Man Ajax DPC 2802le Om PDF
Man Ajax DPC 2802le Om PDF
Man Ajax DPC 2802le Om PDF
Contract 10520
Engine Compressor
Model Serial Number Model Serial number
DPC-2802LE 85257 13” YK11F 14369
6” YK11CD 14367
Contents
Section 3 – Engine
Section 6 – Cooler
Section 7 – Compressor
Detailed Contents
Engine Operating with Fuel Containing H2S ........ Ajax TIB 050610
Section 2 – Package Drawings
Section 3 – Engine
F1 820 AM Pump,
Section 6 – Cooler
Section 7 – Compressor
Warranty......................................................................... Ajax
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97
TDI TURBOTWINTM
Engine Air Starters
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97
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ESS-F-963
Title: Keyless Flywheel Installation And Timing
Installation
1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.
! Caution
Firmly secure the flywheel to prevent it from falling over.
2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove
ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied
locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not,
lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent.
3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel.
4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is
required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN
Figure 1
Flywheel Collar
Hardened
Washer
Inner Ring
Crankshaft
Locking
Screw
5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both
for assembly.
6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between
.001”-.003”. Do not over-lubricate.
Note
Step 6 should only be performed during initial engine assembly. Do not lubricate on field units.
7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create
a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the
Note
Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat
and possibly gall the surface of the crankshaft.
8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to
the crankshaft.
9. Remove the crosshead side access door from power cylinder one.
10. Set the timing pointer on the ignition bracket, allowing 1/8” clearance from the flywheel. Adjust the
pointer until it is located in the middle of vertical slot on the bracket.
Note
You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then
marks #2 and T. These distances should be equal.
19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200
and 2800 engines use a 48” diameter flywheel. This means that:
3° = 1ÿ” Flywheel O.D. distance
9° = 3¾” Flywheel O.D. distance
11° = 4-5/8” Flywheel O.D. distance
20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3°, 9°
or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel.
21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crank-
shaft in the general range of normal ignition timing.
22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be
installed between the sheave and end cover. See Figure 2. This picture shows the method of locking
the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field
installation.
23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that
Figure 2
Figure 3
End of Crankshaft
Side
DC
#1 T
ESS-L-981
ABSTRACT
The jet cell concept is required for low emission or emission reduction engines. The high-
energy torch issuing from the pre-chamber allows the main chamber to be operated with a
leaner mixture and consistently ignited, as compared to a conventional spark plug
ignition of a lean mixture.
Also, the jet cell is applied to units to improve combustion stability and improve fuel
consumption when operating at variable speeds and reduced torque. This paper describes
the jet cell operation and general maintenance procedures relating to AJAX Low
Emissions Two-Cycle Engines.
The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head.
The nozzle end is designed with a specific volume and has a communicating angled exit
orifice. A spark plug for ignition and a fuel admission check valve complete the
necessary operational components.
Pilot fuel headers supply fuel to each admission check valve. The supply to the header is
taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with
an additional regulator.
The ignitor fuel pressure is thus regulated manually according to site conditions.
For one cycle of operation, as the piston comes up on compression, the pressure within
the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When
1 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
the pressure within the cylinder becomes greater than the fuel pressure, then the pilot
check valves close.
The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs
within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this
energy release forces the burning mixture to exit through the nozzle orifice across the top
of the piston in the main combustion chamber, igniting the main combustible charge.
IGNITION TIMING
In standard spark ignited engines, the spark plugs ignite the charge and a progressive
flame front occurs within the combustion chamber. Due to the time required for this
flame propagation, the ignition timing is approximately 9°-12° before top dead center
(BTDC).
With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fuel/air
mixture within the main combustion chamber. The mixture is ignited uniformly by this
higher energy source, which promotes faster burning. For this reason, the ignition timing
is set at 3° BTDC.
For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs
7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day
(24 hrs), and 30 days of operation would equal 19,008,000 times.
MAINTENANCE
The jet cell, when installed into the cylinder head, has a round Armco iron gasket which
acts as a fire seal; a graphoil seal employed as a bottom water seal, and an ‘O’ ring as the
top water seal.
The unit is held in place with a two-bolt flange and torqued to 70 ft-lbs.
If a cell is removed from the head, it is important that the access hole for the cell is clean
and free of any scale build-up. New gaskets and seals should be installed and the unit
properly torqued. A locating dowel is used to assure proper orientation of the exit orifice
of the cell in relation to the main combustion chamber.
SPARK PLUGS
Cooling of the spark plug is accomplished primarily through the spark plug gasket
seating surface and the threads. These areas within the cell have thin metal sections and
are surrounded with engine coolant.
In service, the center and ground electrodes will deteriorate, which increases the spark
plug gap. Erratic firing will occur once the gap increases 0.005”-0.010” from the original
setting and the plugs should be replaced.
2 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion
RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to 0.018″ was used. The
main chamber spark plug utilized the Champion W-18 (BM-1022). Current production
models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022)
spark plug is used with an initial gap of 0.020″. This allows use of the same spark plug
for both the main chamber and igniter. The current production jet cell (YK-8209-C-1)
identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage
may occur to igniter and/or spark plug threads as the result of thread depth and thread
reach respectively.
The secondary ignition wiring and associated components should always be in good
condition.
The primary check valve (P/N YK-8338-A) is most important in the operation of the jet
cell. As noted previously, the number of cyclic operations relates to the unit’s speed, with
fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and
being shut off the cylinder pressure increases. The check valve also withstands the high
pressure within the cell at time of ignition.
Present production check valves use a ceramic ball with tool steel enclosure and seat.
Ajax continues to improve the life and operation of the valves with ongoing research and
development programs.
From the primary check valve, the fuel gas enters the cell through drilled communication
holes. Due to fuel entrapment, incomplete combustion can occur in these passages, which
tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to
the check valve’s operation, but in other cases it can be severe. If this build-up becomes
heavy, erratic operation of the check valves will occur and they should be removed,
cleaned and tested.
Whenever the spark plugs are replaced, it would be appropriate to remove and clean the
check valves. Some end users have a spare set of check valves which are installed at this
time, and the removed set is cleaned for reinstallation at a later date.
An orifice (P/N K-8050) is installed on the inlet side of the primary check valve to allow
pilot fuel pressures to be comparable to main fuel pressure. The orifice resembles a 1/8″
toe nipple. Ensure this is an orifice by visual inspection, noting a small 0.038″ internal
hole. Clean when servicing the primary check valve.
Connected directly upstream of the orifice is a secondary check valve (P/N BM-21064).
This is utilized only as a backup to the primary check valve.
3 Revised 07/98
ESS-L-981
AJAX LOW EMISSIONS ENGINES
A jet cell-equipped engine does require some additional maintenance over a standard
combustion engine. This additional maintenance is offset by gains in combustion
stability, lower emissions and improved fuel economy.
4 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
ESS-L-983
The new AJAX Low Emissions (LE) Engine utilizes a squish design combustion
chamber that includes a jet cell (ignitor cell). The assembly procedure is basically the
same as on a standard engine, with the following additions and changes in gas valve
timing, ignition timing and power piston position.
A) The piston used on the LE engine does not incorporate notches or tapped holes in
the crown for installation as compared to the standard combustion engine. It is
recommended that a rod wrench (or strap wrench) be used to install or remove the
power piston.
B) Screw piston into crosshead until approximately three (3) threads are left
showing. Do not tighten rod nut at this time.
1 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
Figure 1. Measuring Proper Piston-To-Head Distance
E) Once clearance is set, torque rod nut and check clearance again. Piston has a
tendency to turn out slightly when tightening nut.
Refer to ESS-T-911 as a basis for fuel injection timing. The following changes must
be made when converting an engine to LE application.
A) The flywheel and gear shield must be removed in order to remove layshaft and
reset cam timing.
B) Cam timing is retarded from the standard 13° ABDC beginning of injection to 37°
ABDC. DO NOT GO BEYOND 37° ABDC! If gears do not line up with cams at
37° ABDC, go back towards BDC (i.e. 35° ABDC). Beginning of injection is 37°
2 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
ABDC on all LE engines but the method of setting the timing is different on
DPC-800s & DPC-2804s.
C) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2)
cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders.
#2 & #4 cylinders run off the other cam. Refer to Figure 2.
#1 power cylinder gas cam timing is referenced off #3 bank on the control box.
The crankshaft should be rotated in a clockwise direction to 26° ABDC #1 power
cylinder. DO NOT GO BEYOND 26° ABDC! If gears do not line up with cams at
26° ABDC, go back towards BDC (i.e. 24° ABDC). The crankshaft is positioned
at 26° ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is
due to the way the cam is installed on the layshaft. The result will be injection
beginning at 37° ABDC. Refer to FIG 3. The cam can now be set using the
method illustrated in ESS-T-911.
D) Once the preceding is complete, the layshaft gear should be installed and re-
indexed.
3. IGNITION TIMING:
Ignition timing is changed on all LE engines to 3° BTDC. New mag pickup brackets
are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate
the timing change.
3 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator
must be removed and re-indexed to 3° BTDC (refer to the standard DPC-800/DPC-
2804 Operation & Maintenance Manual for procedure).
A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in
the LE power head. This ensures proper direction of ignitor exit orifice. It is very
important that they are lined up properly! Misalignment will result in severe
piston crown damage. It should be noted that when ignitor is torqued into head,
the roll pin will not completely set into slot. This is only an alignment reference.
B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small
amount of grease to hold gasket in place when installing ignitor into the head.
Insure O-ring is installed on ignitor at this time also.
4 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
Figure 4. Ignitor Assembly
D) Install ignitor into head being very careful not to damage water seal. This may
take some hand fitting of seal. Torque down in progressive 5 ft-lb increments to
70 ft-lbs.
5. SPARK PLUGS:
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a
Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to
0.018″ was used. The main chamber spark plug utilized the Champion W-18
(BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized,
use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020″. This
allows use of the same spark plug for both the main chamber and igniter. The current
production jet cell (YK-8209-C-1) is identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell.
Damage may occur to ignitor and/or spark plug threads as the result of thread depth
and thread reach, respectively.
5 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE
6. GAS INJECTION VALVES:
The gas injection valve used in the LE power end is of the same basic design as the
one used in the standard combustion assembly but the valve housing and plunger
housing are not interchangeable. The gas injection valve assembly on the LE engine
has a longer valve body housing and a shorter plunger housing to accommodate the
profile of the power head.
7. MISCELLANEOUS:
In addition to the preceding requirements, engines that are converted to the LE design
must have:
6 Revised 07/98
Technical Information
Bulletin # 020718 r2
August 24, 2004
The following component dimensional specifications and wear limits should be used as a
guide for preventative maintenance programs for Ajax equipment. Problems can be
detected early before failures occur.
These specifications are based on data gathered from a broad range of Ajax installations
covering many decades of operating experience.
Specific unit performance and maintenance requirements may vary based on application
conditions and preventative maintenance practices.
2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot
exhaust pipe and ignite .
As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a
pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing
adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas
injection valve assembly is mishandled during servicing.
Figure 1
As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve
minimizes damage potential, and permits more efficient purging of the hydraulic system.
Convert to the current design by replacing the injection valve’s cap with the current design.
A parts kit for the conversion is available, or individual pieces can be specified. See the
appropriate table below for a kit P/N or the individual P/Ns.
Use of divider valve designs provides a simple, reliable and predictable approach to engine cylinder and compressor
cylinder lubrication. Simplicity is enhanced by use of a lubrication monitor that senses divider valve operation, and
displays pints/day of lube oil consumption based on RPM and a divider valve assembly’s displacement volume.
The following rates for engine cylinders are based on the use of dry gas, and lube oil per Ajax engineering standard
ES-1006. HP listings are at standard conditions of 100ºF and <1500’ elevation.
Engine lubrication rates for normal operations are based on 1 pint/30 HP.
The following rates for compressor cylinders are based on the use of clean and dry gas, and lube oil per Ajax
engineering standard ES-1006. Rates listed are based on MWP and maximum bore size and include the rod packing’s
requirements. Refer to the O & M manual for other conditions.
NOTE: to attain the total lube rate for a compressor unit, add the lube rates for the individual cylinders.
Individual cylinder and rod packing assembly lubrication rates are based on the following formula:
Example: YK11G, 14” bore, 11” stroke, @ 440 RPM, 400 psig
(0.0000314 x 14 x 11 x 440) = 2.13
(0.000333 x 400) = 0.13
0.75 = 0.75
3.00 pints/day
The lube monitor’s rate display is calculated by using the divider valve assembly’s cycle signal, and a
BLOCK TOTAL of the assembly. The assembly’s BLOCK TOTAL is determined by adding the “sizing number”
for each element within the assembly. Refer to the following table for the sizing number for a particular SMX
element:
DropSa Element Sizing Number
SMX-08 5
SMX-12 8
SMX-16 10
SMX-25 15
SMX-35 20
SMX-40 25
SMX-50 30
Assure that the correct values are used for the engine’s divider valve assembly, and the compressor cylinder’s divider
valve assembly. (Metering element designation (the SMX number) is stamped on each element’s nameplate.)
Installation Design for Permanent Ajax Compressor Packages
When designing the engine-compressor installation, several factors should be taken into
consideration which can affect the overall performance of the installation:
• An adequate foundation must be provided to assure a stationary mounting base for the engine-
compressor skid and any accessory equipment not mounted on the skid. If the unit is installed
inside a building or adjacent to other machinery, sufficient space must be allowed around the
unit to facilitate maintenance and service work (refer to the unit’s foundation drawing).
• Avoid arrangements that allow hot air from the muffler or cooler to flow to the air inlet of the
cooler or air cleaner.
• It is recommended that the engine-compressor skid and accessories be placed on grouting on
the foundation to ensure full, even bearing support under the equipment. Grouting is poured
after the equipment has been properly set and aligned on the foundation. For a grouted instal-
lation, the foundation top surface should have a rough surface (not trowelled) to ensure an
optimal grout-to-cement bond.
• Air cleaners may be located outside the building to avoid heat generated by the unit; however,
direction of prevailing winds should be considered in their location.
• Installation of units inside buildings should be designed to allow for the passage of hot air
from the coolers to the outside through adequate natural ventilation or through ducting to the
outside of the building. Unitized vertical discharge coolers may frequently be installed outside
the building to ease the disposal of heated air.
• The exhaust system must be properly designed for the operating conditions of the engine-
compressor, both for proper scavenging of the power cylinders, and for correct dissipation of
exhaust heat.
• The instrument panel should be placed in a location convenient for the operator.
NOTICE: The size and construction of the foundation must be selected to suit the soil
conditions at the unit location.
In designing the foundation, the static and dynamic loads must both be considered. The
unbalanced forces and couples of each engine-compressor unit are available, on request, from the
service branch or factory. In well compacted, high load capacity soils, (6 tons/ft2 minimum) the
minimum dimensions shown on the appropriate foundation drawing supplied should be adequate
for a reinforced concrete foundation (refer to the unit’s foundation drawing).
! "#
The foundation design must include anchor bolts to secure the engine-compressor unit. Anchor
bolts must be located to achieve precise alignment with the skid’s anchor bolt holes (refer to the
unit foundation drawing). Use sufficiently long anchor bolts to ensure deep placement and
adequate length above the foundation (account for full thread engagement of nuts and space
required for grouting).
Preferred practice is to set anchor bolts while pouring concrete for the foundation. A common
practice is to use canister-style anchor bolts to afford position adjustment capability. Here, the
anchor bolt is centered inside a piece of 2” to 2-1/2” pipe and positioned so the top of the pipe is
flush with the top of the completed foundation. The open pipe end should be blocked to keep
foundation concrete out. This approach is illustrated in Figure 1.
% & '
If the foundation has already been poured, then anchor bolts may be set by first drilling holes in
the foundation and then placing and grouting the anchor bolts in. Sulphuring, a means to dissolve
concrete, may also be used to create anchor bolt holes.
In soils having a low load support capacity, a wider and longer foundation or one which angles out
at the bottom should be used to distribute the load over a larger area on the bottom face of the
foundation.
NOTICE: In general, it is poor practice to economize on the amount of concrete used on the
engine compressor unit foundation.
If the soil load bearing capacity is questionable, it is highly recommended that a soil analysis be
made prior to designing or pouring the foundation. If unsuitable soil is encountered, the
foundation design must be changed to accommodate the soil.
$
Allow foundation concrete to cure for at least 28 days before installing an engine-compressor
package. Using ASTM guidelines, a concrete physical properties test may be performed to ensure
that sufficient curing has occurred. Any concrete-related problems that may exist, such as low
tensile or compressive strength, may be detected at this time. If the concrete is ready for engine-
compressor installation and grouting, then proceed with foundation surface preparation.
In order to achieve optimal grout-to-concrete bonding, prepare surfaces for grouting by chipping
away all laitance, oil-soaked concrete, and damaged concrete until 50% aggregate is exposed (the
foundation contractor may have already prepared the foundation in this manner). A chipping
hammer or 15-pound chipping gun (with chisel point) may be used for chipping.
NOTICE: Avoid heavy chipping guns as they may create micro fractures within the foundation.
Rebar wickets or dowels may be used to provide additional mechanical locks between grout and
concrete. These may be set by drilling into the foundation and inserting the wickets or dowels.
Locate the wickets/dowels away from foundation anchor bolts. Exposed length above the
foundation surface should be limited to ≈60% of the grout thickness (1-1/2” maximum for 2-1/2”
grout thickness).
Determine whether or not grout expansion joints are required. Foam strips or other suitable
(compressible, temporary) material may be used. Strips may be secured to the foundation with
glue; apply wax to exposed surfaces to allow easy removal after the grout has cured. If a crane is
to be used to place the engine-compressor unit, then expansion joints may be installed in advance.
If jacks and rollers are used, then expansion joints should be added prior to lowering the unit.
Set leveling planes in level position on the foundation under the leveling screw locations.
Clean all residual paint, oil, grease, and dirt from foundation surfaces that will come into contact
with grout. For final cleaning, use the grout manufacturer’s recommended solvent using clean
solution and clean cloth for the last wash. Lacquer thinner may be substituted if necessary;
however, mineral spirits cannot be used for this purpose.
If cement-based grout is to be used then pre-soak the foundation with water to help ensure that
foundation concrete does not draw water away from the grout after placement.
If epoxy resin grout is to be used, then use compressed air to blow away all dust and debris and
dry all moist foundation surfaces.
NOTICE: Grout may adhere to levelling screws, tools, forms or other items which have not
been protected with paste type wax.
The end result is a properly prepared foundation ready for setting the engine-compressor package.
( % ) * % +
! "#
It is recommended that the skid bottom in contact with grout be free from all paint, grease, primer,
or other material that could inhibit grout bonding. A light film of rust is usually acceptable. Use
evaporative solvent to wipe down all skid surfaces to be bonded to grout.
The engine-compressor skid is normally set directly upon the foundation block. Where overhead
space and/or crane capacity permit, the unit may be lifted using brackets or lifting lugs (provided)
and placed over the foundation anchor bolts. Lifting cables must be provided with spreaders so
that the lifting cables will remain parallel to the vertical center-line of the unit.
If overhead lifting capacity is not available, then jacks and rollers (cribbing) may be used to move
the unit into place over the foundation anchor bolts.
Lower the engine-compressor unit to its final elevation. Allow 2” nominal clearance between the
foundation and skid (1-3/4” minimum, 2-1/2” maximum). This clearance is recommended to
allow sufficient room for placing grout to all necessary locations beneath the skid. Use leveling
screws to make final skid elevation adjustments such that all mounting pads are at the prescribed
elevation.
Perform web deflection measurements on the engine to check crankshaft alignment. Use these
measurements to fine-tune the engine-compressor elevation using the leveling screws. For long-
term engine performance it is essential that web deflections are held within specification (see
Ajax-Superior Engineering Standard ES-4025: Crankshaft Web Deflections for Three- and Four-
Cylinder Ajax Engines).
Install belts on cooler drive and check alignment. Accurate alignment is essential to ensure
acceptable drive component service life and to eliminate detrimental loads and vibrations.
The drive alignment is checked by drawing a string taut between adjacent faces of the two
sheaves (pulleys), lined up to intersect the two hubs. When the drive is properly aligned, the string
will barely touch the face of each sheave at the points where the string crosses the sheave rims
(see Figure 2 below).
% , % - ( ) % .
Primary Sheave Critical Alignment Point
Secondary Sheave
Line
% $& / % (
After properly positioning the engine-compressor unit, then finish up by taping off or paste-
waxing all leveling screw threads so screws can be removed after the grout has cured.
Grout may be either of the conventional (cement based) type or of the epoxy resin type.
Each type has advantages and disadvantages:
Working Time: Check the grout specifications. Working time may vary from as little as 15-20
minutes to over 1 hour. Select a product that will allow adequate mixing, handling, and placing
time.
Working Temperature: Check the grout specifications. Manufacturers often recommend that
foundation, equipment, and grout materials attain equilibrium temperature on the order of 70°F
before mixing and pouring. If possible, avoid grouting at temperatures below 50°F, although
grouts for use at such temperatures are available. Note, however, that temperature can affect grout
working time.
Flowability: Most grout manufacturers will claim that their products are “flowable,” but this is a
relative term. Grout viscosity should not be too low (runny, not stackable) or too high (not
pourable). Grout flowability may be increased by reducing the amount of aggregate used. Consult
with the grout manufacturer’s technical representative if questions arise here.
*
! "#
Compressive Strength and Curing Time: Epoxy-resin grouts, although more costly, provide
greater compressive strength and cure much more quickly than do cement-based grouts.
Long-Term Performance: Properly mixed, installed, and cured cement-based grouts have very
good long-term dimensional stability but may degrade structurally (cracking) under continual,
excessive vibration input. Epoxy-resin grouts have better long-term structural integrity but, being
viscoelastic materials, are subject to creep that is heightened by elevated temperatures.
Tables 1 and 2 provide examples of cement-based grout and epoxy resin grout respectively.
0 &, - * 1 2
* ' / %
% 1 2 1 2
Unisorb V-1® Non-Shrink Grout 11,800 28
0 $& , , 3 * 1 2
* ' / %
% 1 2 1 2
L&M Construction Chemicals’ Epogrout 758 13,200 7
Affirm that the selected grout will meet the installation load requirement, the working
temperature condition, and the working time requirement. Grouts such as those listed in Tables 1
and 2 have sufficient compressive load strength to support typical AJAX engine-compressor and
cooler packages.
*
Table 3 provides compressive load estimates for 2801-, 2802-, 2803-, and 2804-based units. Skid
footprint is the skid base area that will be in direct contact with the grout. The cooler load is
computed separate from the engine-compressor load for 2803- and 2804-based units.
NOTICE: The estimates in Tables 1,2, and 3 are for reference purposes only!
Be aware that total package weight is dependent on the number and size of compressor cylinders,
and the number of compression stages and associated pressure vessels. If needed, grout
manufacturer representatives can help in the grout selection process.
0 +& * / % 3 5 , 1
2
! " 6 9 9 8*
7 % 1 0 82 ) /
6 * % ;1 2
$2
:1
2801 31,000 26.3 8.6
All longitudinal skid members must be grouted. Major load-bearing lateral skid members should
also be grouted. Grout the skid base using procedures suitable to the application or unit involved.
The final grout level should be approximately up to the skid flange thickness. Care must be taken
to provide adequate forms to retain grout. Remove any excess grout before it has been completely
set.
After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all
levelling screws.
NOTICE: This is essential to insure that the unit is being supported only by the grout, not by
the screws.
Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment.
Remove temporary expansion joint materials and fill expansion joints with joint compound.
* % 4
Section 2 – Package Drawings
Ignitor......................................................................... YK-8209-C-2
1 ” travel (ref.)
Adjust Starter Pinion
main fuel pressure regulator
to 15 psig (typically). Ring Gear
Flywheel
(Ajax p/n 2040 6430)
(Fisher Type 627) 0.06” minimum
” minimum
engagement
TP 02-22-T01C-001-150 rev 3
Fuel Gas Vent Piping
TP 02-22-T07B-001
WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation.
✔ Follow all safety warnings of the machine manufacturer.
Model M5081
✔ Read and follow all installation instructions.
Approved*
]
]
g.)
bar]
]
[254.0]
bar
bar
bar
.28 k
(closed), seat closes (C).
.38
.69
0.34
.07
9.0
g.)
[228.6]
) [1
) [0
) [2
z. (0
The vent (D) opens to relieve trapped downstream fuel
a) [
11 k
Inches water column (∆p) drop across valve.
kPa
kPa
kPa
8.0
10 o
4 kP
[203.2]
. (0. to vent to a non-hazardous area.
Millimeters water column in brackets [ ].
38
07
(69
ig (3
g (1
g (2
4 oz
7.0
sig
[177.8]
psi
psi
5 ps
10 p
20
30
6.0
[152.4] TYPICAL MODEL (M5081) SHOWN
5.0
Terminal Block is
[127.0]
4.0
[101.6] within this case.
3.0
[76.2]
F
2.0
[50.8]
1.0
[25.4]
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
E
[7.08] [14.16] [21.24] [28.32] [35.40] [42.48] [4956] [56.64] [63.72] [70.80] [77.88] [84.96]
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
G
B
C
A
M5081 and D
M5180 Series Vent to relieve trapped fuel
outside the hazardous area. H Pipe Plug (remove to
install vent tube).
Inches water column (∆p) drop across valve.
Millimeters water column in brackets [ ].
g.)
1k
(.1
A. Main Stem
z.
3.0
4o
.)
[76.2]
kg
2.0
ar]
[50.8]
a ) [.6
9b D. Vent Seal Gland
k P
sig
(69
[1.38
bar] E. Reset Knob (latches valve open)
10 p 38 kPa)
1.0
[25.4]
20 p
sig (
1
2.07
bar] F. Manual Trip Knob (not available for M5081FS)
k Pa) [
30 ps
ig (2 0 7
G. Indicator Button (out with valve open)
H. Pipe Plug
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
[14.16] [28.32] [42.48] [56.64] [70.80] [84.96] [99.12] [113.28] [127.44] [141.60]
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
NOTE: If the vent-after-tripping feature is not used,
remove O-ring (D), to avoid condensation accumulation
that can hamper trip action.
Be sure to replace Pipe Plug (H) and to clean vent
periodically.
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M2582 M2582-P
1/4 in. (6 mm) tube connection; control
1/2 NPT Conduit pressure 3 psi (21 kPa) [0.21 bar] minimum,
Reset Knob Connection Latch Arm (see NOTE) 75 psi (517 kPa) [5.17 bar] maximum.
Manual Trip
Knob
1 NPT Breather/Vent
(2 places) 1/16 in. (2 mm)
1 NPT
(2 places)
6-9/16 in.
7-5/16 in. 1/4 NPT (167 mm)
1/4 NPT (186 mm) Vent and
Vent and Plug Plug
3-3/32 in.
3-3/32 in. (79 mm)
(79 mm) 5-1/2 in. (140 mm)
5-1/2 in. (140 mm)
NOTE: Thumb operated opening latch (2.5 psi [17 kPa]
[0.17 bar] required to release cocking latch)
M5180-P
Latch Arm (see NOTE 2)
NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control.
NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch).
1-23/32 in.
Panel Mount screws (44 mm)
10-24 N.C. x 31/32 in.
5/16 in. (8 mm) long (25 mm)
2-7/16 in.
(62 mm)
15/32 in. GND ALT1 ALT2 SW
(12 mm)
Terminal screws
8-32 N.C. x
1/4 in. (6 mm) long
Installation M-7980N page 3 of 12
DIMENSIONS continued
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
3-7/16 in.
Indicator (87 mm)
Button
4-1/16 in.
2 NPT (103 mm)
Vent and Plug (2 places)
1/2 NPT
3 in. (76 mm)
9-3/8 in. (238 mm) 7-3/4 in. (197 mm)
45°
3-5/8 in.
(92 mm) dia.
WARNING: STOP THE ENGINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION. BEGIN THE
INSTALLATION BY SECURING AREA OF ANY HAZARDOUS CONDITIONS. SHUTOFF THE FUEL GAS SUPPLY. FOR HAZARDOUS
APPLICATIONS REFER TO NATIONAL ELECTRICAL CODE SPECIFICATIONS.
CAUTION: DO NOT TWIST THE VALVE BODY HOUSING. Remove plug and attach vent line.
FUEL FLOW Route to non-hazardous area.
5. To mount flanged models, follow the appropriate installation codes
and ordinances for the application. (For dimensions see page 4.)
6. A vent line (to allow gas trapped forward between fuel valve and the
carburetor to escape) should be attached to the vent connection at the
bottom of the valve housing. Remove the plug and install the line. Figure 2
(Refer to Figure 1.) Pull the lever up, and press the latch
down into ridge with thumb.
Connecting Pneumatic Models
M2582-P and M5180-P
1. Repeat the steps above (1 thru 5), and observe the necessary cautions. Level Arm (Handle)
2. A lever/arm (handle) and a cocking latch are provided to allow manual
opening of the valve. The thumb-operated latch can be locked in place
to hold the lever/arm latched. The cocking latch will be released when Control Pressure
Connection
pilot pressure reaches 2.5 psi (17 kPa) [0.17 bar]). M2582-P and
M5180-P automatically open at 2 psi (14 kPa) [0.14 bar], and fully Thumb-operated
Cocking Latch
open at 3 psi (21 kPa) [0.21 bar]. See Specifications, page 12 for Breather
maximum control pressure. Vent
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT
WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
Valve
Coil
Ground Switch 2 (Note) Switch 1
65700053 (was 65020126): For use with
negative ground ignitions up to 240 VDC. +
65700054 (was 65020127): For use with
positive ground ignitions up to 450 VDC.
