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SERIAL N U M BER

CUSTOMER: GOLDER ASSOCIATES

EMERSON RENO SO#: 269278

TAG NUMBER: 420-ZMZ-981 217030


PASCAL#: 217030

Manufacturers of Custom Fluid Systems

Hydraulic Power Unit


O&M Manual
P ASCAL SYSTEM S

O peration and M aintenance M anual

 Pascal Systems
2350 Del Monte Street
Phone (916)-372-5411 • Fax (916)-373-0952

Pascal Systems has used its best efforts to manufacture a safe and reliable fluid power system.
Pascal Systems recommends the customer read and practice the techniques and procedures
included in this operation and maintenance manual. The information contained in this document
is, to the best of our knowledge, accurate. This manual is designed to augment the customers’
existing safety, operation and maintenance procedures. The information contained herein is
limited to the equipment supplied by Pascal Systems. Pascal Systems assumes no responsibility
for the resultant use of the information contained in this document.
O & M M A N U A L

Table of Contents
Section 1 Section 3
Safety Precautions 1 Maintenance and Spares 18
General Practices 3 System Cleanliness 18
General Safety Rules 4 Scheduled Maintenance 19
Spares List 22
Section 2
Installation and Operation 5 Section 4
ASME Relief Valves (Sound Level) 5 Factory Settings and Schematics 24
System Cleanliness 5 Factory Settings Table 25
System Flushing 6 Actual Test Data 26
Reynolds Number 6 Hydraulic Schematic with BOM 30
ISO Codes 8 Layout Drawing 31
Installation: Electrical Schematic 32
Service Connections 9 Control Philosophy 38
Indoor Locations 10
Outdoor Locations 10 Section 5
Placement Recommendations 10 General Troubleshooting 43
Integration Tips 11 Troubleshooting Table 45
Working Fluid 12
Fluid Type 12 Section 6
Fluid Manufacturer Examples 12 Component Cut Sheets 47
Initial Filling 12
Adding Fluid 12
Initial Start-Up 15
Preliminary 15
Adding Power to HPU (Isolated) 16
Adding Power to HPU (Connected) 17
O & M M A N U A L Section

1
Safety
Precautions

Safety is of the utmost concern to all persons involved with this


system. Careful review of this section is highly recommended.

T
he safety of personnel and preservation of equipment is the prime concern
during installation, testing, operation and maintenance of this equipment. This
safety section is as an addition to established safety procedures and practices in
place at this equipments final destination. These safety precautions are meant
as suggestions only. Pascal Systems is not responsible or liable for personnel safety or
the safe operation of the equipment provided. Pascal Systems assumes no liability for
the resultant use of these documents General Precautions.

Listed below are caution statements and symbols. Next to each symbol is a brief
description of the symbols meaning. These symbols will be used throughout this
manual. Please refer to these symbols and descriptions.

C A U T I O N S
This hydraulic system has operating pressures in excess of 3000
psi working on movable surfaces. These surfaces can generate
 Movable Surfaces large forces, which is a potential hazard for personnel. Care
should be taken while operating or maintaining the system to monitor the resulting
motion to prevent injury.

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O & M M A N U A L

Normal operations of hydraulic systems are at temperatures at


C A U T I O N S
and below levels to cause discomfort on unprotected skin. There
 High Temperature are conditions at which the fluid and surfaces will be above
138F that will cause burns to unprotected skin. Extreme caution and safety clothing
should be used while in contact with these surfaces.

The majority of hydraulic systems use an electric motor as the


C A U T I O N S
prime mover. This system may also include switches, solenoids
 Electrical Shock and/or motor starters running at high voltages. These high
voltages are at lethal levels. All electrical power must be disconnected anytime
maintenance is performed on this unit. Only qualified electricians should maintain the
electrical system of this unit.

This unit may be installed in an explosion prone area. Extreme


C A U T I O N S
caution should be taken in these areas. Area must be free of
 Explosion Area explosive gases, vapors and/or dust before any personnel enter
the area. Electrical power should be turned off before any maintenance is performed in
these areas. Extreme care should be taken to eliminate any form of sparking or other
ignition in this area.

Hydraulic fluid is flammable. Other debris in this area may be


C A U T I O N S
flammable as well. There should be no smoking or other forms
 No Smoking, of ignition in and around the location of this unit.
Flammable Area

Hydraulic systems operate with high pressure in the system.


C A U T I O N S
These pressures are present anytime the unit is in operation. This
 Pressurized Fluid system may also include energy storage devices (i.e.:
accumulators). These devices may allow high fluid pressures to remain in the system
when the system is not operating. Ensure the fluid is depressurized anytime maintenance
is performed on the unit. Though the hydraulic pressure is relieved, a gas pre-charge is
still present in the accumulators. This pressurized gas and fluid can cause serious injury
or death if accidentally discharged.

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O & M M A N U A L

G eneral Practices
Listed below are general practice statements and symbols. Next to each symbol is a brief
description of the symbols meaning. These symbols will be used throughout this
manual. Please refer to these symbols and descriptions.

Personnel are performing service or maintenance; the system


G E N E R A L
should be shutdown and locked out. Lock out tags and locks
P R A C T I C E S should be placed on the power disconnect for this system. If
 Lock-out Procedure multiple people are working on this system, then each person
should have a lock and tag on the main power disconnect of
this system. Any other controls related to this system should also be locked out at the
same time.

This unit includes complex hydraulic and/or electrical


G E N E R A L
systems. Only qualified personnel should service these
P R A C T I C E S systems. Qualified electricians familiar with local and federal
 Qualified Personnel laws and codes should service electrical systems. Personnel
not familiar with fluid power system should not maintain,
service, modify or adjust this system.

G E N E R A L Eye protection should be worn at all times in an industrial


P R A C T I C E S
environment. Fluid power systems have pressures that if
become un-contained can pose serious potential for eye
 Eye Protection injury.

Hearing protection should be worn at all times in an industrial


G E N E R A L environment. Fluid power systems have the potential of
P R A C T I C E S creating sound levels above 85 dB. Exposure to sound levels
 Hearing Protection above 85 dB can cause hearing damage.

Hydraulic systems can operate at elevated temperature and


G E N E R A L
with fluids that may cause tissue damage. Protective clothing
P R A C T I C E S is recommended when a hydraulic system is being serviced or
 Protective Clothing maintained. Hardhats may be required in certain areas and/or
situations.

When this system is being serviced, maintained or altered a


G E N E R A L record should be made of the procedure and the results.
P R A C T I C E S
Record keeping will allow “back tracking” if the desired
 Record Keeping results are not obtained. This manual includes a copy of the
original test results for base reference. Records should also
be kept of fluid contamination levels, change intervals and general service intervals.

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O & M M A N U A L

G eneral Safety Rules


Each person involved with the operation, maintenance or testing of this equipment
should coordinate his or her tasks with the on-site supervisor

All personnel involved with this equipment should familiarize themselves with the job
site and job site procedures. These persons should attend brief safety meetings offered
by on-site safety personnel.

This system contains pressurized fluid and should not be


G E N E R A L
tapped when the power unit is active or power is available to
P R A C T I C E S the power unit. The hydraulic and electrical systems should
 Lock-out Procedure be properly locked out before anyone enters the system area.

Two or more people should be present anytime equipment is being serviced in remote
locations.

Caution must be observed anytime tools or possible ignition


C A U T I O N S
sources are used on or near the equipment. These sources of
 Electrical Shock ignition may also be in the form of electrical components when
 Explosion Area an electrical enclosure is opened. A fire extinguisher must be
 No Smoking, kept nearby at all times.
Flammable Area

Loose clothing should be avoided around moving or rotating equipment. Gloves and
other safety clothing should be worn when handling hydraulic fluid. Safety glasses must
be worn at all times.

Never place containers, liquids or other items on the surface of the equipment

A first aid kit should always be kept nearby. All persons on the job site should know
where the first aid kit is and how to use it.

Always work safely. Never take undue risks that can cause harm to personnel or
equipment.

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O & M M A N U A L

Section

2
Installation and O peration

This section on Installation and Operation is a guide to help the


personnel installing and operating this unit. Since these units are
used in diverse environments, this section provides helpful tips for
the install and operation of this unit. This is not a comprehensive
installation and operation procedure.

Q
ualified personnel are required for the proper installation and operation of
this unit and associated systems. This section is not meant to be a step-by-
step procedure to guide unqualified personnel through this process. If in
doubt, qualified and licensed electrical and mechanical contractors should be
utilized for these requirements. These contractors will be familiar with the
local laws and codes concerning industrial equipment and the proper installation and use
of such equipment.

A special note on relief valves: Some power units are constructed with ASME
rated direct acting relief valves. The relief valves on the valve actuation power
units are also used for maximum pressure regulation. Anytime only 1 valve is
actuated, the power unit will supply more flow than is required. The excess flow
will be diverted back to the reservoir through the reliefvalve. When this happens,
the ASMEstyle relief valves are extremely loud – approximately 105 dBa. This
high sound level is no problem for the power unit, but destructive to human
hearing. Appropriate hearing protection MUSTbe worn at all times.

System Cleanliness
The main piping system to which this power unit/system is connected is to be properly
cleaned and flushed prior to operation. This flushing of the piping of the system will
help minimize system contaminates and promote longer system and component life.

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O & M M A N U A L

Contaminated fluid is the primary reason for fluid power failures. Pascal Systems
warranty is based on fluid cleanliness. Refer to the warranty section in the proposal
governing the purchase of this system.

System Flushing

The hydraulic system and piping requires flushing PRIOR to


G E N E R A L the connection of this power unit/system. Proper flushing
P R A C T I C E S requires a dedicated flushing skid with integral or remote
 Qualified Personnel reservoir. These skids are available for rent from most fluid
power distributors. Check your local phone directory for
fluid power distributors in your area.

Proper flushing will require use of a flushing fluid or hydraulic fluid compatible with
the intended working fluid of the system. Flushing also requires spare filter elements as
contamination may necessitate continual filter element replacement.

Reynolds N um ber

Once the fluid, filter skid and filters are in place, the fluid must flow at a rate and
temperature high enough to obtain a Reynolds number above 4000. The Reynolds
number calculation is shown below:
Re = Reynolds Number
Q = Flow Rate in GPM
d = Inside Pipe Diameter in Inches
 = Viscosity of Fluid at Operating Temperature in SSU

Re > 4000
Re = (14,646 X Q)
( X d)
The viscosity is indirectly proportional to the fluid temperature. This means as the
temperature increases, the viscosity decreases. As seen from the equation above, the
same fluid at the same flow rate will have a higher Reynolds Number at a higher
temperature because the fluid viscosity will decrease.

Flushing Tips

The flushing is for the piping only. All hydraulic components


G E N E R A L
in the system should be removed or “plumbed around”
P R A C T I C E S during the flushing process. Sub-plate mounted valves are to
 Protective Clothing be removed and “flushing blocks” bolted on in their place.
The hydraulic power unit is not to be plumbed into the
system; it is to be “plumbed around” like all the other components. The power unit and
all other components should be “clean, flushed and capped” from their respective

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O & M M A N U A L

manufacturers. Consult testing documentation supplied with this equipment for ISO
cleanliness test specifications.

All components and/or power unit to remain capped and/or bagged until flushing is
complete and the components are to be installed on the system.

As flushing commences, it is common to get large quantities of air out of the system and
into the flushing skid. This may cause excessive fluid aeration and pump cavitation. This
will be perceived as the pump being excessively noisy. If this condition persists,
shutdown the unit and allow the air to “settle out” and recommence flushing once fluid
is clear.

Flush one leg of the hydraulic system at a time. This will help ensure the Reynolds
Number remains above 4000. Flexing or vibrating will aid the flushing process

Strike pipe welds with a hammer during the flushing process.


G E N E R A L This will help loosen any weld slag in the pipe.
P R A C T I C E S

 Eye Protection

Constantly monitor the filter element conditions. The filters


G E N E R A L
must be changed before the elements go into a bypass
P R A C T I C E S condition. Replace the elements on indication. If the filters
 Protective Clothing go into a bypass condition, the filter elements must be
replaced and the flushing process restarted.

The system must be flushed following the above-mentioned tips and guidelines for a
minimum of one hour per 100 feet of pipe. This length is for the combined length of
pressure, working and return lines per leg.

Once flushing is near completion, the flushing oil must have an oil analysis to check the
contamination level. The contamination levels must be as listed in the table below, or
better:

Water Level Particulate Filter Rating Preference


Contamination Level Status
<200 ppm 19/18/16 Β10=200 Maximum Acceptable
<100 ppm 17/15/13 Β5=200 or Β3=200 Preferred

The oil sample is to be taken from the return side of the flushing skid while in operation.
This must be a dynamic sample to get an accurate reading.

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O & M M A N U A L

Many flushing skids have automatic particulate counters. This may be used in place of
an oil sample and lab or comparator analysis.

Once the cleanliness reaches the levels stated in the above table, the flushing of that line
is complete. This must be done to all lines in the piping system. Components (such as
power units, cylinders, valves, etc.) are not to be flushed. Flushing is only needed on the
field installed piping.

It should be noted that welded pipe will require longer flushing times than tubing that is
connected via non-weld type couplings (Swagelock compression, 37º JIC Flare, etc)

ISO Codes are listed below:

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O & M M A N U A L

Installation

Service Connections

Electrical: Electrical connections vary from system to system. Refer to section 4 of this
manual for detailed electrical requirements. The electrical
G E N E R A L connection will be to the motor starter panel (if so equipped)
P R A C T I C E S
or directly to the motor(s) and other electrical devices
mounted on this unit. The electrical connections should be
 Qualified Personnel the same NEMA rating as the device being powered. All
 Electrical Shock these connections must be in accordance with the National
Electric Code and local laws and codes. Only qualified and licensed electrician familiar
with industrial systems should make these connections.

Water: Water connections are needed for units equipped with water to oil cooling
systems. The water supply should be clean and of sufficient temperature and flow for
adequate cooling of the system. Refer to section 4 for water requirements. The water
supply line should include a shutoff-valve and strainer located at the unit if the unit is
not equipped with such devices. The return line of the heat exchanger must be
connected to facility drain. This should include a check valve at the unit if this unit is
not equipped with this valve.

Hydraulic: Hydraulic connections are located on the power unit and are the pressure,
return and working ports. These ports have been designed and applied for the units
intended flow and pressure requirements. Refer to section 4 of this manual for detailed
hydraulic interface connections. The connections made to the unit should be the same
size as on the unit. Pressurized connection lines should be rated for 4:1 minimum safety
factor. Assume the system pressure to be the compensation pressure for maximum
pressure on pressure compensated units or the relief valve setting on fixed displacement
units. Ensure these connections are flushed as described in the Flushing portion in this
section. Seals and flexible lines must be compatible with the working fluid.

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O & M M A N U A L

Location

The proper location and placement of the power unit is critical to the unit’s longevity.
The location and placement is dependent on the design of the unit and accessories
included on the unit. The units are either designed for indoor use only or covered
outdoor usage. Refer to section 4 for the rating of this unit. Each system design
requirements are briefly discussed below:

Indoor U se U nits

Indoor use units are to be located indoors in a clean and dry environment only. The
unit is not designed for water exposure, this means rain or water and/or chemical wash
down. The ambient temperature must remain between 32F and 130F (see fluid
recommendations in section 4).

O utdoor U se U nits

Outdoor units can be placed outside as long as they are covered. The covering should
be sufficient to repel direct rain on the unit. The unit will tolerate indirect rain and low-
pressure water wash down. No harsh cleaning solvents or high-pressure water spray
should be used on this unit. The unit must be kept free of snow and ice. The ambient
temperature must remain between 32F and 130F (see fluid recommendations in
section 4).

Placem ent Recom m endations

These placement guidelines are valid for both indoor and outdoor units.

The unit should have easy access to all sides for ease of maintenance. It is recommended
a minimum of 36” free of obstructions on all sides. If this unit is equipped with an
electrical panel, the National Electric Code has strict access requirements for electrical
panels. Please refer to a qualified electrician for compliance to compliance to National
Electric Code and any local laws and codes.

The flow of air to the cooling fan on the electric motor must not be obstructed. It is
recommended there is at least 24” free space behind the electric motor.

Should this unit be equipped with a forced air-cooling system, the unit must have at least
48” free space on the exhaust side of the cooler and 36” free space on the inlet side of
the cooler. As these cooling fans usually generate high sound levels, the placement of
the unit must take into account the interaction of people and the sound levels.

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O & M M A N U A L

Integration Tips

An important factor in the longevity of this unit is the attention paid to cleanliness on
installation. The majority of contaminates are introduced into the system on installation
or service. Below are some preventative measures to help minimize the introduction of
contaminates into the system.

All ports on this unit and other components must remain plugged until just before
connection to the overall system. These ports should have tightly fitting metal or plastic
plugs and/or covers. These are only to be removed at the time of installation.

Any fluid conductor not flushed must be clean, free of rust, scale or other contaminates
and tightly capped. The caps are only to be removed at the time of installation of the
conductor into the system.

All openings on the reservoir must remain closed during installation. Examples of these
are filler/breather caps, clean-out covers and access covers.

Pipe thread connections are to be avoided if possible. If pipe


G E N E R A L
threads are used, they should be sealed with an appropriate
P R A C T I C E S
sealing compound. Loctite “PST” thread sealant is
 Qualified Personnel recommended for pipe threads. Teflon tape is not
recommended. Qualified fluid power technicians should be used during installation.

Ensure the unit is properly secured in its final location and all fasteners are torqued
properly. All connections are to be checked for proper assembly. The system should
be complete with the exception of the working fluid.

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O & M M A N U A L

W orking Fluid

Fluid Type

This power unit is designed to use a standard mineral based hydraulic fluid. ISO 46
grade is best suited to a wide variety of conditions. Examples of this fluid are as follows:

Ambient Temperature ISO Grade Hydraulic Fluid Manufacturers Examples


Range
Chevron Rykon 32
-20°F* to 80°F 32 Shell Tellus Premium 32
Mobil DTE 24
Chevron Rykon 46
10°F to 100°F 46 Shell Tellus Premium 46
Mobil DTE 25
Chevron Rykon 68
40°F to 120°F 68 Shell Tellus Premium 68
Mobil DTE 26
* Reservoir Heater needed at temperatures below 10°F

Phosphate Ester or water glycol fluids are not acceptable for this power unit.

Synthetic oils are acceptable as long as they are compatible with the above mentioned
brand of oil.

Initial Filling

Once the system has been properly flushed, the unit properly installed and all
connections (electrical and mechanical) have been checked and verified correct, fluid can
then be introduced into the system. The following guidelines are for the initial filling of
the reservoir. Topping off and bringing the system to proper fluid levels are discussed
in the “Adding Fluid” portion of this section.

The correct fluid is critical to the proper operation of any fluid power system. Refer to
section 4 of this manual for recommended fluid types. Poor performance may be caused
by improper fluid type.

Before the initial filling of the reservoir, ensure there is enough fluid on-hand for the
system. This fluid amount will be at least the “Total Reservoir Volume”, not the
working volume. More fluid may be necessary dependent on the amount of plumbing,
actuator type and system design. This manual only describes the hydraulic power unit,
and not the entire system.

The fluid used should be from the same manufacturer and be the same type and
viscosity. Mixing fluids is not recommended.

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O & M M A N U A L

The fluid is to be filtered into the unit. Pouring the fluid into the unit is NOT
recommended. The fluid should be transferred with a filtered fluid transfer cart. The
filter should be a 6=200 rated filter minimum.

The reservoir should be filled ¾ of the way up the sight glass*. This is a good initial
starting point for starting the system. Refer to the initial start-up portion in this section.

*Note: This starting fluid level is only appropriate if all the knife gate valves ate in the
open position. If the valves are not in the open position, it is recommended to use a
Hydra-Helper or other such portable power unit to ensure all valves are open. This must
be done prior to filling the hydraulic reservoir of the main power unit.

If the power unit has accumulators, the accumulators are to be charged to the
appropriate Nitrogen pre-charge level as described in section 4. This must be done prior
to start-up and prior to filling of the reservoir.

Once the valves are verified as all open and the reservoir is filled up to the ¾ level on
the sight glass, the power unit is ready for the initial start up.

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O & M M A N U A L

Adding Fluid

Maintaining proper fluid levels is essential to the proper operation of fluid power
systems. Some guidelines to adding fluid to an established system are presented below.

The addition of fluid is recommended when the system is


C A U T I O N S powered down. Cylinders are recommended to be fully retracted.
 Pressurized Fluid Accumulators are to be discharged back to the reservoir. When
these steps are followed, this will yield the true reservoir volume.
Failure to follow these procedures may result in reservoir overflow upon system
shut down.

Do not add fluid while the system is in operation. See above.

The correct fluid is critical to the proper operation of any fluid power system. Refer to
section 4 of this manual for recommended fluid types. Poor performance may be caused
by improper fluid type.

The fluid should be from the same manufacturer and be the same type and viscosity.
Mixing fluids is not recommended.

The fluid is to be filtered into the unit. Pouring the fluid into the unit is NOT
recommended. The fluid should be transferred with a filtered fluid transfer cart. The
filter should be a 6=200 rated filter minimum.

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O & M M A N U A L

Initial Start-up

Prelim inary

Ensure the unit is properly secured in its final location and all fasteners are torqued
properly. All connections are to be checked for proper assembly. The system should
be complete filled with the working fluid as outlined earlier in “Initial Filling”.

Accumulators should be charged with nitrogen to the specified


C A U T I O N S
precharge pressure. The precharge pressure is given in section 4
 Pressurized Fluid if the accumulator is built into this unit. If the accumulators are
 Explosion Area integrated into the system, and not part of this unit, refer to the
system integrator for proper precharge levels. Fill with
Nitrogen only. Do not use shop air. Any other gas than dry nitrogen can be an
explosion hazard.

Vertical power units have self-filling cases.

Suction and case line valves need to be full open to the pump. Vertical units do not use
suction and case line valves.

Should the unit be equipped with pressure and/or return ball valves, these should be full
open.

Electrical power connections should be verified. Verify


G E N E R A L
correct wiring of the motor starter panels and/or electric
P R A C T I C E S motors. A qualified electrician should do this only.
 Qualified Personnel
 Electrical Shock Power should be connected to the motor starter panel on the
unit if so equipped. If there is not a starter panel on the unit,
power should be connected to the motor controller. The power to the motor should
remain off. A qualified electrician should make these connections.

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O & M M A N U A L

Appling Pow er to Pow er U nit (Isolated from the System )*

*This has been completed at the factory – does not need to be completed in the field.
Skip to section (Applying Power to Power Unit – Connected to the System).

Use the motor starter panel and controls (either on the unit or mounted remotely) to jog
the pump/motor set. This should be done in Local mode if this system can be either
remotely or locally controlled.

When power is applied to the motor starter panel, ensure there are no fault conditions
(i.e.: low level fault, high temperature, etc.). This applies to systems with fault indicators
only.

Jog the motor to check for proper rotation. A rotation sticker


G E N E R A L
is affixed on the motor and/or pump. The motor should not
P R A C T I C E S run for more than 2 seconds. Reconnect wiring to change
 Qualified Personnel motor direction if needed. A qualified electrician should do
 Electrical Shock this only.

Once correct rotation is confirmed, check rotation of other pump motor sets if so
equipped.

Note: Jog the pump/motor set for 4-6 seconds. Repeat this 3-5 times to aid the pump to pull
This has been a proper prime and vertical power unit pumps allow the cases to fill.
completed at
Pascal Systems Start the pump/motor set and let run under a no load condition for 30-60 seconds.
factory and is Gradually apply pressure as shown below:
not needed to be
completed in the No Load for 30 seconds
field. 500 psi for 30 seconds
Back to no load for 30 seconds
This is for 1000 psi for 30 seconds
reference only. Back to no load for 30 seconds
1500 psi for 30 seconds
And so on until full system pressure is reached.
Repeat for each pump/motor set.

Shut-off power to electric motors and allow system to


C A U T I O N S
depressurize. If accumulators are present on the unit, allow them
 Pressurized Fluid to discharge back to the reservoir. This discharge may be
automatic or may have to be done manually. Refer to the system hydraulic schematic as
needed.

Connect the unit to the system. Ensure the connections are clean and correct for this
application.

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O & M M A N U A L

Appling Pow er to Pow er U nit (Connected to the System )

The guidelines in this portion of Section 2 should only be


G E N E R A L
used after the two afore mentioned sections are completed.
P R A C T I C E S Due to uncertainty in reaction in systems on initial start-ups,
 Qualified Personnel qualified Fluid Power Technicians or other similarly qualified
personnel should perform initial start-ups.
All electrical connections should have been tested and verified by this point.

The unit should be connected to the system. The fluid level in the reservoir should be a
level ¾ the way up the sight glass. If fluid needs to be added, refer to the “Adding Fluid”
section.

If the unit has an accessible means of controlling the pump pressure (either remote
Note: compensator or relief valve), turn the adjustment out fully counter-clockwise to its
lowest pressure setting.
This section may be
skipped if the field Start the pump/motor set and allow to come up to the now lower pressure setting. If
installed piping or the unit or system is equipped with a pressure bypass valve, slowly close the valve and
tubing has either allow the system to come to pressure.
been pressure
checked, hydro- Slowly raise the pressure to a level that allows the system to run in a no-load condition.
tested of inspected Allow the air from the system to be purged back to the reservoir. If the pump begins to
to be sure all cavitate due aerated fluid, shutdown the system and allow the entrained air to settle out.
connections are
correct and designed Once the air is purged from the system, check the fluid level in the reservoir. See
for the operating “Adding Fluid” previous in this section.
pressure the system
is able to produce. Run the system and check for proper operation and
G E N E R A L
If this cannot be movement. Keep the pressure just high enough to operate
done, then follow P R A C T I C E S the system in a no-load condition. Retract all cylinders and
the steps outlined in  Qualified Personnel allow accumulators to discharge back to tank. Shutdown
this boxed section. pressure to the system and add fluid to a level of ½ way up
the sight glass. See “Adding Fluid” previous in this section.

Start the pump/motor set again and resume bringing the system up to it normal
operating pressure. Begin to load the system and allow the system to come up to
operating temperature (see section 4 for details). Check for any leaks at this time. Repair
leaks as needed.

Restore pressure compensator and/or relief valve preset


G E N E R A L
pressures as shown in section 4. This may have to be done
P R A C T I C E S by isolating the power unit from the system.
 Record Keeping

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O & M M A N U A L

Section

3
M aintenance and Spares

Proper maintenance of industrial equipment is fundamental to safe


and proper operation. The longevity is directly proportional to the
level of proper maintenance.

ost industrial systems are designed for years of reliable service. Even with

M the best designs and components, this service life will not be realized without
proper maintenance. This maintenance section is for the unit for which this
manual is written only. Should there be other maintenance procedures and
schedules for the overall system, these procedures should be considered “in addition to”
and not in place of those procedures.

System Cleanliness
System cleanliness should be given top priority in any maintenance procedure. The
majority of hydraulic failures are linked to contamination of the fluid.

Check filters routinely. Systems that operate daily should have filters replaced on
indication or every six months, which ever occurs first. Replace only with equal or better
grade filter media with the same micron and same or better beta ratio.

This fluid system has been supplied with quality filter elements designed to maintain
proper fluid cleanliness over the life of the filter element. Note: Replacement elements
are not equal even though they are advertised as interchangeable. Use of inferior
replacement elements jeopardize the life of your equipment and may void the warranty.

System cleanliness is also considered outside cleanliness. Clean up any spills immediately.
Keep the unit free of excessive dust or debris. Observe good house keeping at all times.

18
O & M M A N U A L

Scheduled M aintenance

There are times when maintenance requires the shutdown of the unit. Should this be
true, then follow “Normal Shutdown” in section 2 of this manual. Observe proper
lockout procedures.

A shutdown may be needed for maintenance reasons. If so,


G E N E R A L follow proper lockout procedures. Isolate power from the
P R A C T I C E S
unit via the main power disconnect. Physically lock the unit
 Qualified Personnel with a keyed lock to which there is only one key. Tag for
maintenance as appropriate. Discharge any pressure in the
 Pressurized Fluid system back to the reservoir. This may have to be done
 Lock-out Procedure manually via accumulator dump valves.

Daily

Check fluid level in reservoir. Refer to “Adding Fluid” in section 2 of this manual if fluid
addition is required.

Check fluid temperature. This may be a capillary or dial type thermometer on the
reservoir sight glass. Shutdown if fluid temperature is too high (refer to section 4 of this
manual for operating fluid temperatures), refer to section 2 “Normal Shutdown” if
needed.

Keep surface of unit clean and free of any debris.

