Baker hughes hpump operation and maintenance manual

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

©2008 Baker Hughes Centrilift. Centrilift, Canteslope, and AutographPC are all registered trademarks of Baker Hughes, Inc. HPump is a trademark of Baker Hughes, Inc.. All rights reserved. Printed in the U.S.A. CEN-08-14530 Revised 02-08

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Table of Contents Topic

Page 5

Introduction

Section 1 – Health, Safety, and Environment Considerations A. B. C. D.

Installation Concerns Operation Concerns Maintenance Concerns Explosive and Hazardous Atmosphere Concerns

Section 2 – Equipment Component Descriptions A. Overview B. Skid C. Driver I. Driver Coupling D. Horizontal Thrust Chamber I. 1.XE / 1.XT II. 3.X III. 875 IV. 4.X / 5.X V. Mechanical Process Fluid Seal E. Intake Assembly F. Pump G. Discharge Assembly H. Instrumentation

Section 3 – Storage and Handling A. Storage I. Motor II. Horizontal Thrust Chamber III. Pump B. Handling

Section 4 – Installation A. General B. Foundation I. Onshore Installation II. Offshore Installation C. Mounting and Leveling D. Pipework I. Intake Plumbing II. Discharge Plumbing

5 5 5 5 6

6 6 7 7 7 8 8 9 9 9 10 11 11 12 12

12 12 13 13 13 13

14 14 15 15 15 15 16 16 17

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E. System Alignment and Soft Foot Correction F. Driver I. Motor II. Engine G. Instrumentation and Electrical Devices I. Standard Instrumentation II. Additional Instruments and Electrical Devices III. Driver Instrumentation

Section 5 – Operation A. General B. Startup Procedures C. Pump I. Fluid Supply II. Purge III. Discharge Valves IV. Operating Precautions D. Horizontal Thrust Chamber E. Driver Coupling F. Motor G. Engine I. Speed Increasing Gearbox H. Driver Control Panel I. Operating Check J. Shutdown Procedures K. Instrumentation

Section 6 – Maintenance A. General I. Monitoring II. Preventative Maintenance III. Alignment B. Maintenance Schedule & Lubrication I. Pump II. Horizontal Thrust Chamber a. Mechanical Process Fluid Seal b. HTC Cooling System III. Driver a. Lubrication Service – Electric Motor (Ball Bearings) b. Lubrication Service – Electric Motor (Sleeve Bearings) c. Lubrication Service – Engine d. Filters – Electric Motors e. Filters – Engines IV. Driver Coupling a. Lubrication Service – Flex Type b. Lubrication Service – U-Joint Type

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17 18 18 19 19 20 20 21

21 21 21 22 22 22 22 22 23 23 23 23 23 24 24 24 24

24 24 24 25 25 26 26 26 27 27 27 27 28 28 29 29 29 29 29

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Section 7 – System Troubleshooting A. Pump B. Motor C. Horizontal Thrust Chamber

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30 30 31 33

Section 8 – Recommended Spare Parts

34

Section 9 – Terms, Conditions, and Warranty

34

Appendix A – Mechanical Process Fluid Seal IOM Manuals (Centrilift Standard Offering) Appendix B – Instrumentation IOM Manuals (Centrilift Standard Offering) Appendix C – Driver Coupling IOM Manuals (Centrilift Standard Offering) Appendix D – Reference Drawings Appendix E – HTC Oil Cooler System and Accessory Information

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INTRODUCTION: Proper use of these instructions will increase reliability and performance of the horizontal surface pumping system (HPump). Reading this manual before operation will provide the most benefit. The manual should be kept close to the equipment or in a convenient location. These instructions are intended to be general guidelines. Specific questions should be directed to your Centrilift sales and service representative.

SECTION ONE: Healthy, Safety, and Environment Considerations A.

INSTALLATION CONCERNS • • • • • • • •

B.

OPERATION CONCERNS • • • • •

C.

Always follow established HSE procedures.

Always wear proper PPE (eyes, hearing, clothing, footgear, hard hat, etc).

Always properly ground all electrical equipment.

Always follow correct startup procedures and read user manuals.

Verify correct driver rotation before operation, or after any electrical work has been done.

When lifting any equipment, follow recommended procedures and use approved equipment (hoists, chains, slings, cranes, spreader bars, shackles, etc).

Inspect the pump system for correct valving (location of one-way check and throttling valves), plumbing (pressure rating), and controls/instrumentation compatibility before operation.

Some units may start or stop automatically. Install warning signs to alert site personnel.

Never operate equipment without proper guarding and shutdown systems in place.

Never operate the equipment at dead head or no flow conditions.

Never operate equipment outside its recommended operating range.

Be aware of extremely hot or cold surfaces (motor, HTC, pump, etc.).

Never smoke or use open flame around equipment.

MAINTENANCE CONCERNS • • • • • •

Follow recommended service intervals.

Always follow lock out/tag out procedures when servicing the unit.

Always use the correct and recommended tools.

Always depressurize equipment before servicing.

Be aware of sharp edges and corners.

If attempting to move heavy components, use a lifting device rated appropriately for the load.

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• • • • •

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Never apply heat to remove any component (i.e. induction heaters and torches).

Remove jewelry (rings, watches, necklaces, etc) when working on rotating equipment.

Always use the buddy system.

If abnormal operating conditions cause the pump to reach 482° F, do not handle fluro-elastomer parts (i.e. Viton o-rings) without wearing proper PPE. The decomposition of the elastomer will make the parts hazardous.

Dispose of used lubricants and drained fluids in an environmentally conscious manner using approved containers.

EXPLOSIVE AND HAZARDOUS ATMOSPHERE CONCERNS It is the responsibility of the equipment facilities plant designer or end user to comply with any and all hazardous area classifications and local regulations.

• • • • • •

Avoid excess temperature rise.

Properly ventilate area to avoid the build up of explosive and hazardous mixtures.

Prevent spark generation.

Prevent fluid leakages.

Maintain equipment to prevent unsafe changes in operating conditions.

Install monitoring equipment and warning signs to alert site personnel of potentially unsafe conditions.

SECTION TWO: Equipment Component Descriptions A.

OVERVIEW

Major components of the system are a Centrilift multi-stage centrifugal pump, horizontal thrust chamber (HTC), fluid intake and discharge, instrumentation, and a driver mounted on a common fabricated steel skid.

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SKID

The skid is a fabricated steel assembly that provides a platform to mount the driver, HTC, pump, and any associated instrumentation. The complete system is typically laser aligned at the factory prior to shipment. The skid’s rigidity minimizes misalignment during transportation, installation, and operational shock and vibration.

The pump is supported by independent cross members bolted to a V-shaped cradle (trough). A series of clamped caps restrain the pump in the cradle. Independent cross members allow for vertical and horizontal pump adjustment during alignment.

C.

DRIVER HPump systems can use a wide variety of motors and engines. For specific information, refer to the manufacturer’s nameplate or IOM manual.

I.

DRIVER COUPLING Close Coupled (Grid Type)

Spacer (Grid Type)

Grid-style couplings are used to connect the thrust chamber to the motor.

Close coupled and spacer styles are offered. The spacer coupling allows for removal and service of the HTC without disturbing process piping.

Refer to Appendix C for coupling IOM manuals.

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HORIZONTAL THRUST CHAMBER The Horizontal Thrust Chamber (HTC) is an oil lubricated device that serves three purposes. The first purpose is to transmit the torque from the motor to the pump. The second purpose is to isolate the motor from the thrust produced by the pump. The third purpose is to seal the pumped fluid from the environment.

The thrust chamber uses a modular mount to accommodate various motor shaft heights.

Four different HTC models are offered based on thrust capacity required: 1.XE, 1.XT, 3.X, and 875. Each HTC is comprised of a housing, a shaft, bearings, shaft seals, and a mechanical process fluid seal. A variety of instrumentation is offered to monitor HTC vibration, lubrication oil level, and temperature.

I.

1.XE / 1.XT

The 1.XE and 1.XT are foot mounted thrust chambers. The 1.XT uses a different thrust bearing assembly and an oil cooler system to achieve higher thrust capacity.

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3.X

The 3.X is a flange mounted HTC. The motor end is bolted to a vertical mount. The 3.X is capable of higher thrust loads than the 1.XT. The 3.X requires a pressurized oil lubrication and cooling system.

III.

875

The 875 HTC is a foot mounted assembly. This HTC has the same footprint and uses the same style mount as the 1.XE and 1.XT. This thrust chamber has the same thrust capacity as the 3.X and also requires a lubrication system.

IV.

4.X / 5.X The 4.X and 5.X HTC are used in cartridge seal applications. The 4.X is a modified version of the 3.X HTC. A 5.X HTC is a modified version of the 1.XE/1.XT. In both versions, a longer shaft is added to accommodate a seal chamber and cartridge seal.

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V.

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MECHANICAL PROCESS FLUID SEAL The process fluid seal is designed to keep the pumped fluid from escaping to the environment. Typically the seal is installed in the head of the HTC or in the seal chamber. A variety of mechanical seals and seal flush systems are available to meet each application. Fluid properties and service conditions dictate the type of seal and flush system to be provided.

Manufacturer IOM manuals for Centrilift’s standard offering of seals can be found in Appendix A. Standard Type 2 Shaft Seal in HTC Head

Optional Cartridge Seal (Shown in Black) in Seal Chamber

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INTAKE ASSEMBLY

The welded intake assembly bolts to the pump and the HTC. The intake allows fluid to enter the pump. Intakes are offered in a variety of pipe sizes and flange classes to match different pumping conditions. Intake orientation can be changed in the field (minimum 90° increments) to match the piping location.

F.

PUMP The pump is a multistage centrifugal pump, mounted horizontally. It has multiple stationary diffusers and rotating impellers. The pump head attaches to the discharge assembly. The pump base attaches to the intake assembly. Two types of pumps are offered depending on pressure and flow requirements: housed and bolted bowl.

Housed

Bolted Bowl

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DISCHARGE ASSEMBLY

The welded discharge assembly bolts to the pump head. The discharge directs the pressurized fluid out of the pump. A variety of pipe sizes and flange classes are offered to match pumping conditions. The discharge assembly consists of a lap-joint type flange which is free to rotate around the stub pipe to facilitate bolt alignment.

H.

INSTRUMENTATION The HPump standard instrumentation package monitors the following: HTC vibration, HTC oil level, and pump intake and discharge pressures. Instrumentation to measure HTC oil temperature is available upon request. The instruments can be wired to a Centrilift variable speed drive or a customer’s control system to safeguard the equipment.

Manufacturer IOM manuals for Centrilift’s standard instrumentation can be found in Appendix B.

SECTION THREE: Storage and Handling A.

STORAGE If the HPump unit is not going to be installed and operated soon after it arrives on site, secure and store it. Storage procedures should also be considered if the unit ever sits idle for more than 30 days. The storage environment should be clean, dry, and well ventilated.

Preferably, this will be an indoor, protected, and secure environment. If stored outdoors, the unit should be placed on concrete or wooden supports. Additionally, the unit should be covered to avoid direct exposure to the weather. Never store the unit near sources of vibration or in the vicinity of welding activity.

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The following recommendations should be followed when storing your HPump: I.

MOTOR Refer to the OEM manual for storage and handling recommendations.

Typically the motor shaft should be turned by hand 15-30 revolutions every 30 days to avoid false brinelling of the bearings. Connect space heaters, if supplied, to drive moisture from the windings.

II.

HORIZONTAL THRUST CHAMBER Fill the thrust chamber with oil to prevent oxidation. 1.XE, 1.XT, and 875 thrust chambers should be capped during storage to avoid oil leakage.

Typically the HTC shaft should be turned by hand 15-30 revolutions every 30 days to avoid false brinelling of the bearings. On HTC models equipped with a desiccant breather, monitor and replace per the recommendations in Appendix E.

III.

PUMP For long term storage, the pumps should be filled with a preservative (antifreeze or oil) and capped.

Store spares, loose shipped items or electrical components in a similar manner, preferably in a secure and climate controlled indoor location.

B.

HANDLING

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Confirm that lifting equipment is appropriately rated for the weight of the entire skid assembly.

All chains, slings, spreader bars, and shackles should also be appropriately rated.

Use a four point lift to move the skid and mounted equipment.

Do not allow rigging to contact the mounted equipment.

Avoid jarring the skid.

Never attempt to lift the skids from anywhere except the provided lifting eyes.

Individual components should be lifted via appropriately rated slings.

Lift tandem skid sections separately. Never lift the skids when bolted together.

For heavy components that require maintenance or removal, or that ship loose and require installation, use 2 man lifting techniques with correct lifting devices.

SECTION FOUR: Installation A.

GENERAL As with all precision equipment, proper installation is required to provide maximum service life and to ensure the unit is covered under warranty. API Recommended Practice 686 is the preferred reference for HPump foundation and installation issues. Basic installation requirements are: • A firm foundation, including precise leveling of the skid.

• Flexibility in the intake and discharge plumbing.

• Control of the intake and discharge pressures.

Site installation of a new unit should include the following steps. Refer to the specific topic within this section for more information.

1. Level the skid assembly.

2. Correct soft foot conditions for the motor, HTC mounting bracket, and HTC (if installed on site).

3. Laser align any system components installed on site. Check alignment of all components and compare to factory alignment values.

4. Check and set HTC and pump shaft extensions (a reference document is available from HPump Engineering).

5. Replace HTC lubrication oil and fill to proper level.

6. Review customer piping for proper support.

7. Connect unit to piping and re-check laser alignment.

8. Start unit.

9. Perform hot alignment after 24 hours.

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FOUNDATION See the typical foundation drawing in Appendix D for specific foundation recommendations.

I.

ONSHORE INSTALLATION Mounting to a one piece concrete pad is preferred. The foundation should be designed to accept the weight of the equipment per guidelines specified in API-RP686. Anchor bolts must be provided at regular support points to secure the skid to the foundation.

II.

OFFSHORE PLATFORM Refer to the platform engineering contractor for recommendations specific to a particular offshore installation.

C.

MOUNTING AND LEVELING The skid requires support at each anchor location. Metal shims are normally used. Shims should be a minimum of 8 x 8 inch (203 x 203 mm) steel or steel alloy plates, in a selection of 1/8 inch (4 mm) thick and greater, depending on surface irregularities. The quantity of shims at each anchor location should be minimized. The steps below should be followed in the order presented: 1. The skid should be placed between the anchor bolts and leveled lengthwise with a 48� long digital level. The skid should be leveled within 0 to 1/10 of 1°. A hydraulic jack placed under skid cross member beams may be used to raise the skid for shimming.

CAUTION: Do not use the hydraulic jack directly on the intake assembly, the pump housing, or the discharge flange.

2. In order to ensure that the factory alignment is maintained once the skid is level lengthwise, it must be leveled laterally. Starting at the motor end, place the level across the skid and secure the bottom beam flange to the foundation with the first two anchor bolts. After tightening each bolt, check the level to make sure the skid has not deflected. If deflection occurs, adjust the quantity of shims at the anchor bolt location until no level change is registered.

3. Working towards the discharge end of the skid, securely tighten each pair of anchor bolts. Continue to adjust the quantity of shims if necessary. Check the level laterally above each bolt location to be sure the skid is free of twist.

4. If installing tandem skids, level the second skid lengthwise following the same procedure as Step 1.

5. Insert the dowel pins in the skid connection plates. Loosely bolt the plates together.

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6. Place the level laterally across the connection plates. Adjust the shim packs on the extension skid until the plates are level to each other. Firmly tighten the connecting plate bolts.

7. Following the procedure in Step 3, tighten the remaining anchor bolts.

CAUTION: The HPump system must be electrically grounded per standard or local codes to ensure personnel protection and safety.

D.

PIPEWORK Piping to the intake and discharge connections should have at least 0.5 inch/13 mm of flexibility in all directions. Where conditions do not allow rubberized piping or couplings, other methods (such as a heat loop) are strongly recommended. This allows for thermal expansion of the pump and pipe work. Another benefit is isolation from mechanical shock.

CAUTION: Suction and discharge piping should be supported independently from the pump or skid and field fitted to prevent induced nozzle loading.

CAUTION: Suction and discharge headers should not be jacked, pulled, or otherwise forced to mate with the intake or discharge flanges. This may cause excessive pipe strain, vibration, system misalignment, or damage.

NOTE:

I.

Piping entering or leaving the unit should be straight for 5-10 times the nominal pipe diameter. This will prevent cavitation and other flow restriction problems.

INTAKE PLUMBING The standard pump intake supplied is an ANSI raised face flange. A flexible hose, flanged at both ends, is recommended for connection between the intake and the fluid supply to limit nozzle loading.

A burst disk or pressure safety valve is recommended upstream of the intake. This helps prevent damage to fluid seals in the event of discharge check valve failure or pressure surges from other sources. A check valve in the intake supply line is discouraged, as unsafe pressures may be present when the pump is shut down. When pumping from a tank, pressure relief devices are not normally needed, but the intake piping should be as short and straight as possible.

The intake may be rotated by removing the bolts fastened to the intake body through the HTC and pump head flanges. Do not rotate the HTC head or pump base. The intake can then be carefully rotated to the desired

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position. Ensure that the bolts are reinstalled with thread lubrication and tightened securely. New HTC and pump o-rings should be installed any time the intake is removed. Before reinstalling, check that the pump and HTC shaft extensions are properly set.

II.

DISCHARGE PLUMBING Discharge plumbing must have some flexibility. Bracing or support will prevent pump misalignment from thermal expansion or other forces at the pump discharge. Supports should be designed so that settling, pressure surges, or maintenance work will not place stress on the pump.

The installation of a discharge spool is recommended to be mounted between the discharge flange and the header. This spool will allow for easier field assembly and provides a removable discharge header section to assist in pump maintenance. If a discharge hose is supplied, the recommended spool is not necessary. When installing the discharge, make sure to use the bolts that shipped loose with the discharge.

CAUTION: Do not use the shipping cap bolts to install the discharge.

Discharge bolts are specially designed to handle the high fluid pressure.

A reverse flow check valve is recommended downstream of the pump to prevent back flow and excessive back pressures at the intake. Any valves should be installed at least 5-10 times the nominal pipe diameter away from the discharge. If a recirculation line is used, the line should be piped to the fluid source, not directly to the intake.

For applications where the pump could be started and operated at a very low discharge pressure for several minutes (example: injection well on vacuum), a choke valve must be installed to allow backpressure to be simulated. This will reduce equipment up thrust wear damage.

E.

SYSTEM ALIGNMENT AND SOFT FOOT CORRECTION Soft foot is another name for distortion. This condition exists when the frame of a component is deformed during attachment to the skid. Soft foot results in high vibration and misalignment. The distortion is caused by mounting surface imperfections, usually on motors, HTC brackets, and 1.XE/1.XT and 875 HTC models. A dial indicator or laser alignment system can diagnose which surface is causing the soft foot condition. It can be corrected by shimming each mounting location separately.

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Laser alignment should be performed when installing the motor, pump, or HTC. The alignment between all components should also be checked before and after installing piping. Centrilift recommends that a hot alignment be performed after approximately 24 hours run time. This ensures optimal service life.

F.

DRIVER Two types of drivers are generally used on HPump units. Electric motors are the most common choice. In some locations, an electric motor may be impractical. For these applications, diesel or natural gas engines can be used.

I.

MOTOR Wiring size must meet the motor manufacturer's specification. It should be connected to a balanced power supply by a control panel containing suitable fuses and overload protection. When using a variable speed drive (VSD), the typically preferred output waveform is PWM mode. Refer to the motor OEM for their specific waveform recommendation.

CAUTION: The HPump system must be electrically grounded per standard or local codes to ensure personnel protection and safety.

Rotation is counter clockwise when facing the non-drive end of the motor.

TEFC type motors are normally equipped with condensation drain plugs in the bottom of each end shield. If present, these should be removed prior to startup. If using a sleeve bearing motor with a limited end float kit, properly locate the motor magnetic center before installing the coupling assembly.

Motor instrumentation could include winding RTDs, bearing RTDs, space heater, winding thermostat, or a WPII differential pressure switch. These options should be wired into the proper monitoring or control device.

Wiring schematics are available from the motor OEM. If using a Centrilift VSD, contact Controls Engineering for specific instructions on wiring motor instrumentation to the drive.

CAUTION: Motor fan rotation may be uni-directional or bidirectional. A fan rotating in the wrong direction may allow the motor to overheat. In this case, it will be necessary to reverse the fan mounting or replace the fan.

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ENGINE Engines are connected to the thrust chamber either by use of an integral speed increaser mounted to the engine bell housing, or through a separately mounted parallel shaft speed increaser. The internal gear arrangement of the speed increaser must result in a counter clockwise input rotation for the HTC. Engine accessories may include electric start, radiator cooling, clutch operator, automatic speed control, and safety shutdown panel.

CAUTION: All engine-driven HPump applications should be coordinated with HPump Engineering and the engine packager.

G.

INSTRUMENTATION AND ELECTRICAL DEVICES Switches and/or sight glasses provide monitoring functions for the unit. Standard instrumentation available includes: HTC vibration, HTC fluid level, pump intake and discharge pressure switches. Optional HTC oil temperature instrumentation is available upon request. Appendix B contains the manufacturer’s installation information for Centrilift’s standard instrumentation.

On the 1.XE and 1.XT HTC, a visual sight level gauge is standard equipment. On all HTC models, only the thrust chamber oil level switch will be plumbed during factory assembly. Typically the intake and discharge pressure switches will be mounted to the skid but not plumbed. For optimal accuracy, the intake and discharge pressure switches should be plumbed to the customer’s piping system.

Typically, instrumentation wiring and wiring connections will not be provided by the factory. Instructions on connecting instruments to a Centrilift VSD should be obtained from the Controls Engineering group. Refer to the set point charts that follow for instructions on configuring each instrument.

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I.

STANDARD INSTRUMENTATION

Instrument

Model

Intake Pressure Switch Discharge Pressure Switch HTC Oil Level Switch HTC Vibration Switch

Murphy 45 APE (range shown on instrument) Murphy 45 APE (range shown on instrument) Dependent on HTC Model Murphy VS2

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Set Point Instructions

Detailed IOM Information

Low SP: just above cavitation point of pump High SP: MAWP of seal or MAWP of intake (whichever is lower) Low SP: max flow operating point of pump High SP: min flow operating point of pump

See Appendix B

Low SP: HTC or reservoir sight glass “low” mark High SP: HTC or reservoir sight glass “high” mark Start unit and verify that vibration at all locations is less than 0.156 in/sec. Follow sensitivity adjustment instructions in Appendix B to obtain set point.

See Appendix B

See Appendix B

See Appendix B

ADDITIONAL INSTRUMENTS AND ELECTRICAL DEVICES

Instrument

Model

Set Point Instructions

Detailed IOM Information

3.X HTC Oil Temp RTD

Thermo Sensors 310R-4P138PS36B1/2A34-2.5

See Appendix B

875 HTC Oil Pressure Switch HTC Lube Oil Cooler Fan Motor (XP)

CCS 6900GZE

100Ω Platinum, Range: -58° to 752°F, 3-Wire, Single Element, 2.5” Insertion Depth. No transmitter/reader (to be supplied with starter/VSD). Set monitor to trip at 210°-220°F. Instrument is pre-set. Low pressure switch is set at 10 psi decreasing. High pressure switch is set at 100 psi increasing.

Set fan motor to start when main unit starts. Set time delay start in starter/VSD for 1-2 minutes.

Thermal protection provided, not wired. Shutdown on thermal overload, instrument trip, or main unit shutdown.

Control oil pump motor with starter/VFD HOA switch. Use Hand mode to start lube motor independent from main unit for maintenance. Use Auto mode for time delay start (1-2 minutes) for HTC pre-lube.

See standard 1.XT set point instructions above.

Baldor L4003A

1.XT HTC Lube Oil Pump Motor (Non-XP)

Leeson C6C17FK5H (110908)

1.XT HTC Lube Oil Pump Motor (XP) 875 HTC Lube Oil Pump Motor

Contact HPump™ Engineering

Dependent on specific installation

See standard 1.XT set point instructions above.

See Appendix B

Wiring diagram and electrical data in Appendix E

Wiring diagram and electrical data in Appendix E

Contact HPump Engineering

Contact HPump Engineering

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DRIVER INSTRUMENTATION A wide array of instrumentation is available for electric motor and engine packages. Centrilift’s standard electric motor instrumentation varies depending on the application. Common options include a winding space heater, winding thermostat, winding RTDs, and bearing RTDs. Motors with a WPII enclosure may be provided with a differential pressure switch for intake filters. Refer to the motor manufacturer for specific motor option installation instructions.

SECTION FIVE: Operation A.

GENERAL The multi-stage centrifugal pump is designed to operate over a specific range of pressures and flows. A copy of the specific application design is available from your Centrilift sales representative. It is calculated from the published head/flow curve for the specific pump stage type. Operation outside this range may cause thrust wear to the stages and a reduction of equipment life. Operation within the recommended range increases efficiency and reduces power costs. Minimum intake pressure will vary with the pump type and series. Contact your Centrilift sales representative for more information.

B.

START UP PROCEDURES There are several items that need to be checked at the initial startup and whenever the system has been shutdown for a significant period of time.

• • • • • • • • •

Verify that the pump turns the proper direction by “bump” starting the driver.

Check thrust chamber oil level sight glass or gauge for sufficient oil prior to starting the pump.

If equipped with an HTC cooling system, start the system before operation and make sure all air is purged from the system.

Check the installation of all bolting, piping and wiring.

Check all gauges, valves, and instrumentation for proper working order. Verify that instrumentation trip settings are properly set and operational.

Make sure the suction valve is fully open.

Ensure that the pumps are primed and any gas has been purged.

Check to be sure the discharge valve is at least 25% open. It may be necessary to adjust back pressure to stay within the pump application range until the system has stabilized.

Verify that the unit is level and free of excessive vibration (when operating).

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If operating with a variable speed drive, start at a reduced speed to check components for leaks at a reduced pressure.

PUMP Severe environments may require modifications to operating and maintenance instructions. Pumps that are shut down during periods of freezing weather should be drained and heat tape applied to prevent internal damage.

I.

FLUID SUPPLY Ensure that intake line valves are open and that fluid is available from the tank and/or suction header. If a boost pump is being used, it should be in operable condition. Intake filters, if any, should be clean.

II.

PURGE Bleed any air from the intake line, pump intake, and pump. Ensure that the pump is primed and flooded prior to start-up.

III.

DISCHARGE VALVES Ensure that discharge valves are properly adjusted and equipment downstream is ready to receive fluid. Adequate back pressure must be present to ensure the pump does not experience excessive up thrust wear during flow stabilization (example: disposal well on vacuum).

IV.

OPERATING PRECAUTIONS To prevent overheating, excessive wear or damage to the pump, do not operate under the following conditions: • • • • •

Operation outside of application design range.

Extended operation at the minimum head/flow rates.

When pump runs dry or loses prime.

When pumped liquid contains excessive gas or air.

When the pumped fluid contains sand or other abrasives. Small amounts of abrasives will have a gradual damaging effect. Centrilift makes no guarantee against the erosive action of these abrasives.

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HORIZONTAL THRUST CHAMBER For the 1.XE and 1.XT, check the HTC oil level in the sight glass and add oil if necessary (oil level should be within the area identified on the sight glass decal). The oil level should be checked while the equipment is running and warm. If too much oil is added, oil may run out the shaft seals.

NOTE:

External lube oil pump systems must be started before the main driver is started for proper lubrication.

3.X thrust chambers have a remote oil reservoir on top of the heat exchanger. There is a sight glass on the reservoir.

875 thrust chambers do not have a sight glass. Refer to the oil level plumbing drawing in Appendix D for instructions on checking and adjusting the oil level.

E.

DRIVER COUPLING Ensure that the coupling guard and other safety equipment are in place prior to startup.

The standard coupling is a steel flex grid type suitable for the application horsepower and RPM. The steel flex design should be greased per the manufacturer’s IOM manual and the service schedule shown in Section Six. Refer to Appendix C for standard coupling IOM manuals.

Other coupling types are available upon request. For special couplings, refer to the manufacturer’s IOM manual.

F.

MOTOR The driver is normally a two pole (3600 RPM) electric motor with either ball type antifriction or sleeve type journal bearings on each end of the shaft. It should not be operated beyond the speed limits set by the manufacturer. Follow lubrication instructions on the driver nameplate. Refer to the motor manufacturer’s performance datasheet or nameplate for frequency, speed, voltage, amperage, and service factor information.

G.

ENGINE Optionally, a gas or diesel fueled driver may be supplied. Operation of this engine should be per the manufacturer’s operating manual.

I.

