 Pipe Tee, 1" NPT, 2000# Ball Valve, 1" NPT, 2000# Tubing, ¾" x 0.049 Wall
P/N
Qty
2003 6225 2507 1606 2527 1006 2539 8608 2545 4010 2549 2107 5551 4912
1 2 1 2 1 1 19"
00-02-0483 Revised 03-06 Section 15
Installation and Operation Manual for DVU Series Dump Valves Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120
Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes. GENERAL INFORMATION
Fig. 2 Dimensions (all models)
WARNING
A Pressure Inlet Port 1/8 in.-27 NPT
Manual Valve Operator
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
Description The DVU Series models are pneumatically controlled dump valves. The valves open and close automatically by pneumatic control from a Murphy L1200NDVOR or similar level controller and dump valve operator. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi (207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] vessel pressure (depending on the model). A key benefit of this design is a hex union that provides the ability to replace the seat without removing the valve from piping.
Fig. 1 Control Pressure vs. Working Pressure Control Pressure (PSIG)
C
Connection
D
E
shown G (dimension for reference only)
Plug Seal
Model
A
B
C
D
E
F
G
DVU2120 DVU2115 DVU2105 DVU175 DVU150
7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191)
8.0 (203) 8.0 (203) 8.0 (203) 6.75 (171) 6.75 (171)
2.75 (70) 2.75 (70) 2.75 (70) 2.06 (52) 2.06 (52)
1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25)
2-11.5 NPT 2-11.5 NPT 2-11.5 NPT 1-11.5 NPT 1-11.5 NPT
1-11.5 NPT 1-11.5 NPT 1-11.5 NPT 3/4”-14 NPT 1/2”-14 NPT
1.03 1.03 1.03 1.03 1.03
NOTE: Dimensions are in inches and (millimeters)
DVU2120
DVU2115
60
Specifications
50 40
Valve Open/Closed Indicator Button
F Drain
Minimum Actuation Pressure 70
B
Vent Weep Hole Union
DVU150/175
DVU2105
30 20 10 0
500
1000
2000
1500
Vessel Pressure (PSIG)
Model DVU2120 DVU2115 DVU2105 DVU175 DVU150
Inlet 2 NPT 2 NPT 2 NPT 1 NPT 1 NPT
Outlet 1 NPT 1 NPT 1 NPT 3/4 NPT 1/2 NPT
Trim Size 0.436 in. (11 mm) 0.576 in. (15 mm) 0.859 in. (22 mm) 0.359 in. (9 mm) 0.359 in. (9 mm)
Operating Temperature: -30 to 250°F (-34.4 to +121°C) Valve Operating Pressure: Refer to chart, Fig 1. Maximum Process Pressure: DVU2120: 2000 psi (13.8 MPa) [138 bar]. DVU2115: 1500 psi (10.3 MPa) [103 bar]. DVU2105: 500 psi (3.44 MPa) [34 bar]. DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar]. Flow Characteristics: See chart, page 4 (DVU150/175 models only). Body Material: Electroless Nickel Plated 12L14 Carbon Steel Internal Wetted Parts: Plug Seal: 90 Durometer Urethane. Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.). Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.). Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
Installation 00-02-0483 page 1 of 4
TYPICAL INSTALLATION ON GAS COMPRESSORS
Fig. 3 Scrubber/Separators Basic Operation As condensate rises in the scrubber, the float on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber. Once the pressure enters the pilot chamber it forces the diaphragm and valve stem forward thus opening the valve seat (valve open/closed indicator button pops out) and releasing condensate through the valve stem and out the drain. As the condensate level drops, the L1200NDVOR pneumatic valve closes to shut off the pressure to the dump valve causing it to close. If for any reason the condensate continues to rise beyond normal dump levels, model L1200 operates the alarm and/or shuts down the equipment. The L1200NDVOR Filter/Regulator and the MURPHYGAGE® help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.
NOTE: Always use clean, dry, instrument quality gas.
The Murphy Gas Compressor Scrubber Level System (SLS) The system provides for liquid control in gas scrubber applications, by dumping liquids to drain and protecting compressors with a high liquid level switch. Wetted metal parts are made to survive constant use in corrosive environments. See Bulletin: SLS-04005B for more details.
High Level Shutdown Switch Stainless steel float actuated level switches to alarm and/or shutdown the equipment. L1200: 2” NPT pipe connection; Rated 2000 psi (13.7MPa) [137bar]; Class I, Division 1. SPDT snap-switch standard. DPDT Optional. All Stainless Steel available.
Filter/Regulator & MURPHYGAGE®
Control Panel
“Instrument Quality Air/Gas Supply”
Pneumatic Level Control Float actuated level snap-acting switch controls pneumatic pressure to open and close dump valve.
Pneumatic Dump Valves See DVU-01069B
L1200NDVOR: Dump Valve Operator,
for more details. Two piece union design with manual valve operator allows soft plug and hard seat to be replaced without disassembling outlet piping or scrubber pipe connection. Diaphragm actuated valves operate on 30-70 psi (207-483 kPa; 2-5 bar).
pressure regulator, and pressure indicating MURPHYGAGE.®
DUMP VALVE INSTALLATION
DVU Series Installation Upper Assembly (removable)
CAUTION: ALWAYS USE “NON-SPARKING TOOLS” WHEN GAS IS KNOWN TO BE PRESENT.
Valve Union
Fig. 4 Typical Dump Valve Installation
Maintenance Bolt Valve Indicator Vessel Wall
The following describes the “Direct Mounting” method to the tank wall. 1. Install the valve so the drain connection is on the bottom. Use pipe thread sealant on all the connections. 2. Be sure the unit is screwed tight and does not leak. 3. Install the piping for the pneumatic input signal into the 1/8 NPT threaded connection of the pressure inlet port (on top of the diaphragm housing of the DVU). 6. Install a union between the DVU drain connection and the condensate out line. Use pipe thread sealant on all the connections.
Pneumatic Input Signal
Weep Hole Drain Connection Union Condensate Out 2-Way (Manual Drain) Shutoff Valve
Installation 00-02-0483 page 2 of 4
REPAIR PROCEDURE
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSIBLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED.
Suggested Tools (Sizes listed are wrench openings. Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, flat edge screwdriver with 1/4” blade width, can also be used .) Model
Valve Body
Union Nut
Plug Seal Hex
Stem Nut
3” 3” 3” 2-1/4”
3” 3” 3” 2-1/4”
7/8” 1” 1-1/4” 3/4”
1/2” 1/2” 1/2” 3/8”
DVU2120 DVU2115 DVU2105 DVU150/DVU175
Replacing the Plug and Seat 1. Close the pressure block valves (suction & discharge valves) on the inlet and outlet of the skid. Lock them closed if possible. 2. Open the blowdown valve to remove pressure from the unit. Lock the blowdown valve open if possible. 3. After taking all possible precautions to insure there is no pressure in the vessel. (If the condensate line is pressurized, it must also be blocked and locked.) Open the manual drain valve so it bleeds into the vessel so it can also be bled down. Disconnect the pneumatic input signal connection after insuring it also has been de-pressurized. 4. Using a back-up wrench on the valve body, with a quick "breaking" action loosen the union nut on the valve. There is a "weep" hole in the nut. If at any time while loosening and taking off the nut pressure is escaping through the "weep" hole, immediately stop loosening the nut. Retighten the nut and check the preceding procedures to ensure the pressure is bled off the vessel. Never remove the assembly if pressure is coming through the weep hole. See Figure 4 on page 2. 5. With the upper assembly removed from the vessel the plug and/or seat can be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of the diaphragm cover. Spin the nut up against the head of the bolt. Tighten the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN.
Fig. 5 Plug
Seat
Stem
Stem Packing
O-Ring Seals Against Outlet
Washer(s)*
Stem Nut
O-Ring
Crush Washer Seal
Seat butts into here
*Number of washers varies depending on the model from 1 to 3.
Fig. 6
Seal Washer Pressure Inlet
Maintenance Bolt 1/2" Nut
Diaphragm
Backup Plate
1-1/8" or 1" round nut
Stem
Spring
Diaphragm Housing
Diaphragm Assembly
6. Using a back-up wrench on the plug, remove the stem nut on the shaft under the plug. Once the stem nut is broken loose, the 9/16” head maintenance bolt and top assembly will keep the stem from turning. The plug turns freely on the stem once loose. The plug and seat can now be removed. All soft seals should be replaced. Refer to kit part numbers under service parts on page 4.
Replacing the Diaphragm 6A. If the diaphragm is to be replaced, all preceding steps have to be done. Additionally, do the following: 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm spring to relax, and the stem to retract. Make alignment marks on the top and bottom halves of the diaphragm assembly for alignment during re-assembly. 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing together. 6D. Using a straight edge screwdriver, gently separate the 2 halves of the diaphragm housing, and remove the top, or outside portion. 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex or 1” round nut on the bottom of the diaphragm assembly to be accessible to a wrench and not have the spring interfere. If it is desired to replace the packing, pull the stem all the way out. The packing can be easily removed using a small screwdriver to pry the packing out. The new packing can be simply pressed in, making sure the orientation of the packing installed is the same as the orientation of the packing removed. The packing is wider toward the plug end. You will have to use the seat to hold the packing in place when re-inserting the stem. 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a wrench to loosen and remove the 1/2" nut on top of the diaphragm. The diaphragm can now be removed and replaced. 6G. With the new diaphragm in place and the 1/2" nut tightened, place the assembly, diaphragm down on a clean, smooth sturdy surface. 6H. Have the seat, plug, washers and stem nut handy (if any of these parts are to be replaced, use the old parts for this procedure). Press down evenly and smoothly on the bottom of the diaphragm assembly to cause stem to come up. Place the seat and plug in place. Then push the bottom of the diaphragm assembly down far enough to install the washers and stem nut on the stem. Tighten the stem nut enough to hold against the diaphragm spring. 6J. Align the diaphragm holes to the bolt holes (bottom half of the housing). Install the upper diaphragm housing using the alignment marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the bolts evenly going from one bolt then 180° around to the next bolt, then either 120°or 240° around to the next bolt and so forth until all 8 bolts are evenly tight. 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem out until the 9/16"bolt stops – DO NOT OVERTIGHTEN. 6L. Remove the stem nut holding the plug. (If old parts were used, prepare to install the new parts now.)
7. Install the seat and plug. Place the O-ring on the stem, followed by the washer and stem nut. 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one turn past the point where it is no longer in contact with the stem. Tighten the 9/16" jam nut holding the 9/16” head maintenance bolt. 9. Replace the crush washer and the O-ring hidden by the union nut. NOTE: If pressure or fluid comes out the weep hole of the union nut, either the O-ring under the union nut is leaking, or the packing could be leaking through the internal weep hole above that O-ring. 10. The assembly is ready to be re-installed. Check for relative position of the pneumatic input signal connections before tightening the union nut.
Installation 00-02-0483 page 3 of 4
PRESSURE VS. FLOW CHART
Pressure vs. Flow for DVU150 and DVU175 models only
Fig. 7 250 250
200 200
Pressure (psid)
150 150
100 100
50 50
0
0
5
10
15
20
25
30
35
40
45
Flow (gpm)
SERVICE PARTS
Part No.
Typical Diaphragm Repair Kit includes: Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate (1 or 2 pcs.), Packing, “O” Ring, Stem, Seal Washer for Maintenance Bolt.
Description
DVU2120 55-00-0237 55-00-0236
Seal Kit (includes plug) Diaphragm Kit
The DVU Series Valve is included in the following Scrubber Levels Systems.
DVU2115 55-00-0241 55-00-0240
Seal Kit (includes plug) Diaphragm Kit
(Includes L1200, L1200NDVOR, and DVU valve) SLS2120: Includes DVU2120 valve SLS2115: Includes DVU2115 valve SLS2105: Includes DVU2105 valve SLS175: Includes DVU175 valve SLS150: Includes DVU150 valve -LR: Less Regulator option
DVU2105 55-00-0245 55-00-0244
Seal Kit (includes plug) Diaphragm Kit
DVU175 55-00-0230 55-00-0231
Seal Kit (includes plug) Diaphragm Kit
DVU150 55-00-0230 55-00-0231
Seal Kit (includes plug) Diaphragm Kit
Warranty
Typical Seal Kit includes: Nut, Washer (1 to 3), “O” Ring, Plug and Seal, Seat, Crush Washer.
www.fwmurphy.com 918.317.4100 Email:
[email protected]
A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0483 page 4 of 4
Page 1 of 4
Installation, Operation and Maintenance Manual
W-K-M® DynaSeal® 310F 2-Piece Flanged End Ball Valve
9 8 6 5 4 3 2 11 12
13 14
10
1
10 17
15
310F 1"F thru 2" R
16
Table of Contents Scope ...................................................... 1 Nameplate Information ............................ 2 Storage...................................................... 2 Installation ............................................... 2-3 Operation .................................................. 3 Routine Maintenance ............................... 3 Trouble Shooting ..................................... 4
8 6 5 4 7 3 2
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Description Body Packing Compression Ring Bonnet Cap Cap Screws Stop Plate Retainer Ring Handle/Lever Lock Nut Seat Ring Stem Seal Stem Ball Tailpiece Gasket Tailpiece Nut Stud
11 12
1 17 13 10 15 16
14
10
310F 2"F thru 4" R
Scope The W-K-M DynaSeal 310F ball valve is designed to meet tougher industry requirements while maintaining key features of the W-K-M floating ball valve. It has deep-pocketed seats, an adjustable, replaceable stem packing and is available in carbon steel and stainless. The 310F is offered in sizes 1F" to 4"R and class 150, 300 and 600 flanged ends.
W-K-M DynaSeal 310F 2-PieceBall Valve Installation, Operation and Maintenance Manual
Publication TC-1473
Page 2 of 4
Nameplate Information W -K -M
Item 1 2 3 4 5
Description Assembly part number Nominal valve size and type designation Model number Ball-Stem material designation Body & Seat-seal code designation
Storage After valves are assembled and tested, they are placed in the full open position, flange seal surfaces and bores are greased and end protectors are installed. This will provide adequate protection for indoor storage. Extended outdoor storage requires periodic inspection and the addition of a corrosion inhibitor. Contact your CCV representative for extended storage guidelines. Valves should only be stored in the full open or full close position to prevent seat distortion.
Installation DynaSeal 310F ball valves may be installed in any position with flow from either direction. However, for best service life there is a preferred vertical or horizontal position to maximize sealing and minimize the accumulation of sediment. In the vertical position it is preferred to have the upstream pressure from above so the weight of the ball will assist the pressure in sealing. With the run of the valve in a horizontal position, it is preferred to have the stem lying horizontal (i.e. toward the viewer) with pressure from the right. During operation, flow will act as a siphon and minimize retention of sediment. When handling or installing a valve, keep the valve in the full open position whenever possible to prevent foreign object damage to the ball.
Publication TC-1473
Item 6 7 8 9
Description Maximum operating pressure Maximum working pressure Maximum temperature Date of manufacture
Flanged-End valves may be bolted into the line using two open or boxed end wrenches. 1. Threads of flange bolts and nuts should be lubricated to obtain maximum loading of bolts. 2. Finger tighten all nuts first. 3. When tightening bolts, use the crisscross method and torque each bolt to ANSI or gasket manufacturer specification. Field testing, if performed after the valve has been properly installed into the line, should be done in accordance with the following procedure: Caution: Ensure that all test fluids contain corrosion inhibitors and are compatible with valve seat and seal material. 1. Preliminary Testing - Completely flush the system or the line to minimize damage to the seats and ball surface which might be caused by weld slag or other foreign matter resulting from installation procedures. 2. Line Testing - When performing this test, the valve should be in the half-open position to ensure that the body cavity is completely filled with the test media and to prevent accidental over pressure of the seats. NOTE: Line may be tested at a maximum of 1-1/2 times the valve's cold working pressure rating without consulting the factory. 3. Seat Testing - When testing the seats with the
W-K-M DynaSeal 310F 2-PieceBall Valve Installation, Operation and Maintenance Manual
Page 3 of 4
valve in the closed position, do not exceed the valve's cold working pressure rating. 4. Upon completion of testing, purge all test fluids from the valve.
Operation DynaSeal 310F ball valves operate from fully open to fully close by a 90-degree turn of the handle. The handle aligned with the pipe always means the valve is open and with the handle perpendicular to the pipe means the valve is closed. Additionally, the stems have flats that align the handle and can be used to indicate ball position. The bore of the ball is parallel with the faces of the stem flats. DynaSeal 310F valves may be power actuated. Pneumatic and hydraulic actuators, whether of the fail-open, fail-close, or fail-last position type, have "Open-Close" indicators on the top of each unit. On a pneumatic actuator, make sure filters and lubricators (if recommended by the actuator manufacturer) are installed prior to valve and actuator installation. Should any maintenance be necessary, obtain the part number from the unit's nameplate and contact Cooper Cameron Valves or the nearest representative.
Routine Maintenance Due to its design and simplicity the 310F ball valve requires very little maintenance. It's nonlubricated, self-cleaning ball can provide reliable, leak-free performance over a long period of time. The only preventative maintenance recommended is to periodically inspect the valve for leaks around the stem or actuator. Should a leak be noticed, the following procedure is for adjusting the packing. Stem Packing Adjustment 1. With an Allen wrench, snug up each of the two packing adjustment screws in a clockwise direction. 2. Snug up each screw an equal amount only as much as required to stop the leak, not to exceed the maximum specified in the following table. 3. The following table gives torque values that will seal stem packing in good condition. Torque values above this indicate seals are worn and need replacement and excessive tightening will also cause an unacceptable increase in valve stem torque.
Torque Values for Packing Adjustment Screws Valve Size
Torque (Packing) Screw Size in-lb (kg-m)
1F
1/4-20 NC
36-60
(0.4-0.7)
1-1/2F & 2R
5/16-18 NC
60-120
(0.7-1.4)
2F & 3x2
3/8-16 NC
120-180
(1.4-2.1)
3F & 4R
1/2-13 NC
180-240
(2.1-2.8)
W-K-M DynaSeal 310F 2-PieceBall Valve Installation, Operation and Maintenance Manual
Publication TC-1473
Page 4 of 4
Warning: Valves should be placed in a partially open position prior to working on valve or removing it from service to vent pressure or drain product that may be trapped in the body cavity.
Troubleshooting Chart Trouble Will not open or close
Probable Cause a. Iced up due to restricted flow or low temperature. b. Pressure locked. (Condition in which the body pressure exceeds the line pressure by an excessive amount.
Remedy a. Flush out with warm material. b. Reduce valve temperature or pressurize line to rated working pressure to reduce pressure differential sufficient to operate valve.
Hard to operate
a. Accumulation or solidification of material in the body of valve. b. Swelling seats c. Corrosion between stem and valve body. d. Operator not installed properly
a. Flush valve to get material out of body. b. Install correct trim.* c. Apply penetration oil around stem. If still won't operate disassemble valve and polish stem.* d. Check operator.
Will not seal properly
a. Worn or damaged seats and/ or ball. b. Foreign matter between seat and ball. c. Operator stops not properly set.
a. Replace worn parts.* (Requires valve removal and disassembly) b. Operate several times to wipe clean. c. Adjust stops to proper setting.
Valve leaking between body and tailpiece
a. Leaking tailpiece gasket b. Tailpiece and valve body are not tightened together properly.
a. Replace gasket.* (Requires valve removal and disassembly) b. Tighten parts to specified torque.*
Leaking around stem
a. Loose stem packing b. Worn or damaged stem packing.
a. Adjust stem packing screws. b. Replace stem packing.*
*Contact your CCV representative for a Repair Manual
Headquarters Cooper Cameron Valves 16500 South Main Street Missouri City, TX 77489-1300 Phone: 281-499-8511 800-323-9160 Fax: 281-499-6965
USA Cooper Cameron Valves 845 S.E. 29th Street Oklahoma City, OK 73147 Phone: 405-631-1321 Fax: 405-629-0420
Scotland Cooper Cameron Valves Houstoun Industrial Estate houstoun Road West Lothian EH54-5BZ Livingston, Scotland Phone: 44-1506-444-000 Fax: 44-1224-783-355
http://www.ccvalve.com ©Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 02-01 / TC-1473 W-K-M® and DynaSeal® are trademarks of Cooper Cameron Corporation
Publication TC-1473
W-K-M DynaSeal 310F 2-PieceBall Valve Installation, Operation and Maintenance Manual
MODEL 15A GAGE VALVES APPLICATION— Pressure Rating:
3000 PSI @ -20°F to 100F
2850 PSI @ 300°F
2625 PSI @ 500°F
INSTALLATION—
DO Plumb tailpieces to avoid misalignment.
DON’T Create additional misalignment. Some misalignment is usually present due to errors in concentricity of pipe threads, weld distortion in couplings, etc. Don’t make it worse!
DO Make up unions tight. Use at least an 18” wrench. Union is designed to crush solid metal along a high ridge, creating a “line” seal between the taper and the flat surfaces. Union will seal pressure without need for O-ring if alignment is good enough and if the installation torque has been efficiently transmitted into tightening the joint. However, if there is significant misalignment in the piping arrangement then some of the “umpf” experienced during make-up has been diverted into deflecting the piping. This causes resistance to further turning of the nut and may leave insufficient tightness in the metal to metal seat of the union for sealing. In this case the O-ring will finish the job. The joint needs to be tight enough (close enough) to close the extrusion gap for O-ring to maintain its seal.
1.5° TAPER (Union Nut omitted for clarity)
More severe MISALIGNMENT can lead to leaks at the union or broken pipe nipples or broken tailpieces. If you are experiencing these difficulties ask for Inferno SPHERICAL UNIONS available as a separate male x male union or built into the valve itself.
DO Make up unions using a BACK-UP WRENCH on the valve body. Failure to use back-up wrench causes excessive stress on the connecting nipple and can lead to breakage of nipple or harmful twisting to sight glass.
BACK-UP WRENCH POINTS
OPERATION— BALL CHECKS... Open valves full open during operation to assure safety action of ball check in case of glass or gasket failure. Stem must be open more than 1-1/2 turns before ball is allowed to back seat. Extension on end of stem will deny ball a seating position until valve is opened sufficiently. At this point the extension of the stem retreats enough to allow ball to check closed in event of sudden loss of pressure in the sight glass. Ball checks are designed to limit flow from vessel in case of accidental glass or gasket failure. They can be of great help in limiting the blow-out effect of pressure acting on a shattered glass. But— they are not intended to provide a perfect seal. Dirt, trash and corrosion in the ball check cavity and back seat area will limit the tightness of the emergency shut-off. In such cases there may be some degree of leakage past the ball checks. Ball check will not activate in case of seepage caused by a leaky gasket. Ball check may not activate at all if cavity is packed with M031196 sheet 1/2
1 1/03
Ball checks cont’d... corrosion. Ball check requires pressure in the vessel to activate. About 7” head of water is sufficient pressure to check the ball in water service with a full flow leak. More pressure is required to check with a choked off leak. Performance in other fluids will vary. Ball check may not activate in extremely viscous fluids. If in doubt as to whether ball checks are present in an existing installation or whether or not they are working properly you can test as follows: Close off the upper gage valve. Leave the lower valve open. Open a drain valve rapidly and listen for the ball to make an audible “click”. Now repeat process reversing the upper and lower valve position. Restore fluid level in sight glass by closing drain and then moving both valves into the cracked open position. Cracking the valves open will cause the stem extension to unseat the ball and allow it to drop back into its normal resting place. If sight glass fails and balls are activated then manually close both valves. Be aware that a small amount of fluid will escape as the balls are dislodged and before stem has a chance to fully close. Take necessary precaution. BLOW-DOWN... DON’T blow down sight glass with valves open. High velocity flow will cut seat and lead to failure of valve to close without leakage. This problem is especially common in steam and hot water applications. However if it is not convenient to blow-down the hot water sight glass with valves in the closed position then DO install a second valve (ball or gate) to insure that a tight shut-off can be made for maintenance purposes during normal plant operation. A double block system may be required if you experience cutting in the seat area. Shut off upper and lower valves first, then blow down sight glass through the lower valve’s drain connection, or through an additional outlet at the bottom of the sight glass. Restore fluid level in sight glass by closing vent and drain and then cracking open the upper and lower valves. Cracking the valves open prevents nuisance ball checking. After level has been reestablished open the valves full open. In the full open position the ball is able to check autmatically in case of glass failure. In cracked position it will not check. SHUTDOWNS... It is usually best to leave valves in normal full open position as the system is de-pressurized. This prevents excessive thermal stress on the sight glass and valves and prevents trapping high pressure fluid. During START-UP pressure and temperature are allowed to equalize slowly in the sight glass.
SPARE PARTS FORMODEL 15A— O-ring, Viton™, Size 2-116 (90 durometer) P/N 4761
3/4” NPT Tailpiece, Steel P/N 4613 1/2” NPT Tailpiece, Steel P/N 4612 Union Nut, Steel P/N 3882
Stem Packing, Teflon™ standard, to 500°F P/N 4347
Optional Materials O-Ring, EPDM E0962-90, Size 2-116, for hot water & steam P/N 4938 O-Ring, Parofluor Ultra, Size 2-116, for hot water & steam to 525F P/N 6965 Stem Packing, Grafoil™, over 500°F P/N 3509 New Item Spherical Union- Corrects for angular misalignment in piping.. reduces all piping strain.Re-usable joint seals gas-tight multiple times. Best when used with Close Hook-up (CH) level gages having side or back outlets. Position the spherical union between the side or back outlets of the “CH” level gage and the gage valve. If C-C does not match, rotate the vessel connection of the valves until the ball will fit into socket. By allowing the valves to rotate non-parallel to each other the spherical union will correct a relatively large C-C difference between assembly and vessel. Purpose of spherical joint between gage and valve is to eliminate piping strain. May also be used with CH level gage without valves for direct connection to vessel or piping Should be used in conjunction with a plain, flat, “Floating Union” in a matched set. In this way angular misalignment and C-C difference may be overcome. Available in Steel and Stainless, Std. O-Ring is Viton 1/2” x 1/2” 3/4” x 3/4” 1/2” x 3/4”
COMMENTS AND SUGGESTIONS WELCOME INFERNO MFG. CORP. SHREVEPORT, LOUISIANA www.infernomfg.com TEL: 318-221-8454 FAX: 318-222-4106 email:
[email protected]
M031196 sheet 2/2
1 1/03
OPERATING and MAINTENANCE MANUAL SERIES 7100 “FLO-LIFT”© PISTON CHECK VALVE SCOPE
2.0
DISASSEMBLY
This manual provides information on installation, operation, maintenance, and parts for Norriseal Series 7100 Piston Check Valve.
Note: Numbers in parentheses refer to items shown in figure 1 and figure 2. 1.
GENERAL DESCRIPTION The Series 7100 Piston Check Valve is designed for lowpressure drop and positive prevention of backflow. It is suitable for use with either gas or liquid systems. The control orifice and ball check built into the plug provide a cushioning or dampening effect for the plug making this valve suitable for pulsating flows of gas or air. 1.0
CHART I STUD SIZE 0.62 0.75 0.88 1.00 1.12 1.25 1.38 1.50 2.00
INSTALLATION 1.
Before installing the valve, inspect for shipping damage and/or any foreign material that may have collected during crating and shipping. Remove flange protectors.
2.
Flush out inlet piping to remove pipe scale, chips, welding slag, and other foreign materials.
3.
Valve must be installed so that flow is in direction indicated by the arrow tag attached to the side of body. Also note the word "INLET" engraved in flange O.D. at inlet end of body.
4.
5.
6.
Install the valve using good piping practice. For flanged bodies, use a suitable gasket between the body and pipeline flange. If continuous operation is required during maintenance and inspection, install a conventional three-way bypass around the body. The bodies are rated at 150, 300, 600, 900, 1500 and 2500 ANSI class. Do not install the valve in a system where the operating pressures exceed those specified in the standards.
2.0 NORMAL MAINTENANCE SCHEDULE CAUTION: Before starting any repair or maintenance, make sure that all pressure has been released from valve body. Before unbolting bonnet, SLOWLY LOOSEN pipe plug in top center of bonnet. While loosening plug, listen for sound of gas pressure escaping around plug. Do not remove bonnet until all trapped pressure, if any, has escaped.
Remove nuts (14A) from bonnet studs (14B). Required wrench sizes are as follows:
WRENCH SIZE 1.06 1.25 1.44 1.62 1.81 2.00 2.19 2.38 3.12
2.
Lift bonnet (6) straight up and remove from body (13).
3.
Remove load spring (5) by lifting straight up and out of body.
4.
Valve plug (1), cage (3), and guide (4) may be removed by means of lifting attachment (1D) screwed into top of plug.
5.
After removal from body, the plug, cage, and guide may be separated by lifting guide (4), then cage (3) over top of plug.
6.
Remove plug seal (11) from recess in lower end of guide.
7.
Remove seat (2) and seat gasket (9) by lifting them out of recess in body.
2.1
INSPECTION Follow valve disassembly as outlined above; carefully inspect individual components as follows: 1.
Plug Seal: Construction consists of a stainless steel spring surrounded by a TFE jacket. Examine spring to be sure it is not bent or permanently crimped. The TFE jacket should be carefully examined under good lighting conditions. In order to function properly, the jacket must be free of scratches, cuts, and tears.
Caution: Before disassembly or maintenance, all pressures in this device must be relieved. Failure to relieve pressures may result in personal injury or device damage. The resulting uncontrolled venting or spilling of line fluids may cause personal injury, loss of process control, or environmental contamination. January 2002
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 1 of 6
ITEM 1 2 3 4 5 6 7 8 9 11 12 13 14 15
DESCRIPTION Piston Assembly Seat Valve Cage Piston Guide Piston Spring Piston Bonnet Valve Gasket Bonnet Gasket Guide Gasket Seat Seal Piston Plug Vent Body Stud Bonnet w/Nut Eye Bolts
FIGURE 1 .2
Valve Plug: Inspect plug as follows: O.D. of plug slides through seal ring and therefore must be free of nicks and scratches that could damage the TFE jacket. Handle plug carefully to avoid damage during maintenance. Examine seating surface for scratches, nicks, or gouges that could impair shutoff. If plug has a non-metallic soft insert, this item should be closely examined, as it is particularly susceptible to damage. Construction may be solid (1-piece), or may be an assembly of three or more basic components as described below.
.2B Composition (Non-Metallic)-to-Metal Seating (Figure 3):
.1
1” valve size consists of five basic components assembled and secured with a screw.
.2
1.5” valve size consists of three basic components assembled and secured by a castellated nut and cotter pin.
.3
2.0” valve size consists of three basic components assembled and secured with two screws.
.4
3” & 4” valve sizes consist of four basic components assembled and secured by a screw.
.5
6” & 8” valve sizes consist of four basic components assembled and secured by four screws.
.6
10” valve size consist of four basic components assembled and secured by six screws.
.2A Metal-to-Metal Seating (Figure 2) .1
1”, 1.5”, 2”, 3”, and 4” valve size: Plug is solid 1-piece construction with integral seating surface machined near-bottom of plug.
.2
6”, 8”, 10”, and 12” valve size: Plug is multi-piece construction with replaceable seating insert secured to plug butt with four screws.
January 2002
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 2 of 6
HARD TRIM – FIGURE 2
ITEM 1A 1B 1C 1D 1E 1F 1G 1I 1J 1L
January 2002
DESCRIPTION Orifice Plug Check Plug Nut Screw Lifting Screw Lifting Piston Butt Piston Retainer Piston O-Ring Retainer Screw Retainer Washer Lock Spring
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 3 of 6
SOFT TRIM – FIGURE 3
ITEM 1A 1B 1C 1D 1F 1G 1H 1I 1J 1L 1M 1N
January 2002
DESCRIPTION Orifice Plug Check Plug Nut Screw Lifting Screw Lifting Butt Piston Retainer Piston Insert Piston O-Ring Retainer Screw Retainer Washer Lock Spring
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 4 of 6
.7 12” valve size consist of four basic components assembled and secured by twelve screws.
back against seat. After inspection and cleaning, reinstall ball check in valve plug. Examine orifice for presence of foreign matter and clean as required. Reinstall orifice plug in valve plug. This completes inspection and maintenance of valve plug.
If inspection of insert-type plug shows all components to be in good condition, it is not necessary to disassemble plug and remove insert. However, if disassembling plug for replacement of insert, proceed as follows: (Refer to Figure 3). A) Plug may be secured in inverted position in a vise for disassembly. However, if using a vise, place blocks of wood or other soft material on both sides of plug to protect surface finish.
.3
Valve Seat: Beveled seating surface must be free of nicks and scratches. Inspect under-side of seat for scratches or other imperfections that would impair proper sealing against seat gasket.
.4
Cage, Guide, and Load Spring: These components should not suffer any adverse effects from normal operation. However, with valve disassembled, they should be examined to verify that they are in good condition.
.5
Valve Body: With seat and bonnet gaskets removed from body, inspect gasket recesses for scratches or foreign matter that would impair gasket sealing. Clean gasket recesses as required.
B) Remove cap screws (1J) using wrench size from Chart 2. C) Remove retainer, insert, and o-ring seal from butt-plug. D) To reassemble plug, install o-ring, insert, and retainer in their respective positions. E) Reinstall cap screws. Recommended values for torquing cap screws are: Valve Size 1” 1.5” 2” 3” 4” 6” 8” 10” 12”
# Of Screws 1 1 2 1 1 4 4 6 12
Screw Size 5/16-24 7/16-20 3/8-24
Torque (Ft. Lbs.) 8 30 15
Wrench Size ½” 11/16” 9/16”
½-13
60
¾”
5/8-11
70
15/16”
# Of Ball Checks 0 1 2 3 3
Orifice plug and ball check contain small fluid passages, which must be free of foreign matter for proper valve operation. Ball check may be removed from valve plug using a socket or wrench. Examine ball check and remove any foreign matter present. Operation of ball check may be verified by inserting a small rod, less than 0.25" diameter from upper end. Only light finger pressure should be required to push ball off seat. With pressure removed, ball should snap
January 2002
REASSEMBLY NOTE: Each Series 7100 Piston Check Valve requires three (3) gaskets of three (3) different sizes. .1
Place seat gasket in body recess, and install seat on top of gasket. IMPORTANT: Seat must be oriented with 45 degree beveled surface facing upward.
Following reassembly of plug, place in upright position for inspection of orifice plug and ball check. All valves have one (1) orifice plug installed in top of valve plug, but number of ball checks varies with valve size as follows: Valve Size 1” 1.5”, 2”, 3” 4” 6”, 8” 10”, 12”
2.2
.2
Place plug guide on work surface in inverted position (deep recess facing upward).
.3
Install plug seal in deep recess in guide. Orientation of seal must be so that open side of seal, with spring visible, faces upper end of guide. Thus, with guide in inverted position, only the TFE jacket will be visible after seal is installed.
.4
Place valve plug on work surface in normal upright position. Place valve cage over plug with extended shoulder on cage oriented toward top of plug.
.5
Turn guide over to its normal position and slip over top of plug. NOTE: Due to seal ring being squeezed between guide and plug, it may be necessary to gently tap guide into place.
.6
Place smallest of three (3) gaskets into recess in top of guide
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 5 of 6
.7
Entire plug/cage/guide assembly may be picked up by lifting attachment in center of plug. Place the assembly into valve body, carefully positioning cage over locating shoulder on seat.
.8
Install load spring in recess in top of plug.
.9
Install remaining gasket in recess in top of body.
.10 Install bonnet on top of body.
.12 Tighten bleeder plug (pipe plug) in top of bonnet. This completes valve reassembly. 3.0 PREVENTIVE MAINTENANCE .1
SEAT: Check seat every six (6) months if in normal service, i.e., no sand or abrasives and low pressure drop. If in severe service, i.e., highpressure drop and sanding condition, check every sixty (60) days.
.2
PISTON: Same as .1.
.3
GENERAL: When disassembling any portion of valve, always check seal rings and gaskets for damage or wear before reassembly.
.4
BODY: Under normal conditions, body should last years. However, under severe conditions, i.e., corrosion, sand and high-pressure drop, valve life could be numbered in days only.
.11 CAUTION: Tighten the bonnet-to-body bolts to the recommended torques given in the following table (Follow good bolting practice and lubricate bolts). The Bonnet Bolt Torque Chart below shows stud size in inches and recommended torque value in FT-LBS for valve sizes and pressures classes, as listed. NOTE: Spiral wound gasket bolt-up characteristics are such that tightening of one bolt may loosen an adjacent bolt. This will occur on subsequent tightening of all the bolts until the bonnet-to-body seal is made. This requires several trials on each bolt until the nut does not turn at the given torque.
VALVE SIZE Stud 1” Torque Stud 1.5” Torque Stud 2” Torque Stud 3” Torque Stud 4” Torque Stud 6” Torque Stud 8” Torque Stud 10” Torque Stud 12” Torque
January 2002
BONNET BOLT TORQUE CHART ANSI PRESSURE CLASS 150 300 600 900 1500 .75” 110 120 .62” .75” 85 160 .75” 75 80 175 .75” 1.00” 90 140 275 .88” 1.00” 145 225 280 .88” 1.25” 280 375 680 1.12” 1.25” 1.38” 425 465 1200 1.00” 1.12” 1.38” 1.88 300 550 1000 2750 1.00” 1.25” 1.50” 2.00” 375 750 1300 3600
2500 .88” 250
1.00” 375 1.38” 875 1.50” 1400
707000M - © 2002 P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
Page 6 of 6
Section 9 – Control Panel and Instrumentation Vendor
Bulletin No.
Conduit and Sensor Assembly ....................................... Ajax
00-32-T010-367
Conduit for Thermocouples..............................................Ajax
00-32-T010-368
Vibration Switch and Conduit ......................................... Ajax
01-32-T020-318
Altronic Mag Pickup..........................................................Ajax
00-98-T000-307
Liquid Level Switch, L1200, O&M Bulletin.................................. Murphy
00-02-0175
Vibration Switch Bulletin, VS2 .................................................... Murphy
VS-7037N
Control Panel Drawing ................................................... Murphy
50-30-7327
Centurion Panel Sequence of Operations......................................... Murphy Centurion Panel Installation and Operation........................................Murphy
00-02-0590
Pressure Swichgage, OPLFC..................................................... Murph
00-02-0161
Pulsation Dampener, PD-8184................................................... Murphy
PD-95145B
Manual Speed Pressure Murphygage ........................................ Murphy
00-02-0162
Pressure Regulator, Model 67CR-206 ....................................... Fisher
5469
Engine-Compressor Package Service Manual
00-02-0175 Revised 03-06 Section 15
Installation for L1100, L1200, L1200N Series Liquid Level Switches and DVU150, DVU175, and DVU2105/2115/2120 Series Dump Valves.
Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting. GENERAL INFORMATION **
Description Series L1100 and L1200 Liquid Level Switches are float activated to operate an electrical SPDT snap switch (optional DPDT on some models) for alarm or shutdown of an engine or electric motor. They screw directly into the wall of the vessel. Series L1200 can also be used with a weld collar or external float chamber.
