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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

©2008 Baker Hughes Centrilift. Centrilift, Canteslope, and AutographPC are all registered trademarks of Baker Hughes, Inc.

HPump is a trademark of Baker Hughes, Inc.. All rights reserved. Printed in the U.S.A. CEN-08-14530 Revised 02-08

IOM Manual Revision Date: Feb. 2008 Page Number: 2 of 34

Table of Contents Topic Page Introduction 5 Section 1 – Health, Safety, and Environment Considerations 5

A. Installation Concerns 5 B. Operation Concerns 5 C. Maintenance Concerns 5 D. Explosive and Hazardous Atmosphere Concerns 6

Section 2 – Equipment Component Descriptions 6

A. Overview 6 B. Skid 7 C. Driver 7

I. Driver Coupling 7 D. Horizontal Thrust Chamber 8

I. 1.XE / 1.XT 8 II. 3.X 9

III. 875 9 IV. 4.X / 5.X 9 V. Mechanical Process Fluid Seal 10

E. Intake Assembly 11 F. Pump 11 G. Discharge Assembly 12 H. Instrumentation 12

Section 3 – Storage and Handling 12

A. Storage 12 I. Motor 13

II. Horizontal Thrust Chamber 13 III. Pump 13

B. Handling 13 Section 4 – Installation 14

A. General 14 B. Foundation 15

I. Onshore Installation 15 II. Offshore Installation 15

C. Mounting and Leveling 15 D. Pipework 16

I. Intake Plumbing 16 II. Discharge Plumbing 17


E. System Alignment and Soft Foot Correction 17 F. Driver 18

I. Motor 18 II. Engine 19

G. Instrumentation and Electrical Devices 19 I. Standard Instrumentation 20

II. Additional Instruments and Electrical Devices 20 III. Driver Instrumentation 21

Section 5 – Operation 21

A. General 21 B. Startup Procedures 21 C. Pump 22

I. Fluid Supply 22 II. Purge 22

III. Discharge Valves 22 IV. Operating Precautions 22

D. Horizontal Thrust Chamber 23 E. Driver Coupling 23 F. Motor 23 G. Engine 23

I. Speed Increasing Gearbox 23 H. Driver Control Panel 24 I. Operating Check 24 J. Shutdown Procedures 24 K. Instrumentation 24

Section 6 – Maintenance 24

A. General 24 I. Monitoring 24

II. Preventative Maintenance 25 III. Alignment 25

B. Maintenance Schedule & Lubrication 26 I. Pump 26

II. Horizontal Thrust Chamber 26 a. Mechanical Process Fluid Seal 27 b. HTC Cooling System 27

III. Driver 27 a. Lubrication Service – Electric Motor (Ball Bearings) 27 b. Lubrication Service – Electric Motor (Sleeve Bearings) 28 c. Lubrication Service – Engine 28 d. Filters – Electric Motors 29 e. Filters – Engines 29

IV. Driver Coupling 29 a. Lubrication Service – Flex Type 29 b. Lubrication Service – U-Joint Type 29


Section 7 – System Troubleshooting 30

A. Pump 30 B. Motor 31 C. Horizontal Thrust Chamber 33

Section 8 – Recommended Spare Parts 34 Section 9 – Terms, Conditions, and Warranty 34 Appendix A – Mechanical Process Fluid Seal IOM Manuals (Centrilift Standard Offering) Appendix B – Instrumentation IOM Manuals

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

(Centrilift Standard Offering) Appendix D – Reference Drawings Appendix E – HTC Oil Cooler System and Accessory Information

IOM Manual Revision Date: Feb. 2008 Page Number: 5 of 34 INTRODUCTION: Proper use of these instructions will increase reliability and performance of the horizontal surface pumping system (HPump). Reading this manual before operation will provide the most benefit. The manual should be kept close to the equipment or in a convenient location. These instructions are intended to be general guidelines. Specific questions should be directed to your Centrilift sales and service representative.

SECTION ONE: Healthy, Safety, and Environment Considerations

A. INSTALLATION CONCERNS

• Always follow established HSE procedures. • Always wear proper PPE (eyes, hearing, clothing, footgear, hard hat, etc). • Always properly ground all electrical equipment. • Always follow correct startup procedures and read user manuals. • Verify correct driver rotation before operation, or after any electrical work has

been done. • When lifting any equipment, follow recommended procedures and use approved

equipment (hoists, chains, slings, cranes, spreader bars, shackles, etc). • Inspect the pump system for correct valving (location of one-way check and

throttling valves), plumbing (pressure rating), and controls/instrumentation compatibility before operation.

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

B. OPERATION CONCERNS

• Never operate equipment without proper guarding and shutdown systems in place. • Never operate the equipment at dead head or no flow conditions. • Never operate equipment outside its recommended operating range. • Be aware of extremely hot or cold surfaces (motor, HTC, pump, etc.). • Never smoke or use open flame around equipment.

C. MAINTENANCE CONCERNS

• Follow recommended service intervals. • Always follow lock out/tag out procedures when servicing the unit. • Always use the correct and recommended tools. • Always depressurize equipment before servicing. • Be aware of sharp edges and corners. • If attempting to move heavy components, use a lifting device rated appropriately

for the load.


• Never apply heat to remove any component (i.e. induction heaters and torches). • Remove jewelry (rings, watches, necklaces, etc) when working on rotating

equipment. • Always use the buddy system. • If abnormal operating conditions cause the pump to reach 482° F, do not handle

fluro-elastomer parts (i.e. Viton o-rings) without wearing proper PPE. The decomposition of the elastomer will make the parts hazardous.

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

D. EXPLOSIVE AND HAZARDOUS ATMOSPHERE CONCERNS

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

• Avoid excess temperature rise. • Properly ventilate area to avoid the build up of explosive and hazardous mixtures. • Prevent spark generation. • Prevent fluid leakages. • Maintain equipment to prevent unsafe changes in operating conditions. • Install monitoring equipment and warning signs to alert site personnel of

potentially unsafe conditions. SECTION TWO: Equipment Component Descriptions A. OVERVIEW

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

IOM Manual Revision Date: Feb. 2008 Page Number: 7 of 34 B. SKID

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

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

C. DRIVER

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

I. DRIVER COUPLING Close Coupled (Grid Type) Spacer (Grid Type)

Grid-style couplings are used to connect the thrust chamber to the motor. Close coupled and spacer styles are offered. The spacer coupling allows for removal and service of the HTC without disturbing process piping. Refer to Appendix C for coupling IOM manuals.

IOM Manual Revision Date: Feb. 2008 Page Number: 8 of 34 D. HORIZONTAL THRUST CHAMBER

The Horizontal Thrust Chamber (HTC) is an oil lubricated device that serves three purposes. The first purpose is to transmit the torque from the motor to the pump. The second purpose is to isolate the motor from the thrust produced by the pump. The third purpose is to seal the pumped fluid from the environment. The thrust chamber uses a modular mount to accommodate various motor shaft heights. Four different HTC models are offered based on thrust capacity required: 1.XE, 1.XT, 3.X, and 875. Each HTC is comprised of a housing, a shaft, bearings, shaft seals, and a mechanical process fluid seal. A variety of instrumentation is offered to monitor HTC vibration, lubrication oil level, and temperature.

I. 1.XE / 1.XT

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


II. 3.X

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

III. 875

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

IV. 4.X / 5.X

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


V. MECHANICAL PROCESS FLUID SEAL

The process fluid seal is designed to keep the pumped fluid from escaping to the environment. Typically the seal is installed in the head of the HTC or in the seal chamber. A variety of mechanical seals and seal flush systems are available to meet each application. Fluid properties and service conditions dictate the type of seal and flush system to be provided. Manufacturer IOM manuals for Centrilift’s standard offering of seals can be found in Appendix A.

Standard Type 2 Shaft Seal in HTC Head

Optional Cartridge Seal (Shown in Black) in Seal Chamber

IOM Manual Revision Date: Feb. 2008 Page Number: 11 of 34 E. INTAKE ASSEMBLY

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

F. PUMP

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

Housed

Bolted Bowl

IOM Manual Revision Date: Feb. 2008 Page Number: 12 of 34 G. DISCHARGE ASSEMBLY

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

H. INSTRUMENTATION

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

SECTION THREE: Storage and Handling A. STORAGE

If the HPump unit is not going to be installed and operated soon after it arrives on site, secure and store it. Storage procedures should also be considered if the unit ever sits idle for more than 30 days. The storage environment should be clean, dry, and well ventilated. Preferably, this will be an indoor, protected, and secure environment. If stored outdoors, the unit should be placed on concrete or wooden supports. Additionally, the unit should be covered to avoid direct exposure to the weather. Never store the unit near sources of vibration or in the vicinity of welding activity.


The following recommendations should be followed when storing your HPump:

I. MOTOR Refer to the OEM manual for storage and handling recommendations. Typically the motor shaft should be turned by hand 15-30 revolutions every 30 days to avoid false brinelling of the bearings. Connect space heaters, if supplied, to drive moisture from the windings.

II. HORIZONTAL THRUST CHAMBER Fill the thrust chamber with oil to prevent oxidation. 1.XE, 1.XT, and 875 thrust chambers should be capped during storage to avoid oil leakage. Typically the HTC shaft should be turned by hand 15-30 revolutions every 30 days to avoid false brinelling of the bearings. On HTC models equipped with a desiccant breather, monitor and replace per the recommendations in Appendix E.

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

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

B. HANDLING


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

• All chains, slings, spreader bars, and shackles should also be appropriately rated. • Use a four point lift to move the skid and mounted equipment. • Do not allow rigging to contact the mounted equipment. • Avoid jarring the skid. • Never attempt to lift the skids from anywhere except the provided lifting eyes. • Individual components should be lifted via appropriately rated slings. • Lift tandem skid sections separately. Never lift the skids when bolted together. • For heavy components that require maintenance or removal, or that ship loose and

require installation, use 2 man lifting techniques with correct lifting devices.

SECTION FOUR: Installation A. GENERAL

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

• A firm foundation, including precise leveling of the skid. • Flexibility in the intake and discharge plumbing. • Control of the intake and discharge pressures.

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

1. Level the skid assembly. 2. Correct soft foot conditions for the motor, HTC mounting bracket, and HTC (if

installed on site). 3. Laser align any system components installed on site. Check alignment of all

components and compare to factory alignment values. 4. Check and set HTC and pump shaft extensions (a reference document is available

from HPump Engineering). 5. Replace HTC lubrication oil and fill to proper level. 6. Review customer piping for proper support. 7. Connect unit to piping and re-check laser alignment. 8. Start unit. 9. Perform hot alignment after 24 hours.

IOM Manual Revision Date: Feb. 2008 Page Number: 15 of 34 B. FOUNDATION

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

I. ONSHORE INSTALLATION

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

II. OFFSHORE PLATFORM

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

C. MOUNTING AND LEVELING

The skid requires support at each anchor location. Metal shims are normally used. Shims should be a minimum of 8 x 8 inch (203 x 203 mm) steel or steel alloy plates, in a selection of 1/8 inch (4 mm) thick and greater, depending on surface irregularities. The quantity of shims at each anchor location should be minimized. The steps below should be followed in the order presented:

1. The skid should be placed between the anchor bolts and leveled lengthwise with a 48” long digital level. The skid should be leveled within 0 to 1/10 of 1°. A hydraulic jack placed under skid cross member beams may be used to raise the skid for shimming.

CAUTION: Do not use the hydraulic jack directly on the intake assembly,

the pump housing, or the discharge flange.

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

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

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

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


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

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

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

D. PIPEWORK Piping to the intake and discharge connections should have at least 0.5 inch/13 mm of

flexibility in all directions. Where conditions do not allow rubberized piping or couplings, other methods (such as a heat loop) are strongly recommended. This allows for thermal expansion of the pump and pipe work. Another benefit is isolation from mechanical shock.

CAUTION: Suction and discharge piping should be supported independently

from the pump or skid and field fitted to prevent induced nozzle loading.

CAUTION: Suction and discharge headers should not be jacked, pulled, or

otherwise forced to mate with the intake or discharge flanges. This may cause excessive pipe strain, vibration, system misalignment, or damage.

NOTE: Piping entering or leaving the unit should be straight for 5-10 times

the nominal pipe diameter. This will prevent cavitation and other flow restriction problems.

I. INTAKE PLUMBING

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

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

The intake may be rotated by removing the bolts fastened to the intake

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


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

II. DISCHARGE PLUMBING

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

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

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

A reverse flow check valve is recommended downstream of the pump to prevent back flow and excessive back pressures at the intake. Any valves should be installed at least 5-10 times the nominal pipe diameter away from the discharge. If a recirculation line is used, the line should be piped to the fluid source, not directly to the intake. For applications where the pump could be started and operated at a very low discharge pressure for several minutes (example: injection well on vacuum), a choke valve must be installed to allow backpressure to be simulated. This will reduce equipment up thrust wear damage.

E. SYSTEM ALIGNMENT AND SOFT FOOT CORRECTION

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


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

F. DRIVER

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

I. MOTOR

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

standard or local codes to ensure personnel protection and safety.

Rotation is counter clockwise when facing the non-drive end of the motor. TEFC type motors are normally equipped with condensation drain plugs in the bottom of each end shield. If present, these should be removed prior to startup. If using a sleeve bearing motor with a limited end float kit, properly locate the motor magnetic center before installing the coupling assembly. Motor instrumentation could include winding RTDs, bearing RTDs, space heater, winding thermostat, or a WPII differential pressure switch. These options should be wired into the proper monitoring or control device. Wiring schematics are available from the motor OEM. If using a Centrilift VSD, contact Controls Engineering for specific instructions on wiring motor instrumentation to the drive.

CAUTION: Motor fan rotation may be uni-directional or bi-

directional. A fan rotating in the wrong direction may allow the motor to overheat. In this case, it will be necessary to reverse the fan mounting or replace the fan.


II. ENGINE

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

CAUTION: All engine-driven HPump applications should be

coordinated with HPump Engineering and the engine packager.

G. INSTRUMENTATION AND ELECTRICAL DEVICES

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

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

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


I. STANDARD INSTRUMENTATION

Instrument Model Set Point Instructions Detailed IOM Information

Intake Pressure Switch

Murphy 45 APE (range shown on

instrument)

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

See Appendix B

Discharge Pressure Switch

Murphy 45 APE (range shown on

instrument)

Low SP: max flow operating point of pump High SP: min flow operating point of pump

See Appendix B

HTC Oil Level Switch

Dependent on HTC Model

Low SP: HTC or reservoir sight glass “low” mark High SP: HTC or reservoir sight glass “high” mark

See Appendix B

HTC Vibration

Switch

Murphy VS2 Start unit and verify that vibration at all locations is less than 0.156 in/sec. Follow sensitivity adjustment instructions in Appendix B to obtain set point.

See Appendix B

II. ADDITIONAL INSTRUMENTS AND ELECTRICAL DEVICES

Instrument Model Set Point Instructions Detailed IOM

Information 3.X HTC Oil Temp RTD

Thermo Sensors 310R-4P138PS36-

B1/2A34-2.5

100Ω Platinum, Range: -58° to 752°F, 3-Wire, Single Element, 2.5” Insertion Depth. No transmitter/reader (to be supplied with starter/VSD). Set monitor to trip at 210°-220°F.

See Appendix B

875 HTC Oil Pressure Switch

CCS 6900GZE Instrument is pre-set. Low pressure switch is set at 10 psi decreasing. High pressure switch is set at 100 psi increasing.

See Appendix B

HTC Lube Oil Cooler Fan Motor

(XP)

Baldor L4003A Set fan motor to start when main unit starts. Set time delay start in starter/VSD for 1-2 minutes. Thermal protection provided, not wired. Shutdown on thermal overload, instrument trip, or main unit shutdown.

Wiring diagram and electrical data

in Appendix E

1.XT HTC Lube Oil

Pump Motor (Non-XP)

Leeson C6C17FK5H

(110908)

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

Wiring diagram and electrical data

in Appendix E

1.XT HTC Lube Oil

Pump Motor (XP)

Contact HPump™ Engineering

See standard 1.XT set point instructions above. Contact HPump Engineering

875 HTC Lube Oil

Pump Motor

Dependent on specific

installation

See standard 1.XT set point instructions above. Contact HPump Engineering


III. DRIVER INSTRUMENTATION

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

SECTION FIVE: Operation A. GENERAL

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

B. START UP PROCEDURES

There are several items that need to be checked at the initial startup and whenever the system has been shutdown for a significant period of time. • Verify that the pump turns the proper direction by “bump” starting the driver. • Check thrust chamber oil level sight glass or gauge for sufficient oil prior to starting

the pump. • If equipped with an HTC cooling system, start the system before operation and make

sure all air is purged from the system. • Check the installation of all bolting, piping and wiring. • Check all gauges, valves, and instrumentation for proper working order. Verify that

instrumentation trip settings are properly set and operational. • Make sure the suction valve is fully open. • Ensure that the pumps are primed and any gas has been purged. • Check to be sure the discharge valve is at least 25% open. It may be necessary to

adjust back pressure to stay within the pump application range until the system has stabilized.

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


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

C. PUMP

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

I. FLUID SUPPLY

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

II. PURGE

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

III. DISCHARGE VALVES

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

IV. OPERATING PRECAUTIONS

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

• Operation outside of application design range. • Extended operation at the minimum head/flow rates. • When pump runs dry or loses prime. • When pumped liquid contains excessive gas or air. • When the pumped fluid contains sand or other abrasives. Small

amounts of abrasives will have a gradual damaging effect. Centrilift makes no guarantee against the erosive action of these abrasives.

IOM Manual Revision Date: Feb. 2008 Page Number: 23 of 34 D. HORIZONTAL THRUST CHAMBER

For the 1.XE and 1.XT, check the HTC oil level in the sight glass and add oil if necessary (oil level should be within the area identified on the sight glass decal). The oil level should be checked while the equipment is running and warm. If too much oil is added, oil may run out the shaft seals. NOTE: External lube oil pump systems must be started before the main

driver is started for proper lubrication. 3.X thrust chambers have a remote oil reservoir on top of the heat exchanger. There is a sight glass on the reservoir. 875 thrust chambers do not have a sight glass. Refer to the oil level plumbing drawing in Appendix D for instructions on checking and adjusting the oil level.

E. DRIVER COUPLING Ensure that the coupling guard and other safety equipment are in place prior to startup. The standard coupling is a steel flex grid type suitable for the application horsepower and RPM. The steel flex design should be greased per the manufacturer’s IOM manual and the service schedule shown in Section Six. Refer to Appendix C for standard coupling IOM manuals. Other coupling types are available upon request. For special couplings, refer to the manufacturer’s IOM manual.

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

G. ENGINE

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

I. SPEED INCREASING GEARBOX

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


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

H. DRIVER CONTROL PANEL

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

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

J. SHUTDOWN PROCEDURES The following sequence is suggested when stopping the unit: • Throttle the pump discharge valve to minimum flow. • Stop the driver at the control panel. • Shut the pump discharge valve. • When the pump shaft stops rotating, close the suction valve. CAUTION: Do not close the suction valve until the pump shaft stops rotating.

K. INSTRUMENTATION

Instrument trip points should be verified and properly set prior to operation. A general set point chart can be found in Section Four. If using Centrilift’s standard instrumentation, refer to Appendix B for the manufacturer’s operation instructions. NOTE: Changing fluid properties, such as specific gravity or viscosity, or

changing pump speed will require instrument trip setting adjustments. SECTION SIX: Maintenance A. GENERAL

I. MONITORING

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


recording of the operating parameters. Refer to the table below for in-service checks.

In-service Check Corrective Action

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

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

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

Tighten or replace as necessary.

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

Repair as necessary.

Check instrumentation and wiring for possible damage.

Replace or repair as necessary.

Check lubrication level and condition. See Thrust chamber paragraph. Check mechanical seal for minimal leakage through HTC weep hole.

Replace or repair as necessary.

Auxiliary equipment.

Refer to applicable manufacturer’s instructions.

II. PREVENTATIVE MAINTENANCE

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

III. ALIGNMENT

Replacement of the driver or thrust chamber requires careful realignment of the components to ensure maximum run life. Driver replacement requires alignment to the thrust chamber, while thrust chamber replacement requires alignment to both the driver and the pump. Movement or repositioning of the skid should be followed by leveling the unit to factory specifications. Replacement of the pump should only require alignment if the cradle has moved or the HTC is also being replaced. It is always good practice to check system alignment when servicing any component.

IOM Manual Revision Date: Feb. 2008 Page Number: 26 of 34 B. MAINTENANCE SCHEDULE & LUBRICATION

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

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

Twenty four hours per day operation or shock loading, vibration, or in dirty or dusty environment @ 104°-122ºF (40-50ºC) ambient temperature.

I. PUMP

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

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

II. HORIZONTAL THRUST CHAMBER

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

MODEL

LUBRICATION

VOLUME FREQUENCY LUBRICANT

(Centrilift P/N) 1.XE 1.XT 3.X 875

8 quarts (8 liters) 5 gallons (19 liters) 5 gallons (19 liters) 5 gallons (19 liters)

(applies to all) Six months for

standard conditions. Three months for severe conditions.

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


a. Mechanical Process Fluid Seal

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

b. HTC Cooling System

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

III. DRIVER

a. Lubrication Service – Electric Motor with Ball Bearings

Lubrication procedure and grease type vary from manufacturer to manufacturer. The type and volume of grease may change, as well as recommendation to lubricate with the motor operating or stationary. Frequency of lubrication service is based on the severity of duty. Specific lubrication instructions are available from the motor manufacturer. All manufacturers recommend removal of any grease plug located below the bearings for relief during lubrication, and to loosen any

COMPONENT LUBRICATION VOLUME

FREQUENCY LUBRICANT

Driver (Motor or Engine)

Refer to manufacturer’s recommendation.

Refer to manufacturer’s recommendation.

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


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

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

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

CAUTION: It is possible to over-lubricate the motor

bearings. Excess grease can build up inside the motor on the windings and may cause isolated hot spots.

b. Lubrication Service – Electric Motor with Sleeve Bearings

Maintain proper lubrication by checking the oil level periodically, adding oil when necessary. The initial clearing action of the bearing and the expansion of the oil as it comes up to the operating temperature will cause the oil to be lighter after the motor has been in operation. Overfilling should be avoided because the thermal expansion may force the oil over the oil sleeve and onto the rotor. Also, an operating oil level that is too high prevents the bearing from clearing itself of excess oil. If the oil level goes above the maximum shown on the sight gauge during operation, drain enough oil to bring the level back to within the recommended operating range.

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

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

c. Lubrication Service - Engine

Reference the manufacturer’s operating instructions and recommended service schedule.


d. Filters – Electric Motors

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

e. Filters – Engines

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

IV. DRIVER COUPLING

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

a. Lubrication Service - Flex Type

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

b. Lubrication Service - U-Joint Type

Refer to the manufacturer’s approved grease types, and manufacturer’s recommended service interval.

COMPONENT LUBRICATION VOLUME

FREQUENCY LUBRICANT (Centrilift P/N)

Flex Type Driver Coupling

6.0 ounces (175 grams)

Every HTC service

Falk LTG (60955) or manufacturer’s

recommendation

IOM Manual Revision Date: Feb. 2008 Page Number: 30 of 34 SECTION SEVEN: System Troubleshooting A. PUMP

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

TROUBLE PROBABLE CAUSE REMEDY

Reduced flow or low discharge pressure

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

a. Check suction line for leaks b. Check driver speed c. Check suction side of system for flow

restrictions, air leaks d. Clean out suction line strainer e. If unable to clear chemically, return

pump to Centrilift for disassembly and repair or exchange

f. Return pump to Centrilift for disassembly and repair or exchange

g. Check driver rotation h. Return pump to Centrilift for

disassembly and repair or exchange No flow or low flow a. Pump not primed

b. Speed too low c. Plugged impellers d. Clogged suction strainer e. Damaged impellers f. Wrong rotation g. Discharge valve is shut

a. Prime pump b. Check driver speed c. If unable to clear chemically, return

pump to Centrilift for disassembly and repair or exchange

d. Clean out suction line strainer e. Return pump to Centrilift for

disassembly and repair or exchange f. Check driver rotation g. Check valve setting

Excessive pump vibration a. Clogged impellers b. Damaged impellers c. Misalignment d. Foundation provides

inadequate support

a. If unable to clear chemically, return pump to Centrilift for disassembly and repair or exchange

b. Return pump to Centrilift for disassembly and repair or exchange

c. Check driver, HTC, and pump alignment d. Have qualified foundation designer

inspect and repair foundation

IOM Manual Revision Date: Feb. 2008 Page Number: 31 of 34 B. ELECTRIC MOTOR

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


Motor won’t start a. Motor improperly connected b. Incorrect line voltage c. Overload relay tripped d. Fuses blown or defective e. Open circuit in stator or rotor f. Short circuit in stator g. Grounded winding

a. Check motor connection and control connections

b. Check nameplate for required voltage; measure voltage at motor terminals

c. Correct and reset d. Replace fuses e. Check for open circuit f. Check for short circuit g. Check for a ground

Motor noisy a. Winding single-phased b. Loose mounting c. Noisy bearing d. Coupling halves loose e. Vibration f. Loose covers g. Uneven air gap

a. If winding is single-phased unit will not start; stop unit and try to restart

b. Check and correct c. Check and correct d. Inspect alignment and tighten e. Check alignment with driver

disconnected; check feet plane; correct balance of motor rotor if necessary; check key unbalance on coupling

f. Tighten down g. Check gap

Excessive bearing temperature (anti-friction bearing)

a. Excessive lubrication b. Inadequate lubrication c. Bent shaft d. Coupling misalignment e. Inadequate internal clearance f. Inadequate ventilation

a. Clean out grease reservoir b. Add lubricant per nameplate instructions c. Replace shaft d. Realign unit e. Incorrect replacement bearing – consult manufacturer

f. Clean filters; check to see if louvers are blocked


Excessive bearing temperature (sleeve bearing)

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

a. Refer to nameplate requirements and correct; check for proper fill, oil, leaks, gauge level

b. Locate cause and eliminate; check coupling float, shaft level, air baffle balance

c. Draw and refill; if filters are provided, replace with new ones; determine source of contamination and correct

d. Check bore and O.D. clearance e. Straighten and refinish f. Check for damage or reason for binding – roundness, burrs, shaft level – and correct.

g. Dress down, scrape, and refit h. Dress and polish shaft i. Realign bearing or reseat bearing; check feet flatness and reshim

j. Realign motor k. Insulate bearing and isolate shaft from ground

Excessive temperature a. Overload b. Restricted ventilations c. Electrical

a. Reduce load to nameplate rating or replace with larger unit

b. Check openings and duct work for obstructions and correct

c. Check for grounded or shorted coils and unbalanced voltages between phases

Oil leak (sleeve bearing units)

a. Overfilled b. Sealing surface of bearing cap not flat

c. Screws loose d. Pipe fittings loose e. Bearing air pressure vent passage clogged

f. Wrong sealing compound used on bearing cap surface

a. Drain to proper level or adjust oiler elevation

b. Stone or file flat, remove burrs c. Tighten down d. Retighten or replace worn threaded parts e. Clear out passage f. Use a non-hardening gasket sealer; refer to manufacturer

Oil leak (pressure lube systems)

a. Too much oil flow in pressure lube system

b. Drain line too small c. Air pressure imbalance

a. Reduce flow (change orifice) b. Use larger lines c. Clear venting pipes

Excessive vibration a. Coupling misalignment b. Coupling imbalance c. Coupling key imbalance d. Foundation structure improperly supported

e. Rotor imbalance f. Worn bearing g. Coupled equipment h. Shaft bent

a. Realign to operating condition b. Rebalance c. Rebalance d. Correct foundation under skid base e. Rebalance rotor f. Replace bearing if bore oversized g. Check uncoupled, and if necessary, rebalance equipment

h. Straighten without residual stress to avoid springback, or replace shaft

IOM Manual Revision Date: Feb. 2008 Page Number: 33 of 34 C. HORIZONTAL THRUST CHAMBER

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


Abnormally hot bearings

a. Improper lubrication b. Cooling system problems c. Contaminated oil d. Defective bearings e. Misalignment

a. Check lubrication level b. Contact Centrilift to examine system for

problems c. Drain and clean all components in

contact with oil, refill with clean oil d. Contact Centrilift for repair or

replacement e. Verify alignment

Lubrication oil leaks a. Oil level is too high b. Shaft seals are worn c. Cooling system leak

a. Drain oil to middle of sight glass b. Contact Centrilift for repair or

replacement c. Contact Centrilift for system service

Excessive mechanical process fluid seal leakage through HTC weep holes

a. Worn internal parts b. Seal flush line is plugged c. Atmospheric side of seal has

excess deposits

a. Replace or repair seal; analyze pumped fluid for presence of abrasive or corrosive substances

b. Contact Centrilift for cleaning c. Contact Centrilift for cleaning

Excessive vibration a. Internal bearing problems b. Pump is worn c. Misalignment d. Coupling gap is not correct e. Foundation provides

inadequate support

a. Contact Centrilift for HTC repair or replacement

b. Replace pump c. Check driver side and pump side

alignment d. Reset coupling gap to factory

specifications e. Have qualified foundation designer

inspect and repair foundation

IOM Manual Revision Date: Feb. 2008 Page Number: 34 of 34 SECTION EIGHT: Recommended Spare Parts The following table lists the spare part stocking recommendations. This list assumes a single HPump™ unit is installed. Depending on a unit’s specific features, there may be items not listed below that should be stocked. Contact your Centrilift sales and service representative for required quantities for a specific system. Refer to the driver manufacturer for spare parts information related to a specific motor or engine.

RECOMMENDED DATE COMPONENT Start-Up 0-2 Years 2+ Years METHOD OF STORAGE

Coupling Grease (if required) X X X In original packaging, capped Coupling Grid (if required) X X Away from potential

contaminants Coupling Gasket (if required) X X Away from potential

contaminants HTC Oil X X X Capped

HTC Breather (if supplied) X X In original packaging, away from moisture

HTC Lubrication Cooling System Oil Filter (if supplied)

X X In original packaging, away from potential contaminants

HTC Lubrication Cooling System (if supplied)

X In original packaging, away from vibration sources

Complete HTC Unit X Capped, filled with oil, away from vibration sources

Cartridge Process Fluid Seals (if supplied)

X X In manufacturer’s unopened packaging

Intake O-Rings X X Discharge O-Rings X X X

HTC O-Rings X X

In original packaging, away from contaminants

Pump(s) X Capped, filled with preservative, away from

vibration sources Complete Spare HPump™ X Away from vibration sources

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

IOM Manual Appendix A

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

Seal Manufacturer’s IOM Manual

Maximum Pressure Rating

Rating Basis

John Crane Type 2 “Type 2 Elastomer Bellows Instruction Manual”

150 psi Water < 175°F

John Crane Type 2B “Type 2 Elastomer Bellows Instruction Manual”


John Crane 8B1-O “John Crane Simple Shaft Seal Installation and Troubleshooting for Type 8-1 and Type 9 Seals”


John Crane 38BO “John Crane Simple Shaft Seal Installation and Troubleshooting for Type 8-1 and Type 9 Seals”

Application Specific

Application Specific

I-2 - 1 -

5. If the pumped fluid is hazardous or toxic, appropriate precautionsmust be taken to ensure that any seal leakage is adequatelycontained. Further information on sealing hazardous or toxic fluidsshould be obtained from John Crane prior to seal installation.

6. Fluorocarbon components should never be burned or incinerated as the fumes and residues are highly toxic. If fluorocarbons areaccidentally heated above 400˚C/750˚F, they can decompose.Therefore, protective gloves should be worn as hydrofluoric acid may be present.

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

ForewordThese instructions are provided to familiarize the user with the seal and itsdesignated use. The instructions must be read and applied whenever workis done on the seal, and must be kept available for future reference.

These instructions are for the installation and operation ofa seal as used in rotating equipment and will help to avoiddanger and increase reliability. The information requiredmay change with other types of equipment or installationarrangements. These instructions must be read in conjunc-tion with the instruction manuals for both the pump and any ancillary equipment.

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

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

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

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

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

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

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

Safety Instructions1. The following designations are used in the installation instructions to

highlight instructions of particular importance.

NOTE: Refers to special information on how to install oroperate the seal most efficiently.

Refers to special information or instructions directedtoward the prevention of damage to the seal or itssurroundings.

Refers to mandatory instructions designed to preventpersonal injury or extensive damage to the seal or itssurroundings.

2. Installation, removal, and maintenance of the seal must be carried outonly by qualified personnel who have read and understood theseinstallation instructions.

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

4. The seal must only be used in technically perfect condition, andmust be operated within the recommended performance limits stated inthe published Technical Data Sheet and the instructions in this manual.Copies of the Technical Data Sheet are available from John Crane.

Before Starting the Equipment1. Check the pump at the coupling for proper alignment of the driver

or motor.

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

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

4. Consult all available equipment operating instructions to check forcorrectness of all piping and connections, particularly regarding sealrecirculation/flush, heating or cooling requirements, and servicesexternal to the seal.

This mechanical seal is designed to operate in a liquidso the heat energy it creates is adequately removed.Therefore, the following check should be carried outnot only after seal installation, but also after any period of equipment inactivity.

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

!

!

I-2

ATTENTION

ATTENTION

Type 2 Elastomer Bellows Instruction Manual

ATTENTION

ATTENTION

ATTENTION

Lead-On ChamferFor ease of installation, the lead-on edge of the shaft or sleeve should bechamfered as shown.

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

Shaft/Sleeve Outside Diameter Refer to Dimension Tables

Seal Chamber Bore Diameter Refer to Dimension Tables

Shaft/Sleeve Finish under the 1.00" to 3.125" dia./63 Ra/1.6µmSeal Unit 3.125" dia. & up/32 Ra

Shaft/Sleeve Ovality/Out-of-Roundness <0.1mm/0.004"

Concentricity of the Seal Chamber <0.15mm/0.006" FIMto the Shaft/Sleeve

Shaft/Sleeve Run-out with respect <0.08mm/0.003" FIM _<1800 rpmto the Seal Chamber <0.15mm/0.006" FIM >1800 rpm

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

I-2 - 2 -

General Instructions1. Study the Engineering seal layout drawing to confirm the proper seal

arrangement for the pump being used. The Type 2 seal is designedfor versatility and can be assembled in various ways. The followinginstructions describe the standard configurations.

2. To assure satisfactory operation, handle seal with care. Take particular caution to see that the lapped sealing faces are notscratched or damaged.

Typical Type 2 Seal Arrangement

Part Name1 Bellows 6 Spring 2 Face/Primary Ring 7 Spring Holder3 Retainer 8 Seat/Mating Ring4 Disc 9 Collar5 Drive Band

Typical Type 2 Seal Arrangement

Preparing the Equipment1. Check seal chamber dimensions and finishes.

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

3. Determine squareness of seal chamber face to shaft:Rotating Mating Ring

- 0.13mm/0.005" FIM max.

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

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

NOTE: If measured dimensionsexceed those valuesgiven, correct theequipment to meetspecifications prior toseal installation.

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

NOTE: It is essential to use a suitable lubricant when fitting the seal. The recommended lubricants for elastomeric bellows are softhand soap and water, or glycerine; do not use washing-up liquid,liquid soaps, or hand cleaning gels. Light mineral oil may be usedsparingly with most elastomers.

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

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

Check that the seal face is located in the retainer with thelapped face outwards, and take care that the face does notdrop out of the retainer when handling and fitting the seal.

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

Installation of the seal unit to its working length should becompleted within 15 minutes to ensure that the elastomerbellows is correctly positioned before the neck of thebellows grips the shaft.

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

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

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

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

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

I-2 - 3 -

Decommissioning the Equipment1. Ensure that the pump is electrically isolated.

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

2. Ensure that the pump is isolated by the appropriate valves. Check that the fluid is drained and pressure fully released.

Removing the Seal1. Referring to the pump instruction manual, dismantle the equipment

sufficiently to expose the gland plate and seal housing.

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

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

NOTE: Although the original seal position may be marked on the shaftor sleeve as a reference point before seal removal, the locationmust be checked even if the same seal and seat/mating ringspecification is intended as a replacement.

A seal unit should always be serviced after removal from duty. It isrecommended that used seals are returned to a John Crane ServiceCentre, since rebuilding to as-new specification must be carried out byqualified personnel.

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

ATTENTION

ATTENTION

ATTENTION

!

!

Quality AssuranceThis seal has been assembled in accordance with John Crane QualityAssurance Standards and with proper maintenance and use will give safeand reliable operation to the maximum recommended performance asshown in any relevant approved John Crane publication.

Operation and MaintenanceAlthough the seals should be looked at regularly for signs of leakage, acorrectly selected mechanical seal will normally run for long periods withoutattention and it should not be disturbed unnecessarily.

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

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

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

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

It is the responsibility of the equipment user to ensure that any partsbeing sent to a third party have appropriate safe handling instructionsexternally attached to the package.

!

I-2 - 4 -

Storage and TransportInstructions for the handling, packaging, storage and transport of sealunits and seats/mating rings are given in the John Crane InstructionSheet ref. I-Storage, available on request.

North AmericaMorton Grove, Illinois USA

Tel: 1-847-967-2400Fax: 1-847-967-39151-800-SEALING

Europe, Middle East, AfricaSlough, UK

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

Asia PacificSingapore

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

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

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

©2001 John Crane Print 1/01 www.johncrane.com ISO Certified

John Crane

Latin AmericaSão Paulo, Brazil

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

63

14"/

45˚

John CraneSimple Shaft SealInstallation andTroubleshooting forType 8-1 andType 9 Seals

I-8/9-A

INSTALLATION

Square Tool Stock

Suggested Marking Tool

Polish shaft surface to 25-32 Ra.

Check for properradius or chamfer.Remove burrs.

Step 2:

Mark the face of the stuffing box on the shaft.Step 1:

20˚

.040"MIN.

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

Inst. Ref.

19/16

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

InstallationReference

Put the mating ring andgland together and slideover shaft. Do not damagemating ring.

John Crane Inc.

INSTALLATION (continued)Step 3:

Step 4:

Step 5:

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

Slide seal over shaft.Locate rear oninstallationdimension andtighten set screws.

Lubricate thewedge or o-ring

with light oil.

Some Type 8-1 and Type 9seals may use differentmating rings. If your sealdoes, then:

- Lubricate seal ring (A) checkfor corner break (B)

- Protect sealing face (C) withclean cloth and press matingring firmly in place.

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

O-Ring seatA

D

B

C

A

D

BC

TFE mtd. “L” shaped seat

TROUBLESHOOTING

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

Check bearings for shaft end play.

Check bearings for radialshaft movement.

.002"max.

.002"max.

Check shaft straightness.

.002"max.

INSTALLATION (continued)

Step 6:

Step 1: Seal Wears Out Shaft

Step 2: Seal is Burned UpReason - Not enough liquid flow to seal.

- Seal is overcompressed.

Check flush line tobe sure it is clear.

Check installation reference.

Did the pump cavitate or run dry?

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

Reason - Pump is in poor mechanical condition. Check squareness of stuffing box face to shaft centerline (.002" max. ).

.002"max.

TROUBLESHOOTING (continued)To seal

To low pressure

In

STEP 3: Seal is Worn Out

Reason - Abrasives are in the seal cavity. Thepumped liquid may be carrying dirt, rust orsuspended abrasive particles.

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

A filter will also work.

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

John Crane mechanical seals are very reliable. If you are notobtaining good service life, contact your local John Cranerepresentative.

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

©1998 John Crane Print 9/98 www.johncrane.com ISO 9001 Certified

John CraneEngineered Sealing Systems

John Crane Sealol®

Cranston, Rhode Island USA

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

North and Latin AmericaMorton Grove, Illinois USA

Tel: 1-847-967-2400Fax: 1-847-967-37001-800-SEALING

Europe, Middle East, AfricaSlough, UK

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

Asia PacificSingapore

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

John Crane Flexibox®

Manchester, UK

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

John Crane Safematic®

Muurame, Finland

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

IOM Manual Appendix B

Appendix B – Instrumentation IOM Manuals Centrilift Standard Instrumentation Offering

Instrument Manufacturer Manufacturer’s IOM Manual

Standard Model

Explosion Proof Model

Intake and Discharge Pressure Switch

Murphy “Installation for 4-1/2 in. (114 mm) dial Pressure Murphygage® and Swichgage® instruments”

45APE 45APE-EX

HTC Vibration Switch

Murphy “Shock/Vibration Control Switches Installation Instructions”

VS2 VS2EX

“Installation Instructions for L129 Series Level Swichgage® instrument”

L129-CK-1 N/A 1.XE/1.XT and 875 HTC Lubrication Level Switch

Murphy “Installation Instructions for Level Maintainers Model Series LM300”

N/A LM303-EX

3.X HTC Lubrication Reservoir Level Switch

Murphy “Installation Instructions for L971 Series Crankcase Level Switch”

N/A L971-C

3.X HTC Internal Temperature RTD

Thermo Sensors “Industrial Thermocouples: Installation and Maintenance”

N/A 310R-4P138PS36-B-1/2A34-

2.5 875 HTC Lubrication Oil Pressure Switch

CCS “Series: 6900 GZE” N/A 6900GZE12 6900GZE16

Installation for 4-1/2 in. (114 mm) dialPressure Murphygage® and Swichgage® instruments

00-02-0161Revised 03-06

Section 05

OPLC and OPLFC Swichgage instruments have high and low limitcontacts to monitor, alarm or shut down. The OPLC has a flanged case. A methodto override the low limit contact for start-up is provided on most models. SeeOperation Test section–page 3.OPLFC can be direct or panel mounted (see page 2).

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

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

45APE and 45APEF Series are versions of the OPLC Seriesfeaturing 2 snap-acting SPDT switches instead of the pointer type contacts.These units do not include low contact lockout.

OPLBP and 45APEBP are versions of the OPLC and 45APEfeaturing pilot duty limit switches connected to an internal latching controlrelay for “on/off” control directly or through a motor starter.

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

SpecificationsDial: White on black, dual scale, psi/kPa standard, 4-1/2 in. (114 mm) diameter.Case: Die cast aluminum, surface or panel mount.Process Connection: 1/4 NPTM thru 1000 psi; 1/2 NPTM 1500 - 10,000 psi.

Sensing Element: Bronze or 316 stainless steel bourdon tube.Gage Accuracy:All models and 45APE/45APEF between switch points:±2% for first and last quarters of scale; middle half of scale is ±1%.Model 45APE/45APEF

Indicating Pointer above or below set point:Range Accuracy (±% F.S.) above and below s.p. only<100 (except 15 psi) 1015 15100-300 4400-1500 22000 123000-5000 8

Based on testing performed with switch point at mid scale which represents worst case.

Switch Point Accuracy: ±1.5% (45APE/45APEF).Switch Reset Deadband: Approximately 10% FS (45APE/45APEF).Snap-Acting Switches: See wiring information (page 4) (45APE/45APEF).

Overrange: Do not exceed 10% FS above full range.Pressure Relief Disc: Back of case (except EX models).Dry Relay Contact (“BP” Models): 10 A @ 28 VDC or 10 A @ 120 VAC.Wire Connections (Surface Mount): 1/2 NPTF conduit/ terminal block.Wire Connections (Panel Mount): Wire leads, 18 AWG (1.0 mm2) x 9 in. (229 mm) long.Wire Connections (-ES, -OS): 1/2 NPTM conduit and wire leads,

All except 45APEF:18 AWG (1.0 mm2) x 33 in. (838 mm) long.

45APEF24 AWG (0.22 mm2) x 33 in. (838 mm) long.

Item Weight: 5 lbs 6 oz (2.4 kg) approximately.Explosion-proof models: 21 lb. (9.5 kg) approx.

Item Dimensions: 10 x 9 x 6 in. (254 x 229 x 152 mm) approximately.Explosion-proof models: 12 x 12 x 9 in. (305 x 305 x 229 mm) approximately.

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

GENERAL INFORMATION

Model Series: OPLC, OPLG, OPLBP, 45APE, 45APEBP, PT167EX and 45 SeriesOptions: -OS, -ES, -P4 and -P6Please read the following instructions before installing. A visual inspection is recommended before mounting. General Informationand these installation instructions are intended for all 4-1/2 in. (114 mm) dial pressure models.

WARNINGBEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.

Precautions: Do NOT exceed rated pressure range.Dope or use teflon tape on connection threads. Do not blockthe inlet orifice. For direct mount into the process, a vertical

or ninety degree mounting is recommended.Use wrench on shank to tighten or loosen connection. Do not twistcase when installing, this will damage internal components and willvoid the warranty. Do not overtighten.Use shock mounts as necessary to prevent excessive vibration.If liquid in the system freezes, it will expand and will damage the tube.For 45APE Series – Low setpoint should be limited to the lower 1/2scale and upper setpoint should be limited to the upper 1/2 scale.

Installation 00-02-0161 page 1 of 4

INCREASING ERRORFOR INDICATING

POINTER

MAXIMUM ERROR

HIGH SET POINTPOINTER LOCATION

50

500

60

600

40

40030 300

20

200

10

100

0 PSI

PRESSURE

kPa0

70

80

90

100

INCREASING ERRORFOR INDICATING

POINTER

MAXIMUM ERROR

LOW SET POINTPOINTER LOCATION

50

500

60

600

40

40030 300

20

200

10

100

0 PSI

PRESSURE

kPa0

70

80

90

100


panelgaugeshock mount

DETAIL

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

FL

OW

pulsation dampener

7-7/8 in.(200 mm)

1/2 NPTFConduit

1/4 or 1/2 NPTF

4-1/

32 in

.(1

02 m

m) 3-15/16 in.

(100 mm)

3-3/8 in.(86 mm)

8-7/16 in (214 mm)

9/32 in.(7 mm) dia. 3 places

2-57/64 in.(73 mm)

6-3/4 in.(171 mm)

5-7/16 in. (138 mm)

1/4 or 1/2 NPTM Pressure Connection

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

Optional (-BC) 1/2 NPTM Pressure connection

-OS and -ES models only120 120

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

OPL Series Flush MountRound case design to be mounted in a panel from 1/32 in. (1 mm) to 1/8 in.(3 mm) thick. It can also be direct mounted. Shown with pulsation dampener.

8 in.(203 mm)

6-25/64 in.(162 mm)

8 in.(203 mm)

3/8-16 UNC-2B thread

7/8 in. (22 mm) deep, 8 plc's

6-3/4 in.(171 mm)

6-3/4 in.(171 mm)

13/32 in.(10 mm)diameter4 places

7-35/64 in.(192 mm)diameter

3-3/8 in.(86 mm)

3-3/8 in.(86 mm)

1/2 in.(13 mm) optional

rear or side conduit

*Mounting hole not required for

Wall mount

3-3/8 in.(86 mm)

4-1/

32 in

.(1

02 m

m)

8-7/16 in.(214 mm)

1/2NPTF conduit

1/4 NPTM or 1/2 NPTM Pressure Connection

7-7/8 in.(200 mm)

3-15/16 in.(100 mm)

9/32 in.(7 mm) dia. 3 places

6-3/4 in.(171 mm)

2-57/64 in.(73 mm)

5-7/16 in.(138 mm)

1/4 NPTM or 1/2 NPTM Pressure Connection

Optional (-BC) 1/2NPTMPressure Connection

-OS and ES models only120 120

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

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

Flush mount/Wall mount*

5-7/16 in.(138 mm)

2-23/32 in.(69 mm)

6-3/4 in.(171 mm)

2-57/64 in.(73 mm)

1/2 in.(13 mm)conduit

Optional backconnection

120

120

120

Mounting Hole4-3/4 in. (121 mm)diameter

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

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

45APE Series Wall Mount

45APE Series Flush Mount

-OS and -ES (oil sealed and environment sealed case) for corrosiveenvironment, feature a panel mount case or screw directly into the process.See Case Mounting (p-2).

-P6Sealed mechanism with a typical application foroil well lead lines. Its 2 NPT housing and diaphragm sealfilled with silicon fluid attaches directly into a 2 NPT teeon the lead line. Tighten only the 2-5/8 in. (67 mm) hexfitting.CAUTION: Do not tamper with or break sealedconnections.

-P4L is a remote seal mechanism with stainless steel armored capillary toprotect the gage from highly viscous and/or corrosive fluids.1. Loosen the eight housing bolts until the bottom

housing is free to turn.

CAUTION: Do Not unscrew the green diaphragmcapsule.

2. Tighten the bottom housing to the pressure source. 3. Tighten the eight housing bolts to 25±3 foot lbs.

by staggering the tightening for even clamping.4. Route capillary away from heat source such as

exhaust manifold. Excess capillary should becarefully coiled and secured to avoid damage.

CAUTION: Do Not cut capillary or make sharp bends.

TransmittingTube

Housing Bolts

DiaphragmHousing

See Note 1

2 NPT

Swichgage instrument

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

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

OPL and 45 Series Indicating Pointer AdjustmentsTo reset to zero or to a known value do as follows:1. Turn off electrical power. Remove the snap

ring and very carefully remove the lens andcontact assembly (or open hinged cover).

2. Hold the pointer hub with thumb andforefinger then turn screw to desiredpoint. See DETAIL “A”.

3. Replace lens and contact assembly andsnap ring (or close hinged cover), and turnon the power.

45APE Series Pointer AdjustmentsTo reset to zero or to a known value proceed as follows:1. Turn off electrical power. Remove the snap

ring and very carefully remove the lens andcontact assembly (or open hinged cover).

2. Hold the the Switch Operator and thepointer hub with thumb andforefinger, then turn the PointerAdjustment screw to the desiredpoint. See DETAIL “B”.

3. If the Switch Operator needs adjustment,hold the Switch Operator and the pointerhub with thumb and forefingers as show onDETAIL “C”, and turn the adjustment screwuntil the Switch Operator aligns with theindicating pointer.

4. Replace the lens and contact assemblyand the snap ring (or close hingedcover). Turn the power back on.

OPTIONS

OPLC, OPLFC and OPLBP1. Perform operation test after the unit is installed and wired appropriately.

(See the typical wiring diagram, on page 4.)2. When pressure is applied to the instrument, the pointer will travel in a

clockwise direction. Adjust the limit contacts to the desired settings. 3. To start, place the toggle switch in the “start”position or otherwise

override low contact.4. After the indication pointer rises above the low limit contact, return the

toggle switch or override device to the “run”position. 5. To test the limit contacts, turn the limit contact to be tested until it touches

the pointer. That will trip the control circuit.6. Reset the shutdown or alarm circuit device and repeat above sequence for each

contact/trip point.

45 Series1. Repeat steps 1 and 2. (See OPLC operation test instructions.) 2. Press the semi-automatic pushbutton located on the low contact knob. 3. Reset the magnetic switch pushbutton.4. After the indication pointer rises above the low limit contact, the lockout -

pushbutton automatically disengages and the low limit is armed.5. Repeat steps 5 and 6. (See OPLC operation test instructions.)

45APE, 45APEF and 45APEBP1. Repeat steps 1 and 2. (See OPLC operation test instructions.) 2. To test the switches, turn the trip point indicator until it is aligned with the

Swichgage pointer. This is the approximate trip point.Continue to rotate until the snap switch operates.

3. Reset the shutdown or alarm circuit device.

OPERATION TEST INSTRUCTIONS

ADJUSTMENTS

Turn to lower pointer

Turn to raise pointer

DETAIL “A”

Turn CW to Lower Switch Operator

Turn CCW to RaiseSwitch Operator

Switch Operator

DETAIL “C”

Adjustment

Turn CW to Raise Pointer

Turn CCW to Lower Pointer

DETAIL “B”

PointerAdjustment



Red White Black

TYPICAL ELECTRICAL DIAGRAMS

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

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

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

45APEBPContact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram belowshows the Swichgage pointer in the at rest (shelf) position.

45APE and 45APEFContact Rating: 2-SPDT snap-switches (one for high and low pressure), 2 A inductive, 250 VAC each switch. NOTE: Diagram below shows theSwichgage pointer in the at rest (shelf) position. Low setpoint should belimited to the lower 1/2 scale and upper setpoint should be limited to theupper 1/2 scale.

45 Series with MS2100Models available for Battery ignition, CD ignition, Magneto or 110VACsystems. Contact Rating: 12/32 VDC coil, 10 A, 32 VDC battery ignitioncontacts; Magneto ignition coil,10 A magneto ignitions contacts;CD ignition coil, 10 A CDignition contacts; 120 VAC coil,10 A, 120 VAC contacts.NOTE: The diagram at right showsthe Swichgage pointer in theoperating position.

Typical Circuit

OPLC

Red White Black

OPLFC

Transformer Relay AssembliesFor higher voltages, Murphy TR Assemblies can be used in conjunctionwith any Swichgage instrument.

120 VAC

BLUEYELLOW

BROWN

WHITE

= 18 GA.

= 16 GA.

BLACK

RED

OR

AN

GE

LOW(RESET)

HIGH(SET)

SET

RESET3

6

4

1

7

9

A B

8

3

5

4

1

26

COMMON

12 VDC24 VDC

LINE

NEUTRAL(-)

(+)

N.C.–Orange3

21

6

5

4Common–Yellow

N.O.–Brown

N.C.–Black

LOW SWITCH HIGH SWITCH

N.O.–Blue

Common–Red

120 VAC12 VDC24 VDC

BLUEYELLOW

BROWN

WHITE

= 18 GA.

= 20 GA.

= 16 GA.

BLU

EORANGE

BR

OW

N

LOW(RESET)

HIGH(SET)

SET

RESET3

6

4

1

7

9

A B

8

3

5

4

1

2

6

LINE

NEUTRAL

COMMON

YELLOW

RED

(-)

(+)

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

G 1 2 3

To CD Ignitionor Magneto.

MS2100

6 2 3 541

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

www.fwmurphy.com918.317.4100 Email: [email protected]

Shock/Vibration Control SwitchesInstallation InstructionsModels: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94

GENERAL INFORMATION

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

Model VS2EX

LISTED*WARNINGBEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT


VS-7037NRevised 09-06

Section 20(00-02-0185)

R

VS-7037N page 1 of 8

DescriptionThe Murphy shock and vibration switches are available in a variety ofmodels for applications on machinery or equipment where excessivevibration or shock can damage the equipment or otherwise poses athreat to safe operation. A set of contacts is held in a latched positionthrough a mechanical latch and magnet mechanism. As the level ofvibration or shock increases an inertia mass exerts force against thelatch arm and forces it away from the magnetic latch causing the latcharm to operate the contacts. Sensitivity is obtained by adjusting theamount of the air gap between the magnet and the latch arm plate.Applications include all types of rotating or reciprocating machinerysuch as cooling fans, engines, pumps, compressors, pump jacks, etc.

ModelsVS2: Base mount; non hazardous locations.VS2C: C-clamp mount; non hazardous locations.VS2EX: Explosion-proof; Class I, Div. 1,

Groups C and D.VS2EXR: Explosion-proof with remote reset.VS2EXRB: Explosion-proof; Class I, Div. 1, Group B; with

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

Remote Reset Feature (VS2EXR, VS2EXRB and VS94 only)Includes built-in electric solenoid which allows reset of tripped unit from aremote location. Standard on VS2EXR and VS2EXRB. Optional onVS94 (options listed below).

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

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

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

WarrantyA limited warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by goingto www.fwmurphy.com/support/warranty.htm


DIMENSIONS

3 in.(76 mm)

4-3/4 in.(121 mm)

2-1/4 in.(57 mm)

5-1/8 in.(130 mm)

Mounting Holes

SlottedSensitivityAdjustmentReset

PushButton4-19/32 in.

(116 mm) Plug

1/4 x 1/2 in.(6 mm x 13 mm)

Slot 2 places

3 in.(76 mm)

4-3/4 in.(121 mm)

SlottedSensitivityAdjustment

5-7/16 in.(138 mm)

ResetPushButton Weatherproof

Strain ReliefBushing

C-Clamp

27/32 in.(21 mm)

1/2 NPT Conduit

5-5/8 in.(143 mm)

3 in.(76 mm)

Mounting Holes

ResetPushButton

SlottedSensitivityAdjustment

5-1/4 in.(133 mm)

Mounting Holes

4-7/8 in.(124 mm)

6-3/8 in.(162 mm)

3/8 in.(10 mm)4 places

1-3/4 in.(44 mm)

10-5/8 in.(270 mm)

6 in.(152 mm)

4-1/2 in.(114 mm)

Mounting Centers

1/2 NPTConduit

9-1/8 in.(232 mm)

Mounting Centers

10-3/16 in.(259 mm)

8-5/8 in.(219 mm)

2-1/2 in.(64 mm)

VS2 VS2C

VS2EX and VS2EXR

VS2EXRB

7-9/64 in.(181 mm)

4 in.(102 mm)

6-1/2 in.(165 mm)

6-29/32 in.(176 mm)

ManualResetPush-button

Mounting slot5/16 x 9/16 in.(8 x 14 mm)4-places.

6-1/2 in.(165 mm)

4-5/8 in.(118 mm)

1-5/8 in.(41 mm)

4 in.(102 mm)

3/4 NPTconduit fitting

VS94


SPECIFICATIONS

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

VS2: Base mountVS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cablehold down clamps.

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

VS2EX• Case: Explosion-proof and weatherproof aluminum alloy housing;

meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C &D; UL and CSA listed.*VS2EX: base mount.

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

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

VS2EXR• Case: Same as VS2EX.• Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A

resistive, 1A inductive, up to 30 VDC.• Remote Reset (optional):

Option Operating Current-R15: 350 mA @ 115 VAC-R24: 350 mA @ 24 VDC

• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.• Normal Operating Temperature: -40 to 140°F (-40 to 60°C).

VS2EXRB• Case: Explosion-proof aluminum alloy housing; rated Class I,

Division 1, Group B hazardous areas.• Snap-switch: 1-SPDT snap-switch with reset coil (option available for

additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,up to 30 VDC.

• Remote Reset:Option Operating Current-R15: 350 mA @ 115 VAC-R24: 350 mA @ 24 VDC

• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.

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

types 4 and 12.• Conduit Fitting: 3/4 NPT conduit fitting connection.• Normal Operating Ambient Temperature:

0 to 140°F (-18 to 60°C).• Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A

resistive, 1A inductive, up to 30 VDC.• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.• Heater (optional):

Option Operating CurrentH15 .023 A @ 115 VACH24 .12 A @ 24 VDC

• Remote Reset (optional):Option Operating CurrentR15 .17 A @ 115 VACR24 .36 A @ 24 VDC

• Time Delay (optional):Option Operating Current Standby CurrentT15 .360 A @ 115 VAC .01 A @ 115 VACT24 1.15 A @ 24 VDC .01 A @ 24 VDC

• Time Delay/Remote Reset: Adjustable 20-turn potentiometer from 5 seconds to 100 seconds (5 seconds per turn approximately).

*CSA and UL listed with 480 VAC rating.

The VS2 and VS94 series shock switches are sensitive to shock andvibration in all three planes of motion - up/down, front/back and side/side.Front/back is the most sensitive (The reset pushbutton is located on the“front” of the unit). For maximum sensitivity mount the unit so that thefront faces into the direction of rotation of the machine. (See Dimensions onpage 2 for sensitivity adjustment location). The VS2 and VS94 Series must be firmly attached/mounted to the machineso that all mounting surfaces are in rigid contact with the mounting surfaceof the machine. For best results, mount the instrument in-line with thedirection of rotating shafts and/or near bearings. In other words, the resetpush 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 toattach the VS2 and VS94 Series to the machine. The mounting bracketshould be thick enough to prevent induced acceleration/vibration upon theVS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. Seeillustrations on page 5 for typical mounting locations.

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

orientation should be on a horizontal plane or with the sensitivity adjustmentpointing down. Sensitivity adjustment for model VS2 is covered by a plug.The plug must be in place and tight to prevent moisture or dust intrusion.

C-Clamp Installation (VS2C model only)A C-Clamp is supplied with the VS2C model only.The C-Clamp is shipped installed on the VS2Cbut must be installed on the VS2EX andVS2EXR switches.1. The C-Clamp (B) will already be installed on

a 1/4 in. (6 mm) thick steel mounting plate(A). Bolt the VS2 switch to the mountingplate as illustrated — with four 5/16 in.bolts, nuts, and washers.

2. The mounting location should provideconvenient access to the TATTLETALE®

push button (C).3. The hardened set screw and nuts (D) are used to

tighten the switch to an I-Beam or cross member such as aSampson post of an oilwell pumpjack.

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

C

A

B

D

INSTALLATION

Continued on next page.

All Models

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

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

2. Make the necessary electrical connections to the vibration switch. SeeInternal Switches, page 6 for electrical terminal locations and page 7 fortypical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENTRATINGS OF THE CONTACTS. Follow appropriate electricalcodes/methods when making electrical connections. Be sure that the run ofelectrical cable is secured to the machine and is well insulated fromelectrical shorting. Use of conduit is recommended.

NOTE: If the electrical cable crosses a pivot point such as at the pivot ofthe walking beam, be sure to allow enough slack in the cable so that nostress is placed on the cable when the beam moves.

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

Sensitivity Adjustment

All models of the VS2 and VS94 Series cover a wide range of sensitivity.Each model is adjusted to the specific piece of machinery on which it isinstalled. After the switch has been installed in a satisfactory location (seepage 5) the sensitivity adjustment will be increased or decreased so that theswitch does not trip during start-up or under normal operating conditions.This is typically done as follows:

1. REPLACE ALL COVERS, LIDS, AND ELECTRICAL ENCLOSURES.

2. Press the reset push button to engage the magnetic latch. To be sure themagnetic latch has engaged, observe latchthrough the window on the VS2 andVS2C (see DETAIL “A”). On theVS2EX, VS94 series the reset buttonwill remain depressed meaning themagnetic latch has engaged.

3. Start the machine.

4. If the instrument trips on start-up,

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

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

5. If the instrument does NOT trip on start-up, stop the machine. Turn the sensitivityadjustment 1/4 turn counter-clockwise.Repeat the start-up/stop process until theinstrument trips on start-up. Turn thesensitivity adjustment 1/4 turn clockwise(less sensitive). Restart the machine toverify that the instrument will not trip onstart-up.

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

VS94 Time Delay Adjustment1. Apply power to the time delay circuit. (see

page 7 for time delay circuit). The time delay function will be initiated.

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

3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.

NOTE: Allow 30 seconds bleed-time between turning thepower “OFF” and “ON”. 4. Locate the time adjustment pot (DETAIL “C”).

The time is factory-set at the lowest setting (5seconds approximately). To increase time,rotate the 20-turn pot clockwise as needed(5 seconds per turn approximately).

5. Repeat the above steps as necessary toobtain desired time delay.

NOTE: An external time delay can be usedwith the remote reset feature of the VS2EXRseries to provide a remote reset and override of the tripoperation on start-up. Time delay must automatically disconnect afterequipment start-up.

DETAIL “B”

Sensitivityadjustment

More Sensitive

LessSensitive


INSTALLATION Continued

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

DETAIL “A”

SensitivityAdjustment

Reset Push button

DETAIL “C”

Turn toincrease

Pot

Turn todecrease

WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE

OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.

WARNING: REMOVE ALL POWER BEFORE OPENINGTHE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE AQUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKESURE IT CONFORMS WITH NEC AND LOCAL CODES. DO

NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STANDCLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.

WARNING: REMOVE ALL POWER BEFORE OPENINGACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE AQUALIFIED PERSON ADJUST THE UNIT, AND MAKE SUREIT CONFORMS WITH NEC AND LOCAL CODES.


TYPICAL MOUNTING LOCATIONS

Engine Compressor Turbine Centrifugal Compressor

EngineandVertical ShaftPump

“Y” Type Reciprocating Compressor

Generator Sets

Cooling Tower Fan orHeat Exchanger

Pumping Unit2-Throw Balance-Opposed Compressor

NOTE: If installing on cylinders, 2 vibration/shockswitches are recommended-1 for each cylinder.

Reset

Reset

Reset

Reset

Reset

Reset

Reset

Reset

Reset

These are typical mounting locations for best operation. Other mountings are possible. See Installation section on page 3.NOTE:


INTERNAL SWITCHES

NC NO COM

NC NO COM

NC NO COM

NO1 NC COM NO2

VS2 and VS2C VS2EXR

VS2EX VS2EXB and VS2EXRB

VS94

NC NO COM

NC NO COM

Time Delay and/or Remote Reset Terminal (Optional)


SPDT Snap-Switch

SPDT Snap-Switch




Heater Board Terminal (Optional)

GroundTerminal

NC NO COM

NC NO COM

SPDTSnap-Switch

SPDTSnap-Switch


GroundTerminal

SPDT Switch TerminalsSPDT Snap-Switch

SPDTSnap-Switch Optional SPDT

Snap-Switch (VS2EXRB only)

GroundTerminal

GroundTerminal

Remote ResetTerminal

Remote ResetTerminal


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

ELECTRICAL

To good engine ground

CD Ignition1

CD Ignition2

Ignition Coil Distributor Battery

IgnitionSwitch

Ammeter

Diesel Fuel Shutoff Valve

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94Typical Wiring Diagram for Distributor Ignition or Diesel

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94Typical Wiring Diagram for Electric Motors

Maintained Contact forTime Delay

Momentary Contact forRemote Reset only

TimeDelay

2-SPDT Switches (DPDT)

Time Delay or Remote Reset

(Optional)

Heater Board(Optional)

N.C.N.O.

Contacts shown in the RESET position

Contacts shownin the RESET position

Contacts shownin the RESET position Switch Terminals

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

Switch Terminals

N.C.N.O.(see Note)

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

N.O.(see Note)

N.C.N.O.

115 VAC or 24 VDC*

115 VAC or24 VDC*

*Voltage is specified when ordered.

L1 L2 L3

MOTOR

Push-buttonStation

HC

H A

HC

Hand OffAutomaticSelector

VS2EXR and VS2EXRBTypical Wiring Diagram for Single or Dual CD Ignitions

VS94Typical Wiring Diagram for Single or Dual CD Ignitions

Remote Reset

MomentaryPush Button

115 VAC or 24 VDC (Voltageis specified when ordered).

N.C.N.O.

†Additional Switch Optional on VS2EXRB only

SPDT Switch(Optional 2-SPDT [DPDT])†


COMCOM

COM

COM COM

COM

N.C.N.O.


Resistor(100 Ω, 3 Watt)




CD Ignition2

CD Ignition1

VS2EXTypical Wiring Diagram for Single or Dual CD Ignitions

N.C.N.O.

SPDT Switch(Optional 2-SPDT [DPDT])†


COM

COM

N.C.N.O.



CD Ignition2

VS2 and VS2CTypical Wiring Diagram for Single or Dual CD Ignition

COM

SPDT Switch

NO2NCNO1

Contacts shown in the RESET position.

To good engine groundResistor

(100 Ω, 3 Watt)

CD Ignition2

CD Ignition1


CD Ignition1


SERVICE PARTS

PART NO. DESCRIPTION

VS2 20000030 Movement assembly20000031 Glass and gasket assembly20000032 Reset push button assembly

VS2C 20000030 Movement assembly20000031 Glass and gasket assembly20000032 Reset push button assembly20050021 Mounting clamp20000185 VS2C 5-clamp hardware package assembly.20050465 2-Conductor electrical cable, 45 feet (13.7 meters)

VS2EX 20010091 Movement assembly20050087 Cover00000309 Cover gasket20010090 Snap-switch and insulator kit (1 switch per kit)

prior to September 1, 1995.*20000288 Snap-switch and insulator kit (1 switch per kit) for models

manufactured on September 1, 1995 or later.*20000289 C-clamp conversion mounting kit

VS2EXR 20000262 Movement assembly20050087 Cover00000309 Cover gasket20010090 Snap-switch and insulator kit (1 switch per kit)


manufactured on September 1, 1995 or later.*20000049 Reset solenoid assembly (115 VAC) 20000234 Reset solenoid assembly (24 VDC)20000289 C-clamp conversion mounting kit

PART NO. DESCRIPTION

VS2EXRB 20010090 Snap-switch and insulator kit (1 switch per kit)


manufactured on September 1, 1995 or later.*20000057 Inside snap-switch and insulator kit (1 switch per kit) for

model VS2EXRB-D prior to September 1, 1995.* 20000058 Outside snap-switch and insulator kit (1 switch per kit) for

model VS2EXRB-D prior to September 1, 1995.*20000287 Outside snap-switch and insulator kit (1 switch per kit) for model

VS2EXRB-D manufactured on September 1, 1995 or later.*20000290 Inside snap-switch and insulator kit (1 switch per kit) for model

VS2EXRB-D manufactured on September 1, 1995 or later.*20050077 Adjustment shaft20000262 Movement assembly20000049 Reset solenoid assembly (115 VAC) 20000234 Reset solenoid assembly (24 VDC)

VS94 Series 25050506 Dust boot00000232 Conduit fitting20010090 Snap-switch and insulator kit (1 switch per assembly)

prior to September 1, 1995.**20000288 Snap-switch and insulator kit (1 switch per assembly)

for models manufactured on September 1, 1995 or later.***

* If no date code is found, refer to the old switch. Models with date 0895 and before use old switch. Dated 0995 after, use straight snap-switch arm, no rollers.

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

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

CONTROL SYSTEMS & SERVICES DIVISIONP.O. Box 1819Rosenberg, Texas 77471 USAPhone: 281.633.4500 Fax: 281.633.4588E-mail: [email protected] site: www.fwmurphy.com

FRANK W. MURPHY, LTDChurch Rd LaverstockSalisbury SP1 1QZ UKPhone: +44 1722 410055 Fax: +44 1722 410088E-mail: [email protected] site: www.fwmurphy.co.uk

COMPUTRONIC CONTROLS, LTD41 - 43 Railway Terrace NechellsBirmingham B7 5NG UKPhone: +44 121 327 8500 Fax: +44 121 327 8501E-mail: [email protected] site: www.computroniccontrols.com

FW MURPHY INSTRUMENTS (HANGZHOU) CO. LTD 77 23rd StreetHangzhou Economic & Technological Development AreaHangzhou, Zhejiang, 310018, ChinaPhone: +86 571 8684 8886 Fax: +86 571 8684 8878

FW MURPHYP.O. Box 470248Tulsa, Oklahoma 74147 USA +1.918.317.4100 Fax: +1.918.317.4266 E-mail: [email protected]

INDUSTRIAL PANEL DIVISIONFax: 918.317.4124E-mail: [email protected]

MURPHY POWER IGNITIONWeb site: www.murphy-pi.com

www.fwmurphy.comPrinted in U.S.A. 078792

DescriptionThe L129 Series Lube Level Swichgage instrument is a com-bination lube level indicating gauge with adjustable low andhigh limit switches. It provides protection against low oil level or high levelcaused by overfill or fuel or water seepage into the crankcase. A 6-3/4 inch(171 mm) deep sight gauge allows you to check the condition and level ofyour oil without shutting down the equipment.Fingertip adjustable limit switch contacts are adjustable thru 4-7/8 inch (122mm) range. When the float touches the high or low limit contact, a normal-ly open circuit will close which can activate alarms and/or shutdown theequipment. There are two models in the L129 Series: L129 and L129CK1. The L129model is designed for grounded, low voltage electrical systems. It features aone-wire-to-ground electrical circuit. The L129CK1 is designed for applica-tions requiring a three-wire, above ground electrical circuit. It featuresungrounded contacts and a conduit hub for electrical wiring connection.

SpecificationsCase: Die Cast Aluminum.Lens: Tempered Glass.Maximum Working Pressure: 10 psi (68.9 kPa) [0.69 bar].Process Connection: 1/2 NPT.Float Material: Brass.Contact Rating: 2 A @ 30 VAC/DC, pilot duty.

Flow Restrictor Plug Order SeparatelyFlow Restrictor Plug restricts oil flow between thecrankcase and the L129 Series. It is typically used onsome mobile applications such as marine and mobileequipment. Part no. 15050241.

Installation Instructions forL129 Series Level Swichgage® instrument

L-95006NRevised 06-06

Section 1500-02-0174

Please read the following information before installing. A visual inspection of this product fordamage during shipping is recommended before mounting.

GENERAL INFORMATION



8 in.(203 mm)

3-3/16 in.(81 mm)

2-31/64 in.(63 mm)

Shock Mount(2 supplied)

Keps nut(2 supplied)

Low LevelAdjust

High LevelAdjust

1-1/2 in.(38 mm)

2 in.(51 mm)

1/2 NPT Closed Nipple(2 supplied)

1/2 NPT Union(1 supplied)

HighContact

LowContact

Float

+ +

+ +

+ +

+ +

-

-

-

-

9-55/64 in.(250 mm)

HighContact

1/2 NPTConduit

LowContact

Float

4-55/64 in.(123 mm)

2-31/64 in.(63 mm)

Low LevelAdjust

High LevelAdjust

1-1/2 in.(38 mm)

2 in.(51 mm)

1/2 NPT Closed Nipple(2 supplied)

1/2 NPT Union(1 supplied)

+

+ +

+ +

+ +

+ -

-

-

-

Shock Mount(2 supplied)

Keps nut(2 supplied)

L129CK1

enile

Dimensions

*

L129

CAUTION: Certain danger to human and to equipmentsuch as applied in a mobile or marine application may occur ifsome equipment is stopped without pre-warning. It is therefore,recommended that monitored functions be limited to alarm

only or to alarm before shutdown in such applications.

Repair KitsSpecify part number.

L12915000888 Full Repair Kit (less castings and glass assÕy) fo r date

code T2 and later.

15000480 Bezel, Glass and Gasket Set for date code W7 and later

15000485 Glass and Gasket Set for all date codes

15050241 Restrictor plug for all date codes

L129CK115000480 Bezel, Glass and Gasket Set for date code W7 and later

15000485 Glass and Gasket Set for all date codes

15050241 Restrictor plug for all date codes

L-95006N page 1 of 2*Complete with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.

L-95006N page 2 of 2

NOTE: Read all instructions before beginning installation.Mounting1. Determine which side of the engine to mount the L129. This will normally be the

side of the engine from which it is started. Weld a slotted mounting plate to theengine skid or attach the mounting plate to the crankcase. If a mounting plate isnot used, a support strap is recommended (see Typical Installation below).

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

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

Connecting Hoses and Fittings1. DRAIN THE CRANKCASE. If the crankcase does not have an auxiliary plug or

connection, connect the L129 to the crankcase drain plug connection. This con-nection will normally be a straight (parallel) thread which seals with a copper orfiber washer. NOTE: If the drain plug on the crankcase is used for the connection,we recommend installation of a tee to allow draining of the crankcase for service.

2. Flexible hose or rigid pipe can be used to attach the L129 to the enginecrankcase. Flexible hose is to be 1/2 in. (13 mm) I.D. minimum and made ofquality material. Use of flexible hose will allow you to adjust the height of theL129 to properly reflect the oil level in the crankcase. Also, a swivel connectionon one end of the hose will assist in properly aligning the L129.

Rigid pipe is to be 1/2 inch pipe. If the length of the pipe is relatively short, noadditional support for the L129 may be needed, although it is recommended. Apipe union is provided in the installation kit.Attach the hose or pipe from the L129 process connection (1/2 NPT) to thecrankcase.

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

L129 vent back to the crankcase. If you do not do this, the L129 will indicatehigh level with a pressurized crankcase and a low level with a vacuum crankcase.In extreme cases a pressurized system will blow oil out the vent tube or in vacu-um crankcases can suck oil out of the L129. To vent the L129 back to the crankcase, install a 1/4 inch (6 mm) O.D. or larg-er tubing (copper or flexible) from the L129 vent fitting to a point in thecrankcase above the full oil level or in the fill pipe that is not restricted by baf-fles, filters or other obstructions. If connecting directly into the crankcase, besure the entry point is clear of oil splash that can plug the tube opening.

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

WiringFollow appropriate wiring for the alarm or engine shutdown system you are using.Diagrams below are shown with the float in the “full” position.

Operation TestThe following test is to be performed after the L129 has been installed and thecrankcase has been filled to the proper oil level.1. With equipment running, turn the high and low adjust knobs one at a time until

they “make” contact with the float. When contact is made the alarm or shutdowncircuit should actuate.

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

WarrantyA limited warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by goingto www.fwmurphy.com/support/warranty.htm

INSTALLATION and OPERATION

518PH

C S

117PH

BG NC SW1 SW2 B

BLACK

RED

WHITE

HI

HI LOW

LOW

COM.

L129

Magnetic Switches

L129CK1

_+Ignition Coil

Rack PullSolenoid

Fuel Valve Battery

CAUTION: Perform all wiring connections with the battery dis-connected. Observe all contact ratings and voltages.

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

Customer SuppliedSupport Strap

MountingPlate

Shockmount

Vent Contact Adjustment Knobs

High and LowContacts

Tee

Crankcase

SightGlass

Typical Installation

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

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

www.fwmurphy.com918.317.4100 Email: [email protected]

LM-92164NRevised 10-03

Section 15(00-02-0176)

Installation Instructions for Level MaintainersModel Series LM300

LM300: Level Maintainer only (no switches).LM301: Low switch contacts for low level shutdown or alarm. Four wires, SPDT. LM302: Two switches for low and high level shutdown or alarm. Four wires,DPST, wired N.O. in normal operating ranges.LM303: Two switches for low and high level shutdown or alarm. Four wires,DPST, wired N.C. in normal operating ranges.LM304: Two switches. Alarm before shutdown on low level and shutdown onlow-low level. Four wires, DPST, wired N.O. in normal operating ranges.LM305: Two switches. Alarm before shutdown on low level and shutdown on low-low level. Four wires, DPST, wired N.C. in normal operating ranges.

SpecificationsCase/Cover: Die cast aluminum.Switch Housing: Aluminum.Approval Rating: LM301 thru LM305 : CSA certified†† for non hazardous

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

Float: Rigid polyurethane foam. Polyurethane coated.Maximum Ambient Temperature: 250°F (121°C)Oil Inlet Connection: Top entry 1/2-14 NPT with built-in filter screen (removable

for cleaning).Inlet Orifices: 1/4 in. (6 mm) standard. 1/8 in. (3 mm) available.Wire (switch models): 18 AWG x 13 in. (1.0 mm2 x 330 mm).Maximum Inlet Pressure (MIP):

Max. Differential: 2 in. (51 mm) between running and stationary oil level.30 psi (207 kPa) [2.07 bar].

with 1/8 in. (3 mm) orifice.15 ft. oil (4.6 m oil)

with 1/4 in. (6 mm) orifice.Maximum Case Pressure (MCP): 15 psi (103 kPa) [1.03 bar]. Orifice Seal†: Buna-N Thumb-Valve™Switch Contact: Silver, SPDT snap acting, 10A @ 125, 250VAC; 10A @ 30VDC.

(1 only for low level; 2 only for high & low; or 2 only for low with alarm before shutdown)

Outlet Connection: 3/4-14 NPT left side, right side, and bottom.Crankcase Balance Vent Fitting: 1/2-14 NPT.Mounting: Accepts Murphy pipe mounting or universal mounting brackets.Lens: Clear “Frog Eye” non-staining, high impact, high temperature nylon; UV

and heat stabilized.Dial: High visibility white background with green and white “index” lines for

normal level indication.Test Knob: Rotate to test switch operation. Turn clockwise for low level test

and turn counterclockwise for high level test.Flow Rate Test: Using SAE 30 @ 32°F (0°C).

Optional Hose Kit: 15000355Quantity Description

1 1/2 in. (13 mm) I.D. x 3 ft. (914 mm) long hose

1 1 in. (25 mm) I.D. x 3 ft. (914 mm) long hose

2 1/2 in. (13 mm) worm gear clamp2 1 in. (25 mm) worm gear clamp2 1/2 NPT x 1/2 in. (13 mm) barbed fitting2 3/4 NPT x 1 in. (25 mm) barbed fitting

††CSA certified with switch contacts rated at 10 A @ 250 VAC (standard).

** Products covered by this bulletin comply with EMC Council directive89/336/EEC regarding electromagnetic compatibility except as noted.

GENERAL INFORMATION

Read the following instructions before installing. A visual inspection of this product fordamage during shipping is recommended before mounting. These installation instructions areintended for all LM300 series models.

Patent5493086

LM301-EXShown with optional hose kit fittings


Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

**

OrificeDiameter1/4 in.*(6 mm)

1/8 in. (3 mm)

Pressure

4 ft. oil – 15 ft. oil(1.2 m oil – 4.6 m oil)

10 psig – 30 psig (68.9 kPa – 207 kPa)

[.69 – 2.07 bar]

Flow Rates

4.7 GPH - 31.0 GPH(17.8 LPH - 117.3 LPH)

16.9 GPH - 32.1 GPH(63.7 LPH - 121.5 LPH)

*StandardNOTE: Friction losses due to piping NOT considered.

LM-92164N page 1 of 4


DIMENSIONS

TYPICAL INSTALLATION

8-1/4 in.(210 mm)

CrankcaseVent

1/2-14 NPT

Oil Inlet Connection* 1/2-14 NPT

with removable screen

6 in.(152 mm)

TestKnob

ElectricalConduit1/2-14

NPT

Monitoring Port Connection3 places, 3/4-14 NPT*Applies to level maintaining models only.

7-3/16 in.(183 mm)

5-3/16 in.(132 mm)

3/8-16 UNC-2BMountingHoles, 2 places

2-3/4 in.(70 mm)

Snap SwitchCase Assembly

5-15/16 in.(151 mm)

LM300 Series Enclosures Mounting Brackets with Hardware

4.50 in.(114 mm)

5.20 in.(132 mm)

2.50 in.(64 mm)

Hole .88 in.(22 mm) dia.

1/4-20 NC2 places

.376 in.(10 mm)minimumbottom surface2 places

1.75 in.

(44 mm)

7.50 in.

(191 mm)

Slot, .390 in. (10 mm)x 4.71 in. (120 mm)3 places

6.69 in.(170 mm)

Slot, .390 in. (10 mm)x 2 in. (51 mm)4 places

4.50 in.(114 mm)

5.19 in.(132 mm)

15000371 pipe bracket

15000370 universal bracket

The dimensions below are for the optional -EX model enclosure. Thestandard model enclosure dimensions are the same except the height andwidth which are: 7 in. (178 mm) H, 7-7/8 in. (200 mm) W.

Mounting (all LM300 Series models)NOTE: Mount the LM300 series level maintainers as close as possibleto the crankcase. Also, excessive vibration can cause overfill. Be suremounting brackets are supported.The following instructions are based on the usage of the pipe and universalmounting brackets shown above.

Pipe Bracket Mounting1. Mount a nominal 1/2 inch (21 mm) diameter pipe to the deck of the engine.

2. Install the pipe bracket to the LM300 using two 3/8-16 UNC x 1 inchbolts supplied. See Figure 1A.

3. Slip the LM300 onto the pipe and install the two adjustment bolts. Eachadjustment bolt consists of a 3/8-16 UNC x 1 inch bolt and two nuts. SeeFigure 1B. DO NOT tighten the adjustment screws too tightly becauseyou will have to adjust the LM300 later in the installation process.

Mounting with Universal BracketThe universal bracket has two mounting methods: deck mounting and pan mounting.

Deck Mounting1. Install the universal bracket to the deck as shown in Figure 2A with two

flat washers and two 3/8 inch (10 mm) diameter bolts (not supplied).

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

Pipe Crankcase

AdjustmentBolts

Figure 1B

LM300

PipeBracket

Figure 1A

AdjustmentBolts

Figure 2B

Crankcase

Deck

UniversalBracket

Threadedhole

Figure 2A

Additional HardwareSupplied(4) 3/8-16 UNC x 1 inch

(25 mm) screws

(4) 3/8-16 nut

(4) 3/8 I.D. lock washer

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

Additional HardwareSupplied(2) 3/8-16 UNC x 1 inch

(25 mm) screws

(4) 3/8 I.D. flat washer

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

(2) 3/8-16 nut


TYPICAL INSTALLATION continued

Crankcase (Oil Pan) Mounting1. Install the universal bracket to the crankcase using the existing

crankcase bolts (Figure 3A). Crankcase bolt diameter must be no largerthan 7/16 inch (11 mm).

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

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

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

Connecting Fittings and HosesThe following instructions are for all LM300 series level maintainers.All steps that reference oil inlet or oil supply tank DO NOT apply tonon-level-maintaining models. Also, these instructions are based on theMurphy optional hose kit described on page 1. If you did not order theoptional hose kit, gather the hoses, clamps and fittings as specified inthe optional hose kit.1. Install the LM300 fittings in their proper locations. NOTE: Apply a

sealant such as teflon, to all threaded connections.2. Attach the 1 inch (25 mm) diameter, flexible monitoring hose to the

crankcase and the monitoring port on the LM300. See Figure 4.CAUTION: The hose must slope slightly downward from the LM300and MUST NOT have any droop or low spots.

NOTE: If the drain plug on the crankcaseis used for the connection, werecommend installation of a tee toallow draining of the crankcasefor service.

3. Install the 1/2 inch (13 mm)I.D. x 3 ft. (914 mm) hose tothe vent connection on theLM300 to the vent connectionon the crankcase. See Figure 4.The vent connection on thecrankcase must be well above theregulated oil level. All hoses mustbe clear of obstructions.

BEFORE CONTINUING, VERIFY THAT ALL HOSE CLAMPSARE TIGHT.

4. Fill the crankcase to the proper oil levels. With the engine running andwarm, loosen the mounting bracket adjustment bolts and adjust theLM300 so that the oil level in the sight gauge is aligned with the white“index line” on the dial (Figure 4). Tighten the adjustment bolts securely.

Connecting the LM300 to an Oil Supply Tank(level maintaining models only) 1. Remove the caplug from the oil inlet connection. Be sure the filter, inside

the connection, is clear of debris. Install the oil inlet connection.

2. Connect a 1/2 inch I.D. (13 mm) or larger hose to oil inlet fitting on the LM300 and to the shutoffvalve on the oil supply tank. See Figure 5. Formodels LM300 thru LM305 recommendedminimum mounting of the oil supplytank above the LM is 4 ft. (1.2m);maximum 15 ft. (4.6m). Thehose must maintain adownward slope and not havelow spots or droops.Maximum head pressurerating using standard 1/4 in. (6mm) orifice is 15 ft. (4.6meters). See Flow Rate test on page 1 for additional orifice pressureratings.

3. Before filling the supply tank withoil, be sure the tank is clean and dry andthe shutoff valve is closed.Also, be sure all hoses and clamps are tight. Fill the tank with CLEANoil.

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

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

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

IMPORTANT: Always replace boot aftertesting.

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

3. Turn the knob 1/4 turn to the left(counterclockwise), for high test indication. DO NOT FORCETHE TEST KNOB TO TURN.

NOTE: After the engine shuts down, you will notice that the oil in thesight gauge glass will rise above normal running level, possiblyshowing an overfill condition. This is a result of “drain-back” to theengine crankcase and it is normal. Therefore, on models LM302 andLM303 it may be necessary to wire the high level shutdowns into aclass “B” or “C” (bypass until first time safe) lockout, so as to allow apermissive start. After the engine is re-started the level will pull downto the normal running level and the shutdown features will be active. Amodulating valve (Thumb-Valve™) in the level maintaining modelswill allow oil usage to be made-up continuously during operation.

AdjustmentBolt

Figure 3B

Crankcase

UniversalBracket

CrankcaseBolt

Note Clearancebefore mounting

Figure 3A

ViewingLens

Monitoring Hose

CrankcaseOil Level

RunningEngine

VentHose

Oil InletHose

Figure 4

Oil InletHose

Oil SupplyTank

Figure 5

Figure 6

WARNING: Overfill condition can be caused by excessiveinlet pressure, (maximum inlet pressure depends on orifice),and/or improper “vent to crankcase” installation. See Flow Rate Test on page 1 for maximum pressure.


OPERATING RANGES OF SWITCHES

3/4 in.(19 mm)

Normal Operating Range

Low Zone Shutdown or Alarm

High Zone Shutdown or Alarm

3/8 in.(10 mm)

3/8 in.(10 mm)

3/4 in.(19 mm)


Low Zone AlarmLow-Low Zone Shutdown

3/4 in.(19 mm)

3/8 in.(10 mm)

1/4 in.(6 mm)

SWITCH WIRING DIAGRAMS

LM301SPDT

LM302High/Low N.O.

DPST

LM303High/Low N.C.

DPST

Green

BlackNormal

RedLow

Float

Yellow

Green

BlackHigh

Float

High

RedLow

Yellow

Normal

Low

Normal

Green

High

Float

High

Low

Blue

Normal

Low

Normal

Brown

Orange

Green

Normal

Float

Normal

Low-Low

Yellow

Low

Low-Low

Low

Black

Red

Green

Normal

Float

Normal

Low-Low

Blue

Low

Low-Low

Low

Brown

Orange

LM304Alarm before

shutdown N.O.DPST

LM305Alarm before

shutdown N.C.DPST


Low Zone Shutdown or Alarm

3/4 in.(19 mm)

3/8 in.(10 mm)

Figure 7: LM301 Figure 9: LM304/LM305

Figure 8: LM302/LM303

This section applies only to models that have built-in switches. The illustrationsbelow and to the right show the dials and their operating ranges of the switches.If levels are within the designated zones the switch(es) will activate. Notice thata switch is capable of activating approximately 3/8 in. (10 mm) from the top ofthe high zone and 3/8 in. (10 mm) from the bottom of the low zone. The dial inFigure 9 shows that if level continues to drop into the low-low zone, ashutdown will occur.

NOTE: Color zones on dial face show approximate normal operating zones.Actual conditions may vary depending upon operating characteristics of theengine. Placement of the LM300 according to the above instructions willcompensate for these conditions.

WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE CONNECTING ANY WIRES.

CONTROL SYSTEMS & SERVICES DIVISIONP.O. Box 1819; Rosenberg, Texas 77471; USA+1 281 633 4500 fax +1 281 633 4588 e-mail [email protected]

MURPHY DE MEXICO, S.A. DE C.V.Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336Villahermosa Office +52 993 3162117e-mail [email protected]

FRANK W. MURPHY, LTD.Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.+44 1722 410055 fax +44 1722 410088 e-mail [email protected]

MURPHY SWITCH OF CALIFORNIA41343 12th Street WestPalmdale, California 93551-1442; USA+1 661 272 4700 fax +1 661 947 7570e-mail [email protected]

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

MACQUARRIE CORPORATION1620 Hume HighwayCampbellfield, Vic 3061; Australia +61 3 9358 5555 fax +61 3 9358 5558e-mail [email protected] FW Murphy

P.O. Box 470248Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail [email protected] www.fwmurphy.com

REGISTERED

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

Printed in U.S.A.

WarrantyA 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

Installation Instructions for L971 Series Crankcase Level Switch

L-94071NRevised 09-97

Section 15(00-02-0173)

DescriptionThe Murphy L971 Series Level Switch detects low oil level in a com-pressor’s crankcase. It is designed for Ingersoll-Rand Type 30, Type 40and ESH compressors, yet can be adapted to fit other compressors thathave an inspection plate extending below normal operating oil level.The L971 has a 1/2 NPT process connection and features an explosion-proof enclosure, durable SPDT snap-switch and rigid polyurethanefoam float.

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

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

Switch Rating: 4 A @ 250 VAC.

MaterialCase: Aluminum (explosion-proof).Mounting Adaptor: Brass.Floats:

• Rigid polyurethane. • 304 stainless steel (L971-C only).

Other Wetted Parts: 303, 304, and 316 stainless steel.O-Ring Seals: Viton and Buna.

Process Connection:1/2 NPT.

Enclosure Rating: UL and CSA listed for Class I, Groups C & D; Class II, Groups F & G, Hazardous Locations.

Conduit Connection: 1/2 NPT.

Wire: 18 AWG (0.75 mm2).

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

GENERAL INFORMATION

®


Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions. R

®

Dimensions

WarrantyA two year limited warranty on materials and workmanship is pro-vided with this Murphy product. Details are available on requestand are packed with each unit.

A B C D EL971 2-5/8 (67) 5-7/8 (149) 30 (762) 2-1/2 (64) 2-27/32 (72)

L971-A 2-5/8 (67) 5-7/8 (149) 30 (762) 2-1/2 (64) 2-27/32 (72)

L971-B 4-13/16 (122) 8-1/16 (205) 30 (762) 4-5/8 (117) 2-27/32 (72)

L971-C 2-13/16 (71) 6-1/16 (154) 30 (762) 2-7/8 (73) 3-1/8 (79)

L971-D 3-7/8 (98) 7-1/8 (181) 30 (762) 3-3/4 (95) 2-27/32 (72)

L971-E 4-13/16 (122) 8-1/16 (205) 30 (762) 5-1/8 (130) 2-27/32 (72)

L971-F 2-5/8 (67) 5-7/8 (149) 40 (1016) 2-1/2 (64) 2-27/32 (72)

L971-G 2-5/8 (67) 5-7/8 (149) 40 (1016) 2-1/2 (64) 2-27/32 (72)

*Millimeter dimensions are shown in parenthesis ( ).

Dimensions in inches* (see drawing above)

Models

D

AFloat arm is adjustable but cannot beremoved.

1/2 NPT

Float is removableand replaceable

3 in.(76 mm)

1/2 NPT

B C

E

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

**

INSTALLATION

Compressors With Inspection Plate1. Drain crankcase.2. Remove crankcase inspection plate (Figure 1).3. Drill and tap a 1/2 NPT female pipe thread into the inspection plate at

point “A” (Figure 2). CAUTION: Clean area of metal shavings. Thehole is to be a minimum of 2 in. (51 mm) below normal running oillevel (Figure 3).

4. Unscrew and remove float on the L971 switch.5. Apply pipe dope to the process connection threads.6. Thread the L971 switch into crankcase hole until “TOP” label is up (Figure

4). Be sure the float moves freely and there are no obstructions. 7. If adjustment of shutdown level is required, loosen hex set screw on float

attachment. Rotate float attachment to desired level. Retighten set screw.8. Replace float and reinstall inspection plate and gasket in original position.9. Install drain plug.10. Wire accordingly. 11. Fill crankcase to proper level.

Compressors Without Inspection Plate1. If installing into a thick wall crankcase, drill and tap a 1/2 NPT

female pipe thread into the crankcase. CAUTION: Clean area ofmetal shavings. The hole is to be a minimum of 2 in. (51 mm) belownormal running oil level (Figure 3).If installing into a thin wall crankcase, drill a hole in the crankcaseslightly larger than outside diameter of a 1/2 in. coupling. The hole is tobe a minimum of 2 in. (51 mm) below normal running oil level (Figure3). CAUTION: Clean area of metal shavings. Weld a half collar (1/2NPT) into the hole.

2. Follow steps 4 thru 11 above.

NormalOil Level

Hole 2 in. (51 mm) Minimum

InspectionPlate

Crankcase

A

Oil Level

Crankcase Float

90°“TOP” Label

InspectionPlate

Conduit

Figure 1

Figure 4

Figure 2

Figure 3

Shutdown Circuit for H.O.A. Operation

HO

A

HCYellow

Black

Line Voltage

Shutdown and Alarm CircuitControl Voltage

HO

A

HC

CrankcaseSwitch

CrankcaseSwitch

CrankcaseSwitch

CrankcaseSwitch

Alarm Silencer

Alarm

YellowBlackRed

Alarm Without Shutdown Circuit

Power Supply

Alarm Silencer

Alarm

Yellow

Red

Shutdown Circuit for Start-Stop Push-button Operation

HC Yellow

Start

Stop

Black

TYPICAL WIRING

REPLACEMENT PARTS

Description Part NumberCover 15050443Cover Gasket 15050369Snap-switch 00002326

Description Part NumberFloat

Polyurethane 15050679Stainless Steel 15050356

Prin

ted

in U

.S.A

.

®FRANK W.

MFR.

Frank W. Murphy ManufacturerP.O. Box 470248; Tulsa, Oklahoma 74147; USAtel. (918) 627-3550 fax (918) 664-6146 e-mail [email protected]

Frank W. Murphy Southern DivisionP.O. Box 1819; Rosenberg, Texas 77471; USAtel. (281) 342-0297 fax (281) 341-6006 e-mail [email protected]

Since 1939

Frank W. Murphy, Ltd.Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.tel. +44 1722 410055 fax +44 1722 410088 tlx 477088e-mail [email protected] Frank W. Murphy Pte., Ltd.26 Siglap Drive; Republic of Singapore 456153tel. +65 241-3166 fax +65 241-8382 e-mail [email protected] Murphek Pty., Ltd.1620 Hume Highway; Campbellfield, Vic 3061; Australiatel. +61 3 9358-5555 fax +61 3 9358-5558

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. Murphy de México, S.A. de C.V.Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 tel. +52-48-206264 fax +52-48-206336e-mail [email protected] Murphy Switch of CaliforniaP.O. Box 900788; Palmdale, California 93590; USAtel. (805) 272-4700 fax (805) 947-7570e-mail [email protected] Frank W. Murphy Francetel. +33 1 30 762626 fax +33 1 30 763989

© 2005 Thermo Sensors Corporation | Design by Visual Applications

Installation and Maintenance

Thermocouple Installation

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

2. Locating the thermocouple where the hot end can be seen assures visual confirmation of the junction location. 3. Immerse the thermocouple far enough to ensure that the measuring junction is entirely included in the temperature area

to be measured. a depth ten times that of the diameter of the protection tube is recommended. Heat which is conducted away from the hot junction will cause a lower reading due to "stem loss."

4. Keep the connecting head and cold junction in coolest ambient temperature available. 5. To prevent breakage due to thermal shock, never insert a ceramic tube into a hot area rapidly. Preheat gradually while

installing. 6. Avoid direct flame impingement on protecting tube. Impingement shortens the tube life and causes temperature readings

to be inaccurate. 7. When measuring high temperatures, install the thermocouple vertically, whenever possible. Such installation minimizes

sagging of the tube or sheath.

Extension Wire Installation

1. Be sure to select the correct type of extension wire for a given calibration of thermocouple. (See Bulletin 300). 2. Use the color coding of individual wires as a guide for connecting the negative wire to the negative-wire terminal at both

the thermocouple connection head and the instrument. Red is always Negative (-). 3. To prevent spurious EMF due to electrostatic and electromagnetic noise, never run thermocouple extension wire in same

conduit, parallel to the conduit or near any power source. Keep thermocouple wire at least 12" from power source. 4. In "high noise" areas, use thermocouple extension wire with twisted and shielded conductors and a drainwire. 5. Select the proper insulation to meet the specific conditions under which it must perform. (See Bulletin 300).

General Maintenance

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

2. Keep rotary switches clean and free of oxidation at contact points. 3. When reinserting a thermocouple, it is extremely important that the depth of insertion not be changed. Be especially

careful not to decrease the depth. Wires which are not homogeneous, due to exposure to the process, will cause errors in regions of temperature gradients.

4. A type K thermocouple should not be exposed to temperatures of 1600° F or higher if it is to be used for accurate measurements below 1000° F.

5. Do not use thermocouples with burned-out protecting tubes. Thermocouples can become damaged with contamination if allowed to remain within tubes of poor condition.

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

Industrial Thermocouples Return to Industrial Thermocouples Index

Return to Industrial Thermocouples Index

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

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

e-mail: [email protected] • http://www.ccsdualsnap.com

4 EXTERNAL ADJUSTMENTWIDE RANGEDIAPHRAGMSS PORT

PRESSURE

INSTALLATION DRAWING

6900GZE

6900GZESHIPPING WT.APPROX. 19 OZ.(539 GRAMS)

PRESSURE SWITCHESMODEL 6900GZE

1/2” STAINLESS STEELPRESSURE PORT ANDDIAPHRAGM

• WettedParts

316 SSTViton

MaxSys.

Press.psi

5005001500150020003000

750750

2000200030004500

3–209–75

18–15045–375

300–1000700–2500

1–183–69

6–13815–345

225–925520–2320

26

123075

180

6900GZE126900GZE146900GZE166900GZE186900GZE206900GZE22

6900GZEM126900GZEM146900GZEM166900GZEM186900GZEM206900GZEM22

Proof(Test)Press.psi

On Incr.Press.psi

On Decr.Press.psi

Approx.Dead–bandpsi

MODELSPDT–Std.

MODELDPDT “M”

Adjustable Set–Point Range Model No.

OPERATING AND ORDERING DATA:

ELECTRICAL CHARACTERISTICS:RATING OF SWITCH ELEMENT

AMPERESSPDTRes.11115.5

DPDT “M”Res.11115.5

125 AC – 50/60 Hz250 AC – 50/60 Hz30 DC125 DC

VOLTS

SCHEMATIC AND WIRING CODE:SPDT–Standard DPDT “M”

Press. 1 to 2500 psi

SERIES:6900GZE

Standard Features:• U.L./CSA

Explosion Proof: Div. 1, 2

• NEMA: 4, 7, 9, 13

AMBIENT TEMP. RANGE–30° to 160° F–34° to 71° C

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

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

catalog mg 9/5/02 9:48 AM Page 6

http://www.ccsdualsnap.com

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

e-mail: [email protected] • http://www.ccsdualsnap.com

29

Surge and RipplesThe Disc Spring design used in DUAL–SNAP® switchesmakes them relatively impervious to surges or pump ripples that may be expected in conventional hydraulicsystems.

This resistance to sharp pressure changes in the mediahas been the prime reason for many customers changingto DUAL–SNAP® pressure switches after experiencingfalse shutdown and failure with other competitive designprinciples such as flat metal diaphragms, bourdon tubesand bellows type.This makes DUAL–SNAP ® switchesparticularly suitable for rugged applications on off theroad machinery, heavy presses,and systems using pulsating piston pumps

Pressure SwitchApplication ConditionsAmbient Temperature: The pressure switch should beinstalled wherever possible in a location that has the mostconstant ambient temperature available.

Steam Service: For steam or other high temperatureapplications the pressure switch should be mounted withthe pressure connection up and with three or four circularloops,or pigtails, in the pressure lines. The verticalmounting allows condensate to accumulate in the deadended pressure line and to be cooled in the pigtail whichacts as a temperature buffer between the sensing element and the steam.

Corrosive FluidsOccasionally liquids or gases are encountered that are notcompatible with the “wetted parts ”as shown in the catalog. When this occurs it is common practice to use achemical seal as an interface between the corrosive fluidand the pressure switch.Custom Control Sensors does notmanufacture or accept orders for chemical seals. Thereason for this is to insure that the customer gets exactlywhat he needs for his application.

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

Typical and readily available CHEMICAL SEALS

Pressure Switch InstallationThe pressure switches can be mounted in any position.When the electrical conduit is connected, it is recommended that the conduit line (if it is over 6 feet inlength)be clamped firmly close to the switch to keepthermal expansion from causing it to place a high stressload onto the housing of the pressure switch.If moisture inthe conduit line is a potential problem, it is recommendedthat a potting Y connection be placed between the switchand the conduit.This will eliminate drainage from theelectrical conduit into the pressure switch housing.

Line mounting is possible and recommended for any ofour “Compact ”pressure switches.Installation must notimpose loads on connections.

Seismic Shock and VibrationDue to their unique design principle, DUAL–SNAP® pressure and temperature switches will meet allthe conventional seismic shock and vibration specifications now being applied to many projects such aspower plants for ecological protection.These specifications by their severity eliminate the use of mercury filled switching elements and many vibrationcritical sensing elements found in most competitivedesigns.

APPLICATION AND TECHNICAL INFORMATION

Approximate Pressure SensingPerformance Characteristics

PRESSURE SWITCH

IOM Manual Appendix C

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

Coupling Manufacturer Manufacturer’s IOM Manual

Standard Models

T10 – Close Coupled

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

1070T10 1080T10 1090T10

T31 – Spacer (Used with Cartridge Seals)

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

1070T31 1080T31 1090T31

Limited End Float Kit (Used with Sleeve Bearing Motors)

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

1070 1080 1090

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

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2

Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4

Annual Maintenance, Relube & Disassembly . . . . . . . Page 4

Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5

Parts Identification & Parts Interchangeability . . . . . . . Page 6

CAREFULLY FOLLOW THE INSTRUCTIONS IN THISMANUAL FOR OPTIMUM PERFORMANCE AND TROUBLEFREE SERVICE.

INTRODUCTIONThis manual applies to Sizes 1020T thru 1140T and 20T thru140T10 Falk SteelfIex Tapered Grid Couplings. Unlessotherwise stated, information for Sizes 1020T thru 1140Tapplies to Sizes 20T thru 140T respectively, e.g. 1020T =20T, 1100T = 100T, etc. These couplings are designed tooperate in either the horizontal or vertical position withoutmodification. Beginning in year 1994 through 2003, thesecouplings were being supplied with one set of inch seriesfasteners and one set of Metric fasteners. Beginning in year2004 only Metric fasteners are being supplied. Refer to Page6 for part interchangeability.

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

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

WARNING: Lockout starting switch of prime mover and removeall external loads from drive before installing or servicingcouplings.

LUBE FITTINGSCover halves have 1/8 NPT Iube holes. Use a standard greasegun and Iube fitting as instructed on Page 4.

LIMITED END FLOATWhen electric motors, generators, engines, compressors andother machines are fitted with sleeve or straight rollerbearings, limited axial end float kits are recommended forprotecting the bearings. Falk Steelflex couplings are easilymodified to limit end float; refer to Manual 428-820 forinstructions.

LUBRICATIONAdequate lubrication is essential for satisfactory operation.Page 2 provides a list of typical lubricants and specificationsfor general purpose and long term greases. Because of its

superior lubricating characteristics and low centrifugeproperties, Falk Long Term Grease (LTG) is highlyrecommended. Sizes 1020T to 1090T10 are furnished with apre-measured amount of grease for each coupling. Thegrease can be ordered for larger size couplings.

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

Long Term Grease (LTG)The high centrifugal forces encountered in couplings separatethe base oil and thickener of general purpose greases. Heavythickener, which has no lubrication qualities, accumulatesin the grid-groove area of Steelflex couplings resulting inpremature hub or grid failure unless periodic lubrication cyclesare maintained.

Falk Long Term Grease (LTG) was developed specifically forcouplings. It resists separation of the oil and thickener. Theconsistency of Falk LTG changes with operating conditions. Asmanufactured it is an NLGI #1/2 grade. Working of thelubricant under actual service conditions causes it to becomesemifluid while the grease near the seals will set to a heaviergrade, helping to prevent leakage.

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

Steelflex couplings initially lubricated with LTG will not requirere-lubrication until the connected equipment is stopped forservicing. If a coupling leaks grease, is exposed to extremetemperatures, excessive moisture, or experiences frequentreversals, more frequent lubrication may be required.

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

USDA ApprovalLTG has the United States Department of Agriculture FoodSafety & Inspection Service approval for applications wherethere is no possibility of contact with edible products. (H-2ratings).

CAUTION: Do not use LTG in bearings.

Rexnord Industries, LLC, Coupling Group 428-1105555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 May 2004

Fax: 262-796-4064 e-mail: [email protected] web: www.rexnord.com Supersedes 2-03

Falk™ Steelflex® Couplings • Installation and Maintenance

Type T10 • Sizes 1020–1140 & 20–140 (Page 1of 6)

TYPE T10 STEELFLEX COUPLING

Specifications — Falk LTGThe values shown are typical and slight variations arepermissible.

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

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

THICKENER — Lithium & soap/polymer.

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

NLGI GRADE (ASTM D-217) — 1/2

CONSISTENCY (ASTM D-217) — 60 stroke workedpenetration value in the range of 315 to 360 measured at77°F (25°C)

MINIMUM DROPPING POINT — 350°F (177°C) minimum

MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do notcorrode steel or swell or deteriorate synthetic seals.

Packaging14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of 10or 30.

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

General Purpose GreaseAnnual Lubrication — The following specifications andlubricants for general purpose grease apply to Falk Steelflexcouplings that are lubricated annually and operate withinambient temperatures of 0°F to 150°F (-18°C to 66°C). Fortemperatures beyond this range (see Table 1), consultthe Factory.

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

Specifications — General Purpose CouplingLubricantsThe values shown are typical and slight variations arepermissible.

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

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

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

LIQUID CONSTITUENT — Possess good lubricatingproperties equivalent to a high quality, well refined petroleumoil.

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

CLEAN — Free from foreign inclusions.

General Purpose Greases Meeting RexnordSpecificationsLubricants listed below are typical products only and shouldnot be construed as exclusive recommendations.

INSTALLATION OF TYPE T10 STEELFLEXTAPERED GRID COUPLINGS

InstallationOnly standard mechanics tools, wrenches, a straight edge andfeeler gauges are required to install Falk Steelflex couplings.Coupling Sizes 1020T thru 1090T are generally furnishedfor CLEARANCE FIT with setscrew over the keyway. Sizes1100T and larger are furnished for an INTERFERENCE FITwithout a setscrew.

CLEARANCE FIT HUBS — Clean all parts using a non-flammable solvent. Check hubs, shafts and keyways for burrs.Do not heat clearance fit hubs. Install keys, mount hubs withflange face flush with shaft ends or as otherwise specified andtighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews.Heat hubs to a maximum of 275°F (135°C) using an oven,torch, induction heater or an oil bath. To prevent seal damage,DO NOT heat hubs beyond a maximum temperature of 400°F(205°C).

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

Rexnord Industries, LLC, Coupling Group428-1105555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060May 2004

Fax: 262-796-4064 e-mail: [email protected] web: www.rexnord.comSupersedes 2-03

Installation and Maintenance • Falk™ Steelflex® Couplings

(Page 2 of 6) Type T10 • Sizes 1020–1140 & 20–140

TABLE 1 — General Purpose Greases

Ambient TemperatureRange

0°F to 150°F(-18°C to 66°C)

-30°F to 100°F(-34°C to 38°C)

Manufacturer Lubricant † Lubricant †

Amoco Oil Co. Amolith Grease #2 Amolith Grease #2BP Oil Co. Energrease LS-EP2 Energrease LS-EP1Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2

Exxon Company, USA Unirex EP2 Unirex EP2E.F. Houghton & Co. Cosmolube 2 Cosmolube 1Imperial Oil Ltd. Unirex EP2 Unirex EP2Kendall Refining Co. Lithium Grease L421 Lithium Grease L421

Keystone Div. (Pennwalt) 81 EP-2 81 EP-1Lyondell Petrochemical(ARCO)

Litholine H EP 2 Grease Litholine H EP 2 Grease

Mobil Oil Corp. Mobilux EP111 Mobilith AW1Petro-Canada Products Multipurpose EP2 Multipurpose EP1

Phillips 66 Co. Philube Blue EP Philube Blue EPShell Oil Co. Alvania Grease 2 Alvania Grease 2Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP

Texaco Lubricants Starplex HD2 Multifak EP2Unocal 76 (East & West) Unoba EP2 Unoba EP2Valvoline Oil Co. Multilube Lithium EP Grease . . .

Grease application or re-lubrication should be done at temperatures above 20°F(-7°C). If grease must be applied below 20°F (-7°C), consult the Factory.

† Lubricants listed may not be suitable for use in the food processing industry; checkwith lube manufacturer for approved lubricants.

WARNING: If an oil bath is used, the oil must have a flashpoint of 350°F (177°C) or higher. Do not rest hubs on thebottom of the container. Do not use an open flame in acombustible atmosphere or near combustible materials.

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

Maximize Performance And LifeThe performance and life of couplings depend largely uponhow you install and maintain them. Before installingcouplings, make certain that foundations of equipment to beconnected meet manufacturers’ requirements. Check for softfoot. The use of stainless steel shims is recommended.Measuring misalignment and positioning equipment withinalignment tolerances is simplified with an alignment computer.These calculations can also be done graphically ormathematically.

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

1— Mount Seals And HubsLock out starting switch of prime mover. Clean all metal partsusing a non-flammable solvent. Lightly coat seals with greaseand place on shafts BEFORE mounting hubs. Heatinterference fit hubs as previously instructed. Seal keyways toprevent leakage. Mount hubs on their respective shafts so thehub face is flush with the end of its shaft unless otherwiseindicated. Tighten setscrews when furnished.

2 — Gap and Angular Alignment

Use a spacer bar equal in thickness to the gap specified inTable 2, Page 5. Insert bar as shown below left, to same depthat 90° intervals and measure clearance between bar and hubface with feelers. The difference in minimum and maximummeasurements must not exceed the ANGULAR installationlimits specified in Table 2.

3 — Offset Alignment

Align so that a straight edge rests squarely (or within the limitsspecified in Table 2) on both hubs as shown above and also at90° intervals. Check with feelers. The clearance must notexceed the PARALLEL OFFSET installation limits specified inTable 2. Tighten all foundation bolts and repeat Steps 2 and3. Realign coupling if necessary.

4 — Insert Grid

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





MOUNTSEALFIRST

5 — Pack With Grease And Assemble Covers

Pack the spaces between and around the grid with as muchlubricant as possible and wipe off excess flush with top of grid.Position seals on hubs to line up with grooves in cover.Position gaskets on flange of lower cover half and assemblecovers so that the match marks are on the same side (seeabove). If shafts are not level (horizontal) or coupling is to beused vertically, assemble cover halves with the lug and match

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

ANNUAL MAINTENANCEFor extreme or unusual operating conditions, check couplingmore frequently.

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

2. Check tightening torques of all fasteners.

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

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

Periodic Lubrication

The required frequency of lubrication is directly related to the typeof lubricant chosen, and the operating conditions. Steelflexcouplings lubricated with common industrial lubricants, such asthose shown in Table 1, should be relubed annually. The use ofFalk Long Term Grease (LTG) will allow relube intervals to beextended to beyond five years. When relubing, remove both lubeplugs and insert lube fitting. Fill with recommended lubricant untilan excess appears at the opposite hole. CAUTION: Makecertain all plugs have been inserted after lubricating.

Coupling Disassembly And Grid Removal

Whenever it is necessary to disconnect the coupling, removethe cover halves and grid. A round rod or screwdriver that willconveniently fit into the open loop ends of the grid is required.Begin at the open end of the grid section and insert the rod orscrewdriver into the loop ends. Use the teeth adjacent to eachloop as a fulcrum and pry the grid out radially in even,gradual stages, proceeding alternately from side to side.





VERTICAL COUPLINGS

MATCH MARK LUG UP

MATCH MARK

MATCH MARK

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

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

Values may be combined for an installation or operatingcondition.

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

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

Angular misalignment is dimension X minus Y as illustrated below.

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

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





GAP

Y

X

F F

ANGULAR MISALIGNMENT

P

P

PARALLEL OFFSET MISALIGNMENT END FLOAT

1020-1070T10

1080-1090T10

1100-1140T10

SAE Grade 8

SAE Grade 8

SAE Grade 5

SAE Grade 8

SAE Grade 8

SAE Grade 5

10.9

8.8

10.9

Property Class 10.9

Property Class 10.9

Property Class 8.8

TABLE 2 — Misalignment & End Float

SIZE

Installation Limits Operating Limits Cover FastenerTightening

Torque ValuesInch or Metric

Series Fasteners

AllowSpeed(rpm)

Lube WtParallelOffset-P

Angular(x-y)

Hub Gap 10%

ParallelOffset-P

Angular(x-y)

End FloatPhysical Limit

(Min) 2 x F

MaxInch

Maxmm

MaxInch

Maxmm

Inch mmMaxInch

Maxmm

MaxInch

Maxmm

Inch mm (lb-in) (Nm) lb kg

1020T .006 0,15 .003 0,08 .125 3 .012 0,30 .010 0,25 .210 5,33 100 11,3 4500 .06 0,031030T .006 0,15 .003 0,08 .125 3 .012 0,30 .012 0,30 .198 5,03 100 11,3 4500 .09 0,041040T .006 0,15 .003 0,08 .125 3 .012 0,30 .013 0,33 .211 5,36 100 11,3 4500 .12 0,051050T .008 0,20 .004 0,10 .125 3 .016 0,41 .016 0,41 .212 5,38 200 22,6 4500 .15 0,071060T .008 0,20 .005 0,13 .125 3 .016 0,41 .018 0,46 .258 6,55 200 22,6 4350 .19 0,09

1070T .008 0,20 .005 0,13 .125 3 .016 0,41 .020 0,51 .259 6,58 200 22,6 4125 .25 0,111080T .008 0,20 .006 0,15 .125 3 .016 0,41 .024 0,61 .288 7,32 200 22,6 3600 .38 0,171090T .008 0,20 .007 0,18 .125 3 .016 0,41 .028 0,71 .286 7,26 200 22,6 3600 .56 0,251100T .010 0,25 .008 0,20 .188 5 .020 0,51 .033 0,84 .429 10,90 312 35 2440 .94 0,431110T .010 0,25 .009 0,23 .188 5 .020 0,51 .036 0,91 .429 10,90 312 35 2250 1.1 0,51

1120T .011 0,28 .010 0,25 .250 6 .022 0,56 .040 1,02 .556 14,12 650 73 2025 1.6 0,741130T .011 0,28 .012 0,30 .250 6 .022 0,56 .047 1,19 .551 14,00 650 73 1800 2.0 0,911140T .011 0,28 .013 0,33 .250 6 .022 0,56 .053 1,35 .571 14,50 650 73 1650 2.5 1,14

TABLE 3 — Coupling Cover Fastener Identification

SIZEInch Series Fasteners

METRIC FASTENERSOld Style New Style

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

PARTS IDENTIFICATIONAll coupling parts have identifying part numbers as shownbelow. Parts 3 and 4 (Hubs and Grids), are the same for bothType T10 and T20 couplings. All other coupling parts are unique toType T10. When ordering parts, always SPECIFY SIZE and TYPEshown on the COVER.

PARTS INTERCHANGEABILITYParts are interchangeable between Sizes 20T and 1020T, 30Tand 1030T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use blueor non-painted grids. Older models, 20T thru 140T, useorange grids.

CAUTION: Blue or non-painted grids may be used in allapplications, but DO NOT substitute orange grids for blue ornonpainted.

COVERS — CAUTION: DO NOT mix cover halves of differentdesigns. Sizes 1020T thru 1070T10 covers have beenmanufactured in several different two-rib designs and 80T thru140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru1070T10, utilized socket head cap screws with capturedlocknuts. The new style covers use hex head cap screws (eitherinch or metric from year 1994 through 2003 and only Metricbeginning in 2004). Specify the style cover when orderingreplacement parts.





PART DESCRIPTION1. Seal (T10)

2. Cover (T10)

3. Hub (Specify boreand keyway)

4. Grid

5. Gasket (T10)

6. Metric Fasteners (T10).

7. Lube Plug

ORDER INFORMATION1. Identify part(s) required by

name above.

2. Furnish the followinginformation.

EXAMPLE:Coupling Size: 1030Coupling Type: T10Model: BBore: 1.375Keyway: .375 x .187

3. Contact your RexnordDistributor or Rexnord forprice and availability.

PART NUMBER LOCATION

COUPLINGSIZE

TYPE MODEL

PRODUCTCLASSIFICATION

SIZESIZE &PARTNUMBER

SIZE, PART NUMBER &BORE

SIZE

PART NUMBER

PART NUMBER

1030 T 10 B

(6.)

(7.)

(2.) COVER

(4.) GRID(1.) SEAL (3.) HUB

(5.) GASKET

How to Use This ManualThis manual provides detailed instructions on maintenance,lubrication, installation, and parts identification. Use the tableof contents below to locate required information.

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . Page 1

Lube Fittings . . . . . . . . . . . . . . . . . . . . . Page 1

Limited End Float . . . . . . . . . . . . . . . . . . Page 1

Lubrication . . . . . . . . . . . . . . . . . . . Pages 1-2

Installation & Alignment Instructions . . . . . . . . Pages 2-4

Annual Maintenance, Relube & Disassembly . . . . . Page 4

Installation & Alignment Data . . . . . . . . . . . . Page 5

Parts Identification & Parts Interchangeability . . . . . Page 6

CAREFULLY FOLLOW THE INSTRUCTIONS IN THISMANUAL FOR OPTIMUM PERFORMANCE AND TROUBLEFREE SERVICE.

INTRODUCTIONThis manual applies to Sizes 1020T thru 1140T and 20T thru140T31 standard Falk SteelfIex Pre-assembled SpacerCouplings. Unless otherwise stated, information for Sizes 1020Tthru 1140T applies to Sizes 20T thru 140T respectively, e.g.1020T = 20T, 1100T = 100T, etc. For couplings furnished withspecial features, refer to assembly drawing furnished withcoupling for proper assembly arrangement and any additionalinstallation or maintenance requirements. The Pre-AssembledSpacer Assembly permits installation (or removal, as shown onPage 3) without disturbing coupling cover, grid or grease. Thesecouplings are designed to operate in either the horizontal orvertical position without modification. However, for verticalapplications, the match mark shown on Page 4 must be up.Beginning in 1994, these couplings may be supplied with eitherinch series cover fasteners or metric cover fasteners dependingon domestic or foreign shipping destinations. Refer to Page 6for part interchangeability.

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

WARNING: Consult applicable local and national safety codesfor proper guarding of rotating members. Lockout starting switchof prime mover and remove all external loads from drive beforeinstalling or servicing couplings. Observe all safety rules wheninstalling or servicing couplings.

LUBE FITTINGSCover halves have 1

8 NPT lube holes. Use a standard greasegun and lube fitting as instructed on Page 4.

LIMITED END FLOATWhen electric motors, generators, and other machines are fittedwith sleeve or straight roller bearings, limited axial end float kitsare recommended for protecting the bearings. Falk Steelflexcouplings are easily modified to limit end float; refer to Manual428-820 for instructions.

NOTE: To drop-in a pre-assembled spacer fitted with limitedend float, the sleeve bearing shaft must have enough axialmovement to separate and clear the shaft hub registers.

LUBRICATIONAdequate lubrication is essential for satisfactory operation. Page2 provides a list of typical lubricants and specifications forgeneral purpose greases. Because of its superior lubricatingcharacteristics and low centrifuge properties, Falk Long TermGrease (LTG) is highly recommended. LTG is provided in allpre-assembled spacer couplings.

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

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

Falk Long Term Grease (LTG) was developed specifically forcouplings. It resists separation of the oil and thickener. Theconsistency of Falk LTG changes with operating conditions. Asmanufactured it is an NLGI #1/2 grade. Working of thelubricant under actual service conditions causes it to becomesemifluid while the grease near the seals will set to a heaviergrade, helping to prevent leakage.

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

Steelflex couplings initially lubricated with LTG will not requirere-lubrication until the connected equipment is stopped forservicing. If a coupling leaks grease, is exposed to extremetemperatures, excessive moisture, or experiences frequentreversals, more frequent lubrication may be required.

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

USDA ApprovalLTG has the United States Department of Agriculture FoodSafety & Inspection Service approval for applications where there isno possibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

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

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

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

THICKENER — Lithium & soap/polymer.

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

NLGI GRADE (ASTM D-217) — 1/2

CONSISTENCY (ASTM D-217) — 60 stroke workedpenetration value in the range of 315 to 360 measured at 77°F(25°C)

MINIMUM DROPPING POINT — 350°F (177°C) minimum

MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do not corrode

®Steelflex® Pre-Assembled Spacer Couplings • Installation & Maintenance

Type T31 • Sizes 1020–1140 & 20–140 (Page 1 of 6)

The Falk Corporation, P.O. Box 492, Zip 53201-0492 428-3103001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 June 2000

Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com Supersedes 7-94

steel or swell or deteriorate synthetic seals.

Packaging14 oz. (0,4 kg) CARTRIDGES — Individual or case lots of 10 or 60

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

General Purpose GreaseANNUAL LUBRICATION — The following specifications andlubricants for general purpose grease apply to Falk Steelflexcouplings that are lubricated annually and operate withinambient temperatures of 0°F to 150°F (–18°C to 66°C). Fortemperatures beyond this range (see Table 1), consult Falk.

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

General Purpose Greases MeetingFalk SpecificationsLubricants listed below are typical products only and should notbe construed as exclusive recommendations.

Specifications – General Purpose Coupling LubricantsThe values shown are typical and slight variations arepermissible.

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

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

SEPARATION & RESISTANCE — Low oil separation rate andhigh resistance to separation from centrifuging.

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

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

CLEAN — Free from foreign inclusions.

INSTALLATION OF TYPE T31 STEELFLEXTAPERED GRID COUPLINGS

InstallationOnly standard mechanics tools, wrenches, a straight edge andfeeler gauges are required to install Falk Steelflex couplings.Clean all parts using a non-flammable solvent. Check hubs,shafts and keyways for burrs. Coupling Sizes 1020T thru 1090Tare generally furnished for CLEARANCE FIT with setscrew overthe keyway. Sizes 1100T and larger are furnished for anINTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Clean all parts using anon-flammable solvent. Check hubs, shafts and keyways forburrs. Do not heat clearance fit hubs. Install keys, mount hubswith flange face flush with shaft ends or as otherwise specifiedand tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews. Heathubs to a maximum of 275°F (135°C) using an oven, torch,induction heater or an oil bath. To prevent damage DO NOTheat hubs beyond a maximum temperature of 400°F(205°C).

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

WARNING: If an oil bath is used, the oil must have a flashpoint of 350°F (177°C) or higher. Do not rest hubs on thebottom of the container. Do not use an open flame in acombustible atmosphere or near combustible materials.

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

Maximize Performance & LifeThe performance and life of couplings depend largely uponhow you install and maintain them. Before installing couplings,make certain that foundations of equipment to be connectedmeet manufacturers’ requirements. Check for soft foot. The useof stainless steel shims is recommended. Measuringmisalignment and positioning equipment within alignmenttolerances is simplified with an alignment computer. Thesecalculations can also be done graphically or mathematically.

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

®Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings


The Falk Corporation, P.O. Box 492, Zip 53201-0492428-3103001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131June 2000

Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.comSupersedes 7-94

TABLE 1 — General Purpose Greases

Ambient Temperature Range0°F to 150°F

(-18°C to 66°C)-30°F to 100°F(-34°C to 38°C)

Manufacturer Lubricant † Lubricant †

Amoco Oil Co. Amolith Grease #2 Amolith Grease #2BP Oil Co. Energrease LS-EP2 Energrease LS-EP1Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1Citgo Petroleum Corp. Prem. Lithium Grease EP2 Prem. Lithium Grease EP1

Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2Exxon Company, USA Unirex N2 Unirex N2E.F. Houghton & Co. Cosmolube 2 Cosmolube 1Imperial Oil Ltd. Unirex N2L Unirex N2L

Kendall Refining Co. Lithium Grease L421 Lithium Grease L421Keystone Div. (Pennwalt) 81 EP-2 81 EP-1Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Litholine H EP 2 GreaseMobil Oil Corp. Mobilux EP111 Mobilith AW1

Petro-Canada Products Multipurpose EP2 Multipurpose EP1Phillips 66 Co. Philube Blue EP Philube Blue EPShell Oil Co. Alvania Grease 2 Alvania Grease 2Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2

Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EPTexaco Lubricants Starplex HD2 Multifak EP2Unocal 76 (East & West) Unoba EP2 Unoba EP2Valvoline Oil Co. Multilube Lithium EP Grease . . .

Grease application or re-lubrication should be done at temperatures above20°F (-7°C). If grease must be applied below 20°F (-7°C), consult Falk.

† Lubricants listed may not be suitable for use in the food processing industry;check with lube manufacturer for approved lubricants.

Installation of Spacer Assembly

1— Mount Shaft Hubs

Lock out starting switch of prime mover. Heat interference fithubs as previously instructed. Mount shaft hubs on theirrespective shafts so that hub face is flush with the end of theshaft unless otherwise indicated. Position drives for approximatedistance between shaft ends with minimum angular and offsetmisalignment.

2 — Angular AlignmentDetermine Dimension (X = BE + 2Y) and then take micrometerreadings between flange faces at 90° intervals. Refer to Table 2on page 5 for “BE” dimension tolerance. If a dial indicator isused, place the indicator on one shaft hub and rotate that hub360° while taking readings from the other hub face. Thedifference in minimum and maximum measurements must notexceed the ANGULAR installation limits specified in Table 2 onPage 5.

3 — Offset AlignmentAlign so that a straight edge rests squarely (or within the limitsspecified in Table 2) on both hubs as shown above and also at

90° intervals. Check with feelers. The clearance must notexceed the PARALLEL OFFSET installation limits specified inTable 2 on Page 5. If a dial indicator is used, place it on oneshaft hub and rotate that hub through 360° while takingreadings from the flange outside diameter of the other hub. TheTIR reading must not exceed two times the installation limitsspecified in Table 2. Tighten all foundation bolts and repeatSteps 2 and 3. Realign coupling if necessary.

4 — Insert Steelflex SpacerInsert fasteners as shown – do not allow them to protrudebeyond flange face. Remove pipe plugs to vent and compressspacer to eliminate its gap. Then insert between shaft hubs.Carefully engage the hub registers and then alternately tightenfasteners. Torque to specifications in Table 2 on Page 5.Replace pipe plugs.

Removal of Spacer Assembly

Remove Spacer Assembly

Remove pipe plugs and all but two fasteners opposite eachother in each hub. Loosen these about one-quarter inch andtap them with a mallet to disengage Steelflex spacer from theshaft hubs. Remove fasteners and spacer.





BE

BE

XY Y

SIZE1020-1090 = .0401100-1110 = .0621120-1140 = .094

Y-INCHES

VERTICAL COUPLINGS

MATCH MARK UP

ANNUAL MAINTENANCEFor extreme or unusual operating conditions, check couplingmore frequently.1. Check alignment per steps on Page 3. If the maximum

operating misalignment limits are exceeded, realign thecoupling to the recommended installation limits. See Table2 on Page 5 for installation and operating alignment limits.

2. Check tightening torques of all fasteners.

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

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

Periodic Lubrication

The required frequency of lubrication is directly related to thetype of lubricant chosen, and the operating conditions. Steelflexcouplings lubricated with common industrial lubricants, such asthose shown in Table 1, should be relube annually. The use ofFalk Long Term Grease (LTG) will allow relube intervals to beextended to beyond five years. When relubing, remove bothlube plugs and insert lube fitting. Fill with recommendedlubricant until an excess appears at the opposite hole.CAUTION: Make certain all plugs have been inserted afterlubricating.

Coupling Disassembly & Grid Removal

Whenever it is necessary to disconnect the coupling, remove thecover halves and grid. A round rod or screwdriver that willconveniently fit into the open loop ends of the grid is required.Begin at the open end of the grid section and insert the rod orscrewdriver into the loop ends. Use the teeth adjacent to eachloop as a fulcrum and pry the grid out radially in even, gradualstages, proceeding alternately from side to side.

Pack with Grease & Assemble Covers

Pack the spaces between and around the grid with as muchlubricant as possible and wipe off excess flush with top of grid.Position seals on hubs to line up with grooves in cover. Positiongaskets on flange of lower cover half and assemble covers sothat the match marks are on the same side (see above). If shaftsare not level (horizontal) or coupling is to be used vertically,assemble cover halves with the lug and match mark UP or on

the high side. Push gaskets in until they stop against the sealsand secure cover halves with fasteners, tighten to torquespecified in Table 2 on Page 5. Make sure gaskets stay inposition during tightening of fasteners. CAUTION: Make certainlube plugs are installed before operating.

Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings




®

MATCH MARK

MATCH MARK

VERTICAL COUPLINGS

MATCH MARK LUG UP

INSTALLATION & ALIGNMENT DATAMaximum life and minimum maintenance for the coupling andconnected machinery will result if couplings are accuratelyaligned. Coupling life expectancy between initial alignment andmaximum operating limits is a function of load, speed andlubrication. Maximum operating values listed in Table 2 arebased on cataloged allowable rpm.

Values listed are based upon the use of standard couplingcomponents, standard assemblies and cataloged allowablespeeds. Values may be combined for an installation or operatingcondition.

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

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

Angular misalignment is dimension X minus Y as illustrated below.

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

End float (with zero angular and parallel misalignment) is theaxial movement of the hubs(s) within the cover(s) measuredfrom “O” gap.





TABLE 2 — Misalignment & End Float

SIZE

Installation Limits Operating LimitsFastener Tightening

Torque Values

AllowSpeed(rpm)

Lube WtParallelOffset-P

Angular(x-y)

Hub Gap

± 10%ParallelOffset-P

Angular(x-y)

End FloatPhysical Limit

(Min) 2 x FCover Flange

MaxInches

Maxmm

MaxInches

Maxmm

Inches mmMax

InchesMaxmm

MaxInches

Maxmm

Inches mmInch SeriesFasteners

(lb-in)

MetricFasteners

(Nm)

Inch SeriesFasteners

(lb-in)lb kg

1020T .006 .15 .003 .08 .188 5 .012 .30 .010 .25 .210 5.33 100 11.3 120 3600 .06 .031030T .006 .15 .003 .08 .188 5 .012 .30 .012 .30 .198 5.03 100 11.3 120 3600 .09 .041040T .006 .15 .003 .08 .188 5 .012 .30 .013 .33 .211 5.36 100 11.3 120 3600 .12 .051050T .008 .20 .004 .10 .188 5 .016 .41 .016 .41 .212 5.38 200 23.6 250 3600 .15 .071060T .008 .20 .005 .13 .188 5 .016 .41 .018 .46 .258 6.55 200 23.6 440 3600 .19 .09

1070T .008 .20 .005 .13 .188 5 .016 .41 .020 .51 .259 6.58 200 23.6 440 3600 .25 .111080T .008 .20 .006 .15 .188 5 .016 .41 .024 .61 .288 7.32 200 23.6 825 3600 .38 .171090T .008 .20 .007 .18 .188 5 .016 .41 .028 .71 .286 7.26 200 23.6 1640 3600 .56 .251100T .010 .25 .008 .20 .250 6 .020 .51 .033 .84 .429 10.90 312 35 2940 2440 .94 .431110T .010 .25 .009 .23 .250 6 .020 .51 .036 .91 .429 10.90 312 35 2940 2250 1.1 .51

1120T .011 .28 .010 .25 .375 10 .022 .56 .040 1.02 .556 14.12 650 73 4560 2025 1.6 .741130T .011 .28 .012 .30 .375 10 .022 .56 .047 1.19 .551 14.00 650 73 6800 1800 2.0 .911140T .011 .28 .013 .33 .375 10 .022 .56 .053 1.35 .571 14.50 650 73 8900 1650 2.5 1.14

“BE” dimension tolerance is ±10% of hub gap listed.

TABLE 3 — Coupling Cover Fastener Identification

SIZEInch Series Fasteners

Metric FastenersOld Style New Style

1020-1070T10 SAE Grade 8 † SAE Grade 8 Property Class 10.9

1080-1090T10 SAE Grade 8 SAE Grade 8 Property Class 10.9

1100-1140T10 SAE Grade 5 SAE Grade 5 Property Class 8.8

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

GAP

Y

X

F F

ANGULAR MISALIGNMENT

P

P

PARALLEL OFFSET MISALIGNMENT END FLOAT

PARTS IDENTIFICATIONAll coupling parts have identifying part numbers as shownbelow. Parts are interchangeable between the 10 series and1000 series spacer couplings. However, to utilize the higher1000 series ratings, the 1000T – Blue Grid, Spacer Hubs, ShaftHubs and Hardware must be used. When ordering parts,always SPECIFY SIZE and TYPE. Sizes 80 through 140T10covers have been manufactured with two and three ribs; DONOT mix these cover halves.

PARTS INTERCHANGEABILITYParts are interchangeable between Sizes 20T and 1020T, 30Tand 1030T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use bluegrids. Older models, 20T thru 140T, use orange grids.

CAUTION: Blue grids may be used in all applications, but DONOT substitute orange grids for blue.

COVERS — CAUTION: DO NOT mix cover halves of differentdesigns. Sizes 1020T thru 1070T10 covers have beenmanufactured in several different two-rib designs and 80T thru140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru1070T10, utilized socket head cap screws with capturedlocknuts. The new style covers use hex head cap screws (eitherinch or metric) and unrestrained locknuts. Specify either inchseries SOCKET head or inch or metric series HEX head capscrews when ordering replacement parts.

Installation & Maintenance • Steelflex Pre-Assembled Spacer Couplings




®

PART NUMBERS1. Seal (T10)

2. Cover (T10)

4. Grid

5. Gasket (T10)

6. Fasteners (T10) — Couplingmay be supplied with one seteach of inch series fastenersand metric fasteners.

7. Lube Plug

8. T31 Spacer Hub(Specify Length)

9. Shaft Hub

10. Flange Fastener

ORDER INFORMATION1. Identify part(s) required by

name above.

2. Furnish the followinginformation.

EXAMPLE:Coupling Size: 1030Coupling Type: T31Model: BBore: 1.375Keyway: .375 x .187

Distance Between ShaftEnds (BE): 5.0

3. Price parts from appropriatePrice List and discount sheet.

PART NUMBER LOCATION

MATCH MARKMUST BE UPFOR VERTICALAPPLICATIONS

10

5

6

6

4

7

92

1

8

SHAFT HUBSIZE, PART NUMBERAND BORE

SPACERHUB

SIZE ANDPART NUMBER SEAL

SIZE ANDPART NUMBER

COVER

COUPLINGSIZE

GASKET

PART NUMBER

GRID SIZE

PRODUCTCLASSIFICATION

1030 T 10

TYPE MODEL

B

PART NUMBERSIZE

INTRODUCTIONWhen it is necessary to limit the end float of Falk Steelflexcouplings, carefully follow these instructions. This manualapplies to Sizes 30 thru 260T10 & T20 and Sizes 1030 thru1260T10 & T20 Falk Steelflex Tapered Grid Couplings. Unlessotherwise stated, information for Sizes 1030 thru 1260 appliesto Sizes 30 thru 260 respectively, e.g. 1030 = 30, 1100 =100, etc.

CAUTION: Consult applicable local and national safety codesfor proper guarding of rotating members. Observe all safetyrules when installing or servicing couplings. Lockout startingswitch of prime mover and remove all external loads from drivebefore installing or servicing couplings. During assembly, sealkeyways to prevent leakage.

Sizes 1030 thru 1210T standard couplings connecting ahorizontal shaft without axial movement (end float) to one withaxial movement (such as in sleeve bearing motors), will limit theshaft end float to approximately 0.06 inches when assembledwith gap disc and rung spacers as specified herein.

For Sizes 1220 thru 1260T couplings, spacer rings and gapdiscs limit the end float to approximately 0.19 inches. Whenend float is specified on the coupling purchase order, thespacer rings are welded to the hubs at the Factory as shown inFigure 2. When the coupling is modified in the field, it will bethe customer’s responsibility to weld the spacer rings to thehubs.

Falk™ Steelflex Couplings • Limited End Float Installation

Sizes 20-260 & 1030-1260 (Page 1 of 2)

Rexnord Industries, LLC, Coupling Group 428-8205555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 October 2001


TABLE 1 — Sizes 1030 thru 1210TDimensions — Inches †

CPLGSIZE

Gap Disc Rung Spacers-Fig.4CplgGapDia Thickness

PerCplg

L

1030 2.188 0.062 8 0.315 0.0921040 2.500 0.062 8 0.315 0.0921050 2.750 0.062 8 0.371 0.0921060 3.000 0.062 8 0.371 0.092

1070 3.750 0.062 16 0.460 0.0921080 4.375 0.125 16 0.500 0.1551090 5.250 0.125 16 0.630 0.1551100 6.000 0.188 16 0.650 0.2181110 6.750 0.188 20 0.780 0.218

1120 7.500 0.250 20 0.830 0.2801130 9.000 0.250 24 0.890 0.2801140 10.500 0.250 32 1.010 0.2801150 12.000 0.250 24 0.920 0.2801160 13.500 0.250 32 1.120 0.280

1170 15.500 0.250 40 1.320 0.2801180 17.000 0.250 32 1.000 0.2801190 18.250 0.250 40 1.160 0.2801200 21.500 0.250 40 1.360 0.2801210 23.250 0.500 56 1.820 0.530

Manufacturing tolerance is .020 inches.† 1020T — Limited End Float Not Available.

TABLE 2 — Sizes 1220 thru 1260TDimensions — Inches

CPLGSIZE

Gap Disc Spacer Rings-Figure 1 CplgGapDia Thickness A B C

1220 25.88 0.500 24.5 23.5 0.250 0.5901230 28.30 0.500 26.0 25.0 0.250 0.5751240 31.00 0.500 27.5 26.5 0.250 0.5751250 34.00 0.500 30.0 29.0 0.250 0.5751260 37.20 0.500 32.0 31.0 0.188 0.582

CSPACERRING

A - DIA.

B - DIA. HUB AND SPACER RING DETAIL

FIGURE 1 – Sizes 1220 thru 1260T

TACK WELD ONE INCH LONG SPACED AS SHOWNUSE AWS E-7016 ORE-7018 ELECTRODES SPLIT SPACER RING

SEE FIG. 1 DETAIL

PROTECT MACHINED SURFACESFROM WELD SPLATTER

GAP DISC

TACK WELD

CPLG. GAP

NOTE: COVER & GRID, REMOVED FOR SPACER RING WELDING,ARE SHOWN FOR ORIENTATION ONLY.

FIGURE 2 – Sizes 1220 thru 1260T Modification

ASSEMBLY INSTRUCTIONSSizes 1030 thru 1260T1. Mount coupling hubs and seal rings as instructed in the

coupling service manual.

2. Position the floating shaft at the mid-point of travel andsecure the shaft axially in this position for alignment.

3. Position equipment and align per the service manual.

IMPORTANT: Use the coupling gap specified in Table 1 for1030 thru 1210T and Table 2 for 1220 thru 1260T. Whensetting gap, position the floating shaft at mid-point (center oftravel).

4. Insert the gap disc between coupling hubs.

5. Pack coupling gap and hub grooves with lubricant and insertgrids per service manual instructions.

Sizes 1030 thru 1210T6. Insert rung spacers as follows per Figure 4.

Sizes 1030 thru 1060T — Insert FOUR rung spacers atPositions A & B in the last two loops at the end of theone-piece grid. Then insert four more at 180.

Sizes 1070 thru 1090T — Insert rung spacers at PositionsA, B, C and D in the last four loops of EACH grid segment(eight spacers per grid segment).

Sizes 1100 thru 1210T — Insert rung spacers in everyother grid loop as shown in Figure 4 at the right. Whereadditional rung spacers are provided, evenly space them inthe open grid loops around the circumference of the grid.

Sizes 1030 thru 1260T7. Complete coupling assembly and lubrication per the service

manual. NOTE: Position cover halves so lugs inside thecover do not interfere with grid or any rung spacers. Coverhalves should come together at split with a minimumamount of force.

Limited End Float Installation • Falk™ Steelflex® Couplings

(Page 2 of 2) Sizes 20-260 & 1030-1260

Rexnord Industries, LLC, Coupling Group428-8205555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060October 2001


L

D

B

C

A

A

C B

DGAP DISC

ENDS OF GRIDSEGMENTS

RUNG SPACERLENGTH

L

SIZES 1100 THRU 1210T

FIGURE 4 – Sizes 1030 thru 1210T Rung Spacer Locations

GAPDISC

RUNG SPACER

AXIALLYMOVABLESHAFT

AXIALLYFIXEDSHAFT

GAP

MAXIMUM ROTOREND - FLOAT

(ONE - HALF FLOAT EACH SIDE)

FIGURE 3 – Sizes 1220 thru 1210T Typical Limited End Float

INSERTRUNG SPACERSPER STEP 6

SIZES 1030THRU 1060TILLUSTRATED

IOM Manual Appendix D

Appendix D – Reference Drawings Centrilift Drawings

Drawing Title Component(s) “Typical Foundation Plan & Anchor Detail for Horizontal Unit” Skid Foundation “Oil Level Piping / Drain Piping Plan 1.XE & 1.XT” 1.XE / 1.XT HTC

Murphy L129-CK-1 “Oil Level Piping / Drain Piping Plan 1.XE & 1.XT, XP Proof Gauge” 1.XE / 1.XT HTC

Murphy LM303-EX “875 HTC Oil Level Gauge Piping Assembly” 875 HTC

Murphy L129-CK-1 “Plan 11 Assembly” HTC

Plan 11 Seal System “Assembly Plan 53” Cartridge Seal HTC

Plan 53 Seal System

IOM Manual Appendix E

Appendix E – HTC Oil Cooler System and Accessory Information Component Manufacturer Manufacturer’s

Information Model/ DWG

Number Explosion

Proof? 1.XT, 3.X, and 875 HTC Lubrication Oil Heat Exchanger

Thermal Transfer General Dimensions, Piping, Lubrication Details, and IOM

M/N: AO15-FB

N/A

1.XT, 3.X, and 875 HTC Lubrication Oil Heat Exchanger Fan Motor

Baldor Electrical Connection Drawing Performance Data

DWG: CD0885

M/N:

L4003A

Yes

1.XT HTC Lubrication Oil Pump

Haight IOM Manual M/N: 6U w/o Relief Valve

N/A

1.XT HTC Lubrication Oil Pump Motor

Leeson Electrical Connection Drawing Performance Data, Technical Data, Test Data, and IOM

DWG: 005005-01

M/N:

110908

No (XP Info- Contact

HPump™ Eng.)

1.XT HTC Lubrication Oil Filter

Parker Specifications and Parts List

M/N: IL2110QMP25YMY

M-1

N/A

1.XE/1.XT HTC Desiccant Breather

Parker Specifications and IOM

M/N: 934330T

N/A

1.XT HTC Lubrication Oil Cooling System N/A

3.X HTC Lubrication Oil Cooling System N/A

875 HTC Lubrication Oil Cooling System N/A

AO

[email protected] 262.554.83308

FLUID COOLING | Industrial AO Series

AIR

CO

OL

ED

AO

/AOR

Materials

Tubes Copper

Fins Aluminum

Turbulators Steel

Fan Blade Aluminum with steel hub

Fan Guard Zinc plated steel

Cabinet Steel with baked enamel fi nish

Manifolds Steel

Connections Steel

FEATURES Young Interchange – OCH

Adjustable Louvers

Medium Flow Rates

Moderate Heat Removal

One or Two Pass

Fluid Power Systems

Gear Drives

Injection Molding Machines

Machine Tools

Torque Converters

Hydraulic Presses

Ratings

Operating Pressure - 300 psi

Test Pressure - 300 psi

Operating Temperature - 400° F

OPTIONSSAE & Metric ConnectionsRelief Bypass Foot BracketsCorrosive Resistant Marine Coating

One Pass (Medium to High Oil Flows)

Model Number Flow Range GPM (USA)

AOR - 5-1 2 - 80

AOR - 10-1 3 - 80

AOR - 15-1 4 - 80

AOR - 20-1 5 - 80

AOR - 25-1 6 - 100

AOR - 30-1 7 - 100

AOR - 35-1 8 - 112

AOR - 40-1 9 - 118

Two Pass (Low to Medium Oil Flows)

Model Number Flow Range GPM (USA)

AOR - 5-2 2 - 25

AOR - 10-2 2 - 30

AOR - 15-2 2 - 30

AOR - 20-2 2 - 40

AOR - 25-2 2 - 40

AOR - 30-2 2 - 40

AOR - 35-2 3 - 40

AOR - 40-2 4 - 40

One Pass

Two Pass

How to Order

ModelSeries

AOAOR-Includes

Bypass

Foot Mounted Brackets Blank - No

BracketsFB - Foot Brackets

Specify MotorRequired

Single PhaseSingle Phase Expl. Proof

Three PhaseThree Phase 575 Volt

Three Phase Expl. Proof

–

ConnectionType

Blank - NPTS - SAE

M - Metric

Number of Passes*Blank - No Bypass

1 - One Pass2 - Two Pass

Relief BypassSetting*30-30 psi60 - 60 psi

– – ––

*ADD FOR AOR MODELS ONLY: Relief Bypass Setting & Number of Passes

Model SizeSelected

Weights

MODEL Net Weight (LBS)

AO-5 47

AO-10 62

AO-15 72

AO-20 86

AO-25 120

AO-30 135

AO-35 160

AO-40 185

–

AO

[email protected] 262.554.8330 9

AIR

CO

OL

ED

AO

/AOR

Specifi cationsElectric motor & Fan data*

*Published electrical ratings are approximate, and may vary because of motor brand. Actual ratings are on motor nameplate.** Catalog dB(A) sound levels are at seven (7) feet. dB(A) sound levels increase by six (6) dB(A) for halving this distance and decrease by six (6) dB(A) for doubling this distance.

*D Squirrel Cage** Catalog dB (A) sound levels at seven (7) feet. dB (A) sound levels increase by six (6) dB (A) for halving this distance, and decrease by six (6) dB (A) for doubling this distance.

Explosion Proof Motors (Class I GP.D & Class II GP.F, G)*

575 Volt

*Published electrical ratings are approximate, and may vary because of motor brand. Actual ratings are on motor nameplate.

Lubrication NotesCaution: Do not over oil or over grease. Ball bearings – No grease needed at start up. Grease as follows:

5,000 Hours / Year 5 Year Grease Interval

Continuous 2 YearsNormal Applications

Seasonal Service 1 YearMotor is idle for 6 months or moreContinuous 6 MonthsHigh ambients, dirty or moist locations, high vibration

AO

[email protected] 262.554.833010

AIR

CO

OL

ED

AO

/AOR

Dimensions

NOTE: All dimensions in inches.

Fan Rotation Clockwise/Facing Motor ShaftInstallation Piping Diagram

* See dimension chart for NPT or optional internal SAE connection size.

One Oil Pass Two Oil Passes

CV Viscosity Correction OIL SAE 5 SAE 10 SAE 20 SAE 30 SAE 40 50-50Average 110 SSU at 100°F 150 SSU at 100°F 275 SSU at 100°F 500 SSU at 100°F 750 SSU at 100°F Ethylene GlycolOil Temp °F 40 SSU at 210°F 43 SSU at 210°F 50 SSU at 210°F 65 SSU at 210°F 75 SSU at 210°F & Water

100 1.14 1.22 1.35 1.58 1.77 1.11150 1.01 1.05 1.11 1.21 1.31 1.02200 .99 1.00 1.01 1.08 1.10 .96250 .95 .98 .99 1.00 1.00 .95

AO


AIR

CO

OL

ED

AO

/AOR

One Pass Oil

Performance Curves

Two Pass Oil

Selection ProcedurePerformance Curves are based on 100SSU oil leaving the cooler 40°F higher than the ambient air temperature used for cooling.This is also referred to as a 40°F approach temperature.

STEP 1 Determine the Heat Load.This will vary with different systems, but typically coolers are sized to remove 25 to 50% of the input nameplate horsepower. (Example: 100 HP Power Unit x .33 = 33 HP Heat load.)

If BTU/Hr. is known: HP = BTU/Hr 2545

STEP 2 Determine Approach Temperature. Desired oil leaving cooler °F – Ambient air temp. °F = Actual Approach

STEP 3 Determine Curve Horsepower Heat Load. Enter the information from above:

Horsepower heat load x 40 x Cv = Curve Horsepower Actual Approach

STEP 4 Enter curves at oil flow through cooler and curve horsepower. Any curve above the intersecting point will work.

STEP 5 Determine Oil Pressure Drop from Curves: = 5 PSI; = 10 PSI; = 14 PSI; = 20 PSI. Multiply pressure drop from curve by correction factor found in oil P correction curve.

Desired Reservoir Temperature

Return Line Cooling: Desired temperature is the oil temperature leaving the cooler. This will be the same temperature that will be found in the reservoir.

Off-Line Recirculation Cooling Loop: Desired temperature is the oil tem-perature entering the cooler. In this case, the oil temperature change must be determined so that the actual oil leaving temperature can be found. Calculate the oil temperature change (oil T) with this formula: Oil T = (BTU’s/Hr.) / (GPM Oil Flow x 210). To calculate the oil leaving temperature from the cooler, use this formula: Oil Leaving Temp. = Oil Entering Temp – Oil T. This formula may also be used in any application where the only temperature available is the entering oil temperature.

Oil Pressure Drop: Most systems can tolerate a pressure drop through the heat exchanger of 20 to 30 PSI. Excessive pressure drop should be avoided. Care should be taken to limit pressure drop to 5 PSI or less for case drain applications where high back pressure may damage the pump shaft seals.

Oil TemperatureTypical operating temperature ranges are:

Hydraulic Motor Oil 110° - 130°FHydrostatic Drive Oil 130° - 180°FBearing Lube Oil 120° - 160°FLube Oil Circuits 110° - 130°F


INS

TAL

LA

TIO

N

& S

ER

VIC

E

Heat Exchangers – AO, AOVH, AOHM, AOF, & AOVHM Series General Information1. Air cooled oil coolers are built for operation with maximum oil pressures of

300 psi and temperatures of 400°F.

2. The motors furnished are specially built for fan duty. They are guaranteed by the manufacturer for operation in a maximum ambient temperature of 104°F. Consideration should be given to installation location so motors are not subjected to temperatures above this level.

3. Air/oil coolers that are to be installed for utilization of waste heat for the space heating should be mounted 7 to 14 feet above the fl oor depending on the structure, for proper heat distribution.

Installation

1. “AO” and “AOF” coolers are designed for suspension by eye bolts or threaded hangar rods screwed into the upper and lower covers in 1/2” to13 threaded holes; “AOVH” coolers have 6 to 12 holes (0.56” diameter) in the base for mounting. Refer to product page for location and quantity.

2. Units should not be located in corrosive atmospheres as rapid deterioration of casing, cooling coil, fan and motor may take place resulting in reduced life.

3. For proper air fl ow, a minimum of 12” should be allowed between the oil cooler fan and any walls or obstructions.

4. Piping should be sized based on oil fl ow and pressure drop requirements and not on the oil coolers supply and return connection size. Piping should also be properly supported to prevent excessive strain to connection, manifolds, etc.

5. Filter located ahead of the cooler should be installed to trap scale, dirt or sludge that may be present in piping and equipment, or that may accumulate with use. A thermostatic or spring loaded by-pass relief valve installed ahead of the cooler may be helpful to speed warm-up and relieve the system of excessive pressure. All accessories should be considered in the original heat rejection and piping calculations.

6. Electric Motors: CAUTION To prevent possible electrical shock, it is important to make sure this unit is grounded properly. Connect motor only to a power supply of the same characteristics as shown on the motor nameplate. Voltage may vary 10% of nameplate voltage. Be sure to provide proper fusing to prevent possible motor burnout. Follow wiring diagram printed on motor nameplate or in terminal box. Before starting motor, follow motor manufacturer recommendations. Turn fan manually to eliminate possible motor burn out in the event the fan has become damaged in shipment. Observe operation carefully after motor is started for the fi rst time.

7. Hydraulic Motors: Connect motor, port B, to inlet oil line and return line to port A for correct rotation. A fi lter is highly recommended upstream of the motor rated at 25 micron nominal. Controlling oil fl ow rate as specifi ed on motor data sheet with cooler is very important. Maximum oil pressure to motor is 2000 psi, minimum pressure is shown on motor data sheet. Do not allow dirty oil to enter the motor. Excessive fl ows will cause fan blade failure. Insuffi cient fl ows to motor will reduce cooling capacity.

Maintenance Inspect the unit regularly for loose bolts and connections, rust and corrosion, and dirty or clogged heat transfer surfaces (cooling coil).

Heat Transfer Surface Dirt and dust should be removed by brushing the fi ns and tubes and blowing loose dirt off with an air hose. Should the surface be greasy, the motor should be removed and the fi ns and tubes brushed or sprayed with a mild alkaline solution, or a non-fl ammable degreasing fl uid. Follow with a hot water rinse and dry thoroughly. A steam hose may also be used effectively.

Casing, Fan and Motor: Dirt and grease should be removed from these parts. Rusty or corroded surfaces should be sanded clean and repainted.

Internal Cleaning: At lease once a year piping should be disconnected and a degreasing agent or fl ushing oil circulated through the unit to remove sludge from turbulators and internal tube surfaces to return the unit to full capacity. A thorough cleaning of the entire system in the same manner is preferable to avoid carry-over from uncleaned piping, pump and accessories. The strainer of any fi ltering devices should be removed and serviced following this cleaning operation.

Electric Motor Keep outside surface free of dirt and grease so motor will cool properly. Make sure cooling air over motor is not obstructed. Prelubricated ball bearing motors are normally furnished and require no grease for about 5 to 10 years. Sleeve bearing motors require oil after three years.

Hydraulic Motor Change any oil fi lter(s) in the motor circuit as frequently as necessary to assure that good, clean oil is maintained.

Units with Replaceable Air Filters Examine fi lters for dirt and grease accumulation twice yearly, or more if operating conditions dictate. If disposable fi lters are used, replace as required. If the washable aluminum fi lters are used, wash with a warm water and soap solution that will remove dirt and cut grease build-up. Make sure that the aluminum fi lter is completely dry before replacing the unit. This fi lter can be made more effective if treated with a lightweight oil before placing in service. It is recommended that a spare aluminum fi lter be kept in stock to minimize downtime during the fi lter cleaning operation.

Repair or Replacement of Parts When ordering replacement parts or making inquiry regarding service, mention model number, serial number and the original purchase order number. Any reference to the motor must carry full nameplate data.

Performance Data: L4003A

* For certified information, contact your local Baldor office.

Product Nameplate Data :

Rated Output .25 HP Hertz 60 NEMA Nom. Eff. 55

Volts 115/208-230 Phase 1 Power Factor 57

Full Load Amps 5/2.6-2.5 NEMA Design Code N Service Factor 1

Speed 1725 LR KVA Code L Rating - Duty 40C AMB-CONT

(Typical performance - Not guaranteed values)

General Characterstics at 230 V, 60 Hz, 0.25 HP

Full Load Torque 0.781 LB-FT Starting Current 11 Amps

Start Configuration DOL No-Load Current 2.34 Amps

Break Down Torque 3.72 LB-FT Line-line Resistance @ 25° C 8.77 Ohms

Pull-Up Torque 2.15 LB-FT Temperature Rise, C @ FL (in deg) 0

Locked-Roter Torque 2.79 LB-FT Temp. Rise @ S.F. Load (in deg) 0

Load Characteristics at 230 V, 60 Hz , 0.25 HP

% of Rated Load 25 50 75 100 125 150 S.F.

Power Factor 36 45 53 60 66 72 0

Efficiency 31.6 42.2 50 54.7 56.3 56.5 0

Speed (rpm) 1767 1752 1738 1719 1698 1672 0

Line Amperes 2.32 2.36 2.42 2.53 2.7 2.93 0

--| Home --| AC Motors --| Front Page --| Performance Data

Front Page Spl Instr Nameplate Oracle/Rev FP Print Test Limit BOM

Performance Data

Motor No. 110908.00 Suffix L NP Seq 0

Winding C634256 R Number FR Group/Subgroup / 3 D

Phase 1 Poles 4 No. of Speeds 0

Base Voltage 230 Base Freq 60 Base HP 1.0

Rotor Weight 0.0 Inertia (WK²) 0 Guarenteed Eff 0.0

Res. Main 1.9 Ohms Res. Aux 1.32 Ohms Connection

KVAR Max KVAR 95 0.0 KVAR 90 0.0

WK Max 0.1 Start Max Safe Stall Time

Req. Velocity Sound Pressure 64 dBA@3' Sound Power 73 dBA

CFM 0 FL Frame Temp 0 Torque UOM

Base Voltage(Freq 1) 230 Base Voltage(Freq 2) NONENONE Ratio

Load Curve @ 60 Hz, 230 Volts, 1 Horsepower

Load Amps KW RPM Torque Eff PF Rise By Resis Frame Rise0.0 4.2 0.151 1798 0.0 0.0 15.6 0.0 0.00.25 4.45 0.407 1778 1.0 62.1 39.8 0.0 0.00.5 4.75 0.547 1768 1.5 68.9 50.0 0.0 0.00.75 5.5 0.776 1751 2.25 72.1 61.3 0.0 0.01.0 6.4 1.02 1738 3.1 75.0 69.2 73.0 50.01.25 7.4 1.259 1717 3.75 72.6 74.0 0.0 0.01.5 8.6 1.531 1694 4.5 70.7 77.2 0.0 0.0SOURCE: DATABASE GROUP: 3

Speed Torque Curve @ 60 Hz, 230 Volts

Curve Point Amps Amps(%) Torque Torque(%) RPM KW PF HPBD - 0.0 7.0 233.0 0 0.0 0.0 1.0PU - 0.0 6.3 210.0 0 0.0 0.0 1.0LR 33 0.0 9.0 300.0 0 0.0 0.0 1.0SOURCE: CALCULATED GROUP: 3

Renameplate @ 230 Volts

Approved Hz Volts HP FL Amps SF Amps SF RPM Eff PF R/R Design KVA Remarks No Renameplate Data!

Rerates for 110908.00

Assigned toWinding Group Rework # Rating OK Hertz HP RPM Volts Low Volts High Duty Encl SF Max Amb Insul Design

No Rerates Found!

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Spl Instr Nameplate Perf Data Oracle/Rev FP Print Test Limit Rerate BOM

Product Features

Motor No. 110908.00 Catalog 110908.00 Edited By poullpj

Model C6C17FK5L Effective Date 09/21/2007 (L)

Description 1HP..1725RPM.56.TEFC./V.1PH.60HZ.CONT.NO NP Seq 0

Product Line 56 4P 1PH Channel LEC Status Active

Auth BOM/RT N,N Stock Class S Source Location BRF

Nameplate Data

Hertz 60 Volts 115/208-230 Hertz Volts

HP 1 HP

KW 0.75 FL Amps 12.8/6.4 KW FL Amps

FL PF (Cos) 68 ( 0.68 ) FL PF

(Cos)

FL Eff 75 SF Amps 13.6/6.8 FL Eff SF Amps

Eff. 75% Eff. 75%

SF 1.15 RPM 1725 SF RPM

Assembly Mtg NAN NP Frame 56C Motor Type CF

NEMA Design N Phase 1 Insulation Class B4

Duty CONTINUOUS Max Amb(C') 40 Enclosure TEFC

Full Load Rise 0.0 IP Code 54 IC Code 41

KVA Code K PE Bearing 6203 OPE Bearing 6203

UL Y CSA Y

CC Number EXEMPT RoHS Y CE N

Protector NONE Prot. Number Thermostats NONE

Wdg. RTDs NONE Lead Desc. UNK

Hazardous Loc NONE Thermistors NAN

Stack Length 2.63 Max KVAR 0.0 Elevation 3300

Motor Image Protector Code CrAmps

Inverter Duty Motor Information

Inverter Type Inverter Load NONE Inv. Spd Range NONE

Max Safe RPM 5400 Rtr WK 0 No Load Amps 0

Hertz HP RPM Torque Volts Amps

0 0 0 0 0 0

0 0 0 0 0 0

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0 0 0 0 0 0

0 0 0 0 0 0

R1 R2 X1 X2 XM

0 0 0 0 0

Additional Mechanical Parameters

Frame Material ROLLED STEEL Severe Duty FALSE Mtr. Orientation NAN

Mount Type RIGID C Application GENERAL PURPOSE DE Bracket C-FACE

ODE Bracket STANDARD Shaft Type NAN Shaft Material NAN

DE Spl. Shaft NAN Shaft Diameter 5/8 IN

ODE Spl. Shaft NAN Shipping Wt. 33

Mech. Features NAN Final Asm. Drg.

Brg. RTDs NONE

Nameplate Drg. 993500 Nameplate Conn Dia 004012.NP Nameplate

Logo LEESON

Nameplate Type MYLAR GENERAL PURPOSE

Lubrication POLYREX EM Brake Prov. NONE Enoder Prov. NONE

DE Brg Type BALL Brake Mfg. NONE Enoder Mfg. NONE

ODE Brg Type BALL Brake Series NONE Enoder Model NONE

Drive Method DIRECT Brake Torque Enoder PPR NONE

Outline Drg. 028794-650B Packaging B Pallet Quantity 0

C/Box Type STANDARD

Carton Label Leeson Gen Purpose Paint STANDARD

Additional Electrical Parameters

Electrical Type CAP START IND RUN Poles 4 Base Winding C634256

Start Method ACROSS THE LINE Ins. System STANDARD Wdg. Rerate FR

Efficiency STANDARD Rotation SELECTIVE CCW Wdg. Group 3

Heater Volts NAN Heater Watts Wdg. Subgrp D

Conn Diag 005005.01 Conn Diag2 Test Card 01

Shipped Conn NA

Standard Order Variables

StdPck BOX StdVlt NA StdRot SELECT CCW StdMnt NAN

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Front Page Spl Instr Nameplate Perf Data Oracle/Rev FP Print BOM

General Information

Motor No. 110908.00 Winding C634256 Effective Date 06/06/2006

Type AC Group 3 Expiration Date

Ext. Diagram 005005.01 Test Card 01 Frequency 60

Test Limits

Amps Watts Load MSV Volts Max Min Max Min

High NL 230 5 3.9 240 160

Low

Comments

Torque

Pullup Full Load Pull-In Pull-Out Locked Rotor

High

65

IN-LB

Low

Speed

Max Min Insulation 1752

High 1800 1795 Inertia Comp

Low

Switch Cut-Out RPM 1500 1300

For SUBFRAC Motors Only

Capacitor MFD Capacitor Volts

Revision

Revision Rev Engineer Rev Date

Comments

Production Call

Engineer Prod Call Date

Comments

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LubricationThis motor is supplied with pre-lubrication ball bearings. No lubrication required before start up.

Relubrication IntervalsThe following intervals are suggested as a guide:

Lubrication

Use high quality ball bearing lubricant. Use consistency of lubricant suitable for class of insulation stamped onnameplate as follows:

Procedure

If motor is equipped with Alemite fitting, clean tip of fitting and apply grease gun. Use 1 to 2 full strokes onmotors in NEMA 215T frame and smaller. Use 2 to 3 strokes on NEMA 254T thru NEMA 365 T frame. Use 3to 4 strokes on NEMA 404T frames and larger. On motors having drain plugs, remove drain plug and operatemotor for 20 minutes before replacing drain plug.

On motors equipped with slotted head grease screw, remove screw and apply grease tube to hole. Insert 2 to3 inch length of grease string into each hole on motors in NEMA 215T frame and smaller. Insert 3 to 5 inchlength on larger motors. For motors having drain plug and operate motor for 20 minutes before replacing drainplug.

CAUTION: Keep lubricant clean. Lubricate motors at standstill. remove and replace drain plugs at standstill. Donot mix petroleum lubricant and silicone lubricant in motor bearings.

Lubrication InstructionsFor Ball Bearing Motors

H.P. RANGESub Fractional to 7 1/2

10 to 4050-200

Sub Fractional to 7 1/210 to 4050 to 200

All

Sub Fractional to 4050 to 200

SUGGESTED RELUBRICATION INTERVALSHOURS OF SERVICE PER YEAR

5,000

Continuous Normal Applications

Season Service MotorIdle 6 Months or More

Continuous High AmbientsDirty or Moist Locations

High VibrationsWhere Shaft End is Hot (Pumps-Fans)

RELUBE INTERVAL5 Years3 Years1 Year2 Years1 Year

9 Months1 Year

(Beginning of Season)6 Months3 Months

300-088.02

CONSISTENCY

Medium

LUBRICATION CONSISTENCYINSULATION

CLASS

B & F

F & H

TYPICALLUBRICATION

Shell Dolium Rand/or

Chevron SR1 2

FRAMETYPE

Sub Fractionalto 447T

All

TYPE

Polyurea

1001212121212121012812612412410282816141404

1501212121210128126124124102828160604002

0002

200121212121012812612412410282616004002

0002

00000

30012121012812610410410281606004

00002

00002

2500

30000

500101281261048281806

0004

0004

00002

3000

3000

50000500000

SINGLE PHASE MOTORS - 230 VOLTS

H.P.

1 1/2235

7 1/2

100

1010866

150

88844

200

88643

300

66421

500

44200

TRANSFORMERKVA

335

7 1/210

DISTANCE - MOTOR TO TRANSF. IN FT.

InstallationAfter unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections,check for proper grounding of motor and application. All electrical contacts and connections must be properlyinsulated and enclosed. Couplings, belts, chains or other mounted devices must be in proper alignment, balanceand secure to insure safe motor operation.

Electrical Wiring

Prior to connecting to the power line, check nameplate for proper voltage and rotation connection. This motorshould be installed in compliance with the National Electrical Code and any other applicable codes. Voltage atmotor not to exceed + or -10% of nameplate. Authorized person should make all electrical connections.

Mounting

This motor should be securely mounted to the application. Sufficient ventilation area should be provided toinsure proper operation.

RECOMMENDED COPPER WIRE & TRANSFORMER SIZE

Installation Maintenance InstructionsAC Induction Motors

VOLTS230460230460230460230460230460230460230460230460230460230460230460230460230460230460

THREE PHASE MOTORS - 230 & 460 VOLTS

H.P.1 1/21 1/2

223355

7 1/27 1/2

101015152020252530304040505060607575

TRANSFORMERKVA

3333557

1/27 1/2

101015152020

ConsultLocalPower

Company

DISTANCE - MOTOR TO TRANSF. IN FT.

Moduflow™ SeriesILP and RFP Low Pressure Filters

27

Low Pressure Filters Moduflow™ Series

Parker Hannifin CorporationHydraulic Filter DivisionMetamora, OH

Applications for Moduflow Filters

Power Unit Fabrication

Off-line Filter Loops

Mobile Equipment

The Moduflow filter is widely considered the most versatile filter available on the market. The unique diverter valve assembly, and inside to outside flow through the element, allows the Moduflow to be configured for in-line, in-tank or suction filtration.

The flow diverter minimizes turbulence and pressure loss through the filter, improving system performance.

Mounting / Porting Styles

RFP Return Filter

ILP In-Line Filter

IN

BRACKET924904

BOWL

OUT

FILTERHEAD

RETURN

BOWL

TANK

OUTLETPORT

28

The newly designed closed bottom elements for the RFP and ILP models insures all contamination remains trapped within the element as the filter is serviced.

A wide variety of visual and electrical indicators allows you to know exactly when the element needs to be serviced. There is even a “no element” indicator that can sense when there is not an element installed in the filter.

From top to bottom, the Moduflow filter series provides the high level of filtration and long term dependability so vital to today’s hydraulic systems.

Parker’s new patented Moduflow element was designed with built-in diverter cone and bypass valve, to meet your application needs.



Flanges NPT or

SAE ¾” to 2” Lightweight

aluminum

Bypass (not visible) Integral 35 psi bypass replaced

with every element change

Indicators Visual or electrical Mounted on either side Standard “no element”

indication

Cover Slotted for quick

release Lightweight

aluminum

Bowl Single or double

length Durable steel

construction

Element (not visible) Available in cellulose,

wire mesh or high performance Microglass III media

Single or double length

29

Features

Feature Advantage Benefit

l Top access element service l Oil remains in housingl Quicker elements change

l No Spills l Reduced maintenance costs

l Slotted cover l Quick release coverl Cap screws remain in housing

l Reduced maintenance costs l No loose parts to lose

l Closed bottom elements

l Removes all contaminant during element service

l No downtime contamination from servicing

l Visual or electrical indicators l Know exactly when to service elements l Helps prevent bypass condition l No premature disposal

l Flange face ports l Flexible mounting (3/4” to 2”) l Easy plumbing to your system


Parker Hannifin CorporationHydraulic Filter DivisionMetamora, OH30

RFP-1 & ILP-1 Element Performance

Efficiency %Efficiency

Beta Rating

1000

10000

99.9

99.599.0100

200

20

2 50.0

95.0

Micron Size (c)

2Q

10Q

20Q

5Q

0 4 8 12 16 20

0 50 100 150 200 250 300 350

0 20 40 60 80 100

20

16

12

8

4

0

02Q

20Q

10Q

05Q

LPM

PSID

GPM

1.2

1.0

0.8

0.6

0.4

0.2

0.0

BAR

150SUS

Flow vs. Pressure Loss

CapacityBARPSID

0

10

20

30

40

50

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0 20 40 60 80 100Capacity grams

2Q5Q10Q20Q

0 50 100 150 200 250 300 350

0 20 40 60 80 100

20

16

12

8

4

0

2” SAE flange

LPM

PSID

GPM

0.6

0.5

0.4

0.3

0.2

0.1

0.0

BAR

150SUS

1½” SAE

Empty Housing

Multipass tests run @ 40 gpm to 50 psid terminal - 5mg/L BUGL


Parker Hannifin CorporationHydraulic Filter DivisionMetamora, OH31

RFP-2 & ILP-2 Element Performance

0 100 200 300 400 500

0 25 50 75 100 125 150

20

16

12

8

4

0

02Q

20Q10Q

05Q

LPM

PSID

GPM

1.2

1.0

0.8

0.6

0.4

0.2

0.0

BAR

150SUS

0 100 200 300 400 500

0 25 50 75 100 125 150

10

8

6

4

2

0

LPM

PSID

GPM

0.6

0.5

0.4

0.3

0.2

0.1

0.0

BAR

150SUS

2” SAE flange

1½” SAE

Empty Housing

Flow vs. Pressure Loss

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0

10

20

30

40

50

0 20 40 60 80 100 120 140 160

Capacity grams

BARPSID

Capacity

2Q5Q

10Q20Q

Efficiency %Efficiency

Beta Rating

1000

10000

99.9

99.599.0100

200

20

2 50.0

95.0

Micron Size (c)

2Q

10Q

20Q

5Q

0 4 8 12 16 20

Multipass tests run @ 80 gpm to 50 psid terminal - 5mg/L BUGL



Specifications: RFP, ILPPressure Ratings:Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar)Design Safety Factor: 2:1Rated Fatigue Pressure: 150 psi (10.3 bar)

Element Burst Rating: 70 psid (4.8 bar)

Filter Materials: Head, Cover, Flanges: die cast aluminumBowl: steel

Operating Temperatures:Nitrile: -40°F to 225°F (-40°C to 107°C)Fluorocarbon: -15°F to 275°F (-26°C to 135°C)

Weight (approximate):Single: 20 lbs. (9.1 kg)Double: 25 lbs. (11.3 kg)

Indicators:Visual (optional)Electrical (optional) 15A @ 250VAC / .5A @ 125 VDCElectrical (“D” option) 5A @ 250VAC / 3A @ 28 VDC

Color Coding: White (normally closed)Red (normally open)Black (common)

168.06.6

A

OPTIONALTANK FLANGE

(99 OPTION) RFP-1 OUTLET 4 1” HOLES

2-11½” NPTFOPTIONALFITTING

69.92.75

D

RFP OUTLET

BCOPTIONAL MOUNTING BRACKET

78.73.1

MINIMUM ELEMENT REMOVAL CLEARANCE

345.913.62

482.619.00

Single:

Double:

168.06.7

108.54.27

196.37.7

OPTIONAL 3-PINMALE RECEPTACLEILP OUTLET

OPTIONAL PORT FLANGE

77.83.062

38.91.53

42.91.68

30.21.19 12.7

0.50

21.30.84

228.69.0

IL & RF INLET

32

Linear Measure: millimeterinch

Dimensions: mminch

Model A B C DRFP-1 without optional 2” fitting

65.02.56

330.213.0

_ 110.04.3

ILP-1 65.02.56

330.213.0

N/A 110.04.3

RFP-1 with optional 2” fitting

68.32.69

_ 383.415.07

114.04.5

RFP-2 68.32.69

617.524.31

623.824.56

114.04.5

ILP-2 68.32.69

617.524.31

N/A 114.04.5



Specifications: DILPPressure Ratings:Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar)Design Safety Factor: 2:1Rated Fatigue Pressure: 150 psi (10.3 bar)

Element Burst Rating: 70 psid (4.8 bar)

Filter Materials: Diverter Valve Assembly: die cast aluminumCheck Valve Assembly: die cast aluminumFilter Assembly: see IL2 specifications

Operating Temperatures:Nitrile: -40°F to 225°F (-40°C to 107°C)Fluorocarbon: -15°F to 275°F (-26°C to 135°C)

Weight (approximate):Single: 55 lbs. (24.9 kg) / Double: 65 lbs. (29.5 kg)

Indicators:Visual (optional) Electrical (optional) 15A @ 250VAC / .5A @ 125 VDCElectrical (“D” option) 5A @ 250VAC / 3A @ 28 VDC

Color Coding: White (normally closed)Red (normally open)Black (common)

479.318.87

30.21.19

OPTIONALFLANGE

345.913.62

INLET

OUTLET

AIR BLEED EACH FILTER

177.87.00

402.815.86

OPTIONAL MECHANICAL INDICATOR

SINGLE

DOUBLE

¼-18 NPTDRAIN VENT

CONNECT TO TANK 173.0

6.81

½-13 SHCSTORQUE

32-38 FT-LB

110.54.35

79.03.11

116.84.60

76.2

617.524.31

330.213.0

3.00

25

20

15

10

5

1.75

1.5

1.25

0.75

0.5

0.25

0

1

FLOW LPMGPM

LPM

GP

MD

IFF.

PR

ESSU

RE

0 10 20 30 40 50 60 70 80 90 100

0 25 50 75 100 125 375150 175 200 225 250 275 300 325

3000 SUS

200 SUS

(Add to differential pressure of filter assembly for total duplex pressure differential)

*Diverter/check valves combined

(Add to differential pressure of filter assembly for total duplex pressure differential)

*Diverter/check valves combined

Typical Flow/Pressure Curves For Duplex ValvesApproximate handle torque required for changeover.

System Pressure (psi)

Torq

ue (

Ft-L

bs)

30

20

10

100 200 30000

3.3.013

33


BOTH CHECK VALVESMOVE SAME DIRECTION

FILTER SCHEMATIC

DRAIN VENT

BYPASS BYPASS

FILTERFILTER

OUTLET

INLET



For return line applications (RFP), the fluid returning to the reservoir holds the check valve open. When the system is shut down, the check valve closes automatically.

RFPSINGLE ELEMENT

452.117.8

RFPDOUBLE ELEMENT

688.327.1

MAX. O.D.OVER WELD

117.14.61

(RFP & DOUBLE LENGTH)

3.0

2.5

2.0

1.5

1.0

0.5

0.0

Flow (GPM)

Pre

ssur

e Lo

ss (p

sid)

Check Valve Flow/Pressure Drop

0 10 20 30 40 50 60 70 80 90 100

*Check valve pressure drop must be added to assembly pressure drop to get total

34




Accessories

OPTIONAL MOUNTING BRACKET (924904)

35


10.30.406

DIA. THRU 8 PLACES

OPTIONAL TANK FLANGE (925167)

8.70.344

DIA. THRU 6 PLACES

4.60.18

MATERIALTHICKNESS

149.25.875

DIA. B.C.

196.97.750

TYPICAL

98.43.875

TYPICAL

235.09.25

122.94.84

161.56.5

114.34.500

13.50.531

DIA. THRU4 PLACES

114.34.500

R

60TYP 7.9

0.31

8.70.344

DIA. THRUPLACES

6.440.25

114.3 4.500

25.41.00

57.2 2.25

13.5 .531

41.11.62

DIA. THRU TYP.

“M” OPTION-VISUAL INDICATOR, NO ELEMENT WARNING

“E” OPTION-ELECTRICAL INDICATOR122.94.84



38B6

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

10

8

6

4

2

00 5025 75 100 125 150 175 200 225

(PSI

)D

IFF.

PR

ESS.

(BA

R)

(GPM) INLET FLOW (LPM)

0 450 525 600 675

TYPICAL FLOW/PRESSURE CURVES FOR MODEL MM

750 825 900

250

37575 150 225 300

200

SUS

36

Lower Cost than many single unit filters. Moduflow™ Manifold Extended Filter Range

Use Model MM Manifold to handle return line flows up to 130 gpm. l Rated static pressure: 300 psi l Typical burst pressure: 900 psi l Easily mounted on ModuFlow™

High Flows At Low Cost

The model MM manifold is designed to extend the flow range of ModuFlowTM Filters when operating with 10 Micron and finer filter media. When mounted to a pair of RFP-2 or ILP-2 filters, this manifold will allow flows up to 130 gpm in return lines (15 fps velocity). Note: The Model MM manifold is not applicable to suction lines due to its pressure drop characteristics.

When used with two ModuFlowTM filters, the total cost is often less than a single unit filter rated for 130 gpm flow. Tank-top mounted (Model RFP) filters will require only one manifold on the filter inlet pports. In-line mounted (Model ILPav) filters will require two manifolds, one on the inlet and one on the outlet ports.

Multiple Uses

Although designed for manifold ModuFlowTM filters, the Model MM can be used in a variety of applications which require: l Splitting flow between components

Such applications are frequently encountered on mobile equipment, machine tools, and large lubricating systems. In such applications, use of a manifold can often reduce total piping and installation costs.

Proven Reliability

The rugged design of the Model MM manifold has been proven in demanding mobil equipment applications, At the factory, we have cycle tested the Model MM through the full range of rated flow and pressure to insure reliable service.

Parker Filter Division maintains the same high standards in delivery, quality, and service. Considering this, plus features, flexibility, price, and performance, the Model MM manifold is a valuable addition to your fluid power component list.

FLOW/PRESSURE CURVE



155.6mm 6.125

88.9mm 3.50

12.7mm .50 177.8mm

7.00 88.9mm 3.50

66.8mm 2.63

66.8mm 2.63

77.8mm 3.062 42.9mm

1.688

(TORQUE SCREWS TO 32-38 FT-LBS)

C C

273.8mm 10.78

42.9mm 1.688

77.8mm 3.062

(TORQUE SCREWS TO 32-38 FT-LBS)

VIEW AT C-C

STANDARD OUTLET, 2 PLS 2-0 SAE 4-BOLT FLANGE WITH 2-228 O-RING GROOVE

To one decimal place: To two decimal places: To three decimal places: Linear Measure:

TOLERANCES 3.0mm

0.12

0.8mm 0.03

0.4mm 0.015

Millimeter Inch

INSTALLATION DIMENSIONS

37

HOW TO ORDER MANIFOLDS:

MANIFOLD SPECIFICATIONS

Rated Static Pressure, maximum: 20.7 bar (300 psi)Typical Burst Pressure: 62.1 bar (900 psi)Operating Temperature (Buna seals): +121ºC to —40ºC (+250ºF to 40ºF)

Housing Material: ANSI 356-T6 cast aluminumApproximate Shipping Weight: 3.6 kg (8 lbs)Porting: See Options Below

Order Screws and O-Rings Seperately: Inlet & outlet screws (12 required): Order P/N 900228Outlet port o-rings (2 required): Nitrite: Order P/N N72228 Fluorocarbon: Order P/N V92228

* Tank-top mounted RFP filters will require one manifold on filter inlets: in-line mounted ILP filters will require two manifolds on both inlets and outlets.

OPTIONNUMBER

Part Number Description

926466 Moduflow Manifold



RFP / ILP / DILP Replacement Elements

Flange Kits (flange, 4 bolts, o-ring)

38

Size CodeBuna Fluorocarbon

¾ inch NPTF YB 924788 926013

1 inch NPTF YC 924787 926012

1¼ inch NPTF YD 924912 926004

1½ inch NPTF YE 924786 926011

2 inch NPTF YF 924785 926010

SAE - 12 YM 924784 926009

SAE - 16 YN 924783 926008

SAE - 20 YO 924913 926005

SAE - 24 YP 924782 926007

BLANK FLANGE — 924782 926006

Part Number

Media New SingleReplaces Old

Single New DoubleReplaces Old

Double New SingleReplaces Old

Single New DoubleReplaces Old

Double

02Q 937393Q 932686Q 937397Q 932692Q 937401Q 932689Q 937405Q 932695Q

05Q 937394Q 932687Q 937398Q 932693Q 937402Q 932690Q 937406Q 932696Q

10Q 937395Q 932688Q 937399Q 932694Q 937403Q 932691Q 937407Q 932697Q

20Q 937396Q 933116Q 937400Q 933117Q 937404Q 933118Q 937408Q 933119Q

Nitrile Seals Fluorocarbon Seals



6

4 10 11

3 5

21

6 7 8

9

12

15

14

13

Index Description Part No. Quantity

11 Check Valve Assy. ......................... 925120 1

12 Flange Kits..................................... Refer to Table 1

13 Plug Kit, Fastener, self-sealing, o-ring seal included with fastener

925974 2

14 Indicator Electrical35 psid.............................................35 psid, 3-pin male receptacle.....

926643926753

Optional

15 Indicator Visual35 psid 4-band...............................

Flange, In-tank mounting..........Bracket, Inline mounting...........Indicator Kit, Remote mount.....

926748925167924904924894

Optional

OptionalOptionalOptional

16

17

Not Shown

Changeover Valve Assy., Duplex

Check Valve Assy., Duplex............

Drain Plug, SAE-24 for RFP modelNitrile............................................Fluorocarbon................................

926758

926757

909992928363

Optional

Optional

11

39

Parts ListIndex Description Part No. Quantity

1 Screws, Nameplate....................... 900028 2

2 Name Plate, Unstamped............... 920928 1

3 Cover Screws, 5/16-18 UNC x 1”.. 926633 6

4 Bowl Screws, 5/16-18 UNC x 1”... 926633 6

5 Cover, Without nameplate............ 924634 1

6 O-Ring, coverNitrile............................................Fluorocarbon................................

N72350V72350

22

7 Element SealNitrile............................................Fluorocarbon................................

937410937411

11

8 Element.......................................... Refer to Table 1

9 Head, Machined only..................... 2” SAE Flange 1½”SAE Flange 1½” NPTF

925972926164925949

111

10 Bowl, Select desired model ILP-1.............................................ILP-2.............................................RFP-1............................................RFP-1 with 2 inch NPTF fitting...RFP-2............................................RFP-2 with 2 inch NPTF fitting...

925916924816937626924676937627924818

1

Filter AssemblyExploded View

16 17



1) First pair of symbols denotes inlet for all filter styles; second pair of symbols denotes outlet.2) Four symbols required: two for inlet, two for outlet.3) Unused ports in filters come plugged with a blank flange.4) See Flange Kits table for port flange options. Flange Kits are ordered separately.

HOW TO ORDER: Select the desired symbol (in the correct position) to construct a model code.Example:

40

BOX 1 BOX 2 BOX 3 BOX 4 BOX 5 BOX 6 BOX 7 BOX 8

ILP 1 10Q B MP 35 Y9Y9 1

BOX 1: Filter Series Symbol Description

RFP Return-line filter, inlet on side outlet on bottom

ILP In-line filter

DILP In-line duplex

Filter Model

Y9 2” flange face 99 No fitting

P9 SAE-24integral threads

F9 2” NPTF

E9 1½ NPTF inte-gral threads

F8 External check valve

Y9 2” flange face 99 No fitting

P9 SAE-24 integral threads

P9 SAE-24 integral threads

E9 1½ NPTF integral threads

E9 1½ NPTF integral threads

Y9 2” flange face Y9 2” flange face

BOX 7: Port Options

Inlet Symbol/Description

OutletSymbol/Description

RFP

ILP

DILP

Note: First letter of indicator code = left side of filter head when looking into inlet with bowl down; second letter = right side of filter head when looking into inlet with bowl down.

BOX 2: Element Length Symbol Description

1 Single

2 Double

BOX 3: Media Code Symbol Description

02Q Microglass III, 2 micron




WR Water Removal

BOX 4: SealsSymbol Description

B Nitrile

E EPR

V Fluorocarbon

BOX 5: IndicatorSymbol Description

P Pressure ports drilled & plugged only; no indicator

M Visual indicator w/”no element” warning

E Electrical indicator only

D Electrical indicator only, 3-pin male receptacle

BOX 6: Bypass Setting Symbol Description

35 35 psid

BOX 8: Options Symbol Description

1 None


Foam Pads

Isolates the removal materials from

contact with heavy reservoir mist and

securely holds materials in place.

Filter Pads

Specially designed filter pads

remove solid particulate on upstream

side and then regenerate by releas-

ing those particles when air flow

reverses direction. Lower pad

removes airborne contamination and

second pad protects against any

migration of desiccant.

Air Intakes

A total of eight air intakes may be

exposed to allow air to freely flow in

and out of the TriCeptor.

Breathers

Desiccant Type

Specifications:Materials: Casing: Clarified copolymer polypropylene.Cap: Copolymer polypropylene.Stand pipe: PVC.Filtration Element: Polyester, silica gel.Operating Temperatures: -20oF (-29oC) to 250oF (121oC).Seals: None.Maximum Allowable Operating Pressure (MAOP): 5 psi (.34 bar).Particle Removal Efficiency: 98.7% (beta 75) @ 3 micron99.5% (beta 200) @ 4 micron99.9% (beta 1000) @ 5.3 micronWeight: 934330T 1.25 lbs. (.57 kg) each.934331T 1.75 lbs. (.79 kg) each.934332T 2.25 lbs. (1.02 kg) each.

Silica Gel Desiccant

Has the highest removal

capability by volume of any

adsorption method. Indicates

condition by changing color.

Foam pad

Insures filter pad is properly

positioned and protects it

from external damage.

Molded Housing

Durable shock absorbing

casing provides reliable service

and simple press in mounting.

Features

Reservoir AccessoriesBreathers

200


0 4 8 12 16 20

PS

ID

BA

R

2.5

2.0

1.5

1.0

.5

0

3.0

SCFM

Liters/Second

0 1.88 3.78 5.66 7.55 9.44

3.5 .241

.207

.172

.138

.103

.068

.034

0 30 60 90 120 150

PS

ID

BA

R

2.5

2.0

1.5

1.0

.5

0

3.0

3.5 .241

.207

.172

.138

.103

.068

.034

GPM (fluid exchange rate)

41.66

33.53

1.32

101.6

127.0

9.0

98.55

3.88

1.64

4.0

5.0

178.0

7.0

229.0

1“ NPT

Thread

Installation

TriCeptor breathers are designed for simple installation on most equipment, regardless of mounting connection. Since TriCeptor breathers are disposable, the threaded connection allows for quick and easy maintenance. Several mounting adapters (shown below) are available to provide the desired mounting. The installation/replacement pro-cess consists of four easy steps:

1. Remove from protective plastic wrap.

2. Remove 1" blue cap from standpipe.

3. Remove foil label to expose the necessary amount of air intake holes.

4. Twist TriCeptor into mounting adapter.

Servicing the TriCeptor breather is also very easy. When the silica gel changes color from blue to a pink, the breather is no longer active and needs to be replaced. Simply remove the unit and discard properly.

Air Flow Performance

The curves below show the air flow performance of the three TriCeptor breathers. To insure the longest life possible, the initial clean pressure drop should not exceed 1.5 psid (.103 bar).

Field Adapter Flange Adapter

Part Number

934330T

934331T

934332T

937546

937463

Model

5" Breather

7" Breather

9" Breather

Field Adapter

Flange Adapter

Reservoir AccessoriesBreathers

Quantity

6 pcs.

6 pcs.

6 pcs.

1 pc.

1 pc.

Linear Measurement= mmin

201

installation, operation and maintenance manualcalroc.ca/equipment/media/baker-hughes-hpump... ·...

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