Professional Documents
Culture Documents
Contract 10878
Engine Compressor
Model Serial Number Model Serial number
DPC-2803LE 85608 13” YK11FA 14717
YK11DAECT 15000
Contents
Section 3 – Engine
Section 6 – Cooler
Section 7 – Compressor
Section 12 - Catalyst
Warranty......................................................................... Ajax
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97
TDI TURBOTWINTM
Engine Air Starters
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97
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ESS-F-963
Title: Keyless Flywheel Installation And Timing
Installation
1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.
! Caution
Firmly secure the flywheel to prevent it from falling over.
2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove
ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied
locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not,
lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent.
3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel.
4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is
required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN
Figure 1
Flywheel Collar
Hardened
Washer
Inner Ring
Crankshaft
Locking
Screw
5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both
for assembly.
6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between
.001”-.003”. Do not over-lubricate.
Note
Step 6 should only be performed during initial engine assembly. Do not lubricate on field units.
7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create
a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the
Note
Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat
and possibly gall the surface of the crankshaft.
8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to
the crankshaft.
9. Remove the crosshead side access door from power cylinder one.
10. Set the timing pointer on the ignition bracket, allowing 1/8” clearance from the flywheel. Adjust the
pointer until it is located in the middle of vertical slot on the bracket.
Note
You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then
marks #2 and T. These distances should be equal.
19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200
and 2800 engines use a 48” diameter flywheel. This means that:
3° = 1ÿ” Flywheel O.D. distance
9° = 3¾” Flywheel O.D. distance
11° = 4-5/8” Flywheel O.D. distance
20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3°, 9°
or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel.
21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crank-
shaft in the general range of normal ignition timing.
22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be
installed between the sheave and end cover. See Figure 2. This picture shows the method of locking
the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field
installation.
23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that
Figure 2
Figure 3
End of Crankshaft
Side
DC
#1 T
ESS-L-981
ABSTRACT
The jet cell concept is required for low emission or emission reduction engines. The high-
energy torch issuing from the pre-chamber allows the main chamber to be operated with a
leaner mixture and consistently ignited, as compared to a conventional spark plug
ignition of a lean mixture.
Also, the jet cell is applied to units to improve combustion stability and improve fuel
consumption when operating at variable speeds and reduced torque. This paper describes
the jet cell operation and general maintenance procedures relating to AJAX Low
Emissions Two-Cycle Engines.
The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head.
The nozzle end is designed with a specific volume and has a communicating angled exit
orifice. A spark plug for ignition and a fuel admission check valve complete the
necessary operational components.
Pilot fuel headers supply fuel to each admission check valve. The supply to the header is
taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with
an additional regulator.
The ignitor fuel pressure is thus regulated manually according to site conditions.
For one cycle of operation, as the piston comes up on compression, the pressure within
the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When
1 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
the pressure within the cylinder becomes greater than the fuel pressure, then the pilot
check valves close.
The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs
within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this
energy release forces the burning mixture to exit through the nozzle orifice across the top
of the piston in the main combustion chamber, igniting the main combustible charge.
IGNITION TIMING
In standard spark ignited engines, the spark plugs ignite the charge and a progressive
flame front occurs within the combustion chamber. Due to the time required for this
flame propagation, the ignition timing is approximately 9°-12° before top dead center
(BTDC).
With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fuel/air
mixture within the main combustion chamber. The mixture is ignited uniformly by this
higher energy source, which promotes faster burning. For this reason, the ignition timing
is set at 3° BTDC.
For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs
7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day
(24 hrs), and 30 days of operation would equal 19,008,000 times.
MAINTENANCE
The jet cell, when installed into the cylinder head, has a round Armco iron gasket which
acts as a fire seal; a graphoil seal employed as a bottom water seal, and an ‘O’ ring as the
top water seal.
The unit is held in place with a two-bolt flange and torqued to 70 ft-lbs.
If a cell is removed from the head, it is important that the access hole for the cell is clean
and free of any scale build-up. New gaskets and seals should be installed and the unit
properly torqued. A locating dowel is used to assure proper orientation of the exit orifice
of the cell in relation to the main combustion chamber.
SPARK PLUGS
Cooling of the spark plug is accomplished primarily through the spark plug gasket
seating surface and the threads. These areas within the cell have thin metal sections and
are surrounded with engine coolant.
In service, the center and ground electrodes will deteriorate, which increases the spark
plug gap. Erratic firing will occur once the gap increases 0.005”-0.010” from the original
setting and the plugs should be replaced.
2 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion
RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to 0.018″ was used. The
main chamber spark plug utilized the Champion W-18 (BM-1022). Current production
models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022)
spark plug is used with an initial gap of 0.020″. This allows use of the same spark plug
for both the main chamber and igniter. The current production jet cell (YK-8209-C-1)
identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage
may occur to igniter and/or spark plug threads as the result of thread depth and thread
reach respectively.
The secondary ignition wiring and associated components should always be in good
condition.
The primary check valve (P/N YK-8338-A) is most important in the operation of the jet
cell. As noted previously, the number of cyclic operations relates to the unit’s speed, with
fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and
being shut off the cylinder pressure increases. The check valve also withstands the high
pressure within the cell at time of ignition.
Present production check valves use a ceramic ball with tool steel enclosure and seat.
Ajax continues to improve the life and operation of the valves with ongoing research and
development programs.
From the primary check valve, the fuel gas enters the cell through drilled communication
holes. Due to fuel entrapment, incomplete combustion can occur in these passages, which
tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to
the check valve’s operation, but in other cases it can be severe. If this build-up becomes
heavy, erratic operation of the check valves will occur and they should be removed,
cleaned and tested.
Whenever the spark plugs are replaced, it would be appropriate to remove and clean the
check valves. Some end users have a spare set of check valves which are installed at this
time, and the removed set is cleaned for reinstallation at a later date.
An orifice (P/N K-8050) is installed on the inlet side of the primary check valve to allow
pilot fuel pressures to be comparable to main fuel pressure. The orifice resembles a 1/8″
toe nipple. Ensure this is an orifice by visual inspection, noting a small 0.038″ internal
hole. Clean when servicing the primary check valve.
Connected directly upstream of the orifice is a secondary check valve (P/N BM-21064).
This is utilized only as a backup to the primary check valve.
3 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
A jet cell-equipped engine does require some additional maintenance over a standard
combustion engine. This additional maintenance is offset by gains in combustion
stability, lower emissions and improved fuel economy.
4 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
ESS-L-983
The new AJAX Low Emissions (LE) Engine utilizes a squish design combustion
chamber that includes a jet cell (ignitor cell). The assembly procedure is basically the
same as on a standard engine, with the following additions and changes in gas valve
timing, ignition timing and power piston position.
A) The piston used on the LE engine does not incorporate notches or tapped holes in
the crown for installation as compared to the standard combustion engine. It is
recommended that a rod wrench (or strap wrench) be used to install or remove the
power piston.
B) Screw piston into crosshead until approximately three (3) threads are left
showing. Do not tighten rod nut at this time.
1 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
Figure 1. Measuring Proper Piston-To-Head Distance
E) Once clearance is set, torque rod nut and check clearance again. Piston has a
tendency to turn out slightly when tightening nut.
Refer to ESS-T-911 as a basis for fuel injection timing. The following changes must
be made when converting an engine to LE application.
A) The flywheel and gear shield must be removed in order to remove layshaft and
reset cam timing.
B) Cam timing is retarded from the standard 13° ABDC beginning of injection to 37°
ABDC. DO NOT GO BEYOND 37° ABDC! If gears do not line up with cams at
37° ABDC, go back towards BDC (i.e. 35° ABDC). Beginning of injection is 37°
2 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
ABDC on all LE engines but the method of setting the timing is different on
DPC-800s & DPC-2804s.
C) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2)
cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders.
#2 & #4 cylinders run off the other cam. Refer to Figure 2.
#1 power cylinder gas cam timing is referenced off #3 bank on the control box.
The crankshaft should be rotated in a clockwise direction to 26° ABDC #1 power
cylinder. DO NOT GO BEYOND 26° ABDC! If gears do not line up with cams at
26° ABDC, go back towards BDC (i.e. 24° ABDC). The crankshaft is positioned
at 26° ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is
due to the way the cam is installed on the layshaft. The result will be injection
beginning at 37° ABDC. Refer to FIG 3. The cam can now be set using the
method illustrated in ESS-T-911.
D) Once the preceding is complete, the layshaft gear should be installed and re-
indexed.
3. IGNITION TIMING:
Ignition timing is changed on all LE engines to 3° BTDC. New mag pickup brackets
are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate
the timing change.
3 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator
must be removed and re-indexed to 3° BTDC (refer to the standard DPC-800/DPC-
2804 Operation & Maintenance Manual for procedure).
A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in
the LE power head. This ensures proper direction of ignitor exit orifice. It is very
important that they are lined up properly! Misalignment will result in severe
piston crown damage. It should be noted that when ignitor is torqued into head,
the roll pin will not completely set into slot. This is only an alignment reference.
B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small
amount of grease to hold gasket in place when installing ignitor into the head.
Insure O-ring is installed on ignitor at this time also.
4 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
Figure 4. Ignitor Assembly
D) Install ignitor into head being very careful not to damage water seal. This may
take some hand fitting of seal. Torque down in progressive 5 ft-lb increments to
70 ft-lbs.
5. SPARK PLUGS:
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a
Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to
0.018″ was used. The main chamber spark plug utilized the Champion W-18
(BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized,
use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020″. This
allows use of the same spark plug for both the main chamber and igniter. The current
production jet cell (YK-8209-C-1) is identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell.
Damage may occur to ignitor and/or spark plug threads as the result of thread depth
and thread reach, respectively.
5 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
6. GAS INJECTION VALVES:
The gas injection valve used in the LE power end is of the same basic design as the
one used in the standard combustion assembly but the valve housing and plunger
housing are not interchangeable. The gas injection valve assembly on the LE engine
has a longer valve body housing and a shorter plunger housing to accommodate the
profile of the power head.
7. MISCELLANEOUS:
In addition to the preceding requirements, engines that are converted to the LE design
must have:
6 Revised 07/98
Technical Information
Bulletin # 020718 r2
August 24, 2004
The following component dimensional specifications and wear limits should be used as a
guide for preventative maintenance programs for Ajax equipment. Problems can be
detected early before failures occur.
These specifications are based on data gathered from a broad range of Ajax installations
covering many decades of operating experience.
Specific unit performance and maintenance requirements may vary based on application
conditions and preventative maintenance practices.
2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot
exhaust pipe and ignite .
As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a
pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing
adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas
injection valve assembly is mishandled during servicing.
Figure 1
As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve
minimizes damage potential, and permits more efficient purging of the hydraulic system.
Convert to the current design by replacing the injection valve’s cap with the current design.
A parts kit for the conversion is available, or individual pieces can be specified. See the
appropriate table below for a kit P/N or the individual P/Ns.
Use of divider valve designs provides a simple, reliable and predictable approach to engine cylinder and compressor
cylinder lubrication. Simplicity is enhanced by use of a lubrication monitor that senses divider valve operation, and
displays pints/day of lube oil consumption based on RPM and a divider valve assembly’s displacement volume.
The following rates for engine cylinders are based on the use of dry gas, and lube oil per Ajax engineering standard
ES-1006. HP listings are at standard conditions of 100ºF and <1500’ elevation.
Engine lubrication rates for normal operations are based on 1 pint/30 HP.
The following rates for compressor cylinders are based on the use of clean and dry gas, and lube oil per Ajax
engineering standard ES-1006. Rates listed are based on MWP and maximum bore size and include the rod packing’s
requirements. Refer to the O & M manual for other conditions.
NOTE: to attain the total lube rate for a compressor unit, add the lube rates for the individual cylinders.
Individual cylinder and rod packing assembly lubrication rates are based on the following formula:
Example: YK11G, 14” bore, 11” stroke, @ 440 RPM, 400 psig
(0.0000314 x 14 x 11 x 440) = 2.13
(0.000333 x 400) = 0.13
0.75 = 0.75
3.00 pints/day
The lube monitor’s rate display is calculated by using the divider valve assembly’s cycle signal, and a
BLOCK TOTAL of the assembly. The assembly’s BLOCK TOTAL is determined by adding the “sizing number”
for each element within the assembly. Refer to the following table for the sizing number for a particular SMX
element:
DropSa Element Sizing Number
SMX-08 5
SMX-12 8
SMX-16 10
SMX-25 15
SMX-35 20
SMX-40 25
SMX-50 30
Assure that the correct values are used for the engine’s divider valve assembly, and the compressor cylinder’s divider
valve assembly. (Metering element designation (the SMX number) is stamped on each element’s nameplate.)
Table 1: Torque Table for Critical Ajax Fasteners
! & "'( %
"# "$
$ %
) %
Cylinder Head:
! & "'( %
"# "$
$ %
) %
! & "'( %
"# "$
$ %
) %
#8 32 2 2.5
#8 36 2 2.5
#10 24 3 3.7
#10 32 3 3.7
1/4” 20 5 6
28 6 7.5
-
* +,
5/16” 18 10 12
24 11 13
3/8” 16 17 20
24 18 21
7/16” 14 28 34
20 30 36
1/2” 13 43 53
20 50 60
9/16” 12 62 75
18 71 85
5/8” 11 85 103
18 100 120
1” 8 340 415
12 385 460
14 400 475
6
Table 2: General Torque Table for Fasteners
7
Section 2 – Package Drawings
Ignitor......................................................................... YK-8209-C-2
1 ZBM-21152-30 GOVERNOR 24 vdc 30MM P/N 8404-2027 Rev NEW, AJAX CONFIG FILE #0427041
2 ZYAE-5583-A CONTROL, ELECTRICAL ASSY., V1-A IGTB 1
3 ZBM-21146 O'RING 1.424 ID - .103WD 2
4 ZK-8256-A FLANGE, GOVERNOR OUTLET 1
5 ZK-8256-C FLANGE, GOVERNOR INLET LE IGTB GOVERNORS 1
6 ZBM-11473-0324-40 SCREW SOCKET HD 4
7 ZBM-11782-A-03 LOCKWASHER SPLIT 4
8 ZK-8256-B BRACKET, SUPPORT 1
9 ZBM-11900-1011-26 BOLT HEX HEAD HEX HEAD CAPSCREW - 5/8-11 X 3-1/4" LONG - 2
10 ZBM-11918-12-N WASHER PLAIN 2
11 ZK-7889-1 BRACKET, FUEL FILTER (LE) 1
12 ZBM-11782-A-06 LOCKWASHER SPLIT 4
13 ZBM-11900-0616-08 BOLT HEX HEAD 4
14 Z2549 0057 VALVE NEEDLE VLVNDL 1/4 H5VIC-22 2
15 Z2015 3312 GAUGE PRESSURE GAUGE, PRESSURE, 2-1/2" 0-30 2
16 ZBM-11950-02 PLUG PIPE 1
17 ZBM-11573-S-4-4 ELBOW TUBE COMPN ELBOW - TUBE COMPN 1
18* ZK-8263-A-24 HOSE, FLEXIBLE METAL 1" X 24" MALE/MALE STEEL UNION, NACE COMPLIANT. 1
19 ZK-8262-A-30 HOSE, FLEXIBLE METAL, 1/1-2" X 30" 4" PIPE NIPPLE, 3000# FORGED STEEL UNION, NACE 1
20 ZBM-11932-12-08 NIPPLE PIPE 1
21 ZBM-11969-08 1" 45 DEG. THREADED STREET ELL 1
22 ZBM-21152-C-48 CABLE ASSY, IGTB V1-A GOVERNOR 1
24 ZYAE-1561-E-1 ALTERNATOR DRIVE ASSY 1
25 ZK-6258-C GASKET GASKET, GOVERNOR 1
26 ZA-4658 GEAR, DRIVE HELIX, P.D. 4.8996 1
27 ZBM-11095-A SCREW SET 2
28 ZK-8095-0616-18 STUD, 3/8-16UNC X 2-1/4" 4
29 ZBM-11918-08-W WASHER PLAIN 8
30 ZBM-11782-A-06 LOCKWASHER SPLIT 6
31 ZBM-11904-0616 NUT PLAIN HEX HEX NUT, PLAIN HEAVY - 3/8-16 - GRADE 5 4
32 ZBM-21156 ALTERNATOR 24 vdc FLANGE MOUNT, TWO SLOTS, O-RING GROOVE. 1
34 ZBM-11900-0616-10 BOLT HEX HEAD HEX HEAD CAPSCREW - 3/8-16 X 1-1/4" - GRADE 5 2
38 ZYAE-5581 LUBRICATOR DRIVE ASSY 1
40 Z2049 1291 PICKUP MAGNETIC MAGNETIC PICK UP 1
42 Z8025 9400 BRACKET SENSOR SPEED SENSOR BRACKET WELDMENT W/5/8-18 UNF 1
43 ZBM-16348-F-236 SEAL O RING O RING SEAL 1
44 ZA-1944-A-2 PLATE PLATE 1
45 ZA-2233 GASKET FLAT RECT GASKET 1
46 ZA-2115 TROUGH TROUGH 1
47 ZA-2117 GASKET FLAT OVAL 1
48 ZK-8095-0813-16 STUD STUD 1/2-13 UNC-2A X 2" 5
DPC-2802LE IGTB V1A Control System
1302-000-08
50 ZBM-11900-0616-10 BOLT HEX HEAD HEX HEAD CAPSCREW - 3/8-16 X 1-1/4" - GRADE 5 2
51 ZBM-11573-S-6-4 ELBOW TUBE COMPN ELBOW - TUBE COMPN 2
52 ZBM-11900-0813-10 BOLT HEX HEAD HEX HEAD CAPSCREW - 1/2-13 X 1-1/4" LONG - 2
53 ZBM-21071-3-035 1 TUBING WELDED 3/8" SS WELDED TUBING, .035WL 2640ST 1900CYC 3
54 ZBM-11623-S-6-6 UNION TUBE COMPN UNION 1
Unshielded Ignition System
Assembly #1802-000-03
Ref # Description Part Number Qty Ref # Description Part Number Qty
17 Lockwasher Split BM-11782-A-04 2 ea
2 Clip 706-799-001 3 ea 18 Coil, CD Ignition 706-788-000 4 ea
3 Altronic I Assembly YAE-6052-H-1 1 ea 19 Bracket, Angle A-3341-C 1 ea
A Electronic Box BM-11440-F 1 ea 20 Bracket, P/U Coil A-3740-A 1 ea
B Gasket BM-11791 1 ea 22 Nut, Plain Hex BM-11904-0420 2 ea
C Cover BM-11788 1 ea 23 Bracket K-4741-C-3 2 ea
D Seal BM-11770 1 ea 24 Bolt, Hex Head BM-11900-0518-06 8 ea
E Spacer BM-11771 1 ea 25 Lockwasher BM-11920-06 8 ea
F Stator BM-11439-A 1 ea 26 Nut, Plain Hex BM-11904-0518 8 ea
G Magnet BM-11784 1 ea 27 Washer, Plain BM-11918-07-W 16 ea
H Housing BM-11787 1 ea 28 Tee, Conduit 706-719-001 1 ea
J Pin BM-11774 1 ea 29 Capscrew, Hex Head BM-11900-1409-18 2 ea
K Shaft BM-11783 1 ea 30 Nut, Jam BM-11910-0616 1 ea
L Coupling BM-11773 1 ea 31 Cable, Altronic I-to-Coils BM-11298-G 1 ea
M Grommet BM-11789 1 ea 32 Wire, Electrical BM-11810-B-19 9 ft
N Screw BM-11790 2 ea 33 Terminal, Wire BM-11780-5 2 ea
4 Pick Up-Cable Assembly BM-11298-AA 1 ea 34 Washer, Plain BM-11918-08-N 2 ea
5 Kit, Spark Plug & Lead BM-1022-M-2 2 ea
Spark Plug BM-1022-P 2 ea
Secondary Lead, 24" BM-11422-E 2 ea
6 Kit, Spark Plug & Lead BM-1022-M-3 2 ea
Spark Plug BM-1022-P 2 ea
Secondary Lead, 15" BM-11422-F 2 ea
7 Terminal, Wire BM-11780-2 12 ea
8 Screw, Machine BM-11931-3716-07 1 ea
9 Pointer, Flywheel A-4530 -1 1 ea
10 Conduit, Flexible 706-737-002 6 ft
11 Bolt, Hex Head BM-11900-0616-12 3 ea
12 Washer, Plain BM-11918-08-W 4 ea
13 Nut, Plain Hex BM-11904-0616 2 ea
14 Lockwasher Split BM-11782-A-06 2 ea
15 Bolt, Hex Head BM-11900-0420-12 2 ea
16 Washer, Plain BM-11918-06-W 4 ea
Assembly # 1802-000-03
AIR COOLED EXCHANGERS, INC.
P.O. BOX 577 - BROKEN ARROW, OKLAHOMA 74013
Ph (918) 251-7477
Fax (918) 258-1833
E-MAIL: MAILHUB@ACE-COOLERS.COM
Fuel Outlet
Fuel Inlet
Front View Rear View
Introduction The Types 67C and 67CS are the standard instrument
supply regulatorswithout a filter or internal relief.
Scope of Manual The Types 67CF and 67CFS are equipped with a
filter for removing particles from the supply gas.
This manual provides instructions and parts lists for
67C Series instrument supply regulators. Instructions The Types 67CR and 67CSR have an internal
and parts lists for other equipment mentioned in this relief valve with a soft seat for reliable shutoff with no
instruction manual, as well as for other 67 Series discernible leakage.
regulators, are found in separate manuals. The Types 67CFR and 67CFSR have a filter and
internal relief valve with a soft seat for reliable shutoff
with no discernible leakage.
Product Descriptions
The 67C Series direct-operated regulators are Specifications
typically used to provide constantly controlled,
reduced pressures to pneumatic and electropneumatic Some general 67C Series ratings and other
controllers and other instruments. They are suitable specifications are given on page 2. A label on the
for most air or gas applications. Other applications spring case gives the control spring range for a given
include providing reduced pressures to air chucks, air regulator as it comes from the factory.
jets, and spray guns.
EMERSONL
Process Management
BULLETIN NO. IM120/05
(Supersedes IM120/03)
Mid-West
Instrument
®
®
Model 120 Series “Filter Minder”
Installation and Operating Instructions
(Fig. 1)
Supplementar y 120 Dimensional/Mounting Data
(Fig. 2)
(Fig. 3)
➆➇
6. Perfluoroelastomer K. Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
9. Special (Uncoded Options) L. One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
*Viton® is a Registered Trademark of DuPont Dow Elastomers. M. Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
**Teflon® is a Registered Trademark of DuPont. Z. Special (Uncoded Options)
(1)
Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G.
(2)
Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G.
(3)
5000 PSIG Working Pressure.
➄ CONNECTIONS
(NOTE: Models 120M and 120N available only with end connections)
0.
2.
1/4" FNPT Back Connections (Standard)
1/4" FNPT End Connections
➇ ELECTRICAL SPECIFICATIONS (For Resistive Loads)
A. S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%)
6. 7/16" - 20 Str. Thd. O-Ring Port (Back Connections) E. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%)
7. 1/2" FNPT Stainless Steel Adaptors F. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed)
8. 1/2" FNPT Monel Adaptors (Switch adjustable range of 25-95%)
9. Special (Uncoded Options) G. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4)
H. S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%)
Z. Special (Uncoded Options)
(4)
Available with Electrical Configurations B, D, F, H, K and M only.
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.
NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)
NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE.
ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY. (Fig. 4)
R E P R E S E N T E D B Y:
Mid-West
Instrument
®
Printed in U.S.A.
hms-
A Free Floating Guided Lever Drain Traps
For Loads to 9,500 lblhr(4.309 kglhr) ...Pressures to 570 psig (39 bar)
Armstrong's stainless steel, free-floating guided lever drain The hemispherical valve, seat and leverage of the 11-LD,
traps use the same bodies, caps, lever mechanisms, valves 22-LD and 13-LD stainless steel traps are identical in design,
and seats of Armstrong inverted bucket steam taps that materials and workmanship to those for saturated steam
have been proven in years of service. Elliptical floats and service up to 570 psig (39 bar) with the exception of the
high leverage make it possible to open large orifices to addition of a guidepost to assure a positive, leaktight valve
provide adequate capacity for drain tap size and weight. closing under all conditions.
List of Materials For a fully detailed certified drawing, refel to list below:
11-LD CD #I066
I I I
I b L D and 22-LD CD #I086
I NO. I
Model Valve&
Seat I Leverage
Svstern
loa at Body & Cap Gasket I
11~LD Sealed
22.~0 Stainless Steel Stainless Steel. -
13-LD 304L
For intomatianon special materials, consull the Armstrang Application
Figure LO-34.
No. 11-LD. 22-LD and 13-LD stainless steel guided lever
liquid drain trap with sealed, tamperproof construction.
Physical Data
All dimensions and weights are appmximafe. Use ceriffledprlnf lor exact dlmenrlons. Deslgn and malerlals are SubIect to change without notice.
Armstrong Steam and Condensate Group. 816 Maple St.. P.O.Box 408. Three Rivers. MI 49093 -USA Phone: (269) 273-1415 Fax: (269)278-6555
LO-39 w.armrtrong-intl.com
00-02-0175
Installation for L1100, L1200, L1200N Series Revised 03-06
Section 15
Description **
Series L1100 and L1200 Liquid Level Switches are float activated to
WARNING operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT valves or similar devices. This model screws directly into the vessel or can be
✔ Disconnect all electrical power to the machine. mounted via an external float chamber. It cannot be used with weld collar 15050375.
✔ Make sure the machine cannot operate during installation. Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
✔ Follow all safety warnings of the machine manufacturer.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
✔ Read and follow all installation instructions. L1200NDVOR series carry Canadian Registration Number OF1476.2.