Check filters indicators. Replace elements as needed. Refer to section 2 “Normal


Shutdown” as needed.

W eekly

Perform all daily services.

Check entire system for external leakage. Repair immediately. Clean up any spilled fluid
immediately. Observe good house keeping practices.

Check fan guard on electric motor. Clean and/or repair as needed.

Should this unit be equipped with an air to oil heat exchanger, clean air passages and
cooling fins.

19
O & M M A N U A L

M onthly

Perform all daily and weekly services.

Check accumulator precharge. Refer to “Accumulator Precharge” late in this section.

Should this unit be a foot mounted style pump, check coupling alignment and wear.
Replace and/or lubricate as needed.

This unit may include air-bleed valves. Check for proper functionality.

Q uarterly

Perform all daily, weekly and monthly services.

Pull a fluid sample for a fluid analysis report. Have this fluid
G E N E R A L
analyzed by an outside lab and keep records of the findings.
P R A C T I C E S Most labs can perform these reports and send to you at
 Record Keeping reasonable rated. Check with a local fluid power distributor
for access to these types of services. The fluid cleanliness
should be as shown in the table below:

Water Level Particulate Filter Rating Preference


Contamination Level Status
<200 ppm 19/18/16 Β10=200 Maximum Acceptable
<100 ppm 17/15/13 Β5=200 or Β3=200 Preferred
Yearly

Perform all daily, weekly, monthly and quarterly services.

Lubricate bearings on electric motors.

Replace air breather filter or breather cap.

Every 5 years

Check drive couplings on C-face mounted pump/motor sets. Repair and/or replace as
needed.

Clean or replace suction strainers if so equipped

Inspect and Replace, as needed, all hoses and soft parts.

20
O & M M A N U A L

Spares List

Below is the recommended spared list for this unit. This list is only for the unit covered
in this manual and not for the system for which this unit is attached. Please refer to the
system integrator for complete and detailed information on the entire system.

These are recommended spares only. The list may need to be expanded dependent of
operating and ambient conditions to which this unit is subject.

Commissioning Spares: These are consumable spares that will usually be expended
in the normal start-up of a fluid power system. The quantities are set for a standard start-
up of the system. The usage may be higher or lower dependent on individual
requirements.

Consumable Spares: These are spares used in normal operation. The quantities are
set for a year of use of the fluid system as initially designed.

Breakdown Spares: These are spares associated with catastrophic failure of the system
that could result in loss of production.

21
O & M M A N U A L

Description M anufacturer M anufacturer Part Q TY


N um ber

Commissioning Spares

Return Filter Element Stauff RE130G05B 1

Consumable Spares

Return Filter Element Stauff RE130G05B 2/year

Desiccated Air Breather Stauff SDB93 1/year

Breakdown Spares

3.6 GPM pump @ 1800 RPM Permco PT7BS-B02-1R00-A1-01 1

Adjustable Relief Valve Sun Hydraulics RPGC-LWN Set 3500 psi 1

Soft Seat PO Check Module Sun Hydraulics CKCA-LCN-EBY 1

Air Bleed Soft-Start Valve Sun Hydraulics NQED-XBN 1

Drive Coupling Insert Magnaloy M370H 1

Solenoid Valve, 2 Solenoid Yuken DSG-01-3C4-A120-7090 1

Solenoid Valve, 1 Solenoid Yuken DSG-01-2B2-A120-7090-L 1

2 Pos 2 Way Poppet Valve Hydraforce SV12-23-12T-N-120AP 1

Pressure Switch, Set 2900/3000 IFM Efector PN4221, E18243, E30006 1

15 Gallon Bladder Repair Kit Accumulators Inc. AI-15-3KT 1

22
O & M M A N U A L

N otes:

23
O & M M A N U A L

Section

4
Factory Settings &
Schem atics

The factory settings and schematics provide a road map to the


performance characteristics of this unit.

T
his section details in table and drawing form how this unit left the factory. This
is an excellent section for referral back to original settings if settings of this unit
get changed. This section includes hydraulic and electrical schematics (as
applicable). The other useful document is a copy of the actual test report. This
is the actual test data recorded on this unit prior to shipping.

Factory Settings
The factory settings page is a quick reference table on frequently needed information on
specific units. The data is specific to this serial number unit only; it is not data for the
system, which this unit is integrated.

Schem atics & Bill of M aterials


The schematics in this manual are electronic copies of as-built drawings. These drawings
include the bill of materials of major components used in the manufacture of this unit.
Major component cut sheets later in this manual are based on this bill of materials.

Actual Test Data


A copy of the actual test report for this unit is included in this section.

24
O & M M A N U A L

Factory Settings Sum m ary Table

Electrical 460-480 VAC 3 Phase 60 Hertz 30 Amp Recommended Supply

Settings and Capacities

Reservoir Pump 1 Flow Pump 2 Flow Accumulator Relief Valve 1 Relief Valve 2

100 gallon 3.6 GPM 3.6 GPM 2000 PSI* 3500 PSI 3500 PSI

Fixed Fixed * Shipped at


Displacement Displacement 0 PSI

Heater T’Stat Low Level Low Level High Level High Temp High Temp
Warning Shutdown Warning Warning Shutdown

80°F N/A 1/3 Full N/A N/A 150°F

Recommended Fluid ISO 46 Hydraulic Fluid (Shell Tellus 46 or Equal)

Ambient Conditions Outdoors (Cover Min Temp: Max Temp:


Recommended) 20°F 110°F

Hydraulic Connections

Pressure Port N/A Return Port N/A Valve Working #12 SAE
Ports (4 each) O’Ring Boss

Electrical Connection(s)

Main Power Breaker in NEMA 4X Panel Conduit Connection to be Installed on Site

25
26
27
28
29
30
31
32
33
34
35
36
37
O & M M A N U A L

Control Philosophy
This control philosophy is to be used with the hydraulic schematic of this system as this narrative refers
to components in the schematic.

References:
Hydraulic Schematic Drawing Number: SC217030-FS Revision F

Controlled Elements:
Item 2 Reservoir Temperature/Level Gauge
Item 5 Low Level Switch
Item 6 Hydraulic Pump #1 & 2
Item 7 Electric Motor for Pump #1 & 2
Item 19 High Temperature Switch
Item 15 Pressure Gauge for Pump #1 & 2
Item 22 Return Filter and Return Filter Pressure Gauge
Item 26 Fail Last D03 Directional Control Solenoid Valve
Item 28 Flow Control Valve
Item 31 Combined Pump Pressure Gauge
Item 34 Accumulators
Item 33 Accumulator Flow Solenoid Valve
Item 36 Pressure Switch, 2900 psi closed, 3000 psi open
Item 38 Fail Close D03 Directional Control Solenoid Valve
Item 31 Accumulator Pressure Gauge

Theory of Operation

Accumulator Control

The pump motor sets (Items 6&7) are used only to keep the accumulators charged between 2900 psi and
3000 psi. This works exactly the same as an air compressor. Anytime the accumulator (item 34) shown
on pressure gauge (item 39) pressure is below 2900 psi, the pressure switch closes (item 36), calling the
pump motor set 1 (item 6&7) to energize. Pump motor set 1 runs until the accumulator pressure reached
3000 psi, at which time the pressure switch contact opens. When the pressure switch contact opens, the
pump motor set is to turn off. When the accumulator pressure falls below 2900 psi and the pressure
switch contact closes, alternate to pump motor set 2 to energize. Run pump motor set 2 until the
pressure in the accumulator reached 3000 psi and the pressure switch contact opens. When the pressure
switch contact opens, shut down pump motor set 2. Repeat as needed, alternating between pump motor
set 1 and pump motor set 2. At all times, except when a knife gate valve is to be opened or closed,
accumulator flow solenoid (item 33) is to remain energized.

38
O & M M A N U A L

Anytime a pump motor set is being started, monitor the pump pressure gauge (item 15) and combiner
pressure gauge (item 31). If this pressure does not rise above 500 psi in 15 seconds, shut down the pump
motor set and trigger fault for that pump motor set. Energize the alternate pump motor set to charge the
accumulator bank. If this pump motor set fails to build to 500 psi in 15 seconds, fault the entire power
unit.

At any time a pump motor set is running, monitor the reservoir level (item 5). If the level falls low and
actuates the level switch (contact opens on low level), shut down the pump motor set and fault the power
unit. The pump motor sets must never run on a low level condition.

At any time a pump motor set is running, monitor the reservoir temperature (item 19). If the
temperature goes high and actuates the temperature switch (contact opens on high temperature), shut
down the pump motor set and fault the power unit. The pump motor sets must never run on an over
temperature condition.

Knife Gate Valve Actuation


The pump motor sets are completely controlled via the pressure switch to keep the accumulators
charged. Any time a knife gate valve is operated, the accumulators will lose pressure and the
pump motor sets will run as outlined on the previous section “Accumulator Control”. The pump
motor sets do not directly actuate the knife gate valves.

Fail-Last Valve Control (Valve 1)


Assumed condition: Emerson Knife Gate Valve is in position.

1 An Emerson Knife Gate Valve is commanded to either open or close.

2 The open or close solenoid is energized on the directional solenoid valve (Item 26).

3 Accumulator Flow Solenoid (item 33) is de-energized to allow flow into the valve bank to
actuate the knife gate valves.

4 A pump motor set will automatically start as outlined in “Accumulator Control” section.

5 As the knife gate valve is moving, Monitor Return Filter (Item 22) with integral gauge.
5A If pressure goes high – Show Filter Warning (40 PSI)
5B Maintain power unit running
5C Filter should be serviced at earliest convenience.

6 Maintain Accumulator Flow Solenoid as de-energized until:


6A Emerson Knife Gate Valve is in position as shown by Knife Gate Limit Switch
6B If unit has run more than 10 minutes and valve is not in position
6B1 Shut down power unit and have a Valve Position Fault
6B2 Have inspection of the knife gate valve and see if it has made position or
not.
6B3 Correct Problem

39
O & M M A N U A L

7 Once the knife gate valve is in position, de-energize the directional control valve solenoid
(item 26)

8 At the same time the knife gate valve comes into position and the directional control valve
solenoid is de-energized, energize the Accumulator Flow Solenoid (item 33) to stop flow to
the valve bank and to the knife gate valves.

9 Unit is now back to the Assumed Condition: Knife Gate Valve are in position.

10 Repeat for further valve operations

Fail-Close Valve Control with power (Valve 2)


Assumed condition: Emerson Knife Gate Valve is in position.

1 An Emerson Knife Gate Valve is commanded to either open or close (Valve 2).

2 The open or close solenoid is energized on the directional solenoid valve (Item 38).
3A If the valve is commanded open, the open solenoid must be energized for the
knife gate valve to open.
3B If the knife gate valve is commanded close, the directional open solenoid must be
de-energized, but no close solenoid is present. The valve is spring biased to close,
so a close command only requires the open solenoid to be de-energized.

3 Accumulator Flow Solenoid (item 33) is de-energized to allow flow into the valve bank to
actuate the knife gate valves.

4 A pump motor set will automatically start as outlined in “Accumulator Control” section.

5 As the knife gate valve is moving, Monitor Return Filter (Item 22) with integral gauge.
5A If pressure goes high – Show Filter Warning (40 PSI)
5B Maintain power unit running
5C Filter should be serviced at earliest convenience.

6 Maintain Accumulator Flow Solenoid as de-energized until:


6A Emerson Knife Gate Valve is in position as shown by Knife Gate Limit Switch
6B If unit has run more than 10 minutes and valve is not in position
6B1 Shut down power unit and have a Valve Position Fault
6B2 Have inspection of the knife gate valve and see if it has made position or
not.
6B3 Correct Problem

7 Once the knife gate valve is in position:


7A If closed, no action is taken with the directional control valve. The open solenoid
must remain off.
7B If the knife gate valve is to be open, the open solenoid must remain energized.

40
O & M M A N U A L

This solenoid is to remain on at all times that Valve 1is to remain open. When
Valve 1 is open, the open solenoid it to remain on. If Valve 1 is to be closed,
the open solenoid it to be off.

8 At the same time the knife gate valve comes into position and the directional control valve
solenoid is de-energized, energize the Accumulator Flow Solenoid (item 33) to stop flow to
the valve bank and to the knife gate valves.

9 It is to be noted: Solenoid valve for knife gate Valve 1 is a fail close biased solenoid. There
is no blocked position like knife gate solenoids for Valve 2. As such, anytime the pump
motor set charges the accumulator bank, pressure is also directed to knife gate valve cylinder
for Valve 1. If the solenoid open solenoid is energized and the knife gate valve is open, it will
only re-affirm the knife gate valve is open. If the open solenoid is off and the knife gate valve
is closed, it will only re-affirm the knife gate valve is closed.
If the valve is open and the open solenoid is not energized, the pressure from the
pump motor set to charge the accumulators will force the valve closed.

10 Unit is now back to the Assumed Condition: Knife Gate Valve are in position.

11 Repeat for further valve operations

Fail-Close Valve Control on loss of power (Valve 1)


Assumed condition: Emerson Knife Gate Valves are in position and there is power to the control panel.

1 The power unit control panel loses power.

2 The open solenoid loses power on the directional solenoid valve (Item 38).

3 Accumulator Flow Solenoid (item 33) loses power to allow flow into the valve bank to actuate
the knife gate valves.

4 A pump motor sets cannot run due to loss of power.

5 As the knife gate valve is moving, Monitor Return Filter (Item 22) with integral gauge.
5A If pressure goes high – Show Filter Warning (40 PSI)
5B Maintain power unit running
5C Filter should be serviced at earliest convenience.

6 Flow from the accumulator set will be directed to knife gate valve: Valve 1. This flow will
force knife gate valve closed. Once closed, there will be pressure left in the accumulator bank
and on the knife gate valve cylinder.

7 At this point, Valve 2 is left in their last position. Valve 1 is in its closed position.

8 Power is returned to the power unit.

9 The pump motor sets will start and run as described in section “Accumulator Control”

41
O & M M A N U A L

10 Pump flow will be directed to knife gate valve 3830-XV-00507. If the open solenoid remains
de-energized, the valve will remain closed. If the open solenoid is energized, the valve will
open before the accumulator set charges.

Cooling of hydraulic fluid


The fluid will not over temperature as long as the power unit runs as described above. If
the unit runs past when the accumulator bank is fully charged, the pressure will be regulated by the
relief valves (Item 14). When this occurs, excessive heat will be generated. This will eventually cause
a system shut-down via the high temperature switch (Item 19). If this occurs, the system must be
shut down and allowed to cool.

It is to be noted:

Valve closing and opening times should be monitored visually or via the on-site DCS. This is not
monitored in the control panel on the HPU.

The DCS logic to the control panel should de-energize the close solenoid the instant the closed limit
switch is triggered.

The DCS logic control panel should de-energize the open solenoid and energize the accumulator flow
solenoid (item 33) 5 seconds after the open limit switch is triggered. This ensures the knife gate valve
is fully open, and is deep in the sensing range of the limit switch. It also insures the open portion of
the cylinder has full system pressure to keep the cylinder piston seals sealed tight on the cylinder bore.
This will help with nuisance knife gate valve not open trips.

End of Control Philosophy.

42
O & M M A N U A L

Section

5
Troubleshooting

Whether initial start-up or longtime running system, eventually


problems arise. Before any repairs can begin, the problem must be
found. This is where troubleshooting begins.

M
any times the initial perceived problem is actually a symptom of the real
underlying problem in the system. The initial perceived problem might get
fixed only to reoccur shortly after the repair. Due to the complexity of fluid
power systems and components, this section gives brief guidelines and an
abbreviated troubleshooting table. This section is not necessarily specific to this unit as
it can be applied to a variety of fluid power systems.

G eneral Troubleshooting
The unit for which this manual is written is not highly
G E N E R A L
complex for qualified personnel. Personnel not familiar with
P R A C T I C E S this system or fluid power in general may find
 Qualified Personnel troubleshooting overwhelming. It is suggested qualified
 Pressurized Fluid mechanical and/or electrical personnel perform
troubleshooting on this unit.

Before making any changes to the system, verify the problem actually exists. The
occasional perceived abnormality may be standard operation for this system.

Write down the steps to be taken on troubleshooting this


G E N E R A L
system. Then record the results. This will leave a path to
P R A C T I C E S restore original settings. Some changes made may entail
 Record Keeping significant time to revert back to original if not correct.

Never change or replace more than one component at a time. This will allow the
recording of a direct result of that single change instead of trying to record multiple
changes and their interactions.

43
O & M M A N U A L

Always work safely. Never take undue risks that can


G E N E R A L endanger you, coworkers or equipment. Follow proper
P R A C T I C E S
lockout procedures. Be sure to communicate with other
people your intentions and the type of work that is being
 Lock-out Procedure
performed. Coordinate you activities with the facility
manager as needed.

Share your ideas with people familiar with this or other fluid power systems. Many times
ideas, actions and plans can be generated from these discussions. Two or more people
bring multiple perspectives to a problem. This can be an efficient means of
troubleshooting.

Use the drawings, bill of materials and tables offered in this manual. This information
is the design of the system and how the system is to operate. Verify the system is in
compliance with these drawings and tables. Many time substitutions or changes have
been made without a record made of these changes. Careful checking to see if the unit
is the same as delivered can uncover problems quickly.

The following pages include an abbreviated troubleshooting


G E N E R A L
table. This table is basic troubleshooting only. Should the
P R A C T I C E S problem be more complex than covered in this section, the
 Qualified Personnel use of a qualified mechanical and/or electrical technician is
recommended.

44
Troubleshooting Table

SYM PTO M FAILU RE REM EDY


ELECTRIC MOTOR WILL CIRCUIT BREAKER or CLOSE BREAKER
NOT START MAIN SWITCH OPEN
FUSE(S) OPEN REPLACE FUSE(S)
POWER IS OFF RESTORE POWER
WIRING NOT ATTACHED TO CONNECT WIRING
MOTOR LEADS
HEATERS ARE TRIPPED RESET HEATERS
CONTROL POWER NOT RESTORE CONTROL POWER
CONNECTED
STARTER RELAY IS FAULTY REPAIR RELAY
PUSH-BUTTON FAULTY REPLACE PUSH-BUTTON
MOTOR WINDINGS FAULTY REPAIR MOTOR
ELECTRIC MOTOR STARTS, STARTER COIL HOLDING REPLACE RELAY CONTACTS
BUT WILL NOT CONTINUE CONTACT FAULTY OR RELAY
TO RUN
HEATER CONTACT TRIPPING ON CHECK HEATER SETTING
START OVERLOAD
SYSTEM INTERLOCKS, IF USED, CHECK ELECTRICAL
ARE NOT MADE DIAGRAM FOR INTERLOCKS,
ASSURE THEY ARE
SATISFIED
ELECTRIC MOTOR STARTS, POWER IS LOST IN ON OR MORE RESTORE POWER
BUT WILL NOT DEVELOP LEADS OF INCOMING LINES
POWER
MOTOR WINDINGS SHORTED REPLACE ELECTRIC MOTOR
Inde

45
Troubleshooting Table, Continued
SY M PTO M F A ILU R E R EM ED Y
ELECTRIC MOTOR IS NOISY BEARINGS WORN REPLACE BEARINGS
WHEN ROTATING OR
VIBRATES
FAN IS LOOSE TIGHTEN FAN
PUMP COUPLING IS LOOSE TIGHTEN COUPLING
PUMP MIS-ALIGNED CHECK ALIGNMENT
HOLD DOWN BOLTS LOOSE TIGHTEN BOLTS
PUMP VIBRATES WHILE COUPLING LOOSE TIGHTEN COUPLING
TURNING
SUCTION VALVE CLOSED OPEN SUCTION
PUMP INTERNALS WORN REPLACE PUMP
PUMP MIS-ALIGNED CHECK ALIGNMENT
PUMP HAS A LOUD NOISE NO FLUID IN RESERVOIR TOP UP FLUID
WHILE TURNING
FLUID TOO COLD WARM FLUID TO
OPERATING TEMPERATURE

PUMP ROTATING BACKWARDS CHECK ROTATION

SUCTION LINE OPEN TO SECURE SUCTION LINE


ATMOSPHERE
PUMP WILL NOT DELIVER COUPLING DISCONNECTED RESTORE COUPLING
FLOW
PUMP INTERNALS WORN REPLACE PUMP
NO FLUID IN RESERVOIR TOP UP FLUID
PUMP ROTATING BACKWARDS CHECK ROTATION

SUCTION LINE OPEN TO SECURE SUCTION LINE


ATMOSPHERE
PUMP PRODUCES FLOW SYSTEM BYPASS OPEN CLOSE BYPASS
BUT WILL NOT DEVELOP
PRESSURE
GAUGE FAULTY REPLACE GAUGE
GAUGE SHUTOFF VALVE OPEN VALVE
CLOSED
PUMP IS WORN SEE PUMP SECTION
FILTERS CLOG OFTEN FLUID IS CONTAMINATED CHANGE FLUID AND FILTER
ELEMENTS
CONTAMINATION IS LIMIT CONTAMINATION
INTRODUCED IN PIPELINES INPUT FROM PIPELINES
PRESSURE GAUGES DO GAUGE FAULTY REPLACE GAUGE
NOT REGISTER PROPERLY

GAUGE SHUTOFF CLOSED OPEN VALVE

46
Section

6
Com ponent
M anufacturers Cut
Sheets

Component cut sheets provide excellent information


on the components used in the construction of this
unit.

ut sheets are vital information for this unit. These can be used for

C clarification on individual component performance,


interchangeability, and other relevant data. This data can be used
in troubleshooting the system, selecting a proper replacement for
a failed component or help give a better understanding on the design of
the system.

Attached Cut Sheets


The attached cut sheets are arranged, in general, in the same order as the
components are listed on the bill of materials on the schematics.

These cut sheets are not photocopies. These cut sheets have been
electronically scanned and are an integral part of this manual.

The cut sheets are based on “as-built” drawings.

Should a component not have a cut sheet available, an equal component


cut sheet will be provided. This is only done on less critical components
such as filler caps, sight glasses, etc.

47
FRONT MOUNTING LIQUID LEVEL GAGES
A patented dual purpose closed circuit style liquid level gage that provides both instant and positive visual check of fluid
levels and temperature in either hydraulic or oil reservoirs. Maximum sight protection is provided by the heavy precision
machined bar stock body. Thermometer series gages have a protected sensing element that extends well into the tank -
unaffected by unrelated ambient temperature. Gages are furnished complete including O-ring seals and hex nuts for
mounting. A .06 (1.52mm) alignment adjustment at each stud facilitates mounting. This gage can be installed from the
outside on 1/2-20UNF tapped holes when reservoirs do not have access to the interior and tank wall thickness permits
tapping. For installations where gage is bolted to cylindrical tank wall, conical sleeves are available. Please specify when
ordering. Front mounting gages can be made to order with mounting centers up to 142.00 (3606.80mm) in 1.00 (25.40mm)
increments. Stainless steel dial thermometer: 1.38 (35.05mm) dia. dual scale Fahrenheit (50 / to 300/), Centigrade (10/ to
150/). For back mount gages see our SERIES G610 and G620 on Bulletin F327-10/-20.
STANDARD MATERIALS: HOW TO ORDER:
! Aluminum construction Use code letters for body material: Use code number for seal material:
! Buna N seals A - Aluminum gage body (standard) 1 - Buna N seals (standard)
B - Brass gage body (optional) 2 - Butyl seals (optional)
! Borosilicate glass with redline on white S - Steel gage body(optional) 3 - Viton A® seals (optional)
background for distinct level reading and Y - Stainless Steel gage body 4 - Ethylene propylene seals
maximum fluid compatibility (optional) 10- Neoprene seals (optional)
First, specify series number, then mounting centers, then kind of metal, and
OPERATING CONDITIONS: finally seal material, separating each with a dash (-):
! See ENG. STD. 109 EXAMPLE: G615-05-A-1
SERIES SERIES
B - SIGHT C - LENGTH Buna N seals
G605 G615 A - CENTERS
INCHES INCHES Aluminum gage body
WITHOUT WITH INCHES (mm)
(mm) (mm)
THERM. THERM. 5.00 (127.00mm) Centers
G605 G615 03 (76.20) 1.50 (38.10) 4.62 (117.35) SERIES G615
G605 G615 04 (101.60) 2.50 (63.50) 5.62 (142.75)

G605 G615 05 (127.00) 3.50 (88.90) 6.62 (168.15) NOTE: The sight opening in all cases is 1.50
G605 G615 06 (152.40) 4.50 (114.30) 7.62 (193.55)
(38.10mm) less than mounting centers and overall
length is 1.62 (41.15mm) greater than mounting
G605 G615 07 (177.80) 5.50 (139.70) 8.62 (218.95) centers. Gages with 13.00 (330.20mm) and greater
G605 G615 08 (203.20) 6.50 (165.10) 9.62 (244.35) mounting centers are furnished with spacer sleeves to
space gage from tank allowing for bowing of the tank
G605 G615 09 (228.60) 7.50 (190.50) 10.62 (269.75)
wall in larger reservoirs. Center mounting kits are
G605 G615 10 (254.00) 8.50 (215.90) 11.62 (295.15) furnished with gages 48.00 (1219.20mm) and greater
G605 G615 11 (279.40) 9.50 (241.30) 12.62 (320.55) mounting centers.

G605 G615 12 (304.80) 10.50 (266.70) 13.62 (345.95)


SERIES G615
SERIES G605 - SIGHT ONLY WITH DIAL THERMOMETER

FRONT MOUNTING LIQUID LEVEL GAGES


LUBE DEVICES, INC. WITH AND WITHOUT THERMOMETER
1864 NAGLE AVE., P.O. BOX 1810, MANITOWOC, WI 54221-1810
PHONE: (920) 682-6877 FAX: (920) 684-7210
E-MAIL: sales@lubedevices.com WEBSITE: www.lubedevices.com
4/02 BULLETIN F327-5 / -15
48
FILLER BREATHERS
DESICCANT AIR BREATHERS

SPECIFICATIONS
• Combination Air Breather and Water Removal Filter to
Handle Air Flows up to 395 gpm
• 3 Micron Absolute Synthetic Media Air Breather
• Desiccant Material - Silica Gel

OPTIONS
• Available in Two Models With 3/4” BSPConnection and
Two Models with 1 1/4” BSPConnection
• Adaptor Plate Available for use on Standard 6-Bolt
Mounting Pattern (Includes Bolts)
• Filter Minder Available for use as an Air Breather Indicator.

DIMENSIONS

o90
60

4.

1- Gel Protector
5.

3. 2- Adaptor
Silica Gel
Silica Gel

3- Silica Gel
KL96 = 150
KL93 = 90

4- Air Filter
1.
5- Coarse Foam Filter
5.
30

2.

ACCESSORIES
Thread E
Desiccant Breather
Adaptor Plate Filter Minder
*Remove bottom seal and plug before use. •Dimensions in mm (FM 1)
For available Adaptors, see page 148.

DIMENSIONS – DESICCANT BREATHERS ADAPTOR PLATE


PART NO. A B C D E PART NO. A B C
in. 3.54" 2.36” 3.54” 1.18” in. 3.46" 1.97”
SDB93 3/4” BSP AP1 3/4” BSP
mm 90.0 60.0 90.0 30.0 mm 88.0 50.0
in. 3.54” 2.36” 5.90” 1.18” in. 3.94” 2.75”
SDB 96 3/4” BSP AP2 1 1/4” BSP
mm 90.0 60.0 150.0 30.0 mm 100.0 70.0
in. 5.22” 4.00” 11.18” 1.55”
SDB 121 1 1/4” BSP
mm 132.5 102.0 284.0 40.0
in. 5.22” 4.00” 15.50” 1.55’
SDB 122 1 1/4” BSP
mm 132.5 102.0 394.0 40.0
3/00

49
150
FILLER BREATHERS
DESICCANT AIR BREATHERS (CONT.)

CONDENSATION IN RESERVOIRS

When the reservoir breathes, air containing water vapor is ingested into the system. Temperature fluctuations will cause
the water vapor to condense. This condensed water will speed up the oxidation of the oil and lead to damage in the
machine. The catalytic action of metal particles present in the contamination process speeds up both these processes.
The Stauff Air conditioner first dries the air as it passes through the silica gel granules and the dry air passes through a 3
micron ß rated synthetic media element to remove any solid contamination particles.

The expelled air reaches the atmosphere via the same route but in the opposite direction.

MOUNTING

Direct mount onto the reservoir or use an adaptor plate which fits the standard 6 bolt pattern for filler breathers.
Note: Protective covering must be removed from silica gel holes before installation.