SPEED INCREASING GEARBOX Normally, an engine driver operates at a RPM that is unsuitable for efficient pump operation. In these applications, a speed increaser is used to elevate pump RPM in relation to engine RPM. A gearbox of this type may

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require some form of lubrication oil cooling. Refer to the manufacturer for more information.

H.

DRIVER CONTROL PANEL If supplied, operation should be per the manufacturer’s operating instructions. Contact your Centrilift service representative for variable speed drive operation instructions.

I.

OPERATING CHECK All gauges and instruments should indicate safe and normal conditions and pump speed should be verified. If trouble occurs, shut the system off and refer to the troubleshooting chart in Section Seven.

J.

SHUTDOWN PROCEDURES The following sequence is suggested when stopping the unit: • Throttle the pump discharge valve to minimum flow.

• Stop the driver at the control panel.

• Shut the pump discharge valve.

• When the pump shaft stops rotating, close the suction valve.

CAUTION: Do not close the suction valve until the pump shaft stops rotating.

K.

INSTRUMENTATION Instrument trip points should be verified and properly set prior to operation. A general set point chart can be found in Section Four. If using Centrilift’s standard instrumentation, refer to Appendix B for the manufacturer’s operation instructions.

NOTE:

Changing fluid properties, such as specific gravity or viscosity, or changing pump speed will require instrument trip setting adjustments.

SECTION SIX: Maintenance A.

GENERAL I.

MONITORING Monitoring of system performance is recommended to establish maintenance requirements. A schedule should be established for periodic

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recording of the operating parameters. Refer to the table below for inservice checks.

In-service Check Look for and record trends in driver, thrust chamber and pump operating conditions (intake and discharge pressure, heat rise, vibration, noise, etc.).

Check the integrity of the skid, thrust chamber, pump, and driver mounting bolts.

Check all piping for evidence of leakage due to loosening or damage.

Check instrumentation and wiring for possible damage.

Check lubrication level and condition.

Check mechanical seal for minimal leakage through HTC weep hole.

Auxiliary equipment.

II.

Corrective Action Compare with other records to determine whether the condition is normal or not. Take corrective action if necessary.

Tighten or replace as necessary.

Repair as necessary.

Replace or repair as necessary.

See Thrust chamber paragraph.

Replace or repair as necessary.

Refer to applicable manufacturer’s instructions.

PREVENTATIVE MAINTENANCE Routine preventative maintenance enables early detection of most common problems. Dismantling of the pump and HTC for inspection is not recommended. Contact your Centrilift service representative if excessive wear or other internal damage is suspected. These problems may be represented as vibration, corrosion, or leaks from the pump or thrust chamber.

III.

ALIGNMENT Replacement of the driver or thrust chamber requires careful realignment of the components to ensure maximum run life. Driver replacement requires alignment to the thrust chamber, while thrust chamber replacement requires alignment to both the driver and the pump.

Movement or repositioning of the skid should be followed by leveling the unit to factory specifications. Replacement of the pump should only require alignment if the cradle has moved or the HTC is also being replaced. It is always good practice to check system alignment when servicing any component.

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MAINTENANCE SCHEDULE & LUBRICATION Lubrication should be done as part of a planned maintenance schedule. For definition of service conditions, see the table below.

STANDARD CONDITIONS

Eight hours per day, normal or light loading, clean environment @ 104ºF (40ºC) maximum ambient temperature.

I.

SEVERE CONDITIONS

Twenty four hours per day operation or shock loading, vibration, or in dirty or dusty environment @ 104°-122ºF (4050ºC) ambient temperature.

PUMP Repair or maintenance of the pump cannot be undertaken on site. The pump should be returned to Centrilift or a Centrilift designated facility for service or repair. Special tools and knowledge are required to disassemble the pump. The pump bearings are lubricated by the fluid passing through it and require no periodic maintenance.

A worn pump can produce down thrust at a level far beyond the original design limits of the thrust bearings. This down thrust can be very destructive, causing premature bearing failure. If you experience the need for thrust chamber replacement, investigate the wear condition of your pump.

II.

HORIZONTAL THRUST CHAMBER Several components require replacement during the life of the thrust chamber. If a 1.XE or 1.XT HTC is installed, the breather on top of the thrust chamber will need to be replaced periodically. The element will turn pink when it is time to order a replacement. If a cooling system is installed, then the oil filter will require replacement. It is good practice to change the filter whenever the oil is changed. For complete lubrication procedures, refer to your Centrilift service representative. The following table outlines recommended lubrication frequency.

MODEL

LUBRICATION VOLUME

1.XE

8 quarts (8 liters)

1.XT

5 gallons (19 liters)

3.X

5 gallons (19 liters)

875

5 gallons (19 liters)

FREQUENCY

LUBRICANT (Centrilift P/N)

TC200 (301221) (applies to all) Six months for standard conditions.

Three months for severe conditions.

TC200 (301221) CL4 (42288) CL5E (62708-5)

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a.

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Mechanical Process Fluid Seal Proper maintenance of the pumped fluid mechanical seal will prevent environmental contamination and premature HTC failure.

It is recommended that the weep holes on the HTC head be regularly flushed with a lubricant or cleaner. The flush fluid should be compatible with the pumped fluid. Do not allow the flush fluid to flood the weep hole chamber past the bottom of the shaft. For complete flushing procedures, refer to your Centrilift service representative. Keeping the atmospheric side of the seal clean and lubricated will extend seal life.

b.

HTC Cooling System When replacing any thrust chamber connected to an external oil cooler system, it is important to clean the entire system. This includes all hoses, fittings, heat exchangers, pumps, and filters. Old oil, sludge, residue, and metal particles can circulate through replacement thrust chambers without performing this service. This contamination can lead to premature failure. A Centrilift service representative should be contacted to perform this service. If cleaning and flushing are not effective, the affected cooling system components must be replaced.

III.

DRIVER COMPONENT

Driver (Motor or Engine)

a.

LUBRICATION VOLUME

FREQUENCY

Refer to manufacturer’s recommendation.

Refer to manufacturer’s recommendation.

LUBRICANT

Verify manufacturer’s recommendation in motor manual or on nameplate.

Lubrication Service – Electric Motor with Ball Bearings Lubrication procedure and grease type vary from manufacturer to manufacturer. The type and volume of grease may change, as well as recommendation to lubricate with the motor operating or stationary. Frequency of lubrication service is based on the severity of duty. Specific lubrication instructions are available from the motor manufacturer.

All manufacturers recommend removal of any grease plug located below the bearings for relief during lubrication, and to loosen any

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hardened grease that may block the drain. Also, a minimum period of operation should be observed immediately after adding grease.

CAUTION: Do not mix different kinds of grease (i.e.

Polyurea vs. Lithium based). Mixing grease with different type of thickeners may destroy its composition and physical properties. Even if the thickeners are of the same type, possible differences in the additive may cause detrimental effects.

CAUTION: It is possible to over-lubricate the motor bearings. Excess grease can build up inside the motor on the windings and may cause isolated hot spots. b.

Lubrication Service – Electric Motor with Sleeve Bearings Maintain proper lubrication by checking the oil level periodically, adding oil when necessary. The initial clearing action of the bearing and the expansion of the oil as it comes up to the operating temperature will cause the oil to be lighter after the motor has been in operation. Overfilling should be avoided because the thermal expansion may force the oil over the oil sleeve and onto the rotor.

Also, an operating oil level that is too high prevents the bearing from clearing itself of excess oil. If the oil level goes above the maximum shown on the sight gauge during operation, drain enough oil to bring the level back to within the recommended operating range.

The stationary oil level will be at the center of the oil gauge. Refer to the motor manufacturer for the proper replacement oil. Do not permit the operating level to fall below the minimum level shown on the gauge.

Reference the manufacturer’s instructions and nameplate for additional recommendations of lubrication type and service schedule.

c.

Lubrication Service - Engine Reference the manufacturer’s recommended service schedule.

operating

instructions

and

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d.

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Filters – Electric Motors Certain motor enclosure types, such as Weather Protected WP II, may include air filters inside the sheet metal enclosure. Reference the manufacturer’s operating instructions and recommended service schedule.

e.

Filters – Engines Engine filters, including air, oil, and fuel, should be replaced according to the manufacturer’s recommended service schedule.

IV.

DRIVER COUPLING All steel-flex grid type couplings require periodic lubrication. Refer to the following table and coupling manufacturer’s recommendations in Appendix C. For all couplings refer to OEM recommendations.

COMPONENT

LUBRICATION VOLUME

FREQUENCY

LUBRICANT (Centrilift P/N)

Flex Type Driver Coupling

6.0 ounces (175 grams)

Every HTC service

Falk LTG (60955) or manufacturer’s recommendation

a.

Lubrication Service - Flex Type Lubricated couplings are filled at the factory but will need to be charged with grease regularly. The plugs need to be removed and a grease fitting installed in one of the holes in the cover kit. After charging with grease, the fitting should be removed and the solid plugs tightly re-installed prior to restart.

b.

Lubrication Service - U-Joint Type Refer to the manufacturer’s approved grease types, and manufacturer’s recommended service interval.

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SECTION SEVEN: System Troubleshooting A.

PUMP The following chart contains potential pump problems and their causes. The list of possible remedies is listed only as a reference. Contact your Centrilift sales and service representative with questions about pump service.

TROUBLE Reduced flow or low discharge pressure

PROBABLE CAUSE a. Air leaks in suction b. Speed too low c. NPSH too low d. Clogged suction line e. Clogged impellers f. Impellers damaged g. Wrong rotation h. Worn pump

No flow or low flow

a. Pump not primed b. Speed too low c. Plugged impellers d. Clogged suction strainer e. Damaged impellers

Excessive pump vibration

f. Wrong rotation g. Discharge valve is shut a. Clogged impellers b. Damaged impellers c. Misalignment d. Foundation provides inadequate support

REMEDY a. Check suction line for leaks b. Check driver speed c. Check suction side of system for flow restrictions, air leaks d. Clean out suction line strainer e. If unable to clear chemically, return pump to Centrilift for disassembly and repair or exchange f. Return pump to Centrilift for disassembly and repair or exchange g. Check driver rotation h. Return pump to Centrilift for disassembly and repair or exchange a. Prime pump b. Check driver speed c. If unable to clear chemically, return pump to Centrilift for disassembly and repair or exchange d. Clean out suction line strainer e. Return pump to Centrilift for disassembly and repair or exchange f. Check driver rotation g. Check valve setting a. If unable to clear chemically, return pump to Centrilift for disassembly and repair or exchange b. Return pump to Centrilift for disassembly and repair or exchange c. Check driver, HTC, and pump alignment d. Have qualified foundation designer inspect and repair foundation

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ELECTRIC MOTOR The following troubleshooting chart lists problems and possible remedies. This list should only be used as a reference. Certain remedies should only be performed by a motor manufacturer’s qualified service center. Contact the motor manufacturer with motor service questions.

TROUBLE Motor won’t start

PROBABLE CAUSE a. Motor improperly connected b. Incorrect line voltage

Motor noisy

c. Overload relay tripped d. Fuses blown or defective e. Open circuit in stator or rotor f. Short circuit in stator g. Grounded winding a. Winding single-phased b. Loose mounting c. Noisy bearing d. Coupling halves loose e. Vibration

Excessive bearing temperature (anti-friction bearing)

f. Loose covers g. Uneven air gap a. Excessive lubrication b. Inadequate lubrication c. Bent shaft d. Coupling misalignment e. Inadequate internal clearance f. Inadequate ventilation

REMEDY a. Check motor connection and control connections b. Check nameplate for required voltage; measure voltage at motor terminals c. Correct and reset d. Replace fuses e. Check for open circuit f. Check for short circuit g. Check for a ground a. If winding is single-phased unit will not start; stop unit and try to restart b. Check and correct c. Check and correct d. Inspect alignment and tighten e. Check alignment with driver disconnected; check feet plane; correct balance of motor rotor if necessary; check key unbalance on coupling f. Tighten down g. Check gap a. Clean out grease reservoir b. Add lubricant per nameplate instructions c. Replace shaft d. Realign unit e. Incorrect replacement bearing – consult manufacturer f. Clean filters; check to see if louvers are blocked

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Excessive bearing temperature (sleeve bearing)

Revision Date: Page Number:

a. Inadequate oil supply b. Excessive end thrust c. Contaminated oil d. Tight clearance e. Bent shaft f. Oil rings not functioning g. Bearing material torn h. Rough shaft or corrosion i. Bearing misalignment j. Coupling misalignment k. Shaft current

Excessive temperature

a. Overload b. Restricted ventilations c. Electrical

Oil leak (sleeve bearing units)

Oil leak (pressure lube systems) Excessive vibration

a. Overfilled b. Sealing surface of bearing cap not flat c. Screws loose d. Pipe fittings loose e. Bearing air pressure vent passage clogged f. Wrong sealing compound used on bearing cap surface a. Too much oil flow in pressure lube system b. Drain line too small c. Air pressure imbalance a. Coupling misalignment b. Coupling imbalance c. Coupling key imbalance d. Foundation structure improperly supported e. Rotor imbalance f. Worn bearing g. Coupled equipment h. Shaft bent

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a. Refer to nameplate requirements and correct; check for proper fill, oil, leaks, gauge level b. Locate cause and eliminate; check coupling float, shaft level, air baffle balance c. Draw and refill; if filters are provided, replace with new ones; determine source of contamination and correct d. Check bore and O.D. clearance e. Straighten and refinish f. Check for damage or reason for binding – roundness, burrs, shaft level – and correct. g. Dress down, scrape, and refit h. Dress and polish shaft i. Realign bearing or reseat bearing; check feet flatness and reshim j. Realign motor k. Insulate bearing and isolate shaft from ground a. Reduce load to nameplate rating or replace with larger unit b. Check openings and duct work for obstructions and correct c. Check for grounded or shorted coils and unbalanced voltages between phases a. Drain to proper level or adjust oiler elevation b. Stone or file flat, remove burrs c. Tighten down d. Retighten or replace worn threaded parts e. Clear out passage f. Use a non-hardening gasket sealer; refer to manufacturer a. Reduce flow (change orifice) b. Use larger lines c. Clear venting pipes a. Realign to operating condition b. Rebalance c. Rebalance d. Correct foundation under skid base e. Rebalance rotor f. Replace bearing if bore oversized g. Check uncoupled, and if necessary, rebalance equipment h. Straighten without residual stress to avoid springback, or replace shaft

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HORIZONTAL THRUST CHAMBER The following troubleshooting chart lists problems and possible remedies. This list should only be used as a reference. Contact your Centrilift sales and service representative with thrust chamber service questions.

TROUBLE Abnormally hot bearings

PROBABLE CAUSE a. Improper lubrication b. Cooling system problems c. Contaminated oil d. Defective bearings

Lubrication oil leaks

Excessive mechanical process fluid seal leakage through HTC weep holes

Excessive vibration

e. Misalignment a. Oil level is too high b. Shaft seals are worn c. Cooling system leak a. Worn internal parts b. Seal flush line is plugged c. Atmospheric side of seal has excess deposits a. Internal bearing problems b. Pump is worn c. Misalignment d. Coupling gap is not correct e. Foundation provides inadequate support

REMEDY a. Check lubrication level b. Contact Centrilift to examine system for problems c. Drain and clean all components in contact with oil, refill with clean oil d. Contact Centrilift for repair or replacement e. Verify alignment a. Drain oil to middle of sight glass b. Contact Centrilift for repair or replacement c. Contact Centrilift for system service a. Replace or repair seal; analyze pumped fluid for presence of abrasive or corrosive substances b. Contact Centrilift for cleaning c. Contact Centrilift for cleaning a. Contact Centrilift for HTC repair or replacement b. Replace pump c. Check driver side and pump side alignment d. Reset coupling gap to factory specifications e. Have qualified foundation designer inspect and repair foundation

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SECTION EIGHT: Recommended Spare Parts The following table lists the spare part stocking recommendations. This list assumes a single HPump™ unit is installed. Depending on a unit’s specific features, there may be items not listed below that should be stocked. Contact your Centrilift sales and service representative for required quantities for a specific system. Refer to the driver manufacturer for spare parts information related to a specific motor or engine.

Coupling Grease (if required) Coupling Grid (if required)

RECOMMENDED DATE Start-Up 0-2 Years 2+ Years X X X X X

Coupling Gasket (if required)

X

X

X X

X X

HTC Lubrication Cooling System Oil Filter (if supplied) HTC Lubrication Cooling System (if supplied) Complete HTC Unit

X

X

Cartridge Process Fluid Seals (if supplied) Intake O-Rings Discharge O-Rings HTC O-Rings Pump(s)

X

X

X X X

X X X X

COMPONENT

HTC Oil HTC Breather (if supplied)

X

X X

X

Complete Spare HPump™

X

METHOD OF STORAGE In original packaging, capped Away from potential contaminants Away from potential contaminants Capped In original packaging, away from moisture In original packaging, away from potential contaminants In original packaging, away from vibration sources Capped, filled with oil, away from vibration sources In manufacturer’s unopened packaging In original packaging, away from contaminants Capped, filled with preservative, away from vibration sources Away from vibration sources and weather

SECTION NINE: Terms, Conditions, and Warranty The terms, conditions, and warranty are specific to each order. Refer to your Centrilift sales representative for the terms, conditions, and warranty applicable to this order.

IOM Manual

Appendix A

Appendix A – Mechanical Process Fluid Seal IOM Manuals Centrilift Standard Seal Offering

Seal John Crane Type 2

John Crane Type 2B

John Crane 8B1-O

John Crane 38BO

Manufacturer’s IOM Manual “Type 2 Elastomer Bellows Instruction Manual” “Type 2 Elastomer Bellows Instruction Manual” “John Crane Simple Shaft Seal Installation and Troubleshooting for Type 8-1 and Type 9 Seals” “John Crane Simple Shaft Seal Installation and Troubleshooting for Type 8-1 and Type 9 Seals”

Maximum Pressure Rating

Rating Basis

150 psi

Water < 175°F

345 psi

Water < 175°F

600 psi

Water < 175°F

Application Specific

Application Specific

I-2

Foreword

Type 2 Elastomer Bellows Instruction Manual

These instructions are provided to familiarize the user with the seal and its designated use. The instructions must be read and applied whenever work is done on the seal, and must be kept available for future reference.

ATTENTION These instructions are for the installation and operation of a seal as used in rotating equipment and will help to avoid danger and increase reliability. The information required may change with other types of equipment or installation arrangements. These instructions must be read in conjunction with the instruction manuals for both the pump and any ancillary equipment.

If the seal is to be used for an application other than that originally intended or outside the recommended performance limits, John Crane must be contacted before its installation and use.

Any warranty may be affected by improper handling, installation, or use of this seal. Contact the Company for information as to exclusive product warranty and limitations of liability.

If questions or problems arise, contact your local John Crane Sales/Service Engineer or the original equipment manufacturer, as appropriate.

ATTENTION John Crane mechanical seals are precision products and must be handled appropriately. Take particular care to avoid damage to lapped sealing faces and to flexible sealing rings. Do not excessively compress the seal before or during installation.

Safety Instructions 1. The following designations are used in the installation instructions to highlight instructions of particular importance.

NOTE:

Refers to special information on how to install or operate the seal most efficiently.

ATTENTION

Refers to special information or instructions directed toward the prevention of damage to the seal or its surroundings.

!

5. If the pumped fluid is hazardous or toxic, appropriate precautions must be taken to ensure that any seal leakage is adequately contained. Further information on sealing hazardous or toxic fluids should be obtained from John Crane prior to seal installation.

6. Fluorocarbon components should never be burned or incinerated as the fumes and residues are highly toxic. If fluorocarbons are accidentally heated above 400˚C/750˚F, they can decompose.

Therefore, protective gloves should be worn as hydrofluoric acid may be present.

Refers to mandatory instructions designed to prevent personal injury or extensive damage to the seal or its surroundings.

7. PTFE components should never be burned or incinerated as the fumes are highly toxic.

2. Installation, removal, and maintenance of the seal must be carried out only by qualified personnel who have read and understood these installation instructions.

3. The seal is designed exclusively for sealing rotating shafts. The manufacturer cannot be held liable for use of the seal for purposes other than this.

4. The seal must only be used in technically perfect condition, and must be operated within the recommended performance limits stated in the published Technical Data Sheet and the instructions in this manual.

Copies of the Technical Data Sheet are available from John Crane.

6. Check the correct setting and operation of all alarm systems connected to the sealing system.

Before Starting the Equipment 1. Check the pump at the coupling for proper alignment of the driver or motor.

ATTENTION

2. Ensure that the gland plate nuts/bolts are securely tightened according to the pump manual instructions, and that all screws are securely fastened.

3. Complete the assembly of the pump, and turn the shaft (by hand if possible) to ensure free rotation.

!

4. Consult all available equipment operating instructions to check for correctness of all piping and connections, particularly regarding seal recirculation/flush, heating or cooling requirements, and services external to the seal.

ATTENTION This mechanical seal is designed to operate in a liquid so the heat energy it creates is adequately removed.

Therefore, the following check should be carried out not only after seal installation, but also after any period of equipment inactivity.

5. Check that the seal chamber fluid lines are open and free of any obstruction, and ensure that the seal chamber is properly vented and filled with liquid - refer to the pump instruction manual.

I-2

-1-

Dry-running — often indicated by a squealing noise from the seal area — will cause overheating and scoring or other damage to the sealing surfaces, resulting in excessive leakage or a much shortened seal life.

Before start-up, ensure that all personnel and assembly equipment have been moved to a safe distance so there is no contact with rotating parts on the pump, seal, coupling, or motor.

General Instructions

Typical Type 2 Seal Arrangement

1. Study the Engineering seal layout drawing to confirm the proper seal arrangement for the pump being used. The Type 2 seal is designed for versatility and can be assembled in various ways. The following instructions describe the standard configurations.

2. To assure satisfactory operation, handle seal with care. Take particular caution to see that the lapped sealing faces are not scratched or damaged.

Typical Type 2 Seal Arrangement Part Name 1 Bellows 2 Face/Primary Ring 3 Retainer 4 Disc 5 Drive Band

6 7 8 9

Spring Spring Holder Seat/Mating Ring Collar

Checking the Equipment

Lead-On Chamfer

Successful operation and life of this seal is dependent on acceptable equipment dimensions, alignments, and finishes. Before installation of the seal, the following dimensional checks should be made with respect to the seal housing/shaft alignments, finish and lead-on. Normal equipment to measure these features would include a micrometer and dial indicator.

For ease of installation, the lead-on edge of the shaft or sleeve should be chamfered as shown.

Shaft/Sleeve Outside Diameter

Refer to Dimension Tables

Seal Chamber Bore Diameter

Refer to Dimension Tables

Shaft/Sleeve Finish under the Seal Unit

1.00" to 3.125" dia./63 Ra/1.6Âľm 3.125" dia. & up/32 Ra

Shaft/Sleeve Ovality/Out-of-Roundness

<0.1mm/0.004"

Concentricity of the Seal Chamber to the Shaft/Sleeve

<0.15mm/0.006" FIM

Shaft/Sleeve Run-out with respect to the Seal Chamber

<0.08mm/0.003" FIM < _ 1800 rpm <0.15mm/0.006" FIM >1800 rpm

NOTE: If the measured dimensions exceed the values given, correct the equipment to meet the specifications before installing the seal. If the seal is installed on a sleeve, the sleeve must be liquid- and pressure-tight through its bore. The thickness of the gland plate must be sufficient to retain the service pressure without distortion.

Preparing the Equipment 3. Determine squareness of seal chamber face to shaft: Rotating Mating Ring - 0.13mm/0.005" FIM max.

1. Check seal chamber dimensions and finishes.

Rotating Seal Head - 0.05mm/0.002" FIM max.

4. Measure shaft runout (0.05mm/0.002" FIM max.).

2. Measure shaft end play/axial float (<0.08mm/0.003" FIM max.).

NOTE: If measured dimensions exceed those values given, correct the equipment to meet specifications prior to seal installation.

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Installing the Seal Before starting the installation, read the following instructions carefully, both to be aware of special information and because the fitting sequence may be different depending on the construction of the pump.

ATTENTION

NOTE: It is essential to use a suitable lubricant when fitting the seal.

The recommended lubricants for elastomeric bellows are soft hand soap and water, or glycerine; do not use washing-up liquid, liquid soaps, or hand cleaning gels. Light mineral oil may be used sparingly with most elastomers.

ATTENTION

3. Clean the shaft, and lightly lubricate the shaft and the neck of the bellows.

4. Carefully slide the seal along the shaft beyond the seal location mark. Position as shown in the installation dimensions and secure the abutment collar, then slide the seal unit back against the abutment. Check that the drive ring dogs are correctly engaged, and that the spring, spring holder and spring adapter (if supplied) are correctly located.

Do not use hydrocarbon-based liquids on ethylene propylene bellows, and do not use grease (including silicone grease) on any elastomer bellows.

1. Remove the protective packaging from the seal; check for any damage, and wipe clean.

ATTENTION

Installation of the seal unit to its working length should be completed within 15 minutes to ensure that the elastomer bellows is correctly positioned before the neck of the bellows grips the shaft.

NOTE: Fit the seal by applying a steady pressure directly to the tail of the bellows, preferably using a close-fitting shaft sleeve with the seal spring, holder and adapter temporarily removed.

Check that the seal face is located in the retainer with the lapped face outwards, and take care that the face does not drop out of the retainer when handling and fitting the seal.

5. Wipe the lapped surface of the seal face/primary ring perfectly clean and dry. Install the seal housing; locate the gland plate squarely on the fixing studs, and pull on the plate to compress the seal spring as necessary to fit the retaining nuts.

2. Fit the seat/mating ring into the gland plate as described in the appropriate seat instruction manual. Check that the gland plate o-ring or gasket is in position and will not be displaced during fitting, and then position the gland plate on the shaft clear of the seal location.

6. Tighten the nuts sequentially to the torque recommended by the pump instruction manual. Do not overtighten.

Decommissioning the Equipment

Removing the Seal

1. Ensure that the pump is electrically isolated.

1. Referring to the pump instruction manual, dismantle the equipment sufficiently to expose the gland plate and seal housing.

!

If the equipment has been used on toxic or hazardous fluids, ensure that the equipment is correctly decontaminated and made safe prior to commencing work. Remember that fluid is often trapped during draining and may be present inside the seal chamber. The pump instruction manual should be consulted to check for any special precautions.

2. Evenly slacken and remove the gland plate nuts, and carefully slide the plate off the studs.

3. Remove the seal housing, clean and oil the shaft, and then complete the removal of the seal and the gland plate assembly, in the reverse order to installation.

2. Ensure that the pump is isolated by the appropriate valves.

Check that the fluid is drained and pressure fully released.

NOTE: Although the original seal position may be marked on the shaft or sleeve as a reference point before seal removal, the location must be checked even if the same seal and seat/mating ring specification is intended as a replacement.

A seal unit should always be serviced after removal from duty. It is recommended that used seals are returned to a John Crane Service Centre, since rebuilding to as-new specification must be carried out by qualified personnel.

!

It is the responsibility of the equipment user to ensure that any parts being sent to a third party have appropriate safehandling instructions externally attached to the package.

Operation and Maintenance

Quality Assurance

Although the seals should be looked at regularly for signs of leakage, a correctly selected mechanical seal will normally run for long periods without attention and it should not be disturbed unnecessarily.

This seal has been assembled in accordance with John Crane Quality Assurance Standards and with proper maintenance and use will give safe and reliable operation to the maximum recommended performance as shown in any relevant approved John Crane publication.

If leakage does occur, it should be attended to as soon as possible because the leakage could become a hazard. It should be noted that, while the leakage may be due to worn seal faces, damaged bellows or o-rings, it could also be because of some change in duty conditions or some change in the equipment such as worn bearings or increased vibration.

Check carefully for the root cause for leakage when the equipment is stripped.

No maintenance of a seal is possible while installed. Therefore, it is recommended that a spare seal unit and mating ring be held in stock to allow immediate replacement of a removed seal.

It is recommended that used seals are returned to a John Crane Seal Rebuilding Center, as rebuilding to as-new specifications must be carried out by qualified personnel.

!

I-2

It is the responsibility of the equipment user to ensure that any parts being sent to a third party have appropriate safe handling instructions externally attached to the package.

-3-

Storage and Transport Instructions for the handling, packaging, storage and transport of seal units and seats/mating rings are given in the John Crane Instruction Sheet ref. I-Storage, available on request.

John Crane North America Morton Grove, Illinois USA

Europe, Middle East, Africa Slough, UK

Latin America SĂŁo Paulo, Brazil

Asia Pacific Singapore

Tel: 1-847-967-2400 Fax: 1-847-967-3915 1-800-SEALING

Tel: 44-1753-224000 Fax: 44-1753-224224

Tel: 55-11-3049-9900 Fax: 55-11-3849-8270

Tel: 65-222-9161 Fax: 65-223-5085

For your nearest John Crane facility, please contact one of the locations above.

