NCD095458527_20001108_FCX Inc. (Statesville)_FRBCERCLA RA_O & M Manual for the Air Sparging and Soil Vapor Extraction System OU-3 Volume II - Appendices A - D-OCR

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O&M Manual for the
Air Sparging and
Soil Vapor Extraction System
FCX-Statesville Superfund Site OU3
Statesville, North Carolina
November 2000
Volume II
27-18895.014
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O&M Manual for the
Air Sparging and Soil Vapor Extraction System
FCX-Statesville Superfund Site OU3
Statesville, North Carolina
Volume II
Prepared For:
EL PASO ENERGY CORPORATION
1001 Louisiana Street
Houston, Texas
Prepared By:
BROWN AND CAIDWELL
227 French Landing Drive
Nashville, Tennessee 37228
( 615) 255-2288
November 2000
27-18895.014
\ \BCNSH031PROJECTSIPROJ\t8895\18895.014\0&McwVolll.doc
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CONTENTS
VOLUME I
LETTER OF TRANSMITTAL
CONTENTS
LIST OF TABLES
LIST OF FIGURES
1.0
2.0
3.0
4.0
5.0
Introduction
1.1 Background Information .............................................................................. .
1. 1. 1 Site Location and Description ........................................................... .
1.1.2 Site Conditions ................................................................................. .
1.2 Description of Air Sparging/Soil Vapor Extraction System ........................... .
1.3 Responsibilities and Contacts ....................................................................... .
1.4 Organization of O&M Manual ..................................................................... .
System Description and Process Flow ...................................................................... .
Functional Description of AS/SVE System .............................................................. .
3 .1 Soil Vapor Extraction (SVE) System Operations ........................................... .
3.2 Air Sparging System Operations ................................................................... .
3.3 SCADA System Operations ......................................................................... .
Operations of System Controls ................................................................................ .
4.1 Main Electrical Disconnect Panel ................................................................. .
4.2 Control Panel CPl000 ............................................................................ ; .... .
4.3 Computer Cabinet ....................................................................................... .
4.4 Remote Computer ....................................................................................... .
Operating Procedures .............................................................................................. .
5.1 System Startup
IV
V
1-1
1-2
1-2
1-3
1-3
1-5
1-5
2-1
3-1
3-1
3-6
3-8
4-1
4-1
4-1
4-2
4-3
5-1
5.1.1 Set Process Valve Positions for Startup.............................................. 5-1
5.1.2 Activate SCADA System (Automatic System Startup)......................... 5-2
5.1.3 Start AS/SVE Process Equipment (Manual System Startup)................ 5-3
5.2 System Shutdown . .. . . ... . .. .. .. .. . . . ... ... .. . .. .. . . ... .. . .. . .. . .. . . . .. . .. . . . . . .. . . .. .. . . . . . .. . . . . .. . . . .. . 5-4
5.2.1 Shutdown AS/SVE Process Equipment (Manual System Shutdown)... 5-4
5.2.2 Deactivate SCADA System (Automatic System Shutdown)................. 5-4
5.2.3 Oose Selected Process Valves............................................................ 5-4
6.0 System Monitoring and Maintenance ..................... ,, .. , .. , .. ,,,,,, ........... , .... ,,,,.,,.,,, ....... ,. 6-1
P, IPROJI 18895\ 18895.01; I T=do<
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CONTENTS (continued)
6.1
6.2
6.3
Health and Safety . . . . .. . .. . .. .. . . ... .. .. . ... . . . ... . .. .. .. . .. . . .. . . ... .. . .. . . . .. ... . .. . . . .. . . . . . .. . . ... .. . . 6-1
Routine Monitoring of AS/SVE System........................................................ 6-2
Maintenance of AS/SVE System................................................................... 6-3
6.3.1 Routine Calibration of Instrumentation.............................................. 6-3
6.3.2 Particulate Filter Replacement............................................................ 6-3
6.3.3 GAC Media Replacement.................................................................. 6-3
6.3.4 Other Maintenance........................................................................... 6-4
7.0 Equipment Specifications ........................................................................................ .
7.1 SVE Blowers ............................................................................................... .
7.2 Heat Exchanger ........................................................................................... .
7.3 Air Compressor ........................................................................................... .
7.4 GAC System ............................................................................................... .
APPENDICES
VOLUME II
Appendix A.
AppendixB.
AppendixC.
AppendixD.
VOLUME III
Record Drawings
Drawing 18895-Cl
Drawing 18895-C2
Drawing 18895-Pl
Drawing 18895-P2
Drawing 18895-Ml
Site Plan
Piping and Equipment Layout
Piping and Instrumentation Diagram
Piping and Instrumentation Diagram
Well Construction Details
GAC Vessels and Air Compressor Documentation by Carbonair
SVE Blower Package and Heat Exchanger Documentation by J.E. Gasho and
Associates
Overhead Coiling Door Documentation
Appendix E. SCADA System Documentation by Revere Control Systems
Section A -Equipment Startup and Shutdown Instructions
Section B -Engineer's Manual
Section C -Programmer's Manual
Section D -Equipment Manufacturer's User Manuals
P: \PROJ\ 18895\ 18895.014\ TOC.doc 11
7-1
7-1
7-1
7-2
7-2
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CONTENTS ( continued)
VOLUME IV
Appendix E. SCADA System Documentation by Revere Control Systems (continued)
Section D -Equipment Manufacturer's User Manuals (continued)
Section E -Drawings
Section F -Loop Diagrams
P: \PROJ\ 18895\ 188 95.0H \ TOC.doc
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APPENDIX A
DRAWINGS
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SUITE 1, 216 HARRILL ST
STATESVILL=:, NC
[phone]
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SITE ACCESS
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i SECURITY GATE
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AS HEADER
EW-2/SW-2
MP-9 ...
·-·-·-·-·-·-7
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, MP-12 r· EW-1/SW-1 MP 151
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6:) EW-3
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ELECTRICAL SERVICE METER
AREA OF AS/SVE EQUIPMENT
· ...... 0.T ..... ·-· ~ -o,J.
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EW-1b~'t" .
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OVERHEAD DOOR
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\IICINITY ~ NOT TO SCALE
N
LEGEND
~ SW ....... AS/SVE WELL
EB EW ....... SVE WELL
T MP ....... MONITORING PROBE
MW ....... EXISTING MONITORING WELL
+ ,__ RAILROAD TRACKS
1" AIR SPARGING PIPING
6" SVE PIPING
NOTES:
WELL AND PIPING LOCATIONS PROVIDED BY TED BENBOW & ASSOC.
LAND SURVEYING, PC 8-23-2000 (JOB # 000806A.DWG)
TED BENBOW & ASSOC. LAND SURVEYING PC ASSUMES NO RESPONSIBILITIES
FOR BASE MAP PROVIDED BY BROWN AND CALDWELL.
NOTICE
* This plat was prepared for the exclusive use of the party
named hereon. Said certificates do not extend to any unnamed
person without an express recertification by the surveyor
naming said person.
* This plat represents an actuaf field survey that meets or
exceeds fhe mfnimum requirements of a cfoss B survey in
-~ccNor~c!-.. ,--:',-~h. th~, S_fa_n~~,{d!-,,}'t_.P,ra~_#(fe fo_r L_~~~;,,<¾{_~!~-~:,-~>s---."*'r~~!-~~~~:~l -,n Or ir,· ,._,a, ... 1na.--• -----•=-------
* The ratio of precision before any adjustments is 1
is not a boundary survey.
27,091.
This plat represents on actual field topographic survey that meets or
exceeds the minimum requ{rements of a class C topogcaphic survey in
accordance with the Standards of Practice for Land Surveying in
North~
PLS
50 0 50 1()0 ----SCALE ·FEET
0
'll 1----------------------,---L-IN_E_I_S_2_1N-C~H--E-S--,-------.;....-----------,--------------;::R;::EVl:-:;:::S;:::IO::-N;::S:-----------r-----------------~-------------r-----------------------------n;PRROOjiJE~C:TTi111<ituj;;MAEBiEERR1
B R O W N A N o AT FULL s1zt ZONE REV. DESCRIPTION BY DAlE APP, a PASO ENERGY OORPORATION
u
I ,0
0, ., .,
CALDWELL
SUBMITTED: ...
APPROVED: ------------..
BRO\1.-N AND CALDWFI I
APPROVED: ....... _, __ _
B
DATE:
DATE:-·-·--
DATE:
(IF NOT 2" -SCALE ACC(J<DJNGL Y)
FILE ...• 18895-C1
DRAWN.. JLT . --~-,-·---·--' ··-------·---~
DESIGNED JPM --~
CHECKED _Kf:IQ_.-.....
CHECKED_
C D E
AS-BUILT DRAWING 10/18/2000
F f I
FCX-STATESVILLE SLIIERFUND SITE
OPERABLE UNIT TI!iREE (003)
STATESVILLE, NORt;H CAROLINA t
K L
IECORD DRAWIIG 1889&.013
DRAWING NUMBER
SITE PLAN 18885
SHEET NUMBER
C1
N 0 p
1 C
9
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4
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7
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B C
NOT/C[
* This plat was prepared for the exclusive use -0f the party
named hereon. Said certificates do not extend to any unnamed
person wi!houf an express recertification by the surveyor
-naming said person.
* This plat represents an actuaf field survey that meets or
exceeds the minimum requ;rements of a class B survey in
accordance with the Standards of Pradice for Land Surveying
in North Carofina.
* The ratio of precision before any adjustments is 27,091.
* This is not a boundary survey.
* This plat represents an actual field topographic survey that meets or
exceeds the minimum requirements of a class C topographic survey in
accordance with the Standards of Practice for Land Surveying in
North Carofina.
f/-f;,,tfl> PLS
WlLL ANU PIPE LOCATIONS PROVIDEC BY TEO BENBOW & ASSOC. LANJ SURVlvl~1J, PC.
TED BENBOW & ASSOC LANO SURVEYING :>C ASSUMES
cASl MAP PROVID[D TO TEO BENBOW & /\SSOC. LAND
3ROWN ANJ CALDWELL.
NO RES~'ONSIOIL,TIES FOR BASE MAP
SURVEYING PC BY
FIFI O WORK PERF8RMC:D ON 8-23-2DOC. (.JOB # 000806.DWG)
WELL ELEV11TIONS WE,E ,EFE,EN2ED TO MtJ\N SEA LEVEL OY
USING DATA FROM 8RCWN AND CALD'W'ELL_ O!'J EX!STIN3 WELc.S.
(W-1 5S EL~VATION 965.5 7')
CENTER POINTS OF SANITARY SEWE's 11fNHOLES (N-4979.42, E-4867 02 A~D N-L819.64,
E-1867.02) WE'!E USED AS REFERENCE POl~-s 10 -s-ABLISH HORl70NTAL CO~TR8L FOR
b-:L5-'.W00 SURVEY.
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BLUE PIPE
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◄ MP-1j
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960.70' FLANGE
MP-12 ◄965.52' LID
964.90' FLANGl
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COORWA.Y ---·-·-·-·-·-·-·-·-·-·"'""""·-·
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NOTE:
ALL ELEVATIONS ARE TO THE BO'TTOl.i OF" PIPE, EXCEPT WHERE LABEl.EO FFE.
FF"E (FINISH FLOOR ELEVATION) W/IS TAKEN BECAUSE PIPE WAS ALREADY COVERED UP.
W-9S
1164. 77' TOP
(;,F' ::( _A~:; ~1?,
W-91
S64.52' -i-op
OF SLAB
LOCATION AND DEPTH OF TWO UNDERGROUND PIPES WERE OOCUME:NTED BY -BROWN AND CALDWELL.
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FENCE
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):;: ! : 96;?.57: :ID : a: I 96c.03 -LANGE,
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%0 66' Lill ( ;. I ,}>: m EW-7 96!"'. 1JR' FLAN(;[· i 59 c,, PT NUMBER ELEVATION PT NUMBER ELEVATION PT NUMBER ELEVATION
20 966.56' •• 978.17' 120 974.51'
PT NUMBER ELEVATION 166
166 976.77' EW-9
965.56' LID
965.02' FLANGE
BLUE PIPE --' i' +.c-=,.-:c='--i---,+ 965.59' UD i ◄ ·-·-·--·-·-·--·-·-------~ ;t-',, ___ __J 'b 2 PIP8 967.87' i'i:A!IGE,
MP-59S ◄ ;i .. ~: '. ··,r -.-,····,·-.,l'-_-~r; 21 975.19' 65 977.67' 121 966.52' 167
22 975.17' 66 977.65' 122 978.24' 168
23 975.22' 67 966.53' 123 977.53' 170
24 975.18' 70 966.54' 140 966.4B' 171
25 977.14' 71 976.22' 141 975.86' 179
26 977.16' 72 976.21' 142 975.81' 180
27 976.36' 7J 976.05' HJ 977.72' 181
26 977.25' 90 977.44' 1"4 977.56' 182 .. 966.57' 91 978.62' 1-15 977.74' 183
43 .,3M' .. ··• 111!;.»' 14'! st7tµII' 1M .. 97J.91' 93 9, ,.9!. -14T. $.-,z' 105
45 97.3.94' 94 977.98' 152 gn.ss· 186
47 976.04' 95 978.12' 15J 977.53' 187
" 966.56' 97 977.95' 15-4 977.el'
52 976.27' 99 97tt03' 155 978.24'
53 976.26' 100 976.17' 156 978.34'
55 976.15' 105 966.54' 157 978.39'
57 977.36' 106 978.35' 159 978.50'
58 977.4-4' 107 979.33' 160 97s.n·
59 978.15' 110 978.40' 161 978.12'
60 978.12' 117 977..28' 162 976.39'
62 978.26' 118 978.31' 16< 977.75'
63 977.35' 119 978.17' 165 979,52'
973.-46'
965.55 FFE
974.28'
974,89'
967.47'
976.16'
97B.55'
976.40'
977.30'
976.94'
976.92'
968.71'
968.73'
" :\
DUKE P'.J',l[R
SUB-ST{!;1}0h;
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9E4.99'FLANGE ~ \'. · •··-...._1·'~,i
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S6S.59' I IC
965.08' FLAf<..GE
EW-8
965.61' LID
9.67.87; FLANGE
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VICINrrY w.F' NOT TO SCAL£
L[G[ND
~ sw ....... AS/SV[ WELL
EB EW ....... SVE WELL
T MP ....... MONITORING PROBE
" ,=, MW ....... EXISTING MONITORING WELL
@ SSMH .... SANITARY S[WER MANHOLE
)( )( )( )( )( )(
6" SV[ PIPING
2" SVE PIPING
1" AIR SPARGING PIPING
CHAIN LINK FENCE
({) W--,11
IJ;} 9&4. 77' RtM
w-1s
964.3:3' RIM
COORDINATE TABLE FOR WELL LOCATIONS
DESCRIPTION NORTHING EASTING
EW-1/SW-1 4877.97' 4893.77'
EW-2/SW-2 4874.37' 5017.78'
EW-3 4955.62' 4835.55'
EW-4 4955.88' 4936.1 o·
EW-5 4956.43' 5038.27'
EW-6 4875.99' 5087.20'
EW-7 4774.75' 5036.91'
EW-8 4757.83' 4937.73'
EW-9 4778.98' 4857.20'
EW-10 4860.08' 4775.94'
MP-1 4957.98' 5138.96'
MP-2 4835.29' 4918.56'
MP-3 4773.75' 5137.76'
MP-4 4808.05' 4924.73'
MP-5 4779.52' 4897.65'
MP-6 4777.68' 4980.39'
MP-7 4679.91' 4893.93'
MP-8 4688.48' 5018.50'
MP-9 4827.55' 5028.72'
MP-10 4927.48' 5026.55'
MP-11 4958.50' 4975.34'
MP-12 4968.38' 4893.94'
MP~13 . ' ~Q.36' 48/12.83' . ' ' -.. c-..
MP-14 5025.33' 5016.95'
MP-15 4864.28' 4893.95'
W-11 4871.67' 5240.63'
W-1S 4859.84' 5229.99'
W-91 4860.19' 4748.11'
W-9S 4869.64' 4750.19'
W-161 4935.72' 4611.24'
W-16S 4935.61' 4815.18'
SVE-2 4931.92' 4613,52'
W-7S 5192.59' 4935.60'
20 0 20 40 ----SCALE FEET
p
10
9
8
N
7
6
5
4
3
2
g 3/8'(1=32)
11 1-.::.:..:::...:.;:....::;:;,;_ _______________ -,-________ __,,------------------r-------:i,----r--R'."'.E'.'."V~IS'.'."IO::".N":':S:------------,--------~----------f--------------,--...---------------------------,--;,:P~RO;:-JE~CT~N::-:U:':M~BE;::-R:-f.1
B R O W N A N D u~~ 1
;u~L
1
~(~Es ZONE REV. DESCRIPTION BY DATE APP. EL PASO BERGY CORPORATION
N u I "' "' "' ro
(IF NOT 2"-SCALE ACC~OINGLY) , C A L D w E L L FILE 18895-C2 AS-BUILT DRAWINGS 10/18/2000 :
DRAWN-·--_JLT FCX-STATESVILLE $UPERFUND SITE
SUBMITTED: __ _
PROJECT MANAGER
APPROVED: ___________ _
BROWN AND CALDWELL
APPROVED: ___ _
A B
DATE:.
DATE:
DATE:
DESIGNED JPM
CHECKED ___ ·--~ KHO .. __ _
CHECKED
r• '-' l) E F H
OPERABLE UNIT tftl:IEE (OU3)
STATESVILLE, Na:,TH CAROLINA
,J 'K , I
'
RECORD DRAWIG 18895.013
DRAWING NUMBER
PFIIIG AM> EQUIPMENT LAYOUT 18898
SHEET NUMBER
C2
L 0 p
10
-
9
-
8
-
7
6
-
5
-
4
-
3
A I B
INTERLOC~ FROM SVE BLOWER
! !
. FC:OM
PAtKAGE_'J AIR
SP~RGE SYST'M
! --
iilLIND ~LANGEi 'OR
CONTINGENT '1/EcLS
I C
• I
JSV-2 .
I
NOTES:
-'i :-!!l,:{,.",'c, '
~
' '
D I F I
. .,...
-
-
EW-1
F I G
-/""' : __ .,.,---
/ "',, '. -·-/ '.) ', '\E:J'J3/· ~ :::::;·:;-:,··· ~<~:'.5TITy"
~ ~--,.~
L,.i' r,. WC ·-
..,__ ..,__
L_ -
/
--
--
FW-2
PIPING LEGEND:
I i
'' 5-; ;;,c.·"' "' ,; ----c.A~
H
..,__
LJ
-
EW-4
I I J
/, ~ •·,: , .' C ',, ---< ~:;-~ ~:' ''.~;}"~ ,--~-~cc ,~,-, \; ,i ,: '\J.'t,' ~
-'-~,~-;,: ·-:-_-~-,:;~--\ <';·.TI'".11;·
-o EV-5 --o EV-6 ------..,__
;, --
/
[
\
--
EW-5 EW-6
EXTRACTION WELLS
I I
EnLJIPMENT 1 :f'tcNn: CONTROL LEGEND:
I
--
K I L I M
,.-~---
/ ,..,__ '
r', ''
,p;j(J"./
SC';"',J /
,_. ~-V
<--c~ --> ~;c~ :;~ ~\·-~-.::
-----V ___ ::,._:___
I i
' --< E' -i. 7 I -~
--E' -8 i -,:_ -----
y
• ,:;· , .~i-4,ef,.-,;>,-,-_._ v~, ,, -~
-
EW-7
SYMBOLS:
---
EW-8
EXTR.A.CTED VAPOR Fl OW
INJECTED AIR Fl OW
El_EC7 RICAL SIGNAi
-
EW-9
I 0 j
7-,---------'-s_---
' / ·,, '
/ -:, ·, ',, , D, '
·r), ~,T•o.•• ~t~-.-.T7
~6~c7:-~,. ,~., C ~-·J ~-,-, \_',\_~-
--a EV-10 --..,__
--
-
EW-10
--
BLIND FLANGES FDR
CONTINGENT WCLLS
LllCAL_Y MOUNTED EQ:JIPMENT
(PSI-INS-RUMENT READING)
p
1 (
9
8
,--
7
6
5
4
,--
3
N THE CEH
CSH
l-H 1
EH2
EH3
EH4
FHS
EH6
EH7
EH8
[119
EH10
EFF
SH1
SH2
COMMON EXT~ACTION -EADER
COMMON SPARGE hEAllt R
rXlR.ACTION HEADER 1 --
/1S AIR S~AR) N(;
j3-1 j3LQWEt;; l
S~ 2 --l?LO~-g,
FE FLOW ELE11EN T
Fl FLOW INDICATOR 1/1
~
PA~Ec MOJN-ED EQUlr'lvE~ T
(HAND /OFF/ AUl Cl) .'\,·\j
:,.,_,. -,,--' ,,,.,,,-;i;,1t,.:1i.;\f·.~;tr~-:;·,
-,., ... ~-.,.-., ",~ ;.-(
-
,,
L
-
sw-:
-
SW-2
SPARGE WELLS
2. SEE SHEET···-P2 FO~ ADDI-IONAL ;::>IPING A.ND
INSTRUMENTATPN.
f X IRACTION HEADER 2
EXTRACTION HEADER 3
EXTRACTION HEADER 4
EXTRACTION HEADER 5
EXTRACTION HEADER 6
EXTRACTIO'I HEADER 7
EXTRACTIO'I YEAJ~R 8
EXTRACTION ~EAJC:R 9
EXTRACTION "EAOC:R 10
TREATED EFFLUENT OFF -GAS
Si0 ARGE HEACER 1
SPARCE HEADC:R 2
CAC ::;RANULA.R 'IIATED CARBON
SVE SOL VAPGR EXTRACTION
EV EXTRACT!! HEADER VA VE
SV SPARGf H ADER VA.LVE
AV AIR COMP ESSOR VALVE
CV COMMON H~ADER VALVE
DV DRAIN VA½VE
\
FT FLOW TRAN SM! TTER
HOA HAND/OFF/AUTO
HS HAND-SWITCH
HV HAND VALVE
IE CURRENT ELEMENT
II CURRENT INDICATOR
IT CURRENT T'<ANSf.llTTER
LI LEVEL NDICATOR
LT LEVEL TRANSMITTER
Pl PRESSURE 11\:DICATOR
PT PRFSSURF TRANSMITTFR
MS MOTOR STARTER (RELAY)
PA PRESSURE ALARM
Pl PRESSURE INCICATOR
TE TEMPERATURE ELEMENT
Tl TEMPERATURE INDICATOR
TT TEMPERATURE TRANSMITTER
CO]
~
4
~
SOLENOID VALVE
MANLJAI I Y AC:IUAlfll
MANUALLY ACTUATED
(;I O~f VALVE (LOCKABLE)
BALl VALVE (LOCKABLE)
VAC~cJM RELIEF VALVE
PRESSURf RFGLJLATOR
SAMPLE PORT
I
P-RbGRAM~/AtJLE LOGIC --.
CONTROLLE~ (MOTOR STl\~TE~)
PIPE SIZE IDENTIF:ER
-----,: I BLIND FLANGE FOR CONTINGENT WELL
0 CONDENSATIO"i DRIP TRAP
BLOWER
11 L---------------------r-------+----r------------------,--------------;:-RE;:-:Vl:-;:-;::51:;0::::N~s-----------,---------------r---------------r1----------------------------TiP;;R;;:ojjJ0Ec~TrNNuuMMssiE~R;-, -B R O w N ' LINE IS 2 IN HES ' ,,"""''"~,~~ ! 1' -
0 A N D ' AT FULL~ E . ,.,,·~-" ~~,~--~--, ZONE REV. DESCRIPTION BY DATE APP. EL PASO Et-EAGY CORPORATION RECORD DRAWING 18898.013
o (IF Nor 2·-scALE AC roRDINGLY) j' ..... ~.>-;--:_.:; ... ,":;..,:·· .... '\ [
DRA'MNG NUfllBER
!1--su-?-M1TTE-~-, -____ L ___ --,.-~--c,---",N--."-~----___ E ___ o_A~-E,-=--=_L-=_-:=_-=-_--1 ~1::1:~ED ___ 1-=s89=:k-~i1.= P.E. lyt/,ff ··-----------+--+---f-Fcx;;~"'u:i; ~f'1' I
PFIG AM> INSTRWENTATION DIAGRAM 18896 _-_
·1--==.,.,..-==--t SHEET NUM8ER _ ~ APPROVEO: __ -cc=--~:-ccc:=---DATE: ---_ _ CHECKED --KHO NORTH CARO~jJC.NSE NO. 23295 STATESVLLE, a.1._~ _·-_ -_ . H CAR-.. A :g BROWN A<D CALDWELL BROWN AND CALDWELL e---+--+----------------------j---f\1\111 I ~
-L.'.A:::P::P:RO~VE~O~~--.:-.:· ;.;·-;,;,-;;;;,;.,.;;.~;;;;,..:.:-.:.:.:.:;B-.:-;;..::o:A.:.:TE:;.: ::;;l..:.:..:.:;;:.l..:c~;:EC:K:::E:D:.::::-:,1::::::::::::::~c~. ~22~7~Fr;;_•n~c~~-L~a::;:n~di!;:~aW;;D;r~:·~· _r;N~os;:h~v::;ille:;_,l'"T;,:;•~nn~•~ss~e;:;,e"':'Fb,--..I..-.Lr-1----:G~---r !i ----:H-;--.L...-t--.1..-+1---"'i1 ___ iJ---,-~·'--rK~---,1---~L-----,i----;:tv17'"'--"""i,r---;Nj""'---ri--<O~-----r1--1p~~---·--·
Pl --
2
1
0
9
8
7
6
5
---
4
3
2
•
A I B C I D E I F
TO SPARGE WEL,_ VALVES
--------------------------------------...... - -- ------ - - - - - --- ----------· -
I
,---------,--------------
" , • IIS ,, 1·-~<~/-/!
I
--~
,, -"'-: l~?i
ros1
I I
I
BA1\0Vl':..~
:-,~~;:S,JRc:-
AMBIENT l~SIDE BUILDING
~--------<-------------< CEH-6" )------, '-...:_ _ _,-/
IROM [XTRACTION W[L_S
.~IR INTi\KE
fill cR COMPRESSOR
( ' □~,~~~---
'-------~ 'I
I ----
-~
I \ / \
' ~ ,i;--,-' /...,
GAS
11\NALYLcR
/ "·,
I ., A_
.~~ifC2-:,)
--,,p----
' ' ' --
I
'
,' [""", ·,, I
"-fi870;,:i
',, ,/ : S(FV,/
()TA_
--
RECEIVING TANK AV-1
AIR SPARGE
COMPRESSOR SYSTEM
' ,, I ; \ ;
/ -=--:::->-=.:~-----------~
,,..,,,,_. , _ __,, --_/ ----.... ---~----'--u \ -I ___ __,I /\ : / f--{:_~~SILE"CERi-1 A•IR-B-LEEC-IN
-::) CV -2 CV-1
NOTES:
1 II\ STRUMENT CONTROL (IC) RE:;ERS TO MAIN CONTROL PANEL lN THE
A3/SVE EQUIPMENT AREA CONTAINING HOA SWITC-lt-S,
STATLS LIGHTS, ANC ALARM LIGHTS
MOISTL,E
SEPARATOR 1--------(-w_\--, __ ./
DV-1
Q,I LIO,,ID DRAIN
(NORMALLY LOCKl:_LJ CLO::OU))
PIPING LEGEND:
C:::H
CSH
EH1
:::OM MON EXTRAC 1101\ HcALJl:_R
COMMCN SPARGE HEl'IDER
EXTRACTION HEADER 1
EQUIPMENT LEGEND:
AS
B-I
B-2
AIR SPARGINc;
BLCWER 1
BLOWER 2
G
!
-!G-/ _,:··.~
----
2. SEE SHEET . .1?1 FOR A-ODITION~L PIPING AND
INSTRUMEN.TATION
. .,,_,.,"'_,_, __ "' -n-12
EH3
lH4
[115
EH6
FH7
EH8
EH9
EH1C
EFF
SH1
SH2
EX:J:RACT!Ot<t HEADER 2 ~
EXTRACTION r-EADER 3
EXTRACTION HEADER 4
EXTRACTION HEADER 5
EXTRACTION HEADER 6
EXTRACTION HEADER 7
______ GAQ~
5\/E
EV
SV
AV
CV
DV
GRANULAR ACl]V;t.TED CARS-ON __
SOIL -VA-POR (x'TR:0:CTION
l:_XIRACllON HEADER VALVI:_
EXl RAC I ION Ht:_ALJER 6
EXTRACTION HEADER 9
EXTRACTION HEADER 1 C
TREA ED EFFLUENT OFF-GAS
SPARGE HEADER 1
SFA.RGc_ Hl:_AlJl:_R 2
SPARGE HEADER VALVE
AIR COMPRESSOR VALVE
COMMON HEADER VALVE
DRAIN VALVE
I H I
i I
! I ~,<:_
<, ''..~c)' '
' i I, I
I ,\._
\( :;~-~})
', '.
! --· .·"::::-
1;_: . -// ' ·--·-, :zr
I I
' '
I
l
._________'.2._,
CV-4 :1----: / f--
B-1
SVE BLOWER SYSTEM
CONTROL LEGEND:
fE FLOW cLEMENT
Fl FLOW 1~DICATOR
FT FLOW TRt,~SMITTER
H DA-~)"IJF f / Al IC
HS HAND-4jlllcl;(:H
HV HANG-VALVE
IF CURflFNT El EMFNT
11 CURRENT INDICATOR
IT CURRENT TRA.NSMITER
LI LEVEc INDICATOR
L -LEVE, TRANSMITTER
Pl PRESSURE INDlCA TOR
PT PRESSURE TRANSM TTER
f/S "10TOR STi\RTER (RELAY)
PA PRESSURE ALARM
Pl PRESSURE INCICA TOR
TE TEMPERATU,E ELEMENT
Tl T[MP[RA7J'1[ INDICATOR
11 TlMPcRATl,E TRANSMITTER
I J
,.. ___ _
I •e
SYMBOLS:
1/1
£
KXl
~
I I L
---------+--
CV-7
,,-11,j,,,_,-, -<~: .. ~I~-
I I
AFTERCOOLER
FXTRACTED VA#OR FLOW
I
I Ncl ECTE) A R fLOW
ELE~TRICAL Sl~NAL
M/\.NLJAI I Y ACTIVATED BUTTERFLY VALVE
SOLENOID VAlitE
MANUALLY ACT-ATtD
'
GI. OBE VALVE (LOCKABLE)
MANUALLY ACTUATED BA~L VALVE (LOCKABLE)
r'RESSURE RE4ULATOR
!
S.I\MPL F PClRT ,
I
.
'· ''-<A.~Q-;J
. . : . : ~ ....... ·. . . .. .
., . , . .,. ~ ..
• • ' ~ I • • •••• • "I' . • =. ·. . . . . . .. •.
I
G.AS
i'-NALYZER
GAC-1
I N
--\
GRANULAR ACTIVATED
CARBON ADSORBERS
(SEE OPERATION AND MAINTENANCE MANUAL
FOR EXACT PIPING AND VALVE LAYOUT)
To AIR SPARCE WELLS
-OCALLY MOUNTED EOLJIPM~NT
(PSI l'-ISTRUMEr-. T ~[ADING)
PAl'-.EL MOUNTED lOUlf-'ME~T
(HA~C/OFF /AJTO)
I
C[-3
--rROGRAM~IA~tE LOGft" --• "~--' "/"
CON,ROLL~R (MOTOR S-ARTER)
PIPE SIZE IDENTIFIER
;,.._' ---111 BLIND ILA~GE FOR CCNTINGENT Wl:cL
CONDFNSATION DRIP TRAP
BLOWER
0 i p
TO ATMOSPHERE.
TREATED OFF-GAS
EXHAUST STACK
• L--------------------....------------r-----------------,------------~R:;-;E:;-Vl;.S::;l;;O::-:N;:-S----------7------------------+""".'"------------T-----------------------------np~R:ao01JE~C:-iT~'NINUU1M:iiB3EE:RR, ~ 0 w N I LINE IS 2 INCHES I '
0 B R A N D -AT FULL SIZE ,,,,,,:_'~~"~·;~~~"-ZONE REV, DESCRIPTION BY DATE APP. EL PASO ENERGY qc>RPORATION
A
PFNG AN> NSTIUIENTATION DIAGRAM
~5.013
DRAWINGd-tUMBER
18895
SHEET NUMBER
P2
~ (If NOT 2• -SCALE AljCOROINGL Y) " _,, .. -~ , '
!.__C __ A_L_--~D_W __ E_L __ L---1 FILE 1889~-P~--'l s0"}~i\~~~1~:~ 11/,_/tv) FCX-STATESVUE SllPERFlN) SITE ~ SUBMITTED: ---PR-0-JEC-T-MA-N~ACE_R _ _,____ DATE: ____ ~::i:ED ____ Jt~M--~ R~~~~~~~~~(t,: P.E. I bATE _ _ -+-------t---OPERABLE UNT THREE (OU3) i APPROVE0: ______ 8ROWNANDOAtowrLL ________ DATE: ____ CHECKED ___ fHO_ --------BN;~;Nc~~~:~L~ 23295 -------STATESVILLE, NOr1"itn CAROLNA
"L~A~P:P:R:O~VE~D:'.:;;:;::;::;::;:;;;;:;::;::;::;::;:::.~D~A~TE.:.: :'-~-;;..;.:-:...-:;:-:..,-,LC~H;E~C~K~ED:;;-;:-;:-;;;;:;,;-t:-:.....:;::.....:...--4~2~2~7~F~re!;,n~c~h,_.lL;:;o;:;n~d~in~g~D~r;iv::e.:., _!N:;a;s!h:::v~ill!e;,, .,;T.;e:::n!;.n,;,es~s:;e;:e~--J..-J,----~'.'"'"---ir""'"----;-';'"'-.J.._ .... r_...L, __ ;-____ r ____ 'i" ____ r ___ ""'i, -~----r----r----t----;:::;-----T ____ N ____ T ____ n ____ i ____ p:-----
1 B I C I, D I E I r I G I H I I J I I<, I L M I N • 0 I P
FECORD DRAWN3
1
9
-
8
r--
7
6
r--
5
4
3
2
1
..,-.
\
10
--
9
8
--
-,
I
6
-
5
-
4
-
-
2
--
A B I C I D I E
I I '-f---2' -o" -----.J
2" SOIi
,,...
VAPOR EXTRACTION ~
I"-
" J'._"
r 1/ 1" Al, SP,\RGE
BOc..ARDS INSTALLED AROUND WELLS FOR '~ PROT[CTION OF 0 1P 1NG AND APPURTENANCES~~
1 THRCADEO END PLUG
rFINISHED FLOOR
I
-
SEE WELL L:JGS IN
CONSTRUC',1:JN COMPLETION REPORT
FOR Ac-u.A~ WELL DEPTHS
I,,
i
=
q_
I CONCRETE FLOOR "1: ,1-->---'----<H-----~ ~ ~I ,j ~ CEMENT /BENTCNITE ScAL
j__
I
20' lD
A,'
,/
! ,/--80REIIOLE NOMINAL DIM/ETER -10"
:/'
I •
·-:
! :
ki--·--4--1----4~ ·--.,J,,1:·
!4 I • '
.,
4
I
-i
' I
/-BEi\ TON TE SEAL
., I
d _j
/ 2" PVC SPARG!:.. WELL
!,;' i-
i . <1
4
\ ~-c:
---. i _ .• j
·~--~ !
AS/SVE WELL DETAIL
END CAP
I F I G I
2" SOIL VAPOR
BOLLARJS INSTALL[D AROJNC WELLS FOR
PROTECTION OF FIC"G ASO faPFURTES,'NCES ~
rf-lNISHED FLOOR
4
4·
H
,....
q
0 I
kl
'
l_
1'-0"
I
i J I ".I
'
!
'
~ LJCKABLE CAP FOR G~OUNDW'ATER ~ONITdRING
= I WcLL-SEAL
~--~ a / rn" ~""°"
4
q 411f-,,,of--
'----H-++-~___J·I I
CONCRETE FLOOR
L_ -
i-. ! I
I _,,,-ccMc, 1/,ENTONiTE s01,L ~r
I
1 4'' PV:::; WELL CASING -~ /I
" '
I •
20, TO 25·, 1··
!-·
<1
4
kl
f
! ~
q
"'
I
-. :
l
..,.-BE\JTONITE SEAL I/' ~
r.,/
<1
4
I--:t· ~vc s~ARGE WELL
. I \! .. -
-----·~ ~' u
;, -----.---'-t ---, I
2'-6"'
J_ > •••• '
!
'
' ·. I
I -------~ .. -~·-~ ...... "-~--~ ---
--........................... _ PVC END C/\~
SVE WELL DETAIL
K I L
r
I N I 0 I
1 / 4" BALL VA_VE SAMPLE PORT ~
/-FII\JISll[D FLOOR \,
• l -~ • A • I
[ 4 , I --f---CONCRETE FLOO, ',---;-~-1+-1-+-,-<LJ
I •
I
p
j__
1 '-0"
f
...
,-·-
I
r . -·
20' -c 25•! , .
J
i <J
I-
I-
V CE~E~T/BENTON!TF SCAL ,,
• • 1 4" PVC WELL CAS.NG ~ .
~:-!
I• I-.
,_
f--.·
-BENTONITE SEAL
' . '
I
r
2'-6' _ '·
<1
. / ~2" PV: ~ONITORING WEI I
[;-/
--. . ----·. == ·, == == .
----
-------------PVC MONITORING POINT DETAIi. END CAP
p
-.·::j/irl{t~
i .,
10
9
7
6
5
4
.3
2
1--
Il-----------------------,---L-1N_E_1_s_2_1N_C_H_E_s __ -,-____ ...,;,,. _____________ T""" _____________ R_E_v_1s-1o_N_s ___________ ...,. ________________ -t,----------------r--...-.. ----------------------------,.~P~R~o-J~e:c~r~-~N~u•M~B~E~R--1
B R O W N A N o I AT FULL SIZt I ZONE REV. DESCRIPTION 1
BY DATE (IF NOT 2"-SCALE ACCOftDINGLY) ,,,•''11"''"~ C A L D W E L L ,,,••~,'.\ :1~ .. .-,.,
.;::' ~ .~-~, ._. -. f---t---+-----------------. +----l----l----J-------------------j-------------------1
:~WNc,_ ____ ,_s_s9_.,Js.,L~_M1 .... _ -1.:/)Jj-.~{,J::,"'~·'_::c,'ll~C,,~:.i::~;;.,i{U.a:-:~.,---.,;,-~.c1J',,.~'-------'L¥JPp<t.<-f-~---+--+---------------+--+----+-::-
APP. EL PASO Et4ERG'' CORPORATION
~l-------------------------1
SUBMITTED:· __________ _ DATE: ___ _
PROJECT ',!AI\IAGER
APPROVED: _____________ ···-__ _ DATE: ___ _
BROWN ANO CALOWE~L
APPROVED: DA'fE: ___ .....
I B I
DEs1GNED ----'J'-'--P""'.M__ ROBE!ff.;-t'.,~A,~lf'-.J)(,/P.E. DA~Wt>t)
CHECKED __ __,_K::H.-"0"--~ NORTH Cl\[l'<:n,INA.l~ 'N<l. 23295
BROWN AMi:i"t:i',LD)l/'ELL CHECKED ____ ~--227 French b:rm!iHg Drive, Nashville, Tennessee
C I D I E I F I G H I
FCX-STATESVLLE SUPERFUND SITE
OPERABLE lN' • .11R5E {OU3)
STA TESVI.J E. TH CAROLINA
·•1
I .j K I L
RECORD DRAWING 1'805.013
WELL CONSTRUCTION DETALS I
DRA'MNG "lUMBER
188tl
SHEET NUMBER
M1
N I 0 I p
I
I
I
I
I
I
I
I
I
I
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I
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I
APPENDIXB
GAC VESSELS AND AIR COMPRESSOR
DOCUMENTATION BY CARBONAIR
P: \PROJ\ 18895\ 18895.014 \O&MAPPcvr.doc
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Ga · r/. ___ _
--·.
~
,
0·
(!I) <
.
Ull~nn-·ye,/
. . . . .
OPERA TION/MAINTENANCEi_
MANUAL & PARTS LIST:
OIL-LESS COMPRESSOR Ullirts:.
SINGLE_& TWO STAGE ,
. . . .
. THIS MANUAL CONTAINS IMPORTANTSAFETY INFORMATION AND SHOULD ALWAYS ..
BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT; 1 . . ---·
READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING TfllS •_.· -
EQUIPMENT TO PREVENT INJURY OR EQUiPMENT DAMAGE\ .
. . ... ,.,:.
12T7VTB,20 ,UNf.l;:c
.1301 N. EuclidAw,l'rm:dml,Illinois 61356-9990. Pboac(115) 11,5-3321~ FAX(815)~~i ..
Mammdming Plams in Pri=toa, Illinois• Murt...; Califbiiua ·. · .
Fonn Nci. 63163 Rev~ 3/98
TABLE OF CONTENTS:'.:
Subject
Safety Precautions ........................ : . . . . . . 3 & 4
Introduction ..................... : . . . . . . . . . . . . . . . . . . . 5
Warranty ........................................... 5
Dimensions and Specifications .................... 6, 7 & 8
Installation ................................... : . 9 & 10
Preparation for Initial Start-Up and Operation ,.-,.. . . . . . 10, 11; 12 :
Maintenance ...................... 10,13, 14, 15, 16,& 17
Troubleshooting Guide· ......................... 18, 19 & 20 :
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 -32
Constant Speed Head Unloader Kits . . . . . . . . . . . . . . . . 33-35
Operation and Adjustment of Pilot Valves . .. . . . . . . . . . . . . . . 36
Hazard Decal and Tag Listing .............. ; ... 37, 38 & 39
Maintenance Schedule Fill-In Cha~ .......... 40, 41; 42 & 43 .
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SAFETY AND OPERATION PRECAUTIONS
Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions should
be observed as with any piece of machinery of this type where carelessness in operation or maintenance is
hazardous to personnel. In addition to the many obvious safety rules that should be followed with this type of .
machinery, the additional safety precautions as listed below must be observed:
1. Read all instructions completely before operating air compressor or unit. _ _
2. For installation, follow all local electrical and safety codes, as well as the National Electrical Code (NEC)
and the Occupational Safety and Health Act (OSHA).
3. Eiectric motors must be securely and adequately grounded. This can be accomplished by wiring with a
grounded, metal-clad raceway system to the starter; by using a separate ground wire connected to the
bare metal of the motor frame; or other suitable means.
4. Protect the power cable from coming in contact with sharp objects. Do not kink power cable and never
allow the cable to come in coniact with oil, grease, hot surfaces, or chemicals".-
5. Make certain that the power source conforms to the requirements of your equipment
6. Pull main disconnect switch and disconnect any separate control lines, if used: before attempting to work·-
or perform maintenance on the air compressor or unit. ''Tag Out'' or "Lock Out" disconnect switch. ·
7. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.'.
8. Do not attempt to service any part while machine is in,.qfl operational mode.
9. Do not operate the compressor at pressures in excess of its rating.
10. Periodically check all safety devices for proper operation. Do not change pressure setting or restrict
operation in any way.
11. Do not use flammable solvents, gasoline or fuel oil for cleaning the air inlet filter or element and other
parts. _
12. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by covering
parts and exposed openings with clean cloth or Kraft paper. · ·
13. Do not operate the compressor without guards, shields and screens in place.
14. Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design and
size, is installed in the line between the compressor unit and shut-off valve.
15.. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
16. Be careful when touching the exterior_ of a recently run motor -it may be hot enough to be painful or cause
injury. With modem motors this condition is normal if operated at rated load -modem motors are built to
operate at higher temperatures. · ·
17. Inspect unit daily to observe and correct any unsafe operating conditions found~ _
18. Do not "play around" with compressed air, nor direct air stream at body, because this can cause injuries,_
19. Compressed air from this machine absolutely must not be used for food processing or tireatliing air
without adequate d_ownstream filters, purifiers and controls, -_ . _
20. Always use an air pressure regulating device at the poini of use, and do not use air pressure greater than_ ·
marked maximum pressure of attachment : ·
21. Check hoses for weak or worn condition before each use and make certain that all conriecti_ons are
secure."-
22. Always wear safety glasses when using compressed air gun. -
nie user of any air compressor package manufactured by Gardner-Oenver Machinery Inc. is hereby warned-that·
failure to follow the preceding Safety and Operation Precautions can result in injuries or equipment dam_ag~>
However, Gardner Denver Machinery Inc. does not state as fact nor does not mean to imply that the precedi_ilg list·-
of Safety and Operating Precautions is all inclusive, and further ihat the observance of this list will_ preverif:all.-
-injuries or equipment dam~ge. . - -
3
EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS
I• WARNING I
,. CAUTION I
· Indicates immediate hazards which will result in severe injury or death.
Indicates hazards or unsafe practice which could result in severe . injury or death.
Indicates hazards or unsafe practice which could result in · damage to the compressor or minor injury. · ·
OBSERVE, UNDERSTAND AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION DECALS AS SHOWN IN THE PARTS LIST SECTION. · .
·A~DANGER ·-· ' This on-Less compressor must not be ·used for breathing air, unless proper downstream fiHration and purification is added. To use for breathing air without proper downstream equipment will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use: Any and all liabnities for damage or loss due to Injuries, death and/or property damage including consequential damages stemming from the use of this compressor to supply breathing air, without proper downstream filtration and purification, will be disclaimed by the manufacturer. ·
IA WARNING I ·The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air. is strictly non-approved and can result in equipment damage and/or injury.· Non-approved uses will also · wid the warranty.
·14 CAUTIONj·
This unit may be equipped with special .options which may not tie included in this manual. User must read, understand and retain all information sent with special options. ·
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INTRODUCTION
Your new Gardner Denver Oil-Less N.r Compressor is constructed to e,cac:ting standards of material and wor1unanship.
The instructions in this manual have been prepared to ensure that Gardner Denver will give long and satisfactory service.
A copy of this manual must be given to the personnel responsible for installing and operating a Gardner Denver air compressor or unit.
Although precautions have been taken to prevent damage to your compressor or unit by freight carrier, the unit must be carefully eicamined and the carrier notified within 24 hours in the event of mishandling.
All requests for information, service, spare parts or Operation Manual replacement should include machine serial number and be directed to: •
GARDNER DENVER MACHINERY, INC, ·
1301 N. Euclid Avenue
Princeton, Illinois 61356 USA·
Phone: [phone] Fax [phone]
Express Limited Warranty
Gardner Denver Machinery, Inc. (the "Compan)") warrants each new piece of ORess equipment manufactured by the Company to be free from defects In material and workmanship under normal use and service for a period of twelve (12) months from date of installation or fifteen (15) months from date of shipment by the Company or the Company authorized dist. :butor, whichever may occur first, except as noted below:
1. Compression & Guide Rings ........ 3 Years or 10,000 Hours,
whichever occurs first 2 Driving Set ..........•.......... 3 Years or 10,000 Hours,
whichever occurs first 3. Crankshaft Bearing Set ........... 3 Years or 20,000 Hours, ·
wh·ichever occurs first
The Company makes no warranty In respect to components and accessories furnished to the Company by .third parties, such as ELECTRIC MOTORS, GASOLINE ENGINES and CONTROLS, which are warranted only to the · extent of the original manufacture(s warranty to the Company. To have warranty consideration,· electric motors must be equipped with thermal overload protection.
When a compressor pump, or component Is changed or replaced during the warranty period, the newly replaced item is warranted for only the remainder of the original warranty period. ·
Repair, replacement or refund In the manner and witliin the time provided shall constitute the Comp.any's sole liability· and your exclusive remedy resulting from any nonconformity or defect THE COMPANY SHALL NOT IN. ANY.. EVENT BE LIABLE FOR ANY DAMAGES, WHETHER BASED ON CONTRACT, WARRANTY; NEGLIGENCE;, STRICT LIABILITY OR OTHERWISE, INCLUDING WITHOUT LIMITATION ANY CONSEQUENTIAL, INCIDENTAL · OR SPECIAL DAMAGES, ARISING WITH RESPECT TO THE EQUIPMENT OR ITS FAILURE TO OPERATE· EVEN IF THE COMPANY HAS BEEN ADVISED OF THE POSSIBILITY THEREOF ..
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND, EXCEPT THAT OF. TITLE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WAR~IES . OF .. MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY., • · DISCLAIMED. NO SALESMAN OR OTHER REPRESENTATIVE OF THE COMPANY HAS AUTHORITY TQ MAKE ANY WARRANTIES,.
5
OIL-LESS COMPRESSOR UNIT DIMENSIONS
--

