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AJAX Engine-Compressor Package Service Manual

Contract# 10754

Engine

Model
DPC-2802LE

Serial Number
85486

Compressor

Model
23 YK1111MB
13 YK11F

Contents
Section 1 Supplementary Documentation
Section 2 Package Drawings
Section 3 Engine
Section 4 Fuel System
Section 5 Cooling System
Section 6 Cooler
Section 7 Compressor
Section 8 Process Gas Equipment
Section 9 Control Panel and Instrumentation
Section 10 Lubrication System
Section 11 IGTB RPM Control

Engine-Compressor Package Service Manual

Serial number
14787
14824

Section 1 Supplementary Documentation


Vendor

Bulletin No.

Warranty......................................................................... Ajax
Mathematical Conversion Tables ................................... Ajax
Lube Oil & Low Temp Starting
Recommendations .................................................... Ajax

ES 1006

Trimming for Sour Gas Applications............................... Ajax

ES 25

Installation of Sheave and Flywheel ............................... Ajax

ESS-F-961

Flywheel Installation and Ignition Timing........................ Ajax

ESS-F-963

Jet Cell Operation and Maintenance............................... Ajax

ESS-L-981

Jet Cell System Installation..............................................Ajax

ESS-L-983

General PM Schedule .................................................... Ajax

TIB 020326

Component Wear Limits................................................. Ajax

TIB 020718

% Load vs Engine Coolant Temperature........................ Ajax

TIB 030910

Hydraulic Fuel Injection System Purging........................ Ajax

TIB 031104

Lubrication Rates ........................................................... Ajax

TIB 040910

Installation Design for Permanent Packages.................. Ajax

TIB 061115

Engine Operating with Fuel Containing H2S................... Ajax

TIB 050610

Torque Tables for Ajax Fasteners....................................Ajax

TIB 061212

Engine-Compressor Package Service Manual

WARRANTY
Warranties To Original Purchaser (Non-Transferable).

a)
"Material and Workmanship Warranty": The Seller warrants
to the Purchaser that the Equipment of Seller's own manufacture to
be supplied hereunder will be complete in all its parts, and, for the
*Warranty Period - The warranty period shall extend for 12 months
from date of start-up, but shall not exceed 18 months from date of
shipment from factory. Warranty Period specified will be free from
defects in material or workmanship caused by the Seller and arising
under normal and proper operating conditions; and that such
Equipment will be delivered free from any lawful security interest or
other lien or encumbrance known to the Seller, except security
interests or other liens or encumbrances arising hereunder. The
obligation of the Seller and the Purchaser's sole and exclusive
remedy hereunder shall be limited at the Seller's option:
1)

To replacement or repair of any Equipment or parts thereof


which are returned to the Seller's works within the Warranty
Period, transportation charges prepaid.

2)

Should the Equipment or parts thereof be determined by the


Seller to be so defective, however, as to preclude the
remedying of warranty defects by replacement or repair, the
Purchaser's sole and exclusive remedy shall then be a refund
of the purchase price, less a reasonable charge for any
utilization of the Equipment by Purchaser.

3)

Nothwithstanding the foregoing, the Seller shall have no


obligation as a result of improper storage, installation,
repairs or modifications not made by the Seller, or as a result
of removal, improper use, or misapplication of the
Equipment after it has been delivered to the Purchaser.

4)

Purchaser shall pay freight charges in connection with the


return or replacement of the defective Equipment or parts.

b)

"Performance Warranty": The Seller warrants that the


Equipment of its own manufacture, when shipped and/or
installed, will operate within any performance characteristics
which are expressly specified herein as a performance
guarantee. Any performance characteristics indicated herein
which are not expressly stated as guarantees are expected,
"but not guaranteed". When factory testing is conducted for
measuring any performance guarantee of the Equipment
purchased, then certified test results verifying any such
guarantees shall be considered both by the Purchaser and the
Seller as conclusive.
The Purchaser may have a
representative present when such factory tests are conducted,

if requested at the time an order is placed. Should Purchaser


desire to conduct a field performance test to verify any
performance guarantee, such test must be conducted by
Purchaser, at his expense, within thirty (30) days from the
date of initial start-up of the Equipment, and in accordance
with the appropriate ASME Power Test Code, except as
otherwise agreed in writing by Seller. Seller shall be entitled
to have a representative or representatives present to witness
such test and Purchaser shall reimburse Seller for the time
and expense of such representatives at the Seller's service
rates then in effect at the time of the test. Purchaser shall
give Seller fifteen (15) days written notice prior to the date
Purchaser intends to commence such test. If the field
performance test is not conducted within the aforesaid period
all performance guarantees shall be deemed to have been
met. In the event any Equipment performance guarantee
which is to be verified by the field performance test is not
successfully demonstrated within thirty (30) days from the
commencement of such test, the obligation of the Seller and
the Purchaser's sole and exclusive remedy hereunder shall be
that set forth in paragraph (a) above.
c)

"OSHA" Warranty": The Seller warrants for installations


within the United States that Equipment of its own
manufacture, when shipped, will be in compliance with the
Occupational Safety and Health Act, and any and all
amendments thereto and regulations promulgated thereunder
that may be in effect as of the date of the Seller's quotation
insofar as said law and regulations may pertain to the
physical characteristics of the Equipment "provided
however", the Seller does not warrant such compliance with
respect to the circumstances of use of said Equipment and
"provided further", the Seller makes no warranty with
respect to the noise level of said Equipment, when put into
operation, since such noise levels will be influenced by and
dependent upon the environment into which the Equipment
may be placed. The Seller's obligation and the Purchaser's
sole remedy with respect to this warranty shall be providing
notice of any such non-compliance is given within one year
from the date of delivery of said Equipment to Purchaser, to
repair or replace any part of said Equipment that is proven to
Seller's satisfaction not to have been in compliance with the
Act as amended and regulations thereto in effect as of the
date of quotation or, if it be determined by Seller that the
Equipment or parts thereof cannot be repaired or replaced in
such a manner as to put the Equipment in compliance,
Purchaser's sole and exclusive remedy shall then be a refund
of the purchase price less a reasonable charge for any
utilization of the Equipment by Purchaser. Purchaser shall
pay freight charges in connection with the return or
replacement of any Equipment or parts that are found not to
be in compliance.

Notwithstanding the foregoing, the Seller shall have no


obligation under this warranty as a result of installation,
repairs or modifications not made by the Seller, or as a result
of removal, improper use, improper operation, or misapplication of the Equipment after it has been delivered to
the Purchaser.
d)

"Warranty As To Equipment Not Made By The Seller":


Equipment parts and accessories made by other
manufacturers and supplied hereunder by the Seller are
warranted only to the extent of the original manufacturer's
warranty to the Seller.

e)

"EXCEPT AS SET FORTH HEREIN, AND EXCEPT


AS TO TITLE IT IS EXPRESSLY AGREED":
"THAT THERE IS NO IMPLIED WARRANTY OF
MERCHANTABILITY, NOT OTHER WARRANTY,
EXPRESS, IMPLIED, OR STATUTORY, NOR ANY
AFFIRMATION OF FACT, OR PROMISE BY THE
SELLER WITH REFERENCE TO THE EQUIPMENT
OR PARTS THEREOF, OR OTHERWISE, WHICH
EXTENDS BEYOND THE DESCRIPTION OF THE
EQUIPMENT AS SET FORTH HEREIN, AND (2)
THAT THE PURCHASER ACKNOWLEDGES THAT
IT IS PURCHASING THE EQUIPMENT SOLELY ON
THE BASIS OF THE COMMITMENTS OF THE
SELLER EXPRESSLY SET FORTH HEREIN".

DAMAGES. "IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL,


CONSEQUENTIAL OR INCIDENTAL DAMAGES, NOR FOR LOSS OF
ANTICIPATED PROFITS NOR FOR LOSS OF USE OF ANY EQUIPMENT,
INSTALLATION SYSTEM, OPERATION OR SERVICE INTO WHICH THE
GOODS OR PARTS MAY BE PUT, OR WITH RESPECT TO WHICH ANY
SERVICES MAY BE PERFORMED BY SELLER". "THIS LIMITATION ON
SELLER'S LIABILITY SHALL APPLY TO ANY LIABILITY FOR
DEFAULT UNDER OR IN CONNECTION WITH THE GOODS, PARTS OF
UNIT SALES OR SERVICESDELIVERED HEREUNDER, WHETHER
BASED ON WARRANTY, FAILURE OF OR DELAY IN DELIVERY OR
OTHERWISE". "ANY ACTION FOR BREACH OF CONTRACT
HEREUNDER MUST BE COMMENCED WITHIN ONE YEAR AFTER THE
CAUSE OF ACTION HAS ACCRUED".

TDI TURBOTWINTM
Engine Air Starters

MATHEMATICAL CONVERSION TABLE


UNITS

TO CONVERT

INTO

P
R
E
S
S
U
R
E

Bars
Kilograms/Sq. Centimeter
Kilopascals
PSIG
PSIG
PSIG

PSIG
PSIG
PSIG
Bars
Kilograms/Sq Centimeter (Kg/cm)
Kilopascals (Kpa)

14.5
14.22
0.145
0.069
0.070
6.895

V
O
L
U
M
E

Liters
Gallons
Gallons
Cubic Centimeters
Cubic Inches
Cubic Inches
Cubic Feet
Cubic Inches

Cubic Inches (in3)


Cubic Inches (in3)
Cubic Feet (ft3)
3
Cubic Inches (in )
Liters (L)
Gallons (Gal)
Gallons (Gal)
Cubic Centimeters (cm3)

61.023
232.56
0.135
0.061
0.0164
0.0043
7.413
16.39

T
O
R
Q
U
E

Newton Meters
Kilogram Meters
Foot Pounds
Foot Pounds
Kilogram Meters

Foot Pounds (Ft-lb)


Foot Pounds (Ft-lb)
Newton Meters (N-m)
Kilogram Meters (K-gm)
Newton Meters (K-gm)

0.7376
7.233
1.356
0.1383
9.807

F
L
O
W

Standard Cubic Feet per Minute


Cubic Meters/Hr
Standard Cubic Feet per Minute

Cubic Meters/Hr (m/h)

1.70
0.588
0.0750

Horsepower
Horsepower
Kilowatts

Kilowatts (KW)
Ft-lbsp/Second
Horsepower (HP)

P
O
W
E
R

Standard Cubic Feet per Minute


(SCFM)

Pounds per Minute (Lb/Min.)

MULTIPLY
BY

0.746
550.0
1.340

AN03-147 9/97

TDI TURBOTWINTM
Engine Air Starters

MATHEMATICAL CONVERSION TABLE


UNITS

TO CONVERT

INTO

P
R
E
S
S
U
R
E

Bars
Kilograms/Sq. Centimeter
Kilopascals
PSIG
PSIG
PSIG

PSIG
PSIG
PSIG
Bars
Kilograms/Sq Centimeter (Kg/cm)
Kilopascals (Kpa)

14.5
14.22
0.145
0.069
0.070
6.895

V
O
L
U
M
E

Liters
Gallons
Gallons
Cubic Centimeters
Cubic Inches
Cubic Inches
Cubic Feet
Cubic Inches

Cubic Inches (in3)


Cubic Inches (in3)
Cubic Feet (ft3)
3
Cubic Inches (in )
Liters (L)
Gallons (Gal)
Gallons (Gal)
Cubic Centimeters (cm3)

61.023
232.56
0.135
0.061
0.0164
0.0043
7.413
16.39

T
O
R
Q
U
E

Newton Meters
Kilogram Meters
Foot Pounds
Foot Pounds
Kilogram Meters

Foot Pounds (Ft-lb)


Foot Pounds (Ft-lb)
Newton Meters (N-m)
Kilogram Meters (K-gm)
Newton Meters (K-gm)

0.7376
7.233
1.356
0.1383
9.807

F
L
O
W

Standard Cubic Feet per Minute


Cubic Meters/Hr
Standard Cubic Feet per Minute

Cubic Meters/Hr (m/h)

1.70
0.588
0.0750

Horsepower
Horsepower
Kilowatts

Kilowatts (KW)
Ft-lbsp/Second
Horsepower (HP)

P
O
W
E
R

Standard Cubic Feet per Minute


(SCFM)

Pounds per Minute (Lb/Min.)

MULTIPLY
BY

0.746
550.0
1.340

AN03-147 9/97




 
   


 
 




   

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ESS-F-963
Title: Keyless Flywheel Installation And Timing

Engineering Sales &


Service Bulletin
Ajax-Superior
Oklahoma City, OK 73129

Engines/
Compressors
ESS-F-963

Keyless Flywheel Installation and Ignition Timing


This procedure applies to all Ajax models 2200 and 2800 series Ajax engines. It covers the installation of
the keyless ringfeder locking device fitted on flywheels on 2200 and 2800 series engines. The procedure
explains the method used to find top dead center (TDC) and proper ignition timing of the engine.

Installation
1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.

! Caution
Firmly secure the flywheel to prevent it from falling over.
2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove
ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied
locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not,
lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent.
3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel.
4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is
required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN

 Figure 1
Flywheel
Hardened
Washer

Collar
Inner Ring
Crankshaft

Locking
Screw

5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both
for assembly.
6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between
.001-.003. Do not over-lubricate.

Note
Step 6 should only be performed during initial engine assembly. Do not lubricate on field units.
7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create
a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the
Page 1 of 4

Released: 6/8/99

ESS-F-963
Title: Keyless Flywheel Installation And Timing

flywheel and the end of the crankshaft are even.

Note
Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat
and possibly gall the surface of the crankshaft.
8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to
the crankshaft.
9. Remove the crosshead side access door from power cylinder one.
10. Set the timing pointer on the ignition bracket, allowing 1/8 clearance from the flywheel. Adjust the
pointer until it is located in the middle of vertical slot on the bracket.

Finding TDC and Timing Degree Marks


11. Place a 4 bar or equivalent between the end of the crosshead and the pack flange. Bar the engine
over clockwise until the bar stops against the packing. Hold the flywheel in this position, keeping
the crosshead against the bar.
12. Mark the flywheel on the outer diameter (O.D.) with an ink marker at the pointer location. This is
Temporary Mark #1.
13. Remove the tension on the bar in the crosshead and remove.
14. Rotate the engine clockwise until is has passed TDC far enough to re-insert the bar.
15. Reinsert the bar and rotate the engine counter-clockwise until the bar stops the crosshead against the
packing. Hold the flywheel in this position.
16. Mark the flywheel on the O.D. with an ink marker at the pointer location. This is Temporary Mark
#2.
17. Release the tension from the bar and remove. Rotate the engine to allow access to both of the temporary marks.
18. Measure the distance between the marks. Divide the distance by two and, using an ink marker, create a third mark equidistant between the two marks. This will be Temporary Mark #T. Mark T
represents the Top Dead Center (TDC) of the crankshaft.

Note
You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then
marks #2 and T. These distances should be equal.
19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200
and 2800 engines use a 48 diameter flywheel. This means that:

3 = 1 Flywheel O.D. distance


9 = 3 Flywheel O.D. distance
11 = 4-5/8 Flywheel O.D. distance
20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3, 9
or 11 (depending on model) before TDC or clockwise from the T mark on the flywheel.
21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crankshaft in the general range of normal ignition timing.
22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be
installed between the sheave and end cover. See Figure 2. This picture shows the method of locking
the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field
installation.
23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that
Page 2 of 4

Released: 6/8/99

ESS-F-963
Title: Keyless Flywheel Installation And Timing

the scribed line located on the end of the crankshaft is positioned below horizontal. See Figure 3.
24. Loosen the ringfeder bolts to free up the flywheel on the crankshaft.

 Figure 2

 Figure 3

End of Crankshaft
Horizontal

Power Cylinder
Side

DC
#1 T

Page 3 of 4

Released: 6/8/99

ESS-F-963
Title: Keyless Flywheel Installation And Timing

Engineering Sales &


Service Bulletin
Ajax-Superior
Oklahoma City, OK 73129

Engines/
Compressors
ESS-F-963

Setting Timing Of the Flywheel


25. Ensure that the ignition pickup coils are in the proper holes:





3 - Top Holes
9 - Two Holes From The Bottom
11 - Bottom Holes

26. Rotate the flywheel on the crankshaft, without moving the crankshaft itself, until the recessed magnet is centered over the number 1 pickup coil. This is the A pickup coil or the one closest to the
power end.
27. While keeping the magnet aligned, re-tighten the ringfeder to the flywheel. Now place a permanent
timing mark on the flywheel and mark it either 3, 9, 11 accordingly.
28. Permanently mark the TDC location and then erase all of the temporary marks made on the flywheel.
29. Remove all crankshaft locking devices and find TDC as in the above procedures to verify that the
TDC position and the ignition timing mark have been correctly located relative to the magnet position.
30. When certain that the permanent marks are correct, tighten and torque all flywheel bolts.
31. Match mark the flywheel coincident with the scribe line on the end of the crankshaft using a chisel.
Stamp a 1 next to this mark.
32. Stamp the engine serial numbers on the crankshaft and hub of the flywheel.
33. Chisel mark a line on the OD of the flywheel at TDC. Metal stamp a 0 next to this mark.
34. Chisel mark a line at either the 3, 9, or 11 (depending on model) on the OD of the flywheel. Metal
stamp the correct timing value next to this mark.
35. It may be necessary after engine start-up to readjust the timing pointer. The pickup coil should be
centered over the cylinder #1 recessed magnet when the pointer is pointing at the timing mark.

2804 (DPC-800) Engines Only


These engines do not use flywheel magnets and pickup coils. When finished with Step 20 above go
directly to Step 29.The magneto should be adjusted via the slotted holes on the mounting flange until the
cylinder #1 is aligned with the flywheel timing marks.

Page 4 of 4

Released: 6/8/99

ESS-L-981
AJAX LOW EMISSIONS ENGINES

 

    

 

  
      
ESS-L-981
Date: July 13,1998
Supercedes ESS-L-921
AJAX LOW EMISSIONS ENGINES
AJAX JET CELL OPERATION AND MAINTENANCE
ABSTRACT
The jet cell concept is required for low emission or emission reduction engines. The highenergy torch issuing from the pre-chamber allows the main chamber to be operated with a
leaner mixture and consistently ignited, as compared to a conventional spark plug
ignition of a lean mixture.
Also, the jet cell is applied to units to improve combustion stability and improve fuel
consumption when operating at variable speeds and reduced torque. This paper describes
the jet cell operation and general maintenance procedures relating to AJAX Low
Emissions Two-Cycle Engines.
JET CELL OPERATION
The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head.
The nozzle end is designed with a specific volume and has a communicating angled exit
orifice. A spark plug for ignition and a fuel admission check valve complete the
necessary operational components.
Pilot fuel headers supply fuel to each admission check valve. The supply to the header is
taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with
an additional regulator.
The ignitor fuel pressure is thus regulated manually according to site conditions.
For one cycle of operation, as the piston comes up on compression, the pressure within
the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When
1

Revised 07/98

ESS-L-981
AJAX LOW EMISSIONS ENGINES

the pressure within the cylinder becomes greater than the fuel pressure, then the pilot
check valves close.
The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs
within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this
energy release forces the burning mixture to exit through the nozzle orifice across the top
of the piston in the main combustion chamber, igniting the main combustible charge.
IGNITION TIMING
In standard spark ignited engines, the spark plugs ignite the charge and a progressive
flame front occurs within the combustion chamber. Due to the time required for this
flame propagation, the ignition timing is approximately 9-12 before top dead center
(BTDC).
With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fuel/air
mixture within the main combustion chamber. The mixture is ignited uniformly by this
higher energy source, which promotes faster burning. For this reason, the ignition timing
is set at 3 BTDC.
For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs
7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day
(24 hrs), and 30 days of operation would equal 19,008,000 times.
MAINTENANCE
The jet cell, when installed into the cylinder head, has a round Armco iron gasket which
acts as a fire seal; a graphoil seal employed as a bottom water seal, and an O ring as the
top water seal.
The unit is held in place with a two-bolt flange and torqued to 70 ft-lbs.
If a cell is removed from the head, it is important that the access hole for the cell is clean
and free of any scale build-up. New gaskets and seals should be installed and the unit
properly torqued. A locating dowel is used to assure proper orientation of the exit orifice
of the cell in relation to the main combustion chamber.
SPARK PLUGS
Cooling of the spark plug is accomplished primarily through the spark plug gasket
seating surface and the threads. These areas within the cell have thin metal sections and
are surrounded with engine coolant.
In service, the center and ground electrodes will deteriorate, which increases the spark
plug gap. Erratic firing will occur once the gap increases 0.005-0.010 from the original
setting and the plugs should be replaced.
2

Revised 07/98

ESS-L-981
AJAX LOW EMISSIONS ENGINES

On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion
RW77N (BM-1022-2) spark plug with an initial gap of 0.015 to 0.018 was used. The
main chamber spark plug utilized the Champion W-18 (BM-1022). Current production
models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022)
spark plug is used with an initial gap of 0.020. This allows use of the same spark plug
for both the main chamber and igniter. The current production jet cell (YK-8209-C-1)
identified with a 3/4 stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage
may occur to igniter and/or spark plug threads as the result of thread depth and thread
reach respectively.
The secondary ignition wiring and associated components should always be in good
condition.
FUEL ADMISSION CHECK VALVES
The primary check valve (P/N YK-8338-A) is most important in the operation of the jet
cell. As noted previously, the number of cyclic operations relates to the 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

Figure 1. Measuring Proper Piston-To-Head Distance

E) Once clearance is set, torque rod nut and check clearance again. Piston has a
tendency to turn out slightly when tightening nut.
2. GAS CAM TIMING:
Refer to ESS-T-911 as a basis for fuel injection timing. The following changes must
be made when converting an engine to LE application.
A) The flywheel and gear shield must be removed in order to remove layshaft and
reset cam timing.
B) Cam timing is retarded from the standard 13 ABDC beginning of injection to 37
ABDC. DO NOT GO BEYOND 37 ABDC! If gears do not line up with cams at
37 ABDC, go back towards BDC (i.e. 35 ABDC). Beginning of injection is 37
2

Revised 07/98

ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE

ABDC on all LE engines but the method of setting the timing is different on
DPC-800s & DPC-2804s.
C) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2)
cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders.
#2 & #4 cylinders run off the other cam. Refer to Figure 2.

Figure 2. Control Box And Cams

#1 power cylinder gas cam timing is referenced off #3 bank on the control box.
The crankshaft should be rotated in a clockwise direction to 26 ABDC #1 power
cylinder. DO NOT GO BEYOND 26 ABDC! If gears do not line up with cams at
26 ABDC, go back towards BDC (i.e. 24 ABDC). The crankshaft is positioned
at 26 ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is
due to the way the cam is installed on the layshaft. The result will be injection
beginning at 37 ABDC. Refer to FIG 3. The cam can now be set using the
method illustrated in ESS-T-911.
D) Once the preceding is complete, the layshaft gear should be installed and reindexed.
3. IGNITION TIMING:
Ignition timing is changed on all LE engines to 3 BTDC. New mag pickup brackets
are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate
the timing change.
3

Revised 07/98

ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE

On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator
must be removed and re-indexed to 3 BTDC (refer to the standard DPC-800/DPC2804 Operation & Maintenance Manual for procedure).

Figure 3. Alignment Of Crankshaft

4. IGNITOR ASSEMBLY INSTALLATION: Refer to FIG 4


A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in
the LE power head. This ensures proper direction of ignitor exit orifice. It is very
important that they are lined up properly! Misalignment will result in severe
piston crown damage. It should be noted that when ignitor is torqued into head,
the roll pin will not completely set into slot. This is only an alignment reference.
B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small
amount of grease to hold gasket in place when installing ignitor into the head.
Insure O-ring is installed on ignitor at this time also.
C) Install water seal (P/N 2-013-129-002) into head.

Revised 07/98

ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE

Figure 4. Ignitor Assembly

D) Install ignitor into head being very careful not to damage water seal. This may
take some hand fitting of seal. Torque down in progressive 5 ft-lb increments to
70 ft-lbs.
5. SPARK PLUGS:
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a
Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015 to
0.018 was used. The main chamber spark plug utilized the Champion W-18
(BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized,
use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020. This
allows use of the same spark plug for both the main chamber and igniter. The current
production jet cell (YK-8209-C-1) is identified with a 3/4 stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell.
Damage may occur to ignitor and/or spark plug threads as the result of thread depth
and thread reach, respectively.

Revised 07/98

ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE

6. GAS INJECTION VALVES:


The gas injection valve used in the LE power end is of the same basic design as the
one used in the standard combustion assembly but the valve housing and plunger
housing are not interchangeable. The gas injection valve assembly on the LE engine
has a longer valve body housing and a shorter plunger housing to accommodate the
profile of the power head.
7. MISCELLANEOUS:
In addition to the preceding requirements, engines that are converted to the LE design
must have:
A) Dry-type, low restriction intake system
B) Ring gear start system on 15 bore engines
C) 3/8 hydraulic supply lines on gas injection system
D) Exhaust line adjustment to compensate for length of insertion pipe in muffler
If you have any questions or problems pertaining to an LE retrofit conversion, contact
your local AJAX-SUPERIOR representative.

Revised 07/98

Technical Information
Bulletin # 020718 r2
August 24, 2004

Subject: Ajax Component Wear Limits


all 15 Bore x 16 Stroke (Includes DPC-180, -360, -600, -800, & 2800 Series models)
all 13 Bore x 16 Stroke (Includes DPC-115, -140, -230, -280, & 2200 Series models)
The following component dimensional specifications and wear limits should be used as a
guide for preventative maintenance programs for Ajax equipment. Problems can be
detected early before failures occur.
These specifications are based on data gathered from a broad range of Ajax installations
covering many decades of operating experience.
Specific unit performance and maintenance requirements may vary based on application
conditions and preventative maintenance practices.

Engine End Data


Item

As New Limits

15 Cylinder Bore

14.997- 15.001

15 Piston Skirt Diameter

14.968 14.970

Max. Acceptable
Up to 15.013,
Max .002 TIR
Down to 14.961

15 Piston-to-Cylinder Clearance

.027 - .033

Up to .045

15 Piston Ring 1 & 2 Side Clearance

.010 - .0125

Up to .015

15 Piston Ring 3 & 4 Side Clearance

.008 - .0105

Up to .013

15 Piston Ring End Gap

.115 - .135

13 Cylinder Bore

13.247 13.251

13 Piston Skirt Diameter

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

13 Piston Ring 1 & 2 Side Clr.

.010 - .0125

Up to .015

13 Piston Ring 3 & 4 Side Clr.

.008 - .0105

Up to .013

13 Piston Ring End Gap

.100 - .126

Up to .145

Piston Rod

2.497 2.500

Down to 2.495

Crosshead Guide

12.000 12.002

Up to 12.004

Crosshead O.D.

11.987 11.989

Down to 11.985

Crosshead-To-Guide Clearance
.009 - .013
Up to .016
*Note: determine the minimum clearance by passing the thickest feeler gauge
possible over the top of the crosshead to project out the opposite side. Then slide the
gauge along the entire length of the crosshead-to-guide fit.

Engine End Data (continued)


Item

r2>

As New Limits

Max. Acceptable

Conn Rod Pin Bushing I.D.

5.5044 5.5069

Up to 5.509

Conn Rod Side Clearance

.010 - .026

Crosshead Pin O.D.

5.4995 5.5000

Crosshead-to-Pin Clearance

.0044 - .0074

Conn Rod Bearing Bore

7.503 7.505

Crank Pin O.D.

7.499 7.500

Crank Pin-to-Bearing I.D. Clearance

.0044 - .006

Up to .029
Down to 5.4985
Max .001 TIR
Up to .0085
Up to 7.507
Max .001 TIR
Down to 7.4975
Max .0015 TIR
Up to .0075

Main Brg. Journal O.D.

8.374 8.375

Main Bearing I.D.

8.3796 8.3816

Main Journal-to-Bearing I.D.

.0046 - .0076

Down to 8.3725
Up to 8.3831
Max .002 TIR
Up to .0091

Main Bearing Thrust,

.010 - .020

Up to .022

Layshaft Bearing Bore

1.502 - 1.503

Up to 1.504

Layshaft O.D.
Layshaft O.D.-to-Bearing Bore
Clearance
Center Main Bearing I.D. on Twins

1.498 - 1.500

Down to 1.497

.002 - .005

Up to .007

7.754 - 7.756

Up to 7.757

7.749 - 7.750

Down to 7.748

.004 - .007

Up to .0084

DPC-600, DPC-800, DPC-2803, DPC-2804 only

Crankshaft Journal on Twins


Center Main-to-Journal Clearance on
Twins

Compressor End Data


Item
As New Limits
Max. Acceptable
Cylinder Bore
**
**
Piston Rings & Riders
**
**
Piston-to-Cylinder Clearance
**
**
** contact the Technical Support department at Ajax
Piston Rod, 2"
2.497 2.500
2.495
Piston Rod, 2 "
2.249 2.250
2.2455
Crosshead Guide
11.999 - 12.001
Up to 12.008
Crosshead O.D.
11.984 - 11.986
Down to 11.982
Crosshead-To-Guide Clr.*
.011 - .015
Up to .018
*Note: determine the minimum clearance by passing the thickest feeler gauge
possible over the top of the crosshead to project out the opposite side. Then slide the
gauge along the entire length of the crosshead-to-guide fit.
Connecting Rod Pin Bushing I.D.
4.5035 - 4.5062
Up to 4.507
Crosshead Pin O.D.
4.4995 - 4.500
Down to 5.4985
Pin Bushing-to-Pin Clearance
.0044 - .006
Up to .0066
Connecting Rod Bearing I.D.
7.503 - 7.505
Up to 7.506
Crank Pin O.D.
7.499 - 7.500
Down to 7.498
Crank Pin-to-Rod Bearing Clearance
.0042 - .0066
Up to .008

Technical Information
Bulletin # 031104
November 4, 2003
Subject: Hydraulic Fuel Injection System
a) Potential Fire Hazard
b) Purging Procedure
c) Recommended System Modifications
A potential fire hazard exists on Ajax engines with hydraulic fuel injection:
1) An incorrect purging procedure can allow hydraulic fluid to
contact a hot exhaust pipe and ignite. Use the following procedure:
Hydraulic System Purging Procedure:

1.
2.
3.
4.
5.
6.
7.
8.

Shut the engine off.


Pressurize the hydraulic reservoir to 15-20 psig.
Open the flow control valve (at control box) for the gas injection valve line to be purged.
Connect a 10-12 length of clear plastic 3/8 hose to the bleed valve.
Slowly open the bleed valve while directing purged fluid and bubbles into a clean container for reclamation.
After the fluid runs without bubbles, close the bleed valve.
Close the flow control valve at the control box.
Check the reservoirs fluid level. Be certain to depressurize the reservoir before replenishing the fluid.
Note
Use Ajax hydraulic fluid p/n YAE-2150-2.
Do not use other fluids.

2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot
exhaust pipe and ignite .
As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a
pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing
adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas
injection valve assembly is mishandled during servicing.

Traditional bleed valve location for


purging of the hydraulic injection system.

Figure 1

As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve
minimizes damage potential, and permits more efficient purging of the hydraulic system.

Relocated bleed valve


for improved purging
of the hydraulic
injection system.

Bend tubing to 45 for


optimum fluid flow and
vibration resistance

Clear plastic 3/8 hose


temporarily connected
for purging the system.

Figure 2

Convert to the current design by replacing the injection 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: SPEC 7456-SS


(ss valve & fittings)

P/N
A-2565-F-4
BM-10936
BM-11573-S-6-4

Qty
1
1
1

Item
1
2
3

BM-21147-S-4-2

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

Total Lube Rate- Pints/Day


@ 440 RPM - @ 300 RPM

Individual cylinder and rod packing assembly lubrication rates are based on the following formula:
(0.0000314 x Cylinder Bore x Stroke x RPM) + (0.000333 x Discharge Pressure) + 0.75
Example: YK11G, 14 bore, 11 stroke, @ 440 RPM, 400 psig
(0.0000314 x 14 x 11 x 440) = 2.13
(0.000333 x 400)
= 0.13
0.75
= 0.75
3.00 pints/day
The lube 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.)

Installation Design for Permanent Ajax Compressor Packages

When designing the engine-compressor installation, several factors should be taken into
consideration which can affect the overall performance of the installation:

An adequate foundation must be provided to assure a stationary mounting base for the enginecompressor skid and any accessory equipment not mounted on the skid. If the unit is installed
inside a building or adjacent to other machinery, sufficient space must be allowed around the
unit to facilitate maintenance and service work (refer to the 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.

It is recommended that the engine-compressor skid and accessories be placed on grouting on


the foundation to ensure full, even bearing support under the equipment. Grouting is poured
after the equipment has been properly set and aligned on the foundation. For a grouted installation, the foundation top surface should have a rough surface (not trowelled) to ensure an
optimal grout-to-cement bond.

Air cleaners may be located outside the building to avoid heat generated by the unit; however,
direction of prevailing winds should be considered in their location.

Installation of units inside buildings should be designed to allow for the passage of hot air
from the coolers to the outside through adequate natural ventilation or through ducting to the
outside of the building. Unitized vertical discharge coolers may frequently be installed outside
the building to ease the disposal of heated air.

The exhaust system must be properly designed for the operating conditions of the enginecompressor, both for proper scavenging of the power cylinders, and for correct dissipation of
exhaust heat.

The instrument panel should be placed in a location convenient for the operator.

NOTICE: The size and construction of the foundation must be selected to suit the soil
conditions at the unit location.
In designing the foundation, the static and dynamic loads must both be considered. The
unbalanced forces and couples of each engine-compressor unit are available, on request, from the
service branch or factory. In well compacted, high load capacity soils, (6 tons/ft2 minimum) the
minimum dimensions shown on the appropriate foundation drawing supplied should be adequate
for a reinforced concrete foundation (refer to the 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.

Make certain that the unit is set


level, accurately aligned with the
cooler, aligned with any other offskid accessories, and adequately
supported so that all bearing
surfaces on the bottom of the skid
have full contact to avoid
deflections in the bed or skid

Perform web deflection measurements on the engine to check crankshaft alignment. Use these
measurements to fine-tune the engine-compressor elevation using the leveling screws. For longterm engine performance it is essential that web deflections are held within specification (see
Ajax-Superior Engineering Standard ES-4025: Crankshaft Web Deflections for Three- and FourCylinder Ajax Engines).
Install belts on cooler drive and check alignment. Accurate alignment is essential to ensure
acceptable drive component service life and to eliminate detrimental loads and vibrations.
The drive alignment is checked by drawing a string taut between adjacent faces of the two
sheaves (pulleys), lined up to intersect the two hubs. When the drive is properly aligned, the string
will barely touch the face of each sheave at the points where the string crosses the sheave rims
(see Figure 2 below).

, %

) %

Primary Sheave

Critical Alignment Point

Secondary Sheave
Line
Bring Line toward the Critical
Alignment Point to establish
Secondary Sheave alignment

Line Attachment

$&

After properly positioning the engine-compressor unit, then finish up by taping off or pastewaxing all leveling screw threads so screws can be removed after the grout has cured.

Grout should have the following characteristics:

A consistency that allows for proper placement

High bonding strength

High dimensional stability

Strength to transmit static and dynamic forces from unit to foundation

Grout may be either of the conventional (cement based) type or of the epoxy resin type.
Each type has advantages and disadvantages:
Working Time: Check the grout specifications. Working time may vary from as little as 15-20
minutes to over 1 hour. Select a product that will allow adequate mixing, handling, and placing
time.
Working Temperature: Check the grout specifications. Manufacturers often recommend that
foundation, equipment, and grout materials attain equilibrium temperature on the order of 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.

&,

'

/
%

Unisorb V-1 Non-Shrink Grout


Five Star Products High Strength Grout

$& ,
*

11,800

28

10,000 - 14,000

28

8,400

28

Philadelphia Resins Chockfast ITWPRC 100 Non-Shrink

'

/
%

%
2

L&M Construction Chemicals Epogrout 758

13,200

Tristar Masterflow 648CP

15,900

Ceilcote 848 Grout

8,000

3-10

Epoxy resin type grouting materials


may present certain health hazards.
The grout manufacturers handling
instructions should be strictly
followed.

Affirm that the selected grout will meet the installation load requirement, the working
temperature condition, and the working time requirement. Grouts such as those listed in Tables 1
and 2 have sufficient compressive load strength to support typical AJAX engine-compressor and
cooler packages.

Table 3 provides compressive load estimates for 2801-, 2802-, 2803-, and 2804-based units. Skid
footprint is the skid base area that will be in direct contact with the grout. The cooler load is
computed separate from the engine-compressor load for 2803- and 2804-based units.

NOTICE: The estimates in Tables 1,2, and 3 are for reference purposes only!
Be aware that total package weight is dependent on the number and size of compressor cylinders,
and the number of compression stages and associated pressure vessels. If needed, grout
manufacturer representatives can help in the grout selection process.

+& *

! "
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

: Minimum footprint comprised of primary longitudinal skid members only.


: Compressive Strength (Pressure) = Unit Weight / Skid Footprint Area.

All grout should be mixed according to manufacturers instructions and recommendations.


All longitudinal skid members must be grouted. Major load-bearing lateral skid members should
also be grouted. Grout the skid base using procedures suitable to the application or unit involved.
The final grout level should be approximately up to the skid flange thickness. Care must be taken
to provide adequate forms to retain grout. Remove any excess grout before it has been completely
set.

After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all
levelling screws.

NOTICE: This is essential to insure that the unit is being supported only by the grout, not by
the screws.
Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment.
Remove temporary expansion joint materials and fill expansion joints with joint compound.

Table 1: Torque Table for Critical Ajax Fasteners


!
"#
$

&

"'( %

"$
%
)

Frame and Crankshaft:


End covers/bearing supports

Bolts

150

Front end bearing support

Bolts

1&2

25

Center main bearing

Bolts

95

Center main bearing cap

Bolts

250 - 265

Stud nuts

520 - 600

Flywheel ringfeder

Bolts

All

185

Drive shaft ringfeder

Bolts

All

185

Main bearing cap

Studs

3&4

250

Main bearing cap

Stud nuts

3&4

360

Tie bars to frame

Bolts

3&4

260

Top Center for crosshead guide

Bolts

100

Power cylinder to frame

Bolts

All

490

Connecting rod caps

Bolts

All, P & C

650 - 700

Allen Bolts

All

38

Studs

15 Bore

220 -250

Crankshaft counterweight

Power cylinder side cover plate


Cylinder Head:
Head to cylinder

* +,
Table 1: Torque Table for Critical Ajax Fasteners
!
"#
$

&

"'( %

"$
%
)

Head to cylinder

Stud nuts

15 Bore

600

Head to cylinder

Studs

13-1/4 Bore

8-1/8 height

Head to cylinder

Stud nuts

13-1/4 Bore

490

Precambrian hold down flange

Bolts

All LE

70

Pilot fuel check valve clamp

Bolts

All LE

15

Spark plugs

Plugs

All

60

Indicator cock

Valve

All

70

Control Box and Layshaft


Control box to frame

Stud nuts

95

Control box to frame

Stud nuts

2,3, & 4

160

Support bracket on crank end of


layshaft

Bolts

All

45

Cover on crank side of control


box

Bolts

All

10 -12

Caps for hydraulic power


plungers

Bolts

All

11

Cover on top of control box

Bolts

All

25

Gears in control box

Set Screws

All

25

Cams in control box

Set Screws

All

25

Ajax governor drive gear

Nut

All

0.003 - 0.006
clearance

Woodward gov. drive gear

Nut

All

7 - 15 (line up with
pin)

Crosshead and Piston Rod:

Table 1: Torque Table for Critical Ajax Fasteners


!
"#
$

&

"'( %

"$
%
)

Compressor guide to frame

Stud nuts

All, C

280 - 300

Rod packing assy to x-head


guide

Bolts

All

38

Nut

All, P & C

3200

Set screws

All

55

Nuts

All

50

Piston rod to crosshead


Crosshead set screws
Crosshead jam nuts

Note #1: Key to Type of Unit Abbreviations


1 = 2201 & 2801
2 = 2202 & 2802
3 = 2803
4 = 2804
C = Compressor
P = Power Side

Note #2: Torques are based on the use of Lubriplate


Table 2: General Torque Table for Fasteners
) 2
$

. /
'
)0

&
"'(
%3
45

&
"'( %
3
45

#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

Table 2: General Torque Table for Fasteners


) 2
$

. /
'
)0

1-3/4

&
"'(
%3
45

&
"'( %
3
45

1
8
10
12

1920
1990
2050

2260
2330
2400

Torque values are for Grade 5 fasteners.

Values are Based on the use of Lubriplate.

For torques less than 10 lb-ft, a lb-in torque wrench should be used to improve accuracy (multiply the torques in this table by 12 to get lb-in).

Section 2 Package Drawings


Vendor

Bulletin No.

General Arrangement..........................................Ajax

02-00-T05E-397

P&ID....................................................................Ajax

02-00-T00A-307

Foundation(unit)..................................................Ajax

02-00-T050-363

Foundation(cooler)..............................................Ajax

02-00-T050-362

Engine-Compressor Package Service Manual

Section 3 Engine
Operation and Maintenance Manual
Integral Engine-Compressors .......................... Ajax
Frame and Engine Crossheads ..................... 0102-000
Crankshaft and Flywheel................................ 0202-000
Power Connecting Rod .................................. 0300-000
15 Power Cylinder......................................... 0500-200
Fuel Distribution System ................................ 0802-002-01
Gas Injection Valve................................................... YAE-5100
Ignitor......................................................................... YK-8209-C-2

Control Box and Layshaft ............................... 0902-000


Air Intake Manifold...........................................GD-0043
Cooling System .............................................. 1102-200
Divider Block Lubrication System................... 1202-000-03
Integrated Governor Throttle Body................. 1302-000-04
Lubricator Drive Assembly ......................................... YAE-5581
Alternator Drive Assembly .......................................... YAE-1561-E

Compressor Crossheads and Guides ............ 1402-000


Compressor Connecting Rod ......................... 1512-000
Shielded Ignition System................................ 1802-000-06
Altronic III Service Manual................................... Altronic

AIII SM 12-96

Altronic III Installation .......................................... Altronic

AIII II 04-92

Ignition Coil, 591-010-S....................................... Altronic

Engine-Compressor Package Service Manual

591-010-S

Frame with Counterweights and Solid Pin on Throw # 1 Crosshead


Assembly Drawing 0102-000
Ref #
1
2
3
4
5
*
*
*
*
6
7
8
C
D
E
F
G
H
K
L
M
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26

Desscription
Bed
Compressor
Nameplate
Screw
Drive
Support
Bearing
Support
Bearing
Support
Bearing
Cap
Bearing
Nut
Castle
Bolt
Support
Bearing
Washer
Plain
Packing
Engine Rod
Scraper
Ring Set
Plate
Cup
Adapter
Cup
Bolt
Wire
Bolt
Slinger
Ring
Retaining
Plug
Pipe
Plug
Pipe
Plug
Pipe
Cover
Rect
Bolt
Hex Head
Cover
Square
Breather
Support
Bearing
Shield
Gasket
Flat Rect
Gasket
Flat Rd
Gasket
Flat Rect
Baffle
Washer
Plain
Gasket
Flat Rd

P/N

Qty
K-6000-J
1 ea
BM-10003-M-1
1 ea
BM-1386-A
8 ea
K-6015-C
1 ea
YAE-5549-3
1 ea
A-3320
1 ea
A-3321-1
1 ea
BM-11916-1614
4 ea
P-5455-2
4 ea
A-2581-F-1
1 ea
A-573
6 ea
YAE-5014-A
2 ea
A-3649
1 ea
BM-1328-L-1
1 ea
A-3666
1 ea
A-3667
1 ea
A-3665-A
1 ea
A-3668-A
1 ea
K-7021-D-5
3 ea
XAISI 1010 WR 15GA 2 ft
BM-11900-C-0616-20 3 ea
A-1264-A-1
2 ea
Q-6316-A
1 ea
BM-11953-06
4 ea
BM-11958-08
2 ea
BM-11953-04
4 ea
A-1944-A-1
1 ea
BM-11900-0813-08
8 ea
K-6013-F
2 ea
BM-776-F
2 ea
K-6018-B
1 ea
A-2579-E
1 ea
A-4522
1 ea
A-4521-A
1 ea
A-2233
1 ea
K-6243
2 ea
A-4675
8 ea
A-2227-A
2 ea

Ref #
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
*
*
*

Desscription

Gasket
Gasket
Flat Rd
Gasket
Bolt
Hex Head
Bolt
Hex Head
Bolt
Hex Head
Bolt
Hex Head
Bolt
Hex Head
Bolt
Hex Head
Stud
Nut
Plain Hex
Bearing
Journal
Shim
Laminated
Shim
Solid
Pin
Cotter
Crosshead Power Rod
Solid Pin
Crosshead
CounterweightCrosshead
Bolt
Hex Head
Washer
Plain

P/N

A-2253-B
A-2235-A
K-6241
BM-11900-C-0420-06
BM-11900-C-0813-08
BM-11900-0813-10
K-7021-28
K-7021-B-9
BM-11900-1409-18
K-8095-0813-16
BM-11904-0813
A-3310-A
A-3326-D
A-3326-D-1
BM-11925-05-07
A-1220-K
A-1222-D
K-6343-L-1
BM-11900-0813-18
BM-11918-10-N

Qty
2 ea
2 ea
2 ea
8 ea
10 ea
41 ea
6 ea
8 ea
12 ea
16 ea
18 ea
1 ea
2 ea
2 ea
4 ea
2 ea
1 ea
2 ea
8 ea
8 ea

NOTE: components are not shown; see SK-9059-R for the counterweighting
components used on throw # 1.

45
46
47
48
49
50
51
52
53
55
56
57
58
59
60

Plate
Screw
Screw
Screw
Nut
Flange
Gasket
Plug
Bolt
Wire
Bracket
Bolt
Pin
Stud
Decal

A-4629
2 ea
BM-11921-1210-32-CP 2 ea
BM-11921-1210-20-DP 2 ea
BM-11921-1210-20-CP 2 ea
BM-11910-A-1210
6 ea
K-8010-B
2 ea
K-8011-A
2 ea
BM-11953-02
1 ea
BM-11900-1409-16
8 ea
XAISI 1010 WR 15GA 14 ft
K-7257-K
1 ea
Hex Head
BM-11900-1409-22
4 ea
Dowel
T-278-A
2 ea
Double End 913-942-013
2 ea
Hyd System BM-21164
1 ea
Set
Set
Set
Jam
Orifice
Flat Rd
Pipe
Hex Head

Frame with Counterweights and Solid Pin on Throw #1 Crosshead


Assembly Drawing 0102-000

020205

Power Connecting Rod


Assembly # 0300-000
Ref #
Description
1 Conn Rod Power
B Bearing
C Pin
D Wire
E Dip
F Bushing
G Screw
H Screw
J Pin

P/N
C600-3-1A
A-2894-E-2
BM-16475-6-8
XAISI 1010 WR 15GA
A-2933
A-1223-3
BM-11090
K-6650
BM-11548-24-64

Qty
2 ea
1 ea
1 ea
3 ft
2 ea
1 ea
1 ea
2 ea
2 ea

Ref #

Power Connecting Rod


Assembly # 0300-000

Description

P/N

Qty

022002

15" Power Cylinder, LE Cylinmder Head, Piston-Rod, and Mixing Valve


Assembly # 0500-200
Ref #
1
3
4
A
6
7
9
10
11
13
14
15
17
18
19
*
*
20
21
22
23
24
A
B
C
D
E
F
G

Description
Cylinder, 15" Power
Stud
Valve
Indicator
Gasket
Head, LE
Power
Gasket
Head
Screw
Twelve Pt
Washer
Finished
Plug
Pipe
Lockwasher Split
Stud
Tap End
Nut
Plain Hex
Nut
Gasket, Cyl-to-Frame
Piston/Rod
Engine
Piston
Rod
Ring
Piston
Nut
Piston Rod
Gasket, Cyl-to-Exh Pipe
Capscrew
Hex Head
Valve
Mixing
Valve Plate
Stop
Stop
Spring
Bolt
Seat
Pin

P/N
K-7201-E
K-8093-1608-32
BM-16556
A-3794
A-4502-N
A-4513-C-1
K-8142
BM-11808
BM-11953-04
SF-115-2-036
1-04F-001-108-106
1-08F-005-108
BM-11904-1608
A-474-B
YAE-7516-B-2
A-4506-A
XTGSDI0208-041062
A-4711-A
A-1278-B
A-4514
BM-11900-1409-16
YAE-7510-B-1
A-2693-F
A-4512
A-4512-1
M-1485
BM-11900-C-0420-08
A-4527-2
01RP121600

Qty
2 ea
8 ea
2 ea
1 ea
2 ea
2 ea
16 ea
28 ea
2 ea
28 ea
28 ea
28 ea
8 ea
2 ea
2 ea
1 ea
1 ea
8 ea
2 ea
2 ea
24 ea
2 ea
10 ea
2 ea
2 ea
20 ea
10 ea
1 ea
20 ea

Ref #

Description

15" Power Cylinder, LE Cylinder Head, Piston-Rod, and Mixing Valve


Assembly # 0500-200

P/N

Qty

010307

DPC-2802 Divider Block with Proximity Switch Lubrication System


Assembly # 1202-000-03
Ref #
Description
1 Lubricator (ref 5.33:1 ratio)
A Pump, "
B Pump, "
C Rupture Disc 1750 psi
D Rupture Disc 2950 psi
E Check Valve Assembly
2 Bracket
3 Capscrew
4 Capscrew
5 Bracket
6 Bolt
Hex Head
7 Capscrew
Hex Head
8 Washer
Plain
9 Nut
Plain Hex
10 Tubing
Stainless
11 Bracket
Angle
12 Capscrew
Hex Head
13 Valve
Divider
E Filter
Assembly
F Filter Element 10 Micron
G Switch
Proximity
H Valve
Check
J Cycle
Indicator
14 Bolt
Hex Head
15 Nut
Plain Hex
16 Lockwasher Split
17 Connector
Tubing
18 Elbow
Tubing
19 Valve
Check
20 Elbow
Tubing
21 Capscrew
Hex Head
22 Union
Tubing

P/N
BM-21087-C-2
BM-21136-1
BM-21137-1
BM-21138-17
BM-21138-29
BM-21171
K-8016-A
BM-11900-0616-10
BM-11900-0616-18
K-8016-B
BM-11900-0813-16
BM-11901-0820-06
BM-11918-10-N
BM-11904-0813
BM-21071-2-035
K-7193-17-A
BM-11900-0813-08
BM-11083-W-2
BM-21135
BM-21135-A
BM-21133
BM-21171-1
BM-21134
BM-11900-0420-16
BM-11904-0420
BM-11782-A-04
BM-11610-S-4-2
BM-11573-S-4-4
BM-10885-F-1
BM-11573-S-4-2
BM-11900-0813-08
BM-11623-S-4-4

Qty
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
2 ea
2 ea
1 ea
2 ea
2 ea
6 ea
2 ea
40 ft
1 ea
4 ea
1 ea
1 ea
1 ea
1 ea
6 ea
1 ea
2 ea
5 ea
5 ea
6 ea
1 ea
6 ea
2 ea
3 ea
1 ea

Ref #
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
42
43

Description
Tubing
Stainless
Connector
Tubing
Union
Tubing
Elbow
Tubing
Gasket
Flat Oval
Capscrew
Hex Head
Trough
Clamp
Tubing
Clamp
Tubing
Screw
Machine
Gasket
Clamp
Tubing
Clamp
Tubing
Clamp
Tubing
Nut
Hex
Capscrew
Hex Head
Lockwasher Split

DPC-2802 Divider Block with Proximity Switch Lubrication System


Assembly # 1202-000-03

P/N
BM-21071-1-3-035
BM-11610-S-6-4
BM-11623-S-6-6
BM-11573-S-6-4
A-2117
BM-11900-0616-10
A-2115
T-112
T-110-A
BM-11929-2520-04
A-3175
2516 0402
2516 0403
2516 0404
BM--11468-0420
BM-11900-0420-20
BM-11782-A-06

Qty
3 ft
1 ea
1 ea
1 ea
1 ea
2 ea
1 ea
2 ea
2 ea
6 ea
1 ea
3 ea
3 ea
2 ea
12 ea
1 ea
2 ea

032807

Integrated Governor Throttle Body (Mechanical Assembly)


1302-000-04
Ref #
1
2*
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
24
25
26
27
28
29
30
31
32
34
37*
38

Description
IGTB Governor, 30mm, 24VDC
Cable & J-box Assembly
O-ring
Outlet Flange
Inlet Flange
SHCS #10-24 x 5 UNC
Lock Washer, #10
Support Bracket
HHCS, -11 UNC x 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

Note: refer to Manual's section 11 for additional


information about the IGTB system.
*shipped separately

Integrated Governor Throttle Body (Mechanical Assembly)


1302-000-04

091205

Section 4 Fuel / Start System


Vendor
Fuel Filter Drawing .............................................. Ajax

Bulletin No.
TP 00-22-T05A-002

Instrument Gas Pressure Regulator, 67CFR-225........... Fisher

Form 5469

Differential Pressure Gauge, 120-AA-00-00-30 .............. Mid-West

IM 120/05

Drain Trap, 22-LD ........................................................... Armstrong

LD-39

Level Controller, L1200NDVO, O & M ............................ Murphy

00-02-0175

Dump Valve, DVU-150, O & M........................................ Murphy

00-02-0483

Fuel / Start Gas Piping Drawing.......................... Ajax

TP 02-22-T010-331

Starter Relief Valve...............................................Ajax

00-22-T010-307

Starter / Relief Valve Vent Header....................... Ajax

02-48-T010-388

Regulator, Main Fuel, Type 627, O&M ........................... Fisher

5252

Fuel Shutdown Valve, M5081-C-LS................................ Murphy

M-7980

Mercer Relief Valve 8100 Series O & M.......................... Mercer


Mercer Relief Valve 9100 Series O & M.......................... Mercer
Regulator, PCC Fuel Pressure, Type 64
Operation and Maintenance........................................ Fisher

1245

Shutoff Valve, PCC Fuel, Type 119


Operation and Maintenance........................................ Fisher

5204

Starter Motor, BM-11679-Q-1, 90 PSIG, IOM ................ TDI

T1-702

Starter Motor Service Manual ......................................... TDI

T1-701

Performance Curve, T121-B, Natural Gas...................... TDI

AN00-639 8/00

Engine-Compressor Package Service Manual

Flange Fastener Tightening Torques


The vessels closing flange
gasket p/n is 3050 0160.

Thread Size Torque, Lbs-ft


3/4-10

190

Notes:
1. The threads and nut faces must be
lubricated to attain the correct clamping
force. Use only crankcase oil or Lubriplate.

At 12-14 psid, replace


the filter element.

2. Use a criss-cross star pattern to tighten


the bolts in sequence.

Set the instrument gas


pressure regulator at
30-50 psig.

Replacement element p/n


is 6321 9734.
The elements retaining
cap should be tightened
to 5-10 lbs-ft only.

3. The torque should be applied in a minimum


of three increments.

Warning

Fuel Inlet

All repair and resetting of


safety relief valves should be
performed by a National Board
certified valve repair shop
holding a VRstamp.

Fuel Outlet

Front View

Connect to the
liquid drain system

Rear View

Manual Drain Valve

Fuel Filter Assembly


TP 00-22-T05A-002 r2

Fuel Filter Assembly


TP 00-22-T05A-002 r2
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

Description

P/N

Ball Valve, " NPT


2549 2094
Bushing, " x " NPT
2527 0402
Bushing, " x " NPT
2527 0604
Bushing, " x " NPT
2527 0602
Bushing, 2" x 1" NPT
2527 2010
Differential Pressure Gauge, 0-30 psid
2015 0116
Drain Trap, 22-LD
2051 0102
Male Tubing Elbow, " Tube x " NPT
2507 4204
Male Tubing Elbow, "Tube x " NPT
2507 4202
Male Tubing Elbow, "Tube x " NPT
2507 4201
Male Tubing Elbow, "Tube x " NPT
2507 4606
Pressure Regulator, Instrument Gas
2040 0063
Gauge Glass Valve Set
2015 3169
Level Controller, L1200NDVO
2005 9124
Male Connector, " Tube x " NPT
2507 1404
Male Connector, " Tube x " NPT
2507 1202
Male Connector, " Tube x " NPT
2507 1606
Male Connector, 1" Tube x 1" NPT
2507 1808
Relief Valve, 1" x 1" 155 psig
63ME2M2FVAC0155
Dump Valve, DVU 150
2003 6222
Needle Valve, "
2549 0028
Pipe Nipple, Close, Sch 80, " NPT
2539 4404
Pipe Nipple, Close, Sch 80, " NPT
2539 4200
Pipe Nipple, Close, " NPT x 3 LG
2539 4414
Pipe Plug, Hex Head, 2" NPT
2541 6020
Pressure Gauge, 0-60 psig
2015 0220
Red Line Gauge Glass
2015 0158
Tee Tube, "
2545 4004
Tee Tube, "
2507 6504
Tubing, 316SS, " x 0.035 Wall
5551 3508
Tubing, 316SS, " x 0.035 Wall
5551 3508
Tubing, 316SS, " x 0.035 Wall
5551 3508
Tubing, 316SS, " x 0.035 Wall
5551 3504
Tubing, 316SS, " x 0.035 Wall
5551 3504
Tubing, 316SS, " x 0.035 Wall
5551 3504

Qty

Item

1
2
1
1
1
1
1
2
6
2
1
1
1
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
11"
8"
25"
32"
46"
20"

36
37
38
39

Fuel Filter Assembly


TP 00-22-T05A-002 r2

Description

P/N

Qty

Tubing, 316SS, " x 0.035 Wall


Tubing, 316SS, " x 0.035 Wall
Tubing, 316SS, " x 0.049 Wall
Tubing, 316SS, 1" x 0.049 Wall

5551 3504
5551 3504
5551 4912
5551 4916

18"
16"
9"
47"

Filter Element
Flange Gasket

6321 9734
3050 0160

1
1

120804

67C Series

Instruction Manual
Form 5469
May 2006

67C Series Instrument Supply Regulators

TYPE 67CF FILTER REGULATOR


WITH OPTIONAL GAUGE

TYPE 67C OR67CR REGULATOR

Figure t Typical 6 7C Series Regulators

Introduction

The Types 67C and 67CS are the standard instrument


supply regulatorswithout a filter or internal relief.

Scope of Manual

The Types 67CF and 67CFS are equipped with a


filter for removing particles from the supply gas.

This manual provides instructions and parts lists for


67C Series instrument supply regulators. Instructions
and parts lists for other equipment mentioned in this
instruction manual, as well as for other 67 Series
regulators, are found in separate manuals.

Product Descriptions
The 67C Series direct-operated regulators are
typically used to provide constantly controlled,
reduced pressures to pneumatic and electropneumatic
controllers and other instruments. They are suitable
for most air or gas applications. Other applications
include providing reduced pressures to air chucks, air
jets, and spray guns.

The Types 67CR and 67CSR have an internal


relief valve with a soft seat for reliable shutoff with no
discernible leakage.
The Types 67CFR and 67CFSR have a filter and
internal relief valve with a soft seat for reliable shutoff
with no discernible leakage.

Specifications
Some general 67C Series ratings and other
specifications are given on page 2. A label on the
spring case gives the control spring range for a given
regulator as it comes from the factory.

EMERSONL

Process Management


Mid-West
Instrument

BULLETIN NO. IM120/05


(Supersedes IM120/03)

Model 120 Series Filter Minder


Installation and Operating Instructions

INSPECTION
Before installation check the nameplate on each
instrument against the receiving paperwork and the
intended application for correct part number,
materials of construction, working pressure, dial
range, etc. If equipped with switches, check electrical
rating, type of enclosure, etc. Inspect for shipping
damage and, if damaged, report it immediately.
NOTE - Before attempting repairs contact your
local Mid-West Representative or our factor y.
Failure to do so will void any warranty.
PRODUCT DESCRIPTION

The Model 120 Series "Filter Minder" is a rugged,


medium-range differential pressure instrument
available as a switch, a gauge, or both. See "Part
Numbering System". (Fig. 4) for available options.
Differential pressure is sensed by the movement of a
floating piston magnet against a calibrated spring. The
magnetically coupled gauge pointer outside the
pressure housing follows the movement of the piston
magnet and indicates differential pressure on the dial
scale.
When equipped with switches, a contact is made or
broken by the magnetic field of the piston magnet.
See Bulletin ELECIM120/latest for gauges with
switches.
The unit provides full over-range protection to the
rated working pressure of the housing in either
direction.

The precise piston/bore fit allows minimal leakage


from high to low sides. This leakage is only 5 to 15
SCFH air at ambient conditions and a pressure
differential of 100 PSID.
INSTALLATION

Model 120 Series "Filter Minder" is calibrated and


tested prior to shipment and is ready for immediate
installation. Use of the following installation
procedures should eliminate potential damage and
provide optimum trouble-free operation.
1. CONNECTIONS
1/4 FNPT are provided as standard but check
paperwork for connections ordered. There are two
connections on the housing identified as hi and lo
for high pressure and low pressure (Fig. 2). Be sure
these get plumbed to the proper connections on your
system. Improper connection will not damage the
instrument, but it will not function properly. Flexible
tubing is recommended to minimize the effect of any
vibration that may exist.
2. INSTRUMENT LOCATION
On liquid service the instrument should be mounted
below the process connections to facilitate selfbleeding. On gas service it should be located above
the process connections to promote self-draining. If
the process contains particulates, a pigtail loop or
drop leg (manometer U-tube configuration) in the
tubing will minimize the possibility of it migrating into
the instrument.

3. PANEL MOUNTING
Gauges with 2-1/2 dials can only be mounted
through the rear of the panel. Make the proper panel
cutout as indicated in (Fig.1). Remove the (4) bezel
screws. Insert the gauge front through the rear of the
panel and reinstall the bezel screws through the front
of the panel and into the gauge bezel. Tighten the
screws securely, alternating in a diagonal pattern.
Gauges with 3-1/2" dial should be mounted from the
front of the panel. Contact factory for mounting
information and dimensional data.
Gauges with 4-1/2" dial should be mounted from the
front of the panel. Make the cutout as indicated in (Fig.
1). Insert the (4) panel mounting studs, finger tight, into
the metal inserts located in the rear of the bezel. Insert
the gauge through the panel, aligning the panel
mounting studs with the holes in the panel. Install the (4)
#8-32 nuts onto the studs and tighten securely.

TROUBLE SHOOTING
1. Gaug e does not indicate differential.
A. Check for proper hook up, high to hi and low
to lo.
B. Make certain block valves are open and, if using
a 3-valve manifold, that the equalizer (balance)
valve is closed.
C. If A & B check out correctly, loosen or
disconnect the high pressure line to determine
if there is pressure to the instrument.
D. If there is pressure to the instrument, check to
determine that there is differential across the
unit being monitored. If so, contact the factory
for assistance and/or an RGA (return goods
authorization) number to return the instrument
for repair or replacement.

4. PIPE MOUNTING
An optional pipe mounting kit is available for mounting
the gauge to a 2 vertical or horizontal pipe (Fig. 3).

Model 120 2-1/2 Inch Dial (Std.)

Model 120 4-1/2 Inch Dial (Opt'l)

(Fig. 1)

Supplementar y 120 Dimensional/Mounting Data

(Fig. 2)

(Fig. 3)
NOTES: 1. Drawings show standard gaug e nominal dimensions. (not to scale)
2. Dimensions shown in parentheses are in millimeters.
3. Manufacturer reserves the right to chang e specifications without prior notice .

STANDARD MODEL SPECIFICATIONS


120-AA-00-OO
6000 P.S.I.G. Working Pressure Aluminum Body, Stainless Steel Piston, Ceramic Magnets, Buna N Seals,
2-1/2" Engineering Plastic Case with Shatter-Resistant Lens. 1/4" FNPT Back Connections.
Accuracy +3-2-3% Full Scale (Ascending).
2

MATERIAL
A.
M.
N.
S.
Z.

Aluminum Body, S.S. Piston (Standard)


Monel Body (See 120 ABM) (5000 P.S.I.G. working pressure)
Aluminum Bronze Body (See 120 ABM) (5000 P.S.I.G. working pressure)
316 S.S. Body & S.S. Piston (Standard)
SPECIAL (Uncoded Options)

DIAL TYPE
A.
B.
C.
D.
E.
F.
G.
H.
T.
Z.

2-1/2 Round Uni-Directional Engrd. Plastic Housing Assy. (Standard)


2-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
4-1/2 Round Uni-Directional Engrd. Plastic Housing Assy.
4-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
3-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
3-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
4-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
4-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
Non-Indicating Differential Pressure Switch Only (Select Appropriate Electrical Option)
Special (Uncoded Options)

OPTIONS (Up to four options)


O.
A.
B.
C.
D.
F.
L.
M.
T.
U.
V.
W.
X.
Z.

BASIC MODEL NUMBER

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)

marked, except E, F, J & K)

None
One (1) Switch in STD. Enclosure with Grommet Wire Seal
Two (2) Switches in STD. Enclosures with Grommet Wire Seal
One (1) Switch in STD. Enclosure with 1/4 FNPT Electrical Connection NEMA 4X
Two (2) Switches in STD. Enclosures with 1/4 FNPT Electrical Connection NEMA 4X
One (1) Switch in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
Two (2) Switches in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
One (1) Switch & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
Two (2) Switches & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
One (1) Switch in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
Special (Uncoded Options)

(Up to three options)

PART NUMBERING SYSTEM

Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G.
Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G.
5000 PSIG Working Pressure.

CONNECTIONS
(NOTE: Models 120M and 120N available only with end connections)
0.
2.
6.
7.
8.
9.

1/4" FNPT Back Connections (Standard)


1/4" FNPT End Connections
7/16" - 20 Str. Thd. O-Ring Port (Back Connections)
1/2" FNPT Stainless Steel Adaptors
1/2" FNPT Monel Adaptors
Special (Uncoded Options)

ELECTRICAL SPECIFICATIONS (For Resistive Loads)


A.
E.
F.
G.
H.
Z.
(4)

S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%)
S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%)
S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed)
(Switch adjustable range of 25-95%)
S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4)
S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%)
Special (Uncoded Options)
Available with Electrical Configurations B, D, F, H, K and M only.

NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.


NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)

(Fig. 4)

NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE.
ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY.

Manufacturer reserves the right to change specifications without prior notice.


PROOF PRESSURE: 12,000 PSI for models 120-A and 120-S.
10,000 PSI for models 120-M and 120-N.
TEMPERATURE LIMITS: -40F(-40C) to +200F (+93C) - These limits are based on the entire instrument being saturated to
these temperatures. System (process) temperatures may exceed these limitations with proper installation. Contact our customer
service representative for details.
STANDARDS: All Model 120 Series differential pressure gauges either conform to and/or are designed to the requirements of the
following standards:
ASME B1.20.1
ASME B40.100
CSA-C22.2 No. 14.25 and 30
EN-61010-1

NACE MR0175
NEMA Std. No. 250
SAE J514
UL Std. No. 50,508 and 1203

R E P R E S E N T E D B Y:

Mid-West
Instrument
6500 Dobry Dr. Sterling Heights, MI 48314 U.S.A.
(586) 254-6500 FAX (586) 254-6509
E-mail: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.

Free Floating Guided Lever Drain Traps


For Loads to 9,500 lblhr(4.309 kglhr) ...Pressures to 570 psig (39 bar)

hms-

Armstrong's stainless steel, free-floating guided lever drain


traps use the same bodies, caps, lever mechanisms, valves
and seats of Armstrong inverted bucket steam taps that
have been proven in years of service. Elliptical floats and
high leverage make it possible to open large orifices to
provide adequate capacity for drain tap size and weight.

The hemispherical valve, seat and leverage of the 11-LD,


22-LD and 13-LD stainless steel traps are identical in design,
materials and workmanship to those for saturated steam
service up to 570 psig (39 bar) with the exception of the
addition of a guidepost to assure a positive, leaktight valve
closing under all conditions.

List of Materials

For a fully detailed certified drawing, refel to list below:


11-LD
CD #I066
I b L D and 22-LD CD #I086

Model Valve&
NO.

11~LD
22.~0
13-LD

Seat

Leverage
Svstern

I I
loa at

Stainless Steel

Body & Cap

Sealed

Stainless Steel.
304L

Gasket

For intomatianon special materials, consull the Armstrang Application

Figure LO-34.
No. 11-LD. 22-LD and 13-LD stainless steel guided lever
liquid drain trap with sealed, tamperproof construction.

Physical Data

NOD: Vessel aes pn press~remay exceeo lloatcollapre pressure n some carer


Pce rile 01 vent conne?on s sme as mar 01 P ?I
anc a l e : c0nPe:I 01s

",T115mm1o.net

"ha sde caqnecnoi

All dimensions and weights are appmximafe. Use ceriffledprlnf lor exact dlmenrlons. Deslgn and malerlals are SubIect to change without notice.

LO-39

Armstrong Steam and Condensate Group. 816 Maple St.. P.O.Box 408. Three Rivers. MI 49093 -USA Phone: (269) 273-1415 Fax: (269)278-6555
w.armrtrong-intl.com

00-02-0175
Revised 03-06
Section 15

Installation for L1100, L1200, L1200N Series


Liquid Level Switches and DVU150, DVU175,
and DVU2105/2115/2120 Series Dump Valves.

Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting.
GENERAL INFORMATION
**

Description
Series L1100 and L1200 Liquid Level Switches are float activated to
operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.
OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment.
BE SURE all pressure HAS BEEN REMOVED from the
vessel before opening any pressure connections.

Specifications

L1100

Series L1200N is a float-activated, pneumatic-vent level device used to operate dump


valves or similar devices. This model screws directly into the vessel or can be
mounted via an external float chamber. It cannot be used with weld collar 15050375.
Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
L1200NDVOR series carry Canadian Registration Number OF1476.2.
Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
pneumatic input signal to cause an orifice to open or close allowing liquid
condensate to be drained from a pressure vessel. A pop up button indicates valve
open/closed. Stainless steel versions available.
L1111

L1200

L1200N

L1200NDVO

L1200NDVOR

Body
Standard: Electroless Nickel plated steel
Optional: 316 Stainless Steel

A
A

A
A

B
B

B
B

B
B

B
B

Pressure Rating
15 psi (103 kPa) [1.03 bar] Polyethylene Float
1500 psi (10.3 MPa) [103.42 bar] Stainless Float
2000 psi (13.8 MPa) [138 bar] BUOYGLAS Float

Temperature Rating
Standard: -20/175F (-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)

Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)

Specific Gravity
Standard: 0.5 with BUOYGLAS float
Optional: 0.65 with 304 Stainless Steel
Standard 0.73 Polyethylene Float

O-Rings: Viton
Valve: Two-way snap-action vent type
1/8 in. (3 mm) orifice w/Viton A seat
1/8 NPT inlet; 1/4 NPT vent
30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar. 1/8 NPT inlet, outlet & vent.
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge.
Maximum input 300 psi (2.07 MPa) [20.68 bar].
1/8 NPT in/out.
Operation:
H=For high level, L=For low level

Meets NACE standard MR-01-75 for direct exposure to H S service.


*Not available with DPDT snap-switch.
A =1-1/2 NPT
B =2 NPT
2
**Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.
Installation 00-02-0175 page 1 of 6

DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage

L1100 and L1200


11 in.
(279 mm)

Pressure
Regulator
with 20BPG
Pressure Gage

3-1/2 in.
(89 mm)

2-3/16 in.
(56 mm)

New Dump Valve


Operator Assembly
p/n 15010216

See
Note 2

1/2 NPT

See
Note 1
3-5/8 in.
(92 mm)

Note 1:
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm)
SF option:
L1100: 1-1/2 (38 mm)
L1200: 1-3/4 (44 mm)

1/8 NPT
Old Round Dump Valve
Operator Assembly
p/n 15000940

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

1/8 NPT
INLET

3-5/8 in. (92 mm)

5 in. (127 mm.) minimum


clearance is required for
float movement.

3/4 Hex
(See Note)

2-3/16 in.
(56 mm)

1/4 NPT
VENT

1-9/16 in.
(40 mm)
SF option=
1-3/4 in.
(44 mm)

2" 11-1/2 NPT

3-1/2 in. (89 mm)


SF= 3-3/4 in. (95 mm)
11 in. (279 mm) SF option= 11-1/4 in. (286 mm)
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).

L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)

2-3/16 in.
(56 mm)

DVU150, DVU175, DVU2105/2115/2120


Series Dump Valves

See
Note

1/2 NPT

1-1/2 NPT
3-5/8 in.
(92 mm)

Note: 1-9/16 (40 mm)

Pressure
Inlet Port
1/8 in.-27 NPT

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

Manual Valve
Operator

Vent
Weep Hole
Union

Valve Open/Closed
Indicator Button

Electrical installation to be done by


qualified person according to the NEC.

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

NOTE: Dimensions are in inches and (millimeters)

Installation 00-02-0175 page 2 of 6

REPLACING AND INSTALLING THE DVOA ASSEMBLY

When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Replacing and Installing the DVOA
Assembly For Models L1200NDVO &
L1200NDVOR

NOTE: Clean, dry instrument quality gas should be used.


Use of filters will improve service life and reliability.

Tools Needed: Strap or pipe wrench; 3/4 Hex wrench; 9/16 hex
wrench; needle nose pliers; tubing cutters and benders and the
appropriate tools for the fittings.
1.

Block off and bleed the instrument gas pressure supply to the
L1200NDVO.
2.
Remove the tubing between the L1200NDVO and the
separator dump valve, and remove the supply gas tubing
(regulator [-R] if used).
3.
Remove the L1200NDVO from the vessel (optional).
4.
If the L1200N was removed from the vessel, mount it in a
suitable vise on a work bench (if possible).
5.
Using the proper tools, disconnect the Inlet, Outlet and
Exhaust fittings from the existing DVO (see fig. 1). You will
re-connect these to the new DVOA in a later step.
NOTE: The following steps must be done with the DVO in the
upright position (on top of the L1200N).
6.
Remove the L1200N cover (this will aid with the alignment
of the new DVOA Valve Bushing). The use of a strap
wrench or a pipe wrench may be needed.
7.
Insert the new Valve Bushing through the new DVOA (see
fig. 2). The markings on top of the DVOA must be facing
up. This will be needed in step 9.
8.
With a 3/4 hex wrench loosen the existing DVO, valve
stem, and static seal (see fig. 3). Once the assembly is
loosened, VERY CAREFULLY use needle nose pliers to
hold the Valve Seat Assembly in place. Remove the existing
DVO making sure the Valve Seat Assembly inside the
L1200NDVO is aligned and straight (see fig. 4).

Old DVO

Outlet
(opposite side)

Inlet

Exhaust

Figure 1

Figure 2

New DVOA

Figure 3

CAUTION: MAKE SURE the Valve Seat Assembly inside


the L1200N remains in place after removing the DVO.
Holding the Seat Assembly up with the needle nose pliers
inside the L1200NDVO body, place the tip of the new
DVOA valve bushing through the spring and into the hole in
the center of the valve seat, and tighten the valve bushing.
The Valve Seat Assembly should be able to move freely up
and down after the bushing has been tighten. The DVO red
button must face away from the vessel.
10.With the new DVOA aligned over the hex on the L1200NDVO
body, tighten the Valve Bushing using the 9/16 hex wrench.
You may need to hold the DVOA while tightening the Valve
Bushing to keep it from rotating (see fig. 5).
11.If the L1200N is in the vise, operate the float and inspect for
smooth and proper operation of the Valve Seat Assembly.
12.Replace the L1200NDVO cover (see fig. 6).
13.Using the appropriate tools re-install the Inlet, the Outlet and
the Exhaust fittings to the new DVOA (see fig. 5).
14 If the L1200N was removed from the vessel re-install it at this
time.
15.Modify existing or install new tubing to connect the Inlet, the
Outlet and Exhaust fittings.

Valve
Bushing

Valve Seat
Assembly

9.

Outlet

Figure 4

Inlet

Installation 00-02-0175 page 3 of 6

Exhaust

New DVOA

Figure 5

L1200N
Cover

Figure 6

PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N

Direct Installation into the Wall of the


Pressure Vessel
1. Determine that the float travel is not
obstructed by the coupling in
Tank
the vessel wall, internal
Wall
baffles, etc.
Do NOT use more than
one arm extension P/N
15050395.
Explosion proof
2. BE SURE that the float
Level
conduit seal
Switch
and extension are tight
where required.
and that the lock washer is
in place.
3. Before installing the level
switch a suitable pipe thread sealant
is recommended. Screw the unit directly into the threaded
connection in the wall of the pressure vessel.
4. Be sure that the electrical connection is positioned at the
bottom. For L1200N the 1/8 NPT pneumatic connection
should be on top (the 1/4 NPT vent connection should be on
the bottom). See Pneumatic models section for further
instructions for the L1200N.
5. Make the electrical wiring connections according to
appropriate wiring diagrams for the alarm or shutdown
system to be used. The electrical connection is 1/2-14 NPT.
Electrical wiring and conduit should be installed by qualified
personnel according to the NEC.
6. BE SURE all electrical connections are insulated and the
cover is fully installed before reconnecting electrical power.
7. BE SURE all pressure connections are tight before
pressurizing the system.
Installation with a Weld
Collar
Tank Wall
1. The weld collar, P/N
Weld Collar
15050375, must be welded
into the wall of the
pressure vessel according
to code standards and
good welding practices.
L1200
2. Follow above instructions
for installation directly into
Explosion proof
the wall of the pressure
conduit seal
vessel.
where required.
3. NOTE: Weld collar 15050375 can
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External
Float Chamber 15051098

positioned away from the tank wall.


2. A tee is typically installed at the bottom of the lower 1 inch
pipe riser to allow draining of the float
chamber for servicing or replacement.
NOTE: A typical installation
Float
with Blocking and Bleed valves is Chamber
Tank
shown at right.
Block
Valves
3. Install the L1200 or
L1200N
Level
in the 2 NPT connection Switch
of
Tee
the float chamber.
Bleed
BE SURE float travel
Valve
is not restricted and that the
Explosion proof
float is tight onto
conduit seal
where required.
the float shaft.
4. To complete installation and
wiring, follow the instructions for
mounting directly into wall of the vessel and for wiring.
Pneumatic Models
1. All pneumatic models
operate on the vent
Filter/Regulator
Tank
principle. The
New Dump Valve
Operator Assembly
pneumatic signal
Pneumatic
p/n 15010216
Signal
source MUST BE
CLEAN AND DRY.
The input pneumatic MURPHYGAGE
signal must be
regulated between 30
L1200N
and 70 psi (207-483
kPa) [2.07-4.83 bar].
If produced gas is used as the
signal source, it should be taken
after gas passes through the final scrubber.
A suitable filter must be positioned before the L1200NDVO
to prevent liquids and/or particulates from entering the dump
valve operator.
NOTE: Check filter periodically for wear and tear and
elements that hamper the flow of the pneumatic signal.
2. All pressure connections must be tight and maintained tight
so as not to leak air/gas.
3. Valve seat adjustment can be made if air/gas begins to leak.
Care should be taken when adjusting as only slight movement
is necessary to stop the leakage; excessive force will bind the

Hex Socket Set Screw


loosen for adjustment
tighten after adjustment

L1200N

CAUTION: USE NON SPARKING TOOLING.


1. Install the float chamber 15051098 on the outside wall of the
pressure vessel using 1 NPT piping. Position the 2 NPT
threaded connection at the height where you want the level
switch to operate. The 2 NPT threaded connection must be

Hex Adjustment Nut


turn left until air
seepage stops
Caution: only slight
adjustment is neededtoo
much will lock up mechanism

Installation 00-02-0175 page 4 of 6

Trip Cam (float down)


should be in
this position
non-adjustable

TYPICAL INSTALLATION ON GAS COMPRESSORS

Basic Operation
As condensate rises in the scrubber, the float on
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter
the dump valve pilot chamber. Once the pressure
enters the pilot chamber it forces the diaphragm
and valve stem forward thus opening the valve seat
(valve open/closed indicator button pops out) and
releasing condensate through the valve stem and
out the drain. As the condensate level drops, the
L1200NDVOR pneumatic valve closes to shut off
the pressure to the dump valve causing it to close.
If for any reason the condensate continues to rise
beyond normal dump levels, model L1200
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the
MURPHYGAGE help keep the control pressure
clean and dry. They also allow the operator to
adjust pressure to recommended levels.

Typical/Scrubber/Separators
VESSEL
Minimum control
pressure 30 psi
(207 kPa) [2.07 bar]

Rising Level Shutdown


L1200 (with snap-switch)

Explosion proof
conduit seal required
for Class I. Div 1, not
required for intrinsically
safe or non-incendive
circuits like FWM TTD.

Rising
Level
Trips
DVO

Electrical
Conduit

L1200NDVOR
Dump Valve
Operator
Union

Air Supply Maximum


300 psi (2.07 MPa)
[20.70 bar]

Filter/Regulator
with MURPHYGAGE

Minimum control pressure


30 psi (207 kPa) [2.07 bar]

DVU Series Dump Valve


Union
Condensate Line (Out)
Manual Drain Valve

REPLACEMENT PARTS

ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection

Black N.O.

White COM.

Red N.C.

Switch Rating: 5 A @ 125-250- 480 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
2A @ 6-30 VDC Resistive
1A @ 6-30 VDC Inductive

Green Grd. Connection

Black N.O.

White COM.

Red N.C.
Blue N.C.

Yellow COM.

Orange N.C.

Switch Rating: 10 A @ 125-250 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
10 A @ 6-24 VDC
Inductive/Resistive

Order by part number designation.


L1100/L1200*
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200
15000937: Stainless Steel float for L1100
15000124: SPDT snap switch assembly
15010213: L1100 counter balance assembly
15010214: L1200 counter balance assembly
L1200N
15050420: Cam spring return
15050421: Cam
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
55050621: Regulator only
05706499: 20BPG-D-75 Pressure MURPHYGAGE
0-75 psi (517 kPa) [5.17 bar]
15010216: DVOA assembly (New rectangular style)
15000940: DVO assembly (Old round style)
*To maintain hazardous location listings, all other repairs must be made by the factory.

Installation 00-02-0175 page 5 of 6

ACCESSORIES

Order by part number designation.

55050617: DVU150/DVU175 Adapter Bushing

15050375: Weld Collar

Material: 2-1/2 Hex bar stock C.R.S


2-1/16 in
(52 mm)
1-1/16 in
(27 mm)

2 NPT

2-1/2 in
(64 mm)

2-7/8 in
(73 mm)
3-5/8 in.
(92 mm)

1 NPT

4-1/2 in
(114 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

2 NPT

15051098: External Float Chamber


3 in.
(76 mm)

1-11.5 NPT (2 places)

2-11.5 NPT
10.5 in.
(266 mm)

3 in.
(76 mm)

1/2-20 UNF-2B
(4 places)
7.55 in.
(192 mm)

3.5 in.
(89 mm)

Material: Cast Steel, WCB

7.01 in.
(179 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

15000892: Float Shaft Extension


10-32 UNF

10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)

Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

www.fwmurphy.com
918.317.4100 Email: 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.

Installation 00-02-0175 page 6 of 6

00-02-0483
Revised 03-06
Section 15

Installation and Operation Manual for


DVU Series Dump Valves
Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120

Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended
before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes.
GENERAL INFORMATION

Fig. 2 Dimensions (all models)

WARNING

A
Pressure
Inlet Port
1/8 in.-27 NPT

Manual Valve
Operator

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

Description
The DVU Series models are pneumatically controlled dump valves.
The valves open and close automatically by pneumatic control from a
Murphy L1200NDVOR or similar level controller and dump valve operator. Diaphragm actuated, the DVU series dump valves operate at 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.

Fig. 1 Control Pressure vs. Working Pressure


Control Pressure (PSIG)

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

NOTE: Dimensions are in inches and (millimeters)

DVU2120

DVU2115

60

Specifications

50
40

Valve Open/Closed
Indicator Button

F Drain

Minimum Actuation Pressure


70

Vent
Weep Hole
Union

DVU150/175

DVU2105

30
20
10
0

500

1000

2000

1500

Vessel Pressure (PSIG)

Model
DVU2120
DVU2115
DVU2105
DVU175
DVU150

Inlet
2 NPT
2 NPT
2 NPT
1 NPT
1 NPT

Outlet
1 NPT
1 NPT
1 NPT
3/4 NPT
1/2 NPT

Trim Size
0.436 in. (11 mm)
0.576 in. (15 mm)
0.859 in. (22 mm)
0.359 in. (9 mm)
0.359 in. (9 mm)

Operating Temperature: -30 to 250F (-34.4 to +121C)


Valve Operating Pressure: Refer to chart, Fig 1.
Maximum Process Pressure:
DVU2120: 2000 psi (13.8 MPa) [138 bar].
DVU2115: 1500 psi (10.3 MPa) [103 bar].
DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).

Installation 00-02-0483 page 1 of 4

TYPICAL INSTALLATION ON GAS COMPRESSORS

Fig. 3
Scrubber/Separators
Basic Operation
As condensate rises in the scrubber, the float
on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber.
Once the pressure enters the pilot chamber it
forces the diaphragm and valve stem forward
thus opening the valve seat (valve open/closed
indicator button pops out) and releasing condensate through the valve stem and out the
drain. As the condensate level drops, the
L1200NDVOR pneumatic valve closes to shut
off the pressure to the dump valve causing it to
close.
If for any reason the condensate continues to
rise beyond normal dump levels, model L1200
operates the alarm and/or shuts down the
equipment.
The L1200NDVOR Filter/Regulator and the
MURPHYGAGE help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.

NOTE: Always use clean, dry,


instrument quality gas.

The Murphy Gas Compressor Scrubber Level System (SLS)


The system provides for liquid control in gas scrubber
applications, by dumping liquids to drain and protecting
compressors with a high liquid level switch. Wetted metal
parts are made to survive
constant use in corrosive
environments.
See Bulletin: SLS-04005B for
more details.

High Level Shutdown Switch


Stainless steel float actuated level switches to alarm
and/or shutdown the equipment.
L1200: 2 NPT pipe connection; Rated 2000 psi
(13.7MPa) [137bar]; Class I, Division 1. SPDT
snap-switch standard. DPDT Optional.
All Stainless Steel available.

Filter/Regulator &
MURPHYGAGE

Control
Panel

Instrument
Quality Air/Gas
Supply

Pneumatic Level Control


Float actuated level snap-acting switch
controls pneumatic pressure to open
and close dump valve.

Pneumatic Dump
Valves See DVU-01069B

L1200NDVOR: Dump Valve Operator,

for more details.


Two piece union design with manual valve operator
allows soft plug and hard seat to be replaced without disassembling outlet piping or scrubber pipe
connection. Diaphragm actuated valves operate on
30-70 psi (207-483 kPa; 2-5 bar).

pressure regulator, and pressure indicating MURPHYGAGE.

DUMP VALVE INSTALLATION

DVU Series Installation


Upper Assembly
(removable)

CAUTION: ALWAYS USE NON-SPARKING TOOLS


WHEN GAS IS KNOWN TO BE PRESENT.

Valve
Union

Fig. 4
Typical
Dump Valve
Installation

Maintenance
Bolt
Valve Indicator
Vessel Wall

The following describes the Direct Mounting method to the


tank wall.
1. Install the valve so the drain connection is on the bottom. Use
pipe thread sealant on all the connections.
2. Be sure the unit is screwed tight and does not leak.
3. Install the piping for the pneumatic input signal into the
1/8 NPT threaded connection of the pressure inlet port (on
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the
condensate out line. Use pipe thread sealant on all the connections.

Pneumatic
Input Signal

Weep Hole
Drain
Connection
Union
Condensate Out
2-Way (Manual Drain)
Shutoff Valve

Installation 00-02-0483 page 2 of 4

REPAIR PROCEDURE

CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD


ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSIBLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED.

Suggested Tools (Sizes listed are wrench openings.


Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches,
flat edge screwdriver with 1/4 blade width, can also be used .)
Model

Valve Body

Union Nut

Plug Seal Hex

Stem Nut

3
3
3
2-1/4

3
3
3
2-1/4

7/8
1
1-1/4
3/4

1/2
1/2
1/2
3/8

DVU2120
DVU2115
DVU2105
DVU150/DVU175

Replacing the Plug and Seat


1. Close the pressure block valves (suction & discharge valves) on the inlet
and outlet of the skid. Lock them closed if possible.
2. Open the blowdown valve to remove pressure from the unit. Lock the
blowdown valve open if possible.
3. After taking all possible precautions to insure there is no pressure in the
vessel. (If the condensate line is pressurized, it must also be blocked and
locked.) Open the manual drain valve so it bleeds into the vessel so it
can also be bled down. Disconnect the pneumatic input signal connection
after insuring it also has been de-pressurized.
4. Using a back-up wrench on the valve body, with a quick "breaking"
action loosen the union nut on the valve. There is a "weep" hole in the
nut. If at any time while loosening and taking off the nut pressure is
escaping through the "weep" hole, immediately stop loosening the nut.
Retighten the nut and check the preceding procedures to ensure the pressure is bled off the vessel. Never remove the assembly if pressure is
coming through the weep hole. See Figure 4 on page 2.
5. With the upper assembly removed from the vessel the plug and/or seat can
be replaced. Loosen the 9/16 jam nut on the maintenance bolt on top of
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN.

Fig. 5
Plug

Seat

Stem

Stem
Packing

O-Ring Seals
Against Outlet

Washer(s)*

Stem
Nut

O-Ring

Crush Washer Seal

Seat butts into here

*Number of washers varies depending on the model from 1 to 3.

Fig. 6

Seal Washer
Pressure Inlet

Maintenance
Bolt
1/2" Nut

Diaphragm

Backup
Plate

1-1/8" or
1" round nut

Stem

Spring

Diaphragm
Housing

Diaphragm
Assembly

6. Using a back-up wrench on the plug, remove the stem nut on the shaft
under the plug. Once the stem nut is broken loose, the 9/16 head maintenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
removed. All soft seals should be replaced. Refer to kit part numbers
under service parts on page 4.

Replacing the Diaphragm


6A. If the diaphragm is to be replaced, all preceding steps have to be
done. Additionally, do the following:
6B. Loosen the 9/16 head maintenance bolt, allowing the diaphragm
spring to relax, and the stem to retract. Make alignment marks on
the top and bottom halves of the diaphragm assembly for alignment during re-assembly.
6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
together.
6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
or 1 round nut on the bottom of the diaphragm assembly to be
accessible to a wrench and not have the spring interfere. If it is
desired to replace the packing, pull the stem all the way out. The
packing can be easily removed using a small screwdriver to pry the
packing out. The new packing can be simply pressed in, making
sure the orientation of the packing installed is the same as the orientation of the packing removed. The packing is wider toward the
plug end. You will have to use the seat to hold the packing in place
when re-inserting the stem.
6F. With the 1-1/8" hex or 1 round nut held by a wrench, use a
wrench to loosen and remove the 1/2" nut on top of the diaphragm.
The diaphragm can now be removed and replaced.
6G. With the new diaphragm in place and the 1/2" nut tightened, place
the assembly, diaphragm down on a clean, smooth sturdy surface.
6H. Have the seat, plug, washers and stem nut handy (if any of these
parts are to be replaced, use the old parts for this procedure). Press
down evenly and smoothly on the bottom of the diaphragm assembly to cause stem to come up. Place the seat and plug in place.
Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
6J. Align the diaphragm holes to the bolt holes (bottom half of the
housing). Install the upper diaphragm housing using the alignment
marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180 around to the next bolt,
then either 120or 240 around to the next bolt and so forth until
all 8 bolts are evenly tight.
6K. Using the 9/16 head maintenance bolt, tighten, pushing the stem
out until the 9/16"bolt stops DO NOT OVERTIGHTEN.
6L. Remove the stem nut holding the plug. (If old parts were used, prepare to install the new parts now.)

7. Install the seat and plug. Place the O-ring on the stem, followed by the
washer and stem nut.
8. Tighten the stem nut. Loosen the 9/16 head maintenance bolt by at least one
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16 head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
leaking through the internal weep hole above that O-ring.
10. The assembly is ready to be re-installed. Check for relative position of
the pneumatic input signal connections before tightening the union nut.

Installation 00-02-0483 page 3 of 4

PRESSURE VS. FLOW CHART

Pressure vs. Flow for DVU150 and DVU175 models only

Fig. 7
250
250

200
200

Pressure (psid)

150
150

100
100

50
50

10

15

20

25

30

35

40

45

Flow (gpm)

SERVICE PARTS

Part No.

Typical Diaphragm Repair Kit includes:


Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate
(1 or 2 pcs.), Packing, O Ring, Stem, Seal Washer for Maintenance Bolt.

Description

DVU2120
55-00-0237
55-00-0236

Seal Kit (includes plug)


Diaphragm Kit

The DVU Series Valve is included in the


following Scrubber Levels Systems.

DVU2115
55-00-0241
55-00-0240

Seal Kit (includes plug)


Diaphragm Kit

(Includes L1200, L1200NDVOR, and DVU valve)


SLS2120: Includes DVU2120 valve
SLS2115: Includes DVU2115 valve
SLS2105: Includes DVU2105 valve
SLS175: Includes DVU175 valve
SLS150: Includes DVU150 valve
-LR: Less Regulator option

DVU2105
55-00-0245
55-00-0244

Seal Kit (includes plug)


Diaphragm Kit

DVU175
55-00-0230
55-00-0231

Seal Kit (includes plug)


Diaphragm Kit

DVU150
55-00-0230
55-00-0231

Seal Kit (includes plug)


Diaphragm Kit

Warranty

Typical Seal Kit includes: Nut, Washer (1 to 3), O Ring, Plug and
Seal, Seat, Crush Washer.

www.fwmurphy.com
918.317.4100 Email: sales@fwmurphy.com

A limited warranty on materials and workmanship is given with this FW


Murphy product. A copy of the warranty may be viewed or printed by going
to www.fwmurphy.com/support/warranty.htm

MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
(c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
their respective owners and are used for identification purposes only.

Installation 00-02-0483 page 4 of 4

Warning
All repair and resetting of safety relief valves should
be performed by a National Board certified valve
repair shop holding a VRstamp.
See engine assemblies for details
Service the PCC fuel filter every 800 hours.

Tubing Fitting, Item 43,


with 0.030" orifice supplies
positive head pressure to
hydraulic system.

Starter motor Ajax p/n BM-11679-Q-1.


Maximum inlet pressure = 90 psig.
Pinion-to-ring gear backlash = 0.020 to 0.030

Starter Pinion

1 travel (ref.)

Ring Gear
Flywheel
Adjust
main fuel pressure regulator
to 15 psig (typically).

0.06 minimum
minimum
engagement

(Ajax p/n 2040 6430)


(Fisher Type 627)

Starter Motor Gas Supply


Maximum pressure = 90 psig
Approximate maximum flow rate = 2028 scfm
(values based on typical natural gas properties)

Adjust PCC fuel shut off relay valve


(item 57) to actuate at 5 psig.
(Fisher Type 119)
Adjust PCC fuel (LE)
pressure regulator (item 58)
to 13-14 psig (typically).
(Fisher 64 Series)

"#
" # !$

2802LE Starter/Fuel Gas Piping


TP 02-22-T010-331-90

2802LE Starter/Fuel Gas Piping


TP 02-22-T010-331-90
Item

Description

P/N

Qty

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

Tubing " x 0.035 Wall


Tubing " x 0.035 Wall
Angle, 2" x 2" x " x 28" Lg.
Ball Valve, "NPT, 2000#
Ball Valve, 1"NPT
Ball Valve, 2" Spring
Bushing, "NPT x "NPT, 3000#
Bushing, "NPT x "NPT, 3000#
Bushing, 1"NPT x 1" NPT, 3000#
Bushing, 1"NPT x "NPT, 3000#
Bushing, 1"NPT x "NPT, 3000#
Bushing, 2"NPT x 1"NPT, 3000#
Elbow, 1"NPT, 2000#
Elbow, 1"NPT, 3000#
Elbow, 2"NPT, 2000#
Elbow, Male Tubing, " Tube x "NPT
Elbow, Male Tubing, " Tube x " NPT
Flat Bar, "NPT x 2" x 6" L
Gauge, 0-30 psig
Male Connector, " Tube x " NPT
Male Connector, "Tube x "NPT
Male Connector, 1" Tube x 1" NPT
Mercer Relief Valve, 1" In x 1" Out
Needle Valve, ", 6000#
Close Nipple, "NPT, Sch 80
Close Nipple, 2"NPT, Sch 80
Nipple, "NPT x 2" L, Sch 80
Nipple, "NPT x 3"L, Sch 80
Nipple, 1"NPT x 2L, Sch 80
Nipple, 1"NPT x 6"L, Sch 80
Nipple, 1"NPT x 8"L, Sch 80
Nipple, 2"NPT x 8"L, Sch 80
Pipe 1", Sch 40
Pipe 1", Sch 40
Pipe 2", Sch 80

5551 3504
5551 3504
7004 2020
2549 2004
2549 2006
2549 2012
2527 0402
2527 0604
2527 1410
2527 1004
2527 1002
2527 2010
2535 3010
2535 4010
2535 3020
2507 4204
2507 4202
7040 0420
2015 3312
2507 1404
2507 1202
2507 1808
63ME2M2FVA0080
2549 0057
2539 4200
2539 4909
2539 4408
2539 4414
2539 4610
2539 4626
2539 4628
2539 4928
4053 0102
4053 0102
4053 0205

55"
73"
1
1
1
1
1
2
1
1
1
3
1
1
2
3
2
1
2
1
1
2
1
2
1
1
1
2
4
2
1
1
13"
12"
27"

36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

Description
Pipe 2", Sch 80
Pipe 2", Sch 80
Pipe 2", Sch 80
Pipe 2", Sch 80
Plug, Hex Head, 2"NPT, 3000#
Fuel Shutdown Valve, 2"NPT
Street Elbow, 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

2802LE Starter/Fuel Gas Piping


TP 02-22-T010-331-90

P/N
4053 0205
4053 0205
4053 0205
4053 0205
2541 6020
2090 2521
2535 8014
2507 1325
2545 4004
2545 4002
2545 4010
2545 4020
2507 6205
5551 3508
5551 4908
5551 4916
1590 0100
1590 0103
2547 5010
2547 5020
7020 2558
BM-16089-K
2-04V-034-003

Qty
11"
15"
23"
58"
2
1
1
1
1
1
3
2
1
15"
48"
14"
1
3
1
2
2
1
1

M2582, M5081, and M5180 Series


Electromechanical and Pneumatic, Fuel Gas Shutoff Valves Installation and Operation Instructions

M-7980N
Revised 11-02
Section 55
(00-02-0206)

Please read the following instructions before installing. A visual inspection of this product for damage during shipping is
recommended before mounting. It is your responsibility to have a qualified person install the unit and make sure installation
conforms with NEC and local codes.
GENERAL INFORMATION

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

Model M5081
Approved*

M2582 and M5081Series


Tripping Power From Engine Ignition System or Battery
(Models available for magneto, CD ignition or 12/24 V battery)
These fuel shut-off valves are semi-automatic devices for shutdown of
natural gas fueled engines. The standard valve opens by manual
operation of the reset handle. A latch in the upper body of the valve will
set and hold the valve open. At this point no electric power is used.
The electromagnetic coil is de-energized, the snap-switch(es) is SET.
If a SWICHGAGE contact closes, a circuit is completed from power
through the snap-switch and coil. Now energized, the electromagnet
trips the latch, (latch can be tripped manually), the valve closes, and the
snap-switch resets. Power switches from the coil circuit to your choice
of an open line, an electrical ground, or an alarm. After tripping, the
vent seal opens, and on the M50 models, the open/close indicator (green
button) retracts to indicate that the valve is closed.
Valve body is sandcast aluminum. Optional cast steel for M5081 models.
M2582-P and M5180-P
MURPHY-NUMATIC Pneumatic Version for Pressure
The M2582-P and M5180 pneumatically controlled valves can operate
from pressure, and are designed to open and close automatically or semiautomatically (the supply can be air, oil or gas).
NOTE: If using oil as a pressure source, use a lightweight oil.
These valves will open on rising control pressure and close on
decreasing control pressure. M2582-P and M5180-P automatically open
at 2 psi (14 kPa) [0.14 bar] and fully open at 3 psi (21 kPa) [0.21 bar].
All models include a built-in lever to aid in opening the valve manually.
The M2582-P can be manually opened against inlet pressure of 80 psi
(552 kPa) [5.52 bar]. The M5180-P valve can be opened against inlet
pressure of 100 psi (689 kPa) [6.89 bar].
Standard models include an escape vent for gas trapped forward in the
line after shut-off.

M5081FS
Normally Energized Circuit
The M5081FS is manually opened, electrically latched open and tripped
by interrupting the coil power circuit.

Magnetic Switch Adapter

As ignition systems wear from usage, their power output becomes less
and less. Ignition may not have the capacity to reliably trip the Fuel
Valve. Therefore, the use of a Magnetic Switch Adapter for CD
ignition systems is recommended. The Magnetic Switch Adapter is a
device that stores energy from the CD ignition to trip the Fuel Valve.
Three models are available:
65700053 (was 65020126): For use with negative ground ignitions
up to 240 VDC.
65700054 (was 65020127): For use with positive ground ignitions
up to 450 VDC.
65700055 (was 65020155): For use with negative ground ignitions
up to 450 VDC.

100 ohm, 2 watt Resistor

For Capacitor Discharge Ignitions that are specified to be grounded when


the valve closes, and a Magnetic Switch Adapter is in use. The resistor
must be connected in the system to prevent damage to the snap-switches
in the fuel shut-off valve (see typical wiring diagrams).

Diode Package

The Murphy diode package (65010065) is designed to allow the fuel shutoff valve to be used with dual Magneto Ignition systems.
NOTE: All aluminum versions of the M5081 Series Fuel Valve carry
Canadian Registartion Number OC1476.2.
* M5081 model is CSA approved for Class I, Division 1, Groups C and D.
See Specifications on page 12.

Installation M-7980N page 1 of 12

VALVE CUT-OUT

FLOW CHARACTERISTICS

Understanding the Basic Operation


of the Fuel Shut-off Valve
M2582 Series
4 oz
. (0.
11 k
g.)
10 o
5 ps
z. (0
ig (3
.28 k
4 kP
g.)
10 p
a) [
0.34
sig
(69
bar]
kPa
) [0
20
.69
psi
bar
g (1
]
38
kPa
) [1
30
.38
psi
bar
g (2
]
07
kPa
) [2
.07
bar
]

10.0
[254.0]

Inches water column (p) drop across valve.


Millimeters water column in brackets [ ].

9.0
[228.6]
8.0
[203.2]
7.0
[177.8]
6.0
[152.4]

The valve below is shown in the run (open) position.


Pressure is equalized, seat (B) is open, allowing
the fuel to flow. When valve is in the tripped position
(closed), seat closes (C).
The vent (D) opens to relieve trapped downstream fuel
to vent to a non-hazardous area.
TYPICAL MODEL (M5081) SHOWN

5.0
[127.0]

Terminal Block is
within this case.

4.0
[101.6]
3.0
[76.2]

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.)

Inches water column (p) drop across valve.


Millimeters water column in brackets [ ].

M5081 and
M5180 Series

3.0
[76.2]

2.0
[50.8]

ar]
9b
) [.6
a
P
k
bar]
(69
sig
[1.38
10 p 38 kPa)
1
bar]
sig (
2.07
20 p
Pa) [
k
7
0
ig (2
30 ps

1.0
[25.4]

500
1000 1500 2000 2500 3000 3500 4000 4500 5000
[14.16] [28.32] [42.48] [56.64] [70.80] [84.96] [99.12] [113.28] [127.44] [141.60]

H Pipe Plug (remove to


install vent tube).

A. Main Stem
B. Pressure Disc/seal (in run/open)
C. Pressure Disc/seal (in trip/closed)
D. Vent Seal Gland
E. Reset Knob (latches valve open)
F. Manual Trip Knob (not available for M5081FS)
G. Indicator Button (out with valve open)
H. Pipe Plug

Standard cubic feet per hour. Cubic meters per hour in brackets [ ].

NOTE: If the vent-after-tripping feature is not used,


remove O-ring (D), to avoid condensation accumulation
that can hamper trip action.
Be sure to replace Pipe Plug (H) and to clean vent
periodically.

Installation M-7980N page 2 of 12

DIMENSIONS
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.

M2582

M2582-P
1/2 NPT Conduit
Connection

Reset Knob

1/4 in. (6 mm) tube connection; control


pressure 3 psi (21 kPa) [0.21 bar] minimum,
75 psi (517 kPa) [5.17 bar] maximum.

Latch Arm (see NOTE)

Manual Trip
Knob
1 NPT
(2 places)

Breather/Vent
1/16 in. (2 mm)
1 NPT
(2 places)

1/4 NPT
Vent and Plug

6-9/16 in.
(167 mm)

1/4 NPT
Vent and
Plug

7-5/16 in.
(186 mm)

3-3/32 in.
(79 mm)
5-1/2 in. (140 mm)

3-3/32 in.
(79 mm)
5-1/2 in. (140 mm)

NOTE: Thumb operated opening latch (2.5 psi [17 kPa]


[0.17 bar] required to release cocking latch)

M5180-P
Latch Arm (see NOTE 2)

Breather Vent
(see NOTE 1)

6-1/8 in.
(156 mm)

10-7/16 in. (265 mm)


1/4 in. (6 mm)
connection;
control pressure
3 psi (21 kPa)
[0.21 bar] minimum,
80 psi (552 kPa)
[5.52 bar] maximum
(see NOTE 1)

2 NPT
(2 places)

4-3/8 in.
(111 mm)

Vent and Plug


1/2 NPT
4-1/4 in.
(108 mm)

9-3/8 in. (238 mm)

NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control.
NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch).

65700053

Magnetic Switch Adapters


65700054 (was 65020127); 65700055 (was 65020155)

(was 65020126);

2-5/16 in. (59 mm)


1-15/32 in.
(37 mm)
Panel Mount screws
10-24 N.C. x
5/16 in. (8 mm) long

3/8 in.
(10 mm)

2-5/8 in. (67 mm)

1-23/32 in.
(44 mm)

31/32 in.
(25 mm)
15/32 in.
(12 mm)

GND ALT1

Terminal screws
8-32 N.C. x
1/4 in. (6 mm) long
Installation M-7980N page 3 of 12

ALT2

SW

2-7/16 in.
(62 mm)

DIMENSIONS continued
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.

M5081 and M5081FS


Manual Trip Knob
(M5081 only)

Reset Knob

Inlet
Breather

1/2 NPT Conduit


Connection (2 plcs.)

1-3/8 in. (35 mm)

10-5/16 in.
(262 mm)
3-7/16 in.
(87 mm)

Indicator
Button

2 NPT
(2 places)

Vent and Plug


1/2 NPT

4-1/16 in.
(103 mm)

3 in. (76 mm)


9-3/8 in. (238 mm)

7-3/4 in. (197 mm)

M5081-3 Steel Flanged Option

45
3-5/8 in.
(92 mm) dia.

2 in. (51 mm) dia. 2 places


150# RF (raised face) pipe flange
14-25/64 to 14-29/64 in.
(366/367 mm)

Installation M-7980N page 4 of 12

3/4 in. (19 mm) dia.


(4 places) each end
equally spaced on a
15/32 in. (121 mm) b.c.
(bolt circle)

INSTALLATION
WARNING: STOP THE ENGINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION. BEGIN THE
INSTALLATION BY SECURING AREA OF ANY HAZARDOUS CONDITIONS. SHUTOFF THE FUEL GAS SUPPLY. FOR HAZARDOUS
APPLICATIONS REFER TO NATIONAL ELECTRICAL CODE SPECIFICATIONS.

Connecting the Fuel Shut-off Valve

Figure 1
1. Before connecting the unit, apply pipe dope to plumbing male threads
Physical Location and Plumbing (typical)
that will be inserted into the valve. Do not apply pipe dope to the valve.
2. Make sure that the arrow on the side of the valve indicates the correct
Fuel Shut-off Valve
direction of the flow.
3. Fuel shut-off valves can be installed in all three planes. However, Master Regulator
Bypass
Fuel
mounting the valve horizontally (with vent pointing down) is (High pressure)
Regulator
Filter Carburetor
recommended. Do not install valve with top down. (Refer to Figure 1.)
4. Hold valve in position, (use a tool on valve wrench flats) and tighten
plumbing into inlet and outlet ends. (Refer to dimensions on pages 3-4.)
Wrench Flats

CAUTION: DO NOT TWIST THE VALVE BODY HOUSING.

5. To mount flanged models, follow the appropriate installation codes


and ordinances for the application. (For dimensions see page 4.)
6. A vent line (to allow gas trapped forward between fuel valve and the
carburetor to escape) should be attached to the vent connection at the
bottom of the valve housing. Remove the plug and install the line.
(Refer to Figure 1.)

FUEL FLOW

Remove plug and attach vent line.


Route to non-hazardous area.

Figure 2
Pull the lever up, and press the latch
down into ridge with thumb.

Connecting Pneumatic Models


M2582-P and M5180-P
1. Repeat the steps above (1 thru 5), and observe the necessary cautions.
2. A lever/arm (handle) and a cocking latch are provided to allow manual
opening of the valve. The thumb-operated latch can be locked in place
to hold the lever/arm latched. The cocking latch will be released when
pilot pressure reaches 2.5 psi (17 kPa) [0.17 bar]). M2582-P and
M5180-P automatically open at 2 psi (14 kPa) [0.14 bar], and fully
open at 3 psi (21 kPa) [0.21 bar]. See Specifications, page 12 for
maximum control pressure.

Level Arm (Handle)


Control Pressure
Connection

CAUTION: BE SURE PNEUMATIC SOURCE


RELEASES THE MECHANICAL LATCH WHEN RUNNING.

3. If vacuum control is desired, swap the Control Pressure connection


fitting and the Breather Vent fitting on your M5180-P model (see Fig. 2).

Installation M-7980N page 5 of 12

Thumb-operated
Cocking Latch
Breather
Vent

WIRING INFORMATION
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE OFF AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT
WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.

M2582 Internal Wiring

Wiring shown in normal mode of operation (seat open). The 20 AWG


(0.75 mm2) wire is color coded to the coil:
For CD ignitions: White and Orange
For Magneto ignitions: White and Green
For Battery: White and Blue
Conduit Installation
Install a 1/2 NPT conduit from the M2582 conduit connection to the
power source. See M2582 Dimensions (page 3) for location.
For wiring the M2582 fuel valve to Solid-State TATTLETALE
annunciators, refer to pages 9, 10, and 11.

M5081 Internal Wiring

Wiring shown in normal mode of operation (seat open). The 18 AWG


(1.0 mm2) wire is color coded to the coil:
For CD Ignitions: White and Orange
For Magneto Ignitions: White and Green
For Battery: White and Blue

Internal Wiring
for M2582
Optional
Resistor
(Note)

White
Black

NOTE:
For grounding the ignition (CD models only)
through the fuel valve snap-switch, use a
Magnetic Switch Adapter (see Magnetic
Switch Adapter, below) and install a 100
ohm; 2 watt resistor (included on page 11).

M5081 Internal
Wiring

Valve
Coil

Red

Ground

Disconnect
Switches
Ignition 1
Ignition 2

Conduit Installation
Install a 1/2 NPT conduit from the M5081 conduit connection to the
power source. Refer to Dimensions (on page 4) for location.
Ground

For typical wiring of the M5081 models refer to pages 7 and 8.


For wiring the M5081 fuel valves to Solid-State TATTLETALE
annunciators, refer to pages 9, 10, and 11.

M2582-C-LS Wiring
White

Orange

White

Orange

FV+ (IGN)

FV+ (IGN)

For typical Wiring refer to page 8.


For wiring the M5081FS to MARK IV 12/24 refer to page 10.

Valve
Coil
(Note)

8 7 6

3 2 1

Jumper

Optional
Resistor
(See Note)

FV

M5081FS Internal Wiring

Switch 2

Jumper

M5081-C-LS Wiring

FV

Ground

10 9

NOTE: For grounding the ignition (CD models only) through the fuel
valve snap-switches, use a Magnetic Switch Adapter, see Magnetic
Switch Adapter, below and the TO CLOSE THE FUEL VALVE and
GROUND THE IGNITION attachment, and install a 100 ohm; 2
watt resistor (included with your attachment).

Magnetic Switch Adapters for Use with


Capacitor Discharge Ignitions
Connect the Magnetic Switch Adapter between the fuel Valve
terminal 1 and the CD Ignition. See wiring diagrams (pages 7 and 11).

Switch 1

65700053 (was 65020126): For use with


negative ground ignitions up to 240 VDC.

65700054 (was 65020127): For use with


positive ground ignitions up to 450 VDC.
10 9

8 7 6

65700055 (was 65020155): For use with


negative ground ignitions up to 450 VDC.

3 2 1

GND

ALT
1

IN4007

ALT
2

SW

Negative ground
Magnetic Switch Adapter shown

NOTE: Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2)
wire is red color for both options: 12 VDC and 24 VDC.
Installation M-7980N page 6 of 12

TYPICAL WIRING for M5081-C (CD IGNITION MODELS)

M5081-C
CD Ignition Models
GND ALT1 ALT2 SW

Terminal Block

10 9

8 7 6

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.

TYPICAL WIRING for M5081-B (BATTERY IGNITION MODELS)

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

Installation M-7980N page 7 of 12

6 1

4 5

To additional
TATTLETALE

TYPICAL WIRING for M5081-A (MAGNETO IGNITION MODELS)

M5081-A
Magneto Ignition Models
Terminal Block

10 9

8 7 6

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.

TYPICAL WIRING for M5081FS (NORMALLY ENERGIZED MODELS)

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

Installation M-7980N page 8 of 12

Diode
* forIN4005
flyback protection

TYPICAL WIRING to SOLID-STATE TATTLETALE Annunciators


WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE OFF AND THE AREA MADE NON-HAZARDOUS.

MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD
CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.

M2582-C to LCDT-PS-CD (R)-P (positive ground)

M5081-C to LCDT-PS-CD (R)-P (positive ground)

LCDT-PS-CD (R)-P
M2582 Fuel Valve

White

IGN 1

10 9

GND

Black
Red

jumper

NO

3 2 1

IGN 1

jumper

FV(-)

Relay
Contacts

Relay
Contacts

NO
C
NC

* FV(-) FET output rated: 0.5 A @ 250 VDC max.

Ground

Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC

Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC

M2582-C to LCDT-PS-CD-N (negative ground)

M5081-C to LCDT-PS-CD-N (negative ground)

LCDT-PS-CD-N

Red

FV

Black

GND

NC

White

8 7 6

FV(+)
FV(-)

M2582 Fuel Valve

LCDT-PS-CD (R)-P
Terminal block

M5081 Terminal block

IGN 1

10 9

FV(+)
FV(-)

LCDT-PS-CD-N
Terminal block

M5081 Terminal block

8 7 6

3 2 1

IGN 1
FV(+)

FV(-)

GND

jumper

NO

jumper

Relay
Contacts

C
NC

GND

Relay
Contacts

NO
C
NC

* FV(-) FET output rated: 0.5 A @ 250 VDC max.

Ground

Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC

* Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC

M2582-C to MARK IV-N (negative ground)

M5081-C to MARK IV-N (negative ground)


M5081 Terminal block

M2582 Fuel Valve


+

White

10 9

8 7 6

3 2 1

jumper

Ground

jumper

GRD
F/VF/V+
IGN 1

Red

MARK IV-N
terminal block

* MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.

Installation M-7980N page 9 of 12

GRD
F/VF/V+
IGN 1

Black

MARK IV-N *
terminal block

TYPICAL WIRING to SOLID-STATE TATTLETALE Annunciators


WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE OFF AND THE AREA MADE NON-

HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.

M5081FS to MARK IV-12/24

M5081-B to MARK IV-12/24


M5081-B

M5081FS Terminal Block

8 7 6

3 2 1

10 9

Diode
* forIN4005
flyback protection

8 7 6

jumper

M5081FS Terminal Block

3 2 1

12/24
S/D
FV
ALM
GRD

MARK III has FET outputs rated:


0.5 A @ 250 V max.
Auxiliary Relays must be
hermetically-sealed, third party
certified for use in Class I,
Division 2, Gps. C & D areas.

*
*

K2

+
+

*
+

K2

K2 K1

+
-DC Power
source

MARK IV-12/24
terminal block

MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.


Remove shunt jumper E2 for ignition ground time delay.

M5081 Terminal block


10 9

8 7 6

Alarm Relay
K1

Power
Supply

3 2 1

Ignition

jumper

Auxiliary Relay

K1

K1

M5081-C to MARK III-N

+
-12/24 VDC
Power source

MARK III-12/24
terminal block

* IN4005 Diode for flyback protection


2

jumper

* for flyback protection

3 2 1

IN4005 Diode

MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.

8 7 6

+
-DC Power
source

M5081FS to MARK III-12/24

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

IGN 90-250 Vdc


+FV
-FV
ALM
GRD

jumper

* IN4005 Diode for flyback protection

MARK III-N

MARK III has FET outputs rated:

terminal block

0.5 A @ 250 V max.

Alarm Relay must be

hermetically-sealed, third party


certified for use in Class I,
Division 2, Gps. C & D areas.

M2582-C to TTDJ-IGN-(T)

M5081-C to TTDJ-IGN-(T)
M5081 Terminal block
10 9

8 7 6

jumper

jumper

M2582 Fuel Valve

3 2 1
IGN
NA
GRD
FV+
FVALR
NA
NA

Installation M-7980N page 10 of 12

White
Black

Red

+
IGN
NA
GRD
FV+
FVALR
NA
NA

TYPICAL WIRING to SOLID-STATE TATTLETALE Annunciators continued


WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE OFF AND THE AREA MADE NONHAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.

(B) M2582-B to TTDJ-DC-(T)

(A) M5081-B to TTDJ-DC-(T)

10 9

8 7 6

jumper

To 12 or 24 VDC
power supply

To 12 or 24 VDC
power supply

M5081 Terminal block

M2582 Fuel Valve

3 2 1

jumper

K2

Black

SD
10-32VDC
GRD
NA
FV
ALR
MPU
GRD

K1

* 1N4005 diode for flyback protection.

TTDJ-DC-(T) to Relays
Connections Shown for Use with
Diagrams (A), (B), (C), and (D) on this page.

10 9

8 7 6

K1 and K2 are hermetically Sealed


auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas.

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

K1 and K2 are hermetically Sealed


auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas.

M5081FS Terminal Block

12-24 VDC
Power supply

M5081FS to TTDJ-DC-(T)

K1

K2

Red

K1 and K2 are hermetically Sealed


auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas.

IGNITION RELAY +

SD
10-32VDC
GRD
NA
FV
ALR
MPU
GRD

White

* 1N4005 diode for flyback protection.

* 1N4005 diode for flyback protection.

(C) M2582-C w/Magnetic

(D) M5081-C w/Magnetic

Switch Adaptor to CD Ignition


Magnetic
Switch
Adapter

Switch Adaptor to CD Ignition

GND ALT1 ALT2 SW

M2582 Fuel Valve

White

K2

Black

10 9

8 7 6

3 2 1
+

jumper
Red

GND ALT1 ALT2 SW

M5081 Terminal block

jumper

K2
1

K2 is hermetically sealed auxiliary relay, third party


certified for use in Class I, Div. 2, Gps. C & D areas.

K2 is hermetically sealed auxiliary relay, third party


certified for use in Class I, Div. 2, Gps. C & D areas.

Installation M-7980N page 11 of 12

Magnetic
Switch
Adapter

SPECIFICATIONS
Valve Body: Sandcast aluminum, painted red (corrosion resistance);
Optional cast steel available for M5081 and M5081FS models only.
Valve Seat: Buna-N
Maximum Valve Inlet Pressure:
M2582/M2582-P: 80 psi (552 kPa) [5.52 bar]
M5081/M5081FS/ M5180-P: 100 psi (689 kPa) [6.89]
Maximum Control Pressure (Pneumatic Models):
M2582-P: 75 psi (517 kPa) [5.17 bar]
M5180-P: 80 psi (552 kPa) [5.52 bar]
Snap-switch: M2582: One SPDT, 5 A @ 480 VAC
M5081, and M5081FS: Two SPDT, 5 A @ 480 VAC
Wiring: M2582: Wire leads; M5081, and M5081FS: Terminal blocks
NOTE: All aluminum versions of the M5081 Series Fuel Valve carry
Canadian Registartion Number OC1476.2.
SERVICE PARTS
Coil Assembly
Battery
CD Ignition
Magneto Ignition

Coil Rating: Intermittent duty; coil type must match power source;
CD ignition coil resistance: 72
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

----------------------------------

----------------------------------

----------------------------------

M5081FS Coil Assembly


12 VDC
24 VDC
Latch Block Assembly
Latch block assembly
Latch block switch and coil assembly
Latch block switch and mounting bracket assembly

-----------------------

-----------------------

55000158
55000159

-----------------------

------------

55000095
-----------------------

55000074
-----------55000118

----------------------55000196

----------------------------------

----------------------------------

Handle and Latch Kit


Handle and latch kit
Handle kit

-----------55000096

55000102
------------

55000102
------------

5500148
------------

55000154
------------

Manual DIsconnect Assembly

55000097

55000137

---------------

---------------

---------------

Snap Switch Assembly

55000098

55000072

55000160

---------------

---------------

------------

Close/Open Indicator Assembly

------------

55000138

55000138

---------------

---------------

Stem and Seat Kit

55000093

55000075

55000135

55000147

55000135
55000155

Top Works Complete Valve Less Body and Vent

55000146

55000131

55000161

55000150

Vent Bushing Assembly

55000143

55000132

55000132

55000143

55000132

55000184

55000153

Diaphragm Assembly

------------

------------

------------

Pilot Diaphragm

------------

------------

------------

00007908

55050420

Diode Package for Dual Magneto Ignitions

------------

65010065

------------

------------

------------

Magnetic Switch Adapter for CD Ignitions


Single/Dual ign. negative ground up to 240 VDC

65700053

65700053

------------

------------

------------

Single/Dual ign. positive ground up to 450 VDC

65700054

65700054

------------

------------

Single/Dual ign. negative ground up to 450 VDC

65700055

65700055

------------

------------

-----------------------

Warranty

A two year limited warranty on materials and workmanship is provided with this Murphy product.
Details are available on request and are packed with each unit.

FWMurphy
P.O. Box 470248
Tulsa, Oklahoma 74147 USA
(918) 317-4100
fax (918) 317-4266
e-mail sales@fwmurphy.com
www.fwmurphy.com

CONTROL SYSTEMS & SERVICES DIVISION


P.O. Box 1819; Rosenberg, Texas 77471; USA
(281) 342-0297 fax (281) 341-6006
e-mail sales@fwmurphy.com
MURPHY DE MEXICO, S.A. DE C.V.
Blvd. Antonio Rocha Cordero 300, Fraccin del Aguaje
San Luis Potos, S.L.P.; Mxico 78384
+52-444-8206264 fax +52-444-8206336
Villahermosa Office +52-993-3162117
e-mail ventas@murphymex.com.mx
www.murphymex.com.mx

FRANK W. MURPHY, LTD.


Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
+44 1722 410055 fax +44 1722 410088
e-mail sales@fwmurphy.co.uk
www.fwmurphy.co.uk

MACQUARRIE CORPORATION
1620 Hume Highway
Campbellfield, Vic 3061; Australia
+61 3 9358-5555 fax +61 3 9358-5558
e-mail murphy@macquarrie.com.au

Installation M-7980N page 12 of 12

RE

MURPHY SWITCH OF CALIFORNIA


41343 12th Street West
Palmdale, California 93551-1442; USA
GI
STER
(661) 272-4700 fax (661) 947-7570
e-mail sales@murphyswitch.com
www.murphyswitch.com
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A.

0966106

Type 119

Instruction Manual

Fisher Controls

Type 119 Control Valve

June 1990

Form 5204

Introduction
Scope of Manual
This instruction manual provides installation, spring adjustment, maintenance, and parts information for the Type 119
control valve.

Description
The Type 119 control valve (figure 1) is used for on-off or
throttling control of noncorrosive or mildly corrosive liquids
and gases. It is designed to meet the low-pressure liquid
and gas application requirements in many varied industries.
As loading pressure is applied to the Type 119 control valve
diaphragm, the disk holder is pulled off the orifice. As loading pressure is reduced, the opposing spring force moves
the disk holder toward the closed position, resulting in
spring-close action should a loss of supply pressure occur.

W3735-1

Figure 1. Type 119 Control Valve

Specifications
Table 1 lists specifications for the Type 119 control valve.
Some of the specifications for a given control valve as it
originally comes from the factory are stamped on a nameplate (figure 2) located on the spring case flange.

the service conditions do not exceed the limits shown in table 1. The leak-off and spring
case vents must be kept open. To avoid danger of fire or explosion from venting of flammable or otherwise hazardous fluid into a
closed or poorly vented location, pipe the
vents to a well-ventilated location, away
from any buildings or windows so as not to
create a further hazard.

WARNING
To avoid personal injury or property damage
caused by controlled process fluid or bursting of pressure-retaining parts, be certain
eFisher Controls International, Inc. 1982, 1990; All Rights Reserved

2. The control valve can be installed in any position, but


the normal orientation is with the actuator portion vertical
above the body. If installing the control valve at an outside
location, point the spring case and bonnet vents in the
downward direction to protect them from moisture or foreign
materials.

D100261X012

1. Before installing the valve, be sure the valve body and


associated equipment are free of damage and foreign material.

Installation

Type 119
Table 1. Specifications
Maximum Inlet Pressure(1)
150 psig (10.3 bar)
Spring Ranges

Material Temperature Capabilities(1)


With Nitrile Elastomers: -20 to 170_F (-29 to 77_C)
With Fluoroelastomers: 0 to 250_F (-18 to 121_C)
Note: Not for use with hot water or ammonia.
Flow Direction
Up through the seat ring

See table 2
Maximum Control Pressure to Diaphragm
150 psig (10.3 bar)
Maximum Pressure Drop(1)
150 psi (10.3 bar) for all port diameters

Spring Case Vent and Bonnet Leak-Off Connection


1/4-inch NPT female
Approximate Weight
6 lb (2.7 kg)

1. The pressure and temperature limitations in this manual, and any applicable code
limitation, should not be exceeded.

Table 2. Spring Selection


SPRING RANGE
Psig

Bar

3-15
5-20
5-35
30-60

0.2-1.0
0.3-1.4
0.3-2.4
2.1-4.1

SPRING PART
NUMBER
1D8923 27022
1D7515 27022
1D6659 27022
1D7455 27142

SPRING
COLOR
CODE
Red
Cadmium
Blue
Green

1E5427-F

Material
Code
AI/N
SST/N
SST/V

Orifice
Seat Disk Material
Aluminum/Nitrile
Stainless steel/Nitrile
Stainless steel/Fluoroelastomer

Spring Adjustment

Figure 2. Type 119 Nameplate

The control valve spring has been selected to meet the


pressure condition requirements of the application as specified on the order. This pressure condition is stamped on
the actuator nameplate.

3. Install the valve using accepted piping practices. Make


sure that the valve is oriented so that flow through the body
will match the flow direction arrow on the body.

The spring has a fixed pressure span over which loading


pressure will stroke the valve. Adjustment of the spring
compression shifts the span so that more or less loading
pressure is required to start travel. Since the span does not
change, there will be a corresponding increase or decrease
in the pressure requirements at the end of the valve stroke.

4. If continuous operation is required during maintenance


and inspection, install a three-valve bypass around the control valve.
5. Connect the control pressure line to the 1/4-inch NPT
connection in the valve body bonnet marked PILOT.

If the control valve has been disassembled or pressure


conditions have changed, the spring may need adjustment
to make the valve travel coincide with the diaphragm pressure range. Make the adjustment in the following manner.
Key numbers refer to figure 3.

Type 119
1. Loosen the locknut (key 13) on the spring case.
2. Turn the adjusting screw (key 12) clockwise to
compress the spring (key 16) or counterclockwise to
decrease spring compression. Increased spring compression results in increased loading pressure necessary to
start travel. Decreased spring compression results in less
loading pressure required to start travel.
3. After adjustment, tighten the locknut. Note that the
spring can be identified by the color code. Depending on
how much conditions are changed, it may be necessary to
install a new spring, using appropriate steps in the Maintenance section. After changing the spring, adjust the valve
using the above steps in this section, and indicate the new
spring range on the nameplate.

7/8-inch socket wrench, and replace it with a new seat ring


of the proper size.
4. Remove the bonnet O-ring (key 11), and inspect it for
wear and damage.
5. Unscrew and remove the spring case cap screws (key
14). Remove the spring case, upper spring seat, and spring
(keys 2, 17 and 16). Do not lose the nameplate (key 20)
when removing the spring case.
6. Pull the hair pin clip (key 6) from the stem and remove
the disk holder assembly (key 4).
7. Pull the diaphragm/stem assembly (key 5) out of the
bonnet (key 9), and inspect for damage or deterioration. If
necessary, replace the entire diaphragm assembly.
8. Without removing the O-rings and bushing spacers
(keys 8 and 7) inspect their inside diameter surfaces for
damage or deterioration.

Maintenance
Valve parts are subject to normal wear and must be
inspected and replaced as necessary. Inspection and
maintenance depends on the severity of the service
conditions.

WARNING
To avoid personal injury or property damage
caused by sudden release of pressure or
uncontrolled process fluid, isolate the
control valve from the pressure system, and
release all pressure from the valve body and
actuator before performing maintenance
operations.
The following describes the procedure for complete
disassembly and assembly of the actuator-valve body
combination. When inspection or repairs are required,
disassemble only those parts necessary to accomplish the
job. Key numbers refer to figure 3.

Disassembly
1. Isolate the control valve from all pressure, and release
pressure from the valve body and actuator. Loosen the locknut (key 13), and remove all spring compression from the
control valve by turning the adjusting screw (key 12) out of
the spring case.
2. Remove the two bonnet cap screws (key 15, not shown)
that secure the bonnet to the body, and lift the spring case,
bonnet, and trim assembly from the body.
3. Examine the seating edge of the orifice (key 3). If it is
nicked or rough, unscrew it from the body with a thinwall
1. Trademark of Never-Seez Corp.
2. Trademark of Tretolite Div. of Petrolite Corp.

Note
The following step should be performed
only when there is an indication of O-ring or
bushing spacer failure.
9. Remove the internal retaining rings, stem wipers, Orings, and bushing spacers (keys 10, 19, 8 and 7). Inspect
these parts for wear or deterioration, and replace if necessary.

Assembly
This procedure assumes that the control valve has been
completely disassembled. If the control valve has been only
partially disassembled, start these instructions at the appropriate step.
1. If the orifice (key 3) was removed during disassembly,
lubricate the threads with Never-Seez(1) lubricant (key 21)
or equivalent, and screw it into the valve body using a thinwall 7/8-inch socket wrench.
2. Lubricate the bushing spacers, O-rings, stem wipers,
and internal retaining rings (keys 7, 8, 19 and 10) with Dow
Corning(2) No. 111 silicon-base lubricant (key 22) or equivalent, and install as shown in figure 3.
3. Carefully slide the diaphragm assembly (key 5) into and
through the O-rings and bushing cavity. Turn the diaphragm
assembly to line up the diaphragm holes with the bonnet
holes.
4. Slide the disk holder assembly (key 4) all the way into
the stem. Connect the disk holder assembly with the hair pin
clip (key 6).
5. Coat the bonnet O-ring (key 11) with Dow Corning No.
111 lubricant (key 22) or equivalent. Install the O-ring in the
recessed notch in the bonnet (key 9).
3

Type 119
6. Mount the bonnet (key 9) on the valve body (key 1), insert two cap screws (key 15, not shown), and tighten to 7
foot-pounds (9 newton-meters).

Key

Part Kits
Kits include keys 4, 5, 6, 8, 10, 11, and 19.
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/aluminum
disk holder nitrile diaphragm, and
nitrile disk & O-rings
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/aluminum disk
holder, nitrile diaphragm and nitrile
disk & O-rings
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/stainless
steel disk holder, nitrile diaphragm
and nitrile disk & O-rings
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/stainless steel disk
holder, nitrile diaphragm and nitrile
disk & O-rings
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/stainless
steel disk holder and fluoroelastomer
diaphragm, disk, & O-rings and
stainless steel disk holder
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/stainless steel disk
holder and fluoroelastomer diaphragm,
disk & O-rings

7. Put the spring (key 16) on the diaphragm assembly (key


5), and place the upper spring seat (key 17) in the end of the
spring.
8. Lubricate the point and threads of the adjusting screw
(key 12) with Never Seez lubricant (key 21) or equivalent.
9. Position the spring case (key 2) and nameplate (key 20)
on the diaphragm assembly (key 5). Insert the cap screws
(key 14).
10. Tighten all cap screws until finger tight. Then, following
a crisscross pattern, tighten each cap screw.
11. Connect the control piping to the control connection in
the bonnet.
12. Adjust the spring by following the procedures in the
Spring Adjustment section, and remark the nameplate if
necessary.

When contacting your Fisher sales office or sales representative for technical assistance or ordering replacement
parts, include the type number and all other pertinent information stamped on the nameplate attached to the spring
case.

Parts List
Key

Part Number

Note
In this parts list, parts marked NACE are intended for corrosion-resistant service as detailed in the National
Association of Corrosion Engineers (NACE) standard
MR-01-75.

Description

Part Number

R119X 000A12

R119X 000A22

R119X 00SN12

R119X 00SN22

R119X 00SV12

R119X 00SV22

NACE Construction
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm),
5/16 (7.9 mm), and 3/8 (9.5 mm) inch orifices
w/aluminum disk holder, fluoroelastomer
diaphragm, disk and O-rings
R119X N0SV32
For 1/2 (12.7 mm) and 9/16 (14.3 mm) inch
orifices w/aluminum disk holder,
fluoroelastomer diaphragm,
disk and O-rings
R119X N0SV42

Parts Ordering

When ordering replacement parts, also be sure to include


the 11-character part number for each part required from the
following parts list.

Description

3*

Valve Body
Cast iron
3/4-inch
1-inch
1-1/4-inch
Steel
3/4-inch
1-inch
Spring Case
Aluminum
Orifice
Aluminum
1/8-inch (3.2 mm) diameter
3/16-inch (4.8 mm) diameter
1/4-inch (6.4 mm) diameter
5/16-inch (7.9 mm) diameter
3/8-inch (9.5 mm) diameter
1/2-inch (12.7 mm) diameter
9/16-inch (14.3 mm) diameter
Stainless steel
1/8-inch (3.2 mm) diameter
3/16-inch (4.8 mm) diameter
1/4-inch (6.4 mm) diameter
5/16-inch (7.9 mm) diameter
3/8-inch (9.5 mm) diameter
1/2-inch (12.7 mm) diameter
9/16-inch (14.3 mm) diameter

*Recommended spare parts

1E9871 19012
1E9873 19012
1E9875 19012
1E9871 X0012
1E9873 X0012
2P9015 08012

1A9367 09012
009912 09012
0B0420 09012
0B0421 09012
0B0422 09012
1A9288 09012
1E9852 09022
1A9367 35032
009912 35032
0B0420 35032
0B0421 35032
0B0422 35032
1A9288 35032
1C4252 35032

Type 119
Key
4*

5*

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

Cap Screw, zinc plated steel (2 reqd)


(not shown)
Actuator Spring, zinc plated steel

17
18
19
20

Upper Spring Seat, zinc plated steel


Type Y602-12 Vent (not shown)
Stem Wiper(1), TFE (2 reqd)
Nameplate, aluminum

21

Never-Seez Lubricant, 1 gal (3.81 L) can


(not furnished with valve)
Dow Corning 111 Lubricant, 10 lb (4.53 kg) can
(not furnished with valve)
Vent Screen, stainless steel (not shown)
Nace Tag
Tag Wire

23
24
25

18A7020 X022
18A7020 X032

1B7877 24052
See table 2

1A8328 X0122

22

18A7019 X022
18A7019 X022
48A7025 X012

13A5559 X012
1D9954 48702
1A3537 24122
1A3917 24052

12
13
14

19A0347 X012
19A0347 X022
18A7021 X012

18A7019 X012

Bonnet O-Ring(1)
Nitrile
Fluoroelastomer (high-temperature,
corrosion) & Nace MR-01-75
Adjusting Screw, zinc plated steel
Locknut, zinc plated steel
Cap Screw, zinc plated steel (8 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

*Recommended spare part.


1. Included in repair kit.
2. Trademark of DuPont Co.

Type 119

V APPLY LUB/SEALANT
37A8078-C

Figure 3.Type 119 Control Valve

While this information is presented in good faith and believed to be accurate,


Fisher Controls does not guarantee satisfactory results from reliance upon such
information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness

Fisher Controls

or any other matter with respect to the products, nor as a recommendation to


use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of the
products described herein.

For information, contact Fisher Controls:


Marshalltown, Iowa 50158 USA
Cernay 68700 France

Sao Paulo 05424 Brazil


Singapore 2158
Printed in U.S.A.