If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use.

In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling products made from PTFE. Old and new PTFE products must not be incinerated. Š2001 John Crane Print 1/01

I-2

www.johncrane.com

ISO Certified

-4-

I-8/9-A

John Crane Simple Shaft Seal Installation and Troubleshooting for Type 8-1 and Type 9 Seals

INSTALLATION Step 1:

Mark the face of the stuffing box on the shaft.

/4"

1

Square Tool Stock

45˚

Suggested Marking Tool

Step 2:

Polish shaft surface to 25-32 Ra.

.040" MIN.

20˚ Check for proper radius or chamfer.

Remove burrs.

63

INSTALLATION (continued) Step 3:

Look at pump installation drawing. Locate installation reference dimension (the dimension from the face of the seal chamber to the rear of the seal).

Inst. Ref. 1 9/16

John Crane Inc.

Step 4:

Measure the installation reference dimension from the scribe line and mark the shaft with a felt tip pen, layout dye or marking tool.

Installation Reference

An alternate method is to measure from the face to the seal chamber to the end of the shaft. Then, subtract the installation dimension. This gives you the dimension from the end of the shaft to the rear of the seal.

Step 5:

Some Type 8-1 and Type 9 seals may use different mating rings. If your seal does, then: - Lubricate seal ring (A) check for corner break (B) - Protect sealing face (C) with clean cloth and press mating ring firmly in place.

- Inspect rear of seal (D) to be sure it is properly positioned.

Put the mating ring and gland together and slide over shaft. Do not damage mating ring.

Lubricate the wedge or o-ring with light oil.

Slide seal over shaft.

Locate rear on installation dimension and tighten set screws.

A

B O-Ring seat C

D

A

B C

D TFE mtd. â&#x20AC;&#x153;Lâ&#x20AC;? shaped seat

INSTALLATION (continued) Step 6:

Reassemble pump. Slide gland/mating ring assembly into place and tighten stud nuts; connect piping.

TROUBLESHOOTING Step 1:

Seal Wears Out Shaft

Check bearings for shaft end play.

Reason - Pump is in poor mechanical condition.

Check squareness of stuffing box face to shaft centerline (.002" max. ).

.002" max.

Check bearings for radial shaft movement. .002" max.

Check shaft straightness. .002" max.

Step 2:

Seal is Burned Up Reason - Not enough liquid flow to seal.

- Seal is overcompressed.

.002" max.

Check flush line to be sure it is clear.

Check location or flush port. It should be as close to seal face as possible.

Did the pump cavitate or run dry?

Check installation reference.

TROUBLESHOOTING (continued) STEP 3:

Seal is Worn Out

To seal

Reason - Abrasives are in the seal cavity. The pumped liquid may be carrying dirt, rust or suspended abrasive particles.

If so, install an abrasives separator in the flush line.

A filter will also work.

If the liquid carries dissolved solids, contact your local John Crane Representative.

In

To low pressure

John Crane mechanical seals are very reliable. If you are not obtaining good service life, contact your local John Crane representative.

John Crane Engineered Sealing Systems North and Latin America Morton Grove, Illinois USA

Europe, Middle East, Africa Slough, UK

Asia Pacific Singapore

John Crane Sealol® Cranston, Rhode Island USA

John Crane Safematic® Muurame, Finland

John Crane Flexibox® Manchester, UK

Tel: 1-847-967-2400 Fax: 1-847-967-3700 1-800-SEALING

Tel: 44-1753-224000 Fax: 44-1753-224224

Tel: 65-222-9161 Fax: 65-223-5035

Tel: 1-401-463-8700 Fax: 1-401-463-6198

Tel: 338-14-600-611 Fax: 338-14-600-600

Tel: 44-161-8722484 Fax: 44-161-8489812

If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use. In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling products made from PTFE. Old and new PTFE products must not be incinerated. ©1998 John Crane Print 9/98

www.johncrane.com

ISO 9001 Certified

IOM Manual

Appendix B

Appendix B – Instrumentation IOM Manuals Centrilift Standard Instrumentation Offering

Instrument

Manufacturer

Manufacturer’s IOM Manual

Standard Model

Explosion Proof Model

Intake and Discharge Pressure Switch

Murphy

45APE

45APE-EX

HTC Vibration Switch

Murphy

“Installation for 4-1/2 in.

(114 mm) dial Pressure Murphygage® and Swichgage® instruments” “Shock/Vibration Control Switches Installation Instructions” “Installation Instructions for L129 Series Level Swichgage® instrument” “Installation Instructions for Level Maintainers Model Series LM300” “Installation Instructions for L971 Series Crankcase Level Switch” “Industrial Thermocouples: Installation and Maintenance” “Series: 6900 GZE”

VS2

VS2EX

L129-CK-1

N/A

N/A

LM303-EX

N/A

L971-C

N/A

310R4P138PS36B-1/2A342.5 6900GZE12 6900GZE16

1.XE/1.XT and 875 HTC Lubrication Level Switch 3.X HTC Lubrication Reservoir Level Switch 3.X HTC Internal Temperature RTD 875 HTC Lubrication Oil Pressure Switch

Murphy

Murphy

Thermo Sensors

CCS

N/A

00-02-0161 Revised 03-06 Section 05

Installation for 4-1/2 in. (114 mm) dial Pressure Murphygage® and Swichgage® instruments Model Series: OPLC, OPLG, OPLBP, 45APE, 45APEBP, PT167EX and 45 Series Options: -OS, -ES, -P4 and -P6

Please read the following instructions before installing. A visual inspection is recommended before mounting. General Information and these installation instructions are intended for all 4-1/2 in. (114 mm) dial pressure models.

GENERAL INFORMATION

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT ✔ Disconnect all electrical power to the machine. ✔ Make sure the machine cannot operate during installation. ✔ Follow all safety warnings of the machine manufacturer. ✔ Read and follow all installation instructions.

OPLC and OPLFC Swichgage instruments have high and low limit contacts to monitor, alarm or shut down. The OPLC has a flanged case. A method to override the low limit contact for start-up is provided on most models. See Operation Test section–page 3.

OPLFC can be direct or panel mounted (see page 2).

OPLG and OPLFG Murphygage indication-only pressure instrument are similar to OPLC and OPLFC models, without switch (limit) contacts.

45 Series includes a magnetic switch to stop an engine or electric motor each time the gage contact operates. A lockout push button overrides low contact for startup. Other variations available.

Sensing Element: Bronze or 316 stainless steel bourdon tube.

Gage Accuracy: All models and 45APE/45APEF between switch points: ±2% for first and last quarters of scale; middle half of scale is ±1%.

Model 45APE/45APEF Indicating Pointer above or below set point: Range Accuracy (±% F.S.) above and below s.p. only <100 (except 15 psi) 10 15 15 100-300 4 400-1500 2 2000 12 3000-5000 8 Based on testing performed with switch point at mid scale which represents worst case.

LOW SET POINT POINTER LOCATION

HIGH SET POINT POINTER LOCATION

50

40 300

30

400

200 PRESSURE

20 100

70 500

INCREASING ERROR FOR INDICATING POINTER

featuring pilot duty limit switches connected to an internal latching control relay for “on/off” control directly or through a motor starter.

PT167EX The Murphy PT167EX is a pressure Swichgage instrument connected to a threaded pressure diaphragm housing. The Swichgage instrument is enclosed in an explosion-proof case and is CSA rated for Class I, Division 1, Groups C and D.

Specifications Dial: White on black, dual scale, psi/kPa standard, 4-1/2 in. (114 mm) diameter.

Case: Die cast aluminum, surface or panel mount.

Process Connection: 1/4 NPTM thru 1000 psi; 1/2 NPTM 1500 - 10,000 psi.

Precautions:

Do NOT exceed rated pressure range.

Dope or use teflon tape on connection threads. Do not block the inlet orifice. For direct mount into the process, a vertical or ninety degree mounting is recommended.

Use wrench on shank to tighten or loosen connection. Do not twist case when installing, this will damage internal components and will void the warranty. Do not overtighten.

Use shock mounts as necessary to prevent excessive vibration.

If liquid in the system freezes, it will expand and will damage the tube.

For 45APE Series – Low setpoint should be limited to the lower 1/2 scale and upper setpoint should be limited to the upper 1/2 scale.

60 400

200 PRESSURE

70 500 80 600 90

10

90

0

0

45APE and 45APEF Series are versions of the OPLC Series

OPLBP and 45APEBP are versions of the OPLC and 45APE

30

600 kPa

300

100

kPa

0 PSI

100 MAXIMUM ERROR

featuring 2 snap-acting SPDT switches instead of the pointer type contacts.

These units do not include low contact lockout.

INCREASING ERROR FOR INDICATING POINTER

20

80

10 0 PSI

50

40

60

100

MAXIMUM ERROR

Switch Point Accuracy: ±1.5% (45APE/45APEF).

Switch Reset Deadband: Approximately 10% FS (45APE/45APEF).

Snap-Acting Switches: See wiring information (page 4) (45APE/45APEF).

Overrange: Do not exceed 10% FS above full range.

Pressure Relief Disc: Back of case (except EX models).

Dry Relay Contact (“BP” Models): 10 A @ 28 VDC or 10 A @ 120 VAC. Wire Connections (Surface Mount): 1/2 NPTF conduit/ terminal block.

Wire Connections (Panel Mount): Wire leads, 18 AWG (1.0 mm2) x 9 in. (229 mm) long.

Wire Connections (-ES, -OS): 1/2 NPTM conduit and wire leads, All except 45APEF: 18 AWG (1.0 mm2) x 33 in. (838 mm) long.

45APEF 24 AWG (0.22 mm2) x 33 in. (838 mm) long.

Item Weight: 5 lbs 6 oz (2.4 kg) approximately.

Explosion-proof models: 21 lb. (9.5 kg) approx.

Item Dimensions: 10 x 9 x 6 in. (254 x 229 x 152 mm) approximately.

Explosion-proof models: 12 x 12 x 9 in. (305 x 305 x 229 mm) approximately.

Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm. *Selected configurations are third party listed. Consult factory for details.

Installation 00-02-0161 page 1 of 4

OPL Series Wall Mount

45APE Series Wall Mount

Flanged case design intended for wall mount, it can also be direct mounted. Shown with shock mounts and pulsation dampener.

3-15/16 in.

(100 mm)

4-1/32 in.

(102 mm)

3-3/8 in.

(86 mm)

8-7/16 in (214 mm)

4-1/32 in.

(102 mm)

8-7/16 in.

(214 mm)

3-3/8 in.

(86 mm)

3-15/16 in.

(100 mm)

1/2NPTF conduit

1/2 NPTF Conduit

7-7/8 in.

(200 mm)

9/32 in.

(7 mm) dia.

3 places

1/4 NPTM or 1/2 NPTM Pressure Connection

45APE Series Flush Mount

1/4 or 1/2 NPTF

5-7/16 in.

(138 mm)

DETAIL FLOW

9/32 in.

(7 mm) dia.

3 places

7-7/8 in.

(200 mm)

shock mount panel

gauge

2-57/64 in.

(73 mm) 6-3/4 in.

(171 mm)

pulsation dampener

-OS and ES models only

120

120

1/4-20 nut & lockwasher (2 each required)

1/4 in. (6 mm) dia. holes (3 places) on 5-1/4 in. (133 mm) B.C. 120° apart, clocking as shown.

OPL Series Flush Mount Round case design to be mounted in a panel from 1/32 in. (1 mm) to 1/8 in.

(3 mm) thick. It can also be direct mounted. Shown with pulsation dampener.

120

2-57/64 in.

(73 mm)

5-7/16 in.

(138 mm) Mounting Hole 4-3/4 in.

(121 mm) diameter

6-3/4 in.

(171 mm) 120

Optional (-BC) 1/2NPTM Pressure Connection

Options “OS” and “ES” (flush mount case)

2-57/64 in.

(73 mm)

5-7/16 in. (138 mm)

1/4 NPTM or 1/2 NPTM Pressure Connection

-OS and -ES models only

6-3/4 in.

(171 mm) 120

120

1/2 in.

(13 mm) conduit

1/4 or 1/2 NPTM Pressure Connection

1/4 in. (6 mm) dia.

Holes (3-places) on 5-1/4 in. (133 mm) B.C. 120° apart, clockingas shown

Optional (-BC) 1/2 NPTM Pressure connection

1/4 in. (6 mm) dia. holes (3 places) on 5-1/4 in. (133 mm) B.C. 120° apart, clocking as shown.

120

Optional back connection

2-23/32 in.

(69 mm)

Explosion-proof Case Mount Explosion-proof case can be mounted from face or rear.

Flush mount/Wall mount* 6-25/64 in.

8 in.

(203 mm)

(162 mm)

1/2 in.

(13 mm) optional rear or side conduit 8 in.

(203 mm)

7-35/64 in.

(192 mm) diameter

*Mounting hole

6-3/4 in.

(171 mm) 3-3/8 in.

(86 mm)

3-3/8 in.

(86 mm)

not required for Wall mount

3/8-16 UNC-2B thread 7/8 in. (22 mm) deep, 8 plc's

Installation 00-02-0161 page 2 of 4

13/32 in.

(10 mm) diameter 4 places

6-3/4 in.

(171 mm)

OPTIONS CAUTION: Do Not unscrew the green diaphragm -OS and -ES (oil sealed and environment sealed case) for corrosive capsule. environment, feature a panel mount case or screw directly into the process.

See Case Mounting (p-2).

2.

Tighten the bottom housing to the pressure source.

Swichgage instrument 3. Tighten the eight housing bolts to 25±3 foot lbs.

-P6 Sealed mechanism with a typical application for by staggering the tightening for even clamping. oil well lead lines. Its 2 NPT housing and diaphragm seal 4. Route capillary away from heat source such as filled with silicon fluid attaches directly into a 2 NPT tee See exhaust manifold. Excess capillary should be Note 1 on the lead line. Tighten only the 2-5/8 in. (67 mm) hex carefully coiled and secured to avoid damage. fitting.

CAUTION: Do Not cut capillary or make sharp bends.

CAUTION: Do not tamper with or break sealed

Transmitting Tube Housing Bolts

Diaphragm Housing

2 NPT

connections.

-P4L is a remote seal mechanism with stainless steel armored capillary to protect the gage from highly viscous and/or corrosive fluids.

1. Loosen the eight housing bolts until the bottom housing is free to turn.

ADJUSTMENTS

OPL/45 Series Limit Contact Adjustments Facing the dial, left side knob is the “Low limit” contact and the “High limit” contact is located to the right. To set the limit contacts simply turn the fingertip type knob to the desired point on the scale.

45APE Series Trip Point Adjustments The 45APE Series features a stacked limit indicator adjustments knob. The bottom half knob adjusts the “Low” limit indicator, the top half is to adjust the “High” limit indicator. To set the limit contacts simply turn the fingertip type knob to the desired point on the scale.

OPL and 45 Series Indicating Pointer Adjustments To reset to zero or to a known value do as follows: 1. Turn off electrical power. Remove the snap DETAIL “A” ring and very carefully remove the lens and Turn to lower pointer contact assembly (or open hinged cover).

2. Hold the pointer hub with thumb and forefinger then turn screw to desired point. See DETAIL “A”.

3. Replace lens and contact assembly and Turn to raise pointer snap ring (or close hinged cover), and turn on the power.

45APE Series Pointer Adjustments To reset to zero or to a known value proceed as follows: 1. Turn off electrical power. Remove the snap DETAIL “B” ring and very carefully remove the lens and contact assembly (or open hinged cover).

2. Hold the the Switch Operator and the Turn CW to Turn CCW Raise Pointer to Lower pointer hub with thumb and Pointer forefinger, then turn the Pointer Adjustment screw to the desired point. See DETAIL “B”.

Pointer Adjustment 3. If the Switch Operator needs adjustment, hold the Switch Operator and the pointer hub with thumb and forefingers as show on DETAIL “C”, and turn the adjustment screw until the Switch Operator aligns with the DETAIL “C” indicating pointer.

4. Replace the lens and contact assembly Turn CW to Lower Turn CCW Switch Operator to Raise and the snap ring (or close hinged Switch Operator Switch cover). Turn the power back on.

Operator Adjustment

OPERATION TEST INSTRUCTIONS

OPLC, OPLFC and OPLBP 1. Perform operation test after the unit is installed and wired appropriately.

(See the typical wiring diagram, on page 4.)

2. When pressure is applied to the instrument, the pointer will travel in a clockwise direction. Adjust the limit contacts to the desired settings.

3. To start, place the toggle switch in the “start”position or otherwise override low contact.

4. After the indication pointer rises above the low limit contact, return the toggle switch or override device to the “run”position.

5. To test the limit contacts, turn the limit contact to be tested until it touches the pointer. That will trip the control circuit.

6. Reset the shutdown or alarm circuit device and repeat above sequence for each contact/trip point.

45 Series 1. Repeat steps 1 and 2. (See OPLC operation test instructions.)

2. Press the semi-automatic pushbutton located on the low contact knob.

3. Reset the magnetic switch pushbutton.

4. After the indication pointer rises above the low limit contact, the lockout pushbutton automatically disengages and the low limit is armed.

5. Repeat steps 5 and 6. (See OPLC operation test instructions.)

45APE, 45APEF and 45APEBP 1. Repeat steps 1 and 2. (See OPLC operation test instructions.)

2. To test the switches, turn the trip point indicator until it is aligned with the Swichgage pointer. This is the approximate trip point.

Continue to rotate until the snap switch operates.

3. Reset the shutdown or alarm circuit device.

Installation 00-02-0161 page 3 of 4

TYPICAL ELECTRICAL DIAGRAMS WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF”. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE SWICHGAGE RATINGS. BEFORE WIRING DETERMINE VOLTAGE AND POLARITY FOR THE APPLICATION. USE THE APPROPRIATE WIRE SIZE. ALL CONNECTIONS SHOULD BE MADE USING A SPADE (FORKED) OR RING TERMINALS. FOR PIGTAIL CONNECTIONS USE WIRE NUTS. CONDUIT IS RECOMMENDED TO PROTECT WIRES FROM DAMAGE.

OPLC and OPLFC Contact Rating: 1 SPDT, Center Off; 2 A, 30 VDC, 1 A, 125 VAC pilot duty.

OPLC

OPLFC

OPLBP Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position.

YELLOW

COMMON

4

BLUE

3

RESET

5

SET

1 7 4 3 9

= 18 GA.

Red White Black

Red White Black

6

BROWN

= 16 GA.

NOTE: Diagrams above show the Swichgage pointer in the at rest (shelf) position.

Contact Rating: 2-SPDT snap-switches (one for high and low pressure), 2 A inductive, 250 VAC each switch. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position. Low setpoint should be limited to the lower 1/2 scale and upper setpoint should be limited to the upper 1/2 scale.

1

WHITE B

A

120 VAC

12 VDC 24 VDC

ORANGE

45APE and 45APEF

8

(-) NEUTRAL

RED

LOW (RESET) (+) LINE

2

6

BLACK

HIGH (SET)

45APEBP LOW SWITCH

3 2 1

Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram below shows the Swichgage pointer in the at rest (shelf) position.

HIGH SWITCH

N.C.–Orange

N.C.–Black

N.O.–Blue

N.O.–Brown Common–Yellow

Common–Red

YELLOW

6

COMMON

5

4

BLUE

3

RESET

5

SET

1 7 4

4 3

= 20 GA.

45 Series with MS2100

6

BROWN

= 16 GA.

1

2

8

(-) NEUTRAL

1

WHITE

ORANGE

12 VDC 24 VDC

120 VAC

RED

(+) LINE

2

6

B

BLUE

A

BROWN

Models available for Battery ignition, CD ignition, Magneto or 110VAC systems. Contact Rating: 12/32 VDC coil, 10 A, 32 VDC battery ignition contacts; Magneto ignition coil, MS2100 10 A magneto ignitions contacts; CD ignition coil, 10 A CD ignition contacts; 120 VAC coil, 10 A, 120 VAC contacts.

6 1 2 3 4 5 NOTE: The diagram at right shows the Swichgage pointer in the operating position.

G

9

= 18 GA.

LOW (RESET)

YELLOW

HIGH (SET)

3

Transformer Relay Assemblies

Typical Circuit To CD Ignition or Magneto.

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

For higher voltages, Murphy TR Assemblies can be used in conjunction with any Swichgage instrument.

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

Installation 00-02-0161 page 4 of 4

VS-7037N Revised 09-06 Section 20 (00-02-0185)

Shock/Vibration Control Switches Installation Instructions Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94

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

GENERAL INFORMATION

R

WARNING

LISTED*

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

Description The Murphy shock and vibration switches are available in a variety of models for applications on machinery or equipment where excessive vibration or shock can damage the equipment or otherwise poses a threat to safe operation. A set of contacts is held in a latched position through a mechanical latch and magnet mechanism. As the level of vibration or shock increases an inertia mass exerts force against the latch arm and forces it away from the magnetic latch causing the latch arm to operate the contacts. Sensitivity is obtained by adjusting the amount of the air gap between the magnet and the latch arm plate.

Applications include all types of rotating or reciprocating machinery such as cooling fans, engines, pumps, compressors, pump jacks, etc.

Models VS2: Base mount; non hazardous locations.

VS2C: C-clamp mount; non hazardous locations.

VS2EX: Explosion-proof; Class I, Div. 1, Groups C and D. VS2EXR: Explosion-proof with remote reset.

VS2EXRB: Explosion-proof; Class I, Div. 1, Group B; with remote reset.

VS94: Base mount; non hazardous locations, NEMA 4X/IP66.

Model VS2EX

Remote Reset Feature (VS2EXR, VS2EXRB and VS94 only) Includes built-in electric solenoid which allows reset of tripped unit from a remote location. Standard on VS2EXR and VS2EXRB. Optional on VS94 (options listed below).

-R15: Remote reset for 115 VAC -R24: Remote reset for 24 VDC

Time Delay Option (VS94 only) Overrides trip operation on start-up. For VS94 series models, the delay time is field-adjustable from 5 seconds up to 100 seconds with a 20-turn potentiometer (5 seconds per turn approximately). Options listed below: -T15: Time delay for 115 VAC -T24: Time delay for 24 VDC

Space Heater Options (VS94 only) This optional space heater board prevents moisture from condensing inside the VS94 Series case. Options listed below: -H15: Space heater for 115 VAC -H24: Space heater for 24 VDC

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

VS-7037N page 1 of 8

DIMENSIONS VS2

VS2C

3 in.

(76 mm)

4-3/4 in.

(121 mm)

Reset Push Button

4-19/32 in.

(116 mm)

3 in.

(76 mm)

Slotted Sensitivity Adjustment

5-1/8 in.

(130 mm) Mounting Holes

Slotted Sensitivity Adjustment

Reset Push Button

5-7/16 in.

(138 mm)

Plug

2-1/4 in.

(57 mm)

4-3/4 in.

(121 mm)

1/4 x 1/2 in.

(6 mm x 13 mm) Slot 2 places

Weatherproof Strain Relief Bushing

27/32 in.

(21 mm) C-Clamp

VS2EX and VS2EXR 5-5/8 in.

(143 mm) Reset Push Button

1/2 NPT Conduit

1-3/4 in.

(44 mm) 3/8 in.

(10 mm) 4 places

4-7/8 in.

(124 mm)

Slotted Sensitivity Adjustment 5-1/4 in.

(133 mm) 6-3/8 in. Mounting Holes (162 mm)

3 in.

(76 mm) Mounting Holes

VS2EXRB 10-5/8 in.

(270 mm)

6 in.

(152 mm)

8-5/8 in.

(219 mm)

1/2 NPT Conduit

2-1/2 in.

(64 mm) 4-1/2 in.

(114 mm) Mounting Centers

10-3/16 in.

(259 mm)

9-1/8 in.

(232 mm) Mounting Centers

VS94 6-29/32 in.

(176 mm)

Manual Reset Push-button

7-9/64 in.

(181 mm)

6-1/2 in.

(165 mm)

4-5/8 in.

(118 mm) 3/4 NPT conduit fitting

1-5/8 in.

(41 mm) 4 in.

(102 mm)

Mounting slot 5/16 x 9/16 in.

(8 x 14 mm) 4-places.

6-1/2 in.

(165 mm)

4 in.

(102 mm)

VS-7037N page 2 of 8

SPECIFICATIONS

VS2 and VS2C • Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas.

VS2: Base mount VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable hold down clamps.

• Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

VS2EX • Case: Explosion-proof and weatherproof aluminum alloy housing; meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & D; UL and CSA listed.* VS2EX: base mount.

• Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* 2A resistive, 1A inductive, up to 30 VDC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

• Normal Operating Temperature: -40 to 140°F (-40 to 60°C).

VS2EXR • Case: Same as VS2EX. • Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A resistive, 1A inductive, up to 30 VDC. • Remote Reset (optional): Option Operating Current -R15: 350 mA @ 115 VAC -R24: 350 mA @ 24 VDC • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

• Normal Operating Temperature: -40 to 140°F (-40 to 60°C).

VS2EXRB • Case: Explosion-proof aluminum alloy housing; rated Class I, Division 1, Group B hazardous areas.

• Snap-switch: 1-SPDT snap-switch with reset coil (option available for

additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive, up to 30 VDC. • Remote Reset: Option Operating Current -R15: 350 mA @ 115 VAC -R24: 350 mA @ 24 VDC • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

VS94 • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA types 4 and 12.

• Conduit Fitting: 3/4 NPT conduit fitting connection.

• Normal Operating Ambient Temperature: 0 to 140°F (-18 to 60°C).

• Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A resistive, 1A inductive, up to 30 VDC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

• Heater (optional): Option Operating Current H15 .023 A @ 115 VAC H24 .12 A @ 24 VDC • Remote Reset (optional): Option Operating Current R15 .17 A @ 115 VAC R24 .36 A @ 24 VDC • Time Delay (optional): Option Operating Current Standby Current T15 .360 A @ 115 VAC .01 A @ 115 VAC T24 1.15 A @ 24 VDC .01 A @ 24 VDC • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from 5 seconds to 100 seconds (5 seconds per turn approximately).

*CSA and UL listed with 480 VAC rating.

INSTALLATION WARNING: STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.

The VS2 and VS94 series shock switches are sensitive to shock and vibration in all three planes of motion - up/down, front/back and side/side.

Front/back is the most sensitive (The reset pushbutton is located on the “front” of the unit). For maximum sensitivity mount the unit so that the front faces into the direction of rotation of the machine. (See Dimensions on page 2 for sensitivity adjustment location).

The VS2 and VS94 Series must be firmly attached/mounted to the machine so that all mounting surfaces are in rigid contact with the mounting surface of the machine. For best results, mount the instrument in-line with the direction of rotating shafts and/or near bearings. In other words, the reset push button should be mounted pointing into the direction of shaft rotation (see page 5). It may be necessary to provide a mounting plate or bracket to attach the VS2 and VS94 Series to the machine. The mounting bracket should be thick enough to prevent induced acceleration/vibration upon the VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See illustrations on page 5 for typical mounting locations.

CAUTION: A dust boot is provided on the reset pushbutton for all series to prevent moisture or dust intrusion. The sensitivity adjustment for model VS2EX is not sealed; therefore, mounting

orientation should be on a horizontal plane or with the sensitivity adjustment pointing down. Sensitivity adjustment for model VS2 is covered by a plug.

The plug must be in place and tight to prevent moisture or dust intrusion.

C-Clamp Installation (VS2C model only) A C-Clamp is supplied with the VS2C model only.

The C-Clamp is shipped installed on the VS2C but must be installed on the VS2EX and VS2EXR switches.

1. The C-Clamp (B) will already be installed on a 1/4 in. (6 mm) thick steel mounting plate (A). Bolt the VS2 switch to the mounting A plate as illustrated — with four 5/16 in.

B bolts, nuts, and washers.

2. The mounting location should provide convenient access to the TATTLETALE® push button (C).

3. The hardened set screw and nuts (D) are used to tighten the switch to an I-Beam or cross member such as a Sampson post of an oilwell pumpjack.

VS-7037N page 3 of 8

Continued on next page.

C

D

INSTALLATION Continued

All Models WARNING: STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.

1. Firmly secure the unit to the equipment using the base foot mount or C-Clamp if applicable. See C-Clamp Installation page 3.

For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson post or walking beam. See Typical Mounting Locations page 5.

2. Make the necessary electrical connections to the vibration switch. See Internal Switches, page 6 for electrical terminal locations and page 7 for typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT RATINGS OF THE CONTACTS. Follow appropriate electrical codes/methods when making electrical connections. Be sure that the run of electrical cable is secured to the machine and is well insulated from electrical shorting. Use of conduit is recommended.

