Documente Academic
Documente Profesional
Documente Cultură
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
Serial number
14787
14824
Bulletin No.
Warranty......................................................................... Ajax
Mathematical Conversion Tables ................................... Ajax
Lube Oil & Low Temp Starting
Recommendations .................................................... Ajax
ES 1006
ES 25
ESS-F-961
ESS-F-963
ESS-L-981
ESS-L-983
TIB 020326
TIB 020718
TIB 030910
TIB 031104
TIB 040910
TIB 061115
TIB 050610
TIB 061212
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)
2)
3)
4)
b)
e)
TDI TURBOTWINTM
Engine Air Starters
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
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
0.7376
7.233
1.356
0.1383
9.807
F
L
O
W
1.70
0.588
0.0750
Horsepower
Horsepower
Kilowatts
Kilowatts (KW)
Ft-lbsp/Second
Horsepower (HP)
P
O
W
E
R
MULTIPLY
BY
0.746
550.0
1.340
AN03-147 9/97
TDI TURBOTWINTM
Engine Air Starters
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
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
0.7376
7.233
1.356
0.1383
9.807
F
L
O
W
1.70
0.588
0.0750
Horsepower
Horsepower
Kilowatts
Kilowatts (KW)
Ft-lbsp/Second
Horsepower (HP)
P
O
W
E
R
MULTIPLY
BY
0.746
550.0
1.340
AN03-147 9/97
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Hardened
Washer
Collar
Inner Ring
Crankshaft
Locking
Screw
9 :-
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# ++#
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Flywheel
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ESS-F-963
Title: Keyless Flywheel Installation And Timing
Engines/
Compressors
ESS-F-963
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
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.
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:
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
Engines/
Compressors
ESS-F-963
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.
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 units 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 valves 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.
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.
Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
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.
#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).
Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
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.
Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
Revised 07/98
Technical Information
Bulletin # 020718 r2
August 24, 2004
As New Limits
15 Cylinder Bore
14.997- 15.001
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
.010 - .0125
Up to .015
.008 - .0105
Up to .013
.115 - .135
13 Cylinder Bore
13.247 13.251
13.220 13.222
Up to .145
Up to 13.263,
Max .002 TIR
Down to 13.213
13 Piston-to-Cylinder Clearance
.025 - .031
Up to .045
.010 - .0125
Up to .015
.008 - .0105
Up to .013
.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.
r2>
As New Limits
Max. Acceptable
5.5044 5.5069
Up to 5.509
.010 - .026
5.4995 5.5000
Crosshead-to-Pin Clearance
.0044 - .0074
7.503 7.505
7.499 7.500
.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
8.374 8.375
8.3796 8.3816
.0046 - .0076
Down to 8.3725
Up to 8.3831
Max .002 TIR
Up to .0091
.010 - .020
Up to .022
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
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.
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.
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.
Figure 2
Convert to the current design by replacing the injection valves 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 NPT
Reducer, NPT(F)
x 1/2 NPT(M)
Tube Nut & Ferrules
3/8 Tube Nut & Ferrules
Tubing, 316SS
3/8 Tubing, 316SS
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
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 NPT
Reducer, NPT(F)
x 1/2 NPT(M)
Tube Nut & Ferrules
3/8 Tube Nut & Ferrules
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
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 assemblys 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 100F 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
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 packings
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
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 monitors rate display is calculated by using the divider valve assemblys cycle signal, and a
BLOCK TOTAL of the assembly. The assemblys 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 engines divider valve assembly, and the compressor cylinders divider
valve assembly. (Metering element designation (the SMX number) is stamped on each elements nameplate.)
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 units 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.
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 units 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 skids 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 manufacturers 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.
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
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 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 70F
before mixing and pouring. If possible, avoid grouting at temperatures below 50F, 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 manufacturers 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.
&,
'
/
%
$& ,
*
11,800
28
10,000 - 14,000
28
8,400
28
'
/
%
%
2
13,200
15,900
8,000
3-10
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.
+& *
! "
7
6
1 0 82
3 5
2
1
9
8*
)
%
*
:1
/
;1 2
$2
2801
31,000
26.3
8.6
2802
57,300-67,300
43.3
9.2-10.8
2803
70,000
35.2
13.8
2804
85,000
66.4
8.9
After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all
levelling screws.
NOTICE: This is essential to insure that the unit is being supported only by the grout, not by
the screws.
Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment.
Remove temporary expansion joint materials and fill expansion joints with joint compound.
&
"'( %
"$
%
)
Bolts
150
Bolts
1&2
25
Bolts
95
Bolts
250 - 265
Stud nuts
520 - 600
Flywheel ringfeder
Bolts
All
185
Bolts
All
185
Studs
3&4
250
Stud nuts
3&4
360
Bolts
3&4
260
Bolts
100
Bolts
All
490
Bolts
All, P & C
650 - 700
Allen Bolts
All
38
Studs
15 Bore
220 -250
Crankshaft counterweight
* +,
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
Bolts
All LE
70
Bolts
All LE
15
Spark plugs
Plugs
All
60
Indicator cock
Valve
All
70
Stud nuts
95
Stud nuts
2,3, & 4
160
Bolts
All
45
Bolts
All
10 -12
Bolts
All
11
Bolts
All
25
Set Screws
All
25
Set Screws
All
25
Nut
All
0.003 - 0.006
clearance
Nut
All
7 - 15 (line up with
pin)
&
"'( %
"$
%
)
Stud nuts
All, C
280 - 300
Bolts
All
38
Nut
All, P & C
3200
Set screws
All
55
Nuts
All
50
. /
'
)0
&
"'(
%3
45
&
"'( %
3
45
#8
32
2.5
#8
36
2.5
#10
24
3.7
#10
32
3.7
1/4
20
28
5
6
6
7.5
* +,
Table 2: General Torque Table for Fasteners
) 2
$
. /
'
)0
&
"'(
%3
45
&
"'( %
3
45
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
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
. /
'
)0
1-3/4
&
"'(
%3
45
&
"'( %
3
45
1
8
10
12
1920
1990
2050
2260
2330
2400
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).
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
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
AIII SM 12-96
AIII II 04-92
591-010-S
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
020205
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 #
Description
P/N
Qty
022002
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
P/N
Qty
010307
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
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
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 3
Flat Washer, "
PCC Fuel Filter Bracket
Lock Washer, "
HHCS, -16 UNC x 1
Needle Valve
Gauge, 0-30 PSIG
Hex Head Plug, " NPT
Male Tubing Elbow, "
Flexible Hose, 1"
Flexible Hose, 1"
Pipe Nipple, 1" x 4"L
Street Elbow, 45, 1" NPT
Alternator Drive Assy, 5.33:1
Drive Assembly Gasket
Drive Gear, 5.33:1 System
Set Screw
Stud, -16 UNC x 2"L
Flat Washer, "
Lock Washer, "
Hex Nut, -16 UNC
V1 Alternator, 24VDC
HHCS, -16 UNC x 1"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
091205
Bulletin No.
TP 00-22-T05A-002
Form 5469
IM 120/05
LD-39
00-02-0175
00-02-0483
TP 02-22-T010-331
00-22-T010-307
02-48-T010-388
5252
M-7980
1245
5204
T1-702
T1-701
AN00-639 8/00
190
Notes:
1. The threads and nut faces must be
lubricated to attain the correct clamping
force. Use only crankcase oil or Lubriplate.
Warning
Fuel Inlet
Fuel Outlet
Front View
Connect to the
liquid drain system
Rear View
Description
P/N
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
Description
P/N
Qty
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
Introduction
Scope of Manual
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.
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
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
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).
(Fig. 1)
(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 .
MATERIAL
A.
M.
N.
S.
Z.
DIAL TYPE
A.
B.
C.
D.
E.
F.
G.
H.
T.
Z.
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)
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)
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)
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.
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.
(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.
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: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.
hms-
List of Materials
Model Valve&
NO.
11~LD
22.~0
13-LD
Seat
Leverage
Svstern
I I
loa at
Stainless Steel
Sealed
Stainless Steel.
304L
Gasket
Figure LO-34.
No. 11-LD. 22-LD and 13-LD stainless steel guided lever
liquid drain trap with sealed, tamperproof construction.
Physical Data
",T115mm1o.net
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
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
Specifications
L1100
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: -20/175F (-29/79C)
Standard: -20/300F (-29/149C)
Optional: -20/400F (-29/204C)*
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)
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
DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage
Pressure
Regulator
with 20BPG
Pressure Gage
3-1/2 in.
(89 mm)
2-3/16 in.
(56 mm)
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
1/8 NPT
INLET
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)
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
2-3/16 in.
(56 mm)
See
Note
1/2 NPT
1-1/2 NPT
3-5/8 in.
(92 mm)
Pressure
Inlet Port
1/8 in.-27 NPT
Manual Valve
Operator
Vent
Weep Hole
Union
Valve Open/Closed
Indicator Button
F Drain
Connection
shown
G (dimension
for reference only)
Plug Seal
Model
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
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
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
Valve
Bushing
Valve Seat
Assembly
9.
Outlet
Figure 4
Inlet
Exhaust
New DVOA
Figure 5
L1200N
Cover
Figure 6
L1200N
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]
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
Filter/Regulator
with MURPHYGAGE
REPLACEMENT PARTS
ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Black N.O.