-
-I
0
···----·-__ _,--,__L/
~·-••----'
1------------<
D
6
::i;i-%~.'!l~~t~-~~~-c~r~~r;KJ%W:;
ll<nDIL -_, --In. In. ,_ In. "" ........
,.12 U17 175
MS35 ,.12 5Na7Y,,:l7"8 B80
10VTS35 .C.72 I.QT 57Vd:37Yis37-3.8 912 .
15WfS55 4.72 2.l; ~,3.8 1034
<:V1ti!i~~.:tw0STAGE;Ell:~11JT0R·D!ll'll:lla:;fi;.Tt
e-a.. ...... -A,,poz.
lllodll Ill. In. LiWltl Ill.. Nee Wgt. I&
~ '-'12XZ56 U7 = ... 170
MR:!) •·= U7 ""'37'/d07-3e 170
10WTR45 '72JC35' 1.97 571<x:l7V,d7-3e 1040
15WT!l'5 ··= 1.97 57¼<1"""'7-3.8 ""'
TAIIC IDllff ,SIIGl.E 5UGE, !UCTRIC lllTal 0IWEli
ll<n DIL ,._ Dlm,oalon ~· -In. In. uw.liln. ""Wgl. ""-
12TSVTS3S ,.12 1.97 ""37fu<7 1250
= '-72 1~7 112'3,V,,73 "'' 1217VIS35 4.72 1.117 ""'7\\,61 1255
2517VIS35 '-72 U7 112'3,V,,73 1650
12T10VTS35 4.72 U7 ""'7\\,61 129! •• 25T1CVTS35 '-72 1.97 ""'""'" 170)
12T1.5WTSS5 4.72 "" -7 1'3>
25T15WTSS5 ,.12 2.l6 ""3,V,,73 1""
· TAIi( llllJIII', twO STAGE, EI.ECTl!IC DR1>'91 ll7Till!:
ll<nDIL ...... °"""""" ~
-1· In. In. ,_ In. NII W;t. lb&.
12T5VTR2D U2l2.56 1.97 &3J3Tn.c&? "" = 4.72'2.56 1.97 112'3,V,, 73 16'0
12T7VmZl -4.7212.56 1.117 -= 12'5
2ST7VmZl •·= 1.97 92<),V,,73 16'0
12nawn:ws 4.72<1.SI U7 ""'37'M7 1415 ·
2ST10Wlll'5 4.72<1.SI 1.lil7 112'3,V,,73 18211
12T15Wffi,LS •·= U7 --7 1"6
2ST15Wll!'5 4.72<1.SI U7 112'3,V,,73 "'"
ll\JIUX TN« 11:JUNT, SIIGI£ STAGE, a.ECTRIC lllTCIIIDRIVEII
e-a.. -°"""'""" --I In. In. ,_ In. ...........
12T5VTS3S ,.12 1.97 IISY~ 2125 •
251'5VTS35 ,.12 1.97 M:iS7ln 2520
12TDMS3S '-72 U7 ·-2135
== '-72 w .... 7'72 2530 ..
12T010VTS35 ,.12 1.97 -210I
25TD1-VTS35 4.72 1.97 .... 7'72 ·2112 .
12'TD1SWTSSS ,.12 2.35 -....
2511)15Wl'500 4.72 2.35 ..,.,.72 ·-'~TANK llllJlll',TW0 STAGE; EfCl'.IIIC IIDTCIRDIIMII :
ll<nDIL ...... 1)1,mo,bi --I In. In. uWl!fln. ...........
1211l5VIR20 4.72l2.56 1.97 -2125
25lllSVTlt!l ,.72'2.56 1.97 &i,071,72 2531
12TDM1'20 ,.72x2.56 1,lil7' IISY~· Z!27
2511)M1'20 ,.72'2.56 1.97 6hS7ln · •. zsjo .
12lt>1C\VTJUS 4.72<1.SI U7 -.3171
25iD1CWTR,LS -4.7'2x3.5' 1.97 ""'-'72 . 2i<0
12l01SWTP,i5 U2l:l.5' 1.97 -·2'00.
2Sl015WTR4.5 . '-72':l.5' 1;97 Mdii'ln · .. -.
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Specifications -Oil-Less Compressors
Model HP
VTS35 5
VTS35 7.5
VTS35 10
WTS55 15
Model HP•
VTR20 5
VTR20 7.5
WTR45 10
WTR45 15
SINGLE STAGE, ELECTRIC MOTOR DRIVEN
Motor Cooling Water
Displ. Pulley Air Flow Cooled Flow
Pump RPM CFM oo· CFM GPM
VTS 740 29.5 5.30 1900 1.5
VTS 1065 42.5 7.35 2740 1.5
VTS 1450 57.8 9.75 3650. 1.5
WTS 1140 86.7 7.75 2870 2.0
lWO STAGE ELECTRIC MOTOR DRIVEN •
Motor Cooling Water
Dlspl. Pulley Air Flow Cooled Flow
Pump RPM CFM oo· CFM-•CPM
VTR 1000 19.9 6.75 2570 1
VTR 1300 25.9 8.95 3340 1
WTR 1065 42.5 7.35 2740 1.5
WTR 1450 57.8 9.75 3650 2
• -Based on 1750 RPM Motor Speed
Heat
Rejection
BTU/HR
10,180
15,260
20.350
30,500
Heat
Rejection
BTU/HR
10,180
15,260
20.350
30,500
Maximum Pressure: 100 PSIG
Maximum Speed: 1450 RPM VTS35
.. 1140 RPM WTS55
Maximum Pressure: 175 PSIG
Maximum Speed: 1300 RPM VTR20
1450 RPM WTR45
-Watercooled Oi~Less units must maintain a discharge water temperature between 100"F and 150'F.
-A flow regulating device should be installed in the discharge water line to assure that the temperature limits
are not exceeded.
-Maximum inlet water temperature: 80"F.
-Minimum ambient temperature: 32"F
-Maximum ambient temperature: 1 oo•F
ELECTRIC WIRING (BASED ON 1996 NEC)
Wire Size (Rubber Covered) AWG NO.
Copper Conductor -75'C Temp Rating -30"C Ambient
3 PHASE 1 PHASE
MOTOR
HP 200/208V 230V 460V 575V 115V 208V
5 10 (8) 12 (8) 14 (12) 14 (14) . 8 (6)
.
7.5 8 (6) 10 (6) 14 (10) 14 (10) . .
10 8 (4) 8 (4) 12 (8) · 14 (10) . .
15 4 (2) 6 (3) 10 (6) 10 (8) . .
230V
8(6)
6 (3)
.
-
VALUES in () for Duplex Units w/one incoming power line to both motors.
7
25 50
VTS35 1 (1) 1 (1)
WTS55 1 (1-1/4) 1 (1-1/4)
VTR20 · 3/4 (3/4) 3/4 (3/4)
WTR45 3/4 (1-1/4) 1 (1-1/4)
VALUES in () for Duplex Un.its.
PIPE SIZES FOR COMPRESSED AIR LINES
(Base<! on Clean, Smooth Schedule 40 Pipe)
LENGTH OF PIPE LINES IN FEET
75 100 150 200
1 (1) 1 (1) 1 (1-1/4) 1 (1-1/4)
1 (1-1/4) 1 (1-1/4) 1-1/4 (1-1/2) 1-1/4 (1-1/2)
3/4 (1) 3/4 (1) 3/4 (1) 3/4 (1)
1 (1-1/4) 1 (1-1/4) 1 (1-1/2) 1 (1-1/2)
16 WARN.ING I
250 300
1 (1-1/4) 1 (1-1/4)
1-1/4 (1-1/2) 1-1/4 (1-1/2)
3/4 (1) 3/4 (1)
1 (1-1/2) 1 (1-1/2)
Never use plastic pipe or improperly rated metal pipe. Improper piping materials can burst and cause injury or property damage.
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INSTALLATION
1. Permanently installed compressors must
be located In a clean, well ventilated
dry room so compressor receives
adequate supply of fresh, clean, cool
and dry air. It is recommended that a
compressor, used for painting, be located
in a separate room from that area wherein
body sanding and painting is done.
Abrasive particles or paint, found to have
clogged the air intake filters and intake
valves, shall automatically void warranty.
2. Compressors should never be located so
close to a wall or other obstruction that
flow of air through the fan bladed flywheel,
which cools the compressor, is impeded ..
Permanently mounted units should
have flywheel at least 36" from wall, for
proper air circulation and ease of
maintenance.
3.
I""
Place stationary compressors on firm
level ground or flooring. Pennanent
installations require bolting to floor.
Bolt holes in tank or base feet are
provided. Before bolting or lagging down,
shim compressor level. Bolt or lock nut
should only be "snug", not tight.
Avoid putting stress on a tank foot by
pulling it down to floor. As an
alternative, install unit on optional vibro-
isolator pads. Units bolted directly to a
concrete floor without padding will not I
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4.
,rr,:
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be warranted against cracking. ·
Once the unit is in place, loosen the bolts
securing the wood shipping blocks
between the sub-base and the unit base.
Remove the blocks and bolts.
IMPORTANT NOTICE
This compressor is equipped with a
vibration isolation system, which consists
of an inner baseplate (pump mounting
base) suspended on 4 springs.· For
shipping purposes ONLY, the base is
locked down with 2 wood blocks which are
inserted between the inner basepl_ate and
outer frame. This is to prevent damage .
from the unit shifting around on the
springs during transit. These BOLTS
AND WOOD BLOCKS MUST BE
, REMOVED prior to starting the unit.
To remove· the shipping blocks, first
loosen and remove the 2 bolts located. at
5,
9
the ends of the inner baseplate (see
diagram below). Then remove the 2
shipping blocks which are accessed
through the 2 forklift slots in the frame,
intake filter side of unit. To simplify
access, a short piece of wire is attached
to each block. Grab the wire and extract
the block through the slot in the frame.
For best vibration control, the 4 spring
isolators may require slight adjustment to
match each compressor, or compensate
for any off-level floor conditions. A bolt
with lock nut is provided at each comer for
this purpose. The inner and outer bases
should be approximately flush with each
other, if the springs are properly set
1~~1<ffl1 '.!i,l I
\RDtOVI: 'ntESI: IIOLn, A.NO REMOVE !DtIPPllfG / • IILOCK3 LCICATED l!IETl«EK llOIJ!:R AJID OOTt:M !1.\.5:r::s.
IA CAUTION I
Failure to remove shipping blocks may
result in excessive vibration and unit
damage.
If installing a bare pump, make certain the •
system has adequate pressure limiting
controls. Controls could be a pressure -
switch for start/stop operation or a pilot
valve for continuous operation. If a pilot ·
valve is used, the compressor must be .
equipped with head unloaders or suction
unloader.
t 11•t;1~®AA;1 · Do not install isolating valves between.
compressor outlet and air receiver •.
This will cause excessive pressure jf
valve Is closed and cause injury and
equipment damage.· -
I~ WARNING I
Always use an air pressure regulating
device at the point of use. Failure to
do so can result in injury or equipment
damage.
INSTALLATION (CONT'D.) IA CAUTION I
• Do not install In an area where ambient
temperature is below 32 degrees For
above 100 degrees F.
• Do not install unit in an area where air
is dirty and/or chemical laden.
• Unit is not to be installed outdoors.
ELECTRICAL POWER SUPPLY
(See also Wiring Diagram -Figure 1.)
It is essential that the power supply and
the supply wiring are adequately sized and that the
voltage correspond to the unit specifications.
All wiring should be performed by a
licensed electrician or electrical contractor. Wiring
must meet applicable codes for area of installation.
Recommended electrical wrnng
specifications are listed in "Specifications" section.
If ordered with a mounted starter,
compressor unit is pre-wired at factory. It is
necessary only to bring lines from properly sized
disconnect switch to magnetic starter mounted on
compressor, and attach to terminals as indicated
on schematic diagram located inside the cover of
the starter. Be sure that power circuit and
voltage correspond with the specifications.
IA CAUTION I
Wiring must be such that when viewing
compressor from opposite shaft end, rotation
of shaft is clockwise as shown by arrow on
guard. Wrong direction rotation for any length
of time will result in damage to compressor.
For base mounted units, a pressure switch
must be mounted on the air receiver and wired as
shown in the wiring diagram.
A terminal board is furnished with each
base mounted unit. The hourmeter and solenoid
valve{s) are prewired to this. It will be necessary
to make connections from this terminal board to
the starter as shown in the .diagram.
GROUNDING INSTRUCTIONS
This product should be connected to a
grounded, metallic, permanent wiring system, or
an equipment-grounding terminal or lead on the
product.
10
AIR LINE PIPING
{See also Piping Diagram -Figure 2)
An adequately sized air receiver must be
used with a base mounted Oil-Less compressor
unit. The minimum receiver size for the 5, 7½ and .
10 HP units should be 80 gallon and the 15 HP
unit should be 120 gallon.
The check valve furnished with a base mounted
unit must be Installed between the receiver and
the compressor outlet, as shown in the piping
diagram. The air receiver should be installed
within 10 feet of the compressor unit for proper
unloading when unit is shut down. An adequately
sized pressure relief valve must be mounted in the
air receiver and also a pressure gauge with a dial
that reads to 300 PSIG maximum. ·
For compressor units equipped with
optional constant speed unloading, a connecting
¼" tubing line from the receiver to the pilot valve is
required.
•• Connection to air system should be of the
same size, or larger, than discharge pipe out of
unit. For recommended piping · sizes, · see
"Specifications" section. A union connection to the
unit and water drop leg is recommended. Plant air
piping should be periodically inspected for leaks
using a soap and water solution for detection on all
pipe joints. Air leaks waste energy and are
expensive.
PREPARATION FOR INITIAL START-.
UPAND OPERATION
1. Pull main disconnect switch to unit to
assure that no power is coming into the
unit. Connect power leads to starter.
IA WARNING I
Do not attempt to operate compressor ·
on voltage other than that specified on
order or on compressor motor.
2. Inspect unit for any visible signs of
damage that ·would have occurred in
shipment or during installation.
3. Activate main disconnect switch.
4. • Jog" motor and check for proper rotation
by direction arrow. If rotation is wrong,
reverse input connections on the magnetic.
starter.
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NOTES:
1MTR
10L
1M
1M-1
1PS
1TS
1SS
1SOL
2SOL
1ETN
FIGURE 1
OIL-LESS COMPRESSOR TERMINAL WIRING DIAGRAM
1. AU WIRING TO BE IN ACCORDANCE WITii NEC. 2. SEE MOTOR NAMEPLAETE FOR CORRECT MOTOR CONNECTION. 3. TEMPERATURE SWITCH (1TS) IS OPTIONAL REMOVE JUMPER A WHEN CONNECTING THIS OPTION. "lWO OR MORE OPTIONS BETWEEN X2 & L2 MUST BE WIRED IN SERIES.
4. REMOVE JUMPER 1 WHEN CONNECTING ANY ONE OF THE 1SS/1PS OPTIONS SHOWN.
5. BRANCH CIRCUIT PROTECTION. FUSED DISCONNECT DR CIRCUIT BREAKER MUST BE PROVIDED BY INSTAUER IF PANEL IS NOT EQUIPPED WITH FUSIBLE DISCONNECT.
LEGEND:
_MOTOR
OVERLAND RELAY & CONTACT
MAG STARTER COIL & CONTACTORS
AUXILIARY INTERLOCK (NORMALLY OPEN)
PRESSURE SWITCH
HIGH AIR TEMPERATURE SWITCH
OFF-ON OR H-0-A SELECTOR SWITCH
UNLOAD SOLENOID SWITCH
WATER CONTROL SOLENOID VALVE
(WATER COOLED UNITS ONLY)
ELASPED TIME METER
r --~-WIROfaom:,NS----,
I (S£EN0TESJ14) I
IJJ II!. Or
u ~ J o----0 o-----o
ll I PS l
0----7----0
IJf m !II
U lfi _j__ ) o----oy-...a o---o
IS! •.a.'
ll 4 l 0-------o
(111)1., '
I I .._ -