MONITORING

Air Dryer - As moisture is absorbed the silica gel gran- Air Filter - The adaptor plate has a connection for the
ules will gradually change color from a deep blue to “filter minder.” This gives a static indication of the air
pink. When the granules are pink, replace the silica gel. breather. The unit can be reset when the element is
changed.
ACCESSORIES

BLUE PINK

FILTER MINDER
3/00

50
151
FILLER BREATHERS
DESICCANT AIR BREATHERS (CONT.)

TECHNICAL DETAILS
FILLER BREATHER TYPE SDB93 SDB96 SDB121 SDB122
DESICCANT VOLUME ml 300 600 1000 2000
cu-in 18.3 36.6 61.0 122
MAXIMUM FLOW RATE gpm 135 395
(NOMINAL) lpm 500 1500
OVERALL WT. lb 2.21 3.31 6.39 9.48
kg 1.00 1.5 2.9 4.3
MOUNTING CONNECTOR* 3/4” BSP 1 1/4” BSP
AMBIENT TEMPERATURE -22o F TO 140oF
(-30o C TO 60oC)
DESICCANT SILICA GEL
DENSITY 56.16 lb/cu ft
900 kg/m3
GRANULE SIZE .11” to .24”
FILLING WEIGHT lb 0.5 1.0 1.7 3.3
grams 225 450 750 1500
MAXIMUM lb 0.16 0.32 0.53 1.06
WATER
UPTAKE grams 72 144 240 480

ORDERING INFORMATION

SDB96 AP FM

ACCESSORIES
PRODUCT TYPE OPTIONS REQUIRED AIR FILTER INDICATOR
SDB 93 Desiccant Air Breather AP Adaptor Plate FM Filter Minder
SDB 96 Desiccant Air Breather – Desiccant Air Breather only Omit Not Included
SDB 121 Desiccant Air Breather
SDB 122 Desiccant Air Breather

For available Adaptors, see page 148.

REPLACEMENT SILICA GEL CARTRIDGE REPLACEMENT AIR-BREATHER


DESICCANT AIR REPLACEMENT SILICA GEL VOLUME DESICCANT AIR AIR-BREATHER
BREATHER CARTRIDGE CU IN ML BREATHER
SDB 93 RD 93 18.3 300
SDB 93/96 SGB 90
SDB 96 RD 96 36.6 600
SDB 121 RD 121 61.0 1000 SDB 121/122 SGB 120
3/00

SDB 122 RD 122 122 2000

51
152
Bulletin E-73

Series L4 Float Switch

Specifications - Installation and Operating Instructions

Rugged and reliable the Flotect® L4 Level switch operates automatically SPECIFICATIONS
to indicate tank level. Perfect for starting or stopping pumps, opening or Service: Liquids compatible with wetted materials.
closing valves, or actuate level alarm signals. A unique magnetically Wetted Materials: Float and Rod: 316 SS; Body: Brass or 316 SS
actuated switching design gives superior performance. There are no standard; Magnet Keeper: 430 SS standard, 316 SS or nickel optional.
bellows, springs, or seals to fail. Instead, the free-swinging float attracts Temperature Limits: 4 to 275°F (-20 to 135°C) standard, MT high
a magnet within the solid metal switch body, actuating a snap switch by temperature option 400°F (205°C) [MT option not UL, CSA, ATEX or
means of a simple lever arm. Float arm hinge design limits the arm angle IECEx]. ATEX, IECEx options: Ambient temperature -4 to 163°F (-20 to
to prevent vertical hangup. 73°C); Process temperature -4 to 163°F (-20 to 73°C).
Pressure Limit: Brass body 1000 psig (69 bar), 316 SS body 2000 psig
FEATURES (138 bar). Standard float rated 100 psig (6.9 bar). For other floats see
• Leak proof body machined from bar stock model chart on next page.
• Choice of floats dependent on maximum pressure and specific gravity Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL
• Weatherproof, designed to meet NEMA 4 and CSA for Class I, Groups C and D; Class II, Groups E, F, and G.
• Explosion-proof (listings included in specifications) ATEX 0518 II 2 G Ex d IIB T6 Gb -20°C≤Tamb≤73°C.
• Installs directly and easily into tank with a thredolet or flange -20°C≤Process Temp≤73°C.
(see application drawings on page 4) EC-Type Certificate No.: KEMA 03 ATEX 2383.
• Electrical assembly can be easily replaced without removing the unit ATEX Standards: EN60079-0: 2009; EN60079-1: 2007.
from the installation so that the process does not have to be shut down IECEx Certified: For Ex d IIB T6 Gb -20°C≤Tamb≤73°C. -20°C≤Process
• Horizontal installation or optional top mount vertical installation Temp≤73°C.
IECEx Certificate of Conformity: IECEx DEK 11.0071.
APPLICATIONS IECEx Standards: IEC 60079-0: 2007; IEC 60079-1: 2007.
• Direct pump control for maintaining level Switch Type: SPDT snap switch standard, DPDT snap switch optional.
• Automatic tank dump operations Electrical Rating: UL, FM, ATEX or IECEx models: 10A @ 125/250 VAC
• Control levels or provide alarms in sumps, scrubber systems, hydro- (V~). CSA models: 5A @ 125/250 VAC (V~); 5A res., 3A ind. @ 30 VDC
pneumatic tanks, low pressure boilers, and various waste (V ). MV option: 1A @ 125 VAC (V~); 1A res., .5A ind. @ 30 VDC (V ).
water/sewage treatment processes MT option: 5A @ 125/250 VAC (V~). [MT and MV option not UL, CSA, FM,
ATEX or IECE].
Electrical Connections: UL and CSA models: 16 AWG, 6˝ (152 mm)
long. ATEX or IECEx unit: terminal block.
Process Connection: 1-1/2˝ male NPT standard, 2-1/2˝ male NPT
standard optional floats.
Mounting Orientation: Horizontal installation standard, optional vertical
top mount.
Weight: 4 lb 9 oz (2.07 kg).
Dead Band: 3/4˝ (19 mm) for standard float.
Specific Gravity: 0.7 minimum with standard float. For other floats see
model chart.

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com


P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A. Fax: 219/872-9057 e-mail: info@dwyermail.com
52
Example L4 SS D C F 2 C 1 L4-SS-D-C-F2C1
Construction L4 Side Mount, Brass Body, SPDT Switch
L4-TOP Top Mount, Brass Body, SPDT Switch (Specify rod length)
Wetted Material SS 316 SS Body with 430 SS Magnet Keeper
Options 316 316 SS Body and Magnet Keeper (Order with SS option)
NI Nickel 20 Magnet Keeper
Switch Options D DPDT Switch
Float Options 50 2-1/2˝ Spherical, 304 SS rated 50 psi (3.5 bar), > 0.5 s.g.
150 2-1/2˝ Spherical, 316 SS rated 150 psi (10.3 bar), > 0.7 s.g.
300 2-1/2˝ Spherical, 304 SS rated 300 psi (20.7 bar), > 0.7 s.g.
Other Options AT ATEX
IEC IECEx
EPOXY Epoxy Coated Housing
MT High Temperature* (See specifications for rating)
MV Gold Contact Snap Switch* (See specifications for rating)
NB Neoprene Boot*
NH No Electrical Housing*
TBC Terminal Block Wire Connections*
TRD Time Delay Relay* (On flow decrease)
TRI Time Delay Relay* (On flow increase)
Flange* F Flange Process Connection
Flange Size 2 2˝
3 3˝
4 4˝
Flange Material C Carbon Steel
S 316 SS
Flange Rating 1 150 #
3 300 #
6 600 #
9 900 #
Bushing* B Bushing Process Connection
Bushing Size 1 2˝
2 2-1/2˝
4 4˝
Bushing Type H Hex
F Flush
Bushing B Brass
Material C Carbon Steel
S 316 SS
4 304 SS
*Options that do not have ATEX or IECEx
Attention: Units without the “AT” suffix are not Directive 2014/34/EU (ATEX) compliant. These units are not intended for use in potentially hazardous atmospheres in the
EU. These units may be CE marked for other Directives of the EU.

FLOAT ARM & BLOCK SWITCH BODY 1-1/2 MALE NPT


FLOAT 316 STNLS. STL. BRASS OR MOUNTING CONNECTION
316 STNLS. STL OR BRASS 316 STNLS. STL. 16 GA. LEADS
(STANDARD) 6 [152.40] LONG

Ø2-1/2 PARTS LIST


Ø1-5/8 [63.50] 3-11/32
[41.28] [84.93]
MAGNET 1. Cover lock. (ATEX/IECEx unit only).
5 6 3
[127.00] [152.40] KEEPER [76.20]
430 STNLS. 5 3/4 FEMALE NPT 2. External ground. (ATEX/IECEx unit only).
STL. [127.00] CONDUIT
8-7/32 CONNECTION
[208.76] 3. Enclosure housing and cover.
19-7/32
[488.16] 4. Terminal block. (ATEX/IECEx unit only,
UL/CSA unit has 6˝ leads).
UL/CSA unit
5. Internal ground.
6 5 3 2 1
1-1/2 NPT *6. Magnet arm and switch assembly.

7. Switch body.
2-1/2
1-5/8 [63.50] 3-11/32
[41.28] [84.93] *8. Float, arm and block assembly.
5 6 *Approved replacement parts
[127.00] [152.40] 3
[76.20] 3/4 NPT
5
8-7/32 [127.00]
[208.76]
19-7/32
[488.16]
ATEX/IECEx unit
53
Bulletin E-73

INSTALLATION NOTE: ATEX and IECEx units only: The temperature class is
determined by the maximum ambient and/or process temperature. Units
NOTES: are intended to be used in ambient of -20°C ≤Tamb≤73°C. Units may be
• Check all ratings given in the instructions and on the product to make used in process temperatures up to 133°C providing the enclosure and
sure that the product is suitable for your application. Do not exceed switch body temperature do not exceed 73°C. The standard
electrical ratings, pressure ratings, or temperature ratings of the product. Temperature Class is T6 Process Temp ≤73°C.

• Disconnect power supply before beginning installation to prevent 5. For units supplied with both internal ground and external bonding
possible equipment damage or electrical shock. terminals, the ground screw inside the housing must be used to ground
the control. The external bonding screw is for supplementary bonding
1. Remove packing material from switch body-cap and remove tape from when allowed or required by local code. When external bonding
magnet keeper. Install standard switch in thredolet previously welded to conductor is required, conductor must be wrapped a minimum of 180°
tank. Install optional switch mountings per application drawings. Make about the external bonding screw. See below.
sure locknuts on float are tight.

2. When mounting switch in the side of a tank, the arrow on the side of
LOCKWASHER CONDUCTOR
the switch must point up.
SCREW
3. Wiring: UL and CSA units only: Thread connecting wires through
conduit and connect. Wire in accordance with local electrical codes.
Black - Common
Blue - N.O.
Red - N.C.

NOTE: Double pole, double throw switches have dual black, blue and
red leads. These are connected in the same manner as single pole,
double throw switches, as described above. CLAMP

ATEX and IECEx Installation Instructions: FRONT VIEW DETAIL SIDE VIEW DETAIL
Cable Connection
The cable entry device shall be certified in type of explosion
protection flameproof enclosure “d”, suitable for conditions of use
and correctly installed. Cable entry may exceed 70°C. Conductors
and cable gland rated ≥90°C shall be used.

Conduit Connection
An Ex d certified sealing device such as a conduit seal with setting
compound shall be provided immediately to the entrance of the
valve housing. Cable entry may exceed 70°C. Conductors and cable
gland rated ≥90°C shall be used. SPDT DPDT

TERMINAL CONNECTIONS
NOTE: The switch is deactivated and contacts are in normal condition
when the liquid is below the float.

4. Make sure conduit or cable are properly sealed. Electrical


components must be kept free of moisture, including condensation, at all MAINTENANCE
times. Inspect and clean wetted parts at regular intervals. The cover should be
in place at all times to protect the internal components from dirt, dust,
CAUTION: To prevent ignition of hazardous atmosphere, disconnect the and weather, and to maintain hazardous location ratings. Disconnect
device from the supply circuit before opening. Keep assembly tightly device from the supply circuit before opening to prevent ignition of
closed when in operation. hazardous atmosphere. Repairs to be conducted by Dwyer Instruments,
Inc. Units in need of repair should be returned to the factory prepaid.

Limited Warranty: The Seller warrants all Dwyer instruments and equipment to be free from defects in workmanship or material under normal use and service for a period
of one year from date of shipment. Liability under this warranty is limited to repair or replacement F.O.B. factory of any parts which prove to be defective within that time or
repayment of the purchase price at the Seller’s option provided the instruments have been returned, transportation prepaid, within one year from the date of purchase. All
technical advice, recommendations and services are based on technical data and information which the Seller believes to be reliable and are intended for use by persons
having skill and knowledge of the business, at their own discretion. In no case is Seller liable beyond replacement of equipment F.O.B. factory or the full purchase price. This
warranty does not apply if the maximum ratings label is removed or if the instrument or equipment is abused, altered, used at ratings above the maximum specified, or otherwise
misused in any way.

THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTATIONS MADE BY ADVERTISEMENTS OR BY AGENTS AND ALL
OTHER WARRANTIES, BOTH EXPRESS AND IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE FOR GOODS COVERED HEREUNDER.

Buyers Remedies: THE BUYER’S EXCLUSIVE AND SOLE REMEDY ON ACCOUNT OF OR IN RESPECT TO THE FURNISHING OF NON-CONFORMING OR DEFECTIVE
MATERIAL SHALL BE TO SECURE REPLACEMENT THEREOF AS AFORESAID. THE SELLER SHALL NOT IN ANY EVENT BE LIABLE FOR THE COST OF ANY LABOR
EXPENDED ON ANY SUCH MATERIAL OR FORM ANY SPECIAL, DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES TO ANYONE BY REASON OF THE FACT THAT
IT SHALL HAVE BEEN NON-CONFORMING OR DEFECTIVE.

54
APPLICATION DRAWINGS FOR FLOTECT®
AUTOMATIC FLOAT SWITCHES

1-1/2 THREDOLET
CUT HOLE 1-15/16 [49] DIA.

STANDARD INSTALLATION

ANSI RF
3/4 NPT
THREADED
REDUCING
ANSI RF THREADED
FLANGE
REDUCING FLANGE

11-3/4
3/4 NPT
[298.5]
*FLANGE FACE TO CENTERLINE OF FLOAT
SPECIFIED BY CUSTOMER NORMALLY HORIZONTAL, FLANGE INSTALLATION
SHOULD NOT EXCEED 20' [508 MM].
VERTICAL, FLANGE INSTALLATION

2-1/2 CUT HOLE


THREDOLET 2-7/8 [73] DIA.

2-1/2 X 1-1/2
FACE BUSHING

HORIZONTAL, 2-1/2 THREDOLET INSTALLATION


WITH OPTIONAL 2-1/2 [64] SPHERICAL FLOAT

© Copyright 2016 Dwyer Instruments, Inc. Printed in U.S.A. 4/16 FR# 82-440631-00 Rev. 6

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com


P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A. Fax: 219/872-9057 e-mail: info@dwyermail.com
55
B02=3.6 gpm @ 1800

B03=5.5 gpm @ 1800

PT7BS-B02-1R00-A1-01
PT7 = 5000 PSI Vane Pum p
BS = SAE B 2 Bolt Mount
B02 = 3.6 GPM at 1800 RPM
B03 = 4.7 GPM at 1500 RPM
1 = 7/8" X 1/4" X 2.81" Shaft
R = Right Rotation
00 = Pressure and Suction 180 Degrees
01 = 3/4" Code 61 Pressure
1 1/2" Code 61 Suction

56
57
®
841 PLUS Motors
Horizontal A.C. Motors, Totally Enclosed Fan Cooled

Horsepower: 1 – 200 HP
Frame Sizes: 143 – 447
Pole Designs: 2, 4, 6, 8
Design Voltages: 460 and 575 Volts at 60 Hz
Requirements: Meets or exceeds Energy Independence
and Security Act of 2007 (EISA);
Meets or exceeds IEEE 841 Standard-2009;
Meets vibration requirements of GM7E-TA
Warranty: 5-year limited warranty

Product Overview and Options

Designed to exceed the industry’s most stringent IEEE • Division 2 suitable per NEC article 500 (NFPA 70)
841 standards, the U.S. MOTORS ® brand 841 PLUS ® motors • AFBMA bearing numbers on nameplate
are commonly used in severe duty environments for pumps, • Protective coating on each rotor and shaft from bearing
compressors, fans, blowers, and other material processing journal to bearing journal
applications. These rugged motors are ideal for constant speed
or inverter duty applications typically found in the petroleum, Inverter Duty
chemical, pulp and paper, wastewater, automotive and mining Nidec Motor Corporation’s patented inverter grade insulation
industries. system allows the U.S. MOTORS brand 841 PLUS motor to
withstand spike and transient voltages induced by insulated
U.S. MOTORS brand 841 PLUS motors are rated NEMA
bipolar gate transistor drives, making it fully compliant with
Premium ®† efficient. Low-loss silicon steel construction and
NEMA MG-1, Part 31. This is made possible through:
streamlined design enables the motor to operate at lower
temperatures resulting in lower energy costs. This motor is • Pulse-resistant magnetic wire that provides protection against
designed to operate in ambient temperatures of -30°C to 40°C, high-voltage spikes
in altitudes of up to 1,000 meters above sea level and with
• Additional lacing on the end turns improve coil rigidity
NEMA Design B torque-current characteristics. Inertiaload
acceleration capabilities for the 841 Plus motor meet the • Multiple bake cycles to help prevent coil-to-coil circuits
stringent requirements of NEMA MG 1-2009, Section 12.54. • Phase paper to help prevent phase-to-phase arcs
• Adjustable frequency of 5:1 constant torque or 10:1 variable
Product Features: torque for the full product line.
• NEMA Premium®† efficient
• 1.15 Service Factor on sine wave power; 1.0 Service Factor
on Inverter Duty
• Class B temperature rise at 1.0 Service Factor by resistance
with sine wave power
• Class F insulation materials to increase motor life
• Exceeds NEMA MG1 Part 31 Inverter Duty
• Polyurea grease
• Stainless-steel nameplate
• Variable frequency drive or full voltage, across-the-line starting
• Ground on frame
841 PLUS ®

58
PDS 241-202 Rev. 01/17 www.usmotors.com
841 PLUS Motors, Horizontal A.C. Motors, Totally Enclosed Fan Cooled
®

Product Overview and Options continued

Typical 841 PLUS ® Motor Construction:


1. Corrosion resistant zinc dichromate-plated hardware 1
2. Heavy duty cast-iron enclosure for long life and reduced vibration 2
3. Inverter grade insulation
3
4. Inpro/Seal “VBXX” on both ends provides IP56 protection
TM

and prolongs motor life by shielding bearings from


contaminants in even the harshest environments 4
5. Special shaft runouts for ball bearing motors of 0.0010
5
inches for shafts up to 1.625 inches and 0.0015 inches for
larger shafts.
6. Same size oversized bearings on each end. Cast iron inner
bearing caps
7. Brass breather drains 6
8. Oversized, double-gasketed and rotatable conduit box to
protect against contaminants and correctly position non-braided, 7
non-wicking motor leads 8
9. Foot flatness machined to within 0.005 inch tolerance ensures
easy installation and proper alignment 10 9
10. Corrosion-resistant mill and chemical duty paint capable of
withstanding a 500-hour salt spray test

Options and Accessories


Nidec Motor Corporation offers the following custom-design 841 Plus Stock Motors
options on the U.S. MOTORS brand 841 PLUS motor: • 1 – 200 HP
• 2, 4, 6 pole designs
• SKF CARBTM roller bearings where applicable • 460 and 575 Volts
• Horizontal or vertical mounting • Constant or variable torque
• Vibration detectors • 1–10 HP C-Face Footless
• Sealed insulation treatments, available on form wound, medium
Custom and Conversion Motors
voltage motors above 200 HP, to help shield motor windings • 1 – 500 HP
• Winding and bearing thermal protection for motors • 2, 4, 6, 8 pole designs
250 HP and up • 200, 230, 460, 575, 2300, 4000 Volts
• Inpro/SealTM MGS grounding shaft rings • Constant or variable torque
• C & D flange kits available 140 – 440 frame
• API 661 Duty

Testing and Inspection


Nidec Motor Corporation conducts extensive testing and • Insulation resistance test by megohmeter and polarization index
inspections on each of its U.S. MOTORS brand 841 PLUS motors. • Precision balanced to typical vibration levels of less than
0.05 inches per second
• No load current, power and speed
• Optional complete test, including full load test
• High-potential test on stator windings

For additional information, please refer to our Full Line Standard Motor Catalog (FL600) or contact your Nidec Motor Corporation representative.

† All marks shown within this document are properties of their respective owners.

8050 W. Florissant Avenue | St. Louis, MO 63136


Nidec Motor Corporation, 2017; All Rights Reserved. U.S. MOTORS® is a registered trademark of Nidec Motor Corporation.
Nidec Motor Corporation trademarks followed by the ® symbol are registered with the U.S. Patent and Trademark Office. Phone: 888-637-7333 | Fax: 866-422-7758

59
PDS 241-202 Rev. 01/17 www.usmotors.com
730 Eaton Way, Annacis Business Park
Delta, B.C. Canada V3M 6J9
Phone: (604) 521-1170 Toll Free 1-800-928-1170
INDUSTRIES LTD. Fax: (604) 522-0070 Website: www.sealum.com

Pump Motor Adapters

SAE Pump
Motor Size
O.D.

I.D.

1.50" Access Slot


c/w Plastic Cover

Motor SAE Part WT Motor SAE Part WT


O.D. I.D. L O.D. I.D. L
Size Pump No. LB Size Pump No. LB
3.50 1416-1 5.00 1424-1
1.78 10 A 24
4.25 1416-3 6.81 1424-2
Nema 4.00 1417-1 6.81 1425-1
AA 11
56 TC 4.50 1417-3 B 7.63 1425-2 27
To 6.75 4.00 Nema
4.00 1418-3 8.81 1425-3
145 TC 284 TC
4.50 1418-4 To 11.00 7.00 6.81 1426-1
A 11
5.25 1418-5 286 TC C 7.63 1426-2 27
5.75 1418-6 8.81 1426-3
4.00 1419-1 8.00 1427-3
1.78 15 D 30
5.00 1419-2 9.19 1427-4
4.50 1420-1 6.81 1428-1
AA 16
5.68 1420-2 B 7.63 1428-2 35
4.88 1421-1 8.81 1428-3
Nema
182 TC A 5.68 1421-2 16 6.81 1429-1
To 9.00 5.50 6.68 1421-3 Nema 7.63 1429-2
C 35
256 TC 5.00 1422-1 324 TC 8.81 1429-3
To 13.00 8.13
B 5.81 1422-2 17 10.50 1429-4
405 TC
6.81 1422-3 8.00 1430-4
5.00 1423-1 D 9.19 1430-5 48
C 5.81 1423-2 20 10.88 1430-6
6.81 1423-3 10.88 1431-3
E 68
12.00 1431-2
- All dimensions are in inches
- Pump/Motor Adapters are suitable for 2-bolt & 4-bolt pumps. Nema 9.00 1432-1
D 80
- See page 62-2 For NEMA motor and SAE pump specifications. 444 TC 12.00 1432-2
- Material: G40.21-44W Steel. To 16.50 10.00
9.00 1433-1
- Complete with bolt kits. 445 TC E 100
12.00 1433-2

60
62-3
Magnaloy Coupling Design Features

“Load-Lock” Design is simple and effective. The drive-lug


configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-
lock design protects bearings and equipment by eliminating
end thrust in both directions... and it requires only one
set-screw in each hub.

Radial Lug Design is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking
and associated heat generation. Magnaloy Coupling’s drive lugs
are in a true radial orientation. Applied forces are evenly distributed
in the compressive direction only, eliminating the heat generating
radial component. True compressive loading reduces internal heat
generation and improves elastomer life.

F
MAGNALOY COUPLING DESIGN
F Under loaded conditions, the resultant forces applied
on the element segments are evenly distributed in the
compressive direction only. This results in no radial
F forces to multiply the internal heat generation.
F

Fc Fr CONVENTIONAL DESIGN A
F Under loaded conditions this jaw design results in the
applied forces exerting components in the compressive
and radical directions. These forces change direction
and magnitude along the jaw arc which greatly increase
F the internal movement of the element which causes heat
Fc generation.
Fr

Fc
CONVENTIONAL DESIGN B
Fr
This more conventional straight sided jaw design also
F exerts component forces in the compressive and radial
directions when under load. The radial component is
outward (acting to extrude the element) and changes
Fc in magnitude only, as does the compressive component,
along the jaw surface. The component forces resulting
F
Fr from this design also causes increased internal
movement in the element.

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 2


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
67 61
Magnaloy ®is a registered trademark of the Douville Johnston Corp.
Premium Flexible Drive Couplings

Magnaloy is the original lightweight, heavy-duty


flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter
than cast iron and 36% lighter than aluminum units...
and they’re stronger than either!
The benefits are many... Reduced loads on
bearings, shafts and pumps, for longer component
life. Easier handling and installation. Rust proof and
corrosion resistant.
Magnaloy’s close machining tolerances
(TIR of .002”) assures vibration - free operation and
easy, accurate alignment without need for special
tools. Solid magnesium alloy permanent mold
castings are heat treated and offer the highest
strength-to-weight ratio available.