White COM.
Red N.C.
Blue N.C.
Yellow COM.
Orange N.C.
ACCESSORIES
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)
2 NPT
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)
7.01 in.
(179 mm)
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: sales@fwmurphy.com
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.
00-02-0483
Revised 03-06
Section 15
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
WARNING
A
Pressure
Inlet Port
1/8 in.-27 NPT
Manual Valve
Operator
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 3070 psi
(207483 kPa) [2.074.83 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.
Connection
shown
G (dimension
for reference only)
Plug Seal
Model
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
DVU2120
DVU2115
60
Specifications
50
40
Valve Open/Closed
Indicator Button
F Drain
Vent
Weep Hole
Union
DVU150/175
DVU2105
30
20
10
0
500
1000
2000
1500
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)
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.
Filter/Regulator &
MURPHYGAGE
Control
Panel
Instrument
Quality Air/Gas
Supply
Pneumatic Dump
Valves See DVU-01069B
Valve
Union
Fig. 4
Typical
Dump Valve
Installation
Maintenance
Bolt
Valve Indicator
Vessel Wall
Pneumatic
Input Signal
Weep Hole
Drain
Connection
Union
Condensate Out
2-Way (Manual Drain)
Shutoff Valve
REPAIR PROCEDURE
Valve Body
Union Nut
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
Fig. 5
Plug
Seat
Stem
Stem
Packing
O-Ring Seals
Against Outlet
Washer(s)*
Stem
Nut
O-Ring
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.
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.
Fig. 7
250
250
200
200
Pressure (psid)
150
150
100
100
50
50
10
15
20
25
30
35
40
45
Flow (gpm)
SERVICE PARTS
Part No.
Description
DVU2120
55-00-0237
55-00-0236
DVU2115
55-00-0241
55-00-0240
DVU2105
55-00-0245
55-00-0244
DVU175
55-00-0230
55-00-0231
DVU150
55-00-0230
55-00-0231
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: sales@fwmurphy.com
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.
Warning
All repair and resetting of safety relief valves should
be performed by a National Board certified valve
repair shop holding a VRstamp.
See engine assemblies for details
Service the PCC fuel filter every 800 hours.
Starter Pinion
1 travel (ref.)
Ring Gear
Flywheel
Adjust
main fuel pressure regulator
to 15 psig (typically).
0.06 minimum
minimum
engagement
"#
" # !$
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
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, 1"NPT, 3000#
" Male Tubing Conn. w/0.030" Orifice
Tee, "NPT, 2000#
Tee, "NPT, 2000#
Tee, 1"NPT, 2000#
Tee, 2"NPT, 2000#
Tee Reducing Union, " x "
Tubing " x 0.035 Wall
Tubing " 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
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
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
Model M5081
Approved*
M5081FS
Normally Energized Circuit
The M5081FS is manually opened, electrically latched open and tripped
by interrupting the coil power circuit.
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.
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.
VALVE CUT-OUT
FLOW CHARACTERISTICS
10.0
[254.0]
9.0
[228.6]
8.0
[203.2]
7.0
[177.8]
6.0
[152.4]
5.0
[127.0]
Terminal Block is
within this case.
4.0
[101.6]
3.0
[76.2]
2.0
[50.8]
1.0
[25.4]
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
A
D
Vent to relieve trapped fuel
outside the hazardous area.
10
oz
4o
. (.
z.
28
(.1
kg
1k
.)
g.)
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]
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]
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 [ ].
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
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)
M5180-P
Latch Arm (see NOTE 2)
Breather Vent
(see NOTE 1)
6-1/8 in.
(156 mm)
2 NPT
(2 places)
4-3/8 in.
(111 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
(was 65020126);
3/8 in.
(10 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.
Reset Knob
Inlet
Breather
10-5/16 in.
(262 mm)
3-7/16 in.
(87 mm)
Indicator
Button
2 NPT
(2 places)
4-1/16 in.
(103 mm)
45
3-5/8 in.
(92 mm) dia.
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.
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
FUEL FLOW
Figure 2
Pull the lever up, and press the latch
down into ridge with thumb.
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.
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
M2582-C-LS Wiring
White
Orange
White
Orange
FV+ (IGN)
FV+ (IGN)
Valve
Coil
(Note)
8 7 6
3 2 1
Jumper
Optional
Resistor
(See Note)
FV
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).
Switch 1
8 7 6
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
M5081-C
CD Ignition Models
GND ALT1 ALT2 SW
Terminal Block
10 9
8 7 6
Magnetic
Switch
Adapter
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
MS2100
4 5
6 1
4 5
To additional
TATTLETALE
NOTE 1: To CLOSE FUEL VALVENOT 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 VALVENOT 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.
M5081-B
Battery Models
+
-DC Power
source
Terminal Block
10 9
8 7 6
3 2 1
Ground
Jumpers
MS2110
Diode
*forIN4005
flyback protection
MS2110
Start-run
timer
6 1
4 5
6 1
4 5
To additional
TATTLETALE
M5081-A
Magneto Ignition Models
Terminal Block
10 9
8 7 6
3 2 1
Magneto
Ground
65010065
Diode Package
(See Notes 2/4)
Additional
Magneto
Jumpers
MS2120
Start-run
timer
6 1
MS2120
4 5
6 1
4 5
To additional
TATTLETALE
NOTE 1: To CLOSE FUEL VALVENOT 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 VALVENOT 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.
M5081FS
12 or 24 VDC Models
Terminal Block
10 9
8 7 6
Ground
MS2110
6 1
Ground
3 2 1
+
-DC Power
source
*
MS2110
4 5
6 1
4 5
*
Start-run timer
Diode
* forIN4005
flyback protection
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.
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
Ground
LCDT-PS-CD-N
Red
FV
Black
GND
NC
White
8 7 6
FV(+)
FV(-)
LCDT-PS-CD (R)-P
Terminal block
IGN 1
10 9
FV(+)
FV(-)
LCDT-PS-CD-N
Terminal block
8 7 6
3 2 1
IGN 1
FV(+)
FV(-)
GND
jumper
NO
jumper
Relay
Contacts
C
NC
GND
Relay
Contacts
NO
C
NC
Ground
White
10 9
8 7 6
3 2 1
jumper
Ground
jumper
GRD
F/VF/V+
IGN 1
Red
MARK IV-N
terminal block
GRD
F/VF/V+
IGN 1
Black
MARK IV-N *
terminal block
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.
8 7 6
3 2 1
10 9
Diode
* forIN4005
flyback protection
8 7 6
jumper
3 2 1
12/24
S/D
FV
ALM
GRD
*
*
K2
+
+
*
+
K2
K2 K1
+
-DC Power
source
MARK IV-12/24
terminal block
8 7 6
Alarm Relay
K1
Power
Supply
3 2 1
Ignition
jumper
Auxiliary Relay
K1
K1
+
-12/24 VDC
Power source
MARK III-12/24
terminal block
jumper
3 2 1
IN4005 Diode
8 7 6
+
-DC Power
source
10 9
K1 and K2:
External
Relay(s)
12/24V
SD
F/V
GRD
GRD
F/V
S/D
12/24V
10 9
MARK IV-12/24
terminal block
Auxiliary or
Shutdown Relay
jumper
MARK III-N
terminal block
M2582-C to TTDJ-IGN-(T)
M5081-C to TTDJ-IGN-(T)
M5081 Terminal block
10 9
8 7 6
jumper
jumper
3 2 1
IGN
NA
GRD
FV+
FVALR
NA
NA
White
Black
Red
+
IGN
NA
GRD
FV+
FVALR
NA
NA
10 9
8 7 6
jumper
To 12 or 24 VDC
power supply
To 12 or 24 VDC
power supply
3 2 1
jumper
K2
Black
SD
10-32VDC
GRD
NA
FV
ALR
MPU
GRD
K1
TTDJ-DC-(T) to Relays
Connections Shown for Use with
Diagrams (A), (B), (C), and (D) on this page.
10 9
8 7 6
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
K2
K1
12-24 VDC
Power supply
M5081FS to TTDJ-DC-(T)
K1
K2
Red
IGNITION RELAY +
SD
10-32VDC
GRD
NA
FV
ALR
MPU
GRD
White
White
K2
Black
10 9
8 7 6
3 2 1
+
jumper
Red
jumper
K2
1
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
CD ignition primary voltage: 1.38 to 3.8 A
M5081FS: Energized to Run (continuous-duty coil) coil resistance:
12 V model: 33 ;
24 V model: 136
Magneto ignition coil resistance: 0.5
Magneto primary voltage: 1 to 5 A
Battery coil resistance : 7
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
----------------------------------
----------------------------------
----------------------------------
-----------------------
-----------------------
55000158
55000159
-----------------------
------------
55000095
-----------------------
55000074
-----------55000118
----------------------55000196
----------------------------------
----------------------------------
-----------55000096
55000102
------------
55000102
------------
5500148
------------
55000154
------------
55000097
55000137
---------------
---------------
---------------
55000098
55000072
55000160
---------------
---------------
------------
------------
55000138
55000138
---------------
---------------
55000093
55000075
55000135
55000147
55000135
55000155
55000146
55000131
55000161
55000150
55000143
55000132
55000132
55000143
55000132
55000184
55000153
Diaphragm Assembly
------------
------------
------------
Pilot Diaphragm
------------
------------
------------
00007908
55050420
------------
65010065
------------
------------
------------
65700053
65700053
------------
------------
------------
65700054
65700054
------------
------------
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 sales@fwmurphy.com
www.fwmurphy.com
MACQUARRIE CORPORATION
1620 Hume Highway
Campbellfield, Vic 3061; Australia
+61 3 9358-5555 fax +61 3 9358-5558
e-mail murphy@macquarrie.com.au
RE
0966106
Type 119
Instruction Manual
Fisher Controls
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
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
D100261X012
Installation
Type 119
Table 1. Specifications
Maximum Inlet Pressure(1)
150 psig (10.3 bar)
Spring Ranges
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
1. The pressure and temperature limitations in this manual, and any applicable code
limitation, should not be exceeded.
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
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.
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
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
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.
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
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
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*
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 reqd)
Key
8*
Assembly(1)
1C4248 000B2
1A8328 000A2
9
10
1C4248 000A2
11*
1A8328 000M2
Description
O-Ring(1) (2 reqd)
Nitrile
Fluoroelastomer (high-temperature,
corrosion)
Nace MR-01-75, fluoroelastomer
Bonnet, aluminum
Internal Retaining Ring(1) (2 reqd)
Nitrile & fluoroelastomer
Nace MR-01-75, fluoroelastomer
1D6671 25072
27A5516 X012
18A7024 X012
1E5427 11992
15
1C4248 X0182
16
17
18
19
20
21
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 reqd)
1C4248 X0052
17A8080 X032
17A8080 X022
17A8080 X012
19A0348 X022
Part Number
1K5949 06562
1M5239 06992
1M5283 06992
0L0783 43062
19A6034 X012
1U7581 X0022
Type 119
V APPLY LUB/SEALANT
37A8078-C
Fisher Controls
AN 95-414
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
3
3
3.0
3.1
3.2
3.3
3.4
3.5
3.6
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
6.0
7.0
TURBOTWIN WARRANTY
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
(STD MESH)
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
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
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.
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
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.
TDI TURBOTWIN
FROM TECH
.015 inch
.025 inch
DEVELOPMENT INC
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.
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
speed.
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
PROBABLE CAUSE
SOLUTION
E. Remove lubricator.
F. Clean strainer.
3. Reduced Starter
output power.
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 TDIs
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 TDIs
examination to be defective, or by mutual agreement, refund the users 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
TDIs 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
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
TDI TURBOTWIN
FROM TECH
Page 10
DEVELOPMENT INC
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
11
TDI TURBOTWIN
FROM TECH
Page 12
DEVELOPMENT INC
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
13
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
TORQUE
Nm LB.FT
POWER
HP KW
100 74.6
476 350
150 psig
408 300
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
340
250
204
150
100
60
30
35
40
45
50
55
POWER
HP KW
Maximum Torque
Transmitted by Drive
Nm3/h
2652
2140
1054
74.6
80
59.6
60
44.8
40
29.8
20
14.9
ps
ig
30
psi
g
50
Page 14
25
100
300
200
68
20
350
272
136
15
90 psig
408
10
TORQUE
Nm LB.FT
476
500
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
TORQUE
Nm LB. FT
POWER
HP KW
238 175
50 37.2
150 psig
204 150
12
0p
170 125
90
136 100
102 75
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
500
TORQUE
Nm LB.FT
238 175
POWER
HP KW
Maximum Torque
Transmitted by Drive
204 150
60
170 125
ps
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
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
15
TDI TURBOTWIN
FROM TECH
DEVELOPMENT INC
408 300
15
0
340 250
272
12
0p
200
ps
ig
Page 16
60 p
s
50
80 59.6
SCFM
1050
850
670
460
Nm3/h
1785
1445
1139
782
60 44.8
40 29.8
136 100
Inlet Pressure
150 psig
120 psig
90 psig
60 psig
sig
90
psi
g
204 150
68
POWER
HP KW
TORQUE
Nm LB.FT
476 350
500
20 14.9
ig
0
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
SERVICE MANUAL
TDI TURBOTWIN
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
Page
Title
Page
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
Page: i
TDI TURBOTWIN
FROM
Page 1
TDI TURBOTWIN
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 starters Part Number,
Serial Number, Operating Pressure, and Direction of
Rotation information before calling your TDI distributor
or dealer.
TDI TURBOSTART
ENGINE AIR STARTERS
FROM TECH DEVELOPMENT, INC.
BARBER-COLEMAN - a Siebe Company
6800 POE AVE., DAYTON, OH 45414
MODEL NO.
SERIAL NO.
T112-B
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
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Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)
Publication T1-701
Issued Dec 11, 1998
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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.
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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.
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Issued Dec 11, 1998
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4.1 CLEANING
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- 165F.
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- 180F.
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.
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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
Planet Pins
Washers
Gearbox Housing
Sungear / Turbine
Shaft
Spacers
Turbine Housing
Ring Gear
Seal Assembly
Seal Spacer
Needle Bearings
Ball bearings
Containment
Ring/ Nozzle
Turbine Rotors
cracks
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 .005 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.
Publication T1-701
Issued Dec 11, 1998
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PART DESCRIPTION
LIMIT, Inches
Ring gear / Turbine Housing
Internal
measurement
between two .084 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 .0864 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
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Press the aft seal (17) into nozzle 1 (19) using press
tool P/N 2-26943 per Figure 20 with the lips facing up.
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Install the 2 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.
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.
Publication T1-701
Issued Dec 11, 1998
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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.
gearbox
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5.5.
DRIVE/GEARBOX HOUSING
(T106F/T112F)
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
5.4.1
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.
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Issued Dec 11, 1998
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Key No.
Description
Part Number
Screw (6)
11F- 25020-072
2-20831
Screen
2-26148
Screw
19F- 25028-012
Washer
9-93047
Rotor 2
2-26604
Woodruff Key
9-90211-006
9-93083-001
2-26719
10
Bearing (2)
9-91224
11
O-ring (2)
9-90001-027
12
9-90439
13i
2-27333-00R
13ii
2-27333-00L
14
O-ring
9-90001-050
15
Rotor 1
2-26603
16
Woodruff Key
9-90211-009
17
Lip Seal
2-22376
18
Screw (14)
14F-19024-008
19i
2-26718-21R
19ii
2-26718-21L
19iii
2-26718-12R
19iv
2-26718-12L
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Key Number
Description
Part Number
19v
2-26718-06R
19vi
2-26718-06L
20
Pipe Plug
9-93556-004
21
O-ring
9-90001-034
22
14F-31218-016
23
Inlet Flange
1-18967
24
O-ring
9-90001-037
25
52F-50013-016
26
2-27045
27
Screw (6)
14F-25020-016
28
Pipe Plug
9-93501-004
29
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
9-92001-001
35
2P-20156-006
36
Washer (6)
9-93004
37
1-19441
38
9-91004-001
39
2P-20182
40
9-90211-019
41
Bearing (2)
9-91351
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Key
Description
Part Number
42
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
2-22795
50ii
2-22796
51
Retaining Ring
52
Spring
53
Set Screw
54
Needle Bearing
9-91393
55
Adapter Plate
2-22794
56
Screw
14F-31218-020
57i
1-18828
57ii
1-19083
58
Gearbox Housing
1-18810
59
9-92107-015
60
Screw (6)
11F-31218-024
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
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Issued Dec 11, 1998
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Key
Description
Part Number
66
Snap Ring
9-92001-006
67
Lock Nut
9-92105-008
68i
2-22147
68ii
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
2-27069
76
Spring, Compression
9-90408-016
77
Post
2-27223
78
Drive Housing
2-25617
79
Screw (12)
11F-31218-024
80
Needle Bearing
9-91423
Model
B
D
F
P
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PART NUMBER
RELAY VALVES
1" STAINLESS STEEL (AMOT) 52-93505
2" STAINLESS STEEL (AMOT)
52-93505-100
1" 316 SST MANUALLY
OPERATED
2" 316 SST MANUALLY
OPERATED
1" NPT; BUNA N
1" NPT; BUNA N
1" NPT; VITON
1" NPT; VITON
12VDC; 1"; BUNA N
12VDC; 1"; 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
RLVA-25683-012-2
RLVA-25683-012-2-01
RLVA-25683-024-1
RLVA-25683-024-1-01
RLVA-25683-024-2
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
1" 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
Y-STRAINERS
1" CARBON STEEL BODY, #40 52-93549-100
MESH, SST SCREEN
2" CARBON STEEL BODY, #40
52-93549-200
MESH, SST SCREEN
1" CAST IRON BODY, #40
52-93550-100
MESH, SST SCREEN
2" CAST IRON BODY, #40 MESH, 52-93550-200
SST SCREEN
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701
TORQUE
N~
~b.ft
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
Bulletin No.
TP 02-04-T010-307
02-04-T020-300
TP 02-04-T03A-001
4845749
4852918
TC 1512
Note
The pumps 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
pumps 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
pumps 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.
Description
P/N
Qty
1
2
3
4
5
6
7
8
Belt, 5V
Sheave, 2 Groove 5V x 5" SDS
Pump, Peerless
Bushing, SDS 1 " Dia., " x 1" Key
Set Screw, " x 6" C.P.
Angle 2 x 2 x x 7 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.
Description
Material
P/N
Casing
Cast Iron
order by S/N
Bronze
V1735B-449
Shaft
Steel
2681134-492
Casing Ring
Bronze
284006-186
2691519-199092
13
14
Shaft Sleeve
Bronze
16
Inboard Bearing
Steel Assembly
1100750-000
17
17B
17C
17D
18
Outboard Bearing
Steel Assembly
266935-000
19
Bearing Frame
Cast Iron
order by S/N
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
Rubber/Steel Assembly
2681122-000
51
Rubber/Steel Assembly
2681123-000
65
Ni-Resist
268716501-000
71
Adapter
Cast Iron
order by S/N
22
24A
26
73A
Casing Gasket
Fiber
80
119
Viton
V2377A5
V1774A-122
268716501-000
2691534-199
Page 1 of 12
DEMCO
Resilient Seated
Butterfly
Valve
Publication
TC1512
Page 2 of 12
Publication TC1512
Publication
TC1512
Page 3 of 12
Table of Contents
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TC1512
Page 4 of 12
Bill of Materials
DESCRIPTION
Body
Seat
Disc
Upper Stem
Lower Stem
Spring Pin
Retainer
Top O-Ring
Stem O-Ring
Bearing
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TC1512
Page 5 of 12
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
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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
Nameplate Information
4
ITEM
1
2
3
4
5
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
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
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
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TC1512
Page 8 of 12
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
WAFER BODY
Flange Bolts Recommended bolt and stud lengths for installation in ANSI flanges are provided in Table 2.
MSS flanges require longer bolts.
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")
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
Figure 10
Publication
TC1512
Flanges -
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.
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
Publication
TC1512
Page 10 of 12
Troubleshooting
Trouble
Probable Cause
Remedy
Replace Seat.*
Disc is bent.
Replace seat.*
Clockwise rotation of
Gear Operator handwheel
opens valve. Open-Shut
indicators do not coincide
wth valve disc position.
Flange leaks.
Page 11 of 12
NOTES
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
Section 6 Cooler
Vendor
Bulletin No.
07366-C
7249PW
E72-9
6"
3"
n7/8"
6"
SECTION A-A
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
1" NPT
1" NPT
85"
ADD 2" LOUVERS OPEN
74 3/4"
91"
ACCESS
DOOR
(N.S.)
24 5/16"
36 7/16"
56 3/4"
56 1/4"
NC
A
78"
76"
B
END ELEVATION
SIDE ELEVATION
RPM= 636
HP= 12.5 PER FAN
BLADE ANGLE= 32
UNIT: 0736601 02
TAG: CT. 10753 54
JOB: 07366
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)2150RF
(1)2150RF
N/A
18.375
N/A
150 PSI
NOZZLES OUT
OTHER NOZZLE
NC
EJW
112.75
IC
113.75
AUTO
215 PSI
(1)6150RF
(1)6150RF
N/A
18.875
AC
113.75
AUTO
350 PSI
(1)6300RF
(1)6300RF
N/A
18.875
BY
DATE
REV1
DB
10/25/07
REV 2
KG 110807
DESCRIPTION
SHOW MISSING NOZZLE
AID
DHB
CHECKED BY:
DRAWN BY:
P.O:
CKD
DHB
4501415535
07366
CAMERON COMPRESSION
QT. 07126 - Purneftagas
E72-9
PROPOSAL NUMBER
DATE
PAGE
7249PW
10/12/2007
1
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
Fan Shaft
###
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
Long with
##
0
Dia.
Long with
Idler Bearing
Electric Motor
###
15
TEFC
1500
HP
Enclosure
380
RPM
254T
Frame Size
WITH
$295.00
PRICE EACH
$0.00
PRICE EACH
$249.00
PRICE EACH
$0.00
SlideBase
$2,006.00
Volt
636
Fan RPM:
PRICE EACH
Idler Shaft
Fan Bearing
5/6 RAD
PRICE EACH
Keyway
Phase
50
PRICE EACH
$1,149.00
Motor Sheave
O.D.
2-5V5.2Type
Groove
0 Bore
PRICE EACH
$0.00
Fan Sheave
O.D.
2-5V11 Type
Groove
0 Bore
PRICE EACH
$0.00
V-Belts
$0.00
5VX780
PRICE EACH
PRICE EACH
PRICE EACH
LOUVER FOR IC
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
108 IN X 30.75 IN ALUMINUM AUTO WITH JOHNSON 3153-5 AIR MOTOR AND KIMRAY T12 T.C.
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
PRICE EACH
$0.00
0
0
0
0
Cycle
Before any start up procedure is begun, a thorough inspection of the Air Cooled
Exchanger should be made.
1.)
2.)
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.)
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.)
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.)
g.)
If manually adjusted pitch fans are provided, check fan pitch and
re-pitch per manufacturer's instructions if required.
h.)
i.)
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
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
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
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
44
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
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
-
Rotation
1Z,2Z,4Z
1Z,2Z,4Z
5Z
5Z
6Z
6Z
R
L
R
L
R
L
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
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
44
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.
Multi-Wing America
A Crowley Company
Ph.
440 834 9400
Fax
440 834 0449
Toll free 800 311 8465
Lightweight, non-combustible
Telescoping Linkage
Agency Recognized
A pplication
I nstallation
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.
R epair Information
Field repairs must not be made. For a replacement
D-3153 body, contact the nearest Johnson Controls
representative.
Stroke
Force lb (Newton)
8 to 13
Power
105 (467)
(56 to 91)
Return
120 (534)
5 to 10
Power
150 (667)
(35 to 70)
Return
75 (334)
3 to 7
Power
195 (867)
(21 to 49)
Return
45 (200)
68 inlb (8 Nm)
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)
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)
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 )
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
Table 3: Accessories
Description
Shipping Weight
lb (Kg)
Code Number
0.2 (0.09)
D-3073-100
0.3 (0.11)
D-3073-604
1.0 (0.45)
D-9999-100
0.5 (0.23)
D-3153-101
0.5 (0.23)
D-3153-108
0.5 (0.23)
D-3153-109
2.0 (0.91)
D-3153-102
1.0 (0.45)
D-3153-103
0.5 (0.23)
D-3153-104
2.0 (0.91)
D-9502-8
Ball Joint
0.5 (0.23)
D-9999-104
0.5 (0.23)
D-3153-110
0.5 (0.23)
D-3153-111
0.5 (0.23)
D-3153-112
3.5 (1.13)
D-3153-105
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-3153-1 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 250F (121C) 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
Printed in U.S.A.
Section 7 Compressor
Vendor
Bulletin No.
MB-0000
F-0000
TBP 97U
NOTICE:
WARNING!
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 15.56C.
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
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
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
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
010407
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
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
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 #
Description
P/N
Qty
021804
Bulletin No.
02-18-T020-353
00-02-0175
TP 00-06-T01A-001
02-48-T010-388
02-17-T020-393
Blowcase Piping...............................................................Ajax
Norriseal 3023 Control Valve, O & M...........................................Norriseal
Blowdown Piping..............................................................Ajax
Morin Actuator O & M...................................................................Morin
00-06-T010-320
OM 704004M
02-47-T010-324
OMI 0802
02-50-T010-356
00-06-T02A-001
F1-4
M031196
Gauge Valves...............................................................................Inferno
00-18-T020-351
707000M
00-02-0175
Revised 03-06
Section 15
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
Specifications
L1100
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: -20/175F (-29/79C)
Standard: -20/300F (-29/149C)
Optional: -20/400F (-29/204C)*
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)
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
DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage
Pressure
Regulator
with 20BPG
Pressure Gage
3-1/2 in.
(89 mm)
2-3/16 in.
(56 mm)
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
1/8 NPT
INLET
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)
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
2-3/16 in.
(56 mm)
See
Note
1/2 NPT
1-1/2 NPT
3-5/8 in.
(92 mm)
Pressure
Inlet Port
1/8 in.-27 NPT
Manual Valve
Operator
Vent
Weep Hole
Union
Valve Open/Closed
Indicator Button
F Drain
Connection
shown
G (dimension
for reference only)
Plug Seal
Model
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
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
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
Valve
Bushing
Valve Seat
Assembly
9.
Outlet
Figure 4
Inlet
Exhaust
New DVOA
Figure 5
L1200N
Cover
Figure 6
L1200N
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]
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
Filter/Regulator
with MURPHYGAGE
REPLACEMENT PARTS
ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Black N.O.
White COM.
Red N.C.
Blue N.C.
Yellow COM.
Orange N.C.
ACCESSORIES
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)
2 NPT
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)
7.01 in.
(179 mm)
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: sales@fwmurphy.com
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.
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.
Murphy DVU175
Dump Valve Assembly
TP 00-06-T01A-001 Rev 2
Description
Dump Valve, Murphy 1" NPT x " NPT
Male Connector, " Tube x " NPT
Bushing, 1" x " NPT, 3000#
Pipe Nipple, 1" NPT x 2"L, Sch 160
Pipe Tee, 1" NPT, 2000#
Ball Valve, 1" NPT, 2000#
Tubing, " 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
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
WARNING
A
Pressure
Inlet Port
1/8 in.-27 NPT
Manual Valve
Operator
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 3070 psi
(207483 kPa) [2.074.83 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.
Connection
shown
G (dimension
for reference only)
Plug Seal
Model
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
DVU2120
DVU2115
60
Specifications
50
40
Valve Open/Closed
Indicator Button
F Drain
Vent
Weep Hole
Union
DVU150/175
DVU2105
30
20
10
0
500
1000
2000
1500
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)
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.
Filter/Regulator &
MURPHYGAGE
Control
Panel
Instrument
Quality Air/Gas
Supply
Pneumatic Dump
Valves See DVU-01069B
Valve
Union
Fig. 4
Typical
Dump Valve
Installation
Maintenance
Bolt
Valve Indicator
Vessel Wall
Pneumatic
Input Signal
Weep Hole
Drain
Connection
Union
Condensate Out
2-Way (Manual Drain)
Shutoff Valve
REPAIR PROCEDURE
Valve Body
Union Nut
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
Fig. 5
Plug
Seat
Stem
Stem
Packing
O-Ring Seals
Against Outlet
Washer(s)*
Stem
Nut
O-Ring
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.
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.
Fig. 7
250
250
200
200
Pressure (psid)
150
150
100
100
50
50
10
15
20
25
30
35
40
45
Flow (gpm)
SERVICE PARTS
Part No.
Description
DVU2120
55-00-0237
55-00-0236
DVU2115
55-00-0241
55-00-0240
DVU2105
55-00-0245
55-00-0244
DVU175
55-00-0230
55-00-0231
DVU150
55-00-0230
55-00-0231
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: sales@fwmurphy.com
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.
Page 1 of 4
W-K-M
DynaSeal
310F 2-Piece
Flanged End
Ball Valve
9
8
6
5
4
3
2
11
12
13
14
10
10
17
15
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
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.
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
Page 3 of 4
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 (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)
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
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
INSTALLATION
DO Plumb
tailpieces to
avoid misalignment.
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.
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.
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
Stem Packing,
Teflon
standard, to 500F
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 500F
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
1 1/03
2.0
DISASSEMBLY
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.
2.
3.
4.
5.
6.
WRENCH SIZE
1.06
1.25
1.44
1.62
1.81
2.00
2.19
2.38
3.12
2.
3.
4.
5.
6.
7.
2.1
INSPECTION
Follow valve disassembly as outlined above;
carefully inspect individual components as follows:
1.
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
.1
.2
.3
.4
.5
.6
.2
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
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
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
.3
.4
.5
# 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
11/16
9/16
-13
60
5/8-11
70
15/16
# Of Ball Checks
0
1
2
3
3
January 2002
REASSEMBLY
NOTE: Each Series 7100 Piston Check Valve
requires three (3) gaskets of three (3) different
sizes.
.1
2.2
.2
.3
.4
.5
.6
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
.8
.9
.2
.3
.4
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
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
Bulletin No.
00-32-T010-367
00-32-T010-368
01-32-T020-318
00-98-T000-307
00-02-0175
VS-7037N
50-30-7327
00-02-0590
00-02-0161
PD-95145B
00-02-0162
5469
00-02-0175
Revised 03-06
Section 15
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
Specifications
L1100
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: -20/175F (-29/79C)
Standard: -20/300F (-29/149C)
Optional: -20/400F (-29/204C)*
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)
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
DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage
Pressure
Regulator
with 20BPG
Pressure Gage
3-1/2 in.
(89 mm)
2-3/16 in.
(56 mm)
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
1/8 NPT
INLET
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)
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
2-3/16 in.
(56 mm)
See
Note
1/2 NPT
1-1/2 NPT
3-5/8 in.
(92 mm)
Pressure
Inlet Port
1/8 in.-27 NPT
Manual Valve
Operator
Vent
Weep Hole
Union
Valve Open/Closed
Indicator Button
F Drain
Connection
shown
G (dimension
for reference only)
Plug Seal
Model
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
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
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
Valve
Bushing
Valve Seat
Assembly
9.
Outlet
Figure 4
Inlet
Exhaust
New DVOA
Figure 5
L1200N
Cover
Figure 6
L1200N
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]
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
Filter/Regulator
with MURPHYGAGE
REPLACEMENT PARTS
ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection
Black N.O.
White COM.
Red N.C.
Black N.O.
White COM.
Red N.C.
Blue N.C.
Yellow COM.
Orange N.C.
ACCESSORIES
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)
2 NPT
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)
7.01 in.
(179 mm)
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: sales@fwmurphy.com
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.
VS-7037N
Revised 04-05
Section 20
(00-02-0185)
WARNING
LISTED*
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
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)
Weatherproof
Strain Relief
Bushing
27/32 in.
(21 mm)
C-Clamp
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
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 Gs; 0 - 100 Hz /0.100 in. displacement.
Normal Operating Temperature: -40 to 140F (-40 to 60C).
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 Gs; 0 - 100 Hz /0.100 in. displacement.
Normal Operating Temperature: -40 to 140F (-40 to 60C).
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
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 140F (-18 to 60C).
Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
resistive, 1A inductive, up to 30 VDC.
Range adjustment: 0 - 7 Gs; 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).
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
VS-7037N page 3 of 8
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.
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.
Sensitivity Adjustment
WARNING: REMOVE ALL POWER BEFORE OPENING
Less
Sensitive
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
NOTE:
These are typical mounting locations for best operation. Other mountings are possible.
See Installation section on page 3.
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
Reset
Engine Compressor
Turbine Centrifugal
Compressor
Reset
VS-7037N page 5 of 8
Reset
INTERNAL SWITCHES
VS2EXR
Remote Reset
Terminal
Sensitivity
Adjustment
Sensitivity
Adjustment
NC
NO1
NC
COM
NO COM
Ground
Terminal
NO2
SPDT Snap-Switch
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
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.
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 , 3 Watt)
To good
engine ground
Resistor
(100 , 3 Watt)
N.O.
To good
engine
ground
CD Ignition
1
CD Ignition
1
To good
engine ground
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
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 , 3 Watt)
CD Ignition
1
CD Ignition
1
Contacts shown
L2
L3
(see Note)
CD Ignition
2
Resistor
(100 , 3 Watt)
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
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
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 sales@fwmurphy.com
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).
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
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
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
2.5.2
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.
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)
TYPE
NC
NO
NO
IN#
DI-1
DI-2
DI-3
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
TYPE
RELAY(1)
OUT#
1
NOT USED
DESCRIPTION
RELAY(2)
NOT USED
RELAY(3)
NOT USED
RELAY(4)
FET(1)
NOT USED
FET(2)
NOT USED
FET(3)
FET(4)
90 (-OUT)
91 (DC-)
92 (-OUT)
93 (DC-)
IGBT(1)
NOT USED
IGBT(2)
10
IGNITION GROUND
TYPE
4-20mA
OUT#
DESCRIPTION
AO-1 RPM VS SUCTION PRESSURE CONTROL
4-20mA
AO-2
NOT USED
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
TYPE
K
IN#
TC-1
DESCRIPTION
EXHAUST CYLINDER #1 TEMPERATURE
TC-2
TC-3
NOT USED
TC-4
TC-5
TC-6
NOT USED
TC-7
TC-8
Description
Core Digital Inputs Bitmap
Read Only
Read/Write
R
42002
17-32
42003
42004
42005
42006
42007
42008
42009
42010
42011
42012
10
42013
11
42014
12
42015
13 (1)
42016
14 (2)
42017
15 (3)
42018
16 (4)
42019
17 (5)
42020
18 (6)
42021
19 (7)
42022
20 (8)
42023
42024
42025
42026
42027
42028
42029
42030
42031
9 (1)
42032
10 (2)
42033
11 (3)
42034
12 (4)
42035
13 (5)
42036
14 (6)
42037
15 (7)
42038
16 (8)
42039
1-16
42040
42041
42042
3 (1)
Expansion Thermocouple
Inputs
R
R
Data format
Page 7 of 15
42043
4 (2)
42044
5 (3)
42045
6 (4)
Engine Speed
RPM
40101
STATE
40102
RPM
STATUS
Status bits
42046
Status Polling area
40107
1-16
1
STATUS_FLT_SHTDWN
STATUS_ESD
STATUS_ALARM
STATUS_START
STATUS_LCL_RMT
STATUS_TEST_TMR
STATUS_B1_TMR
STATUS_B2_TMR
STATUS_C_TMR
10
STATUS_S1_TMR
11
STATUS_S2_TMR
12
STATUS_S3_TMR
13
STATUS_S4_TMR
14
STATUS_S5_TMR
15
STATUS_NF_TMR
16
STATUS_BAD_CONFIG
40108
STATE_TIMER
40109
TEST_TIMER
40110
B1
40111
B2
40112
Page 8 of 15
40113
S1
40114
S2
40115
S3
40116
S4
40117
S5
40118
NF
Hour Meter
40119
HOURMETER_HOURS
R/W
Hourmeter hours.
40120
HOURMETER_MINUTES
R/W
0-59
40121
HOURMETER_SECONDS
R/W
0-59
SHUTDOWN
NUM_ALARMS
BATTERY_VOLTAGE
In tenths of a volt
40147
NUM_CRANKS_LEFT
40148
CORE_AMBIENT_TEMP
Tenths of a degree
40149
EXP_AMBIENT_TEMP
Tenths of a degree
1-8
CTL_OUT_AUTO
R/W
40152
1-4
PID_ENABLED
40153
1-4
PID_OVERRIDE
CLASS_ARMED
B1_ARMED
0x0001
B2_ARMED
0x0002
C_ARMED
0x0004
S1_ARMED
0x0008
S2_ARMED
0x0010
S3_ARMED
0x0020
S4_ARMED
0x0040
S5_ARMED
0x0080
NF_ARMED
0x0100
PID status.