-
7
I I I .....L., fP5
L-O 0---o-ro-J IID:I 0,
a 111 u c---~ -

-
-0
L ______________ .J
·,.._
1 ,.
--·x
11
y y
• J
I
I j'!"JJ I
0 ll u .....
, .
,.
II 11
'"''"
y
ul
0
.. ..
OPTIONAL AIR·COOLED
AFTERCOOLER
WATER INLET LOCATIONS•
I. WATER-COOLED ONLY J/e• NPJ •·
2, WITH OPTIONAL
WATER·COOLEO
AFTERCOOLER, • 318" NPT,
OPTIONAL WATER-COOLED
AFTERCOOLER,
---
OIL-LESS COMPRESSOR PIPING DIAGRAM
C·203
FIGURE 2
-..
PRESSURE
SWITCH
--
PRESSURE
RELIEF VALVE
PRESSURE
GAUGE
ffllll--TO COMPRESSED
AIR SYSTEM.
OPTIONAL AIR
DRYER LOCATION
---
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PREPARATION/INITIAL START-UP (CONrD.)
5. Close receiver outlet hand valve and start
unit.
6. With receiver hand valve closed, let
machine pump up to operating pressure.
At this stage the automatic controls will
take over. Check for proper cycling
operation.
7. Check for proper operation of any options,
e.g. suction unloading with pilot valve.
Refer to individual option instruction
sheet.
8. Open receiver hand valve. The air
compressor unit is now ready for use.
GUIDE TO MAINTENANCE
To obtain reliable and satisfactory service, this unit
requires a consistent preventive maintenance
schedule. A maintenance schedule form is
included to aid in keeping the proper records.
IA WARNING I
Before performing any maintenance
function, switch main disconnect
switch to "otr' position to assure no
power Is. entering unit. "Lock Out" or
"Tag Out" all sources of power .. Be
sure all air pressure in unit Is relieved.
Failure to do this may result in injury
or equipment damage.
DAILY MAINTENANCE
1. Drain moisture from tank by opening
tank drain cock located in bottom of tank.
Do no open drain valve if tank pressure
exceeds 25 PSIG.
2. Tum off compressor at the end of each
day's operation. Turn off power supply at
wall switch.
WEEKLY MAINTENANCE
1. Clean dust and foreign matter from
cylinder head, motor, fan blade, air lines,
intercooler and tank.
13
2.
3.
Remove and clean intake air filters.
IA WARNING/
Do not exceed 15 PSIG nozzle pressure
when cleaning element parts with
compressed air. Do not direct
compressed air against human skin.
Serious Injury could result. Never wash
elements in fuel oil, gasoline or
flammable solvent.
Check V-belts for tightness. The V-
belts must be tight enough to transmit the
necessary power to the compressor.
Adjust the V-belts as follows:
Remove bolts and cabinet to access
compressor drive.
Loosen mounting hardware which secures
motor to base. Slide motor within slots of
baseplate to desired position.
Apply pressure with finger to one belt at
midpoint span. Tension is correct if top of
belt aligns with bottom of adjacent belt.
Make further adjustments if necessary.
Check the alignment of pulleys. Adjust if
necessary.
Tighten mounting hardware to secure
motor on base.
Re-install cabinet and secure bolts.
IA WARNING I
Never operate unit without cabinet and
cover in place. Removal° will expose
rotating parts which can cause injury
or equipment damage.
EVERY 90 DAYS OR 500 HOURS
MAINTENANCE
1. Check entire system for air leakage
around fittings, connections, and gaskets,
using soap solution and brush.
2. Tighten nuts and capscrews as
required.
3. Pull ring on all pressure relief valves to,
assure proper operation.
SPECIAL MAINTENANCE
In addition to the maintenance intervals
given above, the Oil-Less compressor has
some additional maintenance
requirements for rings, drive sets and
shaft bearings. These intervals are given
in Figure 3. ·
GENERAL MAINTENANCE NOTES
ELECTRIC MOTOR: For service refer to separate
manual or chart attached to equipment
PRESSURE RELIEF VALVE: The pressure relief
valve is an automatic pop valve. Each
valve is properly adjusted for the ·
maximum pressure of the unit on which it
is installed. If it should pop, it will be
necessary to drain all the air out of the
tank in order to reset properly. Do no
readjust.
TANK DRAIN VALVE: Drain valve is located at
bottom of tank. Open drain valve daily to
drain condensation. Do not open drain
valve if tank pressure exceeds 25 PSIG.
The automatic tank drain equipped
compressor requires draining manually
once a week.
PRESSURE SWITCH: The pressure switch is
automatic and will start compressor at the
low pressure and stop when the maximum
pressure is reached. It is adjusted to start
and stop compressor at the proper
pressure for the unit on which it is
installed. Do not readjust
BEL TS: Drive belts must be kept tight enough lo
prevent slipping. If belts slip or squeak.
see V-belt maintenance in preceding
section.
I i6 CAUTION I
If belts are too tight, overload will be
put on motor and motor bearings.
COMPRESSOR VALVES: · Al every 5000
hours, or if compressor fails lo pump air or
seems slow in filling up tank, disconnect
· unit from power source and remove
valves and clean thoroughly, using
compressed air or a soft wire brush. After
cleaning exceptional care must be taken
that valves are replaced in exactly the
same position and all joints must be tight
or the compressor will not function
properly. When all valves are replaced
and connections tight, dose hand valve at
14.
tank outlet for final test. Valve gaskets
should be replaced each time valves are
removed from pump.
CHECK VALVE: The check valve closes when
the compressor stops operating,
preventing air from flowing out of the tank
through the solenoid release. After the
compressor stops operating, if air
continues to escape through the solenoid
valve, it is an indication that the check
valve is leaking. This can be corrected by
removing check valve and cleaning disc
and seat. If check valve is worn badly,
replace same.
....
14 WARNING I
Before removing check valve be sure
all air is drained out of tank and power
is disconnected. Failure to do so may
result in injury or equipment damage.
THE INTERSTAGE PRESSURE RELIEF VALVE
on two stage compressors is provided to protect
against interstage over pressure and is factory set
for maximum pressure of 75 PSIG.
DO NOT RESET !
If the pressure relief valve pops, it
indicates trouble. Shut down the unit
immediately and determine and correct
the malfunction. Inspect the head valves.
Serious damage can result if not corrected
and can lead to complete destruction of
the unit. Tampering with the interstage
pressure relief valve, or plugging the
opening destroys the protection provided
and voids all warranty.
PISTON RINGS: The piston rings are designed
for 10,000 hours operating life. However,
installations may vary, so Figure 4 is given
which shows maximum ring wear before
rings must be replaced.
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FIGURE 3
MAINTENANCE CHART
Pe!lod of Time. Chedc Item Maintenance WOl1c
Every 10,000 Hours (reading from PislDn Rings, Guide Rings Ct-eek and replace ff necessary
hourmeter) (See FJQUre 4)
or Driving Set (Connecting Rod Big End, Replace
Bearings and Bushings)
3 Years Piston Sets (Piston \\ith Connecting Replace
Rod small end)
Every 20,000 Hours (reading from Crankshalt Bearings Replace
hourmeter) Consul! faCIDry for exchange
or aankshalt assembly prices
3 Years ....
CAUTION: The compressor must not be lubricated with any greases or oils, because all bearings have penmanently sealed
special lubrication and the sliding surfaces run dry on alloyed PTFE Rings.
FIGURE 4
Gulde Rings and Plsl0n Rings roost be replaced by new sets, if the radial ring lhlcmess Is out of the range glYl!ll on the
following table.
RING SPECIRCATIONS
Top Compression
Plst0n Gulde Rings Compression Rings · Ring
Orlglnal Minimum Original Mlnlmum Original Minimum
Diameter Thickness Thickness Thickness Thlckness Thickness Thickness.
4.7 inches .118 inch .102 inch .28 inch .185 inch . .26 inch .232 inch .
(120 mm) (3.0 mm) (2.6 mm) (7.0 mm) (4.7 mm) (6.6 mm) · (5.89 mm)
3.5 inches .118 inch .102 inch .24 inch .157 inch .23 inch .212 inch
(90 mm) (3.0 mm) (2.6 mm) (6.0 mm) (4.0 mm) (5.84 mm) (5.37mm)
. 2.6 inches .118 inch .110 inch .20 inch .130 inch --
(65 mm) (3.0 mm) (2,8 mm) (5.0 inm) (3.3 mm)
15
MAINTENANCE PROCEDURES
IA WARNING I ALWAYS DISCONNECT ELECTRICAL POWER FROM COMPRESSOR
UNIT BEFORE PERFOMRING ANY MAINTENANCE. "LOCK OUT" OR "TAG our· SWITCH. RELIEVE TANK PRESSURE. FAILURE TO DO so CAN RESULT IN EQUIPMENT DAMAGE OR INJURY.
REPLACEMENT OF COMPRESSION & GUIDE
RINGS -Every 10,000 hours of run time, as indicated by the hourmeter, the compression
and guide rings may need to be replaced as
defined in the Maintenance Chart. The
procedure for disassembly and reassembly is as
follows:
1. Remove canopy and tubing to head.
2. Remove capscrews holding cylinder to
crankcase.
3. Carefully pull straight away from the
crankcase the cylinder/head subassembly.
Removing the cylinder/head will expose the.
piston.
4. Remove the compression rings, guide rings
and "O" rings (See Figure 5).
5. Clean piston and ring grooves thoroughly
with a clean lint-free cloth and install new
compression rings. The compression rings
are not taper faced so there is no top
position. Position the rings so that joints are
staggered around the piston. (See Figure
5.)
6. Install "O" rings in the grooves provided at
the top end of each guide ring.
7. Install guide rings and position so that joints
are staggered and "O" rings are visible.
8. Wipe out cylinder bore surface with a clean,
lint-free cloth.
9. Carefully reinstall cylinder/head assembly
over piston and rings. The cylinder should
slide freely over rings. Make certain guide
rings are not compressed over "O" rings. If
resistance is encountered, "twist'' guide ring
to properly position on piston. ·
10. Reinstall cap screws and retighten cylinder
to crankcase.
11. Reinstall tubing to head and canopy.
16
REPLACEMENT OF PISTON AND DRIVING SET -
Every 10,000 hours of run time, as indicated by the hourmeter, the Piston Set and Driving Set
must be replaced. It is strongly recommended
that the compressor be returned to the factory
for this replacement. The procedure for
replacement of these parts is as follows:
1. Remove canopy, tubing to head and
crankcase end cover.
2. Remove cylinders as described in the
section on "Replacement of Compression
and Guide Rings".
3. • • Loosen the con rod fasteners and remove
Piston Set (Piston and upper half of con
rod). See Figure 5.
4. Remove fastener holding balance weight to
crankshaft assembly.
5. Using the special bolt from the Disassembly
Tool Set, (See Figure 6) thread into end of
balance weight and crankshaft. Continue to
turn bolt until balance weight has been
disengaged from the assembly.
6. Place spacer from Disassembly Tool Set to
this exposed end of crankshaft, locating it
with its pin to the pin hole in the crankshaft.
7. Put snap ring in snap ring groove in ID of
Driving Set Bushing. (See Figure 7.)
8. Using the special bolt from the Disassembly
Tool Set, thread into this spacer. Continue
to turn bolt until bushing has been
disengaged from the crankshaft throw. This
will free the driving set and allow it to be
removed from the compressor.
9. To install the new driving set, first heat the
bushing and assembly to 200· F on a hot
plate. Then push this assembly as far as
possible onto the crankshaft throw. Be
certain that the shoulder end of the bushing
is engaged on the shaft first.
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REPLACEMENT OF PISTION & DRIVING SET (CONrD.)
10. If the drive set fails to slide all the way to the shoulder of the crankshaft throw, use either· the spacer and snap ring or the bar of the Disassembly Tool Set and the capscrew that holds the balance weight to the shaft. If using · the spacer and snap rings. insert snap ring in groove of bushing and place spacer outside of this ring. Then thread capscrew in end of · crankshaft and tighten to move drive set to the shoulder of the crankshaft throw. 11. Remove capscrew, spacer and snap ring if used.
12. Place balance weight in proper position, thread in capscrew and tighten. This completes the installation of the driving set. 13. Install piston set to driving set by positioning upper half of con rod to lower half, using the key for proper location. Insert and tighten con rod bolts. This completes the installation of the piston set.
14. Mount cylinder/head assembly by referring to mounting instructions given in the section on replacement of Compression and Guide Rings.
15. Reinstall crankcase end cover, tubing to heads and canopy.
REPLACEMENT OF CRANKSHAFT BEARINGS • Every 20,000 hours of run time, as indicated by the hourmeter, the crankshaft bearings must be replaced. The p4mp must be taken out of service and should be returned to an authorized distributor for these bearing replacements. Exchange crankshaft assembly with bearings or Exchange rebuilt pumps are available -consult factory.
TORQUE CHART
FOR COMPRESSOR FASTENERS
All Manifolds 24 Ft.-Lb.
Connecting Rod Bolls, Cylinder-to-
Crankcase Bolts, Counterweight Bolt. 50 Ft-Lb. Crankcase End Cover Bolts
Cylinder Head Nuts 50 Ft.-Lb.
Fan Hub Bolt PO5390A 50 Ft.-Lb.
AIR RECEIVERS-Tank Mount Only
PO5945D 120 Gallon ASMECODED PO5946D 250 Gallon ASMECODED
17
SNAP. RI NG GROOVE ··'
PISTON SET
AGURES
AGURE6
DRIVING SET
AGURE7
A
8
C
D
E
F
G
H
J
K
L
M
N
0
TROUBLE SHOOTING CHART FOR COMPRESSOR UNIT
SERVICE PROBLEM
Motor will not Start
Motor is Noisy or Overheating
Motor Stops
Compressor Runs Hot
Compressor Pumps Too Slowly
Compressor Won't Shut Off ·
Noisy Check Valve .
Excessive Sett Wear
Abnormal Pressure Fluctuation
Air Escapes From Unloader Muffler of Solenoid When Running
Interstage Pressure Relief Valve Pops off Continuously
Compressor Cycles (runs) too Often
Compressor Kicks Out
Receiver Loses Pressure When Compressor Stops Running
and Air Demand is Low
Compressor Knocking· Noise During Operation
,---,-:P==O=S==S=IB=L=E===C=A=US=E===O::::F=:P:=R::::O;B;L=E=M'-------1-0:::...J...:.N:...j..:::M+L::...J....:_K:...j...:'.J+:_i...'..H:..+-G~_:F_.i.::E~D~· C
1 Main Switch and Fuses
2 Magnetic Starter Heater Coil
3 Magnetic Starter Tripped
4 Points in Pressure Switch
5 Diaphragm in Pressure Switch Defective
6 Low Voltage
7 Motor Lacks Lubrication
8 Excess Water in Air Receiver
9 Pilot Valve Dirty
10 "V' Belts Improperly Tensioned
11 Improper Fan Rotation
12 Compressor Pump Valves
13 Pipeline Leaks
14 Check Valve or Line to Receiver is Leaking or Plugged
15 Check Valve is Worn
16 Belts Misaligned
17 Dirty Intake Muffler
18 Pressure Setting Incorrect
19 Solenoid Valve forWatercooled Compressor Defective
20 Solenoid Valve for Unloading Start is Leaking
21 Pressure Relief Valve on Tank is Leaking
22 Drive Set Defective
FOR EXPLANATION SEE NEXT PAGE L K J H G C
I~-WARNING I
Always disconnect unit from power supply and relieve all pressure from air tank
before performing any maintenance. "Tag Out" or "Lock Out" disconnect swit~ti-
Failure to do so may result in equipment damage or injury.
Never operate unit without beit guard in place.
B
B
Never use gasoline or flammable solvent on or around compressor unil Explosion
may result
18
A
7.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
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EXPLANATION OF TROUBLE SHOOTING CHART
1 /2. Check all fuses and switches on lines to motor to be sure it is receiving power. Check for broken wire.
3. A magnetic starter embodies a reset button which may be used to place the motor back in service after some unusual power conditions.
4/5. A pressure switch uses a diaphragm to open and close a set of points. Points may become pitted. or dirty thru use. Clean by "touching" up with sandpaper or replace. See instructions in pressure switch cover.
I A WARNING I ~!~~h~nect unit from power source before checking pressure
6. Low voltage is prime cause of motor trouble. Ask your power company to test for low voltage.
7. Most electric motors are of the sealed bearing type. Check motor manufacturer's recommendation.
8. Water in the form of vapor is compressed along with incoming air and condenses in tank. Tank must be drained daily so that full storage capacity of tank may be used. To drain, open pet cock on bottom of horizontal or vertical tank. This is required week/~ if compressor is equipped with automatic tank ... drain. I A WARNING I Do not open drain valve if tank pressure exceeds 25 PSIG.
9. See instruction of pilot valve.
10.
11.
'V belts must be tight enough to transmit the necessary power to the compressor. If too tight they will overload the motor. If, by pushing down on one belt. its top lines up with the bottom of the belt next to it, the tension is correct. Should it be necessary to change the tension, disconnect the unit, from power supply and slide the motor in slots in baseplate to desired position.
I A W'ARNING I Disconnect unit from power source before checking or adjusting I'\ belts. Always reinstall guarding after adjusting belts. ===--------'
The fan blade rotation must be blowing air toward cylinders.
12. For valves, remove the screws and pry valve plates apart.
Should damage be found to the valve reeds, complete valve must be replaced. No hard tools should be used for cleaning valve parts. In order to protect the anti-rust plating, valve plates should be neither lapped nor ground.
The valve and gaskets must be well tightened between the cylinder & head by the four studs and nuts. The valve gasket must be replaced after each dismantling. Checking for leakage can be done with soapy water while the compressor is running under pressure. In case of leakage, the screws ,must be re-tightened.
13. · All air lines from compressor to tank and from tank to air operated devices should be tight. A soap · solution will show bubbles when put on a leaky joint.
19
EXPLANATION OF TROUBLE SHOOTING CHART (CONTD.) I
14/15. Check Valve: The check valve closes when the compressor stops operating, preventing air from ,,
flowing out of the tank through the pressure release valve. After the compressor stops operating, if
air continues to escape through the release valve it is an indication that the check valve is leaking.
This can be corrected by removing check valve cap and cleaning disc and seat If check valve is worn I
badly, replace same.
I A W'ARNING I Disconnect_ ~nlt'from power source and relieve tank pressure I I\ before servrcmg these components .. ~==----------
16.
17.
18.
Motor pulley and flywheel must be in line to prevent wear on sides of belts. If misaligned, disconnect
power supply and move pulley in or out by loosening set screw on key and tapping pulley in
appropriate direction.
I A WARNING I Disconnect power source before adjusting pulley.
Intake filter should be cleaned periodically to allow unrestricted flow· of entering air. To service filter,
remove from canister by removing wing nut and canil;ter top. May be cleaned by blowing compressed
air from inside of element toward outer surface.
For Single Stage Units:
For Two-Stage Unils:
Pressure switch setting is 70 psig cut -in and 100 psig cut-out.
Pressure switch setting is 140 psig cut-in and 175 psig cut-out.
19. Solenoid valve controls the water flow. If the valve closes when running. it needs to be_ replaced.
20. When the compressor stops the solenoid valve will open to unload the compressor. This prevents
overloading the motor when starting. If air continues to escape through the muffler of solenoid valve
while operating, this is an indication it may be held by foreign substance which has lodged on the
valve. The solenoid valve must be replaced.
21. Pressure Relief Valve: The pressure relief valve is an automatic pop valve. Each valve is properly
adjusted for the maximum pressure permitted by tank specifications and working pressure of the unit
on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank in order
to reset properly. Do not readjust
22. Remove cylinder and check by moving the piston from side to side to see whether the connecting rod
bearing or the small end bearing is defective. Should either be damaged, the complete driving set or
piston set must be exchanged.
20
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TANK MOUNTED UNITS (Model Prefix)
12T =120 Gallon
25T = 250 Gallon
12TD = 120 Gallon Duplex
25TD = 250 Gallon Duplex
I I
\ f::!:•'•' I 0 G,;,__J
c::::J
0
• . ..__ r··1------________ _,
' '--'
DRIVE INFORMATION
PULLEY V-BELTS
UNIT MOTOR HP PULLEY BUSHING KEY 3 Required
CHECK VALVE
PRESSURE SWITCH
PART NUMBER
5VTS
5VTR
7VTR
7VTS
10VTS
10WTR
15WTR
15WTS
(all models)
CUTIN
P05007 A Single Slage 70 PSIG
140 PSIG P05007 A Two Stage
PRESSURE RELIEF VALVE FACTORY
5 P07485A P05608A U-8 5L-760
5 P05291A P05608A U-8 B-76
7½ P05345A P05607A M2027 B-78
7½ P11873C M2027 B-76
10 P09521B M2027 B-78
10 P11873C M2027 B-76
15 P09312B RE-20-8 B-80
15 P11872C RE-20-8 B-78
UNIT COMPONENT LIST
P07460A
PILOT VALVE Constanl speed or dual conlrol (oplional)
CUTOUT
100 PSIG
175 PSIG
PART NUMBER CUT IN.
M2855
M2853
M547
Single Stage 70 PSIG
Two Stage 140 PSIG
Needle Valve
(Dual Control
Only)
115V 200V
CUTOUT
95 PSIG
170 PSIG
230V 460V
PART NUMBER SETPSIG. PART# PART# PART# PART#
M2839 Single Stage 150 Hourmeter P04232A P05290A P05302A P05303A
M2843 Two Stage 200 Two Stage P05787A P05304A P05300A P05301A
Unloader Solenoid P05327A
Water Solenoid P10472A P05328A P05329A
Single Stage P10469A P10470A P10471A
Unloader Solenoid ' ...
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21
I
VTS PUMP • CRANKCASE, CRANKSHAFT, DRIVING SET & PISTON SETS
7
10 g
.:; '-\ 5 2
B
14 11 BA
12
ITEM NO. PART NO. DESCRIPTION REQ'D
1 P05144D Crankcase 1
2 Z1243 .. MAIN BEARING SET 1
3 P05106A Spacer Bushing 1
4 P050~2B Spacer Bushing 1
5 M2250 Snap Ring 1
6 P05135D .. Crankshaft 1
7 Z1101 DRIVING SET 1
8 P05129C Balance Weight 1
SA P05189A Screw-Headless 1
9 P05195A Washer, Flat 1
10 M2251 Washer, Lock 1
11 M2239 Screw· 1
12 Z1102 CRANKCASE COVER 1
13 P05196A Washer Lock 3
14 M2695 Screw 3
15 Z1241 PISTON SET 2
16 Z1242 RING SET 2
17 P05195A Washer, Flat 4
18 P05196A Washer Lock 4
19 M2254 Screw 4
•· Contact Factory • Pump Exchange Recommended ·
22.
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1
1A
ITEM NO.
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
VTS PUMP-CYLINDERS, HEADS & VALVES
13 14
j
9 0 ~JJ
0 ,
11
4
PART NO. DESCRIPTION REQ'D
P05126C Cylinder, Water Cooled 2·
P11725D Cylinder, Air Cooled 2
P05196A Washer, Lock 12
M2254 Screw 12
M2246 Stud, Cylinder 8
P10886A O-Ring 2
P05188A Stud, Valve P!ate 4
P11136B Valve Plate 2
P101138 Gasket 2
P05137D Cylinder Head 2
P05190A Washer, Copper 4
P05193A Nut, Acom 4
P05195A Washer, Flat 8
P05196A Washer, Lock 8
P05198A Nut, Hex 8
P051088 Water Jacket 2·
M2245 O-Ring 4•
• Water Cooled Pumps Only ..
23
VTS PUMP -INTAKE MANIFOLD & EXHAUST MANIFOLD
2 3
ITEM ITEM NO. PART NO. DESCRIPTION REQ'O NO. PART NO. DESCRIPTION
1 P051990 Flywfleol 1 11 M2264 Screw 1A M2273 Key, Aywt,eol 1 12 P103JBA Connector, Elbow, Tube 2 P05739A Wa.u,er, Fan Hub 1 13 P10337A Cq 3 P04247A Fan 1 14 P09936A Tubing Intake .4 P05390A Fan Hub Bott 1 15 P10340A Connector, Slraight. Tube 5 M3256 Key, Fan Hub 1 16 M3145 Nipple. Clme . 6 P07177A Cor!1ires.sion Frtting 2 17 M3189 Tee. 11/2" · 7 P05213A Manifold Flange 2 18 P0993SA Filter, Intake 8 P05226A Ga.,ket 4 19 P0553JA -Element, Filter 9 P09959A Manifold Aange 2 20 21248 Eihaust Manifold Kit 10 P05219A Washer, lack 16 21 MJ194 Nipple, 1 ll" I 4 ll"
24
REQ'D
16
1
2
2 Ft
1
1
1
1
1
1
1
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VTR PUMP -CRANKCASE, CRANKSHAFT, DRIVING SET & PISTON SET
F''
15
20 21
19
3
6 18
7
10 9
" ~ ~ r~~\
14 11
4
17
5 2
12
I ITEM PART ITEM PART
RED'D .1 NO. NO. DSCRIPTION REQ'D NO. NO. DESCRIPTION
1 P05144D Crankcase 1 11 M2239 Screw 1
2 21243•• MAIN BEARING SET 1 12 21102 Crankcase Cover 3
3 P05106A Spacer Bushing 1 13 P05196A Washer Lock 3
4 P050928 Spacer Bushing 1 14 M2695 Screw 1
5 M2250 Snap Ring 1 15 21237 PISTON SET 1
6 P05135D Crankshaft 1 16 21238 RING SET 1
7 21101 DRIVING SET 1 17 21241 PISTON SET 1
B P05129C Balance Wei~ht 1 18 21242 RING SET 4
SA P05189A Screw, Headless 1 19 P05195A Washer, Flat 4
9 P05195A Washer, Flat 1 20 P05196A Washer, Lock 4
10 M2251 Washer, Lock 1 21 M2254 Screw
•· Conlacl Factory -Pump Exchange Recommended
25
ITEM
NO.
1
1A
2
3
4
5
6
7
8
9
10
11
17
12A
VTR PUMP-CYLINDERS, HEADS & VALVES
15 25
13
-~
1 V-'
1412~~:--~ •
' ' ,, .
10
ITEM
PART NO. DESCRIPTION RED'D NO.
P05126C Cylinder 2· 13
P11725D Cyfinder 2 14 ·
M2246 Stud, Cylinder 4 15
P10886A 0-Ring 1 16
P05188A Stud, Valve Plate 2 17
P111368 Valve Plate 1 18
P101138 Gasket 1 19
P051370 Cyfinder Head 1 20
P05190A Washer, Copper 2 21
P05193A Nut, Acom 2 22
M2247 Stud, Cyfinder 4 23
M2242 0-Ring 1 24
P05118C Cyfinder 2' 25
Pl 17230 Cyfinder 1
PART
NO.
P10973A
P05142B
P05124B
P05138D
P05196A
M2254
P05195A
P05196A
P05198A
P051088
M2245
P05103B
M2243
• Water Cooled Pumps Only
26
6
4
3
DESCRIPTION
0-Ring
Valve Plate
Gasket
Cyfinder Head
Washer Lock
Screw
Washer, Flat
Washer, Lock
Nut, Hex
Water Jacke~ LP
0-Ring, LP
Water Jacket, HP
0-Ring, HP
.J ..
0 , .----9
s
REO'D
1
1
1
12
12
8 a
8
2·
4•
1·
2·
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1•
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VTR PUMP -INTAKE FILTER, INTERCOOLER, FLYWHEEL & COOLING FAN
19
12 11 10
~-12.~1"< 10A 9 1
1A >
4
\\ ____ ~-~\\:: Ii 7 °
3
12
22
ITEM PART ITEM PART
NO. NO. DESCRIPTION REO'D NO. NO. DESCRIPTION REQ'D
1 P051990 Flywheel 1 11 21318 Condensate Collector 1
1A M2273 Key, Flywheel 1 12 P05226A Gasket 4
2 P05739A Washer, Fan Hub 1 13 P05213A Manifold Range 1
3 PD4247A Fan 1 14 P05219A Washer lock 16 ·
4 P05390A fan Hub Boll 1 15 M2256 Screw 16
5 M3256 Key, fan Hub 1 16 P09935A filler, Intake 1
6 P05213A Manifold Range 1 17 P05533A Element, filter 1
7 M3009 Elbow, Street, so· 1 18 P09959A Manifold, Flange 1
8 P07177A Compression fitting 1 19 P03592A Pressure Relief Valve 1
'9 21252 lntercooler Tube Kit 1 20 M3087 Elbow, Street, 45" 1
10 M1418 Compression Nut 1 21 M1601 Checi< Valve 1
lOA P06064A Compression Ferrule 1 22 M3191 Nipple, 111· x s· 1
27
WTS PUMP -CRANKCASE, CRANKSHAFT, PISTON SET & DRIVING SET ·
3
6
15
5 2
12
ITEM PART ITEM PART
NO. NO. DESCRIPTION REQ'D NO. NO. DESCRIPTION REO'D
1 P05145D Crankcase 1 10 M2251 Washer. Lock 1 2 21243 .. MAIN BEARING SET 1 11 M2239 Screw 1 3 P05106A Spacer Bushing 1 12 21102 CRANKCASE COVER 1 4 P05092B Spacer Bushing 1 13 P05196A Washer, Lock 3 5 M2250 Snap Ring 1 14 M2695 Screw 3 6 P10550D Cranksh~ft .. 1 15 21241 PISTON SET 3 7 21100 DRIVING SET 1 16 21242 RING SET 3 8 P10551C Balance Weight 1 17 P05195A Washer. Flat 6 SA P05189A Screw, Headless 1 18 P05196A Washer, Lock 6 9 P05195A Washer. Rat 1 19 M2254 · Screw 6
-Contact Factory -Pump Exchange Recommended
28
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ITEM
NO.
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20 ,
21
PART NO.
P106240
P117260
P05196A
M2254
P10886A
M2246
P05188A
P11136B
P101138
P051370
P05226A
P05213A
P09959A
P05226A
P05219A
M2264
P05190A
P05193A
P05195A
P05196A
P05198A
P10338A
WTS PUMP -CYLINDERS, HEADS, VALVES,
INTAKE MANIFOLD, EXHAUST MANIFOLD,
FLYWHEEL & COOLING FAN
ITEM PART
DESCRIPTION REQ'D NO. NO. DESCRIPTION
Cylinder .. 3• 22 P10337A Clamp
Cylinder 3 23 P09936A Tubing, Intake
Washer, Lock 18 24 P10340A Connector, Straight. Tube
Screw 18 25 M3157 Cross
0-Ring 3 26 M3145 Nipple, Close
Stud, Cylinder 12 27 P05533A Element, Filter
Stud, Valve Plate 6 28 P09935A Filter, Intake
Valve Plate 3 29 M3006 Nipple
Gasket 3 30 M3008 Tee
Cylinder Head 3 31 M3009 Elbow, Street, 90"
Gasket 3 32 P07177A Compression Fitting
Manifold Flange 3 33 21256 Exhaust Manifold Kit
Manifold Flange 3 34 M3007 Elbow, Street, 45"
Gasket 3 35 P051990 Flywheel
Washer, Lock 24 35A M2273 Key, Flywheel
Screw 24 36 P05739A Washer, Fan Hub
Washer, Copper 6 37 P04247A Fan
Nut, Acorn 6 38 M3256 Key, Fan Hub
Washer, Rat 12 39 P05J90A Fan Hub Bolt
Washer.Lock 12 40 P051088 Water Jacket
Nut, Hex 12 41 M2245 0-Ring
Connector, Elbow, Tube 2 42 MJ194 Nipple, 1½"x4½"
•• After Serial Number OF3800 • Water Cooled Pumps Only
29
REQ'O
4
3Ft.
2
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
3•
5•
1
WTR PUMP ~ CRANKCASE, CRANKSHAFT, PISTON SET & DRIVING SET
12
ITEM PART
NO. NO.
1 P05145D
2 Z1243 ..
3 P05106A
4 P05092B
5 M2250
6 P05136D
7 21100
8 P05128C
BA P05189A
9 P05195
10 M2251
3
6
7
5 2
ITEM
DESCRIPTION REQ'D NO.
Crankcase 1 11
MAIN BEARING SET 1 12·
Spacer Bushing 1 13
Spacer Bushing 1 14
Snap Ring 1 15
Crankshaft .. 1 16
DRIVING SET 1 17
Balance Weight 1 18
Screw, Headless .1 19
Washer, Flat 1 20
Washer, lock 1 21
PART
NO.
M2239
Zl 102
P05196A
M2695
Z1241
21239
21242
21240
P05195A
P05196A
M2254
16
®
_..........-1s
19
~18
'!'"--17
15
DESCRIPTION
Screw
Crankcase Cover
Washer, lock
Screw
PISTON SET
PISTON SET
RING SET
RING SET
Washer, Flat
Washer, lock
Screw
•• Contact Factory -Pump Exchange Recommended
30
REQ'D
1
1
3
3
2
1
2
1
6
6
6
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I
WTR PUMP -CYLINDER, HEADS, VAl.VES, FLYWHEEL & COOLING FAN
16
11· 1{
1s::\l)
14 \.
7
29 6 , ,
5 , 28 ,
, , , 21A 24
22 \ (
I ;\5 I
J -
1A ~ 207~
19
27 23
26 21
ITEM PART ITEM PART NO. NO. DESCRIPTION REQ'D NO. NO. DESCRIPTION REQ'D
1 P05126C Cylinder 2· 15 P05196A Washer, Lock 12 TA P11725D Cylinder 2 16 P05198A Nut, Hex 12 2 P10886A 0-Ring 2 17 P05190A Washer, Copper 4 3 M2246 Stud, Cylinder 8 18 P05193A Nut, Acom 4 4 P05188A Stud, Valve Plate 4 19 P05196A Washer, Lock 18 5 P!11368 Valve Plate 2 20 M2254 Screw 18 6 Pl01138 Gasket 2 21 P05199D Rywheel 1 7 P05137D Cylinder Head 2 21A M2273 Key, Flywheel 1 8 P051270 Cylinder 1 • 22 P05739A Washer. Fan Hub 1 BA P117240 Cylinder 1 23 P04247A Fan 1 9 P!D972A 0-Ring 1 24 M3256 Key, Fan Hub 1 10 M2246 Stud, Cylinder 4 25 P05390A Fan Hub Bolt 1 11 P05143B Valve Plate 1 26 P05108B Water Jacket 2· 12 P05120B . Gaskel 1 27 M2245 0-Ring 4• 13 P05130C Cyfmder Head 1 28 P05109B Water Jacket 1· 14 P05195A Washer, Flat 12 29 M2244 0-Ring 2·
• Water Cooled Pumps OnlY
31
wrR PUMP -INTAKE MANIFOLD, EXHAUST MANIFOLD, INTERCOOLER & INLET
24 21
ITEM. ' ITEM NO. PART NO. DESCRIPTION RED'D !JO. PART ND. DESCRIPTION
1 PD5226A Gasket 6 13 M2264 Screw 2 PD5213A Manifold flange 3 14 P1D338A Connector, Elbow, Tube 3 Z8150 lntercoo.ler Tube Kit 1 15 P10337A Clamp 4 P07177A Compression fitting 3 16 P09936A Tubing, In tab 5 M3009 Elbow, Street, so• 1 17 P10340A CoMector, Straight, Tube . 6 M3007 Elbow, Street, 45' 1 18 M3189 Tee, 11/2" 7 Z1260 Exhaust Manifold Kit 1 19 M3145 Nipple, Close
8 P0521BA Compll!SSion frtting 1 20 P05533A Element, Filter 9 P03592A Pressure Relief Vane 1 21 P09935A Filter. Intake 10 Z131B Condensate Collector 1 22 M3087 Elbow, Street, 45 ° 11 P09959A Manifold, Aange 2 23 M1601 Check Valve 12 P05219A Washer, lock 24 24 M3194 Nipple, 11\" x 4½"
32
FILTER
REQ'D
24
1 .
2
1ft.
1
1
1
1
1
1
1
1
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CONSTANT SPEED HEAD UNLOADER KITS
For Air Compressor Pump Models VTS, WTS VTR & WTR
NOTE: This is optional equipment and may not be
included on your unit
The purpose of constant speed unloading is to
provide a means of stopping or starting the
compression of air by the compressor without
stopping or starting the electric motor.
predetermined cut-out setting, this air.is released
to a suction unloader valve. The compressor stops
compressing air, but continues to runs until the
pilot valve senses that the pressure in the tank has.
dropped to the predetermined cut-in setting. At
this time the air is released from the suction
unloader valve, and the compressor starts
compressing air again. To accomplish this, an air pilot valve is used to
replace the pressure switch used for stop-start
operation. The pilot valve senses storage tank
pressure, and when the pressure is raised to a
The parts called out below replace or are
substituted for those found in the regular parts list
II
TO NEEOLE I B
VALVE ON ~
TANK '4:)
5 ~;A
----..I._ ._ rROM SUCTION ~ UNl.OAOER
PILOT VALVE ASSEMBLY
EXISTING
INLET TU81NG
EXISTING
FILTER
VTS SUCTION UNLOADER KIT· Z6B04
ITEM
NO. PART NO.
1 MJ194
2 MJ190
3• Z6JJ4
4 MJOSS
5 M2B68
6 P08084A
7 M2855
8 P05526A
9 M914A
10 M2360
11 M2862
12 M3170
DESCRIPTION
Brass Pipe, 1 JI x 4 JI
Locknut, 1 JI
SUCTION UNLOADER ASSEMBLY
Pipe Plug, 1 JI•
90 • Compression Fitting, Brass
Plastic Tubing, ll" 0.0.
Pilot Valve• Air
Bracket, Pilot Valve
lock Washer, 3/8'. Std.
Capscrew, 318 • 16UNC x,Y,·
Straight fitting, % • Compression
Elbow, Street, 1 JI x so.•
• Includes: P09287B • Plunger
P09937 A • Gasket
P05029A • Air Cylinder
33
I
J
RED'D
1
1
1
1
2
1
1
1
1
1
1
1
ITEM
NO.
1
2
3•
4
5
6
7
8
9
10
11
ITEM
NO.
1
2
3•
4
5
6
7
8
9
10
11
12
WTS SUCTION UNLOADER KIT· 26808
PART NO. DESCRIPTION
M3194
M3190
26334
M2868
P08084A
M2855
P05526A
M914A
M2360
M2862
M3170
Brass Pipe, 1 ½ x 4½
Locknut, 1½
SUCTION UNLOADER ASSEMBLY
90' Compression Fitting, Brass
Plastic Tubing, l4 • 0.0.
Pilot Valve• Air
Bracket, Pilot Valve
Lock Washer, 3/8" Std.
Capmew, 3/8 • 16UNC x II"
Straight Fitting, l4" Compression
Elbow, Street, 1½ x 90'
• Includes: P09287B • Plunger
P09937 A • Gasket
P05029A • Air Cylinder
VTR SUCTION UNLOADER KIT· Z6807
PART NO.
M3194
M3190
26334
M3099
M2868
P08084A
M285J
P05526A
M914A
M2360
M2B62
MJ170
DESCRIPTION
Brass Pipe, 111 x 411
Locknut, 111
SUCTION UNLOADER ASSEMBLY
Pipe Plug, 111"
90' Compression Fitting, Brass
Plastic Tubing. !4 • 0.0.
Pilot Valve
Bracket, Pilot Valve
Lock Washer, 3/8" Std.
Capscrew, 3/8 -16UNC x 11·
Straight Fitting, l4 • Compression
Elbow, Slreet, 111 x 90'
• lndudes: P09287B • Plunger
P09937 A · Gasket
P05029A • Aii Cylirider
REQ'D
1
1
1
2
1
1
1
1
1
1
1
REQ'O
1
1
1
2
2
1
1
1
1
1
1
1
34
10
To\NK ' :lo b
6A
:~~•gc~• ~ 7
'4 r-A0M 5UCTICN
t.M..0AO£R
PILOT VALVE Aa&E.MBLY
TO PILOT I
VALVE ASSY ~ S
b
10
II r::-9
TO NEEOL~E
1 8 VALVE OH
TANK · ....._ 7
.. 5.
1"R0111SUCTIOH
\.1'4l..OAOER
PILOT VALVE ABSEMSLY
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ITEM
NO.
1
2
3
4•
5
6
7
8
~
10
11
12
2
II (,,o
12
TO NEECt.E y' q ·•,._ VALVE ON /0
TANK ' ;.,, B
b~OW SUCTION
UN..OAOEA
PILOT VALVE ASSEMBLY
WTR SUCTION UNLOADER KIT· Z6806
PART NO.
M3194
M3170
M3190
26334
MJ099
M2868
P08084A
M2853
P05526A
M914A
M2360
M2862
DESCRIPTION
Brass Pipe, 1 ½ x 4 ½
90" Brass Elbow, 1½"
locknut, 1 ½
SUCTION UNLOADER ASSEMBLY
Pipe Plug. 1 ½"
90 • Compression Fitting, Brass
Plastic Tubing, ¼ • 0.0.
Pilot Valve· Air
Bracket, Pilot Valve
lock Washer, 3/8" Std.
Capscrew, 3/8 x 16UNC x ½"
Straight Fitting, ¼ • Compression
• Includes: P092878 • Plunger
P09937 A · Gasket
P05029A · Air Cylinder
35
REQ'D
1
1
1
1
1
2
1
1
1
1
1
1
OPERATION AND ADJUSTMENT OF PILOT VALVES
MTG THREAD
,.........4-1.._~#l
#4 ~~1/#3
/12
/
(ACTUATING TUBE
1---4----ITO HEAD UNLOADERS)
t
(SENSING TUBE FROM
AIR RECEIVER)
PILOT VALVES
ASSEMBLY PART
NO.
M2855
M2853
PRESSURE RANGE,
PSIG
70-95
140 -170
36
The Pilot Valve is designed to act as an automatic "on"
and "off' air switch. When in the "on" position it allows air
to flow from the tank through the valve to some device
such as a compressor suction unloader, thus actuating it
In the "off' position this valve stops the flow of air through
the valve and releases the pressure in the line to the
device. ·
The Pilot Valve works as follows: Tank air pressure acts
.on the bottom of the valve. When pressure is great
enough to overcome spring force holding valve down on
lower seat, it lifts off seat and allows air to flow around
valve and out through side opening in Pilot Valve. When
valve lifts off lower seat it moves up and seats on upper
seat where it is held by tank pressure. When pressure in
tank and on valve drops, spring forces valve back down
on lower seat. Air in line to device being actuated can
then escape through upper seat and out vent hole. The
press11r,e at which the Pilot Valve is "on" or "off' is
controlled by the spring which has been installed at the
factory. A small adjustment can be made in the field by
changing the spring force by compressing the spring
more or less with the adjusting screw provided on the
Pilot Valve.
COMPRESSOR PILOT VALVE
PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor
is running:
1. Loosen locknut (4) and back off several turns. Do not
turn differential adjuster (3).
2. Check reading on the tank pressure gauge. Set the
compressor maximum pressure at 95 psig. Tum
threaded cap (1) clockwise to increase pressure or
counterclockwise to decrease pressure.
3. After pressure is set, tighten locknut (4). Be careful
not to move the threaded cap (1 ).
COMPRESSOR PILOT VALVE
DIFFERENTIAL PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor
is running:
1. Loosen locknut (2) and back off several turns.
2. Check reading on the tank pressure gauge. Set the
pressure to 25 psig differential (unload at 95 psig,
reload at 70 psig). Tum nut (3) clockwise to increase
differential pressure or counterclockwise to decrease
differential pressure.
3. After pressure is set, tighten locknut (2) .. Be careful
not to move nut (3).
I
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I HAZARD DECAL LISTING
I ITEM DESCRIPTION PART NO.
A Retain Labels P09879A I B · DANGER -Breathing Air P09376B
C DANGER -Drain Tank Daily P09430B
D DANGER -Valves P097508 ,, E DANGER -High Voltage P04934A
F DANGER -Auto Start P093848
I G WARNING -Pressure/Safety Valve P09752B
H WARNING -Rotating Parts .P093738 I WARNING -Hot Surfaces P09758A
I
J WARNING -Tank Pressure P04983A
K CAUTION -Clean Filters • M1736 •.
L Rotation Direction M422
M Pressure Setting: Master P09388A I' N Pressure Setting: 140-175 PSIG (Two Stage) P04988A
Pressure Setting: 70-100 PSIG (Single Stage) P04987A
I 0 Service Information P04995A ..
I
'I, HAZARD TAG LISTING
I p IMPORTANT -Electrical Specs P05257A
Q DANGER -Valve Instructions P09852A
R WARNING -Read Owners Guide P04996A
'I
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I
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I ~
I ~7.
A
B
C
D
Read. undetstlnd, & retlln afl I.Ille/a llld Owners Manuals bmre using this equipment. _,.
F .------.-----
G }, f: ~. A.WARNING
~ : ' '
(
••
I .------,--:-------=i
A.WARNING
J
38
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CAUTION, SERVICE FILTER
ELEMENTS WEEKLY
MOM Of'Tl:N tN DUSTY COIIIDfflOfd .,,..
flOTAT'Ol ■OlflEC'TOI Ol 11«/'#
..... 2
tu:/IINf JO 1101.U3wla • NOUUOII
UNIT PRESSURE FACTORY SET AT
140-175 PSIG
SERVICE INFORMATION
FOR SERV1CE CAll. "SERVICE DEPARTMENT' AT
815/875-3321 OR WRITE TO:
0
0
GARDNER DENVER MACHINERY INC.
1301 NORTH EUCLID AVE
PRINCETON. IWNOIS 61356
IMPORTANT NOTICE!
1lllS UNIT IS WIRED FOR AJl 1,/; QRCUIT OF
0 115 VOLT O 60 CYCLE D 1 PHASE
0 230 VOLT □ OTHER □ l PltA&
□ ~60VOLT
OTHER aECTRICAL Sl'fCS ____ ~
''""'
IMPORTANT
MOTOR BURN-OIITS AIIE NOT COVERED BY
WAIIRANTY • Uni.., -Is oqupped wll!I
F1<10ryinstl~CM<1oodpo1'dlan
(In elll><t-orSW11n; -~
Q
R WARNING
DO NOT OPERATE UNIT BEFORE !!EADING AND
UNDERSTANDING OWNERS GUIDE FOR INSTAJ.-
1.ATIO!I. ASSEMBLY. AND OPERATION OF nllS
EQU!PMDIT. FAILURE TO COMPLY CAN CAUSE
INIURY AND/OR PROPERTY DAMAGE.
RECORD OF MAINTENANCE SERVICE
DAILY
• DRAIN MOISTURE FROM TANK
WEEKLY MONTHLY. • CLEAN FILTER • INSPECT AIR SYSTEM • CLEAN COMPRESSOR
• CHECK V-BEL TS
•
CS9t15
40
EVERY 3 MONTHS
• TIGHTEN ALL FASTENERS
• TEST PRESSURE RELIEF VALVE
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-1,s ,·~
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RECORD OF MAINTENANCE SERVICE
DAILY
• DRAIN MOISTURE FROM TANK
WEEKLY. MONTHLY EVERY 3 MONTJiS • CLEAN AL TEA • INSPECT AJA SYSTEM • TIGHTEN ALL FASTENERS • CLEAN COMPRESSOR ·• TEST PRESSURE RELIEF VALVE • CHECK V-BEL TS
••
-41
RECORD OF MAINTENANCE SERVICE
DAILY
• DRAIN MOISTURE FROM TANK
WEEKLY MONTHLY
• CLEAN ALTER • INSPECT AIR SYSTEM • CLEAN COMPRESSOR
• CHECK V-BELTS
.,
-
CS9115
42
EVERY 3 MONTHS
• TIGHTEN ALL FASTENERS
• TEST PRESSURE RELIEF VAL VE
I
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I _)
I
DAILY
• DRAIN MOISTURE FROM TANK
WEEKLY
• CLEAN FILTER
• CLEAN COMPRESSOR
• CHECK V-BEL TS
-
RECORD OF MAINTENANCE SERVICE
MONTHLY EVERY 3 MONTHS
• INSPECT AIR SYSTEM • TIGHTEN ALL FASTENERS
• TEST PRESSURE RELIEF VALVE
• •
.
43
FOR PARTS: · REFER TO PARTS DEPOT LIST
ACCOMPANYING TIDS MANUAL.
. . (.
Gaadl10r
. IUIIE!nver
<0 Copyright Gardner Denver Machinery Inc. J 998
I
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--II!!!! l!IB =mi -iiiil --.. -----liiil ---
SERIES FLOW PROCESS
VESSELS IN SERIES # 1 TO #2 VALVES OPEN
1 5
3
VESSELS IN SERIES #2 TO #1 VALVES OPEN
2 6
4
PARALLEL OPERATION
VALVES CLOSED
2 6
4
VALVES CLOSED
1 5
3
VALVES OPEN
2 4
VALVES CLOSED
6
3 5
SINGLE VESSEL OPERATION
OPERATING VESSEL #
2
1
NOT OPERATING #
OPERATING VESSEL #2
1 NOT OPERATING #
VALVES OPEN
3 4
VALVES OPEN
2 5
VALVES CLOSED
1 5
2 6
VALVES CLOSED
1 4
3 6
INFLUENT
VESSEL #1
EFFLUENT
EFFLUENT
VESSEL #1
REV ECO
4
APPROVAL DATE
~ SHS 6/12/00
l)IIISC,O,I,.( 1.00 .375
TOLERANCES UNL£SS NOTED OTH£RWISE PROJECT WNW:ER:
DECIMAL FAACTl0N"L
.03 1/32"
TITLE
THESE UATERW.S ARE COHF1JENTW.. ~ ........... , m ...--:-7 Sil[ AND ARE TH[ PROPRlETAR'f INFORW.T-,-.....,.,,.,..,., w-c::==r
REVISIONS
DESCRIPTION DATE OWN
EFFLENT
VESSEL #2
INFLUENT
INFLUENT
VESSEL #2
CARBONAIR
WAITR AND AIR O[CONTAMINATION @2000 MINNEA.POUS. MINNESOTA
SCHEM VAPOR DECON
OWG. NO.
ION or CARBONAIR SEIMCES, we. AND f--'----~.,....:..--=---1 A
:~,~~T ~ ~~~ ~r=R UNl[SS OTH[R'NISE SPECIFIED: f-__JL.__~-----~-~L_----j
scRVICis. LNC. : ~~io~co:.wt~Es SCALE 1 = 1 EQUIP. "'°· Sl-££1 1 oF 1
211620
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BULLETIN E-106
_ __.-.,.11.wye,: SERIES 71160 PRESSURE INDICATING TRANSMITTER
SPECIFICATIONS -INSTALLATION AND OPERA TING INSTRUCTIONS
The Dwyer 71160 Series Pressure Indicating Transmitter
simultaneously provides local indication on a large, easily read
3 ½ digit liquid crystal display while also converting that
pressure into a standard two wire, 4-20 mA signal for ranges
from 0-15 to 0-500 PSI. Positive compatible gas pressure is
measured to the accuracy of ±0.5% of full scale. The electrical
signal and conditioning is produced by a piezoresistive
pressure cell for precision measurement of compatible gases
and liquids. A 316 stainless steel connection block features
· convenient ¼" NPT female and ½" NPT male pressure
connection.
s . enes 7116 DE nnlish Models & Ranaes
MODEL MAXIMUM
NUMBER RANGE PRESSURE
71160-0015 0-15.0 PSIG 30 PSIG
7116D-G030 0-30.0 PSIG 60 PSIG
71160-G050 0-50.0 PSIG 100 PSIG
71160-0100 0-100.0 PSIG 200 PSIG
71160-0500 0-500 PSIG 1000 PSIG
S . 71160 M t. M d I & R er1es enc o es anaes
MODEL MAXIMUM
. NUMBER RANGE PRESSURE
71160-B001 0-1.00 bar 2.0 bar
7116D-B002 0-2.00 bar 4.1 bar
71160-B004 0-4.00 bar 6.9 bar
7116D-B007 0-7.00 bar 13.8 bar
7116O-B040 0-40.0 bar 69.0 bar
------------=
ii
FIG.A
SPECIFICATIONS
GENERAL
Maximum Pressure:
Media Compatibility:
Housing:
· Wetted Parts:
Finish:
ELECTRICAL
2 X maximum range
pjr and non-corrosive gases
and liquids.
Polycarbonate
Stainless steel connection block,
316L
Black
Power Supply: 10-35 voe -2. 3, or 4 wire
Output Signal: 4-20 mADC (Limited at 38mADC)
Loop Resistance: DC; O -1100 ohms
Warm-UP: 10 minutes ·
Current Consumption: DC; 38mA max.
PERFORMANCE AT 70°F (21.1°C)
Zero Output: 4 mA DC
Full Span Output: 20 mA DC
Span: 16 mADC
Accuracy:(lncludes linearity,
hysteresis & repeatability) ±0.5% of span
Stability: 1% F.S.Jyear
ENVIRONMENTAL
Operating Temperature: 20•-120°F(-6.7" to 49 Cl
Thermal Errors: ±0.02%/'F
MECHANICAL
Weight
Span and Zero
Adjustments:
Pressure connections:
1 lb .• 9 oz. (709 grams)
potentiometers, accessible from
back of gage
¼" NPT female/½" NPT male
---------. 1. Select a location free from excessive vibration where the temperature limits of 20" to 120"F (-6.7" to 49"C) will not be exceeded. Mounting surface should be vertical to match the position in which all standard gages are calibrated. Avoid locations in direct sunlight which may cause accelerated discoloration of the clear acrylic lens or where exposure to oil mist or other airborne vapors could likewise result in lens damage.
2. See Fig. A for mounting hole instructions.
3. A ¼" NPT female / ½" NPT male pressure connection is furnished to allow you the choice of vertical (from below the gage) piping. When making the pressure connection, use a minimal amount of thread sealant Too much could block the internal pressure passage. CAUTION: When installing fittings or pipe always use a second wrench on the 718" connection block. DO NOT allow torque to be transmitted from the block to the case.
FIG.B
ELECTRICAL CONNECTIONS
CAUTION: DO NOT EXCEED SPECIFIED SUPPLY VOLTAGE RATINGS. PERMANENT DAMAGE NOT COVERED BY WARRANTY WILL RESULT. THIS UNIT IS NOT DESIGNED FOR 120 OR 240 VOLT· AC LINE OPERATION.
Electrical connections to the Series 71160 Pressure Indicating Transmitter are made on the backside of the enclosure unit. Feed stripped and tinned leads to the terminal block screw,i marked 1 and 2. Refer to figure B for locations of the terminal block, span and zero adjustments.
Wire Length -The maximum length of wire connecting transmitter and receiver is a function of wire size and receiver resistance. Wiring should not contribute to more than 10% of receiver resistance to total loop resistance. For extremely long runs (over 1000 feet), choose receivers with higher resistance's to minimize size and cost of connecting leads. When the wiring length is under 100 feet, lead wire as small as 22 AWG can be used.
2-Wlre· Operation -An external power supply delivering 10 -35 VDC with minimum current capability of 40 mA DC (per transmitter) must be used to power the control loop. See Fig. C for connedlon of the power supply, transmitter, and receiver. The range of the appropriate receiver load resistance (RL) for the DC power supply voltage available is expressed by the formula and graph in Fig. D. Shielded two wire cable is recommended for control loop wiring. If grounding is required use negative side of control loop after ·receiver. In Fig. C below, if power supply lead to terminal 1 is positive, ground should be connected to wiring at right of receiver. Otherwise, in 2 wire operation It is not necessary to observe polarity of control loop connections.
PRESSURE
XMTR
+
,•VVltlt: 1.,;UNNt:I.,; 1 IUN
FIG.C
POWER
SUPPLY
10-35VDC
POWER SUPPLY VOLTAGE-VDC (2-WIRE CONNECTII
1500
1400 MAXIMUM VALUE (1300 0) 1300 g 1200
~ 1100 i1 1000 ~ 900 R MAX.• Vps-10.0 ~ 800 L 20mAOC
; 700
w · 600 ~ 500
a! 400 OPERATING g 300 MEGION 200
100 so..l...-~-./4l4-1-l-ll~l.l.l.l..Lf.l.J.Ju+.LLJ~--;
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I' 0 5 40 voe
FIG. D I
Pressure Ranging I Each standard Series 71160 Pressure lndicabng Transmitter is factory calibrated to produce 4 mA at zero IC8le reading and 20 mA at full scale reading. The foll0Wltl9 prna,dure should be used if the pressure versus output sigr,al ~P needs to I be checked.
1. With the 7116D Pressure .-.x.aong Transmitter connected to the companion rece,vw. --1 an accurate I milfiammeter in series with the CU'1'W1I 100p. Full scale range should be approximately 30 ..,,._ 2. Connect a controllable pressure IO<l'0e to one leg of a tee with the second leg conneded to ,,.,. on,ssure port of the 711 SD Pressure lndicanng ~ .r,wM!el ~ the third leg to a test gage or manometer haw>Q ., 8QCllac:y of 0.125% or better.
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3. Apply electrical power to the uni and ...,,., rt to stabilize for 1 O minutes.
4. Alter the transmitter ZERO AOJVS T -on the front of the display ( See Fig. Al t,y ~ the UP ( 1') or DOWN ("-) switches so that 1rie ~ ,. on me middle of Its zero pressure reading --o ;,rauu,11 is being applied. i.e. Wrth an UP reading cl ;O 22) and a DOWN reading of (-0.14), the display WOUid oe aoiusted so that a reading of (0.04) would be a,gp&ayec1 0ltlDr1I proceeding to the next step.
5. ·Again, with no pressure appllfJO to i,,. T 1160 Pressure Indicating Transmitter, adjust me rRAHSMITTER ZERO control, located through the bac:1< or the """'-so that loop current is 4.00 mA. See Fig. A. 6. Apply. full range pressure ana a0JUS1 loop current to 20 mA using the TRANSMITTER SPAN conlrol See Fig. A. 7. Relieve pressure and allow P<11UUre Indicating Transmitter to stabilize for 2 minutes. 8. Zero and span controls may be shghtty interactive, so repeat steps 4 though 7 until zero ana tuJI range pressure consistently produce loop currents of 4 and 20 mA respectively.
9. Remove the milliammeter from the current loop and proceed with final installation of the pressure Indicating Transmitter and receiver.
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CARBONAIR
Vapor-phase carbon is frequently used to treat
contaminated air with high humidity, such as
off-gas from air strippers arid soil-venting
extraction units treating moist soil. Unavoid-
ably, volatile organic compounds (VOCs) will be
adsorbed by carbon along with the humidity.
The adsorbed humidity can hinder the adsorp-
tion of VOCs and significantly reduce the
adsorption capacity, causing a premature
breakthrough. This article discusses the effects
of humidity, temperature, and heating humid air
on carbon efficiency.
HUMIDITY ADSORPTION
Carbon adsorbs water vapor in the same
manner as it adsorbs VOCs. The adsorption
mechanisms at different concentration levels is
illustrated in Figure No.1.
At low vapor concentrations, vapor is adsorbed
by means of electromotive forces, and the
Figure No. 1
Vapor-Phase Carbon Adsorption Mechanisms
Increase In concentra\ion
FACT SHEET #4
Vapor-Phase Carbon: ·
Effects of Humidity/ Temperature
carbon surface will not be completely covered
by the adsorbed molecules. When the vapor
concentration reaches a certain level; the walls
of the carbon pores will be completely covered
by the adsorbed molecules. .As the vapor
concentration passes that level, the adsorbed
molecules start to fill each carbon pore, forming
a-concave surface of condensate at the bottom
of the ·pore. Based on the theory of surface
chemistry, the concave surface can reduce
vapor pressure of the solute and subsequently
accelerate the adsorption. This phenomenon is
called "capillary condensation."
Figure No. 2 shows the amounts of water
adsorbed on a typical carbon at various relative
humidities.
Figure No. 2
Amounts of Water Adsorbed on Carbon
at Different Relative Humidities
••-, --------------, I
C j o I of 40 :-.
G I ~ I ;:; 30-···
C -~
l20
~ ~
3: 10
G ,!!
01L-""""==~-'---'---'---'---'--_J o 10 20 :so 40 so eo 10 ao ao 100
RelaUve Humidity (%)
Copyright O 1994 Carbonair Environmental Systems, Inc. (11/07/94! 1
The relative humidity (RH) is defined as a ratio
of the actual partial pressure of vapor to the
partial pressure if saturated at the existing
temperature. It is evident that capillary
condensation becomes prominent when the RH
is above 50%, causing a significant increase in the amount of water adsorbed. It will also be noticed that this particular carbon can adsorb