Coupling Performance Specifications


Rated Torsional Horse Power Rating@
Coupling Maximum Wr2 Insert Torque Rigidity 100 1200 1800
Model Bore lb.- ft2. Number lb.- in. lb-in/Deg rpm rpm rpm
170N 340.7 42 .55 6.5 9.8
100 1-1/8 .0046 170U 511.0 53 .82 9.8 14.7
170H 1,022.1 182 1.65 19.8 29.7
270N 398.3 55 .64 7.6 11.5
200 1-3/8 .0068 270U 597.4 68 .96 11.5 17.2
270H 1,194.9 234 1.92 23.0 34.5
370N 701.4 81 1.12 13.5 20.2
300 1-5/8 .022 370U 1,052.1 148 1.68 20.2 30.3
370H 2,104.2 336 3.36 40.4 60.6
470N 1,056.3 138 1.69 20.3 30.4
400 1-7/8 .031 470U 1,584.5 310 2.5 30.4 45.6
470H 3,168.9 488 5.1 60.8 91.3
570N 2,194.8 314 3.5 42.1 63.2
500 2-3/8 .071 570U 3,292.2 695 5.3 63.2 94.8
570H 6,584.4 1,571 10.5 126.4 189.6
670N 4,946.7 676 7.9 94.9 142.5
600 2-5/8 .16 670U 7,420.1 1,510 11.9 142.5 213.7
670H 14,840.1 2,960 23.7 284.9 427.4
770N 11,639.8 1,805 18.6 223.5 335.2
700 2-7/8 .34 770U 17,459.7 2,104 27.9 335.2 502.8
770H 29,099.5 - 46.5 558.75 838.0
870N 21,889.4 3,680 35.0 420.3 630.4
800 3-7/8 .95 870U 32,834.1 - 52.5 630.4 945.6
870H 47,062.2 - 75.2 903.0 1,354.5
970N 47,842.3 8,428 76.5 918.6 1,377.9
900 4-3/4 4.20
970U 71,763.5 - 114.8 1,377.9 2,066.8

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 3


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
62
Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
X
Models 100, 200, 300, 400 T W
100 200 300 400
A 2.54 3.1 0 3.58 4.24
B 2.600 2.900 3.450 3.980
C 2.00 2.25 2.90 3.05
D 0.56 0.68 0.78 1 .00
E 0.68 0.84 0.96 1 .06 C B
F 0.42 0.42 0.44 0.54
G 0.31 0.43 0.56 0.73
W 1 /1 6 1 /1 6 1 /1 6 1 /1 6
X 0.90 0.90 0.98 1 .20
T 1 /4-20 5/1 6-1 8 5/1 6-1 8 3/8-1 6

D E F G
TOLERANCES: 2 Place Decimals + .01
3 Place Decimals + .001 A

X
Model 500 T W
500
A 4.67
B 4.800
C 4.00 X*: Maximum Space between
D 1 .04 shaft ends to allow full
E 1 .23
shaft engagement
in Hub Bore.
CB
F 0.64
G 0.70 Y*: Minimum spacing
between shaft ends.
W 1 /1 6
X 1 .41
T 3/8-1 6
* Given for reference only.
TOLERANCES: 2 Place Decimals + .01
D E F G
3 Place Decimals + .001 A
X
Models 600, 700, 800, 900 T W
600 700 800 900
A 5.98 6.99 7.99 1 0.1 5
B 5.975 6.900 8.600 11 .400
C 4.50 5.19 7.00 8.30
D 1 .60 2.08 2.25 2.75
E 1 .33 1 .32 1 .62 2.20 C B
F 0.62 0.89 1 .00 1 .32
G 1 .1 3 1 .1 3 1 .58 1 .88
W 1 /1 6 1 /1 6 1 /1 6 1 /1 6
X 1 .36 1 .97 2.25 2.89
T 3/8-1 6 1 /2-13 1 /2-1 3 3/4-1 0

TOLERANCES: 2 Place Decimals + .01 D E F G


3 Place Decimals + .001 A

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 4


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
63
Bore & Keyway Combinations

Standard Bore and Keyway Combinations


Magnaloy “Standard” Bore & Key Combinations Magnaloy “Standard” Bore & Key Combinations
Model Bore/Key Model Model Bore/Key Model

100
200
300
400
500
600
700
800

100
200
300
400
500
600
700
800
900
900
Code Code Bore Key Code Code Bore Key
M __ __ __ 01203 3/8 x 3/32 • • M __ __ __ 12414 1 3/4 x 7/16 • • • • •
M __ __ __ 01403 7/16 x 3/32 • • M __ __ __ 12816 1 7/8 x 1/2 • • • • • •
M __ __ __ 01404 7/16 x 1/8 • • M __ __ __ 13016 1 15/16 x 1/2 • •
M __ __ __ 01604 1/2 x 1/8 • • • M __ __ __ 20016 2 x 1/2 • • • • •
M __ __ __ 01804 9/16 x 1/8 • • • M __ __ __ 20416 2 1/8 x 1/2 • • • • •
M __ __ __ 02005 5/8 x 5/32 • • • M __ __ __ 20816 2 1/4 x 1/2 • • • • •
M __ __ __ 02006 5/8 x 3/16 • • • • M __ __ __ 21220 2 3/8 x 5/8 • • • • •
M __ __ __ 02206 11/16 x 3/16 • • • • M __ __ __ 21620 2 1/2 x 5/8 • • • •
M __ __ __ 02404 3/4 x 1/8 • • • M __ __ __ 22020 2 5/8 x 5/8 • • • •
M __ __ __ 02406 3/4 x 3/16 • • • • • • M __ __ __ 22420 2 3/4 x 5/8 • • •
M __ __ __ 02806 7/8 x 3/16 • • • • • • M __ __ __ 22824 2 7/8 x 3/4 • • •
M __ __ __ 02808 7/8 x 1/4 • • • • • • M __ __ __ 30024 3 x 3/4 • •
M __ __ __ 03008 15/16 x 1/4 • • M __ __ __ 30824 3 1/4 x 3/4 • •
M __ __ __ 10006 1 x 3/16 • • • • • • M __ __ __ 31228 3 3/8 x 7/8 • •
M __ __ __ 10008 1 x 1/4 • • • • • • M __ __ __ 31628 3 1/2 x 7/8 • •
M __ __ __ 10408 1 1/8 x 1/4 • • • • • • M __ __ __ 32028 3 5/8 x 7/8 • •
M __ __ __ 10608 1 3/16 x 1/4 • • M __ __ __ 32428 3 3/4 x 7/8 • •
M __ __ __ 10808 1 1/4 x 1/4 • • • • • M __ __ __ 32832 3 7/8 x 1 • •
M __ __ __ 10810 1 1/4 x 5/16 • • • • • • • M __ __ __ 40032 4 x 1 •
M __ __ __ 11210 1 3/8 x 5/16 • • • • • • • M __ __ __ 40432 4 1/8 x 1 •
M __ __ __ 11212 1 3/8 x 3/8 • M __ __ __ 40832 4 1/4 x 1 •
M __ __ __ 11412 1 7/16 x 3/8 • • • M __ __ __ 41232 4 3/8 x 1 •
M __ __ __ 11610 1 1/2 x 5/16 • • • M __ __ __ 41632 4 1/2 x 1 •
M __ __ __ 11612 1 1/2 x 3/8 • • • • • • M __ __ __ 41640 4 1/2 x 1 1/4 •
M __ __ __ 12012 1 5/8 x 3/8 • • • • • • M __ __ __ 42040 4 5/8 x 1 1/4 •
M __ __ __ 12412 1 3/4 x 3/8 • • • • • M __ __ __ 42440 4 3/4 x 1 1/4 •
Shaded Area: AGMA semi-standard bore key combinations.
Bore Tolerances
Part Number Usage: Magnaloy Coupling Hub part numbers Over Include Tolerance
may be specified using the following format: Start with let- -- 1 +.0008/ +.0003
ter “M” designating Magnaloy, followed by 3 digit Model 1 2 +.0013/ +.0005
2 3 +.0018/ +.0008
Code (100, 200, etc.), then the specific 5 digit Bore Key 3 4 +.0020/ +.0010
Code. 4 5 +.0023/ +.0010

Example: Model 500 hub with a 1 3/8 bore and 5/16 key-
way would be specified as: M50011210 - No bore hubs are
designated as ‘R’ code, ie: M500R.

Additional Coupling Specifications


Model Number 100 200 300 400 500 600 700 800 900
Maximum Bore 1-1/8 1-3/8 1-5/8 1-7/8 2-3/8 2-5/8 2-7/8 3-7/8 4-3/4
Complete Coupling Approx. Wght. 3/4 1 2 3 4 7 12 18 38
(Solid Hub)

Number of Drive Lugs 3 3 3 3 4 6 6 6 6


Hub Movement for Insert Removal .74 .74 .75 .98 1.12 1.02 1.50 1.63 2.27
Basic Insert Number 170 270 370 470 570 670 770 870 970

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 5


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
70 64
Insert Selection Guide

Magnaloy Coupling’s full range of flexible inserts


permit custom design performance for a wide range
of applications. All insert materials offer complete
electrical insulation, as Magnaloy’s design elimi-
nates all metal-to-metal contact.

Neoprene (Code N) - Black material -


Standard material with Magnaloy Coupling.
Good general purpose material offering good
resiliency
o
and
o
load
o
capabilities.
o
Temp range -
30 F to +250 F (-34 C to =121 C) optional 80A
durometer (painted gold) and 90A durometer
(painted silver) are available for slight
increased load capability and less resiliency.
Nitrile (Buna N) (Code B) - Painted blue -
Excellent material with petroleum products.
Excellent compression set and abrasion o
resistance
o o
characteristics.
o
Temp range -60 F to
+250 F (-51 C to +121 C).
Urethane (Code U) - Yellow
Excellent mechanical and physical
properties. Offers good medium duty
durability and resiliency. Urethane tends to
soften in higher temperatureso
ando humid con-
ditions.
o
Temp o
Range -30 F to +150 F
(-34 C to +66 C).
Part Number Usage: Magnaloy Coupling Viton (Fluorocarbon) (Code V) - Red material -
Insert part numbers may be specified using Excellent fluid compatibility and high
the following format: Start with letter ‘M’ temperature characteristics. Good
designating Magnaloy followed by 3 digit compression
o o
set and
o
resiliency.
o
Temp range -
20 F to +350 F (-29 C to +177 C).
insert model size (170, 270, etc.) then the
specific material code letter. If an optional Hytrel (Code H) - Blue-green material - Superior
durometer is being specified, after the physical and mechanical properties and
material code letter supply the durometer excellent fluid compatibility and high temper-
number divided by 10. ature characteristics. Hardness (50D)
EXAMPLES: Urethane insert for Model 300, M370U; approaches that of plastic and offers little
80 Duro Neoprene for Model 200, M270N8. resiliency. Excellent performanceo under heavy
o
dutyo conditions.
o
Temp range -65 F to +300 F
(-54 C to +149 C).
Other materials are available for special applications.
Consult factory for recommendations and availability.

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 8


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
65
Insert Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0* 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*

Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts,
infrequent reversals, peak torque may exceed average rate of prime
mover by 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak
torque may exceed average rating of prime mover by 150%.
*Recommend use of Urethane or Hytrel Insert.

Drive Unit Load Sym. Selection Method


Agitators U 1. Several specifics must be considered to make the best
Blowers U choice of couplings:
Compressors • Centrifugal U
• Rotary M A. Type of prime mover and load characteristics
• Reciprocating H* (see table above).
Conveyors U B. Shaft diameter and key size or spline configuration
• Reciprocating M
• Screw M (No. of teeth, pitch ratio, pressure angle).
• Shaker H C. Horsepower rating of loads to be transmitted.
Cranes & Hoists M D. Maximum operating speed (rpm).
Crushers H* E. Maximum operating misalignment.
Elevators M
• Freight & Pass. H* F. Clearance limitations.
Fans • Centrifugal U 2. Calculate effective hp/100 rpm by use of table above
• Propeller M and select the minimum size couplings recommended.
• Cooling Tower H
3. VERIFY YOUR SELECTION:
Generators U
• Welding H A. Check for maximum bore size.
Mills H* B. Check dimensions for adequate clearance.
Machine Tools M C. Indicate any special insert specification and/or
Mixers M coupling coating for environmental protection, if
Paper Mill Machinery M
required.
Pumps • Centrifugal U
• Rotary M Equation: Effective HP per 100 RPM = rated HP x Service
• Reciprocating H* Factor x 100/RPM
• On Injection H*
Molding Equip. Example: 150 HP 4 cyl. Diesel Engine Driving
Screens • Air & Water U Reciprocating Irrigation Pump operating
Washing at 3250 RPM
• Freight & Pass. H
Service Factor = 3.0 (Hytrel Insert recommended)
Stokers U
Textile Machinery M Eff. HP per 100 RPM = 150 HP x 3.0 x 100/3250
Woodworking Machinery M RPM = 13.85 HP/100 RPM Model 600 rating with
Winches H* Hytrel Insert is 23.7 HP/100 RPM
NOTE: Above service factors are intended for use as a general guide only.
* Recommend use of Steel Bushing and Clamp with Splined Bores.

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 9


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
66
Installation Instructions

Shaft spacing should be within range given by


dimensions ‘W’ and ‘X’ as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard “push fit” tolerances,
if a tight fit exists check shaft for burrs.
Maximum benefits are obtained with hubs posi-
tioned to allow complete shaft engagement within
bore. However, some equipment designs do not
permit this condition - maximum shaft engagement
should be utilized in any case.

Alignment - Place a straight edge (scale) at top


and side of coupling. Use a .005 inch feeler gauge
under scale for final inspection. This will indicate
accurate parallel and angular alignment.
Magnaloy’s precision tooled outside surfaces
permit this simple, but accurate alignment method.

Secure equipment mounts and recheck alignment


for movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or creep . Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be necessary
to slightly loosen the set-screw over the keystock.
When securing the coupling to the shaft, first tighten
the clamp bolt, then tighten the set--screw against
the keystock.

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 10


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
73 67
Mis-Alignment Capabilities

Magnaloy couplings offer four-way flexibility (parallel,


angular, axial and torsional) and require no lubrica-
tion. They are easily installed and properly aligned
without use of special tools or equipment - a straight
edge and hex wrench are the only tools required.
Magnaloy’s insert reduces noise and vibration and
permits needed flexibility for proper operation within
alignment capabilities.
Recommended Torques
for Fasteners
Model Set Screw Clamp Screw
100 60-70 in. lbs. 130-140 in. lbs.
200 130-140 in. lbs. 130-140 in. lbs.
300 130-140 in. lbs. 210-220 in. lbs.
400 190-200 in. lbs. 210-220 in. lbs.
500 190-200 in. lbs. 300-310 in. lbs.
600 190-200 in. lbs. 35-36 ft. lbs.
700 300-310 in. lbs. 35-36 ft. lbs.
800 300-310 in. lbs. 49-50 ft. lbs.
900 100-110 ft. lbs. 100-110 ft. lbs.
Intended as a general guide for fastener torques
with Magnaloy Couplings.

Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain,


and misaligned equipment produces excess stress on bearings and coupling. Magnaloy’s
insert design will accept misalignment strain and, when excessive, will cause insert wear as
a visual and audible indication of misalignment problems. However, Magnaloy’s inserts are
inexpensive and easily replaced; under normal conditions the insert seldom requires
replacement.

Maximum
1 o Angular
Mis-Alignment
Mis - A lign m e n t
Cap ab ilitie s

Maximum
.015 in. Parallel
Mis-Alignment

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 11


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
74 68
Technical Bulletin & Notes
Keystock Interference with Drive Lug
Since the Magnaloy Coupling keyway in a bored and keyed hub is broached between the
drive lugs, there is a potential for interference with the keystock of the drive lugs and the
driver lugs of the driven hub. Interference will result when ALL the following conditions exist:
A) The shaft diameter is GREATER than listed below.
B) T h i s shaft extends into the hub insert core area.
C) The keystock on this shaft extends with the shaft.
The interference condition can be corrected by shortening the keystock so it does not
extend into the coupling hub insert core area.
Interference Potential exists when
shaft diameters are greater than Area of Interference Cut Keystock even
shown in this chart with this Surface

Model Size Shaft Diameter Key Size


100 7/8 1/4
200 1 - 3/16 1/4
300 1 - 5/16 5/16
400 1 - 1/2 3/8
500 1 - 15/16 1/2
600 2 - 1/2 5/8
700 2 - 3/4 5/8
800 3 - 1/2 7/8
900 4 - 1/2 1 - 1/4

Failure to correct this condition will result in assembly difficulty and could cause damage
to the drive or driven equipment.

Notes

magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 12


A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
75 69
MODEL Pilot operated, balanced piston relief valve
RPGC SERIES 2 / CAPACITY: 50 gpm / CAVITY: T-3A

snhy.com/RPGC

CONFIGURATION
Pilot-operated, balanced-piston relief cartridges are normally closed pressure regulating valves. When the pressure
L Control Standard Screw Adjustment
at the inlet (port 1) reaches the valve setting, the valve starts to open to tank (port 2), throttling flow to regulate the
pressure. These valves are accurate, have low pressure rise vs. flow, they are smooth and quiet, and are
W Adjustment 150 - 4500 psi (10,5 - 315 bar), moderately fast.
Range 1000 psi (70 bar) Standard
Setting
TECHNICAL DATA NOTE: DATA MAY VARY BY CONFIGURATION. SEE CONFIGURATION SECTION.
N Seal Material Buna-N
(none)Material/Coating Standard Material/Coating Cavity T-3A
Series 2
Capacity 50 gpm
Factory Pressure Settings Established at 4 gpm
Maximum Operating Pressure 5000 psi
Response Time - Typical 10 ms
Maximum Valve Leakage at 110 SUS (24 cSt) 3 in³/min.@1000 psi
Adjustment - No. of CW Turns from Min. to Max. Setting 5
Valve Hex Size 1 1/8 in.
Valve Installation Torque 45 - 50 lbf ft
Adjustment Screw Internal Hex Size 5/32 in.
Locknut Hex Size 9/16 in.
Locknut Torque 80 - 90 lbf in.
Seal kit - Cartridge Buna: 990203007
Seal kit - Cartridge EPDM: 990203014
Seal kit - Cartridge Polyurethane: 990003002
Seal kit - Cartridge Viton: 990203006
Model Weight 0.57 lb.

NOTES For Series 1 cartridges configured with an O control (panel mount handknob), a .75 in. (19 mm) diameter hole is required in the panel.

76 70
c 2017 Sun Hydraulics Corporation
 See www.sunhydraulics.com for detailed product information 1 of 3
CONFIGURATION OPTIONS Model Code Example: RPGCLWN
CONTROL (L) ADJUSTMENT RANGE (W) SEAL MATERIAL (N) MATERIAL/COATING
L Standard Screw Adjustment W 150 - 4500 psi (10,5 - 315 bar), 1000 N Buna-N Standard Material/Coating
C Tamper Resistant - Factory Set psi (70 bar) Standard Setting E EPDM /AP Stainless Steel, Passivated
J Capped Screw Adjustment A 100 - 3000 psi (7 - 210 bar), 1000 psi V Viton /LH Mild Steel, Zinc-Nickel
K Handknob (70 bar) Standard Setting
O Handknob with Panel Mount B 50 - 1500 psi (3,5 - 105 bar), 1000 psi
(70 bar) Standard Setting
W Hex Wrench Adjustment
C 150 - 6000 psi (10,5 - 420 bar), 1000
Y Tri-Grip Handknob
psi (70 bar) Standard Setting
D 25 - 800 psi (1,7 - 55 bar), 400 psi (28
bar) Standard Setting
E 25 - 400 psi (1,7 - 28 bar), 200 psi (14
bar) Standard Setting
N 60 - 800 psi (4 - 55 bar), 400 psi (28
bar) Standard Setting
Q 60 - 400 psi (4 - 28 bar), 200 psi (14
bar) Standard Setting

TECHNICAL FEATURES

All 2-port relief cartridges (except pilot reliefs) are physically and functionally interchangeable (same flow path, same cavity for a given frame size).
Will accept maximum pressure at port 2; suitable for use in cross port relief circuits. If used in cross port relief circuits, consider spool leakage.
Main stage orifice is protected by a 150 micron stainless steel screen.
Not suitable for use in load holding applications due to spool leakage.
Back pressure on the tank port (port 2) is directly additive to the valve setting at a 1:1 ratio.
Cartridges configured with EPDM seals are for use in systems with phosphate ester fluids. Exposure to petroleum based fluids, greases and lubricants will damage
the seals.
W and Y controls (where applicable) can be specified with or without a special setting. When no special setting is specified, the valve is adjustable throughout its full
range using the W or Y control. When a special setting is specified, this setting represents the maximum setting of the valve.
Corrosion resistant cartridge valves are intended for use in corrosive environments and are identified by the model code suffix /AP for external stainless steel
components, or /LH for external zinc-nickel plated components. See the CONFIGURATION section for all options. For further details, please see the Materials of
Construction page located under TECH RESOURCES.
Incorporates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive installation torque and/or cavity/cartridge
machining variations.

PERFORMANCE CURVES

77 71
c 2017 Sun Hydraulics Corporation
 See www.sunhydraulics.com for detailed product information 2 of 3
72
Duragauge® Pressure Gauge
Type 1279, ASME B 40.1
Grade 2A (±0.5% of span)

• 41/˝
/22 full-size bourdon tube - See pages 6-7 for details
• Patented Duratube™ with as-welded- - Order as option XLL
tube construction controls stress • Epoxy-coated system for superior
for longer life corrosion resistance
• “Round Cap Tip”construction
lowers stresses for longer life Type 1279 Duragauge® pressure
• Easily adjustable, self-locking gauge is offered in 41/2˝ phenolic
micrometer pointer case for superior chemical and heat
resistance. Solid-front case design
• Burn-resistant phenol turret case
with blow-out back for safety. Dry,
• Exclusive Teflon coated 400 series liquid-filled, hermetically sealed,
stainless steel rotary movement weatherproof or PLUS! options avail-
for longer life
able. Field convertible to liquid-fill
• NewPLUS!™ Performance Option: with conversion kit (detailed on page
- Liquid-filled performance in a dry 243). All case styles provide full tem-
gauge perature compensation.
- Fights vibration and pulsations
without liquid-filled headaches

BOURDON SYSTEM SELECTION STANDARD RANGES


Ordering Bourdon Tube & Tip Material(1) Socket Tube Range Selection NPT Pressure Compound
Code (all joints TIG welded except “A”) Material Type Limits (psi) Conn.(2) psi psi
Phosphor Bronze 1
0/15 30 in.Hg/15 psi
A Tube-Brass Tip, Silver Brazed Brass C-Tube 12/1000 /4, 1⁄22

0/30 30 in.Hg/30 psi


1 1
C-Tube 12/1500 ⁄⁄,
4 ⁄2

2 0/60 30 in.Hg/60 psi


R 316L stainless steel 1019 steel
Helical 2000/20,000 1
⁄⁄,1
4 ⁄2

2 0/100 30 in.Hg/100 psi


C-Tube 12/1500 1
⁄⁄,1
4 ⁄2

2
0/160 30 in.Hg/150 psi
S 316L stainless steel 316L stainless steel 0/200 30 in.Hg/300 psi
1 1
Helical 2000/20,000 ⁄⁄,
4 ⁄2

2
0/300
1 1
C-Tube 15/1500 ⁄⁄,
4 ⁄2

2
P(3) K Monel Monel 400 0/400 Vacuum
1 1 (4)
Helical 2000/30,000 ⁄⁄,
4 ⁄2

2 0/600 30/0 in.Hg


(1) For selection of the correct bourdon system material, see the
0/800 34/0 ftH2O
media application table on page 243. 0/1000
(2) Other connections available on application. 0/1500
(3) Use for applications where NACE standard MR-01-75 is
specified. 0/2000
(4) 30,000 psi range supplied with 1⁄4 high pressure 0/3000
connection, 1⁄2 NPT optional.
0/5000
NOTE:
0/10,000 Equivalent standard
0/20,000 kg/cm2, and kPa metric
0/30,000 ranges are available.

TO ORDER THIS 1279 DURAGAUGE:


Select: 45 1279 SS* 04L XXX 2000#
1. Dial size–41⁄˝
⁄2
2. Case type–1279
Ring–threaded reinforced polypropylene
3. Bourdon system selection ordering code
4. Connection–1⁄4 NPT (02), 1⁄2 NPT (04), Lower (L), Back (B)
5. Optional features–see page 239
6. Standard pressure range
7. Accessories–see pages 233-238 ( ) “S” denotes solid front case design
*
Consult factory for guidance in product selection
Phone (203) 385-0217, Fax (203) 385-0602 or 72
MADE IN U.S.A. visit our web site at www.ashcroft.com
Capacity:

Free flow nose to side, Check valve 40 gpm (160 L/m in.)

Functional Group: Model:

Products : Cartridges : Check Valve : 2 Port : Free Flow Nose to Side CXFA

Product Description
Free-flow, nose-to-side check valves are on/off circuit components that allow free flow from the inlet (port 1)
to the outlet (port 2) and block flow in the opposite direction.

Technical Features
l Two-port check valves share the same cavity l Check valves offer extremely low leakage rates
for a given frame size, however, pay close with a maximum leakage of less than 1 drop
attention as flow paths may be in opposite per minute.
directions.
l W ill accept 5000 psi (350 bar) at ports 1 and 2. l Incorporates the Sun floating style construction
to eliminate the effects of internal parts binding
due to excessive installation torque and/or
cavity/cartridge machining variations.

Technical Data

US Units Metric Units


Cavity T-5A
Capacity 40 gpm 160 L/min.
Maxim um Operating Pressure 5000 psi 350 bar
Maxim um Valve Leakage at 110 SUS (24 cSt) 1 drops/min. 0,07 cc/min.
Series 2
Valve Hex Size 1 1/8 in. 28,6 mm
Valve Installation Torque 45 - 50 lbf ft 60 - 70 Nm
Model W eight .40 lb 0,20 kg
Seal Kits Buna: 990-203-007
Seal Kits Viton: 990-203-006
Displayed Model W eight 0.40 lb 0.18 kg

Option Selection

CXFA-X C N

73
Preferred Options
External
Control Cracking Pressure Material/Seal
Material
X Not Adjustable A 4 psi (0,3 bar) N Buna-N

C 30 psi (2 bar)

Standard Options
B 15 psi (1 bar) V Viton

D 50 psi (3,5 bar)

E 75 psi (5 bar)

F 100 psi (7 bar)

Additional Options
The following options are not widely used and m ay be application specific. Please contact
your Sun distributor for application inform ation.
Z 1 psi (0,07 bar) P Stainless/Buna-
N

W Stainless/Viton

Custom er specified setting stam ped on hex +$1.10

Copyright © 2003 Sun Hydraulics Corporation.


All rights reserved.

Term s and Conditions - Statem ent of Privacy

74
Ball Valves
Holmbury

BV*2 SERIES
2 WAY HIGH PRESSURE BALL VALVES

INTRODUCTION
Holmbury BVC2 ball valves are designed to suit a wide
range of applications including mobile plant and indus-
trial equipment.
These valves should not be used as ow control valves
and should therefore always be fully open or fully
closed.

FEATURES
• Full bore valves provide an unrestricted ow path for
negligible pressure drop.
• Floating ball on pre-compressed seals minimizes
wear and provides an excellent seal at positive and
negative pressures.
• Operating temperature range: -20 C (-4 F) to
+100 C (+212 F).
• Open to close in 1/4 turn (90 ).
• Offset handles are incorporated to provide good
clearance for the operators hands.

MATERIALS
• Body and port adaptor are Trivalent plated steel
(38SMn PB 10).
• Handle - steel forging, Trivalent plated.
• Ball - carbon steel.
• Ball seals - DELRIN (polyacetalic resin).
1 - Port adaptor
2 - ‘O’ ring • Shaft seal - nitrile.
3 - Shaft
4 - Shaft seal Also available in AISI 316 stainless steel construction
5 - Shaft bearing and Viton® Seals (BVS) are available for corrosive
6 - Handle environments or for use with corrosive uids.
7 - Body
8 - Ball OPTIONAL COMPONENTS
9 - Ball seals
Locking Devices
DS9 for sizes 04-13
Order Codes DS14 for sizes 20-25
BVC 2 - 20 - N Replacement Offset handles
Thread Type SW9 for sizes 04-13
G = BSP N = NPT SW14 for sizes 20-25
BVC = Carbon Steel S = O Ring Boss
BVS = Stainless Steel Body Thread Size
04 = 1/8” 13 = 1/2” 32 = 1-1/4”
2 = 2 Way 06 = 1/4” 20 = 3/4” 40 = 1-1/2”
10 = 3/8” 25 = 1” 50 = 2”
Note: Not all thread types and sizes are available as stock items.
Minimum order quantity may be required. Consult factory for details.

www.holmburyUSA.com 1.866.465.6287
75
Ball Valves
Holmbury

BV*2 SERIES, 2 WAY


HIGH PRESSURE
BALL VALVES

2 Way High Pressure


Ball Valve Dimensions Across ats
(Sizes 4-25)
Nominal Max. Oper A B C E F G CH J L M
CODE Size Diameter Pressure.
Bar Dimensions in millimeters
inches mm
PSI Dimensions in inches
500 37 32 28 26 5 4.5 22 13 69 44.5
BV*2-04 1/8” 4
7250 1.46 1.26 1.10 1.02 0.20 0.18 0.87 0.51 2.72 1.75
500 37 32 28 26 5 4.5 22 13 69 44.5
BV*2-06 1/4” 6
7250 1.46 1.26 1.10 1.02 0.20 0.18 0.87 0.51 2.72 1.75
500 42 40 32 32 5 6.5 27 17 72 52.5
BV*2-10 3/8” 10
7250 1.65 1.57 1.26 1.26 0.20 0.26 1.06 0.67 2.83 2.07
500 48 40 35 37.5 4.8 6.5 30 17 83 52.5
BV*2-13 1/2” 13
7250 1.89 1.57 1.38 1.48 0.19 0.26 1.18 0.67 3.27 2.07
500 60 57 48 45 6.5 6.5 41 24 95 75
BV*2-20 3/4” 20
7250 2.36 2.24 1.89 1.77 0.26 0.26 1.61 0.94 3.74 2.95
500 65 64 57 55 6 6.7 50 28.5 113 82
BV*2-25 1” 25
7250 2.56 2.52 2.24 2.17 0.24 0.26 1.97 1.12 4.45 3.23
Inches=mm/25.4
lbs=kg x 2.204622

CH
M
B

2 Way High Pressure


Ball Valve Dimensions A
L C
(Sizes 32, 40, 50)
All dimensions shown
Nominal Max. Oper A B C CH J L M are for guidance only, if
CODE Size Diameter Pressure.
critical contact Holmbury
Bar Dimensions in millimeters Technical Department
inches mm
PSI Dimensions in inches
350 84 84 75 60 37.5 120 104.5
BV*2-32 1-1/4” 32
5075 3.31 3.31 2.95 2.36 1.48 4.72 4.11
350 91 95 85 70 42.5 130 115.5
BV*2-40 1-1/2” 40
5075 3.58 3.74 3.35 2.76 1.67 5.12 4.55
350 100 112.5 105 80 52.5 140 133
BV*2-50 2” 50
5075 3.94 4.43 4.13 3.15 2.07 5.51 5.24

1.866.465.6287 www.holmburyUSA.com
76
Screw Plug Heaters
APPLICATIONS Type 2P - 2" NPT Plug
90 W atts Per Square Inch
For heating clean water only in commercial and/or
residential applications. Element life is sacrificed in
favor of a low initial heater cost.
60 and 45 W atts Per Square Inch
Industrial water heating - many aqueous solutions
which are compatible with steel and Incoloy.
23 and 20 W atts Per Square Inch
For heat transfer oil, cleaners, high temperature air
and gas heating.
15 and 12 W atts Per Square Inch
For lubricating oils, medium viscosity oils, high
temperature air and gas heating.
8 and 6 W atts Per Square Inch
For #5 and #6 fuel oil heating, viscous materials,
raw crude oil, residual oils, high temperature air
and gas heating.