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions. OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment. ✔ BE SURE all pressure HAS BEEN REMOVED from the vessel before opening any pressure connections.
Specifications
L1100
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump valves or similar devices. This model screws directly into the vessel or can be mounted via an external float chamber. It cannot be used with weld collar 15050375. Model variations include a dump valve operator with or without a filter/pressure regulator and indicating pressure gauge. NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and L1200NDVOR series carry Canadian Registration Number OF1476.2. Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a pneumatic input signal to cause an orifice to open or close allowing liquid condensate to be drained from a pressure vessel. A pop up button indicates valve open/closed. Stainless steel versions available. L1111
L1200
L1200N
L1200NDVO
L1200NDVOR
Body • Standard: Electroless Nickel plated steel • Optional: 316 Stainless Steel†
✗A ✗A
✗A ✗A
✗B ✗B
✗B ✗B
✗B ✗B
✗B ✗B
Pressure Rating • 15 psi (103 kPa) [1.03 bar] Polyethylene Float • 1500 psi (10.3 MPa) [103.42 bar] Stainless Float • 2000 psi (13.8 MPa) [138 bar] BUOYGLAS™ Float
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Temperature Rating • Standard: -20/175°F (-29/79°C) • Standard: -20/300°F (-29/149°C) • Optional: -20/400°F (-29/204°C)*
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
✗
✗ ✗
✗ ✗
✗ ✗
✗ ✗
Electrical • Standard SPDT: 5 A @ 125/480 VAC (see p. 3 for full ratings) • Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings)
✗ ✗
✗ ✗
✗ ✗
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
Specific Gravity • Standard: 0.5 with BUOYGLAS™ float • Optional: 0.65 with 304 Stainless Steel† • Standard 0.73 Polyethylene Float
O-Rings: Viton Valve: Two-way snap-action vent type • 1/8 in. (3 mm) orifice w/Viton “A” seat • 1/8 NPT inlet; 1/4 NPT vent • 30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure Dump Valve Operator: Operates Murphy DV Series dump valves or similar. 1/8 NPT inlet, outlet & vent. Pressure Regulator/Filter and Murphy 20BPG: 0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. Maximum input 300 psi (2.07 MPa) [20.68 bar]. 1/8 NPT in/out. Operation: H=For high level, L=For low level
✗
H
L
H
H
H
†Meets NACE standard MR-01-75 for direct exposure to H S service. *Not available with DPDT snap-switch. A =1-1/2 NPT B =2 NPT 2 **Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility. Installation 00-02-0175 page 1 of 6
H
DIMENSIONS L1200N, L1200NDVO and L1200NDVOR with Dump Valve Operator, Pressure Regulator and Gage
L1100 and L1200 11 in. (279 mm)
Pressure Regulator with 20BPG Pressure Gage
3-1/2 in. (89 mm)
2-3/16 in. (56 mm)
New Dump Valve Operator Assembly p/n 15010216
See Note 2
1/2 NPT
See Note 1 3-5/8 in. (92 mm)
Note 1: L1100: 1-1/2 NPT L1200: 2 NPT Note 2: 1-9/16 (40 mm) SF option: L1100: 1-1/2 (38 mm) L1200: 1-3/4 (44 mm)
1/8 NPT Old Round Dump Valve Operator Assembly p/n 15000940
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
1/8 NPT INLET
3-5/8 in. (92 mm)
5 in. (127 mm.) minimum clearance is required for float movement.
3/4 Hex (See Note)
2-3/16 in. (56 mm)
1/4 NPT VENT
1-9/16 in. (40 mm) SF option= 1-3/4 in. (44 mm)
2" 11-1/2 NPT
3-1/2 in. (89 mm) SF= 3-3/4 in. (95 mm) 11 in. (279 mm) SF option= 11-1/4 in. (286 mm) Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111 11-5/16 in. (287 mm) 3-53/64 in. (97 mm)
2-3/16 in. (56 mm)
DVU150, DVU175, DVU2105/2115/2120 Series Dump Valves
A
See Note
1/2 NPT
1-1/2 NPT 3-5/8 in. (92 mm)
Note: 1-9/16 (40 mm)
Pressure Inlet Port 1/8 in.-27 NPT
Float travel between Operate and Reset= 0.25 in. (6 mm). Switch operates on Rising Level w/ float at horizontal centerline ±0.25 in. (6 mm).
Manual Valve Operator
B
Vent Weep Hole Union
Valve Open/Closed Indicator Button
Electrical installation to be done by qualified person according to the NEC.
F Drain
C
Connection
D
E
shown G (dimension for reference only)
Plug Seal Model
A
B
C
D
E
F
G
DVU2120 DVU2115 DVU2105 DVU175 DVU150
7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191) 7.50 (191)
8.0 (203) 8.0 (203) 8.0 (203) 6.75 (171) 6.75 (171)
2.75 (70) 2.75 (70) 2.75 (70) 2.06 (52) 2.06 (52)
1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25)
2-11.5 NPT 2-11.5 NPT 2-11.5 NPT 1-11.5 NPT 1-11.5 NPT
1-11.5 NPT 1-11.5 NPT 1-11.5 NPT 3/4”-14 NPT 1/2”-14 NPT
1.03 1.03 1.03 1.03 1.03
NOTE: Dimensions are in inches and (millimeters)
Installation 00-02-0175 page 2 of 6
REPLACING AND INSTALLING THE DVOA ASSEMBLY
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR. Replacing and Installing the DVOA Assembly For Models L1200NDVO & L1200NDVOR
NOTE: Clean, dry instrument quality gas should be used. Use of filters will improve service life and reliability.
Tools Needed: Strap or pipe wrench; 3/4” Hex wrench; 9/16” hex wrench; needle nose pliers; tubing cutters and benders and the appropriate tools for the fittings. 1.
Block off and bleed the instrument gas pressure supply to the L1200NDVO. 2. Remove the tubing between the L1200NDVO and the separator dump valve, and remove the supply gas tubing (regulator [-R] if used). 3. Remove the L1200NDVO from the vessel (optional). 4. If the L1200N was removed from the vessel, mount it in a suitable vise on a work bench (if possible). 5. Using the proper tools, disconnect the Inlet, Outlet and Exhaust fittings from the existing DVO (see fig. 1). You will re-connect these to the new DVOA in a later step. NOTE: The following steps must be done with the DVO in the upright position (on top of the L1200N). 6. Remove the L1200N cover (this will aid with the alignment of the new DVOA Valve Bushing). The use of a strap wrench or a pipe wrench may be needed. 7. Insert the new Valve Bushing through the new DVOA (see fig. 2). The markings on top of the DVOA must be facing up. This will be needed in step 9. 8. With a 3/4” hex wrench loosen the existing DVO, valve stem, and static seal (see fig. 3). Once the assembly is loosened, VERY CAREFULLY use needle nose pliers to hold the Valve Seat Assembly in place. Remove the existing DVO making sure the Valve Seat Assembly inside the L1200NDVO is aligned and straight (see fig. 4).
Old DVO
Outlet (opposite side)
Inlet
Exhaust
Figure 1
Figure 2
New DVOA
Figure 3
CAUTION: MAKE SURE the Valve Seat Assembly inside the L1200N remains in place after removing the DVO. Holding the Seat Assembly up with the needle nose pliers inside the L1200NDVO body, place the tip of the new DVOA valve bushing through the spring and into the hole in the center of the valve seat, and tighten the valve bushing. The Valve Seat Assembly should be able to move freely up and down after the bushing has been tighten. The DVO red button must face away from the vessel. 10.With the new DVOA aligned over the hex on the L1200NDVO body, tighten the Valve Bushing using the 9/16” hex wrench. You may need to hold the DVOA while tightening the Valve Bushing to keep it from rotating (see fig. 5). 11.If the L1200N is in the vise, operate the float and inspect for smooth and proper operation of the Valve Seat Assembly. 12.Replace the L1200NDVO cover (see fig. 6). 13.Using the appropriate tools re-install the Inlet, the Outlet and the Exhaust fittings to the new DVOA (see fig. 5). 14 If the L1200N was removed from the vessel re-install it at this time. 15.Modify existing or install new tubing to connect the Inlet, the Outlet and Exhaust fittings.
Valve Bushing
Valve Seat Assembly
9.
Outlet
Figure 4
Inlet
Installation 00-02-0175 page 3 of 6
Exhaust
New DVOA
Figure 5
L1200N Cover
Figure 6
PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N
Direct Installation into the Wall of the Pressure Vessel 1. Determine that the float travel is not obstructed by the coupling in Tank the vessel wall, internal Wall baffles, etc. Do NOT use more than one arm extension P/N 15050395. Explosion proof 2. BE SURE that the float Level conduit seal Switch and extension are tight where required. and that the lock washer is in place. 3. Before installing the level switch a suitable pipe thread sealant is recommended. Screw the unit directly into the threaded connection in the wall of the pressure vessel. 4. Be sure that the electrical connection is positioned at the bottom. For L1200N the 1/8 NPT pneumatic connection should be on top (the 1/4 NPT vent connection should be on the bottom). See “Pneumatic models” section for further instructions for the L1200N. 5. Make the electrical wiring connections according to appropriate wiring diagrams for the alarm or shutdown system to be used. The electrical connection is 1/2-14 NPT. Electrical wiring and conduit should be installed by qualified personnel according to the NEC. 6. BE SURE all electrical connections are insulated and the cover is fully installed before reconnecting electrical power. 7. BE SURE all pressure connections are tight before pressurizing the system. Installation with a Weld Collar Tank Wall 1. The weld collar, P/N Weld Collar 15050375, must be welded into the wall of the pressure vessel according to code standards and good welding practices. L1200 2. Follow above instructions for installation directly into Explosion proof the wall of the pressure conduit seal vessel. where required. 3. NOTE: Weld collar 15050375 can be used ONLY with model L1200. It cannot be used with L1200N. Installation Using External Float Chamber 15051098
positioned away from the tank wall. 2. A tee is typically installed at the bottom of the lower 1 inch pipe riser to allow draining of the float chamber for servicing or replacement. NOTE: A typical installation Float with Blocking and Bleed valves is Chamber Tank shown at right. Block Valves 3. Install the L1200 or L1200N Level in the 2 NPT connection Switch of Tee the float chamber. Bleed BE SURE float travel Valve is not restricted and that the Explosion proof float is tight onto conduit seal where required. the float shaft. 4. To complete installation and wiring, follow the instructions for mounting directly into wall of the vessel and for wiring. Pneumatic Models 1. All pneumatic models operate on the vent Filter/Regulator Tank principle. The New Dump Valve Operator Assembly pneumatic signal Pneumatic p/n 15010216 Signal source MUST BE CLEAN AND DRY. The input pneumatic MURPHYGAGE® signal must be regulated between 30 L1200N and 70 psi (207-483 kPa) [2.07-4.83 bar]. If produced gas is used as the signal source, it should be taken after gas passes through the final scrubber. A suitable filter must be positioned before the L1200NDVO to prevent liquids and/or particulates from entering the dump valve operator. NOTE: Check filter periodically for wear and tear and elements that hamper the flow of the pneumatic signal. 2. All pressure connections must be tight and maintained tight so as not to leak air/gas. 3. Valve seat adjustment can be made if air/gas begins to leak. Care should be taken when adjusting as only slight movement is necessary to stop the leakage; excessive force will bind the
Hex Socket Set Screw • loosen for adjustment • tighten after adjustment
L1200N
CAUTION: USE “NON SPARKING TOOLING”. 1. Install the float chamber 15051098 on the outside wall of the pressure vessel using 1 NPT piping. Position the 2 NPT threaded connection at the height where you want the level switch to operate. The 2 NPT threaded connection must be
Hex Adjustment Nut • turn left until air seepage stops • Caution: only slight adjustment is needed—too much will lock up mechanism
Installation 00-02-0175 page 4 of 6
Trip Cam (float down) • should be in this position • non-adjustable
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation As condensate rises in the scrubber, the float on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber. Once the pressure enters the pilot chamber it forces the diaphragm and valve stem forward thus opening the valve seat (valve open/closed indicator button pops out) and releasing condensate through the valve stem and out the drain. As the condensate level drops, the L1200NDVOR pneumatic valve closes to shut off the pressure to the dump valve causing it to close. If for any reason the condensate continues to rise beyond normal dump levels, model L1200 operates the alarm and/or shuts down the equipment. The L1200NDVOR Filter/Regulator and the MURPHYGAGE® help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.
Typical/Scrubber/Separators VESSEL Minimum control pressure 30 psi (207 kPa) [2.07 bar]
Rising Level Shutdown L1200 (with snap-switch)
Explosion proof conduit seal required for Class I. Div 1, not required for intrinsically safe or non-incendive circuits like FWM TTD.
Rising Level Trips DVO
Electrical Conduit
L1200NDVOR Dump Valve Operator Union
Air Supply Maximum 300 psi (2.07 MPa) [20.70 bar]
Filter/Regulator with MURPHYGAGE®
Minimum control pressure 30 psi (207 kPa) [2.07 bar]
DVU Series Dump Valve Union Condensate Line (Out) Manual Drain Valve
REPLACEMENT PARTS
ELECTRICAL INFORMATION DPDT (Snap Switch) SPDT (Snap Switch) Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Switch Rating: 5 A @ 125-250- 480 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 2A @ 6-30 VDC Resistive 1A @ 6-30 VDC Inductive
Green Grd. Connection
Black N.O.
White COM.
Red N.C. Blue N.C.
Yellow COM.
Orange N.C.
Switch Rating: 10 A @ 125-250 VAC 1/2 A @ 125 VDC 1/4 A @ 250 VDC 10 A @ 6-24 VDC Inductive/Resistive
Order by part number designation. L1100/L1200* 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200 15000937: Stainless Steel float for L1100 15000124: SPDT snap switch assembly 15010213: L1100 counter balance assembly 15010214: L1200 counter balance assembly L1200N 15050420: Cam spring return 15050421: Cam 15000893: BUOYGLAS™ float 15000894: Stainless Steel float for L1200N 15050453: Valve stem 15010189: Counter balance assembly L1200NDVO and L1200NDVOR 55050621: Regulator only 05706499: 20BPG-D-75 Pressure MURPHYGAGE® 0-75 psi (517 kPa) [5.17 bar] 15010216: DVOA assembly (New rectangular style) 15000940: DVO assembly (Old round style) *To maintain hazardous location listings, all other repairs must be made by the factory.
Installation 00-02-0175 page 5 of 6
ACCESSORIES
Order by part number designation.
55050617: DVU150/DVU175 Adapter Bushing
15050375: Weld Collar
Material: 2-1/2 Hex bar stock C.R.S 2-1/16 in (52 mm) 1-1/16 in (27 mm)
2 NPT
2-1/2 in (64 mm)
2-7/8 in (73 mm) 3-5/8 in. (92 mm)
1 NPT
4-1/2 in (114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
2 NPT
15051098: External Float Chamber 3 in. (76 mm)
1-11.5 NPT (2 places)
2-11.5 NPT 10.5 in. (266 mm)
3 in. (76 mm)
1/2-20 UNF-2B (4 places) 7.55 in. (192 mm)
3.5 in. (89 mm)
Material: Cast Steel, WCB
7.01 in. (179 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar]. Operating Temperature: 400°F (204°C).
15000892: Float Shaft Extension 10-32 UNF
10-32 UNF 3/8 in (10 mm) 1-3/8 in (35 mm)
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
www.fwmurphy.com 918.317.4100 Email:
[email protected]
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0175 page 6 of 6
VS-7037N Revised 04-05 Section 20
Shock/Vibration Control Switches Installation Instructions
(00-02-0185)
Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes. GENERAL INFORMATION
R
WARNING
LISTED*
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
Description The Murphy shock and vibration switches are available in a variety of models for applications on machinery or equipment where excessive vibration or shock can damage the equipment or otherwise poses a threat to safe operation. A set of contacts is held in a latched position through a mechanical latch and magnet mechanism. As the level of vibration or shock increases an inertia mass exerts force against the latch arm and forces it away from the magnetic latch causing the latch arm to operate the contacts. Sensitivity is obtained by adjusting the amount of the air gap between the magnet and the latch arm plate. Applications include all types of rotating or reciprocating machinery such as cooling fans, engines, pumps, compressors, pump jacks, etc.
Models VS2: Base mount; non hazardous locations. VS2C: C-clamp mount; non hazardous locations. VS2EX: Explosion-proof; Class I, Div. 1, Groups C and D. VS2EXR: Explosion-proof with remote reset. VS2EXRB: Explosion-proof; Class I, Div. 1, Group B; with remote reset. VS94: Base mount; non hazardous locations, NEMA 4X/IP66.
Model VS2EX
Remote Reset Feature (VS2EXR, VS2EXRB and VS94 only) Includes built-in electric solenoid which allows reset of tripped unit from a remote location. Standard on VS2EXR and VS2EXRB. Optional on VS94 (options listed below). -R15: Remote reset for 115 VAC -R24: Remote reset for 24 VDC
Time Delay Option (VS94 only) Overrides trip operation on start-up. For VS94 series models, the delay time is field-adjustable from 5 seconds up to 6-1/2 minutes with a 20turn potentiometer (15 seconds per turn approximately). Options listed below: -T15: Time delay for 115 VAC -T24: Time delay for 24 VDC
Space Heater Options (VS94 only) This optional space heater board prevents moisture from condensing inside the VS94 Series case. Options listed below: -H15: Space heater for 115 VAC -H24: Space heater for 24 VDC
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
VS-7037N page 1 of 8
DIMENSIONS VS2
VS2C
3 in. (76 mm)
4-3/4 in. (121 mm)
Reset Push Button
4-19/32 in. (116 mm)
3 in. (76 mm)
Slotted Sensitivity Adjustment
5-1/8 in. (130 mm) Mounting Holes
Slotted Sensitivity Adjustment
Reset Push Button
5-7/16 in. (138 mm)
Plug
2-1/4 in. (57 mm)
4-3/4 in. (121 mm)
1/4 x 1/2 in. (6 mm x 13 mm) Slot 2 places
Weatherproof Strain Relief Bushing
27/32 in. (21 mm) C-Clamp
VS2EX and VS2EXR 5-5/8 in. (143 mm) Reset Push Button
1/2 NPT Conduit
1-3/4 in. (44 mm) 3/8 in. (10 mm) 4 places
4-7/8 in. (124 mm)
Slotted Sensitivity Adjustment 5-1/4 in. (133 mm) 6-3/8 in. Mounting Holes (162 mm)
3 in. (76 mm) Mounting Holes
VS2EXRB 10-5/8 in. (270 mm)
6 in. (152 mm)
8-5/8 in. (219 mm)
1/2 NPT Conduit
2-1/2 in. (64 mm) 4-1/2 in. (114 mm) Mounting Centers
10-3/16 in. (259 mm)
9-1/8 in. (232 mm) Mounting Centers
VS94 6-29/32 in. (176 mm)
Manual Reset Push-button
7-9/64 in. (181 mm)
6-1/2 in. (165 mm)
4-5/8 in. (118 mm) 3/4 NPT conduit fitting
1-5/8 in. (41 mm) 4 in. (102 mm)
Mounting slot 5/16 x 9/16 in. (8 x 14 mm) 4-places.
6-1/2 in. (165 mm)
4 in. (102 mm)
VS-7037N page 2 of 8
SPECIFICATIONS
VS2 and VS2C • Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas. VS2: Base mount VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable hold down clamps. • Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS2EX • Case: Explosion-proof and weatherproof aluminum alloy housing; meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & D; UL and CSA listed.* VS2EX: base mount. • Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* 2A resistive, 1A inductive, up to 30 VDC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Normal Operating Temperature: -40 to 140°F (-40 to 60°C).
VS2EXR • Case: Same as VS2EX. • Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A resistive, 1A inductive, up to 30 VDC. • Remote Reset (optional): Option Operating Current -R15: 350 mA @ 115 VAC -R24: 350 mA @ 24 VDC • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Normal Operating Temperature: -40 to 140°F (-40 to 60°C). VS2EXRB • Case: Explosion-proof aluminum alloy housing; rated Class I, Division 1, Group B hazardous areas. • Snap-switch: 1-SPDT snap-switch with reset coil (option available for
additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive, up to 30 VDC. • Remote Reset: Option Operating Current -R15: 350 mA @ 115 VAC -R24: 350 mA @ 24 VDC • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS94 • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA types 4 and 12. • Conduit Fitting: 3/4 NPT conduit fitting connection. • Normal Operating Ambient Temperature: 0 to 140°F (-18 to 60°C). • Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A resistive, 1A inductive, up to 30 VDC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Heater (optional): Option Operating Current H15 .023 A @ 115 VAC H24 .12 A @ 24 VDC • Remote Reset (optional): Option Operating Current R15 .17 A @ 115 VAC R24 .36 A @ 24 VDC • Time Delay (optional): Option Operating Current Standby Current T15 .360 A @ 115 VAC .01 A @ 115 VAC T24 1.15 A @ 24 VDC .01 A @ 24 VDC • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from 5 seconds to 6-1/2 minutes (15 seconds per turn approximately).
*CSA and UL listed with 480 VAC rating.
INSTALLATION WARNING: STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
The VS2 and VS94 series shock switches are sensitive to shock and vibration in all three planes of motion - up/down, front/back and side/side. Front/back is the most sensitive (The reset pushbutton is located on the “front” of the unit). For maximum sensitivity mount the unit so that the front faces into the direction of rotation of the machine. (See Dimensions on page 2 for sensitivity adjustment location). The VS2 and VS94 Series must be firmly attached/mounted to the machine so that all mounting surfaces are in rigid contact with the mounting surface of the machine. For best results, mount the instrument in-line with the direction of rotating shafts and/or near bearings. In other words, the reset push button should be mounted pointing into the direction of shaft rotation (see page 5). It may be necessary to provide a mounting plate or bracket to attach the VS2 and VS94 Series to the machine. The mounting bracket should be thick enough to prevent induced acceleration/vibration upon the VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See illustrations on page 5 for typical mounting locations. CAUTION: A dust boot is provided on the reset pushbutton for all series to prevent moisture or dust intrusion. The sensitivity adjustment for model VS2EX is not sealed; therefore, mounting
orientation should be on a horizontal plane or with the sensitivity adjustment pointing down. Sensitivity adjustment for model VS2 is covered by a plug. The plug must be in place and tight to prevent moisture or dust intrusion.
C-Clamp Installation (VS2C model only) A C-Clamp is supplied with the VS2C model only. The C-Clamp is shipped installed on the VS2C but must be installed on the VS2EX and VS2EXR switches. 1. The C-Clamp (B) will already be installed on a 1/4 in. (6 mm) thick steel mounting plate (A). Bolt the VS2 switch to the mounting A plate as illustrated — with four 5/16 in. B bolts, nuts, and washers. 2. The mounting location should provide convenient access to the TATTLETALE® push button (C). 3. The hardened set screw and nuts (D) are used to tighten the switch to an I-Beam or cross member such as a Sampson post of an oilwell pumpjack.
VS-7037N page 3 of 8
Continued on next page.
C
D
INSTALLATION Continued
All Models WARNING: STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
1. Firmly secure the unit to the equipment using the base foot mount or C-Clamp if applicable. See C-Clamp Installation page 3. For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson post or walking beam. See Typical Mounting Locations page 5. 2. Make the necessary electrical connections to the vibration switch. See Internal Switches, page 6 for electrical terminal locations and page 7 for typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT RATINGS OF THE CONTACTS. Follow appropriate electrical codes/methods when making electrical connections. Be sure that the run of electrical cable is secured to the machine and is well insulated from electrical shorting. Use of conduit is recommended. NOTE: If the electrical cable crosses a pivot point such as at the pivot of the walking beam, be sure to allow enough slack in the cable so that no stress is placed on the cable when the beam moves. If conduit is not used for the entire length of wiring, conduit should be used from the electrical supply box to a height above ground level that prevents damage to the exposed cable from the elements, rodents, etc. or as otherwise required by applicable electrical codes. If conduit is not attached directly to the VS2 and VS94 Series switch, use a strain relief bushing and a weatherproof cap on the exposed end of the conduit. A “drip loop” should be provided in the cable to prevent moisture from draining down the cable into the conduit should the weathercap fail.
allow the machine to stop. Turn the sensitivity adjustment 1/4 turn clockwise, (adjustment for VS94 and VS2EXRB models is located within the box, see DETAIL “B”). WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.
Depress the reset button and restart the machine. Repeat this process until the unit does not trip on start-up. DETAIL “B” 5. If the instrument does NOT trip on startup, stop the machine. Turn the sensitivity adjustment 1/4 turn counter-clockwise. Repeat the start-up/stop process until the instrument trips on start-up. Turn the sensitivity adjustment 1/4 turn clockwise (less sensitive). Restart the machine to verify that the instrument will not trip on start-up.
THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.
All models of the VS2 and VS94 Series cover a wide range of sensitivity. Each model is adjusted to the specific piece of machinery on which it is installed. After the switch has been installed in a satisfactory location (see page 5) the sensitivity adjustment will be increased or decreased so that the switch does not trip during start-up or under normal operating conditions. This is typically done as follows: 1. REPLACE ALL COVERS, LIDS, AND ELECTRICAL ENCLOSURES. 2. Press the reset push button to engage the magnetic latch. To be sure the magnetic latch has engaged, observe latch DETAIL “A” through the window on the VS2 and VS2C (see DETAIL “A”). On the Reset Push button VS2EX, VS94 series the reset button will remain depressed meaning the magnetic latch has engaged. 3. Start the machine. 4. If the instrument trips on start-up,
Sensitivity adjustment
More Sensitive
6. Verify that the unit will trip when abnormal shock/vibration exists.
VS94 Time Delay Adjustment 1. Apply power to the time delay circuit. (see page 7 for time delay circuit). The time delay function will be initiated. 2. Time the length of the delay with a watch. Let time delay expire. After it expires, the override circuit will de-energize the solenoid, allowing the latch arm to trip. A clicking noise is heard. WARNING: REMOVE ALL POWER BEFORE OPENING ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND LOCAL CODES.
Sensitivity Adjustment WARNING: REMOVE ALL POWER BEFORE OPENING
Less Sensitive
3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT. NOTE: Allow 30 seconds bleed-time between turning the power “OFF” and “ON”. DETAIL “C” 4. Locate the time adjustment pot (DETAIL “C”). The time is factory-set at the lowest setting (5 seconds approximately). To increase time, rotate the 20-turn pot clockwise as needed Turn to (15 seconds per turn approximately). decrease 5. Repeat the above steps as necessary to obtain desired time delay.
Pot
Turn to NOTE: An external time delay can be used increase with the remote reset feature of the VS2EXR series to provide a remote reset and override of the trip operation on start-up. Time delay must automatically disconnect after equipment start-up.
Sensitivity Adjustment
VS-7037N page 4 of 8
TYPICAL MOUNTING LOCATIONS
NOTE:
These are typical mounting locations for best operation. Other mountings are possible. See Installation section on page 3.
2-Throw Balance-Opposed Compressor
Pumping Unit
Reset
NOTE: If installing on cylinders, 2 vibration/shock switches are recommended1 for each cylinder.
Engine and Vertical Shaft Pump
Reset
“Y” Type Reciprocating Compressor
Reset
Reset
Reset
Generator Sets
Reset
Cooling Tower Fan or Heat Exchanger
Reset
Engine Compressor
Turbine Centrifugal Compressor
Reset
VS-7037N page 5 of 8
Reset
INTERNAL SWITCHES
VS2 and VS2C
VS2EXR Remote Reset Terminal Sensitivity Adjustment
Sensitivity Adjustment
NC NO1
NC
COM
NO COM Ground Terminal
NO2 SPDT Snap-Switch
SPDT Switch Terminals
VS2EXB and VS2EXRB
VS2EX
Remote Reset Terminal Sensitivity Adjustment
SPDT Snap-Switch
NC
NO COM
NC
NO COM
Sensitivity Adjustment
NC Ground Terminal
SPDT Snap-Switch
SPDT Snap-Switch
VS94 SPDT Snap-Switch
NC
NO COM
NC
NO COM
SPDT Snap-Switch
NC
Time Delay and/or Remote Reset Terminal (Optional)
Ground Terminal
Sensitivity Adjustment
Heater Board Terminal (Optional)
VS-7037N page 6 of 8
NO COM NO COM
Ground Terminal Optional SPDT Snap-Switch (VS2EXRB only)
ELECTRICAL WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.
VS2 and VS2C Typical Wiring Diagram for Single or Dual CD Ignition
VS2EX Typical Wiring Diagram for Single or Dual CD Ignitions
SPDT Switch Contacts shown in the RESET position.
NO1
NC
COM
CD Ignition 2
SPDT Switch (Optional 2-SPDT [DPDT])† Contacts shown in the RESET position CD Ignition 2
NO2
N.C.
COM
N.O.
N.C.
COM
Resistor (100 Ω, 3 Watt)
To good engine ground
Resistor (100 Ω, 3 Watt)
N.O.
To good engine ground
CD Ignition 1
CD Ignition 1 To good engine ground
VS2EXR and VS2EXRB Typical Wiring Diagram for Single or Dual CD Ignitions
Remote Reset Momentary Push Button
SPDT Switch (Optional 2-SPDT [DPDT])† Contacts shown in the RESET position N.O.
115 VAC or 24 VDC (Voltage is specified when ordered).
VS94 Typical Wiring Diagram for Single or Dual CD Ignitions
N.O.
N.C.
N.C.
COM
To good engine ground
COM
†Additional Switch Optional on VS2EXRB only
115 VAC or 24 VDC*
Maintained Contact for Time Delay
Time Delay
115 VAC or 24 VDC* *Voltage is specified when ordered.
To good engine ground
CD Ignition 2
Time Delay or Remote Reset (Optional)
Momentary Contact for Remote Reset only
2-SPDT Switches (DPDT) Contacts shown in the RESET position
N.O.
N.C.
COM
N.O.
N.C.
COM
Heater Board (Optional)
To good engine ground
To good engine ground
Resistor (100 Ω, 3 Watt)
CD Ignition 1
CD Ignition 1
VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 Typical Wiring Diagram for Electric Motors
VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 Typical Wiring Diagram for Distributor Ignition or Diesel
Contacts shown
NOTE: Terminal N.O. is terminal NO1 on models VS2 and VS2C. L1
L2
L3
Switch Terminals in the RESET position N.O. N.C. COM
(see Note)
CD Ignition 2
Resistor (100 Ω, 3 Watt)
NOTE: Terminal N.O. is terminal NO1 on models VS2 and VS2C.
Switch Terminals N.O.
(see Note)
N.C.
COM
Contacts shown in the RESET position Ignition Switch
Push-button Station
Ammeter HC
Diesel Fuel Shutoff Valve H
MOTOR
A
Hand Off Automatic Selector HC
VS-7037N page 7 of 8
Ignition Coil
Distributor
Battery
SERVICE PARTS PART NO.
DESCRIPTION
PART NO.
VS2 20000030 20000031 20000032
VS2EXRB Movement assembly Glass and gasket assembly Reset push button assembly
20010090
20000057 Movement assembly Glass and gasket assembly Reset push button assembly Mounting clamp VS2C 5-clamp hardware package assembly. 2-Conductor electrical cable, 45 feet (13.7 meters)
20000058 20000287 20000290
VS2EX 20010091 20050087 00000309 20010090 20000288 20000289
Movement assembly Cover Cover gasket Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* C-clamp conversion mounting kit
VS2EXR 20000262 20050087 00000309 20010090 20000288 20000049 20000234 20000289
Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* Inside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D prior to September 1, 1995.* Outside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D prior to September 1, 1995.* Outside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D manufactured on September 1, 1995 or later.* Inside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D manufactured on September 1, 1995 or later.* Adjustment shaft Movement assembly Reset solenoid assembly (115 VAC) Reset solenoid assembly (24 VDC)
20000288
VS2C 20000030 20000031 20000032 20050021 20000185 20050465
DESCRIPTION
Movement assembly Cover Cover gasket Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* Reset solenoid assembly (115 VAC) Reset solenoid assembly (24 VDC) C-clamp conversion mounting kit
FW Murphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail
[email protected]
www.fwmurphy.com
20050077 20000262 20000049 20000234
VS94 Series 25050506 00000232 20010090
Dust boot Conduit fitting Snap-switch and insulator kit (1 switch per assembly) prior to September 1, 1995.** Snap-switch and insulator kit (1 switch per assembly) for models manufactured on September 1, 1995 or later.***
20000288
* If no date code is found, refer to the old switch. Models with date 0895 and before use old switch. Dated 0995 after, use straight snap-switch arm, no rollers. ** Models dated Q1 thru Q8 (formed snap-switch arm and rollers). ***Models date coded Q9 thru Q12 and R1 thru R12 (straight snap-switch arm, no rollers).
CONTROL SYSTEMS & SERVICES DIVISION
FRANK W. MURPHY, LTD.
P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail
[email protected]
Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail
[email protected] www.fwmurphy.co.uk
INDUSTRIAL PANEL DIVISION
P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail
[email protected]
MURPHY DE MEXICO, S.A. DE C.V.
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail
[email protected] Printed in U.S.A. www.murphymex.com.mx
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
VS-7037N page 8 of 8
078792
SEQUENCE OF OPERATION Centurion Controller DRAWING# 50-30-7327 SEQUENCE# 50-32-7327 rev A PROGRAM# 50-34-7327 rev A CAMERON COMPRESSION December 12, 2007 Revised December 14, 2007
TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
TYPE OF SYSTEM STARTING SEQUENCE RUNNING SEQUENCE STOPPING SEQUENCE SHUTDOWN SEQUENCE CONTROLLER I/O MODBUS ADDRESS LIST MCONFIG PRO REPORT (refer to attached PDF file)
Page 1 of 15
1.0 TYPE OF SYSTEM 1.1 The control system for this project is one FWMurphy Centurion Configurable Controller with custom firmware installed. This system is designed for use in Class I, Division 2 hazardous areas, powered by user supplied 24VDC. The controller will monitor various analog and switch inputs and shutdown the motor/compressor package as noted in this document. The controller will interface with an Ajax Engine Driven Integral Reciprocating compressor. 1.2 GENERAL OPERATING INSTRUCTIONS 1.2.1
Upon powerup, the display will first show the “default” home page as configured using Mconfig Pro software. To navigate the display, use the UP, DOWN, RIGHT, and LEFT arrow keys. To start the unit in local mode, press the RUN/STOP key to start and stop the start sequence. Pressing the RESET key will reset any fault shutdowns.
1.2.2
From any main page, the HOME key can be used to return to the default home page.
1.2.3
Timers will be shown on the 2 to the bottom of the display. The panel state message will be displayed across the bottom of the display.
1.2.4
The Class B1, B2, and S timers can be reset, or zeroed by pressing the RESET, or TIMER 0 (Zero) key. The test mode can be initiated by pressing the TEST key.
nd
1.3 SETPOINTS 1.3.1
To edit setpoints within the controller, press the SETUP/ENTER key. The appropriate numeric password must be entered to make changes to setpoints. No password is necessary to view setpoints.
1.3.2
The Centurion uses a different approach to enter values than previous Murphy controllers. Instead of holding in the arrow keys until the desired number is displayed, the Centurion display allows individual editing of each position of the desired number. This is accomplished by entering the Edit Mode and using the UP/DOWN arrow keys (1) to adjust the number above the blinking cursor (2) between 0 and 9. To edit another position, simply use the LEFT/RIGHT (3) arrow keys to move the cursor to that position (4) and repeat the edit process until the desired number is displayed. In this way, values are “built” rather than “scrolled” through.
1.3.3
Some digits may not be allowed to increment if it would result in exceeding range limits. Values which can be positive or negative will have a sign (±) to the left of the number. To change the sign value simply move the cursor to the sign using the LEFT arrow key and “toggle” between + and – using the U and DOWN arrow keys. If the range of the value will exceed range limits the sign may not be allowed to change. In this case, try reducing the number by decrementing the left most digit by one or more and attempt to change the sign again.
1.3.4
In some instances, a word rather than a value is represented in the Edit Mode. This works like the sign value as an ON/OFF or YES/NO prompt where the value is “toggled” between choices using the UP/DOWN arrow keys. The value is not active in the controller until the ENTER key has been pressed to send the value to the controller. Pressing the ESC key will discard any changes and keep the original value prior to entering the Edit Mode.
Page 2 of 15
2.0 STARTING SEQUENCE 2.1 When power is first applied, and if no class A or ESD shutdown conditions exist, the controller will be in the “MANUAL STOP” state. 2.2 This panel is equipped with custom programming to control a nitrogen purge valve. A panel mounted On-Off-Auto switch will control how this cycle works. 2.2.1
OFF-the nitrogen purge valve will not operate, and will remain closed. The max purge timer is reset.
2.2.2
HAND- If the panel is in the MANUAL STOP or SHUTDOWN states, the nitrogen purge valve will be immediately opened. It will remain open until switched back to OFF, or unit the max nitrogen purge time delay expires (SETPOINT #49). During this time, the RUN/STOP key will be ignored and no starting will be allowed. If the panel is not in MANUAL STOP or SHUTDOWN states, the purge valve will remain closed.
2.2.3
AUTO- If the panel has detected an ESD event type shutdown, the nitrogen purge valve will be immediately opened. It will remain open until the RESET key is pressed, or unit the max nitrogen purge time delay expires (SETPOINT #49).
2.3 The Sleep Control output will energize to latch power onto the control system. An external programmable timer is used to break power from the system in the event of a shutdown after a set time delay. NOTE: the programmable timer should be set longer than the MAX PURGE TIME SETPOINT to ensure that the Nitrogen Purge cycle will complete before losing power. 2.4 The Ignition and M5081-C-LS Fuel outputs will remain deenergized. 2.5 When the RUN/STOP key is pressed, the following start sequence will occur: 2.5.1
The state message will read “WAITING ON START”.
2.5.2
The Ignition G-Lead Output will energize to Un-ground the Ignition.
1.1.1
The M5081-C-LS Fuel Valve output will energize to allow the fuel valve to be manually opened.
1.1.2
The controller will monitor for a run signal from the MPU input. Confirmation must be received before the Waiting ON Start Timer expires otherwise the unit will shutdown on “FAILURE TO START ENGINE”.
1.1.3
When the Engine RPM is seen above the Run RPM setting, the unit will be considered running and the Running sequence will begin.
3.0 RUNNING SEQUENCE 3.1 The controller will read “RUNNING”. 3.2 The internal hourmeter will begin timing. The class B1, B2, and S lockout delays begin timing. 3.3 The RPM vs Suction pressure control loop is enabled. 3.4 The RPM vs Suction pressure is controlled by suction pressure. If the suction pressure drops below the setpoint, the speed output to the engine decreases and vice-versa. 3.5 TEST MODE
Page 3 of 15
3.5.1
While the unit is running, a test mode feature will be available. When the TEST key on the Centurion display is pressed, all functions identified as Class A, B1, B2, or C shutdowns will be able to be tested without shutting down the Unit for the duration of the Test timer. The test mode can be ended by pressing the TIMER “0” key.