water up to 40% maximum.
EFFECT OF HUMIDITY
When both VOCs and humidity are present in the air, all the molecules of VO Cs including
water will compete with each other for the carbon adsorption sites. The water adsorbed
on carbon will make the adsorption of VOCs even more difficult by_ preventing the VOCs from directly contacting the carbon surface.
Furthermore, the VOC concentrations are.
usually relatively small compared to the water
vapor concentrations. For instance, VOC
concentration levels of less than 100 and 1000
ppmv are typically found in off-gas from air strippers and soil venting extraction systems, respectively, whereas the water vapor concen-
tration is approximately 1 0000-20000 ppmv at a RH of 100%. Therefore, the VOC adsorption
capacity will be greatly reduced unless the humidity is controlled.
Figure No. 3
Effect of Relative Humidity
on Benzene Adsorption Capacity
---~,,-.......... ,: ........ ,_
Figure 3 shows the effect of the increase in RH
on the adsorption of benzene with a concentra-
tion of 10 ppmv at 60°F and 1 atm. It can be
seen that the benzene adsorption capacity
decreases rapidly due to the capillary condensa-
tion of water vapor when the RH is greater than 50%. At a RH of 100%, the adsorption·
capacity will be reduced by 85 % .
EFFECT OF HEATING
It is possible to diminish the effect of high humidity on adsorption capacity by heating the
air. When air is heated, its volume increases,
while the amount of water vapor remains the same. This results in the reduction of water
vapor partial pressure or RH. As previously
shown in Figure No. 3, less water vapor will be adsorbed by carbon at a ·lower RH. However,
carbon should not be operated at an exces-sively high air temperature since its adsorption
efficiency will decrease as the temperature
increases. Figure No. 4 shows the effect of the increase in temperature on the adsorption of
benzene with a concentration of 10 ppmv at 60° F and 1 atm, assuming no humidity is present in the air.
Figure No. 4
Effect of Temperature
on Benzene Adsorption Capacity
·•~------------~ C 0 ,f 12 • u :910
C> ~ .
= ... • C j 4
2 all
70 80
Temperature (F)
10 100
a.-... Concentn.llon 10 PPlll't' (SO F): Ralattv. Humld1ty K; ,,,.._,. t atm
2 Copyright O 1994 Carbonair Environmental Systems, Inc. 111/07/94)
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Temperature generally has a considerably less adverse effect on carbon efficiency than RH. It can be seen from Figures 3 and 4 that the carbon will lose its adsorption capacity by 85 % at 100% RH and only 40% at 100°F, as compared to the adsorption capacity at zero humidity .. Therefore, there exists an optimum air temperature at which the effect of humidity will be minimized.
When humid air is heated, both the increase in temperature and the decrease in RH will simultaneously affect carbon efficiency. Figure No. 5 shows the effect of heating the air containing a benzene concentration of 10 ppmv initially at 60°F and 100% RH.
Figure No. 5
Effect of Heating Humid Air
on Benzene Adsorption Capacity
, .....
·······.J,. •'-~~-~~--~~-'-~~ o 10 ~ 30 40 ~ h -~ 10 10 1~
Relative Humidity (%)
The RH corresponding to its temperature can be determined from a humidity chart. It can be seen that a temperature of between 80°F and 90°F provides a maximum adsorption capacity. This optimum temperature range is valid for other concentration levels and types of VOCs when the initial air temperature is between 50°F and 60°F and the initial RH Is near 100%.
Copyright O 1994 Carbonair Environmental Systems, Inc. (11/07/94) 3
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Multiple Receiver Installation
An advantage of the standard 4-20 mA DC output signal used in Series 71160 Pressure Indicating Transmitters is the compatibility with a wide range of receivers. Devices such as the A-701 Digital Readout, A-702 Digital Readout-with alarms, an analog panel meter, a chart recorder and other process control equipment can be operated simultaneously. It is only necessary that all devices.be designed for a standard 4-20 mA input, the proper polarity of input connections must be observed and the combined receiver resistance's . must not exceed the maximum for the current loop. If the receiver indicates a negative or down scale reading , the signal .input leads are reversed.
Maintenance
No lubrication or periodic seMcmg is required after final installation of the Series 71160 Pressure Indicating Transmitter. A periodic check of calibration is recommended following the procedure under PRESSURE RANGING. Except for this, these transmitters are not field serviceable and should be returned, freight prepaid, to the factory if repair is needed. Be sure to include a clear description of the problem plus any application information available.
Repairs
Field repair should not be attempted and may void warranty. Gages needing calibration or other service should be returned prepaid to:
Dwyer Instruments, Inc. Attn.: Repair Department
102 Highway 212
Michigan City, In 46360
<l>Copyright 1997 Dwyer Instruments, Inc. Printed In U.S.A. 12/97 Fr. No. 01413028-00
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CARBONAIR®
CONTENTS
1. 0 Safety Precautions ..................... 1
2. 0 Equipment Description ................ 2
3. 0 Process Description .................... 2
4:0 Installation ................................ 3
4. 1 Inspection ......................... 3
4. 2 Loading & Unloading ........... 3
4. 3 Connections ..................... 3
5. 0 Start-Up ................................... 4
6. 0 Operation .................................. 4
7. 0 Trouble Shooting ....................... 5
8.0 Maintenance ............................. 6
8. 1 Spent Carbon Removal ....... 6
8. 2 Fresh Carbon Loading ........ 6
8. 3 Vessel Inspections ............. 7
8.4 Condensate Drainage ......... 7
8. 5 Waste Disposal ................. 7
9.0 Spare Parts ............................... 7
10. 0 Pressure Drop Chart ................... 7
11.0 Drawings .................................. 9
12. 0 Specific Operating Parameters .... 10
Fact Sheet #4 ......................... Attached
1 .0 SAFETY PRECAUTIONS
Operation &
Maintenance Manual
Carbonair Model GPC-5R, 7R,.
13R, 20R, 28R, 50R
Gas Phase Carbon Adsorber
• Always wear gloves, eye protection &
protective clothing when working with the
carbon vessel.
• Obtain an activated carbon Material Safety
•· Data Sheet (MSDS) for more detailed safety
& handling information (available upon
request).
• WARNING: Never enter the GPC vessel
without adequate ventilation, atmospheric
testing and proper safety equipment. The
activated carbon depletes the air of
oxygen. Entering the vessel without
sufficient ventilation could be fatal. The
vessel is considered a confined space and
therefore OSHA confined space entry
safety procedures must be followed (29
CFR 1910.146).
• Take time to record your specific operating
parameters on page 1 0.
Figure No. 1
Typical GPC Unit
Failure to observe these precautions could
result in serious bodily lnjury and/or property
damaoe. · :,:-· .,.c.., c'.··. ·.-.'i'.
• Be sure you thoroughly read & understand
this O & M Manual before beginning
operation. If you have any questions,
please call Carbonair Environmental
Systems, Inc. at (BOO) 526-4999.
• Be sure all electrical disconnects are "OFF"
and locked out before servicing.
CopyrightC 1997 Carbonalr Environmental Systems, lnc.17/21/99} H:\TAMMYIO&M\OPCR.OOC
2.0 EQUIPMENT DESCRIPTION
Carbonair"s gas phase carbon (GPC) adsorbers
are constructed of welded steel which provides
exceptional strength & durability. The units are
skid mounted and forklift compatible making
installation quick & trouble-free. The interior is
double coated with a corrosive-resistant epoxy
polyamide which makes GPC units suitable for
most gas phase applications, including
airstripper and soil venting off-gas treatment.
The GPC-R series gas phase carbon adsorber
has a carbon steel grate which serves as a
supporting structure for the wire mesh and
carbon material which lay on top of the grate
(refer to the assembly drawings on page 9.
The grate is mounted off the bottom of the
vessel on a ledge.
The wire mesh openings are sized smaller than
the smallest activated carbon particle size to
prevent the carbon from falling through the
mesh into the plenum at the bottom of the GPC
unit.
The following table outlines the specifications
of the GPC-5R, 7R, 13R, 20R, and 50R gas
phase carbon adsorber unit.
Table No. 1
MOD!iLS GPC SR GPC 7R
OIMENSIONS 30" 00 3' 00
(0.76 M) (0.91ml
5'8"H 7'2"H
11.73ml 12.18 ml
BED AREA 4.91 sq. ft. 7.07 sq. ft.
10.53 sq.m) 10.76 sq.m)
FLOW RANGE 40-380 elm 76-500 elm
(1 -10m3/min) (2-15 m3/min)
CARBON 500 lbs 1,000lbs
CAPACITY 1228 kg) 1456 kgl
FITTINGS 4 ½" nozzle 6 518" nozzle
121 ½" half (21 ½" half
couplings couplings
11) 30" access 11) 24" access
port port
EMPTY WEIGHT 375 lbs 700 lbs
1170 kg) 1317 kg)
OPERATING 900 lbs 1,800 lbs WEIGHT 1408 kg) 1816 kg}
INLET/OUTLET _4 ½." 6 BIB•
NOZZLES l11.43 cm) (16.83 cm)
Standard GPC feature;
✓ an access port for carbon removal and/or
inspections,
✓ two sampling ports located upstream and
downstream from the carbon bed, ✓-four hoisting rings for shipping
convenience,
✓ and a forkliftable base.
GPC 13R GPC 20R ·GPC 28R GPC SOR
4' OD 5' OD 6'00 8' OD
(1.2 m) (1.5 m) (1-83 ml (2.44 ml
7'2"H 7'2"H 7'2"H 7'2"H
12.18 ml 12,18 ml 12.18 m) 12.18 ml
12.57 sq.ft, 19.63 sq. ft. 28.27 sq ft. 50.27 sq.ft.
11.35 sq.ml 12.11 sq.ml 12, 3 m 15.41 sq.m)
120-800 elm 200-1.800 elm 240-2,200 cfm 480-4,000 elm
13-24 m3/minl (6-54 m3/min) (7-64 m31/minl (14-120 m3/minl
1,500 lbs 2,000 lbs 3,000 lbs 5,000 lbs
1681 kg) 1908 kg) (1,360 kg) 12,270 kg}
8 518• nozzle 8 518" nozzle 8 518" nozzle 12 ¾" nozzle
121 ½" half (21 ½" half 12) ½" half 12) ½" half
couplings couplings couplings couplings
(1) 24" access (1) 24" access (1) 24" access 111 24" access
port port port port
950 lbs 1,200 lbs 1,600 lbs 2,900 lbs
1431 kg) 1544 kgl 1725 kg) (1,315 kgl
2.450 lbs 3,200 lbs 4,600 lbs 8,000 lbs
11,111kg) (1,452 kgl 12,085 kgl 13,629 kgl
8 51811 8 S/811 8 5,a,. 12 ¾"
(21.9 cml 121.9 cm) 121.9 cml (32.38 cml
3.0 PROCESS DESCRIPTION
Carbonair's GPC gas phase carbon adsorbers
are designed to provide an efficient and
economical means in which to control odor,
toxic vapors and corrosive gases. Several
types of activated carbons are available for a
variety of applications. For specific information
on the activated · carbon selected for this
2 CopyrightC 1997 Carbonair Environmental Systems, Inc. 17/21/99) \\CEa-HO.ffWSVR01\VOL110ATA\USERS\Tl'IElOS\TAMMY\OlM\GPCR.DOC
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particular project, refer to the "Specific
Operating Parameters" section at the end of
this manual.
Activated carbon is highly porous and has a
large surface area for adsorption. Adsorption is
the process by which compounds adhere to the
carbon surface. The portion of the carbon bed
where adsorption occurs is referred to as the
"mass transfer zone". The zone moves upward
from the bottom of the bed as the carbon
becomes saturated with contaminants. When
the bed becomes completely saturated,
breakthrough occurs resulting in a loss of
treatment performance. The carbon should be
replaced. before this happens to prevent
discharge permit violations and/or excessive
odors.
Contaminated air 1s normally introduced into
the bottom of the GPC vessel beneath the
fiberglass grate through the inlet port. As the
air is blown into the vessel, the pressure forces
the gases up through the grate, the wire mesh,
the carbon bed, and then out the discharge
stack at the top of the unit. As .the gases pass
through the carbon bed, contaminants are
transferred from the gases to the carbon.
Moisture, which falls out of the gas stream,
collects as condensate at the bottom of the
vessel and is removed by way of the
condensate drain.
Carbonair strongly"recommends that a process
air 'heater be installed prior to the inlet of the
GPC. unit to reduce the relative humidity. This
will . increase .the contaminant . removal
efficiency.· minimize · condensat,Yaccu~utati~n
and Increase the longevity oi,_;the aptivated ca;;,on. a•·.': • • • • ':' O"' --• C ' ' •
4.0 INSTALLATION
Be . -sure. to carefully Jead . all installation
insiiuctionsbefore b~ginning -theJnstaliaiion_ of . ·:-.-•.I,;"'::" ,. -,"~·:_, .. ·,•):'-'i•,c· ;.,s.'.:;,\,1:·:. ·/f: .. •_.·_,•• ·· -~-;i'.
the GPC vessel gas phase carbon adsorber.·',>;; .'
4.1 Inspection
Upon receipt of the GPC unit, and before the
unit is removed from the truck, be sure to
inspect the vessel for damage to the shell, all
the fittings and the inlet/outlet ports.
Structural damage to these items could.
compromise the integrity of the system.
DO NOT operate the unit if it has been
damaged since this could result in contaminant
spills, damage to other equipment, or personal
iniury. If the GPC vessel sustains damage
during transit, notify the carrier and call
Carbonair immediately at [phone].
4.2 Loading & Unloading
The GPC unit can be loaded or unloaded by
using an overhead crane or forklift. Hoisting
rings are available on top of the vessel at each
corner for connecting cables. In addition, the
vessel is mounted on a skid making the unit
forklift compatible.
• When· handling the GPC be careful not to
damage the outer shell, fittings, and inlet/outlet
ports. The vessel is usually shipped with
activated carbon as defined in the design
specifications.
Be sure to use the proper lifting equipment and
follow proper _safety procedures when loading
& unloadina the 'GPC unit.
4.3 Connections
After the GPC has been properly inspected and
positioned on site, process connections can be
made.
The GPC unit is shipped with all nozzles and
ports covered. This is done as a safety
precaution and to prevent moisture from
contaminating the activated carbon in the
vessel. The covers must be removed prior to
making the necessary piping connections.
If the vessel is shipped with a piping kit, make
the necessary connections as outlined below.
If a kit is not provided, piping and fitting
instructions can be obtained by calling
Carbonair at [phone].
1 . Attach the exhaust stack, avoiding
unnecessary restrictions in the off-gas
ducting. Ducting should be sized for
minimum friction loss according to the
design air flow rate for the unit. When in
CopyrlghtlC 1997 Carbonair Environmental Systems. Inc. 0/21/99) \\C£S.1-10-NWSVROIWOL110.ATA\USEAS\TRElDS\TAMMY\0&.M\OPCR.OOC 3
doubt, ducting should match the size of the
GPC vessel air outlet port.
Note: Be sure to install e cap (which does
not significantly restrict the airflow) on the
discharge stack to prevent water from
entering the carbon vessel -if one has not
already been provided.
' 2. Connect the inlet air piping to the influent
flange or coupling. All interconnecting
piping should be self-supporting.
3. Carbonair recommends installing a pressure
gauge {rated in inches of water) and
sampling tap in both the inlet and the outlet
piping to assist in the evaluation of GPC
system performance. The inlet and outlet
pressure gauges provide the ability to
' calculate the pressure drop across the unit.
The sample taps provide the ability to
collect representative gas samples for
contaminant removal performance
determinations.
4. Connect the drain pipe and isolation valve
to the drain fitting at the bottom of the
vessel.
5. Sample piping can be installed in the vessel
and connected to the two full sample port
couplings if required. However, turbulence
and other unique operating conditions may
adversely affect the accuracy of sampling
at these points. It may be preferable to
install sampling ports on the inlet & outlet
piping to avoid sampling complications as
stated in #3 above.
5.0 START-UP
After all the necessary connections are made,
proceed with the following start-up procedures:
1. Verify that the drain valve is closed.
2. Start the process air source to begin the
introduction of air into the GPC unit.
3. Record the inlet and outlet pressures and
note the pressure drop across the unit.
Measure the inlet air flow and then check
the Pressure Drop Chart in Figure No. 2 a &
b, page 8. Verify that the unit is operating
according to the design curve.
4. To achieve optimum performance of the
GPC unit during initial start-up, check:
✓ the air flow rate
✓ the pressure drop
✓ for air leaks
✓ the inlet air temperature
✓ the inlet air relative humidity
Refer to the Specific Operating Parameters
Section on page 10.
6.0 OPERATION
After initial start-up & successful checkout of
the GPC unit, long term continuous operation
can be.initiated.
The GPC gas phase carbon adsorber is
designed for an optimum relative humidity of
50% and a maximum inlet operating
temperature of 100° F. The inlet flow rate,
relative humidity and the temperature must be
regularly monitored to verify compliance with
GPC design operating criteria. This will ensure
optimum contaminant removal performance of
the unit.
NOTE: For further information regarding the
effects of humidity & temperature on vapor
phase carbon performance, refer to the
attached fact sheet.
Performance of the GPC unit should be checked
periodically by measuring the pressure drop
across the unit and evaluating the contaminant
removal of the carbon bed by sampling inlet
and outlet gas streams. Measurement &
sampling frequencies will be dictated by
process air flows and inlet contaminant
concentrations.
As the carbon bed adsorbs contaminants and
moisture from the flow stream, the pressure
drop across the unit may increase. The
operation should be terminated and the carbon
replaced when the effluent concentration of the
critical contaminant approaches the discharge
limit. Again, replacement frequency will
depend on specific operating conditions.
4 Copyright© 1997 Carbonair Environmental Systems, Inc. {7/21 /99) \\CE5-HQ.MYSl/fl1J1\VOL1\0ATA\USERS\TRELOS\TAMMY\06M1GPCR.DOC
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Refer to the maintenance section in this manual
for details on carbon removal and replacement.
7 .0 TROUBLE SHOOTING
There are a few situations which may arise
while operating the GPC which can adversely
effect the performance of the unit and/or result
in abnormally high maintenance costs. If any
situations cannot be corrected using the
following trouble shooting guide, contact
Carbonair at [phone] for additional
help.
1. Situation:
'
Frequent activated carbon media
replacement because of fast breakthrough.
Cause:
If the pressure drop, air flow, temperature
and relative humidity are within normal
ranges and breakthrough occurs more
frequently than expected, check inlet gas
stream contaminant components and
concentrations. Inlet contaminant
concentrations may be greater than the
design concentrations or additional
compounds may be present in the process
air stream that were not taken into account
during design.
Solution:
Verify that the contaminants in the air
stream are the design contaminants and are
present at or near the design
concentrations. If the concentrations are
significantly higher, or additional
compounds are present, contact Carbonair
to evaluate the design and recommend a
solution.
2. Situation:
Excessively high pressure drop across the
vessel when compared to the pressure drop
curve.
Cause:
A high pressure drop across the activated
carbon bed may be caused by:
✓ High inlet air relative humidity.
✓ High inlet air flow.
✓ Accumulation of particles.
✓ Plugged holes in the grate and/or wire
mesh.
✓ Wet carbon.
Solution:
• Check the relative humidity,
temperature and flow rate of the inlet
flow stream -verify that they are within
design specifications.
• If the relative humidity is higher than
the design level, process air heater
adjustments are recommended. If there
is no process ai, heater, Carbonair
recommends that one be added to the
system. Call Carbonair for assistance.
•
•
•
•
An inlet air flow rate, significantly
higher than design, will decrease the
bed life of the carbon. This occurs
because of the increase in the mass
loading rate of the contaminants onto
the carbon. If the inlet air flow rate is
significantly higher than the design
rate, adjustments in the air flo-;i at the
source may be required to reduce· the
pressure drop and the mass loading
rate. If air flow adjustments are not
possible, additional vessels may be
required to provide additional bed mass
for treatment. Please call Carbonair for
recommendations.
Sample the activated carbon and have
it tested to determine if solids are
clogging the carbon bed. Back track to
determine the source of the solids if
they are present.
The presence of a high relative humidity
in the inlet air stream can cause a build-
up of condensate (water) in the .vessel
making the carbon wet and restricting
airflow through the bed. Carbonair
recommends that process heater
adjustments be made to correct the
problem if possible. In order to dry out
the carbon, drain the condensate from
the vessel and pump clean-dry air
through the vessel.
As a last resort, remove carbon and
inspect the grate and wire mesh.
Verify that the holes in the grate and
the mesh are clear.
CopyrfghtC 1997 Carbonair Environmental Systems, Inc. (7/21/99) \ICEs.HO-NWSYR01\VOLI\OATA\USERS\TFIE1DS\TAMMY\O&M\GPCR.OOC 5
3. Situation:
'
Unusually low pressure drop across the unit
(see the Pressure Drop Chart, Figure No. 2
a & b, page 9).
Cause:
_This could be caused by the following:
✓ Low activated carbon level on carbon
bed.
✓ Low inlet gas flow.
✓ Larger activated carbon particle size
being used than is required.
Solution:
•
•
•
Verify inlet gas flows .
Check the carbon bed depth .
Verify the activated carbon particle size
against the design specification
8.0 MAINTENANCE
There are several maintenance tasks which
must be performed periodically to ensure
continued, trouble free operation. These tasks
are discussed in subsequent sections.
8. 1 Spent Carbon Removal
Periodically, the spent carbon will have to be
removed and replaced,
The _spent acti'{ated carbon_ can be sent to . Carbonalrfor reacti~ation 'o'r a ifcensed
reacii;,ati;n facilify for rec)cling. However,
before the ·contaminated material can be
'shipped, a.· ~Spent ca;bon identification siiefi~li,d ~·tsJ,1ffit"p;;~b'i{Ijii'rice of Retdrn
. form~ niust b~-compiet~d ;;,{ii sent to . · .. ~~~~•*ff !{;~~:~li~~~?~fff~}ii,~~J~(fo blJ Tflquired . ilepe11dmg on ·the hazardouslnon-hazardous ·"• ,' _· . ,._.-,. ·-,. ,,., .. ,..,,:··, .. clast;ification of the con'taininahts adsorbed.
. Cai-bonliir vvill ~dt accept lipeiit carbon until
all t{ii ~~~~ss~;t/~rn1sj;J~ef"J,~er1 completed. • Jz;:f:X''fbf:;Zti;:i1'1~'/l1!_ft11Pt._ . ::'' -:.' ::_;~·:~·/\~·-:-Jf.~.\,:}?(~!:'.('·_ '?'·?:)\,{i2ii~-~f( ... · .. ).,·
WARNING: Before attempting to remove the
carbon from the vessel it must bti understood
that the material may be considered a
hazardous waste. Consequently, the use of
respirators and protective clothing is required.
Removal of the carbon must be initiated from
the outlet. Carbonair recommends that a
vacuum extraction method of removal be
employed so that the carbon can be transferred
with minimal handling, directly to drums or
supersacks for proper disposal. In addition,
Carbonair recommends that a licensed
contractor provide this service to ensure that
the removal is conducted safely and cost
effectively,
After the carbon is removed, be sure to inspect
the integrity of the fiberglass grate, the wire
mesh and the inside structural supports. Also
check the bottom of the vessel and clean as
necessary to ensure proper drainage (see
Section 8.3 for details).
WARNING: Never enter the GPC vessel without
adequate ventilation, proper atmospheric
testing and safety equipment. The activated
carbon depletes the air of oxygen so entering
the vessel without sufficient ventilation could
be fatal The vessel is considered a confined
space and therefore OSHA confined space
entry safety procedures must be followed (29
CFR 1910. 146).
8.2 Fresh Carbon Loading
It is important to note that carbor,, .with particle
sizes smaller than the wire mesh opening)inust.
not be used or the carbon ;,.,i1i';,i.ss thiough' the ;
wire mesh reducing operating peHorm'anc//j,i,d
possibly plugging the inlet. and/or 'c;;i,dJhsate .
drain. .-\;(fi.
Dry carbon is introduced into the vessel
through the outlet pipe opening. To load
carbon into the unit, follow the steps outlined
below:
1. Inspect the inside of the vessel as specified
in Section 8.3.
2. Re-install the access cover and Gasket.
6 Copyrighti:0 1997 Carbonair Environmental Systems, lnc.17/21/99) \\~HQ.HWSVfl01WOL1\DATA\USERS\TFIELOS\TAMMY\O&M\Gl'CR.00C
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3. Add fresh activated carbon to the vessel
through the outlet port until the activated
carbon level is no less than 6-inches from
the top of the vessel -carbon densities will
affect the volume which can be added to
the GPC unit.
4. Verify that the carbon is evenly distributed
over the carbon bed to prevent the
possibility of the air flow stream channeling
through thinner sections of the bed.
5. Reconnect the outlet pipe.
8.3 Vessel Inspections
The inside of the vessel should be inspected
periodically to verify the integrity of the internal
components. Inspections should be conducted
in a manner which is consistent with confined
space safety procedures.
WARNING: Never enter the GPC vessel without
adequate ventilation, atmospheric testing and
proper safety equipment. The activated carbon
depletes the air of oxygen so entering the
vessel without sufficient ventilation could be
fatal. The vessel is considered a confined
space and therefore OSHA confined space
entry safety procedures must be followed (29
CFR 1910.146).
To inspect the GPC vessel, follow the steps
outlined below:
1. Remove the outlet pipe (ventilation).
2. Remove the access cover.
3. Closely examine the wire mesh to ensure
that the holes are clear and is properly
secured on the vessel ledge.
4. Closely examine the fiberglass grate to
ensure that the openings are clear in that it
is properly secured to the vessel ledge.
5. Make sure that flange fasteners are secure.
6. Check the bottom of the vessel and clean
if necessary to ensure proper condensate
drainage.
After the inspections have been successfully
completed, re-connect the outlet pipe, re-install
the acces.s cover and verify that the drain valve
is closed.
8.4 Condensate Drainage
Drainage of condensate from the bottom of the
GPC vessel may be required periodically
depending on the inlet gas stream moisture
content. This is done by opening the
condensate drain valve at the bottom of the
vessel.
If the vessel is pressurized, the condensate will
flo)IV more ·readily but may cause some
splattering when air begins to pass through the
line.
Carbonair recommends that the blower be shut
down before the drain valve is opened and then
restarted when the valve is closed ..
8.5 Waste Disposal
Proper disposal of spent carbon and
contaminated condensate is essential. Be sure
to follow all local, state and federal regulations
for handling, storing, transporting, disposal and
reactivation of spent carbon and condensate.
9.0 SPARE PARTS
When ordering spare parts, refer to the
drawings at the end of this manual. Be sure to
provide the vessel model number and the
complete description of the part.
10.0 PRESSURE DROP CHART
The following pressure drop chart shows the
pressure drop across the bed in inches of water
at different gas flow rates through the GPC gas
phase carbon adsorber with virgin CECA 4 x 10
GE Carbon @ 70° F. Piping and inlet losses
must also be designed for.
CopyrightO 1997 Carbonair Environmental Systems, Inc. (7/21/99) \\cts-HQ..HWSVR01\VOL1\0ATA.\USERS\Tl'la0S\TAMMY\06M\GPCA.OOC 7
'
B
16.0
c2° 14.0
~ i 12.0
u. 0
~ 10.0 :,:
0 ~ 8.0 ..
0 "' 6.0 C w "' ::, 4.0 "' "' w "' .. 2.0
0.0
0
Figure No. 2a
Pressure Drop for GPC 5R, 7R, 13R
FIGURE 3a, PRESSURE CROP VERSUS FLOW FOR GAS PHASE CARBON UNITS WITH 4X10 CARBON
I I
GPC-5R, J I GPC-13R :, V
"" I r-----GPC-7R / 1/ /
I / _v
// ./ /
p
/".'. c----
100 200
-~
300
,.
400 500 600
AIR FLOW RATE (CFM)
Agure No. 2b
700
FIGURE 3b, PRESSURE CROP VERSUS
800
FLOW FOR GAS PHASE CARBON UNITS WITH 4X10 CARBON
16.0
11. ii: 14.0 ~ ~ 12.0
0 3: 10.0 w u. ~ o a.a
~ ffl 6.0
~ 5 4.0
a.~ 2.0
0.0
,,,
""", .. J
/
/ ./
//
~
I /
/ ,/
J / /
~ ...,,.,,.
, '<OO ,OR
I~ ---
900
~
1000
0 600 1000 1600 2000 2500 3000 3500 4000 4500 5000
FLOW RATE (SCFM)
Pressure Drop for GPC 20R, 50R
CopyrightCI 1997 Carbonair Environmental Systems, Inc. 17/21199) \\CE~(Hffl'l'IR01WOL1\0ATA\USERS\TAELDS\TAMMY\O&M\GPCJ\.DOC
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11.0 DRAWINGS
Assembly drawings have been included on page 10 to simplify the part identification and ordering process. A parts list is included.along with the corresponding order number.
'
0
Table No. 2 GPC-13R Assembly Drawing Parts List & Order Numbers
SST Screen 18 X 1 8 Mesh
2 Gasket
129693
114820
CopyrightC 1997 Carbonair Environmental Systems, Inc. (7/21/99) \\CE5-HQ-NWSVA01\VOL1\DATA\USERS'ITJla.DS\TAMM't\06M\GPC
R
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-9
13.0 SPECIFIC OPERA TING PARAMETERS
Job---------------------------------
Carbonair's Serial Number ___________ -'-----------------
Recommended Activated Carbon _______________________ _
Activated Carbon Particle Size Range·-----~-----------------
Wire Mesh Specifications
Wire Mesh Opening Dimensions ________________________ _
Minimum Allowable Carbon Size. _______________________ _
ln~t Air Flow Rate
Inlet Temperature ('F)
Inlet Relative Humidity(%) _________________________ _
Contaminant Description, __________________________ _
Contaminant Concentration. _________________________ _
Contaminant Mass Flow, __________________________ _
NOTES. _______________________________ _
Copyrightl.CI 1997 Carbon air Environmental Systems, Inc. 17 /21 /99) \\CES-HQ.NWSVR01WOl1\DATA\USERS\TFlELOS\TAAIMY\06M\GPCR.DOC
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Operations and Maintenance Manual
Prepared For:
Brown & Caldwell
Statesville, NC
Prepared by:
CARBONAIR Environmental Systems, Inc.
2 731 Nevada A venue North
New Hope, MN 55>427s2864
Project Manager: Mike Keilen
CARBONAIRProjectNo.: 11504
June 23, 2000
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CONTENTS
I. INTRODUCTION
2. SYSTEM DESCRIPTION
Figure I.
Figure 2.
Process Description
Plot and Elevation Diagram
3. CONTROLS DESCRIPTION
4. STARTUP AND SHUTDOWN PROCEDURE
5. MAINTENANCE SCHEDULE
6. TROUBLE SHOOTING GUIDE
7. TESTING REPORTS
APPENDICES
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INTRODUCTION
CARBONAIR Environmental Systems Incorporated is the supplier of the ground
water/soil remediation equipment for Brown & Caldwell to be installed at the Statesville,
North Carolina site. This Operation and Maintenance Manual contains important
documentation and provides specific operation and maintenance information for this
system and individual components.
Section 2 provides a description of the groundwater treatment system. This section is
useful for learning about the process and system operating conditions. Included in this
section are a Process and Instrumentation Diagram (P&ID) and a Plot and Elevation
Diagram.
Section 3 contains the Control Panel Schematic and a description of the system controls.
Section 4 contains start up and shut down procedures.
Section 5 contains a maintenance schedule for the system; the provided schedule is a
summary of the recommended routine maintenance items .. Additional maintenance items
or shorter maintenance intervals may be required depending on operating conditions.
Section 6 contains troubleshooting guide for the system. The troubleshooting guide has
been created to aid in simple troubleshooting tasks. More involved troubleshooting
methods can be found in the appendices, or by calling CARBON AIR.
Section 7 includes the test reports generated prior to shipping the equipment.
The appendices contain the original equipment manufacturers' operation and
maintenance manuals, specification sheets, and modeling.
If you have any questions or problems please contact CARBONAIR at [phone].
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2. SYSTEM DESCRIPTION
Scope
The SVE/groundwater treatment system described in this section is located at the
Statesville, NC site. This system description is provided as a written summary of the
items shown in the Process and Instrumentation Diagram (P&ID) and the Plot and
Elevation Diagram. All operators should read this description and study the P&ID for a
full understanding of the system. The Plot and Elevation diagram shows the layout and
installation requirements of the site.
The System Component Summary lists the major items in each system. The System
Description describes how the contaminated water/air moves through the system listing
each of the major components. The reader should refer to the P&ID for a visual
representation of the system while reading this description. CARBON AIR provided
equipment for the Soil Vapor Extraction System. For details on each of the items listed,
refer to the Component Description immediately following the System Description.
• System Component Summary
The following table lists the major items in each system:
Item Descrintion P&ID Desienation Manufacturer Model#
Vapor Phase Carbon Carbonair GPC20R's
Vessels
Vanor Phase Header Carbonair 6" steel header
Air Compressor Gardner 12DI0VTS35
Denver/Chamoion
System Description
(2) Carbonair model GPC 20R vapor phase carbon vessels with carbon
2000 lbs 4x1 O mesh virgin bituminous vapor phase carbon in each vessel
Carbon steel construction with epoxy/urethane finish inside and out
Air plenum on inlet to balance airflow across carbon bed
Steel carbon support grate with stainless steel screen
22" dia bolt on top manway for easy access (Access Only)
200-1800 cfm max flow range
Less than 7" w.c.drop per vessel at 1000 cfm
6" nozzle inlet on sidewall of vessel
6" outlet nozzle on top of vessel near edge of vessel
Misc. leveling plates for under GAC vessels to ease interconnection problems
Each vessel is capable of being unloaded and placed in the building with a forklift or
pallet jack
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(1) Piping header for series, parallel or single vessel operation of (2) vessels
6" schedule 40 carbon steel piping, Cl flanged elbows & tees
6" Butterfly valves
Mueller Steam Service model 56ANK61
Cast iron body, 416 SS stem, bronze disc, EPDM seat, 10 position
handle, lockable in fully open or fully closed position
Sample valves on influent and effluent of each vessel
6" 150# flanged influent, effluent
Pipe supports to support interconnecting piping to vessel from header
Skid for support of piping header
(1) Compressor, Gardner Denver Champion Model 12D1 0VTS35 oil-less compressor
10 hp, 208VAC, 30, TEFC motor
35.2 acfm capacity, 100 psi maximum pressure
NEMA 1 pressure switch
120 gallon horizontal ASME reservoir tank
In line air filter with replaceable element
Air cooled aftercooler
Automatic condensate drain
Pressure gage on receiver discharge
Pressure relief valve
(1) Pressure transmitter/gage, Dwyer model 7116D
Pages
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GPC-20R
APROX. 8'-6"
#1
JNLEr FROM
SVE
#2
5· PIPING
APPROX. a·-o·
DISCHARGE
SAMPLE/PRESSURE
GAUGE LOCATION
(lYP. BOTH VESSELS)
INLET SAMPLE/ PRESSURE GAUGE
LOCATION INLET Fl.ANGE SPOOL
(TYP. BOTH VESSELS)
err GAS TO
STACK
1---------------,-u·-o·------------------,
GPC-20R
REVISIONS
REV ECO DESCRIPTION OAiE 0
••
... ,..,.._
SHs · CARBONAIR
_,., 12
..,,.....,.. ............ ---IIK FOR GPC 2OR ~ W '",':" !.-"'""";;;~,.-,--:-:,,:=c-::-:----1 BROWN & CALDWELL-STATESVILLE, NC
4
~TEI ANO AR otCOKtAMIMATDt 0--ooo JilDCNlNl0IJ!. WINN[SQTA ~
IT1LE 6 8.1. HEADER
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3. CONTROLS DESCRIPTION
Carbonair supplied a terminal box with disconnect on the air compressor. An HOA
switch is also installed on the terminal box to allow feed back to the PLC for mode of air
compressor operation.
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MAIN INCOMING POWER 208 VAC.. J•. 80 HZ
L1 L2Ll
' ' ' I I I w 150 AlAP NON-F"USEO CISCQNNECT SWITCH (NOT SERVICE ENTR.A.N'CE RAT£0)
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I I I Ll L++-------ui L+--------L . . LI
AIR COMPRESSOR
IOHP, 208VAC Jo 2S.5FlA PR£SSURE TRA.'LSI.IITTER
(0-IOOPSIC)
TERl•IINAl STRIP rs-, ~-,.--' ~..,.·\--~-l 11 11 :-y--f---4. 2
l.._ SHLO L-.J
J _..; ___ 4. -~------4. I XCO •
--L -----4. ' oox
.. --.
• •
REV ECO
A
REVISIONS
DESCRIPTION DATE
RELEASED FOR SUBMITTAL 05/17 /00
RELEASED FOR RESUBMITTAL 05/31/00
RELEASED FOR PRODUCTION 05/05/00
AS 8Utl T 05/07 /00
LEGEND
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TERMINAL IN PANEL
LOCATED JN PAl-!El
FlEl.O MOUNTED 0£'JICE
LOCATED ON PANEL DOOR
uOTOR CONTACTOR
CONTROL RELAY
GREEN PILOT LICHT
RED PILOT UCHT
WHJTE PllOT LICHT
YELLOW PILOT LICHT
F'LOAT SWITCH CLOSES
ON RISING LEVEL
F'l.OAT SWITCH OPENS
ON RISING LEVEL
PRESSURE SWITCH ClOSES
ON RISING PRESSURE
PRESSURE SWITCH OPENS ON RISING PRESSURE-
T(l,lf>tRATIJRE SWITCH OPENS · ON RISING TEMPERATURE
NORMAU.Y OPEN CONTACT
NORMAU.Y CLOSED CONTACT
FIELD Wll~NG
NORMALLY OPEH PUSI-IBUTTON MOMENTARY
n-tREE POSITION H.0.A SELECTOR SW'ITo-1-ILLUMINATtO (SPRING RETURN IN HANO POS)
SEL£CTOR SWITOI
ORN
RLC
RLC
RLC
RLC
::,____
0 0 AOomoNAL CONTACTS MAY 8£ AOOEO
,----,
1----H----1
L~J
NOTE:
MOTOR C!RC1JIT PROTECTOR (PROVIOES MACNETIC TRIPS AND OV(Rl.ClAO PROT(CTION)
MOTOR ORCUfT PROTECTOR AUXJU.AR'I' CONTACTS (N.O. COHTACTS/~~ WHEH START BUTTON OEPR )
t. DRAWING NOT TO SCALE 2. NORMAL STATE, DEVICE ENERGIZED
~~?a~ =le;!~ o I 0
""" NO. 211 550 , ... A •n«:a.1f K 0:NSD!f r, ~ • ~ .utt .. NOC I 1
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4. STARTUPANDSHUTDOWNPROCEDURE
Start up Procedures:
Before starting any system, thoroughly inspect the system for signs of damage. Use the provided P&ID to verify that the system has been connected correctly. Then, read the start up procedure.
AIR COMPRESSOR
1. Check the oil level (unless oilless compressor) in the compressor. Verify that all effluent connection have been made, and close any bleed valves on the compressor tank.
2. Verify that the panel is operational and installed is correctly (see panel start up procedures)
3. Bump the compressor to verify rotation by placing the AIR COMPRESSOR switch in the "HAND" position for a few seconds and observe the compressor. Rotation arrows are located on the compressor to signify proper rotation. If rotation is backwards, have an electrician exchange two of the power leads: Be sure to lock out and tag the main incoming power. Verify that there is not power with a multimeter.
4. Once rotation has been confirmed to be correct, enable the air compressor. The compressor should run for IO to I 5 minutes and automatically shut off. Closely observe the compressor to ensure the pressure in the tank is rising. The pressure should not exceed 180 psi. If it does exceed the maximum pressure, the compressor should be disabled immediately. Refer to the troubleshooting guide for more information 1•
5. Open the all valves to the pneumatic wells and adjust the pressure regulator to the desired pressure. If a solenoid is used to control the flow of the pump, place the MAIN AIR SOLENOID HOA in the "AUTO" position.
6. Once the system has reached operating conditions, record the following applicable operating ·conditions:
Duty cycle (The amount of time the compressor actually runs divided by the amount of time that the compressor is enabled)
Compressor motor amp draw
High pressure set point (pressure when compressor shuts off)
Low pressure set point (pressure when the compressor turns on) _______ _
Notes: I-depending on the interlock schedule, the blower may not run until all of the appropriate alarms have been cleared and the correct pieces of equipment enabled. The remaining steps can be finished when the system is completely enabled.
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Vapor Phase Carbonair
1. Position valves for desired operation
2. Record operating pressures.
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Shut Down Procedures
CAUTION! -When disabling any motor or piece of equipment be certain that all source
of power and fluid have been locked out and tagged,
Air Compressor
• Turn switch to off
• Drain tank
Vapor Phase Carbon
• Drain bottom of tanks
• Replace carbon if it is spent
..
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5. MAINTENANCE
This section should be used as a guide for general maintenance items. The recommended
maintenance intervals are based upon past experience with the equipment and equipment
manufactures' literature. It is important to use discretion when implementing the
maintenance schedule. Unforeseen operating condition may require additional
maintenance.
Maintenance Schedule
Svstem Task Recommended frequency
GPC Carbon As needed, depending on operating
replacement condition. See any carbon modeling to
estimate the bed life of the carbon.
Drain any As, needed depending on the humidity of the
condensate. process stream. Monthly is a conservative
guideline.
Air compressor Clean/replace inlet As needed, depending on air quality
filters condition. Recommend minimum cleaning -
monthlv
Check Oil Weekly, (unless oilless type compressor)
Change Oil with After first month of operation, then yearly.
SAE 30 weight (unless oilless type compressor)
non-detergent Oil
Check belt tension Monthlv
Clean auto drain Monthly
valve
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6. TROUBLE SHOOTING
Trouble Shooting Operational Notes
A. Any switch in the "HAND" position will operate the corresponding circuit under any
alarm condition, except for a motor temperature fault or a circuit overload. The "HAND"
position is for diagnostics orto clear alarms. The system should never be left unattended
while any switch is in the "HAND" position.
System Problem Possible cause Solution
Air Compressor will run Alarm condition Clear any alarm condition and reset the control Compressor in "HAND' but not in panel. See "Section 3" for alarm interlocks.
'AUTO'
Pressure to high The Compressor will not run until ii reach the low
Compressor will not pressure set point.
run in the 'HAND" Tripped circuit Open the inner door and reset the circuit position •
protector protector. A tripped circuit protect can be an
indication of a problem. Inspect the system
thoroughly and check the operating conditions.
Motor temperature Check to see that the motor temperature switch
switch is inoperative has been wired, or that there is a jumper, if a
switch is not present.
Faulty motor Refer to Appendix or contact CARBONAIR for
Compressor help in diaanosina faultv oumo.
operating, but at Cloaaed filters Clean/reolace filter
reduced performance Faulty pressure Replace pressure switch
Compressor runs switch
continuously Compressor size Contact CARBONAIR to verify any compressor
inadequate sizing
Leak in system Inspect system for leaks
Compressor
knocks/rattles Loose belt Replace belt.
Excessive cycling
Water in tank Drain tank and clean auto drain valve
Leak in system Locate and repair leak
Compressor under Contact CARBONAIR to verify any compressor
sized sizina
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7. TESTING REPORTS
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Control Panel Full Load Amp Settings (for overload protector devise)
Ovc:rlo.id Amp Set -J Overload AmpScd Overload Amp Set ✓ Overload
..
Control Panel Checklist
Description Opcrat1on V Description
Photos of control panel ,✓ Testing: Wiring
As-built drawings ✓ PLC Program
Special O&M Manuals: Autodialer . ,Ip Telemetry Interface
Modem . If} UL Sticker
Other ' 11 NEC Panel Sticker
Service Entrance I ✓A Total Current Draw
T cnninals Tightness . Ir/ Carbon air "TESTED" sticker ( dated & signed) ... . .
Spare Fuses or Bulbs Quantity Size Spare Fuses or Bulbs Quantity .
' . IJ!ri. . ., .
Control Panel Notes:
'
PM Sign-off .. Sales Manager Sign-off
Controls Sign-off Engineering Sign-off
....
Amp Set ✓
Operation -..J
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✓
✓
.JIA
✓
Size
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Gardner
AUTOMATIC Denver service data for air TANK
compressor components DRAIN VALVE
REPLACEMENT PARTS LIST
ITEM PART NO, REC'D DESCRIPTION
1 M2399 NUT, Timar lock
2 TD·B SCREW, Timar
3 TD-5 BODY, Timer
4 TD·2 COVER, Diaphragm
5 TD-9 DIAPHRAGM .
6 TD·4 PLATE, Diaphragm
7 TD-1 BODY, Valve
8 TD·16 RING, 0
9 TD•7 STEM, Valve
10 TD-3 DISC, Valve
11 TD·IB WASHER, Disc Backup • 12 M745 NUT, Hex Brass
13 P01882A SPRING, Valve
14 TD·17 GASKET
15 TD-10 PLUG, Intake •' 10 16 M2881 1 ATTING, Compression 11 17 M2863 2 FITTING, Compression
18 M3473 8 SCREW, Rllister Haat Machine
19 M1651 1 SCREEN 19 --14
z.TD-1 1 TANK DRAIN ASSEMBLY, Complete
Z-TD•1A TANK DRAIN w/installation Kit (Champion Units)
·~g
15
,1o/16
~QP Z-TD-1C DRAIN w/Kit (Commandair Units)
Z-5941 REPAIR KIT Includes items 5 & 8 thru 14
OPERATION_
At the end of each pumping cycle, any compressor equipped
with a centrifugal unloader* or pressure switch with a
pressure release valve, exhausts air from the lines between
compressor and tank. This exhausted air is used to actuate
the Gardner Denver Automatic Tank Drain Valve.
The exhausted air is delivered into the diaphragm cover, 141
depressing the diaphragm 15). This forces the diaphragm ·
plate 161 and valve stem (9) down, unseating valve disc (10).
Storage tank pressure then forces moisture accumulation
at the bottom of tank through flexible tube and tank drain
INSTALLATION
The Gardner Denver valve may be mounted vertically or
horizontally as required. It must be mounted rigidly to
compressor or tank using mounting flange. The flange has
been drilled to accommodate ¼ • bolts. A new tank drain
fitting with flexible tube attached may be ordered or
existing manual drain fitting and tube may be retained and
used. Make sure flexible tube reaches bottom of tank.
Connect as shown using 1/8" or 1/4" compression fittings.
valve (see diagram reverse side). Timer 11, 2 & 3) allows the
exhaust air depressing the diaphragm to bleed off. The length of
time required to bleed off air determines draining time of valve.
The timer screw 121 opens or closes air bleed holes providing the
operating range necessary to assure complete drainage.
*Only compressors equipped with centrifugal unloaders or
unloader-type pressure switches can use this valve. The auto tank
drain WILL NOT WORK with gasoline driven or continuous run
units using head unloader .
Where necessary to run connection into diaphragm cover on timer
side, timer may be unscrewed and placed on the opposite side.
When adjusting timer, timer screw should be turned to give
draining time just long enough to exhaust all trace of moisture.
Turning timer screw 121 CLOCKWISE LENGTHENS DISCHARGE
TIME . COUNTER-CLOCKWISE SHORTENS DISCHARGE TIME.
Tighten lock nut 111 when timer screw is set.
FOAM NO. G3043 REV. 3/99
SERVICING
IF VALVE FAILS TO OPEN. Check for leaks in line from
unloader or pressure release valve to automatic drain
valve. Check to see that timer has not been unscrewed
too far. If trouble persists, remove intake plug 1151 and
clean chamber. If this fails, remove diaphragm cover 141
and check diaphragm and diaphragm plate for cause of
non-operation.
IF VALVE FAILS TO CLOSE. Check timer adjust'llent to see
that air is bleeding out.
If air continuously bleeds from timer while compressor IS
running, centrifugal unloader or pressure switch release
valve is leaking. Check compressor or pressure switch
instructions for remedy.
If air continuously bleeds from timer when compressor IS NOT
running, inspect compressor check valve. Replace check valve disc
if air is leaking back from tank.
If timer works correctly and valve fails to close, remove intake
plug 1151, spring 1131 and valve stem assembly. This assembly
includes valve stem 191, ·o· ring 181, disc 1101 and nut (121. They
are not attached to diaphragm plate (61 and will drop out through
bottom of valve chamber opening. Clean intake chamber and disc
(101. Replace disc if scored.
IF VALVE OPENS AND ONLY AIR IS EXHAUSTED. Check flexible
tube in tank. It must reach to the bottom of the tank and be free of
. leaks.
Timer may be adjusted under operating conditions.
16 WARNING I
Drain tank completely of air and water before installing or servicing valve.
Failure to relieve pressure may cause injury or equipment damage
FROM COMPRESSOR
CENTRIFUGAL UNLOADER
HOUSING ON PUMP
1/8" x 1/4" COMPRESSION
FITTING AND BUSHING
TUBE TO EXHAUST POAT OF
CENTRIFUGAL UNLOADER OR
PRESSURE RaEASE VALVE OUTLET
OF PRESSURE SWITCH
1/8" X 1/4" COMPRESSION
FITTING
1/4" EXHAUST TUBE
TO CONTAINER
FOR PROPER DISPOSAL
~ 1/6" x 1/4" COMPRESSION
FITTING
AUTOMATIC TANK
DRAIN VALVE
INTAKE TUBE
1/4"TUBING
TANK DRAIN
FITTING
TANK
FLEXIBLE TUBE
INSTALLATION OF GARDNER DENVER AUTOMATIC TANK DRAIN FOR COMPRESSORS
EQUIPPED WITH CENTRIFUGAL UNLOADER
Gardner
Denver 1301 N. Euclid Ave .• Princeton. Illinois 61356-9990
Phone [phone] • FAX [phone]
Manufacturing Plants in Princeton", Illinois · Manteca, California
O Copyright Gardner Denver, Inc, 1999
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I ------IS-C62E
• • -----• . -----~ -------------------C628 Combination Unit
WARNING! The polycarbonate plastic marerial us_ed 10 manufacture
the plastic bowls and the sight glasses on the filter and lubricator ma.y
be anacked by certain cheriiicals. DO NOT use these units en systems
with air supplied by a compressor lubricated with synthetic oils or oils
containing phosphate eaters or chlorinated hydrocarbons. These oils
carry over into the air fines and chemically anack and possibly rupture
the bowls and sight glasses. Also. DO NOT expose these units 10 ma-
terials such as carbon tetrachloride, trichlorethylene, acetone, paint
thinner, cleaning fluids. or other /"larmful materials. for they too will
cause the plastic to craze ·and/or rupture. For use· in environments - ·
where any ol lhese chemicals m3y be present, consult rhe factory for
approval prior to installation.
Installation
Before lnslalling. blow out pipe line 10 remove scale and other loreign
maner. These units have OA)'SEAL pipe threads; use "pipe compound
c,r !ape sparingly to male threads only. Install units in pipeline so air will
:tow in direciion indicated on bodies. Install as near as possible vertical
to pipe line.
F602 FILTER
• --,--.. "" '
STEEL JOO PSI 1so'°'r
STEEL OR. ZINC UO PSI l50°F !JISICHTGU.SS
Maintenance
To maintain maximum filtering efficiency and to avoid excessive pres•