✔ OBSERVE all pressure and electrical ratings and require- Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
ments for the devices and the operating environment. pneumatic input signal to cause an orifice to open or close allowing liquid
✔ BE SURE all pressure HAS BEEN REMOVED from the condensate to be drained from a pressure vessel. A pop up button indicates valve
vessel before opening any pressure connections. open/closed. Stainless steel versions available.
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Pressure Manual Valve
Inlet Port Operator
1/2 NPT 1-1/2 NPT Float travel between Operate 1/8 in.-27 NPT
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-5/8 in. w/ float at horizontal centerline
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
Weep Hole Valve Open/Closed
Union Indicator Button
Electrical installation to be done by
qualified person according to the NEC.
F Drain
Connection C
E D
Plug Seal G (dimension shown
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
NOTE: Dimensions are in inches and (millimeters)
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Direct Installation into the Wall of the positioned away from the tank wall.
Pressure Vessel 2. A tee is typically installed at the bottom of the lower 1 inch
1. Determine that the float travel is not pipe riser to allow draining of the float
obstructed by the coupling in chamber for servicing or replacement.
the vessel wall, internal Tank
Wall NOTE: A typical installation Float
baffles, etc. with Blocking and Bleed valves is Chamber
Do NOT use more than shown at right. Tank
Block
one arm extension P/N Valves
3. Install the L1200 or
15050395.
L1200N
2. BE SURE that the float Explosion proof Level
Level conduit seal in the 2 NPT connection Switch
and extension are tight Switch where required. of Tee
and that the lock washer is the float chamber.
in place. Bleed
BE SURE float travel Valve
3. Before installing the level is not restricted and that the Explosion proof
switch a suitable pipe thread sealant float is tight onto conduit seal
is recommended. Screw the unit directly into the threaded where required.
the float shaft.
connection in the wall of the pressure vessel. 4. To complete installation and
4. Be sure that the electrical connection is positioned at the wiring, follow the instructions for
bottom. For L1200N the 1/8 NPT pneumatic connection mounting directly into wall of the vessel and for wiring.
should be on top (the 1/4 NPT vent connection should be on
the bottom). See “Pneumatic models” section for further Pneumatic Models
instructions for the L1200N. 1. All pneumatic models
5. Make the electrical wiring connections according to operate on the vent Filter/Regulator
appropriate wiring diagrams for the alarm or shutdown principle. The Tank
New Dump Valve
system to be used. The electrical connection is 1/2-14 NPT. pneumatic signal Pneumatic Operator Assembly
p/n 15010216
Electrical wiring and conduit should be installed by qualified source MUST BE Signal
personnel according to the NEC. CLEAN AND DRY.
6. BE SURE all electrical connections are insulated and the The input pneumatic MURPHYGAGE®
cover is fully installed before reconnecting electrical power. signal must be
7. BE SURE all pressure connections are tight before regulated between 30
pressurizing the system. and 70 psi (207-483 L1200N
kPa) [2.07-4.83 bar].
Installation with a Weld If produced gas is used as the
Collar Tank Wall
signal source, it should be taken
1. The weld collar, P/N after gas passes through the final scrubber.
15050375, must be welded Weld Collar A suitable filter must be positioned before the L1200NDVO
into the wall of the to prevent liquids and/or particulates from entering the dump
pressure vessel according valve operator.
to code standards and NOTE: Check filter periodically for wear and tear and
good welding practices. elements that hamper the flow of the pneumatic signal.
L1200 2. All pressure connections must be tight and maintained tight
2. Follow above instructions
for installation directly into so as not to leak air/gas.
the wall of the pressure Explosion proof 3. Valve seat adjustment can be made if air/gas begins to leak.
conduit seal
vessel. where required. Care should be taken when adjusting as only slight movement
3. NOTE: Weld collar 15050375 can is necessary to stop the leakage; excessive force will bind the
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External L1200N
Hex Socket Set Screw
Float Chamber 15051098 • loosen for adjustment
• tighten after adjustment
CAUTION: USE “NON SPARKING TOOLING”.
Hex Adjustment Nut
• turn left until air Trip Cam (float down)
1. Install the float chamber 15051098 on the outside wall of the seepage stops • should be in
pressure vessel using 1 NPT piping. Position the 2 NPT • Caution: only slight this position
adjustment is needed—too • non-adjustable
threaded connection at the height where you want the level much will lock up mechanism
switch to operate. The 2 NPT threaded connection must be
Installation 00-02-0175 page 4 of 6
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation
As condensate rises in the scrubber, the float on
Typical/Scrubber/Separators
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter VESSEL
the dump valve pilot chamber. Once the pressure Minimum control
Rising Level Shutdown
enters the pilot chamber it forces the diaphragm L1200 (with snap-switch) pressure 30 psi
(207 kPa) [2.07 bar]
and valve stem forward thus opening the valve seat Air Supply Maximum
300 psi (2.07 MPa)
(valve open/closed indicator button pops out) and [20.70 bar]
releasing condensate through the valve stem and Explosion proof
conduit seal required
out the drain. As the condensate level drops, the for Class I. Div 1, not
Filter/Regulator
required for intrinsically
L1200NDVOR pneumatic valve closes to shut off safe or non-incendive L1200NDVOR
with MURPHYGAGE®
circuits like FWM TTD.
the pressure to the dump valve causing it to close. Dump Valve
Electrical Rising Operator
If for any reason the condensate continues to rise Level Minimum control pressure
Conduit 30 psi (207 kPa) [2.07 bar]
Trips Union
beyond normal dump levels, model L1200 DVO
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the DVU Series Dump Valve
4-1/2 in
(114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar].
2 NPT
Operating Temperature: 400°F (204°C).
2-11.5 NPT
1/2-20 UNF-2B
(4 places)
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
WARNING Pressure
Inlet Port
A
Manual Valve
Operator
1/8 in.-27 NPT
Description
The DVU Series models are pneumatically controlled dump valves. F Drain
The valves open and close automatically by pneumatic control from a Connection C
Murphy L1200NDVOR or similar level controller and dump valve opera-
E D
tor. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi
(207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] Plug Seal G (dimension shown
for reference only)
vessel pressure (depending on the model).
A key benefit of this design is a hex union that provides the ability
to replace the seat without removing the valve from piping.
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
Fig. 1 Control Pressure vs. Working Pressure DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
60
50 Specifications
40
DVU2105 DVU150/175 Operating Temperature: -30 to 250°F (-34.4 to +121°C)
30 Valve Operating Pressure: Refer to chart, Fig 1.
20
Maximum Process Pressure:
10 DVU2120: 2000 psi (13.8 MPa) [138 bar].
0 500 1000 1500 2000 DVU2115: 1500 psi (10.3 MPa) [103 bar].
Vessel Pressure (PSIG) DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Model Inlet Outlet Trim Size
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
DVU2120 2 NPT 1 NPT 0.436 in. (11 mm) Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
DVU2115 2 NPT 1 NPT 0.576 in. (15 mm) Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
DVU2105 2 NPT 1 NPT 0.859 in. (22 mm) Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
DVU175 1 NPT 3/4 NPT 0.359 in. (9 mm) Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
DVU150 1 NPT 1/2 NPT 0.359 in. (9 mm)
1/8 NPT threaded connection of the pressure inlet port (on Weep Hole
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the Drain
condensate out line. Use pipe thread sealant on all the con- Connection
nections.
Union
Condensate Out
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD 6. Using a back-up wrench on the plug, remove the stem nut on the shaft
ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED under the plug. Once the stem nut is broken loose, the 9/16” head main-
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
tenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSI- removed. All soft seals should be replaced. Refer to kit part numbers
BLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME under service parts on page 4.
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED. Replacing the Diaphragm
6A. If the diaphragm is to be replaced, all preceding steps have to be
Suggested Tools (Sizes listed are wrench openings. done. Additionally, do the following:
Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm
flat edge screwdriver with 1/4” blade width, can also be used .) spring to relax, and the stem to retract. Make alignment marks on
Model Valve Body Union Nut Plug Seal Hex Stem Nut the top and bottom halves of the diaphragm assembly for align-
DVU2120 3” 3” 7/8” 1/2” ment during re-assembly.
DVU2115 3” 3” 1” 1/2” 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
DVU2105 3” 3” 1-1/4” 1/2” together.
DVU150/DVU175 2-1/4” 2-1/4” 3/4” 3/8” 6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
Replacing the Plug and Seat 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
1. Close the pressure block valves (suction & discharge valves) on the inlet or 1” round nut on the bottom of the diaphragm assembly to be
and outlet of the skid. Lock them closed if possible. accessible to a wrench and not have the spring interfere. If it is
2. Open the blowdown valve to remove pressure from the unit. Lock the desired to replace the packing, pull the stem all the way out. The
blowdown valve open if possible. packing can be easily removed using a small screwdriver to pry the
3. After taking all possible precautions to insure there is no pressure in the packing out. The new packing can be simply pressed in, making
vessel. (If the condensate line is pressurized, it must also be blocked and sure the orientation of the packing installed is the same as the ori-
locked.) Open the manual drain valve so it bleeds into the vessel so it entation of the packing removed. The packing is wider toward the
can also be bled down. Disconnect the pneumatic input signal connection plug end. You will have to use the seat to hold the packing in place
after insuring it also has been de-pressurized. when re-inserting the stem.
4. Using a back-up wrench on the valve body, with a quick "breaking" 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a
action loosen the union nut on the valve. There is a "weep" hole in the wrench to loosen and remove the 1/2" nut on top of the diaphragm.
nut. If at any time while loosening and taking off the nut pressure is The diaphragm can now be removed and replaced.
escaping through the "weep" hole, immediately stop loosening the nut. 6G. With the new diaphragm in place and the 1/2" nut tightened, place
Retighten the nut and check the preceding procedures to ensure the pres- the assembly, diaphragm down on a clean, smooth sturdy surface.
sure is bled off the vessel. Never remove the assembly if pressure is 6H. Have the seat, plug, washers and stem nut handy (if any of these
coming through the weep hole. See Figure 4 on page 2.
parts are to be replaced, use the old parts for this procedure). Press
5. With the upper assembly removed from the vessel the plug and/or seat can
down evenly and smoothly on the bottom of the diaphragm assem-
be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of
bly to cause stem to come up. Place the seat and plug in place.
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN. Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
Fig. 5 Stem O-Ring Seals 6J. Align the diaphragm holes to the bolt holes (bottom half of the
Plug Seat Stem Packing Against Outlet housing). Install the upper diaphragm housing using the alignment
Washer(s)* marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180° around to the next bolt,
then either 120°or 240° around to the next bolt and so forth until
all 8 bolts are evenly tight.
Stem O-Ring 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem
Nut Crush Washer Seal Seat butts into here out until the 9/16"bolt stops – DO NOT OVERTIGHTEN.
*Number of washers varies depending on the model from 1 to 3. 6L. Remove the stem nut holding the plug. (If old parts were used, pre-
pare to install the new parts now.)
Seal Washer Maintenance 7. Install the seat and plug. Place the O-ring on the stem, followed by the
Fig. 6 Bolt Diaphragm
Pressure Inlet washer and stem nut.
Housing 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one
Diaphragm 1/2" Nut
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16” head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
Backup leaking through the internal weep hole above that O-ring.
1-1/8" or Diaphragm 10. The assembly is ready to be re-installed. Check for relative position of
Plate Spring
1" round nut Stem Assembly the pneumatic input signal connections before tightening the union nut.
Fig. 7 Pressure vs. Flow for DVU150 and DVU175 models only
250
250
200
200
150
150
Pressure (psid)
100
100
50
50
0
0 5 10 15 20 25 30 35 40 45
Flow (gpm)
SERVICE PARTS
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
TP 02-50-T020-305
Installation, Operation and Maintenance Manual Pg 1 of 4
W-K-M®
DynaSeal®
210A / 210L
Ball Valve
Table of Contents
Scope ........................................ 1
Nametag Information ............. 2
Storage ..................................... 2
Installation ............................... 2
Operation ................................. 3
Routine Maintenance ............. 3
Troubleshooting ...................... 3
11
Item Description
1 Body 10
2 Grease Fitting1 12
3 Seat O-Ring2 9
4 Seat Ring
5 Ball 8
6 Tailpiece Gasket 13
7 Tailpiece
8 Stem 14
9 Stem Seal
10 Stem O-Rings 24
16
2
15
11 Handle3
12 Lock Nut3 (or Retainer Clip)
13 Retainer Ring
14 Locking Plate
15 Stop Pin
1
Old option (discontinued 1998), not on all valves.
00
20
2
Used with old style delrin seat with notched back. New CW
P
43 delrin seat does not require o-ring, nor does the
02 or 42 teflon seat.
3
Optional
1 2 3 4 5 4 3 6 7
Scope
The W-K-M DynaSeal 210 floating ball valve is a 2 piece, threaded end valve design.The 210A is
rugged, but economical ductile iron ball valve ideal offered in sizes 1 to 4x 3and pressure ratings
for oilfield applications. It has deep-pocketed seats, 1000 psi, 1500 psi and 2000 psi. The 210L is offered
double O ring stem seals and is available with API in 2, 3 and 4 reduced port sizes with a maximum
Line Pipe threaded outlets. The 210A and 210L are a 1000 psi pressure rating.
Nametag Information
1 2
Item Description
CWP:
WO: 1 Maximum cold working pressure
2 Work order number
DESC:
3 Assembly part number
P/N REV. 4 NACE compliance mark
5 Valve size and type
(model and body trim designation
3 4 5 6
6 Revision level
Storage
After valves are assembled and tested, they are body and the other on the adjacent pipe. (ie. DO
placed in the full open position, bores are NOT apply wrench to the body section when making
greased and end protectors are installed. This up pipe to the tailpiece as this may result in break-
will provide adequate protection for indoor ing loose the threaded tailpiece-tobody joint).
storage. Extended outdoor storage requires Conventional pipe thread compound is recommended
periodic inspection and the addition of a corro- when installing 210, ductile ball valves. Teflon tape
sion inhibitor. Contact your CCV representative can cause threads to gall. Field testing, if performed
for extended storage guidelines. Valves should after the valve has been properly installed into the
only be stored in the full open or full close line, should be done in accordance with the following
position to prevent seat distortion. procedure:
Operation
DynaSeal 210 ball valves operate from fully open to lubricators (if recommended by the actuator
fully close by a 90 degree turn of the handle. The manufacturer) are installed prior to valve and
handle aligned with the pipe always means the valve actuator installation. Should any maintenance
is open and with the handle perpendicular to the be necessary, obtain the part number from the
pipe means the valve is closed. Additionally, the units nameplate and contact Cooper Cameron
stems have flats that align the handle and can be Valves or the nearest representative.
used to indicate ball position. The bore of the ball is
parallel with the faces of the stem flats.
Warning: Valves should be placed in a partially open position prior to working on a valve or removing
it from service to vent pressure or drain product that may be trapped in the body cavity. When remov-
ing threaded end valves from the line, apply wrenches in the same manner used for installation and
NOT to the valve body section as this may result in breaking loose the threaded tailpiece to body joint.
Troubleshooting Chart
Trouble Probable Cause Remedy
a. Iced up due to restricted flow or a. Flush out with warm material.
low temperatures.
b. Pressure locked. (Condition in b. Reduce valve temperature or pressurize line to rated
Will not open or close
which the body pressure exceeds working pressure to reduce pressure differential
the line pressure by an excessive sufficient to operate valve.
amount)
a. Worn or damaged seats and/or a. Replace worn parts* (Requires valve removal and
ball. disassembly)
Will not seal properly
b. Foreign matter between seat and b. Operate several times to wipe clean.
ball.
c. Operator stops not set properly. c. Adjust stops to proper setting.
Leaking around stem a. Worn or damaged stem seals. a. Replace O-ring stem seals.* (Requires valve removal
and disassembly)
Headquarters
Phone: 281-499-8511
800-323-9160
Fax: 281-499-6965
USA
Phone: 405-631-1321
Fax: 405-629-0420
Scotland
Phone: 44-1506-444-000
Fax: 44-1224-783-355
http://www.ccvalve.com
” minimum
engagement
TP 02-22-T010-322-150
Fuel Block & Vent Valve
FW Murphy M2582-CD
p/n: 2090 2510
WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation.
✔ Follow all safety warnings of the machine manufacturer.
Model M5081
✔ Read and follow all installation instructions.
Approved*
]
]
g.)
bar]
]
[254.0]
bar
bar
bar
.28 k
(closed), seat closes (C).
.38
.69
0.34
.07
9.0
g.)
[228.6]
) [1
) [0
) [2
z. (0
The vent (D) opens to relieve trapped downstream fuel
a) [
11 k
Inches water column (∆p) drop across valve.
kPa
kPa
kPa
8.0
10 o
4 kP
[203.2]
. (0. to vent to a non-hazardous area.
Millimeters water column in brackets [ ].
38
07
(69
ig (3
g (1
g (2
4 oz
7.0
sig
[177.8]
psi
psi
5 ps
10 p
20
30
6.0
[152.4] TYPICAL MODEL (M5081) SHOWN
5.0
Terminal Block is
[127.0]
4.0
[101.6] within this case.
3.0
F
[76.2]
2.0
[50.8]
1.0
[25.4]
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
[7.08] [14.16] [21.24] [28.32] [35.40] [42.48] [4956] [56.64] [63.72] [70.80] [77.88] [84.96]
E
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
G
B
C
A
M5081 and D
M5180 Series Vent to relieve trapped fuel
outside the hazardous area. H Pipe Plug (remove to
install vent tube).
Inches water column (∆p) drop across valve.
Millimeters water column in brackets [ ].
g.)
1k
(.1
A. Main Stem
z.
3.0
4o
.)
[76.2]
kg
2.0
ar]
[50.8]
a ) [.6
9b D. Vent Seal Gland
k P
(69 bar] E. Reset Knob (latches valve open)
sig [1.38
10 p 38 kPa)
1.0
20 p
sig (
1
2.07
bar] F. Manual Trip Knob (not available for M5081FS)
Pa) [
[25.4]
0 7 k
30 ps
ig (2 G. Indicator Button (out with valve open)
H. Pipe Plug
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
[14.16] [28.32] [42.48] [56.64] [70.80] [84.96] [99.12] [113.28] [127.44] [141.60]
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
NOTE: If the vent-after-tripping feature is not used,
remove O-ring (D), to avoid condensation accumulation
that can hamper trip action.
Be sure to replace Pipe Plug (H) and to clean vent
periodically.
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M2582 M2582-P
1/4 in. (6 mm) tube connection; control
1/2 NPT Conduit pressure 3 psi (21 kPa) [0.21 bar] minimum,
Reset Knob Connection Latch Arm (see NOTE) 75 psi (517 kPa) [5.17 bar] maximum.
Manual Trip
Knob
1 NPT Breather/Vent
(2 places) 1/16 in. (2 mm)
1 NPT
(2 places)
6-9/16 in.
7-5/16 in. 1/4 NPT (167 mm)
1/4 NPT (186 mm) Vent and
Vent and Plug Plug
3-3/32 in.
3-3/32 in. (79 mm)
(79 mm) 5-1/2 in. (140 mm)
5-1/2 in. (140 mm)
NOTE: Thumb operated opening latch (2.5 psi [17 kPa]
[0.17 bar] required to release cocking latch)
M5180-P
Latch Arm (see NOTE 2)
NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control.
NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch).
1-23/32 in.
Panel Mount screws (44 mm)
10-24 N.C. x 31/32 in.
5/16 in. (8 mm) long (25 mm)
2-7/16 in.
(62 mm)
15/32 in. GND ALT1 ALT2 SW
(12 mm)
Terminal screws
8-32 N.C. x
1/4 in. (6 mm) long
Installation M-7980N page 3 of 12
DIMENSIONS continued
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
3-7/16 in.
Indicator (87 mm)
Button
4-1/16 in.
2 NPT (103 mm)
Vent and Plug (2 places)
1/2 NPT
3 in. (76 mm)
9-3/8 in. (238 mm) 7-3/4 in. (197 mm)
45°
3-5/8 in.
(92 mm) dia.
WARNING: STOP THE ENGINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION. BEGIN THE
INSTALLATION BY SECURING AREA OF ANY HAZARDOUS CONDITIONS. SHUTOFF THE FUEL GAS SUPPLY. FOR HAZARDOUS
APPLICATIONS REFER TO NATIONAL ELECTRICAL CODE SPECIFICATIONS.
CAUTION: DO NOT TWIST THE VALVE BODY HOUSING. Remove plug and attach vent line.
FUEL FLOW Route to non-hazardous area.
5. To mount flanged models, follow the appropriate installation codes
and ordinances for the application. (For dimensions see page 4.)
6. A vent line (to allow gas trapped forward between fuel valve and the
carburetor to escape) should be attached to the vent connection at the
bottom of the valve housing. Remove the plug and install the line. Figure 2
(Refer to Figure 1.) Pull the lever up, and press the latch
down into ridge with thumb.
Connecting Pneumatic Models
M2582-P and M5180-P
1. Repeat the steps above (1 thru 5), and observe the necessary cautions. Level Arm (Handle)
2. A lever/arm (handle) and a cocking latch are provided to allow manual
opening of the valve. The thumb-operated latch can be locked in place
to hold the lever/arm latched. The cocking latch will be released when Control Pressure
Connection
pilot pressure reaches 2.5 psi (17 kPa) [0.17 bar]). M2582-P and
M5180-P automatically open at 2 psi (14 kPa) [0.14 bar], and fully Thumb-operated
Cocking Latch
open at 3 psi (21 kPa) [0.21 bar]. See Specifications, page 12 for Breather
maximum control pressure. Vent
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT
WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
Valve
Coil
Ground Switch 2 (Note) Switch 1
65700053 (was 65020126): For use with
negative ground ignitions up to 240 VDC. +
65700054 (was 65020127): For use with
positive ground ignitions up to 450 VDC.
IN4007
65700055 (was 65020155): For use with ALT ALT
10 9 8 7 6 5 4 3 2 1 GND 1 2 SW
negative ground ignitions up to 450 VDC.
Negative ground
Magnetic Switch Adapter shown
NOTE: Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2)
wire is red color for both options: 12 VDC and 24 VDC.
M5081-C
CD Ignition Models Magnetic
Switch
GND ALT1 ALT2 SW Adapter
Terminal Block
10 9 8 7 6 5 4 3 2 1
CD ignition Additional
CD ignition
Ground Jumpers
MS2100 MS2100
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single CD Ignition Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 6.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect second ignition to Magnetic Switch Adapter terminal ALT2.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect a 100 ohm, 2 watt resistor between valve terminals 1-2. Ground terminal 6.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual CD Ignition Systems) Remove the jumper on terminals 6-5. Connect a 100 ohm,
2 watt resistor between valve terminals 1-2. Ground terminal 6. Connect second ignition to Magnetic Switch Adapter terminal ALT2.
M5081-B
Battery Models + --
DC Power
Terminal Block source
10 9 8 7 6 5 4 3 2 1
Ground
Jumpers
* *forIN4005 Diode
flyback protection
MS2110 MS2110
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
Installation M-7980N page 7 of 12
TYPICAL WIRING for M5081-A (MAGNETO IGNITION MODELS)
M5081-A
Magneto Ignition Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
Magneto
Ground
65010065 Additional
Diode Package
(See Notes 2/4) Jumpers Magneto
MS2120 MS2120
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single Magneto Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 5.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual Magneto Systems) Remove the factory-installed jumpers on terminals 6-5 and 9-8.
Add 65010065 diode package as shown. Do NOT ground terminals.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single Magneto Systems) The factory-installed jumpers (6-5 and 9-8) must be in place.
Add ground wire to terminal 5.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual Magneto Systems) Remove the jumper on terminals 9-8.
Add 65010065 diode package as shown. Add ground wire to terminal 5.
M5081FS
12 or 24 VDC Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
+ --
Ground Ground * DC Power
source
MS2110 MS2110
6 1 2 3 4 5 6 1 2 3 4 5
* forIN4005 Diode
flyback protection
* *
Start-run timer
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD
CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582-C to LCDT-PS-CD (R)-P (positive ground) M5081-C to LCDT-PS-CD (R)-P (positive ground)
C
Relay NO
Contacts C
NC
NC
Ground
* FV(-) FET output rated: 0.5 A @ 250 VDC max.
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
LCDT-PS-CD-N LCDT-PS-CD-N
+ M5081 Terminal block Terminal block
–
M2582 Fuel Valve
IGN 1 – +
White 10 9 8 7 6 5 4 3 2 1 IGN 1
FV(+)
FV(+)
Black FV(-) * Relay
FV(-) *
GND
jumper jumper GND
Contacts
Red
NO
C
Relay NO
Contacts C
NC
NC
M2582-C to MARK IV-N (negative ground) M5081-C to MARK IV-N (negative ground)
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
F/V
S/D
GRD
+
12/24V
--
DC Power
source -- +
DC Power
* forIN4005 Diode
flyback protection
IN4005 Diode
* for flyback protection source
MARK IV-12/24 1
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max. terminal block
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
Remove shunt jumper E2 for ignition ground time delay.
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
TTDJ-DC-(T) to Relays
Connections Shown for Use with M5081FS to TTDJ-DC-(T)
Diagrams (A), (B), (C), and (D) on this page.
To 12 or 24 VDC
M5081FS Terminal Block power supply
1
IGNITION RELAY + –
K1
10 9 8 7 6 5 4 3 2 1 SD
*
10-32VDC
12-24 VDC GRD
NA
Power supply 1
FV
*
SD
+ – ALR
K2 10-32VDC
MPU
GRD GRD
* NA
FV
ALR
1 K1 and K2 are hermetically Sealed MPU
GRD
auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas. * 1N4005 diode for flyback protection.
* 1N4005 diode for flyback protection.
Black 1 –
jumper jumper K2
Red 1
1 K2 is hermetically sealed auxiliary relay, third party 1 K2 is hermetically sealed auxiliary relay, third party
certified for use in Class I, Div. 2, Gps. C & D areas. certified for use in Class I, Div. 2, Gps. C & D areas.
Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product.
Details are available on request and are packed with each unit.
CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
(281) 342-0297 fax (281) 341-6006 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358-5555 fax +61 3 9358-5558
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
MURPHY SWITCH OF CALIFORNIA
(918) 317-4100 San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
fax (918) 317-4266 +52-444-8206264 fax +52-444-8206336 Palmdale, California 93551-1442; USA
D
RE
e-mail sales@fwmurphy.com
www.fwmurphy.com e-mail ventas@murphymex.com.mx e-mail sales@murphyswitch.com
www.murphymex.com.mx www.murphyswitch.com
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A. 0966106
Installation M-7980N page 12 of 12
Installation, Operation and Maintenance Manual Pg 1 of 4
W-K-M®
DynaSeal®
210A / 210L
Ball Valve
Table of Contents
Scope ........................................ 1
Nametag Information ............. 2
Storage ..................................... 2
Installation ............................... 2
Operation ................................. 3
Routine Maintenance ............. 3
Troubleshooting ...................... 3
11
Item Description
1 Body 10
2 Grease Fitting1 12
3 Seat O-Ring2 9
4 Seat Ring
5 Ball 8
6 Tailpiece Gasket 13
7 Tailpiece
8 Stem 14
9 Stem Seal
10 Stem O-Rings 24
16
2
15
11 Handle3
12 Lock Nut3 (or Retainer Clip)
13 Retainer Ring
14 Locking Plate
15 Stop Pin
1
Old option (discontinued 1998), not on all valves.
00
20
2
Used with old style delrin seat with notched back. New CW
P
43 delrin seat does not require o-ring, nor does the
02 or 42 teflon seat.
3
Optional
1 2 3 4 5 4 3 6 7
Scope
The W-K-M DynaSeal 210 floating ball valve is a 2 piece, threaded end valve design.The 210A is
rugged, but economical ductile iron ball valve ideal offered in sizes 1 to 4x 3and pressure ratings
for oilfield applications. It has deep-pocketed seats, 1000 psi, 1500 psi and 2000 psi. The 210L is offered
double O ring stem seals and is available with API in 2, 3 and 4 reduced port sizes with a maximum
Line Pipe threaded outlets. The 210A and 210L are a 1000 psi pressure rating.
Nametag Information
1 2
Item Description
CWP:
WO: 1 Maximum cold working pressure
2 Work order number
DESC:
3 Assembly part number
P/N REV. 4 NACE compliance mark
5 Valve size and type
(model and body trim designation
3 4 5 6
6 Revision level
Storage
After valves are assembled and tested, they are body and the other on the adjacent pipe. (ie. DO
placed in the full open position, bores are NOT apply wrench to the body section when making
greased and end protectors are installed. This up pipe to the tailpiece as this may result in break-
will provide adequate protection for indoor ing loose the threaded tailpiece-tobody joint).
storage. Extended outdoor storage requires Conventional pipe thread compound is recommended
periodic inspection and the addition of a corro- when installing 210, ductile ball valves. Teflon tape
sion inhibitor. Contact your CCV representative can cause threads to gall. Field testing, if performed
for extended storage guidelines. Valves should after the valve has been properly installed into the
only be stored in the full open or full close line, should be done in accordance with the following
position to prevent seat distortion. procedure:
Operation
DynaSeal 210 ball valves operate from fully open to lubricators (if recommended by the actuator
fully close by a 90 degree turn of the handle. The manufacturer) are installed prior to valve and
handle aligned with the pipe always means the valve actuator installation. Should any maintenance
is open and with the handle perpendicular to the be necessary, obtain the part number from the
pipe means the valve is closed. Additionally, the units nameplate and contact Cooper Cameron
stems have flats that align the handle and can be Valves or the nearest representative.
used to indicate ball position. The bore of the ball is
parallel with the faces of the stem flats.
Warning: Valves should be placed in a partially open position prior to working on a valve or removing
it from service to vent pressure or drain product that may be trapped in the body cavity. When remov-
ing threaded end valves from the line, apply wrenches in the same manner used for installation and
NOT to the valve body section as this may result in breaking loose the threaded tailpiece to body joint.
Troubleshooting Chart
Trouble Probable Cause Remedy
a. Iced up due to restricted flow or a. Flush out with warm material.
low temperatures.
b. Pressure locked. (Condition in b. Reduce valve temperature or pressurize line to rated
Will not open or close
which the body pressure exceeds working pressure to reduce pressure differential
the line pressure by an excessive sufficient to operate valve.
amount)
a. Worn or damaged seats and/or a. Replace worn parts* (Requires valve removal and
ball. disassembly)
Will not seal properly
b. Foreign matter between seat and b. Operate several times to wipe clean.
ball.
c. Operator stops not set properly. c. Adjust stops to proper setting.
Leaking around stem a. Worn or damaged stem seals. a. Replace O-ring stem seals.* (Requires valve removal
and disassembly)
Headquarters
Phone: 281-499-8511
800-323-9160
Fax: 281-499-6965
USA
Phone: 405-631-1321
Fax: 405-629-0420
Scotland
Phone: 44-1506-444-000
Fax: 44-1224-783-355
http://www.ccvalve.com
Introduction
Scope of Manual
This instruction manual provides installation, spring adjust-
ment, maintenance, and parts information for the Type 119
control valve.
Description
The Type 119 control valve (figure 1) is used for on-off or
throttling control of noncorrosive or mildly corrosive liquids
and gases. It is designed to meet the low-pressure liquid
and gas application requirements in many varied industries.
Table 1. Specifications
1E5427-F
Material Orifice
Code Seat Disk Material
AI/N
SST/N
Aluminum/Nitrile
Stainless steel/Nitrile
Spring Adjustment
SST/V Stainless steel/Fluoroelastomer
The control valve spring has been selected to meet the
pressure condition requirements of the application as spe-
cified on the order. This pressure condition is stamped on
Figure 2. Type 119 Nameplate the actuator nameplate.
2
Type 119
1. Loosen the locknut (key 13) on the spring case. 7/8-inch socket wrench, and replace it with a new seat ring
of the proper size.
2. Turn the adjusting screw (key 12) clockwise to
compress the spring (key 16) or counterclockwise to 4. Remove the bonnet O-ring (key 11), and inspect it for
decrease spring compression. Increased spring compres- wear and damage.
sion results in increased loading pressure necessary to
start travel. Decreased spring compression results in less 5. Unscrew and remove the spring case cap screws (key
loading pressure required to start travel. 14). Remove the spring case, upper spring seat, and spring
(keys 2, 17 and 16). Do not lose the nameplate (key 20)
when removing the spring case.
3. After adjustment, tighten the locknut. Note that the
spring can be identified by the color code. Depending on 6. Pull the hair pin clip (key 6) from the stem and remove
how much conditions are changed, it may be necessary to the disk holder assembly (key 4).
install a new spring, using appropriate steps in the Mainte-
nance section. After changing the spring, adjust the valve 7. Pull the diaphragm/stem assembly (key 5) out of the
using the above steps in this section, and indicate the new bonnet (key 9), and inspect for damage or deterioration. If
spring range on the nameplate. necessary, replace the entire diaphragm assembly.
The following describes the procedure for complete 1. If the orifice (key 3) was removed during disassembly,
disassembly and assembly of the actuator-valve body lubricate the threads with Never-Seez(1) lubricant (key 21)
combination. When inspection or repairs are required, or equivalent, and screw it into the valve body using a thin-
disassemble only those parts necessary to accomplish the wall 7/8-inch socket wrench.
job. Key numbers refer to figure 3.
2. Lubricate the bushing spacers, O-rings, stem wipers,
and internal retaining rings (keys 7, 8, 19 and 10) with Dow
Corning(2) No. 111 silicon-base lubricant (key 22) or equiva-
Disassembly lent, and install as shown in figure 3.
1. Isolate the control valve from all pressure, and release
3. Carefully slide the diaphragm assembly (key 5) into and
pressure from the valve body and actuator. Loosen the lock-
through the O-rings and bushing cavity. Turn the diaphragm
nut (key 13), and remove all spring compression from the
assembly to line up the diaphragm holes with the bonnet
control valve by turning the adjusting screw (key 12) out of
holes.
the spring case.
4. Slide the disk holder assembly (key 4) all the way into
2. Remove the two bonnet cap screws (key 15, not shown) the stem. Connect the disk holder assembly with the hair pin
that secure the bonnet to the body, and lift the spring case, clip (key 6).
bonnet, and trim assembly from the body.
5. Coat the bonnet O-ring (key 11) with Dow Corning No.
3. Examine the seating edge of the orifice (key 3). If it is 111 lubricant (key 22) or equivalent. Install the O-ring in the
nicked or rough, unscrew it from the body with a thinwall recessed notch in the bonnet (key 9).
6. Mount the bonnet (key 9) on the valve body (key 1), in- Key Description Part Number
sert two cap screws (key 15, not shown), and tighten to 7 Part Kits
foot-pounds (9 newton-meters). Kits include keys 4, 5, 6, 8, 10, 11, and 19.
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
7. Put the spring (key 16) on the diaphragm assembly (key (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
5), and place the upper spring seat (key 17) in the end of the mm) inch orifices w/aluminum
disk holder nitrile diaphragm, and
spring. nitrile disk & O-rings R119X 000A12
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
8. Lubricate the point and threads of the adjusting screw orifices w/aluminum disk
(key 12) with Never Seez lubricant (key 21) or equivalent. holder, nitrile diaphragm and nitrile
disk & O-rings R119X 000A22
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
9. Position the spring case (key 2) and nameplate (key 20)
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
on the diaphragm assembly (key 5). Insert the cap screws mm) inch orifices w/stainless
(key 14). steel disk holder, nitrile diaphragm
and nitrile disk & O-rings R119X 00SN12
10. Tighten all cap screws until finger tight. Then, following For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
a crisscross pattern, tighten each cap screw. orifices w/stainless steel disk
holder, nitrile diaphragm and nitrile
disk & O-rings R119X 00SN22
11. Connect the control piping to the control connection in For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
the bonnet. (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/stainless
12. Adjust the spring by following the procedures in the steel disk holder and fluoroelastomer
Spring Adjustment section, and remark the nameplate if diaphragm, disk, & O-rings and
stainless steel disk holder R119X 00SV12
necessary.
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/stainless steel disk
holder and fluoroelastomer diaphragm,
disk & O-rings R119X 00SV22
NACE Construction
Parts Ordering For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm),
5/16 (7.9 mm), and 3/8 (9.5 mm) inch orifices
When contacting your Fisher sales office or sales represen- w/aluminum disk holder, fluoroelastomer
tative for technical assistance or ordering replacement diaphragm, disk and O-rings R119X N0SV32
parts, include the type number and all other pertinent in- For 1/2 (12.7 mm) and 9/16 (14.3 mm) inch
formation stamped on the nameplate attached to the spring orifices w/aluminum disk holder,
case. fluoroelastomer diaphragm,
disk and O-rings R119X N0SV42
5* Diaphragm/Stem Assembly(1) 17 Upper Spring Seat, zinc plated steel 1D6671 25072
Aluminum/nitrile 17A8080 X032 18 Type Y602-12 Vent (not shown) 27A5516 X012
Stainless steel/nitrile 17A8080 X022 19 Stem Wiper(1), TFE (2 req’d) 18A7024 X012
Stainless steel/fluoroelastomer 17A8080 X012 20 Nameplate, aluminum 1E5427 11992
Nace MR-01-75, Aluminum/fluoroelastomer 19A0348 X022
6 Hair Pin Clip(1) 21 Never-Seez Lubricant, 1 gal (3.81 L) can
All except NACE 19A0347 X012 (not furnished with valve) 1M5239 06992
NACE MR-01-75 19A0347 X022 22 Dow Corning 111 Lubricant, 10 lb (4.53 kg) can
7 Bushing Spacer, Delrin 500(2) (2 req’d) 18A7021 X012 (not furnished with valve) 1M5283 06992
23 Vent Screen, stainless steel (not shown) 0L0783 43062
24 Nace Tag 19A6034 X012
25 Tag Wire 1U7581 X0022
5
R
Type 119
V APPLY LUB/SEALANT
37A8078-C
While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or guar- the right, without notice, to alter or improve the designs or specifications of the
antee, express or implied, regarding the performance, merchantability, fitness products described herein.
TABLE OF CONTENTS
LIST OF FIGURES
1.0 GENERAL INFORMATION This aerodynamic speed control helps protect the
TURBOTWIN starter from damage caused by starter motor
This manual provides instructions for the installation and over speed.
operation of the TDI T100 TURBOTWIN Starters (Series:
B,D,F,P). If there are questions not answered in this The T100 TURBOTWINS employ a 7.5:1 or 9:1 ratio
manual, please contact your TDI TURBOTWIN distributor or planetary gearbox. This low gear ratio allows the turbine
dealer for assistance. motor to spin at low speeds for long bearing life. At a
typical 3000 rpm pinion speed, the turbine is cruising at a
The T100 TURBOTWIN models are turbine driven starters low 22500 rpm (7.5:1 ratio). Reliability and part commonality
with an inertially engaged starter drive. Depending on the are designed into all TURBOTWINS.
starter model and engine installation, the TURBOTWIN
starters have applications ranging from 1200 CID (20 Liters) A simple and reliable inertia drive delivers the torque to the
on diesel engines and up to 15000 CID (250 Liters) on gas pinion. The pinion is thrown out to engage the engine's ring
engines. The TURBOTWIN models are suited to operate gear by the turbine motor's acceleration. Lighter weight
within a wide range of inlet pressures and ambient rotating parts used in the TURBOTWIN provide low inertia
temperatures. The engine size and parasitic loading will and even "softer" engagement. In the event of over-
determine the exact minimum pressure that will assure pressure, the friction clutch used in every TURBOTWIN
reliable starting. protects ring gear teeth from static torque overloads. In
addition, an inertia engaged starter eliminates the need for
The T100 TURBOTWIN starters are designed for operation complex pre-engagement control plumbing...and is easier to
with compressed air or natural gas; materials used are install and maintain than pre-engaged type starters.
compatible with “sour” natural gas and marine environments.
Small amounts of foreign matter or liquid in the air stream Compressed air or natural gas is used to power T100
will not adversely affect TURBOTWIN starters. As with all TURBOTWIN air starters through the inlet port. The air or
other TDI starters, no lubrication is required in the air supply. gas is expanded through the first nozzle or stators. The high
velocity gas impinges on the first stage rotor to yield torque
Please review the rest of this manual before installing the to the gearbox. The gas is further expanded through the
T100 TURBOTWIN series air starter. second stage stators, which impart additional torque to the
second stage rotor.
WARNINGS, CAUTIONS AND NOTES
1.2 PRODUCT IDENTIFICATION
Certain types of information are highlighted in this manual
for your attention: The starter nameplate which is attached to the turbine
housing contains the following information: model number,
WARNING - used where injury to personnel or serial number, part number, direction of rotation and the
damage to the equipment is likely. maximum rated operating pressure.
CAUTION - used where there is the possibility of The directions of rotation are either right hand or left hand
damage to the equipment. rotation as shown in Figure 1. Right Hand rotation is defined
as clockwise rotation as viewed from the pinion end of the
NOTE - used to point out special interest starter, and Left Hand rotation is counter clockwise rotation
information. viewed from the pinion end of the starter.
WARNING
If a fuel (pulse) lubricator has previously been installed in the
system, disconnect and plug the line to eliminate spraying
diesel fuel on the engine.
WARNING
Do not operate this starter unless it is properly connected to
an engine.
WARNING
Be sure to either bleed the pressurized air reservoir and/or
Figure 1. Direction of Rotation viewed from Pinion End. safety the system such as closing all valves prior to installing
starter supply line.
1.3 PERFORMANCE
The T100 TURBOTWIN series air starters come standard
Graphs of the performance curves feature pinion torque with a 2" NPT female pipe thread for the inlet connection
versus pinion speed (rpm) at constant drive air pressures port. The supply line consists of the line from the air source,
and shaft horsepower versus pinion speed at constant drive
a pressure regulator (when necessary), a manual or relay
air pressures. Pinion speed is shown on the horizontal axis.
valve, and the connection to the starter inlet. Hard piping
The pinion torque is shown along the left edge vertical axis.
may be used, but a section of flexible tubing should be
The shaft horsepower is shown along the right edge vertical
installed at the starter to prevent leaks due to engine
axis. Air consumption rates are given for the various drive
vibration.
pressure lines. These performance curves feature air as the
drive gas and have open exhaust (standard exhaust guard)
Care must be taken to ensure that all inlet supply line piping
which have no back pressure.
is no less than 1.5" and all components used are capable of
passing the required air flow.
2.0 ORIENTATION OF THE STARTER
NOTE
2.1 GENERAL Valves with a Cv of 40 or higher are recommended.
If the factory orientation of the starter’s pinion housing
If the supply line must be longer than 20 feet, the inlet supply
assembly in relation to the inlet port does not fit your engine
line piping should be increased to 2" in diameter to ensure
installation, these components can easily be re-oriented.
proper performance by your TURBOTWIN.
All TURBOTWINS have the capability to rotate the inlet port
Because turbine starters such as the T100 TURBOTWIN
relative to the drive opening for the optimum inlet port
series are sensitive to flow restrictions, care must be taken
location. The number of different positions is 6 to 12
to use uniform hose or tubing and fittings for connection of
depending on model.
the supply line. Tees, elbows and line length must be kept
to a minimum. TDI recommends that hose or flex couplings
3.0 INSTALLING THE STARTER are installed to eliminate possible leakage caused by strain
on the supply line.
A turbine air starter does not require lubrication in the supply
air. Therefore, if a vane type starter motor is being replaced, Normally, an air strainer is not required. However, in dirty
TDI recommends that all lubrication devices and lines environments use of a #40 mesh Y-strainer is
removed to minimize flow restrictions. recommended. The T100 TURBOTWIN series is highly
tolerant of dirt in the air line, however, starter life can be
increased with the use of an air strainer.
A pressure regulator is required when the air supply installed at the pressure check port and electrical lines
pressure is great enough to exceed the starter operating routed to a digital display at the operator's station.
pressure (at the inlet port) and/or the maximum torque.
This pressure port is invaluable in diagnosing air starter
A manual ball valve may be used to admit drive air/gas to and/or installation problems.
the starter. The manual valve should be located in a safe
position away from the engine. 3.3 EXHAUST PIPING
A preferred valve is pilot-operated, which can be The turbine exhaust may be plumbed away from the starter
pneumatically or electrically actuated. The valve should be area. All starters using natural gas must be piped according
located close to or even on the starter inlet for best to industry codes and local regulations.
performance. Pneumatic or electrical control lines may be
routed virtually anywhere for the customer's preferred The performance of a turbine starter will be decreased
operating station. This type of valve actuates from a fully because of back pressure when smaller than recommended
closed to a fully open position very rapidly. TDI offers a exhaust piping is installed. If back pressure hampers starter
variety of relay valves such as P/N RLVA-25683-001-2-01, performance, compensation can be made by increasing the
which is a 1-1/2" port, pneumatically actuated valve. supply pressure. Consult your TDI distributor for advice.
The supply line should be dry-fitted for proper alignment Exhaust piping should be routed downward to help prevent
/location prior to final assembly. All pipe threaded joints any accumulation of condensation in the starter motor.
should be sealed with Loctite Pipe Thread Sealant (TDI P/N
9-94085) or equivalent for leak tight joints prior to final If the overhung section of the starter is not otherwise
assembly. Be sure to tighten all joints to proper torque after supported, TDI recommends supporting the exhaust piping
final assembly. with a suitable bracket(s).
Pipe unions must be type approved by GL. Downstream of mounting bolts. Torque the three 5/8" screws to 100 lb-ft.
the pressure regulator a pressure relief valve is to be
provided. 4.0 STARTER OPERATION
3.6 BACKLASH Prior to operation, check that all connections are tight and
free from leaks. Check the 1/4" NPT pipe plug or a pressure
Backlash is the "free play" between the mesh of two gears. gauge/transducer that may be connected to the pressure
Figure 15 shows the backlash between two gears. port on the starter inlet.
Maintaining the proper gear backlash setting allows the
gears to mesh smoothly. Proper backlash and alignment WARNING
allows smooth engagement/disengagement of the pinion Do not operate the TDI TURBOTWIN starter with air pressure
gear and loads the tooth face surfaces evenly producing greater than the pressure rating on the nameplate. This
longer gear life. The correct backlash setting for 6/8 pressure is measured at the starter inlet while the starter is
diametral pitch gearing used on larger engines is as follows: running.
Minimum backlash .015 inch
The maximum operating pressure limit is the inlet pressure
Maximum backlash .025 inch
measured at the starter’s inlet pressure check port. In order
to check the starter, a 1/4"NPT pipe tap connection is
To check the backlash, the pinion will need to be rolled out
provided in the inlet housing to attach a pressure
onto the end of the drive prior to starter installation. This can
gauge/transducer). The maximum pressure assumes an
be accomplished by using a hex drive wrench to rotate the
open exhaust (standard turbine exhaust guard). The
turbine end of the starter while holding the pinion from
standard exhaust guard causes no back pressure.
rotating. The pinion will simply walk to the end of the shaft.
An access hole to reach the turbine screw is provided in the
The static non-flowing supply pressure will always be higher
turbine exhaust guard. The starter must then be installed on
than the operating (dynamic) pressure. The maximum
the engine. Checking backlash can be accomplished using
pressure limit (proof pressure) that the TDI TURBOTWIN
a dial indicator or a simple blade-type feeler gauge. Because
starter housings may be subjected to is 600 PSIG (42 BAR).
ring gears are not usually perfectly round, it is necessary to
System pressure that exceeds the maximum operating limit
must use a pressure reducing device to ensure that the
operating pressure limit to the TDI TURBOTWIN starter is
maintained.
System static pressure that exceeds the 600 PSIG (42 BAR)
limit must, in addition to pressure reducer devices
incorporate a pressure relief valve set below 600 PSIG (42
BAR) in the supply air line.
NOTE
For maximum life of the starter pinion and for the protection
of the engine ring gear, limit the operating pressure to that
necessary to start the engine at its most difficult starting
Figure 2. Checking Backlash conditions.
check backlash at several (six or more) points around the All appropriate local pressure codes and pressure limitations
circumference of the ring gear. Average the highs and lows on other system components must be adhered to and
to allow a setting that is in the range cited above. supersede the guidelines given in this manual.
Setting the correct backlash may involve "shimming" and/or Consult your TDI distributor if you have exhaust plumbing
moving the starter bracket(s). An adjustable starter bracket that creates back pressure and reduces starter
design will simplify this procedure. Always re-check the performance. You may be able to increase the supply
backlash after a ring gear replacement. pressure to restore the lost power.
Follow the engine manufacturer’s instructions for starting the
Liberally grease the starter’s drive teeth with chassis lube engine.
and then mount the TURBOTWIN starter on the engine.
Tighten all mounting hardware as appropriate. Make sure to
use Loctite Threadlocker #290 or equivalent on the starter 4.1 BASIC OPERATION
Publication T1-702, Rev 1
Issued January 22, 2001 5
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
speed.
The basic operation of the starter is as follows:
The automated start panel should monitor engine speed to
Pressurized air or natural is admitted to the starter by determine air on and air off. Do not simply use time as a
opening of the manual or relay valve. The air expands control parameter. Avoiding excessive operation of the
through the turbine, which produces shaft rotation and starter after the engine is firing will maximize the starter life.
torque. The acceleration of the drive assembly causes the
pinion to advance and engage the ring gear of the engine. 5.0 PREVENTIVE MAINTENANCE
The starter motor torque causes the engine to accelerate. The TDI TURBOTWIN starters provide distinct advantages
This acceleration causes the pinion to be disengaged from of size and efficiency as compared to electric motor, vane-
the ring gear. The fuel and ignition systems now fire the type or other turbine-type starters. It is important to properly
engine. Closing the relay valve stops the starter. install the starter to receive full benefit of these advantages.
Repair technicians or service organizations without turbine
The operator may decrease starter life by the continual starter experience should not attempt to repair this machine
operation of the starter after the engine has started. Upon a until they receive factory approved training from TDI, or its
successful engine start, turn the air off to the starter representatives.
immediately. Minimizing the time the starter is operating
unloaded (i.e. the engine is running) will maximize starter Proper operation and repair of your TDI TURBOTWIN
life. If a start is aborted, a restart may be attempted after the starter will assure continued reliable and superior
engine and the starter has come to rest. performance for many years.
4.2 AUTOMATED START PANEL 5.1.3 Place a small amount of chassis lube on the starter’s
pinion teeth.
The starter drive pressure measured at the starter inlet must
be set. As noted above, for maximum life of the starter 5.2 Every Three (3) Months
pinion and for the protection of the engine ring gear, limit the
operating pressure to that necessary to start the engine at its Follow the six (6) month procedures if there is severe starter
most difficult starting conditions. loading or extended duration crank cycles. Also perform
these procedures every three (3) months when starter is
The speed control parameter will then need to be set. used for motoring the engine for maintenance or valve
Engine starting speed along with the cranking ratio number adjustments.
can be used to determine starter pinion speed. The pinion
speed is usually 2000-3500 rpm for a typical engine starting Motoring Crank Cycle: 10 -60 seconds
speed. Once the start sequence has begun, the air is
admitted to the starter. The starter begins to accelerate the Extended Crank Cycle: 60 seconds or longer
engine. Once the firing speed of the engine is reached, the
automated start panel may deliver fuel to the engine. The starter, use only genuine TDI replacement parts. The
engine will begin to accelerate under its own power. The component part numbers are found in the Illustrated Parts
starter should be dropped out of the sequence at a rpm Breakdown.
higher than the firing speed, but less than the engine idle
Page 6 Publication T1-702, Rev 1
Issued January 22, 2001
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
2. Starter does not A. Broken turbine rotor. A. Replace all damaged parts.
run; normal air flow
from exhaust. B. Broken gear train. B. Repair or replace geartrain.