3.5.2
The tested points can be seen on the EVENTS page of the Mview display.
3.5.3
Some functions are designated as Class ESD, which will not be in the TEST mode. An example is Panel ESD. It is never locked out.
3.5.4
All shutdowns must be clear, and the reset key must be pressed before the test timer expires, or prior to exiting the test mode or else a shutdown will occur. (note: this will also reset and restart the B1, B2 and S lockout timers)
4.0 NORMAL STOP SEQUENCE 4.1 Pressing the RUN/STOP key on the Centurion faceplate for 2 seconds and releasing will signal a normal stop. 4.2 The controller will read “STOPPING”. 4.3 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve. 4.4 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition. During this time, the state message will read “STOPPING”. 4.5 The unit state will return to “MANUAL STOP” and await the next start sequence. 5.0 FAULT SHUTDOWN SEQUENCE 5.1 The Class B1, B2, C and S shutdowns are disarmed. 5.2 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve. 5.3 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition. During this time, the state message will read “STOPPING”. In cases of ESD type faults, this delay is skipped. 5.4 The unit state will read to “SHUTDOWN”. 5.5 The cause of the shutdown will be displayed on the shutdown history page. Use the LEFT and RIGHT arrow keys to navigate to this page. The shutdown event is stored in the Shutdown History Page with an hourmeter time stamp. After the shutdown condition is corrected, press the RESET key to clear the shutdown condition and return to “PANEL READY”. 5.6 The Sleep Control output will deenergize upon a fault shutdown. An external programmable time delay will remove power from the control system after a configured time. To restore power to the system, Press and hold the “Power Up From Sleep” panel mounted pushbutton for 3 seconds. 6.0 CENTURION CONTROLLER INPUTS/OUTPUTS 6.1 DIGITAL INPUTS TB# 30 31 32
TYPE NC NO NO
IN# DI-1 DI-2 DI-3
LOCAL EMERGENCY STOP SPARE DI02 SHUTDOWN REMOTE SHUTDOWN Page 4 of 15
DESCRIPTION
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO
DI-4 DI-5 DI-6 DI-7 DI-8 DI-9 DI-10 DI-11 DI-12 DI-13 DI-14 DI-15 DI-16 DI-17 DI-18 DI-19 DI-20 DI-21 DI-22 DI-23 DI-24 DI-25 DI-26 DI-27 DI-28 DI-29 DI-30 DI-31 DI-32
SPARE DI03 SHUTDOWN ENGINE LUBRICATOR FLOW PULSE (PROXIMITY SWITCH) COMPRESSOR LUBRICATOR FLOW PULSE (PROXIMITY SWITCH) LOW ENGINE OIL LEVEL LOW COOLANT LEVEL SPARE DI09 SHUTDOWN HIGH SUCTION SCRUBBER LIQUID LEVEL HIGH INTERSTAGE SCRUBBER LIQUID LEVEL HIGH DISCHARGE SCRUBBER LIQUID LEVEL SPARE DI13 SHUTDOWN HIGH FRAME VIBRATION HIGH COOLER VIBRATION SPARE DI16 SHUTDOWN SPARE DI17 SHUTDOWN SPARE DI18 SHUTDOWN SPARE DI19 SHUTDOWN SPARE DI20 SHUTDOWN NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NITROGEN PURGE AUTOMATIC SWITCH SELECTION NITROGEN PURGE ON SWITCH SELECTION NOT AVAILABLE-FIRMWARE USE
6.2 DIGITAL OUTPUTS TB# 70 (NO) 71 (COM) 72 (NC) 73 (NO) 74 (COM) 75 (NC) 76 (NO) 77 (COM) 78 (NC) 79 (NO) 80 (COM) 81 (NC) 82 (DC+) 83 (+OUT) 84 (DC+) 85 (+OUT) 86 (DC+) 87 (+OUT) 88 (DC+) 89 (+OUT)
TYPE RELAY(1)
OUT# 1 NOT USED
DESCRIPTION
RELAY(2)
2
NOT USED
RELAY(3)
3
NOT USED
RELAY(4)
4
SLEEP CONTROL (ENERGIZED DURING NON-FAULT, DEENERGIZED ON SHUTDOWN)
FET(1)
5
NOT USED
FET(2)
6
NOT USED
FET(3)
7
NITROGEN PURGE VALVE OPEN
FET(4)
8
M5081-C-LS FUEL VALVE (ENERGIZED TO RUN TO INTERFACE WITH MAGNETIC SWITCH ADAPTER THROUGH A NC RELAY CONTACT TO TRIP ON SHUTDOWN) Page 5 of 15
90 (-OUT) 91 (DC-) 92 (-OUT) 93 (DC-)
IGBT(1)
9
NOT USED
IGBT(2)
10
IGNITION GROUND
6.3 ANALOG OUTPUTS TB# 66 (DC +) 67 (OUT) 68 (DC +) 69 (OUT)
TYPE 4-20mA
OUT# DESCRIPTION AO-1 RPM VS SUCTION PRESSURE CONTROL
4-20mA
AO-2
NOT USED
6.4 ANALOG INPUTS TB# 18 19 20 21 22 23 24 25 26 27 28 29
TYPE 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA
IN# AI-1 AI-2 AI-3 AI-4 AI-5 AI-6 AI-7 AI-8 AI-9 AI-10 AI-11 AI-12
SUCTION PRESSURE INTERSTAGE PRESSURE DISCHARGE PRESSURE NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED
DESCRIPTION
6.5 THERMOCOUPLE INPUTS TB# 1(+) 2(-) 3(+) 4(-) 5(+) 6(-) 7(+) 8(-) 9(+) 10(-) 11(+) 12(-) 13(+) 14(-) 15(+) 16(-)
TYPE K
IN# TC-1
DESCRIPTION EXHAUST CYLINDER #1 TEMPERATURE
K
TC-2
EXHAUST CYLINDER #2 TEMPERATURE
K
TC-3
NOT USED
K
TC-4
DISCHARGE CYLINDER #1 TEMPERATURE
K
TC-5
DISCHARGE CYLINDER #2 TEMPERATURE
K
TC-6
NOT USED
K
TC-7
ENGINE COOLANT TEMPERATURE
K
TC-8
COMPRESSOR COOLANT TEMPERATURE
7.0 MODBUS ADDRESS LIST The Centurion uses MODBUS RTU protocol. Data is formatted as 16 bit Signed Holding Registers except where noted. Port 1 is configurable for either 3 wire RS-232 or 2 wire RS-485 communication. Analog Reading and Setpoints will be shown with no decimal place. Reference the Mconfig Pro Report or Mview Display to determine the proper number of decimals places. Refer to the Mconfig Pro Report for event enumerations, and engine state enumerations. Page 6 of 15
Translated I/O Polling area 42001 1-16
Description Core Digital Inputs Bitmap
Read Only Read/Write R
Bit 1 = lsb…bit 16 = msb
Core Digital Inputs Bitmap
R
Bit 1 = lsb…bit 16 = msb
Core Analog Inputs
R
Scaled to engineering units as shown in Mconfig Pro Report
42002
17-32
42003
1
42004
2
R
42005
3
R
42006
4
R
42007
5
R
42008
6
R
42009
7
R
42010
8
R
42011
9
R
42012
10
R
42013
11
R
42014
12
R
42015
13 (1)
42016
14 (2)
R
42017
15 (3)
R
42018
16 (4)
R
42019
17 (5)
R
42020
18 (6)
R
42021
19 (7)
R
42022
20 (8)
R
42023
1
42024
2
R
42025
3
R
42026
4
R
42027
5
R
42028
6
R
42029
7
R
42030
8
R
42031
9 (1)
42032
10 (2)
42033
11 (3)
R
42034
12 (4)
R
42035
13 (5)
R
42036
14 (6)
R
42037
15 (7)
R
42038
16 (8)
R
42039
1-16
42040
1
42041
2
42042
3 (1)
Expansion Analog Inputs
R
Core Thermocouple Inputs
Expansion Thermocouple Inputs
R
R R
Data format
Scaled to engineering units as shown in Mconfig Pro Report
Scaled to deg C or F as shown in Mconfig Pro Report
Scaled to deg C or F as shown in Mconfig Pro Report
Core Digital Outputs Bitmap
R
Bit 1 = lsb…bit 16 = msb
Core Analog Outputs
R
Percent x 100 (0 – 10000)
R
Percent x 100 (0 – 10000)
R
Percent x 100 (0 – 10000)
Expansion Analog Outputs
Page 7 of 15
42043
4 (2)
R
Percent x 100 (0 – 10000)
42044
5 (3)
R
Percent x 100 (0 – 10000)
42045
6 (4)
R
Percent x 100 (0 – 10000)
Engine Speed
R
RPM
40101
STATE
R
40102
RPM
R
State enumeration (1 – 19) note: not all states may be used, and may be renamed for a specific application…refer to the Mconfig Pro Report for state descriptions. 1 = PANEL READY (*MANUAL STOP) 2 = START DELAY 3 = PRE-HEAT 4 = PRE-LUBE 5 = START VALVE 6 = CRANK STOP 7 = CRANK (*READY TO START) 8 = CRANK REST 9 = MOTOR ON 10 = WARMUP 11 = WAIT FOR LOAD 12 = RUN LOADED (*RUNNING) 13 = COOLDOWN (*COOLDOWN) 14= STOP ENGINE (*STOPPING) 15 = MOTOR OFF 16 = STOP VALVE 17 = POST-LUBE 18 = RESTART DELAY 19 = SHUTDOWN (*SHUTDOWN) Engine RPM
STATUS
R
Status bits
42046 Status Polling area
40107
1-16 1
STATUS_FLT_SHTDWN
0x0001 Fault Shutdown in progress.
2
STATUS_ESD
0x0002 Emergency Shutdown in progress.
3
STATUS_ALARM
0x0004 Have Active alarms
4
STATUS_START
0x0008 Start/Stop indicator. 1=Start
5
STATUS_LCL_RMT
0x0010 1=Remote, 0=Local.
6
STATUS_TEST_TMR
0x0020 1=TEST timer is running.
7
STATUS_B1_TMR
0x0040 1=B1 timer is running.
8
STATUS_B2_TMR
0x0080 1=B2 timer is running.
9
STATUS_C_TMR
0x0100 1=C timer is running.
10
STATUS_S1_TMR
0x0200 1=S1 timer is running
11
STATUS_S2_TMR
0x0400 1=S2 timer is running
12
STATUS_S3_TMR
0x0800 1=S3 timer is running.
13
STATUS_S4_TMR
0x1000 1=S4 timer is running.
14
STATUS_S5_TMR
0x2000 1=S5 timer is running.
15
STATUS_NF_TMR
0x4000 1=NF timer is running.
16
STATUS_BAD_CONFIG
0x8000 1=Configuration is bad.
40108
STATE_TIMER
R
Timer for the current State
40109
TEST_TIMER
R
Test Mode Timer.
40110
B1
R
Primary Lockout Timer
40111
B2
R
Secondary Lockout Timer
40112
C
R
Class C Arming Timer
Page 8 of 15
40113
S1
R
40114
S2
R
40115
S3
R
40116
S4
R
40117
S5
R
40118
NF
R
Special Timer; Like B1 for individual assignment Special Timer; Like B1 for individual assignment Special Timer; Like B1 for individual assignment Special Timer; Like B1 for individual assignment Special Timer; Like B1 for individual assignment No-Flow Delay Before Shutdown Timer
Hour Meter 40119
HOURMETER_HOURS
R/W
Hourmeter hours.
40120
HOURMETER_MINUTES
R/W
0-59
40121
HOURMETER_SECONDS
R/W
0-59
Shutdown Table (Single entry) 40144
SHUTDOWN
R
Enumeration, zero = none; (1 - 128)
NUM_ALARMS
R
Number of active alarms
BATTERY_VOLTAGE
R
In tenths of a volt
40147
NUM_CRANKS_LEFT
R
Number of crank attempts left
40148
CORE_AMBIENT_TEMP
R
Tenths of a degree
40149
EXP_AMBIENT_TEMP
R
Tenths of a degree
Number of Active Alarms 40145 Miscellaneous data 40146
Control Output Auto/Manual 40151
1-8
CTL_OUT_AUTO
R/W
1=Auto Mode, 0=Manual
40152
1-4
PID_ENABLED
R
1=Enabled, 0=Not Enabled
40153
1-4
PID_OVERRIDE
R
1=Override on, 0=Override off
CLASS_ARMED
R
Class Armed status.
1
B1_ARMED
R
0x0001
2
B2_ARMED
R
0x0002
3
C_ARMED
R
0x0004
4
S1_ARMED
R
0x0008
5
S2_ARMED
R
0x0010
6
S3_ARMED
R
0x0020
7
S4_ARMED
R
0x0040
8
S5_ARMED
R
0x0080
9
NF_ARMED
R
0x0100
PID status.
Bit flags indicating that a class of Faults is armed or not. 40154
1-9
Page 9 of 15
Current percent open of control outputs 40155
CTL_OUT_1_PERCENT
R
Current percent Control output.
40156
CTL_OUT_2_PERCENT
R
Current percent Control output.
40157
CTL_OUT_3_PERCENT
R
Current percent Control output.
40158
CTL_OUT_4_PERCENT
R
Current percent Control output.
40159
CTL_OUT_5_PERCENT
R
Current percent Control output.
40160
CTL_OUT_6_PERCENT
R
Current percent Control output.
40161
CTL_OUT_7_PERCENT
R
Current percent Control output.
40162
CTL_OUT_8_PERCENT
R
Current percent Control output.
Manual Percent Change to Control Outputs 40163
CTL_OUT_CHG_1
R/W
Percent to change Control Output
40164
CTL_OUT_CHG_2
R/W
Percent to change Control Output
40165
CTL_OUT_CHG_3
R/W
Percent to change Control Output
40166
CTL_OUT_CHG_4
R/W
Percent to change Control Output
40167
CTL_OUT_CHG_5
R/W
Percent to change Control Output
40168
CTL_OUT_CHG_6
R/W
Percent to change Control Output
40169
CTL_OUT_CHG_7
R/W
Percent to change Control Output
40170
CTL_OUT_CHG_8
R/W
Percent to change Control Output
Current computed PID setpoint. (May have changed because of overrides.) (See also PIDx_ADJUST at 40597-40600.) 40171
PID_TARGET_1
R
Current computed target.
40172
PID_TARGET_2
R
Current computed target.
40173
PID_TARGET_3
R
Current computed target.
40174
PID_TARGET_4
R
Current computed target.
Digital Output Force Mode Timer. Fixed duration 5 minutes (300 seconds). Zero means not in force mode, non-zero represents time left in force mode. 40175
DIG_FORCE_TIMER
R
In seconds. 5 minutes fixed.
Active Alarms (NUM_ALARMS has # of entries.) Alarm enumerations explanation. The top 1 bit of the alarm enumerations are masked off to get the enumeration. The top 1 bit indicates if an alarm has been acked. 40201
ALARM1
R
Enumeration, zero = none
40202
ALARM2
R
Enumeration, zero = none
40203
ALARM3
R
Enumeration, zero = none
40204
ALARM4
R
Enumeration, zero = none
40205
ALARM5
R
Enumeration, zero = none
40206
ALARM6
R
Enumeration, zero = none
40207
ALARM7
R
Enumeration, zero = none
40208
ALARM8
R
Enumeration, zero = none
40209
ALARM9
R
Enumeration, zero = none
Page 10 of 15
40210
ALARM10
R
Enumeration, zero = none
40211
ALARM11
R
Enumeration, zero = none
40212
ALARM12
R
Enumeration, zero = none
40213
ALARM13
R
Enumeration, zero = none
40214
ALARM14
R
Enumeration, zero = none
40215
ALARM15
R
Enumeration, zero = none
40216
ALARM16
R
Enumeration, zero = none
40217
ALARM17
R
Enumeration, zero = none
40218
ALARM18
R
Enumeration, zero = none
40219
ALARM19
R
Enumeration, zero = none
40220
ALARM20
R
Enumeration, zero = none
Maintenance Timers (time remaining) Maintenance Timers have the Hours kept in the most significant word. Minutes are in the high byte of the least significant word; Seconds in the low byte. 40301
MAINT1_HOURS
R
Hours
40302
MAINT1_MIN_SEC
R
Minutes, Seconds.
40303
MAINT2_HOURS
R
Hours
40304
MAINT2_MIN_SEC
R
Minutes, Seconds.
40305
MAINT3_HOURS
R
Hours
40306
MAINT3_MIN_SEC
R
Minutes, Seconds.
40307
MAINT4_HOURS
R
Hours
40308
MAINT4_MIN_SEC
R
Minutes, Seconds.
40309
MAINT5_HOURS
R
Hours
40310
MAINT5_MIN_SEC
R
Minutes, Seconds.
40311
MAINT6_HOURS
R
Hours
40312
MAINT6_MIN_SEC
R
Minutes, Seconds.
40313
MAINT7_HOURS
R
Hours
40314
MAINT7_MIN_SEC
R
Minutes, Seconds.
40315
MAINT8_HOURS
R
Hours
40316
MAINT8_MIN_SEC
R
Minutes, Seconds.
40317
MAINT9_HOURS
R
Hours
40318
MAINT9_MIN_SEC
R
Minutes, Seconds.
40319
MAINT10_HOURS
R
Hours
40320
MAINT10_MIN_SEC
R
Minutes, Seconds.
Shutdown History Log 6 bytes per entry including Hour Meter and Shutdown enumeration. A zero enumeration ends the list. Note the list is sorted in descending order from most recent to oldest. 40401
SHUTDOWN1_HOURS
R
Hours
40402
SHUTDOWN1_MIN_SEC
R
Minutes, Seconds
40403
SHUTDOWN1_ENUM
R
Shutdown enumeration
40404
SHUTDOWN2_HOURS
R
Hours
40405
SHUTDOWN2_MIN_SEC
R
Minutes, Seconds
40406
SHUTDOWN2_ENUM
R
Shutdown enumeration
Page 11 of 15
40407
SHUTDOWN3_HOURS
R
Hours
40408
SHUTDOWN3_MIN_SEC
R
Minutes, Seconds
40409
SHUTDOWN3_ENUM
R
Shutdown enumeration
40410
SHUTDOWN4_HOURS
R
Hours
40411
SHUTDOWN4_MIN_SEC
R
Minutes, Seconds
40412
SHUTDOWN4_ENUM
R
Shutdown enumeration
40413
SHUTDOWN5_HOURS
R
Hours
40414
SHUTDOWN5_MIN_SEC
R
Minutes, Seconds
40415
SHUTDOWN5_ENUM
R
Shutdown enumeration
40416
SHUTDOWN6_HOURS
R
Hours
40417
SHUTDOWN6_MIN_SEC
R
Minutes, Seconds
40418
SHUTDOWN6_ENUM
R
Shutdown enumeration
40419
SHUTDOWN7_HOURS
R
Hours
40420
SHUTDOWN7_MIN_SEC
R
Minutes, Seconds
40421
SHUTDOWN7_ENUM
R
Shutdown enumeration
40422
SHUTDOWN8_HOURS
R
Hours
40423
SHUTDOWN8_MIN_SEC
R
Minutes, Seconds
40424
SHUTDOWN8_ENUM
R
Shutdown enumeration
40425
SHUTDOWN9_HOURS
R
Hours
40426
SHUTDOWN9_MIN_SEC
R
Minutes, Seconds
40427
SHUTDOWN9_ENUM
R
Shutdown enumeration
40428
SHUTDOWN10_HOURS
R
Hours
40429
SHUTDOWN10_MIN_SEC
R
Minutes, Seconds
40430
SHUTDOWN10_ENUM
R
Shutdown enumeration
40431
SHUTDOWN11_HOURS
R
Hours
40432
SHUTDOWN11_MIN_SEC
R
Minutes, Seconds
40433
SHUTDOWN11_ENUM
R
Shutdown enumeration
40434
SHUTDOWN12_HOURS
R
Hours
40435
SHUTDOWN12_MIN_SEC
R
Minutes, Seconds
40436
SHUTDOWN12_ENUM
R
Shutdown enumeration
40437
SHUTDOWN13_HOURS
R
Hours
40438
SHUTDOWN13_MIN_SEC
R
Minutes, Seconds
40439
SHUTDOWN13_ENUM
R
Shutdown enumeration
40440
SHUTDOWN14_HOURS
R
Hours
40441
SHUTDOWN14_MIN_SEC
R
Minutes, Seconds
40442
SHUTDOWN14_ENUM
R
Shutdown enumeration
40443
SHUTDOWN15_HOURS
R
Hours
40444
SHUTDOWN15_MIN_SEC
R
Minutes, Seconds
40445
SHUTDOWN15_ENUM
R
Shutdown enumeration
40446
SHUTDOWN16_HOURS
R
Hours
40447
SHUTDOWN16_MIN_SEC
R
Minutes, Seconds
40448
SHUTDOWN16_ENUM
R
Shutdown enumeration
40449
SHUTDOWN17_HOURS
R
Hours
40450
SHUTDOWN17_MIN_SEC
R
Minutes, Seconds
40451
SHUTDOWN17_ENUM
R
Shutdown enumeration
Page 12 of 15
40452
SHUTDOWN18_HOURS
R
Hours
40453
SHUTDOWN18_MIN_SEC
R
Minutes, Seconds
40454
SHUTDOWN18_ENUM
R
Shutdown enumeration
40455
SHUTDOWN19_HOURS
R
Hours
40456
SHUTDOWN19_MIN_SEC
R
Minutes, Seconds
40457
SHUTDOWN19_ENUM
R
Shutdown enumeration
40458
SHUTDOWN20_HOURS
R
Hours
40459
SHUTDOWN20_MIN_SEC
R
Minutes, Seconds
40460
SHUTDOWN20_ENUM
R
Shutdown enumeration
Event History Log 6 bytes per entry including Hour Meter and Event enumeration. A zero enumeration ends the list. Note the list is sorted in descending order from most recent to oldest. 40501
EVENT1_HOURS
R
Hours
40502
EVENT1_MIN_SEC
R
Minutes, Seconds
40503
EVENT1_ENUM
R
Event enumeration
40504
EVENT2_HOURS
R
Hours
40505
EVENT2_MIN_SEC
R
Minutes, Seconds
40506
EVENT2_ENUM
R
Event enumeration
40507
EVENT3_HOURS
R
Hours
40508
EVENT3_MIN_SEC
R
Minutes, Seconds
40509
EVENT3_ENUM
R
Event enumeration
40510
EVENT4_HOURS
R
Hours
40511
EVENT4_MIN_SEC
R
Minutes, Seconds
40512
EVENT4_ENUM
R
Event enumeration
40513
EVENT5_HOURS
R
Hours
40514
EVENT5_MIN_SEC
R
Minutes, Seconds
40515
EVENT5_ENUM
R
Event enumeration
40516
EVENT6_HOURS
R
Hours
40517
EVENT6_MIN_SEC
R
Minutes, Seconds
40518
EVENT6_ENUM
R
Event enumeration
40519
EVENT7_HOURS
R
Hours
40520
EVENT7_MIN_SEC
R
Minutes, Seconds
40521
EVENT7_ENUM
R
Event enumeration
40522
EVENT8_HOURS
R
Hours
40523
EVENT8_MIN_SEC
R
Minutes, Seconds
40524
EVENT8_ENUM
R
Event enumeration
40525
EVENT9_HOURS
R
Hours
40526
EVENT9_MIN_SEC
R
Minutes, Seconds
40527
EVENT9_ENUM
R
Event enumeration
40528
EVENT10_HOURS
R
Hours
40529
EVENT10_MIN_SEC
R
Minutes, Seconds
40530
EVENT10_ENUM
R
Event enumeration
40531
EVENT11_HOURS
R
Hours
40532
EVENT11_MIN_SEC
R
Minutes, Seconds
Page 13 of 15
40533
EVENT11_ENUM
R
Event enumeration
40534
EVENT12_HOURS
R
Hours
40535
EVENT12_MIN_SEC
R
Minutes, Seconds
40536
EVENT12_ENUM
R
Event enumeration
40537
EVENT13_HOURS
R
Hours
40538
EVENT13_MIN_SEC
R
Minutes, Seconds
40539
EVENT13_ENUM
R
Event enumeration
40540
EVENT14_HOURS
R
Hours
40541
EVENT14_MIN_SEC
R
Minutes, Seconds
40542
EVENT14_ENUM
R
Event enumeration
40543
EVENT15_HOURS
R
Hours
40544
EVENT15_MIN_SEC
R
Minutes, Seconds
40545
EVENT15_ENUM
R
Event enumeration
40546
EVENT16_HOURS
R
Hours
40547
EVENT16_MIN_SEC
R
Minutes, Seconds
40548
EVENT16_ENUM
R
Event enumeration
40549
EVENT17_HOURS
R
Hours
40550
EVENT17_MIN_SEC
R
Minutes, Seconds
40551
EVENT17_ENUM
R
Event enumeration
40552
EVENT18_HOURS
R
Hours
40553
EVENT18_MIN_SEC
R
Minutes, Seconds
40554
EVENT18_ENUM
R
Event enumeration
40555
EVENT19_HOURS
R
Hours
40556
EVENT19_MIN_SEC
R
Minutes, Seconds
40557
EVENT19_ENUM
R
Event enumeration
40558
EVENT20_HOURS
R
Hours
40559
EVENT20_MIN_SEC
R
Minutes, Seconds
40560
EVENT20_ENUM
R
Event enumeration
40561
EVENT21_HOURS
R
Hours
40562
EVENT21_MIN_SEC
R
Minutes, Seconds
40563
EVENT21_ENUM
R
Event enumeration
40564
EVENT22_HOURS
R
Hours
40565
EVENT22_MIN_SEC
R
Minutes, Seconds
40566
EVENT22_ENUM
R
Event enumeration
40567
EVENT23_HOURS
R
Hours
40568
EVENT23_MIN_SEC
R
Minutes, Seconds
40569
EVENT23_ENUM
R
Event enumeration
40570
EVENT24_HOURS
R
Hours
40571
EVENT24_MIN_SEC
R
Minutes, Seconds
40572
EVENT24_ENUM
R
Event enumeration
40573
EVENT25_HOURS
R
Hours
40574
EVENT25_MIN_SEC
R
Minutes, Seconds
40575
EVENT25_ENUM
R
Event enumeration
40576
EVENT26_HOURS
R
Hours
40577
EVENT26_MIN_SEC
R
Minutes, Seconds
Page 14 of 15
40578
EVENT26_ENUM
R
Event enumeration
40579
EVENT27_HOURS
R
Hours
40580
EVENT27_MIN_SEC
R
Minutes, Seconds
40581
EVENT27_ENUM
R
Event enumeration
40582
EVENT28_HOURS
R
Hours
40583
EVENT28_MIN_SEC
R
Minutes, Seconds
40584
EVENT28_ENUM
R
Event enumeration
40585
EVENT29_HOURS
R
Hours
40586
EVENT29_MIN_SEC
R
Minutes, Seconds
40587
EVENT29_ENUM
R
Event enumeration
40588
EVENT30_HOURS
R
Hours
40589
EVENT30_MIN_SEC
R
Minutes, Seconds
40590
EVENT30_ENUM
R
Event enumeration
40591
EVENT31_HOURS
R
Hours
40592
EVENT31_MIN_SEC
R
Minutes, Seconds
40593
EVENT31_ENUM
R
Event enumeration
40594
EVENT32_HOURS
R
Hours
40595
EVENT32_MIN_SEC
R
Minutes, Seconds
40596
EVENT32_ENUM
R
Event enumeration
Percent 2 dec. places 0 to 10000 Percent 2 dec. places 0 to 10000 Percent 2 dec. places 0 to 10000 Percent 2 dec. places 0 to 10000 Dynamically computed P change. Dynamically computed I change. Dynamically computed D change.
PID adjustment calculations Each cycle through a PID it should adjust these values. 40597
PID1_ADJUST
R
40598
PID2_ADJUST
R
40599
PID3_ADJUST
R
40600
PID4_ADJUST
R
40601
PROPORTIONAL_ADJ
R
40602
INTEGRAL_ADJ
R
40603
DERIVATIVE_ADJ
R
40604
LS16 ACCUM ERROR
R
40605
MS16 ACCUM ERROR
R
Setpoints range (1-128) 43516 – 43644
SETPOINT 01 – SETPOINT 128
R/W
8.0 MCONFIGPRO REPORT (refer to attached PDF File)
Page 15 of 15
CENTURION™ Configurable Controller Installation and Operations Manual 00-02-0590 10-10-06 Section 50
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.
Warranty - A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
FW MURPHY has made efforts to ensure the reliability of the Centurion controller and to recommend safe usage practices in system applications. Please note that in any application, operation and controller failures can occur. These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the Centurion controller. Good engineering practices, electrical codes, and insurance regulations require that you use independent external protective devices to prevent potentially dangerous or unsafe conditions. Assume that the Centurion controller can fail with outputs full on, outputs full off, or that other unexpected conditions can occur. BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT: •
Please read the following information before installing the Centurion controller. This installation information is intended for Centurion controller only. Before installing, visually inspect the product for any damage during shipping.
•
Disconnect all power and be sure machine is inoperative before beginning installation.
•
Installation is to be done only by qualified technician.
•
Observe all Warnings and Cautions at each section in these instructions.
•
Device shall be wired in accordance with Class I, Division 2 wiring methods.
•
This equipment is suitable for use in Class I, Division 2, Groups B, C, and D hazardous Areas.
•
WARNING–Explosion Hazard–Substitution of components may impair suitability for Class I, Division 2.
•
Please contact Murphy immediately if you have any questions.
Table of Contents 1 Overview ............................................................................................................................... 1 1.1 Basic Components and Key Features of the C3 Series .........................................2 1.2 Optional Components.............................................................................................3 2 Input/Output Types .............................................................................................................. 4 2.1 Power Supply Wiring ..............................................................................................4 2.2 Input/Output Types and Specifications for the Main I/O Module ............................5 2.3 Input/Output Types and Specifications for the Optional Expansion Module ...........9 3 Hazardous Area Operation ............................................................................................... 11 4 Hardware Installation and Wiring..................................................................................... 12 4.1 Mounting the Controller ........................................................................................12 4.2 Mounting the Display............................................................................................12 4.3 Wiring the Display ................................................................................................13 4.4 Wiring the Controller.............................................................................................14 5 Using the Display............................................................................................................... 16 5.1 Features ...............................................................................................................16 5.2 Operational Screens.............................................................................................21 5.3 Setup Screens and Menus ...................................................................................27 5.4 Additional Navigational Aids.................................................................................54 6 Communications................................................................................................................ 55 6.1 Communication Ports ...........................................................................................55 6.2 Downloading Configurations and Firmware Updates ...........................................56 6.3 Modbus™ RTU Protocol .......................................................................................62 6.4 Transferring Data in Modbus................................................................................63 6.5 Modbus Register Address Listings .......................................................................63 7 Replacement Parts and Assemblies................................................................................ 63 8 Accessories........................................................................................................................ 63 8.1 Configuration Software.........................................................................................63 9 Glossary.............................................................................................................................. 64 10 Appendices....................................................................................................................... 66 10.1 Back Panel LED Description ..............................................................................66 10.2 Controller Accuracies, and Tolerances...............................................................66 10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens ...................67 10.4 Set Up Sheet......................................................................................................67
(THIS PAGE INTENTIONALLY LEFT BLANK)
1 Overview The Centurion configurable controller is a display and controller combination expressly designed to meet the requirements of three specific kinds of applications: •
Screw Compressors
•
Reciprocating Compressors
•
Pumps
The heart of the Centurion system is the main input/output (I/O) module or controller, which can be mounted on a standard DIN rail. While it is designed to work with any Modbus (Master) compliant HMI (Human Machine Interface) or with no operator interface at all, it is optimally configured and field-configurable through MConfigPro™, powerful software developed to configure the controller. Parameters can be modified in the field without special need for laptop or software by utilizing Murphy’s specially programmed controller display. The controller is designed to monitor, control, protect, and optimize small to medium sized gas operated compressors and pumps in the field. Proper operation is maintained by monitoring set points and digital, analog, and thermocouple input points and providing the logic to take corrective and/or proactive steps. The controller also allows for controlled shut down and no-flow monitoring as well as auto start up, and engine control capabilities. The controller provides real-time data via communications ports to a connected display and/or supervisory system. This advanced system offers multiple options for remote communications and operation. The industry standard RTU Modbus protocol means greater support for a wide variety of communication equipment including radio and satellite communications systems.
Section 50 10-10-06
00-02-0590 -1-
1.1 Basic Components and Key Features of the C3 Series The C3 series consists of a display module, a main I/O module, and optional expansion I/O module. No special cables are required. The Centurion system is designed for use within a weatherproof enclosure only. Display module (C3-3) 128 x 64 LCD graphic display (-40 to 85) °C •
Power 10 - 32 VDC: 1W typical, 6W (max) Storage power able to withstand 12V crank NOTE: Maximum power ratings based on display heater operating at maximum with 10V supply. Heater is only operational below -10C. Typical based on 24V supply.
•
Package and design Same 5” x 5” design as annunciators 12 key keypad
•
Communications LED active indication for each port RS232/485 (Modbus Master) RS232/485/USB 1.1 compliant port
•
Approvals CSA, CLASS 1, DIVISION 2, Groups B, C and D certifications are approved.
Main I/O module (C3-1) • 32 digital inputs (DI) • 10 digital outputs (DO) •
Direct input for analog and thermocouple inputs: o 12 analog input (AI) o 8 thermocouples (TC)
•
1 magnetic pickup (MPU)
Section 50 10-10-06
00-02-0590 -2-
1.2 Optional Components The C3-1 hardware may be configured with 2 analog outputs and it may be augmented through an expansion module (C3-2) which provides analog outputs and additional analog and thermocouple inputs. Main I/O Module with analog outputs (C3-1-A) •
Same specifications and I/O as C3-1, plus 2 analog outputs
Expansion I/O Module (C3-2) • • •
8 analog inputs (AI) 8 thermocouple inputs (TC) 4 analog outputs (AO)
Section 50 10-10-06
00-02-0590 -3-
2 Input/Output Types 2.1 Power Supply Wiring NOTE: Maximum power ratings based on all I/O operating in the ON position with 10V supply. Typical based on 24V supply.
2.1.1 Centurion I/O Module Requirements: (10 to 32) VDC: 30W (max) There are two screw terminal connectors for power hookup at terminals 62 and 63, labeled B+ and B- respectively.
2.1.2 Centurion (Optional) Expansion I/O Module Requirements: (10 to 32) VDC: 6W typical, 30W (max) There are three screw terminal connectors for power hookup at terminals 134 to 136, labeled B+, B and B- respectively.
NOTE: Run power directly from battery posts to controller power terminals when battery is the power supply.
Section 50 10-10-06
00-02-0590 -4-
2.2 Input/Output Types and Specifications for the Main I/O Module
Section 50 10-10-06
00-02-0590 -5-
2.2.1 Digital Inputs (DI) Number of devices: 32 Device types: discrete input, normally open (N/O) or normally closed (N/C), active high/active low, non-incendive. There is one screw terminal connector for each digital input. Terminals 30 to 61 are DI terminals. Green LEDs give visual indication of active input signal.
2.2.2 Analog Inputs (AI) Number of devices: 12 Device types: analog input, (4 to 20) mA or (0 to 5) V, 10 bit hardware. There is one screw terminal connector for each analog input. Terminals 18 to 29 are AI terminals.
Section 50 10-10-06
00-02-0590 -6-
2.2.3 Thermocouple Inputs (TC) Number of devices: 8 Device types: thermocouple input, type J or K, 12 bit hardware. Use ungrounded thermocouples only. Grounded thermocouples are not supported. Errors in readings with grounded thermocouples can be the result of differences in grounding between devices. Open thermocouple detection: drives terminal reading high (max of scale). Automatic cold junction compensation is built-in. There are two screw terminal connectors for each thermocouple. Terminals 1 to 16 are TC terminals where white or yellow indicate positive inputs and red indicates negative inputs. NOTE: An additional terminal connector is provided, identified as SHD, which isolates thermocouple shields. This connection, at terminal 17, is intended to be wired to an isolated bus bar for thermocouple shield wires. If shields are grounded, do connect shields to SHD terminal. Connect all shields to SHD or to ground but never both.
2.2.4 Magnetic Pickup (MPU) Number of devices: 1 Device types: magnetic pickup (MPU), (5 to 120) Vrms, (30 to 10k) Hz. There are two screw terminal connectors for the magnetic pickup. Terminals 64 and 65 are MPU terminals.
Section 50 10-10-06
00-02-0590 -7-
2.2.5 Digital Outputs (DO) Number of devices: 10 Device types: discrete output, normally open (N/O) or normally closed (N/C) •
four (4) relay outputs, form C, dry contacts
•
four (4) FETs (high speed)
•
two (2) IGBTs (high power)
There are three screw terminal connectors for each relay output and two screw terminal connectors for each FET and IGBT output. Terminals 70 to 81 are for the four relay terminals. Terminals 82 to 89 are for the four FET terminals. Terminals 90 to 93 are for the two IGBT terminals. Green LEDs give a visual indication of active output signal.
Warning: A heat sink is attached to the cover using acorn style nuts. The surface area around these fasteners can become very hot. Avoid contact.
Section 50 10-10-06
00-02-0590 -8-
2.2.6 Optional Analog Outputs (AO) Number of devices: 2 Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware There are two screw terminal connectors for each analog output. Terminals 66 to 69 are AO terminals. The optional AO module is added to the C3-1 at the factory inside the DIN enclosure. While these terminals are present on all models the feature may not be installed.
2.3 Input/Output Types and Specifications for the Optional Expansion Module 2.3.1 Analog Inputs (AI) Number of devices: 8 Device types: analog input, (4 to 20) mA or (0 to 5) V, 12 bit hardware. There is one screw terminal connector for each analog input. Terminals 126 to 133 are AI terminals.
Section 50 10-10-06
00-02-0590 -9-
2.3.2 Thermocouple Inputs (TC) Number of devices: 8 Device types: thermocouple input, type J or K, 12 bit hardware Open thermocouple detection: drives channel reading high (max of scale). There are two screw terminal connectors for each thermocouple input. Terminals 109 to 124 are TC channels where white or yellow indicate positive inputs and red indicates negative inputs. NOTE: An additional terminal connector is provided, identified as SHD, which isolates thermocouple shields. This connection, at terminal 125, is intended to be wired to an isolated bus bar for thermocouple shield wires. If shields are grounded, do connect shields to SHD terminal. Connect all shields to SHD or to ground but never both.
2.3.3 Analog Outputs (AO) Number of devices: 4 Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware There are two screw terminal connectors for each analog output. Terminals 137 to 144 are AO terminals.