STANDARD FEATURES

Heating Elements
· Incoloy 800 Sheath Material
· Heavy W all (.035 in.)
· Large diameter (.475 in.)
· Sealed Terminals
Screw Plug
· Solid Bar Stock Construction
· Type 304 Stainless Steel SPECIAL FEATURES
· Precision Spaced and Drilled
· Single Pole Thermostat (A) 50-250°F
Spacers
· Over-Temp Cutout (C1) 225°F, (C2) 300°F, (C3) 535
· High Temp Alloy Material
· Rugged Design · Double Pole Thermostat (A1) 0-100°F, (A) 50-
250°F, (A3) 150-550°F
· "Evenflow" Configuration
Construction · Explosion Resistant Terminal Enclosure
· W elded Heating Elements · Moisture Resistant Terminal Enclosure
· W elded Terminal Housing · Sheath Sensing Type K(J) Thermocouple
· W elded Spacers attached to one element for overheat protection.
Installation · Type 316 Stainless Steel Screw Plug
· Flying Leadwires Provided
· Terminal Housing Potted with Silicone
· Only Standard Materials Needed in Field
· Space Heater Mounted in Terminal Enclosure
Service
· W iring Modifiable in Field · Offset (Spaced Away) Terminal Housing

· Assembly Repairable at Factory · Other Features not Listed Above

11/19/2001 Page 1 of 10
GAUM ER COM PANY, INC. · 13616 Hem pstead Road · Houston · Texas · 77040 · Ph: 713.460.5200
Ph: 800.460.5200 · Fx: 713.460.1444 · Fx: 800.460.5700 · www.gaum er.com · sales@gaum er.com

77
Screw Plug Heaters
Type 2P - 2" NPT Plug

W att Density: 12

Gaum er Catalog Num ber kW Volts Ph Quantity Im m ersed W eight (lbs.)


Elem ents Length

2P3N13H2D 1.1 120 1 3 13 10


2P3N13H4D 1.1 240 1,3 3 13 10
2P3N18H2D 1.5 120 1 3 18 10
2P3N18H4D 1.5 240 1,3 3 18 10
2P3N20H2D 1.9 120 1 3 20 11
2P3N20H4D 1.9 240 1,3 3 20 11
2P3N25H2D 2.3 120 1 3 25 12
2P3N25H4D 2.3 240 1,3 3 25 12
2P3N33H2D 3.0 120 1 3 33 13
2P3N33H4D 3.0 240 1,3 3 33 13
2P3N40H2D 3.8 120 1 3 40 19
2P3N40H4D 3.8 240 1,3 3 40 14
2P3N48H2D 4.5 120 1 3 48 16
2P3N48H4D 4.5 240 1,3 3 48 15
2P3N61H4D 6.3 240 1,3 3 61 18
2P3N78H4D 8.3 240 1,3 3 78 21
2P3N88H4D 9.4 240 1,3 3 88 23
2P3N106H4D 10.4 240 1,3 3 106 26
2P3N120H4D 11.3 240 1,3 3 120 29

W att Density: 8

Gaum er Catalog Num ber kW Volts Ph Quantity Im m ersed W eight (lbs.)


Elem ents Length

2P3N13M2Y 0.7 240 3 3 13 10


2P3N13M4Y 0.7 480 3 3 13 10
2P3N17M2Y 1.0 240 3 3 17 9
2P3N17M4Y 1.0 480 3 3 17 9
2P3N20M2Y 1.2 240 3 3 20 11
2P3N20M4Y 1.2 480 3 3 20 11
2P3N25M2Y 1.5 240 3 3 25 12
2P3N25M4Y 1.5 480 3 3 25 12
2P3N32M2Y 2.0 240 3 3 32 13
2P3N32M4Y 2.0 480 3 3 32 13
2P3N40M2Y 2.5 240 3 3 40 14
2P3N40M4Y 2.5 480 3 3 40 14
2P3N47M2Y 3.0 240 3 3 47 16
2P3N47M4Y 3.0 480 3 3 47 16
2P3N64M2Y 4.2 240 3 3 64 19
2P3N64M4Y 4.2 480 3 3 64 19
2P3N76M2Y 5.0 240 3 3 76 21
2P3N76M4Y 5.0 480 3 3 76 21
2P3N88M4Y 5.2 480 3 3 88 23
2P3N106M4Y 6.3 480 3 3 106 26
2P3N120M4Y 7.8 480 3 3 120 29
2P3N140M4Y 8.8 480 3 3 140 32
2P3N160M4Y 10.0 480 3 3 160 36

11/19/2001 Page 8 of 10
GAUM ER COM PANY, INC. · 13616 Hem pstead Road · Houston · Texas · 77040 · Ph: 713.460.5200
Ph: 800.460.5200 · Fx: 713.460.1444 · Fx: 800.460.5700 · www.gaum er.com · sales@gaum er.com

78
Immersion Heater Installation, Operations, and M aintenance M anual

IM M ERSION HEATERS
INSTALLATION, OPERATIONS, AND M AINTENANCE M ANUAL

INSTALLATION

This heater must be used only in the process for which it was designed. Contact the Customer Care Department at Gaumer Process Heaters
before placing the heater in any other service.

Care must be taken to ensure that the heated length of the heater is completely immersed in the process fluid or gas at all times. Gaumer is
not responsible for any heater which is not completely immersed in p rocess fluid or gas at all times Unless the heater is specifically
designed for the service, care must be taken that the heater elements are not in contact with sludge.

The gasket surface must be clean and dry before installing the heater. Use a new gasket suitable for the service and pressure rating. Use a
proper tightening sequence and torque on the bolts to ensure even gasket seating.

The heater housing must remain sealed until the wiring is ready for installation. It is extremely important that the terminals are protected
from moisture or vapor at all times. It is the responsibility of the user to ensure that the heater housing is properly rated for the area
electrical classification.

Low M egohm Condition- Prior to connecting the power wiring to the heater, a resistance reading should be made between each leg of each
heater circuit and ground. The refractory material used in electric heaters may absorb some moisture during transit, storage, or when
subjected to high humidity. A low megohm condition can be corrected by removing the terminal hardware and baking the heater in an
oven at 250° to 350° F for several hours. If an oven is not readily available, an alternate procedure is to energize the heater at low voltage
until the megohm reading returns to normal. W hen energizing heaters in air, the sheath temperatures should not exceed 750° F for steel or
Incoloy elements. Specially designed heaters with long non-heated lengths and/or low watt densities must be bake dried. For assistance,
contact the Gaumer Process Heaters Customer Care Department.

ELECTRICAL CONNECTIONS
a. Please refer to the enclosed wiring diagram for proper installation of wiring for the heater.
b. Each heater must be protected by a suitably rated over current device.
c. Conduit connections have been provided in heater housing for power wiring and temperature sensor wiring. It is NOT
recommended to run temperature sensor wiring in the same conduit or cable as the power wiring.
d. W ire sizing for power wiring and temperature sensing wiring is the responsibility of the end user recognizing the current
load of the heater, the distance from the power source, and the system over-current protection. The requirements of the
National Electrical Code (NEC)/(Canadian Electric Code (CEC) in Canada) must be followed. W ire must be rated per NEC
(CEC) considering system ambient temperature in the housing and the current carrying capacity.
e. If temperatures in the heater housing are anticipated to rise above standard wire rating, high temperature wiring may be
required for installation to the heater. Please contact Gaumer Process Heaters for assistance with high temperature wire
requirements.
NEM A 7 CONSIDERATIONS
Gaumer provides flying leads rated at 1000°f (537°C) as a standard. If connecting to these leads outside of the terminal housing,
an external junction box certified for the area classification with a seal (EYS) must be used. Refer to local code requirements for
maximum distance of the seal from the heater housing. The overall hazardous location designation of the heater is governed by
the device with the lowest hazardous location rating (E.G. Terminal box/cover ratings).
i.
OVER-TEM PERATURE PROTECTION

A high temperature limit device is required to protect the heater and provide a safety limit when heating hazardous liquids or gases.
DO NOT make any modifications to high limit devices provided without consulting with factory. If a high temperature limit device is
not provided, the end user is responsible for providing high temperature limit control. Gaumer Process Heaters assumes no
responsibility for operating the heater without a high temperature limit control.

13616 Hem pstead Road · Houston, Texas 77040 · (713) 460-5200 · (800) 460-5200
Fx: (713) 460-1444 · Fx: (800) 460-5700 · www.gaum er.com · sales@gaum er.com
Page 1 of 2
Doc. IOM -IH
Rev. 1 M C
79
Immersion Heater Installation, Operations, and M aintenance M anual
If an over temperature controller (OTC) or high temperature switch (TSH/TSHH) has been provided in the control panel, it must be set
to the appropriate temperature setting before the system is put into service. W ARNING – W HEN HEATING FLAM M ABLE OR
COM BUSTIBLE GASES OR LIQUIDS, DO NOT SET THE OTC HIGHER THAN 80% OF THE AUTO-IGNITION
POINT OF THE GAS OR LIQUID! Typical analog OTC’s will be mounted on the back pan of the control panel and will have an
adjustable dial. This dial should be set to the proper temperature before energizing the system. If a digital indicating OTC has been
provided, it must be energized before a temperature setting can be set.

GENERAL INFORM ATION

Immersion Heaters with 120 volt or 240 volt elements can be connected in series for high voltage operation except when uneven wattage is
supplies on the respective elements. Bending the heating elements is not recommended. If bending is necessary, contact the Customer
Care Department at Gaumer for assistance.

CORROSION

The sheath is believed to be satisfactory for the stated purpose. The rate of corrosion is affected by temperature, concentration, erosion,
inhibitors, flux, impurities in the heated medium, etc. GAUM ER COM PANY, INC., therefore, cannot guarantee this unit against damage
resulting from corrosion, electrolysis or other operating conditions beyond our control.

M AINTENANCE

In order to extend the life of your heater, the following maintenance functions should be performed. Gaumer Process Heaters can assist
and/or provide this maintenance work for you. Contact the Gaumer Customer Care Department for details.

W hen performing any maintenance on the heater, all site safety regulations must be followed. Approved safety lockout procedures must be
followed before opening the heater or heater electrical housing.

Semi-Annually
1. Open terminal housing and ensure it is dry and clean.
2. Check the resistance between each circuit leg and ground. If the reading is less than one megohm, contact the Customer Care
Department at Gaumer Process Heaters for assistance.
3. Check all terminals for damage and to ensure that all terminals are tight and secure. Care should be taken not to over-tighten
terminals.
4. If any problems are found with the items above, contact the Customer Care Department at Gaumer Process Heaters for
assistance.
5. Check enclosure gasket and replace if damaged.

Annually
1. Open the terminal housing. M ark and disconnect all incoming wiring. Disconnect conduit. Check the housing to ensure it is
clean and dry.
2. Note the position of the over-temp thermocouple. This is marked on the heater flange. Remove bolts from heater and pull heater
bundle. Care must be taken in removing the bundle not to damage the elements.
3. Check heater bundle for any sign of buildup of foreign materials. If buildup is noted, clean the elements. Check over-temp
thermocouple to ensure it is prop erly secured to element. If the thermocouple is removed for any reason, it must be re-attached to
the same element in the same location.
4. Perform items 2 through 5 of Semi-Annual maintenance shown above.
5. Re-install heater bundle using new gasket and taking care not to damage the elements. Note position of over-temp thermocouple.
Heater bundle M UST be re-installed in the same orientation as when it was removed.
6. W hen bolting the heater into place, proper tightening procedures and torque must be used to ensure proper seating of the gasket.
7. Reconnect conduit and wires using care to reconnect to the proper terminals.
8. Close housing cover using new gasket if necessary.
9. W hen re-starting the heater, monitor for leaks.

13616 Hem pstead Road · Houston, Texas 77040 · (713) 460-5200 · (800) 460-5200
Fx: (713) 460-1444 · Fx: (800) 460-5700 · www.gaum er.com · sales@gaum er.com
Page 2 of 2
Doc. IOM -IH
Rev. 1 M C
80
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Filter Size RF
Thread Connection G
014 030 045 070 090 130
BSP 3/4 1 1 -1 /4 1 -1 /2 2 2
NPT 3/4 1 1 -1 /4 1 -1 /2 2 2
SAE O-ring Thread 1 -1 /1 6–1 2 1 -5/1 6–1 2 1 -5/8–1 2 1 -7/8–1 2 1 -7/8–1 2 1 -7/8–1 2
SAE Flange 3000 PSI - - - - 2 2

Filter Size RF
Dimensions (mm/in)
014 030 045 070 090 130
89 89 1 20 1 20 1 50 1 50
b1
3.50 3.50 4.72 4.72 5.91 5.91

b2
80 80 110 110 1 35 1 35 D
3.1 5 3.1 5 4.33 4.33 5.31 5.31
88 88
b3 - - - -
3.47 3.47
1 02 1 02
b4 - - - -
4.02 4.02
42,9 42,9
b5 - - - -
1 .69 1 .69
77,8 77,8
b6 - - - -
3.06 3.06
73 73 1 00 1 00 1 26 1 26
d1
2.87 2.87 3.94 3.94 4.96 4.96
57,5 57,5 84 84 1 1 2,5 1 1 2,5
d2
2.26 2.26 3.31 3.31 4.43 4.43
36 36 48 48 54,5 54,5
d3
1 .42 1 .42 1 .89 1 .89 2.1 5 2.1 5
17 17 28 28 37,5 37,5
d4
.67 .67 1 .1 1 .1 1 .48 1 .48
1 00 1 00 1 35 1 35 1 70 1 70
d5
3.94 3.94 5.31 5.31 6.69 6.69
78 78 1 05 1 05 1 31 1 31
d6
3.07 3.07 4.1 3 4.1 3 5.1 6 5.1 6
33 33 41 41 47 47
h1
1 .30 1 .30 1 .61 1 .61 1 .85 1 .85
66 66 86 86 98 98
h2
2.60 2.60 3.39 3.39 3.86 3.86
91 ,5 1 59,5 119 1 80 1 72,5 252,5
h3
3.60 6.28 4.69 7.09 6.79 9.94
1 57,5 225,5 206 267 273,5 353,5
h4
6.20 8.88 8.1 1 1 0.51 1 0.77 1 3.91
23,5 23,5 24 24 27 27
h5
.93 .93 .95 .95 1 .06 1 .06
1 40 21 0 1 80 240 235 31 5
h6
5.51 8.27 7.09 9.45 9.25 1 2.40
48 48 66 66 85 85
I1
1 .89 1 .89 2.60 2.60 3.35 3.35
G1 or G1 or G1 -1 /4 or G1 -1 /4 or G1 -1 /2 or G1 -1 /2 or
G2
1 NPT 1 NPT 1 -1 /4 NPT 1 -1 /4 NPT 1 -1 /2 NPT 1 -1 /2 NPT

G3 - - - - M1 2x1 5 M1 2x1 5

M6 or M6 or M8 or M8 or M1 0 or M1 0 or
G4
1 /4–20 UNC 1 /4–20 UNC 5/1 6–1 8 UNC 5/1 6–1 8 UNC 3/8–1 6 UNC 3/8–1 6 UNC
36 36 50 50 55 55
Hex
1 .42 1 .42 1 .97 1 .97 2.16 2.1 6

91

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ReWXUn-LLne FLlWeUV

5eWXUQ/LQe )LlWeU +RXVLQJV  &RPSleWe )LlWeUV ƒ 7\Se 5)

RF  070  G  10  %  G24  G42NO - D - O - L1 / X


          
 Type  Sealing Materials  Outlet Style
5etXrn/ine Filter RF 1%5 %Xna‹ % Size Connection thread Code
F.0 9itRn‹ V
 Group (3'0 ( all :ithRXt thread 0
Flow Size 1Rte 2ther VealinJ PaterialV Rn reTXeVt 6tandard RXtlet
 lPin  1  86 G30 014 014 / 030 1" BSP / 1" NPT G16 / N16
1 1  lPin   86 G30 030 045 / 070 1 1 /4 BSP / 1 1/4 NPT G20 / N20
D 1  lPin  5 86 G30 045 90 / 130 1 1 /2 BSP / 1 1 /2 NPT G24 / N24
 lPin   86 G30 070
 lPin   86 G30 090
 Connection Style
5 lPin  1  86 G30 130 Connection Thread Group Code Group Code Group Code Group Code Group Code Group Code
Style Style 014 030 045 070 090 130
1Rte ([aFt ƃRZ Zill deSend Rn the VeleFted Ƃlter elePent
FRr teFhniFal data SleaVe Vee SaJeV 5   BSP - 3/4 G12 1 G16 1-1 /4 G20 1-1 /2 G24 2 G32 2 G32
BSP - 1 /2 G08 1 /2 G08 1-1 /2 G24 1-1 /4 G20 1-1 /4 G20 1-1 /4 G20
 Filter Material BSP - 1 G16 3/4 G12 - - - - 1-1 /2 G24 1-1 /2 G24

Micron NPT - 3/4 N12 1 N16 1-1 /4 N20 1-1 /2 N24 2 N32 2 N32
max.
Material Ūp*collapse ratings Code NPT - 1 N16 3/4 N12 1-1 /2 N24 1-1 /4 N20 1-1 /2 N24 1-1 /2 N24
available SAE O-ring Th
read - 1-1 /16 U12 1-5/1 6 U16 1-5/8 U20 1-7/8 U24 1-7/8 U24 1-7/8 U24
:LWKRXW ƂOWHU SAE O-ring Th
read - 1-5/1 6 U16 1-1 /16 U12 1-7/8 U24 1-5/8 U20 1-5/8 U20 1-5/8 U20
- - 0
element
SAE Flange 3000 PSI metric - - - - - - - - 2 C332M 2 C332M
,QRUJ JODVV ƂEUH 25 bar / 363 PSI G
3, 5, 10, 20 SAE Flange 3000 PSI UNC - - - - - - - - 2 C332U 2 C332U
6WDLQOHVV ƂEUH 30 bar / 435 PSI A
1Rte %Rld t\SeV identiI\ SreIerred FRnneFtiRn Vt\leV
Filter paper 10 bar / 145 PSI 10, 20 N
Stainless mesh 30 bar / 435 PSI 25, 50, S  Clogging Indicator  Additional Features
100, 200 :ithRXt &lRJJinJ IndiFatRr 0 Position*
1Rte &RllaSVeEXrVt reViVtanFe aV Ser I62 1 2ther 9iVXal &lRJJinJ IndiFatRr V :ithRXt leaNaJe Ril FRnneFtiRn - none
PaterialV Rn reTXeVt (leFtriFal &lRJJinJ 6ZitFh  9 12 G42NO /eaNaJe Ril FRnneFtiRn 1 2 L
(leFtriFal &lRJJinJ 6ZitFh  9 1& G42NC 1Rte 3RVitiRn RI the leaNaJe Ril FRnneFtiRn Vee SaJe 
 Micron Rating (leFtriFal &lRJJinJ 6ZitFh 1 1  9   9 :ithRXt an\ FRde aVVePEl\ in the Piddle RI the
G230
 ’P 03 tZRZa\ FRntaFt Rnl\ IRr &Rde : Ƃlter FRYer
5 ’P 05
1  ’P 10  Option Clogging Indicator  Design Code
 ’P 20 G42NO, G42NC and G230 2nl\ IRr inIRrPatiRn X
5 ’P 25 3lXJ FRnneFtRr 0
5 ’P 50 01  [ 1 5 M12
1  ’P 100 $03 SlXJ A
 ’P 200 'eXtVFh SlXJ D
1Rte 2ther PiFrRn ratinJV Rn reTXeVt 5XEEer ERRt S
 deJree 3Rl\aPide FaS Rnl\ IRr &Rde G W

)LlWeU (lePenWV ƒ 7\Se 5(

5(  014  G  10  %  X
     
 Type  Micron Rating  Sealing Materials
Filter (lePent 6erieV 5(  ’P 03 1%5 %Xna‹ %
5 ’P 05 F.0 9itRn‹ V
 Group 1  ’P 10 (3'0 (
$FFRrdinJ tR Ƃlter hRXVinJ  ’P 20 1Rte 2ther VealinJ PaterialV Rn reTXeVt
5 ’P 25
 Filter Material 5 ’P 50  Design Code
Max. Micron 1  ’P 100 2nl\ IRr inIRrPatiRn X
Material Ūp*collapse ratings Code  ’P 200
available 1Rte 2ther PiFrRn ratinJV Rn reTXeVt
,QRUJ JODVV ƂEUH 25 bar / 363 PSI G
3, 5, 10, 20
6WDLQOHVV ƂEUH 30 bar / 435 PSI A
Filter paper 10 bar / 145 PSI 10, 20 N
Stainless mesh 30 bar / 435 PSI 25, 50, S
100, 200
1Rte &RllaSVeEXrVt reViVtanFe aV Ser I62 1 2ther
PaterialV Rn reTXeVt

92

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ReWXUn-LLne FLlWeUV

ReWXUn-LLne FLlWeUV ƒ 7\Se RF


(leFWULFal CloJJLnJ SZLWFK

7he VZitFh iV XVed Zhere an eleFtriFal ViJnal iV needed tR indiFate Zhen the elePent needV 6tandard t\Se Zith SlXJ FRnneFtRr and rXEEer FaS $YailaEle Zith '(876&H '73 SlXJ
tR Ee FhanJed 7he VZitFh Fan tXrn Rn a liJht Rr VhXt the PaFhine dRZn Rr an\ IXrther indXVtrial Vtandard $03 -XniRr 7iPer SlXJ indXVtrial Vtandard and ƂYeSin FirFXlar
IXnFtiRn FRntrRlled E\ an eleFtriF ViJnal 7he VZitFhinJ SreVVXre iV 5 Ear  5 36I FRnneFtRr 01 $FRded aFFRrdinJ tR I(& 111
and thiV allRZV the elePent tR Ee FhanJed EeIRre the E\SaVV VettinJ RI  Ear  5 36I iV
reaFhed

7eFKnLFal DaWa
Limit-Switch G42NO+NC Limit-Switch G230
6ZitFhinJ &aSaFit\ 1 00 VA 1  9$
9RltaJe 1 0ࡕ42 VAC 1 f5 9$&
&Xrrent 1 0mAࡕ4A
6ZitFhinJ $FFXraF\
6ZitFhinJ FreTXenF\
± 0,5 bar at room temp. andnew state
200/min
D
Pa[ 3reVVXre 5aPS 5ate ž  EDUPV
'eJree RI 3rRteFtiRn IP65, plugs
7ePSeratXre 5anJe -30°C ࡕ +1 00°C & f 1 &

OUGeU CoGe

LLPLW-SZLWFK - G42NO - S - M10 - %25


    

 Type  Plug Type  Thread Type


LLPLW-SZLWFK 01 FiYe3in &RnneFtRr aFFRrdinJ tR I(& 111 M12 01  [ 1 M10
$03-XniRr7iPer 3lXJ A
 Connector Type '(876&H 3lXJ '73 D  Pressure Setting
(leFtriFal &lRJJinJ 6ZitFh  9 12 G42NO 5XEEer ERRt S 5 Ear   36I %25
(leFtriFal &lRJJinJ 6ZitFh  9 1& G42NC  deJree 3Rl\aPide FaS W
(leFtriFal &lRJJinJ 6ZitFh 1 1  9   9 Rnl\ IRr &RnneFtRr 7\Se G
G230
tZRZa\ FRntaFt Rnl\ IRr 3lXJ 7\Se :

DLPenVLonV 3lXJ 7\Se

M12 A D S W

2 4
P
3 1 1 2 1
1 2
 1 
 
1 
1 5 
 
 5

 5

 5

 5
 5

01 [1 01 [1 01 [1 01 [1 01 [1

1Rte 7he FXVtRPer  XVer FarrieV the reVSRnViEilit\ IRr the eleFtriFal FRnneFtiRn

'iPenViRnal draZinJV $ll diPenViRnV in PPin


93

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ReWXUn-LLne FLlWeUV

ReWXUn-LLne FLlWeUV ƒ 7\Se RF


VLVXal CloJJLnJ ,nGLFaWoU

7he JaXJe YiVXall\ diVSla\V the deJree RI FRntaPinatiRn RI the elePent VLVXal CloJJLnJ ,nGLFaWoU
7he FRlRred VeJPentV allRZ TXiFN YiVXal FheFNinJ Ø
1 5
Jreen   5 Ear   f 5 36I (lePent haV VerYiFe liIe leIt
\ellRZ 5   Ear  5  5 36I (lePent iV FRntaPinated and VhRXld Ee FhanJed
red ! Ear  !5 36I %\SaVV YalYe RSen XnƂltered Ril SaVVinJ tR tanN


1

1 5
,5
OUGeU CoGeV 1
51
SPG-C-040-00004-02-P-M10-402922

1 7,5

01 [1

D 
1 

 Type  Ear
9iVXal &lRJJinJ IndiFatRr SPG-C-040-00004-02-P-M10-402922

FLlWeU %oZl ZLWK 7KUeaGeG ConneFWLon 7KUeaGeG OXWleW

8nder VRPe FirFXPVtanFeV VXFh aV a tall reVerYRir Rr Rne Zith Ril leYelV ZhiFh Yar\ Jreatl\ dXrinJ RSeratiRn it iV neFeVVar\ tR
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7he RStiRnal ERZl Zith a IePale thread allRZV an e[tenViRn tR Ee Ƃtted TXite ViPSl\

h5
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LeaNaJe OLl ConneFWLon

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G1 
1  137 Rn reTXeVt

FLlWeU %oZl ZLWK 7KUeaGeG ConneFWLon anG DLIIXVeU 7KUeaGeG OXWleW ZLWK SRV

'iIIXVerV PRXnted tR the Ƃlter ERZl PiniPiVe IRaPinJ and redXFe nRiVe RI hiJh 5etXrn/ine ƃRZV FRr IXrther detailV Rn
67$8FF 'iIIXVerV SleaVe reIer tR the &alatRJXe 1R 1  H\draXliF $FFeVVRrieV G
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He[
for Return-Line Dimensions (mm/in)
Size SRV
Filter Size øD L Thread G Hex
SRV-114-G16 60 139 G1 46
RF-014/030
SRV-114-N16 2.36 5.47 1 NPT 1.81
SRV-200-G20 82 139 G1-1 /4 60
RF-045/070
SRV-200-N20 3.23 5.47 1-1 /4 NPT 2.36
L

SRV-227-G24 82 200 G1-1/2 60


RF-090/130
SRV-227-N24 3.23 7.87 1-1 /2 NPT 2.36

Ø'

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ReWXUn-LLne FLlWeUV

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7he IRllRZinJ FharaFteriVtiFV are Yalid IRr Pineral RilV Zith a denVit\ RI ,5 NJdP and the NinePatiF YiVFRVit\ RI  PPV F6t 7he FharaFteriVtiFV haYe Eeen deterPined in aFFRrdanFe
tR I62  0XltiSaVV Ƃlter ratinJV haYe Eeen REtained in aFFRrdanFe tR I62 1 7he hRXVinJ SreVVXre drRS iV direFtl\ SrRSRrtiRnal tR the Ril denVit\ &RntaFt 67$8FF IRr detailV

+oXVLnJV RF-014/030 +oXVLnJV RF-045/070 +oXVLnJV RF-090/130


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r

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ųp

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7.5 7.5 7.5
5 5 5

6  6  6 

4.5  4.5  4.5 

3 3 3
D
  

1 .5 1 1 .5 1 1 .5 1

0  0  0 


 5 5 75 1  1 5 4 in lPin  5 1  1 5  5 4 in lPin  1     5 4 in lPin

0 5 10 15 20 25 30 Q in US GPM 0 1 2.5 25 37.5 50 62.5 Q in US GPM 0 25 50 75 1 00 1 25 Q in US GPM

FLlWeU (lePenWV FLlWeU (lePenWV FLlWeU (lePenWV


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7.5 $ $5 7.5 $ $5 7.5


$ $5
5 5 5

6  6 6
 

4.5  4.5  4.5 


$1  $1 
3  3 3 $1 
 
$ $ $
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0  0  0 


 1    5  4 in lPin      1  1  4 in lPin    1  1  4 in lPin

0 2.5 5 7.5 10 1 2.5 15 Q in US GPM 0 5 10 15 20 25 30 Q in US GPM 0 10 20 30 40 Q in US GPM