NOTE: If the electrical cable crosses a pivot point such as at the pivot of the walking beam, be sure to allow enough slack in the cable so that no stress is placed on the cable when the beam moves.

If conduit is not used for the entire length of wiring, conduit should be used from the electrical supply box to a height above ground level that prevents damage to the exposed cable from the elements, rodents, etc. or as otherwise required by applicable electrical codes. If conduit is not attached directly to the VS2 and VS94 Series switch, use a strain relief bushing and a weatherproof cap on the exposed end of the conduit. A “drip loop” should be provided in the cable to prevent moisture from draining down the cable into the conduit should the weathercap fail.

allow the machine to stop. Turn the sensitivity adjustment 1/4 turn clockwise, (adjustment for VS94 and VS2EXRB models is located within the box, see DETAIL “B”).

WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.

Depress the reset button and restart the machine. Repeat this process until the unit does not trip on start-up.

DETAIL “B” 5. If the instrument does NOT trip on startup, stop the machine. Turn the sensitivity adjustment 1/4 turn counter-clockwise.

Repeat the start-up/stop process until the instrument trips on start-up. Turn the sensitivity adjustment 1/4 turn clockwise (less sensitive). Restart the machine to verify that the instrument will not trip on start-up.

All models of the VS2 and VS94 Series cover a wide range of sensitivity.

Each model is adjusted to the specific piece of machinery on which it is installed. After the switch has been installed in a satisfactory location (see page 5) the sensitivity adjustment will be increased or decreased so that the switch does not trip during start-up or under normal operating conditions.

This is typically done as follows: 1. REPLACE ALL COVERS, LIDS, AND ELECTRICAL ENCLOSURES. 2. Press the reset push button to engage the magnetic latch. To be sure the magnetic latch has engaged, observe latch DETAIL “A” through the window on the VS2 and VS2C (see DETAIL “A”). On the Reset Push button VS2EX, VS94 series the reset button will remain depressed meaning the magnetic latch has engaged.

3. Start the machine.

4. If the instrument trips on start-up,

Sensitivity adjustment

More Sensitive

6. Verify that the unit will trip when abnormal shock/vibration exists.

VS94 Time Delay Adjustment 1. Apply power to the time delay circuit. (see page 7 for time delay circuit). The time delay function will be initiated.

2. Time the length of the delay with a watch. Let time delay expire. After it expires, the override circuit will de-energize the solenoid, allowing the latch arm to trip. A clicking noise is heard.

WARNING: REMOVE ALL POWER BEFORE OPENING ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND LOCAL CODES.

Sensitivity Adjustment WARNING: REMOVE ALL POWER BEFORE OPENING THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.

Less Sensitive

3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT. NOTE: Allow 30 seconds bleed-time between turning the power “OFF” and “ON”.

DETAIL “C” 4. Locate the time adjustment pot (DETAIL “C”).

The time is factory-set at the lowest setting (5 seconds approximately). To increase time, rotate the 20-turn pot clockwise as needed Turn to (5 seconds per turn approximately). decrease 5. Repeat the above steps as necessary to obtain desired time delay.

Pot

Turn to NOTE: An external time delay can be used increase with the remote reset feature of the VS2EXR series to provide a remote reset and override of the trip operation on start-up. Time delay must automatically disconnect after equipment start-up.

Sensitivity Adjustment

VS-7037N page 4 of 8

TYPICAL MOUNTING LOCATIONS

NOTE:

These are typical mounting locations for best operation. Other mountings are possible.

See Installation section on page 3.

2-Throw Balance-Opposed Compressor

Pumping Unit

Reset

NOTE: If installing on cylinders, 2 vibration/shock switches are recommended1 for each cylinder.

Engine and Vertical Shaft Pump

Reset

“Y” Type Reciprocating Compressor

Reset

Reset

Reset

Generator Sets

Reset

Cooling Tower Fan or Heat Exchanger

Reset

Engine Compressor

Turbine Centrifugal Compressor

Reset

VS-7037N page 5 of 8

Reset

INTERNAL SWITCHES

VS2 and VS2C

VS2EXR Remote Reset Terminal Sensitivity Adjustment

Sensitivity Adjustment

NC NO1

NC

COM

NO COM Ground Terminal

NO2 SPDT Snap-Switch

SPDT Switch Terminals

VS2EXB and VS2EXRB

VS2EX

Remote Reset Terminal Sensitivity Adjustment

SPDT Snap-Switch

NC

NO COM

NC

NO COM

Sensitivity Adjustment

NC Ground Terminal

SPDT Snap-Switch

SPDT Snap-Switch

VS94 SPDT Snap-Switch

NC

NO COM

NC

NO COM

SPDT Snap-Switch

NC

Time Delay and/or Remote Reset Terminal (Optional)

Ground Terminal

Sensitivity Adjustment

Heater Board Terminal (Optional)

VS-7037N page 6 of 8

NO COM NO COM

Ground Terminal Optional SPDT Snap-Switch (VS2EXRB only)

ELECTRICAL WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.

VS2 and VS2C Typical Wiring Diagram for Single or Dual CD Ignition

VS2EX Typical Wiring Diagram for Single or Dual CD Ignitions

SPDT Switch Contacts shown in the RESET position.

NO1

NC

COM

CD Ignition 2

SPDT Switch (Optional 2-SPDT [DPDT])† Contacts shown in the RESET position CD Ignition 2

NO2

N.C.

COM

N.O.

N.C.

COM

Resistor (100 Ω, 3 Watt)

To good engine ground

Resistor (100 Ω, 3 Watt)

N.O.

To good engine ground

CD Ignition 1

CD Ignition 1 To good engine ground

VS2EXR and VS2EXRB Typical Wiring Diagram for Single or Dual CD Ignitions

Remote Reset Momentary Push Button

SPDT Switch (Optional 2-SPDT [DPDT])† Contacts shown in the RESET position N.O.

115 VAC or 24 VDC (Voltage is specified when ordered).

VS94 Typical Wiring Diagram for Single or Dual CD Ignitions

N.O.

N.C.

N.C.

COM

To good engine ground

COM

†Additional Switch Optional on VS2EXRB only

115 VAC or 24 VDC*

Maintained Contact for Time Delay

Time Delay

115 VAC or 24 VDC* *Voltage is specified when ordered.

To good engine ground

CD Ignition 2

Time Delay or Remote Reset (Optional)

Momentary Contact for Remote Reset only

2-SPDT Switches (DPDT) Contacts shown in the RESET position

N.O.

N.C.

COM

N.O.

N.C.

COM

Heater Board (Optional)

To good engine ground

To good engine ground

Resistor (100 Ω, 3 Watt)

CD Ignition 1

CD Ignition 1

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 Typical Wiring Diagram for Electric Motors

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 Typical Wiring Diagram for Distributor Ignition or Diesel

Contacts shown

NOTE: Terminal N.O. is terminal NO1 on models VS2 and VS2C. L1

L2

L3

Switch Terminals in the RESET position N.O. N.C. COM

(see Note)

CD Ignition 2

Resistor (100 Ω, 3 Watt)

NOTE: Terminal N.O. is terminal NO1 on models VS2 and VS2C.

Switch Terminals N.O.

(see Note)

N.C.

COM

Contacts shown in the RESET position Ignition Switch

Push-button Station

Ammeter HC

Diesel Fuel Shutoff Valve H

MOTOR

A

Hand Off Automatic Selector HC

VS-7037N page 7 of 8

Ignition Coil

Distributor

Battery

SERVICE PARTS PART NO.

DESCRIPTION

PART NO.

VS2 20000030 20000031 20000032

Movement assembly Glass and gasket assembly Reset push button assembly

20010090 20000288

VS2C 20000030 20000031 20000032 20050021 20000185 20050465

20000057 Movement assembly Glass and gasket assembly Reset push button assembly Mounting clamp VS2C 5-clamp hardware package assembly.

2-Conductor electrical cable, 45 feet (13.7 meters)

20000058 20000287 20000290

VS2EX 20010091 20050087 00000309 20010090 20000288 20000289

Movement assembly Cover Cover gasket Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* C-clamp conversion mounting kit

VS2EXR 20000262 20050087 00000309 20010090 20000288 20000049 20000234 20000289

DESCRIPTION

VS2EXRB

Movement assembly Cover Cover gasket Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* Reset solenoid assembly (115 VAC) Reset solenoid assembly (24 VDC) C-clamp conversion mounting kit

20050077 20000262 20000049 20000234

Snap-switch and insulator kit (1 switch per kit) prior to September 1, 1995.* Snap-switch and insulator kit (1 switch per kit) for models manufactured on September 1, 1995 or later.* Inside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D prior to September 1, 1995.* Outside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D prior to September 1, 1995.* Outside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D manufactured on September 1, 1995 or later.* Inside snap-switch and insulator kit (1 switch per kit) for model VS2EXRB-D manufactured on September 1, 1995 or later.* Adjustment shaft Movement assembly Reset solenoid assembly (115 VAC) Reset solenoid assembly (24 VDC)

VS94 Series 25050506 00000232 20010090 20000288

Dust boot Conduit fitting Snap-switch and insulator kit (1 switch per assembly) prior to September 1, 1995.** Snap-switch and insulator kit (1 switch per assembly) for models manufactured on September 1, 1995 or later.***

* If no date code is found, refer to the old switch. Models with date 0895 and before use old switch.

Dated 0995 after, use straight snap-switch arm, no rollers. ** Models dated Q1 thru Q8 (formed snap-switch arm and rollers). ***Models date coded Q9 thru Q12 and R1 thru R12 (straight snap-switch arm, no rollers).

FW MURPHY

CONTROL SYSTEMS & SERVICES DIVISION

COMPUTRONIC CONTROLS, LTD

P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1.918.317.4100 Fax: +1.918.317.4266 E-mail: sales@fwmurphy.com

P.O. Box 1819 Rosenberg, Texas 77471 USA Phone: 281.633.4500 Fax: 281.633.4588 E-mail: sales@fwmurphy.com Web site: www.fwmurphy.com

41 - 43 Railway Terrace Nechells Birmingham B7 5NG UK Phone: +44 121 327 8500 Fax: +44 121 327 8501 E-mail: info@computroniccontrols.com Web site: www.computroniccontrols.com

FRANK W. MURPHY, LTD

FW MURPHY INSTRUMENTS (HANGZHOU) CO. LTD

Church Rd Laverstock Salisbury SP1 1QZ UK Phone: +44 1722 410055 Fax: +44 1722 410088 E-mail: sales@fwmurphy.co.uk Web site: www.fwmurphy.co.uk

77 23rd Street Hangzhou Economic & Technological Development Area Hangzhou, Zhejiang, 310018, China Phone: +86 571 8684 8886 Fax: +86 571 8684 8878

INDUSTRIAL PANEL DIVISION

Fax: 918.317.4124 E-mail: ipdsales@fwmurphy.com MURPHY POWER IGNITION

Web site: www.murphy-pi.com

www.fwmurphy.com

Printed in U.S.A. 078792

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

VS-7037N page 8 of 8

L-95006N Revised 06-06 Section 15 00-02-0174

Installation Instructions for L129 Series Level Swichgage® instrument Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting.

GENERAL INFORMATION

Dimensions L129

WARNING

High Level Adjust

+

+

-

+

+

-

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

8 in.

(203 mm)

Float

+

+

-

Read and follow all installation instructions.

+

-

Shock Mount (2 supplied)

1-1/2 in.

(38 mm)

High Contact

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Low Level Adjust

2 in.

(51 mm)

Keps nut (2 supplied)

1/2 NPT Closed Nipple (2 supplied)

Low Contact +

CAUTION: Certain danger to human and to equipment such as applied in a mobile or marine application may occur if some equipment is stopped without pre-warning. It is therefore, recommended that monitored functions be limited to alarm only or to alarm before shutdown in such applications.

3-3/16 in.

(81 mm)

2-31/64 in.

(63 mm)

1/2 NPT Union (1 supplied)

L129CK1 High Level Adjust

Low Level Adjust

*

Description

The L129 Series Lube Level Swichgage instrument is a combination lube level indicating gauge with adjustable low and high limit switches. It provides protection against low oil level or high level caused by overfill or fuel or water seepage into the crankcase. A 6-3/4 inch (171 mm) deep sight gauge allows you to check the condition and level of your oil without shutting down the equipment.

Fingertip adjustable limit switch contacts are adjustable thru 4-7/8 inch (122 mm) range. When the float touches the high or low limit contact, a normally open circuit will close which can activate alarms and/or shutdown the equipment.

There are two models in the L129 Series: L129 and L129CK1. The L129 model is designed for grounded, low voltage electrical systems. It features a one-wire-to-ground electrical circuit. The L129CK1 is designed for applications requiring a three-wire, above ground electrical circuit. It features ungrounded contacts and a conduit hub for electrical wiring connection.

+

+

-

+

+

-

High Contact 9-55/64 in.

(250 mm) Float

Shock Mount (2 supplied)

1-1/2 in.

(38 mm) 2 in.

(51 mm)

Keps nut (2 supplied)

1/2 NPT Conduit +

+

-

+

-

1/2 NPT Closed Nipple (2 supplied)

Low Contact +

4-55/64 in.

(123 mm)

2-31/64 in.

(63 mm)

1/2 NPT Union (1 supplied)

Repair Kits Specify part number.

Specifications Case: Die Cast Aluminum.

Lens: Tempered Glass.

Maximum Working Pressure: 10 psi (68.9 kPa) [0.69 bar].

Process Connection: 1/2 NPT. Float Material: Brass.

Contact Rating: 2 A @ 30 VAC/DC, pilot duty.

L129

Flow Restrictor Plug Order Separately

L129CK1

Flow Restrictor Plug restricts oil flow between thee crankcase and the L129 Series. It is typically used onn ile some mobile applications such as marine and mobile equipment. Part no. 15050241.

15000888

Full Repair Kit (less castings and glass assÕy) fo r date code T2 and later.

15000480

Bezel, Glass and Gasket Set for date code W7 and later

15000485

Glass and Gasket Set for all date codes

15050241

Restrictor plug for all date codes

15000480

Bezel, Glass and Gasket Set for date code W7 and later

15000485

Glass and Gasket Set for all date codes

15050241

Restrictor plug for all date codes

*Complete with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.

L-95006N page 1 of 2

INSTALLATION and OPERATION NOTE: Read all instructions before beginning installation.

Mounting 1. Determine which side of the engine to mount the L129. This will normally be the side of the engine from which it is started. Weld a slotted mounting plate to the engine skid or attach the mounting plate to the crankcase. If a mounting plate is not used, a support strap is recommended (see Typical Installation below).

2. Install the shockmounts in the threaded holes provided in the mounting bosses on the rear of the L129. NOTE: We recommend using the shockmounts provided to minimize “contact bounce” resulting in improper operation.

3. Attach the L129 to the mounting plate as shown below but do not tighten TOO TIGHT since you will have to adjust the L129 later in the installation process.

Typical Installation Customer Supplied Vent Support Strap Shockmount

L129 vent back to the crankcase. If you do not do this, the L129 will indicate high level with a pressurized crankcase and a low level with a vacuum crankcase.

In extreme cases a pressurized system will blow oil out the vent tube or in vacuum crankcases can suck oil out of the L129.

To vent the L129 back to the crankcase, install a 1/4 inch (6 mm) O.D. or larger tubing (copper or flexible) from the L129 vent fitting to a point in the crankcase above the full oil level or in the fill pipe that is not restricted by baffles, filters or other obstructions. If connecting directly into the crankcase, be sure the entry point is clear of oil splash that can plug the tube opening.

4. Refill the crankcase to proper oil level. With the engine running and warm, loosen the L129 from the mounting bracket and adjust the L129 so that the oil level shows approximately midway or above in the sight glass. Tighten shockmount nuts.

Wiring Follow appropriate wiring for the alarm or engine shutdown system you are using.

Diagrams below are shown with the float in the “full” position.

Contact Adjustment Knobs

CAUTION: Perform all wiring connections with the battery disconnected. Observe all contact ratings and voltages.

Mounting Plate

Magnetic Switches

Crankcase Sight Glass

HI

LOW

L129

High and Low Contacts

G

Connecting Hoses and Fittings

2. Flexible hose or rigid pipe can be used to attach the L129 to the engine crankcase. Flexible hose is to be 1/2 in. (13 mm) I.D. minimum and made of quality material. Use of flexible hose will allow you to adjust the height of the L129 to properly reflect the oil level in the crankcase. Also, a swivel connection on one end of the hose will assist in properly aligning the L129.

WARNING: If both flexible hose and shockmounts are used, a ground wire must be added between the L129 and the engine.

Rigid pipe is to be 1/2 inch pipe. If the length of the pipe is relatively short, no additional support for the L129 may be needed, although it is recommended. A pipe union is provided in the installation kit.

Attach the hose or pipe from the L129 process connection (1/2 NPT) to the crankcase.

3. For vented crankcases, install the tube fitting and copper cane provided in the installation kit into the top of the L129. Venting to atmosphere will allow the oil level to rise in the L129 to the same level as in the crankcase, (the pressure/vacuum in the L129 and the crankcase must be equal). If the crankcase develops a positive (pressure) or negative (vacuum) pressure, you MUST connect the

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

NC

SW1

SW2 B

C

S

B

HI BLACK

1. DRAIN THE CRANKCASE. If the crankcase does not have an auxiliary plug or connection, connect the L129 to the crankcase drain plug connection. This connection will normally be a straight (parallel) thread which seals with a copper or fiber washer. NOTE: If the drain plug on the crankcase is used for the connection, we recommend installation of a tee to allow draining of the crankcase for service.

918.317.4100

117PH

518PH

Tee

LOW RED COM. WHITE

L129CK1 Rack Pull Solenoid

Fuel Valve

Ignition Coil

+

_

Battery

Contact Rating: 2 A @ 30 VAC/DC, pilot duty.

Operation Test The following test is to be performed after the L129 has been installed and the crankcase has been filled to the proper oil level.

1. With equipment running, turn the high and low adjust knobs one at a time until they “make” contact with the float. When contact is made the alarm or shutdown circuit should actuate.

2. Return high and low adjustment knobs to the proper contact position before operating equipment.

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

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

L-95006N page 2 of 2

LM-92164N Revised 10-03 Section 15

Installation Instructions for Level Maintainers

(00-02-0176)

Model Series LM300 Read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before mounting. These installation instructions are intended for all LM300 series models.

GENERAL INFORMATION

LM301-EX Shown with optional hose kit fittings

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

LM300: Level Maintainer only (no switches).

LM301: Low switch contacts for low level shutdown or alarm. Four wires, SPDT. LM302: Two switches for low and high level shutdown or alarm. Four wires, DPST, wired N.O. in normal operating ranges.

LM303: Two switches for low and high level shutdown or alarm. Four wires, DPST, wired N.C. in normal operating ranges.

LM304: Two switches. Alarm before shutdown on low level and shutdown on low-low level. Four wires, DPST, wired N.O. in normal operating ranges.

LM305: Two switches. Alarm before shutdown on low level and shutdown on lowlow level. Four wires, DPST, wired N.C. in normal operating ranges.

Specifications Case/Cover: Die cast aluminum.

Switch Housing: Aluminum.

Approval Rating: LM301 thru LM305 : CSA certified†† for non hazardous locations. Enclosure Type 4 certified.

LM301-EX thru LM305-EX: CSA certified†† for Class I, Groups C and D; Class II, Groups F and G hazardous locations. Enclosure Type 4 certified.

Float: Rigid polyurethane foam. Polyurethane coated.

Maximum Ambient Temperature: 250°F (121°C) Oil Inlet Connection: Top entry 1/2-14 NPT with built-in filter screen (removable for cleaning).

Inlet Orifices: 1/4 in. (6 mm) standard. 1/8 in. (3 mm) available.

Wire (switch models): 18 AWG x 13 in. (1.0 mm2 x 330 mm).

Maximum Inlet Pressure (MIP): Max. Differential: 2 in. (51 mm) between running and stationary oil level.

30 psi (207 kPa) [2.07 bar]. with 1/8 in. (3 mm) orifice.

15 ft. oil (4.6 m oil) with 1/4 in. (6 mm) orifice.

Maximum Case Pressure (MCP): 15 psi (103 kPa) [1.03 bar].

Orifice Seal†: Buna-N Thumb-Valve™ Switch Contact: Silver, SPDT snap acting, 10A @ 125, 250VAC; 10A @ 30VDC. (1 only for low level; 2 only for high & low; or 2 only for low with alarm before shutdown)

**

Patent 5493086

Outlet Connection: 3/4-14 NPT left side, right side, and bottom.

Crankcase Balance Vent Fitting: 1/2-14 NPT. Mounting: Accepts Murphy pipe mounting or universal mounting brackets.

Lens: Clear “Frog Eye” non-staining, high impact, high temperature nylon; UV and heat stabilized.

Dial: High visibility white background with green and white “index” lines for normal level indication.

Test Knob: Rotate to test switch operation. Turn clockwise for low level test and turn counterclockwise for high level test.

Flow Rate Test: Using SAE 30 @ 32°F (0°C).

Orifice Flow Rates Pressure Diameter 4 ft. oil – 15 ft. oil 4.7 GPH - 31.0 GPH 1/4 in.* (6 mm) (1.2 m oil – 4.6 m oil) (17.8 LPH - 117.3 LPH) 10 psig – 30 psig 1/8 in. (68.9 kPa – 207 kPa) 16.9 GPH - 32.1 GPH (3 mm) [.69 – 2.07 bar] (63.7 LPH - 121.5 LPH)

*Standard

NOTE: Friction losses due to piping NOT considered.

Optional Hose Kit: 15000355 Quantity Description

1 1 2 2 2 2

1/2 in. (13 mm) I.D. x 3 ft. (914 mm) long hose 1 in. (25 mm) I.D. x 3 ft. (914 mm) long hose 1/2 in. (13 mm) worm gear clamp 1 in. (25 mm) worm gear clamp 1/2 NPT x 1/2 in. (13 mm) barbed fitting 3/4 NPT x 1 in. (25 mm) barbed fitting

††CSA certified with switch contacts rated at 10 A @ 250 VAC (standard). ** Products covered by this bulletin comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility except as noted.

LM-92164N page 1 of 4

DIMENSIONS

LM300 Series Enclosures

Mounting Brackets with Hardware

The dimensions below are for the optional -EX model enclosure. The standard model enclosure dimensions are the same except the height and width which are: 7 in. (178 mm) H, 7-7/8 in. (200 mm) W. Oil Inlet Connection* 1/2-14 NPT with removable screen Crankcase Vent 1/2-14 NPT

6 in.

(152 mm) Electrical Conduit 1/2-14 NPT

15000371 pipe bracket 5.20 in.

(132 mm)

Additional Hardware Supplied (4) 3/8-16 UNC x 1 inch (25 mm) screws

4.50 in.

(114 mm) Hole .88 in.

(22 mm) dia.

(4) 3/8-16 nut (4) 3/8 I.D. lock washer (2) 3/8 I.D. flat washer

Test Knob

.376 in.

(10 mm) minimum bottom surface 2 places

2.50 in.

(64 mm)

1/4-20 NC 2 places

8-1/4 in.

(210 mm)

*Applies to level maintaining models only.

Monitoring Port Connection 3 places, 3/4-14 NPT

15000370 universal bracket

7-3/16 in.

(183 mm)

Slot, .390 in. (10 mm) Additional Hardware x 2 in. (51 mm) Supplied 4 places (2) 3/8-16 UNC x 1 inch (25 mm) screws Slot, .390 in. (10 mm) in. (120 mm) (4) 3/8 I.D. flat washer x3 4.71 places

Snap Switch Case Assembly

5-15/16 in.

(151 mm)

(17 6.69 0 m in. m)

.

5 in 1.7 mm) (44

(2) 3/8 I.D. lock washer

(11 4.50 4 in (13 5.19 mm) .

2 m in. m)

3/8-16 UNC-2B Mounting Holes, 2 places

2-3/4 in.

(70 mm)

(1 7.5 91 0 i m n. m )

(2) 3/8-16 nut

5-3/16 in.

(132 mm)

TYPICAL INSTALLATION

Mounting (all LM300 Series models)

Mounting with Universal Bracket

NOTE: Mount the LM300 series level maintainers as close as possible to the crankcase. Also, excessive vibration can cause overfill. Be sure mounting brackets are supported.

The following instructions are based on the usage of the pipe and universal mounting brackets shown above.

The universal bracket has two mounting methods: deck mounting and pan mounting.

Deck Mounting 1. Install the universal bracket to the deck as shown in Figure 2A with two flat washers and two 3/8 inch (10 mm) diameter bolts (not supplied).

Pipe Bracket Mounting 1. Mount a nominal 1/2 inch (21 mm) diameter pipe to the deck of the engine.

2. Install the pipe bracket to the LM300 using two 3/8-16 UNC x 1 inch bolts supplied. See Figure 1A. 3. Slip the LM300 onto the pipe and install the two adjustment bolts. Each adjustment bolt consists of a 3/8-16 UNC x 1 inch bolt and two nuts. See Figure 1B. DO NOT tighten the adjustment screws too tightly because you will have to adjust the LM300 later in the installation process.

Crankcase Universal Bracket

Deck

Pipe Bracket

Threaded hole

Figure 2A Adjustment Bolts

LM300

Figure 1A

Pipe

Crankcase

Adjustment Bolts

Figure 2B

2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1 inch (25 mm) bolts supplied (Figure 2B). DO NOT tighten the adjustment screws too tightly. You will have to adjust the LM300 later in the installation process.

Figure 1B LM-92164N page 2 of 4

TYPICAL INSTALLATION continued

Crankcase (Oil Pan) Mounting 1. Install the universal bracket to the crankcase using the existing crankcase bolts (Figure 3A). Crankcase bolt diameter must be no larger than 7/16 inch (11 mm).

Connecting the LM300 to an Oil Supply Tank (level maintaining models only)

Crankcase Bolt Universal Bracket Note Clearance before mounting

4. Fill the crankcase to the proper oil levels. With the engine running and warm, loosen the mounting bracket adjustment bolts and adjust the LM300 so that the oil level in the sight gauge is aligned with the white “index line” on the dial (Figure 4). Tighten the adjustment bolts securely.

Crankcase

Adjustment Bolt

Figure 3A

Figure 3B

NOTE: Check clearance between crankcase and mounting bracket before installing the mounting bracket. If space between the crankcase and mounting bracket does not allow installation and access to the adjustment bolts advance to Step 3.

2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1 inch bolts supplied. DO NOT tighten the adjustment bolts too tight. You will have to adjust the LM300 later in the installation process.

3. If space between the crankcase and mounting bracket is narrow, install the universal mounting bracket to the LM300 before installing to the crankcase oil pan.

Connecting Fittings and Hoses The following instructions are for all LM300 series level maintainers.

All steps that reference oil inlet or oil supply tank DO NOT apply to non-level-maintaining models. Also, these instructions are based on the Murphy optional hose kit described on page 1. If you did not order the optional hose kit, gather the hoses, clamps and fittings as specified in the optional hose kit.

1. Install the LM300 fittings in their proper locations. NOTE: Apply a sealant such as teflon, to all threaded connections.

2. Attach the 1 inch (25 mm) diameter, flexible monitoring hose to the crankcase and the monitoring port on the LM300. See Figure 4.

CAUTION: The hose must slope slightly downward from the LM300 and MUST NOT have any droop or low spots.

NOTE: If the drain plug on the crankcase is used for the connection, we recommend installation of a tee to Oil Inlet Vent Hose allow draining of the crankcase Hose for service.

Viewing Running 3. Install the 1/2 inch (13 mm) Lens Engine I.D. x 3 ft. (914 mm) hose to Crankcase Oil Level the vent connection on the LM300 to the vent connection on the crankcase. See Figure 4.

Monitoring Hose The vent connection on the crankcase must be well above the regulated oil level. All hoses must Figure 4 be clear of obstructions.

BEFORE CONTINUING, VERIFY THAT ALL HOSE CLAMPS ARE TIGHT.

1. Remove the caplug from the oil inlet connection. Be sure the filter, inside the connection, is clear of debris. Install the oil inlet connection.

2. Connect a 1/2 inch I.D. (13 mm) or larger hose Oil Supply to oil inlet fitting on the LM300 and to the shutoff Tank valve on the oil supply tank. See Figure 5. For models LM300 thru LM305 recommended minimum mounting of the oil supply Oil Inlet tank above the LM is 4 ft. (1.2m); Hose maximum 15 ft. (4.6m). The hose must maintain a downward slope and not have low spots or droops.

Maximum head pressure rating using standard 1/4 in. (6 mm) orifice is 15 ft. (4.6 meters). See Flow Rate test on page 1 for additional orifice pressure ratings.