Section 50 10-10-06
00-02-0590 - 10 -
3 Hazardous Area Operation The Centurion certifications for CSA, CLASS 1, DIVISION 2, Groups B, C and D are approved.
Warning: Explosion hazard – Do not disconnect the equipment unless the power has been switched off, or the area is known to be nonhazardous.
Section 50 10-10-06
00-02-0590 - 11 -
4 Hardware Installation and Wiring 4.1 Mounting the Controller The Centurion controller can be mounted vertically or horizontally on a standard DIN rail. Three clamp-type feet along the bottom of the controller attach to the DIN rail, however, rail stops are recommended to prevent sliding.
4.2 Mounting the Display The Centurion display can be mounted in the same hole cutout of other Murphy display modules. Four screws attach the display bezel to the mounting surface.
Section 50 10-10-06
00-02-0590 - 12 -
4.3 Wiring the Display
Section 50 10-10-06
00-02-0590 - 13 -
4.4 Wiring the Controller
Section 50 10-10-06
00-02-0590 - 14 -
Wiring the Controller (continued)
Section 50 10-10-06
00-02-0590 - 15 -
5 Using the Display The display module is a highly integrated operator interface specially programmed to complement and support the Centurion controller. The primary purpose of the display is to: •
view controller operational information
•
view/edit controller operational parameters
•
send commands to controller, such as stop, edit, and reset
5.1 Features 5.1.1 Keypad Description and Navigation
The keypad for the display has 12 keys. The following table describes the keys and their function for each of the three screen types: •
Operating status screens
•
Setup screens (password required)
•
Edit screens (password required)
Many of the keys have a modified action relative to the current location of the cursor and the current page being displayed. Section 50 10-10-06
00-02-0590 - 16 -
Key
ID HOME
ESC/ACK
Fn (Function Key)
SETUP/ENTER
RESET
Section 50 10-10-06
Description Operating Status Screen Allows the user to get to the first line of the current screen, or if pressed again, to get to the default operating status screen. Set Up Screen Allows the user to get to the first line of the current screen. Edit Screen No associated action. Operating Status Screen Acknowledge the active message/alarm that is currently displayed in the alarm banner. Acknowledges all active messages and alarms displayed in the active alarm screen. Set Up Screen Exit Setup mode. Edit Screen Exit without saving changes to the current configuration. Operating Status Screen Enter “Function mode” and display a dialog box with additional available functions. Automatically cancels upon moving to the next mode, or if no subsequent function is chosen within five seconds. Set Up Screen No associated action. Edit Screen No associated action. Operating Status Screen Enter Setup Mode. Set Up Screen Enter Edit mode or Sub-menu. Edit Screen Accept and save changes made to a current parameter before exiting edit mode. Operating Status Screen Reset any active timers and alarms/faults. Set Up Screen No associated action. Edit Screen No associated action.
00-02-0590 - 17 -
Key
ID RUN/STOP
ARROW UP
ARROW DOWN
ARROW LEFT
Section 50 10-10-06
Description Operating Status Screen Initiate or cancel a start sequence. (hold for 2 seconds) Set Up Screen No associated action in either shutdown mode, or remote mode on standby. Initiate stop only sequence when held for two seconds, if equipment is running. Edit Screen No associated action. Operating Status Screen Scroll up one line. Automatically repeats if held down continuously until reaching the first line. For history screens, scrolls up one history (for example: shutdown or event). Set Up Screen Scroll up one line. Automatically repeats if held down continuously until reaching the first line. Edit Screen Increase the digit selected by the cursor (from 0 to 9). The user will not be allowed to increase the selected digit if it would result in exceeding range limits. Operating Status Screen Scroll down one line. Automatically repeats if held down continuously until reaching the final line. For history screens, scrolls down one history (i.e. shutdown or event). Set Up Screen Scroll down one line. Automatically repeats if held down continuously until reaching the final line. Edit Screen Decrease the digit selected by the cursor (from 0 to 9). The user will not be allowed to decrease the selected digit if it would result in exceeding range limits. Operating Status Screen Display previous screen. Automatically repeats if held down continuously until reaching the first screen. Set Up Screen Display previous screen. This key has no action when in a sub-menu. Edit Screen Move the cursor left one position when a numeric value is displayed.
00-02-0590 - 18 -
Key
ID ARROW RIGHT
TEST
TIMER “0”
Section 50 10-10-06
Description Operating Status Screen Display next screen. Automatically repeats if held down continuously until reaching the final screen. Set Up Screen Display next screen. This key has no action when in a submenu. Edit Screen Move the cursor right one position when a numeric value is displayed. Operating Status Screen Enter test mode and start test timer. This is not applicable in shutdown mode. Set Up Screen No associated action. Edit Screen No associated action. Operating Status Screen Zero displayed timer (global timers, state timers, etc.) Set Up Screen No associated action. Edit Screen No associated action.
00-02-0590 - 19 -
5.1.2 Display Context The graphic LCD displays are organized around operating status screens and setup screens. The actual number of status screens will be related to the total number of end devices configured for the controller. In either screen set, ten (10) lines are visible at a time; with up and down arrow characters indicating more lines are available on the page. Also, for both screen sets, navigation between screens is accomplished by pressing the left or right arrow keys.
5.1.3 Numeric Entry The Centurion display allows individual editing of each position of the desired number. This is accomplished by entering the edit mode and using the UP/DOWN arrow keys (1) to adjust the number above the blinking cursor (2) between 0 and 9. To edit another position, simply use the LEFT/RIGHT (3) arrow keys to move the cursor to that position (4) and repeat the edit process until the desired number is displayed.
In this way, values are “built” rather than “scrolled” through. Some digits may not be allowed to increase if it would result in exceeding range limits. Values which can be positive or negative will have a sign (±) to the left of the number. To change the sign value simply move the cursor to the sign using the LEFT arrow key and “toggle” between + and – using the UP and DOWN arrow keys. If the range of the value will exceed range limits the sign may not be allowed to Section 50 10-10-06
00-02-0590 - 20 -
change. In this case, try reducing the number by decreasing the left most digit by one or more and attempt to change the sign again. In some instances, a word rather than a value is represented in the Edit Mode. This works like the sign value as an ON/OFF or YES/NO prompt where the value is “toggled” between choices using the UP/DOWN arrow keys. The value is not active in the controller until the ENTER key has been pressed to send the value to the controller. Pressing the ESC key will discard any changes and keep the original value prior to entering the Edit Mode.
5.2 Operational Screens In addition to the set up screens reviewed in the “Setup Screens and Menus” section, the display offers a number of operational displays. On the Operating Status screens, the two bottom lines display the state, hours, mode and active timer status. This information is key to understanding the “status” of the controller. Mode refers to the Operating Mode of the controller and can be LOCAL or REMOTE. Depending on the configuration active in the controller, the operation may differ depending on what Mode the controller is currently displaying. NOTE: The Mode can be changed by pressing certain keys, if the configuration allows for REMOTE mode. Pressing RESET or RUN/STOP is a Local function and will change the Mode to Local if it is in REMOTE. Pressing Fn before pressing RESET or RUN/STOP is a REMOTE function and will change the Mode to REMOTE if it is in LOCAL.
5.2.1 Default Operating Screen After turning on the power, the user will view the Murphy logo screen for three seconds before the next screen displays, which is a software-configured default operating screen. The MConfigPro software allows users to configure up to five screens with controller I/O groupings. Possible custom screen types that may have been configured as a default operating screen, or which may be also displayed, include: a) “Custom Line by Line” allows process data to be displayed in a list format with description and value. b) “Custom Gage” allows user to display four (4) most important pieces of data on a 2 x 2 table in larger font. c) “Custom PID” up to 4 PID screens. For more information on configuring the optional screens through the MConfigPro software, please refer to the MConfigPro Installation and Operations Manual.
Section 50 10-10-06
00-02-0590 - 21 -
5.2.2 Murphy Logo Screen
The Murphy logo is the first screen in the sequence of display screens and can be viewed by holding down the left arrow until scrolling left ceases.
5.2.3 Corporate and Version Information Screen
Following the Murphy Logo screen is the Murphy corporate contact information which also lists firmware version information for the Centurion display, the main I/O module and the MConfigPro Software.
Section 50 10-10-06
00-02-0590 - 22 -
5.2.4 Digital Input Status
The user can see the state of each digital input in a table—whether it is open or closed.
5.2.5 Shutdown History Screen
The history of the last 20 shutdowns is displayed on this screen, with the most recent at the top of the list and the oldest at the bottom. Each event is displayed with the shutdown label on one line and the hour meter reading on the following line. Pressing the up/down arrows will scroll up/down one shutdown at a time rather than one line at a time. The “1/3” at the right end of the top line means the user is viewing shutdown one of a total of three stored. The newest shutdown will always be number one and it will push the older shutdowns further down the list.
Section 50 10-10-06
00-02-0590 - 23 -
5.2.6 Shutdown Snapshot The shutdown snapshot screen is a capture of the values displayed on the Line-by-Line custom screen at the time of a Fault SD or ESD event. These values will be retained and display on the shutdown snapshot screen until the next Fault SD or ESD event occurs. An asterisk displayed instead of a value indicates the shutdown snapshot has not captured any data or is not functioning. NOTE: Only the first Line-by-Line screen configured will be captured. If no Line-by-Line custom screen is configured, the shutdown snapshot will not function. 5.2.7 Event History Screen
The history of the last 32 events is displayed on this screen, with the most recent at the top of the list and the oldest at the bottom. Events include shutdowns, starts, stops, resets, etc. The user easily can view the events (alarms, etc.) logged before and after a shutdown.
Section 50 10-10-06
00-02-0590 - 24 -
5.2.8 Active Alarms Screen
All active alarms and warnings will be displayed on this screen. If there are more than six active alarms, there will be up/down arrow icons at the bottom of the screen and the user can press the up/down arrow keys to scroll up or down. Unacknowledged alarms will be preceded by a musical note character and acknowledged alarms will have a bar through the staff of the note. Pressing ACK on this screen will acknowledge all active alarms. A maximum of twenty (20) active alarm will be displayed. NOTE: Alarms are warnings based on setpoints and/or digital inputs which are separate from shutdowns.
This screen shows the alarm annunciation as it will appear on a status screen. The alarm message(s) will overwrite the bottom line of the active screen area and then briefly clear once a second. This will continue until it is acknowledged with the ACK key, unless it is a self-clearing alarm. If there is more than one unacknowledged alarm active, each alarm will be displayed for one second each until acknowledged. The ACK key will acknowledge the alarm currently displayed. Pressing the Fn key followed by the ACK key will switch to the active alarms screen.
Section 50 10-10-06
00-02-0590 - 25 -
5.2.9 Gage Display This is an example of a custom gage display. MConfigPro software arranges the data as needed. This display provides larger characters for easier viewing as well as a means to prominently display items of interest. Unacknowledged alarms will overwrite the bottom half of the lower two gage boxes. The two bottom lines are used to display the mode, hours, state and active timer status.
5.2.10 Line-By-Line
This is an example of a custom line-by-line status screen. The MConfigPro software arranges the data as needed. Notice that there are no up/down arrows at the bottom of the screen because there are no additional lines to be displayed on this screen.
This is an example of a custom line-by-line status screen with more parameters. If the parameters do not fit in the viewable area of the screen, up/down arrow icons at the bottom of the screen can be used to scroll up or down. The two bottom lines are used to display the mode, hours, state and active timer status.
Section 50 10-10-06
00-02-0590 - 26 -
5.2.11 Custom PID Screen
The user may choose to display any configured PID functions in this convenient format. The control output will be displayed as a percentage of the range. The bottom two lines are used to display the mode, hours, state and active timer status.
5.3 Setup Screens and Menus The setup screens provide access to system parameters. These settings can be modified with appropriate password access. The two bottom lines in the setup screens display navigation and command options available such as EDIT, ACCEPT, CANCEL and MORE MENUS.
5.3.1 Password Screen Some settings are password protected, including the setup screens. This is the first screen seen when the SETUP/ENTER key is pressed. The password need only be entered once during any editing session. The password will reset when the editing session is exited, or is timed-out due to keyboard inactivity. Section 50 10-10-06
00-02-0590 - 27 -
The cursor begins at the last digit on the right. The user can adjust the value of each digit with the up/down arrows while the left/right arrows are used to select the digit to edit. Passwords are assigned using the MConfigPro software and each digit can range from zero to nine (except the first digit on the left) for a total range of 00000 to 65535 for the complete password. The user will not be allowed to increase the selected digit if it would result in exceeding range limits. NOTE: If the Standard password is not zero and a password of all zeroes is entered, the user will have “view only” access. Inactivity Timeout: Setup procedures must be started and completed in a timely manner. NOTE: After 3 minutes without activity, the keypad returns the default operational screen and a password must be re-entered to return to the setup and edit menus.
There are three separate levels of passwords to accommodate several security needs: “Standard” password – Allows access to every feature except the super user menu. Valid standard passwords can be zero or any number between 100 and 65535. If the standard password is set to zero, the result is that anyone can have read/write access to setup menus.
“Super User” password – Adds the super user menu to the standard menus. Valid super user passwords can be in the range of 100 to 65535. The super user password can not be the same as the standard password and cannot be set to zero.
Section 50 10-10-06
00-02-0590 - 28 -
“Download Only” password – This special 35 jump code allows access to a download menu and is set to a fixed value of 35. This allows a configuration to be downloaded in the event that the current passwords are lost or no initial configuration has been downloaded.
5.3.2 Digital Input For up to 32 configured digital input devices, the user may edit: a) Signal Type - Select normally open (N/O) or normally closed (N/C). b) Signal Filter - Select None to disable filter function for the digital input. This will not disable the digital input for normal operation. Select Pulse for lubricator divider blocks with a proximity switch output. Select DB to debounce or delay input detection for unstable inputs such as surge tank level. c) Filter Timing - Delay time in seconds for the selected filter type. For Pulse, this delay is the transition time for the lubricator divider block to cycle. For DB, this is the duration the digital input must remain either ON or OFF before the input will be recognized and accepted as ON or OFF by the sequence. If the input does not remain ON or OFF for the duration of the delay, the timer will reset. d) Total Pulses - Total number of pulses counted when the filter type is set to Pulse. The value is expressed in hundreds of pulses; a displayed reading of 1 is equal to 100 pulses. Section 50 10-10-06
00-02-0590 - 29 -
5.3.3 Digital Output
Digital output: For up to 10 configured digital output devices, the user may select whether an output is normally open (N/O), or normally closed (N/C).
Section 50 10-10-06
00-02-0590 - 30 -
5.3.4 Analog Input
For up to 20 configured analog input devices, the user may edit: a) Moving Average Samples. (1, 2, 4). b) Raw Count Offset to determine the lowest reading expected from the device. Typically 147 for 4-20mA or 0 for 0-5VDC c) Raw Count Span to determine the span from the lowest to highest reading expected from the device. Typically 586 for 4-20mA or 1023 for 0-5VDC d) Minimum to apply the appropriate minimum engineering scale. Example: 0 PSI for a 0-100 PSI PXT. e) Maximum to apply the appropriate maximum engineering scale. Example: 100 PSI for a 0-100 PSI PXT.
NOTE: Minimum and Maximum are used to define the input scaled in engineering units. Dual scales are not supported.
Section 50 10-10-06
00-02-0590 - 31 -
5.3.5 Analog Output
For up to 6 analog output devices, the user may edit: a) Raw Count Offset, the lowest reading expected from the device. Typically set to 0. b) Raw Count Span to determine the span from the lowest to highest reading expected from the device. Typically set to 10000. c) Minimum to apply the appropriate engineering scale. In most cases, 0% addresses a typical application and it is the Centurion’s default value. d) Maximum to apply the appropriate engineering scale. In most cases, 100% (10000) addresses a typical application and it is the Centurion’s default value.
Section 50 10-10-06
00-02-0590 - 32 -
5.3.6 Thermocouple Input
For up to 16 thermocouple devices, the user may edit: a) Thermocouple Type. Identify whether the calibration type should be set to J or K. b) Thermocouple Offset. Assign the thermocouple offset value.
Section 50 10-10-06
00-02-0590 - 33 -
5.3.7 General Timer Setup
User may edit all general purpose timers. Generally, global timers affect engine operation. They also help define an event. B1: All event types can be associated with, and locked out by, a Bx timer. B1 is the first global timer used for delaying an event condition detection. The timer starts in a running State (10 – 13) depending on which timers have been marked “In Use”. B1 is also known as the “Lockout Timer”, start bypass or start/run timer. B2: The second global timer used for delaying event condition detection. B2 is also known as a secondary “Lockout Timer.” NOTE: The Bx timers start after the Start key has been pressed and the controller has reached a "Running" state. States 10-13 are the "Running" states. C: The delay allowing a clear reading before beginning testing for the arming of Class C events. The default and typical time for most applications is 2 seconds. S: Users have up to five (5) options to assign additional special global timers to signals. The Sx timers begin concurrently with the Bx timers. No Flow: The global delay used for delaying the triggering of a no flow event. This global no flow timer is enabled after B1 expires, and begins timing after any of the pulse transition times configured in the digital input dialog expires.
Section 50 10-10-06
00-02-0590 - 34 -
Test: Time given to allow for maintenance testing of end devices without triggering a fault or shutdown condition. The timer initiates when switched to test mode. Ignition Off Delay: Time delay before the assigned ignition output turns off. This is typically used to burn remaining fuel vapors after the fuel valve is turned off. Ignition On Delay: Time delay before the assigned ignition output turns on. This is typically used to delay ignition until engine has started cranking (also known as a purge delay). Fuel On Delay: Time delay before the assigned fuel valve output is turned on. This is typically used to delay fuel until ignition has been turned on.
Section 50 10-10-06
00-02-0590 - 35 -
5.3.8 Maintenance Timer Setup
The user may access and edit the ten (10) maintenance settings for timer duration.
The user may also access and reset all timer duration and time remaining settings. All maintenance timer units are in hours. NOTE: While these are configured through MConfigPro, they must be manually initiated, or restarted, in Centurion display.
To initiate or reset timers, position cursor on TIME REMAINING and press the reset key.
Section 50 10-10-06
00-02-0590 - 36 -
5.3.9 Setpoints Setup User can edit any of the 128 setpoints that are configured. Setpoints further configure variable input types such as MPU, analog, or thermocouples by defining a threshold, exception or any other out-of-limit event that may require action. Multiple setpoints are often applied to a process and they may be configured as often as needed to meet changing conditions. Common alarm and shutdown setpoints a user might have configured include: • • • • •
High shutdown (High-High) High warning (High) Open warning (Open or Fail) Low warning (Low) Low shutdown (Low-Low)
To edit a configured setpoint: a) Assign numeric threshold that if crossed, triggers the setpoint.
b) Adjust the sign of the threshold value as plus (+) or minus (-) by moving the cursor to the sign symbol position and use the up and down keys to toggle the sign. For more on setpoints, please refer to the MConfigPro Installation and Operations Manual.
Section 50 10-10-06
00-02-0590 - 37 -
5.3.10 Control Output Setup The Centurion controller allows users to define up to eight (8) outputs to augment control not otherwise defined by digital output assignments. The Centurion can be configured through MConfigPro software to define an analog output, a digital output, a single pulsed digital output, or two pulsed digital outputs. NOTE: Control outputs 1 through 4, are directly related to PID calculation loops and are further defined in the PID dialog screens described in the PID Setup section. For example, PID 1 is assigned its control from control output 1, PID 2 from control output 2, and so on. If the configured output is a pulsed cycle, the user may edit those behaviors by assigning values the following: a) Increase Max On Time. Set limit of maximum on-time for Increase pulses. b) Increase Off Time. Set fixed off-time for Increase pulses. c) Increase Changeover On Time. Set fixed on-time for single pulse on direction change for Increase. d) Increase Changeover Off Time. Set fixed off-time for single pulse on direction change for increase. e) Decrease Max On Time. Set limit of maximum on-time for decrease pulses. f) Decrease Off Time. Set fixed off-time for decrease pulses. g) Decrease Changeover On Time. Set fixed on-time for single pulse on direction change for decrease. h) Decrease Changeover Off Time. Set fixed off-time for single pulse on direction change for decrease.
Section 50 10-10-06
00-02-0590 - 38 -
5.3.11 Proportional Integral Derivative (PID) Setup Users may view and edit up to four (4) MConfigPro software configured PID calculation loops. A PID provides a constant feedback loop, in which the PID can correct for a measured process variable against a desired set point, output the corrective action to the process and wait for and recalculate the next measurement. The ultimate goal of the PID is to reduce the error to zero while maintaining the control setpoint (e.g. speed, load, pressure). NOTE: During the time a PID is enabled, the PID always overrides control output settings found in the states dialog. PID 1 assumes control of control output 1, PID 2 assumes control of control output 2, and so on. To view and edit PID settings: a) Setpoint: Assign the desired goal—the target feedback base value. b) DeadBand: Assign a value around the setpoint during which the PID will not calculate error or take action. c) Ramp Time: Assign a time interval for the PID to calculate error. d) Max % of Change: Assign a percentage rate of change of the output, greater than which may cause harm to the system. e) Minimum Output: Assign a percentage as minimum output. Typically 0 (zero). f) Maximum Output: Assign a percentage as maximum output. Typically 10000 (100.00%) g) Proportional: Assign a constant value for the proportional coefficient of the PID loop calculation that causes a portion of the output to be a fixed amount proportional to the size of the error. h) Integral: Assign a value for the integral coefficient of the PID loop calculation that causes a portion of the calculated output to change with accumulated error over time.
Section 50 10-10-06
00-02-0590 - 39 -
i) Derivative: Assign a constant value for the derivative coefficient of the PID loop calculation that causes a portion of the calculated output to change with the change in the size of error versus time. j) OverRide Ramp Time: Assign a time interval value to wait before making the next override adjustment. NOTE: Override settings are only used when there is a configuration for overriding the primary PID control loop with another process variable. k) OverRide Ramp Amount: Determine the increments in a given direction (positive or negative) that the primary setpoint should be altered to regain balanced processes. In the example of the discharge and suction pressure application, this value would indicate how much the PID should resist its goal in reaching the setpoint. l) OverRide Max Change: Assign a maximum allowed change. This represents the total amount of change allowed into or out of the ramp amount from the setpoint. The maximum change value should be large enough to effect change.
For more on PID, please refer to the MConfigPro Installation and Operations Manual.
Section 50 10-10-06
00-02-0590 - 40 -
5.3.12 Initial RPM Setup
Assign values for: a) Warmup RPM. b) Wait to Load RPM. c) Run Loaded RPM. d) Cooldown RPM.
Section 50 10-10-06
00-02-0590 - 41 -
5.3.13 Miscellaneous Setup User can access and edit the miscellaneous settings. a) Crank Attempts (1-99): Define a value for number of crank attempts after which an over-crank sequence will be triggered in the event logic. b) Port 1 Slave Address (1-255): Provide the value for the Modbus address for port 1. The factory default is 1. c) Port 1 Mode: Select communication port 1 as RS232, or RS485. d) Port 1 Reply Delay (0-32767): To ensure sufficient time for the Modbus reply, assign appropriate time value for delay Modbus reply port 1. Typically set to 18. This setting only applies to Port Mode RS485. e) Port 1 Baud Rate: Select appropriate transmission baud rate (9600; 19200; 38400; 57600; 115200) f) Port 2 Mode: Select communication port 2 as RS232, or RS485. g) Port 2 Reply Delay (0-32767): To ensure sufficient time for the Modbus reply, assign appropriate time value for delay Modbus reply port 2. Typically set to 18. This setting only applies to Port Mode RS485. h) Port 2 Baud Rate: Select appropriate transmission baud rate (9600; 19200; 38400; 57600; 115200) NOTE: All ports use: -Parity: NONE -Data Bits: 8 -Stop Bits: 1
Section 50 10-10-06
00-02-0590 - 42 -
i) Flywheel Teeth: Define a value for flywheel teeth (Pulses Per Revolution) used to calculate RPM.
WARNING: The following cold temperature offset values should only be adjusted by personnel with a full working knowledge of the Centurion in conjunction with calibrated reference equipment.
j) Core Cold Temp Offset: Enter a nonzero value for core temperature adjustment (in tenths) to adjust the temperature readings for all thermocouple inputs on the main I/O module (C3-1). Entering a non-zero value will adjust the cold junction compensation reading used to calculate temperature. k) Exp Cold Temp Offset: Enter a non-zero value for expansion board temperature adjustment (in tenths) to adjust the temperature readings for all thermocouple inputs on expansion I/O (C3-2). Entering a non-zero value will adjust the cold junction compensation reading used to calculate temperature. l) Hour Meter: The user may make hour meter adjustments. The range is 0 – 65535 hours.
Section 50 10-10-06
00-02-0590 - 43 -
5.3.14 Pulse Input Status
Pulsed inputs are designed to accept a cycling digital output from a lubricator divider block; typically from a general purpose proximity switch. The user may view information about the pulsed inputs. If a digital input is designated for use as a pulsed input, it will display how much time elapsed before the last transition, and how much time has elapsed since that transition. If the input is not designated as a pulsed input, there will be zeros displayed. Both have a maximum value of 999.
5.3.15 Super User Menu The super user menu will only be visible if the super user password has been entered. a) Com Fail Disable: Set to Yes to prevent the Com Fail message from appearing when communication is lost or cannot be established. b) Setup T/O Disable: Set to Yes to prevent automatic logout from the Setup menus when no keys are pressed for the timeout period. c) Config Fail Disable: Set to Yes to prevent the Invalid Configuration screen from appearing when the display and controller configurations do not match. NOTE: Settings a thru c are for troubleshooting purposes and are not retained on power cycle.
Section 50 10-10-06
00-02-0590 - 44 -
d) Reset Fault History: Set to Yes to clear the Shutdown History screen. e) Reset Event History: Set to Yes to clear the Event History screen.
NOTE: The Reset History commands do not permanently switch to Yes when entered, but instead toggle back to No after sending the command to the controller. Also, the message “HISTORY CLEARED” will be displayed until another key is pressed.
f) Restore Defaults: Set to Yes to overwrite all settings changed through the display to the original configuration settings from the last download. NOTE: The Restore Defaults command does not permanently switch to Yes when entered, but instead toggles back to No after sending the command to the controller. Also, the message “DEFAULTS RESTORED” will be displayed until another key is pressed.
g) Standard Password: Set to Yes to enter the Standard User Password edit screen. The current password is displayed and can be changed. h) Superuser Password: Set to Yes to enter the Superuser Password edit screen. The current password is displayed and can be changed. Section 50 10-10-06
00-02-0590 - 45 -
NOTE: The Password commands do not permanently switch to Yes when entered, but instead toggle back to No after returning from the Password view/edit menu.
The P1 and P2 signify communication port 1 and communication port 2 and are for setting up the RS485 interfaces on the display’s serial ports. i) & k) PU/PD designates internal pull-up and pull-down resistors. These can be connected or disconnected by these settings. j) & l) TERMINATION designates internal terminating resistors. These can be connected or disconnected by these settings. NOTE: By default, both PU/PD and TERMINATION settings are set to YES for both Port 1 and Port 2 to enable these features for RS485. m) P1 Config Download n) P2 Config Download o) USB Config Download p) Firmware Download NOTE: Items m thru p communication port functions are also available for the configuration download menu. Refer to the section “Downloading Configurations to the Display” for details on download functions.
Section 50 10-10-06
00-02-0590 - 46 -
5.3.16 Configuration Download This menu allows for download only and can be accessed through the special jump code 35. It is the only screen available by entering the password 35. New configurations can be downloaded to the display by selecting the desired connection. (Com 1 Config Download, COM 2 Config Download, and USB Config Download) After enabling the download, download progress is indicated on the left side of the edit box as a percentage complete. After selecting Yes for download, and until No is selected after download is complete, only the enter key will be active. See the “Operational Screens” section for further details about downloading configurations. a) Com 1 Config Download: Selecting Yes initiates configuration download through communication port 1. b) Com2 Config Download: Selecting Yes initiates configuration download through communication port 2. c) USB Config Download: Selecting Yes initiates configuration download through USB port. d) Firmware Download: Selecting Yes initiates firmware download. This feature only supports USB download. The USB cable must be plugged into the USB port and connected to a pc before activating this selection. A firmware update mode screen will remain until the unit has been reset by remote command or a power cycle. See section “Downloading Firmware Updates to the display” for downloading new firmware.
Section 50 10-10-06
00-02-0590 - 47 -
5.3.17 Display Board Status
The user may view diagnostic information that reflects the operating conditions of the display only. a) Battery Volts - Indicates internal voltage measurement of display VDC input. b) Board Current - Indicates internal power measurement of display. Typical current measured at 24VDC is .04A or 40 milliamperes. NOTE: This value is higher when ambient temperature is below -10F. During this time the LCD heater will be active and consuming more power. c) Temperature - Indicates internal temperature measurement of display. This is used primarily to monitor ambient temperature to operate LCD heater. d) Heater PWM % - Refers to the LCD heater which only operates in cold temperature conditions. e) Reset Source - Indicates the cause of the last reset. Possible causes include external reset, power-up, brown-out and watch dog.
Section 50 10-10-06
00-02-0590 - 48 -
5.3.18 Digital Output Status
For each of the devices configured as “In Use” by MConfigPro, the user can see the state of each output and has the ability to force an output for the purpose of testing. A force is associated with a timeout so that it will be automatically cancelled when returning to normal operation. Each force operation resets the timeout to 5 minutes. The force timer expires after 5 minutes if no other forces are activated or when the user navigates away from the digital output status screen. The Force timer is shown in the bottom right corner of the digital output status screen when forces have been activated.
5.3.19 Analog Input Status The user can view the raw counts of the analog inputs for troubleshooting. NOTE: These values are used to establish the offset and span settings. Typical approximate raw readings for 4-20mA input: 4mA = 147 20mA = 733 The Span (16mA) is 586, therefore: 8mA = 293 12mA = 439 16mA = 585
Section 50 10-10-06
00-02-0590 - 49 -
5.3.20 Analog Output Status The user can see the state of each output, and if in test mode, has the ability to force an output for the purpose of testing. To force the output, enter a value from 0.00% = 4mA to 100.00%.= 20mA Any value in between will output a portion of the 16mA span proportional to the percent value. Analog outputs under the control of PID or other control output settings cannot be forced. To force a PID controlled output, place the PID in manual mode and operate the manual output value.
Section 50 10-10-06
00-02-0590 - 50 -
5.3.21 Thermocouple Status
The user may view the raw counts of the thermocouple inputs for troubleshooting.
Section 50 10-10-06
00-02-0590 - 51 -
5.3.22 Communication Status
Users may view the statistics for both of the display unit serial ports, including Modbus requests and responses. a) P1 Receive Count b) P1 Transmit Count c) P1 Frame Errors d) P1 HW Overruns e) P2 SW Overruns f) P2 Receive Count g) P2 Transmit Count h) P2 Frame Errors i) P2 HW Overruns j) P2 SW Overruns k) Modbus Requests l) Modbus Responses m) Modbus Exceptions n) Modbus Invalid Response o) Modbus No Response p) Clear Statistics q) Modbus Register
Section 50 10-10-06
00-02-0590 - 52 -
5.3.23 PID Diagnostics
For each of four (4) possible configured PIDs, user may edit: a) Display PID Bar Graph: Monitors the results of modifying the PID components. b) Proportional: Edit the proportional coefficient value. c) Integral: Edit the integral coefficient value. d) Derivative: Edit the derivative coefficient value. e) Auto/Manual: Setting to manual mode allows the corresponding Set Output value to be adjusted. f) Set Output (Manual): In manual mode allows adjustment from 000.00 to 100.00. The output will correspond to the control output associated with the PID. g) Reference Line Select: Setting to select the display value that will appear on the line above the separator line and below the PID name. This setting is useful for showing the process value of a different analog, thermocouple, or speed input that may be effected by changes to the PID output. Select from available analog, thermocouple, or speed inputs or None to disable the Reference Line Select feature.
Section 50 10-10-06
00-02-0590 - 53 -
5.4 Additional Navigational Aids 5.4.1 Function Key
Pressing the function (Fn) key from any screen will display a dialog box on the bottom half of the screen. All available function key commands will be displayed there. The user can then press a single key for the available commands. In this case, the user can select from a help screen, the alarms screen or issue a remote mode command. If the Fn key is not followed by another key press in five seconds, function mode will time out and the dialog box is replaced with the previous screen. NOTE: In all cases the Fn key options will be context sensitive. Some options will only be available from certain screens or under certain conditions.
5.4.2 Help Key
This is the help screen the user will see by pressing the HOME key from the Fn dialog box or by pressing the Fn key followed by the HOME key from a normal screen.
Section 50 10-10-06
00-02-0590 - 54 -
6 Communications 6.1 Communication Ports 6.1.1 Port 1 (SERIAL) Port 1 is intended as the primary port for the local device, the display, and should be utilized for display in order for the boot loader mode to properly execute in pass-through mode. Interface: Refer to the sequence of operations to determine how the communication port has been configured. Protocol: Modbus RTU (slave) Connection: There are three (3) screw terminal connectors for RS485. These are identified as A, B, and SHD. There are three (3) screw terminal connectors for RS232. These are identified as RX, TX, and DTR. SHD is common for both ports.
6.1.2 Port 2 (SERIAL) Interface: Refer to the sequence of operations to determine how the communication port has been configured. Protocol: Modbus RTU (slave), Proprietary (binary) Connection: There are three (3) screw terminal connectors for RS485. These are identified as A, B, and SHD. There are three (3) screw terminal connectors for RS232. These are identified as RX, TX, and DTR. SHD is common for both ports. Modbus RTU Slave Address Configuration: The operator may assign a unique Modbus address to each controller (slave) unit that may be in the system. This allows the master controller to differentiate between the modules. For example, to name the controller address 21, place the shunts on LK1, LK4, and LK16 (1 + 4 +16 = 21). Typically, this configuration is set to (1) by the factory.
Section 50 10-10-06
00-02-0590 - 55 -
6.1.3 Port 2 (USB) Interface: USB 1.1 compliant port capable of emulating RS232 communications via royaltyfree pc driver. Protocol/Services: Modbus RTU (slave), Proprietary (binary) Connection: There is a USB type B connector. Automatic selection of USB is provided when a signal is detected on the USB type B connector. Connections for RS485 and RS232 will not be enabled on port 2 when USB is connected.
6.1.4 Port 3 (CAN) Protocol/Services: Proprietary (binary) Connection: There are three (3) screw terminal connectors for CAN. These are identified as HI, LOW, and SHD. On Main I/O Module Located next to the USB connector is the CAN OK (COP). When in the boot loader the COP LED does not flash. When the program is running properly the COP LED will flash on and off every 0.5 seconds. If the checksum in the configuration file does not match the calculated checksum of the file, then the program will flash the COP LED 3 times at 0.5 second intervals and then stay off for 1.5 seconds. On the Expansion I/O Module When the program is running properly the COP LED will flash on and off every 0.5 seconds.
6.2 Downloading Configurations and Firmware Updates The Centurion controller and display are configured and upgradeable through software transfers using a PC or laptop computer. Configurations provide the necessary instructions to the controller and display and install default parameters that can be adjusted through the display or Modbus RTU. Firmware defines the available features that can be configured in the controller and display using the MConfigPro software. Since no chips are used to change the behavior of the equipment, Murphy can provide future enhancements and support changes to process requirement for customers using a simple email. Section 50 10-10-06
00-02-0590 - 56 -
6.2.1 Boot Loader It is necessary for the Centurion controller to enter boot loader mode in order to receive downloads for a firmware update, and configurations from MConfigPro. During boot loader mode the Centurion is able to receive configuration updates from the MConfigPro software and transmit configuration updates to display through pass-through. Communications will operate according to default state parameters for configuration transfers. During boot loader mode, the transfer rate is 9600, N, 8, 1 and assumes a serial communication port setting of RS485 or a USB connection. The controller recognizes whether the incoming data is for a configuration, or firmware update. In order for the Centurion configurable controller to enter boot loader mode, the address jumpers are removed during power up (power cycled). The display and third party HMI devices will not receive a response to polls on port 1 while the boot loader is active. Power on the Centurion must be cycled with the jumper installed to resume normal operation, or run mode. See section “Port 2 (Serial)” in the Controller Communication Ports chapter for more details on address jumpers.
6.2.2 Pass-through During boot loader, the Centurion controller allows users to remain connected to both the PC and the display and update the two devices with a single connection. The Centurion controller accepts the message through one port (port 2) and passes it through another port (port 1) directly to the display, as if the pc and display were directly connected.
Section 50 10-10-06
00-02-0590 - 57 -
6.2.3 Downloading Configurations to the Display All configuration downloads will use a baud rate of 9600. The com 1 selection will use the hardware setup of the current configuration. The com 2 selection is a fixed hardware setup for RS485. Selecting USB for configuration download connects the USB adapter to com 2 internally. All normal communication with the controller is stopped while in download mode. The display will indicate the transfer is complete by displaying 100%. Special 35 Jump Code In the case that no configuration has been downloaded, or a password has been lost, the display allows a “Download Only” password that will allow access to the download menu. The password is set to a fixed value of 35.
6.2.4 Downloading Configurations via MConfigPro Software The Centurion controller allows the user to easily download a configuration through the MConfigPro software. 1. Connect your PC to the controller using either the RS485 or USB connection on Port 2. For USB, a PC device driver must be installed. Upon initial connection to the WellPro, a new Com Port will be activated on the PC device manager. Take note of the new Com Port assignment to be used for all future communications with the WellPro. 2. Remove address jumpers from the controller located near the USB connector and cycle power to the controller. Take note of the original location of the jumpers to re-install them correctly after download. 3. Click on the Transfer menu, and then choose Configurations. 4. Select the configuration file supplied by FW Murphy from dialog and click Open. You may need to change the selection for Files of Type to find the file type you wish to download. In most cases, this will be *.MCP, however, other file types are available for specific configuration types.
Section 50 10-10-06
00-02-0590 - 58 -
5. After selecting the configuration file, the next dialog will provide a choice for the target device and PC Com Port to transfer the data. Choose the appropriate Com Port and controller as the target device and click next. 6. Click Begin Transfer from the dialog box that appears and the transfer will begin. When the Status message displays Transmitting 148 lines, the connection has been establish and should be providing a progress bar. 7. While the transfer is in progress, the display can be setup to accept the new configuration. 8. From the display keypad, press SETUP and enter password 00035 and press ENTER.. 9. The display will show the CONFIGURATION DOWNLOAD screen. Make sure the cursor is positioned on the line COM 1 CONFIG DOWNLOAD and press ENTER. 10. Change the NO to YES in the edit line at the bottom of the screen using the UP ARROW key and press ENTER. The display is now ready to accept a download.. 11. At this step, wait for the controller download to complete and click close on the MTransfer dialog. 12. Repeat steps 3 - 6 choosing the display as the target device in Step 5. 13. Click Begin Transfer from the dialog box that appears and the transfer will begin. When the Status message displays Transmitting 655 lines, the connection has been establish and should be providing a progress bar. 14. Once the transfer is complete click Close on the dialog and replace the address jumpers on the controller. 15. Cycle power on the controller and display and the new configuration will be loaded and running.
Section 50 10-10-06
00-02-0590 - 59 -
6.2.5 Downloading Firmware Updates to the Display Firmware updates for the display require a USB connection. While boot loader mode for the display is not required for configuration downloads, it is required for firmware updates. The boot loader can be entered by menu selection if the USB cable is currently connected, otherwise the display will reset and restart the current application firmware. Optionally, the boot loader can be entered by connecting the USB cable and cycling power. (This method will leave the display blank while in the boot loader.) Upon entry to the boot loader, all communication from the display to the controller will stop. There is a red status LED below the USB connector that will blink three times and then remain on while the boot loader is active. While a file is being transferred, the com 2 transmit LED will be lit continuously. A successful download should complete in approximately five minutes. Special 35 Jump Code The Centurion display allows a “Download Only” password that will allow access to the download menu. The password is set to a fixed value of 35. Once at the “Download Only” screen on the display, the user will select to download a firmware update. Super User Menu The super user menu is used to download firmware updates. All normal communication with the controller is stopped while in download mode. The display will indicate the transfer is complete by displaying 100%. Section 50 10-10-06
00-02-0590 - 60 -
6.2.6 Error Messages On occasion an invalid configuration error might display because the configuration between the Centurion controller and its devices are out of synch -- the checksums do not match. The invalid configuration screen will appear briefly after downloading configurations until comparisons are made. The user may direct the error message to be ignored through a setting at the super user menu. At “CONFIG FAIL DISABLE”, the user would select Yes to ignore the data mismatch. This setting is temporary. Once power is cycled-on, the error message will continue until comparisons between the devices yield no configuration mismatch. Two options are available for synchronizing data when fine-tuning changes are made in the field. They are: •
A super user could choose to also download the configuration from the super user menu on display.
•
A user without access to the super user menu could activate the download through the special jump code 35.
This screen indicates that the controller is not responding to poll requests. There are only two ways to exit this screen, either by normal responses resuming or if the SETUP/ENTER key is pressed.
Section 50 10-10-06
00-02-0590 - 61 -
This screen will be displayed when a configuration fault is detected. Possible sources of the fault include a corrupt or missing configuration in the display, a corrupt or missing configuration in the controller or a mismatch of configurations in the display and controller. This screen will appear briefly after configuration downloads and may appear briefly after initial communication is established until comparisons are complete. The fault can be resolved by downloading the proper configuration to one or both devices NOTE: This error message does not always indicate a problem, but may only signify that initial comparisons between devices do not match.
6.3 Modbus™ RTU Protocol The Centurion configurable controller was programmed with the Modbus protocol which is a system based on a “master” and “slave” relationship. With Modbus protocol, the master and slave are able to continue to communicate with each other through defined messages over a variety of network types. The master initiates the queries or commands, and the slave responds to the query with a message or takes action based on the query. In this case, the master is either MConfigPro (or another Modbus client software), or display, but never both simultaneously as there can only ever be a single Modbus master. The Centurion system communicates through Modbus using remote terminal unit (RTU) transmission mode to maximize data processing. As with all numeric data defined within Modbus, the programming is limited to accepting integers (whole numbers only, no decimals). This is important whenever a decimal point is defined for analog inputs. For example, for the controller to properly read “100.0” with an implied decimal point of 1, the user would need to enter “1000” and 1000 would be stored in the appropriate Modbus register. From the display, the value will be represented with a decimal in the fixed position. For additional information, please refer to the “MConfigPro Configuration Software Installation and Operations Manual”. Section 50 10-10-06
00-02-0590 - 62 -
6.4 Transferring Data in Modbus Note that text visible in the MConfigPro software and on the display is not stored in the Centurion controller. Except for the version description in the version and security dialog for each configuration file, descriptions assigned in the configuration are not stored in the Centurion controller. Descriptions for various I/O and processes are downloaded to the display and reside as a configuration in that device only. Configurations of the display are one way only. Parameter changes made in the display are actually communicated to the Centurion controller where the logic resides. No changes made through the display affect the display configuration as the display merely reads from, and writes to the Centurion main I/O module. As such, the display can write numeric parameters to the controller.
6.5 Modbus Register Address Listings For a complete Modbus address map, please refer to the Centurion Modbus reference document.
7 Replacement Parts and Assemblies C3-1 Plug Kit
(00000504)
C3-2 Plug Kit
(00000505)
C3-3 Plug Kit
(00000543)
Choke
(50000774)
Printed replacement terminal plugs for Centurion Main I/O module Printed replacement terminal plugs for Centurion Expansion I/O module Printed replacement terminal plugs for Centurion display module Ignition noise (choke) filter
8 Accessories 8.1 Configuration Software 8.1.1 MConfigPro MConfigPro is the configuration software for modifying sequence of operation, set points, timers, faults, and displays* for Centurion. Includes file transfer utilities for configuration and firmware upgrades. CD, MConfigPro (50-70-0989) MConfigPro configuration software. *Display configuration and other settings for display are only for use with the display Module.
Section 50 10-10-06
00-02-0590 - 63 -
9 Glossary Analog Input
Terminals 18 to 29 are analog inputs on the Centurion Main I/O module. Accepts voltage signals within the range of (0 to 5) VDC or (4 to 20) mA and are compared to controller set points and/or displayed.
Boot Loader
Means by which the Centurion controller communicates with display and MConfigPro to receive and transfer new or updated configurations and firmware; and ensure data and configuration synchronization.
Controller Setpoints
User defines normal operating range for the controller to optimize the equipment. Setpoints can also define some other threshold, exception or event that may require action. Multiple setpoints are often applied to a process and they may be manipulated as needed to meet changing conditions.
DeadBand
The user set range at which input may fluctuate without the controller taking any action. The range may be fixed or variable.
Digital Input
Terminals 30 to 61 are the digital input channels. User selects whether digital input is normally open (N/O), or normally closed (N/C). Users may also associate these inputs with transition times for indicating noflow conditions on divider blocks.
Event
Defines the action required by the controller in response to any number of parameters. Event actions range from simple alarm message to emergency shutdown (ESD).
No-flow
Designed to protect against compressor or engine failures, the controller monitors the cycle time of lubrication system cycles and if that cycle time falls under a user assigned value, the controller will activate a defined associated action such as an alarm or shutdown.
Offset
User defined value to correct for known variance in the raw data.
Panel Ready
In states, the first logical step in start up.
Permissive
A process condition, (digital input or analog setpoint), that must be met in order for the sequence to proceed to the next state.
Signal
An electrical quantity of voltage or current that is used to represent or signify some other physical quantity such as the state of a switch (ON/OFF) or the status of a device (SHUTDOWN/OK)
Span
The difference between the full scale output and the offset as raw data.
Start Delay
A time delay function to prevent premature start up.
Section 50 10-10-06
00-02-0590 - 64 -
State
Predefined step of multiple logical steps (or states) needed to successfully start and operate a compressor.
Terminal Emulator
Allows a user to modify the firmware to allow upload or download of a record to either the display or the controller. Always download a configuration after a firmware change.
Thermocouple
A device for measuring temperature consisting of two dissimilar metals of high purity for an accurate temperature/voltage relationship. User defines whether the calibration is J or K. Terminals 1 to 17 are for thermocouple inputs. Type J uses Red (-) and White (+) insulation. Type K uses Red (-) and Yellow (+) insulation.
Section 50 10-10-06
00-02-0590 - 65 -
10 Appendices 10.1 Back Panel LED Description There are a total of seven (7) LED indicators on the back panel, labeled as follows:
10.1.1 (Port 1) TX – Turned on while port 1 is transmitting data. RX – Turned on while port 1 is receiving data.
10.1.2 (Port 2) TX – Turned on while port 2 is transmitting data. RX – Turned on while port 2 is receiving data.
10.1.3 USB LINK Turns on while there is a USB connection to a computer.
10.1.4 STAT 1 Turns on for one half second and then turns off for one half second, repeating as long as there is a valid configuration running. NOTE: This indicator is not active while the boot loader is running.
10.1.5 STAT 2 This LED is only active while the boot loader is running. It flashes briefly three times when the boot loader starts up and then stays on until leaving the boot loader.
10.2 Controller Accuracies, and Tolerances Refer to the Centurion Configurable Controller Specification Sheet for a detailed breakdown of specifications.
Section 50 10-10-06
00-02-0590 - 66 -
10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens Due to a combination of the limited space and the spirit of the design objectives, there are certain restrictions imposed upon the formatted size of numbers in display screens. •
Positive numbers with no decimals can be displayed with up to four digits.
•
Negative numbers are limited to three digits.
•
Numbers of either sign with a decimal place are limited to three digits.
•
Numbers with more than two decimal places will not be displayed at all, but will be replaced with dashes.
If a number with decimals is larger than the imposed limits, the display algorithm will attempt to adjust the precision so as to display as many of the most significant digits as possible.
10.4 Set Up Sheet Refer to The Centurion Configuration Worksheet for a detailed workbook to document field changes to configuration parameters.
Section 50 10-10-06
00-02-0590 - 67 -
Section 50 10-10-06
00-02-0590 - 68 -
MURPHY, the Murphy logo, Centurion™ and MConfigPro™ are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Section 50 10-10-06
00-02-0590 - 69 -
OPERATIONAL SCREENS
CENTURION DISPLAY SCREEN MAP
LOGO
VERSION INFORMATION
DIGITAL STATUS
NAVIGATION Use left and right arrow keys to move between top level screens.
SHUTDOWN HISTORY
SHUTDOWN SNAPSHOT
EVENT HISTORY
ACTIVE ALARMS
CUSTOM 1
CUSTOM 2
CUSTOM ...
CUSTOM 5
CUSTOM SCREENS Up to 5 custom screens can be configured using MConfig Pro. Screens can be arranged in any order. However, all custom screens will appear after the ACTIVE ALARMS screen.
PASSWORD
PASSWORD ENTRY 0 (zero) = Read ONLY access to the Setup Screens. 35 = Download ONLY
SETUP SCREENS
Passwords for “Standard” and “Super User” are configured using MConfig Pro. Refer to 00-02-0590 pg. 25 for additional information on password functionality.
SETPOINTS 1-16 17-32 33-48 …...
GENERAL TIMERS
STATE TIMERS
SETPOINT ###-### SUBMENU
FN MENU
HELP SCREEN
NAVIGATION Use left and right arrow keys to move between top level screens.
MAINTENANCE TIMERS
PID
MAINTENANCE TIMER # SUBMENU
PID # SUBMENU
INITIAL RPM
MISCELLANEOUS
CONTROL OUTPUTS
DIGITAL INPUTS
CONTROL OUTPUT # SUBMENU
DIGITAL INPUT # SUBMENU
PULSE INPUT STATUS
DIGITAL OUTPUTS
continued...
SETUP SCREENS
NAVIGATION Use left and right arrow keys to move between top level screens.
ANALOG INPUTS
ANALOG OUTPUTS
THERMOCOUPLES
ANALOG INPUT # SUBMENU
ANALOG OUTPUT # SUBMENU
THERMOCOUPLE # SUBMENU
SUPER USER MENU
DISPLAY BOARD STATUS
DIGITAL OUTPUT STATUS
ANALOG INPUT STATUS
ANALOG OUTPUT STATUS
THERMOCOUPLE STATUS
COMMUNICATION STATUS
PID DIAGNOSTICS
PID # OPTIONS
NAVIGATION Use left and right arrow keys to move between top level screens.
HOME Up to 5 custom screens can be configured using MConfig Pro. One custom screen is configured as the default or “HOME” screen. While viewing the OPERATIONAL SCREENS, pressing the HOME key will jump from the currently displayed screen to the configured default screen. NAVIGATION Look for cues on screens to indicate what navigation is possible.
This function is not available in SETUP SCREENS. However, pressing this key on any multi-line display when the first line is not being displayed will jump to the top or “HOME” line on that screen.
00-02-0161 Revised 03-06 Section 05
Installation for 4-1/2 in. (114 mm) dial Pressure Murphygage® and Swichgage® instruments Model Series: OPLC, OPLG, OPLBP, 45APE, 45APEBP, PT167EX and 45 Series Options: -OS, -ES, -P4 and -P6
Please read the following instructions before installing. A visual inspection is recommended before mounting. General Information and these installation instructions are intended for all 4-1/2 in. (114 mm) dial pressure models. GENERAL INFORMATION
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT ✔ Disconnect all electrical power to the machine. ✔ Make sure the machine cannot operate during installation. ✔ Follow all safety warnings of the machine manufacturer. ✔ Read and follow all installation instructions.
OPLC and OPLFC Swichgage instruments have high and low limit contacts to monitor, alarm or shut down. The OPLC has a flanged case. A method to override the low limit contact for start-up is provided on most models. See Operation Test section–page 3. OPLFC can be direct or panel mounted (see page 2). OPLG and OPLFG Murphygage indication-only pressure instrument are similar to OPLC and OPLFC models, without switch (limit) contacts. 45 Series includes a magnetic switch to stop an engine or electric motor each time the gage contact operates. A lockout push button overrides low contact for startup. Other variations available.
Sensing Element: Bronze or 316 stainless steel bourdon tube. Gage Accuracy: All models and 45APE/45APEF between switch points: ±2% for first and last quarters of scale; middle half of scale is ±1%. Model 45APE/45APEF Indicating Pointer above or below set point: Range Accuracy (±% F.S.) above and below s.p. only <100 (except 15 psi) 10 15 15 100-300 4 400-1500 2 2000 12 3000-5000 8 Based on testing performed with switch point at mid scale which represents worst case. LOW SET POINT POINTER LOCATION
HIGH SET POINT POINTER LOCATION
50
40 300
30
400
200 PRESSURE
20 100
70 500
INCREASING ERROR FOR INDICATING POINTER
featuring pilot duty limit switches connected to an internal latching control relay for “on/off” control directly or through a motor starter.
PT167EX The Murphy PT167EX is a pressure Swichgage instrument connected to a threaded pressure diaphragm housing. The Swichgage instrument is enclosed in an explosion-proof case and is CSA rated for Class I, Division 1, Groups C and D.
Specifications Dial: White on black, dual scale, psi/kPa standard, 4-1/2 in. (114 mm) diameter. Case: Die cast aluminum, surface or panel mount. Process Connection: 1/4 NPTM thru 1000 psi; 1/2 NPTM 1500 - 10,000 psi.
Precautions: Do NOT exceed rated pressure range. Dope or use teflon tape on connection threads. Do not block the inlet orifice. For direct mount into the process, a vertical or ninety degree mounting is recommended. Use wrench on shank to tighten or loosen connection. Do not twist case when installing, this will damage internal components and will void the warranty. Do not overtighten. Use shock mounts as necessary to prevent excessive vibration. If liquid in the system freezes, it will expand and will damage the tube. For 45APE Series – Low setpoint should be limited to the lower 1/2 scale and upper setpoint should be limited to the upper 1/2 scale.
60 400
200 PRESSURE
70 500 80 600 90
10
90
0
0
45APE and 45APEF Series are versions of the OPLC Series
OPLBP and 45APEBP are versions of the OPLC and 45APE
30
600 kPa
300
100
kPa
0 PSI
100 MAXIMUM ERROR
featuring 2 snap-acting SPDT switches instead of the pointer type contacts. These units do not include low contact lockout.
INCREASING ERROR FOR INDICATING POINTER
20
80
10 0 PSI
50
40
60
100
MAXIMUM ERROR
Switch Point Accuracy: ±1.5% (45APE/45APEF). Switch Reset Deadband: Approximately 10% FS (45APE/45APEF). Snap-Acting Switches: See wiring information (page 4) (45APE/45APEF). Overrange: Do not exceed 10% FS above full range. Pressure Relief Disc: Back of case (except EX models). Dry Relay Contact (“BP” Models): 10 A @ 28 VDC or 10 A @ 120 VAC. Wire Connections (Surface Mount): 1/2 NPTF conduit/ terminal block. Wire Connections (Panel Mount): Wire leads, 18 AWG (1.0 mm2) x 9 in. (229 mm) long. Wire Connections (-ES, -OS): 1/2 NPTM conduit and wire leads, All except 45APEF: 18 AWG (1.0 mm2) x 33 in. (838 mm) long. 45APEF 24 AWG (0.22 mm2) x 33 in. (838 mm) long. Item Weight: 5 lbs 6 oz (2.4 kg) approximately. Explosion-proof models: 21 lb. (9.5 kg) approx. Item Dimensions: 10 x 9 x 6 in. (254 x 229 x 152 mm) approximately. Explosion-proof models: 12 x 12 x 9 in. (305 x 305 x 229 mm) approximately.
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm. *Selected configurations are third party listed. Consult factory for details.
Installation 00-02-0161 page 1 of 4
OPL Series Wall Mount
45APE Series Wall Mount
Flanged case design intended for wall mount, it can also be direct mounted. Shown with shock mounts and pulsation dampener.
3-15/16 in. (100 mm)
4-1/32 in. (102 mm)
3-3/8 in. (86 mm)
8-7/16 in (214 mm)
4-1/32 in. (102 mm)
8-7/16 in. (214 mm)
3-3/8 in. (86 mm)
3-15/16 in. (100 mm)
1/2NPTF conduit
1/2 NPTF Conduit
7-7/8 in. (200 mm)
9/32 in. (7 mm) dia. 3 places
1/4 NPTM or 1/2 NPTM Pressure Connection
45APE Series Flush Mount
1/4 or 1/2 NPTF
5-7/16 in. (138 mm)
DETAIL FLOW
9/32 in. (7 mm) dia. 3 places
7-7/8 in. (200 mm)
shock mount panel
gauge
2-57/64 in. (73 mm) 6-3/4 in. (171 mm)
pulsation dampener
-OS and ES models only
120
120
1/4-20 nut & lockwasher (2 each required)
1/4 in. (6 mm) dia. holes (3 places) on 5-1/4 in. (133 mm) B.C. 120° apart, clocking as shown.
OPL Series Flush Mount Round case design to be mounted in a panel from 1/32 in. (1 mm) to 1/8 in. (3 mm) thick. It can also be direct mounted. Shown with pulsation dampener.
120
2-57/64 in. (73 mm)
5-7/16 in. (138 mm) Mounting Hole 4-3/4 in. (121 mm) diameter
6-3/4 in. (171 mm) 120
Optional (-BC) 1/2NPTM Pressure Connection
Options “OS” and “ES” (flush mount case)
2-57/64 in. (73 mm)
5-7/16 in. (138 mm)
1/4 NPTM or 1/2 NPTM Pressure Connection
-OS and -ES models only
6-3/4 in. (171 mm) 120
120
1/2 in. (13 mm) conduit
1/4 or 1/2 NPTM Pressure Connection
1/4 in. (6 mm) dia. Holes (3-places) on 5-1/4 in. (133 mm) B.C. 120° apart, clockingas shown
Optional (-BC) 1/2 NPTM Pressure connection
1/4 in. (6 mm) dia. holes (3 places) on 5-1/4 in. (133 mm) B.C. 120° apart, clocking as shown.
120
Optional back connection
2-23/32 in. (69 mm)
Explosion-proof Case Mount Explosion-proof case can be mounted from face or rear. Flush mount/Wall mount* 6-25/64 in. 8 in. (203 mm)
(162 mm)
1/2 in. (13 mm) optional rear or side conduit 8 in. (203 mm)
7-35/64 in. (192 mm) diameter
*Mounting hole
6-3/4 in. (171 mm) 3-3/8 in. (86 mm)
3-3/8 in. (86 mm)
not required for Wall mount
3/8-16 UNC-2B thread 7/8 in. (22 mm) deep, 8 plc's
Installation 00-02-0161 page 2 of 4
13/32 in. (10 mm) diameter 4 places
6-3/4 in. (171 mm)
OPTIONS CAUTION: Do Not unscrew the green diaphragm -OS and -ES (oil sealed and environment sealed case) for corrosive capsule. environment, feature a panel mount case or screw directly into the process. See Case Mounting (p-2). 2. Tighten the bottom housing to the pressure source. Swichgage instrument 3. Tighten the eight housing bolts to 25±3 foot lbs. -P6 Sealed mechanism with a typical application for by staggering the tightening for even clamping. oil well lead lines. Its 2 NPT housing and diaphragm seal 4. Route capillary away from heat source such as filled with silicon fluid attaches directly into a 2 NPT tee See exhaust manifold. Excess capillary should be Note 1 on the lead line. Tighten only the 2-5/8 in. (67 mm) hex carefully coiled and secured to avoid damage. fitting. CAUTION: Do Not cut capillary or make sharp bends. CAUTION: Do not tamper with or break sealed 2 NPT connections.
Transmitting Tube Housing Bolts
Diaphragm Housing
-P4L is a remote seal mechanism with stainless steel armored capillary to protect the gage from highly viscous and/or corrosive fluids. 1. Loosen the eight housing bolts until the bottom housing is free to turn. ADJUSTMENTS
OPL/45 Series Limit Contact Adjustments Facing the dial, left side knob is the “Low limit” contact and the “High limit” contact is located to the right. To set the limit contacts simply turn the fingertip type knob to the desired point on the scale. 45APE Series Trip Point Adjustments The 45APE Series features a stacked limit indicator adjustments knob. The bottom half knob adjusts the “Low” limit indicator, the top half is to adjust the “High” limit indicator. To set the limit contacts simply turn the fingertip type knob to the desired point on the scale. OPL and 45 Series Indicating Pointer Adjustments To reset to zero or to a known value do as follows: 1. Turn off electrical power. Remove the snap DETAIL “A” ring and very carefully remove the lens and Turn to lower pointer contact assembly (or open hinged cover). 2. Hold the pointer hub with thumb and forefinger then turn screw to desired point. See DETAIL “A”. 3. Replace lens and contact assembly and Turn to raise pointer snap ring (or close hinged cover), and turn on the power.
45APE Series Pointer Adjustments To reset to zero or to a known value proceed as follows: 1. Turn off electrical power. Remove the snap DETAIL “B” ring and very carefully remove the lens and contact assembly (or open hinged cover). 2. Hold the the Switch Operator and the Turn CW to Turn CCW Raise Pointer to Lower pointer hub with thumb and Pointer forefinger, then turn the Pointer Adjustment screw to the desired point. See DETAIL “B”. Pointer Adjustment 3. If the Switch Operator needs adjustment, hold the Switch Operator and the pointer hub with thumb and forefingers as show on DETAIL “C”, and turn the adjustment screw until the Switch Operator aligns with the DETAIL “C” indicating pointer. 4. Replace the lens and contact assembly Turn CW to Lower Turn CCW Switch Operator to Raise and the snap ring (or close hinged Switch Operator Switch cover). Turn the power back on. Operator Adjustment
OPERATION TEST INSTRUCTIONS
OPLC, OPLFC and OPLBP 1. Perform operation test after the unit is installed and wired appropriately. (See the typical wiring diagram, on page 4.) 2. When pressure is applied to the instrument, the pointer will travel in a clockwise direction. Adjust the limit contacts to the desired settings. 3. To start, place the toggle switch in the “start”position or otherwise override low contact. 4. After the indication pointer rises above the low limit contact, return the toggle switch or override device to the “run”position. 5. To test the limit contacts, turn the limit contact to be tested until it touches the pointer. That will trip the control circuit. 6. Reset the shutdown or alarm circuit device and repeat above sequence for each contact/trip point.
45 Series 1. Repeat steps 1 and 2. (See OPLC operation test instructions.) 2. Press the semi-automatic pushbutton located on the low contact knob. 3. Reset the magnetic switch pushbutton. 4. After the indication pointer rises above the low limit contact, the lockout pushbutton automatically disengages and the low limit is armed. 5. Repeat steps 5 and 6. (See OPLC operation test instructions.) 45APE, 45APEF and 45APEBP 1. Repeat steps 1 and 2. (See OPLC operation test instructions.) 2. To test the switches, turn the trip point indicator until it is aligned with the Swichgage pointer. This is the approximate trip point. Continue to rotate until the snap switch operates. 3. Reset the shutdown or alarm circuit device.
Installation 00-02-0161 page 3 of 4
TYPICAL ELECTRICAL DIAGRAMS WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF”. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE SWICHGAGE RATINGS. BEFORE WIRING DETERMINE VOLTAGE AND POLARITY FOR THE APPLICATION. USE THE APPROPRIATE WIRE SIZE. ALL CONNECTIONS SHOULD BE MADE USING A SPADE (FORKED) OR RING TERMINALS. FOR PIGTAIL CONNECTIONS USE WIRE NUTS. CONDUIT IS RECOMMENDED TO PROTECT WIRES FROM DAMAGE.
OPLC and OPLFC
OPLBP
Contact Rating: 1 SPDT, Center Off; 2 A, 30 VDC, 1 A, 125 VAC pilot duty. OPLC
OPLFC
Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position. COMMON
4
YELLOW
BLUE
3
RESET
5
SET
1 7 4 3 9
= 18 GA.
Red White Black
Red White Black
6
= 16 GA.
NOTE: Diagrams above show the Swichgage pointer in the at rest (shelf) position.
Contact Rating: 2-SPDT snap-switches (one for high and low pressure), 2 A inductive, 250 VAC each switch. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position. Low setpoint should be limited to the lower 1/2 scale and upper setpoint should be limited to the upper 1/2 scale.
1
8
WHITE
B
A
120 VAC
12 VDC 24 VDC
ORANGE
45APE and 45APEF
(-) NEUTRAL
BROWN
RED
LOW (RESET) (+) LINE
2
6
BLACK
HIGH (SET)
45APEBP LOW SWITCH
2 1
HIGH SWITCH
N.C.–Orange
N.C.–Black
N.O.–Blue
N.O.–Brown Common–Yellow
Common–Red
6
COMMON
5
4
3
RESET
5
SET
1 7 4
4
3
= 20 GA.
9
= 18 GA.
45 Series with MS2100
6
BROWN
= 16 GA.
1
2
(-) NEUTRAL 12 VDC 24 VDC
1
8
WHITE
ORANGE A
120 VAC
RED
(+) LINE
2
B
LOW (RESET)
YELLOW
6
BROWN
Models available for Battery ignition, CD ignition, Magneto or 110VAC systems. Contact Rating: 12/32 VDC coil, 10 A, 32 VDC battery ignition contacts; Magneto ignition coil, MS2100 10 A magneto ignitions contacts; CD ignition coil, 10 A CD ignition contacts; 120 VAC coil, 10 A, 120 VAC contacts. 6 1 2 3 4 5 NOTE: The diagram at right shows the Swichgage pointer in the operating position. G
YELLOW
BLUE
BLUE
3
Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position.
HIGH (SET)
3
Transformer Relay Assemblies
Typical Circuit To CD Ignition or Magneto.
www.fwmurphy.com 918.317.4100 Email:
[email protected]
For higher voltages, Murphy TR Assemblies can be used in conjunction with any Swichgage instrument.
MURPHY, the Murphy logo, Murphygage® and Swichgage® are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0161 page 4 of 4
PD-95145B Revised 11-03 Catalog Section 55
Pulsation Dampener
(00-02-0125)
PD8100 Series ■ Used
On Controllers, Instruments and Recorders to Dampen Pressure Pulsation ■ Eliminate Gage Pointer Flutter ■ Aids In Providing More Accurate Pressure Indication ■ Decreases Wear On Gage’s Geared Movement NOT INTENDED FOR USE AS A SHUTOFF VALVE Description
Specifications
The PD8100 Series eliminates pointer flutter on pressure indicating SWICHGAGE® devices which are subject to pulsating pressure from reciprocating pumps or compressors. It also allows a close setting of high and low contact points providing for more accurate pressure indication and control of equipment. The PD8100 Series decreases wear on geared movements and increases the life of pressure indicating instruments by eliminating excessive gage strain and unnecessary movement. A necessity which quickly pays for itself by protecting any pressure indicating and control instrument which is subject to pulsation. PD8100 SERIES NOT FOR USE ON OXYGEN OR LIQUID OXYGEN APPLICATIONS. Quality built with a large diameter valve stem wheel for ease of adjustment with clearly printed operating instructions. Machined from 1-3/8 in. (35 mm) hex bar stock. A two degree taper on valve and stem assure positive dampening. Available in brass, carbon steel, 303 stainless steel or 316 stainless steel to meet pressure and environmental requirements with either 1/2 NPT or 1/4 NPT inlet connections.
See “How to Order” section for available inlet and outlet connections. PD8183: All wetted parts are Brass. Rated to MURPHY SWICHGAGE 3,000 psi (20.68 MPa) [206.80 bar]. PD8184: All wetted parts are Carbon steel. Rated to 5,000 psi (34.47 MPa) [344.70 bar]. PD8185: All wetted parts are 303 stainless steel. Rated to 10,000 psi (68.95 MPa) [689.50 bar]. PD8190: All wetted parts are 316 stainless steel. Rated to 10,000 psi (68.95 MPa) [689.50 bar]. Meets NACE standard MR01-75 for direct exposure to H2S. Operating Temperature: MURPHY SWICHGAGE Make SWICHGAGE instruments -15 to 400°F (-26 to 204°C) and recorders operate like this. Shipping Weight (all models): 2 lbs.(0.9 kgs.) MURPHY SWICHGAGE Shipping Dimensions (all models): 4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121 x 83 mm)
Eliminate pointer flutter like this.
RUN
START
®
RUN
START
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY SW
Service Parts DESCRIPTION (see drawing–right)
PD8183
PD8184
PD8185
PD8190
A. 1/2 NPT inlet x 1/4 NPT outlet* 1/2 NPT inlet x 1/2 NPT outlet* B. Bonnet Fitting C. Valve Stem D. Packing Nut E. Hand Wheel (with 10-32 nut) F. Strainer Bushing Assembly † G. Molded Packing Gland H. ‘O’ Ring Bonnet Seal J. Stainless Steel Mesh Filter **
65-05-0104 65-05-0105 65-05-0099 65-05-0175 65-05-0098 55-00-0179 55-00-0174 00-00-0936 00-00-0302 65-05-0214
65-05-0210 65-05-0212 65-05-0209 65-05-0208 65-05-0211 55-00-0179 55-00-0173 00-00-0936 00-00-0302 65-05-0214
65-05-0204 65-05-0206 65-05-0203 65-05-0202 65-05-0205 55-00-0179 55-00-0175 00-00-0936 00-00-0302 65-05-0214
65-05-1136 65-05-1135 65-05-1139 65-05-1140 65-05-1137 55-00-0179 55-00-0206 00-00-0936 00-00-0302 65-05-0214
E
C
G
D B
A
H
INLET
OUTLET
†Provided only for units with 1/4 NPT inlet.
*For 1/4 NPT inlet use with strainer bushing assembly. **Provided in units with 1/2 NPT inlet.
J
F
Dimensions
How to Order PD8185
-
1/4 x 1/4
Base Model PD8183 PD8184 PD8185 PD8190
3-7/8 in. (99 mm)
FLOW
Connection Size 1/4 x 1/4 = 1/4 NPT inlet x 1/4 NPT outlet 1/4 x 1/2 = 1/4 NPT inlet x 1/2 NPT outlet 1/2 x 1/2 = 1/2 NPT inlet x 1/2 NPT outlet 1/2 x 1/4 = 1/2 NPT inlet x 1/4 NPT outlet
3 in. (76 mm)
Mounting for the OPLFC Pressure SWICHGAGE® and PD8100 Series The PD8100 Series pulsation dampener is mounted directly below the OPLFC.
Precautions: Dope or use teflon tape on connection threads. Do not block the inlet orifice. 4-3/4 in. (121 mm) diameter
OPLFC Mounting Hole
1/4 in. (6 mm) dia. holes (3 pls.) on 5-13/64 in. (132 mm) B.C.,120° apart, clocking as shown 1/2 in. radius typical
1 in. (25 mm)
MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail
[email protected] www.murphymex.com.mx
FRANK W. MURPHY, LTD. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail
[email protected] www.fwmurphy.co.uk MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA +1 661 272 4700 fax +1 661 947 7570 e-mail
[email protected] www.murphyswitch.com
MACQUARRIE CORPORATION 1620 Hume Highway Campbellfield, Vic 3061; Australia +61 3 9358 5555 fax +61 3 9358 5558 e-mail
[email protected]
GI
D
CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail
[email protected]
RE
FW Murphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail
[email protected] www.fwmurphy.com
The PD's are recommended for use on piston pumps and compressors to eliminate pointer contact flutter and gage wear.
5-5/16 in. (135 mm)
E
PD8100 2 in. Series Mounting (51 mm) Hole
Shown at right, is a typical MURPHYMATIC® compressor panel featuring three Pulsation Dampeners and Murphy’s OPLFC gages.
STER
USA–ISO 9001:2000 FM 28221 UK–ISO 9001:2000 FM 29422
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
PD-95145B page 2 of 2
Printed in U.S.A.
Installation Instructions for Pressure and Vacuum 2 and 2-1/2 in. (51 and 64 mm) Dial Murphygage® and Swichgage® Instruments. 20, 25, A20, A25 Series
00-02-0162 Revised 02-06 Section 05
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended. GENERAL INFORMATION
Typical Mounting Dimensions
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
20 Series shown
Mounting Hole
Low Pressure Port (DP Series) 1/8-27 NPTM Pressure Port
Mounting Clamp
See Note
Description The 2 and 2-1/2 in. (51 and 64 mm) dial size Murphygage and Swichgage instruments are diaphragm-actuated, pressure or vacuum gages with a 1/8-27 NPTM pressure port connection (2 pressure ports for differential pressure models). Models with face-adjustable contact(s) are rated for 2 A @ 30 V (pilot duty). If the gage case is steel (20P, 25P, 20DP, 25DP etc.) the ground path for the contact circuit is through the case. Therefore, the case must be installed in the ground plane of the electrical power supply. If the case is polycarbonate (A20P, A20DP, A25P, A25DP etc.) the ground path is isolated and is made through the “C” or “P” terminals on the back of the gage case (“C” for A20 models; “P” for A25 models). Models 20PE, 25PE, A20PE, A25PE etc. have a snap-acting switch instead of the face adjustable pointer type contact. Electrical rating is 3 A @ 30 VDC, 4 A @ 125 VAC. Reset differential for the switch is approximately 10% of the scale. NOTE: Select a scale so your normal operating pressure is in the upper middle of the scale.
A
A B C D
D
B
C
20 Series
A20 Series
25 Series
A25 Series
2-7/32 (56)
2-9/16 (65)
2-1/8 (54)
1-51/64 (46)
2-15/64
2-1/4
3-1/8
(79)
2-29/32 (74)
(57)
(57)
1-5/16 (33)
1-1/4 (32)
1-3/8 (35)
1-27/64 (36)
2-1/16
2-1/16
2-11/16
2-11/16 (68)
(53)
(53)
(68)
NOTES: 20/25 Series: 18 AWG pigtails. A20/A25 series: #4/#6 screws. The dimensions above are in inches and (millimeters).
Panel Mounting All models can be installed in a panel from 0.032 to 0.250 in. (1 to 6 mm) thick. Remove the mounting bracket and insert the gage from the front side of the panel. Replace bracket and secure it. Do NOT overtighten. (See Figure 2).
Connecting the Pressure Port CAUTION: Certain dangers to human safety and to equipment may occur if some equipment is stopped without pre-warning. It is recommended that monitored functions be limited to alarm-only or to alarm before shutdown.
Alarm Before Shutdown Models The 20PABS, A20PABS, 25PABS and A25PABS feature a front limit contact for equipment shut-down and an internal SPDT snap switch for Alarm Before ShutDown. When the low side (preset point) of the snap switch trips, the N.C. terminal completes a circuit to activate an alarm. A continued decrease in pressure will complete the shutdown circuit. An increase in pressure of approximately 10% of scale is necessary before the snap-switch (alarm) will reset and open the circuit. NOTE: Face contact shut-down limit setting and snap switch low point are factory-set; specify when ordering if setting is other than standard.
Typical Tattletale® Magnetic Switch Murphy manufactures several, patented Magnetic Switches for protection of the pilot duty Swichgage contacts and to ensure positive shut-down of equipment. There are magnetic switches for CD ignition, Magneto, Battery systems and electric motor driven equipment. Tattletale annunciators show the cause of shut-down. The first one to trip will lockout all other Tattletale annunciators. Be sure the type of magnetic switch or Tattletale annunciator matches the power source used to trip it. NOTE: At equipment start-up (for models not having a built-in time delay) the reset button must be held in until normal operation occurs, or an external time delay may be used. Instructions are packed with each Magnetic Switch orTattletale annunciator. Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility except as noted.
1. Pressure tubing is generally not provided. Use of good quality flexible pressure
tubing/hose and fittings is strongly suggested. Use at least 3/16 in. (5 mm) I.D. tubing. If using copper or rigid tubing, install at least 12 in. (305 mm) flexible hose from the gage to the rigid tubing. This prevents damaging vibration from reaching the gage. For most models a pulsation orifice, within the pressure port, is provided and it is removMounting Panel Bracket able for cleaning (Figure 2). 2. Connect tubing to the 1/8-27 NPTM port. Use of non-hardening thread sealing comGage pound is recommended although thread is “dry seal”. Pressure tubing Port IMPORTANT: Make sure or hose NOT to foul pressure orifices Pulsation Orifice Wire Lead Wrench with sealant. NEVER exceed maximum pressure rating for the gage range; see chart on p-2. Figure 2
IMPORTANT: Swichgage instruments, magnetic switches and shutdown or alarm devices, properly used, are effective tools in any preventive maintenance program. For optimum performance, check these tools periodically: look for frozen pointers, kinked/worn tubing, broken wiring or loose connections; operate the contacts and watch for expected results. Replace damaged/worn parts; clean/repair as necessary. Check for correct/complete wiring, unbroken insulation and no accidental grounds. Do not run shut-down wires with ignition wiring. Check all tubing and connections for leaks. Mount magnetic switches and valves upright, to prevent moisture collection.