C. Damaged starter drive. C. Repair or replace starter drive.
3. Reduced Starter A. Inlet air pressure too low. A. Increase air pressure in 10 PSIG (0.6 BAR)
output power. increments; DO NOT EXCEED OPERATING LIMIT.
B. Inlet supply piping too small. B. Supply piping must be a minimum of 1.5" diameter.
C. Pressure regulator orifice too C. Increase orifice size or replace pressure regulator
small.
D. Inlet supply line valve (ball, D. Install larger valve.
gate, relay, plug) too small.
E. In line lubricator installed in E. Remove lubricator.
supply line.
F. Y-Strainer in supply line F. Clean strainer.
clogged.
G. Excessive back pressure; G. Clean exhaust piping or increase size to at least the
exhaust restricted. minimum diameter recommended.
H. Damaged turbine nozzle. H. Replace turbine nozzle.
I. Broken started drive. I. Repair or replace starter drive.
J. Wrong rotation starter. J. Replace with starter or proper rotation.
K. Wrong size starter. K. Check the Application Guide for the correct starter.
4. Engine cranks too A. Inlet air pressure too high. A. Decrease air pressure in 10 PSIG (0.6 BAR)
quickly. increments.
OR
If there is a manual shut-off valve in the supply line,
partially close it.
OR
Install a restriction orifice in the inlet supply line.
B. Wrong size starter. B. Check the Application Guide for the correct starter.
7.0 WARRANTY
Tech Development Inc. shall, at its option, either repair or replace, without charge, any such starter product found by TDI’s
examination to be defective, or by mutual agreement, refund the user’s purchase price in exchange for such starter product.
Repairs or replacements are warranted for the remainder of the original warranty period.
Tech Development Inc. makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY WARRANTY OR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
This warranty constitutes the entire obligation of Tech Development Inc. relating to the sale and use of such product, and
TDI’s maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TDI be
liable for incidental, indirect, consequential or special damages of any nature arising from the sale or use of such engine
starter product.
90 psig 60 44.8
272 200
204 150
60 psig 40 29.8
136 100
20 14.9
68 50
0 0 0
0 5 10 15 20 25 30 35 40 45 50 55
340 250
60
ps
ig
60 44.8
272 200
204 150
40 29.8
30
psi
g
136 100
20 14.9
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TORQUE
T106-F Performance Curve POWER
Nm LB. FT 6 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175 50 37.2
150 psig Inlet Pressure SCFM Nm3/h
150 psig 680 1156
204 150 Maximum Torque 120 psig 550 935
Transmitted by Drive 90 psig 430 731 40 29.8
12
0p 60 psig 310 527
sig
170 125
90 30 22.4
136 100 ps i g
102 75
60 20 14.9
p sig
68 50
10 7.5
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TORQUE
T112-F Performance Curve POWER
Nm LB.FT 12 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175
90 psig
Maximum Torque Inlet Pressure SCFM Nm3/h
Transmitted by Drive 90 psig 860 1462
204 150 60 psig 610 1037 45 33.5
30 psig 370 629
60
ps
170 125 ig
102 75 30
ps i
g
68 50 15 11.2
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
POWER
TORQUE
Nm LB.FT
T109-P Performance Curve HP KW
9 Nozzles, Compressed Air, 9.0:1 RATIO
476 350 80 59.6
Inlet Pressure SCFM Nm3/h
408 300 150 psig 1050 1785
15 120 psig 850 1445
0 DRIVE TORQUE LIMIT 90 psig 670 1139
ps 60 psig 460 782 60 44.8
340 250
12 ig
0p
sig
272 200
90
psi 40 29.8
g
204 150
136 100
20 14.9
60 p
s ig
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
SERVICE MANUAL
LIST OF ILLUSTRATIONS
WARNING NOTE
Failure to properly install the starter or failure to operate You should always have the starter’s Part Number,
it according to instructions provided byTDI may result in Serial Number, Operating Pressure, and Direction of
damage to the starter or engine, or cause personal Rotation information before calling your TDI distributor
injury. DO NOT OPERATE THIS STARTER UNLESS or dealer.
IT IS PROPERLY ATTACHED TO AN ENGINE.
2.4 BENDIX DRIVE ASSEMBLY The other end of the drive unit is mounted into a needle
bearing (54), which is installed in the nose of the drive
The Bendix drive assembly, refer to figure 8, consists of housing.
an inertial engagement drive or “bendix” (57) and drive
housing (61). The bendix is mounted to the output
shaft with two keys and a retaining set screw (53).
Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)
Do not disassemble the starter any further than Remove the six screws (22). Mark position of bendix
necessary to replace a worn or damaged part pinion opening relative to gearbox housing for reference
during reassembly. Pull drive housing (49) from
Always have a complete set of seals and o-rings on gearbox housing (44). If drive housing is too tight, tap it
hand before starting any overall of a Turbotwin T100 with a mallet to loosen.
series starter. Never use old seals or o-rings.
3.3.2 Removal of Bendix Drive
The tools listed in Table 1 are suggested for use by
technicians servicing the Turbotwin T100 series In loaded spring area of drive (57) remove retaining ring
starters. The best results can be expected when these (51) from set screw (53) slot.
tools are used, however the use of other tools are
acceptable. Remove set screw using a flat head screwdriver, Figure
9, and pull the bendix assembly from the starter carrier
TOOL DESCRIPTION TDI/PN shaft.
Spanner wrench 52-20134
Spanner wrench 52-21345 Remove spring (52). This spring fits loosely between
Shaft Removal Tool 2-26945 the bendix assembly and carrier shaft. Remove the
Stage 2 Rotor Puller Tool 52-20076 needle bearing (62), if necessary, by simply tapping out
Carrier Shaft Holding Tool 52-20202 the “welch” plug from the front of the drive housing and
Tool, Bearing Pressing 52-20143 press bearing out.
Tool, Bearing/Seal 2-26943
Table 1. T100 Series Service Tools
3.4 DRIVE/GEARBOX HOUSING Remove bearing (65) from shaft by pressing shaft
while supporting inner race of bearing. Remove
(T106F/T112F)
bearing retainer plate (64).
3.4.1 Removal of Drive Housing
3.4.3 Planet Gear Disassembly
Mark position of bendix pinion opening relative to
Remove snap ring (34) from planet shaft (39) using
turbine housing (26) for reference during reassembly.
snap ring pliers and push shaft through holes in
Per Figure 10, remove the six screws (27). Pull drive
assembly.
housing (69) from turbine housing. If drive housing is
too tight, tap it with a mallet to loosen.
Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.
Mount the carrier shaft assembly on the TDI holding Remove the six screws (27) and lift the gearbox
tool P/N 52-20202 placing the three holes on the assembly from the turbine assembly. If the gearbox
gearbox over the dow pins. Refer to Figure11. assembly is too tight, tap it with a mallet to loosen).
Place TDI tool P/N 52-21345 (Spanner Wrench) over 3.5.2 Gearbox Disassembly
shaft and into slots of retainer nut (67). Hold down
carrier shaft and remove nut. Mount the gearbox on the TDI holding tool P/N 52-
20202 placing the three holes on the gearbox over the
dow pins. Refer to Figure 11.
Remove woodruff keys (40) from shaft by tapping them Slide the planet gear (37) out from the carrier shaft and
with a chisel and hammer remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
With screwdriver remove tang of lockwasher (47) from removal is necessary, simply press bearing out.
slot of retainer nut (48).
3.6 TURBINE HOUSING
Place TDI tool P/N 52-20134 (Spanner Wrench) over
shaft and into slots of retainer nut. Hold gearbox down
3.6.1 Stage 2 Rotor Removal
and remove nut.
Remove the six screws (27) that connect the gearbox
In most cases the gearbox housing (58, D-44) can be
assembly to the turbine housing and separate the two
removed from the carrier shaft (35) by holding shaft
assemblies. Remove the four screws (18) and the
down and pulling directly up on housing. If this is not
clamping plate (32).
the case, press carrier shaft from housing per Figure
12.
Turn the turbine to the (exhaust) end up and remove
the six screws (1), screen support ring (2), and the
screen (3). For the T109P, remove six screws (74) and
Exhaust Cover Housing (75).
Hold the stage 2 rotor (6) and remove the turbine screw
(4) and washer (5).
Remove snap ring (34) from planet shaft (39) and push Figure 13. Turbine Rotor Removal
shaft through holes in assembly.
Page 10 Publication T1-
701
Issued Dec 11, 1998
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, INC.
3.6 Turbine Shaft Removal Separate the stage 2 nozzle assembly (13) from the
turbine assembly (26) by firmly holding the turbine
Using the shaft removal tool P/N 2-26945 per figure 14, assembly, while tapping nozzle 2 with a mallet. If
press on the turbine shaft (33) while supporting the nozzle 2 is too tight, it can be removed by installing two
turbine housing. threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly. Refer
Press the shaft assembly (33) through the aft bearing to Figure 15.
(10) and continue pressing until the shaft assembly is
completely out of the housing (26). Rotate the stage 1 rotor if necessary to allow the jacks
to travel through the large holes in the rotor. The jacks
Remove the woodruff key (16), seal spacer (8), bearing will damage the stage 1 rotor if pressure is applied to
spacer (30), and bearing (10) from the shaft. The them while removing nozzle 2.
bearing can be removed from the shaft by pressing the
shaft through the bearing. Note that if T100 is the The stage 1 rotor (15) may now be removed.
original design (SN: 9501-239 to9611-191), the bearing
will be pressed inside a spacer. Remove the four screws (18) and nozzle 1 (19) from
the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
SECTION 4.0 CLEANING and Clean aluminum parts using the solutions per Table 2;
soak for 5 minutes. Remove parts, rinse in hot water,
INSPECTION
and dry thoroughly.
4.2 INSPECTION
Check all bearing bores for wear and scoring. Bearing
Use Table 3 as a guide to check for acceptable bores shall be free of scoring lines, not to exceed
condition of the parts listed. 0.005² width and 0.005² depth.
Check all threaded parts for galled, crossed stripped, or Check gear teeth and turbine housing ring gear for
broken threads. wear. In general, visually check for spalling, fretting,
surface flaking, chipping, splitting, and corrosion. If
Check all parts for cracks, corrosion, distortion, scoring, wear is apparent, check the gear teeth dimensions in
or general damage. accordance with Table 4. Nicks and dents that cannot
be felt with a .020 inch radius scribe are acceptable.
5.1 GENERAL
The tools listed in Table 1 are suggested for use by
technicians servicing the T100 Series starters. The
best results can be expected when the proper tools are
used, however, use of other tools is acceptable.
CAUTION
Replace all screws , O-rings, lip seals, and bearings
when the T100 Series starter is reassembled. These
parts are included in the overhaul kits shown in
Section 6.0
NOTE
Always press the inner race of a ball bearing when
installing a bearing on a shaft. Always press the outer Figure 17. Pressing Front Turbine Bearing
race of a ball bearing when installing into a housing.
MATERIALS SOURCE
Petroleum Jelly Commercially Available
Parker-O-Ring Lube Commercially Available
Loctite RC290 Commercially Available
Grease, gearbox TDI P/N 9-94121-001
Table 5. Materials for Assembly
CAUTION
The screws that secure the Containment Ring/ Stage 2
Nozzle must have a drop of Loctite RC290 applied to
the threads before being used.
Figure 18. Pressing Spacer onto Bearing
5.2 TURBINE HOUSING T100 is the original design (SN: 9501-239 to 9611-191),
press the spacer (31) onto the outer race of the bearing
5.2.1 Turbine Shaft Installation (10) per Figure 18 by supporting the bearing outer race,
and then press the bearing/spacer (10, 31) onto the
Press the bearing (10) onto the shaft (33) until seated. shaft.
Support the shaft and press on the inner race only with
press tool P/N 2-26943 per Figure 17. Note that if Press the bearing/shaft assembly, keyway end first, into
bearing housing of the turbine housing. Use press tool
P/N 2-26943 if required per Figure 19. Do not press on
the end of the shaft because the load could damage the
balls of the bearing.
Publication T1-701 Page 15
Issued Dec 11, 1998
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT INC.
Install bearing retainer plate (32) and secure with four Install nozzle 1 onto the turbine housing (26). Orient
screws (18). Torque screws to 30 in-lbs. the nozzles facing the air inlet (23). Install four screws
(18) to secure the nozzle. Do not tighten the screws at
this time.
5.2.3 Rotor 1 Installation
Install the woodruff key (large key) (16) for stage 1 rotor
into the shaft (33).
5.2.2 Nozzle 1 Installation Install O-ring (14) onto the outer diameter of nozzle 2.
Install the seal spacer (8) onto the shaft with the small
end facing the aft bearing (10).
Install the wavy spring washer (12) into the bearing bore
of the stage 2 nozzle.
Support the sun gear end of the shaft. Press the aft
bearing (10) onto the shaft by pressing onto the inner
and outer race simultaneously. Use press tool per
Figure 21. Press until bearing is seated.
Place the O-ring (24) into the groove on the air inlet
(23).
Install the 2² NPT air inlet flange (23) and secure with
six screws (22). Tighten the six screws to 170 in-lb.
Press the lip seal (9) into the stage 2 nozzle using press
tool P/N 2-26943 with lip seal facing up.
Install the stage 2 woodruff key (7) into the shaft (33).
Install the stage 2 rotor (6) onto the shaft. Use press
tool P/N 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that the
direction of rotation was oriented properly. This turbine
can be installed backwards.
Install the rotor washer (5) and secure with screws (4).
Tighten screw to 100 in-lb.
Figure 22. Planet Gear Carrier Shaft Assembly
Install the exhaust screen (3) and back plate (2).
Secure with six screws (1). Tighten the screws to 80 in-
lb.
NOTE
Make sure that anti-rotation pins on shafts are properly
located in retaining slots of carrier shaft (35).
Press rear bearing (41) onto carrier shaft (35) using TDI
Tool P/N 52-20143 per Figure 23. Pressing force
should be on the inner race of bearing.
NOTE
Make sure anti-rotation pins on shafts are properly
located in the retaining slots of the carrier shafts (63).
Figure 25. Tightening Retainer Nut
5.5.2 Planetary Carrier Bearing Installation
5.4 DRIVE HOUSING
(T112B/T121B, T112D/T121D, T109P/T115P) Install bearing retainer plate (64) over carrier shaft (63)
5.4.1 Bendix Drive Installation Press bearing (65) onto shaft making sure pressing
force is on inner race of bearing only.
Install two woodruff keys (40). Ensure keys are
properly installed per Figure 26. Place carrier shaft assembly onto TDI Tool P/N 52-
20202, see Figure 27. Thread retainer nut (67) onto
Position bendix assembly (57) on shaft with retainer set shaft (63). Hold carrier assembly down and torque nut
screw (53) removed. Install spring ( 52) between to 600-800 lb.-in. with spanner wrench, TDI Tool P/N
bendix cavity and end of output shaft. Slide bendix over 52-21345.
shaft until set screw hole aligns with set screw hole in
shaft.
3 Screen 2-26148
5 Washer 9-93047
6 Rotor 2 2-26604
14 O-ring 9-90001-050 ü ü ü ü
15 Rotor 1 2-26603
21 O-ring 9-90001-034 ü ü ü ü
24 O-ring 9-90001-037 ü ü ü ü
47 Lockwasher 9-93061-007
56 Screw 14F-31218-020 ü
65 Bearing 9-91356 ü
77 Post 2-27223
Model Overhaul Kit for S/N’s before: 9611-191 Overhaul Kit for S/N’s after: 9611-192
B T10B-27618 T10B-27634
D T10D-27619 T10D-27635
F T10F-27617 T10F-27633
P T10P-27620 T10P-27636
F1 820 AM Pump,
! "#
" # !$
TP 02-04-T01A-001
Note
The pump’s bearings must be lubricated.
Inject grease once per month as follows:
3.0 ounces in the inboard bearing
4.7 ounces in the outboard bearing
DEMCO®
Resilient Seated
Butterfly
Valve
Table of Contents
Bill of Materials
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer
22. 1 Top O-Ring
23. * Stem O-Ring
24. 2 Bearing
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer**
23. * Stem O-Ring
24. 2 Upper bearing
25. 1 Lower bearing
Scope
Demco resilient seated butterfly valves are an pressure and are capable of throttling service.
economical alternative to ball, gate or plug valves They are easily adapted to automatic actuators.
in many applications. They are light weight The Demco butterfly valve is available in flangeless
quarter turn devices with few parts. They are wafer design or single flange tapped lug configu-
designed for bubble tight sealing up to rated ration.
Nameplate Information
4 3 2 1
ITEM STAMP
1 Product ID Number
2 Product Description
3 Body Material
4 Disc Material
5 Seat Material
6 Stem Material
Storage
Demco butterfly valves are shipped in the partial
open position to minimize permanent deforma-
tion of the resilient seat. The disc edge is
contained within the flange faces of the valve to
prevent damage to the sealing area (Figure 4).
Installation
Direction -
Demco butterfly valves are bi-directional and will
operate in any position. Normally the valve is
installed with the upper stem pointing upward
(Figure 5). Elevated valves with gear operators and
chainwheels should be installed with the upper
stem pointing down (Figure 6) so the open-closed
indicator is visible from the ground and the chain
does not drag on the pipe.
End-of-Line Service -
Demco tapped lug butterfly valves are suitable for
liquid service end-of-line applications with down-
Figure 5
stream piping removed (Figure 7). Only weld neck
or socket weld flanges can be used for this service.
Since the upstream pressure is excluded between
the flange and the seat face by the exclusive
Demco flange seal, there is no effective force to
slide the seat downstream.
Gaskets
Flange gaskets are not required nor recommended
for use with positive shut-off Demco butterfly
valves. An integral flange seal is molded into the
edge of the rubber seat eliminating the need for
flange gaskets.
Flanges -
Steel Class 150 ANSI (or MSS SP-44) weld neck, slip-
on, threaded and socket weld as well as stub end
type C flanges are suitable for use with 2 thru 24
Demco butterfly valves. 30 and 36 Demco
butterfly valves fit between ANSI 125 flanges (or
MSS SP-44).
Other flange types may be applicable also, but
should be thoroughly checked to assure proper seal
makeup. Plastic flanges are subject to damage at
installation by over-tightening the bolting and
may deflect or cup resulting in flange leaks.
Figure 7
WAFER BODY
Flange Bolts -
Recommended bolt and stud lengths for installa-
STUDS & HEX NUTS
Figure 10
Troubleshooting
Trouble Probable Cause Remedy
Operator stops are not set properly. Adjust stops to proper setting.
The valve will not open. Disc hits on side of pipe. Check for proper pipe clearance.
The valve is leaking Disc is bent. Replace disc, stems and seat as required.*
around stem.
Correct flange seal leak to prevent fluid
Flange seal is leaking. from migrating behind seat and out stem.
Handle or actuator does not provide Restrain disc with handle or actuator.
The valve closes with line proper restraint.
flow.
Line flow too great. Choose larger valve or slow down flow.
Clockwise rotation of
Gear operator has been rotated 90o on
Gear Operator handwheel
valve top. Rotate gear operator 90o on valve top to put input
opens valve. Open-Shut
Hand-wheel shaft aligns with pipe shaft perpendicular with pipe axis.
indicators do not coincide
(should be perpendicular).
wth valve disc position.
Automatic actuator slams Speed control valves missing or not Install and/or adjust speed control valves.
valve shut or open. adjusted.
NOTES
Manufacturing
http://www.ccvalve.com
59 1/2"
51 1/2"
27 5/8"
D 26 1/8" D
22"
REMOVABLE
FAN GUARD
1" NPT
AIR FLOW
6"
98 9/16"
95 9/16"
97 1/2"
3
LOUVER
2" 3"
8"
64 9/16"
1 15/16" W/ STD KEYWAY
TRAVEL
21"
54 11/16"
41 13/16"
45 3/8"
31 7/8"
24 5/8"
19 3/8"
13 7/16"
B B
6 1/2"
2" NPT
1" NPT
6" OUTRIGGER 8 1/2"
39" 6" 112 1/4" 6" 10"
47" 13 5/8"
59 1/2"
RPM= 567
HP= 16.9 PER FAN
SHAFT END ELEVATION
SIDE ELEVATION
BLADE ANGLE= 19
UNIT: 741501
SEE CL BELOW - THESE DIMENSION (S) ARE SYMETRICAL TAG: 10706
ABOUT THE CENTER OF COOLER. JOB: 07415
DESIGN DESIGN
FLAG SERVICE CL LOUVERS NOZZLES IN NC
NOTES PRESSURE TEMPERATURE
NOZZLES OUT OTHER NOZZLE
AIR COOLED EXCHANGERS, LLC
1 EJW 123.75 N/A 150 PSI 350 Deg F/−20 Deg F (1)2−150RF (1)2−150RF N/A N/A
1. WEIGHT: 5588 POUNDS
SCALE: 1:1 (FIT TO PLOT) DRAWN BY: AID
2. FINISH: ACE std prep. w/ one coat QL-5505 primer
2 IC1 125.75 MANUAL 645 PSI 350 Deg F/−20 Deg F (1)6−300RF (1)6−300RF N/A N/A
DATE: 11/26/2007
ACE MODEL C78−10 CHECKED BY:
A (1)4−600RF A
3 IC2 123.75 W/IC1 1284 PSI 350 Deg F/−20 Deg F (1)4−600RF N/A N/A
3. FAN DRIVEN BY V-BELT DRIVE BY OTHERS CUSTOMER: CAMERON COMPRESSION P.O: 4501434318
4 AC 123.75 W/IC1 1440 PSI 350 Deg F/−20 Deg F (1)3−900RTJ (1)3−900RTJ N/A N/A
4. ASME CODE AND NATIONAL BOARD ON IC1,IC2,AC, BY DATE DESCRIPTION CK’D DRAWING NUMBER REV
07415 −C 0
8 7 6 5 4 3 2 1
AIR COOLED EXCHANGERS, INC.
P.O. BOX 577 - BROKEN ARROW, OKLAHOMA 74013
Ph (918) 251-7477
Fax (918) 258-1833
E-MAIL: MAILHUB@ACE-COOLERS.COM
Fan Make & Model 1 6.5 Dia. 5 Blades 19 deg. Pitch at CLEVIS Fan RPM: 567
MOORE 10000 24 HDVT LEFT HAND Bore with STD Keyway PRICE EACH $3,120.00
Fan Shaft ## 2.1875 Dia. 24.5 Long with 9 in Keyway Fan end 6 in Keyway other end
### ## PRICE EACH $324.00
Idler Shaft 1.9375 Dia. 19 Long with Keyway one end PRICE EACH $289.00
Fan Bearing 2 2.1875 in REXNORD MODEL ZA-2203 PRICE EACH $294.00
Idler Bearing 2 1.9375 in REXNORD MODEL ZA-2115 PRICE EACH $264.00
Electric Motor ### 0 HP 0 RPM 0 Volt 0 Phase 0 Cycle
0 Enclosure 0 Frame Size WITH SlideBase 0
0 PRICE EACH $0.00
Motor Sheave 1 0 O.D. 0 Type 0 Groove 0 Bore PRICE EACH $0.00
Fan Sheave 1 0 O.D. 0 Type 0 Groove 0 Bore PRICE EACH $0.00
V-Belts 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH
0 0 0 PRICE EACH
LOUVER FOR IC1,IC2,AC 0 54.5 IN X 120 IN ALUMINUM MANUAL PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0
0
0
0
Contents
2.0 INSTALLATION .......................................................................................................................... 2
2.2A INSTALL HUB AND AIR SEAL ................................................................................................ 3
2.2B INSTALL HUB AND AIR SEAL ................................................................................................ 4
2.3 INSTALL AND ADJUST BLADES .............................................................................................. 5
2.4 START-UP PROCEDURES .......................................................................................................... 6
3.0 MAINTENANCE ........................................................................................................................ 7
3.2 ANNUAL INSPECTION .................................................................................................................... 8
3.4 WARRANTY ....................................................................................................................................... 9
3.5A PARTS LIST ....................................................................................................................................10
3.5B PARTS LIST .................................................................................................................................... 11
4.0 OPERATION .............................................................................................................................. 12
4.2 BLADE OVERLOAD ......................................................................................................................13
4.3 CAUSES OF IMPROPER BLADE LOADING ..........................................................................14
4.4 CHECKING BLADE LOAD .........................................................................................................15
4.4.1 SAMPLE GRAPH of BLADE ANGLE IN DEGREES ......................................................16
4.5 DAMAGING OPERATING CONDITIONS .................................................................................17
4.5.3 OBSTRUCTIONS ....................................................................................................................18
MOORE FANS LLC, MARCELINE, MO 64658 PHONE (660) 376-3575 FAX (660) 376-2909 E-MAIL info@moorefans.com
INSTALLATION
ABOUT THIS MANUAL ....... before or after unpacking, the delivering carrier
Moore is as interested as are its customers that Moore should be promptly notified so that an inspection
fans operate at top efficiency for many, many years. This
manual has been written to achieve that result and is based may be made by the claims adjustor. It is the
on more than 50 years of experience as a manufacturer of responsibility of the consignee to file damage
axial flow fans. claims with the carrier. Although Moore will not
Moore fans represent the highest degree of axial fan be responsible for shipping damage, it is requested
development and are in all respects, regardless of price, the
finest obtainable for their intended purpose. As for any fine that any damage, even of a minor nature, be re-
equipment, certain precautions are necessary and certain ported to the factory at once.
abuses must be avoided in order to insure the best perform-
ance over the longest period of time If you have any
questions regarding the installation or operation of your
IDENTIFY YOUR FANS FEATURES
Moore fan(s), please contact the Company for assistance. Section 1 consisting of your units specifica-
tions will be found on the Order Information Sheet
INSPECTION attached. Section 2 Getting Started should be
All Moore units are carefully balanced, inspected read carefully before installation begins. Moore
and packed at the factory. If any damage is evident fans have several unique features.
2.0 INSTALLATION
2.1 GETTING STARTED
2.1.1 FAN IDENTIFICATION Moore keeps records indexed by serial and job
Every fan, or group of identical fans, is assigned a Job numbers of all fans produced for at least forty years in
Number. This number will be found on the Order Informa- order to provide proper maintenance advice and infor-
tion Sheet showing fan specifications. A copy is attached to mation on spare parts and replacements.
this manual. If non-identical fans are shipped together, a Job
Number is assigned to each fan or group and a set of 2.1.2 PLANNING THE INSTALLATION
Information Sheets will be included for each Job Number. The sequence given for the installation may be
The Job Number is written in semi-permanent ink on changed if the conditions warrant. For example, the
each blade, hub and air seal. All fan parts bearing the same air seal may be installed on the hub before the hub is
Job Number are entirely interchangeable. (Blades of the installed on the drive shaft. (In fact, for inverted fans,
same Series and Diameter are also interchangeable between it is necessary to install the air seal first.) The instal-
Job Numbers.) lation should be planned before beginning so that the
Fan components covered by more than one Job Num- steps required are taken in the most convenient order.
ber may be crated together. The Job Number that is written If you need information not found here, please contact
on each part, however, will make sorting simple. Moore.
Each individual fan produced by Moore is assigned a Class 10000 fans are suitable for horizontal or vertical
Serial Number. This Serial Number is embossed on a perma- mounting, for electric motor or engine drive and may be
nent metal tag and attached to each fan hub. The Fan designed for clockwise (right hand) or counterclockwise (left
Information Sheet provided for each Job Number lists all of hand) rotation. Some drawings illustrating the installation
the individual Serial Numbers of the identical fans assume vertical mounting and need to be mentally rotated
covered by that Job Number so that, in future years, for horizontal mounting. Be sure to refer to the dimensional
reference to the fan specifications provided will iden- drawing(s) provided. These will illustrate the proper orien-
tify the characteristics of each individual fan. tation of the fan and the rotation direction.
Page 2 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
Q D TYPE HUB (CAST IRON BUSHING) INSTALLATION
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 3
HT BUSHING HUB (ALUMINUM BUSHING) INSTALLATION
Hub installation instructions DO NOT apply lubricant between the bushing bore and the
shaft.
Some Moore Class 10000 hubs are shipped with Moore Installation:
Hi-Torque (HT) Aluminum Bushings. The following Install the bushing in the hub by aligning the threaded
paragraph details the installation procedure for these holes on the I.D. of the hub with the slots on the OD of the
hubs. bushing with the cap screws captured between the bush-
ing and the hub. Insert the bushing in the hub. Using a
Lubrication: hex key wrench, sequentially tighten the socket head cap
If the bushing was pre-installed in the hub at the factory, screws until the bushing is almost fully engaged in the
no further lubrication is required prior to installation. hub. Leave slight play between the bushing and hub to
If the bushing was not installed in the hub at the factory, facilitate installation on the shaft.
it is imperative to apply high quality grease to the Place the hub/bushing on the shaft. (Preferably cap
following surfaces: screw heads will be towards free end of shaft.) Insert the
key, and tighten the setscrew to secure the hub and key to
1. The cap screw threads the shaft. Now begin sequentially tightening the socket
2. The underside of the cap screw heads head cap screws (approximately 2-3 turns per cap screw
3. The bushing taper / hub bore initially) to firmly engage the bushing in the hub and seat
Bushing
the bushing on the shaft. Once the bushing/hub is firmly
Bushing OD Allen Head Hex Key
FAN TYPE RequiredTorque seated on the shaft, continue tightening the cap screws
Bold Size
HUB sequentially until the specified torque, shown in the
U 4" 12 mm 10 mm 50 ft-lb (6.9m-kg)
W 5.5" 16 mm 14 mm 90 ft-lb (12.5m-kg) following table, is reached. DO NOT over-tighten cap
X 5.5 " Long 16 mm 14 mm 135 ft-lb (18.7m-kg) screws as this could cause damage to the hub.
Z 7" 16 mm 14 mm 135 ft-lb (18.7m-kg)
Caution:
If bushing is expected to see frequent oscillating loads (Greater
Bushing than 50% of nominal expected Static Torque), Fan should be
operated for approximately 15 minutes and then re-torque
bushing cap screws.
Cap Screws
To install the airseal:
If the airseal is to be installed on the shaft side of the fan,
RODEND cut out the center to provide clearance for the bushing.
Locate the air seal installation hardware in the plastic bag
AIR SEAL
taped to one of the hub tubes. Install the air seal studs on the
appropriate side of the hub tube. Finger tighten.
RESILIENT HUB TUBE Place one resilient washer on each stud as shown in the
WASHER drawings at left. Place the air seal onto the studs and install the
remaining hardware, following the sequence shown in the
drawings. Do not lubricate this end of the studs.
Note that the diameter of the resilient washers, before
they are compressed, is slightly less than the diameter of the
aluminum washer. Tighten each nut until the resilient washer's
ALUMINUM NUT
diameter is the same as the aluminum washer. Do not
overtighten. Overtighteness exists when the resilient washer
ALUMINUM has expanded in diameter larger than the diameter of the
WASHER aluminum washer.
RESILIENT Note: Some air seals are provided with more mounting
WASHER holes than may be required. This is done intentionally to
AIR SEAL STUD
make the air seals more interchangeable between units.
AIR SEAL INSTALLATION ON HUB For example, an air seal with 8 mounting holes can be used
with either a 4-blade or an 8-blade unit.
Page 4 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
INSTALLATION
CLAMP
ROD
END
HUB
TUBE
R E S I L I E N T
MOUNT
BLADE BOLT
the bolt into the second resilient mount lightly. A 3/4" drive
BEFORE INSTALLING BLADES. . . . torque wrench with a short extension may be used. The blade
Check to see that the hub is level. If the drive shaft is not mounting bolt is supplied from the factory with grease on the
truly horizontal (or vertical), causing the hub to be cocked, it threads and conical face. Do NOT clean the grease from
will be difficult to adjust blade angles accurately. Eccentric ro- the bolt.
tation of the fan can also cause serious vibration problems. Complete the installation of one blade by holding the
If misalignment, vibration or unbalance in the system is blade so that the blade extends straight out from the hub tube.
present, it will be more easily identified and corrected at this Holding the blade in this position, tighten the bolt using a
time. torque wrench set to 200 ft-lb (28 m-kg) making sure the
rod end and the resilient mounts seat.
After installing the first blade, manually rotate the fan
Moore fan blades are carefully balanced to the same moment at the while moving the blade tip in and out to be sure the blade
factory. Any Class 10000 blade of the same series and diameter may clears the ring or throat at all points. When the blade is held
be installed on any hub furnished on the job. They are completely in alignment with the blade tube (that is, straight outward
interchangeable. from the hub), it should clear the fan ring by a distance
Moore Class 10000 Fans are designed for engine adequate to provide for any relative motion between the fan
drive and other applications with the more severe re- wheel and the ring. Excess clearance between the blade tips
quirements of this service. Proper installation, with and the ring, however, should be avoided to prevent backflow
particular attention to tightening nuts to the specified which seriously reduces fan efficiency. If clearance is exces-
torque, is essential to maintain the design integrity of sive, the diameter may be adjusted at this time. See Section
these units. 2.3.2.
Installoneblade:Cleananydirtorgreasefromtherodendand Install the rest of the blades so that they are identical
the surfaces of the resilient mounts. Align the rod end hole with with the first blade. Torque all bolts to 200 ft-lbs (28 m-
the holes in the resilient mounts and insert the blade mount- kg). If blades are installed properly, they will return to their
ing bolt first through the resilient mount with the recess to undisturbed position if the tips are pressed in the axial
accept the bolt head, then through the rod end hole and screw direction with moderate force (10 to 20 lb).
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 5
INSTALLATION
Hubs are shipped from the factory with the rod end set
for the blade angle indicated by the design performance. A
HEAVY DOTTED LINE
change in blade angle is sometimes necessary, however, to
INDICATES LOCATION FOR
adjust to actual site conditions. Failure to adjust the blade angle MEASURING BLADE ANGLE
when required may result in blade overload. The causes of
improper blade loading are explained in Section 4.3 of this
manual. Section 4.4 "Checking Blade Load" provides a simple
method of determining the maximum blade angle allowable
in terms of static pressure vs blade angle. Please refer to these
sections before increasing blade angle.
To adjust, loosen the Clamp Nut just enough to allow
the blade to be turned. Place a inclinometer on the flat surface
of the mounts end as shown in the illustration at right. Turn
the blade until the desired angle is achieved.. Make a
permanent record of the final angle selected and take care
that all blades on the fan are set at the same angle. A typical
adjustment may be +/- 3o. The maximum recommended
blade angle is 30o.
Retighten the Clamp Nut to 18 ft-lbs (2.5 m-kg).
Recheck each blade angle before tightening.
Page 6 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
3.0 MAINTENANCE
3.1 PERIODIC INSPECTION
As with any industrial equipment, before entry into fan chamber, strict adherence to ALL Lock-
out / Tag-out procedures is well advised!
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 7
MAINTENANCE
Page 8 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
3.3.5 THROAT FLUTTER If in doubt that throat flutter is the cause of
Any fan that is effectively moving air at the tips vibration, reduce the angle of the blades until the
of the blades will develop a reduced pressure area (or fan is doing little or no work. If the vibration ceases
suction) on the fan throat or ring at the tip of the under this condition, it is certain that throat flutter
blade. This suction tends to draw the throat toward is present when the blades are loaded.
the tip of each blade, which means that a four blade
fan would tend to draw the throat into something 3.3.6 FIELD BALANCING
approaching a square while a six blade fan would Unbalance in older fans may develop because
draw it into something resembling a hexagon, etc. of some structural change or by installing one new
Since the fan is rotating, the effect on the throat is that blade on an old fan where the existing blades had
of continually drawing it into a rotating polygon. changed in weight in the course of operation.
The resulting throat flutter is frequently mistaken Use wire to attach a small weight in succes-
for fan unbalance. sion to each of the air seal studs until the best
A substantial throat or ring will be sufficiently location for the weight is found. The weight should
rigid that flutter will not exist. A weak or flexible then be increased or decreased until the best bal-
throat, particularly when used with a fan of a low ance is achieved. The permanent weight may then
number of blades, will be greatly affected by this be secured to the stud or hub tube, whichever is the
type of vibration. Throat flutter is easily detected due most convenient for the type and shape of weight
to the fact that it is invariably of a frequency of the fan to be used. One or more pieces of metal shaped like
RPM times the number of blades on the fan. a washer could be placed over the stud, on the hub
Throat flutter will cause no damage to the fan so tube, behind the stud, or over the threaded portion of
long as the throat does not disintegrate and fall into the rod end. Aluminum or stainless weights should be
the fan blades. It may be eliminated by stiffening or used and weights should not be attached to the blade
bracing the throat. skin.
3.4 WARRANTY
MOORE FANS LLC (the Seller) warrants only to Buyer, damage on account of misuse, neglect or accident or
as its purchaser for resale, that the fans manufactured shipping damage, or if repairs or part replacements have
and sold by Seller to Buyer under this Agreement will been made or attempted without Seller's prior written
be free from all defects in material and workmanship authorization. SELLER SHALL NOT BE LIABLE IN ANY EVENT FOR ANY
under ordinary use for a period of two (2) years from INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF THIS OR ANY
the date of shipment or one (1) year from the date the WARRANTY. THIS WARRANTY IS IN LIEU OF ALL OTHER GUARANTEES OR
fan is installed on a customer's premises, whichever EXPRESSED WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING
occurs first. This warranty period shall apply only if THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR
Seller receives written notice of any defect within the A PARTICULAR PURPOSE. DUE TO THE VARIETY OF CONDITIONS UNDER
warranty period. Upon receipt of such notice, Seller, at WHICH THE FANS MAY BE USED, RISKS OF RESULTS OBTAINED FROM USE
its option, may require Buyer to return the fan at OF THE FANS, WHETHER USED ALONE OR IN COMBINATION WITH OTHER
Buyer's cost to Seller for inspection by Seller. If the fan PRODUCTS, IS ENTIRELY BUYER'S. THE ABOVE LIMITATIONS ON DAMAGE
is found to be defective on inspection by Seller, as a sole AND EXCLUSION OR LIMITATION OF IMPLIED WARRANTIES ARE NOT
and exclusive remedy, Seller will, at its option, either APPLICABLE TO THE EXTENT PROHIBITED BY STATE LAW.
repair or replace the fan. This warranty shall not apply to
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 9
MAINTENANCE
1
5
8
3
6
4
7
9 SHOP
DWG. PART
NO. NO. DESCRIPTION
15
1 2883 ROD END CLASS 10000 HEAVY DUTY
10 1 4269 ROD END CLASS 10000 STANDARD DUTY
Page 10 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
8 3
5 6 4
7
12
9 SHOP
DWG. PART
NO. NO. DESCRIPTION
10
1 2883 ROD END CLASS 10000 HEAVY DUTY
1 4269 ROD END CLASS 10000 STANDARD DUTY
11
2 2871 RESILIENT MOUNT, THREADED
14 U BUSHING (4" )
W BUSHING (5.5")
X BUSHING LONG (5.5")
Z BUSHING (7")
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 11
OPERATION
4.0 OPERATION
4.1 AERODYNAMIC ABUSE
4.1.1 ABOUT THIS SECTION . . . . Under such conditions, the unit stresses in the blades
It is widely acknowledged that the kinds of mechanical would not be expected to vary more than plus or minus
abuse described on the preceding pages are destructive for 50%. Fan design based on such assumptions is entirely
all types of operating equipment. It is less well recognized reasonable and, with proper drives and installation con-
that for fans aerodynamic stresses are an even more ditions, has proven highly successful.
serious hazard. This section deals with the causes of destruc-
tive aerodynamic stresses and how they can be avoided.
Although this information is given primarily for the
4.1.3 ABNORMAL CONDITIONS
benefit of operators of Moore equipment, it may be applied
Abnormal operating conditions result in destructive
to fans of any manufacture.
repetitive stresses that can seriously shorten fan life. The
Unlike smaller fans, which are typically furnished
aerodynamic abuses discussed in this section can cause
complete with their surroundings, the large fan wheel is
repeated flexing of the fan blades and hub. Violent displace-
supplied as an unprotected component of the system and is
ment of the resiliently mounted Moore fan blades may
installed in innumerable types of surroundings. Not only do
occur a greater displacement than would occur in rigidly
the types and conditions of the drives for these fan wheels
mounted blades. The resilient mounting, of course, mini-
vary widely, but the entrance and exit conditions and the
mizes the structural unit stresses which would be transmit-
enclosure for the wheel assume a myriad of possible com-
ted to the root of the blade and into the hub and drive.
binations. In designing his product, the manufacturer of fan
Although Moore units may be expected to resist greater
wheels must anticipate the operating conditions based upon
stress than units of conventional design, such repetitive
his knowledge of what is reasonable and customary for the
stresses may exceed the capability of the resilient mounts
industry. He may over-design for abnormal stresses only
to absorb them. If so, fatigue of the mounts and metal may
until the practical limit is reached to avoid excessive weight,
develop, adjusting linkages may wear, and ultimate failure
cost and inefficiency.
becomes a possibility.
Some of the abuses set out in the following text are
4.1.2 NORMAL OPERATING CONDITIONS far less important than others. All of them may occur in
The fan manufacturer assumes a fairly reasonable atmo- varying degrees.
sphere for the operation of his product, including the follow- Specifically, abuse due to serious repetitive stresses
ing: can lead to mount failure and, if carried to extremes, can
The fan selection will be reasonably in line with the require blade replacement. In units of other manufacture
performance the unit is expected to maintain, with an with rigidly mounted blades, repetitive stresses of this type
adequate blade area for the pressure required at the
given RPM. Blades will not be loaded beyond their may lead to blade breakage, probably near the root or at
capacity to maintain air flow. the point of attachment to the hub where stresses are
highest, or may lead to failure of the hub itself. The resilient
A fan ring will be provided that is round, rigid and of mount design, unique with Moore fans, dampens these
a depth at least sufficient to cover the tips of the blades. vibrational forces and results in a fan that is far less
Tip clearances will be uniform and controlled. vulnerable to failure from these conditions than other units
with rigidly mounted blades. Even so, extreme conditions
The approach air will represent a relatively uniform
and axial flow with, of course, some unavoidable can cause damage.
turbulence expected. Adequate open area will be pro- A well-designed fan can be expected to operate for
vided at the inlet of the fan. many years without trouble under normal operation as
described above. The extreme repetitive stresses de-
Major obstructions will not be present at either the scribed below, however, will certainly reduce the life of
inlet or discharge of the fan. the fan, causing failure many years sooner than would
occur if the fan were operated as intended. Fortunately,
The RPM of the fan will be within the design limits.
these destructive conditions are readily observable to
The relative direction and velocity of approaching air someone who is knowledgeable about them, and they
to the blades will be fairly constant and protection will can be corrected with reasonable effort and expense
be provided from extreme wind conditions. once they are observed.
Page 12 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 13
OPERATION
Page 14 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
velocity in the same direction as the rotation of the fan, which the fan, even though it does not reach the full rated pressure.
reduces the relative velocity between the fan blades and the
air by some portion of this rotational velocity. 4.3.5 CONCLUSION
Moore fans are designed in contemplation of a maxi- As can be seen by the various points discussed in this
mum deflection of 50o at the hub, decreasing to a very small section, there are a number of complex factors which tend to
value at the tip. This deflection is considered in the determi- cause fans to be operated in a condition of improper blade
nation of the pressure which may be provided by each blade loading which can shorten fan life or lower efficiency. When
over its full length. If fans are selected, or if conditions exist, blade angles are set to consume the specified horsepower (at
which cause the deflection to exceed 50o at the hub, the velocity the fan shaft), the resulting performance should be very close
of the blades relative to the air is less than anticipated and the to the specified performance. If this is not the case and the
blades will not provide the rated pressure. The test below, problem cannot be identified or corrected, please contact
however, will show the full allowable pressure capability of Moore for assistance.
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 15
OPERATION
1.2 120
SELECTED BLADE ANGLE
1.1 110
.9 90
.8 80
STATIC
.7 PRESSURE 70
FINAL % RATED FAN HP
.6 60
.5 50
.4 40
BLADE ANGLE VS % RATED FAN HP
.3 30
.2 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Note in the chart above that static pressure (and air flow) has angle is 5% below the point where the static pressure curve
reached its maximum at an 11 degree blade setting and blade becomes level. The horsepower curve has been added to illus-
overload is beginning. With further increase in blade angle, trate the point that in an overload condition, horsepower will
anything may happen, as indicated by the dotted extensions increase without increased performance.
into the shaded overload area. Note that the final selected blade
STATIC PRESSURE
Page 16 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
4.5.2 WIND
With a vertically mounted fan blowing outward
into the wind and surrounded by a short fan ring or stack,
high winds may cause some concern. The farther the ring
extends beyond the fan, the less effect would be expected
from wind. It is a fact, however, that wind across the face
of the ring will affect the direction of air flow well down
into the ring. In the case of a fan installed near the outlet hour) with a horizontal component of wind velocity (VW)
of the ring, the direction from axial of the fan discharge of 20 miles per hour. Note that the velocity (VR) of the fan
may be increased by as much as 45O under high wind blade relative to the air varies by a factor of 1.43. The
conditions. blade load varies as the square of this velocity, or 2.05.
THE EFFECT OF AIR LOAD ON HUB AND DRIVE In conventional fans with rigidly attached blades,
Moore fan blades are attached to the hub by a pivot. the bending moment at the shaft due to the air load is equal
As the fan rotates, centrifugal force causes the blades to rise to the load (FA) multiplied by the distance from the fan
(as do the blades of a helicopter). The air load (FA) is centerline to the point of application of the force on the
uniform over the blade, but there is a point (shown on the blade (RF). This moment will be from 2 to 4 times as great
blade in the drawing below) where, if the total load were as that produced by the Moore fan under the same condi-
applied at that point, the effect would be the same. The
resultant of the air load (FA), assumed in this example to
be downward, and the horizontal centrifugal force (FC) is
the force on the blade (FB). The blade automatically posi-
tions.
Also of concern with the conventional fan is the
tions itself in the direction of this force with the result that bending moment due to the air load at the point of
the force is translated inward to the pivot point, as illus- attachment of the blades to the hub since this is usually the
trated by the dotted line. The effect of this arrangement is structurally weakest area of the fan. The moment due to
exactly as if the total air load (FA) were applied at the pivot the air load at this point is the load (FA) times the distance
point rather than at the point outward on the blade. The (D). For the Moore fan, this moment is zero since the
maximum bending moment applied to the shaft by the air blades are attached at the pivot point.
load is equal to the load (FA) multiplied by the distance A more complete discussion of the Moore fan design
from the fan centerline to the pivot point (RP). can be found in The Moore Companys General Catalog.
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 17
OPERATION
In this rather common wind condition, then, it can be through the fan. This area should be distributed reasonably
seen that the blade load on the side where the blade is going uniformly. It would be unwise to attempt to operate a fan
against the wind will be double the load on the side where with one-half or one-third of the fan area completely blanked
the blade is going with the wind. In a 40 mile per hour wind, off. Such a condition would cause stalling of the fan blade
the blade load would vary by a factor greater than 4. In a 60 through one-half the revolution but create a condition of
mile per hour wind, the load would vary by a factor of more overload in the half which was not blocked off. Excessive
than 10! It is obvious that operation under such conditions vibration would result. Any condition which forces the air to
will impose tremendous repetitive loadings on the fan approach the fan in a non-axial direction should be avoided.
blades.
In areas of unusually high wind velocities, it may be 4.5.4 UNEVEN TIP CLEARANCE
advisable to shield the fan in some manner. Where fan rings are out of round or not centered with
the fan, the tip clearance of each blade will vary as it makes
4.5.3 OBSTRUCTIONS a revolution. If tip clearance is tight at one point and excessive
Obstructions of one type or another in the air stream, at another, proper flow will establish itself at the tight point,
ahead of or beind the fan, are to be expected. In fact, it would loading the blade to the very tip, while at the loose point the
be virtually impossible to eliminate all obstructions. Struc- air will flow from the high pressure side of the blade through
tural supporting members, foundations and the like, need the opening between the blade tip and the ring and nullify the
not be of serious concern although all obstructions, even negative pressure on the under side of the blade. This will
small ones, will increase the static pressure and must be unload the blade near the tip within the area of excessive
taken into consideration by the system designer in specify- tip clearance. Under this condition, the blade will load and
ing the fan performance. unload near the tip one or more times per revolution,
The total free area from which the fan can draw air resulting in an undesirable repetitive vibration. Every
should be twice the net area of the fan (fan area minus hub effort should be made to keep the tip clearance to a
area). In other words, the air approaching the inlet of the fan minimum and to have this clearance as constant as pos-
should have no more than half the velocity of the air passing sible around the entire ring.
Page 18 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
Mechanical VBD-IM
Installation and
Maintenance of
V-BELT DRIVES
Po we r i n g Yo u r S u c c e s s
®
Contents
3
4
6
®
1
®
2
®
3
®
Belt Selection
4
®
Classical Minimum*
Belt Section Pitch Diameter
Narrow Minimum
Belt Section Sheave Diameter
5
®
6
®
Safety Tips
7
®
Drive Installation
8
®
9
®
10
®
11
®
12
®
13
®
14
®
15
®
16
®
Ts CROSS SECTION
Per
Strand
(lbs.) 5V 8V BP CP
3V DP BX CX DX
5V1700 5V1800 8V1700 8V1800 BP144 Over CP144 Over All All All
& under & over & under & over & under BP144 & under CP144 Sizes Sizes Sizes
17
®
18
®
19
®
20
®
21
®
Wood’s sheaves are constructed of fine grain, high tensile cast iron, and have been carefully engineered
to assure maximum performance over a long life span. Behind each sheave is one of the most extensive
engineering design and testing programs in the industry.
Alternately, our sizing software, eAjax ™, is available for your use without
charge. It is Windows® based, and user-friendly. If you have access to the
World Wide Web, go to www.aciservicesinc.com/ajax to download a
current version of the software.
WARNING!
_______________________
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 1 2
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12970 13062 13062 13701 14322 14322
Max Gas RL-Tension (lbs): 12298 16853 16853 12905 16653 16653
Max Net RL-Cmpress (lbs): 10128 11477 11477 9841 12852 12852
Max Net RL-Tension (lbs): 9106 14767 14767 10253 15076 15076
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 12.60 13.50 0.00 30.48 13.50 0.00
* HE's VVP Setting (in): 0.00 0.00 0.00 2.75 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 12.11 13.50 10.30 21.22 13.50 10.30
Z-Suction: 0.9944 0.9846 0.9555 0.9927 0.9828 0.9511
Z-Discharge: 0.9924 0.9821 0.9539 0.9903 0.9802 0.9495
Minimum HE VE Suct. (%): 72.5 78.4 100.0 49.0 78.7 100.0
Minimum CE VE Suct. (%): 74.3 100.0 86.0 78.6 100.0 87.5
Suction Press. (psig): 20.0 112.3 358.8 30.0 127.0 396.7
Discharge Press. (psig): 114.6 360.4 900.0 129.5 398.5 900.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 250.8 278.3 252.7 229.3 276.3 239.2
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.79 2.97 2.50 3.27 2.93 2.28
Load Per Stage (BHP): 139.9 122.8 92.6 137.8 135.9 92.4
Load Per Unit (BHP): 355.3 355.3 355.3 366.1 366.1 366.1
Per Unit Flow (BHP/MMscfd): 209.24 209.23 209.23 191.35 191.34 191.34
Flow (MMscfd): 1.70 1.70 1.70 1.91 1.91 1.91
User Notes: Run#1 Run#1 Run#1 Run#2 Run#2 Run#2
Cooler (psi): 2.34=2% 1.62=0% 17.65=2% 2.57=2% 1.83=0% 21.74=2%
VVP Throw#1 (in): 0.00 2.75
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 1 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 3 4
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12993 13196 13196 13289 14196 14196
Max Gas RL-Tension (lbs): 12319 17865 17865 12509 17700 17700
Max Net RL-Cmpress (lbs): 10128 11470 11470 9152 12714 12714
Max Net RL-Tension (lbs): 9128 15518 15518 9932 15754 15754
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 12.60 13.50 0.00 33.73 13.50 0.00
* HE's VVP Setting (in): 0.00 0.00 0.00 3.25 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 12.11 13.50 10.30 22.87 13.50 10.30
Z-Suction: 0.9944 0.9846 0.9551 0.9927 0.9832 0.9517
Z-Discharge: 0.9924 0.9821 0.9541 0.9904 0.9806 0.9506
Minimum HE VE Suct. (%): 72.4 78.3 100.0 45.5 78.5 100.0
Minimum CE VE Suct. (%): 74.3 100.0 85.2 79.2 100.0 86.5
Suction Press. (psig): 20.0 112.5 361.7 30.0 124.0 391.7
Discharge Press. (psig): 114.8 363.3 950.0 126.5 393.4 950.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 251.0 279.3 259.2 226.3 277.7 248.3
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.80 2.98 2.61 3.20 2.95 2.43
Load Per Stage (BHP): 140.0 123.5 97.4 131.8 133.9 97.7
Load Per Unit (BHP): 360.9 360.9 360.9 363.4 363.4 363.4
Per Unit Flow (BHP/MMscfd): 212.62 212.61 212.62 194.63 194.62 194.63
Flow (MMscfd): 1.70 1.70 1.70 1.87 1.87 1.87
User Notes: Run#4 Run#4 Run#4 Run#5 Run#5 Run#5
Cooler (psi): 2.34=2% 1.61=0% 16.81=2% 2.50=2% 1.77=0% 19.83=2%
VVP Throw#1 (in): 0.00 3.25
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 2 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 5 6
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 13015 13328 13328 13101 14203 14203
Max Gas RL-Tension (lbs): 12341 18881 18881 12328 18732 18732
Max Net RL-Cmpress (lbs): 10129 11609 11609 8887 12598 12598
Max Net RL-Tension (lbs): 9151 16344 16344 9837 16541 16541
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 12.60 13.50 0.00 35.35 13.50 0.00
* HE's VVP Setting (in): 0.00 0.00 0.00 3.50 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 12.11 13.50 10.30 23.70 13.50 10.30
Z-Suction: 0.9944 0.9845 0.9548 0.9927 0.9833 0.9518
Z-Discharge: 0.9924 0.9820 0.9544 0.9904 0.9807 0.9513
Minimum HE VE Suct. (%): 72.4 78.1 100.0 43.7 78.3 100.0
Minimum CE VE Suct. (%): 74.3 100.0 84.5 79.4 100.0 85.6
Suction Press. (psig): 20.0 112.6 364.5 30.0 122.7 390.7
Discharge Press. (psig): 115.0 366.1 1000.0 125.1 392.4 1000.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 251.2 280.2 265.3 224.9 278.8 255.7
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.80 3.00 2.72 3.17 2.98 2.55
Load Per Stage (BHP): 140.1 124.1 101.9 129.0 133.2 102.6
Load Per Unit (BHP): 366.1 366.1 366.1 364.9 364.9 364.9
Per Unit Flow (BHP/MMscfd): 215.87 215.86 215.86 197.81 197.81 197.81
Flow (MMscfd): 1.70 1.70 1.70 1.84 1.84 1.84
User Notes: Run#7 Run#7 Run#7 Run#8 Run#8 Run#8
Cooler (psi): 2.33=2% 1.59=0% 16.05=2% 2.47=2% 1.73=0% 18.53=2%
VVP Throw#1 (in): 0.00 3.50
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 3 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 7 8
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12794 13308 13308 12918 14211 14211
Max Gas RL-Tension (lbs): 12128 19926 19926 12151 19768 19768
Max Net RL-Cmpress (lbs): 9843 11586 11586 8641 12548 12548
Max Net RL-Tension (lbs): 9009 17067 17067 9662 17239 17239
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 14.23 13.50 0.00 36.98 13.50 0.00
* HE's VVP Setting (in): 0.25 0.00 0.00 3.75 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 12.94 13.50 10.30 24.53 13.50 10.30
Z-Suction: 0.9944 0.9847 0.9550 0.9927 0.9835 0.9519
Z-Discharge: 0.9924 0.9823 0.9553 0.9904 0.9809 0.9521
Minimum HE VE Suct. (%): 69.8 77.9 100.0 42.0 78.2 100.0
Minimum CE VE Suct. (%): 74.6 100.0 83.6 79.7 100.0 84.8
Suction Press. (psig): 20.0 111.1 362.8 30.0 121.3 389.8
Discharge Press. (psig): 113.4 364.4 1050.0 123.8 391.5 1050.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 249.3 281.4 273.0 223.5 279.9 262.9
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.75 3.03 2.86 3.14 3.00 2.68
Load Per Stage (BHP): 136.4 123.2 106.1 126.3 132.5 107.2
Load Per Unit (BHP): 365.7 365.7 365.7 366.1 366.1 366.1
Per Unit Flow (BHP/MMscfd): 219.01 219.01 219.01 200.90 200.90 200.90
Flow (MMscfd): 1.67 1.67 1.67 1.82 1.82 1.82
User Notes: Run#10 Run#10 Run#10 Run#11 Run#11 Run#11
Cooler (psi): 2.29=2% 1.55=0% 14.94=1% 2.43=2% 1.70=0% 17.36=2%
VVP Throw#1 (in): 0.25 3.75
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 4 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 9 10
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12580 13293 13293 12742 14219 14219
Max Gas RL-Tension (lbs): 11922 20976 20976 11981 20807 20807
Max Net RL-Cmpress (lbs): 9503 11426 11426 8335 12555 12555
Max Net RL-Tension (lbs): 8807 17910 17910 9581 18062 18062
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 15.85 13.50 0.00 38.60 13.50 0.00
* HE's VVP Setting (in): 0.50 0.00 0.00 4.00 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 13.77 13.50 10.30 25.36 13.50 10.30
Z-Suction: 0.9944 0.9849 0.9552 0.9927 0.9836 0.9520
Z-Discharge: 0.9924 0.9825 0.9563 0.9904 0.9811 0.9529
Minimum HE VE Suct. (%): 67.2 77.6 100.0 40.4 78.0 100.0
Minimum CE VE Suct. (%): 75.0 100.0 82.6 79.9 100.0 84.0
Suction Press. (psig): 20.0 109.5 361.2 30.0 120.1 388.9
Discharge Press. (psig): 111.8 362.7 1100.0 122.5 390.6 1100.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 247.5 282.6 280.4 222.2 281.0 269.9
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.71 3.05 3.01 3.11 3.02 2.81
Load Per Stage (BHP): 133.0 122.2 109.9 123.7 131.9 111.5
Load Per Unit (BHP): 365.1 365.1 365.1 367.1 367.1 367.1
Per Unit Flow (BHP/MMscfd): 222.06 222.06 222.06 203.90 203.90 203.90
Flow (MMscfd): 1.64 1.64 1.64 1.80 1.80 1.80
User Notes: Run#13 Run#13 Run#13 Run#14 Run#14 Run#14
Cooler (psi): 2.25=2% 1.52=0% 13.94=1% 2.40=2% 1.67=0% 16.30=1%
VVP Throw#1 (in): 0.50 4.00
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 5 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 11 12
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12376 13301 13301 12386 14116 14116
Max Gas RL-Tension (lbs): 11726 22027 22027 11639 21874 21874
Max Net RL-Cmpress (lbs): 9159 11396 11396 7765 12352 12352
Max Net RL-Tension (lbs): 8686 18764 18764 9277 18919 18919
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 17.48 13.50 0.00 41.85 13.50 0.00
* HE's VVP Setting (in): 0.75 0.00 0.00 4.50 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 14.59 13.50 10.30 27.01 13.50 10.30
Z-Suction: 0.9944 0.9851 0.9553 0.9927 0.9839 0.9525
Z-Discharge: 0.9924 0.9827 0.9572 0.9904 0.9814 0.9542
Minimum HE VE Suct. (%): 64.8 77.4 100.0 37.3 77.7 100.0
Minimum CE VE Suct. (%): 75.4 100.0 81.6 80.4 100.0 83.0
Suction Press. (psig): 20.0 108.1 360.2 30.0 117.5 384.7
Discharge Press. (psig): 110.3 361.7 1150.0 119.9 386.3 1150.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 245.8 284.0 287.3 219.5 282.3 277.9
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.66 3.08 3.15 3.05 3.04 2.96
Load Per Stage (BHP): 129.6 121.4 113.3 118.7 130.0 115.3
Load Per Unit (BHP): 364.3 364.3 364.3 364.0 364.0 364.0
Per Unit Flow (BHP/MMscfd): 225.03 225.02 225.03 206.86 206.86 206.87
Flow (MMscfd): 1.62 1.62 1.62 1.76 1.76 1.76
User Notes: Run#16 Run#16 Run#16 Run#17 Run#17 Run#17
Cooler (psi): 2.21=2% 1.48=0% 13.04=1% 2.34=2% 1.62=0% 15.09=1%
VVP Throw#1 (in): 0.75 4.50
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 6 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 13 14
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12179 13313 13313 12226 14144 14144
Max Gas RL-Tension (lbs): 11536 23083 23083 11485 22916 22916
Max Net RL-Cmpress (lbs): 8822 11405 11405 7531 12291 12291
Max Net RL-Tension (lbs): 8498 19628 19628 9174 19760 19760
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 19.10 13.50 0.00 43.48 13.50 0.00
* HE's VVP Setting (in): 1.00 0.00 0.00 4.75 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 15.42 13.50 10.30 27.84 13.50 10.30
Z-Suction: 0.9944 0.9853 0.9554 0.9927 0.9841 0.9525
Z-Discharge: 0.9924 0.9828 0.9582 0.9904 0.9816 0.9551
Minimum HE VE Suct. (%): 62.4 77.1 100.0 35.7 77.5 100.0
Minimum CE VE Suct. (%): 75.7 100.0 80.6 80.6 100.0 82.1
Suction Press. (psig): 20.0 106.7 359.2 30.0 116.4 384.3
Discharge Press. (psig): 108.8 360.7 1200.0 118.7 385.9 1200.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 244.1 285.4 294.1 218.2 283.5 284.3
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.62 3.11 3.29 3.02 3.07 3.08
Load Per Stage (BHP): 126.4 120.6 116.4 116.3 129.4 119.0
Load Per Unit (BHP): 363.4 363.4 363.4 364.7 364.7 364.7
Per Unit Flow (BHP/MMscfd): 227.92 227.92 227.91 209.70 209.70 209.70
Flow (MMscfd): 1.59 1.59 1.59 1.74 1.74 1.74
User Notes: Run#19 Run#19 Run#19 Run#20 Run#20 Run#20
Cooler (psi): 2.17=2% 1.45=0% 12.29=1% 2.31=2% 1.58=0% 14.18=1%
VVP Throw#1 (in): 1.00 4.75
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 7 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 15 16
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 11988 13325 13325 12069 14177 14177
Max Gas RL-Tension (lbs): 11352 24136 24136 11334 23961 23961
Max Net RL-Cmpress (lbs): 8493 11238 11238 7270 12325 12325
Max Net RL-Tension (lbs): 8378 20500 20500 8946 20610 20610
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 20.73 13.50 0.00 45.10 13.50 0.00
* HE's VVP Setting (in): 1.25 0.00 0.00 5.00 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 16.25 13.50 10.30 28.67 13.50 10.30
Z-Suction: 0.9944 0.9854 0.9555 0.9927 0.9842 0.9526
Z-Discharge: 0.9924 0.9830 0.9592 0.9904 0.9817 0.9561
Minimum HE VE Suct. (%): 60.0 76.9 100.0 34.2 77.2 100.0
Minimum CE VE Suct. (%): 76.0 100.0 79.6 80.8 100.0 81.2
Suction Press. (psig): 20.0 105.3 358.4 30.0 115.3 384.1
Discharge Press. (psig): 107.4 359.8 1250.0 117.5 385.6 1250.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 242.4 286.8 300.6 217.0 284.7 290.4
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.58 3.13 3.43 2.99 3.09 3.21
Load Per Stage (BHP): 123.3 119.9 119.3 114.0 128.9 122.3
Load Per Unit (BHP): 362.5 362.5 362.5 365.2 365.2 365.2
Per Unit Flow (BHP/MMscfd): 230.73 230.73 230.72 212.46 212.46 212.46
Flow (MMscfd): 1.57 1.57 1.57 1.72 1.72 1.72
User Notes: Run#22 Run#22 Run#22 Run#23 Run#23 Run#23
Cooler (psi): 2.13=2% 1.41=0% 11.49=1% 2.28=2% 1.55=0% 13.33=1%
VVP Throw#1 (in): 1.25 5.00
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 8 of 9
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11DAEAT [9.5]/[5.75] (HE equipped with a manual VVP.) {Plate Valves}
ARRANGEMENT: One Double Acting Cylinder Stage-1, One Tandem Cylinder for Stages 2 & 3.
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 17 18
============================================================================================
Stage : Throw: 1 : 1 2 : 2 3 : 2 1 : 1 2 : 2 3 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 0 0 : 1 1 : 1 1 : 0 0 : 1
* Cyl. Bore Diameter (in): 13.00 9.50 5.75 13.00 9.50 5.75
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 12011 13464 13464 11914 14211 14211
Max Gas RL-Tension (lbs): 11374 25165 25165 11185 25008 25008
Max Net RL-Cmpress (lbs): 8517 11384 11384 6987 12283 12283
Max Net RL-Tension (lbs): 8378 21446 21446 8739 21554 21554
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 13.50 0.00 12.60 13.50 0.00
* HE Set Clearance (%): 20.73 13.50 0.00 46.73 13.50 0.00
* HE's VVP Setting (in): 1.25 0.00 0.00 5.25 0.00 0.00
* CE Clearance (%): 11.60 0.00 10.30 11.60 0.00 10.30
* FC Clearance (%): 16.25 13.50 10.30 29.49 13.50 10.30
Z-Suction: 0.9944 0.9854 0.9552 0.9927 0.9844 0.9526
Z-Discharge: 0.9924 0.9830 0.9598 0.9905 0.9819 0.9571
Minimum HE VE Suct. (%): 59.9 76.7 100.0 32.7 77.0 100.0
Minimum CE VE Suct. (%): 76.0 100.0 78.9 81.0 100.0 80.3
Suction Press. (psig): 20.0 105.5 361.4 30.0 114.2 383.8
Discharge Press. (psig): 107.6 362.8 1300.0 116.4 385.3 1300.0
Suction Temp. (°F): 80.0 130.0 130.0 80.0 130.0 130.0
Discharge Temp. (°F): 242.6 287.7 305.3 215.8 285.9 296.4
Cooler Temp. (°F): 135.0 135.0 125.0 135.0 135.0 125.0
Compression Ratio: 3.58 3.15 3.53 2.97 3.12 3.34
Load Per Stage (BHP): 123.4 120.5 122.5 111.7 128.4 125.4
Load Per Unit (BHP): 366.3 366.3 366.3 365.5 365.5 365.5
Per Unit Flow (BHP/MMscfd): 233.39 233.39 233.39 215.15 215.15 215.15
Flow (MMscfd): 1.57 1.57 1.57 1.70 1.70 1.70
User Notes: Run#25 Run#25 Run#25 Run#26 Run#26 Run#26
Cooler (psi): 2.13=2% 1.40=0% 11.05=1% 2.24=2% 1.52=0% 12.55=1%
VVP Throw#1 (in): 1.25 5.25
VVP Throw#2 (in): 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 9 of 9
13" YK11FA Compressor Cylinder with Poppet Valves
Assembly # FA-0000
Asssembly # FA-0000
13" YK11FA Compressor Cylinder with Poppet Valves
Assembly # FA-0000
Asssembly # FA-0000
9.5" x 5.75" YK11DAEAT Compressor Cylinder
Assembly # DAECT-0000
Description **
Series L1100 and L1200 Liquid Level Switches are float activated to
WARNING operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT valves or similar devices. This model screws directly into the vessel or can be
✔ Disconnect all electrical power to the machine. mounted via an external float chamber. It cannot be used with weld collar 15050375.
✔ Make sure the machine cannot operate during installation. Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
✔ Follow all safety warnings of the machine manufacturer.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
✔ Read and follow all installation instructions. L1200NDVOR series carry Canadian Registration Number OF1476.2.
✔ OBSERVE all pressure and electrical ratings and require- Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
ments for the devices and the operating environment. pneumatic input signal to cause an orifice to open or close allowing liquid
✔ BE SURE all pressure HAS BEEN REMOVED from the condensate to be drained from a pressure vessel. A pop up button indicates valve
vessel before opening any pressure connections. open/closed. Stainless steel versions available.
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Pressure Manual Valve
Inlet Port Operator
1/2 NPT 1-1/2 NPT Float travel between Operate 1/8 in.-27 NPT
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-5/8 in. w/ float at horizontal centerline
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
Weep Hole Valve Open/Closed
Union Indicator Button
Electrical installation to be done by
qualified person according to the NEC.
F Drain
Connection C
E D
Plug Seal G (dimension shown
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
NOTE: Dimensions are in inches and (millimeters)
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Direct Installation into the Wall of the positioned away from the tank wall.
Pressure Vessel 2. A tee is typically installed at the bottom of the lower 1 inch
1. Determine that the float travel is not pipe riser to allow draining of the float
obstructed by the coupling in chamber for servicing or replacement.
the vessel wall, internal Tank
Wall NOTE: A typical installation Float
baffles, etc. with Blocking and Bleed valves is Chamber
Do NOT use more than shown at right. Tank
Block
one arm extension P/N Valves
3. Install the L1200 or
15050395.
L1200N
2. BE SURE that the float Explosion proof Level
Level conduit seal in the 2 NPT connection Switch
and extension are tight Switch where required. of Tee
and that the lock washer is the float chamber.
in place. Bleed
BE SURE float travel Valve
3. Before installing the level is not restricted and that the Explosion proof
switch a suitable pipe thread sealant float is tight onto conduit seal
is recommended. Screw the unit directly into the threaded where required.
the float shaft.
connection in the wall of the pressure vessel. 4. To complete installation and
4. Be sure that the electrical connection is positioned at the wiring, follow the instructions for
bottom. For L1200N the 1/8 NPT pneumatic connection mounting directly into wall of the vessel and for wiring.
should be on top (the 1/4 NPT vent connection should be on
the bottom). See “Pneumatic models” section for further Pneumatic Models
instructions for the L1200N. 1. All pneumatic models
5. Make the electrical wiring connections according to operate on the vent Filter/Regulator
appropriate wiring diagrams for the alarm or shutdown principle. The Tank
New Dump Valve
system to be used. The electrical connection is 1/2-14 NPT. pneumatic signal Pneumatic Operator Assembly
p/n 15010216
Electrical wiring and conduit should be installed by qualified source MUST BE Signal
personnel according to the NEC. CLEAN AND DRY.
6. BE SURE all electrical connections are insulated and the The input pneumatic MURPHYGAGE®
cover is fully installed before reconnecting electrical power. signal must be
7. BE SURE all pressure connections are tight before regulated between 30
pressurizing the system. and 70 psi (207-483 L1200N
kPa) [2.07-4.83 bar].
Installation with a Weld If produced gas is used as the
Collar Tank Wall
signal source, it should be taken
1. The weld collar, P/N after gas passes through the final scrubber.
15050375, must be welded Weld Collar A suitable filter must be positioned before the L1200NDVO
into the wall of the to prevent liquids and/or particulates from entering the dump
pressure vessel according valve operator.
to code standards and NOTE: Check filter periodically for wear and tear and
good welding practices. elements that hamper the flow of the pneumatic signal.
L1200 2. All pressure connections must be tight and maintained tight
2. Follow above instructions
for installation directly into so as not to leak air/gas.
the wall of the pressure Explosion proof 3. Valve seat adjustment can be made if air/gas begins to leak.
conduit seal
vessel. where required. Care should be taken when adjusting as only slight movement
3. NOTE: Weld collar 15050375 can is necessary to stop the leakage; excessive force will bind the
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External L1200N
Hex Socket Set Screw
Float Chamber 15051098 • loosen for adjustment
• tighten after adjustment
CAUTION: USE “NON SPARKING TOOLING”.
Hex Adjustment Nut
1. Install the float chamber 15051098 on the outside wall of the • turn left until air Trip Cam (float down)
seepage stops • should be in
pressure vessel using 1 NPT piping. Position the 2 NPT • Caution: only slight this position
adjustment is needed—too • non-adjustable
threaded connection at the height where you want the level much will lock up mechanism
switch to operate. The 2 NPT threaded connection must be
Installation 00-02-0175 page 4 of 6
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation
As condensate rises in the scrubber, the float on
Typical/Scrubber/Separators
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter VESSEL
the dump valve pilot chamber. Once the pressure Minimum control
Rising Level Shutdown
enters the pilot chamber it forces the diaphragm L1200 (with snap-switch) pressure 30 psi
(207 kPa) [2.07 bar]
and valve stem forward thus opening the valve seat Air Supply Maximum
300 psi (2.07 MPa)
(valve open/closed indicator button pops out) and [20.70 bar]
releasing condensate through the valve stem and Explosion proof
conduit seal required
out the drain. As the condensate level drops, the for Class I. Div 1, not
Filter/Regulator
required for intrinsically
L1200NDVOR pneumatic valve closes to shut off safe or non-incendive L1200NDVOR
with MURPHYGAGE®
circuits like FWM TTD.
the pressure to the dump valve causing it to close. Dump Valve
Electrical Rising Operator
If for any reason the condensate continues to rise Level Minimum control pressure
Conduit 30 psi (207 kPa) [2.07 bar]
Trips Union
beyond normal dump levels, model L1200 DVO
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the DVU Series Dump Valve
4-1/2 in
(114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar].
2 NPT
Operating Temperature: 400°F (204°C).
2-11.5 NPT
1/2-20 UNF-2B
(4 places)
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
NOTE
If pressure or fluid comes out the weep
hole of the union nut, either the o-ring
under the union nut is leaking, or the
packing could be leaking through the
internal weep hole above that o-ring.
Murphy DVU175
Dump Valve Assembly
TP 00-06-T01A-310
Murphy DVU175 Dump Valve Assembly
TP 00-06-T01A-310
WARNING Pressure
Inlet Port
A
Manual Valve
Operator
1/8 in.-27 NPT
Description
The DVU Series models are pneumatically controlled dump valves. F Drain
The valves open and close automatically by pneumatic control from a Connection C
Murphy L1200NDVOR or similar level controller and dump valve opera-
E D
tor. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi
(207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] Plug Seal G (dimension shown
for reference only)
vessel pressure (depending on the model).
A key benefit of this design is a hex union that provides the ability
to replace the seat without removing the valve from piping.
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
Fig. 1 Control Pressure vs. Working Pressure DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
60
50 Specifications
40
DVU2105 DVU150/175 Operating Temperature: -30 to 250°F (-34.4 to +121°C)
30 Valve Operating Pressure: Refer to chart, Fig 1.
20
Maximum Process Pressure:
10 DVU2120: 2000 psi (13.8 MPa) [138 bar].
0 500 1000 1500 2000 DVU2115: 1500 psi (10.3 MPa) [103 bar].
Vessel Pressure (PSIG) DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Model Inlet Outlet Trim Size
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
DVU2120 2 NPT 1 NPT 0.436 in. (11 mm) Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
DVU2115 2 NPT 1 NPT 0.576 in. (15 mm) Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
DVU2105 2 NPT 1 NPT 0.859 in. (22 mm) Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
DVU175 1 NPT 3/4 NPT 0.359 in. (9 mm) Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
DVU150 1 NPT 1/2 NPT 0.359 in. (9 mm)
1/8 NPT threaded connection of the pressure inlet port (on Weep Hole
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the Drain
condensate out line. Use pipe thread sealant on all the con- Connection
nections.
Union
Condensate Out
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD 6. Using a back-up wrench on the plug, remove the stem nut on the shaft
ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED under the plug. Once the stem nut is broken loose, the 9/16” head main-
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
tenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSI- removed. All soft seals should be replaced. Refer to kit part numbers
BLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME under service parts on page 4.
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED. Replacing the Diaphragm
6A. If the diaphragm is to be replaced, all preceding steps have to be
Suggested Tools (Sizes listed are wrench openings. done. Additionally, do the following:
Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm
flat edge screwdriver with 1/4” blade width, can also be used .) spring to relax, and the stem to retract. Make alignment marks on
Model Valve Body Union Nut Plug Seal Hex Stem Nut the top and bottom halves of the diaphragm assembly for align-
DVU2120 3” 3” 7/8” 1/2” ment during re-assembly.
DVU2115 3” 3” 1” 1/2” 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
DVU2105 3” 3” 1-1/4” 1/2” together.
DVU150/DVU175 2-1/4” 2-1/4” 3/4” 3/8” 6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
Replacing the Plug and Seat 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
1. Close the pressure block valves (suction & discharge valves) on the inlet or 1” round nut on the bottom of the diaphragm assembly to be
and outlet of the skid. Lock them closed if possible. accessible to a wrench and not have the spring interfere. If it is
2. Open the blowdown valve to remove pressure from the unit. Lock the desired to replace the packing, pull the stem all the way out. The
blowdown valve open if possible. packing can be easily removed using a small screwdriver to pry the
3. After taking all possible precautions to insure there is no pressure in the packing out. The new packing can be simply pressed in, making
vessel. (If the condensate line is pressurized, it must also be blocked and sure the orientation of the packing installed is the same as the ori-
locked.) Open the manual drain valve so it bleeds into the vessel so it entation of the packing removed. The packing is wider toward the
can also be bled down. Disconnect the pneumatic input signal connection plug end. You will have to use the seat to hold the packing in place
after insuring it also has been de-pressurized. when re-inserting the stem.
4. Using a back-up wrench on the valve body, with a quick "breaking" 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a
action loosen the union nut on the valve. There is a "weep" hole in the wrench to loosen and remove the 1/2" nut on top of the diaphragm.
nut. If at any time while loosening and taking off the nut pressure is The diaphragm can now be removed and replaced.
escaping through the "weep" hole, immediately stop loosening the nut. 6G. With the new diaphragm in place and the 1/2" nut tightened, place
Retighten the nut and check the preceding procedures to ensure the pres- the assembly, diaphragm down on a clean, smooth sturdy surface.
sure is bled off the vessel. Never remove the assembly if pressure is 6H. Have the seat, plug, washers and stem nut handy (if any of these
coming through the weep hole. See Figure 4 on page 2.
parts are to be replaced, use the old parts for this procedure). Press
5. With the upper assembly removed from the vessel the plug and/or seat can
down evenly and smoothly on the bottom of the diaphragm assem-
be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of
bly to cause stem to come up. Place the seat and plug in place.
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN. Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
Fig. 5 Stem O-Ring Seals 6J. Align the diaphragm holes to the bolt holes (bottom half of the
Plug Seat Stem Packing Against Outlet housing). Install the upper diaphragm housing using the alignment
Washer(s)* marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180° around to the next bolt,
then either 120°or 240° around to the next bolt and so forth until
all 8 bolts are evenly tight.
Stem O-Ring 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem
Nut Crush Washer Seal Seat butts into here out until the 9/16"bolt stops – DO NOT OVERTIGHTEN.
*Number of washers varies depending on the model from 1 to 3. 6L. Remove the stem nut holding the plug. (If old parts were used, pre-
pare to install the new parts now.)
Seal Washer Maintenance 7. Install the seat and plug. Place the O-ring on the stem, followed by the
Fig. 6 Bolt Diaphragm
Pressure Inlet washer and stem nut.
Housing 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one
Diaphragm 1/2" Nut
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16” head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
Backup leaking through the internal weep hole above that O-ring.
1-1/8" or Diaphragm 10. The assembly is ready to be re-installed. Check for relative position of
Plate Spring
1" round nut Stem Assembly the pneumatic input signal connections before tightening the union nut.
Fig. 7 Pressure vs. Flow for DVU150 and DVU175 models only
250
250
200
200
150
150
Pressure (psid)
100
100
50
50
0
0 5 10 15 20 25 30 35 40 45
Flow (gpm)
SERVICE PARTS
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
W-K-M®
DynaSeal®
210A / 210L
Ball Valve
Table of Contents
Scope ........................................ 1
Nametag Information ............. 2
Storage ..................................... 2
Installation ............................... 2
Operation ................................. 3
Routine Maintenance ............. 3
Troubleshooting ...................... 3
11
Item Description
1 Body 10
2 Grease Fitting1 12
3 Seat O-Ring2 9
4 Seat Ring
5 Ball 8
6 Tailpiece Gasket 13
7 Tailpiece
8 Stem 14
9 Stem Seal
10 Stem O-Rings 24
16
2
15
11 Handle3
12 Lock Nut3 (or Retainer Clip)
13 Retainer Ring
14 Locking Plate
15 Stop Pin
1
Old option (discontinued 1998), not on all valves.
00
20
2
Used with old style delrin seat with notched back. New CW
P
43 delrin seat does not require o-ring, nor does the
02 or 42 teflon seat.
3
Optional
1 2 3 4 5 4 3 6 7
Scope
The W-K-M DynaSeal 210 floating ball valve is a 2 piece, threaded end valve design.The 210A is
rugged, but economical ductile iron ball valve ideal offered in sizes 1 to 4x 3and pressure ratings
for oilfield applications. It has deep-pocketed seats, 1000 psi, 1500 psi and 2000 psi. The 210L is offered
double O ring stem seals and is available with API in 2, 3 and 4 reduced port sizes with a maximum
Line Pipe threaded outlets. The 210A and 210L are a 1000 psi pressure rating.
Nametag Information
1 2
Item Description
CWP:
WO: 1 Maximum cold working pressure
2 Work order number
DESC:
3 Assembly part number
P/N REV. 4 NACE compliance mark
5 Valve size and type
(model and body trim designation
3 4 5 6
6 Revision level
Storage
After valves are assembled and tested, they are body and the other on the adjacent pipe. (ie. DO
placed in the full open position, bores are NOT apply wrench to the body section when making
greased and end protectors are installed. This up pipe to the tailpiece as this may result in break-
will provide adequate protection for indoor ing loose the threaded tailpiece-tobody joint).
storage. Extended outdoor storage requires Conventional pipe thread compound is recommended
periodic inspection and the addition of a corro- when installing 210, ductile ball valves. Teflon tape
sion inhibitor. Contact your CCV representative can cause threads to gall. Field testing, if performed
for extended storage guidelines. Valves should after the valve has been properly installed into the
only be stored in the full open or full close line, should be done in accordance with the following
position to prevent seat distortion. procedure:
Operation
DynaSeal 210 ball valves operate from fully open to lubricators (if recommended by the actuator
fully close by a 90 degree turn of the handle. The manufacturer) are installed prior to valve and
handle aligned with the pipe always means the valve actuator installation. Should any maintenance
is open and with the handle perpendicular to the be necessary, obtain the part number from the
pipe means the valve is closed. Additionally, the units nameplate and contact Cooper Cameron
stems have flats that align the handle and can be Valves or the nearest representative.
used to indicate ball position. The bore of the ball is
parallel with the faces of the stem flats.
Warning: Valves should be placed in a partially open position prior to working on a valve or removing
it from service to vent pressure or drain product that may be trapped in the body cavity. When remov-
ing threaded end valves from the line, apply wrenches in the same manner used for installation and
NOT to the valve body section as this may result in breaking loose the threaded tailpiece to body joint.
Troubleshooting Chart
Trouble Probable Cause Remedy
a. Iced up due to restricted flow or a. Flush out with warm material.
low temperatures.
b. Pressure locked. (Condition in b. Reduce valve temperature or pressurize line to rated
Will not open or close
which the body pressure exceeds working pressure to reduce pressure differential
the line pressure by an excessive sufficient to operate valve.
amount)
a. Worn or damaged seats and/or a. Replace worn parts* (Requires valve removal and
ball. disassembly)
Will not seal properly
b. Foreign matter between seat and b. Operate several times to wipe clean.
ball.
c. Operator stops not set properly. c. Adjust stops to proper setting.
Leaking around stem a. Worn or damaged stem seals. a. Replace O-ring stem seals.* (Requires valve removal
and disassembly)
Headquarters
Phone: 281-499-8511
800-323-9160
Fax: 281-499-6965
USA
Phone: 405-631-1321
Fax: 405-629-0420
Scotland
Phone: 44-1506-444-000
Fax: 44-1224-783-355
http://www.ccvalve.com
Description **
Series L1100 and L1200 Liquid Level Switches are float activated to
WARNING operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT valves or similar devices. This model screws directly into the vessel or can be
✔ Disconnect all electrical power to the machine. mounted via an external float chamber. It cannot be used with weld collar 15050375.
✔ Make sure the machine cannot operate during installation. Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
✔ Follow all safety warnings of the machine manufacturer.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
✔ Read and follow all installation instructions. L1200NDVOR series carry Canadian Registration Number OF1476.2.
✔ OBSERVE all pressure and electrical ratings and require- Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
ments for the devices and the operating environment. pneumatic input signal to cause an orifice to open or close allowing liquid
✔ BE SURE all pressure HAS BEEN REMOVED from the condensate to be drained from a pressure vessel. A pop up button indicates valve
vessel before opening any pressure connections. open/closed. Stainless steel versions available.
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Pressure Manual Valve
Inlet Port Operator
1/2 NPT 1-1/2 NPT Float travel between Operate 1/8 in.-27 NPT
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-5/8 in. w/ float at horizontal centerline
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
Weep Hole Valve Open/Closed
Union Indicator Button
Electrical installation to be done by
qualified person according to the NEC.
F Drain
Connection C
E D
Plug Seal G (dimension shown
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
NOTE: Dimensions are in inches and (millimeters)
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Direct Installation into the Wall of the positioned away from the tank wall.
Pressure Vessel 2. A tee is typically installed at the bottom of the lower 1 inch
1. Determine that the float travel is not pipe riser to allow draining of the float
obstructed by the coupling in chamber for servicing or replacement.
the vessel wall, internal Tank
Wall NOTE: A typical installation Float
baffles, etc. with Blocking and Bleed valves is Chamber
Do NOT use more than shown at right. Tank
Block
one arm extension P/N Valves
3. Install the L1200 or
15050395.
L1200N
2. BE SURE that the float Explosion proof Level
Level conduit seal in the 2 NPT connection Switch
and extension are tight Switch where required. of Tee
and that the lock washer is the float chamber.
in place. Bleed
BE SURE float travel Valve
3. Before installing the level is not restricted and that the Explosion proof
switch a suitable pipe thread sealant float is tight onto conduit seal
is recommended. Screw the unit directly into the threaded where required.
the float shaft.
connection in the wall of the pressure vessel. 4. To complete installation and
4. Be sure that the electrical connection is positioned at the wiring, follow the instructions for
bottom. For L1200N the 1/8 NPT pneumatic connection mounting directly into wall of the vessel and for wiring.
should be on top (the 1/4 NPT vent connection should be on
the bottom). See “Pneumatic models” section for further Pneumatic Models
instructions for the L1200N. 1. All pneumatic models
5. Make the electrical wiring connections according to operate on the vent Filter/Regulator
appropriate wiring diagrams for the alarm or shutdown principle. The Tank
New Dump Valve
system to be used. The electrical connection is 1/2-14 NPT. pneumatic signal Pneumatic Operator Assembly
p/n 15010216
Electrical wiring and conduit should be installed by qualified source MUST BE Signal
personnel according to the NEC. CLEAN AND DRY.
6. BE SURE all electrical connections are insulated and the The input pneumatic MURPHYGAGE®
cover is fully installed before reconnecting electrical power. signal must be
7. BE SURE all pressure connections are tight before regulated between 30
pressurizing the system. and 70 psi (207-483 L1200N
kPa) [2.07-4.83 bar].
Installation with a Weld If produced gas is used as the
Collar Tank Wall
signal source, it should be taken
1. The weld collar, P/N after gas passes through the final scrubber.
15050375, must be welded Weld Collar A suitable filter must be positioned before the L1200NDVO
into the wall of the to prevent liquids and/or particulates from entering the dump
pressure vessel according valve operator.
to code standards and NOTE: Check filter periodically for wear and tear and
good welding practices. elements that hamper the flow of the pneumatic signal.
L1200 2. All pressure connections must be tight and maintained tight
2. Follow above instructions
for installation directly into so as not to leak air/gas.
the wall of the pressure Explosion proof 3. Valve seat adjustment can be made if air/gas begins to leak.
conduit seal
vessel. where required. Care should be taken when adjusting as only slight movement
3. NOTE: Weld collar 15050375 can is necessary to stop the leakage; excessive force will bind the
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External L1200N
Hex Socket Set Screw
Float Chamber 15051098 • loosen for adjustment
• tighten after adjustment
CAUTION: USE “NON SPARKING TOOLING”.
Hex Adjustment Nut
1. Install the float chamber 15051098 on the outside wall of the • turn left until air Trip Cam (float down)
seepage stops • should be in
pressure vessel using 1 NPT piping. Position the 2 NPT • Caution: only slight this position
adjustment is needed—too • non-adjustable
threaded connection at the height where you want the level much will lock up mechanism
switch to operate. The 2 NPT threaded connection must be
Installation 00-02-0175 page 4 of 6
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation
As condensate rises in the scrubber, the float on
Typical/Scrubber/Separators
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter VESSEL
the dump valve pilot chamber. Once the pressure Minimum control
Rising Level Shutdown
enters the pilot chamber it forces the diaphragm L1200 (with snap-switch) pressure 30 psi
(207 kPa) [2.07 bar]
and valve stem forward thus opening the valve seat Air Supply Maximum
300 psi (2.07 MPa)
(valve open/closed indicator button pops out) and [20.70 bar]
releasing condensate through the valve stem and Explosion proof
conduit seal required
out the drain. As the condensate level drops, the for Class I. Div 1, not
Filter/Regulator
required for intrinsically
L1200NDVOR pneumatic valve closes to shut off safe or non-incendive L1200NDVOR
with MURPHYGAGE®
circuits like FWM TTD.
the pressure to the dump valve causing it to close. Dump Valve
Electrical Rising Operator
If for any reason the condensate continues to rise Level Minimum control pressure
Conduit 30 psi (207 kPa) [2.07 bar]
Trips Union
beyond normal dump levels, model L1200 DVO
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the DVU Series Dump Valve
4-1/2 in
(114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar].
2 NPT
Operating Temperature: 400°F (204°C).
2-11.5 NPT
1/2-20 UNF-2B
(4 places)
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
Installation Instructions
Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before
mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes.
GENERAL INFORMATION
WARNING LISTED*
VS-7037N page 1 of 8
DIMENSIONS
VS2 VS2C
3 in. 4-3/4 in.
(76 mm) (121 mm) 3 in. 4-3/4 in.
Slotted (76 mm) (121 mm)
Sensitivity Slotted
Reset Adjustment Sensitivity
Push Reset Adjustment
4-19/32 in. Button Push
(116 mm) Plug 5-7/16 in.
(138 mm) Button Weatherproof
Strain Relief
Bushing
VS2EXRB
6 in.
(152 mm)
1/2 NPT
Conduit
2-1/2 in.
(64 mm)
4-1/2 in. 9-1/8 in.
(114 mm) (232 mm)
Mounting Centers 10-3/16 in. Mounting Centers
(259 mm)
VS94
6-29/32 in.
(176 mm)
Manual
7-9/64 in. Reset
(181 mm) Push-button 4-5/8 in.
(118 mm)
6-1/2 in.
(165 mm) 3/4 NPT
1-5/8 in. conduit fitting
(41 mm)
4 in.
(102 mm)
Mounting slot
5/16 x 9/16 in. 4 in. 6-1/2 in.
(8 x 14 mm) (102 mm) (165 mm)
4-places.
VS-7037N page 2 of 8
SPECIFICATIONS
VS2 and VS2C additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,
• Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas. up to 30 VDC.
VS2: Base mount • Remote Reset:
VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 Option Operating Current
AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable -R15: 350 mA @ 115 VAC
hold down clamps. -R24: 350 mA @ 24 VDC
• Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS94
VS2EX • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA
• Case: Explosion-proof and weatherproof aluminum alloy housing; types 4 and 12.
meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & • Conduit Fitting: 3/4 NPT conduit fitting connection.
D; UL and CSA listed.* • Normal Operating Ambient Temperature:
VS2EX: base mount. 0 to 140°F (-18 to 60°C).
• Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* • Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
2A resistive, 1A inductive, up to 30 VDC. resistive, 1A inductive, up to 30 VDC.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). • Heater (optional):
Option Operating Current
VS2EXR H15 .023 A @ 115 VAC
• Case: Same as VS2EX. H24 .12 A @ 24 VDC
• Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A • Remote Reset (optional):
resistive, 1A inductive, up to 30 VDC. Option Operating Current
• Remote Reset (optional): R15 .17 A @ 115 VAC
Option Operating Current R24 .36 A @ 24 VDC
-R15: 350 mA @ 115 VAC • Time Delay (optional):
-R24: 350 mA @ 24 VDC Option Operating Current Standby Current
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. T15 .360 A @ 115 VAC .01 A @ 115 VAC
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). T24 1.15 A @ 24 VDC .01 A @ 24 VDC
VS2EXRB • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from
• Case: Explosion-proof aluminum alloy housing; rated Class I, 5 seconds to 6-1/2 minutes (15 seconds per turn approximately).
Division 1, Group B hazardous areas.
• Snap-switch: 1-SPDT snap-switch with reset coil (option available for *CSA and UL listed with 480 VAC rating.
INSTALLATION
orientation should be on a horizontal plane or with the sensitivity adjustment
WARNING: STOP THE MACHINE AND DISCONNECT ALL pointing down. Sensitivity adjustment for model VS2 is covered by a plug.
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
The plug must be in place and tight to prevent moisture or dust intrusion.
The VS2 and VS94 series shock switches are sensitive to shock and
C-Clamp Installation (VS2C model only)
vibration in all three planes of motion - up/down, front/back and side/side.
Front/back is the most sensitive (The reset pushbutton is located on the A C-Clamp is supplied with the VS2C model only.
“front” of the unit). For maximum sensitivity mount the unit so that the The C-Clamp is shipped installed on the VS2C
front faces into the direction of rotation of the machine. (See Dimensions on but must be installed on the VS2EX and
page 2 for sensitivity adjustment location). VS2EXR switches.
The VS2 and VS94 Series must be firmly attached/mounted to the machine 1. The C-Clamp (B) will already be installed on C
so that all mounting surfaces are in rigid contact with the mounting surface a 1/4 in. (6 mm) thick steel mounting plate
of the machine. For best results, mount the instrument in-line with the (A). Bolt the VS2 switch to the mounting A
direction of rotating shafts and/or near bearings. In other words, the reset plate as illustrated — with four 5/16 in.
bolts, nuts, and washers. B
push button should be mounted pointing into the direction of shaft rotation
(see page 5). It may be necessary to provide a mounting plate or bracket to 2. The mounting location should provide
attach the VS2 and VS94 Series to the machine. The mounting bracket convenient access to the TATTLETALE® D
should be thick enough to prevent induced acceleration/vibration upon the push button (C).
VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See 3. The hardened set screw and nuts (D) are used to
illustrations on page 5 for typical mounting locations. tighten the switch to an I-Beam or cross member such as a
Sampson post of an oilwell pumpjack.
CAUTION: A dust boot is provided on the reset pushbutton
for all series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting
Continued on next page.
VS-7037N page 3 of 8
INSTALLATION Continued
All Models allow the machine to stop. Turn the sensitivity adjustment 1/4 turn
clockwise, (adjustment for VS94 and VS2EXRB models is located within
WARNING: STOP THE MACHINE AND DISCONNECT ALL
the box, see DETAIL “B”).
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE
1. Firmly secure the unit to the equipment using the base foot mount or OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.
C-Clamp if applicable. See C-Clamp Installation page 3.
For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson Depress the reset button and restart the machine. Repeat this process until
post or walking beam. See Typical Mounting Locations page 5. the unit does not trip on start-up. DETAIL “B”
2. Make the necessary electrical connections to the vibration switch. See 5. If the instrument does NOT trip on start-
Internal Switches, page 6 for electrical terminal locations and page 7 for up, stop the machine. Turn the sensitivity Less Sensitivity
Sensitive adjustment
typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT adjustment 1/4 turn counter-clockwise.
RATINGS OF THE CONTACTS. Follow appropriate electrical Repeat the start-up/stop process until the
codes/methods when making electrical connections. Be sure that the run of instrument trips on start-up. Turn the
electrical cable is secured to the machine and is well insulated from sensitivity adjustment 1/4 turn clockwise
electrical shorting. Use of conduit is recommended. (less sensitive). Restart the machine to
NOTE: If the electrical cable crosses a pivot point such as at the pivot of verify that the instrument will not trip on More Sensitive
the walking beam, be sure to allow enough slack in the cable so that no start-up.
stress is placed on the cable when the beam moves. 6. Verify that the unit will trip when abnormal shock/vibration exists.
If conduit is not used for the entire length of wiring, conduit should be
used from the electrical supply box to a height above ground level that VS94 Time Delay Adjustment
prevents damage to the exposed cable from the elements, rodents, etc. or 1. Apply power to the time delay circuit. (see
as otherwise required by applicable electrical codes. If conduit is not page 7 for time delay circuit). The time delay function will be initiated.
attached directly to the VS2 and VS94 Series switch, use a strain relief 2. Time the length of the delay with a watch. Let time delay expire. After it
bushing and a weatherproof cap on the exposed end of the conduit. A expires, the override circuit will de-energize the solenoid, allowing the latch
“drip loop” should be provided in the cable to prevent moisture from arm to trip. A clicking noise is heard.
draining down the cable into the conduit should the weathercap fail. WARNING: REMOVE ALL POWER BEFORE OPENING
ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A
Sensitivity Adjustment QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE
IT CONFORMS WITH NEC AND LOCAL CODES.
WARNING: REMOVE ALL POWER BEFORE OPENING
THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A 3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.
QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE NOTE: Allow 30 seconds bleed-time between turning the
SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO power “OFF” and “ON”.
NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND
4. Locate the time adjustment pot (DETAIL “C”). DETAIL “C”
CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.
The time is factory-set at the lowest setting (5
All models of the VS2 and VS94 Series cover a wide range of sensitivity. seconds approximately). To increase time,
Each model is adjusted to the specific piece of machinery on which it is rotate the 20-turn pot clockwise as needed
Turn to
installed. After the switch has been installed in a satisfactory location (see (15 seconds per turn approximately). decrease
page 5) the sensitivity adjustment will be increased or decreased so that the 5. Repeat the above steps as necessary to
switch does not trip during start-up or under normal operating conditions. obtain desired time delay.
Pot
This is typically done as follows: Turn to
NOTE: An external time delay can be used increase
1. REPLACE ALL COVERS, LIDS, AND with the remote reset feature of the VS2EXR
ELECTRICAL ENCLOSURES. series to provide a remote reset and override of the trip
2. Press the reset push button to engage the magnetic latch. To be sure the operation on start-up. Time delay must automatically disconnect after
magnetic latch has engaged, observe latch equipment start-up.
through the window on the VS2 and DETAIL “A”
VS2C (see DETAIL “A”). On the
VS2EX, VS94 series the reset button Reset Push button
VS-7037N page 4 of 8
TYPICAL MOUNTING LOCATIONS
These are typical mounting locations for best operation. Other mountings are possible.
NOTE: See Installation section on page 3.
2-Throw Balance-Opposed Compressor Pumping Unit
Reset
NOTE: If installing on
cylinders, 2 vibration/shock Reset
switches are recommended-
1 for each cylinder.
Reset
Reset
Engine Compressor
Turbine Centrifugal Reset
Compressor
Reset
VS-7037N page 5 of 8
INTERNAL SWITCHES
NC NO COM
Ground
NO1 NC COM NO2 Terminal
SPDT Snap-Switch
SPDT Switch Terminals
NC NO COM NC NO COM
Ground
Ground Terminal
Terminal SPDT NC NO COM
SPDT Snap-Switch Snap-Switch Optional SPDT
Snap-Switch
(VS2EXRB only)
VS94
Time Delay and/or
Remote Reset
SPDT Terminal (Optional)
Snap-Switch
NC NO COM Ground
Terminal
NC NO COM Sensitivity
Adjustment
SPDT
Snap-Switch
Heater Board
Terminal (Optional)
VS-7037N page 6 of 8
ELECTRICAL
WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.
CD Ignition Resistor
2 To good (100 Ω, 3 Watt)
Resistor engine ground
(100 Ω, 3 Watt)
CD Ignition
N.O. N.C. COM
1
CD Ignition
1
To good
engine ground
VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Typical Wiring Diagram for Electric Motors Typical Wiring Diagram for Distributor Ignition or Diesel
Contacts shown Switch Terminals Contacts shown
Switch Terminals in the RESET position NOTE: Terminal N.O. is in the RESET position
NOTE: Terminal N.O. is N.O. N.C. COM
N.O. N.C. COM terminal NO1 on models
terminal NO1 on models (see Note)
(see Note) VS2 and VS2C.
VS2 and VS2C.
Ignition
Switch
L1 L2 L3 Push-button
Station
Ammeter
HC
Diesel Fuel
Shutoff Valve Ignition Coil Distributor Battery
H A
VS-7037N page 7 of 8
SERVICE PARTS
VS-7037N page 8 of 8
TTD Series SELECTRONIC®
Fault Annunciator
Installation and
Operations Manual
TTD-98055N
Revised 12-05-04
Section 50
(00-02-0329)
TTD-98055N page 1 of 36
Table of Contents
Contents page #
Warnings and Limited Warranty ................................2
Description .................................................................3
WARNING! Optional features ....................................... .........3
Display Head ......................................................3
Power and Control Inputs/Outputs ......................3
FW MURPHY has made efforts to ensure the reliability Installation Diagrams TTD-2 (50080718) ................4/5
of the TTD System and to recommend safe usage Typical Installations for PSU-2 ..................................6
practices in system applications. Please note that in Neg Grnd/CD IGN Power Inst .............................6
any application, operation and controller failures can DC Power/DC IGN Inst .......................................6
occur. These failures may result in full control outputs Alarm and Pre/Postlube Functions ............. .........7
or other outputs which may cause damage to or Tachometer Hourmeter Functions ...................... .7
unsafe conditions in the equipment or process con- Setup A Output Mode Configuration . ................. .8
nected to the TTD system. Input Terminal Block Connections .......................8
TTD G-Lead Choke Installation ...........................9
Good engineering practices, electrical codes, and
Backup Battery Replacement ............................10
insurance regulations require that you use independent
The TTD System .......................................................11
external protective devices to prevent potentially dan-
The Intuitive Display .................................................12
gerous or unsafe conditions. Assume that the TTD sys- Front Panel Key Functionality ............................12
tem can fail with outputs full on, outputs full off, or that TTD Keypad Features ..............................................13
other unexpected conditions can occur. Shutdown Mode ...............................................13
Please read the following information before Run Mode ........................................................13
installing the TTD annunciator. Setup Mode Menus ...........................................14
This installation information is intended for all TTD Setup Mode Edit Settings .................................14
Operational Display Messages ................................15
Series models. A visual inspection of this product
Backlight Used as Status Indicator ........................16
before installation for any damage during shipping is
Configuration Setup of Navigational Screens..........17
recommended.
Access During Run and Shutdown .................... 18
Disconnect all power and be sure machine is inopera- Password Protected Settings ............................18
tive before beginning installation. Inactivity Time Out ............................................18
Installation is to be done only by qualified technician. Setup 1 Timers Setup ..................................18/19
Setup 2 Sensor Mode .......................................20
Observe all Warnings and Cautions at each section in Emulation Template Settings .............................20
these instructions. Terminal Block Configuration for DD-20 .............21
Terminal Block Configuration for DD-40 .............21
Device shall be wired in accordance with Class I,
Setup 3 Sensor Type ........................................22
Divisions 1 & 2 wiring methods.
Setup 4 Remote Reset Remote Lockout
This equipment is suitable for use in Class I, Division 1 and No-Flow Enable Delay ...........................22/23
& 2, Groups B, C, and D hazardous Areas. Setup 5 Hourmeter ...........................................24
Setup 6 Speed Calibration ................................24
WARNING–Explosion Hazard–Substitution of compo-
Setup 7 Tachometer Overspeed Options ...........25
nents may impair suitability for Class I, Division 2.
Setup 8 Tachometer Underspeed Options .........25
Please contact FW MURPHY immediately if you have Setup 9 Communications Settings .....................25
any questions. Setup A Output Mode .......................................26
Setup B Unit ID ................................................26
Setup C Factory Default ...................................27
Voltage Readings .............................................27
Warranty Software Version ...............................................28
A limited warranty on materials and workmanship Special Features (Password Code) ..................28
is given with this FW Murphy product. Modbus Register Addresses ...........................29/30/31
Specifications ...........................................................32
A copy of the warranty may be viewed or printed by going to
TTD Numbering and Replacement Parts .................33
www.fwmurphy.com/support/warranty.htm
Dimensions ...............................................................34
TTD Worksheet ....................................................35/36
TTD-98055N page 2 of 36
Description
• Running hours
Optional Features:
• Pre/Post lube timed functionality
• Tachometer w/ Overspeed and Underspeed setpoints
TTD-98055N page 3 of 36
Installation Diagram TTD-2 (50080718) page 1
TTD-98055N page 4 of 36
Installation Diagram TTD-2 (50080718) page 2
TTD-98055N page 5 of 36
Typical Installations for PSU-2
Murphy M5081FS-B
Fuel Valve w/ DC coil Valve GND
Coil TX
Ground Switch 2 (Note) Switch 1
RX
B
Common
Chassis A
Ground MPU
AUX
10 9 8 7 6 5 4 3 2 1 ALR
FV-
FV+
Customer supplied DC
10-32VDC Power Supply
IGN Shutdown Relay GND
DC
IGN SHDN
IGN
Common Chassis
Ground
Note: TTD unit shown for typical DC setup. Refer to SETUP A for
options on output actions. Upon fault shutdown both (FV-) and
(IGN SHDN) open to ground if SETUP A is set to 1.
They both conduct to ground on nornal run mode. PSU-2 Power Supply
TTD-98055N page 6 of 36
Typical Installations for PSU-2 continued
Note: TTD annunciator is supplied with the (ALR) output which will con-
duct to ground upon detecting an ALARM condition to turn on an audible
horn, light or other interface device. This output will open when either
the [RESET] key is pressed or the ALARM condition returns to normal. The
ALARM message will remain on the display until the [RESET] key is PSU-2 Power Supply
pressed acknowledging the alarm.
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
TTD-98055N page 8 of 36
Typical Installations for PSU-2 continued
2. Lay the wire across the inside of the choke as shown (2).
2.
3. Wrap the wire around the outside of the choke as shown (3).
4. Wrap the wire back across the inside of the choke as shown.
The wire should lie next to the wire from step 2 (4).
3.
4. 5.
TTD-98055N page 9 of 36
Typical Installations for PSU-2 continued
TTD-98055N page 10 of 36
TTD System
TTD-H Annunciator
SENSORS
DCS or Computer
SUPPLY
VOLTAGE Running
MConfig Pro
software
SPEED
INPUT
TTD-98055N page 11 of 36
The Intuitive Display
Icons Description
The TTD features a static LCD display (A) with backlight (external DC
is required). The operating temperature is between -40° to 85°C. RUN – Run mode
The applicable icon and number (B, C and D) will be displayed to clari- RPM – Screen Value
fy the display readings or alert the operator to an operating condition. HOURS – Screen Value
TYPE – Channel Type Configuration
(A) LOW BATT – Low Battery Warning (displayed if the condition
exists)
The operator can interface with the TTD Annunciator in one of two ways. One is via the Front Panel keypad.
The second way an operator can interface is with the Murphy MConfig® software. This provides the user with a
Template displaying the TTD Annunciator setup and status by reading the Modbus registers. Setup selections
can be made and the configuration saved to file for future reference. The software is free and can be down-
loaded from www.fwmurphy.com
TTD-98055N page 12 of 36
TTD Keypad Features
Note: Because the keys have more than one function depending on the operational mode the system is in at the time,
the following TTD Keypad Functionality blocks indicate the keypad action seen if that key is pressed.
Shutdown Mode
NOTE:
The LOW BATT icon can show in any mode if the battery charge is low.
(A)
SHUTDOWN indicates the TTD identified a fault condition and alerts the operator
with cause of shutdown code.
(A) The current condition on the display is: the SHUTDOWN icon is on.
Key Function
Read Hours (B) Shows the operation hours for the displayed History record*.
(B)
Setup/Enter Press and hold the key for 5 seconds to access the Setup Menu:
The model number displays(C) and then the SETUP icon displays (D).
For more information, see the Setup Mode or Setup Screens.
Up Arrow Shows the previous History record (E)*.
(C) Down Arrow Shows the next History record*.
Reset Press [RESET] to start the Run Mode. For more information,
refer to the Run Mode.
* When not in the Setup Mode. History contains records for last 10 shutdowns and last 4 alarms.
(D)
(E)
Run Mode
(F) The condition on the display are: the RUN and RPM icons show and the ALARM icon
may be on.
TTD-98055N page 13 of 36
TTD Keypad Features continued
(I)
Key Function
Setup/Enter If the unit is in SETUP 0, pressing [ENTER] exits the unit from the
Setup Mode. If the unit is in any other Setup, pressing [ENTER]
accesses the sub-menu for that Setup. For more information,
review Setup Mode – Edit Settings or Setup Screens.
Up Arrow Press [UP ARROW] to navigate to the next menu.
Down Arrow Press [DOWN ARROW] to navigate to the previous menu.
Reset/ESC Press [ESC] to exit from the Setup Menu and return to the
operational display for the current mode.
Stop If the system is in Run Mode, pressing and holding the [STOP]
key for 2 seconds will begin the Shutdown sequence.
Key Function
Setup/Enter Press [ENTER] to exit or advance a Setup menu and save changes.
Up Arrow Press [UP ARROW] to increment the value to the maximum range.
Holding the key accelerates the incrementing action.
Down Arrow Press [DOWN ARROW] to decrement the value to the minimum
range. Holding the key accelerates the decrementing action.
Reset/ESC Press [ESC] to exit or advance the Setup Menu without saving
your changes.
Stop If the system is in Run Mode, pressing and holding the
[STOP] key for 2 seconds will begin the Shutdown sequence.
TTD-98055N page 14 of 36
Operational Display Messages
Pre-lubrication Timer Reading Several messages display during the start-up and run sequence. This tutorial
shows the screens that will display as the system starts.
With the unit in shutdown state and ready to start, press the [RESET] key. If
Class A inputs are not faulted, and the unit is equipped with the Pre/Post
Lube option, the unit goes into the PreLube cycle. If the unit does not have
the PreLube option, it will go to the B1 Timer display.
(A)
(A) Lube Timer 5 shows the remaining time on the cycle and the LUBE icon
B1 Timer Reading
shows on the display.
The PreLube cycle can be completed either by the timer reaching “zero,” or
the operator pressing [TIMER 0]. Pressing the [TIMER 0] key will zero the time
on the active visible timer only; all other active undisplayed timers will remain
(B) the same.
B2 Timer Reading
(B) Once the PreLube cycle completes, the outputs change state, and the B1
and B2 timers start. This display shows TIMER 1 as the remaining B1 time
counts down.
NOTE: If this is a TTD unit with optional Tachometer, the display alternates
between the active TIMER and RPM readings. If the TTD unit does not have
(C) Tachometer, the active TIMER reading alternates with the HOURS reading.
RPM Reading - Shows RPM**- Run Mode (C) Once the B1 Timer finishes, any time remaining on the B2 timer will show
in the display and the TIMER 2 icon will be visible in the lower right hand corner
of the display.
(D) On TTD models supplied with tachometer, once the B1 and B2 timers
have expired, the unit goes to a normal Run Mode. Both the RUN and RPM
(D)
icons will be visible, and the display gives the RPM reading. TTD units without
the Tachometer display the HOURS reading.
(E) Any conditions such as LOW BATT or ALARM alert the operator by having the
icon show on the display.
LOW BATT indicates low voltage on the Backup battery, and may indicate it is
(E)
time to replace the battery.
Ignition Delay Timer Reading
(F) At the detection of a fault, the TTD starts the shutdown sequence. The
ignition delay timer shows the time remaining on the timer before the ignition
is grounded or turned off. In addition, the fault channel shows on the left side
of the display and flashes.
(F)
(G) If the TTD is equipped with the Pre/Post Lube option and there is time
Post-lubrication Timer Reading remaining in the sequence, the POSTLUBE icon and the TIMER 6 icon displays
showing the remaining time on the timer.
( H ) When the PostLube time counts down, the Fault Channel numeric dis-
play moves to the right. The HISTORY icon is visible and the current shutdown is
(G) indicated in the lower right hand corner by 01.
This is the only time History records are available from the Front panel.
Shutdown Code - Shows Channel Tripped
History records can be read via the Modbus registers at any time.
(H)
TTD-98055N page 15 of 36
Operational Display Messages continued
(J) If this is a TTD unit with Tachometer option, and the unit is in the Run
Mode, when the [READ HOURS] key is pressed, the display shows the run-
ning hours for 5 seconds. The display then returns to the RPM reading (K).
(J)
(L) Push the [TEST] key to start the Test Timer for up to 5 minutes. The TEST
Run Mode Showing RPM Reading icon shows in the display.
Test Mode allows the operator to simulate faults without the outputs chang-
ing state. In Test Mode, all other functions operate normally. Faulted inputs
display, but the system is not shutdown and the ALARM is not turned on.
When more time is needed to simulate inputs, the operator can press [TEST]
(K)
again for up to an additional 5 minutes of time.
Test Timer Reading Press [RESET] to reset the fault and then press the [TIMER 0] to exit the Test
Timer. These shutdowns override Test Mode:
- Emergency Shutdown (47,48)
- Overspeed (50)
- Manual Stop (52)
(L) - Underspeed (51)
- Loss of Ignition (49)
Alarm Code - Shows the Channel Tripped
- Optional Additional ESD, if chosen as ESD
If Class "C" functions are used, they will need to be bypassed to test other
sensors. When exiting Test Mode with Class "C" functions, press the [RESET]
and [TIMER 0] keys simultaneously.
(M)
(M) In an alarm situation, the ALARM icon is turned on and
the alarm point or channel displays. If the unit is equipped
(N) with a Tachometer option, the active point or channel alter-
Fault Codes Description nates with the running hours at the time of the alarm.
1-48 Indicates the input that has faulted or alarmed If a fault is detected or an alarm occurs, the appropriate
49 Loss of Ignition (When the CD ignition falls below fault codes display (N).
90 VDC± 10%, the firmware activates the fault)
50 Overspeed Backlight used as Status Indication
51 Underspeed If AC or DC power is connected the backlight function-
ality is implemented on Div. 2 power supplies.
52 Manual Stop
Run Mode – The backlight will be yellow under this
60 Watchdog Timer condition.
61 Loss of SPI Link Shutdown Mode – The backlight will turn red under this
condition. When a shutdown fault is detected, the back-
light will blink. The backlight blinking will continue for 5
minutes, and can be aborted if the user presses any key.
After 5 minutes, the backlight stays red. During manual
shutdown sequence the backlight will be red.
TTD-98055N page 16 of 36
Configuration / Setup of the TTD Annunciator
E
A
F G
D C
(H)
TTD Setup and Navigational Screens
The TTD Annunciator can be setup by using the Front Panel.
Setting up the TTD from the Front Panel requires using the following keys:
(A) [SETUP or ENTER]
(B) [UP ARROW]
(I) (C) [DOWN ARROW]
(D) [ESC (ESCAPE) KEY]
The Setup Mode can be entered from either RUN or SHUTDOWN. However, settings
can only be changed when the SETUP icon is blinking.
Easy reference to Timer information (E), Sensor Types (F), and Setup Numbers
(G) is provided on the Front Panel.
(J) To enter the Setup Mode, press the [SETUP/ENTER] key (A) and hold until the
display shows HOLD (H). Continue to press the [SETUP/ENTER] key until the
model number is displayed.
The HOLD display counts down for 6 seconds, shows the (I) model number for
3 seconds and then shows (J) SETUP 0 to indicate the unit is in Setup Mode.
Press the [UP ARROW] (C) or [DOWN ARROW] key (B) to move through the
(K) Setup values.
After selecting a different Setup to view, press the [SETUP/ENTER] key to dis-
play the current configuration of that setup value.
To change a setting, press [SETUP/ENTER] again to access the menu choices.
Enter changes by using the [UP ARROW] or [DOWN ARROW] key. The only
(L) time a new value can be entered is when the Setup icon is blinking.
Press the [SETUP/ENTER] key again to save the new value. The display will
show SAVE (K) for a few seconds and then return to the Setup menu.
To exit without saving the change, press [ESC]. Press [ESC] again to exit from
the Setup Mode completely. The display will show ESC (L) and then return to
the operational screen.
TTD-98055N page 17 of 36
Configuration / Setup of the TTD Annunciator continued
(T)
Timer 7 Delay Before No-Flow Shutdown
When an internal input detects a No-Flow condition, the Channel number that
detected the condition is displayed along with Timer 7 and its countdown.
If Timer 7 countdown expires the TTD will begin the shutdown sequence.
(T) Shows the Timer 7 display during No-flow delay before shutdown.
(U) (U) Shows Setup 1 – Timer 7 menu.
Timer 7 will not be armed until Timer 1 has expired. During Timer 1 count-
down, the channels enabled as No-Flow (CH41 - CH44) will be ignored.
Setting Timer 7 to zero (Ø) will cause an immediate shutdown when Timer 1
has expired If No-Flow is detected on any of the four enabled channels.
To enable or disable the No-Flow function use SETUP 4b thru 4E.
NOTE:
During Run Mode if more than one Timer is active at the same time, the Timers
will be displayed by the TTD in the following priority:
1. Timer 3
2. Timer 1
3. Timer 2
4. Timer 7
Timers not active during the Run Mode will not occur at the same time.
TTD-98055N page 19 of 36
Configuration / Setup of the TTD Annunciator continued
Once the unit is in Shutdown Mode, enter SETUP 2 and choose from one of the
eight pre-configured “Emulation Template Settings (E).” Review the template set-
tings in the first column of the Emulation Table and enter that number to select the
template (F).
Emulation Table
(E)
B1 B2 Over Remote Remote Local Remote
TEMPLATE SETTINGS Class A Class C
Lockout Lockout speed Reset Lockout ESD ESD
0 O n ly w h e n S E T U P 2 is s e t t o " 0 " c a n in d iv id u a l c h a n n e ls b e s e t in S E T U P 3
1 TTD Default N/A N/A (1-46) N/A N/A (45*) (46*) (47)**) (48**)
32 (1-15,
2 TTD Mark II 8 (16-23) N/A 4 (41-44) N/A (45*) (46*) (47)**) (48**)
24-40)
31 (10-30,
3 TTD Mark III 9 (1-9) N/A 4 (41-44) N/A (45*) (46*) (47)**) (31**)
32-40, 48)
Mark IV,
4 TTD 15 (1-15) N/A 25 (16-40) N/A N/A (45*) (46*) (47)**) (48**)
LCDT
Mark IV,
5 TTD 15 (1-15) N/A 25 (16-40) 4 (41-44) N/A (45*) (46*) (47)**) (48**)
LCDT+
6 TTD Generic 16 (1-16) 4 (17-20) 20 (21-40) 4 (41-44) N/A (45*) (46*) (47)**) (48**)
11 (20-27,
20 DD-20 Altronic 8 (10-17) N/A N/A N/A (45*) (46*) N/A N/A
30-32)
16 (10-17 , 24 (30-37,
40 DD-40 Altronic N/A N/A N/A (45*) (46*) N/A N/A
20-27) 40-47, 1-8)
* - If Remote Reset and Remote Lockout are selected in SETUP 4, any previous setting on channel 45 and 46 will be overridden.
** - Channel 47 and 48 are defaulted to Class ESD which means they will override the Te s t function and shutdown the unit.
They can be changed if desired.
( ) - numbers in parenthesis indicate terminal/channel numbers. The number in front of the () is the number of points in that template.
Note: When using the Altronic DD20 or 40 Emulation in a non-tachometer TTD, the overspeed channel must be configured.
TTD-98055N page 20 of 36
Configuration / Setup of the TTD Annunciator continued
(G) After selecting and saving a template, any point can be reconfigured by chang-
ing a single channel in SETUP 3. To do this, return to SETUP 2 and enter "0" as
the template setting (G). The points on the template originally selected are not
changed with this action. Next, go to SETUP 3 and change channels, as neces-
sary, to the preferred configurations.
(H) NOTES:
Terminals 45 & 46 are enabled in SETUP 4 for Remote Reset and Remote
Lockout functionality. If they are not enabled, they can be configured the same
as the other points. If they are enabled, they will override any previous setting.
Remote Reset can only be used in terminal 45 and Remote Lockout can only be
used in terminal 46.
(I)
Terminals 47 and 48 are defaulted to Class ESD. This means they will override
the Test function and Shutdown the unit. The functionality on these channels
can be changed, if desired.
When Template 20 is selected (H), the channel assignments will duplicate the
DD20 (J). Remaining channels are configured as inactive, but can be modified in
SETUP 3 once SETUP 2 is set to “0.” This also applies to Template 40 (K); with
the exception of channels 50 to 57 are assigned to TTD terminals 1 to 8.
If Template 20 or Template 40 is used in a unit without the tachometer option,
the overspeed channel must be configured.
(J) TTD
TTD Terminal
TerminalBlock Configuration
Block NO/NC forNO/NC
Configuration DD-20 for DD-20
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
TTD-98055N page 21 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
PASSWORD PROTECTED
TTD-98055N page 22 of 36
Configuration / Setup of the TTD Annunciator continued
(G)
Setup 4 - continued
No-Flow Switch Transition Time
Use SETUP 4b thru 4E to set No-Flow switch transition times.
Digital input channels 41 to 44 can be configured for detecting a transition of
the switches on a divider block of a compressor system. The channels are
(H) scanned to determined if a transition has occured in an acceptable time. The
time range settings are from 0 to 59 seconds. (The default setting is zero).
(G) SETUP 4b is the No-flow screen for CH41
(H) SETUP 4C is the No-flow screen for CH42
(I) SETUP 4d is the No-flow screen for CH43
(J) SETUP 4E is the No-flow screen for CH44
(I)
Setting the value to 0 (zero) on any channel will disable the No-flow function
for that channel and allows SENSOR MODE (SETUP 2) or SENSOR TYPE
(SETUP 3) to determine the Sensor channel functionality.
A non-zero value enables No-flow function for that channel and defines the
timeout for the channel. Enabling No-flow function overwrites the channel
SENSOR TYPE or SENSOR MODE configuration (reserves the channel only
(J)
for No-flow use).
The Test Mode will be ignored if the No-flow is enabled for the channel.
Because these inputs are always in transition, the inputs are always tested for
open and close.
NOTE:
Use SETUP 1 to configure (TMR7) Timer 7 delay before No-Flow shutdown.
TTD-98055N page 23 of 36
Configuration / Setup of the TTD Annunciator continued
(K)
PASSWORD PROTECTED
Setup 5 - Hourmeters
(K) This setup is for reading and/or resetting the hourmeter. There are two sepa-
rate hourmeters:
(L) - Hourmeter 5A can be reset.
- Hourmeter 5B is the TTD internal hourmeter and keeps track
of total RUN HOURS.
(L) 5A Hourmeter Setting. Range 0 to 65535 hrs. (This hourmeter can be reset.)
M) 5B Product Life Timer. Range 0 to 65535 hrs. (7.48 years non-stop. This
(M) hourmeter cannot be reset.) The Product Life Timer reading can also be
accessed through the Modbus or via the Setup menu.
Note: The hourmeter registers are in the display head not in the power supply,
and are not reset by changing the power supply.
(N)
PASSWORD PROTECTED
TTD-98055N page 24 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
(C)
(E)
(H)
2 - 19200,N,8,1
3 - 19200,N,8,2
4 - 38400,N,8,1 (only if the pulses/rev setting is greater than 16.5)
5 - 38400,N,8,2 (only if the pulses/rev setting is greater than 16.5)
TTD-98055N page 25 of 36
Configuration / Setup of the TTD Annunciator continued
(I)
PASSWORD PROTECTED
(J) There are four choices (J), terminals are shown in shutdown state:
GND “0”
TX Setting FV - IGN SHDN
RX “1”
B
“2”
0 Closed Closed
A
MPU “3” 1 Open Open
AUX
ALR 2 Open Closed
FV- “0”
FV+ “1” 3 Closed Open
DC
GND “2”
IGN SHDN
“3” Table Note: Closed indicates a closed to ground state and open indicates an
IGN
open to ground state when the TTD unit is in Shutdown Mode.
(K) Use the [UP ARROW] or [DOWN ARROW] key to select the Output Mode
setting. Press [ENTER] to save the setting.
(K)
(L)
TTD-98055N page 26 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
PASSWORD PROTECTED
(D)
CAUTION:
Executing SETUP C resets all settings, registers, and hours. Shutdown and
alarm histories will also be erased.
(E)
Voltage Readings
(E) The internal backup battery, external DC, and ignition voltage readings are
available in the VOLT menu after SETUP C. These readings are updated
approximately every 4 seconds and are read-only.
(F) Press the [ENTER] key to view each of the readings:
- Internal Backup Battery voltage (F)
- External DC (G)
- Ignition Voltage, peak, if the ignition is wired to the TTD unit (H)
(G) If Internal Backup Battery, External DC, and CD Ignition are connected and
operational, power for the TTD has the following priority:
First - External DC is used unless voltage falls below 9VDC,
Next - CD Ignition is used unless peak voltage falls below 90VDC,
Next - Internal Backup Battery is used when no other voltage is present.
(H)
NOTE:
The TTD will operate normally under Internal Backup Battery power except
communication functions and backlight will be disabled.
If Underspeed (pg.25) and/or Loss of Ignition (pg.24) are enabled, the TTD may
Shutdown when CD Ignition is not present. The tolerance for CD Ignition
detection ±10%.
TTD-98055N page 27 of 36
Configuration / Setup of the TTD Annunciator continued
(I)
Software Version
The Version menu (I) offers a quick and easy way to check the firmware ver-
sions in the TTD components.
To verify the current firmware, press [ENTER] to access the Version SETUP H
or SETUP P. Press [ENTER] the first time to view SETUP H. Pressing [ENTER]
(J)
a second time reaches SETUP P.
SETUP H indicates the software version in the Display Head. In this sample (J),
the version is 6.3. (Read 6 point 3)
SETUP P indicates the software version in the Power Supply. In this sample
(K)
(K), the version is 6.2. (Read 6 point 2)
(L)
Special Features (Password Code)
To view and/or change the code, press and hold the [READ HOURS] key while
the TTD is powered up (L).
Set the code by pressing the [UP ARROW] and [DOWN ARROW] keys in the
range of 0 to 99.
Entering a code Ø, disables the password protection. All the menus protected
can be accessed for read and write without restrictions and the Entry Code will
be disabled.
Pressing the [SETUP/ENTER] key saves the code.
TTD-98055N page 28 of 36
Communications
Communication Port
A single bi-color (GREEN/RED) LED will be provided to give visual indication of active transmit and receive traffic. Only
one connection will be active at any time.
Interface: Factory configured for RS485; field-selectable for RS232 or RS485.
Baud/Configuration: 9600, 19.2K, 38.4K(*);N,8,1;N,8,2 (setup configuration is in SETUP 9)
Protocol: Modbus (Slave)
Connection: There will be 2 screw terminal connectors for RS485.
These will be printed or labeled as A and B.
There will be 2 screw terminal connectors for RS232.
These will be printed or labeled as RX and TX.
There will be 1 screw terminal common for both ports.
This will be printed or labeled as GND.
(*) 38.4K Baud will not be available when IGN input is selected as the source for RPM calculations. When MPU is selected, this feature is available for selection.
TTD-98055N page 29 of 36
Communications continued
TTD-98055N page 30 of 36
Communications continued
Address Description Type Min Value Max. Value Default Value
40,085 Test Timer Setting (TMR3) R/W** 0 300 300
40,086 Life Timer R - - -
40,087 TTD-H Firmware x10 R - - -
40,088 PSU-X Firmware x10 R - - -
40,089 PSU Type R - - -
120- Base Model + No Flow
121- Base Model + Tach + No Flow
122- Base Model + Lube + No Flow
123- Base Model + Tach + Lube + No Flow
124- Base Model
125- Base Model + Tach
126- Base Model + Lube
127- Base Model + Tach + Lube
TTD-98055N page 31 of 36
Specifications
TTD-98055N page 32 of 36
TTD Numbering System