Figure 5 3. Before filling the supply tank with oil, be sure the tank is clean and dry andthe shutoff valve is closed.

Also, be sure all hoses and clamps are tight. Fill the tank with CLEAN oil.

WARNING: Overfill condition can be caused by excessive inlet pressure, (maximum inlet pressure depends on orifice), and/or improper “vent to crankcase” installation.

See Flow Rate Test on page 1 for maximum pressure.

4. After oil supply tank is full, open the shutoff valve.

Next, make the proper electrical connections for the application. See contact ratings on page 1 and schematics on page 4.

Switch Test (switch models only) To test the shutdown and/or alarm functions perform the following: 1. Unscrew protective boot from test knob.

IMPORTANT: Always replace boot after testing.

2. Turn the test knob 1/4 turn to the right (clockwise), for low test indication (Figure 6).

Figure 6 3. Turn the knob 1/4 turn to the left (counterclockwise), for high test indication. DO NOT FORCE THE TEST KNOB TO TURN. NOTE: After the engine shuts down, you will notice that the oil in the sight gauge glass will rise above normal running level, possibly showing an overfill condition. This is a result of “drain-back” to the engine crankcase and it is normal. Therefore, on models LM302 and LM303 it may be necessary to wire the high level shutdowns into a class “B” or “C” (bypass until first time safe) lockout, so as to allow a permissive start. After the engine is re-started the level will pull down to the normal running level and the shutdown features will be active. A modulating valve (Thumb-Valve™) in the level maintaining models will allow oil usage to be made-up continuously during operation.

LM-92164N page 3 of 4

SWITCH WIRING DIAGRAMS

WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE CONNECTING ANY WIRES. LM301 SPDT

LM302 High/Low N.O. DPST Green

Green

Black

Black

Normal

Yellow

LM303 High/Low N.C. DPST

Red

Green High

Normal

Normal

Normal

Low

Brown

Yellow

Normal

Red

Float

Normal

Normal

Orange

Yellow

Blue

Low

Orange Low

Red

Low

Low

Low-Low

Low-Low

High

Blue

Normal

Brown Normal Low

Black

Low

High

Float

Green

Green

High

Low

Low

LM305 Alarm before shutdown N.C. DPST

LM304 Alarm before shutdown N.O. DPST

Low-Low

Low-Low

Float

Float

Float

OPERATING RANGES OF SWITCHES This section applies only to models that have built-in switches. The illustrations below and to the right show the dials and their operating ranges of the switches.

If levels are within the designated zones the switch(es) will activate. Notice that a switch is capable of activating approximately 3/8 in. (10 mm) from the top of the high zone and 3/8 in. (10 mm) from the bottom of the low zone. The dial in Figure 9 shows that if level continues to drop into the low-low zone, a shutdown will occur.

3/8 in.

(10 mm)

3/4 in.

(19 mm)

Normal Operating Range

3/4 in.

(19 mm)

NOTE: Color zones on dial face show approximate normal operating zones.

Actual conditions may vary depending upon operating characteristics of the engine. Placement of the LM300 according to the above instructions will compensate for these conditions.

Normal Operating Range

High Zone Shutdown or Alarm

3/4 in.

(19 mm)

Low Zone Shutdown or Alarm 3/8 in.

(10 mm)

Figure 8: LM302/LM303

Normal Operating Range

3/4 in.

(19 mm)

Low Zone Shutdown or Alarm

Low Zone Alarm Low-Low Zone Shutdown 3/8 in. 1/4 in.

(10 mm) (6 mm)

3/8 in.

(10 mm)

Figure 7: LM301

Figure 9: LM304/LM305

Warranty A limited warranty on materials and workmanship is given with this FW Murphy product.

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

GI

D

MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA +1 661 272 4700 fax +1 661 947 7570 e-mail sales@murphyswitch.com www.murphyswitch.com

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

E

MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail ventas@murphymex.com.mx www.murphymex.com.mx

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

RE

FW Murphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail sales@fwmurphy.com www.fwmurphy.com

CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail sales@fwmurphy.com

STER

USA–ISO 9001:2000 FM 28221 UK–ISO 9001:2000 FM 29422

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

Printed in U.S.A.

LM-92164N page 4 of 4

L-94071N Revised 09-97 Section 15

Installation Instructions for L971 Series Crankcase Level Switch

(00-02-0173) ®

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

GENERAL INFORMATION

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

®

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

Description

** R

Dimensions

The Murphy L971 Series Level Switch detects low oil level in a compressor’s crankcase. It is designed for Ingersoll-Rand Type 30, Type 40 and ESH compressors, yet can be adapted to fit other compressors that have an inspection plate extending below normal operating oil level.

The L971 has a 1/2 NPT process connection and features an explosionproof enclosure, durable SPDT snap-switch and rigid polyurethane foam float.

D

Float is removable and replaceable 1/2 NPT

E 3 in.

(76 mm)

A

Float arm is adjustable but cannot be removed.

Specifications

B

C

Operating Temperature: -15 to 275°F (-26 to 135°C).

1/2 NPT

Maximum Working Pressure: 30 psi (206 kPa) [2.06 bar].

Switch Rating: 4 A @ 250 VAC. Material Case: Aluminum (explosion-proof).

Mounting Adaptor: Brass.

Floats: • Rigid polyurethane.

• 304 stainless steel (L971-C only).

Other Wetted Parts: 303, 304, and 316 stainless steel.

O-Ring Seals: Viton and Buna.

Process Connection: 1/2 NPT. Enclosure Rating: UL and CSA listed for Class I, Groups C & D; Class II, Groups F & G, Hazardous Locations.

Conduit Connection: 1/2 NPT. Wire: 18 AWG (0.75 mm2).

Dimensions in inches* (see drawing above)

A

B

C

D

E

2-5/8 (67)

5-7/8 (149)

30 (762)

2-1/2 (64)

2-27/32 (72)

Models L971 L971-A

2-5/8 (67)

5-7/8 (149)

30 (762)

2-1/2 (64)

2-27/32 (72)

L971-B

4-13/16 (122)

8-1/16 (205)

30 (762)

4-5/8 (117)

2-27/32 (72)

L971-C

2-13/16 (71)

6-1/16 (154)

30 (762)

2-7/8 (73)

3-1/8 (79)

L971-D

3-7/8 (98)

7-1/8 (181)

30 (762)

3-3/4 (95)

2-27/32 (72)

L971-E

4-13/16 (122)

8-1/16 (205)

30 (762)

5-1/8 (130)

2-27/32 (72)

L971-F

2-5/8 (67)

5-7/8 (149)

40 (1016)

2-1/2 (64)

2-27/32 (72)

L971-G

2-5/8 (67)

5-7/8 (149)

40 (1016)

2-1/2 (64)

2-27/32 (72)

*Millimeter dimensions are shown in parenthesis ( ).

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

** Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility except as noted.

INSTALLATION

TYPICAL WIRING

Compressors With Inspection Plate

Shutdown and Alarm Circuit

1. Drain crankcase.

2. Remove crankcase inspection plate (Figure 1).

3. Drill and tap a 1/2 NPT female pipe thread into the inspection plate at point “A” (Figure 2). CAUTION: Clean area of metal shavings. The hole is to be a minimum of 2 in. (51 mm) below normal running oil level (Figure 3).

Line Voltage

Control Voltage

H

Yellow Black Red

Alarm Silencer Crankcase Switch

Alarm

Inspection Plate

A

Shutdown Circuit for H.O.A. Operation

H

Figure 2 “TOP” Label

A

HC

Crankcase

Figure 1

O

O

A

Yellow

HC Black

90°

Oil Level

Normal Oil Level Hole

Crankcase Switch

Inspection Plate

2 in. (51 mm) Minimum

Conduit

Shutdown Circuit for Start-Stop Push-button Operation

Crankcase

Figure 3

Float Start

Figure 4 Yellow

HC

4. Unscrew and remove float on the L971 switch.

5. Apply pipe dope to the process connection threads.

6. Thread the L971 switch into crankcase hole until “TOP” label is up (Figure 4). Be sure the float moves freely and there are no obstructions.

7. If adjustment of shutdown level is required, loosen hex set screw on float attachment. Rotate float attachment to desired level. Retighten set screw.

8. Replace float and reinstall inspection plate and gasket in original position.

9. Install drain plug.

10. Wire accordingly.

11. Fill crankcase to proper level.

Stop Black Crankcase Switch

Alarm Without Shutdown Circuit Alarm Alarm Silencer Yellow

Compressors Without Inspection Plate 1. If installing into a thick wall crankcase, drill and tap a 1/2 NPT female pipe thread into the crankcase. CAUTION: Clean area of metal shavings. The hole is to be a minimum of 2 in. (51 mm) below normal running oil level (Figure 3).

If installing into a thin wall crankcase, drill a hole in the crankcase slightly larger than outside diameter of a 1/2 in. coupling. The hole is to be a minimum of 2 in. (51 mm) below normal running oil level (Figure 3). CAUTION: Clean area of metal shavings. Weld a half collar (1/2 NPT) into the hole.

2. Follow steps 4 thru 11 above.

Power Supply

Red

Crankcase Switch

REPLACEMENT PARTS Description Cover Cover Gasket Snap-switch

Part Number 15050443 15050369 00002326

Description Part Number Float Polyurethane 15050679 Stainless Steel 15050356

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. ®

FRANK W.

Since 1939

MFR.

Printed in U.S.A.

■ Frank W. Murphy Manufacturer P.O. Box 470248; Tulsa, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail fwmurphy@ionet.net ■ Frank W. Murphy Southern Division P.O. Box 1819; Rosenberg, Texas 77471; USA tel. (281) 342-0297 fax (281) 341-6006 e-mail murphysd@intertex.net

■ Frank W. Murphy, Ltd. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. tel. +44 1722 410055 fax +44 1722 410088 tlx 477088 e-mail sales@fwmurphy.co.uk ■ Frank W. Murphy Pte., Ltd. 26 Siglap Drive; Republic of Singapore 456153 tel. +65 241-3166 fax +65 241-8382 e-mail fwmsales@fwmurphy.com.sg ■ Murphek Pty., Ltd. 1620 Hume Highway; Campbellfield, Vic 3061; Australia tel. +61 3 9358-5555 fax +61 3 9358-5558

■ Murphy de México, S.A. de C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 tel. +52-48-206264 fax +52-48-206336 e-mail murmexsl@sanluis.podernet.com.mx ■ Murphy Switch of California P.O. Box 900788; Palmdale, California 93590; USA tel. (805) 272-4700 fax (805) 947-7570 e-mail sales@murphyswitch.com ■ Frank W. Murphy France tel. +33 1 30 762626 fax +33 1 30 763989

Industrial Thermocouples

Return to Industrial Thermocouples Index

Installation and Maintenance Thermocouple Installation 1.

2.

3.

4.

5.

6.

7.

Carefully select the location and insertion depth at a point where the temperature is most likely representative of the process temperature. It is important to avoid stagnant areas of the measured media which do not have representative temperatures.

Locating the thermocouple where the hot end can be seen assures visual confirmation of the junction location.

Immerse the thermocouple far enough to ensure that the measuring junction is entirely included in the temperature area to be measured. a depth ten times that of the diameter of the protection tube is recommended. Heat which is conducted away from the hot junction will cause a lower reading due to "stem loss."

Keep the connecting head and cold junction in coolest ambient temperature available.

To prevent breakage due to thermal shock, never insert a ceramic tube into a hot area rapidly. Preheat gradually while installing.

Avoid direct flame impingement on protecting tube. Impingement shortens the tube life and causes temperature readings to be inaccurate.

When measuring high temperatures, install the thermocouple vertically, whenever possible. Such installation minimizes sagging of the tube or sheath.

Extension Wire Installation 1.

2.

3.

4.

5.

Be sure to select the correct type of extension wire for a given calibration of thermocouple. (See Bulletin 300).

Use the color coding of individual wires as a guide for connecting the negative wire to the negative-wire terminal at both the thermocouple connection head and the instrument. Red is always Negative (-).

To prevent spurious EMF due to electrostatic and electromagnetic noise, never run thermocouple extension wire in same conduit, parallel to the conduit or near any power source. Keep thermocouple wire at least 12" from power source.

In "high noise" areas, use thermocouple extension wire with twisted and shielded conductors and a drainwire.

Select the proper insulation to meet the specific conditions under which it must perform. (See Bulletin 300).

General Maintenance 1.

2.

3.

4.

5.

6.

Monthly maintenance checks are usually sufficient for base metal thermocouples. Individual conditions, however, may require more frequent checks.

Keep rotary switches clean and free of oxidation at contact points.

When reinserting a thermocouple, it is extremely important that the depth of insertion not be changed. Be especially careful not to decrease the depth. Wires which are not homogeneous, due to exposure to the process, will cause errors in regions of temperature gradients.

A type K thermocouple should not be exposed to temperatures of 1600° F or higher if it is to be used for accurate measurements below 1000° F. Do not use thermocouples with burned-out protecting tubes. Thermocouples can become damaged with contamination if allowed to remain within tubes of poor condition.

If thermocouples are to be connected in series, parallel or differential, refer to the diagrams on Page 3.

Return to Industrial Thermocouples Index Thermo Sensors Corporation • P.O. Box 461947 • Garland, Texas 75046 • 1-800-889-5478 • 972-494-1566

© 2005 Thermo Sensors Corporation | Design by Visual Applications

catalog mg

4

9/5/02

9:48 AM

Page 6

WIDE RANGE DIAPHRAGM SS PORT

EXTERNAL ADJUSTMENT

PRESSURE

INSTALLATION DRAWING

Press. 1 to 2500 psi

SERIES: 6900GZE

6900GZE

Standard Features: • U.L./CSA Explosion Proof: Div. 1, 2 • NEMA: 4, 7, 9, 13 AMBIENT TEMP. RANGE –30° to 160° F –34° to 71° C 6900GZE SHIPPING WT. APPROX. 19 OZ. (539 GRAMS)

OPERATING AND ORDERING DATA: PRESSURE SWITCHES

MODEL 6900GZE • Max Sys. Press. psi

Proof (Test) Press. psi

500 500 1500 1500 2000 3000

750 750 2000 2000 3000 4500

1/2” STAINLESS STEEL PRESSURE PORT AND DIAPHRAGM Adjustable Set–Point Range

Model No.

On Decr.

Press. psi

Approx.

Dead– band psi

3–20 9–75 18–150 45–375 300–1000 700–2500

1–18 3–69 6–138 15–345 225–925 520–2320

2 6 12 30 75 180

RATING OF SWITCH ELEMENT

125 AC – 50/60 Hz 250 AC – 50/60 Hz 30 DC 125 DC

316 SST Viton

On Incr.

Press. psi

ELECTRICAL CHARACTERISTICS: VOLTS

Wetted Parts

AMPERES DPDT “M” SPDT Res. Res. 11 11 11 11 5 5 .5 .5

MODEL SPDT–Std.

MODEL DPDT “M”

6900GZE12 6900GZE14 6900GZE16 6900GZE18 6900GZE20 6900GZE22

6900GZEM12 6900GZEM14 6900GZEM16 6900GZEM18 6900GZEM20 6900GZEM22

SCHEMATIC AND WIRING CODE: SPDT–Standard

DPDT “M”

Options Code: “F” Ethylene Propylene O–ring “7008” Gold Contacts “7042” SST Body “7043” SST Body & Gold Contacts “7044” Monel Port & Diaphragm “7045” Hastelloy Port & Diaphragm “7052” Exp. Proof w/3’ Leads “7054” Exp. Proof w/6’ Leads “7065” Exp. Teflon Wire & SST Diaphragm

ENCLOSURE/CERTIFICATIONS: Div. 1 explosion–proof and hermetically sealed electrical assembly Part No. 46–1058 (46–1061 for “M” model option), listed by both Underwriter’s Laboratories, Inc. (File No. E32961) and CSA Testing Laboratories (File No. 22921) for hazardous locations, Class 1, Groups A, B, C, and D; Class 2 Groups E, F, and G.

HOW TO ORDER: Specify model number, add desired “options” listing letter codes first followed by numbers: Custom Control Sensors, Inc. • 21111 Plummer Street, Chatsworth, CA 91311 • Tel: (818)341-4610 • Fax: (818)709-0426 e-mail: switchnet@ccsdualsnap.com • http://www.ccsdualsnap.com

29

APPLICATION AND TECHNICAL INFORMATION PRESSURE SWITCH Approximate Pressure Sensing Performance Characteristics

Corrosive Fluids

Occasionally liquids or gases are encountered that are not compatible with the “wetted parts ”as shown in the catalog. When this occurs it is common practice to use a chemical seal as an interface between the corrosive fluid and the pressure switch.Custom Control Sensors does not manufacture or accept orders for chemical seals. The reason for this is to insure that the customer gets exactly what he needs for his application.

We will drop ship switches to any manufacturer of chemical seals that the customer may specify,or we can recommend a suitable source of supply if asked (Note: The customer can then place a purchase order with appropriate instructions directly with his source of supply so that the supplier can then coordinate the customer’s wishes with the chemical seal that will be assembled, filled,calibrated and tested to fit the needs outlined).

Typical and readily available CHEMICAL SEALS

Surge and Ripples

The Disc Spring design used in DUAL–SNAP® switches makes them relatively impervious to surges or pump ripples that may be expected in conventional hydraulic systems.

This resistance to sharp pressure changes in the media has been the prime reason for many customers changing to DUAL–SNAP® pressure switches after experiencing false shutdown and failure with other competitive design principles such as flat metal diaphragms, bourdon tubes and bellows type.This makes DUAL–SNAP ® switches particularly suitable for rugged applications on off the road machinery, heavy presses,and systems using pulsating piston pumps

Pressure Switch Application Conditions Ambient Temperature: The pressure switch should be installed wherever possible in a location that has the most constant ambient temperature available.

Steam Service: For steam or other high temperature applications the pressure switch should be mounted with the pressure connection up and with three or four circular loops,or pigtails, in the pressure lines. The vertical mounting allows condensate to accumulate in the dead ended pressure line and to be cooled in the pigtail which acts as a temperature buffer between the sensing element and the steam.

Pressure Switch Installation

The pressure switches can be mounted in any position.

When the electrical conduit is connected, it is recommended that the conduit line (if it is over 6 feet in length)be clamped firmly close to the switch to keep thermal expansion from causing it to place a high stress load onto the housing of the pressure switch.If moisture in the conduit line is a potential problem, it is recommended that a potting Y connection be placed between the switch and the conduit.This will eliminate drainage from the electrical conduit into the pressure switch housing.

Line mounting is possible and recommended for any of our “Compact ”pressure switches.Installation must not impose loads on connections.

Seismic Shock and Vibration

Due to their unique design principle, DUAL– SNAP® pressure and temperature switches will meet all the conventional seismic shock and vibration specifications now being applied to many projects such as power plants for ecological protection.These specifications by their severity eliminate the use of mercury filled switching elements and many vibration critical sensing elements found in most competitive designs.

HOW TO ORDER: Specify model number, add desired “options” listing letter codes first followed by numbers: Custom Control Sensors, Inc. • 21111 Plummer Street, Chatsworth, CA 91311 • Tel: (818)341-4610 • Fax: (818)709-0426 e-mail: switchnet@ccsdualsnap.com • http://www.ccsdualsnap.com

IOM Manual

Appendix C

Appendix C – Driver Coupling IOM Manuals Centrilift Standard Driver Coupling Offering

Coupling

Manufacturer

Manufacturer’s IOM Manual

Standard Models

T10 – Close Coupled

Falk

T31 – Spacer (Used with Cartridge Seals) Limited End Float Kit (Used with Sleeve Bearing Motors)

Falk

“Falk™ Steelflex® Couplings • Installation and Maintenance Type T10 • Sizes 1020–1140 & 20–140” “Steelflex® Pre-Assembled Spacer Couplings • Installation & Maintenance Type T31 • Sizes 1020–1140 & 20–140”

1070T10 1080T10 1090T10 1070T31 1080T31 1090T31

“Falk™ Steelflex® Couplings • Limited End Float Installation Sizes 20-260 & 1030-1260”

1070 1080 1090

Falk

Falk™ Steelflex® Couplings • Installation and Maintenance Type T10 • Sizes 1020–1140 & 20–140

(Page 1of 6)

TYPE T10 STEELFLEX COUPLING

How To Use This Manual This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification. Use the table of contents below to locate required information.

Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2 Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4 Annual Maintenance, Relube & Disassembly . . . . . . . Page 4 Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5 Parts Identification & Parts Interchangeability . . . . . . . Page 6 CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.

INTRODUCTION This manual applies to Sizes 1020T thru 1140T and 20T thru 140T10 Falk SteelfIex Tapered Grid Couplings. Unless otherwise stated, information for Sizes 1020T thru 1140T applies to Sizes 20T thru 140T respectively, e.g. 1020T = 20T, 1100T = 100T, etc. These couplings are designed to operate in either the horizontal or vertical position without modification. Beginning in year 1994 through 2003, these couplings were being supplied with one set of inch series fasteners and one set of Metric fasteners. Beginning in year 2004 only Metric fasteners are being supplied. Refer to Page 6 for part interchangeability.

The performance and life of the couplings depend largely upon how you install and service them.

CAUTION: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings.

WARNING: Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings.

LUBE FITTINGS Cover halves have 1/8 NPT Iube holes. Use a standard grease gun and Iube fitting as instructed on Page 4.

LIMITED END FLOAT When electric motors, generators, engines, compressors and other machines are fitted with sleeve or straight roller bearings, limited axial end float kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float; refer to Manual 428-820 for instructions.

LUBRICATION Adequate lubrication is essential for satisfactory operation.

Page 2 provides a list of typical lubricants and specifications for general purpose and long term greases. Because of its

superior lubricating characteristics and low centrifuge properties, Falk Long Term Grease (LTG) is highly recommended. Sizes 1020T to 1090T10 are furnished with a pre-measured amount of grease for each coupling. The grease can be ordered for larger size couplings.

The use of general purpose grease requires re-lubrication of the coupling at least annually.

Long Term Grease (LTG) The high centrifugal forces encountered in couplings separate the base oil and thickener of general purpose greases. Heavy thickener, which has no lubrication qualities, accumulates in the grid-groove area of Steelflex couplings resulting in premature hub or grid failure unless periodic lubrication cycles are maintained.

Falk Long Term Grease (LTG) was developed specifically for couplings. It resists separation of the oil and thickener. The consistency of Falk LTG changes with operating conditions. As manufactured it is an NLGI #1/2 grade. Working of the lubricant under actual service conditions causes it to become semifluid while the grease near the seals will set to a heavier grade, helping to prevent leakage.

LTG is highly resistant to separation, easily out performing all other lubricants tested. The resistance to separation allows the lubricant to be used for relatively long periods of time.

Steelflex couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required.

Although LTG grease is compatible with most other coupling greases, the mixing of greases may dilute the benefits of LTG.

USDA Approval LTG has the United States Department of Agriculture Food Safety & Inspection Service approval for applications where there is no possibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

428-110 May 2004 Supersedes 2-03

Installation and Maintenance • Falk™ Steelflex® Couplings (Page 2 of 6)

Type T10 • Sizes 1020–1140 & 20–140

Specifications — Falk LTG The values shown are typical and slight variations are permissible.

AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F (121°C). Min. Pump = 20° F (-7° C).

MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @ 100°F (38°C).

THICKENER — Lithium & soap/polymer.

CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM #D4425 (Centrifuge Test) — K36 = 2/24 max., very high resistance to centrifuging.

NLGI GRADE (ASTM D-217) — 1/2 CONSISTENCY (ASTM D-217) — 60 stroke worked penetration value in the range of 315 to 360 measured at 77°F (25°C) MINIMUM DROPPING POINT — 350°F (177°C) minimum MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do not corrode steel or swell or deteriorate synthetic seals.

Packaging 14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of 10 or 30.

35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg) DRUMS.

General Purpose Greases Meeting Rexnord Specifications Lubricants listed below are typical products only and should not be construed as exclusive recommendations.

TABLE 1 — General Purpose Greases H Ambient Temperature Range

0°F to 150°F (-18°C to 66°C)

-30°F to 100°F (-34°C to 38°C)

Manufacturer Amoco Oil Co. BP Oil Co. Chevron U.S.A. Inc. Citgo Petroleum Corp.

Conoco Inc. Exxon Company, USA E.F. Houghton & Co. Imperial Oil Ltd. Kendall Refining Co. Keystone Div. (Pennwalt) Lyondell Petrochemical (ARCO) Mobil Oil Corp.

Petro-Canada Products Phillips 66 Co. Shell Oil Co. Shell Canada Ltd. Sun Oil Co. Texaco Lubricants Unocal 76 (East & West) Valvoline Oil Co.

Lubricant † Amolith Grease #2 Energrease LS-EP2 Dura-Lith EP2 Premium Lithium Grease EP2 EP Conolith Grease #2 Unirex EP2 Cosmolube 2 Unirex EP2 Lithium Grease L421 81 EP-2 Litholine H EP 2 Grease

Lubricant † Amolith Grease #2 Energrease LS-EP1 Dura-Lith EP1 Premium Lithium Grease EP1 EP Conolith Grease #2 Unirex EP2 Cosmolube 1 Unirex EP2 Lithium Grease L421 81 EP-1 Litholine H EP 2 Grease

Mobilux EP111 Multipurpose EP2 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige 2EP Starplex HD2 Unoba EP2 Multilube Lithium EP Grease

Mobilith AW1 Multipurpose EP1 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige 2EP Multifak EP2 Unoba EP2 ...

H Grease application or re-lubrication should be done at temperatures above 20°F

(-7°C). If grease must be applied below 20°F (-7°C), consult the Factory. † Lubricants listed may not be suitable for use in the food processing industry; check

with lube manufacturer for approved lubricants.

General Purpose Grease Annual Lubrication — The following specifications and lubricants for general purpose grease apply to Falk Steelflex couplings that are lubricated annually and operate within ambient temperatures of 0°F to 150°F (-18°C to 66°C). For temperatures beyond this range (see Table 1), consult the Factory.

If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture or experiences frequent reversals, more frequent lubrication may be required.

Specifications — General Purpose Coupling Lubricants The values shown are typical and slight variations are permissible.

DROPPING POINT — 300°F (149°C) or higher.

CONSISTENCY — NLGI No. 2 with 60 stroke worked penetration value in the range of 250 to 300.

SEPARATION AND RESISTANCE — Low oil separation rate and high resistance to separation from centrifuging.

LIQUID CONSTITUENT — Possess good lubricating properties equivalent to a high quality, well refined petroleum oil.

INACTIVE — Must not corrode steel or cause swelling or deterioration of synthetic seals.

CLEAN — Free from foreign inclusions.

428-110 May 2004 Supersedes 2-03

INSTALLATION OF TYPE T10 STEELFLEX TAPERED GRID COUPLINGS Installation Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required to install Falk Steelflex couplings.

Coupling Sizes 1020T thru 1090T are generally furnished for CLEARANCE FIT with setscrew over the keyway. Sizes 1100T and larger are furnished for an INTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Clean all parts using a nonflammable solvent. Check hubs, shafts and keyways for burrs.

Do not heat clearance fit hubs. Install keys, mount hubs with flange face flush with shaft ends or as otherwise specified and tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews.

Heat hubs to a maximum of 275°F (135°C) using an oven, torch, induction heater or an oil bath. To prevent seal damage, DO NOT heat hubs beyond a maximum temperature of 400°F (205°C).

When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hubs near the center of their length in several places on hub body with a temperature sensitive crayon, 275°F (135°C) melt temperature. Direct flame towards hub bore using constant motion to avoid overheating an area.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

Falk™ Steelflex® Couplings • Installation and Maintenance Type T10 • Sizes 1020–1140 & 20–140 WARNING: If an oil bath is used, the oil must have a flash point of 350°F (177°C) or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials.

Heat hubs as instructed above. Mount hubs as quickly as possible with hub face flush with shaft end. Allow hubs to cool before proceeding. Insert setscrews (if required) and tighten.

(Page 3of 6)

Use a spacer bar equal in thickness to the gap specified in Table 2, Page 5. Insert bar as shown below left, to same depth at 90° intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR installation limits specified in Table 2.

3 — Offset Alignment

Maximize Performance And Life The performance and life of couplings depend largely upon how you install and maintain them. Before installing couplings, make certain that foundations of equipment to be connected meet manufacturers’ requirements. Check for soft foot. The use of stainless steel shims is recommended.

Measuring misalignment and positioning equipment within alignment tolerances is simplified with an alignment computer.

These calculations can also be done graphically or mathematically.