Installation 00-02-0162 page 1 of 4
Pressure Ranges and Factory Settings Ranges Available
Maximum Pressure
Std. Settings*
20/25PABS Settings
Hi Settings**
Start-up Lockout Settings
Alarm†
Low
Contact
Bar
psi
Bar
psi
Bar
psi
Bar
30 psi (21 MPa) 3 (21) 60 psi (21 MPa) 7 (48) 100 psi (21 MPa) 10 (69) 150 psi (21 MPa) 15 (103) 200 psi (21 MPa) 20 (138) 300 psi (3.4 MPa) 30 (207)
0.2 0.4 0.8 1.0 1.5 2.0
12 (83) 24 (165) 40 (276) 60 (414) 80 (552) 120 (827)
0.8 1.6 2.8 4.0 5.5 8.0
3 (21) 7 (48) 10 (69) 15 (103) 20 (138) 30 (207)
0.2 0.4 0.8 1.0 1.0 1.5
6 (41) 10 (69) 13 (90) 18 (124) 23 (159) 33 (228)
0.3 0.6 1.0 1.5 1.5 2.0
3 (21) 4 (28) 10 (69) 10 (69) 20 (138) 20 (138)
400 psi (3.4 MPa) 50 (345) 500 psi (3.4 MPa) 75 (517)
3.0 150 (1 MPa) 10 5.0 225 (1.6 MPa) 15
50 (345) 75 (517)
3.0 53 (365) 5.0 78 (538)
28 500 psi (3.4 MPa) 150 (1MPa) 7.0 300 (2.1 MPa) 20
75 (517)
psi
Bar
0-15 (103) 0-30 (207) 0-50 (345) 0-75 (517) 0-100 (690) 0-150 (1.0 MPa)
1.0 2.0 3.5 5.0 7.0 10
0-200 (1.4 MPa) 0-300 (2.1 MPa)
14 20
0-400 (2.8 MPa)
psi
psi
Lockout
Release (max.)
Bar
psi
Bar
0.2 0.4 0.5 0.7 1.0 1.5
4 (28) 7 (48) 13 (90) 15 (103) 25 (173) 30 (207)
0.3 0.5 1.0 1.0 2.0 2.0
psi
Bar
4.0 5.0
40 (276) 3.0 50 (345) 3.5
50 (345) 75 (517)
3.5 70 (482) 4.8 5.0 105 (724) 7.2
5.0 150 (1MPa) 10
100 (690) 6.0
–––
7.0 150 (1MPa) 10
6 (41) 10 (69) 20 (138) 23 (159) 35 (241) 45 (310)
0.4 0.7 1.4 1.6 2.4 3.1
Values in ( ) are mathematical conversions from psi to kPa/MPa–they do not reflect second scale range. U.S.A. standard scale is psi/kPa; U.K. standard scale is psi/bar. Consult factory for other scales. * Standard setting for 20P/25P and 20PE/25PE models. ** Low settings for Hi/Lo option same as standard settings. Hi/Lo option available for 20P/25P models only. † SPDT Snap-switch is the alarm switch.
Connecting Vacuum Models The vacuum instruments measure intake manifold vacuum and gives an indication of the load applied to the engine. 1. Mount the gage in a suitable location so that the face is visible and easily accessible.
Panel
Port
Tube or Fittings Tubing
Gage
CAUTION: Make SURE NOT TO FOUL the pressure orifices with pipe dope or dirt or the SWICHGAGE instrument will not operate. 2. Connect suitable tubing to the 1/8-27 NPT port of the gage and to an open
port in the intake manifold. Mounting kit V5179 is suggested and includes tubing and necessary fittings. The manifold fitting is 1/4 NPT. Figure 3 shows a typical mounting using V5179 kit. A Murphy PD2160 is also recommended. 3. Be sure connections are tight—gage will not operate properly if line leaks.
Wire Lead(s) Intake Manifold Fittings Intake Manifold
Figure 3
PD2160 Pulsation Dampener
Connecting Differential Pressure Models Differential pressure models are typically applied to indicate restriction in oil/fuel filters. The “High” pressure port (center mounted) is piped to the Inlet side of the filter. The “Low” pressure port (top center mounted) is piped to the Outlet side of the filter. CAUTION: Make SURE NOT TO FOUL the pressure orifices with pipe dope or dirt or the SWICHGAGE® instrument will not operate.
2. You MUST use a second wrench on the Low Pressure port when tightening tube
fittings. (Figure 4). Notice that a wrench is used for holding the low pressure port while a second wrench will tighten the pressure tubing/hose fitting onto the port. WARNING: Failure to use a second wrench on the low pressure port when tightening tube fittings may result in damage to the internal mechanisms.
1. To connect the high pressure tubing use at least 3/16 in. (5 mm) I.D. flexible
pressure tubing/hose and fittings. If using copper or rigid tubing, install at least 12 in. (305 mm) flexible hose from the gage to the rigid tubing (to prevent damaging vibration to the gage, see Figure 2). Gage Case Back View
DO NOT TWIST Low Pressure Port; Hold Port with Wrench
IMPORTANT: NEVER exceed maximum static pressure or differential pressure ratings for your gage range; stated in chart below. Ranges* Available
Figure 4 Attach tubing with Wrench
High High Pressure Pressure Port Port
0-15 (0-103) [0-1.0] 0-30 (0-207) [0-2.0] 0-50 (0-345) [0-3.5] 0-75 (0-517) [0-5.0] 0-100 (0-690) [0-7.0]
Max. Static Pressure
Max. Differential Pressure
Contact Setting
200 (1.4) [14] 300 (2.1) [20] 300 (2.1) [20] 300 (2.1) [20] 300 (2.1) [20]
30 (207) [2.0] 60 (414) [4.0] 100 (690) [7.0] 150 (1.0) [10] 200 (1.4) [14]
10 (69) [0.8] 20 (138) [1.0] 30 (207) [2.0] 50 (345) [3.5] 60 (414) [4.0]
*Values are shown in psi, (kPa/MPa) and [bar]. Values in kPa/MPa and bar are mathematical conversions from psi–they do not reflect actual second scale range.
Installation 00-02-0162 page 2 of 4
Setting the Swichgage instrument contacts
Testing the Contacts 1. With equipment running; use a 1/16 in. hex wrench to rotate contact until it
touches the pointer. Do NOT force contact against the gage pointer. Equipment should shut down and/or alarm should operate. Reset the contact (See Figure 5). 2. VERY IMPORTANT Each time you start the machine, observe that the SWICHGAGE® is indicating pressure or vacuum. Visual inspection and regular testing should be normal procedure to ensure proper operation and to achieve maximum results from your Swichgage instrument.
IMPORTANT:: If the Swichgage has a lockout push button on the face, a contact setting higher than the factory setting will make the lockout device inoperative. For 20PE, 25PE, 25DPE, A20PE, A25PE and A25DPE models the switch trip point CANNOT be set at either the lowest or the highest extremes of the scale. Trip point MUST allow for the switch reset differential. For adjustable switch versions, the switch point is adjustable ONLY over the lower half of the scale.
PRESSURE
1. All contacts are set using a 1/16 in. hex wrench (Figure 5). 2. Some models such as A20PE, A25PE, etc. may not have field adjustment.
Consult the factory if in doubt. For adjustable models, 1/4 turn clockwise lowers switch operating point approximately 7% of scale. 3. Observe the “normal operating” pressure or vacuum readings. Set the contact slightly below minimum reading observed or slightly above minimum pressure recommended by equipment manufacturer. For differential pressure models set the contact slightly below the desired maximum differential pressure.
Switch Adjustment (if applicable)
Figure 5
Wiring Installation WARNING:
DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING THE WIRING INSTALLATION.
FOR BATTERY IGNITION SYSTEMS, DISCONNECT THE BATTERY GROUND STRAP. FACE ADJUSTED POINTER TYPE CONTACTS ARE PILOT DUTY. DO NOT EXCEED CONTACT RATINGS ON ANY SWICHGAGE® MODEL.
20 and 25 Series models wire leads are 18 AWG or 20 AWG, 12 in. (305 mm) long. A20 and A25 Series models have number 4 or number 6 screw terminals. When installing the Swichgage instrument on an ungrounded panel, you MUST provide a ground wire from the Swichgage instrument to a common ground. Install ONLY in a 12 or 24 V system. Warning lights or audible signal must be of the same voltage as the battery. Current draw should never exceed Swichgage contact ratings.
The pictorial below shows typical wirings for each base model. Look for specific typical wiring diagram with your base model number and wire accordingly. The pointer is shown in the Shelf Position. Face adjusted pointer type contacts are rated pilot duty 2 A @ 30 VAC/DC. Snap-switch contacts are rated 3 A @ 30 VDC; 4 A @ 125 VAC. CAUTION: On some models pointer contact and ABS switch share the same “Common”. Voltage source must be the same. Maximum voltage is 30 V. Consult factory for applications with 120 VAC systems.
CAUTION: Ordinary incandescent lights are damaging to Swichgage contacts. We recom-
mend using our direct connected alarms TL-7 flashing lamp and/or SAH mini-siren. 20DP and 25DP
20P and 25P
20P-HL and 25P-HL 20V and 25V
HIGH
LOW Red
Red
Black
A20P
HIGH
N. C.
C
N. C.
N. O.
C
C
L
HIGH P
H
L
P
H
HIGH
LOW L
P
H
N. O. Black
RESET
SET
H
Installation 00-02-0162 page 3 of 4
L
A20DPE
SET
RESET
N. O.
C
N.C.
C
RESET
SET
N. C.
C
A25PE N.C.
N.O. RESET
LOW P
C. White
N. C.
A25PABS-HL N.O.
C
LOW L
N.O.
C
A25PABS SET
LOW
N. O. Black
A20PE
ABS
N.C.
N.C.
N. C. Red
Red
LOW
N. O.
A25P-HL and A25V
A25DP
A25P
N. C.
N. O.
N. C. Red C. White
A20PABS
HIGH
LOW
20PE, 20DPE, 25PE and 25DPE
LOW
Black
A20P-HL and A20V
A20DP
LOW
HIGH
LOW
20PABS and 25PABS
C
A25DPE N. O. RESET
SET
N. O.
N.O.
N.C. RESET
SET
HIGH P
H
L
P
H
L
P
H
Installing The Magnetic Switch WARNING:
DISCONNECT THE BATTERY OR POWER SOURCE BEFORE BEGINNING THE INSTALLATION. SEE SPECIFIC WIRING INSTRUCTIONS PACKED WITH EACH MAGNETIC SWITCH OR TATTLETALE ANNUNCIATOR.
1. Mount with electrical lugs down. Drill mounting holes in panel. 2. Clean away burrs and filings. Position the magnetic switch in the
NOTE: Murphy components are easily wired and maintained. Use good quality wire and terminals. The type of magnetic switch differs for various applications. See typical wirings below. Wiring and instructions are packed with each magnetic switch.
panel, making sure the pilot stud is in place. 3. Add decal, then washer, then nut and tighten.
M
117 Magnetic Switch
20P-F Pressure ® SWICHGAGE
20T-F Temperature ® SWICHGAGE
Y SWICHGA PH GE UR ®
Y SWICHGAG PH E® UR F
Y SWICHGA PH GE UR ®
20
0 0
PSI 40 60
80
M
20
10
0
0
300 60 0 kPa PRESSURE
0
C
S
B
PSI 40 60
M
20P Pressure SWICHGAGE®
80
130
10
0
300 60 0 kPa PRESSURE
160 190 220
518PH Magnetic Switch
25
R
0
60
80 100 12
C
0
G
NC
SW1 SW2
B
TEMPERATURE
N.O. SWICHGAGE® instruments
Energized To Run Devices
_
_
+ Battery
N.C. switches option
Energized To Run Devices
+
Battery
Troubleshooting DO THIS FIRST: Look for broken wiring, frozen pointer, dirty contacts (will not make), burnt pointer or contact. Verify that all wiring is intact and connections are tight. Verify that Swichgage has not been damaged (hit or dropped). Verify that there is pressure/vacuum supplied to the gage. Verify that the Swichgage is operative (it reads). Verify that the alarm or shutdown device is fully operable; and check other components such as spark plugs, ignition, fuel pump and filter, etc. Reset magnetic switch and verify that it stays latched. SYMPTOM
CAUSE
TEST/REMEDY
Engine will not start.
1. Short or open circuit, be sure the magnetic switch latches and puts out power to 1. Reset magnetic switch and make sure it stays latched. Refer to installthe run device or removes ground (ignition). Check for power/ground at run device. ation instructions for 518PH magnetic switch (provided with unit). 2. Control circuit overloaded by accessories (blown fuse in magnetic switch). 2. Find blown fuse and replace (use 14 A fuse). Reroute the accessories. 3. False ground in control circuit. 3. Repair.
False shutdown.
1. Swichgage circuit has intermittent open or short. 2. Vibration causes the Magnetic Switch to trip.
1. Check all wiring and repair/replace as necessary. 2. Repair and relocate the switch as needed.
Swichgage closes but does not trip the magnetic switch or kill the engine.
1. Incomplete shutdown circuit. 2. Dirty Swichgage contacts. 3. Ignition not providing power to primary terminal post. 4. Swichgage case may not be grounded. 5. Incorrect magnetic switch for type of power.
1. Locate open circuit and repair. 2. Clean and check that contacts make. 3. Repair ignition. 4. Ground case. 5. Replace with correct magnetic switch.
Magnetic switch tripped but engine is still running.
1. Open circuit between the magnetic switch and the shutdown device. 2. Lost ground to kill the engine.
1.Check wiring from magnetic switch to shutdown device, repair or replace. 2. Check all wiring and connections and repair.
Pointer will not operate properly. Inaccurate reading.
1. Frozen pointer 2. Loose pointer spring (caused by hitting or dropping gage). 3. Plugged pressure orifice. 4. Over Pressure
1. Return for repair or replacement. 2. Return for repair or replacement. 3. Remove and clean. 4. Return for repair or replacement.
Pointer/contact burned-in two.
Without exception this condition is caused by incorrect wiring or short circuit.
Recheck wiring; replace Swichgage or return for repair.
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
www.fwmurphy.com 918.317.4100 Email:
[email protected]
MURPHY, the Murphy logo, and Murphygage® are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
Installation 00-02-0162 page 4 of 4
67C Series
Instruction Manual Form 5469 May 2006
67C Series Instrument Supply Regulators
TYPE 67CF FILTER REGULATOR WITH OPTIONAL GAUGE
TYPE 67C OR67CR REGULATOR
Figure t Typical 6 7C Series Regulators
Introduction
The Types 67C and 67CS are the standard instrument supply regulatorswithout a filter or internal relief.
Scope of Manual
The Types 67CF and 67CFS are equipped with a filter for removing particles from the supply gas.
This manual provides instructions and parts lists for 67C Series instrument supply regulators. Instructions and parts lists for other equipment mentioned in this instruction manual, as well as for other 67 Series regulators, are found in separate manuals.
Product Descriptions The 67C Series direct-operated regulators are typically used to provide constantly controlled, reduced pressures to pneumatic and electropneumatic controllers and other instruments. They are suitable for most air or gas applications. Other applications include providing reduced pressures to air chucks, air jets, and spray guns.
The Types 67CR and 67CSR have an internal relief valve with a soft seat for reliable shutoff with no discernible leakage. The Types 67CFR and 67CFSR have a filter and internal relief valve with a soft seat for reliable shutoff with no discernible leakage.
Specifications Some general 67C Series ratings and other specifications are given on page 2. A label on the spring case gives the control spring range for a given regulator as it comes from the factory.
EMERSONL
Process Management
Section 10 – Lubrication System Vendor
Bulletin No.
Separators Drain Piping.................................................. Ajax
01-23-T01A-301
Crankcase Drain Piping....................................................Ajax
02-23-T010-317
Oil Reservoir Piping with Day Tank..................................Ajax
TP 00-24-T01B-001
Kim Hotstart Oil Heater Piping..........................................Ajax
TP 04-02-T010-317
Kim Hotstart O & M...........................................................KHT Lube Op System Schematic........................................... Prog.
2802-MA-F-MCP
SMX Divider Valve Bulletin......................................................... Prog. DLM-926 Operation and Wiring ................................................. Deliron
DLM-926
Proximity Switch Bulletin ............................................................ Deliron
169LIT D-PRXSW
Rupture Disc Drawing .................................................... Ajax
BM-21138
Lubricator Pump, Model P-55UR,
” ............................. Ajax
BM-21136-1
Lubricator Pump, Model P-55UR, ¼” ............................. Ajax
BM-21137-1
Operation and Maintenance of Divider Block Lubrication Systems©2001(used with permission) Crankcase Oil Level Controller & Switch, LM301 Installation and Operation........................................................ Murphy
Engine-Compressor Package Service Manual
LM-92164N
Drain the air scavenging chambers every 800 hours of operation.
WARNING Drain the compressor crosshead guides every 800 hours of operation. Record the amount of oil collected. Unusual amounts of oil indicate excessive cylinder or packing lubrication rates, or worn wiper packing.
Do not open the scavenging chamber drains while the engine is running. Unstable combustion and rpm control may result. Record the amount of oil collected per cylinder. Unusual amounts of oil indicate excessive cylinder lubrication rates, or worn wiper packing.
Drain the crankcase every 8000 hours of operation. Perform crankcase maintenance requirements. Refill with 30 gallons of oil per Engineering Standard # ES 1006. Also, see TP 00-24-T01A-001 in Tab 10.
DPC-2802 Crosshead Guide, Scavenging Chamber, & Frame Drains TP 01-23-T01A-301
DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains TP 01-23-T01A-001 Item 1 2 3 4 5 6
Description Ball Valve, ¾” NPT, 600# Ball Valve, ¾” NPT, Locking Handle Male Connector, ¾"Tube x ¾"NPT SS Tubing, ¾” x 0.049” SS Tubing, ¾” x 0.049” SS Tubing, ¾” x 0.049”
P/N 2549 2065 2549 2075 2507 1606 5551 4912 5551 4912 5551 4912
Qty
Item
Description
2 1 6 164” 77” 118”
DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains TP 01-23-T01A-001
P/N
Qty
Approximate crankcase oil capacity = 30 gallons (U.S.) The correct full oil level is determined when the engine is stopped.
Full crankcase oil level = 27.5” from the frame’s top machined surface to the surface of the oil. Set the level controller’s safety shutdown point while the engine is running.
Crankcase oil level controller & low level limit switch p/n: BM-21072
Frame Mounted Lube Oil Reservoir TP 00-24-T01B-001 rev 1
Frame Mounted Lube Oil Reservoir TP 00-24-T01B-001 rev 1 Item
Description
P/N
Qty
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Oil Reservoir, 55 Gallons Ball Valve, ½"NPT, 600# Male Tubing Elbow, ½" Tube x ½" NPT ¼" Flat Bar, 1" ¼" Flat Bar, 1" " Strap,1"x 51"L (Form To Fit Reservoir) Male Connector , ½" Tube x ½" NPT Pipe Nipple, Sch 80, ½"NPT x 3"L Oil Reservoir Support Stand Plug, ½" Tube Fitting Rubber Pad, " Thk. x 3"W x 30"L Street Elbow, Std, ½"NPT ½" Tubing Tee Tubing, 316SS, ½" x 0.035 Wall Tubing, 316SS, ½" x 0.035 Wall Tubing, 316SS, ½" x 0.035 Wall Tubing, 316SS, ½" x 0.035 Wall ½" Tubing Union
6553 5500 2549 2094 2507 4204 7040 0210 7040 0210 7040 0110 2507 1404 2539 4414 800-1000-00013 2513 9500 6840 3000 2535 7004 2507 6504 5551 3508 5551 3508 5551 3508 5551 3508 2507 8004
1 3 1 4" 8" 2 3 1 1 1 2 1 1 23.3" 66.4" 2" 64.1" 1
Item
Description
P/N
Qty
Warning
Connect to the Engine’s.prelube pipe cross fitting. Refer to Manual’s Section 3, drawing “Modified 1704-000” Remove pipe plug, item 14, from pipe cross, item 13, and install tube fitting, item 9, shown below.
All repair and resetting of safety relief valves should be performed by a National Board certified valve repair shop holding a “VR”stamp. Replaceable element p/n 6522 0005.
Connect to the Engine’s crankcase drain. Refer to Manual’s Section 10, drawing TP 04-23-T01A-001 Replace pipe elbow, item 5, at pipe nipple, item 8, with pipe tee, item 16, shown below.
Connect to the Oil Outlet of the Oil Heater To Kim Hotstart Pressure Switch Connect to the Oil Inlet of the Oil Heater
See TP 04-02-T010-316 in Tab 5 for Connection Details
To Water Pump Housing
Circulating Heating System COLER 3180/0603-08B1 Refer to vendor’s Installation & Operating instructions included in Section 10. Refer to the General Arrangement drawings for mounting location.
To Kim Hotstart Water Outlet
To Kim Hotstart Water Inlet
Circulating Heating System Inlet & Outlet Tubing TP 04-02-T010-317
Circulating Heating System Inlet & Outlet Tubing TP 04-02-T010-317 Item
Description
P/N
Qty
Item
1 2 3 4 5 6 7 8 A 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Ball Valve, ¾" NPT Ball Valve, 1" NPT Bushing, 1½" x 1" NPT Bushing, 1" x ¾" NPT Elbow, ¾" NPT Tubing Elbow, Male, 1" Tube x 1" NPT Kim Hotstart Oil Heater COLER 3180/0603-08B1 LHA Spin On Oil Filter Filter Element Tubing Connector, Male, ¾" Tube x ¾" NPT Tubing Connector, Male, 1" Tube x 1" NPT Pipe Nipple, Sch 80, ¾" NPT x 2 " Pipe Nipple, Sch 80, ¾" NPT x 3 " Pipe, Sch 80, ¾" Relief Valve Set At 25 psig, 1" x 1" Tee, ¾" NPT Tee, 1½" NPT Tee, 1" NPT Tubing, 316SS, ¾" x 0.049 Wall Tubing, 316SS, ¾" x 0.049 Wall Tubing, 316SS, ¾" x 0.049 Wall Tubing, 316SS, 1" x 0.049 Wall Tubing, 316SS, 1" x 0.049 Wall Tubing, 316SS, 1" x 0.049 Wall Tubing, 316SS, ¾" x 0.049 Wall Union ¾" NPT Union Tubing ¾" Rubber Hose, 1¼" Straight Hose Connector, 1¼" Rubber Hose, 1" Straight Hose Connector, 1" Hose Clamp ¾" x 1¼" Connector ¼" x ¼" Tubing ¼" x .049 wall Bushing, 1-½" x 3"
2549 2065 2549 2085 2527 1410 2527 1006 2535 4006 2507 4808 6390 2098 6522 0003 6522 0005 2507 1606 2507 1808 2539 4508 2539 4514 4053 0065 63ME2M2FTA0025 2545 4006 2545 4014 2545 4010 5551 4912 5551 4912 5551 4912 5551 4916 5551 4916 5551 4916 5551 4912 2547 5006 2507 8006 3521 4018 2520 3020 3521 4016 2520 3016 2520 9106 2507 1202 5551 4904 2539 4814
3 1 1 4 2 1 1 1 1 6 3 9 2 14" 1 4 1 1 174" 30" 6" 120" 36" 100" 120" 2 1 1 2 1 2 4 2 20 ft 2
35 36 37
Description Ball Valve Bushing, 1-½" x 1-¼" Ball Valve, 1-½"
P/N 2549 2142 2527 1412 2549 2142
Qty 1 2 1
OER & OWT Oil Heating System Installation & Operation Manual
216203-000 rev 3
KIM HOTSTART Mfg., Co., Inc. P.O. Box 11245 Spokane WA 99211-0245 Customer Support: (509) 536-8660
NOTICE When ordering replacement parts for your heating system, always reference the heating system’s Model Number and Serial Number.
CAUTION ALL CONNECTIONS IN THE JUNCTION BOX SHOULD BE CHECKED PRIOR TO INSTALLATION. VIBRATION DURING SHIPMENT CAN CAUSE SCREWS TO LOOSEN. ALL CONNECTIONS IN THE JUNCTION BOX SHOULD BE CHECKED AT REGULAR INTERVALS. EXCESSIVE VIBRATION WILL EVENTUALLY CAUSE CONNECTIONS TO LOOSEN OVER TIME. WIRING TO HEATING SYSTEM TO BE PERFORMED BY A QUALIFIED ELECTRICIAN AND CONFORM TO ALL NATIONAL, STATE AND LOCAL ELECTRICAL CODES. KIM HOTSTART MANUFACTURING COMPANY EAST 5723 ALKI AVENUE • P.O. BOX 11245 SPOKANE, WASHINGTON • 99211-0245 • USA Phone: (509) 534-6171 • Fax: (509) 534-4216
Notices This manual was prepared to assist you with the installation, operation, and maintenance of two Kim Hotstart oil heating systems: the Oil Water Tight (OWT) system, and the Oil Explosion Resistant (OER) heating system. OWT systems comply with the NEMA 12 standard, and OER systems comply with the Class 1, Group D, Division I and II explosion standard. We encourage you to use this manual and the attached documentation in the appendix as your primary source of information for your heating system. For additional information, contact: Kim Hotstart Manufacturing Company P.O. Box 11245 Spokane, WA 99211-0245 Telephone: (509) 536-8660 Fax: (509) 534-4216 The instructional material and the corresponding illustrations in this manual are based on the typical OWT and OER heating systems with standard components and the most frequently requested options. Your particular heating system configuration may vary from the heating systems described in this manual. For your reference, available replacement parts and component options are listed in this manual. See Appendix A in the back of this manual for your system drawings and wiring diagrams.
Identifying Your System Kim Hotstart OWT and OER oil heating systems are compact oil heating systems designed for use in marine propulsion, diesel-powered generator sets, or any large-engine applications. These models are pre-wired, pre-plumbed, and assembled on a steel plate and mounting channel. Each heating system has an identification plate usually located next to the control box. An example of the identification plate is shown on the following page. NOTE: When ordering replacement parts, be sure to reference your heating system’s model and serial numbers found on the identification plate. Model numbers ending in other than –Xnn are custom systems. Reference the drawings included with your system for parts specific to your system.
i
ii
iii
Table Of Contents NOTICES........................................................................................................................................ i IDENTIFYING YOUR SYSTEM ................................................................................................ i HEATING SYSTEM OVERVIEW.......................................................................................... 1-1 Oil Water Tight (OWT) Standard Models .................................................................. 1-2 Oil Explosion Resistant (OER) Standard Models....................................................... 1-4 The Kim Hotstart System.............................................................................................. 1-5 Lube Oil Inlet/Outlet Process .................................................................................... 1-6 Lube Oil Flow Detection ........................................................................................... 1-7 INSTALLATION AND SYSTEM START-UP....................................................................... 2-1 Basic System Installation............................................................................................... 2-1 Main Power Supply.................................................................................................... 2-1 Oil Supply Line.......................................................................................................... 2-2 Oil Discharge Line..................................................................................................... 2-4 System Mounting Requirements .................................................................................. 2-5 Lube Oil Pump........................................................................................................... 2-5 System Start-Up ............................................................................................................. 2-6 Lube Oil Heating System Start-Up ............................................................................ 2-6 SYSTEM COMPONENTS ....................................................................................................... 3-1 Control Box..................................................................................................................... 3-1 Time Delay Relay ..................................................................................................... 3-2 Magnetic Contactors .................................................................................................. 3-2 Remote Control.......................................................................................................... 3-2 Motor Protective Switch ............................................................................................ 3-3 Other MPS Features................................................................................................... 3-4 Fuses ........................................................................................................................ 3-4 Transformer................................................................................................................ 3-4 Oil Heating Tank Assembly .......................................................................................... 3-5 Heating Tank Assembly Parts ...................................................................................... 3-6 Heating Element Replacement................................................................................... 3-6 High-Limit Thermostat Replacement ........................................................................ 3-8 System Thermostat Replacement............................................................................... 3-9 Tank O-Ring ............................................................................................................ 3-10 Flow Detection Switch............................................................................................. 3-10 Pump and Motor Assembly......................................................................................... 3-11
iv
Oil Pressure Switch...................................................................................................... 3-11 SYSTEM MAINTENANCE ..................................................................................................... 4-1 Control Box..................................................................................................................... 4-1 Plumbing Connections................................................................................................... 4-1 Electrical Connections ................................................................................................... 4-1 Electrical Contacts ......................................................................................................... 4-1 Heating Tank.................................................................................................................. 4-2 Flow Detection Switch ................................................................................................... 4-3 Pump and Motor Assemblies ........................................................................................ 4-4 System Mounting ........................................................................................................... 4-4 Troubleshooting ............................................................................................................. 4-5 APPENDIX A SYSTEM DRAWINGS............................................................................................................. A-1
v
Heating System Overview The Kim Hotstart Oil Water Tight (OWT) and Oil Explosion Resistant (OER) lube-oil circulating heating systems for industrial engines are designed and constructed for ease of operation and minimal maintenance. These heating systems are just a few of a variety of products available to meet your cold start requirements. Each unit is a unique pre-heating system that eliminates needless engine idling and results in: •
Quicker engine start-up in cold weather
•
A reduction in engine oil consumption
•
Significant operations and fuel savings
•
Consistent engine temperature
•
A reduction in engine wear
•
Minimal maintenance
•
Fail-safe protection
Engine for Pre-Lubing
for Continuous Lubing Oil Sump
Oil Outlet Check Valve
Oil Heating System OFF ON
owtlg1.eps
Oil Inlet Shut Off Valve
Section 1 Heating System Overview
engoil.eps
1-1
Oil Water Tight (OWT) Standard Models The OWT models shown on the following page are designed according to the NEMA 12 standard and come in three oil-pumping capacities: small, medium, and large. All standard small-, medium-, and large-capacity OWT models share the same design in operation and component layout. The major differences between models are the motor, pump, and heating element (in the tank assembly). The standard OWT models are listed below. Other features included are: •
Adjustable pressure switch or electronic signaling for automatic operation
•
A universal mounting platform for compatibility with various mounting configurations
•
80° to 100°F fixed-thermostats with 140°F high limit
•
An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for manual prelube.
•
VITON mechanical seal pumps for extended seal life
•
Flow detection switch for fail-safe operation
OIL WATER TIGHT (OWT) STANDARD MODELS
Part No. OWT10252 OWT1025C OWT3025D OWT30254
Capacity (Gallons) 25 to 100 25 to 100 25 to 100 25 to 100
SMALL CAPACITY KW Voltage Hertz 2.5 240V 60 2.5 240V 50 2.5 380V 50 2.5 480V 60
Phase 1 1 3 3
Amps. 18.1 18.1 7.5 5.9
HP/GPM 1 HP/2.8 GPM 1 HP/2.4 GPM 1 HP/2.4 GPM 1 HP/2.8 GPM
Part No. OWT10602 OWT1060C OWT3060D OWT30604
Capacity (Gallons) 75 to 250 75 to 250 75 to 250 75 to 250
MEDIUM CAPACITY KW Voltage Hertz 6 240V 60 6 240V 50 6 380V 50 6 480V 60
Phase 1 1 3 3
Amps. 33 33 12.9 10.2
HP/GPM 1 HP/10 GPM 1 HP/8.3 GPM 1 HP/8.3 GPM 1 HP/10 GPM
Part No. OWT10902 OWT1090C OWT3090D OWT30904
Capacity (Gallons) 200 to 500 200 to 500 200 to 500 200 to 500
LARGE CAPACITY KW Voltage Hertz 9 240V 60 9 240V 50 9 380V 50 9 480V 60
Phase 1 1 3 3
Amps. 53.4 53.4 19.6 16.6
HP/GPM 2 HP/20 GPM 2 HP/16 GPM 2 HP/16 GPM 2 HP/20 GPM
Section 1 Heating System Overview
1-2
OWT and OER Configurations
Section 1 Heating System Overview
1-3
Oil Explosion Resistant (OER) Standard Models All OER models are designed to meet Explosion Resistant Class 1, Group D, Division 1 and 2, and NEMA 4 standards. The OER models come in three oil-pumping capacities: small, medium, and large. All standard small-, medium-, and large-capacity OER models share the same design in operation and component layout. The major differences between models are the motor, pump, and heating element (in the tank assembly). The standard OER models are listed below. Other features included are: •
Adjustable pressure switch or 24VDC relay for automatic operation
•
A universal mounting platform for compatibility with various mounting configurations
•
80° to 100°F fixed-thermostats with 140°F high limit
•
An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for manual prelube
•
PVC jacketed MI cabling (resistant to sour gas)
•
VITON mechanical seal pumps for extended seal life and temperature operation (to 350°F)
•
Flow detection switch for fail-safe operation
•
An external motor-protective-switch RESET button
OIL EXPLOSION RESISTANT (OER) STANDARD MODELS
Part No. OER10252 OER1025C OER3025D OER30254
Capacity (Gallons) 25 to 100 25 to 100 25 to 100 25 to 100
SMALL CAPACITY KW Voltage Hertz 2.5 240V 60 2.5 240V 50 2.5 380V 50 2.5 480V 60
Phase 1 1 3 3
Amps. 18.1 18.1 7.5 5.9
HP/GPM 1 HP/2.8 GPM 1 HP/2.4 GPM 1 HP/2.4 GPM 1 HP/2.8 GPM
Part No. OER10602 OER1060C OER3060D OER30604
Capacity (Gallons) 75 to 250 75 to 250 75 to 250 75 to 250
MEDIUM CAPACITY KW Voltage Hertz 6 240V 60 6 240V 50 6 380V 50 6 480V 60
Phase 1 1 3 3
Amps. 33 33 12.9 10.2
HP/GPM 1 HP/10 GPM 1 HP/8.3 GPM 1 HP/8.3 GPM 1 HP/10 GPM
Capacity (Gallons) 200 to 500 200 to 500 200 to 500 200 to 500
LARGE CAPACITY KW Voltage Hertz 9 240V 60 9 240V 50 9 380V 50 9 480V 60
Phase 1 1 3 3
Amps. 53.4 53.4 19.6 16.6
HP/GPM 2 HP/20 GPM 2 HP/16 GPM 2 HP/16 GPM 2 HP/20 GPM
Part No. OER10902 OER1090C OER3090D OER30904
Section 1 Heating System Overview
1-4
The Kim Hotstart System The Kim Hotstart standard OWT and OER medium pumping capacity models are shown below. All models (small, medium, and large) are identical in operation. Each heating system consists of a lube oil heating process. The oil is continuously circulated through the heating tank. Only the heating element inside the tank is cycled on and off. The heating element is controlled by a thermostat sensing unit located at the inlet of the heating tank. The lube oil inlet/outlet and heating process is described on the following page. All oil systems are designed to maintain warm-oil take over. They are not designed to take over on a cold-oil start up. Oil Water Tight (OWT) NEMA 12 Model Oil Outlet Oil Tank
OFF ON
NEMA 12 Control Box
Oil Motor and Pump
Oil Inlet
Oil Explosion Resistant (OER) Model Oil Outlet Oil Tank
RESET
OFF ON
Oil Inlet Explosion Resistant Control Box
Oil Motor and Pump
2med.eps
Heating Element in Tank
tank1.eps
Section 1 Heating System Overview
1-5
Lube Oil Inlet/Outlet Process Upon a system start-up, engine lube oil is taken from at least 2-inches above the lowest point of the lube oil sump and circulated by a positive displacement rotary gear pump through the oil heating tank and back to the engine. Options are available on the return line. In most cases, heated oil is circulated directly back to the oil sump. Other options include: continuous lubing and pre-lubing before start-up. •
The system must be mounted as low as possible to minimize suction lift to the pump.
•
The size of the oil supply line must be calculated using the supplied table. Please refer to section 2-2 and 2-3.
•
The Oil supply line may be flexible or rigid and must be sized to the pump.
•
The 7 to 10gpm pump must have at least a 1-inch I.D. line.
•
The 16 to 30gpm pumps must have at least a 1½-inch I.D. line.
•
Oil must be taken from at least two inches above the bottom of the sump.
•
Place full-flow valves in the supply and discharge lines to allow for maintenance. Valve size must conform to the line size. Kim Hotstart heating systems should be mounted as near as possible to the suction port on the oil sump. If possible mount the pump below the level of the oil to provide flooded suction to the pump. The oil suction plumbing is critical to the proper operation of the heating system. If the suction plumbing is under-sized, to long or has too many fittings in it, the pump will not work correctly. Some of the problems this can cause are: Pump seal leaking, cavitation, oil foaming and break down, noisy pump, excessive vibration, and internal pump damage.
Section 1 Heating System Overview
1-6
For heating, the heating system continuously pumps oil to the engine’s oil sump. For pre-lubing, plumbing is routed back to the top of the engine in order to pre-lube the engine prior to start-up. This is done by means of a teed junction with a manual or solenoid valve. NOTE: Kim Hotstart does not specify the volume or pressure of oil to the top of the engine for pre-lubing. See engine manufacturer.
Lube Oil Flow Detection Following lube oil’s inlet and circulation through the heating tank, the oil passes through a flow detection switch. The flow detection switch immediately shuts off the heating element anytime there is an interruption or loss of flow, and activates the time delay relay located inside the control box. The pump continues to circulate the oil to restore flow. If proper flow is not reestablished, the time delay relay shuts down the entire heating system according to a preset time. The time delay relay is adjustable from 0 to 180 seconds. Upon an initial system start-up, the time delay relay should be adjusted to the maximum of 180 seconds. Once flow is achieved, Kim Hotstart recommends a setting of 30 seconds.
OWT Model Flow Detection Switch
OFF ON
L1 L2 L3 513
Time Delay Relay
OER Model
Flow Detection Switch
RESET
OFF ON
L1 L2 L3
trelay.eps 2inbx.eps
This automatic system shut-down Time Delay Relay feature protects the heating element and other major components from damage. The time delay relay and flow detection are discussed in more detail in Time Delay Relay and Flow Detection Switch sections of this manual. NOTE:
Heating elements vary. All standard voltages and a variety of wattage’s are available. To accomplish any temperature range requirement, a variety of thermostats are also available in our custom units.
Upon a system shut down, the heating system must be reset and restarted. For complete system start-up instructions, refer to System Start-Up section in this manual.
Section 1 Heating System Overview
1-7
Installation and System Start-Up The Kim Hotstart OWT and OER heating systems come pre-wired and pre-plumbed for ease of installation. This section describes proper installation of the basic OWT or OER heating systems. Complete step-by-step instructions for system start-up are also included in this section. If you need additional assistance installing or starting your particular system, please contact: Kim Hotstart Manufacturing Company (509) 536-8660
Basic System Installation Following are complete instructions for proper installation of the: • • •
Main Power Supply Oil Supply Line Oil Discharge Line
CAUTION:
VIBRATION DURING SHIPMENT OF THE HEATING SYSTEM CAN CAUSE SCREWS IN THE CONTROL BOX TO LOOSEN. PLEASE CHECK ALL CONNECTIONS IN THE CONTROL BOX AFTER INSTALLATION AND PERIODICALLY DURING OPERATION.