IN4007
65700055 (was 65020155): For use with ALT ALT
GND SW
10 9 8 7 6 5 4 3 2 1 negative ground ignitions up to 450 VDC. 1 2
Negative ground
Magnetic Switch Adapter shown
NOTE: Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2)
wire is red color for both options: 12 VDC and 24 VDC.
M5081-C
CD Ignition Models Magnetic
Switch
GND ALT1 ALT2 SW Adapter
Terminal Block
10 9 8 7 6 5 4 3 2 1
CD ignition Additional
CD ignition
Ground Jumpers
MS2100 MS2100
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single CD Ignition Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 6.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect second ignition to Magnetic Switch Adapter terminal ALT2.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect a 100 ohm, 2 watt resistor between valve terminals 1-2. Ground terminal 6.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual CD Ignition Systems) Remove the jumper on terminals 6-5. Connect a 100 ohm,
2 watt resistor between valve terminals 1-2. Ground terminal 6. Connect second ignition to Magnetic Switch Adapter terminal ALT2.
M5081-B
Battery Models + --
DC Power
Terminal Block source
10 9 8 7 6 5 4 3 2 1
Ground
Jumpers
* *forIN4005 Diode
flyback protection
MS2110 MS2110
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
Installation M-7980N page 7 of 12
TYPICAL WIRING for M5081-A (MAGNETO IGNITION MODELS)
M5081-A
Magneto Ignition Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
Magneto
Ground
65010065 Additional
Diode Package
(See Notes 2/4) Jumpers Magneto
MS2120 MS2120
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single Magneto Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 5.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual Magneto Systems) Remove the factory-installed jumpers on terminals 6-5 and 9-8.
Add 65010065 diode package as shown. Do NOT ground terminals.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single Magneto Systems) The factory-installed jumpers (6-5 and 9-8) must be in place.
Add ground wire to terminal 5.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual Magneto Systems) Remove the jumper on terminals 9-8.
Add 65010065 diode package as shown. Add ground wire to terminal 5.
M5081FS
12 or 24 VDC Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
+ --
Ground Ground * DC Power
source
MS2110 MS2110
6 1 2 3 4 5 6 1 2 3 4 5
* forIN4005 Diode
flyback protection
* *
Start-run timer
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD
CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582-C to LCDT-PS-CD (R)-P (positive ground) M5081-C to LCDT-PS-CD (R)-P (positive ground)
C
Relay NO
Contacts C
NC
NC
Ground
* FV(-) FET output rated: 0.5 A @ 250 VDC max.
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
LCDT-PS-CD-N LCDT-PS-CD-N
+ M5081 Terminal block Terminal block
–
M2582 Fuel Valve
IGN 1 – +
White 10 9 8 7 6 5 4 3 2 1 IGN 1
FV(+)
FV(+)
Black FV(-) * Relay
FV(-) *
GND
jumper jumper GND
Contacts
Red
NO
C
Relay NO
Contacts C
NC
NC
M2582-C to MARK IV-N (negative ground) M5081-C to MARK IV-N (negative ground)
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M5081-B
M5081FS Terminal Block K1 and K2:
MARK IV-12/24 1 External
terminal block 10 9 8 7 6 5 4 3 2 1 – –
10 9 8 7 6 5 4 3 2 1 Relay(s)
K1 *
+
K2 *
+
12/24V *
SD jumper jumper
* K2 K1
F/V
GRD
F/V
S/D
GRD
12/24V
-- +
DC Power
source -- +
DC Power
* forIN4005 Diode
flyback protection * for flyback protection
IN4005 Diode source
MARK IV-12/24 1
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max. terminal block
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
Remove shunt jumper E2 for ignition ground time delay.
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
TTDJ-DC-(T) to Relays
Connections Shown for Use with M5081FS to TTDJ-DC-(T)
Diagrams (A), (B), (C), and (D) on this page.
To 12 or 24 VDC
M5081FS Terminal Block power supply
1
IGNITION RELAY + –
K1
10 9 8 7 6 5 4 3 2 1 SD
10-32VDC
*
12-24 VDC GRD
NA
Power supply 1
SD FV
+ – * ALR
K2 10-32VDC
MPU
GRD GRD
* NA
FV
ALR
MPU
1 K1 and K2 are hermetically Sealed GRD
auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas. * 1N4005 diode for flyback protection.
* 1N4005 diode for flyback protection.
Black 1 –
jumper jumper K2
Red 1
1 K2 is hermetically sealed auxiliary relay, third party 1 K2 is hermetically sealed auxiliary relay, third party
certified for use in Class I, Div. 2, Gps. C & D areas. certified for use in Class I, Div. 2, Gps. C & D areas.
Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product.
Details are available on request and are packed with each unit.
CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
(281) 342-0297 fax (281) 341-6006 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358-5555 fax +61 3 9358-5558
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
MURPHY SWITCH OF CALIFORNIA
(918) 317-4100 San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
fax (918) 317-4266 +52-444-8206264 fax +52-444-8206336 Palmdale, California 93551-1442; USA
D
RE
Introduction
Scope of Manual
This instruction manual provides installation, spring adjust-
ment, maintenance, and parts information for the Type 119
control valve.
Description
The Type 119 control valve (figure 1) is used for on-off or
throttling control of noncorrosive or mildly corrosive liquids
and gases. It is designed to meet the low-pressure liquid
and gas application requirements in many varied industries.
Table 1. Specifications
1E5427-F
Material Orifice
Code Seat Disk Material
AI/N
SST/N
Aluminum/Nitrile
Stainless steel/Nitrile
Spring Adjustment
SST/V Stainless steel/Fluoroelastomer
The control valve spring has been selected to meet the
pressure condition requirements of the application as spe-
cified on the order. This pressure condition is stamped on
Figure 2. Type 119 Nameplate the actuator nameplate.
2
Type 119
1. Loosen the locknut (key 13) on the spring case. 7/8-inch socket wrench, and replace it with a new seat ring
of the proper size.
2. Turn the adjusting screw (key 12) clockwise to
compress the spring (key 16) or counterclockwise to 4. Remove the bonnet O-ring (key 11), and inspect it for
decrease spring compression. Increased spring compres- wear and damage.
sion results in increased loading pressure necessary to
start travel. Decreased spring compression results in less 5. Unscrew and remove the spring case cap screws (key
loading pressure required to start travel. 14). Remove the spring case, upper spring seat, and spring
(keys 2, 17 and 16). Do not lose the nameplate (key 20)
when removing the spring case.
3. After adjustment, tighten the locknut. Note that the
spring can be identified by the color code. Depending on 6. Pull the hair pin clip (key 6) from the stem and remove
how much conditions are changed, it may be necessary to the disk holder assembly (key 4).
install a new spring, using appropriate steps in the Mainte-
nance section. After changing the spring, adjust the valve 7. Pull the diaphragm/stem assembly (key 5) out of the
using the above steps in this section, and indicate the new bonnet (key 9), and inspect for damage or deterioration. If
spring range on the nameplate. necessary, replace the entire diaphragm assembly.
The following describes the procedure for complete 1. If the orifice (key 3) was removed during disassembly,
disassembly and assembly of the actuator-valve body lubricate the threads with Never-Seez(1) lubricant (key 21)
combination. When inspection or repairs are required, or equivalent, and screw it into the valve body using a thin-
disassemble only those parts necessary to accomplish the wall 7/8-inch socket wrench.
job. Key numbers refer to figure 3.
2. Lubricate the bushing spacers, O-rings, stem wipers,
and internal retaining rings (keys 7, 8, 19 and 10) with Dow
Corning(2) No. 111 silicon-base lubricant (key 22) or equiva-
Disassembly lent, and install as shown in figure 3.
1. Isolate the control valve from all pressure, and release
3. Carefully slide the diaphragm assembly (key 5) into and
pressure from the valve body and actuator. Loosen the lock-
through the O-rings and bushing cavity. Turn the diaphragm
nut (key 13), and remove all spring compression from the
assembly to line up the diaphragm holes with the bonnet
control valve by turning the adjusting screw (key 12) out of
holes.
the spring case.
4. Slide the disk holder assembly (key 4) all the way into
2. Remove the two bonnet cap screws (key 15, not shown) the stem. Connect the disk holder assembly with the hair pin
that secure the bonnet to the body, and lift the spring case, clip (key 6).
bonnet, and trim assembly from the body.
5. Coat the bonnet O-ring (key 11) with Dow Corning No.
3. Examine the seating edge of the orifice (key 3). If it is 111 lubricant (key 22) or equivalent. Install the O-ring in the
nicked or rough, unscrew it from the body with a thinwall recessed notch in the bonnet (key 9).
6. Mount the bonnet (key 9) on the valve body (key 1), in- Key Description Part Number
sert two cap screws (key 15, not shown), and tighten to 7 Part Kits
foot-pounds (9 newton-meters). Kits include keys 4, 5, 6, 8, 10, 11, and 19.
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
7. Put the spring (key 16) on the diaphragm assembly (key (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
5), and place the upper spring seat (key 17) in the end of the mm) inch orifices w/aluminum
disk holder nitrile diaphragm, and
spring. nitrile disk & O-rings R119X 000A12
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
8. Lubricate the point and threads of the adjusting screw orifices w/aluminum disk
(key 12) with Never Seez lubricant (key 21) or equivalent. holder, nitrile diaphragm and nitrile
disk & O-rings R119X 000A22
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
9. Position the spring case (key 2) and nameplate (key 20)
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
on the diaphragm assembly (key 5). Insert the cap screws mm) inch orifices w/stainless
(key 14). steel disk holder, nitrile diaphragm
and nitrile disk & O-rings R119X 00SN12
10. Tighten all cap screws until finger tight. Then, following For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
a crisscross pattern, tighten each cap screw. orifices w/stainless steel disk
holder, nitrile diaphragm and nitrile
disk & O-rings R119X 00SN22
11. Connect the control piping to the control connection in For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
the bonnet. (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/stainless
12. Adjust the spring by following the procedures in the steel disk holder and fluoroelastomer
Spring Adjustment section, and remark the nameplate if diaphragm, disk, & O-rings and
stainless steel disk holder R119X 00SV12
necessary.
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/stainless steel disk
holder and fluoroelastomer diaphragm,
disk & O-rings R119X 00SV22
NACE Construction
Parts Ordering For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm),
5/16 (7.9 mm), and 3/8 (9.5 mm) inch orifices
When contacting your Fisher sales office or sales represen- w/aluminum disk holder, fluoroelastomer
tative for technical assistance or ordering replacement diaphragm, disk and O-rings R119X N0SV32
parts, include the type number and all other pertinent in- For 1/2 (12.7 mm) and 9/16 (14.3 mm) inch
formation stamped on the nameplate attached to the spring orifices w/aluminum disk holder,
case. fluoroelastomer diaphragm,
disk and O-rings R119X N0SV42
5* Diaphragm/Stem Assembly(1) 17 Upper Spring Seat, zinc plated steel 1D6671 25072
Aluminum/nitrile 17A8080 X032 18 Type Y602-12 Vent (not shown) 27A5516 X012
Stainless steel/nitrile 17A8080 X022 19 Stem Wiper(1), TFE (2 req’d) 18A7024 X012
Stainless steel/fluoroelastomer 17A8080 X012 20 Nameplate, aluminum 1E5427 11992
Nace MR-01-75, Aluminum/fluoroelastomer 19A0348 X022
6 Hair Pin Clip(1) 21 Never-Seez Lubricant, 1 gal (3.81 L) can
All except NACE 19A0347 X012 (not furnished with valve) 1M5239 06992
NACE MR-01-75 19A0347 X022 22 Dow Corning 111 Lubricant, 10 lb (4.53 kg) can
7 Bushing Spacer, Delrin 500(2) (2 req’d) 18A7021 X012 (not furnished with valve) 1M5283 06992
23 Vent Screen, stainless steel (not shown) 0L0783 43062
24 Nace Tag 19A6034 X012
25 Tag Wire 1U7581 X0022
5
R
Type 119
V APPLY LUB/SEALANT
37A8078-C
While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or guar- the right, without notice, to alter or improve the designs or specifications of the
antee, express or implied, regarding the performance, merchantability, fitness products described herein.
TABLE OF CONTENTS
LIST OF FIGURES
1.0 GENERAL INFORMATION This aerodynamic speed control helps protect the
TURBOTWIN starter from damage caused by starter motor
This manual provides instructions for the installation and over speed.
operation of the TDI T100 TURBOTWIN Starters (Series:
B,D,F,P). If there are questions not answered in this The T100 TURBOTWINS employ a 7.5:1 or 9:1 ratio
manual, please contact your TDI TURBOTWIN distributor or planetary gearbox. This low gear ratio allows the turbine
dealer for assistance. motor to spin at low speeds for long bearing life. At a
typical 3000 rpm pinion speed, the turbine is cruising at a
The T100 TURBOTWIN models are turbine driven starters low 22500 rpm (7.5:1 ratio). Reliability and part commonality
with an inertially engaged starter drive. Depending on the are designed into all TURBOTWINS.
starter model and engine installation, the TURBOTWIN
starters have applications ranging from 1200 CID (20 Liters) A simple and reliable inertia drive delivers the torque to the
on diesel engines and up to 15000 CID (250 Liters) on gas pinion. The pinion is thrown out to engage the engine's ring
engines. The TURBOTWIN models are suited to operate gear by the turbine motor's acceleration. Lighter weight
within a wide range of inlet pressures and ambient rotating parts used in the TURBOTWIN provide low inertia
temperatures. The engine size and parasitic loading will and even "softer" engagement. In the event of over-
determine the exact minimum pressure that will assure pressure, the friction clutch used in every TURBOTWIN
reliable starting. protects ring gear teeth from static torque overloads. In
addition, an inertia engaged starter eliminates the need for
The T100 TURBOTWIN starters are designed for operation complex pre-engagement control plumbing...and is easier to
with compressed air or natural gas; materials used are install and maintain than pre-engaged type starters.
compatible with “sour” natural gas and marine environments.
Small amounts of foreign matter or liquid in the air stream Compressed air or natural gas is used to power T100
will not adversely affect TURBOTWIN starters. As with all TURBOTWIN air starters through the inlet port. The air or
other TDI starters, no lubrication is required in the air supply. gas is expanded through the first nozzle or stators. The high
velocity gas impinges on the first stage rotor to yield torque
Please review the rest of this manual before installing the to the gearbox. The gas is further expanded through the
T100 TURBOTWIN series air starter. second stage stators, which impart additional torque to the
second stage rotor.
WARNINGS, CAUTIONS AND NOTES
1.2 PRODUCT IDENTIFICATION
Certain types of information are highlighted in this manual
for your attention: The starter nameplate which is attached to the turbine
housing contains the following information: model number,
WARNING - used where injury to personnel or serial number, part number, direction of rotation and the
damage to the equipment is likely. maximum rated operating pressure.
CAUTION - used where there is the possibility of The directions of rotation are either right hand or left hand
damage to the equipment. rotation as shown in Figure 1. Right Hand rotation is defined
as clockwise rotation as viewed from the pinion end of the
NOTE - used to point out special interest starter, and Left Hand rotation is counter clockwise rotation
information. viewed from the pinion end of the starter.
WARNING
If a fuel (pulse) lubricator has previously been installed in the
system, disconnect and plug the line to eliminate spraying
diesel fuel on the engine.
WARNING
Do not operate this starter unless it is properly connected to
an engine.
WARNING
Be sure to either bleed the pressurized air reservoir and/or
Figure 1. Direction of Rotation viewed from Pinion End. safety the system such as closing all valves prior to installing
starter supply line.
1.3 PERFORMANCE
The T100 TURBOTWIN series air starters come standard
Graphs of the performance curves feature pinion torque with a 2" NPT female pipe thread for the inlet connection
versus pinion speed (rpm) at constant drive air pressures port. The supply line consists of the line from the air source,
and shaft horsepower versus pinion speed at constant drive
a pressure regulator (when necessary), a manual or relay
air pressures. Pinion speed is shown on the horizontal axis.
valve, and the connection to the starter inlet. Hard piping
The pinion torque is shown along the left edge vertical axis.
may be used, but a section of flexible tubing should be
The shaft horsepower is shown along the right edge vertical
installed at the starter to prevent leaks due to engine
axis. Air consumption rates are given for the various drive
vibration.
pressure lines. These performance curves feature air as the
drive gas and have open exhaust (standard exhaust guard)
Care must be taken to ensure that all inlet supply line piping
which have no back pressure.
is no less than 1.5" and all components used are capable of
passing the required air flow.
2.0 ORIENTATION OF THE STARTER
NOTE
2.1 GENERAL Valves with a Cv of 40 or higher are recommended.
If the factory orientation of the starter’s pinion housing
If the supply line must be longer than 20 feet, the inlet supply
assembly in relation to the inlet port does not fit your engine
line piping should be increased to 2" in diameter to ensure
installation, these components can easily be re-oriented.
proper performance by your TURBOTWIN.
All TURBOTWINS have the capability to rotate the inlet port
Because turbine starters such as the T100 TURBOTWIN
relative to the drive opening for the optimum inlet port
series are sensitive to flow restrictions, care must be taken
location. The number of different positions is 6 to 12
to use uniform hose or tubing and fittings for connection of
depending on model.
the supply line. Tees, elbows and line length must be kept
to a minimum. TDI recommends that hose or flex couplings
3.0 INSTALLING THE STARTER are installed to eliminate possible leakage caused by strain
on the supply line.
A turbine air starter does not require lubrication in the supply
air. Therefore, if a vane type starter motor is being replaced, Normally, an air strainer is not required. However, in dirty
TDI recommends that all lubrication devices and lines environments use of a #40 mesh Y-strainer is
removed to minimize flow restrictions. recommended. The T100 TURBOTWIN series is highly
tolerant of dirt in the air line, however, starter life can be
increased with the use of an air strainer.
A pressure regulator is required when the air supply installed at the pressure check port and electrical lines
pressure is great enough to exceed the starter operating routed to a digital display at the operator's station.
pressure (at the inlet port) and/or the maximum torque.
This pressure port is invaluable in diagnosing air starter
A manual ball valve may be used to admit drive air/gas to and/or installation problems.
the starter. The manual valve should be located in a safe
position away from the engine. 3.3 EXHAUST PIPING
A preferred valve is pilot-operated, which can be The turbine exhaust may be plumbed away from the starter
pneumatically or electrically actuated. The valve should be area. All starters using natural gas must be piped according
located close to or even on the starter inlet for best to industry codes and local regulations.
performance. Pneumatic or electrical control lines may be
routed virtually anywhere for the customer's preferred The performance of a turbine starter will be decreased
operating station. This type of valve actuates from a fully because of back pressure when smaller than recommended
closed to a fully open position very rapidly. TDI offers a exhaust piping is installed. If back pressure hampers starter
variety of relay valves such as P/N RLVA-25683-001-2-01, performance, compensation can be made by increasing the
which is a 1-1/2" port, pneumatically actuated valve. supply pressure. Consult your TDI distributor for advice.
The supply line should be dry-fitted for proper alignment Exhaust piping should be routed downward to help prevent
/location prior to final assembly. All pipe threaded joints any accumulation of condensation in the starter motor.
should be sealed with Loctite Pipe Thread Sealant (TDI P/N
9-94085) or equivalent for leak tight joints prior to final If the overhung section of the starter is not otherwise
assembly. Be sure to tighten all joints to proper torque after supported, TDI recommends supporting the exhaust piping
final assembly. with a suitable bracket(s).
Pipe unions must be type approved by GL. Downstream of mounting bolts. Torque the three 5/8" screws to 100 lb-ft.
the pressure regulator a pressure relief valve is to be
provided. 4.0 STARTER OPERATION
3.6 BACKLASH Prior to operation, check that all connections are tight and
free from leaks. Check the 1/4" NPT pipe plug or a pressure
Backlash is the "free play" between the mesh of two gears. gauge/transducer that may be connected to the pressure
Figure 15 shows the backlash between two gears. port on the starter inlet.
Maintaining the proper gear backlash setting allows the
gears to mesh smoothly. Proper backlash and alignment WARNING
allows smooth engagement/disengagement of the pinion Do not operate the TDI TURBOTWIN starter with air pressure
gear and loads the tooth face surfaces evenly producing greater than the pressure rating on the nameplate. This
longer gear life. The correct backlash setting for 6/8 pressure is measured at the starter inlet while the starter is
diametral pitch gearing used on larger engines is as follows: running.
Minimum backlash .015 inch
The maximum operating pressure limit is the inlet pressure
Maximum backlash .025 inch
measured at the starter’s inlet pressure check port. In order
to check the starter, a 1/4"NPT pipe tap connection is
To check the backlash, the pinion will need to be rolled out
provided in the inlet housing to attach a pressure
onto the end of the drive prior to starter installation. This can
gauge/transducer). The maximum pressure assumes an
be accomplished by using a hex drive wrench to rotate the
open exhaust (standard turbine exhaust guard). The
turbine end of the starter while holding the pinion from
standard exhaust guard causes no back pressure.
rotating. The pinion will simply walk to the end of the shaft.
An access hole to reach the turbine screw is provided in the
The static non-flowing supply pressure will always be higher
turbine exhaust guard. The starter must then be installed on
than the operating (dynamic) pressure. The maximum
the engine. Checking backlash can be accomplished using
pressure limit (proof pressure) that the TDI TURBOTWIN
a dial indicator or a simple blade-type feeler gauge. Because
starter housings may be subjected to is 600 PSIG (42 BAR).
ring gears are not usually perfectly round, it is necessary to
System pressure that exceeds the maximum operating limit
must use a pressure reducing device to ensure that the
operating pressure limit to the TDI TURBOTWIN starter is
maintained.
System static pressure that exceeds the 600 PSIG (42 BAR)
limit must, in addition to pressure reducer devices
incorporate a pressure relief valve set below 600 PSIG (42
BAR) in the supply air line.
NOTE
For maximum life of the starter pinion and for the protection
of the engine ring gear, limit the operating pressure to that
necessary to start the engine at its most difficult starting
Figure 2. Checking Backlash conditions.
check backlash at several (six or more) points around the All appropriate local pressure codes and pressure limitations
circumference of the ring gear. Average the highs and lows on other system components must be adhered to and
to allow a setting that is in the range cited above. supersede the guidelines given in this manual.
Setting the correct backlash may involve "shimming" and/or Consult your TDI distributor if you have exhaust plumbing
moving the starter bracket(s). An adjustable starter bracket that creates back pressure and reduces starter
design will simplify this procedure. Always re-check the performance. You may be able to increase the supply
backlash after a ring gear replacement. pressure to restore the lost power.
Follow the engine manufacturer’s instructions for starting the
Liberally grease the starter’s drive teeth with chassis lube engine.
and then mount the TURBOTWIN starter on the engine.
Tighten all mounting hardware as appropriate. Make sure to
use Loctite Threadlocker #290 or equivalent on the starter 4.1 BASIC OPERATION
Publication T1-702, Rev 1
Issued January 22, 2001 5
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
speed.
The basic operation of the starter is as follows:
The automated start panel should monitor engine speed to
Pressurized air or natural is admitted to the starter by determine air on and air off. Do not simply use time as a
opening of the manual or relay valve. The air expands control parameter. Avoiding excessive operation of the
through the turbine, which produces shaft rotation and starter after the engine is firing will maximize the starter life.
torque. The acceleration of the drive assembly causes the
pinion to advance and engage the ring gear of the engine. 5.0 PREVENTIVE MAINTENANCE
The starter motor torque causes the engine to accelerate. The TDI TURBOTWIN starters provide distinct advantages
This acceleration causes the pinion to be disengaged from of size and efficiency as compared to electric motor, vane-
the ring gear. The fuel and ignition systems now fire the type or other turbine-type starters. It is important to properly
engine. Closing the relay valve stops the starter. install the starter to receive full benefit of these advantages.
Repair technicians or service organizations without turbine
The operator may decrease starter life by the continual starter experience should not attempt to repair this machine
operation of the starter after the engine has started. Upon a until they receive factory approved training from TDI, or its
successful engine start, turn the air off to the starter representatives.
immediately. Minimizing the time the starter is operating
unloaded (i.e. the engine is running) will maximize starter Proper operation and repair of your TDI TURBOTWIN
life. If a start is aborted, a restart may be attempted after the starter will assure continued reliable and superior
engine and the starter has come to rest. performance for many years.
4.2 AUTOMATED START PANEL 5.1.3 Place a small amount of chassis lube on the starter’s
pinion teeth.
The starter drive pressure measured at the starter inlet must
be set. As noted above, for maximum life of the starter 5.2 Every Three (3) Months
pinion and for the protection of the engine ring gear, limit the
operating pressure to that necessary to start the engine at its Follow the six (6) month procedures if there is severe starter
most difficult starting conditions. loading or extended duration crank cycles. Also perform
these procedures every three (3) months when starter is
The speed control parameter will then need to be set. used for motoring the engine for maintenance or valve
Engine starting speed along with the cranking ratio number adjustments.
can be used to determine starter pinion speed. The pinion
speed is usually 2000-3500 rpm for a typical engine starting Motoring Crank Cycle: 10 -60 seconds
speed. Once the start sequence has begun, the air is
admitted to the starter. The starter begins to accelerate the Extended Crank Cycle: 60 seconds or longer
engine. Once the firing speed of the engine is reached, the
automated start panel may deliver fuel to the engine. The starter, use only genuine TDI replacement parts. The
engine will begin to accelerate under its own power. The component part numbers are found in the Illustrated Parts
starter should be dropped out of the sequence at a rpm Breakdown.
higher than the firing speed, but less than the engine idle
Page 6 Publication T1-702, Rev 1
Issued January 22, 2001
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
2. Starter does not A. Broken turbine rotor. A. Replace all damaged parts.
run; normal air flow
from exhaust. B. Broken gear train. B. Repair or replace geartrain.
C. Damaged starter drive. C. Repair or replace starter drive.
3. Reduced Starter A. Inlet air pressure too low. A. Increase air pressure in 10 PSIG (0.6 BAR)
output power. increments; DO NOT EXCEED OPERATING LIMIT.
B. Inlet supply piping too small. B. Supply piping must be a minimum of 1.5" diameter.
C. Pressure regulator orifice too C. Increase orifice size or replace pressure regulator
small.
D. Inlet supply line valve (ball, D. Install larger valve.
gate, relay, plug) too small.
E. In line lubricator installed in E. Remove lubricator.
supply line.
F. Y-Strainer in supply line F. Clean strainer.
clogged.
G. Excessive back pressure; G. Clean exhaust piping or increase size to at least the
exhaust restricted. minimum diameter recommended.
H. Damaged turbine nozzle. H. Replace turbine nozzle.
I. Broken started drive. I. Repair or replace starter drive.
J. Wrong rotation starter. J. Replace with starter or proper rotation.
K. Wrong size starter. K. Check the Application Guide for the correct starter.
4. Engine cranks too A. Inlet air pressure too high. A. Decrease air pressure in 10 PSIG (0.6 BAR)
quickly. increments.
OR
If there is a manual shut-off valve in the supply line,
partially close it.
OR
Install a restriction orifice in the inlet supply line.
B. Wrong size starter. B. Check the Application Guide for the correct starter.
7.0 WARRANTY
Tech Development Inc. shall, at its option, either repair or replace, without charge, any such starter product found by TDI’s
examination to be defective, or by mutual agreement, refund the user’s purchase price in exchange for such starter product.
Repairs or replacements are warranted for the remainder of the original warranty period.
Tech Development Inc. makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY WARRANTY OR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
This warranty constitutes the entire obligation of Tech Development Inc. relating to the sale and use of such product, and
TDI’s maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TDI be
liable for incidental, indirect, consequential or special damages of any nature arising from the sale or use of such engine
starter product.
90 psig 60 44.8
272 200
204 150
60 psig 40 29.8
136 100
20 14.9
68 50
0 0 0
0 5 10 15 20 25 30 35 40 45 50 55
340 250
60
ps
ig
60 44.8
272 200
204 150
40 29.8
30
psi
g
136 100
20 14.9
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TORQUE
T106-F Performance Curve POWER
Nm LB. FT 6 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175 50 37.2
150 psig Inlet Pressure SCFM Nm3/h
150 psig 680 1156
204 150 Maximum Torque 120 psig 550 935
Transmitted by Drive 90 psig 430 731 40 29.8
12
0p 60 psig 310 527
sig
170 125
90 30 22.4
136 100 ps ig
102 75
60 20 14.9
p sig
68 50
10 7.5
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TORQUE
T112-F Performance Curve POWER
Nm LB.FT 12 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175
90 psig
Maximum Torque Inlet Pressure SCFM Nm3/h
Transmitted by Drive 90 psig 860 1462
204 150 60 psig 610 1037 45 33.5
30 psig 370 629
60
ps
170 125 ig
102 75 30
ps i
g
68 50 15 11.2
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
POWER
TORQUE
Nm LB.FT
T109-P Performance Curve HP KW
9 Nozzles, Compressed Air, 9.0:1 RATIO
476 350 80 59.6
Inlet Pressure SCFM Nm3/h
408 300 150 psig 1050 1785
15 120 psig 850 1445
0 DRIVE TORQUE LIMIT 90 psig 670 1139
ps 60 psig 460 782 60 44.8
340 250
12 ig
0p
sig
272 200
90
psi 40 29.8
g
204 150
136 100
20 14.9
60 p
s ig
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
SERVICE MANUAL
LIST OF ILLUSTRATIONS
WARNING NOTE
Failure to properly install the starter or failure to operate You should always have the starter’s Part Number,
it according to instructions provided byTDI may result in Serial Number, Operating Pressure, and Direction of
damage to the starter or engine, or cause personal Rotation information before calling your TDI distributor
injury. DO NOT OPERATE THIS STARTER UNLESS or dealer.