Alignment is shown using spacer bar and straight edge. This practice has proven to be adequate for many industrial applications. However, for superior final alignment, the use of dial indicators (see Manual 458-834 for instructions), lasers, alignment computers or graphical analysis is recommended.

MOUNT SEAL FIRST

Align so that a straight edge rests squarely (or within the limits specified in Table 2) on both hubs as shown above and also at 90° intervals. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Table 2. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.

4 — Insert Grid

1— Mount Seals And Hubs Lock out starting switch of prime mover. Clean all metal parts using a non-flammable solvent. Lightly coat seals with grease and place on shafts BEFORE mounting hubs. Heat interference fit hubs as previously instructed. Seal keyways to prevent leakage. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft unless otherwise indicated. Tighten setscrews when furnished.

2 — Gap and Angular Alignment

Pack gap and grooves with specified lubricant before inserting grid. When grids are furnished in two or more segments, install them so that all cut ends extend in the same direction (as detailed in the exploded view picture above); this will assure correct grid contact with non-rotating pin in cover halves. Spread the grid slightly to pass over the coupling teeth and seat with a soft mallet.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

428-110 May 2004 Supersedes 2-03

Installation and Maintenance • Falk™ Steelflex® Couplings Type T10 • Sizes 1020–1140 & 20–140

(Page 4 of 6)

5 — Pack With Grease And Assemble Covers

ANNUAL MAINTENANCE For extreme or unusual operating conditions, check coupling more frequently.

1. Check alignment per steps on Page 3. If the maximum operating misalignment limits are exceeded, realign the coupling to the recommended installation limits. See Table 2 for installation and operating alignment limits.

2. Check tightening torques of all fasteners.

3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace.

4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using new gasket as instructed in this manual.

Periodic Lubrication MATCH MARK

MATCH MARK

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid.

Position seals on hubs to line up with grooves in cover.

Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side (see above). If shafts are not level (horizontal) or coupling is to be used vertically, assemble cover halves with the lug and match MATCH MARK

LUG UP

The required frequency of lubrication is directly related to the type of lubricant chosen, and the operating conditions. Steelflex couplings lubricated with common industrial lubricants, such as those shown in Table 1, should be relubed annually. The use of Falk Long Term Grease (LTG) will allow relube intervals to be extended to beyond five years. When relubing, remove both lube plugs and insert lube fitting. Fill with recommended lubricant until an excess appears at the opposite hole. CAUTION: Make certain all plugs have been inserted after lubricating.

Coupling Disassembly And Grid Removal

VERTICAL COUPLINGS

mark UP or on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tighten to torque specified in Table 2. Make sure gaskets stay in position during tightening of fasteners. CAUTION: Make certain lube plugs are installed before operating.

428-110 May 2004 Supersedes 2-03

Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required.

Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

Falk™ Steelflex® Couplings • Installation and Maintenance Type T10 • Sizes 1020–1140 & 20–140

Values may be combined for an installation or operating condition.

Example: 1060T max. operating misalignment is .016" parallel plus .018" angular.

NOTE: For applications requiring greater misalignment, refer application details to the Factory.

Angular misalignment is dimension X minus Y as illustrated below.

Parallel misalignment is distance P between the hub center lines as illustrated below.

End float (with zero angular and parallel misalignment) is the axial movement of the hubs(s) within the cover(s) measured from “0” gap.

TYPE T COUPLING INSTALLATION & ALIGNMENT DATA Maximum life and minimum maintenance for the coupling and connected machinery will result if couplings are accurately aligned. Coupling life expectancy between initial alignment and maximum operating limits is a function of load, speed and lubrication. Maximum operating values listed in Table 2 are based on cataloged allowable rpm.

Values listed are based upon the use of the gaps listed, standard coupling components, standard assemblies and cataloged allowable speeds.

ANGULAR MISALIGNMENT

(Page 5of 6)

END FLOAT

PARALLEL OFFSET MISALIGNMENT

F

Y

F

P P X

GAP

TABLE 2 — Misalignment & End Float Installation Limits Parallel Offset-P

SIZE

1020T 1030T 1040T 1050T 1060T 1070T 1080T 1090T 1100T 1110T 1120T 1130T 1140T

Angular (x-y)

Operating Limits Hub Gap ± 10%

Parallel Offset-P

Angular (x-y)

End Float Physical Limit (Min) 2 x F

Cover Fastener Tightening Torque Values Inch or Metric Series Fasteners

Max Inch

Max mm

Max Inch

Max mm

Inch

mm

Max Inch

Max mm

Max Inch

Max mm

Inch

mm

(lb-in)

.006 .006 .006 .008 .008 .008 .008 .008 .010 .010 .011 .011 .011

0,15 0,15 0,15 0,20 0,20 0,20 0,20 0,20 0,25 0,25 0,28 0,28 0,28

.003 .003 .003 .004 .005 .005 .006 .007 .008 .009 .010 .012 .013

0,08 0,08 0,08 0,10 0,13 0,13 0,15 0,18 0,20 0,23 0,25 0,30 0,33

.125 .125 .125 .125 .125 .125 .125 .125 .188 .188 .250 .250 .250

3 3 3 3 3 3 3 3 5 5 6 6 6

.012 .012 .012 .016 .016 .016 .016 .016 .020 .020 .022 .022 .022

0,30 0,30 0,30 0,41 0,41 0,41 0,41 0,41 0,51 0,51 0,56 0,56 0,56

.010 .012 .013 .016 .018 .020 .024 .028 .033 .036 .040 .047 .053

0,25 0,30 0,33 0,41 0,46 0,51 0,61 0,71 0,84 0,91 1,02 1,19 1,35

.210 .198 .211 .212 .258 .259 .288 .286 .429 .429 .556 .551 .571

5,33 5,03 5,36 5,38 6,55 6,58 7,32 7,26 10,90 10,90 14,12 14,00 14,50

100 100 100 200 200 200 200 200 312 312 650 650 650

Lube Wt

Allow Speed (rpm)

(Nm) 11,3 11,3 11,3 22,6 22,6 22,6 22,6 22,6 35 35 73 73 73

4500 4500 4500 4500 4350 4125 3600 3600 2440 2250 2025 1800 1650

lb

kg

.06 .09 .12 .15 .19 .25 .38 .56 .94 1.1 1.6 2.0 2.5

0,03 0,04 0,05 0,07 0,09 0,11 0,17 0,25 0,43 0,51 0,74 0,91 1,14

TABLE 3 — Coupling Cover Fastener Identification Inch Series Fasteners SIZE

METRIC FASTENERS Old Style

New Style

H

1020-1070T10

SAE Grade 8

1080-1090T10

SAE Grade 8

SAE Grade 8

1100-1140T10

SAE Grade 5

SAE Grade 5

SAE Grade 8

1 0. 9

1 0. 9

8. 8

Property Class 10.9

Property Class 10.9

Property Class 8.8

H Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

428-110 May 2004 Supersedes 2-03

Installation and Maintenance • Falk™ Steelflex® Couplings Type T10 • Sizes 1020–1140 & 20–140

(Page 6 of 6)

PARTS IDENTIFICATION All coupling parts have identifying part numbers as shown below. Parts 3 and 4 (Hubs and Grids), are the same for both Type T10 and T20 couplings. All other coupling parts are unique to Type T10. When ordering parts, always SPECIFY SIZE and TYPE shown on the COVER.

PARTS INTERCHANGEABILITY Parts are interchangeable between Sizes 20T and 1020T, 30T and 1030T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use blue or non-painted grids. Older models, 20T thru 140T, use orange grids.

CAUTION: Blue or non-painted grids may be used in all applications, but DO NOT substitute orange grids for blue or nonpainted.

COVERS — CAUTION: DO NOT mix cover halves of different designs. Sizes 1020T thru 1070T10 covers have been manufactured in several different two-rib designs and 80T thru 140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru 1070T10, utilized socket head cap screws with captured locknuts. The new style covers use hex head cap screws (either inch or metric from year 1994 through 2003 and only Metric beginning in 2004). Specify the style cover when ordering replacement parts.

PART NUMBER LOCATION PART DESCRIPTION 1. Seal (T10) 2. Cover (T10) 3. Hub (Specify bore and keyway) (2.) COVER (7.)

SIZE & (1.) SEAL PART NUMBER

(3.) HUB

SIZE, PART NUMBER & BORE

COUPLING SIZE PRODUCT CLASSIFICATION

(4.) GRID

PART NUMBER

4. Grid

B TYPE

MODEL

5. Gasket (T10) 6. Metric Fasteners (T10).

7. Lube Plug

ORDER INFORMATION 1. Identify part(s) required by name above.

2. Furnish the following information.

PART NUMBER (6.)

May 2004 Supersedes 2-03

10

SIZE

(5.) GASKET

SIZE

428-110

1030 T

EXAMPLE: Coupling Size: 1030 Coupling Type: T10 Model: B Bore: 1.375 Keyway: .375 x .187 3. Contact your Rexnord Distributor or Rexnord for price and availability.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

®

Steelflex® Pre-Assembled Spacer Couplings • Installation & Maintenance Type T31 • Sizes 1020–1140 & 20–140

(Page 1 of 6)

How to Use This Manual

LUBRICATION

This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification. Use the table of contents below to locate required information.

Adequate lubrication is essential for satisfactory operation. Page 2 provides a list of typical lubricants and specifications for general purpose greases. Because of its superior lubricating characteristics and low centrifuge properties, Falk Long Term Grease (LTG) is highly recommended. LTG is provided in all pre-assembled spacer couplings.

The use of general purpose grease requires re-lubrication of the coupling at least annually.

Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . Page 1 Lube Fittings . . . . . . . . . . . . . . . . . . . . . Page 1 Limited End Float . . . . . . . . . . . . . . . . . . Page 1 Lubrication . . . . . . . . . . . . . . . . . . . Pages 1-2 Installation & Alignment Instructions . . . . . . . . Pages 2-4 Annual Maintenance, Relube & Disassembly . . . . . Page 4 Installation & Alignment Data . . . . . . . . . . . . Page 5 Parts Identification & Parts Interchangeability . . . . . Page 6 CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.

INTRODUCTION This manual applies to Sizes 1020T thru 1140T and 20T thru 140T31 standard Falk SteelfIex Pre-assembled Spacer Couplings. Unless otherwise stated, information for Sizes 1020T thru 1140T applies to Sizes 20T thru 140T respectively, e.g.

1020T = 20T, 1100T = 100T, etc. For couplings furnished with special features, refer to assembly drawing furnished with coupling for proper assembly arrangement and any additional installation or maintenance requirements. The Pre-Assembled Spacer Assembly permits installation (or removal, as shown on Page 3) without disturbing coupling cover, grid or grease. These couplings are designed to operate in either the horizontal or vertical position without modification. However, for vertical applications, the match mark shown on Page 4 must be up.

Beginning in 1994, these couplings may be supplied with either inch series cover fasteners or metric cover fasteners depending on domestic or foreign shipping destinations. Refer to Page 6 for part interchangeability.

The performance and life of the couplings depend largely upon how you install and service them.

WARNING: Consult applicable local and national safety codes for proper guarding of rotating members. Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings. Observe all safety rules when installing or servicing couplings.

LUBE FITTINGS Cover halves have 18 NPT lube holes. Use a standard grease gun and lube fitting as instructed on Page 4.

LIMITED END FLOAT When electric motors, generators, and other machines are fitted with sleeve or straight roller bearings, limited axial end float kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float; refer to Manual 428-820 for instructions.

NOTE: To drop-in a pre-assembled spacer fitted with limited end float, the sleeve bearing shaft must have enough axial movement to separate and clear the shaft hub registers.

Long Term Grease (LTG) The high centrifugal forces encountered in couplings separate the base oil and thickener of general purpose greases. Heavy thickener, which has no lubrication qualities, accumulates in the grid-groove area of Steelflex couplings resulting in premature hub or grid failure unless periodic lubrication cycles are maintained.

Falk Long Term Grease (LTG) was developed specifically for couplings. It resists separation of the oil and thickener. The consistency of Falk LTG changes with operating conditions. As manufactured it is an NLGI #1/2 grade. Working of the lubricant under actual service conditions causes it to become semifluid while the grease near the seals will set to a heavier grade, helping to prevent leakage.

LTG is highly resistant to separation, easily out performing all other lubricants tested. The resistance to separation allows the lubricant to be used for relatively long periods of time.

Steelflex couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required.

Although LTG grease is compatible with most other coupling greases, the mixing of greases may dilute the benefits of LTG.

USDA Approval LTG has the United States Department of Agriculture Food Safety & Inspection Service approval for applications where there is no possibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

Specifications — Falk LTG The values shown are typical and slight variations are permissible.

AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F (121°C). Min. Pump = 20° F (-7° C).

MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @ 100°F (38°C).

THICKENER — Lithium & soap/polymer.

CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM #D4425 (Centrifuge Test) — K36 = 2/24 max., very high resistance to centrifuging.

NLGI GRADE (ASTM D-217) — 1/2 CONSISTENCY (ASTM D-217) — 60 stroke worked penetration value in the range of 315 to 360 measured at 77°F (25°C) MINIMUM DROPPING POINT — 350°F (177°C) minimum MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do not corrode

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

428-310 June 2000 Supersedes 7-94

(.pdf revision)

Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings (Page 2 of 6)

®

Type T31 • Sizes 1020–1140 & 20–140

steel or swell or deteriorate synthetic seals.

INSTALLATION OF TYPE T31 STEELFLEX TAPERED GRID COUPLINGS

Packaging 14 oz. (0,4 kg) CARTRIDGES — Individual or case lots of 10 or 60

Installation

35 lb. (16 kg) PAIL, 120 lb. (54 kg) KEG & 400 lb. (181 kg) DRUMS.

Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required to install Falk Steelflex couplings.

Clean all parts using a non-flammable solvent. Check hubs, shafts and keyways for burrs. Coupling Sizes 1020T thru 1090T are generally furnished for CLEARANCE FIT with setscrew over the keyway. Sizes 1100T and larger are furnished for an INTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Clean all parts using a non-flammable solvent. Check hubs, shafts and keyways for burrs. Do not heat clearance fit hubs. Install keys, mount hubs with flange face flush with shaft ends or as otherwise specified and tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews. Heat hubs to a maximum of 275°F (135°C) using an oven, torch, induction heater or an oil bath. To prevent damage DO NOT heat hubs beyond a maximum temperature of 400°F(205°C).

General Purpose Grease ANNUAL LUBRICATION — The following specifications and lubricants for general purpose grease apply to Falk Steelflex couplings that are lubricated annually and operate within ambient temperatures of 0°F to 150°F (–18°C to 66°C). For temperatures beyond this range (see Table 1), consult Falk.

If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture or experiences frequent reversals, more frequent lubrication may be required.

General Purpose Greases Meeting Falk Specifications Lubricants listed below are typical products only and should not be construed as exclusive recommendations.

TABLE 1 — General Purpose Greases H Ambient Temperature Range

0°F to 150°F (-18°C to 66°C)

Manufacturer

Lubricant †

Amoco Oil Co. Amolith Grease #2 BP Oil Co. Energrease LS-EP2 Chevron U.S.A. Inc. Dura-Lith EP2 Citgo Petroleum Corp.

Prem. Lithium Grease EP2 Conoco Inc. EP Conolith Grease #2 Exxon Company, USA Unirex N2 E.F. Houghton & Co. Cosmolube 2 Imperial Oil Ltd. Unirex N2L Kendall Refining Co. Lithium Grease L421 Keystone Div. (Pennwalt) 81 EP-2 Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Mobil Oil Corp.

Mobilux EP111 Petro-Canada Products Multipurpose EP2 Phillips 66 Co. Philube Blue EP Shell Oil Co. Alvania Grease 2 Shell Canada Ltd. Alvania Grease 2 Sun Oil Co. Ultra Prestige 2EP Texaco Lubricants Starplex HD2 Unocal 76 (East & West) Unoba EP2 Valvoline Oil Co. Multilube Lithium EP Grease

-30°F to 100°F (-34°C to 38°C) Lubricant † Amolith Grease #2 Energrease LS-EP1 Dura-Lith EP1 Prem. Lithium Grease EP1 EP Conolith Grease #2 Unirex N2 Cosmolube 1 Unirex N2L Lithium Grease L421 81 EP-1 Litholine H EP 2 Grease Mobilith AW1 Multipurpose EP1 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige 2EP Multifak EP2 Unoba EP2 ...

H Grease application or re-lubrication should be done at temperatures above

20°F (-7°C). If grease must be applied below 20°F (-7°C), consult Falk.

† Lubricants listed may not be suitable for use in the food processing industry;

check with lube manufacturer for approved lubricants.

Specifications – General Purpose Coupling Lubricants The values shown are typical and slight variations are permissible.

DROPPING POINT — 300°F (149°C) or higher.

CONSISTENCY — NLGI No. 2 with 60 stroke worked penetration value in the range of 250 to 300.

SEPARATION & RESISTANCE — Low oil separation rate and high resistance to separation from centrifuging.

LIQUID CONSTITUENT — Possess good lubricating properties ... equivalent to a high quality, well refined petroleum oil.

INACTIVE — Must not corrode steel or cause swelling or deterioration of synthetic seals.

CLEAN — Free from foreign inclusions.

428-310 June 2000 (.pdf revision) Supersedes 7-94

When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hubs near the center of their length in several places on hub body with a temperature sensitive crayon, 275°F (135°C) melt temperature. Direct flame towards hub bore using constant motion to avoid overheating an area.

WARNING: If an oil bath is used, the oil must have a flash point of 350°F (177°C) or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials.

Heat hubs as instructed above. Mount hubs as quickly as possible with hub flange face flush with shaft end. Allow hubs to cool before proceeding. Insert setscrews (if required) and tighten.

Maximize Performance & Life The performance and life of couplings depend largely upon how you install and maintain them. Before installing couplings, make certain that foundations of equipment to be connected meet manufacturers’ requirements. Check for soft foot. The use of stainless steel shims is recommended. Measuring misalignment and positioning equipment within alignment tolerances is simplified with an alignment computer. These calculations can also be done graphically or mathematically.

Alignment is shown using spacer bar and straight edge. This practice has proven to be adequate for many industrial applications. However, for superior final alignment, the use of dial indicators (see Manual 458-834 for instructions), lasers, alignment computers or graphical analysis is recommended.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

Steelflex® Pre-Assembled Spacer Couplings • Installation & Maintenance

®

Type T31 • Sizes 1020–1140 & 20–140

Installation of Spacer Assembly 1— Mount Shaft Hubs

(Page 3 of 6)

90° intervals. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Table 2 on Page 5. If a dial indicator is used, place it on one shaft hub and rotate that hub through 360° while taking readings from the flange outside diameter of the other hub. The TIR reading must not exceed two times the installation limits specified in Table 2. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.

VERTICAL COUPLINGS MATCH MARK UP

BE

Lock out starting switch of prime mover. Heat interference fit hubs as previously instructed. Mount shaft hubs on their respective shafts so that hub face is flush with the end of the shaft unless otherwise indicated. Position drives for approximate distance between shaft ends with minimum angular and offset misalignment.

Y-INCHES SIZE 1020-1090 = .040 1100-1110 = .062 1120-1140 = .094

Y

4 — Insert Steelflex Spacer Insert fasteners as shown – do not allow them to protrude beyond flange face. Remove pipe plugs to vent and compress spacer to eliminate its gap. Then insert between shaft hubs.

Carefully engage the hub registers and then alternately tighten fasteners. Torque to specifications in Table 2 on Page 5.

Replace pipe plugs.

BE X

Removal of Spacer Assembly Y

Remove Spacer Assembly

2 — Angular Alignment Determine Dimension (X = BE + 2Y) and then take micrometer readings between flange faces at 90° intervals. Refer to Table 2 on page 5 for “BE” dimension tolerance. If a dial indicator is used, place the indicator on one shaft hub and rotate that hub 360° while taking readings from the other hub face. The difference in minimum and maximum measurements must not exceed the ANGULAR installation limits specified in Table 2 on Page 5.

Remove pipe plugs and all but two fasteners opposite each other in each hub. Loosen these about one-quarter inch and tap them with a mallet to disengage Steelflex spacer from the shaft hubs. Remove fasteners and spacer.

3 — Offset Alignment Align so that a straight edge rests squarely (or within the limits specified in Table 2) on both hubs as shown above and also at

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

428-310 June 2000 Supersedes 7-94

Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings (Page 4 of 6)

®

Type T31 • Sizes 1020–1140 & 20–140

Pack with Grease & Assemble Covers

ANNUAL MAINTENANCE For extreme or unusual operating conditions, check coupling more frequently.

1. Check alignment per steps on Page 3. If the maximum operating misalignment limits are exceeded, realign the coupling to the recommended installation limits. See Table 2 on Page 5 for installation and operating alignment limits.

2. Check tightening torques of all fasteners.

3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace.

4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using new gasket as instructed in this manual.

Periodic Lubrication MATCH MARK

The required frequency of lubrication is directly related to the type of lubricant chosen, and the operating conditions. Steelflex couplings lubricated with common industrial lubricants, such as those shown in Table 1, should be relube annually. The use of Falk Long Term Grease (LTG) will allow relube intervals to be extended to beyond five years. When relubing, remove both lube plugs and insert lube fitting. Fill with recommended lubricant until an excess appears at the opposite hole.

CAUTION: Make certain all plugs have been inserted after lubricating.

Coupling Disassembly & Grid Removal

428-310

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid.

Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side (see above). If shafts are not level (horizontal) or coupling is to be used vertically, assemble cover halves with the lug and match mark UP or on MATCH MARK

Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required.

Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

June 2000 Supersedes 7-94

MATCH MARK

LUG UP

VERTICAL COUPLINGS

the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tighten to torque specified in Table 2 on Page 5. Make sure gaskets stay in position during tightening of fasteners. CAUTION: Make certain lube plugs are installed before operating.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

Steelflex® Pre-Assembled Spacer Couplings • Installation & Maintenance

®

Type T31 • Sizes 1020–1140 & 20–140

Example: 1060T max. operating misalignment is .016" parallel plus .018" angular.

INSTALLATION & ALIGNMENT DATA Maximum life and minimum maintenance for the coupling and connected machinery will result if couplings are accurately aligned. Coupling life expectancy between initial alignment and maximum operating limits is a function of load, speed and lubrication. Maximum operating values listed in Table 2 are based on cataloged allowable rpm.

Values listed are based upon the use of standard coupling components, standard assemblies and cataloged allowable speeds. Values may be combined for an installation or operating condition.

ANGULAR MISALIGNMENT

(Page 5 of 6)

NOTE: For applications requiring greater misalignment, refer application details to the Factory.

Angular misalignment is dimension X minus Y as illustrated below.

Parallel misalignment is distance P between the hub center lines as illustrated below.

End float (with zero angular and parallel misalignment) is the axial movement of the hubs(s) within the cover(s) measured from “O” gap.

END FLOAT

PARALLEL OFFSET MISALIGNMENT

F

Y

F

P P X

GAP

TABLE 2 — Misalignment & End Float Installation Limits

SIZE

1020T 1030T 1040T 1050T 1060T 1070T 1080T 1090T 1100T 1110T 1120T 1130T 1140T

Parallel Offset-P

Angular (x-y)

Fastener Tightening Torque Values

Operating Limits Hub Gap H ± 10%

Parallel Offset-P

Angular (x-y)

End Float Physical Limit (Min) 2 x F

Max Inches

Max mm

Max Inches

Max mm

Inches

mm

Max Inches

Max mm

Max Inches

Max mm

Inches

mm

.006 .006 .006 .008 .008 .008 .008 .008 .010 .010 .011 .011 .011

.15 .15 .15 .20 .20 .20 .20 .20 .25 .25 .28 .28 .28

.003 .003 .003 .004 .005 .005 .006 .007 .008 .009 .010 .012 .013

.08 .08 .08 .10 .13 .13 .15 .18 .20 .23 .25 .30 .33

.188 .188 .188 .188 .188 .188 .188 .188 .250 .250 .375 .375 .375

5 5 5 5 5 5 5 5 6 6 10 10 10

.012 .012 .012 .016 .016 .016 .016 .016 .020 .020 .022 .022 .022

.30 .30 .30 .41 .41 .41 .41 .41 .51 .51 .56 .56 .56

.010 .012 .013 .016 .018 .020 .024 .028 .033 .036 .040 .047 .053

.25 .30 .33 .41 .46 .51 .61 .71 .84 .91 1.02 1.19 1.35

.210 .198 .211 .212 .258 .259 .288 .286 .429 .429 .556 .551 .571

5.33 5.03 5.36 5.38 6.55 6.58 7.32 7.26 10.90 10.90 14.12 14.00 14.50

Cover

Lube Wt

Allow Speed (rpm)

Flange

Inch Series Metric Inch Series Fasteners Fasteners Fasteners (lb-in) (Nm) (lb-in) 100 100 100 200 200 200 200 200 312 312 650 650 650

11.3 11.3 11.3 23.6 23.6 23.6 23.6 23.6 35 35 73 73 73

120 120 120 250 440 440 825 1640 2940 2940 4560 6800 8900

3600 3600 3600 3600 3600 3600 3600 3600 2440 2250 2025 1800 1650

lb

kg

.06 .09 .12 .15 .19 .25 .38 .56 .94 1.1 1.6 2.0 2.5

.03 .04 .05 .07 .09 .11 .17 .25 .43 .51 .74 .91 1.14

H “BE” dimension tolerance is ±10% of hub gap listed.

TABLE 3 — Coupling Cover Fastener Identification SIZE

Inch Series Fasteners Old Style

New Style

Metric Fasteners

1020-1070T10

SAE Grade 8 †

SAE Grade 8

Property Class 10.9

1080-1090T10

SAE Grade 8

SAE Grade 8

Property Class 10.9

1100-1140T10

SAE Grade 5

SAE Grade 5

Property Class 8.8

† Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

428-310 June 2000 Supersedes 7-94

Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings (Page 6 of 6)

Type T31 • Sizes 1020–1140 & 20–140 GRIDS — Size 1020T thru 1140T Steelflex couplings use blue grids. Older models, 20T thru 140T, use orange grids.

CAUTION: Blue grids may be used in all applications, but DO NOT substitute orange grids for blue.

COVERS — CAUTION: DO NOT mix cover halves of different designs. Sizes 1020T thru 1070T10 covers have been manufactured in several different two-rib designs and 80T thru 140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru 1070T10, utilized socket head cap screws with captured locknuts. The new style covers use hex head cap screws (either inch or metric) and unrestrained locknuts. Specify either inch series SOCKET head or inch or metric series HEX head cap screws when ordering replacement parts.

PARTS IDENTIFICATION All coupling parts have identifying part numbers as shown below. Parts are interchangeable between the 10 series and 1000 series spacer couplings. However, to utilize the higher 1000 series ratings, the 1000T – Blue Grid, Spacer Hubs, Shaft Hubs and Hardware must be used. When ordering parts, always SPECIFY SIZE and TYPE. Sizes 80 through 140T10 covers have been manufactured with two and three ribs; DO NOT mix these cover halves.

PARTS INTERCHANGEABILITY Parts are interchangeable between Sizes 20T and 1020T, 30T and 1030T, etc. except as noted.

MATCH MARK MUST BE UP FOR VERTICAL APPLICATIONS 8

9

®

7

PART NUMBERS 1. Seal (T10)

2

2. Cover (T10)

6 1

4. Grid

4

5. Gasket (T10) 6. Fasteners (T10) — Coupling may be supplied with one set each of inch series fasteners and metric fasteners.

7. Lube Plug 8. T31 Spacer Hub (Specify Length)

5

9. Shaft Hub

10

10. Flange Fastener 6

PART NUMBER LOCATION

ORDER INFORMATION

COVER 1030

SHAFT HUB SIZE, PART NUMBER AND BORE

SPACER HUB SIZE AND PART NUMBER

SIZE

T 10

COUPLING SIZE

SEAL SIZE AND PART NUMBER

PRODUCT CLASSIFICATION

GRID

GASKET

SIZE

PART NUMBER

B TYPE

MODEL

1. Identify part(s) required by name above.

2. Furnish the following information.

EXAMPLE: Coupling Size: 1030 Coupling Type: T31 Model: B Bore: 1.375 Keyway: .375 x .187 Distance Between Shaft Ends (BE): 5.0 3. Price parts from appropriate Price List and discount sheet.

PART NUMBER

428-310 June 2000 Supersedes 7-94

The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com

Falk™ Steelflexâ Couplings • Limited End Float Installation Sizes 20-260 & 1030-1260

INTRODUCTION When it is necessary to limit the end float of Falk Steelflex couplings, carefully follow these instructions. This manual applies to Sizes 30 thru 260T10 & T20 and Sizes 1030 thru 1260T10 & T20 Falk Steelflex Tapered Grid Couplings. Unless otherwise stated, information for Sizes 1030 thru 1260 applies to Sizes 30 thru 260 respectively, e.g. 1030 = 30, 1100 = 100, etc.