Main Power Supply Connect the specified voltage and phase to the terminal block located in the main control box. For 3-phase applications, the terminal block is labeled L1, L2 and L3. For single phase applications, the terminal block is labeled L1 and L3. The heating element and the circulating pump of the heating system derive power from the main power source to the system. The circuitry in the control box determines the duty cycle of the heating element and circulating pump. A transformer, which drops the main supply voltage to 120 VAC, powers the control circuit. The transformer and control circuit are overload protected with fuses. OWT Model
OER Model
L1 L2 L3
L1 L2 L3
513
L123.eps
Transformer Fuses Terminal Block
Section 2 Installation and System Start-Up
Transformer
Fuses
Terminal Block
2-1
Oil Supply Line Kim Hotstart heating systems should be mounted as near as possible to the suction port on the oil sump. If possible, mount the pump below the level of the oil to provide flooded suction to the pump. The oil suction plumbing is critical to the proper operation of the heating system. If the suction plumbing is under-sized, too long or has too many fittings in it, the pump will not work correctly. Some of the problems this can cause are: Pump seal leaking, cavitation, oil foaming and break down, noisy pump, excessive vibration, and internal pump damage. The pump requires not more than 15inHg ( 7.5psi ) suction lift to the pump. The factors that control that are: The height the pump is above the top of the oil in the sump, the viscosity of the oil, the size and configuration of the suction line, and the altitude (barometric pressure). The suction line size must be determined using the following calculations: Determine each of the 3 following values and add them together to determine if your system meets the requirements of less than 7.5psi suction lift. SAE 40 motor oil is used for these calculations. If your calculated value is too high, increase the line size or move the heater closer to the suction port of the engine. These figures are only estimates. The flow rate of the pump on your system is listed on page 1-4 of this manual. The table on the next page shows friction losses in a smooth line at specified flows. Use the table on 2-3 to determine the frictional losses in the line you intend to use. If the pump is above the oil level to calculate the suction pressure multiply the number of feet the pump is above the oil level by 0.38 to get the psi of the suction lift. If the pump is below the oil level this can be negative. Next, determine the altitude the pump will be at. For every 1000 feet above sea level multiply that number by 0.5 to get psi loss for altitude (barometric pressure). Add the three numbers together. If they are greater than 7.5 psi reduce your pipe length or increase the diameter to reduce the frictional losses from the pipe. If they are less than 7.5psi your pump should work properly. •
If the oil supply line is excessively long or the heating tank is mounted higher than the sump, install a check valve near the oil supply to prevent oil from draining back to the sump when the heating system is off. Installation of a check valve also eliminates repeated priming of the pump on heating system start-up. Make sure all suction pipe connections are tight. A loose connection will not allow the pump to circulate oil.
•
To allow for heating system maintenance without draining the engine sump, install a shut-off valve between the sump and the rotary gear pump.
•
To minimize foreign material from entering the heating system, install the suction line at least 2 inches above the lowest point of the oil sump.
NOTE: To avoid premature failure of the heating element, be sure to position the heating tank so that a complete oil fill is accomplished while in operation.
Section 2 Installation and System Start-Up
2-2
VIKING OIL PUMP SUCTION LINE SIZING CHART (SAE 40 MOTOR OIL AT 80 - 100 Of)
FIND LINE SIZE & LENGTH THAT WILL PROVIDE LESS THAN 7.5psi SUCTION LIFT INCLUDING ADDERS FOR PUMP LEVEL AND ALTITUDE (SEE "ADD" BELOW)
Line Size ID 0.75in 1in 1.25in
2-3 gpm friction losses in length (psi) 5 6 7 8 9 10 4.0
4.8
5.5
6.3
1.5
1.8
2.2
2.5
2.8
3.1
3.1
3.7
4.3
4.9
5.5
6.2
0.5
0.6
0.7
0.8
1.0
1.1
1.0
1.2
1.4
1.6
1.8
2.0
0.6
0.7
0.8
0.9
1.0
1.1
1.5in
Line Size ID 1in 1.25in 1.5in
10 gpm friction losses in length (psi) 5 6 7 8 9 10
20 gpm friction losses in length (psi) 5 6 7 8 9 10
4.4
5.3
6.2
7.0
1.5
1.8
2.1
2.4
2.7
3.0
2.9
3.4
4.0
4.6
5.1
5.7
0.8
1.0
1.1
1.3
1.4
1.6
1.6
1.9
2.2
2.5
2.9
3.2
0.6
0.7
0.8
0.9
1.0
1.1
2in
Line Size ID 1.25in 1.5in 2in
7 gpm friction losses in length (psi) 5 6 7 8 9 10
25 gpm friction losses in length (psi) 5 6 7 8 9 10
30 gpm friction losses in length (psi) 5 6 7 8 9 10
3.6
4.3
5.1
5.8
6.5
7.2
4.4
5.3
6.2
7.0
2.0
2.4
2.8
3.2
3.6
4.0
2.3
2.7
3.2
3.7
4.1
4.6
0.7
0.9
1.0
1.2
1.3
1.5
0.9
1.1
1.2
1.4
1.6
1.8
0.4
0.5
0.6
0.7
0.8
0.9
2.5in
ADD: FOR EVERY FOOT PUMP IS ABOVE OIL LEVEL ADD: 0.38 psi / foot FOR EVERY 1000 FOOT ABOVE SEA LEVEL ADD: 0.5 psi / 1000 feet
Section 2 Installation and System Start-Up
2-3
Oil Discharge Line Connect a 1-inch or 1 1/2-inch N.P.T. line from the heating system outlet to the engine sump. Size the pipe line according to the size of the pump’s outlet port. For large capacity OWT and OER systems, the outlet port normally takes a 1 1/2-inch I.D. pipe. For small and medium capacity OWT and OER systems, the outlet port normally takes a 1-inch I.D. pipe. Note: Upon completion of oil return line installation, top off oil levels to compensate for the oil used to fill the lines and heating tank.
Section 2 Installation and System Start-Up
2-4
System Mounting Requirements Be sure to mount the Kim Hotstart OWT or OER heating system as low as possible with the discharge line exiting from the top of the OWT or OER heating system. This allows the heating tank to completely fill at all times and prevents premature element failure. Turn OFF the heating system before starting up the engine.
Lube Oil Pump The Kim Hotstart OWT or OER heating system heats the lube oil and can continuously heat the engine, or pre-lube it before start-up. On the suction side of the Kim Hotstart lube oil pump, oil is taken from at least 2-inches above the lowest point of the oil sump (not directly at the bottom of the oil sump) and pumped through the OWT or OER system’s heater and discharged back to the engine. The discharge oil line should be sized according to the size of the pump’s discharge port. The Kim Hotstart lube pump can be configured for continuous heating, or teed off with (solenoid or manual) valving for prelubing the engine prior to start-up. NOTE: All oil pump relief valves are preset to 50 PSI.
Section 2 Installation and System Start-Up
2-5
System Start-Up After system installation has been completed, follow these steps for proper OWT or OER heating system start-up.
Lube Oil Heating System Start-Up Step 1 Check and tighten all electrical and plumbing connections. Step 2 Open the control box. Turn the control knob on the oil time delay relay inside the control box clockwise to the maximum setting of 180 seconds. OWT Model
OER Model
Time Delay Relay Time Delay Relay
L1 L2 L3
L1 L2 L3
513
trelay2.eps
Step 3 Energize the oil heating system by turning the switch on the control box to the ON position. The red light on the control panel is lit. Bump start the system (by rocking the power switch ON and OFF) and check for proper rotation of the motor/pump assembly. If the pump motor is turning the wrong direction, switch any two electrical leads on the POWER IN block located in the control box for 3 phase systems. WARNING: DO NOT RUN THE MOTOR/PUMP ASSEMBLY DRY. Step 4
If the minimum flow rate is not achieved or flow restriction in the suction line has occurred, the heating system will automatically shut down approximately 3 minutes after start-up. Turn the system OFF and check plumbing lines for any leaks or restrictions. Air entrapment may also occur in the oil lines or pump. Repeat steps 2, 3, and 4. NOTE:
Step 5
On initial start-up, it may take several attempts to achieve proper flow.
Once operation is satisfactory; turn the control knob on the oil time delay relay to the desired setting. Kim Hotstart recommends a setting of 30 seconds. Turn the heating system off and then back on to activate a new setting.
Section 2 Installation and System Start-Up
2-6
System Components This section describes the components used in the Kim Hotstart OWT and OER heating systems, including the: • • •
Control Box Heating Tank Assembly Pump and Motor Assembly
Control Box The control boxes used in the Kim Hotstart OWT and OER heating systems are shown below. Both models are identical in operation. The control boxes contain the electrical control components for the lube oil heating system. Following is an overview of operation and replacement instructions for the standard parts located in the control box, including: •
Time Delay Relay
•
Magnetic Contactors
•
Motor Protective Switch
•
Fuses
•
Transformer
Parts in the control box may vary, depending on the particular system configuration you purchased. For your convenience, available replacement parts are listed. NOTE: A Vaseline type petroleum film should be kept on the machined surface of OER boxes as a barrier to external contaminates. All bolts must be kept in place and torqued to 55 ft. lbs.
Section 3 System Components
3-1
Time Delay Relay The time delay relay is a safety device that works in conjunction with the flow detection switch. If, for any reason, the heating system’s minimum flow rate (G.P.M.) is interrupted, the flow detection switch immediately shuts off the heating element and activates the time delay relay. The time delay relay allows the pump/motor to operate for a preset length of time, from 0 to 180 seconds, in an attempt to restore the heating system’s minimum flow rate. The recommended preset time is 30 seconds. If the minimum flow rate is not achieved by the preset time, the time delay relay automatically shuts down the entire heating system, preventing damage to the heating element and pump/motor. The system will then have to be restarted manually. The time delay relays for OWT and OER models are shown in the illustration on the previous page. To reset the time delay relay, turn the system power OFF and follow the step-by-step instructions for system start-up described in the Installation and System Start-Up section of this manual. The time delay relay requires no maintenance. To order a replacement, reference the replacement part number listed below. Time-Delay Relay Replacement Part Number: PRP224046-000
Magnetic Contactors Because of their low drop out voltage, definite purpose magnetic contactors (shown on the previous page) are used as voltage switching controls in Kim Hotstart OWT and OER heating systems. The contactors use 120 volt coils. In case of contactor failure, check the coil voltage for continuity. The contactor contacts are made of silver cadmium oxide and should be inspected periodically for welding, arc erosion, and mechanical wear. If any of these conditions exist, clean the contacts or replace the contactor. Magnetic Contactor Replacement Parts Amps
Voltage
Hertz
Part Number
30 (32A Resistive)
120
50/60
PRP232047-000
60 (65A Resistive)
120
50/60
PRP232049-000
Remote Control The OER and OWT systems are both equipped with a pressure switch or a 24VDC relay for remote switching of the heater. The pressure switch is designed to plumb into the engine’s oil system. This configuration allows the heater to disengage upon engine startup and re-engage when the engine shuts down. The 24VDC relay works on the same principle except it uses a 24VDC electrical signal to stop and start the heater. Please refer to the wiring diagram in the Appendix for details. Section 3 System Components
3-2
Motor Protective Switch The Motor Protective Switch (MPS) used in your Kim Hotstart heating system was engineered to achieve a level of quality that is unsurpassed in the industry. The MPS (shown below) provides short-circuit protection, thermal overload protection, switching and signaling. Short Circuit Protection A wide variety of applications range from 0.1 to 25 FLA at voltages up to 600V. In the event of a short circuit, the contacts are opened by non-adjusting, magnetic tripping elements in less than 1 /1000 of a second. This results in the extremely rapid buildup of an arc voltage that limits the current of the short circuit to a very low level. Because of this superb current limiting capability, the MPS has an extremely high short-circuit capacity of 50 KA at 600V. Motor Overload Protection Each MPS is calibrated at the factory for the smallest and largest current to ensure an accurate time/current characteristic curve. In addition, the MPS is a “Class 10” device that will trip within 10 seconds under a locked rotor condition (6 x FLA). The MPS provides protection from single-phase conditions at a maximum of 1.25 x FLA. Accurate adjustment of the overload trip ensures effective motor protection — even with a phase loss. To maintain constant trip times, the MPS is also equipped with automatic ambient temperature compensation that continually adjusts to surrounding temperatures.
ST
T R
START (GREEN)
ST
P T TO E S ES R
TEST
STOP RESET (RED)
T1
T2
T3
2
4
6
TO RESET THE SWITCH 1. Press red STOP RESET button. TE
S
ST
2. Press the green START button.
T R
TA
P T TO E S ES R
TE
S
ST
TA T R
P T TO E S ES R
On OWT models, it is necessary that you open the control box to reset the motor protective switch:
TE
TE
L3
T R
L2
TA
L1
Switch tripped if both buttons are up
5
S
3
TA
1
BUTTON POSITIONS NEUTRAL NORMAL
S
On OER models, to reset the switch, simply press the RESET button on the control box’s lid.
Motor Protective Switch
P T TO E S ES R
Reset Buttons Both the OWT and OER control boxes contain a motor protective switch to safeguard against overloads and short-circuits.
resetsw.eps
1. Check the position of the green START and the red STOP RESET buttons on the motor protective switch. In normal operation the red STOP RESET button is up and the green START button is down. 2. If both buttons are up, the switch has been tripped. To reset, first press the red STOP RESET button and then press the green START button.
Section 3 System Components
3-3
Other MPS Features •
UL and CSA listed for group installations.
•
Trip-free mechanism prevents manual closure on short circuits or overloads.
•
“Tripped” ON and OFF push-button indicators are placed vertically on the device for easy detection of which unit has tripped if using more than one MPS.
•
A full line of snap-on accessories include side mount auxiliary contact blocks.
•
The MPS requires no maintenance. MPS Replacement Parts Amps
(Range)
Part Number
1.0
(0.6 - 1.0)
PRP232036-000
1.6
(1.0 - 1.6)
PRP232036-001
2.5
(1.6 - 2.5)
PRP232036-002
4.0
(2.5 - 4.0)
PRP232036-003
6.3
(4.0 - 6.3)
PRP232036-004
10
(6.3 - 10.0)
PRP232036-005
16
(10.0 - 16.0)
PRP232036-006
Fuses There are two different types of fuses located in the control box: Transformer Primary This type of fuse provides short-circuit protection to the transformer. Transformer Secondary This type of fuse provides secondary current protection for the control components. NOTE: The physical size and shape of the oil heating element fuses vary. Order replacement fuses by system part number and serial number.
Transformer The transformer is an electrical component that steps down the primary voltage to 120 volts. Wiring information is listed on the top of the transformer. This transformer is normally overload protected with two fuses.
Section 3 System Components
3-4
Transformer Replacement Parts System Voltage
Transformer Part Number
208
PRP235062-000
240
PRP235030-000
277
PRP236052-000
380
PRP235050-000
400
PRP235050-000
415
PRP235050-000
480
PRP235030-000
575
PRP235050-000
600
PRP235050-000
Oil Heating Tank Assembly The lube oil heating tank assembly is shown (right).
Oil Water Tight (OWT) NEMA 12 Model Oil Outlet
Following is an overview of operation and replacement instructions for the standard heating tank assembly parts, including:
Oil Tank
OFF ON
•
Oil Heating Element
•
Oil High-Limit Thermostat Sensing Unit
•
Oil System Thermostat Sensing Unit
Optional lube oil heating tank assembly parts include: •
NEMA 12 Control Box
Oil Motor and Pump
Oil Inlet
Oil Explosion Resistant (OER) Model Oil Outlet
Solenoid Valves
Heating tank assembly parts may vary slightly, depending on your particular system configuration. For your convenience, available replacement parts are also listed.
Oil Tank
RESET
OFF ON
Oil Inlet Explosion Resistant Control Box
Section 3 System Components
Oil Motor and Pump
2med.eps
3-5
Heating Tank Assembly Parts Heating Element Replacement The heating element, shown below, heats the engine oil. The oil tank has a high-limit temperature sensing unit in the cup of the heating element housing. Instructions for disassembling the high-limit sensor follow. To order a new oil heating element, refer to the part number on the heating element label. NOTE: The oil heating system is designed to maintain the temperature of warm lubricating oil. Be sure to run the engine until the oil is warm prior to starting the oil heating system. If the heating system is energized when the engine is cold, you may trip the motor protective switch. If tripped, this switch must be manually reset.
To replace the heating element or perform routine maintenance, follow these steps. Be sure to allow at least 30 inches of space for element removal. The wattage and phase of the heating element are listed on the identification label on the outside of the element. WARNING DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THE HEATING SYSTEM. Cap
Step 1 Turn the Kim Hotstart Heating system OFF. Step 2 Drain the fluid from the heating tank.
Heating Element Wattage Information
Step 3 Remove the cap from the heating element.
Heating Element
V-Clamp O-Ring Tank elmntre.eps
Section 3 System Components
3-6
Step 4 The wire connections inside the cup of the heating element correspond to one of the phase configurations shown below. Note your unit’s phase configuration. Remove the green-ground and power electrical wires from the posts inside the cup. Step 5 Remove the conduit conductor and electrical wires from the heating element. Step 6 Remove the V-clamp to remove the heating element from the heating tank as shown on the previous page.
Ground (Green)
Power (Black)
cup.eps
Step 7 Replace the heating element or perform the necessary cleaning procedure.
Power (Black)
To reassemble the heating element and tank, follow the steps listed above in reverse order. Make sure the green-ground and power electrical wires are properly reconnected using the washers, lug cups and nuts supplied. To order a new heating element, refer to part number on the label of the element. NOTE: When replacing the element, apply anti-ceasing or thread lubrication to the elements that have a threaded adapter. Single Phase Metal Strap Ground Screw
3 Phase WYE
3 Phase DELTA cupphase.ai
Section 3 System Components
3-7
High-Limit Thermostat Replacement The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over heating of the oil in the event that the heating system’s System Thermostat fails. The sensing unit is located inside the element housing and is fixed at 140°F (On)/160°F (Off). To replace the high-limit thermostat sensing unit, follow these steps. WARNING DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Remove the enclosure cover of the element housing. Step 2 For 3-phase applications only, remove the element jumper strap which crosses over the top of the high-limit sensing unit (red wires). Step 3 Pull the sensor and seat straight out and disconnect the sensor from its seat. Step 4
Sensor Seat Heat Shrink Cover Thermostat Sensor
Reconnect the new sensor.
Reassemble in reverse order. hisenr2.eps
High-Limit Sensing Unit Replacement Parts Sensing Unit
Temp. On
Temp. Off
Part No.
LSU 14
140ºF (60ºC)
160ºF (71ºC)
HLC 4*
*Replacement stats will come with lock ring and sensor seat.
Section 3 System Components
3-8
System Thermostat Replacement The System Thermostat Sensing Unit is located inside the thermostat housing at the inlet end (bottom) of the oil heating tank as shown below. To replace the system thermostat, follow these steps. CAUTION DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THIS HEATING SYSTEM. Step 1 Remove the cover of the service entrance enclosure. Step 2 Pull the thermostat sensor and seat straight out of the housing chamber.
Tank
Step 3 Replace the sensor by pulling it off the seat. Reassemble the new thermostat in reverse order. When pushing in thermostat, take care not to warp the face of the thermostat. Reconnect the electrical connections and the service entrance enclosure.
Thermostat Housing Thermostat Sensor Heat Shrink Cover
NOTE: Remove heat shrink tubing from old sensor and place it on the new sensor before installing.
Sensor Seat
Lo_sensr2.eps
System Thermostat Sensing Unit Replacement Sensing Unit
Temp. On
Temp. Off
Part No.
LSU 4
40ºF (5ºC)
60ºF (15ºC)
HLC 4
LSU 6
60ºF (15ºC)
80ºF (27ºC)
HLC 6
LSU 8
80ºF (27ºC)
100ºF (38ºC)
HLC 8
LSU 10
100ºF (38ºC)
120ºF (49ºC)
HLC 10
LSU 12
120ºF (49ºC)
140ºF (60ºC)
HLC 12
LSU 14
140ºF (60ºC)
160ºF (71ºC)
HLC 14
Section 3 System Components
3-9
Tank O-Ring Shown below is an illustration for changing the O-ring found between the top and bottom section of the heating tank. CAUTION DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THIS HEATING SYSTEM.
Tank
Step 1 Drain the tank. V-Clamp
Step 2 Remove the V-clamp that holds the tank and adapter together. Step 3 Replace the O-ring between the sections.
O-Ring
Step 4 Reassemble the tank. V-Clamp with O-Ring Replacement Part No: PRP215113-000
Adapter
O-Ring Replacement Part No: PRP203093-000 oring1.eps
Flow Detection Switch The Flow Detection Switch (shown on right) is a safety device designed to protect the heating and pumping system. This switch is located on the outlet end of the oil heating tank. If, for any reason, the oil heating system’s minimum flow rate (G.P.M.) is interrupted, the flow detection switch immediately shuts off the heating element and activates the time delay relay. The minimum flow rate required for most heating systems is 2 GPM. To order a flow detection switch, reference the part number listed on the following page. The 2.8 GPM systems use a 0.5 GPM flow switch. NOTE: The flow detection switch should be checked periodically for foreign matter that may build up on the shuttle body. For cleaning instructions, refer to page 4-3 in the System Maintenance section of this manual.
Section 3 System Components
OWT Model Flow Detection Switch
OFF ON
L1 L2 L3 513
Time Delay Relay
OER Model
Flow Detection Switch
RESET
OFF ON
L1 L2 L3
trelay.eps 2inbx.eps
Time Delay Relay
3-10
Standard:
OWT Flow Detection Switch Replacement Part No: PRP224033-000
Standard:
OER Flow Detection Switch Replacement Part No: PRP224033-200
Small OWT (2.8 GPM):
Flow Detection Switch Replacement Part No: PRP224032-000
Small OER (2.8 GPM):
Flow Detection Switch Replacement Part No: PRP224032-200
Pump and Motor Assembly Pump and motor assemblies vary according to the customer’s need. Order replacement parts using the system part number.
Oil Pressure Switch Shown below is the pressure switch used on the OER heating system. The pressure switch is normally connected to the pressure side of the engine - not the suction side. When oil pressure drops below the switch’s lower limit, the switch turns On the oil heating system; when oil pressure increases above its high limit, the switch turns Off the oil heating system. NOTE: When PRP224078-000 is used, the hex inlet fitting of the pressure switch should never be turned when connecting the oil line. Hold the hex nut fitting firmly when attaching the oil line.
Pressure Switch Replacement Part Numbers Model
Part Number
Range
OER
PRP224078-000
5 – 30 PSI
OWT
PRP224008-000
8 – 20 PSI
pressw.eps
1/4-Inch N.P.T
DO NOT TURN. Hold firmly when attaching oil line.
Section 3 System Components
3-11
System Maintenance and Troubleshooting This section describes maintenance procedures for the Kim Hotstart Model OWT/OER Heating System and provides tips for troubleshooting.
System Maintenance The following maintenance procedures are provided to ensure trouble-free operation of your heating system: • Control Box • Plumbing Connections • Electrical Connections and Contacts • Heating Tanks/Elements • Flow Detection Switch • Pump & Motor Assemblies • System Mounting WARNING DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM MAINTENANCE.
Control Box
Periodically check gaskets for proper seals.
Check the control box for moisture (if necessary, add desiccant packets).
Plumbing Connections
Periodically check plumbing connections for leaks and, if necessary, tighten connections. A loose connection on the suction side will cause a loss of flow.
Electrical Connections
Excessive vibration will eventually cause terminals to loosen. Tighten at startup and check again in a week. Periodically tighten all electrical connections every 3 months.
Electrical Contacts
Inspect electrical contacts for wear. Worn contacts should be replaced with new contactors.
Section 4 System Maintenance & Troubleshooting
4-1
Heating Tank
At least once per year, clean the interior of the heating tank and the heating element with a wire brush and/or damp cloth. Periodically check the element for sediment build-up around the hairpins. Any scaling or build-up will shorten element life. Maintenance and replacement procedures for the heating element are described in System Components of this manual.
Following lengthy system shut downs, remove the terminal covers of the element assembly as shown in System Components and check for any moisture or condensation. Electric tubular heating elements contain a granular refractory material called magnesium oxide (MGO) to insulate the resistor coil from the outer metal sheath. MGO is hygroscopic, which means it has the ability to absorb moisture from the air. MGO contaminated with moisture reduces the insulating value of the MGO which is measured with an Ohm meter and read as resistance on the megohms range (1 meg-ohms = 1 million ohms = 1M Ohms) . Low resistance (less than 1M Ohms) is a transient condition experienced on first heat-up under normal periodic heater usage. Moisture absorption under normal conditions does not affect heater efficiency or life. The minimum required resistance value is 1.0M Ohms for full power voltage operation. However, heating elements with a moisture barrier sealant such as RTV silicone or epoxy potting will require a minimum value of 5.0M Ohms. Resistance values should be measured with an Ohm meter by applying one lead to the termination and the other to ground. When the heater does not meet the required resistance value, the unit will have to be dried out prior to full power operation. If the heater has 0.1M Ohms (100K Ohms), or better, but less than 1M Ohms, the heater should be operated at half the rated voltage for 30 minutes to dissipate the accumulated moisture. Disconnect the power after 30 minutes and check the resistance. An alternative to applying voltage is to manually dry the heaters in an oven at 300°F for 4 hours then check its resistance again. If the resistance is higher than it was originally, repeat the process until the value reaches the minimum requirement of 1M Ohms. The heater can then be operated at full rated voltage. A resistance reading of 0.0 megohms, or a reading lower than originally measured, indicates the heater has absorbed a considerable amount of moisture. Remove the wires and jumper straps from the element as shown in Heating Element Replacement section of this manual and check element resistance to ground. After drying, reassemble the element in reverse order.
Section 4 System Maintenance & Troubleshooting
4-2
Flow Detection Switch
Inspect the flow detection (flow control) switch periodically for foreign buildup on the shuttle body. To clean the flow detection switch, follow these steps:
Step 1 Shut OFF the oil supply to the heating system. Step 2 Remove the bonnet nut and lift out the entire switch assembly.
Flow Detection Switch
Bonnet Nut
Step 3 Remove accumulated sediment from the switch body with a damp cloth. Step 4 Check the switch for proper operation by sliding the shuttle and magnet up over the main shaft as shown below. If the shuttle hangs up or does not slide smoothly, remove the lock ring from the bottom of the switch assembly and slide the shuttle, magnet and spring off.
flowdect1.ai
Step 5 Remove foreign matter and rough spots from the shaft with denatured alcohol.
Bonnet Nut
Step 6 Reassemble the switch and check it again for proper operation (reference step 4). Step 7 To test operation of the switch assembly, turn ON the main power. When the magnet on the shuttle is slid up the shaft, the magnetic contactor that operates the heating element should close.
Switch Body
CAUTION: When testing the flow switch, do not operate the heating system any longer than 5 seconds or damage to the heating element may occur. Step 8
Tension Spring
Magnet
Once the switch assembly is working properly, reassemble the flow switch and set the time delay relay to the desired setting. The recommended setting is 30 seconds.
Plunger Body
Lock Ring
Base flwdect2.ai
Section 4 System Maintenance & Troubleshooting
4-3
Pump and Motor Assemblies
Two different types of motors are used: one uses sealed bearings and the other ball bearings. Sealed bearings require no maintenance. For ball bearing motors, lubricate fittings periodically (usually every 6 to 12 months for normal applications).
Pumps - replace seals and gaskets as required. See Appendix A.
Seal life is very difficult to estimate due to a variety of controlled and uncontrolled conditions the seal operates in. Pump seals by nature will weep some even when new.
The mechanical seal faces cannot be permitted to be in contact in a dry environment. Some liquid must pass between the rotating and stationary face in order to minimize friction and to carry away the heat generated. If this leakage evaporates when reaching the atmosphere, then there is no visible leakage. If it doesn’t, leakage in the order of 10 drops per day might be the best achievable. Some seal manufacturers rely on high face loading to minimize leakage but at the expense of seal longevity. Others do the opposite, which provides longer life but greater leakage. Field installation of the seals is not as exact a procedure as is possible when this is done in a factory environment with experienced assemblers. It is possible to experience some minor leakage on field installed seals. Excessive leakage can also be an early indication of seal failure, warning of the need for impending maintenance. Before installing, repairing, or performing maintenance on pumps, read and understand the pump’s instructions completely. Undersized or excessively long suction lines can cause excessive vacuum on the seal and cause leakage from the seal. Please see page 2-2.
System Mounting
Excessive vibration may cause mounting bolts to loosen. Periodically check and tighten all mounting bolts.
To allow air to escape, the system must be mounted with the outlet of the tank at the top of the system.
Section 4 System Maintenance & Troubleshooting
4-4
Troubleshooting
The Fluid Does Not Heat Probable Causes: • No electrical power • Blown fuse • Problem with the flow switch • Problem with the thermostat • Problem with the heating element Recommended Repairs: Electrical Power - Make sure that the control box’s “ON/OFF” switch is in the “ON” position. Observe the power light on the control box. If the power light is not on, make sure that the main power supply and the 24 V supply are ON. If the power supplies are ON but the power light on the control box is OFF, troubleshoot the electrical system. Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the control box. Replace any blown fuse. If the fuse is blown again, troubleshoot the electrical system. Flow Switch - If the flow switch is not operating properly, the flow switch can improperly remove the power supply from the heating element. Make sure that the flow switch is operating correctly. Inspect the flow switch and clean the flow switch. For instructions, refer to page 4-3. Replace the flow switch if necessary. Thermostat - The thermostat’s contactor is normally open. If the temperature is less than the thermostat’s rating, the thermostat’s contactor closes in order to energize the heating element. If the temperature becomes greater than the thermostat’s rating, the thermostat opens again. To verify whether there is a problem with the thermostat, measure the thermostat’s resistance at a temperature that is less than the thermostat’s closing temperature. If the resistance is greater than 200,000 ohms, the contactor is open. Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s closing temperature. If the resistance is less than 5 ohms, the contactor is closed. Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s opening temperature. If the resistance is greater than 200,000 ohms, the contactor is open. For the thermostats’ operating temperatures, refer to page 3-9. If the thermostat fails to operate correctly, replace the thermostat.
Section 4 System Maintenance & Troubleshooting
4-5
Heating Element - Deposits and moisture will reduce the heating element’s efficiency. Clean the heating element and check the heating element for a short circuit to ground. For instructions, refer to page 3-6.
The Flow of Fluid is Inadequate Probable Causes: • Closed ball valves • Air leaks in the suction side • Obstruction in the supply lines and/or the return lines • The pump is not primed. • Incorrect pump rotation • No electrical power • Blown fuse • Problem with the flow switch • Pump cavitation • Improper impeller clearance or improper assembly Recommended Repairs: Ball Valves - If the ball valves are closed, the heater is isolated from the engine’s fluid. Open the ball valves. Air Leaks - Inspect the lines and the fittings on the suction side of the pump. Repair any leaks. Make sure that the fittings are secure. Obstruction in the Lines - Restriction of the suction lines will not allow the pump to fill properly. Restriction of the return lines causes excessive resistance to the pumping. Inspect the lines for obstructions and remove any restriction. Pump Priming - An air pocket in the inlet side of the pump will prevent the pump from operating properly. Open a port in the output side of the pump and operate the pump for a few seconds in order to purge the air. When fluid appears at the port, close the port. Pump Rotation - Compare the pump rotation to the directional arrow on the housing. If the rotation is incorrect, switch any two of the three wires from the main power supply at the control box. Electrical Power - Make sure that the control box’s “ON/OFF” switch is in the “ON” position. Observe the power light on the control box. If the power light is not on, make sure that the main power supply and the 24V supply are ON. If the power supplies are ON but the power light on the control box is OFF, troubleshoot the electrical system. Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the control box. Replace any blown fuse. If the fuse is blown again, troubleshoot the electrical system.
Section 4 System Maintenance & Troubleshooting
4-6
Flow Switch - If there is a problem with the flow switch, the flow switch can improperly activate the time delay relay and the power supply will be removed from the pump motor. Make sure that the flow switch is operating correctly. Inspect the flow switch and clean the flow switch. For instructions, refer to page 4-3. Replace the flow switch if necessary.
The Pump Motor is Overheating Probable Causes: • Obstruction in the supply lines and/or return lines • Inadequate fluid flow • Problem with the main power supply • Problem with a thermostat • Problem with the motor’s protective switch • Problem with the pump shaft or the motor’s bearing • Oil Viscosity Recommended Repairs: Obstruction in the Lines - Restriction of the suction lines and/or the return lines causes excessive resistance to the pumping. The pump motor will work too hard and the motor will overheat. Inspect the lines for obstructions and remove any restriction. Fluid Flow - The pump is partially cooled and lubricated by the fluid flow. An inadequate fluid flow can result in overheating of the pump motor. If a problem with the fluid flow is suspected, refer to “The Flow of Fluid is Inadequate”. Main Power Supply - The pump motor must have the correct voltage and frequency. Otherwise, the motor will attempt to compensate for the inadequate supply and the motor will overheat. Check the quality of the main power supply and compare the data to the motor’s rating. Make sure that the main power supply is correct. Thermostat - The thermostat’s contactor is normally open. If the temperature is less than the thermostat’s rating, the thermostat’s contactor closes in order to energize the heating element. If the temperature becomes greater than the thermostat’s rating, the thermostat opens again. To verify whether there is a problem with the thermostat, measure the thermostat’s resistance at a temperature that is less than the thermostat’s closing temperature. If the resistance is greater than 200,000 ohms, the contactor is open. Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s closing temperature. If the resistance is less than 5 ohms, the contactor is closed.
Section 4 System Maintenance & Troubleshooting
4-7
Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s opening temperature. If the resistance is greater than 200,000 ohms, the contactor is open. For the thermostats’ operating temperatures, refer to page 3-9. If the thermostat fails to operate correctly, replace the thermostat. Motor’s Protective Switch - If there is a problem with the motor’s protective switch, the switch can incorrectly remove power from the pump motor. Exchange the switch with a switch that is known to be good. Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor bearing will result in overheating. Inspect the parts for wear. Make the necessary repairs. Oil Viscosity – Viscosity of oil is too thick causing the motor to over-work. The motor protective switch over heats and trips out. All oil systems are designed to maintain warm oil takeover. They are not designed to take over on a cold oil start-up.
The Pump’s Seal is Leaking Probable Causes: • Improper assembly • Damaged seal • Contaminated fluid • High fluid temperature • Dry operation Recommended Repairs: Damaged Seal - The seal is worn over time. The seal will eventually become damaged from use. Replace the seal. For instructions on disassembly and assembly of the pump, refer to pump vendor information in Appendix. Contaminated Fluid - Abrasive material and/or corrosive chemicals in the fluid will damage the seal. Other moving parts can also be damaged. Obtain an analysis of the fluid. Replace the fluid, if necessary. Refer to the engine’s Operation and Maintenance Manual. Replace the seal. For instructions on disassembly and assembly of the pump, refer to pump vendor information in Appendix. High Fluid Temperature - If the temperature of the fluid is too high, there is probably a problem with the thermostat. The thermostat’s contactor is normally open. If the temperature is less than the thermostat’s rating, the thermostat’s contactor closes in order to energize the heating element. If the temperature becomes greater than the thermostat’s rating, the thermostat opens again. To verify whether there is a problem with the thermostat, measure the thermostat’s resistance at a temperature that is less than the thermostat’s closing
Section 4 System Maintenance & Troubleshooting
4-8
temperature. If the resistance is greater than 200,000 ohms, the contactor is open. Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s closing temperature. If the resistance is less than 5 ohms, the contactor is closed. Continue to measure the thermostat’s resistance and increase the temperature to the thermostat’s opening temperature. If the resistance is greater than 200,000 ohms, the contactor is open. For the thermostats’ operating temperatures, refer to page 3-9. If the thermostat fails to operate correctly, replace the thermostat. Dry Operation - The pump is partially cooled and lubricated by the fluid flow. A lack of fluid or an inadequate fluid flow can result in overheating of the pump. This can damage the seal and the pump’s moving parts. If a problem with the fluid flow is suspected, refer to “The Flow of Fluid is Inadequate”.
Excessive Noise or Vibration Probable Causes: • Improper assembly • Problem with the pump shaft or the motor’s bearing • Pump cavitation Recommended Repairs: Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor bearing will result in overheating. Inspect the parts for wear. Make the necessary repairs.
Section 4 System Maintenance & Troubleshooting
4-9
System Drawings This section contains system drawings specific to your heating system
Appendix A
A-1
Progressive Equipment Incorporated 14028 Aston Avenue Houston, Texas 77040 USA
Telephone (713) 462-1061 Fax (713) 462-4027 Or Contact Us Via E-Mail:
[email protected]
DropsA SMX Series Divider Valves
“Your Single Source For Any Lubrication Application”
GENERAL FEATURES x x x x x x x x
Integral Porting Adapter for Simple Single to Twin Outlet Conversion, Reduces Inventory Levels Air Bleeds Built Into Base Plate Maximum Pressure 7,200 PSI (500 BAR) Operates With Oil or Grease Full Monitoring Capability NPTF-Metric-BSP-SAE Threads Available Modular Design—Base and Metering Elements Zinc Plated Components
ADVANTAGES x x x x x x
Modular Design Eliminates Tie Rods Metering Elements Can Be Serviced Without Disturbing Piping or Tubing Internal Cross Porting Auxiliary By-Pass Element Available Easy Conversion From Twin to Single, No Need to Stock Twin and Single Metering Elements No Limitation To The Maximum Number of Metering Elements
Notes: 1. A Minimum of 3 Metering Elements is Required to Operate The Assembly. 2. Each Base And Metering Element Undergoes a Thermal Explosive Process to Eliminate Foreign Matter. DESCRIPTION DropsA’s SMX is a Modular Design Series Progressive Divider Valve Consisting of Two Main Parts; the Base and Metering Elements. BASE The Base is made up of a minimum of three segments: x x x
Inlet Base Section Intermediate Base Section End Base Section
And can be increased in number by the addition of Intermediate Base Sections. This revolutionary system makes the assembly easy and flexible; there is no need to determine in advance the size of the base, just add on intermediate base sections by means of Threaded Inserts and Cap Screws (Patented).
METERING ELEMENTS The Metering Elements are fixed to the base by means of two cap screws (provided). The SMX Metering Elements are available in a wide range of deliveries (See Chart on Page 2). Cycle Indicator Pins are available on most size elements (See Chart on Page 2). A By-Pass element is also available which allows an addition or reduction of lubrication points at any time without having to disconnect any piping or tubing. Bridge Elements (Internally Cross Ported) are available. These interconnect and discharge into the next element. The Metering Elements are supplied with either one or two outlets, Conversion Plugs are available for field conversion from one to two outlets (See Chart Below). All Metering Elements are fully interchangeable in various positions on the base.
Conversion Plugs Plug Type
Plug Part No.
Plug Color
“S” Single Outlet
641708
Silver
“T” Two Outlets
641709
Gold
Base Plate Assemblies
Metering Elements
No. of Elements
Part Number
3
643523
SMX-08
4
643524
5
643525
6
643526
7
643527
8
643528
9
643529
Metering Delivery In3 Element Size (Twin)
Note: Bases For 10 or More Sections are available, contact Progressive Equipment for Part Number and Ordering Information. TECHNICAL DATA Maximum Pressure: 7,200 PSI (500 BAR) Minimum Pressure: 215 PSI (15 BAR)
Delivery In3 (Single)
Part Number
.005
.010
641516
SMX-12
.0075
.015
641790
SMX-16
.010
.020
641517
SMX-25
.015
.030
641518
SMX-35
.020
.040
641519
SMX-40
.025
.050
641520
SMX-50
.030
.060
641521
SMX-60
.035
.070
641522
SMX-65
.040
.080
641523
SMX-00
By-Pass
By-Pass
641514
Note: 3 Working Metering Elements are Required to Complete an Assembly. A By-Pass is not considered a Working Element.
O-Ring Material: Buna, Standard * Viton, Optional
Adapter Single/Twin
Temperature Range: Buna Seals: -220 F (-300 C) to +2120 F (+1000 C) Viton Seals: -40 F (-250 C) to + 3920 F (+2000 C) Maximum No. of Strokes Per Minute: 500* Depending on Pressure and Delivery. Oil Viscosity: Minimum 15 cSt (77.31 SSU) Grease: Maximum 200 ASTM (NLGI-4)
Top View of Metering Element
O-Ring (9 Per Element)
Weight of Single Element: .68 Lb. (0.31 Kg) Inlet Thread: 1/4” NPT Outlet Thread: 1/8” NPT (Consult Pro-Gress for Metric Sizes) MONITORING OF PISTON MOVEMENT
Bottom View of Metering Element
The following Types of Switches are available to monitor Piston movement: x
DNFT—Digital No-Flow Timers (Request DNFT Brochure)
x
Deliron Proximity Switch (Request The Deliron Proximity Switch Brochure)
x
DELIRON—Magnetic Cycle Indicator (leak-proof)
PIN INDICATORS (High Pressure, Blocked or Plugged Line Indication).
x
Pin Indicator, Pressure Type w/ Memory Available in pressure ratings of: 1500, 2000, 2500, 3000, 3500, 4000 and 5000 PSI.
DLM-926-PM PANEL MOUNT DELIRON MONITOR
Features Failsafe Open or Closed Modes
Specifications Material: Aluminum
2-Line Digital Readout Displays Engine and Compressor Oil Consumption in Pints Per Day, Total Cycles and Cycle Time
Input Power w/ Power Interface Module 90-180 VDC @ .0005 AMPS 90-120 VAC @ .0005 AMPS
User Programmable Alarm Time (3 to 250 Seconds)
Input Power w/o Power Interface Module: 6-24 VDC @ .04 AMPS
Fits Directly Into The 4-1/2” Cutout In Your Control Panel
Alarm Switch Rating: 6-240 VDC @ 10VA / 5-120 VAC @ 2.5VA
Monitors Engine & Compressor Lubrication
Operating Temperature: -200C to +700C (-40F to +1580F)
Description Progressive Equipment Incorporated is proud to announce the release of the new DLM-926-PM Dual Zone Deliron Lubrication Monitor for installation directly into the 4-1/2” cutout in your Control Panel. The DLM-926-PM is a digital micro processor control device specifically designed to protect Gas Compressors from damage due to loss of lubrication. Lubrication to the Engine/Compressor flows through a Divider Block Type Lubrication System forcing an internal piston to cycle back and forth. By installing a Proximity Switch on one of the Metering Elements on each of the Master Divider Blocks, the back and forth movement of the pistons result in an On/Off state which the DLM-926-PM continuously analyzes.
Model DLM-926-PM (Part No. 000551) Consisting of: 1 Each DLM-926-PM Monitor 2 Each DLM-D-PRX Proximity Switches 1 Each PM970 Power Interface Module
DLM-926-PM Deliron Monitor With Glass Cover Removed
Programming Method Four Switches mounted underneath the glass cover. Remove Glass Cover to access switches. (Spanner Wrench Is Required)
Determining Divider Block Total
MODE Push to access program functions
Metering Element SMX-08 SMX-12 SMX-16 SMX-25 SMX-35 SMX-40 SMX-50 SMX-60 SMX-65
UP Push to increase parameter value Down Push to decrease parameter value Exit Push to exit program mode
If no movement is detected within the preset Alarm Delay Time (3 to 250 Seconds, User Adjustable) a “shutdown” of the compressor will occur preventing damage to the engine and/or compressor from loss of lubrication.
PRESSING MODE & UP or DOWN Changes from one menu item to next
Progressive Equipment Incorporated PO Box 40067 Houston, Texas 77240-0067 USA www.progressive-equipment.com Tel (713) 462-1061 Fax (713) 462-4027 E-Mail:
[email protected]
Menu Items (Modes 1 Through 8)
Manufactured By: DELIRON LIMITED - Odessa, Texas Telephone (800) 337-3412 Website: www.noflo.com
DLM-926-PM PANEL MOUNT DELIRON LUBRICATION MONITOR
PRESSING UP & DOWN (Mode 8) Pushed at the same time will zero the stroke count and run time hours
To determine the divider block total add the values shown below for each size metering element: Value 5 8 10 15 20 25 30 35 40
Examples: SMX-3 (35S-35S-16T) = 50 SMX-4 (16T-16T-08S-12T) = 33
1. Set Compressor Lube Block Total (18 to 144)
5. Select Alarm Logic Mode (Open Loop or Closed Loop)
2. Set Engine Lube Block Total (18 to 144)
6. Read Back of Last 100 Cycle Times Compressor Lube Block
3. Set Compressor Alarm Time (20 to 244 Seconds)
7. Read Back of Last 100 Cycle Times Engine Lube Block
4. Set Engine Alarm Time (20 to 244 Seconds)
8. Reset Stroke Count and System Total Run Time
551LIT DLM926-3 04.10.02
Digital Lubrication Monitor WIRING INSTRUCTIONS Model DLM-926 - Part# 000551
DUAL DIVIDER BLOCK SYSTEM MONITOR WITH RUN TIME HOUR METER & NO-FLOW SHUTDOWN MAGNETO
TO ALARM -- COMPRESSOR TO ALARM -- COMPRESSOR TO ALARM -- ENGINE TO ALARM -- ENGINE
COMPRESSOR
POWER
6-24 VDC + l
ALARM
ENGINE
PROXIMITY SWITCH ENGINE COMPRESSOR
ENGINE PROXIMITY SWITCH
COMPRESSOR PROXIMITY SWITCH 24S
24S
24S
24S
24S
24S
COMPRESSOR MASTER DIVIDER BLOCK
GREEN WIRE GROUND SECURELY
ENGINE MASTER DIVIDER BLOCK
Odessa, TX USA 1-800-337-3412 www.noflo.com
Manufactured and Assembled in the U.S.A. By DELIRON LIMITED *ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.
GREEN WIRE GROUND SECURELY
PROXIMITY SWITCH
169LIT D-PRX SWI 07/18/01
DL-D-PRX
SWITCH HOUSING (B)
MAGNET HOUSING (C)
#24 AWG 18" LEADS (3) YELLOW YELLOW
1.125" 3.250"
(Switch Connections)
MAGNET (H)
SPECIFICATIONS
GREEN
(Ground)
ALLEN HEAD SPACER SPRING SET SCREWS (A)
RATINGS
Part Number....................................................... 000169 Material..................................Stainless Steel, Aluminum o o Temperature Range..............................-40 F to +185 F Switch Rating.....10 VA / 200 VDC ½ AMP MAX 125 VAC ...................................MINIMUM BREAKDOWN 300 VDC Epoxy Encapsulated............UL LISTED EL-CAST VFR 641
CLASS 1, Div 1 Grps A,B,C,D
LR108334-1
NRTL/C
FOR TRABON, LINCOLN MANZEL & DROPSA DIVIDER BLOCK LUBRICATION SYSTEMS R
R
R
INSTALLATION AND ADJUSTMENT PROCEDURE
1. Loosen all (2) Allen head set screws (A) on switch housing (B) and remove magnet housing (C). Do not remove magnet, spring, and spacer from magnet housing. 2. Remove end plug (D) from divider valve where proximity switch will be installed. Proximity switch can be installed on any available divider valve section. 3. Screw magnet housing (C) into end of divider valve. Torque to 15 foot pounds max. Be sure 0-ring or metal gasket (F) is in place on magnet housing (C) if required. 4. Slide switch housing (B) all the way onto magnet housing (C). Connect ohmmeter to yellow switch leads. Do not tighten set screws at this time. 5.To properly adjust switch housing (B), divider valve assembly (G) must be cycling so magnet (H) is moving back and forth. This can be achieved with lubrication system functioning or by manually pumping clean oil through divider valve assembly with a hand pump. 6. If a cycle is not detected, adjustment is made by sliding switch housing (B) out in 1/16" increments. Continuity meter connected to yellow wires will indicate a switch closure. Adjust 1/16" out until correct adjustment is confirmed. Torque set screws to 25 inch pounds max. 7. Use 10 to 12 inches of flexible conduit on the switch housing for ease of adjustment or maintenance. All conduit and connections should be appropriate for area classification. CAUTION: Conduit and fittings must be supported to avoid bending magnet assembly.
0-RING
(F) INTERNAL VIEW OF MAGNET DIVIDER VALVE HOUSING (H) (E)
R
SWITCH HOUSING (B)
24S 24S 24S
DIVIDER VALVE ASSEMBLY (G)
MAGNET HOUSING (C) END PLUG (D)
WIRE LEADS (I)
ORDERING INFORMATION MODEL
DESCRIPTION
PART NUMBER
DL-D-PRX
DROPSA
000169
DL-L-PRX
LINCOLN - O-RING STYLE
000170
DL-TG-PRX
TRABON - GASKET STYLE “1994” AND EARLIER TRABON - O-RING STYLE “1995” AND LATER
000171
DL-TO-PRX
DISTRIBUTED BY
Odessa, TX USA 1-800-337-3412 www.noflo.com Manufactured and Assembled in the U.S.A. By DELIRON LIMITED *ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.
000172
LM-92164N Revised 10-03 Section 15
Installation Instructions for Level Maintainers
(00-02-0176)
Model Series LM300 Read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before mounting. These installation instructions are intended for all LM300 series models. GENERAL INFORMATION
LM301-EX Shown with optional hose kit fittings
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
LM300: Level Maintainer only (no switches). LM301: Low switch contacts for low level shutdown or alarm. Four wires, SPDT. LM302: Two switches for low and high level shutdown or alarm. Four wires, DPST, wired N.O. in normal operating ranges. LM303: Two switches for low and high level shutdown or alarm. Four wires, DPST, wired N.C. in normal operating ranges. LM304: Two switches. Alarm before shutdown on low level and shutdown on low-low level. Four wires, DPST, wired N.O. in normal operating ranges. LM305: Two switches. Alarm before shutdown on low level and shutdown on lowlow level. Four wires, DPST, wired N.C. in normal operating ranges.
Specifications
Case/Cover: Die cast aluminum. Switch Housing: Aluminum. Approval Rating: LM301 thru LM305 : CSA certified†† for non hazardous locations. Enclosure Type 4 certified. LM301-EX thru LM305-EX: CSA certified†† for Class I, Groups C and D; Class II, Groups F and G hazardous locations. Enclosure Type 4 certified. Float: Rigid polyurethane foam. Polyurethane coated. Maximum Ambient Temperature: 250°F (121°C) Oil Inlet Connection: Top entry 1/2-14 NPT with built-in filter screen (removable for cleaning). Inlet Orifices: 1/4 in. (6 mm) standard. 1/8 in. (3 mm) available. Wire (switch models): 18 AWG x 13 in. (1.0 mm2 x 330 mm). Maximum Inlet Pressure (MIP): Max. Differential: 2 in. (51 mm) between running and stationary oil level. 30 psi (207 kPa) [2.07 bar]. with 1/8 in. (3 mm) orifice. 15 ft. oil (4.6 m oil) with 1/4 in. (6 mm) orifice. Maximum Case Pressure (MCP): 15 psi (103 kPa) [1.03 bar]. Orifice Seal†: Buna-N Thumb-Valve™ Switch Contact: Silver, SPDT snap acting, 10A @ 125, 250VAC; 10A @ 30VDC. (1 only for low level; 2 only for high & low; or 2 only for low with alarm before shutdown)
**
Patent 5493086
Outlet Connection: 3/4-14 NPT left side, right side, and bottom. Crankcase Balance Vent Fitting: 1/2-14 NPT. Mounting: Accepts Murphy pipe mounting or universal mounting brackets. Lens: Clear “Frog Eye” non-staining, high impact, high temperature nylon; UV and heat stabilized. Dial: High visibility white background with green and white “index” lines for normal level indication. Test Knob: Rotate to test switch operation. Turn clockwise for low level test and turn counterclockwise for high level test. Flow Rate Test: Using SAE 30 @ 32°F (0°C). Orifice Flow Rates Pressure Diameter 4 ft. oil – 15 ft. oil 4.7 GPH - 31.0 GPH 1/4 in.* (6 mm) (1.2 m oil – 4.6 m oil) (17.8 LPH - 117.3 LPH) 10 psig – 30 psig 1/8 in. (68.9 kPa – 207 kPa) 16.9 GPH - 32.1 GPH (3 mm) [.69 – 2.07 bar] (63.7 LPH - 121.5 LPH)
*Standard
NOTE: Friction losses due to piping NOT considered.
Optional Hose Kit: 15000355 Quantity Description
1 1 2 2 2 2
1/2 in. (13 mm) I.D. x 3 ft. (914 mm) long hose 1 in. (25 mm) I.D. x 3 ft. (914 mm) long hose 1/2 in. (13 mm) worm gear clamp 1 in. (25 mm) worm gear clamp 1/2 NPT x 1/2 in. (13 mm) barbed fitting 3/4 NPT x 1 in. (25 mm) barbed fitting
††CSA certified with switch contacts rated at 10 A @ 250 VAC (standard).
** Products covered by this bulletin comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility except as noted.
LM-92164N page 1 of 4
DIMENSIONS
LM300 Series Enclosures
Mounting Brackets with Hardware
The dimensions below are for the optional -EX model enclosure. The standard model enclosure dimensions are the same except the height and width which are: 7 in. (178 mm) H, 7-7/8 in. (200 mm) W. Oil Inlet Connection* 1/2-14 NPT with removable screen Crankcase Vent 1/2-14 NPT
6 in. (152 mm) Electrical Conduit 1/2-14 NPT
15000371 pipe bracket 5.20 in. (132 mm)
Additional Hardware Supplied (4) 3/8-16 UNC x 1 inch (25 mm) screws (4) 3/8-16 nut (4) 3/8 I.D. lock washer (2) 3/8 I.D. flat washer
Test Knob
4.50 in. (114 mm) Hole .88 in. (22 mm) dia. .376 in. (10 mm) minimum bottom surface 2 places
2.50 in. (64 mm)
1/4-20 NC 2 places
8-1/4 in. (210 mm)
*Applies to level maintaining models only.
Monitoring Port Connection 3 places, 3/4-14 NPT
15000370 universal bracket
7-3/16 in. (183 mm)
Slot, .390 in. (10 mm) Additional Hardware x 2 in. (51 mm) Supplied 4 places (2) 3/8-16 UNC x 1 inch (25 mm) screws Slot, .390 in. (10 mm) in. (120 mm) (4) 3/8 I.D. flat washer x3 4.71 places
Snap Switch Case Assembly
5-15/16 in. (151 mm)
(17 6.69 0 m in. m)
. 5 in 1.7 mm) (44
(2) 3/8 I.D. lock washer 3/8-16 UNC-2B Mounting Holes, 2 places
2-3/4 in. (70 mm)
(11 4.50 4 in (13 5.19 mm) . 2 m in. m)
5-3/16 in. (132 mm)
(1 7.5 91 0 i m n. m )
(2) 3/8-16 nut
TYPICAL INSTALLATION
Mounting (all LM300 Series models)
Mounting with Universal Bracket
NOTE: Mount the LM300 series level maintainers as close as possible to the crankcase. Also, excessive vibration can cause overfill. Be sure mounting brackets are supported. The following instructions are based on the usage of the pipe and universal mounting brackets shown above.
Deck Mounting
The universal bracket has two mounting methods: deck mounting and pan mounting. 1. Install the universal bracket to the deck as shown in Figure 2A with two flat washers and two 3/8 inch (10 mm) diameter bolts (not supplied).
Pipe Bracket Mounting
1. Mount a nominal 1/2 inch (21 mm) diameter pipe to the deck of the engine. 2. Install the pipe bracket to the LM300 using two 3/8-16 UNC x 1 inch bolts supplied. See Figure 1A. 3. Slip the LM300 onto the pipe and install the two adjustment bolts. Each adjustment bolt consists of a 3/8-16 UNC x 1 inch bolt and two nuts. See Figure 1B. DO NOT tighten the adjustment screws too tightly because you will have to adjust the LM300 later in the installation process.
Crankcase Universal Bracket
Deck
Pipe Bracket
Threaded hole
Figure 2A Adjustment Bolts
LM300
Figure 1A
Pipe
Crankcase
Adjustment Bolts
Figure 2B
2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1 inch (25 mm) bolts supplied (Figure 2B). DO NOT tighten the adjustment screws too tightly. You will have to adjust the LM300 later in the installation process.
Figure 1B LM-92164N page 2 of 4
TYPICAL INSTALLATION continued
Crankcase (Oil Pan) Mounting
1. Install the universal bracket to the crankcase using the existing crankcase bolts (Figure 3A). Crankcase bolt diameter must be no larger than 7/16 inch (11 mm).
Connecting the LM300 to an Oil Supply Tank (level maintaining models only)
Crankcase Bolt Universal Bracket Note Clearance before mounting
4. Fill the crankcase to the proper oil levels. With the engine running and warm, loosen the mounting bracket adjustment bolts and adjust the LM300 so that the oil level in the sight gauge is aligned with the white “index line” on the dial (Figure 4). Tighten the adjustment bolts securely.
Crankcase Adjustment Bolt
Figure 3A
Figure 3B
NOTE: Check clearance between crankcase and mounting bracket before installing the mounting bracket. If space between the crankcase and mounting bracket does not allow installation and access to the adjustment bolts advance to Step 3. 2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1 inch bolts supplied. DO NOT tighten the adjustment bolts too tight. You will have to adjust the LM300 later in the installation process. 3. If space between the crankcase and mounting bracket is narrow, install the universal mounting bracket to the LM300 before installing to the crankcase oil pan.
Connecting Fittings and Hoses The following instructions are for all LM300 series level maintainers. All steps that reference oil inlet or oil supply tank DO NOT apply to non-level-maintaining models. Also, these instructions are based on the Murphy optional hose kit described on page 1. If you did not order the optional hose kit, gather the hoses, clamps and fittings as specified in the optional hose kit. 1. Install the LM300 fittings in their proper locations. NOTE: Apply a sealant such as teflon, to all threaded connections. 2. Attach the 1 inch (25 mm) diameter, flexible monitoring hose to the crankcase and the monitoring port on the LM300. See Figure 4. CAUTION: The hose must slope slightly downward from the LM300 and MUST NOT have any droop or low spots. NOTE: If the drain plug on the crankcase is used for the connection, we recommend installation of a tee to Oil Inlet Vent Hose allow draining of the crankcase Hose for service. Viewing Running 3. Install the 1/2 inch (13 mm) Lens Engine I.D. x 3 ft. (914 mm) hose to Crankcase Oil Level the vent connection on the LM300 to the vent connection on the crankcase. See Figure 4. Monitoring Hose The vent connection on the crankcase must be well above the regulated oil level. All hoses must Figure 4 be clear of obstructions. BEFORE CONTINUING, VERIFY THAT ALL HOSE CLAMPS ARE TIGHT.
1. Remove the caplug from the oil inlet connection. Be sure the filter, inside the connection, is clear of debris. Install the oil inlet connection. 2. Connect a 1/2 inch I.D. (13 mm) or larger hose Oil Supply to oil inlet fitting on the LM300 and to the shutoff Tank valve on the oil supply tank. See Figure 5. For models LM300 thru LM305 recommended minimum mounting of the oil supply Oil Inlet tank above the LM is 4 ft. (1.2m); Hose maximum 15 ft. (4.6m). The hose must maintain a downward slope and not have low spots or droops. Maximum head pressure rating using standard 1/4 in. (6 mm) orifice is 15 ft. (4.6 meters). See Flow Rate test on page 1 for additional orifice pressure ratings. Figure 5 3. Before filling the supply tank with oil, be sure the tank is clean and dry andthe shutoff valve is closed. Also, be sure all hoses and clamps are tight. Fill the tank with CLEAN oil.
WARNING: Overfill condition can be caused by excessive inlet pressure, (maximum inlet pressure depends on orifice), and/or improper “vent to crankcase” installation. See Flow Rate Test on page 1 for maximum pressure. 4. After oil supply tank is full, open the shutoff valve. Next, make the proper electrical connections for the application. See contact ratings on page 1 and schematics on page 4.
Switch Test (switch models only) To test the shutdown and/or alarm functions perform the following: 1. Unscrew protective boot from test knob. IMPORTANT: Always replace boot after testing. 2. Turn the test knob 1/4 turn to the right (clockwise), for low test indication (Figure 6). Figure 6 3. Turn the knob 1/4 turn to the left (counterclockwise), for high test indication. DO NOT FORCE THE TEST KNOB TO TURN. NOTE: After the engine shuts down, you will notice that the oil in the sight gauge glass will rise above normal running level, possibly showing an overfill condition. This is a result of “drain-back” to the engine crankcase and it is normal. Therefore, on models LM302 and LM303 it may be necessary to wire the high level shutdowns into a class “B” or “C” (bypass until first time safe) lockout, so as to allow a permissive start. After the engine is re-started the level will pull down to the normal running level and the shutdown features will be active. A modulating valve (Thumb-Valve™) in the level maintaining models will allow oil usage to be made-up continuously during operation.
LM-92164N page 3 of 4
SWITCH WIRING DIAGRAMS
WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE CONNECTING ANY WIRES. LM301 SPDT
LM302 High/Low N.O. DPST Green
Green
Black
Black
High
Normal
Yellow
LM303 High/Low N.C. DPST Green
Normal Low
Float
Red
Low High
Yellow
Low
Normal
Normal
Low
Brown
High
Blue
Normal
Normal
Red
Orange
Normal Low
Black
Normal
Yellow
Normal
Blue
Low
Low
Red
Orange
Low-Low
Low-Low
Float
Float
Float
Brown
Low-Low
Low-Low
Low
Float
Green
Green
High
Low
LM305 Alarm before shutdown N.C. DPST
LM304 Alarm before shutdown N.O. DPST
OPERATING RANGES OF SWITCHES This section applies only to models that have built-in switches. The illustrations below and to the right show the dials and their operating ranges of the switches. If levels are within the designated zones the switch(es) will activate. Notice that a switch is capable of activating approximately 3/8 in. (10 mm) from the top of the high zone and 3/8 in. (10 mm) from the bottom of the low zone. The dial in Figure 9 shows that if level continues to drop into the low-low zone, a shutdown will occur.
3/8 in. (10 mm)
3/4 in. (19 mm)
Normal Operating Range
3/4 in. (19 mm)
NOTE: Color zones on dial face show approximate normal operating zones. Actual conditions may vary depending upon operating characteristics of the engine. Placement of the LM300 according to the above instructions will compensate for these conditions.
Normal Operating Range
High Zone Shutdown or Alarm
3/4 in. (19 mm)
Low Zone Shutdown or Alarm 3/8 in. (10 mm)
Figure 8: LM302/LM303
Normal Operating Range
3/4 in. (19 mm)
Low Zone Shutdown or Alarm
Low Zone Alarm Low-Low Zone Shutdown 3/8 in. 1/4 in. (10 mm) (6 mm)
3/8 in. (10 mm)
Figure 7: LM301
Figure 9: LM304/LM305
Warranty
A two-year warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.asp.
MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail
[email protected] www.murphymex.com.mx
MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA +1 661 272 4700 fax +1 661 947 7570 e-mail
[email protected] www.murphyswitch.com
MACQUARRIE CORPORATION 1620 Hume Highway Campbellfield, Vic 3061; Australia +61 3 9358 5555 fax +61 3 9358 5558 e-mail
[email protected]
RE
P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail
[email protected] www.fwmurphy.com
FRANK W. MURPHY, LTD. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail
[email protected] www.fwmurphy.co.uk
GI
D
FWMurphy
CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail
[email protected]
STER
E
®
USA–ISO 9001:2000 FM 28221 UK–ISO 9001:2000 FM 29422
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. Printed in U.S.A.
LM-92164N page 4 of 4
Section 11 – IGTB RPM Control Vendor IGTB Assembly Illustrated Parts List ................... Ajax
Bulletin No. TP 1302-000-04
IGTB Operation and Problem Diagnostics ..................................................... Ajax
TP 1300-000r2
V1 System Junction Box Assembly ..................... Ajax
TP YAE-5583
V1 System Junction Box Wiring Schematic ......... Ajax
TP BM-21161-C
V1 System Panel Mounting ................................. Ajax
02-19-T01A-300
Alternator Output vs Engine RPM w/5.33:1 Ratio........... Ajax
11-24-03
V1 Alternator Installation Instructions ............................. Altronic
ALT II 2-01
V1 Alternator Service Instructions................................... Altronic
A24 SI 2-01
Engine-Compressor Package Service Manual
Integrated Governor Throttle Body (Mechanical Assembly) 1302-000-04 Ref # 1 2* 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 34 37* 38
Description IGTB Governor, 30mm, 24VDC Cable & J-box Assembly O-ring Outlet Flange Inlet Flange SHCS #10-24 x 5 UNC Lock Washer, #10 Support Bracket HHCS, -11 UNC x 3¼ Flat Washer, " PCC Fuel Filter Bracket Lock Washer, " HHCS, -16 UNC x 1 Needle Valve Gauge, 0-30 PSIG Hex Head Plug, ¼" NPT Male Tubing Elbow, ¼" Flexible Hose, 1" Flexible Hose, 1½" Pipe Nipple, 1½" x 4"L Street Elbow, 45º, 1" NPT Alternator Drive Assy, 5.33:1 Drive Assembly Gasket Drive Gear, 5.33:1 System Set Screw Stud, -16 UNC x 2¼"L Flat Washer, " Lock Washer, " Hex Nut, -16 UNC V1 Alternator, 24VDC HHCS, -16 UNC x 1¼"L Battery Pack Lubricator Drive Assy, 5.33:1
P/N BM-21152-30 YAE-5583 BM-21146 K-8256-A K-8256-C BM-11473-0324-40 BM-11782-A-03 K-8256-B BM-11900-1011-26 BM-11918-12-N K-7889-1 BM-11782-A-06 BM-11900-0616-08 2549 0057 2015 3312 BM-11950-02 BM-11573-S-4-4 K-8263-A-24 K-8262-A-30 BM-11932-12-09 BM-11969-08 YAE-1561-E K-6258-C A-4658-A BM-11095-A K-8095-0616-18 BM-11918-08-W BM-11782-A-06 BM-11904-0616 BM-21156 BM-11900-0616-10 BM-21158 YAE-5581
Qty 1 ea 1 ea 2 ea 1 ea 1 ea 4 ea 4 ea 1 ea 2 ea 2 ea 1 ea 2 ea 8 ea 2 ea 2 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 4 ea 8 ea 6 ea 4 ea 1 ea 2 ea 1 ea 1 ea
Ref # 40 41* 42 43 44 45 46 47 48 49 50 51 52 53 54
Description Magnetic Pick Up, -18 x 3" Mag P/U Cable Assembly Mag P/U Bracket O-ring, Alternator Flange Plate Gasket Flat Oval Trough Gasket Flat Oval Stud Nut Plain Hex Bolt Hex Head Elbow Tube Compn Bolt Hex head Tubing Welded Union Tube Compn
P/N 2049 1291 3850 0033 8025 9400 BM-16348-F-236 A-1944-A-2 A-2233 A-2115 A-2117 K-8095-0813-16 BM-11904-0813 BM-11900-0616-10 BM-11573-S-6-4 BM-11900-0813-10 BM-21071-3-035 1 BM-11623-S-6-6
Qty 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 2 ea 2 ea 2 ea 5 ea 3 ea 1 ea
Note: refer to Manual's section 11 for additional information about the IGTB system. *shipped separately
Integrated Governor Throttle Body (Mechanical Assembly) 1302-000-04
091205
The IGTB is a combination of a throttle and an electronic governor, therefore “integrated governor throttle body” or IGTB. Its function is to maintain an established RPM set point through out the load range of the engine. Note: the throttle is not a shut off valve. There is enough clearance between the body and the throttle plate to allow the engine to run under certain conditions at less than rated idle RPM when the governor is not powered. As shown in Figure 1, the governor measures the RPM with a magnetic pick up and compares it to the set point RPM supplied by the pressure transducer. 24vdc supply 294 pulses/rev
3-15 psig = 300-440 RPM
1-5vdc
MPU
Fuel Inlet
Fuel Outlet
IGTB
Figure 1 RPM set point is established by a pneumatic 3 to 15 psig signal to the pressure-to-voltage transducer: RPM Voltage Pressure 300 1.8 3 335 2.6 6 370 3.4 9 405 4.2 12 440 5.0 15
When the set point is changed to an increased value the rate of acceleration to that value is 6 RPM/second. When the set point is changed to a decreased value the rate of deceleration is 12 RPM/second. An attained RPM set point is maintained by PID values for best response to changes in load.
The governor has an operating voltage range of 18 to 28 Vdc with a nominal voltage of 24V. The governor consumes 32W maximum power at a peak current of 1.3A (24V) assuming 4 ohms stator resistance at 77ºF. Its operating temperature range is -40ºF to 221ºF. Protect the system with a 6A fuse in the voltage supply line. The governor will not consume power when the engine is stopped. However, if the engine will be out of service for an extended time, it is best to disconnect the input power.
NOTE The governor should not be used for engine shutdown. Ground the ignition system and shut in the fuel supply to assure engine shutdown.
Cooper Compression 2101 S.E. 18th Street Oklahoma City, OK 73129-8351
IGTB Operation and Problem Diagnostics TP 1300-000 r2
The governor’s tuning values (gain, reset, etc.) are optimized for conventional compressor RPM control operations, and step load operations. The values are fixed, and are not field adjustable. Ring gear tooth count and RPM set point vs set point voltage can be altered by use of a downloadable file from Woodward, a data link wiring harness (p/n A-4669), and a PC’s RS-232 port. Instructions accompany the A-4669 data link wiring harness. When the engine is operating at rated load and speed, adjust the fuel supply pressure to be 4 to 6 psig above the fuel pressure downstream of the governor. Assure that the engine will idle without load at that pressure setting. If it does not, reduce the supply pressure slightly so that no load, idle RPM can be achieved. Problem Diagnostics Use the throttle’s fuel supply pressure gauge and fuel outlet pressure gauge to help analyze governor performance. For example, notice the outlet pressure at engine light off, or the outlet pressure at typical operating conditions. (Be certain that the isolation/dampening valves are adjusted for credible readings.) When performing electrical diagnostics, use a digital voltmeter connected to the governor’s wiring harness plug. The appropriate pin connections are listed in the table below, and on the wiring harness assembly drawing. All voltages will be Vdc. If your voltmeter does not have an RMS function to measure the MPU signal level, use Vac for that signal only. (Be certain that the engine’s ignition will be grounded, and the fuel supply will be shut in for these tests.) Problem Engine does not start
Possible Cause Power not applied MPU gap too large MPU signal connection open Stuck throttle shaft
Engine starts, but shuts down.
MPU gap too large
Engine starts, but does not accelerate to idle RPM
Inadequate electrical power
Engine starts and runs, but is unstable
Unable to attain rated RPM with a slight load.
Ignition misfire Precombustion Chamber fuel supply Gas Injection Valve Adjustment Pressure transducer output low
Unable to develop full load RPM Unable to idle at no load
Low fuel pressure High fuel pressure
Suggested Test/Correction Disconnect harness from governor. Test for +24V between plug socket # 1 and # 5. Rotate engine manually to check for 0.020” to 0.030” gap. Disconnect harness from governor. Reset the annunciator. Test for at least 2 Vrms between pin 11 and pin 3 during cranking. Remove the governor. Move throttle by hand. Assess smoothness, friction, and return spring force. Rotate engine manually to check for 0.020” to 0.030” gap. Assure that 18-28Vdc is supplied to governor pin connections #1 (+Vdc) and #5 (–Vdc). Manually switch off governor power. Then switch it on, and restart the engine. If RPM control does not occur, replace the governor. Troubleshoot the ignition system Check for normal PCC fuel pressure, and fouled or stuck check valves Using combustion pressure measurement, balance the firing pressures. A 3-15 psig input signal should produce a 1.85vdc output signal. Apply 15 psig to the transducer input. If 5vdc is not measured between plug’s pin 8 (Vdc+) and pin 3 (Vdc-), replace the transducer. Increase the fuel supply pressure Decrease the fuel supply pressure
NOTE The governor should not be used for engine shutdown. Ground the ignition system and shut in the fuel supply to assure engine shutdown.
Cooper Compression 2101 S.E. 18th Street Oklahoma City, OK 73129-8351
IGTB Operation and Problem Diagnostics TP 1300-000 r2
Socket # 1 2
Wire Color Red
3
Black
4 5 6 7 8 9 10 11 12 ------
Not used
Not used
Black Not used Not used
White Not used Not used
Red Not used
Green
Label +24vdc -----MPU- & Aux------24vdc ----------Aux+
Signal Value 18-28vdc --------Electrical ground
RPM
--------Electrical ground ----------------5vdc (max) @ 15 psi input
300 335 370 405 440
-----MPU+ -----Shield
--------5-8vdc at 100 RPM (min) --------Electrical ground
RPM Set Point vs Signal (Vdc or PSIG)
Vdc PSIG 1.8 3 2.6 6 3.4 9 4.2 12 4.9 15
To MPU cable and panel’s electrical ground Do not allow the cable to be strained. Support it if necessary.
Item A B C D E F G H J
Description Junction Box Assy Wiring Schematic Aux 24vdc Warning Nameplate Governor Cable Voltage Reg Cable Voltage Regulator V1 Alternator Cable Pressure Transducer
P/N BM-21161 BM-21161-C BM-21161-D BM-21161-B BM-21152-A-25 BM-21159 BM-21157 BM-21160 2515 0063
Qty 1 1 1 1 1 1 1 1 1
Cooper Compression 2101 S.E. 18th Street Oklahoma City, OK 73129-8351
To 24Vdc battery ONLY
Cable & Junction Box Assembly IGTB with V1 Alternator System TP YAE-5583 r2
Note If an electrical RPM set point signal is desired instead of a 3-15 psig pneumatic set point, connect the 1-5vdc from the set point’s source to Terminal 6, (WH). An electrical ground common with the j-box is necessary.
Cooper Compression 2101 S.E. 18th Street Oklahoma City, OK 73129-8351
Input from V1 System Battery Box only.
IGTB with V1 Alternator 24VDC Supply System – J-box Wiring TP BM-21161-C r3i
RPM vs Alternator Current @ 5.33:1 460 440 420 400
Engine RPM
380 360 340 320 300 280 260 240 2.0
2.5
3.0 Alternator Current
3.5
4.0
ALTR0N86 24VDC ALTERNATOR ENGINE DRIVEN POVdER PACWGES
1.I
The Aitoonic 24VDC alternatorlregulator packages provide a reliable, engine-mounted source of DC power for ABtronic DC-power& digital Igwt~ionsystems, dher Altronic engine accessories and Alcrsnic Controls panels. There are two versions available. VERSION I - The 590110 series (coupSing driven) or 5901 $ 6 series (belt driven) provide up to 70 watts (3 amps) output ar 1,800 RPM. VERSION 81 -The 5WI 11 ssries (coupling driven) or 5W1 I7 series (beEr driven) provide direct power for the AIPronic CDI, CPU-90 and DlSN ignition system thus @ofistilutinga self-power&, digital ignition system.
1.2
The SslEowing components are required: 1. 2. 3. 4.
Alternaios Unit Regulator (586 501 or 581502) Cable A s s ~ ~ b i y Battery Pack (591100) - used only wtth Version 6 series alternators
2.0 ALTERNATOR UNlT 2.1
COUPLING DRIVEN UNIT: The alternator is available with several flange assembiies to facilitale mounting to most engines h a v i n ~a Range magneto drive. The alternator shou%abe secured to the mounting using 318"-16 screws; tighten the screws securely.
2.2
BELT DRIVEN UNIT: The alternator must be driven with a pulley having an adjustable 518" I.D. hub. Use a p~lYey diameter Po achieve a speed necessary to satisfy the ~ r i l p urequirements t of %heapplication - refer to the chart on drawing 509 0598 persion I) or 509 OBOA (Version El). The alternator should be secured to a mounting bracket using two 318"-16 screws; tighten the screws securely.
2.3
The maximum recomrmended continuous operating RPM for the alternator drive shafi is 2,000 WPM.
3.1
Be sure ;he regulator is the ccprrecr model for the alternator being used; the regulator pari no. must match that printed on the alternator label.
3.2
Locate a suitabse m o u n t i ~ gposition for the regulator unit within reach of the cable assembly and where the ambient temperature does not exceed 150" F. (65" C.).
3.3
Secure the regulator with four 114" screws
4.0 BABrERV PACK (used oniy wlth Version l series alternator and 581501 regulator) ,
4.1
bocs$e3 sL&ebIa mcdf-;r.;,i-tg ismitic;; c;r the banct\l !-~ack an-ib~enttempersture does nor exceed 122' F. (5$ C.).
4.2
The battery pack IS fum3shec.v~ilthshock mounts and 314" mounting l-iardware. Tighten all isui rzt~tssee2ie3y
i~\iithinrest?? oi
c&;e e$se;;-;oii, "
z,iqc i ~ ; ? ~ :I;,; re
5.8 NfIRGNG HOOK-UP 5.f
5.2
Refer l o the drawil-igs for rnouriting dimensions for the various system componei?;s: - For alternator dimensions, see drawing 509 056A. - For regciator dims.&~ns, see drawing 509 357A. - For battery pack dimensions, see drawing 509 058. Refer l o fi-ie diagrams for the proper wiring hook-up for the particlala; altemator1reguiaPor version 5sing - For the Version i system, see drawing 509 053A or 503 063W (shielded system). - For the Vswior: il system, see drawing 509 060A or 509 0644 (shielded system).
~s2j-4:
~ E R S I O NI MODEL
I
VERSION II MODEL
I
PILOT DIAMETER *D"
5901 10/590111
/
FLANGE
ORIENTATION
SERIES
r-i
b:
MAX. SYSTEM WTPUT
1
NO. OF .44 S L O J
NOTE: 1. MUST BE USED M T H A BATTERY BACK-UP: A) ALTRONIC BATTERY PACK 591100; OR B) TWO BATTERIES POWER SONIC MODEL PS-1242 OR EQlJlVALENT 12V, 4.0 AMP-HR., WRED IN SERIES 2. POWER FOR ALTRONIC CD1, CPU-90.
DlSN SYSTEMS ONLY.
AmRNAToR~p ~l l I usE
ONLY WITH
REWUlW WTFWT
NO',
k i G u L A T O R >I WULD BE MOUNTED IN A L0CATlCI.I WHERE MAXIMUM AMBlENr TEMPERATURE DOES NOT EXCEED 1 5 0 F
1 MENc10L!5
lh
INCHES AND (MM)
-
27 WC