IT IS PROPERLY ATTACHED TO AN ENGINE.
2.4 BENDIX DRIVE ASSEMBLY The other end of the drive unit is mounted into a needle
bearing (54), which is installed in the nose of the drive
The Bendix drive assembly, refer to figure 8, consists of housing.
an inertial engagement drive or “bendix” (57) and drive
housing (61). The bendix is mounted to the output
shaft with two keys and a retaining set screw (53).
Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)
Do not disassemble the starter any further than Remove the six screws (22). Mark position of bendix
necessary to replace a worn or damaged part pinion opening relative to gearbox housing for reference
during reassembly. Pull drive housing (49) from
Always have a complete set of seals and o-rings on gearbox housing (44). If drive housing is too tight, tap it
hand before starting any overall of a Turbotwin T100 with a mallet to loosen.
series starter. Never use old seals or o-rings.
3.3.2 Removal of Bendix Drive
The tools listed in Table 1 are suggested for use by
technicians servicing the Turbotwin T100 series In loaded spring area of drive (57) remove retaining ring
starters. The best results can be expected when these (51) from set screw (53) slot.
tools are used, however the use of other tools are
acceptable. Remove set screw using a flat head screwdriver, Figure
9, and pull the bendix assembly from the starter carrier
TOOL DESCRIPTION TDI/PN shaft.
Spanner wrench 52-20134
Spanner wrench 52-21345 Remove spring (52). This spring fits loosely between
Shaft Removal Tool 2-26945 the bendix assembly and carrier shaft. Remove the
Stage 2 Rotor Puller Tool 52-20076 needle bearing (62), if necessary, by simply tapping out
Carrier Shaft Holding Tool 52-20202 the “welch” plug from the front of the drive housing and
Tool, Bearing Pressing 52-20143 press bearing out.
Tool, Bearing/Seal 2-26943
Table 1. T100 Series Service Tools
3.4 DRIVE/GEARBOX HOUSING Remove bearing (65) from shaft by pressing shaft
while supporting inner race of bearing. Remove
(T106F/T112F)
bearing retainer plate (64).
3.4.1 Removal of Drive Housing
3.4.3 Planet Gear Disassembly
Mark position of bendix pinion opening relative to
Remove snap ring (34) from planet shaft (39) using
turbine housing (26) for reference during reassembly.
snap ring pliers and push shaft through holes in
Per Figure 10, remove the six screws (27). Pull drive
assembly.
housing (69) from turbine housing. If drive housing is
too tight, tap it with a mallet to loosen.
Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.
Mount the carrier shaft assembly on the TDI holding Remove the six screws (27) and lift the gearbox
tool P/N 52-20202 placing the three holes on the assembly from the turbine assembly. If the gearbox
gearbox over the dow pins. Refer to Figure11. assembly is too tight, tap it with a mallet to loosen).
Place TDI tool P/N 52-21345 (Spanner Wrench) over 3.5.2 Gearbox Disassembly
shaft and into slots of retainer nut (67). Hold down
carrier shaft and remove nut. Mount the gearbox on the TDI holding tool P/N 52-
20202 placing the three holes on the gearbox over the
dow pins. Refer to Figure 11.
Remove woodruff keys (40) from shaft by tapping them Slide the planet gear (37) out from the carrier shaft and
with a chisel and hammer remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
With screwdriver remove tang of lockwasher (47) from removal is necessary, simply press bearing out.
slot of retainer nut (48).
3.6 TURBINE HOUSING
Place TDI tool P/N 52-20134 (Spanner Wrench) over
shaft and into slots of retainer nut. Hold gearbox down
3.6.1 Stage 2 Rotor Removal
and remove nut.
Remove the six screws (27) that connect the gearbox
In most cases the gearbox housing (58, D-44) can be
assembly to the turbine housing and separate the two
removed from the carrier shaft (35) by holding shaft
assemblies. Remove the four screws (18) and the
down and pulling directly up on housing. If this is not
clamping plate (32).
the case, press carrier shaft from housing per Figure
12.
Turn the turbine to the (exhaust) end up and remove
the six screws (1), screen support ring (2), and the
screen (3). For the T109P, remove six screws (74) and
Exhaust Cover Housing (75).
Hold the stage 2 rotor (6) and remove the turbine screw
(4) and washer (5).
Remove snap ring (34) from planet shaft (39) and push Figure 13. Turbine Rotor Removal
shaft through holes in assembly.
Page 10 Publication T1-
701
Issued Dec 11, 1998
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, INC.
3.6 Turbine Shaft Removal Separate the stage 2 nozzle assembly (13) from the
turbine assembly (26) by firmly holding the turbine
Using the shaft removal tool P/N 2-26945 per figure 14, assembly, while tapping nozzle 2 with a mallet. If
press on the turbine shaft (33) while supporting the nozzle 2 is too tight, it can be removed by installing two
turbine housing. threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly. Refer
Press the shaft assembly (33) through the aft bearing to Figure 15.
(10) and continue pressing until the shaft assembly is
completely out of the housing (26). Rotate the stage 1 rotor if necessary to allow the jacks
to travel through the large holes in the rotor. The jacks
Remove the woodruff key (16), seal spacer (8), bearing will damage the stage 1 rotor if pressure is applied to
spacer (30), and bearing (10) from the shaft. The them while removing nozzle 2.
bearing can be removed from the shaft by pressing the
shaft through the bearing. Note that if T100 is the The stage 1 rotor (15) may now be removed.
original design (SN: 9501-239 to9611-191), the bearing
will be pressed inside a spacer. Remove the four screws (18) and nozzle 1 (19) from
the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
SECTION 4.0 CLEANING and Clean aluminum parts using the solutions per Table 2;
soak for 5 minutes. Remove parts, rinse in hot water,
INSPECTION
and dry thoroughly.
4.2 INSPECTION
Check all bearing bores for wear and scoring. Bearing
Use Table 3 as a guide to check for acceptable bores shall be free of scoring lines, not to exceed
condition of the parts listed. 0.005² width and 0.005² depth.
Check all threaded parts for galled, crossed stripped, or Check gear teeth and turbine housing ring gear for
broken threads. wear. In general, visually check for spalling, fretting,
surface flaking, chipping, splitting, and corrosion. If
Check all parts for cracks, corrosion, distortion, scoring, wear is apparent, check the gear teeth dimensions in
or general damage. accordance with Table 4. Nicks and dents that cannot
be felt with a .020 inch radius scribe are acceptable.
5.1 GENERAL
The tools listed in Table 1 are suggested for use by
technicians servicing the T100 Series starters. The
best results can be expected when the proper tools are
used, however, use of other tools is acceptable.
CAUTION
Replace all screws , O-rings, lip seals, and bearings
when the T100 Series starter is reassembled. These
parts are included in the overhaul kits shown in
Section 6.0
NOTE
Always press the inner race of a ball bearing when
installing a bearing on a shaft. Always press the outer Figure 17. Pressing Front Turbine Bearing
race of a ball bearing when installing into a housing.
MATERIALS SOURCE
Petroleum Jelly Commercially Available
Parker-O-Ring Lube Commercially Available
Loctite RC290 Commercially Available
Grease, gearbox TDI P/N 9-94121-001
Table 5. Materials for Assembly
CAUTION
The screws that secure the Containment Ring/ Stage 2
Nozzle must have a drop of Loctite RC290 applied to
the threads before being used.
Figure 18. Pressing Spacer onto Bearing
5.2 TURBINE HOUSING T100 is the original design (SN: 9501-239 to 9611-191),
press the spacer (31) onto the outer race of the bearing
5.2.1 Turbine Shaft Installation (10) per Figure 18 by supporting the bearing outer race,
and then press the bearing/spacer (10, 31) onto the
Press the bearing (10) onto the shaft (33) until seated. shaft.
Support the shaft and press on the inner race only with
press tool P/N 2-26943 per Figure 17. Note that if Press the bearing/shaft assembly, keyway end first, into
bearing housing of the turbine housing. Use press tool
P/N 2-26943 if required per Figure 19. Do not press on
the end of the shaft because the load could damage the
balls of the bearing.
Publication T1-701 Page 15
Issued Dec 11, 1998
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT INC.
Install bearing retainer plate (32) and secure with four Install nozzle 1 onto the turbine housing (26). Orient
screws (18). Torque screws to 30 in-lbs. the nozzles facing the air inlet (23). Install four screws
(18) to secure the nozzle. Do not tighten the screws at
this time.
5.2.3 Rotor 1 Installation
Install the woodruff key (large key) (16) for stage 1 rotor
into the shaft (33).
5.2.2 Nozzle 1 Installation Install O-ring (14) onto the outer diameter of nozzle 2.
Install the seal spacer (8) onto the shaft with the small
end facing the aft bearing (10).
Install the wavy spring washer (12) into the bearing bore
of the stage 2 nozzle.
Support the sun gear end of the shaft. Press the aft
bearing (10) onto the shaft by pressing onto the inner
and outer race simultaneously. Use press tool per
Figure 21. Press until bearing is seated.
Place the O-ring (24) into the groove on the air inlet
(23).
Install the 2² NPT air inlet flange (23) and secure with
six screws (22). Tighten the six screws to 170 in-lb.
Press the lip seal (9) into the stage 2 nozzle using press
tool P/N 2-26943 with lip seal facing up.
Install the stage 2 woodruff key (7) into the shaft (33).
Install the stage 2 rotor (6) onto the shaft. Use press
tool P/N 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that the
direction of rotation was oriented properly. This turbine
can be installed backwards.
Install the rotor washer (5) and secure with screws (4).
Tighten screw to 100 in-lb.
Figure 22. Planet Gear Carrier Shaft Assembly
Install the exhaust screen (3) and back plate (2).
Secure with six screws (1). Tighten the screws to 80 in-
lb.
NOTE
Make sure that anti-rotation pins on shafts are properly
located in retaining slots of carrier shaft (35).
Press rear bearing (41) onto carrier shaft (35) using TDI
Tool P/N 52-20143 per Figure 23. Pressing force
should be on the inner race of bearing.
NOTE
Make sure anti-rotation pins on shafts are properly
located in the retaining slots of the carrier shafts (63).
Figure 25. Tightening Retainer Nut
5.5.2 Planetary Carrier Bearing Installation
5.4 DRIVE HOUSING
(T112B/T121B, T112D/T121D, T109P/T115P) Install bearing retainer plate (64) over carrier shaft (63)
5.4.1 Bendix Drive Installation Press bearing (65) onto shaft making sure pressing
force is on inner race of bearing only.
Install two woodruff keys (40). Ensure keys are
properly installed per Figure 26. Place carrier shaft assembly onto TDI Tool P/N 52-
20202, see Figure 27. Thread retainer nut (67) onto
Position bendix assembly (57) on shaft with retainer set shaft (63). Hold carrier assembly down and torque nut
screw (53) removed. Install spring ( 52) between to 600-800 lb.-in. with spanner wrench, TDI Tool P/N
bendix cavity and end of output shaft. Slide bendix over 52-21345.
shaft until set screw hole aligns with set screw hole in
shaft.
3 Screen 2-26148
5 Washer 9-93047
6 Rotor 2 2-26604
14 O-ring 9-90001-050 ü ü ü ü
15 Rotor 1 2-26603
21 O-ring 9-90001-034 ü ü ü ü
24 O-ring 9-90001-037 ü ü ü ü
47 Lockwasher 9-93061-007
56 Screw 14F-31218-020 ü
65 Bearing 9-91356 ü
77 Post 2-27223
Model Overhaul Kit for S/N’s before: 9611-191 Overhaul Kit for S/N’s after: 9611-192
B T10B-27618 T10B-27634
D T10D-27619 T10D-27635
F T10F-27617 T10F-27633
P T10P-27620 T10P-27636
To engine coolant
inlet piping
From compressor
coolant outlet piping
! "#
" # !$
Item Description / Size P/N Qty Item Description / Size P/N Qty
1 2" Hose Barbed Connector x 2 NPT(M) 2520 3025 2 37 Pipe 1" x (0.1"33 Wl) Sch 40 4053 0102 19"
2 Angle, 2" x 2 x ¼ 7004 2020 24" 38 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 132"
3 Angle, 2" x 2" x ¼" x 24" Lg. 7004 2020 2 39 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 6"
4 Angle, 2" x 2" x ¼" x 4" Lg. 7004 2020 2 40 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 6"
5 Ball Valve ¾"-600# NPT 2549 2065 1 41 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 28"
6 Ball Valve 1"-600# NPT 2549 2085 2 42 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 26"
7 Bush 1½" x 1"-3000# NPT 2527 1410 1 43 Pipe 2" x (0.154 Wl) Sch 40 4053 0202 3"
8 Bush 2½" 2" x 2" 3000# NPT 2527 2420 1 44 Pipe 2" x (0.154 Wl) Sch 40 (Cut To Suit) 4053 0202 23"
9 Bush 2" x ¾" 3000# NPT 2527 2006 3 45 Pipe 2" x (0.154 Wl) Sch 40 (Cut To Suit) 4053 0202 104"
10 Bush 2" x 1" 3000# NPT 2527 2010 3 46 Pipe 2" x (0.154 Wl) Sch 40 (Cut To Suit) 4053 0202 27"
11 Bush 3" x 2" 3000# NPT 2527 3020 1 47 Pipe 2" x (0.154 Wl) Sch 40 (Cut To Suit) 4053 0202 27"
12 Butterfly Valve 2"-150# Lug Body 2549 2290 3 48 Plug Square Head ¾"-3000# NPT 2541 4006 2
13 2" Hose Swivel Connector 2521 3032 2 49 Street Elbow 1" Std 90 Deg NPT 2535 7010 1
14 Couplet ¾"-3000# NPT 2562 3060 1 50 Tee 2"-Std# NPT 2545 2020 5
15 Coupling 2"-3000# NPT 2531 6020 1 51 Thermostatic Valve 2"-150# 2549 9243 1
16 Elbow ¾" -Std# 90 Deg NPT 2535 2006 1 52 Tubing 1" x 0.049 Wall 5551 4916 1
17 Elbow 1"-Std# 90 Deg NPT 2535 2010 1 53 U-Bolt 2" 1590 0103 6
18 Elbow 2"-Std# 90 Deg NPT 2535 2020 5 54 U-Bolt 4" 1590 0400 2
19 Flange 2"-150# Slip-On Rf 2576 1520 4 55 Union 2"-150# NPT 2547 1020 4
20 Flat Bar, ½" x 2" x 22" Lg. 7040 0420 1 56 Unistrut, 2-7/16" x 1 " 7020 2558 1
21 Flat Bar, ½" x 2" x 30" Lg. 7040 0420 1 57 Unistrut, 2-7/16" x 1 " 7020 2558 1
22 Flat Bar, ¼" x 2" x 5" Lg. 7040 0220 2
23 Heavy Hex Bolt, " x 1½" Lg. 6829 0170 24
24 2" Hose Straight Adapter 2520 4200 2
25 2" Hose Straight Adapter 2533 4200 1
26 2" Hose Clamp 2520 9109 8
27 2" Hose, Rubber 402H 3521 4032 26"
28 2" Hose, Rubber 402H 3521 4032 31"
29 Male Connector 1" Tube x 1" NPT 2507 1808 2
30 Nipple Close Pipe 2" NPT Sch 80 2539 4909 1
31 Nipple Pipe ¾" NPT x 2" Lg Sch 80 2539 4508 2
32 Nipple Pipe 1" NPT x 2½" Lg Sch 80 2539 4610 1
33 Nipple Pipe 1" NPT x 2" Lg Sch 80 2539 4609 1
34 Nipple Pipe 2" NPT x 2" Lg Sch 80 2539 4908 3
35 Nipple Pipe 2" NPT x 3" Lg Sch 80 2539 4912 4
36 Nipple Pipe 2" NPT x 4" Lg Sch 80 2539 4917 2
Package Coolant Piping
TP 02-04-T01A-001
Note
The pump’s bearings must be lubricated.
Inject grease once per month as follows:
3.0 ounces in the inboard bearing
4.7 ounces in the outboard bearing
DEMCO®
Resilient Seated
Butterfly
Valve
Table of Contents
Bill of Materials
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer
22. 1 Top O-Ring
23. * Stem O-Ring
24. 2 Bearing
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer**
23. * Stem O-Ring
24. 2 Upper bearing
25. 1 Lower bearing
Scope
Demco resilient seated butterfly valves are an pressure and are capable of throttling service.
economical alternative to ball, gate or plug valves They are easily adapted to automatic actuators.
in many applications. They are light weight The Demco butterfly valve is available in flangeless
quarter turn devices with few parts. They are wafer design or single flange tapped lug configu-
designed for bubble tight sealing up to rated ration.
Nameplate Information
4 3 2 1
ITEM STAMP
1 Product ID Number
2 Product Description
3 Body Material
4 Disc Material
5 Seat Material
6 Stem Material
Storage
Demco butterfly valves are shipped in the partial
open position to minimize permanent deforma-
tion of the resilient seat. The disc edge is
contained within the flange faces of the valve to
prevent damage to the sealing area (Figure 4).
Installation
Direction -
Demco butterfly valves are bi-directional and will
operate in any position. Normally the valve is
installed with the upper stem pointing upward
(Figure 5). Elevated valves with gear operators and
chainwheels should be installed with the upper
stem pointing down (Figure 6) so the open-closed
indicator is visible from the ground and the chain
does not drag on the pipe.
End-of-Line Service -
Demco tapped lug butterfly valves are suitable for
liquid service end-of-line applications with down-
Figure 5
stream piping removed (Figure 7). Only weld neck
or socket weld flanges can be used for this service.
Since the upstream pressure is excluded between
the flange and the seat face by the exclusive
Demco flange seal, there is no effective force to
slide the seat downstream.
Gaskets
Flange gaskets are not required nor recommended
for use with positive shut-off Demco butterfly
valves. An integral flange seal is molded into the
edge of the rubber seat eliminating the need for
flange gaskets.
Flanges -
Steel Class 150 ANSI (or MSS SP-44) weld neck, slip-
on, threaded and socket weld as well as stub end
type C flanges are suitable for use with 2 thru 24
Demco butterfly valves. 30 and 36 Demco
butterfly valves fit between ANSI 125 flanges (or
MSS SP-44).
Other flange types may be applicable also, but
should be thoroughly checked to assure proper seal
makeup. Plastic flanges are subject to damage at
installation by over-tightening the bolting and
may deflect or cup resulting in flange leaks.
Figure 7
WAFER BODY
Flange Bolts -
Recommended bolt and stud lengths for installa-
STUDS & HEX NUTS
Figure 10
Troubleshooting
Trouble Probable Cause Remedy
Operator stops are not set properly. Adjust stops to proper setting.
The valve will not open. Disc hits on side of pipe. Check for proper pipe clearance.
The valve is leaking Disc is bent. Replace disc, stems and seat as required.*
around stem.
Correct flange seal leak to prevent fluid
Flange seal is leaking. from migrating behind seat and out stem.
Handle or actuator does not provide Restrain disc with handle or actuator.
The valve closes with line proper restraint.
flow.
Line flow too great. Choose larger valve or slow down flow.
Clockwise rotation of
Gear operator has been rotated 90o on
Gear Operator handwheel
valve top. Rotate gear operator 90o on valve top to put input
opens valve. Open-Shut
Hand-wheel shaft aligns with pipe shaft perpendicular with pipe axis.
indicators do not coincide
(should be perpendicular).
wth valve disc position.
Automatic actuator slams Speed control valves missing or not Install and/or adjust speed control valves.
valve shut or open. adjusted.
NOTES
Manufacturing
http://www.ccvalve.com
Notes:
Coil Volumes: EJW=20 gal. IC=11 gal. AC=13 gal.
Estimated Plot size Length, ft.: 10.5 Width, ft.: 7.4 Height, ft.: 7.7 Weight: 5200#
Cooler Service Company, Inc Spare Parts Quotation
Total $0
2/26/2007
Cooler Service
Company Inc.
OPERATION AND MAINTENANCE MANUAL
www.coolerservice.com
AIR COOLED HEAT EXCHANGERS
GENERAL INFORMATION
The CSCI Air Cooled Heat Exchanger should be inspected thoroughly by receiving
personnel. Damage in transit will be the result of dropping or being struck by heavy objects.
Observe sub-skid flanges, plenum side panels and coil sections for obvious physical damage.
Dents, bent flanges, crushed tubes, damaged instruments or piping among other things should be
described on receiving documents presented by the carrier. Prompt claim filing will expedite
early compensation from the offending carrier.
The unit should be placed on its foundation as soon as practical after being received.
Basically this unit is a completely shop assembled cooling unit. Occasionally special accessory
devices will be required which must be shipped disassembled to meet height or width limitations
of the carrier.
In the event some assembly of this type is required, the appropriate assembly instructions will
accompany the shipment. Detail parts to be installed will normally be secured in place on the
skid base (if the unit is so designed) or in the plenum chamber. Examine the interior of the
plenum for any storage.
Coil piping should be installed in accordance with engineering instructions supplied in connection
therewith. Attention is invited to the approved cooler drawings, which identify the "INLET" and
"OUTLET" nozzles.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
1
START UP PROCEDURE
Prior to Run-In:
It is imperative that the units be checked for good working order prior to run-in. The following
general check list is provided to insure that all equipment has been properly installed and is
ready to go on stream.
1. HYDROSTATIC TEST
CSCI tube bundles are hydrostatically tested to one and a half times the design pressure
before being released for shipment. To ensure that no damage has been done during
shipment and/or erection, it is good practice to hydrostatically test the entire system,
including piping, heat exchangers, pumps, etc., prior to start-up.
2. BEARINGS
Check bearings for lubrication. Caution: Do not over grease. Manufacturer greased the
bearings and no additional grease is necessary to start. Remote lubrication lines when
provided should be loosened at the bearing end, and then filled with grease from fitting end.
This will ensure that the lube lines are full of grease and free of air and debris.
3. FANS
The fan should be rotated by hand to ensure that the shaft, speed reducer and driver turn
freely.
The fan should also be checked for adequate fan blade tip clearance. To measure this, first
move all blades past a fixed point on the inside of the fan ring and observe which blade has
the least amount of clearance at that point. Then move the blade selected 360 degrees to
the point of minimum clearance. Refer to section on fans.
Switch on the fan driver momentarily to check for proper direction of rotation and fan
blade orientation. The leading edge of the fan blade is the thick edge. When properly
pitched, this leading edge will be the lower edge.
If the starting torque trips the vibration switch turn the adjusting screw located on the right
hand side of the vibration switch to the right (clockwise) for a heavier setting. Please see
the section on vibration switches.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
2
4. V-BELT DRIVES (when applicable)
Check V-Belt tension in accordance with V-Belt tensioning section of this manual.
5. GEAR BOX
Check gearbox for oil. Gears are shipped without oil and must be filled and serviced in
accordance with the instructions contained later in this operating manual.
6. LOUVERS
Check all mounting brackets and bolts for tightness. On manually operated units, manual
operator should be moved from full open to full closed several times to ensure proper
linkage adjustment and that louvers will operate freely. On air motor operated (automatic)
units, all air supply line fittings should be checked for tightness and air motor should be
energized to ensure proper linkage adjustment and that louvers operate freely with
sufficient air supply.
Bolt-up structures are to be erected per erection drawing furnished. All pieces should be
installed per position shown on drawing and part number marked on piece.
Bolt-up structures are to be erected with bolts loose then plumbed, and finally all bolts
thoroughly tightened.
Some structures are primed with structural steel primers, but most units are galvanized.
When repainted, outdoor paints or enamels should be used along with good preparation
and painting practices.
Bolts attaching return header(s) to sideframe(s) must be removed prior to this unit being
put in service, to allow for the thermal expansion of the bundle(s).
Failure to remove these bolts may result in serious damage to the bundle.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
3
PERFORMANCE
Prior to or following the initial "start-up" and the final determination that the mechanical
equipment is performing as designed, the product to be cooled may be valved into the
cooling coils. The temperature-indicating equipment should be observed closely to detect
the anticipated temperature drop, which should occur at a time interval dependent on
proper response of temperature control equipment, louver settings (if any), piping distances,
previous temperature and heat rejection rates.
In the event it appears that the product is not being cooled as designed, the following
inspections should be made. Any one or a combination of the following could impact the
equipment performance:
2. By-pass equipment, if any, should be checked for proper flow control for the existing
conditions.
4. Carefully analyze the temperature control system to ensure that temperature sensing
elements are properly installed and calibrated, and that the electrical circuits are sound and
energized. Where temperature sensing equipment is designed to cause a reactive response
in the product flow, motor speeds, fan pitch or louver settings, such reaction should be
examined to determine that the reaction is correct as to proportion, direction or amount.
The operational instructions provided by the control equipment supplier should provide
troubleshooting procedures, which will expose a malfunction, if one exists.
5. Louvers should be checked for full open position of proportional setting if required by the
temperature control equipment.
6. Fan speed should be checked and compared to design speeds shown on data sheet.
7. Fan blade pitch settings should be inspected and confirmed on data sheets.
9. The coils should be inspected for obstructions such as protective panels which have not
been removed, weeds, lint, and matted insects. If such an obstruction does exist, the drive
equipment should be shut down and the obstruction removed.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
4
10. To isolate the cause if the equipment fails to cool, a simple test may be made by disabling
the temperature control equipment and manually positioning the louvers and motor speed
setting to design maximum. If this does not produce the desired cooling response and the
foregoing items have revealed no cause for malfunction, the system should be shut down
and the factory notified for instructions.
It is important for the operating personnel to know that the probability of the cooling
elements of the equipment being defective is extremely remote based on improbability of
error and past performance records. Usually, a methodical examination of the elements
mentioned above will reveal the cause of the malfunction, and following correction, the
continued year-in and year-out reliable performance, as designed, will result.
RUN-IN
1. Start fan driver and check as outlined in general motor information section of this operating
manual.
2. Check unit for excessive vibration. When vibration is present, check bolting for tightness.
5. Tube Bundles
A. On plug type headers, plugs are installed at room temperature in our plant. Frequently,
it is necessary to tighten plugs in the field when coils are hot to avoid minor leaking
through plugs.
B. Fins should be kept as free as possible of excessive debris, oil, bugs, and other fouling
material. This may be done by steam cleaning or directing a stream of hot water over
outside of coil.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
5
PROCESS START-UP
1. The process start-up procedure should be conducted in a manner that will minimize thermal
shock of the tube bundles and prevent overcooling of critical services during periods of low
ambient temperature and low heat load.
2. For low pour point and low viscosity services, admit the process fluid at a low rate, and
gradually increase the flow to the design rate. Start the fans one at a time as the process
fluid begins to exceed the design operating temperature, until all the fans are on or the
process fluid is at the design temperature.
3. Special precautions should be observed in starting up units with process streams of (a) high
viscosity fluids and (b) fluids with pour points above the prevailing air temperature. For
units of either type, admit the process stream to the tube bundle readily to prevent excessive
cooling of the first liquid to reach the cold tubes. Care must be exercised to prevent undue
shock from causing a "hammering" effect. When normal flow is attained, start the fans one
at a time until the desired fluid outlet temperature is reached.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
6
INTERNAL CLEANING OF TUBES
The internal cleaning of air cooler tubes used the same method as conventional shell and tube units.
1. MECHANICAL CLEANING
This consists of using drills, (or wire brushes), on long rods, and rotating the rods with air or electric motors. This type of cleaning
is usually followed by water wash or air purge. This type of cleaning is not good for "Tarry" materials.
The Elliot Company handles a complete line of these cleaners and will be glad to furnish recommendations on inquiry.
2. CHEMICAL CLEANING
This consists of circulating hot chemical solutions through the tubes. The solutions contain inhibitors to avoid corrosion of the
tube walls.
Among the companies specializing in this work are: Dowell, Halliburton, and the Oakite Company. They require a sample of the
fouling material to determine the required chemical solution to be used in cleaning.
One and one-half inch to three-inch inlet and outlet nozzles to each bundle are required for circulation of the solutions. They also
require a solution makeup tank and circulating pump. In some localities these companies have portable equipment on trucks.
The use of chemical cleaning is growing rapidly in process plants, as it saves downtime and disassembly of units. It is not suitable
with plugged tubes.
The use of high-pressure water sprays of "Hydro Jets" has been increasing in the United States and Europe. In the United States,
several service companies specialize in cleaning tubes with portable high pressure pumps mounted on trucks. Water capacity is
usually 25 gpm with pump discharge pressure up to 9,000 psig.