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$ $5 $ $


7.5 7.5 7.5
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$5 $5
6  6 6
 

4.5  4.5  4.5 


$1 
3 $1  $1 
 3  3 
$
$ $
1 .5 1 1 .5 1 1 .5 1

0  0  0 


   1  1    4 in lPin  11   4 in lPin  1     5 4 in lPin

0 10 20 30 40 50 60 Q in US GPM 0 30 60 90 Q in US GPM 0 25 50 75 1 00 1 25 Q in US GPM

FLlWeU (lePenWV FLlWeU (lePenWV


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0.9  65 0.9  1

0.6 
65 0.6 
61 
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0  0 
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4 aV a SerFentaJe RI the nRPinal IlRZ 4 aV a SerFentaJe RI the nRPinal IlRZ

95

ZZZVtaXIIFRPen75 &atalRJXe  ƒ (ditiRn 1 1 7 75


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ųS PSI

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r

r
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Ea

Ea
R(-014-G R(-030-G R(-045-G
in

in

in
in

in
in
ųp

ųp

ųp
G G
37.5 37.5 37.5
5 5 5
G
G5
30  30  30  G5
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D 1 5 1 5 1 5

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0  0  0 
 1    5  4 in lPin      1  1  4 in lPin    1  1  4 in lPin

0 2.5 5 7.5 10 1 2.5 1 5 Q in US GPM 0 5 10 15 20 25 30 Q in US GPM 0 10 20 30 40 Q in US GPM

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   1  1    4 in lPin  11   4 in lPin  1     5 4 in lPin

0 10 20 30 40 50 60 Q in US GPM 0 30 60 90 Q in US GPM 0 25 50 75 1 00 1 25 Q in US GPM

96

76 &atalRJXe  ƒ (ditiRn 1 1 7 ZZZVtaXIIFRPen7


730 Eaton Way, Annacis Business Park
Delta, B.C. Canada V3M 6J9
Phone: (604) 521-1170 Toll Free 1-800-928-1170
INDUSTRIES LTD. Fax: (604) 522-0070 Website: www.sealum.com

Bar M anifold - Parallel and Series

D03
D05
D05H
D05HE
D07
D08

97
23-1
730 Eaton W ay, Annacis Business Park
Delta, B.C. Canada V3M 6J9
Phone: (604) 521-1170 Toll Free 1-800-928-1170
INDUSTRIES LTD.
Fax: (604) 522-0070 W ebsite: www.sealum.com

Parallel Bar

D03 PARALLEL - STANDARD FLOW

M C391-0-10-10-8A
A - 6061T6 ALUM INUM 3000 PSI RELIEF VALVE
S - C1018 STEEL 5000 PSI (P NOSE) #10-24NC
A AND B #8 SAE ORB
P AND T #10 SAE ORB BOTH END
NO. OF STATIONS: 10 M AX.
0 - NO CAVITY A A A
M - C-10-2 CAVITY
S - SUN T-10A CAVITY P T P T P T

B B B

2.13 TYP.

B B B
No. Of L No. Of L T P
Valves (Inch) Valves (Inch) G
3.00

1 2.00 6 12.63
0.31

2 4.13 7 14.75
3 6.25 8 16.88 A A A
4 8.38 9 19.00
0.31 1.00 1.00
5 10.50 10 21.13
5/16-18NC 2.69 L
2 HOLES
3.00
G (GAGE ON P): #4 SAE ORB BOTH ENDS

D03 PARALLEL - HIGH FLOW

M C1346-0-14-16-10A
RELIEF VALVE
A - 6061T6 ALUM INUM 3000 PSI (P NOSE) #10-24NC
S - C1018 STEEL 5000 PSI
A AND B #10 SAE ORB
P #12 SAE ORB BOTH END
T #16 SAE ORB BOTH END
NO. OF STATIONS: 14 M AX. A A A
0 - NO CAVITY
M - C-16-2 CAVITY P T P T P T
S - SUN T-3A CAVITY
B B B

2.13 TYP.

No. Of L No. Of L
Valves (Inch) Valves (Inch) T B B B
P
1 2.63 8 17.63 G
3.50

2 4.88 9 19.75
0.31

3 7.00 10 21.88
4 9.13 11 24.00
A A A
5 11.25 12 26.13
6 13.38 13 28.25 0.81 1.38 1.38
7 15.50 14 30.38 5/16-18NC 3.19 L
2 HOLES 4.00
G (GAGE ON P): #4 SAE ORB BOTH ENDS

98
23-2
Pub: ALA-0402-70

DIRECTIONAL
CONTROLS
SOLENOID OPERATED DIRECTIONAL CONTROL VALVES
(F-)(S-)DSG-01-Â-Â-70 / 7090
Up to 5075 PSI (350 BAR), 26.4 GPM (100 l/min)

MOUNTING SURFACE: NFPA-D03, CETOP-3, NG6, ISO 4401-03-02-0-94

1/8” (CETOP3) Sub-Plate Mounting


(F-)(S-)DSG-01-Â-Â-70 / 7090

DESIGN APPROVALS:
UL, CE, & CSA
ALA INDUSTRIES LIMITED
Yuken Master Distributor
1150 Southpoint Drive, Suite D
Valparaiso, IN 46385
Toll Free: 877-419-8536
Tel: 219-465-4197
Fax: 219-477-4194

99
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
1/8” Sub-plate mounting. Mounting surface: ISO 4401-
03-02-0-94, CETOP 3. NFPA-D01
■ FEATURE HIGHLIGHTS AND COMPARISON
7090 Design 6090 Design
(old)
High Pressure 5075 PSI 4570 PSI Port P, A, B
High Back Pressure 3045 PSI 2320 PSI Port T
High Flow Rate 26.4 GPM 16.6 GPM Both AC & DC
Low Pressure Drop 130 PSI 145 PSI 15.8 GPM, P to A
AVAILABLE IN THE FOLLOWING TYPES Power Consumption 29 W 29 W DC Solenoid
Overall Length 8.05 inch 8.27 inch DC Solenoid
Standard Type DSG-01 Mass 4.1 lb 4.9 lb Double Solenoid
Low Energy Consumption L-DSG-01 Protection IP65 IP64
Soft Shift Type S-DSG-01 Approval UL, CSA, CE UL, CSA, CE
Electrical Relay Inc. Type T-DSG-01

■ FEATURES
These Solenoid Operated Directional Valves feature high current solenoids which can be used by connecting directly
pressure, high flow, high speed, low energy consumption to the AC power source. They have, like other DC
and low pressure drop. These features are achieved using solenoids, such advantages that the sound in on-off
powerful, wet pin type solenoids and state-of-the-art flow operation is quite low and the coils are rarely burnt out
channel designs. even if the spool is stuck at the half way point of its
changeover. Moreover, they can be used almost
• Standard type: Useable at high pressure: 5075 PSI permanently without being affected by a surge voltage
and high flow: 26.4 U.S.GPM from the outside. Thus, they are the solenoids of high
reliability and durability.
• Soft Shift type: Noise at spool changeover and
vibration in piping is reduced to a minimum. • Solenoid Insulation Class: Class H

Stable operation • Solenoid Connectors


With a strong magnet and spring force, the valves are ⇒ (DIN connector)
tough against contamination and ensure a stable The solenoid connectors conform to the
operation. international standard ISO 4400 (Three-pin
electrical plug connectors). All valves with this
Solenoids option come standard with the DIN connectors
• AC Solenoids included.
50 to 60 Hz common service solenoids do not require
rewiring when frequency is changed. ⇒ Terminal Box Connection
The terminal box connection incorporates the use
• DC Solenoids of removable coils that connect to a terminal strip
These DC solenoids have incorporated surge absorbers. within the electrical conduit box via two sealed
Advantages are: pins molded into the coils. This allows for easy
⇒ Surge voltage can be controlled at a very low removal of the coils without requiring re-wiring of
figure and electronic control devices, such as a the terminals. The terminal strip includes internal
computer, can be used without any noise grounds that may be used to reduce wiring. All
interference. valves with the terminal box option come standard
⇒ Sparkless contacts extend the life of the relay. with indicator lights and dual 1/2” NPT ports to
⇒ Time lag for spool return after de-energization of allow for conduit connections to the terminal box.
the solenoid is very short.
⇒ Lead Wire Connection
• R Type Solenoids The lead wire connection uses a pair of 20 gauge
These are rectifier and surge absorber incorporated direct wires per coil, each 15.7 inches in length.

ALA INDUSTRIES LIMITED PAGE 2


100
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ RATINGS
Max Max
Max. Max.
T-Line Change Approx.
Flow Oper. Protection
Valve Type Model Numbers Back Over Mass
(US Press. IEC 529
Press. Frequency (Lb)
GPM) (PSI)
(PSI) Cyc./min.
(F)-DSG-01-3C*-*-7090
4.1
Standard Type (F)-DSG-01-2D2-*-7090 26.1* 5075 300
(F)-DSG-01-2B*-*-7090 3045 3.1 IP65
(F)-S-DSG-01-3C*-*-7090 4.1
Soft Shift Type 16.6* 3625 120
(F)-S-DSG-01-2B*-*-7090 3.1
*The maximum flow depends on the type of spool and the operating condition. Refer to the list of spool
functions Maximum Flow Rate tables for details.

■ SOLENOID RATINGS
Voltage (V) Current and Power ■ Insulation class: H
Electrical Coil Freq.
Source Type Hz Source Serviceable Inrush Holding Power
Rating Range (A) (A) (W)
50 100 80~110 2.42 0.51
A100 100 2.14 0.37
60 90~120
110 2.35 0.44
50 96~132 2.02 0.42
A120 120
60 108~144 1.78 0.31
AC -
50 200 160~220 1.21 0.25
A200 200 1.07 0.19
60 180~240
220 1.18 0.22
50 192~264 1.01 0.21
A240 240
60 216~288 0.89 0.15
D12 12 10.8~13.2 2.45
D24 24 21.6~26.4 1.23
D48 48 43.2~52.8 0.61
DC D100 - 100 90~110 - 0.296 29
D110 110 99~121 0.27
D200 200 180~220 0.149
D220 220 198~242 0.135
R100 100 90~110 0.33
AC to DC R110 50 / 110 99~121 0.30
- 29
Rectified R200 60 200 180~220 0.16
R220 220 198~242 0.15

■ ORIFICES
Orifices can be inserted in either P, A, B or T ports. However, in such cases, differential pressure at the
orifice should be set less than 3050 PSI.

In cases where an orifice is inserted in the T-port, tank line pressure in the valve should be less than the
specified maximum T-line back pressure.

In the event that differential pressure at the orifice exceeds 3050 PSI, consult Yuken for specific design
valve which has threaded P, A, & B ports.

ALA INDUSTRIES LIMITED PAGE 3


101
■ MODEL NUMBER DESIGNATION

F- -S DSG -01 -2 B 2 A -D24 -C -N -70 90 -L


Sol.

Design

Manual
Reverse

Override

required)
Standard

Electrical

Coil Type

Valve Size
Number of
connection

(Omit if not

Valve Type
Spool Type
Models with

Mounting of

spool types)
Special Two

Spool Spring
Arrangement
position valve

Special Seals
7 for available
(See page 5 &

Series Number
Valve Positions
Design Number

ALA INDUSTRIES LIMITED


3: 2, 3, 4, 40, AC:
C: Spring A100 None:
Three 60, 9, 10,
Centered A120 Terminal Box None:
position 11, 12
- A200 Type Japanese -
D: No A240 None: Standard
None: Manual None:
Spring 2 DC
Standard Override Pin 15.7 in. lead 90:
Detented D12
Type 2:
D24 wire type North
F: For Two
DSG: D100 C: Push (See design American
phosphate position
Solenoid B: Spring A1 R: Button & standard) Standard
ester type 01 2, 3, 8 70 L
operated Offset B R100 Lock Ass’y
fluids (omit if
dir. valve R110 N: Plug-in 905:
not required)
P: Connector CSA
3: DC Push Pin with Type (DIN) Approval
C: Spring
Three 2, 4, 40, 60 D12 Rubber Dust -
Centered D24 2
position Cover N1 : Pug-in 912:
S: Soft Shift
- D100 Connector 15.7 in. lead
Type 2: R: Type with wire option
B: Spring
Two 2 R100 L
Offset Indicator Light
position R110

1 Special two position spools are available. Refer to “Valves with Center Position and one
offset position” for details.
2 N1 is not available for R type solenoids

102
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES

PAGE 4
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ MAXIMUM FLOW RATES FOR STANDARD VALVES
Maximum Flow Rate U.S. GPM

ALA INDUSTRIES LIMITED PAGE 5


103
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ PRESSURE DROP
Pressure drop curves are based on viscosity of 164 SSU and specific gravity of 0.850
■ For Standard Valves models with AC, DC or R (Rectified solenoids)

(∆P)
Spring Centered

For corresponding spool types, see Maximum Flow Rate tables. For any
other viscosity, multiply the factors in the table below

Viscosity
80 100 150 200 250 300 350 400 450
(SSU)
Factor 0.820 0.875 0.975 1.05 1.115 1.165 1.215 1.255 1.290

For any other specific gravity, (G), the pressure drop (∆P1) may be
obtained from the following formula: ∆P1 = ∆P x (G/0.850)

1/8” (CETOP3) Sub-Plate Mounting


(F-)(S-)DSG-01-Â-Â-70 / 7090

ALA INDUSTRIES LIMITED PAGE 6


104
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ MAXIMUM FLOW FOR SOFT SHIFT (S-) MODELS.

Spring Centered

■ PRESSURE DROP
Pressure drop curves are based on viscosity of 164 SSU and specific gravity of 0.850
■ For Soft Shift (S-) Valves Models with DC & R solenoids
(∆P)

For any other specific


gravity, (G), the pressure
drop (∆P1) may be
obtained from the
following formula:
∆P1 = ∆P x (G/0.850)

For corresponding spool types, see Maximum Flow Rate tables above.
For any other viscosity, multiply the factors in the table below
Viscosity SSU 77 98 141 186 232 278 324 371 417 464
Factor .81 .87 .96 1.03 1.09 1.14 1.19 1.23 1.27 1.30

ALA INDUSTRIES LIMITED PAGE 7


105
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ SPECIAL TWO-POSITION VALVE CONFIGURATION
Reverse Mounting of Solenoid.
In spring offset type, it is a standard configuration that the solenoid is mounted onto the valve in the SOL b position
(side). However, in this particular spool-spring arrangement, the mounting ofthe solenoid onto the valve in the reverse
position -SOL a side- is also available. The graphic symbol for this reverse mounting is as shown below.
As for the valve type 2B∗A and 2B∗B, please refer to the explanation under the heading of "Valves Using Neutral
Position and Side Position" given below.

A B A B

SOL b SOL a
a
b
P T P T

Standard Mtg. of Solenoid Reverse Mtg. of Solenoid

Valves Using Neutral Position and Side Position. (Special Two position Valve)
Besides the use ofthe standard 2-position valves aforementioned in the "List of Standard Models and Maximum Flow",
the 3-position valves also can be used as the 2-position valves using the two of their three positions. In this case, there
are two kinds ofthe valve available. One is the valve using the neutral position and SOL a position (2B ∗A) and another
is the valve using the neutral position and SOL b position (2B∗B).

(Example) In case of Spool Type "2"


Neutral Position
SOL. a Energised SOL. b Energised
Position Position
A B
a b

P T

2B2A 2B2B
A B A B

b b
P T P T
"A": Use of Neutral and "B": Use of Neutral and
SOL. a Energised SOL. b Energised
Position (2B2A) Position (2B2B)

■ ALTERNATE TWO-POSITION SPOOL CONFIGURATIONS

ALA INDUSTRIES LIMITED PAGE 8


106
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES

1.30

■ SUB-PLATE
Sub-plate model shown is bottom ported, NPT, cast iron.
Other models are available as follows:
• Aluminum, Side ported, Multiple Station Manifolds, SAE
(O-ring) ports

Contact your Yuken representative for details or request a


Yuken sub-plate catalog.

ALA INDUSTRIES LIMITED PAGE 9


107
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES

ALA INDUSTRIES LIMITED PAGE 10


108
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ INSTRUCTIONS
⇒ MOUNTING ⇒ HYDRAULIC FLUID
No-spring detented models not energized continuously must Type of Fluid
be installed so that the spool axis (See “L” to “L” in • Petroleum based fluids: Equivalent to ISO VG32 or
dimensional information) will be horizontal. Other models are 46.
not restricted to mounting horizontally. • Synthetic fluids: Phosphate ester or Polyol ester type
• Water Containing Fluids: Water-glycol fluids or W/O
⇒ ENERGIZATION emulsion type.
On double solenoid valves, do not energize both solenoids at
the same time. Solenoid burn-out may occur. Recommended Viscosity and Temperature
• Always be sure to use hydraulic fluids within the
⇒ VALVE TANK PORT stipulated conditions as follows:
Avoid connection of the valve tank port to a line where surge Viscosity: 77 to 1800 SSU
pressure is likely to occur. Pipe end of tank line should be Oil Temperature: 5 to 160 degrees F
submerged in oil.
Control of Contamination
⇒ TIGHTENING TORQUE OF MOUNTING BOLTS. • Due caution must be used to maintain control over
44 - 62 in/lbs (53 - 62 in/lbs applicable for working pressures contamination of hydraulic fluids which may
more than 3025 PSI.) otherwise lead to breakdown and shorter valve life.
• Please maintain the degrees of contamination
⇒ OPERATING FORCE BY MANUAL ACTUATOR between NAS 1638-Grade 12, Use 9.8 x 10 inch or
Take care as the operating force by the manual actuator filter line filter
increases in proportion to the tank line back pressure. (See
graph below)
⇒ SOFT SHIFT TYPE
In order to benefit from the shockless operation, it is
necessary to fill the tank line with operating oil. Start
operation of the valve on a regular basis only after the tank
line has been filled.

■ TYPICAL CHANGEOVER TIME


Time (s)
Type Model Number
T1 T2
Standard AC (F-)DSG-01-***-A*-7090 0.01-0.02 0.02-0.04
Standard DC (F-)DSG-01-***-D*-7090 0.03-0.045 0.02-0.03
Standard Rectified (F-)DSG-01-***-R*-7090 0.04-0.05 0.10-0.20
Soft Shift DC (F-)S-DSG-01-***-D*-7090 0.10-0.20 0.05-0.10
Soft Shift Rectified (F-)S-DSG-01-***-R*-7090 0.10-0.20 0.15-0.20

[Test Conditions]

Pressure: 2320 PSI


Flow Rate: 8.3 U.S. GPM
Viscosity: 164 SSU
Voltage: 100%V
(After coil temperature rises and saturated.)

ON
Solenoid OFF OFF

Spool Shift 0 0

Max.

T1 T2

ALA INDUSTRIES LIMITED PAGE 11


109
SOLENOID OPERATED DIRECTIONAL VALVES - DSG-01 70 / 7090 SERIES
■ LEAD WIRE CONNECTION AND DETAILS OF RECEPTACLE
Type of
Electrical Conduit Double Solenoid Type Single Solenoid Type
Connection

Power Supply 3
(For SOL.a) Power Supply 3

Power Supply 3
Ground 1
(For SOL.b)

Indicator Light
Terminal
Box Type
SOL. a SOL. b SOL. b

Common Plate 2 Indicator Light Indicator Light

3 Ground
Common Ground 1

1 Ground
1
Plug-in 1-Power Supply 3
Connector

3
Type 2-Power Supply 3
2

2
3

1. There are two grounding terminals. You can use either one.
2. If you do not need the common plate, remove it. DANGER
3. With DC solenoids, polarity is no question.
Do not perform wiring while the power is on.
Doing so may result in electric shock, burns or death.
Make the wiring properly. Improper wiring will cause an
irregular movement of the machine, resulting in a grave
accident.

■ ELECTRICAL CIRCUIT
Electrical Circuit
Type of Electric Source
Electrical Conduit
Connection AC DC AC → DC Rectified
Indicator Light
Voltage-Surge
Indicator Light Indicator Light Suppressor
Power Power Power
Supply Supply Supply
Terminal
Box Type SOL. SOL. SOL.

Common Common Common


Ground Ground Voltage-Surge Ground Rectifier
Suppressor Circuit

Indicator Light
(Integrated in "N1"
model only) Voltage-Surge
SOL. Suppressor
1-Power 1-Power 1-Power
Supply Supply Supply
Plug-in SOL. SOL.
Connector 2-Power 2-Power 2-Power
Type Supply Supply Supply
Ground Ground Ground Rectifier
Voltage-Surge Circuit
Indicator Light Suppressor
(Integrated in "N1" (Circuit composed
model only) in coil)

Produced for ALA Industries Limited by Kevin Hagen, February 2005

ALA INDUSTRIES LIMITED PAGE 12


110
snhy.com/991-027

MODEL Series 1 protective cap control kit


991-027

COMPONENTS Sun's Proctective Cap is constructed of flexible polyethylene plastic which press-fits onto the L-Control
cartridge shoulder creating a snug, vacuum seal. Since this cap is both removable and replaceable,
Part Description Quantity
protection from corroding elements is provided along with the ability to make field adjustments to the
270-016 Cap 10 cartridge's setting. This cap is available from Sun as a kit containing ten pieces.

999-991-027 Literature 1 TECHNICAL DATA


For Cartridge Models Series 1
NOTES
Material Black plastic
Ensure the screw adjustment mechanism ("L "
Control) is set to the proper setting. Overall Height 1.91 in.

Press the protective cap over the end of the Valve Hex Size 7/8 in.
cartridge assembly as shown.
Using the ball of your hand or a rigid surface,
press FIRMLY against the end of the protective
cap until the cap lip stretches over the beginning
of the cartridge hex, expelling the air within the
chamber.
To remove the protective cap, gently pull away
from cartridge hex until the cap comes loose.
Replace the protective cap with a new one if any
abrasions, nicks or tears are evident along cap lip
incluiding interior edge and sealing lip.

Copyright © 2002-2014 Sun Hydraulics Corporation. All rights reserved.

117 111
Capacity:
Pilot-to-open check valve w ith standard pilot and
15 gpm (60
Delrin seat L/m in.)

Functional Group:
Model:
Products : Cartridges : Pilot-to-Open Check : 3-Port, Non-Vented : Sealed
CKCA
Pilot, Steel Seat

Product Description

This valve is a pilot to open check valve. It has a non-sealed pilot, a Delrin seat, and is
non-vented. It allows free flow from the valve (port 2) to the load (port 1) and blocks
flow in the opposite direction. Pressure at the pilot (port 3) will open the valve,
allowing flow from port 1 to port 2. Pilot pressure needed at port 3 to open the valve is
directly proportional to the load pressure at port 1. Pressure at port 2 directly opposes
pilot pressure.

Technical Features
Provides hose break protection, prevents loads Pilot-to-open check cartridges are locking valves,
from drifting and positively locks pressurized not m otion control valves. For m otion control
loads. applications, use counterbalance valves.

Optional external porting out of the hex end of the The Delrin seat is suitable for dirty, m edium
cartridge is available for external piloting. In this pressure system s that are not subjected to high
configuration, port 3 is blocked. See Control flows or tem peratures.
options E, and P.

This 3 port pilot-to-open check valve and 3 port Standard unsealed pilot allows air trapped in the
counterbalance valves are physically pilot line to be purged from the circuit.
interchangeable (i.e. sam e cavities, sam e flow
path for a given fram e size). However, cartridge

112
extension dim ensions from the m ounting surface
m ay vary.

Extrem ely low leakage. If the load drifts due to the Incorporates the Sun floating style construction to
valve, the seat has probably been dam aged by m inim ize the possibility of internal parts binding
contam ination and the valve should be replaced. due to excessive installation torque and/or
cavity/cartridge m achining variations.

For m odels with m anual load release control


option, turn load release clockwise to release load.

Technical Data
U.S. Units M etric Units
Model W eight 0.28 lb. 0.13 kg.
Cavity T-11A
Capacity 15 gpm 60 L/m in.
Pilot Ratio 3:1
Maxim um Operating Pressure 2500 psi 175 bar
Maxim um Valve Leakage at 110 SUS (24 cSt) 1 drops/m in. 0,07 cc/m in.
Series (from Cavity) Series 1
Valve Hex Size 7/8 in. 22,2 m m
Valve Installation Torque 30 - 35 lbf ft 45 - 50 Nm
Seal Kits - Cartridge Buna: 990-011-007
Seal Kits - Cartridge Viton: 990-011-006

CKCA-XCN

External M aterial/Seal
Control Cracking Pressure
M aterial

Standard Options

L Manual Load Release A 4 psi (0,3 bar) N Buna-N

X Standard Pilot B 15 psi (1 bar) V Viton

C 30 psi (2 bar)

D 50 psi (3,5 bar)

E 75 psi (5 bar)

F 100 psi (7 bar)

113
Flow Restrictor Valves
DGMFN-3-4*

Typical Section
General Description
These valves regulate flow by means
of an adjustable orifice which is not
pressure compensated, and flow
through the valve is entirely dependent
upon pressure drop at any particular
setting of the orifice.
Dual service-line models with an integral
non-return valve around each control
orifice provide for meter-in or meter-out
control; single line versions of these are
available.

For flow restriction in P or T lines (where


reverse free flow is not required) models
without check valves are available.
Model Code for Flow Restrictor Valves
Adjustment options are either
screw/locknut or handknob. DGMFN-3- * - * * * (- * * * )- 4*

1 2 3 4 5 6 7 8
Functional Sym bols
DGMFN-3-X-A**-B** 1 Direction of flow control (with 6 Type of control needle/orifice
P T B A respect to m achine actuator) (second line of dual m odels)
X = Meter-in control, applicable to lines Options as in 3
A and B Omit for single models
Y = Meter-out control, applicable to
lines A and B 7 Adjuster type (second line of dual
Z =Meter-in control, line P only and m odels)
meter-out control, line T only. Options as in 4
DGMFN-3-Y-A**-B**
Omit for single models
P T B A
2 Location of control function
(single m odel or first line of dual 8 Design num ber, 40 series
m odel)
Subject to change. Installation
P = Line P (single model only) dimensions unaltered for design
T = Line T (single model only) numbers 40 to 49 inclusive.
A = Line A (single model or first line of
DGMFN-3-Z-P** dual model)
P T B A B = Line B(single model only)

3 Type of control needle/orifice


(single m odel or first line of dual
m odel)
1 = Fine control
DGMFN-3-Z-T** 2 = Standard control
P T B A
4 Adjuster type (single m odel or
first line of dual m odel)
H = Handknob
W = Screw/locknut

5 Control in second line


B = Line B(use for dual models with
“A” specified at 2 )
Omit for single models

114
19
Perform ance Characteristics

Pressure Drop
Typical performance with mineral oil at 21 cSt (102 SUS) and at 50_C(122_F)
Type “1 ” needle (see model codes 3 and 6 ) Type “2” needle (see model codes 3 and 6 )

psi bar Number of turns of adjuster psi bar Number of turns of adjuster
60 60
800 1 2 3 4 5 6 800 1 2 3 4
50 50
Pressure drop

600

Pressure drop
40 600 40

30 30
400 400 5
20 20
6
200 200
10 10

0 0
0 10 20 30 40 50 60 L/min 0 10 20 30 40 50 60 L/min

0 4 8 12 1 6 USgpm 0 4 8 12 1 6 USgpm
Flow rate Flow rate

Free flow through check valve

psi bar
200 14
12
Pressure drop

1 50 10
8
1 00
6
50 4
2
0
0 10 20 30 40 50 60 L/min

0 4 8 12 1 6 USgpm
Flow rate

For other viscosities see “Further Information”.

115
20
Installation Dimensions in mm (inches)

DGMFN-3-X-***(-***)-4*
DGMFN-3-Y-***(-***)-4*
DGMFN-3-Z-***-4*

Models with type W adjuster


To adjust valve setting, slacken off locknut and turn
screw . Re-tighten locknut after completing
adjustment.

Line A or line T adjustment Line Bor line P adjustment


(according to model type) (according to model type)

T T
A A

B B
P 4 (5/32) A/F hex. socket P

12,7 (1 /2) A/F hex. locknut .


Torque to 25-30 Nm (18-22 lbf ft)

A max. D max.
47 (1 .85)
Bmax.
max.

40
(1 .57)
E max. E max.

Ø3 (0.12 dia)
3,5 (0.14)

4 holes through: Ø5,3 (0.21 dia) 4 off “O” seals supplied for this interface

P
47,6 46 B
(1 .87) (1 .8)
A
T

39 (1 .54)
45 (1 .8) 76 (3)
max.
C max.

Type H adjuster

Turn clockwise to decrease flow (increase restriction);


counter-clockwise to increase flow (reduce restriction).

Ø32 (1 .26 dia) Model A B C D E

DGMFN-3-X-A*W-4* 1 21 (4.76) – – – 1 6,75 (0.7)


DGMFN-3-X-A*W-B*W-4* – – 1 67 (6.6) – 1 6,75 (0.7)
DGMFN-3-X-B*W-4* – 1 22 (4.8) – – 1 6,75 (0.7)
56 (2.2) DGMFN-3-Y-A*W-4* 1 21 (4.76) – – – 23,25 (0.9)
M4 locking screw
max. DGMFN-3-Y-A*W-B*W-4* – – 1 67 (6.6) – 23,25 (0.9)
2 (5/64) A/F hex. socket
DGMFN-3-Y-B*W-4* – 1 22 (4.8) – – 23,25 (0.9)
DGMFN-3-Z-P*W-4* – – – 1 23 (4.8) 1 6,75 (0.7)
DGMFN-3-Z-T*W-4* – – – 1 23 (4.8) 23,25 (0.9)

116
21
Series
VALVES
HNV
Needle Valve 1-Valve Block Manifold
For Use with Gas and Liquids, Pressures Up to 6000 psi

H MAX

CONNECTION SIZE
Valves, Needle

L A

Dimensions in (mm)
Connection A L H Connection A L H
1/8˝ F x F 1-31/32 (50.01) 1/2˝ F x F 2-9/16 (65.09)
1/8˝ M x F 7/8 (22.3) 2-11/64 (55.17) 2-3/8 (60.33) 1/2˝ M x F 1-17/64 (32.15) 2-49/64 (70.25) 2-49/64 (70.25)
1/4˝ F x F 2-3/8 (60.33) 3/4˝ F x F 2-61/64 (59.13)
1/4˝ M x F 63/64 (25) 2-9/16 (65.09) 2-9/16 (65.09) 3/4˝ M x F 1-1/2 (38.10) 3-5/32 (80.17) 3-23/64 (85/33)
3/8˝ F x F 2-3/8 (60.33) 1˝ F x F 3-23/64 (85.33)
3/8˝ M x F 63/64 (25) 2-9/16 (65.09) 2-9/16 (65.09) 1˝ M x F 1-25/32 (45.24) 4-7/64 (104.38) 3-3/4 (95.25)

Series HNV Block Manifold is a barstock style needle valve that is designed for isolating SPECIFICATIONS
instruments from liquids or gases. The valve series features fine threading and large seat Service: Gases and liquids compatible with wetted materials.
area to ensure tight shutoff. Wetted materials are 316 SS and PTFE making these ideal for End Connections: NPT.
use with corrosives. The HNV has been tested to assure vibration and thermal stability. Wetted Materials: 316 SS and PTFE packing.
Body includes a lock pin to prevent accidental bonnet disengagement. The HNV is available Pressure Limits: 6000 psi (431 bar) @ 200°F (93°C). 4000 psi (276 bar) @ 464°F
in male x female and female x female connections from 1/8 to 1. Tee handle is constructed (240°C).
of 316 SS and allows low torque operation. Temperature Limits: 464°F (240°C).
Other Materials: Handle: 316 SS.

HNV Needle Valve


Female X Female Female X Male
Pipe Size Model Model
1/8˝ HNV-SSS31B HNV-SSS21B
1/4˝ HNV-SSS32B HNV-SSS22B
3/8˝ HNV-SSS33B HNV-SSS23B
1/2˝ HNV-SSS34B HNV-SSS24B
3/4˝ HNV-SSS35B HNV-SSS25B
1˝ HNV-SSS36B HNV-SSS26B

117
508 DWYER INSTRUMENTS, INC. | www.dwyer-inst.com
730 Eaton Way, Annacis Business Park
Delta, B.C. Canada V3M 6J9
Phone: (604) 521-1170 Toll Free 1-800-928-1170
INDUSTRIES LTD. Fax: (604) 522-0070 Website: www.sealum.com

ORB (O’Ring Boss) Tee Header Blocks (All Ports Connected)

3065 – X – X – X X Length
E Port A C
Space
# of Stations Work Port D Dia. x B off
End Port Size End Port
Work Port Size F G

Material:
S = C1018 Steel
SS = 316 Stainless
A = 6061-T6 Aluminum
G
Pressure Ratings:
5000 PSI in C1018 Steel
5000 PSI in 316L Stainless
3000 PSI in 6061-T6 Aluminum
Number End Work Length A B C D Port E F G
of Stations Port Size Port Size Spacing
2 4.75 —– 4
3 6.75 —– 4
4 #12 ORB #8 ORB 8.75 —– 4 2.38 9/32 2.00 1.38 1.50 2.00
6 (1-1/16”-12) (3/4”-16) 12.75 5.00 6
8 16.75 7.00 6
10 20.75 9.00 6
2 5.50 —– 4
3 8.00 —– 4
4 #16 ORB #12 ORB 10.50 —– 4 2.75 9/32 2.50 1.50 1.75 2.50
6 (1-5/16”-12) (1-1/16”-12) 15.50 6.25 6
8 20.50 8.75 6
10 25.50 11.25 6
2 6.25 —– 4
3 9.00 —– 4
4 #20 ORB #16 ORB 11.75 —– 4 3.13 13/32 2.75 1.75 2.25 3.00
6 (1-5/8”-12) (1-5/16”-12) 17.25 6.88 6
8 22.75 9.63 6
10 28.25 12.38 6
2 7.50 —– 4
3 11.00 —– 4
4 #24 ORB #20 ORB 14.50 —– 4 3.75 17/32 3.50 2.00 2.50 3.50
6 (1-7/8”-12) (1-5/8”-12) 21.50 10.50 6
8 28.50 12.25 6
2 8.25 —– 4
3 12.25 —– 4
#32 ORB #24 ORB 4.13 17/32 4.00 2.13 3.00 4.00
4 (2-1/2”-12) (1-7/8”-12) 16.25 —– 4
6 24.25 10.00 6

118
SOLENOID VALVES

SV12-23 Poppet, 2-Way, Normally Open


DESCRIPTION
A solenoid-operated, 2-way, normally open, poppet-type, screw-in hydraulic cartridge
valve, designed to function as a load holding or blocking valve in applications
requiring low internal leakage.

OPERATION
When de-energized, the SV12-23 allows bidirectional flow from  to .
When energized, the valve’s poppet closes to block flow from  to . In this mode,
the cartridge allows free reverse flow from  to  after overcoming the solenoid force
(requires 3.4 to 10.3 bar [50 to 150 psi]).
Operation of Manual Override Option: To override, push and hold override button.
FEATURES
• Continuous-duty rated solenoid.
• Hardened seat for long life and low leakage.
• Optional coil voltages and terminations.
• Efficient wet-armature construction.
• Cartridges are voltage interchangeable.
• Unitized, molded coil design.
• Manual override option.
• Optional waterproof E-Coils rated up to IP69K.
SYMBOLS • Cost effective cavity.

USASI: ISO: RATINGS


Operating Pressure: 240 bar (3500 psi)
Flow: See Performance Chart
Internal Leakage: 0.35 cc/minute (7 drops/minute) max. at 240 bar (3500 psi)
Temperature: -40 to 120°C with standard Buna seals
Coil Duty Rating: Continuous from 85% to 115% of nominal voltage
Initial Coil Current Draw at 20°C: Standard Coil: 1.67 amps at 12 VDC; 0.18 amps
at 115 VAC (full wave rectified). E-Coil: 2.0 amps at 12 VDC; 1.0 amps at 24 VDC
PERFORMANCE (Cartridge Only) Minimum Pull-in Voltage: 85% of nominal at 207 bar (3000 psi)
 to  — (d);  to  - - - (e) Filtration: See page 9.010.1
32 cSt/150 ssu oil at 40°C Fluids: Mineral-based or synthetics with lubricating properties at viscosities of
PRESSURE DROP bar/psi

10.3/150 7.4 to 420 cSt (50 to 2000 ssu)


8.3/120 Installation: No restrictions; See page 9.020.1
6.2/90
Cavity: VC12-2; See page 9.112.1
Cavity Tool: CT12-2XX; See page 8.600.1
4.1/60 Seal Kit: SK12-2X-T; See page 8.650.1
2.1/30 Standard Coil Nut: Part No. 7004426
E-Coil Nut: Part No. 4503610
37.9 75.8 113.6
10 20 30
FLOW lpm/gpm

119
1.054.1
®
HYDRA FORCE

SV12-23
DIMENSIONS
1.84 (46.7) DIA.

1.62
41.1

2.80
E-Coil
Standard 71.1 View
Coil View

TORQUE -
35 ft-lbs
(26.2 Nm)
max.

MATERIALS TO ORDER
Cartridge: Weight: 0.25 kg. SV12-23 __ - __ __ __ - __ - __ __ __ __ __
(0.55 lbs.); Steel with hardened
work surfaces. Zinc-plated
exposed surfaces. Buna N Termination (VDC)
O-rings and polyester elastomer Options Std. Coil
Voltage
back-up standard. None (Blank) DS Dual Spades
0 Less Coil**
Standard Ported Body: Weight: Manual Override DG DIN 43650
without Knob P 10 10 VDC†
0.57 kg. (1.25 lbs.); Anodized DL Leadwires (2)
Manual Override 12 12 VDC
high-strength 6061 T6 aluminum DL/W Leads w/Weatherpak®
with Knob K 24 24 VDC
alloy, rated to 240 bar (3500 Connectors
36 36 VDC
psi); See page 8.012.1. Steel DR Deutsch DT04-2P
bodies available; consult factory. Porting 48 48 VDC
Cartridge Only 0 110 110 VDC Termination (VAC)
Standard Coil: Weight: 0.27 kg. Std. Coil
SAE 10 10T 24 24 VAC
(0.60 lbs.); Unitized thermoplas-
SAE 12 12T 115 115 VAC AG DIN 43650
tic encapsulated, Class H high
SAE 16 16T 230 230 VAC AP 1/2 in. Conduit
temperature magnetwire;
See page 3.200.1. 3/4 in. BSP* 6B **Includes Std. Coil Nut
Termination (VDC)
1 in. BSP* 8B Available only
†
E-Coil: Weight: 0.41 kg. (0.9 lbs.); with DS, DW or DL E-Coil
Perfect wound, fully encapsu- *BSP Body; terminations ER Deutsch DT04-2P
lated with rugged external metal U.K. Mfrs. Only (IP69K Rated)
Voltage
shell; Rated up to IP69K with EY Metri-Pack® 150
E-Coil (IP69K Rated)
integral connectors; Note: See Seals
page 3.400.1 for all E-Coil 12 12 VDC
Buna N (Std.) N Coils with internal diode are
retrofit applications. 24 24 VDC available. Consult factory.
Fluorocarbon V
120
1.054.2
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Standard Part Number List


(Basic part numbers without optional configurations)
Accumulators: Bottom Repairable New!
Size/Pressure 3000 psi 4000 psi 5000 psi 6000 psi 10,000 psi
1 quart A1QT3100 *** A1QT5100 *** ***
1 gal A13100 A14100 *** A15100 ***
2.5 gal A2.53100 A2.54100 *** A2.56100 A2.510100
5 gal A53100 A54100 *** A56100 A510100
10 gal A103100 A104100 *** A106100 A1010100
11 gal A113100 *** *** *** ***
15 gal A153100 A154100 *** A156100 A1510100

Accumulators: Top or Bottom Repairable New!


Size/Pressure 3000 psi 4000 psi 5000 psi 6000 psi 10,000 psi
2.5 gal A2.5TR3100 A2.5TR400 *** A2.5TR6100 A2.5TR10100
5 gal A5TR3100 A5TR4100 *** A5TR6100 A5TR10100
10 gal A10TR3100 A10TR4100 *** A10TR6100 A10TR10100
11 gal A11TR3100 *** *** *** ***
15 gal A15TR3100 A15TR4100 *** A15TR6100 A15TR10100

Bladder Kits New!


Size/Pressure 3000 psi 5000 psi 6000 psi 10,000 psi
1 quart AI-1QT-3KT AI-1QT-5-3KT *** ***
1 gal AI-1-3KT AI-1-5-3KT AI-1-5-3KT ***
2.5 gal AI-2.5-3KT AI-2.5-6-3KT AI-2.5-6-3KT AI-2.5-10-3KT
5 gal AI-5-3KT AI-5-6-3KT AI-5-6-3KT AI-5-10-3KT
10 gal AI-10-3KT AI-10-6-3KT AI-10-6-3KT AI-10-10-3KT
11 gal AI-11-3KT *** *** ***
15 gal AI-15-3KT AI-15-6-3KT AI-15-6-3KT AI-15-10-3KT

Oil Port Assemblies 3000/5000/6000 psi New!


Thread/Type 1 quart 1 gal 2.5-15 gal 10,000 psi
NPT AI-1QT-400 AI-1-400 AI-S-400
AI-1QT-5-400 AI-1-5-400 AI-S6-400 Call
SAE (-3) AI-1QT-400-3 AI-1-400-3 AI-S-400-3 Factory
AI-1QT-5-400-3 AI-1-5-400-3 AI-S6-400-3 for
Split Flange (-4) AI-1QT-400-4 AI-1-400-4 AI-S-400-4 Option
AI-1QT-5-400-4 AI-1-5-400-4 AI-S6-400-4

Copyright, Accumulators, Inc. 1987-2009 Page 3


Print Date: 2009-06-15 121
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Accumulator Ordering Table


(For Catalog Items)
Use the table below to determine the part number for your desired accumulator. For help
selecting your bladder elastomer, visit our website at www.accumulators.com/technical-information.html.
You can also use our website to request a quote on accumulators and all our other products at
www.accumulators.com/products_online_esp.html, or contact us by phone at 713-465-0202 or by email at
info@ accumulators.com.

Select the desired option from each list and place the corresponding code in its proper place

Approval Size Model Pressure Oil Port Bladder Service


Code

Exam ple: A 15 ____ 3100 1 ____ SS = A1531001SS

Option Code Option Code Option Code Option Code

APPROVAL CODE MODEL 1 QUART OIL PORTS BLADDER


1
ASME only 1
A Bottom BLANK 3/4” NPT 1
BLANK Buna-Nitrile BLANK
Repairable1
DNV N 1 1/16”-12 SAE 3 Butyl B
Top TR
ABS B Code 61, 3/4” SAE EPR E
Repairable Split Flange
4

CE P Fluorocarbon V
Float F 1 GAL. OIL PORTS
CRN R Low-Temp L
High Flow H 1 1/4” NPT 1
BLANK
ABS & DNV D High Flow, Top Extreme
HT 1 5/8”-12 SAE 3 X
Repairable Low-Temp
SIZE Code 61, 1 1/2” SAE
Gas Bottle GX3 Split Flange
4 SERVICE4
1 Quart 1QT
Transfer TBX 3
2.5-15 GAL OIL PORTS Oil Service1 BLANK
1 Gallon 1 Barrier
2” NPT 1
BLANK W ater
2.5 Gallon 2.5 WS
PRESSURE Service
1 1/4” NPT 1
5 Gallon 5 3000 PSI 3100 Chemical
50mm 2 PS
Service
10 Gallon 10 4000 PSI 4100
1 7/8”-12 SAE 3 Special
11 Gallon 11 5000 PSI 5100 SS
Code 61, 2” Service
SAE Split Flange
4
15 Gallon 15 6000 PSI 6100
Extreme
Code 62, 1.5” SAE XS
40 Gallon 2
40 10000 PSI 10100 15 Service
Split Flange

Code 62, 1.5” SAE Economy


CS
Split Flange; 98 Service
Seal Sub, Male

1, Standard
2. 40 Gallon size only available in Float model; please contact Sales Dept.
3. Several options available; see our website of contact us for assistance

Only the most popular options are shown above.


W e have many more options and products available.
Contact us at 713-465-0202 or at info@ accumulators.com

Copyright, Accumulators, Inc. 1987-2009 Page 4


Print Date: 2009-06-15 122
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

9" 2.5-15 Gallon 3000 psi Top Repairable


1
Accumulators
2
1
List of Component Parts Alternate Service
3
Description Part Number (OS) WS SS XS
4 1 Safety Cap AI-S-308 N/A
2
N/A
2

2 2
1 Safety Cap O-Ring AI-S-309 N/A N/A
5
21 2 Protective Cap AI-306 -SS -4-SS -4-SS
6 3 Valve Cap AI-S-303
18 7 4 Valve Core AI-S-304
19 8 5 GT Gas Valve AI-GT3-309
5 Gas Valve O-Ring AI-GT3-311
20 9 3
6 Bladder Kit
Buna Nitrile AI-X-3KT -SS -SS
Butyl AI-X-3KT-B -SS -SS
EPR AI-X-3KT-E -SS -SS
10 Fluorocarbon AI-X-3KT-V -SS -SS
Hydrin AI-X-3KT-H -SS -SS
Low Temp Buna AI-X-3KT-L -SS -SS
22 7 Top Load Adapter AI-TR3-208 -W S -SS -SS
8 Locknut, Qty 2 AI-S-403 -W S -SS -SS
LENGTH

9 Spacer, Qty 2 AI-S3-406 -W S -SS -SS


10 Anti-Extrusion Ring, Qty 2
Buna-Nitrile AI-S-407 -W S -W S -W S
EPDM AI-S-407-E -W S -W S -W S
Fluorocarbon AI-S-407-V -W S -W S -W S
11 Bleed Plug
17 ¼
” NPT AI-S-418 -SS -SS -SS
6 7
/16”-20 SAE AI-S-419 -SS -SS -SS
4
12 Fluid Port AI-S3-402 -W S -SS -SS
13 Stop Nut AI-S-408 -SS -SS -SS
10 14 Piston AI-S-405 -SS -SS -SS
16 15 Spring AI-S-409 -SS -SS -SS
16 Poppet AI-S-404 -SS -SS -SS
17 Shell (3000 psi) Not for Sale N/A N/A N/A
15
18 M etal Back-Up Ring, QTY 2 AI-S-412 -SS -SS -SS
18 19 O-Ring, Qty 2
3.5" 19 Buna-Nitrile AI-S-410
9 Butyl AI-S-410-B
8 EPR AI-S-410-E
Fluorocarbon AI-S-410-V
14 20 Rubber Back-Up Ring, Qty 2 AI-S-411
20
13 21 Hex Jam Nut AI-S-305 -SS -SS -SS
11 22 Caution Label AI-S-421
3.00" 12

5
Standard Configuration Dimensions
SA 372 Chrome-moly Steel Shell Part Number Length W eight
2 Piece Replaceable Gas Valve A2.5TR3100 21” 78 lbs
C-1018 and 4130 or 4140 Components A5TR3100 33” 118 lbs
2” NPT Female Fluid Port A10TR3100 54” 214 lbs
Buna-Nitrile Rubber Components A11TR3100 60” 232 lbs
A15TR3100 78” 298 lbs
Optional Configuration (at extra cost)
AN Gas Valve
Resin Coatings, Internal (W S)
Electroless Nickel Plating, Internal & External (SS) Fluid Port Options
Resin Coating – ID, 3 Part M arine Epoxy Paint – OD (XS) Fluid Port Type Designation
Stainless Steel Components 2” NPT Female None
1
Foreign and Domestic Codes 1 /4” NPT Female -1
Call Factory for Other Options M etric Female -2
7
1 /8”-12 SAE Female -3
Code 61, 2” SAE Split Flange -4
Other Call
Special M aterials Call
1 OS-Oil Service, W S- W ater Service, SS-Special Service, XS-Extreme Service
2 Special service accumulator uses a solid protective cap
3 Insert the size of the accumulator for X, i.e. AI-2.5-3KT for a 2.5 gallon bladder kit. Bladder kit consists of the following parts: 3, 4, 5, 6, 18, 19, and 20
4 See Oil Port Configuration for options
+
5 Nominal dimensions. M anufacturing variations will occur. Allow /-2”.

Copyright, Accumulators, Inc. 1987-2009 Page 13


Print Date: 2009-06-15 123
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Gas Valve Specifications


2

1
For use with transfer barrier
adapter (AI-TB-321-Y)
and tube (AI-TB-320-Z)
C

1 3

A
F A

1 Quart 3000 psi 2 Piece Standard 3000 psi Standard Transfer Barrier
AI-1QT-3KT AI-X-3KT AI-X-TB-3KT
1 Gallon 3000 psi 1 Gallon Transfer Barrier
2
AI-1-3KT AI-1-TB-3KT
2 1 Quart Transfer Barrier
2
AI-1QT-TB-3KT
1

C C
C

5
4 5

E
E E

B
Also available in top
A
A repairable model
GTR 6000 psi
AI-X-GTR5-3KT

2 Piece Core and Lock Standard 6000 psi GT 6000 psi


3000 psi AI-X-6-3KT AI-X-GT-3KT
AI-X-TP-3KT 1 Gallon 6000 psi
AI-1-6-3KT
1 Quart 5000 psi
AI-1QT-5-3KT

Component Part Numbers Thread Specifications


1 Valve Core AI-S-304 A 7/8"-14 UNF-2A
2 Valve Cap AI-S-303 B 2"-12 UNF-2A
3 Gas Valve, 3000 psi (Core only) AI-GT3-309 C .305"-32 UNEF
4 Gas Valve, 3000 psi (Core and Lock) (AN-6287) AI-S3-309 D 3/8"-24 UNF-2A
5 Gas Valve, 6000 psi (Lock only) AI-S6-309 E 1/2"-20 UNF-2A
6 1 Quart Valve Cap AI-1QT-303 F 5/8"-18 UNF-2A
7 Gas Valve, 10000 psi (Lock only, not shown) AI-S10-309 G 1/2"-20 UNF-2A

The part number under the valve stem references the bladder kit for the valve stem shown.
Valve stems are only sold after molding as a bladder. Other special bladders are available
upon request. "X" references the size of the accumulator (2.5, 5, 10, 11, or 15 gallon).
"Y" references the type of transfer barrier adapter. "Z" references the type of transfer
barrier tube.

Other custom designs are available including European styles

Copyright, Accumulators, Inc. 1987-2009 Page 30


Print Date: 2009-06-15 124
® 2009 Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Shell Cleaning Procedures


LEVEL I- ALL UNITS
A. Sand Blast or high speed rotary brush
B. Remove any foreign materials such as metal shavings, sand or grit
C. Clean with high pressure air
D. Inspect for residual
E. Repeat if necessary
LEVEL II - CUSTOMER REQUEST (Additional charges will apply)
A. Bath fully in environmentally safe solution for 5 to 10 minutes
B. Rinse thoroughly in water
C. Bathe fully in commercial grade, environmentally safe emulsifiable degreaser (10% solution) for 2
to 5 minutes
D. Rinse thoroughly with water
E. High pressure water wash
F. Inspect for residual
G. Repeat if necessary
LEVEL III - AccuFlushSM
Certified Accumulator Flushing Services. Cleanliness to NAS 1638, SAE 4059D, ISO 4405, AS
4059, API, Department of Defense or other customer required Standards. Call factory for
complete details.
CUSTOMER REQUEST
Customer specified procedures

Corrosion Protection Specifications


Part W ater Service (W S) Special Service (SS) Extreme Service (XS)

Protective Cap 303 Stainless Steel 300 Series Stainless 300 Series Stainless
Hex Jam Nut 304 Stainless Steel 300 Series Stainless 300 Series Stainless
Oil Port Electroless Nickel 316 Stainless Steel 316 Stainless Steel
Poppet 304 Stainless Steel 304 Stainless Steel 304 Stainless Steel
Spring 302 Stainless Steel 302 Stainless Steel 302 Stainless Steel
Piston 303 Stainless Steel 300 Series Stainless 300 Series Stainless
Nut 303 Stainless Steel 300 Series Stainless 300 Series Stainless
Anti-Extrusion Ring Electroless Nickel Electroless Nickel Electroless Nickel
Spacer Electroless Nickel 316 Stainless Steel 316 Stainless Steel
Locknut Electroless Nickel 316 Stainless Steel 316 Stainless Steel
Interior Shell Phenolic Coating Electroless Nickel Phenolic Coating
Exterior Shell White Enamel Electroless Nickel 3-Coat White Marine Epoxy
Bleed Plug 316 Stainless Steel 316 Stainless Steel 316 Stainless Steel
Gas Valve Stem 12L14 316 Stainless Steel 316 Stainless Steel
Metal Backup Ring 304 Stainless Steel 300 Series Stainless 300 Series Stainless

“WS”: Designed with internal protection only. Not recommended for outdoor service.
“SS & XS” Designed with internal and external protection

Also available: CS & PS options:


CS. Combination Service: Same as XS but with no special internal or external coatings.
PS. Prime/Stainless Service: Same as XS but no special external coating.

Other special order materials are also available at additional cost and lead time.

Copyright, Accumulators, Inc. 1987-2009 Page 43


Print Date: 2009-06-15 125
® 2009 Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

FAQs
About Accumulators, Inc. Products, Designs and Facilities

1. Are Accumulators, Inc. accumulators interchangeable with other manufacturers’ accumulators?

Yes, Accumulators, Inc. catalog accumulators are interchangeable with accumulators supplied by other
manufacturers. Accumulators, Inc. units are part for part interchangeable with major competitors and
interchangeable for form, fit and function for most of the rest. Our SPECIAL ORDER units are proprietary for
each customer, and may not be fully interchangeable

2. Are Accumulators, Inc. components interchangeable with the components manufactured by other
accumulator manufacturers?

For the most parts, yes. Accumulators, Inc. catalog components are 100% interchangeable with the
competition. In some cases, however, Accumulators, Inc. parts are of newer design and not fully
interchangeable. Many of those older type designs, however, are available from Accumulators, Inc. ACC.INC.
SPECIAL ORDER components are only available from Accumulators, Inc. An extensive cross-referencing
service is available. Contact the Accumulators, Inc. Sales Department for detailed information.

3. Do Accumulators, Inc. pressure vessels meet any type of codes?

Most Accumulators, Inc. units are designed to the strict guidelines of the ASME Boiler and Pressure Vessel
Code and are so stamped with the “U” symbol and registered with the National Board of Boiler and Pressure
Vessel Inspectors. Many other design approvals or authority reviews, such as CE (PED), DNV, ABS, API,
CRN, Lloyds, etc. are available by request at additional cost. Acc Inc can also modify existing units under the
ASME “R” stamp.

4. What type of testing do Accumulators, Inc. pressure vessels receive?

Most Accumulators, Inc. pressure vessels are subject to ASME specified high-pressure hydro tests, magnetic
particle tests, chemical analysis, physical analysis, hardness tests, charpy test analysis, and dimensional
inspections. Other tests are available, some at additional cost.

5. Does Accumulators, Inc. have a quality control program?

Yes, Accumulators, Inc. has an extensive quality control program that is periodically reviewed by local, state,
national and international agencies. All code designs, code quality control records, quality control manuals
and procedures are open to authorized inspectors.

The Accumulators, Inc. main facility in Houston, Texas is ASME approved to affix the “U” and “R” stamps and
is authorized to register vessels with the National Board of Boiler and Pressure Vessel Inspectors. The
facility also has approved Manufacturing Assessments by DNV and ABS.

6. Are certifications and traceability available from Accumulators, Inc. and what is the fee?

ASME U-1A Data Reports are available upon request at no charge. Certifications, or Material Certificates
appropriate to the respective code(s) are available at additional cost. Shells are traceable to the day of
manufacture and bladders to the month of manufacture. All accumulator vessels are registered with the
National Board of Boiler & Pressure Vessel Inspectors.

7. Are Accumulators, Inc. products covered by any warranties?

Yes, We believe that the Accumulators, Inc. product warranty is the strongest in the industry. Our full
warranty is located in the back of this catalog.

8. What is the proper method of bladder storage?

To obtain the maximum storage life:

1. Leave bladder in the black UV bags they were shipped in.


2. Store in a closed box, lay flat. Avoid folding. If space permits, bladders can be slightly inflated.
3. Do not expose to light, particularly sunlight or fluorescent lighting.
4. Avoid extreme temperatures. Optimal storage temperature is 65 o- 70o F.
5. Avoid dirt, dust, grease, chemicals and fumes.

Note: It is recommended that prior to installation, Accumulator Units


be stored inside, away from extreme cold or heat

Copyright, Accumulators, Inc. 1987-2009 Page 44


Print Date: 2009-06-15 126
® 2009 Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

9. Why use dry nitrogen gas (N2)?


Nitrogen is a safe, inert, non-explosive gas that is readily available at reasonable costs.
W ARNING! NEVER USE SHOP AIR OR OXYGEN!
Shop air has oxygen and when exposed to petroleum based fluids or grease, can diesel (explode) under
pressure. Pure oxygen is even more volatile. Other gases are expensive, corrosive or explosive. Helium is not
recommended due to permeability, molecular structure, cost and availability.
Caution! W hile nitrogen is non-explosive, it is still very dangerous when pressurized
There are several grades of nitrogen gas available. For use in bladder accumulators, we recommend
Commercial/Industrial Grade. This is the most common grade available and the most cost effective. It has
been used with bladder accumulators for over 50 years. The average purity is 99.5%. Higher grade gas is,
of course, acceptable. The MSDS is available from the factory.
10. What oil port threads are available?
NPT is standard; SAE and Split Flange are optional at no additional cost. Many metric, special NPT, BSP,
Flange seal and others are special order items. Call the factory for availability and pricing.