sure drop, the filter must be kept clean. On standard filters. open drain
cock (turn clockwise) periodically and drain otf any bowl accumulation
before it reaches level ot lower battle. Bowl drainage is automatic in lhe
·Pts1on Drain· mode:, however. m.:inualdraining.can ~!so be do.ne t;)y re•
moving the bowl. A visible coating of dirt or condensate on lhe filter
element surface or an excessive pressure drop is an indicatiOr'I that
cleaning is necessary.
Cleaning
To clean. it is not necessary to remove filter lrom the line. disassembly
Is simple and does not require I00/s-use the drawings on the reverse
side ol lhis sheel as a guide. Before disassembly. shul otf the air supply
and de pressurize filter. Clean all parts except plastic bowl and/or sight
glass with alcohol and blow out filter body be/ore reassembly, Was'h
hlter element in alcohol and blow out lrom the inside. Plaslic boW'ls or
metal bowls with s,ghl glass must~ cleaned with ~~use hold soap o~ly.
'"Auto Drain'" Operation · ·\· .
·Auto.Drain· tilters are equipped with a lloat actuate~ d_evice which
autom'atically ejects liquid contaminates. II supplied in kit form, Part No.
SA602MO-M3. the ·Auto Drain· can be installed by simply removing the
flange ring and bowl and then removing the dr~incock lrom the bowl.
Insert the '"Auto Drain· in place ol th~ removed draincock and reas·
semble in reverse order. Maximum pressure: 175 PSI.
"Piston Drain"" Operation
The •Piston Drain· mechanism is operated by the pressure drop created
as air flow is initiated or as the air line is depressurized. In order to drain
properly, there must be sutticienl dynamic pressure drop;to trigger the
drain mechanism. The •Piston Drain· will not fune1ion with minimal flow
and pressure variations or on constant flow .:pplications. When sup•
plied in k.it lorm, remove bowl and replace with •Piston Drain· assembly.
MaximUm_pressure: 175 PSI. ·
R119 REGULATOR
Reduc.d p.....,,. AdJuotment
MAX PRESS '300 PSI
MAX TEMP 120-F
Ck>ckwise Nming of the adjusting · screw increases the reduced or
regulated p,essuro. With relieving-type reoulators the reduced pres•
sure fellows the adjustment ot the screw. with non-relieving regulators
adjustment fOf' lower reducod pres.sure will not be obtained until the
Muced prnauro 1y.tom is "'bled ctr or until air tlow starts.
Maintenance
ll the air supply is kepi clean, the regulator should provide lorig periods
cl uninterrupted service. Erratic regulator operaIion or las~ of regulaIion
is most always due to dirt in the disc area and cleaning is in order.
Cleaning
Oepressurize r~gulator, remove bonom plug, spring, and ~isc. Clean
parts with denatured alcohol. wi~ c;,H seat and blow out body with
· compressed air. Reassemble parts as a unit and· screw into regulator
belore tightening bonom plug mak1:; Sure disc is in center hole in body.
Should regulator continue to malfunction. obtain repair kit and replace
parts indicated. · · • •'
L606 LUBRICATOR .
.. ,I" , .. -.
STUL 300 PSI 1ao'"r
~tn' O11."ZIHC 2S0 PSI 150°F WISIClUCU.SS Lubricant
•For average condilions, lhe use of tiigh.Quality SAE #10 (S,U.V> 150·
200 SEC. @100°F) oil is recommended. Other lubricants as specified
by the maker of the equipment to be lubricated may be used if not
heavier than SAE #40 (S.U.V. 800 SEC. @100°F).
FIiiing·
Lubricators can be filled while under pressure and without shuning
down equipment-slowly remove either !ill plug and lilfto 114• to top of
bowl using correct oil. For best r_esults use a long spout oil can so that
. ~h~_Jip can be inserted into top of bowl.
Adjustment
The, •oial Ser knob is factory set so that when turned to zero (0) no oil
is delivered to the venturi tor atomization and equipment is not being
lubricated. To adjust oil drip rate, turn on the air, stan flow and set.know·
to obtain the desired drip rate--visible through the sight glass. ·As a
start. one to two drops per minute is suggested--correct lubrication
being a maner cl experience and demand. Clockwise rotation of knob
decreases oil feed rate. To check'lubricatiorrhold thumbnail or a mirror
near the equipment exhaust. A heii.vy film indicates over-lubrication
and the drip rate should be reduced: by turning know to a lower $¢?ting."
Operation
For pr~per automatic fill operation_the'oil inlet pressure to h.ibncator
mus! be maintained between 10 and 200 PSI above air Pressure to
lubricator. ·
Maintenance-Cleaning
II bolh air and oil are kept clean and the oH level never allowed below
end of tube in the bowl the lubri~tor should providEt long periods of
unattended service. Cessation of Oil dripping through.. !he sight glass.
irrespective of knob adjustment is an indication that cleaning is neces· sary. · .. ,;
·.·. .I. To clean, it is not necessary to'. remove lubricator-; from tlie line.
Depressurize and disassemble using drawing as a·tguide. In most
instances cleaning is needed on_!Y in the oil metering area. Pull oH
ad1us1ing knob and remove need!~ valve assembly by turning out large
hex nut. remove needle valve seat and clean removed parts with
alcohol-making sure hole in seat is clear. With a #57 9rill make sure
hole in bottom of sight gla'ss area is open. Blowout lubricator body with
compressed air before reassembly. Caution: Plastic bowl• and
metal bowls with sight glass must be cleaned with household
soap only.
See ~ther side for Replacement Parts List.
,....,
1/atts FluidAir
,-C62B 8711
PAA-:' IUtHl
Plnoo<
DMlNi::x:,t
"THX"
"RX"
---- -• .. '
' ' • • -
REPLACEMENT PARTS
Order by Repair K,1 Number
SlCHTCLASS REPAlR KIT (SRX)
KIT NO. SIZE BC\Jl REPU.C"XEST KIT (BRK) -·
RKS60SWY 1/4" • J/8"
RXJ!60SwA 1 /2"
KIT ·NO • SOUL SIZE
BK602Y PLASTIC I /4" • l/8"
BK602A PU.STIC I /2" ..
RKB60SWB 3/ 4" t hru 21 BK60JA STEEL I I 2"
BK603B
BK605WA
BK6051./B
BAFFLE REPAIR KlT (BFX)
KlT NO. SlZE
RX602Y l / 4" • 3/8'"
RX602A 1 / 2"
RX602B l/4'" • I"
RX602C 1~· • lo"
RX602G 2" & 2½'"
•pIJT0N DMUI• rILTtJI
JUT HMt. KIT NU1'1Btll.S 11,· ,, •.. l'1"
PISTON '11uouy j ltUOZSA DllAIH IUf ..
TEE HAN'Dt.E KIT (THK)
KIT NO, SIZE
TK16'i I /4" & J/8"·
TKl 19A l / 2"
TK~l9B ]/4" thru I½"
REPAik KIT (RElIEVINC)
KIT NO. SIZE
RKl 19Y l 14" & ]18"
R.Kl 19A 1/2" --~-
RKl l 9R 3/4" • l"
RK.l 19D }I,.." • 11-i"
STEEL 31• thru i~
ZlNC W/SIGHTGU.SS 1/2'" .•
ZINC W/SIGHTGU.SS J/ 4" th:-u 2½"
ELEHENT REPAIR KIT (ERK)
KIT•NO,. SIZE ELE.'1.EN1'
EK602Y I I 4" • ]/ 8 .. 40m
EK602'1Y I /4:' • 3/8" Sm
EK602A 1 /2't .. 40m
EK602VA -1-1-:l"· =
EK602B 3/4'' thru 1,. 40m
EK602VB 3/4 thru lo Sm
EK602G 2" & 2~" 40m
"AUTO ORAIN""
SA·602M0•MJ
,.UUIU.l,I( •1Jlju..-u11
lMll J'l'II
01st ,IJSfWBl "f ;-)~•-~ · .I\IJAI A5stl.l9l "f -.,msu · .. --~
STIIJilfrlfll
V!( Sf.1,l ......
REPAIR KIT (NON-RELIEVING) (RX)
KIT NO. SIZE
RK118Y } / 4" • J/8"
RK 118A 1/2"
RKl 188 J/4" • I"
RK 1180 t!:" • l ,.., ..
•.-. I
SlCHTCLASS REPAIR KIT' (SRK-1) .. NEEDLE VALVE REPAIR KIT (NVK)' KIT N'O. SIZE -' KIT NO. SIZE RKB60S\JY 'i'Ki&osuA·-· ~ l/4'.' • 3/8" R.K606Y-l 1/4" thru l½" 112"
RKS60SUS J/4" t hru~. I½"
RKB605Xl0,J · r12" (2 OT. B01.ll.l
SIGHT DOME
0
REPAIR' KI-T (SOK)
.KIT NO. "SIZE
RKB605Xl0-,,, JW' thru .I½" (2 OT. B0\.11.) Rl<606::;y l/4" thru 11l" ..
B01.ll. REPLACEMENT KIT (BRK-1)
Y.IT NO.
BK606'i
BK606A
BK60]A
BK603B
BX609YA
BK609"'8
BY.606XJ0A
BK606XJOB
--· -----------
B01./l. .,,.
PLASTIC I /4" • 3/8" PLASTIC 1 /2"
STEEL l / 2"
STEEL J/4" thru I"" ZINC W/SIGHTGLASS 1/2".
ZINC ll/SICHTGLASS 3/4" thru l½" - I •••
STEE-L (2 OT. WISICHTCLASS) l t 2"
STEeL (2 OT. W/SIGHTGLASS)· 3/4" thru I""
---------
\'"'''I Ow••··,.;~. ,;.:.c~..., .... , .... UC"O"OQ,,,(l~o.'-....... , ..... ,..a_.._,.,...io,,o-_ol_ , • ., .. _,....,u.~IW~~ .,,.,. ... -oii..c:.;--,:i,_,,..,.p,__,_-od .,..c-...,..-M-TIQlll'Ol't
••.,.M:t o, •..:.-t ... ,,.. ---1 C"..,O-T"" '"-"' ~lrl,ol• If"!•-~,__, ,0,-o,u,,•~ •a<•~ -l"<I C0-11<1"'1Vo.l""OI0.•-1-<o,-,-◄--110,~1~c,a,-,,.A9•I __,,,..,_..,_.,,_~•lllf-CO"I •n..,....., "•-••-C"•9" """''' ,_.,,.,_ ""9"9•nc• ~ u .. \H 11'1 •or•,q,,, ...,.,....,,i .,.,... l•-~• "'
CO"O-~OI'\ C"...-.C:.11\ 0, ...,.,l,... C•C-1-ll'Cn .... _,c:,, 11\9 c __ , "'' "O'°"WOI TM .... ,&Illy il,fl.all 0. -•"4ll1.0 o,
jry 10..H -,,., •.... Ulllpl<lo,_ 0, ---•"llllMar,o,, o• -O'Oduel ------, .. Eco...,..,. .. """"($ NQQJ,-,fA WAAA,fiNfV ALL o, .. u, w•AR,fiNf1,s OR•L OR WfllrT!N l!X .. R!SSl:O CA
'"''"LIi O ...c~uO•~ WAAAANTl!S o, M!RC ..... NT Alll~ITY OR FITNl!SS ,OR "' SPtc,,,c P\JA .. OSt •RE .. f R,11v
t •C•UOEO 4N0 O•SCL••l,lfQ .,. HQ (llfNr 5'"'•U h,t CQr,11>ANT llt Ll•BI..! ,oPHNCIO(NT"I. 0111 CON:1,(QIJf .. ll,fi~
.O•Y4G!S • Kittery. Maine USA 03904-0902 .f ,.,,~~0--•1ol"'•C-...-,1o, ... 'OloiOIG-a,;-e•~""'Ot, __ ,.....,,.,....,a-..o,1•~-"'°"""0,NC,,Ctl_,,,_ .-• ,._.,.,....,_ ,,._.. .. _,.o,_ .... ••'-oJ--C-P,<1 olJfte ~OC,OOS-•~IOl"<f lcr11 Of C .....
oci; .... ...,
0894010 PRINTED IN U.S.A.
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Oil-Less Compressor Registration & Start-Up Report
I. Description of Unit
Compressor Unit sold by (distributor) _____________________ _
Customer Number ___________ City _________ State
Compressor Model Unit Serial ______________ _
Motor Name Plate Volts Phase ________ Amps
0 Air-Cooled · 0 Water-Cooled O Aftercooler
0 Suction Unloader O Standard Air Filter
II. Information Recorded at Start up of unit •
Shipping blocks removed? 0 Hourmeter Working? 0
Spring Isolator Adjustment Checked? (Horizontal VT & WT only) 0
Volts & Amps Recorded with Unit Running
Volts ____ Amps _____ Cut-in Pressure ____ Cut-Out Pressure ___ _
Operation of all Controls Checked?
CSL (Hospital) Filter O Connection of CSL Filter(s) to Remote Intake plumbing checked? 0
Factor air filters must be installed at the pump inlet for warranty to apply.
Use CSL filter to pipe remote inlet air to the pump.
This certifies that compressor has been installed, starter and checked for proper operation on
----------------------~ 19 ____ (Start-Up Date)
Unit Location
Approved by
for Owner Champion Representative or Distributor
Remarks--------------------------------
One copy of this form must be sent to
' FAX # [phone] ·
Attention: Service Department
Champion
1301 North Euclid Avenue
Princeton, IL 61356
THIS FORM MUST BE SUBMITTED TO CHAMPION WITHIN 10 DAYS OF START-UP
TO ENSURE ELIGIBILITY FOR FULL WARRANTY COVERAGE.
COMPLETE REVERSE SIDE -->
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End-User Name --------~-------------------Jf
' Address
City/ST/Zip ___________________________ ,,
Phone ( ) ___________ Fax ( ) _________ _
Contact _____________ Title _______________ _
THIS FORM MUST BE SUBMimD TO CHAMPION WITHIN 10 DAYS OF START-UP TO ENSURE ELIGIBILITY
FOR FULL WARRANTY COVERAGE.
Form # 3171 REV999
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Owner's Responsibilities
INSTALLATION:
Compressor must be located in a clean, well-ventilated, dry room to insure an adequate supply of
fresh, clean, cool and dry air.
Compressor cooling fan should have a minimum clearance of 14" from any obstruction to insure
proper cooling of unit.
Lagging compressor unit to the floor is required. Tank-mounted units must have the legs shimmed
to avoid undue stress on the tank welds. For warranty to apply, tank must be mounted on vibro
isolator pads. Lag bolts should be "snug", and not tight.
Necessary electrical wiring and connections should be made by a qualified electrician and must be
installed in accordance with all national and local electrical codes.
MAINTENANCE:
Refer to owner's manual for safety rules and detailed maintenance instructions and service schedule.
Refer to Maintenance Schedule outline in Owners Manual and perform maintenance based on
accumulated running time on hourmeter.
Keep complete unit clean
Keep intake filters clean. Inspect and clean valves every 5,000 hours.
Keep belts adjusted properly.
Keep nuts, bolts, capscrews and all fittings tight. Refer to manual for torque recommendations.
Failure of owner to comply with safety rules, installation and maintenance procedures
outlined in Owner's Manual will void warranty.
FREIGHT DAMAGE:
Freight damages do not constitute warranty of service adjustment. Gardner Denver Machinery
Inc. terms are FOB point of shipment/factory, and Gardner Denver Machinery Inc. responsibility
ceases upon delivery of material to carrier and obtaining receipt for same. It is the responsibility of
the receiving customer to file damage, shortage and concealed damage claim with the delivering
carrier on receipt of material.
1301 N. EUCLID AVE. • PRINCETON, ILLINOIS • 61356-9990
PHONE: stS.875-3321 • FAX: [phone]
FOllM JHZ llEV. JU
Garmier
Denver
Gardner Denver Machinery, Inc.
Five Year Warranty
Lubricated Compressors
Gardner Denver Machinery, Inc. ("the Company'') warrants each new compressor pump manufactured by the Company, mounted on a factory assembled unit, to be free from defects in material and workmanship under normal use and service for a period of sixty-six (66) months from date of shipment by the Company or the Company authorized distributor, whichever may occur first Applies to the compressor pump only excluding head valves. Valves, controls and accessories are warranied for the first year only. Compressor pumps purchased separately would carry a one year warranty.
This five year extended warranty will be prorated over the 5 years as follows:
First Year 100% Allowance, Parts and Labor
Second Year
Third Year
Fourth Year
Fifth Year
90% Allowance, Parts and Labor
80% Allowance, Parts and Labor
70¾ Allowance, Parts and Labor
60% Allowance, Parts and Labor
Applies to the Company logo, tank or base mounted complete compressors only.
Express Limited Warranty
The Company warrants each new air compressor unit manufactured by the Company to be free from defects in material and workmanship under normal use and service for a period of twelve (12) months from date· of installation of fifteen ( 15) months from date of shipment by the Company or the Company authorized distributor, which may occur first.
The Company makes no warranty in respect to components and accessories furnished to the Company by third parties, such as ELECTRIC MOTORS, GASOLINE ENGINES AND CONTROLS, which are warranted only to the extent of the original manufacture(s warranty to the Company. To have warranty consideration, electric motors must be equipped with thermal overload protection.
The extended five year warranty will apply to ASME air receivers provided they are installed on. rubber vibro isolator pads.
When a compressor pump, or component is changed or replaced during the warranty period, the new/replaced item is warranted for only the remainder of the original warranty period.
Repair, replacement or refund in the manner and within the time provided shall constitute the COMPANY'S sole liability and your exclusive remedy resulting from any nonconformity or defect. THE COMPANY SHALL NOT NOT INANY EVENT BE LIABLE FOR ANY DAMAGES, WHETHER BASED ON CONTRACT, WARRANTY, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE, INCLUDING WITHOUT LIMITATION ANY CONSEQUENTIAL, INCIDENTIAL OR SPECIAL DAMAGES, ARISING WITH RESPECT TO THE EQUIPMENT OR ITS FAILURE TO OPERATE, EVEN IF THE COMPANY HAS BEEN ADVISED OF THE POSSIBILITY THEREOF. .
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND, EXCEPT THAT OF TITLE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY DISCLAIM ED. NO SALESMAN OR OTHER REPRESENTATIVE OF THE COMPANY HAS AUTHORITY TO MAKE ANY WARRANTIES.
BK-65 4198
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Gold Ring™ Solenoid Valve
Bulletin 7288
Revision C
Effective 1Apr95
Revised 30Jan97
Parker Gold Ring™ Solenoid Valve Temperature Limitations
Parker Hannifin Corporation
Skinner Valve Division
The following table provides fiuid and ambient temperature data for Parker Gold Ring™ solenoid valves.
Coil Maximum
Series or Watt Ins. Class Ambient Fluid
Catala~ Number Rating (See Note 2) Temperature "F Temperature "F
Series 20 9,5 130 77 200
Series P,20,22,24,25,26,30,34,38 6,6,6,6,9,7,5,6.1 155 130 180
Series 20,23,24,25,26,28,34,35,38,48 11, 11.8, 12.6, 13.9 155 130 180
Series 20,22,23,24,25,26,28,30,34,35,38,48 6,6.8,8.9, 7 .5,8.1, 11, 11.6, 12.6, 13.9 180 167 216
Series 20,30 10.2,10.4,10.8, 12.3, 12. 7 155 77 180
Series 20,30,34 16,16,7,17.4 155 77 200
Series 22 16,16.7,17.4 155 77 175
Series 20,22,30,34 10.2, 10.4, 10.8, 12.3, 12. 7, 16. 7, 17.4 . 180 113 236
Series 30 11,11.6 155 130 200
Exception 12F25 8,8.8,8.9,8, 1, 11 155 77 175
Exception 12F25 6,8,8,8,9,8,1, 11 180 113 236
Exceplions
04F20C2410ACH 11, 11.6, 12.6, 13.9 180 130 344
06F20C2410ACH 11, 11.6, 12.6, 13.9 180 130 344
04F20C6414ACH 11 11.6, 12,6, 13.9 180 130 316
06F20C6414ACH 11, 11.6, 12.6,13.9 180 130 316
04F20C6418ADF 16 16.7 17.4 155 77 307
06F20C6418ADF 16,6.7,17.4 155 77 307
04F20C6408ACH 1111.617.4 180 130 353
06F20C6408ACH 11,11.6,17.4 180 130 353
Seven digit may also be 3
All 9,5 155 77 120
All 11.5 155 77 150
Exce lions
With "5" in 8th digit 11,5 155 77 140
With "20" before A3F 11,5 155 77 180
With "28" before A3F 11,5 155 77 180
04F20O1103 11.5 155 77 140
04F20O1106 11,5 155 77 140
Serles 48 11,5 155 77 104
04F25 11.5 155 77 160
Note 1 • Valves with case Urethane discs (8th digit is 5) have a maximum 14D°F maximum fluid temperature.
Note 2 • Insulation class is maximum allowable insulation material temperature, 0 c .
CAUTION
(Rectified Coil Only)
This solenoid coil contains solld state components that can be damaged by voltage spikes, transient voltage, over temperature, over voltage or improper
assembly. To protect against premature coil failure, please read and adhere to the following:
1. If this coil is used in an inductive circuit with other inductive loads either In series or in parallel, this coils should be protected by a voltage suppression
device with a minimum rating of 1.4 times the input voltage and sufficient capacity to dissipate the inductive load.
2. This coil is designed to operate In a maximum of n°F (25°C) ambient which should not be exceeded for an extended period of time.
3. If solenoid Is disassembled, all components must be reassembled correctly, Do not energize the solenoid unless it Is assembled to a valve.
4. Operating voltage is 85-100% of rated voltage. These limits should not be exceeded.
Parker Hannifin Corporation
Climate & Industrial Controls Group
Skinner Valve Division
147 West Hoy Road
Madison, MS 39110
[phone]
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GOLD RING™ SOLENOID VALVE
Installation and Maintenance Instructions
2-Way Direct Acting
Normally Open
NEMA1
Series 20 & 21
NPT 1/8 -1/4 -3/8
Orifices 3/64 Through 9/32
Bulletin 721 0
Revision D
Effective 1 Nov85
Revised 31 Jan92
Warnings
J
Parker Hannifin Corporation
Skinner Valve Division
, . If you purchase a Unit Valve and a Unit Solenoid, be sure the last two digits of the Unit Valve number match the first two
digits of the Unit Solenoid number. If they do not match, do not Install.
2.
3.
4.
5.
02F20O1108AAF Untt Valve
AFGC05 Unit Solenoid
Check data label for correct catalog number, pressure, voltage and service. Do not Install tf unsuitable.
For protection and proper operation of the solenoid valve, install a strainer or filter suitable for the service involved as close
to the valve inlet as possible.
This valve requires periodic cleaning and Inspection depending on the·servlce. This should be done at leMt once every 12
months or ovory 500,000 cycles, whlchovor occurs first.
Turn off electrical power supply and line pre:s:suro to the valve. Bleed trapped pressure from the lines before inspecting,
cleaning, servicing, or repairing the valve.
Oesc iption: 2. Positioning
Series, 10 solenoid valves are direct acting and have integral seats. Serles-. For best results mount with Unit Solenold vertical and .up-
21 dlre1 t acting solenoid valves come stand&rd with Inserted :stainless right Unit valve may be mounted In any position.
steel se its for steam applications up to a maximum 353° F. Valves with
watertlt ht NEMA Type 4 or explosion proof NEMA Type 7 enclosures are 3. Piping
covere< by I & M Instructions, Bulletin 7220.
Connect piping to vaJve according to markings on vaJve body.
Operat ~ Apply pipe compound or sealing material oparingly to male pipe
threads only. If applied to valve thread, it may enter valve and
NORMJ LL YOPEN couao operational difficulties. Pipe strain should be _avoided by
proper support and alignment of piping. Do not use vaJve ea a
Open Y hen de-energized; closed when energized. lever when tightening pipe .
Installation: 4. Wiring
1. Application
Refer to manufacturer's catalog for application Information.
Wiring must comply with local and national eloctrlcal cod ...
Housing for all solenoid are made with connections for 1/2•Inch
conduit. The enclosures may b8 rotated to facilitate wiring.
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5. Unit Solenoid Installation
Turn off electrical power supply. Slide unit solenoid over plunger tube. Place data label on top. Squeeze gold ring firmly to-
gether, pressing it against the data label. This compresses the
anti~vibration fingers.
6. Solenoid Te'!lperature
·standard catalog Valves are supplied with coils designed for
continuous duty service. When the solenoid Is energized for a
long period, the solenoid enclosure becomes hot and can be touched with the bare hand for only an instant This ls a safe
operating temperature. Excessive heating will be Indicated by
the smoke and odor of burning coil insulation.
Maintenance:
1. Cleaning
Periodic cleaning of solenoid valves is recommended. Fr► quency will depend on fluid and service, but should never be less
than every 12 months or 500,000 cycles whichever occurs first.
In general, If the voltage to the coll la correct, sluggish opera-
tion, excessive leakage or noise will Indicate cleaning or repair Is
required. Clean valve filter or strainer when cleaning valve. See . valve disassembly and reassembly Instructions below. 'I 2. Preventive Meintenanco
3.
a. Keep media flowing through valve as free from dirt and
foreign matter as possible.
b, While not In service, operate valve at least once a month to
Insure proper opening and closing.
c. Periodic inspection (depending on media and service
conditions) of Internal valve parts for damage or axcessive
wear Is recommended. Inspect at least every 12 months or 500,000 cycles, whichever occurs first Thoroughly clean all
parts. Replace wom or damaged parts with Gold Ring™
Spare Pa~s Kit. Uoe all parts for best results. Clean valve
filter or strainer when cleaning valve.
Troubleshooting Guido
a. Faulty Controls Clrcutt
Chock the electrical system by energizing the eolenold. A
metallic click signifles solenoid is operating. Absence of
click Indicates loss of power supply. Check for loose or blown
out fuses, open~circJit or grounded coil, broken lead wires oc splices.
b. Burned.Out Coil
Check for 0pen-circutt: coil. Replace unit solenoid if
necessary.
c. Low Voltage
Check voltage across the coil lead. Voltage must be at least
85% of data label rating.
d. Incorrect Pressure
Check valve pressure. Pressure to valve must be within
range speeHied on data label.
e. Excessive Leakage
..
Disassemble valve and clean all parts. Replace worn or
damaged parts with a Gold Ring™ Spare Parts Kit. Use all perts for best results. Install filtration if indicated. See
valve disassembly and reassembly Instructions.
4. Unit Solenoid Replacement
Tum off electrical power supply and disconnect coil lead wires.
(Refer to Exploded View) .
a. Remove gold ring by Inserting a 3/16" wide
.screwdriver in the curved slot While h_oldlng the gold ring firmly against the unit solenoid gently twist screwdriver
counterelockwise. Gold ring will open. Lift off data label
and unit .solenoid.
b. Reassemble by sliding unit solenoid over plunger
tube. Place data label on top. Press gold ring against ·
data label to compress anti-vibration fingers. Squeeze the
gold ring firmly together.
5. Vetve Oi.sBS3embly and Reassembly
(Refer to Exploded Views)
Tum off electrical power supply and line pressure. Bleed
trapped pres.sure from lines.
a. Remove gold ring by Inserting a 3/1 s• wide screwdriver In
the cuNed slot While holding the gold ring firmly against
the unit solenoid gently twist e:crewdrfver counterclockwise.
Gold ring will open. Lift off data label and unit solenoid.
b. For 1/4' and 3/8' NPT, unscrew bonnet of plunger tube
....,mbly and remove plunger ... embly, spring and body
g .. kel
For 11a• NPT, une:crew bonnet, remove bonnet, o-ring,
plunger tube asaembly, plunger ... embly, opring and body
gasket
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c. All parts are now accessible for cleaning or replacement
Replace worn or damaged parts with Gold Ring™ Spare Parts
K'rt. Use all parts for best results.
d. Inspect valve body seat for scratches, nicks, dents or other
blemishes. Replace if damaged.
e. Reassemble In reverse order of disassembly, paying careful
attention to Exploded Views provided. Apply 175 .± 25 inch
pounds of torque when tightening the bonnet on the 1/4"
and 3/8 "NPT models. The 1/B"NPT requires 90 ± 10 inch
pounds. Lubricate all gaskets with Dow Corning Corpora-
tions Molykote (2D Ill compound or an equivalent high grade
silicone grease.
f, 00 NOT alter, modify, or use parts not obtained in Spare
Parts Kit from original manufacturer.
Parker Gold Ring™ Spare Parts Kits
Spare Parts K"rts and Unit Solenoids are available for Gold Ring™ Valves.
Parts marked with an asterisk (•) are included in Spare Parts Kits (See
Exploded Views).
Ordering Information for Spara Parts Kits
When ordering Parker Gold Ring™ Spare Parts Kits or Unit Solenoids,
specify Valve Catalog Number, Serlal Number and Voltage.
Note: This product may contain chemicals known to the state of Calttornla
to cause cancer, birth defects, or other reproductive harm.
This warning Is given In compliance with California Proposrtlon 65, as de-.
tectable amounts of chemicals subject to Proposition 65 may be contained
In this product.
..
NORMALLY OPEN 3/S"NPT
BRASS-316 STAINLESS STEEL FASTENER*
/~NUT*
~RETAINER* T RING
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* PARTS INCLUDED IN REBUILD KITS
'
®)>----SPACER*
cs:----DATA LABEL
~ PLUNGER TUBE * '¥' -ASSEMBLY GASKET
TORQUE PLWGER TuBE
ASSEltil. Y
175,25 INClt-POLNDS
FASTENER*
,,.i!b-NUT *
~RETAINER* RING
NORMALLY OPEN 1/8" & l/4"NPT
BRASS-STAINLESS STEEL
~GOLD
I
RING*
LABEL
*GOLD RING~ /j" / TOR!lJE B!WET fllD SPRING SEAT CLOSUlE Y0,10 11(:H-POltlDS
* PARTS 11(:LUDED IN REBUILD KITS
V ®--SPACER*
~DATA LABEL
PLUNGER TUBE* ASSEMBLY
TORO\£ PLlN,fR Tl.llE
ASSElfll..Y 175,25 11(:IH'Ol.tlDS
,ill. DISC HOLDER * , ASSEMBLY
,
NOTES:
PLUNGER TUBE ASSEMBLY GASKET*
BODY
(1/4 NPT)
BONNET--i,l.f~
* BONNET GASKET
*
PLUNGER TUBE ASSEMBLY
•
ie.QRI_3__ELUGGEUl
MQUMIIMG_BRBCKEI
(OPTIONAL)
SEE NOTE l.~
@ -"
* SPECIAL ~RENCH FOR VALVE BONNET
, FROM PLUNGER ASSEMBLY
-PLUNGER SPRING *
PLUNGER ASSEMBLY *
PLUNGER TUBE ASSEMBLY GASKET*
BODY ( 1/8 NPT)
ll!JI-DISC HOLDER * ~ ASSEMBLY t DISC SPRING *
q:>-cLOSURE GASKET*
~ ;PRING SEAT ~CLOSURE
I. FOR MOUNTING, A FLAT SURFACE MUST BE PROVIDED ACROSS THE ENTIRE LENGTH OF THE BRACKET. THE VALVE BODY BECOMES SECURE TO BRACKET, ~HEN BRACKET IS TIGHTENED IN TO POSITION.
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APPENDIX C
BLOWER PACKAGE AND HEAT EXCHANGER
DOCUMENTATION BY J.E. GASHO AND ASSOCIATES
P:\PROJ\ 18895\ 18895.014 \O&MAPPcvr.doc
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~ Y'fi'1 J E GASHO tf~ ';;;< • • ~tfJ & Assoc., Inc.
460 West Gay St reel
West. O,ester, PA 19380
Phone: [phone] Fax: [phone]
E-Mail: [e-mail]
Brown and Caldwell
227 French Landing Drive
Nashville, TN 37228-1605
FCX -Statesville Superfund Site
P.O.# T000301-002
June 21, 2000
Rotron EN909BG72WL Regenerative Blower
Moisture Separator, Silencers
Soil Vapor Extraction System JG00D-1401
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Item Qty.
1 2
2 1
3 1
3A 1
4 2
4A 2
5 3
6 1
7 1
9 1
10 1
11 2
12 2
13 1
14 2
15 3
16 2
17 4
18 2
19 2
1
1
J. E. GASHO & ASSOCIATES, INC.
Authorized Manufacturer's Representative
Air I Gas Moving Equipment
460 W. GAY STREET
WEST CHESTER, PA 19380
PHONE: [phone] FAX: [phone]
Brown and Caldwell
227 French Landing Drive
Nashville, TN 37228-1605
P. 0. No. 00-0033
FCX -Statesville Superfund Site
J. E. Gasho & Assoc., Inc.
Quotation W9887 Rev. 1
Soil Vapor Extraction System JG00D-1401
Supplier Description . Part Number Misc ID
Rotron Blower EN909BG72WL P/N038629
Metal Masters Base 4x 12skid
Dwyer Flow element DS300-4 FE0201, FE0203
Dwyer Flow Transmitter 604D-2 FE0201, FE0203
Dwyer Flow element DS300-6 FE0202
Dwyer Flow Transmitter 604D-2 FE0202
Dwyer Pressure Transmitter 604D-100 PE0201,PE0203,PE0204
EM Inlet Filter EMS-4
Mueller Dilution Valve 4" 4-65M-ANl-6-1 4" Butterfly Valve
Dwyer Pressure Transmitter 604D-40 PE0202
EM lnline Filter EMl-6
Gasho Pressure Gauge 0-160 IWC
Gasho Vacuum Gauge 0-160 IWC
Gasho Moisture Separator GX120
Dwyer Level switch L6-EP13-B-S-3-0 LI0202,(LI0202)
McMaster Carr Temperature transmitter 40705K4 (0-300) TE0202, TE0203, TE0204
Fisher Vacuum RV 289H-3 2"
Mueller Shut off Valves 4-65M-ANl-6-1 4" Butterfly Valve
Gasho Sample Ports W/Swagelok fitting
EM Products Absorbtive silencer BIU-4
Following items Shipped loose For field installation
Xchanger Air to Air heat exchanger AA-500
Mueller Dilution Valve 4" 4-65M-ANl-6-1 4" Butterfly Valve
As built 6-21-2000
4 X f 9/16
3/4
8 <<FLOW<<
16
48 >>fLOW>>
24
l -3/4~
12
u
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6" fLANGE JJ
>>FLOW>>
·h <<FLOW<< __I J
25 1/4 15• fLANGE
-t
120----~-------
144
' • 71
-f
• iii=iiiiii5,
-:f:::=j-c:::_ -
--iJ, II ...., . r
l -
~
A
REV. DATE
.r;: -u
__,CJ --
144
1 AS BUn.T
DESCRIPTION
-00 7m'e1NSON 5-8
SHEET 1 OF 1
102
"1
--j I
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CJ J -l .
J.E.GASHO & Asso.c., Inc.
-460 w. CAY ST. PENNSYLVAtAA 19J80 ST CHESTER,
A
29
1 2 1 30
FE020I ~ E020.J ~
4 3 4 31
4 32
5 33
6 34
7 35
8 36
9 37
10 38
11 39
12 40
13 41
14 U0201 C 42
15 43
16 44
17 ll0202 C 45
18 re
46
19 47
20 48
21 49
22 50
23 51
24 52
25 53
26 54
27 55 -~ J.E.GASHO & Assoc., Inc. M. WITTE 6-7-00
460 W. GAY 5T. 28 56 WEST CHESTER, PENNSYlVANIA. 19l80
DIMENSIONS IN INCHES TERMINAL STRIP
WIRING DIAGRAM
REV. DATE DESCRIPTION SHEET 1 OF 1 1401-C-WD
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EN 909 & CP 909
Explosion-Proof Regenerative Blower
FEATURFS
• Manufactured in the USA -ISO 9001 compliant • Maximum flow: 600 SCFM
• Maximum pressure: 120 IWG
• Maximum vacuum: 100 IWG
• Standard motor. 15 HP, explosion-proof
• Cast aluminum blower housing, cover, impeller & manifold; cast iron flanges (threaded); teflon lip seal
• UL & CSA approved motor with permanently
sealed ball bearings for explosive gas atmospheres Class I Group D minimum • Sealed blower assembly
• Quiet operation within OSHA standards
MOTOR OPTIONS
• International voltage & frequency (Hz)
• Chemical duty, high efficiency, inverter duty or industry-specific designs
• Various horsepowers for application-specific needs
BLOWER OPTIONS
• Corrosion resistant surface treatments & sealing options • Remote drive (motorless) models
• Slip-on or face flanges for application-specific needs
ACCESSORIES (See Catalog Accessory Section) • Flowmeters reading in SCFM
• Filters & moisture separators • Pressure gauges, vacuum gauges & relief valves • Switches -air flow, pressure, vacuum or temperature • External mufflers for additional silencing
• Air knives (used on blow-off applications) • Variable. frequency drive package
BLOWER PERFORMANCE AT STANDARD CONDffiONS
AIR FLOW RA TE (M'/MIN) AIR FLOW RATE (M3/MIN)
2.0 4.o e.o a.o 10.0 12.0 14.0 1e.o 11.0 2.0 4.0 11.0 8,0 1O.O 12.0 14.O 18.O 18.O . s.o 140 350 ' ' ' ' ' I 10 -140 350 ' '
120 PRESSURE ,. ... , A•MAX PRESSURE '" POINT 300 •120 SUCTION A·MAto,.wr'ON 300 4.0 m' .. ...... ' A-15 HP B-10 HP
~ I . 250 • ► f100 §
"
.... A-15 HP 8-10 HP
••• ~ t--~ 3.0 ; BO ~ !!;
~a 200 ~ ; . ; ... .. ... •• 200 ~
2.0 ; .. 80Hz
' ' " l! .. 50Hz .
' 1.0 ' 20
'\ '\
0 100 200 300 400 100 800 700
AIR FLOW RA TE (SCFM)
~I; 1:l I I Ff Ft Ebb Pl H I
!~~:§1 11 fEFbt bffitJ I
!Ii 1
~1 11 th r:tt-H-J 113 I
m
1&11 E
100
,o
l!; 0 ; ... m • Ii " l! l!""'
' , __
Hz . '
Hz
'
~ 150
100
2 ... . ' ,o
' ' 0 100 200 300 400 IOO IOO 700
AIR FLOW RATE (SCFM) I'
Iii 1
: 11 i 411 t 4 4 4 11 t1 I
!~~ :§.11 # # 4 4 I ~ 4 J ] ID I
I l i:fi 1-1-'-'-' 111
AMETEK ROTRON TMD, SAUGERTIES, NY 12477 •email: [e-mail] • internet: www.rotrontmd.com
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EN 909 & CP 909
Explosion-Proof Regenerative Blower
,90
7.9
25 ~
20.97 532.6
2957
751.1
24,68 REF.
626.9
-7.23 r-~7 1.19
. 183:,i; 4116.1 . 30.2
>,
7 -~
--r---.. --~--' -.
-= '
~
:'!:
, ) • • I . .
-"~-~·-352 241.3 76.2
~~ 15.50
275.8 393.7
,75 X 2.00 SLOT
, (4) PLACES
DIMENSIONS: -1,.r
TOLERANCES: .XX * tr
(UNLESS OTHERWISE NOTED) [!::::>-1.25• NPT CONDUrT CONNECTION AT I O'CLOCK POsmoN
SPEOflCATIONS
MODEL EN909BG72WL EN9098G86WL
Part No. 038629 038634
Motor Enclosure -Shaft Material Exnfosion-nroof -CS Exnlosion-□roof -CS
Horsennwer 15 15
Phase -Freauencv 1 Three· 60 Hz Three -60 Hz
Volta□e 1 230 460 575
Motor Name□iate Amos 36 18 14.4
Max. Blower Amos , 44 22 18
Inrush Amns 240 120 100
Starter Size 2 2 2
Service Factor 1.0 1.0
Thermal Protection 2 Class B -Pilot o, "'' Class B -PIiot o, "''
XP Motor Class -Grou□ I-D 11-F&G I-D. 11-F&G
Shipping Weight 584 lb. (265 kg) 584 lb (265 kg)
I Scale CAD drawing IIVllll■bla upon request. /
211.B r 8,341
OUT IN
. 8.46
L,...+--18.75 ~ 'ill'
11.28 286
EN9098D72WL
080071
214.9
Ex□iosion-□roof -CS
10
Three• 60 Hz
230 460
22.2 11.1
26 13
162 81
2 1
1.0
Class B • Pilot D11hi
I-D, 11-F&G
564 lb (256 kg)
4"-8 NPSC
FEMALE THREAD
BOTH PORTS
ROTATION
'( DIRECTION
CP909GA72WLR
038982
Chem XP-SS
Same as
EN909BG72WL -
038629
except add
Chemical Processing
(CP)
featums
from
catalog
inside front cover
1 Rotron motors are designed to handle a broad range of wortd voltages and power supply vartatlons. Our dual voltage 3 phese motors are
factory tested and certified to operate on both: 208-230/415-460 VAC-3 ph-60 Hz and 190-208/380-415 VAC·3 ph-50 Hz. Our dual
voltage 1 phese motors are factory tested and certified to operate on both: 104-115/208-230 VAC·1 ph-60 Hz and 100-110/200·220
VAC-1 ph-50 Hz. All voltages above can handle a :10% voltage fluctuation. Special wound motors ·can be ordemd for voltages outside our
certified range.
2 Maximum operaHng temperaturs: Motor winding temperature (winding rise plus ambient) should not exceed 140°C for Class F rated motors
or 120°0 for Class B rated motors. Blower outlet air temperature should not exceed 140"C (air temperature rise plus Inlet temperature).
Performance curve maximurii pressure and suctton points are based on a 40°C Inlet end ambient temperature. Consult factory fer Inlet or
ambient temperatures above 40"C.
, Maximum blower amps corresponds to the performance point at which the motor or blower temperature rtse with a 40"C Inlet and/or
ambient temperature reaches the maximum operating temperature.
Specifications aubJa;t to change without notice. Pleeae consult your Local F1eld saiu Engineer for epeclflcatJon updates.
AMETEK ROTRON TMD, SAUGERTIES, NY 12477 •email: [e-mail] • internet: www.rotrontmd.com lfPI
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WARRANTY, INSTALLATION, MAINTENANCE AND
TROUBLESHOOTING INSTRUCTIONS
iMi!llfi!JfD
ROTRON TECHNICAL MOTOR DIVISION .
Industrial Products
75 North Stree~ Saugerties, NY 12477 U.S.A.
Telephone:[phone] Fax:[phone]
AMETEK
1. No Fault Policy -AMETEK Rotron DR, EN and HiE regenerative direct drive blowers are
guaranteed for one full year from the date of installation (limited to 18 months from the date of
shipment) to the original purcilaser only. Should the blower fail, regardless of the cause of
failure, we will at our option repair or replace the blower.
2. Standard Policy -AMETEK Rotron Minispiral, Revaflow, Multiflow, Nautilair, remote drive
blowers, moisture separators, packaged units, CP blowers, Nasty Gas™ models and special built
(EO) products are guaranteed for one full year from date of shipment for workmanship and
material defect to the original purchaser only. Should the blower fail, we will evaluate the failure. If
failure is determined to be worBQnanship or material defect related, we will at our option repair or
replace the blower.
3. Parts Policy -AMETEK Rotro111 spare parts and accessories are guaranteed for three months from
date of shipment for workmanship and material defect to the original purchaser only. If failure is
determined to be workmanship or material defect related we will at our option repair or replace the
part.
Corrective Action -A written report will be provided indicating reason(s) for failure, with suggestions
for corrective action. Subsequent customer failures due to abuse, misuse, misapplication or repeat
offense will not be covered. AMETEK Rotron will then notify you of your options. Any failed unit that
is tampered with by attempting repair or diagnosis will void the warranty, unless authorized by the
factory. · ·
Terms and Conditions -Our wanranty covers repairs or replacement of regenerative blowers only,
and will not cover labor for installation, outbound and inbound shipping costs, accessories or other
itenis not considered integral blowe,rparts. Charges may be incurred on products returned for reasons
other than failures covered by their appropriate warranty. Out-of -warranty product and in warranty
product returned for failures determined to be caused by abuse, misuse, or repeat offense will: be
subject to an evaluation charge. rl.taximum liability will in no case exceed the value of the product
purchased. Damage resulting fromt mishandling during shipment is not covered by this warranty. It is
the responsibility of the purchaser le file claims with the carrier. • Other terms and conditions of sale are
stated on the back of the order ackraowledgement
Installation Instructions for SL DR. f:N. CP. and HiE Series Blowers
1. Bolt It Down -Any blower must be secured against movement prior to starting or testing to
prevent injury or damage. The blower does not vibrate much more than a standard electric motor.
2, Filtration -All blowers should be filtered prior to starting. Care must be taken so that no foreign
material enters the blower. If foreign material does enter the blower, it could cause internal
damage or may exit at extremelj/ high velocity.
1 Revised 09/20/99
Should excessive amounts. of material pass through the blower, it is suggested that the cover(s)
and impeller(s) be removed periodically and cleaned to avoid impeller imbalance. Impeller
imbalance greatly speeds bearing wear, thus reducing blower life. Disassembling the blower will
void warranty, so contact the factory for cleaning authorization.
3. Support the Piping -The blower flanges and nozzles are designed as connection points only and
are not designed to be support memb~rs.
Caution: Plastic piping should not be used on blowers larger than 1 HP that are operating near
their maximum pressure or suction point. Blower housing and nearby piping
temperatures can exceed 200°F. Access by personnel to the blower or nearby piping
should be limited, guarded, or marked, to prevent danger of bums.
4. Wiring -Blowers must be wired and protected/fused in accordance with local and national
electrical codes. All blowers must be grounded to prevent electrical shock.. Slo-Blo or time delay
fuses should be used to bypass the first second of start-up amperage.
5. Pressure/Suction Maximums -The maximum pressure and/or suction listed on the model label ·
should not be exceeded. This can be monitored by means of a pressure or suction gage (available
from Rotron), installed in the piping at the blower outlet or inlet. Also, if problems do arise, the
Rotron Field representative will need to know the operating pressure/suction to properly diagnose
the problem.
6. Excess Air -Bleed excess air off. DO NOT throttle to reduce flow. When bleeding off excess air,
the blower draws less power and rims cooler.
Note: Remote Drive (Motorless) Blowers -Properly designed and installed guards should be used
on all belts, pulleys, couplings, etc. Observe maximum remote drive speed allowable. Due to the
range of uses, drive guards are the responsibility of the customer or user. Belts should be
tensioned using belt gauge.
Maintenance Procedure
When property piped, filtered, and applied, little or no routine maintenance is required. Keep
the filter clean. Also, all standard models in the DR, EN, CP, and HiE series have sealed
bearings that require no maintenance. Bearing shouid be changed after 15,000 to 20,000
hours, on average. Replacement bearing information is specified on the chart below.
Bearing Part Number Size Seal Material Grease Heat Stabilized 510217 205 Nye Rheotemp 500 510218 206 Polyacrylic 30% +/-5% Fill Yes-325F
510219 207
510449 203
516440 202 BunaN Shell .Dolium "R" 25-40% Fill NO
516648 307
516840 206 Shell Dolium "R" 516841 207 BunaN 30%+/-5% Fill NO
516842 208
516843 210
516844 309
516845 310
516846 311
516847 313
2 Revised 09/20/99
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T, rou es ooma bl h t·
POSSIBLE CAUSE OUT OF WARRANTY REMEDY -
b "O 1. • One phase of power llne not connected 1. Connect
C ::, 2. • One phase of stator winding open 2. Rewind or buy new motor z 0
UI UI 3. Bearings defective 3. Change bearings w a, oz C 4. Impeller Jammed by foreign material 4. Clean and add flHer C It: e ili i: E 5. Impeller jammed against ·housing or cover 5. Adjust ::, :::l :c 6. -Capacitor open 6. Change capacitor
w 1. • Two phases of power line not connected 1. Connect 11. 0 § 'C .!i z ,j! 2. • Two phases of stator winding open 2. Rewind or buy new motor
i : 1. Insufficient fuse capacity 1. Use time delay fuse of proper
0::, 2. Short circuit rating
iii u. 2. Repair
1. High or low voHage 1. Check input voltage
~ 0 2. • Operating in single phase condition 2. Check connections "O .. ::? ,e. 3. Bearings defective 3. Check bearings .. ~ m I-4. Impeller rubbing against housing or cover 4 . Adjust .c: ~ ~o
UI m-5. Impeller or air passage clogged by fareign material 5. Clean and add fitter > u z o.! a: ~ 0 6. Unit operating beyond performance range 6. Reduce system pressure/vacuum ::, 0 ~ I--11. 7. Capacitor shorted 7. Change capacitor 0 a: :;; w 8. • One phase of stator winding short circuited 8. Rewind or buy new motor .J .J 1. Impeller rubbing against housing or cover 1. Adjust w
~-0 11. .!i ~= 2. impeller or air passages clogged by fareign 2. Clean and add filter 0::, material co 3. Change bearings
.Cl "' < 3. Bearings defective
"O 1. Leak in piplng 1. Tighten m ~ u .. C "O 2. Piping and air. passages clogged 2. Clean " C e iJl 3. Impeller rotation reversed 3. Check wiring
0;,: 4. Leak in blower 4. Tighten cover, flange 't: 0 lm 5. LowvoHage 5. Check input voltage "' • 3 phase units
•• 1 phase units
-Disassembly and repair of new blowers or motors will void the Rotron warranty. Factory should be contacted
prior to any attempt to field repair an In-warranty unit .
Blower Disassembly:
WARNING: Attempting to repair or diagnose a blower may void Rotron's warranty. It may also
be difficult to successfully disassemble and reassemble the unit
1) Disconnect the power leads. CAUTION: Be sure the power is disconnected before doing any work
whatsoever on the unit.
2) Remove or separate piping and/or mufflers and filters from the unit.
3) Remove the cover bolts and then the cover. NOTE: Some units are equipped with seals. It is
mandatory that these seals be replaced once .the unit has been opened.
4) Remove the impeller bolt and washers and then remove the. impeller. NOTE: Never pry on the
edges of the impeller. Use a puller as necessary.
5) Carefully note the number and location of the shims. Remove and set them aside. NOTE: If the
disassembly was for inspection and cleaning the unit may now be reassembled by reversing the
a~ove steps. If motor servicing or replacement and/or impeller replacement is required the same
shims may not be used. It will be necessary to re-shim the impeller a=rding to the procedure
explained under asse_inbly. · ·
3 Revised 09/20/99
6) Remove the housing bolts and remove the motor assembly (arbor/.housing on remote drive models).
7) Arbor disassembly (Applicable on remote drive models only):
a) Slide the bearing retraining sleeve off the shaft at the blower end.
b) Remove the four (4) screws and the bearing retaining plate from the blower end. c) Lift the shaft assembly far enough out of the arbor to allow removal of the blower end snap ring.
d) Remove the shaft assembly from the arbor.
e) If necessary, remove the shaft dust seal from the pulley end of the arbor.
Muffler Material Replacement
1) Remove the manifold cover bolts and them manifold cover.
2) The muffler material can now be removed and replaced if necessary .. On blowers with fiberglass acoustical wrap the tubular retaining screens with the fiberglass matting before sliding the muffler pads over the screens.
3) Reassemble by reversing the procedure.
NOTE: On DR068 models with tubular mufflers it is necessary to remove the cover and impeller accessing the muffler material from the housing cavity.
Blower Reassembly:
1) Place the assembled motor (assembled arbor assembly for remote drive models) against the rear of the housing and fasten with the bolts and washer.
2) To ensure the impeller is centered within the housing cavity re-shim the impeller according to the procedure outlined below.
3) If blower had a seal replace the seal with a new one.
4) . Place the impeller onto the shaft making sure the shaft key is in place and fasten with the bolt, washer and spacer as applicable. Torque the impeller bolt per the table below. Once fastened carefully rotate the impeller to be sure it turns freely.
5) Replace the cover and fasten with bolts.
6) Reconnect the power leads to the motor per the motor nameplate.
Bolt Size Tort1ue
1/4-20 6.25 +/-0.25
5/16-18 11.5 +/-0.25
3/8-16 20.0 +/-0.5
1/:z-13 49.0 +/-1
5/8-11 90.0 +/-2
4 Revised 09/20/99
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Impeller Shimming Procedure:
WARNING: This unit may be difficult to shim. Extreme care may be exercised.
Tools Needed:Machinist's Parallel Bar
Vernier Caliper with depth measuring capability
Feeler gauges or d~pth gauge
Measure the Following:
Distance from the flange face to the housing (A)
Distance from the flange face to the motor ~haft shoulder, (B)
Impeller Thickness (C)
Measurements (A) and (B) are made by laying the parallel bar across the housing flange face and
measuring to the proper points. Each measurement should be made at three points, and the average
of the readings should be used.
Shim Thickness = B -(A+C)/2
After the impeller installation (step #4 above) the impeller/cover clearance can be checked with feeler
gauges, laying the parallel bar across the housing flange face. This clearance should nominally be ·
(A+C)/2.
r-7\'\\w=t=~Nt""Km==~cr--1-r
C
l._____ll::~==~~==~=±L___J_l
5 Revised 09/20/99
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SERVICE AND PARTS MANUAL FOR
EN6, EN-S58, EN909, EN14
DIRECT DRIVE ·
REGENERATIVE BLOWER
'\~CJ
. . ,: \'-.: .·
--
......
·ROTRON lndustrlal Products
,75 North Street, Saugerties, NY 12477 U.SA
Telephone: [phone] Fax: [phone]
e-mail: [e-mail]
internet: www.rotron.com '
Your Choice. Our Commitment.™
. .AMETEK
WIRING DIAGRAMS, XP MOTORS
H. 10, 6 WIRE
115 VAC 230 VAC
1~LINE
INTERCHANGE LEADWIRES 5 & B to REVERSE ROTATION
K. 30, 9WIRE
7
230 VAC
___ >OLINE
460 VAC
2
3
4
7
5
8
6
9
--I~
LINE
LINE
LINE --<◊>---
__ 'J)
INTERCHANGE ANY TWO LEAD LINES TO REVERSE ROTATION
M.10230VAC
SINGLE VOLTAGE
5
--~>\.----LINE
4
B
--~>'----LINE
INTERCHANGE LEADWIRES 5 & B TO REVERSE ROTATION
1.10, 7WIRE
115VAC
1
==:::o-uNE 3
230VAC
1--(r-LINE
:~
4
==:o---LINE B
5~
9
INTERCHANGE LEADWIRES 5 & B to REVERSE ROTATION
L. PILOT DUTY THERMAL OVERLOADS
J ----<◊
J ----<◊
HOOK J LEADS TO CONTROL CIRCUITRY
N. 30 575 VAC «''
I ----{ v}----LINE
-----1A)..---2 V LINE
3 A ----{,}----LINE
INTERCHAGE ANY TWO LEAD LINES TO REVERSE ROTATION
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~
-•· ~vi~ ~G~l'1------- - - - - - -
E1~6 Et~8S8 EN909 ENl4
11PELLER
89
/1JFFLER HOUSING
B20
IU:FLER LINER
B6
REl AlltR PLATE
818
HWSt-!G
B4
KEY '--..
SrnEW -WELLER
BIO
SCREW -MNIFOLD
B2
MmFOLD
B7
SHl'1S
88
LOCKWASI-ER -MOTOR
. ~ 817
\
SCREW -MOTOR
'"-. BS
WASHER -N'ELLER
\ 812
' LOCKWASI-ER -11PELLER
Bl
TI-READED FLN-JGE
B3
~-SCREW -r-u=FLER
~ 1319
MOTOR
SCREW -RAL
823
~RAL
B26
-~ -LOCKWASI-ER -RAL
~824
t-1.JT -RAl
825
----- ----- ------
EN 6/858/909/14
Service and Parts Manual Parts Breakdown
Model: ENS EN858 EN909 EN14 EN14 Part No.: 038381 038744 038629 038782 038760
038180 038745 038634 038781
038438 080070 080071 Item Qty.
No. Roq'd DoscrlpUon
M3 1 Key Motor Shaft 510212 511532 511532 155066 511532 B1 6 Screw, Flange (4 pcs) 120255 !4~) 155067 140016 140016 140016 B2 Screw, Manifold Not Used Not Used Not Used Not Used Not Used B3 2 Flange See Next Page · 511614 529912 529912 529912 2 O-rlng Not Used Not Used 155377 155377 155377 Elbow90" See Next Page · Not Used Not Used Not Used Not Used B4 Housing 516747 516764 515356 516799 516797 B5 4 Screw, Hsg /Motor 251792 155034 140014 120205 120205 B6 54 Muffler Materiel Not Used (32) 550020 (40 pcs) 529943 550073 550073 2 Matting, Fiberglass Not Used 550075 550077 550116 550116 B7 Manifold Plate Not Used Not Used Not Used Not Used Not Used B8 Shim .002" ·272703 511547 511547 515991 511547 Shim .005" 272704 511548 511548 515992 511548 Shim .010" 272705 511549 511549 515993 511549 Shim .020'' 272706 511550 511550 515994 511550 Shim ·.030" Not Used Not Used Not Used Not Used Not Used B9 Impeller 515484 515249 515270 515509 515683 B10 1 Bolt, Impeller 251791 120210 140015 155068 120251 B11 1, Lockwasher, Impeller 251787 251788 251788 251788 251788 B12 1 Washer, Impeller Not Used Not Used Not Used Not Used Not Used B13 1 Cover 515488 515247. 515359 515910 515910 B14 8 Screw, Cover 251790 140016 140016 155069 155069 B15 1 Eye Bolt Not Used 140019 140019 140019 140019 B16 Spacer, Impeller Bolt 478336 515555 511529 515990 515990 Shaft Sleeve ,".;'. Not Used Not Used Not Used Not Used Not Used B17 Lockwasher, Housing Not Used Not Used Not Used Not Used Not Used B18 1 Screen, Muffler Retaining, Right (tt) Not Used 515407 529939 550040 550040 1 Screen, Muffler Retaining, Left(**) Not Used 515408 529940 550042 550042 B19 6 Bolt, Muffler Hsg/Hsg Not Used 155025 155025 155067 155067 B19A 4 Bolt, Muffler/Housing Not Used 120214 120214 120214 120214 B20 Muffler Housing Not Used 550019 529932 550039 550039 1 Muffler Discrete 522948 Not Used Not Used Not Used Not Used Bolt, Motor/Muffler Not Used Not Used Not Used Not Used Not Used Lockwasher, Motor/Muffler Not Used Not Used ·Not Used Not Used Not Used Washer, Motor/Muffler Not Used Not Used Not Used Not Used Not Used Spacer, Motor/Muffler Not Used Not Used Not Used Not Used Not Used B21 Heat Slinger Not Used Not Used Not Used Not Used Not Used