The high pressure water jet heads are placed on the ends of hollow rods, similar to mechanical cleaning, and pushed through the
individual tubes. The correct water pressure to the jet is determined by trial. Usually, the softer the fouling deposit, the lower the
required jet pressure. For instance, an amine cooler deposit can usually be cleaned at about 2,000 psig. A water carbonate scale
requires higher pressure in the range of 6,000 - 9,000 psig. Again it should be stated that this process won't work on plugged
tubes. They must be drilled out mechanically.
Among the service companies who specialize in "Hydro Jet" cleaning are:
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
7
INSTRUCTIONS FOR FIELD INSTALLATION OF
TUBES IN A SECTION
1. Shut off flow and let section drain through outlet connection.
b. Completely drain section either through drain provided in header or by removing a plug
in the bottom row of tubes.
2. Remove plugs opposite both ends of bad tube and for 3 or 4 tubes all around faulty tubes to
allow ample working space.
3. The section will not need to be removed from the top of the structure if the faulty tube is
close to the top of the section.
If the tube is closer to the bottom of the section it is advisable to remove the section from
the structure and turn it upside down, thus minimizing tube replacement.
4. If louvers or recirculation panels are on top of the section, these must be removed.
In some cases, not all of the recirculation panels will need to be removed unless the section
is to be removed from the structure.
If the unit is an induced draft type, everything above the section must be removed.
Faulty tube
Additional tubes that must be
removed to replace faulty tube
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
8
FIELD INSTALLATION cont.
6. Now remove 2 bolts in each end of each tube binder and remove each tube binder on the
top only.
If the section has been removed from the structure, be sure that it is supported well so that
no damage will be done to the fins and that it cannot “fall.”
If the section has been turned over (bottom side up) remove the tube binder on the top
only.
NOTICE: DO NOT loosen the supports on the “down” side as this will allow the
tubes to “sag.”
7. You are now ready to remove the tubes from the section:
b. Cut off both ends of each tube to be removed, about 1/8” to 1/4” back from tube sheet
and lift out the tubes in top row.
d. With an abrasive grinder or hack saw, cut the tube support bars on top of the tubes on
inner rows, then lift out tubes.
e. After all required tubes have been cut off and taken out, remove the short pieces from
each tube sheet as follows:
1). Select a “drift pin” about .010” smaller than the O.D. of the tube with a shoulder
1/2” long and the same I.D. as the tube.
2). Insert the drift pin through the plug hole and into the end of the tube and force the
tube end out of the tube sheet, either with a pneumatic tool or a hammer.
8. After all tube ends have been removed from the tube sheets, install new tubes in the section:
a. “Bow” tube up in the middle and place each end in hole in tube sheet. Keep a slight
upward “bow” in the tube until it is determined that each end of the tube protrudes
through the tube sheet about equal on each end, then press the tube down firmly on the
support bar beneath it. It may be necessary to take a screwdriver and push 1 or 2 fins
apart to allow the tube to rest securely on the support bar.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
9
FIELD INSTALLATION cont.
b. Where support bars were cut out, cut a new piece of similar metal long enough to
extend over one tube on each side of tubes removed. Slide the new piece between the
tubes and then back so that it will rest on the tube on each side and be next to the
original bar.
Put in new pieces at each tube support where the original bar was put.
d. If the protrusion of the tube ends through the tube sheets are not equal (1/16”), “drift”
the tube from the longer end until equal (1/16”).
9. Replace the top tube keepers and bolt the end tightly to side frame.
Be sure support is pressed down securely against top of the tubes and held until the bolts in
the ends are tightened.
10. Roll tubes into tube sheets in accordance with “INSTRUCTIONS FOR TUBE
EXPANDING BY HAND” (next section). The same rolling procedure is followed for a
power roller.
11. Replace plugs in headers and hydrostatically test section at 1.5 times the design pressure
shown on the name plate and check new tubes for leaks. If a leak appears, re-roll tube end
and test again.
CSCI
5500 E Independence
Tulsa, OK 74115
918-834-0002 Phone
918-834-0128 Fax
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
10
INSTRUCTIONS FOR TUBE EXPANDING BY HAND
2. Set the expander for the proper location in the tube sheet. The end of the rolls should be
set flush with the tube side of the tube sheet. The adjustment can be visualized by holding
the tube expander on top of the header and parallel to the tube axis with the bearing collar
against the plug sheet, similar to the cross section view below. If the rolls protrude through
the tube sheet, the rolls will tend to cut the tube on the inside.
If the rolls do not protrude in the tube sheet far enough, there is danger of getting inadequate
surface bond.
To set the rolls: loosen the Allen screw on the thrust collar and screw in or out to position
the rolls.
3. After inserting the tube expander into the tube, turn the Mandrel clockwise. This rotation
progresses the Mandrel forward.
Since the Mandrel is tapered, this forward progression forces the rolls against the tube wall.
• A few rotations of the Mandrel begin to bring the rolls up against the tube. At this point
the Mandrel gets harder to turn. From this initial point of contact, expanding is in
progress.
• In installing a new tube that has not been previously expanded, progress the Mandrel
3/8” beyond the point of the initial contact.
4. Tubes are originally expanded in our plant to a specified torque rating by electronically
controlled equipment.
Cooler Service Company Incorporated¨ Tulsa, OK 74158¨ Phone: (918)834-0002¨ Fax: (918)834-0128
11
START-UP PROCEDURES FOR CHECO FANS
a)Set the blade angle as marked on the blade or on the certified outline drawing. To
accomplish this:
d) Observing the bubble on the protractor, tap the blade shank with a rubber mallet until
bubble centers.
Follow the above procedure for all blades. Be sure that blades are installed in pairs as
marked in order to assure perfect balance.
CHECK ROTATION
b) Check to make sure the motor and gear or belt sheave speeds are correct.
MAINTENANCE
Your Checo fan, properly installed, requires little if any maintenance. However, all bolts and
clamps should be checked occasionally to ensure tightness. At the same time, inspect blades
for any nicks or cracks. For greatest air movement efficiency, blades should be kept clean.
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START-UP PROCEDURES FOR MOORE FANS
Hubs are shipped from the factory with the clevises set for the blade angle indicated
by the design performance. A change in the blade angle is usually necessary to
adjust to actual site conditions. Failure to adjust the blade angle when required may
result in motor overload. To check, measure the input amps to the motor while the
fan is operating. See “Start-up Procedures” below. If the current draw is higher or
lower than desired, slightly decrease or increase the blade angle.
WARNING! The fan is designed to consume the horsepower stated on the Fan
Specification Sheet. This is not necessarily the full load horsepower of the motor.
Increasing the blade angle to fully load an oversize motor can cause serious blade
overload, which will stall the blades. In this condition, the fan will actually deliver less
air and blade life may be shortened.
NOTE: If the hub is not level, the blade angles will not be accurately measured. To
check, rotate the fan while checking the angle of a blade. If the measured angle
varies as the fan is rotated, find the two locations, 180°apart, where the angles are
identical. Only at these two points will the angle measured be accurate. Set each
blade angle with the blade rotated to one of these two positions.
Place a protractor level on the flat upper or lower surface of the clevis as shown in
the illustration below. (This is the point of measurement of the blade angle stated on
fan specifications.) Make a permanent record of the final clevis angle selected and
take care that all blades on the fan are set at the same angle. A typical adjustment
may be + 3°. The maximum recommended clevis angle is 15°. For all fans except
Series 19, the blade angle is changed by loosening the clamp nut, rotating the clevis
and retightening. Torque all clamp nuts to 50 ft.-lb (7m-kg).
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Read the previous section and follow all the precautions stated. To adjust, remove the blade,
Flatten the tab on the locking clip and loosen the hub bolt just enough to allow the clevis to be
turned. Place a protractor level on the flat upper side of the clevis and rotate the clevis in the
desired direction. Retighten the hub bolt to 90 to 100 ft-lb (12.5 to 13.8 m-kg) of torque. Recheck
the angle after tightening. Bend one corner of the locking tab against a flat side of the bolt head to
secure the bolt from turning. Operate the fan and recheck the current draw. Repeat adjustment if
necessary until amperage readings are as desired.
START-UP PROCEDURES
Before starting the fan, manually Inspect the inner surface of the fan
check all bolts or nuts to see if they are ring and the blade tips for any indications of
tightened. Take care not to exceed the scoring.
stated torque limits. Check the motor amperage and
Lift each blade to the horizontal consult the motor manufacturer’s
position and walk the blade around while specification sheet for the actual motor output
checking for proper clearance. horsepower for that amperage. The HP given
For API 661 coolers, the radial on the Fan Specifications is the calculated
clearance between the fan tip and the fan HP (at the fan shaft) that is required for the
orifice ring shall not exceed 1/2 percent of the specified performance. The motor output HP
fan diameter or 3/4 inch (19mm), whichever is may be allowed to be 3% or 5% above the
smaller; in no case shall the clearance be specified fan HP to allow for gear drive or belt
less than 3/8 inch (9mm). drive losses respectively.
To check for compliance, raise the Consult the factory or the fan curve
blade to 1/2 the distance between the stop before increasing the blade angle for the fan
droop position and the horizontal position to consume more than the specified HP.
(approx. 2-1/2” + 1/2”). This will simulate the
fan position under load.
Start the fan and watch it in
operation. All blades should lift to the same
operating position, indicating that the blade
angles are properly set and that all blades are
equally loaded.
If vibration or unbalance is evident,
see maintenance section.
After the fan has been operating for
several minutes, stop the fan and observe the
blades as the fan comes to rest. All of the
blades should fall to their droop position at
the same rate.
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MAINTENANCE
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should be shut off rather than reducing the some obstacle. Minor dents may sometimes
motor speed beyond this point. be repaired by drilling a small hole in the
CRACKS, DENTS AND CORROSION center of the dent and pulling outward on the
Skin cracking may be caused by the blade skin. Blades may be ordered from the
tips dragging on the fan ring, or it may be the factory for replacement. If there is any
result of long-term fatigue due to continued evidence of this type of damage, the hub
operation under conditions of vibration or should be carefully inspected.
unbalance. Skin cracking can also be The type 5052 aluminum, a marine
caused by continued operation under overload alloy, used as the blade material on Moore
conditions. fans works well with either fresh or sea water.
Cracking in air seals can occur if the Waters that are acid, alkaline or contain
air seal has been improperly installed. Check copper salts, however, should be avoided for
to be sure the resilient washers are present all aluminum alloys. If you have questions
and the nuts properly tightened. regarding the suitability of the fan materials
The fatigue strength of materials, under certain water conditions, please
whether metal or plastic may be lowered by contact the factory.
long-term exposure to water.
Dents in blades are caused by
objects falling into the fan or the fan striking
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VIBRATION SWITCH INSTALLATION INSTRUCTIONS
Murphy Models
VS2-EX/VS2-EXR
VS2-EXR-B
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ELECTRIC MODELS
Make the necessary electrical connections to the vibration switch. Do not exceed voltage or
current rating 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.
PNEUMATIC MODELS
Attach a pressure source of 20-80 psig (138-552 kPag) to the supply port. Best operation is
obtained with 60 psi (414 kPag). Pressure medium must be clean, dry air or gas. Use a filter
and pressure regulator as necessary.
Connect an exhaust line to the exhaust port and to the equipment shutdown device to be
operated.
SENSITIVITY ADJUSTMENT
2. If the vibration switch trips on start-up, allow the machine to stop. Turn the sensitivity
adjustment ¼ turn clockwise. Depress the reset button and restart the machine. Repeat
process until the vibration switch does not trip on start-up.
3. If the vibration switch does not trip on start-up, stop the machine. Turn the sensitivity
adjustment ¼ turn counter clockwise. Repeat start-up/stop process until the vibration
switch trips on start-up. Turn the sensitivity adjustment ¼ turn clockwise (less sensitive).
Restart the machine to verify that the vibration switch will trip when abnormal shock or
vibration exists.
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TYPICAL WIRING DIAGRAMS
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HTD AND V-BELT INSTRUCTIONS
This tensioning method assumes average static tensions for drives, thereby eliminating the need
for calculating static tension. Use this method if the small sheave diameter, small sheave rpm
and speed ratio fall within the limits as given in table number 1; the number of belts used
corresponds to the number recommended in this manual; and the drive has at least 2 belts.
Step 1: Determine the force required to deflect one belt 1/64" per inch of span
length
• At the center of the span measure the force required to deflect one belt on the drive 1/64
per inch of span length from its normal position. The adjacent belt can be used as a
reference for measuring the deflection. (see figure pg. 22) Be sure to apply the force
perpendicular to the belt.
• Measure the force required to deflect a band of belts 1/64 per inch of span length as
discussed above. Divide the value by the number of belt strands in the band to find the
deflection force per belt.
Note: Lay a steel bar or a narrow block of wood across the belt and apply the deflection force
to the bar so that all of the individual strands in the band are deflected the same amount. If
more than one belt is used in the drive, the neighboring band can be used as a reference for
measuring the deflection, just as is done with individual belts. If only one band is used, lay a
straightedge or stretch a string from sheave-to-sheave to use as a reference for measuring the
deflection. Lay the straightedge or string across the back of the belt on the sheaves.
Step 2: Compare this deflection with the range of forces given in TABLE NUMBER
1.
• If it is less than the minimum recommended force, the belts should be retensioned.
• If it is more than the maximum recommended force, the drive is tighter than it needs to be.
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TABLE NUMBER 1
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HTD BELT INSTALLATION PROCEDURE
BELT TENSION
HTD drives do not require as much tension as other belt drives that depend on friction to
transmit the load. HTD belts should be installed with a snug fit, neither too taut nor too loose.
After the belt has been so tensioned, a force to deflect the belt by a certain amount to assure
proper tension can be measured. Stop the drive and measure the belt span (see sketch). Using
a spring scale, apply a perpendicular force to the center of the belt width and the center of the
belt span. Measure the force required to deflect the belt 1/64" for each inch of belt span. For
example, the deflection for a 32" belt span is 32 x 1/64 = 1/2" deflection. The force required to
deflect the belt this amount at the proper tension is listed in table below.
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GENERAL MOTOR INFORMATION
ATMOSPHERE
BEARINGS:
Nothing required. Ball bearings grease-packed at factory.
RODENTS:
Prevent rodents or other small animals from nesting inside motor.
LONG STORAGE:
(Over six months)
If in an controlled environment - nothing more is required.
3. Remove condensation drain plugs (if present). Insert silica gel (desiccant)
plugs in openings.
4. Cover completely to exclude dirt, dust, moisture and foreign materials. If possible,
insert motor in strong transparent plastic bag. Attach moisture indicator to side of
motor, place several bags of silica-gel inside, then seal plastic bag.
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5. If motor cannot be sealed in bag and relative humidity exceeds 50%, use
space heaters (installed inside motor when possible) to keep it at least 10°F above
ambient air.
EXTERNAL WIRING
Starting and over-load control devices must be matched to motor rating. For
safety or convenience they may need to be installed some distance from the
motor. Follow the control manufacturer’s instructions to make proper
installation and connections.
OPERATION
A. INITIAL START
After installation is completed, but before motor is put into regular service, make an
initial start as follows:
1. Motor starting and control device connections must agree with wiring diagrams.
2. Voltage, phase and frequency of line circuit (power supply) must agree with
motor nameplate.
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3. Check motor service record and tags accompanying motor to be certain
bearings have been properly lubricated. Bearings should be lubricated when
shipped from factory to give six months of satisfactory service.
4. If possible, remove external load (disconnect drive) and turn shaft by hand to
insure free rotation.
• If drive is disconnected interrupt the starting cycle after motor has accelerated to low speed.
Carefully observe for unusual conditions as motor coasts to a stop. Repeat several times if
necessary.
• If drive is not disconnected, interrupt the starting cycle after motor has accelerated to low
speed. Carefully observe for unusual conditions as motor coasts to a stop. Repeat several
times if necessary.
CAUTION! Repeated trial starts can overheat the motor (particularly for
across the line starting). If repeated trial starts are made, allow sufficient time
between trials to permit heat to dissipate from windings or rotor to prevent
overheating. Starting currents are several times running currents and heating
varies as the SQUARE of the current.
B. NORMAL OPERATION
Start the motor in accordance with standard instructions for the starting
equipment used. Some loads should be reduced to the minimum, particularly
reduced voltage starts and/or high inertia connected loads.
Run high temperature motors (Class H insulation) at reduced load until bearings
reach operating temperature.
C. VOLTAGE REGULATION
Motors will operate successfully under the following conditions of voltage and
frequency variation, but not necessarily in accordance with the standards
established for operating under rated conditions:
• When the variation in voltage does not exceed 10% above or below normal,
with all phases balanced.
• When the variation in frequency does not exceed 5% above or below normal.
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• When the sum of the voltage and frequency variations does not exceed 10%
above or below normal (provided the frequency variation does not exceed 5%).
REGULAR MAINTENANCE
Several of the more important items of good maintenance are discussed in the following
paragraphs. Others should be added when adverse or unusual conditions exist.
Inspection:
Each motor should be inspected at regular intervals. The frequency and thoroughness
will depend on the amount of operation, nature of service and the environment.
Cleanliness:
The motor exterior should be kept free of oil, dust, dirt, water and chemicals. For fan-
cooled motors, it is particularly important to keep the air intake opening free of foreign
material. Do not block air outlet.
Moisture:
On non-explosion proof TEFC motors, a removable plug in the bottom center of the
motor frame permits removal of any accumulated moisture. Drain regularly.
Lubrication Schedule:
Relubricate bearings each six months (more often if conditions require) as follows:
1. Stop the motor. Lock out the switch, particularly if end shield is to be withdrawn.
2. Thoroughly clean off and remove the pipe plugs from bearing housing.
4. Add grease to inlet with hand gun until small amount of new grease is forced out drain.
Catch used grease in suitable container.
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For best results, grease should be compounded from a lithium soap base and a good grade of
petroleum oil. It should be of No. 2 consistency and stabilized against oxidation. Operating
temperature range should be from -15°F to +250°F for Class B insulation and to +300°F
for Class F and H. Most major oil companies have special bearing greases that are satisfactory.
NOTE:
For vertical shaft motors, it is wise to check the inner cap of the top bearing for
grease slumping through the bearing and filling the inner cap grease reservoir.
Since it is necessary to remove the housing, this check is best done during
periodic shut down inspections. (Bottom bearing inner cap should be 2/3 full.)
5. Remove excess grease from ports, replace inlet plugs and run motor 1/2 hour
before replacing drain plug.
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INSTRUCTIONS FOR BEARINGS
WARNING! To ensure that drive is not unexpectedly started, turn off and lock out
or tag power source before proceeding. Failure to observe these precautions could
result in bodily injury.
The bearing has been greased at the factory and is ready to run. The following table is a general
guide for relubrication. However, certain conditions may require a change of lubricating periods
as dictated by experience.
Many ordinary cup greases will disintegrate at speeds far below those at which bearings will
operate successfully if proper grease is used. Bearings have been lubricated at the factory with
number two consistency lithium base grease which is suitable for normal operating conditions.
Relubricate with lithium base grease or a grease which is compatible with original lubricant and
suitable for ball bearing service. In unusual or doubtful cases the recommendation of a
reputable grease manufacturer should be secured.
LUBRICATION GUIDE
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CHECO ACTUATOR
1 1 CLEVIS
2 1 GUIDE BUSHING
3 1 LOWER HOUSING
4 1 SNAP RING
5 1 STEM
6 8 HOUSING NUT
7 12 LOCKWASHER
8 12 HOUSING SCREW
9 1 DIAPHRAGM
10 3 LOCKNUT
11 1 DIAPHRAGM PLATE
12 1 UPPER HOUSING
13 1 DIAPHRAGM WASHER
14 1 CONNECTOR NUT
15 1 O-RING
16 4 SPRING COVER SCREW
17 1 SPRING ROD
18 1 MAIN SPRING
19 1 SPRING COVER
20 1 SPRING WASHER
21 1 WASHER
22 1 POSITIONER SPRING
23 1 POSITIONER WASHER
24 1 GASKET
25 1 POSITIONER
26 6 POSITIONER SCREW
27 6 LOCKWASHER
28 6 COVER PLATE SCREW
29 1 COVER PLATE
30 1 WASHER
31 1 LOCKNUT
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FISHER ACTUATORS
INSTALLATION
If the actuator is mounted on a valve body, follow the specific valve body instruction
sheet when installing the control valve in the pipeline. For actuator’s that are
shipped separately, four holes are tapped in the yoke boss to provide a method of
securing it to a mounting plate or bracket (factory will supply mounting plate or
bracket when specified).
A ¼” npt loading pressure connection is located in the top of the upper diaphragm
case. Using either pipe or tubing, connect either the loading pressure connection or
valve positioner input connection (if a valve positioner if furnished, the loading
pressure connection to the actuator will be made at the factory) to the output
pressure connection on the controller. Keep the length of the pipe or tubing as short
as possible to avoid transmission lag in the control signal.
ADJUSTMENT
When the actuator is completely installed and connected to the controller, it should
be checked for correct travel, freedom for friction, and correct action “push-down-to-
open” or “push-down-to-close”.
The actuator spring and diaphragm have been selected to meet the requirements of
the application. It should be noted that the actuator spring has a constant rate of
compression, and that adjustment of the spring compression merely shifts the initial
spring set point up or down to make the actuator travel within the initial spring set
point and the maximum diaphragm pressure indicated on the actuator nameplate.
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POSITIONER INSTRUCTIONS
Reconnect the flexible air lines. The supply line enters the top of the union.
The positioner must be adjusted for proper operation. First, remove the small adjustment cover
on the top of the positioner. This cover is held in place with a small screw. Set the instrument
air pressure to 4 psi*. With the adjustment cover removed you will see a brass hexagonal shaft
with a slot in it. The shaft must be turned until the blades just begin to move (because the
positioners very, the shaft may have to be adjusted either up or down.) When the adjustment is
made, change the instrument pressure to 15 psi*. The blade should cycle through a full pitch
change. If not, repeat the zero adjustment.
*NOTE: If the instrument air signal range is not 3-15 psig, choose the beginning pressure 1
psig over your minimum and adjust the pressure to your maximum to check change in
pitch.
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GEAR INSTRUCTIONS
LUBRICATION INSTRUCTIONS
Type of oil:
Lubricating oil for use in air-cooled heat exchangers should be an extreme pressure type
lubricant compounded with sulfur phosphorous in a well-refined oil. The lubricant must not be
corrosive to gears or roller bearings; must be neutral in reaction; contain no grit, abrasive or
other foreign material; should have good de-foaming properties and moisture resisting
characteristics. It must have good resistance to oxidation and a pour point of 0° F to 5° F. It
must not be corrosive to a copper strip at 212° F.
The user should consult his regular lubricant supplier for recommendations of brand names to
meet the above specifications.
For units equipped with a backstop, do not use EP-type oil as this may cause the backstop to
become ineffective. Use only straight mineral oil of the same viscosity.
Synthetic oils have been used in enclosed gear drives for special operating conditions. Synthetic
lubricants can be advantageous over standard oils in that they are generally more stable, have a
longer life, and operate over a wider temperature range.
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INSTRUCTIONS FOR INSTALLATION AND STARTING NEW UNIT
1. When units leave the factory, the internal parts are protected by a polar rust
preventive film. Flushing of this film is not required since it is soluble in the lubricant.
Merely fill the case with the recommended lubricant to the proper oil level.
NOTE: units are shipped without oil and must be filled before starting.
2. The gears are carefully set-up with respect to each other during factory assembly to
give proper tooth contact. Nothing should be done to disturb this factory setting.
3. Gear units are shipped with the breather port plugged. Prior to operation, a
breather type plug (supplied with the unit) must be installed in the upper housing.
4. Each unit is given a short run-in at the factory as part of the inspection procedure.
When circumstances allow, it is recommended that the fan blades be set at a
minimum output pitch and the reducer operated for one or two days to allow final
“break-in” of gears. After this “break-in” period, fan blades can be set to produce
rated load on unit.
5. Coupling connections should be aligned for minimum parallel and angular
misalignment.
6. Where it is required to shim the unit for alignment, care must be taken to prevent
distortion of the housing. Note: coupling and unit alignment should be
rechecked after two weeks ope ration.
7. When units furnished with force feed lubrication are first started up, it should be
observed that oil is being pumped.
8. For cold temperature operation where oil viscosity on starting is greater than 5,000
SUV, heaters must be used. For units with pressure lubrication systems, check that
pump is pumping cold oil.
9. Minimum viscosity required under operating conditions ranges from 150 to 400
SUV. Oils having this viscosity under operating conditions are not normally
satisfactory for cold temperature starting and heaters must be used.
10. Where unit will not heat up under intermittent operating conditions, low-viscosity oil
may be selected for cold temperature operation.
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OIL CHANGES
After a gear unit is first installed, the first oil should be changed after two weeks of operations.
If desired, the original oil may be strained and replaced. Do not use a strainer finer than 25
microns to avoid filtering out the additives. After the original oil has been drained, fill the case to
the indicated level with SAE-10 straight run mineral flushing oil containing no additives. Fan
should be started, brought up to speed and shut down immediately as a flushing procedure.
Drain off flushing oils and fill with recommended lubricant to the proper level.
After this initial oil change, an oil change every six months should be sufficient unless there are
unusually high temperature conditions combined with intermittent high loads where the
temperature of the gear case rises rapidly and then cools off quickly. This condition may cause
sweating on the inside wall of the unit thus contaminating the oil and forming sludge. Under
these conditions, or if the oil temperature is continuously above 200°F, or if the unit is subjected
to an unusually moist atmosphere, oil changes may be necessary at one, two or three month
intervals, as determined by field inspection of the oil.
Every precaution should be taken to prevent any foreign matter from entering the gear case.
Dust, dirt moisture, and chemical fumes form sludge – the biggest enemy of proper and
adequate lubrication.
1. Check oil level once a week. Level should be checked with unit stopped since the
indicated oil level will rise when unit is running. Lubricant level should not be more than
¼” below specified level.
2. The lubrication instructions for oil change and for shutdown periods should be followed.
3. Units should be given daily routing inspection consisting of visual inspections and
observations for oil leaks or unusual noises. If either occurs, unit should be shut down,
cause of leakage or noise found and corrected.
4. The operating temperature of the unit is the temperature of the oil inside the housing. The
maximum operation should not exceed 200°F.
5. This sump temperature is considered maximum because many lubricants lose stability
properties when exposed to temperatures above the stated maximum.
If unit will be idle for a period longer than one week, it will be necessary to run the unit for ten
minutes every week it is idle. This short operation will keep the gears and bearings coated with
oil and prevent rusting due to condensations of moisture resulting from temperature changes.
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COUPLINGS
EQUIPMENT ALIGNMENT
Although couplings can withstand gross misalignment, care should be taken for best possible
alignment to assure optimum performance. The caliper/straightedge alignment procedure is
described below. If greater alignment accuracy is desired, a dial indicator method is
recommended. There are occasions when equipment manufactures require more specific
alignment tolerances, in which case the manufacture’s recommendations should be followed.
1. To correct for angular misalignment use calipers to check toe gap between hubs.
Adjust or shim equipment until the gap is the same at all points around the hubs.
2. To correct parallel offset, place a straightedge across the hub flanges in two places at
90 degrees to each other. Adjust or shim equipment until the straightedge lays flat on
both sides.
4. Install elastomer element, tightening all capscrews to the values shown in Table.
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RECOMMENDED CAPSCREW TORQUES FOR PROPER
INSTALLATION
Important! Capscrews have self-locking patches which should not be reused more than twice.
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OPERATING INSTRUCTIONS LOUVERS
Louvers are shipped assembled, which makes them easier to install. Due to aluminum
construction, louvers are lightweight and can easily be handled by two men.
When lifting equipment is required to move large sections of louvers, it is suggested that two
pieces of crating lumber be placed beneath the section at 1/3 and 2/3 the length. Then slings
may be used to lift the louver section to the top of the cooler on which they are to be used.
Spreader bars must be used to prevent damage to the louver sideframe.
Manually operated louvers are furnished with an operating handle, which may be adjusted to the
preferred position. To adjust this handle simply loosen the tightening bolts, reset handle to
desired position and then re-tighten. Automatically operated louvers are shipped with operator
bracket already mounted. The operator will be in a separate crate. Bolts are furnished for
bolting this operator to the bracket. Connecting link should be attached, adjusted and then
tightened.
For louvers to be connected end-to-end, a connecting link is furnished. This link connects the
actuating rods of each set together.
For louvers to be connected side-by-side, a torque tube clamp is provided. Place clamp on
torque tubes to be connected and close all blades. Then tighten the bolts provided. Any end-
to-end adjustment in tourque tubes must be made by loosening collars and the actuator levers.
Slide torque tube to desired position and retighten collars and actuator lever. If both sections
do not close evenly, adjust actuator lever and/or clamps. DO NOT OVER-TIGHTEN
BOLTS.
Plywood or boards of some type should be placed on CLOSED blades for walking on.