11. What are the advantages of bladder accumulators versus piston or the non-separator type?
1. Rapid response to pressure changes and work cycle.
2. Complete separation of gas and fluid.
3. Highly resistant to fluid contamination.
4. Low maintenance, trouble-free operation.
5. Readily available, low cost replacement parts.
6. Eliminates costly down time on expensive systems due to simple repair.
12. What is the correct pre-charge for an accumulator?
Each application has different pre-charge requirements. Consult the Applications Section of this catalog for
guidance or contact the Accumulators, Inc. Sales Applications Department.
13. How often should the pre-charge be checked while the accumulator is in service?
If the accumulator unit is on a high cycle application it should be checked weekly.
If the unit is used for emergency standby, or pressure holding, it should be checked at least once every
month.
14. What is the correct way to pre-charge an accumulator?
Consult the instructions listed on the accumulator, shipped with replacement bladder kits and in the
Accumulators, Inc. Product Catalog.
Generally: Use an Acc Inc C&G Assembly and a regulator to slowly (35 psig) pre-charge the unit. This is the
most critical part of the pre-charge. Next you may begin to high charge your unit to the pressure required to
operate appropriately.
15. What is the proper way to mount an accumulator?
The preferred orientation is vertical; however, a horizontal mounting is acceptable with a small loss of
efficiency when lubricated properly. Accumulators, Inc. recommends bolting the accumulator to the skid
unit using approved mounting brackets. Acc Inc manufactures several acceptable types.
16. Can Accumulators, Inc. make a special accumulator for my application?
Yes. We’re experts in Special Orders design and manufacture. Among our clientele are Fortune 500
companies, government agencies and the military. Each design is proprietary to the customer.

17. Does Accumulators, Inc. accept any major credit cards? YES!
18. How can I request a quote?
Use our RFQ tool, available on-line, to receive price and availability on any of our products. Of course you
can always call us at 713-465-0202, fax us at 713-468-1618 or email us at info@accumulators.com

19. Is Accumulators, Inc. environmentally conscious?


Our final manufacturing processes produce no pollution and use only minimal electricity. In addition, we
recycle cardboard, office paper, junk mail, glass, plastic and aluminum. Employees are encouraged to bring
their recyclables from home as well. We pride ourselves on being Earth-friendly .

Need more Info? See our website at www.accumulators.com. Or call us as 713-465-0202

Copyright, Accumulators, Inc. 1987-2009 Page 45


Print Date: 2009-06-15 127
® 2009 Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Bladder Material Specifications


The following chart is for typical applications at moderate cycles and is based on laboratory results. System fluid
and contamination can significantly affect performance. Since real world usage can vary widely, Acc. Inc. cannot
warrant the acceptability of any particular system or the expected life of an elastomer product.

RUBBER CODE PEAK OPTIM AL RANGE (F) PERM EANCE HARDNESS TENSILE ELONGATION
COM POUND RANGE (F) SHORE (A) (PSI) (% )
Buna-Nitrile (None) -10 to 210 35 to 160 5 60 2000 500
Low Temp Buna-Nitrile L -60 to 200 -25 to 145 26 45 1500 500
Butyl B -45 to 200 35 to 160 3 60 1500 475
Ethylene- Propylene (EPR) E -55 to 300 35 to 250 20 60 1500 500
Fluoro-Elastomer V +10 to 480 35 to 350 2 60 1200 400
Extreme Low Temp Nitrile XL -80 to 200 -25 to 145 * 60 1600 400
High Temp Nitrile XH +10 to 300 35 to 250 * 60 2400 700

Temperature Ranges (F). PEAK: Upper value is based on polymer vendor data. Lower value is based on
ASTM D-1053. OPTIMAL: Based on good hydraulic practices. Extended operation beyond these
temperatures will shorten the life of the bladder. *Unavailable at press time

The use of compatible clean fluids is highly recommended. Proper filtration is necessary. High
Temperature applications should use oil coolers. Low temperature applications require fluid that is in a
liquid state.

Permeance to Nitrogen. Parts per million based on ASTM D-1434.

Physical Properties. Values are nominal and are based on Laboratory results.

Bladder Elastomer Compatibility


There are literally thousands of chemical compounds that bladder elastomer compounds have been
tested with. An up-to-date listing of the most popular fluids can be found on our website at
www.accumulators.com/rubber-compatibility.html
We also maintain an extensive library of elastomer manufacturers’ compatibility tables.
Please contact our Sales Applications Department, for you application.

Bladder Special Orders


Accumulators, Inc. manufactures a wide range of special accumulators and bladders
that can be adapted to most customer applications.

Bladders can be made with many different types of gas valves, with a wide range of
materials, and at many pressure ranges. M any elastomers are available.

Accumulators, Inc. can help you design your special parts.

Copyright, Accumulators, Inc. 1987-2009 Page 46


Print Date: 2009-06-15 128
BLADDER INSTALLATION,
OPERATION & CARE
FOR BLADDER ACCUMULATORS

www.accumulators.com

The user is the sole responsible party to ensure proper selection, installation, operation
and maintenance of these products and to follow all safety procedures. Please see
accumulators.com for detailed instructions and warranty information, as well as our
terms and conditions of sale. Contact the Acc Inc sales department with any questions.

Copyright Accumulators, Inc.


Accumulators, Inc. AccuMight, accumulators.com and Acc Inc names and logos are registered trademarks and service marks of Accumulators, Inc.
18435 Morton Road Houston, TX 77084 USA
P: 713-465-0202 F: 713-468-1618 E: info@accumulators.com
For more detailed instructions, please visit our website at: www.accumulators.com
R2: NOVEMBER 2017

129
WARNING
READ ALL WARNINGS BEFORE PROCEEDING WITH INSTRUCTIONS!
FAILURE TO FOLLOW INSTRUCTIONS WILL VOID YOUR WARRANTY!
For 2,000 thru 10,000-psi Bladder Accumulators. For charging other pressure vessels, contact us.
High Pressure Gas in Dangerous!
Only a qualified service technician should perform a precharge.
Never use oxygen or shop air!
Precharge with industrial grade dry nitrogen (N2) gas or better only!
Do not operate an accumulator without a proper nitrogen gas precharge.
Release all system hydraulic and pneumatic pressure before attempting any maintenance or service.
Use only genuine ACC INC approved charging and gauging equipment for precharging and pressure check.
Wear proper eye protection, steel-toed shoes, and take proper safety precautions before attempting any maintenance or service.
Slowly increase initial precharge pressure to approximately 35 psig until the bladder is fully inflated. Precharge to a minimum of 30% of maximum
available working pressure. Only introduce high pressure to the desired psig after the bladder has fully inflated and the poppet has closed.

WARNING
NOTE: All bladders are shipped from the factory with no precharge. Most 1. Follow all procedures above. DO NOT remove the TR adapter at the
accumulators are shipped with just minimal pressure. It is solely the gas end.
responsibility of the user to determine the proper precharge level and to B. Option 2: Removing the bladder from the top without removing the
ensure that suitable pressure is maintained at all times. In general, precharge accumulator from the system:
should equal 30% to 80% of the maximum system pressure, depending on the 1. Follow steps 1-7 in the BLADDER REPLACEMENT-REMOVAL
application. section above.
2. DO NOT remove the accumulator from the system.
DO NOT BEND OR FOLD THE BLADDER! THIS CAN CAUSE THE
3. Remove the TR adapter lock nut at top end of unity using an
BLADDER TO BURST.
Accumulators, Inc. approved spanner wrench (AI-505) then remove
BLADDER REPLACEMENT- BOTTOM the spacer and rings.
4. Push the TR adapter into the accumulator and through the AE ring.
REPAIRABLE REMOVAL
Remove the AE ring by folding it ½ and pulling it through the hole.
1. Turn off your system (equipment), release all fluid pressure. 5. Pull the TR adapter and bladder out of the accumulator.
2. Remove protective cap and valve cap from accumulator. 6. Remove the hex jam nut from the bladder stem. Separate the bladder
3. Install genuine ACC INC approved charging and gauging assembly from the TR adapter.
appropriate to the system pressure rating on gas valve stem by
attaching the air chuck to the bladder gas valve by hand tightening its BLADDER REPLACEMENT- INSTALLATION
swivel hex connection, see photo 1. For all top-repairable models use a 1. Remove the valve core on a 3000-psi supplied bladder OR remove
TR Valve Extension (AI-TR-015). the gas valve supplied on a 4000 psi or higher accumulator from the
A. For 3000 psi accumulators. Turn the air chuck “ T “ handle clockwise until new bladder. Squeeze all the air out by rolling the bladder like a tube
it stops. This opens the valve core. of toothpaste.
B. For 4000 psi and higher accumulators. Open the valve by turning its top 2. Replace the valve core or gas valve. Unfold bladder completely.
(small) hex nut, counter-clockwise. The use of a second wrench to hold the 3. Reinstall the valve core or gas valve and unroll the bladder.
chuck in-place is recommended (AI-515), see photo 2. 4. Lubricate all surfaces of the bladder and shell liberally with system fluid to
1. Bleed off all nitrogen gas by opening up the bleed valve located on the prevent sticking.
charging head completely. (For 4000 psi or higher accumulators, the gas 5. Attach a bladder pull rod to the bladder by carefully threading the
valve must also be opened). female end to the male end of the gas-valve. Insert the rod through the
2. Remove the gauging device from gas valve stem. accumulator bottom and pull it through the top hole. Do not allow the
3. Release any remaining gas pressure from accumulator. (For a 3000 psi bladder to bind or kink. Make sure the gas valve and gas stem are sticking
accumulator, remove the valve core from gas stem using core tool. For out completely at the top end hole.
4000 psi or higher accumulators, open the gas valve fully, then remove 6. Remove the pull rod.
gas valve). 7. Attach the nameplate and hex nut to the exposed gas valve stem.
4. Remove accumulator from system, then remove the hex jam nut and Hand tighten.
nameplate from the gas end. Remove the lock nut from bottom of unit 8. Push the plug and poppet assembly with threads facing out,
using an Accumulators, Inc. approved spanner wrench and remove followed by the anti-extrusion ring flat side facing the bladder into the
the spacer and rings. accumulator.
5. Push the plug and poppet assembly into the accumulator and through 9. Pull the plug and poppet assembly back through the anti-extrusion ring.
the Anti-Extrusion ring, remove AE ring by tri-folding it and pulling it Seat ring in hole, metal side down.
through the hole. 10. Install a NEW metal back up ring (AI-S-412), o-ring (be careful not to
6. Remove the plug and poppet assembly. pinch the o-ring), rubber back up ring (AI-S-411), spacer, and lock nut
7. Pull the old bladder out of the bottom of the accumulator. (hand tighten). Precharge the accumulator (see instructions below).
11. Hand tighten the hex jam nut making sure the gas valve stem DOES NOT
TOP REPAIRABLE REMOVAL rotate or that the bladder twists, see photo 3. The use of two (2) wrenches
is recommended. Tighten locknut on fluid end to maximum torque.
A. Option 1 (preferred method): removing through the bottom (fluid) end:
130
clockwise until it stops. This closes the valve core.
TOP REPAIRABLE INSTALLATION For 4000 psi and higher: close the valve by turning its top hex nut
A. If using Option 1 (the preferred method) through the bottom, follow steps clockwise.
1-10 above in the BLADDER REPLACEMENT-INSTALLATION section. Remove the charging assembly from the accumulator. Check for
gas leakage. (The use of gas leak detection fluid or soapy water is
B. If using Option 2 (through the top), follow steps below:
recommended). Put the valve cap on if pressure stays constant after
1. Follow steps 1-3 in the BLADDER REPLACEMENT-INSTALLATION 30 minutes. If not, repeat steps 1-11. When pressure is constant, install
section. protective cap. Tighten hex jam nut firmly.
2. Attach a bladder pull rod to the bladder, carefully threading it to the Install the protective cap and Accumulators, Inc. nameplate and hand
gas valve. Push the bladder down through the open top end hole. DO tighten.
NOT allow the bladder to bind or kink. If not previously installed, install the accumulator on the system. Check
3. Push bladder stem into the accumulator. for fluid leakage.
4. Install the TR adapter by placing it outside the rod and pushing it into the Pressurize system and operate. Precharge to minimum of 30% of
accumulator. operating pressure.
5. Place an AE ring over the rod and drop it into the accumulator by folding
it 1/3rd.
PRECHARGE MAINTENANCE
6. Pull the bladder stem through the AE ring and TR adapter and pull the • For cycling applications, check the precharge weekly.
entire assembly out of the accumulator making sure to seat the AE, • For non-cycling applications, check monthly.
bladder and TR adapter. • Some gas will be lost over time due to premeance.
7. Attach the hex jam nut following steps 9-10 in the BLADDER • A more rapid loss may indicate a gas valve or bladder problem.
REPLACEMENT-INSTALLATION section.
1. Release system fluid pressure, not the gas precharge.
PRECHARGING INSTRUCTIONS 2. Remove gas protective cap and valve cap. DO NOT REMOVE THE
GAS VALVE.
If the accumulator is already installed on a system: 3. Install Accumulators, Inc. approved gauging device on the gas
A. Pump or pour a small amount of system fluid (10% of accumulator valve stem.
4. For 3000 psi accumulators: Screw down air chuck “T” handle and
capacity) into the accumulator, at low pressure.
check pressure.
B. Turn off all power to the system and make sure all fluid pressure is
5. For 4000 psi and higher: Open gas valve top hex fitting keeping
released prior to precharge.
bottom hex tight, see photo 2. Check gas pressure.
OR 6. Add additional dry nitrogen gas if necessary using the above procedures,
steps 5-12, 14.
If accumulator is not yet installed: 7. To release excess nitrogen gas (if any), open the bleed valve located
NOTE: Accumulators should be installed as soon as possible after reciept. at the bottom of the gauging device until desired pressure is achieved.
If the accumulator will be kept in storage longer than 30 days, contact us Recheck the gas precharge.
for instructions.
BLADDER SPECIAL ORDERS
A. The accumulator will normally be fully lubricated at the factory and
Accumulators, Inc. manufactures a wide range of special accumulators
charged with a
and bladders that can be adapted to most customer applications. Bladders
minimal precharge to close the poppet valve.
can be made with many different types of gas valves and with a wide range
If the poppet is open (indicated by a fluid leak at the fluid end, if the of materials and at many pressure ranges. Many elastomers are available.
accumulator has been exposed to heat, or stored longer than 90
days), manually install fluid to 10% of the accumulator volume. See RECOMMENDED ACCESSORIES
commissioning instructions shipped with the accumulator for more
information.
1. Remove the protective cap and valve cap. DO NOT REMOVE THE GAS
VALVE.
2. Attach the gland and nut portion of the charging assembly (AI-CG3-
3KT-SS for 3000 psi accumulators, AI-CG6-6KT-SS for 4000 psi and
higher) to a dry nitrogen gas bottle and tighten securely, see photo 4.
NOTE: If the gland and nut do not fit, the wrong gas or wrong pressure
is being used.
3a. For 3000 psi accumulators: Rotate “T” handle counter clockwise so it is
all the way out before attaching air chuck, opening the valve core. Attach
the air chuck to the bladder accumulator gas valve by hand, tightening
its swivel hex connection, see photo 1. Tighten with a hand wrench if
loose. For top-repairable models, use a TR Valve Extension (AI-TR-015).
Connect the swivel connector to the tank valve located on the charging
head assembly and tighten.
3b. For 4000 psi and higher accumulators: Open the valve by turning its
top hex nut counter-clockwise, making sure not to twist the bladder,
see photo 3.
4a. If using a nitrogen gas regulator, temporarily set it to 35 psig and open
the nitrogen gas valve, then set the regulator to the desired psig level.
4b. If you are not using a nitrogen gas regulator, care should be taken to
slowly “crack” the valve open. The use of a nitrogen gas regulator is
strongly reccommended since the valve can be opened fully using a
regulator set to 35 psig.
5. Begin precharge slowly (35 psig) using dry nitrogen gas, until the
bladder is fully inflated. (Full inflation is indicated by the sound of the
poppet closing).
6. Continue precharging to desired pressure by increasing gas flow
slowly. Gas will adjust to ambient temperature following precharge.
Recheck pressure after 15 minutes.
7a. For 3000 psi accumulators: Turn the air chuck “T“ handle counter-
131
DRAWINGS ACCESSORIES

6K Top Repairable Gas End


1
Bladder Accumulator 1
Full Assembly

3K Top Repairable
2
2
3

Gas End
2
4 3

8 6
9 5
10
7 Nitrogen source regulator attached with gland
8 9 and nut
9

1 1
6K Bottom Repairable Gas End

3K Bottom Repairable Gas End


2
AI-CG3-3KT-SS
2 (3000 psi Charging Assembly)
3

6 4

11 8 8
9
9

AI-CG6-6KT-SS
1. Protective Cap 5. 3K Gas Valve with O-Ring 9. Hex Jam Nut
(6000 psi Charging Assembly)
2. Valve Cap 6. 6K Gas Valve with O-Ring 10. Bladder
3. Valve Core 7. Transer Barrier Adapter 11. Plug and Popppet
4. Gas Valve Body with O-Ring 8. Bladder Valve Stem Assembly

STEPS

AI-505 (Spanner Wrench)

Attaching Air Chuck

Servicing TR model with special wrenches Tightening hex jam nut, making sure not to twist AI-TKIT-1
the bladder. Deluxe 3kpsi & 6kpsi Maintenance Kit

132
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Charging and Gauging Kits for 3000 psi Accumulators


AI-CG3-3KT-SS (3000 psig gauge) and AI-CG3-6KT-SS (6000 psig gauge)

AI-CG3-3KT-SS AI-CG3-6KT-SS
Sold only in Kit Form : See Page 34 for Kit Com ponents

List of Component Parts


Description Part Number
1 3000 psi Gauge AI-CG3-001 Kit with 3000 psi Gauge AI-CG3-3KIT-SS
6000 psi Gauge AI-CG6-001-SS Kit with 6000 psi Gauge AI-CG3-6KIT-SS
2 Air Chuck AI-CG-002
3 Adapter Block AI-CG-003 See Page 37 for Kit Components
4 Swivel Connector AI-CG-004
5 Tank Valve AI-CG-005 Charging and Gauging Kits consist of a Hose Assembly, Gauging & Head Assembly,
6 Coupler AI-CG-006 TR adapter, (AI-TR-015) and case (AI-519).
7 Hose AI-CG-007-SS
8 Gland (Nipple) AI-CG-008
9 Bleed Valve AI-CG-009 Also Available:
10 Nut AI-CG-011 ¾ Complete Accumulator Repair Kits;
11 Copper W asher AI-CG-020 ¾ N2 Gas Regulators;
12 Gauging & Head Assembly, 3000 psi Gauge AI-CG3-013 ¾ Special Order C&G Kits with different connections and Different hose lengths.
Gauging & Head Assembly, 6000 psi Gauge AI-CG6-013
13 Head Assembly, 3000 psi Gauge AI-CG3-014
Head Assembly, 6000 psi Gauge AI-CG6-014
14 Hose Assembly AI-CG-017-SS
Valve Core (internal) AI-S-304

W ARNING! AI-CG3-3KIT-SS and AI-CG3-6KIT-SS Kits are rated for a M AW P Accumulator of 3000 psi.
The 6000 psig

Copyright, Accumulators, Inc. 1987-2009 Page 31


Print Date: 2009-06-15 133
® Product Catalog
voice: 713-465-0202 fax: 713-468-1618
e-mail: info@ accumulators.com
accum ulators.com

Charging and Gauging Kit for 3000psi to 6000 psi Accumulators

8
3

7
6

AI-CG6-6KT-SS
Also Sold in Kit Form : See Page 34 for Kit Com ponents

Full Assembly Hose Assembly Gauging & Head Assembly


List of Component Parts List of Component Parts List of Component Parts
Description Part Number Description Part Number Description Part Number
Complete Kit AI-CG6-6KIT-SS Head Assembly AI-CG6-517-SS Gauging & Head Ass’y AI-CG6-513-SS
1 Gauge, 6000 psi AI-CG6-501-SS 4 J.I.C. Adapter AI-CG6-506-SS 1 Gauge, 6000 psi AI-CG6-501-SS
2 Air Chuck AI-CG6-502-SS 5 Hose, 8 ft. AI-CG6-507-SS 3 Cross, SS AI-CG6-503-SS
3 Cross, SS AI-CG6-503-SS 7 Air Chuck AI-CG6-502-SS 4 J.I.C. Adapter AI-CG6-506-SS
4 J.I.C. Adapter AI-CG6-506-SS 6 Cylinder Valve Tube AI-CG6-508-SS
5 Hose, 8 ft. AI-CG6-507-SS All materials stainless steel. 7 Bleed Valve AI-CG6-509-SS
6 Cylinder Valve Tube AI-CG6-508-SS 8 Cylinder Valve Nut AI-CG6-511-SS
7 Bleed Valve AI-CG6-509-SS Also Available: *Complete Accumulator Repair Kits; *N2 Gas Regulators; *Special Order
8 Cylinder Valve Nut AI-CG6-511-SS C&G Kits with different connections and Different hose lengths

Charging and Gauging Kits consist of a Hose Assembly, Gauging & Head Assembly, TR adapter, (AI-TR-015) and case (AI-519).

Copyright, Accumulators, Inc. 1987-2009 Page 32


Print Date: 2009-06-15 134
PN4221
PN-250-SBN14-HFBOW/LS/ /V Pressure sensors

1: 7-segment LED display


2: Programming button
Made in Germany

Product characteristics
Electronic pressure monitor
Quick disconnect
Process connection: ¼'' NPT
Function programmable
Switching output
7-segment LED display
Measuring range: 0...250 bar / 0...3630 psi / 0...25 MPa
Application
Application Type of pressure: relative pressure
Liquids and gases
Use in gases at pressures > 25 bar only after contacting the manufacturer ifm
Pressure rating 400 bar 5800 psi 40 MPa
Bursting pressure min. 850 bar 12300 psi 85 MPa
Medium temperature [°C] -25...80
Electrical data
Electrical design AC / triac
Operating voltage [V] 85...265 AC
Nominal voltage [V] 90...250 AC (45...65 Hz)
Voltage tolerance [%] -5 / +10
Current consumption [mA] < 10
Insulation resistance [MΩ] > 100 (500 V DC)
Protection class II
Reverse polarity protection no
Outputs
Output Switching output
Output function normally open / closed programmable
Current rating [mA] 2.5A (20°C), 1.5A (45°C), 1A (60°C), 0.25A (70°C)
Voltage drop [V] <2 135
PN4221
PN-250-SBN14-HFBOW/LS/ /V Pressure sensors

Short-circuit proof no
Overload protection no
Switching frequency [Hz] ≤ 160
Measuring / setting range
Measuring range 0...250 bar 0...3630 psi 0...25 MPa
Setting range
Set point, SP 2...250 bar 40...3630 psi 0.2...25.0 MPa
Reset point, rP 1...249 bar 20...3610 psi 0.1...24.9 MPa
in steps of 1 bar 10 psi 0.1 MPa
Accuracy / deviations
Accuracy / deviations
(in % of the span)
Switch point accuracy < ± 1.0
Linearity < ± 0.5
Hysteresis < ± 0.1
Repeatability **) < ± 0.1
Long-term stability ***) < ± 0.1
Temperature coefficients (TEMPCO) in the temperature range -25...80° C (in % of the span per 10 K)
Greatest TEMPCO of the zero point < ± 0.2
Greatest TEMPCO of the span < ± 0.3
Reaction times
Power-on delay time [s] 0.2
Delay time programmable dS, dr [s] 0, 0.2,...10, 11,...50
Damping for the switching output
(dAP) [s] 0...4
Integrated watchdog yes
Software / programming
Programming options hysteresis / window function; N.O. / N.C; on delay, off delay; damping; calibration of
displayed values; display can be rotated / deactivated; display unit
Adjustment of the switch point Programming button
Environment
Ambient temperature [°C] -25...80
Storage temperature [°C] -40...100
Protection IP 67
Tests / approvals
EMC EN 61000-4-2 ESD: 4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m
EN 61000-4-4 Burst: 2 kV
EN 61000-4-6 HF conducted: 10 V
Shock resistance DIN IEC 68-2-27: 50 g (11 ms)
Vibration resistance DIN IEC 68-2-6: 20 g (10...2000 Hz)
MTTF [Years] 224.58
Mechanical data
Process connection ¼'' NPT
Materials (wetted parts) stainless steel (303S22); ceramics; FPM (Viton)
Housing materials stainless steel (304S15); PC (Makrolon); PBT (Pocan); PA; FPM (Viton)
136
Switching cycles min. 100 million
PN4221
PN-250-SBN14-HFBOW/LS/ /V Pressure sensors

Weight [kg] 0.386


Displays / operating elements
Display Switching status LED red
Function display 7-segment LED display
Measured values 7-segment LED display
Electrical connection
Connection 1/2" UNF-Connector
Wiring Pin 1 = Red/W hite (120 VAC Supply)

Pin 2 = Red (120 VAC Common)


Programming of the output function: Pin 3 = Green (Not Used)
Hno = hysteresis / N.O.
Pin 4 = Red/Yellow (Output Switch 1)
Hnc = hysteresis / N.C.
Pin 5 = Red/Black (Output Switch Common)
Fno = window function / N.O.
Fnc = window function / N.C. Use IFM Cable

E18027 - 4 Meters 90 Degree

E18243 - 10 Meters 90 Degree

Note: miniature fuse to IEC60127-2 sheet 1,


≤ 5 A (fast acting)
Remarks
Remarks n.c. = not connected
**) with temperature fluctuations < 10 K
***) in % of the span per year
Recommendation: check the unit for reliable function after a short
circuit.
Pack quantity [piece] 1
ifm efector, inc. 782 Springdale Drive, Exton, PA 19341 — We reserve the right to make technical alterations without prior notice. — US — PN4221 — 21.11.2012

137
CHECK VALVES
RV SERIES

SPECIFICATIONS
• Sizes to 2”
• Carbon Steel Body
• Working pressure to 5000 PSI (350 bar)
• Metal to Metal Seat
• Yellow Chromated Zinc Plated Finish

OPTIONS
• NPT or SAE
• Two Spring Cracking Pressures
7 PSI (0.5 bar) or 65 PSI (4.5 bar)
A B
• Special Spring Cracking Pressures
Available On Request.

DIMENSIONAL INFORMATION

OPERATING
DN PORT G D L WEIGHT
NOMINAL PRESSURE
SIZE
mm inch NPT SAE Bar PSI mm inch mm inch kg lbs
RV8 8 0.31 1
Ú4" NPT 7
Ú1 6-20 500 7250 25 .98 55 2.1 7 0.2 0.44
RV1 0 10 0.39 3
Ú8" NPT 9
Ú1 6-1 8 500 7250 30 1 .1 8 65 2.56 0.4 0.88
RV1 2 12 0.47 1
Ú2" NPT 3
Ú4-1 6 500 7250 35 1 .38 73 2.87 0.7 1 .54
RV1 6 16 0.63 3
Ú4" NPT 1 1Ú1 6-1 2 500 7250 45 1 .77 88 3.46 1 .2 2.64
RV20 20 0.79 1 " NPT 1 5Ú1 6-1 2 500 7250 50 1 .97 1 27 5.00 2 4.4
RV25 25 0.98 1 Ú4" NPT
1
1 Ú8-1 2
5
400 5800 60 2.36 1 43 5.63 3.3 7.26
RV30 30 1 .1 8 1 1 Ú2" NPT 1 7Ú8-1 2 31 5 4500 70 2.75 1 43 5.63 4.2 9.24
RV40 40 1 .57 2” NPT 2 Ú2-1 2
1
31 5 4500 90 3.54 1 65 6.49 7.2 1 5.84

ORDERING INFORMATION

RV 16 7 S
PRODUCT TYPE THREAD TYPE
RV – CheckValve N NPT
S SAE
PORT SIZE
8 1
Ú4” SPRING SETTING
VALVES

10 3
Ú8” 7 7 Psi(0.5 Bar)
12 1
Ú2” 65 65 Psi(4.5 Bar)
16 3
Ú4”
20 1”
25 1 1Ú4”
30 1 1Ú2”
40 2”
3/00

144 138
211