• As Needed •~ewect looking at Inlet/outlet ports
2/3/00 Rev.D
------· --· .. --- - - - --
EN 6/BfjB/909/14
Service and Parts Manual earts Br1alldQlt!!!I
Model: ENS EN656 EN909 EN14 EN14 Part No.: 038361 038744 038629 038762 038760
038180 038745 038634 036761
038438 080070 080071 Item Qty.
No. Rag'd Daacrlptlon
B22 Guard Heat slinger Not Used Not Used Not Used Not Used Not Used B23 4 Bolt,Rail 251791 120007 155095 120256 155025 B24 4 lockwasherRail 251787 251787 251787 251788 251788 B24A 8 Washer, Rail/Motor Not Used Not Used 155091 Not Used Not Used B25 6 Nut, Rail 251789 251789 251789 155070 155070 B26 2 Rall Mounting 478338 595301 595301 516242 518242 Lip Saal 516691 516693 516693 516694 516693
Model Part No. Motor Wiring Dlagr■m ~peclfic Parts aeartng, IaearIng,
Rear (M11 Impeller End (M21
B3 Flange 511480
(2 pcsj EN6F5L 038381 529475 M+L Elbow 120153
(2 pcs)
EN6F72L 038160 500297 K+L B3 Flange 478341
' (2 pcs)
Elbow Not Used
Screen Guard, Flange 511479 {2 pcs) 510217 510218
EN6FB8L " 038438 529634 N+L B3 Flange 476341
(2 pcs)
-'.~ Elbow Not Used :t Screen Guard, Flange 511479 (2 pcs) -,.
EN8588D72WL 038744 515556 K+L
EN8588D88WL 038745 528627 N+L 516844 EN858BA72W 080070 515558 K+L
EN909BG72Wl 038829 511512 K+L
EN909BG66WL 038634 528631 N+L 516842 518844 EN9098D72WL 080071 550675 K+L
EN14DXB8MWL 038762 529632 N+L 518844 516846 EN14DX72MWL 038761 516095 K+L
EN14BK72MWL 038760 511513 K+L 516842 516844
• As Needed "Viewed look Ing at inleVoutlet ports
2/3/00 Rev.D
1 1 How To Order
lft · Merely determine the pipe size into which the flow sensor will be mounted and designate the size as a suffix to Model DS-300. For ex-I ample, a flow sensor to be mounted in a 2" pipe would be a Model No. DS-300-2";
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Options and Accessories
Less Valves (DS-300) -To order, add suffix -L\I. Example: DS-300-2'-LV
A-160 Thredolet-3'' NPT, forged steel, 3000 psi
A-161 Bushing -¼" x 9'' brass bushing
For non~tical water and air flow monitoring applications, the chart below can be utilized for ordering a stock CapsuheJic• differ-ential pressure gage for use with the DS-300 flow sensor. Simply lo-cate the maximum flow rate for the media being measured under the appropriate pipe size and read the CapsuheJic• gage range in inches of water column to the left. The DS-300 sensor is supplied with installation and operating instructions, Bulletin F-50. It also inc1udes complete flow conversion information for the three media conditions shown in the chart below. This information enables the user to create a complete differential pressure to flow rate conver-sion table for the sensor and differential pressure gage employed.
Both the Dwyer CapsuheliC-gage and flow sensor feature excellent repeatability so, once the desired flow rate is determined, devia-tion from that flow in quantitative measure can be easily deter-. mined. You may wish to order the adjustable signal flag.option for the Capsuhelic• gage to provide an easily identified reference point for the proper flow.
Capsuhelic• gages with special ranges and/or direct reading scales in appropriate flow units are available on special order for more critical applications. Customer supplied data for the full scale flow (quantity and units) is required along with the differential pressure reading at that full flow figure. Prior to ordering a special
GAGE
RANGE MEDIA@7O"F (IN. W.C.) 1· 1.-1l!"
Water (GPM) 4.8 8.3 11.5 2 Air@ 14.7 PSIA (SCFM) 19.0 33.0 42.0 Air@ 100 PSIG (SCFM) 50.0 90.5 120.0
Water (GPM) 7.7 14.0 18.0 5 Air@ 14.7 PSIA (SCFM) 30.0 51,0 66.0 Air@ 100 PSIG (SCFM) 83.0 142.0 190.0
Water (GPM) 11.0 19.0 25.5 10 Air@ 14.7 PSIA (SCFM) 41.0 72.0 93.0 Air@ 100 PSIG (SCFM) 120.0 205.0 275.0
Water(GPM) 18.0 32.0 40.5 25 Air@ 14.7 PSIA (SCFM) 63.0 112.0 155.0 Air@ 100 PSIG (SCFM) 185.0 325.0 430.0
50 Water (GPM) 25.0 44.0 57.5 Air@ 14.7 PSIA (SCFM) 90.0 161.0 205.0 Air@ 100 PSIG (SCFM) 260.0 460.0 620.0
Water(GPM) 36.5 62.0 82.0 100 Air@ 14.7 PSIA (SCFM) 135.0 230.0 300.0 Air@ 100 PSIG (SCFM) 370.0 660.0 870.0
MGdel A-471 Portable Kit
The Dwyer Series 4000 Capsuhelic4' differential pressure gage is ideally suited for use as a read-0ut device with the DS-300 Flow Sensors. The gage may be used on system pressures of up to 500 PSIG even when the flow sen-sor differential pressure to be read is less than 0.5" w.c. With accuracy of ±3% of full scale, the Capsubelic4' gage can be used in ambient temperatures from 32"F to 200°F. Zero and range adjustments a.re made from outside the gage. The standard gage with a die cast aluminum housing can be u.sed with the flow sensor for air or oil applications. For water flow measurement.s, the op-tional forged brass housing should be specified. The Capsuhelic gage may be J>anel or surface mounted and permanently plumbed to the flow sensor if desired. The optional A-610 pipe mounting bracket allows the gage to be easily attached to any I¼" -2" borizontal or vertical pipe.
Large ¾ Inch Diameter for Extra Strength In Lengths
to 24 Inches
0S400
3M(llll5)DCA.
0S400
Capsuhelic• differential pressure gage for flow read~ut, we rec-ommend you request Bulletin F-50 to obtain complete data on con-verting flow rates of various media to the sensor differential
pressure output. With this bulletin and after making a few simple calculations, the exact range gage required can easily be determined.
FULL RANGE FLOWS BY PIPE SIZE (APPROXIMATE)
2" z.-
20.5 30
65.0 113 210.0 325
34.0 47 118.0 178
340.0 610
45.5 67
163.0 250 470.0 740
72.0 108
255,0 390
760.0 1200
100.0 152
360.0 560 1050.0 1700
142.0 220
505.0 800 1500.0 2300
For portable
operation, the A-471
Capsuhelic Portable
Gage Kit is available
complete with tough
polypropylene
carrying case, mount,.
fng bracket, 3-way
manifold valve, two 10'
high pressure hoses,
and all neeeBS3.l')'
fittings. See Bulletin
A-30-P for complete
information on the
Capsuhelie gage ....•
$271.00
3"
49
183
510
78
289
820
110
410
1100
173
640
1800
247
900
2600
350
1290
3600
4" 6" a-10"
86 205 350 560 330 760 1340 2130 920 2050 3600 6000
138 320 560 890 510 1200 2150 3400 1600 3300 5700 10000
195 450 800 1260 725 1690 3040 4860 2000 4600 8100 15000
310 720 1250 2000 1130 2630 4860 7700 3300 7200 13000 22000
435 1000 1800 1600 3700 6400
4600 10000 18500
620 1500
2290 5000
6500 15000
CAPSUHEUC GAGE SHOWN
INSTALLED IN A-471 PORTABLE KIT I Dwyer Instruments, Inc. P.O. Box 373/Mlchigan City, Indiana 46361/Phone [phone]Fax [phone] • U.K Phone [phone] • Australia Phone [phone] F
Series
OS . Flow Sensors I
I For use with the Dwyer Capsuhelic® differential pressure gage to measure
high flow rates of air or water in pipes.
H
Model DS-200
Valves -Standard, brass wfth
Teflon• seat and S'una-N 0-ring
Nameplate -Stain-
less steel pennanently
attached with spilt ring.
Includes complete size
and model lnfonnatlon.
Head -Machined stainless steet.
Packing gland -Parker CPI brass
compmsslon fitting.
Sensor tube -304 stainless steel.
Sensing ports -Multiple upstream
and downstream ports sized and posi-
tioned to provide effective accurate
pressure averaging, even at lower
velocities.
Dwyer Flow Sensors are averaging pitot tubes that provide ac-
curate and convenient flow rate sensing. When purchased with a
Dwyer .Capsuhelic111 differential pressure gage of appropriate
range, the result is a flow indicating system delivered off the shelf
at an economical price.
Pitot tubes have been used in flow measurement for years. Con-
ventional pitot tubes sense velocity pressure at only one point in
the flowing stream. Therefore, a series of measurements must be
taken across the stream to obtain a meaningful average flow rate.
The Dwyer flow sensor eliminates _the need for "traversing" the
flowing stream because of its multiple sensing points and built-in
averaging capabilicy.
Series D5·200 models are available in ten insertion lengths from
1" -10". Operation ls similar to DS-300 units. Basic differences are
the multi-tum shutoff valves, ¾" NPT mounting and installed W
SAE 46 · flared pressure connections. ·
Dwyer Series 05-300 flow sensors are designed to be insert-
ed in the pipeline through a compression fitting. They are fur-
nished with instrument shut-off valves on both pressure
connections. Valves are fitted with 1/a" NPT female connections.
Accessories include adapters with ¼" SAE 45° flared ends com-
patible with hoses supplied with the Model A-471 Portable Cap-
subelic kit. Standard valves are rated at 200 psig (13. 7 bar) and
200°F (93.3°C). Where valves are not required, they can be omit-
ted at reduced cost. Series DS-300 flow sensors are available for
pipe sizes from 1" to 10". If replacing a ns.200 flow sensor or
using an A-160 thredolet with a DS-300, an optional ¼" X ¾"
bushing, P /N A-161 is required.
05-400 Averaging Row Sensors are qualicy constructed from
extra strong ¾ • dia. stainless steel to resist increased forces encoun,
tered at higher flow tares with both air and water. This extra strength
also allows them to be made in longer insertion lengths up to 24 inch-
1M [1.571 D.EA1W1CE
Jp
I I I _,
,....
[f1.21]1YP.
,.,..
(411151 APPROX.
wnr
""''
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es (61 cm). All models include conveni.ent and quick-acting quar' 1 turn ball valves to isolate the sensor for zeroing. Process connecti~
to the valve assembly are 1/s' NPT female. A pair of 1/s" NPr X W
SAE 45 • flared adapters are included, compatible with hoses used in
the Model A-471 Portable CapsuheJic• Gage Kit Supplied solidabra.ss:
mounting adapter bas a 1/." dia. compression fitting to lock in re ·
insertion length and a :Y,• NP!' male thread for mounting in a thr,d-
o-let (not included).
STOCKED MODELS I
Prices -Select model with suffix which matches pipe siz
os-200-1• ___ _,110.00® os-300-1• s.oo ,
05-200-11,,(• 172.00®
DS-200-1½" 176.00®
OS-200-2" 179.00®
OS-200--2W' 185.00®
os-200-3• 15.00®
D5•2Q0..4" 22200®
D5-200-6" 330.00®
os-20o-a· _ 70.00®
D5•200--10• 400.00®
05-400-6" 195.00
05--400-8" 23Q.OO
08--400--10'---~79.00
05--400--12• ... _______ :119.oo
05--400-14",----'149,00
D5-400-16"----"79,00
D5--400--18".----409,00
OS-400·20• _____ 439.00
OS-400-24"----'499,00
D5--300-1 !'" ----~•5.00 ! 5.oi ------•5. ___ .,,,5, .
05-300-1}(''
D5-300--2"
Ds.300-2½u ........
09-300--3' -----109.00)
.... 129.100 •
-----185.
_ ___ ,..,209.
DS-300--4.
DS-300-6"
OS-300--8'
DS-300-10" ----~49.00 !
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A-160 Th,adolet.~• NPT, forged steel, 3000 p~ ........................................... 7.1
A-161 Brass Bushing, ¼" x %" .................................................................... :.1
Less Valves (DS-300) To order. add suffix ·LV ................................ deduct
@ Items subject to Schedule B dlscounts
24F Dwyer Instruments, Inc. P.O. Box 373/Michlgan City, lndlana 46361/?hone 219 879-8000/Fax 219 an-9057 • U.K. Phone [phone] • Australia Phone [phone] I
!
.. \t/?flt11;l~f ~2/'t •.. I
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SERIES DS-300 FLOW SENSORS
Installation and Operating Instructions,
Flow Calculations
INSPECTION
Inspect the sensor upon receipt of shipment to be certain
It 1s as ordered and not damaged. If damaged. contact
camer. ·
INSTALLATION
General -The sensing ports 9f the flow sensor must be
correctly positioned for measurement accuracy. The instru•
ment connections on the sen,snr indicate correct position•
ing. The side connection is for total or high pressure and
should be pointed upstream. The top connection ls for
· static or low pressure.
Location -The sensor should be instailed in the flowing line
with as much straight run of pipe upstream as possible.
This wm provide a flow profile as ideal as possible. A rule of
thumb is to allow 1 0-15 pipe diameters upstream and 5
down. The table below lists recommended up and down
piping:
PRESSURE AND TEMPERATURE
Maximum 200 psig .at 200°F.
IPSTREAM AND DOWNSTREAM DIMENSIONS IN TERMS OF INTERNAL DIAMETER OF PIPE
ifsEE NOTE #1
MINIMUM DIAMETER OF STRAIGHT PIPE
UPSTREAM I tPSTREAM =NDmoN DOWNSTREAM
1 lone Sbow or lee
IN-PLANE OUT OF PLANE
7 9 5
Two 90" Sends in Same Plane 8 12 5
~WO 90° Bends In Diff818fll Plane . 18 24 5
Reducers or Expande!s 8 8 s
Er valves
SeeNote2 24 24 5
l ote #1: Values shown are recommended spacing, in tenns of internal diameter for normal industrial metering requirements.
For laboratory or high accuracy work, add 25% to values.
•Note#2: .I
Includes gale, globe, plug and other throttling valves !hat are only partially opened. If valve is to be fully open,
use values for pipe size change. CONTROL VALVES SHOULD BE LOCATED AFTER THE FLOW SENSOR.
a~2
•osrnoN
:e certain there is sufficient clearance between the mount-
Ig position· and other pipes, walls, structures, etc, so that
1e sensor can be inserted through the mounting unit once
,e mounting unit has been installed onto the pipe.
'low Sensors should be positioned to keep air out of the
'lSb'Ument connecting lines on liquid flows and condensate
,ut of the lines on gas flows. The easiest wey to assure this
• to inct::111 the sensor into thA pipe so 'that air will bleed
,,to, or condensate will drain back to, the pipe.
For air or gas flow:
Install In uppet
quadrant of_ pipe
For liquid or steam flow:
Install in lower
quadram gf pipe
BLEED
L
L
BLEED
H
H
FLOW
PIPE
WATER FLOW
Condensate drains
back to pipe
Air bleeds back
to pipe.
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~SEN~OR
INSTALLATION
1. When using an A-160 ltlred-o-l1:1t, weld it to tho pipe
wall. If replacing a DS-200 unit, an A-161 bushing
r1,•x3/a") will.be needed.
2. Drill through the center of the thred·o-let into the pipe.
with a drill that Is slightly larger than the flow sensor
diameter.
3. Install the packing gland using proper pipe sealant If the
pacKing gland i:; disa:;:sembled, note that the taper-Ad
end of the ferrule goes into the fitting body.
4. Insert the sensor until it bottoms against the opposite
wall of the pipe, then withdraw 1/16" to allow for thermal
e,cpansion. .
5. lighten packing gland nut finger tight Then tighten the
nut with a wrench an additional 11/, turns. Be sure to
hold the sensor body with a second wrench to prevent
the sensor from turning.
· INSiRUMENT CONNECTION
Connect the side pressure tap to the high pressure port of
the Magnehelic (air only) or Capsuheflc gage or transmitting
instrument and the top connection tc the low pressure port.
See the connection schematics below.
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t:lleed air from im,"lrurnent piping on liquid flows. Drain any I
condensate from the lnst/Ument piping on air and gas flows.
Open valves to instrument to place flow meter into seivice.
For permanent installations, a 3-valve manifold is recom-
mended to allow the gage to be_ zero checked without
interrupting the flow. The Dwyer A-471 Portable Test Kit
includes such a device.
DRAIN
L
FLOW
AIR OR GAS FLOW
SENSOR
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•
f sei:t1es os-300 Ft.ow SENSORS
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1'¼" 149.211
1/4 NPT
,,, •• 11.571
CUAIIANCE
0
i
1W[4t27j TVP. •
i
1 ¾" [42.86] AP1'ROX.
1¼" [36.521
t
1----+-S/16" [7.93B)
FLOW CALCULATIONS AND CHARTS
The following information contains tables and equations for
determining the differential pressure developed by th" DS·
300 Flow Sensor for various flow rates of water, steam, air
or other gases in different pipe sizes.
This information can be used to prepare conversion charts
to translate the differential pressure readings being sensed
into the equivalent flow rate. Where direct readout of flow Is
required, use this information to calculate the full flow dif-
ferential pressure in order to specify the exact range of
Dwyer Magneh&lic or Capsuhelic gage required. Special
ranges and calculations are available for these gages at
minimal extra cost. See bulletins A-30 and F-41 for addi-
tional information on Magnehelic and Capsuhelic gages
and DS-300 flow sensors.
For additional useful information on making flow calculations,
the following reference is recommended: Crane Valve Co.
Technical Paper No. 410 "Flow of Fluids Through Valves,
Rttings and Pipe.• It is available from Crane Valve Co., 104
N. Ghicago St, Jollet, IL 60431. Phon., 815/727-2600. !"rice
including shippirg Is $20.00
Using the appropriate differential pressure equation from page 4, calculate the differential pressure generated by the sensor
I under normal opP.r.'lting conditions of the system. Check the chart below to determine if this value is within the recom-
mended operating range for the sensor. Note that the data in this chart is limited to standard conditions o1 air at oo·f (15.6"C)
and 14. 7 psia static line pressure or water at 70°F (21. 1 °C). To determine recommended operating ranges for other gases, liq· I fiids and/or operating conditions, consult the factory. .
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Note thg column on the right sirlA of the chart which defines velocity ranges to avoid. Continuous operation within these can
result in damage to the flow sensor caused by excess vibration.
Flow Operating Ranges Operating Ranges Velocity Ranges
Pipe Size Coefficient Air @ 80°F & 14. 7 psia Water @ 70"F Not Recommended
(Sclu,dule 40) "K" (DIP Inches W.CJ (DIP Inches W.CJ (Feet per Second)
1 0.52 1.10to186 4.00 l0675 146to220
i¼ 0.58 1.15 to 157 4.18to568 113to170
1½ 0.58 0.38to 115 1.36l0417 96IO 144
2 0.64 0.75to 75 2.72 to 271 71 to 108
2½ 0.62 1.72to 53 6.22 to 193 0010 OS
3 0.67 0.39to 35 1.43to 127 42!0 64
4 0.67 0.28to 34 1.02 to 123 28to 43
6 0.71 0.64!0 1, 2.31 to 40 15 to 23
8 0,87 o.,oto 10 0.37 to 37 9.5IO 15
10 0.70 0.17to 22 0.6010 79 6.4 to 10
~
FLOW EQUATIONS
1. Any Liquid
Q (GPM) = 5.668 x K x 0 2 x -..j L:.P/Sf
DIFFERENTIAL PRESSURE EQUATIONS
1. Any Liquid
6P (in. WC) = ____ 0_2_x_S~f __ _
2. Steam or Any Gas
Q (lb/Hr) = 3!59.1 x K x o• x -..J fJ x .6P
3. Any Gas
2. Steam or Any Gas
6P (in. WC) =
Q (SCFM) = 128.8 x K X 0 2 x / P x 6P 3. Any Gas · 1/ (T+460) X Ss L:.P (In. WC) =
TECHNICAL NOTATIONS
The following notations apply:
6P = Differential pressure expressed in inches of water column.
Q = Flow cxprc,:i,:icd in GPM, SCFM or PPH '1$ shown in equation.
K = Flow coefficient -·See Values Tabulated on page 3.
D = Inside diameter of line size expressed .in inches. For square
& rectangular ducts use D= -J 4 x Height x Width
-rr
P = Static Line pressure (psia) .
T = Temperature in degrees Fahrenheit (plus 460=0Rankin)
p = Density of medium in pounds per cubic foot Sf ~ Sp Gr at flowing conditions
Ss = Sp Gr at GOOF
SCFM TO ACFM EQUATION
SCFM -ACFM ( 14.7 + PSIG) . X 14.7 (
s20· )
460 + °F
ACFM -SCFM x ( 14_7 ~-7PSIG ) ( 460 + °F )
520 ·
K2 x [)4 X 32.14
Q2
K2 X 04 X p X 128,900
02 x Ss x (T +460)
K2 X 1)4 X P X 16,590
POUNDS PER STD POUNDS PER ( 14.7 ) ( 460 + °F )
CUBIC FOOT • -CUBIC FOOT ACT. x 14.7 + PSIG 520
POUNDS PER ACT POUNDS PER STD ( 14.7 + PSIG) ( 520 )
CUBIC FOOT . -CUBIC FOOT . x 14.7 ···450 + ·•F
1 CUBIC FOOT OF AIR -0.076 POUNDS PER CUBIC FOOT AT 60°F AND 14.7 PSIA
•cs20 = 460 + 60°) Std. Temp. Rankine
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IX:opyright 1996 Dwyer Instruments, lne. Printed in U.S.A. 6/96 FR 72-440451-01
.... , .. _,,.,,rl
TOTAL P.05 I
BULLETIN E-34
SIEflllES 6040 !NIDICA'i!NG P!RESSURIE TRANSMITTER
I,
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Specifications -Installation and Operatnng Instructions
. 13/1!4 [5.1S] DIA. MOUlll1NG HOLES 2-PI.ACES
---I r-27/64 [10.69)
I
1m
[5.53)
1-3/1!4
2-3/16
[56.56]
2-9116
[65.06)
13'32 [10.31)
I [26.58) 1-21m f---------i-[46.61) I HIGH PRESSURE
• LOW PRESSURE 1------1---HV.32 [32.62)
3-1/64[76,58) ---
le Dwyer Serles 6040 Indicating Transmitter simultaneously pro-
vides local indication on a compact, easy to read analog scale
I ., "' also converting that pressure into a standard 2, 3 or 4 wire,
mA signal for ranges as low as 0-0.5 in. w.c. Posillve, nega-
tive or differential pressures can be measured within :!:5% of full
Ee (gage reading) or :!:2% of full span output (transmitter sig-
The basic mechanical components of the Series 6040 units
similar to those used in the popular, time-proven Mlniheli~
differential pressure gage. However, the Serles 6040 models add
l lectrlcal conditioning and arnpllflcati. on of a resistance change
reduced by a silicon strain gage cemented to the range spring.
This resistance change is the result of a slight flexing which results
~m spring deflection as pressure is applied to the diaphragm
l'hich is mechanically linked to the spring. ·
leries 6040 nndicating lhlnsmitter Models & Ranges
i Model Number Range, Inches W.C. Minor Divisions
6040-0 0--0.5 .02
1r 6040-1 0-1.0 .05
6040-2 0-2.0 .10
6040-3 Q-3.0 .10
I 6040-5 o-5.0 .20
6040-10 0-10 .50
6040-20 0-20 1.0
6040-40 0-40 2.0
I 604O-<iO 0-SO 2.0
6040-100 0-100 5.0
I
Ag.A
SPECIFICATIONS
GENERAL
Maximum Pressure:
Media Compatibility:
Materials:
a.ECTRICAL ·
Power SUpply:
Connections:
Cable Gland:
OUtput Signal:
Loop Resistance:
CUmmt Consumption:
WllmH.lp Time:
30 psig (207 kPa) continuous
50 psig (344 kPa) momenta,y surge
AJr and non-<:ombustlble,
non-corrosive gases
Mineral and glass filled nylon housing,
high impact acrylic cover. silicone
rubber diaphragm
13-35 VDC -2. 3 or 4 wire
18-26 VAC -4 wire
4 screw tenninal block
Flis .10-25 in. (2.5-6 mm) 0.D .. cabie
4-20 mA DC, llmlted at 38 mA DC'
DC, 0-1100 ohms; AC, 0-1130 ohms
DC, 38 mA max.; AC, 76 mA max.
10mlnutes
PERFORMANCE AT l'O"F (21.1'C)
Zero Ou1put: 4 mA DC
Full Span 0u1put: 20 mA DC
Aecuracy, Gage: :!:5% of full scale
Accuracy, Transmltlel': :!:2% of full span output ~ncludes linearity,
hysteresis and repeatablDty)
Slabillty: 1 % of full span per year
ENVIRONMENTAL
Operating Temperature:
Thennal Errors:
MECHANICAL
Weight:
Span arid Zero Contn>Js:
Pnisswe Connections:
Standarcl A: : e 1 aorfes:
20 to 120'F (-6.7 to 49•q
:!:1% perSO'F
a ounces (227 grams)
Internally accessible potentiometers
Barbed for 3/16" (4-5 mm) I.D. tubing
1wo #10X1" pan head sheet metal
screws, one .050" hex alien wrnnch
INSTALLATION
LOCATION: Select a location where the temperature of the unit
will be between 20°F and 120°F. Distance from the receiver is lim-
ited only by total loop resistance. See "Electrical Connections."
The tubing feeding pressure to the instrument can be run practi-
cally any length required but long lengths will increase response
time sHghtly. Avoid surfaces with excessive vibration.
POSmON: All models are calibrated with the scale in a vertical
plane and units with ranges under 5 in. w.c. should only be used
in that position due to the sensitivity to gravitational forces which
cannot be corrected by zero adjustment. Higher range models
can operate in other planes but zero (both mechanical and electrical)
and span adjustments may be necessary to maintain accuracy.
PRESSURE CONNECTIONS: Two barbed connectors are pro-
vided for use with 3/16" I.D. vinyl or rubber tubing. Attach tubing
from positive pressure source to HI port. Leave LO port vented.
For negative (vacuum) pressure, connect to LO port and leave HI
port vented. For differential pressures, connect the higher to HI
port and lower to LO port.
MOUNTING: Attach the Serles 604D Indicating Transmitter to a
vertical surface using the 1 • --#1 O pan head sheet miatal screws
provided. Mounting holes are located In upper left and lower right
comers of case.
GAGE ZEROING: After Installation, check to confirm that gage
·reads exactly zero with both pressure connections open and vented
to atmosphere. If adjustment is necessary, grip case firmly with
one hand and place palm of the other hand flat on clear cover. If
difficult to grip, try placing a thin sheet of rubber between hand
and cover. Rotate counter-clockwise to remove. Zero adjust
screw is located at bottom of scale just to left of the indicating
pointer and slightly behind it. Use the .050" hex alien wrench
included. Replace cover.
ELECTRICAL CONNECTIONS
CAUTION: DO NOT EXCEED SPECIRED SUPPLY VOLTAGE
RATINGS. PERMANENT DAMAGE NOT COVERED BY WAR-
RANTY WILL RESULT. THIS UNIT IS NOT DESIGNED FOR 120 ·
OR 240 VOLT AC LINE OPERATION.
Electrical connections to the Series 604D Indicating Transmitter
are made inside the enclosure on the left side of untt. Remove
cover and feed 4 conductor cable through the cable gland at bot-
tom of housing. Make electrical connections to the 4-screw termi-
nal block shown in Fig. B. See following instructions and drawings
for details on your specific appllcatlon. When connections are
complete, tighten cable gland and replace.cover.
ZERO AOJUSTMEIIT
SPAN AOJUSJMEIIT
TERMINAL BlDCK
fig. B
Wire LI!11g1h -The maximum length of wire connecting transmit-,
ter and receiver is a function of wire size and receiver resistance. .
Wiring should not contribute more than 10% of receiver resis-
tance to total loop resistance. For extremely long runs (over 1000 1 feet), choose receive I s to minimize size
and cost of connecting s. Where wiring I_ is under 1 oc
feet, lead wire as sm as 22 AWG can be used. '.
2-Wlre Operation - n external power supply slivering 13-351
VDC with minimum cu ability of DC (per transmit-
ter) must be used to power the control loop. See Fig. C for con-
nection of the power supply, transmitter and receiver. Note the
jumper between terminals 3 and 4. The range of appropriate I
receiver load resistance [RJ for the DC power supply voltage
available is expressed by the formula and graph.in Fig. F. Shielded
two wire cable is recommended for control loop wiring. If ground-
ing is required use negative side of control loop after receiver. In •.
Fig. C below, ~ power supply lead to terminal 1 is positive, ground
should be connected to wiring at right of receiver. Otherwise, in 2
wire operation ~ is not necessary to observe polarity of control
loop connections.
2 WIRE CONNECTION
JUMPER WIRE
Ag.C
+
POWER
SUPPLY
13-35 voe
3-Wire Operation -An external power supply delivering 13-35
VDC with minimum current capabiltty of 40 mA DC (per trans-
mitter) is required. See Fig. D for connection of power supply,
transmitter and receiver. The range of appropriate receiver load
resistance (RJ for the DC power supply available is expressed by
the formula and graph in Fig. F. Shielded cable is recommended
for control loop wiring. Do not employ a separate ground in 3 wire
operation. Unit will not function properly and/or damage could
result. Control loop polarity must be observed in the following
respect. Although power supply terminals 1 and 2 are not polar-
ized, the receiver must be connected between terminal 4 of trans-
mitter and negative side of power supply.
3 WIRE CONNECTION
1 +
SERIES6040 2 POWER
PRESSURE 3 l -SUPPLY
mANSMITTER 4 +--13-35 voe.
~ RECBVER
fig.D
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4-Wire Operation -An external power supply delivering 13-35
VDC with minimum current capability ·of 40 mA DC (per transmit-
ter) or 18-26 VAC With minimum current capability of 80 mA AC
(per transmitter) is required. See Fig. E for connection of power
supply, transmitter and receiver. The range of appropriate load
resistance (RJ for the. DC or AC power· supply available is
expressed by the formulas and graphs in Figs. F and G. Shielded
cable is recommended for control loop wiring. Do not employ a
separate ground in 4 wire operation. Unit will notfunctlon properly
and/or damage could result. Control loop polarity· must be
observed, terminal 3 is negative and terminal 4 Is positive. Power
supply terminals 1 and 2 are not polarized.
4 WIRE CONNECTION
1 +
· SERIES 6040 2 POWER
PRESSURE 3 RH»W" -SUPPIY
TRANSMITTEH • - -l
13.JSVDC 4 18-26VAC
~
Rg.E
POWER SUPPLY VOLTAGE -VDC (2. 3 or 4 wirel
1400
1300
1200
1100
1000
900
800
700
600
500
400
300
200
100
I\ MAX_ Vps-13.0
20mADC
MAXIMUM VALUE (11DDn)
50 J...-~-._...a..W-L.ll.LU..L.U..U.l..U.ll.LU.--J
0 5 10 1315 20 25 30 35 40
Rg.F
POWER SUPPLY VOLTAGE -VAC (4 wire)
1400~----------------
1200
MAXIMUM VALlJE (1130llJ
C: i 1000-J..
i;;
I\ MAX • l/5(Vps) -560
~ 900
j 800 L 0PEHATING_--ll __ _
REGION
600,J.. I
' ' 0 5 10 15 18 20 2526 30
Rg.G
1/oflage Input -Series 6040 Indicating Pressure 1lansmitters can
be. easily acapted for receivers requiring 1-5 or 2-10 voe input
Insert a 249 ohm, 1/2 watt (1-5 VDC) or 499 ohm (2-10 VDC) resis-
tor in series with the current loop but in parallel with the receiver
input. Locate this resistor as close as possible to the input.
Because resistor accuracy directly influences output signal accu-
racy,· we recommend use of a precision :!:0.1 % tolerance resistor
to minimize this effect. See Figs. Hand J.
3-WIRE CONNECTION (1-5/2-10 voe OUTPU1)
1 +
SEHIES6040 2 POWER
PRESSURE , 3 -SUPPLY
IBANSMllTEH 4 +--13-3SVDC
I '-' L A A J vvv
Fig. H
4-WIRE CONNECTION (1-512-10 voe OUTPUT)
1 ,
SERIES 6040 2 POWER
PRESSURE 3 -SUPPLY
TRANSMITTER I 13-3SVDC 4 •--18-26VAC I = ' L A A vvv J
Rg.J
OU'T?UT RANGING
Each Series 604D Indicating Transmitter is factory calibrated
to produce 4 mA at zero scale reading and 20 mA at full scale
reading. The following procedure should be .used to check the
accuracy of the transmitter output.
1. With unrt connected to its companion receiver, insert an accu-
rate milliammeter wrth a full scale reacing of approximately 30 mA
in series wrth the current loop.
2. Connect a controllable source of pressure to one leg of a tee,
one leg to the high pressure port of the unrt being tested and the
third leg to a test gage or manometer wrth 2% or better accuracy.
Be sure the low pressure port Is vented to atmosphere. This cali-
bration check must be done in the saine position in which the unrt
will be operated. Vertical is recommended.
3. Apply electrical power to the system and allow 1 O minutes
warm-up time for components to stabilize.
4. With no pressure applied to the system adjust ZERO control
inside electrical enclosure to produce exactiy 4 mA current.
5. Apply full scale pressure as observed on the test gage or
manometer and adjust SPAN control for exactiy 20 mA 9urrent
6. ZERO and SPAN controls are slightly interactive so steps 4 and
5 -should be repeated until outputs are consistently 4 and 20 mA,
respectively.
7. Remove the milllammeter and test gage from the setup, make
connections to system pressure source(s) and place unrt in service.
MULTIPLE RECl:lVEfl !NSTAUATION
An acvantage of the standard 4-20 mA DC output signal used in
Series 604D tran~mitters is the compatibility wrth a wide range of
receivers. Devices ·such as the A-701 Digital Readout, A-702
Digital Readout with alarms, an analog panel meter, a chart
recorder and other process. control equipment. can be operated
simurtaneously. It is only necessary that all devices be designed
for a standard 4-20 mA input, the proper polarity of input connec-
tions be observed and the combined receiver resistances must
not exceed the maximum for the current loop. If any receiver indi-
cates a negative or downscale reading, the signal input·leacs are
reversed.
MAINTENANCE
After final installation of the Series 6040 Indicating Pressure Trans-
mitter, no routine maintenance is required. A periodic check of out-
put calibration is recommended following the procedure described
under OUTPUT RANGING. Otherwise, the transmitters are not field
repairable and should be returned, freight prepaid, to the address
below W service Is needed. Be sure to include a clear description of
the problem plus any application Information available.
Dwyer Instruments, Inc.
Attn: Repair Dept.
102 Highway 212
Michigan Crty, IN 46360
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l.05%
'F.
' ,n,
,o
L r .t
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t
Series
604D Minihelic® Differential Pressure Dial Gage Indication; 2, 3 or 4-Wire Indicating Transmitter 4-20 mA Output ( E ~r!~t{J';·;~;ff.i-: :. --. . -· -~tti:{~{~[~~/'.?~t.'o:·~-·--·-·-· ~~-•--..... "-"""""" --
~f
/tl f'·
f~·· !::'·
Toe Dwyer Series 604D Mlnihellc" Indicating 1ransmiller oombinee vi,' sual monit.oring wit.h eJectronic control of low differential air or compatible gas pressures. This versatile device is ideal for building HVAC systems where local indication is needed during maintenance checks or when troubleshooting the system. The transmitter design employs the latest ,i!ioon ,train -techno~ ogy and operates in 2. 3 or 4 wire control loop circuitll. Separate Zero and Span controls plus a 4-screw terminal strip are protected in a gasketed side enclo-aure. Cable gland fit., .10-.26" round cable. A 13-36 VDC or 18-26 VAC (4-wire only) p<lWlll' supply ia requjred.
STOCKED MODELS
PHYSICAL DATA
GENERAL
Maximum Prltaur'e: 30 psig (207 kPa) contnuous, 50 ~ (344 kPa) surge Mlldla Compatlbl.llty: Ai & nM-COrTOSMt, oon-ccmoos,ble,.,..
Materials: Mlneral and glass fflled n-,ion holl3ing, high Impact acrylic ca.-er, Sillcooe ,ubbo-dlap/vngm
ELECTRICAL
Power Supply: 13-35 voe-2, J or 4 Wl"e: 18·26 VAC-4 w1rn
Output Signal: 4-20 mA DC, limited at 38 mAOC
Loop Rff!atanc« CC, 0-1100 ohrm; AC. 0-1130 ohms
CUrrent Consumption: CC, 38 mA max.; AC, 76 mA max.
Wann-Up Tlme: 1 0 minutes
,.-i' Series
6D5
Magnehellc"' Differential Pressure Indicating Transmitter
The Dwyer Series 605 MagneheUc" Indicating Transmitter provides for both visual monitoring and electronic control of very low differential. pressure. The Series 605 is ideal for control applications in building HVAC systems where local in-dlcation is deaired during routine maintenance checks or necessary when trouble shooting the system. The easily read dial gage is complemented by the two-wire, 4-20 mA control signal u1lllzing the t1m_,, Dwyer Magnehelic" gage me<hanical design and Series 600 strain.gage tranamitter technology. The two-wire design with terminal strip on the rear simpllflea connection in any 4--20 mA control loop P""-<I by a 12,3-36 VDC auppl;y.
STOC:<ED MODELS in bold
fBO$:OON:\ tos.~0;!:2ot iS1a1t~o~· :-:i).:&Qs;30~ N'~o;a~:tfS ~89:oo_:i:J ;'iH)'.'. M~W.~J1:uai ;J=!~ ~l~i;1; i~ilr~ ao}~i".Y ti·ll-l.O'iii, i"ii'loD;oo,i '605,25011oc, )i,µ0,250U'•i,-j:'~169.~::'it' .· ~r.: lf ~;!}l !~1:S~ fi:ti; i;;i;;I ~~;;ii;;; OS:20 .",. 0-20;• .•. i "•16W,DOiS ,605°1C5kl'a•.• ;;.• .•0•t:5-•,,,-.,, ,,;,,119; :.,t
PHYSICAL DATA
GENEAAL
Maximum Pressure: 25 PSIG Media C-Ompattblllty, Air & non-combustible, non-corrosive gases. ELECTRICAL .
Po..., Supply: 12.3 to 35 voe
~ Signal: 4 to 20 mA DC, 2 win> (limited at 38 mA max.)
Loop Resistance: 0-1135 ohms from 12.3to35VOC
Current Consumption: 38 mA DC (max.)
MATERIAL
Die cast aluminum case 'Mth baked dark gray hammenoid finlSl1, aayllc '°"" MECHANICAL
Weight 2 lb., 8 oz.
PERFORMANCEAT70•F (21.1•C) Zeto Output 4 mA. DC Fwl Sp#n Output: 20 mA OC Ac:cunacy, Gage: :596 ot ful scale Accuracy. Thinamitt.r. =296 of full span output Pnctudes &iBettty, hyste.-esis and f'8P6818billty)
Stablllty:-1% ofM span pt)ryear
ENVIRONMENTAL
Openrtlng Temparaturr. 20 to 12o-F (-6. 7 ID 49"q
ThotlT!al Errol'S:j:196 per50"F
MECHANICAL
WeJ;ht: a ounces (227 grams) Span and Zero Controls: I~ eoces-sible potent!Ometers
Pniasuro CoMactlona: Barbed, for~.• (4• 5 mm) t.O. tubing Standard Acc11Uorln.: 1wo #10 X 1 ' pan head sheet metal saews, one .050' hex --
Dial Gage Indication,
lwn-Wire 4-20 mA Output
CE
Span and Zero adjua'bnenta:
Protected potentiometers
Pressure connections: ~-NPT
-rlgh and Jow pressuru lllps
PERFORMANCE AT 70°F ZIH'o output 4 mA
FuU ""'°' output 20 mA Accumcy (lnc:Judos llnaarily,
--19peatablllty): ±2% at tun span output
Span and Zero: Adjusrab/e to 0.05%
olful span
W8m'H1p tfme: 10 mrotes
ENVIRONMENTAL
Operating temperature: 30" to 120'"F Thermal Error: ± 1 %/50°F typical
STANDARD ACCESSORIES
Span and zero adjust tod, rro.Jl11ing
haidwara kit
Dwyer lnstrumen~. Inc P.O. Box 373/Mlcltigan Clly, Indiana 46361/Phona 219 679-6000/Fa, 219 672-9057 • U.K Phone [phone] • Australia Phone [phone]P
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41 Air Intake Filter/Silencers
I I
lM
EM PRODUCTSTII
PHIWPS & TEMRO INDUSTRIES
Model EMS·-Series
The "EMS" Series air Intake filterisilencer is
designed for both indoor and outdoor applications
requiring 6 - 8 dB noise reduction and a high
degree of filtration. The unique heavy gauge
construction reduces noise transmission and
enhances durability in even the most severe
environments. This series is ideal for applications
such as reciprocating engines, positive
displacement blowers and centrifugal compressors.
Easy filter element access reduces maintenance
time during filter element replacement
Standard. Construction Features
• Available in sizes froin 1 Inch to 16 inch
• Female NPT discharge connection sizes 1 inch
to 4 inch
• 125/150# ANSI drilled plate flanges for sizes 5
inch to 16 inch
• Carbon steel construction
• Removable weathemooi:l
• Available with pap~r. felt and wire mesh filter
element
• Removable weathemood
• Gray phenolic resin based fast drying primer
suitable for overcoating with urethanes,
aaylics, epoxies and industrial enamels.
Standan:I two mil thickness
• 1/8" NPT pressure tab
Optional Construction Features
and Accessories
• stainless steel construction
• Aluminum construction
• Special finish per specification
• Pre-filter wraps
• Special filtration and back-pressure designs
• Special acoustic designs
• OVersized flanges
• Contact factory for additional features to ·meet
your requirements ·
10.93
SBBC-2004
I EM Products• 5380 Cottonwood Lane• Prior Lake, MN 55372 • (612) 44~00 • Fax: [phone] • [e-mail]
.
--~ ...
Air Intake Filter/Silencers ,D Model EMS -Series EM PRODUCTS"' _i,;i,
PHlUPS 6 l!llll0 DCUSnU!S ~ ·.~i.
' ,
1/8"-27FNPT \ 1/B"-27 FNPT \ TAP TAP
\ 7 \ C I '-
I i t ' t i R R I i J J :
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iJ
I I 8 B D
I I SJ J_ i _J ! I I A N i
FNP L-l-l N ;I
1 • to 4" Female NPT Connection ..
5" and Larger-125/150# ANSI Drilled Plate Flange
(4" flange connection available upon requrest) (5" FNPT connection available upon request) I
Element Model.Number ~1 Model No. A C B D . N R Weight CFM Paper Felt j:_· i ' Wire
EMS.1 1 91/2 6 5/8 5 3/B 9/16 21/4 8 35 P-642 F-642 W-642
EMS-125 11/4 9 1/2 6 5/8 5 3/B . 9/16 21/4 8 35 P-642 F-642 W-642 I EMS-15 11/2 9 1/2 6 5/8 5 3/B 9/16 21/4 8 75 P-642 F-642 W-642
EMS-2 2 9 1/2 6 5/8 5 7/16 518 21/4 8 120 P-642 F-642 W-642 1, EMS-25 21/2 14 7/8 12 11 7/8 13/16 4 7/16 20 200 P-974 F-974 W-974
EMS-3 3 14 7/8 12 13 5/8 13/16 4 7/16 20 275 P-974 F-974 W-974
EMS-35 3 1/2 14 7/8 12 13 518 13/16 6 7/16 25 375 P-976 F-976 W-976 I EMS-4 4 14 7/8 12 13 5/8 1 6 7/18 25 500 P-976 F-976 W-976
EMS-5 5 14 7/8 12 25 1/2 3 7 3/8 36 750 P-1197 F-1197 W-1197 I EMS-6 6 22 18 261/4 3 0 5/8 53 1100 P-13118 F-13118 W-13118
EMS-8 8 22 18 25 3 10 3/4 70 2200 P-171310 F-171310 W-171310
EMS-10 10 22 18 25 3 10 3/4 95 3000 P-171310 F-171310 W-171310 I EMS-12. 12 22 18 25 3 10 3/4 108 .4300 P-171310 F-171310 W-171310
EMS-14 14 30 24 40. 4 15 3/4 180 5900 P-231914 F-231914 W-231914 I EMS-16 16 30 24 40 4 15 3/4 190 7700 P-231914 F-231914 W-231914
• When ordering specify paper (P); felt (F) or wire mesh (W) filter element
• 1 inch to 4 Inch-standard female NPT connection; 4 Inch flange connection available upon request I • 5 inch to 16 inch standard 125/150# ANSI drilled plate flange connection; 5 inch female NPT connection available upon
request .
Dimensions in inches, weights In pounds. Dimensions and weights are nominal and may vary slightly with production models. 1 Request certified drawings for exact dimensions.
EM Products • 5380 Cottonwood Lane • Prior Lake, MN 55372 • [phone] • Fax: [phone] • [e-mail] I
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I PRESSURE RATING
125 lb Class
I 200 PSI WOG
'-----------"
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Model 65M
Model 66M
,1, Material list
?tiJ?it~: ~:L~PeciflC!f_tlbnT;_!'if.~~~~T~:
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Body
Stems
Seat
"'
I 10
Cast Iron
416 Stainless Steel
EPDM, Buna-N
NI Coaled Ductile Iron
316 Stainless Steel
Aluminum Bronze
Model 65M & 66M
2" thru 12"
.
Mueller Steam Specialty soft seated butterfly valves, rated for 200 psi [wog], are
designed for general applications such as on-off, throttling, isolation and dead-end
service in commercial and industrial piping systems. They are also suited for control
of water, steam, air, oil and gases.
Features
• Cost effective design.
• The dual durometer seat is made of highly wear resistant elastomer bonded
to a phenolic backup ring. This combination provides a soft, elastic seat
which will not collapse under vacuum or high velocity service and also eliminates
the need for flange gaskets.
• Valves can be furnished in a variety of trim materials. Pneumatic, hydraulic or
electric actuators, solenoids, positioners and limit switches can be specified
for automated operation.
• Temperature limitations are dependent on seat and body materials and service
conditions. For throttling service, line velocity should not exceed 20 ft/sec ( 6
m/sec) for liquids and 15,000 ft/min (4,500 m/min) for gases. Corrosive media
applications depend on trim materials selected.
• Valves are designed to meet ANSI 125/150 lb class bolting as well as MSS-
SP-25, MSS-SP-67, and API .609 specifications.
• All valves are 100% hydrostatically tested on both s_ides and rated for
drop-tight shut-off at 200 psi [ wog].
• Disc and stem assembly with taper stem.
•
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dia. of boles,,,
K
' ' '
bolt circle
Dimensions Uni approx
•~\-i.,:.,1··1~~ ... \\ifil';;¼,. . • 1u:$.~'SIZ ,.k~~~~
A in 10 5/8 11 5/8 12 1/8
mm 270 295 308
B in 6 3/8 6 7/8 71/8
mm 162 175 181
C in 3 3 1/2 3 3/4
mm 76 89 95
D in 1.772 1.874 1.929
mm 45 48 49
in 1 2 1 2 1 2 E mm 13 13 13
F in 214 2 1/4 2 1 4
mm 57 57 57
G in 17 64 17 64 17 64
mm 7 7 7
•hol• 4 4 ..... 4 4 4
in 11/16 11/16 11 16 J mm 17 17 17
in 4 4 51/2 6 K mm 121 140 152
in 2 2 1/2 3 L mm 51 64 76
in 8 11 58 1 M mm 16 16
lb 5 7 8 65M kg 127 178 203
66M lb 7 8 9
kg 178 203 229
,,.
13 5/8 14 518
346 371
778 8 3/8
200 213
41/2 5
114 127
2.154 2.283
58
11 15
279 381
17 21
432 533
)imensions and weights approximate. Apply for certified drawings. ·
15 518
397
8 7/8
225
5 1/2
140
2.307
59
4
19
483
25
635
/1~..---H
no. of holes·
I
tap size
dia. of holes
K
bolt circle
19 3/8 21 1/4 241/2
492 540 622
10 1/4 11 1/2 13 1/14
260 292 332
7 3/4 8 9 1/2
197 203 241
2.496 2.756 3.154
63 70 80
78 1 1/8 1 1 4
22 29 32
31/2 31/2 4 1/4
89 89 108
916 9 16 9 16
14 14 14
4 4 4
8 12 12
13/16· 15/16 1 16
21 24 24
141 4 17
362
10
34 59 94
864 1499 2388
2 112
1067 1854 2845
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ELASTOMER GUIDE
"i"''•'l,.._.'fP, ~•.,!;;, iit~rumaHWfl!~fi!!l~~·;wi,rrt[ilftMl~~U(/?Nli~ffnMt_liifi H.rµ,f/il{ii!fl/ltmm;t~~Wtj#.~!,:(~fii,t,Wii#WfiJHffHHfflfl~j "•\.0~11:v..-1•1t·"•·'P" r:r'TP.~~~-rn-;f.,f!n~
I Excellent resistance to petroleum
Water Acatone, ketones, strong acids, ozone, brake fluid,
Buna-N phosphates, esters, carbon tetrachloride, trichoethylene 0°F to 200°F
Generally resistant to many hydrocarbons, fats. oils, and phosphate est~r hydraullc fluid
greases. hydraulic fluids, ethylene glycol and chemicals. .
Exct1Uent resistance to low pressure steam (30 PSI max),
hot and cold water
I EPOM Generally resistant to animal and vegetable oils, ozone, Petroleum, oila, DI-ester based lubricants, aromatic -40"F lo 275°F strong and oxldlzlng chemicals hydrocarbons, mineral alls, solvents
Phosphate ester hydraulic fluid. Good for dilute acids
(Ph 5-7) and alkalles, brake fluid and ketones (MEK acetone)
Hypalon Excellent resistance to moderate chemicals, acids, ozone, Strong, oxidizing acids, esters, ketones, chlorinated, aromatic 4QDF to 250°F fats, greases and solvents andnltro hydrocarbons. Not recommended tor steam service.
Excellent resistance to chemicals at elevated temperatures
Including aliphatic, aromatic and hayogenated hydrocarbons
Vlton animal and vegetable oils. Steam, ketones, hot hydraunc acid, anhydrous ammonia, low For phenolic:
molecular weight esters and nitro containing compounds 0°F to 275°F
Good for most gasoline, fuel, solvents, petroleum, oils
and ozone.
I
Teflon or Excellent resistance to high temperatures, oils, acids, Fuming acids, gases or cyrogenic service -10°F to 2so°F
Buna Base solvents and most chemicals. Continuous
Neoprene Generally resistant to moderate chemicals and acids, Strong, oxidizing acids, esters, ketones, chlorinated, aromatic eo·F to 2oo·F ozone, oils, fal:I, grease and solvents, and nitro hydrocarbons.
I MATERIALS Of CONSTRUCTION
I' Materials List
~teiiiiU~1fid!t?j Cdae ;Wf&1Jffaii?H;~i ;:in£mf?i}N1~fW~F.~fi 1~~ji f.ti rtiJi /.11 : ": ?j J: 1:;::1 'axi•ii1:• : .. , : i'M~1en1':1: 1r; ri:~1 ,;,? ,..,! :::~:; .j i;w"m 1o;!Vi•~..i 1 ;~tt·:-;, :~_i _; :•":1: :•i t .. :
A Cast Iron, ASTM A·126-B H 316 Stainless Steel, ASTM Gr. CFSM
BODIES C M Metal, ASTM B-61 I Ductile Iron, ASTM A-536 Class 65-45-12
D. Carbon Steel, ASTM A-216 Gr. WCB E Ductile Iron, Epoxy coated (59G only)
STEMS H 316 Stainless Sleel, ASTM A-276 p Alloy 20, ASTM A-473
N 416 Stainless Sleel, ASTM A-582 a Monel, ASTM B-164
H 316 Stainless Sleel, ASTM A-351 Gr. CFSM y Oudile Iron, Hala,. coated
I . Ductile Iron NI Coated, ASTM A-536 w Ductile Iron, Kynar-coated DISCS Class 65-45·12 or ASTM A395 R Ductile Iron, Rilsan .. (Nylon ·11) coaled
K Bronze, ASTM B-62 3 DuctUe Iron, Buna~N encapsulated (59G only} a Monel, ASTM A-494 Grade M35-1 6 Ductile Iron, EPDM encapsulaled (59G only)
3 Buna-N, ASTM D-2000 MZBF 717 B14 B34 7 Telfon·, Buna base
E014 E034 8 Black Neoprene (food grade), ASTM D-2000 M3BC
SEATS 4 Vlton•, ASTM D-2000 M4HK 707 710 A14 E104 E034
5 Hypalon•, ASTM D-2000 MZCE 717 A16 B15 9 White Neoprene (food grade), ASTM D-2000
6 EPDM, ASTM D-2000 MZCA 714 A25 B44 M5BC 714 B14 E014 G21/FDA TIiie 21, ~,n.2600
EA14 S17 E Epoxy coating on 59G body (repeat code)
0 Without operator 5 Gear Operator
1 10 position handle 6 Electric Operator
OPERATORS 2 1 O position handle with memory 7 Hydraulic Operator
3 Infinite position handle 8 Pneumatic Operator
4 Infinite position handle with memory 9 Other Operator (Chain wheel, extension, etc.)
*DuPont trademark •• Elf Aquitaine trademark I' 12
The flow characteristic of a valve is described
as its C, value. C, is defined as the maximum
flow of 60' F water expressed in GPM (Gallons
~Per Minute) which produces a 1PSI drop
across the valve.
Formula for fluids
C =Q' 1G , Vt"f,
Q=FlowGPM
DP=Pressure Drop in PSI
G=Specific Gravity
To size a valve:
For "On/Off' service: use C, data 30' to 60'
disc opening value for C, table.
Valve sizing for throttling, follow these steps.
1. Flow required in the system (Q).
Maximum allowable pressure drop (P).
Specific Gravity of pipe line medium
(G).
2. Calculate C, using above formula.
3. Determine valve size and degree disc
must be open from C, table.
4. Make sure that maximum line velocity
does not exceed the recommended
maximum valve velocity, i.e., LIQUIDS:
20ft/second. GASES: 15,000 ft/min
V= Q x .321 (liquid only)
A
A=area of pipe in square inches
Example: Throttling Service
Given: Q=5,000 GPM (flow)
DP=1.75 PSI (pressure drop)
G=.750 (specific gravity/gasoline)
.1. c,= a~ =sooovP-;~ =3273
2.
3.
From C, table: 12" valve has c, range
825-3450, 30' -60' open disc.
Velocity=V= Q x ,321 =
A
sooo x .321 =14 2ft/sec 113.1 .
which is within the limits, so for the given
conditions a 12" valve should be used.
• ' ' '
Maximum Flow valve full open
1• no,· 3• .. •· •· •• 11• 12• 11• 11• 1r tr u . ' ,
I I \ I ; I II :1 I
I /', : I I I /' ' ! 1 1 J I 1 ; 7 / / /1./1 : ,
1 o ,,11, ..... Z 1, 1,111-.-.
Flow Rate GPM
Sizes
2
Cv Values 1 · -• • . ' I , . , . • ,
130 87 60 43 25 14 6
2-1/2 190 127 87 63 36 21 9
3 360 241 166 119 68 39 18
4 650 435 300 214 123 71 32
5 1,400 938 644 462 266 154 70
1,900 1,273 875 627 361 209 95
8 3,300 2,200 1,518 1.089 627 363 165
10 5,000 3,350 2.300 1.650 950 550 250
12 7,500 5,025 3,450 2475 1,425 825 375
14 9,500 6,365 4,370 3,135 1,800 1,050 475
16 13,400 8,978 6,165 4,420 2,550 1,475 670
18 17,200 11,500 7,910 5,676 3,270 1,892 860
20 21,300 14,270 9,800 7,030 4,050 2350 1,065
24 30,000 20,100 13,800 9,900 5.700 3,300 1,500
I I / / / -FULL 72• 60' 50' 40• 30° 20·
OPEN
!
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13
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ii ,,,
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1·
;lfilB::2~~~st~:altsa.~r.t~Jlat~~
Number Description Quantity
1 Body 1
2 Seat 1
3 Disc 1
4 Stem {upper) 1
5 Siem (lower) 1
6 Bushing 1
7 0-ring (upper) 1
6 O-ring (lower) 1
9 Self-locking screw 1
10 Q-.ring (seat) 2
11 Stem screw 1 •• ..... .,
, __ if!:lfsi!!_;r,;,;
Number Description Quantity
1 Body 1
2 Seat 1
3 Oise 1
4 Stem (upper) 1
5 Stem (lower) 1
6 Bushing 1
7 0-ring (upper) 1
8 0-ring (lower) 1
9 Seit-locking screw 1
10 Stem screw 1
14"-24"
t!, a,,.,,,,
;/ with Chain Wheel ..
Gear Operator with
Position Indicating Flag
Safety Lock
14 Extended Neck
© .. -
"' © 0 Y-
. ..2.. '-.... . ( -=---_'/.:.'I' © .
• ..,. © .:::.:' Q~
l. c--.____ 0
1 _.*
2/. -~-)___---------~--✓ /' •
© . :::
2"-12"
~11.!\!tit4ti.~·!Ylt~~~l\1{S~~~~(,-~itSll'il
OPERATORS
3-Way Diverter Assemblies
. 1 O Position Handle > a:
10 Position Handle
with Memory
Infinite Position
Handle
is
Infinite Position Handle
with Memory
Number Description Quantity
1 Body 1
2 Seat 1
3 Oise 1
4 Stem (upper) 1
5 Bushing 3
6 Disc pin 2
8 Welch pin 4
Pneumatic Actuator
Electric Actuator
tt Gear Operator
ORDERING INFORMATION
•, EXAMPLE: 20·2-59G-EN6°E•O
~ 20 ea. 2" grooved end Model 59G, D.I. epoxy coated body, 416 SS stem,
D.I. EPDM coated disc, D.I. epoxy (repeat body), no operator. QUANTITY___j I 66M Full lug, dual durometer seal, 2•-12• SJZE: 2• -36"
65M Wafer, dual durometer seat 2"-12" (declma!s)
2l2· Z ·llal.l· E ti § • E · Q
59G Grooved end 2•-12· .
55 Flanged, phenollc backed seat 14'-18" MODEL 56 Full lug, soft seat 2"·12"
NUMBER 55 Wafer, soft seat 2"·12'
53 Semi-lug, phenolic backed seat 2•-12•
52M Full lug, phenollc backed seat 14'-36"
52 Full lug, phenolic backed seat 2'-12"
51M Wafer, pheno/Jc backed seat 14'-24"
51 Wafer, phenoUc backed seat 2"-12" I
' . A,.Available. NAt1NOt Available 51 51M 52 52M 53 55 56 56 59G 65M 66M SO:Spec!al Order, Consult Factory I "'·12' 14'-24' 2"-12" 14"-36" I 2"•12' 1-,•.,2• ?"-1"" 14'-PI.' "'·12" I ?'.1?" 2"-1?"
A cast Iron NA A NA A so A A -

-
A A \ C M Metal A so so so so so so --NA NA
BODY D Carbon Steel so so so so A so so A -NA NA
H 316 SS so so so so A so so A -NA NA
I Ductile Iron A so A A so so so --NA NA
E 0.1. Epoxy Coated --

-
---

-

-
A NA NA
H 318S$ A A A A A A A A A NA NA \
STEM N 416 S$ A A A A A A A A so A A
P AUoy20 A A A A A A A A -NA NA Q Monel A so A so A A A A -NA NA
H 316 SS A A A A A A A A -A A
I 0.1. NI Coated A A A A A A A A -A A
K Bronze A A A A A A A A -A A
Q Monet A so A so so A A A -NA NA
DISC COATED
\ 3 0.1. with Buna-N --

-
---

-

-
A NA NA ' 6 DJ. with EPDM --

-
-

-

-
--A NA NA ,
W DJ.With Kyna..-A so A so A -

-

-
-NA NA y 0.1. with Halal"" A so A so A -

-

-
-NA NA
R Allsan••, Nylon 11 A so A so A ---

-
NA NA
3 Btma-N A A A A A A A -

-
A A
4 Vllon* A A A A A so so --NA NA
5 Hypalon* A A A A A -

-

-
-NA NA
6 EPDM A A A A A A A ·A -A A SEAT 7 Teflon· {Buna Base) A so A so A -

-

-
-NA NA
6 Black Neoprene•--A A A A A -

-

-
-NA NA
9 White Neoprene·--A A A A A -

-

-
-NA NA
E Epoxy coating on 59G --

-
-----A NA NA
body forms seat
0 Wllhout operator A A A A A A A A A A A
1 10 position handle*••• A -A -A A A -A A A
2 10 position w/memory•--A -A ·-A A A -A NA NA 3 Infinite pos. handle•-• A -A -A A A -A NA NA
4 Jnflnlla pos. w/memory•-• A -A -A A A -A NA NA OPERATOR 5 Gear Operator A A A A A A A A A A A
6 Electric Actuator A A A A A A A A A NA NA
7 HydrauUc Actuator A A A A A A A A A NA NA
8 PnuemaUc Actuator A A A A A A A A A NA NA
9 Other Operator A A A A A A A A .A NA NA
• duPont trademark
-Elf Aquitaine trademark
-.♦ food grade
r•**Handles not rocommended for sizes larger than 8j
15
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TM
EM PRODUCTS™
PHILLIPS & TEMRO INDUSTRIES
I r·
The 'EMI" Series in-line guard filter is designed
for use in close loop or in-line applications requiring
air and inert gas filtration. This series can be used
in a variety of applications, either upstream or
downstream of positive displacement blowers and
centrifugal compressors operating below 15 psig
and 200' F.
Standard Construction Features
• Available in sizes from 2 inch to 16 inch
• Male NPT inlet and discharge connection sizes
2 inch to 4 inch
• 125/150# ANSI drilled plate flanges for sizes 5
inch to 16 inch
• Full welded carbon steel construction shell
• Available with paper, felt and wire mesh filter
element
• 1/8" NPT pressure tap
• Bolted top cover
lnline Air Filters
Model EM I -Series
•
•
•
•
•
•
•
•
•
•
•
•
•
Please
consult factory
for
information
to
meet
your
requirements.
Gray phenolic resin based fast drying primer
suitable for overcoating with urethanes,
acrylics, epoxies and industrial enamels.
Standard two mil thickness
15 psig pressure and 20· Hg vacuum design
Optional Construction Features
and Accessories
Stainless steel construction
Aluminum construction
Special connections for relief valves and
instrumentation
Oversized flanges
Special finish per specification
Special acoustic and/or filtration design
High temperature design
Air leak tests
ASME code construction
Horizontal or vertical mounting supports
Contact factory for additional features to meet
your requirements
10/98
98BC-2006
EM Products• 5380 Cottonwood Lane, Prior Lake, MN 55372 • [phone] • Fax: [phone] • [e-mail]
Gauges
These gauges are reliable and rugged.
SPECIFICATIONS:
Pressure/Vacuum
CASE -Drawn Steel Finished
in Black Enamel
DIAPHRAGM -Bronze
LENS -Clear Plastic
ACCURACY -2%
WEIGHT -½ lb.
Temperature
CASE-Steel
LENS-Glass
ACCURACY -1%
WEIGHT -¼ lb.
Accessory Part Number Range
Gauoe, Pressure 0-60 IWG (2 PSIG)
Gauge, Pressure 0-160 IWG (6 PSIG)
Gauae, Vacuum 0-60 IWG (4.5 IHGl
Gauae, Vacuum 0-160 IWG (12 IHG)
Reference Connection
Blower Model Inlet Face
ALL 1/.11" NPT 21/,c" Dia.
ALL 1/-4" NPT 21/,,. Dia.
ALL 1/"" NPT 2v .. " Dia.
ALL 1/," NPT 21/•" Dia.
-----111111!1! .. .. (8111:
' I
'
1/4 NPT I
' I __[2
4" NPT
36
1" NPT
j 4
4
1" NPT HALF COUPLING
19 1/ 4
WITH BASKET INSERT & 8x6 FLANGE LID
-,,. , ... , -•.Jlll!I' '.11!1111' -~ ---PORTS:
(7) 1· HALF COUPLINGS
(2) s· FLANGE
(1) 4• FLANGE
(1) 4• NPT
(1) 1/ 4' HALF C_OUPLING
24
D
8" -FLANGE
3/8 THICK
4• -FLANGE
8" -FLANGE
3/8 THICK
24
----.,. , , ~---rt-~'
__[4
/
-r 1" NPT
12 36
8
4J
~+=+=====1-~•o~e•~NS~ON!p.s~-~15::!-0~o J,E,GASHO & Assoc,, Inc. I-460 W. GA.Y ST.
WEST CH[STER. PENNSYl.VANtA. 19J80
OlWDISIONS IN INCHES GX-120 EEE====l-==t::=~ MOISTURE SEPARATOR
REV. D,t.TE DESCRIPTION SHEET 1 OF 1 2000-C - 1 20G
I BULLETIN E-20
,~,__F_11._0_1e_c_i_~_M_o_o_e_L_L_-6_FL_o_t.._J" __ s_w_1_rc_H _______ _
I,, -. installation and Operating Instructions
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VETTED MATERIALS CHART
Model Brass Bronze Ceramic Polypropylene 3D1SS 303SS 304SS
B.S-3-A X X X X
B.S-3-B X X X X X
B-S-3-C X X X X
B.S-3-H X X X X X
B.S-3-0 X X X X
S.S-3-A X X X X
S.S-3-C X X X X
S-S-3-1. X X X X
S-S-3-0 X X X X
S.S-3-S X X X X
INSTALLATION: .
Unpack switch and remove any packing material found Inside lower
housing or float chamber.
Switch must be installed with body In a horizontal plane and arrow on
side pointing down.
If switch has an external float chamber (tee), connect it to vertical sec•
lions of 1" NPT pipe Installed outside vessel walls at appropriate levels.
If unit has no external float chamber, It must be mounted In a 1" NPT
half coupling welded to the vessel wall. The coupling must extend
through the wall.
Inspect and clean wetted parts at regular Intervals.
ELECTRICAL CONNECTIONS:
Connect win, leads in accordance with local electrical codes and switch
action required. N.O. contacts will close and N.C. contacts will open when
uld level causes float to rise. They will return to "normal" condition
., decreasing liquid level. Black = common, Blue = N.O. and Red
= N.C.
For units supplied with both Internal and external grounds, the ground
screw Inside the housing must be used to ground the control. The
Explosion-Proof; U.L. and C.S.A. Listed -
Class I, Groups *A, 8, C & D
Class II, Groups E, F & G
CENELEC: EExd IIC T6 (T amb=75°C)
•(Group A, stainless steel body only)
PHYSICAL DATA
Temperature Limit: 220°F (105oC) maximum
Maximum Pressure: See chart below
Switches: One or two SPOT snap switches
Electrfcal Rating: U.L.: 5A @ 125/250 VAC.
C.S.A. and CENELEC: 5A @ 125/250 VAC, 5A resistive,
3A inductive @ 30 voe. .
Optional ratings: MV opHon--Gold contacts for dry circuits.
Rated 0.1A@ 125 VAC MT option: 400'F
(205oC) 5A @ 125/250 VAC (not listed).
Wiring Connections: 3-18" (460mm) wire leads, 18 ga.
CENELEC models only: push-in type terminal blocks
Black = common, blue = N.O., red = N.C. ·
Minimum Specific Gravity:
Polypropylene float -0.9
Round SS float • 0.7
Cylindrical SS float • 0.5
Switch Body: Brass 3/4" NPT conduit connection.
For SS switch body, change model no. to LBEPS.
Piping/Mounting Connection: 1" NPT
Jnstalletlon: Horizontal, index arrow pointing down.
Weight: 1 lb. (.5 KG); w/external chamber 1-3/4 lb. (.8 KG)
MAXIMUM PRESSURE CHART
Model Number Float Pressure Rating
PSJG (KG/CM')
LSEPB-B.S-3-A Cylindrical SS 200 (14)
L6EPB-B.S-3-B Polypropylene 250 (18)
L6EPB-B.S-3-C Round SS 350 (25)
L6EPB-B.S-3-H Round SS 250 (18)
LSEPB·B.S-3-0 Polypropylene 1000 (70)
L6EPB.S.S-3-A Cylindrical SS 200 (14)
LSEPB.S.S-3-C Round SS 350 (25)
L6EPB.S.S-3-L Round SS 350 (25)
LBEPB-S.S-3-0 Polypropylene 2000 (140)
LBEPB.S.S-3-S Polypropylene 2000 (140)
external ground screw is tor supplementary bonding when allowed or
required by local code. Some CSA listed models are furnished with a
separate green ground wire. Such units must be equipped with a junc-
tion box, not supplied but available on special order.
CENELEC certified models Include a junction box. Cable should enter
enclosure through an approved EX cable gland, not supplied. Push strip•
ped and tinned leads Into appropriate openings In terminal block(s).
To connect fine stranded leads or to remove any wire, depress spring
release with small screwdriver first.
All wiring, conduit and enclosures must meet applicable codes for
hazardous areas. Conduits and enclosures must be properly sealed.
For outdoor or other locations where temperatures vary widely, precau-
tions should be taken to prevent condensation inside switch or enclosure.
Electrical components must be kept dry at all times. CAUTION: To pre•
vent ignition of hazardous atmospheres, disconnect the device from
the supply circuit before opening. Keep assembly lightly closed when
In use.
Dimensions on reverse
F11..o&!ecTN MODEL l-6 FLOAT SWiTCH -DIMENSION DRAWINGS I
, ..
(l!A}OIA. Fl.00'
1 NPTM
3,14," • 314 NPTM CONOUrT CONNECTlON
CUl1J :;:;---1------~------i
Polypropylene Float
t=: -~~_-J __ --t_r_._;,_'"_"_"™_CO_~ CONNECOON
Cyllndrlcal Stainless Steel Float
1" DIA. .... ,
-------i~i----... ----~•12" __ __
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_j 1-. .... ,. NPTM CONDUIT CONNECTION I ., =---.,, ... 1,..,.._•_._,, ____ ~-----,... ~OIA. :
.. Round Stainless Steel Float
1 ..... -1_;,__-:--.1---:-=-.1 I i--1 il-W!lloll I J(7UI, I :1-UI,.., I J(JUI ,... r,..., ,.,..~ •"'21'•al.ll 3-11111'."1 ~11:m.11 _j
HI i 11111 1=
1f, ,,
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314 NPTM CONDUIT CONNECTION ,. ... ,DIA.,,
With External Float Chamber (Tee) R·~ I ,,
-
3-11132"
-~ T sL-..... ~=:::::c,,j.._.t
I
CSA, CENELEC Conduit Enclosure
I
Umltad Wmntnty: The Seller warrants all Dwyer lnstrumenl:II and equipment to be free from defects In wortcmenshlp or material undat nonnal use and service for a period of one year frcm d818 ol shipment. ,
UabUUy under thla warranty !s llmlted to repair or replacement FO.a lacUJty of any pa.rm which prove to be detttcifve within that time or repayment ot the purct,au price at the Seller's opinion pmvided 1•
the Instruments have been returned, transportation~. within one year trom lhe date of putehaae. Ail technical advice. recommendallons and s8MCN are basad on technical data and Information
which the Seller bellews to be reliable and are Intended for uae by per.sons having aklll and knawledgi,-ot the buslneas, Bl their own dlacredon. In no case Is Seller !labia beyond replacement of equipment •
FD.a !actDry or the luU purchase prtco. Thia warrantydoea not apply tr 11'1• maximum ratings lamN Is remcwd or lf11'1a Instrument or aq~pment IS abused, altered, used at radng:i ab!M lhe maximum apecffled, ,,\
or ottierwlee mlaused In any way.
THIS E<PAESS UMrTED 'NAAAANTY IS IN LIEU OF ANO e>a::WOES ALL OTHER REPRESENTR'JONS MACE BY ADVERTISEMENTS OR BV AGENTS AND ALL OTHER WARRANTIES. Son-t EXPRESS ·,
AND IMPLIED. THERE ARE NO IMPLIED 'MRRANTIES OF MERCHANTABILITY OR OF FITNESS-FOR A PARTICULAR PURPOSE FOR GOODS COVERED HEREUNDER. .
Buyam RamedleS: THE BUYER'S EXCLUSIVE AND SOLE REMECY ON ACCOUNT OF OR IN RESPECT10 THE FURNISHING OF NONCONFORMtNG OR OEFECTlVE M.IUEAlAl. SHALL BE10 SECURE I
REPLACEMENT THEREOF AS AFORESAJn THE SELLER SHALL NOf IN ANY EVENT BE UABLE FOR THE cosr OF ANY LABOR EXPENDED ON ANY SUCH MPJ"ERIAL OR FOR ANY SPECIAL
DIRECT, lNOJRECT OR CONSEQUENTIAL DAMAGES lO AN'tONE BY REASON OF 11-!E FACT" TI-tM IT SHALL HAVE BEEN NON-CONFORMING OR OEFECTTVE. ,
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cMASTER-cARR
SUPPLY COMPANY
NEW BRUNSWICK, NEW JERSEY
Temperature . "l'transmitter Assemblies .
Our transmitter assemblies
produce a 4-20 mA output di-.
rectty proportional to the tem-
perature. Use with controllers,
Spring Loaded Sheath panel meters, and recorders.
Compresses 1/2-Each has a 1 OOfl platinum
RTD sensor mounted in a ¼"
OD spring-loaded Type 316 stainless steel sheath with a Type 316
stainless steel NPT male hex nipple fitting. Transmitter fits inside the
cast aluminum head (cover is removable). Accuracy is ±0.1 %. Operate
on 13 to 40 voe. Process connection is½' NPT male.
iittl•m/4Jl Please specify temperature range from chart below.
Available Ranges
o• to +100° F
0° to +200° F a• to +300° F
0° to +400° F
Insertion
Length · Each
6" ..................................... 40705K4 .... $198.55
9• ..................................... 407051<5 .... 198.55
12" ..................................... 40705K6 .,.. 198.55
RTD
WH
+ INDICATOR -
OONTRot.L.EiR .
OCPOWE1' __
SUPPLY I
1.080"
EXAMPLE ORDER NUMBER: '
ORDER
CODE DESCRIPTION
1 Non Programable, Linearized
Non Isolated, .1 % Accuracy
ORDER
CODE RTD
85• 100 Ohm PlaUnum .00385
91 100 Ohm Platinum .00392
RANGE TEMPERATURE RANGE CODE RANGE CODE
1110 -10010 100° ForC 3065.
1380 -SOio so• ForC 3116
1725 a to so• Fo,C 3200
1750 Oto 100° ForC 3208
1n5 Oto 150° ForC 3213
1800 0 to 200° Fo,C 3218
1826 0 to 250'" F.,,.c 3224
-1850 Oto 300° ForC 3505
1875 Oto 350° ForC 3515
1900 Oto 400' ForC 3520
1925 Oto 450° ForC 3668
1950 Oto 500° ForC 3573
2000 0 to 600° ForC
2100 Oto 800° F orC
2200 0 lo 1000° ForC
+ _L
-
TEMPERATURE RANGE
20 to 120° Foi-C
30-to 2ao0 Fo,C.
50 to 100• Fa..C
50 to 150'" F"' C so to 200' Fa..C
50 to 2!i0° ForC
50 to 300'" Fo,C
100 to 200• Fo,C
100 to 300" Fo,C
100 to 400° C
. Cop,y,rlghlD1IMIS. Pyrun,aflon, Ina.
( \ I
!1.01 5"
11_ .140"
2.20"MAX
ORDER
CODE DESCRIPTION
OD UpscaleBumout-4-20mAOutput
01 DownscaleBumout-4-20mAOutput
ORDER
CODE DESCRIPTION
F Degrees F
C Degrees C
. JNTEGRALLVMOONTEQ\!llhBIQASSEMBLYMQl2fil.
Tc order as an Integral part of an.RT□ assembly use the catalog RTO assemblynumberfollowed by suffix T' and
theordertngcodenumberabove.
R1T185L48063 -00 • 33 -T (401 -185 -1825F -01)
RTO Assembly! I Transmitter !Vlocfel
.......... ,._ P~MATION®, INC.
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Fisher Controls
[ FISHER'] .
).~t-.r~.
Introduction ·
Scope of Manual
This Instruction .manual provides Installation, mainte-
nance, and parts ordering Information tor the 289 Series
relief valves. Instructions for other equipment used with
these relief valves can be found In separate Instruction
manuals.
Description
The 289 Serles pressure relief valves (see figure 1) are
throttling relief valves used downstream of pressure
regulators to protect the downstream system from over-
pressure. These relief valves can be used tor natural
gas, air, propane, or other noncorrosive, gas-flow
service.
Specifications
Specifications tor the 289 Series relief valves are given
In table 1.
Installation
WARNING•· ..
fnstalllng a 289 Serles rellef valve where Its
capabilities can be exceeded or where
proper operation might be Impaired may
cause personal Injury, property damage, or
leakage due to bursting of. pressure-con-
taining parts or explosion of accumulated
gas. To avoid such conditions, Install a 289
Series relief valve where:
• Service conditions are within the unit
capabllltles specified In tables 1 and 2, and
CIFlahar Contml!l lntmnatlonat me._ 1Anl 1mm, An Al..-i:, _____ ..,
289 Series
Instruction Manual
289 Series Relief Valves
August 1990 Form 1724
TYPE 2B9L RELIEF VALVE
TYPE 2B9H RELIEF VALVE
Figure 1. Typical 289 Serles Rel/of Valves
• The reffef valve Is protected from expo-
sure to physical damage and/or corrosive
substances.
1. When Installing a · 289 Series relief valve, make sure
that the Installation of the system compiles with applica-
ble local, state, or federal codes or regulat19ns.
2. Use qualified personnel when Installing,. operating,
and maintaining a 289 Series relief valve. Before Instal-
lation, make sure there Is no damage to or foreign
material in the relief valve and that all piping Is clean and
unobstructed.
3. For Installation of Type 289H, 289HH, and 289L relief
valves, the vent In the spring case must remain plugged
or undrilled In • order for the pilot tube to function
properly.
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289 Series [ FISHER")
Tabla 1. Spec/flcatJons
Available Configurations
See table 2
Body Sizes and End Connection Styles
Type 289L: ■ 3/4 or ■ 1 In. NPT screwed
Types 289A and 289U: 1 /4 In. NPT screwed
Type 289H: ■ 1 or ■ 2 In. NPT screwed ·
Type 289H~: 1 In. NPT screwed
Maximum Allowable Relief (Inlet) Pressure and
· Relief Pressure Set Ranges .
See table 2
Material Temperature Capabllltles
With Nltrile and Neoprene Elastomers: -20 to
150°F ( -29 to 66°C)
With Fluoroelastomeri•~ 20 to 300°F ( -.7 to
149°C); available with Types 289H and 289HH
only
1. Bubble-tight ahutoff can not be attained at settings below !I palg (.34 bar) with
nuornelaatomer 0-tlng seat.
4. The 2B9 Serles relief valves may be Installed In any
orientation. However, If Installing the relief valve at an
outside location, adequate protection, such as ralncaps
or elbow piping (see figure 2), must be attached to the
outlet to keep the relief valve from getting plugged or
from collecting moisture, corrosive chemicals, or other
foreign materials. If piping Is to be attached to the valve
outlet, the following parts (If they are connected to the
valve outlet as shown In figures 4 through 8) must first
be removed: the screen (key 9), the snap ring (key 13),
and the gasket (key 15). A typical Installation of a 2B9
Serles relief valve Is shown In figure 2.
WARNING
If using a 289 Serles relief valve on hazard•
· ous or flammable gas service, personal In-
jury and property damage could occur due
to fire or explosion of vented gas that may
have acumulated. To prevent such Injury or
. damage, provide piping or tubing to vent
the gas to a safe, well-ventilated area. Also,
when venting a hazardous gas, the piping
or tubing should be located far enough
away from any bulldlngs or windows so to
not create a further hazard, and the vent
opening should be protected against any-
thing that could clog It.
5. Apply pipe compound to the male pipeline threads
only; do not apply pipe compound to the Internal body
threads. Then Install the relief valve so that the flow
through it will match the direction arrow or marking cast
on the valve body.
2
Pressure Setting Adlustment
Adjusting screw
Pressure Registration
Internal
Approximate Weight, LS (kg)
Types 289A and 289U: 0. 75 (0.3)
Type 289H:
1 In. Size: 4 (1.8)
2 IN. Size: 1.5 (0.7)
Type 289HH: 4 (1.8)
Type 289L: 1.5 (0.7)
Addltlonal Speciflcatlona
For construction materials, see parts list
...... _,
r.,.51
PROTECT VENT PIP! --"""J ! WlTH RAJN CAP __..-: 1
Figure 2. Typ/caJ /nsta/lat/on
' '
289 SERIES
REUEP VALVE
Startup
Key numbers are shown In figures 4 through 8 .
With proper lnstallatlon completed and system equip-
ment properly adjusted, close any vent valves, and
slowly open the upstream shutoff valve while using
pressure gauges to monitor pressure.
Note
To ensure proper operation al the pltot
tube, ii present, the spring case (key 2)
must be tightly sealed. It Is recommended
that the gasket (key 15) l!e replaced when-
ever the closing cap (key 14) Is removed.
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Errata Sheet
for
289 Series Relief Valves
Form1724,August1990
289 Series Relief Valves
Septe"mber 1994
When Installing the molded diaphragm in the 289 Series Relief Valves, make sure the diaphragm convolution is installed In the down position as shown In flgure1.
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Rgurs 1. Installation of Diaphragm
~ Contra■ lnlarnatlonaf. Inc. 191M; Al Rlghb Aeaerved
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INSTALL DIAPHRAGM
CONVOLUTION DOWN
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Table 2. Maximum Allowable Rella( (Inlet) Pressure
AVAILABLI! BODY SIZE,_ SPRING PART COLOR CON FIGURA TJON INCH NUMBER CODE
288A 1/4 020583 27022
1 B2882 27022 Silver
1 F8269 27052 Pink
1 108923 27022 Red
107515 27022 Sliver
289H 107455 27142 Green
1 B5385 27052 · Dark blue
2 1 B5388 27052 Gray
1 B5388 27052 Dark green
185389 27052 Red S1ripe
289HH 1 1D7455 27142 Green
1 B4135 27222 Sliver
289L 3/4 or 1 1N3112 X0012 Stafnless steel
13A7917 X012 Sliver
13A7918 X012 Sliver
289U 1/4 OV0602 27022 Sliver
OF0582 27022 SIiver
1. Thie value lndlcatn lhe rellet prusura setting ptua pressure buildup.
Antlselzing sealant should be applied to
the adjusting screw (key 6) threads on valves without closing caps.
If set pressure adjustment Is necessary, monitor the Inlet pressure with a gauge during the adjustment proce-dure. Remove the closing cap (key 14), or loosen the hex nut (key 11), and turn the adjusting screw (key 6) clock-wise to Increase or counterclockwise to decrease the relief pressure setting.
For 2-lnch Type 289H relief valves, when changing from one spring range to another, It Is recommended that a new spring case be used so that the travel stop drive screw will be positioned correctly for the corresponding
spring range. Each spring range requires that the travel stop drive screw be positioned appropriately In the spring case to prevent setting the relief valve pressure too high. The location of the travel stop drive screw for each s prl ng and spring range Is shown In figure 3.
Shutdown
Close the upstream shutoff valve, and release all pres-sure from the relief valve.
Maintenance
Relief valve parts are subject to normal wear and should be Inspected periodically for maintenance. The frequen-
cy of inspection and replacement of parts depends upon the severity of service conditions.
289 Series
MAXIMUM ALLOWABLE SPRING RANGE Rl!LJEF (INLET} (RELIEF PRESSURE PRESSURE(11 SETTINGS) Pala Bar
3 Jo 13 pslg 0.2 Io 0.9 bar 45 3.1 11 Jo 22 psla 0.8 Io 1.5 bar
1 Jo 4.5 pslg 69 Jo 310 mbar
4 Jo 15 pslg 0.3 Jo 1.0 bar 100 8.9 10 Jo 20 pslg 0.7 Jo 1.4 bar
15 Jo 50 pslg 1.0 Io 3.4 bar
7 lo 18 Inch WC 17 to 45 mbar
0.5 to 2.25 pslg 35 Jo 155 mbar 25 1.7 1.75 to 7 pslg 121 Jo 483 mbar
4 Jo 10 pslg 0.3. to 0.7 bar
45 to 75 pslg 3.1 to 5.2 bar 100 8.9
3 to 8 Inch WC 7 to 20 mbar
5 to 18 Inch wc 12 to 45 mbar 7 0.5 10 to 18 Inch wc 25 to 45 mbar
12 to 40 Inch WC 30 to 100 mbar
5 to 25 Inch WC 12 to 82 mbar 10 0.7 20 Inch we to 3 pslg 50 to 208 mbar
SPRING SPRING RANGE DIMENSION A
PART NUMBER
1 B5385 27052
1 B5366 27052
1 85368 27052
185389 27052
(RELIEF PRESSURE SETTING) Inch mm
7 to 18 Inch WC
0.5 to 2.25 pslg
1.75 to 7 pslg
4 to 10 pslg
17 to 45 mber Drive screw
not required
36 to 155 mbar 1-17/32 ; 39
121 to 483 mbar 2-5/32 55
0.3 to 0.7 bar 2-5/16 59
TYPB 289H SPAlNQ CASE
I.
Figure 3. Location of Travel Stop Drive SCl8w for 2-/nch, Type 289H Relief Valve
This section contains Information for Inspection and maintenance of 289 Serles relief valves. Maintenance
procedures are presented for relief valve conflguratlons of similar .construction. Refer to the appropriate proce-dure and figure for the particular relief valve configura-tion .when changing the control spring to one of a
different range or when Inspecting, cleaning, or replac-ing any other relief valve parts. The screen (key 9, figures 4 through 7) and vent piping, if present, should be free of foreign material that might Impair relief flow.
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289 Serles
Note
The rellef valve body (key 1, figures 4
through 8) may remain In the plpellne during
maintenance unless replacement of the
valve body Is necessary.
WARNING.
Avoid personal Injury or property damage
from sudden release of pressure or explo·
slon of accumulated gas. Before starting
disassembly:
• Isolate the reUef valve from llne pres-
sure, and
• Release trapped pressure from the
valve body and pressure llne.
Type 289A Relief Valves
All key numbers are shown In figure 4.
1. Loosen the hex nut (key 11 ), and unscrew the ad)ust-
lng screw (key 6) to relieve spring compression.
2. Unscrew the machine screws (key 8), and remove the
spring case (key 2), the spring seat (key 4), the spring
(key 7), the diaphragm head (key 3) and the diaphragm
(key 5).
3. Inspect the diaphragm and seating surfaces for dam-.
age or wear, and replace parts as necessary. To remove
the orifice (key 10) unscrew It from the body.
4. Reinstall the orifice, the diaphragm, the diaphragm
head, the spring, and the spring seat.
5. Reattach the spring case using the machine screws.
6. If a new spring with a different range Is Installed,
stamp the spring case with the new spring range.
7. Ad)ust the spring compression according to the pro-
cedures outlined In the Startup section.
Type 289U Relief Valves
All key numbers are shown In figure 5.
1. Loosen the hex nut (key 11 ), and unscrew the ad)ust-
lng screw (key 6) to relieve spring compression .
2. Unscrew the machine screws (key 8), and remove the
spring case (key 2), the spring seat (key 4), the spring
(key 7), and the diaphragm assembly (key 5).
4
( FISHER"}
3. Inspect the diaphragm assembly and seating sur-
faces for damage or we~r, and replace parts as
necessary.
4. Reinstall the diaphragm assembly, the spring, and
the spring seat.
5. Reattach the spring case using the machine screws.
6. If a new spring with a different' range Is Installed,
stamp the spring case. with the new spring range.
7. Ad)ust the spring compression according to the pro-
cedures outlined In the Startup section.
Type 289L Relief Valves
All key numbers are shown In figure 6.
1. Remove the closing cap (key 14) and the gasket (key
15), and then unscrew the .ad)ustlng screw (key 6) to
relieve spring compres!\ron.
2. Unscrew the machine screws (key 8), and then re-
move the spring case (key 2), the spring (key 7), and the
diaphragm assembly (key 5).
3. Inspect the diaphragm and seating surfaces for dam-
age or wear, and replace parts as necessary. To remove
the orifice (key 1 OJ, unscrew It from the body. Check the
pltot tube In the diaphragm assembly for blockage, and
remove any foreign material that might Impair proper
operation of the relief valve.
4. Reinstall the orifice, the diaphragm assembly, and
· the spring.
5. Reattach the spring case using the machine screws.
6. If a new spring with a different range Is Installed,
stamp the closing cap with the new spring range.
7. Ad)ust the spring compression accon;flng to the pro-
cedures outlined In the Startup section, and then rein-
stall the closing cap and gasket.
Type 289HH and 1-lnch Type 289H
Relief Valves ·
All key numbers are shown In figure 7.
1. Loosen the hex nut (key 11 ), and then unscrew the
adjusting scr,ew (key 6) to relieve spring compression.
2. Unscrew the machine screws (key 8), and remove the
spring case (key 2), the spring seat (key 4), and the
spring (key 7).
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3. Unscrew the hex nut (key 24), and remove the lower
spring seat (key 17), the diaphragm head (key 3), and the
diaphragm (key 5).
4. Unscrew the machine screws (key 29), and then
remove the stem guide assembly (key 31 J and attached
parts from the valve body (key 1 ).
5. Slide the spacer (key 23) and the pitot tube (key 18)
and attached parts from the valve body.
6. Remove. the washer (key 27), the gasket (key 19), the
spacer, the O-rings (key 30), the O-rlng holder (key 21),
the O-ring (key 20), and the O-rlng washer (key 22) from
the pltot tube.
7. Inspect the O-rlngs, the gaskets, the spacer, the
orifice, and the seating surfaces ·for damage or wear,
and replace parts as necessary.
8. Apply antlselzlng sealant to the adjusting screw
threads, and to the end of the adjusting screw that
contacts the spring seat.
9. Slide the O-rlng washer, the O-rlngs (keys 30 and 20),
the O-rlng holder, the 0-rlng (key 30), the spacer, the
stem guide assembly, the gasket, and the washer (key
27) onto the pltot tube.
10. Reinstall the stem guide assembly with attached
parts Into the valve body,.and then attach this assembly
with the machine screws (key 29).
11. Replace the diaphragm, the diaphragm head, and
the lower spring seat, and then secure these parts with
the hex nut (key 24).
12. Reinstall the spring and the spring seat, and then
attach the spring case to the valve body using the
machine screws (key 8).
13. If a new spring with a different range Is installed,
stamp the spring case with the new spring range.
14 .. Adjust the spring compression according to the
procedures outlined in the Startup sectfon.
2-lnch Type 289H Relief Valves
All key numbers are shown In figure 8.
1 . Remove the closing cap and the gasket (keys 14 and
15), .and then unscrew the adjusting screw (key 6) to
relieve spring compression.
2. Unscrew the machine screw (k_ey 8), and remove the
spring case (key 2), the washer (key 27), and the spring
(key 7).
289 Series
3. Unscrew the hex nut (key 24), unscrew the llftlng
stem (key 25), and then unscrew the hex nut (key 11 ).
4. Remove the lower spring seat (key 17), the dia-
phragm head (key 3), the diaphragm (key 5), the lower
diaphragm head (key 26), and the gasket (key 19).
5. Unscrew the machine screws (key 29), and then
remove the stem guide assembly (key 31) and attached
parts.
6. Slide the spacer (key 23) and the pltot tube (key 18)
and attached parts out of the stem guide assembly.
7. Remove the gaskets (key 19), the spacer (key 23),
and the O-rlng washer (key 22) from the pltot tube, Then
remove the O-rlng washer (key 20) and the orifice (key
1 OJ from the valve body (key 1 ).
8. Inspect the O-rlngs, the gaskets, the spacer, the
orifice, and the seating surfaces for damage or wear,
and replace parts as necessary.
9. Apply antlselzlng sealant to the orifice threads, and
then to the adjusting screw threads.
10. Reinstall the orifice and the O-rlng (key 20) Into the
valve body.
11. Slide the gasket, the O-rlng washer, the gasket, the
spacer, the stem guide assembly, and the gasket onto
the pitot tube.
12. Reinstall the stem guide assembly with attached
parts Into the valve body, and attach It with the machine
screws (key 29).
13. Replace the lower diaphragm head, the diaphragm,
the dlaphrahm head, and the lower spring seat; then
secure these parts with the hex nut (key 11 ). Screw in
the lifting stem, and lock It In place with the hex nut
(key 24).
14. Reinstall .the spring and the washer.
Note.
For 2-lnch Type 289H relief valves, when
changing from one spring range to another,
use a new spring case to position the travel
stop drive screw correctly tor the corre-
sponding spring range. Each spring. range
requires that the travel stop drive screw be
positioned appropriately In the spring case
to prevent setting the relief valve pressure
too high. The location of the travel stop
drive screw tor each spring and spring
range Is shown In figure 3.
5
I' . 289 Serles [ FISHER")
I' , -• Attach the spring case to the valve body using the Key DeacrlpUan Part Number
l:,e. .;hine screws (key 8). 3 Diaphragm Head
Type 289A, zinc OT0227 44022 If a new spring with a different range Is Installed, Type 289H, plated steel stamp the spring case with the new spring range. 1-lnch body 108884 28982
1)7. Adjust the spring compression according to the
2-inch body OW0202 25072
Type 289HH, zinc plated steel 1 P9014 25062
4 Spring Seat _ procedures outlined In the Startup section. Then Install Type 28SA, braes _ _ OT0228 14012 the gasket and the closing cap. Type 289U, zinc tB3725 44022 1, Types 289H 11-lnch body) and 289HH,
Plated steel 108671 25072
Parts Ordering 5• · Diaphragm/Diaphragm Assembly
.'Nhen corresponding with your Fisher sales office or
Type 289A, neoprene 1A5052 02102
Types 289H (1-lnch body) and 289HH
Nltr11e 1 E6066 02052 • ·iales representative about this equipment, always refer-Auoroelastomer 1 E6066 02342 ence the equipment serial number stamped on the Type 289H (2-lnch body)
(tpring case (key 2) or the closing cap (key 14). When Nltrila 107800 02052
.,irderlng replacement parts, spe_clfy the complete 11-Auoroelaatomer 107800 02332
Type 289L • · ·:haracter part number of each required part as found In Nltrilal1> gihe following parts 11st. 3/4 & 1-lnch body, standard AL4088 OOOA2
Fluoroelas10mer<21 (1-lnch body) 1N3130 X0012
Type 289U13J, nltrile 18A281 5X012
8 AdJusUng Screw
rarts List Type 289A, brass 1A5884 14012
Types 289H (1-lnch body) and
289HH, plated steel 109954 48702
-,'8y Type 289H (2-lnch body) zinc 185379 44012 OeacrtpUon Part Number Type 2B9L, Delrlnl•I T10071 06842
I Type 289U, brass OF0581 14012 Parts Kit 0ncluded are keys 5, 9, 15, 19, 7 Spring See table 2 ~~, 20, 30 and 38). Screen Is stainless steel 8 Machine Screw, plated steel
and gaskets are composlUon and neoprene. Typo 289A (6 req"d) 18777 4 28982
I Types 289H end 289HH, 1-lnch body Type 289A Oncludes only keys 5 (B req'd) 1A3917 24052 and 9) Type 289H, 2-lnch body (8 req'd) 1 A4078 24052 Neoprene diaphragm R289A X00012 Type 289L (8 req'd w/o wire seal, ·. i Type 289L.Qnciudes only keys 5, 9, and 15) 7 req'd w/wtre seal) 182856 28962
I Nllrlla diaphragm end CJ.rings Type 289L (1 req'd wfwlre seaQ 1 L9277 28962 3/4-lnch body R289L X00012 Type 269U (8 req'd)_ 1 A3451 28962 1-lnch body R289L X00022
Type 289H (1-lnch body) and 289HH 9 Screen, Stainless steel Nllrlle diaphragm and 0-rlngs R289H X00012 Type 289L
I Fluoroelastomer diaphragm and 0-rfngs R289H X00032 3/4-lnch body 186335 38392
Type 289H, 2-lnch body Oncludes keys 5, 1-lnch body 1E5648 43122 9, 15, 19, 20 end 38) Types 289A end 289U OL0763 43082 i Nltrile diaphragm and 0-rfngs R289H X00022 Types 289H end 289HH, 1-lnch body 1E5848 43122
I Fluoroelastomer diaphragm and 0-rlngs R289H X00042 Type 289H, 2-lnch body 1181994 X012 Type 289U Oncludea only keys 5 end 9) 10 Orifice Nltr11e diaphragm R289U X00012 Type 289A,
Aluminum OT0225 09012
Type 289H (2-lnch body) 11 Valve Body Brass 1E7028 13012 Type 289A, zinc OY0710 44022 Stainless steel 1 E7026 35072 Type 289U, zinc 180438 44012 Type 289L ·
Types 289H (1-lnch body) end 289HH, Aluminum 1 L4084 09012
I Aluminum 3U8882 08012 11 Hex Nut Type 289H (2-lnch body), cast Iron 3181992 X012 Types 289A end 289U, Brass 1A5054' 18992 Type 289L. alumlnum Types 289H (1-inch body) end 289HH, 3/4-lnch body 3L4070 08012 Zinc plated steel 108877 28962 1-lnch body 3L4089 08012 Type 289H (2-lnch body), 12 Spring Case/Spring Csae Assembly Zinc plated steel D7B01 24272 Type 289A, zinc 1 A5051 44022 13 Snap Ring Types 289H (1-inch body) and 289HH, Type 289L. Stainless steel
Aluminum 1P9017 08012 3/4-lnch body 1811336 38992 -Type 289H (2-lnch body), zinc/steel 1 E7020 OOOA2 1-lnch body 1 E5849 37022 Type 289L.; aluminum 3L3338 X0012
Type 289U, zinc 080616 44022
• Recmnmencted spare Plrt.
1. Assembly also lndude• an afumlnum pltot tube and bruahlng, a zinc plated steel
I lJ)rlng ,eat and diaphragm head, and a neoprene aellt ped. 2. Auembly allo lnclUdea an atumfnum pltot tube, buahfng, and diaphragm ftlad. a 302 stalnleq atNI ,=. sut. and a llOOprene uat pad. 3. Asttmbly 1U10 I I a zinc diaphragm had. .
I -4. Ttadem..,_ of E.I, duPont de N8fflOUl'I; Co.
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Figure 4. Type 289A Relief Valve
Figure 5. Type 289U Relief Velve
Key DeacripUon l'1lrt Number
13 Snap Ring (Cont.)
Types 2B9H snd 289HH, 1-lnch body
Plated steel 13A993 BX012
Type 289H, 2-lnch body 1089241. X012
14 Closing cap
Type 2B9H, 2-lnch body, zinc 185418 44012
Type 289L
W/o wire seal, plas11c T10072 06992
W/o wire sem, zJnc 1H9889 X0012 ·
-Recmnrnanded apara part.
289 Series
Figure 6. Type· 289L Relief Valve•
Figure 7. Typical of Type 289HH and 1./nch
Type 289H Relief Valves
Key DescrtpUon Part Number
15" Gasket
Types 289H snd 2B9HH, 1-lnch body
Neoprene 13A9929 X012
Type 289H, 2-lnch body
Neoprene 1 P7533 06992
Type 2B9L
Neoprene 1E1056 08992
16 Nameplate, aluminum
Types 289H and 289HH, 1-lnch body 1F6627 11992
7
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1.!89 Series
Kay Daacrtptlon Part Number
17 Lower Sprtng Seat
Types 289H and 289HH, 1-lnch body
Plated steel 1 □8888 25072
Type. 2B9H, 2-lnch body, zinc plated S18el 1 D7799 250B2
18 Pltot Tube
Types 289H and 289HH, 1-lnch body
Aluminum·
Type 289H, 2-lnch body
Brass
Stalnlesa steel
19• Gasket, composition
Type 289HH, 1-lnch body (1 req'd)
Type 289H, 2-lnch body (3 req'd)
20" 0-Rlng
Type 289H, 1-inch body
Nltrlle
Fluoroelastomer
Type 289H, 2 In. body
Nltrtle
Fluoroelastomer
Type 289HH
Nltrlle
FluorOelastomer
21 0-Rlng Holder, alumlnum
22
23
24
25
28
27
2B
29
30"
Types 289H and 289HH, 1-lnch body
0-Alng Washer
Types 289H and 289HH, 1-lnch body
Aluminum
Types 289H, 2-lnch body, stainless steel
Spacer
Types 289H and 289HH, 1-lnch body
Stainless steel
Type 289H, 2-lnch body
Braas
Stalnlees S18el
Hex Nut, plated S18el
Types 289H and 289HH, 1-lnch body
Type 289H, 2-lnch body
Uftlng Stem, plated S18el
Type 2B9H, 2-lnch body
Lower Diaphragm Head, plated steel
Type 289H, 2-lnch body
Washer, aluminum
Types 289H and 289HH, 1-lnch body
Type 289H, 2-lnch body
Pipe Plug, plated steel
Types 289H and 289HH
Machine Screw, plated steel (noi shown)
Types 289H and 289HH
1-lnch body (2 req'd)
Type 289H, 2-lnch body (4 req'd)
o-Rlng (2 req'd)
Types 289H and 289HH, 1 In. body
Nltrlle
Auoroelastomer
1F8282 09012
1E7019,14012
1E7019 35032
1 F8288 04022
1D7798 04022
1 F8288 08992
1F2692 X0012
1 P3381 06992
1 V8848 08382
1F2892 08992
1 F2692 X0012
1F8284'09012
1F8285 09012
1 E7021 36072
1 F8283 35242
1 E7022 14172
1E7022 35182
1A4997 24122
182282 28982
107802 24092
· 1 E7031 25072
1 F8287 09012
1 C8805 11032
1 D7548 28982
103889 28982
1F3885 28992
1D8875 06992
1 N4304 08382
While this Information is presented In good faith and betleved to be accurate,
Fisher C~trols does not guarantee satisfactory resuUa from reliance upon such
Information. Nothing contained herein is to be. construed ss a warranty or
guanmtee, expl8SS or Implied, reganffng thtl pe,formsnce, merchantability, ntness
[FISHIER"] Fisher Controls
[ FISHER")
Figure 8. 2-inch Type 289H Relief Vslves
Key
31
32
33
Descrlptfon
Stem Guide Assembly
Type 289HH, I-Inch body
Zlnc/brasa
Zlnc/303 stainless steel
Type 289H, 2 In, body
Cast Iron/brass
Cast lron/303 stainless steel
LIiting Lever (not shown)
Type 289H, 2-lnch body
Wire Seel (not shown)
Type 2891.., 1-lnch body
Part Number
1F8272 00OA2
1F9272 X0012
1 E702B 00OA2
1 E7028 X00A2
0R0817 25092 .
1 D8947 99012
34 Diaphragm Protector (not shown)
Types 289A and 289U 10A511 8X012
11B1993 X012 38" Gaska~ Type 289H, 2-lnch body
-..........
or any other matter with respect to the products, nor as a recommendation to
use any product or process in conflict with any patent. Fisher Controts reserves
the right, without notlca, to alter or improve the desigm or speciffcatfons of
the products described herein.
For Information. contact Fisher Controls:
Ma,shalllown, Iowa 50158 USA
~Y 68700 France
Sao Paulo 05424 Bnull
Singapore 2158
0,,i..,..,,j 1 .. , , ...
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Absorptive Type Silencers
TM
EM PRODUCTS™ Model BIU -Series
PHILLIPS & TEMRO INDUSTRIES Straight-Through Absorptive Type Intake/Discharge Silencer
The ·s1u· Series is a premium straight through
absorptive silencer. It is designed with a high length
to diameter ratio for superior noise attenuation.
Characteristics of this silencer are its compact size
and low pressure drop. These features make it a
superb choice for inlets of small high speed positiVe
displacement and centrifugal blowers, or the
discharge of vacuum pumps.
Approved Applications
• Blower inlet
• Air valve discharge
• Low pressure vents
• Any high frequency noise source
Standard Construction Features
• Available in sizes from 2 inch to 14 inch
• Male NPT inlet and discharge connections sizes
2· inch to 4 inch
• Full welded carbon steel .construction
• 125/150# ANSI drilled plate flanges for sizes 5
inch to 14 inch
• High temperature fiberglass pack material
wrapped with 304 SS wire mesh cloth and
encased in a carbon steel perforated facing
• High temperature satin black finish
Optional Construction Features
and Accessories
• Stainless steel construction
• Aluminized steel construction
• Aluminum construction
• Polyester pack material
• Vertical mounting legs
• Round mounting bands
• Horizontal mounting saddles
• Horizontal and vertical shell lugs
• Special finish per specification
• Oversized flanges
• Air leak test
• Contact factory for additional features to meet
your requirements
10/98
988C-3000
I EM Products• 5380 Cottonwood Lane• Prior Lake, MN 55372 • [phone] • Fax: [phone] • [e-mail] .. L__----------------,-----'
' "
--~™ Absorptive Type Silencers
EM PRODUCTS™ Model BIU -Series
PHILLIPS & TEMRO INCUSTRIES
REPRESENTATIVE ATTENUATION CURVE PRESSURE DROP VERSUS SILENCER EXIT
40 VELOCITY AT 14.7 PSIA AND 70° F iii .. 4 :!!. 30 0 z .. -~ .-·:. V-· .. ....._ C 3 ... .. w-J......-i,, 20 .. .. q, 2 . .. :::, .. V .. :::, :,: i---z ... ., -L--~ 10 . ., 1 .. ~ w -.. < .. 0 0
i,l "' SI ~ ~ § § ~ 0 § § ~ ; ; § § ~ ; ; § § ~ ~ ~ ~ "' -"' .. ,.. -~ "' .., -OCTAVE CENTER BAND FREQUENCY (Hz) EXIT VELOCITY (FEET PER MINUTE)
-a• AND SMALLER;·· - -10" AND LARGER
' ~
I
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!
Model No. A B D N G Weight T
! BIU-2 2 6 23 1 5/8 19 3/4 10 1~1
~ BIU-25 2 1/2 N 6 27 1 7/8 23 1/4 12 I "
EilU-3 3 8 1/2 30 ' 2 1/8 25 3/4 19 I
' BIU-35 3 1/2 8 1/2 31 2 5/8 25 3/4 22 I .
' BIU-4 4 9 36 2 1/2 31 26 I
' BIU-5 5 10 48 3 42 60 I
BIU-6 6 10 60 3 54 75 -s-GD
BIU-8 8 14 66 3 60 140 I
' BIU-10 10 16 70 3 64 180 I ,.
BIU-12 12 18 70 3 64 225 I
' BIU-14 14 20 88 3 82 340 r
' I .
' -• N
ORAi~. t
• 2 inch to 4 inch standard with male NPT connections; 4 inch flange connections available upon request
• 5 inch to 1_4 inch standard with 125/150# ANSI drilled plate flange connections; 5 inch male NPT connections
available upon request
Dimensions in inches, weights jn pounds. Dimensions and weights are nominal and may vary slightly with
production models. Request certified drawings for exact dimensions.
. EM Products• 5380 Cottonwood Lane• Prior Lake, MN 55372 • [phone] • Fax: [phone] • [e-mail]
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-------------------32101 Xchanger Inc.
Hopkins, Minnesota
CUSTOMER P.O.: I 11716
IJ.E. GASHO & ASSOCIATES. INC.
MODEL NUMBER:. I M-500 P/N: 32101
SERIAL NUMBER: 0500-86B74
PERFORMANCE AND CONSTRUCTION PER DATA ,SHEET j153584A
QUANTITY OF - 1 -REQUIRED
PROCESS INLET
6 X 150# ANSI PATTERN 1 PROCESS OUTLET
PLATE FLANGE, 3/6" THICK ~· · ~~J5~tA~~t i/~):E~ICK
LI~-< ~I~
2 SQ.
f---217 91/2
i-----1-----40------
(4) 5/6" HOLES
20 ----tt--t-5 1 /2
-1-1----, 21----5 1YP.
-----31 --------~
f'l ..: f'l w De:
. TOl£RANCES , X h
(UNLESS OTHERWISE NOTED) C anger I 1401 SOUTH 7TH ST MODEL AA-"-500 nc • HOPK1Ns, MN 55343 ·HEAT EXCHANGER ASSEMBLY
DECIMAL
± .25
FRACTIONAL . DRAWN BY: MJR
± l/ 4 APPROVED BY: ~:;,....
SCALE: NONE
DATE: 05/15/0D
JOB NUMBER SHEET
86874 1 OF 1
DRAWING NUMBER REV.
32101
I
I
1 Xc.b.anger, Inc. Rating for Model AA-500 ref #53584 Rev. A Pagel of l
I 2
3
4
Enqineer: David Wanqensteen May 10, 2000
l?reoared for: .
J.E. Gasho & Associates, Inc.
5 Jim Gasho Jr.
I 6
7
PH: 610-692-5650, FAX: [phone]
8 Pl!:RPORMANCB PROCBSS MBDIA SIDE SERVICE MEDIA SIDE
I 9
10
11
Fluid Circulated Air Air
Volumetric Flow Rate 500.0 Std. ft"3/min 2,100.8 Std. ft"3/min
Total Fluid Enterina 2,250.0 lbthr 9,453.5 lb/hr
12 Liquid
I 13
14
15
Vaoor
Non·Condensibles 2,250.0 lb/hr 9,453.5 lb/hr I Vaporized or (Cond.)
16 Temnerature In 210.0 •F 90.0 •F
I 17
18
19
Te=erature out 109. 6 •F 113.9 • F Inlet Pressure (Absolute) 15.696 lb/in• l4. 696 lb/in!
Velocitv (Standard) 2,797.7 ft/min l.,209.5 ft/min
20
I 21
22
Pressure Loss 5.9 in. water 0.6 in. water
Fouling Factor 0.00010 ft•-•F-hr/BTU 0.00010 ft•-•F-hr/BTU
Total Heat Exchanged: 54,237 BTU/hr
23
24 I 25
26
AVKRAGB MBDIA PROPIIRTIES
Thermal Conductivitv 0.01692 BTU/hr-ft-•F 0.01559 BTU/hr-ft-•F
Specific Heat 0.24000 BTU/lb-•F 0.23960 BTU/lb-•F '.'27
I '2s
29
30
Viscosity 0.04977 lb/ft-hr 0.04624 lb/ft-hr
Densitv 0.06850 lb/ft"3 0.07073 lb/ft"3
Latent Heat of Vapor
31 CONSTRUCTION
I 32
33
34
Design Tenmerature 250.0 •F Not Annlicable
Design Pressure (Gauge) '90 .0 lb/in• Not Annlicable
Test Pressure (Gauae) 40.0 lb/in• Not Annlicable
35 Cyclic Pressure No Not Annlicable
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37
38
Flow Direction Right Hand Horizontal Vertical nn
Coating None None
39
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41
!?late-Fin Core : Aluminum Exhaust Hood : Galvanized Steel
Fan Guard ' Coated Carbon Steel venturi Frame : Coated Carbon Steel
Drawina Number : Weiaht : 160 .o lb
42
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45
CONJIBCTJ:ONS
Process Inlet : 6 inch 150 lb. ANSI pattern FFF, 3 la" thick . Process Outlet : 6 inch 150 lb. ANSI pattern FFF, 3/8" thick
46 Instrument •· :
I 47
48
49
llll!Cl!ANJ:CAL BQUIPKBNT
Fan Diameter : 18 inch Motor : l.00 HP TEFC
50 Fan Qty/Speed : l / 1725 RPM Matar Qt...,JSneed : l / 1725 RPM
I 51
52
53
Fan TVDe : 4 Blade Painted Steel Motor Electrical: 208-230/460/3/60
ROTES
54
I 55
56
Construction material suitability must be determined bv customer.
The process .flow mu.at be unifonn, smooth and free of pulsation.
This unit is not designed for cyclinq process aas oressure.
57
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59
60
61
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Xchanger, :Inc. Tel: [phone], Fax: (612) 933•5647, Web: www.xchanger.com
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06/19/00 MON 16:55 FA.I 16129335647 !changer Inc
Xchanger,
Certificate of Compliance
Xchanger job: B-6874
Manufactured for: J.E. Gasho & Associates, Inc.
on purchase order: 11716
This is to certify that the following heat exchanger(s) shipped on this order
have been successfully pressure tested as indicated on the data sheet and have
been inspected and found to be in compliance with the purchase order, certified
drawing and our manufacturing procedures. ·
--Quantity
Ordr/Slrip/Back Part No
1 1 0 32101 A
Description
AA-500, Heat Exchanger Asm, Ref #53584A
oa~fffo
1401 South 7th Street Hopkins, MN 55343 phi [phone] tax: [phone] emaili !nfoOxchangor.eom
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APPENDIXD
OVERHEAD COILING DOOR DOCUMENTATION
P:\PRO.J\ 18895\ 18895.014 \O&MAPPcvr.doc
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OWNER'S MANUAL·
'MODELGH
INDUSTRIAL DUTY DOOR OPERATOR
Serial# _______ _
(located on electrical box cover)
Installation Date _____ _
Wiring Type ______ _
NOT FOR RESIDENTIAL USE
4186
c®us
LISTED DOOR OPERATOR
MOTOR
TYPE: ................................. Continuous duty
HORSEPOWER: ................ 1/2, 3/4, 1 & 1-1/2 Hp
Single or Three phase
2 HP Three phase
SPEED: ............................... 1725 RPM
VOLTAGE: ......................... 115, 220,230 Single phase
230, 460, 575 Three phase
CURRENT: ......................... See motor nameplate
MECHANICAL
DRIVE REDUCTION: ............. 40:1 Reduction
Heavy duty bronze ...orm
gear reducer
OUTPUT SHAFT SPEED: ..... 43 R.P.M.
DOOR SPEED: ..................... .4 • 1 O" per sec.
depending on door
BRAKE: ................................. Solenoid actuated disc
brake
HOIST WHEEL: ..................... Standard mounting on
left or right side
WEIGHTS AND DIMENSIONS
. HANGING WEIGHT: ......... 80-110 LBS.
-14.oo·-
-:---0
(II J ~ I ~ ... ~ :el 7 y
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See ·oo
SeeJ -Note #1 ...
Note #2 ' ..
= ~ 0 ·O . ·. e
V'--
ELECTRICAL
TRANSFORMER: ............. 24VAC
CONTROL STATION: ..... NEMA 1 three button station.
OPEN/CLOSE/STOP
WIRING TYPE: ................. C2 (Standard)
Momentary contact to OPEN/CLOSE/STOP plus wiring
for sensing device to reverse and auxiliary devices to
open and close with open override.
(Other types available. See chart, Pg. 8)
LIMIT ADJUST: ................ Linear driven, fully
adjustable screw type cams. Adjustable to 30 feet.
SAFETY
DISCONNECT: ............. Floor level chain hoist with elect-
rical interlock for emergency manual door operation
CLUTCH: (optlonal) .... Adjustable torque limiter type
REVERSING EDGE: ..... (Optional) Electric or pneumatic
sensing device attached to the bottom edge of door.
A REVERSING EDGE IS STRONGLY
RECOMMENDED FOR ALL COMMERCIAL
OPERATOR INSTALLATIONS. REQUIRED WHEN
THE 3 BUTTON CONTROL STATION IS OUT OF
SIGHT OF DOOR OR ANY OTHER CONTROL
(AUTOMATIC OR MANUAL) IS USED.
DIMENSIONS
HP PHASE
A B C D
1/2 1 11-1/2 25-3/4 12-63/64 3
3/4 1 12-1/2 26-3/4 12-63/64 3
1 1 12-3/4 27 12-63/64 3
1-1/2 r· 12-3/4 27 13-63/64 3-1/2
1/2. 3 11 25-1/4 12-63/64 3
3/4 3 11 25-1/4 12-63/64 3
1 3 12 26-1/4 12-63/64 3
1-1/2 3 12-1/2 26-3/4 13-63/64 3-1/2
-t-X-~ "' See 2 3 12-3/4 27 13-63/64 3-1/2
-Note #3
Hand Chain Wheel 3 3 13-1/4 28-5/8 15-15/64 3
HQIJ;;S:
1) Output Shaft with 1" x 1/4" Key for 1/2 thru 2Hp operators, 1-1/4" x 1/4" Key for 3Hp operators.
2) MTG CENTERS: X = 4-3/4"; Y = 5-1/2" for 1/2 thru 2Hp operators
X = 7-17/32"; Y = 9-1/16" for 3Hp operators
3) Hand Chain Wheel extends 1-5/8" beyond operator in vertical mounting position as shown.
2
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TO AVOID DAMAGE TO DOOR AND OPERATOR,
MAKE ALL DOOR LOCKS INOPERATIVE. SECURE
LOCK(S) IN "OPEN" POSITION •.
IF THE DOOR LOCK NEEDS TO REMAIN
FUNCTIONAL, INSTALL AN INTERLOCK SWITCH.
DO NOT CONNECT ELECTRIC POWER UNTIL
INSTRUCTED TO DO SO.
·,
n is imperative that the wall or mounting surface
provide adequate support for the operator.
This surface must: ..
a) Be rigid to prevent play between operator and .
door shaft.
b) Provide a level base.
c) Permit the operator to be fastened securely and
with the drive shaft parallel to the door shaft.
The safety and wear of the operator will be adversely
affected if any of the above requirements are not met.
For metal buildings, fasten 2" x 2" x 3/16" (or larg~r)
angle iron frames to the building purlins. Retain
5-1 /2" between frames. See Figure 1.
KEEP DOOR BALANCED. STICKING OR BINDING
DOORS MUST BE REPAIRED. DOORS, DOOR
SPRINGS, CABLES, PULLEYS, BRACKETS AND
THEIR.HARDWARE MAY BE UNDER EXTREME
TENSION AND CAN CAUSE SERIOUS PERSONAL
INJURY.. CALL A PROFESSIONAL DOOR
SERVICEMAN TO MOVE OR ADJUST DOOR
SPRINGS OR HARDWARE.
Shaft Support Bracket
with Bearing (Not Supplied)
.l'2ll<-1-I--DoorSprocket · · ·
. FIGURE 1
~.tJJ'i•'.',tl ,1x·.•····u•1c.,iJJ?•·1•• •1·[•··•·· ''7<1.Je;E$ATQJ-t'P8EPA(f:$ATION•·"''.:('.•. t·:••····•·····(' .. '."••··,·1~\/ .. •················.; ;.:\':':ll
The GH operator may be mount.ad on either the right (standard} or left side of door, and in either a vertical
(standard)· or horizontal mounting position. Refer to the steps below if you require the hand chain and/or
disconnect chain to be on the opposite side of the operator; Or if the operator is being mounted in a horizontal
position.
Hand Chain Right/Left Conversion
Remove the two snap rings (1 pc. outer, 1 pc inner)
on r.-;ind chain shaft assembly. Position roll-pin to fit
through cutout in frame and slide complete shaft
assembly through housing and bevel gear. Insert
shalt assembly on opposite side of housing, and
replace bevel gear, bearing, hardware, and snap rings
on the opposite side of shaft in the same manner.
Disconnect Lever Right/Left Conversion
Remove cotter pins on the ends of the disconnect
shaft (square shaft), move the disconnect lever arm to
the opposite side, and replace the cotter pins. Be
sure to keep two(2) 12ga. washers on the side without
the lever arm.
Horizontal Mounting Conversion.
Remove cotter pins on the ends of the disconnect
shaft (square shaft), and remove lever. Replace lever
using square hole on opposite end of lever.
Reposition sash chain to opposite end of lever also.
Replace cotterplns.
3
Chain Guide~ -~ -· -· --~ .
Hand
Chain Wheel
t .. -·/ '. .
Cutout for Rollpin t (typical both sides)
Disconnect Lever
Cotterpin
FIGURE2
Before your operator Is Installed, be sure the door has been properly aligned and is working smoothly. The I
operator may be wall mounted or mounted on a bracket or sheH. If necessary, refer to the operator preparations .
on page 3. Refer to the illustration and Instructions below that suits your application.
1 a. Wall Mounting
The operator should generally be Installed below
the door shaft, and as close to the door as
· possible. The optimum distance between the door
shaft and operator drive shaft is between 12" • 15".
Refer to Figure 3.
Optimum Distance
12 • 15"
Typical Right Hand
Wall Mounted Operator
FIGURE3
1c. Place door sprocket on the door shaft. Do not
insert the key at this time.
2. Place drive sprocket on the appropriate side of
the operator. Do not insert the key at this time.
3. Wrap drive chain around door sprocket and join
roller chain ends.together with master link.
4. Raise operator to approximate mounting position
and position chain over operator sprocket.
5. Raise or lower operator until the chain is taut (not
tight). Make sure the operator output shaft is
parallel to door shaft and sprockets are aligned.
When in position, secure the operator to wall or
mounting bracket.
6. Align sprockets and secure, (see Figure 5).
4
tb. Bracket or SheH Mounting I
The operator may be mounted either above or
below the door shaft. The optimum distance 1·
between the door shaft and operator drive shaft Is .
between 12• -15". Refer to Figure 4.
OPTIONAL
gBm
PIN 08-9098
~ ~
Optimum Distance 12 -15"
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IMPORTANT: The shelf or bracket must
provide adequate support, prevent play
between operator and door shaft, and permit
operator to be fastened securely and with the
drive shaft parallel to the door shaft.
•1 I ,
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FIGURE 4
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Be sure door
sprocket is properly
aligned with drive
before securing to
the shaft. ·
~c~,~
FIGURES
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7. Install Hand Chain
Place hand chain around hand chain wheel. Se
sure to pass it through both openings in the chain
guide. Remove enough links so chain hangs
approximately two feet above the floor
8. · Mount Chain Keeper/ Kayhcle E!rackat
Using suitable hardware mount the chain keeper
approximately 4 feet above the floor, near the free
hanging chain. Remove disconnect sash chain
from bag and place the end through the keyhole
in the the chain keeper. Remove excess links if
necessary.
rs····· ·:·······•·\:····fo;:·······•}' :'.ef4e.fle~~cv,;,M1t~vA1.;vo:ireatktlP~:: .... i : •_.,e,_,.·;.,.: ... E.::.:::I;
This operator has provisions for manually operating the door in case of emergency or power failure. Refer to the
appropriate instructions below for your model operator.
Model GH
These operators are equipped with a manual hoist.
An electrical interlock will disable the electrical
controls when the hoist is used.
To operate the hoist:
1. Pull the disconnect cl 1ain (small chain) to engage
the hoist mechanism. The disconnect chain may be
locked in position by slipping the end through the
keyhole of the chain keeper mounted on the wall.
. 2. Operate the door in the desired direction by pulling
on one side or the other of the continuous loop hoist
chain {large chain).
3, The disconnect chain must be released from the
chain keeper before the door wiU operate again
electrically.
TURN OFF POWER TO THE OPERATOR BEFORE
MANUALLY OPERATING YOUR DOOR.
Chain Keeper
{with pad locking provisions)
The brake is adjusted at the factory and should not need additional adjustment for the the life of the friction pad.
Replace friction pads when necessary. Refer to the illustration for identification of components for the solenoid
type brake system.
Solenoid Brake System r----Plate Assembly
,----Release Lever
L-----Actuator Plate
5
llliltJt~ffifitlffia"..F!!lF."l'li~~~~~<WitlE!~~-
sENSING EDGES
All types of sensing edges with an isolated normally
open (N.O.) output are compatible with your operator.
This includes pneumatic and electric edges. If your
door does not have a bottom sensing edge and you
wish to purchase. one, contact the supplier of your
operator.
If not pre-installed by the door manufacturer, mount
the sensing edge on the door according to the
instructions provided with the edge. The sensing
edge may be eTectrically connected by either coiled
cord or take-up reel. Refer to the steps below.
Important Notes:
a) Proceed with Limit Switch Adjustments before
making any sensing edge wiring connections to
operator as described below.
b) Electrician must hardwire the junction box tC' the
operator electrical box in accordance with local
codes.
IT IS STRONGLY RECOMMENDED THAT A
SENSING EDGE OR OTHER ENTRAPMENT
PROTECTION DEVICE BE USED IN
CONJUNCTION WITH THIS OPERATOR.
WIRING:·
For wiring of your sensing device to the operator,
refer to the wiring diagram supplied with your
operator. See field connection terminals identified
as Sensing Device or Safety Edge.
TAKE-UP REEL: Take-up reel should be installed
12' above the top of the door.
COIL CORD: Connect operator end of coil cord to
junction box (not supplied) fastened to the wall
approximately halfway up the door opening.
---~1mt§wmi:tIW&~!l:t1;§lriM:§J;Jrif&--•
MAKE SURE THE LIMIT NUTS ARE POSITIONED BETWEEN THE LIMIT SWITCH ACTUATORS BEFORE
PROCEEDING WITH ADJUSTMENTS.
1. To adjust limit nuts depress retaining plate to allow
nut to spin freely. After adjustment, release plate
and ensure it seats fully in slots of both nuts.
2. To increase door travel, spin nut away from
actuator. To decrease door travel, spin limit nut
toward actuator.
3. · Adjust open limit nut so that door will stop in open
position with the bottom of the door even with top
of door opening.
4. Repeat Steps 1 and 2 for close cycle. Adjust close
limit nut so that actuator is engaged as door fully
seats at the floor.
CLOSE Limit Switch
0
SAFETY
(Aux. Close) Limit Switch
6
TO AVOID SERIOUS PERSONAL INJURY OR DEATH
FROM ELECTROCUTION, DISCONNECT ELECTRIC
POWER BEFORE MANUALLY MOVING LIMIT NUTS.
If other problems persist, call our toll-free number for
assistance -1-800-528-2806.
OPEN Limit Switch
Actuator
0 Retaining Plate
Aux. OPEN Limit Switch
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Remove the cover from the electrical enclosure. Inside this enclosure you will find the wiring dlagram(s)
for your unit. Refer to the diagram (glued on the inside of the cover) for all connections described below.
If this diagram Is missing, call the number on the back of this manual. DO NOT INSTALL ANY WIRING OR
ATTEMPT TO RUN THIS OPERATOR WITHOUT CONSULTING THE WIRING DIAGRAM.
DISCONNECT POWER AT THE FUSE BOX BEFORE
PROCEEDING.
OPERATOR MUST BE PROPERLY GROUNDED AND
PERMANENTLY WIRED IN ACCORDANCE WITH
LOCAL ELECTRICAL CODES. NOTE: THE
OPERATOR SHOULD BE ON A SEPARATE FUSED
LINE OF ADEQUATE CAPACITY.
ALL ELECTRICAL CONNECTIONS MUST BE MADE
BY A QUALIFIED INDIVIDUAL.
TO AVOID DAMAGE TO DOOR AND OPERATOR,
MAKE ALL DOOR LOCKS INOPERATIVE. SECURE
LOCK(S) IN "OPEN" POSITION.
IF THE DOOR LOCK NEEDS TO REMAIN
FUNCTIONAL, INSTALL AN INTERLOCK SWITCH.
ON THREE PHASE MACHINES ONLY!
Incorrect phasing of the power supply will cause the
motor to rotate in the wrong direction (open when
CLOSE button is pressed and vice-versa). To correct
this, interchange any two of the incoming three phase
power lines.
CONDUIT ACCESS
1-1 /16' Dia Knockout for
power wiring conduit access
(1 nearside)
1. Be sure that the power supply is of the correct
voltage, phase, frequency, and amperage to supply
the operator. Refer to the operator nameplate on the
cover.
2. Using the 1-1 /16" dia conduit access knockout
as shown below, bring supply lines to the operator
and connect wires to the terminals indicated on the
WIRING CONNECTIONS DIAGRAM.
DO NOT TURN POWER ON UNTIL YOU HAVE
FINISHED MAKING ALL POWER AND CONTROL
1/Vl'RING CONNECTIONS AND HAVE COMPLETED
THE LIMIT SWITCH ADJUSTMENT PROCEDURE.
IMPORTANT: THIS UNIT MUST BE PROPERLY
GROUNDED. A GROUND SCREW IS SUPPLIED IN
THE ELECTRICAL BOX FOR CONNECTION OF
THE POWER SUPPLY GROUND WIRE. FAILURE
TO PROPERLY GROUND THIS UNIT COULD
RESULT IN ELECTRIC SHOCK AND SERIOUS
INJURY.
•
0
0 0 f---1--_l_--\-'
7 /8" Dia Knockouts for
power wiring conduit access
(2 on end panel)
7
DETERMINE WIRlt:lG TYPE
Refer to the wiring diagram located on the inside cover the electrical box to determine the type of control wiring.
Standard C2 or B2 Wiring
Standard operators are shipped from the factory with
jumper set for C2 wiring, which requires constant
pressure on button to close the door. If momentary
contact on close direction is desired (82 wiring) you
must include an entrapment protection device. See
close control jumper setting below.
• Constant pressure on close (C2 wiring)
Red jumper wire was placed on terminal #2 in
electrical enclosure. The operator will require
constant pressure on close control in order to keep
door moving in the close dire9tion.
· • Momentary contact on close (B2 wiring) · ...
Move red jumper wire from terminal #2 to terminal
#3. The operator will require only momentary
contact to close the door.
. ■@iiiWIS!!Cll:llll~HmA!:ltl!lWJB.IN.I.Tfil@lliri::
If your operator was shipped from the factory with
non-standard control wiring or with optional
accessories that require addition instructions, refer to
the wiring diagram(s) indicated in the special control
wiring data box. When a replacement wiring diagram
Is present, wiring diagrams in this manual will not
apply. Refer only to the replacement wiring diagram
for all connections.
LOCATING THE CONTROL STATION
REPLACEMENT WIRING DIAGRAM
Note: Supplemental Wiring Diagrams are
to be used in addition to 1742•1.
Replacement Wiring Diagram is to be used
In place of 1742-1.
WI
Wiring
Type
Wiring Diagram label on Inside cover
of electrical box
IMPORTANT NOTE: If your wiring diagram la
miss/rig, or you are unsure of the wiring type for
your operator, contact the customer service
department @ 1-800-528-2806.
All operators are supplied with some type of control station. Generally a three .button station
(OPEN/CLOSE/STOP) is provided. A two-posttion key switch or control station (OPEN/CLOSE) may be added or
substituted when requested at the time of order. Mount the control station near the door.
INSTALL THE CONTROL STATION WHERE THE
DOOR IS VISIBLE, BUT AWAY FROM THE DOOR AND
ITS HARDWARE. IF CONTROL STATION CANNOT BE
INSTALLED WHERE DOOR IS VISIBLE, OR.IF ANY
DEVICE OTHER THAN THE CONTROL STATION IS
u'sED TO ACTIVATE THE DOOR, A REVERSING
EDGE MJ.!.SI BE INSTALLED ON THE BOTTOM OF
THE DOOR. FAILURE TO INSTALL A REVERSING
EDGE UNDER THESE CIRCUMSTANCES MAY
RESULT IN SERIOUS INJURY OR DEATH TO
PERSONS TRAPPED BENEATH THE DOOR.
a
IMPORTANT: Mount WARNING NOTICE beside or
below the push button station.
Push
Buttons
Control Station
0 0
TO PReYl!HT EKTR.APMlHT
DO NOT START DOOR DOWNWARD
UNU!S8 DOORWA 'I' 18 CUWI
0 0
WARNINGNollco
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Radio Controls
On all models with type B2 control wiring, a terminal
bracket marked R1 R2 R3 is located on the outside of
the electrical enclosure. All standard radio control
receivers (single channel residential type) may be
mounted to this bracket. The operator will then open
a fully closed door, close a fully open door, and
reverse a closing door from the radio transmitter.
However, for complete door control from a
transmitter, a commercial three-channel radio set
(with connections for OPEN/CLOSE/STOP) is
recommended.
Additional Access Control Equipment
DO NOT USE RADIO CONTROLS WITH YOUR
OPERATOR UNLESS YOU HAVE INSTALLED
SOME TYPE OF ENTRAPMENT PROTECTION
DEVICE. THE USE OF RADIO CONTROLS -
PRESENTS POTENTIAL HAZARDS DUE TO THE
USER'S ABILITY TO OPEN OR CLOSE THE
DOOR WHEN OUT OF SIGHT OF THE DOOR.' IN
ADDITION, IF A SINGLE CHANNEL CONTROL IS
USED, THE USER WILL NOT BE ABLE TO STOP
THE DOOR FROM THE TRANSMITTER.
Locate any additional access control equipment as desired (but so that the door will be in clear sight of the
person operating the equipment), and connect to the terminal block in the electrical enclosure as shown on the
FIELD WIRING CONNECTIONS diagram. Any control with a·'ii°ormally (N.O.) isolated output contact may be
connected in parallel with the OPEN button. More than one device may be connected in_ this manner. Use 16
gauge wire or larger for all controls.· DO NOT USE THE CONTROL CIRCUIT TRANSFORMER (24VAC) IN THE
OPERATOR TO POWER ANY ACCESS CONTROL EQUIPMENT OTHER THAN A STANDARD RESIDENTIAL
TYPE RADIO RECEIVER.
External Interlock Switch
The operator has a terminal connection for-an external interlock switch. This switch must be a normally closed -
(N.C.) two-wire device with a contact rating of at least 3 amps @ 24VAC. When such a switch is connected as
shown on the FIELD WIRING CONNECTIONS diagram, the control circuit will be disabled when the switch Is
actuated, thereby preventing electrical operation of the door from the control devices.
1. Loosen set screws on clutch nut.
_ 2. Back off clutch nut until there is very little tension
on the clutch spring.
3. Tighten clutch nut gradually until there is just
enough tension to permit the operator to move the
door smoothly but to allow the clutch to slip if the door
is obstructed. When the clutch is properly adjusted, it
should generally adjusted, it should generally be
possible to stop the door by hand during travel.
TO AVOID SERIOUS PERSONAL INJURY OR DEATH
FROM ELECTROCUTION, DISCONNECT ELECTRIC
POWER TO OPERATOR BEFORE ADJUSTING SLIP
CLUTCH.
9
(3)SET
-SCREWS
CAUTION: The torque limiter clutch Is NOT an
automatic reversing device. An electric or
pneumatic reversing edge can be added to bottcm
edge of door H desired.
IF CONTROL STATION CANNOT BE INSTALLED
WHERE DOOR IS VISIBLE, OR IF ANY DEVICE OTHER
THAN THE CONTROL STATION IS USED TO ACTIVATE
1 THE DOOR, A REVERSING EDGE MJJ§I BE IN5rALLED
ON THE BOTTOM OF THE DOOR. FAILURE TO INSTALL
A REVERSING EDGE UNDER THESE CIRCUMSTANCES
MAY RESULT IN SERIOUS PERSONAL INJURY OR
DEATH TO PERSONS TRAPPED BENEATH THE DOOR.
NOTICE:
The operator has been pre-wired to accept
connection of a reversing edge device. Connect the
normally open contacts to terminals T 4 and TB on the
low voltage terminal block. A cut-off switch will de-
activate the safety device during the last few inches
of the door's downward travel.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, rriay cause harmful interference .to radio communications. Operation of this
equipment in a residential area is likely to cause harmful Interference, in which case \he
user will be required to correct the interference at his own expense.
Tum on power. Test all controls and safety devices
to make sure they are working properly. It will be
necessary to refer back to page 6 for fine adjustment
o1 the limit switches.
IMPORTANT NOTES:
• Do not leave operator power on unless all safety
and entrapment protection devices have been
tested and are working properly.
• Be sure you have read and understand all Safety
Instructions included in this manual.
• Be sure the owner or person(s) responsible for
operation of the door have read and understand
the Safety Instructions, know how to electrically
operate the door in a safe manner, and know how
to use the manual disconnect operation of the
door open1tlng system.
10
DO NOT PLACE HANDS OR TOOLS IN OR
NEAR Tl:IE OPERATOR WHEN THE POWER IS
ON OR WHEN TESTING CONTROL OR SAFETY
DEVICES. ALWAYS DISCONNECT POWER
BEFORE SERVICING OR ADJUSTING THE
OPERATOR.
I
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Check at the intervals listed in the following chart .
ITEM PROCEDURE
Drive Chain Check for excessive slack.
Check & adjust as required.
I . . .
Sorockets Check set screw tinhtness
Fasteners Check & tiahten as reauired
Manual Disconnect Check & Operate
Bearings & Shafts Check for wear & lubricate
• Use SAE 30 011 (Never use grease or slllcone spray).
ti Repeat ALL procedures.
EVERY EVERY
3 MONTHS &MONTHS
• • • • •
■ Do not lubrlcate motor. Motor bearings are rated for continuous operation.
■ Inspect and service whenever a malfunction Is observed or suspected.
EVERY
12 MONTHS
II'
ti
II'
II'
II'
■ CAUTION: BEFORE SERVICING, ALWAYS DISCONNECT OPERATOR FROM POWER SUPPLY.
HOW TO ORDER REPAIR PARTS
OUR LARGE SERVICE ORGANIZATION
SPANS AMERICA
INSTALLATION AND SERVICE INFORMATION
ARE AVAILABLE 6 DAYS A WEEK
CALL OUR TOLL FREE NUMBER • 1-800·528·2806
HOURS 7:00 TO 3:30 p.m. (Mountain Std. Time)
MONDAY Through SATURDAY
WHEN ORDERING REPAIR PARTS
PLEASE SUPPLY THE FOLLOWING INFORMATION:
PART NUMBER DESCRIPTION MODEL NUMBER
ADDRESS ORDER TO:
THE CHAMBERLAIN GROUP, INC.
Electronic Parts & Service Dept.
2301 N. Forbes Blvd., Suite 104
TUCIOII, /ltZ. 85745
11
L ___ _
BLACK/BLUE
115 VOLT· 1 PHASE
MOTOR CONNECTION
(BK)
7
I
OVERLOAD ·;·i •
~
~)
BLACK/BLUE
230 VOLT -1 PHASE
MOTOR CONNECTION
:---·:, 4 ~1-, ... ._-----•►,--11 ,
! ( OP CL
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I 1 PHASE
POWER IN
(B
cL I ot:i·
~------:--'-.... -! I 3 I , , I 1---, ... ----"'
'-..'.---l IR \....-----.1.!!!L--:-:
(SEE NOTE #1) 230V MODELS___.+--! ow
(BL)
TO MOTOR' (PUR)
115VMODELS-<"'""":""CcL~w-' ..... __________ __,
~B 5 F ~, ____________________________________ ,
BR
EXTERNAL
~-~3:...-,iiS~T,:Oj,P----(~~ ••• _1_'.';E~~~~-.. __ .. 5 BR
HAND CHAIN
INTL'K SWITCH
(WHEN PRESENT)
~l..-:.-.,
NC C
OPEN 1 ~ OR
AUX.CLOSE
UMJTSWITCH RED
NC C (GY)
OR R1 (OR) (OR)
NC
OPEN&CLOSE 7 EL AUX.OPEN
C LIMIT SWITCH
RADIO TO (YEL) NO OPEN&CLOSE
L R2 (PUR)
~E 2
C
NOTE:
1, Voltage 11&11111 a llM vollaga. 12
A1
(BAN)
' ' '
PAI.:
= T1 (SEE NOTE #1)
24VAC SEC. (YEL)
OPEN
OP
(OR) UMrT SWITCH OR WIRE
A2
R1
NC C
RED R3 ED
CLOSE LIMIT SWITCH
NC C
PUR
NUT
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,----,r,,a
RADIO ~ ~
3
R~ED-; _____ +,
RECEIVER -'c::J
TO TERMINAL 12 ~PWIPLEG TIMER
~PURPLE
TO TERIIIHAI. 13 (OPTIONAL)
-
'----~AUX.TERWW. RED---------,
Bt.OCX FOR RADIO ~-1=:;----YEU.Ow---~ r...;7=m1=---=----, ~ OPEN
~~,_:_•CH~--E-:_S-:_·-_-_-_-_-_:-t-t-H-t-t-+--,
~-~ ,...t--GREY NC SAFETY
0 "'
CLOSE ~::i~s
l CONTACTOR . ....... ......, _
.....__ RED. 13 a.OS! U PUAJIU!-": ._ 1-R r-;:=========-m.LOW, S !--J 1-BUCIC --llRfY• 1-, • ~-eu.cx-:t•:
,----------PURPlE '1 2 230V. : : -3"~!.!:
,----------BUJI! . 11~y b\ !
WIITE ~y... • .'l
rOAANG! 1
YEllOW 1 I WIITE -+--t-M
· I rPURPU! . IIUCI(
-·""""t .~ •• UNI!
-m.1.ow
TI rt-++-WHJTE
WVIENUT
~ • euat+-+H--HH-+-+-Hl+t-+tt+--_ =:::::i~!::-::=c: IO ,-fl.11-;;!M';;"' 2 I-WIIT! -OVER LOAD
Iii~ ~ ~ ~ e
~ ,::
BRAKE
( WHEN REQ'D )
BUCK --
~--RED -----=:t::1=::1::t::t=:::rtitilt"i111tl Bl.ACX ,--PUilPl! -----1-~ r"' ..... ___ __,
r±.,-lu~o 'uhH Rt
C J«J NC n D D RELAY
-I-i....1-I-
,.....
-r-'--ollANGl!-----
-oRANGE----l'-ll+t-+H-1+----
~--RED i.!:::~-,..,..._..,..
10
,-,
r*SEl!NOTI!
aaow
(OPTIONAL)
: .------, I '9 INTERLOCK ~--·'-+t-tHttttt--,1 ~blHdH f I Iii i
BL-BK
115V. CONNECTION
......
......
230V. CONNECTION
!I(
111 i .~ II! i~ I
STOP -r.rc--SAF£TY
·r-:.
L1 L2
~
**1 PHASE
POWER IN
l!i-1-t,~
D RBAY ...
PURPLE
BUCK
GROUND
.. -Transformer Primary & Relay Voltage same as Line Voltage.
EDGE • • Shipped from Fadory
rl!•W=!i•i~ll;J•l:IWlilUl®•IQiU'is.E-fii
l!lll-iiilli:4111!1111!1l!I:l!ill
13
w~ B BIJBK ------------,· ' ,,w GY 1
BIJBK r·····-······~
GY --...;t.:::..-01 ! i,r.....,,
OIL* t .. .,
OIL* t IC W PUR ,.a..,.s ml!; g~
PUR BRN .............. ; .. ··2: Olli! t
BAN·· •••••••••••• _. 'l ' y .,_,,,
' ., ' ·BUBK: "'! BRN ' BUBK: ____________ , ____________ , YEL--..... --03 :
BUBK: ~--------... ···'
230 VOLT • 3 PHASE •·SEE NOTE 12
MOTOR CONNECTION
460 VOLT • 3 PHASE
MOTOR CONNECTION
575 VOLT • 3 PHASE
MOTOR CONNECTION
OVERLOAD
(SEE N_OTE 112)
L3
-,,_
3 PHASE L2\li (BK) POWER IN 'X.,
' (BK) ' L1
BR
CL • 5 ~o~ ~ 1-I -3◄•--------<► I '
HAND CHAIN
INTl'K SWITCH
B
OVERLOAD
G
OP
I • CL
I 2 TO MOTOR
(PUR)
(YEL)
(BK)
PAI.
(SEE NOTE 112) =T1 (SEENOTE#1) EXTERNAL (WHEN PRESENT)
,-~3 ___ ,.ST'--o,,P ___ ~.4 ••. INTE~OCK •••••• {1)=5'-'B,::R,:N,__"Nca<;'--...,.
0
____ ...:1,.1-__ ,..,.,.,...;.;...:..:.c:.
(YEL) ,.1
OP
(BAN) (BAN) 24VAC
SEC. (YEL)
OPEN OPEN _,__ 1 (OR) 1:S OR (OR) LIMIT SWITCH OR) WIRE +----------------m---'='--' ~-~~-A-,-<Qp A2 NC C NUT
OR
SAFETY EDGE
R1 OR
OPEN&CLOSE
RADIO TO OPEN&CLOSE
AUX.CLOSE
10 QY LIMIT SWITCH
NC C · (GY)
7 EL
C
(YEL)
1• ••••• • •••••• I u
~~------!'TIMER TOCLOSE,~-"'-""'----f
:(RED) " (OPTIONAL) 0
~----------------------------------
NOTE:
1. Voltage oame aa Una voltage
~-----~•~•o~ _ __,R1 1---.i,Ao,Ea,,D,_--lt>R=J_.,R,aEDeLJ
(OR)
NC
AUX.OPEN
LIMIT SWITCH
NO
CLOSE
UMrTSWrTCH
NC C
* -Shipped from Factory
PU
2. O\erlced In motar lor modllla up to 314 Hp, located In limit box for 1 Hp and above.
14
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!18'
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RADIO i!l~=------r,
RECEIVER iii RED ======:,i
-RED '----'---·.'"'-
""""'""'"""" YE1.LOW ----7 r.;;;! .. ,..,u,_-,:-.. -1:~~~t~;;;;;; = -
'Q'= OPEN
LIMIT SWITCHES
OAANGE----7
OAANal!
WIIYE
rOAANGE• -Al
ORANGE ;:
,., ,. ,,
3 ~ r, '2 _,....~_
.-----------::""
PIJAPLE .C" PIJAPI.E
R:~y Ji f iJ
OAANGI!
YEllOW
"-"" 8lACI(
BlACK
-=====;ill ~--RE0---7L-
IJHIIPlBaOW)
TOTERMlNALn r=----,
--PIJAPI.E 1: TIMER (OPTIONAL)
--PIJAPI.E ~-----TOTER M!N AL '3
-;::::: :: --{~c ::tJ
CLOSE
LIMITSWITCHE~
. PURPI.E ~
rPURPLE
' ' '
' ' ' ' ' ' ' ' '· I!:!!. ' '
L1 ••••
' ' .... --' V L2 ------
I 1 HP & ASOVEl--4.:: ·. ·,·-.-INT_ER_L_O_C_K_lJ 1 r *SEE NOTE:-....... ..
~ ~
BRAKE •
( WHEN REO'D )
.a
( 114 HP l BELOW} (OPT10NAL)
480V. CONNECTION
Prt • .., Voltage same as Line Voltage. •• • Transfonner m-,
+ + +
OPEN
-1...
15
+ + + + +
EXT.
INTLK. L1 L2 L3 TO OPEN ,-------"-----AND CLOSE
GROUND -1 **3 PHASE
POWER IN
--:J'[j.
SAFETY
EDGE
* _ Shipped from Factory
REPAIR PARTS LIST -ELECTRICAL BOX
Below are replacement kits av~ilable for your operator. For replacement of electrical box, motor or brake components be sure
to match model number of your unit to kit number below to ensure proper voltage requirements. Optional modifications
and/or accessories included with your operator may add or remove certain components from these lists. Please consult a
parts and service representative regarding availability of individual components of kits specified below. Refer to page 11 for
all repair part ordering information.
Complete Electrical Box Replacement Kits
To order a complete electrical box replacement kit, add a
K-prefix to the model number of your operator. For
example:
GH5011 M (Operator) = K-GH5011 M (Elec. Box Kit)
Electrical Box Sub-Assembly Kits
1<72-12510 Limit Shaft Assembly
1<75-12511 Limit Switch Assembly
Complete Gear Reducer Housing Kits
See Page 18 for more information
Shaft Assembly Kits
. 1<72-12789 Hand Chain Shaft Assembly
1<72-13379 Hand Chain Shaft Assembly
. 1<75-12783 • Disconnect Assembly
Complete Brake Assembly Kits
1<75-12584 115V Models
1<75-12585 . 230-460V Models
1<75-12586 . 575V Models
Brake Solenoid Plate Assembly Kits
1<75-11034 115V Models
1<75-11035 ... 230-460V Models
1<75-11036 575V Models
.Q.M!UieTI;li;l;.J;CJBl(:;~l,hl;lQ)!i KlllJ;i WM\¥
Hem PIN . Description Qty
1 03-8024-K Contactor 1
2 10-10444M1 · Electncal Box (No Tabs) 1
3 10-10115X ElectncalBoxCover
Motor Kits
K20-1050C2
K20-3050C4
K20-3050M5
K20-5150C6
K20-1075C2
K20-3075C4
K20-3075C5
K20-5175C6
K20-1100C2
K20-3100C4
K20-31 00C5T
K20-5110C6
K20-1150C2
K20-3150C4
K20-3150CST
K20-5115C6
K20-3200C4
K20-3200C5
K20-3300C4
Models GH5011 M, GH5021 M
Models GH5023M, GH5043M, GH503BM
Model GH5053M
Models GH5025M
Models GH7511M, GH7521M
Models GH7523M, GH7543M, .GH753BM
Model GH7553M
Model GH7525M
Models GH1011M, GH1021M
Models GH1023M, GH1043M, GH103BM
Model GH1053M
Model GH1025M
Models GH1511M, GH1521M
Models GH1523M, GH1543M, GH1538M
Model GH1553M
Model GH1525M.
Models GH2023M, GH2043M, GH2038M
Model . GH2053M
Models GH3023M, GH3043M, GH3038M
Individual Components
21-5115 Transformer, 115V Operators
21-5230 Transformer, 230V Operators
21-5460 Transformer, 380-460V Operators
21-5575 Transformer, 575V Operators
24-115-1 Relay, 11 SV 1 Ph Operators
24-230-5 Relay, 230V 1 Ph Operators
4 21-5xxx (See Individual Components)
5 23-10916 SPDT Interlock Switch
6 24-xxx-x (See Individual Components)
7 24-24-1 24VAC DPDT Relay 1
ITEMB ITEM 9 R'
g~g~1if 5lll ~l ;i;f "'l ;i;f ~t Ni N.a: N N 8"" 8~ ~~ 8<:! :;::,q
8 25-2xxx (See Overloads) 1
9 25-4xxx (See Overloads) 1
10 42-10040 Terminal Block, Radio 1
11 42-110 Terminal Block, 10 Position. 1 .
• Electncal Box Kits include parts from K72-12510 and K75-12511
.L'.!9:?d~§.1Q.·.·.A.JMIT:•.$ttAFfAl:i$f#.Ml!l.t;Y:grn ... ·••-···•··
Hem .PIN Description Qty
L1 11-10021 UmitShalt,StandardT 1
L2 12-10028 Flange Beanng, 3/8" I.D. 2
L3 13-10024 Lim~ Nut 2
L4 15-48B9AXX Sprocket 48B9 x 3/8' Bore 1
L5 80-10025 Washer, Shim 3/8" I.D. x .050 THK. 1
L6 80-10026 Washer, Shim 3/8" I.D. x .010 THK. 4
L7 86-RP04· 100 . Roll Pin, 1/8 DIA. x 1" Long 1
LB 87-E-038 E Ring, 3/8" . 1
Hem PIN
S1 10-10013
S2 18-10036
S3 23-10041
S4 31-10043
S5 82-PX04-19
S6 82-PX06-16
S7 84-DT-04
S8 84-LH-06
S9 85-IG-04
Description
Depress Plate
Spnng, Depress Plate
Li~ Switch
Standoff, Limit ~ch
Scmw, #4-40 x 1-3/8' Pan Head Ph
Screw, #6-32 x 1' Pan Hd Phil
Nut, Double Tinnerman
Locknut, #6-32 Nylon Hex
l.ockwasher, t4 Internal T oofh
Qty
1
2
4
8
8
2
4
2
8
OPERATOR
GH5011M
GH5021M
GH5025M
GH7511M
GH7521M
GH7525M
GH1011M
GH1021M
GH1023M
GH1043M
GH1053M
GH1025M
GH1038M
GH1511M
GH1521M
GH1523M
GH1543M
GH1553M
GH1525M
GH1538M
GH2023M
GH2043M
GH2053M
GH2038M
GH3023M
GH3043M
GH3038M
16
~cg~~ ~~ ~~ ~~ ~ :,;~ :,;~ :,;:,: o::
~" "'" "' o,.; ,~~ m· • • e • 0-• • • • I • • • • g, • • .,
u· • • • • n e • • • n • • • • o·
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3
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17
REPAIR PARTS LISTS -MODEL GH 'I
_,........., ____ ,,,...... ______________ _ Refer to the parts lists below for replacement kits available for your operator. If optional modifications and/or accessories are included with your operator, certain components may be added or remove from these lists. I· Individual components of each kit may not be available. Please consult a parts and service representative "' regarding availability of individual components. Refer to page 11 for all repair part ordering information.
ITEM PART# DESCRIPTION QTY
10-11045 Elec. Box Mounting Bracket
2 15-48B18LGE Sprocket, "8818 LGE
15-48818QGH Sprocket, 48818 QGH (3HP Models)
3 15-50812LGH Sprocket, 50812 LGH
15-8089QGH Sprocket, 8089 QGH (3HP Models)
4 See Page 16 Electrical Box
5 See Page 16 Motor
6 See Var. Comp. Gear Reducer
rn•;m~Z!Rlm3#Q}§~QNN§P!ll)A§§!:MeP¥ Kllli Mi ITEM PART# DESCRIPTION QTY
D1 10-11021 GH Disconnect Lever
D2 10-11023
D3 10-11024
D4 10-11029
OS 10-11030
D6 11-11106
D7 18-11007
DB 19-8A-12
D9 82-PX08-04T .
D10 82-SHl0-14
D11 82-WX10-08T
D12 . -84-FN-10
D13 85-FW-50
D14 85-LS-10
D15 86-CP04-112
D16 86-RP06-300
Bevel Gear Yoke
Brake Release
Actuator Bracket
Switch Actuator
Disconnect Shaft
GH Tension Spring
12ft. Of Sash Chain
Screw, #8-32 x 114" SeHap 1
Screw, #10-32 x 7/8" Long 2
Screw, #10-32 x 1/2" Serrated Fl. 2
Nut, #10-32 Serrated Flange 2
USS Ratwasher, 314• 3
#10 Lockwasher ZP 2
Cotter Pin, 1/8" x 1-314" Long 3
Roll Pin, 3116" x 3" Black Oxide 1
KIT REQUIRED FOR OPERATOR(S)
1<75-12829 Up to 1HP, 115 Volts
1<75-12830 Up to 1HP, 230-460 Volts
1<75-12831 Up to 1HP, 575 Volts
K75-12832 1.5 to 2HP, 230-460 Volts
1<75-12833 1.5 to 2HP; 575 Volts
1<75-12834 3HP, 230-460 Volts
ITEM PART# DESCRIPTION QTY
G1 10-11006 Housing Support Bracket 2
G2 10-11026M1 Gear Brake Housing
10-12453M1 Gear Brake Housing (3HP Models)
G3 10-11046M1 Housing Cover
• Gear Housing Kits also include:
1<75-12788 Disconnect Assembly Kit
1<72-12789 Hand Chain Shaft Kit
1<72-13379 Hand Chain Shaft Kit (3HP Models)
K75-12584 Brake Assembly Kit (115V Models)
1<75-12585 Brake Assembly Kit (230-460V Models)
K75-12586 Brake Assembly Kit (575V Models)
• Brake Kit Voltage same es Operator Voltage.
18
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ITEM PART#
H1 08-11012
75-13334
H2 06-11013
08-13333
H3 10-10882
H4 11-11105
HS 12-10029
H6 12-10883
H7 18-11008
HB 75-10884
H9 80-10022
H10 80-11014
H11 86-RP06-108
H12 86-RP10-110
H13 86-RPl 0-208
H14 87-E-062
H15 87-E-075
KIT REQUIRED
1<75-12584
1<75-12585
1<75-12586
ITEM PART#
81 07-10179
82 10-10190
83 10-10191
84 11-10192
85 11-10193
86 18-10194
87 31-10186
BB 75-10184
89 75-11034
75-11035
75-1t036
810 80-9001
811 87-P-062
DESCRIPTION
Bevel Gear, 5/8' ID
Bevel Gear Assy, 314• ID (3HP)
Bevel Gear, 314' ID
Bevel Gear, 314" ID 24 Tooth (3HP)
Hand Chain Guide
Hand Chain Shatt, GH
Bearing, 314' I.D.
Nyliner Bearing
Compression Spring, _GH
Chain Wheel Assembly
Shim Washer, Thick
Washer, .656 I.D. x 1.25 0.0.
_Roll Pin, 1/4' x 1-1/2" Long
Roll Pin, 5/16" x 1-5/8" Long
Roll Pin, 5/16' x 2-1/2' Long
E Ring, 5/8"
E Ring, 3/4"
FOR OPERATOR(S)
115 Volt Models
230-460 Volt Models
575 Volt Models
DESCRIPTION
Brake Hub
Brake Release Lever
Brake Disk
Spring Cup for Brake Assembly
Brake Stud
Spring, Compression x .87"
Spacer, .20" x .31" Long
Brake Pressure Plate Assembly
Brake Solenoid Assembly (115V)
Brake Solenoid Assembly (230V)
Brake Solenoid Assembly (575V)
Feather Key
Push on Faslener, 5/8" Int. Star
QTY
1
1
2
4
1
1
4
QTY
1
1
4
4
4
2
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.,,,,,,.,..,,,,,,,,,,,.,.,.,,,.,,.,,,.,,,,=========-=mm ~ ;;;:x:v:::.; ;;;;;;:.VAf;l!A~1J;:.~QMRP~1;NT~r· ;:;;; rnren
ITEM PART# DESCRIPTION QTY I 75-11034 Brake Solenoid Assy (115V Opers) 1 •
89 75-11035 Brake Solenoid Assy (230-460V Opers)
75-11036 Brake Solenoid Assv (575V Opers)
32-11009 Gear Reducer (1 HP Opers, 45:1)
6 32-11010 Gear Reducer (1.5-2 HP Opers, 45:1)
32-11011 Gear Reducer (3 HP Opers, 45:1)
.··~
-~2 '@§) D16
~ > ·,
D7 ·,.
·, ·, .
..............................
. . D1
· · H13 .
. !)
H12 _,,.
/
H5
..
'
--.. ---· ---) --lill', ------1!1111
a, . ....
IMPORTANT NOTES:
1) The 3-Button Control Station provided must be connected for operation.
2) If a STOP button is not used, a jumper must be placed between termianls 3 and 4.
3) Auxiliary control equipment may be any normally open two wire device such as
pullswitch, single button, loop detector, card key or such device.
ATTENTION ELECTRICIAN:
USE 16 GAUGE OR HEAVIER WIRE
FOR ALL CONTROL CIRCUIT WIRING.
:=:,:.,:""""'""'==··-,:, =·"'-=··=::,.~:,:,'""'•"'""'= .. = ~~K&R~1'0f:
STANDARD
1 2 3 4
2OR MORE
2 3 4
KEY LOCKOUT
1 2 3 4
Keyswitch
ALL CONTROL WIRING TYPES ALL CONTROL WIRING TYPES ALL CONTROL WIRING TYPES
STANDARD
2 4 2
SEENOTE#2
Close
ALL CONTROL WIRING TYPES
Sensing Device
ALL CONTROL WIRING TYPES
~,~--"",•
, :' E;li0~¾='~i
Warning Light will activate 15 sec. before door closes.
; 11 12 ·-13·-14, ! (f> --~---__ '?.!:uxil:ry Terminal Block
4iJ LO--Power Supply for
Timer Defeat / ' Warning Light
Switch
Tt CONTROL WIRING ONLY
SEE NOTE #2
3 7
~ SEE NOTES
#2 AND #3
OPEN/CLOSE
B2 orT1
WIRING TYPES ONLY
*OPEN TIMER TO CLOSE
__ ~ TER~~~~~~~CK
RADIO CONTROL I
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ONE 2ORMORE
ALL CONTROL WIRING TYPES
©2000, The Chamber1aln Group, Ire.
11-11091D Al rttt,ta RasaMd
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NEMA 4 MODIFICATION
ADDENDUM
0
' ~®--~ Model H
This addendum is to be used in conjunction with the owner's manual included with this
operator. Refer to the manual for all mounting an_d wiring instructions. The NEMA 4 mod-ification includes a TEFC motor, Watertight/Oiltight Control Enclosure, watertight/oiltight
3-button control station, and nickel-plated chain in lieu of all standard components of the
operator. . For service or replacement part requirements, use this addendum in lieu of those included with the manual.
Model GH
Item 15 present with 115 & 230V
models only. Items 16 & 17 present
with 460 & 575V models only.
Below is a parts list for a standard NEMA 4 enclosure for model GH. Optional modifications and/or accessories may add or remove certain parts from this list. Reier to owners ,~'1nual for·all repair part ordering information. ·
ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 03-8024 TEL 24V Reversing Contactor 1 14 44-1210-4XD Fiberglass Enclosure & Cover 1
2 10-10476 Depress Plate 1 15 42-110-1 Terminal Block, 10Pos. 300V 1
3 10-10478 Llm!t Switch Mtg. Brackel 1 16 42-108 Terminal Block, 8Pos. 600V 1
4 10-11160 Carwash Sub Panel 1 17 42-103 Terminal Block, 3Pos. 600V 1
5 11-10480 Umit Shaft, NEMA 12 1 ·1s 23-10916 Interlock Switch 1
6 12-10481 Bearing BFM-0375-A 2 19 24•24·1 Relay, Small 24VAC DPDT 1
7 12-10483 Bearing Seal, 3/8-I.D. 2 20 24•24-2 Relay, Large 24VAC DPDT 1
8 13·10516 Neoprene Gasket, REV A Print 2 21 24·264-4 Relay, Small 24VDC DPDT 1
9 15-48B9A1 Limit Sprocket 4889 1 22 24-115·1 Relay, Small 24VAC DPDT 1.
10A, 21-7115 Transformer, 1 PH 115/230V 1 23 24-230-5 Relay, 230V 3DPDT (IR) 1
10B 21-7460 Transformer, 3PH 230/460V 1 24 29-448 Bridge Rectifier 1
11 23-10041 Limit Switch 4 25 27-8004·K Contactor Block 2
12 31-10043 Spacer, Limit Switch 4 26 Sea Manual Overload 1
13 13-10024 Limit Nut, 1/2-20 Thread 2
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Models H, J, Tf & GT
• Interlock Switch (Item 16) present
with models H and J only.
7
Below is a parts list for a standard NEMA 4 enclosure for models H, J, T, and GT. Optional modifications and/or acces-sories may add or remove certain parts from this list. Refer to owners manual for all repair part ordering information.
ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 03-8024 TEL 24V Reversing Contactor 1 13 13-10024 Limit Nut, 1/2-20 Thread 2
2 10-10476 Depress Plate 1 14 44-1210-4XD Fiberglass Enclosure & Cover 1
3 10-10478 Limit Switch Mtg. Bracket 1 15 42-110 Terminal Block, 10Pos. 300V 1
4 10-10477 Carwash Elec. Panel 1 '16 23-10916 Interlock Switch 1
5 11-10480 Umit Shaft, NEMA 12 1 17 24-24·1 Relay, Small 24VAC DPDT 1
6 12-10481 Bearing BFM-0375-A 2 18 24-24·2 Relay, Large 24VAC 0PDT 1
7 12-10483 Bearing Sear, 319-l.D. 2 19 24-264-4 Relay, Small 24VDC DPDT 1
8 13-10516 Neoprene Gasket, REV A Print 2 20 24-115·1 Relay, Small 24VDC DPDT 1
9 15-4889A1 Limit Sprocket 48B9 1 21 24-230·5 Relay, 230V 3POT (IA) 1
10A 21-7115 Transformer, 1 PH 115/230V 1 22 29-448 Bridge Rectifier 1
10B 21-7460 Transformer, 3PH 230/460V 1 23 27-8004-K Contactor Blocks 2
11 23-10041 Limit Sw!lch 4 24 See Manual Overload 1
12 31-10043 Spacer, Limit Switch 4
© 1997, The Chamberlain Group, lnc.
01-116628 All rights Reserved
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