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COIL SECTION & STRUCTURE LIFTING DETAIL
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CLASS 10000 FANS
OWNER'S MANUAL
INSTALLATION
MAINTENANCE
OPERATION
Contents
2.0 INSTALLATION .......................................................................................................................... 2
2.2A INSTALL HUB AND AIR SEAL ................................................................................................ 3
2.2B INSTALL HUB AND AIR SEAL ................................................................................................ 4
2.3 INSTALL AND ADJUST BLADES .............................................................................................. 5
2.4 START-UP PROCEDURES .......................................................................................................... 6
3.0 MAINTENANCE ........................................................................................................................ 7
3.2 ANNUAL INSPECTION .................................................................................................................... 8
3.4 WARRANTY ....................................................................................................................................... 9
3.5A PARTS LIST ....................................................................................................................................10
3.5B PARTS LIST .................................................................................................................................... 11
4.0 OPERATION .............................................................................................................................. 12
4.2 BLADE OVERLOAD ......................................................................................................................13
4.3 CAUSES OF IMPROPER BLADE LOADING ..........................................................................14
4.4 CHECKING BLADE LOAD .........................................................................................................15
4.4.1 SAMPLE GRAPH of BLADE ANGLE IN DEGREES ......................................................16
4.5 DAMAGING OPERATING CONDITIONS .................................................................................17
4.5.3 OBSTRUCTIONS ....................................................................................................................18
MOORE FANS LLC, MARCELINE, MO 64658 PHONE (660) 376-3575 FAX (660) 376-2909 E-MAIL info@moorefans.com
INSTALLATION
ABOUT THIS MANUAL ....... before or after unpacking, the delivering carrier
Moore is as interested as are its customers that Moore should be promptly notified so that an inspection
fans operate at top efficiency for many, many years. This
manual has been written to achieve that result and is based may be made by the claims adjustor. It is the
on more than 50 years of experience as a manufacturer of responsibility of the consignee to file damage
axial flow fans. claims with the carrier. Although Moore will not
Moore fans represent the highest degree of axial fan be responsible for shipping damage, it is requested
development and are in all respects, regardless of price, the
finest obtainable for their intended purpose. As for any fine that any damage, even of a minor nature, be re-
equipment, certain precautions are necessary and certain ported to the factory at once.
abuses must be avoided in order to insure the best perform-
ance over the longest period of time If you have any
questions regarding the installation or operation of your
IDENTIFY YOUR FANS FEATURES
Moore fan(s), please contact the Company for assistance. Section 1 consisting of your units specifica-
tions will be found on the Order Information Sheet
INSPECTION attached. Section 2 Getting Started should be
All Moore units are carefully balanced, inspected read carefully before installation begins. Moore
and packed at the factory. If any damage is evident fans have several unique features.
2.0 INSTALLATION
2.1 GETTING STARTED
2.1.1 FAN IDENTIFICATION Moore keeps records indexed by serial and job
Every fan, or group of identical fans, is assigned a Job numbers of all fans produced for at least forty years in
Number. This number will be found on the Order Informa- order to provide proper maintenance advice and infor-
tion Sheet showing fan specifications. A copy is attached to mation on spare parts and replacements.
this manual. If non-identical fans are shipped together, a Job
Number is assigned to each fan or group and a set of 2.1.2 PLANNING THE INSTALLATION
Information Sheets will be included for each Job Number. The sequence given for the installation may be
The Job Number is written in semi-permanent ink on changed if the conditions warrant. For example, the
each blade, hub and air seal. All fan parts bearing the same air seal may be installed on the hub before the hub is
Job Number are entirely interchangeable. (Blades of the installed on the drive shaft. (In fact, for inverted fans,
same Series and Diameter are also interchangeable between it is necessary to install the air seal first.) The instal-
Job Numbers.) lation should be planned before beginning so that the
Fan components covered by more than one Job Num- steps required are taken in the most convenient order.
ber may be crated together. The Job Number that is written If you need information not found here, please contact
on each part, however, will make sorting simple. Moore.
Each individual fan produced by Moore is assigned a Class 10000 fans are suitable for horizontal or vertical
Serial Number. This Serial Number is embossed on a perma- mounting, for electric motor or engine drive and may be
nent metal tag and attached to each fan hub. The Fan designed for clockwise (right hand) or counterclockwise (left
Information Sheet provided for each Job Number lists all of hand) rotation. Some drawings illustrating the installation
the individual Serial Numbers of the identical fans assume vertical mounting and need to be mentally rotated
covered by that Job Number so that, in future years, for horizontal mounting. Be sure to refer to the dimensional
reference to the fan specifications provided will iden- drawing(s) provided. These will illustrate the proper orien-
tify the characteristics of each individual fan. tation of the fan and the rotation direction.
Page 2 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
Q D TYPE HUB (CAST IRON BUSHING) INSTALLATION
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 3
HT BUSHING HUB (ALUMINUM BUSHING) INSTALLATION
Hub installation instructions DO NOT apply lubricant between the bushing bore and the
shaft.
Some Moore Class 10000 hubs are shipped with Moore Installation:
Hi-Torque (HT) Aluminum Bushings. The following Install the bushing in the hub by aligning the threaded
paragraph details the installation procedure for these holes on the I.D. of the hub with the slots on the OD of the
hubs. bushing with the cap screws captured between the bush-
ing and the hub. Insert the bushing in the hub. Using a
Lubrication: hex key wrench, sequentially tighten the socket head cap
If the bushing was pre-installed in the hub at the factory, screws until the bushing is almost fully engaged in the
no further lubrication is required prior to installation. hub. Leave slight play between the bushing and hub to
If the bushing was not installed in the hub at the factory, facilitate installation on the shaft.
it is imperative to apply high quality grease to the Place the hub/bushing on the shaft. (Preferably cap
following surfaces: screw heads will be towards free end of shaft.) Insert the
key, and tighten the setscrew to secure the hub and key to
1. The cap screw threads the shaft. Now begin sequentially tightening the socket
2. The underside of the cap screw heads head cap screws (approximately 2-3 turns per cap screw
3. The bushing taper / hub bore initially) to firmly engage the bushing in the hub and seat
Bushing
the bushing on the shaft. Once the bushing/hub is firmly
Bushing OD Allen Head Hex Key
FAN TYPE RequiredTorque seated on the shaft, continue tightening the cap screws
Bold Size
HUB sequentially until the specified torque, shown in the
U 4" 12 mm 10 mm 50 ft-lb (6.9m-kg)
W 5.5" 16 mm 14 mm 90 ft-lb (12.5m-kg) following table, is reached. DO NOT over-tighten cap
X 5.5 " Long 16 mm 14 mm 135 ft-lb (18.7m-kg) screws as this could cause damage to the hub.
Z 7" 16 mm 14 mm 135 ft-lb (18.7m-kg)
Caution:
If bushing is expected to see frequent oscillating loads (Greater
Bushing than 50% of nominal expected Static Torque), Fan should be
operated for approximately 15 minutes and then re-torque
bushing cap screws.
Cap Screws
To install the airseal:
If the airseal is to be installed on the shaft side of the fan,
RODEND cut out the center to provide clearance for the bushing.
Locate the air seal installation hardware in the plastic bag
AIR SEAL
taped to one of the hub tubes. Install the air seal studs on the
appropriate side of the hub tube. Finger tighten.
RESILIENT HUB TUBE Place one resilient washer on each stud as shown in the
WASHER drawings at left. Place the air seal onto the studs and install the
remaining hardware, following the sequence shown in the
drawings. Do not lubricate this end of the studs.
Note that the diameter of the resilient washers, before
they are compressed, is slightly less than the diameter of the
aluminum washer. Tighten each nut until the resilient washer's
ALUMINUM NUT
diameter is the same as the aluminum washer. Do not
overtighten. Overtighteness exists when the resilient washer
ALUMINUM has expanded in diameter larger than the diameter of the
WASHER aluminum washer.
RESILIENT Note: Some air seals are provided with more mounting
WASHER holes than may be required. This is done intentionally to
AIR SEAL STUD
make the air seals more interchangeable between units.
AIR SEAL INSTALLATION ON HUB For example, an air seal with 8 mounting holes can be used
with either a 4-blade or an 8-blade unit.
Page 4 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
INSTALLATION
CLAMP
ROD
END
HUB
TUBE
R E S I L I E N T
MOUNT
BLADE BOLT
the bolt into the second resilient mount lightly. A 3/4" drive
BEFORE INSTALLING BLADES. . . . torque wrench with a short extension may be used. The blade
Check to see that the hub is level. If the drive shaft is not mounting bolt is supplied from the factory with grease on the
truly horizontal (or vertical), causing the hub to be cocked, it threads and conical face. Do NOT clean the grease from
will be difficult to adjust blade angles accurately. Eccentric ro- the bolt.
tation of the fan can also cause serious vibration problems. Complete the installation of one blade by holding the
If misalignment, vibration or unbalance in the system is blade so that the blade extends straight out from the hub tube.
present, it will be more easily identified and corrected at this Holding the blade in this position, tighten the bolt using a
time. torque wrench set to 200 ft-lb (28 m-kg) making sure the
rod end and the resilient mounts seat.
After installing the first blade, manually rotate the fan
Moore fan blades are carefully balanced to the same moment at the while moving the blade tip in and out to be sure the blade
factory. Any Class 10000 blade of the same series and diameter may clears the ring or throat at all points. When the blade is held
be installed on any hub furnished on the job. They are completely in alignment with the blade tube (that is, straight outward
interchangeable. from the hub), it should clear the fan ring by a distance
Moore Class 10000 Fans are designed for engine adequate to provide for any relative motion between the fan
drive and other applications with the more severe re- wheel and the ring. Excess clearance between the blade tips
quirements of this service. Proper installation, with and the ring, however, should be avoided to prevent backflow
particular attention to tightening nuts to the specified which seriously reduces fan efficiency. If clearance is exces-
torque, is essential to maintain the design integrity of sive, the diameter may be adjusted at this time. See Section
these units. 2.3.2.
Installoneblade:Cleananydirtorgreasefromtherodendand Install the rest of the blades so that they are identical
the surfaces of the resilient mounts. Align the rod end hole with with the first blade. Torque all bolts to 200 ft-lbs (28 m-
the holes in the resilient mounts and insert the blade mount- kg). If blades are installed properly, they will return to their
ing bolt first through the resilient mount with the recess to undisturbed position if the tips are pressed in the axial
accept the bolt head, then through the rod end hole and screw direction with moderate force (10 to 20 lb).
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 5
INSTALLATION
Hubs are shipped from the factory with the rod end set
for the blade angle indicated by the design performance. A
HEAVY DOTTED LINE
change in blade angle is sometimes necessary, however, to
INDICATES LOCATION FOR
adjust to actual site conditions. Failure to adjust the blade angle MEASURING BLADE ANGLE
when required may result in blade overload. The causes of
improper blade loading are explained in Section 4.3 of this
manual. Section 4.4 "Checking Blade Load" provides a simple
method of determining the maximum blade angle allowable
in terms of static pressure vs blade angle. Please refer to these
sections before increasing blade angle.
To adjust, loosen the Clamp Nut just enough to allow
the blade to be turned. Place a inclinometer on the flat surface
of the mounts end as shown in the illustration at right. Turn
the blade until the desired angle is achieved.. Make a
permanent record of the final angle selected and take care
that all blades on the fan are set at the same angle. A typical
adjustment may be +/- 3o. The maximum recommended
blade angle is 30o.
Retighten the Clamp Nut to 18 ft-lbs (2.5 m-kg).
Recheck each blade angle before tightening.
Page 6 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
3.0 MAINTENANCE
3.1 PERIODIC INSPECTION
As with any industrial equipment, before entry into fan chamber, strict adherence to ALL Lock-
out / Tag-out procedures is well advised!
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 7
MAINTENANCE
Page 8 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
3.3.5 THROAT FLUTTER If in doubt that throat flutter is the cause of
Any fan that is effectively moving air at the tips vibration, reduce the angle of the blades until the
of the blades will develop a reduced pressure area (or fan is doing little or no work. If the vibration ceases
suction) on the fan throat or ring at the tip of the under this condition, it is certain that throat flutter
blade. This suction tends to draw the throat toward is present when the blades are loaded.
the tip of each blade, which means that a four blade
fan would tend to draw the throat into something 3.3.6 FIELD BALANCING
approaching a square while a six blade fan would Unbalance in older fans may develop because
draw it into something resembling a hexagon, etc. of some structural change or by installing one new
Since the fan is rotating, the effect on the throat is that blade on an old fan where the existing blades had
of continually drawing it into a rotating polygon. changed in weight in the course of operation.
The resulting throat flutter is frequently mistaken Use wire to attach a small weight in succes-
for fan unbalance. sion to each of the air seal studs until the best
A substantial throat or ring will be sufficiently location for the weight is found. The weight should
rigid that flutter will not exist. A weak or flexible then be increased or decreased until the best bal-
throat, particularly when used with a fan of a low ance is achieved. The permanent weight may then
number of blades, will be greatly affected by this be secured to the stud or hub tube, whichever is the
type of vibration. Throat flutter is easily detected due most convenient for the type and shape of weight
to the fact that it is invariably of a frequency of the fan to be used. One or more pieces of metal shaped like
RPM times the number of blades on the fan. a washer could be placed over the stud, on the hub
Throat flutter will cause no damage to the fan so tube, behind the stud, or over the threaded portion of
long as the throat does not disintegrate and fall into the rod end. Aluminum or stainless weights should be
the fan blades. It may be eliminated by stiffening or used and weights should not be attached to the blade
bracing the throat. skin.
3.4 WARRANTY
MOORE FANS LLC (the Seller) warrants only to Buyer, damage on account of misuse, neglect or accident or
as its purchaser for resale, that the fans manufactured shipping damage, or if repairs or part replacements have
and sold by Seller to Buyer under this Agreement will been made or attempted without Seller's prior written
be free from all defects in material and workmanship authorization. SELLER SHALL NOT BE LIABLE IN ANY EVENT FOR ANY
under ordinary use for a period of two (2) years from INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF THIS OR ANY
the date of shipment or one (1) year from the date the WARRANTY. THIS WARRANTY IS IN LIEU OF ALL OTHER GUARANTEES OR
fan is installed on a customer's premises, whichever EXPRESSED WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING
occurs first. This warranty period shall apply only if THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR
Seller receives written notice of any defect within the A PARTICULAR PURPOSE. DUE TO THE VARIETY OF CONDITIONS UNDER
warranty period. Upon receipt of such notice, Seller, at WHICH THE FANS MAY BE USED, RISKS OF RESULTS OBTAINED FROM USE
its option, may require Buyer to return the fan at OF THE FANS, WHETHER USED ALONE OR IN COMBINATION WITH OTHER
Buyer's cost to Seller for inspection by Seller. If the fan PRODUCTS, IS ENTIRELY BUYER'S. THE ABOVE LIMITATIONS ON DAMAGE
is found to be defective on inspection by Seller, as a sole AND EXCLUSION OR LIMITATION OF IMPLIED WARRANTIES ARE NOT
and exclusive remedy, Seller will, at its option, either APPLICABLE TO THE EXTENT PROHIBITED BY STATE LAW.
repair or replace the fan. This warranty shall not apply to
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 9
MAINTENANCE
1
5
8
3
6
4
7
9 SHOP
DWG. PART
NO. NO. DESCRIPTION
15
1 2883 ROD END CLASS 10000 HEAVY DUTY
10 1 4269 ROD END CLASS 10000 STANDARD DUTY
Page 10 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
8 3
5 6 4
7
12
9 SHOP
DWG. PART
NO. NO. DESCRIPTION
10
1 2883 ROD END CLASS 10000 HEAVY DUTY
1 4269 ROD END CLASS 10000 STANDARD DUTY
11
2 2871 RESILIENT MOUNT, THREADED
14 U BUSHING (4" )
W BUSHING (5.5")
X BUSHING LONG (5.5")
Z BUSHING (7")
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 11
OPERATION
4.0 OPERATION
4.1 AERODYNAMIC ABUSE
4.1.1 ABOUT THIS SECTION . . . . Under such conditions, the unit stresses in the blades
It is widely acknowledged that the kinds of mechanical would not be expected to vary more than plus or minus
abuse described on the preceding pages are destructive for 50%. Fan design based on such assumptions is entirely
all types of operating equipment. It is less well recognized reasonable and, with proper drives and installation con-
that for fans aerodynamic stresses are an even more ditions, has proven highly successful.
serious hazard. This section deals with the causes of destruc-
tive aerodynamic stresses and how they can be avoided.
Although this information is given primarily for the
4.1.3 ABNORMAL CONDITIONS
benefit of operators of Moore equipment, it may be applied
Abnormal operating conditions result in destructive
to fans of any manufacture.
repetitive stresses that can seriously shorten fan life. The
Unlike smaller fans, which are typically furnished
aerodynamic abuses discussed in this section can cause
complete with their surroundings, the large fan wheel is
repeated flexing of the fan blades and hub. Violent displace-
supplied as an unprotected component of the system and is
ment of the resiliently mounted Moore fan blades may
installed in innumerable types of surroundings. Not only do
occur a greater displacement than would occur in rigidly
the types and conditions of the drives for these fan wheels
mounted blades. The resilient mounting, of course, mini-
vary widely, but the entrance and exit conditions and the
mizes the structural unit stresses which would be transmit-
enclosure for the wheel assume a myriad of possible com-
ted to the root of the blade and into the hub and drive.
binations. In designing his product, the manufacturer of fan
Although Moore units may be expected to resist greater
wheels must anticipate the operating conditions based upon
stress than units of conventional design, such repetitive
his knowledge of what is reasonable and customary for the
stresses may exceed the capability of the resilient mounts
industry. He may over-design for abnormal stresses only
to absorb them. If so, fatigue of the mounts and metal may
until the practical limit is reached to avoid excessive weight,
develop, adjusting linkages may wear, and ultimate failure
cost and inefficiency.
becomes a possibility.
Some of the abuses set out in the following text are
4.1.2 NORMAL OPERATING CONDITIONS far less important than others. All of them may occur in
The fan manufacturer assumes a fairly reasonable atmo- varying degrees.
sphere for the operation of his product, including the follow- Specifically, abuse due to serious repetitive stresses
ing: can lead to mount failure and, if carried to extremes, can
The fan selection will be reasonably in line with the require blade replacement. In units of other manufacture
performance the unit is expected to maintain, with an with rigidly mounted blades, repetitive stresses of this type
adequate blade area for the pressure required at the
given RPM. Blades will not be loaded beyond their may lead to blade breakage, probably near the root or at
capacity to maintain air flow. the point of attachment to the hub where stresses are
highest, or may lead to failure of the hub itself. The resilient
A fan ring will be provided that is round, rigid and of mount design, unique with Moore fans, dampens these
a depth at least sufficient to cover the tips of the blades. vibrational forces and results in a fan that is far less
Tip clearances will be uniform and controlled. vulnerable to failure from these conditions than other units
with rigidly mounted blades. Even so, extreme conditions
The approach air will represent a relatively uniform
and axial flow with, of course, some unavoidable can cause damage.
turbulence expected. Adequate open area will be pro- A well-designed fan can be expected to operate for
vided at the inlet of the fan. many years without trouble under normal operation as
described above. The extreme repetitive stresses de-
Major obstructions will not be present at either the scribed below, however, will certainly reduce the life of
inlet or discharge of the fan. the fan, causing failure many years sooner than would
occur if the fan were operated as intended. Fortunately,
The RPM of the fan will be within the design limits.
these destructive conditions are readily observable to
The relative direction and velocity of approaching air someone who is knowledgeable about them, and they
to the blades will be fairly constant and protection will can be corrected with reasonable effort and expense
be provided from extreme wind conditions. once they are observed.
Page 12 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 13
OPERATION
Page 14 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
velocity in the same direction as the rotation of the fan, which the fan, even though it does not reach the full rated pressure.
reduces the relative velocity between the fan blades and the
air by some portion of this rotational velocity. 4.3.5 CONCLUSION
Moore fans are designed in contemplation of a maxi- As can be seen by the various points discussed in this
mum deflection of 50o at the hub, decreasing to a very small section, there are a number of complex factors which tend to
value at the tip. This deflection is considered in the determi- cause fans to be operated in a condition of improper blade
nation of the pressure which may be provided by each blade loading which can shorten fan life or lower efficiency. When
over its full length. If fans are selected, or if conditions exist, blade angles are set to consume the specified horsepower (at
which cause the deflection to exceed 50o at the hub, the velocity the fan shaft), the resulting performance should be very close
of the blades relative to the air is less than anticipated and the to the specified performance. If this is not the case and the
blades will not provide the rated pressure. The test below, problem cannot be identified or corrected, please contact
however, will show the full allowable pressure capability of Moore for assistance.
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 15
OPERATION
1.2 120
SELECTED BLADE ANGLE
1.1 110
.9 90
.8 80
STATIC
.7 PRESSURE 70
FINAL % RATED FAN HP
.6 60
.5 50
.4 40
BLADE ANGLE VS % RATED FAN HP
.3 30
.2 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Note in the chart above that static pressure (and air flow) has angle is 5% below the point where the static pressure curve
reached its maximum at an 11 degree blade setting and blade becomes level. The horsepower curve has been added to illus-
overload is beginning. With further increase in blade angle, trate the point that in an overload condition, horsepower will
anything may happen, as indicated by the dotted extensions increase without increased performance.
into the shaded overload area. Note that the final selected blade
STATIC PRESSURE
Page 16 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION
4.5.2 WIND
With a vertically mounted fan blowing outward
into the wind and surrounded by a short fan ring or stack,
high winds may cause some concern. The farther the ring
extends beyond the fan, the less effect would be expected
from wind. It is a fact, however, that wind across the face
of the ring will affect the direction of air flow well down
into the ring. In the case of a fan installed near the outlet hour) with a horizontal component of wind velocity (VW)
of the ring, the direction from axial of the fan discharge of 20 miles per hour. Note that the velocity (VR) of the fan
may be increased by as much as 45O under high wind blade relative to the air varies by a factor of 1.43. The
conditions. blade load varies as the square of this velocity, or 2.05.
THE EFFECT OF AIR LOAD ON HUB AND DRIVE In conventional fans with rigidly attached blades,
Moore fan blades are attached to the hub by a pivot. the bending moment at the shaft due to the air load is equal
As the fan rotates, centrifugal force causes the blades to rise to the load (FA) multiplied by the distance from the fan
(as do the blades of a helicopter). The air load (FA) is centerline to the point of application of the force on the
uniform over the blade, but there is a point (shown on the blade (RF). This moment will be from 2 to 4 times as great
blade in the drawing below) where, if the total load were as that produced by the Moore fan under the same condi-
applied at that point, the effect would be the same. The
resultant of the air load (FA), assumed in this example to
be downward, and the horizontal centrifugal force (FC) is
the force on the blade (FB). The blade automatically posi-
tions.
Also of concern with the conventional fan is the
tions itself in the direction of this force with the result that bending moment due to the air load at the point of
the force is translated inward to the pivot point, as illus- attachment of the blades to the hub since this is usually the
trated by the dotted line. The effect of this arrangement is structurally weakest area of the fan. The moment due to
exactly as if the total air load (FA) were applied at the pivot the air load at this point is the load (FA) times the distance
point rather than at the point outward on the blade. The (D). For the Moore fan, this moment is zero since the
maximum bending moment applied to the shaft by the air blades are attached at the pivot point.
load is equal to the load (FA) multiplied by the distance A more complete discussion of the Moore fan design
from the fan centerline to the pivot point (RP). can be found in The Moore Companys General Catalog.
TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 17
OPERATION
In this rather common wind condition, then, it can be through the fan. This area should be distributed reasonably
seen that the blade load on the side where the blade is going uniformly. It would be unwise to attempt to operate a fan
against the wind will be double the load on the side where with one-half or one-third of the fan area completely blanked
the blade is going with the wind. In a 40 mile per hour wind, off. Such a condition would cause stalling of the fan blade
the blade load would vary by a factor greater than 4. In a 60 through one-half the revolution but create a condition of
mile per hour wind, the load would vary by a factor of more overload in the half which was not blocked off. Excessive
than 10! It is obvious that operation under such conditions vibration would result. Any condition which forces the air to
will impose tremendous repetitive loadings on the fan approach the fan in a non-axial direction should be avoided.
blades.
In areas of unusually high wind velocities, it may be 4.5.4 UNEVEN TIP CLEARANCE
advisable to shield the fan in some manner. Where fan rings are out of round or not centered with
the fan, the tip clearance of each blade will vary as it makes
4.5.3 OBSTRUCTIONS a revolution. If tip clearance is tight at one point and excessive
Obstructions of one type or another in the air stream, at another, proper flow will establish itself at the tight point,
ahead of or beind the fan, are to be expected. In fact, it would loading the blade to the very tip, while at the loose point the
be virtually impossible to eliminate all obstructions. Struc- air will flow from the high pressure side of the blade through
tural supporting members, foundations and the like, need the opening between the blade tip and the ring and nullify the
not be of serious concern although all obstructions, even negative pressure on the under side of the blade. This will
small ones, will increase the static pressure and must be unload the blade near the tip within the area of excessive
taken into consideration by the system designer in specify- tip clearance. Under this condition, the blade will load and
ing the fan performance. unload near the tip one or more times per revolution,
The total free area from which the fan can draw air resulting in an undesirable repetitive vibration. Every
should be twice the net area of the fan (fan area minus hub effort should be made to keep the tip clearance to a
area). In other words, the air approaching the inlet of the fan minimum and to have this clearance as constant as pos-
should have no more than half the velocity of the air passing sible around the entire ring.
Page 18 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
Mechanical VBD-IM
Installation and
Maintenance of
V-BELT DRIVES
Po we r i n g Yo u r S u c c e s s
®
Contents
3
4
6
®
1
®
2
®
3
®
Belt Selection
4
®
Classical Minimum*
Belt Section Pitch Diameter
Narrow Minimum
Belt Section Sheave Diameter
5
®
6
®
Safety Tips
7
®
Drive Installation
8
®
9
®
10
®
11
®
12
®
13
®
14
®
15
®
16
®
Ts CROSS SECTION
Per
Strand
(lbs.) 5V 8V BP CP
3V DP BX CX DX
5V1700 5V1800 8V1700 8V1800 BP144 Over CP144 Over All All All
& under & over & under & over & under BP144 & under CP144 Sizes Sizes Sizes
17
®
18
®
19
®
20
®
21
®
Wood’s sheaves are constructed of fine grain, high tensile cast iron, and have been carefully engineered
to assure maximum performance over a long life span. Behind each sheave is one of the most extensive
engineering design and testing programs in the industry.
Alternately, our sizing software, eAjax ™, is available for your use without
charge. It is Windows® based, and user-friendly. If you have access to the
World Wide Web, go to www.aciservicesinc.com/ajax to download a
current version of the software.
WARNING!
_______________________
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 1 2 3
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 22328 11359 26203 10630 27233 10311
Max Gas RL-Tension (lbs): 21213 7674 24848 6740 25744 6327
Max Net RL-Cmpress (lbs): 18505 10414 22611 10247 23093 10189
Max Net RL-Tension (lbs): 17546 6305 21308 5779 22531 5570
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 12.60 17.85 12.60 17.85 21.05 17.85
* HE's VVP Setting (in): 0.00 0.00 0.00 0.00 1.30 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 12.11 16.62 12.11 16.62 16.41 16.62
Z-Suction: 0.9927 0.9751 0.9910 0.9707 0.9894 0.9688
Z-Discharge: 0.9901 0.9722 0.9879 0.9675 0.9858 0.9655
Minimum HE VE Suct. (%): 64.5 74.6 65.9 79.4 52.0 81.2
Minimum CE VE Suct. (%): 66.9 78.0 68.2 82.1 71.7 83.6
Suction Press. (psig): 30.0 191.0 40.0 228.0 50.0 244.7
Discharge Press. (psig): 194.1 550.0 232.0 550.0 249.0 550.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 284.2 268.3 278.5 244.3 262.9 235.0
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.74 2.78 4.56 2.36 4.11 2.21
Load Per Stage (BHP): 192.6 126.4 234.8 131.3 236.6 131.8
Load Per Unit (BHP): 319.1 319.1 366.1 366.1 368.4 368.4
Per Unit Flow (BHP/MMscfd): 161.35 161.33 147.12 147.10 135.29 135.27
Flow (MMscfd): 1.98 1.98 2.49 2.49 2.72 2.72
User Notes: Run#1 Run#1 Run#2 Run#2 Run#3 Run#3
Cooler (psi): 3.05=1% 4.79=1% 3.94=2% 7.21=1% 4.30=2% 8.46=2%
VVP Throw#1 (in): 0.00 0.00 1.30
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 1 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 4 5 6
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 28067 10047 28875 9773 22548 12012
Max Gas RL-Tension (lbs): 26451 5972 27132 5610 21425 8199
Max Net RL-Cmpress (lbs): 23375 10094 23744 9972 18640 10984
Max Net RL-Tension (lbs): 23529 5370 24526 5158 17766 6753
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 29.44 17.85 37.30 17.85 12.60 17.85
* HE's VVP Setting (in): 2.59 0.00 3.80 0.00 0.00 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 20.69 16.62 24.69 16.62 12.11 16.62
Z-Suction: 0.9877 0.9670 0.9860 0.9652 0.9927 0.9749
Z-Discharge: 0.9838 0.9637 0.9818 0.9619 0.9901 0.9721
Minimum HE VE Suct. (%): 41.0 82.6 32.5 83.9 64.1 73.5
Minimum CE VE Suct. (%): 74.5 84.8 76.6 85.9 66.6 77.1
Suction Press. (psig): 60.0 260.0 70.0 275.0 30.0 192.8
Discharge Press. (psig): 264.6 550.0 280.0 550.0 195.8 575.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 249.9 227.3 239.3 220.1 285.5 273.4
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 3.77 2.10 3.50 1.99 4.77 2.87
Load Per Stage (BHP): 237.1 131.6 238.5 130.6 192.9 130.4
Load Per Unit (BHP): 368.7 368.7 369.1 369.1 323.3 323.3
Per Unit Flow (BHP/MMscfd): 125.48 125.43 117.04 117.05 164.25 164.23
Flow (MMscfd): 2.94 2.94 3.15 3.15 1.97 1.97
User Notes: Run#4 Run#4 Run#5 Run#5 Run#6 Run#6
Cooler (psi): 4.62=2% 10.10=2% 4.96=2% 11.46=2% 3.00=1% 4.57=1%
VVP Throw#1 (in): 2.59 3.80 0.00
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 2 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 7 8 9
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26240 11302 27103 11003 27770 10754
Max Gas RL-Tension (lbs): 24885 7292 25619 6905 26164 6573
Max Net RL-Cmpress (lbs): 22512 10786 22828 10694 22948 10637
Max Net RL-Tension (lbs): 21356 6228 22420 6003 23342 5832
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 13.19 17.85 22.16 17.85 31.13 17.85
* HE's VVP Setting (in): 0.09 0.00 1.47 0.00 2.85 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 12.41 16.62 16.98 16.62 21.55 16.62
Z-Suction: 0.9910 0.9707 0.9894 0.9688 0.9877 0.9672
Z-Discharge: 0.9879 0.9675 0.9858 0.9656 0.9838 0.9639
Minimum HE VE Suct. (%): 64.5 78.3 49.9 80.0 38.4 81.4
Minimum CE VE Suct. (%): 68.2 81.1 71.8 82.6 74.7 83.8
Suction Press. (psig): 40.0 228.5 50.0 244.0 60.0 258.1
Discharge Press. (psig): 232.4 575.0 248.2 575.0 262.5 575.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 278.7 250.2 262.4 241.5 248.8 234.2
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.57 2.46 4.10 2.31 3.74 2.20
Load Per Stage (BHP): 232.5 136.3 232.1 137.3 230.6 137.7
Load Per Unit (BHP): 368.7 368.7 369.4 369.4 368.3 368.3
Per Unit Flow (BHP/MMscfd): 149.87 149.85 137.96 137.95 128.07 128.03
Flow (MMscfd): 2.46 2.46 2.68 2.68 2.88 2.88
User Notes: Run#7 Run#7 Run#8 Run#8 Run#9 Run#9
Cooler (psi): 3.85=2% 6.79=1% 4.18=2% 7.89=1% 4.47=2% 9.30=2%
VVP Throw#1 (in): 0.09 1.47 2.85
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 3 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 10 11 12
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 28583 10474 22766 12667 26114 12000
Max Gas RL-Tension (lbs): 26852 6207 21635 8724 24762 7875
Max Net RL-Cmpress (lbs): 23215 10546 18869 11501 22250 11348
Max Net RL-Tension (lbs): 24352 5638 17986 7225 21248 6713
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 38.99 17.85 12.60 17.85 14.29 17.85
* HE's VVP Setting (in): 4.06 0.00 0.00 0.00 0.26 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 25.55 16.62 12.11 16.62 12.97 16.62
Z-Suction: 0.9860 0.9654 0.9927 0.9747 0.9910 0.9708
Z-Discharge: 0.9818 0.9622 0.9901 0.9720 0.9879 0.9677
Minimum HE VE Suct. (%): 30.2 82.7 63.8 72.4 62.0 77.0
Minimum CE VE Suct. (%): 76.8 84.9 66.3 76.2 68.3 80.1
Suction Press. (psig): 70.0 273.2 30.0 194.5 40.0 227.8
Discharge Press. (psig): 278.0 575.0 197.5 600.0 231.5 600.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 238.3 226.8 286.7 278.3 278.2 256.6
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 3.48 2.09 4.81 2.97 4.55 2.57
Load Per Stage (BHP): 232.3 137.3 193.1 134.1 227.7 140.8
Load Per Unit (BHP): 369.7 369.7 327.2 327.2 368.5 368.5
Per Unit Flow (BHP/MMscfd): 119.59 119.60 167.04 167.03 152.51 152.50
Flow (MMscfd): 3.09 3.09 1.96 1.96 2.42 2.42
User Notes: Run#10 Run#10 Run#11 Run#11 Run#12 Run#12
Cooler (psi): 4.80=2% 10.59=2% 2.96=1% 4.36=1% 3.74=2% 6.33=1%
VVP Throw#1 (in): 4.06 0.00 0.26
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 4 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 13 14 15
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26974 11698 27624 11445 31337 10628
Max Gas RL-Tension (lbs): 25495 7486 26024 7152 29504 6140
Max Net RL-Cmpress (lbs): 22566 11259 22673 11205 25922 10150
Max Net RL-Tension (lbs): 22309 6481 23215 6293 26840 5721
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 23.26 17.85 32.30 17.85 35.61 37.95
* HE's VVP Setting (in): 1.64 0.00 3.03 0.00 3.54 2.21
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 17.54 16.62 22.14 16.62 23.83 27.62
Z-Suction: 0.9894 0.9689 0.9877 0.9673 0.9860 0.9629
Z-Discharge: 0.9858 0.9658 0.9838 0.9641 0.9817 0.9596
Minimum HE VE Suct. (%): 47.8 78.8 36.5 80.2 30.2 68.4
Minimum CE VE Suct. (%): 71.9 81.6 74.8 82.8 74.7 85.6
Suction Press. (psig): 50.0 243.2 60.0 257.2 70.0 294.8
Discharge Press. (psig): 247.3 600.0 261.6 600.0 299.2 600.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 261.9 247.7 248.3 240.3 248.5 222.1
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.09 2.42 3.73 2.30 3.73 2.02
Load Per Stage (BHP): 227.6 142.5 226.2 143.3 242.0 128.1
Load Per Unit (BHP): 370.1 370.1 369.5 369.5 370.1 370.1
Per Unit Flow (BHP/MMscfd): 140.56 140.54 130.62 130.56 122.04 121.96
Flow (MMscfd): 2.63 2.63 2.83 2.83 3.03 3.03
User Notes: Run#13 Run#13 Run#14 Run#14 Run#15 Run#15
Cooler (psi): 4.06=2% 7.37=1% 4.34=2% 8.66=1% 4.34=1% 9.76=2%
VVP Throw#1 (in): 1.64 3.03 3.54
VVP Throw#2 (in): 0.00 0.00 2.21
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 5 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 16 17 18
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 22994 13320 25968 12703 26827 12398
Max Gas RL-Tension (lbs): 21855 9248 24622 8463 25353 8072
Max Net RL-Cmpress (lbs): 19107 12077 21970 11911 22287 11824
Max Net RL-Tension (lbs): 18155 7678 21121 7206 22181 6967
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 12.60 17.85 15.46 17.85 24.43 17.85
* HE's VVP Setting (in): 0.00 0.00 0.44 0.00 1.82 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 12.11 16.62 13.57 16.62 18.14 16.62
Z-Suction: 0.9927 0.9745 0.9910 0.9709 0.9894 0.9690
Z-Discharge: 0.9901 0.9719 0.9879 0.9680 0.9858 0.9660
Minimum HE VE Suct. (%): 63.5 71.3 59.4 75.7 45.6 77.6
Minimum CE VE Suct. (%): 66.0 75.2 68.4 79.0 72.0 80.5
Suction Press. (psig): 30.0 196.3 40.0 226.9 50.0 242.4
Discharge Press. (psig): 199.2 625.0 230.5 625.0 246.3 625.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 288.0 283.0 277.6 262.9 261.4 253.9
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.85 3.06 4.53 2.68 4.07 2.52
Load Per Stage (BHP): 193.3 137.6 222.7 144.9 222.9 147.2
Load Per Unit (BHP): 330.9 330.9 367.6 367.6 370.1 370.1
Per Unit Flow (BHP/MMscfd): 169.74 169.74 155.08 155.07 143.08 143.07
Flow (MMscfd): 1.95 1.95 2.37 2.37 2.59 2.59
User Notes: Run#16 Run#16 Run#17 Run#17 Run#18 Run#18
Cooler (psi): 2.91=1% 4.17=1% 3.62=1% 5.90=1% 3.94=2% 6.89=1%
VVP Throw#1 (in): 0.00 0.44 1.82
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 6 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 19 20 21
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 27355 12155 23228 13973 26021 13379
Max Gas RL-Tension (lbs): 25765 7754 22080 9771 24673 9017
Max Net RL-Cmpress (lbs): 22279 11713 19207 12662 22034 12462
Max Net RL-Tension (lbs): 22971 6746 18388 8151 21183 7666
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 33.92 17.85 12.60 17.85 15.98 17.85
* HE's VVP Setting (in): 3.28 0.00 0.00 0.00 0.52 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 22.97 16.62 12.11 16.62 13.83 16.62
Z-Suction: 0.9877 0.9675 0.9927 0.9743 0.9910 0.9708
Z-Discharge: 0.9838 0.9644 0.9901 0.9719 0.9879 0.9680
Minimum HE VE Suct. (%): 34.0 79.0 63.1 70.2 58.1 74.6
Minimum CE VE Suct. (%): 75.0 81.7 65.7 74.3 68.4 78.0
Suction Press. (psig): 60.0 255.5 30.0 198.2 40.0 227.5
Discharge Press. (psig): 259.7 625.0 201.0 650.0 231.0 650.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 247.3 246.8 289.3 287.5 277.9 268.2
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 3.70 2.40 4.89 3.15 4.54 2.77
Load Per Stage (BHP): 220.2 148.5 193.5 140.8 220.6 148.9
Load Per Unit (BHP): 368.7 368.7 334.3 334.3 369.5 369.5
Per Unit Flow (BHP/MMscfd): 133.09 133.03 172.36 172.35 157.60 157.58
Flow (MMscfd): 2.77 2.77 1.94 1.94 2.34 2.34
User Notes: Run#19 Run#19 Run#20 Run#20 Run#21 Run#21
Cooler (psi): 4.20=2% 8.01=1% 2.86=1% 3.99=1% 3.54=1% 5.59=1%
VVP Throw#1 (in): 3.28 0.00 0.52
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 7 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 22 23 24
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26700 13097 27209 12842 23460 14628
Max Gas RL-Tension (lbs): 25231 8656 25624 8330 22304 10295
Max Net RL-Cmpress (lbs): 22030 12386 22005 12273 19450 13205
Max Net RL-Tension (lbs): 22072 7454 22841 7227 18621 8638
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 25.54 17.85 35.09 17.85 12.60 17.85
* HE's VVP Setting (in): 1.99 0.00 3.46 0.00 0.00 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 18.70 16.62 23.57 16.62 12.11 16.62
Z-Suction: 0.9894 0.9691 0.9877 0.9676 0.9927 0.9741
Z-Discharge: 0.9858 0.9662 0.9838 0.9646 0.9901 0.9718
Minimum HE VE Suct. (%): 43.6 76.4 32.1 77.8 62.8 69.2
Minimum CE VE Suct. (%): 72.2 79.5 75.1 80.7 65.4 73.4
Suction Press. (psig): 50.0 241.7 60.0 254.6 30.0 200.0
Discharge Press. (psig): 245.5 650.0 258.7 650.0 202.8 675.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 260.9 259.8 246.8 252.7 290.6 291.8
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.06 2.62 3.69 2.50 4.94 3.24
Load Per Stage (BHP): 218.6 151.5 215.9 153.2 193.7 143.8
Load Per Unit (BHP): 370.0 370.0 369.1 369.1 337.5 337.5
Per Unit Flow (BHP/MMscfd): 145.54 145.53 135.47 135.46 174.89 174.88
Flow (MMscfd): 2.54 2.54 2.72 2.72 1.93 1.93
User Notes: Run#22 Run#22 Run#23 Run#23 Run#24 Run#24
Cooler (psi): 3.83=1% 6.45=1% 4.09=2% 7.30=1% 2.81=1% 3.82=1%
VVP Throw#1 (in): 1.99 3.46 0.00
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 8 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 25 26 27
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 25875 14085 26575 13798 27091 13548
Max Gas RL-Tension (lbs): 24533 9608 25110 9242 25511 8919
Max Net RL-Cmpress (lbs): 21755 13087 21775 12945 21765 12874
Max Net RL-Tension (lbs): 21056 8168 21981 7945 22742 7715
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 17.15 17.85 26.64 17.85 36.20 17.85
* HE's VVP Setting (in): 0.70 0.00 2.16 0.00 3.63 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 14.43 16.62 19.26 16.62 24.13 16.62
Z-Suction: 0.9910 0.9709 0.9894 0.9692 0.9877 0.9677
Z-Discharge: 0.9879 0.9683 0.9858 0.9665 0.9838 0.9648
Minimum HE VE Suct. (%): 55.6 73.3 41.5 75.2 30.4 76.7
Minimum CE VE Suct. (%): 68.5 77.0 72.3 78.5 75.2 79.8
Suction Press. (psig): 40.0 226.6 50.0 240.9 60.0 254.0
Discharge Press. (psig): 230.0 675.0 244.6 675.0 257.9 675.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 277.2 274.1 260.4 265.6 246.4 258.4
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.53 2.89 4.05 2.73 3.68 2.60
Load Per Stage (BHP): 215.7 152.3 214.3 155.4 211.9 157.6
Load Per Unit (BHP): 368.0 368.0 369.6 369.6 369.5 369.5
Per Unit Flow (BHP/MMscfd): 160.03 160.02 147.93 147.92 137.86 137.80
Flow (MMscfd): 2.30 2.30 2.50 2.50 2.68 2.68
User Notes: Run#25 Run#25 Run#26 Run#26 Run#27 Run#27
Cooler (psi): 3.42=1% 5.22=1% 3.71=1% 6.05=1% 3.96=1% 7.01=1%
VVP Throw#1 (in): 0.70 2.16 3.63
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 9 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 28 29 30
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 23692 15283 25925 14764 26432 14503
Max Gas RL-Tension (lbs): 22527 10820 24581 10165 24973 9832
Max Net RL-Cmpress (lbs): 19691 13751 21670 13619 21505 13533
Max Net RL-Tension (lbs): 18795 9114 21114 8686 21916 8444
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 12.60 17.85 17.67 17.85 27.81 17.85
* HE's VVP Setting (in): 0.00 0.00 0.78 0.00 2.34 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 12.11 16.62 14.69 16.62 19.86 16.62
Z-Suction: 0.9927 0.9738 0.9910 0.9708 0.9894 0.9693
Z-Discharge: 0.9901 0.9718 0.9879 0.9684 0.9858 0.9668
Minimum HE VE Suct. (%): 62.5 68.1 54.3 72.3 39.4 74.0
Minimum CE VE Suct. (%): 65.1 72.5 68.4 76.0 72.4 77.5
Suction Press. (psig): 30.0 201.9 40.0 227.1 50.0 240.1
Discharge Press. (psig): 204.6 700.0 230.5 700.0 243.7 700.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 291.9 295.9 277.5 279.1 259.9 271.4
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.98 3.33 4.53 2.98 4.03 2.83
Load Per Stage (BHP): 193.8 146.7 213.5 155.7 209.8 158.9
Load Per Unit (BHP): 340.5 340.5 369.2 369.2 368.7 368.7
Per Unit Flow (BHP/MMscfd): 177.34 177.34 162.41 162.40 150.26 150.26
Flow (MMscfd): 1.92 1.92 2.27 2.27 2.45 2.45
User Notes: Run#28 Run#28 Run#29 Run#29 Run#30 Run#30
Cooler (psi): 2.77=1% 3.66=1% 3.35=1% 4.95=1% 3.60=1% 5.67=1%
VVP Throw#1 (in): 0.00 0.78 2.34
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 10 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 31 32 33
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 28921 13887 23924 15938 25968 15445
Max Gas RL-Tension (lbs): 27274 9071 22750 11345 24622 10723
Max Net RL-Cmpress (lbs): 23515 12885 19897 14337 21695 14233
Max Net RL-Tension (lbs): 24401 7949 19026 9576 21167 9158
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 33.92 27.13 12.60 17.85 18.26 17.85
* HE's VVP Setting (in): 3.28 1.02 0.00 0.00 0.87 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 22.97 21.70 12.11 16.62 14.99 16.62
Z-Suction: 0.9877 0.9660 0.9927 0.9736 0.9910 0.9708
Z-Discharge: 0.9838 0.9632 0.9901 0.9718 0.9879 0.9686
Minimum HE VE Suct. (%): 30.4 66.9 62.1 67.1 52.9 71.1
Minimum CE VE Suct. (%): 73.7 80.2 64.7 71.6 68.4 75.0
Suction Press. (psig): 60.0 268.3 30.0 203.7 40.0 227.6
Discharge Press. (psig): 272.0 700.0 206.4 725.0 230.9 725.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 253.8 255.8 293.1 299.9 277.8 284.0
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 3.87 2.55 5.02 3.41 4.54 3.08
Load Per Stage (BHP): 217.9 152.0 193.9 149.4 211.1 158.7
Load Per Unit (BHP): 369.8 369.8 343.3 343.3 369.8 369.8
Per Unit Flow (BHP/MMscfd): 139.94 139.93 179.73 179.72 164.72 164.72
Flow (MMscfd): 2.64 2.64 1.91 1.91 2.24 2.25
User Notes: Run#31 Run#31 Run#32 Run#32 Run#33 Run#33
Cooler (psi): 3.70=1% 6.41=1% 2.72=1% 3.52=0% 3.26=1% 4.69=1%
VVP Throw#1 (in): 3.28 0.00 0.87
VVP Throw#2 (in): 1.02 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 11 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 34 35 36
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26471 15183 31768 14052 24942 16442
Max Gas RL-Tension (lbs): 25010 10391 30015 9009 23731 11689
Max Net RL-Cmpress (lbs): 21554 14122 26344 12576 20706 14614
Max Net RL-Tension (lbs): 21964 8962 26986 8030 19987 9954
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 28.33 17.85 30.61 41.13 12.60 22.49
* HE's VVP Setting (in): 2.42 0.00 2.77 2.56 0.00 0.51
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 20.12 16.62 21.28 29.37 12.11 19.16
Z-Suction: 0.9894 0.9692 0.9877 0.9634 0.9927 0.9727
Z-Discharge: 0.9858 0.9669 0.9837 0.9606 0.9901 0.9709
Minimum HE VE Suct. (%): 38.2 72.9 31.1 54.2 60.7 59.6
Minimum CE VE Suct. (%): 72.3 76.6 71.3 81.3 63.4 71.7
Suction Press. (psig): 50.0 240.5 60.0 290.4 30.0 211.7
Discharge Press. (psig): 244.1 725.0 293.7 725.0 214.3 750.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 260.1 276.2 264.7 249.6 298.6 299.4
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.04 2.93 4.16 2.45 5.20 3.40
Load Per Stage (BHP): 207.7 162.5 227.6 142.1 194.4 145.3
Load Per Unit (BHP): 370.1 370.1 369.7 369.7 339.7 339.7
Per Unit Flow (BHP/MMscfd): 152.54 152.54 142.00 141.98 181.89 181.88
Flow (MMscfd): 2.43 2.43 2.60 2.60 1.87 1.87
User Notes: Run#34 Run#34 Run#35 Run#35 Run#36 Run#36
Cooler (psi): 3.52=1% 5.38=1% 3.38=1% 5.97=1% 2.53=1% 3.26=0%
VVP Throw#1 (in): 2.42 2.77 0.00
VVP Throw#2 (in): 0.00 2.56 0.51
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 12 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 37 38 39
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 25861 16149 26352 15888 32729 14563
Max Gas RL-Tension (lbs): 24519 11310 24895 10979 30941 9364
Max Net RL-Cmpress (lbs): 21459 14787 21309 14694 27293 12871
Max Net RL-Tension (lbs): 21077 9683 21861 9463 27868 8401
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 19.36 17.85 29.44 17.85 30.02 44.95
* HE's VVP Setting (in): 1.04 0.00 2.59 0.00 2.68 2.98
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 15.55 16.62 20.69 16.62 20.98 31.46
Z-Suction: 0.9910 0.9708 0.9894 0.9693 0.9877 0.9625
Z-Discharge: 0.9879 0.9689 0.9858 0.9672 0.9837 0.9599
Minimum HE VE Suct. (%): 50.4 69.8 36.2 71.7 30.5 49.6
Minimum CE VE Suct. (%): 68.5 73.9 72.4 75.5 70.5 81.1
Suction Press. (psig): 40.0 227.1 50.0 239.9 60.0 297.9
Discharge Press. (psig): 230.2 750.0 243.3 750.0 301.1 750.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 277.3 289.4 259.6 281.6 268.2 250.8
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.53 3.19 4.02 3.03 4.26 2.47
Load Per Stage (BHP): 206.6 161.0 203.5 165.4 228.6 141.3
Load Per Unit (BHP): 367.5 367.5 368.8 368.8 369.9 369.9
Per Unit Flow (BHP/MMscfd): 166.97 166.97 154.77 154.76 144.10 144.08
Flow (MMscfd): 2.20 2.20 2.38 2.38 2.57 2.57
User Notes: Run#37 Run#37 Run#38 Run#38 Run#39 Run#39
Cooler (psi): 3.15=1% 4.39=1% 3.42=1% 5.06=1% 3.22=1% 5.63=1%
VVP Throw#1 (in): 1.04 2.59 2.68
VVP Throw#2 (in): 0.00 0.00 2.98
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 13 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 40 41 42
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 25905 16831 26386 16570 26117 17490
Max Gas RL-Tension (lbs): 24562 11869 24929 11539 24766 12398
Max Net RL-Cmpress (lbs): 21400 15401 21219 15293 21621 15989
Max Net RL-Tension (lbs): 21130 10188 21906 9953 21344 10682
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 19.95 17.85 30.02 17.85 19.95 17.85
* HE's VVP Setting (in): 1.13 0.00 2.68 0.00 1.13 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 15.85 16.62 20.98 16.62 15.85 16.62
Z-Suction: 0.9910 0.9708 0.9894 0.9693 0.9910 0.9706
Z-Discharge: 0.9879 0.9691 0.9858 0.9674 0.9879 0.9691
Minimum HE VE Suct. (%): 49.0 68.6 34.9 70.6 48.6 67.7
Minimum CE VE Suct. (%): 68.4 72.9 72.4 74.6 68.2 72.1
Suction Press. (psig): 40.0 227.5 50.0 240.3 40.0 229.2
Discharge Press. (psig): 230.6 775.0 243.6 775.0 232.3 800.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 277.6 294.0 259.8 286.2 278.6 297.7
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.54 3.28 4.03 3.12 4.57 3.36
Load Per Stage (BHP): 204.1 163.4 201.1 168.2 204.0 166.1
Load Per Unit (BHP): 367.5 367.5 369.3 369.3 370.2 370.2
Per Unit Flow (BHP/MMscfd): 169.17 169.17 156.93 156.93 171.31 171.31
Flow (MMscfd): 2.17 2.17 2.35 2.35 2.16 2.16
User Notes: Run#40 Run#40 Run#41 Run#41 Run#42 Run#42
Cooler (psi): 3.07=1% 4.17=1% 3.33=1% 4.80=1% 3.02=1% 4.01=0%
VVP Throw#1 (in): 1.13 2.68 1.13
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 14 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 43 44 45
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26420 17253 26117 17490 26420 17253
Max Gas RL-Tension (lbs): 24961 12100 24766 12398 24961 12100
Max Net RL-Cmpress (lbs): 21129 15908 21621 15989 21129 15908
Max Net RL-Tension (lbs): 21949 10464 21344 10682 21949 10464
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 30.61 17.85 19.95 17.85 30.61 17.85
* HE's VVP Setting (in): 2.77 0.00 1.13 0.00 2.77 0.00
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 21.28 16.62 15.85 16.62 21.28 16.62
Z-Suction: 0.9894 0.9692 0.9910 0.9706 0.9894 0.9692
Z-Discharge: 0.9858 0.9676 0.9879 0.9691 0.9858 0.9676
Minimum HE VE Suct. (%): 33.6 69.5 48.6 67.7 33.6 69.5
Minimum CE VE Suct. (%): 72.3 73.6 68.2 72.1 72.3 73.6
Suction Press. (psig): 50.0 240.7 40.0 229.2 50.0 240.7
Discharge Press. (psig): 243.9 800.0 232.3 800.0 243.9 800.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 260.0 290.7 278.6 297.7 260.0 290.7
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.03 3.21 4.57 3.36 4.03 3.21
Load Per Stage (BHP): 198.8 170.7 204.0 166.1 198.8 170.7
Load Per Unit (BHP): 369.5 369.5 370.2 370.2 369.5 369.5
Per Unit Flow (BHP/MMscfd): 159.04 159.04 171.31 171.31 159.04 159.04
Flow (MMscfd): 2.32 2.32 2.16 2.16 2.32 2.32
User Notes: Run#43 Run#43 Run#44 Run#44 Run#45 Run#45
Cooler (psi): 3.25=1% 4.56=1% 3.02=1% 4.01=0% 3.25=1% 4.56=1%
VVP Throw#1 (in): 2.77 1.13 2.77
VVP Throw#2 (in): 0.00 0.00 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 15 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 46 47 48
============================================================================================
Stage : Throw: 1 : 1 2 : 2 1 : 1 2 : 2 1 : 1 2 : 2
Speed (RPM): 440 440 440 440 440 440
Active HEs : CEs: 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00 13.00 6.00 13.00 6.00
Stroke (in): 11.00 11.00 11.00 11.00 11.00 11.00
Max Gas RL-Cmpress (lbs): 26733 18069 27126 17818 27540 18620
Max Gas RL-Tension (lbs): 25359 12833 25641 12517 26136 13232
Max Net RL-Cmpress (lbs): 22122 16417 21860 16323 22818 16819
Max Net RL-Tension (lbs): 21896 11119 22579 10892 22631 11494
Min Rod Reversal (°): Passed Passed Passed Passed Passed Passed
Rod Diameter (in): 2.50 2.50 2.50 2.50 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85 12.60 17.85 12.60 17.85
* HE Set Clearance (%): 19.95 20.21 30.02 20.21 19.36 22.49
* HE's VVP Setting (in): 1.13 0.26 2.68 0.26 1.04 0.51
* CE Clearance (%): 11.60 15.13 11.60 15.13 11.60 15.13
* FC Clearance (%): 15.85 17.91 20.98 17.91 15.55 19.16
Z-Suction: 0.9910 0.9700 0.9894 0.9686 0.9910 0.9693
Z-Discharge: 0.9879 0.9687 0.9858 0.9671 0.9879 0.9682
Minimum HE VE Suct. (%): 47.5 63.4 33.2 65.5 47.5 59.5
Minimum CE VE Suct. (%): 67.5 71.7 71.7 73.4 66.6 71.6
Suction Press. (psig): 40.0 234.2 50.0 246.3 40.0 240.4
Discharge Press. (psig): 237.0 825.0 249.4 825.0 243.2 850.0
Suction Temp. (°F): 80.0 130.0 80.0 130.0 80.0 130.0
Discharge Temp. (°F): 281.6 299.3 263.1 291.9 285.3 299.9
Cooler Temp. (°F): 130.0 120.0 130.0 120.0 130.0 120.0
Compression Ratio: 4.65 3.40 4.12 3.24 4.77 3.41
Load Per Stage (BHP): 203.7 164.9 200.0 170.2 205.8 164.1
Load Per Unit (BHP): 368.6 368.6 370.2 370.2 369.9 369.9
Per Unit Flow (BHP/MMscfd): 173.30 173.29 160.99 160.99 175.23 175.22
Flow (MMscfd): 2.13 2.13 2.30 2.30 2.11 2.11
User Notes: Run#46 Run#46 Run#47 Run#47 Run#48 Run#48
Cooler (psi): 2.89=1% 3.78=0% 3.13=1% 4.34=1% 2.79=1% 3.62=0%
VVP Throw#1 (in): 1.13 2.68 1.04
VVP Throw#2 (in): 0.26 0.26 0.51
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 16 of 17
Cameron Compression Systems, Ajax Division eAjax Performance Software
CYLINDER ON THROW #1: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11CD [6] (HE equipped with a manual VVP.) {Poppet Valves}
Standard Conditions: Base Pressure of 14.6500 psia and Base Temperature of 60.00°F.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 49
============================================================================================
Stage : Throw: 1 : 1 2 : 2
Speed (RPM): 440 440
Active HEs : CEs: 1 : 1 1 : 1
* Cyl. Bore Diameter (in): 13.00 6.00
Stroke (in): 11.00 11.00
Max Gas RL-Cmpress (lbs): 27686 18405
Max Gas RL-Tension (lbs): 26180 12961
Max Net RL-Cmpress (lbs): 22312 16688
Max Net RL-Tension (lbs): 23069 11304
Min Rod Reversal (°): Passed Passed
Rod Diameter (in): 2.50 2.50
* HE Fixed Clearance (%): 12.60 17.85
* HE Set Clearance (%): 30.02 22.49
* HE's VVP Setting (in): 2.68 0.51
* CE Clearance (%): 11.60 15.13
* FC Clearance (%): 20.98 19.16
Z-Suction: 0.9894 0.9680
Z-Discharge: 0.9858 0.9668
Minimum HE VE Suct. (%): 31.9 61.4
Minimum CE VE Suct. (%): 71.1 73.0
Suction Press. (psig): 50.0 250.8
Discharge Press. (psig): 253.8 850.0
Suction Temp. (°F): 80.0 130.0
Discharge Temp. (°F): 265.6 293.8
Cooler Temp. (°F): 130.0 120.0
Compression Ratio: 4.19 3.28
Load Per Stage (BHP): 199.0 169.0
Load Per Unit (BHP): 367.9 367.9
Per Unit Flow (BHP/MMscfd): 162.90 162.90
Flow (MMscfd): 2.26 2.26
User Notes: Run#49 Run#49
Cooler (psi): 2.98=1% 4.08=0%
VVP Throw#1 (in): 2.68
VVP Throw#2 (in): 0.51
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 17 of 17
13" YK11FA Compressor Cylinder with Poppet Valves
Assembly # FA-0000
Asssembly # FA-0000
13" YK11FA Compressor Cylinder with Poppet Valves
Assembly # FA-0000
Asssembly # FA-0000
6.00" YKCD Compressor Cylinder with Poppet Valves
Assembly # CD-0000
CONTENTS
1.0 GENERAL
2.0 INSTALLATION
3.0 OPERATION
4.0 MAINTENANCE
1.0 GENERAL
Page 2
1.2 Specifications
Output
0-20 / 0-30 psig 3-15 / 6-30 psig
Page 3
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
N.O,
Screw Terminals
GROUND (green)
N.O. - 1 (blue)
COM - 1 (brown)
N.C. - 1 (red)
Double Pole –
Double Throw
N.O. - 2 (purple)
COM - 2 (yellow)
N.C. - 2 (black)
Free Leads
Maximum Pressure
Material
Psig Bar
PVC 6170 426
Acrylic 6170 426
2000 @ 180°F1 138 @ 82°C1
316 SST
1595 @ 400°F 110 @ 204°C
1. 2000 psig pressure rating is based @ 180°F (82°C). The maximum pressure rating @ 400°F (204°C) is 1595 psig
(110 bar). For applications requiring higher pressure ratings for SST displacers @ 400°F (204°C), consult
Factory or your local Mallard Representative.
Page 4
1.2.6 Materials of Construction / Temperature Rating
Wetted Part
Part Material
Temperature Rating
Screwed or butt-weld: 1018
Body steel -20 to 600°F
Flanged: 1018 / A105 steel
Case & Cover Anodized Die Cast Aluminum N/A
Pilot Body Anodized Aluminum N/A
Buna-N -20 to 180°F
Pilot Gaskets / Diaphragm
Viton (optional) -20 to 400°F
Pilot Internal Valving 303 SST N/A
303 SST -70 to 600°F
Shaft
316 SST (optional) -70 to 600°F
303 SST -70 to 600°F
Bearing Blocks
316 SST (optional) -70 to 600°F
Bearings 440C SST -70 to 600°F
Buna-N -20 to 180°F
Seals
Viton (optional) -20 to 400°F
PVC -20 to 140°F
Displacer Acrylic (optional) -20 to 200°F
316 SST (optional for NACE) -70 to 600°F
Displacer Arm 302 SST -70 to 600°F
Vertical Hanger (Swivel) 316 SST -70 to 600°F
Vertical Displacer Extension
302 SST -70 to 600°F
Chain
Bronze
Gauges 316 SST (optional) N/A
316 SST liquid-filled (optional)
Aluminum
Torque Bar N/A
303 SST (Marine option)
Flapper Bar 303 SST N/A
Fulcrum Nylon N/A
Spring SST N/A
Aluminum
Spring Adjusting Knob N/A
303 SST (Marine option)
Page 5
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
Page 6
Page 7
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
Page 8
Page 9
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
1.5 Dimensions
1. 16.15” dimension based upon standard v ertical service configuration of 15” arm with a 12” lg. displacer. Other arm lengths and displacer sizes
are available upon request. 24.50” dimension based upon standard horizontal service configuration of 12.50” arm with a 12” lg. displacer.
Other arm lengths and displacer sizes are available upon request.
Dimension “F”
Body Size
Vessel Connection
2.00 3.00 4.00 6.00 8.00
Butt-Weld Sch. 40 6.00 - - - -
Sch. 80 6.00 - - - -
Sch. 160 6.00 - - - -
Sch. XXH 6.00 - - - -
Slip-on 6.00 - - - -
Screwed Male NPT 6.00 - - - -
Grooved 6.00 6.88 6.94 6.04 *
150# RF 6.50 6.56 6.56 6.50 *
150# RTJ 6.69 6.88 6.88 6.69 *
300# RF 6.81 6.75 6.88 6.94 *
300# RTJ 7.06 7.00 7.25 7.19 *
600# RF 7.19 7.12 7.50 7.62 *
600# RTJ 7.25 7.31 7.56 7.69 *
900# RF 8.00 9.63 10.13 * *
900# RTJ 8.06 9.69 10.19 * *
1500# RF 8.00 10.25 10.63 * *
1500# RTJ 8.06 10.31 10.69 * *
2500# RF 8.50 11.06 11.75 * *
2500# RTJ 8.56 11.13 11.81 * *
* Consult Factory.
Page 10
2.0 INSTALLATION
2.1 Assembly
When you receive your new Mallard model 3200 Level Controller, you should find the following pieces in
the shipping container:
• Controller
• Displacer
• Displacer Arm
Other miscellaneous pieces may be included as well, depending on the specifications for your
application.
2.2 Start-up
a. Rock the torque bar back and forth by hand to verify that the displacer arm is not resting against the
vessel nozzle. The displacer arm should be centered in th e nozzle. Adjust the balance spring
compression with the adjusting knob to position the displacer arm.
To raise the displacer arm, turn the adjusting knob CLOCKWISE (increasing spring compression). To
lower the displacer arm, turn the adjusting knob COUNTERCLOCKWISE (decreasing spring
compression).
b. Adjust controller proportional band (sensitivity) by sliding the fulcrum along the flapper bar. To
decrease the proportional band (increase controller sensitivity), loosen the thumb screw and slide
the fulcrum away from the pivot point (toward the pilot). Tighten the thumb screw when finished.
To increase the proportional band (decrease controller sensitivity), loosen the thumb screw and
slide the fulcrum toward the pivot point (away from the pilot). Tighten the thumb screw when finished.
Page 11
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
3.0 OPERATION
Figure 1
To INCREASE the liquid level control point, DECREASE BALANCE SPRING COMPRESSION. An
increase in liquid level causes an decrease in the relative weight of the displacer, thereby requiring less
opposing force to achieve balance.
Page 12
To DECREASE the liquid level control point, INCREASE BALANCE SPRING COMPRESSION. A decrease
in liquid level causes an increase in the relative weight of the displacer, thereby requiring more opposing
force to achieve balance.
1. Position fulcrum approximately ¼” from the torque bar snap ring, and slowly reduce spring
compression to allow the upper fluid to rise and submerge the displacer.
2. Once submerged in the upper fluid, slowly increase spring compression until an output
signal increase is obtained, then slowly remove compression again until the output signal
returns to zero. At this point, the controller is ready to control the lower fluid level.
To decrease the proportional band (increase controller sensitivity), loosen the thumb screw and
slide the fulcrum away from the pivot point (toward the pilot). Tighten the thumb screw when
finished.
To increase the proportional band (decrease controller sensitivity), loosen the thumb screw and
slide the fulcrum toward the pivot point (away from the pilot). Tighten the thumb screw when
finished.
Page 13
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
The model 3200 Liquid Level Controller can be set up as Right Hand Mount or Left Hand Mount. The
orientation of the level controller mounted to the vessel, while facing the front of the controller,
determines the mounting style, illustrated in Figure 5. If the controller is to be mounted on the right side
of the vessel, then it is considered “Right Hand”. If the controller is to be mounted on the left side of the
vessel, then it is considered “Left Hand”. The mounting orientation can be easily reversed in the field.
Disassembly:
1. Position controller case on controller body to achieve the desired mounting configuration,
and install the two hex head cap screws into the case mounting holes. Tighten to 6 ft-lbs of
torque.
2. Slide spacer on the shaft, then slide the level adjusting bar in place on the shaft. Make sure
that the level adjusting screw is positioned such that there is an equal number of threads
exposed above and below the level adjusting bar.
3. Snug up the two hex head cap screws on the level adjusting bar. Do not fully tighten yet.
4. Slide the torque bar onto the shaft temporarily to position the level adjusting bar. Position
the level adjusting bar so that the torque bar is parallel with the displacer arm when the
round tip of the level adjusting screw is touching the torque bar. Remove the torque bar
while holding the level adjusting bar in position, then tighten the cap screws to firmly secure
the level adjusting bar in place. Tighten the screw nearest the slotted end of the level
adjusting bar first.
Page 14
5. Slide the torque bar back onto the shaft. Make sure that the countersunk hole for the
balance spring upper retainer is facing down. Install the lock nut on the end of the shaft to
hold the torque bar in place.
6. Slide the flapper bar onto the pivot pin (see Section 3.5, Controller Action, to determine the
proper installation of the flapper bar for your application) and install the retaining lock nut.
The flapper bar must be free to pivot. Therefore, do not apply an excessive amount of torque
to the lock nut.
7. Install balance spring stud bolt and lower spring retainer. For left-hand mounting, the stud
bolt is installed on the right side. For right-hand mounting, the stud bolt is installed on the
left side.
8. Install the balance spring and the upper spring retainer. Engage the upper spring retainer
with the countersunk hole in the torque bar.
9. Apply compression to the balance spring with the spring adjusting knob.
Controller action is determined by the installation of the flapper bar, as shown in Figure 5. Control is
considered “Direct-Acting” when the controller output changes in the same direction as the liquid level.
For example, the controller output signal will increase as the liquid level increases, and vice versa.
Control is considered “Reverse-Acting” when the controller output changes in the opposite direction as
the liquid level. For a direct-acting controller, the flapper bar pivot point is on the same side as the
balance spring. For a reverse-acting controller, the flapper bar pivot point is on the opposite side as the
balance spring.
To convert the controller from Direct-Acting to Reverse-Acting, or vice versa, the following
procedure should be followed:
Page 15
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
3. Remove the thumb screw from the fulcrum, and replace the thumb screw into the screw
hole on the opposite side of the fulcrum.
4. Connect the flapper bar to the pivot pin on the opposite side of the controller housing.
5. Install the pivot pin lock nut to hold the flapper bar in place.
6. Adjust the balance spring compression with the adjusting knob.
Page 16
3.6 Snap Pilot Operation
A simultaneous action occurs as force from the flapper bar on the thrust pin “Y” is removed. When this
happens, the supply pressure will unseat the thrust pin and open the exhaust port in the pilot and ball “X”
will re-seat and close off the supply port. The difference in seating areas give this pilot its “snap” action.
Page 17
Model 3200 / 3201
Installation, Operation and Maintenance Instructions
4.0 MAINTENANCE
The model 3200 Level Controller is specifically designed to provide maintenance-free service in the
harsh environments found in oil and gas production and transmission facilities, and should last for
many years without any special maintenance requirements. Should leakage occur, replace the O-ring
seals. Refer to the parts list in Section 1.3 for ordering information on replacement parts and repair kits.
4.2 Troubleshooting
(continued)
Page 18
4.2 Troubleshooting (continued)
Page 19
Set the control signal
pressure at 45 psig.
Mallard 5100
Dump Valve Assembly
TP 00-06-T01C-001
Mallard 5100 Dump Valve Assembly
TP 00-06-T01C-001
MODEL 5100
Jan 2005
CONTENTS
1.0 GENERAL
3.0 MAINTENANCE
1.0 GENERAL
1.1 Model Number Information
1.2 Specifications
Page 2
1.3 Parts List
Page 3
Model 5100
Installation, Operation and Maintenance Instructions
Page 4
1.4 Dimensions
Page 5
Model 5100
Installation, Operation and Maintenance Instructions
2.0 INSTALLATION
1. Prior to valve installation, inspect the unit for damages which might have occurred during shipment and
handling. Remove any items covering the process connections of the valve. Inspect the inlet and outlet
connections to assure that no debris has become lodged inside the valve.
WARNING: Working pressure of control valve body does not necessarily reflect the shut-off
pressure of which the actuator is capable. Check actuator shut-off charts or call the factory.
3.0 MAINTENANCE
WARNING: System pressure must be bled off to 0 psig prior to any maintenance involving
disassembly of the valve or valve actuator.
3. Actuator Diaphragm
Inspect once a year
4. Body
Check for wear or damage every time the actuator is removed.
3.2 Troubleshooting
Valve will not open Pressure drop across valve seat Increase actuating air pressure to
is too great. 35 psig. If this does not solve the
problem, then the orifice is too
large. Consult pressure drop table
or contact factory.
Supply air leaking out of Diaphragm is worn out or torn. Remove pressure and
diaphragm housing breather plug disassemble. Tighten If diaphragm
during operation is damaged, replace. If nuts that
Diaphragm plates have worked hold diaphragm plates are loose,
loose and need to be tightened. tighten.
Page 6
Final Pressure Relief Valve
1250 PSIG Set Point
p/n: 64ME2M2FTA1250
TP 02-48-T01G-001
Section 9 – Control Panel and Instrumentation
Connect only the red extension wire to the red E Cooler Vibration Switch
thermocouple pigtail lead, and only the yellow
F Engine Coolant Thermowell
extension wire to the yellow thermocouple
pigtail lead. G Compressor Coolant Thermowell
N Ignition Wire
Note
Repeat these steps for the companion
vibration switch
! "#
" # !$
TP 02-32-T02A-001
Vibration Switch Mounting
TP 02-32-T02A-001
Description **
Series L1100 and L1200 Liquid Level Switches are float activated to
WARNING operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT valves or similar devices. This model screws directly into the vessel or can be
✔ Disconnect all electrical power to the machine. mounted via an external float chamber. It cannot be used with weld collar 15050375.
✔ Make sure the machine cannot operate during installation. Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
✔ Follow all safety warnings of the machine manufacturer.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
✔ Read and follow all installation instructions. L1200NDVOR series carry Canadian Registration Number OF1476.2.
✔ OBSERVE all pressure and electrical ratings and require- Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
ments for the devices and the operating environment. pneumatic input signal to cause an orifice to open or close allowing liquid
✔ BE SURE all pressure HAS BEEN REMOVED from the condensate to be drained from a pressure vessel. A pop up button indicates valve
vessel before opening any pressure connections. open/closed. Stainless steel versions available.
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Pressure Manual Valve
Inlet Port Operator
1/2 NPT 1-1/2 NPT Float travel between Operate 1/8 in.-27 NPT
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-5/8 in. w/ float at horizontal centerline
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
Weep Hole Valve Open/Closed
Union Indicator Button
Electrical installation to be done by
qualified person according to the NEC.
F Drain
Connection C
E D
Plug Seal G (dimension shown
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
NOTE: Dimensions are in inches and (millimeters)
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Direct Installation into the Wall of the positioned away from the tank wall.
Pressure Vessel 2. A tee is typically installed at the bottom of the lower 1 inch
1. Determine that the float travel is not pipe riser to allow draining of the float
obstructed by the coupling in chamber for servicing or replacement.
the vessel wall, internal Tank
Wall NOTE: A typical installation Float
baffles, etc. with Blocking and Bleed valves is Chamber
Do NOT use more than shown at right. Tank
Block
one arm extension P/N Valves
3. Install the L1200 or
15050395.
L1200N
2. BE SURE that the float Explosion proof Level
Level conduit seal in the 2 NPT connection Switch
and extension are tight Switch where required. of Tee
and that the lock washer is the float chamber.
in place. Bleed
BE SURE float travel Valve
3. Before installing the level is not restricted and that the Explosion proof
switch a suitable pipe thread sealant float is tight onto conduit seal
is recommended. Screw the unit directly into the threaded where required.
the float shaft.
connection in the wall of the pressure vessel. 4. To complete installation and
4. Be sure that the electrical connection is positioned at the wiring, follow the instructions for
bottom. For L1200N the 1/8 NPT pneumatic connection mounting directly into wall of the vessel and for wiring.
should be on top (the 1/4 NPT vent connection should be on
the bottom). See “Pneumatic models” section for further Pneumatic Models
instructions for the L1200N. 1. All pneumatic models
5. Make the electrical wiring connections according to operate on the vent Filter/Regulator
appropriate wiring diagrams for the alarm or shutdown principle. The Tank
New Dump Valve
system to be used. The electrical connection is 1/2-14 NPT. pneumatic signal Pneumatic Operator Assembly
p/n 15010216
Electrical wiring and conduit should be installed by qualified source MUST BE Signal
personnel according to the NEC. CLEAN AND DRY.
6. BE SURE all electrical connections are insulated and the The input pneumatic MURPHYGAGE®
cover is fully installed before reconnecting electrical power. signal must be
7. BE SURE all pressure connections are tight before regulated between 30
pressurizing the system. and 70 psi (207-483 L1200N
kPa) [2.07-4.83 bar].
Installation with a Weld If produced gas is used as the
Collar Tank Wall
signal source, it should be taken
1. The weld collar, P/N after gas passes through the final scrubber.
15050375, must be welded Weld Collar A suitable filter must be positioned before the L1200NDVO
into the wall of the to prevent liquids and/or particulates from entering the dump
pressure vessel according valve operator.
to code standards and NOTE: Check filter periodically for wear and tear and
good welding practices. elements that hamper the flow of the pneumatic signal.
L1200 2. All pressure connections must be tight and maintained tight
2. Follow above instructions
for installation directly into so as not to leak air/gas.
the wall of the pressure Explosion proof 3. Valve seat adjustment can be made if air/gas begins to leak.
conduit seal
vessel. where required. Care should be taken when adjusting as only slight movement
3. NOTE: Weld collar 15050375 can is necessary to stop the leakage; excessive force will bind the
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External L1200N
Hex Socket Set Screw
Float Chamber 15051098 • loosen for adjustment
• tighten after adjustment
CAUTION: USE “NON SPARKING TOOLING”.
Hex Adjustment Nut
• turn left until air Trip Cam (float down)
1. Install the float chamber 15051098 on the outside wall of the seepage stops • should be in
pressure vessel using 1 NPT piping. Position the 2 NPT • Caution: only slight this position
adjustment is needed—too • non-adjustable
threaded connection at the height where you want the level much will lock up mechanism
switch to operate. The 2 NPT threaded connection must be
Installation 00-02-0175 page 4 of 6
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation
As condensate rises in the scrubber, the float on
Typical/Scrubber/Separators
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter VESSEL
the dump valve pilot chamber. Once the pressure Minimum control
Rising Level Shutdown
enters the pilot chamber it forces the diaphragm L1200 (with snap-switch) pressure 30 psi
(207 kPa) [2.07 bar]
and valve stem forward thus opening the valve seat Air Supply Maximum
300 psi (2.07 MPa)
(valve open/closed indicator button pops out) and [20.70 bar]
releasing condensate through the valve stem and Explosion proof
conduit seal required
out the drain. As the condensate level drops, the for Class I. Div 1, not
Filter/Regulator
required for intrinsically
L1200NDVOR pneumatic valve closes to shut off safe or non-incendive L1200NDVOR
with MURPHYGAGE®
circuits like FWM TTD.
the pressure to the dump valve causing it to close. Dump Valve
Electrical Rising Operator
If for any reason the condensate continues to rise Level Minimum control pressure
Conduit 30 psi (207 kPa) [2.07 bar]
Trips Union
beyond normal dump levels, model L1200 DVO
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the DVU Series Dump Valve
4-1/2 in
(114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar].
2 NPT
Operating Temperature: 400°F (204°C).
2-11.5 NPT
1/2-20 UNF-2B
(4 places)
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.
Installation Instructions
Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before
mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes.
GENERAL INFORMATION
WARNING LISTED*
VS-7037N page 1 of 8
DIMENSIONS
VS2 VS2C
3 in. 4-3/4 in.
(76 mm) (121 mm) 3 in. 4-3/4 in.
Slotted (76 mm) (121 mm)
Sensitivity Slotted
Reset Adjustment Sensitivity
Push Reset Adjustment
4-19/32 in. Button Push
(116 mm) Plug 5-7/16 in.
(138 mm) Button Weatherproof
Strain Relief
Bushing
VS2EXRB
6 in.
(152 mm)
1/2 NPT
Conduit
2-1/2 in.
(64 mm)
4-1/2 in. 9-1/8 in.
(114 mm) (232 mm)
Mounting Centers 10-3/16 in. Mounting Centers
(259 mm)
VS94
6-29/32 in.
(176 mm)
Manual
7-9/64 in. Reset
(181 mm) Push-button 4-5/8 in.
(118 mm)
6-1/2 in.
(165 mm) 3/4 NPT
1-5/8 in. conduit fitting
(41 mm)
4 in.
(102 mm)
Mounting slot
5/16 x 9/16 in. 4 in. 6-1/2 in.
(8 x 14 mm) (102 mm) (165 mm)
4-places.
VS-7037N page 2 of 8
SPECIFICATIONS
VS2 and VS2C additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,
• Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas. up to 30 VDC.
VS2: Base mount • Remote Reset:
VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 Option Operating Current
AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable -R15: 350 mA @ 115 VAC
hold down clamps. -R24: 350 mA @ 24 VDC
• Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS94
VS2EX • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA
• Case: Explosion-proof and weatherproof aluminum alloy housing; types 4 and 12.
meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & • Conduit Fitting: 3/4 NPT conduit fitting connection.
D; UL and CSA listed.* • Normal Operating Ambient Temperature:
VS2EX: base mount. 0 to 140°F (-18 to 60°C).
• Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* • Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
2A resistive, 1A inductive, up to 30 VDC. resistive, 1A inductive, up to 30 VDC.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). • Heater (optional):
Option Operating Current
VS2EXR H15 .023 A @ 115 VAC
• Case: Same as VS2EX. H24 .12 A @ 24 VDC
• Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A • Remote Reset (optional):
resistive, 1A inductive, up to 30 VDC. Option Operating Current
• Remote Reset (optional): R15 .17 A @ 115 VAC
Option Operating Current R24 .36 A @ 24 VDC
-R15: 350 mA @ 115 VAC • Time Delay (optional):
-R24: 350 mA @ 24 VDC Option Operating Current Standby Current
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. T15 .360 A @ 115 VAC .01 A @ 115 VAC
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). T24 1.15 A @ 24 VDC .01 A @ 24 VDC
VS2EXRB • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from
• Case: Explosion-proof aluminum alloy housing; rated Class I, 5 seconds to 6-1/2 minutes (15 seconds per turn approximately).
Division 1, Group B hazardous areas.
• Snap-switch: 1-SPDT snap-switch with reset coil (option available for *CSA and UL listed with 480 VAC rating.
INSTALLATION
orientation should be on a horizontal plane or with the sensitivity adjustment
WARNING: STOP THE MACHINE AND DISCONNECT ALL pointing down. Sensitivity adjustment for model VS2 is covered by a plug.
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
The plug must be in place and tight to prevent moisture or dust intrusion.
The VS2 and VS94 series shock switches are sensitive to shock and
C-Clamp Installation (VS2C model only)
vibration in all three planes of motion - up/down, front/back and side/side.
Front/back is the most sensitive (The reset pushbutton is located on the A C-Clamp is supplied with the VS2C model only.
“front” of the unit). For maximum sensitivity mount the unit so that the The C-Clamp is shipped installed on the VS2C
front faces into the direction of rotation of the machine. (See Dimensions on but must be installed on the VS2EX and
page 2 for sensitivity adjustment location). VS2EXR switches.
The VS2 and VS94 Series must be firmly attached/mounted to the machine 1. The C-Clamp (B) will already be installed on C
so that all mounting surfaces are in rigid contact with the mounting surface a 1/4 in. (6 mm) thick steel mounting plate
of the machine. For best results, mount the instrument in-line with the (A). Bolt the VS2 switch to the mounting A
direction of rotating shafts and/or near bearings. In other words, the reset plate as illustrated — with four 5/16 in.
bolts, nuts, and washers. B
push button should be mounted pointing into the direction of shaft rotation
(see page 5). It may be necessary to provide a mounting plate or bracket to 2. The mounting location should provide
attach the VS2 and VS94 Series to the machine. The mounting bracket convenient access to the TATTLETALE® D
should be thick enough to prevent induced acceleration/vibration upon the push button (C).
VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See 3. The hardened set screw and nuts (D) are used to
illustrations on page 5 for typical mounting locations. tighten the switch to an I-Beam or cross member such as a
Sampson post of an oilwell pumpjack.
CAUTION: A dust boot is provided on the reset pushbutton
for all series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting
Continued on next page.
VS-7037N page 3 of 8
INSTALLATION Continued
All Models allow the machine to stop. Turn the sensitivity adjustment 1/4 turn
clockwise, (adjustment for VS94 and VS2EXRB models is located within
WARNING: STOP THE MACHINE AND DISCONNECT ALL
the box, see DETAIL “B”).
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE
1. Firmly secure the unit to the equipment using the base foot mount or OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.
C-Clamp if applicable. See C-Clamp Installation page 3.
For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson Depress the reset button and restart the machine. Repeat this process until
post or walking beam. See Typical Mounting Locations page 5. the unit does not trip on start-up. DETAIL “B”
2. Make the necessary electrical connections to the vibration switch. See 5. If the instrument does NOT trip on start-
Internal Switches, page 6 for electrical terminal locations and page 7 for up, stop the machine. Turn the sensitivity Less Sensitivity
Sensitive adjustment
typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT adjustment 1/4 turn counter-clockwise.
RATINGS OF THE CONTACTS. Follow appropriate electrical Repeat the start-up/stop process until the
codes/methods when making electrical connections. Be sure that the run of instrument trips on start-up. Turn the
electrical cable is secured to the machine and is well insulated from sensitivity adjustment 1/4 turn clockwise
electrical shorting. Use of conduit is recommended. (less sensitive). Restart the machine to
NOTE: If the electrical cable crosses a pivot point such as at the pivot of verify that the instrument will not trip on More Sensitive
the walking beam, be sure to allow enough slack in the cable so that no start-up.
stress is placed on the cable when the beam moves. 6. Verify that the unit will trip when abnormal shock/vibration exists.
If conduit is not used for the entire length of wiring, conduit should be
used from the electrical supply box to a height above ground level that VS94 Time Delay Adjustment
prevents damage to the exposed cable from the elements, rodents, etc. or 1. Apply power to the time delay circuit. (see
as otherwise required by applicable electrical codes. If conduit is not page 7 for time delay circuit). The time delay function will be initiated.
attached directly to the VS2 and VS94 Series switch, use a strain relief 2. Time the length of the delay with a watch. Let time delay expire. After it
bushing and a weatherproof cap on the exposed end of the conduit. A expires, the override circuit will de-energize the solenoid, allowing the latch
“drip loop” should be provided in the cable to prevent moisture from arm to trip. A clicking noise is heard.
draining down the cable into the conduit should the weathercap fail. WARNING: REMOVE ALL POWER BEFORE OPENING
ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A
Sensitivity Adjustment QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE
IT CONFORMS WITH NEC AND LOCAL CODES.
WARNING: REMOVE ALL POWER BEFORE OPENING
THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A 3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.
QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE NOTE: Allow 30 seconds bleed-time between turning the
SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO power “OFF” and “ON”.
NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND
4. Locate the time adjustment pot (DETAIL “C”). DETAIL “C”
CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.
The time is factory-set at the lowest setting (5
All models of the VS2 and VS94 Series cover a wide range of sensitivity. seconds approximately). To increase time,
Each model is adjusted to the specific piece of machinery on which it is rotate the 20-turn pot clockwise as needed
Turn to
installed. After the switch has been installed in a satisfactory location (see (15 seconds per turn approximately). decrease
page 5) the sensitivity adjustment will be increased or decreased so that the 5. Repeat the above steps as necessary to
switch does not trip during start-up or under normal operating conditions. obtain desired time delay.
Pot
This is typically done as follows: Turn to
NOTE: An external time delay can be used increase
1. REPLACE ALL COVERS, LIDS, AND with the remote reset feature of the VS2EXR
ELECTRICAL ENCLOSURES. series to provide a remote reset and override of the trip
2. Press the reset push button to engage the magnetic latch. To be sure the operation on start-up. Time delay must automatically disconnect after
magnetic latch has engaged, observe latch equipment start-up.
through the window on the VS2 and DETAIL “A”
VS2C (see DETAIL “A”). On the
VS2EX, VS94 series the reset button Reset Push button
VS-7037N page 4 of 8
TYPICAL MOUNTING LOCATIONS
These are typical mounting locations for best operation. Other mountings are possible.
NOTE: See Installation section on page 3.
2-Throw Balance-Opposed Compressor Pumping Unit
Reset
NOTE: If installing on
cylinders, 2 vibration/shock Reset
switches are recommended-
1 for each cylinder.
Reset
Reset
Engine Compressor
Turbine Centrifugal Reset
Compressor
Reset
VS-7037N page 5 of 8
INTERNAL SWITCHES
NC NO COM
Ground
NO1 NC COM NO2 Terminal
SPDT Snap-Switch
SPDT Switch Terminals
NC NO COM NC NO COM
Ground
Ground Terminal
Terminal SPDT NC NO COM
SPDT Snap-Switch Snap-Switch Optional SPDT
Snap-Switch
(VS2EXRB only)
VS94
Time Delay and/or
Remote Reset
SPDT Terminal (Optional)
Snap-Switch
NC NO COM Ground
Terminal
NC NO COM Sensitivity
Adjustment
SPDT
Snap-Switch
Heater Board
Terminal (Optional)
VS-7037N page 6 of 8
ELECTRICAL
WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.
CD Ignition Resistor
2 To good (100 Ω, 3 Watt)
Resistor engine ground
(100 Ω, 3 Watt)
CD Ignition
N.O. N.C. COM
1
CD Ignition
1
To good
engine ground
VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Typical Wiring Diagram for Electric Motors Typical Wiring Diagram for Distributor Ignition or Diesel
Contacts shown Switch Terminals Contacts shown
Switch Terminals in the RESET position NOTE: Terminal N.O. is in the RESET position
NOTE: Terminal N.O. is N.O. N.C. COM
N.O. N.C. COM terminal NO1 on models
terminal NO1 on models (see Note)
(see Note) VS2 and VS2C.
VS2 and VS2C.
Ignition
Switch
L1 L2 L3 Push-button
Station
Ammeter
HC
Diesel Fuel
Shutoff Valve Ignition Coil Distributor Battery
H A
VS-7037N page 7 of 8
SERVICE PARTS
VS-7037N page 8 of 8
TTD Series SELECTRONIC®
Fault Annunciator
Installation and
Operations Manual
TTD-98055N
Revised 12-05-04
Section 50
(00-02-0329)
TTD-98055N page 1 of 36
Table of Contents
Contents page #
Warnings and Limited Warranty ................................2
Description .................................................................3
WARNING! Optional features ....................................... .........3
Display Head ......................................................3
Power and Control Inputs/Outputs ......................3
FW MURPHY has made efforts to ensure the reliability Installation Diagrams TTD-2 (50080718) ................4/5
of the TTD System and to recommend safe usage Typical Installations for PSU-2 ..................................6
practices in system applications. Please note that in Neg Grnd/CD IGN Power Inst .............................6
any application, operation and controller failures can DC Power/DC IGN Inst .......................................6
occur. These failures may result in full control outputs Alarm and Pre/Postlube Functions ............. .........7
or other outputs which may cause damage to or Tachometer Hourmeter Functions ...................... .7
unsafe conditions in the equipment or process con- Setup A Output Mode Configuration . ................. .8
nected to the TTD system. Input Terminal Block Connections .......................8
TTD G-Lead Choke Installation ...........................9
Good engineering practices, electrical codes, and
Backup Battery Replacement ............................10
insurance regulations require that you use independent
The TTD System .......................................................11
external protective devices to prevent potentially dan-
The Intuitive Display .................................................12
gerous or unsafe conditions. Assume that the TTD sys- Front Panel Key Functionality ............................12
tem can fail with outputs full on, outputs full off, or that TTD Keypad Features ..............................................13
other unexpected conditions can occur. Shutdown Mode ...............................................13
Please read the following information before Run Mode ........................................................13
installing the TTD annunciator. Setup Mode Menus ...........................................14
This installation information is intended for all TTD Setup Mode Edit Settings .................................14
Operational Display Messages ................................15
Series models. A visual inspection of this product
Backlight Used as Status Indicator ........................16
before installation for any damage during shipping is
Configuration Setup of Navigational Screens..........17
recommended.
Access During Run and Shutdown .................... 18
Disconnect all power and be sure machine is inopera- Password Protected Settings ............................18
tive before beginning installation. Inactivity Time Out ............................................18
Installation is to be done only by qualified technician. Setup 1 Timers Setup ..................................18/19
Setup 2 Sensor Mode .......................................20
Observe all Warnings and Cautions at each section in Emulation Template Settings .............................20
these instructions. Terminal Block Configuration for DD-20 .............21
Terminal Block Configuration for DD-40 .............21
Device shall be wired in accordance with Class I,
Setup 3 Sensor Type ........................................22
Divisions 1 & 2 wiring methods.
Setup 4 Remote Reset Remote Lockout
This equipment is suitable for use in Class I, Division 1 and No-Flow Enable Delay ...........................22/23
& 2, Groups B, C, and D hazardous Areas. Setup 5 Hourmeter ...........................................24
Setup 6 Speed Calibration ................................24
WARNING–Explosion Hazard–Substitution of compo-
Setup 7 Tachometer Overspeed Options ...........25
nents may impair suitability for Class I, Division 2.
Setup 8 Tachometer Underspeed Options .........25
Please contact FW MURPHY immediately if you have Setup 9 Communications Settings .....................25
any questions. Setup A Output Mode .......................................26
Setup B Unit ID ................................................26
Setup C Factory Default ...................................27
Voltage Readings .............................................27
Warranty Software Version ...............................................28
A limited warranty on materials and workmanship Special Features (Password Code) ..................28
is given with this FW Murphy product. Modbus Register Addresses ...........................29/30/31
Specifications ...........................................................32
A copy of the warranty may be viewed or printed by going to
TTD Numbering and Replacement Parts .................33
www.fwmurphy.com/support/warranty.htm
Dimensions ...............................................................34
TTD Worksheet ....................................................35/36
TTD-98055N page 2 of 36
Description
• Running hours
Optional Features:
• Pre/Post lube timed functionality
• Tachometer w/ Overspeed and Underspeed setpoints
TTD-98055N page 3 of 36
Installation Diagram TTD-2 (50080718) page 1
TTD-98055N page 4 of 36
Installation Diagram TTD-2 (50080718) page 2
TTD-98055N page 5 of 36
Typical Installations for PSU-2
Murphy M5081FS-B
Fuel Valve w/ DC coil Valve GND
Coil TX
Ground Switch 2 (Note) Switch 1
RX
B
Common
Chassis A
Ground MPU
AUX
10 9 8 7 6 5 4 3 2 1 ALR
FV-
FV+
Customer supplied DC
10-32VDC Power Supply
IGN Shutdown Relay GND
DC
IGN SHDN
IGN
Common Chassis
Ground
Note: TTD unit shown for typical DC setup. Refer to SETUP A for
options on output actions. Upon fault shutdown both (FV-) and
(IGN SHDN) open to ground if SETUP A is set to 1.
They both conduct to ground on nornal run mode. PSU-2 Power Supply
TTD-98055N page 6 of 36
Typical Installations for PSU-2 continued
Note: TTD annunciator is supplied with the (ALR) output which will con-
duct to ground upon detecting an ALARM condition to turn on an audible
horn, light or other interface device. This output will open when either
the [RESET] key is pressed or the ALARM condition returns to normal. The
ALARM message will remain on the display until the [RESET] key is PSU-2 Power Supply
pressed acknowledging the alarm.
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
TTD-98055N page 8 of 36
Typical Installations for PSU-2 continued
2. Lay the wire across the inside of the choke as shown (2).
2.
3. Wrap the wire around the outside of the choke as shown (3).
4. Wrap the wire back across the inside of the choke as shown.
The wire should lie next to the wire from step 2 (4).
3.
4. 5.
TTD-98055N page 9 of 36
Typical Installations for PSU-2 continued
TTD-98055N page 10 of 36
TTD System
TTD-H Annunciator
SENSORS
DCS or Computer
SUPPLY
VOLTAGE Running
MConfig Pro
software
SPEED
INPUT
TTD-98055N page 11 of 36
The Intuitive Display
Icons Description
The TTD features a static LCD display (A) with backlight (external DC
is required). The operating temperature is between -40° to 85°C. RUN – Run mode
The applicable icon and number (B, C and D) will be displayed to clari- RPM – Screen Value
fy the display readings or alert the operator to an operating condition. HOURS – Screen Value
TYPE – Channel Type Configuration
(A) LOW BATT – Low Battery Warning (displayed if the condition
exists)
The operator can interface with the TTD Annunciator in one of two ways. One is via the Front Panel keypad.
The second way an operator can interface is with the Murphy MConfig® software. This provides the user with a
Template displaying the TTD Annunciator setup and status by reading the Modbus registers. Setup selections
can be made and the configuration saved to file for future reference. The software is free and can be down-
loaded from www.fwmurphy.com
TTD-98055N page 12 of 36
TTD Keypad Features
Note: Because the keys have more than one function depending on the operational mode the system is in at the time,
the following TTD Keypad Functionality blocks indicate the keypad action seen if that key is pressed.
Shutdown Mode
NOTE:
The LOW BATT icon can show in any mode if the battery charge is low.
(A)
SHUTDOWN indicates the TTD identified a fault condition and alerts the operator
with cause of shutdown code.
(A) The current condition on the display is: the SHUTDOWN icon is on.
Key Function
Read Hours (B) Shows the operation hours for the displayed History record*.
(B)
Setup/Enter Press and hold the key for 5 seconds to access the Setup Menu:
The model number displays(C) and then the SETUP icon displays (D).
For more information, see the Setup Mode or Setup Screens.
Up Arrow Shows the previous History record (E)*.
(C) Down Arrow Shows the next History record*.
Reset Press [RESET] to start the Run Mode. For more information,
refer to the Run Mode.
* When not in the Setup Mode. History contains records for last 10 shutdowns and last 4 alarms.
(D)
(E)
Run Mode
(F) The condition on the display are: the RUN and RPM icons show and the ALARM icon
may be on.
TTD-98055N page 13 of 36
TTD Keypad Features continued
(I)
Key Function
Setup/Enter If the unit is in SETUP 0, pressing [ENTER] exits the unit from the
Setup Mode. If the unit is in any other Setup, pressing [ENTER]
accesses the sub-menu for that Setup. For more information,
review Setup Mode – Edit Settings or Setup Screens.
Up Arrow Press [UP ARROW] to navigate to the next menu.
Down Arrow Press [DOWN ARROW] to navigate to the previous menu.
Reset/ESC Press [ESC] to exit from the Setup Menu and return to the
operational display for the current mode.
Stop If the system is in Run Mode, pressing and holding the [STOP]
key for 2 seconds will begin the Shutdown sequence.
Key Function
Setup/Enter Press [ENTER] to exit or advance a Setup menu and save changes.
Up Arrow Press [UP ARROW] to increment the value to the maximum range.
Holding the key accelerates the incrementing action.
Down Arrow Press [DOWN ARROW] to decrement the value to the minimum
range. Holding the key accelerates the decrementing action.
Reset/ESC Press [ESC] to exit or advance the Setup Menu without saving
your changes.
Stop If the system is in Run Mode, pressing and holding the
[STOP] key for 2 seconds will begin the Shutdown sequence.
TTD-98055N page 14 of 36
Operational Display Messages
Pre-lubrication Timer Reading Several messages display during the start-up and run sequence. This tutorial
shows the screens that will display as the system starts.
With the unit in shutdown state and ready to start, press the [RESET] key. If
Class A inputs are not faulted, and the unit is equipped with the Pre/Post
Lube option, the unit goes into the PreLube cycle. If the unit does not have
the PreLube option, it will go to the B1 Timer display.
(A)
(A) Lube Timer 5 shows the remaining time on the cycle and the LUBE icon
B1 Timer Reading
shows on the display.
The PreLube cycle can be completed either by the timer reaching “zero,” or
the operator pressing [TIMER 0]. Pressing the [TIMER 0] key will zero the time
on the active visible timer only; all other active undisplayed timers will remain
(B) the same.
B2 Timer Reading
(B) Once the PreLube cycle completes, the outputs change state, and the B1
and B2 timers start. This display shows TIMER 1 as the remaining B1 time
counts down.
NOTE: If this is a TTD unit with optional Tachometer, the display alternates
between the active TIMER and RPM readings. If the TTD unit does not have
(C) Tachometer, the active TIMER reading alternates with the HOURS reading.
RPM Reading - Shows RPM**- Run Mode (C) Once the B1 Timer finishes, any time remaining on the B2 timer will show
in the display and the TIMER 2 icon will be visible in the lower right hand corner
of the display.
(D) On TTD models supplied with tachometer, once the B1 and B2 timers
have expired, the unit goes to a normal Run Mode. Both the RUN and RPM
(D)
icons will be visible, and the display gives the RPM reading. TTD units without
the Tachometer display the HOURS reading.
(E) Any conditions such as LOW BATT or ALARM alert the operator by having the
icon show on the display.
LOW BATT indicates low voltage on the Backup battery, and may indicate it is
(E)
time to replace the battery.
Ignition Delay Timer Reading
(F) At the detection of a fault, the TTD starts the shutdown sequence. The
ignition delay timer shows the time remaining on the timer before the ignition
is grounded or turned off. In addition, the fault channel shows on the left side
of the display and flashes.
(F)
(G) If the TTD is equipped with the Pre/Post Lube option and there is time
Post-lubrication Timer Reading remaining in the sequence, the POSTLUBE icon and the TIMER 6 icon displays
showing the remaining time on the timer.
( H ) When the PostLube time counts down, the Fault Channel numeric dis-
play moves to the right. The HISTORY icon is visible and the current shutdown is
(G) indicated in the lower right hand corner by 01.
This is the only time History records are available from the Front panel.
Shutdown Code - Shows Channel Tripped
History records can be read via the Modbus registers at any time.
(H)
TTD-98055N page 15 of 36
Operational Display Messages continued
(J) If this is a TTD unit with Tachometer option, and the unit is in the Run
Mode, when the [READ HOURS] key is pressed, the display shows the run-
ning hours for 5 seconds. The display then returns to the RPM reading (K).
(J)
(L) Push the [TEST] key to start the Test Timer for up to 5 minutes. The TEST
Run Mode Showing RPM Reading icon shows in the display.
Test Mode allows the operator to simulate faults without the outputs chang-
ing state. In Test Mode, all other functions operate normally. Faulted inputs
display, but the system is not shutdown and the ALARM is not turned on.
When more time is needed to simulate inputs, the operator can press [TEST]
(K)
again for up to an additional 5 minutes of time.
Test Timer Reading Press [RESET] to reset the fault and then press the [TIMER 0] to exit the Test
Timer. These shutdowns override Test Mode:
- Emergency Shutdown (47,48)
- Overspeed (50)
- Manual Stop (52)
(L) - Underspeed (51)
- Loss of Ignition (49)
Alarm Code - Shows the Channel Tripped
- Optional Additional ESD, if chosen as ESD
If Class "C" functions are used, they will need to be bypassed to test other
sensors. When exiting Test Mode with Class "C" functions, press the [RESET]
and [TIMER 0] keys simultaneously.
(M)
(M) In an alarm situation, the ALARM icon is turned on and
the alarm point or channel displays. If the unit is equipped
(N) with a Tachometer option, the active point or channel alter-
Fault Codes Description nates with the running hours at the time of the alarm.
1-48 Indicates the input that has faulted or alarmed If a fault is detected or an alarm occurs, the appropriate
49 Loss of Ignition (When the CD ignition falls below fault codes display (N).
90 VDC± 10%, the firmware activates the fault)
50 Overspeed Backlight used as Status Indication
51 Underspeed If AC or DC power is connected the backlight function-
ality is implemented on Div. 2 power supplies.
52 Manual Stop
Run Mode – The backlight will be yellow under this
60 Watchdog Timer condition.
61 Loss of SPI Link Shutdown Mode – The backlight will turn red under this
condition. When a shutdown fault is detected, the back-
light will blink. The backlight blinking will continue for 5
minutes, and can be aborted if the user presses any key.
After 5 minutes, the backlight stays red. During manual
shutdown sequence the backlight will be red.
TTD-98055N page 16 of 36
Configuration / Setup of the TTD Annunciator
E
A
F G
D C
(H)
TTD Setup and Navigational Screens
The TTD Annunciator can be setup by using the Front Panel.
Setting up the TTD from the Front Panel requires using the following keys:
(A) [SETUP or ENTER]
(B) [UP ARROW]
(I) (C) [DOWN ARROW]
(D) [ESC (ESCAPE) KEY]
The Setup Mode can be entered from either RUN or SHUTDOWN. However, settings
can only be changed when the SETUP icon is blinking.
Easy reference to Timer information (E), Sensor Types (F), and Setup Numbers
(G) is provided on the Front Panel.
(J) To enter the Setup Mode, press the [SETUP/ENTER] key (A) and hold until the
display shows HOLD (H). Continue to press the [SETUP/ENTER] key until the
model number is displayed.
The HOLD display counts down for 6 seconds, shows the (I) model number for
3 seconds and then shows (J) SETUP 0 to indicate the unit is in Setup Mode.
Press the [UP ARROW] (C) or [DOWN ARROW] key (B) to move through the
(K) Setup values.
After selecting a different Setup to view, press the [SETUP/ENTER] key to dis-
play the current configuration of that setup value.
To change a setting, press [SETUP/ENTER] again to access the menu choices.
Enter changes by using the [UP ARROW] or [DOWN ARROW] key. The only
(L) time a new value can be entered is when the Setup icon is blinking.
Press the [SETUP/ENTER] key again to save the new value. The display will
show SAVE (K) for a few seconds and then return to the Setup menu.
To exit without saving the change, press [ESC]. Press [ESC] again to exit from
the Setup Mode completely. The display will show ESC (L) and then return to
the operational screen.
TTD-98055N page 17 of 36
Configuration / Setup of the TTD Annunciator continued
(T)
Timer 7 Delay Before No-Flow Shutdown
When an internal input detects a No-Flow condition, the Channel number that
detected the condition is displayed along with Timer 7 and its countdown.
If Timer 7 countdown expires the TTD will begin the shutdown sequence.
(T) Shows the Timer 7 display during No-flow delay before shutdown.
(U) (U) Shows Setup 1 – Timer 7 menu.
Timer 7 will not be armed until Timer 1 has expired. During Timer 1 count-
down, the channels enabled as No-Flow (CH41 - CH44) will be ignored.
Setting Timer 7 to zero (Ø) will cause an immediate shutdown when Timer 1
has expired If No-Flow is detected on any of the four enabled channels.
To enable or disable the No-Flow function use SETUP 4b thru 4E.
NOTE:
During Run Mode if more than one Timer is active at the same time, the Timers
will be displayed by the TTD in the following priority:
1. Timer 3
2. Timer 1
3. Timer 2
4. Timer 7
Timers not active during the Run Mode will not occur at the same time.
TTD-98055N page 19 of 36
Configuration / Setup of the TTD Annunciator continued
Once the unit is in Shutdown Mode, enter SETUP 2 and choose from one of the
eight pre-configured “Emulation Template Settings (E).” Review the template set-
tings in the first column of the Emulation Table and enter that number to select the
template (F).
Emulation Table
(E)
B1 B2 Over Remote Remote Local Remote
TEMPLATE SETTINGS Class A Class C
Lockout Lockout speed Reset Lockout ESD ESD
0 O n ly w h e n S E T U P 2 is s e t t o " 0 " c a n in d iv id u a l c h a n n e ls b e s e t in S E T U P 3
1 TTD Default N/A N/A (1-46) N/A N/A (45*) (46*) (47)**) (48**)
32 (1-15,
2 TTD Mark II 8 (16-23) N/A 4 (41-44) N/A (45*) (46*) (47)**) (48**)
24-40)
31 (10-30,
3 TTD Mark III 9 (1-9) N/A 4 (41-44) N/A (45*) (46*) (47)**) (31**)
32-40, 48)
Mark IV,
4 TTD 15 (1-15) N/A 25 (16-40) N/A N/A (45*) (46*) (47)**) (48**)
LCDT
Mark IV,
5 TTD 15 (1-15) N/A 25 (16-40) 4 (41-44) N/A (45*) (46*) (47)**) (48**)
LCDT+
6 TTD Generic 16 (1-16) 4 (17-20) 20 (21-40) 4 (41-44) N/A (45*) (46*) (47)**) (48**)
11 (20-27,
20 DD-20 Altronic 8 (10-17) N/A N/A N/A (45*) (46*) N/A N/A
30-32)
16 (10-17, 24 (30-37,
40 DD-40 Altronic N/A N/A N/A (45*) (46*) N/A N/A
20-27) 40-47, 1-8)
* - If Remote Reset and Remote Lockout are selected in SETUP 4, any previous setting on channel 45 and 46 will be overridden.
** - Channel 47 and 48 are defaulted to Class ESD which means they will override the Te s t function and shutdown the unit.
They can be changed if desired.
( ) - numbers in parenthesis indicate terminal/channel numbers. The number in front of the () is the number of points in that template.
Note: When using the Altronic DD20 or 40 Emulation in a non-tachometer TTD, the overspeed channel must be configured.
TTD-98055N page 20 of 36
Configuration / Setup of the TTD Annunciator continued
(G) After selecting and saving a template, any point can be reconfigured by chang-
ing a single channel in SETUP 3. To do this, return to SETUP 2 and enter "0" as
the template setting (G). The points on the template originally selected are not
changed with this action. Next, go to SETUP 3 and change channels, as neces-
sary, to the preferred configurations.
(H) NOTES:
Terminals 45 & 46 are enabled in SETUP 4 for Remote Reset and Remote
Lockout functionality. If they are not enabled, they can be configured the same
as the other points. If they are enabled, they will override any previous setting.
Remote Reset can only be used in terminal 45 and Remote Lockout can only be
used in terminal 46.
(I)
Terminals 47 and 48 are defaulted to Class ESD. This means they will override
the Test function and Shutdown the unit. The functionality on these channels
can be changed, if desired.
When Template 20 is selected (H), the channel assignments will duplicate the
DD20 (J). Remaining channels are configured as inactive, but can be modified in
SETUP 3 once SETUP 2 is set to “0.” This also applies to Template 40 (K); with
the exception of channels 50 to 57 are assigned to TTD terminals 1 to 8.
If Template 20 or Template 40 is used in a unit without the tachometer option,
the overspeed channel must be configured.
(J) TTD
TTD Terminal
TerminalBlock Configuration
Block NO/NC forNO/NC
Configuration DD-20 for DD-20
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24
25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36
37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48
TTD-98055N page 21 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
PASSWORD PROTECTED
TTD-98055N page 22 of 36
Configuration / Setup of the TTD Annunciator continued
(G)
Setup 4 - continued
No-Flow Switch Transition Time
Use SETUP 4b thru 4E to set No-Flow switch transition times.
Digital input channels 41 to 44 can be configured for detecting a transition of
the switches on a divider block of a compressor system. The channels are
(H) scanned to determined if a transition has occured in an acceptable time. The
time range settings are from 0 to 59 seconds. (The default setting is zero).
(G) SETUP 4b is the No-flow screen for CH41
(H) SETUP 4C is the No-flow screen for CH42
(I) SETUP 4d is the No-flow screen for CH43
(J) SETUP 4E is the No-flow screen for CH44
(I)
Setting the value to 0 (zero) on any channel will disable the No-flow function
for that channel and allows SENSOR MODE (SETUP 2) or SENSOR TYPE
(SETUP 3) to determine the Sensor channel functionality.
A non-zero value enables No-flow function for that channel and defines the
timeout for the channel. Enabling No-flow function overwrites the channel
SENSOR TYPE or SENSOR MODE configuration (reserves the channel only
(J)
for No-flow use).
The Test Mode will be ignored if the No-flow is enabled for the channel.
Because these inputs are always in transition, the inputs are always tested for
open and close.
NOTE:
Use SETUP 1 to configure (TMR7) Timer 7 delay before No-Flow shutdown.
TTD-98055N page 23 of 36
Configuration / Setup of the TTD Annunciator continued
(K)
PASSWORD PROTECTED
Setup 5 - Hourmeters
(K) This setup is for reading and/or resetting the hourmeter. There are two sepa-
rate hourmeters:
(L) - Hourmeter 5A can be reset.
- Hourmeter 5B is the TTD internal hourmeter and keeps track
of total RUN HOURS.
(L) 5A Hourmeter Setting. Range 0 to 65535 hrs. (This hourmeter can be reset.)
M) 5B Product Life Timer. Range 0 to 65535 hrs. (7.48 years non-stop. This
(M) hourmeter cannot be reset.) The Product Life Timer reading can also be
accessed through the Modbus or via the Setup menu.
Note: The hourmeter registers are in the display head not in the power supply,
and are not reset by changing the power supply.
(N)
PASSWORD PROTECTED
TTD-98055N page 24 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
(C)
(E)
(H)
2 - 19200,N,8,1
3 - 19200,N,8,2
4 - 38400,N,8,1 (only if the pulses/rev setting is greater than 16.5)
5 - 38400,N,8,2 (only if the pulses/rev setting is greater than 16.5)
TTD-98055N page 25 of 36
Configuration / Setup of the TTD Annunciator continued
(I)
PASSWORD PROTECTED
(J) There are four choices (J), terminals are shown in shutdown state:
GND “0”
TX Setting FV - IGN SHDN
RX “1”
B
“2”
0 Closed Closed
A
MPU “3” 1 Open Open
AUX
ALR 2 Open Closed
FV- “0”
FV+ “1” 3 Closed Open
DC
GND “2”
IGN SHDN
“3” Table Note: Closed indicates a closed to ground state and open indicates an
IGN
open to ground state when the TTD unit is in Shutdown Mode.
(K) Use the [UP ARROW] or [DOWN ARROW] key to select the Output Mode
setting. Press [ENTER] to save the setting.
(K)
(L)
TTD-98055N page 26 of 36
Configuration / Setup of the TTD Annunciator continued
(A)
PASSWORD PROTECTED
(D)
CAUTION:
Executing SETUP C resets all settings, registers, and hours. Shutdown and
alarm histories will also be erased.
(E)
Voltage Readings
(E) The internal backup battery, external DC, and ignition voltage readings are
available in the VOLT menu after SETUP C. These readings are updated
approximately every 4 seconds and are read-only.
(F) Press the [ENTER] key to view each of the readings:
- Internal Backup Battery voltage (F)
- External DC (G)
- Ignition Voltage, peak, if the ignition is wired to the TTD unit (H)
(G) If Internal Backup Battery, External DC, and CD Ignition are connected and
operational, power for the TTD has the following priority:
First - External DC is used unless voltage falls below 9VDC,
Next - CD Ignition is used unless peak voltage falls below 90VDC,
Next - Internal Backup Battery is used when no other voltage is present.
(H)
NOTE:
The TTD will operate normally under Internal Backup Battery power except
communication functions and backlight will be disabled.
If Underspeed (pg.25) and/or Loss of Ignition (pg.24) are enabled, the TTD may
Shutdown when CD Ignition is not present. The tolerance for CD Ignition
detection ±10%.
TTD-98055N page 27 of 36
Configuration / Setup of the TTD Annunciator continued
(I)
Software Version
The Version menu (I) offers a quick and easy way to check the firmware ver-
sions in the TTD components.
To verify the current firmware, press [ENTER] to access the Version SETUP H
or SETUP P. Press [ENTER] the first time to view SETUP H. Pressing [ENTER]
(J)
a second time reaches SETUP P.
SETUP H indicates the software version in the Display Head. In this sample (J),
the version is 6.3. (Read 6 point 3)
SETUP P indicates the software version in the Power Supply. In this sample
(K)
(K), the version is 6.2. (Read 6 point 2)
(L)
Special Features (Password Code)
To view and/or change the code, press and hold the [READ HOURS] key while
the TTD is powered up (L).
Set the code by pressing the [UP ARROW] and [DOWN ARROW] keys in the
range of 0 to 99.
Entering a code Ø, disables the password protection. All the menus protected
can be accessed for read and write without restrictions and the Entry Code will
be disabled.
Pressing the [SETUP/ENTER] key saves the code.
TTD-98055N page 28 of 36
Communications
Communication Port
A single bi-color (GREEN/RED) LED will be provided to give visual indication of active transmit and receive traffic. Only
one connection will be active at any time.
Interface: Factory configured for RS485; field-selectable for RS232 or RS485.
Baud/Configuration: 9600, 19.2K, 38.4K(*);N,8,1;N,8,2 (setup configuration is in SETUP 9)
Protocol: Modbus (Slave)
Connection: There will be 2 screw terminal connectors for RS485.
These will be printed or labeled as A and B.
There will be 2 screw terminal connectors for RS232.
These will be printed or labeled as RX and TX.
There will be 1 screw terminal common for both ports.
This will be printed or labeled as GND.
(*) 38.4K Baud will not be available when IGN input is selected as the source for RPM calculations. When MPU is selected, this feature is available for selection.
TTD-98055N page 29 of 36
Communications continued
TTD-98055N page 30 of 36
Communications continued
Address Description Type Min Value Max. Value Default Value
40,085 Test Timer Setting (TMR3) R/W** 0 300 300
40,086 Life Timer R - - -
40,087 TTD-H Firmware x10 R - - -
40,088 PSU-X Firmware x10 R - - -
40,089 PSU Type R - - -
120- Base Model + No Flow
121- Base Model + Tach + No Flow
122- Base Model + Lube + No Flow
123- Base Model + Tach + Lube + No Flow
124- Base Model
125- Base Model + Tach
126- Base Model + Lube
127- Base Model + Tach + Lube
TTD-98055N page 31 of 36
Specifications
TTD-98055N page 32 of 36
TTD Numbering System