CAUTION: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings. Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings. During assembly, seal keyways to prevent leakage.

Sizes 1030 thru 1210T standard couplings connecting a horizontal shaft without axial movement (end float) to one with axial movement (such as in sleeve bearing motors), will limit the shaft end float to approximately 0.06 inches when assembled with gap disc and rung spacers as specified herein.

For Sizes 1220 thru 1260T couplings, spacer rings and gap discs limit the end float to approximately 0.19 inches. When end float is specified on the coupling purchase order, the spacer rings are welded to the hubs at the Factory as shown in Figure 2. When the coupling is modified in the field, it will be the customer’s responsibility to weld the spacer rings to the hubs.

FIGURE 1 – Sizes 1220 thru 1260T SPACER RING

B - DIA. A - DIA.

C

(Page 1 of 2)

TABLE 1 — Sizes 1030 thru 1210T Dimensions — Inches † Gap Disc

Rung Spacers-Fig.4

CPLG SIZE

Dia

Thickness

Per Cplg

LH

Cplg Gap

1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 1200 1210

2.188 2.500 2.750 3.000 3.750 4.375 5.250 6.000 6.750 7.500 9.000 10.500 12.000 13.500 15.500 17.000 18.250 21.500 23.250

0.062 0.062 0.062 0.062 0.062 0.125 0.125 0.188 0.188 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.500

8 8 8 8 16 16 16 16 20 20 24 32 24 32 40 32 40 40 56

0.315 0.315 0.371 0.371 0.460 0.500 0.630 0.650 0.780 0.830 0.890 1.010 0.920 1.120 1.320 1.000 1.160 1.360 1.820

0.092 0.092 0.092 0.092 0.092 0.155 0.155 0.218 0.218 0.280 0.280 0.280 0.280 0.280 0.280 0.280 0.280 0.280 0.530

H Manufacturing tolerance is ± .020 inches. † 1020T — Limited End Float Not Available.

TABLE 2 — Sizes 1220 thru 1260T Dimensions — Inches Gap Disc

Spacer Rings-Figure 1

CPLG SIZE

Dia

Thickness

A

B

C

Cplg Gap

1220 1230 1240 1250 1260

25.88 28.30 31.00 34.00 37.20

0.500 0.500 0.500 0.500 0.500

24.5 26.0 27.5 30.0 32.0

23.5 25.0 26.5 29.0 31.0

0.250 0.250 0.250 0.250 0.188

0.590 0.575 0.575 0.575 0.582

HUB AND SPACER RING DETAIL

FIGURE 2 – Sizes 1220 thru 1260T Modification

TACK WELD ONE INCH LONG SPACED AS SHOWN USE AWS E-7016 OR E-7018 ELECTRODES

TACK WELD SPLIT SPACER RING SEE FIG. 1 DETAIL

GAP DISC CPLG. GAP PROTECT MACHINED SURFACES FROM WELD SPLATTER NOTE: COVER & GRID, REMOVED FOR SPACER RING WELDING, ARE SHOWN FOR ORIENTATION ONLY.

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

428-820 October 2001 Supersedes 7-96

Limited End Float Installation • Falk™ Steelflex® Couplings (Page 2 of 2)

Sizes 20-260 & 1030-1260 FIGURE 3 – Sizes 1220 thru 1210T Typical Limited End Float RUNG SPACER

GAP DISC

MAXIMUM ROTOR END - FLOAT (ONE - HALF FLOAT EACH SIDE)

GAP

AXIALLY FIXED SHAFT

AXIALLY MOVABLE SHAFT

ASSEMBLY INSTRUCTIONS

Sizes 1030 thru 1210T

Sizes 1030 thru 1260T

6. Insert rung spacers as follows per Figure 4.

Sizes 1030 thru 1060T — Insert FOUR rung spacers at Positions A & B in the last two loops at the end of the one-piece grid. Then insert four more at 180.

Sizes 1070 thru 1090T — Insert rung spacers at Positions A, B, C and D in the last four loops of EACH grid segment (eight spacers per grid segment).

Sizes 1100 thru 1210T — Insert rung spacers in every other grid loop as shown in Figure 4 at the right. Where additional rung spacers are provided, evenly space them in the open grid loops around the circumference of the grid.

1. Mount coupling hubs and seal rings as instructed in the coupling service manual.

2. Position the floating shaft at the mid-point of travel and secure the shaft axially in this position for alignment.

3. Position equipment and align per the service manual.

IMPORTANT: Use the coupling gap specified in Table 1 for 1030 thru 1210T and Table 2 for 1220 thru 1260T. When setting gap, position the floating shaft at mid-point (center of travel).

4. Insert the gap disc between coupling hubs.

5. Pack coupling gap and hub grooves with lubricant and insert grids per service manual instructions.

L

Sizes 1030 thru 1260T 7. Complete coupling assembly and lubrication per the service manual. NOTE: Position cover halves so lugs inside the cover do not interfere with grid or any rung spacers. Cover halves should come together at split with a minimum amount of force.

FIGURE 4 – Sizes 1030 thru 1210T Rung Spacer Locations RUNG SPACER LENGTH L

INSERT RUNG SPACERS PER STEP 6

D C B A ENDS OF GRID SEGMENTS A

C

B

GAP DISC

SIZES 1030 THRU 1060T ILLUSTRATED

D

SIZES 1100 THRU 1210T

428-820 October 2001 Supersedes 7-96

Rexnord Industries, LLC, Coupling Group 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com

IOM Manual

Appendix D

Appendix D – Reference Drawings Centrilift Drawings

Drawing Title “Typical Foundation Plan & Anchor Detail for Horizontal Unit” “Oil Level Piping / Drain Piping Plan 1.XE & 1.XT” “Oil Level Piping / Drain Piping Plan 1.XE & 1.XT, XP Proof Gauge” “875 HTC Oil Level Gauge Piping Assembly” “Plan 11 Assembly” “Assembly Plan 53”

Component(s) Skid Foundation 1.XE / 1.XT HTC Murphy L129-CK-1 1.XE / 1.XT HTC Murphy LM303-EX 875 HTC Murphy L129-CK-1 HTC Plan 11 Seal System Cartridge Seal HTC Plan 53 Seal System

IOM Manual

Appendix E

Appendix E – HTC Oil Cooler System and Accessory Information Component Manufacturer Manufacturer’s Information 1.XT, 3.X, and 875 HTC Lubrication Oil Heat Exchanger 1.XT, 3.X, and 875 HTC Lubrication Oil Heat Exchanger Fan Motor 1.XT HTC Lubrication Oil Pump 1.XT HTC Lubrication Oil Pump Motor

1.XT HTC Lubrication Oil Filter 1.XE/1.XT HTC Desiccant Breather

Model/ DWG Number

Explosion Proof?

M/N: AO15-FB

N/A

Electrical Connection Drawing

DWG: CD0885

Yes

Performance Data

M/N: L4003A

Thermal Transfer General Dimensions, Piping, Lubrication Details, and IOM Baldor

Haight

IOM Manual

Leeson

Parker

Parker

M/N: 6U w/o Relief Valve

N/A

Electrical Connection Drawing

DWG: 005005-01

Performance Data, Technical Data, Test Data, and IOM Specifications and Parts List

M/N: 110908

No (XP InfoContact HPump™ Eng.)

Specifications and IOM

M/N: IL2110QMP25YMY M-1 M/N: 934330T

N/A

N/A

1.XT HTC Lubrication Oil Cooling System

N/A

3.X HTC Lubrication Oil Cooling System

N/A

875 HTC Lubrication Oil Cooling System

N/A

FLUID COOLING | Industrial AO Series FEATURES

AIR COOLED AO/AOR

■

Young Interchange – OCH

■

Adjustable Louvers

■

Medium Flow Rates

■

Moderate Heat Removal

■

One or Two Pass

■

Fluid Power Systems

■

Gear Drives

■

Injection Molding Machines

■

Machine Tools

■

Torque Converters

■

Hydraulic Presses

OPTIONS SAE & Metric Connections Relief Bypass Foot Brackets Corrosive Resistant Marine Coating

Weights

Ratings

Materials

Operating Pressure - 300 psi

Tubes Copper

Test Pressure - 300 psi

Fins Aluminum

MODEL AO-5

Operating Temperature - 400° F

Turbulators Steel

AO-10

62

Fan Blade Aluminum with steel hub

AO-15

72

Fan Guard Zinc plated steel

AO-20

86

Cabinet Steel with baked enamel finish

AO-25

120

Manifolds Steel

AO-30

135

Connections Steel

AO-35

160

AO-40

185

One Pass

Two Pass

(Medium to High Oil Flows)

Model Number AOR - 5-1

Flow Range GPM (USA) 2 - 80

One Pass

(Low to Medium Oil Flows)

Model Number AOR - 5-2

Net Weight (LBS) 47

/IL /54

/IL ).

Flow Range GPM (USA) 2 - 25

AOR - 10-1

3 - 80

AOR - 10-2

2 - 30

AOR - 15-1

4 - 80

AOR - 15-2

2 - 30

AOR - 20-1

5 - 80

AOR - 20-2

2 - 40

AOR - 25-1

6 - 100

AOR - 25-2

2 - 40

AOR - 30-1

7 - 100

AOR - 30-2

2 - 40

AOR - 35-1

8 - 112

AOR - 35-2

3 - 40

AOR - 40-1

9 - 118

AOR - 40-2

4 - 40

Two Pass

/IL /54

/IL ).

How to Order

AO Model Series AO AOR-Includes Bypass

–

– Model Size Selected

– Number of Passes* Blank - No Bypass 1 - One Pass 2 - Two Pass

*ADD FOR AOR MODELS ONLY: Relief Bypass Setting & Number of Passes

8

TTPSales@thermasys.com 262.554.8330

–

– Connection Type Blank - NPT S - SAE M - Metric

Relief Bypass Setting* 30-30 psi 60 - 60 psi

– Foot Mounted Brackets Blank - No Brackets FB - Foot Brackets

Specify Motor Required Single Phase Single Phase Expl. Proof Three Phase Three Phase 575 Volt Three Phase Expl. Proof

Specifications Electric motor & Fan data*

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*Published electrical ratings are approximate, and may vary because of motor brand. Actual ratings are on motor nameplate. **Catalog dB(A) sound levels are at seven (7) feet. dB(A) sound levels increase by six (6) dB(A) for halving this distance and decrease by six (6) dB(A) for doubling this distance.

AIR COOLED AO/AOR

-ODEL

!/

Explosion Proof Motors (Class I GP.D & Class II GP.F, G)* -ODEL

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# $ # $ # $ # $ # $ # $ # $ # $

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9ES

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"

9ES

"

9ES

"

9ES

"

9ES

"

9ES

"

9ES

"

*Published electrical ratings are approximate, and may vary because of motor brand. Actual ratings are on motor nameplate.

575 Volt -ODEL

!/ !/ !/ !/ !/ !/ !/ !/

#&-

3OUND D" !

AT FT

(ORSE 0OWER

6OLTS

0HASE

&ULL ,OAD !MPS

(Z

.EMA &RAME

20-

4YPE

4%&# 4%&# 4%&# 4%&# 4%&# 4%&# 4%&# 4%&#

#IRCUIT

$ $ $ $ $ $ $ $

4HERMAL /VERLOAD

.O .O .O .O .O .O .O .O

"EARING " "AL 3 3LEEVE " " " " " " " "

*D Squirrel Cage **Catalog dB (A) sound levels at seven (7) feet. dB (A) sound levels increase by six (6) dB (A) for halving this distance, and decrease by six (6) dB (A) for doubling this distance.

Lubrication Notes 5,000 Hours / Year Continuous Normal Applications Seasonal Service Motor is idle for 6 months or more Continuous High ambients, dirty or moist locations, high vibration

5 Year Grease Interval 2 Years 1 Year 6 Months

AO

Caution: Do not over oil or over grease. Ball bearings â&#x20AC;&#x201C; No grease needed at start up. Grease as follows:

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9

Dimensions

-ODEL

!

!/ !/ !/ !/ !/ !/ !/ !/

" #

$

%

&

'

(

* +

- -

3!% .04 v 3!%

v 5. " 4HREAD v

v v 3!%

v 5. " v 4HREAD

v

,

.

0

4

Â&#x2C6; Â&#x2C6; Â&#x2C6; Â&#x2C6; Â&#x2C6;

AIR COOLED AO/AOR

NOTE: All dimensions in inches.

Installation Piping Diagram One Oil Pass

Fan Rotation Clockwise/Facing Motor Shaft

Two Oil Passes

/IL /54

5.# 0LACES 0LACES ON !/

4OP "OTTOM

/IL /54 #AP

/IL ).

/IL ). !)2

*See dimension chart for NPT or optional internal SAE connection size.

&,/7

./4% -/4/2 -/5.4).' "2!#+%4 /. !/ !/ )3 2/4!4%$ Â&#x2014;

CV Viscosity Correction OIL Average Oil Temp °F

100 150 200 250

AO 10

SAE 5 110 SSU at 100°F 40 SSU at 210°F

SAE 10 150 SSU at 100°F 43 SSU at 210°F

SAE 20 275 SSU at 100°F 50 SSU at 210°F

SAE 30 500 SSU at 100°F 65 SSU at 210°F

SAE 40 750 SSU at 100°F 75 SSU at 210°F

50-50 Ethylene Glycol & Water

1.14 1.01 .99 .95

1.22 1.05 1.00 .98

1.35 1.11 1.01 .99

1.58 1.21 1.08 1.00

1.77 1.31 1.10 1.00

1.11 1.02 .96 .95

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Performance Curves

Selection Procedure

One Pass Oil

Performance Curves are based on 100SSU oil leaving the cooler 40°F higher than the ambient air temperature used for cooling.This is also referred to as a 40°F approach temperature.

STEP 1 Determine the Heat Load.This will vary with different systems,

!/

STEP 2 Determine Approach Temperature. Desired oil leaving cooler !/

°F â&#x20AC;&#x201C; Ambient air temp. °F = Actual Approach

!/

STEP 3 Determine Curve Horsepower Heat Load. Enter the

information from above:

b

b

M

V

!/

!/

!/

!/

Horsepower heat load x

STEP 4 Enter curves at oil flow through cooler and curve horsepower.

Any curve above the intersecting point will work.

STEP 5 Determine Oil Pressure Drop from Curves:

/), b 0 b

V M

â&#x2014;? = 5 PSI; â&#x2013; = 10 PSI; â&#x2013;˛ = 14 PSI; â&#x153;&#x203A; = 20 PSI. Multiply pressure drop from curve by correction factor found in oil â&#x2013;˛ P correction curve.

V 03) M b

03) 03) 03)

&,/7 '0-

Off-Line Recirculation Cooling Loop: Desired temperature is the oil temperature entering the cooler. In this case, the oil temperature change must be determined so that the actual oil leaving temperature can be found.

Calculate the oil temperature change (oil â&#x2013;˛ T) with this formula: Oil â&#x2013;˛ T = (BTUâ&#x20AC;&#x2122;s/Hr.) / (GPM Oil Flow x 210).

To calculate the oil leaving temperature from the cooler, use this formula: Oil Leaving Temp. = Oil Entering Temp â&#x20AC;&#x201C; Oil â&#x2013;˛ T. This formula may also be used in any application where the only temperature available is the entering oil temperature.

M

b

b

!/

!/

Oil Pressure Drop: Most systems can tolerate a pressure drop through the heat exchanger of 20 to 30 PSI. Excessive pressure drop should be avoided.

Care should be taken to limit pressure drop to 5 PSI or less for case drain applications where high back pressure may damage the pump shaft seals.

!/

!/

!/

!/

!/ /), b 0 V 03) M b

03) 03) 03)

&,/7 '0-

/), 0 #/22%#4)/. #526%

Hydraulic Motor Oil Hydrostatic Drive Oil Bearing Lube Oil Lube Oil Circuits

Oil Temperature Typical operating temperature ranges are:

V

b

M

b

M

!/

/), 0 -5,4)0,)%2

V

b

M

V

M

b

M

V

V

b

M

V

b

M

V

V

Desired Reservoir Temperature Return Line Cooling: Desired temperature is the oil temperature leaving the cooler. This will be the same temperature that will be found in the reservoir.

Two Pass Oil

40 x Cv = Curve Horsepower Actual Approach

/), 6)3#/3)49 335

110° - 130°F 130° - 180°F 120° - 160°F 110° - 130°F

AO

M

V

b

V M

AIR COOLED AO/AOR

V

(/23%0/7%2 4/ "% 2%-/6%$

(/23%0/7%2 4/ "% 2%-/6%$

Mb

M b

V

!/

Mb

V

Mb

V

but typically coolers are sized to remove 25 to 50% of the input nameplate horsepower.

(Example: 100 HP Power Unit x .33 = 33 HP Heat load.)

If BTU/Hr. is known: HP = BTU/Hr 2545

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11

Heat Exchangers – AO, AOVH, AOHM, AOF, & AOVHM Series General Information 1. Air cooled oil coolers are built for operation with maximum oil pressures of 300 psi and temperatures of 400°F. 2. The motors furnished are specially built for fan duty. They are guaranteed by the manufacturer for operation in a maximum ambient temperature of 104°F. Consideration should be given to installation location so motors are not subjected to temperatures above this level.

3. Air/oil coolers that are to be installed for utilization of waste heat for the space heating should be mounted 7 to 14 feet above the floor depending on the structure, for proper heat distribution.

Installation 1. “AO” and “AOF” coolers are designed for suspension by eye bolts or threaded hangar rods screwed into the upper and lower covers in 1/2” to13 threaded holes; “AOVH” coolers have 6 to 12 holes (0.56” diameter) in the base for mounting. Refer to product page for location and quantity.

2. Units should not be located in corrosive atmospheres as rapid deterioration of casing, cooling coil, fan and motor may take place resulting in reduced life.

3. For proper air flow, a minimum of 12” should be allowed between the oil cooler fan and any walls or obstructions.

4. Piping should be sized based on oil flow and pressure drop requirements and not on the oil coolers supply and return connection size. Piping should also be properly supported to prevent excessive strain to connection, manifolds, etc.

5. Filter located ahead of the cooler should be installed to trap scale, dirt or sludge that may be present in piping and equipment, or that may accumulate with use. A thermostatic or spring loaded by-pass relief valve installed ahead of the cooler may be helpful to speed warm-up and relieve the system of excessive pressure. All accessories should be considered in the original heat rejection and piping calculations.

6. Electric Motors: CAUTION To prevent possible electrical shock, it is important to make sure this unit is grounded properly. Connect motor only to a power supply of the same characteristics as shown on the motor nameplate. Voltage may vary 10% of nameplate voltage. Be sure to provide proper fusing to prevent possible motor burnout. Follow wiring diagram printed on motor nameplate or in terminal box. Before starting motor, follow motor manufacturer recommendations. Turn fan manually to eliminate possible motor burn out in the event the fan has become damaged in shipment. Observe operation carefully after motor is started for the first time.

Heat Transfer Surface Dirt and dust should be removed by brushing the fins and tubes and blowing loose dirt off with an air hose. Should the surface be greasy, the motor should be removed and the fins and tubes brushed or sprayed with a mild alkaline solution, or a non-flammable degreasing fluid.

Follow with a hot water rinse and dry thoroughly. A steam hose may also be used effectively.

Casing, Fan and Motor: Dirt and grease should be removed from these parts.

Rusty or corroded surfaces should be sanded clean and repainted.

Internal Cleaning: At lease once a year piping should be disconnected and a degreasing agent or flushing oil circulated through the unit to remove sludge from turbulators and internal tube surfaces to return the unit to full capacity. A thorough cleaning of the entire system in the same manner is preferable to avoid carry-over from uncleaned piping, pump and accessories.

The strainer of any filtering devices should be removed and serviced following this cleaning operation.

Electric Motor Keep outside surface free of dirt and grease so motor will cool properly. Make sure cooling air over motor is not obstructed.

Prelubricated ball bearing motors are normally furnished and require no grease for about 5 to 10 years. Sleeve bearing motors require oil after three years.

Hydraulic Motor Change any oil filter(s) in the motor circuit as frequently as necessary to assure that good, clean oil is maintained.

Units with Replaceable Air Filters Examine filters for dirt and grease accumulation twice yearly, or more if operating conditions dictate. If disposable filters are used, replace as required. If the washable aluminum filters are used, wash with a warm water and soap solution that will remove dirt and cut grease build-up. Make sure that the aluminum filter is completely dry before replacing the unit. This filter can be made more effective if treated with a lightweight oil before placing in service. It is recommended that a spare aluminum filter be kept in stock to minimize downtime during the filter cleaning operation.

Repair or Replacement of Parts When ordering replacement parts or making inquiry regarding service, mention model number, serial number and the original purchase order number. Any reference to the motor must carry full nameplate data.

7. Hydraulic Motors: Connect motor, port B, to inlet oil line and return line to port A for correct rotation. A filter is highly recommended upstream of the motor rated at 25 micron nominal. Controlling oil flow rate as specified on motor data sheet with cooler is very important. Maximum oil pressure to motor is 2000 psi, minimum pressure is shown on motor data sheet. Do not allow dirty oil to enter the motor. Excessive flows will cause fan blade failure. Insufficient flows to motor will reduce cooling capacity.

INSTALLATION & SERVICE

Maintenance Inspect the unit regularly for loose bolts and connections, rust and corrosion, and dirty or clogged heat transfer surfaces (cooling coil).

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201

Performance Data: L4003A Product Nameplate Data : Rated Output

.25 HP

Hertz

60

NEMA Nom. Eff.

55

Volts

115/208-230

Phase

1

Power Factor

57

Full Load Amps 5/2.6-2.5

NEMA Design Code N

Service Factor

1

Speed

LR KVA Code

Rating - Duty

40C AMB-CONT

1725

L

(Typical performance - Not guaranteed values)

General Characterstics at 230 V, 60 Hz, 0.25 HP Full Load Torque

0.781 LB-FT

Starting Current

11 Amps

Start Configuration

DOL

No-Load Current

2.34 Amps

Break Down Torque

3.72 LB-FT

Line-line Resistance @ 25° C

8.77 Ohms

Pull-Up Torque

2.15 LB-FT

Temperature Rise, C @ FL (in deg)

0

Locked-Roter Torque

2.79 LB-FT

Temp. Rise @ S.F. Load (in deg)

0

Load Characteristics at 230 V, 60 Hz , 0.25 HP % of Rated Load Power Factor

25

50

75

100

125

150

S.F.

36

45

53

60

66

72

0

Efficiency

31.6

42.2

50

54.7

56.3

56.5

0

Speed (rpm)

1767

1752

1738

1719

1698

1672

0

Line Amperes

2.32

2.36

2.42

2.53

2.7

2.93

0

* For certified information, contact your local Baldor office.

OTIS --| AC Motors --| Front Page --| Performance Data

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Front Page Spl Instr Nameplate Oracle/Rev FP Print Test Limit BOM Performance Data Motor No. 110908.00

Suffix L

Winding C634256

NP Seq 0

R Number FR

Phase 1

Group/Subgroup 3

Poles 4

Base Voltage 230

No. of Speeds 0

Base Freq 60

Rotor Weight 0.0

Base HP 1.0

Inertia (WK²) 0

Res. Main 1.9 Ohms

Guarenteed Eff 0.0

Res. Aux 1.32 Ohms

KVAR Max

Connection

KVAR 95 0.0

WK Max 0.1

KVAR 90 0.0

Start Max

Safe Stall Time

Sound 64 dBA@3' Pressure

Req. Velocity

Sound Power 73 dBA

FL Frame 0 Temp

CFM 0

Base Voltage(Freq 1) 230

/ D

Torque UOM

Ratio

Base Voltage(Freq 2) NONE

Load Curve @ 60 Hz, 230 Volts, 1 Horsepower Load

Amps

KW

RPM

Torque

Eff

PF

Rise By Resis

Frame Rise

0.0 0.25 0.5 0.75 1.0 1.25 1.5

4.2 4.45 4.75 5.5 6.4 7.4 8.6

0.151 0.407 0.547 0.776 1.02 1.259 1.531

1798 1778 1768 1751 1738 1717 1694

0.0 1.0 1.5 2.25 3.1 3.75 4.5

0.0 62.1 68.9 72.1 75.0 72.6 70.7

15.6 39.8 50.0 61.3 69.2 74.0 77.2

0.0 0.0 0.0 0.0 73.0 0.0 0.0

0.0 0.0 0.0 0.0 50.0 0.0 0.0 SOURCE: DATABASE GROUP: 3

Speed Torque Curve @ 60 Hz, 230 Volts Curve Point

Amps

Amps(%)

Torque

Torque(%)

RPM

KW

PF

HP

BD PU LR

33

0.0 0.0 0.0

7.0 6.3 9.0

233.0 210.0 300.0

0 0 0

0.0 0.0 0.0

0.0 0.0 0.0

1.0 1.0 1.0

SOURCE: CALCULATED GROUP: 3

Renameplate @ 230 Volts Approved

Hz

Volts

HP

FL Amps

SF Amps

SF

RPM

Eff

PF

R/R

Design

KVA

Remarks

No Renameplate Data!

Rerates for 110908.00 Assigned to Winding Group Rework # Rating OK Hertz HP RPM Volts Low Volts High Duty Encl SF Max Amb Insul Design

No Rerates Found!

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Spl Instr Nameplate Perf Data Oracle/Rev FP Print Test Limit Rerate BOM Product Features Motor No. 110908.00

Catalog 110908.00

Edited By poullpj Effective Date 09/21/2007 (L)

Model C6C17FK5L Description 1HP..1725RPM.56.TEFC./V.1PH.60HZ.CONT.NO Product Line 56 4P 1PH

NP Seq 0

Channel LEC

Auth BOM/RT N,N

Status Active Source BRF Location

Stock Class S

Nameplate Data Hertz 60

Volts 115/208-230

Hertz

HP 1

Volts

HP

KW 0.75

FL Amps 12.8/6.4

KW

FL PF 68 ( 0.68 ) (Cos) FL Eff 75

FL Amps

FL PF (Cos) SF Amps 13.6/6.8

FL Eff

Eff. 75%

SF Amps

Eff. 75%

SF 1.15

RPM 1725

Assembly Mtg NAN

RPM

NP Frame 56C

NEMA Design N

Motor Type CF

Phase 1

Duty CONTINUOUS

Insulation Class B4

Max Amb(C') 40

Full Load Rise 0.0

IP Code

K

KVA Code

SF

Enclosure TEFC

54

IC Code

PE Bearing 6203

OPE Bearing 6203

UL Y CC Number EXEMPT

RoHS

Protector NONE

41

Y

Prot. Number

CSA

Y

CE

N

Thermostats NONE

Wdg. RTDs NONE

Lead Desc. UNK

Hazardous Loc NONE

Thermistors NAN

Stack Length 2.63

Max KVAR 0.0

Motor Image

Elevation 3300

Protector Code

CrAmps

Inverter Duty Motor Information Inverter Type Max Safe RPM

Inverter Load NONE 5400

Hertz

Inv. Spd Range NONE

Rtr WK 0 HP

No Load Amps 0

RPM

Torque

Volts

Amps

0

0

0

0

0

0

0

0

0

0

0

0

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110908.00 --| OTIS --| AC Motors --| Front Page

Page 2 of 2

0

0

0

0

0

0

0

0

0

0

0

0

R1 0

R2 0

X1

X2

0

0

XM 0

Additional Mechanical Parameters Frame Material ROLLED STEEL Mount Type RIGID C

Severe Duty FALSE Application GENERAL PURPOSE

ODE Bracket STANDARD

Shaft Type NAN

Mtr. Orientation NAN DE Bracket C-FACE Shaft Material NAN

DE Spl. Shaft NAN

Shaft Diameter 5/8

ODE Spl. Shaft NAN

Shipping Wt. 33

Mech. Features NAN

IN

Final Asm. Drg.