Publication T1-702, Rev. 1


Dated: January 22, 2001

INSTALLATION AND OPERATING


MANUAL

MODELS: T100-B, T100-D, T100-F, T100-P

TURBOTWIN Engine Air Starters

AN 95-414

From Tech Development Inc


6800 Poe Ave. Dayton OH 45414
Tel: (937) 898-9600 Fax: (937) 898-8431

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

TABLE OF CONTENTS
SECTION

SUBJECT

PAGE

1.0
1.1
1.2
1.3

GENERAL INFORMATION
DESCRIPTION
PRODUCT IDENTIFICATION
PERFORMANCE

2
2
2
3

2.0
2.1

ORIENTATION OF THE STARTER


GENERAL

3
3

3.0
3.1
3.2
3.3
3.4
3.5
3.6

INSTALLING THE STARTER


SUPPLY LINE INSTALLATION
NLET PRESSURE PORT
EXHAUST PIPING
NATURAL GAS INSTALLATION
PIPING SYSTEM
BACKLASH

3
3
4
4
4
4
5

4.0
4.1
4.2

STARTER OPERATION
BASIC OPERATION
AUTOMATED START PANEL

5
6
6

5.0

PREVENTIVE MAINTENANCE

6.0

TROUBLE SHOOTING GUIDE

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

Publication T1-702, Rev 1


Issued January 22, 2001

(STD MESH)

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

1.0 GENERAL INFORMATION


This manual provides instructions for the installation and
operation of the TDI T100 TURBOTWIN Starters (Series:
B,D,F,P). If there are questions not answered in this
manual, please contact your TDI TURBOTWIN distributor or
dealer for assistance.
The T100 TURBOTWIN models are turbine driven starters
with an inertially engaged starter drive. Depending on the
starter model and engine installation, the TURBOTWIN
starters have applications ranging from 1200 CID (20 Liters)
on diesel engines and up to 15000 CID (250 Liters) on gas
engines. The TURBOTWIN models are suited to operate
within a wide range of inlet pressures and ambient
temperatures. The engine size and parasitic loading will
determine the exact minimum pressure that will assure
reliable starting.
The T100 TURBOTWIN starters are designed for operation
with compressed air or natural gas; materials used are
compatible with sour natural gas and marine environments.
Small amounts of foreign matter or liquid in the air stream
will not adversely affect TURBOTWIN starters. As with all
other TDI starters, no lubrication is required in the air supply.
Please review the rest of this manual before installing the
T100 TURBOTWIN series air starter.
WARNINGS, CAUTIONS AND NOTES
Certain types of information are highlighted in this manual
for your attention:
WARNING - used where injury to personnel or
damage to the equipment is likely.
CAUTION - used where there is the possibility of
damage to the equipment.
NOTE - used to point out special interest
information.
NOTE
Throughout this manual, the term air is used to designate
the starter drive medium. Unless other wise stated, air
means either compressed air or natural gas.
1.1 DESCRIPTION
All models feature three basic subassemblies: a unique two
stage turbine motor section, a planetary gearbox section and
an inertia drive assembly.
The two stage motor section features greater stall torque
than a single stage turbine plus aerodynamic speed control.
Page 2

This aerodynamic speed control helps protect the


TURBOTWIN starter from damage caused by starter motor
over speed.
The T100 TURBOTWINS employ a 7.5:1 or 9:1 ratio
planetary gearbox. This low gear ratio allows the turbine
motor to spin at low speeds for long bearing life. At a
typical 3000 rpm pinion speed, the turbine is cruising at a
low 22500 rpm (7.5:1 ratio). Reliability and part commonality
are designed into all TURBOTWINS.
A simple and reliable inertia drive delivers the torque to the
pinion. The pinion is thrown out to engage the engine's ring
gear by the turbine motor's acceleration. Lighter weight
rotating parts used in the TURBOTWIN provide low inertia
and even "softer" engagement. In the event of overpressure, the friction clutch used in every TURBOTWIN
protects ring gear teeth from static torque overloads. In
addition, an inertia engaged starter eliminates the need for
complex pre-engagement control plumbing...and is easier to
install and maintain than pre-engaged type starters.
Compressed air or natural gas is used to power T100
TURBOTWIN air starters through the inlet port. The air or
gas is expanded through the first nozzle or stators. The high
velocity gas impinges on the first stage rotor to yield torque
to the gearbox. The gas is further expanded through the
second stage stators, which impart additional torque to the
second stage rotor.
1.2 PRODUCT IDENTIFICATION
The starter nameplate which is attached to the turbine
housing contains the following information: model number,
serial number, part number, direction of rotation and the
maximum rated operating pressure.
The directions of rotation are either right hand or left hand
rotation as shown in Figure 1. Right Hand rotation is defined
as clockwise rotation as viewed from the pinion end of the
starter, and Left Hand rotation is counter clockwise rotation
viewed from the pinion end of the starter.
The maximum operating pressure is also stamped on the
nameplate. This pressure is measured at the check port on
the starter inlet with the starter in operation.
CAUTION
Exceeding the maximum pressure shown on the nameplate
may result in drive failure, damage to the starter, or damage
to the engine.
The housing proof pressure is 600 psig and is also shown
on the nameplate. This means the turbine housing will not
burst when subjected to a static pressure of 600 psig.
Publication T1-702, Rev 1
Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

WARNING
If a fuel (pulse) lubricator has previously been installed in the
system, disconnect and plug the line to eliminate spraying
diesel fuel on the engine.
The starter should be installed with the inlet in a position
between horizontal and straight down. Any condensation will
be restricted to the air lines and not in the starter.
WARNING
Do not operate this starter unless it is properly connected to
an engine.
3.1 SUPPLY LINE INSTALLATION

Figure 1. Direction of Rotation viewed from Pinion End.


1.3 PERFORMANCE
Graphs of the performance curves feature pinion torque
versus pinion speed (rpm) at constant drive air pressures
and shaft horsepower versus pinion speed at constant drive
air pressures. Pinion speed is shown on the horizontal axis.
The pinion torque is shown along the left edge vertical axis.
The shaft horsepower is shown along the right edge vertical
axis. Air consumption rates are given for the various drive
pressure lines. These performance curves feature air as the
drive gas and have open exhaust (standard exhaust guard)
which have no back pressure.

2.0 ORIENTATION OF THE STARTER


2.1 GENERAL
If the factory orientation of the starters pinion housing
assembly in relation to the inlet port does not fit your engine
installation, these components can easily be re-oriented.
All TURBOTWINS have the capability to rotate the inlet port
relative to the drive opening for the optimum inlet port
location. The number of different positions is 6 to 12
depending on model.

3.0 INSTALLING THE STARTER


A turbine air starter does not require lubrication in the supply
air. Therefore, if a vane type starter motor is being replaced,
TDI recommends that all lubrication devices and lines
removed to minimize flow restrictions.

Publication T1-702, Rev 1


Issued January 22, 2001

WARNING
Be sure to either bleed the pressurized air reservoir and/or
safety the system such as closing all valves prior to installing
starter supply line.
The T100 TURBOTWIN series air starters come standard
with a 2" NPT female pipe thread for the inlet connection
port. The supply line consists of the line from the air source,
a pressure regulator (when necessary), a manual or relay
valve, and the connection to the starter inlet. Hard piping
may be used, but a section of flexible tubing should be
installed at the starter to prevent leaks due to engine
vibration.
Care must be taken to ensure that all inlet supply line piping
is no less than 1.5" and all components used are capable of
passing the required air flow.
NOTE
Valves with a Cv of 40 or higher are recommended.
If the supply line must be longer than 20 feet, the inlet supply
line piping should be increased to 2" in diameter to ensure
proper performance by your TURBOTWIN.
Because turbine starters such as the T100 TURBOTWIN
series are sensitive to flow restrictions, care must be taken
to use uniform hose or tubing and fittings for connection of
the supply line. Tees, elbows and line length must be kept
to a minimum. TDI recommends that hose or flex couplings
are installed to eliminate possible leakage caused by strain
on the supply line.
Normally, an air strainer is not required. However, in dirty
environments use of a #40 mesh Y-strainer is
recommended. The T100 TURBOTWIN series is highly
tolerant of dirt in the air line, however, starter life can be
increased with the use of an air strainer.

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

A pressure regulator is required when the air supply


pressure is great enough to exceed the starter operating
pressure (at the inlet port) and/or the maximum torque.
A manual ball valve may be used to admit drive air/gas to
the starter. The manual valve should be located in a safe
position away from the engine.

installed at the pressure check port and electrical lines


routed to a digital display at the operator's station.
This pressure port is invaluable in diagnosing air starter
and/or installation problems.
3.3 EXHAUST PIPING

A preferred valve is pilot-operated, which can be


pneumatically or electrically actuated. The valve should be
located close to or even on the starter inlet for best
performance. Pneumatic or electrical control lines may be
routed virtually anywhere for the customer's preferred
operating station. This type of valve actuates from a fully
closed to a fully open position very rapidly. TDI offers a
variety of relay valves such as P/N RLVA-25683-001-2-01,
which is a 1-1/2" port, pneumatically actuated valve.

The turbine exhaust may be plumbed away from the starter


area. All starters using natural gas must be piped according
to industry codes and local regulations.

The supply line should be dry-fitted for proper alignment


/location prior to final assembly. All pipe threaded joints
should be sealed with Loctite Pipe Thread Sealant (TDI P/N
9-94085) or equivalent for leak tight joints prior to final
assembly. Be sure to tighten all joints to proper torque after
final assembly.

Exhaust piping should be routed downward to help prevent


any accumulation of condensation in the starter motor.

CAUTION
In cold weather climates, care should be taken while
designing your installation to prevent condensation from
developing in the starter system. In systems with a regulator
valve or relay valve, there is the possibility of freeze-ups.

Exhaust piping should be routed downward to help prevent


any accumulation of condensate in the starter motor.

A tee connection with a quick disconnect can be added to


the inlet. This will allow an external air source to be used to
accomplish a blow start if the system freezes. Once the
engine has been started, the other system components may
be thawed.
CAUTION
On new installations, it is strongly recommended to blow out
the supply line with air to remove possible dirt and welding
slag prior to final connection to the TURBOTWIN starter. Be
sure to secure the free end of the supply line prior to blowing
out the line.
3.2 INLET PRESSURE PORT
A 1/4" NPT port is located on the air inlet. This port may be
used to check the supply pressure at the starter when the
starter is operating. Remove the 1/4" NPT pipe plug and
save for later use. Install a 1/4" minimum size tubing to the
port. Route the tubing away from the starter to a safe
location away from the engine. Install a pressure gauge on
the tubing. This pressure monitoring line/gauge may be
permanently installed. Use Loctite Pipe Thread Sealant or
equivalent. Alternately, a pressure transducer may be
Page 4

The performance of a turbine starter will be decreased


because of back pressure when smaller than recommended
exhaust piping is installed. If back pressure hampers starter
performance, compensation can be made by increasing the
supply pressure. Consult your TDI distributor for advice.

If the overhung section of the starter is not otherwise


supported, TDI recommends supporting the exhaust piping
with a suitable bracket(s).

3.4 NATURAL GAS INSTALLATION


The installation of the starter using natural gas is similar to
the air installation except all fittings, piping, valves and
regulators must be compatible with natural gas.
Proper control of natural gas is a major consideration when
used in the starter system. All starters using natural gas
must pipe the exhaust according to industry codes and local
regulations.
There is a natural gas vent port in the turbine housing that is
plugged for compressed air use. This vent is used to remove
any natural gas that could leak past the primary turbine shaft
seal. Remove this 3/8"NPT plug and install a line to carry
gas away from the starter area.
WARNING
Do not connect the turbine housing vent line to the turbine
exhaust line. Exhaust gas can pressurize the housing.
3.5 PIPING SYSTEM
Only type approved metallic hose assemblies are approved
in permanently pressurized compressed air lines of starters.
Non-metallic hose assemblies are allowed only in case the
piping system will be emptied after the starting procedure.
Publication T1-702, Rev 1
Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

Pipe unions must be type approved by GL. Downstream of


the pressure regulator a pressure relief valve is to be
provided.
3.6 BACKLASH
Backlash is the "free play" between the mesh of two gears.
Figure 15 shows the backlash between two gears.
Maintaining the proper gear backlash setting allows the
gears to mesh smoothly. Proper backlash and alignment
allows smooth engagement/disengagement of the pinion
gear and loads the tooth face surfaces evenly producing
longer gear life. The correct backlash setting for 6/8
diametral pitch gearing used on larger engines is as follows:
Minimum backlash
Maximum backlash

.015 inch
.025 inch

To check the backlash, the pinion will need to be rolled out


onto the end of the drive prior to starter installation. This can
be accomplished by using a hex drive wrench to rotate the
turbine end of the starter while holding the pinion from
rotating. The pinion will simply walk to the end of the shaft.
An access hole to reach the turbine screw is provided in the
turbine exhaust guard. The starter must then be installed on
the engine. Checking backlash can be accomplished using
a dial indicator or a simple blade-type feeler gauge. Because
ring gears are not usually perfectly round, it is necessary to

DEVELOPMENT INC

mounting bolts. Torque the three 5/8" screws to 100 lb-ft.

4.0 STARTER OPERATION


Prior to operation, check that all connections are tight and
free from leaks. Check the 1/4" NPT pipe plug or a pressure
gauge/transducer that may be connected to the pressure
port on the starter inlet.
WARNING
Do not operate the TDI TURBOTWIN starter with air pressure
greater than the pressure rating on the nameplate. This
pressure is measured at the starter inlet while the starter is
running.
The maximum operating pressure limit is the inlet pressure
measured at the starters inlet pressure check port. In order
to check the starter, a 1/4"NPT pipe tap connection is
provided in the inlet housing to attach a pressure
gauge/transducer). The maximum pressure assumes an
open exhaust (standard turbine exhaust guard). The
standard exhaust guard causes no back pressure.
The static non-flowing supply pressure will always be higher
than the operating (dynamic) pressure. The maximum
pressure limit (proof pressure) that the TDI TURBOTWIN
starter housings may be subjected to is 600 PSIG (42 BAR).
System pressure that exceeds the maximum operating limit
must use a pressure reducing device to ensure that the
operating pressure limit to the TDI TURBOTWIN starter is
maintained.
System static pressure that exceeds the 600 PSIG (42 BAR)
limit must, in addition to pressure reducer devices
incorporate a pressure relief valve set below 600 PSIG (42
BAR) in the supply air line.

Figure 2. Checking Backlash

NOTE
For maximum life of the starter pinion and for the protection
of the engine ring gear, limit the operating pressure to that
necessary to start the engine at its most difficult starting
conditions.

check backlash at several (six or more) points around the


circumference of the ring gear. Average the highs and lows
to allow a setting that is in the range cited above.

All appropriate local pressure codes and pressure limitations


on other system components must be adhered to and
supersede the guidelines given in this manual.

Setting the correct backlash may involve "shimming" and/or


moving the starter bracket(s). An adjustable starter bracket
design will simplify this procedure. Always re-check the
backlash after a ring gear replacement.

Consult your TDI distributor if you have exhaust plumbing


that creates back pressure and reduces starter
performance. You may be able to increase the supply
pressure to restore the lost power.
Follow the engine manufacturers instructions for starting the
engine.

Liberally grease the starters drive teeth with chassis lube


and then mount the TURBOTWIN starter on the engine.
Tighten all mounting hardware as appropriate. Make sure to
use Loctite Threadlocker #290 or equivalent on the starter
Publication T1-702, Rev 1
Issued January 22, 2001

4.1 BASIC OPERATION


5

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC
speed.

The basic operation of the starter is as follows:


Pressurized air or natural is admitted to the starter by
opening of the manual or relay valve. The air expands
through the turbine, which produces shaft rotation and
torque. The acceleration of the drive assembly causes the
pinion to advance and engage the ring gear of the engine.
The starter motor torque causes the engine to accelerate.
This acceleration causes the pinion to be disengaged from
the ring gear. The fuel and ignition systems now fire the
engine. Closing the relay valve stops the starter.
The operator may decrease starter life by the continual
operation of the starter after the engine has started. Upon a
successful engine start, turn the air off to the starter
immediately. Minimizing the time the starter is operating
unloaded (i.e. the engine is running) will maximize starter
life. If a start is aborted, a restart may be attempted after the
engine and the starter has come to rest.
CAUTION
Do not engage the starter while the engine is running.
The drive air pressure is the primary starter control
parameter. It is important, especially on new installations, to
measure this pressure during several engine starts. The
secondary parameter is the starter pinion speed. This speed
is usually measured by knowledge of the engine starting
speed and the starter cranking ratio. The cranking ratio is
the number of ring gear teeth divided by the number of
pinion teeth. The starter pinion speed is then found by
multiplying the engine speed by the cranking ratio. The
pinion speed is usually 2000-3500 rpm at typical engine
starting speed.
4.2 AUTOMATED START PANEL
The starter drive pressure measured at the starter inlet must
be set. As noted above, for maximum life of the starter
pinion and for the protection of the engine ring gear, limit the
operating pressure to that necessary to start the engine at its
most difficult starting conditions.
The speed control parameter will then need to be set.
Engine starting speed along with the cranking ratio number
can be used to determine starter pinion speed. The pinion
speed is usually 2000-3500 rpm for a typical engine starting
speed. Once the start sequence has begun, the air is
admitted to the starter. The starter begins to accelerate the
engine. Once the firing speed of the engine is reached, the
automated start panel may deliver fuel to the engine. The
engine will begin to accelerate under its own power. The
starter should be dropped out of the sequence at a rpm
higher than the firing speed, but less than the engine idle
Page 6

The automated start panel should monitor engine speed to


determine air on and air off. Do not simply use time as a
control parameter. Avoiding excessive operation of the
starter after the engine is firing will maximize the starter life.

5.0 PREVENTIVE MAINTENANCE


The TDI TURBOTWIN starters provide distinct advantages
of size and efficiency as compared to electric motor, vanetype or other turbine-type starters. It is important to properly
install the starter to receive full benefit of these advantages.
Repair technicians or service organizations without turbine
starter experience should not attempt to repair this machine
until they receive factory approved training from TDI, or its
representatives.
Proper operation and repair of your TDI TURBOTWIN
starter will assure continued reliable and superior
performance for many years.
5.1 Every Six (6) Months
Perform the following procedures at six(6) months intervals
if the normal cranking cycle is 0 - 10 seconds.
5.1.1 Check the amount and condition of grease in the
planetary gearbox. If gearbox requires re-greasing, only use
TDI grease. Approximately one (1) pint of grease is needed
to repack the gearbox.
5.1.2 Check the turbine bearing and carrier output bearings
for freedom of rotation without excessive play between
races. If bearings are damaged, replace them with genuine
TDI parts. Refer to TDI Service Manual for part numbers.
5.1.3 Place a small amount of chassis lube on the starters
pinion teeth.
5.2 Every Three (3) Months
Follow the six (6) month procedures if there is severe starter
loading or extended duration crank cycles. Also perform
these procedures every three (3) months when starter is
used for motoring the engine for maintenance or valve
adjustments.
Motoring Crank Cycle: 10 -60 seconds
Extended Crank Cycle: 60 seconds or longer
starter, use only genuine TDI replacement parts. The
component part numbers are found in the Illustrated Parts
Breakdown.
Publication T1-702, Rev 1
Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

6.0 TROUBLESHOOTING CHART


TROUBLE

PROBABLE CAUSE

SOLUTION

1. Starter does not


A. Relay valve not fully open.
run; small air flow from
B. Nozzle blockage.
exhaust.

A. Repair or replace relay valve.

2. Starter does not


run; normal air flow
from exhaust.

A. Broken turbine rotor.

A. Replace all damaged parts.

B. Broken gear train.

B. Repair or replace geartrain.

C. Damaged starter drive.

C. Repair or replace starter drive.

A. Inlet air pressure too low.

A. Increase air pressure in 10 PSIG (0.6 BAR)


increments; DO NOT EXCEED OPERATING LIMIT.

B. Inlet supply piping too small.

B. Supply piping must be a minimum of 1.5" diameter.

C. Pressure regulator orifice too


small.

C. Increase orifice size or replace pressure regulator

D. Inlet supply line valve (ball,


gate, relay, plug) too small.

D. Install larger valve.

E. In line lubricator installed in


supply line.

E. Remove lubricator.

F. Y-Strainer in supply line


clogged.

F. Clean strainer.

G. Excessive back pressure;


exhaust restricted.

G. Clean exhaust piping or increase size to at least the


minimum diameter recommended.

H. Damaged turbine nozzle.

H. Replace turbine nozzle.

I. Broken started drive.

I. Repair or replace starter drive.

J. Wrong rotation starter.

J. Replace with starter or proper rotation.

K. Wrong size starter.

K. Check the Application Guide for the correct starter.

A. Inlet air pressure too high.

A. Decrease air pressure in 10 PSIG (0.6 BAR)


increments.
OR
If there is a manual shut-off valve in the supply line,
partially close it.
OR
Install a restriction orifice in the inlet supply line.

B. Wrong size starter.

B. Check the Application Guide for the correct starter.

3. Reduced Starter
output power.

4. Engine cranks too


quickly.

Publication T1-702, Rev 1


Issued January 22, 2001

B. Remove blockage or obstruction from nozzles.

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

Publication T1-702, Rev 1


Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

Publication T1-702, Rev 1


Issued January 22, 2001

DEVELOPMENT INC

TDI TURBOTWIN
FROM TECH

Page 10

DEVELOPMENT INC

Publication T1-702, Rev 1


Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

Publication T1-702, Rev 1


Issued January 22, 2001

DEVELOPMENT INC

11

TDI TURBOTWIN
FROM TECH

Page 12

DEVELOPMENT INC

Publication T1-702, Rev 1


Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

Publication T1-702, Rev 1


Issued January 22, 2001

DEVELOPMENT INC

13

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

T112-B / T112-D Performance Curve


12 Nozzles, Compressed Air, 7.5:1 RATIO

TORQUE
Nm LB.FT

POWER
HP KW
100 74.6

476 350
150 psig

408 300

Inlet Pressure SCFM Nm3/h


150 psig
1360 2312
120 psig
1090 1853
90 psig
860 1462
60 psig
610 1037

Maximum Torque
Transmitted by Drive

120 psig
340 250
90 psig

60 44.8

60 psig

40 29.8

272 200

204 150

80 59.6

136 100
20 14.9
68 50

340

250

204

150

100

60

30

35

40

45

50

55

POWER
HP KW

Maximum Torque
Transmitted by Drive

Inlet Pressure SCFM


90 psig
1560
60 psig
1070
30 psig
620

Nm3/h
2652
2140
1054

74.6

80

59.6

60

44.8

40

29.8

20

14.9

ps
ig

30
psi
g

50

Page 14

25

100

300

200

68

20

350

272

136

15

21 Nozzles, Compressed Air, 7.5:1 RATIO

90 psig
408

10

T121-B / T121-D Performance Curve

TORQUE
Nm LB.FT
476

500

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Publication T1-702, Rev 1


Issued January 22, 2001

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

T106-F Performance Curve

TORQUE
Nm LB. FT

POWER
HP KW

6 Nozzles, Compressed Air, 7.5:1 RATIO

238 175

50 37.2
150 psig

204 150
12

0p

170 125
90

136 100

102 75

Inlet Pressure SCFM Nm3/h


150 psig
680
1156
120 psig
550
935
90 psig
430
731
60 psig
310
527

Maximum Torque
Transmitted by Drive
sig

30 22.4

ps ig

60
p

40 29.8

20 14.9

sig

68 50
10 7.5
34 25

500

T112-F Performance Curve

TORQUE
Nm LB.FT
238 175

POWER
HP KW

12 Nozzles, Compressed Air, 7.5:1 RATIO


90 psig

Maximum Torque
Transmitted by Drive

204 150
60

170 125

ps

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Inlet Pressure SCFM Nm3/h


90 psig
860 1462
60 psig
610 1037
30 psig
370
629

45 33.5

ig

136 100

30 22.4

102 75

30

ps i
g

68 50

15 11.2

34 25

0
0
Publication T1-702, Rev 1
Issued January 22, 2001

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0
5500

15

TDI TURBOTWIN
FROM TECH

DEVELOPMENT INC

9 Nozzles, Compressed Air, 9.0:1 RATIO

408 300

15
0

340 250
272

12
0p

200

ps
ig

DRIVE TORQUE LIMIT

Page 16

60 p
s

50

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

T109-P Performance Curve

TORQUE
Nm LB.FT
476 350

500

20 14.9

ig

0
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Publication T1-702, Rev 1


Issued January 22, 2001

Publication T1-701, Edition 1


Dated: December 1998

SERVICE MANUAL

T100 Series (T112B/T121B,

T112D/T121D, T106F/T112F, T109P/T115P)

TURBOTWIN ENGINE AIR STARTERS

From Tech Development Inc


6800 Poe Ave. Dayton OH 45414
Tel: (937) 898-9600 Fax: (937) 898-8431

TDI 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

T100 Series Service Tool Kits..


Cleaning Materials & Compounds..
Parts Inspection Check Req.
Parts Wear Limits..
Materials for Assembly..

TECH DEVELOPMENT, INC.

Page

Title

Page

Pressing Bearing onto Shaft.. 18


Installing Shaft into Gearbox Hsg.. 18
Tightening Retainer Nut.. 19
Woodruff Key Installation 19
Tightening Retainer Nut (T106F).. 20
Drive Hsg. Installation (T106F). 20
Illustrated Parts Breakdown (B) 25
Illustrated Parts Breakdown (P) 26
Illustrated Parts Breakdown (D) 27
Illustrated Parts Breakdown (D) 28
Illustrated Parts Breakdown (F) 29

8
12
13
14
15

LIST OF ILLUSTRATIONS
Figure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Title

Page

TDI Turbotwin Nameplate. 2


T30 Series Part Number Coding.. 3
Turbine Housing Assembly 4
Gearbox Housing Assembly (B/P) 5
Gearbox Housing Assembly (F) 5
Gearbox Housing Assembly (D/Std) 6
Gearbox Housing Assembly (D/Lg). 6
Bendix Drive Assembly. 7
Bendix Drive Removal 8
Bendix Drive Removal (F). 9
Gearbox Retainer Nut Removal 9
Pressing Out Carrier Shaft. 10
Turbine Rotor Removal... 10
Turbine Shaft Removal... 11
Nozzle 2 Removal 11
Gear Teeth Wear Allowance.. 14
Pressing Front Turbine Bearing. 15
Pressing Spacer onto Bearing15
Installation of Turbine Shaft16
Installing the Aft Seal into Nozzle 1...16
Pressing Aft Bearing onto Shaft 17
Planet Gear Carrier Shaft Assembly. 17
Publication T1-701
Issued Dec 11, 1998

Page: i

TDI TURBOTWIN
FROM

SECTION 1.0 INTRODUCTION


1.1 GENERAL INFORMATION
This manual provides information for servicing,
disassembly, and reassembly of the TDI Turbotwin
T100 series air starters. If there are questions not
answered by this manual, please contact your local TDI
distributor or dealer for assistance. Illustrations and
exploded views are provided to aid in disassembly and
reassembly.
The TDI Turbotwin T100 series of engine starters are
specially designed for starting todays automated, lowemission engines. The Turbotwin uses aerodynamic
speed control, eliminating the need for a mechanical
automatic trip valve (ATV) to control starter motor
speed.
The Turbotwin T100 series air starters are suited to
operate within a wide range of inlet pressures and
ambient temperatures. These starters are designed for
operation with either compressed air or natural gas.
The robust turbine motor design in the Turbotwin T100
series starters has no rubbing parts, and is therefore
tolerant of hard and liquid contamination in the supply
gas with almost no adverse affects. The motor is well
adapted to running on sour natural gas.
As with all TDI air starter products, there are no rubbing
parts so there is no lubrication required.
This
eliminates failures due to lubricator problems, the
expense of installing and maintaining the system, and
the messy and hazardous oil film around the starter
exhaust. The starter is factory grease packed for the
life of the starter so it requires no maintenance.
NOTE
Throughout this manual, the term air is used to donate
the starter drive medium. Unless otherwise stated, air
means compressed air or natural gas.
Please review the rest of this manual before attempting
to provide service to the TDI Turbotwin T100 series
starters.

1.2 WARNINGS, CAUTIONS, & NOTES


Throughout this manual, certain types of information will
be highlighted for your attention:
WARNING - used where injury to personnel or damage
to equipment is likely.
Publication T1-701
Issued Dec 11, 1998

TECH DEVELOPMENT, INC.

CAUTION - used where there is the possibility


of damage to equipment.
NOTE - use to point out special interest
information.

1.3 DESCRIPTION OF OPERATION


The Turbotwin T100 series starters are powered by a
pair of axial flow turbines coupled to a simple planetary
gear reduction set.
The T100 series starters
incorporate an inertia bendix drive coupled to the starter
gearbox drive train to provide a means of disengaging
the pinion from the engines ring gear.
The high horsepower of the turbine air motor combined
with the planetary gear speed reducer results in a very
efficient and compact unit. The Turbotwin T100 series
starters can be used over a wide range of drive
pressures from 30 psig (2 BAR) to 150 psig (10 BAR)
and are suitable for operation on either air or natural
gas.
The Turbotwin T106F & T112F weighs approximately
47 pounds (21 KG) and each is capable of delivering
over 44 HP (33 kW) of cranking power at their
maximum pressure of either 150 psig (10 BAR) or 90
psig (6 BAR) respectively.
The Turbotwin T112B & T121B weighs approximately
55 pounds (25 KG) and each is capable of delivering
over 80 HP (60 kW) of cranking power at their
maximum pressure of either 150 psig (10 BAR) or 90
psig (6 BAR) respectively.
The Turbotwin T112D &T121D weighs approximately
70 pounds (32 KG) and each is capable of delivering
over 80 HP (60 kW) of cranking power at their
maximum pressure of either 150 psig (10 BAR) or 90
psig (6 BAR) respectively.
The Turbotwin T109P & T115P weighs approximately
59 pounds (27 KG) and is capable of delivering over 60
HP (41 kW) of cranking power at their maximum
pressure of either 150 psig (10 BAR) or 90 psig (6
BAR) respectively.

1.4 INSTALLATION AND SERVICE


It is important to properly install and operate the TDI
Turbotwin T100 series starters to receive the full
benefits of the turbine drive advantages. It must be
installed in accordance with the instructions provided by
Tech Development, Inc. (TDI).

Page 1

TDI 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

1.5 NAMEPLATE INFORMATION


The nameplate, located on the turbine housing,
provides
important
information
regarding
the
construction of your T100 series starters, refer to Figure
1. The part number coding explanation, refer to Figure
2, can help you when talking to your distributor.

TECH DEVELOPMENT INC.

9609-124

PART NUMBER
T112-60001-B1R
CW (RH)
X

CCW (LH)
AIR or NAT. GAS
USAGE

MAX PRESS.
150
PSIG
MAESURED AT INLET WHILE OPERATING
PROOF PRESSURE OF HOUSING IS 600 PSIG

WARNING:DO NOT OPERATE UNLOADED OR WITHOUT


TURBINE GUARD OR EXHAUST FITTING
U.S PATENT 4509896

Figure 1. TDI Turbotwin Nameplate

Page 2

Publication T1-701
Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

Figure 2. Part Number Coding

Publication T1-701
Issued Dec 11, 1998

Page 3

TDI TURBOTWIN
FROM

SECTION 2.0 DESCRIPTION OF


BASIC GROUPS
2.1 GENERAL
The TDI Turbotwin T100 Series air starters are
lightweight, compact units driven by a dual stage turbine
type air motor. The starter is composed of three basic
assembly groups: Turbine Housing Assembly; Gearbox
Housing Assembly; and Bendix Drive Assembly.

TECH DEVELOPMENT INC.

2.2 TURBINE HOUSING ASSEMBLY


The Turbine housing assembly, refer to figure 3,
consists of a stage one (15) and a stage two (6) turbine
wheel mounted on sungear shaft (33) . The front
bearing (10) is secured by a retainer plate (32). The aft
bearing is preloaded by wavy spring (12).
The ring gear (29) is heat shrunk into the front of the
turbine housing (26) and secured by a setscrew (25).

Figure 3. Turbine Housing Assembly

Page 4

Publication T1-701
Issued Dec 11, 1998

TDI TURBOTWIN
FROM

2.3 GEARBOX HOUSING ASSEMBLY


The gearbox housing assembly, refer to figures 4,
consist of a planet gear carrier and output shaft (35),
three planet gears (37), needle bearings (38), spacers
(36), and bearing pins (39).

TECH DEVELOPMENT, INC.

The carrier shaft is mounted on two ball bearings (41) in


the gearbox housing (58). The retainer nut (48)
secures the carrier shaft in the gearbox housing. The
front bearing (41) is secured by a retainer plate (46).
The back bearing is preloaded by use of a spring
washer (42).

Figure 4. Gearbox Housing Assembly (T112B/T121B/T109P/T115P)

Figure 5. Gearbox/Bendix Assembly (T106F/T112F)


Publication T1-701
Issued Dec 11, 1998

Page 5

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

Figure 6. Gearbox Assembly (T112D/T121D STD MESH)

Figure 7. Gearbox Assembly (T112D/T121D LONG MESH)

Page 6

Publication T1-701
Issued Dec 11, 1998

TDI TURBOTWIN
FROM

2.4 BENDIX DRIVE ASSEMBLY


The Bendix drive assembly, refer to figure 8, consists of
an inertial engagement drive or bendix (57) and drive
housing (61). The bendix is mounted to the output
shaft with two keys and a retaining set screw (53).

TECH DEVELOPMENT, INC.

The other end of the drive unit is mounted into a needle


bearing (54), which is installed in the nose of the drive
housing.

Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)

Publication T1-701
Issued Dec 11, 1998

Page 7

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

SECTION 3.0 DISASSEMBLY


3.1 GENERAL
Always mark adjacent parts on the starter housing;
Nozzle 2/ Containment Ring (13), Turbine Housing (26),
Gearbox Housing (58), and Bendix Drive Housing (61)
so these parts can be located in the same relative
position when the starter is reassembled.
Do not disassemble the starter any further than
necessary to replace a worn or damaged part
Always have a complete set of seals and o-rings on
hand before starting any overall of a Turbotwin T100
series starter. Never use old seals or o-rings.
The tools listed in Table 1 are suggested for use by
technicians servicing the Turbotwin T100 series
starters. The best results can be expected when these
tools are used, however the use of other tools are
acceptable.
TOOL DESCRIPTION
TDI/PN
Spanner wrench
52-20134
Spanner wrench
52-21345
Shaft Removal Tool
2-26945
Stage 2 Rotor Puller Tool
52-20076
Carrier Shaft Holding Tool
52-20202
Tool, Bearing Pressing
52-20143
Tool, Bearing/Seal
2-26943
Table 1. T100 Series Service Tools

Remove the needle bearing (62), if necessary, by


simply tapping out the welch plug from the front of the
drive housing and press bearing out.

3.3 DRIVE HOUSING


(T112D/T121D)
3.3.1 Removal of Drive Housing
Remove the six screws (22). Mark position of bendix
pinion opening relative to gearbox housing for reference
during reassembly.
Pull drive housing (49) from
gearbox housing (44). If drive housing is too tight, tap it
with a mallet to loosen.
3.3.2 Removal of Bendix Drive
In loaded spring area of drive (57) remove retaining ring
(51) from set screw (53) slot.
Remove set screw using a flat head screwdriver, Figure
9, and pull the bendix assembly from the starter carrier
shaft.
Remove spring (52). This spring fits loosely between
the bendix assembly and carrier shaft. Remove the
needle bearing (62), if necessary, by simply tapping out
the welch plug from the front of the drive housing and
press bearing out.

3.2 DRIVE HOUSING


(T112B,T121B,T109P,T115P)
3.2.1 Removal of Drive Housing
Mark position of bendix pinion opening relative to
gearbox housing for reference during reassembly.
Remove the six bolts (60) and lock nuts (59). Pull drive
housing (61) from gearbox housing (58). If drive
housing is too tight, tap it with a mallet to loosen.
3.2.2 Removal of Bendix Drive
In loaded spring area of drive (57) remove retaining ring
(51) from set screw (53) slot.
Remove set screw using a flat head screwdriver, Figure
9 and pull the bendix assembly from the starter carrier
shaft. Remove spring (52). This spring fits loosely
between the bendix assembly
and carrier shaft.
Page 8

Figure 9. Bendix Drive Removal

Publication T1-701
Issued Dec 11, 1998

TDI TURBOTWIN
FROM

3.4 DRIVE/GEARBOX HOUSING


(T106F/T112F)
3.4.1 Removal of Drive Housing
Mark position of bendix pinion opening relative to
turbine housing (26) for reference during reassembly.
Per Figure 10, remove the six screws (27). Pull drive
housing (69) from turbine housing. If drive housing is
too tight, tap it with a mallet to loosen.

TECH DEVELOPMENT, INC.

Remove bearing (65) from shaft by pressing shaft


while supporting inner race of bearing.
Remove
bearing retainer plate (64).
3.4.3 Planet Gear Disassembly
Remove snap ring (34) from planet shaft (39) using
snap ring pliers and push shaft through holes in
assembly.
Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.

Figure 10. Bendix Drive Removal (T106F/T112F)


3.4.2 Removal of Bendix Drive
Remove four screws (31). Pull carrier shaft assembly
(63) from drive housing (69). The bendix (68) will
remain in the drive housing. With snap ring tool,
remove snap ring (66) and bendix drive (68)from drive
housing.

Figure 11. Gearbox Retainer Nut Removal

3.5 GEARBOX HOUSING


(T112B/T121B,T112D/T121D,T109P/T115P)
* The drive housing removal procedure should be
performed before performing this procedure.

If it is necessary to remove needle bearing (70) from


drive housing, simply press bearing out.

3.5.1 Removal of Gearbox Housing

Mount the carrier shaft assembly on the TDI holding


tool P/N 52-20202 placing the three holes on the
gearbox over the dow pins. Refer to Figure11.

Remove the six screws (27) and lift the gearbox


assembly from the turbine assembly. If the gearbox
assembly is too tight, tap it with a mallet to loosen).

Place TDI tool P/N 52-21345 (Spanner Wrench) over


shaft and into slots of retainer nut (67). Hold down
carrier shaft and remove nut.

3.5.2 Gearbox Disassembly

Publication T1-701
Issued Dec 11, 1998

Mount the gearbox on the TDI holding tool P/N 5220202 placing the three holes on the gearbox over the
dow pins. Refer to Figure 11.
Page 9

TDI TURBOTWIN
FROM

Remove woodruff keys (40) from shaft by tapping them


with a chisel and hammer
With screwdriver remove tang of lockwasher (47) from
slot of retainer nut (48).
Place TDI tool P/N 52-20134 (Spanner Wrench) over
shaft and into slots of retainer nut. Hold gearbox down
and remove nut.
In most cases the gearbox housing (58, D-44) can be
removed from the carrier shaft (35) by holding shaft
down and pulling directly up on housing. If this is not
the case, press carrier shaft from housing per Figure
12.

TECH DEVELOPMENT INC.

Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.

3.6 TURBINE HOUSING


3.6.1 Stage 2 Rotor Removal
Remove the six screws (27) that connect the gearbox
assembly to the turbine housing and separate the two
assemblies. Remove the four screws (18) and the
clamping plate (32).
Turn the turbine to the (exhaust) end up and remove
the six screws (1), screen support ring (2), and the
screen (3). For the T109P, remove six screws (74) and
Exhaust Cover Housing (75).
Hold the stage 2 rotor (6) and remove the turbine screw
(4) and washer (5).
Install the rotor puller tool P/N 52-20076 and remove
the stage 2 rotor per Figure 13.
Remove the woodruff key (7) using a hammer and
chisel.

Figure 12. Pressing Out Carrier Shaft


The aft bearing (41), spring washer (42), and bearing
spacer (43) will come out with the shaft. Remove aft
bearing (41) from shaft by pressing shaft while
supporting bearing.
If the aft bearing (41) is retained in the gearbox
housing when the carrier shaft is removed, apply
pressure through housing to the bearing to remove it. It
will be necessary to elevate the housing with a brace to
remove the bearing completely.
Remove the six screws (18) and retainer plate (46).
The front bearing may then be removed by lightly
tapping.
3.5.3 Planet Gear Disassembly
Remove snap ring (34) from planet shaft (39) and push
shaft through holes in assembly.
Page 10
701

Figure 13. Turbine Rotor Removal


Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

3.6 Turbine Shaft Removal


Using the shaft removal tool P/N 2-26945 per figure 14,
press on the turbine shaft (33) while supporting the
turbine housing.
Press the shaft assembly (33) through the aft bearing
(10) and continue pressing until the shaft assembly is
completely out of the housing (26).
Remove the woodruff key (16), seal spacer (8), bearing
spacer (30), and bearing (10) from the shaft. The
bearing can be removed from the shaft by pressing the
shaft through the bearing. Note that if T100 is the
original design (SN: 9501-239 to9611-191), the bearing
will be pressed inside a spacer.

TECH DEVELOPMENT, INC.

Separate the stage 2 nozzle assembly (13) from the


turbine assembly (26) by firmly holding the turbine
assembly, while tapping nozzle 2 with a mallet. If
nozzle 2 is too tight, it can be removed by installing two
threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly. Refer
to Figure 15.
Rotate the stage 1 rotor if necessary to allow the jacks
to travel through the large holes in the rotor. The jacks
will damage the stage 1 rotor if pressure is applied to
them while removing nozzle 2.
The stage 1 rotor (15) may now be removed.
Remove the four screws (18) and nozzle 1 (19) from
the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
On the stage 2 nozzle (13), remove the seal spacer (8)
from the forward side of the nozzle. Place the stage 2
nozzle on the exhaust end. Press through the lip seal
nd
onto the bearing until it, including the 2 lip seal and
seal spacer disengages from the nozzle. Turn the
nozzle over and press on the lip seal to remove.

Figure 14. Turbine Shaft Removal

Figure 15. Nozzle 2 Removal

Publication T1-701
Issued Dec 11, 1998

Page 11

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

SECTION 4.0 CLEANING and


INSPECTION

Clean aluminum parts using the solutions per Table 2;


soak for 5 minutes. Remove parts, rinse in hot water,
and dry thoroughly.

4.1 CLEANING

Clean corroded steel parts with a commercially


approved stripper.

Degrease all metal parts, except bearings, using a


commercially approved solvent. Refer to Table 2.
NOTE
Never wash bendix assembly or bearings in cleaning
solvents. It is recommended that the bearings be
replaced with new parts.

Clean corroded aluminum parts by cleaning as stated


above and then immerse the parts in chromic-nitricphosphoric acid pickle solution per Table 2. Rinse in
hot water and dry thoroughly.

MATERIAL or COMPOUND
Degreasing Solvent (Trichloroethylene) (O-T-634)
Acetone
Aluminum Cleaning Solution

MANUFACTURER
Commercially Available
Commercially Available
Diversey Corp., 212 W. Monroe, Chicago, IL 60606
Dissolve 5 oz of Diversey 808 per gallon of water at
155- 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.

Page 12
701

Check all bearing bores for wear and scoring. Bearing


bores shall be free of scoring lines, not to exceed
0.005 width and 0.005 depth.
Check gear teeth and turbine housing ring gear for
wear. In general, visually check for spalling, fretting,
surface flaking, chipping, splitting, and corrosion. If
wear is apparent, check the gear teeth dimensions in
accordance with Table 4. Nicks and dents that cannot
be felt with a .020 inch radius scribe are acceptable.

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

Part
Description
Bendix
Drive Housing
Planet Gear

Check For
Worn, loose, or missing parts
Cracks and breakage
Cracked, chipped, or galled
teeth. Wear must not exceed
limits per Table 4.

Carrier Shaft

Cracks, scoring or raised


metal in planet shaft holes and
keyways. Integrity of knurl
connection.

Planet Pins

Wear grooves or flat spots

Washers
Gearbox Housing
Sungear / Turbine
Shaft

Wear created grooves


Cracks and Breakage
Cracks, scoring, wear created
grooves, chipped or broken
gear- teeth, galling or scoring
on bearing surface of shaft.
Raised metal on the keyway.
Parallelism of end surfaces
Cracks and breakage

Spacers
Turbine Housing

Ring Gear
Seal Assembly
Seal Spacer
Needle Bearings
Ball bearings
Containment
Ring/ Nozzle
Turbine Rotors

Cracks, wear, chipped, or


broken gear teeth.
Wear grooves or scratched
surfaces on carbon ring.
Wear Grooves
Freedom of needle rollers
Freedom of rotation without
excessive play between races
Corrosion, erosion, cracks
and broken nozzle edges.
Corrosion, erosion,
and broken edges.

cracks

TECH DEVELOPMENT, INC.

Requirements
(Defective Parts Must Be Replaced)
Defective unit to be replaced. Use figure 5
as a guideline for acceptable pinion wear.
Cracks are not acceptable
Wear must not exceed limits per table 4.
There shall be no evidence of excessive
wear.
Deformation of metal smearing in planet
pin holes & keyways not acceptable.
Scoring on bearing diameter not to
exceed .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.

Wear must not exceed limits per Table 4.


Ends must be parallel within 0.0005.
Cracks and breakage are not acceptable.
Minor surface damage is permitted if
function is not impaired.
Wear must not exceed limits per Table 4.
Wear is not permitted.
No wear permitted.
Replace bearings
Replace bearings
Cracks and breakage are not acceptable.
Minor surface damage is permitted if
function is not impaired.
Minor tip rub is permitted if function is not
impaired.

Tip wear; bore and key way Wear is not permitted.


wear
Table 3. Parts Inspection Check Requirements

Publication T1-701
Issued Dec 11, 1998

Page 13

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

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

Figure 16. Gear Teeth Wear Allowances

Page 14
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

SECTION 5.0 ASSEMBLY


5.1 GENERAL
The tools listed in Table 1 are suggested for use by
technicians servicing the T100 Series starters. The
best results can be expected when the proper tools are
used, however, use of other tools is acceptable.
CAUTION
Replace all screws , O-rings, lip seals, and bearings
when the T100 Series starter is reassembled. These
parts are included in the overhaul kits shown in
Section 6.0
NOTE
Always press the inner race of a ball bearing when
installing a bearing on a shaft. Always press the outer
race of a ball bearing when installing into a housing.

Figure 17. Pressing Front Turbine Bearing

Refer to Section 6.0, for a list of kits and components,


which are available to aid in rebuilding T100 Series
starters.
Lubricate all O-rings with petroleum jelly or Parker-ORing Lube before assembly. Refer to Table 5 for a list
of materials to be use during assembly.
MATERIALS
SOURCE
Petroleum Jelly
Commercially Available
Parker-O-Ring Lube
Commercially Available
Loctite RC290
Commercially Available
Grease, gearbox
TDI P/N 9-94121-001
Table 5. Materials for Assembly
CAUTION
The screws that secure the Containment Ring/ Stage 2
Nozzle must have a drop of Loctite RC290 applied to
the threads before being used.
Figure 18. Pressing Spacer onto Bearing

5.2 TURBINE HOUSING


5.2.1 Turbine Shaft Installation
Press the bearing (10) onto the shaft (33) until seated.
Support the shaft and press on the inner race only with
press tool P/N 2-26943 per Figure 17. Note that if

Publication T1-701
Issued Dec 11, 1998

T100 is the original design (SN: 9501-239 to 9611-191),


press the spacer (31) onto the outer race of the bearing
(10) per Figure 18 by supporting the bearing outer race,
and then press the bearing/spacer (10, 31) onto the
shaft.
Press the bearing/shaft assembly, keyway end first, into
bearing housing of the turbine housing. Use press tool
P/N 2-26943 if required per Figure 19. Do not press on
the end of the shaft because the load could damage the
balls of the bearing.
Page 15

TDI TURBOTWIN
FROM

Install bearing retainer plate (32) and secure with four


screws (18). Torque screws to 30 in-lbs.

TECH DEVELOPMENT INC.

Install nozzle 1 onto the turbine housing (26). Orient


the nozzles facing the air inlet (23). Install four screws
(18) to secure the nozzle. Do not tighten the screws at
this time.
5.2.3 Rotor 1 Installation
Install the woodruff key (large key) (16) for stage 1 rotor
into the shaft (33).
Install the stage 1 rotor (15), while supporting sun gear
end of shaft, onto the turbine shaft by aligning the slot in
the rotor with the woodruff key and hand press the rotor
until firmly seated. Use press tool P/N 2-26943 if
required.
Visually inspect that the key was not pushed out
during assembly. Note that the direction of rotation
was oriented properly. This turbine rotor can be
installed backwards.

Figure 19. Installation of Turbine Shaft


Place turbine housing front surface (sungear end) on
flat surface. Install long bearing space (30) over shaft.
Install the seal spacer (8) onto the shaft. Note the small
end of the spacer faces the long bearing spacer.
Install the O-ring (21) into the aft face of the turbine
housing (26).

Temporarily install Nozzle 2 on the turbine housing.


Tighten the four screws that secure nozzle 1 (18) to 30
in-lb. The four screws can be accessed via the holes in
nozzle 2 and the first stage turbine rotor. Remove
Nozzle 2 when the four screws are tight.
5.2.3 Nozzle 2 Installation
Press the lip seal (9) into the forward side of nozzle 2
with seal lip facing up. Use press tool P/N 2-26943.
Install the O-ring (11) into the bearing bore of nozzle 2
(13). DO NOT LUBRICATE THIS O-RING.

5.2.2 Nozzle 1 Installation

Install O-ring (14) onto the outer diameter of nozzle 2.

Press the aft seal (17) into nozzle 1 (19) using press
tool P/N 2-26943 per Figure 20 with the lips facing up.

Install nozzle 2 (13) onto the turbine housing (26). The


three flats of nozzle 2 are always oriented opposite the
turbine housing air inlet (SN 9505-213 to 9611-191).
Install the seal spacer (8) onto the shaft with the small
end facing the aft bearing (10).
Install the wavy spring washer (12) into the bearing bore
of the stage 2 nozzle.
Support the sun gear end of the shaft. Press the aft
bearing (10) onto the shaft by pressing onto the inner
and outer race simultaneously. Use press tool per
Figure 21. Press until bearing is seated.

Figure 20. Installing the aft seal into Nozzle 1

Page 16
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

5.2.5 Air Inlet Installation


Place
(23).

the O-ring (24) into the groove on the air inlet

Install the 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.

5.3 GEARBOX HOUSING


(T112B/T121B, T112D/T121D, T109P/T115P)
5.3.1 Planetary Gear Carrier Reassembly
If disassembled, press needle bearing (38) into planet
gears (37). The planet gears are not identified by part
number, therefore, dimensionally check if correct gears
are being used.
Use table 4 for over the wire
measurements.
With a thrust washer (36) on each side of gear, slide
gear into carrier shaft slots (35), and align with pin
holes.

Figure 21. Pressing Aft Bearing onto Shaft

Lightly slide plant shafts into aligned holes, making sure


snap ring groove on end of pins goes in first per Figure
22.

Install the seal spacer (8) with the small end facing the
aft bearing (10).
Press the lip seal (9) into the stage 2 nozzle using press
tool P/N 2-26943 with lip seal facing up.
Install the stage 2 woodruff key (7) into the shaft (33).
5.2.4 Stage 2 Rotor Installation
Install the stage 2 rotor (6) onto the shaft. Use press
tool P/N 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that the
direction of rotation was oriented properly. This turbine
can be installed backwards.
Install the rotor washer (5) and secure with screws (4).
Tighten screw to 100 in-lb.

Figure 22. Planet Gear Carrier Shaft Assembly

Install the exhaust screen (3) and back plate (2).


Secure with six screws (1). Tighten the screws to 80 inlb.

Publication T1-701
Issued Dec 11, 1998

Page 17

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

NOTE
Make sure that anti-rotation pins on shafts are properly
located in retaining slots of carrier shaft (35).
Install snap ring (34) with a snap ring tool.
5.3.2 Gearbox Reassembly
Press the bearing (41) into the forward side of the
gearbox housing (58, D-44). Pressing force should be
on the outer race only.
Install retainer plate (46) and secure with six screws
(18).
Press rear bearing (41) onto carrier shaft (35) using TDI
Tool P/N 52-20143 per Figure 23. Pressing force
should be on the inner race of bearing.
Install spring washer (42) and bearing spacer (43) onto
shaft and locate against bearing.

Figure 23. Pressing Rear Bearing onto Carrier Shaft

Position carrier shaft assembly (35,41,42,43) into


bearing bore of the gearbox housing (58). Lift up on
housing and slide shaft down. If shaft will not slide into
bearing bore, press housing per Figure 24 until bearing
is seated (41).
Place gearbox assembly on TDI Tool P/N 2-20202 per
Figure 25. Install lockwasher (47) and then retainer nut
(48). Torque to 600-800 in-lb. Tang lockwasher into
retainer nut slot.
Place O-ring (14) onto outer diameter of
assembly.

gearbox

Thoroughly grease planet gears, ring gear and sun


gear using the grease specified in Table 5 and pack the
center of the gears with grease.
5.3.3 Gearbox to Turbine Housing Assembly
Rotate carrier shaft (35) slightly, and at the same time,
align gearbox into the front of turbine housing (26).
Install six screws and torque 90-120 in-lbs.

Figure 24. Installing Carrier Shaft into Gearbox


Housing

Page 18
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

5.5.

TECH DEVELOPMENT, INC.

DRIVE/GEARBOX HOUSING
(T106F/T112F)

5.5.1 Planetary Gear Carrier Reassembly


If disassembled, press needle bearing (38) into planet
gears (37). The planet gears are not identified by part
number, therefore, dimensionally check if correct gears
are being used.
Use table 4 for over the wire
measurements.
With a thrust washer (36) on each side of gear, slide
gear into carrier shaft slots (63), and align with pin
holes.
Lightly slide plant shafts (39) into aligned holes, making
sure snap ring groove on end of pins goes in first.

Figure 25. Tightening Retainer Nut

NOTE
Make sure anti-rotation pins on shafts are properly
located in the retaining slots of the carrier shafts (63).
5.5.2 Planetary Carrier Bearing Installation

5.4 DRIVE HOUSING


(T112B/T121B, T112D/T121D, T109P/T115P)

Install bearing retainer plate (64) over carrier shaft (63)

5.4.1

Press bearing (65) onto shaft making sure pressing


force is on inner race of bearing only.

Bendix Drive Installation

Install two woodruff keys (40).


properly installed per Figure 26.

Ensure keys are

Position bendix assembly (57) on shaft with retainer set


screw (53) removed. Install spring ( 52) between
bendix cavity and end of output shaft. Slide bendix over
shaft until set screw hole aligns with set screw hole in
shaft.

Place carrier shaft assembly onto TDI Tool P/N 5220202, see Figure 27. Thread retainer nut (67) onto
shaft (63). Hold carrier assembly down and torque nut
to 600-800 lb.-in. with spanner wrench, TDI Tool P/N
52-21345.

Install set screw and tighten firmly. Slip retainer (51)


ring into set screw slot.
5.4.2 Bendix Drive Housing Installation
If disassembled, press needle bearing (62, P-80) into
drive housing (61) until flush with bottom surface.
Mount drive housing over bendix drive, and align holes
for desired bendix opening orientation with starter inlet
connection. Torque bolts and nuts to 90-120 in-lbs.
Figure 26. Woodruff Key Installation

Publication T1-701
Issued Dec 11, 1998

Page 19

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

Figure 28. Gearbox/Drive Housing Installation


(T106F/T112F)
Figure 27. Tightening Retainer Nut (T106F, T112F)
5.5.3 Bendix Drive Installation
Install bendix drive (68) into drive housing (69), aligning
bendix shaft into front needle bearing (70).
With snap ring tool, install snap ring (66)into drive
housing (69).
Align carrier shaft assembly (63) into bendix drive and
push assembly until seated against snap ring (66) per
Figure 28.
Install six screws (27) and torque 90 to 120 lb.-in.

Page 20
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

SECTION 6.0 PARTS LIST


The components illustrated and/or described
in this section are for the Turbotwin T100 series
air starters. When rebuilding a T100 series
starter, it is recommended to purchase, and
completely install the appropriate service kit(s).

Key No.

Description

Part Number

Screw (6)

11F- 25020-072

Screen Support Ring

2-20831

Screen

2-26148

Screw

19F- 25028-012

Washer

9-93047

Rotor 2

2-26604

Woodruff Key

9-90211-006

Seal Spacer (3)

9-93083-001

Seal, Lip (2)

2-26719

10

Bearing (2)

9-91224

11

O-ring (2)

9-90001-027

12

Wave Spring Washer

9-90439

13i

Nozzle 2/Containment Ring


R.H.

2-27333-00R

13ii

Nozzle 2/Containment Ring


L.H.

2-27333-00L

14

O-ring

9-90001-050

15

Rotor 1

2-26603

16

Woodruff Key

9-90211-009

17

Lip Seal

2-22376

18

Screw (14)

14F-19024-008

19i

Nozzle 1, R.H. 21 Noz

2-26718-21R

19ii

Nozzle 1, L.H. 21 Noz

2-26718-21L

19iii

Nozzle 1, R.H. 12 Noz

2-26718-12R

19iv

Nozzle 1, L.H. 12 Noz

2-26718-12L

Publication T1-701
Issued Dec 11, 1998

Page 21

TDI TURBOTWIN
FROM

Page 22
701

Key Number

Description

Part Number

19v

Nozzle 1, R.H. 6 Noz

2-26718-06R

19vi

Nozzle 1, L.H. 6 Noz

2-26718-06L

20

Pipe Plug

9-93556-004

21

O-ring

9-90001-034

22

Screw (6) or (12 for


T112D/T121D std)

14F-31218-016

23

Inlet Flange

1-18967

24

O-ring

9-90001-037

25

Set Screw (See Note 1)

52F-50013-016

26

Turbine Housing (See Note


1)

2-27045

27

Screw (6)

14F-25020-016

28

Pipe Plug

9-93501-004

29

Ring Gear (See Note 1)

1-18780

30

Bearing Spacer

9-93091-001

31

Screw (4)

14F-25020-008

32

Clamping Plate

2-26750

33

Turbine Shaft

2-26554

34

Retainer Ring (3)

9-92001-001

35

Planet Gear Carrier Shaft

2P-20156-006

36

Washer (6)

9-93004

37

Planet Gear (3)

1-19441

38

Needle Roller Bearing (3)

9-91004-001

39

Planet Shaft (3)

2P-20182

40

Woodruff Key (2)

9-90211-019

41

Bearing (2)

9-91351

TECH DEVELOPMENT INC.


B

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

Key

Description

Part Number

42

Wave Spring Washer

9-90402-025

43

Bearing Spacer

9-93007

44

Gearbox Housing

2-22226

45

Screw (6)

14F-25020-028

46

Retainer Plate

1-18817

47

Lockwasher

9-93061-007

48

Retainer Nut

9-92127-007

49

Drive Housing

2-22301

50i

Inertia Drive Assembly, R.H.

2-22795

50ii

Inertia Drive Assembly, L.H.

2-22796

51

Retaining Ring

Included with item 50 or 57

52

Spring

Included with item 50 or 57

53

Set Screw

Included with item 50 or 57

54

Needle Bearing

9-91393

55

Adapter Plate

2-22794

56

Screw

14F-31218-020

57i

Inertia Drive Assembly, R.H.

1-18828

57ii

Inertia Drive Assembly, L.H.

1-19083

58

Gearbox Housing

1-18810

59

Lock Nut (6)

9-92107-015

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

Publication T1-701
Issued Dec 11, 1998

Page 23

TDI TURBOTWIN
FROM

Key

Description

Part Number

66

Snap Ring

9-92001-006

67

Lock Nut

9-92105-008

68i

Inertia Drive Assembly, R.H.

2-22147

68ii

Inertia Drive Assembly, L.H.

2-22148

69

Drive Housing

2-20826

70

Needle Bearing

9-91380

71

Washer, Flat

9-93018-011

72

Nut, Hex

9-92108-003

73

Cover, Plate

2-20192

74

Screw (6)

11F-25020-072

75

Housing, Exhaust Cover

2-27069

76

Spring, Compression

9-90408-016

77

Post

2-27223

78

Drive Housing

2-25617

79

Screw (12)

11F-31218-024

80

Needle Bearing

9-91423

Model
B
D
F
P

Page 24
701

TECH DEVELOPMENT INC.

Overhaul Kit for S/Ns before: 9611-191


T10B-27618
T10D-27619
T10F-27617
T10P-27620

Overhaul Kit for S/Ns after: 9611-192


T10B-27634
T10D-27635
T10F-27633
T10P-27636

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

Figure 29. Illustrated Parts Breakdown (T112B/T121B)

Publication T1-701
Issued Dec 11, 1998

Page 25

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

Figure 30. Illustrated Parts Breakdown (T109P/T115P)


Page 26
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

Figure 31. Illustrated Parts Breakdown (T112D/T121D, Standard Mesh)


Publication T1-701
Issued Dec 11, 1998

Page 27

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

Figure 32. Illustrated Parts Breakdown (T112D/T121D, Long Mesh)


Page 28
701

Publication T1Issued Dec 11, 1998

TDI TURBOTWIN
FROM

TECH DEVELOPMENT, INC.

Figure 33. Illustrated Parts Breakdown (T106F/T112F)


Publication T1-701
Issued Dec 11, 1998

Page 29

TDI TURBOTWIN
FROM

TECH DEVELOPMENT INC.

SECTION 7.0 ACCESSORIES


SIZE

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

12VDC; 1"; VITON

RLVA-25683-012-2

12VDC; 1"; VITON


24VDC; 1"; BUNA N
24VDC; 1"; BUNA N

RLVA-25683-012-2-01
RLVA-25683-024-1
RLVA-25683-024-1-01

24VDC; 1"; VITON

RLVA-25683-024-2

24VDC; 1"; VITON


110VDC; 1"; VITON
120VAC; 1"; VITON

RLVA-25683-024-2-01
RLVA-25683-110-2-01
RLVA-25683-120-2-01

SIZE

PART NUMBER

GAUGES
REAR CENTER MOUNT
U-CLAMP REAR CENTER
MOUNT
BOTTOM MOUNT

52-21982
52-21982-100
52-21982-200

52-93508-400

PRESSURE REGULATORS
2" GAS 300
52-93552
2" GAS 125
52-93553
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

CONTROL & SOLENOID VALVES


1/8" NPT STR CONROL VALVE 52-93504
1/4", 24 VDC, CONDUIT
52-21981
1/4", 12 VDC, GROMMET
52-21981-002
1/4", 120 VAC, CONDUIT
52-93506-100
1/4", 120 VAC, GROMMET
52-93506-200
1/4", 24 VDC, CONDUIT
52-93506-300
1/4", 24 VDC, GROMMET
52-93506-400
1/4" 72 VDC
52-93506-500

Y-STRAINERS
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

Page 30
701

Publication T1Issued Dec 11, 1998

Model: T I 21-B, T I 21-D Performance Curve


21 Nozzles, Natural Gas, 7.5:l Ratio

TORQUE
N~
~b.ft

Inlet Pressure
90 psig

90 psig

500

POWER
HP KW

SCFM Nm31h
2028 3448
1391 2365
806
1370 Y~
-

1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 6,500

Output Speed, rpm

Section 5 Cooling System


Vendor

Bulletin No.

Coolant System Drawing................................................ Ajax

TP 02-04-T010-307

Compressor Cylinder Coolant System ........................... Ajax

02-04-T020-300

Water Pump and Mounting............................................. Ajax

TP 02-04-T03A-001

F1 820 AM Pump, Illustrated Parts List (8 Impeller) ............... Ajax


Pump Maintenance Bulletin........................................................ Peerless

4845749

Pump Lubrication Guide ............................................................. Peerless

4852918

Thermostatic Control Valve Bulletin ........................................... FPE


Butterfly Valve, 2, O&M Bulletin ................................................ DEMCO

Engine-Compressor Package Service Manual

TC 1512

Note
The 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.

4. Check the tension after the first 24


hours of initial operation, and
retension if necessary. Tighten the
belt by turning the two adjusting
screws (item 5) an equal amount of
CW turns.

Coolant Pump & Mounting


Assembly
TP 02-04-T03A-001

Coolant Pump & Mounting Assembly


TP 02-04-T03A-001
Item

Description

P/N

Qty

1
2
3
4
5
6
7
8

Belt, 5V
Sheave, 2 Groove 5V x 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.

Peerless Pump Model F1-820AM for Ajax DPC-2802 Series

Peerless F1-820AM Pump for Ajax P/N 5027 2825


Item

Description

Material

P/N

Casing

Cast Iron

order by S/N

Impeller, Trimmed to 8" Diameter

Bronze

V1735B-449

Shaft

Steel

2681134-492

Casing Ring

Bronze

284006-186
2691519-199092

13

not used, see #65 & #81

14

Shaft Sleeve

Bronze

16

Inboard Bearing

Steel Assembly

1100750-000

17

not used, see #65 & #81

17B

not used, see #65 & #82

17C

not used, see #65 & #83

17D

not used, see #65 & #84

18

Outboard Bearing

Steel Assembly

266935-000

19

Bearing Frame

Cast Iron

order by S/N

Bearing Lock Nut


Impeller Washer
Impeller Cap Screw

Steel
Steel
Nylon/18-8 Stainless Steel

2681602-056
2698080-079
2698078-641

32

Impeller Key

Steel

V2343A-064

40

Deflector

Rubber

2675921-118

46

Coupling Key

Steel

49

Outboard Bearing Grease Retainer

Rubber/Steel Assembly

2681122-000

51

Inboard, Bearing Grease Retainer

Rubber/Steel Assembly

2681123-000

65

Mechanical Seal Seat

Ni-Resist

268716501-000

71

Adapter

Cast Iron

order by S/N

22
24A
26

73A

Casing Gasket

Fiber

80

Mechanical Seal Rotary

Steel (Metal & Spring)

119

Shaft Sleeve "O" Ring

Viton

V2377A5

V1774A-122
268716501-000
2691534-199

Page 1 of 12

Installation, Operation and Maintenance Manual

DEMCO
Resilient Seated
Butterfly
Valve

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Page 2 of 12

Publication TC1512

Published May 2000

DEMCO is a trademark of Cooper Cameron Corporation


Cooper Cameron Corporation, Cooper Cameron Valves Division, 2000.
All rights reserved.

Publication
TC1512

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Page 3 of 12

Table of Contents

Bill of Materials ................................................ 4


Scope .............................................................. 6
Nameplate Information .................................... 6
Storage .............................................................. 6
Installation ........................................................ 7
Disc to Pipe Clearance ................................ 8
Flange Bolts ................................................ 8
Procedure .................................................... 9
Operation .......................................................... 9
Trouble Shooting ............................................ 10

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Page 4 of 12

Bill of Materials

Figure 1 - Demco 2" thru 12" Resilient Seated Butterfly Valve

Demco 2" thru


ITEM
1.
2.
3.
4.
6.
7.
14.
22.
23.
24.

12" Parts List


REQ'D
1
1
1
1
1
2
1
1
*
2

DESCRIPTION
Body
Seat
Disc
Upper Stem
Lower Stem
Spring Pin
Retainer
Top O-Ring
Stem O-Ring
Bearing

* 4 Req'd for throttling valves only.

Publication
TC1512

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Page 5 of 12

Figure 2 - Demco 14" thru 36" Resilient Seated Butterfly Valve

Demco 14" thru


ITEM
1.
2.
3.
4.
6.
7.
14.
23.
24.
25.

36" Parts List


REQ'D

DESCRIPTION

1
1
1
1
1
2
1
*
2
1

Body
Seat
Disc
Upper Stem
Lower Stem
Spring Pin
Retainer**
Stem O-Ring
Upper bearing
Lower bearing

* 4 Req'd for throttling valves only.


** 24" 36" Spacer

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Page 6 of 12

Scope
Demco resilient seated butterfly valves are an
economical alternative to ball, gate or plug valves
in many applications. They are light weight
quarter turn devices with few parts. They are
designed for bubble tight sealing up to rated

pressure and are capable of throttling service.


They are easily adapted to automatic actuators.
The Demco butterfly valve is available in flangeless
wafer design or single flange tapped lug configuration.

Nameplate Information
4

Figure 3 - Demco Resilient Seated Butterfly Valve Nameplate.


5

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

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Page 7 of 12

Installation
Direction Demco butterfly valves are bi-directional and will
operate in any position. Normally the valve is
installed with the upper stem pointing upward
(Figure 5). Elevated valves with gear operators and
chainwheels should be installed with the upper
stem pointing down (Figure 6) so the open-closed
indicator is visible from the ground and the chain
does not drag on the pipe.
End-of-Line Service Demco tapped lug butterfly valves are suitable for
liquid service end-of-line applications with downstream piping removed (Figure 7). Only weld neck
or socket weld flanges can be used for this service.
Since the upstream pressure is excluded between
the flange and the seat face by the exclusive
Demco flange seal, there is no effective force to
slide the seat downstream.

Figure 5

Caution: The valve must not be opened or


closed with the downstream piping removed as the seat might be shifted breaking the flange seal and allowing pressure
to slide the seat downstream.
Gaskets
Flange gaskets are not required nor recommended
for use with positive shut-off Demco butterfly
valves. An integral flange seal is molded into the
edge of the rubber seat eliminating the need for
flange gaskets.
Throttling Valves, only, utilize an o-ring stem
seal that must be assisted with flange gaskets for a
proper seal.

Figure 6

Flanges Steel Class 150 ANSI (or MSS SP-44) weld neck, slipon, threaded and socket weld as well as stub end
type C flanges are suitable for use with 2 thru 24
Demco butterfly valves. 30 and 36 Demco
butterfly valves fit between ANSI 125 flanges (or
MSS SP-44).
Other flange types may be applicable also, but
should be thoroughly checked to assure proper seal
makeup. Plastic flanges are subject to damage at
installation by over-tightening the bolting and
may deflect or cup resulting in flange leaks.
Figure 7

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Page 8 of 12

Disc to Pipe Clearance Before beginning installation, disc/pipe clearance


should be checked to avoid the possibility of
scraping the disc edge on the pipe ID and damaging the sealing surface. Minimum pipe ID requirements are given in Table 1.
Valve Disc Swing
Opens into:
Size
Clearance Std Pipe
Sch 40
Sch 80

2"
2-1/2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"
20"
24"
30"
36"

PIPE I.D.
DISC
CHORD

Figure 8

1.467"
2.144"
2.743"
3.601"
4.582"
5.624
7.428"
9.382"
11.35"
12.86"
14.72"
16.61"
18.53"
22.57"
28.67"
34.70"

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x

Table 1 - Disc Clearance

WAFER BODY

Flange Bolts Recommended bolt and stud lengths for installation in ANSI flanges are provided in Table 2.
MSS flanges require longer bolts.

STUDS & HEX NUTS

Valve
Size
2"
2-1/2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"
20"
24"
30"
36"

Bolt
Size

Wafer Body
Stud
Screw
Qty
Length Length
"A"(in.) "B"(in.)

5/8"-11
4
5/8"-11
4
5/8"-11
4
5/8"-11
8
3/4"-10
8
3/4"-10
8
3/4"-10
8
7/8"-9
12
7/8"-9
12
1"-8
12
1"-8
16
1-1/8"-7
16
1-1/8"-7
20
1-1/4"-7
20
1-1/4"-7 24 (8)
1-1/2"-6 28 (16)

5"
5-1/2"
5-1/2"
5-3/4"
6-1/2"
6-1/2"
7"
7-1/2"
8-1/4"
8-1/4"
10"
10-1/2"
11-3/4"
12-1/2"
13-1/2"
16"

(4")
(4")

Table 2 - Flange Bolt Size

Lug Body
Screw
Qty.
Length
"B"(in.)
8
8
8
16
16
16
16
24
24
24
32
32
40
40
56
64

1-1/2"
1-1/2"
1-1/2"
1-3/4"
1-3/4"
2"
2-1/4"
2-1/4"
2-1/2"
2-1/2"
3-1/4"
3-1/2"
4"
4"
4"
4"

Figure 9

Figure 10

Publication
TC1512

Flanges -

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Page 9 of 12

Procedure
The following procedure applies to new installation between standard ANSI pipe flanges. When
replacing a valve from an existing installation,
clean flange faces and check for excessive corrosion or other damage to the sealing face of the
flange.

wafer body is equal to the inside of the bolt


circle of the flanges, so the valves are selfcentering.) Install the remaining flange bolts.
3. Lug bodies have tapped holes coinciding with
those in the flanges. They should be positioned between the flanges and the capscrews
inserted through the flange holes into the
threaded lug holes.
1. Remove the valve from any packaging mate4. Tighten all bolts or capscrews in a crossover or
rial. Close the valve disc so that it is contained
star pattern to assure even sealing. Tighten
within the flange faces. It is not necessary to
sufficiently to assure metal-to-metal contact
fully close the valve; the disc must be conbetween the flange face and the metal buttertained within the confines of the valve body
fly valve body. No further tightening is reso it will slip between the mating flanges
quired.
without contact with the flanges.
5. Carefully check disc clearance by placing the
2. When installing wafer valves, install the lower
valve in the full open position. Any binding or
flange bolts without tightening. Position the
scraping should be investigated and corrections
valve between the flanges, within the pocket
made.
formed by the flange bolts. (The OD of the

Operation
Demco butterfly valves should never be operated
without a handle or other means of controlling
the disc.
Caution: Failure to restrain the disc under
flow conditions can result in the disc
slamming closed and possible damaged or
broken parts.
2 thru 12 Demco butterfly valves have flats on
the upper stem. 14 and larger valves have a
single square key. Stem flats or the square key
indicate valve position. When they are in line
with the flow stream, the valve is open. When
perpendicular, the valve is closed.
Manually operated
Demco butterfly valves operate from fully open to
fully closed by a 90 turn of the handle. The
handle is marked with a flow arrow. When this
arrow is in line with the pipe axis, the valve is

Figure 11 Valve shown open

open (Figure 11). When perpendicular to the pipe,


the valve is closed (Figure 12).
Worm gear operated
Worn gear operators are recommended for valves
larger than 6 inches. Clockwise rotation of the
handwheel closes the butterfly valve. Counterclockwise rotation opens the valve. Gear operators
are always mounted with the input shaft perpendicular to the pipe axis for handwheel clearance.
Each operator has an arrow on the top of the gear,
which indicates the OPEN CLOSED position of
the valve (Figure 13).
Automated valves
Butterfly valves with their quarter turn operation
are easily adapted to automatic actuators for
remote operation. To prevent water hammer,
actuators should close the valve slower than 6 to 8
seconds, open-to-close. Rapid closure causes water
hammer which can break or otherwise damage
valve parts.

Figure 12 Valve shown closed

Figure 13 Valve with gear operator

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Page 10 of 12

Troubleshooting
Trouble

Probable Cause

Remedy

The seat and/or disc is worn or


damaged.

Replace worn parts.*

Foreign matter is present between seat


and disc.

Operate several times to wipe clean.

Operator stops are not set properly.

Adjust stops to proper setting.

Build up of solids or roughness is on


edge of disc.

Operate several times to wipe clean or disassemble


valve and clean disc edge.*

Operator is not installed properly.

Reistall operator in proper alignment with valve


stem.

Disc hits on side of pipe.

Check for proper pipe clearance.

Seat is damaged or worn.

Replace Seat.*

Disc is bent.

Replace disc, stems and seat as required.*

Flange seal is leaking.

Correct flange seal leak to prevent fluid


from migrating behind seat and out stem.

Handle or actuator does not provide


proper restraint.

Restrain disc with handle or actuator.

Line flow too great.

Choose larger valve or slow down flow.

Flange seal surface on seat is damaged.

Replace seat.*

Flange surfaces are damaged or


corroded.

Clean, repair or replace flanges.

Flange bore is too large.

Replace with proper flanges.

Clockwise rotation of
Gear Operator handwheel
opens valve. Open-Shut
indicators do not coincide
wth valve disc position.

Gear operator has been rotated 90o on


valve top.
Hand-wheel shaft aligns with pipe
(should be perpendicular).

Rotate gear operator 90o on valve top to put input


shaft perpendicular with pipe axis.

Automatic actuator slams


valve shut or open.

Speed control valves missing or not


adjusted.

Hard, soft or cracked


seat damage is present.

Heat or chemical damage to seat.

The valve will not seal


properly.

The valve is hard to


operate.

The valve will not open.

The valve is leaking


around stem.

The valve closes with line


flow.

Flange leaks.

Install and/or adjust speed control valves.

Replace elastomer seat with compatible material


and/or correct offending fluid conditions.

*Contact your CCV representative for repair manual


Publication
TC1512

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Page 11 of 12

NOTES

DEMCO Resilient Seated Butterfly Valve


Installation, Operation and Maintenance Manual

Publication
TC1512

Headquarters
Cooper Cameron Valves
16500 South Main Street, Missouri City, TX 77489-1300
Phone: 281-499-8511, 800-323-9160, Fax: 281-499-6965
Manufacturing
Cooper Cameron Valves
Demco Products
P.O. Box 94700
Oklahoma City, OK 73143
Phone: 405-631-1321, Fax: 405-631-0420
http://www.ccvalve.com

DEMCO is a trademark of Cooper Cameron Corporation


c Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 5-00 / TC1512

Section 6 Cooler
Vendor

Bulletin No.

E72-9 Cooler Drawing ..................................................ACE

07366-C

Cooler Spec Sheet .........................................................ACE

7249PW

Cooler Spare Parts List ..................................................ACE

E72-9

Cooler Start Up Procedures.................................................ACE


Cooler Operation and Maintenance Instructions .................ACE
Bearing Lubrication Schedule
Fan O&M Bulletin................................................................Crowley

Engine-Compressor Package Service Manual

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

SEE CL BELOW - THESE DIMENSION (S) ARE SYMETRICAL


ABOUT THE CENTER OF COOLER.
FLAG

NOTES
1. WEIGHT: 7239 POUNDS
2. FINISH: ACE std prep. w/ one coat QL-5505 primer
A
3. FAN DRIVEN BY V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR

SERVICE

CL

LOUVERS

DESIGN
PRESSURE

DESIGN
TEMPERATURE

NOZZLES IN
(1)2150RF

(1)2150RF

N/A

18.375

N/A

150 PSI

350 Deg F/20 Deg F

NOZZLES OUT

OTHER NOZZLE

NC

EJW

112.75

IC

113.75

AUTO

215 PSI

350 Deg F/20 Deg F

(1)6150RF

(1)6150RF

N/A

18.875

AC

113.75

AUTO

350 PSI

350 Deg F/20 Deg F

(1)6300RF

(1)6300RF

N/A

18.875

AIR COOLED EXCHANGERS, LLC


SCALE: 1:1 (FIT TO PLOT)
DATE: 10/18/2007

BY

DATE

REV1

DB

10/25/07

REV 2

KG 110807

DESCRIPTION
SHOW MISSING NOZZLE

AID
DHB

CHECKED BY:

CUSTOMER: CAMERON COMPRESSION

4. ASME CODE ON IC,AC,

DRAWN BY:

ACE MODEL E729

P.O:
CKD
DHB

4501415535

DRAWING NUMBER REV

07366

MOVE NOZ ON EJW PER SALES KG

AIR COOLED EXCHANGERS, INC.


P.O. BOX 577 - BROKEN ARROW, OKLAHOMA 74013
Ph (918) 251-7477
Fax (918) 258-1833
E-MAIL: MAILHUB@ACE-COOLERS.COM

COOLER PERFORMANCE SPECIFICATION


CUSTOMER
REFERENCE
MODEL

CAMERON COMPRESSION
QT. 07126 - Purneftagas
E72-9

PROPOSAL NUMBER
DATE
PAGE

7249PW
10/12/2007
1

PERFORMANCE OF ONE UNIT


EJW
IC
AC

SERVICE
FLOW
FLUID
TEMPERATURE IN, F
TEMPERATURE OUT, F
INLET PRESSURE, PSIG
PRESSURE DROP, PSI
DUTY, BTU/HOUR
CORRECTED MTD
BARE TUBE RATE
FOULING
BARE SURFACE, SQ. FT.
TOTAL SURFACE SQ. FT.

121.5GPM
50%GLY
165.0
150.0
5.4
801200
34.1
207.4
0.00050
113
2710

3.01MMSCFD
.947
162.8
130.0
41.9
1.9
148245
33.7
56.8
0.00200
77
1848

3.01MMSCFD
.947
191.0
120.0
80.0
2.3
326450
35.4
61.7
0.00200
149
3572

CONSTRUCTION
NO. SECTIONS
NO. TUBES/SECTION
LENGTH
NO. ROWS
NO. PASSES
COUNTERFLOW
TUBE O.D. AND BWG
TUBE MATERIAL
DESIGN PRESSURE, PSI
DESIGN TEMPERATURE, F
NOZZLES-INLET
NOZZLES-OUTLET
HEADER TYPE
HEADER MATERIAL
ASME CODE STAMP
GROOVED TUBE SHEET
CORROSION ALLOWANCE
PLUGS, TYPE
PLUGS, MATERIAL
TURBULATORS
ACCELERATORS
LOUVERS
STRESS RELIEVE
NDE
ADDITIONAL CODES
CANADIAN REGISTRATION
ADDITIONAL COUPLINGS
BYPASS NOZZLE
FINS

1
66
9.0
4
3

1
45
9.0
6
1

1
87
9.0
6
2

.75X16BWG
SA214(WLD)
150
350/-20
2-150RF
2-150RF
RECT TUBE
STEEL

.75X16BWG
SA214(WLD)
215
350/-20
6-150RF
6-150RF
BOX W/PLUGS
SA-516-70
YES

.75X16BWG
SA214(WLD)
350
350/-20
6-300RF
6-300RF
BOX W/PLUGS
SA-516-70
YES

TAPER
STEEL

TAPER
SA-105

TAPER
SA-105

NO

AUTO
NO
100% X-RAY

AUTO
NO
100% X-RAY

YES

1
ALUMINUM

1
ALUMINUM

ALUMINUM

AIR DATA
INLET AIR, F
OUTLET AIR, F

100.0
131.1

ELEVATION, FT.
TOTAL SCFM

1500
37861

MECHANICALEQUIPMENT
1
12.5
637
72
NO FANS
HP/FAN
RPM
DIA
FAN
CROWLEY 9WL
FAN MATERIAL ALUM
NUMBER OF BLADES 5 PITCH 32 DEGREES
V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR
FORCED
DRAFT TYPE
7239
WIDTH 6.9
LENGTH 10.4
HEIGHT 7.1
EST SHIPPING WEIGHT
ACCESSORIES
FINISH ACE std prep. w/ one coat QL-5505 primer

Parts List

Air Cooled Exchangers, LLC


1201 S. 9th Street
Broken Arrow, Oklahoma 74012
Phone: 918-251-7477
Fax: 918-251-7482

Customer: CAMERON COMPRESSION


ACE Serial Number(s): 0

Cooler Model: E72-9


Fan Make & Model

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

4.25 in Keyway Fan end

Long with

##
0

Dia.

Long with

1.4375 in REXNORD MODEL ZA-2107

Idler Bearing

Electric Motor

###

15
TEFC

1500

HP
Enclosure

Keyway one end

380

RPM

254T

Frame Size

WITH

$295.00

PRICE EACH

$0.00

PRICE EACH

$249.00

PRICE EACH

$0.00

SlideBase

$2,006.00

6 in Keyway other end

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

FAN, SHAFT, BEARINGS & V-BELTS ARE RECOMMENDED SPARE PARTS.


ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE.
ALL INQUIRiES AND ORDERS MUST BE ACCOMPANIED BY COOLER SERIAL NUMBER.

Cycle

AIR COOLED HEAT EXCHANGER


SUGGESTED START UP PROCEDURE

Before any start up procedure is begun, a thorough inspection of the Air Cooled
Exchanger should be made.
1.)

Be sure all bolted connections are properly tightened.

2.)

After tube bundle and piping hydrotest, remove hydrotest connections.


Be sure tube bundle is properly drained, and if required, dried. Connect
process piping and any auxiliary connections.

3.)

Inspect all process connection, as well as, vent drain, temperature and
pressure, or any other auxiliary connections to be sure they are plugged
or connected properly.

4.)

Check mechanical equipment before starting process through the tube


bundle(s).
a.)

Thoroughly check the plenum and fan drive area to be sure all
tools and construction materials are removed.

b.)

Rotate the fan by hand and check fan tip clearance and alignment
of belts and sheaves.

c.)

Check belt tension.

d.)

Check all fan drive bolts to be sure they are properly tightened.
This includes bearing bolts, fan and sheave bushing bolts, set
screws, motor bolts and fan blades attachment bolts.

e.)

If air operated auto-variable pitch fans are used, check for proper
pitch with the air off. Fans may go to either minimum or maximum
pitch at air failure. Check specifications for requirements. If fan
pitch is not satisfactory, set pitch per manufacturer's instructions
(see Operation and Maintenance Instructions). If fan pitch is
satisfactory, cycle fan through it's range, using plant air and an air
regulator.
Page 1

5.)

f.)

If air operated louvers are provided, it is advisable to disconnect


the air motor linkage and cycle the louvers by hand to assure
there is no binding or obstruction of the louvers blades. If binding
occurs, check to be sure louver frames are square. Attaching
bolts may have to be loosened and frames shifted to ease binding.
If louvers operate smoothly, reconnect air motor. Cycle the air
motor, using plant air and an air regulator.

g.)

If manually adjusted pitch fans are provided, check fan pitch and
re-pitch per manufacturer's instructions if required.

h.)

If manual operated louvers are provided, check for binding of the


blades, as in instruction (f). Operate louvers to be sure there is no
linkage obstruction or binding.

i.)

Remove condensate drain plugs, if provided, in electric motors


and other electrical components to drain any condensation that
might have occurred during storage. If space heaters are
furnished in electric motors, louver actuators, controls, etc.,
activate the space heaters and allow approximately 24 hours
before starting equipment.

j.)

After all the applicable steps previously stated are completed, the
mechanical equipment may be cycled.

k.)

Be sure all personnel and equipment are away from the fan and
fan drive area. For safety reasons, equipment guards should be
installed. Activate the drive motor and let it reach speed. Check
for vibration and excessive noise. If vibration or excessive noise
occurs, immediately shut motor down, and check for loose
connections or insufficient clearance between moving parts. If the
system is running smoothly, replace any guards removed and
move to the next drive and repeat above steps.

Start the process through the tube bundle(s). Open the inlet valves
slowly and let the process "Warm" the bundles slowly. This will allow the
components of the tube bundle to expand at the same rate and lessen the
thermal shock.

Page 2

OPERATING AND MAINTENANCE INSTRUCTIONS FOR ACE COOLERS


IMPORTANT
Before start up, check set screws and bolts in the fan assembly and set screws in
locking collars of all bearings and sheaves. These items should be checked
again several days after start up.
FAN & DRIVE
Although the fan and drive are inspected before shipment, clearance between
the fan blades and the fan ring and guard, and alignment of the fan shaft should
be checked to assure that rough handling during shipment has not loosened
bearing mounting bolts or caused misalignment.
V-belt drives should be adjusted until tight enough to prevent excessive belt
slippage. The belt is generally tight enough when it can be twisted one-quarter of
a turn with the thumb and fore-finger.
LUBRICATION
Bearings should be greased in accordance with normal maintenance practice.
Over-lubrication is the most common cause of bearing failure. In general, about
one cubic inch of grease in each bearing every 2 to 3 months is adequate. The
operating temperature of the bearing may indicate how much lubrication is
required.
Normal temperature may range from cool to warm to touch up to a point too
hot to touch for more than a few seconds depending on bearing size and speed,
and surrounding conditions. Unusually high temperature accompanied by
excessive leakage of grease indicates too much grease. High temperature with
no grease showing at the seals, particularly if the bearing seems noisy, usually
indicates too little grease. Normal temperature and slight showing of grease at
the seals indicates proper lubrication.
Page 1

TUBE CLEANING
Operating conditions sometimes cause an accumulation of dirt on the outside fin
surface. This can be removed by directing compressed air, or a greaseless
solvent followed by a water spray through the fins in a direction opposite the
normal air flow. The inside of the tubes will require periodic inspection and
cleaning as necessary. Removal of access plugs allows visual inspection, and if
necessary, the use of mechanical tube cleaners.
PLUG LEAKS
Should tapered plugs develop leaks, additional tightening is normally all that is
required. Thread dope may be used if tightening alone is not sufficient. If
shoulder type plugs develop leaks, the gaskets should be replaced. Tapered
plugs that are removed for the tube inspection or cleaning should be replaced in
the same hole.
TUBE LEAKS
Tube leaks can be of two types: (1) leaks in the tubewall itself (usually corrosion)
and (2) leaks in the tube to tubesheet joint. In the first case, it is usually most
practical to plug both ends of the tube with the resulting loss in heat transfer
surface. When so many tubes have been plugged that performance is affected,
retubing will be necessary. If leaks develop in the tube to tubesheet joints, rerolling of the tube will be required. Care must be used in selection of the proper
tube expander for the size and BWG of the tube being used. As with all rolled
tube joints, over-rolling must be avoided.
GENERAL
If it is ever necessary to contact our plant for service or replacement parts, it is
essential that our serial number or other identifying data be obtained from the
metal nameplate attached to the cooler. This is the only way to positively identify
the correct parts that may be required.

Page 2

Multi-Wing Z Series Fans


Blade Pitch Angle Setting Instructions
Before You Begin:
To maintain balance of fan:
Mark the hub castings across a joint, so the fan hub can be reassembled in the same orientation.
Mark the location of any balancing weight. Balancing weight will be on the outer bolt circle, in the
form of washers, and/or longer bolts, or an additional balancing nut.
Number the blades and blade sockets, so that they are replaced into their original position.
If possible, note the location of the pitch setting pin in the blade socket when disassembling the fan, and
whether pin is located in the Hub or Retainer half of the fan (see step 7 for detailed definition).
Step 1 Determine Blade Type: 1Z, 2Z, 4Z, 5Z, or 6Z
If the blade has a sickle shape, then look for 1Z or 2Z molded on the blade.
If the blade is wider at the tip than at the base near the hub, then you have a 6Z.
Otherwise, look for 4Z or 5Z markings on blade which are in one of two places:
Look on cone section at base of blade (visible when fan is assembled), or
Look inside the bottom of the socket (blade must be removed from hub).
Alternatively, measure the width of the blade at the widest portion at base of blade:
4Z blade is approximately 4-1/2 inches, 5Z blade is approximately 5-1/4 inches.
Step 2 Determine Rotation Code: L or R
R rotation rotates clockwise facing air discharge, L rotation is counterclockwise facing air discharge.
The 1Z and 2Z blade profiles have an arrow showing rotation molded into the blade on inlet side.
The 6Z is universal and can be used as an R or L rotation, depending on how pitch angle is set.
For 4Z and 5Z blades, the rotation code is molded into the blade, either on the cone section at base of
blade, or inside bottom of the socket.
Examples of rotation for 4Z blades as viewed from end of socket are below, and 5Z is similar.
R, or clockwise

L, or counterclockwise

P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com

44

Multi-Wing America - Z Series Pitch Setting Instructions - Page 2 of 4

Step 3 Determine Boss location code: A or B


The boss is the center section of the hub through which the fan is mounted to the shaft, and typically
contains either setscrews or a center-tapered hole where the bushing inserts.
Select boss location A or B:
A is the boss on air inlet, including A, AR, and AS configurations.
B is the boss on air discharge, including B, BR, and BS.
See examples in drawing below.
For flange mounted (engine) fans, use boss location A for blower fans, and boss location B for suction
fans.

Step 4 Find Blade Pitch Angle:

20, 25, 27.5, 30, 32.5, 35, 37.5, 40, 45, or 50

The blade pitch angle can be found several ways:


First, by knowledge of the Multi-Wing fan part number.
The pitch angle precedes the blade material code in the part number. For example, the pitch angle is
30 degrees in this part number: 36/9-9/30/PPG/5ZR/ SH 1-3/8 /AS
Second, by careful disassembly with this method:

Disassemble fan on flat surface, and note in which groove the pin is
located. See number code in picture to the right.
Using pictures in step 7 on next page, determine if the pin was in the
hub (HUB) or retainer side (RET) of fan.
Using table in step 6 below, find the possible blade pitch.
Using table in step 5 below, select your blade angle based on whether
your pin was in the HUB or RET.

Third, by calling a sales engineer at Multi-Wing America for assistance in selecting a blade pitch angle
for your application.

P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com

Multi-Wing America - Z Series Pitch Setting Instructions - Page 3 of 4

44

Step 5 Determine Hub/Retainer Code: HUB or RET


Find HUB or RET in chart below:
Type

Rotation

Boss
Pos.

1Z,2Z,4Z
1Z,2Z,4Z
5Z
5Z
6Z
6Z
6Z
6Z

R or L
R or L
R or L
R or L
R
R
L
L

A
B
A
B
A
B
A
B

Blade Pitch Angle


32.5
35
37.5

20

25

27.5

30

40

45

RET

RET

RET

RET

HUB

HUB

HUB

HUB

50
-

HUB

HUB

HUB

HUB

RET

RET

RET

RET

RET

RET

RET

RET

HUB

HUB

HUB

HUB

HUB

HUB

HUB

HUB

RET

RET

RET

RET

RET

RET

HUB

RET

HUB

RET

HUB

HUB

RET

HUB

RET

HUB

HUB

HUB

RET

HUB

RET

HUB

RET

RET

HUB

RET

HUB

RET

37.5
3
2
4
1
-

40
2
3
3
2
-

45
1
4
2
3
-

50
1
4
-

Step 6 Determine Groove Number: 1 or 2 or 3 or 4


Find the groove number in chart below:
Type

Rotation

1Z,2Z,4Z
1Z,2Z,4Z
5Z
5Z
6Z
6Z

R
L
R
L
R
L

Blade Pitch Angle


20
4
1
1
1

25
3
2
4
1
2
2

27.5
1
4

30
2
3
3
2
3
3

32.5
1
4
2
3
2
3

35
4
1
1
4
4
4

Step 7 Final Assembly


Definition of HUB and RET for purposes of these instructions:
For 2-piece hubset like below:

Top half is the HUB, and bottom half is the RET or retainer ring.

P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com

Multi-Wing America - Z Series Pitch Setting Instructions - Page 4 of 4

44

Step 7 Final Assembly continued


For 3-piece hubset as below:

Top two pieces together are considered the HUB, and bottom piece is considered the RET or retainer ring.
Using the HUB or RET code found in Step 5:
If code is HUB, place the hub down on work surface first (one or two pieces, depending on above).
If code is RET, place one retainer ring only down on the work surface first.
A weighted coffee can could be used to elevate the fan from the work surface.
Using the Groove Number found in Step 6:
Using picture to right, place the locking pin in the groove number that you
found in Step 6 above.
Finally, Insert Blades:

Place the blade over the pin in the hub/retainer blade socket, so that the
pin also fits into the appropriate pitch angle groove in the blade. See
example picture to the right.
For 6Z fans, use the pitch angle groove in the blade marked with your
rotation (R or L) and pitch angle. Example: L35 is L rotation and 35degree pitch angle.

Repeat for all blades.

Assemble hubset together, aligning the match marks you made.

Replace any balancing weight to its original position.

To finish, tighten the bolts in a cross pattern to 5 to 6 foot-pounds of torque.


P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com

Z pitch setting Rev 1


1/25/05

INSTRUCTIONS FOR BLADE PITCH ADJUSTMENT


FOR THE LARGE SERIES MULTI-WING W BLADES
1) NOTE ORIGINAL POSITION OF RETAINING PLATES, CENTER BOSS AND ALL HARDWARE
INCLUDING ADDITIONAL HARDWARE USED FOR BALANCING
2) REMOVE ALL THE BOLTS AND NUTS.
3) DETERMINE BLADE ROTATION ON THE CONCAVE SIDE OF THE BLADE IS A BLADE
MARKING SHOWING 6WR, 6WL, 7WL, 7WR, OR 9WR. THE L AND R DENOTE THE ROTATION
OF THE BLADE.
4) REPLACE THE PITCH INSERT IN THE BLADE ROOT WITH AN INSERT OF THE DESIRED PITCH.
PITCH IS DETERMINED BY COUNTING DIAL MARKS ON THE INSERT FROM THE SIDE OF
APPROPRIATE BLADE ROTATION FOUND IN STEP 3. EACH LARGE MARK REPRESENTS 5
DEGREES. THE ENDS OF THE INSERT ARE 20 AND 50 DEGREES ACCORDINGLY.

5) REPLACE BLADES TO THEIR ORIGINAL LOCATION.


6) REPLACE ALL NUTS, BOLTS, AND WASHERS ON THE FAN HUB.
7) REPLACE RETAINING PLATES AND CENTER BOSS TO ORIGINAL LOCATION.
7) TIGHTEN NUTS AND BOLTS TO:
14 FOOT POUNDS OF TORQUE
(REV. 9/7/05)

Multi-Wing America
A Crowley Company

P.O. Box 425


15030 Berkshire Industrial Pk.
Burton, Ohio 44021
info@multi-wing.net
www.multi-wing.net

Ph.
440 834 9400
Fax
440 834 0449
Toll free 800 311 8465

ISO 9001 QEC-15013


SAI Global

FANs 268.1, 1628.3


Product Bulletin D-3153
Issue Date 0596

D-3153 Pneumatic Actuator

The D-3153 Pneumatic Actuator is a multipurpose


positioning device used primarily for operating
ventilating dampers in response to the output signals
of a pneumatic controller or electro-pneumatic
transducer.
The D-3153 can be used with dampers up to a
maximum area of 16 square feet for proportional
volume control and 25 square feet for two position
actuation provided that the torque requirements are
compatible with the specific application.
The D-3153 is UL component recognized for use on
UL classified 555/555S smoke and combination
fire/smoke dampers which have been tested and
approved to a degradation temperature of 250F
(121C).
Figure 1: D-3153

Features and Benefits


All-aluminum Housing

Lightweight, non-combustible

Telescoping Linkage

Fast, flexible installation

Long Life and Reliable

Over a million now in service

2-way Swivel Head

Ensures full power delivery

Agency Recognized

UL Recognized component for fire and smoke


applications to 250F (121C)

1996 Johnson Controls, Inc.


Code No. LIT-2681054P

A pplication

I nstallation

When used with proportional control, the damper size


is limited to 16 square feet maximum. As a 2-position
control, damper size is limited to 25 square feet.

Two standard mounting packages are available with


the D-3153 pneumatic piston actuator. The models
with universal mounting bracket assemblies provide all
of the parts and instructions required for applying the
actuator to Johnson Controls D-1300 damper
applications: duct (wall) mounting or frame mounting-either normally open or normally closed.

Three nominal spring ranges are available:


3-7 psi (D-3153-7), 5-10 psi (D-3153-3 and -6),
and 8-13 psi (D-3153-1, 2, 4, 5, and 18). The control
air pressure for normal HVAC operation is 0-20 psig.
The minimum control pressure for safety damper
functions is 20 psig with the maximum pressure of
30 psig. When used for both proportional and safety
applications, a separate air signal should be provided
to override normal HVAC operation and cause safety
damper functions.
The D-3153 incorporates several internal and external
features that add functional flexibility. A 2-way swivel
connection on the actuator cylinder head provides
non-binding movement. All actuators have a
telescoping piston rod for easy linkage of the damper
for attachment points up to 8-3/4 inches (222 mm)
away from the face of the actuator. A swivel ball joint
and slotted crank arm connector are furnished on all
actuators for optional methods of linkage to the damper.
The UL component recognized D-3153 actuator with
universal and auxiliary mounting brackets are
specifically designed for use with Johnson Controls
safety dampers up to 250F (121C).

peration
O
Air pressure from a pneumatic controller is applied to
the diaphragm of the actuator, which moves the piston
against the forces of the internal spring and the load.
The external load force shifts the operating range from
the nominal spring range. The piston will move to a
position where the applied force and the spring plus
external forces are in equilibrium. However, with a
pilot positioner added, the piston will move to a position
proportional to the control signal regardless of the load.

The auxiliary mounting bracket assembly facilitates


applying the D-3153 actuator to allied equipment
manufacturers products, and non-Johnson Controls
installations for actuator conversions. These
assemblies are furnished with a crank arm linkage and
pedestal style bracket. Two positions are provided on
the pivot post for attaching the actuator to the
mounting bracket so that force can be more directly
applied to linkage points that are neither perpendicular
nor parallel to the actuator mounting plane.
A stop screw kit is available for special applications to
limit the power stroke of the actuator when required.
A 4 foot (122 cm) linkage rod is also available for
special applications to reach extended linkage when
required.
Where precision sequential operation is desired, or
additional positioning power is necessary, a D-9502
positioner should be used. Up to four more D-3153
actuators may be slaved from one pilot for coupled
dampers. A D-9502 kit is also available to enable
2-stage actuator control for providing minimum outdoor
air during occupation (refer to D-9502 literature).
Refer to the appropriate D-3153 Installation Bulletin for
more details.

R epair Information
Field repairs must not be made. For a replacement
D-3153 body, contact the nearest Johnson Controls
representative.

Table 1: Force Values at 20 psig (140 kPa) Supply


Spring Range psig
(kPa)

Stroke

Force lb (Newton)

Torque Output for


90 Rotation

8 to 13

Power

105 (467)

158 inlb (18 Nm)

(56 to 91)

Return

120 (534)

180 inlb (20 Nm)

5 to 10

Power

150 (667)

225 inlb (25 Nm)

(35 to 70)

Return

75 (334)

113 inlb (13 Nm)

3 to 7

Power

195 (867)

293 inlb (33 Nm)

(21 to 49)

Return

45 (200)

68 inlb (8 Nm)

2 D-3153 Pneumatic Actuator Product Bulletin

D imensions
P isto n R o d E xten sion S et S crew
S wiv e l B a ll Jo int
M axim u m T ele sco p ing
6-1/2 (1 65 )

Crankarm

2 -1 /4
(5 7)

5-1 /4 (1 3 3)

7 -2 3/3 2 (19 6 )
1 1-5 /8 (2 9 5)

Figure 2: D-3153, inches (mm)

D -9502
P ositioner

8-7 /8
(2 2 5)

6- 9/1 6
(167 )

15-7/16 (39 2 )

6-9/32 (16 0)

Figure 3: D-3153 with Universal Mounting Bracket, inches (mm)


D -95 0 2 P o sitio ne r

7 -7 /8
(20 0 )

P ositio n B
3 -2 5/3 2 (96 )
5-9/1 6
(1 41 )

P iv o t P o st
A u xilia ry M o un ting B ra cket
1 1-5/8 (2 95 )

4 (1 0 2)

P ositio n A
2-15 /16 (7 5 )

Figure 4: D-3153 with Auxiliary Mounting Bracket, inches (mm)

Table 2: Ordering Information


Nominal Spring Range

With Universal
Mounting Bracket

With Auxiliary
Mounting Bracket

Body Only

8-13

D-3153-2

D-3153-5

D-3153-6003

8-13 w/D-9502

D-3153-1

D-3153-4

D-3153-18

5-10

D-3153-3

D-3153-6

D-3153-6002

3-7

D-3153-7

D-3153-6001

0-3 and 9-13 w/2-stage Pilot

D-3153 Pneumatic Actuator Product Bulletin 3

Table 3: Accessories
Description

Shipping Weight
lb (Kg)

Code Number

Rubber Boot Kit

0.2 (0.09)

D-3073-100

Ball Joint weather resistant

0.3 (0.11)

D-3073-604

Blade Arm Kit

1.0 (0.45)

D-9999-100

Crank Arm 1/2 inch adjustable to 2-3/4 inch radius

0.5 (0.23)

D-3153-101

Crank Arm 3/8 inch adjustable to 2-3/4 inch radius

0.5 (0.23)

D-3153-108

Crank Arm 7/16 inch adjustable to 2-3/4 inch radius

0.5 (0.23)

D-3153-109

Linkage Rod 4 ft. (122 cm)

2.0 (0.91)

D-3153-102

Linkage Rod replacement

1.0 (0.45)

D-3153-103

Stop Screw Kit, 1/4 - 24 x 3 inches

0.5 (0.23)

D-3153-104

Proportional Pilot Positioner Kit

2.0 (0.91)

D-9502-8

Ball Joint

0.5 (0.23)

D-9999-104

Pivot Post, 5 per kit

0.5 (0.23)

D-3153-110

E-rings for Pivot Post, 10 per kit

0.5 (0.23)

D-3153-111

Mounting Nuts for Pivot Post, 10 per kit

0.5 (0.23)

D-3153-112

Universal Mounting Bracket

3.5 (1.13)

D-3153-105

Auxiliary Mounting Bracket

1.0 (0.45)

D-3153-106

2.0 (0.91)
2-stage Positioner Kit
Note:
Positioner kit includes: positioner, mounting plate, spring, and mounting hardware.

D-9502-9

Specifications
Product
Stroke
Control Air Pressure

Air Connections
Ambient Operating Conditions
Effective Diaphragm Area
Materials
Dimensions (H x W x D)

D-3153 Pneumatic Actuators


3 inches (76 mm)
0-20 psig for HVAC
20 psig (137 kPa) minimum for safety damper functions
30 psig (205 kPa) maximum w/o pilot
1/8 inch NPT straight barbed fitting for 5/32 or 1/4 inch O.D. polytubing (furnished)
compression fitting for 1/4 inch O.D. copper tubing (optional)
-20 to 150F (-29 to 66C)
15 inch2 (97 cm2)
Body - Die-cast Aluminum, Diaphragm - Synthetic elastomer
See Figures 2 through 4.

Shipping Weight, lb (Kg)

D-3153-1 11.5 (5.2) D-3153-3 10.0 (4.5) D-3153-5 8.5 (3.9) D-3153-7 8.5 (3.9)
D-3153-2 10.0 (4.5) D-3153-4 10.5 (4.8) D-3153-6 8.5 (3.9) D-3153-18 10.5 (4.8)

Agency Listing

UL Recognized component to 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

4 D-3153 Pneumatic Actuator Product Bulletin

Printed in U.S.A.

Section 7 Compressor
Vendor

Bulletin No.

Performance Request Form ........................................... Ajax


Performance Runs ......................................................... Ajax
Illustrated Parts List, 23 Cylinder .................................. Ajax

MB-0000

Illustrated Parts List, 13 Cylinder .................................. Ajax

F-0000

Rod Packing Manual .................................................................... C.L.Cook

Engine-Compressor Package Service Manual

TBP 97U

NOTICE:

Cameron Ajax furnishes compressor design performance to assist


you in compressor operation. If operating conditions change beyond
the ranges shown, new performance conditions can be obtained by
supplying your Cooper Compression Sales Representative with the
information on the accompanying form.
Alternately, our sizing software, eAjax , is available for your use without
charge. It is Windows based, and user-friendly. If you have access to the
World Wide Web, go to www.aciservicesinc.com/ajax to download a
current version of the software.

WARNING!

Improper setting of variable volume pockets, fixed volume pockets,


valve unloaders, improperly de-activated ends, or other unloading
devices can result in dangerous operation and possible damage and/or
injury to equipment or personnel. Operating this unit without
clearance and unloading information can result in failure due to
overloading, excessive rod loads or high temperature.

Fill out and return to:

Cameron Compression Systems- Ajax


Application Engineering
2101 Southeast 18th Street
Oklahoma City, OK 73129-8351
Or Fax: 405-672-8103

Package Contract Number:


Engine Model & S/N:
Compressor Cylinder Model & S/N:
Compressor Cylinder Model & S/N:
Compressor Cylinder Model & S/N:
Site Elevation (Feet):
Max. Ambient Temperature (Deg. F):
Suction Gas Temperature (Deg. F):
Gas Specific Gravity:
Gas N Value:
Design Suction Pressure (PSIG):
Anticipated Suction Pressure Range (PSIG):
Design Discharge Pressure (PSIG):
Alternate Discharge Pressure (PSIG):
In addition to the above data a complete gas analysis should be supplied.
Return address for performance:
_______________________

Cameron Compression Systems, Ajax Division

eAjax Performance Software

DATE: Friday, June 01, 2007


TIME: 11:17:57 AM

Version = 02.05.02

QUOTE:
MODEL: DPC-2802LE

2-Throws

CYLINDER ON THROW #1: YK11MA [23] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
ARRANGEMENT: Two Double Acting Cylinders, One Cylinder per Stage.
Elevation (m):
Ambient Temperature (C):
Gas Gravity:
Gas Compress. Used:
KW Available for Compression:

199.9
Barometric Pressure (Bars):
37.8
Gas to be Compressed:
1.3370
Ratio of Specific Heats:
Redlich-Kwong
Rated Speed (RPM):
287.8
Non-lube Factor:

0.989
User Entered Gas Analysis
1.1440
440
1.00

Standard Conditions: Base Pressure of 1.0101 Bars and Base Temperature of 15.56C.
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

23" YK11MB Compressor Cylinder


Assembly MB-0000
Ref #
1
2
3
*
*
*
*
4
5
6
7
8
9
10
A
B
11
12
13
SA
SB
SC
SD
SE
SF
SG
14
DA
DB
DC
DD
DE
DF
DG
21

Description
Body
Head
Piston/Rod
Piston Half
Piston Half
Stud
Nut
Ring
Rider Ring
Seal
Rod
Collar
Nut
Packing
Packing Ring
Gasket
Cover
Cage
Valve
Seat
Guard
Poppet
Spring
Screw
Pin
Spring
Valve
Seat
Guard
Poppet
Spring
Screw
Pin
Spring
Gasket

Compr Cyl
Compr Rear
Compressor

Self Lock
Compr Seg
O Ring
Compr Pstn
Thrust
Self Lock
Compr Rod
Set
Wire
Compr Vlv
Valve
Poppet Suct

Wire

Belleville
Poppet Dis

Wire

Belleville
Wire

P/N
K-6955-B-1
K-6957-A-1
YK11M-2302-3
K-6966
K-6966-1
K-6967
BM-16428-E-1011
BM-17042-14
BM-17011-B-34
BM-16348-F-393
K-6598-L
K-7074-C
K-4799-F
BM-16154-H
BM-16012-D
BM-16689-7
7-065636-001
K-6937-B
VPP971-026
SPP9710&01
GPP9710&01
VPX-118&01
VXPS-005&01
1-02F-017-016-012
1-10F-001-008-003
VPX-065&1
VPP971-027
SPP9711&01
GPP9711&01
VPX-118&01
VXPS-005&01
1-02F-017-016-014
1-10F-001-008-003
VPX-065&1
BM-15777-G-6

Qty
1 ea
1 ea
1 ea
1 ea
1 ea
6 ea
12 ea
2 ea
2 ea
2 ea
1 ea
2 ea
1 ea
1 ea
5 ea
1 ea
12 ea
12 ea
6 ea
1 ea
1 ea
28 ea
28 ea
2 ea
2 ea
2 ea
6 ea
1 ea
1 ea
28 ea
28 ea
2 ea
2 ea
2 ea
16 ea

Ref #
22
23
25
26
27
28
29
31
33
34
35
36
38
39
42
43
45
48
49
50
51
52
53
61
62
63
75
76
77
78
79
80
81
82
83

23"YK11MB Compressor Cylinder


Assembly MB-0000

Description
Gasket
Stud
Stud
Stud
Screw
Nut
Nut
Nut
Connector
Valve
Elbow
Tubing
Plug
Nut
Bushing
Nameplate
Tack
Bushing
Valve
Connector
Tubing
Tee
Nipple
Stud
Nut
Gasket
Guide
Fitting
Screw
Bar
Handwheel
Key
Nut
Screw
Seal

Flat

Set
Plain Hex
Plain Hex
Tube Compn
Check
Tube Compn
Stainless
Pipe
Piston Rod
Pipe Redn
Metal
Pipe Redn
Needle
Tube Compn
Stainless
Pipe Thded
Pipe

Flat Rd
Grease
Drive

Square
Plain Hex
Socket Hd

P/N
BM-17047-30
K-8093-1409-32
K-8098-2
K-8093-A-1808-42
BM-16485-1
06HN1400PC
BM-19067-A-1409
BM-19067-1808
BM-11610-SS-4-2
BM-11580
BM-16310-A
04TU070240
BM-11950-04
A-1278-B
BM-11942-02-01-S
BM-10003-N-1
907-004-001
BM-11942-04-02-S
BM-17025-N
BM-11610-SS-6-4
06TU040240
BM-11961-02
BM-11934-02-05
K-8094-1409-35
BM-19067-A-1409
K-6293-B
K-6455-A
BM-10046
BM-1386-A
K-6456-1
K-6960
K-6457-A
BM-11917-2408
BM-11473-1608-28
BM-16741-A

Qty
12 ea
72 ea
14 ea
32 ea
6 ea
72 ea
14 ea
32 ea
4 ea
3 ea
2 ea
1 ea
5 ea
1 ea
1 ea
1 ea
4 ea
1 ea
2 ea
2 ea
2 ea
1 ea
1 ea
4 ea
4 ea
1 ea
1 ea
1 ea
2 ea
1 ea
1 ea
1 ea
1 ea
10 ea
1 ea

010407

23" YK11MB Compressor Cylinder


Assembly MB-0000
Ref #
84
85
86
*
*
87
88
89
90
91
92

Description
Plate
Aluminum
Head
Compressor
Piston/Rod
Adj Clear
Piston
Compressor
Rod
Compr Piston
Ring
Compn
Seal
O Ring
Adapter
Stud
Nut
Gasket
Flat Rd

P/N
BM-16417-A
K-6956
YK11M-2307
K-7134
K-6426-C
BM-16247-278
BM-16348-F-278
K-6698
K-8093-2007-44
06HN2000PC
BM-19016-Z

Qty
1 ea
1 ea
1 ea
1 ea
1 ea
2 ea
2 ea
1 ea
8 ea
8 ea
1 ea

Ref #

Description

P/N

Qty

Not shown: cylinder-to-guide gasket


p/n: K-6293-B

23"YK11MB Compressor Cylinder


Assembly MB-0000

010407

13" YK11F Compressor Cylinder with Poppet Valves


Assembly # F-0000
Ref #
1
2
3
4
5
6
7
8
9
10
11
A
B
12
13
14
15
16
SA
SB
SC
SD
SF
SE

18
19
20
21
26
27
28
29
30
31

Description
Body, 13"
Cylinder
Head
Crank End
Piston
Compressor
Collar
Piston
Ring
Piston
Rider Ring Piston
Plug
Clearance
Cage
Valve
Rod
Piston
Nut
Self Locking
Packing
Rod
Packing
Ring
Gasket
Wire
O Ring
Head-to-Cyl
Connector
Tubing
Tubing
Stainless
Gasket
Valve-to-Body
Valve
Suction
Seat
Guard
Poppet
Spring
Pin
Screw
Gasket, Valve Cap-to-Body
Valve Cap
Stud
Valve Cap
Nut
Plain Hex
Stud
Cyl-to-Head
Nut
O Ring
Cyl-to-Head
Gasket, Clr Plug-to-Body
Plug
Pipe
Flange, Clearance Plug

P/N
K-6791-D
K-6957-C-1
YK11F-1302-2
K-7074
BM-17042-3
BM-17011-B-54
K-6348-V-3
K-7783-B
K-6598-E
K-4799-F
BM-16154-K
BM-16011-K
BM-16689-7
BM-16348-F-383
BM-11610-SS-4-2
04TU040240
BM-17047-14
VHP771-004
SHP7710&1
GHP7710&7
VPX-119&01
VPS-017&6
CSA-152-1-008-003
1-02F-015-024-012
BM-15777-G-9
K-6790-A
K-8093-1409-33
06HN1400PC
K-8093-2007-44
06HN2000PC
BM-16348-F-224
BM-19016-F
BM-11950-04
K-6433-D-6

Qty
1 ea
1 ea
1 ea
2 ea
2 ea
1 ea
2 ea
8 ea
1 ea
1 ea
1 ea
5 ea
1 ea
2 ea
4 ea
1 ft
8 ea
4 ea
1 ea
1 ea
19 ea
19 ea
2 ea
2 ea
8 ea
8 ea
32 ea
32 ea
16 ea
16 ea
8 ea
2 ea
3 ea
2 ea

Ref #
32
33
34
35
36
37
38
DA
DB
DC
DD
DF
DE

39
41
42
43
45
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67

Description
Stud
Clr Plug Flange
Nut
Plain Hex
Gasket, Water Jacket
Cover, Water Jacket
Capscrew
Hex Head
Plug
Pipe
Valve
Discharge
Seat
Guard
Poppet
Spring
Pin
Screw
Set Screw
Valve Cage
Stud, Packing Case-to-Head
Nut
Piston Rod
Nut
Tack
Metal
Plug
Pipe
Valve
Check
Elbow
Tubing
Gasket, JW In/Out Cover
Cover, JW In/Out
Capscrew
Hex Head
Bushing
Pipe
Nameplate Identification
Nameplate Danger
Stud, CE Head-to-Guide
Nut
Valve
Needle
Connector Tubing
Tubing
Stainless
Tee
Pipe
Nipple
Pipe

13" YK11F Compressor Cylinder with Poppet Valves


Asssembly # F-0000

P/N
K-8093-1011-26
06HN1000PC
K-6769
K-6768
BM-11900-0813-07
BM-11950-01
VHP771-003
SHP7711&2
GHP7711&1
VPX-119&01
VPS-017&6
CSA-152-1-008-003
1-02F-015-024-013
BM-16485-2
K-8094-1409-35
A-1278-B
BM-19067-A-1409
907-004-001
BM-11958-10
BM-11580
BM-16310-A
K-7844
K-7845
BM-11900-0813-10
BM-11942-02-01-S
BM-10003-N
914-175-001
K-8098-2
BM-19067-A-1409
BM-17025-N
BM-11610-SS-6-4
06TU040240
BM-11961-02
BM-11934-02-05

Qty
16 ea
16 ea
2 ea
2 ea
20 ea
1 ea
4 ea
1 ea
1 ea
19 ea
19 ea
2 ea
2 ea
4 ea
4 ea
1 ea
4 ea
8 ea
2 ea
2 ea
1 ea
4 ea
4 ea
24 ea
1 ea
1 ea
1 ea
14 ea
14 ea
2 ea
2 ea
2 ft
1 ea
1 ea

021804

13" YK11F Compressor Cylinder with Poppet Valves


Assembly # F-0000
Description
P/N
Bushing
Pipe Redn
BM-11942-04-02-S
not shown Gasket, Cylinder-to-Guide
K-6293-B
75
Guide
VVP
K-6455-1
76
Fitting, VVP Grease
BM-10046
77
Screw
Drive
BM-1386-A
78
Bar
Locking
K-6456-1
79
Handwheel VVP
K-6429-B
80
Key
Square
K-6457
81
Nut
06HN1600PC
82
Screw
Socket Hd
BM-11473-1608-28
83
Seal
VVP Sten
BM-16741-A
84
Scale
VVP
BM-16417
85
Head
Cylinder
K-6689
86
Piston/Rod VVP
YKPC-1307
*
Piston
Compressor
K-7133
*
Rod
Piston CompressorK-6426-B
87
Ring
VVP Piston
BM-16247-275
88
O Ring
VVP Piston
BM-16348-F-275
89
Adapter, VVP Guide-to-Head K-6677
90
Stud, Adaptor-to-Head
K-8093-1807-42
91
Nut
06HN1800PC
92
Gasket, Adaptor-to-Head
BM-19016-Y
Ref #
68

Qty
1 ea
1 ea
1 ea
1 ea
2 ea
1 ea
1 ea
1 ea
1 ea
10 ea
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
2 ea
2 ea
1 ea
8 ea
8 ea
1 ea

Ref #

13" YK11F Compressor Cylinder with Poppet Valves


Asssembly # F-0000

Description

P/N

Qty

021804

Section 8 Process Gas Equipment


Vendor
Process Control Tubing Schematic ................................ Ajax

Bulletin No.
02-18-T020-353

Murphy L1200N DVO Liquid Level Controller


Installation and Operation Manual........................................... Murphy

Dump Valve Assembly ................................................... Ajax

00-02-0175

TP 00-06-T01A-001

Murphy DVU-175 Dump Valve O & M........................................ Murphy

Vent Header Piping......................................................... Ajax

02-48-T010-388

Relief Valves and Fittings.................................................Ajax

02-17-T020-393

Mercer Relief Valve, 9100, O & M................................................Mercer

Blowcase Piping...............................................................Ajax
Norriseal 3023 Control Valve, O & M...........................................Norriseal

Blowdown Piping..............................................................Ajax
Morin Actuator O & M...................................................................Morin

Bypass Piping ................................................................ Ajax

00-06-T010-320
OM 704004M

02-47-T010-324
OMI 0802

02-50-T010-356

Ball Valve, WKM, 310F O & M.....................................................Ajax

Gauge Glass Assembly...................................................Ajax

00-06-T02A-001

Liquid Level Gauge Glass, Model RA-16.....................................Inferno

F1-4

Gauge Valves, Model 15A............................................................Inferno

M031196

Gauge Valves...............................................................................Inferno

A031231 & A031226

Auto Blowdown ESD Schematic......................................Ajax


Norriseal Piston Check Valve.......................................................Norriseal

Engine-Compressor Package Service Manual

00-18-T020-351
707000M

00-02-0175
Revised 03-06
Section 15

Installation for L1100, L1200, L1200N Series


Liquid Level Switches and DVU150, DVU175,
and DVU2105/2115/2120 Series Dump Valves.

Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting.
GENERAL INFORMATION
**

Description
Series L1100 and L1200 Liquid Level Switches are float activated to
operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.
OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment.
BE SURE all pressure HAS BEEN REMOVED from the
vessel before opening any pressure connections.

Specifications

L1100

Series L1200N is a float-activated, pneumatic-vent level device used to operate dump


valves or similar devices. This model screws directly into the vessel or can be
mounted via an external float chamber. It cannot be used with weld collar 15050375.
Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
L1200NDVOR series carry Canadian Registration Number OF1476.2.
Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
pneumatic input signal to cause an orifice to open or close allowing liquid
condensate to be drained from a pressure vessel. A pop up button indicates valve
open/closed. Stainless steel versions available.
L1111

L1200

L1200N

L1200NDVO

L1200NDVOR

Body
Standard: Electroless Nickel plated steel
Optional: 316 Stainless Steel

A
A

A
A

B
B

B
B

B
B

B
B

Pressure Rating
15 psi (103 kPa) [1.03 bar] Polyethylene Float
1500 psi (10.3 MPa) [103.42 bar] Stainless Float
2000 psi (13.8 MPa) [138 bar] BUOYGLAS Float

Temperature Rating
Standard: -20/175F (-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)

Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)

Specific Gravity
Standard: 0.5 with BUOYGLAS float
Optional: 0.65 with 304 Stainless Steel
Standard 0.73 Polyethylene Float

O-Rings: Viton
Valve: Two-way snap-action vent type
1/8 in. (3 mm) orifice w/Viton A seat
1/8 NPT inlet; 1/4 NPT vent
30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar. 1/8 NPT inlet, outlet & vent.
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge.
Maximum input 300 psi (2.07 MPa) [20.68 bar].
1/8 NPT in/out.
Operation:
H=For high level, L=For low level

Meets NACE standard MR-01-75 for direct exposure to H S service.


*Not available with DPDT snap-switch.
A =1-1/2 NPT
B =2 NPT
2
**Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.
Installation 00-02-0175 page 1 of 6

DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage

L1100 and L1200


11 in.
(279 mm)

Pressure
Regulator
with 20BPG
Pressure Gage

3-1/2 in.
(89 mm)

2-3/16 in.
(56 mm)

New Dump Valve


Operator Assembly
p/n 15010216

See
Note 2

1/2 NPT

See
Note 1
3-5/8 in.
(92 mm)

Note 1:
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm)
SF option:
L1100: 1-1/2 (38 mm)
L1200: 1-3/4 (44 mm)

1/8 NPT
Old Round Dump Valve
Operator Assembly
p/n 15000940

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

1/8 NPT
INLET

3-5/8 in. (92 mm)

5 in. (127 mm.) minimum


clearance is required for
float movement.

3/4 Hex
(See Note)

2-3/16 in.
(56 mm)

1/4 NPT
VENT

1-9/16 in.
(40 mm)
SF option=
1-3/4 in.
(44 mm)

2" 11-1/2 NPT

3-1/2 in. (89 mm)


SF= 3-3/4 in. (95 mm)
11 in. (279 mm) SF option= 11-1/4 in. (286 mm)
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).

L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)

2-3/16 in.
(56 mm)

DVU150, DVU175, DVU2105/2115/2120


Series Dump Valves

See
Note

1/2 NPT

1-1/2 NPT
3-5/8 in.
(92 mm)

Note: 1-9/16 (40 mm)

Pressure
Inlet Port
1/8 in.-27 NPT

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

Manual Valve
Operator

Vent
Weep Hole
Union

Valve Open/Closed
Indicator Button

Electrical installation to be done by


qualified person according to the NEC.

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

NOTE: Dimensions are in inches and (millimeters)

Installation 00-02-0175 page 2 of 6

REPLACING AND INSTALLING THE DVOA ASSEMBLY

When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Replacing and Installing the DVOA
Assembly For Models L1200NDVO &
L1200NDVOR

NOTE: Clean, dry instrument quality gas should be used.


Use of filters will improve service life and reliability.

Tools Needed: Strap or pipe wrench; 3/4 Hex wrench; 9/16 hex
wrench; needle nose pliers; tubing cutters and benders and the
appropriate tools for the fittings.
1.

Block off and bleed the instrument gas pressure supply to the
L1200NDVO.
2.
Remove the tubing between the L1200NDVO and the
separator dump valve, and remove the supply gas tubing
(regulator [-R] if used).
3.
Remove the L1200NDVO from the vessel (optional).
4.
If the L1200N was removed from the vessel, mount it in a
suitable vise on a work bench (if possible).
5.
Using the proper tools, disconnect the Inlet, Outlet and
Exhaust fittings from the existing DVO (see fig. 1). You will
re-connect these to the new DVOA in a later step.
NOTE: The following steps must be done with the DVO in the
upright position (on top of the L1200N).
6.
Remove the L1200N cover (this will aid with the alignment
of the new DVOA Valve Bushing). The use of a strap
wrench or a pipe wrench may be needed.
7.
Insert the new Valve Bushing through the new DVOA (see
fig. 2). The markings on top of the DVOA must be facing
up. This will be needed in step 9.
8.
With a 3/4 hex wrench loosen the existing DVO, valve
stem, and static seal (see fig. 3). Once the assembly is
loosened, VERY CAREFULLY use needle nose pliers to
hold the Valve Seat Assembly in place. Remove the existing
DVO making sure the Valve Seat Assembly inside the
L1200NDVO is aligned and straight (see fig. 4).

Old DVO

Outlet
(opposite side)

Inlet

Exhaust

Figure 1

Figure 2

New DVOA

Figure 3

CAUTION: MAKE SURE the Valve Seat Assembly inside


the L1200N remains in place after removing the DVO.
Holding the Seat Assembly up with the needle nose pliers
inside the L1200NDVO body, place the tip of the new
DVOA valve bushing through the spring and into the hole in
the center of the valve seat, and tighten the valve bushing.
The Valve Seat Assembly should be able to move freely up
and down after the bushing has been tighten. The DVO red
button must face away from the vessel.
10.With the new DVOA aligned over the hex on the L1200NDVO
body, tighten the Valve Bushing using the 9/16 hex wrench.
You may need to hold the DVOA while tightening the Valve
Bushing to keep it from rotating (see fig. 5).
11.If the L1200N is in the vise, operate the float and inspect for
smooth and proper operation of the Valve Seat Assembly.
12.Replace the L1200NDVO cover (see fig. 6).
13.Using the appropriate tools re-install the Inlet, the Outlet and
the Exhaust fittings to the new DVOA (see fig. 5).
14 If the L1200N was removed from the vessel re-install it at this
time.
15.Modify existing or install new tubing to connect the Inlet, the
Outlet and Exhaust fittings.

Valve
Bushing

Valve Seat
Assembly

9.

Outlet

Figure 4

Inlet

Installation 00-02-0175 page 3 of 6

Exhaust

New DVOA

Figure 5

L1200N
Cover

Figure 6

PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N

Direct Installation into the Wall of the


Pressure Vessel
1. Determine that the float travel is not
obstructed by the coupling in
Tank
the vessel wall, internal
Wall
baffles, etc.
Do NOT use more than
one arm extension P/N
15050395.
Explosion proof
2. BE SURE that the float
Level
conduit seal
Switch
and extension are tight
where required.
and that the lock washer is
in place.
3. Before installing the level
switch a suitable pipe thread sealant
is recommended. Screw the unit directly into the threaded
connection in the wall of the pressure vessel.
4. Be sure that the electrical connection is positioned at the
bottom. For L1200N the 1/8 NPT pneumatic connection
should be on top (the 1/4 NPT vent connection should be on
the bottom). See Pneumatic models section for further
instructions for the L1200N.
5. Make the electrical wiring connections according to
appropriate wiring diagrams for the alarm or shutdown
system to be used. The electrical connection is 1/2-14 NPT.
Electrical wiring and conduit should be installed by qualified
personnel according to the NEC.
6. BE SURE all electrical connections are insulated and the
cover is fully installed before reconnecting electrical power.
7. BE SURE all pressure connections are tight before
pressurizing the system.
Installation with a Weld
Collar
Tank Wall
1. The weld collar, P/N
Weld Collar
15050375, must be welded
into the wall of the
pressure vessel according
to code standards and
good welding practices.
L1200
2. Follow above instructions
for installation directly into
Explosion proof
the wall of the pressure
conduit seal
vessel.
where required.
3. NOTE: Weld collar 15050375 can
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External
Float Chamber 15051098

positioned away from the tank wall.


2. A tee is typically installed at the bottom of the lower 1 inch
pipe riser to allow draining of the float
chamber for servicing or replacement.
NOTE: A typical installation
Float
with Blocking and Bleed valves is Chamber
Tank
shown at right.
Block
Valves
3. Install the L1200 or
L1200N
Level
in the 2 NPT connection Switch
of
Tee
the float chamber.
Bleed
BE SURE float travel
Valve
is not restricted and that the
Explosion proof
float is tight onto
conduit seal
where required.
the float shaft.
4. To complete installation and
wiring, follow the instructions for
mounting directly into wall of the vessel and for wiring.
Pneumatic Models
1. All pneumatic models
operate on the vent
Filter/Regulator
Tank
principle. The
New Dump Valve
Operator Assembly
pneumatic signal
Pneumatic
p/n 15010216
Signal
source MUST BE
CLEAN AND DRY.
The input pneumatic MURPHYGAGE
signal must be
regulated between 30
L1200N
and 70 psi (207-483
kPa) [2.07-4.83 bar].
If produced gas is used as the
signal source, it should be taken
after gas passes through the final scrubber.
A suitable filter must be positioned before the L1200NDVO
to prevent liquids and/or particulates from entering the dump
valve operator.
NOTE: Check filter periodically for wear and tear and
elements that hamper the flow of the pneumatic signal.
2. All pressure connections must be tight and maintained tight
so as not to leak air/gas.
3. Valve seat adjustment can be made if air/gas begins to leak.
Care should be taken when adjusting as only slight movement
is necessary to stop the leakage; excessive force will bind the

Hex Socket Set Screw


loosen for adjustment
tighten after adjustment

L1200N

CAUTION: USE NON SPARKING TOOLING.


1. Install the float chamber 15051098 on the outside wall of the
pressure vessel using 1 NPT piping. Position the 2 NPT
threaded connection at the height where you want the level
switch to operate. The 2 NPT threaded connection must be

Hex Adjustment Nut


turn left until air
seepage stops
Caution: only slight
adjustment is neededtoo
much will lock up mechanism

Installation 00-02-0175 page 4 of 6

Trip Cam (float down)


should be in
this position
non-adjustable

TYPICAL INSTALLATION ON GAS COMPRESSORS

Basic Operation
As condensate rises in the scrubber, the float on
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter
the dump valve pilot chamber. Once the pressure
enters the pilot chamber it forces the diaphragm
and valve stem forward thus opening the valve seat
(valve open/closed indicator button pops out) and
releasing condensate through the valve stem and
out the drain. As the condensate level drops, the
L1200NDVOR pneumatic valve closes to shut off
the pressure to the dump valve causing it to close.
If for any reason the condensate continues to rise
beyond normal dump levels, model L1200
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the
MURPHYGAGE help keep the control pressure
clean and dry. They also allow the operator to
adjust pressure to recommended levels.

Typical/Scrubber/Separators
VESSEL
Minimum control
pressure 30 psi
(207 kPa) [2.07 bar]

Rising Level Shutdown


L1200 (with snap-switch)

Explosion proof
conduit seal required
for Class I. Div 1, not
required for intrinsically
safe or non-incendive
circuits like FWM TTD.

Rising
Level
Trips
DVO

Electrical
Conduit

L1200NDVOR
Dump Valve
Operator
Union

Air Supply Maximum


300 psi (2.07 MPa)
[20.70 bar]

Filter/Regulator
with MURPHYGAGE

Minimum control pressure


30 psi (207 kPa) [2.07 bar]

DVU Series Dump Valve


Union
Condensate Line (Out)
Manual Drain Valve

REPLACEMENT PARTS

ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection

Black N.O.

White COM.

Red N.C.

Switch Rating: 5 A @ 125-250- 480 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
2A @ 6-30 VDC Resistive
1A @ 6-30 VDC Inductive

Green Grd. Connection

Black N.O.

White COM.

Red N.C.
Blue N.C.

Yellow COM.

Orange N.C.

Switch Rating: 10 A @ 125-250 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
10 A @ 6-24 VDC
Inductive/Resistive

Order by part number designation.


L1100/L1200*
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200
15000937: Stainless Steel float for L1100
15000124: SPDT snap switch assembly
15010213: L1100 counter balance assembly
15010214: L1200 counter balance assembly
L1200N
15050420: Cam spring return
15050421: Cam
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
55050621: Regulator only
05706499: 20BPG-D-75 Pressure MURPHYGAGE
0-75 psi (517 kPa) [5.17 bar]
15010216: DVOA assembly (New rectangular style)
15000940: DVO assembly (Old round style)
*To maintain hazardous location listings, all other repairs must be made by the factory.

Installation 00-02-0175 page 5 of 6

ACCESSORIES

Order by part number designation.

55050617: DVU150/DVU175 Adapter Bushing

15050375: Weld Collar

Material: 2-1/2 Hex bar stock C.R.S


2-1/16 in
(52 mm)
1-1/16 in
(27 mm)

2 NPT

2-1/2 in
(64 mm)

2-7/8 in
(73 mm)
3-5/8 in.
(92 mm)

1 NPT

4-1/2 in
(114 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

2 NPT

15051098: External Float Chamber


3 in.
(76 mm)

1-11.5 NPT (2 places)

2-11.5 NPT
10.5 in.
(266 mm)

3 in.
(76 mm)

1/2-20 UNF-2B
(4 places)
7.55 in.
(192 mm)

3.5 in.
(89 mm)

Material: Cast Steel, WCB

7.01 in.
(179 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

15000892: Float Shaft Extension


10-32 UNF

10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)

Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

www.fwmurphy.com
918.317.4100 Email: 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.

Installation 00-02-0175 page 6 of 6

Set the control signal


pressure at 45 psig.

NOTE
If pressure or fluid comes out the weep
hole of the union nut, either the o-ring
under the union nut is leaking, or the
packing could be leaking through the
internal weep hole above that o-ring.

Dump valve operating temperature is -30F to 250F.


Dump valve maximum process pressure is 1800 psi.
Refer to the manufacturers bulletin for details.

Murphy DVU175
Dump Valve Assembly
TP 00-06-T01A-001 Rev 2

Murphy DVU175 Dump Valve Assembly


TP 00-06-T01A-001 Rev 2
Item
1
2
3
4
5
6
7

Description
Dump Valve, Murphy 1" NPT x " 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

Installation and Operation Manual for


DVU Series Dump Valves
Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120

Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended
before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes.
GENERAL INFORMATION

Fig. 2 Dimensions (all models)

WARNING

A
Pressure
Inlet Port
1/8 in.-27 NPT

Manual Valve
Operator

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

Description
The DVU Series models are pneumatically controlled dump valves.
The valves open and close automatically by pneumatic control from a
Murphy L1200NDVOR or similar level controller and dump valve operator. Diaphragm actuated, the DVU series dump valves operate at 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.

Fig. 1 Control Pressure vs. Working Pressure


Control Pressure (PSIG)

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

NOTE: Dimensions are in inches and (millimeters)

DVU2120

DVU2115

60

Specifications

50
40

Valve Open/Closed
Indicator Button

F Drain

Minimum Actuation Pressure


70

Vent
Weep Hole
Union

DVU150/175

DVU2105

30
20
10
0

500

1000

2000

1500

Vessel Pressure (PSIG)

Model
DVU2120
DVU2115
DVU2105
DVU175
DVU150

Inlet
2 NPT
2 NPT
2 NPT
1 NPT
1 NPT

Outlet
1 NPT
1 NPT
1 NPT
3/4 NPT
1/2 NPT

Trim Size
0.436 in. (11 mm)
0.576 in. (15 mm)
0.859 in. (22 mm)
0.359 in. (9 mm)
0.359 in. (9 mm)

Operating Temperature: -30 to 250F (-34.4 to +121C)


Valve Operating Pressure: Refer to chart, Fig 1.
Maximum Process Pressure:
DVU2120: 2000 psi (13.8 MPa) [138 bar].
DVU2115: 1500 psi (10.3 MPa) [103 bar].
DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).

Installation 00-02-0483 page 1 of 4

TYPICAL INSTALLATION ON GAS COMPRESSORS

Fig. 3
Scrubber/Separators
Basic Operation
As condensate rises in the scrubber, the float
on the L1200NDVOR rises and trips its pneumatic valve. The valve opens allowing pressure to enter the dump valve pilot chamber.
Once the pressure enters the pilot chamber it
forces the diaphragm and valve stem forward
thus opening the valve seat (valve open/closed
indicator button pops out) and releasing condensate through the valve stem and out the
drain. As the condensate level drops, the
L1200NDVOR pneumatic valve closes to shut
off the pressure to the dump valve causing it to
close.
If for any reason the condensate continues to
rise beyond normal dump levels, model L1200
operates the alarm and/or shuts down the
equipment.
The L1200NDVOR Filter/Regulator and the
MURPHYGAGE help keep the control pressure clean and dry. They also allow the operator to adjust pressure to recommended levels.

NOTE: Always use clean, dry,


instrument quality gas.

The Murphy Gas Compressor Scrubber Level System (SLS)


The system provides for liquid control in gas scrubber
applications, by dumping liquids to drain and protecting
compressors with a high liquid level switch. Wetted metal
parts are made to survive
constant use in corrosive
environments.
See Bulletin: SLS-04005B for
more details.

High Level Shutdown Switch


Stainless steel float actuated level switches to alarm
and/or shutdown the equipment.
L1200: 2 NPT pipe connection; Rated 2000 psi
(13.7MPa) [137bar]; Class I, Division 1. SPDT
snap-switch standard. DPDT Optional.
All Stainless Steel available.

Filter/Regulator &
MURPHYGAGE

Control
Panel

Instrument
Quality Air/Gas
Supply

Pneumatic Level Control


Float actuated level snap-acting switch
controls pneumatic pressure to open
and close dump valve.

Pneumatic Dump
Valves See DVU-01069B

L1200NDVOR: Dump Valve Operator,

for more details.


Two piece union design with manual valve operator
allows soft plug and hard seat to be replaced without disassembling outlet piping or scrubber pipe
connection. Diaphragm actuated valves operate on
30-70 psi (207-483 kPa; 2-5 bar).

pressure regulator, and pressure indicating MURPHYGAGE.

DUMP VALVE INSTALLATION

DVU Series Installation


Upper Assembly
(removable)

CAUTION: ALWAYS USE NON-SPARKING TOOLS


WHEN GAS IS KNOWN TO BE PRESENT.

Valve
Union

Fig. 4
Typical
Dump Valve
Installation

Maintenance
Bolt
Valve Indicator
Vessel Wall

The following describes the Direct Mounting method to the


tank wall.
1. Install the valve so the drain connection is on the bottom. Use
pipe thread sealant on all the connections.
2. Be sure the unit is screwed tight and does not leak.
3. Install the piping for the pneumatic input signal into the
1/8 NPT threaded connection of the pressure inlet port (on
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the
condensate out line. Use pipe thread sealant on all the connections.

Pneumatic
Input Signal

Weep Hole
Drain
Connection
Union
Condensate Out
2-Way (Manual Drain)
Shutoff Valve

Installation 00-02-0483 page 2 of 4

REPAIR PROCEDURE

CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD


ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSIBLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED.

Suggested Tools (Sizes listed are wrench openings.


Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches,
flat edge screwdriver with 1/4 blade width, can also be used .)
Model

Valve Body

Union Nut

Plug Seal Hex

Stem Nut

3
3
3
2-1/4

3
3
3
2-1/4

7/8
1
1-1/4
3/4

1/2
1/2
1/2
3/8

DVU2120
DVU2115
DVU2105
DVU150/DVU175

Replacing the Plug and Seat


1. Close the pressure block valves (suction & discharge valves) on the inlet
and outlet of the skid. Lock them closed if possible.
2. Open the blowdown valve to remove pressure from the unit. Lock the
blowdown valve open if possible.
3. After taking all possible precautions to insure there is no pressure in the
vessel. (If the condensate line is pressurized, it must also be blocked and
locked.) Open the manual drain valve so it bleeds into the vessel so it
can also be bled down. Disconnect the pneumatic input signal connection
after insuring it also has been de-pressurized.
4. Using a back-up wrench on the valve body, with a quick "breaking"
action loosen the union nut on the valve. There is a "weep" hole in the
nut. If at any time while loosening and taking off the nut pressure is
escaping through the "weep" hole, immediately stop loosening the nut.
Retighten the nut and check the preceding procedures to ensure the pressure is bled off the vessel. Never remove the assembly if pressure is
coming through the weep hole. See Figure 4 on page 2.
5. With the upper assembly removed from the vessel the plug and/or seat can
be replaced. Loosen the 9/16 jam nut on the maintenance bolt on top of
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN.

Fig. 5
Plug

Seat

Stem

Stem
Packing

O-Ring Seals
Against Outlet

Washer(s)*

Stem
Nut

O-Ring

Crush Washer Seal

Seat butts into here

*Number of washers varies depending on the model from 1 to 3.

Fig. 6

Seal Washer
Pressure Inlet

Maintenance
Bolt
1/2" Nut

Diaphragm

Backup
Plate

1-1/8" or
1" round nut

Stem

Spring

Diaphragm
Housing

Diaphragm
Assembly

6. Using a back-up wrench on the plug, remove the stem nut on the shaft
under the plug. Once the stem nut is broken loose, the 9/16 head maintenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
removed. All soft seals should be replaced. Refer to kit part numbers
under service parts on page 4.

Replacing the Diaphragm


6A. If the diaphragm is to be replaced, all preceding steps have to be
done. Additionally, do the following:
6B. Loosen the 9/16 head maintenance bolt, allowing the diaphragm
spring to relax, and the stem to retract. Make alignment marks on
the top and bottom halves of the diaphragm assembly for alignment during re-assembly.
6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
together.
6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
or 1 round nut on the bottom of the diaphragm assembly to be
accessible to a wrench and not have the spring interfere. If it is
desired to replace the packing, pull the stem all the way out. The
packing can be easily removed using a small screwdriver to pry the
packing out. The new packing can be simply pressed in, making
sure the orientation of the packing installed is the same as the orientation of the packing removed. The packing is wider toward the
plug end. You will have to use the seat to hold the packing in place
when re-inserting the stem.
6F. With the 1-1/8" hex or 1 round nut held by a wrench, use a
wrench to loosen and remove the 1/2" nut on top of the diaphragm.
The diaphragm can now be removed and replaced.
6G. With the new diaphragm in place and the 1/2" nut tightened, place
the assembly, diaphragm down on a clean, smooth sturdy surface.
6H. Have the seat, plug, washers and stem nut handy (if any of these
parts are to be replaced, use the old parts for this procedure). Press
down evenly and smoothly on the bottom of the diaphragm assembly to cause stem to come up. Place the seat and plug in place.
Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
6J. Align the diaphragm holes to the bolt holes (bottom half of the
housing). Install the upper diaphragm housing using the alignment
marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180 around to the next bolt,
then either 120or 240 around to the next bolt and so forth until
all 8 bolts are evenly tight.
6K. Using the 9/16 head maintenance bolt, tighten, pushing the stem
out until the 9/16"bolt stops DO NOT OVERTIGHTEN.
6L. Remove the stem nut holding the plug. (If old parts were used, prepare to install the new parts now.)

7. Install the seat and plug. Place the O-ring on the stem, followed by the
washer and stem nut.
8. Tighten the stem nut. Loosen the 9/16 head maintenance bolt by at least one
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16 head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
leaking through the internal weep hole above that O-ring.
10. The assembly is ready to be re-installed. Check for relative position of
the pneumatic input signal connections before tightening the union nut.

Installation 00-02-0483 page 3 of 4

PRESSURE VS. FLOW CHART

Pressure vs. Flow for DVU150 and DVU175 models only

Fig. 7
250
250

200
200

Pressure (psid)

150
150

100
100

50
50

10

15

20

25

30

35

40

45

Flow (gpm)

SERVICE PARTS

Part No.

Typical Diaphragm Repair Kit includes:


Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate
(1 or 2 pcs.), Packing, O Ring, Stem, Seal Washer for Maintenance Bolt.

Description

DVU2120
55-00-0237
55-00-0236

Seal Kit (includes plug)


Diaphragm Kit

The DVU Series Valve is included in the


following Scrubber Levels Systems.

DVU2115
55-00-0241
55-00-0240

Seal Kit (includes plug)


Diaphragm Kit

(Includes L1200, L1200NDVOR, and DVU valve)


SLS2120: Includes DVU2120 valve
SLS2115: Includes DVU2115 valve
SLS2105: Includes DVU2105 valve
SLS175: Includes DVU175 valve
SLS150: Includes DVU150 valve
-LR: Less Regulator option

DVU2105
55-00-0245
55-00-0244

Seal Kit (includes plug)


Diaphragm Kit

DVU175
55-00-0230
55-00-0231

Seal Kit (includes plug)


Diaphragm Kit

DVU150
55-00-0230
55-00-0231

Seal Kit (includes plug)


Diaphragm Kit

Warranty

Typical Seal Kit includes: Nut, Washer (1 to 3), O Ring, Plug and
Seal, Seat, Crush Washer.

www.fwmurphy.com
918.317.4100 Email: sales@fwmurphy.com

A limited warranty on materials and workmanship is given with this FW


Murphy product. A copy of the warranty may be viewed or printed by going
to www.fwmurphy.com/support/warranty.htm

MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
(c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
their respective owners and are used for identification purposes only.

Installation 00-02-0483 page 4 of 4

Page 1 of 4

Installation, Operation and Maintenance Manual

W-K-M
DynaSeal
310F 2-Piece
Flanged End
Ball Valve

9
8
6
5
4
3
2
11
12

13
14

10

10
17

15

310F 1"F thru 2" R

16

Table of Contents
Scope ...................................................... 1
Nameplate Information ............................ 2
Storage...................................................... 2
Installation ............................................... 2-3
Operation .................................................. 3
Routine Maintenance ............................... 3
Trouble Shooting ..................................... 4

8
6
5
4
7
3
2

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Description
Body
Packing
Compression Ring
Bonnet Cap
Cap Screws
Stop Plate
Retainer Ring
Handle/Lever
Lock Nut
Seat Ring
Stem Seal
Stem
Ball
Tailpiece Gasket
Tailpiece
Nut
Stud

11
12

1
17
13
10
15
16

14

10

310F 2"F thru 4" R

Scope
The W-K-M DynaSeal 310F ball valve is designed to meet tougher
industry requirements while maintaining key features of the W-K-M
floating ball valve. It has deep-pocketed seats, an adjustable,
replaceable stem packing and is available in carbon steel and
stainless. The 310F is offered in sizes 1F" to 4"R and class 150, 300
and 600 flanged ends.

W-K-M DynaSeal 310F 2-PieceBall Valve


Installation, Operation and Maintenance Manual

Publication
TC-1473

Page 2 of 4

Nameplate Information
W -K -M

Item
1
2
3
4
5

Description
Assembly part number
Nominal valve size and type designation
Model number
Ball-Stem material designation
Body & Seat-seal code designation

Storage
After valves are assembled and tested, they are
placed in the full open position, flange seal
surfaces and bores are greased and end protectors
are installed. This will provide adequate protection for indoor storage. Extended outdoor storage
requires periodic inspection and the addition of a
corrosion inhibitor. Contact your CCV representative for extended storage guidelines. Valves
should only be stored in the full open or full close
position to prevent seat distortion.

Installation
DynaSeal 310F ball valves may be installed in any
position with flow from either direction. However, for best service life there is a preferred
vertical or horizontal position to maximize sealing
and minimize the accumulation of sediment. In
the vertical position it is preferred to have the
upstream pressure from above so the weight of
the ball will assist the pressure in sealing. With the
run of the valve in a horizontal position, it is
preferred to have the stem lying horizontal (i.e.
toward the viewer) with pressure from the right.
During operation, flow will act as a siphon and
minimize retention of sediment.
When handling or installing a valve, keep the
valve in the full open position whenever possible
to prevent foreign object damage to the ball.

Publication
TC-1473

Item
6
7
8
9

Description
Maximum operating pressure
Maximum working pressure
Maximum temperature
Date of manufacture

Flanged-End valves may be bolted into the line


using two open or boxed end wrenches.
1. Threads of flange bolts and nuts should be
lubricated to obtain maximum loading of bolts.
2. Finger tighten all nuts first.
3. When tightening bolts, use the crisscross
method and torque each bolt to ANSI or gasket
manufacturer specification.
Field testing, if performed after the valve has
been properly installed into the line, should be
done in accordance with the following procedure:
Caution: Ensure that all test fluids contain
corrosion inhibitors and are compatible with
valve seat and seal material.
1. Preliminary Testing - Completely flush the
system or the line to minimize damage to the
seats and ball surface which might be caused by
weld slag or other foreign matter resulting
from installation procedures.
2. Line Testing - When performing this test, the
valve should be in the half-open position to
ensure that the body cavity is completely filled
with the test media and to prevent accidental
over pressure of the seats. NOTE: Line may be
tested at a maximum of 1-1/2 times the valve's
cold working pressure rating without consulting
the factory.
3. Seat Testing - When testing the seats with the

W-K-M DynaSeal 310F 2-PieceBall Valve


Installation, Operation and Maintenance Manual

Page 3 of 4

valve in the closed position, do not exceed the


valve's cold working pressure rating.
4. Upon completion of testing, purge all test fluids
from the valve.

Operation
DynaSeal 310F ball valves operate from fully open
to fully close by a 90-degree turn of the handle.
The handle aligned with the pipe always means
the valve is open and with the handle perpendicular to the pipe means the valve is closed. Additionally, the stems have flats that align the handle and
can be used to indicate ball position. The bore of
the ball is parallel with the faces of the stem flats.
DynaSeal 310F valves may be power actuated.
Pneumatic and hydraulic actuators, whether of the
fail-open, fail-close, or fail-last position type, have
"Open-Close" indicators on the top of each unit.
On a pneumatic actuator, make sure filters and
lubricators (if recommended by the actuator
manufacturer) are installed prior to valve and
actuator installation. Should any maintenance be
necessary, obtain the part number from the unit's
nameplate and contact Cooper Cameron Valves or
the nearest representative.

Routine Maintenance
Due to its design and simplicity the 310F ball
valve requires very little maintenance. It's nonlubricated, self-cleaning ball can provide reliable,
leak-free performance over a long period of time.
The only preventative maintenance recommended is to periodically inspect the valve for
leaks around the stem or actuator. Should a leak
be noticed, the following procedure is for adjusting the packing.
Stem Packing Adjustment 1. With an Allen wrench, snug up each of the two
packing adjustment screws in a clockwise
direction.
2. Snug up each screw an equal amount only as
much as required to stop the leak, not to
exceed the maximum specified in the following table.
3. The following table gives torque values that
will seal stem packing in good condition.
Torque values above this indicate seals are
worn and need replacement and excessive
tightening will also cause an unacceptable
increase in valve stem torque.

Torque Values for Packing


Adjustment Screws
Valve Size

Torque (Packing)
Screw Size
in-lb
(kg-m)

1F

1/4-20 NC

36-60

(0.4-0.7)

1-1/2F & 2R

5/16-18 NC

60-120

(0.7-1.4)

2F & 3x2

3/8-16 NC

120-180

(1.4-2.1)

3F & 4R

1/2-13 NC

180-240

(2.1-2.8)

W-K-M DynaSeal 310F 2-PieceBall Valve


Installation, Operation and Maintenance Manual

Publication
TC-1473

Page 4 of 4

Warning: Valves should be placed in a partially open position prior to working on valve or
removing it from service to vent pressure or drain product that may be trapped in the body
cavity.

Troubleshooting Chart
Trouble
Will not open or close

Probable Cause
a. Iced up due to restricted flow
or low temperature.
b. Pressure locked. (Condition in
which the body pressure
exceeds the line pressure by
an excessive amount.

Remedy
a. Flush out with warm material.
b. Reduce valve temperature or
pressurize line to rated working
pressure to reduce pressure
differential sufficient to operate valve.

Hard to operate

a. Accumulation or solidification
of material in the body
of valve.
b. Swelling seats
c. Corrosion between stem
and valve body.
d. Operator not installed
properly

a. Flush valve to get material out of body.


b. Install correct trim.*
c. Apply penetration oil around stem. If
still won't operate disassemble valve
and polish stem.*
d. Check operator.

Will not seal properly

a. Worn or damaged seats and/


or ball.
b. Foreign matter between seat
and ball.
c. Operator stops not properly
set.

a. Replace worn parts.* (Requires valve


removal and disassembly)
b. Operate several times to wipe clean.
c. Adjust stops to proper setting.

Valve leaking between


body and tailpiece

a. Leaking tailpiece gasket


b. Tailpiece and valve body are
not tightened together
properly.

a. Replace gasket.* (Requires valve


removal and disassembly)
b. Tighten parts to specified torque.*

Leaking around stem

a. Loose stem packing


b. Worn or damaged stem
packing.

a. Adjust stem packing screws.


b. Replace stem packing.*

*Contact your CCV representative for a Repair Manual

Headquarters
Cooper Cameron Valves
16500 South Main Street
Missouri City, TX 77489-1300
Phone: 281-499-8511
800-323-9160
Fax:
281-499-6965

USA
Cooper Cameron Valves
845 S.E. 29th Street
Oklahoma City, OK 73147
Phone: 405-631-1321
Fax:
405-629-0420

Scotland
Cooper Cameron Valves
Houstoun Industrial Estate
houstoun Road
West Lothian EH54-5BZ
Livingston, Scotland
Phone: 44-1506-444-000
Fax:
44-1224-783-355

http://www.ccvalve.com
Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 02-01 / TC-1473
W-K-M and DynaSeal are trademarks of Cooper Cameron Corporation

Publication
TC-1473

W-K-M DynaSeal 310F 2-PieceBall Valve


Installation, Operation and Maintenance Manual

MODEL 15A GAGE VALVES


APPLICATION
Pressure Rating:

3000 PSI @ -20F to 100F

2850 PSI @ 300F

2625 PSI @ 500F

INSTALLATION

DO Plumb
tailpieces to
avoid misalignment.

DONT Create additional misalignment.


Some misalignment is usually present due
to errors in concentricity of pipe threads,
weld distortion in couplings, etc. Dont
make it worse!

DO Make up unions tight. Use at least an 18 wrench. Union is designed to crush solid metal along a high ridge, creating a line
seal between the taper and the flat surfaces.
Union will seal pressure without need for O-ring if alignment is good enough and if the installation torque has been efficiently transmitted into tightening the joint.
However, if there is significant misalignment in the piping arrangement then some of the umpf
experienced during make-up has been diverted into deflecting the piping. This causes resistance to further
turning of the nut and may leave insufficient tightness in the metal to metal seat of the union for sealing.
In this case the O-ring will finish the job. The joint needs to be tight enough (close enough) to close the
extrusion gap for O-ring to maintain its seal.

1.5 TAPER (Union Nut


omitted for clarity)

More severe MISALIGNMENT can lead to leaks at the union or broken pipe nipples or broken
tailpieces. If you are experiencing these difficulties ask for Inferno SPHERICAL UNIONS available as a separate male x male union or built into the valve itself.

DO Make up unions using a BACK-UP WRENCH on the valve body.


Failure to use back-up wrench causes excessive stress on the connecting nipple and can lead to
breakage of nipple or harmful twisting to sight glass.

BACK-UP WRENCH POINTS

OPERATION
BALL CHECKS...
Open valves full open during operation to assure safety action of ball check in case of glass or gasket failure. Stem must be open
more than 1-1/2 turns before ball is allowed to back seat. Extension on end of stem will deny ball a seating position until valve is
opened sufficiently. At this point the extension of the stem retreats enough to allow ball to check
closed in event of sudden loss of pressure in the sight glass.
Ball checks are designed to limit flow from vessel in case of accidental glass or gasket failure. They can
be of great help in limiting the blow-out effect of pressure acting on a shattered glass. But they are not
intended to provide a perfect seal. Dirt, trash and corrosion in the ball check cavity and back seat area
will limit the tightness of the emergency shut-off. In such cases there may be some degree of leakage past the ball checks.
Ball check will not activate in case of seepage caused by a leaky gasket. Ball check may not activate at all if cavity is packed with
M031196 sheet 1/2

1 1/03

Ball checks contd...


corrosion. Ball check requires pressure in the vessel to activate. About 7 head of water is sufficient pressure to check the ball in
water service with a full flow leak. More pressure is required to check with a choked off leak. Performance in other fluids will vary. Ball
check may not activate in extremely viscous fluids.
If in doubt as to whether ball checks are present in an existing installation or whether or not they are working properly you can test
as follows: Close off the upper gage valve. Leave the lower valve open. Open a drain valve rapidly and listen for the ball to make an
audible click. Now repeat process reversing the upper and lower valve position.
Restore fluid level in sight glass by closing drain and then moving both valves into the cracked open position. Cracking the valves
open will cause the stem extension to unseat the ball and allow it to drop back into its normal resting place.
If sight glass fails and balls are activated then manually close both valves. Be aware that a small amount of fluid will escape as the
balls are dislodged and before stem has a chance to fully close. Take necessary precaution.
BLOW-DOWN... DONT blow down sight glass with valves open. High velocity flow will cut seat and lead to failure of valve to close
without leakage. This problem is especially common in steam and hot water applications. However if it is not convenient to blow-down
the hot water sight glass with valves in the closed position then DO install a second valve (ball or gate) to insure that a tight
shut-off can be made for maintenance purposes during normal plant operation. A double block system may be required if you experience cutting in the seat area.
Shut off upper and lower valves first, then blow down sight glass through the lower valves drain connection, or through an additional
outlet at the bottom of the sight glass. Restore fluid level in sight glass by closing vent and drain and then cracking open the upper
and lower valves. Cracking the valves open prevents nuisance ball checking. After level has been reestablished open the valves full
open. In the full open position the ball is able to check autmatically in case of glass failure. In cracked position it will not check.
SHUTDOWNS... It is usually best to leave valves in normal full open position as the system is de-pressurized. This prevents excessive
thermal stress on the sight glass and valves and prevents trapping high pressure fluid. During START-UP pressure and temperature
are allowed to equalize slowly in the sight glass.

SPARE PARTS FORMODEL 15A


O-ring, Viton, Size 2-116 (90 durometer)
P/N 4761

3/4 NPT Tailpiece, Steel


P/N 4613
1/2 NPT
Tailpiece, Steel
P/N 4612
Union Nut, Steel
P/N 3882

Stem Packing,
Teflon
standard, to 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

COMMENTS AND SUGGESTIONS WELCOME


INFERNO MFG. CORP. SHREVEPORT, LOUISIANA www.infernomfg.com
TEL: 318-221-8454 FAX: 318-222-4106 email: inferno@infernomfg.com

M031196 sheet 2/2

1 1/03

OPERATING and MAINTENANCE MANUAL


SERIES 7100 FLO-LIFT PISTON CHECK VALVE
SCOPE

2.0

DISASSEMBLY

This manual provides information on installation, operation,


maintenance, and parts for Norriseal Series 7100 Piston
Check Valve.

Note: Numbers in parentheses refer to items shown


in figure 1 and figure 2.
1.

GENERAL DESCRIPTION
The Series 7100 Piston Check Valve is designed for lowpressure drop and positive prevention of backflow. It is
suitable for use with either gas or liquid systems. The
control orifice and ball check built into the plug provide a
cushioning or dampening effect for the plug making this
valve suitable for pulsating flows of gas or air.
1.0

CHART I
STUD SIZE
0.62
0.75
0.88
1.00
1.12
1.25
1.38
1.50
2.00

INSTALLATION
1.

Before installing the valve, inspect for shipping


damage and/or any foreign material that may have
collected during crating and shipping. Remove
flange protectors.

2.

Flush out inlet piping to remove pipe scale, chips,


welding slag, and other foreign materials.

3.

Valve must be installed so that flow is in direction


indicated by the arrow tag attached to the side of
body. Also note the word "INLET" engraved in
flange O.D. at inlet end of body.

4.

5.

6.

Install the valve using good piping practice. For


flanged bodies, use a suitable gasket between the
body and pipeline flange.
If continuous operation is required during
maintenance and inspection, install a conventional
three-way bypass around the body.
The bodies are rated at 150, 300, 600, 900, 1500
and 2500 ANSI class. Do not install the valve in a
system where the operating pressures exceed those
specified in the standards.

2.0 NORMAL MAINTENANCE SCHEDULE


CAUTION:
Before starting any repair or maintenance, make sure that all
pressure has been released from valve body. Before
unbolting bonnet, SLOWLY LOOSEN pipe plug in top
center of bonnet. While loosening plug, listen for sound of
gas pressure escaping around plug. Do not remove bonnet
until all trapped pressure, if any, has escaped.

Remove nuts (14A) from bonnet studs (14B).


Required wrench sizes are as follows:

WRENCH SIZE
1.06
1.25
1.44
1.62
1.81
2.00
2.19
2.38
3.12

2.

Lift bonnet (6) straight up and remove from body


(13).

3.

Remove load spring (5) by lifting straight up and


out of body.

4.

Valve plug (1), cage (3), and guide (4) may be


removed by means of lifting attachment (1D)
screwed into top of plug.

5.

After removal from body, the plug, cage, and guide


may be separated by lifting guide (4), then cage (3)
over top of plug.

6.

Remove plug seal (11) from recess in lower end of


guide.

7.

Remove seat (2) and seat gasket (9) by lifting them


out of recess in body.

2.1

INSPECTION
Follow valve disassembly as outlined above;
carefully inspect individual components as follows:
1.

Plug Seal: Construction consists of a stainless steel


spring surrounded by a TFE jacket. Examine
spring to be sure it is not bent or permanently
crimped. The TFE jacket should be carefully
examined under good lighting conditions. In order
to function properly, the jacket must be free of
scratches, cuts, and tears.

Caution: Before disassembly or maintenance, all pressures in this device must be relieved. Failure to relieve
pressures may result in personal injury or device damage. The resulting uncontrolled venting or spilling of
line fluids may cause personal injury, loss of process control, or environmental contamination.
January 2002

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 1 of 6

ITEM
1
2
3
4
5
6
7
8
9
11
12
13
14
15

DESCRIPTION
Piston Assembly
Seat Valve
Cage Piston
Guide Piston
Spring Piston
Bonnet Valve
Gasket Bonnet
Gasket Guide
Gasket Seat
Seal Piston
Plug Vent
Body
Stud Bonnet w/Nut
Eye Bolts

FIGURE 1
.2

Valve Plug: Inspect plug as follows:


O.D. of plug slides through seal ring and therefore
must be free of nicks and scratches that could
damage the TFE jacket. Handle plug carefully to
avoid damage during maintenance.
Examine
seating surface for scratches, nicks, or gouges that
could impair shutoff. If plug has a non-metallic soft
insert, this item should be closely examined, as it is
particularly susceptible to damage. Construction
may be solid (1-piece), or may be an assembly of
three or more basic components as described
below.

.2B Composition (Non-Metallic)-to-Metal Seating


(Figure 3):

.1

1 valve size consists of five basic components


assembled and secured with a screw.

.2

1.5 valve size consists of three basic


components assembled and secured by a
castellated nut and cotter pin.

.3

2.0 valve size consists of three basic


components assembled and secured with two
screws.

.4

3 & 4 valve sizes consist of four basic


components assembled and secured by a
screw.

.5

6 & 8 valve sizes consist of four basic


components assembled and secured by four
screws.

.6

10 valve size consist of four basic


components assembled and secured by six
screws.

.2A Metal-to-Metal Seating (Figure 2)


.1

1, 1.5, 2, 3, and 4 valve size: Plug is solid


1-piece construction with integral seating
surface machined near-bottom of plug.

.2

6, 8, 10, and 12 valve size: Plug is


multi-piece construction with replaceable
seating insert secured to plug butt with four
screws.

January 2002

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 2 of 6

HARD TRIM FIGURE 2

ITEM
1A
1B
1C
1D
1E
1F
1G
1I
1J
1L

January 2002

DESCRIPTION
Orifice Plug
Check Plug
Nut Screw Lifting
Screw Lifting
Piston
Butt Piston
Retainer Piston
O-Ring Retainer
Screw Retainer
Washer Lock Spring

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 3 of 6

SOFT TRIM FIGURE 3

ITEM
1A
1B
1C
1D
1F
1G
1H
1I
1J
1L
1M
1N

January 2002

DESCRIPTION
Orifice Plug
Check Plug
Nut Screw Lifting
Screw Lifting
Butt Piston
Retainer Piston
Insert Piston
O-Ring Retainer
Screw Retainer
Washer Lock Spring

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 4 of 6

.7 12 valve size consist of four basic


components assembled and secured by twelve
screws.

back against seat. After inspection and cleaning,


reinstall ball check in valve plug.
Examine orifice for presence of foreign matter and
clean as required. Reinstall orifice plug in valve plug.
This completes inspection and maintenance of valve
plug.

If inspection of insert-type plug shows all components to be


in good condition, it is not necessary to disassemble plug
and remove insert. However, if disassembling plug for
replacement of insert, proceed as follows: (Refer to Figure
3).
A) Plug may be secured in inverted position in a vise for
disassembly. However, if using a vise, place blocks of
wood or other soft material on both sides of plug to
protect surface finish.

.3

Valve Seat: Beveled seating surface must be


free of nicks and scratches. Inspect under-side
of seat for scratches or other imperfections that
would impair proper sealing against seat gasket.

.4

Cage, Guide, and Load Spring:


These
components should not suffer any adverse
effects from normal operation. However, with
valve disassembled, they should be examined to
verify that they are in good condition.

.5

Valve Body: With seat and bonnet gaskets


removed from body, inspect gasket recesses for
scratches or foreign matter that would impair
gasket sealing.
Clean gasket recesses as
required.

B) Remove cap screws (1J) using wrench size from Chart


2.
C) Remove retainer, insert, and o-ring seal from butt-plug.
D) To reassemble plug, install o-ring, insert, and retainer
in their respective positions.
E) Reinstall cap screws. Recommended values for
torquing cap screws are:
Valve
Size
1
1.5
2
3
4
6
8
10
12

# Of
Screws
1
1
2
1
1
4
4
6
12

Screw
Size
5/16-24
7/16-20
3/8-24

Torque
(Ft. Lbs.)
8
30
15

Wrench
Size

11/16
9/16

-13

60

5/8-11

70

15/16

# Of Ball Checks
0
1
2
3
3

Orifice plug and ball check contain small fluid


passages, which must be free of foreign matter for
proper valve operation. Ball check may be removed
from valve plug using a socket or wrench. Examine
ball check and remove any foreign matter present.
Operation of ball check may be verified by inserting a
small rod, less than 0.25" diameter from upper end.
Only light finger pressure should be required to push
ball off seat. With pressure removed, ball should snap

January 2002

REASSEMBLY
NOTE: Each Series 7100 Piston Check Valve
requires three (3) gaskets of three (3) different
sizes.
.1

Place seat gasket in body recess, and install seat


on top of gasket.
IMPORTANT: Seat must be oriented with 45
degree beveled surface facing upward.

Following reassembly of plug, place in upright


position for inspection of orifice plug and ball check.
All valves have one (1) orifice plug installed in top of
valve plug, but number of ball checks varies with
valve size as follows:
Valve Size
1
1.5, 2, 3
4
6, 8
10, 12

2.2

.2

Place plug guide on work surface in inverted


position (deep recess facing upward).

.3

Install plug seal in deep recess in guide.


Orientation of seal must be so that open side of
seal, with spring visible, faces upper end of
guide. Thus, with guide in inverted position,
only the TFE jacket will be visible after seal is
installed.

.4

Place valve plug on work surface in normal


upright position. Place valve cage over plug
with extended shoulder on cage oriented toward
top of plug.

.5

Turn guide over to its normal position and slip


over top of plug.
NOTE: Due to seal ring being squeezed
between guide and plug, it may be necessary to
gently tap guide into place.

.6

Place smallest of three (3) gaskets into recess in


top of guide

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 5 of 6

.7

Entire plug/cage/guide assembly may be picked


up by lifting attachment in center of plug. Place
the assembly into valve body, carefully
positioning cage over locating shoulder on seat.

.8

Install load spring in recess in top of plug.

.9

Install remaining gasket in recess in top of body.

.10 Install bonnet on top of body.

.12 Tighten bleeder plug (pipe plug) in top of


bonnet.
This completes valve reassembly.
3.0 PREVENTIVE MAINTENANCE
.1

SEAT: Check seat every six (6) months if in


normal service, i.e., no sand or abrasives and low
pressure drop. If in severe service, i.e., highpressure drop and sanding condition, check every
sixty (60) days.

.2

PISTON: Same as .1.

.3

GENERAL: When disassembling any portion of


valve, always check seal rings and gaskets for
damage or wear before reassembly.

.4

BODY: Under normal conditions, body should


last years. However, under severe conditions,
i.e., corrosion, sand and high-pressure drop,
valve life could be numbered in days only.

.11 CAUTION: Tighten the bonnet-to-body bolts to


the recommended torques given in the following
table (Follow good bolting practice and lubricate
bolts).
The Bonnet Bolt Torque Chart below shows stud
size in inches and recommended torque value in
FT-LBS for valve sizes and pressures classes, as
listed.
NOTE:
Spiral
wound
gasket
bolt-up
characteristics are such that tightening of one
bolt may loosen an adjacent bolt. This will occur
on subsequent tightening of all the bolts until
the bonnet-to-body seal is made. This requires
several trials on each bolt until the nut does not
turn at the given torque.

VALVE
SIZE
Stud
1
Torque
Stud
1.5
Torque
Stud
2
Torque
Stud
3
Torque
Stud
4
Torque
Stud
6
Torque
Stud
8
Torque
Stud
10
Torque
Stud
12
Torque

January 2002

BONNET BOLT TORQUE CHART


ANSI PRESSURE CLASS
150
300
600
900
1500
.75
110
120
.62
.75
85
160
.75
75
80
175
.75
1.00
90
140
275
.88
1.00
145
225
280
.88
1.25
280
375
680
1.12
1.25
1.38
425
465
1200
1.00
1.12
1.38
1.88
300
550
1000
2750
1.00
1.25
1.50
2.00
375
750
1300
3600

2500
.88
250

1.00
375
1.38
875
1.50
1400

707000M - 2002
P.O. Box 40525 Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com

Page 6 of 6

Section 9 Control Panel and Instrumentation


Vendor

Bulletin No.

Conduit and Sensor Assembly ....................................... Ajax

00-32-T010-367

Conduit for Thermocouples..............................................Ajax

00-32-T010-368

Vibration Switch and Conduit ......................................... Ajax

01-32-T020-318

Altronic Mag Pickup..........................................................Ajax

00-98-T000-307

Liquid Level Switch, L1200, O&M Bulletin.................................. Murphy

00-02-0175

Vibration Switch Bulletin, VS2 .................................................... Murphy

VS-7037N

Control Panel Drawing ................................................... Murphy

50-30-7327

Centurion Panel Sequence of Operations......................................... Murphy


Centurion Panel Installation and Operation........................................Murphy

00-02-0590

Pressure Swichgage, OPLFC..................................................... Murph

00-02-0161

Pulsation Dampener, PD-8184................................................... Murphy

PD-95145B

Manual Speed Pressure Murphygage ........................................ Murphy

00-02-0162

Pressure Regulator, Model 67CR-206 ....................................... Fisher

5469

Engine-Compressor Package Service Manual

00-02-0175
Revised 03-06
Section 15

Installation for L1100, L1200, L1200N Series


Liquid Level Switches and DVU150, DVU175,
and DVU2105/2115/2120 Series Dump Valves.

Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting.
GENERAL INFORMATION
**

Description
Series L1100 and L1200 Liquid Level Switches are float activated to
operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.
OBSERVE all pressure and electrical ratings and requirements for the devices and the operating environment.
BE SURE all pressure HAS BEEN REMOVED from the
vessel before opening any pressure connections.

Specifications

L1100

Series L1200N is a float-activated, pneumatic-vent level device used to operate dump


valves or similar devices. This model screws directly into the vessel or can be
mounted via an external float chamber. It cannot be used with weld collar 15050375.
Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
L1200NDVOR series carry Canadian Registration Number OF1476.2.
Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
pneumatic input signal to cause an orifice to open or close allowing liquid
condensate to be drained from a pressure vessel. A pop up button indicates valve
open/closed. Stainless steel versions available.
L1111

L1200

L1200N

L1200NDVO

L1200NDVOR

Body
Standard: Electroless Nickel plated steel
Optional: 316 Stainless Steel

A
A

A
A

B
B

B
B

B
B

B
B

Pressure Rating
15 psi (103 kPa) [1.03 bar] Polyethylene Float
1500 psi (10.3 MPa) [103.42 bar] Stainless Float
2000 psi (13.8 MPa) [138 bar] BUOYGLAS Float

Temperature Rating
Standard: -20/175F (-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)

Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)

Specific Gravity
Standard: 0.5 with BUOYGLAS float
Optional: 0.65 with 304 Stainless Steel
Standard 0.73 Polyethylene Float

O-Rings: Viton
Valve: Two-way snap-action vent type
1/8 in. (3 mm) orifice w/Viton A seat
1/8 NPT inlet; 1/4 NPT vent
30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar. 1/8 NPT inlet, outlet & vent.
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge.
Maximum input 300 psi (2.07 MPa) [20.68 bar].
1/8 NPT in/out.
Operation:
H=For high level, L=For low level

Meets NACE standard MR-01-75 for direct exposure to H S service.


*Not available with DPDT snap-switch.
A =1-1/2 NPT
B =2 NPT
2
**Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.
Installation 00-02-0175 page 1 of 6

DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with
Dump Valve Operator, Pressure
Regulator and Gage

L1100 and L1200


11 in.
(279 mm)

Pressure
Regulator
with 20BPG
Pressure Gage

3-1/2 in.
(89 mm)

2-3/16 in.
(56 mm)

New Dump Valve


Operator Assembly
p/n 15010216

See
Note 2

1/2 NPT

See
Note 1
3-5/8 in.
(92 mm)

Note 1:
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm)
SF option:
L1100: 1-1/2 (38 mm)
L1200: 1-3/4 (44 mm)

1/8 NPT
Old Round Dump Valve
Operator Assembly
p/n 15000940

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

1/8 NPT
INLET

3-5/8 in. (92 mm)

5 in. (127 mm.) minimum


clearance is required for
float movement.

3/4 Hex
(See Note)

2-3/16 in.
(56 mm)

1/4 NPT
VENT

1-9/16 in.
(40 mm)
SF option=
1-3/4 in.
(44 mm)

2" 11-1/2 NPT

3-1/2 in. (89 mm)


SF= 3-3/4 in. (95 mm)
11 in. (279 mm) SF option= 11-1/4 in. (286 mm)
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).

L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)

2-3/16 in.
(56 mm)

DVU150, DVU175, DVU2105/2115/2120


Series Dump Valves

See
Note

1/2 NPT

1-1/2 NPT
3-5/8 in.
(92 mm)

Note: 1-9/16 (40 mm)

Pressure
Inlet Port
1/8 in.-27 NPT

Float travel between Operate


and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
w/ float at horizontal centerline
0.25 in. (6 mm).

Manual Valve
Operator

Vent
Weep Hole
Union

Valve Open/Closed
Indicator Button

Electrical installation to be done by


qualified person according to the NEC.

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

NOTE: Dimensions are in inches and (millimeters)

Installation 00-02-0175 page 2 of 6

REPLACING AND INSTALLING THE DVOA ASSEMBLY

When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Replacing and Installing the DVOA
Assembly For Models L1200NDVO &
L1200NDVOR

NOTE: Clean, dry instrument quality gas should be used.


Use of filters will improve service life and reliability.

Tools Needed: Strap or pipe wrench; 3/4 Hex wrench; 9/16 hex
wrench; needle nose pliers; tubing cutters and benders and the
appropriate tools for the fittings.
1.

Block off and bleed the instrument gas pressure supply to the
L1200NDVO.
2.
Remove the tubing between the L1200NDVO and the
separator dump valve, and remove the supply gas tubing
(regulator [-R] if used).
3.
Remove the L1200NDVO from the vessel (optional).
4.
If the L1200N was removed from the vessel, mount it in a
suitable vise on a work bench (if possible).
5.
Using the proper tools, disconnect the Inlet, Outlet and
Exhaust fittings from the existing DVO (see fig. 1). You will
re-connect these to the new DVOA in a later step.
NOTE: The following steps must be done with the DVO in the
upright position (on top of the L1200N).
6.
Remove the L1200N cover (this will aid with the alignment
of the new DVOA Valve Bushing). The use of a strap
wrench or a pipe wrench may be needed.
7.
Insert the new Valve Bushing through the new DVOA (see
fig. 2). The markings on top of the DVOA must be facing
up. This will be needed in step 9.
8.
With a 3/4 hex wrench loosen the existing DVO, valve
stem, and static seal (see fig. 3). Once the assembly is
loosened, VERY CAREFULLY use needle nose pliers to
hold the Valve Seat Assembly in place. Remove the existing
DVO making sure the Valve Seat Assembly inside the
L1200NDVO is aligned and straight (see fig. 4).

Old DVO

Outlet
(opposite side)

Inlet

Exhaust

Figure 1

Figure 2

New DVOA

Figure 3

CAUTION: MAKE SURE the Valve Seat Assembly inside


the L1200N remains in place after removing the DVO.
Holding the Seat Assembly up with the needle nose pliers
inside the L1200NDVO body, place the tip of the new
DVOA valve bushing through the spring and into the hole in
the center of the valve seat, and tighten the valve bushing.
The Valve Seat Assembly should be able to move freely up
and down after the bushing has been tighten. The DVO red
button must face away from the vessel.
10.With the new DVOA aligned over the hex on the L1200NDVO
body, tighten the Valve Bushing using the 9/16 hex wrench.
You may need to hold the DVOA while tightening the Valve
Bushing to keep it from rotating (see fig. 5).
11.If the L1200N is in the vise, operate the float and inspect for
smooth and proper operation of the Valve Seat Assembly.
12.Replace the L1200NDVO cover (see fig. 6).
13.Using the appropriate tools re-install the Inlet, the Outlet and
the Exhaust fittings to the new DVOA (see fig. 5).
14 If the L1200N was removed from the vessel re-install it at this
time.
15.Modify existing or install new tubing to connect the Inlet, the
Outlet and Exhaust fittings.

Valve
Bushing

Valve Seat
Assembly

9.

Outlet

Figure 4

Inlet

Installation 00-02-0175 page 3 of 6

Exhaust

New DVOA

Figure 5

L1200N
Cover

Figure 6

PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N

Direct Installation into the Wall of the


Pressure Vessel
1. Determine that the float travel is not
obstructed by the coupling in
Tank
the vessel wall, internal
Wall
baffles, etc.
Do NOT use more than
one arm extension P/N
15050395.
Explosion proof
2. BE SURE that the float
Level
conduit seal
Switch
and extension are tight
where required.
and that the lock washer is
in place.
3. Before installing the level
switch a suitable pipe thread sealant
is recommended. Screw the unit directly into the threaded
connection in the wall of the pressure vessel.
4. Be sure that the electrical connection is positioned at the
bottom. For L1200N the 1/8 NPT pneumatic connection
should be on top (the 1/4 NPT vent connection should be on
the bottom). See Pneumatic models section for further
instructions for the L1200N.
5. Make the electrical wiring connections according to
appropriate wiring diagrams for the alarm or shutdown
system to be used. The electrical connection is 1/2-14 NPT.
Electrical wiring and conduit should be installed by qualified
personnel according to the NEC.
6. BE SURE all electrical connections are insulated and the
cover is fully installed before reconnecting electrical power.
7. BE SURE all pressure connections are tight before
pressurizing the system.
Installation with a Weld
Collar
Tank Wall
1. The weld collar, P/N
Weld Collar
15050375, must be welded
into the wall of the
pressure vessel according
to code standards and
good welding practices.
L1200
2. Follow above instructions
for installation directly into
Explosion proof
the wall of the pressure
conduit seal
vessel.
where required.
3. NOTE: Weld collar 15050375 can
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External
Float Chamber 15051098

positioned away from the tank wall.


2. A tee is typically installed at the bottom of the lower 1 inch
pipe riser to allow draining of the float
chamber for servicing or replacement.
NOTE: A typical installation
Float
with Blocking and Bleed valves is Chamber
Tank
shown at right.
Block
Valves
3. Install the L1200 or
L1200N
Level
in the 2 NPT connection Switch
of
Tee
the float chamber.
Bleed
BE SURE float travel
Valve
is not restricted and that the
Explosion proof
float is tight onto
conduit seal
where required.
the float shaft.
4. To complete installation and
wiring, follow the instructions for
mounting directly into wall of the vessel and for wiring.
Pneumatic Models
1. All pneumatic models
operate on the vent
Filter/Regulator
Tank
principle. The
New Dump Valve
Operator Assembly
pneumatic signal
Pneumatic
p/n 15010216
Signal
source MUST BE
CLEAN AND DRY.
The input pneumatic MURPHYGAGE
signal must be
regulated between 30
L1200N
and 70 psi (207-483
kPa) [2.07-4.83 bar].
If produced gas is used as the
signal source, it should be taken
after gas passes through the final scrubber.
A suitable filter must be positioned before the L1200NDVO
to prevent liquids and/or particulates from entering the dump
valve operator.
NOTE: Check filter periodically for wear and tear and
elements that hamper the flow of the pneumatic signal.
2. All pressure connections must be tight and maintained tight
so as not to leak air/gas.
3. Valve seat adjustment can be made if air/gas begins to leak.
Care should be taken when adjusting as only slight movement
is necessary to stop the leakage; excessive force will bind the

Hex Socket Set Screw


loosen for adjustment
tighten after adjustment

L1200N

CAUTION: USE NON SPARKING TOOLING.


1. Install the float chamber 15051098 on the outside wall of the
pressure vessel using 1 NPT piping. Position the 2 NPT
threaded connection at the height where you want the level
switch to operate. The 2 NPT threaded connection must be

Hex Adjustment Nut


turn left until air
seepage stops
Caution: only slight
adjustment is neededtoo
much will lock up mechanism

Installation 00-02-0175 page 4 of 6

Trip Cam (float down)


should be in
this position
non-adjustable

TYPICAL INSTALLATION ON GAS COMPRESSORS

Basic Operation
As condensate rises in the scrubber, the float on
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter
the dump valve pilot chamber. Once the pressure
enters the pilot chamber it forces the diaphragm
and valve stem forward thus opening the valve seat
(valve open/closed indicator button pops out) and
releasing condensate through the valve stem and
out the drain. As the condensate level drops, the
L1200NDVOR pneumatic valve closes to shut off
the pressure to the dump valve causing it to close.
If for any reason the condensate continues to rise
beyond normal dump levels, model L1200
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the
MURPHYGAGE help keep the control pressure
clean and dry. They also allow the operator to
adjust pressure to recommended levels.

Typical/Scrubber/Separators
VESSEL
Minimum control
pressure 30 psi
(207 kPa) [2.07 bar]

Rising Level Shutdown


L1200 (with snap-switch)

Explosion proof
conduit seal required
for Class I. Div 1, not
required for intrinsically
safe or non-incendive
circuits like FWM TTD.

Rising
Level
Trips
DVO

Electrical
Conduit

L1200NDVOR
Dump Valve
Operator
Union

Air Supply Maximum


300 psi (2.07 MPa)
[20.70 bar]

Filter/Regulator
with MURPHYGAGE

Minimum control pressure


30 psi (207 kPa) [2.07 bar]

DVU Series Dump Valve


Union
Condensate Line (Out)
Manual Drain Valve

REPLACEMENT PARTS

ELECTRICAL INFORMATION
DPDT (Snap Switch)
SPDT (Snap Switch)
Green Grd. Connection

Black N.O.

White COM.

Red N.C.

Switch Rating: 5 A @ 125-250- 480 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
2A @ 6-30 VDC Resistive
1A @ 6-30 VDC Inductive

Green Grd. Connection

Black N.O.

White COM.

Red N.C.
Blue N.C.

Yellow COM.

Orange N.C.

Switch Rating: 10 A @ 125-250 VAC


1/2 A @ 125 VDC
1/4 A @ 250 VDC
10 A @ 6-24 VDC
Inductive/Resistive

Order by part number designation.


L1100/L1200*
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200
15000937: Stainless Steel float for L1100
15000124: SPDT snap switch assembly
15010213: L1100 counter balance assembly
15010214: L1200 counter balance assembly
L1200N
15050420: Cam spring return
15050421: Cam
15000893: BUOYGLAS float
15000894: Stainless Steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
55050621: Regulator only
05706499: 20BPG-D-75 Pressure MURPHYGAGE
0-75 psi (517 kPa) [5.17 bar]
15010216: DVOA assembly (New rectangular style)
15000940: DVO assembly (Old round style)
*To maintain hazardous location listings, all other repairs must be made by the factory.

Installation 00-02-0175 page 5 of 6

ACCESSORIES

Order by part number designation.

55050617: DVU150/DVU175 Adapter Bushing

15050375: Weld Collar

Material: 2-1/2 Hex bar stock C.R.S


2-1/16 in
(52 mm)
1-1/16 in
(27 mm)

2 NPT

2-1/2 in
(64 mm)

2-7/8 in
(73 mm)
3-5/8 in.
(92 mm)

1 NPT

4-1/2 in
(114 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

2 NPT

15051098: External Float Chamber


3 in.
(76 mm)

1-11.5 NPT (2 places)

2-11.5 NPT
10.5 in.
(266 mm)

3 in.
(76 mm)

1/2-20 UNF-2B
(4 places)
7.55 in.
(192 mm)

3.5 in.
(89 mm)

Material: Cast Steel, WCB

7.01 in.
(179 mm)

Operating Pressure: 2000 psi (13.8 MPa) [138 bar].


Operating Temperature: 400F (204C).

15000892: Float Shaft Extension


10-32 UNF

10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)

Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

www.fwmurphy.com
918.317.4100 Email: 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.

Installation 00-02-0175 page 6 of 6

VS-7037N
Revised 04-05
Section 20

Shock/Vibration Control Switches


Installation Instructions

(00-02-0185)

Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94


Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before
mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes.
GENERAL INFORMATION

WARNING

LISTED*

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

Description
The Murphy shock and vibration switches are available in a variety of
models for applications on machinery or equipment where excessive
vibration or shock can damage the equipment or otherwise poses a
threat to safe operation. A set of contacts is held in a latched position
through a mechanical latch and magnet mechanism. As the level of
vibration or shock increases an inertia mass exerts force against the
latch arm and forces it away from the magnetic latch causing the latch
arm to operate the contacts. Sensitivity is obtained by adjusting the
amount of the air gap between the magnet and the latch arm plate.
Applications include all types of rotating or reciprocating machinery
such as cooling fans, engines, pumps, compressors, pump jacks, etc.

Models
VS2: Base mount; non hazardous locations.
VS2C: C-clamp mount; non hazardous locations.
VS2EX: Explosion-proof; Class I, Div. 1,
Groups C and D.
VS2EXR: Explosion-proof with remote reset.
VS2EXRB: Explosion-proof; Class I, Div. 1, Group B; with
remote reset.
VS94: Base mount; non hazardous locations, NEMA 4X/IP66.

Model VS2EX

Remote Reset Feature (VS2EXR,


VS2EXRB and VS94 only)
Includes built-in electric solenoid which allows reset of tripped unit from a
remote location. Standard on VS2EXR and VS2EXRB. Optional on
VS94 (options listed below).
-R15: Remote reset for 115 VAC
-R24: Remote reset for 24 VDC

Time Delay Option (VS94 only)


Overrides trip operation on start-up. For VS94 series models, the delay
time is field-adjustable from 5 seconds up to 6-1/2 minutes with a 20turn potentiometer (15 seconds per turn approximately). Options listed
below:
-T15: Time delay for 115 VAC
-T24: Time delay for 24 VDC

Space Heater Options (VS94 only)


This optional space heater board prevents moisture from condensing
inside the VS94 Series case. Options listed below:
-H15: Space heater for 115 VAC
-H24: Space heater for 24 VDC

Warranty
A limited warranty on materials and workmanship is given with this FW
Murphy product. A copy of the warranty may be viewed or printed by going
to www.fwmurphy.com/support/warranty.htm

VS-7037N page 1 of 8

DIMENSIONS
VS2

VS2C

3 in.
(76 mm)

4-3/4 in.
(121 mm)

Reset
Push
Button

4-19/32 in.
(116 mm)

3 in.
(76 mm)

Slotted
Sensitivity
Adjustment

5-1/8 in.
(130 mm)
Mounting Holes

Slotted
Sensitivity
Adjustment

Reset
Push
Button

5-7/16 in.
(138 mm)

Plug

2-1/4 in.
(57 mm)

4-3/4 in.
(121 mm)

1/4 x 1/2 in.


(6 mm x 13 mm)
Slot 2 places

Weatherproof
Strain Relief
Bushing

27/32 in.
(21 mm)
C-Clamp

VS2EX and VS2EXR


5-5/8 in.
(143 mm)
Reset
Push
Button

1/2 NPT
Conduit

1-3/4 in.
(44 mm)
3/8 in.
(10 mm)
4 places

4-7/8 in.
(124 mm)

Slotted
Sensitivity
Adjustment
5-1/4 in.
(133 mm)
6-3/8 in. Mounting Holes
(162 mm)

3 in.
(76 mm)
Mounting Holes

VS2EXRB
10-5/8 in.
(270 mm)

6 in.
(152 mm)

8-5/8 in.
(219 mm)

1/2 NPT
Conduit

2-1/2 in.
(64 mm)
4-1/2 in.
(114 mm)
Mounting Centers

10-3/16 in.
(259 mm)

9-1/8 in.
(232 mm)
Mounting Centers

VS94
6-29/32 in.
(176 mm)

Manual
Reset
Push-button

7-9/64 in.
(181 mm)

6-1/2 in.
(165 mm)

4-5/8 in.
(118 mm)
3/4 NPT
conduit fitting

1-5/8 in.
(41 mm)
4 in.
(102 mm)

Mounting slot
5/16 x 9/16 in.
(8 x 14 mm)
4-places.

6-1/2 in.
(165 mm)

4 in.
(102 mm)

VS-7037N page 2 of 8

SPECIFICATIONS

VS2 and VS2C


Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas.
VS2: Base mount
VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16
AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable
hold down clamps.
Contacts: SPDT double make leaf contacts, 5A @ 480 VAC.
Range adjustment: 0 - 7 Gs; 0 - 100 Hz /0.100 in. displacement.

VS2EX
Case: Explosion-proof and weatherproof aluminum alloy housing;
meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C &
D; UL and CSA listed.*
VS2EX: base mount.
Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;*
2A resistive, 1A inductive, up to 30 VDC.
Range adjustment: 0 - 7 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

additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,


up to 30 VDC.
Remote Reset:
Option Operating Current
-R15:
350 mA @ 115 VAC
-R24:
350 mA @ 24 VDC
Range adjustment: 0 - 7 Gs; 0 - 100 Hz /0.100 in. displacement.

VS94
Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA
types 4 and 12.
Conduit Fitting: 3/4 NPT conduit fitting connection.
Normal Operating Ambient Temperature:
0 to 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).

*CSA and UL listed with 480 VAC rating.

INSTALLATION
WARNING: STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.

The VS2 and VS94 series shock switches are sensitive to shock and
vibration in all three planes of motion - up/down, front/back and side/side.
Front/back is the most sensitive (The reset pushbutton is located on the
front of the unit). For maximum sensitivity mount the unit so that the
front faces into the direction of rotation of the machine. (See Dimensions on
page 2 for sensitivity adjustment location).
The VS2 and VS94 Series must be firmly attached/mounted to the machine
so that all mounting surfaces are in rigid contact with the mounting surface
of the machine. For best results, mount the instrument in-line with the
direction of rotating shafts and/or near bearings. In other words, the reset
push button should be mounted pointing into the direction of shaft rotation
(see page 5). It may be necessary to provide a mounting plate or bracket to
attach the VS2 and VS94 Series to the machine. The mounting bracket
should be thick enough to prevent induced acceleration/vibration upon the
VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See
illustrations on page 5 for typical mounting locations.
CAUTION: A dust boot is provided on the reset pushbutton
for all series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting

orientation should be on a horizontal plane or with the sensitivity adjustment


pointing down. Sensitivity adjustment for model VS2 is covered by a plug.
The plug must be in place and tight to prevent moisture or dust intrusion.

C-Clamp Installation (VS2C model only)


A C-Clamp is supplied with the VS2C model only.
The C-Clamp is shipped installed on the VS2C
but must be installed on the VS2EX and
VS2EXR switches.
1. The C-Clamp (B) will already be installed on
a 1/4 in. (6 mm) thick steel mounting plate
(A). Bolt the VS2 switch to the mounting
A
plate as illustrated with four 5/16 in.
B
bolts, nuts, and washers.
2. The mounting location should provide
convenient access to the TATTLETALE
push button (C).
3. The hardened set screw and nuts (D) are used to
tighten the switch to an I-Beam or cross member such as a
Sampson post of an oilwell pumpjack.

VS-7037N page 3 of 8

Continued on next page.

INSTALLATION Continued

All Models
WARNING: STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.

1. Firmly secure the unit to the equipment using the base foot mount or
C-Clamp if applicable. See C-Clamp Installation page 3.
For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson
post or walking beam. See Typical Mounting Locations page 5.
2. Make the necessary electrical connections to the vibration switch. See
Internal Switches, page 6 for electrical terminal locations and page 7 for
typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT
RATINGS OF THE CONTACTS. Follow appropriate electrical
codes/methods when making electrical connections. Be sure that the run of
electrical cable is secured to the machine and is well insulated from
electrical shorting. Use of conduit is recommended.
NOTE: If the electrical cable crosses a pivot point such as at the pivot of
the walking beam, be sure to allow enough slack in the cable so that no
stress is placed on the cable when the beam moves.
If conduit is not used for the entire length of wiring, conduit should be
used from the electrical supply box to a height above ground level that
prevents damage to the exposed cable from the elements, rodents, etc. or
as otherwise required by applicable electrical codes. If conduit is not
attached directly to the VS2 and VS94 Series switch, use a strain relief
bushing and a weatherproof cap on the exposed end of the conduit. A
drip loop should be provided in the cable to prevent moisture from
draining down the cable into the conduit should the weathercap fail.

allow the machine to stop. Turn the sensitivity adjustment 1/4 turn
clockwise, (adjustment for VS94 and VS2EXRB models is located within
the box, see DETAIL B).
WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE
OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.

Depress the reset button and restart the machine. Repeat this process until
the unit does not trip on start-up.
DETAIL B
5. If the instrument does NOT trip on startup, stop the machine. Turn the sensitivity
adjustment 1/4 turn counter-clockwise.
Repeat the start-up/stop process until the
instrument trips on start-up. Turn the
sensitivity adjustment 1/4 turn clockwise
(less sensitive). Restart the machine to
verify that the instrument will not trip on
start-up.

THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A


QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE
SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO
NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND
CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.

All models of the VS2 and VS94 Series cover a wide range of sensitivity.
Each model is adjusted to the specific piece of machinery on which it is
installed. After the switch has been installed in a satisfactory location (see
page 5) the sensitivity adjustment will be increased or decreased so that the
switch does not trip during start-up or under normal operating conditions.
This is typically done as follows:
1. REPLACE ALL COVERS, LIDS, AND
ELECTRICAL ENCLOSURES.
2. Press the reset push button to engage the magnetic latch. To be sure the
magnetic latch has engaged, observe latch
DETAIL A
through the window on the VS2 and
VS2C (see DETAIL A). On the
Reset Push button
VS2EX, VS94 series the reset button
will remain depressed meaning the
magnetic latch has engaged.
3. Start the machine.
4. If the instrument trips on start-up,

Sensitivity
adjustment

More Sensitive

6. Verify that the unit will trip when abnormal shock/vibration exists.

VS94 Time Delay Adjustment


1. Apply power to the time delay circuit. (see
page 7 for time delay circuit). The time delay function will be initiated.
2. Time the length of the delay with a watch. Let time delay expire. After it
expires, the override circuit will de-energize the solenoid, allowing the latch
arm to trip. A clicking noise is heard.
WARNING: REMOVE ALL POWER BEFORE OPENING
ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A
QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE
IT CONFORMS WITH NEC AND LOCAL CODES.

Sensitivity Adjustment
WARNING: REMOVE ALL POWER BEFORE OPENING

Less
Sensitive

3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.


NOTE: Allow 30 seconds bleed-time between turning the
power OFF and ON.
DETAIL C
4. Locate the time adjustment pot (DETAIL C).
The time is factory-set at the lowest setting (5
seconds approximately). To increase time,
rotate the 20-turn pot clockwise as needed
Turn to
(15 seconds per turn approximately).
decrease
5. Repeat the above steps as necessary to
obtain desired time delay.

Pot

Turn to
NOTE: An external time delay can be used
increase
with the remote reset feature of the VS2EXR
series to provide a remote reset and override of the trip
operation on start-up. Time delay must automatically disconnect after
equipment start-up.

Sensitivity
Adjustment

VS-7037N page 4 of 8

TYPICAL MOUNTING LOCATIONS

NOTE:

These are typical mounting locations for best operation. Other mountings are possible.
See Installation section on page 3.

2-Throw Balance-Opposed Compressor

Pumping Unit

Reset

NOTE: If installing on
cylinders, 2 vibration/shock
switches are recommended1 for each cylinder.

Engine
and
Vertical
Shaft
Pump

Reset

Y Type
Reciprocating
Compressor

Reset

Reset

Reset

Generator
Sets

Reset

Cooling Tower Fan or


Heat Exchanger

Reset

Engine Compressor

Turbine Centrifugal
Compressor

Reset

VS-7037N page 5 of 8

Reset

INTERNAL SWITCHES

VS2 and VS2C

VS2EXR
Remote Reset
Terminal
Sensitivity
Adjustment

Sensitivity
Adjustment

NC
NO1

NC

COM

NO COM
Ground
Terminal

NO2
SPDT Snap-Switch

SPDT Switch Terminals

VS2EXB and VS2EXRB

VS2EX

Remote Reset
Terminal
Sensitivity
Adjustment

SPDT Snap-Switch

NC

NO COM

NC

NO COM

Sensitivity
Adjustment

NC
Ground
Terminal

SPDT
Snap-Switch

SPDT Snap-Switch

VS94
SPDT
Snap-Switch

NC

NO COM

NC

NO COM

SPDT
Snap-Switch

NC

Time Delay and/or


Remote Reset
Terminal (Optional)

Ground
Terminal

Sensitivity
Adjustment

Heater Board
Terminal (Optional)

VS-7037N page 6 of 8

NO COM
NO COM

Ground
Terminal
Optional SPDT
Snap-Switch
(VS2EXRB only)

ELECTRICAL
WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.

VS2 and VS2C


Typical Wiring Diagram for Single or Dual CD Ignition

VS2EX
Typical Wiring Diagram for Single or Dual CD Ignitions

SPDT Switch
Contacts shown in the RESET position.

NO1

NC

COM

CD Ignition
2

SPDT Switch
(Optional 2-SPDT [DPDT])
Contacts shown in the
RESET position
CD Ignition
2

NO2

N.C.

COM

N.O.

N.C.

COM

Resistor
(100 , 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

VS2EXR and VS2EXRB


Typical Wiring Diagram for Single or Dual CD Ignitions

Remote Reset
Momentary
Push Button

SPDT Switch
(Optional 2-SPDT [DPDT])
Contacts shown in the
RESET position
N.O.

115 VAC or
24 VDC (Voltage
is specified
when ordered).

VS94
Typical Wiring Diagram for Single or Dual CD Ignitions

N.O.

N.C.

N.C.

COM

To good
engine
ground

COM

Additional
Switch
Optional
on VS2EXRB
only

115 VAC or 24 VDC*

Maintained
Contact for
Time Delay

Time
Delay

115 VAC or
24 VDC*
*Voltage is specified
when ordered.

To good
engine ground

CD Ignition
2

Time Delay or
Remote Reset
(Optional)

Momentary
Contact for
Remote
Reset only

2-SPDT
Switches (DPDT)
Contacts shown in the
RESET position

N.O.

N.C.

COM

N.O.

N.C.

COM

Heater Board
(Optional)

To good
engine
ground

To good
engine ground

Resistor
(100 , 3 Watt)

CD Ignition
1

CD Ignition
1

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94


Typical Wiring Diagram for Electric Motors

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94


Typical Wiring Diagram for Distributor Ignition or Diesel

Contacts shown

NOTE: Terminal N.O. is


terminal NO1 on models
VS2 and VS2C.
L1

L2

L3

Switch Terminals in the RESET position


N.O.
N.C.
COM

(see Note)

CD Ignition
2

Resistor
(100 , 3 Watt)

NOTE: Terminal N.O. is


terminal NO1 on models
VS2 and VS2C.

Switch Terminals
N.O.

(see Note)

N.C.

COM

Contacts shown
in the RESET position
Ignition
Switch

Push-button
Station

Ammeter
HC

Diesel Fuel
Shutoff Valve
H

MOTOR

Hand Off
Automatic
Selector
HC

VS-7037N page 7 of 8

Ignition Coil

Distributor

Battery

SERVICE PARTS
PART NO.

DESCRIPTION

PART NO.

VS2
20000030
20000031
20000032

VS2EXRB
Movement assembly
Glass and gasket assembly
Reset push button assembly

20010090

20000057
Movement assembly
Glass and gasket assembly
Reset push button assembly
Mounting clamp
VS2C 5-clamp hardware package assembly.
2-Conductor electrical cable, 45 feet (13.7 meters)

20000058
20000287
20000290

VS2EX
20010091
20050087
00000309
20010090
20000288
20000289

Movement assembly
Cover
Cover gasket
Snap-switch and insulator kit (1 switch per kit)
prior to September 1, 1995.*
Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
C-clamp conversion mounting kit

VS2EXR
20000262
20050087
00000309
20010090
20000288
20000049
20000234
20000289

Snap-switch and insulator kit (1 switch per kit)


prior to September 1, 1995.*
Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
Inside snap-switch and insulator kit (1 switch per kit) for
model VS2EXRB-D prior to September 1, 1995.*
Outside snap-switch and insulator kit (1 switch per kit) for
model VS2EXRB-D prior to September 1, 1995.*
Outside snap-switch and insulator kit (1 switch per kit) for model
VS2EXRB-D manufactured on September 1, 1995 or later.*
Inside snap-switch and insulator kit (1 switch per kit) for model
VS2EXRB-D manufactured on September 1, 1995 or later.*
Adjustment shaft
Movement assembly
Reset solenoid assembly (115 VAC)
Reset solenoid assembly (24 VDC)

20000288

VS2C
20000030
20000031
20000032
20050021
20000185
20050465

DESCRIPTION

Movement assembly
Cover
Cover gasket
Snap-switch and insulator kit (1 switch per kit)
prior to September 1, 1995.*
Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
Reset solenoid assembly (115 VAC)
Reset solenoid assembly (24 VDC)
C-clamp conversion mounting kit

FW Murphy
P.O. Box 470248
Tulsa, Oklahoma 74147 USA
+1 918 317 4100 fax +1 918 317 4266
e-mail 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).

CONTROL SYSTEMS & SERVICES DIVISION

FRANK W. MURPHY, LTD.

P.O. Box 1819; Rosenberg, Texas 77471; USA


+1 281 633 4500 fax +1 281 633 4588
e-mail sales@fwmurphy.com

Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.


+44 1722 410055 fax +44 1722 410088
e-mail sales@fwmurphy.co.uk
www.fwmurphy.co.uk

INDUSTRIAL PANEL DIVISION

P.O. Box 470248


Tulsa, Oklahoma 74147 USA
+1 918 317 4100 fax +1 918 317 4266
e-mail sales@fwmurphy.com

MURPHY DE MEXICO, S.A. DE C.V.

Blvd. Antonio Rocha Cordero 300, Fraccin del Aguaje


San Luis Potos, S.L.P.; Mxico 78384
+52 444 8206264 fax +52 444 8206336
Villahermosa Office +52 993 3162117
e-mail ventas@murphymex.com.mx
Printed in U.S.A.
www.murphymex.com.mx

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

VS-7037N page 8 of 8

078792

SEQUENCE OF OPERATION
Centurion Controller
DRAWING# 50-30-7327
SEQUENCE# 50-32-7327 rev A
PROGRAM# 50-34-7327 rev A
CAMERON COMPRESSION
December 12, 2007
Revised December 14, 2007

TABLE OF CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0

TYPE OF SYSTEM
STARTING SEQUENCE
RUNNING SEQUENCE
STOPPING SEQUENCE
SHUTDOWN SEQUENCE
CONTROLLER I/O
MODBUS ADDRESS LIST
MCONFIG PRO REPORT (refer to attached PDF file)

Page 1 of 15

1.0 TYPE OF SYSTEM


1.1 The control system for this project is one FWMurphy Centurion Configurable Controller with
custom firmware installed. This system is designed for use in Class I, Division 2 hazardous
areas, powered by user supplied 24VDC. The controller will monitor various analog and
switch inputs and shutdown the motor/compressor package as noted in this document. The
controller will interface with an Ajax Engine Driven Integral Reciprocating compressor.
1.2 GENERAL OPERATING INSTRUCTIONS
1.2.1

Upon powerup, the display will first show the default home page as configured
using Mconfig Pro software. To navigate the display, use the UP, DOWN,
RIGHT, and LEFT arrow keys. To start the unit in local mode, press the
RUN/STOP key to start and stop the start sequence. Pressing the RESET key will
reset any fault shutdowns.

1.2.2

From any main page, the HOME key can be used to return to the default home
page.

1.2.3

Timers will be shown on the 2 to the bottom of the display. The panel state
message will be displayed across the bottom of the display.

1.2.4

The Class B1, B2, and S timers can be reset, or zeroed by pressing the RESET,
or TIMER 0 (Zero) key. The test mode can be initiated by pressing the TEST
key.

nd

1.3 SETPOINTS
1.3.1

To edit setpoints within the controller, press the SETUP/ENTER key. The
appropriate numeric password must be entered to make changes to setpoints.
No password is necessary to view setpoints.

1.3.2

The Centurion uses a different approach to enter values than previous Murphy
controllers. Instead of holding in the arrow keys until the desired number is
displayed, the Centurion display allows individual editing of each position of the
desired number. This is accomplished by entering the Edit Mode and using the
UP/DOWN arrow keys (1) to adjust the number above the blinking cursor (2)
between 0 and 9. To edit another position, simply use the LEFT/RIGHT (3) arrow
keys to move the cursor to that position (4) and repeat the edit process until the
desired number is displayed. In this way, values are built rather than scrolled
through.

1.3.3

Some digits may not be allowed to increment if it would result in exceeding range
limits. Values which can be positive or negative will have a sign () to the left of
the number. To change the sign value simply move the cursor to the sign using
the LEFT arrow key and toggle between + and using the U and DOWN arrow
keys. If the range of the value will exceed range limits the sign may not be
allowed to change. In this case, try reducing the number by decrementing the left
most digit by one or more and attempt to change the sign again.

1.3.4

In some instances, a word rather than a value is represented in the Edit Mode.
This works like the sign value as an ON/OFF or YES/NO prompt where the value
is toggled between choices using the UP/DOWN arrow keys. The value is not
active in the controller until the ENTER key has been pressed to send the value
to the controller. Pressing the ESC key will discard any changes and keep the
original value prior to entering the Edit Mode.

Page 2 of 15

2.0 STARTING SEQUENCE


2.1 When power is first applied, and if no class A or ESD shutdown conditions exist, the controller
will be in the MANUAL STOP state.
2.2 This panel is equipped with custom programming to control a nitrogen purge valve. A panel
mounted On-Off-Auto switch will control how this cycle works.
2.2.1

OFF-the nitrogen purge valve will not operate, and will remain closed. The max
purge timer is reset.

2.2.2

HAND- If the panel is in the MANUAL STOP or SHUTDOWN states, the nitrogen
purge valve will be immediately opened. It will remain open until switched back to
OFF, or unit the max nitrogen purge time delay expires (SETPOINT #49). During
this time, the RUN/STOP key will be ignored and no starting will be allowed. If
the panel is not in MANUAL STOP or SHUTDOWN states, the purge valve will
remain closed.

2.2.3

AUTO- If the panel has detected an ESD event type shutdown, the nitrogen purge
valve will be immediately opened. It will remain open until the RESET key is
pressed, or unit the max nitrogen purge time delay expires (SETPOINT #49).

2.3 The Sleep Control output will energize to latch power onto the control system. An external
programmable timer is used to break power from the system in the event of a shutdown after
a set time delay. NOTE: the programmable timer should be set longer than the MAX
PURGE TIME SETPOINT to ensure that the Nitrogen Purge cycle will complete before
losing power.
2.4 The Ignition and M5081-C-LS Fuel outputs will remain deenergized.
2.5 When the RUN/STOP key is pressed, the following start sequence will occur:
2.5.1

The state message will read WAITING ON START.

2.5.2

The Ignition G-Lead Output will energize to Un-ground the Ignition.

1.1.1

The M5081-C-LS Fuel Valve output will energize to allow the fuel valve to be
manually opened.

1.1.2

The controller will monitor for a run signal from the MPU input. Confirmation
must be received before the Waiting ON Start Timer expires otherwise the unit
will shutdown on FAILURE TO START ENGINE.

1.1.3

When the Engine RPM is seen above the Run RPM setting, the unit will be
considered running and the Running sequence will begin.

3.0 RUNNING SEQUENCE


3.1 The controller will read RUNNING.
3.2 The internal hourmeter will begin timing. The class B1, B2, and S lockout delays begin timing.
3.3 The RPM vs Suction pressure control loop is enabled.
3.4 The RPM vs Suction pressure is controlled by suction pressure. If the suction pressure drops
below the setpoint, the speed output to the engine decreases and vice-versa.
3.5 TEST MODE

Page 3 of 15

3.5.1

While the unit is running, a test mode feature will be available. When the TEST
key on the Centurion display is pressed, all functions identified as Class A, B1,
B2, or C shutdowns will be able to be tested without shutting down the Unit for the
duration of the Test timer. The test mode can be ended by pressing the TIMER
0 key.

3.5.2

The tested points can be seen on the EVENTS page of the Mview display.

3.5.3

Some functions are designated as Class ESD, which will not be in the TEST
mode. An example is Panel ESD. It is never locked out.

3.5.4

All shutdowns must be clear, and the reset key must be pressed before the test
timer expires, or prior to exiting the test mode or else a shutdown will occur.
(note: this will also reset and restart the B1, B2 and S lockout timers)

4.0 NORMAL STOP SEQUENCE


4.1 Pressing the RUN/STOP key on the Centurion faceplate for 2 seconds and releasing will
signal a normal stop.
4.2 The controller will read STOPPING.
4.3 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve.
4.4 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition.
During this time, the state message will read STOPPING.
4.5 The unit state will return to MANUAL STOP and await the next start sequence.
5.0 FAULT SHUTDOWN SEQUENCE
5.1 The Class B1, B2, C and S shutdowns are disarmed.
5.2 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve.
5.3 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition.
During this time, the state message will read STOPPING. In cases of ESD type faults, this
delay is skipped.
5.4 The unit state will read to SHUTDOWN.
5.5 The cause of the shutdown will be displayed on the shutdown history page. Use the LEFT
and RIGHT arrow keys to navigate to this page. The shutdown event is stored in the
Shutdown History Page with an hourmeter time stamp. After the shutdown condition is
corrected, press the RESET key to clear the shutdown condition and return to PANEL
READY.
5.6 The Sleep Control output will deenergize upon a fault shutdown. An external programmable
time delay will remove power from the control system after a configured time. To restore
power to the system, Press and hold the Power Up From Sleep panel mounted pushbutton
for 3 seconds.
6.0 CENTURION CONTROLLER INPUTS/OUTPUTS
6.1 DIGITAL INPUTS
TB#
30
31
32

TYPE
NC
NO
NO

IN#
DI-1
DI-2
DI-3

LOCAL EMERGENCY STOP


SPARE DI02 SHUTDOWN
REMOTE SHUTDOWN
Page 4 of 15

DESCRIPTION

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61

NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO

DI-4
DI-5
DI-6
DI-7
DI-8
DI-9
DI-10
DI-11
DI-12
DI-13
DI-14
DI-15
DI-16
DI-17
DI-18
DI-19
DI-20
DI-21
DI-22
DI-23
DI-24
DI-25
DI-26
DI-27
DI-28
DI-29
DI-30
DI-31
DI-32

SPARE DI03 SHUTDOWN


ENGINE LUBRICATOR FLOW PULSE (PROXIMITY SWITCH)
COMPRESSOR LUBRICATOR FLOW PULSE (PROXIMITY SWITCH)
LOW ENGINE OIL LEVEL
LOW COOLANT LEVEL
SPARE DI09 SHUTDOWN
HIGH SUCTION SCRUBBER LIQUID LEVEL
HIGH INTERSTAGE SCRUBBER LIQUID LEVEL
HIGH DISCHARGE SCRUBBER LIQUID LEVEL
SPARE DI13 SHUTDOWN
HIGH FRAME VIBRATION
HIGH COOLER VIBRATION
SPARE DI16 SHUTDOWN
SPARE DI17 SHUTDOWN
SPARE DI18 SHUTDOWN
SPARE DI19 SHUTDOWN
SPARE DI20 SHUTDOWN
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NITROGEN PURGE AUTOMATIC SWITCH SELECTION
NITROGEN PURGE ON SWITCH SELECTION
NOT AVAILABLE-FIRMWARE USE

6.2 DIGITAL OUTPUTS


TB#
70 (NO)
71 (COM)
72 (NC)
73 (NO)
74 (COM)
75 (NC)
76 (NO)
77 (COM)
78 (NC)
79 (NO)
80 (COM)
81 (NC)
82 (DC+)
83 (+OUT)
84 (DC+)
85 (+OUT)
86 (DC+)
87 (+OUT)
88 (DC+)
89 (+OUT)

TYPE
RELAY(1)

OUT#
1
NOT USED

DESCRIPTION

RELAY(2)

NOT USED

RELAY(3)

NOT USED

RELAY(4)

SLEEP CONTROL (ENERGIZED DURING NON-FAULT, DEENERGIZED ON


SHUTDOWN)

FET(1)

NOT USED

FET(2)

NOT USED

FET(3)

NITROGEN PURGE VALVE OPEN

FET(4)

M5081-C-LS FUEL VALVE (ENERGIZED TO RUN TO INTERFACE WITH


MAGNETIC SWITCH ADAPTER THROUGH A NC RELAY CONTACT TO
TRIP ON SHUTDOWN)
Page 5 of 15

90 (-OUT)
91 (DC-)
92 (-OUT)
93 (DC-)

IGBT(1)

NOT USED

IGBT(2)

10

IGNITION GROUND

6.3 ANALOG OUTPUTS


TB#
66 (DC +)
67 (OUT)
68 (DC +)
69 (OUT)

TYPE
4-20mA

OUT#
DESCRIPTION
AO-1 RPM VS SUCTION PRESSURE CONTROL

4-20mA

AO-2

NOT USED

6.4 ANALOG INPUTS


TB#
18
19
20
21
22
23
24
25
26
27
28
29

TYPE
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA

IN#
AI-1
AI-2
AI-3
AI-4
AI-5
AI-6
AI-7
AI-8
AI-9
AI-10
AI-11
AI-12

SUCTION PRESSURE
INTERSTAGE PRESSURE
DISCHARGE PRESSURE
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

DESCRIPTION

6.5 THERMOCOUPLE INPUTS


TB#
1(+)
2(-)
3(+)
4(-)
5(+)
6(-)
7(+)
8(-)
9(+)
10(-)
11(+)
12(-)
13(+)
14(-)
15(+)
16(-)

TYPE
K

IN#
TC-1

DESCRIPTION
EXHAUST CYLINDER #1 TEMPERATURE

TC-2

EXHAUST CYLINDER #2 TEMPERATURE

TC-3

NOT USED

TC-4

DISCHARGE CYLINDER #1 TEMPERATURE

TC-5

DISCHARGE CYLINDER #2 TEMPERATURE

TC-6

NOT USED

TC-7

ENGINE COOLANT TEMPERATURE

TC-8

COMPRESSOR COOLANT TEMPERATURE

7.0 MODBUS ADDRESS LIST


The Centurion uses MODBUS RTU protocol. Data is formatted as 16 bit Signed Holding Registers except
where noted. Port 1 is configurable for either 3 wire RS-232 or 2 wire RS-485 communication. Analog
Reading and Setpoints will be shown with no decimal place. Reference the Mconfig Pro Report or Mview
Display to determine the proper number of decimals places. Refer to the Mconfig Pro Report for event
enumerations, and engine state enumerations.
Page 6 of 15

Translated I/O Polling


area
42001
1-16

Description
Core Digital Inputs Bitmap

Read Only
Read/Write
R

Bit 1 = lsbbit 16 = msb

Core Digital Inputs Bitmap

Bit 1 = lsbbit 16 = msb

Core Analog Inputs

Scaled to engineering units as shown in


Mconfig Pro Report

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 Analog Inputs

Core Thermocouple Inputs

Expansion Thermocouple
Inputs

R
R

Data format

Scaled to engineering units as shown in


Mconfig Pro Report

Scaled to deg C or F as shown in Mconfig


Pro Report

Scaled to deg C or F as shown in Mconfig


Pro Report

Core Digital Outputs Bitmap

Bit 1 = lsbbit 16 = msb

Core Analog Outputs

Percent x 100 (0 10000)

Percent x 100 (0 10000)

Percent x 100 (0 10000)

Expansion Analog Outputs

Page 7 of 15

42043

4 (2)

Percent x 100 (0 10000)

42044

5 (3)

Percent x 100 (0 10000)

42045

6 (4)

Percent x 100 (0 10000)

Engine Speed

RPM

40101

STATE

40102

RPM

State enumeration (1 19) note: not all


states may be used, and may be renamed
for a specific applicationrefer to the
Mconfig Pro Report for state descriptions.
1 = PANEL READY (*MANUAL STOP)
2 = START DELAY
3 = PRE-HEAT
4 = PRE-LUBE
5 = START VALVE
6 = CRANK STOP
7 = CRANK (*READY TO START)
8 = CRANK REST
9 = MOTOR ON
10 = WARMUP
11 = WAIT FOR LOAD
12 = RUN LOADED (*RUNNING)
13 = COOLDOWN (*COOLDOWN)
14= STOP ENGINE (*STOPPING)
15 = MOTOR OFF
16 = STOP VALVE
17 = POST-LUBE
18 = RESTART DELAY
19 = SHUTDOWN (*SHUTDOWN)
Engine RPM

STATUS

Status bits

42046
Status Polling area

40107

1-16
1

STATUS_FLT_SHTDWN

0x0001 Fault Shutdown in progress.

STATUS_ESD

0x0002 Emergency Shutdown in progress.

STATUS_ALARM

0x0004 Have Active alarms

STATUS_START

0x0008 Start/Stop indicator. 1=Start

STATUS_LCL_RMT

0x0010 1=Remote, 0=Local.

STATUS_TEST_TMR

0x0020 1=TEST timer is running.

STATUS_B1_TMR

0x0040 1=B1 timer is running.

STATUS_B2_TMR

0x0080 1=B2 timer is running.

STATUS_C_TMR

0x0100 1=C timer is running.

10

STATUS_S1_TMR

0x0200 1=S1 timer is running

11

STATUS_S2_TMR

0x0400 1=S2 timer is running

12

STATUS_S3_TMR

0x0800 1=S3 timer is running.

13

STATUS_S4_TMR

0x1000 1=S4 timer is running.

14

STATUS_S5_TMR

0x2000 1=S5 timer is running.

15

STATUS_NF_TMR

0x4000 1=NF timer is running.

16

STATUS_BAD_CONFIG

0x8000 1=Configuration is bad.

40108

STATE_TIMER

Timer for the current State

40109

TEST_TIMER

Test Mode Timer.

40110

B1

Primary Lockout Timer

40111

B2

Secondary Lockout Timer

40112

Class C Arming Timer

Page 8 of 15

40113

S1

40114

S2

40115

S3

40116

S4

40117

S5

40118

NF

Special Timer; Like B1 for individual


assignment
Special Timer; Like B1 for individual
assignment
Special Timer; Like B1 for individual
assignment
Special Timer; Like B1 for individual
assignment
Special Timer; Like B1 for individual
assignment
No-Flow Delay Before Shutdown Timer

Hour Meter
40119

HOURMETER_HOURS

R/W

Hourmeter hours.

40120

HOURMETER_MINUTES

R/W

0-59

40121

HOURMETER_SECONDS

R/W

0-59

Shutdown Table (Single entry)


40144

SHUTDOWN

Enumeration, zero = none; (1 - 128)

NUM_ALARMS

Number of active alarms

BATTERY_VOLTAGE

In tenths of a volt

40147

NUM_CRANKS_LEFT

Number of crank attempts left

40148

CORE_AMBIENT_TEMP

Tenths of a degree

40149

EXP_AMBIENT_TEMP

Tenths of a degree

Number of Active Alarms


40145
Miscellaneous
data
40146

Control Output Auto/Manual


40151

1-8

CTL_OUT_AUTO

R/W

1=Auto Mode, 0=Manual

40152

1-4

PID_ENABLED

1=Enabled, 0=Not Enabled

40153

1-4

PID_OVERRIDE

1=Override on, 0=Override off

CLASS_ARMED

Class Armed status.

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.

Bit flags indicating that a class of Faults is armed or not.


40154

1-9

Page 9 of 15

Current percent open of control outputs


40155

CTL_OUT_1_PERCENT

Current percent Control output.

40156

CTL_OUT_2_PERCENT

Current percent Control output.

40157

CTL_OUT_3_PERCENT

Current percent Control output.

40158

CTL_OUT_4_PERCENT

Current percent Control output.

40159

CTL_OUT_5_PERCENT

Current percent Control output.

40160

CTL_OUT_6_PERCENT

Current percent Control output.

40161

CTL_OUT_7_PERCENT

Current percent Control output.

40162

CTL_OUT_8_PERCENT

Current percent Control output.

Manual Percent Change to Control Outputs


40163

CTL_OUT_CHG_1

R/W

Percent to change Control Output

40164

CTL_OUT_CHG_2

R/W

Percent to change Control Output

40165

CTL_OUT_CHG_3

R/W

Percent to change Control Output

40166

CTL_OUT_CHG_4

R/W

Percent to change Control Output

40167

CTL_OUT_CHG_5

R/W

Percent to change Control Output

40168

CTL_OUT_CHG_6

R/W

Percent to change Control Output

40169

CTL_OUT_CHG_7

R/W

Percent to change Control Output

40170

CTL_OUT_CHG_8

R/W

Percent to change Control Output

Current computed PID setpoint. (May have changed because of overrides.)


(See also PIDx_ADJUST at 40597-40600.)
40171

PID_TARGET_1

Current computed target.

40172

PID_TARGET_2

Current computed target.

40173

PID_TARGET_3

Current computed target.

40174

PID_TARGET_4

Current computed target.

Digital Output Force Mode Timer. Fixed duration 5 minutes (300 seconds).
Zero means not in force mode, non-zero represents time left in force mode.
40175

DIG_FORCE_TIMER

In seconds. 5 minutes fixed.

Active Alarms (NUM_ALARMS has # of entries.)


Alarm enumerations explanation.
The top 1 bit of the alarm enumerations are masked off to get the enumeration.
The top 1 bit indicates if an alarm has been acked.
40201

ALARM1

Enumeration, zero = none

40202

ALARM2

Enumeration, zero = none

40203

ALARM3

Enumeration, zero = none

40204

ALARM4

Enumeration, zero = none

40205

ALARM5

Enumeration, zero = none

40206

ALARM6

Enumeration, zero = none

40207

ALARM7

Enumeration, zero = none

40208

ALARM8

Enumeration, zero = none

40209

ALARM9

Enumeration, zero = none

Page 10 of 15

40210

ALARM10

Enumeration, zero = none

40211

ALARM11

Enumeration, zero = none

40212

ALARM12

Enumeration, zero = none

40213

ALARM13

Enumeration, zero = none

40214

ALARM14

Enumeration, zero = none

40215

ALARM15

Enumeration, zero = none

40216

ALARM16

Enumeration, zero = none

40217

ALARM17

Enumeration, zero = none

40218

ALARM18

Enumeration, zero = none

40219

ALARM19

Enumeration, zero = none

40220

ALARM20

Enumeration, zero = none

Maintenance Timers (time remaining)


Maintenance Timers have the Hours kept in the most significant word.
Minutes are in the high byte of the least significant word; Seconds in the low byte.
40301

MAINT1_HOURS

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.

Shutdown History Log


6 bytes per entry including Hour Meter and Shutdown enumeration. A zero enumeration ends the list.
Note the list is sorted in descending order from most recent to oldest.
40401

SHUTDOWN1_HOURS

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

Event History Log


6 bytes per entry including Hour Meter and Event enumeration. A zero enumeration ends the list.
Note the list is sorted in descending order from most recent to oldest.
40501

EVENT1_HOURS

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

Page 14 of 15

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

Percent 2 dec. places 0 to


10000
Percent 2 dec. places 0 to
10000
Percent 2 dec. places 0 to
10000
Percent 2 dec. places 0 to
10000
Dynamically computed P
change.
Dynamically computed I
change.
Dynamically computed D
change.

PID adjustment calculations


Each cycle through a PID it should adjust these values.
40597

PID1_ADJUST

40598

PID2_ADJUST

40599

PID3_ADJUST

40600

PID4_ADJUST

40601

PROPORTIONAL_ADJ

40602

INTEGRAL_ADJ

40603

DERIVATIVE_ADJ

40604

LS16 ACCUM ERROR

40605

MS16 ACCUM ERROR

Setpoints range (1-128)


43516
43644

SETPOINT 01
SETPOINT 128

R/W

8.0 MCONFIGPRO REPORT (refer to attached PDF File)

Page 15 of 15

CENTURION
Configurable Controller
Installation and Operations Manual
00-02-0590
10-10-06
Section 50

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our
specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.

Warranty - A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of
the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

FW MURPHY has made efforts to ensure the reliability of the Centurion


controller and to recommend safe usage practices in system applications.
Please note that in any application, operation and controller failures can
occur. These failures may result in full control outputs or other outputs which
may cause damage to or unsafe conditions in the equipment or process
connected to the Centurion controller. Good engineering practices, electrical
codes, and insurance regulations require that you use independent external
protective devices to prevent potentially dangerous or unsafe conditions.
Assume that the Centurion controller can fail with outputs full on, outputs full
off, or that other unexpected conditions can occur.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT:

Please read the following information before installing the Centurion


controller. This installation information is intended for Centurion
controller only. Before installing, visually inspect the product for any
damage during shipping.

Disconnect all power and be sure machine is inoperative before


beginning installation.

Installation is to be done only by qualified technician.

Observe all Warnings and Cautions at each section in these


instructions.

Device shall be wired in accordance with Class I, Division 2 wiring


methods.

This equipment is suitable for use in Class I, Division 2, Groups B, C,


and D hazardous Areas.

WARNINGExplosion HazardSubstitution of components may


impair suitability for Class I, Division 2.

Please contact Murphy immediately if you have any questions.

Table of Contents
1 Overview ............................................................................................................................... 1
1.1 Basic Components and Key Features of the C3 Series .........................................2
1.2 Optional Components.............................................................................................3
2 Input/Output Types .............................................................................................................. 4
2.1 Power Supply Wiring ..............................................................................................4
2.2 Input/Output Types and Specifications for the Main I/O Module ............................5
2.3 Input/Output Types and Specifications for the Optional Expansion Module ...........9
3 Hazardous Area Operation ............................................................................................... 11
4 Hardware Installation and Wiring..................................................................................... 12
4.1 Mounting the Controller ........................................................................................12
4.2 Mounting the Display............................................................................................12
4.3 Wiring the Display ................................................................................................13
4.4 Wiring the Controller.............................................................................................14
5 Using the Display............................................................................................................... 16
5.1 Features ...............................................................................................................16
5.2 Operational Screens.............................................................................................21
5.3 Setup Screens and Menus ...................................................................................27
5.4 Additional Navigational Aids.................................................................................54
6 Communications................................................................................................................ 55
6.1 Communication Ports ...........................................................................................55
6.2 Downloading Configurations and Firmware Updates ...........................................56
6.3 Modbus RTU Protocol .......................................................................................62
6.4 Transferring Data in Modbus................................................................................63
6.5 Modbus Register Address Listings .......................................................................63
7 Replacement Parts and Assemblies................................................................................ 63
8 Accessories........................................................................................................................ 63
8.1 Configuration Software.........................................................................................63
9 Glossary.............................................................................................................................. 64
10 Appendices....................................................................................................................... 66
10.1 Back Panel LED Description ..............................................................................66
10.2 Controller Accuracies, and Tolerances...............................................................66
10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens ...................67
10.4 Set Up Sheet......................................................................................................67

(THIS PAGE INTENTIONALLY LEFT BLANK)

1 Overview
The Centurion configurable controller is a display and controller combination expressly
designed to meet the requirements of three specific kinds of applications:

Screw Compressors

Reciprocating Compressors

Pumps

The heart of the Centurion system is the main input/output (I/O) module or controller, which
can be mounted on a standard DIN rail. While it is designed to work with any Modbus (Master)
compliant HMI (Human Machine Interface) or with no operator interface at all, it is optimally
configured and field-configurable through MConfigPro, powerful software developed to
configure the controller. Parameters can be modified in the field without special need for laptop
or software by utilizing 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.

Section 50
10-10-06

00-02-0590
-1-

1.1 Basic Components and Key Features of the C3 Series


The C3 series consists of a display module, a main I/O module, and optional expansion I/O
module. No special cables are required. The Centurion system is designed for use within a
weatherproof enclosure only.
Display module (C3-3) 128 x 64 LCD graphic display (-40 to 85) C

Power
10 - 32 VDC: 1W typical, 6W (max)
Storage power able to withstand 12V crank
NOTE: Maximum power ratings based on display heater operating at
maximum with 10V supply. Heater is only operational below -10C.
Typical based on 24V supply.

Package and design


Same 5 x 5 design as annunciators
12 key keypad

Communications
LED active indication for each port
RS232/485 (Modbus Master)
RS232/485/USB 1.1 compliant port

Approvals
CSA, CLASS 1, DIVISION 2, Groups B, C and D certifications are
approved.

Main I/O module (C3-1)


32 digital inputs (DI)
10 digital outputs (DO)

Direct input for analog and thermocouple inputs:


o 12 analog input (AI)
o 8 thermocouples (TC)

1 magnetic pickup (MPU)

Section 50
10-10-06

00-02-0590
-2-

1.2 Optional Components


The C3-1 hardware may be configured with 2 analog outputs and it may be augmented
through an expansion module (C3-2) which provides analog outputs and additional analog and
thermocouple inputs.
Main I/O Module with analog outputs (C3-1-A)

Same specifications and I/O as C3-1, plus 2 analog outputs

Expansion I/O Module (C3-2)

8 analog inputs (AI)


8 thermocouple inputs (TC)
4 analog outputs (AO)

Section 50
10-10-06

00-02-0590
-3-

2 Input/Output Types
2.1 Power Supply Wiring
NOTE: Maximum power ratings based on all I/O operating in the ON
position with 10V supply. Typical based on 24V supply.

2.1.1 Centurion I/O Module


Requirements: (10 to 32) VDC: 30W (max)
There are two screw terminal connectors for power hookup at terminals 62 and 63, labeled B+
and B- respectively.

2.1.2 Centurion (Optional) Expansion I/O Module


Requirements: (10 to 32) VDC: 6W typical, 30W (max)
There are three screw terminal connectors for power hookup at terminals 134 to 136, labeled
B+, B and B- respectively.

NOTE: Run power directly from battery posts to controller power


terminals when battery is the power supply.

Section 50
10-10-06

00-02-0590
-4-

2.2 Input/Output Types and Specifications for the Main I/O Module

Section 50
10-10-06

00-02-0590
-5-

2.2.1 Digital Inputs (DI)


Number of devices: 32
Device types: discrete input, normally open (N/O) or normally closed (N/C), active high/active
low, non-incendive.
There is one screw terminal connector for each digital input.
Terminals 30 to 61 are DI terminals.
Green LEDs give visual indication of active input signal.

2.2.2 Analog Inputs (AI)


Number of devices: 12
Device types: analog input, (4 to 20) mA or (0 to 5) V, 10 bit hardware.
There is one screw terminal connector for each analog input.
Terminals 18 to 29 are AI terminals.

Section 50
10-10-06

00-02-0590
-6-

2.2.3 Thermocouple Inputs (TC)


Number of devices: 8
Device types: thermocouple input, type J or K, 12 bit hardware.
Use ungrounded thermocouples only. Grounded thermocouples are not supported. Errors in
readings with grounded thermocouples can be the result of differences in grounding between
devices.
Open thermocouple detection: drives terminal reading high (max of scale).
Automatic cold junction compensation is built-in.
There are two screw terminal connectors for each thermocouple.
Terminals 1 to 16 are TC terminals where white or yellow indicate positive inputs and red
indicates negative inputs.
NOTE: An additional terminal connector is provided, identified as SHD, which
isolates thermocouple shields. This connection, at terminal 17, is intended to be
wired to an isolated bus bar for thermocouple shield wires. If shields are
grounded, do connect shields to SHD terminal. Connect all shields to SHD or to
ground but never both.

2.2.4 Magnetic Pickup (MPU)


Number of devices: 1
Device types: magnetic pickup (MPU), (5 to 120) Vrms, (30 to 10k) Hz.
There are two screw terminal connectors for the magnetic pickup.
Terminals 64 and 65 are MPU terminals.

Section 50
10-10-06

00-02-0590
-7-

2.2.5 Digital Outputs (DO)


Number of devices: 10
Device types: discrete output, normally open (N/O) or normally closed (N/C)

four (4) relay outputs, form C, dry contacts

four (4) FETs (high speed)

two (2) IGBTs (high power)

There are three screw terminal connectors for each relay output and two screw terminal
connectors for each FET and IGBT output.
Terminals 70 to 81 are for the four relay terminals.
Terminals 82 to 89 are for the four FET terminals.
Terminals 90 to 93 are for the two IGBT terminals.
Green LEDs give a visual indication of active output signal.

Warning: A heat sink is attached to the cover using acorn style nuts.
The surface area around these fasteners can become very hot. Avoid
contact.

Section 50
10-10-06

00-02-0590
-8-

2.2.6 Optional Analog Outputs (AO)


Number of devices: 2
Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware
There are two screw terminal connectors for each analog output.
Terminals 66 to 69 are AO terminals.
The optional AO module is added to the C3-1 at the factory inside the DIN enclosure. While
these terminals are present on all models the feature may not be installed.

2.3 Input/Output Types and Specifications for the Optional Expansion Module
2.3.1 Analog Inputs (AI)
Number of devices: 8
Device types: analog input, (4 to 20) mA or (0 to 5) V, 12 bit hardware.
There is one screw terminal connector for each analog input.
Terminals 126 to 133 are AI terminals.

Section 50
10-10-06

00-02-0590
-9-

2.3.2 Thermocouple Inputs (TC)


Number of devices: 8
Device types: thermocouple input, type J or K, 12 bit hardware
Open thermocouple detection: drives channel reading high (max of scale).
There are two screw terminal connectors for each thermocouple input.
Terminals 109 to 124 are TC channels where white or yellow indicate positive inputs and red
indicates negative inputs.
NOTE: An additional terminal connector is provided, identified as SHD, which
isolates thermocouple shields. This connection, at terminal 125, is intended to be
wired to an isolated bus bar for thermocouple shield wires. If shields are
grounded, do connect shields to SHD terminal. Connect all shields to SHD or to
ground but never both.

2.3.3 Analog Outputs (AO)


Number of devices: 4
Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware
There are two screw terminal connectors for each analog output.
Terminals 137 to 144 are AO terminals.

Section 50
10-10-06

00-02-0590
- 10 -

3 Hazardous Area Operation


The Centurion certifications for CSA, CLASS 1, DIVISION 2, Groups B, C and D are approved.

Warning: Explosion hazard Do not disconnect the equipment unless


the power has been switched off, or the area is known to be nonhazardous.

Section 50
10-10-06

00-02-0590
- 11 -

4 Hardware Installation and Wiring


4.1 Mounting the Controller
The Centurion controller can be mounted vertically or horizontally on a standard DIN rail.
Three clamp-type feet along the bottom of the controller attach to the DIN rail, however, rail
stops are recommended to prevent sliding.

4.2 Mounting the Display


The Centurion display can be mounted in the same hole cutout of other Murphy display
modules. Four screws attach the display bezel to the mounting surface.

Section 50
10-10-06

00-02-0590
- 12 -

4.3 Wiring the Display

Section 50
10-10-06

00-02-0590
- 13 -

4.4 Wiring the Controller

Section 50
10-10-06

00-02-0590
- 14 -

Wiring the Controller (continued)

Section 50
10-10-06

00-02-0590
- 15 -

5 Using the Display


The display module is a highly integrated
operator interface specially programmed to
complement and support the Centurion
controller. The primary purpose of the display is
to:

view controller operational


information

view/edit controller operational


parameters

send commands to controller, such


as stop, edit, and reset

5.1 Features
5.1.1 Keypad Description and Navigation

The keypad for the display has 12 keys. The following table describes the keys and their
function for each of the three screen types:

Operating status screens

Setup screens (password required)

Edit screens (password required)

Many of the keys have a modified action relative to the current location of the cursor and the
current page being displayed.
Section 50
10-10-06

00-02-0590
- 16 -

Key

ID
HOME

ESC/ACK

Fn (Function
Key)

SETUP/ENTER

RESET

Section 50
10-10-06

Description
Operating Status Screen
Allows the user to get to the first line of the current screen, or
if pressed again, to get to the default operating status screen.
Set Up Screen
Allows the user to get to the first line of the current screen.
Edit Screen
No associated action.
Operating Status Screen
Acknowledge the active message/alarm that is currently
displayed in the alarm banner.
Acknowledges all active messages and alarms displayed in
the active alarm screen.
Set Up Screen
Exit Setup mode.
Edit Screen
Exit without saving changes to the current configuration.
Operating Status Screen
Enter Function mode and display a dialog box with
additional available functions. Automatically cancels upon
moving to the next mode, or if no subsequent function is
chosen within five seconds.
Set Up Screen
No associated action.
Edit Screen
No associated action.
Operating Status Screen
Enter Setup Mode.
Set Up Screen
Enter Edit mode or Sub-menu.
Edit Screen
Accept and save changes made to a current parameter before
exiting edit mode.
Operating Status Screen
Reset any active timers and alarms/faults.
Set Up Screen
No associated action.
Edit Screen
No associated action.

00-02-0590
- 17 -

Key

ID
RUN/STOP

ARROW UP

ARROW DOWN

ARROW LEFT

Section 50
10-10-06

Description
Operating Status Screen
Initiate or cancel a start sequence. (hold for 2 seconds)
Set Up Screen
No associated action in either shutdown mode, or remote
mode on standby. Initiate stop only sequence when held for
two seconds, if equipment is running.
Edit Screen
No associated action.
Operating Status Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
For history screens, scrolls up one history (for example:
shutdown or event).
Set Up Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
Edit Screen
Increase the digit selected by the cursor (from 0 to 9). The
user will not be allowed to increase the selected digit if it
would result in exceeding range limits.
Operating Status Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
For history screens, scrolls down one history (i.e. shutdown or
event).
Set Up Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
Edit Screen
Decrease the digit selected by the cursor (from 0 to 9). The
user will not be allowed to decrease the selected digit if it
would result in exceeding range limits.
Operating Status Screen
Display previous screen. Automatically repeats if held down
continuously until reaching the first screen.
Set Up Screen
Display previous screen. This key has no action when in a
sub-menu.
Edit Screen
Move the cursor left one position when a numeric value is
displayed.

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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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5.1.2 Display Context


The graphic LCD displays are organized around operating status screens and setup screens.
The actual number of status screens will be related to the total number of end devices
configured for the controller. In either screen set, ten (10) lines are visible at a time; with up
and down arrow characters indicating more lines are available on the page. Also, for both
screen sets, navigation between screens is accomplished by pressing the left or right arrow
keys.

5.1.3 Numeric Entry


The Centurion display allows individual editing of each position of the desired number. This is
accomplished by entering the edit mode and using the UP/DOWN arrow keys (1) to adjust the
number above the blinking cursor (2) between 0 and 9. To edit another position, simply use the
LEFT/RIGHT (3) arrow keys to move the cursor to that position (4) and repeat the edit process
until the desired number is displayed.

In this way, values are built rather than scrolled through. Some digits may not be allowed to
increase if it would result in exceeding range limits. Values which can be positive or negative
will have a sign () to the left of the number. To change the sign value simply move the cursor
to the sign using the LEFT arrow key and toggle between + and using the UP and DOWN
arrow keys. If the range of the value will exceed range limits the sign may not be allowed to
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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.

5.2 Operational Screens


In addition to the set up screens reviewed in the Setup Screens and Menus section, the
display offers a number of operational displays. On the Operating Status screens, the two
bottom lines display the state, hours, mode and active timer status. This information is key to
understanding the status of the controller.
Mode refers to the Operating Mode of the controller and can be LOCAL or REMOTE.
Depending on the configuration active in the controller, the operation may differ depending on
what Mode the controller is currently displaying.
NOTE: The Mode can be changed by pressing certain keys, if the
configuration allows for REMOTE mode.
Pressing RESET or RUN/STOP is a Local function and will change the
Mode to Local if it is in REMOTE.
Pressing Fn before pressing RESET or RUN/STOP is a REMOTE function
and will change the Mode to REMOTE if it is in LOCAL.

5.2.1 Default Operating Screen


After turning on the power, the user will view the Murphy logo screen for three seconds before
the next screen displays, which is a software-configured default operating screen. The
MConfigPro software allows users to configure up to five screens with controller I/O groupings.
Possible custom screen types that may have been configured as a default operating screen, or
which may be also displayed, include:
a) Custom Line by Line allows process data to be displayed in a list format with
description and value.
b) Custom Gage allows user to display four (4) most important pieces of data on a 2 x 2
table in larger font.
c) Custom PID up to 4 PID screens.
For more information on configuring the optional screens through the MConfigPro software,
please refer to the MConfigPro Installation and Operations Manual.

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5.2.2 Murphy Logo Screen

The Murphy logo is the first screen in the


sequence of display screens and can be
viewed by holding down the left arrow until
scrolling left ceases.

5.2.3 Corporate and Version Information Screen

Following the Murphy Logo screen is the


Murphy corporate contact information which
also lists firmware version information for the
Centurion display, the main I/O module and
the MConfigPro Software.

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5.2.4 Digital Input Status

The user can see the state of each digital


input in a tablewhether it is open or closed.

5.2.5 Shutdown History Screen

The history of the last 20 shutdowns is


displayed on this screen, with the most recent
at the top of the list and the oldest at the
bottom.
Each event is displayed with the shutdown
label on one line and the hour meter reading
on the following line. Pressing the up/down
arrows will scroll up/down one shutdown at a
time rather than one line at a time.
The 1/3 at the right end of the top line
means the user is viewing shutdown one of a
total of three stored. The newest shutdown
will always be number one and it will push the
older shutdowns further down the list.

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5.2.6 Shutdown Snapshot


The shutdown snapshot screen is a capture
of the values displayed on the Line-by-Line
custom screen at the time of a Fault SD or
ESD event. These values will be retained
and display on the shutdown snapshot
screen until the next Fault SD or ESD event
occurs. An asterisk displayed instead of a
value indicates the shutdown snapshot has
not captured any data or is not functioning.
NOTE: Only the first Line-by-Line
screen configured will be captured. If
no Line-by-Line custom screen is
configured, the shutdown snapshot will
not function.
5.2.7 Event History Screen

The history of the last 32 events is displayed


on this screen, with the most recent at the top
of the list and the oldest at the bottom.
Events include shutdowns, starts, stops,
resets, etc.
The user easily can view the events (alarms,
etc.) logged before and after a shutdown.

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5.2.8 Active Alarms Screen

All active alarms and warnings will be


displayed on this screen.
If there are more than six active alarms, there
will be up/down arrow icons at the bottom of
the screen and the user can press the
up/down arrow keys to scroll up or down.
Unacknowledged alarms will be preceded by
a musical note character and acknowledged
alarms will have a bar through the staff of the
note.
Pressing ACK on this screen will
acknowledge all active alarms.
A maximum of twenty (20) active alarm will
be displayed.
NOTE: Alarms are warnings based on
setpoints and/or digital inputs which
are separate from shutdowns.

This screen shows the alarm annunciation as


it will appear on a status screen.
The alarm message(s) will overwrite the
bottom line of the active screen area and
then briefly clear once a second. This will
continue until it is acknowledged with the
ACK key, unless it is a self-clearing alarm. If
there is more than one unacknowledged
alarm active, each alarm will be displayed for
one second each until acknowledged. The
ACK key will acknowledge the alarm currently
displayed. Pressing the Fn key followed by
the ACK key will switch to the active alarms
screen.

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5.2.9 Gage Display


This is an example of a custom gage
display. MConfigPro software arranges the
data as needed.
This display provides larger characters for
easier viewing as well as a means to
prominently display items of interest.
Unacknowledged alarms will overwrite the
bottom half of the lower two gage boxes.
The two bottom lines are used to display
the mode, hours, state and active timer
status.

5.2.10 Line-By-Line

This is an example of a custom line-by-line


status screen. The MConfigPro software
arranges the data as needed.
Notice that there are no up/down arrows at
the bottom of the screen because there are
no additional lines to be displayed on this
screen.

This is an example of a custom line-by-line


status screen with more parameters.
If the parameters do not fit in the viewable
area of the screen, up/down arrow icons at
the bottom of the screen can be used to scroll
up or down.
The two bottom lines are used to display the
mode, hours, state and active timer status.

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5.2.11 Custom PID Screen

The user may choose to display any


configured PID functions in this convenient
format. The control output will be displayed
as a percentage of the range.
The bottom two lines are used to display the
mode, hours, state and active timer status.

5.3 Setup Screens and Menus


The setup screens provide access to system parameters. These settings can be modified with
appropriate password access. The two bottom lines in the setup screens display navigation
and command options available such as EDIT, ACCEPT, CANCEL and MORE MENUS.

5.3.1 Password Screen


Some settings are password protected, including the setup screens.
This is the first screen seen when the SETUP/ENTER key is pressed.
The password need only be entered once during any editing session. The password will reset
when the editing session is exited, or is timed-out due to keyboard inactivity.
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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.

There are three separate levels of passwords


to accommodate several security needs:
Standard password Allows access to
every feature except the super user menu.
Valid standard passwords can be zero or any
number between 100 and 65535. If the
standard password is set to zero, the result is
that anyone can have read/write access to
setup menus.

Super User password Adds the super


user menu to the standard menus. Valid
super user passwords can be in the range of
100 to 65535. The super user password can
not be the same as the standard password
and cannot be set to zero.

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Download Only password This special


35 jump code allows access to a download
menu and is set to a fixed value of 35. This
allows a configuration to be downloaded in
the event that the current passwords are lost
or no initial configuration has been
downloaded.

5.3.2 Digital Input


For up to 32 configured digital input devices,
the user may edit:
a) Signal Type - Select normally open
(N/O) or normally closed (N/C).
b) Signal Filter - Select None to disable
filter function for the digital input. This
will not disable the digital input for
normal operation.
Select Pulse for lubricator divider
blocks with a proximity switch output.
Select DB to debounce or delay input
detection for unstable inputs such as
surge tank level.
c) Filter Timing - Delay time in seconds
for the selected filter type.
For Pulse, this delay is the transition
time for the lubricator divider block to
cycle.
For DB, this is the duration the digital
input must remain either ON or OFF
before the input will be recognized and
accepted as ON or OFF by the
sequence. If the input does not
remain ON or OFF for the duration of
the delay, the timer will reset.
d) Total Pulses - Total number of pulses
counted when the filter type is set to
Pulse. The value is expressed in
hundreds of pulses; a displayed
reading of 1 is equal to 100 pulses.
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5.3.3 Digital Output

Digital output: For up to 10 configured digital


output devices, the user may select whether
an output is normally open (N/O), or normally
closed (N/C).

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5.3.4 Analog Input

For up to 20 configured analog input


devices, the user may edit:
a) Moving Average Samples. (1, 2, 4).
b) Raw Count Offset to determine the
lowest reading expected from the device.
Typically 147 for 4-20mA or 0 for 0-5VDC
c) Raw Count Span to determine the span
from the lowest to highest reading
expected from the device. Typically 586
for 4-20mA or 1023 for 0-5VDC
d) Minimum to apply the appropriate
minimum engineering scale.
Example: 0 PSI for a 0-100 PSI PXT.
e) Maximum to apply the appropriate
maximum engineering scale.
Example: 100 PSI for a 0-100 PSI PXT.

NOTE: Minimum and Maximum


are used to define the input scaled
in engineering units. Dual scales
are not supported.

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5.3.5 Analog Output

For up to 6 analog output devices, the user


may edit:
a) Raw Count Offset, the lowest reading
expected from the device. Typically set to 0.
b) Raw Count Span to determine the span
from the lowest to highest reading expected
from the device. Typically set to 10000.
c) Minimum to apply the appropriate
engineering scale. In most cases, 0%
addresses a typical application and it is the
Centurions default value.
d) Maximum to apply the appropriate
engineering scale. In most cases, 100%
(10000) addresses a typical application and
it is the Centurions default value.

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5.3.6 Thermocouple Input

For up to 16 thermocouple devices, the user


may edit:
a) Thermocouple Type. Identify whether
the calibration type should be set to J or
K.
b) Thermocouple Offset. Assign the
thermocouple offset value.

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5.3.7 General Timer Setup

User may edit all general purpose timers.


Generally, global timers affect engine
operation. They also help define an event.
B1: All event types can be associated with,
and locked out by, a Bx timer. B1 is the first
global timer used for delaying an event
condition detection. The timer starts in a
running State (10 13) depending on
which timers have been marked In Use.
B1 is also known as the Lockout Timer,
start bypass or start/run timer.
B2: The second global timer used for
delaying event condition detection. B2 is
also known as a secondary Lockout
Timer.
NOTE: The Bx timers start after the
Start key has been pressed and the
controller has reached a "Running"
state. States 10-13 are the
"Running" states.
C: The delay allowing a clear reading
before beginning testing for the arming of
Class C events. The default and typical
time for most applications is 2 seconds.
S: Users have up to five (5) options to
assign additional special global timers to
signals. The Sx timers begin concurrently
with the Bx timers.
No Flow: The global delay used for
delaying the triggering of a no flow event.
This global no flow timer is enabled after
B1 expires, and begins timing after any of
the pulse transition times configured in the
digital input dialog expires.

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Test: Time given to allow for maintenance


testing of end devices without triggering a
fault or shutdown condition. The timer
initiates when switched to test mode.
Ignition Off Delay: Time delay before the
assigned ignition output turns off. This is
typically used to burn remaining fuel vapors
after the fuel valve is turned off.
Ignition On Delay: Time delay before the
assigned ignition output turns on. This is
typically used to delay ignition until engine
has started cranking (also known as a
purge delay).
Fuel On Delay: Time delay before the
assigned fuel valve output is turned on.
This is typically used to delay fuel until
ignition has been turned on.

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5.3.8 Maintenance Timer Setup

The user may access and edit the ten (10)


maintenance settings for timer duration.

The user may also access and reset all


timer duration and time remaining settings.
All maintenance timer units are in hours.
NOTE: While these are configured
through MConfigPro, they must be
manually initiated, or restarted, in
Centurion display.

To initiate or reset timers, position cursor on


TIME REMAINING and press the reset key.

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5.3.9 Setpoints Setup


User can edit any of the 128 setpoints that are configured.
Setpoints further configure variable input types such as MPU, analog, or thermocouples by
defining a threshold, exception or any other out-of-limit event that may require action. Multiple
setpoints are often applied to a process and they may be configured as often as needed to
meet changing conditions.
Common alarm and shutdown setpoints a user might have configured include:

High shutdown (High-High)


High warning (High)
Open warning (Open or Fail)
Low warning (Low)
Low shutdown (Low-Low)

To edit a configured setpoint:


a) Assign numeric threshold that if crossed,
triggers the setpoint.

b) Adjust the sign of the threshold value as


plus (+) or minus (-) by moving the cursor to
the sign symbol position and use the up and
down keys to toggle the sign.
For more on setpoints, please refer to the
MConfigPro Installation and Operations
Manual.

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5.3.10 Control Output Setup


The Centurion controller allows users to define up to eight (8) outputs to augment control not
otherwise defined by digital output assignments.
The Centurion can be configured through MConfigPro software to define an analog output, a
digital output, a single pulsed digital output, or two pulsed digital outputs.
NOTE: Control outputs 1 through 4, are directly related to PID calculation
loops and are further defined in the PID dialog screens described in the
PID Setup section. For example, PID 1 is assigned its control from control
output 1, PID 2 from control output 2, and so on.
If the configured output is a pulsed cycle, the
user may edit those behaviors by assigning
values the following:
a) Increase Max On Time. Set limit of
maximum on-time for Increase pulses.
b) Increase Off Time. Set fixed off-time for
Increase pulses.
c) Increase Changeover On Time. Set fixed
on-time for single pulse on direction change
for Increase.
d) Increase Changeover Off Time. Set fixed
off-time for single pulse on direction change
for increase.
e) Decrease Max On Time. Set limit of
maximum on-time for decrease pulses.
f) Decrease Off Time. Set fixed off-time for
decrease pulses.
g) Decrease Changeover On Time. Set
fixed on-time for single pulse on direction
change for decrease.
h) Decrease Changeover Off Time. Set
fixed off-time for single pulse on direction
change for decrease.

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5.3.11 Proportional Integral Derivative (PID) Setup


Users may view and edit up to four (4) MConfigPro software configured PID calculation loops.
A PID provides a constant feedback loop, in which the PID can correct for a measured process
variable against a desired set point, output the corrective action to the process and wait for and
recalculate the next measurement.
The ultimate goal of the PID is to reduce the error to zero while maintaining the control setpoint
(e.g. speed, load, pressure).
NOTE: During the time a PID is enabled, the PID always overrides control
output settings found in the states dialog. PID 1 assumes control of control
output 1, PID 2 assumes control of control output 2, and so on.
To view and edit PID settings:
a) Setpoint: Assign the desired goalthe
target feedback base value.
b) DeadBand: Assign a value around the
setpoint during which the PID will not
calculate error or take action.
c) Ramp Time: Assign a time interval for the
PID to calculate error.
d) Max % of Change: Assign a percentage
rate of change of the output, greater than
which may cause harm to the system.
e) Minimum Output: Assign a percentage
as minimum output. Typically 0 (zero).
f) Maximum Output: Assign a percentage
as maximum output. Typically 10000
(100.00%)
g) Proportional: Assign a constant value for
the proportional coefficient of the PID loop
calculation that causes a portion of the output
to be a fixed amount proportional to the size
of the error.
h) Integral: Assign a value for the integral
coefficient of the PID loop calculation that
causes a portion of the calculated output to
change with accumulated error over time.

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i) Derivative: Assign a constant value for the


derivative coefficient of the PID loop
calculation that causes a portion of the
calculated output to change with the change
in the size of error versus time.
j) OverRide Ramp Time: Assign a time
interval value to wait before making the next
override adjustment.
NOTE: Override settings are only
used when there is a configuration
for overriding the primary PID control
loop with another process variable.
k) OverRide Ramp Amount: Determine the
increments in a given direction (positive or
negative) that the primary setpoint should be
altered to regain balanced processes. In the
example of the discharge and suction
pressure application, this value would
indicate how much the PID should resist its
goal in reaching the setpoint.
l) OverRide Max Change: Assign a
maximum allowed change. This represents
the total amount of change allowed into or out
of the ramp amount from the setpoint. The
maximum change value should be large
enough to effect change.

For more on PID, please refer to the


MConfigPro Installation and Operations
Manual.

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5.3.12 Initial RPM Setup

Assign values for:


a) Warmup RPM.
b) Wait to Load RPM.
c) Run Loaded RPM.
d) Cooldown RPM.

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5.3.13 Miscellaneous Setup


User can access and edit the miscellaneous
settings.
a) Crank Attempts (1-99): Define a value
for number of crank attempts after which an
over-crank sequence will be triggered in the
event logic.
b) Port 1 Slave Address (1-255): Provide
the value for the Modbus address for port 1.
The factory default is 1.
c) Port 1 Mode: Select communication port
1 as RS232, or RS485.
d) Port 1 Reply Delay (0-32767): To ensure
sufficient time for the Modbus reply, assign
appropriate time value for delay Modbus
reply port 1. Typically set to 18. This setting
only applies to Port Mode RS485.
e) Port 1 Baud Rate: Select appropriate
transmission baud rate (9600; 19200; 38400;
57600; 115200)
f) Port 2 Mode: Select communication port
2 as RS232, or RS485.
g) Port 2 Reply Delay (0-32767): To ensure
sufficient time for the Modbus reply, assign
appropriate time value for delay Modbus
reply port 2. Typically set to 18. This setting
only applies to Port Mode RS485.
h) Port 2 Baud Rate: Select appropriate
transmission baud rate (9600; 19200; 38400;
57600; 115200)
NOTE: All ports use:
-Parity: NONE
-Data Bits: 8
-Stop Bits: 1

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i) Flywheel Teeth: Define a value for


flywheel teeth (Pulses Per Revolution) used
to calculate RPM.

WARNING: The following cold


temperature offset values should only
be adjusted by personnel with a full
working knowledge of the Centurion in
conjunction with calibrated reference
equipment.

j) Core Cold Temp Offset: Enter a nonzero value for core temperature adjustment
(in tenths) to adjust the temperature
readings for all thermocouple inputs on the
main I/O module (C3-1). Entering a non-zero
value will adjust the cold junction
compensation reading used to calculate
temperature.
k) Exp Cold Temp Offset: Enter a non-zero
value for expansion board temperature
adjustment (in tenths) to adjust the
temperature readings for all thermocouple
inputs on expansion I/O (C3-2). Entering a
non-zero value will adjust the cold junction
compensation reading used to calculate
temperature.
l) Hour Meter: The user may make hour
meter adjustments. The range is 0 65535
hours.

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5.3.14 Pulse Input Status

Pulsed inputs are designed to accept a


cycling digital output from a lubricator divider
block; typically from a general purpose
proximity switch.
The user may view information about the
pulsed inputs. If a digital input is designated
for use as a pulsed input, it will display how
much time elapsed before the last transition,
and how much time has elapsed since that
transition. If the input is not designated as a
pulsed input, there will be zeros displayed.
Both have a maximum value of 999.

5.3.15 Super User Menu


The super user menu will only be visible if the
super user password has been entered.
a) Com Fail Disable: Set to Yes to prevent
the Com Fail message from appearing when
communication is lost or cannot be
established.
b) Setup T/O Disable: Set to Yes to prevent
automatic logout from the Setup menus when
no keys are pressed for the timeout period.
c) Config Fail Disable: Set to Yes to prevent
the Invalid Configuration screen from
appearing when the display and controller
configurations do not match.
NOTE: Settings a thru c are for
troubleshooting purposes and are not
retained on power cycle.

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d) Reset Fault History: Set to Yes to clear


the Shutdown History screen.
e) Reset Event History: Set to Yes to clear
the Event History screen.

NOTE: The Reset History commands


do not permanently switch to Yes when
entered, but instead toggle back to No
after sending the command to the
controller.
Also, the message HISTORY
CLEARED will be displayed until
another key is pressed.

f) Restore Defaults: Set to Yes to overwrite


all settings changed through the display to the
original configuration settings from the last
download.
NOTE: The Restore Defaults
command does not permanently
switch to Yes when entered, but
instead toggles back to No after
sending the command to the
controller.
Also, the message DEFAULTS
RESTORED will be displayed until
another key is pressed.

g) Standard Password: Set to Yes to enter


the Standard User Password edit screen. The
current password is displayed and can be
changed.
h) Superuser Password: Set to Yes to enter
the Superuser Password edit screen. The
current password is displayed and can be
changed.
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NOTE: The Password commands do


not permanently switch to Yes when
entered, but instead toggle back to
No after returning from the Password
view/edit menu.

The P1 and P2 signify communication port 1


and communication port 2 and are for setting
up the RS485 interfaces on the displays
serial ports.
i) & k) PU/PD designates internal pull-up and
pull-down resistors. These can be connected
or disconnected by these settings.
j) & l) TERMINATION designates internal
terminating resistors. These can be
connected or disconnected by these settings.
NOTE: By default, both PU/PD and
TERMINATION settings are set to
YES for both Port 1 and Port 2 to
enable these features for RS485.
m) P1 Config Download
n) P2 Config Download
o) USB Config Download
p) Firmware Download
NOTE: Items m thru p
communication port functions are
also available for the configuration
download menu. Refer to the section
Downloading Configurations to the
Display for details on download
functions.

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5.3.16 Configuration Download


This menu allows for download only and can
be accessed through the special jump code
35.
It is the only screen available by entering the
password 35.
New configurations can be downloaded to the
display by selecting the desired connection.
(Com 1 Config Download, COM 2 Config
Download, and USB Config Download)
After enabling the download, download
progress is indicated on the left side of the
edit box as a percentage complete. After
selecting Yes for download, and until No is
selected after download is complete, only the
enter key will be active.
See the Operational Screens section for
further details about downloading
configurations.
a) Com 1 Config Download: Selecting Yes
initiates configuration download through
communication port 1.
b) Com2 Config Download: Selecting Yes
initiates configuration download through
communication port 2.
c) USB Config Download: Selecting Yes
initiates configuration download through USB
port.
d) Firmware Download: Selecting Yes
initiates firmware download. This feature only
supports USB download. The USB cable
must be plugged into the USB port and
connected to a pc before activating this
selection. A firmware update mode screen
will remain until the unit has been reset by
remote command or a power cycle.
See section Downloading Firmware Updates
to the display for downloading new firmware.

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5.3.17 Display Board Status

The user may view diagnostic information


that reflects the operating conditions of the
display only.
a) Battery Volts - Indicates internal voltage
measurement of display VDC input.
b) Board Current - Indicates internal power
measurement of display. Typical current
measured at 24VDC is .04A or 40
milliamperes.
NOTE: This value is higher when
ambient temperature is below -10F.
During this time the LCD heater will
be active and consuming more
power.
c) Temperature - Indicates internal
temperature measurement of display. This is
used primarily to monitor ambient
temperature to operate LCD heater.
d) Heater PWM % - Refers to the LCD
heater which only operates in cold
temperature conditions.
e) Reset Source - Indicates the cause of the
last reset. Possible causes include external
reset, power-up, brown-out and watch dog.

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5.3.18 Digital Output Status

For each of the devices configured as In


Use by MConfigPro, the user can see the
state of each output and has the ability to
force an output for the purpose of testing. A
force is associated with a timeout so that it
will be automatically cancelled when
returning to normal operation. Each force
operation resets the timeout to 5 minutes.
The force timer expires after 5 minutes if no
other forces are activated or when the user
navigates away from the digital output status
screen.
The Force timer is shown in the bottom right
corner of the digital output status screen
when forces have been activated.

5.3.19 Analog Input Status


The user can view the raw counts of the
analog inputs for troubleshooting.
NOTE: These values are used to
establish the offset and span
settings.
Typical approximate raw readings for
4-20mA input:
4mA = 147
20mA = 733
The Span (16mA) is 586, therefore:
8mA = 293
12mA = 439
16mA = 585

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5.3.20 Analog Output Status


The user can see the state of each output,
and if in test mode, has the ability to force
an output for the purpose of testing.
To force the output, enter a value from
0.00% = 4mA to 100.00%.= 20mA
Any value in between will output a portion
of the 16mA span proportional to the
percent value.
Analog outputs under the control of PID or
other control output settings cannot be
forced. To force a PID controlled output,
place the PID in manual mode and
operate the manual output value.

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5.3.21 Thermocouple Status

The user may view the raw counts of the


thermocouple inputs for troubleshooting.

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5.3.22 Communication Status

Users may view the statistics for both of the


display unit serial ports, including Modbus
requests and responses.
a) P1 Receive Count
b) P1 Transmit Count
c) P1 Frame Errors
d) P1 HW Overruns
e) P2 SW Overruns
f) P2 Receive Count
g) P2 Transmit Count
h) P2 Frame Errors
i) P2 HW Overruns
j) P2 SW Overruns
k) Modbus Requests
l) Modbus Responses
m) Modbus Exceptions
n) Modbus Invalid Response
o) Modbus No Response
p) Clear Statistics
q) Modbus Register

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5.3.23 PID Diagnostics

For each of four (4) possible configured PIDs,


user may edit:
a) Display PID Bar Graph: Monitors the
results of modifying the PID components.
b) Proportional: Edit the proportional
coefficient value.
c) Integral: Edit the integral coefficient value.
d) Derivative: Edit the derivative coefficient
value.
e) Auto/Manual: Setting to manual mode
allows the corresponding Set Output value to
be adjusted.
f) Set Output (Manual): In manual mode
allows adjustment from 000.00 to 100.00.
The output will correspond to the control
output associated with the PID.
g) Reference Line Select: Setting to select
the display value that will appear on the line
above the separator line and below the PID
name.
This setting is useful for showing the process
value of a different analog, thermocouple, or
speed input that may be effected by changes
to the PID output.
Select from available analog, thermocouple,
or speed inputs or None to disable the
Reference Line Select feature.

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5.4 Additional Navigational Aids


5.4.1 Function Key

Pressing the function (Fn) key from any


screen will display a dialog box on the
bottom half of the screen. All available
function key commands will be displayed
there. The user can then press a single key
for the available commands.
In this case, the user can select from a
help screen, the alarms screen or issue a
remote mode command. If the Fn key is not
followed by another key press in five
seconds, function mode will time out and
the dialog box is replaced with the previous
screen.
NOTE: In all cases the Fn key options will
be context sensitive. Some options will only
be available from certain screens or under
certain conditions.

5.4.2 Help Key

This is the help screen the user will see by


pressing the HOME key from the Fn dialog
box or by pressing the Fn key followed by
the HOME key from a normal screen.

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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.

6.1.2 Port 2 (SERIAL)


Interface: Refer to the sequence of operations to determine how the communication port has
been configured.
Protocol: Modbus RTU (slave), Proprietary (binary)
Connection: There are three (3) screw terminal connectors for RS485. These are identified as
A, B, and SHD.
There are three (3) screw terminal connectors for RS232. These are identified as RX, TX, and
DTR.
SHD is common for both ports.
Modbus RTU Slave Address Configuration: The operator may assign a unique Modbus
address to each controller (slave) unit that may be in the system. This allows the master
controller to differentiate between the modules. For example, to name the controller address
21, place the shunts on LK1, LK4, and LK16 (1 + 4 +16 = 21). Typically, this configuration is
set to (1) by the factory.

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6.1.3 Port 2 (USB)


Interface: USB 1.1 compliant port capable of emulating RS232 communications via royaltyfree pc driver.
Protocol/Services: Modbus RTU (slave), Proprietary (binary)
Connection: There is a USB type B connector.
Automatic selection of USB is provided when a signal is detected on the USB type B
connector. Connections for RS485 and RS232 will not be enabled on port 2 when USB is
connected.

6.1.4 Port 3 (CAN)


Protocol/Services: Proprietary (binary)
Connection: There are three (3) screw terminal connectors for CAN. These are identified as
HI, LOW, and SHD.
On Main I/O Module
Located next to the USB connector is the CAN OK (COP). When in the boot loader the COP
LED does not flash.
When the program is running properly the COP LED will flash on and off every 0.5 seconds. If
the checksum in the configuration file does not match the calculated checksum of the file, then
the program will flash the COP LED 3 times at 0.5 second intervals and then stay off for 1.5
seconds.
On the Expansion I/O Module
When the program is running properly the COP LED will flash on and off every 0.5 seconds.

6.2 Downloading Configurations and Firmware Updates


The Centurion controller and display are configured and upgradeable through software
transfers using a PC or laptop computer.
Configurations provide the necessary instructions to the controller and display and install
default parameters that can be adjusted through the display or Modbus RTU.
Firmware defines the available features that can be configured in the controller and display
using the MConfigPro software.
Since no chips are used to change the behavior of the equipment, Murphy can provide future
enhancements and support changes to process requirement for customers using a simple
email.
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6.2.1 Boot Loader


It is necessary for the Centurion controller to enter boot loader mode in order to receive
downloads for a firmware update, and configurations from MConfigPro. During boot loader
mode the Centurion is able to receive configuration updates from the MConfigPro software and
transmit configuration updates to display through pass-through.
Communications will operate according to default state parameters for configuration transfers.
During boot loader mode, the transfer rate is 9600, N, 8, 1 and assumes a serial
communication port setting of RS485 or a USB connection.
The controller recognizes whether the incoming data is for a configuration, or firmware update.
In order for the Centurion configurable controller to enter boot loader mode, the address
jumpers are removed during power up (power cycled). The display and third party HMI devices
will not receive a response to polls on port 1 while the boot loader is active.
Power on the Centurion must be cycled with the jumper installed to resume normal operation,
or run mode. See section Port 2 (Serial) in the Controller Communication Ports chapter for
more details on address jumpers.

6.2.2 Pass-through
During boot loader, the Centurion controller allows users to remain connected to both the PC
and the display and update the two devices with a single connection.
The Centurion controller accepts the message through one port (port 2) and passes it through
another port (port 1) directly to the display, as if the pc and display were directly connected.

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6.2.3 Downloading Configurations to the Display


All configuration downloads will use a baud
rate of 9600. The com 1 selection will use the
hardware setup of the current configuration.
The com 2 selection is a fixed hardware
setup for RS485. Selecting USB for
configuration download connects the USB
adapter to com 2 internally.
All normal communication with the controller
is stopped while in download mode.
The display will indicate the transfer is
complete by displaying 100%.
Special 35 Jump Code
In the case that no configuration has been
downloaded, or a password has been lost,
the display allows a Download Only
password that will allow access to the
download menu.
The password is set to a fixed value of 35.

6.2.4 Downloading Configurations via MConfigPro Software


The Centurion controller allows the user to easily download a configuration through the
MConfigPro software.
1. Connect your PC to the controller using either the RS485 or USB connection on Port 2.
For USB, a PC device driver must be installed. Upon initial connection to the WellPro, a
new Com Port will be activated on the PC device manager. Take note of the new Com
Port assignment to be used for all future communications with the WellPro.
2. Remove address jumpers from the controller located near the USB connector and cycle
power to the controller. Take note of the original location of the jumpers to re-install
them correctly after download.
3. Click on the Transfer menu, and then choose Configurations.
4. Select the configuration file supplied by FW Murphy from dialog and click Open. You
may need to change the selection for Files of Type to find the file type you wish to
download. In most cases, this will be *.MCP, however, other file types are available for
specific configuration types.

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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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6.2.5 Downloading Firmware Updates to the Display


Firmware updates for the display require a
USB connection. While boot loader mode for
the display is not required for configuration
downloads, it is required for firmware
updates.
The boot loader can be entered by menu
selection if the USB cable is currently
connected, otherwise the display will reset
and restart the current application firmware.
Optionally, the boot loader can be entered by
connecting the USB cable and cycling power.
(This method will leave the display blank
while in the boot loader.)
Upon entry to the boot loader, all
communication from the display to the
controller will stop. There is a red status LED
below the USB connector that will blink three
times and then remain on while the boot
loader is active.
While a file is being transferred, the com 2
transmit LED will be lit continuously. A
successful download should complete in
approximately five minutes.
Special 35 Jump Code
The Centurion display allows a Download
Only password that will allow access to the
download menu. The password is set to a
fixed value of 35. Once at the Download
Only screen on the display, the user will
select to download a firmware update.
Super User Menu
The super user menu is used to download
firmware updates.
All normal communication with the controller
is stopped while in download mode.
The display will indicate the transfer is
complete by displaying 100%.
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6.2.6 Error Messages


On occasion an invalid configuration error might display because the configuration between
the Centurion controller and its devices are out of synch -- the checksums do not match. The
invalid configuration screen will appear briefly after downloading configurations until
comparisons are made.
The user may direct the error message to be ignored through a setting at the super user menu.
At CONFIG FAIL DISABLE, the user would select Yes to ignore the data mismatch.
This setting is temporary. Once power is cycled-on, the error message will continue until
comparisons between the devices yield no configuration mismatch.
Two options are available for synchronizing data when fine-tuning changes are made in the
field. They are:

A super user could choose to also download the configuration from the super user
menu on display.

A user without access to the super user menu could activate the download
through the special jump code 35.

This screen indicates that the controller is not


responding to poll requests. There are only
two ways to exit this screen, either by normal
responses resuming or if the SETUP/ENTER
key is pressed.

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This screen will be displayed when a


configuration fault is detected.
Possible sources of the fault include a corrupt
or missing configuration in the display, a
corrupt or missing configuration in the
controller or a mismatch of configurations in
the display and controller.
This screen will appear briefly after
configuration downloads and may appear
briefly after initial communication is
established until comparisons are complete.
The fault can be resolved by downloading the
proper configuration to one or both devices
NOTE: This error message does not always
indicate a problem, but may only signify that
initial comparisons between devices do not
match.

6.3 Modbus RTU Protocol


The Centurion configurable controller was programmed with the Modbus protocol which is a
system based on a master and slave relationship. With Modbus protocol, the master and
slave are able to continue to communicate with each other through defined messages over a
variety of network types. The master initiates the queries or commands, and the slave
responds to the query with a message or takes action based on the query.
In this case, the master is either MConfigPro (or another Modbus client software), or display,
but never both simultaneously as there can only ever be a single Modbus master.
The Centurion system communicates through Modbus using remote terminal unit (RTU)
transmission mode to maximize data processing.
As with all numeric data defined within Modbus, the programming is limited to accepting
integers (whole numbers only, no decimals). This is important whenever a decimal point is
defined for analog inputs.
For example, for the controller to properly read 100.0 with an implied decimal point of 1, the
user would need to enter 1000 and 1000 would be stored in the appropriate Modbus register.
From the display, the value will be represented with a decimal in the fixed position.
For additional information, please refer to the MConfigPro Configuration Software Installation
and Operations Manual.
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6.4 Transferring Data in Modbus


Note that text visible in the MConfigPro software and on the display is not stored in the
Centurion controller. Except for the version description in the version and security dialog for
each configuration file, descriptions assigned in the configuration are not stored in the
Centurion controller. Descriptions for various I/O and processes are downloaded to the display
and reside as a configuration in that device only. Configurations of the display are one way
only.
Parameter changes made in the display are actually communicated to the Centurion controller
where the logic resides. No changes made through the display affect the display configuration
as the display merely reads from, and writes to the Centurion main I/O module. As such, the
display can write numeric parameters to the controller.

6.5 Modbus Register Address Listings


For a complete Modbus address map, please refer to the Centurion Modbus reference
document.

7 Replacement Parts and Assemblies


C3-1 Plug Kit

(00000504)

C3-2 Plug Kit

(00000505)

C3-3 Plug Kit

(00000543)

Choke

(50000774)

Printed replacement terminal plugs for Centurion Main I/O


module
Printed replacement terminal plugs for Centurion Expansion I/O
module
Printed replacement terminal plugs for Centurion display
module
Ignition noise (choke) filter

8 Accessories
8.1 Configuration Software
8.1.1 MConfigPro
MConfigPro is the configuration software for modifying sequence of operation, set points,
timers, faults, and displays* for Centurion. Includes file transfer utilities for configuration and
firmware upgrades.
CD, MConfigPro (50-70-0989) MConfigPro configuration software.
*Display configuration and other settings for display are only for use with the display Module.

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9 Glossary
Analog Input

Terminals 18 to 29 are analog inputs on the Centurion Main I/O


module. Accepts voltage signals within the range of (0 to 5) VDC or (4
to 20) mA and are compared to controller set points and/or displayed.

Boot Loader

Means by which the Centurion controller communicates with display


and MConfigPro to receive and transfer new or updated configurations
and firmware; and ensure data and configuration synchronization.

Controller Setpoints

User defines normal operating range for the controller to optimize the
equipment. Setpoints can also define some other threshold, exception
or event that may require action. Multiple setpoints are often applied
to a process and they may be manipulated as needed to meet
changing conditions.

DeadBand

The user set range at which input may fluctuate without the controller
taking any action. The range may be fixed or variable.

Digital Input

Terminals 30 to 61 are the digital input channels. User selects whether


digital input is normally open (N/O), or normally closed (N/C). Users
may also associate these inputs with transition times for indicating noflow conditions on divider blocks.

Event

Defines the action required by the controller in response to any


number of parameters. Event actions range from simple alarm
message to emergency shutdown (ESD).

No-flow

Designed to protect against compressor or engine failures, the


controller monitors the cycle time of lubrication system cycles and if
that cycle time falls under a user assigned value, the controller will
activate a defined associated action such as an alarm or shutdown.

Offset

User defined value to correct for known variance in the raw data.

Panel Ready

In states, the first logical step in start up.

Permissive

A process condition, (digital input or analog setpoint), that must be met


in order for the sequence to proceed to the next state.

Signal

An electrical quantity of voltage or current that is used to represent or


signify some other physical quantity such as the state of a switch
(ON/OFF) or the status of a device (SHUTDOWN/OK)

Span

The difference between the full scale output and the offset as raw data.

Start Delay

A time delay function to prevent premature start up.

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State

Predefined step of multiple logical steps (or states) needed to


successfully start and operate a compressor.

Terminal Emulator

Allows a user to modify the firmware to allow upload or download of a


record to either the display or the controller. Always download a
configuration after a firmware change.

Thermocouple

A device for measuring temperature consisting of two dissimilar metals


of high purity for an accurate temperature/voltage relationship. User
defines whether the calibration is J or K. Terminals 1 to 17 are for
thermocouple inputs.
Type J uses Red (-) and White (+) insulation.
Type K uses Red (-) and Yellow (+) insulation.

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10 Appendices
10.1 Back Panel LED Description
There are a total of seven (7) LED indicators on the back panel, labeled as follows:

10.1.1 (Port 1)
TX Turned on while port 1 is transmitting data.
RX Turned on while port 1 is receiving data.

10.1.2 (Port 2)
TX Turned on while port 2 is transmitting data.
RX Turned on while port 2 is receiving data.

10.1.3 USB LINK


Turns on while there is a USB connection to a computer.

10.1.4 STAT 1
Turns on for one half second and then turns off for one half second, repeating as long as there
is a valid configuration running.
NOTE: This indicator is not active while the boot loader is running.

10.1.5 STAT 2
This LED is only active while the boot loader is running. It flashes briefly three times when the
boot loader starts up and then stays on until leaving the boot loader.

10.2 Controller Accuracies, and Tolerances


Refer to the Centurion Configurable Controller Specification Sheet for a detailed breakdown of
specifications.

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10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens


Due to a combination of the limited space and the spirit of the design objectives, there are
certain restrictions imposed upon the formatted size of numbers in display screens.

Positive numbers with no decimals can be displayed with up to four digits.

Negative numbers are limited to three digits.

Numbers of either sign with a decimal place are limited to three digits.

Numbers with more than two decimal places will not be displayed at all, but will be
replaced with dashes.

If a number with decimals is larger than the imposed limits, the display algorithm will attempt to
adjust the precision so as to display as many of the most significant digits as possible.

10.4 Set Up Sheet


Refer to The Centurion Configuration Worksheet for a detailed workbook to document field
changes to configuration parameters.

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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.

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OPERATIONAL
SCREENS

CENTURION DISPLAY SCREEN MAP

LOGO

VERSION
INFORMATION

DIGITAL
STATUS

NAVIGATION
Use left and right arrow keys to move between top level screens.

SHUTDOWN
HISTORY

SHUTDOWN
SNAPSHOT

EVENT
HISTORY

ACTIVE
ALARMS

CUSTOM
1

CUSTOM
2

CUSTOM
...

CUSTOM
5

CUSTOM SCREENS
Up to 5 custom screens can be configured using MConfig Pro.
Screens can be arranged in any order. However, all custom screens will appear after the ACTIVE ALARMS screen.

PASSWORD

PASSWORD ENTRY
0 (zero) = Read ONLY access to the Setup Screens.
35 = Download ONLY

SETUP
SCREENS

Passwords for Standard and Super User are configured using


MConfig Pro. Refer to 00-02-0590 pg. 25 for additional
information on password functionality.

SETPOINTS
1-16
17-32
33-48
...

GENERAL
TIMERS

STATE
TIMERS

SETPOINT
###-###
SUBMENU

FN
MENU

HELP
SCREEN

NAVIGATION
Use left and right arrow keys to move between top level screens.

MAINTENANCE
TIMERS

PID

MAINTENANCE
TIMER #
SUBMENU

PID #
SUBMENU

INITIAL
RPM

MISCELLANEOUS

CONTROL
OUTPUTS

DIGITAL
INPUTS

CONTROL
OUTPUT #
SUBMENU

DIGITAL
INPUT #
SUBMENU

PULSE
INPUT
STATUS

DIGITAL
OUTPUTS

continued...

SETUP
SCREENS

NAVIGATION
Use left and right arrow keys to move between top level screens.

ANALOG
INPUTS

ANALOG
OUTPUTS

THERMOCOUPLES

ANALOG
INPUT #
SUBMENU

ANALOG
OUTPUT #
SUBMENU

THERMOCOUPLE
#
SUBMENU

SUPER
USER
MENU

DISPLAY
BOARD
STATUS

DIGITAL
OUTPUT
STATUS

ANALOG
INPUT
STATUS

ANALOG
OUTPUT
STATUS

THERMOCOUPLE
STATUS

COMMUNICATION
STATUS

PID
DIAGNOSTICS

PID #
OPTIONS

NAVIGATION
Use left and right arrow keys to move between top level screens.

HOME
Up to 5 custom screens can be configured using MConfig Pro.
One custom screen is configured as the default or HOME
screen. While viewing the OPERATIONAL SCREENS, pressing
the HOME key will jump from the currently displayed screen to the
configured default screen.
NAVIGATION
Look for cues on screens to indicate
what navigation is possible.

This function is not available in SETUP SCREENS. However,


pressing this key on any multi-line display when the first line is not
being displayed will jump to the top or HOME line on that
screen.

00-02-0161
Revised 03-06
Section 05

Installation for 4-1/2 in. (114 mm) dial


Pressure Murphygage and Swichgage instruments
Model Series: OPLC, OPLG, OPLBP, 45APE, 45APEBP, PT167EX and 45 Series
Options: -OS, -ES, -P4 and -P6

Please read the following instructions before installing. A visual inspection is recommended before mounting. General Information
and these installation instructions are intended for all 4-1/2 in. (114 mm) dial pressure models.
GENERAL INFORMATION

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
Disconnect all electrical power to the machine.
Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

OPLC and OPLFC Swichgage instruments have high and low limit
contacts to monitor, alarm or shut down. The OPLC has a flanged case. A method
to override the low limit contact for start-up is provided on most models. See
Operation Test 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.

Sensing Element: Bronze or 316 stainless steel bourdon tube.


Gage Accuracy:
All models and 45APE/45APEF between switch points:
2% for first and last quarters of scale; middle half of scale is 1%.
Model 45APE/45APEF
Indicating Pointer above or below set point:
Range
Accuracy (% F.S.) above and below s.p. only
<100 (except 15 psi) 10
15
15
100-300
4
400-1500
2
2000
12
3000-5000
8
Based on testing performed with switch point at mid scale which represents worst case.
LOW SET POINT
POINTER LOCATION

HIGH SET POINT


POINTER LOCATION

50

40
300

30

400

200
PRESSURE

20
100

70
500

INCREASING ERROR
FOR INDICATING
POINTER

featuring pilot duty limit switches connected to an internal latching control


relay for on/off control directly or through a motor starter.

PT167EX The Murphy PT167EX is a pressure Swichgage instrument


connected to a threaded pressure diaphragm housing. The Swichgage instrument is
enclosed in an explosion-proof case and is CSA rated for Class I, Division 1,
Groups C and D.

Specifications
Dial: White on black, dual scale, psi/kPa standard, 4-1/2 in. (114 mm) diameter.
Case: Die cast aluminum, surface or panel mount.
Process Connection: 1/4 NPTM thru 1000 psi; 1/2 NPTM 1500 - 10,000 psi.

Precautions: Do NOT exceed rated pressure range.


Dope or use teflon tape on connection threads. Do not block
the inlet orifice. For direct mount into the process, a vertical
or ninety degree mounting is recommended.
Use wrench on shank to tighten or loosen connection. Do not twist
case when installing, this will damage internal components and will
void the warranty. Do not overtighten.
Use shock mounts as necessary to prevent excessive vibration.
If liquid in the system freezes, it will expand and will damage the tube.
For 45APE Series Low setpoint should be limited to the lower 1/2
scale and upper setpoint should be limited to the upper 1/2 scale.

60
400

200
PRESSURE

70
500
80
600
90

10

90

45APE and 45APEF Series are versions of the OPLC Series

OPLBP and 45APEBP are versions of the OPLC and 45APE

30

600
kPa

300

100

kPa

0 PSI

100
MAXIMUM ERROR

featuring 2 snap-acting SPDT switches instead of the pointer type contacts.


These units do not include low contact lockout.

INCREASING ERROR
FOR INDICATING
POINTER

20

80

10
0 PSI

50

40

60

100

MAXIMUM ERROR

Switch Point Accuracy: 1.5% (45APE/45APEF).


Switch Reset Deadband: Approximately 10% FS (45APE/45APEF).
Snap-Acting Switches: See wiring information (page 4) (45APE/45APEF).
Overrange: Do not exceed 10% FS above full range.
Pressure Relief Disc: Back of case (except EX models).
Dry Relay Contact (BP Models): 10 A @ 28 VDC or 10 A @ 120 VAC.
Wire Connections (Surface Mount): 1/2 NPTF conduit/ terminal block.
Wire Connections (Panel Mount): Wire leads, 18 AWG (1.0 mm2) x 9 in. (229 mm) long.
Wire Connections (-ES, -OS): 1/2 NPTM conduit and wire leads,
All except 45APEF:
18 AWG (1.0 mm2) x 33 in. (838 mm) long.
45APEF
24 AWG (0.22 mm2) x 33 in. (838 mm) long.
Item Weight: 5 lbs 6 oz (2.4 kg) approximately.
Explosion-proof models: 21 lb. (9.5 kg) approx.
Item Dimensions: 10 x 9 x 6 in. (254 x 229 x 152 mm) approximately.
Explosion-proof models: 12 x 12 x 9 in. (305 x 305 x 229 mm) approximately.

Warranty
A limited warranty on materials and workmanship is given with this
FW Murphy product. A copy of the warranty may be viewed or printed by
going to www.fwmurphy.com/support/warranty.htm.
*Selected configurations are third party listed. Consult factory for details.

Installation 00-02-0161 page 1 of 4

OPL Series Wall Mount

45APE Series Wall Mount

Flanged case design intended for wall mount, it can also be


direct mounted. Shown with shock mounts and pulsation dampener.

3-15/16 in.
(100 mm)

4-1/32 in.
(102 mm)

3-3/8 in.
(86 mm)

8-7/16 in (214 mm)

4-1/32 in.
(102 mm)

8-7/16 in.
(214 mm)

3-3/8 in.
(86 mm)

3-15/16 in.
(100 mm)

1/2NPTF
conduit

1/2 NPTF
Conduit

7-7/8 in.
(200 mm)

9/32 in.
(7 mm) dia.
3 places

1/4 NPTM or 1/2 NPTM


Pressure Connection

45APE Series Flush Mount

1/4 or 1/2 NPTF

5-7/16 in.
(138 mm)

DETAIL
FLOW

9/32 in.
(7 mm) dia.
3 places

7-7/8 in.
(200 mm)

shock mount
panel

gauge

2-57/64 in.
(73 mm)
6-3/4 in.
(171 mm)

pulsation
dampener

-OS and ES
models only

120

120

1/4-20 nut & lockwasher


(2 each required)

1/4 in. (6 mm) dia.


holes (3 places) on
5-1/4 in. (133 mm)
B.C. 120 apart,
clocking as shown.

OPL Series Flush Mount


Round case design to be mounted in a panel from 1/32 in. (1 mm) to 1/8 in.
(3 mm) thick. It can also be direct mounted. Shown with pulsation dampener.

120

2-57/64 in.
(73 mm)

5-7/16 in.
(138 mm)
Mounting
Hole
4-3/4 in.
(121 mm)
diameter

6-3/4 in.
(171 mm)
120

Optional (-BC) 1/2NPTM


Pressure Connection

Options OS and ES (flush mount case)

2-57/64 in.
(73 mm)

5-7/16 in. (138 mm)

1/4 NPTM or 1/2 NPTM


Pressure Connection

-OS and -ES


models only

6-3/4 in.
(171 mm)
120

120

1/2 in.
(13 mm)
conduit

1/4 or 1/2 NPTM


Pressure Connection

1/4 in. (6 mm) dia.


Holes (3-places) on
5-1/4 in. (133 mm)
B.C. 120 apart,
clockingas shown

Optional (-BC) 1/2 NPTM


Pressure connection

1/4 in. (6 mm) dia.


holes (3 places) on
5-1/4 in. (133 mm)
B.C. 120 apart,
clocking as shown.

120

Optional back
connection

2-23/32 in.
(69 mm)

Explosion-proof Case Mount Explosion-proof case can be mounted from face or rear.
Flush mount/Wall mount*
6-25/64 in.
8 in.
(203 mm)

(162 mm)

1/2 in.
(13 mm)
optional
rear or side
conduit
8 in.
(203 mm)

7-35/64 in.
(192 mm)
diameter

*Mounting hole

6-3/4 in.
(171 mm)
3-3/8 in.
(86 mm)

3-3/8 in.
(86 mm)

not required for


Wall mount

3/8-16 UNC-2B
thread
7/8 in. (22 mm)
deep, 8 plc's

Installation 00-02-0161 page 2 of 4

13/32 in.
(10 mm)
diameter
4 places

6-3/4 in.
(171 mm)

OPTIONS
CAUTION: Do Not unscrew the green diaphragm
-OS and -ES (oil sealed and environment sealed case) for corrosive
capsule.
environment, feature a panel mount case or screw directly into the process.
See Case Mounting (p-2).
2.
Tighten
the bottom housing to the pressure source.
Swichgage instrument
3. Tighten the eight housing bolts to 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

-P4L is a remote seal mechanism with stainless steel armored capillary to


protect the gage from highly viscous and/or corrosive fluids.
1. Loosen the eight housing bolts until the bottom
housing is free to turn.
ADJUSTMENTS

OPL/45 Series Limit Contact Adjustments


Facing the dial, left side knob is the Low limit contact and the High
limit contact is located to the right. To set the limit contacts simply turn the
fingertip type knob to the desired point on the scale.
45APE Series Trip Point Adjustments
The 45APE Series features a stacked limit indicator adjustments knob. The
bottom half knob adjusts the Low limit indicator, the top half is to adjust
the High limit indicator. To set the limit contacts simply turn the
fingertip type knob to the desired point on the scale.
OPL and 45 Series
Indicating Pointer Adjustments
To reset to zero or to a known value do as follows:
1. Turn off electrical power. Remove the snap
DETAIL A
ring and very carefully remove the lens and
Turn to lower
pointer
contact assembly (or open hinged cover).
2. Hold the pointer hub with thumb and
forefinger then turn screw to desired
point. See DETAIL A.
3. Replace lens and contact assembly and
Turn to raise
pointer
snap ring (or close hinged cover), and turn
on the power.

45APE Series Pointer Adjustments


To reset to zero or to a known value proceed as follows:
1. Turn off electrical power. Remove the snap
DETAIL B
ring and very carefully remove the lens and
contact assembly (or open hinged cover).
2. Hold the the Switch Operator and the
Turn CW to
Turn CCW
Raise Pointer
to Lower
pointer hub with thumb and
Pointer
forefinger, then turn the Pointer
Adjustment screw to the desired
point. See DETAIL B.
Pointer
Adjustment
3. If the Switch Operator needs adjustment,
hold the Switch Operator and the pointer
hub with thumb and forefingers as show on
DETAIL C, and turn the adjustment screw
until the Switch Operator aligns with the
DETAIL C
indicating pointer.
4. Replace the lens and contact assembly
Turn CW to Lower
Turn CCW
Switch Operator
to Raise
and the snap ring (or close hinged
Switch Operator
Switch
cover). Turn the power back on.
Operator
Adjustment

OPERATION TEST INSTRUCTIONS

OPLC, OPLFC and OPLBP


1. Perform operation test after the unit is installed and wired appropriately.
(See the typical wiring diagram, on page 4.)
2. When pressure is applied to the instrument, the pointer will travel in a
clockwise direction. Adjust the limit contacts to the desired settings.
3. To start, place the toggle switch in the startposition or otherwise
override low contact.
4. After the indication pointer rises above the low limit contact, return the
toggle switch or override device to the runposition.
5. To test the limit contacts, turn the limit contact to be tested until it touches
the pointer. That will trip the control circuit.
6. Reset the shutdown or alarm circuit device and repeat above sequence for each
contact/trip point.

45 Series
1. Repeat steps 1 and 2. (See OPLC operation test instructions.)
2. Press the semi-automatic pushbutton located on the low contact knob.
3. Reset the magnetic switch pushbutton.
4. After the indication pointer rises above the low limit contact, the lockout pushbutton automatically disengages and the low limit is armed.
5. Repeat steps 5 and 6. (See OPLC operation test instructions.)
45APE, 45APEF and 45APEBP
1. Repeat steps 1 and 2. (See OPLC operation test instructions.)
2. To test the switches, turn the trip point indicator until it is aligned with the
Swichgage pointer. This is the approximate trip point.
Continue to rotate until the snap switch operates.
3. Reset the shutdown or alarm circuit device.

Installation 00-02-0161 page 3 of 4

TYPICAL ELECTRICAL DIAGRAMS


WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE OFF. MAKE SURE THE VOLTAGE AND CURRENT
REQUIREMENTS ARE WITHIN THE SWICHGAGE RATINGS. BEFORE WIRING DETERMINE VOLTAGE AND POLARITY FOR THE
APPLICATION. USE THE APPROPRIATE WIRE SIZE. ALL CONNECTIONS SHOULD BE MADE USING A SPADE (FORKED) OR RING
TERMINALS. FOR PIGTAIL CONNECTIONS USE WIRE NUTS. CONDUIT IS RECOMMENDED TO PROTECT WIRES FROM DAMAGE.

OPLC and OPLFC

OPLBP

Contact Rating: 1 SPDT, Center Off; 2 A, 30 VDC, 1 A, 125 VAC pilot duty.
OPLC

OPLFC

Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram
below shows the Swichgage pointer in the at rest (shelf) position.
COMMON

YELLOW

BLUE

RESET

SET

1
7
4
3
9

= 18 GA.

Red White Black

Red White Black

= 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

45APE and 45APEF

(-) 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.

45 Series with MS2100

BROWN

= 16 GA.

(-) NEUTRAL
12 VDC
24 VDC

WHITE

ORANGE
A

120 VAC

RED

(+) LINE

LOW
(RESET)

YELLOW

BROWN

Models available for Battery ignition, CD ignition, Magneto or 110VAC


systems. Contact Rating: 12/32 VDC coil, 10 A, 32 VDC battery ignition
contacts; Magneto ignition coil,
MS2100
10 A magneto ignitions contacts;
CD ignition coil, 10 A CD
ignition contacts; 120 VAC coil,
10 A, 120 VAC contacts.
6 1 2 3 4 5
NOTE: The diagram at right shows
the Swichgage pointer in the
operating position.
G

YELLOW

BLUE

BLUE

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)

Transformer Relay Assemblies

Typical Circuit
To CD Ignition
or Magneto.

www.fwmurphy.com
918.317.4100 Email: sales@fwmurphy.com

For higher voltages, Murphy TR Assemblies can be used in conjunction


with any Swichgage instrument.

MURPHY, the Murphy logo, Murphygage and Swichgage are registered and/or common law trademarks of Murphy
Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy
Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names
referenced herein are the property of their respective owners and are used for identification purposes only.

Installation 00-02-0161 page 4 of 4

PD-95145B
Revised 11-03
Catalog Section 55

Pulsation Dampener

(00-02-0125)

PD8100 Series
Used

On Controllers, Instruments and


Recorders to Dampen Pressure Pulsation
Eliminate Gage Pointer Flutter
Aids In Providing More Accurate
Pressure Indication
Decreases Wear On Gages
Geared Movement
NOT INTENDED FOR USE AS A SHUTOFF VALVE
Description

Specifications

The PD8100 Series eliminates pointer flutter


on pressure indicating SWICHGAGE devices
which are subject to pulsating pressure from
reciprocating pumps or compressors. It also
allows a close setting of high and low contact
points providing for more accurate pressure
indication and control of equipment.
The PD8100 Series decreases wear on geared
movements and increases the life of pressure
indicating instruments by eliminating excessive gage strain and unnecessary movement.
A necessity which quickly pays for itself by
protecting any pressure indicating and control
instrument which is subject to pulsation.
PD8100 SERIES NOT FOR USE ON
OXYGEN OR LIQUID
OXYGEN APPLICATIONS.
Quality built with a large diameter valve stem
wheel for ease of adjustment with clearly printed
operating instructions. Machined from 1-3/8 in.
(35 mm) hex bar stock. A two degree taper on
valve and stem assure positive dampening.
Available in brass, carbon steel, 303 stainless
steel or 316 stainless steel to meet pressure
and environmental requirements with either
1/2 NPT or 1/4 NPT inlet connections.

See How to Order section for available inlet


and outlet connections.
PD8183: All wetted parts are Brass. Rated to
MURPHY SWICHGAGE
3,000 psi (20.68 MPa) [206.80 bar].
PD8184: All wetted parts are Carbon steel.
Rated to 5,000 psi (34.47 MPa) [344.70
bar].
PD8185: All wetted parts are 303 stainless
steel. Rated to 10,000 psi (68.95 MPa)
[689.50 bar].
PD8190: All wetted parts are 316 stainless
steel. Rated to 10,000 psi (68.95 MPa)
[689.50 bar]. Meets NACE standard MR01-75 for direct exposure to H2S.
Operating Temperature: MURPHY SWICHGAGE
Make SWICHGAGE instruments
-15 to 400F (-26 to 204C)
and recorders operate like this.
Shipping Weight (all models):
2 lbs.(0.9 kgs.)
MURPHY SWICHGAGE
Shipping Dimensions (all models):
4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121 x 83 mm)

Eliminate pointer flutter


like this.

RUN

START

RUN

START

Warranty
A limited warranty on materials and workmanship
is given with this FW Murphy product. A copy of
the warranty may be viewed or printed by going to
www.fwmurphy.com/support/warranty.htm

MURPHY SW

Service Parts
DESCRIPTION (see drawingright)

PD8183

PD8184

PD8185

PD8190

A. 1/2 NPT inlet x 1/4 NPT outlet*


1/2 NPT inlet x 1/2 NPT outlet*
B. Bonnet Fitting
C. Valve Stem
D. Packing Nut
E. Hand Wheel (with 10-32 nut)
F. Strainer Bushing Assembly
G. Molded Packing Gland
H. O Ring Bonnet Seal
J. Stainless Steel Mesh Filter **

65-05-0104
65-05-0105
65-05-0099
65-05-0175
65-05-0098
55-00-0179
55-00-0174
00-00-0936
00-00-0302
65-05-0214

65-05-0210
65-05-0212
65-05-0209
65-05-0208
65-05-0211
55-00-0179
55-00-0173
00-00-0936
00-00-0302
65-05-0214

65-05-0204
65-05-0206
65-05-0203
65-05-0202
65-05-0205
55-00-0179
55-00-0175
00-00-0936
00-00-0302
65-05-0214

65-05-1136
65-05-1135
65-05-1139
65-05-1140
65-05-1137
55-00-0179
55-00-0206
00-00-0936
00-00-0302
65-05-0214

D
B

INLET

OUTLET

Provided only for units with 1/4 NPT inlet.

*For 1/4 NPT inlet use with strainer bushing assembly.


**Provided in units with 1/2 NPT inlet.

Dimensions

How to Order
PD8185

1/4 x 1/4

Base Model
PD8183
PD8184
PD8185
PD8190

3-7/8 in.
(99 mm)

FLOW

Connection Size
1/4 x 1/4 = 1/4 NPT inlet x 1/4 NPT outlet
1/4 x 1/2 = 1/4 NPT inlet x 1/2 NPT outlet
1/2 x 1/2 = 1/2 NPT inlet x 1/2 NPT outlet
1/2 x 1/4 = 1/2 NPT inlet x 1/4 NPT outlet

3 in.
(76 mm)

Mounting for the OPLFC Pressure SWICHGAGE and PD8100 Series


The PD8100 Series pulsation dampener is mounted directly below the OPLFC.

Precautions: Dope or use teflon tape on connection threads. Do not block the inlet orifice.
4-3/4 in.
(121 mm)
diameter

OPLFC
Mounting
Hole

1/4 in. (6 mm) dia.


holes (3 pls.) on
5-13/64 in. (132 mm)
B.C.,120 apart,
clocking as shown
1/2 in.
radius
typical

1 in.
(25 mm)

MURPHY DE MEXICO, S.A. DE C.V.


Blvd. Antonio Rocha Cordero 300, Fraccin del Aguaje
San Luis Potos, S.L.P.; Mxico 78384
+52 444 8206264 fax +52 444 8206336
Villahermosa Office +52 993 3162117
e-mail ventas@murphymex.com.mx
www.murphymex.com.mx

FRANK W. MURPHY, LTD.


Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
+44 1722 410055 fax +44 1722 410088
e-mail sales@fwmurphy.co.uk
www.fwmurphy.co.uk
MURPHY SWITCH OF CALIFORNIA
41343 12th Street West
Palmdale, California 93551-1442; USA
+1 661 272 4700 fax +1 661 947 7570
e-mail sales@murphyswitch.com
www.murphyswitch.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

GI

CONTROL SYSTEMS & SERVICES DIVISION


P.O. Box 1819; Rosenberg, Texas 77471; USA
+1 281 633 4500 fax +1 281 633 4588
e-mail sales@fwmurphy.com

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

The PD's are recommended


for use on piston pumps and
compressors to eliminate
pointer contact flutter
and gage wear.

5-5/16 in.
(135 mm)

PD8100
2 in.
Series
Mounting (51 mm)
Hole

Shown at right, is a typical


MURPHYMATIC compressor panel featuring three
Pulsation Dampeners and
Murphys OPLFC gages.

STER

USAISO 9001:2000 FM 28221


UKISO 9001:2000 FM 29422

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

PD-95145B page 2 of 2

Printed in U.S.A.

Installation Instructions for Pressure and Vacuum


2 and 2-1/2 in. (51 and 64 mm) Dial Murphygage
and Swichgage Instruments. 20, 25, A20, A25 Series

00-02-0162
Revised 02-06
Section 05

Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended.
GENERAL INFORMATION

Typical Mounting Dimensions

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

20 Series shown

Mounting Hole

Low Pressure
Port (DP Series)
1/8-27 NPTM
Pressure Port

Mounting
Clamp

See Note

Description
The 2 and 2-1/2 in. (51 and 64 mm) dial size Murphygage and Swichgage instruments are diaphragm-actuated, pressure or vacuum gages with a 1/8-27 NPTM pressure port connection (2 pressure ports for differential pressure models).
Models with face-adjustable contact(s) are rated for 2 A @ 30 V (pilot duty). If the
gage case is steel (20P, 25P, 20DP, 25DP etc.) the ground path for the contact circuit
is through the case. Therefore, the case must be installed in the ground plane of the
electrical power supply.
If the case is polycarbonate (A20P, A20DP, A25P, A25DP etc.) the ground path
is isolated and is made through the C or P terminals on the back of the gage
case (C for A20 models; P for A25 models).
Models 20PE, 25PE, A20PE, A25PE etc. have a snap-acting switch instead of
the face adjustable pointer type contact. Electrical rating is 3 A @ 30 VDC, 4 A
@ 125 VAC. Reset differential for the switch is approximately 10% of the scale.
NOTE: Select a scale so your normal operating pressure is in the upper middle of the scale.

A
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)

NOTES: 20/25 Series: 18 AWG pigtails. A20/A25 series: #4/#6


screws. The dimensions above are in inches and (millimeters).

Panel Mounting
All models can be installed in a panel from 0.032 to 0.250 in. (1 to 6 mm) thick.
Remove the mounting bracket and insert the gage from the front side of the panel.
Replace bracket and secure it. Do NOT overtighten. (See Figure 2).

Connecting the Pressure Port


CAUTION: Certain dangers to human safety and to equipment may
occur if some equipment is stopped without pre-warning. It is recommended that monitored functions be limited to alarm-only or to alarm
before shutdown.

Alarm Before Shutdown Models


The 20PABS, A20PABS, 25PABS and A25PABS feature a front limit contact for
equipment shut-down and an internal SPDT snap switch for Alarm Before ShutDown. When the low side (preset point) of the snap switch trips, the N.C. terminal
completes a circuit to activate an alarm. A continued decrease in pressure will complete the shutdown circuit. An increase in pressure of approximately 10% of scale is
necessary before the snap-switch (alarm) will reset and open the circuit.
NOTE: Face contact shut-down limit setting and snap switch low point are factory-set; specify when ordering if setting is other than standard.

Typical Tattletale Magnetic Switch


Murphy manufactures several, patented Magnetic Switches for protection of the pilot
duty Swichgage contacts and to ensure positive shut-down of equipment. There are
magnetic switches for CD ignition, Magneto, Battery systems and electric motor driven equipment. Tattletale annunciators show the cause of shut-down. The first one to
trip will lockout all other Tattletale annunciators. Be sure the type of magnetic switch
or Tattletale annunciator matches the power source used to trip it.
NOTE: At equipment start-up (for models not having a built-in time delay) the reset button must be held in until normal operation occurs, or an external time delay may be
used. Instructions are packed with each Magnetic Switch orTattletale annunciator.
Products covered by this literature comply with EMC Council directive
89/336/EEC regarding electromagnetic compatibility except as noted.

1. Pressure tubing is generally not provided. Use of good quality flexible pressure

tubing/hose and fittings is strongly suggested. Use at least 3/16 in. (5 mm) I.D.
tubing. If using copper or rigid tubing, install at least 12 in. (305 mm) flexible
hose from the gage to the rigid tubing. This prevents damaging vibration from
reaching the gage. For most models a pulsation orifice, within the pressure port,
is provided and it is removMounting
Panel
Bracket
able for cleaning (Figure 2).
2. Connect tubing to the 1/8-27
NPTM port. Use of non-hardening thread sealing comGage
pound is recommended
although thread is dry seal.
Pressure
tubing
Port
IMPORTANT: Make sure
or hose
NOT to foul pressure orifices
Pulsation
Orifice
Wire Lead
Wrench
with sealant. NEVER exceed
maximum pressure rating for
the gage range; see chart on p-2.
Figure 2

IMPORTANT: Swichgage instruments, magnetic switches and shutdown


or alarm devices, properly used, are effective tools in any preventive maintenance
program. For optimum performance, check these tools periodically: look for
frozen pointers, kinked/worn tubing, broken wiring or loose connections; operate
the contacts and watch for expected results. Replace damaged/worn parts;
clean/repair as necessary. Check for correct/complete wiring, unbroken insulation
and no accidental grounds. Do not run shut-down wires with ignition wiring.
Check all tubing and connections for leaks. Mount magnetic switches and valves
upright, to prevent moisture collection.

Installation 00-02-0162 page 1 of 4

Pressure Ranges and Factory Settings


Ranges Available

Maximum
Pressure

Std. Settings*

20/25PABS Settings

Hi Settings**

Start-up Lockout Settings

Alarm

Low

Contact

Bar

psi

Bar

psi

Bar

psi

Bar

30 psi (21 MPa) 3 (21)


60 psi (21 MPa) 7 (48)
100 psi (21 MPa) 10 (69)
150 psi (21 MPa) 15 (103)
200 psi (21 MPa) 20 (138)
300 psi (3.4 MPa) 30 (207)

0.2
0.4
0.8
1.0
1.5
2.0

12 (83)
24 (165)
40 (276)
60 (414)
80 (552)
120 (827)

0.8
1.6
2.8
4.0
5.5
8.0

3 (21)
7 (48)
10 (69)
15 (103)
20 (138)
30 (207)

0.2
0.4
0.8
1.0
1.0
1.5

6 (41)
10 (69)
13 (90)
18 (124)
23 (159)
33 (228)

0.3
0.6
1.0
1.5
1.5
2.0

3 (21)
4 (28)
10 (69)
10 (69)
20 (138)
20 (138)

400 psi (3.4 MPa) 50 (345)


500 psi (3.4 MPa) 75 (517)

3.0 150 (1 MPa) 10


5.0 225 (1.6 MPa) 15

50 (345)
75 (517)

3.0 53 (365)
5.0 78 (538)

28 500 psi (3.4 MPa) 150 (1MPa) 7.0 300 (2.1 MPa) 20

75 (517)

psi

Bar

0-15 (103)
0-30 (207)
0-50 (345)
0-75 (517)
0-100 (690)
0-150 (1.0 MPa)

1.0
2.0
3.5
5.0
7.0
10

0-200 (1.4 MPa)


0-300 (2.1 MPa)

14
20

0-400 (2.8 MPa)

psi

psi

Lockout

Release (max.)

Bar

psi

Bar

0.2
0.4
0.5
0.7
1.0
1.5

4 (28)
7 (48)
13 (90)
15 (103)
25 (173)
30 (207)

0.3
0.5
1.0
1.0
2.0
2.0

psi

Bar

4.0
5.0

40 (276) 3.0
50 (345) 3.5

50 (345)
75 (517)

3.5 70 (482) 4.8


5.0 105 (724) 7.2

5.0 150 (1MPa) 10

100 (690) 6.0

7.0 150 (1MPa) 10

6 (41)
10 (69)
20 (138)
23 (159)
35 (241)
45 (310)

0.4
0.7
1.4
1.6
2.4
3.1

Values in ( ) are mathematical conversions from psi to kPa/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.

Connecting Vacuum Models


The vacuum instruments measure intake manifold vacuum and gives an indication of the load applied to the engine.
1. Mount the gage in a suitable location so that the face is visible and easily
accessible.

Panel

Port

Tube or
Fittings
Tubing

Gage

CAUTION: Make SURE NOT TO FOUL the pressure orifices with


pipe dope or dirt or the SWICHGAGE instrument will not operate.
2. Connect suitable tubing to the 1/8-27 NPT port of the gage and to an open

port in the intake manifold. Mounting kit V5179 is suggested and includes
tubing and necessary fittings. The manifold fitting is 1/4 NPT. Figure 3
shows a typical mounting using V5179 kit. A Murphy PD2160 is also recommended.
3. Be sure connections are tightgage will not operate properly if line leaks.

Wire
Lead(s)
Intake
Manifold
Fittings
Intake
Manifold

Figure 3

PD2160
Pulsation
Dampener

Connecting Differential Pressure Models


Differential pressure models are typically applied to indicate restriction in oil/fuel filters. The High pressure port (center mounted) is piped to the Inlet side of the filter.
The Low pressure port (top center mounted) is piped to the Outlet side of the filter.
CAUTION: Make SURE NOT TO FOUL the pressure orifices with
pipe dope or dirt or the SWICHGAGE instrument will not operate.

2. You MUST use a second wrench on the Low Pressure port when tightening tube

fittings. (Figure 4). Notice that a wrench is used for holding the low pressure port
while a second wrench will tighten the pressure tubing/hose fitting onto the port.
WARNING: Failure to use a second wrench on the low pressure
port when tightening tube fittings may result in damage to the internal
mechanisms.

1. To connect the high pressure tubing use at least 3/16 in. (5 mm) I.D. flexible

pressure tubing/hose and fittings. If using copper or rigid tubing, install at


least 12 in. (305 mm) flexible hose from the gage to the rigid tubing (to prevent damaging vibration to the gage, see Figure 2).
Gage Case
Back View

DO NOT TWIST
Low Pressure Port;
Hold Port with Wrench

IMPORTANT: NEVER exceed maximum static pressure or differential pressure ratings for your gage range; stated in chart below.
Ranges*
Available

Figure 4
Attach tubing
with Wrench

High
High
Pressure
Pressure Port
Port

0-15 (0-103) [0-1.0]


0-30 (0-207) [0-2.0]
0-50 (0-345) [0-3.5]
0-75 (0-517) [0-5.0]
0-100 (0-690) [0-7.0]

Max. Static
Pressure

Max. Differential
Pressure

Contact
Setting

200 (1.4) [14]


300 (2.1) [20]
300 (2.1) [20]
300 (2.1) [20]
300 (2.1) [20]

30 (207) [2.0]
60 (414) [4.0]
100 (690) [7.0]
150 (1.0) [10]
200 (1.4) [14]

10 (69) [0.8]
20 (138) [1.0]
30 (207) [2.0]
50 (345) [3.5]
60 (414) [4.0]

*Values are shown in psi, (kPa/MPa) and [bar]. Values in kPa/MPa and bar are mathematical
conversions from psithey do not reflect actual second scale range.

Installation 00-02-0162 page 2 of 4

Setting the Swichgage


instrument contacts

Testing the Contacts


1. With equipment running; use a 1/16 in. hex wrench to rotate contact until it

touches the pointer. Do NOT force contact against the gage pointer.
Equipment should shut down and/or alarm should operate. Reset the contact
(See Figure 5).
2. VERY IMPORTANT Each time you start the machine, observe that the
SWICHGAGE is indicating pressure or vacuum. Visual inspection and regular testing should be normal procedure to ensure proper operation and to
achieve maximum results from your Swichgage instrument.

IMPORTANT:: If the Swichgage has a lockout push button


on the face, a contact setting higher than the factory setting will
make the lockout device inoperative.
For 20PE, 25PE, 25DPE, A20PE, A25PE and A25DPE models
the switch trip point CANNOT be set at either the lowest or the highest
extremes of the scale. Trip point MUST allow for the switch reset differential.
For adjustable switch versions, the switch point is adjustable ONLY
over the lower half of the scale.

PRESSURE

1. All contacts are set using a 1/16 in. hex wrench (Figure 5).
2. Some models such as A20PE, A25PE, etc. may not have field adjustment.

Consult the factory if in doubt. For adjustable models, 1/4 turn clockwise lowers switch operating point approximately 7% of scale.
3. Observe the normal operating pressure or vacuum readings. Set the contact
slightly below minimum reading observed or slightly above minimum pressure recommended by equipment manufacturer. For differential pressure models set the contact slightly below the desired maximum differential pressure.

Switch Adjustment
(if applicable)

Figure 5

Wiring Installation
WARNING:

DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING THE WIRING INSTALLATION.

FOR BATTERY IGNITION SYSTEMS, DISCONNECT THE BATTERY GROUND STRAP. FACE ADJUSTED POINTER TYPE CONTACTS ARE PILOT DUTY. DO NOT EXCEED CONTACT RATINGS ON ANY SWICHGAGE MODEL.

20 and 25 Series models wire leads are 18 AWG or 20 AWG, 12 in. (305 mm)
long. A20 and A25 Series models have number 4 or number 6 screw terminals.
When installing the Swichgage instrument on an ungrounded panel, you MUST
provide a ground wire from the Swichgage instrument to a common ground.
Install ONLY in a 12 or 24 V system. Warning lights or audible signal must be of the
same voltage as the battery. Current draw should never exceed Swichgage contact
ratings.

The pictorial below shows typical wirings for each base model. Look for specific
typical wiring diagram with your base model number and wire accordingly.
The pointer is shown in the Shelf Position. Face adjusted pointer type contacts
are rated pilot duty 2 A @ 30 VAC/DC. Snap-switch contacts are rated 3 A @
30 VDC; 4 A @ 125 VAC.
CAUTION: On some models pointer contact and ABS switch share the same
Common. Voltage source must be the same. Maximum voltage is 30 V. Consult
factory for applications with 120 VAC systems.

CAUTION: Ordinary incandescent lights are damaging to Swichgage contacts. We recom-

mend using our direct connected alarms TL-7 flashing lamp and/or SAH mini-siren.
20DP and
25DP

20P and 25P

20P-HL and 25P-HL


20V and 25V

HIGH

LOW
Red

Red

Black

A20P

HIGH

N. C.

N. C.

N. O.

HIGH
P

HIGH

LOW
L

N. O. Black

RESET

SET

Installation 00-02-0162 page 3 of 4

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

A20P-HL and A20V

A20DP

LOW

HIGH

LOW

20PABS and
25PABS

A25DPE
N. O.
RESET

SET

N. O.

N.O.

N.C.
RESET

SET

HIGH
P

Installing The Magnetic Switch


WARNING:

DISCONNECT THE BATTERY OR POWER SOURCE BEFORE BEGINNING THE INSTALLATION.


SEE SPECIFIC WIRING INSTRUCTIONS PACKED WITH EACH MAGNETIC SWITCH OR TATTLETALE ANNUNCIATOR.

1. Mount with electrical lugs down. Drill mounting holes in panel.


2. Clean away burrs and filings. Position the magnetic switch in the

NOTE: Murphy components are easily wired and maintained. Use good quality
wire and terminals. The type of magnetic switch differs for various applications.
See typical wirings below. Wiring and instructions are packed with each magnetic switch.

panel, making sure the pilot stud is in place.


3. Add decal, then washer, then nut and tighten.

117 Magnetic Switch

20P-F Pressure

SWICHGAGE

20T-F Temperature

SWICHGAGE

Y SWICHGA
PH
GE
UR

Y SWICHGAG
PH
E
UR
F

Y SWICHGA
PH
GE
UR

20

0
0

PSI
40 60

80

20

10

300 60
0
kPa
PRESSURE

PSI
40 60

20P Pressure
SWICHGAGE

80

130

10

300 60
0
kPa
PRESSURE

160 190 220

518PH Magnetic Switch

25

60

80 100 12

NC

SW1 SW2

TEMPERATURE

N.O. SWICHGAGE
instruments

Energized To Run Devices

+
Battery

N.C. switches option

Energized To Run Devices

Battery

Troubleshooting
DO THIS FIRST: Look for broken wiring, frozen pointer, dirty contacts (will not make), burnt pointer or contact. Verify that all wiring is intact and connections are tight. Verify that Swichgage has not been damaged (hit or dropped). Verify that there is pressure/vacuum supplied to the gage. Verify that the Swichgage
is operative (it reads). Verify that the alarm or shutdown device is fully operable; and check other components such as spark plugs, ignition, fuel pump and filter, etc.
Reset magnetic switch and verify that it stays latched.
SYMPTOM

CAUSE

TEST/REMEDY

Engine will not start.

1. Short or open circuit, be sure the magnetic switch latches and puts out power to
1. Reset magnetic switch and make sure it stays latched. Refer to installthe run device or removes ground (ignition). Check for power/ground at run device.
ation instructions for 518PH magnetic switch (provided with unit).
2. Control circuit overloaded by accessories (blown fuse in magnetic switch).
2. Find blown fuse and replace (use 14 A fuse). Reroute the accessories.
3. False ground in control circuit.
3. Repair.

False shutdown.

1. Swichgage circuit has intermittent open or short.


2. Vibration causes the Magnetic Switch to trip.

1. Check all wiring and repair/replace as necessary.


2. Repair and relocate the switch as needed.

Swichgage closes but does


not trip the magnetic switch
or kill the engine.

1. Incomplete shutdown circuit.


2. Dirty Swichgage contacts.
3. Ignition not providing power to primary terminal post.
4. Swichgage case may not be grounded.
5. Incorrect magnetic switch for type of power.

1. Locate open circuit and repair.


2. Clean and check that contacts make.
3. Repair ignition.
4. Ground case.
5. Replace with correct magnetic switch.

Magnetic switch tripped but


engine is still running.

1. Open circuit between the magnetic switch and the shutdown device.
2. Lost ground to kill the engine.

1.Check wiring from magnetic switch to shutdown device, repair or replace.


2. Check all wiring and connections and repair.

Pointer will not operate


properly. Inaccurate reading.

1. Frozen pointer
2. Loose pointer spring (caused by hitting or dropping gage).
3. Plugged pressure orifice.
4. Over Pressure

1. Return for repair or replacement.


2. Return for repair or replacement.
3. Remove and clean.
4. Return for repair or replacement.

Pointer/contact burned-in two.

Without exception this condition is caused by incorrect wiring or short circuit.

Recheck wiring; replace Swichgage or return for repair.

Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

www.fwmurphy.com
918.317.4100 Email: 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.

Installation 00-02-0162 page 4 of 4

67C Series

Instruction Manual
Form 5469
May 2006

67C Series Instrument Supply Regulators

TYPE 67CF FILTER REGULATOR


WITH OPTIONAL GAUGE

TYPE 67C OR67CR REGULATOR

Figure t Typical 6 7C Series Regulators

Introduction

The Types 67C and 67CS are the standard instrument


supply regulatorswithout a filter or internal relief.

Scope of Manual

The Types 67CF and 67CFS are equipped with a


filter for removing particles from the supply gas.

This manual provides instructions and parts lists for


67C Series instrument supply regulators. Instructions
and parts lists for other equipment mentioned in this
instruction manual, as well as for other 67 Series
regulators, are found in separate manuals.

Product Descriptions
The 67C Series direct-operated regulators are
typically used to provide constantly controlled,
reduced pressures to pneumatic and electropneumatic
controllers and other instruments. They are suitable
for most air or gas applications. Other applications
include providing reduced pressures to air chucks, air
jets, and spray guns.

The Types 67CR and 67CSR have an internal


relief valve with a soft seat for reliable shutoff with no
discernible leakage.
The Types 67CFR and 67CFSR have a filter and
internal relief valve with a soft seat for reliable shutoff
with no discernible leakage.

Specifications
Some general 67C Series ratings and other
specifications are given on page 2. A label on the
spring case gives the control spring range for a given
regulator as it comes from the factory.

EMERSONL

Process Management

Section 10 Lubrication System


Vendor

Bulletin No.

Separators Drain Piping.................................................. Ajax

01-23-T01A-301

Crankcase Drain Piping....................................................Ajax

02-23-T010-317

Oil Reservoir Piping with Day Tank..................................Ajax

TP 00-24-T01B-001

Kim Hotstart Oil Heater Piping..........................................Ajax

TP 04-02-T010-317

Kim Hotstart O & M...........................................................KHT


Lube Op System Schematic........................................... Prog.

2802-MA-F-MCP

SMX Divider Valve Bulletin......................................................... Prog.


DLM-926 Operation and Wiring ................................................. Deliron

DLM-926

Proximity Switch Bulletin ............................................................ Deliron

169LIT D-PRXSW

Rupture Disc Drawing .................................................... Ajax

BM-21138

Lubricator Pump, Model P-55UR,

............................. Ajax

BM-21136-1

Lubricator Pump, Model P-55UR, ............................. Ajax

BM-21137-1

Operation and Maintenance of Divider Block Lubrication


Systems2001(used with permission)
Crankcase Oil Level Controller & Switch, LM301
Installation and Operation........................................................ Murphy

Engine-Compressor Package Service Manual

LM-92164N

Drain the air scavenging chambers


every 800 hours of operation.

WARNING
Drain the compressor crosshead
guides every 800 hours of operation.
Record the amount of oil collected.
Unusual amounts of oil indicate
excessive cylinder or packing
lubrication rates, or worn wiper
packing.

Do not open the scavenging chamber


drains while the engine is running.
Unstable combustion and rpm control
may result.
Record the amount of oil collected per
cylinder.
Unusual amounts of oil indicate
excessive cylinder lubrication rates, or
worn wiper packing.

Drain the crankcase every 8000 hours of operation.


Perform crankcase maintenance requirements.
Refill with 30 gallons of oil per Engineering
Standard # ES 1006.
Also, see TP 00-24-T01A-001 in Tab 10.

DPC-2802 Crosshead Guide,


Scavenging Chamber,
& Frame Drains
TP 01-23-T01A-301

DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains


TP 01-23-T01A-001
Item
1
2
3
4
5
6

Description
Ball Valve, 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

DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains


TP 01-23-T01A-001

P/N

Qty

Approximate crankcase oil capacity = 30 gallons (U.S.)


The correct full oil level is determined when the engine
is stopped.

Full crankcase oil level = 27.5 from the frames top


machined surface to the surface of the oil.
Set the level controllers safety shutdown point while
the engine is running.

Crankcase oil level controller


& low level limit switch
p/n: BM-21072

Frame Mounted Lube Oil Reservoir


TP 00-24-T01B-001 rev 1

Frame Mounted Lube Oil Reservoir


TP 00-24-T01B-001 rev 1
Item

Description

P/N

Qty

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Oil Reservoir, 55 Gallons


Ball Valve, "NPT, 600#
Male Tubing Elbow, " Tube x " NPT
" Flat Bar, 1"
" Flat Bar, 1"
" Strap,1"x 51"L (Form To Fit Reservoir)
Male Connector , " Tube x " NPT
Pipe Nipple, Sch 80, "NPT x 3"L
Oil Reservoir Support Stand
Plug, " Tube Fitting
Rubber Pad, " Thk. x 3"W x 30"L
Street Elbow, Std, "NPT
" Tubing Tee
Tubing, 316SS, " x 0.035 Wall
Tubing, 316SS, " x 0.035 Wall
Tubing, 316SS, " x 0.035 Wall
Tubing, 316SS, " x 0.035 Wall
" Tubing Union

6553 5500
2549 2094
2507 4204
7040 0210
7040 0210
7040 0110
2507 1404
2539 4414
800-1000-00013
2513 9500
6840 3000
2535 7004
2507 6504
5551 3508
5551 3508
5551 3508
5551 3508
2507 8004

1
3
1
4"
8"
2
3
1
1
1
2
1
1
23.3"
66.4"
2"
64.1"
1

Item

Description

P/N

Qty

Warning

Connect to the Engines.prelube pipe cross fitting.


Refer to Manuals Section 3, drawing Modified 1704-000
Remove pipe plug, item 14, from pipe cross, item 13, and
install tube fitting, item 9, shown below.

All repair and resetting of safety relief


valves should be performed by a National
Board certified valve repair shop holding a
VRstamp.
Replaceable element
p/n 6522 0005.

Connect to the Engines crankcase drain.


Refer to Manuals Section 10, drawing TP 04-23-T01A-001
Replace pipe elbow, item 5, at pipe nipple, item 8, with
pipe tee, item 16, shown below.

Connect to the
Oil Outlet of the
Oil Heater
To Kim Hotstart Pressure Switch
Connect to the Oil Inlet
of the Oil Heater

See TP 04-02-T010-316 in Tab 5


for Connection Details

To Water Pump Housing

Circulating Heating System COLER 3180/0603-08B1


Refer to vendors Installation & Operating
instructions included in Section 10.
Refer to the General Arrangement drawings for
mounting location.

To Kim Hotstart Water Outlet

To Kim Hotstart Water Inlet

Circulating Heating System


Inlet & Outlet Tubing
TP 04-02-T010-317

Circulating Heating System Inlet & Outlet Tubing


TP 04-02-T010-317
Item

Description

P/N

Qty

Item

1
2
3
4
5
6
7
8
A
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Ball Valve, " NPT


Ball Valve, 1" NPT
Bushing, 1" x 1" NPT
Bushing, 1" x " NPT
Elbow, " NPT
Tubing Elbow, Male, 1" Tube x 1" NPT
Kim Hotstart Oil Heater COLER 3180/0603-08B1
LHA Spin On Oil Filter
Filter Element
Tubing Connector, Male, " Tube x " NPT
Tubing Connector, Male, 1" Tube x 1" NPT
Pipe Nipple, Sch 80, " NPT x 2 "
Pipe Nipple, Sch 80, " NPT x 3 "
Pipe, Sch 80, "
Relief Valve Set At 25 psig, 1" x 1"
Tee, " NPT
Tee, 1" NPT
Tee, 1" NPT
Tubing, 316SS, " x 0.049 Wall
Tubing, 316SS, " x 0.049 Wall
Tubing, 316SS, " x 0.049 Wall
Tubing, 316SS, 1" x 0.049 Wall
Tubing, 316SS, 1" x 0.049 Wall
Tubing, 316SS, 1" x 0.049 Wall
Tubing, 316SS, " x 0.049 Wall
Union " NPT
Union Tubing "
Rubber Hose, 1"
Straight Hose Connector, 1"
Rubber Hose, 1"
Straight Hose Connector, 1"
Hose Clamp " x 1"
Connector " x "
Tubing " x .049 wall
Bushing, 1-" x 3"

2549 2065
2549 2085
2527 1410
2527 1006
2535 4006
2507 4808
6390 2098
6522 0003
6522 0005
2507 1606
2507 1808
2539 4508
2539 4514
4053 0065
63ME2M2FTA0025
2545 4006
2545 4014
2545 4010
5551 4912
5551 4912
5551 4912
5551 4916
5551 4916
5551 4916
5551 4912
2547 5006
2507 8006
3521 4018
2520 3020
3521 4016
2520 3016
2520 9106
2507 1202
5551 4904
2539 4814

3
1
1
4
2
1
1
1
1
6
3
9
2
14"
1
4
1
1
174"
30"
6"
120"
36"
100"
120"
2
1
1
2
1
2
4
2
20 ft
2

35
36
37

Description
Ball Valve
Bushing, 1-" x 1-"
Ball Valve, 1-"

P/N
2549 2142
2527 1412
2549 2142

Qty
1
2
1

OER & OWT


Oil Heating System
Installation & Operation Manual

216203-000 rev 3

KIM HOTSTART Mfg., Co., Inc.


P.O. Box 11245
Spokane WA 99211-0245
Customer Support: (509) 536-8660

NOTICE
When ordering replacement parts for your heating
system, always reference the heating 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.

Identifying Your System


Kim Hotstart OWT and OER oil heating systems are compact oil heating systems designed for
use in marine propulsion, diesel-powered generator sets, or any large-engine applications. These
models are pre-wired, pre-plumbed, and assembled on a steel plate and mounting channel. Each
heating system has an identification plate usually located next to the control box. An example of
the identification plate is shown on the following page.
NOTE: When ordering replacement parts, be sure to reference your heating systems
model and serial numbers found on the identification plate.
Model numbers ending in other than Xnn are custom systems. Reference the
drawings included with your system for parts specific to your system.

ii

iii

Table Of Contents
NOTICES........................................................................................................................................ i
IDENTIFYING YOUR SYSTEM ................................................................................................ i
HEATING SYSTEM OVERVIEW.......................................................................................... 1-1
Oil Water Tight (OWT) Standard Models .................................................................. 1-2
Oil Explosion Resistant (OER) Standard Models....................................................... 1-4
The Kim Hotstart System.............................................................................................. 1-5
Lube Oil Inlet/Outlet Process .................................................................................... 1-6
Lube Oil Flow Detection ........................................................................................... 1-7
INSTALLATION AND SYSTEM START-UP....................................................................... 2-1
Basic System Installation............................................................................................... 2-1
Main Power Supply.................................................................................................... 2-1
Oil Supply Line.......................................................................................................... 2-2
Oil Discharge Line..................................................................................................... 2-4
System Mounting Requirements .................................................................................. 2-5
Lube Oil Pump........................................................................................................... 2-5
System Start-Up ............................................................................................................. 2-6
Lube Oil Heating System Start-Up ............................................................................ 2-6
SYSTEM COMPONENTS ....................................................................................................... 3-1
Control Box..................................................................................................................... 3-1
Time Delay Relay ..................................................................................................... 3-2
Magnetic Contactors .................................................................................................. 3-2
Remote Control.......................................................................................................... 3-2
Motor Protective Switch ............................................................................................ 3-3
Other MPS Features................................................................................................... 3-4
Fuses ........................................................................................................................ 3-4
Transformer................................................................................................................ 3-4
Oil Heating Tank Assembly .......................................................................................... 3-5
Heating Tank Assembly Parts ...................................................................................... 3-6
Heating Element Replacement................................................................................... 3-6
High-Limit Thermostat Replacement ........................................................................ 3-8
System Thermostat Replacement............................................................................... 3-9
Tank O-Ring ............................................................................................................ 3-10
Flow Detection Switch............................................................................................. 3-10
Pump and Motor Assembly......................................................................................... 3-11

iv

Oil Pressure Switch...................................................................................................... 3-11


SYSTEM MAINTENANCE ..................................................................................................... 4-1
Control Box..................................................................................................................... 4-1
Plumbing Connections................................................................................................... 4-1
Electrical Connections ................................................................................................... 4-1
Electrical Contacts ......................................................................................................... 4-1
Heating Tank.................................................................................................................. 4-2
Flow Detection Switch ................................................................................................... 4-3
Pump and Motor Assemblies ........................................................................................ 4-4
System Mounting ........................................................................................................... 4-4
Troubleshooting ............................................................................................................. 4-5
APPENDIX A
SYSTEM DRAWINGS............................................................................................................. A-1

Heating System Overview


The Kim Hotstart Oil Water Tight (OWT) and Oil Explosion Resistant (OER) lube-oil
circulating heating systems for industrial engines are designed and constructed for ease of
operation and minimal maintenance. These heating systems are just a few of a variety of
products available to meet your cold start requirements. Each unit is a unique pre-heating system
that eliminates needless engine idling and results in:

Quicker engine start-up in cold weather

A reduction in engine oil consumption

Significant operations and fuel savings

Consistent engine temperature

A reduction in engine wear

Minimal maintenance

Fail-safe protection

Engine
for Pre-Lubing

for Continuous Lubing


Oil Sump

Oil Outlet
Check Valve

Oil Heating
System
OFF ON

owtlg1.eps

Oil Inlet
Shut Off Valve

Section 1 Heating System Overview

engoil.eps

1-1

Oil Water Tight (OWT) Standard Models


The OWT models shown on the following page are designed according to the NEMA 12
standard and come in three oil-pumping capacities: small, medium, and large. All
standard small-, medium-, and large-capacity OWT models share the same design in
operation and component layout. The major differences between models are the motor,
pump, and heating element (in the tank assembly). The standard OWT models are listed
below. Other features included are:

Adjustable pressure switch or electronic signaling for automatic operation

A universal mounting platform for compatibility with various mounting


configurations

80 to 100F fixed-thermostats with 140F high limit

An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for
manual prelube.

VITON mechanical seal pumps for extended seal life

Flow detection switch for fail-safe operation

OIL WATER TIGHT (OWT) STANDARD MODELS

Part No.
OWT10252
OWT1025C
OWT3025D
OWT30254

Capacity (Gallons)
25 to 100
25 to 100
25 to 100
25 to 100

SMALL CAPACITY
KW
Voltage
Hertz
2.5
240V
60
2.5
240V
50
2.5
380V
50
2.5
480V
60

Phase
1
1
3
3

Amps.
18.1
18.1
7.5
5.9

HP/GPM
1 HP/2.8 GPM
1 HP/2.4 GPM
1 HP/2.4 GPM
1 HP/2.8 GPM

Part No.
OWT10602
OWT1060C
OWT3060D
OWT30604

Capacity (Gallons)
75 to 250
75 to 250
75 to 250
75 to 250

MEDIUM CAPACITY
KW
Voltage
Hertz
6
240V
60
6
240V
50
6
380V
50
6
480V
60

Phase
1
1
3
3

Amps.
33
33
12.9
10.2

HP/GPM
1 HP/10 GPM
1 HP/8.3 GPM
1 HP/8.3 GPM
1 HP/10 GPM

Part No.
OWT10902
OWT1090C
OWT3090D
OWT30904

Capacity (Gallons)
200 to 500
200 to 500
200 to 500
200 to 500

LARGE CAPACITY
KW
Voltage
Hertz
9
240V
60
9
240V
50
9
380V
50
9
480V
60

Phase
1
1
3
3

Amps.
53.4
53.4
19.6
16.6

HP/GPM
2 HP/20 GPM
2 HP/16 GPM
2 HP/16 GPM
2 HP/20 GPM

Section 1 Heating System Overview

1-2

OWT and OER Configurations

Section 1 Heating System Overview

1-3

Oil Explosion Resistant (OER) Standard Models


All OER models are designed to meet Explosion Resistant Class 1, Group D, Division 1
and 2, and NEMA 4 standards. The OER models come in three oil-pumping capacities:
small, medium, and large. All standard small-, medium-, and large-capacity OER models
share the same design in operation and component layout. The major differences between
models are the motor, pump, and heating element (in the tank assembly). The standard
OER models are listed below. Other features included are:

Adjustable pressure switch or 24VDC relay for automatic operation

A universal mounting platform for compatibility with various mounting


configurations

80 to 100F fixed-thermostats with 140F high limit

An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for
manual prelube

PVC jacketed MI cabling (resistant to sour gas)

VITON mechanical seal pumps for extended seal life and temperature operation (to
350F)

Flow detection switch for fail-safe operation

An external motor-protective-switch RESET button

OIL EXPLOSION RESISTANT (OER) STANDARD MODELS

Part No.
OER10252
OER1025C
OER3025D
OER30254

Capacity (Gallons)
25 to 100
25 to 100
25 to 100
25 to 100

SMALL CAPACITY
KW
Voltage
Hertz
2.5
240V
60
2.5
240V
50
2.5
380V
50
2.5
480V
60

Phase
1
1
3
3

Amps.
18.1
18.1
7.5
5.9

HP/GPM
1 HP/2.8 GPM
1 HP/2.4 GPM
1 HP/2.4 GPM
1 HP/2.8 GPM

Part No.
OER10602
OER1060C
OER3060D
OER30604

Capacity (Gallons)
75 to 250
75 to 250
75 to 250
75 to 250

MEDIUM CAPACITY
KW
Voltage
Hertz
6
240V
60
6
240V
50
6
380V
50
6
480V
60

Phase
1
1
3
3

Amps.
33
33
12.9
10.2

HP/GPM
1 HP/10 GPM
1 HP/8.3 GPM
1 HP/8.3 GPM
1 HP/10 GPM

Capacity (Gallons)
200 to 500
200 to 500
200 to 500
200 to 500

LARGE CAPACITY
KW
Voltage
Hertz
9
240V
60
9
240V
50
9
380V
50
9
480V
60

Phase
1
1
3
3

Amps.
53.4
53.4
19.6
16.6

HP/GPM
2 HP/20 GPM
2 HP/16 GPM
2 HP/16 GPM
2 HP/20 GPM

Part No.
OER10902
OER1090C
OER3090D
OER30904

Section 1 Heating System Overview

1-4

The Kim Hotstart System


The Kim Hotstart standard OWT and OER medium pumping capacity models are shown
below. All models (small, medium, and large) are identical in operation. Each heating
system consists of a lube oil heating process. The oil is continuously circulated through
the heating tank. Only the heating element inside the tank is cycled on and off. The
heating element is controlled by a thermostat sensing unit located at the inlet of the
heating tank. The lube oil inlet/outlet and heating process is described on the following
page. All oil systems are designed to maintain warm-oil take over. They are not
designed to take over on a cold-oil start up.
Oil Water Tight (OWT) NEMA 12 Model
Oil Outlet
Oil Tank

OFF ON

NEMA 12
Control Box

Oil Motor
and Pump

Oil Inlet

Oil Explosion Resistant (OER) Model


Oil Outlet
Oil Tank

RESET

OFF ON

Oil Inlet
Explosion Resistant
Control Box

Oil Motor
and Pump

2med.eps

Heating Element in Tank

tank1.eps

Section 1 Heating System Overview

1-5

Lube Oil Inlet/Outlet Process


Upon a system start-up, engine lube oil is taken from at least 2-inches above the lowest
point of the lube oil sump and circulated by a positive displacement rotary gear pump
through the oil heating tank and back to the engine. Options are available on the return
line. In most cases, heated oil is circulated directly back to the oil sump.
Other options include: continuous lubing and pre-lubing before start-up.

The system must be mounted as low as possible to minimize suction lift to the pump.

The size of the oil supply line must be calculated using the supplied table. Please refer to
section 2-2 and 2-3.

The Oil supply line may be flexible or rigid and must be sized to the pump.

The 7 to 10gpm pump must have at least a 1-inch I.D. line.

The 16 to 30gpm pumps must have at least a 1-inch I.D. line.

Oil must be taken from at least two inches above the bottom of the sump.

Place full-flow valves in the supply and discharge lines to allow for maintenance. Valve
size must conform to the line size.
Kim Hotstart heating systems should be mounted as near as possible to the suction port
on the oil sump. If possible mount the pump below the level of the oil to provide flooded
suction to the pump. The oil suction plumbing is critical to the proper operation of
the heating system. If the suction plumbing is under-sized, to long or has too many
fittings in it, the pump will not work correctly. Some of the problems this can cause are:
Pump seal leaking, cavitation, oil foaming and break down, noisy pump, excessive
vibration, and internal pump damage.

Section 1 Heating System Overview

1-6

For heating, the heating system continuously pumps oil to the 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.

Lube Oil Flow Detection


Following lube oils inlet and
circulation through the heating tank,
the oil passes through a flow
detection switch. The flow
detection switch immediately shuts
off the heating element anytime
there is an interruption or loss of
flow, and activates the time delay
relay located inside the control box.
The pump continues to circulate the
oil to restore flow.
If proper flow is not reestablished,
the time delay relay shuts down the
entire heating system according to a
preset time. The time delay relay is
adjustable from 0 to 180 seconds.
Upon an initial system start-up, the
time delay relay should be adjusted
to the maximum of 180 seconds.
Once flow is achieved, Kim
Hotstart recommends a setting of 30
seconds.

OWT Model
Flow Detection
Switch

OFF ON

L1 L2 L3
513

Time Delay Relay

OER Model

Flow Detection
Switch

RESET

OFF ON

L1 L2 L3

trelay.eps
2inbx.eps

This automatic system shut-down


Time Delay Relay
feature protects the heating element
and other major components from
damage. The time delay relay and flow detection are discussed in more detail in Time
Delay Relay and Flow Detection Switch sections of this manual.
NOTE:

Heating elements vary. All standard voltages and a variety of wattages


are available. To accomplish any temperature range requirement, a
variety of thermostats are also available in our custom units.

Upon a system shut down, the heating system must be reset and restarted. For complete
system start-up instructions, refer to System Start-Up section in this manual.

Section 1 Heating System Overview

1-7

Installation and System Start-Up


The Kim Hotstart OWT and OER heating systems come pre-wired and pre-plumbed for ease of
installation. This section describes proper installation of the basic OWT or OER heating
systems. Complete step-by-step instructions for system start-up are also included in this section.
If you need additional assistance installing or starting your particular system, please contact:
Kim Hotstart Manufacturing Company
(509) 536-8660

Basic System Installation


Following are complete instructions for proper installation of the:

Main Power Supply


Oil Supply Line
Oil Discharge Line

CAUTION:

VIBRATION DURING SHIPMENT OF THE HEATING SYSTEM CAN


CAUSE SCREWS IN THE CONTROL BOX TO LOOSEN. PLEASE
CHECK ALL CONNECTIONS IN THE CONTROL BOX AFTER
INSTALLATION AND PERIODICALLY DURING OPERATION.

Main Power Supply


Connect the specified voltage and phase to the terminal block located in the main control
box. For 3-phase applications, the terminal block is labeled L1, L2 and L3. For single
phase applications, the terminal block is labeled L1 and L3.
The heating element and the circulating pump of the heating system derive power from
the main power source to the system. The circuitry in the control box determines the duty
cycle of the heating element and circulating pump. A transformer, which drops the main
supply voltage to 120 VAC, powers the control circuit. The transformer and control
circuit are overload protected with fuses.
OWT Model

OER Model

L1 L2 L3

L1 L2 L3

513

L123.eps

Transformer
Fuses
Terminal Block

Section 2 Installation and System Start-Up

Transformer

Fuses

Terminal Block

2-1

Oil Supply Line


Kim Hotstart heating systems should be mounted as near as possible to the suction port
on the oil sump. If possible, mount the pump below the level of the oil to provide
flooded suction to the pump. The oil suction plumbing is critical to the proper
operation of the heating system. If the suction plumbing is under-sized, too long or has
too many fittings in it, the pump will not work correctly. Some of the problems this can
cause are: Pump seal leaking, cavitation, oil foaming and break down, noisy pump,
excessive vibration, and internal pump damage.
The pump requires not more than 15inHg ( 7.5psi ) suction lift to the pump. The
factors that control that are: The height the pump is above the top of the oil in the sump,
the viscosity of the oil, the size and configuration of the suction line, and the altitude
(barometric pressure).
The suction line size must be determined using the following calculations:
Determine each of the 3 following values and add them together to determine if your
system meets the requirements of less than 7.5psi suction lift. SAE 40 motor oil is
used for these calculations. If your calculated value is too high, increase the line size or
move the heater closer to the suction port of the engine. These figures are only estimates.
The flow rate of the pump on your system is listed on page 1-4 of this manual. The table
on the next page shows friction losses in a smooth line at specified flows. Use the table
on 2-3 to determine the frictional losses in the line you intend to use.
If the pump is above the oil level to calculate the suction pressure multiply the number
of feet the pump is above the oil level by 0.38 to get the psi of the suction lift. If the
pump is below the oil level this can be negative.
Next, determine the altitude the pump will be at. For every 1000 feet above sea level
multiply that number by 0.5 to get psi loss for altitude (barometric pressure).
Add the three numbers together. If they are greater than 7.5 psi reduce your pipe length
or increase the diameter to reduce the frictional losses from the pipe. If they are less than
7.5psi your pump should work properly.

If the oil supply line is excessively long or the heating tank is mounted higher than
the sump, install a check valve near the oil supply to prevent oil from draining back
to the sump when the heating system is off. Installation of a check valve also
eliminates repeated priming of the pump on heating system start-up. Make sure all
suction pipe connections are tight. A loose connection will not allow the pump to
circulate oil.

To allow for heating system maintenance without draining the engine sump, install a
shut-off valve between the sump and the rotary gear pump.

To minimize foreign material from entering the heating system, install the suction
line at least 2 inches above the lowest point of the oil sump.

NOTE: To avoid premature failure of the heating element, be sure to position the
heating tank so that a complete oil fill is accomplished while in operation.

Section 2 Installation and System Start-Up

2-2

VIKING OIL PUMP SUCTION LINE SIZING CHART


(SAE 40 MOTOR OIL AT 80 - 100 Of)

FIND LINE SIZE & LENGTH THAT WILL PROVIDE LESS THAN 7.5psi SUCTION LIFT
INCLUDING ADDERS FOR PUMP LEVEL AND ALTITUDE (SEE "ADD" BELOW)

Line Size ID
0.75in
1in
1.25in

2-3 gpm friction losses in


length (psi)
5
6
7
8
9
10
4.0

4.8

5.5

6.3

1.5

1.8

2.2

2.5

2.8

3.1

3.1

3.7

4.3

4.9

5.5

6.2

0.5

0.6

0.7

0.8

1.0

1.1

1.0

1.2

1.4

1.6

1.8

2.0

0.6

0.7

0.8

0.9

1.0

1.1

1.5in

Line Size ID
1in
1.25in
1.5in

10 gpm friction losses in length


(psi)
5
6
7
8
9
10

20 gpm friction losses in


length (psi)
5
6
7
8
9
10

4.4

5.3

6.2

7.0

1.5

1.8

2.1

2.4

2.7

3.0

2.9

3.4

4.0

4.6

5.1

5.7

0.8

1.0

1.1

1.3

1.4

1.6

1.6

1.9

2.2

2.5

2.9

3.2

0.6

0.7

0.8

0.9

1.0

1.1

2in

Line Size ID
1.25in
1.5in
2in

7 gpm friction losses in


length (psi)
5
6
7
8
9
10

25 gpm friction losses in length


(psi)
5
6
7
8
9
10

30 gpm friction losses in


length (psi)
5
6
7
8
9
10

3.6

4.3

5.1

5.8

6.5

7.2

4.4

5.3

6.2

7.0

2.0

2.4

2.8

3.2

3.6

4.0

2.3

2.7

3.2

3.7

4.1

4.6

0.7

0.9

1.0

1.2

1.3

1.5

0.9

1.1

1.2

1.4

1.6

1.8

0.4

0.5

0.6

0.7

0.8

0.9

2.5in

ADD:
FOR EVERY FOOT PUMP IS ABOVE OIL LEVEL ADD: 0.38 psi / foot
FOR EVERY 1000 FOOT ABOVE SEA LEVEL ADD: 0.5 psi / 1000 feet

Section 2 Installation and System Start-Up

2-3

Oil Discharge Line


Connect a 1-inch or 1 1/2-inch N.P.T. line from the heating system outlet to the engine
sump. Size the pipe line according to the size of the pumps outlet port. For large capacity
OWT and OER systems, the outlet port normally takes a 1 1/2-inch I.D. pipe. For small
and medium capacity OWT and OER systems, the outlet port normally takes a 1-inch
I.D. pipe.
Note: Upon completion of oil return line installation, top off oil levels to
compensate for the oil used to fill the lines and heating tank.

Section 2 Installation and System Start-Up

2-4

System Mounting Requirements


Be sure to mount the Kim Hotstart OWT or OER heating system as low as possible with
the discharge line exiting from the top of the OWT or OER heating system. This allows
the heating tank to completely fill at all times and prevents premature element failure.
Turn OFF the heating system before starting up the engine.

Lube Oil Pump


The Kim Hotstart OWT or OER heating system heats the lube oil and can continuously
heat the engine, or pre-lube it before start-up. On the suction side of the Kim Hotstart
lube oil pump, oil is taken from at least 2-inches above the lowest point of the oil sump
(not directly at the bottom of the oil sump) and pumped through the OWT or OER
systems heater and discharged back to the engine. The discharge oil line should be sized
according to the size of the pumps discharge port. The Kim Hotstart lube pump can be
configured for continuous heating, or teed off with (solenoid or manual) valving for prelubing the engine prior to start-up.
NOTE: All oil pump relief valves are preset to 50 PSI.

Section 2 Installation and System Start-Up

2-5

System Start-Up
After system installation has been completed, follow these steps for proper OWT or OER
heating system start-up.

Lube Oil Heating System Start-Up


Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Open the control box. Turn the control knob on the oil time delay relay inside
the control box clockwise to the maximum setting of 180 seconds.
OWT Model

OER Model

Time Delay
Relay
Time Delay
Relay

L1 L2 L3

L1 L2 L3

513

trelay2.eps

Step 3 Energize the oil heating system by turning the switch on the control box to the
ON position. The red light on the control panel is lit. Bump start the system (by
rocking the power switch ON and OFF) and check for proper rotation of the
motor/pump assembly. If the pump motor is turning the wrong direction, switch
any two electrical leads on the POWER IN block located in the control box for 3
phase systems.
WARNING: DO NOT RUN THE MOTOR/PUMP ASSEMBLY DRY.
Step 4

If the minimum flow rate is not achieved or flow restriction in the suction line
has occurred, the heating system will automatically shut down approximately 3
minutes after start-up. Turn the system OFF and check plumbing lines for any
leaks or restrictions. Air entrapment may also occur in the oil lines or pump.
Repeat steps 2, 3, and 4.
NOTE:

Step 5

On initial start-up, it may take several attempts to achieve proper


flow.

Once operation is satisfactory; turn the control knob on the oil time delay relay
to the desired setting. Kim Hotstart recommends a setting of 30 seconds. Turn
the heating system off and then back on to activate a new setting.

Section 2 Installation and System Start-Up

2-6

System Components
This section describes the components used in the Kim Hotstart OWT and OER heating systems,
including the:

Control Box
Heating Tank Assembly
Pump and Motor Assembly

Control Box
The control boxes used in the Kim Hotstart OWT and OER heating systems are shown
below. Both models are identical in operation. The control boxes contain the electrical
control components for the lube oil heating system.
Following is an overview of operation and replacement instructions for the standard parts
located in the control box, including:

Time Delay Relay

Magnetic Contactors

Motor Protective
Switch

Fuses

Transformer

Parts in the control box


may vary, depending on
the particular system
configuration you
purchased. For your
convenience, available
replacement parts are
listed.
NOTE: A Vaseline
type petroleum film
should be kept on the
machined surface of
OER boxes as a barrier
to external
contaminates. All bolts
must be kept in place
and torqued to 55 ft.
lbs.

Section 3 System Components

3-1

Time Delay Relay


The time delay relay is a safety device that works in conjunction with the flow detection
switch. If, for any reason, the heating systems minimum flow rate (G.P.M.) is
interrupted, the flow detection switch immediately shuts off the heating element and
activates the time delay relay.
The time delay relay allows the pump/motor to operate for a preset length of time, from 0
to 180 seconds, in an attempt to restore the heating systems minimum flow rate. The
recommended preset time is 30 seconds. If the minimum flow rate is not achieved by the
preset time, the time delay relay automatically shuts down the entire heating system,
preventing damage to the heating element and pump/motor. The system will then have to
be restarted manually. The time delay relays for OWT and OER models are shown in the
illustration on the previous page.
To reset the time delay relay, turn the system power OFF and follow the step-by-step
instructions for system start-up described in the Installation and System Start-Up section
of this manual. The time delay relay requires no maintenance. To order a replacement,
reference the replacement part number listed below.
Time-Delay Relay Replacement Part Number: PRP224046-000

Magnetic Contactors
Because of their low drop out voltage, definite purpose magnetic contactors (shown on
the previous page) are used as voltage switching controls in Kim Hotstart OWT and OER
heating systems. The contactors use 120 volt coils. In case of contactor failure, check
the coil voltage for continuity.
The contactor contacts are made of silver cadmium oxide and should be inspected
periodically for welding, arc erosion, and mechanical wear. If any of these conditions
exist, clean the contacts or replace the contactor.
Magnetic Contactor Replacement Parts
Amps

Voltage

Hertz

Part Number

30 (32A Resistive)

120

50/60

PRP232047-000

60 (65A Resistive)

120

50/60

PRP232049-000

Remote Control
The OER and OWT systems are both equipped with a pressure switch or a 24VDC relay
for remote switching of the heater. The pressure switch is designed to plumb into the
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

Motor Protective Switch


The Motor Protective Switch (MPS) used in your Kim Hotstart heating system was
engineered to achieve a level of quality that is unsurpassed in the industry. The MPS
(shown below) provides short-circuit protection, thermal overload protection, switching
and signaling.
Short Circuit Protection
A wide variety of applications range from 0.1 to 25 FLA at voltages up to 600V. In the
event of a short circuit, the contacts are opened by non-adjusting, magnetic tripping
elements in less than 1 /1000 of a second. This results in the extremely rapid buildup of
an arc voltage that limits the current of the short circuit to a very low level. Because of
this superb current limiting capability, the MPS has an extremely high short-circuit
capacity of 50 KA at 600V.
Motor Overload Protection
Each MPS is calibrated at the factory for the smallest and largest current to ensure an
accurate time/current characteristic curve. In addition, the MPS is a Class 10 device
that will trip within 10 seconds under a locked rotor condition (6 x FLA). The MPS
provides protection from single-phase conditions at a maximum of 1.25 x FLA.
Accurate adjustment of the overload trip ensures effective motor protection even with
a phase loss. To maintain constant trip times, the MPS is also equipped with automatic
ambient temperature compensation that continually adjusts to surrounding temperatures.

ST

T
R

START
(GREEN)

ST

P T
TO E
S ES
R

TEST

STOP
RESET
(RED)

T1

T2

T3

TO RESET THE SWITCH


1. Press red STOP RESET button.
TE

ST

2. Press the green START button.

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

Switch tripped if both buttons are up

TA

BUTTON POSITIONS
NEUTRAL
NORMAL

On OER models, to reset


the switch, simply press the
RESET button on the
control boxs lid.

Motor Protective
Switch

P T
TO E
S ES
R

Reset Buttons
Both the OWT and OER
control boxes contain a
motor protective switch to
safeguard against overloads
and short-circuits.

resetsw.eps

1. Check the position of


the green START and the red STOP RESET buttons on the motor protective switch.
In normal operation the red STOP RESET button is up and the green START button is
down.
2. If both buttons are up, the switch has been tripped. To reset, first press the red STOP
RESET button and then press the green START button.

Section 3 System Components

3-3

Other MPS Features

UL and CSA listed for group installations.

Trip-free mechanism prevents manual closure on short circuits or overloads.

Tripped ON and OFF push-button indicators are placed vertically on the device for
easy detection of which unit has tripped if using more than one MPS.

A full line of snap-on accessories include side mount auxiliary contact blocks.

The MPS requires no maintenance.


MPS Replacement Parts
Amps

(Range)

Part Number

1.0

(0.6 - 1.0)

PRP232036-000

1.6

(1.0 - 1.6)

PRP232036-001

2.5

(1.6 - 2.5)

PRP232036-002

4.0

(2.5 - 4.0)

PRP232036-003

6.3

(4.0 - 6.3)

PRP232036-004

10

(6.3 - 10.0)

PRP232036-005

16

(10.0 - 16.0)

PRP232036-006

Fuses
There are two different types of fuses located in the control box:
Transformer Primary
This type of fuse provides short-circuit protection to the transformer.
Transformer Secondary
This type of fuse provides secondary current protection for the control components.
NOTE: The physical size and shape of the oil heating element fuses vary. Order
replacement fuses by system part number and serial number.

Transformer
The transformer is an electrical component that steps down the primary voltage to 120
volts. Wiring information is listed on the top of the transformer. This transformer is
normally overload protected with two fuses.

Section 3 System Components

3-4

Transformer Replacement Parts


System Voltage

Transformer Part Number

208

PRP235062-000

240

PRP235030-000

277

PRP236052-000

380

PRP235050-000

400

PRP235050-000

415

PRP235050-000

480

PRP235030-000

575

PRP235050-000

600

PRP235050-000

Oil Heating Tank Assembly


The lube oil heating tank
assembly is shown (right).

Oil Water Tight (OWT) NEMA 12 Model


Oil Outlet

Following is an overview of
operation and replacement
instructions for the standard
heating tank assembly parts,
including:

Oil Tank

OFF ON

Oil Heating Element

Oil High-Limit Thermostat


Sensing Unit

Oil System Thermostat


Sensing Unit

Optional lube oil heating tank


assembly parts include:

NEMA 12
Control Box

Oil Motor
and Pump

Oil Inlet

Oil Explosion Resistant (OER) Model


Oil Outlet

Solenoid Valves

Heating tank assembly parts


may vary slightly, depending on
your particular system
configuration. For your
convenience, available
replacement parts are also
listed.

Oil Tank

RESET

OFF ON

Oil Inlet
Explosion Resistant
Control Box

Section 3 System Components

Oil Motor
and Pump

2med.eps

3-5

Heating Tank Assembly Parts


Heating Element Replacement
The heating element, shown below, heats the engine oil. The oil tank has a high-limit
temperature sensing unit in the cup of the heating element housing. Instructions for
disassembling the high-limit sensor follow. To order a new oil heating element, refer
to the part number on the heating element label.
NOTE: The oil heating system is designed to maintain the temperature of warm
lubricating oil. Be sure to run the engine until the oil is warm prior to
starting the oil heating system. If the heating system is energized when the
engine is cold, you may trip the motor protective switch. If tripped, this
switch must be manually reset.

To replace the heating element or perform routine maintenance, follow these steps. Be
sure to allow at least 30 inches of space for element removal. The wattage and phase of
the heating element are listed on the identification label on the outside of the element.
WARNING
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THE HEATING SYSTEM.
Cap

Step 1 Turn the Kim Hotstart Heating system OFF.


Step 2 Drain the fluid from the heating tank.

Heating Element
Wattage Information

Step 3 Remove the cap from the heating element.

Heating
Element

V-Clamp
O-Ring
Tank
elmntre.eps

Section 3 System Components

3-6

Step 4 The wire connections inside the cup of the heating element correspond to one of
the phase configurations shown below. Note your 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

Step 7 Replace the heating


element or perform the
necessary cleaning
procedure.

Power
(Black)

To reassemble the heating element and tank, follow the steps listed above in reverse
order. Make sure the green-ground and power electrical wires are properly reconnected
using the washers, lug cups and nuts supplied.
To order a new heating element, refer to part number on the label of the element.
NOTE: When replacing the element, apply anti-ceasing or thread lubrication to the
elements that have a threaded adapter.
Single Phase
Metal Strap
Ground Screw

3 Phase WYE

3 Phase DELTA
cupphase.ai

Section 3 System Components

3-7

High-Limit Thermostat Replacement


The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over
heating of the oil in the event that the heating systems System Thermostat fails. The
sensing unit is located inside the element housing and is fixed at 140F (On)/160F (Off).
To replace the high-limit thermostat sensing unit, follow these steps.
WARNING
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.

Step 1 Remove the enclosure


cover of the element
housing.
Step 2 For 3-phase applications
only, remove the element
jumper strap which
crosses over the top of the
high-limit sensing unit
(red wires).
Step 3 Pull the sensor and seat
straight out and
disconnect the sensor
from its seat.
Step 4

Sensor Seat
Heat Shrink Cover
Thermostat Sensor

Reconnect the new


sensor.

Reassemble in reverse order.


hisenr2.eps

High-Limit Sensing Unit Replacement Parts


Sensing Unit

Temp. On

Temp. Off

Part No.

LSU 14

140F (60C)

160F (71C)

HLC 4*

*Replacement stats will come with lock ring and sensor seat.

Section 3 System Components

3-8

System Thermostat Replacement


The System Thermostat Sensing Unit is located inside the thermostat housing at the inlet
end (bottom) of the oil heating tank as shown below. To replace the system thermostat,
follow these steps.
CAUTION
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Remove the cover of the service entrance
enclosure.
Step 2 Pull the thermostat sensor and seat straight out
of the housing chamber.

Tank

Step 3 Replace the sensor by pulling it off the seat.


Reassemble the new thermostat in reverse order. When
pushing in thermostat, take care not to warp the face of
the thermostat. Reconnect the electrical connections
and the service entrance enclosure.

Thermostat Housing
Thermostat Sensor
Heat Shrink Cover

NOTE: Remove heat shrink tubing from old sensor


and place it on the new sensor before
installing.

Sensor Seat

Lo_sensr2.eps

System Thermostat Sensing Unit Replacement


Sensing Unit

Temp. On

Temp. Off

Part No.

LSU 4

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

Section 3 System Components

3-9

Tank O-Ring
Shown below is an illustration for changing the O-ring found between the top and bottom
section of the heating tank.
CAUTION
DISCONNECT ALL POWER AT THE SOURCE PRIOR
TO PERFORMING ANY MAINTENANCE TO THIS
HEATING SYSTEM.

Tank

Step 1 Drain the tank.


V-Clamp

Step 2 Remove the V-clamp that holds the tank and adapter
together.
Step 3 Replace the O-ring between the sections.

O-Ring

Step 4 Reassemble the tank.


V-Clamp with O-Ring Replacement Part No: PRP215113-000

Adapter

O-Ring Replacement Part No: PRP203093-000


oring1.eps

Flow Detection Switch


The Flow Detection Switch (shown on
right) is a safety device designed to
protect the heating and pumping
system. This switch is located on the
outlet end of the oil heating tank. If,
for any reason, the oil heating systems
minimum flow rate (G.P.M.) is
interrupted, the flow detection switch
immediately shuts off the heating
element and activates the time delay
relay. The minimum flow rate required
for most heating systems is 2 GPM. To
order a flow detection switch,
reference the part number listed on the
following page. The 2.8 GPM systems
use a 0.5 GPM flow switch.
NOTE: The flow detection switch
should be checked periodically for
foreign matter that may build up on
the shuttle body. For cleaning
instructions, refer to page 4-3 in the
System Maintenance section of this
manual.

Section 3 System Components

OWT Model
Flow Detection
Switch

OFF ON

L1 L2 L3
513

Time Delay Relay

OER Model

Flow Detection
Switch

RESET

OFF ON

L1 L2 L3

trelay.eps
2inbx.eps

Time Delay Relay

3-10

Standard:

OWT Flow Detection Switch


Replacement Part No: PRP224033-000

Standard:

OER Flow Detection Switch


Replacement Part No: PRP224033-200

Small OWT (2.8 GPM):

Flow Detection Switch


Replacement Part No: PRP224032-000

Small OER (2.8 GPM):

Flow Detection Switch


Replacement Part No: PRP224032-200

Pump and Motor Assembly


Pump and motor assemblies vary according to the customers need. Order replacement
parts using the system part number.

Oil Pressure Switch


Shown below is the pressure switch used on the OER heating system. The pressure
switch is normally connected to the pressure side of the engine - not the suction side.
When oil pressure drops below the switchs lower limit, the switch turns On the oil
heating system; when oil pressure increases above its high limit, the switch turns Off the
oil heating system.
NOTE: When PRP224078-000 is used, the hex inlet fitting of the pressure switch
should never be turned when connecting the oil line. Hold the hex nut fitting
firmly when attaching the oil line.

Pressure Switch Replacement Part Numbers


Model

Part Number

Range

OER

PRP224078-000

5 30 PSI

OWT

PRP224008-000

8 20 PSI

pressw.eps

1/4-Inch N.P.T

DO NOT TURN.
Hold firmly when attaching oil line.

Section 3 System Components

3-11

System Maintenance and Troubleshooting


This section describes maintenance procedures for the Kim Hotstart Model OWT/OER Heating
System and provides tips for troubleshooting.

System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of
your heating system:
Control Box
Plumbing Connections
Electrical Connections and Contacts
Heating Tanks/Elements
Flow Detection Switch
Pump & Motor Assemblies
System Mounting
WARNING
DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM
MAINTENANCE.

Control Box


Periodically check gaskets for proper seals.

Check the control box for moisture (if necessary, add desiccant packets).

Plumbing Connections


Periodically check plumbing connections for leaks and, if necessary, tighten


connections. A loose connection on the suction side will cause a loss of flow.

Electrical Connections


Excessive vibration will eventually cause terminals to loosen. Tighten at startup and
check again in a week. Periodically tighten all electrical connections every 3
months.

Electrical Contacts


Inspect electrical contacts for wear. Worn contacts should be replaced with new
contactors.

Section 4 System Maintenance & Troubleshooting

4-1

Heating Tank


At least once per year, clean the interior of the heating tank and the heating element
with a wire brush and/or damp cloth. Periodically check the element for sediment
build-up around the hairpins. Any scaling or build-up will shorten element life.
Maintenance and replacement procedures for the heating element are described in
System Components of this manual.

Following lengthy system shut downs, remove the terminal covers of the element
assembly as shown in System Components and check for any moisture or
condensation. Electric tubular heating elements contain a granular refractory
material called magnesium oxide (MGO) to insulate the resistor coil from the outer
metal sheath. MGO is hygroscopic, which means it has the ability to absorb
moisture from the air. MGO contaminated with moisture reduces the insulating
value of the MGO which is measured with an Ohm meter and read as resistance on
the megohms range (1 meg-ohms = 1 million ohms = 1M Ohms) . Low resistance
(less than 1M Ohms) is a transient condition experienced on first heat-up under
normal periodic heater usage. Moisture absorption under normal conditions does
not affect heater efficiency or life.
The minimum required resistance value is 1.0M Ohms for full power voltage
operation. However, heating elements with a moisture barrier sealant such as RTV
silicone or epoxy potting will require a minimum value of 5.0M Ohms. Resistance
values should be measured with an Ohm meter by applying one lead to the
termination and the other to ground. When the heater does not meet the required
resistance value, the unit will have to be dried out prior to full power operation.
If the heater has 0.1M Ohms (100K Ohms), or better, but less than 1M Ohms, the
heater should be operated at half the rated voltage for 30 minutes to dissipate the
accumulated moisture. Disconnect the power after 30 minutes and check the
resistance. An alternative to applying voltage is to manually dry the heaters in an
oven at 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.

Section 4 System Maintenance & Troubleshooting

4-2

Flow Detection Switch




Inspect the flow detection (flow control) switch periodically for foreign buildup on
the shuttle body. To clean the flow detection switch, follow these steps:

Step 1 Shut OFF the oil supply to the heating


system.
Step 2 Remove the bonnet nut and lift out the
entire switch assembly.

Flow Detection Switch

Bonnet Nut

Step 3 Remove accumulated sediment from the


switch body with a damp cloth.
Step 4 Check the switch for proper operation by
sliding the shuttle and magnet up over
the main shaft as shown below. If the
shuttle hangs up or does not slide
smoothly, remove the lock ring from the
bottom of the switch assembly and slide
the shuttle, magnet and spring off.

flowdect1.ai

Step 5 Remove foreign matter and rough spots


from the shaft with denatured alcohol.

Bonnet Nut

Step 6 Reassemble the switch and check it


again for proper operation (reference
step 4).
Step 7 To test operation of the switch assembly,
turn ON the main power. When the
magnet on the shuttle is slid up the shaft,
the magnetic contactor that operates the
heating element should close.

Switch Body

CAUTION: When testing the flow switch,


do not operate the heating system any
longer than 5 seconds or damage to the
heating element may occur.
Step 8

Tension Spring

Magnet

Once the switch assembly is working


properly, reassemble the flow switch and
set the time delay relay to the desired
setting. The recommended setting is 30
seconds.

Plunger Body

Lock Ring

Base
flwdect2.ai

Section 4 System Maintenance & Troubleshooting

4-3

Pump and Motor Assemblies




Two different types of motors are used: one uses sealed bearings and the other ball
bearings. Sealed bearings require no maintenance. For ball bearing motors,
lubricate fittings periodically (usually every 6 to 12 months for normal
applications).

Pumps - replace seals and gaskets as required. See Appendix A.

Seal life is very difficult to estimate due to a variety of controlled and uncontrolled
conditions the seal operates in. Pump seals by nature will weep some even when
new.

The mechanical seal faces cannot be permitted to be in contact in a dry


environment. Some liquid must pass between the rotating and stationary face in
order to minimize friction and to carry away the heat generated. If this leakage
evaporates when reaching the atmosphere, then there is no visible leakage. If it
doesnt, leakage in the order of 10 drops per day might be the best achievable.
Some seal manufacturers rely on high face loading to minimize leakage but at the
expense of seal longevity. Others do the opposite, which provides longer life but
greater leakage.
Field installation of the seals is not as exact a procedure as is possible when this is
done in a factory environment with experienced assemblers. It is possible to
experience some minor leakage on field installed seals. Excessive leakage can also
be an early indication of seal failure, warning of the need for impending
maintenance. Before installing, repairing, or performing maintenance on pumps,
read and understand the pumps instructions completely. Undersized or excessively
long suction lines can cause excessive vacuum on the seal and cause leakage from
the seal. Please see page 2-2.

System Mounting


Excessive vibration may cause mounting bolts to loosen. Periodically check and
tighten all mounting bolts.

To allow air to escape, the system must be mounted with the outlet of the tank at the
top of the system.

Section 4 System Maintenance & Troubleshooting

4-4

Troubleshooting


The Fluid Does Not Heat


Probable Causes:
No electrical power
Blown fuse
Problem with the flow switch
Problem with the thermostat
Problem with the heating element
Recommended Repairs:
Electrical Power - Make sure that the control boxs ON/OFF switch is in the
ON position. Observe the power light on the control box. If the power light is
not on, make sure that the main power supply and the 24 V supply are ON. If
the power supplies are ON but the power light on the control box is OFF,
troubleshoot the electrical system.
Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the
control box. Replace any blown fuse. If the fuse is blown again, troubleshoot
the electrical system.
Flow Switch - If the flow switch is not operating properly, the flow switch can
improperly remove the power supply from the heating element.
Make sure that the flow switch is operating correctly. Inspect the flow switch
and clean the flow switch. For instructions, refer to page 4-3. Replace the flow
switch if necessary.
Thermostat - The thermostats contactor is normally open. If the temperature is
less than the thermostats rating, the thermostats contactor closes in order to
energize the heating element. If the temperature becomes greater than the
thermostats rating, the thermostat opens again.
To verify whether there is a problem with the thermostat, measure the
thermostats resistance at a temperature that is less than the thermostats closing
temperature. If the resistance is greater than 200,000 ohms, the contactor is
open.
Continue to measure the thermostats resistance and increase the temperature to
the thermostats closing temperature. If the resistance is less than 5 ohms, the
contactor is closed.
Continue to measure the thermostats resistance and increase the temperature to
the thermostats opening temperature. If the resistance is greater than 200,000
ohms, the contactor is open.
For the thermostats operating temperatures, refer to page 3-9. If the thermostat
fails to operate correctly, replace the thermostat.

Section 4 System Maintenance & Troubleshooting

4-5

Heating Element - Deposits and moisture will reduce the heating elements
efficiency. Clean the heating element and check the heating element for a short
circuit to ground. For instructions, refer to page 3-6.


The Flow of Fluid is Inadequate


Probable Causes:
Closed ball valves
Air leaks in the suction side
Obstruction in the supply lines and/or the return lines
The pump is not primed.
Incorrect pump rotation
No electrical power
Blown fuse
Problem with the flow switch
Pump cavitation
Improper impeller clearance or improper assembly
Recommended Repairs:
Ball Valves - If the ball valves are closed, the heater is isolated from the
engines fluid. Open the ball valves.
Air Leaks - Inspect the lines and the fittings on the suction side of the pump.
Repair any leaks. Make sure that the fittings are secure.
Obstruction in the Lines - Restriction of the suction lines will not allow the
pump to fill properly. Restriction of the return lines causes excessive resistance
to the pumping. Inspect the lines for obstructions and remove any restriction.
Pump Priming - An air pocket in the inlet side of the pump will prevent the
pump from operating properly. Open a port in the output side of the pump and
operate the pump for a few seconds in order to purge the air. When fluid
appears at the port, close the port.
Pump Rotation - Compare the pump rotation to the directional arrow on the
housing. If the rotation is incorrect, switch any two of the three wires from the
main power supply at the control box.
Electrical Power - Make sure that the control boxs ON/OFF switch is in the
ON position. Observe the power light on the control box.
If the power light is not on, make sure that the main power supply and the 24V
supply are ON.
If the power supplies are ON but the power light on the control box is OFF,
troubleshoot the electrical system.
Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the
control box. Replace any blown fuse. If the fuse is blown again, troubleshoot
the electrical system.

Section 4 System Maintenance & Troubleshooting

4-6

Flow Switch - If there is a problem with the flow switch, the flow switch can
improperly activate the time delay relay and the power supply will be removed
from the pump motor.
Make sure that the flow switch is operating correctly. Inspect the flow switch
and clean the flow switch. For instructions, refer to page 4-3. Replace the flow
switch if necessary.


The Pump Motor is Overheating


Probable Causes:
Obstruction in the supply lines and/or return lines
Inadequate fluid flow
Problem with the main power supply
Problem with a thermostat
Problem with the motors protective switch
Problem with the pump shaft or the motors bearing
Oil Viscosity
Recommended Repairs:
Obstruction in the Lines - Restriction of the suction lines and/or the return
lines causes excessive resistance to the pumping. The pump motor will work too
hard and the motor will overheat. Inspect the lines for obstructions and remove
any restriction.
Fluid Flow - The pump is partially cooled and lubricated by the fluid flow. An
inadequate fluid flow can result in overheating of the pump motor. If a problem
with the fluid flow is suspected, refer to The Flow of Fluid is Inadequate.
Main Power Supply - The pump motor must have the correct voltage and
frequency. Otherwise, the motor will attempt to compensate for the inadequate
supply and the motor will overheat. Check the quality of the main power supply
and compare the data to the motors rating. Make sure that the main power
supply is correct.
Thermostat - The thermostats contactor is normally open. If the temperature is
less than the thermostats rating, the thermostats contactor closes in order to
energize the heating element. If the temperature becomes greater than the
thermostats rating, the thermostat opens again.
To verify whether there is a problem with the thermostat, measure the
thermostats resistance at a temperature that is less than the thermostats closing
temperature. If the resistance is greater than 200,000 ohms, the contactor is
open.
Continue to measure the thermostats resistance and increase the temperature to
the thermostats closing temperature. If the resistance is less than 5 ohms, the
contactor is closed.

Section 4 System Maintenance & Troubleshooting

4-7

Continue to measure the thermostats resistance and increase the temperature to


the thermostats opening temperature. If the resistance is greater than 200,000
ohms, the contactor is open.
For the thermostats operating temperatures, refer to page 3-9. If the thermostat
fails to operate correctly, replace the thermostat.
Motors Protective Switch - If there is a problem with the motors protective
switch, the switch can incorrectly remove power from the pump motor.
Exchange the switch with a switch that is known to be good.
Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor
bearing will result in overheating. Inspect the parts for wear. Make the
necessary repairs.
Oil Viscosity Viscosity of oil is too thick causing the motor to over-work. The
motor protective switch over heats and trips out. All oil systems are designed to
maintain warm oil takeover. They are not designed to take over on a cold oil
start-up.


The Pumps Seal is Leaking


Probable Causes:
Improper assembly
Damaged seal
Contaminated fluid
High fluid temperature
Dry operation
Recommended Repairs:
Damaged Seal - The seal is worn over time. The seal will eventually become
damaged from use. Replace the seal. For instructions on disassembly and
assembly of the pump, refer to pump vendor information in Appendix.
Contaminated Fluid - Abrasive material and/or corrosive chemicals in the
fluid will damage the seal. Other moving parts can also be damaged. Obtain an
analysis of the fluid. Replace the fluid, if necessary. Refer to the engines
Operation and Maintenance Manual. Replace the seal. For instructions on
disassembly and assembly of the pump, refer to pump vendor information in
Appendix.
High Fluid Temperature - If the temperature of the fluid is too high, there is
probably a problem with the thermostat.
The thermostats contactor is normally open. If the temperature is less than the
thermostats rating, the thermostats contactor closes in order to energize the
heating element. If the temperature becomes greater than the thermostats
rating, the thermostat opens again.
To verify whether there is a problem with the thermostat, measure the
thermostats resistance at a temperature that is less than the thermostats closing

Section 4 System Maintenance & Troubleshooting

4-8

temperature. If the resistance is greater than 200,000 ohms, the contactor is


open.
Continue to measure the thermostats resistance and increase the temperature to
the thermostats closing temperature. If the resistance is less than 5 ohms, the
contactor is closed.
Continue to measure the thermostats resistance and increase the temperature to
the thermostats opening temperature. If the resistance is greater than 200,000
ohms, the contactor is open.
For the thermostats operating temperatures, refer to page 3-9. If the thermostat
fails to operate correctly, replace the thermostat.
Dry Operation - The pump is partially cooled and lubricated by the fluid flow.
A lack of fluid or an inadequate fluid flow can result in overheating of the
pump. This can damage the seal and the pumps moving parts. If a problem with
the fluid flow is suspected, refer to The Flow of Fluid is Inadequate.


Excessive Noise or Vibration


Probable Causes:
Improper assembly
Problem with the pump shaft or the motors bearing
Pump cavitation
Recommended Repairs:
Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor
bearing will result in overheating. Inspect the parts for wear. Make the
necessary repairs.

Section 4 System Maintenance & Troubleshooting

4-9

System Drawings
This section contains system drawings specific to your heating system

Appendix A

A-1

Progressive Equipment
Incorporated
14028 Aston Avenue
Houston, Texas 77040 USA

Telephone (713) 462-1061


Fax (713) 462-4027
Or Contact Us Via E-Mail:
sales@progressive-equipment.com

DropsA
SMX Series
Divider
Valves

Your Single Source For Any Lubrication Application

GENERAL FEATURES
x
x
x
x
x
x
x
x

Integral Porting Adapter for Simple Single to Twin


Outlet Conversion, Reduces Inventory Levels
Air Bleeds Built Into Base Plate
Maximum Pressure 7,200 PSI (500 BAR)
Operates With Oil or Grease
Full Monitoring Capability
NPTF-Metric-BSP-SAE Threads Available
Modular DesignBase and Metering Elements
Zinc Plated Components

ADVANTAGES
x
x
x
x
x
x

Modular Design Eliminates Tie Rods


Metering Elements Can Be Serviced Without
Disturbing Piping or Tubing
Internal Cross Porting
Auxiliary By-Pass Element Available
Easy Conversion From Twin to Single, No Need to
Stock Twin and Single Metering Elements
No Limitation To The Maximum Number of
Metering Elements

Notes:
1. A Minimum of 3 Metering Elements is Required to
Operate The Assembly.
2. Each Base And Metering Element Undergoes a
Thermal Explosive Process to Eliminate Foreign
Matter.
DESCRIPTION
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

Inlet Base Section


Intermediate Base Section
End Base Section

And can be increased in number by the addition of


Intermediate Base Sections.
This revolutionary system makes the assembly easy
and flexible; there is no need to determine in advance
the size of the base, just add on intermediate base
sections by means of Threaded Inserts and Cap
Screws (Patented).

METERING ELEMENTS
The Metering Elements are fixed to the base by
means of two cap screws (provided).
The SMX Metering Elements are available in a wide
range of deliveries (See Chart on Page 2). Cycle
Indicator Pins are available on most size elements
(See Chart on Page 2).
A By-Pass element is also available which allows an
addition or reduction of lubrication points at any
time without having to disconnect any piping or
tubing.
Bridge Elements (Internally Cross Ported) are
available. These interconnect and discharge into
the next element.
The Metering Elements are supplied with either one
or two outlets, Conversion Plugs are available for
field conversion from one to two outlets (See Chart
Below).
All Metering Elements are fully interchangeable in
various positions on the base.

Conversion Plugs
Plug Type

Plug Part No.

Plug Color

S Single Outlet

641708

Silver

T Two Outlets

641709

Gold

Base Plate Assemblies

Metering Elements

No. of Elements

Part Number

643523

SMX-08

643524

643525

643526

643527

643528

643529

Metering
Delivery In3
Element Size
(Twin)

Note: Bases For 10 or More Sections are available,


contact Progressive Equipment for Part Number and
Ordering Information.
TECHNICAL DATA
Maximum Pressure: 7,200 PSI (500 BAR)
Minimum Pressure: 215 PSI (15 BAR)

Delivery In3
(Single)

Part
Number

.005

.010

641516

SMX-12

.0075

.015

641790

SMX-16

.010

.020

641517

SMX-25

.015

.030

641518

SMX-35

.020

.040

641519

SMX-40

.025

.050

641520

SMX-50

.030

.060

641521

SMX-60

.035

.070

641522

SMX-65

.040

.080

641523

SMX-00

By-Pass

By-Pass

641514

Note: 3 Working Metering Elements are Required


to Complete an Assembly. A By-Pass is not considered a Working Element.

O-Ring Material: Buna, Standard * Viton, Optional

Adapter Single/Twin

Temperature Range:
Buna Seals: -220 F (-300 C) to +2120 F (+1000 C)
Viton Seals: -40 F (-250 C) to + 3920 F (+2000 C)
Maximum No. of Strokes Per Minute: 500* Depending on Pressure and Delivery.
Oil Viscosity: Minimum 15 cSt (77.31 SSU)
Grease: Maximum 200 ASTM (NLGI-4)

Top View of Metering Element

O-Ring (9 Per Element)

Weight of Single Element: .68 Lb. (0.31 Kg)


Inlet Thread: 1/4 NPT
Outlet Thread: 1/8 NPT
(Consult Pro-Gress for Metric Sizes)
MONITORING OF PISTON MOVEMENT

Bottom View of Metering Element

The following Types of Switches are available to


monitor
Piston movement:
x

DNFTDigital No-Flow Timers (Request DNFT


Brochure)

Deliron Proximity Switch (Request The Deliron


Proximity Switch Brochure)

DELIRONMagnetic Cycle Indicator (leak-proof)

PIN INDICATORS (High Pressure, Blocked or


Plugged Line Indication).

Pin Indicator, Pressure Type w/ Memory


Available in pressure ratings of: 1500, 2000,
2500, 3000, 3500, 4000 and 5000 PSI.

DLM-926-PM PANEL MOUNT DELIRON MONITOR

Features
Failsafe Open or Closed Modes

Specifications
Material: Aluminum

2-Line Digital Readout Displays


Engine and Compressor Oil
Consumption in Pints Per Day,
Total Cycles and Cycle Time

Input Power w/ Power Interface Module


90-180 VDC @ .0005 AMPS
90-120 VAC @ .0005 AMPS

User Programmable Alarm Time


(3 to 250 Seconds)

Input Power w/o Power Interface Module:


6-24 VDC @ .04 AMPS

Fits Directly Into The 4-1/2


Cutout In Your Control Panel

Alarm Switch Rating:


6-240 VDC @ 10VA / 5-120 VAC @
2.5VA

Monitors Engine & Compressor


Lubrication

Operating Temperature: -200C to +700C


(-40F to +1580F)

Description
Progressive Equipment Incorporated is
proud to announce the release of the
new DLM-926-PM Dual Zone Deliron
Lubrication Monitor for installation
directly into the 4-1/2 cutout in your
Control Panel.
The DLM-926-PM is a digital micro
processor control device specifically
designed to protect Gas Compressors
from damage due to loss of lubrication.
Lubrication to the Engine/Compressor
flows through a Divider Block Type
Lubrication System forcing an internal
piston to cycle back and forth.
By installing a Proximity Switch on one
of the Metering Elements on each of the
Master Divider Blocks, the back and
forth movement of the pistons result in
an On/Off state which the DLM-926-PM
continuously analyzes.

Model DLM-926-PM (Part No. 000551)


Consisting of:
1 Each DLM-926-PM Monitor
2 Each DLM-D-PRX Proximity Switches
1 Each PM970 Power Interface Module

DLM-926-PM Deliron Monitor


With Glass Cover Removed

Programming Method
Four Switches mounted underneath the
glass cover. Remove Glass Cover to
access switches. (Spanner Wrench Is
Required)

Determining Divider Block Total

MODE
Push to access program functions

Metering Element
SMX-08
SMX-12
SMX-16
SMX-25
SMX-35
SMX-40
SMX-50
SMX-60
SMX-65

UP
Push to increase parameter value
Down
Push to decrease parameter value
Exit
Push to exit program mode

If no movement is detected within the


preset Alarm Delay Time (3 to 250
Seconds, User Adjustable) a
shutdown of the compressor will occur
preventing damage to the engine and/or
compressor from loss of lubrication.

PRESSING MODE & UP or DOWN


Changes from one menu item to next

Progressive Equipment Incorporated


PO Box 40067
Houston, Texas 77240-0067 USA
www.progressive-equipment.com
Tel (713) 462-1061
Fax (713) 462-4027
E-Mail:
sales@progressive-equipment.com

Menu Items (Modes 1 Through 8)

Manufactured By:
DELIRON LIMITED - Odessa, Texas
Telephone (800) 337-3412
Website: www.noflo.com

DLM-926-PM
PANEL MOUNT
DELIRON
LUBRICATION
MONITOR

PRESSING UP & DOWN (Mode 8)


Pushed at the same time will zero the
stroke count and run time hours

To determine the divider block total add


the values shown below for each size
metering element:
Value
5
8
10
15
20
25
30
35
40

Examples:
SMX-3 (35S-35S-16T) = 50
SMX-4 (16T-16T-08S-12T) = 33

1. Set Compressor Lube Block Total


(18 to 144)

5. Select Alarm Logic Mode


(Open Loop or Closed Loop)

2. Set Engine Lube Block Total


(18 to 144)

6. Read Back of Last 100 Cycle Times


Compressor Lube Block

3. Set Compressor Alarm Time


(20 to 244 Seconds)

7. Read Back of Last 100 Cycle Times


Engine Lube Block

4. Set Engine Alarm Time


(20 to 244 Seconds)

8. Reset Stroke Count and System


Total Run Time

551LIT DLM926-3
04.10.02

Digital Lubrication Monitor


WIRING INSTRUCTIONS
Model DLM-926 - Part# 000551

DUAL DIVIDER BLOCK SYSTEM MONITOR


WITH RUN TIME HOUR METER & NO-FLOW SHUTDOWN
MAGNETO

TO ALARM -- COMPRESSOR
TO ALARM -- COMPRESSOR
TO ALARM -- ENGINE
TO ALARM -- ENGINE

COMPRESSOR

POWER

6-24 VDC
+
l

ALARM

ENGINE

PROXIMITY SWITCH
ENGINE
COMPRESSOR

ENGINE
PROXIMITY SWITCH

COMPRESSOR
PROXIMITY SWITCH
24S

24S

24S

24S

24S

24S

COMPRESSOR
MASTER DIVIDER BLOCK

GREEN WIRE
GROUND SECURELY

ENGINE
MASTER DIVIDER BLOCK

Odessa, TX USA
1-800-337-3412 www.noflo.com

Manufactured and Assembled in the U.S.A. By DELIRON LIMITED


*ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.

GREEN WIRE
GROUND SECURELY

PROXIMITY SWITCH

169LIT D-PRX SWI


07/18/01

DL-D-PRX

SWITCH HOUSING
(B)

MAGNET
HOUSING
(C)

#24 AWG 18" LEADS (3)


YELLOW
YELLOW

1.125"
3.250"

(Switch
Connections)

MAGNET
(H)

SPECIFICATIONS

GREEN

(Ground)

ALLEN HEAD SPACER


SPRING
SET SCREWS
(A)

RATINGS

Part Number....................................................... 000169


Material..................................Stainless Steel, Aluminum
o
o
Temperature Range..............................-40 F to +185 F
Switch Rating.....10 VA / 200 VDC AMP MAX 125 VAC
...................................MINIMUM BREAKDOWN 300 VDC
Epoxy Encapsulated............UL LISTED EL-CAST VFR 641

CLASS 1, Div 1 Grps A,B,C,D

LR108334-1

NRTL/C

FOR
TRABON, LINCOLN
MANZEL & DROPSA
DIVIDER BLOCK LUBRICATION SYSTEMS
R

INSTALLATION AND ADJUSTMENT PROCEDURE

1. Loosen all (2) Allen head set screws (A) on switch housing (B) and remove
magnet housing (C). Do not remove magnet, spring, and spacer from
magnet housing.
2. Remove end plug (D) from divider valve where proximity switch will be
installed. Proximity switch can be installed on any available divider valve
section.
3. Screw magnet housing (C) into end of divider valve. Torque to 15 foot
pounds max. Be sure 0-ring or metal gasket (F) is in place on magnet
housing (C) if required.
4. Slide switch housing (B) all the way onto magnet housing (C). Connect
ohmmeter to yellow switch leads. Do not tighten set screws at this time.
5.To properly adjust switch housing (B), divider valve assembly (G) must be
cycling so magnet (H) is moving back and forth. This can be achieved with
lubrication system functioning or by manually pumping clean oil through
divider valve assembly with a hand pump.
6. If a cycle is not detected, adjustment is made by sliding switch housing
(B) out in 1/16" increments. Continuity meter connected to yellow wires will
indicate a switch closure. Adjust 1/16" out until correct adjustment is
confirmed. Torque set screws to 25 inch pounds max.
7. Use 10 to 12 inches of flexible conduit on the switch housing for ease of
adjustment or maintenance. All conduit and connections should be
appropriate for area classification. CAUTION: Conduit and fittings must be
supported to avoid bending magnet assembly.

0-RING

(F)
INTERNAL VIEW OF
MAGNET
DIVIDER VALVE HOUSING
(H)
(E)

SWITCH HOUSING
(B)

24S
24S
24S

DIVIDER VALVE
ASSEMBLY
(G)

MAGNET
HOUSING
(C)
END PLUG
(D)

WIRE LEADS
(I)

ORDERING INFORMATION
MODEL

DESCRIPTION

PART
NUMBER

DL-D-PRX

DROPSA

000169

DL-L-PRX

LINCOLN - O-RING STYLE

000170

DL-TG-PRX

TRABON - GASKET STYLE


1994 AND EARLIER
TRABON - O-RING STYLE
1995 AND LATER

000171

DL-TO-PRX

DISTRIBUTED BY

Odessa, TX USA
1-800-337-3412 www.noflo.com
Manufactured and Assembled in the U.S.A. By DELIRON LIMITED
*ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.

000172

LM-92164N
Revised 10-03
Section 15

Installation Instructions for Level Maintainers

(00-02-0176)

Model Series LM300


Read the following instructions before installing. A visual inspection of this product for
damage during shipping is recommended before mounting. These installation instructions are
intended for all LM300 series models.
GENERAL INFORMATION

LM301-EX
Shown with optional hose kit fittings

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine.


Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.

LM300: Level Maintainer only (no switches).


LM301: Low switch contacts for low level shutdown or
alarm. Four wires, SPDT.
LM302: Two switches for low and high level shutdown or alarm. Four wires,
DPST, wired N.O. in normal operating ranges.
LM303: Two switches for low and high level shutdown or alarm. Four wires,
DPST, wired N.C. in normal operating ranges.
LM304: Two switches. Alarm before shutdown on low level and shutdown on
low-low level. Four wires, DPST, wired N.O. in normal operating ranges.
LM305: Two switches. Alarm before shutdown on low level and shutdown on lowlow level. Four wires, DPST, wired N.C. in normal operating ranges.

Specifications

Case/Cover: Die cast aluminum.


Switch Housing: Aluminum.
Approval Rating: LM301 thru LM305 : CSA certified for non hazardous
locations. Enclosure Type 4 certified.
LM301-EX thru LM305-EX: CSA certified for Class I, Groups C and D;
Class II, Groups F and G hazardous locations. Enclosure Type 4 certified.
Float: Rigid polyurethane foam. Polyurethane coated.
Maximum Ambient Temperature: 250F (121C)
Oil Inlet Connection: Top entry 1/2-14 NPT with built-in filter screen (removable
for cleaning).
Inlet Orifices: 1/4 in. (6 mm) standard. 1/8 in. (3 mm) available.
Wire (switch models): 18 AWG x 13 in. (1.0 mm2 x 330 mm).
Maximum Inlet Pressure (MIP):
Max. Differential: 2 in. (51 mm) between running and stationary oil level.
30 psi (207 kPa) [2.07 bar].
with 1/8 in. (3 mm) orifice.
15 ft. oil (4.6 m oil)
with 1/4 in. (6 mm) orifice.
Maximum Case Pressure (MCP): 15 psi (103 kPa) [1.03 bar].
Orifice Seal: Buna-N Thumb-Valve
Switch Contact: Silver, SPDT snap acting, 10A @ 125, 250VAC; 10A @ 30VDC.
(1 only for low level; 2 only for high & low; or 2 only for low with alarm before shutdown)

**

Patent
5493086

Outlet Connection: 3/4-14 NPT left side, right side, and bottom.
Crankcase Balance Vent Fitting: 1/2-14 NPT.
Mounting: Accepts Murphy pipe mounting or universal mounting brackets.
Lens: Clear Frog Eye non-staining, high impact, high temperature nylon; UV
and heat stabilized.
Dial: High visibility white background with green and white index lines for
normal level indication.
Test Knob: Rotate to test switch operation. Turn clockwise for low level test
and turn counterclockwise for high level test.
Flow Rate Test: Using SAE 30 @ 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

NOTE: Friction losses due to piping NOT considered.

Optional Hose Kit: 15000355


Quantity Description

1
1
2
2
2
2

1/2 in. (13 mm) I.D. x


3 ft. (914 mm) long hose
1 in. (25 mm) I.D. x
3 ft. (914 mm) long hose
1/2 in. (13 mm) worm gear clamp
1 in. (25 mm) worm gear clamp
1/2 NPT x 1/2 in. (13 mm) barbed fitting
3/4 NPT x 1 in. (25 mm) barbed fitting

CSA certified with switch contacts rated at 10 A @ 250 VAC (standard).

** Products covered by this bulletin comply with EMC Council directive


89/336/EEC regarding electromagnetic compatibility except as noted.

LM-92164N page 1 of 4

DIMENSIONS

LM300 Series Enclosures

Mounting Brackets with Hardware

The dimensions below are for the optional -EX model enclosure. The
standard model enclosure dimensions are the same except the height and
width which are: 7 in. (178 mm) H, 7-7/8 in. (200 mm) W.
Oil Inlet Connection*
1/2-14 NPT
with removable
screen
Crankcase
Vent
1/2-14 NPT

6 in.
(152 mm)
Electrical
Conduit
1/2-14
NPT

15000371 pipe bracket


5.20 in.
(132 mm)

Additional Hardware
Supplied
(4) 3/8-16 UNC x 1 inch
(25 mm) screws
(4) 3/8-16 nut
(4) 3/8 I.D. lock washer
(2) 3/8 I.D. flat washer

Test
Knob

4.50 in.
(114 mm) Hole .88 in.
(22 mm) dia.
.376 in.
(10 mm)
minimum
bottom surface
2 places

2.50 in.
(64 mm)

1/4-20 NC
2 places

8-1/4 in.
(210 mm)

*Applies to level maintaining models only.

Monitoring Port Connection


3 places, 3/4-14 NPT

15000370 universal bracket

7-3/16 in.
(183 mm)

Slot, .390 in. (10 mm)


Additional Hardware
x 2 in. (51 mm)
Supplied
4 places
(2) 3/8-16 UNC x 1 inch
(25 mm) screws
Slot, .390 in. (10 mm)
in. (120 mm)
(4) 3/8 I.D. flat washer x3 4.71
places

Snap Switch
Case Assembly

5-15/16 in.
(151 mm)

(17 6.69
0 m in.
m)

.
5 in
1.7 mm)
(44

(2) 3/8 I.D. lock washer


3/8-16
UNC-2B
Mounting
Holes, 2 places

2-3/4 in.
(70 mm)

(11 4.50
4 in
(13 5.19 mm) .
2 m in.
m)

5-3/16 in.
(132 mm)

(1 7.5
91 0
i
m n.
m
)

(2) 3/8-16 nut

TYPICAL INSTALLATION

Mounting (all LM300 Series models)

Mounting with Universal Bracket

NOTE: Mount the LM300 series level maintainers as close as possible


to the crankcase. Also, excessive vibration can cause overfill. Be sure
mounting brackets are supported.
The following instructions are based on the usage of the pipe and universal
mounting brackets shown above.

Deck Mounting

The universal bracket has two mounting methods: deck mounting and
pan mounting.
1. Install the universal bracket to the deck as shown in Figure 2A with two
flat washers and two 3/8 inch (10 mm) diameter bolts (not supplied).

Pipe Bracket Mounting

1. Mount a nominal 1/2 inch (21 mm) diameter pipe to the deck of the engine.
2. Install the pipe bracket to the LM300 using two 3/8-16 UNC x 1 inch
bolts supplied. See Figure 1A.
3. Slip the LM300 onto the pipe and install the two adjustment bolts. Each
adjustment bolt consists of a 3/8-16 UNC x 1 inch bolt and two nuts. See
Figure 1B. DO NOT tighten the adjustment screws too tightly because
you will have to adjust the LM300 later in the installation process.

Crankcase
Universal
Bracket

Deck

Pipe
Bracket

Threaded
hole

Figure 2A
Adjustment
Bolts

LM300

Figure 1A

Pipe

Crankcase

Adjustment
Bolts

Figure 2B

2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1
inch (25 mm) bolts supplied (Figure 2B). DO NOT tighten the
adjustment screws too tightly. You will have to adjust the LM300 later in
the installation process.

Figure 1B
LM-92164N page 2 of 4

TYPICAL INSTALLATION continued

Crankcase (Oil Pan) Mounting

1. Install the universal bracket to the crankcase using the existing


crankcase bolts (Figure 3A). Crankcase bolt diameter must be no larger
than 7/16 inch (11 mm).

Connecting the LM300 to an Oil Supply Tank


(level maintaining models only)

Crankcase
Bolt
Universal
Bracket
Note Clearance
before mounting

4. Fill the crankcase to the proper oil levels. With the engine running and
warm, loosen the mounting bracket adjustment bolts and adjust the
LM300 so that the oil level in the sight gauge is aligned with the white
index line on the dial (Figure 4). Tighten the adjustment bolts securely.

Crankcase
Adjustment
Bolt

Figure 3A

Figure 3B

NOTE: Check clearance between crankcase and mounting bracket


before installing the mounting bracket. If space between the crankcase
and mounting bracket does not allow installation and access to the
adjustment bolts advance to Step 3.
2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1
inch bolts supplied. DO NOT tighten the adjustment bolts too tight. You
will have to adjust the LM300 later in the installation process.
3. If space between the crankcase and mounting bracket is narrow, install
the universal mounting bracket to the LM300 before installing to the
crankcase oil pan.

Connecting Fittings and Hoses


The following instructions are for all LM300 series level maintainers.
All steps that reference oil inlet or oil supply tank DO NOT apply to
non-level-maintaining models. Also, these instructions are based on the
Murphy optional hose kit described on page 1. If you did not order the
optional hose kit, gather the hoses, clamps and fittings as specified in
the optional hose kit.
1. Install the LM300 fittings in their proper locations. NOTE: Apply a
sealant such as teflon, to all threaded connections.
2. Attach the 1 inch (25 mm) diameter, flexible monitoring hose to the
crankcase and the monitoring port on the LM300. See Figure 4.
CAUTION: The hose must slope slightly downward from the LM300
and MUST NOT have any droop or low spots.
NOTE: If the drain plug on the crankcase
is used for the connection, we
recommend installation of a tee to
Oil Inlet
Vent Hose
allow draining of the crankcase
Hose
for service.
Viewing
Running
3. Install the 1/2 inch (13 mm)
Lens
Engine
I.D. x 3 ft. (914 mm) hose to
Crankcase
Oil Level
the vent connection on the
LM300 to the vent connection
on the crankcase. See Figure 4.
Monitoring Hose
The vent connection on the
crankcase must be well above the
regulated oil level. All hoses must
Figure 4
be clear of obstructions.
BEFORE CONTINUING, VERIFY THAT ALL HOSE CLAMPS
ARE TIGHT.

1. Remove the caplug from the oil inlet connection. Be sure the filter, inside
the connection, is clear of debris. Install the oil inlet connection.
2. Connect a 1/2 inch I.D. (13 mm) or larger hose
Oil Supply
to oil inlet fitting on the LM300 and to the shutoff
Tank
valve on the oil supply tank. See Figure 5. For
models LM300 thru LM305 recommended
minimum mounting of the oil supply
Oil Inlet
tank above the LM is 4 ft. (1.2m);
Hose
maximum 15 ft. (4.6m). The
hose must maintain a
downward slope and not have
low spots or droops.
Maximum head pressure
rating using standard 1/4 in. (6
mm) orifice is 15 ft. (4.6
meters). See Flow Rate test on
page 1 for additional orifice pressure
ratings.
Figure 5
3. Before filling the supply tank with
oil, be sure the tank is clean and dry andthe shutoff valve is closed.
Also, be sure all hoses and clamps are tight. Fill the tank with CLEAN
oil.

WARNING: Overfill condition can be caused by excessive


inlet pressure, (maximum inlet pressure depends on orifice),
and/or improper vent to crankcase installation.
See Flow Rate Test on page 1 for maximum pressure.
4. After oil supply tank is full, open the shutoff valve.
Next, make the proper electrical connections for the application. See
contact ratings on page 1 and schematics on page 4.

Switch Test (switch models only)


To test the shutdown and/or alarm functions
perform the following:
1. Unscrew protective boot from test knob.
IMPORTANT: Always replace boot after
testing.
2. Turn the test knob 1/4 turn to the right
(clockwise), for low test indication (Figure 6).
Figure 6
3. Turn the knob 1/4 turn to the left
(counterclockwise), for high test indication. DO NOT FORCE
THE TEST KNOB TO TURN.
NOTE: After the engine shuts down, you will notice that the oil in the
sight gauge glass will rise above normal running level, possibly
showing an overfill condition. This is a result of drain-back to the
engine crankcase and it is normal. Therefore, on models LM302 and
LM303 it may be necessary to wire the high level shutdowns into a
class B or C (bypass until first time safe) lockout, so as to allow a
permissive start. After the engine is re-started the level will pull down
to the normal running level and the shutdown features will be active. A
modulating valve (Thumb-Valve) in the level maintaining models
will allow oil usage to be made-up continuously during operation.

LM-92164N page 3 of 4

SWITCH WIRING DIAGRAMS

WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE CONNECTING ANY WIRES.


LM301
SPDT

LM302
High/Low N.O.
DPST
Green

Green

Black

Black

High

Normal

Yellow

LM303
High/Low N.C.
DPST
Green

Normal
Low

Float

Red

Low
High

Yellow

Low

Normal

Normal

Low

Brown

High

Blue

Normal

Normal

Red

Orange

Normal
Low

Black

Normal

Yellow

Normal

Blue

Low

Low

Red

Orange

Low-Low

Low-Low

Float

Float

Float

Brown

Low-Low

Low-Low

Low

Float

Green

Green

High

Low

LM305
Alarm before
shutdown N.C.
DPST

LM304
Alarm before
shutdown N.O.
DPST

OPERATING RANGES OF SWITCHES


This section applies only to models that have built-in switches. The illustrations
below and to the right show the dials and their operating ranges of the switches.
If levels are within the designated zones the switch(es) will activate. Notice that
a switch is capable of activating approximately 3/8 in. (10 mm) from the top of
the high zone and 3/8 in. (10 mm) from the bottom of the low zone. The dial in
Figure 9 shows that if level continues to drop into the low-low zone, a
shutdown will occur.

3/8 in.
(10 mm)

3/4 in.
(19 mm)

Normal
Operating Range

3/4 in.
(19 mm)

NOTE: Color zones on dial face show approximate normal operating zones.
Actual conditions may vary depending upon operating characteristics of the
engine. Placement of the LM300 according to the above instructions will
compensate for these conditions.

Normal
Operating Range

High Zone
Shutdown or Alarm

3/4 in.
(19 mm)

Low Zone
Shutdown or Alarm
3/8 in.
(10 mm)

Figure 8: LM302/LM303

Normal
Operating Range

3/4 in.
(19 mm)

Low Zone
Shutdown or Alarm

Low Zone Alarm


Low-Low Zone Shutdown
3/8 in. 1/4 in.
(10 mm) (6 mm)

3/8 in.
(10 mm)

Figure 7: LM301

Figure 9: LM304/LM305

Warranty

A two-year warranty on materials and workmanship is given with this FWMurphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.asp.

MURPHY DE MEXICO, S.A. DE C.V.


Blvd. Antonio Rocha Cordero 300, Fraccin del Aguaje
San Luis Potos, S.L.P.; Mxico 78384
+52 444 8206264 fax +52 444 8206336
Villahermosa Office +52 993 3162117
e-mail ventas@murphymex.com.mx
www.murphymex.com.mx

MURPHY SWITCH OF CALIFORNIA


41343 12th Street West
Palmdale, California 93551-1442; USA
+1 661 272 4700 fax +1 661 947 7570
e-mail sales@murphyswitch.com
www.murphyswitch.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

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

FRANK W. MURPHY, LTD.


Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
+44 1722 410055 fax +44 1722 410088
e-mail sales@fwmurphy.co.uk
www.fwmurphy.co.uk

GI

FWMurphy

CONTROL SYSTEMS & SERVICES DIVISION


P.O. Box 1819; Rosenberg, Texas 77471; USA
+1 281 633 4500 fax +1 281 633 4588
e-mail sales@fwmurphy.com

STER

USAISO 9001:2000 FM 28221


UKISO 9001:2000 FM 29422

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A.

LM-92164N page 4 of 4

Section 11 IGTB RPM Control


Vendor
IGTB Assembly Illustrated Parts List ................... Ajax

Bulletin No.
TP 1302-000-04

IGTB Operation and Problem


Diagnostics ..................................................... Ajax

TP 1300-000r2

V1 System Junction Box Assembly ..................... Ajax

TP YAE-5583

V1 System Junction Box Wiring Schematic ......... Ajax

TP BM-21161-C

V1 System Panel Mounting ................................. Ajax

02-19-T01A-300

Alternator Output vs Engine RPM w/5.33:1 Ratio........... Ajax

11-24-03

V1 Alternator Installation Instructions ............................. Altronic

ALT II 2-01

V1 Alternator Service Instructions................................... Altronic

A24 SI 2-01

Engine-Compressor Package Service Manual

Integrated Governor Throttle Body (Mechanical Assembly)


1302-000-04
Ref #
1
2*
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
24
25
26
27
28
29
30
31
32
34
37*
38

Description
IGTB Governor, 30mm, 24VDC
Cable & J-box Assembly
O-ring
Outlet Flange
Inlet Flange
SHCS #10-24 x 5 UNC
Lock Washer, #10
Support Bracket
HHCS, -11 UNC x 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

Note: refer to Manual's section 11 for additional


information about the IGTB system.
*shipped separately

Integrated Governor Throttle Body (Mechanical Assembly)


1302-000-04

091205

The IGTB is a combination of a throttle and an electronic governor, therefore integrated governor
throttle body or IGTB. Its function is to maintain an established RPM set point through out the load
range of the engine.
Note: the throttle is not a shut off valve. There is enough clearance between the body and the throttle plate
to allow the engine to run under certain conditions at less than rated idle RPM when the governor is not
powered.
As shown in Figure 1, the governor measures the RPM with a magnetic pick up and compares it to the set
point RPM supplied by the pressure transducer.
24vdc
supply
294 pulses/rev

3-15 psig =
300-440 RPM

1-5vdc

MPU

Fuel
Inlet

Fuel
Outlet

IGTB

Figure 1
RPM set point is established by a pneumatic 3 to 15 psig signal to the pressure-to-voltage transducer:
RPM Voltage Pressure
300
1.8
3
335
2.6
6
370
3.4
9
405
4.2
12
440
5.0
15

When the set point is changed to an increased value the rate of


acceleration to that value is 6 RPM/second.
When the set point is changed to a decreased value the rate of
deceleration is 12 RPM/second.
An attained RPM set point is maintained by PID values for best
response to changes in load.

The governor has an operating voltage range of 18 to 28 Vdc with a nominal voltage of 24V. The
governor consumes 32W maximum power at a peak current of 1.3A (24V) assuming 4 ohms stator
resistance at 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

Engine starts, but shuts down.

MPU gap too large

Engine starts, but does not accelerate to


idle RPM

Inadequate electrical
power

Engine starts and runs, but is unstable

Unable to attain rated RPM with a slight


load.

Ignition misfire
Precombustion Chamber
fuel supply
Gas Injection Valve
Adjustment
Pressure transducer output
low

Unable to develop full load RPM


Unable to idle at no load

Low fuel pressure


High fuel pressure

Suggested Test/Correction
Disconnect harness from governor. Test for
+24V between plug socket # 1 and # 5.
Rotate engine manually to check for 0.020 to
0.030 gap.
Disconnect harness from governor. Reset the
annunciator. Test for at least 2 Vrms between
pin 11 and pin 3 during cranking.
Remove the governor. Move throttle by hand.
Assess smoothness, friction, and return spring
force.
Rotate engine manually to check for 0.020 to
0.030 gap.
Assure that 18-28Vdc is supplied to governor
pin connections #1 (+Vdc) and #5 (Vdc).
Manually switch off governor power. Then
switch it on, and restart the engine. If RPM
control does not occur, replace the governor.
Troubleshoot the ignition system
Check for normal PCC fuel pressure, and
fouled or stuck check valves
Using combustion pressure measurement,
balance the firing pressures.
A 3-15 psig input signal should produce a 1.85vdc output signal. Apply 15 psig to the
transducer input. If 5vdc is not measured
between 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

--------5-8vdc at 100 RPM (min)


--------Electrical ground

RPM Set Point vs Signal (Vdc or PSIG)

Vdc PSIG
1.8
3
2.6
6
3.4
9
4.2
12
4.9
15

To MPU cable and


panels electrical ground
Do not allow the cable to be strained.
Support it if necessary.

Item
A
B
C
D
E
F
G
H
J

Description
Junction Box Assy
Wiring Schematic
Aux 24vdc Warning
Nameplate
Governor Cable
Voltage Reg Cable
Voltage Regulator
V1 Alternator Cable
Pressure Transducer

P/N
BM-21161
BM-21161-C
BM-21161-D
BM-21161-B
BM-21152-A-25
BM-21159
BM-21157
BM-21160
2515 0063

Qty
1
1
1
1
1
1
1
1
1

Cooper Compression
2101 S.E. 18th Street
Oklahoma City, OK
73129-8351

To 24Vdc battery ONLY

Cable & Junction Box Assembly


IGTB with V1 Alternator System
TP YAE-5583 r2

Note
If an electrical RPM set point signal is desired instead of
a 3-15 psig pneumatic set point, connect the 1-5vdc from
the set 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

Input from V1 System


Battery Box only.

IGTB with V1 Alternator 24VDC


Supply System J-box Wiring
TP BM-21161-C r3i

RPM vs Alternator Current @ 5.33:1


460
440
420
400

Engine RPM

380
360
340
320
300
280
260
240
2.0

2.5

3.0
Alternator Current

3.5

4.0

ALTR0N86 24VDC ALTERNATOR


ENGINE DRIVEN POVdER PACWGES

1.I

The Aitoonic 24VDC alternatorlregulator packages provide a reliable, engine-mounted source of DC power for
ABtronic DC-power& digital Igwt~ionsystems, dher Altronic engine accessories and Alcrsnic Controls panels.
There are two versions available.
VERSION I - The 590110 series (coupSing driven) or 5901 $ 6 series (belt driven) provide up to 70 watts
(3 amps) output ar 1,800 RPM.
VERSION 81 -The 5WI 11 ssries (coupling driven) or 5W1 I7 series (beEr driven) provide direct power for the
AIPronic CDI, CPU-90 and DlSN ignition system thus @ofistilutinga self-power&, digital ignition system.

1.2

The SslEowing components are required:


1.
2.
3.
4.

Alternaios Unit
Regulator (586 501 or 581502)
Cable A s s ~ ~ b i y
Battery Pack (591100) - used only wtth Version 6 series alternators

2.0 ALTERNATOR UNlT


2.1

COUPLING DRIVEN UNIT: The alternator is available with several flange assembiies to facilitale mounting to
most engines h a v i n ~a Range magneto drive. The alternator shou%abe secured to the mounting using 318"-16
screws; tighten the screws securely.

2.2

BELT DRIVEN UNIT: The alternator must be driven with a pulley having an adjustable 518" I.D. hub. Use a p~lYey
diameter Po achieve a speed necessary to satisfy the ~ r i l p urequirements
t
of %heapplication - refer to the chart
on drawing 509 0598 persion I) or 509 OBOA (Version El). The alternator should be secured to a mounting
bracket using two 318"-16 screws; tighten the screws securely.

2.3

The maximum recomrmended continuous operating RPM for the alternator drive shafi is 2,000 WPM.

3.1

Be sure ;he regulator is the ccprrecr model for the alternator being used; the regulator pari no. must match that
printed on the alternator label.

3.2

Locate a suitabse m o u n t i ~ gposition for the regulator unit within reach of the cable assembly and where the
ambient temperature does not exceed 150" F. (65" C.).

3.3

Secure the regulator with four 114" screws

4.0 BABrERV PACK (used oniy wlth Version l series alternator and 581501 regulator)
,

4.1

bocs$e3 sL&ebIa mcdf-;r.;,i-tg


ismitic;; c;r the banct\l !-~ack
an-ib~enttempersture does nor exceed 122' F. (5$ C.).

4.2

The battery pack IS fum3shec.v~ilthshock mounts and 314" mounting l-iardware. Tighten all isui rzt~tssee2ie3y

i~\iithinrest?? oi

c&;e e$se;;-;oii,
"

z,iqc i ~ ; ? ~ :I;,;
re

5.8 NfIRGNG HOOK-UP


5.f

5.2

Refer l o the drawil-igs for rnouriting dimensions for the various system componei?;s:
- For alternator dimensions, see drawing 509 056A.
- For regciator dims.&~ns, see drawing 509 357A.
- For battery pack dimensions, see drawing 509 058.
Refer l o fi-ie diagrams for the proper wiring hook-up for the particlala; altemator1reguiaPor version 5sing
- For the Version i system, see drawing 509 053A or 503 063W (shielded system).
- For the Vswior: il system, see drawing 509 060A or 509 0644 (shielded system).

~s2j-4:

~ E R S I O NI
MODEL

VERSION II
MODEL

PILOT DIAMETER *D"

5901 10/590111

FLANGE

ORIENTATION

SERIES

r-i

b:

MAX. SYSTEM WTPUT

NO. OF
.44 S L O J

NOTE:
1. MUST BE USED M T H A BATTERY BACK-UP:
A) ALTRONIC BATTERY PACK 591100; OR
B) TWO BATTERIES POWER SONIC MODEL PS-1242 OR
EQlJlVALENT 12V, 4.0 AMP-HR., WRED IN SERIES
2. POWER FOR ALTRONIC CD1, CPU-90.

DlSN SYSTEMS ONLY.

AmRNAToR~p
~l
l
I
usE

ONLY WITH

REWUlW WTFWT

NO',

k i G u L A T O R >I WULD BE MOUNTED IN A L0CATlCI.I WHERE MAXIMUM AMBlENr TEMPERATURE DOES NOT EXCEED 1 5 0 F

1 MENc10L!5

lh

INCHES AND (MM)

27 WC