1-9
Page 9 of 15
CTL_OUT_1_PERCENT
40156
CTL_OUT_2_PERCENT
40157
CTL_OUT_3_PERCENT
40158
CTL_OUT_4_PERCENT
40159
CTL_OUT_5_PERCENT
40160
CTL_OUT_6_PERCENT
40161
CTL_OUT_7_PERCENT
40162
CTL_OUT_8_PERCENT
CTL_OUT_CHG_1
R/W
40164
CTL_OUT_CHG_2
R/W
40165
CTL_OUT_CHG_3
R/W
40166
CTL_OUT_CHG_4
R/W
40167
CTL_OUT_CHG_5
R/W
40168
CTL_OUT_CHG_6
R/W
40169
CTL_OUT_CHG_7
R/W
40170
CTL_OUT_CHG_8
R/W
PID_TARGET_1
40172
PID_TARGET_2
40173
PID_TARGET_3
40174
PID_TARGET_4
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
ALARM1
40202
ALARM2
40203
ALARM3
40204
ALARM4
40205
ALARM5
40206
ALARM6
40207
ALARM7
40208
ALARM8
40209
ALARM9
Page 10 of 15
40210
ALARM10
40211
ALARM11
40212
ALARM12
40213
ALARM13
40214
ALARM14
40215
ALARM15
40216
ALARM16
40217
ALARM17
40218
ALARM18
40219
ALARM19
40220
ALARM20
MAINT1_HOURS
Hours
40302
MAINT1_MIN_SEC
Minutes, Seconds.
40303
MAINT2_HOURS
Hours
40304
MAINT2_MIN_SEC
Minutes, Seconds.
40305
MAINT3_HOURS
Hours
40306
MAINT3_MIN_SEC
Minutes, Seconds.
40307
MAINT4_HOURS
Hours
40308
MAINT4_MIN_SEC
Minutes, Seconds.
40309
MAINT5_HOURS
Hours
40310
MAINT5_MIN_SEC
Minutes, Seconds.
40311
MAINT6_HOURS
Hours
40312
MAINT6_MIN_SEC
Minutes, Seconds.
40313
MAINT7_HOURS
Hours
40314
MAINT7_MIN_SEC
Minutes, Seconds.
40315
MAINT8_HOURS
Hours
40316
MAINT8_MIN_SEC
Minutes, Seconds.
40317
MAINT9_HOURS
Hours
40318
MAINT9_MIN_SEC
Minutes, Seconds.
40319
MAINT10_HOURS
Hours
40320
MAINT10_MIN_SEC
Minutes, Seconds.
SHUTDOWN1_HOURS
Hours
40402
SHUTDOWN1_MIN_SEC
Minutes, Seconds
40403
SHUTDOWN1_ENUM
Shutdown enumeration
40404
SHUTDOWN2_HOURS
Hours
40405
SHUTDOWN2_MIN_SEC
Minutes, Seconds
40406
SHUTDOWN2_ENUM
Shutdown enumeration
Page 11 of 15
40407
SHUTDOWN3_HOURS
Hours
40408
SHUTDOWN3_MIN_SEC
Minutes, Seconds
40409
SHUTDOWN3_ENUM
Shutdown enumeration
40410
SHUTDOWN4_HOURS
Hours
40411
SHUTDOWN4_MIN_SEC
Minutes, Seconds
40412
SHUTDOWN4_ENUM
Shutdown enumeration
40413
SHUTDOWN5_HOURS
Hours
40414
SHUTDOWN5_MIN_SEC
Minutes, Seconds
40415
SHUTDOWN5_ENUM
Shutdown enumeration
40416
SHUTDOWN6_HOURS
Hours
40417
SHUTDOWN6_MIN_SEC
Minutes, Seconds
40418
SHUTDOWN6_ENUM
Shutdown enumeration
40419
SHUTDOWN7_HOURS
Hours
40420
SHUTDOWN7_MIN_SEC
Minutes, Seconds
40421
SHUTDOWN7_ENUM
Shutdown enumeration
40422
SHUTDOWN8_HOURS
Hours
40423
SHUTDOWN8_MIN_SEC
Minutes, Seconds
40424
SHUTDOWN8_ENUM
Shutdown enumeration
40425
SHUTDOWN9_HOURS
Hours
40426
SHUTDOWN9_MIN_SEC
Minutes, Seconds
40427
SHUTDOWN9_ENUM
Shutdown enumeration
40428
SHUTDOWN10_HOURS
Hours
40429
SHUTDOWN10_MIN_SEC
Minutes, Seconds
40430
SHUTDOWN10_ENUM
Shutdown enumeration
40431
SHUTDOWN11_HOURS
Hours
40432
SHUTDOWN11_MIN_SEC
Minutes, Seconds
40433
SHUTDOWN11_ENUM
Shutdown enumeration
40434
SHUTDOWN12_HOURS
Hours
40435
SHUTDOWN12_MIN_SEC
Minutes, Seconds
40436
SHUTDOWN12_ENUM
Shutdown enumeration
40437
SHUTDOWN13_HOURS
Hours
40438
SHUTDOWN13_MIN_SEC
Minutes, Seconds
40439
SHUTDOWN13_ENUM
Shutdown enumeration
40440
SHUTDOWN14_HOURS
Hours
40441
SHUTDOWN14_MIN_SEC
Minutes, Seconds
40442
SHUTDOWN14_ENUM
Shutdown enumeration
40443
SHUTDOWN15_HOURS
Hours
40444
SHUTDOWN15_MIN_SEC
Minutes, Seconds
40445
SHUTDOWN15_ENUM
Shutdown enumeration
40446
SHUTDOWN16_HOURS
Hours
40447
SHUTDOWN16_MIN_SEC
Minutes, Seconds
40448
SHUTDOWN16_ENUM
Shutdown enumeration
40449
SHUTDOWN17_HOURS
Hours
40450
SHUTDOWN17_MIN_SEC
Minutes, Seconds
40451
SHUTDOWN17_ENUM
Shutdown enumeration
Page 12 of 15
40452
SHUTDOWN18_HOURS
Hours
40453
SHUTDOWN18_MIN_SEC
Minutes, Seconds
40454
SHUTDOWN18_ENUM
Shutdown enumeration
40455
SHUTDOWN19_HOURS
Hours
40456
SHUTDOWN19_MIN_SEC
Minutes, Seconds
40457
SHUTDOWN19_ENUM
Shutdown enumeration
40458
SHUTDOWN20_HOURS
Hours
40459
SHUTDOWN20_MIN_SEC
Minutes, Seconds
40460
SHUTDOWN20_ENUM
Shutdown enumeration
EVENT1_HOURS
Hours
40502
EVENT1_MIN_SEC
Minutes, Seconds
40503
EVENT1_ENUM
Event enumeration
40504
EVENT2_HOURS
Hours
40505
EVENT2_MIN_SEC
Minutes, Seconds
40506
EVENT2_ENUM
Event enumeration
40507
EVENT3_HOURS
Hours
40508
EVENT3_MIN_SEC
Minutes, Seconds
40509
EVENT3_ENUM
Event enumeration
40510
EVENT4_HOURS
Hours
40511
EVENT4_MIN_SEC
Minutes, Seconds
40512
EVENT4_ENUM
Event enumeration
40513
EVENT5_HOURS
Hours
40514
EVENT5_MIN_SEC
Minutes, Seconds
40515
EVENT5_ENUM
Event enumeration
40516
EVENT6_HOURS
Hours
40517
EVENT6_MIN_SEC
Minutes, Seconds
40518
EVENT6_ENUM
Event enumeration
40519
EVENT7_HOURS
Hours
40520
EVENT7_MIN_SEC
Minutes, Seconds
40521
EVENT7_ENUM
Event enumeration
40522
EVENT8_HOURS
Hours
40523
EVENT8_MIN_SEC
Minutes, Seconds
40524
EVENT8_ENUM
Event enumeration
40525
EVENT9_HOURS
Hours
40526
EVENT9_MIN_SEC
Minutes, Seconds
40527
EVENT9_ENUM
Event enumeration
40528
EVENT10_HOURS
Hours
40529
EVENT10_MIN_SEC
Minutes, Seconds
40530
EVENT10_ENUM
Event enumeration
40531
EVENT11_HOURS
Hours
40532
EVENT11_MIN_SEC
Minutes, Seconds
Page 13 of 15
40533
EVENT11_ENUM
Event enumeration
40534
EVENT12_HOURS
Hours
40535
EVENT12_MIN_SEC
Minutes, Seconds
40536
EVENT12_ENUM
Event enumeration
40537
EVENT13_HOURS
Hours
40538
EVENT13_MIN_SEC
Minutes, Seconds
40539
EVENT13_ENUM
Event enumeration
40540
EVENT14_HOURS
Hours
40541
EVENT14_MIN_SEC
Minutes, Seconds
40542
EVENT14_ENUM
Event enumeration
40543
EVENT15_HOURS
Hours
40544
EVENT15_MIN_SEC
Minutes, Seconds
40545
EVENT15_ENUM
Event enumeration
40546
EVENT16_HOURS
Hours
40547
EVENT16_MIN_SEC
Minutes, Seconds
40548
EVENT16_ENUM
Event enumeration
40549
EVENT17_HOURS
Hours
40550
EVENT17_MIN_SEC
Minutes, Seconds
40551
EVENT17_ENUM
Event enumeration
40552
EVENT18_HOURS
Hours
40553
EVENT18_MIN_SEC
Minutes, Seconds
40554
EVENT18_ENUM
Event enumeration
40555
EVENT19_HOURS
Hours
40556
EVENT19_MIN_SEC
Minutes, Seconds
40557
EVENT19_ENUM
Event enumeration
40558
EVENT20_HOURS
Hours
40559
EVENT20_MIN_SEC
Minutes, Seconds
40560
EVENT20_ENUM
Event enumeration
40561
EVENT21_HOURS
Hours
40562
EVENT21_MIN_SEC
Minutes, Seconds
40563
EVENT21_ENUM
Event enumeration
40564
EVENT22_HOURS
Hours
40565
EVENT22_MIN_SEC
Minutes, Seconds
40566
EVENT22_ENUM
Event enumeration
40567
EVENT23_HOURS
Hours
40568
EVENT23_MIN_SEC
Minutes, Seconds
40569
EVENT23_ENUM
Event enumeration
40570
EVENT24_HOURS
Hours
40571
EVENT24_MIN_SEC
Minutes, Seconds
40572
EVENT24_ENUM
Event enumeration
40573
EVENT25_HOURS
Hours
40574
EVENT25_MIN_SEC
Minutes, Seconds
40575
EVENT25_ENUM
Event enumeration
40576
EVENT26_HOURS
Hours
40577
EVENT26_MIN_SEC
Minutes, Seconds
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40578
EVENT26_ENUM
Event enumeration
40579
EVENT27_HOURS
Hours
40580
EVENT27_MIN_SEC
Minutes, Seconds
40581
EVENT27_ENUM
Event enumeration
40582
EVENT28_HOURS
Hours
40583
EVENT28_MIN_SEC
Minutes, Seconds
40584
EVENT28_ENUM
Event enumeration
40585
EVENT29_HOURS
Hours
40586
EVENT29_MIN_SEC
Minutes, Seconds
40587
EVENT29_ENUM
Event enumeration
40588
EVENT30_HOURS
Hours
40589
EVENT30_MIN_SEC
Minutes, Seconds
40590
EVENT30_ENUM
Event enumeration
40591
EVENT31_HOURS
Hours
40592
EVENT31_MIN_SEC
Minutes, Seconds
40593
EVENT31_ENUM
Event enumeration
40594
EVENT32_HOURS
Hours
40595
EVENT32_MIN_SEC
Minutes, Seconds
40596
EVENT32_ENUM
Event enumeration
PID1_ADJUST
40598
PID2_ADJUST
40599
PID3_ADJUST
40600
PID4_ADJUST
40601
PROPORTIONAL_ADJ
40602
INTEGRAL_ADJ
40603
DERIVATIVE_ADJ
40604
40605
SETPOINT 01
SETPOINT 128
R/W
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
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
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 Murphys 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.
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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.
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.
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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.
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2.2 Input/Output Types and Specifications for the Main I/O Module
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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.
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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.
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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:
Many of the keys have a modified action relative to the current location of the cursor and the
current page being displayed.
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Key
ID
HOME
ESC/ACK
Fn (Function
Key)
SETUP/ENTER
RESET
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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.
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Key
ID
RUN/STOP
ARROW UP
ARROW DOWN
ARROW LEFT
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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.
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Key
ID
ARROW RIGHT
TEST
TIMER 0
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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.
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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
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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.
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5.2.10 Line-By-Line
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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.
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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.
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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.
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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.
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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.
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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.
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(00000504)
(00000505)
(00000543)
Choke
(50000774)
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.
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9 Glossary
Analog Input
Boot Loader
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
Event
No-flow
Offset
User defined value to correct for known variance in the raw data.
Panel Ready
Permissive
Signal
Span
The difference between the full scale output and the offset as raw data.
Start Delay
Section 50
10-10-06
00-02-0590
- 64 -
State
Terminal Emulator
Thermocouple
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.
10.1.4 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.
Section 50
10-10-06
00-02-0590
- 66 -
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.
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
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
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.
00-02-0161
Revised 03-06
Section 05
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 sectionpage 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.
50
40
300
30
400
200
PRESSURE
20
100
70
500
INCREASING ERROR
FOR INDICATING
POINTER
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.
60
400
200
PRESSURE
70
500
80
600
90
10
90
30
600
kPa
300
100
kPa
0 PSI
100
MAXIMUM ERROR
INCREASING ERROR
FOR INDICATING
POINTER
20
80
10
0 PSI
50
40
60
100
MAXIMUM ERROR
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.
3-15/16 in.
(100 mm)
4-1/32 in.
(102 mm)
3-3/8 in.
(86 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
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
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
2-57/64 in.
(73 mm)
6-3/4 in.
(171 mm)
120
120
1/2 in.
(13 mm)
conduit
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)
3/8-16 UNC-2B
thread
7/8 in. (22 mm)
deep, 8 plc's
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 253 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
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.
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
YELLOW
BLUE
RESET
SET
1
7
4
3
9
= 18 GA.
= 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.
WHITE
120 VAC
12 VDC
24 VDC
ORANGE
(-) NEUTRAL
BROWN
RED
LOW
(RESET)
(+) LINE
BLACK
HIGH
(SET)
45APEBP
LOW SWITCH
2
1
HIGH SWITCH
N.C.Orange
N.C.Black
N.O.Blue
N.O.Brown
CommonYellow
CommonRed
COMMON
RESET
SET
1
7
4
= 20 GA.
= 18 GA.
BROWN
= 16 GA.
(-) NEUTRAL
12 VDC
24 VDC
WHITE
ORANGE
A
120 VAC
RED
(+) LINE
LOW
(RESET)
YELLOW
BROWN
YELLOW
BLUE
BLUE
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)
Typical Circuit
To CD Ignition
or Magneto.
www.fwmurphy.com
918.317.4100 Email: sales@fwmurphy.com
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.
PD-95145B
Revised 11-03
Catalog Section 55
Pulsation Dampener
(00-02-0125)
PD8100 Series
Used
Specifications
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 drawingright)
PD8183
PD8184
PD8185
PD8190
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
D
B
INLET
OUTLET
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)
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 in.
(25 mm)
MACQUARRIE CORPORATION
1620 Hume Highway
Campbellfield, Vic 3061; Australia
+61 3 9358 5555 fax +61 3 9358 5558
e-mail murphy@macquarrie.com.au
GI
RE
FW Murphy
P.O. Box 470248
Tulsa, Oklahoma 74147 USA
+1 918 317 4100
fax +1 918 317 4266
e-mail sales@fwmurphy.com
www.fwmurphy.com
5-5/16 in.
(135 mm)
PD8100
2 in.
Series
Mounting (51 mm)
Hole
STER
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.
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
WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
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
B
C
D
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)
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).
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
Maximum
Pressure
Std. Settings*
20/25PABS Settings
Hi Settings**
Alarm
Low
Contact
Bar
psi
Bar
psi
Bar
psi
Bar
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)
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
14
20
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)
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/MPathey 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.
Panel
Port
Tube or
Fittings
Tubing
Gage
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 tightgage will not operate properly if line leaks.
Wire
Lead(s)
Intake
Manifold
Fittings
Intake
Manifold
Figure 3
PD2160
Pulsation
Dampener
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
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
Max. Static
Pressure
Max. Differential
Pressure
Contact
Setting
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 psithey do not reflect actual second scale range.
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.
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:
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.
mend using our direct connected alarms TL-7 flashing lamp and/or SAH mini-siren.
20DP and
25DP
HIGH
LOW
Red
Red
Black
A20P
HIGH
N. C.
N. C.
N. O.
HIGH
P
HIGH
LOW
L
N. O. Black
RESET
SET
A20DPE
SET
RESET
N. O.
N.C.
RESET
SET
N. C.
A25PE
N.C.
N.O.
RESET
LOW
P
C. White
N. C.
A25PABS-HL
N.O.
LOW
L
N.O.
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
A20DP
LOW
HIGH
LOW
20PABS and
25PABS
A25DPE
N. O.
RESET
SET
N. O.
N.O.
N.C.
RESET
SET
HIGH
P
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.
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
20
10
300 60
0
kPa
PRESSURE
PSI
40 60
20P Pressure
SWICHGAGE
80
130
10
300 60
0
kPa
PRESSURE
25
60
80 100 12
NC
SW1 SW2
TEMPERATURE
N.O. SWICHGAGE
instruments
+
Battery
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
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. Open circuit between the magnetic switch and the shutdown device.
2. Lost ground to kill the engine.
1. Frozen pointer
2. Loose pointer spring (caused by hitting or dropping gage).
3. Plugged pressure orifice.
4. Over Pressure
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: sales@fwmurphy.com
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.
67C Series
Instruction Manual
Form 5469
May 2006
Introduction
Scope of Manual
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.
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
Bulletin No.
01-23-T01A-301
02-23-T010-317
TP 00-24-T01B-001
TP 04-02-T010-317
2802-MA-F-MCP
DLM-926
169LIT D-PRXSW
BM-21138
............................. Ajax
BM-21136-1
BM-21137-1
LM-92164N
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.
Description
Ball Valve, NPT, 600#
Ball Valve, NPT, Locking Handle
Male Connector, "Tube x "NPT
SS Tubing, x 0.049
SS Tubing, x 0.049
SS Tubing, 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
P/N
Qty
Description
P/N
Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
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
Oil Outlet of the
Oil Heater
To Kim Hotstart Pressure Switch
Connect to the Oil Inlet
of the Oil Heater
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
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-" x 1-"
Ball Valve, 1-"
P/N
2549 2142
2527 1412
2549 2142
Qty
1
2
1
216203-000 rev 3
NOTICE
When ordering replacement parts for your heating
system, always reference the heating systems
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.
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
Minimal maintenance
Fail-safe protection
Engine
for Pre-Lubing
Oil Outlet
Check Valve
Oil Heating
System
OFF ON
owtlg1.eps
Oil Inlet
Shut Off Valve
engoil.eps
1-1
An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for
manual prelube.
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
1-2
1-3
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 and temperature operation (to
350F)
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
1-4
OFF ON
NEMA 12
Control Box
Oil Motor
and Pump
Oil Inlet
RESET
OFF ON
Oil Inlet
Explosion Resistant
Control Box
Oil Motor
and Pump
2med.eps
tank1.eps
1-5
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.
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.
1-6
For heating, the heating system continuously pumps oil to the engines 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.
OWT Model
Flow Detection
Switch
OFF ON
L1 L2 L3
513
OER Model
Flow Detection
Switch
RESET
OFF ON
L1 L2 L3
trelay.eps
2inbx.eps
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.
1-7
CAUTION:
OER Model
L1 L2 L3
L1 L2 L3
513
L123.eps
Transformer
Fuses
Terminal Block
Transformer
Fuses
Terminal Block
2-1
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.
2-2
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
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
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
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
2-3
2-4
2-5
System Start-Up
After system installation has been completed, follow these steps for proper OWT or OER
heating system start-up.
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
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.
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:
Magnetic Contactors
Motor Protective
Switch
Fuses
Transformer
3-1
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
engines 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
ST
T
R
START
(GREEN)
ST
P T
TO E
S ES
R
TEST
STOP
RESET
(RED)
T1
T2
T3
ST
T
R
TA
P T
TO E
S ES
R
TE
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
TA
BUTTON POSITIONS
NEUTRAL
NORMAL
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
3-3
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.
(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.
3-4
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
Following is an overview of
operation and replacement
instructions for the standard
heating tank assembly parts,
including:
Oil Tank
OFF ON
NEMA 12
Control Box
Oil Motor
and Pump
Oil Inlet
Solenoid Valves
Oil Tank
RESET
OFF ON
Oil Inlet
Explosion Resistant
Control Box
Oil Motor
and Pump
2med.eps
3-5
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
Heating Element
Wattage Information
Heating
Element
V-Clamp
O-Ring
Tank
elmntre.eps
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 units 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
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
3-7
Sensor Seat
Heat Shrink Cover
Thermostat Sensor
Temp. On
Temp. Off
Part No.
LSU 14
140F (60C)
160F (71C)
HLC 4*
*Replacement stats will come with lock ring and sensor seat.
3-8
Tank
Thermostat Housing
Thermostat Sensor
Heat Shrink Cover
Sensor Seat
Lo_sensr2.eps
Temp. On
Temp. Off
Part No.
LSU 4
40F (5C)
60F (15C)
HLC 4
LSU 6
60F (15C)
80F (27C)
HLC 6
LSU 8
80F (27C)
100F (38C)
HLC 8
LSU 10
100F (38C)
120F (49C)
HLC 10
LSU 12
120F (49C)
140F (60C)
HLC 12
LSU 14
140F (60C)
160F (71C)
HLC 14
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 2 Remove the V-clamp that holds the tank and adapter
together.
Step 3 Replace the O-ring between the sections.
O-Ring
Adapter
OWT Model
Flow Detection
Switch
OFF ON
L1 L2 L3
513
OER Model
Flow Detection
Switch
RESET
OFF ON
L1 L2 L3
trelay.eps
2inbx.eps
3-10
Standard:
Standard:
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.
3-11
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
Check the control box for moisture (if necessary, add desiccant packets).
Plumbing Connections
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.
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 300F 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.
4-2
Inspect the flow detection (flow control) switch periodically for foreign buildup on
the shuttle body. To clean the flow detection switch, follow these steps:
Bonnet Nut
flowdect1.ai
Bonnet Nut
Switch Body
Tension Spring
Magnet
Plunger Body
Lock Ring
Base
flwdect2.ai
4-3
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).
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.
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.
4-4
Troubleshooting
4-5
Heating Element - Deposits and moisture will reduce the heating elements
efficiency. Clean the heating element and check the heating element for a short
circuit to ground. For instructions, refer to page 3-6.
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.
4-7
4-8
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
DropsA
SMX Series
Divider
Valves
GENERAL FEATURES
x
x
x
x
x
x
x
x
ADVANTAGES
x
x
x
x
x
x
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
DropsAs 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
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 Color
S Single Outlet
641708
Silver
T Two Outlets
641709
Gold
Metering Elements
No. of Elements
Part Number
643523
SMX-08
643524
643525
643526
643527
643528
643529
Metering
Delivery In3
Element Size
(Twin)
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
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)
Features
Failsafe Open or Closed Modes
Specifications
Material: Aluminum
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.
Programming Method
Four Switches mounted underneath the
glass cover. Remove Glass Cover to
access switches. (Spanner Wrench Is
Required)
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
Manufactured By:
DELIRON LIMITED - Odessa, Texas
Telephone (800) 337-3412
Website: www.noflo.com
DLM-926-PM
PANEL MOUNT
DELIRON
LUBRICATION
MONITOR
Examples:
SMX-3 (35S-35S-16T) = 50
SMX-4 (16T-16T-08S-12T) = 33
551LIT DLM926-3
04.10.02
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
GREEN WIRE
GROUND SECURELY
PROXIMITY SWITCH
DL-D-PRX
SWITCH HOUSING
(B)
MAGNET
HOUSING
(C)
1.125"
3.250"
(Switch
Connections)
MAGNET
(H)
SPECIFICATIONS
GREEN
(Ground)
RATINGS
LR108334-1
NRTL/C
FOR
TRABON, LINCOLN
MANZEL & DROPSA
DIVIDER BLOCK LUBRICATION SYSTEMS
R
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)
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
000170
DL-TG-PRX
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
(00-02-0176)
LM301-EX
Shown with optional hose kit fittings
WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
Specifications
**
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 @ 32F (0C).
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
1
1
2
2
2
2
LM-92164N page 1 of 4
DIMENSIONS
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
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)
7-3/16 in.
(183 mm)
Snap Switch
Case Assembly
5-15/16 in.
(151 mm)
(17 6.69
0 m in.
m)
.
5 in
1.7 mm)
(44
2-3/4 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
)
TYPICAL INSTALLATION
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).
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
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
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.
LM-92164N page 3 of 4
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
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
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.
MACQUARRIE CORPORATION
1620 Hume Highway
Campbellfield, Vic 3061; Australia
+61 3 9358 5555 fax +61 3 9358 5558
e-mail murphy@macquarrie.com.au
RE
GI
FWMurphy
STER
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
Bulletin No.
TP 1302-000-04
TP 1300-000r2
TP YAE-5583
TP BM-21161-C
02-19-T01A-300
11-24-03
ALT II 2-01
A24 SI 2-01
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 3
Flat Washer, "
PCC Fuel Filter Bracket
Lock Washer, "
HHCS, -16 UNC x 1
Needle Valve
Gauge, 0-30 PSIG
Hex Head Plug, " NPT
Male Tubing Elbow, "
Flexible Hose, 1"
Flexible Hose, 1"
Pipe Nipple, 1" x 4"L
Street Elbow, 45, 1" NPT
Alternator Drive Assy, 5.33:1
Drive Assembly Gasket
Drive Gear, 5.33:1 System
Set Screw
Stud, -16 UNC x 2"L
Flat Washer, "
Lock Washer, "
Hex Nut, -16 UNC
V1 Alternator, 24VDC
HHCS, -16 UNC x 1"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
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
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 77F.
Its operating temperature range is -40F to 221F.
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 governors 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 PCs 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 throttles 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 governors 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 engines 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
Inadequate electrical
power
Ignition misfire
Precombustion Chamber
fuel supply
Gas Injection Valve
Adjustment
Pressure transducer output
low
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 plugs 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
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
Vdc PSIG
1.8
3
2.6
6
3.4
9
4.2
12
4.9
15
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
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 points 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
Engine RPM
380
360
340
320
300
280
260
240
2.0
2.5
3.0
Alternator Current
3.5
4.0
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
Alternaios Unit
Regulator (586 501 or 581502)
Cable A s s ~ ~ b i y
Battery Pack (591100) - used only wtth Version 6 series alternators
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
4.0 BABrERV PACK (used oniy wlth Version l series alternator and 581501 regulator)
,
4.1
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
5.2
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
VERSION II
MODEL
5901 10/590111
FLANGE
ORIENTATION
SERIES
r-i
b:
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.
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
27 WC