Brg. RTDs NONE Nameplate 004012.NP Conn Dia

Nameplate Drg. 993500

Nameplate LEESON Logo Nameplate Type MYLAR GENERAL PURPOSE

Lubrication POLYREX EM

Brake Prov. NONE

Enoder Prov. NONE

DE Brg Type BALL

Brake Mfg. NONE

Enoder Mfg. NONE

ODE Brg Type BALL

Brake Series NONE

Enoder Model NONE

Drive Method DIRECT

Brake Torque

Outline Drg. 028794-650B

Enoder PPR NONE

Packaging B

Pallet Quantity 0 C/Box Type STANDARD

Carton Label Leeson Gen Purpose

Paint STANDARD

Additional Electrical Parameters Electrical Type CAP START IND RUN Start Method ACROSS THE LINE Efficiency STANDARD Heater Volts NAN

Poles 4 Ins. System STANDARD Rotation SELECTIVE CCW Heater Watts

Conn Diag 005005.01

Base Winding C634256 Wdg. Rerate FR Wdg. Group 3 Wdg. Subgrp D

Conn Diag2

Test Card 01

Shipped Conn NA

Standard Order Variables StdPck BOX

StdVlt NA

StdRot SELECT CCW

StdMnt NAN

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OTIS --| AC Motors --| Front Page --| Test Limits

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Front Page Spl Instr Nameplate Perf Data Oracle/Rev FP Print BOM General Information Motor No. 110908.00

Winding C634256

Type AC

Effective Date 06/06/2006

Group 3

Ext. Diagram 005005.01

Expiration Date

Test Card 01

Frequency 60

Test Limits Amps Load

MSV

High NL

Watts

Volts

Max

Min

Max

Min

230

5

3.9

240

160

Low Comments

Torque Pullup

Full Load

Pull-In

Pull-Out

Locked Rotor

65 High IN-LB Low

Speed Max High 1800

Min 1795

Insulation 1752 Inertia Comp

Low Switch Cut-Out RPM 1500

1300

For SUBFRAC Motors Only Capacitor MFD

Capacitor Volts

Revision Revision

Rev Engineer

Rev Date

Comments

Production Call Engineer

Prod Call Date

Comments

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Lubrication Instructions For Ball Bearing Motors Lubrication This motor is supplied with pre-lubrication ball bearings. No lubrication required before start up.

Relubrication Intervals The following intervals are suggested as a guide:

SUGGESTED RELUBRICATION INTERVALS HOURS OF SERVICE PER YEAR 5,000

Continuous Normal Applications

Season Service Motor Idle 6 Months or More Continuous High Ambients Dirty or Moist Locations High Vibrations Where Shaft End is Hot (Pumps-Fans)

H.P. RANGE Sub Fractional to 7 1/2 10 to 40 50-200 Sub Fractional to 7 1/2 10 to 40 50 to 200 All Sub Fractional to 40 50 to 200

RELUBE INTERVAL 5 Years 3 Years 1 Year 2 Years 1 Year 9 Months 1 Year (Beginning of Season) 6 Months 3 Months

Lubrication Use high quality ball bearing lubricant. Use consistency of lubricant suitable for class of insulation stamped on nameplate as follows:

LUBRICATION CONSISTENCY INSULATION CLASS

CONSISTENCY

TYPE

Medium

Polyurea

B&F F&H

TYPICAL LUBRICATION

FRAME TYPE

Shell Dolium R and/or Chevron SR1 2

Sub Fractional to 447T All

Procedure If motor is equipped with Alemite fitting, clean tip of fitting and apply grease gun. Use 1 to 2 full strokes on motors in NEMA 215T frame and smaller. Use 2 to 3 strokes on NEMA 254T thru NEMA 365 T frame. Use 3 to 4 strokes on NEMA 404T frames and larger. On motors having drain plugs, remove drain plug and operate motor for 20 minutes before replacing drain plug.

On motors equipped with slotted head grease screw, remove screw and apply grease tube to hole. Insert 2 to 3 inch length of grease string into each hole on motors in NEMA 215T frame and smaller. Insert 3 to 5 inch length on larger motors. For motors having drain plug and operate motor for 20 minutes before replacing drain plug.

CAUTION: Keep lubricant clean. Lubricate motors at standstill. remove and replace drain plugs at standstill. Do not mix petroleum lubricant and silicone lubricant in motor bearings.

300-088.02

Installation Maintenance Instructions AC Induction Motors Installation After unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections, check for proper grounding of motor and application. All electrical contacts and connections must be properly insulated and enclosed. Couplings, belts, chains or other mounted devices must be in proper alignment, balance and secure to insure safe motor operation.

Electrical Wiring Prior to connecting to the power line, check nameplate for proper voltage and rotation connection. This motor should be installed in compliance with the National Electrical Code and any other applicable codes. Voltage at motor not to exceed + or -10% of nameplate. Authorized person should make all electrical connections.

Mounting This motor should be securely mounted to the application. Sufficient ventilation area should be provided to insure proper operation.

RECOMMENDED COPPER WIRE & TRANSFORMER SIZE SINGLE PHASE MOTORS - 230 VOLTS H.P.

TRANSFORMER KVA

100

1 1/2 2 3 5 7 1/2

3 3 5 7 1/2 10

10 10 8 6 6

DISTANCE - MOTOR TO TRANSF. IN FT. 150 200 300 8 8 8 4 4

8 8 6 4 3

6 6 4 2 1

500 4 4 2 0 0

THREE PHASE MOTORS - 230 & 460 VOLTS H.P. 1 1/2 1 1/2 2 2 3 3 5 5 7 1/2 7 1/2 10 10 15 15 20 20 25 25 30 30 40 40 50 50 60 60 75 75

VOLTS 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460 230 460

TRANSFORMER KVA 3 3 3 3 5 5 7 1/2 7 1/2 10 10 15 15 20 20

Consult Local Power Company

DISTANCE - MOTOR TO TRANSF. IN 100 150 200 300 12 12 12 12 12 12 12 12 12 12 12 10 12 12 12 12 12 10 10 8 12 12 12 12 10 8 8 6 12 12 12 10 8 6 6 4 12 12 12 10 6 4 4 4 12 12 12 10 4 4 4 2 12 10 10 8 4 2 2 1 10 8 8 6 2 2 2 0 8 8 6 6 2 1 1 00 8 6 6 4 1 0 00 0000 6 6 4 2 1 0 00 0000 4 4 2 2 1 00 000 250 4 2 2 0 0 000 0000 300 4 2 0 00

FT. 500 10 12 8 12 6 10 4 8 2 8 1 8 0 6 000 4 000 4 0000 2 300 0 300 0 500 00 500 000

Moduflowâ&#x201E;¢

Series

ILP and RFP Low Pressure Filters

27

Low Pressure Filters Moduflow™

Series

Applications for Moduflow Filters ■ Power Unit Fabrication ■ Off-line Filter Loops ■ Mobile Equipment

The Moduflow filter is widely considered the most versatile filter available on the market. The unique diverter valve assembly, and inside to outside flow through the element, allows the Moduflow to be configured for in-line, in-tank or suction filtration.

The flow diverter minimizes turbulence and pressure loss through the filter, improving system performance.

The newly designed closed bottom elements for the RFP and ILP models insures all contamination remains trapped within the element as the filter is serviced.

A wide variety of visual and electrical indicators allows you to know exactly when the element needs to be serviced. There is even a “no element” indicator that can sense when there is not an element installed in the filter.

From top to bottom, the Moduflow filter series provides the high level of filtration and long term dependability so vital to today’s hydraulic systems.

Parker’s new patented Moduflow element was designed with built-in diverter cone and bypass valve, to meet your application needs.

Mounting / Porting Styles RFP Return Filter

ILP In-Line Filter FILTER HEAD

RETURN

OUT

IN BRACKET 924904

BOWL BOWL

TANK

OUTLET PORT

28

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

Features

Flanges

Cover

SAE ¾” to 2” ■ Lightweight aluminum

■ Lightweight

■ NPT or

■ Slotted for quick

release

aluminum

Bowl

Indicators

■ Single or double

■ Visual or electrical ■ Mounted on either side ■ Standard “no element”

length

■ Durable steel

construction

indication

Bypass

Element

(not visible) ■ Available in cellulose,

(not visible) ■ Integral 35 psi

wire mesh or high performance Microglass III media ■ Single or double length

bypass replaced with every element change

Feature l

Top access element service

Advantage l l

l

Slotted cover

l l

l

Closed bottom elements

l

l

Visual or electrical indicators

l

l

Flange face ports

l

Oil remains in housing Quicker elements change Quick release cover Cap screws remain in housing Removes all contaminant during element service Know exactly when to service elements Flexible mounting (3/4” to 2”)

29

Benefit l l l l l

No Spills Reduced maintenance costs Reduced maintenance costs No loose parts to lose No downtime contamination from servicing

l

Helps prevent bypass condition No premature disposal

l

Easy plumbing to your system

l

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

RFP-1 & ILP-1 Element Performance

Capacity

Efficiency Beta Rating 10000

Efficiency %

2Q

PSID 50

BAR 2Q 5Q 10Q 20Q

5Q

40

99.9

1000

3.0 2.5

10Q

200

99.5

100

99.0

30

20Q

2.0 1.5

20

20

95.0

1.0 10

2

0.5

50.0 0

4

8

12

16

0

20

0

20

Micron Size (c)

40 60 Capacity grams

80

0.0

100

Multipass tests run @ 40 gpm to 50 psid terminal - 5mg/L BUGL

Flow vs. Pressure Loss

LPM 0 20

50 100 150 200 250 300 350

1.2

02Q 05Q

16

PSID

PSID 4

80

100

0.2

1½” SAE

4

0.2 60

0.3

8

0.4

20Q

40

0.4

2” SAE flange

0

0.0

GPM

0

20

40

60

80

100

0.1 0.0

GPM

30

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

BAR

0.6

12

10Q

20

0.6 0.5

BAR

0.8

8

150SUS Empty Housing

1.0

12

0

50 100 150 200 250 300 350

20

150SUS

16

0

0

LPM

Low Pressure Filters Moduflow™

Series

RFP-2 & ILP-2 Element Performance Capacity

Efficiency Beta Rating 10000

Efficiency %

2Q

BAR

PSID 50

2Q 5Q 10Q 20Q

5Q

40

99.9

1000

3.0 2.5

10Q

200

30

99.5

100

2.0

99.0 20Q

1.5

20

20

95.0

1.0 10

2

0.5

50.0 0

4

8

12

16

0

20

0.0 0

20

40

60

Micron Size (c)

80

100 120

140 160

Capacity grams

Multipass tests run @ 80 gpm to 50 psid terminal - 5mg/L BUGL

Flow vs. Pressure Loss LPM 0 20

100

200

LPM

300

400

500

0 10

150SUS

1.2

16

100

200

300

400

500

150SUS Empty Housing

8

0.6

1.0

05Q

0.6 10Q

4 0

20Q

25

50

75

100

125

150

1½” SAE

0.3

4

0.4

0.2

2” SAE flange

2

0.2 0

0.4

PSID

02Q

8

6

0

0.0

GPM

0.1 0

25

50

75

100

125

150

0.0

GPM

31

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

BAR

0.8

BAR

PSID

12

0.5

Low Pressure Filters Moduflow™

Series

Specifications: RFP, ILP

Dimensions:

Pressure Ratings: Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar) Design Safety Factor: 2:1 Rated Fatigue Pressure: 150 psi (10.3 bar) Element Burst Rating: 70 psid (4.8 bar) Filter Materials: Head, Cover, Flanges: die cast aluminum Bowl: steel Operating Temperatures: Nitrile: -40°F to 225°F (-40°C to 107°C) Fluorocarbon: -15°F to 275°F (-26°C to 135°C)

mm inch

Model

A

B

RFP-1 without optional 2” fitting

65.0 2.56

330.2 13.0

C _

D

ILP-1

65.0 2.56

330.2 13.0

N/A

110.0 4.3

RFP-1 with optional 2” fitting

68.3 2.69

_

383.4 15.07

114.0 4.5

RFP-2

68.3 2.69

617.5 24.31

623.8 24.56

114.0 4.5

ILP-2

68.3 2.69

617.5 24.31

N/A

114.0 4.5

110.0 4.3

Weight (approximate): Single: 20 lbs. (9.1 kg) Double: 25 lbs. (11.3 kg) Indicators: Visual (optional) Electrical (optional) 15A @ 250VAC / .5A @ 125 VDC Electrical (“D” option) 5A @ 250VAC / 3A @ 28 VDC Color Coding: White (normally closed) Red (normally open) Black (common) ILP OUTLET

OPTIONAL 3-PIN MALE RECEPTACLE

MINIMUM ELEMENT REMOVAL CLEARANCE

228.6 9.0

Single: 345.9 13.62 Double: 482.6 19.00

108.5 4.27

168.0 6.6

A 168.0 6.7 78.7 3.1

OPTIONAL TANK FLANGE

IL & RF INLET 196.3 7.7

Linear Measure: millimeter inch

OPTIONAL PORT FLANGE 77.8 3.062

38.9 1.53

C

OPTIONAL B MOUNTING BRACKET

30.2 1.19

12.7 0.50

(99 OPTION) RFP-1 OUTLET 4 1” HOLES

RFP OUTLET 42.9 1.68

69.9 2.75

2-11½” NPTF OPTIONAL FITTING

D

21.3 0.84

32

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Specifications: DILP

Series

3.3 .013

Pressure Ratings: Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar) Design Safety Factor: 2:1 Rated Fatigue Pressure: 150 psi (10.3 bar)

116.8 4.60

79.0 3.11

76.2 3.00

Element Burst Rating: 70 psid (4.8 bar) Filter Materials: Diverter Valve Assembly: die cast aluminum Check Valve Assembly: die cast aluminum Filter Assembly: see IL2 specifications

½-13 SHCS TORQUE 32-38 FT-LB

¼-18 NPT DRAIN VENT CONNECT TO TANK

173.0 6.81

330.2 SINGLE 13.0

Operating Temperatures: Nitrile: -40°F to 225°F (-40°C to 107°C) Fluorocarbon: -15°F to 275°F (-26°C to 135°C)

617.5 DOUBLE 24.31

Weight (approximate): Single: 55 lbs. (24.9 kg) / Double: 65 lbs. (29.5 kg)

110.5 4.35

Indicators: Visual (optional) Electrical (optional) 15A @ 250VAC / .5A @ 125 VDC Electrical (“D” option) 5A @ 250VAC / 3A @ 28 VDC

479.3 18.87

Color Coding: White (normally closed) Red (normally open) Black (common)

AIR BLEED EACH FILTER

30.2 1.19

FILTER SCHEMATIC

OPTIONAL FLANGE

OUTLET

FILTER

Linear Measure: millimeter inch

FILTER

177.8 7.00

INLET BYPASS

INLET

BYPASS

DRAIN VENT

402.8 15.86

OUTLET

345.9 13.62

OPTIONAL MECHANICAL INDICATOR

BOTH CHECK VALVES MOVE SAME DIRECTION

Approximate handle torque required for changeover.

Typical Flow/Pressure Curves For Duplex Valves 1.75 1.5

LPM

30

25

20

0.75

10

0

0.5

0

0.25

100

200

300

0

System Pressure (psi)

33

DIFF. PRESSURE

1

GPM

Torque (Ft-Lbs)

1.25

20

15

(Add to differential pressure of filter assembly for total duplex pressure differential) *Diverter/check valves combined

S SU S 00 SU 0 3 0 20

10

5

0

10 GPM

0

25

20 50

30

40

50 FLOW

60

70

80

90 100 LPM

75 100 125 150 175 200 225 250 275 300 325 375

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflowâ&#x201E;˘

Series

For return line applications (RFP), the fluid returning to the reservoir holds the check valve open. When the system is shut down, the check valve closes automatically.

Check Valve Flow/Pressure Drop 3.0 *Check valve pressure drop must be added to assembly pressure drop to get total

Pressure Loss (psid)

2.5

2.0

1.5

1.0

0.5 0.0 0

10

20

30

40

50

60 70

80

90 100

Flow (GPM)

Linear Measure: millimeter inch

RFP SINGLE ELEMENT 452.1 17.8

RFP DOUBLE ELEMENT 688.3 27.1

117.1 MAX. O.D. 4.61 OVER WELD (RFP & DOUBLE LENGTH)

34

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

Accessories Linear Measure: millimeter inch

“M” OPTION-VISUAL INDICATOR, NO ELEMENT WARNING

OPTIONAL MOUNTING BRACKET (924904)

161. 5 6.5 8.7 0.344 DIA. THR U PLACES

122. 9 4.84

60 TYP

7.9 0.31

114. 3 4.500

R 114. 3 4.500

6.44 0.25 13.5 0.531 DIA. THR U 4 PLA CES

114.3 4.500 57.2 2.25

13.5 .531 DIA. THRU TYP. 41.1 1.62

25.4 1.00

OPTIONAL TANK FLANGE (925167)

10.3 0.406 DIA. THRU 8 PLACES

235.0 9.25

“E” OPTION-ELECTRICAL INDICATOR

122.9 4.84

98.4 3.875 TYPICAL 8.7 0.344 DIA. THRU 6 PLACES

196.9 7.750 TYPICAL

MATERIAL THICKNESS 4.60 .18

149.2 5.875 DIA. B.C.

35

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

Lower Cost than many single unit filters.

Proven Reliability

Moduflow™ Manifold Extended Filter Range

The rugged design of the Model MM manifold has been proven in demanding mobil equipment applications, At the factory, we have cycle tested the Model MM through the full range of rated flow and pressure to insure reliable service.

Use Model MM Manifold to handle return line flows up to 130 gpm. l Rated static pressure: 300 psi l Typical burst pressure: 900 psi l Easily mounted on ModuFlow™

Parker Filter Division maintains the same high standards in delivery, quality, and service. Considering this, plus features, flexibility, price, and performance, the Model MM manifold is a valuable addition to your fluid power component list.

High Flows At Low Cost The model MM manifold is designed to extend the flow range of ModuFlow Filters when operating with 10 Micron and finer filter media. When mounted to a pair of RFP-2 or ILP-2 filters, this manifold will allow flows up to 130 gpm in return lines (15 fps velocity).

Note: The Model MM manifold is not applicable to suction lines due to its pressure drop characteristics.

TM

FLOW/PRESSURE CURVE 0.7

TYPICAL FLOW/PRESSURE CURVES FOR

MODEL MM 38B6

DIFF. PRESS.

6

2

20

0S

US

(BAR)

8

(PSI)

0.6

0.5

When used with two ModuFlow filters, the total cost is often less than a single unit filter rated for 130 gpm flow.

Tank-top mounted (Model RFP) filters will require only one manifold on the filter inlet pports. In-line mounted (Model ILPav) filters will require two manifolds, one on the inlet and one on the outlet ports.

10

TM

0.4

0.3

4

0.2

0.1

Multiple Uses

0

0

0

25

50

75

100

(GPM) 0

Although designed for manifold ModuFlow filters, the Model MM can be used in a variety of applications which require: l Splitting flow between components TM

75

150

225

125

150

175

INLET FLOW 300

375

450

525

200

225

600

675

750

825

Such applications are frequently encountered on mobile equipment, machine tools, and large lubricating systems. In such applications, use of a manifold can often reduce total piping and installation costs.

36

250

(LPM)

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

900

Low Pressure Filters Moduflow™

Series

MANIFOLD SPECIFICATIONS Rated Static Pressure, maximum: 20.7 bar (300 psi) Typical Burst Pressure: 62.1 bar (900 psi) Operating Temperature (Buna seals): +121ºC to —40ºC (+250ºF to 40ºF)

Housing Material: ANSI 356-T6 cast aluminum Approximate Shipping Weight: 3.6 kg (8 lbs) Porting: See Options Below

Order Screws and O-Rings Seperately: Inlet & outlet screws (12 required): Order P/N 900228 Outlet port o-rings (2 required): Nitrite: Order P/N N72228 Fluorocarbon: Order P/N V92228

HOW TO ORDER MANIFOLDS: Part Number Description 926466

Moduflow Manifold

* Tank-top mounted RFP filters will require

one manifold on filter inlets: in-line mounted ILP filters will require two manifolds on both inlets and outlets.

INSTALLATION DIMENSIONS 12.7mm .50 88.9mm 3.50

177.8mm 7.00

88.9mm 3.50

155.6mm 6.125

(TORQUE SCREWS TO 32-38 FT-LBS) 77.8mm 3.062 66.8mm 2.63

42.9mm 1.688

42.9mm 1.688

77.8mm 3.062

(TORQUE SCREWS TO 32-38 FT-LBS)

66.8mm 2.63

VIEW AT C-C 273.8mm 10.78

STANDARD OUTLET, 2 PLS 2-0 SAE 4-BOLT FLANGE WITH 2-228 O-RING GROOVE

TOLERANCES

C

C

To one decimal place:

3.0mm 0.12

To two decimal places:

0.8mm 0.03

To three decimal places:

0.4mm 0.015

Linear Measure:

Millimeter Inch

OPTION NUMBER

37

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

Flange Kits (flange, 4 bolts, o-ring) Part Number

Size

Code

Buna

Fluorocarbon

¾ inch NPTF

YB

924788

926013

1 inch NPTF

YC

924787

926012

1¼ inch NPTF

YD

924912

926004

1½ inch NPTF

YE

924786

926011

2 inch NPTF

YF

924785

926010

SAE - 12

YM

924784

926009

SAE - 16

YN

924783

926008

SAE - 20

YO

924913

926005

SAE - 24

YP

924782

926007

BLANK FLANGE

—

924782

926006

RFP / ILP / DILP Replacement Elements Nitrile Seals

Fluorocarbon Seals

Media

New Single

Replaces Old Single

New Double

Replaces Old Double

New Single

Replaces Old Single

New Double

Replaces Old Double

02Q

937393Q

932686Q

937397Q

932692Q

937401Q

932689Q

937405Q

932695Q

05Q

937394Q

932687Q

937398Q

932693Q

937402Q

932690Q

937406Q

932696Q

10Q

937395Q

932688Q

937399Q

932694Q

937403Q

932691Q

937407Q

932697Q

20Q

937396Q

933116Q

937400Q

933117Q

937404Q

933118Q

937408Q

933119Q

38

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

Parts List Index

Part No.

Quantity

Index

Part No.

Quantity

1

Screws, Nameplate.......................

900028

2

11

Check Valve Assy. .........................

925120

1

2

Name Plate, Unstamped...............

920928

1

12

Flange Kits.....................................

Refer to Table

1

3

Cover Screws, 5/16-18 UNC x 1”..

926633

6

13

925974

2

4

Bowl Screws, 5/16-18 UNC x 1”...

926633

6

Plug Kit, Fastener, self-sealing, o-ring seal included with fastener

5

Cover, Without nameplate............

924634

1

14

6

O-Ring, cover Nitrile............................................

Fluorocarbon................................

Indicator Electrical 35 psid.............................................

35 psid, 3-pin male receptacle.....

926643 926753

N72350 V72350

2 2

15

7

Element Seal Nitrile............................................

Fluorocarbon................................

937410 937411

1 1

Indicator Visual 35 psid 4-band...............................

Flange, In-tank mounting..........

Bracket, Inline mounting...........

Indicator Kit, Remote mount.....

926748 925167 924904 924894

8

Element..........................................

Refer to Table

1

16

Changeover Valve Assy., Duplex

926758

Optional

9

Head, Machined only.....................

2” SAE Flange 1½”SAE Flange 1½” NPTF

17

Check Valve Assy., Duplex............

926757

Optional

925972 926164 925949

Not Shown

Drain Plug, SAE-24 for RFP model Nitrile............................................

Fluorocarbon................................

909992 928363

1 1

Bowl, Select desired model ILP-1 .............................................

ILP-2 .............................................

RFP-1............................................

RFP-1 with 2 inch NPTF fitting...

RFP-2............................................

RFP-2 with 2 inch NPTF fitting...

925916 924816 937626 924676 937627 924818

10

Description

Filter Assembly Exploded View

1 1 1

Description

1

5

Optional Optional Optional Optional

1

4

10

11

6

9 3

Optional

6

7

16

17

8

2

13

12 14 15

39

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™

Series

HOW TO ORDER: Select the desired symbol (in the correct position) to construct a model code.

Example:

BOX 1

BOX 2

BOX 3

BOX 4

BOX 5

BOX 6

BOX 7

BOX 8

ILP

1

10Q

B

MP

35

Y9Y9

1

BOX 1: Filter Series Symbol

Description

BOX 5: Indicator Symbol

BOX 7: Port Options Description

RFP

Return-line filter, inlet on side outlet on bottom

P

Pressure ports drilled & plugged only; no indicator

ILP

In-line filter

M

DILP

In-line duplex

Visual indicator w/”no element” warning

BOX 2: Element Length Symbol

Description

E

Electrical indicator only

D

Electrical indicator only, 3-pin male receptacle

1

Single

2

Double

BOX 3: Media Code Symbol

Description

02Q

Microglass III, 2 micron

BOX 6: Bypass Setting Symbol

Description

05Q

Microglass III, 5 micron

35

35 psid

10Q

Microglass III, 10 micron

20Q

Microglass III, 20 micron

WR

Water Removal

BOX 4: Seals Symbol

Description

B

Nitrile

E

EPR

V

Fluorocarbon

Note: First letter of indicator code = left side of filter head when looking into inlet with bowl down; second letter = right side of filter head when looking into inlet with bowl down.

Filter Model

RFP

ILP

DILP

40

Inlet Outlet Symbol/Description Symbol/Description Y9

2” flange face

99

No fitting

P9

SAE-24 integral threads

F9

2” NPTF

E9

1½ NPTF integral threads

F8

External check valve

Y9

2” flange face

99

No fitting

P9

SAE-24 integral threads

P9

SAE-24 integral threads

E9

1½ NPTF integral threads

E9

1½ NPTF integral threads

Y9

2” flange face

Y9

2” flange face

1) First pair of symbols denotes inlet for all filter styles; second pair of symbols denotes outlet.

2) Four symbols required: two for inlet, two for outlet.

3) Unused ports in filters come plugged with a blank flange.

4) See Flange Kits table for port flange options.

Flange Kits are ordered separately.

BOX 8: Options Symbol

Description

1

None

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Reservoir Accessories Breathers

Breathers Desiccant Type Specifications: Materials: Casing: Clarified copolymer polypropylene.

Cap: Copolymer polypropylene.

Stand pipe: PVC. Filtration Element: Polyester, silica gel.

Operating Temperatures: -20oF (-29oC) to 250oF (121oC).

Seals: None.

Maximum Allowable Operating Pressure (MAOP): 5 psi (.34 bar).

Particle Removal Efficiency: 98.7% (beta 75) @ 3 micron 99.5% (beta 200) @ 4 micron 99.9% (beta 1000) @ 5.3 micron Weight: 934330T 934331T 934332T

1.25 lbs. (.57 kg) each.

1.75 lbs. (.79 kg) each.

2.25 lbs. (1.02 kg) each.

Features Silica Gel Desiccant Has the highest removal capability by volume of any adsorption method. Indicates condition by changing color.

Foam Pads Isolates the removal materials from contact with heavy reservoir mist and securely holds materials in place.

Filter Pads Specially designed filter pads remove solid particulate on upstream side and then regenerate by releasing those particles when air flow reverses direction. Lower pad removes airborne contamination and second pad protects against any migration of desiccant.

Foam pad Insures filter pad is properly positioned and protects it from external damage.

Air Intakes A total of eight air intakes may be exposed to allow air to freely flow in and out of the TriCeptor.

Molded Housing Durable shock absorbing casing provides reliable service and simple press in mounting.

200

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Reservoir Accessories Breathers Installation

Air Flow Performance

TriCeptor breathers are designed for simple installation on most equipment, regardless of mounting connection.

Since TriCeptor breathers are disposable, the threaded connection allows for quick and easy maintenance. Several mounting adapters (shown below) are available to provide the desired mounting. The installation/replacement process consists of four easy steps:

The curves below show the air flow performance of the three TriCeptor breathers. To insure the longest life possible, the initial clean pressure drop should not exceed 1.5 psid (.103 bar).

1. Remove from protective plastic wrap.

.241

3.0

.207

2.5

.172

2.0

.138

1.5

.103

1.0

.068

.5

.034

3. Remove foil label to expose the necessary amount of air intake holes.

4. Twist TriCeptor into mounting adapter.

Servicing the TriCeptor breather is also very easy. When the silica gel changes color from blue to a pink, the breather is no longer active and needs to be replaced.

Simply remove the unit and discard properly.

BAR

PSID

2. Remove 1" blue cap from standpipe.

3.5

0 0

30

60

90

120

150

GPM (fluid exchange rate)

.241

3.0

.207

2.5

.172

2.0

.138

1.5

.103

1.0

.068

.5

.034

101.6 4.0

BAR

PSID

3.5

0 0

4

8

12

16

20

7.55

9.44

SCFM

0

127.0 5.0

1.88

3.78

5.66

Liters/Second

178.0 7.0 229.0 9.0

41.66 1.64

1“ NPT Thread

Field Adapter

Flange Adapter

33.53 1.32 98.55 3.88

Linear Measurement= mm in

Model

Part Number

Quantity

5" Breather

934330T

6 pcs.

7" Breather

934331T

6 pcs.

9" Breather

934332T

6 pcs.

Field Adapter

937546

1 pc.

Flange Adapter

937463

1 pc.

201

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH