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WA9601-MN 991206 WAGON WHEEL RANCH 2.0 HG ELEVATED STORAGE TANK CZ-TY OF COPPELL~ 'TEXAS PRO3ECT NO. WA-96-0Z OPERATZON & MAZNTENANCE MANUAL GENERAL CONTRACTOR CONSUL TZNG ENGZNEER LANDMARK STRUCTURES~ TNC. SHTMEK, ,]ACOBS & FTNKLEA 1665 HARMON ROAD 8333 DOUGLAS AVENUE FORT WORTH, TEXAS 76177 DALLAS, TEXAS 75225 Table of Conterns '*'* 1 ELEVATED TAN K · 2 TAN K COATINGS ~ GATE VALVE w/OPERATOR ~ 3IB CRANE 5 CHLOR'rNE ANALYZER 6 'r NSTRU H ENTATZON 7 CATHOD'rC PROTECTION '~'~",--.--" ~ 8 IRRIGATION T ~ ' i I I ! WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK CZTY OF COPPELL~ TEXAS PRO3ECT NO, WA-96-01 OPERATION & M AZNTENANCE MANUAL ELEVATED TANK DRAWZNGS GENERAL CONTRACTOR LANDMARK STRUCTURES~ INC. 1665 HARMON ROAD FORT WORTH, TEXAS 76177 (817) 439-8888 WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK CITY OF COPPELL~ TEXAS PROJECT NO. WA-96-01 OPERA TION AND MAINTENANCE MANUAL ELEVATED TANK DRAWINGS TABLE OF CONTENTS DWG REV DESCRIPTION S1 TANK ELEVATION S2 TANK SECTION S3-A1 DRILLED PIERS / PIER CAP - PLAN S4-A1 GRADE FLOOR - PLAN S4-A2 PlEa CAP / LOWER WALL SECTION / CONCRETE DETAILS S6-A1 SUPPORT WALL OPENING / SLEEVE LOCATIONS S7-A1 DOME FLOOR SLAB - PLAN S7-A2 UPPER WALL / RING BEAM / DOME SLAB SECTION / CONCRETE DETAILS S10-B STEEL TANK ELEVATION / SECTION S11 STEEL TANK - ROOF PLAN S12-A STEEL TANK ERECTION DETAILS S14 STEEL TANK RING BEAM CONNECTION S15 STEEL TANK ACCESS TUBE / TOP PLATFORM S15-A1 ACCESS TUBE TOP PLATFORM PLAN / SECTION S15-B1 ACCESS TUBE LAYOUT S20-B BAR LIST S20-C BAR LIST S20-D BAR LIST S20-E BAR LIST S21 DRAWDOWN CHART 300-A SUPPORT WALL LADDERS / LANDINGS GENERAL ARRANGEMENT 300-B SUPPORT WALL LADDERS / LANDINGS CATWALK - PLAN 301 -A1 STEEL LADDER STANDARD DETAILS 311-A STEEL LADDER CAGE STANDARD DETAILS 313 SAFETY CLIMB & HARNESS 315-A1 A INTERMEDIATE LANDING PLAN 318-A1 TOP LANDING - PLAN 320-A LANDING AT MANHOLE - LAYOUT 321 36" X 36" - ACCESS HATCH COVER ASSEMBLY / INSTALLATION 322-A ROOF RAIL - ASSEMBLY 323-A TANK ROOF VENT T i '1 ! T il Dwg Rev Description 324-C PAINT RAIL ACCESS HATCH 325-A1 25" TANK FLOOR MANHOLE ASSEMBLY 327-A PAINT RAIL ACCESS LOUVRE 339-A WIRELESS COMMUNICATION EQUIPMENT SUPPORT RINGS 340-A BOLLARD / INTERIOR LOCATION AND DETAILS 341-A ANTENNA SYSTEM BELOW CONDUIT ENTRANCE 341-B ANTENNA SYSTEM UPPER GABLE FEED-THRU PLATE 401 A MECHANICAL LAYOUT PLAN 402-A A MECHANICAL LAYOUT SECTION A - A 402-B A MECHANICAL LAYOUT SECTIONS B - B, 'E' & 'F' 402-C A MECHANICAL LAYOUT SECTION C - C 402-D A MECHANICAL LAYOUT SECTIONS D - D & 'G' 403 FLOOR DRAIN 405-A1 INLET / OUTLET RISER ELEVATION 405-A2 INLET / OUTLET RISER FLOOR PENETRATION / DRAIN DETAILS 410-A A PIPING / MECHANICAL EQUIPMENT LEGEND 410-B A PIPING / MECHANICAL EQUIPMENT LEGEND 424 RISER PIPE EXPANSION JOINT 803-A1 LIGHTNING PROTECTION 803-C LIGHTNING PROTECTION INSTALLATION INSTRUCTION (USA) INTERMEDIA TE FLOOR S 17-E 1.1 GROUND FLOOR PLAN / GENERAL DESIGN S17-E1.2 INTERMEDIATE FLOOR PLAN / GENERAL DESIGN S17-E7 1 TON X 12' JIB CRANE DETAILS &INSTALLATION T i '! I T · .. Oa~e COPPELL, TX - # 802 TANK ELEVATION nz~e05 / 98i o,,~. CADO L A N D M A R K i~, '1 I ! ] i1 ;, 4.3'-5, 112' 16'-0", 877.57 e · 4'- 0'7/8' , Roof f S11 i~ 672.50 :7'~ !1 ~ j HWL i i i ', Steel Tank ! .... Access Tul3e · -- i !, ? Dome Roar · " I Roar Manh 6;32,50 ~ i j i ~RSi6n ~' LWL i } , · , g Beam "~ I ~ t .. · · .~, ~ ~ t! ,;-~ / ..... ~ I ~ //. · 1 · . ..:.*..~ 1 I I °~.~ 'I i .nl,. Wall I ,. i ~iF I Storage Raor ::I i :. t I fS4-A1 u/s P.e cap, r-~j,.%..'.,p~ i 524.5o s2,keo 520.00 <o · "'-?~ ~o ' ~' 1,_~%,_ ~' Rnisll Grade I Pfer Cap /Offlied Pfer Foundation I I I I NOTES: 1. Plan views correspond to sections indicated. Refer to sections for details & material specifications- COPP~LL, 'IX - # 80~ TANK oam 05 / 98 ow,. CA00 L A N D M A ~ K ~ s: G, % s~ -~ ,,%?: ......... ,* , ,' . , ~1.~ I · '~:,' '., ss- , :;.., .,. .\ ! .~ ~ ..:.~ \,,, .,:,'_'"",", .:,'~=~'~ P'~a',' r~1'", ', ...~.~.:''..... ,~ ,'~ -, ., ....~,,,,..?..:~, .- /,/.. .,,.,..,, ~'~,~.2" \. ,, :.~ ,:'', ,,,~9'', ,,'',,.,.'',.., :;v-:' .-.-..~/'~-:~.:',, .;--"'~-~.. i · ',, .,.- :.',., .' ,'t ~=~o~,,,~,, ',,-.-''.,,.' /~ '/ ~. -:'... ,,,,..."'xi':~,z..',' "''~',, ', =-f ..~,..*~:~t,,,'..,,.,.-',,, %7' Ir ',, · .-"' . ' '1~. !z____ R., ~'- r ,, ,."., ", t :']~ ", .N_.g_I:F,.,~ ~ti A4 v/" ,,~"~) .~' - ,,~ · --,, ', .,' p "'~':: , ,"' ',, /___.~__.%," /~ "'--- -.-7- [ ,,',..,.-' ', .,ks. ",-',"'Z'.':'i.,:', ',,',....-.-"'',,~,--' '.,, ../,.,~'-.-.7-?'" %,::,:,...-". 'v''. ...,"-.,. // · ::-.t'.,.',:', ' "., ',, ' "',<"~'-. ~ i \ '., ".,,"./ ,, .1~; i i "' ' "', /i zi,i,i~.. 2 \\~ "' "' "" · 1. Cartcrete ef~cas.e Delaw .Re.r Cap. Refer.to Owg. 13.8,S" - 8' - 6 1/8" f ~.3~" - 7'-8 1/4," I:lr~wlna_ References: · ,S3- A2 - Drilled Piers #4, 5, 6, 7, 8, 15, 16, 17, 18, 19 Concrete / Reinforcing Steel Details · $3-A3 - Drilled Pfers At1. 3, 9, 11.12, 14.. 20, 22 Concrele / Reinforcing Steel Oe~aiis · S3-A4 - Orffied Piers At2. 10. 13, 21 Concrete / Reinforcing Steel gel3jls __//~1 - Mecrta~icaJ Layout - Plan ' --~ c~ DRILLED PIERS / PIER CAP COPPELL, 'IX - # 802 PLAN Dam a5 / 98 own. CADO L A N D M A R K ' i .~'~-\ O4e Panel 'B' Ccnduits Y"" PV fn G..~ \ ~T~', . ,, \ ( see wg. S4 - A2 for details ) '::. ,.~ .!i!- - ..................7;~ ......:----..' .~,:..~,..:' ;,,.... ...... ~". . "..':..,,.. '., ,..-'~r o,.,e~w ;' .. ,,..;:.-'....--" ::~:,;'.)-.. "",... '-::.,.,, ...-. ,:.." .,.' ., .,',"," '~ ( Wp. ).=i ~.' '.'r..... '..·., ~ .. ~,~. .. t ,," ",. ..i ., ""', . .:;':':" · '-, / ~. ..-'.-.. ;' .. / ." ? ' \ "";""'. °-"": '!~i:' '~"" · /';' .~;~'~'~i """' ..:2-''-.. .,,.~., ...-" ~ ~,"..... · ..,,,.-.-", .... ", ". .--" '~,,,, .~ .C.__.-~?__,,." / / =- z' ~,vc \ ~",........-" ,. '/'.~, .....' ., · .:, / ,, .,...- ·/ i'-....' '... .~ ..' · .,~ '.../' / ~.~ ..-' ... . FIef Ca :.,..,.. / ', ..-' ,,,:....'...... .. ......,.,;' ~- ,- ~ -....;/ . '.,,....--.,.' S4oA2 ~' .................... -* ,4,, 'Door Opening ' ' 3' x 7 SIngle Door ~R ' oadway. { typ. ) Op nng 1. Sea Contract Or4wkqGs far additional dellis at~d site requiremerits. ;~;':::" /: -..:?-.1 Omlna References ' · li4-A2 - FMef Cap/Lower Wail - ,Sectlon/C43ncrete Dellill "i!":,..~, ~j~, .~.. · S8- A - Sup13od Waif - Of3enlrtg/Sleeve Locai~rts ~; . - · 3(X3- Series - Boilerall, Ladder. Lar~rtfa arld Appurteflance8 '. _ /'~""'rl430- Series - Mechanical arid OrainmGa Oelajls .. 0.~. GRADE FLOOR COPPELL, TX - # 802 PLAN oam G5 / 98 Own. CAOC) L A N D M A R K [ I 'i ! ~ il NOTES: 1. Select RII to be compected to 95% of standard Proctor maximum dry density at moisture content :_-3% of optimum. ~12',~ · · MaterfaF Sgeclflcatlon - Concrete For lift 14 + Pa=em see Owg. S7"'~~_~ · Refer to concrete matedal mix designs. · 28 day compressire strength: Woddng Slab - (20C~3 psi } 617dt8 PIer Cap - ( 4200 psi ) Uft 13 Support Wall - ( 4200 psi ) Grade Slab - ( 4200 psi ) Cr'4ne Foundation - (4200 psi ) Wail --~ Drawfng Reference~. · S4 - A3 - PIer Cap / Lower Wall - Reinfercing Steel · S6 - A - Support Wall - Opening / Sleeve Locations .. n=zr-o- ¢,- '" '~ i : " 1/z' Expa~on i JoiL0.R~, i 1/2' Expsnsk~l Joint · i /~'.~,,.., 11/2' PVC Etac~'fc Co,-x~lt=' Grade ,SIal3 f 2' i ( m pin for m ..~ i L, ! ' f ~ " i tL 4' Sub - Base :) t ............. .., ......... __ Crane Found~ff~ 520 O0 j ~-, ' "" """' """' /.: " _,Z: ......~ T C Umit of sxcawtlon ...-.,. Rer Cap ,.,_.;,. ,, 2" W~rklng Slab · · ........... :?.. """R=28"-9" ~' R=2,,~-3" / y t ......... ' ~ oam PIER CAP / LOWER WALL COPPELL, 'FX - # 802 SECTION / CONCRETE DETAILS I~ o~i / 98 ow., CAOO L A N D M A R K I I ',r' I I" ' [ I 1,"2' PVC Sieeve for RTU Antenna / ('20'- 6' a~,c,~e No' Pier Cap ) '/"'1 i~ ~.~/. 12' x 12' Truck ~ ) ~ '- ~ 3/4" x 2-13/a,- Antenna C~ble o.\ ~.. Feecl - Thin Opening ~. ~ r b/a Boxout Beyethan - 617.00 · .:. . . "" \ ' ow Sleeve ~. Pro · ".,i / ..-.- ' %%,. . '\i /' .-'" " . .. -.,~ 754.~C~ -/ /.,,.-"" · ¢ .~i · '\ ~ i /"' .,.~.L/- ~. _, ( Boxout . ~ tto La~ Lift ) , ,."' -, "'---SLL'LT~'.: -.. '*""'~' / ' \ "' ' ' ,.,.,..,. . ./ .' -. .,. ~'~,~ · /"' .i i '\ " " .. · ,,.' I "' ; .1' ! '~'~ · \ · .' ~-\. · I' '\. ( Main ( 4'- 6' %eve Vo Rer ~1~ ) / .. ,' ( P ) 3' x 7' le Door Opening ,r. "" NO'TFS: .. Drawing Reference~ · s8- B - SIngle Doer - Opening/Reinforcement Details , · S6- D1 - Overhead Door - Opening/Reinforcement Details Oats SUPPORT WALL COPPELL, 'IX - # 802 OFENING / SLEEVE LOCA'rlONS oa=e 05 / 98ovm.CAOD L.A N D M A R K ~ ~,~ s6-A~ I ! i ~ il \.~,. ' ... ~.~' ,. ...' ~ ,./// .... Lji~.~--~" ,,,, -~. .... ,., , - ~ -- .....-~<.... ..: · , ·: ....- ~_ ~ . ~ . . . ./'// . - '% · , · t.//' -% .~? - ...,~ ~'% ./.',.,--' ,,~-~- ~., ~..~ / ~./~'/ ~[ -.-'.',.- .,, -, ... , ./'/'/' // '/ · /' . I/ '~ ·" I ' "~' .. /'~. " " NO~S: 2. Inse~ anchor locations are indic~t~ by an x. Refer to S7- 8 f~r I~ding insets Iocatian ~d det~ls. Shog Drawing References - S7 - ~ / A3 - Upper Wail / Ring Beam /Oome Slab - S~on / Cen~te Oet~ls ..""' . . . ~~,~; ....~ '["~ · S7- B Dame Slab Inse~ Det~ls · - - * , ' ' ' R,f ' ~te DOME FLOO ' COPPEL~ ~ - ~ 802 P~N L A N D M A R K I '! I Lift SIo~ ~ S/S I 9/2 e~t Frame · I Lift Si0t Plan 2'-3' ~6' ~6' l ~ ! 7'- 11 1/2' ~ Rind Beam Detail · ~ .... ~ .... L ~ Tangent Point ? ? o//m Ring Beam Detail---~ '° . j'/ ', s2, 32 i ! ,,,' ' ~ L.i~ 14. ' , '. / ,, · · t Acces~ / Louvre NOTES; ~" , .... :"' / Opening i Material Soecitication - Concrete/Seat Frame f ....... 8 .18 1. Refer to Materials - Concrete Mix Designs '~i~ ",- 2. 28-day compressive strength LEtt 13 · Support Wall - ( 4000 psi ) ~ i · Dame Slab ( 4000 psi ) i 3. Seat Frame - 1/4'x 11/2'x 11/2" ASTM A36 angle R =27'-0' - galvanized finish (embed in concrete) Orawinq References · S7- A3 - Upper Wall/Ring Beam/Dome Slab - Reinforcing Steel oaw UPPER WALL / RING BEAM / DOME SLAB COPPELL, TX - # 802 SECTION I CONCRETE DETAILS 0ate 05 / 98 Own, CADD S7 - A2 L A N D M A R K T I i i r II C~- Tank 4a'- 8 ' Roof Handrail - I 8'- O" , 40'- 8 I/2' ( 32 pc's )".~ ~ 877.57 _ W=,8 Shell .25' Top Pfsfform W, 7 (8 pds) Shell .32" j (8 I~S) -, .Access Tuige Shell .50° ( 8 p~s ) ~ Cone P~a~e 79 Outer R = 35' - g' (26 pc's . /--.25' Roar Rate ~CT Inner Cor/624.32 Ring 8earn ChNg. S14 j 27"- O' I 1'- 9' ~.- Wall ,,' ~ . .T~ - ; '- t I W' Elevations · ~1 - 624.32 * ~¢ - 647.28 - ~ - 627.32 * ~7 - 673.51 e ~3 ' ~4.32 * ~8 - 6~.57 Orawfn~s References - Sll - Steel T~k - Roof Plan - S12 - Steel T~k - Er~ion Derails · S1~ - S~I T~k - Ring Beam Conn~ion · SI5 - Steel Tank - Acce~ Tu~e/Top ~ Oa~e STEEL TANK COPPELL, ~ - ~ 802 ELEVA~ON / SEC~ON ' oate 05 / 98 ~' CA O O S10 - B L A N D M A R K '\ '\ '\ '\ '\ ',,, '\ , '\ '\ '% '% '% , '% ./., , (~p. of 2~ OD~on ~ ~ V~: · /'/ % ~ Gate ' //'//lnst '%. ././'/ '% , ~ , ,% '* . .. .... NOTES; · S15 - Smel T~k - Acce~ Tube/Tap e 321 - 36"x 36" Acce~ Hatch Cover - A~embly / · 3~ - Root Rail - A~em~ly = 323 - Tank Root Vent ,. · 324 - Paint Rail Access COPPELL ~ - ~ 802 S~EL TANK - ROOF P~N oa~e 05 / 98 ~.. CADD $11 L A N D M A R K c.~ i 1/2' x 8' - Reof Landing Plate ~ 4'J: ~- 6' ~: 3'-~ P'P' ' ~ . eel ,' , ~ Top P~o~ (64 ~ ~uSl~ spaced ) _R = ~r - 8 - ~8' Detail at ~ 8 ~~u~ ~ ~te ~ I · -,~-~ ~.' .,.,. ~ ~.· ~ ,,.'~.. ~~, - : Sh~~- Ve~ical Join~ R~f Plate - Radial Joln~ Shell Plate - Horizontal Join~ ~"':' · .....~.~.~ · ~... .-.; ~ . - .. N~: 2 ~ ~16" ~ T-I~' Oetai[ at ~4 ~ ~ ' I. All buK Jdnt wel~ ~I~ p at~ a~ng R Materfal S~cffi~n (unl~ o~er~ ~) · Rates - AS~ A36 or equ~ Detail - s~uml Shapes ~ Oete STEEL TANK COPPEL~ ~ - ~ 8~ ERECTION D~AILS Oe~ 05 / 98 ~' CADD L A N D M A R K Re<}r Uner PJete .25' 1/2' Hoist Plate ,... .... : .........: 2:2x4 - RSO2(La~-27'), · ·· <Seal F-orrnlng Plate - ( galvan_~ ~ ·/~t~ll~ 3/4, r · (44 pc'sl ~ ' 8' · 7 * 7/8° ·,. i ' / " t R = 2El' - g - 7/8" , . Radlus' Intertot face ot r~ng beach skirt . /',,tl.~..: Conetructlon ,Se<;luenc9 " · Concrete support wail/dng beam/dome slab per Dwg. S7 ·Steet tank at grade includrng c~ne/thrust plate, ring beam plate, palrrters rail and hoist plate · Raise tank to final position and install t'ormlng plate and shim plate · Install reln~'ordng steel and place dng beam key c~ncrete (shaded area ) · Grout void between linear plate ~ concrete rfng beam/dome Materfal SDeclffcatlort · Rlrtg E~eam Concrete - 4200 psi 28 day compressire strength · Grout - flowable sand I cemedt mix - no strength re<;ulrement · Reinfomlng Steel - ASTM A615 Gr. 60 · Steel Plate/Structural Shapes - ASTM A36 or equal Date STEEL TANK COPPELL, TX - # 802 RING BEAM CONNECTION Dale 05 / 98 ~'~- CADD S14 LANDMARK .3 ~- Access TuCe Handrai, 7'- 0" , c " ,~'-a' 8'-o" Tank F~oo~ Vent --- ; 'r ,--Hatch cover(hip.) I' ~ ~ ..-- ' " ~ -38' ~ C.S. Pip~ J I "7 AccesS Tube ~ ( Owg. S15 - S~ 18' OverSaw --~ : 48' dia. x 5'16' wall '" \"' .... ] 1 riser pipe Site ctasure pipe__ ship taose . ~ ~/" .......' _ '~ ROOt Sleeve ~ " ( . -- 632.42 · . -; e ........... "'::::"' ':: ' .... NOTES: Material ~ecific3don ' ~. ~iser ~ipe ASTM-AT39 Gr. 8 2. O~her Componems- ASTM A~6 or ~ual. t ' ' .......... Orawinq References · S~5 - AI - Tap Pfa~o~ - Plan / S~an "~"" · S15 - B~ - Access Tube - Plan / S~/an 15-C -Access Tube ~r Sleeve =-, Oats STEEL TANK COPPELL, ~ - ~ 802 ACCESS TUBE / TOP p~TFORM Oats 05 / 98 own. CADD S15 LA N D MAR K .. i ~ 3'- O' ~. 3' typ. ,6-i .. - '.. , -.-+ .... ,.:=j.-.,.- -.~ ................. ~, 'A' -'- , :.., ~"~ ,// ......... / Access Hatch Hi Y" (WNPi~~ 2 pcs.- 11/2' ~hrough top w/plug. le: Grab Bar 3 pc..- 4: through side of hatch m,3unt angle ~ 90° / pc.- I' ~rough top wl plug.' : ......... ....-""" / ...........~ ..:.:.~ L c / , /-' ...................... :: r0etail'C' O~tail 'O' --~ "~ I ' r " ~" _Top cone ' ~"' i l ' ~ , I ~' P,.te ~ , ....... / -~ / : ! I; ..... + .... [ ~1 Ve ~ Support Cone " ....' 5/16' P al:e Access Tube Sleeve / L-Detail I5' Tank Access Sleeve NOTES: Section "A" 1. Cut ~cp platfarm after fabrication far shipping. Provide inlerior support bracing along cut line (both pieces ). Provide backup bar for field weld. 2. Rnish - prepare surface and coat in shop per contact specification requirements. , Drawing References ~ S15 - A2 - Access Tube Top Platfarm / Details I Oace ACCESS TUBE TOP pLATFORM COPPELL, TX - # 802 PLAN / SECTION .cam 05 / 98 J o,... CAOO S15 - A1 LANDMARK ] ! I I I ! Detail '8'--- CaCle HanGer · ,, //"'e2 5'-0" ,- _ _ ._~_"l__:- ! '. i ". I : "- Jpet'ail 'C' 1'-8' Plan Weir Cone . . -' i i! , :: E:- , i ,, ii !~!' ~;i ste~ Ladde~ I i! , -. ""~. i i'.,,, ~ :! !: !'.i (Owg. 301) O~tail 'A' '--.~- .... ~...' ,.j: " Steel Cage ./~,,, ~. ove~ow _,/ ,.~ ........ :: r :'~ i ii ,:. i, ~ :..... ::= i · . : ' i !i ':F= - , ~,.' _ :~ ~Access Tu~e ~ ~', := 4.8' Q.D. 5/18' Wall ~. Si~e c~o,.~e Pipe ~ " " ........ ',..-i NOTES: 1. Rnish - prepare surface and coat in shop per contract specification requirements. Drawing References · S15-B2 -Access Tube - De~ails 0a~ ACCESS TUBE '~et'~""~r COPPELL, TX - ~ 802 LAYOUT Oa~e Q5 / 98 O,n.CAOO S15 - B1 L A N D M A R K I r' ! "' .a i= ~- - ~ ,~ ~ ., ' ~ __-- ~/"' .-. c ~ i ' C) __ m ' 0 __~, ~ o z _1 I ! ! II 'REV - 70 GAIf ONAG~=CHART CAPACITY- ZJZJ~-Q RAN~-;- 40.00 COPPFLL, TX' - # 802 ' HIGH W / 1 FVFL - 67~.50 10W W I ! I=VFL - 632.50 DRAW GALLONS WATER GALLONS I 100; DRAW DOWN REM/FTI REM/TOT I REMAINING ELEV FT I TOTAL EMAIN DOWN 0 O O 2,000,000 672.50 ' 0 0 2,000 0 I 55 653 55 653' 1,944,347 671.50 56 · 56 1,944 1 2 55 653 111 306 1,888,694 670.50 5 6 111 1,889 2 3 55 653 166 959 1,833,041 669.50 5 6 167 1,633 3 4 55.653 222 612 1,777,388 668.50 5 6 223 1,777 4 5 55 653 . 278 265 1,721,735 667.50 56 278 1,722 5 6 55 653 333 918 1,666,082 666.50 56 334 1,666 6 7 55.653 389.571 1,610,429 665.50 56 390 1,810 7 8 55 653 445 224 1,554,776 664.50 56 445 1,55.5 B 9 55 653 500877 1.499,123 663.50 56 501 1,499 9 10 55 653 556 530 1,443,470 662.50 56 557 1,443 10 11 55 653 612,183 1,387,817 661.50 56 612 1,388 11 12 55 653 667,836 1,332,164 660.50 56 668 1,332 12 13 55 653 723,489 1,276,511 659.50 56 723 1,277 13 14 55 653 779,142 1,220,858 658.50 56 779 1,221 14 15 55.653 834,795 1,165,205 657,50' 56 835 1,165 15 16 55 653 890.448 1,109,552 656.50 56 890 1J1.10 16 17 55 653 946,101 1,053,899 655.50 56 946 1,054 17 18. 55 653 1,001,754 9~)8,246 654.50 56 1,002 998 18 19 55653 1,057,407 942,593 653.50 56 1,057 943 19 20 55 653 1,113,060 886,940 652.50 56 1,113 887 20 21 55 653 1,168,713 831;287 651.50 56 1,169 831 21 22 55 653 1,224,366 775,634 650.50 56 1,224 776 22 23 55 653 1,280,019. 719,981 649.50 56 1,280 720 23 24 55 653 1,335.672' 664,328 648.50 56 1,336 664 24 25 55 653 1,391,325 608,675 647.50 56 1,391 609 25 2 6 54 978 1,446,303 553,697 646.50 5 5 1,446 5 54 2 6 27 52 786 1,499,089 500,.911 645.50 53 1,499 501 27 28 50,580 1,549,669 450 331 644.50 51 1,550 450 28 29 48,421 1,598,090 401 910 643.50 48 1,598 402 29 30 46,309 1,644,399 355601 642.50 46 1,644 '356 30 31 44,244 1,688,643 311 357 641.50 44 1,689 311 31 32 42,226 1,730,869 269 131 640.50 42 1,731 269 32 33 40,255 1,771,124 228 876 639.50 40 1,77~ 229 33 34 38,331 1,809,455 190 545 638.50 38 1,809 191 34 35 36,454 1,845,909 154,091 637.50 36 1,846 154 35 36 34,624 1,880,533 119,467 636.50 35 1,881 119 36 37 '32,841 1,913,374 86,626 635.50 33 1,913 87 37 38 31,105 1,944,479 55,521 634.50 31 1,944 56 38 39 29,485 1,973,964 26,036 633.50 29 1,974 26 39 40 26,238 2,000,000 0 632.50 26 2,000 0 40 ACTUAL TANK CAPACITY 2,072,000 GALLONS [' VOLUME LEFT AT LOW WATER LEVEL .72,000 GALLONS DWG #S - 21 I I ' ' '! ' ' ' 1' ] 11 Access Louvre Antenna Cable Feed Thru Rats · . ~ 624.32 _/___ WpfcaJ of 4 ) s ~. (.t/owall) L3 Antenna Su er~ ~ elev. e19.50 ~ ~ -- ~ 6 ~ 4.20 I 1 ' ' I i : · , _ L2D ,L I _Landing at Access Louvre _Catwalk ~ elev. e1/,.50 see I:]wg, 319 See gwg, 300 - 8 far plan ~7 590.50 ( Intermediate landing ) 128 Ladder -e- ( Intermediate lending ) see t~j. 315 L~dder Cage ~.-Truck Ck~r S~fety Clrmb "~ (~p.) .._ -e- ~ 540.50 I I ~ee Dw~. 313 ( storage floor ) j "~._'~ see Owg. 301 ~ L1 · ~7 524.50 " J I -~ ( slab an grade ) ~'-- Single Door Ngte: Safety Climb is to be provided on all ladders. /'~ I Oete SUPPORT WALL LADDERS / LANDINGS COPPELL, TX - # 802 GENERAL ARRANGEMENT 0~, 05 / 98Own.CADD L A N D M A R K ~... ~oo-A I 'i i [ II ( typ, of 4 @ 9o" ) i ('j" ~ ~ !f I ] see Owg, 34~ - B for details -,, : . . ///~ \ - ~ s i . ' ', ', t _I, j . / \. 't I ' I' / \ . · ..'77 i: ~:: · :. :' ' \ *. % = ! . \ ~'¢ 'e. , ...::..~::. ,, ..%~ .: .:::""i~;.: . \ '\ ' ~ i"-::::' --. \ ' ,,. '\ .\ "' '\.\\ · "" -- /' ° Painlets / Landing at \ /- Access Louvre Top Landin /,,. Access Louvre A 81.00° \.\ \ \ \ , Landing ai~ Manhole \~' i\'. "' · \ '\ Owg. 320 · for derails '\.\ o~.~o '\ . · ./ h' ~, \ \ "- i t \ i 't .' .\ Cat, Nalk typical section see Owg. 316 for details ~OTEES: Handrail not shown for clarity. J Oats SUPPORT WALL LADDERS / LANDINGS j COPPELL, 'IX - # 802 CATWALK - PLAN J Oate 05 / g8 Own. CAOO 300 - B I L A N D M A R K A,=. I 'i ! I' [ J -* ..... I-' i' ;"l ~ -SpEice detail 1/2' 0 Bolt _ S~erail - ~8' x 2" ~atUar ~ .~ " -/ Note Z ,, ., S I~e Plate ~ ~' x 1/2' ~a~ar SDII~ Detail h3/8' 1 '- ~," 3/8"~1 I .-- Rung detail ~ o, "' Rung ~ Odll x 7/8' c ..e~ /--Note 1/3 3/4' O deformed bar ~ ~ ,J -.Y' x 1'-41/2' Rung Detafl NOTFS: . I. Refer to Dwg. 301- BI/B2 for supl:H3rt bracket/connection details. 2. Provide 9/1~i' diameter holes as required for splice connections. support brackets and cage brackets. 3. Maximum spacing of support brackets on caged ladder Is 4'-O". Maximum spacing of support brackets on uncaged ladder section is 7'-0'. Material SDeci~catlon · Siderails/Splice Plate - ASTM A36 or equal · Rungs - ASTM A706 Gr. 60 (low alloy reinforcing steel ) · Fasteners - ASTM A307- galvanized Flnish (unless otherwfse noted) · 7rnc Coating - (Hot Dip Galvanize ) per ASTM A123 Date STEEL LADDER COPPELL, TX - # 802 STANDARD DETAILS Date05 / 98ow..CADD L A N D M A R K 3o' - I 'l i F I II ~ 2'- 4" (dia.) , ~ I Ladder - see Owg. 301 ~f~l~ 13/4 3~ ~%)te 2 '~IT ~ ....,.!..==.-i~,,_ · 1 '- ,~ ' ~ 2 x 2 Bolt A .~ = ........ i~.~T- ~ T~ ~ . , [ '~ 1/4' x 2" fiatbar ~ i~' i i 1/4" x 2" ~ar t ~ = ~ S~tion 'A' ........ NOTES: 1. Refer to Dwg. 301 far ladder detail. 2. Provide 9/16" diameter holes in hoop to connect to ladder siderail/suppa~ bracket. M~imum spacing 4'-0'. 3. Refer to Owg. 311 -B far ~abd~tion details a~ individual ladder cage section. Material Specification (unless a~e~ise noted ) · Fla~ar- AS~ A36 or equal · Fasteners - ASTM A307 - galvanized Rnish ( unless athe~ise noted ) · ~nc Coating - (Hat Dip Galvanize ) per ASTM A123 oats STEEL ~DDER CAGE COPPELL, ~ - ~ 802 STANDARD D~AILS oa~e 05 / 980wn. CAOO L A N D M A R K ~"~. z~-2 ~"- 3~-~ THE TS RAIL SPECIFICATIONS TS TROLLEY is die extruded o'` high strength aluminum allay in a unique, palented design shape geared to maximum satcry and easy installation. Trolley body: Aluminum alloy 6063- T6 extrusion accurately machined in special jigs. /~'Tront portion ot the rail incorporates wheel guides for operating Tensile strength: 30,000 ; ~nment of the trolley on Ihe rail. The hearing wall surface for the n brake pawt has as a sate dan/safety feature, protruding stops die LOCKING PAWL formed at t2" increments. This feature is valuable under wet or possible C- 1020 HRS plate with tensile strength ot approximately 65,(~30 PSI... oily conditions while engaging the trolley brake pawl on the beadng finished with nickel chrome plating. Secure to trolley body by 3/8' surface. diameter type 304 s~ainless steel pin. Tensile strength: 90,000 PSI. Back portion of the TS rail features a continuous slot designed to PAWL SPRINGS retain the hex head of a 3/8' bolt assembly...bolts used for damping Oual spdngs formed fn3m .060' x 1/2' flat stainless steel spring stock the rail to the supporting structure and interconnecting the rail sections secured to trolley bocb/with I/4.'-20 stainless steel machine screws. with s;)lice channels. The slot arrang. ement allows the clamps to be located to suit the attach·merit spacing without spedal drilling or in-field TROLLEY WHEELS alteratons. 4 Oelrin wheels of 5/t6" x .75' diameter. Wheels secured to the trolley body with 1/4,' diameter heat treated holokrome shoulder screws. All rail sections -with the exception ot the bottom and top rails -may Nickel chrome plated. be roy·reed or interchanged, since protrusion stops are idenlicel in bath directions. SHACKLE ANO SNAP HOOK A 5/16' drop forged screw pin shadde with a proof load test ot 3,300 The bottom rail is end cham'`ered for smoother entry of the trolley attd pouncts is LLSed tO alZach drop forged snap hook to the trolley pawl. equipped to retain the ice- guard (optional). The tog rail is fitted with Shackle is hot c~l:~ecl galvanized. Snap hook is drag forged cadmium a bait stop to prevent the trolley user from accidentally moving off the plated with pmo~ Iced test ot 54300 pounds. rail. Rail sections are normally supplied in 20' lengths, alyhough any altemata Ion ths may be sugpd'ed to suit specific requirements without Trolley weight :Approximately 3 pounds losing the e~-'~veness ot the ~systefn. Rail sections may be pulled in or out several degrees by hand during TS SAFETY BELT installation if a sli ht change d directon occurs in the supporting ladder. is nyion body strap and work belt desigt~ed and manufactured est3eclally · Ladders on curv~;? structures, either concave or convex. can be fitted for use with TS equipment. The belt meets all requirements cs:~es and with TS rail pro- formed to a specific radius at the factory (optional). is ecluip0ed with t'No s~e D- rings for attachments of Ionyards or safety stra s. This is prirnariy a climber's belt and does not encompass tool TS rail may be extended above the top of the support ladder or hoI~: I d rs or other accessory ·vices. structure by 3 to 4 feet to Detroit the climber total safety in landing himself on a platform or other structure before disengaging from the rail. SpECIRCATIONS TS RAIL Aluminum alloy 6063 - T6 Extrusion 2-3/16' wide by 1-7/16' deep SPECIFICATIONS 'IS SA~-r..if BELT Tensile slrenglh 30,000 PSI Belt body pad ot 3° width latex impregnated m/Ion webbing. B<>cly belt Standard length 20 feet of 1- 3/4' wictth nytctt webbin using dro~ forged frame and tongue type Protrusion die fortned stops: 3/8' x 1' x 3/32' every 12 inches I~tde. Budde holes reinfo~ with groinroots. Copper rivets ... nylon Continuous C sitaped slot at back ot rail confines hex head balls rot washers under rivet heads. attac.~ment of rail to rung. /"'bcE C.AN.EL o.'r DEE Steel dee ring with proof load test of 5~:)0 pounds for attachment to . ..~minum alloy: 6063- T5 snap hook, Extrusion: 1-13/'32' wide x 1,5/'16' deep x 8' long Tensile strength: 21,000 PSI SIDE DEE RINGS Two drop forged dirde dee rings with proof load test of 5000 pounds MOUNTING BRACKETS 'tipned on eac,~ side of belt for attachment of sa'`ety straps or Tensile strength: Approximately 65.000 PSI. It weight: a;3;)roximalcely 2-1/'2 pour~s, Hot dipped galvanized to ASTM * A- 153 CAP SCREW'S Rail Sections 3/8" -- 16 x 1° grade 5 hex head Lock washer end h. head nut. Hot dipped ga anized to '153. Weight: Rail and attaching parts, apl~roximataly '1.15 pounds per foot. Location LF. Material · Shaft Lower - 4,3' Aluminum TS Trolley is die exlruded oi high strength. aluminum alloy. Predsion machined in · Shaft Mictclle - 2?" Aluminum jigs to provide canter slot and p~n hole rot brake pawl and wheel wells · Sha. tt Upper - 26' Aluminum ,'or the Delrin wheels. The wheels provide quiet, frictonles. operation on the rail. climbing or descending. · Top Landing to Manhole - 9' Aluminum Chrome fated steel brake pawt is confined tO the con'tar 'slot with a climber relaxes or sl'ps during ascent ar desc, e~t. · ACC, Tul3e ~.xl:. - 4.2' Aluminum The dimbet is corm·clod from the brake pawl to the trolley with a st~edal hot dig gelvenized screw pin shackle and a '`orged snap hook Accesor~es with a cluick act~n thumb release. The strap hook of the ~rolley connects directly I:o the center front 0- ring of the cfimbers' belt. Item No. The trolley wei(jht is negli ible a~d causes no res~ction at maneuverebility. If thel climber wnshes to ~engage himself from the trolley at any location Trolley 4 -brake action ot the brake pawl. I~n normal I:~ack slightly to L~dder Ups I rsleasa the brake during the ctiml:)ing operation, there is no need to adjust or move the trolley with the hands. Any number ol diimbers may use one TS installation at the same time if each ctimber is equh0t::ed with 8 TS trolley end belt. Date COPPELL, T'X - # 802 SAFETY CLIMB &HARNESS Date 05 / 98 Own. CTR 313 L A N D M A R K 'l ' I I I' T Assemblies Required - 2 Pc's (1 as shown, 1 opposite hand ) NOTES: Material Soeciftcatton .. · Frame/Brace - ASTM A36 or equal ·Handrail - ASTM A53, Type S, Grade B, Sch. 80 · Grating - l'x 1/8" bearing bar @ 13/16" dc · Fasteners - ASTM A307 - galvanized · Expansion Anchor - FS FF- S- 325, Group II, Type 4, Class I. (zinc plated ) · Hinge - ASTM A312, Type 316L Rni~h · Zinc Coating - (Hot Dip Galvanize ) per ASTM A123/A385 Drawing References · 315 -A2 -Intermediate Landing Sections/Details 7~="~'f Oale INTERMEDIATE LANDING A tO 'cl~ COPPELL, 'rX - # 802 PLAN Date 05 / 98 e,,,n.CAOO 315 - A1 L A N D M A R K ""~- 2,~-,~ ! 'l I I i ii Inserts ( b/p. ) "~ .... ~' /-- 1/2" Wedge Anchors /~ , i_ .............................. .. '. 3/4' Bolts to Dome ( ~p. ) , ""~ · .... 6" x ~" x ~8" Angle ~-r---r~ (~p. oi 4) - III II II · 8" ~nc plat~ U-bo~ ( ~p. ~or handel ) II II 1 112" ~h. 40 Pipe ~ I II I II NOTES: 1 Mate~al - AS~ A36 or equal ' · I III 2. ~nish - hot dipp~ ga~anize ........ 3. El~rodes- E70~ ~'~"'rr~"'T~"'~- 4. Fastenera - ASTM A307 pta~ ' "" 518" ~ (unless'othe~ise noted ~ 5. Anchom - 1/2"~ AS~ A307 plated "' wedge anchors, rain. emb~ment 4'. ~ ~. 4 · ,,, 6. Grating - l" x I/8" beadrig bar ~ I-~16" dc -~ -- Ill e ,, Ill e Ill Ill 6'x3 1~'x916' ~gle ; r' I 'r .. r., '1"' .'~' F :'~' ': r:' r ' F : '[.: :... ~-~.., .~,a% ....:,. ,..: ,:,.: i~'~'-- ['.L ....! .:. i':.,'.':. .' ': :,." '.. ".' .'.'" 'Z' .'- · .' .:" ' ".. :"' Z ':' '.'.' ~'.". .... .........~' ~,~~ "l "~"1, ~;"' ~16'V . ...... , ~ ",. i ", , ", "':"r"":;l" IZ""' If I ' I '-L "' I I' "" ::.'..~:-.r.:...' . '. I[ ~ ~ ~.l': ~: '~ ............. :.'-J · 6'x3/~'xS/16' Angle If'[ I' [ · I'~T !' : .:~.2'2'... 'I F. ~( veni~ ~ ~m~ d=wn ) I[ , -..., .'.: ,...,:.'-":.; "?-: ~"' . _ . J, I I i .i.:, -I':..:--::-,;:, :..'-':-, :-! ' I k ' ' L3' x3' x 1/4' Angle _11/2' ~h. ~ Pipe · - 2 1/4' ~-6' Plen ~ 0am ~NDING AT MANHOLE COPPELL, TX - ~ 802 - ~YOUT Dam 05 / 98 own. CAQO L A N D M A R K I 'i I F' I iI ~_. ~, 36" sq. ~, -- Stainless Steel Hinge t (ill trarne angle ) I / I , .:-';--=::;:::~.--~::;.,:,~,:,:,,:::::::::::.-:;,,. ~ ~ NeDprone Gasket E '. 1/2"x 1" aluminum fiatbar x 4' - ;: !::'-::i" w :: ~ ~i! :! , 0etail A - Hinge Detail u c~ ~" ~ :: " Extedor !i ' - ~ Hasp "' ................................................... ~' Hasp "'11 ' :' Pfaq Padlock Haso · ..--!//,-.- Open Ixtsitian ~'~'~,/<~ / 3/16' Tread Pfal:e :i!..---->:..,, , ...... Gasket " I/2'~ hale in Frame Angle/ '( 2 locations ea. side ) NOTES: Detail '8' - Latch Detail 1. Mounting Angle - fabricate, leg in at tank access/leg out at roof access. Material Specification · Hatch Cover - Tread plate and framing - Aluminum T6061-T651 Pc's Required - 2 · Latch, Hinges, Fasteners - Type 304 Stainless Steel · Handles - Zinc Pfated "/ff'""% Date 36" x 36" - ACCESS HATCH COVER COPPELL, 'I'X - # 802 ASSEMBLY / INSTALLATION o. te05 / 98Own. CADO L A N D M A R K c,,,,. s2'~ Amenna 8racket 1/2' Rate i I '~\ '\ '. ~,- ' ~ ,-' · PlaQ Guest ( ~p. of 2 ) 3' Pi;e ~h. ~ 1/2' Race 3' Pi;e ~h. ~ 3' Pipe ~h. ~ Mk. ~ Mk. ~10 ~Mk. ~1 ~5 /( 3' Pipe ~h. ~ . (~p. ot ~8) 1/4'x 3 W2' Ra~ar ~ 3' Pipe ~h. ~ ' Pipe ~h. Mk. ~8 M~ ~3 Pipe ~h. ~ M~ ~6 (~p. ot 19) (Wp. ot 2) M~ (~p.o(2) (~p. o~ 19) NOTES: Front Elevation 1. Marshal - ASTM A36 or ~ual 2. Finish - field coating in accordance w/contract specification ~tion SC.63 3. El~trodes - E70~ Oats COPPEL~ ~ - ~ 802 ROOF RAIL - ASSEMBLY 0ateQ5 / 98~n. CADO L A N D M A R K 2~-5 ~..- 3~2-A ( Shroud Diameter ) Acorn nuts for shroud removal .^ II Shroud Curb ? A ( Throat Diameter · I:: ( o/o Square Curb Dimensions ( inches ) Quantity Size Model A a C O , , ~ ..... , .: -.- , .: .... ~ .~ .,.: ...., 1 ~ GRS - 3a 30.50 ~.Oa 18.85 5.~ ~.0O NOTES: 1. Manufacturer - Greenhock Fan Corporation, Schofield, WI 2. Model # GRS (all aluminum/stainless construction ) 3. Matedal Spedfication: Curb / Shroud - .064" aluminum Screen - 1/2"X 1/2' s.s. welded wire cloth Threaded Fasteners - stainless steel Rivets - aluminum 4. Fasten vent to mounting curb at 8 locations. Use stainless steel fasteners. Date COPPELL, TX - # 802 TANK ROOF VENT Date 05 98 Own. STD ' L A N D M A R K ~lb:. 10-11 chic 323-A ! ; ! ,~ --lEi - 5/8' holes @ 22.50° O--~ ................................................. "O ..... \__5" x 3" x I/4" C'.S. Angle (foiled to 36' I.O. ) Pl~n { Note i ) i/At' Aluminum Checker Plate { cut to 3'-6' O.D. dd|l ho)e$ to match cur~ ) 3/16' Neoprene Gasket---~ /--16 - I/2' S.B. Bdts c/~ Nuts f~ctlon N(;;}TES: I. Loca~e access &olate/frame as shown on 0wg. 104-A1. 2. Provide 7/16'~ holes in mounting frame and cover plate. Oimensions shown are typical ~'o? each side. Material Soeciflcation · Cover / Frame ASTM A36 or Equal · Fasteners - ASTM A~4,9 Grade Grade BBM stainless steel · Field coating in accordance w/contract specification ' ~ Oate COPPELI_, '13( - # 802 PAINT RAIL ACCESS HATCH 0ale05 / 98 Own.CADO L A N D M A R K ~... 324-C I ! I T" I I/2" dia. Lifting Ring 1/4' x 28" O.O. ~' ASME Dished Head "~,,\ / Hinge Arm Assembly Oeta$1 B \, Seat P a e ~ 'c~ FI outer Plate E ......'~ v '1 ' ' '~ r'¢~ ~ ', ' ' · · 1/4' Root Sleeve pin x 26 - ~" LD. ( Type 3~ s.s. ) MANHOLE ASSEMBLY ~ 1' - 2 - 1/4.' radius 1 ~ ~P t plates 1~16" ~. hole for ~4' dia. Gr. 2 plat~ bolt Refiner Ring Grou~ Ring 3 Section 'A' · , ~: Detail 'B' ~ion 'B' Material SD~ifications · ASTM A36 or equal unless othe~ise noted. · Han~heel/Pin - ASTM ~76 - Type 304 · Fasteners - AS~ A307 - plated ~niih · Root Sleeve/Seat Plate - coa~ in field per contract specifications - Hot Dip Galvanize - all other ~en steel components Installation · Insp~t seat plate and groove. Cle~ and repaint as r~uired. Lay a continuous bead of NSF approved sillcone in groove. Set gaske~ and clean excess silicone. ~Center dished head on gasket. tighten han~heet. As tank is filled, continue ~o ~ghten han~heel: Oate 25" TANK FLOOR MANHOLE COPPEL~ ~ - ~ 802 ASSEMBLY oa~e 05 / 98 ~n. CADO L A N D M A R K ~"~ 2~- : I 'i I r [ I pedestal Wall , t/o wall Mounting Angle / Insect Screen ~ Louvre ~. -' '" h 1/2' sill Intedor~ Interior-- ~ ~eHor Section A NOTES: 1. Coat concrete contact surfaces with shop'applied bituminous coating. Material Soeci~cation · Louvre - aluminum 6(363- T5 alloy - mill ilnish~ Size - 23 3/4" wide x 35 3/4" high x 4'( exact size ) Construction - box frame head/sill with fixed blades { 4" spacing · Mounting Angles - aluminum 6063- T5 alloy - mill finish. Size - 11/4' x 11/4" x I/8' - 2 pc's. @ 36', 2 pc's. @ 24' · Insect Screen - aluminum Size 233/4' wide x 353/4' high / 18x16 mesh 0.11 wire. · Fasteners - stainless steel Extedor- 1/4" expansion anchors (6 pc, s. ) Intedor - 1/4' drops in anchors with 1/4" bolts (4 pcs. ) Oam COPPELL, 'IX - # 802 PAINT RAIL A'CCESS LOUVRE 0ate 05 / 98 (3wn, L A N D M A R K 1Q- 12 ch~ 327 - A I '! ! I' [ NOTFS: 1. These dngs are to support wireless communication equipment and are not designed to support personnel. 2. Communlcat~on Equipment Support Capacity- maximum aGO Ib. point load between artchore brackets. 3. Material -ASTM A36 or equal. 4. Finish - hot dipped galvanize 5. F_jectrades - E70xx 6. Anchors - 1/2" ~ ASTM A307 plated wedge anchors, minimum embedment 4". /' o.~. WIRELESS COMMUNICATION EQUIPMENT COPPELL, TX - # 802 SUPPORT RINGS 0ate 05 / 98C~,.CADO L A N D M A R K ~,,,,. 339' A I '! ! r 11 ~ . · 7~ ./ \ . ./ · / . '\ ' / ' ~ 0 "' · ,,~ / ,.' .~ , .,.-' ~. ~ ' _/ .///./~~~' "'~ ~.~ /./ ,. ( / / Interior Bellards - Plan 5' alia, G~vaniz~ ~ , Steel Pipe ---~x6'-0' g, ~ ~- w/welde~ ~p on One e- ~5 Dowels into Root Slab ~ m~ .. I ~ ~'~ ~ ~ncrete En~ement ( 3000 p~ ) 6' ~, 80 (5,76' t Pf e Sleeve x 3'-0' we~ One ~d Removable Inte~or Bolla~ - S~tiqn Pc's R~uir~ - 5 NOTES: I. Paint bollards w/interior coating system. Provide 2" wide yellow reflective tape stripes at 4" centers. 2. Grease 5' pipe with multipurpose grease pdor to installing in sleeve. BOL,LARD / ~NTERIOR COPPELL, T'X - # 802 LOCATION AND DETAILS Dame05 / 98Own.CADD L A N D M A R K ~,~. ~.~, a4o-A I '! I [ 11 /.-- - End Cap 4' x 4' Joint In Concrete 4'-0' ; Detail 'A'/r-( for future removal to access ." "- .... r_ ,--/524.50 ( Nominal ) .... t" ~[ ................i~ 523.5°~o .i.~ Cap / --End Cap ~7 520,57 I J "~""',. 6' Sch. 40 P.V.C, Conduit j """\ w/pull wire --Long P-.adlus P.V.C. Bend; ( 3 pc's required ) Wrap 3 Ix:. conduit with 1/2' expertskin Joint capstrip. Remove strip & fill void w/ap red self Ievetlng polyurethane see a~n~ Detail 'B' Drawing References S5 - Support Wail - Opening / Sleeve Locations oats ANTENNA SYSTEM COPPELL, TX - # 802 BELOW CONDUIT ENTRANCE Date05 / 98own. CADD L A N D M A R K c.~, 34~-A Section A Antenna Cable Feed-Thru Plate Manufacturer - Andrew Type 4894(3- 6 Multiple Entrance Wall Feed- Thru Plate. Matedal - Aluminum Mauntfnq Angles Size - 2' x 2" x 3/1~5" - 2 pc's. ~ 1' - 5 - ~8', 2 pc's. ~ 1' o 9 o Matedel - aluminum 6(}63- T5 allay, mill finish. Rnlai~ - coat c~ncrete c~ntact surfaces wl~ shop applled bituminous cooing. Installa~lon An~tle/Wall - drfll tangle x 1/2" ~D 8" c/c, Bol~ to wail using ~8' Hl~f Kwik Ptale/Angte - drill ang{e x 5/16' to match l~re-drllled plate. ~'asten with Short Dr~wln~ References S5 - Suppor~ Wall - Opening / Sleeve Locations ,. ~ta ANTENNA SYSTEM COPPE~LL, "1~ - # 802 UPPER CABLE F:EED-THRU PLATE Date05 / 98I:~n.CADD LANDMARK 34 -s I '1 ! I' [ il 1. See Contract Drawings for additional details. Drawing References; · 402-NBICID - Mechanical Layout - Section · 403 - Roar Drain , 405-A1 - inlet/Outlet Riser - Elevation · 406- A1 - Overflow Riser - EJeva[ion · 410 - Piping/Mechanical Equipment- Legend //'"~ev. Oats MECHANICAL LAYOUT A 11/02/98 COPPELL, TX - # 802 PLAN Date 05 / 98Own, CADO 401 L A N D M A R K A,,~c. c.~ I i' '!' , ¢, - 20' Inlet / Outlet /f""' I ~- 18" Overflow · · I Inlet / Outlet Riser ( see Dwg. 405 - A1 ) I -..-- F1 I ~ 01 i I ~ ~ 534,18 ~e~ow Riser ~ ( s~ Owg. 406 - AI ) (side & b ' L 531.14 ~22 ~ , e 4 ," ", ~ 527.50 ~te 2 ( wp- ) R.C.C.P. ~pe ~ ( ~mi~l ) w/~ ~d ~pmved ~ncrete ~1 ~f leveling ~ " Suppo~ : ~l~reffi~e se~t SECTION A - A NOTES: 1. See Contract Drawings for additional details. 2. Support base plate with 1" non shrink grout. Install 4 pc's 3/4" s.s. threaded epoxy anchors - 9' embedment. 3. Provide flange insulation gasket/sleeves/washers at valves and pipe material change. 4. Rotate valve so operator is in the horizontal plane. Drawing References: · 405 - A - Inlet / Outlet Riser · 406- A - Overflow Riser · 410 - Piping / Mechanical Equipment - Legend ,/~.%Rev. Date MECHANICAL LAYOUT A 11/02/98 COPPELL, TX - # 802 SECTION A - A Date 05 / 98own, CADD L A N D M A R K ~,,o=. ~.~ 4o2-A I 'i I r [ ! ~",7 525.25 ~ S S "~ ,.,. M501 ~ 9' ( bend en~ into pier ~p ) M501 ~ 9' M502 ~ 9" -- ~ 520.00 E.F. & E.S.~ -- 20' R.C.C.P, · ~ . 24"/ ~ /__ · / 515.50 ~' ~ /~ 2 ~ 9" E.F. ~ ~ ~ -' . M502 ~ 9' SEC~ON B - B ~ ~ / ~ .. ........ ., 30' ~ Odll~ Piem .. ......~ ~. ~" ~--~-.~...,~....,....~. . M502 ~ 9 . .~. ~ ., ~......~..'~ . ,," ~~ ~L' ~ SE~ON ' - M502 ~ 9' EF. ~ ~ 'E' N~TES: 1. See Contm~ D~wings for additional details. 2. Provide flange insulation gasket/sleeves/washem at pipe mated~ ch~ge. 3. Cut reinforcement to suit. ~ps as requir~ -min. 18". Drawing References: · 410 - Piping/Mechanical Equipment- Legend ~e,.A oats MECHANICAL ~YO~ 11/0~98 COPPELL, oa~e 05 / 98 ~"' CADD L A N D M A R K ! '1 I r f ~ C{_ - 18" Overflow Riser ol Dyedlow Riser ( see Dwg, 406 - A1 ) I 532.55 7,.0o ~. 531.14 _. 20' I.D. PVC Sleeve /"No~_5 (~. 7 Note 2--~ ~ VC~n~re~~ ~ 526.16 M505 ' t 10' x 10' Concrete Rip - Ra w/3' x 3' Inlet ,:, 524.50 ( Nominal ) ' Support rain orcement ) t i ~7 524.004 f /w cap self leveling ~ _ rz 522.68 , palyurethane sealan[ -- -- ~ 1" Grating M504 { 12'-/ M503 @ 12' 05 { 12° L_._ ~7 518.12 ( Invert Elevation ) . j 24' RCCP Pipe SECTION C - C NOTES: 1. See Contract Drawings for additional details. 2. Support base plate with 1' nonshrink grout Install 4 pc's 3/4" s.s. bhreaded epoxy anchors - 9' embedment 3. Epoxy M505 anchors with W.R. Meadows Rezi Weld or equal. Minimum 9" embedment 4. Cut reinforcement to suit. Laps as required - rain. 18'. 5. Grout void after pipe installation. Drawing References: , 402- D - Mechanical Layout/Sections D- D & 'G' , 406-A1 - Overflow Riser e 410 - Piping / Mechanical Equipment - Legend //~,,,,Rev, Date MECHANICAL LAYOUT A 11/02/98 COPPELL, 'IX - # 802 SECTION C - C Date05 / 98Dw,. CADD L A N D M A R K 402-c : I 'l ! I [ ! e..- 20' Inlet/Outlet Riser · '~ M503 @ " Inlet/Outlet Riser F1 ._~f'N __.-_. I a ( see Dwg. 405 - A1 ) i 'i.": '.. : ~ · L~h,t~< ~~ ~ ' , M504 ~ 12" ~ 531.14 , , - .. M505 ji~'j,, ~ s '~a ' " ~ 526:~ , 524.~ ( Nomin~ ) ~ ~ { SEC~ON 'G' 1' ~a~n joint~~ t ~ a~ ~f I~ing _ M504 ~ 12'~ M503 ~ 12'/ 05 ~ 12' SECTION D - D 1. See Contract Drawings for additional details. 2. Support base plate with 1" nonshrink grout. Install 4 pc's 3/4" s.s. threaded epoxy anchors - 9' embedment. 3. Epoxy M505 anchors with W.R. Meadows Rezj Weld or equal. Minimum 9" embedment. 4. Cut reinforcement to suit. Laps as required - rain. 18". Drawing References: · 405 - A1 - Inlet / Outlet Riser · 410 - Piping/Mechanical Equipment Legend Rev. Oats MECHANICAL LAYOUT A 11/02/98 COPPELL, TX - # 802 SECTIONS D - D & "G' o~m 05 1 98own.CADO L A N D M A R K 40 -o i ; '1 I" r Section K - K ~"'l oaw COPPELL, TX - # 802 FLOOR DRAIN Oam 05 / 98Own. CADO 403 L A N D M A R K ,,,,¢- ~.~. 630.01 · -. ._ "L,, ~.....,: Top of Pipe Floor Penetration Detail _/ Owg. 405 - A2 ~l f Range Joint 534.18 Top of Range i 4'- 0 3/4' Expansion Joint ~.- 20' Inlet/Outlet NOTES Drawing References · 405- A2 - Inlet/Outlet Riser- Floor Penetration * 409- A - Riser Pipe - Bracket/Wear Sleeve Detail · 410 - Piping/Mechanical Equipment Legend ~ oat· INLET / OUTLET RISER COPPELL, 'IX - # 802 ELEVATION Oats05 / 98Own,CTR L A N D M A R K c.~. 4os- ~ . ~---= ...............,---~,.'..~moor ~,a,e -,, ', ' Support Flange Grout Detail B Detail A 6,30.01 3/8' round bars @ 6' -~ ~- 20' Inlet/Outlet · ~ I / Root Plate ~ I % i ° ~.... , Grout ~ 628.40 ~ I , l't ,"'~""-;,,'_:'-"'-'T'. :"" b ~ ,A,_,,7:i ....j..,.. ;:- 627.40 Detail ..~ / ~/ "' 4'- 7 1/4" (in skew) I e · ' 4'-0 3/4' NOTES: Riser Pipe Upper End Oatall 1. Cast Mk. D3 and Mk. F3 in dng beam/dome slab. Provide temporary-plug in 6' coupling floor drain (Mk. D3 ). Replace with silt stop ( Mk. 01 ) after painting. 2. Cut height of angle flange (Mk. 02 ) to drain rioor plate locally. 3. Weld flange is shipped loose for field weld. 4. Provide additional reinforcement around penetration. Drawina References · 410 - Piping/Mechanical Equipment- Legend ~/7~,~, Date INLET/OUTLET RISER COPPELL, TX - # 802 FLOOR PENETRATION / DRAIN DETAILS Dam 05 / 98 Own. CADO L A N D M A R K ! 'l i 1' [ Mk. I No. J Siz. j T ickness J JointJ O.=rip.on J Manu,ac,.r.r J Refer. nce Mechanical @ Grade Slab r,,-~.l 1 .~4'/2o' M.J. / FI.q. R.C.C.P. Pipe i 2 1 z0'/~2' .250" FIg. / FIg. Type 304 L S.S. gO" Elbow w/Tee Landmark Owg. 411 - A 3 1 ~-0'/~2". 187"/.250" P.E. /FtcT. Type 304 L S.S. Pipe w/Base Elbow, Reducer, Tee Landmark Dwg, 411 - A 4 1 18 ' .12 5" Fig. / FIg. Type 304 L S.S. Pipe w/Base Elbow. Tee Landmark Owg. 411 - B 5 1 18" .125" FIg./P.E. Type 304 L S.S. 90° Elbow Landmark Dwg. 411 - B A 1 20" FIg./FIg. Gate Valve w/Motor Operator (18"IVf) B 2 12" FIg. / FI.q. Gate Valve ( 14' flf ) 20" Ft.q. Restraint Ran.qe Adaptor - 20.00' O,D. Smith Blair Dw,q. 425- A 12' FTg. Restraint Flan.qe Adaptor -12.75" O.D. Smith 'Blair Dw.q. 425 - A 20' FI.q. / FIg. Expansion~ Joint - Maxi 1015 Gen. Rubber Dw.q. 424 18' FI.q. / FI.q. Swin.q Check Valve w/Buna-N Flapper ( 36" f/f ) APCO -Model 118 1' Thrd. Hose Bib - Brass 1 · Thrd. Couplin.q / Nipple / Corporation Stop - Brass 2 ' Thrd. Coul~lin.q / Nipple / CoreDration Stop - Brass Inlet / Outlet Riser =1 1 20 · .187' R_c;. / Weld Type 304 L S.S. Pipe x 30'- I 1/2' Landmark Owg. 415 - A ~r:2 I 20' .187' P,E./Weld TyI3e304L S.S. Pipe x 30°*0· Landmark Dwcj. 415-A F3 1 2 0 ' .18 7" P,E. / P.E. Type 304 L S.S. Pipe x 35'- 8 1/2' Landmark Dw.q, 415-A/B O1 1 6' .134' Thrd./P.E. Type304L S.S, Silt Stop xl'-41/2"w/Handles Landmark Dw.q. 415-C D2 1 6 · .250' Weld Type 304 L S.S. Adjustable An.qle Ran.qe Landmark Dwg. 415 - C D3 1 6' .134' P.E./FI.q. Type304L S.S. Pipe x 3'-103/8' w/Cpl.q, Landmark Dwg. 415-C 04 2 6 ' .134 ' P.E. / P.E. Type 304 L S.S. 45° Elbow Landmark Dwcl. 415 - C D5 2 6' .134' P-E./P.E. Type304L S.S. Pfpe x 2'-0' Landmark Ow.q. 415-C 5 Pipe Bracket Assembly Landmark Ow.q. 420 Overflow Riser O1 1 18' .125' Rg. /Weld Type 304 L S.S. Pipe x 30'- I 1/2' Landmark Dwg. 416 - A 02 1 18" -125· P,E./Weld TyI~e304L S.S. Pipe x 30'-0' Landmark Dw~.416-A 03 1 18" .125" P.E./FI.q. TYpe304L S.S. Pfpe x 30'-11/2' Landmark Ow,cl. 416-A 04 1 18' .125" Rq. / FI.q. Type 304 L S.S. Pipe w/90° Elbows Landmark Dwg. 416 - B 05 I 18' ,250' R.q. I Weld C.S. Pipe x 2'- 9' Landmark Dwg. 416 - C2 5 Pipe Bracket Assembly Landmark Ow.q. 420 Ray. Data PIPING / MECHANICAL EQUIPMENT ~ A 11/02/98 COPPELL, TX - # 802 LEGEND Date 05 / 98Own.CADD L A N D M A R K 440-A ! 'i ! '[' r 11 Floor / Drain L I 6" FIoar Drain M 2 6" MJ / MJ DI - 90° E~bow N 1 6" PE/PE PVC-Piee x 15'-0' ( cut to suit on site ) Fasteners / Gaskets 60 20" 3 - Belt Sets - I 1/8" x 5" 40 20' 2 - Belt Sets - 11/8" x 3 1/2" Expansion Joint 80 18" 5 - Belt Sets - I 1/8" x 4 3/4" 45 12" 4 - Bolt Sets - 7/8" x 3 3/4' 5 20" I - Restr&int Rod Set - 11/8' x 2' - O' 3 12" 1 - Restraint Rod Set - 7/8' x 1' - 10' 3 20" Full Face Red Rubber Gasket 5 18" Full Face Red Rubber Gasket 4 12' Full Face Red Rubber Gasket 2 18" Hanger Grimell 'Rev, Date PIPING / MECHANICAL EQUIPMENT /~'~' A 11/02/98 COPPELL, TX - # 802 , LEGEND [3ate 05 / 98 own. CADD I 410 ' a ! ' IT · ]' r II ,E. D, I.O. <l -e LI;~, / ' * / Washer I ( Note 3 ) /~' '~' ~ / ,.'[ _, ,: Retaining Rings // :~ ' ~' ~'~""' !~c in Fr s Cover'/ ' ~"' ~' ~--Tul3e Joint Holes Bolts Geometric Data Movement Oata (Ax~) Size OlP S.S. Com- Force I-'lon- Force ( I.O. No. _ Die- Oia. Len(ith Lenq~h A a C O E F pression ( !l~s. ) qalion (113s.) 20 20 11/4' ~ I18" 3 ~4' 3 1~' ~8" ~4' 2 1~" I 114' ~4' 8" 2' 2703 NOTES: 1. Expansion Joint is General Rubber Corporation Style 1015 E. Test pressure 150 psi (rain.). 2. Flange Odlling/OO is per ANSI B 16.1. 3. Provide washers under bolts at the retaining dng. Insert bolts l'rom the expansion joint side. Material SI]ecification: · Tube / Cover - Ethylene - Propylene Diene Monomer ( EPOM ). · Carcass - Polyester with steel reinforcing rings · Retaining Rings - ASTM A- 536 ductile iron - galvanized oate RISER PIPE COPPELL, 'IX - # 802 EXPANSION JOINT 0ace 05 / 98 ~ own. CADO LANDMARK 8-1 JCh.. 424 I '1 ! T' r il obs{ruction light air terminal ~,y y handrail /llll/ / l l U l \ \\\\\\ ~ _ steel - water _- Fstorage tank _:_ roof access /"'tube _, - roof access "ladder " steel - floor ~ __-: plate 2'~ fir~oe~nrf c~amp affix - ~' -" '~ ~' , A walkway/ and tank floor Stru.cluraJ steel \ ~ .r' " ' //--mechanical dOWn '~' ~ nductor <~ ~) Section 'A' cast - ground rod couplers , ground rods Date COPPELL, TX - # 802 LIGHTNING PROTECTION Date 05 / 98 Own.STD L A N D M A R K ~"~. ~e-a ~. sos LIGHTNING PROTECTION ELEVATED WATER STORAGE TANKS The lightning protection system for the structure consists of two copper down conductors, fastened to the intedor of the pedestal 180 degrees apart. At the top of the pedestal, the conductors are extended through the wall and fastened to the thrust dng. At the bottom of the pedestal the conductors are extended through the wall below grade and fastened to buried ground rods. Lighting protection for the obstruction light consist of an air terminal down conductor and bond plate fastened to the tank roof plate. Air terminals consist of 1/2" die. solid copper point. Down conductors consist of not less than 28 wires of soft drawn copper (not less than 14 ga. ) and not less than 4 ounces per fool , Down conductors are fastened to the pedestal with strap fasteners of at least 20 ga. Copper minimum 1/2' in width at a minimum of 3 ft, centers between straps. Down conductors are anchored 6" both sides of any change in direction. Down conductors are placed no closer than 6 ft. from any metal object in the pedestal. Down conductors are installed a minimum of 8 ft. from the edge of the access platform. A y- connection to the down conductor is installed at the bottom elevation of the upper access platform and a lead is run to the access platform fastened with a cast bonding copper plate. At the top the down conductor is fastened to the ring beam and to the ring beam reinforcing, ( See detail Dwg. 803 - A ) Ground rods are galvanized steel, 5/8' in dia. and 8 ft. long. The connection of the down conductor to the ground rod is made with cast ground rod couplers at least 12" below grade. If it is impossible to drive the ground rods because of rock, auxiliary grounding may be used. Auxiliary grounding consists of a trench of at least 2 ft. in depth and 12 ft. in length. The down conductor is laid in the trench and backfilled. A ductile iron watermain may also be used as auxiliary grounding in addition to ground rods. ff~ev. Date LIGHTNING PROTECTION ' COPPELL, 'iX - # 802 INSTALLATION INSTRUCTION ( U.S.A. ) Date 05 / 98Own. STD L A N D M A R K e-3 c.k. 803 - c ' I ' ! i [ i rt.-12' w x 12' H O,(T VI~:HICLE DOOR OPENING """' I ,,-or , s.-o" l .:: ~ RN. FLOOR :' :'" '. .. / ~ - !:: , ~8':9 7/r ' ., .:.-' 270,0" .'P N/ ' ' ' ' ' ' ' ' ' ~ ..... 0"' I ';:'~: 90,000 ': ,, ' ' ~ ' .:~ 95 0' ~../ , ,,R.,'.,, · ... , ,,/-' , !, : . :., / ' 225,000 '\ / /. ~,-SINGLE~ 000R 0 E ~NG .............. I I let s'-o' , e'-ct ROLF PAWSKI 89886 ~.-12° W x 12' H V~H~CLE; DOOR OPENING ~ Rev. O<~te Project COPPELL, TX - #9802 GROUND FLOOR PLAN/GENERAL DESIGN Oct, 02/12/98 I0"n' GP S17-E11 L A N D M A R K sco,.; ,/r.,.-o.c... · I I I II 0° ,. / , ·,." .::'-: _ ~ · ":~'::.. ::.: ~:.. .'~ SElF OWG ~17 F14 :'~; '" '~ "'~~"~Z~" ,.,.,o,.,,~. ~';~ ... · /::' ~\ \, ,s~ 0wG. sIT- C, 20' INLET ....:;:! ,'- , ~ ' ,: ~. ,.5 ~' '~':' 78.5 !i: ~, -- - ,... ' ..--- - - -,.-- - - ,-.-- - . - ,--- - - 270.0' ' ~ --- ' ' '!: 90.0' '; " """":: ......... _Z. ..... :. ' ' ~ ~;"~o- ~'i. ~:~,~' .., 18" OVERFLOW ~ ::.:: .-.. . '::.~: ,. .. '. ':' :"""": :" ,,t-~:,- ..............., NOTES: ~s~.r ' ...........'" ~. system - composite concrete s~ab / stee~ hoar deck. Totc~ slab depth - S'~. ....,,,,,R.,O,,t.,F,,.P~ .........: - Simply supported composite structural steel beam support. ~L~". SOlillS - ~ISC - allowable stress design 3. Design Live Load - 125 psi' ..... 4. Material Specification - Refer to detail drawings. 5. ~nish - galvanize all exposed metal deck and framing - steel trowel concrete slab finish /~"""" Rev. Date Project Title: COPPELL, T× -//9802 INTERMEDIATE FLOOR PI_AN/GENERAL DESIGN Oats 02/12/98 Iown'G° L 'A N D M A R K ~a,.=1/S'-,'-O'c... S17-E1.2 I I ! r' [ 11 MOUNTING BRACKET FABRICATION OETAtL 2 PC'S REQUIR[:O NOTES: I. JIb Crone - Goffey Model 180-WBT -1 ton capacity x 12' span I cord and 2, Hoist - Budglt Man Guard 1 ton electric chain hoist with tog ine electrical 10' control cord. 3. Trolley - Budgit/f82 1 ton. Bey. Dote Project Title: COPPELL, TX -//9802 1 TON X 12' JIB CRANE DETAILS & INSTALLATION Dote 16/12/98 IOwn' ..o.[ S17-E7 L A N D M A R K sc~,,: ,/r-,.-o' I i · F r I1 2 I 'i ' i I I" ' [ WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK CTTY OF COPPELL~ TEXAS PRO3ECT NO. WA-96-03. OPERA TZ'ON & IV[AZNTENANCE ]V[ANUAL PAZNT MATERZAL DATA SUPPLTER TNEMEC CO.t TNC. TECHNO COATZNGS~ ZNC. 6306 WZNDCREST DP, ZVE~ STE, 20Z4 PLANO, TEXAS 75024 (972) 473-6660 Wagon Wheel Ranch 2.0 MG Elevated Storage Tank Project No. WA-96-01 City of Coppell, Texas PAINT MATERIAL DATA Interior Surface Preparation: SSPC-SP10 CoatinQs Tnemec Series Minimum D.F.T. Prime FC20-1255 (Beige) 5.0 mils Finish FC20-WH02 (Tank White) 5.0 mils 10.0 mils Exterior Surface Preparation: SSPC-SP6 Coatings Tnemec Series Minimum D.F.T. Prime FC20-1255 (Beige) 5.0 mils Intermediate 74-Contrast 2.5 mils Finish 74-WH02 (Tank White) 2.5 mils 10.0 mils Logo Tnemec Series Minimum D.F.T. Lettering 74-Black (Outline) 2.5 mils 74-Safety Red (Bottom Lines) 74-Indigo (Top Lines) Clear Coat 76-Clear 2 Coats @ 1.5 mils I ~ m i I II ' ;' ' Pots-Pox (Fast Cure) I '.1 t(~ IlJrl( PROFILE GENERIC DESCRIPTION Polyamide Epoxy COMMON USAGE Fast-curing pmmc~ive co~i~ for use ~n stud ~d concrete ~o~ble w~ev s~ova~e f~cilides. Conmc[ ~ouv Tnemec representative for o~hev s~smms ~nd additional ~n~o~m~io~ on COLOR5 ~er: ]2H Red, ~255 Beige. Topcoat: ~0 ~him, ~0~ Tank ~im, GB0] Delf~ Note: Epox~es chalk wi~h e~mnded e~posu~e ~o sunlight. ~ck oE ventilator, ~xing, miscaml~za~on ov ~he use-of hearers ~ha~ emi~ c~vbon ~oxide and carbon monoxide SPECIAL QUALIFI~TIONS Ceded b~ NSF ~o~ ~ accov~ce wi~ ~S~SF St~ 61 ~ov ~ on ~e ~mble ~mv storage ~s and ve~e~o~ of ~,~ ~Bo~ (]785 L) gpaciW o~ ~mv. Co~o~s m A~A D 102 ~i~ S~ No. X ~d No. 2. Conm~ ~ouv T~emec ~pve~ve for ap~voved ~s~e~ a~d add~fio~l i~omdon on ~cen~l ~s. PERFOR~NCE CRITERIA E~ensive rest da~a available. Conc~a ~ouv Themet vep~ese~m~ive for specific ms~ COATING ~'~1 ~ ~1 PRIMERS Self-pvj~ng, ~-~0. Note: 9~-~0 B ~S~NSF S~d. 6~ ce~ffied b~ as a pv~ev for 5e~es FC20. ~efev ~o ~e ~-~0 pvoduc~ ~m shee~ for ~d~ional jnfovmadom TOPCOATS Xnte~or: Series 20, FC20, ~0, 26~, ~or: Series 20, FC~0, 27, 66, 69, 7L 7~, 74, 75, ~, ~40, ~efev m COLORS on applicable ~opcoa~ dam shee~s fo~ additional i~o~a~ion. Note: Series FC20 exm~ov exposed fo~ ~ wee~ o~ longer Fequives a~ e~o~ imevmedia~e co~ ov sc~fifica[~on pfio~ ~o [opco~[i~g wi~h Series 7]. ~e~ev ~o Series 7~ pvoduc[ da~ shee[ for SU~ACE Z ~ 3 a ~ ~J-J i CI]~ STEEL Imm~ton S~tce: SSPC-SP~0 Neav-~him Blas~ Cleaning Non-lmme~ion S~ce: SSPC-SP~ Commevci~l ~las[ Cleanly8 PRIMED SURFACES imm~ion ~ice: Sc~ ~he Series FC~0 prime co~ su~ace b~ b~sh-blas~ ~bv~sive before mpcoafi~8 if i~ h~s been exposed ~o sgnl~g~ ~ov 60 d~ys ov ~ST/BU~ILE IRON Com~c~ ~o~v T~emec m~vese~mfive ov T~emec Techn~c~l Se~ices. CONCR~E AHow ~ew concrete ~o cure fo~ ~8 days. B~sh-off blas~. ~oles, pi~s, voi~ ~nd crocks s~ould be filled wi~h 6]-]500 HHev and 5u~cev (~Si/NSF S~d. 6] ~LL SURFACES ~ust be clea~, d~ a~d f~ee of off, ~ase and o~hev / TECHNICAL DATA VOLUME SOLIDS* 58.0 · 2.0% R~CO~ENDED D~ ~er: ~.0 m 5.0 mils (75 m ~25 microns) ~e~ coa~. ~t~e~ate, Topcoa~ ~.0 [o 6.0 rafts (~00 ~o ~50 m~c~ons) pe~ coa~. Note: Number oE coa~ and ~ick~ess ~equimmems wil~ va~ wi~h s~bs~mm, application method and exposure. Co~mc~ ~ouv Themet CURING TIME Temp~e To Touch To ~dle To RecoaC i~e~ton 75°F (24°C) 1 hour 2 houm · 3 hours 6 days 65~F (18~C) 2 houm 4 houm 5-6 hours 8 days 55~F (13°C) 3-4 hours ~8 houm 10-12 hours 12 ~ys 45~F (7'C) 6-7 houm 12-14 houm 16-18 h0um 20 ~ys 35~F (2~C) 8-10 hours 16-18 houm 20-22 houm 25 ~ys Curing time ~ies with surhce temperature, air movement, humidi~ and film ~ic~es. V0~II[E 0RG/NIC UnWed ted C0~UND5 2.90-2.97 lbs/~llon 3.2~3.32 Ibs/gallon (347-356 ~ms/litre) (391-398 gmms/litre) · [0RHI~[ C0V[~6[* 930 mil sq ~gal (22.8 m2/L at 25 microns). See ~PLI~ON for coverage rates. NUMBER 0F C0~N[NI5 Two: PaK A and Pa~ B PAC~61N6 5 gallon (18.9L) palls and 1 gallon (3.79L) ca~ -- Order in multiples of 2. N~WEt~BIP[RGA[LON' 12.50 · 0.25 lbs (5.7 · .11 k~ (m~ed) September 1997, by Themet Company, Inc. FC20 I 1 '! ! I .la31g'FC20 Pota-Pox ( ast cure) (D~) Continuous 250°F (121~C) Intermittent 275°F (135~C) ' "' SHELF LIFE 12 months at re~ended storage tempera~re. F~H P01NT- SETA Pa~ A: 82°F (28°C) Pag B: ~°F (18°C) H~LTH g SAFEH Paint products contain chemical ingedien~ which are considered hazardo~. R~d container label warning and Material Safe~ Data Sheet for ~po~ant health and safe~ i~ormtion prior to the use of this pr~uct. Ke~ out of ~e r~ch of ~en. ~PLICA~ON COVE~GE ~S' ge ~t~ite / To~oat D~ ~ Wet ~ ~ Fe~ ~ ~ Wet ~ (~om) (Mi~om) (mV~) (m~o~) (m~o~) (mV~ .Sugested (1) 4.0 (1~) 7.0 (1~) 232 (21.6) 5.0 (125) 8.5 (215) 186 (17.3) Min~um 3.0 (75) 5.0 (125) 310 (28.8) 4.0 (100) 7.0 (180) 232 (21.6) Ma~mum 5.0 (125) 8.5 (215) 186 (17.3) 6.0 (150) 10.5 (265) 155 (14.4) (1) Note: Roller or brush application requires ~o or more coaB to obtain recogended F~m thic~ess. Mlow for overspray and su~ace i~e~lafifies. FHm ~ickne~ ~ rounded to ~e nearest 0.5 rail or 5 micro~. Application of coating below minimum or above 'gum recogended ~ film ~ic~esses may adversely affect coa~g perform~ce. MIXING Power ~ conten~ of ~ch con~iner, ~g ~re no pi~ent r~ on ~e ~om. Pour a m~ured mount of PaR B ~to a clean conm~er hrge enou~ to hold ~ comanche. Add an equal volume of Pa~ A to Pa~ B whae under agitation. Con~ue agitation un~ ~e ~o comDnenB are ~orou~y ~ed. Do not use ged mtefial ~yond ~t ~e 1~. Not~ ~ com~nenB should ~ a~ve 50oF (10°C) p~or to gg. For application to sudac~ ~een 35°F to 50°F (2°C to 10°O, aaow g~ mtefi~ to stand ~ (30) gules ~d res~ ~fore ~g. For opium appli~fion proxies, blended componenB should ~ a~ve ~°F (16~C). '.. POT LIFE 16 hours at 35°F (2°C) 2 hours at ~°F (25°C) 1/2 hour at 100°F (38~C) THIN N[NG Use No. 4 Thinner. For air spray, thin up to I~A or 3A pint (380 ~) per gallon. For airless spray, roller or brush, thin up to 5% or ~A pint (190 mL) per ~llon. ~u~on: Series FC20 NSF ce~i~ca- Lion is based on ~inning with No. 4 Thinner. Use of any o~er ~inner voi~ ANSI/NSF Std. 61 ce~i~cation. SURFACE TEMPErTUNE Minimum 35~F (2°C) Maximum 135~F (57°C) ~e surface should be d~ and at least 5°F (3°C) above ~e dew point. Coating won't cure below ~n~um surface temperature. APPtI~BON EQUIPMENT ~ Spny Gun Fl~d ~ Cap ~ Hose Mat'l HuN A~mt~tng Pot ~p ~ ~ ~e ~s~e DeVilbi~ E 765 5/16" or 3/8" 3/8' or 1/2" 75-1~ psi 1~20 psi MBC or jGA or 78 (7.9 or 9.5 g) (9.5 or 12.7 g) (5.2~.9 bar) (0.7-1.4 bar) Low temperatures or longer h~es require higher pot pressure. ~l~s Tip ice Atoml~Ing ~e Mat'l HUN ~ Mflold Filter 0.015'~.019" 1800-3~ psi 1/4' or 3/8" 60 mesh (~85 microns) (124-207 Mr) (6.4 or 9.5 ~) (250 ~crom) U~ appropmte fip/ato~Eg p~ure for equipment, appE~tor te~que ~d w~er con~fiom. PI~ Compon~t Spny: Cornact your Tnemec representative or Tnemec Tec~cal SeNices. RoB~: Roller appli~tion op~onal when env~omenml res~cao~ do not ~low spraying. Use 3/8" or 1/2" (9.5 g or 12,7 g) ~n~etic nap cove~. B~ R~ogended for g m oily. U~ M~ qu~W nam~ or g~efic b~fle b~h~. C~NUP Flush and clean all equipment iged~tely a~er use ~ ~e recogended ~mer or MEK. Walues may va~ wi~ color. & UMITATION OF SEllErS UADIUff: Tamnit Com~eW, Inc. vetoniT only that its coorings rep~esenled heine roll the ~xmutoHon slnn&uds ~ TnmK Coa~eemr, Inc. . . XlI1~' O~SCIIBEN IN 111E I80YE NAGt~U'H SNAU. ~E IN UEU OF ANY OTHEt WAlljUlia, EXI'ltESSED OR IAIfi. IED, INCLUDING BUT NOT UAUTEO TO Ally IM~ED WAIRANIY OF ~ICHAIITJIIUIT O! F~NESS FOR A PAI~CULAI rUERE AlE NO WAIIANTIES IllAT Ell'END BEYOND THE OESCIIPTION ON IHE FKE HEREOR ~ buy~'s sole and exdL,~ve remedy ogeiml Tnem~ C~ I~ sill ha far relkemmnl d ~ pmde~ in lhe met a date cmlllmon ~c tha lNoditt 5hauL[ ha ireJIM I0 ealsl olld thl exd~ve rmlldy ~ nol have Failed its Isslalid m ~ Iq os TamIt is ,tire{ to ~o~de r.~'~ltiglnma ~odlKl Ii IN [1~1¢. NO OTHFJ I~EBY (INCLUOING. BUT " NOT tIMlIED TO, INCIOENTll. ON CONSEQUENtiAL OIAt~ES FOR LOST PROFITS, LOST SATES, INJURY i'0 ~ERSON OR PROPENrf, ENVIIONMENTAL INJURIES OR lily OBIER INelDEN~t. OI CONSEOUENTIAt LOSS) SHIll. DE iVAtLiDIf TO ITIE BIIY[R. recMkal oral aN~ h~tlea hmi~ is I~d fe~ rha p~ma ~ eslobashing o g~d txofile oF the ceeiq and Wq:w coDHag ap~icatlea p~cmduc~ T~ p~fo~m~ce rasllts wm o~lm~d in a comtoltd a~,~oam~f TnemKC~avpenYmek~smchNm~he~hesetes~s~fanY~heff~s~s~nccuta~dyr~pxesea~"~envi~amm~s.Ma~p~ca~i~a~nvifennim~d~iddes~gnfac~mc~k~v~rYsigni~(mHY~ai~cmdt~ddb~x4Becis~din~hesd~(~i~a~d~ coating. ,mUDUSNED TECHNICAl. DATA ANQ INSTRUCTIONS A~E SUBJECT lO CHANGE WITHOUT NOTICE. CONTACT YOUI TNEIIEC REPRESENTATIVE FON CURlENT TECHNICAL DATA ANO INSTRUCTIONS. FOI INOUSTRIAL USE ONLY. TNEMEC COMPANY INCORPORATED PtlTED ~N USA 6000 COR~DATE DRIYE, laXSAS CITY, ~c:SOURI 64i 20-1372 TEL: 816 483-3400 FC:20 I 1 ! I I T ii Endura-Shield '.SERIES74 GENERIC DESCRIPTION Aliphatic Acrylic Polyurethane COMMON USAGE A coating highly resistant to abrasion, wet conditions, corrosive fumes, chemical contact and exterior weathering. High build quality combines with project specific primers for two-coat, labor saving systems. NOT FOR IMMERSION SERVICE. COLORS Refer to Tnemec ColorBook. Note: Certain colors may require multiple coats depending on method of application and finish coat color. When feasible, the preceding coat should be in the same color family (blue, gray, etc.), but noticeably different. FINISH Gloss PERFORMANCE CRITERIA Extensive test data available. Contact your Tnemec representative for specific test results. COATING SYSTEM PRIMERS Steel: Series 20, 27, 37H, 40, 50-330, 65, 66, 69, 83, 90-97, 104, 135, 140, 160, 161, 163 Galvanized Steel and Non-Ferrous Metal: Series 66, 69, 135, 161, 163 Concrete: Series 66, 69, 104, 161, 163 CMU: 54-660 Note: Before topcoating with Series 74, 50-330 exterior exposed more than 24 hours must first be scarified or receive an intermediate coat of Tnemec polyamide epoxy. Also, Series 69, 83, 104, 135 or 140 exterior exposed more than two months must first be scarified or reprimed with themselves. Brush blasting with fine abrasive is the preferred method of scarification. SURFACE PREPARATION ALL SURFACES Must be clean, dry and free of oil, grease and other contaminants. Jll~tjll~jClF. l ~ DATA VOLUME SOLIDS* 70.0 ± 2.0% (mixed) ' RECOMMENDED DFT 2.0 to 5.0 mils (50 to 125 microns) per coat. Note: Number of coats and thickness require- ments will vary with substrate, application method and exposure. Contact your Tnemec representative. CURING TIME Temperature To Touch To Handle To Recoat ] 75~F (24~C) I 1 hour I 6 hours ] 8 hours ] To resist moisture condensation: 6 hours. Curing time varies with surface temperature, air movement, humidity and film thickness. Note: For faster curing and low-temperature applications, add No. 44-710 Urethane Accelerator; see separate product data sheet. VOLATILE ORGANIC Urmthinned Thinned 10% COMPOUNDS (No. 42 Thinner) Series 74 2.15-2.48 Ibs/gallon 2.56-2.86 lbs/gallon (257-297 grams/litre) (306-342 grams/litre) THEORETICAL COVERAGE* 1,125 mil sq ft/gal (27.6 mVL at 25 microns). NUMBER OF COMPONENTS Two: Part A and Part B PACKAGING Five-Gallon Kit: Cori~ists of four gallons of Part A in a five gallon pail and a one gallon can of Part B. When mixed, yields five gallons (18.9L). One-Gallon Kit: Consists of a partially-filled one gallon can labeled Part A and a partially filled quart can labeled Part B. When mixed, yields one gallon (3.79L). NET WEIGHT PER GALLON* 11.16 + 0.25 lbs (5.06 + .11 kg) STORAGE TEMPERATURE Minimum 20°F (-7°C) Maximum 110°F (43°C) TEMPERATURE RESISTANCE (Dry) Continuous 250°F (121°C) Intermittent 275°F (135°C) SHELF UFE 12 months at recommended storage temperature. FLASH POINT- SETA Part A: 98°F (37°C) Part B: 135°F (57°C) HEALTH & SAFEI'Y Paint products contain chemical ingredients which are considered hazardous. Read contliner label warning and Material Safety Data Sheet for important health and safety information prior to the use of this product. Keep out of the reach of children. September 1997, by Tnemec Company, Inc. 74 I 1 'i ! 1' I i Endura-Shield :" r APPLICATION Conventional Build High-Build ~. .;~ /'"'T COVERAGE RATES* (Spray, Brush or Roller) (Spray Only) Dry Mils Wet Mils Sq Ft/Gal Dry Mils Wet Mils Sq Ft/Gal (Microns) (Microns) (mz/Gal) (Microns) (Microns) (rn2/Gal) Suggested 2.5 (65) 3.5 (90) 449 (41.7) 4.0 (100) 5.5 (140) 281 (26.1) Minimum 2.0 (50) 3.0 (75) 561 (52.1) 3.0 (75) 4.5 (115) 374 (34.7) Maximum 3.0 (75) 4.5 (115) 374 (34.7) 5.0 (125) 7.0 (180) 225 (20.9) Note: Can be spray applied at 3.0 to 5.0 mils (75 to 125 microns) DFT per coat when extra protection or the elimination of a coat is desired. Allow for overspray and surface irregularities. Film thickness is rounded to the nearest 0.5 rail or 5 microns. Application of coating below minimum or above maximum recommended dry film thicknesses may adversely affect coating performance. MIXING Stir contents of the container marked Part A, making sure no pigment remains on the bottom. Add the contents of the can marked Part B to Part A while under agitation. Continue agitation until the two components are thoroughly mixed. When used with 44-710 Urethane Accelerator, f'trst blend 44-710 into Part A under agitation; continue as above. Do not use mixed material beyond pot life ,, limits, Caution: Part B is moisture-sensitive and will react with atmospheric moisture. Keep unused material tightly closed at all times. POT LIFE 2 hours at 77°F (25°C) unthinned 3 hours at 77°F (25°C) thinned 1 hour at 100°F (38°C) unthinned 2 hours at 100°F (38°C) thinned THINNING For air or airless spray, thin up to 100/0 or 3A pint (380 mL) per gallon with No, 42 Thinner. For brush or roller, thin 3% to 5% or s.4 pint (190 mL) per gallon with No. 39 Thinner. Thinning is required for proper application. Caution: Do not add thinner if more than thirty (30) minutes have elapsed after mixing. SURFACE TEMPERATURE Minimum 40°F (4°C) Maximum 120°F (49°C) The surface should be dry and at least 5°F (3°C) above the dew point. Cure time necessary to resist direct contact with moisture at surface temperature: 40°F (4°C): 24 to 32 hours 50°F (10°C): 18 to 24 hours 60°F (16°C): 7 to 10 hours 'T 70°F (2I°C): 4 to 8 hours 90°F (32°C): 2 to 4 hours 100°F (38°C): 1 to 2 hours C~. If the coating is exposed to moisture before the preceding cure parameters are met, dull, fiat or - spotty-appearing areas may develop. Actual times will vary with air movement, film thickness and humidity. APPLICATION EQUIPMENT Air Spray Gun Fluid Air Cap Air Hose Mat'l Hose Atomizing Pot Tip ID ID Pressure Pressure DeVilbiss E 78 5/16" or 3/8" 3/8" or 1/2" 75-90 psi 10-20 psi MBC (7.9 or 9.5 ram) (9.5 or 12.7 ram) (5.2-6.2 bar) (0.7-1.4 bar) Low temperatures or longer hoses require higher pot pressure. Airless Spray Tip Orifice AtOrni~irtg Pressure Mat'l Hose ID Manifold Filter 0.009'-0.013' 3000-3500 psi 1/4' or 3/8' 100 mesh (230-330 microns) (207-241 bar) (6.4 or 9.5 mm) (150 microns) Use appropriate tip/atomizing pressure for equipment, applicator technique and weather conditions. Roller: Use 1/4" (6.4 mm) synthetic nap cover. Do not use medium or long nap roller covers. Two coats are required to obtain dry film thickness above 3.0 mils (75 microns). Brush: Recommended for small areas only. Use high quality natural or synthetic bristle brushes. Note: Two coats are required to obtain recommended film thickness. CLEANUP Flush and clean all equipment immediately after use with the recommended thinher or MEK. *Values may vary with color. ..lrY& UAtlTATION OF SELLERS LIABIUTY: rnemec Corn!amy, Inc. wa~mels only thai its coaliags r~resenmd hem meet the FormulaHun smadords o~: TnoraK Cammy, Inc. , '.ANTY OESCRIBED IN THE ABOVE PARAGRA,°H SHALL BE IN UEU OF ANY OTHER WARRANTY, EXPRESSED OR gAPtIED, INCLUDING BUT NOT UAIITED TO, ANY I/APtIEO WABRAUT~ OF AIERCHANTANIUTY OR FITHESS FOD A PAN~CULAB . THERE ANE NO WABP, ANTIES THAT EXTENO BEYOND THE OESCRIPTION ON THE FKE HEREOR The ixjyor's sde and exckajno rmnody against Tnomnc Cameofly, Inc. shell be for re~ocemet d the ptndncl in Ibe evefit o dlJeC~no ~dna,~on oF the product shodd be found ro exig and Ihs exclusive ramndy sheit tlat have Jailed jls essenNd pu~ose as hag as Teemnc is veilling to ~ovide compatabAe retracemeal pmdncl to Ibe b/for. NO OTHER It~EDY (INCLUDING, BUT NOT UMITEO TO, INCIDENTAL OR CONSEQUENtiAL HA/MRS FOD LOST PROFITS, LOST SALES, INJURY TO P~RSON DR PRO~RTY, ENVIRON~AEUTAL INJURIES OR ANY OTHER INClOEUTAL OR CONSEQUENTIAL LOSS) SKALL BE AVAILABLE TO THE BUYER. Tatht~ eml a~Fdiasltae iedormaliaa be'Ran is proviand for the p~tmse d atlabiishing a general ~o~le o/Ihe coolRag and proN coating aplzkalion procedures. rest peformeace ratadis were oblained in a caat~dled eevimamenl and Tnemnc Camlleny makes no claim thai these lests at a~y Debut tests, astute/ely re~feseal ~sII emmaaelmts. As oplzacaljaa, ff,~onme~led end dasiga hclam can vory s~lificaalty, due cam sheekJ be exe~nd ia the setnc~el end use d Ihe coating. PUBUSHED TECHNICAL OATA AND INSTRUCTIONS ARE SUDJECT TO CHANGE WITHOUT NOTICL CONTACT YOUR TNEAEC REPRESENTATIVE FOR CURRENT TECHNICAL DATA AND INSTRUCTIONS. FOR INDUSTRIAL USE ONLY. TNEMEC COt~PANY ENCOR?ORATEU P~TED IN USA 6800 CORPORATE DRIVE, KANSAS CIZY, AMSSOURI 64120.1372 TEl' 816 483-3400 74 I I 'i ! T' I i , " Endura-Clear GENERIC DESCRIPTION Aliphatic Acrylic Polyurethane COMMON USAGE A unique clear coat used to both en e the finish and extend the long-term weathering qualities of pigmented Endur - ' most graffiti markings. COLOR Clear r coat ~lgmenteEd~~ FINISH H~gh gloss . PERFORMANCE CRITERIA E tensire test ' . emec representative for specific test results. COATING SYSTEM BASE COATS Series 71, 73 5, 175. Note: Series 76 Endurn-Clear should be applied within 7 days of a Series 71 or 175 application; within 14 days of a Series 75 application; and within 21 days of a Series 73 application. TNEMEC 'SURFACE PREPARATION Prepare surfaces by method suitable for 'exl~Gsure and service/(See Primer Product Data Sheet for surface preparation recommendations.) ALL SURFACES Must be clean, dry and free of oil, grease and other conruminants. TECHNICAL DATA VOLUME SOLlOS 66.0 _+ 2.0% (mixed) RECOMMENDED OFT 1.0 to 2.0 mils (25 to 50 microns) per coat. CURING TIME Maximum Temperature To Touch To Handle To Recoat To Recoat * ! 75oF c24oc IhourI 2-3 ho.rs3 hoursI 72 hours I To resist moisture condensation: 3 hours Curing time varies w'ith surface temperature, air movement, humidity and film thickness. · If exceeded, scarify before applying an additional coat. VOLATILE ORGANIC Unthinned Thinned 10% Thinned 20% COMPOUNDS 2.40-2.67 lbs/gallon 2.84-3.09 lbs/gallon 3.21-3.43 lbs/gallon (288-320 grams/litre) (340-370 grams/litre) (384-411 grams/litre) THEORETICAL COVERAGE 1,059 mil sq ft/gal (26.0 mz/L at 25 microns). See APPLICATION for coverage rates. NUMBER OF COMPONENTS Three: Part A, Part B and Part C PACKAGING Large Kit: Consists of two one-gallon cans of Part A, one one-gallon can of Part B and a one- quart plastic bottle of Part C. When mixed yields 3.25 gallons. Small Kit: Consists of a partially filled one-gallon can of Part A, a quart can of Part B and an eight-ounce plastic bottle of Part C. When mLxed yields .81 gallon. NET WEIGHT PER GALLON 8.71 :!: 0.20 lbs (3.95 -+ -09 kg) (mixed) STORAGE TEMPERATURE Minimum 20°F (-7°C) Maximum l lO°F (43°C) TEMPERATURE RESISTANCE (Dry) Continuous 250°F (121°C) Intermittent 275°F (135°C) SHELF IJFE Parts A and B: 12 months at recommended storage temperature. Part C: 6 months at recommended storage temperature. EL~SH POINT-SETA Part A: IIO°F (43~C) Part B: 130°F (54°C) Part C: 102"F (39°C) HEALTH & SAFETY Paint products contain chemical ingredients which are considered hazardous. Read container label warning and Material Safety Data Sheet for important health and safety information prior to the use of this product. Keep out of the reach of children. November 1997, by Tnem¢'c Company, Inc. 76 i i w !' I T II :'-SERIES76 Endura-Clear ' ..... ~PP~ICATION ....... Dry Mils' Wet Mils Sq Ft/Kit (rnz/Kit) (Microns~ (Microns) Large Kit Small Kit Sugj~ested 1.5 (40) 2.0 (50) 2294 (213.3) 572 (53.1) Minimum 1.0 (25) 1.5 (40) 3440 (320.0) 857 (79.6) Maximum 2.0 (50) 3.0 (75) 1720 (160.0) 430 (40.0) Allow for overspray and surface irregularities. Film thickness ts rounded to the nearest 0.5 rail or 5 microns. Application of coating below minimum or above maximum recommended dry film - thicknesses may adversely affect coating performance. MIXING Note: Add Part C Accelerator according to the following chart. Temperature Range Amount of Part C 40°F to 70°F (4°C to 21°C) Full amount supplied (8 oz or 235 mL) 70°F to 80°F (21°C to 27°C) 50°/0 of amount supplied (4 oz or 120 mL) Above 80°F (27°C) 25% of amount supplied (2 oz or 60 mL) Large Kit: Pour both gallon containers of Part A into a dean container large enough to hold all three components. Add Part C Accelerator to Part A while under agitation. Mix thoroughly. Add Part B to the mixture of Part A and Part C while under agitation. Continue agitation until all three components are thoroughly mixed. Small Kit: Add contents of the plastic b_ottle marked Part C Accelerator to Part A while under agitation. MIX thoroughly. Acid contents of the qtiart can marked Part B to the mLxture of Part A and Part C while under agitation. Continue agitation until all three components are thoroughly mixed. Do not use mixed material beyond pot life limits. Part B is moisture-sensitive and will react with atmospheric moisture. Unused material must be kept tightly closed at all times. Part C Accelerator is not for use in Endura-Shield or other Tnemec urethane products. POT LIFE 2 hours at 77°F (25°C) 30 minutes at 100°F (38°C) ~. Note: See chart at the beginning of Mixing instructions. C T~iINNING Use No. 2 Thinner. For air spray, thin 10% or 3A pint (380 mL) to 20% or 1V2 pints (760 mL) per gallon. For roller or brush, thin up to 10% or 3A pint (380 mL) per gallon. Caution! Do not add thinner if more than thirty (30) minutes have elapsed after mixing. Thinning above 20% may adversely affect coating performance. SURFACE TEMPERATURE lVlinimum 40°F (4°C) Maximum 12~°F (49°C) The surface should be dry and at le:~a{ 5°F (3°C) above the dew point, APPUCATION EQUIPMENT :~" Air Spray Gun Fluid Air Cap Air Hose Mat'l Hose Atomizing Pot Tip ID ID Pressure Pressure DeVilbiss E 78 5/16" or 3/8" 3/8" or i/2' 70-90 psi 10-20 psi MBC or JGA (7.9 or 9.5 ram) (9.5 or 12.7 mm) (4.8-6.2 bar) (0.7-1.4 bar) Low temperatures or longer hoses require higher pot pressure. Proper atomization is necessary. to obtain a smooth finish. Roller: Use 1/4' (6.4 ram) synthetic nap cover. Do not use medium or long nap roller covers. Brush: Recommended for small areas only. Use high quality natural or synthetic bristle brushes. Airless Spray: Not recornrnended. CLEANUP Flush and clean all equipment immediately after use with the recommended thinher or xylol. & U/&iTATIQN OF SEI IFR'S LIABIUTY: Toemac Company, inc. warrails only thai ils coallags tapremind heroin rhea{ the formulalEna slandards o| Tnomnc Company, Inc. CQndilien Oj the product should be leund to exist and the exclusive remedy shall nor have faiind its essanlipl purpose es lang .3 Tnemnc is willing Xo provide campcubit titplacement p~Q~u(I to the buyer. NO OTHER REMEDY (INCUJUING, 8UT NOT LIMITED TO, INCIDENTAL OR CONSEQUENTIAL OAIAAGES FOR LOST PROFITS, LOST SALES, INJURY TO PERSON OR PROPER~, ENVIRONMENTAL INJURIES OR ANY OTHER INCIOEHTAL 01~ CONSEQUENtiAL LOSS) SNAU. BE AVAILABLE To THE BUYER. TKhic,d and op~licoliaa in~ffmotian hatein is provided fm the repose o| egabUshig a ganlfi~ piGfill QJ the cooling and pral~ cooling opp~icalioo procedures. Tesl p~mmenca testis were olainnd in a controlled eovimmenl and Tnornnc Company mahl~ an dim thai Ihesa lesls or any other tesls, accurately repllsanl i~1 enviran~ls. As applicmina, anvi~amanlat end clqa faclo6 can very signilkanlly, due cam sM~d be exercisnd in the satKtion ~ usa oJ the cooling. PODUSHED TECHNICAL DATA ~0 INSTRUCTIONS ARE SUBJECT TO CHMGE WITHOUT NOTICE. CONTACT YOUR THEMEC REPRESENTATIVE FOR CURRENT TECHNICAL OATA AND INSTRUCTIONS. FOR INDUSTRIAL USE ONLY. [NE,',~EC C. UMPANY INCORPORArEO PR1NTEO IN USA 6800 CORPORATE DRIVE, ~NSAS CITY, MISSOURI 64120-1312 tEL: 816 483-3400 i T m i r T ] 3 WAGON WHEEL RANCH 2.0 MG .ELEVATED STORAGE TANK CtTY OF COPPELL,, TEXAS PRO3ECT NO, WA-96-0:I. OPERA TZON & M AZNTENANCE MANUAL 20" RES'rL'rENT WEDGE GATE VALVE W'rTH ELECTR'rC OPERATOR L I V 1" T 20" RESILIENT WEDGE GATE VALVE SUPPLIER CLOW VALVE COMPANY 902 SOUTH 2r~D STREET OSKALOOSA, TOWA 52577 (515) 673-8611 CLeW ~ Clow Valve Co. 902 South 2nd Street Telephone: 515 673-8611 Oskaloosa, IA 52577 Fax: 515 673-8269 INSTALLATION. OPERATION AND MAINTENANCE MANUAL RESILIENT HEDGE GATE VALVE AHMA C509 GENERAL: Inspect all valves at time of delivery for shipping damage and to confirm compliance with specifications. Valves are completely tested per the appropriate standards and specifications by the manufacturer.. The valves should be stored in such a manner to protect them from weather and blowing dirt and debris. In cold climates, if water is allowed to freeze in the valve, severe damage to the valve components could result. Any packaging should be replaced if removed for inspection. Proper sllnging and handling methods should be used when moving valves. Do not place slings or other devices around operating stem or through the valve port opening. I. Installation 1. Check that valve and end joints are clean. Again check for damage to the vale. Open. and close valve to insure proper operation. Close wedge before placing valve in trench. 2. Handle valve carefully. Do not drop into position. Do not sling through the port opening. 3. Prepare pipe ends according to manufacturer's instructions. Install valve per proper methods according to end Joint type. All piping should be properly supported to avoid line stress on the valve. Do not use the valves as a jack to force a pipeline, into position. 4. A valve box or vault should be provided for each valve used in buried service application. These should be installed such that no load is transferred to the valve. 5. Before pressurtzation of the ptpeltne and valve, all pressure containing bolting (cover, follower plate, end connection) should be inspected for adequate tightness (usually 90 ft. lb.) 6. Buried valves should be pressurized before backfilling. 7. With valve in open position, the entire system should be thoroughly flushed to clean the system. Debris in the valve could prevent valve from closlng or possibly damage the resilient material on the wedge. A Dillon of McWane, Incorported IF -~ 8. Upon completion of the installation, gate valve location, size, type, date of Installatlon, number of turns to open, direction of opening, and any other special information should be entered on permanent records. II. Operation 1. Do not operate valves in systems that exceed the rated working pressure of the valve, 200 psi. 2. System should be completely flushed before valve is operated in normal cycle. ' 3. The R/W valve opens and closes by turning the main valve stem with an operating nut or a handwheel. The valve closes by compressing the resilient material bonded to wedge against the valve body. As the material is being compressed (at end of closing cycle) torque requirement will approach maximum. Opening the valve requires significantly less torque. 4. If the valve should fall to seal after necessary number of turns, open the valve four or five turns and reseat. EMERGENCY OPERATION Turn the handwheel or operating nut faster in the desired direction. III. Inspection and Maintenance 1. Frequency of inspection should be based on frequency of operation. Semi annual inspections are minimum recommended. Valves should not be disassembled unless a breakdown has occurred. 2. During inspection, the valve should be opened and closed with pressure in the pipellne. The valve should function freely with no binding or vibration. Count the number of turns to full closed, this will reveal an obstruction if correct number of turns are not achieved. See table: Turns to Open , 2" 7.30 6" 19.88 2 1/2" 8.40 8" 26.60 3" 10.47 lO" 32.05 4" 13.78 '12" 37.10 - 3. All gaskets and Joints should be checked for leakage and tightness. 4. Hith the valve closed and pressure against the disc, a check for leakage is possible by "listening" to the valve for flow. A stethescope will help in this procedure. 5. Attached actuators should be inspected per manufacturer's recommendations provided with those units. 6. OS&Y valves should have the exposed stem lubricated at each inspection. Check stuffing box bolts for tightness. 7. A permanent inspection record should be kept for each valve. I 0 & M continued RECORDS ~l. Trouble can be anticipated with a good Inspection P~ogram. Such a program can not exist without good records. Poor records are worse than none. 2. A printed 5 x 8 record card for each valve and hydrant in the system is most convenient. \ a. Identification of each valve and hydrant is essential; Setting up a numbering system is one of the first steps to take. A reasonably simple method is to assign. a number to each street intersection, then identify each valve or hydrant numerically or alphabetically between intersection'numbers For instance: I9-IlO, would be ~the number of second " valve from street intersection number 9 in going toward street intersection number lO. Another convenient device is to assign only odd numbers to existing hydrants. When hydrants are added later they can be given numbers which will fit in the numerical sequence. b. Location should be recorded first. Measurements must be made from property lines or street center lines - not power poles fence lines - or the like. VALVE RECORD NO. Location FT. of Prop. Line of and FT. of Prop. Line of Size Make Type Gearing Bypass Opens Turns to Operate Depth to Nut Remarks MAINTENANCE AND INSPECTION RECORD Date Work Done O.K. BY Date Work Done O.K. BY RESILIENT SEAT GATE VALVE 14"-24" N.R.S. ASSEMBLY MATERIAL LIST CLOW VALVE COMPANY ":, 1 HEX HEAl) BOLTS ZiNC IN.ATEO STEEL ~/307 GRADE B 2 FLAT WA,~HERS Z3NC PLATED STEEL ASTM ,a~01 GRADE 3 OPERAI'I~ NUT OR HANDWHEEl, CA,fr IRON A~TM AI2S Ct,AS~ _ 4 HEX HEAD BOLTS/NUTS ~ IN, ATED St'EEL A,frM A30/' GRN)E 6 5 F-Ot.~R I:~ATE ~ IRON A~ A536 GR. 6145-12 · k "k 6 STEM Ol:UNG BUNAN 7 FOUR Pt..ATE O'RING/GA~v~rr BUNAN 9 STEM BRONZE A,,%"'rM 8584 CO,, 867' 10 HEX, HEAD B~t,T~U'I~ ZINC &etATED ~TF, EL A~TM A301 GRADE ,, cove4 DUCTILE TRON -k .A. 12 COVER O-R~ BUNAN 13 ST194NUT OFlO~ I A,~TMB584COA~44 ,s ~oo~-,u.~es IRON I is WEDGEP~CAP-18'THRU24' · * RECOMHENDED SPARE PARTS i r '~ '! I I I I ~ Clow 0 & M Manual CLeW /F~ Clow Valve Co. 902 South 2nd Street Telephone: 515 673-8611 Oskaloosa, IA 52577 Fax: 515 673-8269 TROUBLESHOOTING GATE VALVES POSSIBLE I(ALFUNCTION SYMPTOMS-CAUSES CORRECTIVE ACTION \ Joint Leakage Bolt'Tension Relaxing Tighten Bolts Seat Leakage Foreign material caught Operate valve to flush in seat. out debris. Seats Dirty/Carroded Flush or dis-assemble and clean. Seats d~maged. Inspect-repair or replace. Leak Past Stem Bolts loose Tighten bolts. <NRS)O-rings worn/ Inspect/Replace. damaged. (OS&Y) Packing worn/ Inspect/Replace damaged ** Inspection for the above should be done semi/annually at the minimum. ' There are no lubrication requirements other than: OS&Y valves should have the exposed stem **lubricated at each inspection. ** Mobi 1 Lube A Division of McWane. Incorporated I r i 'i i I I i ~ ELECTRIC OPERATOR SUPPLIER LIMITORQUE CORPORATION 5114 WOODALL ROAD LYNCHBURG~ VIRGINIA 24506 (804) 528-4400 L-120 Series Type 10 thru 40 Instruction and Maintenance Manual A Product of Limitorque Corporation i r ~ = I ['1 T ~ ] [ I 't i I [ ~ LIMITORQUE TYPE L-120 )' NSTRUCTION & MAINTENANCE MANUAL Your Limitorque Valve Control... Limitorque's L-120 series of actuators is.the most Limitorque actuators control the opening and clos- advanced valve control on the market..the result of ing of the valve and limit the torque and thrust ap- many years of development and an awareness of our plied to the valve stem. As a result, all valve customers' requirements. This booklet has been operating components are protected from overload, i. prepared to help you obtain the most benefit from improper seating or pipeline obstructions. ~ the equipment. It contains instructions on the in- stallation and maintenance of the units, plus helpful Limitorque controllers may be mounted on any size suggestions to enable you to become thoroughly of valve in almost any position or location. Readily familiar with the location and proper use of the adaptable to existing equipment, Limitorque actu- operating controls. ators may be powered by electricity, hydraulic pressure, air or natural gas. Please before you attempt to install or operate your Limitorque Actuator -- be sure to read this booklet at least once. Always keep it available for quick reference. .- Where to Find Information ~"~RINCIPLES OF OPERATION 2 LUBRICATION 2 INSTALLATION TIPS 4 TORQUE SWITCH 5 GEARED LIMIT SWITCH 6 POSITION INDICATION 7 DISASSEMBLY PROCEDURE 8 'STEM NUT REPLACEMENT 11 REASSEMBLY 11 SIDE MOUNTED HANDWHEEL 13 ELECTRICAL START-UP 16 TYPICAL WIRING DIAGRAM 16 To obtain further Information or to order parts for Note: All Inquirles or orders MUST be accompanied your Limitorque Valve control -- contact your local by the following information, which can be obtained representative or write to: from the unit nameplate: Limitorque Corporation Unit size &type 5114 Woodall Rd. Serial number P.O. Box 11318 Limitorque Corporation order number. Lynchburg, Va. 24506 Attn: Manager Parts Dept. (804) 528-4400 Fax: 804-845-9736 L120-11000 Sheet 1 of 16 Issue 10/94 PRINCIPLES OF OPERATION (' Description of Motor actuator is now in the handwheel drive option. Operation: Energizing the motor at this point will cause the latches to drop out and the spring loaded clutch Your Limitorque actuator is always available for sleeve re-engages with the lugs on the worm gear. motor operation whenever the motor is energized. The actuator is once more in motor operation. PLEASE NOTE THAT THE SHIFT FROM MANUAL DO NOT FORCE THE DECLUTCH LEVER INTO TO MOTOR OPERATION IS AUTOMATIC AND DOES NOT REQUIRE EXTERNAL POSITIONING OF THE MOTOR OPERATION POSITION -- THE LEVER RETURNS TO THIS POSITION AUTOMATICALLY DECLUTCH SHAFT. WHEN THE MOTOR IS ENERGIZED. Torque and Travel (Refer to page 8) In motor operation, the motor gear set (#'s 35 & 38) Limiting: drives the wormshaft (#15) and worm gear (#21) The geared limit switch is driven by a bevel gear which in turn rotates th'e clutch sleeve (#19) by connected to the upper drive lugs of the clutch means of driving lugs. The clutch sleeve and worm sleeve. Thus the limit switch is directly connected gear may be assembled to produce either a 'no lost to the output of the actuator and, once properly set, motion' or 'hammerblow' effect. The drive sleeve remains in step with the valve position regardless (#25) is keyed to the clutch sleeve and, hence, of electric or manual operation of the Limitorque rotates producing the required ouput rotary motion. actuator. Description of Manual rotating spring packs. As torque is generated by the Operation: ~ot.~,o~, the worm moves axially against one of the spring packs. Each pack is pre-calibrated and, "~Counterclockwise rotation of the declutch lever (#9) hence, a finite compression represents a finite tor- causes the declutch actuator to lift the clutch qua output. Movement of the worm operates the tor- sleeve out of engagement with the worm gear. Drive qua switch which interrupts the power to the motor. lugs on top of the clutch sleeve engage matching The torque switch is adjustable and can be set to lugs in the handwheel adapter (#26) and, then, lat- operate at pre-determined torque levels. LUBRICATION Lubrication Inspection therefore, it is not unusual to find a very small amount of weeping around shaft seals - especially during l.on9 "' "'~ .I,~';:.";~". 7'-'-' ' ~ '-';t;~':.-~* ."'~**~ -~';:'~'.:~t'--~-'Z;..'~;~Z~,T~'~,;-~:.~..: "~ '-*,:~'.--,~.. . ~`..i~%~!~....~.~.::~:.~:?.~.~:~:~.~i~.~i~t.e.:.i%~:~;`.`~;~:i.~:`Z..`~!.~`~?~.~?~.:::~?:~periods of idleness such as storage. Using grease i:S...:'v:--:-'::-:: ~,:'.::'?'~!.~:'~!~:'};~-'~'~ .~+;.':'¢ .~}~:-._-~.~:':~..':-'_--.' '~;~>~;' Before "opi~fatirig':yb~'ri. actuator;-.in.:~,?:!~:..~..-,',~minimizes this condition as much as possible. If you ·sp~ct ii'fo~"'!~'i"'~)pe~ 16b~:i'~ti6.h.':',:('~l~:e'~i~'i~i~:! find a small amount of weeping at start-up, remove it '~:i~i~ ~iaily if it 1:l~i~!'6~e"fi"~8~d.'.f{~i; 'a' 'ioli'~Ti~:!~iwith a clean rag. Once the equipment is operating, .the ~ ~,:,.>. - -.. '. ', - ...---:'-....-,'.,.,..;',,;:'~..-~',L~.~.'..::~'.. ~-,:~.~ s~:.::-..::~-%.:'~'.'weeping should stop. Lubrication Frequency Limitorque actuators are designed with a totally Base the frequency of lubrication inspections on sealed gear case factory-packed with grease. The gear historical data of your installed equipment. Every case can be mounted in any position (all penetrations actuator application has its own effect on lubricanls. into it are sealed); however. those mounting positions Pattern lubricant inspections based on the needs of which would cause vulnerable areas of the operalor your facility and its applications. The following schedule (e.g., motor, or switch compartment) to be saturated of lubrication inspeclion should be followed until with lubricant should a seal failure occur, should be operating experience indicates otherwise. avoided if possible and are not recommended. No seal can remain absolutely tight at all times; L120-11000 Sheet 2 of 16 Issue 10/94 I · [., ..... Gear Case: Inspect lubrication every 18 months or The standard lubricants used by Limitorque have 500 cycles - whichever occurs first. been proven extremely reliable over years of service. We do not recommend a particular lubricant substitute Inspection for our standard lubricants, but below is a list of .The three primary considerations in a lubrication minimum lubricant qualities required by Limitorque: ~nspection are: 1) Should contain an "EP" additiv~. 1. Quantity - L120 operators are built to operate on the 2) Must be suitable for the temperature range immersion principle. The primary concern in the intended. amount of lubricant is whether the "worm" is totally 3) Must be water and heat resistant and non- immersed in grease. separating. 4) Must not create more than 8% swell in 2. Quality - If dirt, water or other foreign matter are found Buna N or Viton. during lubrication inspection, the units should be 5) Must not contain any grit, abrasive or flushed with a commercial degreaser/cleaner such fillers. as Exxon Varsol #18 which is not corrosive and does 6) Must slump-prefer NLGI grade. not affect seal materials. Repack unit with fresh 7) Must not be corrosive to steel gears, ball lubricant allowing room for grease thermal expan- or roller bearings. sion. 8) Dropping point must be above 316° F for temperature ranges of -20,,°F (-29°C) to +150°F 3. Consistency - Lubricant should be slightly fluid ap- (+66° C) proximating a standard NLGI-0 grade consistency or less. Thinners such as Amoco WAYTAC #31 oil may be added provided the volume of thinner does not exceed 20% of the total lubricant. Factory Lubricants Gear Case: L120 with 1800 RPM motor is factory lubricated with Exxon Nebula EP-0 calcium complex base grease, suitable for temperatures from -20°F (-29°C) to +175°F (+79°C). L120 with 3600 and 1900 RPM motor is factory lubricated with Exxon Nebula EP-00 calcium com- plex base grease, suitable for temperatures from -60°F (-51°C) to + 2500F (+121°C). Geared Limit Switch: Exxon Beacon 325 (no substitute). Limitorque Minimum Lubricant Qualities Required L120-11000 Sheet 3 of 16 Issue 10/94 I [' I T ~ INSTALLATION TIPS CAUTION: Do not attempt to store, install or operate wrong direction, interchange any two leads on your Llmitorque Valve Control without reading the three phase motors or switch the armature instructions and cautionary notes below. leads on D.C. and single phase motors. 6. Use protective stem cover. Check valve stem CAUTION: Do not remove the unit mounting bolts travel and clearance before mounting covers on when the unit is mounted on a rising stem valve rising stem valves. unless the valve is in the fully open position, or 7. Replace all molded plastic conduit and top pro- there is not, nor cannot be, any pressure in the line. tectors (installed for shipping purposes only) with pipe plugs when installation wiring is NOTE: Limit switches are no.t factory set by complete. Limitorque. They must be set when the unit is 8. Set up periodic operating schedule for infre- installed on the valve. quently used valves. 9. Keep the valve stem clean and lubricated. Short Term Storage o. peration if the unit has been dismantled or (less than one year). CAUTION: Shut off incoming power before opening Units are not fully weatherproof until properly in- switch compartment. stalled on the valve or prepared for storage. Units should be stored in a clean, dry, protected D O N warehouse free from excessive vibration and rapid temperature changes. If the units must be stored 1. CAUTION: Do not attempt to work on your outside, they must be stored off the ground, high Limitorque actuator without first shutting off in- enough to prevent their being immersed in water or coming power. buried by snow. 2. Do not attempt to work on your Limitorque actuator while it is mounted on a torque seated Connect the internal heaters (if supplied) or place valve. dessicant i.n the switch compartment. Replace all 3. Do not motor operate the valve without first Set- plastic caps or plugs with pipe plugs and ensure ring or checking the limit switch setting and that all covers are tight. If the unit is mounted on motor rotation direction. avalve and the stem protrudes fromunit, asuitable 4. Do not force the declutch lever into motor stem cover must be provided. operation. LEVER WILL AUTOMATICALLY RETURN TO MOTOR OPERATION WHEN Unit should be stored with the motor and switch MOTOR IS ENERGIZED. compartment horizontal. 5. Do not force the declutch lever into hand opera- tion. If the clutch does not easily engage, rotate FAILURE TO COMPLY WITH THESE RECOM- handwheel slowly while operating the declutch MENDED STORAGE PROCEDURES WILL VOID lever. THE WARRANTY. FOR LONGER TERM STORAGE 6. Do not use a cheater on the handwheel. PLEASE CONSULT LIMITORQUE FOR PRO- 7. Do not use abrasive cloth toclean the contacts CEDURES AND RECOMMENDATIONS. on the limit and torque switches. 8. Do not torque seat 90° operation valves n;3r run them against the stops as this may cause D O: damage to the valve. 9. Do not alternately start/stop the motor to open 1. Mount motors on a horizontal plane, if possible. or close a valve which is too tight for ndrmal -2. Keep the switch compartment clean and dry. operation. 3. Operate the unit by handwheel only, when in- 10, Do not reset torque switch to a setting higher itially setting the limit switches. than the recommended factory maximum. 4. Check all unit wiring to ensure that it coincides 11. Do not attempt to repair gearing in the limit with the applicable wiring diagram. switch. Replace entire gear frame assembly if 5. Carefully check for correct motor rotation direc- necessary. tion. If the motor is driving the valve in the L120-11000 Sheet 4 of 16 Issue 10/94 I I I 'l i ' TORQUE SWITCH i.oo i Balanci n Proced re ~enlng limit switch compartment or working on g U ..e torque switch. If the torque switch has been removed f[om the unit NOTE: If unit has "torqued out", release torque or if a new torque switch is being installed, the buildup by operating the unit manually. torque switch must be rebalanced using the follow- lng procedure: 1. Ensure that the unit is in manual mode and the The torque switch is designed to protect the ac- tuator in open and close directions. The switch was load is removed from the wormshaft spring set at the factory according to information regard- pack. ing necessary torque or thrust output that was pro- 2. Priorto reinstailing the torque switch, note the vided at the time of order. A torque switch calibra- open and close torque switch settings. tion tag was supplied with the unit. 3. Loosen screws (A) and position both pointers (B) at the #1 setting, tighten screw (A). In this CAUTION: A maximum stop setting plate is pro- position the index marks should be aligned. vlded on most units. Do not remove this plate. Do 4. Loosen balancing screws and install the torque not exceed the setting indicated by this limiter plate switch. When properly installed, the base of the without contacting Limitorque. torque switch is flush against the compartment and the hole for the mounting screw is align- ed. Install the mounting screw. Torque Switch Setting now balanced and ready for the pointers to be P rocedU re returned to their original settings. CAUTION: The balancing screws should not be Before adjusting or installing a torque switch, place touched except during the balancing procedure. the L120 unit in manual mode and release the load on the wormshaft spring pack. ~n a loss of torque protection. ~ Should the present switch setting require chang- ing, proceed as follows: MAXIMUM STOP BALANCING 1. For both open or close direction, loosen screw SETTING PLATE SCREWS (A) and move pointer (B) to desired position. A ~ ~ higher number indicates a high torque and/or . thrust output. ~! 2. Tighten screw (A). 3. Operate the valve electrically to seat valve and to ensure tight shut-off. f.t op~ INDEX MARKS I REWS MAXIMUM ST BALANCING SETTING PLATE~ SCREWS . ' ~ Micro-Switch Style Torque Switch INDEX M L120-11000 600 Volt Torque Switch Sheet 5 of 16 Issue 10/94 GEARED LIMIT SWITCH CAUTION; The geared limit switch is not preset at 7. Operate the valve by handwheel to the fully the factory and must be adjusted after the actuator "close" position, reverse direction by one turn has been mounted on its associated equipment. of the handwheel to allow for coast of moving pads. Disconnect all incoming power to the unit prior to 8. Set the other rotors by following steps "1:' opening the limit switch compartment and adjust- through "6:' ing the switch. The rotor segments can be separated and rotated Consult the relevant wiring diagram for limit switch through 90 degrees to give various combinations of contact development. All L120 units are supplied normally open or normally closed contacts for each with 16 contact limit switches -- 4 switches on rotor: · each of 4 rotors. Two rotors are used for end of travel indication. The remaining two rotors may be ad- Proceed as follows: Justed for any intermediate point of travel. 1. Remove nuts (8) and fillet head machine screws (5) (total 2 fasteners on each side of the switch). 2, Complete contact assembly can now be re- Limit Switch Setting Procedure to produce the required combination of contacts. 1. Open compartment cover (~200). 4. Replace contact assembly on back-plate (ensur- 2. Put the actuator into manual operation and use lng that the registers fit correctly) and secure the handwheel to operate the valve in the "open" with machine screw and nuts. direction. While operating the valve, note the direction of the intermediate shaft (B) cor- responding to the rotor or rotors to be set. 3. When the valve is fully open, close it one turn parts. . 4. Push in setting rod (A) and turn one quaderturn. -- The rod'will latch in this depressed position. r~' ' 5. Refer to the applicable wiring diagram for con- tact development. The limit switch contact is ~ ~., ,~ ,m . . closed when the rotor is engaged with the degrees to operate the plunger, turn the in- termediate shaft in the same direction as noted switchs. This rotor is now set correctly. , if the rotor has already tripped, turn inter- ~ ..... mediate shaft (B) in the direction opposite to that noted in "2:' above until the rotor trips. Im- . reedlately reverse direction until the rotor clear- ly trips again. This rotor is now correctly set. If the intermediate position rotor is also to be set at the end of travel position, repeat the set- -ting operation as above. - ......... -' ~ ~ ' setting rod (A) one qua~er turn to the spring PC: ...... ..... intermediate shafts to ensure that they will not ~2 ::2- 8~I~HCONTA~BL~K~SY move. -~ ~1~ ~R~R S~MEN~ ~HO~ CAUTION: Do not operate the valve when the ~ '~4~ ~M~INE'S~.~;',~ ~ · 4: F~T W~HER · - setting rod (A) is in fully depressed position, ~7 ~4~ =~K.W~HER~~ loss of the contact setting will occur and the setting rod will be damaged. ~9 ~, ;R~R SEGMEN~'(~NGI~ L120-110GO Sheet 6 of 16 I~ue 10/94 POSITION INDICATION )/~OCC';~i ' 2. WITH POWER OFF, connect all wires as shown · below except the two on the voltmeter indicator. Connect these two to the test meter. :: !. 1. The local dial position indicator is factory 3. Move the slider of the adjustable resistor to the selected to show valve position but can only be extreme opposite end of the resistor from the adjusted when mounted on the valve. power connection. 2. Disconnect all incoming power and remove 4. Disconnect all incoming power and remove Switch Compartment Cover, (#200). Switch Compartment Cover, (#200). Set screw in 3. Place valve in the fully closed position. small gear which drives the transmitter (poten- 4. Loosen the round head machine screw which tiometer) should already be loose. If it is not, holds the pointer in place, move the pointer to loosen set screw so gear will not drive the the "O" position, and retighten the screw. The transmitter, indicator Is now set. 5. Place the valve in the fully closed position. While valve is moving toward closed, note which NOTE: 'Flip-flop' type indicators are activated by direction the small shaft and gear would be driv- : the end-of-travel rotors of the geared limit ing the wiper arm on the transmitter. switch. This type of indicator will require no fur- 6. When vane is closed, move the wiper arm on ther setting after the geared limit switch has the transmitter to the end of the transmitter coil been adjusted. corresponding to the close position, and tighten set screw on gear. NOTE: For assemblies supplied for remote in- 7. Turn power on. The test meter should now read dication, the Driving Pinion, has been shipped "O" or almost "O". loose in a bag, to protect the potentiometer 8. Place the valve in the full open position. from being damaged by accidental rotation of 9. Move the adjustable resistor slider toward the · the handwheel prior to installation and setting power connected end until the test meter reads on the valve. 10 volts. 10. Turn power off, disconnect the test meter, and Remote connect leads to the voltmeter indicator. '" 11. Turn power on. Indicator should now read full ~""~CAUTION: Typical voltmeter remote indicators fur- open. nished by Limitorque are built to accept a maximum 12. Final adjustment may be necessary. If the in- dicator reads less than full open, carefully move of 10 volts. It is necessary to adjust using a separate test voltmeter with a scale suitable for the max- the adjustable resistor slider ahead being imum incoming control voltage. careful not to exceed the full open position on the dial. If the indicator reads more than "O" when the valve is closed, repeat the setting pro- 1. Mount the adjustable resistor furnished as near as possible to the voltmeter indicator. cedure starting with Step 6. 13. When the indicator properly shows valve posi- tion, lock the adjustable resistor slider in place. 12½ WA'I'r. 50 OHM (BY OTHERS) POTENTIOMETER TYPE VARIABLE RESISTOR REMOTE POSITION INDICATOR MOUNTED IN LIMITOROUE HOUSING 0-10 VOLTS FULL SCALE DEFLECTION I m LIMITORQUE I HOUSING I _ m m I ] [PIlP21P3}· ~ ,..j . I CONTROLVOLTAGE RANGE 110 VOLTS TO 480 VOLTS 175 WA'Fr. 2500 OHM ADJUSTABLE RESISTOR TO BE LOCATED ADJACENT TO REMOTE POSITION INDICATOR FOR VOLTAGE ADJUSTMENT L120-110O0 Sheet 7 of 16 Issue 10/94 NO. QTY. DESCRIPTION PC,. ..... ..: NO. QTY. ""' DESCRIPTI'OI~' '36~ 37 I FLEXLOC NUT · ~1:.~, :.~-1,,'~ .!HOUSING c,~,v~-~<(-~-~;~,.;-.'~3,'~-~, ",,,~38-i~ ~.1.~1' ~MOTOR:PINION'~f-.'.~-~-' 2 1. MOTOR ADAPTER · 39 I KEY :~3,~.," .ai,l~, :,ELECrRICAUCOMPARTMENT.~ .,'40~i* :-%1.~ .'STOP, NUT.:~¢.~~ 4 I · SEAL RETAINER 41 1' WASHER ~-5~ ~NI~: .~WORM'SHAFTr. END CAP-i~.'-.,~';~ ~42:~ ,:!,1~ 6 ' 1*° HSG.'COVER SHIM SET · 46 1 - O-RING 9 .. 1. DECLUTCH LEVER 50. I , HARDWARE KIT -" . ,-'- 11 - I · DECLUTCH CAP 300 I :- TORQUE SWITCH .... · ,,15-."-~ '-.~1~ ~-WORM'-SHAFT,.ASSEMBLY,~:.~ '.-~a05'~ .~l~'~tl tGEAREDi!.'!MIT~SWITOHIIJeII 30 ~-1 .' NIPPLE FLANGE -31',~, ~rl ~ :<MOTOR -..m~.~g,.~,~ra,~:;..',:.{.~.'~.~ * L120-40 Only 32 4" DOWELS ,,35~~ ~,1:~: ~WORM.SHAFT-.GEAR;~,,.-'~-'~--;~ "Not Shown L120-11000 Sheet 8 of 16 Issue 10/94 r r t 't I "' f'r / !1 ""' DISASSEMBLY PROCEDURE ) CAUTION: Do not attempt to perform service on the bolts holding conduit nipple flange (#30). ' t""'T"bimitorque actuator unless all power services have Remove motor, drawing motor leads through een shut off. Minor work, such as replacing geared - from switch compartment. limit switch, torque switch or motor, may be readi- 6. Motor pinion (#38) may be replaced by removing ly performed while the actuator is still on the valve. flex Ioc nut (#40). For more complex work, it is suggested that the ac- 7. Remove worm shaft cap (#5) and dr~w complete tuator be removed from the valve. wormshaft assembly from housing. Note: The wormshaft has been assembled at the factory If the actuator is fitted with a thrust base (#100), it to obtain the correct pre-load on the spring is possibJe to remove the actuator housing while packs. Do not attempt to disassemble further. leaving the bsse on the valve to accept valve thrust. If the worm is worn ordainaged, it is suggested However, it is preferred that the valve be isolated that the complete wormshaft subassembly be from service ~nd, if it is a rising stem, that the valve replaced. be fully open. 8. Remove aleclutch cap (#11). 9. For L-120-10 size, the complete aleclutch To disassemble the L420-10, 20 and 40 units, pro- assembly (#7) may now be drawn from housing. ". ceed as follows: 1. Shut off all power to the unit. For L120-20 and 40 sizes, remove aleclutch in- 2. Remove electrical compartment cover (#200). put pinion (#12) followed by declutch assembly (note: fastening screws are captive in cover). (#7). 3. Disconnect all electrical leads from the torque 10. Remove handwheel and housing cover (#27) and switch (#300) and geared limit switch (#305). En- lift complete drive sleeve subassembly from sure that all leads and terminals are clearly housing. marked to facilitate re-assembly. 4. Remove two screws holding limit switch and one holding torque switch. Remove both items. 5. Remove four bolts holding motor(#31) and three Drive Sleeve & Housing Cover. Disassembly 1. Remove upper bearing (#17), bevel gear (#18), the groove. Continue around the ring until it is declutch spring (#24), and clutch sleeve (#19). free from the groove. 2. Remove lower bearing (#16). 4. Remove wormgear (#21) and lug ring (#20). 3. Spirolox retainer (#22) may now be removed by 5. Handwheel adapter (#26) and Seal (#42) can be inserting small flat blade screwdriver under the removed from housing cover (#27) by removing end of the ring and prying the first layer from retaining ring (#28). i ARTS S:iSf :-!i - --' ",' .... Pc ~r-~_,,,, NO. QTY. DESCRIPTION -16'{-~ ,~1 ~'BALL BEARING .-; ,-' .' ,'."' ,"..~.".~'-;.',' 17 1 BALL BEARING ~18;~..1'.':~'DRIVE SLEEVE BEVEL GEAR · 19 I H.W. CLUTCH SLEEVE %r. ;20:'-~ :":.1 ";'WORM GEAR LUG RING::-:~-".~: ~ ~ ": '-=- ' ' 21 I WORM GEAR '~22.~ :~1 ':' RETAINING RING .'~ ::>',".~-:~'.".~ · 23 I KEY >24~ ;-~1 ' DECLUTCH SPRING ;' ',";.-~?:-'.';~ ~ ' 25 I DRIVE SLEEVE >26"-~ ~':'1 ;. HANDWHEEL ADAFTER '~'~':~ 27 I HOUSING COVER ' ~28~ ;:;1 .:~RETAINING RING: ...... ~.;'-.':'~". 29 I HANDWHEEL ~33~' '-1' '- 'HANDWHEEL COVER PLATE. 34 1° H.W. COVER PLATE GASKET · '42:~ ~-1 ' SEAL KIT ..... ~"~'. ..... ' · "':; "- , 43 I QUAD RING ~'44~, '-':.1 'QUAD RING ',' ".'.""-~'.'-' ' 50 NR HARDWARE · Not shown L120-11000 Sheet 9 of 16 Issue 10/94 I I 'l 'i I " ' f'l I ~ 2. Remove the elastic stop nut (#99) from the rod (#1). Thrust Base Disassembly The torque nut (#95) can now be removed from the bottom of the drive sleeve (#25). C 3. The torque bushing connector (#96) can be removed . '. If thrust base option is present (#100), remove from the torque nut by removing the retaining ring seal retainer (#102) followed by stem nut (#101) (#98). and thrust bearings (~'s 103, 104 and 105). 2. Remove four bolts (~110) and lift thrust base. "~ from main housing. ~ .... 101' I STEM NUT. %102:~ 3~1"~'z :SEAb~RBAIN ER 2~,~V~-';~-:'~'C;~=~: Extended 103 2 NEEDLE BEARING ~1~ :: '(~2'~ 'TH RUST-WAS HER ~=~:"~;~ 105 2 THRUST WASHER Standard &Extended Drive Sleeve Assembly (Ref, dwg, 01-602- 107 2 QUAD RING SEAL 109 1 GREASE FI~ING · -110'~'f'4 7: HEX:HD CAP: SCREW'¢~"~."~:~' Torque Nut Disassembly :......:,v:;. ,:.:; .....,-.-:.:.;--.... The L120 Series actuator can be supplied without F;:~=. Q~.,';:.: ;,2': DESCRIPTION '. the thrust base option for applications requiring torque ~Bk ~;1~ R~AINING only. The torque nut is driven by the drive sleeve lugs ~ 99 .1 ,: ' E~TIC STOP NUT and held in place by the torque bushing connecton ~9~ ~{~ T~E ~S~=W~HER _ '~96'.- ......1 - '.'.; TORQ. BUSHING C~N. ~98~ ¢~1~ R~NINGRING~. Standard Drive Sleeve: ~'95.:- · .'~ ": 1.~'~"< TOR~E NUT:'; ....... To remove the torque nut (~95), remove retaining 12~ ~:~ DRIVE:SEEBE~:~ ring (~183) and drop the torque nut out the bottom of the drive sleeve (~25). plate (#33) and gasket (#34) to provide access to the elastic stop nut (#99). L120-11000 Sheet10 of 16 Issue 10/94 ' i f "tr r ri ~ - STEM NUT REPLACEMENT ' C This section is applicable only to thrust base and locate the bearings in the housing journals. applications. Occasionally the stem nut of the operator Replace the wormshaft cap (#5). may need replacing if used in a threaded stem applica- 7. Install the wormshaft gear (#35) and flex |oc nut tion on rising stem valves. (#37). ' '~' '~~,~:...~iTM ' .., . .. -.. :. ~¢ '~::"-::::. "..: ....' "" ....."' '- · "-.'.-': ::' '..'::.."'4':;_~:Z~::~ .: ,:"..'::b :. Nc~te:' 7"!:"'2~:"': '~.~'~' '~:i: .' :%;'.. ':'~:~':::~"' ~_;~' ~-.'~,i:'.,:.~i:i"".:':..::::..'Z~.. .....g: ;i.': :'--' ..-"'. ':'~-:-T::!:?.'-:.!:r-%'~;!. ,t~.:,~,.,.:'. :.,. ·. :. :-, ..:. "-,-'~."';":-?:, ~. ~-.~i~e.flS~jo~'~:nu('E:~'~y::'b'e':'re~Sed.'a'::;:5:-:.7~-!i2~ -~-r:: ,~:.:,. ............. "--'i~!,,~;i~;F,~ !im!te'd n'amb'.er o.f..t.{.m~s:-It ]~':; ~:or':removing:the'L120--from, the~;;2::~,~ ~!':~,';-~.':.!n.,'J reas:.~embly:.~::~::..?.:;:%'.:'':.' .:".;:. :2',":: ~ !%.moUHting :b.,a.s.e.%..This Will p'.re~ent:~ """' """ ' ' "' "~:"':' "':""; .......' ......""""":~ ;~%!~ Tf~':~ccidehtal start-up during service'c-!:":::~':'-':.'-'!~3~8.Declutch Assembly: ~:.~)'~nit. ~'t:;?':':'.':~'i~i:,i!::::":. ;" "::,.".,-2. ;:- ':.:: ::~:;~:~{.~iSize L-120-10: Install declutch cap (#11) on declutch shaft (#7), ... -,, ensure that the return spring is located correctly in ...... .,, ........................ · .-,-,-; the endcap. Replace declutch lever (#9) on the shaft e~' ~:i:i::,i~'!.:::!7'!"::'=~i'Z ~iniP'g i:~!i.?.':. :2~-!:i'i!:ii~ii ~i~;,~iwith the lever against the stop. While holding the cap !;c';::7::'.:-.-:" :...;~.;:i,.:::';.%:7;..i.-':!:,~:ii::.::':';:: ..':':-.//:',"::~;:%:~% ~!steady rotate the declutch shaft against the spring !'~ P'~ e ' ' ~ tension in the shaft and lever align. ~'' "t"~tiai'-. ..tilth. (Before removifi~ 0'i'dis~i~Sijmblirig:2~ (Insert roll-pin (#10). · ' ~23/oUractuatO~;; in:sure th~itthe'vaive .... ~.~. ..... - .... (#7-2 & #7-3) fit into the groove on the declutch sleeve (#19). Secure declutch cap. Use the following procedure to replace stem nut: ~i,;~:~..:: ~:., :'-'Z j:..!.::':'-- ' ":"'.'i":"':;:'::'. :.' 2. Remove actuator from valve. Note 3. Remove seal retainer (#102)followed by stem ."?~"~!',:.-..v:vhen '.the','deClutCh:~l~v. ef,: nut, bearings and seals. ~~ ~:~]ag~a agair~stthe'd(~810(d~ stop' 4. Check the fit of the new stem nut on the valve stem ~.~ · .~:- t~'r oi58i;atfiSr{'pdSiik )?'..il'i 'd lbiCh':::; ,: i -- ensure that the nut travels freely without binding. ~] '{ii ~,TaCtuatC~i, (#7:i) shodld ~ot 6e ii~ 5. Reassemble the thrust base and remount the actua- '~!:{'clutcli"slSe~e tot on the valve. ~! 6. Remount actuator on thrust base. .gn page.9' 7. Removingtheactuatorfromthevalvewillchangethe limit switch settings. Referto the Geared Limit Switch Size L-120-20 and 40: section of this manual to reset the limit switches. Install declurch cap (#11) on the declutch pinicOn 8. Reconnect power and test for correct functioning. shaft (#12), ensuring that the return spring is cor- rectly located in slots. Install declurch lever (#9) on steady, rotate the pinion shaft (#12) against the (Refer to illustrations on pages 8, 9, and 12) spring tension until the holes in the lever (#9) and 1 .' Install lug ring (#20) onto drive sleeve (#25) followed shaft align. Insert roll pin (#10), 81ide declurch shaft by worm-gear (#21). Ensure that worm-gear lugs (#7) into the housing, ensuring that declutch shaft engage with recesses on lug ring. assembly (#7) fits correctly in the groove in the 2. Install Spirolox retainer (separate layers of retainer handwheel clutch sleeve (#19). sufficiently to begin threading the retainer into the drive sleeve groove. Continue threading until the Install aleclutch cap assembly into housing, finding retainer is firmly located in the groove). the nearest tooth on the internal spur gear which will 3. Now install key (#23) and clutch sleeve (#19). allow the cap to be secured without placing tension 4. Oomplete the assembly, by adding the declutch on the aleclutch actuator (#7-1) (causing it to rub spring (#24), bevel gear (#18), upper bearing (#17), againstthe groove in the handwheel declutch sleeve and lower bearing (#16). (#19)). 5. Replace drive sleeve assembly into main housfng, secure with the housing cover (#27), Ensure that all (Oontinued) seals are in place. 6. Insert wormshaft assembly (#15) into the housing L120-11000 Sheet 11 of 16 Issue 10/94 f 'i "' 9.Install torque and limit switches into switch compart- ment housing. e~ .'~e e · ,' . 10. Install motor pinion (,3e) and elastic stop nut (.40) ' onto motor shaft. M20 10 11. Install motor using the following procedure: :~{'~d."- '~:~::;~{:' Install conduit nipple flange (~30) and seal (~42) onto ~ ~1~ DECE~GH:SH~Y;~ conduit nipple in the flange and secure motor. Fi- .:'-7-1 ::' :~.~-~, 1 .:~':¥,' DECLUTCH ACTUATOR ':.'.-' nally, secure the nipple flange. tZ:~ ~~: DECEUTCH~TGH~(E~'~RI~ 12. Connect all electrical leads in switch compadment ~.-~8 '~ {.~'.~" .1 ::-',~ DECLUTCH RDURN SPRING ,~ and complete assembly by replacing the compa~- ~97~ .~T~ DECL~TGR':~ER.~ ~e~t cover, handwheel adapter, handwheel and :~0''= '."'.'~1 ~ ;~.:' R~bPIN ~:~,~.=.72'-:,~;,.::,~ thrust base if applicable. ~f~ ~1~ DEGE~CR~G~~ '~12-' '.~::' 1' "~:-:., DECLUTCH INPUT PINION ..~'~-;,~;L~ ~42~ .~1~ S~~~ *L12~20/40 ON LY L120-11000 Sheet 12 of 16 Issue 10/94 ELECTRICAL START-UP '~ 1. Check that the actuator has been correctly begins to close -- stop immediately. Incorrect lubricated. This is particularly important if the phase rotation will lead to serious damage if the actuator has been in long-term storage. valve seats. 2. Ensure that the geared limit switch has been 7. Correct the phase rotation by switching any two correctly set per instructions in this manual. of the three power leads forthree-phase power, (see Geared Limit Switch Section). or reversing the armature leads for single-phase 3. If the valve stem is not visible, remove the stem or D.C. power. cover or handwheel cover plate to observe out- 8. The actuator should now operate correctly and put direction of the drive sleeve. will be stopped at the end of travel positions by 4. Engage manual operation and hand crank valve torque or limit switch functions. well away from end of travel positions. 5. Turn on power supply and push button to (Premature stopping .may be caused by incor- "open:' rect limit switch or torque switch settings or 6. Check output rotation -- if phase rotation is line obstructions in the valve.) correct, the valve should begin to open. If valve 9. Replace stem cover or cover plate. TYPICAL WIRING DIAGRAM The wiring diagram below is a representation of a ~ typical application and may not be applicable to your specific actuator. Please refer to the wiring diagram supplied with your unit to confirm the ac- tual equipment supplied. ~ ........ ,_,· " . ...."'-""'-':""~;7": ~ . i ' . _.. . , 'z.'..-.;..'z- :.' ~:::1:::::::~::~:7:;' .-':''""""" ' i i~''':i: .......t .....:,.,-',7,-~"~:-',.~-L'r-' ..... ~ ,", T ,' · , .................. ~,, .' ,,,,:.--m-~ e,,~ ] L 120-11000 Sheet 16 of 16 Issue 10/94 "'T" T' I '! ! '" I' I I .... it""""" '~"" i For further Limitorque -: I:~2600 ~st ~iro[oma Way ' .': ~' Anaheim, ~ 92806 ~:Will~Wbrook, 1~'60521 ' ::.:,:.:~: ~' (708) 887'7.170. "'~;:~:~:~ ~:~:Z(708) 887~8968 :;' :~.' ...':~'~:~ L :; i~l~orque corpo~tlon;..~:L~ .' '.'.'.: ~;G~on, TX 77~0 *:'.' :'..-~.~::~ Limitorque® Limitorque Corporation um|tora. uelnternat~ona~ LlmltorqulofC=n=da, Ltd.- LJmltorqueAutlraJiaLtd. Bone Lane, Newttory 2.S2S Dunwin Drive. UniT, I Division of Control EnZineerinl 5114 Woodall Road ~bh~ RGI4 SEH Endand Hhsbsaul=, Ontario LSL IRg, Canada . (Aust) PTY Ltd. P.O. Box 11318 Phone 44-&35-4&~e~9 Phone (~0S) 820-1013 I 1014 I 1026 II Michellan Cour~ P.O. Box Lynchburg, VA 24506-1318 F~ 44-~.35-36034 Fa~ (~S) 8~0.S1~6 b/swater, Vic~oria 3153. Ausu~lia Telex 851~47214 UMTI~X G Phone &1-3-729-0555 Phone (804) 528-4400 Um~t~nluelna~Ltd. Fax Fax (804) 845-9736 Umitoque/Nipi~nGe=rCo. Ltt E-4SD. ~ Industfal 7 rdnl~ara<ho, F~jlsawl-lhl Plme-II, New DeJhi-110020, Ina'ia Umltorque As|a Pte Ltd. ranapw=-ken, 252 Japan Phone tl-I I.a27-&835 22 Mandai bate Fnone l|-4&&-4S22-S0 Fax ~1-11-683432~ Sinppore. 2572 Fax 81-4~&-4521-83 Telex ~53-31-&2~21 HLID IN Phone 65-3&S-5422 OCopy~lht]994 l~att. diaU.S~L Tdex NGCFU] J47~e& Fax 65-3&5-5418 Bulletin 120-11000 Issue 10/94 Bulletin 401 - 12000 Issue 7/93 , Instruction Maintenance Manuai :; Limitorclue" - ::.. I 1 ' i ! I i Read this'Instruction ManUal carefully and completely be- ., :fore attempting to. :set-up,.operate or troubleshoot -your Urnieorque Modutronic 20 I!. Be aware of electrical hazards " ' ~vithin' it!~e::~-~er~or'and high 'pressure hazards of the · ~,'-qbratingyour!Hodutronic20 !1, ':':~ :::.::.:' ~ ~:'-*': :.'*~:' "~ Copyright 1993, by Limitorque* Corpomti0n All fights reserved. No part of this manual my be reproduced or utilized for information re-sale in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and reuieval system, without written permission from Limitorque* Corporation. Limitorque* Corporation reserves the fight to make changes, without notice, to this document and the products which it describes. Limitorque* Cotlnoratioa shall not be liable for technical or editorial errors or omission made herein; nor for incidental or.. eousequential damages resulting ~'om the furnishing, performance or use of this document. Lirllil[Xl:~' is a registered trademark ofLimitorque Corporatiom T I 'i' I r'l : ~1 Contents Section Page .. Safety Information .................................................................................4 Product Identification ..........................................· ................................4 ; Product Description ............................. :. ...............................................4 " Product Features .............................................................~. ....................4 Operation ...............................................................................................5 Definitions .........................~ ...........................................,..~ .................'... 6 Initial Checkout and Setup .............................................~ .....................7 Ver'~/correct motor rotation (phasing) and OPEN/CLOSE pushbutton operation ............ 7 Three Phase Motor .........................................................................................................................7 Single-phase Motor .......................................................................................................................8 Verify Limit Switch and Torque Switch Settings ........................................................................9 Adjusting the actuator feedback potentiometer ........................, ..................................................9 Initial Connection .......... ~ .....................................................................I I Mod 20 II Presets .................................................................................I I Connecting the Mod 20 II to customer command signal leads ................................................I I Initial settings of the installed Mod 20 II .......................................................................................I I Calibration Procedure ........................................................................13 Troubleshooting ..................................................................................19 Typical Wiring Diagram .....................................................................22 Modutronic 20 II Wiring Diagram ..................................................... 24 ..!~.~.~ Specifications ........................................................................................26 II Read ~his Instruction Hanual carefully and completely before attempting to insU![ or open~te your Hodutronic 20 I.!, Be .. aware of electrical hazards when installing or performing ,, maintenance on your Modutronic, "":. "Product Identification ames~ ~.Ug Is I OprC Indicator Zero, Span, Gain Ca~'bration ' Potentio~:tt: er Indicator Lights On-~me/C)ff-'lime Calibration Potentiometers Figure Product The Modutronic 20 II® is a solid state integrated circuit based controller. It is used Description tooperate electric valve actuators in waste-water, petro-chemicai and other indus- try applications requiring accurate modulation positioning. The standard input consists of a 4-20 mA signal generated by a process controller; the resulting output is used to accmtely and repeatably position a valve actuator through conventional or solid state switching of either single or three phase AC power. Product ui Accuracy and repeatability ofpositioning within 1% of fullscaie for actuator Features stroke times > 30 seconds. O Solid state circuitry for longer life and reliable service. Q 4-20 mA command signal (standard), others are available upon request. Q Can be used to control single or three phase systems. UI Jumper selectable Lock-in-Last or Fail Closed configurations if command signal is losL O 5-parameters available for adjustment allows actuator/application match. O Adjustable ON and OFF motor control timers for use with electro-mechanical / :/"~ contactors or solid state reversers. Q LED indicators display signal, power and control status to simplify calibration Sand monitor performance. / Operation TheM°dulz°nic20II®receivesaninPutsignal'n°rmal!Y4'20mA'fr°mtheextemal process controller. This signal is compared (within the Mod 20 II circuitry) to the present position of the actuator as indicated by the signal from the Feedback Potentiometer attached to the gear train of the actuator. The comparison of these two " signals generates an error signal which dictates the direction and distance the actuator needs to be driven- -' Upon generation of the error signal, the appropriate output trine is enabled and 115 volt control power is directed to the output contactor (this may be an electro- mechanical contactor or a solid state reverser depending upon the application).. As the actuator drives toward the set-point, it enters a region surrounding the set- point where the control function within the Mod 20 II changes from a continuous power application to a pulsing mode. The Mod 20 12I continuously compares the valve's actual position to the desired set-point through its circuitry; motor pulsing is continued until the actuator is accurately positioned at the set-point. The set-point at which the pulsing mode is enabled and spacing/duration of the pulses are all user adjustable on the Mod 20 II. ' Figure 2 - LY with a Modutronic 20 II and associated actuator components ; T 1 i ! I I Definitions Span > ..... Valve Travel ........... ':...:~'~"'7 .... Va~e Tmv~ ...... Ze~ ~ (M~mum Set P~m Signal) Signal) ~gum 3 - Coli~on Commaad Si~d - ~put s~'pm~dcd by:~ m ~si~ ~¢ des~d v~v¢ posi~o~. Posi~on Comment $i~d ~d psi~on Feet~ck Poten~om~ $i~. able o~ ~¢ ~od 20 E D~ S~tch. ~ fiF 13 f~D~$~ ~g c~ G~ ~bg Widow) - coa~ois ~¢ ~t o~ ~e sc~¢ of v~v¢ ~v¢l ~t ~¢ motor ~ ~¢ p~s~g m~¢. ~¢~g G~ d¢~¢s ~¢ ~dow ~dffi). ~ coa~uo~]7 up to ~¢ $~-Point before power is ~¢d o~om ~¢ motor. ~ it approaches ~¢ Oa T~e - Adj~ ~¢ ~¢ ~t ~¢ ele~mec~anicd con~o~ or ~o1~ Off Time - Adj~ ~c ~¢ ~t ~e ele~mec~n~l cont~ or ~ol~ ~t~te ~y.20 ~) ~ffi ~e Pos~n FEE~k ~oten~m~ at ~e Ope~ pOSifioa. T I '/ ! T ] r TI - · Initial Verify correct motor rotation (pha-~ing) and OPEN/ ~:;;~' Checkout and CLOSE pushbutton operation .. Setup It is very important to check for correct motor rotation to insure that serious damage to your valve or other equipme-at does not occur. If the actuator motor rotates in the -' wrong direction, damage cottld occur by over-torquing equipment into a seated position. Prior to being shipped from the factory each actuator is inspected to verify proper option of the Torque and position Limit Switch and to ensure that they function correctly (i.e. closes when the CLOSE pushbutton is depressed, opens with the OPEN pushbutton, etc.). These inspections are made with a properly phased power source connected as described in the actuator manual. To ensure proper operation and to prevent your actuator or other actuated equipment from damage, verify that your ~ "unit is'properly Connected to its power source' ;~ .I...-.. :~..:! ~. .,~:. ": Note:. ' ~dons for. Thr~ph~e, Sin~ph~e and DC moron. Refer to your a~amr~dng di~ br user Spec~c ~dng confirmdon. Three Phase Motor 1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows electrical operation in the valve "safe" area and keeps the OPEN and CLOSED Limit Switches from tripping while testing motor direc- tion). 2. Test motor direction by momentarily pressing the OPEN pushbutton: A) If the actuator moves toward CLOSED, immediately turn all power OFF and reverse the motor leads T1 and T3. Note~ ' Refer to your actuator Wiring diagram for user specific wiring ' :i"' '~'p configuration. / I I 'l ! t m ' I n itial B) If the actuator moves toward OPEN, the motor is wired properly for the Checkout and application. Setup (continued) Single-phase Motor. -. 1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows electrical operation in the valve "safe" area and keeps the · OPEN and CLOSED limit switches from tripping while testing motor direction). 2. Test motor direction by momentarily pressing the OPEN pushbutton: A)If the actuator moves toward CLOSED, immediately turn power OFF and proceed with the following metions that match your application~ 1. Permanent Split Capacitor single phase motors can be connected for opposite rotation by interchanging the leads T 1 and T2 coming from the motor to the terminal strip. 2. Single voltage, capacitor start, induction run, single phase motors interchange leads T2 and T3 coming from the motor to the terminal strip. 3. Dual voltage, capacitor start, induction run, single phase motors can be connected for opposite rotation but the connection depends on whether the motor is operated on low voltage or operated on high voltage. a. Low voltage motors are connected for opposite rotation as shown in the changes between the Standard Rotation configuration and the ' Reverse Rotation configuration in Figure 5. This is accomplished by interchanging the two leads T 1 and T3 coming from the motor with the two leads T6 and T8 also coming from the motor. No other changes are necessary. Standard Rotation, 4 ~'~s~ b-, Reverse Rotatio. n 4 (~v~-Hc/-- Wiring I A c [ Wiring Q~~ J} Te ~ F_.ii~ Te . . TI T4 ' C ~ , T8 10 / L2 ..u C Figure 5 - Standard motor rotat/on and reverse motor rotation · wiring diagrams for dual voltage, copacRor start, induc- tion run, ~ingle phase low voltage motors ~ ;;~ Initial b. High voltage motors are connected for opposite rotation as shown :' Checkout and in the changes between the Standard Rotation configuration and the Reverse Rotation configuration in Figure 6. This is accomplished by ,. Setup interchanging two set of leads. First, interchange the leads T1 and (continued) T8 coming from the motor. Second, interchange leads T3 and T6 at the starting relays R1 and R2..' No other changes are necessary. I I " Standard Flotation 4~m!,r~ !? Fieverse Flotation , .~T~ :? Wiring v. Wiring ~,T~.-$ T'I T4 ! R1 C C O RI g" L1 C C Figure 6 - Standard motor rotation and reverse motor rotation wiling diagrams for dual vo/tage, capacitor start, induction run, single phase high vo/tage motors ~;! B) Test Motor direction again by momentarily pressing the OPEN pushbutton. " If the actuator moves toward OPEN, the motor is wired properly for the application. If not, check your wiring diagram for proper wiring. Verify Limit Switch and Torque Switch Settings Set the OPEN and CLOSE Limit Switch and the Torque Switch according to the instructions in your specific Actuator instruction manual. \ Adjusting the actuator feedback potentiometer Z~Danger -- , Hazardous Voltage. Turn power OFF before calibrating the Feedback Potentiometer. 1. Shut off all power to the actuator. :~.:.,.,,"r""" 2. Using the Handwheel, position the actuator to mid-travel (vaNe at the 50% position). 3. Disconnect the Potentiometer Wiring Harness from where it is plugged in or connected to a Terminal Strip. Initial 4. Using an Ohm Meter verify that the Potentiometer is in mid-travel position. Checkout and The resistance from each End Connection to the Center Connection should~'~ be half of the full resistance of the Potentiometer. Example: 1000 ohm Poten~om- Setup eter should read approximately 500 ohms from one of the End Connections to (continued) the center Connection. " Potentiometer Figure 7- Potent/ometer co~brotion components shown on on LY Position Indicotor 5. If the reading is not correct, proceed to step 6. If the reading is correct proceed to step 7. 6. a. Loosen the small Set Screw that retains the Potentiometer Drive Spur Gear to the Potentiometer Shaft. b. Remove the Spur Gear to allow manual rotation of the Potentiometer Shaft. c. Rotate the Potentiometer Shaft until the correct readings are obtained as described in step 3. d. Reposition the Spur Gear to m-engage with the Gear Train. e. Proceed to step 6. 7. Disconnect the Ohm Meter and re-connect the Potentiometer wiring to original connection. 'T lr ' m~ · I I Initial Connecting the Mod 20 II to customer command ~ 'Connection signalleads Z~Danger " Hazardous Voltage, Turn power OFF before rem'oving the · actuator cover and connecting your command signal. " If the Mod 20 II was factory installed, the only connection required is theuser input command signal leads (normally 4-20mA.). These connections should be made at the terminal strip in accordance with the wiring diagram enclosed with your actuator. [Note: ifyour unit does not have Limitorque supplied pushbuttons, refer to yourig diagram to install a customer supplied pushbutton station]. ; If the you are retro~tting or adding a Mod 20 II to an existing actuator, use the following connections table and your wiring diagram for wire lead designations. I LI20 Non-compact LI20 Compact [ Integral PC. Board Integral RC, Board Description ! (61-825-0337-3) (61-825-0720-3) P I -2 18VokAC · P~r ~u~e P I -3 N ~e 4 -20 ~ dpl ~ I -S } ~20 ~ 17 P I ~ Pod~ 4 -20 ~ sig~ ~ I ~ ; MA ~ 16 ~ P I -S P~ndome~r TB I ~ ~20 · '~ P I ~ Po~n~om~er (~r) ~ I -9 ~2 I P I -7 Potendometer TB I - I 0 PI~ I ISVolcAC (o~ut common) ~2-S P I -9 Close Con~r Ou~ ~2~ P I - I 0 O~n Con~r O~ ~2-7 ~7 Figum 8 - Mod 20 II te~inal conneaions Mod 20 II Initial settings of the installed Med 20 II Presets · I-/~rdous Voltage. Turn power OFF before removing the actuator cover and connecting your command signal. 1. Shut off all power to the actuator to avoid equipment damage or personal injury. 2. Rotate the GAIN P0tentiometer full CCWv'~, then 15 turn CWr"v to reach the midpoint of the Potentiometer. (See Figure 10 for Potentiometer locations). ':., I Note: Each 30 turn Potentiometer will faintly 'click' when rotated to either the maximum or minimum position. I 'I -" ! I ] I Hod 20 II3. Rotate the ZERO Potentiometer fully CCWv~", then 15 tum CW,~'v to reach the midpoint of the Potentiometer. Presets· 4. Rotate the SPAN Potentiometer fully CCW/",, then 15 turn CW~"~ (continued) to reach the midpoint of the Potentiometer. 5. The following initial adjustments to the ON TIME and OFF TIME Potentiom- eters should be made to establish the proper pulsing sequence and duration for~ both electro-mechanical and solid state contactors. . A. Electro-mechanical contactor " 1. Rotate ON TIME and OFF TIME Potenfiometers fully ~CWv''~, then 15 tuna CW,'-',v to the midpoint of the Potentiometer. 2. Rotate both the ON TIME and OFF TIME Poten~ometers the num- ber of times indicated in the figure 9 to obtain the desired operating time. \ \ Off Time { <60 seconds ! i turns CWr~ 30 turns CWr~ 60-120 seconds 13 turns CWr', 30 turns CWr'v ;.120: or > :seconds i*!17 turns cwr', 25 turns CWr~ Figure 9 - ON/OFF potentiometer turns for desired operating t/me B. Solid state feversets 1. Potate ON TIME and OFF TIME Potenti0meters fully CCW('~. 2. Rotate ON TIME Potentiometer 6 rams CWf',v. 3. Rotate OFF TIME Potentiometer 8 turns CW,""v. 4. This will provide a .04 second ON pulse and a .5 second OFF pulse. A. Rotating the ON TIME Potentlometer CVVr-~ will increase the ON tim~ ..... B, Rotating the OFF TIME Potentiometer CWr~ will increase the OFF time, · . !, . C, Adjusting one control (ON or OFF TIME Potentiometer) will affect the adjustment of the other control (ON or OFF Time Potentiometer). :':2. :'::.:-,:-.....-, .:.: . i, .~ ',. ~:':'-" ::;: Note: - Electro:mechanical Starters should not exceed 100 total starts per - Solid State Reversers should not exceed 600 total starts per houn i Calibration Procedure /~Danger ' while calibrating the Mod 20 II with the Actuator Control 'Compartment open and power 0N, ': :.' , :.: The purpose of performing the calibration procedure is to achieve the maximum accuracy obtainable for each particular actuator application while providing stable operation. The actuator gear ratio and many other factors determine the optimum calibration settings. Four DIP Switches mounted On the Mod 20 H, as well as the ZERO, SPAN, GAIN, ON TIME and OFF TIMES are used to obtain the proper settings for your application. This procedure will proceed from the most accurate settings to the least accurate settings until unit stability is achieved. Figure I0 - Calibration adjustments for the Mod 20 II 1. Turn all power to the actuator OFF. 2. Verify that the procedures for the Initial Checkout and Setup (page 6-9), Initial Connection (page 10) and Mod 20 II Presets (pages 10-11) have been properly . completed. 3. To simulate a command signal, connect the mA Calibrator to the Command Input Leads on the Mod 20 IL These terminations are typically connected to :"' 'r'T' the actuator Interconnect Board or if the Mod 20 H is panel mounted, on the '~,:._., Rear Terminal Strip of the panel mount. In either case, these leads are labeled on your wiring diagram and will lead to connections 3 (P l-3[-]) and 4 (Pl-4[+]) on the Mod 20 II. I $ ! [ T il Calibration Procedure - (continued) : ~6 ~r--"--n== mA CAUIRATOR ] or -" '~" . Figure I I -mA Calibrator typically connects to an Interconnect Board Terminal Strip or Terminal Strips located in the rear of a panel mounted Mod 20 II 4. Set the Mod 20 II DIP Switch #3 to the ON position and DIP switch #s 1, 2 and 4 to the OFF position. This will set the error margin (DEADBAND) to 1% accuracy. Zero ~ Figure 12 - Mad 20 II board component Iocot/ons T i '/ ! [ I ,~ Calibration Procedure (continued) · .~ _~ Off Off Off On ~ 1,5 Off Off On On + 2.S Off On Off Off ~4~ ~ ~ · ~ On ~ 6.0 On ~ ~ ~ ~ 7.0 On ~ On ~ · 7~ On ~ ~ ~ · 8~ On On ~ ~ ~ 9.0 ~ ~ ~ ~ ~ 9~ On On On ~ ~ I0.0 On On On On Figure 13 - DIP Switch sett/ng levels of accuracy chart H=~rdous Voltage in Control Compartment, Exercise caution while calibrating the Mod 20 II with the Actuator Control Compartment. Open and power ON. 5. Set the mA Calibrator for the minimum Signal level (normally 4 mA). The INPUT ACTIVE LED on the Mod 20 II should be illuminated. If not, reverse · , the polarity of the rnA calibrator connections. 6. If the Actuator is equipped with an AUTO/MANUAL or LOCAL/REMOTE selector switch, turn the selector to the AUTO or REMOTE position. 7. Apply power to the Actuator and the Mod 20 II. The POWER ON LED on the Mod 20 II should be illuminate& 8. The Actuator may nm in either direction and then stop; A. If the unit stops, proceed to step 9. B. fitfie unit hunts back and forth, decrease the DEADBAND accuracy by ~hang- !~.? ing.the DIP Switch setting (refer to figure 13). Continue to step 9. C. If the unit rims all the way to one end of travel and stops, the Potentiom- eter Leads are probably wired backwards; reverse the Feedback I1 I I 'l ! I I Calibration Potentiometer's polarity by reversing the end leads at the Terminal Procedure st por on the Interconnect Board (if your application uses the Compact Integral Interconnect Board, the Plug-in Harness from the Pot to the.. (continued) /nterco.n t Bo.ra be rotated° to rev rs the pol ity). 9. Adjust the ZERO point This step eah'brates the minimum or zero set-point to correspond to the end-off travel of the Actuator and of the Feedback Potentiometer. '- Rotate the ZERO control slowly in the CWr'~ direction. This will cause the Actuator to be driven slowly towards the minimum control position (nor- really CLOSED). Continue rotating the ZERO control CWr~ until the mini- mum (CLOSED) Position Limit Switch trips and the motor stops. The CLOSE LED should illuminate ..each time the Motor operates. 10. Adjust the control SPAN ThiS Step calibrates the total SPAN of the control function and sets the maxi- mum setting to correspond to the end-of:travel of the Actuator and of the Feedback Potentiometer. A.Set the mA Calibrator to the maximum command signal (nor- mally 20 mA). B. The unit may: 1. Run toward the maximum position and stop short of the Position Limit Switch trip point. or 2. Remain in position. C. Rotate the SPAN Potentiometer slowly CWr"~ This will cause the Actuator to move slowly toward the maximum (normally OPEN) position. Continue rotating the SPAN control CWr~ until the maximum (OPEN) Position Limit Switch trips and the motor stops. The OPEN LED should illuminate each time the Motor operates. 11. ARer initially setting the ZERO and SPAN setting, use the mA Calibrator to set the Command Signal back to the minimum setting (usually 4 mA); allow the actuator to run until it stops. Now free tune the ZERO setting for the position where the Limit Switch just trips. 12. Use the mA Calibrator to set the Command Signal back'to the maximum setting (usually 20 mA); allow the actuator to run until it stops. Now free, tune the SPAN setting for the position where the Limit Switch just trips. ~ ,)-: '.:'....:~.::-':. · :. ' ': ..- ' ....'Note; '".' ' If hunting continues during the calibration. procedure, it may be . necessary to temporarily decrease the GAIN setting or increase the DEADBAND setting to ~et abe ZERO and SPAN settings calibrated, /.,, Calibration 13. Adjust the ON TIME (optional) · .. Procedure This step adjusts the period of time the Motor is'energized in the pulsing mode when it is approaching the final set-point position. · Note: · l"The ON TIME must be adjusted prior to adjusting the OFF TIME Adjusting the ON TIME a~ter adjusting the OFF .TIM I~ 'will require repeating the OFF TIME adjustment_ ' The duration of the ON T[M~ pulse to the Coatactor/Solid State Reverser is increased by rotating the ON E Potentiometer C'~-,v. 14. Adjust the OFF TIM3~ (optional) .... ~ ..... Tl~s step adjusts the pe~od ofti~e the Motor is de-energized in the pulsing mode when it ~s approacl~g the final set-point position. T~s ca~ also be described as the interval between ON T[M~ pulses. The duration of the OFF ~ pulse to the Contactor/Solid State Reverser incre~ed by rotating the OFF ~ Potendometer 15. Adjust the GAIN Tl~s step calibrates the width of the pulsing window arotmd the set-point. This control works in conjunction with the four DIP Switches located on the Mod 20 II circuit board to determine the final accuracy of the unit in regard to set point position. The wider the pulsing window, the greater distance from the set- point the unit enters the pulsing mode. It is desirable to minimize the pulsing window without causing the Actuator to hunt (oscillate uncontrollably' around the set-point). A. For the initial ealibration, ensure that DIP Switch 3 is ON and Dip Switche.s #s 1, 2 and 4 are OFF. This will provide 1% DEADBAND. · Note: If no DIP Switch i~; set to the ON position, the Actuator will not B. Make sure the GAIN Pot is at the midpoint, then rotate the GAIN Potenti- ometer one turn CW?,v.. , C. Start with the mA Calibrator at 4 mA, then make a 5 mA change in the output of the mA Calibrator to provide a significant change of position; now watch the action of the actuator. e,' '~'7 D. 1. If the actuator hunts upon reaching the new set-point, reduce the i2,.,~. GAIN control by mining in the CCW(". direction until the hunting stops and proceed to step F. 2. If the unit continues to hunt after the GAIN control adjustment proceed to step E. Ill I ' I · T I Calibration E. Rotate the GAIN control fully CCWv"'~ and then 15 turns CWr'-,v; adjust Procedure the DEADBAND to a less accurate setting and repeat the GAIN setting procedure starting with step A. For example, if DIP Switch 3 is ON and (continued)' DIP Switches 1, 2 and 4 are OFF the DEADBAND setting is at 1% accu- racy; change the DIP Switch setting to 1-1/2% accuracy and repeat the ' " procedures 13A through 13E until the correct DIP Switch and GAIN. con- trol eliminates actuator hunting. See figure 13 for DIP Switch accuracy setting chart. F.Rotate the GAIN control an extra 1/2 turn CCW("~ to eliminate the possi- bility of future .actuator hunting. 16. Set desired FAIL TO mode A.If LOCK_iN_LAST_pOSITiON i~ desired When loss of input signal occurs, install a jumper at JP1 to connect Pin 1 and 2. B.IfFAIL-TO-4mA-POSITION is desired when loss of input signal oc- curs, install a jmper at IP 1 to connect Pin 2 and 3. Be sure to use one of the two jumper :selections discussed above, failure to jumper.JP I will cause intermittent results, .- :' ~ JP1; ' ' ~ JP1 - 123 123 Figum 14 - JP I DIP Swath po~ons i 17, Yo~ Mod 20 ~ should now ~ pm~rly ~bmted, .--, Troubleshooting Z~/Varning · .. Be: aware 'of electrical hazards when t~ouble-. " shooting or calibrating your Hodutronic 20 !l. Symptom Possible Cause Corrective Action Unit will not operate 1. No power to unit. la. Verify Power Supply electrically in AUTO/ is electrically correct MANUAL. and present at actuaDr.. lb. Verify Power Leads are connected in ,, accordance with the applicable wiring 1 e. Inspect for Blown Fuse, tripped Circuit Breaker overload or OPEN Disconnect Switch. 2. No power to Mod 20 2. Verify incoming 18 lI board. VAC between tenni- nals P 1 - 1 and P 1-2 on Mod 20 II board. 3. Bad Mod 20 II board. 3. Check board for burnt or broken compo- nents. Bypass Mod 20 II board using Push- buttons to verify proper operation. See your specific wiring diagram for bypassing '- Mod 20 II board. 4. Wiring problems. 4. (LYs with internal Mod 20 II board) check push-on terminal between the Integral P.C. Board and the Micro Switches. Cheek for bad Micro Switches on SW Station. 5. Command Signal 5. (L120 Interconnect Leads reversed. P.C. Board) Check that the' Command Signal Leads are wired to terminal TB 16(+) and TB 17(-).m I · · T T i Troubleshooting Symptom Possible Cause Corrective Action (continued) 6. 1oo .6. tions on the Reversing Starter. 7. Bad Potenfiometer/ 7. Check the Pot with Cable. an ohm meter. Un- plug the Pot from the Integral P.C. Board - and take a meter reading between pins 7-1 and 7-2 or 7-2 and 7-3, the meter should have a steady reading. If the meter reading goes to zero or jumps around, verify that Pot is centered. Replace Pot if needed. Check for Cables that may have been pinched be- tween the Housing Cover or Integral Assembly. C~'~ 8. Thermal overloads 8. Measure continuity in have tripped. the circuit. If you have an open circuit, wait for the motor to cool then try to operate actuator. You may need to reduce the number of starts per hour. Unit nms in one direction 9. Shorted output. 9. Verify proper only. MANUAL operation, Using meter, verify proper com- mand signal, verify. all calibrations have been completed properly. If you still have difficulty calibrating the Mod : 20 II after verifying the above settings, .. your board most likely needs replace- ment. .(Continued) ,% TroubleshootingSymptom Possible Cause Corrective Action · (continued)No LOCK-IN-LAST- 10. Missing JP1 Jumper.10. Locate JP1 Jumper POSITION. on the Mod 20 H board and verify connections. Unit will not follow 11. Bad Potentiometer 11. Check Pot as dis- signal. or Poten~ometer is cussed in item #7. If not centered. Pot is OK, place the actuator at 50% and ' check the resistance between terminals 7-1 and 7-2 or 7-2 and 7-3 with an ohm meter. See "Adjust- ing the actuator feedback potentiom- eter" procedure on page 9. Input signal does not 12. Mod 20 II not cali- 12. See pages 13-18 to result in full travel of thebinted correctly. review the calibmtion valve. procedure for the Mod 20 II. ?,' 13. ZERO and SPAN 13. Recalibrate according ..~ adjustments. to procedure on page 16. Large input signal varia- 14. Improper analog 14. Check for proper tions results in little or noInput Signal value. Input Signal value. actuator movement. 15. Limit Switch. 15. Check for proper setting. (see appropri- ate actuator manual for setting the Limit Switches). 16. DEADBAND adjust- 16. Check the DIP ments. Switch accuracy adjustments shown in Figure 13. 17. ZERO and SPAN 17. Reealibrate according adjustments. to procedure on page 16. m I I ' i I I I Typical Wiring Three-phase package: Diagram Thewiringdiagrambe]~wisareprese~tati~n~fatypica~app~icati~nandmayn~tbeapp~icab~t~y~u~speci~cac~at~r. Please refer to the wiring diagram supplied with your unit to confirm the actual equipment supplied. I · u u )> m . J4'J,f 'D "' '' PLUG HARNESS NUMBER Refer to certified data for construction purposes. 16-480-0977-3 ! t"t'PI~I· ,~ ~ :: ....-"'1 · FFFI'IIII II..LLL" ~] "'-~' · ]i ~.: ...:. . :.. :..-, . .' II SW STAT {4) · "----~ ~ · ,, · "',::"'; "'<'>':,;";' ~: : .':~'~ i:- ~ - ' " : ~ ,.-~T , ;: ~' ,'T}-'. T .s-.~...,.;...-.... - "/,&,,,.. - .~e;', LIe _~-o-I1~ ,--e, I PLUG-- ' "' ' ' TERMINAL n,,.a R , , ~. c~ TERMINAL ELBCTRICAL COMPARTMENT ~"~"'~~""';""""~~m/~Sl~~".'-.'. '~o-o,.,.-. i' O · 4 NOTES '- __s -- -- --em · -me e I.--- Opeco, t~-t · ,- -' - -,-- ~.~o,,....= ~ ' ' ~ 4. Roerslm..llk2anbesetat~tvel~sitionMIOPg~LMICLOSED~ ~kMJAL.4HAND).-NJT~ ,_.s _-- _- ~ ~ __---.c,,=,~,,,~ ,kl T I m ! I I i Modutronic 20 I! Wiring Diagram 7.1&K R20 R21 30.1K · R22 ~7 CR5 2.2M 1N4454 CR3 1N4454 .22/25 · )1 ' C13 ,1 :2 "i~ I TT E,~ ,. . ~,= iiii : ~ , ~M 10K . . ~ INPIJT ~ ~ R9 +1 T0K -15~ P1-5 1K · 47~ -1~ PI~ I ~ · 7~K ~K R15 5.1K ~ '47~ CR17 1N4002 P1-2 I I ,.~ C8 ~ C10 << ' t-I'Ii CR18 ~ 200r~ R58 ~ - U~ ot5V LM79158T-15 LED3 ~ I.U4P4700 · FI T i ' .1 ! I : Refer to certified data f;~r .. t/~ constructjoB purposes; ':' I 5-495-0174-4 ".~, ..../ t t · m T T i Specifications Modutronic 20 II specifications ' Derived from actuator supply Power requirements Board power 18VAC or 24VDC (+ 10%). 3VA Accuracy Within +!% (>30'second stroke) Temperature -40°C to +85°C (operating) M~ximum direct output loading Motor current - 4.5 A Inrush, 3 A Holdin~ Deadband Adjust2ble between 1% and 10% Linearit,/ 1% T ~ ' Si f T 11 """" ' For further L/m/torque serv/ce ass/stance call: Umitorque Corporation 2S00 East Miroloma Way Fhone (714) 630-7800 Fax (7~4) e4s Midway Dr~e - %Mgowbrook,!LGOS21 7615 Boeing Drive Greeaboro, NC 2740~-8)47 Fax (~)-60S-S3m · - UmltoqueCe, e~raden.' · ': Fz, rC/J3) 690-!2/7 . Limi ue' Umitorque Corporation Undeer~k&..,,dend ~dCanada, L.~. ~Aum.aaaUd. S114 Woodall Road hdaN~ GI4SEH England ~.-.;-,.4kC)mttoLSL IRg. Camda P.O. BOX 11318 rkm4443S4SgW. Fax44-a3S-3&034 phoae(s0s)e2~10nlm:4/mu I:MaeaeC~r~P.O. eex39e Lynchbur~VA 2450&-1318 TekacmgI'847214UMTRKG Fam(gQS)82O-SON ' Be/swamr, V'tcmrk31S3, Australk Fax (804) 845-9736 7 ra~h~ Re,a,~d, E4SZ20kak bdmm~ A~ Uneeoqm Aria P~ LaL .: ~: Phone 8?~z,~za~-2250, Fax 81-466-4&-2183 Phone 91-114276835, Fag ~1-11-~19329 $kqpp(xL 2572 OCoF/dpz 1993 Printed in U.S~, TdexNG(3:UJJ479N TeimcgS3-31-&2921HLIDIN Phone&S-3&S-S422, FaxL~-3&S-MI8 Bulletin 40 i- 12000 .* Issue 7-93 .'; ..... .. ... .~ ('7 B320 SERIES~ ~' IN STRU CTI O N MANUAL A Product of Limitorque Corporation B320 is a registered trademark of Limitorque Corporation LIMITORQUE B320 SERIES INSTRUCTION AND MAINTENANCE MANUAL Your Limitorque Valve Control... The B320 bevel gear operator is the result of many years and suggestions to enable you to become familiar with of product development and improvement. This booklet the units. has been prepared to help you obtain the most benefit . and use from the equipment. I~LEASE -- before. you do anything. be sure to read through this booklet at least once and then keep it handy This booklet contains the instructions for the installation for ready reference. and maintenance of these units plus some helpful ideas Where t0 Find Information: INSTALLATION TIPS 3 INSTALLATION PROCEDURES 3 LUBRICATION DATA 2 ..- UNIT WEIGHTS 2 ',~ DISASSEMBLY INSTRUCTIONS & PARTS DRAWINGS 4-8 To obtain further information or to order parts for your Limitorque valve operator contact your local representative or write to:-- Limitorque Corporation Note: All inquiries or orders must be accompanied by 5114 Woodall Rd. the following information, which can be obtained from P.O. Box 11318 the unit nameplate: Lynchburg, Va. 24506 Attn. Manager Parts Dept. Unit size &type (804) 528-4400 Telex 82-9448 Serial number Fax: 804-845-9736 Limitorque Corp. order number. 320-11000 Sheet 1 of 8 ]:ssue 6/95 L U B R I C A T I O N Manufacturer Type Temp. Range Limitorque B320 bevel gear operators utilize a totally Century Oils CL2X -63°F +203°F ,' sealed gear case, factory lubricated with grease. Approved alternate lubricants No seal can remain absolutely tight at all times, therefore, Esso Beacon EP2 -22°F +257°F it is not unusual to experience a small amount of weeping Shell Alvania EP1 +5~F +194"F around the shaft seals -- particularly during periods of AMOUNT OF LUBRICANT: long storage. Lbs. Kgs, Small amounts of lubricant can be cleaned before start- Unit wlSGA Unit w/SGA up. Once the equipment is in regular use, this phenomenon should disappear. B320-05 0.5 N/A 0.25 N/A B320-10 0.7 1.2 0.3 0.5 - ~. Lubrication Inspection: . It is recommended that all Limitorque operators be B320-30 1.2' 1.7 0.6 0.8' inspected for correct lubrication prior to operating -- B320-40 1.2 1.7 0.6 0.8 particularly following a period of long storage. B320-50 2.2 2.7 1.0 1.2 B320 units are factory lubricated "for life". Under normal B320-.60 2.2 2.7 1.0 1.2 usage and environmental conditions no topping up nor replacement of the grease should be necessary. We B320-70 4.0 4.5 1.8 2.0 suggest, however, that during an overhaul program, the operators are checked for leakage. B320-80 4.0 4.5 1.8 2.0 B320-90 4.2 6.7 1.9 3.1 Each application has its own effect on the gear operator and the frequency of these inspections should be B320-100 4.5 7.0 2.0 3.2 patterned for specific applications based on operating experience. Unit Weights APPROXIMATE UNIT WEIGHTS Lbs. Kgs. Unit w/SGA Unit wlSGA B320-05 24 N/A 11 N/A B320-10 45 75 21 34 B320-20 51 80 23 36 B320-30 57 86 26 39 B320-40 68 97 31 44 B320-50 143 198 65 90 B320-60 154 209 70 95 B320-70 254 309 115 140 B320-80 418 474 190 215 B320-90 745 875 339 398 B320-100 1000 1130 455 514 Above weights are approximate and exclusive of any 320-11000 packing. Sheet 2 of 8 Zssue sgs T i '/! I ! t INSTALLATION TIPS DO' DO NOT ATTEMPT TO STORE, INSTALL OR OPERATE ' YOUR LIMITOROUE VALVE OPERATOR WITHOUT READING THE INSTRUCTIONS INCLUDED IN THIS 1) Set up a periodic operating schedule on infrequently BOOKLET. used valves. 2) Ensure that limit and/or torque switches on any CAUTION.m actuator fitted to the bevel gear operator are correctly Do not attempt to install or remove a B320 bevel gear and'appropriately adjusted. operator unless there is no possibility of any pressure -D 0 N 0 T: Short Term Storage DO NOT attempt to remove the bevel gear unit from a valve on a pressurized line. (Less than one year) to the bevel gear operator without first checking the limit Operators should be stored in a clean. dry. protected switch setting and correct motor rotation. warehouse and should be stored on wooden skids to 3) DO NOT use a cheater on the handwheel. protect the machined mounting flange. If actuators must be stored outside, they must be covered in polyethylene protection with silica gel crystals to absorb moisture. Input shafts should be rotated every three months to mix the lubricant. FAILURE TO COMPLY WITH THESE STORAGE PROCEDURES WILL VOID THE WARRANTY. INSTALLATION PROCEDURES General Instructions: This series of gear operators has been designed to transmit rotary power as well as linear force. A) INSTALLATION WHEN UNIT SUPPLIED WITH A be taken to ensure that the 'o' ring seal located in the THREADED STEM NUT: inside of the ring is not damaged. If Limitorque supplies the unit with a threaded stem ii) Remove entire thrust nut assembly. This assembly nut. installation is achieved by positioning the unit consists of a bronze drive nut and two needle r,oller above the valve stem and rotating the unit several b~arings with washers. turns until positive engagement between the valve iii) Remove bearings and washers and ensure they stem and operator stem nut occurs. Rotation of the are placed in a clean and dry area until re-assembly. handwheel in the proper direction will lower the unit iv) Thread the drive nut to suit the valve stem. Care onto the valve until contac~ has been made with the should be taken that the clamping devices used _valve flange. Bolt operator securely. during machining do not damage surfaces of the stem B) INSTALLATION WHEN UNIT IS SUPPLIED WITH nut. BLANK STEM NUT: v) Re-assemble the unit after stem nut threading. In the event the operator is supplied for customer stem Make certain no dirt or foreign material enters the unit. nut threading, the following procedure must be vi) Grease the thrust base assembly through grease followed: fitting using the specified lubricant. i) Remove thrust dng from base of operator. Care must viQ Mount operator on valve as described above. 320.11000 Sheet 3 of 8 Issue 6/95 DISASSEMBLY INSTRUCTIONS COMMON PARTS LIST PC. No special tools are required for assembly/disassembly NO. QTY DESCRIPTION /" of the B320 series of bevel gear operators, ~ 1 HOUSING 2 1 BASE 3 I BEVEL WHEEL This manual contains complete cross sectional drawings 4 1 DRIVE NUT or all models which will aid in this task. 5 1 THRUST RING 6 2 NEEDee BEARING Do not perform any work on the unit unless the valve 7 4 THRUST WASHER iS in the full open position. During assembly, all s N~ sAu, 9 1 'O' RING components which are removed should be cleaned and ~o 1 'o" RING placed in an area free of dirt. water or other foreign ~ 1 'o" RING materials. ~2 NR WASHER 13 AIR HEX. SET SCREW Caution should be exercised in the removal of the bevel ~4 I GREASE NIPPLE gear load bearings (8) which are a series of hardened ~s I PLAIN WASHER 16 I CSK. Sk"T. SET SCREW ground balls. The quantity of balls are as follows: ~7 1 NAMEPLATE 18 2 SCREW B320-10 42 ~9 1 GREASE NIPPLE CAP 'B320-20 42 ~o 1 ENDCOVER · 21 1 BEVEL PINION B320-30 57 2,~ 1 'O' RING B320'40 57 ~S NR SH~M B320-50 53 ~s 1 KEY B320-60 53 =7 4 WASHER B320-70 74 2s 4 SCREW 29 1 CIRCLIP B320-80 80 so 1 NPI' PLUG B320-90 66 so I TRANSIT PLUG B320-1 O0 66 60 1 STEM TUBE B320-05 to B320-80 (NO SPUR GEAR ATTACHMENT). -- 1) Remove thrust ring (5) and pull out nut (4) and 6) Reassembly is accomplished by reversing steps 1 - bearings (6) & (7). 5. It is suggested that all seals are replaced during 2) Remove endcover (20), reassembly. 3) Slide out bevel pinion shaft/bearing sub assembly Please note the number and position of any shims. (21), (22), & (23) together with shims (25). Gasket compound is to be used on all metal/metal 4) Remove housing (1) from base (2). faces. PC. 5) Remove bevel gear (3) and ball bearings (8). NO. QTY DESCRIPTION 22 T SPACER B 320-05 T O B 320-40 .,~0, ,, ~ .~ 22 2 SPACER 8320-10, 20 23 2 BALL BEARING B320-30, 40 22 2 SPACER - 320-11000 Sheet 4 of 8 Issue 6/95 Spur Gear Attachments: ~ B320-10 TO B320-40 (WITH 3:1 SGA). 1) Remove cover (31) followed by input pinion (37), idler PARTS LIST (38) and output gear (40). Pc. 2) Remove snap ring (29). The spur gear housing (30) NO. OTY DESCRIPTION may now be removed. 26A 1 KEY 29 I CIRCLIP 3) Continue disassembly by following steps 1 - 5 for main 30 1 SPUR GEAR HOUSING 31 1 SPUR GEAR COVER gearbox. I 32 5 BUSH i 34 4 HEX. HD. SCREW : 35 4 WASHER --.'.':*.'ii 36 1 CQRE~ PLUG ~ , 37 I INPUT SHAFT & PINION 38 I IOLER t 39 I KEY 40 1 OUTPUT GEAR ,, B320-50 TO B320-80 (WITH 6:1 & 10:1 SGA) '.~ 1) Remove endcover (44) followed by input pinion (37) PARTS LIST and one bearing (45). Pc. 2) Remove spur gear cover (3'1) followed by idler shaft NO. QTY DESCRIPTION 21A I BEVEL PINIONISGA sub-assembly (48) and final gear (40). 2SA 2 KEY 3) Remove spur gear housing (30) and continue 3o i SPUR GEARHOUSING 31 1 SPUR GEAR COVER disassembly of main gearbox by following steps 1 - 32 1 BUSH 5 above. 32A 1 BUSH 33 2 DOWEL ~\\\,~~\\\\\\\\.,,,,~ ~ 34 8 HEX. HD. SCREW 35 12 WASHER 36 2 CORE PLUG 37 I INPUT SHAFT & PINION ~ ~~~//~, 39 I KEY 40 I FINAL GEAR 44 I ENDCOVER 45 2 BALL BEARING *\ 46 1 O RING ' , 47 4 HEX. HD. SCREN 48 I GEAR SUB ASSEMBLY .................. 53 8 SK*T. HD. CAP SCREW 320-11 Sheet 7 of 8 Zssue 6/95 t t ' st i I ~ For further Limitorque service assistance ca!l: Limltorque Corporation 2600 East Mirolorna Way Annhelm, CA 92806 Phone (714) 630-7800 Fax (714)630-1691 Limitorque Corporation 8501 W 191 St. Bldg, 5 Mokena, IL 60448 Phone (708) 720-0017 Fax (708) 720-9468 Limltorque Corporation 7615 Boeing Drive Greensboro, NC 27409-8347 Phone (910) 668-087.1 Fax (910) 605-5310 Limltorque Corporation 8901 Jameel Road Suite 180 Houston, TX 77040 Phone (713) 690-1960 Fax (713) 690-1277 · This manual contains information that is correct to the best of Limitorque's knowledge. It is intended to be a guide and should not be considered as a sole source of technical instruction, replacing good technical judgment, since all possible situations cannot be anticipated. If there is any doubt as to exact installation, configuration, and/or use, call Limitorque Corporation, at (804) 528-4400. _ Limitorque® Limitorque Corporation Llmllorque International Limiterque India, Ltd. Llmltofque Austrnlia Ltd. 5114 Woodall Road Bone [jne, Newbu~/ 302/90 Nehru Place Dialsion of Control Engineering Berkshire, RG14 5EH England Mansaroyar (AusL) PTY Ltd. P.O. Box 11318 Phone 44-1-635-46999 New Delhi 110019, India 17 Scoresby Road Lynchburg, VA 24506-1318 Fax 44-1-635,36034 Phone 91-11-B43-1748/643-2749 Bayswater, Victoria 3t53, Australia Phone (804) 528-4400 Telex 851-847214 LI!vlTRK G Fax 91-11-683-9329 Phone 613-9729-0556 Fix 613-9129-8225 Fax (804) 845-9736 Llmltorque/Nippon Gear Co. Ltd. Llmltoque Ado PIe Ud. Tennoz Central Tower, 2-2-4, 75 Buldt Timah Road Higashi-Shlnagawa, Shinagawa-Ku t05-01/02 Boon Sisw Building ""- Tokyo 140, Japan Singapore 229833 Phone 81-3-5460-7516 Phone 65-332-9100 {} Copyright 1995 Printed in U.S.A. F~x 81-3-5460-8396 Fu 65-332-9112 Bulletin 320-11000 Issue 6/95 T I ' i I [ Lirnitorclue Certified Data Sheet Customer Name: CLOW CORPORATION . Customer P,O, Number: 403162 .. ITEM NUMBER .01 '~ .... Type and Size L120-20 Enclosure Type WP A C Unit RPM 48 "' T Heater VolUWatts 120/20 U MDPI Supplied Supplied A T ' Pot Supplied Supplied O Handwheel Diameter R · .. Gear Box Type/Ratio B320-20/3:1 D Gear Box Position N/A A T Gear BoX SGA N/A A Outline Drawing 03-613-0154-1 · . . Wiring Diagram 17-500-0002-3 M Motor Size O Motor Voltage 230 T O Motor Phase 3PH/6OHZ R Motor Horsepower 1.0 D Motor RPM 1700 A Motor LRA 35.6 T A Motor FLA 5.0 Motor Heater: 120/10 P/N TS000943 TAGGING Ta.q.ainc and Information: (1) PRINT ENCLOSED [] - HOLD - Production is being held pending your [] - RELEASE - Please advise us at once should you approval. Please return one copy of each require any changes or corrections, as we are drawing and this sheet with your approval or proceeding to manufacture in accordance with the changes. above information. L'!MITORQUE CORPORA TION Certification Sheet' P.O. Box 11318, Lynchburg Va 24506 Drawing Number Name: RMD/BT No. I By: ~ Date: 278623 Date: ¼~'~ ?. 4r t99~ Revision Sheet f of I t e xea~m, i~"VISlON~J 1 BY DATE (4)5/8-11 X I.OZ ~.. 5.5~ B.C. mT ~ZE ~ M ~ m ~ m p~ ~ mT S~ZE ~ ~ ~ m ~ ~ ~ OO G 14)318-18 C~ K~ LIZ~ZO 18' 13.~ Z.6 5.7 0.51 4.4 16.4 16.0 LIZQ-ZO 457 345 an ,5 13.0 Itz 417 4~ J ~ 'ZO' ~ C~ ~S~ I K~ K ~CT 'D' ~ 'U* D~HSI~ C~ K~ I e ~f .,~ A ~ c ~ O ~ E f , u~ p v w xc ~ B3ZO*O5 1.50 li)3~-II x i.~ ~.. 4.01S I.e. Z.31ZI3-310 . IZ 6. I 3.6 4.9 Z' Z.S 5.1 5.4 LIZO-O~-IO~O~S Z' B3Z0.10 1.77 14~-II X i.O~ ~.. 5.~ B.C. 3-7~13.748 . IZ 7.6 3. I 6.9 Z ~' Z.I~ 4.0 a.Z LIZO~S-10. ZOIB~O-IC t ~ B3zo-40 z.87 1413/t-lo x I., ~.. 1.4N I.e. 5.~/4.998 . IZ 9.4 4.z 8.3 3' 3.~ 5.8 1.l LIZ0*ZO.~/B~O-40 FAR$~ '~' ~A. ~ - ~ ,~ . ~ ~TEICATI~ ~T ~ ~IT 8IZE A C D E F H M P V W AC ST~ IS ~1~ ~.) t J ~ B3Z0-05 ~.1 14NI0-1.5 X 35 ~.. 10Z B.C. ~9.~5/69.90 3 154 90.4 I~ B3Z0-10 4~ (4NI0-1.5 X 35 ~.. 10Z B.C. 8B.gS/ee.g0 3 I9Z ~6.5 IZ5 Z I~' ~.i It6.51ST LTZ0~S-IQ.ZO~3ZO-10~ ~ B3Z0-ZO eO (4NI6-Zl X 35 ~.. 140 B.C. eg.gS/99.~O 3 IgZ 90.5 tT5 Z I~' M.5 131 157 LIZ0~S-10. ZO~3ZO-Z0~ ~ B~-4Q 73 (4N~-Z.5 X 45 ~.. le~ B.C. 1lg.DS/IZg.~ S 240 IM Zl0 3' 13.5 147 ~1 LIZ0-Z0.40~O-4O ~5'9~ B~0.~ g0 (eNIG-Z X 35 ~.. t~ B.C. 1~l.95119g.90 5 3~ IZB ~ 5' 104 180 Z64 LIZ0-Z0.40~-~ ~ 83Z0'70 ToZ ~-Z.5 X 4~ ~.,~6 B,C. ~9.9S/ZU,H 5 426 145 351 ~' tZ~ ;on 3l$ LlZoqoa$~-70 z.5 F~ /~V.~V. ' ~D~.~V. T --w~ . 3-6 13-0154- I ,~Hz!~ld~loloHzlolol~lzloloHTl~lzl~l~l , - - _~ tl~T ~ L~T ~ ~ c O .... ' MOD R~-! MOD~ II ~ ~ LZ ~ ~ ~12~ ~ ~ ~ P~ ~ ~ ~ ..................... ms. m) I c~/sT.~o . I ~ ................ __ --- ~ ' ................ ~ ELECTRIC~ COMPARTMENT M., ~ ::::::: -~ ~ WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK CzTY OF COPPELL, TEXAS PRO3ECT NO. WA-96-01 OPERA TZON & M AZNTENANCE MANUAL WALL MOUNTED 3ZB CRANE WZTH ELECTRZC HOZST ,,~ SUPPLZER CRANE PRO SERVZCES 3219 PEACHTREE ROAD, SUZJTE 149 BALCH SPRZNGS, TEXAS 75180 (972) 557-9990 T' 'IT' I .... OPERATION. SERVICE & PARTS MANUAL 12772A LIFTTECH el'® ~.~.~.=~~=~~, BUDt31T Division of Columbus McKinnon MUSKEGON, MICHIGAN 49443 ~.N~ Printed in U.S.A. APRIL, 1998 COPYRIGHT 1998 LIFT-TECH INTERNATIONAL, DIVISION OF COLUMBUS MCKINNON CORPORATION PART NO. 113535-12 FOREWORD This book contains important information to help you install, The "Accident Prevention Manual for Industrial Operations" operate, maintain and service your new Electric Hoist. We (8th Edition) by the National Safety Council states: recommend that you study its contents thoroughly before /~putting your hoist into use. Then, thru proper installation, "Employees who work near cranes orbassist in hooking on or application of correct operating procedures, and by practicing arranging loads should be instructed to keep out from under the recommended maintenance suggestions you will be as- loads. Supervisors should watch closely to see that this rule is sured maximum lifting service from the hoist. strictly followed. Complete inspection, maintenance and overhaul service is From a safety standpoint, one factor is paramount: conduct all available for BUDGIT Electric Hoists at Authorized Repair lifting operations in such a manner that if there were an Stations. All are staffed by qualified factory-trained service equipment failure, no personnel would be injured. This means men; have authorized testing equipment; and stock a complete keep out from under raised loads!" inventory of factory approved BUDGIT replacement parts. Complete replacement parts information is given in Section IX. THE INFORMATION CONTAINED IN THIS MANUAL IS It will likely be a long time before parts information is needed, FOR INFORMATIONAL PURPOSES ONLY AND LIFT- therefore,after you have completel~ familiarized yourself with TECH INTERNATIONAL DOES NOT WARRANT OR operation and preventive maintenance procedures, we suggest OTHERWISE GUARANTEE (IMPLIEDLY OR EX- that this instruction and parts manual be carefully filed for PRESSLY) ANYTHING OTHER THAN THE COMPO- future reference. NENTS THAT LIFT-TECH MANUFACTURES AND AS~ NOTICE: Use only factory approved BUDGIT replacement SUMES NO LEGAL RESPONSIBILITY (INCLUDING, parts, available from Authorized Repair Stations or BUDGIT BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES) Hoist Distributors. FOR INFORMATION CONTAINED IN THIS MANUAL. INDEX SECTION I GENERAL DESCRIPTION . Page Paragraph 1-1 General ........................ - .............................. - ............................... 3 Paragraph 1-2 Hoist Service Classification ....................................................................... 3 Paragraph 1-3 Basic Construction ............................................................................. 3 Paragraph 1-4 Differences Between Models and Sizes ............................................................. 4 Paragraph 1-5 MAN-GUARD Overload Clutch ~ ................................................................. 4 SECTION II INSTALLATION Paragraph 2-1 General ..................................................................................... 4 Paragraph 2-2 Installation ................................................................................... 4 Paragraph 2-3 Pre-lnstallation Checks ................................................................... . ......5 Paragraph 2-4 Connecting Hoist to Electrical Service .............................................................. 5 trf'~ SECTION III OPERATION Paragraph 3-1 General ...................................................................................... 6 Paragraph 3-2 Operating Hoist ............................................................................... 6 Paragraph 3-3 Pulling and Pivoting Hoist and Load ............................................................... 6 Paragraph 3-4 Upper and Lower Limit Stops .................................................................... 6 Paragraph 3-5 MAN-GUARD Overload Clutch Operation .......................................................... 7 Paragraph 3-6 Operating Precautions ...................................................................... . ....7 SECTION IV LUBRICATION Paragraph 4-1 General ..................................................................................... 8 Paragraph 4-2 Change Gear Case Oil .......................................................................... 8 Paragraph 4-3 Lubricate Load Chain ........................................................................... 8 Paragraph 4-4 Lubricate Upper Hook and Lower Block Assembly .................................................... 8 Paragraph 4-5 Lubricate Limit Lever Control Shaft and Gears ........................................................ 9 SECTION V MAINTENANCE Paragraph 5-1 General ..................................................................................... 9 Paragraph 5-2 Thirty-Day Insepection ......................................................................... 9 Paragraph 5-3 Six*Month Inspection ....................... . ................................................. 12 Paragraph 5-4 Inspection--5000 Hour or Five Year .............................................................. 12 SECTION VI TROUBLE SHOOTING CHART .................................................................. 13-14 SECTION VII DISASSEMBLY AND REASSEMBLY Paragraph 7-1 General . .. ~ ............................ ' ................................................... 14 Paragraph 7-2 Disassembly of Hoist Into Subassemblies .......................................................... 15 Paragraph 7-3 Rebuild of Hoist Frame, Sprocket Gear, Sprocket Shaft and Chain Guide .................................. 17 Paragraph 7-4 Rebuild of Load Brake and Overload Clutch Assembly ................................................ 20 Paragraph 7-5 Rebuild of Lower Block and Load Chain Assembly ................................................... 22 Paragraph 7-6 Rebuild of Electrical Controls and Gear Case Cover Subassembly ........................................ 23 Paragraph 7-7 Rebuild of Push Button Station and Conductor Cable Assembly ......................................... 23 Paragraph 7-8 Rebuild of Contactor Assembly (Push Button Models) ................................................ 24 Paragraph 7-9 Rebuild of Single Phase Motor Assembly ........................................................... 24 Paragraph 7-10 Rebuild of Three Phase Motor Assembly ........................................................... 24 Paragraph 7-11 Reassembly of Hoist From Subassemblies .......................................................... 24. Paragraph 7-12 Testing Hoist ................................................................................ 26 Paragraph 7-13 Test Procedure For Checking Operation of Overload Clutch O ............................................ 26 SECTION IX REPLACEMENT PARTS ....................................................................... 27-71 NOTICE: Information contained in this book is subject to change without notice. Page 2 7 1T 'i [ " 12773A Figure 1-1. Cutaway View Of Typical Budgit Electric Hoist. SECTION I - GENERAL DESCRIPTION ,_,. AWARNING sion built chain ~pe hoists ranging in six rated load Sizes from 1/4 ton thru 5 tons with various li~ing speeds and This equipment is not designed or suitable as a electrical power supplies. In addition' to the capacities, power source for lifting or lowering persons. there are model variations with roller or link ~pe load chains, hook or lug ~pe suspension, and single or ~o c. These hoists meet ANSI/ASME HST-1 M "Performance speed. In addition to standard models, there are four rated Standard for Electric Chain Heirs" hoist du~ cla~ ratings as load sizes of BUDG~ Electric Hoists ranging from 1/4 ton outlin~ in the sal~ bulletin. thru 2 tons suitable for plating hoist seNice with various 1-3. BASIC CONSTRUCTION. All sizes and models of these rifling speeds and electrical power. BUDGIT El~ic Hoi~ are of the same basic design, having 1-2. HOIST SERVICE C~SSIFICATION. many common and interchangeable pa~. They consist prima- rily of an aluminum alloy frame and gear case cover which a. BUDGffele~richoistsatthetimeofmanufa~urecomplY hous~ an automatic load brake and gear ~ain. An electric With our interpretation of applicable sections of ANSI B30.16 driving motor'and external motor brake are mount~ on the rear "Overhead Hoists", National Electric Code ANSI/NFPA 70 of the frame. Electrical control componen~ are mounted on and Occupational Safe~ and Health Act, 1992. front of the g~r ca~ cover and encas~ by aluminum alloy end cover. An upper hook or lug bracket for suspending the hoi~ is b. OSHA places the burden of compliance for hoist a~ach~ to the top of the frame. Either a s~cial nickel steel. installations on the user. The usermu~ install the equipment roller load chain or high strength low alloy coil load chain with ' accordance with the National Electric Code ANSI/NFPA lower block a~mbly is employed to raise and lower loads. A' area. Page 3 bottom of the hoist frame and is connected, by linkage, to a limit switch. Hoist operation is controlled by a pendant push ,,.,,o..,.,,,.. AWARN'iNG /"'"t 1-4. DIFFERENCESBETWEENMODELSANDSIZES.Themain THE MAN-GUARD OVERLOAD CLUTCH IS A .differences between hoist models are in the service clas- PROTECTIVE DEVICE THATWILLPERMITOPERA- si~cation, type of load chain and the suspension employed. TION OF YOUR HOIST WITHIN ITS RATED LOAD These are described in paragraphs (a) thru (d), below. The AND WILL PREVENT LIFTING OF EXCESSIVE differences between sizes of hoists are in the number of gear OVERLOADS WHICH CAN CAUSE PERMANENT reductions used and the reeving of the load chain. Two- DEFORMATION OR WEAKENING OF A PROPERLY reduction gearing is used for 1/4 thru 1/2 ton rated load hoists; MAINTAINED HOIST AND/OR ITS SUSPENSION. three-reduction gearing for 1,2 and 3ton rated hoists. On 1/4 thru I ton rated load hoists, the loadchain is single reeved (one part of chain); on 2 ton rated loads, the chain is double reeved (two parts of chain); on 3 ton rated loads, the chain is triple reeved (three parts ofchain) and on 5ton rated loads, the chain '-~"-~ ,;~'.':::,':'-"~ ', ~' ...... is quintuple reeved (five par~s of chain). ~/ .7. a. Two different types of load chains are used as the lifting · "': ~ ' -'" medium', roller chain and link chain. The roller type chain is a ' . ' special precision manufactured nickel steel chain. Link type . ! i ' i t~ chain is full-flexing electric welded link chain. Both are espe- ~ ~,,' i i. ~ ~. cially designed for use in BUDSIT Electric Hoists and only , ~.~\. ! ..,-i facto approved chai, of the correct size. pitch. hardnes, a.d """" ' ": ;' l strength can be used with these hoists. r,. '.-~: . b. Suspension differences include a conventional hook type mounting and a lug type mounting. Hook suspension allows ~ ~"~ · portability permitting hoist to be easily moved from job to job. _,,~,~,.,',;-i!i,! .,~ Lug suspension permits hoist to be rigidly mounted to over- , .......:: :'.7~ !: ,,.T, head structure or attached to BUDGIT Rigid Mount Trolleys, - -, l' , .... : ,'." :: ~* ..... ,;..,...-7.. affording unusual headroom advantage. Figure 1-2. MAN-GUARD Hoist Identification. c. Some hoists are adaptations of standard model hoists to permit use in some mildly corrosive atmospheres, high ambient SECTION II - INSTALLATION temperatures and high duty cycle operation. They are available only in link chain models in either hook or lug suspension. 2-1. GENERAL. BUDGIT Electric Hoists are completely lubri- Construction variations from standard models are as follows: cared and load tested under their own power before being shipped from the factoN. To place hoist in service, attach to (1) Load chain is zinc plated for corrosion resistance. suitable overhead suspension (par. 2-2) in area to be used; (2) All exposed aluminum parts are prime painted with make pre-instailation check (pan 2-3); and connect to the corrosion resistant paint. proper power supply. (3) Aluminum castings are specially treated. 2-2. INSTALLATION. tric Hoists having a MAN-GUARD label on the sides of the Lubricate load chain 'before operating hoist. See electrical compartment cover (fig. 1-2) are equipped with an overload clutch that is designed to help guard against exces- paragraph 4.3 · sive overloads. The clutch is built into the load brake gear. It is a cone-friction clutch that connects the first reduction gear ~. On hook suspended hoists, select a suitable overhead (load brake gear) to the load brake output pinion shaft. A support in area hoist is to be used (one capable of holding belleville disc spring provides clutch pressure between the gear weight of hoist and its rated load) and hang up hoist. Be and its cone shaped gear center. An excessive overload causes ' ' certain upper hook is firmly seated in center of hook saddle. the load brake gear to rotate without turning the gear center Upper hook is equipped with a spring type hook latch; it may and output pinion shaft. The clutch is located between the load be necessary to remove latch to attach hook to suppo/t. brake and the motor, thus allowing both load brake and motor Replace latch after hoist is installed. ""T"orake to function in their normal manner See paragraph 3-5 for peration. ' b. On lug suspended hoists, select a suitable overhead sup- port in area hoist is to be used (one capable of holding Page 4 weight of hoist and its rated load). Mount hoist using thru 2-3. PRE-INSTALLATION CHECK. bolts, of appropriate size, to fit mounting holes in suspension Check Oil Level (Fig. 4-1 ). The gear case has lug at top of hoist frame. (See table below.) The structure used been filled with oil, to the proper level at the factory. However, .. to suspend hoist must be of sufficient strength to withstand the oil level should be checked before hoist is operated. ;,~asonable forces to which hoist and support may be sub- Remove and discard felt shipping plug from oil filler on side of :ted. Hoist must be aligned with load to avoid side pulls. hoist frame. Check oil level by removing oil level plug (side of c. On lug suspended hoists, the suspension lug is installed frame). Observe if oil level is even with bottom of tapped hole. for cross mounting, (except for 5 ton hoists) the recom- If it is not, add oil, as specified in paragraph 4-2. c. Also check mended condition. To rotate hoist 90° for parallel mounting load chain. Be sure it is properly lubricated. See paragraph 4-3. (a special condition), follow instructions below: (1) On 1/4 thru 1 ton hoists remove suspension lug per 2-4. CONNECTING HOIST TO ELECTRICAL SERVICE. instructions in Section VII, paragraph 7-3. c. (1) and figure 7~ a. All hoists are equipped with a flexible power cable extend- 20. Lift lug from hoist frame, rotate to desired position and ing from the hoist. A grounding type male plug or permanent replace on !ocating pins. Insert suspension bolt and nut. Turn connection in an outlet box may be used for connecting hoist nut on top of lug while holding nut inside of hoist frame to power supply. See table (fig. 2-1 ) for branch circuit con- with drift until grooved pin holes are aligned. On later model ductor sizes. hoists, loosen set screw, rotate hoists in 90° increments and tighten set screw. AWG WIRE SIZE XkWARNING ""' "°""'""" "' "' "°"" 115-1-60 80 130 21 0 330 230-1-60 230 330 835 1/4 200, 230-3-60 465 740 1180 Be certain to replace grooved pin thru nut and 460, 575-3-60 1440 2390 suspension bolt. 115-1-60 45 75 120 190 310 490 230-1-60 195 305 490 775 1235 1/2 200, 230-3-60 280 450 715 1135 (2) On 2 ton hoists, remove hex socket head screw in lower 460, 575-3-60 860 1440 lock plate. Remove lower lock plate. Rotate suspension lug to 115-1-60 · 45 75 120 190 300 selected position and replace lock plate and hex socket head 1 230-1-60 120 190 300 475 720 200, 230-3-60 180 290 460 730 screw. 460, 575-3-60 560 900 (3) On 3 ton hoists, the hanger bracket must first be removed 200, 230-3-60 60 100 150 250 1the hoist to provide access to suspension nut per Section 2~ 460, 575-3-60 260 420 par. 7-2. a. (4) and figures 7-2 and 7-3. To remove lug 'Do not use. bolt, follow instructions in Section VII, par. 7-3. b. (3). With bolt removed lift lug from hanger and reposition as desired. The Figure 2-1. Branch Circuit Conductor Size. Maximum length in lug is located and prevented from turning by integral lugs on feet for maximum wire size based on Horsepower and power adjacentsurfaces of the lug and the hanger. Re-installsuspen- supply. Wire size for entire length of branch circuit and sion bolt, spherical washers and nut. Align hole in nut and permanent wiring to main feeder. Power supply measured at suspension bolt. Reassemble hanger bracket to hoist. hoist, while running and with normal load, must not vary more than +5% of voltage on motor nameplate. electrical service to hoist. Connect power wires in accor- dance with appropriate wiring diagram, Power supply Be certain to replace grooved pin thru nut and must be the same voltage, frequency and phase as specified suspension bolt, on the hoist nameplate. (4) The 5 ton hoist can only be parallel mounted. plates must be properly spaced so trolley will fit I-beam on which hoist will operate. Adjustment for various I-beam sizes is The green wire provided in the power supply accomplished by rearrangement of spacer washers on thru cable is a grounding wire and must be connected bolts which connect trolley side plates to suspension-lug on to a proper ground. (Follow local code require- hoist. Refer to instruction sheet furnished with BUDGIT Rigid ments and/or National Electrical Code Par. 250- Mount Trolleys for complete instructions. 57 or 250-59). SUSPENSION LUG BOLT SIZES AND SPACING c. Dual voltage hoists with re-connectable 230/460 volts, 3 )r.LTHoist Distance phase, 60 hertz are (unless otherwise specified on customer's' Rated Load Bolt Diameter Between Holes Tons Inches Inches o~der) shipped from factory pre-connected for operation or~ 1/4, 1/2, & I 5/8 3-1/8 460 volts. If hoist is to be operated on 230 volts convert I 2 1 5 3 &5 1-1/4 6 Page 5 wiring by changing connections on terminal board. With ' not loaded. Do not use for pulling bridge cranes. Push on load hoist disconnected from power source, remove electrical or load chain or use a hand geared or motor driven type trolley compartment cover and reconnect terminal board leads. to traverse loaded hoists. Also refer to Wiring Diagram. b. To pivot hoist and load, push on one corner of load. The d. Dual voltage'hoists with re-connectable 115/230 volts, I lower hook will pivot thru 360 degrees to permit load to be phase, 60 hertz are (unless otherwise specified on customer's swung to the desired position. The upper hook (hook suspen- order) shipped from factory pre-connected for operation on sion models) is also designed to rotate so that side 'pulls will 230 volts. If hoists are to be operated on 115 volts convert swing hoist to face load, thus reducing side thrust. wiring by changing connections on terminal board. With ~ ,----~.z:'......:~ hoist disconnected from power source, remove electrical compartment cover and reconnect terminal board leads, Also .: '" ' ' '':~ refer to Wiring Diagram. - WARNING Serious damage to the hoist can occur with resulting hazard to operator and load. Three phase hoists must be properly phased each time they are installed or moved to a new power source or when service is performed on main- line (power source). e. To properly phase the hoist follow these steps: ..;, ,~ ~ : . ,... ,~- ._ (1) Temporarily connect hoist to power source. (2) Operate "T" button briefly to determine direction of Figure 3-1. Limit Lever Being Tripped By Actuator travel. Above Lower Block on Single Line Hoist. (3) If hook raises, phase is correct and temporary connec- 3-4. UPPER AND LOWER LIMIT STOPS. A lower block and tions should be made permanent. chain operated limit stop is provided to guard against overtravel of load in either raising or lowering direction, which (4) IF HOOK LOWERS, HOIST IS "REVERSE PHASED" can cause damage to hoist. When highest position is reached, AND MUST BE CORRECTED BY INTERCHANGING ANY limit actuator on the load chain, above the lower block, trips the TWO LEADS AT POWER SOURCE CONNECTION. DO NOT limit lever (fig. 3-1 ). When lowest position is reached, a limit CHANGE INTERNAL WIRING OF HOIST. actuator on the tail end of load chain trips the limit lever (fig. 3-2). The limit lever is connected to a limit switch that f. For connecting hoist to a motor driven trolley, refer to automatically stops the hoist motor. This is intended as a safety instructions furnished in trolley manual. device and should not be used on a routine basis to stop travel of lower block or shut off hoist. SECTION III - OPERATION 3-1. GENERAL. Operation of BUDGIT Electric Hoists is . .,. . controlled by a push button station suspended from the hoist electrical compartment. The station has a built-in mechanical · · "'..:.:.!.:.~'.-.'..:.~.: .... interlock to prevent depressing both buttons simultaneously. ..:.... :.:..;. :..~.: ....;',.,. 3-2. OPERATING HOIST. a. Depress push button marked "T" to raise load. b. Depress push button marked "g' to lower loads .: c. Jogging the push buttons will give "hairline" load move- ment. The quickness of the depressing motion will determine : the amount of movement. Excessive use of this "jogging" : ! ~/t L) ='' I feature will cause premature burning of contact points, motor' . overheating, and rapid motor brake wear. strain cable suitable for pulling trolley suspended hoists when Figure 3-2. Limit Lever Being Tripped by Actuator on Tail End of Load Chain. Page 6 T i '/i i [ ! ' ' ~1 NOTE: On lug ~pe, link chain hoists, the limit lever j. DO avoid swinging of load or load hook. may be tripped by the load chain during side pulps. k. DO make sure that all persons stay clear of the .Load must be lined up with hoist. If moderate side suspended load. pulls cannot be avoided, rotate hoist 90' so it is mounted with side of hoist facing direction of side I. DO warn personnel of an approaching load. pull. See appropriate instruction in Section II, para- m. DO protect load chain from weld splatter or other graph 2-2. c. damaging contaminants. 3-5. MAN-GUARD OVERLOAD CLUTCH OPERATION. The overload clutch is factory preset at assembly so thatthe hoist n. DO promptly report any malfunction, unusual will lift its full rated load but will refuse to lift overloads within performance,or damage of the hoist. a range of 110 percent rated load to 180 percent rated load. o. DO inspect hoist regularly, replace damaged or If the loaf to be lifted exceeds the clutch factory setting, the worn parts, and keep appropriate records of motor will continue to run and will rotate the load brake maintenance. gear without lifting the load. Whenever this occurs, immediately release the "1'" push button to prevent p. DO use the hoist manufacturer's recommended overheating of the clutch friction surfaces and motor, and parts when repairing a hoist. reduce the load to rated hoist capacity. Should it be q. DO use hook latches wherever possible. impractical to reduce the load, replace the hoist with one of suitable rated capacity. r. DO apply lubricant to load chain as recommended. NOTICE s. DO NOT lift more than rated load. Always k~ow load to be lifted. LIFT-TECH does t. DO NOT use the hoist load limiting device to mea- not recommend lifting loads greater than the sure the load. rated load of your hoist. 3-6. OPERATING PRECAUTIONS. u. DO NOT use damaged hoist or hoist that is not working correctly. AWARNING aged or worn chain, Equipment covered herein is not designed or w. DO NOT lift a load unless chain is properly seated suitable as a power source for lifting or lowering in chain wheel(s) or sprocket(s),' persons. Do not use as an elevator. x, DO NOT use load chain as a sling or wrap chain operator aware of dangerous practices to avoid and precau- y. DO NOT lift a load if any binding prevents equal tions to take for his own safety and the safety of others. loading on all supporting chains. Observance of these rules in addition to frequent examinations z. DO NOT apply the load to the tip of the hook, and periodic inspection of the equipment may save injury to aa. DO NOT operate unless load is centered under personnel and damage to equipment. hoist, a. DO read ANSI B30,16 Safety Standard for Overhead Hoists and the Operation, Service and Parts Manual 'ab. DO NOT allow your attention to be diverted from operating the hoist. b. DO be familiar with hoist operating controls, pro- cedures and warnings. ac. DO NOT operate the hoist beyond limits of load chain travel. c. DO make sure hook travel is in the same direction as shown on controls. · ad, DO NOT use limit switches as routine operating stops unless recommended. They are emergency de- d. DO make sure hoist limit switches function vices only, properly, ae, DO NOT use hoist to lift, support or transport e. DO maintain firm footing when operating hoist, people. f, DO make sure that load slings or other appr0ved af. DO NOT lift loads over people. single attachments are properly sized and seated in the hook saddle. ag, DO NOT leave a suspended load unattended unless specific precautions have been taken. g. DO make sure that the hook latch, if used, is closed and not supporting any part of the load, ah. DO NOT allow sharp contact between two hoists or between hoist and obstructions. h. DO make sure that load is free to move and will clear all obstructions. ai. DO NOT allow the chain or hook to be used as e rf ground for welding. 1. DO take up slack carefully, check load balance, lift a ew inches and check load holding action before aj. DO NOT allow the chain or hook to be touched by a live welding electrode. continuing. Page 7 T I I 1' ak. DO NOT remove or obscure the warnings on the hoist. c. Refill gearcase thru oil filler to proper level (bottom of oil level plug hole) using Automatic Transmission Fluid al. DO NOT adjust or repair a hoist unless qualified to DEXRON® II Type. This is an all-weather oil available from all perform hoist maintenance. major oil companies. 1-1/2 pints of oil are required. ~'~am. DO NOT attempt to lengthen the load chain or repair ® Registered trademark of G.M.C. damaged load chain. d. Reinstall oil level plug. an.'DO NOT allow personnel not physically fit or properly ' 4-3. LUBRICATE LOAD CHAIN. A small amount of lubricant qualified to operate the hoist. will greatly increase load chain life, therefore, chain should not ao. DO NOT operate hoist unless upper and lower limit be allowed to run without lubricant. Chain should be cleaned switch stops are operating properly. and lubricated as directed in paragraphs a. and b, below, depending upon type of chain. User should set up a regular ap. DO always be sure there is not twist in link load chain. schedule for chain lubrication after observing operating con- On 2 & 3 ton link chain hoists, check to see that lower ditionsfora fewdays. Use Bar and Chain Oil (LUBRIPLATE or block is not capsized between strands of chain. equal) on load chain. aq. DO avoid operating hoist when hook is not centered under hoist. Be sure that hoist trolley or other support mechanism is correctly positioned for handling the load ,~ ~'~ before lifting. Orr. t'n.L:S:R ar. DO operate hoist within recommended duty cycle and ~'~;~ I (~'~ do not "jog" unnecessarily. as. DO conduct regular visual inspections for signs of O~ ~.slr~. · damage or wear. PLOG ~.({(~ · OIL DRAIN at. DO NOT operate hoist with hooks that have opened PLUG up. See Figures 5-5 and 5-6. au. DO provide supporting structure or anchoring means that has a load rating at least equal to that of the hoist. av. DO NOT use hoists in locations that will not allow r"Toperator movement to be free of the load. aw. DO when starting to lift or pull, move the load a few inches at which time the hoist should be checked for proper load holding action. The operation shall be con- 10077L tinued only after the operator is assured that the hoist is Figure 4-1. Location of Oil Filler and Plugs. operating properly. a. Link Chain. Under ordinary conditions only weekly atten- ax. DO NOT leave a loaded hoist unattended at the end tion will be necessary. Under hot and dirty conditions it may be of a work shift or for extended periods during the work necessary to clean chain at least once a day and lubricate it shift. Where operations are such that this condition several times between cleanings. Thoroughly clean chain with cannot be avoided the operator must be assured that the an oil solvent and relubricate by coating it lightly with oil. Make condition does not create a hazard to personnel or sure that lubricant coats wear surfaces between links. Zinc property. · ' plated load chain should be cleaned and lubricated daily. ay. DO use common sense and best judgemerit whenever b. Roller Chain. Under ordinary conditions only monthly at- operating a hoist. Observe American National Standard tention will be necessary. Under hot and dirty conditions Safety standard, ANSI B30.16, latest issue. weekly attention may be required. Thoroughly clean chain with - an oil solvent and apply oil. Wipe off excess oil. When subjected to excessive moisture or corrosive atmospheres, DO SECTION IV - LUBRICATION (dripless oil) lubricant from American Grease Stick Company is 4-1. GENERAL. The lubrication sewices outlined in para- recommended for use on roller chain in place of regular oil. graphs 4-2 thru 4-5 should be performed at regular intervals to maintain top hoist performance and insure long life. The 4-4. 'LUBRICATE UPPER HOOK AND LOWER BLOCK frequency for lubrication services will depend on the type of ASSEMBLY. hoisting service that hoist is subjected to and should coincide · - a. Apply a few drops of Bar and Chain Oil on shank of upper with periodic preventive maintenance inspection. See Section hook where it enters frame. V- Maintenance. b. Apply a few drops of Bar and Chain Oil on shank of lower 4-2. CHANGE GEAR CASE OIL (Fig. 4-1 ). hook where it enters lower block. Hook rotation bearing may a. Remove drain plug from bottom of hoist frame and drain oil be removed for cleaning and relubricating if necessary. See from gear case. Replace plug. paragraph 7-5. b. Remove oil level plug from side of hoist. c. On lower block assemblies of 2 thru 5 ton capacity hoists, Page 8 also apply heavy duty.lithium soap grease with EP additives is about .01 5" deep. Chain must be replaced before the case is thru pressure fitting in end of sprocketpinto lubricatebearing worn thru. Also check chain for elongation using a vernier in chain sprocket. caliper (fig. 5-2). Select an unworn, unstretched section of chain (usually at slack or tail end) and measure and record the dqOn3and5tonmodelslubricatesprocketinhangerbracket, length over the number of chain links (pitches) indicated in d one sprocket in the 5 ton lower block, with a few drops of figure 5-2. Measure and record the same length of a worn rand Chain Oil in hole provided in center of sprocket hub- section in the load side of the chain. Obtain the amount of wear by subtracting the measurement of the unworn section from 4-5. LUBRICATE LIMIT LEVER CONTROL SHAFT AND the measurement .of the worn section. If the result (amount of GEARS. wear) is greater than the amount specified in the "ALLOW- Apply a few drops of Bar and Chain Oil on limit lever shaft at ABLE CHAIN WEAR" table, the chain has elongated beyond bearing points. the maximum allowable length and must be replaced. Chain with excessively pitted, corroded, nicked, gouged, twisted or worn links should be replaced using only factory approved AWARNIN.G Before performing any internal work on hoist, be certain power is shut off. Lock main service ; t t , , ~,~'7'_'_'_'_'_'_'_~ switch in the open position. · SECTION V- MAINTENANCE 5-1. GENERAL. Preventive maintenance services required on PC~IRILITY OF FALSE R.f. ADING ]~Y NOT MKA~URING inspection procedures to determine condition of hoist compo- nents. Below are suggested inspection procedures, based on daily average hoist usage. Figure 5-2. Checking Coil Chain Using Vernier Caliper. 5-2. THIRTY-DAY INSPECTION. Hoist may be left suspended. ALLOWABLE CHAIN WEAR - ELONGATION HOIST NO. OF a. Inspect Load Chain. RATED LOAD CHAIN SIZE PITCHES MAXIMUM t'P'T (TON) (WIRE DIA.} TO MEAS~IRE WEAR LIMIT I (1) Operate hoist under load and observe operation of chain 1/4 & 1/2 1/4" 13 .145" vet sprocket in both directions of chain travel. Chain should I thru 5 5/16" 11 .142" feed smoothly into and away from the sprocket. If chain binds, jumps or is noisy, first see that it is clean and properly ACAUT!ON depending on type of chain. Do not assume that load chain is safe because it measures below replacement points given herein. Other factors, such as those mentioned in visual ~~ checks above, may render chain unsafe or ready , for replacement long before elongation replace- ment is necessary. , AWARNING /~) ) To avoid serious personal injury from a dropped WEAR-. load caused by possible chain breakage, when replacing link load chain, use only factory approved chain conforming to factory specifications for material, hardness, strength and link dimensions. Chain not conforming to Figure 5-1. Check Chain Wear at Bearing BUDGIT hoist specifications may be dangerous Surfaces Between Links. as it will not fit in the load sprocket and chain (2) Link Type Load Chain. Clean chain for inspection. guide correctly, causing serious internal damage Examine visually for gouges, nicks, weld splatter, corrosion or to hoist, and it will wear prematurely, deform li o i Greatest wear will often occur at sprocket at high or low point of lift, particularly when hoist is subjected to repetitive lifting cycles. Case hardness of chain Page 9 T i / i f" (3) Removing and Replacing Link Load Chain. to tail end of old chain, a~er disconnecting old chain from side of hoist frame and removing limit actuator. New chai~ is then Two "C" links must be used on 1/4, 1/2, and 1 ton capaci~ hoists (fig. 5-4) in order to correctly position run into hoist as old chain is run out. Use open "C" links, end link on tail end.of chain to fit tail end anchor at figures 5-3 and ~4, for a~aching chains. Links must be iden- side of hoist frame; only one "C" link is required on 2 tical in size to hoist chain - 1/4" wire size with .745" pitch len~h th ru 5 ton capaciW hoists.. for 1/4 thru 1/2 ton models, 5/16" wire size with .858" pitch length for 1 thru 5 ton models. Be ce~ain that all welds on links NOTE: Inkall limit a~uator on the 8th link from the of replacement chain face away from center of load sprocket. end and secure with grooved pin. On 2 ton double reeved models, also conne~ opposite end of ~ ~ ~ chain (from lower block) to load chain anchor inside of frame. _~ On 3 ton triple reeved and 5 ton quintuple reeved models, the ~ ~ opposite end of the chain is a~ached to the lower block , - 9~2"- NOTE: In the event the old chain is to be removed Fa~i~te by grinding o~ning ~ ~ (1/4" ~ain) from hoist and rein~alled, a sho~ length of chain in ~ld side of end link on (about 18" long) mu~ be run into hoi~ when the old chain; make from old load - 11/32" - chain is removed. This sho~ length can then be used (5/16" Chain) ~in (tail end). Remove an in the same manner as showd in paragraph 5-2. a.(3). even num~r of links. Be sure to use the pro~r num~r of open "C" links in order to correctly position end link on tail end of chain Figure 5-3. Open "C" Link for Removing and to fit anchor at side of hoist frame. Installing Link Load Chain. To avoid serious internal damage to hoist, when installing link load chain do not a~empt to hand feed chain into hoist, or use a piece of wire in ,~ .*:~ place of the method described herein. To do so may result in serious internal damage to hoist, . .- - . ' as link chain links must be properly seated in '~' ' chain sprocket before chain is run into hoist. / ' = ' ~ Install chain only as described in this manual. ':; WARNING L°~7~ ~ ~ "' Keep fingers clear of chain sprocket when ~c~ ~ ./~'~8~ ' replacing link load chain. "' ~: ' ' (4) Roller Type Load Chain. Visually ch~k for po~ible . Z , ' ' I ~' ...... ' ~ , :.:- ~ists. broken links, wear or elongation. Any links that do not , . ' flex easily, even when lubricate, may be damag~ and should Figure 5-4. Installing Coil Load Chain Using Two be replaced. Check roller chains for elongation from wear by "C" Links (1/4, 1/2, 1 ton hoists). pulling chain taut and measuring as follows: On RC-625, 625 or H-5 size chain (5/8" pitch), measure di~nce over a )ength of 20 pitches (center-to-center di~ance be~een 21 rive~) - it (b) Remove lower block a~embly and actuator from old must not exceed 12-3/4 inches. On RC-750, H-6 or HF size chain and a~ach them to replacement chain at end which was chain (3/4" pitch) measure length of 16 pitch~ (center-to- just run thru hoist. Inkall limit actuator (as noted below) on center distance be~een 17 rivets) - it must not exceed 12-1/4 other end of chain and anchor chain to side of hoist frame. inch~. If chain exceeds the limit, replace damag~ section 'or install new load chain as~mbly. Ch~k chain for ~i~. If ~ist in any 5 foot extension exceeds 15 degrees, replace chain. Check chain for camber. If any s~ion has side bow exceeding 1/4 inch in five feet, replace chain. Page 10 T I ' / I ' ' ~'1 ..... : ........T' ': .... 11 IrE, ,ACAUTION OPENING Do not assume that load chain is safe because it measures below replacement points 9ivan herein. Other factors, such as those mentioned in visual checks above, may render chain unsafe or ready for replacement long before elongation replace- ment is necessary. Do not attempt to splice the chain to replace worn or damaged sections un- less you have the required equipment to prop- HOIST HOOK THROAT OPENING RATED LOAD NORMAL REPLACE HOOK IF OPENING erly spin rivet heads. It is suggested that you have this done by an authorized BUDGIT Repair (TONS) OPENING IS GREATER THAN Station that is equipped with the necessary spe- 1/4, 1/2 1-1/8 1-1/4 cial tools. I 1-1/4 1-7/16 2 1-3/8 1-9/16 3 1-1/2 1-11/16 · AWARNING Figure 5-5. Lower Hook Opening:' When replacing roller type load chain, use only (Shown with latch removed for clarity.) factory approved chain conforming to factory (2) On 2 thru 5 ton hoists, check sprockets and bearings in specifications for material, hardness, tensile lower block for freedom of movement and signs of damage. strength, size and construction. BUDGIT Hoist Lubricate if necessary. Replace damaged parts. Roller chain is specially designed for hoisting (3) Check hook latches. Replace damaged or bent latches or service and is the only type roller chain that can broken springs. safely be used with BUDGIT electric hoists. Chain ACAUTION cations may be dangerous as it will not withstand t)r" heavy impact loads and does not have adequate tensile strength. Hooks, upper or lower, damaged from chemicals, deformation or cracks or having more than 15 percent in excess of normal throat opening or (5) Check anchor end of chain at side of hoist frame for more than 10 degrees twist from the plane of the damage to last link, also connecting link on roller chain hoists. unbent hook, or opened, allowing the hook latch Replace damaged parts. to bypass hook tip must be replaced. (6) Check connection of chain to lower block on 1/4 thru 1, Any hook that is twisted or has excessive throat 3, and 5 ton hoists. Replace parts showing evidence of dam- opening indicates abuse or overloading of the age, twisting or elongation. hoist. Other load bearing components of the hoist should be inspected for damage. (See Section V. (7) Check connection of chain to anchor inside hoist frame Par. 5-2. d. (2) below). on double-reeved, 2-ton hoists. Replace parts showing evi- dence of damage, twisting or elongation. (Also see Sec. VII, ., par. 7-2. a. (2)). (8) Lubricate load chain before using hoist. See paragraph 4-3, Section IV. b. Inspect Lower Block. (1) Check for bent or distorted hook. If hook is opened MEASURE beyond the dimension given in figure 5-5, it must be replaced. OPENING Also check to see that hook swivels and is free to pivot. Lubricate these points if necessary. . . HOIST HOOK THROAT OPENING RATED LOAD NORMAL REPLACE HOOK IF OPENING (TONS) OPENING IS GREATER THAN 1/4, 1/2 1-1/8 1-1/4 - 1 . 1-1/4 1-7/16 I 2 1-3/8 1-9/16 3 1-1/2 1-11/16 Figure 5-6. Upper Hook Opening. (Shown with latch removed for clarity.) Page 11 T IT I' · I: : ~1 c. Inspect Upper Suspension. c. Relubricate Load Chain. See Section IV, paragraph 4-3. (1) On hook suspended models, check for bent or distorted d. Lubricate Upper Hook and Lower Block. See Section hook. If hook is opened beyond the dimension given in figure IV, paragraph 4-4. 5-6, it must be replaced. Also check to see that hook pivots. e. Lubricate Limit Lever Control Shaft. See Section IV, Lubricate if necessary. paragraph 4-5. (2) On lug suspended models, check condition of suspen- sign lug. Replace lug if damaged or cracked. Check to see that 5-4. INSPECTION: 5000 HOURS "ON" TIME OR 5 YEARS lock plate is in place on lug and screw holding it is tight. ELAPSED TIME. Hoist must be removed fror~ overhead (3) On 2-ton hoists, check to see that upper lock plate suspension. securing hook or lug bushing is in place and screws holding it a. Disassemble Hoist into Subassemblies. Follow proce- are tight. Lubricate hook shank. dure outlined in Section VII, paragraph 7-2. (4) Check hook latch. Replace damaged or broken parts.. b. Motor shaft oil seal, sprocket shaft bearing and seal, guide d. Inspect Motor, Frame and Electrical Compartment pin 'O" rings and all gaskets should be replaced. Cover. c. Inspect Load Brake and Overload Clutch. Disassemble (1) Check to see that bolts securing motor to frame are tight. load brake and clutch assembly as outlined in paragraph 7-4. Friction discs should be discarded and replaced with new Also check for any visible damage to motor, such as a cracked discs. Check load brake friction surfaces on flange, ratchet end bell or den,ted stator housing. Replace damaged parts. assembly and gear clutch cone. Replace parts'if badly scored or (2) Check hoist frame for signs of visible damage. If frame worn. Check condition of pawl and ratchet assembly. If pawl, shows evidence of fracture, the hoist should be disassembled ratchet teeth or pawl spring are broken, damaged or badly and inspected for further signs of damage from possible worn, replac. e complete assembly. Check contact faces of load overloading, Replace damaged parts. Also check condition of brake cam and gear clutch cone. Brake gear and pinion teeth limit lever. should be inspected for wear or broken teeth. Clean parts thoroughly with an oil solvent before reassembly. (3) Check for possible damage to electrical compartment cover. Be sure screws holding cover are tight. NOTE: The overload clutch assembly should not be disassembled as it is preset at the factory to provide e. Check Oil Level. Remove oil level plug '(fig. 4-1 ). If oil proper clutch pressure for a specific hoist capacity level is not even with bottom of tapped hole, add Automatic range. If there is evidence of the clutch slipping or Transmission Fluid, DEXRON® II Type, to bring to proper level. wear or damage to the clutch components, the com- plete clutch assembly should be replaced or sent to an 5-3. SIX-MONTH INSPECTION OR 500-750 HOURS OF authorized BUDGIT Hoist Repair Station to OPERATION. Hoist may be left suspended. be rebuilt and properly adjusted to factory a. Inspect Electrical Controls. Shut off power supply to specifications. hoist and remove electrical compartment cover from hoist. Use d. Inspect Sprocket and Intermediate Gears. caution as some covers contain counterweights. Two speed hoists with a 2-1/4 horsepower motor have an externally (1) On 1 thru 5 ton hoists, check condition of gear teeth on mounted counterweight at the electrical compartment cover. intermediategearand pinion shaft assembly. Replaceworn or damaged parts. 1) Check all wiring and terminals. Insulation should be sound and terminals securely crimped to wires. Terminal (2) Check condition of teeth or pockets on chain sprocket screws should be tight and plug-type terminals completely (all capacities). Replace worn or damaged parts. mated. Replace terminals or wires as necessary. e. Inspect Motor Brake. For access to motor brake parts, (2) Check control circuit transformer for evidence of over- except for two speed, remove motor assembly as outlined in heating. Replace if necessary. paragraph 7-2. d. Then, remove brake parts following instruc- tions given for the specific type brake, depending upon model (3) Check control shaft centering spring by operating limit of hoist. Check braking surfaces for wear and scoring. Replace lever. If limit lever does not return to neutral position after it is badly worn or scored parts. Check to see that plate support pins tripped, the spring is probably broken or control shaft is bent. inside frame are tight. Check large compression spring and Replace broken or damaged pans, spring plunger. Replace parts that are worn or damaged. (4) Check limit switch to see that wires are securely soldered For two speed hoist, remove brake housing screws, housing, and mounting screws are tight. support plate screws, support plate assembly, friction disc and stationary discs. Check braking surfaces for wear and scoring. (5) Check contactor solenoid coils and replace coils if they Replace badly worn or scored pars. show evidence of overheating. · - f. Reassemble and Test Hoist. Reassemble hoist from (6) Check control cable wire strain reliever to see that it is in subassemblies following procedure' outlined in paragraph good condition and securely attached to gear case cover. 7-11. After assembly is complete, test hoist as outlined in Replace rubber strain tellever grommets if damaged. paragraphs 7-12 and 7-13. b. Change Gear Case Oil. See Section IV, paragraph 4-2. Page 12 SECTION VI - TROUBLE SHOOTING Trouble Probable Cause Remedy 6-1. Hoist Will Not Operate. a. No power to hoist. a. Check switches, circuit breakers and connections in power supply lines. Check power collectors. b. Wrong voltage. b. Check voltage required on motor data plate against power supply. c. No control voltage. c. Check transformer fuse. If blown, check for grounding and/or short in the push button station. Check the transformer coil for signs of o~er- heating. Replace transformer if · burned out. Verify the transformer secondary is the same voltage as the coils to which it is connected. d. Loose or broken wire con- d. Shut off power supply, remove elec- nections in hoist electrical trical cover from hoist and check system. wiring connections. Also check con- nections in push button station and limit switches. e. Contactor assembly not e. Check for burned out solenoid coil. functioning. See that necessary jumper wires are properly installed. f. Starting switch burned f. Replace burned out parts. out (single phase motor). g. Motor burned out. g. Replace motor. On single-phase motors the starting switch may be burned out. 6-2. Hook Moves in Wrong a. Reverse phasing on three-phase a, Interchange any two of three power Direction. hoists. supply line leads. Do not change green ground lead. Refer to Section II, par. 2-4. b. Hoist wired wrong. b. Check wiring connections with ap- propriate wiring diagram. c. Starting switch not working c. Check for correct starting switch correctly (single phase motor). part number and function. Replace if necessary. 6-3. Hook Will Raise But a. "DOWN" electrical circuit open. a, Check for loose connections. See that Not Lower. necessary jumper wires are properly installed on contactor. Check limit switch condition and electrical connections. b. Contactor assembly not ' b. See that necessary jumper wires are functioning. properly installed. Verify that the con- tactor armatures are free to move. If binding occurs replace contactor. Check for burned out contactor coils. c. Push button inoperative. c. Check push button contacts and wires. d. Load brake locked up and d. Consult Authorized BUDGIT Hoist overload clutch slil3ping, Rel3air Station. Page 13 SECTION VI - TROUBLE SHOOTING (Continued) Trouble Probable Cause Remedy 6-4. Hook Will Lower But Not Raise, a. Excessive Load, causing overload a. Reduce loading to rated load of hoist, clutch to slip. as shown on nameplate. b. Overload clutch out of ado b. Test hoist and replace clutch if hoist justment. will not lift rated load. c. "UP" electrical circuit open. c. Check for loose connections. See that necessary jumper wires are properly installed on contactor. Check limit switch condition and electrical con- nections. d. Contactor assembly not functioning. d. See that necessary 'urnper wires are properly installed. ~erify that the con- tactor armatures are free to move. If binding occu.rs replace contactor. Check for burned out contactor coils. e. Push button inoperative; e. Check push button contacts and wires. 6-5. Hoist Will Not Lift Rated a. Low voltage. a. See that power supply is same voltage Load. listed on motor data plate. Check size of power supply lines. Refer to fig. 2-1. b. Overload clutch out of adjustment. b. Remove and replace clutch assembly. Refer to Section IV, par. 7-2 and 7-4. c. Motor brake not releasing. c. Check brake components. Refer to Section VII, par. 7-2.d, 7-2.e and 7-2.f. 6-6. Excessive Drift When Stopping. a. Excessive load. a. Reduce loading to rated load, shown on nameplate. b. Motor brake not holding. b. Check brake components. Refer to Section VII, par. 7-2.d. c. Load brake not holding. c. Remove load brake and inspect parts. Refer to Section V, par. 5-4. 6-7. Hoist Motor Overhears. a. Excessive load. a. Reduce loading to rated load of hoist, shown on nameplate. b. Excessive duty-cycle. b. Reduce frequency of lifts. c. Excessive "jogging." c. Reduce frequency of jogs. d. Wrong voltage. d. Check voltage rating on motor data plate against power supply. e. Star~ing switch on single-phase e. Refer to Section VII, par. 7-9. b. (3) (b). motors not opening starting winding. Inspect switch. f. Damaged motor or worn bearings in f. Disassemble hoist and inspect for motor or hoist frame. worn or damaged parts. g. Motor brake not releasing. g. Check brake components. Refer to Sec- tion VII, par. 7-2.d. SECTION VII - DISASSEM BLY AN D load chains, rated load sizes and motor voltage ratings), with R EASSEM B LY applicable models specifically noted. 7-1. GENERAL. b. A complete teardown procedure is given, however, if only certain parts require repair or replacement, a partial teardown a. The following disassembly and reassembly instructions may be performed using the applicable portions of the instruc- /,~apply to all models in the line of BUDGIT Electric Hoists with 4 digit catalog numbers and equipped with MAN-GUARD tions. overload clutch. Where needed, variations to instructions are c. For easier handling during disassembly, the following dis- provided to cover differences between models (suspensions, assembly steps may,. where conditions permit, be com- Page 14 T ! '/i I I I ' ' ' ~l pieted before hoist is removed from its overhead suspension or NOTE: If hoist is inoperative it will be necessary to disconnected from its power supply: Remove chain container, wait until after load brake is removed (par. c., below), if hoist is so equipped; remove lower block and load chain then the chain can be pulled thru the hoist by hand. assembly, following procedure outlined in paragraph 7-2. a. (3) On triple-reeved 3 ton and quintuple reeved 5 ton link ~-~ Drain and discard gear case oil, by removing plug at bottom of chain hoists, remove retaining ring and connecting link pin as frame. shown in figures 7-30 and 7-31. Remove connecting link with d. These hoists contain precision machined parts and should chain from lower block. be handled with care at disassembly and at reassembly. When removing or installing parts with press fits, be careful to apply pressure evenly. On ball bearings, apply pressure to face of inner or outer race, Whichever is adjacent to mating part. This . ...~ will avoid damage to bearing races from brinelling by pressing thru bearing balls. Apply a thin film of sealant to parts having a press fit when they are installed. 7-2. DISASSEMBLY OF HOIST INTO SUBASSEMBLIES. a. Removal of Lower Block and Load Chain Sub- assembly. (1) 'On models with single-reeved load chains (1/4 thru 1 ton rated loads) disconnect tail end of load chain from anchor at side of frame. 'Remove spring clip-and connecting link attaching chain to anchor on roller chain models (fig. 721 ). Remove fillister head screw holding end link to frame on link / / chain models. Remove grooved pin from the limit actuator and pull it off end of chain. With hoist connected to power supply, Figure 7-2. 3 Ton Hanger Bracket run chain out of hoist by operating in "lowering" direction. Connection Pin Removed. (See note following paragraph (2) below and note in .Sec. V, par. 5-2. a. (3) for inserting short length of chain.) Tail End of Load Chain (Roller Chain Models). (2) On models with double-reeved load chains (2 ton hoists) disconnect tail end of load chain from anchor at side of Figure 7-3. Removing 3 Ton Hanger hoist frame and remove limit actuator as in (1) above, run chain Bracket from Hoist Frame. out of hoist by operating it in "lowering" direction, and disconnect opposite end of load chain from anchor inside hoist To remove connecting link from chain, take out cotter key and frame. To disconnect this end of chain, remove cotter pin from push anchor pin from connecting link. Chain can now be end of anchor pin, press pin from anchor and withdraw chain. pulled thru hanger bracket and lower block. Unfasten tail chain On roller chain models the anchor in hoist frame must be from hoist frame, remove limit actuator, and if power is avail- rotated about 90' to permit removal of anchor pin. The drive pin able, operate hoist in lowering direction to remove chain. (See securing threaded end of anchor in upper block assembly (at note in Sec. V, par. 5-2. a. (3) for inserting short length ~of top of frame) must be removed in order to rotate the anchor. chain). If hoist is inoperative see note below but be sure to install short length of chain into hoist before removing load chain. Page 15 NOTE: If hoist is unoperable it will be necessary to remove load brake (par. c, below) so chain can be pulled thru the hoist by hand. f"Tiemove retaining ring and connecting rod pin (see fig. 7-2). Rotate hoist approximately 45° (see fig. 7-3) and hanger will slip free from hoist frame. b. Removal of Electrical Compartment Cover, Electri- :~ ~:' · ~ ~.:.~. cal Controls and Gear Case Subassembly. ~.' ..Z'~'--.""! "::' :i '-' (1) Disconnect hoist from power source. Remove three -' '~,-, ':. ' ~',,.~::~: cover retaining screws and lift off cover (fig. 9-1). Cover ' i~,; i~'': .~3.[!-~...:tj screws have retaining rings which hold them in cover. Use caution as some covers contain counterweights. Two speed hoists with a 2-1/4 horsepower motor have an externally ' ~:* ' ::::i:':' ':' mounted counterweight at the electrical compartment cover, (2) Disconnect push button conductor cable leads at plug- in type connectors that can be pulled apart. Remove screw and Figure 7-5. Removing Limit Lever Key From Control Shaft. washer securing strain tellever (fig. 9-8) and pull the cable and ,. groinmet from its slot in gear case cover. .. (3) Disconnect power supply' flexible cable leads from : terminals of contactor. Remove screw attaching ground leads to gear case cover and pull flexible cable and grommet from slot in cover. (4) Disconnect motor leads from electrical control units. ~- ' Number of leads depends on type of motor. (See wiring ' diagrams in Section VIII). ~ :' '~ (5) Remove eight hex socket head screws and lockwashers · securing gear case cover to hoist frame. Pry gear case cover ft'~Tgartially off hoist frame using screw driver at special notches ' provided at opposite corners of cover (fig. 7-4) to provide access for removing limit lever key from control shaft, Tilt Woodruff key in shaft slot using drift punch (fig, 7-5) and pull ~ %." out using pliers. Gear case cover with electrical controls attached can now be lifted from frame (fig. 7-6). Limit lever ~% " will drop free of frame as shaft is removed with cover. Discard ~"~'°:~:L' ~."~-%':.~:'.~ :~-';~" ~l~!r~,~-.,~C.,~ - .::~;; .~',~,.-~,. gear case cover gasket. Figure 7-6. Gear Case Cover With Electrical '*--~_-~ Controls Removed From Frame, _-~- ~'~: c, Removal of Load Brake and Clutch Assembly and __ Intermediate Gear Subassembly. .;!; (1) On 1/4 thru 1/2 ton hoists; pull load brake and overload · "' ! ~': ! ..'. ~ ~"' : · "'{" clutch assembly and the brake shaft washers from inside hoist frame (fig. 7-7). Caution: Grease-retained bearing has 36 : :?!'~-:i:;.: .; ~. rollers (all capacities) and may be reinstailed unless rollers are broken or missing or cup is damaged. Figure 7-4.. Prying Gear Case Cover From Hoist Frame. Page 16 -r i1 '/ i T T i T ~1 ..,~_ ..... - Figure 7-7. Removing Load Brake and Clutch Assembly (1/4 & 1/2 Ton Hoists). Figure 7-9. Removing Motor Assembly. (2) On 1 thru 5 ton hoists, pull load brake and clutch 7-3. REBUILD OF HOIST FRAME, SPROCKET GEAR, assembly and intermediate gear assembly, including the SPROCKET SHAFFAND CHAIN GUIDE. thrust washers for each unit, from hoist frame (fig. 7-8). a. Disassembly of Sprocket Gear, Shaft and Chain :>: (1) Remove retaining ring from end of sprocket shaft and · ' Remove Woodruff key from shaft. Figure 7-8. Removing Load Brake and Clutch and Intermediate Gear Subassemblies (1 thru 5 Ton Hoists). d. Removal of Motor Brake. (1) Remgve acorn nuts holding brake cover and remove brake cover <fig. (2) Disconnect wire nuts on brake rectifier leads. .. (3) Remove brake mounting plate screws (fig. 9-16) and lift brake assembly off to gain access to the motor mounting bolts. Figure 7-10. Pulling Sprocket Gear from Sprocket e. Removal of Motor Assembly. Shaft Using Common Puller. (1) Place hoist frame on wood blocks to protect intergral gear on motor shaft. Loosen four motor mounting bolts and lift motor assembly from frame (fig. 7-9). Guide motor leads through wire passage to avoid damage. Page 17 (2) Unscrew four fillister head machine screws securing sprocket bearing retaining plate and remove plate (fig. 7-11). Remove and discard ring gasket from groove around bearing or remove seal disc (fig. 7-12). .. ............ / " ,.,.~<:~ . ,.-. .. : ,,,, ,, .,. \ ,,, Figure 7-13. Removing Chain Guide Support ,, Pins Using Pry Ban (4) Remove sprocket shaft and front ball bearings assembly from frame by lifting up on end of shaft while prying up on Figure 7-11. View of Sprocket Bearing Retaining Plate. sprocket as illustrated in figure 7-1 ~,. The chain guide will need to be repositioned in frame as sprocket shaft is raised to allow the sprocket to pass thru hole of guide (fig. 7-15). On roller - chain model hoists, the chain stripper must be partly removed ,,, ~ 'J' "~ ~L::' from guide by prying it out using screw driver or other suitable tool. See figures 7-16 and 7-17. · ,\ ,. :-,,~ ~_-----~- ,,, .;-.-.:,:. ~.. :.:. :-.:~.-i~:,.,,:..-'., · ',:,. . ... ..... 2': '- Figure 7-12. Removing sprocket Bearing Ring Gasket. , _,~:; , ,.=~; (On later model hoists ring gasket is replaced ! ,~ ~,~. '- by a seal disk with oil seals.) ~" .... .:'--: - Figure 7:14. Removing SproC~e~"S'~'aff'~nd Front (3) Using suitable pry bar (fig. 7-13) partially raise two chain guide support pins from their bores in frame. Pull them NOTE: Do not remove oil seal, ball bearings, and the rest of the way out using pliers with jaws protected to avoid needle bearings from their bores in the frame unless damaging pins. Remove and discard two "O" ring gaskets from ' they show evidence of wear or damage and require grooves on each support pin. replacement. When replacing rear sprocket. ball bear- ing pack bearing 1/2 full with NLGI No. 2 grease. Page 18 t t '~ i I [l : ]1' ~ b. Disassembly of Upper Hook. (Hook Suspension .... :.,. ~-: Models.) (1) On 1/4 thru 1 ton models, drive pin from hook nut using drift punch and unscrew upper hook. Nut is reached thru ' access hole in side of hoist frame. See figure 7-18. . Figure 7-15. Chain Guide Being Removed From Frame ..~.,-~.,,~~ .,- ] ~un]~ ;: ' ~'.':~:=:'~ as Sprocket Shaft is Lifted Out ~Link Chain Models). , --- =C~ ' ~:":~::~ TM _,~, · From Hoist Frame (1/4 thru I ton models). =~ (2) On 2 ton models, unscrew two hex socket head screws holding suspension bushing lock assembly to upper block (fig. ,~..:,~;,, ' 7-19) and remove lock. Unscrew suspension bushing from ~"~" i "'~7"~;~ ::,.~.P "~ block to remove hook. To disa~emble block from frame "'~'~ remove drive pin from nut inside frame and unscrew nut from stud holding body to frame. Remove drive pin securing threaded end of chain anchor in block and unscrew anchor. ·: .c~ Block can then be lifted off. Removed From Chain Guide (Roller' Chain Model). :' :i ....' 'h ' %~''''''''':' ~ h.~ ' . _.. ~// Figure 7-19. View of Upper Hook ~sembl~ ~ E ~' To Hoist Frame (2 Ton Models). .: ~~ ~ ~-; ....~ ..,..,~ ,.~ .,/ ............ FigUre 7-17. Chain Guide and Stripper Being Removed From Frame as Sprocket Shaft is Li~ Out (Roller Chain Model). Page 19 NOTE: Hook and bushing assembly is not to be d. Reassembly. further disassembled as nut securing bushing to hook shank is welded in place at the factory. Only the (1) Before assembly, all parts should be thoroughly cleaned assembly is available for replacement. and inspected to determine their serviceability. Replace pans that are excessively worn or damaged. (3) On 3 ton models, remove retaining ring from connecting (2) Reassemble suspension hook or lug, chain guide, rod pin and push connecting rod pin through bracket and connecting rod, releasing hanger (see fig. 7-2). Raise sprocket shaft and sprocket gear to frame following a reverse hanger above' hoist frame to provide access to hook nut. Rotate procedure of the disassembly steps listed in paragraphs (a.) hook until grooved pin in nut is visible from end of hanger thru (c.), above. If ball bearing is to be reinstailed on sprocket frame. Using a drift punch, drive grooved pin thru hook nut be certain to position it so that the seal side of bearing faces out, away from sprocket. To help prevent oil seepage, apply until it hits hanger pocket. Remove drift far enough to hold nut sealant on O.D. of sprocket bearing and in seat for the ring from turning and unscrew hook from nut. Thrust washer will fall free. gasket. ~ 7-4. REBUILD OF LOAD BRAKE AND O~/ERLOAD CLUTCH (4) To remove connecting rod (fig. 7-2) on 3 ton and 5 ton ASSEMBLY. hoist drive pin from rod nut using drift punch and unscrew connecting rod. Nut is reached thru access hole in side of hoist a. Disassembly. frame. (See fig. 7-18). (1) Place load brake and clutch assembly, flange up, in a vise equipped with brass or copper jaw plates t,o protect pinion gea, r teeth. Remove snap ring of load brake shaft (fig. 7-21 ). 11761 Figure 7-20. Removing Suspension Lug (1/4 Thru I Ton Model). Figure 7-21. Removing Snap Ring from Load Brake Shaft. c. Disassembly of Suspension Lug (Lug Suspension Models). (1) On 1/4 thru 1 ton models drive grooved pin from the ::~:'~ round nut inside the hoist frame. Hold round nut from rotating .;.'~ .......' ' ' with drift punch thru access hole in side of hoist frame. ';'=':i,.. 'o';.;.'... Unscrew suspension stud assembly by wrenching hex on top Of suSpenSiOn lug (see fig. 7-20). ' ~7."' (2) On 2 ton models, remove three hex socket head screws securing the two lock plates to block at top of frame and pull out locks. Remove suspension lug, using an extra thin 1-1/4" '~---_.~_;~ ,-- _.. .... . ..... open end wrench to Unscrew suspension bushing from block. ---._ ';~-'- ::~'~'~-"" ::~ Instructions for removing block from frame are given in para- graph b. (2). NOTE: The suspension lug is not to be further disassembled, as nut securing ~uspension bolt and """""'~' '~ " bushing to lug is permanently secured in place at the factory. Only the suspension lug assembly is available for replacement. ~-- .. (3) On 3 ton models lug bolt is removed in same manner as hook. See paragraph 7-3. b. (3). Figure 7-22. View Showing Load Brake Flange Removed. Page 20 (2) Using a puller tool, remove brake flange from shaft. A b. Reassembly. groove is provided around outer diameter for this purpose. See (1) Before assembly, all parts should be cleaned and in- figure 7-22. Remove key from shaft and lift off 2 friction discs, spected to determine their serviceability. Replace parts that are and the pawl and ratchet assembly (fig. 7-23). excessively worn or damaged. ..."r~z;T.;-~~._~.~':' ' ~':.!i '~ ~.' .'~-~:~!..~ assembly steps (3)thru (6) below. · ': ":. ~' ": :' '7" , .... .... '~' ';~'; ~:I:~ ..... (3) Before installing spring in its recess in center of clutch ':':""" ""' ' ' ~' ~.!~!~ cone (fig. 7-24) apply a good grade of ball bearing grease to · ..:..!...:. · ,-. ~ inside of recess. Spring must be positioned exactly as illus- ..,. ~.i,: ~:::.'~:::;~;:!!::;~::,-~ ~:~2 , ;~ ~ - trated, abutted against pin. (4) When insta.ing paw and ratchet a emb y on oad brake :: ~';~% shaft, be certain that teeth on ratchet face are in the same i ~!!' ~,~, i:..,/~l' direction ,, shown in fig. 7-23. The ratchet assembly should ~'~"~' "~ ' ~"' ~ clockwise. ~ ~ should engage ratchet teeth when unit is turned .~. · ~ .- ..., ~: ..... (5) When installing brake flange position it with chamfer . facing friction disc, figure 7-22. ~'....~," -- (6) The brake spring must be pre-loaded at a~embly to a : torque of from 6 to 10 Ib. ~. when used with yellow (color Figure 7-2~ Removing Pawl and.Ratchet ~embly code) spring and a torque of .10 to 14 Ib. h. when used with From Load Brake Shaft. plain (no color code) spring. (See Section IX for proper (3) Remove load brake gear and overload clutch assembly spring). This is accomplished using a plumber's strap wrench from output pinion shaft. Pull the spring from its recess in to wind (rotate) load brake gear to set up spring (fig. 7-25) clutch cone (fig. 7-24) but do not fu~her disassemble gear and while preying brake flange into place using an arbor pre~. clutch assembly. See "NOTE" below. Clamp pinion end of sha~ into a po~able vice t0 keep brake from rotating in pre~. Use bra~ or copper jaw plates on vise to NOTE: Disa~embly of the load brake gear and over- prot~t pinion gear teeth. Wind gear counter-clockwise (view- load cinch a~embl~ (fig. 7-24) is not recommended. ing brake from flange end) with strap wrench and press down Clutch pre~ure is preset by the facto~ at assembly to - . on flange until snap ring groove in shaft is exposed allowing provide the correct torque to ~llow the clutch to refuse loads within a specified range(110% of rated snap ring to be installed. Use extreme care not to over wind load to 180% rated load). It is sugge~ed whenever spring as yield will result and final spring torque will be reduced. Do not wind gear beyond point necessa~ to install there is a need to repair or readjust the gear and clutch a~embly that it be sent to an authorize BUDGIT snap ring in groove. Hoist Repair Station where adequate tools, fixtures and appropriate test equipment is available. ' ...."'. -. .. ':.,, .'~.; .... .. . . .:. -. '~t~.t~,;..~ '..~_ . ..' ::'~. . .~,~. . ..- ~ :~':.";.~,~ .... . ' .."~,:,.', . .r. , . · - ', '~,t~.~.,-, ~' '~ ~:~' :L -, ' ~ .5.T. . ............. ~-. .... . . . :.. ...... :. Figure 7-25. Winding Load Brake Gear Figure 7-24. Load Brake Gear and Overload Clutch Using a Strap Wrench to Set Up Load Brake Spring. A~mbly Removed from Load Brake Shaft Showing Brake Spring Installed in Clutch Cone. (4) The load brake pawl and ratchet is a riveted a~embly and is not to be disa~embl~. Page 21 7-5. REBUILD OF LOWER BLOCK AND LOAD CHAIN ASSEMBLY. a. Disassembly (1/4 through 1-ton, single reeved i:~:i! ": "~ '/j ' models). (1) Separate load chain (link or roller type) from lower block assembly. Drive out small roll pin securing lower block pin in ~ .~, ,~ :', ~ lower block yoke and push lower block pin from yoke to release chain. On roller chain models, an adapter is used to attach chain to lower block. This adapter is removed'from end of chain by first driving out small roll pin and then pushing out adapter · pin. (2) Drive grooved pin from limit actuator and pull actuator .. from end of chain. Figure 7-27. Removing Chain Center Guide from 2 thru 5 Ton Lower Block Assembly (Link Chain Model). (3) Ldwer blocks are of a pinned Construction, permitting replacement of body, thrust bearing, or hook and nut assembly. ~,,..-,.., To disassemble, drive spring pin from hook nut (fig. 7-26). ~ .... , ~:~, ;- .... ~:: With pin removed, hold hook nut from turning with drift punch and rotate hook to unscrew it from nut. ," ' .. .,~' 2 ~-" -,,._ . .... ,~.' ""~ ~' '~' Figure 7-28. Removing Sprocket Pin Lock On !;~ .' "'~,' 2 thru 5 Ton Lower Block Assembly (Link Chain Model). ~ :-, , :11868 .... - Figure 7-26. Removing Roll Pin Securing Hook Nut · to Hook Shank. Separate hook, bearing shield, needle bearings and two thrust washers from body. Hook and nut are drilled at assembly and are replaced only as an assembly. b. Disassembly (2-ton, double reared models). Figure 7-29. Removing Coil Chain and Sprocket on 2 thru 5 Ton Lower Block Assembly (Link Chain Model). (1) On 2-ton roller chain models, remove retaining ring from ' (3)" T~o disassemble h~ok and nut, driv~ gr0o~/e ~in' from one end of sprocket pin and press pin from lower block body. hook nut with drift punch. With pin removed, hold hook nut Grasp chain and pull out sprocket and two spring washers from from turning with drift punch and rotate hook to unscrew it body. Do not remove needle bearing from sprocket or pressure from nut. Separate hook, nut, bearing shield, needle bearing lube fitting from sprocket pin unless replacement is necessary. and two thrust washers from body. Hook and nut are drilled at (2) On 2-ton link chain models, remove fillister head screw assembly and are replaced only as an assembly. securing center guide in top of lower block body and lift out ' ' c. Disassembly (3-ton, triple reared models). guide (fig. 7-27) and sprocket pin lock (fig. 7-28). Press sprocket pin from body and pull out chain, sprocket and (1) Remove chain sprocket from lower block following washer (fig. 7-29). Do not remove bushing type bearing from procedure for 2-ton link chain models described in paragraph ~';procket or pressure lube fitting from sprocket pin unless 7-5. b. (2)above. replacement is necessary. Page 22 (2) To disconnect end of chain anchored to lower block, (2) There is an additional pin and sprocket. Remove the remove retaining ring from pin bore (fig.' 7-30). Push connect- retaining ring from one side of the pin, then remove the pin ing link pin from bore by pressing through hole provided in and sprocket. opposite side of block (fig. 7-31 ). Chain connecting link is e. Reassembly of Lower Blocks. now free and can be further disassembled for inspection. (1) Clean, inspect and replace worn or damaged parts. :':~.¥::.~:~i:,;,::~ "":j':'~ (2) Lubricate and reassemble following a reverse procedure · i .... :;~-. '..C.~-..'~ : of the disassembly steps above. .? "' 7-6. REBUILD OF ELECTRICAL CONTROLS AND GEAR , ' ~;i':" ~:~ :': !'' CASE COVER SUBASSEMBLY. · . ~ a. Disassembly. ~II (1) Disconnect two limit switch leads from contactor. Also, ~" "' . if hoist has a transformer, disconnect transformer leads at the , -. ~ .2!~: ~. ,~-:~i~=:%~;:,= contactor or terminal board. *~" ! ~!~:!=':~: 'SS (2) Remove reconnectable terminal I~oard if so equipped. '~'" ~~:~- ' (3) Remove two screws and lift transformer from gear case .... ~:'~ (4) Remo'~,e two screws a~aching contactor assembly to cover and lift off contactor. Refer to paragraph 7-8 for in~ruc- tions for rebuild of contabor assembly. Figure 7-30. Removing Retaining Ring From Bore of Connecting Link Pin - 3 Ton Lower Block Assembly. (5) Remo~e ~o hex socket head screws and lockwashers securing limit switch assembly to gear case cover and pull limit ~ ~ ~ switch assembly and control shaft from cover. ; (6) Loosen ~o nuts and screws holding limit switches to retainer bracket and remove. ~ ~ . off washer, switch activator, centering lever, spring, spacer , , : ..... tube, retainer bracket and washer. ,~ [ "~- NOTE: Do not remove needle bearings from gear -~ ........ .........-':' .......' ~ ':'~=~:~:::':' case cover unless they show evidence of wear or -~;T-"::::.? damage and require replacement. L ~::~ b. Reassembly. ...... and inspected to determine their seNiceabili~. Replace pa~s ..... . :.'% that are worn or damaged. (2) Rea~emble pa~s to gear case cover in reverse of the Figure 7-31. Removing Connecting Link Pin From 3 Ton disa~embly steps above. Ends of centering spring must strad- Lower Block A~embly. die centering levers. Lubricate Contact segments of limit switch with small amount of graphite grease. (3) To remove hook from lower block body, first drive grooved pin from hook nut Then hold nut from turning using drift punch and rotate hook to unscrew it from nut. Separate 7-7. REBUILD OF PUSH BU~ON STATION AND CON- hook, shroud and thrust washer from body. Note that bearing DUCTOR CABLE ASSEMBLY. . surface of washer faces n~t. a. Disassembly;' (4) To remove chain sprocket from upper suspension (1) Remove seven pan head machine screws and lockwash- hanger, fir~ remove hanger as outlined in paragraph 7-2. a. ers from back of push bu~on station and lift off rear cover. (4). With hanger removed, push sprocket pin from hanger and sprocket. NOTE: Sprocket pin must be removed toward side (2) Loosen three terminal screws and remove strain cable having small anti-rotation pin slot in hanger. screw, lockwasher and plain washer. d. Disassembly (5-ton, quintuple reeved models). (3) Remove two pan head machine screws and lockwashers from housing cap and remove cap, grommet and cablq (1) Follow the instru~ions of paragraph 7-5, c, except a~embly. ;~t there is only a bushing under the hook nut, not a (4) Remove ~o pan head screws, contact assembly and bu~on assembly. aring. ' Page 23 b. Reassembly. 7-10. REBUILD OF THREE PHASE MOTOR ASSEMBLY. (1) Before assembly, all parts should be thoroughly cleaned a. Disassembly. and inspected to determine their serviceability. Repla~;e all parts (1) Pull four motor mounting bolts from motor and separate /t~that are worn or damaged. stator assembly from the end bell and rotor shaft assembly. (2) Reassemble push button station and conductor cable (2) Remove external retaining ring from end of motor shaft following a reverse procedure of the disassembly steps listed and press shaft from bearing in end bell. above. (3) Remove internal retaining ring from bearing bore in end NOTE: Do not attempt to Shorten or lengthen push bell and press out bearing assembly. button conductor cable. Odd length conductor cable assemblies for other than standard 10 ft. lift hoists can b. Reassembly. be procured from the factory. (1) Before assembly, all parts should be cleaned and in- spected to determine their serviceability. Replace all parts that 7-8. REBUILD OF CONTACTOR ASSEMBLY. are worn or damaged. a. General. Wear or damage to contractor parts requires (2) Reassemble motor following a reverse procedure of the replacement of complete contactor assembly. disassembly steps listed above. 7-9. REBUILD OF SINGLE PHASE MOTOR ASSEMBLY. 7-11. REASSEMBLY OF HOIST FROM SUBASSEMBLIES. a. Disassembly. a. General. The procedure to be followed to reassemble the hoist from subassemblies is in reverse order of the disassembly (1) To inspect capacitor, remove two co~er mounting screws steps outlined in paragraph 7-2. Listed below are special and lift off capacitor cover. Do not disconnect wires at capac- assembly precautions which should be observed to assure itor unless capacitor must be replaced. proper assembly. (2) Remove external retaining ring from end of shaft and NOTE: Grease retained bearings (see Section VII, press shaft out of bearing in end bell. par, 7-2. c. (1) and fig. 7-7) have loose rollers. When (3) Remove motor end bell from stator assembly. If neces- reassembling hoist, make certain the correct number sary loosen it by tapping with soft mallet. of rollers are held in roller cup with grease before (4) Remove internal retaining ring from bearing bore in end assembling load brake shaft to hoist. '~ell and press out bearing assembly. b. Assembly of Load Brake Thrust Washers. When rein- stalling load brake assembly be certain thrust washers are b. Reassembly. properly installed at both ends of load brake shaft, as noted (1) Before assembly, all parts should be cleaned and'in- below. spected to determine their serviceability. Replace all parts that (1) A bronze thrust washer with a lug on one side belongs are worn or damaged. on pinion end of shaft and must be installed so that its lug (2) Reassemble motor following a reverse procedure of the engages the special slot located on spotface surrounding disassembly steps listed above. bearing bore inside hoist frame or gearcase cover. Use heavy grease to hold washer in proper position in frame or cover (3) After reinstailing hoist motor, connect hoist to power (depending upon hoist capacity) during assembly. supply and carefully complete both checks (a) and (b) below: (2) On hoists with Catalog Number prefix letters "A," 'C," (a) To check direction of rotation, briefly operate" 1'" "D," "L" an 11/16" I.D. plain steel thrust washer must be used button. If hook lowers, interchange motor lead "T1" with "-r4" between end of pinion gear and the bronze thrust washer (fig. at the contactor or controller. Hook must raise when the" 1'" 7-7). push button is operated. (3) A 5/8" I.D. steel thrust washer is to be installed on the (b) To check the starting winding switch, connect brake flange end (end opposite pinion) of load brake assembly. aremeter (minimum 10 ampere) to motor lead "T5". Amperes -. must drop to zero in approximately one second when operating c. Motor 'B~'~ke. Instructions for 'adjusting the b~'~e are hoist in both" T "and" J, "directions. If ampere reading inside the brake cover and are repeated below. Check brake does not drop to zero, interchange motor leads "'F7" and "TB". adjustment after first 30 days of service and regularly thereafter If, after above checks were made with motor having been run . during the six-month inspection procedure. in both directions, the aremeter reading still does not return to Two versions of the motor brake occur in this manual. zero, the motor switch is not functioning properly and should be replaced. kWARNING t Do not change circuit wiring. Severe damage and mallunction of hoist may result. (1) Brake Adjustment. Adjust brake if clearance between ADJUSTING pressure pad and brake disc is more than .040" (see fig. 7-32) SCREW · or if brake is drifting. ~-',/,~'~ (a) Feeler gage (.020" to .040") or equivalent. I (b) Hex key (1/8" size). (3) To Adjust Brake. (a) Minimum clearance between pressure pad and brake disc is .020" to .025" (see fig. 7-32). Set feeler gage between .020" and ,025" and place between pressure pad /./~ and brake disc. Use 1/8" hex key on adjusting screw (located above solenoid coil). Stop turning adjusting screw when contact is made with the pressure pad. Remove feeler gage. (b) After adjustment operate brake by hand to assure i brake disc running clearance. The outboard pressure pad ~CGATING should separate from the brake disc by approximately .010" to .013". ~27ssc (4) Replace brake cover. Figure 7-32A. Hoist Motor Brake - Later Version. d. Assembly of Load Chain. NOTE: Link chain must be installed so welds-on (1) Examine position of indicating tang located below vertical links face away from the load sprocket· the solehold coil {see fig. 7-32A). (1) On link chain and roller chain models install load chain (2) If the tang is below the line by more than 1/8", the over sprocket before load brake assembly is installed. Insert brake should be adjusted to bring theo. Lq.p_ofthetang back anchor end of chain (end opposite lower block on single up alongside the line on the adjust label. reeved models) into chain guide opening on far side of hoist (3) Remove the hex key (1/8" size) from the holster on the (viewing frame from anchor screw side). Rotate sprocket gear cover mounting stud and carefully turn the ADJUSTING by hand counter-clockwise as chain is fed into opening. When sufficient chain has been run into hoist to reach anchor ~-- SCREW (located above the solenoid coil) clockwise. The '~ 'ndicating tang will move a large distance for a small turn of position, plus a slack loop, install limit actuator on anchor end f~he adjusting screw, therefore turn the screw no more than of load chain (see (3) below) and attach end of chain to frame one-quarter turn before checking adjustment. with special fillister head screw. Be certain chain is not twisted. (4) After adjustment operate the brake by hand to assure (2) On roller chain models, the chain may be installed after brake disc running clearance. The outboard brake pad should step (e) below is accomplished, allowing chain to be run into separate from the brake disc by approximately .010". hoist under power. Caution must be exercised so that fingers or hands are not caught in chain while it is being fed into hoist. (5) Replace hex key in holster. (6) Replace brake cover. NOTE: The spring clip connecting link must be attached to anchor end of roller load chain before .0~L0~_~ 040~x chain is run into hoist. Failure to do so may result in Ft/. F'_~~. damage to chain or hoist. pp~Lss~"_~ ed~ (3) When installing limit actuator on anchor end of load PRESSURE chain attach it at link shown below using a grooved pin, See PADS Figure 3-2. NUMBER OF ADJUSTING CHAIN LINKS ......... SCREW. TYPE CHAIN ,. - SIZE CHAIN FROM END UNK BRAKE Link 1/4' Wire Dia. 8 Links COVER Link 5/16" Wire Dia. 8 Links Roller 5/8" Pitch' 8 Links Roller 3/4" Pitch 7 Links e. Wiring Hook-Up. Before installing hoist, connect wiring OR to electrical controls in accordance with applicable wiring BRAKE END diagram. Wires are coded and/or numbered to agree with )%I DISK BELL Wiring diagrams. . f. Lubricate Hoist. Lubricate hoist as outlined in Section IV. Figure 7-32. Hoist Motor Brake - Early Version. Page 25 T I 'I ! I : I~ 7-12. TESTING HOIST. 7-13. TEST PROCEDURE FOR CHECKING OPERATION OF a. General. After completion of reassembly and before plac- MAN-GUARD OVERLOAD CLUTCH. ing hoist in service, hoist should be tested to insure safe a. General. The overload clutch must be tested using operation. To test: suspend hoist from an overhead supporting known weights. The following prerequisites (par. (1) thru (4)) ~ member of sufficient strength to carry rated load; connect to a must be strictly observed in performing this test. power supply of the specified voltage (see data plate attached to motor); and perform the following checks and adjustments. (1) A qualified person shall determine before testing, that all b. Check For Correct Control Operation. Refer to Sec- structures supporting the hoist are adequately 'strong to wit'h- tion II, par. 2-4. d, under "Warning." stand the test load of 200 percent of rated hoist load, whether hoist is tested in installed position or moved to a designated c. Check Upper and Lower Limit Stop Operation. To test facility. determine if upper and lower limit stop functions properly, m_ake the following checks while operating hoist with (2) Loads used for testing must be accurately known. push button control and actuating the limit lever by hand: (3) Test shall be made only by a qualified operator thor- (1) Depress" 1' "push button and with chain running in oughly familiar with the hoist and the purpose of the test. raise direction, pull down on end of limit lever at tail chain side of hoist (left side facing cover end). The "UP" limit switch (4) Provide adequate and proper rigging to insure test loads should cut off power, causing the hoist to stop. are securely attached, properly balanced, and will lift level. (2) Depress" ], "push button and with chain running in b. Test Procedure, With the ~bove .prerequisites satisfied lowering direction, push up on same end of limit lever. The and hoist properly connected to electrical power, proceed with "DOWN" limit switch should cut off power, causing the hoist the test as follows: to stop. (1) Using a known load equal tO rated load of hoist, operate (3) If hoist does not stop in both travel directions, check for hoist to lift load. Raise load high enough to be certain the entire improper wiring. Refer to par. 6-2 and appropriate wiring load is freely suspended. Clutch should not slip at rated diagram. If wiring is correct, check to see that limit switch is load. If hoist does not lift rated load, clutch requires adjust- correctly installed. ment. Refer to Section V, par. 5-4. c. (4) As a final check, operate hoist (no load) in the lowering (2) Increase load to 200 percent rated load and operate hoist direction and allow tail chain limit actuator to trip limit lever. to lift the load. Clutch must slip, causing the hoist to refuse Hook should stop. Repeat check in hoisting direction and to lift the load. If hoist lifts this overload, the overload clutch is {.. '""]allow lower block to trip limit lever. Hook should stop· out-of-adjustment and must be readjusted. Refer to Section V, par. 5-4. c. d. Check Hoist With Rated Load. Attach rated load to lower hook and check hoist operation. If hoist does not lift (3) If clutch slips as required in step (2) above, continue to run hoist (clutch slipping---hoist refusing to lift load) for five rated load, refer to par. 7-13. (5) cycles of one (1) second each. (1) Operate hoist to raise load. When control is released, (4) Remove excess weight to return the load to rated'hoist load hoist should instantaneously stop and hold load at that load. Lift rated load one final time to be certain that the clutch level. does not slip and that the hoist lifts the rated load. (2)Operate hoist to lower load a short distance, then release control. Hoist should stop instantaneously and hold load at that level. (3) If hoist does not stop or hold load refer to Section VI. - ........ XWARNING .....· ......................... DO NOT LIFT MORE THAN RATED LOAD EXCEPT FOR TEST PURPOSES. NOTICE THIS EQUIPMENT MUST BE EFFECTIVELY GROUNDED ACCORDING TO THE NATIONAL ELECTRICAL CODE, ARTICLES 250-57, 250-59, OR 610-61 OR OTHER APPLICABLE CODES. IF THE GROUNDING METHOD USED IS THROUGH THE TROLLEY WHEELS, THEN EACH SECTION OF TRACK MUST BE GROUNDED BY METAL-TO-METAL CONNECTION TO THE BUILDING GROUND OR ELECTRICAL SYSTEM GROUND. I- Page 26 I 'l I " .... ; I"*' ,.i ~ SECTION IX - REPLACEMENT PARTS This section contains complete replacement parts information men; have authorized testing equipment; and stock a complete for your new BUDGIT Electric Hoist. The parts are grouped inventory of genuine BUDGIT replacement parts. and illustrated in exploded view photos to permit easy identi- Ffication.Each part in an illustration is keyed by reference NOTICE: Information herein is subject to change without '! number to a corresponding parts table. In the table will be notice. Pans must be ordered from an Authorized BUDGIT found the BH part number, description and quantity required. Repair Station or from a BUDGIT Hoist Distributor. When ordering replacement parts it will be necessary that you The numbers assigned to the parts of our various include, with your order, the BH part number of parts required, assemblies in our parts lists are not the part hum- plus, hoist catalog number and model number, which will be bers used in manufacturing the part. They are found on the hoist nameplate attached to motor. For motors complete motor nameplate data is required. Complete inspec- identification numbers, that when given with the tion,. maintenance and overhaul service is available for hoist serial number, permit us to identify, select or BUDGIT Electric Hoists at any of the Authorized Repair manufacture, and ship the correct part needed for Stations. 'All are staffed by qualified factory-trained service any hoist. INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS Figure No. Title Page 9-1 Frame and External Parts ....................................................................................................................29-31 9-2 Upper Suspension, Load Chain and Lower Block Parts (2 Ton Hoists) ......................................... 32-33 9-3 Upper Suspension, Load Chain and Lower Block Parts (3 Ton Hoists) ......................................... 34-35 9-17 Upper Suspension, Load Chain and Lower Block Parts (5 Ton Hoists) ......................................... 36-37 9-4 2 and 3 Ton Lower Block Assembly (Link Chain Hoists) ................................................................. 38 9-5 2 Ton Lower Block Assembly (Roller Chain Hoists) ........................................................... : .............39 9-18 5 Ton Lower Block Assembly (Link Chain Hoists) ............................................................................ 40-41 9-6 Gearing and Load Brake Parts (1/4 and 1/2 Ton Hoists) .................................................................. 42-43 ,0t19-7 Gearing and Load Brake Parts (1 thru 5 Ton Hoists) ........................................................................44-45 --- ~ 9-8A Electrical Control Units (Three Phase Single Speed Hoists - Later Version) ................................ 46-47 9-8 Electrical Control Units (Three Phase Single Speed Hoists - Early Version) ................................ 48-49 9-9A Electrical Control Units (Two Speed Hoists Only - Later Version) ................................................. 50-51 9-9 Electrical Control Units (Two Speed Hoists Only - Early Version) ................................................. 52-53 9-10A Electrical Control Units (Single Phase Hoists - Later Version) ....................................................... 54-55 9-10 Electrical Control Units (Single Phase Hoists - Early Version) ................ :; .....................................56 9-11 Limit Lever and Switch Parts ..............................................................................................................57 9-12 Push Button Station and Conductor Cable Assembly (Single Speed Hoists) ............................... 58 9-13A Push Button Station and Conductor Cable Assembly (Two Speed Hoists Only- Later Version) 60-61 9-13 Push Button Station and Conductor Cable Assembly (Two Speed Hoists Only - Early Version) 62-63 9-14A Single Phase Motor Assembly - Later Version ................................................................................. 64 9-14 Single Phase Motor Assembly - Early Version ................................................................................. 65 9-15 Three Phase Motor Assembly ............................................................................................................· 66-67 9-16A Hoist Motor Brake - Later Version .....................................................................................................68-69 9-16 Hoist Motor Brake - Early Version .....................................................................................................70-71 Page 27 To enable us to expedite }'our parts order, always give Model and Cata- log Number and Electric Current of .~. (~ _/:L~ Hoist. (See nameplate.) 11897E Figure 9-1. FRAME AND EXTERNAL PARTS Standard and Plating Service Hoists (Except 2 thru 5 Ton Model Upper Suspension, Load Chain and Lower Block) Ref. Part Qty. No. Number Description Req'd. 1 BH-1001 Hook Assembly--Upper with Latch (Includes Items 21, 22, 23 & 51 ) 1 ' (for 1/4 & 1/2 ton) BH1001A Hook Assembly--Upper with Latch (Includes Items 21, 22, 23 & 51 ) (for 1 ton) B H-1167 Spacer Washer Under Hook - Not Shown 1 3 BH-1003 Frame Assembly (For Hoists with Cat. No. prefix letters A, C, G, H & J. Includes 2 bushings, 1 needle bearing, 1 cup, 1 oil seal, 1 oil filter, 2 pipe plugs, and 2 dowel pins.) 1 BH-1004 Frame Assembly (For Hoists with Cat. No. prefix letters - -~-~ D, K, L, P, M,- S, T, W, &-V. 4ncludes 2 bushings, 2 needle bearings;---' 10il seal, 1 oil filler, 2 pipe plugs, and 2 dowel pins.) 1 BH-1081 Frame Assembly (For 1/4 & 1/2 ton special sealed frame hoists with suffix -4, -5). Includes sealed frame, 2 bushings, I needle bearing, 2 oil seals, I oil filler, 2 pipe plugs, and 2 dowel pins. 1 B H-1094 Frame Assembly (For 1 & 2 ton special sealed frame hoists with suffix -4, -5). Includes sealed frame, 2 bushings, 2 needle bearings, 2 oil seals, 1 oil filler, 2 pipe plugs, and 2 dowel pins. 1 4 BH-1005 Pin--Support, chain guide 2 5 BH-1006 Gasket--"O" Ring 4 · . 6 B H - 1007 G asket--G earcase 1 (Continued on following page.) Page 29 I I 17 I ; "1 ~ Figure 9-1. FRAME AND EXTERNAL PARTS --Continued Ref. Part Qty. No. Number Descril}tion Req'd. 7 BH-1008 Cover AssemblY--Gearcase (For Hoists v~iih Cat. No. Prefix lette'rS A, C, G, H & J. Includes 1 needle bearing, 1 cup and 2 grooved pins). 1 BH-1009 Cover Assembly - Gearcase (For Hoists with Cat. No. prefix letters D, K, L, P, M, S, T, W, & V. Includes 2 needle bearings and 2 grooved pins}. 1 ''''''i BH-1082 Cover Assembly--Gearcase (For 1/4 & 1/2 ton special sealed frame Hoists with suffix :4, -5). Sealed and includes 1 needle bearing, 1 cup and 2 grooved pins.) 1 BH-1095 Cover Assembly--Gearcase (For 1 & 2 ton special sealed frame Hoists with suffix -4, -5). Sealed and includes 2 beedie bearings and 2 grooved pins.) 1 BH-1157 Cover Assembly--Gearcase (For Two Speed Hoists with 2-1/4 Horsepower Motor Only.) 1 8 BH-1 01 0 Cable Assembly--Flexible, 5' (Incl. Items 9 & 10) 1 115 volt, 1 phase, 60 hertz hoists 1 23D volt, I phase, 60 hertz hoists 1 200/230/460/575 volt, 3 phase, 60 hertz hoists 1 9 BH-1096 Grommet--Flexible Cable--3 phase 1 Groinmet--Flexible Cable---1 phase 1 10 BH-1014 Clamp---Flexible Cable 1 11 Cover--Electrical Compartment 1 BH-1168 Without internal counterweight BH-1169 With internal counterweight Capacity Label (Not Shown) ~ 1 BH-1190 1/4 Ton BH-1191 1/2 Ton BH-1192 I Ton BH-1193 2 Ton BH-1194 3 Ton BH-4195 5 Ton 12 BH-1020 Screw--Fillister Head Machine 3 13 BH-1021 Hi-Collar Helical Spring Lock Washer (1/4) 3 14 BH-1022 Ring--Retaining 8 15 BH-1023 Regular Helical Spring Lock Washer (#10 Pltd.) 8 16 BH-1024 Hex Socket Head Cap Screw (# 10-24 x 3/4) 2 17 BH-1025 Grooved Pin (Type D 1/8 x 1/2 PItd.) 1 18 BH-1026 Grommet--(Motor Driven Trolley Models)--Not Shown 2 19 B H -1027 Dowel Pin (3/8 x 3/4) 2 20 BH-1028 Hex Socket Pipe Plug (1/8) 1 21 BH-1029 Washer--'Ehrust, upper hook 1 22 BH-1030 Grooved Pin (Type F 3/16 x 1-1/4 PItd.) 1 23 " Nut--Upper Hook 24 Guide Assembly--Link Load Chain 1 BH-1031 1/4 & 1/2 ton Hoists 8H-1032 1 thru 5 ton Hoists 25 °*' Chain Assembly--Link, load 1' BH-1033 1/4" Dia.--1/4 & 1/2 ton Hoists BH-1034 5/16" Dia.--1 ton Hoists BH-1080 1/4" Dia.--1/4 & 1/2 ton Hoists - Zinc Plated BH*I 086 5/16" Dia.--1 ton Hoists - Zinc Plated 26 "' Chain Assembly--Roller, load 1 B H - 1039 5/8" Pitch--For 1/4, and 1/2 ton Hoists BH-1040 3/4" Pitch--For 1 ton Hoists BH-1075 Repair Link--5/8" Pitch Roller Chain (not shown) 1 BH-1076 Repair Link--3/4" Pitch Roller Chain (not shown) 1 27 BH-1171 Slotted Spring Pin (3/32 x 5/8 Pltd.) 1 28 Adapter Kit--Roller Load Chain (Incl. Items 27, 28, 29, 40 and 41 ) 1 BH-1172 · 5/8" Pitch---For 1/4, and 1/2 ton hoists ..... BH~I 173 3/4" Pitch--F0~ I ton hOistS ................. 29 BH-1043 Pin--Adapter, roller load chain (5/8" Pitch) 1 BH-1044 Pin--Adapter, roller load chain (3/4" Pitch) 1 30 Block Assembly--Lower, link and roller chain (Incl. items 32 thru 39) 1 BH-1035 For 1/4 ton Hoists BH-1035A For 1/2 ton Hoists BH-1036 For 1 ton Hoists Note: Lower block assemblies-do not include attaching pins or roller chain adaptor. Order separately. 32 Body--Lower Block, link and roller chain 1 BH-1174 1/4 ton Hoists BH-1174A 1/2 ton Hoists f'=h BH-1175 1 ton Hoists I Page 30 (Continued on following page.) I I 'l ! ] I ~ Figure 9-1. FRAME AND EXTERNAL PARTS-Continued Ref, Part Qty. No, Number Description Req'd. 33 Hook, Nut and Latch Assembly--Lower Block 1 BH-1176 1/4 and 1/2 ton Hoists BH-1177 1 ton Hoists 34 Latch Kit--Hook, lower 1 BH-1182 1/4, and 1/2 ton Hoists BH-1183 1 ton Hoists 35 BH-1178 Washer--Thrust, needle bearing 2 36 B H-1179 Bearing Assembly--Needle, thrust 1 37 BH-1180 Shield--Bearing 1 38 BH-1181 Grooved Pin (Type F 5/32 x 1-1/8 Pltd.) 1 39 °' Nut-Hook 1 40 Pin--Connecting, lower block 1 BH-1037 1/4 and 1/2 ton Hoists BH-1038 1 ton Hoists 41-- BH-1045 Slotted Spring Pin (3/32 x 3/4 Pltd.) 1 42 Stripper--Roller Chain 1 ' BH-1046 1/4 and 1/2 ton Hoists BHo1047 I & 2 ton Hoists 43 Guide Assembly---Roller Chain 1 BH-1048 1/4 and 1/2 ton Hoists BH-1049 1 & 2 ton Hoists 44 Link Assembly--ROller Chain (For connecting tail end of chain only--Must not be used to join chain.) 1 BH-1050 1/4 & 1/2 ton Hoists BH-1051 1 & 2 ton Hoists 45 BH-1052 Fillister Head, Self Locking Machine Screw (5/16-18 x 3/4 Pltd.) 1 46 Anchor--Link, roller load chain 1 BH-1053 1/4 & 1/2 ton Hoists BH-1054 1 & 2 ton Hoists 47 tt Actuator--Limit Lever 2 BH-1098 For 1/4" Dia. Link Chain and 5/8" Pitch Roller Chain BH-1099 For 5/16" Dia. Link Chain and 3/4" Pitch Roller Chain 48 BH-1184 Grooved Pin (For Actuator BH-1098) (Type F 7/32 x 2 Pltd.) 2 BH-1185 Grooved Pin (For Actuator BH-1099) (Type F 1/4 x 2 Pltd.) 2 49 BH-1057 Bushing--Control Shaft 2 50 B H -1058 Filler Assembly--Oil 1 51 BH-1183 Latch Kit--Hook (upper) 1/4 thru 1 ton 1 52 BH-1089' Slotted Spring Pin (1/4x 11/16 Pltd.) 2 53 BH-1088® Stud-Suspension, nut and pin (Includes item 55) 1 54 B H -1087' Bracket--Suspension 1 ' 55 BH*I 092 Washer (,0747 Thk,) 1 BH-1186 Washer (.0478 Thk.) As Req'd. The following items are for two speed hoists with 2-1/4 horsepower motor only: 58 BH-1158 Insert-Coil 3 59 Support Stud BH -1159 Top 2 BH-1160 Bottom 1 60 BH-1161 Counterweight 1 61 BH-1162 Plain Washer (Type W 1/4 Pltd.) 3 62 BH-1163 Heavy Hex Self-Locking Nut (1/4 - 20) 3 63 Capacity Label 1 BH-1164 1 Ton BH-1165 2 Ton BH-1166 3 Ton BH-4196 5 Ton * Refe~ to Figure 9-;~'for 2 'i'on Model Upper Suspension, Load Chain and Lower Block Parts. Refer to Figure 9-3 for 3 Ton Model Upper Suspension, Load Chain and Lower Block Parts. Later model hoists also have a set screw (BH-1199) to lock rotation. °* Hook and suspension bolt nuts are not serviced separately. They are available only with hook or bolt as assemblies. TYDe Chain 50' Lenmhs Bulk **° Load Chain Assemblies listed are for hoists with ~ Roller (5/8" Pitch) BH-1064 BH-1065 standard 10 ft. lifts. Bulk chain is available in I ft, Roller (3/4" Pitch) BH-1067 BH-1068 increments and 50 ft. lengths as follows: Link (1/4" Dia.) Not Available BH-1066 Link (5/16" Dia.) NotAvailable BH-1069 Link (1/4" Dia. Zinc plate) Not Availalbe BH-1083 Link (5/16" Dia. Zinc plate) Not Available BH-1093 A urethane Bumper (BH-1063) is used over the top of the steel limit level actuator at lower block on all high speed 64 fpm hoists, 32 fpm I Ton (2~ hp) hoists, and single phase 32 fpm hoists, 10251 Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS (2 Ton Hoists) Page 32 Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS - Continued Ref. Part Qty. No. Number Description Req'd. 1 905422 Bracket Assembly Kit-Lug Suspension (Link Chain Model Only. Includes Items 6, 8 and 9). 1 2 BH-1102 Hook Assembly-Upper (Includes Items 5, 6, 7 and 20). 1 3 BH-1030 Grooved Pin (Type F 3/16 x 1-1/4 PItd.) 3 4 B lock Assembly- U pl3er 1 BH-1104 Link Chain Models, Includes Items 3, 10, 11, 14, 16, 19 and 21 BH-1105 Roller Chain Models, Includes Items 3, 10, 12, 13, 14, 19 and 21 5 BH-1106 Lock Assembly-Suspension Bushing 1 6 BH-1107 Regular Helical Spring Lock Washer (//10 Pltd.). 3 7 BH-1108 Hex, Socket Head Cap Screw (//10-24 x 1/2) 2 8' BH-1109 Hex, Socket Head Cap Screw (//10-24 x 3/8) 1 9 BH-1061 Plate - Lock (Link Chain Lug Suspension Models Only) 1 10 * Stud - Upper Block 1 11 ° Anchor - Link Load Chain 1 12 ' Anchor - Roller Load Chain , 1 13 BH-1110 Pin - Roller Chain Anchor 1 14 BH-1111 Cotter Pin (3/32 x 3/4) 1 15** BH-1112 Chdin Assembly-Roller LoaCl (3/4" Pitch) 1 BH-1076 Repair Link-3/4" Pitch Roller Chain (Not Shown) As Req'd. 16 BH-1113 Pin-Link Chain Anchor 1 17 (See Fig. 9-4) Block Assembly-Lower (Link Chain Models)' 1 (See Fig. 9-5) Block Assembly-Lower (Roller Chain Models) 1 18" BH-1114 Chain Assembly-Link Load 1 BH-1115 Chain Assembly-Link Load (Zinc Plated) 1 19 ° Nut-Upper Block Stud 1 20 BH-221 3 Latch Kit-Hook 1 21 B H - 1029 Washer-Thrust 1 22 BH-1099 Actuator-Limit Lever 1 23 BH-1185 Grooved Pin (Type F 1/4 x 2 Pltd.) 1 Not available as individual parts. Order upper block assembly, Item 4. Load Chain Assemblies listed are for hoists with standard 10 ft. lists. Bulk chain is available in ft. increments and 50 ft. lengths as follows: Chain 50' Lengths Bulk (3/4" Pitch) BH-1067 BH-1068 (5/16" Dia.) Not Available BH-1069 (5/16" Dia. Zinc plate) Not Available. BH-1093 Page 33 To enable us to expedite your parts order, always give Model and Cata- log Number and Electric Current of C C (,~~ .i~,' u ' ~o~~ ' '~' ' ~'~' 7~, REF. 11757 B t Figure 9-3. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS (3 Ton Hoists) Page 34 Figure 9-3, UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS-Continued Ref. Part Qty. No. Number Description Req'd. 1 BH-1131 Suspension Pin and Nut Assembly 1 2 BH-1132 Spherical Washer I Pr. 3 905424 Suspension Lug Kit (Includes Items 1, 2, 4 and 26) 1 4 BH-1134 Pin - Grooved (Type A 3/16 x 2 Pltd.) 1 5 BH-1135 Ho.ok/Latch and Nut (Includes Item 6) 1 6 BH-2214 Latch Kit, Hook 1 7 BH-221 7 Washer, Thrust 1 8 BH-1138 Hanger 1 9 B H-1139 Connecting Rod Assembly 1 10 BH-1029 Washer, Thrust 1 11_ BH-1030 Grooved Pin (Type F 3/16 x 1-1/4 Pltd.) ~1 12 BH-1142 Pin, Connection 1 1~3 BH-1143 Ring, Retaining 2 14 BH'-1144 Sprocket &Bushing Assembly (Includes Item 15) 1 15 BH-1145 Bushing 2 16 BH-1146 Pin, Sprocket 1 17 B H- 1147 Grooved Pin (Type A 3/16 x 3/8 Pltd.) 1 18 BH-1148 Chain Assembly, Link Load 1 19 BH-1149 Link, Connecting 1 20 BH-1150 Pin, Anchor 1 21 BH-11 51 Cotter Pin (3/32 x 3/4) 1 22 BH-1152 Dowel Pin (1/2 x 2-1/4) 1 23 BH-1153 Ring, Retaining 1 24 (See Fig, 9-4) Block Assembly, Lower, Link Chain' 25 BH-2210 Washer, Thrust 2 26 BH-1154 Washer 1 27 BH-1099 Actuator - Limit Lever 1 28 BH-1185 Grooved Pin (Type F 1/4 x 2 Pltd'.) I NOTICE Always insist on factory approved BUDGIT Hoist replacement parts when servicing this equipment. Parts are available from your local Authorized Repair Station. Page 35 I · I' ' To enable us to expedite your parts order, always give Model and Catalog Number and Electric Current of Hoist. (See Nameplate) ~ ~ 9~1(~ 14~'/'/'/' REF ....... Z _ ,~ --,, /5,- --,. ,,' '--__~-,,__,~,- , _- ,~<~,, ', , //,_:c~ ,~: ,,,,__, ,~, ~ 12856B Figure 9-17. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS Page 36 (5 Ton Hoists). I I ' '1 ' I ! T ~ Figure 9-17, UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS (5 Ton Hoists) - Continued Ref, Part Qty, No. Number Description Req'd. 1 BH-3527 Hanger 1 2 BH-3502 Retaining Rings 2 3 BH-3503 Connecting Pin 1 4 BH-3504 Connecting Rod AsSembly (Includes Connecting R6d and Nut) 1 * Connecting Rod 1 * Round Nut 1 5 BH-3505 Flat Washer (3/4 ID x 1-1/40D x ,0747) 1 6 BH-3506 GroOved Pin (Type F 3/16 x 1-1/4 Pltd,) 1 7 BH-3507 Limit Actuator 1 8 - BH-3508 Grooved Pin (Type F 1/4 x 2" PItd,) 1 9. BH-3509 Flat Washer (1" ID x 2" OD x ,0478) 2 BH-3510 · Sprocket and Bearing Assembly (includes Ref, Nos, 10 and 11) 1 10 BH-3511 Sprocket 1 11 · BH-3512 Bushings 2 12'* BH-3513 Spring Pin (Slotted Type 3/16 x i" PItd,) 1 13** BH-3514 Upper Sprocket Pin 1 14 BH-3515 Grooved Pin (Type A 3/15 x 3/8 PItd,) 1 15 B H-3516 Sprocket Pin 1 16 BH-3517 Flat Washer (45/64 ID x 1-3/80D x ,020) 2 BH-3518 SiSrocket and Bearing Assembly (includes Ref, Nos, 17 and 18) 1 17 BH-3519 Sprocket 1 18 BH-3520 'Bushings 2 19 BH-3521 Cotter Pin (3/32 x 3/4 Pltd,) 1 20 BH-3522 Anchor Pin 1 21 BH-3523 Load Chain (Plain, 10' Lift) 1 22 See Fig. 9-18 Lower Block Assembly 1 23 BH-3524 Grease Fitting 1 24 BH-3525 Flat Washer (5/16 ID x 3/40D x 1/16) 1 25 BH-3526 Self-Locking Hex Socket Head Cap Screw (1/4-20 x 1/2 Pltd.) 1 Connecting Rod and Nut not sold separately, only as an assembly, version used a pin (Ref, No. 12 - Part .Number BH-3513 - no longer shown) through Ref, No, 13 - Part Number BH-3514, Page 37 I '1 ! ; T 1T To enable us to expedite your parts ~ order, always give Model and Catalog Number and Electric Current of ~ Hoist. (See nameplate.) - 12444A Figure 9-4. 2 and 3 TON LOWER BLOCK ASSEMBLIES (Link Chain Hoists) Ref. Part Quantity Required No. Number Description 2 Ton 3 Ton BH-221 9 Block Assembly--Lower Complete 1 -- BH-221 8 Block Assembly--Lower Complete -- 1 1 BH-2202 Guide---Center 1 1 2 BH-2203 Lock--Sprocket Pin 1 1 3 BH-2204 Sprocket--Link Chain 1 1 4 BH-2205 Bushing--Sprocket I 1 5 BH-2206 Screw--Fillister Head, Self locking I 1 6 BH-2207 Pin-Sprocket 1 1 7 BH-2208 Fitting---Hydraulic Drive I 1 9 BH-2210 Washer, Thrust I 1 10 BH-2211 Body Assembly--Lower Block -- 1 11 BH-221 2 Hook/Latch and Nut (Includes Items 12, 13 and 15) -- 1 12 BH-2213 Latch Kit. Hook 1 -- BH-2214 Latch Kit, Hook -- 1 13 BH-221 5 Pin, Grooved -- 1 14 .BH-2216 Shroud -- 1 15 BH-221 7 Washer, Thrust -- 1 16 BH-2220 Hook/Latch and Nut (Includes Items 12 and 17) 1 -- 17 B H -2221 Pin. Grooved 1 -- 18 BH-2222 Shield, Bearing I -- 19 BH-2223 Bearing Assembly--Needle, Thrust I -- 20 BH-2224 Washer, Thrust 2 -- 21 BH-2225 Body--Lower Block I -- 38 I '1 ! I ~ To enable us to expedite your parts ~ ~,~,~ Hoist, (See nameplate.) 0263B Figure 9-5. 2 TON LOWER BLOCK ASSEMBLY (Roller Chain Hoists) Ref. Part Qty. No. Number Description Req'd. B H -2301 Block Assembly--Lower, Complete 1 1 BH-2302 Washer--Spring Thrust 2 2 BH-2303 Sprocket--Chain 1 3 B H -2304 Bearing Assembly--Needle 1 4 BH-2305 Ring--Retaining, External 2 5 BH-2208 Fitting--Hydraulic Drive 1 6 B H -2307 Pin-~Sprocket 1 7 BH-2308 Hook and Nut Assembly--Lower Block (Includes Item 12 below) 1 8 BH-2311 Pin--Grooved 1 9 BH-231 2 Shroud 1 10 BH-231 3 Washer--Thrust 1 11 B H-231 5 Body Assembly 1 12 BH-2308 Hook and Nut Assembly 1 13 BH-2213 Latch Kit--Hook I NOTICE Always insist on factory approved BUDGIT Hoist replacement parts when servicing this equipment. Parts are available from your local Authorized Repair Station. Page 39 ,z~~~, To enable us to expedite your parts order, always give Model and Catalog Number and Electric Current of Hoist. (See Nameplate} . ¢) 12857A Figure 9-18. 5 TON LOWER BLOCK ASSEMBLY (Link Chain Hoists). Ref. Part Qty. No. Number Description Req'd. BH-3601 Lower Block Assembly (Includes Ref. Nos. 1 thru 23) 1 1 I~N-:~G02 Retaining Ring 1 2 BH-3603 Flat Washers (45/64 ID x 1-3/80D x .020) 2 BH-3604 Sprocket and Bearing Assembly (Includes Ref. Nos. 3 and 4) 1 3 BH-3605 Sprocket 1 4 BH-3606 Bushings 2 5 BH-3607 Center Guide ' ~ 1 6 BH-3608 Pin Lock 1 7 BH-3609 Center Guide 1 8 BH-3610 Flat Washer (1" ID x 2" OD x .0478) 1 ~:: (Continued on following page.) Page 40 I I ' I 'i ! ]' ' ~ Figure 9-18.5 TON LOWER BLOCK ASSEMBLY (Link Chain Hoists). - Continued Ref. Part Qty. No. Number Description Req'd. _d.~! 9 BH-3611 Sprocket 1 · 10 BH-3612 Bushing 1 11 BH-3613 Grooved Pin (Type F 1/4 x 2" Pltd.) 1 12 BH-3614 Hook and Nut Assembly (Includes Hook, Nut &Latch) 1 * Hook 1 * Round Nut 1 BH-3615 Hook Latch Assembly 1 13 BH-3616 Thrust Washer 1 14 BH-3617 Retaining Rings 2 15 BH~3618 Lower Block Anchor Pin 1 16 BH-3619 Connecting Link 1 17 BH-3620 Lower Block Body 1 18 BH-3621 Pin 1 19 BH-3622 Self Locking Fillister Head Machine Screw (1/4-20 x 2-1/4 Pltd.) 1 20 BH-3623 Self Locking Fillister Head Machine Screw (1/4-20 x 2" Pltd.) 1 21 BH-3624 Sprocket Pin 1 22 BH-3625 Spring Pin (Slotted Type 1/8 x 1" Pltd.) 1 23 BH-3626 Hydraulic Drive Fitting (For 3/16 Hole - Ball Check) 2 * Hook and Nut not sold separately, only as an assembly. Page 41 To enable us to expedite your parts 11898 Figure 9-6. GEARING AND LOAD BRAKE PARTS (1/4 and 1/2 Ton Hoists) Ref. Part Qty. No. Number Description Req'd. I BH-1201 Seal--Oil, motor shaft 1 2 BH-1202 Bearing Assembly--Ball, motor shaft 1 3 BH-1203 Ring--Retaining, Internal 1 4 BH-1237 Bearing Assembly--Needle, 11/16" I.D. (36 rollers, grease retained) 1 5 BH-1205 Bearing--Thrust, bronze 1 6 BH-1206 Washer--Thrust, 11/16" I.D. (Used with 14 tooth Pinion Load Brake Shaft--BH-1207 below) 1 7 Shaft &Integral Pinion--load brake, BH-1207 14 teeth 1 BH-1208 23 teeth BH-1209 36 teeth 8 B H - 1 21 0 Key-Woodruff 2 9 BH-1239 Retainer--Spring, load brake 1 10 BH-1212 Spring--load brake (Plain--no color code) 1 BH-1 21 3 {Spring---load brake (Yellow color code) 1 11 BH-1 21 4 Pin--Grooved 2 12 BH-1216 Cam--load brake 1 13 ' Gear &Clutch Assembly--load brake 1 BH-1240 For use with 1/4 H.P. Motor BH-1241 For use with 1/2 H.P. Motor BH-1242 For use with 1 H.P. Motor 14 B H -1 21 8' Disc--Friction, load brake ..... 2 15 BH-1238 Bushing--Ratchet 2 16 BH-1 21 9 Flange--10ad brake 1 17 BH-1 220 Bearing Assembly--Needle, 5/8" I.D. 1 18 BH-1221 Washer--ThrOSt, 5/8" I.D. 1 19 BH-1222 Ring--Snap, brake flange 1 20 B H-1223 Pawl &Ratchet Assembly--load brake (includes item 15) 1 21 BH-1224 Ring--Snap, sprocket gear . 1 22 Gear--Sprocket BH-1225 74 teeth 1 BH-1226 65 teeth B H - 1227 52 teeth ~,.~. (Continued on following page.) I 'i I ' '] T ' ~] Figure 9-6. GEARING AND LOAD BRAKE PARTS - Continued Ref. Part Qty. No. Number Description Req'd. ,~ 23 BH-1228 Screw - Fillister Head Machine 4 ~ 24 BH-1229 Lockwasher - Spring Type 4 25 BH-1230 Plate - Retainer, Sprocket Bearing 1 26** BH-1231 Gasket - Ring, Sprocket Bearing 1 27 BH-1232 Bearing Assembly- Ball, Sprocket 1 BH-1318 Ball Bearing On Later Model Hoists 1 28** BH-1233 Sprocket - Link Chain (I/4" Dia. Wire) 1 29** BH-1234 Sprocket - Roller Chain (5/8" Pitch) 1 30 BH-1235 Bearing Assembly- Ball, Sprocket 31 BH-1236 Key - Woodruff 1 32** BH-1315 O-Ring 33*;* BH-1316 Seal Disk 1 34** BH-1317 Seal - Oil 1 * This gear and clutch assembly should not be field disassembled.. Replace assembly only as clutch pressure is preset at factory based on hoist capacity and motor H.P. ** On later model hoists; Ref. No. 26 is replaced by Ref. Nos. 32, 33 and 34 and BH-1233 and BH-1234 are replaced by BH-1311 and BH-1313. NOTES Page 43 .... i' "1" ......'~ 'wm : ~ ~I To enable us to expedite )our parts order, al~,a.~s gi,ve ~lodel and Cala- 11899 Figure 9-7. GEARING AND LOAD BRAKE PARTS (1 thru 5 Ton Hoists) Ref. Part CIty. No. Number Description Req'd. I BH-1201 Seal--Oil, motor shaft 1 2 BH-1202 Bearing Assembly--Ball, motor shaft 1 3 BH-1203 Ring--Retaining, Internal 1 4 B H -1220 Bearing Assembly--Needle, 5/8" I.D. 2 5 BH-1221 Washer--Thrust, 5/8" I.D. 2 6 BH-1222 Ring--Snap, brake flange 1 7 B H-1 21 9 Range--Load Brake 1 8 BH-1218 Disc--Friction, load brake 2 9 BH-1223 Pawl and Ratchet Assembly--Load Brake (includes item 15) 1 10 BH -1238 Bushing--Ratchet 1 11 · Gear and Clutch Assembly---Load Brake 1 BH-1241 For use with 1/2 H.P. Motor BH-1242 For use with I and 2-1/2 H.P. Motors 12 B H- 1212 Spring--Load Brake (Plain--no color code) 1 13 B H-1216 Cam---Load Brake 1 14 BH-1239 Retainer--Spring, Load Brake 1 15 B H- 1210 Key--Woodruff 2 16 Shaft and Integral PinionsLoad Brake 1 B H - 1207 14 teeth BH-1208 23 teeth 17'** BH-1206 Washer--Thrust, 11/16" I.D. 2 18 B H-1205 BearingsThrust, bronze 1 19 BH-1204 Bearing Assembly--Needle, 11/16" I.D. 1 20 BH-1 21 4 Pin---Grooved -. 2 21 BH-1224 Ring--Snap, intermediate gear 1 22 Gear--Intermediate 1 BH-1225 · 74 teeth BH-1226 65 teeth 23 B H - 1236 Key--Woodruff 1 24 BH-1304 Shaft and Integral PinionsIntermediate 1 25 B H -1237 'Bearing Assembly--Needle, 11/16" I.D. 1 26 BH-1305 RingsSnap, sprocket gear ' ' 1 27 B H-1306 Gear-Sprocket 1 28** BH-1307 Spacer--Sprocket Gear 1 29 BH-1228 Screw--Fillister Head Machine 4 (Continued on following page.) Figure 9-7. GEARING AND LOAD BRAKE PARTS - Continued Ref. Part Qty. No. Number Description Req'd. ///~ 30 BH-1229 Lockwasher - Spring Type 4 31 BH- 1230 Plate - Retainer, Sprocket Bearing 1 '1 32** BH-1231 Gasket - Ring, Sprocket Bearing 1 33 BH-1232 Bearing Assembly - Ball, Sprocket 1 BH-1318 Ball Bearing On Later Model Hoists 1 34 BH-1308 Key - Woodruff, Sprocket ' 1 35** BH-1309 Sprocket ~ Coil Chain 1 Later MOdel Hoists: BH-1311 1/4" Dia. Wire 1 BH-1312 5/16" Dia. Wire 1 36** BH-1310 Sprocket - Roller Chain 1 Later Model Hoists: BH-1313 5/8" Pitch 1 BH-1314 3/4" Pitch 1 37 BH-1235 Bearing Assembly - Ball, Sprocket 1 38** BH-1315 O-Ring 1 39** BH-1316 Seal Disk 1 40** BH-1317 Seal - Oil 1 * This gear and clutch assembly should not be field disassembled. Replace assembly only as clutch pressure is preset at factory based on hoist capacity and motor H.P. ** On later model hoists; Ref. No. 28 is not used, Ref. No. 32 is.;eplaced. by Ref. Nos. 38, 39 and 40 and BH-1309 and BH-1310 are replaced by BH-1311 thru BH-1314 as shown above. *** Ref. No. 17 occurs next to Ref. No. 16 for 14 tooth pinion load brake shaft only. NOTES Page 45 To enable us to expedite your parts order. always gNe Model and Catalog Number and Electric Current of Hoist. (See Nameprate) RECONNECTABLE REF. TERMINAL BOARD 230/460 V., 3 Phase Figure 9-8A. ELECTRICAL CONTROL UNITS Three Phase Single Speed Hoists - Later Version) ~ Ref. Part Qty. No. Number Description Req'd. Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4) 1 BH-3800 Three Phase 24V Control BH-3801 Three Phase 115V Control 1 BH-3802 Mounting Plate - Contactor 1 2 BH-2155 Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8} 5 3 Contactor Assembly 1 BH-3803 Three Phase 24V Control BH-3804 Three Phase 115V Control 4 BH-2189 Pan Head Self Tapping Screw (~8-32 x 1/2) 2 5 BH-2161 Hex Socket Head Cap Screw (~10-24 x 3/8 Pltd.} 2 6 BH-2162 Regular Helical Spring Lock Washer (~10 Pltd.) 2 7 See Fig. 9-11 Limit Switch and Shaft Assembly 1 8 Transformer 1 BH-2166 Three Phase 208V/24V BH-3805 Three Phase 230V/460V/24V BH-2168 Three Phase 575V/24V BH-2169 Three Phase 208V/115V BH-3806 Three Phase 230V/~60V/115V .... " BH-2172 Three PhaSe 575W115V (Continued on following page.) Page 46 I I I 'i !' " "' i' fl Figure 9-8A. ELECTRICAL CONTROL UNITS (Three Phase Single Speed Hoists - Later Version) - Continued Ref. Part Qty. No. Number Description Req'd. ('.~ 9 BH-2173 Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8) 1 .. ~ 10 BH-2174 Plain Washer (Type N 1/4) 2 11 BH-2175 Groinmet 1 12 See Fig. 9-12 Push Button Station and Conductor Cable Assembly 1 13 Fuse, Fuse Holder and Wire Assembly 1 BH-2176 3N250V BH-2177 1/2N250V Fuse Only 1 BH-2178 3AJ250V Rating BH-2179 1/2A/250V Rating 14 BH-3807 Block - Terminal 1 15 BH-2181 Spacer - Terminal Block 2 16 - BH-2182 Regular Helical Spring Lock Washer (#8 Pltd:) 2 17 BH-3808 Round Head Machine Screw (#8-32 x I Pltd.) 2 18' BH-1422 Flanged Sleeve Bearing 1 NOTE: Replacement fuses are standard automotive type and may be purchased locally. NOTES Page 47 ; i To enable us to expedite your parts order, always give Model and Calaleg Number and Electric Current of Hoist. (See Nameplale) RECONNECTABLE REF. TERMINAL BOARD 230~460 V., 3 Phase I Figure 9-8. ELECTRICAL CONTROL UNITS ( (Three Phase Single Speed Hoists - Early Version) Ref. Part Qty. No. N umber Description Req'd. Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4) 1 BH-2150 Three Phase 24V Control BH-21 51 Three Phase 115V Control 1 B H-2154 Mounting Plate---Contactor 1 2 BH-2155 Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8) 4 3 Contactor Assembly 1 BH-2156 Three Phase 24V Control BH-2157 Three Phase 115V Control 4 BH-2160 Round Head Machine Screw (#8-32 x 1/2) 2 5 B H-21 61 Hex Socket Head Cap Screw (# 10-24 x 3/8 Pltd.) 2 6 BH-2162 Regular Helical Spring Lock Washer (#10 Pltd.) 2 7 See Fig. 9-11 Limit Switch and Shaft Assembly 1 8 Transformer 1 BH-2166 Three Phase 200V/24V B H-2164 Three Phase 230V/24V BH-2167 Three Phase 460V/24V BFI-2168 Three Phase 575V/24V BH-2169 Three Phase 200V/115V B H-2170 Three Phase 230V/115V B H -2171 Three Phase 460V/115V BH-2172 Three Phase 575V/115V (Continued on following page.) Page 48 i i m 'm i [' .l' ' ~ Figure 9-8. ELECTRICAL CONTROL UNITS -- Continued Ref. Part Qty. No. Number Description Req'd. 9 B H-2173 Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8) 1 · 10 BH-2174 Plain Washer (Type N 1/4) 1 11 BH-2175 Grommet 1 12 See Fig. 9-12 Push Button Station and Conductor Cable Assembly 1 13 Fuse, Fuse Holder and Wire Assembly 1 BH-2176 3A/24V BH-2177 1/2.A/115V Fuse Only 1 BH-2178 3A/250V Rating B H -2179 1/ZA/250V Rating 14 BH-2180 Block--Terminal 1 15' BH-21 81 Spacer--Terminal Block 2 16 BH-2182 Regular Helical Spring Lock Washer (#8 PItd.) 2 17 BH-2183 Round Head Machine Screw (#8-32 x I Pltd.) 2 18 BH-1422 Flanged Sleeve Bearing 1 NOTE: Replacement fuses are standard automotive type and may be purchased locally. \ \ NOTES Page 49 _,)To enable us to expedite your parts order, always gNe Model y,/' ~ and Catalog Number and Electric Current of Hoist. (See Nameplate) -,d REF. Figure 9-9A. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only - Later Version) Ref. Part Qty. No. Number Description Req'd. Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4) 1 8H-3800 Three Phase 24V Control B H-3801 Three Phase 115V Control I BH-3802 Mounting Plate - Contactor 1 2 BH-2155 Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8) 5 3 Contactor Assembly 1 BH-3803 Three Phase 24V Control BH-3804 Three Phase 115V Control 4 BH-2189 Pan Head Self Tapping Screw (#8-32 x 1/2) 2 5 BH-2161 Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.) 2 6 BH-2162 Regular Helical Spring Lock Washer (#10 Pltd.) 2 7 See Fig. 9-11 Limit Switch and Shaft Assembly 1 8 Transformer 1 BH-2166 Three Phase 208V/24V 8H-2164 Three Phase 230V/24V BH-2167 Three Phase 460V/24V BH-2168 Three Phase 575V/24V BH-2169 Three Phase 208/115V BH-2170 Three Phase 230V/115V BH-2171 . Three Phase 460V/115V BH-2172 Three Phase 575V/115V 9 BH-2173 Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8) 1 10 BH-2174 Plain Washer (Type N 1/4) ' ' 2 11 See Fig. 9-13 Push Button Station and Conductor Cable Assembly 1 (Continued on following page.) Page 50 I i I "i ! I f :" ~ Figure 9-9A. ELECTRICAL CONTROL UNITS (Two Speed Hoists - Later Version) - Continued Ref, Part Qty, No. Number Description Req'd, (. 12 Fuse, Fuse Holder and Wire Assembly 1 · BH-2176 3A/250V I BH-2177 1/2N250V Fuse Only 1 BH-21'78 3A/250V Rating BH-2179 172N250V Rating Contactor and Mounting Plate Assembly (Includes Ref. Nos. 13, 15 and 16) 1 BH-3809 Three Phase 24V Control BH-3810 Three Phase 115V Control 13 BH-3811 Mounting Plate - Contactor 1 14 BH-2193 Sems Round Head Machine Screw with External Lock Washer (#8-32 x 1/2) 2 15 Contactor Assembly 1 BH-3812 Three Phase 24V Control BH-3813 Three Phase 115V Control 16 BH-2199 Pan Head Self Tapping Screw (#8-32 x 3/8) 2 17 BH-1422 Flanged Sleeve Bearing 1 NOTE: Replacement fuses are standard automotive type and may be purchased locally. NOTES Page 51 To enable us to expedite your /~"~ ~ parts order, always give blodel and Catalog Number and Electric '/~' ,/,/~ Current of Hoist. (See Nameplate) ,/ REF. Figure 9-9. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only - Early Version) Ref. Part Qty. No. Number Description Req'd. Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4) 1 BH-2150 Three Phase 24V Control 8H-21 51 Three Phase 115V Control I BH-2154 Mounting Plate -- Contactor 1 2 BH-2155 Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8) 4 3 Contactor Assembly '1 BH-2156 Three Phase 24V Control BH-2157 Three Phase 115V Control 4 BH-2160 Round Head Machine Screw (#8-32 x 1/2) 2 5 BH-2161 Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.) 2 · 6 B H-2162 Regular Helical Spring Lock Washer (#10 Pltd.) 2 7 See Fig. 9-11 Limit Switch and. Shaft Assembly 1 8 Transformer 1 BH-2166 Three Phase 200V/24V BH-2164 Three Phase 230V/24V BH-2167 Three Phase 460V/24V BH-2168 Three Phase 575V/24V' BH-2169 Three Phase 200V/115V BH-2170 Three Phase 230V/115V BH-21 71 Three Phase 460V/115V ' ' BH-2172 Three Phase 575V/115V (Continued on following page.) Page 52 Figure 9-9. ELECTRICAL CONTROL UNITS- Continued Ref. Part Qty. No. Number , Description Req'd. 9 B H-2173 Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8) 1 10 BH-2174 Plain Washer (Type N 1/4) 1 11 See Fig. 9-13 Push Button Station and Conductor Cable Assembly 1 12 Fuse, Fuse Holder and Wire Assembly 1 B H-2176 3A/24V BH-2177 1/2A/115V Fuse Only 1 BH-2178 3A/250V Rating B H-2179 1/2A/250V Rating Contactor and Mounting Plate Assembly (Includes Ref~ Nos. 13, 15 and 16) 1 BH-2190 Three Phase 24V Control BH-21 91 Three Phase 115V Control 13 BH-2192 Mounting Plate--Contactor 1 14 BH-2193 Sems Round Head Machine Screw with External Lock Washer (#8-32 x 1/2) 2 15 Contactor Assembly 1 BH-2194 Three Phase 24V Control BH-2195 Three Phase 115V Control 16 BH-2196 Pan Head Self Tapping Screw (#8-32 x 1/2 Pltd.) 2 17 BH-1422 Flanged Sleeve Bearing 1 NOTE: Replacement fuses are standard a~tomotive type and may be purchased locally. NOTES Page 53 To enable us to expedite your parts order. ahNays give Model -~- and Catalog Number and Electric ,/ Current of Hoist. (See Nameplate) FIEF. 11900H Figure 9-10. ELECTRICAL CONTROL UNITS .~,.,, (Single Phase Hoists - Early Version) Ref. Part Oty. No. Number Description Req'd. BH-3101 Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4) 1 I B H-2154 Mounting Plate--Contactor 1 2 BH-2155 Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8) 4 3 BH-3102 Contactor Assembly 1 4 BH-3103 Pan Head Self Tapping Screw (#8-32 x 1/2 Pltd.) 2 5 BH-2161 Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.) 2 6 BH-2162 Regular Helical Lock Washer (#10 Pltd.) 2 7 See Fig. 9-11 Limit Switch and Shaft Assembly 1 8 BH-2173 Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8) 1 9 BH-2174 Plain Washer (Type N 1/4) 1 10 B H -2175 Grommet 1 11 See Fig. 9-12 Push Button Station and Conductor Cable Assembly 1 12 BH-3104 Mounting Plato Terminal Board 1 13 BH-3105 Pan Head Self Tapping Screw (#10-24 x 3/8 Pltd.) 2 14 BH-3106 Terminal Block 1 15 BH-3107 Pan Head Self Tapping Screw (8-32 x 1/2 Pltd.) 2 16 BH-3108 Mounting Bracket--Starting Switch 1 17 BH-3109 Pan Head Self Tapping Screw (#6-32 x 3/8 Pltd.) 2 18 Starting Switch 1 BH-3110 1/4 Horsepower BH-3111 1/2 Horsepower ' ' BH-3112 I Horsepower 19 BH-3113 Round Head Machine Screw (#6-32 x 5/16 Pltd.) 1 20 BH-3114 Fuse, Fuse Holder and Wire Assembly (1/2A/250V) 1 BH-3115 Fuse Only (1/2A/250V Rating) 1 -'i 21 BH-1422 Flanged Sleeve Bearing 1 "i Replacement fuses are standard automotive type and may be purchased locally. 56 i '! ! ~ enable us to expedite your parts order, alwa>s give Model and Cata- Number and Electric Current of Hoist. (See nameplate. ) 11 ~IA Figure 9-11. LIMIT LEVER AND SWITCH PARTS Ref. Part Qty. No. Number Description Req'd, BH-1850 Limit Switch and Shaft Assembly (Includes Ref. Nos. I thru 14 and 17 and 18) 1 1 BH-1851 Light Hex Self-locking Nut (#4-40 Pltd.) 2 2 B H - 1852 Retainer 1 3 BH-1853 Insulation 2 4 BH-1854 Limit Switch--Upper 1 5 BH-1855 Limit Switch--Lower 1 6 BH-1856 Insulation 1 7 BH-1857 Plate--Cover 1 8 BH-1858 Round Head Machine Screw (#40-40 x 1-1/8 Pltd.) 2 9 BH-1859 Light Thin Hex Self-locking Nut (#10-24 Pltd.) 1 10 BH-1860 Plain Washer (#10 Pltd.) 1 11 BH-1861 Switch Actuator 1 12 B H - 1862 Centering Lever 1 13 B H- 1863 Spring--Control 1 14 B H - 1864 Spacer 1 15 BH-1865 Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.) 2 16 BH-1866 Regular Hetical Spr. ing Lock Washer (#10 Pltd.) 2 17 BH-1867 Plain Washer (Type N 5/16 Pltd.) 1 18 B H - 1868 Control Shaft 1 19 B H - 1869 Key--Woodruff 1 20 BH-1870 Limit Lever I Page 57 2763 Figure 9-12. PUSH BU~ON STATION AND CONDUCTOR CABLE ASSEMBLY (Single Speed Hoists) Ref. Part Qty. No. Number Description Req'd. BH-3401 Push Button Station and Conductor Cable Assembly (Includes Ref. Nos. 1 thru 17) 1 BH-3402 Push Button Station (Includes Ref. Nos. I thru 15)' 1 1 Type I Pan Head Machine Screw (M3.5 x 0.6 x 12 Pltd.) 7 2 ° Lockwasher (M 3.5 Pltd.) 7 3 ° Rear Cover 1 4 B H -3403 Gasket 1 5 ° Type 1 Pan Head Thread Cutting Screw (M 4 x 15 Pltd.) 2 6 B H -3404 Contact Assembly 1 7 BH-3405 Button Assembly 1 8 ° Type 1 Pan Head MaChine Screw (M 6 x 1 x 12 Pltd.) 1 9 ' Lockwasher (M 6 Pltd.) 1 10 ° Plain Washer (M 6 PItd.) 1 11 ' Type I Pan Head Machine SCrew (M 3.5 x 1 x 14 Pltd.) 2 12 ' Lockwasher (M 3,5 Pltd.) 2 13 ' Housing Cap - - 1 14 B H-3406 Grommet 1 15 ° Housing 1 16 BH-3407 Conductor Cable Assembly 1 17 BH-3408 Plastic Warning Tag I ~.:.., available separately. Order Push Button Station, '! '! I 'T T ! NOTES Page 59 I 1 '! I I To enable us to expedite your parts order, always give Model and Catalog Number and Electric Current of Hoist, (See Nameplate) /---,, · !.1 12721A Figure 9-13A. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY (Two Speed Hoists Only - Later Version) Ref. Part Oty. No. Number Description Req'd. BH-1980 Push Button Station and Conductor Cable Assembly (Includes Ref, Nos, 1 thru 30) 1 1 BH-1981 Grommet 1 7 . BH-1982 Conductor Cable 1 11 BH-1971 Operator Warning Label 1 BH-1972 Push Button Station (Includes Ref, Nos, 12 thru 30) 1 12 BH-1973 Sleeve - Conductor 1 13 * Support - Strain Cable 1 14 * Screw - Slotted Head 4 15 * Lockwasher 4 16 * Enclosure - Rear 1 17 * Gasket 1 18 * Screw - Slotted Head ' ' 2 19 * Screw - Slotted Head 2 20 * Clamp - Conductor 1 (Continued on following page.) ~/. Page 60 I I · !' I T I Figure 9-13A. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY (Two Speed Hoists Only - Later Version) - Continued (,/~ Ref. Part Qty. No. Number Description Req'd. 21 * Contact Block Assembly 1 BH-1974 Contact Block 2 BH-1975 Contact Block 2 22 * Interlock - Mechanical 1 BH-1976 Up Push Button Assembly (Includes I Each of Ref. Nos. 23 and 25 thru 29) 1 BH-1977 Down Push Button Assembly (Includes I Each of Ref. Nos. 23, 25 thru 28 and 30) 1 23 ** Ring - Retaining 2 24 * Enclosure - Front 1 25 ** Seat- Spring 2 26 - ** Spring ' 2 27 ** Seal 2 28 ** Plate - Push Button 2 29 ~* Push Button - Up 1 30 ** Push Button - Down 1 · Not available separately. Order Push Button Station. · * Not available separately. Order Push Button Assembly. \ NOTES Page 61 I 1 '1 I '1 ' ' T ! To enable us to expedite your parts ~ ~:~-"~ order, always give Model and Cata- ~ ~ log Number and Electric Current of Hoist. (See nameplate.) 2721 Figure 9-13. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEIVBLY (Two Speed Hoists Only - Early Version) Ref. Part Qty. No. Number Description Req'd. BH-1960 Push Button Station and Conductor Cable Assembly (InclUdes Ref. Nos. I thru 30) 1 I BH-1961 Anchor Bracket--Strain Cable 1 2 B H-1962 Grip Assembly--Conductor 1 3 BH-1963 Connector--Strain Cable 1 4 B H - 1964 Thimble---Strain Cable 2 5 B H-1965 Connector--Conductor to Strain Cable 1 6 B H - 1966 Clamp---Conductor 1 7 BH-1967 Conductor Cable . , 1 8 BH-1968 Strain Cable 1 9 BH-1969 Sleeve--Pressure 1 10 BH-1970 Tie--Conductor As Req'd. { f/T' 11 BH-1971 Operator Warning Label 1 BH-1972 Push Button Station (Includes Ref. Nos. 12 thru 30) 1 (Continued on following page.) Page 62 Figure 9-13. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY - Continued Ref. Part Qty. No. Number Description Req'd. 12 BH-1973 Sleeve---Conductor 1 13 ' Support--Strain Cable ' 1 14 ' Screw--Slotted Head 4 15 ° Lockwasher 4 16 ' Enclosure---Rear 1 17 * Gasket 1 18 * Screw--Slotted Head 2 19 · Screw--Slotted Head 2 20 ' Clamp--Conductor 1 21 ° Contact Block Assembly 1 BH-1974 Contact Block (ZB2-BE101 ) 2 BH-1975 Contact Block (ZB2-BE201) 2 22 * Interlock--Mechanical 1 BH-1976 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and 25 thru 29) 1 BH-1977 Down Push Button Assembly (Includes I Each of Ref. Nos. 23, 25 thru 28 and 30) 1 23 '° Ring--Retaining 2 24 ' Enclosure--Front 1 25 '° Seat--Spring 2 26 " Spring 2 27 '* Seal 2 28 " Plate--Push Button 2 29 °' Push Button---Up 1 30 °° Push Button~Down 1 available separately. Order Push Button Station. available separately. Order Push Button Assembly. NOTES Page 63 To enable us to expedite your parts order, a!ways give Model and Catalog Number and Electric Current of Ho,st. (See Nameplate) 12724B Figure 9-14A. SINGLE PHASE MOTOR ASSEMBLY- Later Version Ref. Part Qty. No. Number Description Req'd. Motor Assembly (Includes Ref. Nos. 1 thru 12) 1 BH-3900 114 Horsepower ~.~ BH-3901 1/2 Horsepower BH-3902 I Horsepower BH-3903 2-1/4 Horsepower I BH-3904 Bell - End 1 2 BH-3905 Ring - Retaining 1 3 BH-3906 Bearing - Ball 1 4 BH-3907 Ring - Retaining 1 5 BH-3908 I(ey - Brake 1 6 ~ Rotor and Shaft AsSembly 1 7 * Stator Assera bly 1 8 Bolt - Motor Mounting 4 BH-3909 1/4 Horsepower BH-3910 1/2 Horsepower BH-3911 1 Horsepower BH-3912 2-1/4 Horsepower 9 Capacitor Assembly 1 BH-3913 1/4 Horsepower BH-3914 1/2 Horsepower BH~3915 I Horsepower BH-3916 2-1/4 Horsepower 10 Cover 1 For Ref. No. 9 BH-3917 · 1/4 Horsepower BH-3918 1/2 Horsepower BHo3919 I Horsepower BH-3919 2-1/4 Horsepower BH-3919 For Ref. No. 12 11 BH-3920 Slotted Hex Head Self Tapping Screw (#8-32 x 5/16) 2 12 Solid State Switch Assembly 1 BH-3921 1/4, 1/2 & 1 Horsepower- BH-3922 2-1/4 Horsepower · Furnished only as part of motor assembly. Page 64 i I · I I ! To enable us to expedite your parts order, al~vays give Model and Catalog Number and Electric Current of I~P~'/ Hoist. (See nameplate,) 11222551 0~ 11221051 01 12724A 11222451 01 Figure 9-14. SINGLE PHASE MOTOR ASSEMBLY - Early Version Ref. Part Qty. No. N umber Description Req'd. Motor Assembly (Includes Ref. Nos. 1 thru 11 ) 1 BH-3001 1/4 Horsepower BH-3002 1/2 Homepower BH-3003 I Horsepower ~ I BH-3004 Bell---End 1 2 BH-3005 Ring--Retaining 1 3 BH-3006 Bearing--Ball 1 4 BH-3007 Ring--Retaining 1 5 BH-3008 Key--Brake 1 6 ° Rotor and Shaft Assembly 1 7 ' Stator Assembly 1 8 Bolt--Motor Mounting 4 BH-301 5 1/4 Homepower BH-301 6 1/2 Homepower BH-301 7 I Horsepower 9 BH-301 8 Capacitor Assembly 1 10 B H -301 9 Capacitor Cover 1 11 B H-3020 Screw 2 · Furnished only as part of motor assembly. NOTES Page 65 To enable us to expedite your parts ~ t order, always give Model and Cata- log Number and Electric Current of Hoist. (See nameplate. } 2724 FiOuro 9-~8. -THREE PHASE MOTO~ ASSEMBLY Ref. Part Qty. No. Number Description Req'd. Motor Assembly (tncludes Ref. Nos. 1 thru 8) 1 1/4 Horsepower (1 Speed) BH-3301 200 Volt B H - 3302 230/460 Volt BH-3303 575 Volt 1/2 Horsepower (1 Speed) BH-3304 200 Volt B H -3305 230/460 Volt BH-3306 575 Volt I Horsepower (1 Speed) BH-3307 200 Volt BH-3308 230/460 Volt BH-3309 575 Volt 2-1/2 Horsepower (1 Speed) BH-2945 200 Volt B H -2946 230/460 Volt BH-2947 575 Volt 1/2 - 1/6 Horsepower (2 Speed) BH-2901 200 Volt BH-2902 230 Volt BH-2903 460 Volt BH-2904 575 Volt 1 - 1/3 Horsepower (2 Speed) BH-2905 200 Volt BH-2906 230 Volt BH-2907 460 Volt BH-2908 575 Volt 2-1/4 - 3/4 Horsepower (2 Speed) BH-2909 200 Volt BH-2910 230 Volt BH-2911 460 Volt BH-291 2 575 Volt I Bell- End 1 BH-3310 1 Speed - 1/4, 1/2 a~d'l HP BH-2913 1 Speed - 2-1/2 HP BH-2913 2 Speed ' (Continued on following page.) Page 66 ' · · I Figure 9-15. THREE PHASE MOTOR ASSEMBLY - Continued Ref. Part Qty. No. N umber Description Req'd. 2 Ring - Retaining 1 BH-3311 1 Speed - 1/4, 1/2 and 1 HP BH-2914 1 Speed ~ 2-1/2 HP BH-2914 2 Speed 3 Bearing- Ball 1 B H-331 2 I Speed - 1/4, 1/2 and I H P BH-2915 1 Speed - 2-1/2 HP BH-291 5 2 Speed 4 Ring- Retaining 1 BH-3313 I Speed - 1/4, 1/2and I HP BH-2916 I Speed - 2-1/2 HP BH-291 6 2 Speed 5 Key- Brake 1 BH-3314 1 Speed - 1/4, 1/2and I HP BH-2917 I Speed - 2-1/2 HP BH-291 7 2 Speed 6 , ' Rotor and Shaft Assembly 1 7 * Stator Assembly 1 8 Bolt - Motor Mounting 4 BHo3315 I Speed - 1/4, 1/2and I HP BH-2954 I ,Speed - 2-1/2 HP B H -2942 2 Speed Furnished only as part of motor assembly. NOTES Page 67 Figure 9-16A. HOIST MOTOR BRAKE - Later Version Ref. Part Qty. No. Number Description Req'd. Motor Brake Assembly (Includes Ref. Nos. 1 thru 31) 1 Hst. Spds. Mtr. HP Voltage BH-3701 1 1/4, 1/2 & 1 115/230 I 2-1/2 200 2 I / 1/3 200 & 230 2 2-1/4 / 3/4 200 & 230 BH-3702 1 1/4 & 1/2 200 & 230/460 1 I 200, 230/460 & 575 1 2-1/2 575 2 1/2 / 1/6 200 & 230 2 I / 1/3 460 2 2-1/4 / 3/4 230/460 & 575 BH-3703 I 1/4 & 1/2 575 2 1/2 / 1/6 460 & 575 2 1 / 1/3 575 BH-3704 I 2-1/2 115/230 BH-3705 I 2-1/2 230/460 I * Acorn Nut - Plated (#10-32) 2 2 BH-3706 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 1 3 * Cover Stud 2 4 * Gasket 1 5 * Phillips Pan Head Self Tapping Screw - Plated (#10-32 x 1-3/4) 4 6 * Solehold Frame Cover ASsembly 1 7 * Hex Key (1/8 - 3/4 x 2) 1 8 * Solenoid Coil Assembly 1 For BH-3701 For BH-3702 ' - For BH-3703 For BH-3704 For BH-3705 fr ~,, (Continued on following page.) Page 68 Figure 9-16A. HOIST MOTOR BRAKE - Later Version _ Continued Ref. Part Qty. No, Number Description Req'd. 9 * Tubing 3 10 * Hex Nut - Plated (#10-32) 2 11 * Solenoid Frame 1 12 * Hex Washer Head Thread Forming Screw - Plated (#10-32 x 3/4) 1 13 * Rectifier Assembly 1 14 * Hex Head Self Locking Nut- Plated (.~10-32) 2 15 BH-3707 Solenoid Support 1 16 * Hex Washer Head Thread Forming Screw- Plated (#10-32 x 1/4) 2 17 * Solenoid Plunger 1 18 * Hex Socket Head Set Screw - Oval Point (1/4-28 x 1) 1 19'* * Hex Socket Shoulder Screw (#10-24 x 1) 1 20** * Hex Self Locking Nut- Plated (#10-24) 1 21 * Brake Spring 1 22 * ' Brake Lever Assembly 1 23 * Pressure Pad 2 24 * Brake Disc (Non-asbestos) 1 25 * Brake Support Stud 2 26 * Separating Spring 2 27 BH-3708 Brake Mounting Plate 1 28 * Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8) 2 29 * Brake Hub 1 30 * Hex Socket Head Screw (3/8-16 x 3/4) 2 31 Lock Washer (3/8) 2 · Wire Nuts - Not Si~own (No. 22 thru 14 AWG) 4 · Not available as individual parts. See replacement kits listed below. Kits include quantities show above. · * On later model hoists Ref. No. 19 is a hex socket head screw (1/4-20 x 1-1/2) and Ref. No. 20 is a hex self locking nut - plated (1/4-20). Kit Description Number Reference Numbers Included Brake Disc BH-3709 23, 24, 26 Brake Lever BH-3710 6, 15, 17, 18, 19, 20, 21 (Zinc Color), 22, Adjusting Screw Label, Brake Adjust Label - Discard Red Spring Rectifier BH-3711 12, 13, 4 Wire Nuts Hardware BH-3712 1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31, Instruction Label, Power Warning Label Brake Hub BH-3713 28, 29, Hub Drive Key (Shown Elsewhere) Solenoid BH-3714 8 (Order Same Part Number) Page 69 ALTERNATE (~) MOTOR END .............. BELL 27560 Figure 9-16. HOIST MOTOR BRAKE - Early Version Ref. Part Qty. No. Number Description Req'd. Motor Brake Assembly (includes Ref. Nos. 1 thru 24) 1 Hst. Spds. Mtr, HP Volteqe BH-3201 1 1/4, 1/2 & 1 115/230 1 2-1/2 200 2 I / 1/3 200 & 230 2 2-1/4 / 3/4 200 & 230 BH-3202 1 1/4 & 1/2 200 & 230/460 1 I 200, 230/460 & 575 1 2-1/2 575 2 1/2 / 1/6 200 & 230 2 1 / 1/3 460 2 2-1/4 / 3/4 230/460 & 575 BH-3203 1 1/4 & 1/2 575 2 1/2 / 1/6 460 2 1 / 1~ 575 BH-3220 I 2-1/2 115/230 BH-3221 I 2-1/2 230/460 1 BH-3225 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 1 2 * Self Tapping Screw (~10-32 x 1/4) 4 3 * Gasket 1 4 * Hex Washer Head Thread Forming Screw (~10-32 x 1-3/4) 4 5 * Solenoid Frame Cover Assembly 1 6 * SOlenoid Coil ~ssembly 1 For BH-3201 For BH-3202 For BH-3203 For BH-3220 For BH-3221 7 * Solenoid Frame 1 8 * Hex Washer Head Thread Forming Screw (~10-32 x 1/4) 2 9 * Brake Spring 1 Page 70 ! Figure 9-16. HOIST MOTOR BRAKE. - Continued Ref. Part Qty. No. Number Description Req'd. 10 * Clevis Pin (3/16 x 1-1/4) 1 Alternate: Clevis Pin (3/16 x 1-1/4) o - 1 Flat Washer (3/16) 1 Cotter Pin (3/32 x 1/2 PItd.) 1 11 * Brake Disc (Nonasbestos) 1 12 * Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8) 2 13 * Brake Hub 1 14 * Hex Washer Head Thread Forming Screw (#10-32'x 3/4) 1 15 * Rectifier Assembly 1 16 * Hex Self Locking Nut (#10-24) 2 17 BH-3226 Solenoid Support 1 18 * Solenoid Plunger 1 19 BH-3215 Hex Socket Head Set Screw ~ Oval Point (1/4-28 x 1) 1 20 * Brake Lever Assembly 1 21 * Pressure Pad '- 2 · 22 * Brake Support Stud 2 23 * Separating Spring 2 24 * Wire Nuts - Not Shown (No. 22 thru 14 AWG) 4 available as individual parts. See replacement kits listed below. Kits include quantities shown above. Kit Pad Description Number Ref. Nos. Included Brake Disc BH-3207 11, 21, 23 Solenoid BH-3208 4, 5, 6, 7, 18 Rectifier BH-3209 14, 15, 24 Brake Lever BH-3210 9, 10, 19, 20 Brake Hub BH-3211 12, 13, Hub Drive Key (Shown Elsewhere) Special Hardware BH-3212 3, 22, and Instruction Label inside cover Hardware BH-3213 2, 4, 8, 10, 14, 16, 19, 12 Page 71 Recommended Spare Parts for Your BUDGIT Hoist Certain parts of your hoist will, in time, require replacement under normal wear conditions. It is suggested that · the following parts be purchased for your hoist as spares for future use. Set of Gaskets Contactor Set of Bearings Transformer Fuse Set of Oil Seals Limit Lever Lower Block Assembly Limit Switch Assembly Load Chain Set of Brake Discs for Load Brake Set of Brake Discs for Motor Brake ' Push Button Station & Cable Assembly Transformer NOTE: When ordering parts always furnish Model and Catalog Number of Hoist and lift of hoist on which the parts are to be used. Parts for your hoist are available from your local authorized BUDGIT/TUGIT repair station. For the location of your nearest repair station, write: IN USA IN CANADA LIFT-TECH INTERNATIONAL LIFToTECH INTERNATIONAL CRANE &HOIST OPERATIONS CRANES &HOISTS P O BOX 769 53-D. COWANSVIEW ROAD MUSKEGON, MI 49443-0769 CAMBRIDGE, ONTARIO N1R 7L2 or phone: 616-733-0821 519-621-3201 or fax: 616-733-3223 519-621-3125 WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY · A. Seller warrants that its products and parts, when shipped, and B. Upon Buyers submission of a claim as provided above and its its work (including installation, construction and start-up), when substantiation, Seller shall at its option either (i) repair or replace performed, will meet applicable specifications, will be of good quai- its product, part or work at either the original f.o.b. point of delivery ity and will be free from defects in material and workmanship. All or at Seller's authorized service station nearest Buyer or (ii) re- claims for defective products or parts under this warranty must be fund an equitable portion of the purchase price. made in writing immediately upon discovery and, in any event, within one (1) year from shipment of the applicable item unless C. This warranty is contingent upon Buyers proper maintenance Seller specifically assumes installation, construction or start-up and care of Sellers products, and does not extend to normal wear responsibility. All claims for defective products or parts when Seller and tear. Seller reserves the right to void warranty in event of specifically assumes installation~ construction or start-up respon- Buyers use of inappropriate materials in the course of repair or sibility, and all claims for defective work. must be made in wrfting immediately upon discovery and, in any event, within one (1) year maintenance, or if Sellera products have been dismantled prior to from completion of the applicable work by Seller, provided; how- submission to Seller for warranty inspection. ever, all claims for defective products and parts must be made in writing no later than eighteen (18) months after shipment. Defec- D; The foregoing is Sellers only obligation and Buyers exclusive tire items must be held for Seller's inspection and return to the remedy for breach of warranty, and is Buyers exclusive remedy original f.o.b. point upon request: THE FOREGOING IS EX- hereunder by way of breach of contract, tort, strict liability or oth* PRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSO- erwise. In no event shall Buyer be entitled to or Seller liable for EVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, incidental or consequential damages. Any action for breach of this WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MER- agreement must I~e commenced within one (1) year after the cause CHANTABILITY AND FITNESS. of action has accrued. LIFTT'ECH ® OIWelet of Columbue McKlnno. MUSKEGON, MICHIGAN 49443 230~460 VOLT RECONNECTABLE, 3 PHASE, SINGLE SPEED HOIST ELEMENTARY DIAGRAM tl )---U I) HL1 ~ ~~) . >> HFU (WHEN ORDERED) H1 H~. / I HCFU HCPT · "~ T xl X2 ~ T1 o-~ GNO tj ~ ~ T3 ...j_ UP 0 (ORG) 0A Ld ~-O O (~ i 1~F ~ ' ' DO'Vm~N > '< ~lk ~e, ~ 1 (BRI',0 I}1.$ 1H (BLUE} HOIST MOTOR CET EqUIPRENT IIQIT [TRE ~15 A'LA TElRE 228260-O1 WIRING DIAGRAM I ~ i~j ~0 m~ ~ '-:j 230V CONNECTIONS 3 PHASE I 'l" ' I' '1 ' '" WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK CZTY OF COPPELL, TEXAS PRO3ECT NO. WA-96-01 OPERAT. I'ON & IV[AZNTENANCE MANUAL CHLORZNE RESZDUAL ANALYZER SUPPLIER COBLER SALES 8t SERVZCEz ZNC, 2141 REGAL PARKWAY EULESSz TEXAS 76040 (817) 354-7411 MANUFACTURER U.S. FZLTER 1901 WEST GARDEN ROAD VZNELAND~ NEW 3ERSEY 08360 I T i' [ MICROI2000® RESIDUAL ANALYZER BOOK NO. IM50.505AA i i i ! ., t I i EQUIPMENT SERIAL NO. DATE OF START-UP START-UP BY ~ii~--'7~ Proram service labia from re.aional offices in principal cities. COBLER SALES & SERVICE, INC. 2141 Rel]al Parkway EULESS, TEXAS 76040 (8].7) 354-74].1 (800) 245-393]. ORDERING INFORMATION In order for us to fill your order immediately and correctly, please order material by description and part number, as shown in this book. Also, please specify the sedal number of the equipment on which the parts will be installed. WARRANTY Seller warrants for a period of one year after shipment that the equipment or material of its manufacture is free from defects in workmanship and materials. Corrosion or other decomposition by chemical action is specifically excluded as a defect covered hereunder, except this exclusion shall not apply to chlodnation equipment. Seller does not warrant (a) damage caused by use of the items for purposes other than those for which they were designed, {b) damage caused by unauthorized attachments or modfficotions, (c) products subject to any abuse, misuse, negligence or accident, (d) products where parts not made, supplied, or approved by Seller are used and in the sole judgement of the Seller such use affects the products' performance, stability or reliability, and (e) products that have been altered or repaired in a manner in which, in the sole judgement of Seller, affects the products' performance, stability or reliability. SELLER MAKES NO OTHER WARRANTY OF ANY KIND, AND THE FOREGOING WARRANTY IS IN UEU OF All OTHER WARRANTIES, EXPRESS OR IMPUED, INCLUDING ANY WARRANTY OF MERCHANTABIUTY OR OF FITNESS OF THE MATERIAL OR EQUIPMENT FOR ANY PARTICULAR PURPOSE EVEN IF THAT PURPOSE 15 KNOWN TO SELLER. If Buyer discovers a defect in material or workmanship, it must promptly notify Seller in wdting; Seller reserves the right to require the return of such defective parts to Seller, transportation charges prepaid, to verity such defect before this warranty is applicable. In no event shall such notification be received by Seller later than 13 months after the date of shipment. No action for breach of warranty shall be brought more than 15 months after the date of shipment of the equipment or material. UMITATION OF BUYER"S REMEDIES. The EXCLUSIVE REMEDY for any breach of warranty is the replacement f.o.b. shipping point of the defective part or parts of the material or equipment. Any equipment or material repaired or replaced under warranty shall cam/the balance of the original warranty period, or a minimum of three months. Seller shall not be liable for any liquidated, special, incidental or consequential damages, including without limitation, loss of profits, loss of savings or revenue, loss of use of the material or equipment or any associated matedal or equipment, the cost of substitute material or equipment, claims of third padies, damage to property, or goodwl, whether based upon breach of warranty, breach of contract, negligence, strict tort, or any other legal theory;, provided, however, that such limitation shall not apply to claims for personal injury. Statements and instructions set forth herein are based upon the best information and practices known to U.S. Filter/Wallace & Tieman, Inc., but it should not be assumed that even/acceptable safety procedure is contained herein. Of necessity this company cannot guarantee that actions in accordance with such statements and instructions will result in the complete elimination of hazards and it assumes no liability for accidents that may occur. __i--'-== WALLACE & TIERNAN 1901 Wed Garden Road, Vineland, New Jersey 08360 1.010-42D 'T ' l' I ' ' ' MICROI2000® INTRODUCTION This instruction book provides installation, operation, and maintenance in- structions for the U.S. F~lter/Wallace & Tieman (USF/W&T) Micro/2000® Analyzer. The Micro/2000 Analyzer is designed to measure chlorine, chlorine dioxide, potassium permanganate, and ozone residual in water. The analyzer consists of two sections: the "wetside" containing the electrochemical cell and the reagent feed system, and the electronics side, housing the CPU, digital display, and keypad. This equipment continuously analyzes a water sample stream, displaying the measured residual in rag/L; outputs a 4-20mA output signal proportional to the measured residual; and provides various status indicating relay outputs. Setup procedures enable configuring for various requirements and self-diagnostic features aid in troubleshooting. The Analyzer is available For wall mounting or pre-mounted in a flee-standing module. To facilitate operation in water prone to biological growth, a relay output is provided to control periodic "dosing~' of the ~rnple line with a cleaning agent (e.g., chio- rine) to eliminate growth in the line. An optional paper chart recorder is available, and may also be mounted inside the free=standing module, or wall mounted. A separate instruction book is provided with the recorder. NOTE: Due to several available variations of this equipment, this in- struction book is organized to cover the most complex variation. Disre- gard information not applicable to your particular system. NOTE: When unpacking, check all items against the packing list to en- sure parts are not discarded with packing material. Whenever possible, unpack the equipment at the installation site. NOTE: When ordering material always specify model and serial number of apparatus. ConUnued on next page IM 50.505AA UA (2-98) introd. ', , , , I MICROi2000® I · ' VERY IMPORTANT SAFETY PRECAUTIONS (CONT'D) '~ NOT~ Minor part number changes may be incorporated into USF/W&T products from time to time that are not immediately reflected in the instruction book. If such a change has apparently been made in your equipment and does not appear to be reflected in your instruction book, contact your local USF/W&T sales office for information. Please include the equipment serial number in all correspondence. It is essential for effective communication and proper equipment identification. IM 50.505AA UA (2-98) SP-4 'T 'W '! ' ' ' T REGIONAL OFFICES ! INSTALLATION, OPERATION, MAINTENANCE, AND SERVICE INFORMATION Direct any questions concerning this equipment that are not answered in the instruction book to the Reseller from whom the equipment was purchased. If the equipment was purchased directly from U.S. Filter/Wallace & Tiernan, contact the nearest office indicated below. ITN1TED STATES Suite 160 I19 So. Wd}er Drive P.O. Box 875 Hightower Trail Chandler, AZ 85226 Shawnee Mission, KS 66201 A~anta, GA 30350 TEL: (602) 961-3500 TEL: (913) 384-3933 TEL: (770) 641-7570 FAX: (602) 961-1907 FAX: (913) 677-5753 FAX: (770) 641-7596 CANADA If the equipment was purchased directly from U.S. Filter/Wallace & Tieman Canada, contact the nearest office indicated below. ONTARIO HALIFAX QUEBEC 925 Warden Avenue P.O. Box 2828, DEPS 243 Blvd. Brien Scarborough, Ontario Dartmouth, Nova Scotia Bureau 210 MiL 4C5 B2W 4R4 Repen~gny, Quebec J6A 61VI4 (902) 468-1964 (5 14) 582-4266 (416) 751-7561 MEXICO If the equipment was purchased directly from U.S. Filter/Wallace & Tieman de Mexico, contact the nearest office indicated below. MEXICO CITY GUADALAJARA Via Jose Lopez Portffio 321 Jose Guadahpe Zuno 2037 Col. Sta. Maria Cuautepec Col. Jardines de Cmadalupe Tuiti~an, Edo. de Mexico Guadalajara, 1alisco 54900 Mexico 44150 Mexico TEL: 525 875 5127 / 525 879 0485 TEL: 523 615 6028 FAX: 525 875 2171 FAX: 523 628 2569 COATZACOALCOS MONTERREY Av. Independencia 500-101 Fray Banolome de ias Casas 739 Esq,,i~ Calle 18 de Marzo Col. Roble None Coatzacoalcos, Veracruz San Nicolas de los Garza, Nuevo Leon 96400 Mexico 66450 Mexico TEL: 52921 521 68 TEL: 528 332 1150 FAX: 52921 470 54 FAX: 528 332 1122 I.OIO-1AX I I ! i " . OT S r. noxtcT .v EQUIPM.ENT ANn CLOTraNG The following Warning appears in several locations in this book. It is general in nature due to the variety of hazardous liquids this equipment is capable of handling. WARNING: WHEN DEALING WITH HAZARDOUS MATERIAL, IT IS THE RESPONSIBILITY OF THE EQUIPMENT USER TO OB- TAIN AND FOLLOW ALL SAFETY PRECAUTIONS RECOM- MENDED BY THE MATERIAL MANUFACTLrRER/SUPPLIER. It is good general practice to make use of 1. Goggles, flexible fitting hooded ventilation ~ protective equipment when handling any (per ANSI Z87.1) hazardous material 2. Face Shield ~ IT IS RECOMMENDED TH,4T SUCH (per ANSI Z87.1) PROTECTIVE EQUIPMENT BE USED 3. Chemical Apron ~ BY ALL PERSONS SERVICING THIS ,,.~' PUMP, ASSOCIATED PIPING, TUBING, VALVES, ,4ND/tCCESSORIES, WHEN 4. Chemical Gloves ~ THE EQUIPMENT I~ HANDLING ANY H/IZ/tRD O US MATERIAL. NOTE: (1) ANSI Z87.1 "practice for occupational ....... eye and face protection" recommends goggles (#1 above) as the "preferred protection" when handling chemicals that present a hazard fi'om splash, acid bums or fumes; for severe exposure, a face shield (#2 above) over the goggles is recommended. (2) An eye flushing fountain and a deluge-type shower may be recommended or required by insurance carriers or governmemal safety agencies, which should be consulted for specific requirements. 1.010-6C 'T ' ' !' ! ' ' 1 '/ · ]I i MICRO/2000® SECTION '1 - TECHNICAL DATA Residual Ranges .1, .2, .5, 1, 2, 5, 10, 20, 50 mg/L Response Time, T90 90 seconds with 2 rpm sample metering pump. 180 seconds with 1 rpm sample metering pump. Reagent Usage 5 weeks/gal. with 2 rpm sample metering pump. (liquid reagent, per reagent) 10 weeks/gal. with 1 rpm sample metering pump. Power Requirements 115/230v ± 10%, 60 Hz, 40W External disconnect and GFI protection required. Customer Wiring Connections Customer wiring terminal block accepts maximum wire size 12awg copper wire. Ambient Operating Temperature 35 to 125°F (2 to 52°C) Sample Temperature 26 to 125°F (-3 to 52°C) Sample Flow to the Analyzer Approximately. 1 to 5 gpm or .5 to 24 liters/minute, (Through the Y-Strainer) depending upon application. Sample Flow Through the Analyzer At less than 5 psi: approximately 0.13 gpm or 0.5 liters/minute. Relay Outputs Three electro-mechanical relay outputs, NO and NC contacts with snubber circuits (snubbers can be disabled). Rating: 5A ~ 250 Vac/5A @ 30 Vdc. 4-20 mA. Analog Output Signal Isolated-600 ohm maximum loop resistance. Electronics Enclosure Rating NEMA 4X, UL94VO-5VA. Internal Fuse Ratings Electronics/CPU 115v-.2A, 25Ov, 5 x 20ram, Fast Acting Fuse 230v-. 1A, 250% 5 x 20ram, Fast Acting Fuse Motors 115v or 230v - .25A, 250v, I/4" X 1-I/4", SLO-BLO Fuse IM 50.50SAA UA (2-98) 1.1 - 'I '!' ! ' ' '1 I !' i ! ! m ~ c ao~2ooo, I sEcTIoN 2 - INSTALLATION List Of Contents PARA./DWG. NO. General ...............................................................................2.1 Location .............................................................................2.2 Unpacking ...........................................................................2.3 Mounting ............................................................................2.4 Wall Mounted ....................................................................2.4.1 Panel Mounted ...................................................................2.4.2 Analyzer Module ................................................................2.4.3 Installing Reagent Hardware ...............................................2.5 Sample Pump ......................................................................2.6 Water Sample and Sample Line Requirements .....................2.7 Wall and Panel Mounted ....................................................2.7.1 Modular Cabinet ................................................................2.7.2 Drain Line ...........................................................................2.8 Wail and Panel Mounted ....................................................2.8.1 Modular Mounted ....................~ ........................................2.8.2 Installation W'u-ing ......................~ .......................................2.9 :~' ~! Power Supply - Mains .......................................................2.9.1 Relay Outputs ....................................................................2.9.2 Sample-Line Dosing Control Wiring ...................................2.9.3 mA Output .........................................................................2.9.4 Illustrations Dimensions - Wall Mounted Arrangement ..........................50. 505.100.010 Dimensions - Modular Arrangement ...................................50.505. I00.020 Typical Installation .............................................................50.505.110.010 Typical Installation .............................................................50.505.110.040 Installation W'ging Wall Mounted ....................................................................50.505.130.010 Wall Mounted Analyzer and Wall Mounted Recorder ......... 50.505.130.020 Module Mounted ...............................................................50.505.130.030 Analyzer in Module and Wall Mourned Recorder ............... 50.505.130.040 Analyzer and Circular Chart Recorder in Module ............... 50.505.130.050 Analyzer and Strip Chart Recorder in Module ....................50. 505 . 130.060 IM 50.50SAA UA (2-98) 2.1 'r '!' '- I ' ! ! MICROi2000e I 2.1 GENERAL 5' Installation of the analyzer typically consists of the following: · Mounting the unit. · Plumbing to provide the water sample to be analyzed. · Plumbing to provid6 a drain connection for analyzer sample discharge. · Wwing to electrical power (main supply). · Wiring of mA and relay outputs. · Plumbing and wiring of dosage pump, [fused for sample-line dosing. 2.2 LOCAT$ON Select a location protected from direct sun, rain, snow, ice, etc., and that provides convenient access for routine service. To minimize analyzer response time (i.e., lag time), locate the unit to minimize sample-line length. A CAUTION: To avoid possible equipment damage if unit is mounted outside, do not mount in direct sunlight as this may cause the electronics to become overheated. 2.3 UNPACKING .~'~ NOTE: When unpacking, check aH items against the packing list to en- sure parts are not discarded with packing material Whenever possible, unpack the equipment at the installation site. a. Remove unit from shipping carton. b. Open front door and remove any ties, padding or fillers used for shipping protection. c.On modular cabinets, remove the shipping crate and unbolt the wooden supports located at the four comers of the module base. A CAUTION: To prevent damage to module, replace shim washers under- neath module after plywood feet are removed. d.Save the black washers (PB2018) for reinstallation when mounting mod- ule to floor. e. Check for loose piping or electrical connections. IM 50.505AA UA (2-98) 2.2 'I "' !" '! ' ' ' I MICROI2000 2.4 MOUNTING 'i 2,4.1 WALL MOUNTED(SEE DWG. 50.505.100.010) a. Mount the unit using the four 3/8-inch diameter mounting holes (5/16-. inch diameter bolts). b. For ease of mounting remove the two brackets from the sides of the analyzer and mount to the wall first. c. Place the unit into position, resting on the support dbs. 2,4,2 PANEL MOUNTED a. Mount the analyzer in a panel up to 1/2-inch thick. The dimensions for ~-, ' the cutout are shown in Figure 2.1. ~-----'-, 1 ~4' I · I ~ 0TO. l/4* I! ~ I ' · I 20-3/16' Figure 2,1 - Dimensions of ~ Cut-Out b. With the panel cut to the dimensions indicated, remove the bolts and washers retaining the mounting brackets to the analyzer. c. Install the unit through the from of the panel and loosely reinstall the mounting brackets and hardware, d. With the bolts loose, slide the brackets down and toward the panel · ~ remove all play. e. Tighten all four mounting bolts. IM S0.S0SAA UA (2-98) 2.3 'I I ! ' ~ T I ! MICROi2000® 2.4 MOUNTING 2.4.1 WALL MOUNTED-~SEE DWG. 50.505.100.010) a. Mount the unit using the four 3/8-inch diameter mounting holes (5/16-. inch diameter bolts). b. For ease of mounting, remove the two brackets from the sides of the analyzer and mount to the wall first. c. Place the unit into position, resting on the support fibs. 2,4,2 PANEL MOUNTED a. Mount the analyzer in a panel up to 1/2-inch thick. The dimensions for ' the cutout are shown in Figure 2. I. 21-1/8' I . ~ ' oro.1/4' R ~ Figure 2.1 - Dimensions of Panel Cut-Out b. With the panel cut to the dimensions indicated, remove the bolts and washers retaining the mounting brackets to the analyzer. c. Install the unit through the from of the panel and loosely reinstall the mounting brackets and hardware. d. With the bolts loose, slide the brackets down and toward the panel to remove all play. e. Tighten all four mounting bolts. IM 50.505AA UA (2-98) 2.3 'I "!' I' " [' "7 ! i MICROI2000® with nuts and washers); however, due to varying requirements, hardware for wall mounting is not included. Before attaching the reagent bottle mounting brackets to mounting surface, install the retaining strap through the slots in the bracket. The brackets should be located within four feet of the analyzer. · Install the reagent tubing as follows: Uncoil the reagent tubing segment(s) (one per liquid reagent) and remove the rigid tubing segments (1/32-inch O.D., 13-inch long) from the protec- tive packaging. Using two of the three tubing segments, firmly insert one rigid tube into one end of each piece of flexible tubing. Then insert the exposed rigid end into the small hole in the cap of each of the reagent bottles mounted in the bottle brackets. Then place the other end of the tubing through the holes located in the back/bottom of the wetside of the analyzer and pull the loose tubing into the analyzer enclosure. · For information on installing or replacing reagent tube units, see para- graph 4.4.6, Pump Tubing Units Replacement. · Tubing Connections: Cut the excess reagent tubing and connect to the reagent fittings at the inlet to the reagent tube units. Install the "T" fitting provided in the tubing at the inlet to Coottom of) the analyzer metering pump. To do this, cut the tubing about one inch from the entrance to the pump and reconnect the tubing using the "T" fitting. This will leave the middle (small) end of the fitting unused. · If two reagent tube units (two liquid reagents) are used: Install two, one-inch segments of the reagent tubing, cut from the eight- foot segment of reagent tube, on the fittings at the discharge (upper) end of the reagent tube units and join the two segments with the "Y" fitting provided. Using approximately seven inches of reagent tubing, connect the reagent discharge fining to the tee fitting at the pump sample intake. Run the tubing behind the panel unit and attach the other end to the remaining (small) end of the "T" fitting at the inlet of the metering pump. IM 5Q.505AA UA (2-.98) 2.5 1' '! ' ' i MICROI2000® I 2.6 SAMPLE PUMP ( ~ A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, MAKE NO CONNECTION THAT MIGHT PERMIT A POTABLE WATER SYSTEM TO BECOME CONTAMINATED. CONSULT YOUR LOCAL 1Tir_,ALTH CODES AND U.S. PUBLIC ITF~ALTH SERVICE BULLETIN #957 (AVAH,&BLE FROM TttF, SUPERINTENDENT OF DOCUMENTS, WASHINGTON, D.C.) FOR ADDITIONAL INFORMATION. Where the supply water pressure is not sufficient, a pump must be installed to deliver a sample of water to be analyzed. The following guidelines are recom- mended for installations where a pump is needed. The pump should be sized to provide the water sample flow pressure per analyzer sample and sample line requirements. Locate intake point of the pump to provide a representative sample. Rigidly fix and position the intake away from the walls or bottom of the chamber or the pipe containing the main flow to be analyzed. The sampling point should allow for adequate contact time and mixing in the process monitored to ensure a stable value for measurement. 2.7 WATER SAMPLE AND SAMPLE LINE REQUIREMENTS Actual requirements will vary with the equipment application, but the follow- ing should be used as general guidelines. Sample plumbing design is the most important part of a reliable monitoring system. A well designed sampling system minimizes response time and prevents foul- ing of the sample line plumbing and the analyzer. Response time is minimized by locating the analyzer close to the point of sample take-off and by designing for a moderately high flow velocity in the sample line, one to 10 i'dsee. Flow velocity also helps in reducing sample line deposits. Plastic pipe or tubing (PVC, AB S, or polyethylene) is preferred for sample line plumbing due to its corrosion resistance, lack of residual demand, and smooth surface firfish, which resists deposits. Sample plumbing pipe (or tubing) size is a function of the. available pressure at the sample point (or sample pump discharge) along with the sample line length and flow velocity required. IM 50.505AA UA (2-98) 2.6 4eelemBe 'T' ' I' ! ' ' MICROi2000® I Potable Water Four characteristics typical of potable water are that, generally, it is low in paniculates, it is available at reasonably high pressure (>15 psi), its use should be minimized, and the analyzer may be mounted within 25 feet of the sample point. In such applications, the sample may be run through 1/ 4-inch pipe or tubing and the bypass flow on the Y-strainer may be shut. It should be opened only intermittently to flush the strainer element and sample line. Then only (approximately) 500 mIJmin of the sample is re- quired, which is the internal analyzer sample requirement. * Wastewater Frequently, wastewater is high in panicUlates and biological growth po- tential. The sample is taken from open channel flow, with no pressure available at the sample point. Additionally, the analyzer must frequently be mounted a significant distance from the sample point (inside and protected from weather). Here, a sample pump is required and the Y- strainer bypass flow valve should be open to allow continuous flushing of the strainer element. A high flow, low pressure, open impellet-type pump works well /"' in this environment. Typical systems use 1/2-inch pipe or tubing that by- passes 2 gpm through the Y-strainer or 3/4-inch pipe that bypasses 5 gpm. This resuks in a flow velocity of about four feet per second and a pressure drop of about 4 psi per 100 ft of sample line. Wastewater will frequently exhibit high biological growth potential; there- fore, the sample line may need to be treated with a cleaning Coiocidal) agent (typically chlorine) to inhibit growth in the sample line. Biological growth may dog fittings in the sample line or analyzer and consume (process) chlorine residual during the sample transit time in the sample line. For sample line dosing, the cleaning agent is periodically injected into the sample line near the sample intake point. 2.7.'! WALL AND PANEL MOUNTED (SEE DWG. 50.510.110.010) A self-flushing, 1/2-inch Y-strainer is provided and should be located at the analyzer. Valves are provided to be installed on the Y-strainer bypass dis- charge to control bypass flow and at the filtered discharge from the Y-strainer to the 1/4-inch sample inlet at the base of the analyzer enclosure to control analyzer sample flow. 2.7.2 MODULAR CABINET (SEE DWG. 50.510.110.010) Modular arrangements of the analyzer come with a prepiped Y-strainer. Ana- lyzer discharge and Y-strainer bypass flow are connected to a drain chamber IM 50.505AA UA (2-98) 2.7 '1 · i " i } MICROi2000® } at the module base. The sample inlet connection is 3/4-inch npt and is located on the rear of the module. 2.8 DRAIN LINE 2.8.1 WALL AND PANEL MOUNTED (SEE DWG. 50.510.110.010) The analyzer enclosure is equipped with a hose adapter drain connection for 1-1/4-inch hose. The fitting is shipped packaged within a cloth bag inside the . left portion of the enclosure. a.To install the fitting insert it through the large opening in the bottom of the analyzer enclosure. It should snap into place when fully seated. b.Slip 1-1/4-inch drain hose over the end of the drain fitting and run hose to a waste drain. c. Connect a hose from the Y-strainer bypass valve to the waste drain. d.Inside the analyzer, insert the analyzer bypass tubing and cell discharge tubing (both 1/4-inch OD translucent) into the drain fitting. 2.8.2 MODULAR MOUNTED (SEE DWG. 50.5'10.110.010) Modular arrangements contain a drain chamber, prepiped to the analyzer enclosure drain fitting, and Y-strainer bypass. The drain chamber has a 1-1/4- inch female npt connection for drain plumbing. 2.9 INSTALLATION WIRING (SEE DWGS. 50.505.130.010, .020, .030, .040, .050, AND .060) A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INIURY OR EQUIPMENT DAMAGE, INSTALLATION WIRING SHOULD BE PERFORMED ONLY BY A QUALWIED ELECTRICIAN AND IN CONFORMANCE WITH APPLICABLE CODES. A CAUTION: Check 115/230 power selector switch on power supply board and jumpers on motor adapter board before connecting power to the unit. Incorrect sdection may cause faulty operation or may damage the unit. NOTE: Fidd wiring must conform to local electrical codes. Installation wiring is made to the terminal block located in the rear of the electronics enclosure on wall-mounted units or in the junction box in the rear of the module on module-mounted units. IM 50.505AA UA (248) 2.8 MICROI2000® I For connection to the terminal block, 12 AWG solid or stranded copper wire is the maximum recommended size. 2.9.1 POWER SUPPLY - MAINS An external power disconnect must be provided to isolate the unit from mains power when servicing the unit. No power switch is provided within the ana- lyzer or module. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, THE UNIT SHOULD BE POWERED WITH GROUND FAULT INTERRUPT PROTECTION. THE UNIT IS FUSED INTERNALLY FOR Tn'F~ PROTECTION OF ELECTRICAL/ ELECTRONIC COMPONENTS ONLY--TtIESE FUSES WILL NOT PROTECT THE USER FROM INJURY CAUSED BY ELECTRICAL SHOCK. WHILE 'ELE~CAL COMPONENTS ARE SUITABLY ISOLATED FOR NORMAL OPERATION, THE PRESENCE OF WATER OR OT!~R POSSIBLY CONDUCTIVE FLUIDS IN COM- BINATION WITH DANGEROUS OPERATING VOLTAGE, PRE- SENTS A SHOCK HAZARD THAT IS BEST MINi3~ZED BY THE USE OF GROUND FAULT INTERRUPT PROTECTION ON THE MAIN POWER SUPPLY. The analyzer is designed to operate on single phase 115 or 230 vok ac + 10%, 60 I-Iz. The operating voltage for the electronics is switch selected by a clearly labeled C 115" or "230") switch on the power supply circuit board inside the analyzer. The motors driving the impeller and metering pump, on the wetside, are sepa- rately powered by the Motor Adapter Board, located in the electronics enclo- sure, and also require selection of the operating voltage. There are two jumpers that must each be positioned for 115v or 230v operation. The electronics and the pump and impeller motors are protected, separately, by two internal fuses. See the Section 1 - Technical Data for fuse ratings. A CAUTION: To avoid possible equipment damage, verify that the voltage sdectors for the dectronics and for the motors are in the proper positions and that the proper fuses are installed before making connection to ac line. 2.9.2 RELAY OUTPUTS Three output relays, designated "A", "B", and "C", are available for external connection. As delivered from the factory, these relays are assigned to High Alarm/System Alarm, Low Alarm/System Alarm, and Dosing Control fune- lM 50.505AA UA 12-98) 2.9 MICROI2000 tions, respectively. The conditions indicated by a respective relay output are customer con~gurable through the menu interface (one relay may be set to indicate any of several conditions). This allows the customer to select the functions most important to them or chang6 the functions or sense of the relays without re-wiring. These selections must be consistent with the installed wir- ing. One common (COM], one normally open (NO), and one normally closed (NC) contact are available for each relay. All contacts are unpowered. Power to the contacts is provided by customer wiring. The "sense" (normally energized or normally de-energized)' of each relay is also user eortfigurable within the soi~cware. Refer to paragraph 3.2, User Interface - Soilware Operation, for more infor- marion about reconfiguring relay outputs. Each of the relay contacts is wired with a snubber circuit that can be disabled by removing the associated jumper on the power supply board. Snubber cir- cuits are provided to protect the relay contacts from voltage spikes on opening and closing, but leakage current though the snubber circuit can be enough to energize low power electronic devices (erratically)---bypassing the relay con- tacts. If this occurs, the associated snubber should be disabled. Remove the snubber from the circuit by removing the associated jumper on the power supply board. CONTACT JUMPER Relay "A",NC J3 Relay "A",NO J4 Relay "B ",NC J5 Relay "B",NO 36 Relay "C",NC J7 Relay "C",NO J8 IM 50.505AA UA (2.-98) 2.10 I '! ! ' ' i MICROI2000® I 2.9.3 SAMPLE-LINE DOSING CONTROL WIRING If sample_line dosing is used, one of the relay outputs must be configured to this function (the default is relay "C'). This relay is used to activate an external dosing means (e.g., a pump) that, when activated, delivers the cleaning agent into the sample line. (See Section 1 - Technical Data under Relay Outputs.) Wire the device so that if power is lost to the analyzer or the wiring connection is broken, the dosing device is de-activated. 2.9,4 mA OUTPUT The analyzer provides an isolated, 4 to 20 mA output proportional to the measured residual, over the measuring range to which the analyzer is config- ured. This output can operate through a 600 ohms (maximum) impedance. IM 50.505M UA (2-98) 2.11 I '! '! ' ' ¢_ MOUNTING HOLES RIB ' -/ 3/8' DIA. ' MOUNTING ~~ ~ / HOLE / t 15- 3_./.. ~. .,-. ~ ~ 13-3/4-, 9' ~ 1/8~ 6-3/16' , ' ' ' ~. HOLES FOR T~G HO~S OR LIfO REA~NT TU~ ~4' FPT SA~E I-I/4' ID ~SE WALL BRACKET I/2' FPT ELECTR~AL CO~ECTI~ DRAH CON~CTION (MOUNTED AGAINST C~CT~ (3) SUPPORT FRONT VIEW SIDE VIEW 5/16' DIA. HOLE 4 -~/4' - - 7/8' ~ 7/16' 6-1/i6' WALL MOUNTING BRACKET FOR REAGENT BOTTLE RESIDUAL ANALYZER - DIMENSIONS Wall Mounted Arragement_ 50.505.100.010 ~SSUE o 04-94 'I '!' '! ......... 'R 'TRIP ~ART ~CORO~ 4 I ~ ~ % a "' 3/4~T ~ Z-Z/g' , ~N~T ~ON . BOX ~314' CO~T ~ ~TH ~T~ IM4' ~AIN VALe. S[~~ C~CT~ . Y-ST~R A~ ~T~e wL~s REAR VIEW SIDE VIEW FRONT VIEW ////,~w~'//// ANALYZER WITH RECORDER T 4' Z' 4~/Z' (~.~C~D) ~' F --1-~4' 3 ~8' ~8' ANALYZER , I ~ - WITHOUT RECORDER I NO~: FLOOR PLAN FOR ONE OR MORE MODULES ,~ ~ NOT FU~ISHED BY U.S. FILTER / W & T. ~ ~ ~ISHED. ONLY IF SPECIFI~LY LI~D IN QUOTA~ON. RESIDUAL ANALYZER - DIMENSIONS M~ular A~angement 50,505.100.020 ISSUE I 02-98 '~ m ~ " [ : I [] CIRCULAR CHART { .... R~CO~DER ,,~ ANAJ, YZE:R ' RESIDUAL INLET fiTTINGS /SUPf"_IED BY W&T ~T~F VALVE ~M~ ~ 48' TYP A~Y~R WALL MOUNTED ARRANGEMENT ~ V[W ' ~4' FPT P~$S~ ~U~ ~ SAtI:~..E ADDITIONAL LIQUID REAG~qT' REQUIRr~D F~ TQT~ I-I/4' ~T DR~ CQ~C~ ~TH ~APTER AN~YZ~R MODULE ARRANGEMENT NOTE: ~ NOT FU~ISHED BY U.S. FILTER / W & T. ~ ~ FURNISHED ONLY IF SPECIFI~LLY U~D IN QUOTA~ON. RESIDUAL ~ALYZER - ~PICAL INSTAL~TION Residual Analysis Usin9 Liquid Reagent 50.505.110.010 ISSUE 0 02-98 'l ' I ! ' ' ' I ; I/2' Y-STRAINER I/2' X 1/4' 1/4" NPT X BUS NG I-I/2" NIPPLE HI I/2' !!SEX I/2' NPT I/2' BALL VALVE 2' HOSE ANALYZER OR 2" PVC PIPE _ I/4" NPT X HOSE ADAPTER BALL VALVE Q!/?" X 314" NPT I/4' BALL VALVE BUSHING ,----- 1/4" NPT X 1/4" "~ TUBING FITTING --..., '] W A TER LINE / -- Qi/2' .PVC MODULE OR SIDE : I/2" HOSE MODULE DRAIN CHAMBER ,,,,,,,,~c>-"- .'',,,- GI-I/4" PiPE X I" HOSE ADAPTER TO DRAIN QQI' HOSE - RUN ON DOWN- GRADIENT WITHOUT TRAPS NOTE: DRAIN CHAMBER NOT FUP, NISHED BY U.S. FILTER / W & T. rTEMS FUltNISHED ONLY IF SPEQFIC. ALLY LISTED IN QUOTATION. WATER LINE AND DRAIN CHAMBER - TYPICAL INSTALLATION 50.505.110.040 ISSUE 0 02~98 ' ! ! ' ' TO MOTOR ADAPTER BOARD r ANALYZER TERMINAL STRIP L~ ~L'~'~ BK L2/N GN~yx w L G G I L2/N P DIGITAL INPUT G 4 G' I w/~ 5 .... E DIGITAL INPUT G 5 G I O.'R 6 R G 7 e/''' R/SK 7 ' S RELAY C NO o 8 U G8G P RELAY C COM G gG R 9 p RELAY C NC e.,~ 10 L RELAY B NO G IOG y GlIG RELAY B COM GlaG w/R I;:> B RELAY B NC e/w 13 0 G!3Q A RELAY A NO G I4~ BL/~K 14 R RELAY A COM GISG B..,w 15 "' D RELAY A NC R.-'W 16 GI6G mA OUTPUT + ' ,gt?..3G w 17 mA OUTPUT - G24~. R 18 C """'/" ~ 19 P U eR 20 ..... " ~ 21-- B SHIELD 22 0 A ~,,y I [ 23-- R BK/R I 24 D BL/W I ' ' NOlt: , FIELD WII~I NG (NOT BY U.S. FILTEI~ / W & 'f) .~UST CONPOP,V, TO LOCAl. EII=Cll~C. AL CODES. WIRING BY U.S. FII.TEI~ W & T. RESIDUAL ANALYZER - INSTALLATION WIRING Wall Mounted ' 50.505.130.010 ISSUE 3 02-98 CIRCULAR CHART RECORDER ANALYZER RECORDER ' ' WITHOUT ' ' + ' ~ ' 'l' ........... TERMINAL STRIP CONTROLLER L N E I' mA OUTPUT + I ~ mA OUTPUT - I 14~ ~ , q~ L. CIRCULAR CHART RECORDER ~,.~. ~.~i I, I~.~t L+' ~-"1.1: ~~. RECORDER WITH ' ~ .... ' .... J TERMINAL CONTROLLER ' ' ~ ' ! ' ~ STRIP L N E I ~A OUTPut +I ~ TO {~ mA OUTPUT - I ....~ CONTROLLER i ~ ~ STRIP CHART RECORDER RECORDER L ~' ! ~' j TERMINAL WITHOUT _ STRIP CONTROLLER ~A OutPut + ! ~ ~A OUTPUT- i ~ STRIP CHART RECORDER I RECORDER WITH ~ ' ~_ ~ f _ J TERMINAL CONTROLLER , STRIP E N L r mA OUTPUT + CONTROLLER I ~ NOTE: FIELD WIRING {NOT BY U.S. FILTER / W & T) MUST CONFORM TO LOCAL ELECTRICAL CODES. WALL MOUNTED ANALYZER & WALL MOUNTED RECORDER ~ INSTALLATION W1RING 50.505.130.020 ISSUE I 02-98 'I · ! ' ' i ! MODULE JUNCTION_BOX r · B~ I Io0ol I LIbel , ~ I NI~ ® ~ L2/N _L~,EI~ I SL ;4 ~ ~ I DIGIT AL INPUT T w/s~ '5 ~ ~ ~ DIGIT AL INPUT O o : I 8~ . RELAY C NO A R ;9 ~ ~ ( RELAY C COM N ezs~ ' I A ~ 10 ~ ~ RELAY C NC L ozs~ ' ) RELAY B Z wm '12 ~ ~ RELAY B COM E e~w I ' R '!3 ~ ~ I RELAY B NC susK '14 ~ ~ I RELAY A NO s~ 15~ ~ i RELAY A COM R~ 16~ ' ; RELAY A NC a~R 2~ ~ I mA OUTPUT ( IoOolI I NOTE: FIELD WIRING (NOT BY U.S. FILTER / W & T) MUST CONFORM TO LOCAL ELECTRICAL CODES. -- WIRING BY U.S. FILTER / W & T. RESIDUAL ANALYZER - INSTALLATION WIRING Module Mounted 50.505.130.030 ISSUE I 02-98 CIRCULAR CHART RECORDER CIRCULAR CHART .... 'TIg,[ T~' ' ' ' RECORDER WITHOUT ' ' I MoDuLE JUNCTION BOX F ~ L N E I ~ I ~AOUTPUT + I ~~t ~ mA OUTPUT - L CIRCULAR CHART RECORDER CIRCULAR CHART ..... RECORDER WITH , ' ' ' TPtl TRY' , ~o.~.o,,~. :1~ I. I~.q L+I- I. I: MoDuLE "' + - t - t~' JUNCTION BOX F" "~ L N E I [T0"0"II mA OUTPUT + . -:} I e ~ mA OUTPUT- TO L, __ j CONTROLLER STRIP CHART RECORDER STRIP CHART RECORDER WITHOUT ~o.~.o,~. i IJ 1~/3- - ~ I,~ I,. I,. I,. I ~ I: MoDuLE JUNCTION BOX I ' E N L I I'6"0'6q I ,,,A OUTPUT + I ~ mA OUTPUT - I_, STRIP CHART RECORDER STRIP CHART , , RECORDER WITH ~o.~.o,.~. : b 1~/3- - -~ i'~ I "I'~ I'~ I '~ I: I I MODULE ,-- - -1-- I f ' ' JUNCTION BOX '=' I ~ E N L I ~ I .,A OUTPUT + i ~ ! mA OUTPUT- TO CONTROLLER I._ J NOTE: FIELD WII~ING (NOT BY U.S. FILTEP, / W & T) ,~US'I' CONFOPJv~ TO LOCAL ELECTRICAL CODES. ANALYZER IN MODULE & WALL MOUNTED RECORDER- INSTALLATION WIRING 50.505.130.040 ISSUE 3 02-98 'i '!' ' ' I ' ! CIRCULAR CHART RECORDER ""~'{)r TB2 I L _L J FUSE MODULE JUNCTION BOX I I Io0olI ' "" I xL~ Lm x N~ ~ L~/N GND __ ~ ~ I BL 'i 4 ~ ~ ', Digit aL iNPUT T W/BK I 5~ ~ DigiTal iNPUT 0 o , ! ~ ~ ~ I RELAY C NO a " I 9~ I RELAY C COM A ~ RELAY C NC L O/BK I '11~ I RELAY B NO Y Z w/R ! '12~ RELAY B COM E .~w I I R Bu~ I 13~ I RELAY B NC .~ i 14 ~ ~ i RELAY a NO 15~ I RELAY A COM R~ ~ : a~R ! 16~ 'l RELAY A NC I/zl~ I e~ I 2~~ I mA OUTPUT (-) ' I 2t ~ mA OUTPUT ( + ) ! Io0ol I ! REMOVE JUMPER TO L. ____ j USE ma OUTPUT NOTE: FIE~ WI~NG (NOT BY U,S. FILTEE / W & ~ ~U~ CONFO~ TO L~ E~GL CODES. -- ~BNG BY U.S. FIL~/W&T. ANALYZER AND CIRCU~R C~RT RECORDER IN MODULE- INSTAL~TION ~RING 50.505.130.050 ISSUE 3 02-98 STRIP CHART RECORDER I , _-- FUSE w/v MODULE JUNCTION BOX r ...... " t I F6'6'O'1 I w I "N ~ (3mj L2/N I . I G _L~.El~ I ~ 4~ ~'~ I DIGITAL INPUT T w~ ,5~)(~ I DI(31TAL INPUT I RELAY C NO o o e~ A R 9 ~J ~ RELAY C COM N ~,~ Iolr/Jr~ I A ~ RELAY C NC /--,, L o/B~ ' I RELAY B NO ~ Y: ~ I Z w~R IZI~I(~;I I RELAY B C:OM E ~N 13j~ ~ RELAY B NC R : I ~ 14~ I RELAY A NO ~ ~ I RELAY A COM ~ ~ J RELAY A NC " /z~ ~ I ~ mA OUTPUT (-) 2~ mA OUTPUT (+) IOOOt I REMOVE JUMPER TO ~ _j USE mA OUTPUT NOTE: FIELD WIRING (NOT BY U.S. FILTER / W &T) MUST CONFORM TO LOCAL ELECTRICAL CODES. WIRING BY U.S. FILTER / W 8, T. ANALYZER AND STRIP CHART RECORDER IN MODULE - INSTALLATION WIRING 50.505.130.060 ISSUE 3 02-98 m ~ c ~oz2ooo~ sEcTioN 3 - OPERATION List Of Contents PARA./DWG. NO. Preparation for Operation ....................................................3. I Sample Flow Adjustment ...................................................3.1.1 Probe Installation ...............................................................3.1.2 Reagent Requirem~ts ........................................................3.1.3 User Interface - Software Operation (Interface Menu Map). 3.2 Keypad Operation and General Interface Procedures .......... 3.2.1 Main Display - Measured Value .........................................3.2.2 Set-up Group Software Configuration of the Analyzer ....... 3.2.3 Measuring Unit/Identifier ..................................................3.2.3.1 Measuring Range ..............................................................3.2.3.2 Cell Voltage Set Point .......................................................3.2.3.3 High and Low Alarm .........................................................3.2.3.4 System Fault Alarm ...........................................................3.2.3.5 Sample Line Dosing Control .............................................3,2.3.6 Setting the Interface Lock .................................................3.2.3,7 I/O (Input/Output) Options GroUp .....................................3.2.4'' ';:~ Digital Input ......................................................................3.2.4.1 Relay Setup [Relays A, B, and C) ......................................3.2.4.2 Alarm Dudband ...............................................................3.2.4.3 Diagnostics Group .............................................................3.2.5 Measured Value ................................................................3.2.5.1 Slope ................................................................................3.2.5.2 mA Output ........................................................................3.2.5.3 Cell Signal .........................................................................3.2.5.4 CeU Voltage ......................................................................3.2.5.5 Cell Temperature ..............................................................3.2.5.6 Software Version ..............................................................3.2.5.7 Serial Number ...................................................................3.2.5.8 System Restart ..................................................................3.2.5.9 System Shutdown .............................................................3.2.5.10 Local Operating Mode ......................................................3.2.5.1 Self-Diagnostic, System Fault Messages ............................3.2.5.1 2 Test Functions Group .........................................................3.2.6 mA Output Test and Calibration ........................................3.2.6.1 Relay and Alarm Tests ......................................................3.2.6.2 Dosing Control Test ..........................................................3.2.6.3 Next Dosing ......................................................................3.2.6.4 Continue on Page 3.2 IM S0.S05AA UA (2-98) 3.1 '1 "! ! ' ' ' "" MICROi2000® List Of Contents (Cont'd) PARA./DWG. NO. General Operation ...............................................................3.3 Start-Up Procedure ............................................................3.3.1 Checks and Maintenance ....................................................3.3.2 Reagent Reservoirs ...........................................................3.3.2.1 Calibration ........................................................................3.3.2.2 · Grit in Cell ........................................................................3.3.2.3 Leaks and Corrosion .........................................................3.3.2.4 Impeller Drive and Grit .....................................................3.3.2.5 Probe Electrolyte Level .....................................................3.3.2.6 Analyzer Metering Pump ...................................................3.3.2.7 Sample-Flow, Y-Strainer, and Sample Pump ..................... 3.3.2.8 Shut-Down/Re- Start ..........................................................3.3.3 Theory of Operation ............................................................3.4 Additional Calibration Tips .................................................3.5 Illustrations Operation ...........................................................................50.505.170.010 Flow Diagram ....................................................................50.505.180.010 IM S0.50SAA UA (2-98) 1 I MICRO!2000® 3.1 PREPARATION FOR OPERATION NOTE: Prior to initial operation, ensure that the procedures detailed in Section 2 - Installation have been followed and completed. 3.1.1 SAMPLE FLOW ADJUSTMENT Before starting the sample pump or otherwise starting sample flow, check that the bypass control valve on the bypass leg of the Y-strainer, at the analyzer, is open and that the sample flow control valve to the inlet of the analyzer is closed. CAUTION: To prevent possible equipment damage, apply up to a maxi- /~ mum of 5 psi water pressure to the analyzer sample input. The tubing in the analyzer metering pump cannot withstand more than 5 psi pressure. ffpressure in excess of 5 psi is applied to the analyzer input, fluid may be sprayed from the analyzer metering pump inlet. Once the flow is started, adjust the Y-strainer bypass valve to: the desired bypass flow. As discussed in paragraph 2.7, Water Sample and Sample Line Requirements: 0-2 gpm for drinking water applications and 1-5 8pm for waste- water applications. Adjust the sample flow control valve at the discharge of the Y-strainer to produce a flow through the analyzer of approxhmtely 500 roYrain to the analyzer sample inlet. Most of the 500 rnYmin flow through the analyzer bypasses the ~ a small portion is metered into the analyzer cell for measurement. NOTE: If the application is for clean water and the supply pressure is greater than 20 psi, it may be desirable to replace the ball valve provided for sample flow control with a flow meter with a needle flow control valve for better adjustability. NOTE: To ensure adequate flushing and minimize fouling, continuous flow (above I gpm) through theY-strainer bypass valve may be required. 3.1.2 PROBE INSTALLATION The probe should be installed in the analyzer after the rest of Lhe analyzer installation (mounting~ plumbing, wiring) is completed and inspected. CAUTION: Do not fdl the probe with dectrolyte until immediately be- fore it is installed in the analyzer. Once the probe is filled with electrolyte, the electrode end must be kept wetted, as it is when installed in the analyzer. ff the probe is failed and the porous element is allowed to dry, / the pores will dog with potassium chloride crystals. IM llft qltaiAA IIA 19,qRI . . 3,3 '! "I' '1 ' " 1 [ " MICROi2000® Fill the probe (through the fill hole in the side of the probe body) with electro- i'-~ lyre. Fill only to a level just below the fill hole when the probe is upright. The hole plug is not watertight. A small breather hole should be made in the plastic hole plug before replacing in the probe. Remove the protective cap from the electrode end of the probe. Check that the electrodes are clean; wipe clean with a paper towel if necessary. Do not touch the electrodes (platinum elements) or the porous element (white element), as finger dirt or oil may impede the probe operation. Also, treat the platinum - electrodes gently because the platinum material is thin and easily punctured or sheared off. The electrodes are not repairable. Allow the probe to stand upright (or hang it by its cord) for about ten minutes until electrolyte emerges from the porous element. If the electrolyte does not emerge shortly, it can be forced through the porous element by pressurizing the reservoir with a rubber squeeze bulb--used to force air into the fill hole. Use a sharp blade or a pointed object to cut a small vent hole in filling hole plug just enough to allow air through the plug to equalize pressure to atmospheric pressure on both sides of the plug. Keplace the hole plug to prevent evapora- tion of the electrolyte. Connect the probe plug into the receptacle labeled "PROBE" inside the ana- lyzer enclosure (wetside) and lay the cable behind the panel unit. Be sure that the probe rests squarely in the flow block. The cable may tend to tilt the probe, but this can be corrected by adjusting the cable. If, during the preceding start-up of the analyzer, the display indicates "Check Probe Junction" error, k means the electrolyte has not yet emerged on the outside surface of the porous element of the probe. Either allow the analyzer to operate until the alarm stops (electrolyte emerges) or pressurize the elec- trolyte reservoir with a squeeze bulb to accelerate flow of electrolyte. 3.1.3 REAGENT REQUIREMENTS NOTE: See paragraph 4.4.1, Preparation of Reagents. · GENERAL The Micro/2000 Residual Analyzer allows the flexibilityto select from several analyzer sample conditioning chemicals (reagents). The choice of conditioning chemical is made to provide the best analyzer performance while considering chemical cost and handling requirements. Some applications require no chemi- cal conditioning ofthe analyzer sample, while others may require a combina- tion of chemicals. Sample conditioning may be used to provide a stable con- - dillon for residual measurement, to eliminate interference from background residuals that are not of interest, and to chemically convert residuals to a form IM 50.505.AA UA {2-98) 3.4. MICROI2000® l that is conveniently measarable by the analyzer. Also, when required (e. g., with wastewater), detergent may be added to the liquid reagents to prevent the accumulation of grease in the analyzer. More specifically, the choice of chemicals for analyzer sample condition-~ ing in a given application is based on three parameters: ? the residual to be monitored ? offier (potentially interfering) residuals present ~ water pH and alkalinity · RESIDUAL FORM ~ Chlorine dioxide and potassium permanganate monitoring The stability of the sample pH is not as critical when monitoring chlo- rine dioxide and potassium permanganate residuals as when measuring chlorine residuals. A sample pH change of 0.2 pH units between cali- bration will cause less than 5% error. Response to chlorine dioxide is somewhat improved at lower pH, however, and for best accuracy (stability) in the monitoring of both residuals, carbon dioxide gas buff- ering of the analyzer sample is recommended. Carbon Dioxide will also help prevent deposits caused by water hardness within the wetted analyzer components. ~ Bromine residual monitoring Bromine residuals are often encountered in chlorinated water with a significant bromide residual (e.g., in saline waters). Bromine residual behaves very similarly to chlorine residual and so the application recommendations for each are the same. ~ Chlorine residual monitoring For the purpose of this description, chlorine species can be grouped as follows: Free chlorine - hypochlorous acid and hypochlorke ion Chloramines monochloramine and dichloramine /'~ Organic chlorine abroad group of compounds with relatively weak disinfecting and oxidizing potential, a byproduct of chlorination Total chlorine the sum of the above residuals IM 50.5HAA UA (2-98) I "l !' ' ........ 7 MICRO/2000® t :~ Free Chlorine monitoring :~'~"~ In applications where the pH is less than pH8 and is stable, free chlorine residual can be monitored with no chemical conditioning. Often the stability of the water sample pH is not certain and a buffer is used to regulate the analyzer sample pH to between pH6 and pH4. If' it is important that the analyzer function accurately under conditions where the pH of the water sampled may vary, buffering is recommended. :I: Total chlorine monitoring Potassium iodide liquid reagent must be added to the analyzer sample for the measurement of total chlorine residual. The sample pH should be maintained between 4.0 and 4.7. INTERFERING RESIDUALS Interfering residuals can cause either positive interference (strong oxi- dants) or negative interference (e.g., organics that combine with chlorine to form organic chlorine forms, some of which can behave as free chlorine or may not be detected at all by the standard method of measurement or by the analyzer). Decreasing the analyzer sample pH (e.g., from pH4 to pH2.5) may, in some applications, cause interference from oxidants but, where acceptable, may also be desirable to improve the response to slug- gish organic chlorine compounds. In the measurement of potassium permanganate or chlorine dioxide re- siduals, ammonium sulfate reagent liquid is used to eliminate the response (interference) to free chlorine when necessary. · BUFFER SELECTION " WARNING: PH4 BUFFER WILL SEVERELY IRRITATE EYES AND CAUSE CHEMICAL BURNS TO SKIN. ALWAYS WEAR APt'RO- PRIATE PROTECTIVE EQUIPMENT DURING HANDLING. WB'EN DH.,UTING ACID, ALWAYS POUR ~ ACID INTO THE WATER, NEVER POUR WATER INTO ACID. USE CAUTION WHEN DIS- CONNECTING THE REAGENT TUBING AND AVOID CONTACT WITH ANY FLUID THAT DRIPS FROM ~ OPEN END. IT IS THE RESPONSIBILITY OF THE USER OF THE EQUIPMENT TO OB- TAINAND FOLLOW THE SAFETY PRECAUTIONS OF TFI'E MANU- FACTURER OF TI:W, lt_AZARDOUS MATERIAL. IM 50,50SAA UA (2-98) 3.6 I MICROI2000® [ ~' CARBON DIOXIDE gas may be used as a buffer for chlorine, potas- sium permanganate, and chlorine dioxide monitoring. The buffered sample pH should be between pH6 and pH5. ~ pH4 BUFFER liquid reagent may be used for sample buffering in chlorine, potassium permanganate, and chlorine dioxide monitoring. It is the preferred buffer for use in waters of low alkalinity for mea- suring total chlorine with a substantial percentage as dichloramine or organic chlorine. USFAV&T supplies pH4 buffer for this purpose. The buffered sample pH should be between pH4.7 and ph4. 3.2 USER INTERFACE - SOFTWARE OPERATION The analyzer is software controlled. Software control allows more flexibility to be incorporated into the hardware and sometimes enables improvements to the operation of already installed units by software upgrades. For example: The analyzer is able to check for failure of the cell temperature sensor. In the event of such a failure, the analyzer warns the user by an alarm and system fault message and changes to the non-temperature compensated mode of operation. The software and set-up and calibration information are stored in non-volatile memory, meaning the information will not be lost in the event of a power loss. In normal operation, the measured residual is displayed. The value is displayed in the upper portion of the display; the units of measure and the identifier are displayed in the lower portion. The lower portion of the display allows two lines of text to be used for various parameter "prompts" and alarm messages. Normally, the measured residual is the only parsmeter that is impormt to the user; however, there is more information the analyzer needs for operation and that it is capable of providing to the user. These other functions and parameters are organized into Display Groups. Some parameters are display only (for information only), and some require inforrrmtion input to confiBure the ana- lyzer to the customer' s requirements. Other than the Main Display, the typical user will hsve an interest only in the Setup Group (at initial start up). There the main functions of interest are the Identifier, the Measuring Range, and the HiBh and Low Alarm Levels. IM S0.gHM UA (2-98) 3.7 '1 "i' ! ' ' ........ ~c.o~2ooo, ! INTERFACE MENU MAP ~ DISPLAY GROUP FUNCTIONS/PARAMETERS (contained in) MAIN Measured Value SETUP Measuring Units Measuring Range Cell Voltage Set Point High Alarm Menu Low Alarm Menu Failure Alarm Warning Alarm Sample Line Dosing Control Menu Interface Lock Status I/O OPTIONS Digital Input Relay "A" Menu Relay "B" Menu Relay "C" Menu Alarm Deadbud DIAGNOSTICS Measured Value Slope mA Output Cell Signal Cell Voltage Cell Temperature Sofia/are Version Unit Serial Number System Kestart System Shutdown Local Operating Mode TEST mA Output TestJCalibrafion Menu Relay/Alarm Test Menu Dosing Comrol Test Time to Next Dosing The only parameter needed for regular operation is the ~ display param- eter. The other functions and parameters are required only for configuration (at the start of operation) and for Troubleshooting. IM S0.S0SAA UA (2..98) 3.8 T I "!' '! r ~ -~sr M RO =000' 3.2.1 KEYPAD OPERATION AND GENERAL INTERFACE PROCEDURES (SEE DWG. 50.505.170.010) User interaction with the analyzer is made using the keypad to view or select (implement) functions aided by prompts on the alphanumeric display. The keypad is located on the front of the analyzer, below the display window. It consists of six keys, listed and briefly described as follows: KEY NAME IDENTIFIER PURPOSE ALARM -~ Acknowledges alarm. ACKNOWLEDGE ESCAPE I Escape a sub-menu, escape from a function, abort a parameter value change sequence, or return to MAIN display. UP · View previous function/pararneter or increase a t'~' selected parameter value. DOWN · View next function/parameter or decrease a selected parameter value. FUNCTION F DISPLAY GROUP selector. ENTEK E Enter a sub-menu, initiate a function, initiate a change to a parameter value, or update/ record a new parmeter value. To change the parameter value, use the FUNCTION key to move to the correct Display Group and the UP and DOWN keys to move within the Display Group to the intended display. At aparameter display (within aDisplay Group), the value of the parmeter will usually be displayed on the lower line. If the lower line reads "menu" (e.g., as is the case with "high alarm"), this is an indication that a sub-menu exists for this parameter. To enter the sub-menu, simply press ENTER, The UP and DOWN keys can then be used to move within the sub-menu. At the intended parameter, press ENTEK to initiate the change sequence. The top line, which is the parmeter name, begins to flash. This flashing display, prompts the user to use the UP and DOWN keys to scroll to a new value. When the desired value is reached, press ENTEK to update/record the setting, or press ESCAPE to abort the change. If'the user is in a sub-menu, press ENTER. at the "exit" display or use the ESCAPE, to close the menu. IM SO.SOSAA UA (2-.98) 3.9 '1 '! '! .... MICROI2000 3.2.2 MAIN DISPLAY - MEASURED VALUE The Main display shows the measured value (residual) and the measuring units and identifier. The Main display is the primary or nominal parmeter of the analyzer. If the interface is Iei~ at another display for more than five minutes without any keyboard activity, the interface will return to the Main display automatically. The Main display is also used to calibrate the analyzer. Refer to the calibration procedure instruction for further detail. 3.2.3 SET-UP GROUP - SOF'I'VVARE CONFIGURATION OF THE ANALYZER (SEE INTER- FACE MENU MAP) While configuration parameters are set to default settings on initial power-up, the settings should be verified to correspond to installation wiring and user preferences or application requirements. Parameters contained in the SET-UP display group are for this purpose. The parameters and their settings may be viewed without altering them; the default settings are also provided in the following instructions. 3.2.3.1 Measuring Unit/Identifier The identifier is a convenience--it modifies the units _"mg/L" displayed on the text line beneath the main display. Available modifiers are: "C102" - chlorine dioxide "CI2 TOT" - total chlorine "C 12 FP,." - flee chlorine "KMnO," - potassium permanganate "Ozone" - ozone The factory default is "C I2 TOT". 3.2.3.2 Measuring Range The Measuring Range is the range of measured residual over which the ana- lyzer will be expected to function, also the range to which the 4 to 20 mA output corresponds. It is elsewhere referred to as the "range of the analyzer." If the range is changed from the factory default, or from any prior setting, the hardware gain switches should also be changed accordingly. The default range is 2.0 mg/L. Refer to the Section 4 - Service for instructions on changing gain. 3.2,3.3 Cell Voltage Set Point The cell voltage is set at the factory to 0.25v and generally needs no adjustment - by the user. If the cell voltage is not correct (if it deviates from the set point), the soilare will report a system fault. IM 50.505AA UA (2-98) 3.10 71 [ MICROi2000® I The cell voltage is a potential maintained on the electro-chemical cell that controls the response to various oxidants (chemicals) in the sample. The cell is able to selectively measure the desired chemical because of the selected potential. This potential is hardware controlled (by a dedicated circuit), but is monitored by the software. A WARNING: TO AVOID ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT, AVOID CONTACT WITH CIRCUIT BOARD COM- PONENTS WHILE MAKING ADJUSTMENTS. TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELEC- TRICAL SHOCK, WI~I~N SERVICE MAY BE REQUIRED TO BE PERFORMED TO THE UNIT WITH POWER CONNECTED, IT SHOULD BE PERFORMED ONLY BY PERSONNEL QUALIFIED TO PERFORM SUCH SERVICE. Adjusting the cell voltage requires access to the electronics and adjustment of a potentiometer on the input board (a component of the CPU board). Refer to paragraph 4.4.14.2 for instructions on cell voltage adjustment. To reset the cell voltage setpoint (sof~are setpoint): a. Initiate the change by pressing ENTER. The top line will flash. The bot- tom line indicates the current measured cell voltage. b. To change the current setting, adjust the potentiometer. c. Press ENTER again. The setpoint is now set at the new value. The factory defauk is set at 0.25v. 3.2.3.4 High and Low Alarm The analyzer can be configured to alarm (to actuate relay outputs) in the event that the measured value varies from a user-selected range. These functions allow the user to set the alarm levels (the ex~emes of the accepted range), configure the alarm as latching or non-latching, and enable or disable the alarm. If the alarm is disabled, the alarm levels set are retained. The analyzer is derivered with alarms enabled and the alarm levels set to the extremes of the default operating range. IM S0.SOSAA UA (2-98) 3.11 I '!' '! ' I" 1 I MICROi2000® Factory Defaults: High Alarm Level = 2.00 rag/1 High Alarm Action = LATCHING High Alarm State = ENABLED Low Alarm Level = 0.00 mg/l Low Alarm Action = LATCHING Low Alarm State = ENABLED 3.2.3.5 System Fault Alarm System faults are errors in the operation of the equipment detected by the self- diagnostic functions. These faults can be classified as either WARNING con- ditions, during which the analyzer can continue to operate, or FAILURE conditions, during which the analyzer cannot continue to operate. The mA output is mined off during FAILURE conditions. Unlike HIGH and LOW alarms, system fault alarms cannot be disabled from appearing on the display. They can only be configured as LATCHING (user acknowledgement required to clear) or NON-LATCHING (selfcanceling when condition is corrected). Factory Defaults: System Failures = LATCHING System Warnings = NON-LATCHING 3.2.3.6 Sample Line Dosing Control The analyzer's Sample Line Dosing Control function provides a relay output for the control of periodic addition of a cleaning agent to the sample flow to inhibit biological growth in the sample line. Sample line dosing is necessary in process water exhibiting a high biological growth potential, and is also neces- sary when a weak or no chlorine residual (i.e., sulfur dioxide residual) is measured in the sample. · FUNCTIONAL DESCRIPTION The procedure is as follows: At some user-selected frequency (dosings per week), the dosing relay is actuated (energized). This closes the dosing relay output contacts (wired to a dosing apparatus pump) and causes a dosing agent to be fed into the sample-line for a selected lime period (dosing time). While the dosing agent is being fed into the sample flow, the anaiyzer will stop the sample metering pump to block the sample flow to the measuring cell (no flow time). The sample flow is blocked during this period because the dosing chemical might disrupt the cell or produce false alarms and a false control or recorded mA signal. Generally, the dosing chemical is chlorine in a IM 50.505AA UA (2-98) 3.12 rd c .o 2ooo concentration of one or more orders of magnitude greater than the process concentration. During the no flow time, the dosed sample is bypassed through the analyzer internal bypass line. Where there is a substantial hydraulic delay between the dosing feed point and the analyzer, the user may want to delay the "no flow time". The reason for this delay is to allow the analyzer to continue to operate during most of the time period from when the dosing agent is fed until it reaches the analyzer. Generally, it is sufficient to configure the analyzer to shut off cell flow immediately. Th~ factory default "delay time" is zero. The analyzer "no flow time" cannot be set less than the "dosing time" plus one minute. If necessary, the "no flow time" is increased automatically, by the analyzer software, to meet this requirement. Alter the flow is resumed to the cell, there is a five minute stabilization delay, during which the analyzer is allowed to stabilize before resuming the mA output; however, the display resumes operation without delay. EXAMPLF- (DELAY TIME SETTING) For a system that has a one-minute hydraulic delay time between the dosing point and the analyzer, and the user chooses to dose 14 times per week for five minutes duration at each dosing: Dosings per week -- 14, and dosing time: 5.0. With Delay Time - set the "delay time". 5 minute (shuts off cell flow before the dosing agent reaches the analyzer) and set the "no flow time" to 6.5 minutes C'dosing time" plus one minute, plus the remaining one-half minute from the hydraulic delay). Without Delay Time - set the "delay time" to zero and set the "no flow time" to 7 minutes C'dosing time" plus one minute, plus the hydraulic delay). As demonstrated in the above example, a moderate dosing period neces- sitates a substantial time period wh~m the analyzer is off-line. Also, in most systems, the reduction in "no flow time" provided by the "delay time" is not great. IM 50.S0SAA UA (2-98) 3.13 'T '1 '! ' ' ' MICRO/2000® · SETTING DOSING CONTROL PARAMETERS A number of parameters must be entered into the analyzer for sample line dosing. In addition, the dosing function may be enabled or disabled. The parameters are: dosings per week dosing time delay time - no flow time These are set through the sample line dosing control sub-menu. Once set, the dosing sequence can be tested in the Test display group. This test runs through the dosing sequence to observe that the installation and set-up and component functions are correct. 3.2.3.7 Setting the Interface Lock The user may configure the system for locked or unlocked mode. In locked mode, the use of any function that requires input is locked and requires the input of a three-digit access code before further input will be accepted. The system is then unlocked until the ESCAPE key or ENTER key is pressed or until it "times-out" (after five minutes) back to locked mode in the MAIN display. There are two security level codes. The Level 1 code (CALIBRATION CODE) allows clearance for system calibration only. The Level 2 code (MASTER CODE) allows access for all parameter changes, functions, and calibration. The purpose of these functions is to prevent accidental or unauthorized per- sormel from tampering with the analyzer. The locking option is a two-step function requiring the selection of an access code and enabling the function. To set the access code, set the calibration code, and lock or unlock the ana- lyzer, do the following: a. Press ENTER at the "lock setup" display. The user will be prompted to accept the present master code or enter a new master code. b. A new code is entered one digit at a time from lef~ to right. To choose the code numbers, press the LIP or DOWN keys until the correct number appears. Press ENTER to record each digit and advance to the next. c. Press ENTER to record the new master code or accept the current code. IM 50.505AA UA (2-98) 3.14 T I "[ ! I I -I.,t MICRO!2000® d. The user ~ be prompted to accept the present calibradon code or enter a new calibrafion code. To change the ca~ibrafion code, follow the procedure in step b. To accept the current code, press e. The user ~ be prompted to lock or unJock the system. Use the T,~ or DO~'N keys to choose the "lock" or "urdocked" code. Press ENTER. to accept the lock selling. The factory default setl~gs are: MA~TER CODE = 000 CALTR1L~TION CODE = 000 UNLOCKED 3.2.4 I/O (INPUT/OUTPUT) OPTIONS GROUP (SEE INTERFACE MENU MAP) The I/O Options display group contains displays for setting up the digital input and relay parameters. 3.2.4.1 Digital Input The voltage used to energize the digital input is user-selectable through a jumper (IP1) on the power supply board. The user can configure the digital input for 24Vac/dc, 115Vac/dc, or 230Vac/dc. The digital input must be valid for one-half second before action is taken. This filters any spikes occurring at the digital input caused by induced noise. The digital input can be configured to act as either a remote "system shutdon" or a remote "alarm acknowledge". The default is "system shutdon". As remote "alarm acknowledge" momentarily energizes the digital input, it will have the same effect as pressing the alarm acknowledge key. As remote "system shutdown" energizes the digital input, it causes the system to go into "sleep mode". The unit acts as if the system had been shutdown through the keypad in the DIAGNOSTIC display group. Pressing any key on the keypad will restart the system. With the digital input in this configuration, the system is looking for a transition at the digital input. That is, to shutdown the system, an unenergized-to-energized transition must occur. To restart the system, an energized-to-unenergized transition must occur. To restart the system remotely, after the system has been shutdown locally using the keypad, energize the digital input for at least one-half second, then de-energize it. IM 50.505AA UA (2-98) 3.15 '1 ' '!' '! ' ' MICROi2000® 3.2.4.2 Relay Setup (Relays A, B and C) · Relay Function: This parameter associates each relay with a function. The available functions are: high alarm high/warn low alarm lo/warn highflow alarm hi/lo/warn system fail faiFwarn high/fail hi/fail/warn low/fail to/fail/warn hi/lo fail all alarms system warn line dosing The factory defaults are: Relay A = hi/fail/warn Relay B = lo/fail/warn Relay C = LINE DOSING · Relay State: This parameter determines if the relay is normally energized or de-energized. For safety, if the relay function is set for line dosing, the relay state is normally de-energized and cannot be modified by the user. The factory defaults are: Relay A = NORMALLY ENERGIZED Relay B = NORMALLY ENERGIZED Relay C = NORMALLY DE-ENERGIZED 3.2.4.3 Alarm Deadband This parmeter determines the mount ofhysteresis that exists around a high or low alarm level. The purpose of this parmeter is to avoid relay "chattering" (chattering would occur only if non-latching alarm operation is selected) or immediate re-triggering when the measured value varies in and out of an alarm condition. By introducing hysteresis, the alarm condition is required to clear ' well beyond the trigger level before re-triggering can occur. The deadband is set in percent of full scale and can be set from 0 to 20%. Example: Range = 0 mg/l - 1.0mg/l High Alarm = 0.5mg/l Deadband = 10% The alarm is triggered if the measured residual exceeds 0. 5mg/l. If LATCHED: After ALARM ACKNOWLEDGE is pressed, the measured residual must drop below 0.4marl [0.5 - (10% * 1.0)] before it can re-trigger the alarm by exceeding the high alarm level. IM 50.50SAA UA (2-98) 3.16 MICROI2000® If UNLATCHED: The measured residual must drop below 0.4rag/1 before the alarm will clear itself. The factory default is 5%. 3.2.5 DIAGNOSTICS GROUP The Diagnostic display group contains a set of"display only" functions, used to aid in troubleshooting performance problems. See paragraph 3.2, User Interface - Soil:ware Operation, for the Interface Menu Map. 3.2.5.1 Measured Value Measured Value is the same as the measured value in the Main display. It is repeated in this group for reference when monitoring diagnostics. In the Di- agnostics Group, however, the measured value is not limited to the user- selected analyzer range. 3.2.5.2 Slope : Slope indicates the constant of proportionality between the measured value and the cell signal (corrected to 77°F (25°C) cell sample temperature), as determined at the time of cah'bration. 3.2.5.3 mA Output The displayed rnA Output value can be used to verify that the output signal is appropriate for the indicated measured value and the value indicated by the receiving device (for the range selected for the analyzer). The indicated value cannot be changed at this display function, but can be toggled to indicate in units of rnilliamps or percent of full scale by pressing the ENTER key. The predicted value can be calculated as: 06 * Measured Value / Range) + 4 3.2.5.4 Cell Signal The Cell Signal is the value of the signal produced by the (amperometric) cell expressed in rnicroamps. It can be used to verify that the siBnal is present and that it is approximately the expected value for the measured value. 3.2.5.5 Cell Voltage Normally, the current value of the cell voltaBe should not change during the operation of the analyzer and should be the same as the cell voltaSe setpoint (a Set-Up function). IM S0.S0SAA UA 12-98) 3.17 f MICROi2000® I 3.2.5.6 Cell Temperature ~"~ The temperature of the water sample in the cell. The indicated value cannot be calibrated, but it can be toggled to indicate in units of degrees Centigrade or Fahrenheit by pressing the ENTER key. 3.2.5.7 Software Version The software version is the EPROM pan number and issue. This information may be needed for service support. 3.2.5.8 Serial Number The serial number of the complete analyzer arrangement is displayed by this function. The serial number consists of two letters followed by five digits. The serial number is also printed on the specification label in the electronics enclo- sure or on the back of the module. 3.2.5.9 System Restart This function allows for a "warm" startup of the system, It simulates a system ~ power-up by resetting the CPU. All parameter values stored in the non-volatile \. , ~ RAM are transferred to the working RAM. Press ENTER to activate this function. This function allows the user to restore operation to a unit when it has become corrupted by electrical noise. Calibration and other important parameters are not lost. Ifa warm restart does not restore proper operation, the system may be forced to re-initialize. At this point, all factory default information is restored, and the user's calibration and set-up parameters are lost. ' To re-initialize, the system must first be unlocked (if it is locked). Then, initiate a warm restan and immediately press and hold the ESCAPE key. The system will respond by indicating that it is re-initializing. User set-up and calibration parameters must then be re-entered. 3.2.5.10 System Shutdown This function puts the system in "sleep mode". The mA output is set to zero, all relays are de-energized, and the pumps are turned off Pressing any key takes it out of"sleep mode". This function can also be done remotely, using """ the digital input (See paragraph 3.2.4, lJO Options). -- IM 50.505AA UA (2-98) 3.18 I I ' "~ · { MICROI2000® J 3.2.5.11 Local Operating Mode This parameter is used to put the system in "SERVICE" mode. In this mode, the mA output is frozen, the system will no longer monitor for alarm condi- tions, and the five-minute "time-out" back to the MAIN display is disabled. The system will automatically switch back to the "NORMAL" operating mode upon leaving the DIAGNOSTIC display group. 3.2.5.12 Self-Diagnostic, System Fault Messages The self-diaSnostic, system fault messuSes are listed here for reference. Refer to paraSraph 4.3, Troubleshootin~, for explanations of the messages. The difference between a System Warning and a System Failure is that the analyzer is usually able to continue to operate under a warning condition. SYSTEM WARNINGS SYSTEM FAIt,URES CELL VOLTAGE DEVIATION CELL VOLTAGE OUT OF RANGE LOSS OF TEMPERATURE CHECK PROBE CONNECTION COMPENSATION , HIGH ALARM CHECK PROBE JUNCTION LOW ALARM CELL INPUT SATURATED HIGH mA LOOP IMPEDANCE SLOPE ERROR 3.2.6 TEST FUNCTIONS GROUP See paragraph 3.2, User Interface - Software Operation, for the Interface Menu Map. 3.2.6.1 mA Output Test and Calibration The analyzer provides an isolated, 4 to 20 mA output, proportional to the measured residual. It can be tested and calibrated using this function. (Also refer to paragraph 2.9.4, mA Output). To test and calibrate the mA output: a. Enter the "mA OUTPUT" sub-menu. b. Press ENTER at the "0% output" display. The unit will output what it determines to be 4mA. IM ~O.~OSAA UA (2-98) 3.19 M cRo/2ooo c.The user is prompted to adjust the output, using the UP and DOWN keys. d.Press ENTER to record the new calibration point and return to normal operation, or press ESCAPE to return to normal operation. Follow the same procedure for the "100% output" display. The "50% output" can only be used to test for linearity; it cannot be adjusted. 3.2.6.2 Relay and Alarm Tests These functions can be used to test the operation of the individual relays and to test the configuration of individual alarms. · To test the relays: a.Enter the "relay tests" sub-menu. At the "ReIay A" display, the nor- mat state of the relay is displayed on the lower line. b. Press ENTER to put the relay in its non-normal state (energized/de- energized). c. Press ENTER or ESCAPE to terminate the test. Follow the same procedure to test "Relay B" and "Relay C". · To test the alarms: a. Enter the "relay tests" sub-menu. At the "high alarm" display, the lower line will show the relay(s) currendy configured for high alarm. b. Press ENTER to put this relay in its alarm state. This is reflected on the display. c. Press ENTER or ESCAPE to terminate the test. Follow the same procedure to test the "low alarm" and "system alarm". 3.2.6.3 Dosing Control Test This function allows the user to activate the dosing control function manually. Unlike an automatically activated dosing sequence, this dosing sequence can be terminated at any time by pressing ESCAPE. · To test the dosing control function: IM 50.505AA UA (2-,q8) 3.20 MICROI2000® a. At the "dosing test" display, the lower line shows the relay(s) cur- rently configured for line dosing. b. Press ENTER to start the test. The upper line shows the configured relay(s), the letter "W" (which represents the pump ('%vetside") con-. trol relay D), and the state of the pumps. The lower line indicates the state of each of these relays ("e" for energized, "d' for de-energized). The short line above the lower lines indicates the time, in seconds, until the next action occurs. c. At the end of this test, whether terminated normally or prematurely by the user, the time until the next line dosing is reset. The next dos- ing occurs as it would if an automatic dosing had just taken place. 3.2.6.4 Next Dosing This display shows the time before the next line dosing sequence will occur. 3.3 GENERAL OPERATION Before attempting to use the analyzer, verify that all preliminary mechanical and electrical requirements have been satisfied according to Sections 2 and 3 of this instruction book. 3.3.1 START-UP PROCEDURE a. Close the valve to the inlet of the analyzer and open the Y-strainer bypass valve before starting the sample flow through the Y-strainer. b. Adjust the Y-strainer bypass flow control valve for desired bypass flow and inspect the sample line for leaks. c. Slowly open the valve at the inlet to the analyzer, while checking for leaks within ~e analyzer. Adjust for a sample flow of approximately 500 mL/min into the analyzer. It may take approximately five minutes for the reagents to prime and for the reagent and sample flow to stabiliT-e. During this time, warnings and alarms may act intermittently. Allow the analyzer to operate at least 30 minutes before attempting initial calibration or expecting stable operation, Observe the analyzer operation upon start-up to be sure all components are functioning properly. IM 50.505AA UA (2-98) 3.21 "'~ '! ' I" ~ [ t M c.o 2ooo When operation is stable, add a small amount of cleaning grit to the cell and calibrate the analyzer. A "rough" calibration of the analyzer is made upon start- up of the analyzer, but calibration should be rechecked at~er 24 hours of operation. If difficulties occur during startup, refer to paragraph 4.3, Troubleshooting, for instructions. 3.3.2 CHECKS AND MAINTENANCE The following checks should be performed regularly. Reagent usage (duration between reservoir refills) will determine the frequency of reagent maintenance checks. 3.3.2.1 Reagent Reservoirs Check reagent reservoir levels regularly. Note the change in level at weekly intervals. If the reagent usage is less than or greater than normally observed, or if'there is backflow into the reagent reservoirs, check the metering pump and reagent tubing units in the pump. 3.3.2.2 Calibration ~'~ Before beginning calibration, be sure the interface is at the Main display func- tion, Measured Value. a. Take a sample of the process water from the analyzer bypass flow within the analyzer wetside. A sample of S00 ml is taken to allow one minute of hydraulic mixing in the sample container. Immediately after the sample is taken, initiate the calibration procedure. b. To initiate the calibration procedure, the interface should be at the Main display function. Press ENTER at the Main display to initiate calibration and enter the access code, if required. The display reads "CALIBRATE". When the function is initiated, the display is frozen indicating the last measured value, but the mA output continues to operate. c. Measure the residual contained in the process sample. Enter this value (correct the value on the display) using the UP and DOWN keys. Press ENTER to set the value. 3.3.2.3 Grit In Cell Check that there is "sufficient" grit in the cell, meaning there is enough grit so - that it is easily visible scouring around the cell, but not enough so that it piles up on the bottom of the cell. IM 50.505AA UA (2-98) 322 T [ "IT' "! ; i;I ....... MICROI2000® To add grit, remove the probe from the cell. Add the grit and replace the probe. Do not allow anything to touch the electrodes. They are easily damaged, and any contact (especially cleaning) may affect calibration. The cell should contain two to four grams of grit. Add approximately one gram at a time. When adding grit initially, it may pile on the bottom or float to the top of the cell. This is normal. Allow the grit to "break in". [lit continues to be a problem, rinse the grit in alcohol. 3.3.2.4 Leaks and Gorrosion Check for signs of leaks (i.e., wetness or corrosion) around the sample line and inside the analyzer wetside. Repair all leaks. 3.3.2.5 Impeller Drive and Grit The impeller functions properly when it rotates steadily and quietly. Occasionally, when there is a lot of grit in the cell, the impellet may be heard striking the grit. An occasional occurrence of this is normal. If this occurs ,/""' ~ frequently, the cell must be removed and the grit rinsed from the ceil. Add a smaller quantity of grit. Restart the analyzer. 3.3.2.6 Probe Electrolyte Level Check the probe electrolyte level approximately once a month. Fill the probe with electrolyte through the tilt hole in the side of the probe body. Fill only to a level just below the fill hole when the probe is upright. The hole plug is not watertight. After filling the probe with electrolyte, replace the plug, then re- place the probe in the cell. 3.3.2.7 Analyzer Metering Pump Check that the metering pump is turning quietly. Tubing should be in place properly and not show excessive wear or leakage, Check that there is flow from the discharge line of the analyzer cell. It will not be steady, but should be consistent. Typical flow is seven drops in rapid suc- cession followed by a pause in flow (8 mL/min for 1 rpm pump, 16 mL/min for 2 rpm pump). /" Note the reagent usage (i.e., the change in reservoir level). Refer to the para- graph 4.3.4, Troubleshooting - Metering Pump, or paragraph 4.4.6, Special Service Instructions - Pump Tubing Units Replacement. IM 50.SOSAA UA (2-98) 3,23 'T ' · ~' r" 7 f MiCROi2000® 3.3.2.8 Sample-Flow, Y-Strainer, and Sample-Pump Check that there is sample flow from the bypass line in the analyzer. It should be a substantial flow, 500 ml/min nominal. The pressure into the analyzer must not be greater than 5 psi. Open the Y-strainer bypass flow to flush the sample line and strainer element (for about one minute). Readjust the valve for the desired bypass flow through the Y-strainer, then open the analyzer sample inlet valve. If flow from the Y-strainer discharge leg is marginal with the bypass valve fully open, check for a clogged sample line, low supply pressure, or a failing sample pump. If flow into the analyzer is marginal with the inlet valve open, check the strainer element in the Y-strainer for clogging. 3.3.3 SHUT-DOWN/RE-START The system may be shut down for short periods of time (up to one week) by turning off the power switch with the sample flow either on or off, closing the valve at the inlet to the analyzer, then turning off the sample pump. For periods of greater than one week duration: Unplug the probe and remove it from the analyzer. For long periods of disuse, wipe the probe clean with a paper towel and place the caplug (as shipped with the probe unit) on the probe tip. The caplug should contain a small amount of water or electrolyte solution. Store the probe in a vertical position (tip down). When the power is disconnected, intentionally or by a power failure, the con- figuration and caiibration settings of the analyzer are maintained. When the system is restarted it resumes operation in the same state as when the power was turned off. Restarting the system is the same as the system start-up procedure. 3.4 THEORY OF OPERATION The measurement of free chlorine is made directly at a buffered pH of 4 with pH 4 buffer or pH of 5 or 6 with carbon dioxide. The measurement of total chlorine is made by reacting the various chlorine species with potassium iodide at the buffered pH, then measuring the resulting iodine concentration. IM 50.505AA UA (2-98) 3.24 ' ' I I 'IT' ' MICROi2000® The net reaction of chlorine with iodide is: Cl2 + H;O -> 2H+ + OC1- + C1- (hydrolysis of chlorine) OC1- + 2I- + 2H+ -> H~O + 2C1- + I~ The analyzer measuring process is as follows: A continuous sample is delivered to the analyzer. A flushing Y-strainer divides the sample into two streams--the larger bypass stream continuously flushes the Y-strainer and the smaller stream, about 500 ml/min, flows into the ana- lyzer. Most of the flow into the analyzer is again bypassed, but a small portion is metered from this flow by a peristaltic metering pump. The reagents, pH 4 buffer or carbon dioxide for the measurement of free chlorine residual and potassium iodide solution with detergent for the measurement of total chlorine residual, are also metered by the same pump. The reagents are then mixed with the sample as the sample is pumped to the analyzer cell. A three-electrode amperometric "probe" is immersed in the sample in the cell. A rotating impeller stirs the sample and maintains a constant sample velocity across the electrode surfaces. It also agitates the grit used to clean deposits from the electrodes, improving the stability ofcalibration. The amperometric cell produces a signal (electrical current) proportional to the oxidant (e.g., chlorine) concentration in the cell. 3.5 ADDITIONAL CALIBRATION TIPS Because the analyzer is on-line, the process should be observed for a few moments before and while taking the sample to insure that the process does not deviate suddenly during sample taking and before initiating the cah'bration. A substantial change in the process during calibration results in an inaccurate calibration. IM 50.505AA UA (2-98) 3.25 'T .... !' ! ' ' ' KEY ~ ,~//~/, , AL R '~"'""""'~ DISPLAY . A ACK KEY - . FUNCTION KEY ESCAPE - KEY - ANALYZER FRONT PANEL- OPERATION 50.505.170.010 ISSUE 3 02-98 T I / ! I TI MIXED SAMPLE PROBE &, REAGENT(S) FLOW AND REAGENT(S) ' /r"~ PUMPED TO CELL "Y" FITTING FOR 2 REAGENTS PROBE SAMPLE LOCATING IBE UNIT PIN REAGENT TUBE UNITS CELL (TWO ~ SHOWN) CELL DISCHARGE PANEL -~ , ,._ PUMP ROTATION IMPELLER "' CCW (ROTATION CCW) OCCLUSION """ RING TO ,._ WASTE REAGENTS SAMPLE .'O~~, (TWO ,"""" BYPASS SHOWN) FLOW - ¢,~,~E~=~~,,~i% ~ TEE FITTING ,- (REAGENTS ENTER SAMPLE) SUPPLY SAMPLE INTAKE 500 roLlrain ": .SAMPLE BYPASS SAMPLE FLOW --'- FLOW DISCHARGE AT LESS 'i~..~N~~r CALIBRATION VALVE (DEOX ONLY) TO DRAIN CAUTION: To prevent poemtie s:e'..,~-nt damage, apply up to a maximum d S pei vmter pressure to the analyzer sample input. ~ tubing in I~e analyzer toeing pump can not ~ m~m Ihan 5 psi pressure. If p_~e___,m in m~f5psiisap~ied~1~eana~in~:~d.~f~uidmaybe~pray~fmm~h~an~y.zm~m~m~i1pumpb~L NOTE: · THE LENGTH OF THIS TUBING FOR MICRO/2000 ANALYZERS IS SEVEN INCHES. THE LENGTH OF THIS TUBING FOR DEOX/2000 ANALYZERS IS EIGHT FEET TO ALLOW FOR SUFRCIENT CHEMICAL REACTION. RESIDUAL ANALYZER - FLOW DIAGRAM 50.505.180.010 ISSUE I 02-98 t t '. e i t MICROI2000® J r--T, SECTION 4 - SERVICE List Of Contents PAR~/DWG. NO. General ...............................................................................4.1 'Preventive Maintenance Recommendations .........................4.2 Sample Pump .....................................................................4.2.1 Y-Strainer ..........................................................................4.2.2 Wearable Items Replacement .............................................4.2.3 Probe .................................................................................4.2.4 Tubing ...............................................................................4.2.5 Troubleshooting ..................................................................4.3 ~ General ..............................................................................4.3.1 System Self-Diagnostics .....................................................4.3.2 Measured Value ................................................................4.3.2.1 Response Slope .................................................................4.3.2.2 mA Output ........................................................................4.3.2.3 Cell Signal .........................................................................4.3.2.4 Cell Voltage ......................................................................4.3.2.5 Cell Temperature ..............................................................4.3.2.6 Software Version ..............................................................4.3.2.7 Unit Serial Number ...........................................................4.3.2.8 System Restart ..................................................................4.3.2.9 System Shutdown ...................... ........................................4.3.2.10 Local Operating Mode ......................................................4.3.2.11 Extended Calibration Method ............................................4.3.2.12 System Error Messages .....................................................4.3.2.13 System Warnings ..............................................................4.3.2.14 System Failures .................................................................4.3.2.1 5 Impellet Drive ....................................................................4.3.3 Metering Pump ..................................................................4.3.4 Probe .................................................................................4.3.5 Electronics .........................................................................4.3.6 Probe and Circuit Boards Wiring ........................................4.3.7 Special Service Instructions .................................................4.4 Preparation of Reagents .....................................................4.4.1 Preparation ofpH4 Buffer .................................................4.4.1.1 Preparation of Potassium Iodide Solution ..........................4.4.1.2 Preparation of Ammonium Sulfate Solution .......................4.4.1.3 Detergent Additive ............................................................4.4.1.4 Re-filling Reagent Reservoirs .............................................4.4.2 Wetside Panel Removal and Replacement ...........................4.4.3 Occlusion Ring Removal and Replacement .........................4.4.4 Continued on Page4.,2 IM 50.505AA UA (2-98) 4.1 M c.o 2ooo I ,,"' *'h List Of Contents (Cont'd) ~ PARA./DWG. NO. Pump Rotor, Rollers, and Thrust Washer Removal and Replacement ..............................................................4,4.5 Pump Tubing Units Replacement ........................................4.4.6 Pump Bearing Replacement ................................................4.4.7 Impeller Shaft Seal Replacement ........................................4.4.8 Impeller Motor Removal and Replacement .........................4.4.9 Impeller Shaft Replacement ................................................4.4.10 Pump Motor Removal and Replacement .............................4.4.11 Probe Electrolyte and Electrodes ........................................4.4.12 Probe Cleaning, Refilling, and Porous Element Replacement ....................................................................4.4.1 3 Electronics .........................................................................4.4.14 Change of Supply (Mains) Voltage ....................................4.4.14.1 CeU Voltage Adjustment ...................................................4.4.14.2 Setting Range Switches .....................................................4.4.14.3 Fuse Replacement .............................................................4.4.14.4 Circuit Boards Removal and Replacement .........................4.4.14.5 Snubber Jumpers ...............................................................4.4.14.6 Identification, Removal, and Replacement of Relays .......... 4.4.14.7 Warning/Caution Summary Page .........................................2 Pages Illustrations Service-U29086 Probe .......................................................50.510.150.010 IM 50.50SAA UA (2-98) 4.2 : I I "i' ~ Ii ~ J MICROI2000® I 4.'1 GENERAL Plan a regular maintenance program to ensure proper operation and avoid unplanned equipment downtime. 4.2 PREVENTIVE MAINTENANCE RECOMMENDATIONS 4.2.'1 SAMPLE PUMP If the installation uses a sample pump, periodic mainten~ce ensures a reliable sample to the analyzer. Consult the manufacturer' s literature for proper main- tenance procedures and schedules. Gradually deteriorating pump performance is not usually evident to the operator, as over 95% of the sample discharge may be discarded through the bypass valves. Adequate flow velocities through the sample lines must be maintained to minimize lag time and fouling that may result in a residual demand. 4.2.2 Y-STRAINER (SEE DWG. 50.500.002.011 ) The Y-strainer (8) contains a porous plastic filter element that removes large particles from the sample flow to the analyzer. This element is continuously flushed by the bypass flow to drain. Depending upon the quality of the water being monitored and to prevent the need for frequent cleaning of the strainer element, a flow of at least I gpm may be necessary. The strainer should be periodically cleaned. Throttling the bypass valve to force sufficient flow through a partially blocked filter accelerates the fouling. Clean the filter as follows: a. Turn off the flow to the analyzer. b. Disconnect the drain line at the strainer bypass valve. c. Unscrew the filter element cap and attached the fittings as a unit. d. Remove and thoroughly clean the element by rinsing in clean water and wiping if necessary. e. Reinstall the element and drain fittings. Ensure that the collar of the ele- ment points away from the cap. Restore the sample flow to the analyzer. IM 50.505AA UA (2-98) 4.3 : T I t MICROI2000® 4.2.3 WEARABLE ITEMS REPLACEMENT The impeller shaft, impeller sha_~ seal, and the sample and reagent tubing units are wearable items. They should be inspected regularly for wear and replaced as needed. Recommended frequency of replacement is every six months to one year, as experience indicates. When the occlusion ring is removed from the pump to inspect or replace the tubing units, check that the pump rollers rotate freely. NOTE: Do not remove the occlusion ring with water pressure applied to the pump inlet, as water will flow through the pump sample tubing and possibly overflow the cell or spray from the disconnected tubing. When the cell, grit guard, and seal adapter are removed to replace the shaft seal, inspect the shaft for wear where the seal rides. If noticeable wear or abrasion has occurred, replace the impeller shaft. 4.2.4 PROBE The probe cannot be disassembled (all joints are cemented) and is not service- able except for the following maintenance operations. NOTE.: The analyzer will perform best when the probe is !eft undisturbed as much as possible. Check the electrolyte level and refill as necessary. Clean the electrodes by wiping with a clean paper towel. Ifthere is a greasy film on the electrodes, this can be removed by cleaning with a paper towel dipped in alcohol. fithere are hard deposits on the electrodes, this can be removed by wiping the electrodes with a clean paper towel dipped in muriatic acid (10% hydrochloric acid). The analyzer will require recalibration al°cer 24 hours of operation alter the electrodes are cleaned. WARNING: HYDROCm,ORIC ACID AND MURIATIC ACID WILL SEVERELY IRRITATE EYES AND CAUSE CI~MICAL BURNS TO SKIN. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIP- MENT DURING HANDLING. WHEN DILUTING ACID, ALWAYS POUR ACID INTO ~ WATER, NEVER POUR WATER INTO ACID. IT IS THE RESPONSIBILITY OF THE USER OF THE EQUII'MENT TO OBTAIN AND FOLLOW THE SAFETY PRECAUTIONS OF THE MANUFACTURER OF THE tLAZARDOUS MATERIAL. IM S0.505AA UA (2-98) 4.4 J 'J '1 'f : r i ~ I MICROi2000® ] If the probe is to be stored for more than a week, the porous element should be removed and the electrolyte drained. The reservoir should be rinsed with distilled water to eliminate any remaining electrolyte. Otherwise, the electrode end must be kept wetted to prevent crystallization of the electrolyte in the pores of the element and clogging of the element. The porous element can be removed and the electrolyte drained as follows: Using a self-tapping screw (a ~5 drywall screw is preferred), tap into the porous element, then pull out the element. The element is approximately 1/4- inch long. This porous element is no longer useable. The electrolyte will drain out slowly. Rinse the reservoir well with distilled water to remove residual electrolyte. When removing the element in this manner, use care not to scar the sides of the element bore as this might prevent insertion of a new piece of porous material or cause excessive leakage of the electrolyte. A new porous element can be created and installed as follows: Do not precut the porous material to length. A clean, sharp razor blade is required to make a dean cut in the porous material. First, using a sawing motion, slice offa thin slice of one end of a length of the porous material. This fresh cut endis then pressed into the element bore. The fit should be snug. The material should be embedded to a 1/4-inch to 3/8-inch depth. Next, saw offmost of the remaining material. Finally, taldng care not to damage the probe end, shave off the remaining material so that the element is flush. It is recommended to periodically replace the probe reference junction and electrolyte. P, jnse the reservoir with distilled water, twice, before adding new electrolyte. Kecommended frequency ofrephcement is every 12 months (more frequently if contamination or junction clogging occurs). This is also a good time to inspect the electrodes for wear and the probe for · signs of deterioration. 4.2.5 TUBING It is recommended to replace all flexible tubing once a year, 4.3 TROUBLESHOOTING 4.3,1 GENERAL Sources of trouble are of four types: mechanical, chemical, electronic/electri- cal, and software (bugs). The frequency of occurrence is approximately in the order indicated. Mechanical problems are the easiest to locate, or rule out. Sources ofmalfunction can be located, or ruled out, by performing the wutine checks described in the Section 3 - Operation. IM 50.505AA UA (2-98) 4.5 I t c .o 2ooo- /-* System fault messages can be helpful when diagnosing problems. The meso sages are brief, but an experienced operator can immediately recognize the probable cause of a system fault message. Ifa fault message is indicated, first acknowledge the condition by pressing the Acknowledge key. This will termi- nate the associated alarm, if present, and allow the system to resume operation (if possible) until the condition is resolved. The fault message flashes periodi- cally on the display until the condition is resolved. The following requirements must be met for an analyzer to operate correc~y: - · correct plumbing/tubing connections · correct and steady flow and pressure of sample to the analyzer ' · correct and steady flow of sample through the analyzer · correct and steady flow of sample metered to the cell · proper reagents (selection, mixture, and reservoirs not empty) · correct and steady flow of reagents metered into the sample · impeller rams smoothly (CCW) and rapidly (600rpm-60Hz, 500rpm-50I-h) · cell body contains sample/reagents and grit · sample/reagents drain through cell drain tube · electrolyte in probe reservoir · probe reference junction is not clogged · temperature sensor functions properly · electrode surface in good condition and not fouled by deposits · probe functions properly · probe and motors connected properly · electronic circuits function properly · proper installation wiring · correct fuse, in good condition · properly configured software · correct calibration · metering pump functions {CCW) · trained operator has read and understood all parts of the instruction book 4.3.2 SYSTEM SELF-DIAGNOSTICS Self diagnostic messages indicate conditions that might otherwise go unob- served. They aid the operator in avoiding or locating the cause of inaccurate performance. Refer to the description of conditions that cause error messages. The Diagnostic functional group contains many functions that can provide information about poor or changes in system performance. IM 50.505AA UA (2-98) 4.6 I I '1 i I [ I MICROI2000® I 4.3.2.1 Measured Value The measured value is repeated here, in addition to showing in the Main display. This is done so that it can be viewed easily, along with the diagnostic functions. Additionally, the Main function measured value indicates values within the functional range only, so that it corresponds strictly with the 4-20 output. The measured value (Diagnostic Function) displays over the full limit of the ampli- fier stage of the electronics (as determined by the amplifier switch settings). 4.3.2.2 Response Slope The response dope is the calibrated dope of the signal from the probe to the amplifier. Its value is fixed at the time of calibration, The amperometric (cur- rent) signal is proportional to the concentration of chlorine (or iodine) in the sample and the constant of proporfionality is the response dope--with units ofuA/(mWl). While this value can vary somewhat from one probe to the next, due to variation in manufacture (a value in the range of 1 to 7 is accepted without warning), it should not vary by more than _+, .2 from one calibration to the next. See paragraph 4.3.2.14, System Warnings - Slope Error. The slope is normally expected to be in the range of 1 to 10. 4.3.2.3 mk Output The calculated mA output signal is reported here. If the mA signal or the chart recorder value does not agree with the calculated (indicated) value, check the range of both the analyzer and the chart recorder. fithe ranges are set correctly, then the nominal value for the mA output can be calculated as: 16*measured value/range + 4. fithe indicated mA is not correct for the range, check that the range is set correctly. If the value is as calculated, measure the mA signal (with an aremeter). If the output is not as measured, perform amA calibration. For more information, see paragraph 3.2.4, I/0 Options. This function can be toggled to display in '~,~" of range or "mA". 4.3.2.4 Cell Signal This is the amperometric signal from the probe to the amplifier in uA (micro- amps). This signal is proportional to the chlorine (or iodine) concentration in the cell. fithe amplifier gain switches are set correctly, the value reported for this silgnal is correct, as the signal is inferred from the anticipated switch setting after being amplified. This value is also used in calculating Response Slope, so, if the switch position is not correct, it can cause Slope Error. IM 50.5HAA UA (2.98) 4.7 I 1 'l' " 1 MICROI2000® I 4.3.2.5 Cell Voltage It is one of the functions of the amplifier circuit to maintain a stable potential across the electrodes of the probe. The actual value is indicated here. This is compared to the Cell-Voltage setpoint, which is normally set to .25V, but can be checked or reset through the Cell Voltage Setpoint function in the Set-Up functional group. 4.3.2.11 Cell Temperature The Cell Signal temperature is used in calculating the measured value. The temperature sensor is located in the wetted end of the probe. Pressing ENTER allows the indicated value to be toggled between degrees F and degrees C. The indicated temperature does not need to be extremely accurate (+ 5 is accept- able). A reasonable displayed value for cell temperature confirms that the sensor is functioning. 4.3.2.? Software Version This information is needed for factory technical support. The software version consists of the EPR. OM part number and issue letter. 4.3.2.8 Unit Serial Humher This information is needed for factory technidal support. The serial number consists of two letters and five digits. It is displayed at this point in the menu and should agree with the number on the label in the electronics enclosure (on wall mounted units) or on the back of the module. 4.3.2.9 System Restart See Section 3 - Operation. 4.3.2.10 System Shutdown This is not a Troubleshooting function. Refer to Section 3 - Operation for information. 4.3.2.11 Local Operating Mode At this function, the operating mode can be toggled from "NORMAL" to "SERVICE" mode. The purpose of the service mode is to prevent unnecessary external alarms that may occur while performing certain types of service (e.g., ~ probe removal for inspection). -- IM 50.505AA UA (2-98) 4.8 I MICROI2000® I In the service mode, the relay outputs are 'frozen in their non-alarm states and the mA output is frozen. The analyzer will not automatically return to the main display once placed in the service mode. The operating mode is automatically reset to normal (re- enabling alarms) when exiting (escaping from) the Diagnostic Group. 4.3.2.12 Extended Calibration Methods This is not a Troubleshooting function. Refer to Section 3 - Operation for information. 4.3.2.13 System Error Messages All system error messages are discussed below. They are grouped as system warning or system failure messages, along with an explanation of the cause and remedy for each error condition. SYSTEM WARNINGS SYSTEM FAILURES CELL VOLTAGE DEVIATION CELL VOLTAGE OUT OF RANGE LOSS OF TEMPERATURE CHECK PROBE CONNECTION COMPENSATION HIGH ALARM CHECK PROBE JUNCTION LOW ALARM CELL INPUT SATURATED HIGH mA LOOP IMPEDANCE SLOPE ERROR 4.3.2.14 System Warnings The system can continue to operate during a system warning condition, even though the wamin8 may be a condition resulting from inaccurate user input or might indicate a condition that prevents the analyzer from operating accu- rately. When a warning condition occurs, the display is blanked, except for the messaBe, until the message is acknowledged. The unit then returns to opera- tion with a normal display and the warning flashed every 30 seconds. Some conditions can cause multiple warnings or warnings and failures. Each mes- sage must then be separately acknowledged. · CELL VOLTAGE DEVIATION - This message occurs if the cell volt- age has changed by more than 50mV from the setpoint value. This is an unusual condition that can be caused by readjusting the cell voltage without IM 50.505AA UA (2-98) 4.9 I I '!' T I MICROi2000® re-entering the setpoint, by a failure of the circuit, or by a faulty probe wiring connection. · LOSS OF TEMPERATURE COMPENSATION - This error indicates that the temperature sensor has failed and that the analyzer is operating in an uncompensated mode. This message is also caused by a faulty electri- cal connection to the sensor and may be the first indication that the probe has been disconnected. On transition from compensated to uncompen- sated mode (on the failure of the sensor), the analyzer accuracy declines. The analyzer will operate, however, and can be reasonably accurate, once ' it is recalibrated, if the sample temperature does not change by more than 10°F (18°C), until the probe can be replaced or the reason for the apparent failure found. · HIGH ALARM - This is a user-enabled warning that indicates the mea- sured value is outside (above) the desired operating range. · LOW ALARM - This is a user-enabled warning that indicates the mea- sured value is outside (below) the desired operating range. · HIGH mA LOOP IMPEDANCE - This message indicates a problem with the mA output operation. The output may be connected to a high impedance or there may be a fault in the connection. · SLOPE ERROK - This error occurs on calibration. It indicates that the response slope is outside the normally expected range. The response slope is calculated from the ratio of the Cell signal (uA) to the net cell residual concentration (process concentration plus bias value) value. This condi- tion most often indicates an inaccurate calibration, wrong range switch setting for the analyzer operating range, low cell output caused by loss of reagent feed or fouling of the probe, or high cell output caused by a failure of the probe. If the gain switch positions are found to be incorrect, set them correctly, in accordance with the analyzer operating range. 4.3.2.15 System Failures · CELL VOLTAGE OUT OF RANGE - This condition is like the Cell Voltage Deviation condition, except that this indicates that the voltage has deviated to the point that the analyzer can no longer function. The likely causes are a disconnected probe or faulty probe wiring, an im- proper cell voltage adjustment, or a circuit failure. IM 50.505AA UA (2-98) 4.10 I I I ' w · r' i' , ~I MICROi2000® J · CHECK PROBE CONNECTION - This message indicates that the probe has been disconnected. Due to the nature of the amplifier circuit, there may be a substantial delay between when the probe is disconnected and when the failure is first reported. Other error messages may be reported before this condition is detected. · CHECK PROBE JUNCTION - This message indicates that the cell volt- age is not measurable, indicating a failure in the electrical connection to the probe, a clogged porous element in the probe, or depleted electrolyte. See paragraph 4.3.5, Troubleshooting - Probe, or paragraph 4.2.4, Pre- ventive Maintenance Kecommendations - Probe. · CELL INPUT SATURATED - This message indicates that the amplifier circuit is saturated. The unit is receiving more current than can be mea- sured for the present range switch settings. This occurs when the mea- sured concentration exceeds the range of the analyzer or if the switches are set incorrectly. If the gain switch positions are found to be incorrect, set them correctly, in accordance with the analyzer operating range. 4.3.3 IMPELLER DRIVE PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION DOES NOT TURN, Too much grit Remove excess grit See paragraph TURNS SLOWLY, 3.3.2.3. TURNS UNSTEADILY, Shaft or shaft seal failure. Replace shaft or shaft seal. See NOISY. , paragraph 4.4.8. Motor failure. Check for incorrect or loose wiring. Replace motor. Motor adapter board failure. Replace motor adapter board. IM S0.S0SAA UA (248) 4.11 MICROI2000® 4.3.4 METERING PUMP PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION DOES NOT TURN, Tubing or occlusion ring not Remove occlusion ring and check TURNS UNSTEADILY, installed correctly. that tubes are located in the roller NOISY. grooves. Also check to make sure tubes are not crossed over each other. Rollers do not turn freely. Remove rollers and inspect bores for damage and pins for wear. Clean or replace parts as required. Motor or bearing failure. Remove motor and inspect motor and bearing. See paragraph 4.4.7. Motor adapter board failure. Replace motor adapter board. LEAKING SAMPLE OR FiRing connections made Check firings. REAGENTS improperly. Tubing cut or worn. Replace tubing. Leaks from cell or past the Inspect and replace cell or shat~ seal impeller shai~ seal. as required. NO SAMPLE OR Incorrect sample flow Check sample flow through the REAGENT FLOW, through analyzer. anal3izer bypass. Correct flow as FLOW INCORRECT. required, check/correct for clogged tubing. No reagents in reservoirs. Refill reagent reservoirs. Occlusion ring installed Install occlusion ring correctly. incorrectly or loose. Tighten occlusion ring. Reagent tubing or pump Clear or replace tubing. tubing units clogged. IM 50.505AA UA (2-98) 4.12 I I '! [] I [ MICROI2000® : [ 4.3.5 PROBE PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION ELECTROLYTE LEVEL Electrolyte level low Refill probe with electrolyte. (Fill LOW through porous element. hole in side of probe.) ELECTROLYTE LEVEL Leak in reference junction Check for excessive leakage from LOW, MORE THAN or probe body. the porous element or lower probe ONCE A MONTH. body. Replace element or repair leak. CLOGGED POROUS Probe allowed to dry out. Replace junction and electrolyte. ELEMENT Electrolyte contamination. Replace junction and electrolyte regularly. LOW CELL OUTPUT Electrode covered with deposits: Greasy deposits. Add detergent to reagents. Clean probe with detergent. Hard deposits. Maintain correct grit level. Clean probe with muriatic acid solution. Improper reagents. Check/replace reagents. Improper reagent feed. Check feed and connections. Replace tube units. Clogged porous element. Replace porous element. ("SLOPE ERROR" - Wrong gain switch settings. Check gain switch settings. SLOPE < 1) ELECTRODES Too much grit. Reduce amount of grit. See DAMAGED paragraph 3.3.2.3. Defective impeller shaft, Check for wobble. Replace impeller causing impellet to wobble shaft. and hit probe. Probe improperly serviced; Check electrodes. Check/replace electrodes sanded or probe probe. damaged in handling. TEMPERATURE Incorrect wiring. Check and correct wiring between SENSOR FAILURE the wetside panel and CPU board. Failed sensor. Replace probe. GENERAL FAIl,IRE Contaminated porous Replace porous element or DUE TO PROBE - HIGH element or electrolyte. electrolyte. CELL OUTPUT OR NO CELL SIGNAL |M 50.50SAA UA (2..,q8) 4.13 [ MICROI2000® 4.3.5 PROBE (CONT'D) :~ PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION ("SLOPE ERROR" - Wrong gain switch settings. Check switch settings. SLOPE < 7) Improper reagents. Check/replace reagents. GENERAL FAII,URE Incorrect or failed wiring. Check/correct wiring. Incorrect DUE TO PROBE wiring can damage probe or may cause an upset to the probe, which requires electrolyte replacement and/or 24 hours to recover. Internal probe failure. Replace probe. Damaged electrodes. Replace probe. 4.3.6 ELECTRONICS WARNING: TO AVOID ELECTRICAL SHOCK TURN POWER OFF BEFORE SERVICING. TO AVOID ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT, AVOID CONTACT WITH CIRCUIT BOARD COMPONENTS WHILE MAKING ADJUSTMENTS. TROUBLESHOOTING AND HARDWARE CALIBRATION OF THE ANALYZER IS PERFORMED WITH A MULTI-METER. ONLY PERSONNEL WHO ARE TRAINED WITH THIS EQUII'MENT AND WHO HAVE A COMBINED KNOWLEDGE OF PROPER SAFETY PRECAUTIONS AND USF/~w&T EQUI1}MENT SHOULD PERFORM ANY TROUBLESHOOTING AND/OR TESTING. None of the circuit boards used in the analyzer are serviceable. The only serviceable parts are the fuse and output relays on the power supply board and the fuse on the motor adapter board. IM 50.505AA UA (2-98) 4.14 i MICROI2000® 4.3.6 ELECTRONICS (CONT'D) PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION NO DISPLAY Power failure. Reset breaker or replace blown fuse. Display board disconnected. Check/reconnect Display board ribbon cable (leads from CPU board to Display board). Software failure. Toggle power (off/on at disconnect) to reset software. Defective Display board. Replace Display board. Defective CPU board. Replace CPU board. Defective Power Supply Replace Power Supply board. board. KEYPAD DOES NOT Alarm condition requires Press Alarm Acknowledge key. FUNCTION. acknowledgement. t,-,~. Keypad disconnected. Check/connect keypad ribbon cable (located under Display board) from Display board to keypad. Software failure. Toggle power (off/on at breaker) to reset software. Defective .keypad. Replace keypad. Defective Display board. Replace Display board. Defective CPU board. Replace CPU board. BOTH PUMP AND Blown fuse on Motor Replace fuse. IMPEI,I.~R MOTORS Adapter board. DO NOT TURN. Incorrect or faulty wiring Inspect and correct wiring. from terminal block to Motor Adapter board. Wetside control relay faulty If'relay is de-energized (Relay "D"), or de-energized (during the condition should be indicated on sample line dosing). the analyzer display. If relay should not be de-energized, check for power.on "motors" terminal of analyzer terminal block. /" Replace relay. IM 50.505AA UA (2-98) 4.15 1 'm ! -' } MICROI2000® J 4.3.6 ELECTRONICS (CONT'D) '~'~' PROBLEM PROBABLE CAUSE(S) CORRECTIVE ACTION PUMP OR IMPELLER Loose or incorrect wiring Inspect and correct wiring. \ MOTOR DOES NOT from motor to the Motor TURN, OR TURNS Adapter board or between UNSTEADILY. Motor Adapter board and terminal strip. Defective Motor board. Replace Motor board. Defective Motor. Replace Motor. mA OUTPUT DOES NOT System failure alarm. Check and repair the cause of the FUNCTION, OR system failure alarm. FUNCTIONS mA output is locked during mA output will resume function INCORRECTLY. calibration procedure. upon completion of calibration. Exit calibration procedure. mA output is out of Calibrate mA output. ealibration. mA receiving device is out Calibrate mA ree~iiving device. of calibration. Loose or incorrect wiring or Tighten or correct wiring. Check "High" mA loop impedance. receiving device input impedance. RELAY OUTPUTS DO Software sense settings Correct sense settings. See the NOT FUNCTION incorrectly set (normally Section 2. CORRECTLY. energized/non-energized) or output connections made to wrong contacts. Loose or incorrect wiring. Tighten or correct wiring. Loose or incorrect wiring Tighten or correct wiring. between terminal strip and Power Supply board. Defective relay. Replace relay. Defective Power Supply Replace Power Supply board. board. 4.3.7 PROBE AND CIRCUIT BOARDS WIRING Refer to Dwg. 50.505.130.010 for an installation wiring diagram of the probe to the CPU board wiring, and of wiring to the power supply, relay outputs, '- digital input, and 4 to 20 mA output (to the CPU and power supply boards through the installation wiring terminal strip). Refer to Dwg. 50. 505.010.020 IM 50.505AA UA 12-98) 4.16 · F I T MICROI2000® I for a depiction of the connections between the keypad and the display board, the display board and the CPU board, and the CPU board and the power supply board. 4.4 SPECIAL SERVICE INSTRUCTIONS A WARNING: TO AVOID ELECTRICAL SHOCK, TURN OFF POWER BEFORE SERVICING. TO AVOID ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT, AVOID CONTACT WITH CIRCUIT BOARD COMPONENTS MAKING ADJUSTMENTS. WEAR RECOMMENDED PROTECTIVE EYEWEAR WHEN SER- VICING ~ WET COMPONENTS OF THE ANALYZER, PARTICU- LARLY WHEN SERVICING REAGENTS AND REAGENT LINES. ~ ANALYZER USES CHEMICALS THAT CAN CAUSE SEVERE PERSONAL INJURY BY CHEMICAL BURNS ON CONTACT WITH EYES. RINSE ANY AREA OF CONTACT IMMEDIATELY. IF CR~.MICALS CONTACT EYES, RINSE FROM EYES AND SEEK IMMEDIATE MEDICAL ATTENTION. 4.4.1 PREPARATION OF REAGENTS A WARNING: PH4 BUFFER AND ACETIC ACID WILL SEVERELY IRRITATE EYES AND CAUSE CtW~MICAL BURNS TO SKIN. AL- WAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENT DUR- DIG HANDLING. WHEN DILUTING ACID, ALWAYS POUR THE ACID INTO THE WATER, NEVER POUR WATER INTO ACID. USE CAUTION WHEN DISCONNECTING THE REAGENT TUBING AND AVOID CONTACT WITH ANY FLUID THAT DRIPS FROM THE OPEN END. IT IS THY~ RESPONSIBH,ITY OF THE USER OF THE EQUIPMENT TO OBTAIN AND FOLLOW THE SAFETY PRECAU- TIONS OF ~ MANUFACTURER OF THF~ HAZARDOUS MATE- RIAL. ~MICALS FOR INDUSTRIAL USE: VAPOR MAY BE HARM- FUL IF INHALED AND MAY BE FATAL IF SWALLOWED. LIQUID MAY CAUSE SEVERE BURNS TO SKIN AND EYES. AVOID CON- TACT WITH EYES, SKIN, OR CLOTHING. WASH THOROUGHLY AFtERHANDLING. IN CASE OF SPILL, SOAK UP WITH SAND OR WHEN SERVICING LIQUID REAGENT LINES, PUMPS, OR FILLING RESERVOIRS, TURN OFF PUMPS (SEE PARAGRAPH 3.3.3, SHUT-DOWN/RE-START) TO AVOID POSSIBLE SQUIRTING iM so.sos,~ UA (2-9S) 4.17 1 'l I' I T II MICROI2000® OF REAGENT. OBSERVE ALL SAFETY PRECAUTIONS RECOM- MENDED BY THE REAGENT MANUFACTURER OR SUPPLIER. WARNING: HANDLE IN ACCORDANCE WITH MANUFACTUR- ER'S RECOMMENDATIONS. DO NOT MIX WITH OTHER CHEM- ICALS. DISPOSE OF ANY CHEMICALS IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL ENVIRONMEN- TAL REGULATIONS. The type and number of reagents are determined by the specific application and residual requirements. 4.4.1.1 Preparation of pH4 Buffer This reagent is available from USF/W&T premixed in one-gallon plastic bottles. It may also be made on-site as follows: dissolve 919 grams of sodium acetate, trihydrate in approximately 1.5 liters of distilled water, then mix with 1.73 liters of glacial acetic acid and dilut~ with distilled water to obtain one gallon of reagent solution. A WARNING: GLACIAL ACETIC ACID WILL SEVERELY IRRITATE EYES AND CAUSE CHEMICAL BURNS TO SKIN. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUWMENT DURING HANDLING. WHEN DILUTING ACID, ALWAYS POUR ACID INTO WATER, NEVER POUR WATER INTO ACID. IT IS THE RESPONSIBILITY OF THE USER OF THE EQUIPMENT TO OBTAIN AND FOLLOW TitF. SAFETY PRECAUTIONS OF TIff, MANUFACTURER OF THE HAZ&RI]OUS MATERIAL. 4.4.1.2 Preparation of Potassium Iodide Solution NOTE: Potassium iodide solution is used only in the measurement of total chlorine. Therefore, this section does not apply to analyzers installed to measure free chlorine or potassium permanganate. Potassium iodide (KI) is added to distilled water and fed into the water sample by the metering pump when measuring total chlorine. The KI reacts with the various forms of chlorine present to release a proportional amount of iodine. The amount of KI required is dependent upon the maximum range of the analyzer. The quantity of KI required is calculated as follows: IM S0.S0SAA UA (2-98) 4.18 T I "i' Fi " i] MICROI2000® J 50 + 4 * range = grams KI Example: Analyzer range: 5 rag/1 50 +4 * 5 = 70 gramsKi CAUTION: Never mix potassium iodide (K1) with sulfuric acid, as free iodine will form immediately. K! Consumption - Gram Range .1 .2 .5 1 2 5 10 20 50 50 51 52 54 58 70 90 130 250 Ki either in tablets or in granular form may be used. When using auxiliary Ki tablets (U11829), one tablet equals 3 grams. 4.4.1.3 Preparation of Ammonium Sulfate Solution Ammonium sulfate is used to eliminate flee chlorine interference in analyzers monitoring potassium permanganate or chlorine dioxide residuals. It should be purchased in crystal form, technical or reagent grade. The crystal is then mixed with distilled water in the proportion of 36 grams per gallon of solution per maximum rnga of free chlorine residual expected in the sample water. For example, ira residual of approximately 0.5 mgrl of free chlorine is the highest concentration normally expected then the reagent should be mixed as 18 grams (36 x 0. 5) of ammonium sulfate with enough distilled water to make one gallon of solution. 4.4.1.4 Detergent Additive Detergent additive (U'XA29142 - one gallon, or U29142 - six ounce) is used to aid in cleaning and wetting of the system while the analyzer is in operation. Add one ounce of additive to one gallon of Ki solution. To avoid cross contamination of the reagents, always use the same reservoir for the same reagent. The reservoirs should be clearly labeled with the reagent they contain. Use a funnel when filling reagent reservoirs. Kefer to paragraph 4.4.2 for instructions on re-filling the reservoirs onc~ the analyzer is in operation. IM 50.505AA UA (2-,98) 4.19 MICROI2000® 4.4.2 RE-FILLING REAGENT RESERVOIRS A WARNINGS: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVE TIFF. FOLLOWING: PH4 BUFFER AND ACETIC ACID WILL SEVERELY IRRITATE EYES AND CAUSE CnY~MICAL BURNS TO SKIN. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENTDURING HANDIXNG. WI:IE~N DH.~UTING ACID, ALWAYS POUR ~ ACID INTO THE WATER, NEVER POURWATER INTO ACID. USE CAUTION WnY~N DISCONNECTING ~ REAGENT TUBING AND AVOID CON- TACT WITH ANY FLUID THAT DRIPS FROM THE OPEN END. IT IS THE RESPONSIBILITY OF ~ USER OF THE EQUIPMENT TO OBTAIN AND FOLLOW ~ SAFETY PRECAUTIONS OF THE MANUFACTURER OF TgE HAZARDOUS MATERIAL C-~rF~MICALS FOR INDUSTRIAL USE: VAPOR MAY BE HARM- FUL IF INHALED AND MAY BE FATAL IF SWALLOWED. LIQUID MAY CAUSE SEVERE BURNS OF SKIN AND EYES. AVOID CON- TACT WITH EYES, SKIN, OR CLOTFHNG. WASH THOROUGRI.Y AFTER HANDLING. IN CASE OF SPILL, SOAK UP WITH SAND OR EARTH. To avoid cross contamination of the reagents, a/ways use each reservoir for the same reagent. The reservoirs should be clearly labeled with the name of the reagent they contain. To fill reagent reservoirs, loosen and move or remove the threaded cap on the reservoir. Use a funnel when filling reagent reservoirs. The use of a funnel allows the reservoir to be filled without removing the rigid length of tubing from the reservoir. If the tubing is removed from the reservoir, keep it clean. Dirt can clog the tubing. If the tubing is removed from the reservoir while the metering pump is operating, air is drawn into the tubing. This causes a momen- tary disruption of service until the tubing is returned to the reservoir and the inducted air is purged from the tubing and pump. 4.4.3 WETSIDE PANEL REMOVAL AND REPLACEMENT (SEE OWG. 50.505.000.010) a. Shut off sample flow to the ana/yzer. b. Disconnect the probe and motor connectors from the connection to the electronics enclosure. c. Remove the probe and set it carefully aside. Do not rest it on its electrode end. If the probe will be removed for more than an hour, place it, with the electrodes, in a beaker of water. IM S0,SOSAA UA (2-98) 420 I MICROI2000® J d. Disconnect the liquid reagent tubing from the inlet and discharge of the metering pump. e. Disconnect the water sample tube from the me'cering pump inlet. f. Move the bypass discharge sample tube from in front 0fthe wetside panel. g. Remove the clamp holding the pump and impellet motor cables. h. Kemove the three screws holding the panel in the enclosure, ,and remove the panel from the enclosure. i. Hold the panel upright while removing it to avoid spilling water trapped in the cell. In an appropriate location, tip the panel upside down to empty the water from the cell. There is also water trapped in the various tubing units and chemical trapped in the reagent tube units. 4.4.4 OCCLUSION RING REMOVAL AND REPLACEMENT (SEE DWG. 50.505.010.010) A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVE ~ FOLLOWING: TURN OFF THE FLOW TO T~E ANALYZER BEFORE REMOVING TBY. OCCLUSION RING FROM THE METERING PUMP. THE OCCLUSION RING STOPS THE FREE FLOW OF LIQUID T~ROUGH THE ANALYZER SAMPLE LINES. IF IT IS REMOVED WITH FLOW STILL PRESENT AT THE ANALYZER, PROCESS WATER WILL BE SPRAYED FROM THE PUMP DISCHARGE LINE AND FROM ~ CELL TOP. SPRAYED PROCESS WATER CAN CREATE AN ELECTRICAL SHOCK HAZARD DUE TO THE PRES- ENCE OF DANGEROUS VOLTAGE POWERING THE IMPELLER AND PUMP MOTORS. DO NOT SERVICE ~ METERING PUMP WHILE IT IS TURN- ING, THE METERI~G PUMP HAS ENOUGH TORQUE TO CAUSE SEVERE PERSONAL INJURY IF HANDS ARE PINCHED IN THE ROTATING PARTS. DISCONNECT T~E PUMP MOTOR CONNEC- TOR BEFORE SERVICING T~F~ PUMP. WEAR RECOM34ENDED PROTECTIVE EYEWEAR WHEN SER- VICING THE WET COMPONENTS OF THE ANALYZER, PARTICU- LARLY W~N SERVICING REAGENTS AND REAGENT LINES. THE ANALYZER USES CHEMICALS THAT CAN CAUSE SEVERE PERSONAL INJURY BY CR'EMICAL BURNS ON CONTACT WITH EYES. RINSE ANY AREA OF CONTACT IMMEDIATELY. IF IM S0.S0SAA UA (2-98) 421 MICROi2000® CHEMICALS CONTACT EYES, RINSE FROM EYES AND SEEK IMIVHEDIATE MEDICAL ATTENTION. · Removal: a. Disconnect power to the wetside of the analyzer by disconnecting the pump motor, impellet motor, and probe from the panel connectors (to the electronics enclosure). b. Turn off the water supply to the analyzer. c.Remove the wetside panel (optional). See paragraph 4.4.3, Wetside Panel Removal and Replacement. d. Using a 7/16-inch socket wrench, remove the two bolts (with wash- ers) attaching the occlusion ring to the panel. L~ off the occlusion ring. Some residue from the tube units accumulates on the ring during usage. This is normal. · Replacement: The occlusion ring may be difficult to reinstall if the following procedure is not followed. Do not use excessive force. Use care not to pinch the tube units (installed on the pump rollers) when installing the occlusion ring. Before reinstailing the occlusion ring check that the pump tube units are properly seated in the roller grooves and in the tube retainer grooves. See paragraph 4.4.6, Pump Tubing Units Replacement. a,Place the occlusion ring loosely in place over the tube units, but do not attempt to clamp the occlusion ring in place yet. b. Hold the ring in place with one hand and slide a bolt, with washer, into the lower mounting hole in the ring until it bottoms against the casting. c. Gently squeeze the ring against the tubing while pushing the bolt into place. The bolt will drop (about 1/4 inch) into place when the ring is properly located. d.Tighten this first bolt a few turns, so that the occlusion ring will pivot on the bolt. e. Slide the second bolt (and washer) into its mounting hole in the ring. IM 50.505AA UA (2-98) 4.22 ,. MICROi2000® f. Firmly squeeze the ring against the pump rotor (squeeze near the second bolt) to obtain leverage against the pivot bolt until the second bolt drops into place. g. Tighten both bolts securely. 4.4.5 PUMP ROTOR, ROLLERS, AND THRUST WASHER REMOVAL AND REPLACEMENT The rotor is fastened to the motor shaft by a set screw requiring a 3/32-inch Allen wrench for adjustment. When the rotor body is removed, check the rollers, roller shafts, thrust washer, the shaft bearing, and shaft bore in the rotor body for signs of excessive wear, damage, or corrosion. Some residue on the roller shafts and inside the rollers is normal. The rotors should function properly for at least one to two years. Do not lubricate the rollers, as some greases may attack the nylon roller material. Lubrication of the rollers is not necessary. I. fany of the roller shafts show significant wear marks and the corresponding roller is loose, the rollers and rotor body unit must be replaced. !~ · Removal !~ .: a. Remove the wetside panel from the enclosure. b. Remove the occlusion ring from the panel unit. c. Remove the sample and reagent tube units from the panel unit. d. Locate the set screw in the hub of the rotor body (just behind the back face of the body) and loosen the set screw one or two turns. NOTE: Hold the panel upright while removing the rotor body to avoid dropping and losing the rollers. To use as a guide for reinstallation, take note of the orientation of the rollers (small groove toward the front of the panel) before removing the rotor. e. Slide the rotor body off the motor shaft. f. The thrust washer (located against the panel assembly) should be moved and set aside so that it does not drop off the panel and become lost. · Keinstallation a. If the thrust washer was removed, reinstall it over the pump hub, against the panel. IM S0.505.A,A UA (2-98) 4.23 ~ 's . -.. I [ t M CRO 2000" b. Install the rollers on their shafts in the position noted during the re- moval of the rotor (small groove toward front). c. Look into the shaft bore in the rotor body and adjust the set screw until it just protrudes into the bore (approximately a half turn). The set screw protruding into the bore helps to locate it on the fiat of the shai~ as the rotor assembly is installed. d. Note the position of the fiat on the pump shai~ and slide the rotor assembly onto the shaft with the set screw over the fiat. The shaft bore has a sliding fit on the shaft, so there may be a slight resistance to the sliding. fithe resistance seems excessive, back-offthe set screw a quarter turn and twist the rotor body back and forth slightly as it slides back onto the shaft. e. Tighten the set screw gently, until it begins to lock in place, on the flat on the shaxt. Be sure that the hub of the rotor is flush against the pump hub (but without pressure) when the set screw is tightened. Using the Allen wrench, tighten the set screw as firmly as is practical. Use pliers to apply additional torque, but not so much as to perma- nemly deform the Allen wrench. NOTE: Ifthe set screw is not tightened sufficiently, the rotor may wobble on the shaft or may slip on the shaft, damaging the shaft and causing the pump to not operate properly. 4.4.6 PUMP TUBING UNITS REPLACEMENT A WARNING: TURN Off ~ FLOW TO THE ANALYZER BEFORE REMOVING THE OCCLUSION RING FROM THE METERING PUMP. THE OCCLUSION RING STOPS THE FREE FLOW OF LIQ- UID THROUGH THE ANALYZER SAMPLE LINES. IF IT IS RE- MOVED WITH FLOW STILL PRESENT AT THE ANALYZER, PRO- /(TESS W A TER WILL BE SPRAYED FROM THE PUMP DISCHARGE LINE AND FROM THE CELL TOP. SPRAYED PROCESS WATER CAN CREATE AN ELECTRICAL SHOCK HAZARD DUE TO THE PRESENCE OF DANGEROUS VOLTAGE POWERING THE IMPEL- LER AND PUMP MOTORS. DO NOT SERVICE THE METERING PUMP WHILE IT IS TURN- DIG, THE METERING PUMP HAS SUffICIENT TORQUE TO CAUSE SEVERE PERSONAL INJURY IF HANDS ARE PINCB'F~D IN ~ ROTATING PARTS. DISCONNECT THE PUMP MOTOR CON- NECTOR BEFORE SERVICING THE PUMP. IM 50.50SAA UA (2-98) 4.24 MICROi2000® WEAR RECOMMENDED PROTECTIVE EYEWEAR WHEN SER- VICING THE WET COMPONENTS OF THE ANALYZER, PARTICU- LARLY WHEN SERVICING REAGENTS AND REAGENT LINES. TITF. ANALYZER USES CREMICALS THAT CAN CAUSE SEVERE PERSONAL INJURY BY CHEMICAL BURNS ON CONTACT WITH EYES. RINSE ANY AREA OF CONTACT IMMEDIATELY. IF CHEMICALS CONTACT EYES, RINSE FROM EYES AND SEEK IMMEDIATE MEDICAL ATTENTION. The sample and reagent tube units include glued stop rings and adapters and fittings. Replace the entire unit when required. The tube units should provide approximately six months of service, but should be observed monthly (without disturbing the analyzer) for signs of wear or leakage. If either condition is noticed, replace the suspected tube units imme- diately. Remove the tube units only when replacement units are readily available, so there is no confusion about how to reconnect the new tube units. Refer to Dwg. 50.505.180.010 (in Section 3) when installing the tube units. · Removal of the tube segments is as follows: a. Disconnect power to the wetside of the analyzer by unplugglng the pump and irnpeHer motor connectors b. Disconnect the sample and reagent tubing from the firings at the ends of the tubing segments. The firings are replaced with the tube units. c. Remove the occlusion ring mounting bolts (requires a 7/16-inch socket). d. Remove the tube units. · Installation of tube units (refer to Figure 4. I): a. Remove the occlusion ring (F). b. Remove the old tube units (A orB) (if replacing). c. Both reagent tube units (A) fit into the small groove (J) on the tube retainer (G), as well as into the small groove (H) on the rollers The sample tube unit (B) fits into the large groove (K) on the tube retainer (G) and the large groove (I) on the rollers IM 50.505AA UA (2-98) 4,25 "~' T I I MICRO!2000® ~ ["') ~K) ......,"],___ ~E) /""'~,' I~::::::::::m-- -~ (J)"""'~""'~/ I~..':'-.'!ttt~.--; _~._p,..,~ . , , J/',,,.\\ (F) A) {:B1 (J) (H) SIDE VIE~I/ (A') t'B) (FI ----....,.,, .........-. - """ ....""' 'L.. -,-/: .:!":; jT:'~ "' .~'j" ..':k~' (B) SAMPLE (A) REAGENT ~"' TUBE UNIT TUBE UNIT 2322 FRONT VIEW Figure 4.'1 Guide the (new) tube unit through the small (J) or large CK) groove in the lower end of the tube retainer (G) and slide the unit up through the groove until the lower tube stop (M) is against the outer surface of the tube retainer (G). d. Lay the tube unit (A Or B) over the pump rollers (E) in the small CH) or large (I) groove, toward the front of the pump rollers. If two re- agent tube units (A) are installed, ensure that the tubes lay side by side and do not cross each other when placed over the rollers (E). NOTE: If the pump is operated with the reagent tube units crossed, the tube units may be damaged. IM 50.50SAA UA (2..98) 4.26 I I '!' i', t MICROI2000® e. Stretch the tubing (N) slightly and guide it through the small (J) or large (K) groove in the upper end of the tube retainer (G), with the upper tube stop (M) above the top surface of the upper end of the tube retainer (G). When tension on the tubing is released, the tube stops should be against the outside surfaces of tube retainer. f. Check that the tube units (A or B) are in their proper small (H) or large (I) groove in the roUer (E). Check that the reagent tubes do not cross. g. Replace the occlusion ring, so that the larger inside radius (in which the sample tubing (B) rides) is facing away from the operator. Locate and start the lower mounting bolt (C) before attempting to squeeze the occlusion ring against the tubing. Then secure the second mount- ing bolt. The tubing exerts side pressure on the retaining bolts, causing some tendency for cross-threading of the bolts as they are reinstailed. Do not force the bolts. If they do not turn smoothly, remove them and install them again. 4.4.7 PUMP BEARING REPLACEMENT ~ a. Remove the wetside pand from the analyzer. b. Kemove the pump occlusion ring, tube units, rotor body (with rollers), and thrust washer from the front of the wetside panel. c. Remove the pump motor from the rear of the wetside panel. d. Drive the bearing out of the front of the casting using the square end of a rod that is approximately 1/'2 inch in diameter by 4 inches long. (A socket wrench socket on an extension will work.) Use care not to scar the bore in which the bearing is pressed. e. Tap in the new bearing until it is flush with the end ofthe bearing support. Place the long side of a flat bladed screwdriver over the bearing face and tap with a hammer. Make sure the new bearing is square to the bearing support bore. 4.4.8 IMPELLER SHAFT SEAL REPLACEMENT · Removal of the Impell er Shaft Seal: a. Disconnect power to the wetside of the analyzer by unplugging the pump and impeller motor connectors. IM SO.SOSAA UA (2-98) 4.27 'l I i T MICROI2000® ! b. Remove the probe from the cell body. Make sure the probe elec- trodes are not scratched or damaged. Lay the probe on its side so that the electrodes do not contact any surface, but in a position so that the electrolyte does not leak from reservoir fill hole. c. Remove the cell body retaining screws and remove the cell body. When removing the cell body take notice of the O-ring that seals the cell body against the seal adapter. This O-ring may cling to the cell body and then fall off. d. Use a 3/32-inch Allen wrench to loosen the set screw holding the impeller on the shaft. This set screw leaves a noticeable mark on the shaft. If the shaft is not replaced, reinstall the impellet in the same position. Tighten the set screw until snug. e. Slide the grit guard off the shaft. f. Slide the seal adapter, with the seal, off the shaR. g.Using a pair of needle nose pliers, grab the center of the seal and remove it from the front of the adapter. h. Rinse the grit from the cell body, cell body sealing O-ring, impellet, and seal adapter. Wipe the sealing surfaces and the shaft (gently) with a paper towel to remove all grit and residue. i. Check the shaft for signs of unusual wear, which indicates that it needs replacement. Refer to Impellet Shaft Replacement instructions. · Installation of Shat~ Seal: a. ff not already done while removing old shaft seal, rinse grit from the cell body, cell body sealing O-ring, impcrier, and seal adapter. Wipe the sealing surfaces and the shaft (gently) with a paper towel to re- move all grit and residue. b. Apply a small quantity of silicone grease to the back side (the front side is the concave side) of the new seal before installation into the seal adapter. c.Install the seal into the seal adapter, making sure the edges are fully seated (flush with the inside diameter of the seal adapter). d.Slide the seal adapter over the irnpeller shaft until it seats in the panel. Wipe any excess grease from the front of the shaft. IM 50,505AA UA (2-98) 4.28 F, ' 11 ) MICROI20'00® i e. Slide the grit guard (small end first) onto the shaft and up against the seal adapter. f. Slide the impeller onto the shaft, up to the grit guard. Retighten the set screw until just snug. g. Install the cell body sealing O-ring on the front of the seal adapter. h. Install the cell body with the retaining screws and washers. i. Replace the probe. c j. Restart the analyzer. k. Once the flow is restarted and the cell body is full of sample, replace the grit. 4.4.9 IMPELLER MOTOR REMOVAL AND REPLACEMENT · Removal a. Remove the panel assembly from the analyzer enclosure. See para- graph 4.4.3, Wetside Panel Removal and Replacement. b. Remove the cell body, impellet, and shaft seal adapter from the front of the panel assembly. See paragraph 4.4.8, Impeller Shaft Seal Re- placement. c. Turn the panel over and remove the ground lug screw and motor ., mounting screws. d. Remove the motor with the impeller shaft e. If the motor is being replaced, remove the impeller shaft and coupling from the motor. · Replacement Replacement is basically the reverse sequence of removal. Grease the impeller shaft seal, with suitable silicone grease, before reinstailing it on the front of the panel assembly. A WARNING: ALWAYS RECONNECT THE GROUNDING LEADS WHEN REMOVED OR BROKEN. GROUNDING LEADS ARE PRO- VIDED FOR SAFETY, TO PREVENT INJIYRY FROM ELECTRICAL SHOCK. IM 50.505A.A UA (2-.98} 4.29 'l · I ' ' i MICRO!2000® I Be sure to reconnect both motor ground leads to the back of the panel before reinstag the panel in the analyzer. Motor replacement is the reverse sequence of removal. Be sure to reattach the motor ground leads before replacing the panel assembly in the analyzer. 4.4.10 IMPELLER SHAFT REPLACEMENT · Impeller Shaft Removal: a. Disconnect power to the wetside of the analyzer by unplugging the pump and impeller motor connectors. b. Stop the flow of sample to the analyzer. c. Disconnect the sample and reagent tubing from the metering pump inlet. d. Remove the cell body, impeller, grit guard, cell sealing O-ring, andO' seal adapter as described in paragraph 4.4.8, Irnpeller Shaft Seal Re- ..... placement. e. Remove the panel assembly from the analyzer. f. Disconnect the impeller motor grounding terminal. g. Remove the impeller motor mounting screws and washers. Remove the impeller motor. h.Loosen the impeller shaft retaining setscrew using a 3/32-inch Allen wrench. i. Remove the impeller sha/~ from the coupling. · Impeller Sha/t Installation: a. If the impeller shaft coupling is removed from the impeller motor install the coupling on the motor shaft against the front face of the motor. Tighten the retaining setscrew (using a 3/32-inch Allen wrench). b. Slide the impeller shaft into the coupling until it bottoms against the end of the motor shaft. Tighten the retaining setscrew snugly (using a- 3/32-inch Allen wrench), about 1/4 turn past the first resistance. IM 50.505AA UA (2-98) 4.30 I MICROI2000® I c. Mount the impeller motor on the back of the panel with the retaining screws and washers. d. Fasten the impeller motor grounding terminal (with pump motor grounding terminal) on the back of the panel with the retaining screw and serrated lockwasher. e. Remount the panel in the analyzer. f. Reattach the sample and reagent tubing to the inlet of the metering pump. g. Apply a small quantity of sillcone grease to the O-ring and impeller shaft h. Reinstall the seal adapter, grit guard, cell sealing O-ring impeller, and cell body and cell retahing screws, as described in paragraph 4.4.8, Impeller ShaR Seal Replacement - Installation of Shaft Seal. 4.4.11 PUMP MOTOR REMOVAL AND REPLACEMENT a. Remove the panel assembly from the analyzer enclosure. Refer to para- graph 4.4.3, Wetside Panel Removal and Replacement. b. Remove the pump rotor and thrust washer from the panel assembly. Re- fer to paragraph 4.4.5, Pump Rotor, Rollers, and Thrust Washer Removal and Replacement. c. Turn the panel over and disconnect the motor ground lead from the back of the panel. d. Turn the panel over again (to its oriSinal position) and remove the two screws that mount the motor to the panel. e. Gently slide the motor out from the back of the panel. The motor shaft has a sliding fit inside the ball bearing in the pump hub. ff it binds while trying to slide it out, check the exposed portion of the shaft for dirt or scratches that may cause binding. Clean off the din or carefully remove scratches with a fine file. The shaft can be damaged by excessive filing. 4.4.12 PROBE ELECTROLYTE AND ELECTRODES The analyzer performs best when the probe is left undisturbed as much as possible. Manual cleaning of the probe electrodes should not be done unless necessary, as this will require recalibration of the analyzer. IM 50.505AA UA (2-98) 4.31 MICROI2000® A CAUTION: Do not sand the probe electrodes! The electrodes are made of a thin film of platinum and cannot be replaced or repaired. If sanded, this thin film of platinum will be quickly removed and the probe will no longer function. If cleaning is necessary, a clean paper towel may be used. Check the electrolyte level occasionally and maintain the level so that it is at least visible through the clear section of the probe with the probe in the installed position. If the electrolyte level drops noticeably in less than a month, the porous element is leaking excessively. The porous element is intended to allow a slight flow of electrolyte and excessive flow will not harm the performance of the analyzer unless the probe is allowed to run out of electrolyte. If excessive use of electrolyte becomes a nuisance (requires constant monitoring of the level), replace the porous element and check the element bore for damage that would hinder the sealing around the element. Also, check if the electrolyte has become contaminated. This is usually indi- cated by a color change or by the electrolyte becoming watery. It is not unusual for the electrolyte to become alternately cloudy and then clear, this can be caused by changes in water or ambient temperature. 4.4.13 PROBE CLEANING, REFILLING, AND POROUS ELEMENT REPLACEMENT The probe cam~ot be disassembled (all joints are cemented). It is not service- able except for the following maintenance operations. NOTE: The audT~er wili perform best when the probe is left uudisturbed as much as possible. Check the electrolyte level and refill as necessary. Clean the electrodes by wipin8 with a clean paper towel. If there is a greasy on the electrodes, this can be removed by clem-ting with a paper towel dipped in alcohol. If there are hard deposits on the electrodes, this can be removed by wiping the electrodes with a clean paper towel dipped in muriatic acid (10% hydrochloric acid). The anaiyzer wiJJ require recalibrations a~ter 24 hours operation after the electrodes are cleaned. A WA3,NI~G: BYDROCH:LOIC AC1]) A1N]) MUilIAT[C ACID WTLL SI~VEREL¥ HLRITATE EYES zqdN'l) CAUSI~ CEEZV~CAL BU]I~S TO SKIN. ALWAYS WEAR kPPROPRIATE PROTI~CTrv~ EQUI~- MENT DIJ'ilJ~G HANDLJ~G. WlTEN Dll,UTING ACH), ALWAYS POLrR ACE) iNTO TRm'. WATER, 1N~VER POU~ WATER INTO ACH). 1T 1S ~ RESPONSIBIliTY OF TEE USER OF TEE EQUE'~_ENT TO OBTAIN A1N]) FOLI,OW TE~ SAFE~ lqtECAUTIONS OF TB~ Y_AH1~ACTUll~R OF ~ E~Z~AtDO1LTS IM 50.505AA UA (2-98) 4.32 7 1 'l' { MICROI2000® J l/the probe is to be stored for more than a week, the porous element should be removed, the electrolyte drained, and the reservoir should be rinsed with distilled water to eliminate any remaining electrolyte. Otherwise the electrode end must be kept wetted to prevent crystallization of the electrolyte in the pores of the element and clogging of the element. The porous element can be removed and the electrolyte drained as follows: Using a self-tapping screw (a ~6 drywall screw is preferred), tap into the porous element, then pull out the element. The element is approximately 1/4- inch long. This porous element is no longer usable. The electrolyte will drain out slowly. Rinse the reservoir well with distilled water to remove residual electrolyte. When removing the element in this manner, use care not to scar the sides of the element bore as this might prevent insertion of a:new piece of porous material or cause excessive leakage of the electrolyte. A new porous element can be created and installed as follows: Do not precut the porous material to length. A clean, sharp razor blade is required to make a clean cut in the porous material. First, using a sawing motion, slice offa thin slice of one end of a length of the porous material. Press this fresh cut end into the element bore. The fit should be snug. The material should be embedded to a 1/4-inch to 3/8-inch depth. Next, saw off most of the remaining material. Finally, taking care not to dinage the probe end, shave off the remaining material so that ~e element is flush. 4.4.14 ELECTRONICS 4.4.14.1 Change of Supply (Mains) Voltage (see Dwgs. 50.505.000.010 and 50.505.010.020) The analyzer can operate from 115/23 0V, 60Hz supply voltage, but this must be set in two locations inside the electronics enclosure. These locations are a selector switch on the power supply board and the two jumpers on the motor board. Also, the power supply board requires a different fuse rating for each operating voltage. See paragraph 4.4.14.4, Fuse Replacement. A CAUTION: Before starting operation of the analyzer, verify that the voltage selecton are set properly and the power supply fuse is the correct rating for the operating voltage provided. Operation with the selecton improperly set may damage the equipment. A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED, AND SERVICED ONLY BY PERSON- NEL WHO ARE THOROUGHLY FAMII JARWITH THE CONTENTS OF THE INSTRUCTION BOOK PROVIDED. IM S0.S05AA UA (2-98) 4.33 r 1 · · · r ': r I MICROI2000® TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELEC- TRICAL SHOCK, DISCONNECT ALL SOURCES OF POWER BE- FORE SERVICING. IN ADDITION TO POWER REQUIRED TO OPERATE THIS UNIT, UNPOWERED RELAY CONTACT CONNEC- TIONS ARE PROVIDED TO WHICH ADDITIONAL, INDEPENDENT SOURCES OF POWER MAY BE WIRED. W~N SERVICE MAY BE REQUIRED TO BE PERFORMED TO THE UNIT WITH POWER CONNECTED, IT SHOULD ONLY BE PERFORMED BY PERSONNEL QUALIFIED TO PERFORM SUCH SERVICE. 4.4.14.2 Cell Voltage Adjustment (see Dwg. 50.505.01 0.020) A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT, AVOID CONTACTING CIRCUIT BOARD COMPONENTS WHILE MAK- ING ADJUSTMENTS. A fine, flat-bladed screwdriver is required to make this circuit adjustment. With the unit operating, open the door to the electronics enclosure and locate the cell voltage adjustment p0tentiometer on the CPU board (next to the range selection switches). Turn the potentiometer and view the cell voltagei0n the display of the analyzer until the vokage is set to the desired value. 4.4.14.3 Setting Range Switches (see Dwg. 50.505.01 0.020) A WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, EQUIPMENT DAMAGE, OR ELECTRICAL SHOCK TURN OFF POWER BEFORE SERVICING. The analyzer requires correct setting of range switches. Input the stage gain selection switches for proper operation. The correct switch position is depen- dent on the range to which the analyzer is set to operate within the software. Disconnect power to the analyzer before opening the electronics enclosure to set the range switches. When setting range switches, the up position is "open" and down position is "closed". IM 50.505AA UA (2-98) 4,34 L MICROI2000® I POWER REQUIREMENTS: 115/230 VAC, 50/60 HZ THE UNIT IS PROTECTED BY INTERNAL FUSES: POWER SUPPLY BOARD .2A(115V)/.1A(230V),250V, FAST ACTING, 5 x 20MM MOTOR ADAPTER BOARD .25A,250V,TIME DELAY, 1/4 x 1-1/4 IN GAIN SWITCHES JUMPERS (PS BOARD): (INPUT/CPU BOARD) JP1 - DIG INPUT RANGE SW POS 1-2 230V AC/DC MICRO DEOX 12 3 4 1-3115VAC/DC 0.1 0 0 0 0 1-424VAC/DC 0.2 0 I 0 0 SNUBBER JUMPERS 0.5 I I 0 0 (REMOVE TO DISABLE) I 0.5 0 0 0 I JP2 RELAY"A"(NC) 2 I 0 I 0 1 JP3 - RELAY"A"(NO) 3 2.5 ---~1 I 0 1 *-- JP4 - RELAY "B" (NC) 10 5 0 0 I I JP5- - RELAY"B"(NO) 20 10 0 I I I JP6 - RELAY"C"(NC) 50 ~fp DowAI I I I 1 JP7 - RELAY"C"(NO) (O = OPEN, 1 = CLOSED) JP8 - WETSIDE CTRL PROBE WIRING CONN. WIRE CPU BD (j3) ·/~ WRK I W 1 REF 2 BK 3 CTR 3 R 2 TEMP 4 BR 4 TEMP 5 G 5 SHIELD 6 - 6 4.4.14.4 Fuse Replacement (see Dwgs. 50.505.000.010 and 50.505.010.020) //~. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, EQUIPMENT DAMAGE, OR ELECTRICAL SHOCK TURN OFF POWER BEFORE SERVICING. Disconnect power to the analyzer before opening the electronics enclosure to replace a fuse. The Power Supply board is located at the top of the electronics enclosure door. The Power Supply board fuse is located at the top left comer of the board (with the door open). ' The Motor Adapter board is located in the le~ side of the electronics enclosure. The Motor Adapter board fuse is located at the bottom of the motor adapter board. See Section 1 - Technical Data for fuse ratings. IM 50.SOSAA UA (2-98) 4.36 I '1 I T T m MICROI2000® 4.4.14.5 Circuit Boards Removal and Replacement (see Dwgs. 50.505.000.01 0 and ~'~' 50.505.010.020) A WARNING: TO AVOID POSS1BLE SEVERE PERSONAL INJURY OR DAMAGE TO ~ EQUIPMENT, THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED, AND SERVICED ONLY BY PERSON- NEL WHO ARE THOROUGHLY FAMH .IAR WITH TI]]E CONTENTS OF THE INSTRUCTION BOOK PROVIDED. TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELEC- TRICAL SHOCK, DISCONNECT ALL SOURCES OF POWER BE- FORE SERVICING. IN ADDITION TO POWER REQUIRED TO OPERATE THIS UNIT, UNPOWERED RELAY CONTACT CONNEC- TIONS ARE PROVIDED TO WHICH ADDITIONAL, INDEPENDENT SOURCES OF POWER MAY BE WIRED. WHEN SERVICE MAY BE REQUIRED TO BE PERFORMED TO ~ UNIT WITH POWER CONNECTED, IT SHOULD BE PER- FORMED ONLY BY PERSONNEL QUALIFIED TO PERFORM SUCH SERVICE. · Motor Board a. Disconnect all sources of power to the analyzer. b.~ Disconnect the pump and impe!ler motors from where they connect · -~ to the bulkhead connectors on the right hand side of the wetside en- closure. c. Remove the screws that attach the bulkhead connectors (two per con- nector with nuts) to the panel between the electronics and wet- sides. d. Remove the bulkhead connectors with the gaskets from the electron- ics side of the panel. e. Disconnect the power leads to the motor board from the terminal strip on the wiring panel. Disconnect the ground lead attached to the panel. f. Pull the leads out from the panel through the holes with grommets. g. Remove the motor board from the plastic snap-on standoffs on the wiring panel. To do this, pinch the head of each standoff, while pull- ing gently on the board. Pull one standoff at a time. IM 50.505AA UA (2-98) 4.36 ' [ '! 'T' i I,,I MICROI2000® I WARNING: ALWAYS RECONNECT THE GROUNDING LEADS WHEN REMOVED OR BROKEN. GROUNDING LEADS ARE PRO- VIDED FOR SAFETY, TO PREVENT INJURY FROM ELECTRICAL SHOCK. Replacement of the motor board is the reverse sequence of removal. Re- attach all grounding leads. · Power Supply Board CAUTION: Replace the (4) plastic standoffs that attach the power sup- ply board to its mounting panel, as they will likely be damaged during removal of the board. a. Disconnect all sources of power to the analyzer before opening the door to the electronics enclosure. b. Disconnect the ribbon cable from the power supply board, where it connects to the CPU board. c. Disconnect the terminal block plug on the left-hand end of the board. It fits tightly, so rock it out one end at a time. Do not pry it out with a tool, as this will damage the connecton d. Remove the four screws and lockwashers attaching the panel (behind the power supply board) to the keypad backing plate. e. Turn the panel/power supply board over and remove the three screws attaching the panel to the circuit board (into the transformer). f. Detach the power supply board by pinching each of the heads of the standoffs (one at a lime) and pulling apart the circuit board and panel. Replacement is the reverse of removal. Be sure to reinstall the serrated lockwashers with the screws attaching the panel behind the Power Supply board to the keypad backing plate. The panel is grounded through these screws and the serrated lockwashers ensure a sound electrical connection. · CPU Board a. Disconnect all sources of power to the analyzer before opening the electronics door for access to the electronics. IM 50.50SAA UA (2-,q8) 4.37 I " · I " MICROi2000® b. Disconnect the ribbon cables from the power supply board and dis- play board where they attach to the CPU board. c. Disconnect the terminal block/plug on the left-hand end of the board. It fits tight, so rock it out one end at a time. Do not pry it out with a tool, as this will damage the connectors. d. Kemove the four screws and lockwashers attaching the CPU board to the keypad backing plate. Remove the CPU board with the plastic insulating panel behind it. Keplacement is the reverse of removal. Be sure to replace the insulating board behind the CPU board. This insulating board is needed to prevent the sharp leads on the back of the board from cutting into the wiring harness. Check that the gain switches and the cell voltage are correct. See para- graphs 4.4.14.2, Cell Voltage Adjustment, and 4.4.14.3, Setting Range Switches. · Display Board a. Disconnect all sources of power before opening the electronics en- ~/ closure door for access to the electronics. b. Remove the power supply and CPU boards. c. Kemove the three screws attaching the display board and remove the display board from the keypad backing plate. d. Remove the extender cable from the display board cable. Note the orientation of the connection to display board cable for reassembly. Replacement is the reverse of removal. Be sure to reinstall the insulating washers under the screw heads of the screws that attach the display board to the backing plate. These washers prevent the screw heads from shorting to the conductors on the display board. Note the red (color-coded) con- ductor on the display board ribbon cable. This conductor should mate with the red conductor on the extender cable, which is keyed to Pin 1 on the CPU board. 4.4.14.6 Snubber Jumpers As discussed in the Section 2 - Installation, the relay output contacts are provided with snubbers. These electrical components extend the life of the contacts when they are providing power to an inductive load (e.g., a solenoid valve or electrical alarm). However, snubbers can cause improper operation IM 50.505AA UA (2-.98) 4.38 MICROI2000® of the output functions if the relay outputs are used to drive low-power, solid- state devices. The leakage current through the snubber may be enough to interfere with the proper actuatiordde-actuation of the driven device. The jumpers can be selectively disabled by removing the associated jumper. 4.4.14.7 Identification, Removal, and Replacement of Relays WARNING: TO AVOID POSSIBI,E SEVERE PERSONAL INJURY OR DAMAGE TO TIRE. EQUIPMENT, THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED, AND SERVICED ONLY BY PERSON- N'EL WHOARE THOROUGHLY FA1MII,IAR WITH THY~ CONTENTS OF THR, INSTRUCTION BOOK PROVIDED. TO AVOID POSSIBLE SEVERE PERSONAL INJIJRY FROM ELEC- TRICAL SHOCK, DISCONNECT ALL. SOURCES OF POWER BE- FORE SERVICING. IN ADDITION TO POWER REQUIRED TO OPERATE THIS UNIT, UNPOWERED RELAY CONTACT CONNEC- TIONS ARE PROVIDED TO WHICH ADDITIONAL, INDEPENDENT SOURCES OF POWER MAY BE WIRED. WREN SERVICE MAY BE REQUIRED TO BE PERFORMED TO THE UNIT WITH POWER CONNECTED, IT SHOULD BE PER- FORMED ONLY BY PERSONNEL QUALIFIED TO PERFORM SUCH SERVICE. There are four relays plugged into sockets on the power supply board, labeled K1 through K4. The relays are referred to elsewhere in this manual as: K1 = Relay "A", K2 = Relay "B', I43 = Relay "C", and K4 = The Wetside Control Relay. The relay outputs C'A", "B", and "C") can be tested through the soft- ware, before opening the electronic side for service. In the test group of functions, the Wetside Control Relay (Relay "D") can be tested through the "Sleep Mode" function in the Diagnostic Functions Group. IM 50.50SAA UA (2-9S) 4,39 r s ' · I ' ' 1 ! ! MICRO!2000® WARNING LABELS AND TAGS The following warning labels and tags have been attached to the equipment. P60792: TO AVOID POSSIBLE SEVERE PERSONAL INIURY FROM ELECTRICAL SHOCK, TURN POWER OFF BEFORE SER- THIS EQUIPMENT MAY HANDLE HAZARDOUS MATERI- ALS SUCH AS ACID OR CAUSTIC WHICH CAN CAUSE SEVERE BURN TYPE INJURIES. WHEN HANDLING ANY HAZARDOUS MATERIAL: USE EXTREME CARE TO AVOID CONTACT WITH THE MATERIAL AND POSSIBLE PERSONAL INJURY. USE EYE PROTECTION AND APPROPRIATE PROTECTIVE CLOTHING. REFER TO THE SAFETY PRECAUTIONS OF THE MANU- FACTURER OF THE HAZARDOUS MATERIAL AND THE EQU]~MENT INSTRUCTIONBOOK FORFURTHER IMPOR- TANT DETAILS AND PRECAUTIONS. TO PREVENT POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED AND SERVICED ONLY BY TRAINED QUALIFIED PERSONNEL WHO ARE THOROUGHLY FAMILIAR WITH THE ENTIRE CONTENTS OF THE INSTRUCTION BOOK PROVIDED. IM S0.S0SAAUA (2-,98) 4A4) I ' l' I ,~ : ff MICROI2000® WARNING LABELS AND TAGS (CONT'D) P60794: TO AVOID POSSIBLE SEVERE PERSONAL INIUKY OR DAMAGE TO THE EQUIPMENT, THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED AND SERVICED ONLY BY PERSONNEL WHO ARE THOROUGHLY FAMIL- IAR WITH THE CONTENTS OF THE INSTRUCTION BOOK PROVIDED. TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELECTRICAL SHOCK, DISCONNECT ALL SOURCES OF POWER BEFORE SERVICING. IN ADDITION TO POWER REQUIRED TO OPERATE THIS UNIT, UNPOWERED RE- LAY CONTACT CONNECTIONS ARE PROVIDED TO WHICH ADDITIONAL, INDEPENDENT SOURCES OF POWER MAY BE WIRED. WHEN SERVICE MAY BE REQUIRED TO BE PERFORMED TO THE UNIT WITH POWER CONNECTED, IT SHOULD ONLY BE PERFORMED BY PERSONNEL QUALIFIED TO PERFORM SUCH SERVICE. CAUTION LABELS AND TAGS The following caution label has been attached to the equipment. L3259: TO PREVENT DAMAGE TO MODULE, REPLACE SHIMS UNDERNEATH MODULE AFTER PLYWOOD FEET ARE REMOVED. IM 50.505AA UA (2-98) 4.41 ~'- CABLE LENGTH APPROX. 30" FILL HOLE -_ - I~ ~ AND PLUG P59158 ~ , RECOIlENDED ' [' ' ' ', ELECTROLYTE U28039 . - - CABLE AND PLUG NOTEH FOR/ L'LEAR RESERVOIR BODY LOCATING PIN ON FLOW BLOCK PLATINUH Z ~ ELECTRODES (2) POROUS ELEMENT RP682260 (CUT FLUSH} WHEN ORDERING MATERIAL ALWAYS SPECIFY MODELAND SERIAL NUMBER OF APPARATUS U29086 PROBE - SERVICE ' 50.510.150.010 ISSUE 1 02-98 I · I T M ~C ro~2ooo® SECTION 5 - ILLUSTRATIONS List Of Contents DRAWING NO. Parts AAA8849 Basic Analyzer .................................................50.505.000.010A-G Panel Unit .........................................................................50.505.010.010A, B&C AAA8963 Electronic Door Unit ........................................50.505.010.020A&B Modular Cabinet ...............................................................50.500.002.011A&B Reagents ...........................................................................50.505.020.010 Modular Enclosure ............................................................25.055.004.010A&B ZIunetion Enelo sure ............................................................50.505.020.020 A&B IM 50.505AA UA (2-98) 5.1 r ! 'e I ', ! , D~ O oo I ~ NO~: , ~ FOR PA~ M~ SEE DWG. 50.505.001 .0 1 0E THOUGH G. ~ FOR TOP ~BLY PA~ NUdERAND DESC~ONS SEE 50.50~.~1.010E BASIO ANALYZER - PART8 ~8~9 Common Pa~s ' 50.505.001.01 OA ISSUE 1 02-98 ' I I '!' I! ~l I '! '1 [ ! 60 71 52 ~ TO PROBE CONNECTION E:TO IMPELLER CONNECTION ' ~ _ CONNECTION (6) ~ /1:,,, ,_~ TO PUMP I 1 t~ _ IMPELLER ,, (ROTATION PuMP CCW) ROTATION COW 53 ,. 51 · 59 ,OiO~- 55 · ~ '---,.. .... 58- t SUPPLY 56 57 TO DRAIN DEOX/2000 AND MICRO/2000 ARRANGEMENT NOTE: FOR PA~S LIST SEE DWG. NO. 50.505.001.010E THROUGH G. ( ) DENOTES REFF..R, ENCED PARTS. A FOR TOP ASSEMBLY PAliT NUMBEI~ AND DESCPJFTIONS SEE 50.505.001.010E ~ USE TFE TAPE ON PIPE THREADS. BASIC ANALYZER - PARTG _ AAA8849 Comman Parts 50.505.001.010C ISSUE 1 02-98 r ~ -61 · (60) CELL ~ , 63~' (6) - ~ ' 64~ ~ (61) ~ ~, .66 - ~ - 67~ 53 t t 69 ~ z GAS INLET ~ I I 1 68 SU LY SAMPLE INTAKE ' O PUMP INLET , TO WASTE TO DRAIN MICRO/2000 USED WITH CARBON DIOXIDE A~NG~ENT D~AIL "B" NO~: ~ P~ ~ ~ TOP ~[Y P~ NUMBE~ ~D DBC~O~ $EE ~.505.001.0}0E ~ USE ~ T~ ON BASIC ANALYZER - PARTS ~8~9 - Common Parts 50.505.001.010D 18SUE I 02-98 'I "!' '1 ' ' DEQX/2000 ANALYZER AAA9005 - MONITOR, WALL MOUNTED AAAgO08 - CONTROL, WALL MOUNTED AAA8933 - MONITOR, MODULE MOUNTED AAA8930 - CONTROL, MODULE MOUNTED MICRO/2000 ANALYZER AAA8918 - MONITOR, WALL MOUNTED NON-REAGENT AAA8915 - CONTROL, WALL MOUNTED NON-REAGENT AAA8906 - MONITOR, WALL MOUNTED ONE-REAGENT AAA8903 - CONTROL, WALL MOUNTED ONE-REAGENT AAA8900 - MONITOR, WALL MOUNTED TWO-REAGENT AAAS897 - CONTROL, WALL MOUNTED TWO-REAGENT AAA864.0 - MONITOR, MODULE MOUNTED, NON-REAGENT AAA88,:37 - CONTROL, MODULE MOUNTED, NON-REAGENT AAA8828 - MONITOR, MODULE MOUNTED, ONE-REAGENT AAA8825 - CONTROL, .MODULE MOUNTED, ONE-REAGENT AAA8822 - MONITOR, MOOULE MOUNTED, TWO-REAGENT AAA8819 - CONTROL, MODULE MOUNTED, TWO-REAGENT MICRO/2000 ANALYZER WITH CARBON DIOXIDE AAA8912 - MONITOR WALL MOUNTED, AAA8909 - CONTROL WALL MOUNTED, . AAA8894- - MONITOR WALL MOUNTED, ONE-REAGENT AAA8891 - CONTROL WALL MOUNTED, ONE-REAGENT AAA883~. - MONITOR MODULE MOUNTED, AAA8831 - CONTROL MODULE MOUNTED, ' AAA8843 - MONITOR MODULE MOUNTED, ONE-REAGENT AAA8816 - CONTROL MODULE MOUNTED, ONE-REAGENT WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. BASIC ANALYZER - PARTS LIST - AAA8849 Common Ports 50.505.001.01 OE ~ssus ~ o2-s8 T I i ! : T ~ KEY. NO. PART NO. QTY. DESCRIPTION · 1 P 19665 5 MACH. SCREW (RD. HD., SS) #10-32X5/8" LG. · 2 P 45188 4 /flO LOCKWASHER (SS) · 3 AAA7385 1 ENCLOSURE · 4 P 29693 1 MACH. SCREW (RD. HD., SS) 1/4-20X1/2" LG. · 5 P 14635 1 1/4" LOCKWASHER (SS) · 6 UXA29380 1 PANEL UNIT (1RPM), (SEE DWG. 50.505.010.010) OR UXB29380 1 PANEL UNIT (2RPM), (SEE DWG. 50.505.010.010) · 7 P 58270 1 DRAIN FITTING · 8 P 54550 1 BULKHEAD FITTING · 9 P 45385 1 GASKET · 10 P 47065 1 NUT (PVC) 3/4" · 11 P 58145 2 BRACKET · 12 P 22616 4 5/16" WASHER (SS) · 13 P' 43049 4 5/16" LOCKWASHER (SS) · 14 P 32755 4 BOLT (HEX. HD., SS) 5/16"-18X1/2" LG. · 15 P 58137 1 GROOV-PIN · 16 U 29551 1 WINDOW UNIT · 17 P 57595 10 PUSH-ON CLIP · 18 U 27934 1 LATCH · 19 P 57548 2 FOAM BUMPER e20 P 60546 1 NAMEPLATE LABEL (DEOX) OR P 60547 1 NAMEPLATE LABEL (MICRO) 21 AAA7394 1 FRONT PANEL (WITHOUT RECORDER) - ~f . ~ ~ · ~ OR ..... ~. AAA7391 1 FRONT PANEL (WITH CIRCULAR CHART RECORDER) OR AAA8741 1 FRONT PANEL (WITH STRIP CHART RECORDER) · 22 AAA7376 1 WET' SIDE DOOR · 23 P 58139 1 PIN · 24 P 40867 1 RETAINING RING · 25 P 58138 1 SPRING · 26 RK31 2260 4FT. RUBBER ROD, 1/4" DIA. · 27 P 27292 3 MACH. SCREW (FIL. HD., SS) #4-40X3/4" LG. · 28 AAA8963 1 ELECTRONIC DOOR UNIT (SEE DWG. 50.505.010.0200 · 29 P 60584 1 TERMINAL MARKER LABEL · 30 P 59080 4 CIRCUIT BOARD SUPPORT · 31 P 8430 2. GROMMET · 32 U 24505 3 1/2" CONNECTOR · 33 U 29400 1 WIRING BRACKET · 34 P 56799 3 MACH. SCREW (PAN HD., SS) #10-32X3/8" LG. · 35 U 29376 1 BOARD &: CABLE NOTE: · PART OF ~A~M48t · PART OF AA/~827 · PART OF AAAg002 F'I PART OF ~ O PART OF AAA8846 I PART OF BASIC ANALYZER · FOR TOP LY PART NUMBERS AN0 DESCRIPTIONS SEE 50.505.001.010E WHEN ORDERING MATERtAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. BASIC ANALYZER - PARTS LIST AAA8849 Common Ports 50.505.001.01 OF ~ssuE ~ o2-9e I ' ', II KEY. NO. PART NO. QTY. DESCRIPTION 56 U 13434 1 TIME DELAY FUSE, 250mA, 250V (PART OF KEY NO. ,.35) · 37 P 45336 3 O-RING · 58 P 41970 2 CLAMP (NYLON) 5/16" ID · 39 P 22644 1 CLAMP (NYLON) 1/2" ID · 40 P 60794 1 WARNING LABEL · ·41 P 58189 3 RECEPTACLE SEAL · 43 P 58258 6 SEEL SCREW, #4-40X3/8" LG. · 1,44 P 60418 1 CONNECTION LOCATION LABEL · 45 P 58259 5 GASKET · 46 P 15562 6 #4 LOCKWASHER (SS) · 47 P 56615 6 HEX. NUT (SS) #4-40 · 48 P 19841 1 MACH. SCREW (RD. HD.,SS) #6-32X1/2" LG. · 49 P 43816 1 #6 SHAKEPROOF WASHER (SS) · 50 P 60793 1 INFORMATION LABEL RK63 4411 4 FT. TUBING (WHITE NORP.) .020" ID X 1/16" OD (DEOX ONLY) 51 OR ' RK63 4411 8 IN. TUBING (WHITEN NORP.) .020" I0 X 1/16" OD. (MICRO ONLY) 152 P 60420 1 "Y" TUBE FITTING eIRP68 4448 5.5 TUBING (PE) 3/16" ID X 1/4" OD 53 OR 0 RP68 4448 4.5 TUBING (PE) 3/16" ID X 1/4" OD · U 29399 2 REAGENT TUBE UNIT (DEOX) OR 54 U 29599 2 REAGENT TUBE UNIT (MICRO, 2 REAGENTS) OR U 29399 1 REAGENT TUBE UNIT (MICRO, 1 REAGENT) · 55 P 60424 1 TEE TUBE FITTING · 56 U 29402 1 CALIBRATION VALVE (DEOX ONLY) · 57 RK63 4442 2 FT. TUBING (NORP.) 1/8"1D X 1/4" OD · 58 P 60554. 2' MALE FITTING (LUER) 0·59 U 29401 1 MALE RUN TEE (1/4" NPT) ~e"60 U 29086 1 PROBE 161 U 28046 5 ELBOW TUBING CONNECTOR, 1/4" NPT X 1/4" OD 162 P 38216 1 TEE (PVC) 1/4" NPT 163 P 35518 1 NIPPLE (PVC) 1/4" NPT X 1-1/2" LG. 164 P 55108 1 REDUCING BUSHING (PVC) 1/2" NPT X 1/4" NPT E365 P 56799 4 MACH. SCREW (SS) 10-32 X 3/8" LG. r"'166 P 45188 4 #10 LOCKWASHER (SS) Q67 P 58128 2 DIFFUSER MOUNTING STRAP [] 68 U 26965 1 C0.2 DIFFUSER · 69 U 28045 1 TUBING CONNECTOR, 1/4" NPT X 1/4" OD 70 P 60792 1 WARNING LABEL · RK65 4411 8 FT. TUBING (WHITE NORP.) .020" ID X 1/16" OO (DEOX ONLY) 71 OR RK63 4411 8 IN. TUBING (WHITEN NORP.) .020" ID X 1/16" OD. (MICRO ONLY) NOTE: · PART OF ~AJv~8__8_,49 · PART OF AAA8827 · PART OF AAAgO02 O. AAA8825' 0 PART OF AAA8846 [] PART r~ · FOR TOP 'ASSE'MI~Y PART NUMBERS AND DESCRIPTIONS SEE 50.505.001.010E WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. BASIC ANALYZER - PARTS LIST AAA8849 Common Ports 50.505.001.010G ~SUE 1 02-98 I' '!' ' " ] KEY NO. PART NO. QTY. DESCRIFT!ON ]. P 57595 1 CLIP 2 P 40282 1 CLAMP 3 P 60414 1 IMPELLER SHAFT 4 P 34673 3 SET SCREW (SS) 6-32 X 3/16" LG. 5 P 60346 1 COUPLING 6 U 29410 1 MOTOR 7 P 43816 3 #6 WASHER (SS) 8 P 46999 3 SCREW (P.HD., SS) 6-32 X 5/16" LG. UXA29379 1 MOTOR, 1 RPM 9 OR UXB 29379 1 MOTOR, 2 RPM 10 P 60384 1 FRAME CASTING 11 P 43747 2 #8 WASHER (SS) 12 FP 2431 2 SCREW (P. HD., SS) 8-32 X 1/2" LG. 13 P 60411 1 THRUST WASHER 14 U 29403 1 BALL BEARING, 1/4" ID X 5/8" OD 3.5 U 29398 1 SAMPLE TUBE UNIT 16 P 60412 3 PUMP ROLLER 17 P 60552 1 SET SCREW (SS) 10-24 X 1/2" LG. 18 U 29378 1 ROTOR BODY UNIT 19 P 60410 1 OCCLUSION RING ;;>0 P 14635 4 1/4" LOCKWASHER (SS) ;:>1 P 12143 2 SCREW 1/4-20 X 2-1/4" LG. ;=2 P 43216 2 SCREW (F.HD,,SS) 1/4-20 X 1-1/4" LG. 23 P 60417 1 CELL 24 PXE 51161 1 O-RING (018) EPR 25 P 60415 1 IMPELLER 26 P 60210 1 SEAL, GRIT 27 P 60207 1 U-CUP (TEFLON) 28 P 60409 1 ADAPTER SEAL 29 RK63 4442 .670 FT TUBING, 1/8" ID X 1/4" OD (NORPRENE) 30 P 60419 2 TUBE FITTING 1/ST X 10-32 ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. UXA29380 - 1 RPM MOTOR, UXB 29380 - 2 RPM MOTOR PANEL UNIT - PARTS LIST 50.505.010.010C _F~_~ 1 02-g8 · · , SUPPLY VOLTAGE27I I) --' ea sELEcToR SW,TcH"'--,,'-, __ (POWER SUPPLY 26 BOARD) "'--..~,' __., [] ~ 16 ~7J8 ~,3 31 , 16.19.20 21,~~~~ 29 ~4 0 9 30765~'4 3 ~ c o z REAR VIEW SIDE VIEW FRONT VIEW ~ ~ ~ CELL VOLTAGE ~ b ~ ADJUSTMENT POT. o GAIN SWITCHES > ~ - PLAN VIEW SIDE VIEW ~ ) KEY NO. PART NO. QTY. DESCRIPTION 1 AAA7379 1 ELECTRONIC DOOR 2 U294-06 1 DISPLAY PANEL 3 P58137 1 GROOV PiN 4 P58129 1 GASKET 5 PC51130 14 MACH. SCREW (PAN HD.,SS) ~8-32 X 3/8" LG. 6 P56608 3 WASHER (NYLON) 7 P4-6650 11 MACH. SCREW (PAN HD.,SS) ~4.-4.0 X 5/16" LG. 8 U294.2,5 1 CPU PRINTED CIRCUIT BOARD UNIT 9 P 15362 4- #4- WASHER (SS) 10 P60753 4- STANDOFF (NYLON) 11 U294-36 1 RIBBON CABLE lEE P4.1970 1 CLAMP, 5/16 13 U29414 I WIRING HARNESS 1.4. P2264.4. 1 CABLE CLAMP 15 FP24-31 1 MACH. SCREW, 8-32 X 5/8" LG. 16 U29577 1 PROBE CABLE UNIT 17 P31220 3FT. 16GA. WIRE (STRANDED) 18 P36655 2 #6 LUG 19 P19841 1 MACH. SCREW, 6-32 X 1/2" LG. EE0 P43816 1 #6 LOCKWASHER EEl UXF961,~6 1 POWER SUPPLY PRINTED CIRCUIT BOARD UNIT EEEE P4-5194 4- #4. WASHER (SS) EE3 P60754 1 SUPPORRT PANEL EE4 U96200 1 LCD MODULE 25 P58138 1 SPRING Z>6 P4-0867 1 RETAINING RING EE7 P58139 1 PIN a8 3 SPACER (NYLON) EE9 3 ~4 SCREW (RD. HD.) SELF-THREADING 30 1 BOARD COVER UXG92568 1 FUSE, 200mA (:21 15V) 3t OR UXD92568 1 FUSE, 100mA (250V) ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA8963 ELECTRIC DOOR UNIT - PARTS LIST 50.505.01 O.020B I 'l" 'i ' ] , -- TOP ' 2 "~ VIEW 4 /' I I 29 ' 28 ~ 27 .'Ix/ 26 2 4 ' \21 / 19 20 ; , , " '~ /15 I I0 /12 14 ~10 ~ ..... .~ · II SIDE VIEW REAR VIEW NOTE: FOR PARTS UST SEE DWG. 50.500.002.011B G2161 - DRAIN CHAMBER, G2177 - SUPPORT HARDWARE, G2405 -WATER LINE MODULAR CABINET - PARTS Additional Parts 50.500.002.011A ISSUE 1 02-98 I 1 'i' KEY NO. PART NO. QTY. DESCRIPTION O 1_ PC62`39 4 HEX. NUT (STL.) 1/4-20 O P P4719 4 MACH. SCREW (HEX. HD., STL.) 1/4-20 X 3/4" LG. 0 3 P59025 2 BRACKET O 4 PC27649 4 1/4" LOCKWASHER (SS) 0 5 PC1 6966 8 1/4" WASHER (STL.) O 6 P35518 1 1/4" NPT NIPPLE PI 7 U28398 1 1/4" BALL VALVE [] 8 P39235 2 90' ELBOW (1/4" X 3/8") [] 9 PXB39234 2 UNION NUT · ].0 P20864 5 HEX. NUT (MONEL) 5/16-18 · 11 P`35125 3 MACH. SCREW (RD.HD.,MONEL) 5/16-18 X 1" LG. · 18 P57050 10 5/16" WASHER (MONEL) · 13 P58959 1 DRAIN CHAMBER BRACKET · 14 P17949 2 MACH. SCRE'W (HEX.HD.,SS) 5/16-18 X 1-1/4" LG. · 15 U25080 1 DRAIN CHAMBER 13 ~.6 RP52 4608 3FT. TUBING 1-1/4" IO (PVC) /"~ [] 17 RK18 4484 ,3FT. TUBING 3/8" ID (HYPALON) n 18 P21189 1 HOSE ADAPTER [] 19 P35108 1 REDUCING BUSHING (1/4" X t/2" NPT) [] PO U24311 1 VALVE [] 81 U27949 1 STRAINER A 88 P37830 1 1/2" NPT NIPPLE [] a3 UXA21673 1 1/2" BAL VALVE [] P4 RP68 4464 3FT. TUBING 1/4-" ID (POLYETHYLENE) · 25 P4-5413 1 INLET BLOCK · 86 P19888 2 1/4" WASHER (SS) · 87 P44567 2 HEX. NUT (SS) 1/4-20 R ~ · 88 P4`3216 2 MACH. SC EW (FL.HD.,SS) 1/4-20 X 1-1/4" LG. · 89 P29713 2 1/4-" LOCKWASHER (SS) NOTE: · PART OF G 2520 ·PART OF G 2161 O PART OF G 24.05 I'1 PART OF G 2177 WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. G21 61 -DRAIN CHAMBER, G2177-SUPPORT HARDWARE, G2405-WATER LINE Additionol ports-MODULE CABINET-PARTS LIST 50.505.002.011B ~SS~E 1 02-98 1 "I' ': 1 : I 4 ,,,..,,,._----I0 5 ! 8 0 5 P ~g"/'1;3 2 114' LOCKWASHER (SS) 0 6 P 42901 2 MACH. SCREW (RD.HD.,SS) 114"-~:1 x 0 7 P44,..56"/ 2 HEX..JAMNUT(SS)I/4'-lO 8 PXB ,52591 I STRAP 9 P 58160 I BO"I'"FOM BRACKET SH~'t.F 10 U 29~g I REAGENT 'TUBE UNIT - P 60424 1 TEE TUI~ FITT1NG (NOT NOTE: · PART OF G 2401. 0 PART OF G 2404. WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. G2401 - WALL MOUNTED, G2404. - MODULE MOUNTED P, EAGENTS ~ PARTS - 50.505.020.010 ISSUE 2 11-97 I ! [] ! " TO RECORDER 21 22 21 / I~ ~ REFL IS 20 _ -OR- I , :. _~ ~ 2 , libel , I$ " " ~1 14' ____ ."e'. : !1 ~ ~! -' I0 I~ ~1" ~ 9 i~ ~1 · ~'. .... TO ANALYZER I~ ~1 ~ 8 I 7 NOTE: FOR PARTS UST SEE DWG. 50.505.020.020B G2402 JUNCTION ENCLOSURE - PARTS 50.505.020.020A ISSUE 1 02-98 KEY NO. PART NO. QTY. DESCRIPTION 1 P 60557 1 MARKER STRIP ' B P 38033 2 3/4" CONDUIT BUSHING 3 U 22761 2 3/4" CONDUIT SEALING O-RING 4 P 45188 1 #10 WASHER (SS) ' 5 P 48246 2 CONDUIT NIPPLE 6 P 38578 2 3/4" PIPE CONDUIT COUPLING 7 P 50475 2 JUMPER 8 U 27943 2 1/2" CONNECTOR 9 P 58207 2'8" 1/2" PVC CONDUIT 1_0 P 60559 1 MOUNTING PANEL 1~ U 29416 1 18PT. TERMINAL BLOCK ],8 P 56635 1 TERMINAL LUG 13 P 31220 5'6" //16 GA. WIRE 14 P 36439 1 #10 TERMINAL LUG 15 U 29418 1 JUNCTION BOX 16 L 2016 1 WARNING LABEL ~ 17 FP 2432 4 MACH. SCREW (PAN HD., SS) #8-32 X 3/4" LG. 18 P 43747 4 #8 LOCKWASHER (SS) 19 P 29488 4 HEX. NUT (SS) #8-32 20 P 56453 1 SEAL HOLE [21 U 28019 2 1/2" X 90' CONNECTOR 122 P 58207 5' 1/2" FLEXIBLE CONDUIT - L 2016 1 LABEL (NOT SHOWN AFFIXED TO KEY NO. 10) NOTE: · NOT PART OF G4-202 ' ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. G2402 JUNCTION ENCLOSURE - PARTS LIST 50.505.020.0208 ~su~, ~-~ ,[CH, FINISHED TH f R. ) .~ ,SEE DE[AIr-| rn 7 ~t FROt~T ' Z ~ (OUTilOE| ,o -~ rn I:~ z ~/,, ~ 2.884 c:: 0 ;a -- ' . 50 ~: o 6 =n · · · o __: o C: -- I""' ~ · z bO t..ll (,,n ~""" t ~' l' I ~ 0 --I KEY NO. DESCRIPTION PART NO. QTY. [Z] 10-32 MONEL NUT P1654.1 2 E~3 #10 MONEL WASHER P33415 2 [Z] 10-32 MONEL SCREW P47607 2 ED CLIP - PUSH P57595 10 ED RAIL TRIM AAA714.5 1 ED PANEL, MODULE END AAA7142 1 (Z::) 3/8-16 X 2" LG. HEX BOLT HD. P56293 4 Q 1/4-20 X 7/8"LG. SCREW P52329 10 (Z:) 3/8 FLAT WASHER P1090 4 (D 3/4 FLAT WASHER PB2018 4 (Z:) 1/4-20 HEX NUT P16542 6 (Z::) 1/4-20 XI"LG MONEL SCREW P165~,5 6 (Z) 1/4" FLAT WASHER P16556 22 ~ (:E) MONEL LOCKWASHER P18102 16 (::D 6-32 X 1/2" LG, SELF TAP SCREW P58573 8 ([~) MODULE FRAME AAA6611 2 (~ TIE STIFFENER NUT P57579 2 (~) TIE STIFFENER PLATE P57580 1 (~ IDENTIFICATION PLATE P58164 1 (~) LOWER FRONT PANEL AAA5735 1 WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS MODULE ENCLOSURE - PARTS LIST 25,055.00¢.01 OB ISSUE 4 6-97 MICROI2000® SECTION 6 - SPARE PARTS LIST Residual Analyzer QUANTITY DESCRIFrlON PART NO. (recommended minimum) 1 Preventive Maintenance Kit G2416 · 1 Sample Tube Assembly (Sample Metering Pump) U29398 · 2 Reagent Tube Assembly (Sample Metering Pump) U29399 · 1 Tube Silicone Grease (for Impellet Shaf~ Seal) U10242 · 1 Impellet Shaft Seal P60207 · 1 Lrnpeller ShaR P60414 · 1 Grit Guard, L-npeller Shaft P60210 · 1 O-ring (For Cell, size #018,EPDM) PXE51161 I6 Feet Reagent Tubing (yellow,5/32 OD,Norprene) RK634411 2 Feet Sample Tubing (black, 1/4" OD,Norprene) RK634442 4 Feet Sample Tubing (translucent, 1/4" OD, L.D.P.E.) RP684448 1 Tube Grit UXB 10846 6" length Probe Junction Material RP682260 12oz. Bottle Probe Eleetrolyte Solution U28039 1 Bottle Potassium Iodide, 500 grams U23661 16oz. Bottle Detergent Additive U29142 OR 1 one-gal. Bottle Detergent Additive UXA29142 · Pan ofG2416. Continued on Page s.2 IM 50.SOSAA UA (2-,q8) 6.1 s ! '! " ! SECTION 6 - SPARE PARTS LIST (CONT'D) QUANTITY DESCRHrFION PART NO. (recommended minh'aum) 1 Fuse, Sx20mm,200mA,250 Power Supply Board(llSv) UXG92568 OR Fuse, 5x20rmn, 100mA,250 Power Supply Board(230v) UXD92568 1 Fuse, l/4 x 1/4, 250 mA, 250% Slo-Blo Motors U13434 1 Caston (4 one~gal. Bottles) pH 4 Buffer Solution U 13765 IM S0.S0SAA UA (2-98) 6.2 T T '= · ~ WAGON WHEEL RANCH 2.0 HG ELEVATED STORAGE TANK CzTY OF COPPELL~ TEXAS PRO3ECT NO. WA-96-O1 OPERA TZON & M AZNTENANCE MANUAL 'rNSTRUMENTATZON ELECTRZCAL CONTRACTOR HARP, ELL & ASSOCZATES, ZNC. 3007 WOODSZDE DRZVE AP, LINGTON, TEXAS 76016 (817) 483-7582 TNSTRUM ENTATZON CONTRACTOR iVlZD-TEX CONTROLS, ]~NC. P.O. BOX 584 LEW:[SVZLLE, TEXAS 75067 (972) 436-9024 RTU AUXILIARY PANEL TABLE OF CONTENTS RTU ENCLOSURE HOFFMAN MODEL #1-302412LP WITH SUBPANEL EA-30P24 2-POSITION SELECTOR SWITCH ALLEN-BRADLEY MODEL #800T-H2A ' RELAY POTTER & BRUMFIELD MODEL #KRP-11AG-120 WITH SOCKET #27E891 24VDC POWER SUPPLY MOORE INDUSTRIES MODEL #DPS-24DC/240MA/117AC(DIN) UPS TRIPP LITE MODEL #BC PERS 450 TERMINAL BLOCK ENTRELEC MODEL #115 116.07 INTRUSION SWITCH SQUARE D MODEL #9007 TYPE C RTU MOTOROLA MODEL MOSCAD T i T Single-Door Type 12 and Type 13 Enclosures Application Construction Accessories See General Accessories index tx~e 9.00 Intended for use in housing electrical and · Enclosure bodies are either 14 gauge or electronic controls, instruments, components, 16 gauge steel (see table).AII doors are Blower Package and associated wiring, these enclosures 14 gauge steel. Corrosion Inhibitors incorporate hinged doors which provide · Seams continuously welded and ground Door Stop Kit convenient access. Designed for indoor use in smooth, no holes or knockouts Drip Shield Kit Electric Heater protecting components from dust, dirt, oil, · External mounting feet and water. Electrical Interlocks · Door and body stiffeners in larger enclosures Enclosure Stabilizers · Rolled lip around three sides of door and all Fan Cooling Products sides of enclosure opening excludes liquids Fast Operating Clamp Assembly and contaminants Floor Stand Kit · Door clamps are quick and easy to operate Folding Shelf Keyboard Kit · Door removed by pulling heavy gauge Latch Kits & Lock Kit continuous hinge pin Lighting Kit - Hasp and staple for padlocking Panel Support Kit - Data pocket is high-impact thermoplastic Panels (See table) · Oil-resistant gasket attached with oil-resistant Rack Mounting Angle Kit adhesive and held in place with steel Swing-Out Panel Kit retaining strips Terminal Kit Assembly · Collar studs provided for mounting Touch-Up Paint (A-TPHS61) Window Kit optional panels Wiring Duct Finish A~r condi~oners and heat exchangers for this White inside with ANSI 61 gray outside finish enclosure can be found in Hoffman~ over phosphatized surfaces. Optional panels SpeC/fier~ Gu/de for Thermal Management Products. are white. Conmct your local Hoffmon 5o~es Industry Standards Representative for information on UL S08Type 12 and Type 13 mnd~cations to this produeL NEHA/EEMAC Type 12 and Type 13 JIC standard EGP-1-1967 (14 ga. only) CSAType 12 IEC 529, IP65 Cross Reference CONCEPT' Single-Door Wall-Mount Price List Page 4.06 Enclosures (page 4.24) 4.34 ©1997 Hoffman Engineering Company ';' ,(uedtuo~) ~u!~aau!~'u:l uetu..u,oH/.66 I@ t~[*~ (~'J, a~ed) saJnsopu:i 90'V aHed ms!'1 a:~!-ad 3unoN-II~AA 'ooa-al~u!S .J.d:I~)NOZ) ~:>ua~aJ.~M ssoj:) S9dl '6~S ~ I adX. L ~ (/,luo 'e~' kl)/.961-I-d9-3 pjepur~s 311' E; I adX. L Pue ~1 adX/3VN:!]/VI,43N l>nlxud s!Lp m suo.no~l.~potu I~ Iad,(/ pue C I adX/805 uo uo.rmtm0Jur ~o./~.nmuesa~cl~l ~ sp.~epue:lS/u3snpuI sateS uou~oH io:>ol .~noX Dmuo3 · am!qAA aje 's~npo~d luamaaouoW iou, uaql ~oJ ~p.~nD s,~a~/.oadS slaued leuo!~dO 'sa=ejjns paz!meqdsoqd JaAO s, uotu~oH u.~ punoJ ~ uo~ ~nsol~u~ qs!u~ ap!nno/~ 19 ISNV q3!~ ap!su! a~,!qA,% s.~qa ~oJ s~aauoq>xa ~>aq puo uauo.m. puo~ qs!u!4 m~nG ~u!J!AA m!~l A~opu!AA slaued leu°-nd° (19SHall-V) ~-u!ed dl'l-q=no/ gu~uno~u ~oJ pap!^o~d spn~s JelloD . XlqtuassV ~OI leu!tu~al sd!j~.s ~u!u!e3aj 1!~1 {aued ~nO-~u!N~S laa~s q~!AR a=eld u! pleq pue aA!saqpe ~!)1 al]uV ]u.~unol,4 ~e~l xue:ts!saj-i!o cp!~ paq=e~e ma~tse~ =uus!saj-i!O . (alqel aaS) slaued =!3seldocujaq3 ~edtu!-q~!q s! ~,a~t~od r.eG · ~-!~1 'uoddnS laued guppolped ~oJ. alde/s pue dseH . ~'!~ ]u!~q~!'l u!d a~u!q snonu!~uo= ~!~ ~=o'I ~g sl!~t q=3rl aBne~' XAeaq ~'uqlnd Xq paAo~uaJ ~ooC1 · ~,DI P~eoqXa)l ' .llaqS ~u!plo:l a~uado o~ ,(sea pue ~!nb aje sdu~ep ~ooCl · mDI Pue~S ~oo1:1 nueu!tuuuo= pue ,(IquuassV dtuel3 ~u.neJadO ~.sq sp!nb!I sapnpxa ~u!uado mjnsol~ua J.o sap!s ~1 II) s~npoJd ~'u!loo:) u~:l IIe pue ~oop J.o sap!s aeJq~ puncue d!l pallo~ · sJa~l!qe:lS a~nsopu:! sa~nsopua Ja~jeI u! s~auage~s Xpoq pue ~ooG . · .aale,~ pue r4~°lJamul le=!~m=al'3 maaj ]u!~uno,,, leuja~3 · ~a~eaH ~!j~=al:I .1!o h_j!p ~snp tuoj~ s~uauodmo= ~u!~amo~d ~!~ PlaNS d!jG s~no~pou~I ~o saloq ou 'qmootus .u! asn joopu! ~o~ pau,~!saG 'ssa=~e mua!ua,~uo= 1!~4 do3S Joo(3 punojg pue papla~ Xlsnonu!muo= stueaS · ap.~oJd q~!q~ sjoop p~u!q amejodjo~u! sJo~!q!qul uo!so~oD -laams a~'ne~ kl sajnsopua asa~ 'gu!~!~ pam~!=osse pue a~r4~ed Ja~olg a~e sJoop IIV'(alqel aas) laams a~'ne~ 91 'slueuodtuo~ 'slua~unj3su! 'sloJ~uo~ ~!uojm=ala ~o a~ne~ t,I ~aqm!a aje sm!poq aJnsopu:l · pue Ir~!J~ale ~u!snoq u! asn .soj papua~ul 00'6 a~ocl xapuf sa~ossa~V imauaD ~S sa!.aossa:~V uo!m3n.a:lsuo:3 uo!le3!lddV sa-ensol:>u:l [ I ad,(1 pue I adX1 'eooCl'al lu!S LISTED i-. 50"- STUDS IF B=LESS · 44 ' C ~ 38 62 "- ~. 25" 2.00" = e I I ' 6 32 51 ""Y .88" t 22 t + · - S.3B' ~ IFTI 8~> C "~ PANEL (ORDER ,, , " DOOR ' 22 ~ ',', X ~ a7 :: X CLA.P .i " ' " I "C Z EE ~ Z 1.81' HASP & , STUDS IF A=LESS :: A- A ',', ~ t T DATA POCKEf' ' I ( SEE NOTE ! ) " F" '~ " , :: 1.50" 1.50" ' 38 : : .. ~ E ., ; '.: .... ....... _ 86 -, u ~ ~ ] B ,, HOUNT~ - I . 62 .44 n ! .25" ~Y FEET ~8 29 I _ ~2 DO0~ ST~FFENE~ ( SEE TABLE ) , NOTE: I. Rem~ble dam p~ket included. ~ ruble for size· b~e ~ ~ket 12.~ x 12.~ (305 x 305); small da9 poc~t (i,2 x 2. ~nels have ~n~es alon8 sides which more ~an 21 .~ inches (508 millimpel) 3. hnels are t2 ~uSe s=eel. NEOP~ENE GASRET DO0~ STZFFENE~ 24 ' 3-S~DES ) I 6, _ GAUGE ~ I . 25" I '~1 ,91" 2~ 33 14 I 32 23 35 , ~ I . 25" .56 35 .56 ' I. 25" C CONTINUOUS HINGE (SEE TABLE) " " I . " · ~' ' '~ ........~- - ....... T .................. ' 4 ~ ~ SECTION Z-Z -.19" ' L ' ' Z · MOUNTING FEET 5 BODY ST FF NER PANEL {ORDER SEPARATELY) 2 SECTION X-X Inch Millimeter Data subject to change without notice t' 612 421 2240 FAX 612 422 2600 4.37 m 'mmmmmmm, i" ll 2 POSITION SELECTOR SWITCH UNITS, Non-Illuminated LEGEND PLATE -- Prices do not include the legend plate. Legend plates are listed on Page 374. O~tor P~ffion I MAINTAINED ~1~ R~RN C~ Con~ L~ 0 = = ~ O~mt~ ~ X Sta~d K~ ~ver o o A O X ~ng Leverl 1 White B X O Cyli~er Left 1N.C. Sta~ard ~ A O X o ~ 1 ~ite B X 0 C~n S~t o · Wing L~erl 2 N.O.- 2 ~ack A O X Cyli~er Le~ 2 N.C. B X O ' R' A O X Sta~d 1 White B X O K~ Lever ~ A O X Coin Sbt , ~, - 8 X O Wi~ Leverl Cylinder { L~ 3 N.O.- 2 ~ck A O X L~king R' 3 N.C. B X O Portion A O X A O X K~b Lever B X O ~in Sbt Wi~ Leverl ,4 N.O .- 2 Bla~ B X O ' R' A 0 X 4 N.C. B X 0 B~rd ~ 1 White A 0 X ~ng Cy,n~r n~eh 1N.O. S~ard K~ Le~r ~ 1 White B X O Wing Levi Cy 1 N.C. St~d "' I White A O X Kn~ Le~ ~ ~ ~in S~t ~ng ~v~ 2 B~ck A O X Cyli~er Le~ 2 N.O. Sta~d 1 White B X O K~ Lever C~n S~{ ~ ~ Wing Lever Cyli~er Le~ 2 N.C. ............ I ~en f~i~ k~, S~e 1 is on t~ ri~t, Side 2 is ~ t~ ~ft. Cylm~r L~k Operat~ Keys are re~a~e ~ly in the I~k~ ~siti~. Tar~t ~es are revers~ from th~ s~wn. I Wing lever units ~ ~ly ~ u~ in a o~ h~e stati~ or always I~t~ at t~ ~ttom of other stat~s or ~nets. SPECIAL COLORS, UNIVERSAL COLOR, SPECIAL LOCKS & EXTRA KEYS -- Refer to Page 360. REPLACEMENT KNOBS AND COLOR INSERT KITS -- Refer to Page 373. SIEMENS GS, SFLA, PU,POSS ,SLAYS KRPA/KRP Sedes - cd · -c · ociltypentug. KRPP-' - Duetcover KRP-11D~ -24 24 472 1.2W I)POT 5 $38.00 · KRPAIslow-coetiRmltieddestgn KRP-11DG -12 12 120 · ,Ap~o:dmaleSize1.41'xl.41'x2.00'h ~Nk~ -24 24 472 38.25 - -110 110 10,000 41.80 Coil ' ~ " -125 125 .l~._n~_ 42.10 hit Number. ,' Input I ~ I Nora. An~ A, np I:~ce, KRP-1,4AY ' -I~0 120 :~gfln , 2VA 3PI)T 5 46.05 -120 120 2,250 2VA 31q)T 10 47.15 Atalon!llld IGIPA ~ , -240 ~40 9. 110 49;95 KRPA-SAY -120 120 2,250 2VA SPOT 5 $15.45 ' , KRP-140G -12 ' 12 120 .- ' . / ' 46.95 .24 24 472 1.2W 3POT ' 10 46.95 KRPA-SAG -24 24 85 2VA SPt)T 10 15.90 -110 110 10f'en 50.65 KRPA..SDY -12 12 120 1.2W SPOT 5 - 15.40 ~.4 24 472 15.40 KRP-11AN ..24 · 24 65 · 43.70 KRPA-GDG .~ 6 32 ,. 15.90 -120 120 2,250 2VA DPDT 10 43.70 -12 . ' 12 120 1.2W SPOT 10 15.90 -24 24 472 ' 15.90 KRP-11DN -12 ! '.* 12 ,120 4340. '- -.24 · 24 .4'3,2. t.2w DPOT '~0 4a.4Q, KRPA-11AY -6 6 6 ' - 17.40 -110 110 10./v~ 46.~i -12 12 24. 17.40 · KRPA-14AN ~4 24 "85 2VA 3PU"T 10 24,70 -24 24 85 2VA DPDT ' 5 17.40 -120 120 2.250 , 24,70 . -120 120 22-.50 17.40 .' KFIPA..14ON -.24 - * 24 472 1.2W 3PDT 10 2435 -240 240 9.110 18.40 , Thelerdayllfenot ULorCSA KRPA-11AG -6 6 6 ' 17.80 KRPA-SAG-24 dl~oteaACcol.. -12 12 24 11.80. KRPA-SDG-24 ! clanoral DC (x)il . ,.- .,.24 24 85 2VA DPOT 10 17.80 KRPA-t~AY..24 "Y" aAgconlactl -120 ...' - 120 2,250 17.80 . -240 ' 240 9,110 18.80 KRPA-SAG24 'G'denotmlAgCdO · KRPA-I1DY -12 12 - 120 17.10 KRPA..11AN-24 q~r'clenoiN rmon~lmp,AgCdOQQ~llct8 · · . -24 24 472 1.2W DPOT 5 17.10 ' KAjI(AP ~ : ~ ' · Relllyl ' -',o ',o '~o.ooo '~8.ao General Pu~ ' . KRPA-11DG ..e, 6 32 . 17.80 FF,.~/'~ .~ '.."' - -12 12 120 17.80 · 10A rating ' ' - ' ,-24 24 472 1.2W D, POT 10 17.80 ..4a 48 1,800' 'm.7's · ~Open~re~y -uo no lo.oQo 19.30 · Qct~plugm~.avabMe(KAP) ,,,,, KRPA-'f4AY -24 24 8~ 21.,.10 -120 120 2,2.5O 2VA 3POT S 21.30 - Hig~/dm:=ientform,,dtchbgligNpow~' .-240. 240 9.110- 22.20 ·/~,p,w, li.de, Size1.92"xl.47"xl.38"h ,.24 24 85 2VA 3PDT 10 21.90 . -24O 24O 9.110 23.10 Pa,.Nunter ~ { ~ ] Nora. ~ Amp lob'be KRPA~14OY -24 24 472 1.2W 3POT' 5 17.10 In KRPA-14DG -12 12 120 21 .'/5 KRP ..24 24 . 472 1.2W 3PDT 10 21.75 2VA SPDT 5 $22.70 ~ ' 48 1,800 : 22~0 KA.-SAY -24 · .24 85 -'llt~ 110 1~ ~,~c45 -120 120 ~ 22.70 ICRPARlilyldlhkltcllorllmp KA-SAG -120 120 2,250 2VA SPOT 10 24,40 KRPA,.11AN -12 , 12 24 20.25 · .24 e 24 85~ 2VA DPOT 10 2025 -240 240 g. 110 21.30 KRPA-11DN -12 * 12 120 20.15 -12 · 12 120 1.2W . SPOT 10 23.00' -24 * 24 472 1.2W DIq)T 10' 20.15 -24 24 472 23.00 -110 110 10.000 21.75 -110 110 l0nfit 26.15 KRPA-14AN -24 w 24 85 24.70 KA-11AY -6 6' 6 27.46 -120 120 2,250 2VA 3PDT 10 24.70 -24 24 85 2VA DPOT. 5 27.46 -240 240 9.110 25.9~ -120 IL1 ~,n 27.4~ KRPA-14DN -.24 , 24 472 1.2W ~ 10 24.35 KAI1AG -12n l'~t p,~Gn ~/A QPQT 10 ~A~ KA*t'IDY -12 1~ l~fi KRPRdmm KA*11DG -12 12 120 28.20 KRP-SAG -120 120 ~ ~q~ 2VA ~ 10 17.80 -24 24 472 1.2W I)PI)'I' 10 28.20 -11Q 110 10,0Q0 30.80 KRP-1 lAY o120. 120 2,250 2VA DPDT 5 37.45 KRP-I lAG -6 6 6 38.40 KA-14AY -120 1J;Q p ~r~ 2VA 3PI)T 5 33.50 -12 12 24 38.44) KA-14AG '-12~ l~q 2 ~r,n 2VA 3P!)T 10 ..24 24 ~5 2VA DPDT 10 34.40 KA141)G -24 24 472 1.2W 8PDT 10 36.80 -120 120 2,250 -, = 38.40 -110 110 10,Q00 39.10 -240 240 9, 110 40.~0 CAm. TON,,BKr!:S CO~6'ANV j RELAY AND SOCKET USAGE CHART "~. RELAY SOCKET TERMINAL ,HOLD DOWN SOCKETRG NOTES: Seepage#279. TYPE SPRING NUMBER CB 27E122 Screw 1 (8.1;inN*tl) 27FP"1 ~ ~3C419 2 7.8 SOCKET FIGURES CB 27E123 Sc,w a I I '2 (11-Din oclal) 27E892 SGrew 20C419 4 7.8 CD 27E122 Screw 1 E~~;~, ~ 1'Bflnn,~l~ 27E891 Screw .; 20C419 2 7.8 CD 27E123 . Screw "- 3 - (1 l-Din 0(2~ 27F.892 Screw 20C419 4 7.8 C(3 27E122 Screw 1 . ' |8-Din ~ 27E891 Screw 20C419 2 7.8 CG 27E123 Screw 3 · CH 27E122 Scaly I 1.572x2.385x.i25h 1.575x2.362x.Be6h (8-ulno~lll} 27E891 ,~xew 20C419 2 7,8 ~. I c. rnsl;3 sc~ a 3 '4 (11-lYatoctel) 27E892 Screw 20C419 4 7.8 '- (8-1Yat o¢1ll) 27E881 Screw ' 20C419 2 7.8 CK 2'/E123 Screw 3 · - (11-~octd) 27E892 Screw 20C419 4 7,8 CL41&CU-41 27E0,13 Solder 20C228 o~2C:3254 5 9 27E0,16 PC 20C228 or20C254 5 9 27E067 QC,& Solder 20C228 o~20C254 5 9 . 27E121' . Screw 20C314 6 10 DIN Flail Mount 27E396 QC & Sdder 20C254 7 2.322 x 2.385 x .g25h 1.575 x 2.362 x .866h 27E400 Solder . 20C254 7 ;TEe. Screw 20C31S a 7.11 5 J. 6 ~ CL.-51 .27E043 Solder ~ 20C247 or20C255 5 12 ~ 27E046 PC 20C247 or20C255 5 12 ' 27E067 QC&Solde 20C247Or20C~___K5 5 12 27E088 Blank 20C241 or20C255 5 :. 12 27E121 Screw 20C314 6 ' 10 27E396 QC&Solder. 20C254 7 - , ,'27E400 · Solder- 20C254 .7 '~ ' 2'}'EBg3 .Screw 20C318 " 8 7,11 (8-plno¢~l) 27E891 Screw 20C419 2 7,8 Screw Holes for mountlng 3.:lS0xl.Sx.895~ -CNS 27E123 Screw ~' 3: (11-Dinocel} .27Ell2 Screw 20C419 ' 2 7.8 7 8'~ CNT 27E123 Screw 3 · (11-T~inoctal} 27E892 Screw 20C419 2 7,8 CR 27E122 Screw ~ 1 {8-1~oclal)" 27E891 Screw 20C419 2 7:8 (s-~nomr) 27891, screw 2oc419 ,: 2 7,e .'.::ii CU41&CL~1) 27E043 S<~der '~ 20C228 or20C254 5 9 .. 27E046 PC ' 20C228 or20C254 5 9 · ' I1~ 2-P,:o67 QCaSek~er 20Ca8 o, 2eC2s4 s 9 27E088 ,, Blank 20C228 or20C254 5 9 27E121 Screw , 20Ca14 .6 10 Chasm Cut..out1.270 x1.395 DNl~Mount .~ · · 27E3~6 QC&8oider 20C254 7 Snaprnoum. 2.g~xl.6~x.ge4h · 27E893 Screw 20C318 8 7,11 ' CU-51 27E043 , Solder 20C247 or20C255 5 12 27E046' ;. PC 20C247or20C255 5 12 27E067 QC&Solder 20C247or20C255 5 12 ' 271;088 Blank 20C247 or20C255 5 12 " . 27E121 Scmw 20C314 ~ 6 10 " 27E893 Screw 20C318 8 7.11 2.650 x 1.409 x .985h Chassis Cut.eat .850 x 1.015 JM-1 &JM-2 : 27E122 Screw 20C419 I 11 t ~ I~ JM-3 27E123 ..- Screw 20C419 3 (11 -pin oclal) 27E892 Screw ' 7 K10 27E487 Screw 20C297 9 27E488 Sotder 20C217 10 - 332 CAm,TON-S^'rB COMPANY n-nl ,oo INDUSTRIES D:.-~.. Po.,..,. s~p~ USER'S MANUAL Februmy 1991 · 14o. 221-703.,00 C Tableof Contents Introduction 1 Description 1 Ce!ibrmtion 3 Installation 5 Troubleshooting 7 Moore Industries' STAR* Center has a 'O in stock and m7 to ship. · Signal Transmitters · Temperature ransmitters · P/I and I/P Converters · Isolators and Converters · Indicators and Displays · Alarm Trips · Integrators and Totalizers al~ · Power Transducers ~_--_~s,,o.e~ ~ · Instrument Power Supplies Tel:(818)894-7111 oTbc8~-1322·Racks. Rails and Enclosures TOLL FREE FAX: tats) em-a;g't 1-800-g99-2900 COeEC'T m.e~q: MeS~RJLVSD~ MOSt instruments can be cuStomized uee engdom ~ u,re ~ M,~ ~. ~ tO meet your needs. Even then. you'll W. Sussex RI-IIO-2QU. United K'atgdom FREE PHONE Tel:o;ms~44e-Tuc r/as7 never have to wait more than a few days. 0800 525107 FAX: oaa saeas~ TOLL FREE NewSoumWe,~.~.~umrd,, .... - .......' Tel; (02) 525-9177 · Tbc 790-75914 008 251928 FAX: {; s2sqa6 CENTER ~) .~ekbrmeSTARCeme *r, eeeet. TedekeiN,leae,.melReeelr(eurauld~4NeR=ll~ Page1 · 240 Milrtamp !~ ,:Introduction ~ ...a.~ b~.~, ~ ~ q,~ ~ o~ for The DPS 240 is Moore Industries' 240 naiamp (rnA) DIN-style Power Supply. It is a highly accurate, The unit is available in 24- or 42-Vclc output oorigura- =d'jJb't~L '9 unit, most often used to power 2-wire lions. A potentiometer on the from panel agows for rnunicalions modules lle Moore Industries' Link (RIM). and is available setto 117, 220, or240Vac, 50/60 Hz. Unt features include continuous shod circuit and The equipment specr~ forthe DPS 240 are and a clera~ed circul design for added dependability. the DPS 240. dent hisfoty is kept on every unit that Moore Industries Description .~0, ,~on. TM ,0,~ ,o.4, is ,tn~d o., The DPS 240 is a compact unit; pafficulmty wei-Modellitmd~r, Moorelrdusffies'moclel~ ~..~ .; enclosed in a standard, DIN-style, aluminum housing model nurrd3er reflects the way the unit was oon~g- designed to be instalidon aslandard 'G-rail' (not uredwhen Itorigina~ leltthefactofif. It is allthat is included). Thisrancen~henbemotnedonawal, ina needed to identity the operaUon~ charactedstk:s cd rad~orhaNEMAenclosure. Each DPS240 is the power tq3f~. The number ~ on the same capable of powering twelve 4-20 mA loops. label as the serial number. The front panel of the the unit features potentiometers The lollowing example outlines the sigruTK~tace of for adjustment of voltage and current limit, test jacks each rmid in a typical DPS 240 model number. for auxiliary connection of caltwalion equipment, and a red LED indicator tr~ lights when do oulput is present. Pa~e 2 M240 Millimp ! EXAMPLE DPS ! 24V!)C / 240 MA / 117AC I -FA [DIN] Unit Type Output Voltage Power Optkms(s) Input Frequency 48 to 62 Hz 81apply Typl: lineal' Oulpu~ 24 or 42 Vdc, 2~ mA (fac~ry-conr~ur~:l ~x:ordin~ ~o' custor~r requiremere). ~llltion: 0.5% rn~xirnum, low in~ ~o hbh line PIrbrrrmn~ Efficilnoy 70% typical, rated at full load i.Did: 1.0e~ maximum, no load b full load RIppll: 50 mV peak4o-~ nu~dmum bolation: I~rdt Housin~, 1100 Vrms Environrnerdal Conditionl Ambbnt T'-,-I~ Ir~,lum Op~rlt~ Panel: 0 to +70 'C (+32 t~ +158 Efbct on Unit: :I:0.()3% p~r °C over the range spr, ified WeigM 765 grams (1 pound, 11 ounces) NOTE: Refer to the InstallSion Section of this manual for unit dimensions. Page3 240 Miliamp IR Calibmtion Gontrob The unirs front panel has two rnuffitum potenliomaters Each power suppy is cartxat~ and checked at the lalalecl "VOLTAGE ADJUST" and 'CURRENT LIMIT'. factory to ensue proper performance before shipping. Voltage adjust allows the user to set dc output However, output values for each unit should be Indicators - 240 from possue damage' due to ovemeaUng. Refer to table I for the equipment specilk:ations of the Them is a red LED indicator on the front panel of the DPS 240. DPS240, which ights when the tmit is producing dc out, a short c~,t, overload, or any other unaccept-Ca!ibration Equipment Table 2 isis the equipment required to calibrate the user. AdFaelable ec Power Souroe Vafiac or equ'Nalent; cepi~ of 105-264 Vat output Vollmeter /4~curate to 0.01 miivdt MIIaen'eneter Accurate to 1.0 millianp Varlabb Pmmt llatMm' Powerst~t, or equ'walent; cmpable of output bad of1751i -G~.awdzlver, ~ Head measuring less than 2.54 mm (0.1 inch) in width k; Page4 M240 Milllamp C Calibration Setup /qop~ the appmprime ac powerto the setup 220, or 240 Vac). The specffic:ations table and the Catrmbnshould be performed in a laborton/ model ruTi~r printed on the serial lag r~ the accept- variables, and to monitor changes in the output more easily. F~ure I depicts the correct calibratjon setup When power is arq3rmd, the from panel "OUTPUT ON" for the DPS 240. LED will FilM, h:licating the presence of dc oulpuL unl asshown, andsetthe Ioadlo 100 ohrns for 24Vdc units, or 175 ohms for42 Vdc units. ADJUSTABLE + + C AC POWER SOURCE VOLTMETER MILUAMME'TER o-o-o o ~ LOAD M VOLTAGE ADJUST · °T Figure 1. DPS 240 Calt73'ation Setup Page5 .~ 240 Milllamp M Calibration Procedure '.' "'12:, ~"V~.T~'~"'~';,~i~i~'~','!:"'. ....:'.,,~.-...:.!..!,:.;?:.~:,'~!~i:~'!.';::!.":.: ::..:~,:',~.: :'::. .. ..,' .! ~.=.~:..:.~i!~.':. ~:"~'-':~'~' .... ' ......,, .,.,: .........., .......,......... · ...'.., ...., ...? ;.:~ :':,~'~,a kiTx:k'~ir,'~ ::' 2 V ~ ~ ~ ....',,"~ ~.~ ~' ~+~'~'~,~.', :.' .::...,~.~.:;,..:. :........,..,. ,.~.>...: ~,~., .~.~.~% ~...~, :.~ ~.: ..,~.~......,, .~.=.~'..,:~::.::;.~.,;7%.~ ~e ~ ~'a ~ ~. 'Av~ '~" ". ' """' ....... """ ~"""" "" '~" "~" ' .....'""" ~' '~' " ~'~" " ' ' ~..~ [~.8~ ~.2 V~ ~r ~V~: .. r. '. '; ~- ~et. or ~9~;1 ~ ir42-V~ '!).' '.': .;.. . . :, ~'..;...~.'..'.'::....::.~:;.. :...,:,,....:',: :....,.',.=. . ...':,:.:.:.,,...'..~,... :..:..,,*.: 3. u. v~T~s ~~ ~.e~. ~.~. ~:.'; ... InstllM~n ~ ~ ~ ~m ~.~ ~. ~ .u~ .' ,,. "., Vdc for~.~:~.~'i.79. V~lor42,V~';';': .... ~~It~.~l a~is~ ~ +"" .un~s (~ d'~~'m~ ~'~i').'. ... ,~ ,Y:,.. :~:,~..:.=;',:~.:~.,~:.'~, ~:'.....:;~ =:?.,..' ,..'.~.~,;.': ..~.' ..~,.... ~. ;.;.:~;;~ ?.,',:' ~ .. ~~, 7" ""~'~':'~::":=~:':.'.'.'~"..~:"""~..:'~"':~';~~ ."~;,;.,.';:.~:.~:~.:. . ....:~.',.'., ...:'.~... ;.,~.,.;,.~.~ .: ........~.. '..... ....~...,.~:.':;.~:..;'.';...~.",:.::::.. ..':..:..~::..v',.~':.;..:.~.:.:.:.;'~.:,.:.'......TO~m~UM.~DIN~S~~~ . . . '..;.:.......: . ... ...... "...,... ...' '.j:~......,....:..~ ....,~.,, . .' mm6ve. ~:' 'bbS~We .that the lED .tu~n'. (~ ~ 2). .. :'and .'t~t ~ '~ :~ m~"~ .ri~. ~. t~ un~ sligM~ ~. ~ ~ t~ ~ '..~mi~k:~10m~:'(~.~~Vi~r ' ~onffie~~lu~r~~dtM 41.~'V~-V~u~)~....~.~.,:..:.... ,:'v."~:.~':.."... ::," DIN rail. 9. ,e~'~: ' ' ' ~ ~ P~' :Ibssl~l'~.mV. .' , . .. :..... .".'..'~".'...:~,'..':L To~~uM.~ll~(f~~m) . , :,..... ..........;'~;~..;..., .y .': ..., ,..., .~, ..,: ,= ...,..,. ,. ~. N~e ~' m~ ~'t ~i s~.... . .=: . . .:.... . . .:, . ., . .,':.::.. .,...... Page6 R240 Milllamp i 66 mm I 94 mm I~ 9 mm ~ ~:=[-- (0.35 in) / SPRING T (P_71 in) -: (1.2e in) " "' / G-RAIL I / I ~ 88 mm a e · 15 mm OPTIONAL (3.4S in) (O.S9 in) ENGRAVED TAG ~ 104 mm ~, FOR CUSTOMER LD. (3.35 in) FIgure 2. Outline Dimensions for b"Je DPS 240 Electrical Connections :.. The use of 14-22 AWG insulated copper wire is re- commended in connecting the DPS 240 terminals. F;gure 3 shows the from panel of the DPS 240 in To avoid tmmim~ and stray pick-ups, it is fecom- detail, and depicts its electrical connection in a typical mended that twisted condu~_.ors be used when application. mnrdng dose to other sewice~ To ensure good contact, strip 5/16 to 3/8 inches ol the insulation from For irffofTnation on the Moore Industries products that the end of the wire. typically work with the DPS 240, contact your local sales representative, or Moore Industries' Customer To connect the DPS 240, loosen the clamping screw Service Departmerit. of the appmpr~e terminal, and insert the un- insulated end of the wire into the socket. T~lhten approp~te acpower, the DPS 240 wtll begin to operate. Emboo DIN HOUSINGS · INDUSTRIES w'.h P')/ SUPPLEMENT May 19~2 To Product Manuals Purpose ^ will provide a macling in lhe range of the unit's output . This supp~nere is being distri:uted a~ong with the rating. See figure I s. The model number of fie unit Users Manual of products packaged in the DIN-style shows its outlx~ range. housing that have front-panel test jacks; marked "+T" and "-'1". In some cases, infommlion regarding these nalrlTnN test jacks was ornrnilled from the product manual. The max/mum ms/stance the Presented here is a brief desc~p6on of the purpose naTEarnm~er can inUt~uce in~ the test and use of these test jack~ jack c/rcu/t and sb~provide accurate realfinDs/s 10 Ohms. ff the rnelammeter readings are not as amicipated, Use of the Test Jacks ~ythat the rellamrneter is rated for no moe than 10 Ohms impedance. ff the Unit is suspect of irr~ The +T and -T test jacks, available on some DIN- proper opera~n, remove it from the loop and perform style un~, am provided as a convenient means of a bench check and callbration as descried in the rnon~toring the process loop to which me product is respective product manual. connected without disconnectir; the unit or interrupt- ing the loop. + ,T U~UJAkNETER MOORE ~NDUS'rTUES' (~0Q roPEDANCE) TRANSMn'TER - -T Figure ls. From Pane/Test Jack Hookup r, e DIN HOUSINGS INDUSTRIES w'.h F,'o,. SUPPLEMENT C May 1992 To Product,Manuds Purpose A milrmmmeer connected to the +T and -T test jacks will provide a reading in the range of the unit's output This supplement is being distributed along with the rating. See figure I s. The model number of the unit User's Manual of products packaged in the DIN-style shows its output range. housing that have front-panel test jacks; marked '+T' and '-T'. In some cases, informmion regarding these P-alrllnlv test jacks was ommitted from the product manual. The max/mum ms/stance the Presented hare is a brief description of the purpose milamttWer can inYoduce irdo the test and use of these test jacks, jack c/rcu/t and st///provide accurate mad/rags/s 10 Ohms. Use of the Test Jacks v,~y~the ~e.,,,~.,~ ~..~o, .o .,o,. t~ 10 Ohms impedance. If the unit is suspect of im- The +T and -T test jacks, available on some DIN-proper operation, remove it from the loop and perform style units, are provided as a convenient means ofa bench check and calibration as described in the monitoring the process loop to which the product isrespective product manual.. connected'without disconnecting the unit or interrupt- ing the loop. + +T MILUAMMETER -. - MOORE INDUSTRIES' (<1 o~ IMPEDANCE) TRANSVUTTER -- -T Figure ls. From Panel Test Jack Hookup I 'm ! ! Page ~5-1 Supplement Low Voltage Directive Equipment Ratings The following guidelines must be followed in order to Moore Industries transmitters do not generate haz- comply with EN 61010-1 (Low Voltage Directive). ardous voltages. They measure voltage or current These items affect the AC versions of the following inputs, and generate low voltages and currents products: DCA, DPS-240, DPS1200, ECA, ECS, (<42Vdc and <50mAdc). Products connected to ECT, FCA, FDT, IST, PIT-4W, PWT, RBA, SCT, Moore Industries transmitters should be designed to SMP, SPA-CE. If these products are to be used in receive these inputs. a non-CE environment, this supplement may be disregarded. Moore Industries alarms do not generate any haz- ardous voltages. Alarm contacts are wired in series with power sources and their intended loads. WARNING: The correct load should be selected for the power source. If this unit is used in a manner not specified by Moore Industries, the protection provided by the equipment may be impaired. Supply Wiring All power connections shall be made with 14 or 16 AWG (.083ram or .064mm) wire. Switches and Circuit Breakers The end of each conductor should be stripped no A switch or circuit breaker must be wired in series more than 8mm. The end of the stdpped wire should be tinned with solder or inserted into a ferrule and with the AC power conductors. This switch or circuit breaker must be located within three meters of crimped before being placed into a terminal block. the unit. Conductors connected to screw type connections must have a ring or spade lug crimped on the end of the wire. WARNING: Terminals on this unit may be connected to hazardous voltages. Before making ANY connections to this unit, ALL hazardous Protective Earth Conductor voltages must be de-energized. The Protective Earth Conductor shall be of equal or larger size wire than the other two power conductors. The circuit breaker or switch will only remove power The P~otective Earth Conductor shall be the first to the unit, hazardous voltages may still be con- conductor connected to the unit when,the unit is be* nected to other terminals on the unit. ing wired. It shall be the last conductor removed when the unit is being un-wired~ Installation Category All terminals are rated CAT II, except for terminals with the RF Option. These terminals are rated CAT I. The Interface Sdution Experts I 'i' ! ....... I " Page S-2 Supplement Maximum Working Voltage Symbols Table 1 -s shows the maximum working voltage for Table 2-s shows the symbols used on Moore Indus- Moore Industries' low voltage products. tries' products, the corresponding IEC/ISO symbol, and its definition. Treble 1-s. Maximum Working Voltage Table 2-s. Symbols on Moore Industries' Products Input Type fJax=mum Working 'Joltage Symbci on Millivolt, Thermocouple, and R'rD 48Vdc IECflSO Moore O~hnition DC Voltage Inputs 48Vdc Symbol industries Product AC Voltage Inputs 264Vac Analog Outputs 48Vdc +PS Relay Contacts 264Vac -PS Direct Current 117Vac Power Terminals 129Vac DCC 240Vac Power Terminals 264Vac AC Alternating Current Contact Closure Outputs 30Vdc /"""""/ ACC Accessories Contact Moore Industdes for information on suitable ~ AC or DC Direct and Alternating Current accessories for our products. GND Mounting ' When mounting the unit or installing it into an appli- cation, ensure that the unit can be easily removed for maintenance or repairs. Protective Conductor Terminal r~ ~l~ Equipment protected throughout by double insulation or Cleaning and Maintenance reinforced insulation (equivalent Maintenance on Moore Industries' products is limited to Class II of IEC 536) tO keeping the unit clean and the wire terminals free r of oxidation. This is best accomplished by installing I I Caution (See manual for the unit in an area protected from dust, heat, tools- information) · ture, and corrosive atmospheres. Yearly visual in- · , · spections should be performed to ensure that the unit is clean and the electrical connections are in Not Specified +IN Positive Input good repair. -IN Negative Input +OUT Positive Output Not Specified -OUT Negative Output NO Normally Open Replacement of NOt Specified NC Normally Closed Consumable Materials cM co.,too. No consumable materials are used in the Moore Not Specified UNO Upper Normally Open Industries products covered by EN 61010-1. UNC Upper Normally Closed Not Specified LNO Lower Normally Open LNC Lower Normally Closed Not Specified TX Transmitter Excitiation The Interface Solution Experts RETURN PROCEDURES To return equipment to Moore Industries for reiNdr, perform the following: live thai you are taturnlng equipment for repair. Furnish the Moore Induatde8' IT, r~ll llhlatlVO lldth the modeJ arid era number(s) of the equipmere to be returned. ,., . .':..'...'.' .. ":"'. 2. in a cover letter or note, ascribe completely the logowing: . .:.. ~ . .. a. the symptom that Indicate the equipment needs .faiNdr . . . . ..... ..: . .. . . . , .; . . .'. ,...'..' ...: '.:........ . ..... ,.,... .......... d. complete shil:~lng ifdO'rmatlon ~or return of the' equipment alter .tapair ,' . .. ...." purchase order or .purchase order number with the equipment. ',., 5. Ship the' equipment t0. the Customer ServiCe Department nearest Fro.. ' : . .. The returned equlpmeM will be inspected and tested at the factory.' A Moore Industdn.~ f,~:~senlative will contact the person deignaM In the cover letter If morn information is needed.. .' in case of repair pursuant to Moore Industries' return 'policy, the detective equipment wig be either replaced, or the purchase price refunded, at Moore Industries option. The equipment or Its replacement will be returned to you In accordance with the .shipping Instructions furnished in your cover letter." !n other cases, the Moore Industries' representative will advise you of the repair cost and estimated return date, ~ requested In your letter. Repair In such Instances must be authorized by a purchase order number before the equipment can be repaired and returned. .. RETURN POLICY Fofalxdeclofledee(l~,,,,~,~,flenthsdaleofddlxn,et, andundenennd AM) OF THE COMPANY. N~D THAT ANY PRIOfI ~ OF THE BUYER WITH mndtkaelusemclawviom, Momlmiumbs('l'heComlany')mllmllsolc/on 'THE CClaPANY DO NOT IMPLY THAT ll. E COMPANY WARRANTS THE (3CXX)6 OR Fe~ mmakormlundlhepun:tnmelMcmlaranyelbmmmlanmmdlmxlucmlmmcl, 5ERVICES IN ANY WAY. upoemNmWlheCm~(b~ .--' ~ ,char0eepmpekiandolhefldaein ANY BUYER OF G(X)0 $ OR SERV"~..~.~ FROM THE COMPANY AGFIEES IN1TH amoelanmwlhbrelEnmemabldmdbyTheGom;mn)4. k~beddecaheln THE COMPANY THAT THE SOLE AND E:XC~---:-e-NEREMED4ESFORBREACHOF nmeddor~ lhlspoleyextmalotheedgindBulmonlyandnotlo ANYWARRANTYCONCEININGTHEG(X)I~OR~ERVICE~IALLBEFORTHE euye~welemeeeftheueeselBuyeflpmduds. mbeikeerleeneegimeq COMPANY, AT ITS OPTION, TO REPAIR OR I~=R),CE THE G(X)!) OR SERVICES axeactorbaelchceeethelxlarsNiesendtoBu,/mtbaneglale oedy. OR REFUND1].E PURCHASE PRICE. 1HEC011PANYIHALLINNOEVEIfi'IE TI/l:~enmR~aylblmm'uclhmlamnEd~ctlodl~mion, ml~me, ncd~lem, LIABLE I:(X!ANYCOIBEQUENTIM. OR INCIDEIrrAL DAMN3ES EVEN IF THE nenlecterlmpeapealSi:alon, lnmaidon, efoperaton. IHECOIIPANYI.IALLIN COMPANY FAILSINANYATTE!IqTOREMB)YDEFECI~INIHEOO008 OR THAN A REFUND OF N. L. MONESPAIDTOTHECOMPANYBYIHEBUYERFOR WARRANTY DISCLAIMER PUeCHASEOFTHEGOOOSORSERV~S. ANY UUSE OF ACnON FOR BREAC~I OF ANY WA,qRANTY BY THE COMPANY SHALL BE BARI~D UM. ES~ THE COMPANY ~ NO EXPRESS, NPLIED OR STATUTORY WARRANTES THE COMPANY RECENES FROM TiE BUYER A WRfTTF. N NOTICE OF THE (N-CLUONG ANY WARRANTY OF MEFICHANTABUTY OR OF FITNESS FOR A ALLEGED DEFECT OR BREACH WITHN TEN DAYS FROM THE EARLEST DATE PARTICULAR PURPOSE) WfrH RESPECT TO ANY G(X)0 S OR SERV~ES SOLD ON WHICH THE BUYER COULD REASONABLY HAVE ~RED THE ALLEGED BY THE COMPANY. THECOMPANYDL.qCLAIMSN.LWARRANTF. SARISNG DEFECT OR BRF_ACH, AND NO ACTION FOR 'THE BREACH OF Nff WARRAN'TY FROM ANY COURSE OF DEALING OR TRADE USAGE, AND ANY WJYER OF SHALLBECOMMENCEDBYTHEBUYERNOLATERTH/iNT'WELVEMONTHS Di~.,OVEREDTHEALLEGEDDEFECTORBREACH. Sepulveda, Califomiag1343-6196, U.S.A. W. SussexFU.IlO-2QU, Uniledl(jngdom NewSoUd~iWaJee~_,~,Aus~ali8 INDUSTRIES Te1:(818)894..7111 oTIx:65-1322 Td: 0 293 514488 ,, TIx: 87667 Tel:(02~525-g177-Tbc790.TS014 Fax: (818) 891-2816 Fsx:0gg3 536852 Fax: (02) 525-7296 PdreedlnU.S.A. I ! '; ' ' OWNER'S MANUAL ~ INSTRUCCIONES DE US() EN ESPANOL r. 18-27 BC PERSONAL® 200-500 ., BC INTERNETTM280-675 INTERNET OFFICE "' 325-450 BC PRO® 450-1400 OMNISMART '" 280-2200 PNP U!'S SYSTEMS WITIt SURGE AND N( ISE SUPPRESSION ) DO NOT PLUG LASER PRINTERS INTO THIS UPS* (USE CAUTION WITH STANDARD PRINTERS) *Except Intemet Office Sedes (which have special "printer" outlets) and OmniSmart 2200 PNP (which may have enough capacity to handle printer loads) 75' TR IPP L I ~'E (~) ~ ~ ~sY~ POWER PROTECTION by Ut to 1111 West 35tb Street, Ghica9o IL 60609 Customer Suppofi: 773/869-1234 Fax: 773/869-1329 · FaxSack: 773/869-1877 Export Customer Support: 773/869-1313 · Export Fax: 77'3/869-1540 E-Mail: info@tdpplits.com · Web:www.1fipplite.com Manu~sofured under one o~ morn of the tollowin~ U.$. patents: 4,760,277; 4,779,007; 5,369,561 OWNER'S MANUAL ADDENDUM TO ALL 120V UPS SYSTEMS WITH FCC CLASS "A" CLASSIFICATION ADDENDUM to Owner's Manual 193-1182 ~7~.,.~__ BC PersonaP 200 ~ z L #'~E FCC BC PersonaP 300 TRIPP .A orrv .TEn E.ENCE ec ,.,o..o,' 300 NOTICE c..~, ~ ... OmniPro* 280 CueMete Iq~xt: pT#) e~ Fax: (r/l) 1111 W. 3Sth Street c.,.;o, ,L ,.0. usa (CLASS 'A .) ,-....: r-,~ .~,.- ups svsTsMs Customer Suppod: (773) ase.1234 eww. t, lNes.ee mew. tHppllte. com ,., BC Personal 200 The new BC Personal 200 shares all of the functions and specifications of the BC Personal 200 in the , accompanying Owner's Manual with 3 exceptions: Note: This equipment has been tested and found to comply with the limits for a Class A digital device, 1) Cabinet dimensions (HxWxD) are 8" x 4" x. 5 '. pursuant tu Part 15 of the FCC Rules. These limits are designed to provide reasonable protection 2) 3 battery backup and surge protected outlets are featured. against harmful interference when the equipment is operated in a commercial environment. This . m equipment generates, uses and can radiate radio frequency energy and, if not installed and used in 3) A battery replacement door is located on the rear panel of the UPS. See Battery Replacement accordance with the instruction manual, may cause harmful interference to radio communications. section on back page for proper precautions. Operation of ~is equipment in a residential area is likely to cause harmful interference in which case BC Personal 300 The new BC Personal 300 shares all of the functions and specifications of the BC ]~ersonal 280 in the the user will be required to correct the interference at his own expense. The user must use shielded accompanying Owner's Manual with 4 exceptions: cables and connectors with this product. Any changes or modifications to this produd not expresdy 1) Output Capecity (VA/Watts) is 300/175 approved by the party responsible for compliance could void the user's authority to operate the . equipment. 2) Cabinet dimension (HxWxD) are 8 ' x 4 ' x 5. 3) 3 battery backup and surge protected outlets are featured. 4) Abattery replacement door is located on the rear panel of the UPS. See Battery Replacement section on back page for proper pn~:autions. BC Internet 300 The new BC Internet 300 shares all of the functions and specifica'tions of the BC internet 280 in the accompanying Owner's Manual with 4 exceptions: 1) Output Capacity (VA/Watts) is 300/175. 2) Cabinet dimensions (HxWxD) are 8 - x 4 - x 5 ". 3) 3 battery backup and surge protected outlets are featured. 4) A battery replacement door is located on the rear panel of the UPS. See Battery Replacement section on back page for proper precautions. OmniPro 280 The new OmniPro 280 shares all of the functions and specifications of the OmniSmart 280 in the accompanying Owner's Manual with 7 exceptions: ]) Cabinet dimensions (HxWxD) are 8" x 4" x 5 ". 2) 3 battery backup and surge protected outlets are featured. 3) OmniPro 280 does not have a serial port and does not include PowerAlert software. 4) OmniPro 280 has only 2 diagnostic LEDs which indicate on-line and on-battery status. 5) OmniPro 280 does not feature an Alarm Mute/Test Switch. 6) OmniPro 280 does not feature a circuit breaker. .~ 7) A battery replacement door is located on the rear panel of the UPS. See P j}y Replacement j) ea-lsN (m200e) ~/e section on back pai;e for proper precautions. '~ ' GWdlht O IRN TdFF LIfe. All fiRhis eewed, "') BA'I'rERY REPLACEMENT The BC Personal 200, BC Personal 300, BC Internet 300 and OrnniPro 280 feature a battery replacement door on the rear panel of the UPS. Under normal conditions, the original battery in the UPS system will last between 3 and 6 years. Qualified service personnel should read and observe all precautions listed below before attempting replacement. FOR QHALIFIED SERVICE PERSONNEL ONLY SAFETY WARNINGS IIII /lk WARNING! RISK OF ELECTRICAL SHOCK DISCONNECT UPS FROM WALL RECEPTACLE BEFORE PERFORMING BATTERY REPLACEMENT Keep all other persons away from the area when performing battery replacement. The batteries contain lead and acid. Do not dispose of the batteries in a fire. Do not open the batteries. Do not short or bridge the battery terminals with any object. Do not touch the loose battery terminal wires together or to any metal part of the UPS cabinet. Except for the replaceable battery, the UPS contains no other replaceable parts. A battery can present a risk of electrical shock or bum from high short- circuit current. Observe the following precautions while replacing batter- ies: 1) Remove watches, rings and all other metal objects 2) Use tools with insulated handles After removing UPS batteries, proper disposal is required. The batteries are recyclable. Refer to your local codes or call 1-800-SAV-LEAD (1-800-728- 5323) for complete recycling information. When replacing batteries, use the 'same number and type batteries originally installed in your UPS. Contact Tripp Life customer support at (773) 869-1234 for further infor- mation on battery replacement. U-1217 (1112O40) 12~1 IMPORTANT SAFETY MA,....A.cE Cal, T,pp Lite Culturea. Sup rt at <773, The UPS nuxiels included in ibis manual do I~o~ require mWExplnin fidly the ~rccived problem to the customer Exposure to high heat andA~r humidi~ should ~ avoided.or give you instructions a~ut retttrn, repair or exchange. depleted ~ndiflon. Batteries left in a di~ha~ed state will ING MAE~AL that came ~th the unit. Adequate suffer a ~mnent I$ of capaciW. ~erefore, if the UPS packing is essential to ensure your UPS is not damaged in CONSERVER CES INSTRUCTIONS. ~ is stored or not u~d for three months or lo~er, the transit. ~ su~ to save the ori~nal ca~ and s~ofoam CEdE NOTICE CeNTlENT DE~ INSTRUCTIONS IMPORTANTES ~ batteries should E fully r~harged ~ plu~ng the UPS inserts. Your warranW may ~ voided if the UPS ~ sent into a live 120V AC, ~ Hz AC outlet, turning the Master back to Trlpp Lite in impr~r packa~ng. "ON~FF" Power Switch ON and letting ~e unit charge 2. Enclose a letter describing the stoptoms of the prob- CONERNANT ~ SECUR[TE, ~ for a 24-hour ~riM. ~ lem. This will help speed turnaround time. ~is mnual contains im~rtant instructions that should ~ followed during installation and mintchance of the UPS 3. If the UPS is ~thin the 2 year wanan~ ~M, enclose and batteries. IF YOU SHOULD NEED SERVICE a c~ of your sales receipt. SEND THE UPS TO: Should you require ~ice which ~s ~yond what is TRIPP LI~ '~ WARNINGI ~ explained in the "Tr~t~ Gu~" section of this 1111 WEST 35th $~E~, CHICAGO IL ~ mnual, do the follo~ng: A~N: REPAIR DEPAR~ENT T~pp ~ d~ ~ rBm~ ~ $e of ~y of ~ U~ ~ ~y Fde s~ ~n ~e a m~ ~ ~lure of a T~pp ~e UPS ~u~ ~e f~ ~ signffi~ aR~ ~e ~o$ d ~liv~ ~ ~ipp~ ~ ~ (wtffi all ~i~ing or dellve~ charg~ p~id} ~: T~pp ~, 1111 W~t 35th ~t, ~ca~ IL ~. ~llff ~ll pay N~ER plug a UPS into RseH. ~is WILL resuR in damage to ~ unit and ~11 ~id your w~ran~. To r~ ~mm ~ippi~ ~a~. Call T~pp Li~ Cust~ff ~m at (~)~-I~ ~[off ~ing any ~uip~t hck f~ ~air. the dsk of fire, ~nne~ only to a circuR prodded ~h 15 timbres m~imum branch circuR over~nent m~ WA~ ~$ N~ AP~Y ~ NO~AL $R OR TO DA~GE ~NG ~OM A~E~, MBUSE, ABSE OR ~GLE~. prot~ion in a~rdance ~th ~e N~tionl Elfrill Code, ANSI~FPA 70. SEL$ ~K$ ~ ~ WA~ ~R ~AN ~ WA$~ EXPR~LY SET ~Rm HE~. EXCEH ~ mE ~m MM~D IN DU~ TO ~ WAR~ ~ S~ ~ A~ A~ ~B WARM~ EXPR~LY EXCLUD~ ALL INCIDE~AL ~ENE~L BAKERY INFORMATION exd~i~ot~d~t,l~u~,ldam~.~a~ettmit,fi~clus~mynota~ly~you.~Wa~v~y~c ~1 d~a, ~ y~ ~y ~ ~ ~e w~ v~ ~ ~ ~ ~1~.) · ~ U~ Chk.go IL ~ ~Re~ repla~ment should ~ pe~o~ on~ by amh0dzed ~monnel. ~ere ~e ~ u~-s~ble p~ WARNING: ~ ~l~uil u~r ~uld M~ ea~ ~ de~ ~ ffi ~ w~ ~ d~e is suitable, id~ ~ gle ~ ~ u~ ~d~. CAgTION ! ~ A~ENTION! v~ d T~ Li~ b ~ ot $t~ .... impmast. S~ca~ ..... ~ to c~nge without notice. ~en replacing baRedes use the same num~ and the foiling ~ ba~es: Seal~ Lead-~td. Pro~ ULTIMATE l ,~IME INSURANCE POLe~ NALIB IN U.S. AND ClNIBI ONL~ dis~BI ~ baRedes is required. R~er to your I~1 codes for dis~l requiring. h ~ are r~l~le. Call 1 ~SAV-L~D (1 -~728-5323} for compete ~IN I~mmatlon. TR~PP L~ wanan~, for the litcHine of t~ p~uct, to ~air ~ ~pla~ (at TRIPP LffE'S option) directly co~ quipment, that is damag~ POUR LE REMP~CEMENT, UTILISER LE MEME NOMBRE DE BATTERIES DU MODELE SUIVANT: iorda~is~oti~udd*P~wer~ami~i~ude~ik~a~dsurg~on~ACPwer~dat~or~e~hone~in~thattheT~PL~rM~have SCENES PLOMB ET ACIDE. L'ELIMINATION DES BAffERIES EST REGLEME~EE. CONSULER LES ~ d~t~ m pmt~ aEainst (fl ~o~iz~ by indust~ ,tandards). CODES L~AUX A CD EFt. Ac Power Line Tnndeab: To claim damage, t~ ~IPP Life p~uct must h plu~ into a pro~rly wi~ and g~und~ outbt. No ex~sion E~cal C~e (NEC}. ~pt ~ pm~d a~ve, ~is wa~anty d~ n~ cover any damage to pro~rly co~t~ e~tr~ic quipment multing CAOTION! tt~ A~ENTIONI ~ti~)~uipm~tup~t~ifl~v.l~(~ULTIMA~*l ........ Poll~Ltmil,).N ...... geisatiow~iordama~ngfmm~lephone A b~R~ $ pr~t a risk of el~l sh~k, burn ~om high sho~-cir~ ~ffent. O~e ~o~ ~- or da~ I~, unlm ~ ~ ~autely pmt~ u d~ ~w. tions. UNE BAffERIE PEUT PRESENTER UN RISQUE DE CHOC ELECTRIQUE, DE BRULURE PAR ?deph~ ..d D.e. LIne T~a.lenb: Tdpp Li~ will ~pair or ~pla~ di~tly c~ ~uipment that is d~ma~ by transi~ ~ ~l~ne a~/~ daU I~ ~ whm .B such paffis .~ pm~ by a T~pp Lile pr~ p~ud(s) and the AC ~wer (utility) ~ b simultan~usly T~NS~RT ~NERGIE. SUITE LEg PRECA~IONS QUI S'IMPOSE~. pm~ ~ a Td~ Li~ ~ff p~on d~ke ~, ,u~ su~r or line c~dffioner) wire Ul~ma~ l~ura~ ~vera~. ~ prMud Rdmbumment dollar limits will ~ ~ual ffi ~at ot the Tripp Lite pwer pro~ti~ unff. Covera~ is exclud~ w~ a suitable ~vimnm~t for /t~ CAUTION! t~ p~ti~ dev~e ~ not p~id~, including, ~t not limi~ ~, lack ola pm~r nfety Smu~. Te~p~ne ~e muipm~t .... ~ include a p~y i~tall~ and ~.ting 'pfima~ prot~" device at the tel~h~ Hw~ ~a~e (such devi~ aN no~ally add~ duHnK tellhone Do not dispose of the baRedes in a fire. Do ~t o~n ~e baRedes. Do not sho~ ~ bridge the baR~ llu te~tnals ~ ~y obje~. DO NOT a~pt to install e~a ~R~H for Io~er ~ckup U~S. BC PER- SONAL, 8C INTERNS, BC PRO, OMNISMART P~P (except for OmniSma~ 22~ PNP) and I~ERNET c~l~ ~.ip~t w~ not u~ under ~al ~mting conditiom ~ in ac~rdan~ with any la~ls or instmcti~, All claims under this OFFICE modes dH~ in ~is manual a~ not dHign~ for ~e installation of e~en~ ~. On~ i waranty must ~ submi~ in writ~8 m Tripp Lite within ~ dap of t~ ~cu~e or t~ claim will not ~ consideal. ~ls warran~ am not OmniSm~ 2~ PNP fHturH exp~dabie ~Re~ Capa~l~. Only 24 ~R b~e~ ~ks ~ld ~ ~ ~l.d, damaF ~ul~ng ~ a~id~t of m~uH, .~ apptie ~ ~e dome~c.(U~ & Canada) u. of th~ pr~uc~ n~ tO ~ Omni~ ~ PNE ~e i~ust~-~ard ~or color ~e f~ ~is vo~e ~ ~D. T,~ Li~ ~.w. t~ t~ht ~ determine whe~ t~ damaF ~ t~ (~ ~uipm~t ts due to matfu~.on ~ ~e Tdpp Lite pr~uct by provi~ by any ~verage of c~t~ ~uipm~t provid~ ~ ~her ~u~., ~)udin~ but n~ limit~ to, any m~ufac~r's wa~nty and/or I ~e ~S ~ int~ded for ins~llation in a tem~mm~-contmll~, ind~ a~a ~ee of conductive conta~n~. 4 any ext~d~ wa.ant~. Ch~ a d~, protected I~ation (or imtallation ~CE~ AS PROVIDED A~VE, TRIW UE MAK~ NO WA~, EXPR~ OR IMPLIED, INCLUDING WAR~ OF MERCHANT- · ~e~ UPS m~els are shied ~th the batteries already imtal~. ~e UPS ~ ~a~ to ~ afo~id limitaria(s) or exclui~(s) may n~ a~ly ~ pu~a~r. fight out of the ca~on; just plug in ~CE~ ~ PR~ID~ A~V~, IN NO ~T ~LL ~IPP Life BE LIABLE FOR DIRECT, INDIRE~, SPECIAL, INCIDE~AL, OR w~cn shippin~ a unit could void y~r Brran~ d dl~, ~ of s~tut~, claim 5~ thid pa~, or ot~i~, 2 at least 12 hours and rarest. A second "replace" indication switch controls the AUX outlet. The ACC switch controls have turned off power to the o' lets. Y~utr I Jl,lisfecl Ic Power Stq~ply means the UPS requires service. the ACC outlet. The MONITOR switch contn,ls the 12. AC LIne Cord, Fixed odeIs except (UPS)/Battery Backup provides a power source for your h. TIffs light will als¢~ ilh.ninare when the UPS is ~ MONH'OR outlet. The (;teen LED indicator light ab4,ve INTERNET OFFICE 420 LP): Pfug this cord into a computer system or other electronic device in the event operating from its batteries and there are approximately i each switch will illuminate when the switch is turned ON. grounded 120V AC, 60 Hz. outlet. DO NOT pull this plug ,ff a power black~mt. The UPS is intended as a tamp- 2 minutes nf battery power remaining prior to automatic I The Master "ON/OFF" Power Switch must he ON for the to test the UPS. See "Testing the UPS S:ystem" for more orary power source and is installed to allow the user enough low voltage cut-off (LVC). When this 2 minute indication ~ individual switches to work. The COMPUTER and UN- information. time to exit their program and shutdown safely. prevent- is displayed, user should commence shutdown of all con- SWITCHED outlets do not have individual control switches. The COMPUTER outlet can only be turned ON Note: a dedicated 20 amp circuit is required for full power ing any data loss. netted equipment. by the MASTER Power Switch. The UNSWITCHED out- output Of the Den Smart 2200 PNP An optional NEMA m 5-20 plug is included with the OmniSmart 2200 PNP and During periods of normal AC power service, equipment ~. Red 'Load' Indicator Ught (only let remains ON and sopplies utility power at all times. should be installed to comply with UL 1778 standards and ph~gged into the UPS is powered directly from the AC on BC PRO ESO, 1050, 14OO and 10. CIrcuit Beaker {all models except BC PER- to deliver full power as mentioned above. power line and baneflu from spike suppsession and line- OMNI~MART PNP 850, tOSO, t400, SONAL~OO&~80, BClNTERNET~80): Protectsthe 13. AC Line Cord, Detachable(onlyonlNTEBNET noise filtering. A small amount of line power is diverted 2~00}: This light will illuminate when the UPS is loaded to keep the battery fully charged. between about 90 and 12096 of its capacity and operating ' UPS from overload. The circuit breaker button will extend OFFICE 420 LP): The AC power cord is detachable and from battery power (either self-test ot standard battery if the breaker trips; remove overload and depress to reset. features an IEC-320 female receptacle on one end and a UP~ CONTROL~ operation), If the unit is loaded beyond 120%, the micro- 1 t. AC Outlets (all models): Supplies either utility NEMA 5-15P plug on the other end. Plug the cord into a processor senses this overload and initiates an automatic or UPS AC power to connected equipment. All the ouc- grounded 120V AC, 60 Hz. outlet. DO NOT pull the plug (see Illustrations on pp. ~.7 for your specific model) shutdown of the UPS. During any self-testing of the UPS, lets are spike and noise filtered. to test the UPS. See "Testing the UPS System" for more 1. Green 'LINE ON' Indicator Ught I it is a good idea to check this light to see if an overload (INTi~RNET OFFICE 325 end 450) 6 outlets total: 3 information. (allmodela}:llhaminatcswhenevertheUPS condition may exist. surge-protected only (white outlets) and 3 surge and bat- 14. LAN Interface Port (only on BC PRO end is connected to normal AC utility line power 6. Green 'Volt Cotreef Indicator / terV-backuppmtected (blackoudets). PLUGEQUIPMENT DMNISMART PNP models): DB9 female connector and the Master "ON/OFF Power Switch is turned ON. LIght (only on OMNIGMART PNP THAT DOES NOTNEED BACKUP POWER (SUCHAS allows connection to a network for automatic, unattended NOTE: For Interact Office 420 LP, this LED ramaim models): Illuminates when the UPS is PRINTERS) INTO THE WHITE OUTLETS. PLUG shutdown. See "SpecialLANSeaioa" for more information. illuminated whenever the unit is plugged into a live AC either Ix~osting or cutting the incoming line voltage, as EQUIPMENTTHATNEEDS BACKUPPOWER(SUCH lS. "RJ' Style Phone Input/Output Connectors outlet, even with the Master Switch OFF. needed. Remember that battery power is NOT used when AS COMPUTERS) INTO THE BLACK OUTLETS. (only on INTERNET OFFICE and BC INTERNET NOTE: The 3 surge-protected outlets ARE NOT con- 2. Rnd "BACKUP Oaf Indh:etor UgM i this light is illuminated. (all models): llhminates whenever the UPS 7. "Une Fault" Red Indicator LigM trolled by the Master "ON/OFF" Power Switch. They will models}: Plug telephone line from wall into jack marked supply utility power co connected devices at all times. "IN". Plug telephone line from modem or other telecommu- is operating from its intemal baKeries. (Only OI! INTERNET OFFICE 420 I.P): nicelions device into jack marked "OUT". These jacks 3. Alarm 'Mute/Test Switch (all mod- m Indicates a wiring fault has been detected. (/NTERNET OFF/CE 420 LP) 6 outlets tntal: 3 surge- provide spike and surge protection from transients present all ex~pt BC PERSONAL 200 & 280, If this LED illuminates at anytime the unit is plugged in, protected only (outlets on the right side of the unit labeled on telephone lines. BC INTERNET 280 and INTERNET thefaukshouldberepairedbyaqualifiedelectticianassoon "AUX", "PRINTER", and "UNSWITCHED") and 3 surge 16. Static DIscharge Pin (only on INTERNET OFFICE 3:~): This switch serves two functiom: as possible, This LED indicates chat phases are reversed, and battery-backup protected {outlets on the left side of the OFFICE 4]0 LP): A shiny metal pin on the front panel a. Alarm 'Mute": during battery operation, moving gvonnd is missing or some other sort of wiring error exists in unit labeled "COMPUTER", "MONITOR" and "ACC'). this switch temporarily silences the alarm that indicates the circuit the unit is plugged into. The Line Fault Detector PLUG EQUIPMENTTHAT DOES NOT NEED BACKUP of the latemet Office 420 LP safely dissipates static that can the UPS is operating on battery power. The audible alarm circuitry will identify mort common wiring faults, but will POWER INTO THE AUX, PRINTER AND UN- damage semitire electronic circuitry. Simply touch this pin sounds in a distinctive pattern of 4 fast beeps followed by not necessarily detect every possible type of faolt. SWITCHED OUTLETS. PLUG EQUIPMENT THAT before starting any work at your computer. NEEDS BACKUP POWER INTO THE COMPUTER, 17. External Battery Pack Connector (only on a Z0 second pause. The delay is built-in so that very 8. Mester 'ON/OFF' Power SwItch (ell models} MONITORANDACCOUTLETS. TheUNSWITCHED OMNISMART]2OOPNPmodels):Connectoptional short power outages do noc become nuisance alarms. The C'l" = '{}If; '{Y' = 'OFF'): This switch turfs the UPS outlet is not controlled by the Master "ON/OFF" Power Tripp Lite BP-24V33 battery packs to this connector. mute function will silence the alarm pattern until there ON and sapplies power to the rear AC outlets. Thin switch Switch. !c will supply utility power co connected devices at Refer to the battery pack instructions for complete informa- ura approximately 2 minutes of battery power left. At this can be used as a master control switch for all connected all times. Connect equipment that ycm want to remain on tion. Only 24 volt battery packs should be used (industry time, the alarm pattern will begin again and cannot be equipment, provided the power switches on the con- continuously (such as a clockorfax machine)evenafreryou standard connector color code for this voltage is RED). silenced by the mute switch. netted equipment are left in their ON positions. b. Setf-'r~c': Du~.g ~a~ AC line q~ra.o. ~whe.! ..........~ .:.~,;~.,:.l~.~.~..~~.W~.~..~ green 'Line On" indicator light is illuminated), moving ~ '.. .... :~:~ initiate a sophisticated self-test of the UPS batteries and ly lit{} N . t ....... . ~.~ full function of the backup system. During the test period, , lhe Mfl~g' POwl' 81Mleh 1o ~ 0on~ the connected load is powered from the UPS batteries ' ""F for about 6 seconds. If battery replacement is indicatedi ...... , '~' j 3 Y 12 by eint,_,micr r __,c,,tryoftheu ,,be "Battery (Bat) l.o~/Replace" light will illuminate and the ' . audible alarm will sound CONTINUOUSLY, but ONLY for the length of time between the weak battery signal and MOTE: (INTERNET OFFICE 325 and 450): The 3 surge- the end of the self-test. if the battery is determined to he in protected outlets ARE NOT controlled by the Master satisfactory condition, neither the "Battery (Bat) Low/ "ON/OFF" Power SwitCh. They will supply utility power to Replace" light nor the alarm will sound. It is a good idea connected devices at all times. to periodically use this function to test the battery while NOTE: (INTERNET OFFiCE 420 LP)The outlet marked the UPS is powering its normal load, but not while any UNSWITCHEDontherearoftheunitisnotcontrolledby · critical computer or load functiom ate being performed, so the Master 'ON/OFF" Power Switch. It will supply utility ~ ~ . '. :,: ,! ;. - ,'.. i ~ i-: .i ~ · . that battery and system integrity can be safely determined. power to connected devkes at all times. Connect equip- 4. Yellow'BaKery (Bet) Low/Bephge' ment that you want to remain on continuously (such as a IndlcatorLIght(allmodelsexcapteC clock0rfaxmachine) even after you have tumed offpower d I ~ 7 ! ; '~ 1 tl ~i i :3 7 ¢ t b PERSONAL 200, 280 420, BC INTER- to the other oudets. NET 280 and INTERNET OFFICE 325): This light 9. IndlvMual Peripheral "ON/OFF" Control displays two functions: Switches with Indicator Lights (only on a. This light will illuminate during a self-test between the IMTERNET OFRCE 4~O I,P}: These four switches 'Y ~ !l'l~t ~: "!' time a weak battery indication is detected by the UPS eithertumONorOFFequipmentconnectedtnfourofthe - circuitry and the end of the self-test. This indicates a weak ' six outlets on the teat of the latemet Office 420 LP. The .... '~Bll[~glllSsm,mmlm~sRm~s,b,n'TC/'/'~ ~ ~ ~ i t i i i i, ~ I I I ~ I ~ _ or under-charged battery. Allow unit to charge on llne for PRINTERswitchcontrolsthePRlNTERoutlet. TheAUX eO~f )ING THE UPS monitors. Small magnetic fields present during backup ~. o- operation can cause monitor interference or disrupt infor- . ..... pit ~e motor-~ef~ ~0 ~enerlors have If the eq.ipment is equip~d with a three-~ong ~tmnded ~ ~ ~ ~ ~ ~ ~ plug, alway ..... it. ~ not use an adapt ..... the~ DESIGNED TO MEET UL 544 REQUIREMENTS tuats bs~ond nominal accepted ran~ss ~a~ the ~otmd pin. Always make sure the e~fipment ~ ~ ~ ~ ~9 ~ ~ U~, ff ~- turned OFF ~fore plu~ing it into t~ U~. Using an FOR MEDICAL AND DENTAL EQUIPMENT ~ tO ~ ~ ~. ~ ~ external surge suppre~r pluged into the O~P~ of the g~or m~a~ur~ m T~pp ~ Gus- UPS may cause the U~ to ~come overloaded when ~ ~ ~ ~ ~ UP8 ~ {~rating from batteW ~r. Since the U~ already has surge suppre~ion built in, a~ing extra surge su~ion ~ ~ ~' NOT recommended. With the UPS mined OFF, plug it into a ~ounded three- prong 120 Volt AC (VAC). ~ Hz. outlet that ~ constantly USIN~ THE UPS AS A $TAND-ALON[ ~wered. OmniSma, 22~ PNP can deliver 125OVA con- Muts/8.1f-~.sV ~a~h on~ i~tallation of the ~tiona[ NEMA 5-20P plug and connec- tion to a dedicated 20 amp circuit ~th NEMA 5-20R recep~cle to deliver i~ ~11 ~wer output. ~n~rm t~ ~r at the outlet d~s not rou~nely ~t shut off. The U~ intersen any AC line ~ilure as a blackout and ~11 s~tch ..... over to batte~ ~wer. Even with the connected equipment " turned off, the batte~ charge would slowly deplete. Turn the Master "ON~ Power S~tch ON. ~e Green "L~E the batteries for 2-4 houn kfore using the u~t. immediate imtallation and equipment connection ~ ~ssible; however, ira ~wer outa~ ~cuts kfore the batte~ is fully charged, , you may not receive hll batteW rantime, as outlined in the ', · s~cificatiom ~ction. W~n shutting do~ your co~uter ~ese mMeh have s~cial circui~ tht allo~ them to for tk day, you may use the m~ter "ON~FF' s~tch to k ~d ~ umu~rted ~er ~u~s. To ac~.te tk U~ shut down the connected equipment. as an umup~ed ~wet mrce, foll~ the ste~ L~t each piece of equipment to k protected (CPU, moni- ' tot, external drives, etc.) and iu nameplate-rated nttage or 1. Veti~ safeW ~ounding. Leave UPS connected -m . VA (volt-am~) draw. hcking up s~ndard printers h hfilding electrical circuit to main~in ~nd c~nuiW NOT ~ended nc~t in ce~n c~cfl a~lica- for ne~orks and to safeW s~eld the ma~ plug, unlm tions. ~ N~ BACK ~ ~SER PR~RS D~ qualified elec~ician or computer technician detemines T~pp Lite Sma~o® 7~ HG, ~niSm~TM450 HG, and ~niSm~TM 14~ HG TO ~EIR LARGE CURRENT DEM~DS. You that g~nd is not nedft. I UPS Systems and Isobar® 6 Ulna HG Surge Suppressor ~Y plug a I~r printer into any of the latemet ~ce 2. Move the "Master P~er S~tch" ~ the ~t panel to MMeh. Make sure the Interact ~ce UPS ~ connected to the "ON" ~ition. ~ ~ ~si~ to m~t UL 5~ s~cifications by alleviating le~age~umnt h~ a 120V AC oudet rated at 15 am~ capaciW. ~e lnternet 3. Hold the "Alarm Mute~elf-T~t" ~tch in the '~eSt" of Conn~tM equipment ~ce U~ mMels ate equi~d Mth 6 AC outlea divided ~ition momentarily. ~e U~ will ~vate and can ~ into t~ banh. ~ U~ ~ desired to accept connection ~ed as ah AC ~w~ ~urce for the time limia of the ~ ~ Hospital-grade AC outleB of a ~ica[ lair p~ter to any of the 3 WMte AC outleB internal batte~. { ~ Diagnostic LEDs provide advance w~ing a~ut ~tential ~wer pmblms that are la~led 'Sur~ ~ No~ Pranced". ~e~ outleB are surge and no~ protected only, but N~ batte~ ~ ~ UPS Systems feature built-in black~t. brownout. surge and line noig protection backup protected. ~ NOT connect a lagr printer to the ; ..................~-'--7 .~ ~ ~d i~lude ~EE ~wer-m~agement soRwe 3 black outle~ la~led "~t~ ~p, Surge ~ U~ ~'~f". ': '..'.'~"'~,,~:V: '~ P~te~. ~nect equipment to ~ batteW backup pro- ~.'5~' 8~ a '~Z ~' teeted to the 3 Uhck AC ~tleB. Make sure equipment ~:. ~ k~ ~ '~.~ that ~ c~n~ted to the Black outlea d~ not exce~ ~ ~ VA backup rating of the UPS. ~wer to the 3 Black AC outleu only ~atte~ backup protected outlet). ~e 3 ~ite outleB are unswitched, and su~ly ~wer to connected equi~ent at all times, ~ga~- UP~ OPE~TION le~ of ~ ~ition of the ~ s~tch on the U~. ~e UPS Systems use an easy to understand i~icator light only, multiply thh num~t ~ 120 to ~tain VA (ie: 1 amp they hahn. x 120 volu = 120 VA). Total all the watta~s ~ VA to obtain the TOTAL WA~AGE OR VA LOAD. ~ toul must ~ equal to ~ I~ than the total rat~ ~ut of the NOR~L OPERA~N {aR ~) U~.~f~tothel~lonthe~roftheUPSf~e~S Mains~r~pre~nt.U~k~i~htte~ready-~ ouput mt~, ~ch m listed in both VA (volt-am~} Green "LINE ON" indicat~ I~ht will ~ illuminated. ~ and ~.~e U~ should ~ ~iti~ed at le~t 6 inc~s Red "BA~UP ON" indicat~ light ~H ~ O~. away from any tonitots or fl~y d~h, except for lnte~t ~ ~ L~'S F~B~.~flV~E A~ {~} 75~ ~ ~E~ ~E~ ~7. ~ 420 .~, ~ch ~ &ai~ to ~ phced und~ , OPE~IATION DURING POWER PROBLEMS Audible ahrm cm~ t~ heard (on m~dels so eq,,ipped). ' .... Trlpp Lite SmartPr0®Net UPS All UPS Systems provide spike, line mfi~ and RFI~MI Red "I~ACKUI' ON" iudicatot lidr will blink. ~e Green ~ltefing (~ "S~ciGcations" ~ction). ~is eliminates the "LINE ON" indicator light will ~ OFF. On m~els .red fi~r a separate surge surrender. equip~d with a "I.OA!)" lid~t, this light nmy nr may not ~ illuminated, dC~nding on the amount o/current drawn ~ UNDERVOLTAGES/OVERVOLTAGES connectedequipment. ~e Yellow "Batte~ ~" light will illuminate when there is a~toximately 2 minutes ~ (Bc pe~nll~c I~le~Ulnlernet ~¢I~C pRO) batte~ ~wet remaining (on mdeb ~ equi~d). ~e When an undervoltage or an ove~oltage ~curs, the alarm ~lt al~ ~und when th~ ~o minute warning ~rid ~.~ ~ PERSONA~ INTE~ETflNTE~ET OFFICE/ is reached. ~e alarm cannot ~ silenced during the last ~ PRO ~ll automatically switch to batte~ ~r in 2-4 2 minut~ of batte~ capaciW. W~n th~ 2 minute ~ming ms. (~ical). ~mplete protection ~ pr~ided, but the ~cuts, shutdo~ shouM ~n immediately[ equipment should ~ shut do~ as ~n ~ psihie to protect ~ainst excessive battaW drain. htte~ ~ ~ing UP~ ~OO[~ WffH INetUOEO discharged and converted to AC power. Audible 8H~O~ SO~[ ON eD-ROM alarm will sound (on mMels so equipped). Use the "Alarm~ute" switch to silence the alarm. The Red TrippLite~Prol050, EProl~andallOMNISMART "BACKUP ON" indicator light will blink. ~e ~een "LINE PNP UPS mMe~ include P~etAle~ sh~d~ ~te ON7 indicator light ~11 ~ O~. on CD-ROM plus ~bling for autotic file savi~ and - ~en AC ~wer returm to nodal, the ~ PER~NAU unattended system shut~. ~mplete imtr~m on K INTE~ETBN~ O~IC~ PRO ~11 aut~ ~f~re imtaHa~on are confined in t~ ~D ME~ file matically tramfer ~ck to the mains. ~e batte~ ~11 ~n of the CD-ROM. chafing. A 5 ~c~d delay will ~cur ~fore t~ U~ OMNISMART PNP mMels a~ work ~th Windo~ 95 --- ' UNDERVOLTAGES/OVERVOLTAGES disruption. / - (OmniSma~) ~ "S~c~ ~ ~e~" ~or more in(o~ation on unattend- O~NISMART models regulate voltages to provide ~temshmd~thP~rA~rtU~m~it~re. smother, mo~e prec~ vdtaF te~lati~. ~ The 0nil UPS That Can vol(a~s ~thout using ba~e~ ~wel. ~wing ba(le~(Poor in, B~e~ & Che~ ~ mill ~wu allo~ lot loner ~ra~on dung ~d~ of total qUi~d ~ "A/~ Mie/h~-Ti S~ch) : ...,,_ .............................. ......., .........Manage Egg UPS When an undervoltage or overvoltage occurs the ~ CAUTIONI N N~ PULL ou~ut vol~ ~th~t using batte~ ~wer. ~e Green ' "L~E ON" indicatm light ~tl ~ illuminated. ~e ~een 1. Allow the U~ to fully char~ i~ ~tte~ for a ~d ~ ~olt ~ect" indicator light ~11 ~ illuminated. U~ 4-6 hou~ under ~rmal utiliW volta~ conditi~. ~ still keeping hue~ ready. 2. Plug a simulated ~ into the U~ equal to When a ~vere unde~olta~ ~ ove~oltage ~curs, the equip~nt load (VA draw}. A r~k~ve I~d eq~l to t~ Freesyou from the limiB of purchasing pmprie~ hard~re and soRware. OMNISMART aut~atically s~tch~ to batte~ per (in VA draw of the equipment can ~ s~ulat~ ~ mt~ ~ Sma~Pro NET Intelligent U~ S~tem Is the on~ UPS that ~n manage 3-6 ~. [OMNISMART 22~} or in 2-4 ~. fall o~er ical incandeKent h~ld li~t bulM. Simply m~ the all the UPS s~tems ony~r networkl OMNISMART m~eb]). ~mplete protec~on ~ provi&d, watta~ off each bulb and add t~ther to ~roximate ~ but the equipment sh~ld ~ shut down as ~n ~ ~ible watta~ draw of the equ~ment that ~ gaily $~. d~hatged and c~vened to maim ~r. Audible alum mu~, ~ ~e U~ ~ ~t ~t overh~d.) . roll ~und. U~ the "Ala~ute" s~tch to silence the SimPlifies network Po~F ~a,a~e~e,t. O.C FREE PowetAletl PI~ CD-ROM ~r~ with all alum. ~e Red ~ACKUP ON" indicator light ~11 blink. 3. With the li~t ~t ~m~ ~ ito the U~, mm~dly mo~ the "Ala~ mute~lf-T~t" ~tch to of your o~raiing s~tems to diagnose Power ~toblems kfore lhey ~come nelwork Problems ~e Green "LINE ON" indicator light ~11 h OFF. the "~lf-Test" ~ition, then ~lel. ~e ~lf-t~t ~ll ht When mira ~wer retu~ to nodal, OMNISMART ~11 for 6 ~c~. ~ mdeb ~th a "~d" indicator li~t, thk automa.caaly t.mfe, back to t~ maim. ~e ~(te~ roll light may or may not ~ illuminated ~nding , t~ ·Evc Power Problem ~;n char~. el~al s~e of the connoted I~d. ~e ~tte~ ~t) ~eplace" li~t ~ll illuminate a~ ~ ata~ ~H ~nd Pr~erves net~rk uptime through ~er~ ~r problem, 5~s~ur data and e~ulpmcnt ONLY ·the ~tte~ is in ~r c~it~n. If the "~ltte~ I ~th reliable battery backup. line conditioning and surge suppre~lon (Bat) Replace" I~ht ilhm~ates aM the ala~ $&, tMy will only stay on for the duration of the ~-tut. ~ng t~ hated ~ the U~ ~rates off httew ~r. Ill I I 16 El I I$ SO, O O O 4. when the ~lf-test end, the c~t sh~ld aUt~ati- cally ~ techar~ the htte~. ~e ~en "L~e ON" 5. lfthe"Bar~Replace"li~twi~tumtnatddu~ngt~ B~CKO~S ~lf-test. let the UPS c~ iu ba~ ~ lZ bonn, the M~ available from 2~VA to ~00VA. 220-240 ~WS0Hz m~els also ~aila~ Maim ~er ~ off ~ ounce the c~ec~oA ran~, BattoW ~t step 3 a~ve. If the "~tte~ (~t) R~l~e" ind~tm F$ ~E I~MAT~ ABOffi ~R FULL L~E ~ SMAR~ NH $ SYSTEMS is ~ing ~. ~ d~harged oBverted to AC line ~r. li~t tu~ ON ~in and the alarm ~un~ dudfig t~ C .. · the first of two messages on screen. A message states that ' or batte~. When all tesB are completed, unplug the tighton batte~ ~wer. bulb fixtures. if the unit fails testing, ~nd it back fin repair. SMARTPRO DATACENTER UPS SYSTEMS ~ TRIPP U~ ~ 2.1 SPECIAL I sN SECTION ~ the UPS o~rates off i~ internal batteries, citcui~ in the unit monitors (he gamut volt~. When the baRe~ With a U~ iratailed on a ~, any resident data in the voita~ dr~ to a certain ~int, the unit transmi~ a ~cond .o, o,; .o Multiple Hetw0fk Pf0tectie Single Purchase Convenience since the UPS allows ample time for the ~mtor to execute~ftware receiv~ the s~nal and d~pla~ the ~ond rues- ' an or~rly, complete shutdown. ~e U~ ~n al~ tell the sage, stating that ba~te~ v~m~ ~ drying and automatic, ~ · ~N ~o shut i~lf down if the ~ ~ ~ui~ ~th orderly shundown is beginning. Shutdown will ~cur s~cial U~ monkSrig ~f~a~. ~ Pro 1050, ~ 1~ whether t~ ~s~em ~ a~tended or unattended. ..a ~. o~s~T mP ~ ~.~.a~ vo.~A~.. E~ended-Run UPS System s~utdo~ so[~are on CD-~O~ plus cabling ~or Novell, ~N~ON ~3 - PR~DED t · ~inaows 95~indo~s NT~inaows 3.1, OS~, ~am, ~ TRIPP U~ ~N ~.1 * Emergency Shutd0wn And Power-Monitoring Software ~[X, HP-~, HP ~nview and ot~r ~ra~g ~ste~. T~e monitoring ~tware can ~aNmit a s~al to the UPS, [mm~cdons for instaltin~ and c~Ggudng t~e P~e~Alert stad~ MN shu t~ ~as ~uffed. ~e U~ receives t~ ,~.~ .~ ~o.,.~.~a ~. ,~ "~D ~E" az. a ~ cD- .~.~ ,.a ..~,. ,. ~.~ ~ o~ ..a ,~. ,~h. N0vell SNMP Agent ROM. If you have a different ~rating system than ~ hck ~ AC line ~et. ~en AC line ~r b r~t~ed, ..w-~ ~ ,,~ cD-~o~ o, ..~ q.~,.o~ .~ ,h. ~,. ~ ~,,., ~h.m~ ,- ~.-~.-. ~ ~,~ -~- ~ Cabling For Up T0 4 PowerAlert shutdo~ ~are ~ CD-ROM, call Tdpp two functi .... It p,~.. ~"~ 5..~.. ~,o~ ~.'., Connected Systems Lite's Cmtmer ~ce ~partment at (312) 755-5~1. deeply dkhargM and thus reduces recharge t~e; and it ~s ~ual appli~ to ~ 2.1 ~S Systm ~ly. also helps provide ~tte~ tese~e in t~ event of multiple AU the ~ mMeb in t~ ~al are S~ Ve~ion ~wet failures over a short time ~riM. SmmPro DataCenter UPS Systems ~e I & 2 compatible. ~ 2.1 u~s ~t~latots and dw con-tac~ and ~rates ~thin voltage ranges of 3 to 20 volts s~i~cally designed to solve the ~wer at 10 milliam~ ~th NEC class 2 limitations. MN 2.1 MOST POPUI ~ laN SO~E ~D problems of m~em networks. With four cabling can ~ conriFted according to the s~cific needs CABLING AVAII IRLF FROM YOUR individual LAN ~s to connect up to of the user, eider ~ntact ~ni~ or c~tact citing to a ~lPP ~ RESEL1 WR four different sewe~, DataCenter Systems common circuit. Tripp Hte recommends the use of Part No. ~dpdon ~mS~eld® ~ine Sure Sup~o~ for any net- let you sup~ your entire network from work imt~don. 75-I~5 Uni~sal P~erAle~ m~ware and cabling. Su~r~ N~ell, Win~ ~, Windo~ a single UPS. And with the included FUNCTION ,1 - PROVIDED 95. Windows 3.1, OS~, Wa~, MN ~rver, PowerAlert® BY TRIPP UTB ~N 2.1 ~IX, HP-UX. etc. CD-ROM and ~en a U~ ~ c~nected via cable to a file ~er or h~t 75-0195 Unive~al PowerAlan PLUS ~are and connoting cables, that has ~,a~ which moniton ~tation o( the U~, ca~ing. Sup~tu Novell, Windo~ NT, data protection ~ enhanced. ~ng a ~wet ~ilure, the Windows 95, Windows 3.1. OS/Z, Warp, you'll get eve~- cable ca~es a signal to the file ~rver or host ~m the U~. ~N ~rver, SIX, HP-UX. HP ~nview, etc. thing you ne~ to Incl~ SNMP aFnt. protect your entire network in a single ~ ~ ~ purchase l AN 2.1 SC~MgIC D~GRAM ~ , .3 P~ 1 Commn/NqatNe M ~ ~ '" . m s · Hot-swappable batte~ Pm a ~.m.I inv~ ~os~ S~ packs for unlimit~ ~ntimes P~ 3 U~ fail O~ ~m~ · 3KVA & 5KVA m~els super all P~ 4 Retumldemal Invest Sh~d~ Sac your ~uipment from a single UPS P~ 5 u~ Fall CIo~ C~ · 4 LAN ~ns monitor up to 4 of 2-MI~e WmI~ Ck~ ~ ~ w ~ different switches, se~ers or ~ voice-mail systems · ~ · $75,~ Ultimate Lifetime Insurance :' ...... ~" ~ ~ · ~c~ lower th~ any other UPS senslUve on~e'2-mlnute© ~ ~ ) ~em+n~ .,, ~;:~ ~,,~~ System in i~ class~ 5 ; .-; .... ~ ,~ . ~';~. :, - , ~ ~ ~ ~ ~(312)7~~ST~E~. ~~L 9 6 Data Shield .,,.. L,,. Superior Surae SuppressionBeat Inconsistent Power! ' ;' for Network Cable Runs ~"',... "Providing protection against power-line surges at the power- Do.,,put your valuable com- -- ."-, ~"'.-,.,,,,,~ line interfaces of devices linked by a data communication -.7..'--, "'~..~ '--,,,.,.. circuit does not gl~araRtee that sl~rge$ occurring in the power- puter equipment and data at -.:'.~-....-7."-~'~'.....,.. line environment will not cause damage to the devices. " .sklTrippLiteLineConditioners ll2/rjJLl3:l:[~] ~ ~' .~'-~-~-:'.,' ~-'. A more comprehensive protection scheme, regulate incoming power, while ~ the dat ~-~ '" coordinating both the power line and . -~ ..... - J' they protect against power ' ' ~ ~ ' a line, is required SUrgDS and line noise, to deliver ' to ensure protection." " --National Bureau of Standards dean, filtered 120V AC power - even when utility power is unre liable. With 87% of all power :~i'. ~'''' ' problems resulting from brown- A minor investment in data communication DataShield Network Surge Suppressors afford to stay unprotected! line-surge protection can provide major redudions Give You High-Performance Protection: All Tripp Lite Line Conditioners in garbled transmissions, system lockups and · Odd-plated contacts provide superior provide consistent power regu- damaged hardware down the road. DataShield conductivity for all data transmissions lation, surge and line noise Network Surge Suppressors end the threat of · Soldered-~'ound wires deliver the best suppression a, nd are backed dataline surges. Installed directly at your data surge-clamping levels available pods, they proted your computer's delicate internal · Balanced arrays of hi~-speed avalanche diodes by up to $25,000 Ultimate circuilry with up 1o 300% more surge-absorbing dived excess energies away from network Lifetime Insurance for conhealed i ~t1~, i,,, power than competitive models. With DataShield components for superior surge suppression equipmenL Surge Suppressors in place, your network · 17 different models from which to choose computers stay protected, and your data passes through cleanly for more reliable network use. BE CAREFUL! why N,t,,,,,,, F-. Sial.i.O.t., Roe Brownouts and overvoltages can occur in any power environment. ... ... Some common causes include: ~ · Ughtning Storms · Widng Problems IBII~ · Refrigerators, Air Conditioners or Other Heavy-Draw Equipment IIIIlll · Laser Pdnters · m..~,.,,,,,,~,h.,,.,.e,,,m,., FEATURES -~ .,,,~e,~, h..te, =.~,,d,d ~ d,..~s Fo..d, ~/ . /Automatic Voltage Regulation (AVR) adjusts incoming voltages from 87 to 140V AC* back .,-.i,~- the ,,,~,,,,, .~-.t .~h ~ :o ~ to 120V AC nominal within ANSI C84.1 specffications -- Suddenly. neiwork cabling is a dired palh to a ~mer"ground rderrnce. Like waler flowing downhill, surgeenerg~seeksoul ~ Built-in surge and noise suppression elminates the need for an additional surge suppressor t~s path ~o ~t to ,,h Together with Tripp Ute's advanced AC surge s' ,/From panel LEDs alert you to current power conditions' -- Rrst edtir~ ~ara~ ~ mt, era~ ire driver dd~, s,~e ~ suppression and UPS solutions, DataShield goes off to dam i~lo ret'dm' drrdits of cot, healed eqeipmeM ~# d~s,~ted Network Surge Suppressors represent an / Models from 600 to 2400 watts - including rackmount versions! -- Ur, e dr/m' ~d rece/wr dradts ~, deerate or r,/-~wterp~t irapedant part in any network protedion strategy. *220/240-volt model from 168 to 278 vdts AC _ Troubleshooting Guide SYMPTOM PROBLEM CORRECTION , not present ~ Hz. o~let. Tum "Master P~er" ~tch ON. "Une Pow~" light should During a bla~o~ or simulation ~e~ e~remely depl~ed or Allow UPS to ch~ge ~eri~ of a blacko~, the "~ Low" ne~ end of ~s life cycle for 12 hour, t~n ~e ~ff-t~t indictor light blinks briefly, b~tion to det~mine st~e of then UPS o~p~ sh~s do~ and ba~e~. ~ '~ Replace" light the indictor light turns off. s~ OFF during tBt, No ~wer is present at UPS o~lets condffion is Btisf~o~ "Ba~ Low" indictor light Ba~e~ near ~d of its life cycle Re,at seffitest. If "BaU~ illuminat~ and ~e audible R~la~" IIgM illuminates alarm sounds dudng a seffitest audible a~ sounds again indictor light and alum turn OFF 'repla~ment is after seffitest ends De~nding on t~ o~c~e, have ~alffi~ t~ load test ~e~ "Load" indicator light (~em ~erbad condition e~s R~uce load on UPS ~uip~) com~ ~ during as ~ss~le unffi "Load" seff-t.t or duri~ ~e~ indictor light g~ OFF o~ration A~ays ~11Tdpp Ute Custom~ Sup~ at (312) 75~01 ~f~e sending any UPS S~ ~pme~ in f~ se~. DC to AC Inve~ers From Tripp Lite Reliable 120-Volt Power Andhere You Need It ,, 'T --,.. saws, sanders, solde~n~ ~ns, test I operate ~thout the nolo, smell or equipment and motel I Come In a varl~ ~ sizes - from 125-waft ~wer models (24 VO" also available) AT (312) 7~ ~ RE,ST ~ ~1. 16 M 4/6 M 4/6 M 4/6.1 M 4/6.T Spacing6 ram+ 0,05 (.238') ~ COlOr coded (~ Sp.cing 6 mm+ 0,05 (.238') Spacing 6 mm+ 0,05 (.238') For more detail, see pages 1.6-1.7. Spacing 6 mm+ 0,05 (.238") · 1.75" w .71 ' center of rail C.J I,~ 18 · · _.., 1,r 23 .91 ' M 4/6 with 1 screw-socket Standard 6 mm block Standard 6 mm block M 4/6 with partition DIA. 2mmt.079" on the Hght Grey body Blue M 416,N 1~ 11&01. Grey body Grey ~dy M 416 115 11&~ Beige M 416 1~ 11&M M ~6,1 115 ~,~ M ~tT 115 Yellow M 41~ 1~ 11&16 Green M416 Orange M 416 1~ ~ Red M 4/6 1~ llS Black M 416 1~ M1,14 0-4 mmz 22-10 AWG 22-10 AWG ~4 mmz ~4 mm~ 0-4 mmz ~4 mmz 22-10 AWG 04 mm~ __ 22-10 AWG 22-10 AWG ~4 m~ ~4 mmz 22-10 AWG 0-4 mmz ~4 mmz 0-4 mmz 0-4 mmJ ~4 mmz 0-4 mm~ 0-4 mmz ~4 mmz 750 Gr.C ~ ~ ~ Cat. C 750 Gr.C ~ ~ ~ ~t.C 7~ Gr.C ~ ~ C~C 7~ Gr.C ~ ~ ~t.C 9~ Gr.C ~ Cat. C ~ Gr.C ~ CaI.C ~ Gr.C ~ Cat. C ~ Gr.C 5~ C~.C 35 30 i 25 ~ 35 30 25 ~ 35 30 ~ 35 ~ 4mmJ 10AWG { 10AWG 2,Smm~ 4ramz 10AWG 10AWG 2.5mmJ 4mmz 10AWG 2,5mmz 4rama 10AWG 2,Smmz ~1 ~ 1B ~.~ ~1 ~ 1~ ~.~ ~1 ~ 1~ ~.N ~1 ~ lg ~.~ ~ ~epunch~ 1~ ~.N ~ prepunch~ 1~ ~.~ ~ prepunch~ 1~ ~.N ~ p~pu~ 1~ ~ ~4 1~ ~.12 ~4 1~ ~.12 ~ 1~ ~.12 ~4 1~ ~.12 ~ prepu~h~ 101 ~ ~ p~pu~h~ 101 g ~ prepu~h~ 101 g ~ prepu~ 1~ g ~M th. 9,1 mm 1~ ~.26 · BAM ~. 9,1 mm 1H ~.26 ~ th. 9,1 mm 1H ~.H ~M ~. 9,1 mm 1~ ~ ~ ~.2,Smm 118~16' ~ ~.~Smm 118~1S ~ ~.2~mm 118~16 ~M6 th. 2,5 ~m 1H ~.21 ~M6 ~. 2,5 mm 103 126.16 ~ th. ~5 mm 1~ ~10 ~M6 113 ~.10 ~ 113 ~.10 ~ 113 ~.10 ~ ~.3mm 1187~.~ ~ ~.3mm ~18~.~ ~ th. 3mm 118~.~ ~ ~.3mm 118~.g ~F6 th. 3 mm 128 707.~ ~ th. 3 mm 1~ 707.~ ~ ~.3mm 114~.N ~ ~.3mm 114E~ ~ ~.3mm 114E~ ~ ~.3mm 114;I A~ (1) DIA. 2 mm _1~ ~.21 A~ (1) DIA. 2 mm 1~ ~.21 ~ DIA. 2 mm 1~ ~21 ~ (1) D[~ 3 mm lg ~I.~ ~ (1) Ol~ 3 mm 1~ UI.N ~ DI~ 3 mm lg ~1.~ ~ yeli~ 173 ~9.03 ~ yellow 173 ~9.~ ~ yell~ 173 ~ (1) 2 poles I~ 518.25 ~M6 (1) 2 poles 1N 516.H ~M6 (2) 2 poles 1~ 516~ ~ (1) 2 ~les 1~ 516~ ~ (1) 4 poles 1H 518.07 ~M6 (1) 4 poles 1~ 518.07 ~M6 (2) 4 poles 1~ 518.07 ~ (1) 4 poles 1H 518.07 ~(1) 5 pdes 1~519.~ ~(1) 5 ~ie lg519.~ ~(2) 5 polea lg519.~ ~(1) 5 ~les 1N519.~ ~M6(1) 10 poles 1~973.07 ~(1) 10 poles 1~ff3.07 ~(2) 10 poles 1~.07 ~M6(1) 10 ~les 1~9fi.07 E~ 173 ~.21 E~ 1~ ~21 E~ 1~ ~21 ~ 1~ ~ (1) 20 ~les (~ a~m,) ~ (1) 20 poles I~ ~.) ~56 (2) 20 poles (me.) ~ (1) 20 ~les (~ ~,) ~(1) I~.) ~M(1) (m~) ~M(2) (m~) ~(1) ~DP ( 1 ) (m a~s.) ~DP ( 1 ) (mm.) ~DP (2) (se ran.) ~ ( 1 ) (se ~ 174 413.14 ~ 174 413.14 I 174 413.14 '~ 174 41~14 ~ 114~ ~ 114~ ~ 114~ ~ 114~ ~ 4 bl~ 1~ ;.17 ~ 4 ~ 1~ ~.17 ~ 4 M~ 1~ ;,17 ffi 4 ~ 1~ ;,17 (1 } Admit mrmr ~ mW ~ reui~ wiffi ~e ue of the~ (2) ~ of meH a~rie ~uims the u.r m cut out ~e pa~Uon. Limit Switches Type C -- Single Pole & Two Pole Selection Information Class 9007 All Type C Switches Are Rated NEMA Type And UL Type 6P · ~'k: ".' Side Plunger Type Lever Am Tyl>e Select Neutral Position Side Side Side Side "[---j' Turret Extra Roller Push Push Push e ~ Head Standard Low Light Plunger Rod Rod Rod F Pra- Differ- Standard Standard Low Operating Main- Spring Plunger Plunger Plunger travel entiai Pre- Pre- Differ- Torque tained Retum Spring Adjust- Main- Select Spring Spnng travel travel eatfat Corttacl Basic Return Return Spring Spring Spring Spring Vertical Return abtal mined Return Rolled Spring Contact Switch Retum Return Return Type /,.~. Return ~ CW & CW & CW & CW & CW & CW & CW (Trip) ~ ,a~ (~ CCW f~ · CCW~ CCW~ CCW CCW CCW CCWi (Reset) Contacts Type Type Type Type Type Type Type Type Type Type Type 1 N.O. C54B2 C54A2 C54N2 C54C C54F C54G C54GD C54H I N.C. $88.00 $95.00 ......... $107.00 $107.00 $115.00 $104.00 S109.00 5122.00 2 N.O. C62B2 C62A2 C62N2 CG2C CG2F CG2G CG2GD CG2H Standard 2 N.C. 107.00 112.00 ......... 125.00 125.00 134.00 122.00 127.00 140.00 Box Plug-in 2 NO. - 2 N.C. CG4BWA CGaT10 CGST5 Neutral Position ...... $112.00 Sl 20.00 .................. 2 N.O. - 2 N.C. CGGB2 CGGA2 CGGN2 C6GF C6GG CGGGD Two Stage 125.00 140.00 ......... 143.00 "' 147.00 133.00 147.00 "' Compact t N.O. C52B2 C52A2 C52N2 C52C C52F C52G C52GD C52H Box 1 N.C. 88.00 95.00 ......... 107.00 107.0Q 115.00 104.00 110.00 122.00 Plug-in UL Listed for I N.O. CR53B2 CR53A2 CR53N2 CR53C CR53F CR53G CR53GD CR53H Hazardous INC. 161.00 1G7.00 ......... 180.00 180.00 189.00 177.00 T83.00 194.00 Location Class I Groups 2 N.O. CR61B2 CRG1A2 CRGIN2 CRGIC CRGIF CR61G CRG1GD CRGIH B,C,D 2 N.C. 180.00 186.00 ......... T99.00 199.lD0 202.00 194.00 202.00 213.00 Class II Groups · E, F and G 2 N.O. - 2 N.C. CRGTT10 CRGTT5 See page 17-94 Neutral Position ......... 199.00 204.00 .................. for Aclditional Hazardous 2 N.O. - 2 N.C. CRG5B2 CRGSA2 CRG5N2 CRG5F CRG5G CRGSGD Location Two Stage 199.00 204.00 ......... 216.00 "' 219.00 213.00 219.Q0 "' · Information I N.O. CF53B2 CF53A2 CF53N2 CF53C CF53F CF53G CF53H 1 N.C. 105.00 104.00 ......... 1T8.O0 118.00 139.00 114.00 "' 135.00 2 N.O. CFGIB2 CFGIA2 CFG1N2 CF61C CFG1F CFGIG CF61H Rush 2 N.C. 118.00 125.00 ......... 140.00 140.00 150.00 135.00 "' 157.00 Moundrig 2 N.O. - 2 N.C. CFGTT10 CFG7T5 Neutral Position ......... 124.00 130.00 .................. 2 N.O. - 2 N.C. CFG5B2 CFG5A2 CFG5N2 CFG5F CFG5G Two Stage 140.00 147.00 ......... 161.00 "' 171.00 157.00 ...... Held Type B A BWA T10 T5 N C F G GD H Onb/ Number 27.50 33.50 $27.50 27.50 33.50 45.70 45.70 55.00 42.OO 48.70 61 Pre-trevel 10° 5° 10° 10° 5~ 10° 45° .08" First 10° 5° 10° Pre- Stage ............... travel Two First to Stage Second 2~/2° 1 V2° . ........ 2V2° ... .02' ... Stage Total Travel 90° 90° 90° 90° 90° 90° 90° .25" Nominal Differential 4° 2o 4° 4~ 2o 4° ... .03" ... Operating Data Reverse Ovenrevel 90~ 90° 90° OO° 90~ 90~ · ........ Operating Torque/Force - 41b-in 41b-in 4ib-in 41b-in 41b-in 2.5oz-in 31b-in 4lbs. 71bs. I Pole & 2 Pole Repeat Accuracy - Linear travel of cam ~.002' +_.001. :1:.002" +.002" _+.002' +_.002" _+.002" .001' ... (1V2' lever arm) Plug-in Replacement The basic switch and head but lees the plug-in receptacle can be ordered by substituting the letters "CO" for the first ~C" in the type number. Units Example: Open type replacement for Type C54B2 is 'Eype CO54B2. · These devices are factory set to operate the contacts in both the CW end CCW 1' Can be converted lo horizonlal roller type in the field. To order horizonlal roller version directions Mode ot operation is field convertible to CW only or CCW only. To order add 1he letter "H" at the end of the equivalent Vertical roller version type number facton/converted devices - for CCW only operation. change the '2" at the end of the (Example: C54F woulcI become C54FH). type numder to '1" (Example: C54B2 becomes C54B1 ) -for CW only operation, delete · To lock the nut in the desired position, crimp the slot near the bottom of the nut. the "2" at the end of 1he type number (Example: C54B2 becomes C54B). · This device is obsolete ar~ has been replaced by ]~ CGaT10. Complete davice~ are dimensionally and functionally equivalent a~are interchangeable. However. Mode Change - Lever Arm Type components are not interchangeable. Customers requiring replacement compenenLs for Mode of operation is easily convertible to Clockwise, ClxtnlercIockwise, or both. Simply pole1 the obsolete Type CG4BW may order: the arrow to the letters representing the desired direction - CW. CCW, or CW/CCW. All pens are captive. Head Only -Type BW -$27.50 m~ Plug-in unit only -Type COG4 .-$79.O0 ~ Note: All available replacement parts are shown in BOLDFACE. Lever Arms ............................... Pages 17-14, 17-15 Dimensions .................................... Page 17-1 Selection Mode Arrow / Application Data ................................. Page 17-5 Acceptable Wire Sizes: ............................ 12-22 AWG Electrical Ratings ................................. Page 174 · Recommended Terminal Clamp Torque ................... 7 in. Ibs. Special Features ............................ Pages 17-2, 17-3 T '~ ~ T i MOSCADTM Remote Terminal Unit Owner's Manual 68P02994G10-B t ! '/ i ~ COMMERCIAL WARRANTY (STANDARD) Motorola radio commumcations products are warranted to be free from defects in material and workmanship for a period of ONE (1) YEAR, (except for crystals and channel elements which are warranted for a period of ten (10) years) from the date of shipment. Parts, including cryslals and channel elements, will be replaced free of charge for the full warranty period but the labor to replace defective parts will only be provided for One Hundred-Twenty (120) days from the date of shipment. Thereafter purchaser must pay for the labor involved in repairing the product or replacing the parts at the prevailing rates together with any transportation charges to or from the place where warranty service is provided. This express warranty is extended by Motorola Communications and Electronics, Inc., 1301 E. Algonquin Road, Schaumburg, Illinois 60196, to the original purchaser only, and only to those pUr-_ chasing for purpose of leasing or solely for commercial, industrial, or governmental use. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED WHICH ARE SPECIFICALLY EXCLUDED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PAR- TICULAR PURPOSE. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW. In the event of a defect, realfunction or failure to conform to specifications established by seller, or if appropriate, to specifications accepted by Seller in writing, during the period shown, Motorola, at its option, will either repair or replace the product or refund the purchase price thereof, and such action on the part of Motorola ShRII be the full extent of Motorola's liability hereunder. This warranty is void if: a. the product is used in other than its normal and customary manner; b. the product has been subject to misuse, accident, neglect or damage; c. unauthorized alterations or repairs have been made, or unapproved parts used in the equipment. This warranty extends only to individual products, batteries are excluded, but carry their own separate limited war- ranty. Because each radio system is unique, Motorola disclaims liability for range, coverage, or operation of the system as a whole under this warranty except by a separate written agreement signed by an officer of Motorola. Non-Motorola manufactured products are excluded from this warranty, but subject to the warranty provided by their manufacturers, a copy of which will be supplied to you on specific written request. In order to obtain performance of this warranty, purchaser must contact its Motorola salesperson or Motorola at the address first above shown, attention Quality Assurance Department. This warranty applies only within the United States. EPS-27734-O COMPUTER SOFTWARE COPYRIGHTS The Motorola products described in this instruction manual may include copyrighted Motorola computer pro- grams stored in semiconductor memories or oth'er media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer pro- grams contained in the Motorola p~'oducts described in this instruction manual may not be copied or reproduced in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive, royalty free license to use that arises by operation of law in the sale of a product. EPS-34440-B (~ ,o,,>.o~, MOSCADTM ,~,~ ,~0~ P~0~,~,, s~,o~Remote Terminal Unit © Motorola Communications Israel Ltd., 1992 Land Mobile Products Sector A subsidiary of Motorola Inc. 16 Kremenetski Street, Tel Aviv 67899 All fights reserved. ~ Owner's Manual Printed in Israel, February, 1994 68P02994G10-B CONTENTS INTRODUCTION ................................................................ 1 1. SCOPE OF THIS MANUAL .......................................................... 1 2. GENERAL DESCRIPTION ........................................................... 2 2.1 RTU Basic Models ........................................................... 3 2.2 Modular Bus and Housing ..................................................... 3 2.3 CPU and Communication Interfaces .............................................. 4- 2.4 I/O Modules ................................................................ 5 2.5 Power Supply and Battery ..................... ................................. 5 INSTALLATION ................................................................. 7 1. GENERAL ........................................................................ 7 2. WALL MOUNTING WITH HOUSING .................................................. 7 3. WALL MOUNTING OF RTU WITHOUT HOUSING ...................................... 10 4. PLUG-IN MODULE INSTALLATION .................................................. 10 5. ELECI~ICAL CONNECTIONS ........................................................ 11 5.1 Ground Connection ............................................................ 11 5.2 Power Connections ........................................................... 11 5.3 Radio Connections ..................... ' ...................................... l 1 5.4 User Connections to I/O Modules ................................................ ! 1 5.5 Interconnection Diagram ...................................................... 12 6. PLUG-IN MODULE REPLACEMENT .................................................. 13 6.1 Module Removal from RTU .................................................... 13 6.2 Module Insertion into RTU ........................... : ......................... 13 7. MODULAR BUS DISASSEMBLY ..................................................... 14 7.1 Motherboard Removal ........................................................ 14 7.2 Removal of Module Slot ....................................................... 15 8. FIELD REPLACEABLE SPARE PARTS ................................................ 15 CPU MODULE .................................................................. 17 1. OVERVIEW ....................................................................... 17 2. INSTALLATION .................................................................... 18 2.1 Module Location ............................................................. 18 2.2 Battery Backup for RAM . ............................................. · ........ 18 2.3 Electrical Connection ......................................................... 18 3. CONTROLS. INDICATORS AND CONNECTORS ........................................ 19 4. REMOVAL AND INSTALLATION ..................................................... 21 4.1 Module Replacement ......................................................... 21 4.2 Lithium Battery (6008261C04) Replacement ....................................... 21 5. FIELD REPLACEABLE SPARE PARTS ................................................ 21 68P02994G 10-B © Motorola Inc., 1992 February, 1994 16 DI, 2 COLINTERS MODULE .................................................... 23 1. OVERVIEW ....................................................................... 23 ~ 2. INSTALLATION .................................................................... 24 2.1 Module Location ............................................................. 24 * -2.2 Electrical Connection .......................... ~ ............ ' .................. 24 2.3 Module Replacement ......................................................... 24 3. DIAGNOSTIC LEDS ................................................................ 26 4. FIELD REPLACEABLE SPARE PARTS ................................................ 26 16 DO MODULE ................................................................. 27 1. OVERVIEW ....................................................................... -27 2. INSTALLATION .................................................................... 28 2.1 Module Location ............................................................. 28 2.2 Electrical Connection ......................................................... 28 2.3 Module Replacement .......................................................... -29 3. DIAGNOSTIC LEDS ................................................................ 29 4. FIELD REPLACEABLE SPARE PARTS ....... ; ........................................ 29 8 AI MODULE ........ , .......................................................... 31 1. OVERVIEW ....................................................................... 31 '~ 2. INSTALLATION ................................ : ......................... ' .......... 32 2.1 Module Location ............................................................. 3-2 2.2 Electrical Connection .......................................................... 32 2.3 Module Replacement ......................................................... 32 3. DIAGNOSTIC LEDS ................................................................ 34 4. FIELD REPLACEABLE SPARE PARTS ................................................ 34 4 AO MODULE .................................................................. 35 1. OVERVIEW ........................................................................ 35 2. INSTALLATION .................................................................... 36 2.1 Module Location ............................................................. 36 2.2 Electrical Connection ......................................................... 36 2.3 Calibration .................................................................. 36 2.4 Module Replacement .................. ; ...................................... 36 3. DIAGNOSTIC LEDS ................................................................ 36 4. FIELD REPLACEABLE SPARE PARTS ................................................ 39 MIXED I/O MODULE ............................................................ 41 !. OVERVIEW ....................................................................... 41 ' l(''''~. 2. MODEL OPTIONS .................................................................. 42 3. INSTALLATION .................................................................... 43 3.1 Module Location ................. : ................................. : ......... 43 3.2 Electrical Connection .......................................................... 43 3.3 Module Replacement ......................................................... 43 4. DIAGNOSTIC LEDS ................................................................ 46 5. FIELD REPLACEABLE SPARE PARTS .......................................... : ..... 46 ' 16 AC DI MODULE ............................................................... 47 1. OVERVIEW - .................................................................... 47 2. INSTALLATION .................................................................... 48 2.1 Module Location ............................................................. 48 2.2 Electrical Connection ......................................................... 48 2.3 Module Replacement .......................................... ' ................ 48 3. DIAGNOSTIC LEDS ................................................................. 50 4. FIELD REPLACEABLE SPARE PARTS ................................................ 50 32 DC DI MODULE .............................................................. 51 1.1 Overview ................................................................... 5 1 1.2 Module Configurations ........................................................ 52 1.3 MOSCAD RTU and Tool Box Software Version Compatibility ........................ 52 2. INSTALLATION .................................................................... 52 2.1 Module Location ............................................................. 52 2.2 Electrical Connectionxs ....................................................... 52 2.3 Module Replacement ......................................................... 52 3. DIAGNOSTIC LEDS ............................................................. i .. 56 4. FIELD REPLACEABLE SPARE PARTS ................................................ 56 32 DO MODULE ................................................................. 57 1. OVERVIEW ....................................................................... 57 1.1 General Description .......................................................... 57 1.2 MOSCAD RTU and Tool Box Software Version Compatibility ........................ 58 2. INSTALLATION .................................................................... 58 2. I Module Location ............................................................. 58 2.2 Electrical Connection ......................................................... 58 2.3 Module Replacement ......................................................... 59 i 3. DIAGNOSTIC LEDS ................................................................ 60 4. FIELD REPLACEABLE SPARE PARTS ............................................... . 60 o,. 111 T I '/ ! ' 60 DI MODULE ............................. ..................................... 61 1. DESCRIPTION ..................................................................... ' '61 ,~ 1.1 Overview .................................................................... 61 1.2 Moscad RTU and Tool Box Software Version Compatibility ........................... 62 2. INSTALLATION .................................................................... 62 2.1 Module Location ............................................................. 62 2.2 Electrical Connection ........................... - .............................. 62 2.3 Module Replacement .................................... ...................... 62 3. DIAGNOSTIC LEDS ................................................................ 66 4. FIELD REPLACEABLE SPARE PARTS ................................................ 66 m LINE INTERFACE UNIT ................................ , ......................... 67 I. OVERVIEW ....................................................................... 67 2. OPTIONS ......................................................................... 67 3. INSTALLATION .................................................................... 69 3.1 Unit Installation ............ ~ .................................................. 69 3.2 Electrical Connection ......................................................... 69 3.3 Line Interface Unit Replacement ................................................ 73 4. DIAGNOSTIC LEDS ................................................................ 74 5. FIELD REPLACEABLE SPARE PARTS ......... ~. ...................................... 74 AC ANALYZER .................................................................. 75 1. OVERVIEW ....................................................................... 75 1.1 Genera~ .................................................................... 75 1.2 MOSCAD RTU and Too1 Box Software Version Compatibility ........................ 75 1.3 Description ................................................................. 77 1.4 Module I/O Connector ........................................................ 78 1.5 AC Analyzer System Specifications .................................... - .......... 79 2. INSTALLATION .................................................................... 81 2.1 AC Analyzer Module Location .................................................. 81 2.2 Termination Panel Mounting ................................................... 8 l 2.3 Electrical Connections ........................................................ 81 2.4 AC Analyzer Module Replacement .............................................. 83 3. SCALING THE ANALOG INPUTS .................................................... 84 3.1 General ......................................... ~ .......................... 84 3.2 Scaling Procedure ............................................................ 84 4. DIAGNOSTIC LEDS ................................................................ 84 5. FIELD REPLACEABLE SPARE PARTS ................................................ 85 iv 8A POWER SUPPLY/CHARGER MODELS FPN5522A, FPN5544A ................................................... 87 1. OVERVIEW ....................................................................... 87 2. ELECTRICAL CONNECTION ........................................................ 88 3. OPERATION ....................................................................... 89 3.1 Controls, Indicators and Connectors .............................................. 89 3.2 Operating Instructions ......................................................... 89 4. REMOVAL AND INSTALLATION ..................................................... 90 5. FIELD REPLACEABLE SPARE PARTS .............................................. ;. 90 MAXTRAC VHF RADIO MAXTRAC UHF RADIO MAXTRAC 800 AND 900 TRUNKED RADIO MAXTRAC 800 CONVENTIONAL RADIO .......................................... 91 1. ELECTRICAL CONNECTIONS ....................................................... 91 2. OPERATION ....................................................................... 91 3. REMOVAL AND INSTALLATION ..................................................... 92 3.1 Removal .................................................................... 92 3.2 Installation .................................................................. ' 92 4. FIELD REPLACEABLE SPARE PARTS ................................................ 92 DARCOM 9000-2 RADIO ......................................................... 93 1. ELECTRICAL CONNECTIONS ........................................................ 93 2. REMOVAL AND INSTALLATION ..................................................... 93 3. FIELD REPLACEABLE SPARE PARTS ................................................ 94 MT 2000 MODEL A4 RADI,0 ...................................................... 95 1. ELECTRICAL CONNECTIONS ....................................................... 95 2. OPERATION ....................................................................... 95 3. REMOVAL AND INSTALLATION ..................................................... 96 3.1 Removal ................................................................... 96 3.2 Installation .................................................................. 96 4. FIELD REPLACEABLE SPARE PARTS ................................................ 96 APPENDIXES Appendix A: CABLES AND ADAPTERS ....................................................... 1 97 1. GENERAL ...................................................... ~ ................. 97 2. RTU-TO-COMPUTER/TERMINAL CONNECTION ....................................... 98 2.1 RTU-to-Computer/Terminal Asynchronous Communications .......................... 98 2.2 RTU-to-Computer/Terminal Synchronous/Asynchronous Communications Adaptor ........ 99 3. RTU-TO-MODEM CONNECT]ON ..................................................... 101 3.1 RTU-to-Modem Asynchronous Connection (DTE-to-DCE) ........................... 101 3.2 RTU-to-Modem Synchronous Connection (DTE-to-DCE) ............................ 102 3.3 RTU-to-Modem Synchronous/Asynchronous Communications Adaptor board (DTE-to-DCE) 103 v 4. RTU-TO-RADIOCONNECTION ...................................................... 104 4. I RTU-to-Darcom 9000-2 Radio with Diagnostics (via port 3) .......................... 104 ~ 4.2 Conventional or Trunked MaxTrac Radio Adaptor FLN6433B (via port 3) ............... 105 4.3 MaxTrac Radio-to-two CPUs Adaptor FLN6423A (via port 3) ......................... 106 4.4 RTU-to-Mc Micro Radio Cable FKN4084A ....................................... 107 4.5 Connecting an EXternal Radio .................................................. 108 5. R'I;U-TO-X.25 CONNECTION ........................................................ 110 5.1 RTU-to-X. 25 Connection via Port 1B (DTE-to-DCE) .......... : ..................... 110 5.2 RTU-to-X.25 Connection via Port 1B (DCE-to-DTE) ................................ 110 6. RTU-TO-RTU CONNECTION ......................................................... 111 6.1 RTU-to-muitiple RTDs Time Synchronization using SYNC Broadcast (Via port 1 B) ........ 111 6.2 RTU-to-RTU Asynchronous Communications Connection ............................ 112 6.3 RTU-to-RTU Synchronous Communications Connection (via port 1B) .................. 113 6.4 RTU-to-RTU RS-232 Synchronous Communications Connection (via port 3) ............. 114 6.5 RTU-to-RTU Communication Connection via Radio Port ............................. 115 7. CONNECTING A USER PORT TO A PRINTER ..... ; · L ................................. '. 116 Appendix B: CONNECTING AN EXTERNAL POWER SUPPLY ................................... 117 vi INTRODUCTION 1. SCOPE OF THIS MANUAL This manual provides instructions for MOSCAD TM Remote Terminal Unit (RTU) installation and operation. It also provides on-site replacement instructions for RTU elements that do not necessarily require shop level assistance. This manual covers the basic six-slot and optional three-slot RTUs and most of the communications and FO options. Other manuals (available separately) contain additional information on the RTU, as follows: 68P02924C10 19" Rack Mounted RTU, Owner's Manual 68P02991G90 MOSCAD RTU Service ManUal 68P02995G 10 MOSCAD Programming Tool Box, Operating Instructions Introduction 2. GENERAL DESCRIPTION The MOSCAD RTU is a remotely located terminal used for monitoring and con- trol of local equipment. The unit is intelligent and can operate in a stand alone mode as well as serve as an intelligent node in a distributed processing system. The MOSCAD RTU is a modular unit, basically made up of plug-in modules installed in a multi-slot rack, power supply, radio and interface equipment. The chapters in this manual separately describe each of the RTU modular elements. The basic model of the MOSC/~D RTU is supplied with a chassis suitable for wall mounting, a six-slot Modular bus (motherboard), power supply, backup battery, ra- dio, and a CPU module assembled by the manufacturer. The basic RTU model is enclosed in a NEMA4 metal housing. Figure 1 provides a general view of the basic Six-Slot RTU (shown without housing). 0 ~~-- CHASSIS - BATTERY MODULE SLOTS POWER __ SUPPLY MOTHERBOARD PROTECTIVE ND MODULE Figure 1. Six-Slot RTU - General View (without housing) l ntroauct~on 2.1 RTU BASIC MODELS The basic RTU model is determined according to the prime communication chan- nel used. These models are detailed in Table 1. Table 1. RTU Basic Modds Model No. Description F6900A' No radio communication interface F6909A External radio (FSK) F6953A MT 2000 VHF radio, 5 W, 136-174 MHz, FSK F6954A MT 2000 UHF radio, 4 W, 403-470 MHz, FSK F6956A Darcom 9000-2 radio, 5 W, 928-960 MHz, 12.5 kHz, FSK F6973A MaxTrac VHF radio, 20 W, 136-174 MHz, DFM F6974A MaxTrac UHF radio, 20 W, 403-430, 449-470 MHz, DFM · F6975A MaxTrac 800 conventional radio, 12 W, 800 MHz, FSK F6984A MaxTrac UHF tmnked radio, 20 W, 403-430, 450-470 MHz, 1200 bps DPSK F6985A MaxTrac 800 trunkad radio, 15 W, 800 MHz, DPSK F6986A MaxTrac 900 trunked radio, 12 W, 900 MHz, DPSK 2.2 MODULAR BUS AND HOUSING The basic RTU includes a six-slot modular bus which houses a CPU module and up to five FO modules. As an option, a three-slot Modular bus is supplied instead of the six-slot Modular Bus. In addition to the CPU, a three-slot modular bus houses up to two I/O modules. The basic RTU is supplied in a NEMA 4 metal housing. Optionally, both the six- slot and three-slot RTUs can be ordered with a NEMA 4 stainless steel housing. The three-slot'RTU can be ordered in aplastic housing. Table 2 details the Modular Bus and HouSing options. Table 2. Modular Bus and Housing Options V89 6-Slot Modular Bus, Stainless Steel Housing V214 3-Slot Modular Bus, Metal Housing V228 3-Slot Modular Bus, Plastic Housing V229 3-Slot Modular Bus, Omit Housing V231 6-Slot Modular Bus, Omit NEMA4 Metal Housing V405 3-Slot Modular Bus, Stainless Steel Hoesing Introduction 2.3 CPU AND COMMUNICATION INTERFACES The main element of the MOSCAD RTU is the CPU module. The standard CPU type is Series 200, which is suitable for most applications. For calculation inten- sive applications, the enhanced CPU Series 300 and math coprocessor options are available. Tables 3, 4 and 5 detail the CPU and communication interface options. Table 3. CPU Options V426 CPU 300 V445 Add Math Coprocessor Table 4. Communications Interface Options For all models (except for F6900) V356 Replace DFM or DPSK with FSK radio interface V370 Replace DFM or FSK with DPSK radio interface V390 Replace FSK with DFM radio interface For F6900 model only V345 RS-232, asynchronous, via port 3 V340 RS-232, synchronous, via port 3 For F6956 model only V127 4800 bps Modem for/Darcom Radio, Port 3, Synchronous V360 4800 bps Modem fo~ Darcom Radio, Port 3, Asynchronous V387 9600 bps Modem for Darcom Radio, Port 3, Asynchronous V388 9600 bps Modern for Darcom Radio, Port 2, Asynchronous V430 9600 bps Modem for Darcorn Radio, Port 3, Synchronous V431 4800 bps Modern for Darcorn Radio, Port 2, Asynchronous Table 5. Modem Options (for F6900 model only) V104 300/1200 bps Line Modern, Auto Answer V219 1200 bps Line Modem, 2 Wire, Half Duplex, Multi-Drop V226 300/1200/2400 bps Line Modem, Auto Answer V285 1200 bps Line Modern, 2/4 wire, Full Duplex V404 2400 bps Line Modern, 2/4 Wire, Full Duplex ] | i ! l' B Introduction 2.4 I/O MODULES The MOSCAD RTU provides a wide range of I/O modules for interfacing with the user equipment (see Table 6). The RTU can house up to either five or two I/O mod- ules according to the Modular Bus option. Table 6. RTU I/O Module Options Vl18 4-AO Module(4-a0mA, 0-SV) V278 8-AI Module (4 - 20 mA) V437 8-AI Module (+ 5 V) V459 8-AI Module ( + 1 mA) V460 8-AI Module (+ 2.5 V) V461 8-AI Module (+ 2 mA) V462 8-AI Module ( + 1 V) V329 16 AC DI Module, input voltage range = 10 - 28 V V379 16 AC DI Module, input voltage range = 20 - 56 V Vl15 16-DI, 2-Counter Module V516 16-DO Module (magnetically latched outputs) V616 16-DO Module (electrically energized outputs) V355 32 DC DI Module, input voltage range = 10 - 28 V V480 32 DC DI Module, input voltage range -- 20 - 56 V V481 32 DC DI Module, input voltage range = 35 - 80 V V314 32 DO Module (Transistorized Outputs) V380 60 DI Module V464 AC Analyzer System (Module and Termination Panel) V245 Mixed I/O Module, 3ML + 1EE, 8DI, 2AI (4 - 20 mA) V436 Mixed I/O Module, 4EE, 8DI, 2AI (4 - 20 mA) 2.5 POWER SLIPPLY AND BATTERY The power supply provides DC power for the RTU operation and charges the RTU backup battery. The power supply and backup battery options are detailed in Table 7. The RTU can be ordered without the power supply and the battery, in which case the FKN5934A external power supply cable is provided. Table 7. Power Supply Options V251 220 V Power Supply (instead of 110 V) V274 Omit Power Supply and Battery V328 Battery expansion to 10 AH The FLN4666A battery, consisting of six subunits, is rated for 5 AH operation. An optional field retrofit kit, FRN5528A, enables the installation of a second FLN4666A battery on top of the existing one. The two batteries are connected in parallel by means of an optional cable kit FKN5895A, providing 10 AH operation. Introduction This Page Intentionally Left Blank ~'~ i i ! I: ~ INSTALLATION 1. GENERAL This chapter covers the following installation procedures: - Wall mounting (with metal, stainless steel or plastic housing, or without hous- ing). - Module preparation and installation. - Electrical connections. In addition, this chapter describes the RTU disassembly procedures and provides a list of the RTU pans that are field replaceable. 2. WALL MOUNTING WITH HOUSING The following housing installation procedures refer to the NEMA4 type housings. The NEMA4 housing sizes are: Large Small Plastic (for 6-Slot RTUs) (for 3-Slot RTUs) (for 3-Slot RTUs) Width: 50 crn (19.7") 38 cm (15") 41.5 cm (16.3") Height: 50 crn (19.7") 38 cm (15") 51.5 cm (20.3") Depth: 21 cm (8.26") 21 cm (8.26") 23 cm (9.05") Convenient installation of the MOSCAD RTU with the NEMA4 housing requires the following available space: Large Small Plastic (for 6-Slot RTUs) (for 3-Slot RTUs) (for 3-Slot RTUs) Width: '56 cm (22") 44 cm (17.5") 47 cm (18.5") Height: 56 cm (22") 44 cm (17.5") 57 cm (22.5") Depth: 28 cm (11") 28 cm (11") 30 cm (11.8") Four mounting brackets are provided, one in each comer of the RTU, for wall mounting of the RTU (see Figures I to 5). To mount the RTU on the wall proceed as follows: (1) Fasten the mounting brackets at the housing back comers. Use the brackets and the screws supplied in the plastic bag. (2) Choose the mounting means (screws, etc.) appropriate for the site and mount the RTU on the wall using the mounting brackets. 7 Installation 17.40" (44.2 cm) 20.86" 17.41Y' (53.0 cm) {44.2 cm) Figure I. Large NEMA 4 Housing - Installation Dimensions 16.2" 12.6" (4'~ .2 crn) ~ {32.0 cm) Figure 2. Small NEMA 4 Housing - Installation Dimensions Figure 3. Mounting the NEMA 4 Housing I ! 'l'i 362 cm (14.25") ~ 562cm ~ {22.12') 462 cm (';e.'~9") Figure 4. Plastic Housing - Installation Dimensions Figure 5. Plastic Housing - Mounting Brackets Installation · Installation 3. WALL MOUNTING OF RTU WITHOUT HOUSING Convenient installation of the MOSCAD RTU without housing requires the fol- lowing available space: 6-Slot RTU 3-Slot RTU Width: 50 cm (20'~ 35 crn (14'~ Height: 50 cm (20") 38 cm (15") Depth: 10" (25 cm) 25 cm (10") Four holes are provided, one in each comer of the RTU, for wall mounting of the RTU. Figure 6 shows the distances between the holes. 41.0cm (16.14") 29.5cm (11.61") (17.4r) 6-Slot Chassis 3-Slot Chassis Figure 6. RTU Chassis Installation Dimensions Choose the mounting means (screws, etc.) appropriate for the site and mount the RTU on the wall. 4. PLUG-IN MODULE INSTALLATION There are six slots (or three slots, as an option) for plug-in module installation. The CPU module must be installed in the leftmost slot. The I/O modules are installed according to the site configuration instructions provided by the Programming Tool Box. Refer to section 6, PLUG-IN MODULE REPLACEMENT, for the module inser- tion instructions. NOTE Turn off the DC power before installing a new module. 10 I I i i Installation 5. ELECTRICAL CONNECTIONS NOTE Make sure that all power and ground connections are made ac- cording to local standards and laws. 5.1 GROUND CONNECTION Connect the line ground directly to .the protective ground strip located under the power supply. 5.2 POWER CONNECTIONS Different internal power supply models can be installed in the RTU. For instruc- tions on how to connect the specific power supply refer to the separate chapter in this manual pertaining to the power supply installed. If you are using an external power supply, refer to Appendix B. 5.3 RADIO CONNECTIONS Different radio models can be installed in the RTU. For instructions on how to con- nect the specific radio refer to the separate chapter in this manual pertaining to the model installed. 5.4 USER CONNECTIONS TO I/O MODULES For instructions regarding user connections to the I/O modules refer to the separate chapter in this manual pertaining to the specific module. NOTES 1. Carefully read instructions for ensuring battery backup for RAM. These instructions are provided in the CPU MODULE chapter of this manual. 2. Turn off the power supply DC output before installing or re- moving of any plug-in module. 11 I 1 ' / ! ! ' ' Installation 5.5 INTERCONNECTION DIAGRAM The RTU is supplied with all internal electrical connections installed. For your convenience, the unit interconnection diagram is also provided (see Figure 7). MOSCAD RTU P.mU~Rv (6-SlOt / 3-Slot) LOGIC POVVER SUPPLY · J'/' ~ MOTHER- BOARD ANTENNA POWER SUPPLY ANTENNA ADAPTOR CABLE RADIO POWER SUPPLY - RADIO DATA CPLI · ~ FO~T3 MODULE COMMUNICATIONS BATTERY CABLE ADAPTOR BAT POWER SUPPLY C + BATrERY r · IN __ J1 .GND © - JUMPER STRIP AC ~,'~' NOTE: REFER TO SECTION 8 FOR COMPONENT PART NUMBERS Figure 7. MOSCAD RTU - Interconnection Diagram Installation 6. PLUG-IN MODULE REPLACEMENT NOTE Turn off the DC power.before replacing a module. 6.1 MODULE REMOVAL FROM RTU (1) Put your finger into the notch in the module front door and open the door. (2) Disconnect all electrical connections from the module TBs and/or ports. . (3) Hold the door firmly at right angles to the module front panel and pull the door outwards - the door is drawn out with its hinge and the module lock is disen- gaged. (4) Keep pulling the door until the module is extracted from the slot. 6.2 MODULE INSERTION INTO RTU (1) Open the module door and pull the door with its hinge out (for about 1/2" [1 cm]). (2) Slide the module into the appropriate RTU slot. (3) While holding the door at right angles with the module front panel, push the door firmly in until you feel that the door lock is latched. (4) Connect all electrical connections disconnected from TBs and/or ports while removing the module. (5) Close the module door. 13 Installation 7. MODULAR BUS DISASSEMBLY ~ The modular bus includes a motherboard and module slots. A special design al- lows easy removal of the bus elements, as described below. 7.1 MOTHERBOARD REMOVAL ( 1 ) Turn off the RTU power supply. (2) Remove all modules (for removal procedure refer to paragraph 6.1 ). (3) Disconnect the cable from connector J7 on the motherboard. NOTE The motherboard is attached to the module slots by the mother- board retaining clips (see Figure 8). (4) Carefully bend one of the outermost clips away from the motherboard; slightly pull the motherboard edge adjacent to the clip outwards, until it is released from the clip (see Figure 8). "--,,,, NODULE PIOTHERBOARD ~ RETAINING CLIPS ' HOTHERBOARD Figure 8. Modular Bus Disassembly (5) Release the motherboard from all remaining clips and remove the mother- board. 14 1 '1 ....... T " g Installation 7.2 REMOVAL OF MODULE SLOT ( 1 ) Remove the motherboard (refer to paragraph 7.1 ). (2) Press the slot retaining clip (see Figure 8) upwards and carefully pull the lower pan of the slot. When the slot retaining clip is released from the chassis re- move the slot. 8. FIELD REPLACEABLE SPARE PARTS Description Part No. Antenna adaptor cable: for 6-slot housings FKN5952A for 3-slot housings FKN4069A Power supply to radio DC cable: for MaxTrac radio FKN5932A for Darcom radio FKN4017A for MT 2000 radio FKN5933A CPU to radio communication cable FKN5953A Communications cable adaptor: for MaxTrac radio FLN6433B for Darcom radio FLN6594A Power supply to battery DC cable: for 6-slot housing FKN5930A for 3-slot housing FKN4047A Power supply to motherboard cable FKN5931A External power supply DC cable FKN5934A Protective ground strip 3102811K01 Jumper strip 3102894K01 Motherboard: 6-slot FRN5547A 3-slot FRN5659A Plastic module slot 1508572S01 Fuse F1 (4A, slow-blow, located on the motherboard) 6500061688 Ejector 6602833G01 15 Installation This Page Intentionally Left Blank 16 CPU MODULE 1. OVERVIEW The main element of the MOSCAD RTU is the CPU module. It controls the FO modules, processes the gathered data and communicates with the outside world. The module is based on the Motorola 68302 microprocessor and includes an on- board memory, communications, FO bus drivers and other circuits. Figure 1. CPU Module - General View The standard CPU type is Series 200, which is suitable for most applications. For calculation intensive applications, the enhanced CPU Series 300 and math copro- cessor are available. CPU Module 2. INSTALLATION 2.1 MODULE LOCATION The CPU module must be installed in the leftmost slot (a corresponding label is printed on the chassis below the slot). 2.2 BATTERY BACKUP FOR RAM The CPU module has a non-rechargeable lithium battery (6008261C04) that pro- vides backup power for the RAM. The battery maintains data stored in the RAM when the power from the line and the main battery is lost. The lithium battery en- ables the CPU to continue operation after power restoration while maintaining the same state that was interrupted. The lithium battery is located on the module front panel behind the door, as shown in Figure 2. Part of CPU Module Front Panel Pores ~ BAR' L- -J BACKUP ~ BATTERY Figure 2. Backup Battery Location The lithium battery is capable of preserving the data stored in the RAM for three months (accumulated time of power losses). In order to maximize the useful life- time of the battery an insulating strip 'is inserted into the battery housing before shipment. The slxip is easily removed by pulling it out. IMPORTANT: We recommend that you remove the insulating strip only after connecting the RTU to the main power. We also recommend that you save the swip, and then reinstall it whenever the RTU is to be shipped for maintenance or will not be used for a prolonged period of time. 2.3 ELECTRICAL CONNECTION The CPU module installed in the RTU is supplied with the FKN5953A cable con- nected between port 3 and the radio. Any other connections (to ports 1,2 or 3) de- pend on the specific application. 18 T I '1 ! I ~ CPU Module CONTROLS, INDICATORS AND CONNECTORS Tables 8 and 9 define the functions of the module diagnostic LEDs, controls and connectors. Table 8. CPU Module - Controls and Connectors Item Name Function I PB1 Pushbutton. PB1 main function is to turn the LEDs of all modules on/off, as follows: · When th, e pushbutton is pressed once momentarily, the display is activated. Every consecutive short pressing of the pushbutton advances the display mode in those modules where more than one display mode is available. · When the pushbutton is pressed twice momentarily, the display immediately turns off. To conserve energy, the display turns off after two minutes even if it is not switched off manually. · When the pushbutton is pressed and held for a few seconds all the LEDs light simultaneously (for LED test). The LEDs extinguish when the switch is no longer pressed. In all modules there are several LEDs that do not turn off when all other LEDs do. These LEDs, including the four LEDs in the leftmost side of the CPU module, indi- cate malfunctions and important events. 2 PB2 Pushbutton. Used for additional tests to be performed by the service technician. NOTE Pressing simultaneously both PB1 and PB2 for about 10 seconds performs a CPU re- start. This deletes the configuration and ap* plication that were loaded into the RTU and redefines the RTU to the default configura- tion. When the RTU is re-started the buzzer sounds. 3 PORT Data port (RS-485). 1A 4 PORT Data port (RS-232). 1B 5 PORT 2 Data port (RS-232). 6 PORT 3 Radio or line, according to the RTU model. F , q CPU Modul~ Table 9. CPU Module Diagnostic LEDs Name Function PWR (Power) Lights as long as the 12 V DC input power is applied to the RTU, indicating that the unit is operating. AC (AC Fail) Lights when the AC power supply to the unit fails (operates on the unit's 12 V battery). CPU (CPU Fail) Lights to indicate a realfunction in the CPU. The nature of the malfunction is indicated by the 16 LEDs situated in the four columns on the right, which light simultaneously with the CPU Fail LED. RST (CPU Flashes upon reset of the CPU, usually by the watchdog timer, indicating that the software is not Reset) running properly. ERR (Error) Lights to indicate one of the following: an illegal state has been detected in the software, a module/board is missing, or other malfunctions. These events are logged in a special error logger in the CPU. The contents of the error logger may be read via the Programming Tool Box. BAT (Low Lights to indicate that the voltage of the lithium battery (which backs up the CMOS RAM when the voltage) 12 V voltage is not supplied to the modules) is low. The lithium battery must be replaced, LOAD Lights to indicate that a Configuration definition or an Application program is being downloaded to the FLASH memory. CONF Lights to indicate that a Site Configuration definition has been loaded into the FLASH memory. (Configuration) APPL Lights to indicate that an Application program has been loaded into the FLASH memory. The APPL (Application) LED flashes in the following situations: · When the application program is in the "STOP SCAN" state for performing diagnostics via the monitoring program of the Tool Box's Application Programmer. ·When the application run-time is too long, caused by a mistake in the Ladder diagram program, such as an infinite loop. · When the application program is in STOP state during hardware test 'performed by the Programming Tool Box. MON (Monitor) Lights when the monitoring program of the Application Programmer performs symbolic debugging of the ladder diagram function. TX1 Lights when the RTU transmits data via Port 1. TX2 Lights when the RTU transmits data via Port 2. TX3 Lights when the RTU transmits data via Port 3. RX1 Lights when the RTU receives data via Port 1. RX2 Lights when the RTU receives data via Port 2. RX3 Lights when the RTU receives data via Port 3. CM1 Lights when the communications channel used by Port 1 is busy. CM2 Lights when the communications channel used by Port 2 is busy. CM3 Lights when the communications channel used by Port 3 is busy. 20 T I 'I T'i ~I 4. REMOVAL AND INSTALLATION 4.1 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 4.2 LITHIUM BATTERY (6008261C04) REPLACEMENT NOTE The lithium battery can be replaced without interrupting the RTU's operation. For easy removal and replacement, a battery holder is provided (see Figure 2). To remove the used battery: (1) Open the CPU module front door. (2) Pull the battery holder handle and remove the battery holder. (3) Pull the battery out of the battery holder. To insert a new battery: (1) Insert the battery into the battery holder with the positive side facing the ~D mark on the battery holder. (2) Insert the battery holder into the CPU's front panel (see Figure 2), while ensur- ing that the battery is placed between the battery contacts. (3) Press the battery holder until latched. 5. FIELD REPLACEABLE SPARE PARTS Description Part No. Door label 5402853D01 Protective plastic strip for the door label 6108874S01 Lithium battery 6008261 C04 Lithium battery holder 1502802E01 21 CPU Module This Page Intentionally Left Blank ~t 22 16 DI, 2 COUNTERS MODULE 1. OVERVIEW The 16 DI, 2 Counters module (DI - Digital Input) can receive up to 16 isolated status inputs and two isolated high speed counter inputs from the user equipment. The module transfers the data to the CPU module. Figure 1 shows a general view of the 16 DI, 2 Counters module. Figure 1.16 DI, 2 Counters Module - General View Each of the 16 discrete inputs withstands high line noise due to software conlxolled filters. The discrete inputs can also be utilized as slow speed counters (up to 500 Hz). The high speed counter inputs can count pulses of up to 10 kHz rate with a mini- mum pulse width of 50 microseconds. 16 DI, 2 Counters Module 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION User connections are the wires originating from sensors and user relay controls. These wires are connected to the user interface TB located on the module front. For NEMA4 housing, thread the wires through the opening provided for this pur- pose at the bottom of the box. TB pin definitions and complete connection instructions are provided by the Tool Box site configuration program following definition of the sensors, controls and the I/O module locations. NOTE Ensure that the plug with connections 1-10 is inserted into the up- per TB and the plug with connections l 1-20 is inserted into the lower TB. Figure 2 shows how to connect both the input devices protected by the RTU inter- ~'~ nal ground and devices protected or grounded externally. 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 24 16 DI, 2 Counters Module I ~ ~~ Internally Protected User ~ Connections I I Externally Protected User Connections I NOTE The user protective potentials should be within ~2.5 kV range relative to the MOSGAD protective ground. Figure 2. 16 DI, 2 Counter Module - User Connections 25 16 DI, 2 Counters Module 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 3) composed of 20 LEDs. The LED functions are as follows: 16 DI, 2 COUNTERS CT1 I 5 9 13 CT2 2 6 10 14 Id00 3 7 11 15 CI, K 4 8 12 16 "~1, INPLTT STATE Figure 3. 16 DI, 2 Counter Module - LED Panel CT1 -. Displays the status of Counter-1 LSB: LED on = "1", LED off- "0". CI'2 - Displays the status of Counter-2 LSB: LED on = "1", LED off'- "0". MOD When lit, indicates that the CPU cannot access the module. This happens when the module has either failed or was installed in a slot assigned for another module. CLK When lit, indicates absence of system clock. 1-16 LEDs Display status of the corresponding input: LED lit - input closed, LED off = input open. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 31 O8509G18 Door label 5402853D03 Protective plastic strip for the door label 6108874S01 Numbering strips for the user connection plugs 5402831KC)I 26 T ! 'I i B 16 DO MODULE 1. OVERVIEW The 16 DO (Digital Output) module (See Figure 1 ) provides 16 relay outputs for controlling user devices. The upper four relays are Double Pole Double Throw (DPDT) and are referred to as the "Form C" relays; the remaining twelve relays are Single Pole Single Throw (SPST) normally open (NO) and are referred to as · the "Form A" relays. The relay commands are received from the CPU module. Figure 1.16 DO Module - General View The 16 DO module is available in the following configurations: · FRN 1492A Relay outputs are magnetically latched (the outputs maintain their state in case of power off or module failure). · FRN 1491A Relay outputs are electrically energized (the outputs return to the non-energized state in case of power off or module failure). 16 DO Module 2. INSTALLATION /.~ 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration pro~am. 2.2 ELECTRICAL CONNECTION User connections are the wires originating from the controlled devices. These wires are connected to the user interface TBs located on the module front. For NEMA4 housing, thread the wires through the opening provided for this purpose at the bottom of the box. Figure 2 shows how to connect the user inputs. Figure 2. 16 DO - User Connections 28 I I i ! ~ ~ 16 DO Module TB pin definitions and complete connection instructions are provided by the Tool Box site configuration program following definition of the controlled devices and the I/O module locations. NOTE Ensure that the plug with connections 1-8 is inserted into the up- per TB, the plug with connections 9-16 is inserted into the middle TB and the plug with connections 17-24 is inserted into the lower 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 3) composed of 20 LEDs. The LED functions are as follows: MOD - When lit, indicates that the CPU ~6DIGffN, OUTPUTS cannot access the module. This happens either when the module I 5 9 has failed or was installed in a slot assigned for another module. 2 6 10 14 I)0 3 7 11 15 CLK - When lit, indicates absence of system clock. CLK 4 8 12 16 l - 16 LEDs - Display status of the correspond- :nt ~N~n' ST^~!i ing Output: Figure 3. 16 DO LED lit = relay is energized/set, Module - LED Panel LED off = relay is not energized/ reset. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 3108509G19 Door label 5402853D02 Protective plastic strip for the door label 6108874S01 Numbering strips for the user connection plugs 5402831K02 29 16 DO Module This Page Intentionally Left Blank 8 AI MODULE 1. OVERVIEW The 8 AI module (AI = Analog Input) can receive up to 8 optically isolated analog inputs. The module converts the analog data into digital format and transfers the digital data to the CPU module. The basic model of the 8 AI module meets .the 4 - 20 mA Interface ihdustry stan- dard. The module is available in additional configurations with other input specifi- cations, as detailed in Table 1. Table 1. 8 AI Module - Field Add-On Types Part No. Description FRN1421A 8 Analog Inputs, 4-20 mA, (Standard) FRN1940A 8 Analog Inputs, + 5 V FRN1972A 8 Analog Inputs, :1:1 mA FRN1973A 8 Analog Inputs, + 1 V FRN1980A 8 Analog Inputs, + 2.5 V FRN1981A 8 Analog Inputs, +2 mA Figure I provides a genera] view of the 8 A1 modu]e. Figure 1.8 AI Module - General View 31 8 AI Modul~ 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION User connections are the wires originating from sensors and user relay controls. These wires are connected to the user interface TB located on the module front. For NEMA4 housing, thread the wires through the opening provided for this pur- pose at the bottom of the housing. TB pin definitions and complete connection instructions are provided by the Tool Box site configuration program following definition of the sensors, controls and the FO module locations. NOTE Ensure that the plug with connections 1-10 is iriserred into the up- per TB and the plug with connections 11-20 is inserted into the 'lower TB. Figure 2 shows how to connect both the input devices protected by the RTU inter- nal ground and the input devices protected or grounded externally. External 2- or 4-wire transmitter and power supply should be connected to the user sensor as shown in Figure 2. 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 32 8 AI Module ! | ' ~ ' ~ Internally Protected User . Connections Externally Protected User Connections · , USER EOUip~EWi. ; \. i" +1 + '\ ' ' DO + / I ;~'~Z""'~ I~*' : , 2 . i ' +. I- ' ' '~-~-/' NOTES 1. The user protective potentials should be within + 2.5 kV range relative to the MOS- CAD protective ground. 2. For best performance, the wires connected to the user sensors should be shielded. Figure 2. 8 AI Module - User ConneCtions 33 Module 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 3) composed of 20 LEDs. The LED functions are as follows: 8 ANALOG INPUTS ~MO I I 5 5 ~M12 2 6 6 iX) 3 3 7 7 CLK 4 4 8 8 =/I, UDF OVF UDF OVF Figure 3. 8 AI Module - LED Panel DM0, DM 1 Not used. MOD When lit, indicates that the CPU cannot access the module. This happens when the module has either failed or was installed in a slot assigned for another module. CLK When lit, indicates absence of system clock. 1-8 UDF LEDs - When lit, indicates that the signal level-in the input, corre- sponding to the LED, is below the nominal range. The thresh- old for the underflow indication is 3.84 mA in the standard models, or 1.024 x (-Full Scale) in the non-standard models. If both the UDF and OVF LEDs of the same channel are lit, the channel is uncalibrated. 1-80VF LEDs - When lit, indicates that the signal level in the input, corre- sponding to the LED, is above the nominal range. The thresh- old for the overflow indication is 20.5 mA in the standard mod- els, or 1.024 x (Full Scale) in the non-standard models. If both the UDF and OVF LEDs of the same channel are lit, the chan- nel is uncalibrated. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 3108509G18 Door label 5402853D04 Protective plastic strip for the door label 6108874S01 Numbering strips for the user connection plugs 5402831K01 ~ 34 4 AO MODULE 1. OVERVIEW The 4 AO (Analog Outputs) module provides four optically-isolated analog output channels for controlling user devices (see Figure 1 ). Each channel has two separate outputs: 4-20 mA Interface industry standard current output and 0~5 V Interface industry standard voltage output. Only one of the outputs can be enabled in a par- ticular channel - either current or voltage. The voltage outputs are self-powered by the RTU internal power supply. The cur- rent outputs must be externally powered - either by the user's or the internal power supply. , Figure 1.4 AO Module - General View 35 4 AO Module 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION User connections are the wires originating from the controlled devices. These wires are connected to the user interface TBs located on the front of the module. For NEMA4 housing thread the wires through .the opening, located at the bottom of the housing. It is recommended to use 14 AWG gage wires. TB pin definitions and complete connection instructions are provided by the Tool Box site configuration program following the definition of the controlled devices and the I/O module locations. NOTE Ensure that the plug with connections 1-t-0 is inserted into the up- per TB and the plug with connections 11-20 is inserted into the lower TB. Figure 2 shows how the user connections to the 4 AO module are made, utilizing an external power supply for driving current outputs. Figure 3 shows how user connections to the 4 AO module are made, utilizing the RTU's power supply for driving current outputs. 2.3 CALIBRATION The 4 AO module is calibrated at the factory by programming an internal E2PROM. If another calibration is required, the Programming Tool Box should be used. 2.4 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 36 NOTE 1. An output can be defined as either current or voltage (not both). 2. An external power supply should be connected to the ExtPSterminals, when current outputs are used. 3. An external power supply is not required only when voltage outputs are used° 4. The user protective potential should be within ± 60 V range relative to the MOSCAD protective ground. Figure 2. 4 AO Module - User Equipment and User's Power Supply Connections 37 ! ~ NOTE 1. An output can be defined as either current or voltage (not both). 2. An external power supply should be connected to the ExtPSterminals, when current outputs are used. 3. An external power supply is not required only when voltage outputs are used. 4. The ExtPS and P. GND outputs should be connected to the Protective Ground Strip directly and by separate wires. Figure 3. 4 AO Module - User Equipment and RTU's Power Supply Connections 38 -~ !' 'T T T I 4 AO Module 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 4) composed of 20 LEDs. The LED functions are as follows: ROM - When lit, indicates a checksum error in the EEPROM. This signifies that all outputs are uncalibrated. 4 ANALOG OUTPUTS CAL When lit, indicates that the channel, whose :tom 'UP[} UPD UPD UPD UCAL LED is lit, is uncalibrated. If none CAt. tr~ tr.& uc~ uc~ of the UCAL LEDs is lit, the uncalibrated channel is one of the channels that are not ~ v v v v ' MOD When lit, indicates that the CPU cannot ac- :AlL ell1 ell2 ell3 ell4 cess the module. This happens when the module has either failed or was installed in Figure 4. 8 AI Module a slot assigned for another module. - LED Panel CLK - When lit, indicates an absence of the system clock. UPD - When blinking indicates that the corresponding channel is being up- dated. UCAL - When lit, indicates that the corresponding output is uncalibrated. IfQ V When lit, indicates that the voltage output is defined and used. I When lit, indicates that the current output is defined and used. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 3108509G19 Door label 5402853D08 Protective plastic strip for the door label 6108874S01 Numbering strips for the user connection plugs 5402831K01 RTU power supply to module TB DC cable FKN4068A 4 A 0 Module This Page Intentionally Left Blank ~'~ 1 ; '1' ' ' I '1 I I I MIXED I/0 MODULE 1. OVERVIEW The Mixed I/O module is designed to provide a combination of different functions, as follows (see Figure 1 ): - It can receive up to two optically isolated analog inputs (AI). The module con- vens the input analog data into digital format and transfers the digital data to the CPU module. Several model options are provided to meet the various interface industry stan- dards.(see section 2). - It can receive up to eight isolated status inputs (DI). The data is transferred to the CPU module. - It can provide four relay outputs (K 1 - K4) for controlling user devices. Relays K 1 and K2 are Double Pole Double Throw (DPDT) and are referred to as the "Form C" relays; relays K3 and K4 are Single Pole Single Throw (SPST) nor- mally open (NO) and are referred to as "Form A" relays. One of the poles is used for user connections, while the other pole is used internally. The outputs of relays K 1 - K3 are either magnetically latched (ML) or electri- cally energized (EE), depending on the model option (see section 2). The out- puts of the magnetically latched relays maintain their state in case of power off or module failure, while the outputs of the electrically latched relays return to the non-energized state in case of power off or module failure. Relay K4 out- put is electrically energized in all model types. Figure 1. Mixed FO Module - General View i 41 Mixed I/0 Module 2. MODEL OPTIONS Table I lists the available Mixed FO module standard options. Table 2 lists addi- tional options that can be supplied upon special order. Table 1. Mixed I/O Module - Standard Model Options Part No. Description FRN1484A 3ML+IEE, 8DI, 2AI(4-20mA) FRN1490A 4EE, 8DI, 2AI (4 - 20 mA) Table 2. Mixed I/O Module - Non-Standard Model Options Part No. Descdption FRN1997A 4EE, 8DI, 2AI (±1 V) FRN1995A 4EE, 8DI, 2AI (+5 V) FRN1996A 4EE, 8DI, 2AI (+ 1 mA) FRN1994A 3ML+ 1EE, 8DI,2AI (+1 V) FRN1992A 3ML + 1EE, 8DI, 2AI ( ± 5 V) FRN1993A 3ML + lEE, 8DI, 2AI (+1 mA)- 42 I I ' I '1 [ T T ! Mixed HO Module 3. INSTALLATION 3.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 3.2 ELECTRICAL CONNECTION User connections are wires that originate from sensors and user relay controls. These wires are connected to the user interface TB located on the module front. For NEM A4 housing, thread the wires through the opening provided at the bottom of the box. TB pin definitions and complete connection instructions are provided by the Tool Box site configuration program following definition of the sensors, controls and FO module locations. NOTE Ensure that the plug with connections l-8 is inserted into the up- per TB, the plug with connections 9-16 is inserted into the middle TB and the plug with connections 17-24 is inserted into the lower TB. Figures 2 and 3 show how to make user connections. Figure 2 shows connections of input devices protected by the RTU internal ground, while Figure 3 shows con- nections of input devices grounded externally. 3.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. M~xed 1/O Module · ' NOTES , Max switching power \ Max switching voltage = 220 VDC, 250 VAC + r--- + Max switching current = 2 A DC/AC I 4-WIRE AI INPUT ' 2. Relays are shown in the normal (non-activated) state. POWER TRANSMITTER SUPPLY 3. For best pedormance, the wires from user analog sensors - I.__ - should be shielded. 2-WIRE TRANSMITTER AI INPUT / + [- - , ~, POWDER / \,_ ,/ . , ,, PROIECT|VE Gi~3 Figure 2. Mixed FO Module - Internally Protected User Connections 44 NOTES 1. The user protective potentials should be within +2.5 kV range relative to the MOSCAD pratedive ground. 2. For best performance, the wires from user analog sensors should be i, shielded. ('~ Figure 3. Mixed I/O Module - Externally Protected User Connections t ;' T 1 '! .... I I ~" Mixed llO Module 4. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 4) composed of 20 LEDs. The LED functions are as follows: MOD When lit, indicates that the MIXFDI/O CPU cannot access the module. This happens when either the 1 5 1 UDF module has failed or was in- 2 6 2 0vv stalled in a slot assigned for t another module. i0O 3 7 ~ 2 CLK When lit, indicates absence of CLK 4 8 4 2 system clock. mt ~ D0 n I - 8 DI LEDs Display status of the corre- sponding input: LED lit = input Figure 4. Mixed I/O - LED Panel closed, LED off = input open. 1 -4 DO LEDS Display status of the corresponding output: LED lit -, relay is energized/set, LED off = relay is not energized/ reset. UDF1, UDF2 When lit, indicates that the signal level in the input, corresponding to the LED, is below the nominal range. The threshold for the underflow indication is 3.84 mA in the standard models, or 1.024 x (- Full Scale) in the non-standard models. If both the UDF and OVF LEDs of the same channel are lit, the channel is uncalibrated. OVF1, OVF2 When lit, indicates that the signal level in the input, corresponding to the LED, is above the nominal range. The threshold for the overflow indication is 20.5 mA in the standard models, or 1.024 x (Full Scale) in the non- standard models. If both the UDF and OVF LEDs of the same channel are lit, the channel is uncalibrated. 5. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 3108509G19 Door label 5402853D09 Protective plastic strip for door label 6108874S01 Numbering strips for user connection plugs 5402831K02 I I ':" i' I T T I 16 AC DI MODULE 1. OVERVIEW The 16 AC DI (DI =: Digital Input) can receive up to 16 isolated ac and dc inputs. The module transfers the data to the CPU module. Figure ! shows a general view of the 16 AC DI module. Figure 1.16 AC DI Module - General View Each of the 16 discrete inputs withstands high line noise, which is effectively sup- pressed by hardware and software controlled filters. The 16 AC DI module is available in the following configurations: · FLN2006A Input Voltage range is 10 to 28 V. · FLN2007A Input Voltage range is 20 to 56 V. 47 16 AC DI Module 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program~ 2.2 ELECTRICAL CONNECTION User equipment is connected to the user interface TB, which is located on the front of the module. For NEMA4 housing, thread the wires through the opening pro- vided at the bottom of the box. TB pin definitions' and complete connection instructions are provided by the Tool Box site configuration program following definition of the sensors, controls and FO module locations. NOTE Ensure that the plug with connections 1-10 is inserted into the up- per TB and the plug with connections 11-20 is inserted into the lower TB. Figure 2 shows how, to make user connections of input devices, which are grounded externally. 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 48 I "; ! " I T I 16 AC DI Module NOTE The u$~ pmt~ive potentials ~O~OAD pm~v~ ground. Figure 2. 16 AC DI Module - Externally Protected User Connections 49 16 AC DI Module 3. DIAGNOSTIC LEDS ,~ The module includes a LED panel (see Figure 3) composed of 18 LEDs. The LED functions are as follows: MOD When lit, indicates that the CPU cannot 16 AG DI communicate with the module. This happens when either the module has 1 5 9 13 failed or was installed in a slot assigned for another module. 2 6 10 14 CLK When lit, indicates absence of system ~0 3 7 11 15 ~ clock. CLK 4 8 12 16 I - 16 LEDs - Display status of the corresponding in- ~ ~NPtn STA~E ' put: LED lit = voltage is present at the input, LED off = no voltage present at Figure 3. 16 AC DI the input. - LED Panel 4. FIELD REPLACEABLE SPARE PARTS Description Part No. User connections plug 3108509G 18 Door label 5402853D10 Protective plastic strip for the door label 6108874S01 Numbering strips for the user connection plugs 5402831K01 50 I 1 '~ i " I 'i T ! 32 DC DI MODULE 1. DESCRIPTION o 1.1 OVERVIEW The 32 DC DI (Digital Input) can receive up to 32 isolated dc status inputs from - user equipment. The module transfers the data to the CPU module. Figure I provides a general view of the 32 DC DI module. Each of the digital inputs withstands high line noise due to software controlled ill- ters. The digital inputs can also be utilized as slow speed counters. The counter speed can be as follows: - Up to 500 Hz for all inputs which are defined by the Tool Box as both serial inputs and counters. - Up to 500 Hz in interrupt application mode. - Up to 50 Hz, according to the application software, for all other inputs. Figure 1.32 DC DI Module - General View 51 32 DC DI Module 1.2 MODULE CONFIGURATIONS The 32 DC DI module is available in the following configurations: · FLN2021A Input Voltage range: 10 to 28 V. · FLN2022A Input Voltage range: 20 to 56 V. · FLN2023A Input Voltage range: 35 to 80 V. 1.3 MOSCAD RTU AND TOOL BOX SOFTWARE VERSION COMPATIBILITY Programming Tool Box The 32 DC DI module is supported by Programming Tool Box versions 2.1 and higher. MOSCAD RTU The 32 DC DI module is supported by MOSCAD RTU software versions 2.0 and higher. 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION The user wires are connected to the 64-pin DIN input connector located on the module front. For NEMA4 housing, thread the wires through the opening provided for this purpose at the bottom of the box. Motorola FKN4162 kit (available sepa- rately) allows for convenient user connections and includes a 64-pin plug, that fits the module input connector, and hood. FO connector pin definitions and complete connection instructions are provided by the Programming Tool Box site configuration program following definition of the sensors, controls and I/O module locations. Figure 2 shows the 64-pin DIN connector pinout (similar data is shown on the module door label). Figures 3 and 4 show how to connect input devices. 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 52 I I "1 i I 7 T ! 32 DC DI Modu~ Figure 2. 32 DC DI Module - Output Connector Pinout 53 i t ! 1' I ~" ]~ 32 DC DI Module USER EOUIPflENT '~_ PROTECTIVE GNO Figure 3. 32 DC DI Module - Internally Protected User Connections 54 ~ ,,* I ' 'l I I ' I 1 i' 32 DC DI Motlule USER EQUIPhlENT O0 O0 O0 O0 O0 O0 O0 O0 O0 O0 . NOTE The user protective potential should be within :1:2.5 kV range relative to the MOSCAD protec- tive ground. Figure 4. 32 DC DI Module - Externally P~otected User Connections 55 :' "1 I ~ )l 32 DC D! Module 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 4) composed of 19 LEDs. The LED functions are as follows: 32 DC DIGITAL INPUT I 5 9 13 DM 17 21 ?5 29 2 6 10 14 i :.:.'i2226 30 3 7 11 15 ~ 19 23 27 3i 4 8 12 16 CLK 20 24 28 32 :AIL INPUT STATE Figure 5. 32 DCDI Module - LED Panel MOD - When lit, indicates that the CPU cannot access the rood- ule. This happens when the module has failed, or was in- stalled in a slot assigned for another module, or the input polarity has been inverted. CLK - When lit, indicates absence of system clock. DM - Display Mode. When off, Input Status LEDs show the status of inputs I-16. When lit, Input Status LEDs show the status of inputs 17-32. 1-I 6/17-32 LEDs - Display status of the corresponding input: LED lit = input is ON, LED off = input is OFF. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. Door label 5402853D 11 Protective plastic strip for the door label 6108874S01 56 ;. I 1 " '1' I T T I .4 32 DO MODULE 1. OVERVIEW 1.1 GENERAL DESCRIPTION The 32 DO (Digital Output) module provides 32 open drain PET outputs for con- trolling user devices. The output commands are received from the CPU module. Figure 1 provides a general view of the 32 DO module. Figure 1.32 DO Module - General View For direct user connections the 32 DO module outputs have the following maxi- mum ratings: voltage - 30 Vdc, current - 0.5 A. Ira higher output rating is required, external relays should be used. Interpose Relay Panels (IRPs), available separately from Motorola, provide the interface required for connecting the controlled de- vices to the 32 DO module. 57 I i '7' ! " I': "7 ] 32 DO Modul~ 1.2 MOSCAD RTU AND TOOL BOX SOFTWARE VERSION COMPATIBILITY Programming Tool Box ~ The 32 DO module is supported by Programming Tool Box versions 2.10 and higher. MOSCAD RTU The 32 DO module is supported by MOSCAD RTU software versions 2.0 and higher. 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION The user wires are connected to the 64 pin DIN connector located on the 32 DO module front. The connections may be made either directly or via an IRP. Motoro- la FKN4162 kit (available separately) allows for convenient user connections to the module 64-pin connector and includes a 64-pin plug and hood. Pin definitions and complete connection instructions are provided by the Program- ming Too1 Box site configuration program following definition of the sensors, controls and I/O module locations. 2.2.1 Direct Connection For direct connection refer to Figure 2 which shows the 64 pin DIN connector pin- out (similar data is shown on the module door label). The controlled device load should not exceed the following ratings: - Switching Voltage: 30 V dc - Switching Current: 0.5 A dc 2.2.2 Connection Via an IRP An IRP contains a control connector to the 32 DO module, Terminal Blocks (TBs) for user connections and sockets for user control relays. The IRP also provides the means to interconnect several IRPs to a single 32 DO module. For using an IRP, refer to your IRP Installation Manual for detailed information on connecting the IRP to the 32 DO module and the user control devices. ,8 32 DO Module - :: 0 0 · {j ~ 0 0 ~ ' 0 0 0 0 j: 0 0 ~ o o 0 0 j 0 0 t o o ~ 0 0 0 0 0 0 0 0 0 0 0 0 ~ 0 0 · 0 0 ~ 0 0 ~ 0 0 · 0 0 0 0 · 0 0 · 0 0 · 0 0 0 0 32C 32A 1C-OUT1 1A-GND 2C-OUT2 2A-GND 32C-0UT32 32A-GND Figure 2. 32 DO Module - Output Connector Pinout 59 32 DO Module 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 3) composed of 19 LEDs. The LED functions are as follows: 32 DIGITal. 1 5 9 13 DM 17 2! 25 29 2 6 10 14 t8 2?. 26 30 3 7 11 15 '100 19 23 27 31 4 8 12 16 CLK 20 24 28.32 :AIL OUTPUT STATE Figure 3. 32 DO - LED Panel MOD - When lit, indicates that the CPU cannot access the mod- ule. This happens when either the module has failed or /.~ was installed in a slot assigned for another module. CLK - When lit, indicates absence of system clock. DM - Display Mode. When off, Output Status LEDs show the status of outputs 1-16.When lit, Output Status LEDs show the status of outputs 17-32. 1 - 16/17-32 LEDs - Display .status of the corresponding output: LED lit - output is ON, LED off = output is OFF. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. Door label 5402853D13 Protective plastic strip for the door label 6108874S01 i i ~ r '1' T T i r 60 DI MODULE 1. DESCRIPTION 1.1 OVERVIEW The 60 DI (Digital Input) can receive up to 60 isolated status inputs from user · equipment (dry contacts). The module transfers the data to the CPU module. Figure 1 provides a general view of the 60 DI module. Each of the digital inputs withstands high line noise due to software controlled fil- ters. The digital inputs can also be utilized as slow speed counters. The counter speed can be as follows: - Up to 500 Hz for all inputs which are defined by the Tool Box as both serial inputs and counters. - Up to 500 Hz in interrupt application mode. - Up to 50 Hz, according to the application software, for all other inputs. Figure 1.60 DI Module - General View 61 60 DI Module 1.2 MOSCAD RTU AND TOOL BOX SOFTWARE VERSION COMPATIBILITY Programming Tool Box The 60 DI module is supported by Programming Tool Box versions 2.1 and higher. MOSCAD RTU The 60 DI module is supported by MOSCAD RTU software versions 2.0 and higher. 2. INSTALLATION 2.1 MODULE LOCATION The module should be installed in a slot designated by the Programming Tool Box site configuration program. 2.2 ELECTRICAL CONNECTION The user wires are connected to' the 64-pin DIN I/O connector located on the rood- ule front. For NEMA4 housing, thread the wires through the opening provided for this purpose at the bottom of the box. Motorola FKN4162 kit (available separately) allows for convenient user connections to the module 64-pin connector and in- cludes a 64-pin plug and hood. I/O connector pin definitions and complete connection instructions are provided by the Programming Too1 Box site configuration program following definition of the sensors, controls and FO module locations. Table* 1 details the module I/O connector pin definitions. Figures 2 and 3 show how to connect input devices. 2.3 MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 62 I' 60 DI Module Table 1. Module FO Connector - Pin Definitions Pin No. Signal Name Pin No. Signal Name IA DI2 IC DII 2A DI4 2C DI3 3A DI6 3C 4A DIS 4C DI7 5A DI I 0 ' 5C DI9 6A D!I2 6C DIll 7A Dl14 7C DII3 8A DIi6 8C DII5 9A DI 17 9C COMMON 10A DII9 10C Di18 11A DI21 11C DI20 12A Di23 12C DI22 13A DI2~ 13C DI24 14A DI27 14C DI26 15A D129 I~C D128 16A DI31 16C DI30 17A COMMON 17C D132 18A DI34 18C D133 i 9A D! 36 19C D135 20A DI38 20C D137 21A DI40 21C DI39 22A D142 22C D!41 23A D144 23C DI43 24A D146 24C DI45 25A D148 25C DI47 26A DI49 26(2 COMMON 27A Dl51 27C D150 28A D153 28C DI52 29A D155 29C DI54 30A D157 30C DI56 31A DI59 31C D158 32A COMMON 32C DI60 63 I '1 ! F : T ~l 60 D! ModuZ~ PRO"I'~CTZVE GI~ Figure 2. 60 DI Module - Internally Protected User Connections 64 60 D! Module USER EQUipMENT F' ' ~mm ', NOTE The user protective potential should be within _+ 2.5 kV range relative to the MOSCAD protective ground. Figure 3. 60 DI Module - Externally Protected User Connections ! T i' 60 DI Module 3. DIAGNOSTIC LEDS The module includes a LED panel (see Figure 4) composed of 20 LEDs. The LED functions are as follows: 60 DIGITAL INPUI' Dli0 1 5 9 13 DM1 2 6 10 14 13D 3 7 11 15 CLK 4 B 12 16 :XIL INPUT STATE Figure 4. 60 DI Module - LED Panel DM0, DM 1 Indicates Display Mode of the status LEDs, according to the table below: Display Mode Status LEDs 1 - 16 DM1 DMO Indicate Inputs: 0 0 I -16 0 I 17- 32 I 0 33 - 48 I I 48 - 60* * Status LEDs 13 - 16 are not used in this Display Mode. MOD When lit, indicates that the CPU cannot access the mod- ule. This happens when the module has failed, or was' installed in a slot assigned for another module. CLK When lit, indicates absence of system clock. 1-16 LEDs Display status of the corresponding input (see definition of DM0 and DM1 LEDs): LED lit = closed input, LED off .- open input. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. Door label 5402853D12 Protective plastic strip for the door label 6108874S01 66 1 '! I I T I LINE INTERFACE UNIT 1. OVERVIEW The Line Interface Unit provides the interface required to connect the internal line modem (installed in the CPU) to various types of communication lines. Figure I provides a general view of the Line Interface Unit. The unit transmitting level is -10 dBm into 600 fl impedance. The receiving dy- namic range is -3 dbm to -47 dBm. The unit's line impedance is 600 fl in both the receiving and transmitting states. 2. OPTIONS The Line Interface Unit has several options, each of which supports a different type of communication line. Table I details the available options. Table 1. Line Interface Unit Options Type Description FRN1985A Interfaces the internal line modem to a telephone line. The telephone line Telephone Line interface operates in full-duplex mode. FRN1986A This option allows the CPU internal line modern to communicate with Multi-Drop several modems in other RTUs using a single pair of wires. The multi- drop interface operates in half-duplex mode. NOTE Only the 1200 BPS internal line modem is supported by the multi-drop option. FRN1987A This option allows for the connection of the CPU internal line modern to · Leased Line a communication line using a dedicated pair or two pairs of wires. The leased line interface operates in full-duplex mode. 67 Line inte~race Unit 2~lepl~one Line Option Leased Line Option Figure 1. Line Interface Unit - Genera/View 68 I Line Interface Unit 3. INSTALLATION NOTE The Line Interface Unit can only be operated when the Internal Modem board (FRN5669A or FRN5639A) is installed in the CPU module. 3.1 UNIT INSTALLATION The unit is easily installed by snapping it into the various RTU chassis. The instal- , lation locations are shown in Figures 2 and 3 (for 19" rack mounted RTU and 6-slot RTU, respectively). For installation instructions refer to section 3.3.2. POWER , o LOC~T,3,S ~ SUppLyN,,..N~ ; UNE INTERFACE uNrr . o @ o o o INTERFACE * · UNIT BATrE @ ..... ~ .... -~. Figure 2. Line Interface Unit - Installation Location (For 19" Rack Chassis) 3.2 ELECTRICAL CONNECTION Perform the instructions given in section 3.2.1 and in the subsection of 3.2.2 that corresponds to the option installed. 3.2.1 Internal Connections (1) Connect communication cable FKN5953 between port FROM MODEM on the line interface unit and port 3 on the CPU. NOTE Several installation locations are provided (see Figure 2). In some cases, the length of cable FKN5953 may not be sufficient and another cable might be required. (2) Connect a grounding wire between terminal 6 of the TB connector located on the Line Interface Unit and the protective ground strip located below the power supply on the RTU chassis. 69 Line Interface Unit 3.2.2 External Connections NOTE For NEMA4 housing, thread the wires through the opening at the bottom of the box. 3.2.2.1 Telephone Line Option See Figure 3. There are two options for connecting the line wire to the Line Interface Unit: - If the telephone line has an RJ ! 1 connector, plug it into the LINE connector on' the unit's front. panel. . - If the telephone line is made of two wires, connect the wires to terminals I and 2 of the unit's front panel TB. The polarity is insignificant. II I L .,_oPT I~.~_. - till I t.._b-"-'g~''l) ~ - IUT[RUAL CABL[: FKI15953 OR "' D[P[ND$ 0tl DISTAg[ Bf'T!ff[ll CPU ~ AND LIIIE-IIITF'IIFAC[ UNIT. Figure 3. Line Interface Unit - Telephone Line Option Electrical Connections (For 6-Slot Chassis) 70 , · 'm m T T I Line Inter]ace Unit 3.2.2.2 Multi-Drop Option See Figure 4. Connect the line wires to terminals 4 and 5 of the unit's front panel TB. o.~ ~ ~ ... PHOT ./.,.,.,.,.,.,.,.,.~? e,, 6ND k~OGRND~T~~II~%~"~~ i r' *')k' - INTERNAL CABLE: FNN5553 OR OTHER, DEPENDS 011 DISTANCE 8[TII[EN CPU , /,.J ,,,--k---'-*k' AID LINE-INTERFACE UNIT. j~ - Figure 4. Line Interface Unit - Multi-Drop Option Electrical Connections (For 6-Slot Chassis) 3.2.2.3 Leased Line Option See Figure 5. This option supports both two- and four-wire connections. Perform the instrue- tions from either section a or b below. a. Two-Wire Line Connection ( 1 ) Set both switches of dip-switch 2W/4W SELECT on the unit's front panel to position 2W. (2) There are two options to connect the line wire to the unit: - If the line has an RJ 11 connector, plug it into the 2~WIRE LINE connector on the unit front panel. or: - If the line does not have an RJ 11 connector, connect the wires to terminals 1 and 2 of the unit's front panel TB. The polarity is insignificant. Line Interface Unit SEE DETAIL · .~i~,%~ 2WLEASED ~ L, NE OPTION 2W TX/RX LEASED LINE THE DIP $11TCH ~- I 4W LEASED LINE OPTION LEASED LINE Figure 5. Line Interface Unit - Leased Line Option Electrical Connections (For 6-slot chassis) 72 ' I ~ '1 ' ' I i I i · Line lnterJitce Unit b. Four-Wire Line Connection ( 1 ) Set both switches of dip-switch 2W/4W SELECT on the unit's front panel to position 4W. (2) Connect the TX line wires to terminals 1 and 2 of the unit's front panel TB. The polarity is insignificant. Note that this line should be connected to the line interface's (modem 's) RX input on the other end of the line (see Fig- ure 6). LINE INTERFACE A LINE INTERFACE B Figure 6. Typical 4-Wire Line Modem Interconnection (3) Connect the RX line wires to terminals 4 and 5 of the TB on the unit front panel. The polarity is insignificant. Note that this line should be connected to the line interface's (modem's) TX input on the other end of the line. ~ 3.3 LINE INTERFACE UNIT REPLACEMENT The following paragraphs provide instructions for replacing the entire Line Inter- facd Unit and for replacing only the Line Interface circuit board installed in the unit. 3.3.1 l,ine Interface Unit Removal Insert a screwdriver into the notch located in the snap securing the unit to the chas- sis. Slightly bend the snap outwards to release it from the chassis's slot, and care- fully pull the unit out. 3.3.2 Line Interface Ut~it Installation (1) Insert the hook, located on the unit's back panel, into the appropriate slot on the chassis. (2) Insert the two guiding pins and the snap into the appropriate slots on the chassis and snap the unit into the chassis. Line Interface Unit 3.3.3 Line Interface Board Removal (1) Remove the connectors connected to the Line Interface Unit. (2) Press the snap securing the front panel to the unit housing and pull out the /'~ front panel.. (3) Pull out the board. 3.3.4 Line Interface Board Installation Perform the instructions in paragraph 3.3.3 in reverse order. NOTE · The Line Interface board can be installed in either of the two available slots on the unit housing, with the front panel positioned accordingly. However, in some installations only one of the ~ above-mentioned orientations is convenient, due to the communi- cation cable length. 4. DIAGNOSTIC LEDS The LED indicator operation of the various Line Interface Unit options is de- ~scribed below. a. Telephone Line Option Off Hook - When lit, indicates that the modern is in the off-hook state. Ring Indication - When lit, indicates incoming call ring indication. b. Multi-Drop Option Tx - When lit, indicates transmission from modem. 5. FIELD REPLACEABLE SPARE PARTS Description Part No. CPU-to-radio communication cable FKN5953A Modem connection TB (6 contacts) 2808508G10 Plastic housing 1502804E01 74 AC ANALYZER 1. OVERVIEW 1.1 GENERAL The MOSCAD AC Analyzer (ACA) system enables the MOSCAD RTU to ana- lyze a three-phase electrical network. It performs various calculations such as power and harmonics, which are transferred to the CPU module for local proces- sing or for reporting to a central facility. The MOSCAD ACA system is a key component in Electrical Distribution Au- tomation systems. It is typically used for Monitoring and Control of Feeder Switches, Capacitor switches and Sub-stations, as well as in End-of-Interval I)e- mand applications. The ACA system includes two major units: ACA Module and ACA Termination Panel. A cable that connects the two units is also supplied. Figure 1 shows a gener- al view of the ACA system. The ACA system is available in the following configurations: · FRN 1988A ACA Module · FRN2031A ACA Termination Panel, 115 V ac operation 1.2 MOSCAD RTU AND TOOL BOX SOFTWARE VERSION COMPATIBILITY Programming Tool Box The ACA System is supported by Programming Tool Box versions 2.10 or higher. MOSCAD RTU System Software The ACA System is supported by MOSCAD RTU system software versions 2.00 or higher. AC Analyzer ACA MODULE POWER SUPPLY ; ~ (NOT A PART OF ACA) INTERCONNECTION · CABLE ACA TERMINATION PANEL Figure 1. ACA System - General View I 1 "" '1 .... I ] I A C' A natyzer 1.3 DESCRIPTION The ACA system is used to analyze the voltage, current and other parameters of an ac electrical network. The system has three pairs of voltage-current analog inputs and a pair of auxiliary analog inputs for monitoring an ac network. In addition, it has eight digital wet inputs and eight relay outputs. All the analog inputs are independent.' The only limitation is that one of the voltage inputs (V 1, V2 or V3) must be connected to synchronize the wave cycle time. User connections are made to the Termination Panel, which is connected to the ACA module via a &C-pin cable. The Termination Panel adjusts the ac network voltage and current input levels to the ACA module levels by transformers and re- sistor networks. The auxiliary analog inputs are adjusted by resistor networks only. In addition, the Termination Panel houses the user control relays and the digital wet inputs. Figure 2 shows the ACA Termination Panel layout. ACA MODULE 12V POWER (J2) CONNECTOR (Jl) 00300oooooo ~ffAL ~ K7 & K0 B & K6 K3 & K4 K1 & ~ AUXIL~ CURR~ CURR~ VOLTAGE PROTE~E INP~S (~) O~S ~S O~S O~S IN~S INP~S I~S I~ GRO~D (~) (J4a) (~C) (~) (~ (~) (~ (~) (~) Figure 2. ACA Termination Panel ~ C A nal~zer 1.4 MODULE I/O CONNECTOR The ACA module and the Termination Panel are interconnected by a 64-pin cable. Table I details the module FO connector pin definitions, which also applies to the Termination Panel J 1 connector. Table 2. Module I/O Connector - Pin Definitions Pin No. Signal Name Pin No. Signal Name IA - IC - 2A VI 2C VIRET 3A GND 3C l ] 4A IIRET 4C V2 5A GND 5C V2RET 6A GND 6C 12 7A 12RET 7C GND 8A V3 8C V3RET 9A GND 9C I3 10A 13RET 10C GND I 1A AUXI I 1C AUXIRET 12A GND 12C AUX2 13A AUX2RET 13C GND 14A RELAYRETI 14C K1 ON 15A K2 ON 15C K3 ON 16A K4ON 16C K5 ON 17A K6 ON 17C RELAYRET2 18A K7 ON 18C K8 ON 19A K9 ON 19C KI0 ON 20A RELAYRET3 20C K11 ON 21A Ki2 ON 21C KI3 ON 22A KI~, ON 22C KI5 ON 23A K 16 ON 23C RELAYRET4 24A - 24C D! 1 25A DI 1RET 25C Dl2 26A DI2RET 26C DI3 27A DI3RET 27C DI4 28A DI4RET 28C D!5 29A DI5RET 29C DI6 30A DI6RET 30C DI7 31A DI7RET 31C D18 32A D!SRET 32C - [ I '1" ~ 'i I I nt. nnauyz~r 1.5 AC ANALYZER SYSTEM SPECIFICATIONS AC ANALYZER MODULE (FRN1988A) INPUTS 8 Analog Inputs 10 V ptp maximum, 50/60 Hz 8 Digital Wet Inputs ON: 7 to 28 V OFF: 0 to 3.5 V OUTPUTS Type 16 Open Drain Maximum Voltage 50 Vdc Maximum Current 0.5 A ON Resistance 0.1 ~2 maximum Maximum Power 1.7 W INDICATIONS 20 LEDs USER CONNECTION 64-pin DIN connector For connection to termination panel AC ANALYZER llSV TERMINATION PANEL (FLN2031A) VOLTAGE INPUTS Number of Transformers 3 Input Voltage FLN2031A: 115 Vac Maximum Input Voltage 300 Vac Dielectric Strength 2500 V between primary and secondary Full Scale Adjustment FLN2031A: Vin - 115 Vac provides Vout - 2.5 to 3 Vac TB Type 8 positions header with plug TB Pin Assignment 6 voltage inputs I protective ground 1 spare TB Rating 12 A, 250 V Number of TBs 1 TB Wire 12 AWG CURRENT INPUTS Number of Transformers 3 Current Sense Range 0 to 5 A at/de typical, 20 A ac peak Dielectric Strength 2500 V between primary and secondary Full Scale Adjustment Iin" 10 Aac provides 3 to 3.3 Vac TB Type 3 connectors, two positions each TB Rating 34 A, 750 V Number of TBs 3 79 AC Analyzer AUXILIARY ANALOG INPUTS Number of Inputs 2 Current Sense Range 0 to 9 Vac ~/~ Full Scale Adjustment Vin - 5 Vac provides 2.4 to 2.9 Vac TB Type 4 positions header with plug TB Pin Assignment 4 positions for voltage inputs TB Rating 12 A, 250 V Number of TBs 1 TB Wire i 2 AWG DIGITAL WET INPUTS Number of Inputs 8 Input Range · ON 81o28V · OFF 01o3.5V ' TB Type 10 positions header with plug TB Pin Assignment Common return for every 4 inputs TB Rating 12 A, 250 V Number of TBs 1 TB Wire 12 AWG 2A ELECTRICALLY ENERGIZED RELAYS Number of Relays 2 Form C Contact Rating 2 A, 250 Vac, 220 Vdc, 60 W, 125 VA ~/~ 2A MAGNETICALLY LATCHED RELAYS Number of Relays 2 Form C Contact Rating 2 A, 250 Vac, 220 Vale, 60 W, 125 VA 8A ELECTRICALLY ENERGIZED RELAYS Number of Relays 2 Form C Contact Rating 8 A, 250 Vac/dc, 150 W, 2000 VA 8A MAGNETICALLY LATCHED RELAYS Number of Relays 2 Form C Contact Rating 8 A, 250 Vac/dc, 150 W, 2000 VA Relays' TB · TB Type 6 positions header with plug · TB Rating 12 A, 250 V · Number of TBs 4 · TB Wire 12 AWG POWER FOR RELAYS Voltage 10.4 Vdc minimum - 16 Vdc maximum Current 253 mA maximum ~ Surge Withstand all I/Os ANSFIEEE C.37.90.1 ~ 80 '! : I I T T I 2. INSTALLATION 2.1 AC ANALYZER MODULE LOCATION The AC Analyzer module should be installed in a MOSCAD RTU slot designated by the Programming Tool Box site configuration program. 2.2 TERMINATION PANEL MOUNTING The Termination Panel location should be selected so that the cables c6nnecting it to the RTU will not interfere with the wires connected to the user connectors. The distance between the Termination Panel and MOSCAD RTU should fit the length of the control and power cables interconnecting the units (the maximum recommended cable length is one meter). The Termination Panel is supplied installed in a plastic rail housing. Side brackets mounted on both of its sides secure the Termination panel to the plastic housing and, in addition, allow for wall mounting of the panel (by means of four screws). The Termination panel kit also includes a 19" DIN rail for installing the Termina- tion Panel in 19" racks and the adaptors for mounting the plastic rail housing on the DIN rail. Figure 3 shows the Termination Panel installation dimensions. 422 mm (16.6") ae '~ 407.5 mm (16.04") ~,__~.V Figure ~. Termination Panel Installation Dimensions 2.3 ELECTRICAL CONNECTIONS ( 1 ) Connect good earth ground directly to the protective ground strip of the MOS- CAD RTU. (2) Connect the earth ground to one of the pins of the protective ground TB (J9) on the Termination Panel (see Figure 4). (3) Connect power cable FKN4090A between the MOSCAD power supply AUX connector and the Termination Panel 12 V IN connector (J2) (see Figures 1 and 4). 81 A C A nalyzer (4) Connect the Interconnection cable between the ACA module user connector and the Terminal Panel's J 1 connector (see Figure 1 ). NOTE For best performance, the interconnection cable length should be limited to I m (40"). (5) Connect the user devices to the user connection TBs. Refer to Figures 4 and 5. IMPORTANT The wires connected 'to analog inputs should be isolated from the other wires, in order to avoid wire crosstalk. J1 J3 J4A J4B J4C J4D J5 J6 J7 J8 J9 12345678910 123456 789101112 131415'161'Tt8132021222324 '1234 I 2 3 I 2 3 123.45678 , 2 3 PROTECTIVE GROUND DIGITAL WET INPUTS PROT. GND. PROT, DI1 PROT. GND. DI2 -- DI3 -- DI4 ~ DI1 - 4 RETURN VOLTAGE II~PUTS DIS SPARE DI6 -- GROUND DI7 -- V1 NEUTRAL DI8 -- V1 HOT DIS - 8 RETURN V2 NEUTRAL K8 COIVlAON ~ V2 HOT K8 NC -- V3 NEUTRAL K8 NO -- V3 HOT K7 NO -- K7 NO K6 COMMON - CURRFNT INPUTS ' ' -- CURRENT1 IN . K5 NO K5 NC -- CURRENT1 OUT 5 COMMON CURRENT2 IN CURRENT2 OUT CURRENT3 IN OUTPUTS K3 NO CURRENT3 OUT K3 NC COMMON AUXILIARY INPUTS K2 COMMON K2 NC -- AUX2 - J K2 NO -- AUX2 + 0 - 9 V AC/DC K1 NO AUX1 - K1 NC -- AUX1 + COMMON Figure 4. User Connectors - Pin Definition 82 ~ i e ~ I T T I A C Analyzer 7 - 28 V clc B~r~rfAL WET INPUT~ VOLTArat: BOPtitS UF_.ASOaF. NEiVT ' DI2 -- GROUND DI3 v1NE. ,L ~ DI4 V1 HOT · V2HOT v3 NE .,,L V3 HOT PH2 NEUTRAL MO$CAD AC ANALYZER RELAY OUTPUTS NF.4SI/rENF. Nr + CURRENT INPUT~ -- CURRENT1 IN ----~ f--K2COMMON CONTROLLED E~ -- CURRENT1 OUT DEVICE -- K2 NC -- ' K2 NO -- -- CURRENT2 IN ~ , K1 NO CURFIENT2 OUT K1 NC -- -- CURRENT3 IN K1 COMMON -- CURRENT3 OUT CURRI=NT INPUTS VOLtAM INPUTS vOL/'~G~: I/F_..4$URF. NENF O CURRENT1 IN -- CURRENT1 OUT -- GROUND O CURRENT2 IN -- MOSCAD w NEUTRAL :~1~E CURRENT2 OUT AC ANALYZER w HOT V2 NOT PH1 PH2 PH1PH2 PH3 Figure 5. Typical User Connections 2.4 AC ANALYZER MODULE REPLACEMENT Refer to the RTU INSTALLATION chapter in this manual. 83 AC Analyzer 3. SCALING THE ANALOG INPUTS 3.1 GENERAL By default, the ACA module reports the results in units as a proportion of the full scale measurements as opposed to physical units. The MOSCAD Programming Tool Box can be used for' scaling the analog input measurements into physical units, e.g. volts and ampers. 3.2 SCALING PROCEDURE The scaling procedure is provided by the Programming Tool Box. 4. DIAGNOSTIC LEDS The ACA module includes a LED panel composed of 20 LEDs (see Figure 4). All the LEDs (except for the CLK LED) light in the corresponding conditions only if they are enabled by the CPU module. The LEDs in the IN/OUT area of the panel are dual-function. The upper (white) labels indicate the status of the module inputs, while the lower (green) labels indi- cate the status of the module outputs. The OUT LED indicates the currently active function. The LED functions are as follows: AC- ANALYZER OUT 1 5 V1 I1 i 5 9 13 2 6 V2 I2 RUt 2 8 10 1~ ~l) L31 7 V3 I3 7 11 15 4 8 SP 1 SP2 CLK q ~ 12 !8 F)IL IN / OUT Figure 6. ACA Module LED Panel OUT Indicates LED display mode. When off, the upper labels of the IN/OUT LEDs indicate the current LED function. When lit, the lower labels of the IN/OUT LEDs indicate the current LED function. RUN - When lit, indicates that the downloading has been per- formed and the module software is running. When off, it indicates that either download has not yet been per- formed, or there is a hardware malfunction. 84 AC Analyz~r MOD When lit, indicates that the CPU cannot access the mod- ule. This happens when either the module has failed or is installed in a slot assigned for another module. CLK When lit, indicates absence of system clock. 1-8 LEDs lf the OUT LED is off.' Display status of the corresponding digital input: LED lit = input is closed (voltage is present); LED off = input is open (no voltage is present). lf the OUT LED is lit: Displays status of the corresponding digital output: LED lit -- output is ON, LED off = output is OFF. VI-V3 LEDs - ApplicableonlywhentheOUTLEDisoff.Whenlit, indi- . cates that the corresponding input voltage is above the predefinod value 'set via the Tool Box. I 1 -I3 LEDs - Applicable only when the OUTLED is off. When lit, indi- cates that the corresponding input current is above a pre- defined value set via the Tool Box. SP I, SP2 LEDs - Applicable only when the OUT LED is off. Represents the AUX I and AUX2 inputs. When lit, indicates that the cor- responding input is above a prodefined value set via the Tool Box. 9-16 LEDs - Applicable only when the OUT LED is lit: Displays status of the corresponding digital output: LED lit - output is ON, LED off - output is OFF. 5. FIELD REPLACEABLE SPARE PARTS Description Part No. 19" DIN Rail 0704858K01 Side Bracket for Plastic Rail Housing 0704851K01 Plastic Rail Housing 1504436E01 ACA Module-to-Termination Panel Interconnection Cable (flat) 3002233C07 ACA Module-to-Termination Panel Interconnection Cable (round) 3002132C16 User's Connection Plug, 4-contacts' 3108509G,?.0 User's Connection Plug, 6-contacts 3108509G21 User's Connection Plug, 8-contacts 3108509G19 User's Connection Plug, 1 O-contacts 3108509G18 Adaptor for DIN Rail 4202922S02 Door label 5402853D14 Protective plastic strip for door label 6108874S01 Power Supply-to-Termination Panel DC Cable FKN4090A 85 A C A nalyzer This Page Intentionally Left Blank 86 8A POWER SUPPLY/CHARGER MODELS FPN5522A, FPN5544A 1. OVERVIEW The power supply provides DC power for the RTU operation and charges the RTU battery. Figure 1 provides a general view of the power supply. o Figure 1. RTU Power Supply - General View The following power supply models are covered by this chapter: FPN5522A Charging power supply 8 A, 120 VAC. FPN5544A Charging power supply 8 A, 220 VAC. 87 8A Power Supply/Charger 2. ELECTRICAL CONNECTION WARNING Make sure that line power is off before connecting it to the RTU. (1) The RTU power supply operating voltage is printed on the power supply front panel above the TB. Make sure that this voltage matches your'line voltage. (2) Remove plastic cover from the power supply TB. Connect the power wiring according to Figure 2. NOTES 1. Use the RTU dedicated ground strip as the source for the line ground input. 2. It is recommended that a 10 A fuse dedicated to the MOSCAD RTU he installed in the site's power distribution panel. 3. The DC ON/OFF switch on the power supply front panel con- trols the 12 VDC voltage only. (3) Mount the plastic cover back on the power supply TB. (4) Make sure the radio DC cable is connected to the power supply connector RADIO (J2). (5) Connect the cable from the battery to the power supply connector BATT (J 1 ). (This cable is deliberately disconnected at factory to remove power from the unit during shipment.) N 0 (~) O U L - ~) T J FROMR{ WHITE (NEUTRAL) N 0 _(~) I LINE N POwE GREEN (GND) PGND Fo ololo1 1ol ] I PROT. GND. STRIP Figure 2. Power Supply TB Layout 88 I ~A Power 5upptyl(.narger ; 3. OPERATION 3.1 CONTROLS, INDICATORS AND CONNECTORS The power supply controls, indicators and connectors are described in Table I and illustrated in Figure 3. Table 1. Power Supply - Controls, Indicators and Connedors Item in Name Function (~) ' -- '~" Figure 3 tr'Z'~:~m~ ~y,~ I LOGIC (J4) Connector. Connects power and O ? logic signals to the motherboard. C LB ' ~o ~ 2 AUX (J3) DC output connector. Supplies 12 VDC power to auxiliary cir- cuits. 3 RADIO (J2) DC output connector. 'Supplies :sj~ 12 VDC power to the radio. 4 BATT (J1) Connector. Used for intercon- necting 12 VDC power between ~?o~w~:F ~(~- the power supply and the battery. 5 F2 10 A fuse (6508448S06). Pro- tects against DC power ovedoad to battery. Tm 6 DC ON/OFF Switch. Controls power supply ~- DC output. . o O o · O Tu ~ 7 DS1 Lamp. Lit when the power supply t O i is on. I . o O . 8 F1 6 A fuse (6508448S10). Protects Pc-,o -~ O J_ against AC power overload. I ~ e,.._% 9 TB1 Terminal block (TB). Provides line power input and output con- nections. Figure 3. Power Supply 10 Screw. Protective ground con- Front Panel nection. 3.2 OPERATING INSTRUCTIONS To turn on the RTU, set the DC switch on the power supply front panel to ON. NOTE If the lithium battery insulating strip is removed and the power supply is off, lithium battery power is used for maintaining data - - stored in the CPU RAM. If this data is not required (i.e. the RTU is currently not operational) insert the insulating strip back into the lithium battery housing. 89 I 'I '! ! F T i' ' n 8A Power 5upplylCharger 4. REMOVAL AND INSTALLATION The power supply is attached to the RTU by two captive screws. 5. FIELD REPLACEABLE SPARE PARTS Description Part No. Fuse F1,6.3 A 6508448S10 ~ Fuse F2, 10 A, slow blow 6508448S06 TB plastic cover 3808448S02 I MAXTRAC® VHF RADIO MAXTRAC® UHF RADIO MAXTRAC® 800 AND 900 TRUNKED RADIO MAXTRAC® 800 CONVENTIONAL RADIO 1. ELECTRICAL CONNECTIONS NOTES Make sure the radio DC cable is connected to the appropriate con- nector of the internal power supply (refer to the specific power supply chapter). Make sure the radio communication cable (the cable with a tele- phone plug at both ends) is connected between PORT 3 connector in the CPU module and the connector on the rear panel of the ra- dio. 2.. OPERATION Set that the radio ON/OFF knob to the ON position. NOTE The volume level does not affect the quality of the RTU operation. It is, therefore, recommended to set the volume to the minimal level, so as to minimize power consumption from the battery in case of power failure. 91 I I :! ! I T I F~ MaxTrac Radios 3. REMOVAL AND INSTALLATION 3.1 REMOVAL ( 1 ) Disconnect the DC power and antenna cables connected to the radio. (2) Disconnect the data cable connected to the 16-pin connector adapter on the ra- dio rear panel. (3) Press the snap fastening the adaptor to the radio (see Figure 1 ) and remove the adaptor. PUSH THIS SNAP TO RELEASE THE ADAPTOR TO CPU <~ ~~ TO RADIO I Figure 1. Radio Communications Cable Adaptor (4) Remove the screw securing the radio to the radio mounting bracket. (5) Partially release (but don't remove!) the screw securing the radio mounting bracket to the RTU chassis, to allow convenient radio removal from the brack- et. 3.2 INSTALLATION Perform the removal instructions in reverse order. 4. FIELD REPLACEABLE SPARE PARTS Description Part No. MaxTrac radio mounting bracket FHN5600B MaxTrac data cable adaptor FLN6433B 92 DARCOM 9000 -2 RADIO 1. ELECTRICAL CONNECTIONS NOTES Make sure the radio DC cable is connected to the appropriate con- hector of the internal power supply (refer to the chapter in this manual pertaining to the power supply installed). Make sure the radio communication cable (the cable with a tele- phone plug at both ends) connects CPU PORT 3 and the connec- tor on the rear panel of the radio. 2. REMOVAL AND INSTALLATION The following procedure applies to a MOSCAD RTU with a basic Darcom 9000-2 radio unit. NOTE MOSCAD system that uses Darcom radios includes a Repeater. Make sure to adjust the repeater according to the tables provided in its manual. Refer to the chapter Using Darcom in MOSCAD Systems (68P02933C30) in the MOSCAD RTU Service manual (68P02991G90). Removal: (1) Disconnect the radio DC power cable from the power supply and the antenna cable from the radio. (2) Disconnect-the data cable connected to the 8-pin phone connector. (3) Release the screws securing the radio mounting bracket to the RTU chassis. (4) Remove the 8-pin phone connector adapter as follows: a. Remove the screws securing the radio mounting bracket to the radio and remove the bracket. b. Remove the radio bottom covet c. Remove the adaptor support bracket. Installation: Perform the removal instructions in reverse order. 93 Darcom 9000-2 Radios 3. FIELD REPLACEABLE SPARE PARTS Description Part No. Darcom radio mounting bracket FHN5626A Adaptor board for Darcom data cable FLN6594A Metal support bracket for the radio cable adaptor board 0702831F01 94 MT 2000TM MODEL A4 RADIO 1. ELECTRICAL CONNECTIONS NOTES Make sure the radio I)C cable is properly connected to the power supply (refer to the chapter in this manual pertaining to thepower supply installed or to appendix B if an external power supply is used). Make sure the radio communication cable (the cable with a tele- phone plug at both ends) connects CPU PORT 3 and the connector on the rear panel of the radio. 2. OPERATION Set the radio ON/OFF knob to the ON position. .- NOTE The volume level does not affect the quality of the RTU operation. It is, therefore, recommended to set the volume to the minimal level, so as to minimize power consumption from the battery in case of power failure. 95 MT 2000 Model A4 Radios 3. REMOVAL AND INSTALLATION 3.1 REMOVAL (1)Disconnect the radio DC power, antenna and data cables connected to the ra- dio. " (2)Release the two screws securing the radio mounting bracket to the RTU chas- sis and remove the radio assembly. (3) Press inwards the two snaps securing the radio plastic base to the bracket. (4) Rotate the radio base and remove it from the mounting bracket. ~~ (5) Hold the radio so that its control panel faces upwards. (6) Press down on the two release levers securing the radio base to the radio. I~ ~ (7) With the release levers pressed down, rotate the radio base away from the ra- dio and separate them. 3.2 INSTALLATION Perform the removal instructions in reverse order. 4. HELD REPLACEABLE SPARE PARTS Description Part No. Interface Board FLN5751A Adaptor Board FLN5753A Plastic Base 1504336K01 Adaptor Board Cover 1504338K01 SMA to BNC Adaptor 5880348833 Mounting Bracket 0704816K01 96 APPENDIX A: CABLES AND ADAPTERS 1. GENERAL This appendix provides supplementary data on cables and adaptors used in various · MOSCAD systems. The following applications are covered: - RTU-to-computer/terminal connections - RTU-to-modem connections - RTU-to-radio connections - RTU-to-X.25 connections - RTU-to-RTU connections - Connecting a user port to a printer 97 Appendix A: Cables and Adaptors 2. RTU-TO-COMPUTER/TERMINAL CONNECTION 2.1 RTU-TO-COMPUTER/TERMINAL ASYNCHRONOUS COMMUNICATIONS Use the FLN6457 cable kit to connect one of the MOSCAD RTU RS232 Ports to a computer or aterminal. The kit includes a cable with RJ45 modular jacks on both ends and a RJ45 to 25-pin female D-Type adaptor (part no. 0198213661, see Fig- ure 1 ). The RTU port configurations are detailed in Table 1. Table 1. RTU-to--Computer/Terminal Asynchronous Communications Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 1B - RS-232 UART Local Computer (MDLC) 2 - RS-232 UART Local Computer (MDLC) 3 FRN5655A RS-232 UART Local Computer (MDLC) 3 FRN5724A RS-232 UART Local Computer (MDLC) NOTE When a User Port is defined as Computer/Terminal with DTR support: l ) The RTU will not transmit unless it receives DTR-on from the computer/terminal. 2) The RTU will not receive unless it receives RTS--on from the computer/terminal. See pin 20 of the 25-pin Female connector. J1 J2 (25-PIN ( RJ45 ) D - TYPE ) TX_DATA >2 s ~< Tx_DATA RX_DATA )1 w 3< RX_.DATA RTS >5 s 4< RTS CTS ) 8 s 5< CTS DSR )7 s 6< DSR GND >4 7< GND DTR ) 3 · 20< DTR ReC_LINE (DCD)>6 s 8<ReC_LINE (DCD) ~ Figure 1. RJ45-to-D-Type Female Connector Adaptor 0198213661 98 ~ I 'T T T I i Appendix A: Cables and Adaptors 2.2 RTU-TO-COMPUTER/TERMINAL SYNCHRONOUS/ASYNCHRONOUS COMMUNICATIONS ADAPTOR The RTU can be connected to a computer or a terminal via its serial communica- tions port and serve as a DCE. This section provides data on the FRN5726A adap- tor which interfaces between the RJ45 connector on the cable connected to the RTU and the 25-pin D-Type connector on the cable connected to the modem (refer to Figure 2). The FRN5726A adaptor includes jumpers that allow it to operate in both the syn- chronous and asynchronous modes (see Table 2). The RTU port configurations are detailed in Tables 3 and 4. Table 2. FRN5726A Adaptor Configuration Mode Jumper Position SYNCIASYNC TxCLK Asynchronous (default) ASYNC NORMAL, ASYNC Synchronous SYNC NORMAL / DTE SOURCE * · According to the TooiBox definition. TO/FROM TERMINAL TO/FROM RTU (D-TYPE 25 PIN, (AS DCE) FEMALE) (RJ45) TxDATA >2 s 2< TXDATA RXDATA >3 s 1< RxDATA RTS )4 m 1~ 5< RTS YNC 2 CTS >5 · o ASYNC n 3 DSR )~ : 2 ~ 3 ASYNC GND )7 SYNC 4< GND DCD >8 s 6< DCD TXCLK >15 s NORMAL,ASYNC ['~ ~ · 7< TXCLK/DSR {uCE SOURCE~ { TxCLX I3 "DTE SOURCE RXCLK >17 · 8< RXCLK/CTS 20 3< DTR DTR > s TXCLK >24 . (DTE SOURCE) Figure 2. FRN5726A R]45-to-D-Type Female Connector Adaptor Appendix A: Cables and Adaptors Table 3. RTU-to-Computer/Terminal Synchronous Communications - Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 1B - RS-232 Sync RTU-to-RTU (MDLC) 3 FRN5654A RS-232 Sync (RTU as DCE) 3 FRN5654A RS-232 Sync (RTU as DCE with TxCLK input) 3 FRN5724A RS-232 Sync (RTU as DCE) 3 FRN5724A RS-232 Sync (RTU as DCE with TxCLK input) Table 4. RTU-to-Computer/Terminal Asynchronous Communications - Port Data CPU Port Used with Piggyback No. Board Toolbox Definition 1B - RS-232 UART Local Computer (MDLC) 2 - RS-232 UART Local Computer (MDLC) 3 FRN5655A RS-232 UART Local Computer (MDLC) 3 FRN5724A RS-232 UART Local Computer (MDLC) I00 Appendix A: Cables and Adaptors 3. RTU-TO-MODEM CONNECTION 3.1 RTU-TO-MODEM ASYNCHRONOUS CONNECTION (DTE-TO-DCE) Use the FLN6458 cable kit to connect one of the MOSCAD RTU RS232 Porxs asynchronously to a Modem (the RTU serves as DTE). The kit includes a cable with RJ45 modular jacks on both ends and a RJ45 to 25-pin female D-Type adap- tor (part no. 0198213662, see Figure 3). Table 5 details the possible RTU configu- rations. - Table 5. RTU-to-Asynchronous Modem Communications - Port Data CPU Used with · Port Piggyback Toolbox Definition No. Board 2 - RS-232 UART External Modem (MDLC) 3 FRN5655A RS-232 Async External Modem, Full Duplex or Multi-Drop Half Duplex 3 FRN5724A RS-232 Async External Modern, Full Duplex or Multi-Drop Half Duplex NOTES I. Before transmitting, the RTU sends RTS=on to the modem, and expects CTS=,on from the modem as a condition for transmitting. 2. The RTU will receive data from the modem only when DCD=on. 3. When using a modem in auto-answer mode (connected to a Computer port) for remote service, the RTU does not support RTS/CTS protocol, as the port is designated to operate with a 1o- cal computer as well as with a modem. Refer to the jumpers set- ting described in the Utilities chapter of the Programming Tool Box Operating Instructions manual. J2 J1 (25-PIN ( RJ45 ) D - TYPE ) TX_DATA >1 ~, 2 < TX_DATA ~~l RX_DATA )2 ,. 3 < Rx_DATA RTS )6 ~, 4< RTS . M CTS >3 . 5< CTS GND >4 7 < GND ]~ DTR >8 u, 20< DTR ReC_LINE (DCD) >5 ,~ 8< ReC_LINE (DCD) +12V )7 NOT USED Figure 3. RJ45-to-D-Type Male Connector Adaptor 0 ] 982 ] 3662 10l ! '! ! I T ! 11 Appendix A: Cables and AdapWrs 3.2 RTU-TO-MODEM SYNCHRONOUS CONNECTION (DTE-TO-DCE) Use the FLN6704A cable kit to connect one of the MOSCAD RTU RS232 Ports synchronously to a Modern (the RTU serves as DTE). The kit includes a cable with RJ45 modular jacks on both ends and a RJ45 to 25-pin female D-Type adaptor (part no. 0198213703, see Figure 4). Table 6 details the possible RTU Port config- urations. Table 6. RTU-to-Modem Synchronous Communications -Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 3 FRN5654A RS-232 Sync External Modem, Full Duplex or Multi-Drop Half Duplex, Darcom Modem, Dar- corn Master/Repeater 3 FRN5724A RS-232 Sync External Modern, Full Duplex or Multi-Drop Half Duplex, Darcom Modem, Dar- com Master/Repeater J2 J1 (25-PIN ( RJ45 ) D - TYPE ) TX_DATA )1 . 2 < TX_DATA Rx_DATA >2 · 3 < Rx_DATA RTS >6 ~ 4 < RTS CTS >3 · 5 < CTS GND >4 7< GND TxCLK >8 · 15 ( TxCLK ReC_LINE >5 a 8 ( ReC_LINE RxCLK >7 , 17 < RxCLK Figure 4. RJ45-to-D-Type Male Connector Adaptor 0198213703 102 Appenmx A: C;ao~es ana AaapWrs 3.3 RTU~TO-MODEM SYNCHRONOUS/ASYNCHRONOUS COMMUNICATIONS ADAPTOR BOARD (DTE-to-DCE) The FRN6893A adaptor board can be configured by jumpers for both synchronous and asynchronous communications with a modem. The adaptor interfaces between the RJ45 connector on the cable connected to the RTU and the 25-pin D-Type male connector on the cable connected to the modern (refer to Figure 5). Table 7 defines the adaptor configurations. Tables 5 and 8 detail the possible RTU Port configura- tions. Table 7. FRN6793A Synchronous/Asynchronous Adaptor Configuration · Mode Jumper Position MODE TxCLK Asynchronous (default) ASYNC NORMAL " Synchronous SYNC NORMAL / DTE SOURCE * · According to the TooiBox definition. Table 8. RTU-to-Modem Synchronous/Asynchronous Communications - Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 3 FRN5654A RS-232 Sync External Modern 3 FRN5724A RS-232 External Modern (MDLC) 3 FRN5724A RS-232 Sync TO/FROM RTU TO/FROM MODEM (RJ45) (DTYPE 25 PIN, MALE) TXDATA >1 ~ 2 < TXDATA RxDATA >2 · 3 ( RXDATA RTS >6 m 4 < RTS GND >4 7 < GND ~ NORMAL 15 < TxCLK ~ SYNC 2 & i (DCE SOURCE) o 3 SYNC_TxCLK/ >8 2o& 1 e ? 24 < TxCLK ASYNC_DTR I 3 DTE SOURCE ( DTE SOURCE ) ASYNC ~ 20 < DTR ( ASYNC ONLY ) SYNC_RxCLK/ )7 · 17 < RxCLK ASYNC_NU Figure 5. FRN6893A Adaptor Board 103 T T I .... 11 Appendix A: Cables and Adaptors 4. RTU-TO-RADIO CONNECTION 4.1 RTU-TO-DARCOM 9000-2 RADIO WITH DIAGNOSTICS (via port 3) Use the FLN6796A cable kit to connect the CPU port 3 to a Darcom 9000-2 radio with diagnostics (option V110AB). The kit includes a cable with RJ45 modular jacks on both ends and a RJ45 to 25-pin D-Type adaptor (part no. 019821386I, see Figure 6). The adaptor interfaces between the R j45 connector on the cable con- neeted to the RTU and the 25-pin D-Type connector on the cable connected to the VF Interface board FRN5005A. Table 9 details the required RTU configuration. . Table 9. RTU-to-Darcom 9000-2 Radio Communications - Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 3 FRN5614A Conventional Radio FSK (MDLC) J2 (RJ45) D-TYPE) RXGND>i · 7<SIGNAL GND RxDATA>2 · 14 <RADIO_Rx_FILTERED TXDATA>6 ~ 24 <RADIO_TX_UNFILT RADIO RXEN>3 · 8< GND GND>4 i<GND PTT>8 · 19<RADIO_pTT RADIO TxEN>5 · 17 <RADIO_CM TXGND>7 · 4 < SIGNAL GND Figure 6. RJ45-to-D-Type Male Connector Adaptor 0198213861 104 i ;; '! [ 'T T I Appendix A: Cables and Adaptors 4.2 CONVENTIONAL OR TRUNKED MAXTRAC RADIO ADAPTOR FLN6433B (via port 3) The RTU can be connected to a MaxTrac radio via CPU port 3. This section pro- vides data on the FLN6433B adaptor which interfaces between the P~45 connector on the cable connected to the RTU and the 16-pin connector on the radio (refer to Figure 7). The adaptor is connected to the CPU according to Table 10). Table 10. RTU-to-Synchronous Modem Communications - Port Data CPU Port Used with Piggyback Toolbox Definition No, Board 3 FRN5546A Conventional Radio DFM (MDLC, used with- out the PL, DPL or Repeating mode) 3 FRN5614A Conventional Radio FSK (MDLC); Trunked FSK (MDLC) 3 FRN5708A Conventional Radio DPSK (MDLC); Trunked DPSK (MDLC) RADIO MODEM J1 J2 7 ' 1 ) GND GND > I · t · 9 · GND EMERGENCY SW > R1 1K 7 ) GND 5 R2 FLAT TX ( ,'VV ~ ) RADIO_TX R4 0 IR3 % 1.2K MIC ( 2 T USED NOT USED PTT ( 3 8 ) PT"'~ Rx AUDIO > 11 2 ) RADIO_Rx CM/RADIO_TxE > 8 5 ) CM/RADIO_TXE RADIO_RxE > 14 3 ) RADIO_IND/RADIO_RxE 15 INT SPEAKER 16 EXT SPEAKER Figure 7. RJ45-to- 16-pin Female Connector Adaptor FLN6433B 105 Appenmx ~: Carries ana ~aaptors 4.3 MAXTRAC RADIO-TO-TWO CPUs ADAPTOR FLN6423A (via port 3) NOTE Adaptor FLN6423A can be ordered only as a special product. Contact your local dealer for details. This adaptor allows for connecting two CPUs of an RTU to a MaxTrac radio. Adaptor FLN6423A interfaces between the R J45 connectors on the cables con- nected to port 3 of the two CPUs and the 16-pin connector on the radio (refer to Figure 8). This adaptor can only be used with conventional VHF/UHF MaxTrac radios, while the appropriate piggyback modem boards should be installed in the RTU CPUs. In addition, the Brand Rex 851-B adaptor connector should be used for signal splitting. RADIO MODEM J1 J2 7 1 ) GND GND > · T '~ · 4 ) GND EMERGENCY SW > 1K 7 ) GND 5 R2 ~ 1 FLAT TX < R4 0 R3 lN% 1.2K MIC ( 2 T USED NOT USED PTT ( 3 8 ) PT~ 11 2) Rx AUDIO > RADIO_Rx 8 CM/RADIO_TxE > 5 ) CM/RADIO_TXE 14 3 RADIO_RxE > ) RADIO_IND/RADIO_RxE 15 INT SPEAKER > 16 EXT SPEAKER > 10 R5 M 3904 47K MBT MMBT _ R6 7K Q Q2 Q1 M MB T 39 04 47R~ _MMBT3904"' Figure 8. RJ45-to-16 pin Female Connector Adaptor FLN6423A 106 I i '1 I [ ] I Appendix A: Cables and Adaptors 4.4 RTU-TO-MC MICRO RADIO CABLE FKN4084A This section provides data on the cable recommended for the RTU-to-MC MICRO radio interconnection (see Figure 9). The cable connects the RTU's CPU port 3 and J5 in the MC MICRO radio. The FSK piggyback board FRN5614A must be installed in the CPU module. PIN NO.8 · ~\ PIN NO.1 '~. RJ45 CONNECTOR MC-MICRO RTU MODEM CONNECTOR J1 CONNECTOR J2 (RJ45) PTTB <1 · GREEN 8< PTTB AUDIO-GND < 2 RED 1< RxGND I YELLOW 7< TXGND RADIO_GND < 3 WHITE 4< RADIO_GND I BROWN 3< RADIO_IND Tx<6 · VIOLET 6( TX RX<7 · ORANGE 2< RX CM< 9 ~, BLUE 5 < CM Figure 9. RTU-to-MC Micro Radio Cable 107 Appendix A: Cables and Adaptors 4.5 CONNECTING AN EXTERNAL RADIO The FKN4091A cable and adaptor kit allows for the connecting of an external ra- dio to the RTU radio port, as shown in Figure 10. TO CPU PORT 3 ~ COMI'IJNICATION C~LE / ( 3008439S01 ) ADAPTeR 0198220070) FKN4091A""'~"""~ t TO RADIO FOR WIRE NUMBER/ COLOR SEE TABLE 11 Figure 10. External Radio Connections The external radio should have a Channel Monitor (CM) and available PTT signal inputS. The MOSCAD external radio adapter includes separate ground signal in- puts for Rx and TX. For best performance, the individual ground wires should be connected to a single ground on the radio side, and not on the RTU side. Table 11 details the radio adaptor signal definitions. Table 11. Adaptor Pin Definition Wire Function Description No. Color 8 Gray Rx GND Receive signal. ground 7 Violet RADIO Rx Receive signal from radio to modern 6 Blue RADIO RxE Indicates radio receive status to modem. When radio does not provide this signal, refer to Table 12 for connection instructions. 5 Green RADIO GND Ground 4 Yellow RADIO CM* Radio Channel Monitor (RADIO TxE) 3 Orange RADIO Tx Transmit signal from modem to radio 2 Red Tx GND Transmit signal ground I Brown PTT Push To Talk * The Radio CM Polarity parameter is set by the ToolBox to BUSY HIGH or BUSY LOW according to radio. 108 I 1 I I [ i T I Table 12. RADIO RxE Signal Connection Radio CM Polarity RADIO RxE BUSY HIGH Connect to ground BUSY LOW Do not connect (leave open) if matching of the RADIO Tx output to the radio input is necessary, add an exter- nal resistor Rs in parallel to the radio input (see Figure 11 ). To calculate the resistor use the following formula: 3 3 Rtx= 4 -4' j~ v.,, v.,. 4 ° where: Ru = Rs II R/n I 3K 4V p~ o ") Rtx R, (~yp~sl) (Radio input 0 Im;acance) I J Figure 11. Radio Input Impedancc Matching 109 Appendix A; Cables and Adaptors 5. RTU-TO-X.25 CONNECTION ' 5.1 RTU-TO-X.25 CONNECTION VIA PORT 1B (DTE-TO-DCE) The RTU can be connected to a X.25 terminal via its serial communications port 1B and serve as a DTE. This section provides data on the adaptor, which interfaces between the RI45 connector on the cable connected to the RTU and the 25-pin D-Type connector on the cable connected to the terminal (refer to Figure 12). The 1B port should be defined by the Tool Box for an X.25 Protocol. J1 J2 (25-PIN (RJ45) D-TYPE) Tx_DATA >1 m ~< Tx_DATA Rx_DATA >2 · 3< Rx_DATA NOT USED ~ NOT USED >'~ NOT USED >/" GND >4 7< GND Tx_CLOCK >6 ~, 24< Tx_CLOCK ( DTE SOURCE ) Rx_CLOCK )3 ~ 17( Rx_CLOCK Figure 12. RJ45-to-D-Type Male Connector Adaptor 0198220121 5.2 RTU-TO-X.25 CONNECTION VIA PORT IB (DCE-TO-DTE) The RTU can be connected to a X.25 terminal via its serial communications port 1B and serve as a DCE. This section provides data on the adaptor, which interfaces between the RJ45 connector on the cable connected to the RTU and the 25-pin D-Type connector on the cable connected to the terminal (refer to Figure 13). The 1 B port should be defined by the Tool Box for an X.25 Protocol. J1 J2 (25-PIN (RJ45) D-TYPE) ~~{ Tx_DATA >2 · ~< TX_DATA RX_DATA >1 m~ 3< RX_DATA . ! NOT USED >~' NOT USED ~~ NOT USED GND >4 7< GND TX CLOCK >6 · 24< TX_CLOCK (DTE SOURCE) Rx_CLOCK >3 ~, 17< RX_CLOCK Figure 13. RJ45-to-D-Type Female Connector Adaptor 0198220098 110 t '~ 'u s I T T I · Appendix A: Cables aad AdaptoH ; 6. RTU-TO-RTU CONNECTION 6.1 RTU-TO-MULTIPLE RTUs TIME SYNCHRONIZATION USING SYNC BROADCAST (via port 1B) The interconnection diagram below describes the Time Synchronization method, which uses a SYNC broadcast via port 1B (refer to Figure 14). BROADCAST [ | TRANSMISSION ~ ( SYNCHRONIZING 1B ~ SITE) ~ TXDATA 1 > ~ · · t_ ~ ^ ^ ^ ^ 2 3 4 PORT 2 3 4 PORT DATA CLK DATA CLK SITE B SITE C ~ [ J I J Fig~'e ~ 4. Time ~>'nc~o~iz~tio~ using ~¥NC Broadcas~ 'I~terco~ecfio~ Dialare ~ !11 i I I ' ! '1 · T ! Appendix A: Cables and A daptors 6.2 RTU-TO-RTU ASYNCHRONOUS COMMUNICATIONS CONNECTION This section provides data on the cable recommended for the RTU-to-RTU RS-232C asynchronous interconnection (not supplied). Refer to Figure 15. Table 13 defines the RTU port for this connection type. Use hand-tooling AMP HT-210 with 8-pin connector header for cable preparation. An appropriate 8-pin cable should be used (e.g. Motorola part no. 3008439S01 ). Table 13. RTU-to-RTU RS-232 Asynchronous Communications - Port Data CPU Port Used with Piggyback Toolbox Definition No. Board 1B - RS-232 UART RTU-to-RTU (MDLC) 2 - RS-232 UART RTU-to-RTU (MDLC) 3 FRN5655A RS-232 UART RTU-to-RTU (MDLC) 3 FRN5724A RS-232 UART RTU-to-RTU (MDLC) PZN NO.8 PIN NO.~ J1 RJ45 CONNECTOR (RJ45) (RJ45) TX_DATA < 1 · · 1 ) TX_DATA RX_DATA < 2 , X , 2 · RX_DATA CTS < 3 , · 3 · CTS GND < 4 ~ 4 ) GND DCD ( 5 · , 5> DCD RTS ( 6 · X · 6 > RTS +12V <__7_ NOT CONNECTED OT CONNECTED 7 > +12V DTR < 8 , · 8 · DTR Figure 15. RTU-to-RTU RS-232 Asynchronous Communications Cable 112 Appendix A: Cables and Adaptors 6.3 RTU-TO-RTU SYNCHRONOUS COMMUNICATIONS CONNECTION (via port 1B) This section provides data on the cable recommended (not supplied) for the RTU- to-RTU synchronous communications via RTU port 1B (see Figure 16). The cable should be connected to the CPU according to Table 14. Use hand-tooling AMP HT-210 with 8-pin connector header for cable preparation. An appropriate 8-pin cable should be used (e.g. Motorola 'part no. 3008439S01 ). Table 14. RTU-to-RTU RS-232 Communications - Port Data CPU Port Used with Piggyback Board Toolbox Definition No. 18 - RS-232 Sync RTU to RTU (MDLC) Full Duplex or Half Duplex PIN NO. 8 RJ45 CONNECTOR J1 J2 (RJ45) (RJ45) TxDATA ~| ~ · ~ TXDATA RXDATA (~ · ~ ~ RXDATA RxCLOCK (3 a · ~ RXCLOCK GND 44 ~ ~ GND TXCLOCK ~6 . , ~ TXCLOCK Figure 16. RTU-to-RTU Synchronous Communications Cable 113 I 'I '1 ! I T Appendix A: Cables and Adaptors 6.4 RTU-TO-RTU RS-232 SYNCHRONOUS COMMUNICATIONS CONNECTION (via port 3) This section provides data on the cable recommended (not supplied) for the RTU- to-RTU RS-232 synchronous communications via RTU port 3. Refer to Figure 17. The cable should be connected to the CPU according to Table 15. Use hand-tooling AMP HT-210 with 8-pin connector header for cable preparation. An appropriate 8-pin cable should be used (e.g. Motorola part no. 3008439S01). Table 15. RTU-to-RTU RS-232 Synchronous Communications - Port Data CPU Port Used with Piggyback Board Toolbox Definition No. 3 FRN5654A RS-232 Sync External Modern, Full Duplex or Multi- Drop Half Duplex 3 FRN5724A RS-232 Sync External Modern, Full Duplex or Multi- Drop Half Duplex PIN NO.8 PIN NO.1 \ RJ45 CONNECTOR J1 J2 (RJ45) (RJ45) TXDATA (l . . ], TXDATA Ready_In <3 . ~ 3< Ready_In GND ~4 ~ ~ GND ~5 5< Ready_Out <6 , , 6< Ready_Out RXCLOCK ~7 , , 7< RxCL~K TXCLOCK (8 ~ ~ · ~ ~CL~K Figure 17. RTU-to-RTU Synchronous Communications Cable 114 Appendix A: Cables and Adaptors 6.5 RTU-TO-RTU COMMUNICATION CONNECTION VIA RADIO PORT This section provides data on the cable recommended (not supplied) for simulating RTU-to-RTU radio interconnection. Refer to Figure 18. The cable should be con- neeted between the RTUs' Modem connectors (CPU port 3; FSK or DFM Mo- dems are required). Use hand-tooling AMP HT-210 with 8-pin connector header for cable preparation. An appropriate 8-pin cable should be used (e.g. Motorola part no. 3008439S01 ). NOTE The Channel Monitor polarity parameter should be set to Busy Low by the Tool Box configuration program. \ \ R345 CONNECTOR MODEM MODEM CONNECTOR Jl CONNECTOR J2 (RJ45) (RJ45) RXGND < 1 1< RXGND RX <2 4 ,. 2< RX RADIO_IND <3 3< RADIO_IND RADIO_GND <4 4< RADIO_GND CM <5 4 ~, 5< CM TX < 6 w , 6 < TX TXGND <7 7< TxGND PTTB <8 ~ . ~ 8< PTTB Figure 18. RTU-to-RTU Radio Simulator Cable 115 Appendix A: Cables and Adaptors 7. CONNECTING A USER PORT TO A PRINTER To connect one of the MOSCAD RTU RS232 Ports defined as User Port to a print- er, use either the FLN6457 or the FLN6458 cable. Since the connection to the printer is not defined by the RS232 standard, printer manufacturers define the con- nectors differently. Therefore, you should select the adapter according to the func- tions of the various pins. If the FLN6457 cable (with the female 25-pin D-type connector) is used, refer to Table 16. Table 16. Connection to Printer (with FLN6457 cable) R8232 25-pin Function Female Used As Direction RX-DATA 3 Printer Rx- to Printer Data DTR 20 Printer from Printer Ready GND 7 Ground If the FLN6458 cable (with the male 25-pin D-type connector) is used, refer to Table 17. Table 17. Connection to Printer (with FLN6458 cable) RS232 Function 25-pin Male Used As Direction TX-DATA 2 Serial Data to Printer CTS 5 Printer from Printer Ready GND 7 Ground 116 APPENDIX B: CONNECTING AN EXTERNAL POWER SUPPLY The RTU option V274 - External Power Supply - includes an additional cable FKN5934A for connecting the RTU to the external power supply. The FKN5934A external dc power cable is provided with a connector on the RTU's side and open wires at the user side. Connect the FKN5934A cable connector to RTU's motherboard connector J7. Use Table l for definitions of the wire functions. Table 1. FKN$934A External DC Power Cable Recommended Wire Color Function Status/Connection Red + 12 V dc + 12 V dc Brown Ground GND/12V-RET Orange AC Power Fail GND/12V-RET Black Battery Disconnect Disable Not connected Green DC Loss (Low Battery indication) GND/12V-RET 117 68P02994G 10- B ~ I I ." '1 1' I PRESSURE MEASURING EQUIPMENT TABLE OF CONTENTS PRESSURE TRANSMITTER ROSEMOUNT MODEL #1151GP-6-S-12-M1B1 CALIBRATED AT 104.61 FT. = 4MA 144.61 FT. = 20MA MANIFOLD D/A MODEL #PTM6TSS STAND O'BRIEN MODEL #FP52 PRESSURE GAUGE ASHCROFT MODEL #45-1009-S-04L-100PSI/230FT. FLEX PAK O'BRIEN MODEL #FSHPK-X-B LINE INSULATION TH ERMAZIP SERIES 100 INSULATION AND ]ACKET HEAT TRACE THERMON MODEL #EL2.5 00809-0100-4593 English Rev. BA Model 1151 Smart Pressure Transmitters · .. ~. ',, .-:. ~. .~' ? -' _' ~ --.~.. .. ,,, ,~ :'e . ,, - --~' . ~, ,'~: :~ ,; ...... . . .. :, . ROSEMOUNT' FISHER-ROSEMOUIIT' Managing The Process Better: Product Manual Model 1151 Smart Pressure Transmitters NOTICE Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product. Within the United States, Rosemount Inc. has two toll-free assistance numbers. Customer Central: 1-800-999-9307 (7:00 a.m. to 7:00p. m. CST) Technical support, quoting, and order-related questions. North American 1-800-654-7768 (24 hours a day - Includes Canada) Response Center: Equipment service needs. For equipment service or support needs outside the United States, contact your local Rosemount representative. C,,,% ;~:,CAUTION The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on Rosemount nuclear-qualified products, contact your local Rosemount Sales Representative. ,.. z May be protected by one or more of the following U.S. Patent Nos. 4,804,958; 4,866,435; 4,878,012; 4,988,990; 5,083,091; 5,094, 109; 5,237,285; Des. 317,266; Des. 318,432. Mexico Pats. Pend. 6057,912237. May depend on model. Other foreign patents issued and pending. Rosemount, the Rosemount IogO~/pe, SMART FAMILY, and HART are registered trademarks of Rosemount Inc. S-Cell is a trademark of Rosemount Inc. Hastelloy is a registered trademark of Cabot Corp. L octite is a registered trademark of L octite Corporation. Monel is a registered trademark of International Nickel Co. Teflon and Viton are registered trademarks of E,I. du Pont de Nemoura & Co. Syltherrn and D C. are registered trademarks of Dow Coming Corp. Neobee M-20 is a registered trademark of Stepan Chemical Co. Alias is a registered trademark of Asahi Glass Co. Ltd. Kynar is a registered trademark of Pennwalt Inc. Noryl is a registered trademark of General Electric. Fluorelube is a registered trademark of Hooker Chemical Co. C E Fisher-Rosemount satisfies all obligations coming from legislation to harmonize product requirements in the European Union. Rosem0unt Inc. 8200 Market Boulevard N96 Chanhassen, MN 55317 USA ROSEMOUNT' x 4310012 Fax (612) 949-7001 © 1999 Rosemount. Inc. rosemo ,, ,. om FISHER-ROSEMOUNT' Managing The Process Better: T" ': : i I Table of Contents SECTION1 Using this Manual ....................................... 1-1 Introduction Models Covered .......................................... 1-2 SECTION 2 Overview ................................................ 2-1 Transmitter Functions Safety Messages ......................................... 2-1 Warnings ............................................ 2-1 Commissioning the Transmitter on the Bench .............. 2-1 Setting Hardware Switches ............................. 2-1 Failure Mode Alarm Switch .......................... 2-2 Transmitter Security (Write-Protection Switch) ......... 2-2 Commissioning the Model 1151 with a HART-Based Communicator ............................ 2-3 Wiring Diagrams (Bench Hook-up) ....................... 2-3 Testing the Equipment and the Loop ..................... 2-4 Communicator Test ................................. 2-4 Transmitter Test ................................... 2-4 Loop Test ......................................... 2-4 Review Configuration Data .......................... 2-4 Checking the Transmitter Output ........................ 2-4 Process Variable ........... ........................ 2-4 Range Points ...................................... 2-4 Calibration Overview .................................. 2-5 Wiring Diagrams (Field Hook-up) ........................ 2-6 Common Functions .................................... 2-7 Setting the Loop to Manual .......................... 2-7 Change Non-Output Related Information ............... 2-7 Sending Data to the Transmitter ....................... 2-7 Configure the Analog Output Parameters ................. 2-7 Setting Units ..................... ' ................. 2-7 Reranging ........................................ 2-7 _ , Reranging with a Communicater Only ................. 2-9 Reranging with a Pressure Input SourCe and a Communicator .................................... 2-9 Reranging Using the Integral Span and Zero Buttons .... 2-10 Setting the Output Type ............................. 2-11 Setting Damping ................................... 2-12 Calibrate the Sensor ................................... 2-12 Digital Trim (Sensor Trim and Analog Output Trim) ..... 2-12 Sensor Trim ....................................... 2-12 Full Trim ......................................... 2-12 Zero Trim ......................................... 2-13 Systematic Error Correction ......................... 2-14 Deciding Whether to Trim the D/A Converter ........... 2-15 Digital to Analog Converter Trim ........................ 2-16 4-20 mA Analog Output Trim ........................ 2-16 4-20 mA Analog Output Trim Using Other Scale ........ 2-16 Advanced Functions ................................... 2-16 Burst Mode .......................................... 2-16 I I '1 ....... "" .... Saving, Recalling, and Cloning Configuration Data ......... 2-17 Multidrop Communication .............................. 2-17 Changing a Transmitter Address ..................... 2-18 Polling a Multidropped Loop ......................... 2-18 Model 1151 Smart Pressure Transmitter ............... 2-19 SECTION 3 Overview ............................................... 3-1 Installation Safety Messages ......................................... 3-2 Warnings ............................................ 3-2 General Considerations ................................... 3-3 Access Requirements .................................. 3-3 Process Flange Orientation .......................... 3-3 Housing Rotation ........................ .......... 3-4 Terminal Side of Electronics Housing .................. 3-4 Circuit Side of Electronics Housing ................... 3-4 Exterior of Electronics Housing ...................... 3-4 Mechanical Considerations ................................. 3-5 Mounting Considerations .................................. 3-7 Mounting Requirements (for Steam, Liquid, Gas) ........... 3-7 Taps ............................................. 3-7 Drain/Vent Valves ................................. 3-8 Impulse Piping .................................... 3-8 Process Connections ............................... 3-9 Mounting Brackets .................................... 3-10 Electrical Considerations .................................. 3-11 Power Supply ........................................ 3-11 Conduit Installation ................................... 3-12 Wiring .............................................. 3-12 Grounding .......................................... 3-13 Signal Wiring ..................................... 3-13 Transmitter Case .................................. 3-13 Grounding Effects ................................. 3-14 Hazardous Locations Certifications ....................... 3-15 Environmental Requirements ........................... 3-15 Installation Options ............................ : ......... 3-15 Mounting Brackets ............. ~ ........... ~: .......... 3-15 Analog Meters ........................................ 3-15 LCD Meters ................................ : ......... 3-16 LCD Meter Configuration ........................... 3-16 Remove the Cover .................................. 3-16 Position the Decimal Point and Select the Meter Function. 3-17 Store the Information .............................. 3-17 Set the Display Equivalent to a 4 mA Signal ........... 3-17 Set the Display Equivalent to a 20 mA Signal .......... 3-17 Replace the Cover ................................. 3-17 LCD Meter Assembly .............................. 3-17 Terminal Blocks ...................................... 3-19 Transient Protection and Filter Terminal Block (Option Code R1) ................................... 3-19 Terminal Block Installation ......................... 3-19 ii SECTION 4 Overview ............................................... 4-1 Troubleshooting Safety Messages ......................................... Warnings ............................................ 4-1 Disassembly Procedure .......... ~ ..................... 4-5 Process Sensor Body ............................... 4-5 Electrical Housing ................................. 4-6 Removing the Sensor from the Electrical Housing ....... 4-6 Reassembly Procedure ................................. 4-6 Preliminary Precaution ............................. 4-6 Connecting the Electrical Housing to the Sensor ........ 4-6 Electrical Housing ................................. 4-6 Process Sensor Body ............................... 4-7 Optional Plug-in Meters ................................ 4-8 Sensor Module Checkout ............................... 4-8 Returning Rosemount Products and/or Materials ........... 4-9 SECTION 5 Functional Specifications .................................. 5-1 Specifications and Performance Specifications ................................ 5-7 Reference Data Physical Specifications ................ : ~ ......' ............ 5-8 Ordering Information ..................................... 5-10 Parts List ........................................... 5-19 Parts List ........................................... 5-27 Specifications and Reference Data for Options ................. 5-30 LCD Meter Specifications .............................. 5-30 Terminal Block Specifications ........................... 5-31 APPENDIX A Introduction ........................ ~ .................... A-1 HART® Communicator Safety Messages ......................................... A-1 Warnings ............................................. A~I Connections and Hardware ................................ A-4 Communicator Keys . ..: :. ................................ A-6 Action Keys .......................................... A-6 Function Keys ........................................ A-7 Alphanumeric and Shift Keys ........................... A~7 HART Fast Key Sequences ................................. A~8 HART Fast Key Example .......... ~: ................... A-8 Menus and Functions ..................................... A-8 Main Menu .......................................... A-8 Online Menu ......................................... A-9 Diagnostic Messages ...................................... Aol0 iii APPENDIX B Introduction ............................................. B-1 Model 268 Communicator Connections and Hardware ................................ B-4 Communicator Keys ...................................... B-5 Dedicated Keys ....................................... B-5 Alphanumeric and Shift Keys ........................... B-6 Function Keys ........................................ B-6 Fast Key Sequences ...................................... B-7 Fast Key Sequence Conventions ......................... B-7 Fast Key Sequence Examples ........................... B-7 Diagnostics Messages ..................................... B-8 APPENDIX C Introduction ............................................. C-1 Retrofitting the Safety Messages ......................................... C-1 Model 1151 Transmitter Warnings ............................................ C-1 Retrofitting Overview ..................................... C-2 l~emoving the Analog Electronics Assembly ................... C-2 Instal]ing the Smart l~etrofit Kit ............................ C-10 Characterization ......................................... C- 13 Before Characterizing the Transmitter ................... C-13 Characterizing with a Model 2?5 Communicator ............ C-13 Characterization with a Mode] 268 Communicator .......... C-14 APPENDIX D ~ Approval Drawings GLOSSARY INDEX 1.1 jv Section Introduction USING THIS MANUAL This manual provides information on installation, operation, and maintenance of Rosemount® Model 1151 Smart Pressure Transmitters. The rest of this manual is organized into the following sections: Section 2-Transmitter Functions This section describes the Model 1151 software functions, configuration parameters, and other on-line variables. Section 3-Installation This section provides mechanical and electrical installation instructions. Section 4-Troubleshooting This section provides troubleshooting techniques for diagnostic messages associated with the transmitter. Section 5-Specifications and Reference Data This section provides reference and specification data for Model 1151 Smart Pressure Transmitters. Appendix A-HARTs Communicator This appendix contains a communicator overview, a HART Communicator menu tree for the Model 1151 Smart Pressure Transmitters, and a table of HART Communicator fast key sequences. A table of diagnostic messages associated with this communicator is also included. Appendix B-Model 268 Communicator This appendix contains a communicator overview, a Model 268 Communicator menu tree for the Model 1151 Smart Pressure Transmitters, and a table of Model 268 fast key sequences. A table of diagnostic messages associated with this communicator is also included. Appendix C-Retrofitting the Model 1151 Transmitter This section describes how the Rosemount Smart Retrofit Kit can be used to retrofit a Model 1151AP, DP, GP, HP, or LT transmitter with 4- 20 mAdc linear or square root output. Appendix D-Approval Drawings This appendix contains intrinsic Safety drawings. Glossary This section provides brief definitions of the terms used in this manual. Index This section provides a comprehensive index. 1-1 Rosemount Model 1151 Smart Pressure Transmitters MODELS COVERED This manual provides basic installation, commissioning, and troubleshooting information for the following Rosemount® Model 115 1 Smart Pressure Transmitters: Model 1151 DP--Differential Pressure Transmitter measures differential pressure from 2 inH20 to 1,000 psi (0.497 to 6895 kPa). Model 1151 HP--Differential Pressure Transmitter for High Line Pressures provides high line pressure from 10 inH20 to 300 psi (2.49 to 2068 kPa). Model 1151GP--Gage Pressure Transmitter measures gage pressure from 2 inH20 to 1,000 psi (0.497 to 41369 kPa). Model 1151AP--Absolute Pressure Transmitter measures absolute pressure from 10 inH20 to 1,000 psi (2.49 to 6895 kPa). Model 1151LT.--Flange-Mounted Liquid Level Transmitter provides precise ]eve] and specific gravity measurements from 25 to 2,770 inH20 (6.2 to 690 kPa) for a wide variety of tank configurations. 1-2 I I '! li 1' ~ Section Transmitter Functions OVERVIEW This section contains information on commissioning and operating Model 1151 Smart Pressure Transmitters. Instructions for setting transmitter switches (prior to installation) and explanations of software functions are provided in this section. Fast key sequences are listed for each software function. Please refer to Appendices A and B for more information on fast key sequences and other communicator operations, SAFETY MESSAGES Warnings (~) Procedures and instructions in this section that raise potential safety issues are indicated by a warning symbol (~). Refer to the following warning messages before performing an operation preceded by this symbol. '~WAR N I N G · Explosions can result in death or serious injury. Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. Commissioning the Commissioning consists of testing the transmitter, testing the loop, and Transmitter on the Bench verifying transmitter configuration data. Model 1151 Smart Pressure Transmitters may be commissioned either before or after installation. We recommend commissioning the transmitter on the bench before installation~ This ensures that all transmitter components are in good working order and heightens familiarity with the device. To avoid exposing the transmitter electronics to the plant environment after installation, set the failure mode and transmitter security switches during the commissioning stage on the bench. Setting Hardware Switches The Model 1151 Smart Pressure Transmitter contains hardware switches that provide user-selectable operation of the failure mode and transmitter security. The switches are located on the electronics assembly just inside the electronics housing cover, as shown in Figure 2-1. 2-1 rlO,~elllOUl"lt IVIfJOel I I~} I Dnl~rt rres~sure irilll,~l!lll. it, r~ FIGURE 2-1, ,//~/ Fail Safe Mode Switch /4~ Transmitter Switch Locations, Transmitter Security Switch Ilitlf --_ P/N 01151-09~,-0204 _ ', NOTE ~ .... -~,--~ /~---' User-seleclable switches are , --_ : _ J--' shown in default position ~, Failure Mode Alarm Switch As part of its normal operation, the Model 1151 Smart continuously monitors its own operation. This automatic diagnostic routine is a timed series of checks repeated continuously. The electronics faceplate (Part No. 01151-0934-xxxx) has HI and LO user-selectable failure mode settings. If the diagnostic routine detects a ~ failure in the transmitter in analog output, the transmitter either drives its output below 3.8 mA or above 21.0 mA, depending on the position of the failure mode alarm switch. NOTE With multidrop (digital) output, the analog output remains at 4 mA, even when a diagnostic failure is detected. This is true for both the HI and LO fail mode switch settings. A bit is enabled in the digital word to indicate a diagnostic failure. Transmitter Security Once the transmitter has been configured, it may be desirable to protect (Write-Protection Switch) the configuration data from changes. The electronics assembly is equipped with a switch labeled SECURITY. Figure 2-1 shows the switch location on the circuit side of the electronics housing. In the ON position, the switch prevents the accidental or deliberate change of configuration data. To enable the sending of configuration data, simply return the transmitter security switch to the OFF position. NOTE The transmitter security switch must be in the OFF position before configuration changes can be made to the transmitter configuration. 2-2 I I i i" '] T I Commissioning the Model Before putting the Model 1151 Smart Pressure Transmitter into 1151 with a HART-Based operation, commission the instrument using a HART-based Corn mu n icator communicator- f~ ~ To commission on the bench, connect a 17 to 45 V dc power supply and a .. current meter, such as the Rosemount Model 282 Validator. Make connections as shown in Figure 2-2. The power supplied to the transmitter should not drop below the transmitter lift-off voltage. If the transmitter is being configured when the power drops below the lift-off voltage, the configuration information may not be interpreted correctly by the transmitter. NOTE To enable communication, a resistance of at least 250 D must be present between the communicator loop connection and the power supply. Wiring Diagrams After the bench equipment is connected as shown in Figure 2-2, turn on (Bench Hook-up) the HART-based communicator by pressing the ON/OFF key. The communicator will search for a HART-compatible device and will indicate when the connection is made. If the connection is not made, the communicator will indicate that no device was found. If this occurs, refer to Section 4 Troubleshooting. FIGURE 2-2. Bench Hook-up. A_+ ~ ~ dC Supply *- + -- NOTE An alternate location to connect an aremeter is on the set of terminals labeled "TEST." Connect the positive lead of the aremeter to the positive test terminal, and the negative lead of the aremeter to the negative test terminal. '~' See "Safet~ Messages" on page 2-1 for complete warning information. L I · I Testing the Equipment Test functions verify that the transmitter, the communicator, and the and the Loop loop are in good working order. Testing is recommended whenever component failure or a problem with loop performance is suspected. Comrnunicator Test A communicator test is performed to ensure the communicater is working properly. Both the HART Communicator Model 275 and the Rosemount Model 268 Communicator perform self-tests after being turned on. If a problem is detected, the communicator will list a diagnostic message. Refer to Appendices A and B for diagnostic messages associated with the communicator. Transmitter Test Although the Model 1151 Smart Pressure Transmitter performs continuous self-diagnostics, a more extensive diagnostic routine can be HART Cornre. 1,2, ~, ~ initiated with the transmitter test function. The transmitter test Model 268 F2, F2 routine can identify an electronics failure. If the transmitter test detects a problem, messages to indicate the source of the problem are displayed. Loop Test The loop test allows verification of the output of the transmitter, the integrity of the loop, and the operation of any recorders or similar HART Cornre. ~, 2, 2 devices. If commissioning the transmitter on the bench, repeat this test Model 26~ F2, F3 after the transmitter has been installed in the field. A reminder appears to set the loop to manual. Do so and proceed. The next display selects a discrete milliampere transmitter output level. To command the transmitter to output 4 mA, for example, select 4 mA. Check the current meter installed in the test loop to verify that it reads 4 mA. If so, end the loop test. If the output is not 4 mA, then the receiving meter is malfunctioning or the transmitter requires a digital trim as described on page 2-12. Review Configuration Data Review of the transmitter factory configuration data is recommended. HART Comm. 1, 5 Model 268 Review Key Checking the Transmitter Output Process Variable Process variable readings can be obtained in engineering units and milliamperes. If the milliampere display does not agree with the actual HART Cornre. 2 loop reading given by a multimeter, a 4-20 rnA trim is required. Model 268 PV The last step of start-up and commissioning is to check the transmitter output. Obtain process variable readings in engineering units and milliamperes. If this display does not agree with the actual loop reading given by a multimeter, a 4-20 mA trim is required (see page 2-16). Range Points The Model 1151 Smart 4 and 20 rnA range points can be viewed and edited with these fast key sequences. HART Comm. 1, 3, 3 Model 268 F3, F2, F1 2-4 i 'm -! [' ': I I Ca I i b ration Overview Complete calibration of the Model 1151 Smart Pressure Transmitter involves the following tasks: Configuring the Analog Output Parameters · Setting process variable units (page 2-7) · Reranging (page 2-7) · Setting output type (page 2-11) · Setting damping (page 2-12) Calibrating the Sensor · Full trim (page 2-12) · Zero trim (page 2-13) Calibrating the 4-20 mA Output · 4-20 mA output trim (page 2-16) or · 4-20 mA output trim using other scale (page 2-16) FIGURE 2-3. Model 1151 Transmitter Data Flow with Calibration Options. (Transmitter Ranged 0 to 100 inH20) Sensor '4 Zgnal o c: o 0 ~,, · 100 inH20 Inl Input Pressure E · N?TES Value on PV line should equal - --~ the input pressure 2) Value on AO line should equal the L "- output device reading 3051 :PT-4001 <:::> - Online ~ 2 PV 100.00 inH20 3 AO 20.00 mA 4 LRV 0.00 inH20 ~ 5 URV 100.00 inH20 Figure 2-3 illustrates the Model 1151 transmitter data flow. This data flow can be summarized in four major steps: 1, A change in pressure is measured by a change in the sensor output (Sensor Signal). 2. The sensor signal is converted to a digital format that can be understood by the microprocessor (Analog-to-Digital Signal Conversion). 3. Corrections are performed in the microprocessor to obtain a digital representation of the process input (Digital PV). 4. The Digital PV is converted to an analog value (Digital-to-Analog Signal Conversion). 2-5 I i I I Rosemount Model 11 51 Smart Pressure Transmitters Figure 2-3 also identifies the approximate transmitter location for each calibration task. Note that the data flows from left to right, and a parameter change affects all values to the right of the changed parameter. Not all calibration procedures should be performed for each Model 1151 transmitter. Furthermore, some procedures are appropriate for bench calibration but should not be performed during field calibration. Table 2-1 identifies the recommended calibration procedures for each type of Model 1151 transmitter for both bench and field calibration. TABLE 2-1. Recommended Calibration Tasks. Transmitter Bench Calibration Tasks Field Calibration Tasks Standard 1. Set output configuration parameters: 1 ) Reconfigure parameters if necessary. Calibration a) Set the Transmitter Range Points. 2) Zero trim the transmitter to compensate Tasks b) Set the Output Units. c) Set the Output Type (linear or square root). for mounting position effects or static 1151DP d) Set the Damping Value. pressure effects. 1151GP 1151HP 2. Optional: Perform a Full Sensor Trim 1151LT --Pressure source required. 3.Optional: Perform an Analog Output Trim --Multimeter required. 1151AP Standard Bench Calibration, 1 ) Reconfigure parameters if necessary. except step 2: 2) Perform Low Trim Value section of 2. Optional: Perform a Full Sensor Trim if Full Sensor Trim procedure to correct for equipment is available (accurate absolute mounting position effects. pressure source required);. otherwise, perform the Low Trim Value section of ~"~ Full Sensor Trim procedure. NOTE A HART-based communicator is required for all sensor and output trim procedures. Wiring Diagrams (Field Hook-up) FIGURE 2-4. Model 1151 Field Wiring Optional Diagram. Model 1151 Smart Chart Pressure Transmitter Recorder RL _> 250 EL -- Power Supply Curran + _ ~ ' Meter _ :__]iJZi Optional ' ~:J~J Indicator NOTE NOTE Signal Loop may be grounded at any A HART Interface may be connected at any termination point in the loop. point or left ungrounded. Signal loop must have 250 ohms minimum Iced for communications. 2-6 I" I I ranSmlUer runCTioRs Common Functions The following tasks are a common part of a transmitter commissioning. Setting the Loop to Manual When preparing to send or request data that would disrupt the loop or change the output of the transmitter, set the loop to manual. Both the HART Communicator Model 275 and the Rosemount Model 268 will prompt for this setting when necessary. Keep in mind that simply acknowledging this prompter does not set the loop to manual. It is only a reminder; the loop must be set to manual as a separate operation. Change Non-Output The Model i151 Smart contains several configuration parameters that Related Information do not directly affect the transmitter output. These parameters include: · Date · Descriptor · Message · Meter type Sending Data to Whenever transmitter configuration data is updated with a HART- the Transmitter based communicator, the entered data must be sent to the transmitter memory. HART Comm. Note Model 268 F3, F4 NOTE Depending on the task, an option to enter the data (or end changes and enter the data) will appear at the end of the configuration function. Follow the on-screen prompts to complete the send data function. Review the transmitter memory to ensure that configuration changes have been entered. Configure the Analog Output Parameters Setting Units By setting the output units, a process can be monitored using the specified units. This is important if a plant uses units which differ from HART Comm. 1,3 those preset by Rosemount Inc. Output units can be selected from Model 268 F3, F2 among 14 output options: · inH20 · inHg · ftH20 · mmH20 · mmHg · psi · bar · mbar * g/cm2 · kg/cm2 * Pa * kPa · torr · atm Reranging One of the most common configuration tasks involves reranging the transmitter 4 and 20 mA points. Reranging matches the transmitter range points with the applied process pressures. It can be performed three ways: using the communicator only, using the communicator and a reference pressure, or using the integral zero and span buttons and a reference pressure. To decide which method is appropriate, consider the following: · Reranging with only the communicator changes the analog 4 and 20 mA points independently without a pressure input. 2-7 Rosemount Model 1151 Smart Pressure Transmitters This means that when you change either the 4 or 20 mA setting, you also change the span. For instance: If the transmitter is ranged so that 4 mA = 0 inH20, and 20 mA = 100 inH20, and you change the 4 mA setting to 50 inH20 using the communicator only, the new settings are: 4 mA = 50 inH20, and 20 mA = 100 inH20. Note that the span was also changed from 100 inH20 to 50 inH20, while the 20 mA setpoint remained at 100 inI-I20. To obtain reverse output, simply set the 4 mA point at a greater numerical value than the 20 mA point. Using the above example, setting the 4 mA point at 100 inH20 and the 20 mA point at 0 inI-I20 will result in reverse output. NOTE The 4 and 20 mA output is based on the transmitter's existing digital calibration. Before reranging with the keypad, make sure the transmitter is correctly interpreting the process variable input. To match the transmitter's reading in engineering units to plant standard, use the sensor trim function under "Digital Trim~ in this section. · Reranging with a pressure input and' the communicator maintains the same analog span. · Reranging with a pressure input and the zero and span buttons maintains the same analog span. For instance, if the transmitter is ranged so that: 4 mA = 0 inH20, and 20 mA = 100 inH20, and you then change the 4 mA setting to 50 inH20 using the communicator (or buttons) and a pressure input, the new settings are: 4 mA = 50 inH20 20 mA = 150 inH20 The 100 inH20 span is maintained. It is also important to note that when using a pressure source, the 4 and 20 mA setpoints are based on the transmitter's interpretation of the pressure input provided. It is possible that when a plant standard is input, the transmitter reads it as a slightly different value. Although the 4 and 20 mA setpoints will operate properly within these applied settings, the transmitter's digital output in engineering units may indicate a slightly different value. The sensor trim function under "Digital Trim" can be used to match the transmitter's reading in engineering units to your plant standard, thereby eliminating any discrepancy. NOTE Reranging only the 4 mA or the 20 mA with a pressure input will maintain the initial span width. ! '! i; 1' T ! NOTE Do not rearing the transmitter such that the 4 and 20 mA range points--upper range value (URV) and lower range value (LRV)--are outside the high and low digital sensor trim values. To optimize performance, the digital trim span should be equal to or slightly greater than the 4-20 mA span. Reranging with a Reranging with the keypad and no pressure input changes the 4 and Communicator Only 20 mA points independently. HART Cornre. 1,2, 3, 1, 1 Model268 F3, F2, F1, F3, F1 Reranging with a Reranging with a pressure input source and the communicator or the Pressure Input Source zero and span buttons allows you to maintain the same analog span. and a Communicator HART Comm, 1,2, 3, 1, 2 Model 268 F3, F2, F1, F3, F2 To-rerange with a reference pressure, apply the desired pressure input to represent the 4 or 20 mA point. Allow the variable reading to stabilize for approximately ten seconds. Press either the 4 mA or 20 mA to make this pressure value either point. 2-9 i I · · T i Reranging Using the Integral It is also possible to rerange the transmitter using the span and zero Span and Zero Buttons buttons located within the circuit side of the electronics housing on the electronics faceplate, as shown in Figure 2-5. FIGURE 2-5. Model 1151 Electronics Faceplate. NOTE co User-selectable switches are shown e in default position. Use the following steps to rerange using the integral span and zero buttons: 1. Using a pressure source with an accuracy three to ten times the desired calibrated accuracy, apply a pressure equivalent to the lower calibrated value to the high side of the transmitter. 2. Remove the circuit side cover to expose the span and zero buttons. Hold both the span and zero buttons down simultaneously for at least five seconds to activate the controls. The buttons remain active for 15 minutes. After 15 minutes the buttons must be reactivated by pressing simu]taneously and holding again. 3. Press the zero button for five seconds to set the 4 mA point. Verif~ that the output is 4 mA. 4. Apply a pressure equivalent to the higher calibrated value to the high side of the transmitter. 5. Press the span button for five seconds to set the 20 mA point. Verif~ that the output is 20 mA. NOTE Both the lower and upper range values must fall within the lower and upper range limits of the sensor module, and meet the minimum and maximum span criteria allowed by the transmitter. O 2-10 Setting the When the square root output option is active the Model 1151 analog Output Type output is proportional to flow. To avoid the extremely high gain that results as the input approaches zero, the Model 1151 automatically HART Comm. 1, 3. 5 switches to a linear output in order to ensure a more stable output near Model 268 F3, F2, F1, F1 zero. Figure 2-6 illustrates this transition point. The transition from linear to square root is not adjustable. It occurs at 0.8% of ranged pressure input or 9.0% of full_scale flow output in transmitters with Revision 5.2. software. In earlier software, the transition point occurred at 4.0% of ranged pressure input, or 20% of full scale flow output. The transition from linear to square root output is smooth, with no step change or discontinuity in output. FIGURE 2-6. Square Root Output Transition Point. Full Scab Output Full Scab (mA dc) Row (%) 20 100-- 90-- 50-- 16. 70-- Square Root 12 50 -- Curve 40-- Full Scale F~ow (%)/,0 7.2 20 -- ull Scale ~F Square OutFput (mA dc) 5.4 Root Transition Point 5.6 10 -- s Curve 4 0 Linear Section of Curve ' "' 0 20 40 60 50 100 5~124 89 S Transition I I I I I I I I I 0.8% Full Scale Pressure (%) Linear 4.8 5 -- Linear Transition 4.096 0.6 -- = / 4 0 I ( ) .6 0~ 1 Full Scale °o From 0.0 percent to 0.6 percent of the ranged pressure input, the slope of the curve is unity (y = x). This allows accurate calibration near zero. Greater slopes would cause large changes in output for small changes at input. From 0.6 percent to 0.8 percent, the slope of the curve equals 42 (y = 42x) to achieve continuous transition from linear to square root at the transition point. 2-11 Setting Damping The Model 1151 Smart Pressure Transmitter has electronic damping that can increase the response time of the transmitter to smooth the NAm' Cornre. l, 3, 6 output when there are rapid input variations. High damping values Me~lel ~ F3, F2,'F2 filter out process noise, but response time is decreased. Low damping values increase response time, but process noise can also be detected. For Model 1151 Smart Pressure Transmitter transmitters, damping values may be set in 0.1 second increments from 0 to 16.0 seconds. The factory default damping value is 0.2 seconds' (0.4 seconds for Range 3). Damping values for inert-filled sensors are slightly higher. Calibrate the Sensor Digital Trim In order to understand the digital trim function, it is necessary to (Sensor Trim and understand that smart transmitters operate differently from Analog Output Trim) conventional analog transmitters. Smart transmitters are factory characterized, which involves comparing a pressure input with the output of each transmitter's sensor module. The information obtained in the comparison is stored in the sensor module EEPROM during the characterization process. In operation, the transmitter uses this information to produce .a process variable output, in engineering units, dependent on the pressure input. The digital trim function allows corrections to be made to this factory-stored curve. The digital trim procedure is a two-step process. The first step, called sensor trim, consists of matching the digital process variable reading of . the transmitter to a precision pressure input. The second step, called 4-20 mA trim, consists of adjusting the output electronics. This procedure should not be confused with reranging. Although you can still match a pressure input to a 4 or 20 mA output through a reranging function, you have not affected the transmitter's interpretation of that input. A sensor trim allows you to alter the transmitters interpretation of the input signal. A 4-20 mA analog output trim allows you to alter the transmitters conversion of that' interpretation into an analog 4-20 mA output. The transmitter can only be as accurate as the equipment used to perform the digital trim. Use precise equipment under stable, ambient conditions for best results. If such equipment is not available, it may be better to return the transmitter to a local Rosemount service center for verification of the trim values. To eliminate the possibility of over- trimming the transmitter, the Model 1151 will accept only trim values that are within 5 percent of its original characterization. Sensor Trim The sensor may be trimmed in two ways: full trim and zero trim. They vary in complexity, and their use is application-dependent. Full Trim A full trim is a two-point sensor calibration where two end-point HART Comm. 1, 2, 3, 3 pressures are applied, and all output is linearized between them. To start the procedure, connect the communicator and a pressure input Model 268 F4, F4, F3, F2, F1 source of at least three times greater accuracy than the Model 1151 Smart Transmitter as shown in Figure 2-7. Always let the variable stabilize for 10 seconds after application of the pressure source before taking its reading. NOTE The Model 1151 Smart Pressure Transmitter allows approximately a 5.0% URL deviation from the characterized curve established at the factory. 2-12 NOTE A full trim requires a pressure source at least three times more accurate than the transmitter. For best accuracy, make sure the applied pressure is equal to or slightly less than the desired 4 mA setpoint, or equal to or slightly greater than the 20 mA setpoint. The last trim/input values used will be displayed briefly. The engineering units shown match those selected under configuration or in transmitter characterization. . In selecting the pressure input values, the low and high values should be equal to or outside the 4 and 20 mA points. Do not attempt to obtain · reverse output by reversing the high and low points. The low trim value should be trimmed first. This provides a stable reference for additional sensor trim adjustment. Adjustment of the low trim value provides an offset correction to the factory-established characterization curve. Adjustment of the high trim value provides a slope or gain correction to the characterization curve based on the low trim value. In neither case is the factory-established characterization curve changed by this procedure. The trim values allow optimized performance over a specified measuring range at the calibration temperature. Zero Trim A zero trim is a simpler, one-point adjustment. It must be zero-based · (in other words, within 3.0% of true zero) and it may be performed when HART Cornre. 1,2, 3, 3, 1 an exact pressure source is not available for the second pressure needed Model 268 F3, F2, F1, F3, F2 in a full trim. It is useful for compensating for mounting position effects or for zero shifts due to static pressure in differential pressure applications. However, since this correction maintains the slope of the characterization curve, it should not be used in place of a full trim over the full sensor range. Zero trim is best performed with the transmitter installed in its final mounting position with static pressure applied (or no pressure for a gage transmitter). NOTE Because a zero trim must be zero-based, it generally should not be used with Model 1151 Absolute Pressure Transmitters. Absolute pressure transmitters reference absolute zero. To correct mounting position effects on a Model 1151 Absolute Pressure Transmitter, perform a low trim within the full sensor trim function. The low trim function provides a "zero" correction similar to the zero trim function but it does not require the input to be zero based. z-__'_',_'_- 20 rnA Point -'_'_'_'-' 20 mA Point , -'_'_',,'-- 4 mA Point [~)__-'_'_'_'-- 4 rnA Point ' '~ H L H NONZERO-BASED ZERO-BASED LEVEL APPLICATION LEVEL APPLICATION ZERO-BASED FLOW APPLICATION 2-13 Rosemount Model 1151 Smart Pressure Transmitters FIGURE 2-7. Digital Trim Connection Drawing Dead Weight Tester (4-20 mA Transmitters). Calibration Standard for Sensor Trim Only 250 ~ Minimum Loop Resistance 24 V dc Power Supply · Model 1151 HART-based Smart Precision Communicator Meter NOTE 4-20 mA wiring shown. See Figure 3-2 for low power wiring. Systematic Error Correction One feature of full tr~m is the ability to use it to improve the Model 1151DP or HP performance by correcting for systematic error because of static pressure. NOTE Corrections can only be made in linear mode. Switch from 'square-root mode to linear mode if necessary. High static pressure causes a systematic span shift in the transmitter. It is linear with static pressure and is easily corrected by performing a full trim. Table 2-1 shows the amount of systematic span shift for Range Codes 3 through 8. Range Code 316L SST Hastelloy'" Monel 3 -1,75% -1.0% -1.00% 4 -0.87%(" -0.60% -0.50% 5 -0.81%(~ ) -0.70% -0.75% 6 -1.45%(~) -1.45% -1.45% 7 -1,05%(~) -1.05% -1.05% 8 -0.55% -0.55% -0.55% (1) Applies also to Model 1151HP. Correction for systematic error is made by simply calculating a correction factor for the high trim and low trim and inputting this correction into the transmitter. 2-14 I ! 'i I T' m T I The following example illustrates the correction procedure: A Model 1151DP 4 (Range 4) with 316L SST isolating diaphragms is to be used in an application where the static line pressure is 1,200 psi. The transmitter is reranged (as stated in Reranging with a Pressure Input Source and a Communicator on page 2-9) so that the transmitter output is4 mA at 50 inH20 and 20 mA at 150 inH20. To correct for systematic error due to static line pressure, use the following formulas to determine a corrected value for Low Trim and High Trim. Low Trim (LT) = LRV + S (LRV) P WhereLT = Corrected Low Trim Value at Atmosphere LRV = Lower Range Value at Pressure P = 50 inH20 S = -(Span Shift from Table 2-1) = -0.0087/1000 psi P = Static Line Pressure = 1200 psi High Trim (HT) = URV + S (URV) P WhereliT = COrrected High Trim Value at Atmosphere URV = Upper Range Value at Pressure P = 150 inH20 S = -(Span shift from Table 2-1) = -0.0087/1000 psi P = Static Line Pressure = 1200 psi In this example: URV = 150 inH20 LRV = 50 inH20 S = +0.0087/1000 psi P = 1200 LT = 50 + (0.0087/1000)(50)(1200) LT = 50.53 inH20 I-IT = 150 + (0.0087/1000)(150)(1200) HT = 151.58 inH20 Entering Corrected Values To input the corrected values for the Low Trim and High Trim, perform a full trim as explained on page 2-12. When applying the low and high pressure values, edit the pressure reading and enter your corrected Low and High Trim values as in the following example: Low trim: Applyre50 in-H20 Enter--50.53 High trim: Apply --150 inH20 Enter--151.58 Deciding Whether to Trim the DIA After the microprocessor conditions the sensor signals, it outputs a Converter digital word. The digital-to-analog (D/A) output circuitry converts the word to an analog signal for the 4-20 mA communications line. It may be necessary to check and trim this circuitry after a period of time. The 4-20 mA output trim function can also be used to make adjustments to allow for peculiarities of a particular readout device in the loop. To determine whether the output must be trimmed, connect the HART- based communicator and a precision milliammeter capable of reading + i micromole in the loop as shown in Figure 2-7. 2-15 Hosemount MoOel 11 bl 5mart Pressure I ransmlRers ' Next, perform a loop test as described on page 2-4, Follow the loop test procedure and set the transmitter to a 4 mA output. Then check the aremeter. The reading should be within +3 p~A of 4 mA. The~ set the transmitter to a 20 mA output and check the ~ milliammeter. The reading should be within + 3 ~tA of 20 mA. The "' output should be trimmed if the values on the meter exceed this tolerance range. When trimming the output, adjustments are made to the output circuitry. The appropriate shire will be made for all intermediate points between 4 and 20 mA. The communicator will allow the D/A converter to be trimmed by using a current meter or voltage meter. When using a current meter, follow the sequence outlined in 4-20 mA Analog Output Trim. When using a voltage meter or a meter whose display does not read out in 4-20 mA, follow the sequence outlined under 4-20 mA Analog Output Trim Using Other Scale. Digital to Analog Converter It may be necessary to calibrate the current output circuitry after a Trim period of time and use. The 4-20 mA output trim function can also be used to make adjustments to allow for peculiarities of a particular readout device in the loop. 4-20 mA Analog Output Trim A 4-20 mA output trim adjusts the transmittermilliampere output'to match a plant's current standard. Use this procedure when trimming HART Comm. 1, 2, 3, 2, ~ the converter using a current meter. Model 268 F4, F4, F3, F1, F1 4-20 mA Analog Output To trim the output using a voltage or other meter, connect the meter Trim Using Other Scale across a resistor in the loop. For best accuracy, use a precision resistor. The scaling function may be used if the meter displays other units, such HART Comm. 1, 2, 3, 2, 2 as 0-100%. Model 268 F4, F4, F3, F1, F2 NOTE If a resistor is added to the loop, before proceeding, ensure that the power supply is sufficient to power the transmitter to a 20 mA output with the additional loop resistance. Advanced Functions Burst Mode When the Model 1151 Smart is configured for burst mode, it provides faster digital communication from the transmitter to the control system HART Comm. 1, 4, 3, 4, 3 by eliminating the time required for the control system to request information from the transmitter. Model 268 F4, F4, F1 Burst mode is compatible with use of the analog signal. Because HART protocol features simultaneous digital and analog data transmission, the analog value can drive other equipment in the loop while the control system is receiving the digital information. Burst mode applies only to the transmission of dynamic data (pressure and temperature in engineering units, pressure in percent of range, and/or analog output in mA or V), and does not affect the way other transmitter data is accessed. 2-16 I '! 'i ! T' I T I Access to information other than dynamic transmitter data is obtained through the normal poll/response method of HART communication. A HART-based communicator or the control system may request any of the information that is normally available while the transmitter is in burst mode. Between each message sent by the transmitter, a short pause allows the HART-based communicator or a control system to initiate a request. The transmitter will receive the request, process the response message, and then continue "bursting" the data approximately three times per second. Saving, Recalling, and Data that was entered off-line can be stored in the communicator C[oning Configuration Data memory and downloaded to other transmitters later. Data also can be copied from a transmitter in order to be sent to other transmitters in a HART Corm. Left Arrow, 3 (Note) process known as "cloning." This is especially useful if when working with a large number of transmitters that require the same Model 268 F4~ F4, F1 configUration data. NOTE The HART Communicator Mode] 275 requires the use of the Transfer Menu to move data between the transmitter memory and the communicator. This menu is available from the Main Menu of the HART Communicator. Press the lef~ arrow to move from the Online Menu to the Main Menu. Press 3 from the Main Menu to access the Transfer Menu. A HART-based communicator may be used to transfer data between transmitters of the same model type. Multidrop Communication Multidropping transmitters refers to the connection of several transmitters to a single communications transmission line. Communication between the host and the transmitters takes place digitally with the analog output of the transmitters deactivated. Many of the Rosemount SMART FAMILY transmitters can be multidropped. With the HART smart communications protocol, up to 15 transmitters can be connected on a single twisted pair of wires or over leased phone lines. Note that burst mode operation is not compatible with multidrop communications. The application of a multidrop installation requires consideration of the update rate necessary from each transmitter, the combination of transmitter models, and the length of the transmission line. Multidrop installations are not recommended where intrinsic safety is a requirement. Communication with the transmitters can be accomplished with commercially available Bell 202 moderns and a host implementing the HART protocol. Each transmitter is identified by a unique address (1-15) and r~sponds to the commands defined in the HART protocol. Figure 2-8 shows a typical multidrop network. 'This figure is not intended as an installation diagram. Contact Rosemount product support with specific requirements for multidrop applications. 2-17 I ! i I r I B Hosemount MOOel 1151 5mart Pressure lransmltters FIGURE 2-8. Typical Multidrop Network. Power ~:Tj ~/ SUpply ( \ '~ '~ r~'-' ~-based commu~icato~s ca~ test, co~5~e, and fo~at a mu]tidropped ~ode] ~5~ jn the same way as it can a Mode] ~5] i~ a standard poet-to-point i~sta]]atio~. NOTE ~e ~ode] ~5~ Sm~ ~ess~e ~s~t~ js set ~ ad~ess 0 at the fac~, ~o~ it to operate ~ the s~nda~ ~i~t-~-~t ma~e~ with a ~20 ~ output siva]. ~o activate mu]tid~op comm~catjo~, the t~s~t~ ad~ess must ~ ch~ed to a numbe~ ~ee~ ~ ~d ~5 (i~c]~ive). ~is ~e deactivates the ~20 ~ ~a}o~ output, se~d~n~ it ~ 4 ~ ~ ~so d~sab]es the fa~]u~e mode a]am si~aZ, which ~s co~t~o]]ed by the upsca]ddow~c~e s~tch. Changing a Transmitter Address To change the address of a multidropped transmitter, follow these lass key sequences. To activate multidrop communication, the transmitter HART Comm. 1,4, 3, 4, I address must be changed to a number from I to 15. Model 268 F1, F4, F4, F2, F3 Polling a Multidropped Loop Polling a multidropped loop determines the model, address, and number of transmitters on the given loop. HART Comm. Left Arrow, 5, I (note) Model 268 F1, F4, F4, F2. F3 NOTE The HART Communicator Model 275 requires the use of the Utility Menu to perform an auto poll. This menu is available from the Main Menu of the HART Communicator. Press the left arrow to move from the Online Menu to the Main Menu. Press 5 from the Main Menu to access the Utility Menu. 2-18 I FIGURE 2-9, Model 1151S Configuration Data Sheet. Model 1151 Smart Pressure Transmitters CONFIGURATION DATA SHEET Customer RO. No, Model No. Line Item SST Tag No. Software Tag:lllllllll(8charactersmaximum) OUTPUT INFORMATION: (Software Select~blei 4 mA = O'k ' KEY 20 mA = Upper Range Limirk 'k Default Values Units = i'1 inH20* [] psi [] Pa i- inH20 for Ranges 3.--5 in. : _R~e_qUir, e_s_c_9~°P~!i°n_, [] inHg [] bar [] kPa 'k psi for Ranges 6--0 in. [] ftH20 [] mbar [] Tort [] mmH20 [] g/crn2 [] Atm [] mmHg [] kg/cm2 Output = [] Linear~r [] Square Root Damping[= seconds (Damping is electronically adjustable in 0.1 seconds in increments from 0.0 to 16.0 seconds.) TRANSMITTER INFORMATION: (Software Selectable) ~""~e's'cr~pt~7:"""ll ll ll ll ll ll ll l l_l_l (16 characters maximum) Message: IIIIIIIIIIIIIIIIIIIIIIIIIIt111111(32charactersmaximum) ) Date: ~ (numeric)(alphabetic) (numeric) IIIIIII III Day Month Year Integral Meter: [] Installed [] None Flange Material: [] 316 SST [] Hastelloy C [] Monel I'~ Carbon Steel [] Special O-ring Material: [] Viton .[] Buna-N [] Ethylene-Propylene [] Teflon [] Special Isolator Material: [] 316 SST [] Hastelloy C [] Monel [] Tamalum [] Gold/Monel [] Special Sensor Fluid: ["q Silicone ~] Inert DrainNent Valves: [] 316 SST [] Hastelloy C [] Monel [] Carbon Steel [] Special Remote Seal Type: [] No Seal [] CTW [] EFW [] PRN ~'1RRN [] RTW [] SCW [] SSW [] Special Remote Seal Fill Fluid [] No Seal [] Sillcone [] Syltherm 800 [] Inert [] GlycerirdH20 [] Prop Gly/H20 [] Neobee M-20 [] Special Remote Seal Isoltr Mat'h [] No Seal [] 316 SST [] Hastelloy C [] Tantatum [] Special Number of Remote Seals: [] No Seal [] One [] Two 2-19 Rosemount Model 1151 Smart Pressure Transmitters ' HARDWARE SELECTABLE INFORMATION: Failure Mode: I [] High [] Low Transmitter Security: [] Off [] On SIGNAL SELECTION: [] 4-20 mA with simultaneous digital signal based on HART protocol ~[] Burst mode of HARTdigital process vadable(~) I Burst mode output options: [] Primary variable in engineering units [] Primary variable in percent of range [] All dynamic variables in engineering units and the primary variable mA value t[] Multidrop Communication(2) I Choose transmitter address (1-15)(3): (1) These options are available with Revision 5. 1 and greater software. (2) This option fixes the transmitters analog output at 4 mA. (3) Default transmitter address is I if multidrop communication is selected. 2-20 I ! ! I I T I Section Installation OVERVIEW This section is designed to guide you through a successful Model 1151 installation. This section contains an installation flow chart; safety messages; general, mechanical, mounting, and electrical installation information; as well as installation guidance for optional parts. Dimensional drawings for each Model 1151 variation and mounting configuration are included. FIGURE 3-1. Model 1151 Installation Flowchart. Pren Both Zero Apply 4 mA-point Check Jumper and Span Button - Pasture and Tare or Switches Simuttaneousiy Zero Screw to Output Mount Apply Zero Point ~ Apply Transmitter 20 mA-point Pressure and Pressure Press Zero Button ; SUt I Range Points 'Wire Yes Subtract Actual Transmitter Apply Span Point Output from Desired Pressure and Press Set Output Span Button Output Type I Power } e Treosmitter Divide Set Refer to Difference Dumping Section 4 by 5 Zero Troubleshooting I Transmitter Turn Span Screw Desired Output by (p ns) Value in Last Step Repeat Steps until Cailbreted 3-1 ' · · r II II(.)~UIIIIJUIIL IVIfJUUI I I,,n I olllilrl r'lu~ljulu i rtlll~llllttur~ ' SAFETY MESSAGES Warnings ( ~ ) Procedures and instructions in this section that raise potential safety issues are indicated by a warning symbol (&). Refer to the following warning messages before performing an operation preceded by this symbol. ~WARNING · Explosions can result in death or serious injury. Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field widng practice. · Process leaks can cause death or serious injury. Install and tighten all four flange bolts before applying pressure, or process leakage may result. Attempting to remove the flange bolts while the transmitter is in service may cause process fluid leaks. · All explosion-proof, flameproof, and dust-ignition-proof installations require insertion of conduit plugs in all unused openings with a minimum of 40 ft-lb (54 N-m) of torque. This will maintain five full threads of engagement. · When adding a meter option to a Model 1151 with an Option Code R1 or R2 terminal block, make sure to change to cemented meter covers with a glass window. Make sure a sticker is located inside the cover that indicates a "cemented cover." This cover is required to maintain explosion-proof approval. · Explosions can cause death or serious injury. Do not remove the instrument cover in explosive atmospheres when the circuit is alive. · Explosions can cause death or serious injury. To meet hazardous location requirements, any transmitter with a tag specifying Option Codes 15, I1, N1, 18, 17, or N7 requires an intrinsically safe analog meter (Part Nos. 01151-2614-0004 through 0009) or an LCD meter (Par~ Nos. 01151-1300-1000, 01151-1300-1001, 01151-1351-1000, or 01151-1351-1001). ! I I T' T I ?'~WARNING Failure to install flange adapter O-rings can cause process leaks, which can result in death or serious injury. There are two styles of Rosemous{ flange adapters, each requiring a unique O-ring, as shown below. Each flange adapter is distinguished by its unique groove. MODEL 3051/2024/3001/3095 i~'i' Flange Adapter ~ _Q-ring Unique O-ring ~_ Grooves ~ ~ ~ ~-- Flange Adapter ", ~ ,~ ring MODEL 1151 Use only the O-ring designed tO seal with the corresponding flange adapter. Refer to the Spare Parts List on page 5-19 for the part numbers of the flange adapters and O-rings designed for the Model 1151 Pressure Transmitter. GENERAL The accuracy of a flow, pressure, or level measurement depends on CONSIDERATIONS proper installation of the transmitter and impulse piping. The piping between the process and transmitter must accurately transmit process pressure to the transmitter. Mount the transmitter close to the process and use a minimum of piping to achieve best accuracy. However, keep in mind the need for easy access, safety of personnel, practical field calibration, and a suitable transmitter environment. In general, install the transmitter so as to minimize vibration, shock, and temperature fluctuations. Installations in food, beverage, and pharmaceutical processes may require sanitary seals and fittings. Regulations may dictate special installation requirements to maintain sanitation and cleanability. See Product Data Sheet 00813-0100-4016 for more information about sanitary pressure instruments from Rosemount Inc. Access Requirements When choosing an installation location and position, take into account the need for access to the transmitter. Process Flange Orientation Orient the process flanges to enable process connections to be made. For safety reasons, orient the drain/vent valves so that process fluid is directed down and away from technicians when the valves are used. This can be accomplished by pointing the hole in the outside valve body downward and away. 3-3 r ! ! ! I I ! Hosemount MOOel I I 01 bmal'E rressure I ransmluers Housing Rotation ,_!~CAUTION Do not rotate the transmitter housing more than 90 degrees without disconnecting the header board. Exceeding 90 degrees rotation will damage the internal sensor module wiring. The electronics housing is designed to be rotated up to 90 degrees in order to provide field access to the two housing compartments. (If rotating the housing more than 90 degrees is necessary, follow the transmitter disassembly procedures in Section 4 Troubleshooting.) To rotate the housing up to 90 degrees, loosen the housing lock nut and turn the housing not more than 90 degrees from the orientation shown in Figure 3,2. NOTE Seal module threads with Loctite® 222 before retightening housing lock nut (see Connecting the Electrical Housing to the Sensor on page 4-6. Terminal Side of Mount the transmitter so that the terminal side of the housing is Electronics Housing accessible by providing: · A 3A-inch clearance for cover removal with no meter · A 3-inch clearance for cover removal with a meter installed If practical, provide approximately 6 inches clearance so that a meter may be installed later. The terminal side is marked on the nameplate located on the side of the transmitter. Circuit Side of The circuit compartment should not routinely need to be opened when Electronics Housing the unit is in service. However, provide 6 inches clearance, if possible, to allow access to the integral zero and span buttons or for on-site maintenance. The circuit side of the housing is marked on the nameplate located on the side of the transmitter. Exterior of Electronics Housing The Model 1151 Smart Pressure Transmitter uses the same housing as the analog Model 1151. For this reason, integral span and zero screws- 'non-functional on the Model 1151 Smart Pressure Transmitter--are located under the nameplate' on the side of the transmitter. [ '1 //111 :' [' I MECHANICAL Rosemount Model 1151 Transmitters may be panel-mounted, wall- CONSIDERATIONS mounted, or attached to a 2-inch pipe through an optional mounting bracket. Figures 3-2 and 3-3 show the transmitter dimensions. /~ 7.5 (191) Max. FIGURE 3-2. Model 1151AP, DR 4 with Optional Meter -- -,,,e e,~ - - 0.75 (19) GRand HP Dimensional Drawings. I/2-14 NPT ---.\ , Clearance for .. Conduit ~ Cover Removal Connection (2 Places) i '\'\\ q__ 4.5 (114) (Typical) , Max. Meter ~\ ( ' ~ -~ Transmitter .o..,.. -, ] E / i r o ~ ThisSide This Side E~ ~-18 NPT on - ~ .... · Flanges for Pressure ~. Connection without ........ Flange Adaptera~ ; D Blank Flange 1/2-14 NPT on Used on AP and GP Flange 4-- A ~ Transmitters Adapters (See Table) Flange Distance · A' Range Center to Center 4.5 (114) ..,~. !nches mm ~ Max. 7 Permanent Tag (Optional) 3, 4, 5 2.125 54 6, 7 2.188 56 ·: ' 8 2.250 57 9 2.281 58 0 2.328 59 Wired-on 1%L(."~'~,~,,,~j4 9.0 (229) Max, Tag--~ (Standard) ~>% ~ Nameplate " %- ~ Valve Side Drain/Vent ~A 18 NPTfor % (i) NOTE 3.375 Flanges Can Dimensions are in inches (millimeters). (86) Be Rotated FLange Adapter 4~ 4.5(114) 3-5 r 'i '! I I II Hosemoun[ MOOel 11 ~)1 ~rnarT yressure I tansminers FIGURE 3-3. Model 1151LT Dimensional Drawing. ..... 11.38 (289) Max. / Gasket Surface D (114) : " Max ~ Flushing " / l ' Connection Wired-on Tag --/ / (standard) / --- '4.45 .... ~-- 2-, 4-, or 6-in. OPTIONAL FLUSHING Flange ~ (113) (51,102, or 152) CONNECTION RING Adapter Max. Extension (LOWER HOUSING) Meter - This Side Housing .......... Nameplate (Remove for ~ ~ ' Span and Zero Adjust) 7.5 (190.5) " .- B Max. with ~ . Optional ~ "~'; ~""~'~2~] Meter ,.,,,,,,,.-,0 .-..,,,:.,: ,'-:! Thia Side / ',, ;:,.,.d.,t co..ect,o.on F,..ge '- ',,-18 N,',' on F,a.ges'' ' Ade e, without the Use of Flange DIAPHRAGM ASSEMBLY ~ 0.75 (19) Clearance for Adapters Cover Removal (typical} AND MOUNTING FLANGE NOTE Dimensions are in Inches (millimeters). TABLE 3-1. Model 1151LT Dimensional Specifications. O,D. Lower Housing Class Pipe Flange Bolt Circle Outside No. Exten. , Thickness Diameter Diameter of Bolt Hole Di~rn Gask. Xmtr Proc. Size Diameter Surf. A B C Bolts D l ~ Side Side E F G ANSI 2 (51) 1.12 (28) 4.75 (121) 6.0 (152) 4 0.75 (19) NA 3.75 (95) 2.9 (74) 2.16 (55) 150 3 (76) 1.31 (33) 6.0 (152) 7.5 (190) 4 0.75 (19) 2.58 (65) 5.0 (127) 3.11 (79) 3.11 (79) 4 (102) 1.31 (33) 7.5 (190) 9.0 (228) 8 0.75 (19) 3.5 (89) 6.81 (173) 4,06 (103) 4.06 (103) ANSI 2 (51) 1.25 (32) 5.0 (127) 6.5 (165) 8 0.75 (19) NA 3.75 (95) 2.9 (74) 2.16 (55) 300 3 (76) 1.50 (38) 6.62 (168) 8.25 (209) 8 0.88 (22) 2.58 (65) 5.0 (127) 3.11 (79) 3.11 (79) 4 (102) 1.62 (41) 7.88 (200) 10.0 (254) 8 0.88 (22) 3.5 (89) 6.81 (173) 4.06 (103) 4.06 (103) ANSI 2 (51) 1.12 (28) 5.0 (127) 6.5 (165) 8 0.75 (19) NA 3.75 (95) 2.9 (74) 2.16 (55) 600 3 (76) 1.37 (35) 6.62 (168) 6.62 (168) 8 0.88 (22) 2.58 (65) 5.0 (127) 3.11 (79) 3.11 (79) DIN DN 50 26 mm 125 mru 165 mm 4 18 turn NA 95 mm 74 mm 55 mm PN 10-40 DIN DN 80 30 mm 160 mru 200 mm 8 18 mm 65 mm 127 mm 79 mm 79 mrn PN 25/40 DN 100 30 mm 190 mm 235 mm 8 22 mm 89 mm 173 rum 103 mm 103 mm DIN PN 10/16 DN 100 26 mm 180 mru 220 mm 8 18 mm 89 mm 173 rum 103 mm 103 mru (1) Tolerances are 0.040 (1.02), -0.020 (0.51). 3-6 .... i i/1' r' MOUNTING The Model 1151 Smart Pressure Transmitter weighs 12 lb. (5.4 kg) CONSIDERATIONS without a meter and 15 lb. (6.8 kg) with a meter. This weight must be securely supported. The transmitter is calibrated in an upright position at the factory. If this orientation is changed during mounting, the zero point will shift by an amount equivalent to the liquid head caused by the mounting position. Full Trim on page 2-12 describes how to correct this shift. NOTE Do not plug the low side with a solid plug. Plugging the low side will cause an output shift. Mounting Requirements The following information applies to steam, liquid, and gas (for Steam, Liquid, Gas) installations. Taps Tap placement location is dependent on the type of process being measured, and on whether the transmitter has side drain/vent valves: a For liquid flow measurement, place taps to the side of the line to prevent sediment deposits, and mount the transmitter beside or below these taps so gases can vent into the process line and away from the transmitter. * For gas flow measurement, place taps in the top or side of the line and mount the transmitter beside or above the taps so liquid will drain away from the transmitter. * For steam flow measurement, place taps to the side of the line with the transmitter mounted below them to ensure that the impulse piping stays filled with condensate. e For transmitters with side drain/vent valves, place taps to the side of the line. (See Drain/Vent Valves on page 3-8 for mounting position of drain/vent valves). See Figure 3-4 for a diagram of these arrangements. FIGURE 3-4. Steam, Liquid, and Gas Service Installation Diagrams. LIQUID SERVICE GAS SERVICE Blocking Flow Valves ~r'/~/Plugged Tee L~// '~ ~ for Steam Service 3-valve Vent/Drain L I for Sealing Fluid Manlfo d Valve S e-mounted L - Drain/Vent ValVe Sufficient ' 3-valve Length for Cooling Flow ! / Manifold L H FI~,,,~ STEAM SERVICE Flow 3-valve m Man.old H \ NOTE For steam service do not blow down Impulse piping Manifold through transmitter. Flush lines with blocking valves closed Drain/Vent and refill lines with water before resuming measurement. Valve 3-7 r 'i '! .... I I Drain/Vent Valves Drain/vent valve orientation is also dependent on the process being measured: · For liquid service, mount the side drain/vent valve upward to allow the gases to vent. · For gas service, mount the drain/vent valve down to allow any accumulated liquid to drain. To change the drain/vent valve orientation from top to bottom, rotate the process flange 180 degrees. Impulse Piping The piping between the process and the transmitter must accurately transfer the pressure in order to obtain accurate measurements. In this pressure transfer, there are five possible sources of error: · Leaks · Friction loss (particularly if purging is used) · Trappod gas in a liquid line · Liquid in a gas line · Temperature-induced or other density variation between the legs The best location for the transmitter in relation to the process pipe depends on the process itself. Consider the following general guidelines in determining transmitter location and placement of impulse piping: · Keep impulse piping as short as possible. · Slope the impulse piping at least I inch per foot (8 centimeters per meter) upward from the transmitter toward the process connection for liquid. - · Slope the impulse piping at least i inch per foot (8 centimeters per meter) downward from the transmitter toward the process connection for gas. · Avoid high points in liquid lines and low points in gas lines. · Make sure both impulse legs are the same temperature. · Use impulse piping large enough to avoid friction effects and prevent blockage. · Vent all gas from liquid piping legs. · For steam service, fill impulse piping with water to prevent contact of live steam with the transmitter. ~CAUTION Steam or other elevated temperature processes can cause damage to the sensor. Do not allow the temperature inside the process flanges to exceed the transmitter limit of 220 °F (104 °C). · When using a sealing fluid, fill both piping legs to the same level. · When purging is necessary, make the purge connection close to the process taps and purge through equal lengths of the same size pipe. Avoid purging through the transmitter. · Keep corrosive or hot process material out of direct contact with the sensor module and flanges. · Prevent sediment deposits in the impulse piping. · Keep the liquid head balanced on both legs of the impulse piping. C I i ' i l: T' ~ ] I Process Connections j~ Flange Adaptors: Model 1151AP, DP, GP, and HP process connections on the transmitter flanges are ¼-18 NPT. Flange adapters are supplied with standard ~ 14 NPT Class 2 connections. The flange adapters allow users to disconnect from the process by removing the flange adapter bolts. Use ' plant-approved lubricant or sealant when making the process connections. Figure 3-2 shows the distance between pressure connections. This distance may be varied ±l/s in. (3.2 ram) by rotating one or both of the flange adapters. On open vessels, the low-side process flange is open to atmosphere and should be mounted with the threaded hole pointed down. On closed vessels, this connection is used for the dry or wet leg. High-pressure-side process connections for the Model 1151LT Transmitter are offered with 2-, 3-, or 4-in., Class 150, 300, or 600 flanges; DN 50 (PN 10-40), DN 80 (PN 25/40), or DN 100 (PN 10/16, 25/40). Low-pressure-side process connections for the Model 1151LT Transmitter are offered with ¼-18 NPT on the flange, and V2-14 NPT on the adapter. O-rings: The two styles of Rosemount flange adapters (Model 1151 and Model 3051/2024/3001/3095) each require a unique O-ring (see Figure 3-5). Use only the O-ring designed for the corresponding flange adaptor. FIGURE 3-5. O-Rings. MODEL 3051/2024/3001/3095 ~ Range Adapter ' Unique O-ring .............. J ~' Grooves .............. ~ i ~ Flange Adapter '1 ................. J MODEL 1151 /A When compressed, Teflon® O-rings tend to "cold flow,~ which aids in their sealing capabilities. NOTE Teflon® O-rings should be replaced if the flange adapter is removed. Tightening the Seal: To ensure a tight seal on the flange adapters or a three-valve manifold, first finger-tighten both bolts, then wrench-tighten the first bolt to approximately 29 ft-lbs (39 N-m). Wrench-tighten the second bolt to approximately 29 ft-lbs (39 N-m). See "Safety Messages" on page 3-2 for complete warning information. 3-9 Rosemount Model 1151 Smart Pressure Transmitters Mounting Brackets Optional mounting brackets permit mounting the transmitter to a wall, a panel, or a 2-inch horizontal or vertical pipe. Figure 3-6 illustrates some typical configurations this mounting brackets. FIGURE 3-6. Mounting Bracket Options. 3,75 (9~) /,65 (42) 3,87 (917 · ,97 - (127) 2.81 . <71, -, MOUNTING BRACKET OPTION CODES B1, B4, AND B7, Mounting Holes 3.75 ~5) ; .65 (42L-/~/"~-3.S7 (98) 0.375 Diameter "' - , // 7:7_"'~/"., ": ........: ~ ~ ':" O ~ (6) 2 81 ' (36) A.5 (114) (6~ PANEL MOUNTING BRACKET OPTION CODES B2 AND B5 ~.~25 (54) - / 1.62 (4~,~ ./; FLAT MOUNTING BRACKET OPTION CODES B3, B6, AND B9 NOTE Dimensions are in inches (millimeters). 3-10 I 'i li I' i I ELECTRICAL NOTE CONSIDERATIONS Make sure all electrical installation is in accordance with national and local code requirements. Power Supply The dc power supply shou]d provide power with less than 2% ripple. The total resistance load is the sum of the resistance of the signal leads and the load resistance of the controller, indicator, and related pieces. The resistance of intrinsic safety barriers, if used, must be included. To use the Rosemount Model 282 Loop Validator to power the loop, connect the Model 282 Validator leads at the set of terminal screws labeled "Signal." Figure 3-7 illustrates power supply load limitations for the transmitter. FIGURE 3-7. Power Supply Load Limitations. Rmax RL Operating Rmin Vmln VS Vmax Elec Code V,~, ,, V~,~, Rm,,~ R,!I:~ RL at Supply Voltage (V,~) (1) A minimum of 250 fi is required ~r communication. Low ~wer minimum I~d im~ance: 3-11 f 1 I ! I I i Rosemount Model 1151 Smart Pressure lransmitters Conduit Installation .~CAUTION If all connections are not sealed, excess moisture accumulation can damage the transmitter. Make sure to mount the transmitter with the electrical housing positioned downward for drainage. To avoid moisture accumulation in the housing, install wiring with 'a drip loop, and ensure the bottom of the drip loop is mounted lower than the conduit connections or the transmitter housing. Recommended conduit connections are shown in Figure 3-8. FIGURE 3-8. Conduit Installation Diagrams; CORRECT CORRECT INCORRECT C Wiring ;:'~CAUTION Do not connect the power signal wiring to the test terminals. Voltage may burn out the reverse-polarity protection diode in the test connection. If the test diode is destroyed, then the transmitter can still be operated without local indication by jumping the test terminals. High voltage (greater than 50 V and greater than 0.005 amperes) can cause damage to the transmitter. Do not apply high voltage to the test terminals. The signal terminals and test terminals are located in a compartment of the electronics housing that is separate from the transmitter electronics. The nameplate on the side of the transmitter indicates the locations of both of these compartments. The upper pair of terminals are the signal terminals and the lower pair are the test terminals. The test terminals have the same 4-20 mA output as the signal terminals and are only for use with the optional integral meter or for testing. 3-12 NOTE An alternate location to connect an aremeter is on the set of terminals labelled "TEST." Connect the positive lead of tl~e aremeter to the positive test terminal, and the negative lead of the aremeter to the negative test terminal. To make connections, remove the cover on the side marked "Terminal" on the nameplate. All power to the transmitter is supplied over the signal wiring. Connect the lead that originates at the positive side of the power supply to the terminal marked %" and the lead that originates at the negative side of the power supply to the terminal marked "-" as shown in Figure 3-9. No additional wiring is required. Do not run signal 'wiring in conduit or open trays with power wiring or near heavy electrical equipment. For improved performance against EMI/RFI effects, refer to page 3-19 for information on transient protection terminal blocks. Shielded cable should be used for best results in electrically noisy environments. NOTE When conduit lines are used, signal wiring need not be shielded, but twisted pairs should be used for best results. Wiring must be 24 AWG or larger and not exceed 5,000 feet (1500 meters). NOTE A minimum loop resistance of 250 ~ is required to cemmunicate with a hand-held HART-based communicator. With 250 II of loop resistance, the transmitter requires a minimum of 17 volts to output 20 mA. ffa single power supply is used to power more than one Model 1151 Smart transmitter, the power supply used, and circuitry common to the transmitters, should not have more than 20 ~1 of impedanco at 1200 Hz. -Grounding J Use the following techniques to properly ground the transmitter signal wiring and case: Signal Wiring Signal wiring may be grounded at any one point on the signal loop or may be left ungrounded. The negative terminal of the power supply is a recommended grounding point. Transmitter Case The transmitter case must be grounded in accordance with national and local electrical codes. The most effective transmitter case grounding method is a direct internal connection to earth ground with minin~al impedance. The transmitter case may also be grounded through the process or conduit connections. Internal Ground Connection: Inside the field terminals side of the electronics housing is the internal ground connection screw. This screw is identified by a ground symbol: . NOTE Grounding the transmitter case via threaded conduit connection may not provide sufficient ground continuity. See "Safety Messages" on page 3-2 for complete warning inlormation. 3-13 NOTE The transient protection terminal block (page 3-19) does not provide transient protection unless the transmitter case is properly grounded. Use the preceding guidelines to ground the transmitter case. Do not run the transient protection ground wire with signal wiring as the ground wire may carry excessive current if a lightning strike occurs. Grounding Effects The capacitance sensing module requires alternating current to generate a capacitance signal. This alternating current is developed in an oscillator circuit with a frequency of approximately 32 kHz. This signal is capacitor-coupled to transmitter-case ground through the sensing module. Because of this coupling, a voltage may be imposed across the load, depending on the choice of grounding. See Figure 3-9. Impressed voltage, which ~s seen as high frequency noise, will have no effect on most instruments. Computers with short sampling times in circuits will detect a significant noise signal, which should be filtered out by using a large capacitor (1 pF) or by using a 32 kHz LC filter across the load. Computers that are wired and grounded, as shown in Figure 3-9, are negligibly affected by this noise and do not need filtering. FIGURE 3-9. Effects of Grounding on Accuracy for Fast Sample Computers. + I Ungrounded System Impressed Voltage: 12 to 22 mVp.p 32 kHz Effect: 0.01% of span, max. LOAD [_~p ~ Ground Between Negative Side of Power Supply and Load Impressed Voltage: 35 to 60 mVp-p 32 kHz _ Effect: 0.03% of span, max. LOAD 4 l --__ ~ _~ Ground Between Positive Side of Transmitter and Power Supply Impressed Voltage: 35 to 60 mVp-p 32 kHz Effect: 0.03% of span, max. LLOAD + Ground Between Negative Terminal of Transmitter and Load Impressed Voltage: 500 to 600 mVp-p T~ _~ 32 kHz Effect: 0.27% of span, max. p__ LOAD -- *The effect caused by the impressed voltage on a computer with a sampling time of 100 microseConds using a 2 to 10 volt signal. 3-14 I 1' I i ! The Model 1151 was designed with an explosion-proof housing and Hazardous Locations AL circuitry suitable for intrinsically safe and nonincendive operation. Certifications Factory Mutual explosion-proof certification is standard for the Model 1151 Smart Transmitter. Individual transmitters are clearly marked with a tag indicating the approvals they carry. Transmitters must be installed in accordance with all applicable codes and standards to maintain these certified ratings. Refer to Hazardous Locations Certifications on page 5-2 for information on these approvals. Environmental Mount the transmitter in an environment that has minimal ambient Requirements temperature change. The transmitter electronics temperature operating limits are -40 to 185 °F (-40 to 85 °C). Section 5 Specifications and Reference Data lists the sensing element operating limits. Mount the transmitter so that it is not susceptible to vibration and mechanical shock and does not have external contact with corrosive materials. INSTALLATION OPTIONS Mounting Brackets (OPTION CODES B1-B7 AND B9) Optional mounting brackets available with the Model 1151 allow mounting to a 2-inch pipe or panel. Figure 3-6 shows bracket dimensions and mounting .configurations for the various bracket options. Pipe Mounting Brackets Option Codes B1, B4, and B7 are sturdy, polyurethane-painted brackets designed for 2-inch pipe mounting. Option Code B1 is constructed of carbon steel with carbon steel bolts. Option Code B4 is the same bracket as Option Code B1, with 316 SST bolts. Option Code B7 is also the same bracket as Option Code B1 with a 316 SST bracket and 316 SST bolts. Panel Mounting Brackets Option Codes B3, B6, and B9 are fiat brackets designed for 2-inch pipe mounting. Option Code B3 is constructed of carbon steel with a carbon steel U-bolt. Option Codes B6 and B9 are the same bracket configuration as Option Code B3. Option Code B6 provides 316 SST bolts and Option Code B9 provides a 316 SST bracket and 316 SST bolts ........ Analog Meters A Option Codes M1-M3 and M6 provide local indication of the transmitter output in a variety of scaling configurations with an indicator accuracy of +2 percent. The plug-in mounting configuration allows for simple installation and removal of the analog meters. The meter scaling options are shown below. M1 Linear analog meter, 0-100% scale M2 Square-root analog meter, 0-100% flow scale M3 Special scaling analog meter, (specify range) M6 Square-root analog meter, 0-100% flow scale //~ See "Safety Messages" on page 3-2 for complete warning information. 3-15 I 'I "! I !I Hosemount MOOel 11 ~)1 binart I-ressure I ransmltters LCD Meters The LCD meter Option Codes, M4 and M7-M9, provide a highly accurate local display of the process variable. A variety of scaling configurations are available and listed as follows: M4 Linear LCD meter, 0 to 100% M7 Special scale LCD meter (specify range, mode, and engineering units) M8 Square-root LCD meter, 0 to 100% M9 Square-root LCD meter, 0 to 10% LCD Meter Configuration The Rosemount LCD meter plugs directly into the Model 1151 Smart Pressure Transmitter to provide a highly accurate digital display of the process variable. This manual explains the configuration and assembly of the LCD meter and includes the applicable functional, performance, and physical specifications. This meter adds no voltage drop in the 4-20 mA current loop when connected directly across the transmitter test terminals. The LCD meter may be configured to meet specific requirements by using the left and right calibration buttons located on the meter face as shown in Figure 3-10. The analog bar graph is also shown in Figure 3-10. The 20-segment bar graph is factory calibrated and represents 4-20 mA directly. FIGURE 3-10. LCD Meter. ........ / ._. Rosemount Analog / -- "' tainlng Bar Graph , _; "' Ring - Left Configurati~ ~iguration o, Button ................................... .,,..'Button o, No calibration equipment is required to configure the LCD meter, but between 4 and 20 mA must be flowing through the loop. The actual value of the current is not significant. In addition, meter configuration does not affect the transmitter/loop current. Use the following nleter configuration procedure to proper]y configure the LCD meter: Remove the Cover 1. Unscrew the retaining ring shown in Figure 3-10 and lift the transparent cover off of the housing. NOTE The LCD meter time-out is approximately 16 seconds. If keys are not pressed within this period, the indicator reverts to reading the current signal. 3-16 I I i ! 1' I T I Position the Decimal Point and 2. Press the left and right configuration buttons simultaneously and Select the Meter Function release them immediately. 3. To move the decimal point to the desired location, press the left configuration button. 4. To scroll through the mode options, press the right configuration button repeatedly until the desired mode is displayed. See Table 3-2. TABLE 3-2. LCD Meter Modes. Options Relationship between Input S~gnal and Digital Display 'L in Linear L inF Linear with five-second filter Srt Square root SrtF Square root with five-second filter Square root function only relates to the digital display. The bar graph output remains linear with the current signal. Square root response The digitat display will be proportional to the square root of the input current where 4 mA=0 and 20 mA=1.0, scaled per the calibration procedure. The transition point from linear to square root is at 25% of full scale flow. Filter response operates upon "present input" and "input received in the previous five second interval" in the following manner: Display = (0.75 x previous input) + (0.25 x present input) This relationship is maintained provided that the previous reading minus the present reading is less than 25% of full scale. Store the Information 5. Press both configuration buttons simultaneously for two seconds. The meter displays "---" for approximately 7.5 seconds while the information is being stored. Set the Display Equivalent 6. Press the left button for two seconds. to a 4 mA Signal 7. To set the display numbers to a lower value, press the left configuration button, and to set the display numbers to a higher value, press the right configuration button. Set the numbers between -999 and 1000. 8. To store the information, press both configuration buttons simultaneously for two seconds. Set the Display Equivalent 9. Press the right button for two seconds. to a 20 mA Signal 10. To set the display numbers to a lower value, press the left configuration button, and to set the display numbers to a higher value, press the right configuration button. Set the numbers between -999 and 9999. The sum of the 4 mA point and the span must not exceed 9999. 11. To store the information, press both configuration buttons simultaneously for two seconds. The LCD meter is now configured. Replace the Cover 12. Make sure the rubber gasket is seated properly, replace the transparent cover, and replace the retaining ring. LCD Meter Assembly Figure 3-11 shows the mounting hardware required to properly install the LCD meter on a transmitter or in the field signal indicator. This mounting hardware may also be used with the Rosemount universal (analog) meter. 3-17 ! '1 I " Rosemount Model 1151 Smart Pressure Transmitters FIGURE 3-11. LCD Meter Exploded View. ~-- Mounting Screw into Housing Mounting Screws ----~\~ d~ ~1~\ 3-18 I Terminal Blocks The terminal block options c~a_n increase the Model 1151 Pressure Transmitter's ability to withstand electrical transients induced by lightning, welding, heavy electrical equipment, or switch gears. The Model 1151 Pressure Transmitter, with the integral transient protection option, meets the standard performance specifications as outlined in this product manual. In addition, the transient protection circuitry meets IEEE Std 587, Category B, and IEEE Std 472, Surge Withstand Capability. FIGURE 3-12. Transient Protection and Filter Terminal Block (Code R1). Transient Protection and Option Code R1 provides EMIfRFI protection and the benefit of integral Filter Terminal Block transient protection. This terminal block can be ordered as a spare part (Option Code R1) to retrofit existing Model 1151 Transmitters with Option Code R2. Terminal Block Installation Use a phillips and a fiat-blade screwdriver and the following steps to install a retrofitable transient protection terminal block: 1. Turn off all power to the Model 1151 on which the terminal block is being installed. ~ 2. Unscrew the transmitter terminal-side (indicated on the housing nameplate) cover (on the high side of the transmitter) exposing the standard terminal block. 3. Disconnect wiring to the terminal block. 4. Remove the single grounding screw and the two signal terminal screws, with terminal eyelet washers, from the standard terminal block. 5. Set the retrofitable transient protection terminal block into the housing, making sure the ground and signal terminals are properly aligned. 6. Insert the short mounting screws with washers in the mounting holes and tighten the terminal ]9lock to the transmitter. 7. Turn the transient protector grounding sleeve, located in the grounding hole, just enough to stabilize the unit on the transmitter. Overtightening the grounding sleeve will shift the terminal block out of alignment. 8. Insert the long grounding screw with the square washer into the grounding hole and tighten. 9. Connect the positive power supply wire to the transient protector terminal screw labeled '% SIGNAL", and the negative power supply wire to the terminal screw labeled "- SIGNAL." 10. Attach the supplied label to the terminal side transmitter cover. ~ 11. Replace the terminal side cover on the transmitter. ~ See "Safety Messages" on page 3-2 for complete warning inlormation. 3-19 Rosemount Model 1151 Smart Pressure Transmitters C 3-20 i · ! I T' T i Section Troubleshooting OVERVIEW Table 4-1 provides summarized troubleshooting suggestions for the most common operating problems. If you suspect a realfunction despite the absence of any diagnostic messages on the communicator display, follow the procedures described here to verify that transmitter hardware and process connections are in good working order. Always deal with the most likely and easiest-to- check conditions first. SAFETY MESSAGES Warnings ) Procedures and instructions in this section that raise potential safety issues are indicated by a warning symbol (i). Refer to the following warning messages before performing an operation preceded by this symbol. ~WARNING · Isolate a failed transmitter from its pressure source as soon as possible. Pressure that may be present could cause death or serious injury to personnel if the transmitter is disassembled or ruptures under pressure. · Explosions can cause death or serious injury. Do not remove the instrument cover in explosive atmospheres when the circuit is alive. · Explosions can cause death or serious injury. Do not break the housing seal in explosive environments. Breaking the housing seal invalidates the explosion- proof housing rating. · Process leaks can cause death or serious injury. An incorrectly installed backup ring can destroy the o-ring and cause process leaks. Install the backup ring using the following procedure. · Exposure to hazardous substances can cause death or serious injury, If a hazardous substance is identified, a Material Safety Data Sheet (MSDS), required by law to be available to people exposed to specific hazardous substances, must be included with the returned goods. · Explosions can cause death or serious injury, Do not disassemble the glass in the meter cover in explosive atmospheres, Disassembling the glass in the meter cover invalidates the explosion-proof meter rating, 4-1 · · ! ' ' r I Rosemount Model 1151 Smart Pressure Transmitters ~,~WARNING · The following performance limitations may inhibit efficient or safe operation. Critical applications should have appropriate diagnostic and backup systems in place. Pressure transmitters contain an internal fill fluid. It is used to transmit the process pressure through the isolating diaphragms to the pressure sensing element. In rare cases, oil leak paths i'n oil- filled pressure transmitters can be created. Possible causes include physical damage to the isolator diaphragms, process fluid freezing, isolator corrosion due to an incompatible process fluid, etc. A transmitter with an oil fill fluid leak can continue to perform normally for a period of time. Sustained oil loss will eventually cause one or more of the operating parameters to exceed published specifications while a small drift in operating point output continues. Symptoms of advanced oil loss and other unrelated problems include: - Sustained drift rate in true zero and span or operating point output or both - Sluggish response to increasing or decreasing pressure or both - Limited output r~te or very nonlinear output or both - Change in output process noise - Noticeable drift in operating point output - Abrupt increase in drift rate of true zero or span or both - Unstable output - Output saturated high or low TABLE 4-1. Troubleshooting Symptoms and Corrective Action. Symptom Potential Source Corrective Action Transmitter does not Loop Wiring Check for a minimum of 250 Q resistance between the power supply and the communicate with the Model 275 communicator connection. Check for adequate voltage to the transmitter. (If the communicator is connected and 250,0, resistance is properly in the loop, then the loop requires a minimum of 17 volts to operate.) Check for intermittent shorts, open circuits, and multiple grounds. Specify the transmitter by tag number. See the display sequence below. I.S. Barrier Refer to appropriate I.S. Barrier documentation. High Output Primary Element Check for restrictions at primary element. Impulse Piping Check for leaks or blockage. Ensure that blocking valves are fully open. Check for entrapped gas in liquid lines and for liquid in dry lines. Ensure that the density of fluid in impulse lines is unchanged. Check for sediment in transmitter process flanges. Power Supply Check the power supply output voltage at the transmitter. It should be 12 to 45 V dc. Transmitter Electronics Connect the Model 268 and enter the XMTR TEST mode to determine any electronic failures. Make sure that post connectors are clean. If the electronics are still suspect, substitute new electronics. Sensing Element The sensing element is not field repairable and must be replaced if found to be defective. See "Disassembly procedure" later in this section for instructions on disassembly. Check for obvious defects, such as a punctured isolating diaphragm or fill fluid loss, and contact the Rosemount National Response Center at 1-800-THE-RSMT (1-800-654-7768). ~ ' · -: T' I T I TABLE 4-1. (continued). Symptom Potent;al Source Correct;ve Action Erratic Output Loop Wiring Check for adequate voltage to the transmitter. It should be 12 to 45 V dc with no load, Check for intermittent shorts, open circuits and multiple grounds. :%CAUTION Do not use over 45 volts to check the loop, or damage to the transmitter electronics may result. Connect the Model 275 and enter the LOOP TEST mode to generate signals of 4 mA, 20 mA, and user~selectec~ values. Process Pulsation Adjust the electronic damping with the Model 275. Transmitter Electronics Connect the communicator and perform a transmitter test to determine any electronic failures. Make sure the post connectors are clean, If the electronics are still suspect, substitute new electronics. Impulse Piping Check for antrapped gas in liquid lines and for liquid in dry lines. 'Low Output or No Output Primary Element Check the insulation and condition of primary element. Note any changes in process fluid properties that may affect output. Loop Wiring Check for adequate voltage to the transmitter. It should be 12 to 45 V dc. Check the milllamp rating of the power supply against the total current being drawn for - all transmitters being powered. Check for shorts and multiple grounds. Check for proper polarity at the signal terminal. Check loop impedance. Check whether the transmitter is in multidrop mode, thus locking the output at 4 mA. Connect the communicator and perform a loop test. Do not use over 45 volts to check the loop, or damage to the transmitter electronics may result. Check wire insulation to detect possible shorts to ground. 'Impulse Piping Ensure that the pressure connection is correct. Check for leaks or blockage. Check for entrappad gas in liquid lines. Check for sediment in the transmitter process flange. Ensure that blocking valves are fully open and that bypass valves are tightly closed. Ensure that density of the fluid in the impulse piping is unchanged. Transmitter Electronics Connect the communicator and check the sensor limits to ensure calibration adjustments are within the sensor range. Connect the communicator and pedorm a transmitter test to determine electronics failure. Make sure the post connectors are clean. If the electronics are still suspect, substitute new electronics. Sensing Element The sensing element is not field repairable and must be replaced if found to be defective. See 'Disassembly procedure" later in this section for instructions on disassembly. Check for obvious defects, such as punctured isolating diaphragm or fill fluid loss, and contact Rosemount National Response Center at 1-800-THE-RSMT(1-800-654-7768). Transmitter Does Not Pressure Source/Correction Check for restrictions or leaks. Characterize Properly Check for proper leveling or zeroing of the pressure source. Check weights/gauge to ensure proper pressure setting. Dotermine if the pressure source has sufficient accuracy. (The pressure source should be at least three times more accurate that the Model 1151 Smart.) 4-3 L I I '1 r f TABLE 4-1. (continued). Symptom Potential Source Corrective Action Transmitter Does Not mA Meter Determine if the mA meter is functioning properly, Characterize Properly Power Supply Check the power supply output voltage at transmitter. It should be 12 to 45 V dc with no load. Check for a minimum of 250 Q resistance between the Model 268 and the power supply. Transmitter Electronics Connect the communicalor and perform a transmitter test to determine any electronic failures, Make sure the post connectors are clean, If electronics are still suspect, substitute with new electronics. Sensing Element The sensing element is not field repairable and must be replaced if found to be defective. See "Disassembly procedure" later in this section for instructions on disassembly. Check for obvious defects, such as punctured isolating diaphragm or fill fluid loss, and contact Rosemount National Response Center at 1-800-THE-RSMT(1-800-654-7768). '! ' ' IT i' '" T I Disassembly Procedure ~ Read the following information carefully before you disassemble a transmitter. General information concerning the process sensor body, electrical housing, and a procedure for their separation follow. Figure 4-1 shows an exploded view of the transmitter. FIGURE 4-1. Differential Pressure Terminal Eyelets (DP) Transmitter Exploded View, Shown with Smart Electronics. Transmitter Security and Board Failure Mode Alarm Switches Spacers Zero and Span Buttons /' Electron: ~~// { , Module "' ~ : /~ Blank Flange for AP and GP · Transmitters Process Flange Process Sensor Body Be aware of the following: · The transmitter should be removed from service before disassembling the sensor body. · Process flanges can be detached by removing the four large bolts. ;.'~CAUTION Do not scratch, puncture, or depress the isolating diaphragms. Damaging the isolating diaphragms can inhibit transmitter performance, · Isolating diaphragms may be cleaned with a soft rag, mild cleaning solution, and clear water rinse. ~CAUTION Do not use chlorine or a~:id solutions to clean the diaphragms. Damaging the isolating diaphragms can inhibit transmitter performance. · Flange adapters and process flanges may be rotated or reversed for mounting convenience. See "Safety Messages" on page 4-1 for complete waming information, 4-5 i · a · : T i Rosemount Model 1151 Smart Pressure I ransmfiters · Electrical Housing ~, Electrical connections are located in a compartment identified as TERMINAL SIDE on the nameplate. The signal and test terminals are accessible by unscrewing the cover on the terminal side. The terminals are permanently attached to the housing and must not be removed, or the housing seal between compartments will be broken. To remove the smart electronics, refer to Appendix C Retrofitting the Model 1151 Transmitter, and reverse the installation sequence described in steps 10 through 15. Removing. the Sensor from the 1. Unscrew the cover on the field terminal side of the transmitter. Electrical Housing 2. Disconnect the power source from the transmitter. 3. Remove the smart electronics and header board. 4. Loosen the lock nut. '~-'CAUTION Do not damage the isolating diaphragms when unscrewing the sensor module. Damaging the isolating diaphragms can inhibit transmitter performance. 5. The threaded connection has a sealing compound on it and will initially be tight. Unscrew the sensing module from the electronics housing, being careful not to damage the sensor leads. Carefully pull the header assembly board through the hole. The sensing module is a welded assembly and cannot be further disassembled. Reassembly Procedure FollOw these procedures carefully to ensure proper reassembly. Preliminary Precaution Inspect all O-rings and replace if necessary. Lightly grease with silicone oil to ensure a good seal.' Use halocarbon grease for inert fill options. Connecting the Electrical ~ 1. Insert the header assembly board through the electronics Housing to the Sensor housing. 2. Use a sealing compound (Loctite 222--Small Screw Threadlocker) on the threads of the sensor module to ensure a watertight seal on the housing. 3. Screw the sensor module into the electrical housing making sure that at least five threads are engaged. Be careful not t° damage or twist the sensor leads. 4. Align the sensor module with the high and low pressure sides oriented for convenient installation. 5. Tighten the lock nut. Electrical Housing The smart electronics and header board can easily be installed in the electrical housing. Steps 10 through 15 in Appendix C Retro~tting the Model 1151 Transmitter describe this assembly. ~_%CAUTION An already characterized transmitter requires recharacterization whenever the sensor module or smart electronics are replaced. Failure to recharacterize can inhibit transmitter performance. (See Appendix C Retrofitting the Model 1151 Transmitter.) 4-6 ~t, See "Safety Messages" on page 4-1 for complete warning information, I ! '! I I' i I Process Sensor Body All HP transmitters and GP Range 9 and 10 transmitters require metal backup rings to ensure O-ring integrity. Figure 4-2 illustrates the position and orientation of the metal backup rings. (Backup rings are not required on AP or DP transmitters or GP Range 3-8 transmitters.) NOTE Handle the backup ring carefully, as it is fragile. Examine the ring carefully. One side is beveled, while the other side is flat. The fiat side appears more shiny when viewed from above. 1. Clean the sealing surfaces carefully. 2. Place the module on a fiat surface, "H' side up. 3. Place the greased flange O-ring around the isolator and push it into the cavity. FIGURE 4-2. Detail Showing Process O-ring and Backup Ring Installation of Module Seal for Model 1151HP and GP Range 9 (GP Range 10 Requires Only One O-ring and Backup O-ring). Process Flange -- Metal Back-up Ring O-ring -~ i - Flat Side (shiny aide) Toward O-ring L Beveled Side Toward Process Flange 4. For all HP transmitters and GP transmitters Ranges 9 and 10, place the backup ring, shiny side down, on top of the O-ring. This places the fiat side of the backup ring against the O-ring. 5. Carefully place the flange on top of the module, beveled side down so that the beveled flange surface mates with the beveled surface of the backup ring. 6. Keeping the flange and module together, turn them over so the "L' side is up. Repeat Steps 3 through 5. As before, the fiat side of the backup ring must rest against the O-ring. 7. Insert the four flange bolts. See "Safety Messages" on page 4-1 for complete warning information. 4-7 · T T T i Rosemount Model 11 51 Smart Pressure lransmfilers 8. Tighten the nuts finger tight, making sure the flanges remain parallel. The transmitter may now be moved without disturbing the O-rings. a. Tighten one bolt until the flanges seat. b. Torque down the bolt diagonally across. c. Torque down the first bolt. d. Torque down the two remaining bolts. e. Inspect the flange-to-sensor seating to be sure that the flanges are not cocked. f. Check that all four bolts are tightened to approximately 33 ft-lb (39 Nm). 9. Recalibrate the transmitter. Optional Plug-in Meters The optional indicating meters available for Rosemount Model 1151 transmitters are listed in Section 5 Specifications and Reference Data. Please be aware of the following information while assembling the meter assembly. Refer to Table 5-12 on page 5-19 for part references. * The meter may be rotated in 90-degree increments for convenient reading. · If the meter cover is removed for any reason, be sure the O-ring is in place between the cover and housing before reattachment. To maintain an explosion-proof condition, the glass in the meter cover should not be disassembled for any reason. Sensor Module Checkout The sensor module is not field repairable and must be replaced if found to be defective. If no obvious defect is observed (such as a punctured isolating diaphragm or fill fluid loss), the sensor module can be checked as follows. 1. Carefully pull the header assembly board off of the post connectors. Rotate the board 180 degrees about the axis formed by the connecting leads. The sensor module and electronics housing can remain attached for checkout. 2. Check internal diode loops, forward and reverse bias: one loop is on pins one and two, the other is on pins three and four. See Figure 4-3. Loop resistance values should be nearly equal. NOTE Do not touch the transmitter housing when checking resistances, or a faulty reading can result. 3. Check the resistance between the sensor module housing and pins one through four. This checks the resistance between both capacitor plates and the sensing diaphragm, which is grounded to the housing. This resistance should be greater than 10 M~z 4. Check the resistance between pin eight and the sensor module to ensure that the module is grounded. Resi'stance should be zero. NOTE The above procedure does not completely test the sensor module. If circuit board replacement does not correct the abnorma] condition, and no other problems are obvious, replace the sensor module. 4-8 ~ See "Safety Messages" on page 4-1 for complete warning information, I ! ~' T' 'T I I FIGURE 4-3. Header Board Connections. (COMPONENT SIDE UP) Returning Rosemount To expedite the return procesS, call the Rosemount National Response Products and/or Materials Center using our 800-654-RSMT (7768) toll-free number. This center, available 24 hours a day, will assist you with any needed information or materials. The center will ask for product model and serial numbers, and will provide a Return Material Authorization (RMA) number. For safety reasons, the center will also ask for the name of the process material the product was last exposed to. ~ The National Response Center will detail the additional information and procedures necessary to return goods exposed to hazardous substances. See "Safely Messages" on page 4-1 Ior complete warning information. 4-9 4-10 * I Section Specifications and ,. Reference Data FUNCTIONAL Service SPECIFICATIONS f,iquid, gas, and vapor applications. Ranges Minimum span equals the upper range limit (URL) divided by rangedown. Rangedown varies with the output code (see Table 5-2). TABLE 5-1. Model 1151 Transmitter Range Availability by Model (URL = Upper Range Limit). Range Code Model 1151 Ranges (URL) DP HP GP DP/GP/Seals AP LT 2 6 inH20 (1.49 kPa) NA NA NA NA NA NA 3 30 inH20 (7,46 kPa) · NA · NA NA NA 4 150 inH20 (31.08 kPa) 5 750 inH20 (186.4 kPa) 6 100 psi (689.5 kPa) 7 300 psi (2068 kPa) - · · NA 8 1,000 psi (6895 kPa) · NA · NA · NA 9 3,000 psi (20684 kPa) NA NA · NA NA NA 0 6,000 psi (41369 kPa) NA NA · NA NA NA TABLE 5-2. Rangeability. ] Output Code Minimum Span Maximum Span S (DP and GP, SST, Range 3-8) URL/15 2 x URLO) S (All others) URU6 2 x URL{~) (1) Transmitter is capable of measuring from -URL to URL. Outputs Code S, Smart 4-20 mA tic, user selectable for linear or square root output. Digital process variable superimposed on 4-20 mA signal, available to any host that conforms to the HART protocol. Power Supply External power supply required. Transmitter operates on: 12 to 45 V dc with no load for Output Code S. Where: Rwllx Operating Region Rmln Vmln VS Vmax Code Vmm Vmax Rmm Rrn~x RL at Supply Voltage (Vs) 1,21451 o 118 ol (1) A minimum of 250 ohms is required for communication. 5-1 r '~ · "' r T Rosemount Model 1151 Smart Pressure Transmitters Span and Zero Output Code S Span and zero may be accessed with ]oca] adjustments or remotely ~,~ via a HART-based communicator. Hazardous Locations Certifications ~lr Stainless steel certification tag is provided. Factory Mutual (FM) Approvals FM Explosion Proof tag is standard. Appropriate tag will be substituted if optional certification is selected. Default Explosion Proof: Class I, Division 1, Groups B, C, and D. Dust-Ignition Proof: Class II, Division 1, Groups E, F, and G. Suitable for use in: Class III, Division 1. Indoor and outdoor use. NE1VIA 4X. Factory Sealed. |5 Intrinsic Safety and Non-incendive Approvals: FM certifications optional for specific Classes, Divisions, and Groups when connected in accordance with the FM entity approvals (see. Table 5-3). Factory Sealed. K5 Combination of Explosion Proof, Intrinsic Safety, and Non- incendive Approvals. TABLE 5-3. FM Entity Approvals. FM Approved for Class I, II, Ill, Division I and 2 11 51 Parameters Equipment Associated Groups Parameters A B C-G VMax = 40 V VOC _< 40 V IMax = 165 mA ISC _< 165 mA Ci = 0 (Standard) CA > 0 Ci = 0.024 i~F (Smart) CA > 0.024 i~F · · · Ci = 0.010 p,F (Standard w/R Option) CA > 0.010 , Ci = 0.034 p,F (Smart w/R Option) CA > 0.034 I-i = 0 (Standard) LA > 0 Li = 20 p,H (w/R Option) LA > 20 ij-H VMax = 40 V VOC _< 40 V Iuax = 225 mA Isc _< 225 mA Ci = 0 (Standard) CA > 0 NA NA · Ci = 0.024 izF (Smart) CA > 0.024 p.F - Li=0 LA>0 Canadian Standards Association (CSA) Approvals E6 Explosion proof for Class I, Division 1, Groups C and D; Class II, Division 1, Groups E, F, and G; Class III, Division 1 Hazardous Locations. Certified for Class I, Division 2, Groups A, B, C, and D; CSA enclosure 4. Factory sealed. 16 .Intrinsic Safety Approvals CSA certifications optional for specific Classes, Divisions, and Groups when connected in accordance with the CSA barrier selection table, Table 5-4. Not available with Output Code G. C6 Combination of 16 and E6, CSA Explosion Proof and Intrinsic Safety Approval. Factory Sealed. K6 CSA/CENELEC Explosion-Proof and Intrinsic Safety Approval. TABLE 5-4. CSA Barrier Selection. CSA Approved for C!ass ~. D~vision 1 and 2 Barrier Manufacturer/Model Groups A B C D Any CSA Approved Barrier < 30 V, > 330 fi or < 28 V, >_300 fi or <_22 V, >_ 180 ~ .... Foxboro Converters 2AS-131-C.GB, 2AI-13V-CGB, 2AI-12V-CGB, 2AS-121-CGB, 3A2- NA · · · 12D CS-F. JCGB-A, 3F4-12DAI CS-F_JCGB-A, 3AD-131A CS-E/CGB-A, 3A2-13D CS-E/CGB-A, and 3A4-12DA CS-E/CGB-A Any CSA Approved Barrier <_ 30 V, >_ 150 ~ NA NA · · Standards Association of Australia (SAA) E7 Flameproof Certification Ex d IIB T6; DIP T6; IP 65. Class I, Zone 1. Special Conditions: For transmitters having NPT or PG cable entry threads, an appropriate flameproof thread adaptor shall be used to facilitate application of certified flameproof cable glands. 17 Intrinsic Safety Certification Smart: Ex ia IIC T6; Class I, Zone 0. Special Conditions: Observe barrier/entity parameters dm'ing installation. N7 Type N Ex n IIC T6 (Tamb = 40 °C). Ex n IIC T5 (Tamb = 70 °C). Class I, Zone 2, Special Conditions: The equipment must be connected to a supply voltage which does not exceed the rated voltage. The enclosure end caps must be correctly fitted whilst the equipment is energized. CESI/CENELEC Flameproof Certification E8 90.C.016: EEx d IIC T6 (without meter). 90.C.017: EEx d IIB+ H2 T6 (with meter). IP 65. CESI/CENELEC Intrinsic Safety Certification 18 EEx ia IIC T6 (Tamb = 40 °C); (Pmax = 0.75 W). EEx ia IIC T5 (Tamb = 55 °C); (Pmax = 1.00 W). EEx ia IIC T4 (Tamb = 80 °C); (Praax = 1.00 W). BASEEFA/CENELEC Intrinsic Safety Certification I1 Smart: Ex ia IIC T5 (Tamb -- 40 °C). EEx ia IIC T4 (Tamb = 80 °C). Special Conditions: When transient protection terminal options (R1 or R9) are installed, the transmitter must be supplied from a galvanically isolated i,s. barrier. BASEEFA Type N (Non-incendive) Certification N1 Smart Ex NII T5 (Tamb = -40 °C to 50 °C); Un = 45 V. Ex N II T4 (Tamb = -40 °C to 80 °C); Un -- 45 V. Special Conditions: The apparatus must be installed in accordance with BS 5345: Part 7:1979 and be cartbed by means of enclosure earth terminal. r '!" · · - - I r ! Schweizerischer Elektrotechnischer Verein (SEV) Intrinsic Safety Certification IC Smart EEx ia IIC T5 (Tamb = 40 °C). EEx ia IIC T4 (Tamb = 80 °C). TABLE 5-5. International Entity Approvals. SAA (Australia) SEV (Switzerland) CESI (Italy) BASEEFA (United Kingdom) Ui = 30 V Ureax = 29.4 V Analog Ui = 30 V Smart Umax:in = 28 V dc Analog Ii = 200 mA Imax = 215 mA Analog Ii = 200 mA Smart Imax:in = 120 mA Analog Ci = 0.034 p,F Pmax = 0.35 W (T6) Analog Pi = 0.75 W (T6) Smart Umax:in = 30 V dc Smart Li = 20 ~H Pmax = 0.65 W (T5) Analog Pi = 1.0 W (T5 and T4) Smart Imax:in = 125 mA Smart Pmax = 0.95 W (T4) Analog Ci = 0.01 ~F Smart Wmax:in = 0.67 W (T5) Smart Cint = 0 Analog Li = 20 p,H Smart Wmax:in = 1.0 W (T4) Smart Umax = 30 V Smart Ceq = 0.034 p,F Smart Irnax = 125 mA Smart Ui = 30 V Code R9 Leq = 20 p,H Smart Pmax = 670 mA Smart Ii = 200 mA Code R9 Cint = 0.22 p,F Smart Pi = 1.0 W Code R9 Lint = 0 (Digital Meter) Smart Ci = 6 nF Code R9 Lint = 0,7 mH (Analog Meter) Smart Li = 20 p.H Code R9 Zero Elevation and Suppression Output Code S Zero elevation and suppression must be such that the lower range value is greater than or equal to the (-URL) and the upper range value is less than or equal to the (+URL). The calibrated span must be greater than or equal to the minimum span. Temperature Limits Ambient --40 to 185 oF (-40 to 85 °C). Process At atmospheric pressures and above. TABLE 5-6. Model 1151 Temperature Limits. Models 1151DP. HP, AP. GP, LT Siltcone Fill Sensor 0~tt: to 220 °F (-40 to 104 °C) Inert Fill Sensor 160 °F (-18 to 71 °C) Model 1151LT High-Side Temperature Limits (Process Fill Fluid) Syltherm® XLT -100 to 300 °F (-73 to 149 °C) D.C.® Siltcone 704 60 to 400 °F (15 to 205 °C) D,C. Siltcone 200 -40 to 400 °F (-40 to 205 °C) Inert -50 to 350 °F (-45 to 177 °C) Glycerin and Water(1) 0 to 200 °F (-18 to 93 °C) Neobe. e M-20¢(2) 0 to 400 °F (-18 to 205 °C) Propylene Glycol and Water(2) 0 to 200 °F (-18 to 93 °C) Syltherm 800 -50 to 400 °F (-45 to 205 °C) (1) Not suitable for vacuum service. (2) Not compatible with Buna-N or Ethylene-Propylene O-ring material. NOTE When specifying Option Codes W4 and W6, sensing element operating temperatures are 32 to 200 °F (0 to 93 °C) for silicone fill and 32 to 160 °F (0 to 71 °C) for inert fill. Storage ~ -60 to 185 °F (-51 to 85 °C). I I IT l' i T I Static Pressure Limits Transmitters operate within specifications between the following limits: Model 1151 DP 0.5 psia to 2,000 psig (3.45 kPa to 13790 kPa). Model 1151HP 0.5 psia to 4,500 psig (3.45 kPa to 31027 kPa). Model 1151AP 0 psia to the URL. Model 1151GP 0.5 psia (3.45 kPa) to the URL. Model 1151 LT Limit is 0.5 psia (3.45 kPa) to the flange rating or sensor rating, whichever is lower. Overpressure Limits Transmitters withstand the following limits without damage: Model 1151DP 0 psia to 2,000 psig (0 to 13790 kPa). Model 1151 HP 0 psia to 4,500 psig (0 to 31027 kPa). Model 1151AP 0 psia to 2,000 psia (0 to 13790 kPa). Model 1151GP: Ranges 3-8: 0 psia to 2,000 psig (0 to 13790 kPa). Range 9: 0 psia to 4,500 psig (31027 kPa). Range 0: 0 psia to 7,500 psig (51710 kPa). Model 1151LT: Limit is 0 psia to the flange rating or sensor rating, whichever is lower. TABLE 5-7. Model 1151LT and Level Flange Rating Limits. Carbon Steel Stainless Steel Standard Class Rating Rating ANSI 150 285 psig(~) 275 psig(~) ANSI 300 740 psig{~) 720 psig(~) ANSI 600 1,480 psig(~) 1,440 psigm DIN PN 10-40 40 bar(2) 40 bar(2} DIN PN 10/16 16 bar(2} 16 bar(2) DIN PN 25/40 40 bar(2) 40 bar(2) (1) At 100 °F (38 °C), the rating decreases with increasing temperature. (2) At 248 °F (120 °C), the rating decreases with increasing temperature. Burst Pressure Limit All models: 10,000 psig (68.95 MPa) burst pressure on the flanges. Humidity Limits 0 to 100% relative humidity. Volumetric Displacement Less than 0.01 in~ (0.16 cm3). 5-5 '! I I' : I ] rlOS(~lTIOUrll. IVI(JfJUI I Io I t.'}llli;ll L r"IU~i,t~.UIU IIklIIti, IIIILLUIti, Failure Mode Alarm When not in multidrop mode, self-diagnosis detects a gross transmitter failure, the analog signal will be driven below 3.9 mA or above 21 mA to alert the user. High or low alarm signal is user selectable. 4-20 mA 4-20 mA Level Saturation Alarm Value Value Low 3.9 mA 3.8 mA High 20.8 mA 21.75 mA Transmitter Security Activating the transmitter security function prevents changes to the transmitter configuration, including local zero and span adjustments. Security is activated by an internal switch. Overpressure Alarm If the sensor detects a negative overpressure value, the analog signal will be driven to 3.9 mA. If the sensor detects a positive overpressure value, the analog signal is driven to 20.8 mA. Damping Numbers given are for silicone fill fluid at room temperature. The minimum time constant is 0.2 seconds (0.4 seconds for Range 3). Inert-filled sensor values would be slightly higher. Output Code S: Time constant is adjustable in 0. 1 second increments from minimum to 16.0 seconds. Turn-on Time Maximum of 2.0 seconds with minimum damping. Low power output is within 0.2% of steady state value within 200 ms after application of power. I 1 ' ! li i' T I PERFORMANCE (Zero-based calibrated ranges, reference conditions, silicone oil fill, 316 SPECIFICATIONS SST isolating diaphragms.) Accuracy Output Code S: Ranges 3 through 8, DP and GP transmitters: ±0.1% of ca]ibrated span for spans from 1:1 to 10:1 of URL. Between 10:1 and 15:1 of URL, accuracy = _ span All other ranges and transmitters: ±0.25% of calibrated span. Output Code S, square mot mode: _+[0.2 + 0.05 x spURaLn3 % of calibrated flow span Stability Output Code S: +0.1% of URL for six months for DP and GP Ranges 3 through 8. (+0.25% for all other ranges and transmitters.) Temperature Effect Output Code S [-20 to 185 °F (-29 to 85 °C)]: For DP and GP transmitter Range 4 through 8: Zero Error = ±0.2% URL per 100 oF (56 °C) Total Error = ±(0.2% URL + 0.18% of calibrated span) per 100 °F; double the effect for other ranges and transmitters. Static Pressure Effect DP Transmitters: Zero Error: ±0.25% of URL for 2,000 psi (13790 kPa) or ±0.5% for Range 3, correctable through rezeroing at line pressure. Span Error: Correctable to ±0.25% of input reading per 1,000 psi (6895 kPa), or to ±0.5% for Range 3. For Output Code J, the span error is correctable to ±0.125% of output reading per 1,000 psi, or to ±0.25% for Range 3. HP Transmitters: Zero Error:. ±2.0% of URL for 4,500 psi (31027 kPa), correctable through rezeroing at line pressure. Span Error: Correctable to ±0.25% of input reading per 1,000 psi (6895 kPa). For Output Code J, the span error is correctable to ±0.125% of output reading per 1,000 psi, or to ±0.25% for Range 3. Vibration Effect 0.05% of URL per g to 200 Hz in any axis. Power Supply Effect Output Code S: Less than 0.005% of output span per volt. 5-7 i I ! ] ] I Load Effect Output Code S: No load effect other than the change in power supplied to the transmitter. EMI/RFI Effect Output shift of less than 0.1% of span when tested to SAMA PMC 33.1 from 20 to 1000 MHz and for field strengths up to 30 V/m (covers on). Mounting Position Effect Zero shift of up to 1 inH20 (0.24 kPa) that can be calibrated out. PHYSICAL Electrical Connections SPECIFICATIONS 1/2-14 NPT conduit with screw terminals and integral test jacks compatible with miniature banana plugs (Pomona 2944, 3690, or equivalent). The communicator connections are fixed to the terminal block on smart transmitters. Process Connections Model 1151DP, HP, GP, AP ¼-18 NPT on 2.125-in. (54-mm) centers on flanges for Ranges 3, 4, and 5. ¼-18 NPT on 2.188-in. (56-ram) centers on flanges for Ranges 6 and 7. ¼-18 NPT on 2.250-in. (57-mm) centers on flanges for Range 8. V2-14 NPT on adaptors. For Ranges 3, 4, and 5, flange adaptors can be rotated to give centers of 2.0 in. (51 mm), 2.125 in. (54 mm), or 2.250 in. (57 mm). Model 1151LT ~ High pressure side: 2-, 3-, or 4-in., Class 150, 300 or 600 flange; 50, 80, or 100 nun, PN 40 or 10/16 flange. Low pressure side: ¼-18 NPT on flange. V2-14 NPT on adapter. Process Wetted Pans Isolating Diaphragms 316L SST, Hastelloy C-276, Monel, gold-plated Monel, or Tantalum. See ordering table for availability per model type. Drain/Vent Valves 316 SST, Hastelloy C-276, or Monel. See ordering table for availability per model type. Process Flanges and Adaptors Plated carbon steel, 316 SST, Hastelloy C, or Monel. See ordering table for availability per model type. Wetted O-rings Viton~x~) (other materials also available). With gold-plated Monel diaphragms (diaphragm Code _6), special ~uorocarbon O-rings are supplied. (1) For enhanced sealing performance below 0 °F, consult factory. I I '! I I' i I Model 1151LT Process Wetted Parfs Ranged Process Connection (Transmitter High Side) Process diaphragms, including process gasket surface 316L SST, Hastelloy C-276, or Tantalum. Extension 316 SST or Hastelloy C-276. Fits schedule 40 and 80 pipe. Mounting Flange Cadmium-plated CS or SST. Reference Process Connection (Transmitter Low Side) Isolating Diaphragms 316L SST, Hastelloy C-276, or tantalum. Reference Flange and Adapter CF-8M (Cast version of 316 SST, material per ASTM-A743). Non-wetted Materials Fill Fluid Silicone oil or inert fill Bolts and Bolting Flange (GP and AP only) Plated carbon steel. Electronics Housing Low-copper aluminium. NEMA 4X. Cover O-rings Buna-N. Paint Polyurethane. Weight 12 lb (5.4 kg) for AP, DP, GP, and HP transmitters, excluding options. TABLE 5-8. Flange Weights with Model 1151LT Transmitter. 2-inch 4-inch E-inch , Flu sh (SOr'nm) ~ 100n m) [ 150n~m) Range Mount Extension Extension Extension 2-in., Class 150 18 (8.2) N/A N/A N/A 3-in., Class 150 23 (10.4) 25 (11.3) 26 (11.8) 27 (12.3) 4-in., Class 150 29 (13.2) 32 (14.5) 34 (15.4) 36 (16.3) 2-in., Class 300 20 (9.1) N/A N/A N/A 3-in., Class 300 28 (12.7) 30 (13.6) 31 (14.1) 32 (14.5) 4-in., Class 300 38 (17.2) 41 (18.6) 43 09.5) 45 (20.4) 2-in., Class 600 22 (10.0) N/A N/A N/A 3-in., Class 600 31 (14.1) 33 (15.0) 34 (15.4) 35 (15.9) DN 50, PN10-40 20 (9.1) N/A N/A' N/A DN 80, PN 25/40 25 (11.3) 27 (12.3) 28 (12.7) 29 (13.2) DN 100, PN 10116 DN 25 (11.3) 28 (12.7) 30 (13.6) 32 (14.5) 100, PN 25/40 29 (13.2) 32 (14.5) 34 (15.4) 36 (16.3) (1) Stainless steel flange weights are listed. ORDERING INFORMATION TABLE 5-9. Model 1151 Differential, High Line, Gage and Absolute Pressure Transmitters. Model Transmitter Type (select one) DP HP GP AP 1151DP Differential Pressure Transmitter · _ _ _ 1151HP Differential Pressure Transmitter for High Line Pressures Key 1151GP Gage Pressure Transmitter t ° I Applicable J _ _ · _ 1151AP Absolute Pressure Transmitter -- Not applicable _ _ _ · Code Pressure Ranges (URL) (select one)--For Rang·ability, see below DP HP GP AP 3 30 inH20 (7,46 kPa) Rangeability · -- · _ 4 150 inH20 (37.3 kPa) · · · · Output Code Min. Span · · 5 750 inH20 (186.4 kPa) S (DP and GP, SST, Range 3-8; URIJ15 6 100 psi (689.5 kPa) HP, SST, Range 4-7) · · · · 7 300 psi (2068 kPa) S (all others) URL/6 · · · · 8 1,000 psi (6895 kPa) E, G, J URL/6 · _ · · L URL/1.1 9 3,000 psi (20684 kPa) M URL/2 ' ' · ' 0 6,000 psi (41369 kPa) -- _ · _ Code Transmitter Output (select one) DP HP GP AP S 4-20 mA/Digital, Smart/Variable Damping · · · · E 4-20 mA, Linear, Analog/Variable Damping · · · · G 10-50 mA, Linear, Analog/Variable Damping · · · · J 4-20 mA, Square Root, Analog/Variable Damping · · -- _ L 0,8 to 3.2 V, Linear, Low Power/Fixed Damping · · · · M 1 to 5 V, Linear, Low Power/Fixed Damping · · · · MATERIALS OF CONSTRUCTION~ Code Flanges/Adapters DrainRents Diaphragms Fill Fluid DP HP GP/2' AP 52 Nickel-plated Carbon Steel 316 SST 316L SST Silicone · · · · 53 Nickel-plated Carbon Steel 316 SST Hastelloy C-276 Silicone · · · · 54 Nickel-plated Carbon Steel 316 SST Monel Silicone · · · · 55 Nickel-plated Carbon Steel 316 SST Tantalum Silicone · -- · -- 56 Nickel-plated Carbon Steel 316 SST Gold-plated Monel Silicone · -- · -- 12 Cadmium-plated Carbon Steel 316 SST 316L SST Silicone · · · · 22 316 SST 316 SST 3i 6L SST Silicone · · · · '- 23 316 SST 316 SST Hastelloy C-276 Silicone · · · · 24 316 SST 316 SST Monel Sillcone · · · · 25 316 SST 316 SST Tamalum Sillcone · -- · -- 26 316 SST 316 SST Gold-plated Monel Silicone · -- · -- 33(3~ Hastelloy C Hastelloy C-276 Hastelloy C-276 Sillcone · · · · 34 Hastelloy C Hastelloy C-276 Monel Silicone · -- · -- 35 Hastelloy C Hastelloy C-276 Tantalum Silicone · -- · -- (I) Bolts and conduit plugs are plated carbon steel. (2) On GP and AP transmitters, the low-side flange is plated carbon steel. I' For a stainless-steel low-side flange, order process connection Option Code D6. (3) These selections meet NACE material recommendations per MR 01-75. 5-10 TABLE 5-9. (continued). MATERIALS OF CONSTRUCTION~!! Code Flanges/Adapters Drain/Vents Diaphragms Fill Flugd DP HP GP': AP 36 Hastelloy 0 '7-1ast~itoy 0-276 Gold-plated Monel Silicone · -- · -- 43 Monel Monel Hastelloy C-276 Silicone · · · · 44 Monel Monel Monel Sillcone · · · · 45 Monel Monel Tantalum Silicone · -- · -- 46 Monel Monel Gold-plaled Monel Silk:one · -- · -- 73(3) 316 SST Hastelloy C-276 Hastelloy C-276 Siftcone · · · · 83(3) Nickel-plated Carbon Steel Hastelloy C-276 Hastelloy C-276 Silicone · · · · 5A Nickel-plated Carbon Steel 316 SST 316L SST Inert · -- · -- 5B Nickel-plated Carbon Steel 316 SST Hastelloy C-276 Inert · -- · -- 5C Nickel-plated Carbon Steel 316 SST Monel Inert · -- · -- 5D Nickel-plated Carbon Steel 316 SST Tantalum Inert · -- · -- 1A Cadmium-plated Carbon Steel 316 SST 316L SST Inert · -- · -- 2A 316 SST 316 SST 316L SST Inert · -- · -- 2B 316 SST 316 SST Hastelloy C-276 Inert · -- · -- 2D 316 SST 316 SST Tantalum Inert · -- · -- 3B Hastelloy C Hastelloy C-276 Hastelloy C-276 Inert · -- · -- 3D Hastelloy C Hastelloy C-276 Tantalum Inert · -- · -- 4B Monel Monel Hastelloy C-276 Inert · -- · -- 4C Monel Monel Monel Inert · -- · -- 4D Monel Monel Tantalum Inert · -- · -- 7B(3) 316 SST Hastelloy C-276 Hastelloy C-276 Inert · -- · -- 8B(3) Nickel-plated Carbon Steel Hastelloy C-276 Hastelloy C-276 Inert · -- · -- (1) Bolts and conduit plugs are plated carbon steel. (2) On GP and AP transmitters, the low-side flange is plated carbon steel. For a stainless-steel low-side flange, order process connections Option Code D6. (3) These selections meet NACE material recommendations per MR 01-75. TABLE 5-9. (continued). Code Mounting Brackets (optional - select one) DP HP GP AP B1 Bracket, 2-in. Pipe Mount · · · · B2 Bracket, Panel Mount · · · · B3 Bracket, Flat, 2-in. Pipe Mount · · · · B4 B1 Bracket w/Series 316 SST Bolts · · · · B5 B2 Bracket w/Series 316 SST Bolts · · · · B6 B3 Bracket w/Series 316 SST Bolts · · · · B7 316 SST B1 Bracket with 316 SST Bolts · · · · B9 316 SST B3 Bracket with 316 SST Bolts · · · · Code Meters (optional - select one) DP HP GP AP M1(~] Analog Scale, Linear Meter, 0-100% · · · · M2(2) Analog Scale, Square Root Meter, 0-100% Flow · · -- _ M3m Analog Scale, Linear Meter, Special Scale · · · · M4m LCD Meter, Linear Meter, 0-100%, User Selectable · · · · M6(2) Analog Scale, Square Root Meter, 1-10',/ · · -- _ M7(3) LCD Meter, Linear Meter, Special Configuration · · · · M8(4) LCD Meter Square Root Meter, 0-100% Flow · · -- -- M9(4) LCD Meter, Square Root Meter, 0-10'] · · -- -- (1) Not available with Output Codes L or M, or Option Codes Zx, V2, or V3. (2) Not available with Output Codes J, L, M, or Option Codes Zx, V2, or V3. (3) NOt available with Output Codes G, L, M, or Option Codes Zx, V2, or V3. (4) Not available with Output Codes G, J, L, M, or Option Codes Zx, V2, or V3. 5-11 r w · m T' T [ HO~el'110Url'! IVIOael II~ I Oll li:ll L I='l~.li, U! l~· I TABLE 5-9. (continued). t Code Certifications (optional - select one) DP HP GP AP E6 Canadian Standards Association (CSA) Explosion-Proof Approval I NOTE I · · · · ~ 15(1) Factory Mutual (FM) Non-incendive and Intrinsic Safety Approval FM explosion-proof · · · · K5 Factory Mutual (FM) Explosion-Proof and Intrinsic Safety Combination approval is standard. · · · · 16(~) Canadian Standards Association (CSA) Intrinsic Safety Approval · · · · C5® Industry and Science Canada (ISC) Approval (Available in Canada Only) · · · · C6n) Combination of 16 and E6; CSA Explosion-Proof and Intrinsic Safety Approval (Requires 42,4 V dc max. power supply) · · · · K6 CSAJCENELEC Explosion-Proof and Intrinsic Safety Approval E4 Japanese Industrial Standards (JIS) Flameproof Certification · · · · E7 Standards Association of Australia (SAA) Flameproof Certification · · · · E8 CESI/CENELEC Flameproof Certification · · · · I1 (3) BASEEFA Intrinsic Safety Certification · · · · 17(4) Standards Association of Australia (SAA) Intrinsic Safety Certification 18® CESI/CENELEC Flameproof Certification · · · · N1(6) BASEEFA Type N Certification · · · · N7 Standards Association of Australia (SAA) Nonincendive Safety Approval · · · · IC® Schweizerischer Eiektrochnischer Verein (SEV) Intrinsic Safety Certification · · · · Q4 Celibmtion Data Sheet · · · · Q8® Material Traceability per EN 10204 3.1B Code Housing DP HP GP AP H1(8) SST Non-wetted Parts on Transmitter without Meter · · · · H2(8) SST Non-wetted Parts on Transmitter with Meter · · · · H3 SST Housing, Covers, Conduit Plug, Lock-nut, without Meter · · · · H4 SST Housing, Covers, Conduit Plug, Lock-nut, with Meter · · · · C1 PG 13.5 Conduit Threads (Available in Germany Only) · · · · C2 M20 Conduit Threads (Available in Germany Only) · · · · J1 G~ Conduit Threads · · · · Code Terminal Blocks DP HP GP AP /~ Rt I Integ lTransient.rot. ion,onlya..ablewithoption esand ela roni )I ·I ·I ·I ·I" Code Bolts for Flanges and Adapters (optional - select one)DPHP GP AP L3 ASTM A193-B7 Flange and Adapter Bolts · · · · L4 316 SST Flange and Adapter Bolts · · · · L5 ASTM A193-B7M Flange and Adapter Bolts · · · · (I) Not available with Output Code G or Option Code Zx. (2) Not available with Option Codes M1-M9. (3) Not available with Output Codes G, J, L, M, or Option Code Zx. (4) Not available with Output Code G or Option Code Zx. I (5) Not available with Output Codes G, J, L, M, S, or Option Code Zx. (6) Not available with Output Codes G, L, M, or Option Code Zx. (7) This option is available for the transmitter flange and adapters. (8) Option includes SST housing, covers, conduit plug, locknut, L4 bolting, and D6 low side blank flange for GP and AP transmitters. Option Codes L4 and D6 parts are included with housing Option Codes H1 and H2. 5-12 I I "' !' i' r T I TABLE 5-9. (continued). Code Process Connections (opt'onafi~/) DP HP GP AP 316 SST · · · · D1 Side Drain/Vent, Top Hastelloy C-276 . · · · Monel · · · · 316SST · · · · D2 Side Drain/Vent, Bottom Hastelloy C-276 · · · · Monel · · · · 316 SST · · · · D3 Process Adapters Deleted Haste~oy C · · · · Monel · · · · D4 Conformance to DIN 19213 and DIN 50049 3.1B Ranges 3, 4, 5 (Available in Germany Only) · · · · D5 Conformance to DIN 19213 and DIN 50049 3.1B Ranges 6, 7, 8, without ¼ NPT Threads or Drain/Vent Valve Connections (Available in Germany Only) · · · · D6 316 SST Low Side Blank Flange -- -- · · "Carbon Steel · · · · 316 SST · · · · D9 JIS Process Connection-RC ¼ Flange with RC ~ Flange Adapter , Hastelloy C · · · · · Monel · · · · G1 DIN Spacing (Single Entry Port, No Side V/D Hole Flange) · · · · G2 DIN Spacing (Single Entry Port, TWO Side V/D Hole Flange) · · · · G3 DIN Spacing (Dual Entry Pod, No Side V/D Hole Flange) · · · · G4 DIN Spacing (Dual Entry Port, One Top Side V/D Hole Flange) · · · · G5 DIN Spacing (Dual Entry Port, One Bottom Side V/D Hole Flange) · · · · G6 DIN Spacing (Dual Entry Port, Two Side V/D Hole Flange) · · · · K1{2) Kynarinsert, ¼-18 NPT · -- · · K2(2) Kynarinsed, 1,~-14 NPT · -- · · S1(3) Attachment of One Remote Seal - See PDS 00813-0100-4016 · -- · -- S2(3) Attachment of Two Remote Seals - See PDS 00813-0100-4016 · -- -- -- S4(4) Attachment of Integral Orifice Assembly - See PDS 00813-01004,686 · · -- -- (1) Allowable combinations are: D1, D3, D6; D2, D3, D6; and D6, S1. (2) The maximum working pressure on this option is 300 psig. Available only with materials of construction Option Codes Ix or 2x. (3) This option may only be used on Ranges 4-8. (4) This option has a maximum static pressure rating of 3, 000 psi, and is available for factory assembly only without associated piping and is available only for Ranges 2, 3, 4, and 5. 5-13 ! i ! " I T i TABLE 5-9. (continued). I ® Code Wetted O-ring Material DP HP GP AP W2 Buna-N · · · · ~ W3 Ethylene-Propylene · · · · W4 Arias · · · · W6(~) Spring-loaded Teflon · i · · Code Procedures DP HP GP AP C9® Software Configuration · · · · P1(3) Hydrostatic Testing, 150% Maximum Working Pressure · · · · P2(4) Cleaning for Special Service · · · · P3 Cleaning for <1 PPM Chlorine/Fluorine · · -- -- P4 Calibrate at Line Pressure · · -- · P5 Calibrate at Specific Temperature · · · · P7(5) Improved Temperature Coefficient · · · -- P8(6) Calibrate to 0.1% Accuracy · · · -- Code Outputs DP HP GP AP V1(7) Reverse Output -- -- · -- V2® 4-20 mV Test Signal · · · · V3® 2000100 mV Test Signal · · · · Z1® 4-wire, 00020 mA Output · · · · ~ Z2® 4-wire, 0--16 mA Output · · · · Z3® 4-wire, 00010 mA Output · · · · Typical Model Number: 11 51DP 4 S 52 B3 M1 (1) Contains a Hastelloy spring that is wetted by the process; consult factory for Teflon O-ring without a spring. (2) Available with Output Code S only. (3) Hydrostatic testing for Range O, 125% maximum working pressure. (4) Fluorolube® grease on wetted O-rings. (5) Not available on Range 10: limited to 1,500 psi on Range 9; not applicable with Output Code S. (6) Available only with stainless steel isolators and for span of 10 inH20 and greater; not applicable with Output Code S; available only with Output Codes E, G, L, or M; not available on AP or DR transmitters. ~ (7) Reverse output option is not needed with smart electronics; configured via HART-based communicator. (8) Not available with Output Codes L or M. ' ~ (9) Not available with Option Codes Mx, Vx, Ix, or Ex, or Output Codes G, L, M, or S. 5-14 .. TABLE 5-10. Model 1151 LT Flange Mounted Liquid Level Transmitter. Model Product Description 1151LT I Alphaline Flange-Mounted Liquid Level Transmitter Code Range 4 0-25 to 0-150 inH20 (0-635 to 0-3,810 mmH20) 5 0-125 to 0-750 inH20 (0-3,175 to 0-19,050 mmH20) Rangeability 6 0-471 to 0-2,770 inH20 (0-11,96 to 0-70.36 mmH20) Output Code Min. Span S URIJ15 E, G URL/6 Code Output S 1151 Smart 4-20 mA dc Electronics (see PDS 00813-0100-4593) E 4-20 mA dc, with Adjustable Damping G 10-50 mA dc, with Adjustable Damping Code Size Material Extension Length GO 2 in./DN 50 316L SST Flush Mount Only } When specifying these option codes, a H0 2 in./DN 50 Hastelloy C-276 Flush Mount Only lower housing must be selected from the J0 2 in./DN 50 Tantalum Flush Mount Only flushing connection options Table 5-11. A0 3 in./DN 80 316L SST Flush Mount A2 3 in./DN 80 316L SST 2 in./50 mm A4 3 inJDN 80 316L SST 4 in./100 mm A6 3 in./DN 80 316L SST 6 in./150 mm B0 4 in./DN 100 316L SST Flush Mount B2 4 in./DN 100 316L SST 2 in./50 mm NOTE B4 4 in./DN 100 316L SST 4 in./100 mm Extension diameters are B6 4 in./DN 100 316L SST 6 in./150 mm sized to fit Schedule 80 CO 3 in./DN 80 Hastelloy C-276 Flush Mount pipe. Consult factory for C2 3 in./DN 80 Hastelloy C-276 2 in./50 mm Schedule 40 pipe. C4 3 in./DN 80 Hastelloy C-276 4 in,/100 mm C6 3 in ./DN 80 Haste~oy C-276 6 in ./150 mm DO 4 in./DN 100 Hastelloy C-276 Flush Mount D2 4 in./DN 100 Hastefioy C-276 2 in./50 mm D4 4 in./DN 100 Hastelloy C-276 4 in./100 mm D6 4 in./DN 100 Haste~oy C-276 6 in J150 mm E0 3 in./DN 80 Tantalum Flush Mount Only F0 4 in./DN 100 Tantalum Flush Mount Only MOUNTING FLANGE Applicable with these High Pressure Side Code Size Rating Material D~aphragm Sizes M 2 in. Class 150 ' CS 2 in./DN 50 A 3 in. Class 150 CS 3 in./DN 80 B 4 in. Class 150 CS 4 in,/DN 100 N 2 in. Class 300 CS 2 in,/DN 50 C 3 in. Class 300 CS 3 in./DN 80 D 4 in. Class 300 CS 4 in,/DN 100 P 2 in, Class 600 CS 2 inJDN 50 E 3 in. Class 600 CS 3 in./DN 80 X 2 in. Class 150 SST 2 in./DN 50 F 3 in. Class 150 -- ANSI SST 3 in./DN 80 G 4 in. Class 150 SST 4 in,/DN 100 Y 2 in. Class 300 SST 2 in./DN 50 H 3 in. Class 300 SST 3 in./DN 80 J 4 in. Class 300 SST 4 in./DN 100 Z 2 in. Class 600 SST 2 in./DN 50 L 3 in. Class 600 -- SST 3 in,/DN 80 Q DN 50 PN 10-40 -- CS 2 in./DN 50 R DN 80 PN 40 CS 3 in./DN 80 S DN 100 PN 40 CS 4 in,/DN 100 V DN 100 PN 10/16 -- DIN CS 4 in./DN 100 K DN 50 PN 10-40 SST 2 in./DN 50 T DN 80 PN 40 SST 3 in./DN 80 U DN 100 PN 40 SST 4 in./DN 100 W DN 100 PN 10/16 -- SST 4 in,/DN 100 5-15 r 'i 'l ' I I i TABLE 5-10. (continued). SENSOR MODULE AND LOW-SIDE MATERIALS OF CONSTRUCTION Low-Side Flange Drain/Vent Low-Side Isolator Low-Side Code and Adapter Valves Diaphragm Fluid Fill 52 Nickel-plated CS 316 SST 316L SST Silicone 12 Cadmium-plated CS 316 SST 316L SST Siftcone 55 Nickel-plated CS 316 SST Tantalum Silicone 22 316 SST 31 6 SST 316L SST Silicone 23 316 SST 316 SST Hastelloy C-276 Sillcone 25 316 SST 316 SST Tantalurn Silicone 33 Hastelloy C Hastelloy C-276 Hastelloy C-276 Sillcone 35 Hastelloy C Hastelloy C-276 Tantalum Siftcone 1A Cadmium-plated CS 316 SST 316L SST Inert 5D Nickel-plated CS 316 SST Tantalum Inert 2A 316 SST 316 SST 316L SST Inert 2B 316 SST 316 SST Hastelloy C-276 Inert 2D 316 SST 316 SST Tantalum Inert 3B Hastelloy C Hastefioy C-276 Hastelloy C-276 Inert 3D Hastefioy C Hastelloy C-276 Tantalum Inert Code Process Fill--High Pressure Side Temperature Limits A Syttherm XLT -100 to 300 °F (-73 to 135 °C) C D.C. Sillcone 704 60 to 400 °F (15 to 205 °C) D D.C. Siftcone 200 -40 to 400 °F (-40 to 205 °C) F Inert -50 to 350 °F (-45 to 177 °C) G Glycerin and Water 0 to 200 °F (-17 to 93 °C) N Neobee M-20 0 to 400 °F (-17 to 205 °C) P Propylene Glycol and Water 0 to 200 °F (-17 to 93 °C) S Syltherm 800 -50 to 400 °F (-45 to 205 °C) 5-16 TABLE 5-10. (continued). Code Options (see complete ap.orovals descriphons) S1(~) One Remote Seal Selected from PDS 00813-0100-4016 METERS M1® Linear Meter, 0-100% Scale M3® Special Scale Meter, Specify Range M4® LCD Meter, 0-100% M7(2) LCD Meter, Linear, Special Configuration HARZARDOUS LOCATIONS CERTIFICATIONS E6 Canadian Standards Association (CSA) Explosion-Proof Approval NOTE J F=ory Mutua, <FM) on-,ncend,ve and ,n,,,ns,c Safety Approva, K5 Factory Mutual (FM) Explosion-Proof and Intrinsic Safety Combination · 16I~l Canadian Standards Association (CSA) Intrinsic Safety Approval C5(4~ Industry and Science Canada (ISC) Approval (Available in Canada Only) C6(~) Combination of 16 and E6; CSA Explosion-Proof and Intrinsic Safety Approval (Requires 42.4 V dc max. power supply) K6 CSAJCENELEC ExplosiomProof and Intrinsic Safety Approval E4 Japanese Industrial Standards (JIS) Flameproof Certification E7 Standards Association of Australia (SAA) Flameproof Certification E8 CESI/CENELEC Flameproof Certification I1(5) BASEEFA Intrinsic Safety Certification 17I~> Standards Association of Australia (SAA) Intrinsic Safety Certification 18(e) CESI/CENELEC Flameproof Certification N1(7) BASEEFA Type N Certification N7 Standards Association of Australia (SAA) Nonincendive Safety Approval IC® Schweizerischer Elektrochnischer Verein (SEV) Intrinsic Safety Certification OTHER OPTIONS W5 Copper O-ring for Vacuum Service (Nonwetted) Q4 Calibration Data Sheet Q8® Material Traceability per EN 10204 3.1B V1 Reverse Output V2 4-20 mV Test Signal V3 20--100 mV Test Signal Z1 (9) 4-wire, 0-20 mA Output Z2® 4-wire, 0-16 mA Output Z3® 4-wire, 0-10 mA Output F_ Select One Code from Flushing Connections Lower Housing Option Table 5-11. TABLE 5-11. Flushing Connections Lower Housing Options. * available - not available Diaphragm Size Code Flushing Connection Ring Flushing Size Material (Lower Housing) Connections 2-in. 3-~n. F1 SST I ¼-18 NPT · · · F2 SST 2 ¼-18 NPT · · F3(~) Hastelloy C-276 I ¼-18 NPT · · · F4(~) Hastelloy C-276 2 ¼-18 NPT · · · FA SST 0 -- -- -- FC® Hastefioy C-276 0 -- -- -- F7 SST I ~-14 NPT · · · F8 SST 2 ~-14 NPT · · F9 Hastelloy C-276 I T~-14 NPT · · F0 Hastelloy C-276 2 ~-14 NPT · · · (1) Not available with high pressure side Option Codes AO, BO, and GO. (2) Not available with high pressure side Option Code GO. Typical ModelNumber: 1151LT 4 S A0 A 52 O F1 (1) For welded capillary assemblies, order sensor module and low-side materials of construction Option Code 22 (refer to PDS 00813-0100-4016 for more information). (2) Not available with Option Codes Zx, V2, or V3. (3) Not available with Output Code G or Option Code Zx. (4) Not available with Option Codes MI-Mg. (5) Not available with Output Codes G, J, L, M, or Option Code Zx. (6) Not available with Output Codes G, J, L, M, S, or Option Code Zx. (7) Not available with Output Codes G, L, M, or Option Code Zx. (8) Available for the diaphragm, upper housing, flange, adapter, extension, and lower housing. (9) Not available with Option Codes Mx, Vx, Ix, or Ex, or Output Codes G, L, M, or S. 5-17 General Notes The ]isted prices are dimensionless. Apply the appropriate mu]tip]ication factor to calcu]ate the price in a specific currenc3~. prices are F.O.B. our plant at Chanhassen, Minnesota. The prices are exclusive of all sales and use taxes. Minimum order is 600 (dimensionless price). Tagging The transmitter will be tagged, at no charge, in accordance with customer requirements. All tags are stninless steel. The standard tag is wired to the transmitter. Tag character height is 0.125 in. (0.318 cm). A permanently attached tag is available upon request. Calibration Transmitters are factor~ calibrated to customer's specified range. If calibration is not spedfled, the transmitters are calibrated at maximum range. Calibration is performed at ambient temperature and pressure. Standard Accessories All models are shipped with flange adapters, drain/vent valves, and one instruction manual per shipment. Optional Three-valve Manifolds Part No. 01166-0073-0001: 3-valve manifo]d, carbon steel for DP (Ranges 6-9), HP (Ranges 6-?). (Anderson, Greenwood & Co., M4AVIC-TR-68). Part No. 01151-0150-0002: 3-valve manifold, 316 SST with carbon steel bo]ts for DP (Ranges 6-9), HP (Ranges 6-7). (Anderson, Greenwood & Co., M4AVIC-TR-68). C 5-18 'I i i I' i ! Parts List Item numbers are references to figure callouts (page 5-26). TABLE 5-12. Model 1151 DP, HP, GP, and AP Alphaline Pressure Transmitters. Electrorots - One spare p3rt recommended for every 25 transmitters. Part Description Item No. Part Numbel S Smart Output Code Smart Retrofit Kit(~) 01151-0935-0001 Smart Transmitter Electronics(2) 24 01151-0934-0204 Board Spacer Kit (pkg of 12) 25 01151-0813-0001 Terminal Eyelet Kit (pkg of 12) 01151-0814-0001 Standoff Kit (pkg of 12) 01151 -O815-0001 Cover(2) 01151-1045-0001 Cover O-ring (pkg of 12) 01151-0033-0003 Sensor Modules (Sillcone Fill)-One spare part recommended for every 50 transmitters. Part Description item No. Part Number Range 3 DP, GP (30 in H20) 19 316L SST 01151-0011-0032 Hastelloy C-276 01151-0011-0033 Menel 01151-0011-0034 Tantalum 01151-0011-0035 Gold-plated Menel 01151-0011-0036 Range 4 DP, GP (150 in H20) 19 316L SST 01151-0011-0042 Hastelloy C-276 0! 151-0011-0043 Menel 01151-0011-0044 Tantalum 01151-0011-0045 Gold-plated Menel 01151-0011-0046 Range 4 HP (150 in H20) 19 316L SST 01151-0112-0042 Hastelloy C-276 01151-0112-0043 Menel- 01151-0112-0044 Range 4 AP (11 in HgA) 19 316L SST 01151-0054-0042 Hastelloy C-276 01151-0054.-0043 Menel 01151-0054-0044 (1) Kit contains enough parts for one transmitter and includes the smart transmitter electronics, board spacers, terminal eyelets, standoffs, cover, and cover O-ring. (2) Package contains quantity required for one transmitter. 5-19 r '! · g I T ! HOSelTIOUrlT MOOel *1 I O I ~>rnart rressure i ransmltters TABLE 5-12. (continued). Sensor Modules (Silicone Fili)-One spare part recommended for every 50 transmitters, Part Description Item No, Part Number Range 5 DP, GP (750 in H20) 19 316L SST 01151-0011-0052 Hastelloy C-276 01151-0011-0053 Monel 01151-0011-0054 Tantalum 01151-0011-0055 Gold-plated Mone! 01151-0011-0056 Range 5 HP (750 in H20) 19 316L SST 01151-0112-0052 Hastelloy C-276 01151-0112-0053 Monel 01151-0112-0054 Range 5 AP (,55 in HgA) 19 316L SST 01151 -(X)54-0052 Hastelloy C-276 01151-0054-0053 Monel 01151-0054-0054 Range 6 DP (100 psid) 19 316L SST 01151-0041-0062 Hastelloy C-2 76 01151-0041-0063 Monel 01151-0041-0064 Tantalum 01151-0041-0065 Gold-plated Monel 01151-0041-0066 Range 6 GP (150 psig) 19 316L SST 01151-0041-0162 Hastefioy C-276 01151-0041-0163 Monel 01151-0041-0164 Tantalum 01151-0041-0165 Gold-plated Monel 01151-0041-0166 Range 6 HP (100 psid) 19 316L SST 01151-0112-0062 Hastefioy C-276 01151-0112-0063 Monel 01151-0112-0064 Range 6 AP (100 psia) 19 316L SST 01151-0054-0062 Hastefioy C-276 01151-0054-0063 Monel 01151-0054-0064 Range 7 DP (300 psid) 19 316L SST 01151-0041-0072 Hastelloy C-276 01151-0041-0073 Monel 01151-0041-0074 Tantalum 01151-0041-0075 Gold-plated Monel 01151-0041-0076 Range 7 GP (300 psig) 19 316L SST 01151-0041-0172 Hastelloy C-276 01151-0041-0173 Monel 01151 ~0041-0174 Tantalum 01151-0041-0175 Gold-plated Monel 01151-0041-0176 Range 7 HP (300 psid) 19 316L SST 01151-0112-0072 Hastelloy C-276 01151-0112-0073 Mone! 01151-0112-0074 Range 7 AP (300 psia) 19 316L SST 01151-0054-0072 Haste~oy C-276 01151-0054-0073 Monel 01151-0054-0074 Range 8 DP (1,000 psid) 19 316L SST 01151-0041-0082 Hastelloy C-276 01151-0041-0083 Monel 01151-0041-0084 Tantalum 01151-0041-0085 Gold-plated Monel 01151-0041-0086 5-20 -e '= · T' ~ I Ol.lt:t.~l lll~dLl~ll lb dllfJ tit:leG:If;lit, t: IJ(aLCl TABLE 5-12. (continued). Sensor Modules (Silicone Fil!)-One spare part recommended for every 50 transmitters, Part Description Item No P;~rt Number Range 8 GP (1,000 paig) 19 316L SST 01151-0041-0182 Hastetloy C-276 01151-0041-0183 Monel 01151-0041-0184 Tantalum 01151-0041-0185 Gold-plated Monel 01151-0041-0186 Range 8 AP (1,000 psia) 19 316L SST 01151-0054-0082 Hastelloy C~276 01151-0054-0083 Monel 01151-0054-0084 Range 9 GP (3,000 psig) 19 316L SST 01151-0112-0092 Hastelloy C-276 01151-0112-0093 Monel 01151-0112-0094 Range 10 GP (6,000 psig) 19 316L SST 01151-0112-0002 Hastelloy C-2 76 01151-0112 -0003 Monel 01151-0112-0004 Sensor Modules (Inert Filli-One spare part recommendec~ for every 50 trans;~nitters, Part Description Item No, Part Number Range 3 DP, GP (30 in H20) 19 316L SST 01151-0230-0032 Hastelloy C-276 01151-0230-0033 Monel 01151-0230-0034 Tantalum 01151-0230-0035 Gold-plated Monel 01151-0230-0036 Range 4 DP, GP (150 in H20) 19 316L SST 01151-0230-0042 Hastetloy C-276 01151-0230-0043 Monel 01151-0230-0044 Tantalum 01151-0230-0045 Gold-plated Monel 01151-0230-0046 Range 5 DP, GP (750 in H20) 19 316L SST 01151-0230-0052 Hastelloy C-276 01151-0230-0053 Monel 01151-0230-0054 Tantalum 01151-0230-0055 Gold-plated Monel 01151-0230-0056 Range 6 DP (100 paid) 19 316L SST 01151-0230-0062 Hastelloy C-276 01151-0235-0063 Monel 01151-0230-0064 Tantalum 01151-0230-0065 Range 6 GP (100 psig) 19 316L SST 01151-0230-O162 Hastelloy C-276 01151-0230-0163 Monel 01151-0230-0164 Tantalum 01151-0230-0165 Range 7 DP (300 psid) 19 316L SST 01151-0230-0072 Hastelloy C-276 01151-0230-0073 Monel 01'151-0230-0074 Tantalum 01151-0230-0075 5-21 r 'w e e' I I TABLE 5-12. (continued). Sensor Modules (Inert Fill)-One spare part recommended for every 50 transmitters. Part Description Item No. Part Number Range 7 GP (300 psig) 19 316L SST 01151-0230-0172 Hastelloy C-276 01151-0230-0173 Monel 01151-0230-0174 Tantalum 01151-0230-0175 Range 8 DP (1,000 in psid) 19 316L SST 01151-0230-0082 Hastelloy Co276 01151-0230-0083 Monel 01151-0230-0084 Tantalum 01151-0230-0085 Range 8 GP (1,000 in psig) 19 316L SST 01151-0230-0182 Hastelloy Co276 01151-0230-0183 Monel 01151-0230-0184 Tantalum 01151 ~0230-0185 Housings, Covers, Flanges, And Valves - One spare part recommended for every 25 transmitters. Part Description item No. Dart Number Electronics Housing 7 01151-0060-0007 Electronics Housing for R1 Option without Terminal Block 01151-2594-0001 Transient Terminal Block Assembly (Optional R1 ) 01151-2591-0003 Electronics Cover 1 01151-1045-0001 Process Flange 17 Nickel-plated Carbon Steel 01151-0236-0005 Cadmium-plated Carbon Steel 01151-0236-0001 316 SST 01151-0213-0002 Hastelloy C-276 01151-0213-0004 Monel 01151-0213-0003 Process Flange for Side Drain/Vent Valve Nickel-plated Carbon Steel 01151-0236-0015 Cadmium-plated Carbon Steel 01151-0236-0011 316 SST 01151-0213-0012 Hastelloy C-276 01151-0213-0014 Monel 01151-0213-0013 Blank Flange 23 Cadmium-plated Carbon Steel 90043-0046-0001 Flange Adapter 21 Nickel-plated Carbon Steel 01151-0211-0005 Cadmium-plated Carbon Steel 90001-0033-0001 316 SST 01151-0211-0002 Hastelloy C-276 01151-0211-0004 Monel 01151-0211-0003 DP and HP Valve Stem and Seat, 316 SST(~) 14,15 01151-0028-0022 GP and AP Valve Stem and Seat, 316 SST(~) 14,15 01151-0028-0012 DP and HP Valve Stem and Seat, 316 SST, Hastelloy C(~) 14,15 01151-0028-0023 GP and AP Valve Stem and Seat, 316 SST. Hastelloy C(~) 14,15 01151-0028-0013 DP and HP Valve Stem and Seat, 316 SST, Monel (~) 14,15 01151-0028-0024 GP and AP Valve Stem and Seat, 316 SST, Monel (~) 14,15 01151-0028-0014 Plug, 316 SST (used with side drain/vent) C50246-0002 Plug, Hastelloy C (used with side draiNvent) 01151-0063-0001 Plug, Monel (used with side drain/vent) 01151-0063-0002 (1) Package contains quantity required for one transmitter. 5-22 I ! '1 ! l' i I 'kl'l,~J~l,,,lllikd,llill. llll) dlllJ rlill~lt:lt~lll~l;~ I, Jlllid TABLE 5-12. (continued). Hardware-One spare part recommended for every 50 transmitters Pa,'t Desc~'iption item No Part N~mbe, Adjustment Kit 01151-0029-0001 Adjustment Screw 10 O-ring for Adjustment Screw 11 Retaining Ring 12 O-dng for Adjustment Screw (pkg of 12) 11 01151-0032-0001 O-ring for Electronics Cover (pkg of 12) 2 01151-0033-0003 O-ring for Process Flange, Viton (pkg of 12) 18 01151-0034-0020 O-ring for Process Flange, Viton and Backup Ring (pkg of 4) 18 01151-0034-0014 O-ring for Process Flange, Buna-N (pkg of 12) 18 01151-0034-0002 O-ring for Process Flange, Buna-N and Backup Ring (pkg of 4) 18 01151-0034-0016 O-ring for Process Flange, Ethylene-propylene (pkg of 12) 18 01151-0034-0004 O-ring for Process Flange, Ethylene-pmpylene and Backup Ring (pkg of 4) 18 01151-0034-0015 O-ring for Process Flange, Atlas (pkg of 4)(1) 18 01151-0034-0019 O-ring for Flange,. Teflon with Hastelloy C Spring (pkg of 4) 18 01151-0034-0021 O-ring for Flange Adapter, Viton (pkg of 12) 20 01151-0035-0009 O-ring for Flange Adapter, Buna-N (pkg of 12) 20 01151-0035-0002 O-ring for Flange Adapter, Ethylene-propylene (pkg of 12) 20 01151-0035-0004 O-ring for Flange Adapter, Atlas (pkg of 12)(2) 20 01151-0035-0008 O-ring for Flange Adapter Process, Teflon (pkg of 12) 20 01151-0035-0003 (1) Kit contains enough parts for two differential or four gage/absolute transmitters. Backup rings are included. (2) Part number is for package of 12 O-rings-only two required per transmitter. 5-23 ,. [ 1 i I' I T I Rosemount Model 1151 Smart Pressure Transmitters TABLE 5-12. (continued). Hardware (continued)-One spare part recommended for every 50 transmitters, Part Description Item No. Part Number Electronics Assembly Hardware(~) 01151-0(;~-'000~' Standoff 8 Standoff 5 Screw 9 Screw 3 Locknut DP and HP Flange Kits, Carbon Steel(~) 01151-0031-0001 Bolt for Flange Adapter 22 (DP & HP Ranges 3-7) Bolt for Process Flange 13 or Nut for Process Flange 16 01151-0031-0034 (DP Range 8) GP and AP Flange Kite, Carbon Steel(~) 01151-0031-0002 Bolt for Flange Adapter, Carbon Steel 22 (AP Ranges 4-7, Bolt for Process Flange, Carbon Steel 13 GP Ranges 3-7) Nut for Process Flange, Carbon Steel 16 or 01151-0031-0035 (AP & GP Range 8) or 01151-0031-0003 (GP Range 9) or 01151-0031-0019 (GP Range 0) DP and HP Flange Kits, 316 SST(~) 01151-0031-0023 Bolt for Flange Adapter 22 (DP & HP Ranges 3-7) Bolt for Process Flange 13 or Nut for Process Flange 16 01151-0031-0038 (DP Range 8) GP and AP Flange KIts, 316 SSTn) 01151-0031-0024 Bolt for Flange Adapter, 316 SST 22 (AP Ranges 4-7, Bolt for Process Flange, 316 SST 13 GP Ranges 3-7) Nut for Process Flange, 316 SST 16 or 01151-0031-0039 (AP & GP Range 8) or 01151-0031-0025 (GP Range 9) or 01151-0031-0026 (GP Range O) DP and HP Flange Kits, ANSI 193-B7(~) 01151-0031-0012 Bolt for Flange Adapter 22 (DP & HP Ranges 3-7) Bolt for Process Flange 13 or Nut for Process Flange 16 01151-0031-0036 (DP Range 8) GP and AP Flange KIts, ANSI 193-B7~> 01151-0031-0013 Bolt for Flange Adapter, ANSI 193-B7 22 (AP Ranges 4-7, Bolt for Process Flange. ANSI 193-B7 13 GP Ranges 3-7) Nut for Process Flange, ANSI 193-B7 16 or 01151-0031-0037 (AP & GP Range 8) or 01151-0031-0014 (GP Range 9) or 01151-0031-0022 (GP Range 0) (1) Package contains quantity required for one trensrnitter. 5-24 T I '! I ! TABLE 5-12. (continued). Indicating Meters (Select approved meter kits for use in intrinsically safe and/or Type N installations) Part Description Item No, Part Number Analog'Meter Kit, ~20 mA (~c%'Ein"~'a';~Scale(') NA 01151-1046-0007 Analog Meter Kit, 4-20 mA dc, Square Root, 0-100% Flow 01151-1046-0009 Analog Meter Kit, 10-50 mA dc, Linear Scale(q) 01151-1046-0011 Analog Meter Kit, 10-50 mA dc, Square Root, 0-100% Flow 01151 -1046-0013 Approved Analog Meter Kit, 4-20 mA tic, Linear Scale(i) 01151-2615-0007 Approved Analog Meter Kit, 4-20 mA dc, Square Root, 0-10(Y'/o Flow 01151-2615-0009 Approved Analog Meter Kit, 10-50 mA dc, Linear Scale(i) 01151-2615-0011 Approved Analog Meter Kit, 10-50 mA dc, Square Root, 0-100% Row 01151-2615-0013 LCD Meter Kit, Linear, 0-100% Flow 01151-1046-0019 LCD Meter Kit, Square Root, 0-100% Flow 01151-1046-0021 Analog Meter, 4-20 mA tic, Linear Scale 01151-0687-0004 Analog Meter, 4-20 mA dc, Square Root, 0-100% Flow 01151-0687-0005 Analog Meter, 4-20 mA dc, Square Root, 0-10 ',/ 01151-0687-0008 Analog Meter, 10-50 mA dc, Linear Scale 01151-0687-0006 Analog Meter, 10-50 mA dc, Square Root, 0-100% Flow 01151-0687-0007 Analog Meter, 10-50 mA dc, Square Root, 0-10 ~/ 01151-0687-0009 Approved Analog Meter, 4-20 mA dc, Linear Scale 01151-2614-0004 Approved Analog Meter, 4-20 mA dc, Square Root, 0-100% Flow 01151-2614-0005 Approved Analog Meter, 4-20 mA dc, Square Root, 0-10 ',/ 01151-2614-0008 Approved Analog Meter, 10-50 mA dc, Linear Scale 01151-2614-0006 Approved Analog Meter, 10-50 mA dc, Square Root, 0-100% Flow 01151-2614-0007 · Approved Analog Meter, 10-50 mA dc, Square Root, 0-10 ~ 01151-2614-0009 Special Scale for Analog Meter See note (1) below LCD Meter, Linear, 0-100% 01151-1300-1000 LCD Meter, Square Root, 0-100% Flow 01151-1300-1001 LCD Meter, Special Configuration(z) 01151-1351 -1000 LCD Meter Engineering Unit Labels 01151-1351 ol 001 Mounting Hardware and Cover Assembly Kit 01151-1046-0005 Mounting Hardware Kit 01151-1046-0006 Cover Assembly Kit 01151-1047-0001 O-ring for Cover (pkg of 12) 01151-00~3 Mounting Brackets Part Description Item No. Part Number B1--Right-angle Bracket for 2-in. Pipe Mounting NA 01151-0036-0001 B2--Right-angle Bracket for Panel Mounting 01151-0036-0004 B3--Flat Bracket for 2-in. Pipe Mounting 01151-0036-0005 B4--Bracket for 2-in. Pipe with Series 300 SST Bolts 01151-0036-0003 B5---Bracket for Panel with Series 300 SST Bolts 01151-0036-0006 B6---Flat Bracket for 2-in. Pipe with Series 300 SST Bolts 01151-0036-0007 B7--316 SST B1 Bracket with SST Bolts 01151-0036-0021 B9--316 SST B3 Bracket with SST Bolts 01151-0036-0022 (1) Meter kit includes meter, mounting hardware, and cover assembly. For meters with special scaling, order the appropriate meter and specify the scale desired. Mounting hardware and cover assembly must be ordered separately. (2) To order a meter with a special configuration, order the appropriate meter ancl indicate configuration desired. TO order a special configuration LCD meter kit, order the meter, and the mounting hardware and cover assembly kit separately. 5-25 r i i i T T ! i~osell~0ur]t ivic)clui i ]o i ol]ld]t rlvo~u]c i FIGURE 5-1. Model 1151 Smart Pressure Transmitter Exploded View. Parts List Item numbers are references to figure callouts (page 5-29). TABLE 5-13. Model 1151LT Flange-Mounted Liquid Level Pressure Transmitter. Part Description Item No. Part Number Spares CategoryI~' Diaphragm and Sensor Module Assembly 13 See Note Below B Flange Adapter Union Cadmium-plated Carbon Steel 21 90001-0033-0001 316 SST 01151-0211-0002 Hastelloy C 01151-0211-0004 Valve Stem and Seal, 316 SST 18, 19 01151-0028-0012 Plug, 316 SST (uSed with side drain/vent) C50246-0002 A Valve Stem and Seat, Hastelloy C 18, 19 01151-0028-0013 Plug, Hastelloy C (used with side drain/vent) C50246-0202 A Bolt for Flange Adaptor Cadmium-plated Carbon Steel 20 01151-0031-0002 316 SST 20 01151-0031-0024 ANSI 193-B7 20 01151-0031-0013 O-ring for Flange Adapter Viton (pkg of 12) 22 01151-0035-0009 Buna-N (pkg of 12) 22 01151-0035-0002 Arias (pkg of 4) 22 01151-0035-0008 Ethylene-Prop. (pkg of 12) 22 01151-0035-0004 SMART OUTPUT CODE - See next page for details -- 01151-0935-0001 B Electronics Housing 7 01151-0060-0007 Electronics Cover 1 01151 ~1045-0001 Adjustment Screw, Retaining Ring, 2 01151-0029-0001 and O-ring for Adjustment Screw O-ring for Electronics Cover (7) 01151 ~0033-0003 Electronics Assembly Hardware Standoff Standoff 01151-0030-0001 Screw Screw Locknut (1) Rosemount recommends one spare part for every 25 transmitters in Category A, and one spare part for every 50 transmitters in Category B. · NOTE The Diaphragm and Sensor Module Assembly is an oil filled system and must be serviced using the proper equipment. Contact your nearest RosemoUnt Service facility should it become necessary to replace or service this assembly. A complete Diaphragm and Sensor Module Assembly including the mounting flange can be ordered by specifying a complete transmitter model number from PPL 00814-0100-4526, adding '7740" to end of the model number, and deducting $300 from the list price of the complete transmitter. (The "T740' eliminates the electronic housing and electronic circuit boards.) For example, 1151LT 4 E A0 A 12 D T740 list price 7 455 (price as of January 31, 1996) less 1 705 = ,5 750 (dimensionless prices). 5-27 [ 'i I' T TABLE 5-13. (continued). {~ * s Output Code (Smart) ~1~ Part/Kit Description Item No. Part Number Smart Retrofit Kit{~) 01151-O935-0001 Smart Transmitter Electronics® 24 01151-0934-0204 Board Spacer Kit (pkg of 12) 25 01151-0813-0001 Terminal Eyelet Kit (pkg of 12) 01151-0814-0001 Standoff Kit (pkg of 12) 01151-0815-0001 Cover(2) 01151-1045-0001 Cover O-ring (pkg of 12) 01151-0033-0003 Indicating Meters Part Description Part Number Analog Meter Kit, 4-20 mA dc, Linear Scale(3) 01151-1046-0007 Analog Meter Kit, 10-50 mA dc, Linear Scale(3) 01151-1046-0011 Approved Analog Meter Kit, 4-20 mA dc, Linear ScaleI~) 01151-2615-0007 Approved Analog Meter Kit, 10-50 mA dc, Linear Scale(~) 01151-2615-0011 LCD Meter Kit, Linear, 0-100% Flow 01151-1046-0019 Analog Meter, 4-20 mA dc, Linear Scale 01151-0687-0004 Analog Meter, 10-50 mA dc, Linear Scale 01151-0687-0006 Approved Analog Meter, 4-20 mA dc, Linear Scale 01151-2614-0004 Approved Analog Meter, 10-50 mA dc, Linear Scale 01151-2614-0006 ~ Special Scale for Analog Meter See note (3) below LCD Meter, Linear, 0-100% 01151-1300-1000 LCD Meter, Special Configuration(4) 01151-1351-1000 LCD Meter Engineering Unit Labels 01151-1351-1001 Mounting Hardware and Cover Assembly Kit 01151-1046-0005 Mounting Hardware Kit 01151-1046-0006 Cover Assembly Kit 01151-1047-0001 O-ring for Cover (pkg of 12) 01151-0033-0003 (1) Kit contains enough parts for one transmitter and includes the smart transmitter electronics, board spacers, terminal eyelets, standoffs, cover, and cover O-rings. (2) Kit contains enough parts for one transmitter. ~=~ (3) Meter kit includes meter, mounting hardware, and cover assembly For meters with special scaling, order the appropriate meter and specify the scale desired. Mounting hardware and cover assembly must be ordered separately (4) To order a meter with a special configuration, order the appropriate meter and indicate configuration desired. To order a special configuration LCD meter kit, order the meter, and the mounting hardware and cover assembly kit separately 5-28 T 1 '1 I T' ~ ! FIGURE 5-2. Model 1151LT Pressure Transmitter Exploded View (Analog Shown). 5-29 w · . " I I i SPECIFICATIONS AND REFERENCE DATA FOR OPTIONS LCD Meter Specifications Input Signal 4-20 mA dc. Meter Indication 4-digit LCD showing ~999 to 9999. A 20-segment bar graph directly represents the 4-20 mA current. Scaling/Calibration 4 mA Point Limits: -999 to 1000. Span limits: 0200 to 9999. The sum of the 4 mA point and span must not exceed 9999. Adjustments are made using non-interactive zero and span buttons. Hazardous Locations CertifiCations Approved for use with Rosemount Models 444, 751, 1135, 1144, and 1151. Overload Limitation 666 mA. Temperature Limits Storage: -40 to 85 °C (-40 to 185 °F). Operating: -20 to 70 °C (-4 to 158 °F). Between temperatures -40 to -20 °C (-40 to -4 °F), the loop is intact and the meter is not damaged. Humidity Limitation 0 to 95% non-condensing relative humidity. Update Period 750 ms. Response Time Responds to changes in input within a maximum of two update periods. If the filter is activated, then the display responds to the change within nine update periods. Digital Display Resolution 0.05% of calibrated range ±1 digit. Analog Bar Graph Resolution 0.05% of calibrated range. Indication Accuracy 0.25% of calibrated range ±1 digit. Stability Over Time: 0.1% of calibrated range ±1 digit per 6 months. Temperature Effect 0.01% of calibrated range per °C on zero. 0.02% of calibrated range per °C on span over the operating temperature range. Power Interrupt All ca]ibration constants are stored in EEPROM memory and are not affected by power loss. 5-30 I I I 1' I I Failure Mode LCD meter failure will not affect transmitter operation. Under/Over Range Indication Input current < 3.5 mA: Display blank. Input current > 22.0 mA: Display flashes 112.5% of full scale value or 9999, whichever is less. Meter Size 2¼-inch diameter face with ~-inch high characters. Terminal Block Hazardous Locations Certifications Specifications Approved for use with I5, KS, I6, C6, E6, EB, I8(~), I1<z~, and N1 approved transmitters. Materials of Construction Noryl® plastic. Loop Resistance 61l Transient Protection Limits IEEE 587 Category B 6 kV Crest (1.2 x 50 ps). 3 kA Crest (8 x 20 ps). 6 kV (0.5 ps at 100 kHz). IEEE 472 SWC 2.5 kV Crest, 1 MHz waveform. Accuracy Specification Same as specified electronics accuracy when transmitter is calibrated with installed retrofitable Transient Protection Terminal Block. When the transient version of the filter module is used in an intrinsically safe installation, supply transmitter from a galvanically isolated barrier. 5-31 1 '1 I [ T i Appendix HART® Communicator INTRODUCTION This appendix provides basic communicator information on the HART Communicator Model 275 when used with a Model 1151 Smart Pressure Transmitter. Included in this appendix are a menu tree, a table of fast key sequences, and information on using the HART Communicator. For more complete information on the HART Communicator, refer to the HART Communicater Product Manual 00809-0100-4275. This brief appendix will familiarize you with the HART Communicater but is not meant to replace the HART Communicator product manual. SAFETY MESSAGES Warnings (A) Procedures and instructions in this section that raise potential safety issues are indicated by a warning symbol (A). Refer to the following warning messages before performing an operation preceded by this symbol. ~WARNING Explosions can result in death or serious injury. Do not make connections to the serial port or NiCad recharger jack in an explosive atmosphere. ,~WARNING Explosions can result in death or serious injury. Before connecting the HART Communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. A-1 FIGURE A-1. HART Communicator Menu Tree for the Model 1151. I PROCESS ~ I Pressure ' VARIABLES 2 Percent Range 3 Analog Output Situs Apply Values AND SERVICE ' 2 Loop Test · .,.A.ALOG --I; I Scaled D/A Tdm 3 CAUBRATION _ OUTPUT I Zero Trim 2 Lower Sensor Trim ' __ 3 Upper Sensor Trim 3 SENSOR TRIM 4 Sensor Trim Points 1Tag 2 Unit 3 RANGE ..~ Keypad Input I VALUES Apply Values 3 BASIC SETUP __ 4 DEVICE INF0 -- 1 Date 5 Transfer Function 2 Descriptor 5 Meter Type I PROCESS % Range I Zero Trim VARIABLES 2 Lower Sensor Tdm 3 Upper Sens4x Trim 2 SENSOR -~12 SENSOR TRIM ~ 4 Sensor Trim Points SERVICE Online Menu :.,,,..:;;~i!~,..i~.,:~::::.~:~:::!:,!!~: I DEVICE SETUP -- ' ~:' ' 1 PROCESS "'l I Pressure 2 PV ' VARIABLES 2 Percent Range 3 AO .~ - -, 4 LRv = SaGNAL' 5 URV .... :?~.~:; ~; ;; : ': CONDITION ::;:.~. ' 2 RANGE VALUES --{ I Keypad Input .:; ,:~: ~':: ': ":" ' ' ' 3 Unit::- · "' ":' 2 Apply Values ! ...... ':"'~' 5 Damp 4 DETAILED . .. ! :~:: I I Percent~ange SETUP :. :.; ;;. :. ::,..;., -,, 3 Analog utput 30UTPLrr * 2 ANALOG ___[~ Loop Test CONDITION -- OUTPUT Digital-to-Analog 'm Scaled D/A Trim 3 Analog Output Alarm I Poll Address 2 Number of Request Preambles 4 HART OUTPUT -- 3 Burst Mode 4 Burst Option I FIELD DEVICE IfO -1 Tag 4 DEVICE 2 Date -- 3 Dascriptor ,.Fo.,,A. ON . SE.SO.,.FO-- 3 Meter Type 3 Fill Type 5 Model 4 ~llaa~ ~t. 6 Write Protect 5 REVIEVV 5 7 Revisions #s 4 Self Test 60-R ng Mat. 7 DVMaL 8#ofRn~Seeh 9 RS'F 10 RS~I. 11 RSRII A-2 TABLE A-1. HART Fast Key Sequences for the Model 1151. Function HART Comrnunicator Fast Key Sequences Analog Output 3 Analog Output Alarm 1, 4, 3, 3 Burst Mode Control 1,4, 3, 4, 3 Burst Operation 1,4, 3, 4, 4 Calibration 1, 2, 3 Characlerize 1,4, 1, 1,2, 2 Damping 1, 3, 6 Date 1, 3, 4, 1 Descriptor 1, 3, 4, 2 Digital-to-Analog Trim (4-20 mA Output) 1, 2, 3, 2, 1 Field Device Information 1,4, 4, 1 Full Trim 1, 2, 3, 3 Keypad Input 1, 2, 3, 1, 1 LOOp Test 1, 2, 2 LOwer Range Value 4, 1 Lower Sensor Trim 1, 2, 3, 3, 2 Message 1, 3, 4, 3 Meter Type 1,3, 4, 5 Number of Requested Preambles 1, 4, 3, 4, 2 Percent Range 1, 1, 2 Poll Address 1,4, 3, 4, 1 Pressure 2 Range Values 1, 3, 3 Rerange 1,2, 3, 1 Scaled D/A Tdm (4-20 mA Output) 1,2, 3, 2, 2 Self-Test (Transmitter) 1,2, 1, 1 Sensor Information 1,4, 4, 2 Sensor Trim Points 1, 2, 3, 3, 4 Status 1, 2, 1, 2 Tag 1,3, 1 Transfer Function (Setting Output Type) 1, 3, 5 Transmitter Security (Write Protect) 1, 3, 4, 4 Trim Analog Output 1, 2, 3, 2 Units (Process Variable) 1, 3, 2 Upper Range Value 5, 2 Upper Sensor Tdm 1,2, 3, 3. 3 Zero Trim 1,2, 3, 3. I A-3 I I I I T ~ T I The HART Communicator Model 275 can interface with a transmitter CONNECTIONS AND /A from the control room, the instrument site, or any wiring termination HARDWARE point in the loop through the rear connection panel as shown in Figure A-2. To communicate, connect the HART Communicator in parallel with the instrument or load resistor. The connections are non-polarized. FIGURE A-2. Rear Connection Panel with Optional NiCad Recharger Pack. Loop Connection Ports A Optional NiCad ~ '~-- ..... '~ /~ '~ ~'*~' .... ~4~,' '< ;:~:~ ' ' ' ' '~ :'" ~rial Pod NOTE The HART Communicator needs a minimum of 250 ohms resistance in the loop to function properly. The HART Communicator does not measure loop current directly. A-4 '~' See "Safety Messages" on page A-1 for complete warning information. I I I I I I FIGURE A-3. Bench Hook-up (Smart Transmitters). Cr /'F' 24VdC ~ - -- ' FIGURE A-4. Field Hook-up (Smart Transmitters). Optional Chart Recorder c~t~rnt -- + -- Optional Indicator A-5 COMMUNICATOR KEYS The keys of the HART Communicator include action, function, and I* alphanumeric and shift keys. * FIGURE A-5. The HART /~ Communicator. , : Function Keys Action Keys Shift Keys Action Keys As shown in Figure A-5, the action keys are the six blue, white, and black keys located above the alphanumeric keys. The function of each key is described as follows: ON/OFF Key r'~ Use this key to power the HART Communicator. When the communicator is turned on, it searches for a transmitter on the 420 mA loop. If a device is not found, the communicator displays the message, "No Device Found. Press OK.' If a HART-compatible device is found, the communicator displays the Online Menu with device ID and tag. Iol I 11 <::1 Use these keys to move the cursor up, down, left, or right. The right arrow key also selects menu options, and the left arrow key returns to the previous menu. HOT Key r'~ Use this key to quickly access important, user-selectable options when connected to a HART-compatible device. Pressing the Hot Key turns the HART Communicator on and displays the Hot Key Menu. See Customizing the Hot Key Menu in the HART Communicator manual for more information. Function Keys Use the four software-defined function keys, located below the LCD, to above a function key indicates the function of that key for the ~ent menu. ~ you move ~ong menus, different function key la~ls appear over the four keys. For example, ~ menus providing access to on-line help, the ~ label may appe~ above the F1 key. In menus providing access to the Online Menu, the ~ label may appear a~ve the F3 key. Simply press the key ~ activate the f~ction. See your ~T Communicator manual for det~ls on specific ~nction key definitions. Alphanumeric and ShiR ~e ~ph~ume~c keys (~re A-6) peffo~ two functions: the fast Keys selection of menu options nd data ent~. FIGURE A-6. HART Communicator Alphanumeric and Shift Keys. Data Entry Some menus require data entzT. Use the a]phanume~c and shift keys to enter all alphanumeric information into the HART Communicat~r. you p~ess a~ a]pha~umedc ~e~ a]o~e f~om wiffii~ a~ edit menu, bold &a~ac~ i~ ~e ce~ of the ~e~ appea~s. ~ese ]~e cha~ac~s i~c]ude ~e ~umbe~s 0 t~ou~h 9, ~e decima] point (.), a~d ~e dash s~bo] (--). · o e~te~ a~ alphabetic &a=acte~, fi~st press the s~ ke~ that co~espo~ds to the positioa of the ]ette~ ~ou wa~t o~ the a]pha~e~c ~e~. ~e~ p~ess the ~ph~umedc ~ey. ~o~ example, ~ e~te~ the ]et~e~ ~, fi~st p~ess the d~ht shi~ ~e~, ~e~ ~e "6' key (see ~i~e A-?). ~ot press these ke~s simu]~eous]~, but o~e a~e~ the FIGURE A-7. Data Entry Key Sequence. I'IE]I PQR / 6 A-7 HART FAST KEY HART fast key sequences provide quick on-line access to transmitter SEQUENCES variables and functions. Instead of stepping your way through the menu structure using the action keys, you can press a HART fast key sequence to move from the Online Menu to the desired variable or function. On- screen instructions guide you through the rest of the screens. HART Fast Key Example HART fast key sequences are made up of the series of numbers corresponding to the individual options in each step of the menu structure. For example, from the Online Menu you can change the Date. Following the menu structure, press i to reach Device Setup, press 3 for Basic Setup, press 4 for Device Info, press 5 for Date. The corresponding HART fast key sequence is 1,3,4,5. HART fast keys are operational only from the Online Menu. If you use them consistently, you will need to return to the Online Menu by pressing m (F3) when it is available. If you do not start at the Online Menu, the HART fast key sequences will not function properly. Use Table A-l, an alphabetical listing of every on-line function, to find the corresponding HART fast key sequences. These codes are applicable only to Model 1151 transmitters and the HART Communicator. MENUS AND FUNCTIONS The HART Communicator is a menu driven system. Each screen provides a menu of options that can be selected as outlined above, or provides direction for input of data, warnings, messages, or other instructions. Main Menu When the HART Communicator is turned on, one of two menus will appear. If the HART Communicator is connected to an operating loop, the communicator will find the device and display the Online Menu (see below). If it is not connected to a loop, the communicator will indicate that no device was found. When you press OK (F4), it will display the Main menu. The Main menu provides the following options: · Offiine--The Offiine option provides access to offiine configuration data and simulation functions. · Online The Online option checks for a device and if it finds one, brings up the Online Menu. '· Transfer--The Transfer option provides access to options for transferring data either from the HART Communicator (memory) to the transmitter (device) or vice versa. Transfer is used to move off-line data from the HART Communicator to the transmitter, or to retrieve data from a transmitter for off-line revision. NOTE Online communication with the transmitter automatically loads the current transmitter data to the HART Communicator. Changes in on- line data are made active by pressing SEND (F2). The transfer function is used only for off-line data retrieval and sending. I 1 I I I i I Appenalx A · Frequency Device-The Frequency Device option displays the frequency output and corresponding pressure output of current- to-pressure transmitters. · Utility-The Utility option provides access to the contrast control for the HART Communicator LCD screen and to the autopoll setting used in multidrop applications. Once selecting a Main menu option, the HART Communicator provides the information you need to complete the operation. If further details are required, consult the HART Communicator manual. Online Menu The Online Menu can be selected from the Main menu as outlined above, or it may appear automatically if the HART Communicator is connected to an active loop and can detect an operating transmitter. NOTE The Main menu can be accessed from the Online Menu. Press the ]ei~ arrow action key to deactivate the on-line communication with the transmitter and to activate the Main menu options. When configuration variables are reset in the on-line mode, the new settings are not activated until the data are sent to the transmitter. Press SEND (F2) when it is activated to update the process variables of the transmitter. On-line mode is used for direct evaluation of a particular meter, re- configuration, changing parameters, maintenance, and other functions. A-9 I i I i i T T i DIAGNOSTIC MESSAGES The following pages contain a list of messages used by the HART Communicator (HC) and their corresponding descriptions. Variable parameters within the text of a message are indicated with <variable parameter>. Reference to the name of another message is identified by [another message]. Message Description Add item for ALL device Asks the user whethe; the hot key item being added should be types or only for this ONE added for all device types or only for the type of device that is device type. connected. Command not The connected device does not support this function. implemented Communication error Either a device sends back a response indicating that the message it received was unintelligible, or the HC cannot understand the response from the device. Configuration memory The configuration stored in memory is incompatible with the not compatible with device to which a transfer has been requested, connected device Device busy The connected device is busy performing another task. Device disconnected Device fails to respond to a command. Device write protected Device is in write-protect mode. Data cannot be written. Device write protected. Device is in write-protect mode. Press YES to turn the HC off and De you still want to shut lose the unsent data. off? Display value of vadable Asks whether the value of the variable should be displayed on hot key menu? adjacent to its label on the hot key menu if the item being added to the hot key menu is a variable. Download data from Prompts user to press SEND softkey to initiate a memory to device configuration memory to transfer. device Exceed field width Indicates that the field width for the current arithmetic variable exceeds the device-specified description edit format. Exceed precision Indicates that the precision for the current arithmetic variable exceeds the device- specified description edit format. Ignore next 50 Asked after displaying device status. Softkey answer determines occurrences of status? whether next 50 occurrences of device status will be ignored or displayed. Illegal character An invalid character for the variable type was entered. Illegal date The day portion of the date is invalid. Illegal month The month portion .of the date is invalid. Illegal year The year portion of the date is invalid. Incomplete exponent The exponent of a scientific notation floating point variable is incomplete. Incomplete field The value entered is not complete for the variable type. Looking for a device Polling for multidropped devices at addresses 1-15. C. A-10 I I '!' I' I I I Message Descrept;on Mark as reed only Asks whether the user should be allowed to edit the variable from variable on hot key the hot key menu if the item being added to the hOt key menu is a menu? variable. No device configuration There is no configuration saved in memory available to re- in configuration memory configure off-line or transfer to a device. No device found Poll of address zero fails to find a device, or poll of all addresses tails to find a device if auto-poll is enabldd. No hot key menu There is no menu named "hot key" defined in the device evaliable for this device. description for this device. No offiine devices There are no device descriptions available to be used to configure available. a device offline. No simulation devices There are no device descriptions available to simulate 8 device. available. No UPLOAD_VARIABLES There is no menu named "upload_variables" defined in the device in ddl for this device description for this device. This menu is required for offline configuration. No valid items The selected menu or edit display contains no valid items. OFF KEY DISABLED Appeam when the user attempts to turn the HC off before sending modified data or before completing a method. Online device There is unsent data for a previously connected device. Press disconnected with RE'FRY to send data, or press OK to disconnect and lose unsent unsent data. RETRY or data. OK to lose data. Out of mentory for hot There is no more memory available to store additional hot key key configuration. Delete items. Unnecessary items should be deleted to make space unnecessary Items. available. Ovenvrite existing Requests permission to overwrite existing configuration either by configuration memory a device-to-memory transfer or by an offline configuration. User answers using the softkeys. Press OK... Press the OK softkey. This message usually appears after an error message from the application or as a result of HART communications. Restore device value? The edited value that was sent to a device was net properly implemented. Restoring the device value returns the variable to its original value. Save data from device to Prompts user to press SAVE softkey to initiate a device-to- configuration memory memory transfer. Saving data to Data is being transferred from a device to configuration memory. configuration memory. Sending data to device. Data is being transferred from configuration memory to a device. There are write only There are write-only variables which have not been set by the variables which have not user. These variables should be set or invalid values may be sent been edited. Please edit to the device. them. A-11 i I I f f I Message Description There is unsent data. Press YES to send unsent data and turn the HC off. Press NO to Send it before shutting turn the HC off and lose the unsent data. off? Too few data bytes Command returns fewer data bytes than expected as determined received by the device description, Transmitter fault Device returns a command response indicating a fault with the connected device. Units for <variable label> The engineering units for this variable have been edited, Send has changed. Unit must engineering units to the device before editing this variable. be sent before editing, or invalid data will be sent. Unsent data to online There is unsent data for a previously connected device which must device. SEND or LOSE be sent or thrown away before connecting to another device. data Use up/down arrows to Gives direction to change the contrast of the HC display. change contrast. Press DONE when done. Value out of range The user-entered value is either not within the range forthe given type and size of variable or not within the mirVmax specified by the device. <message> occurred Either a read/write command indicates too few data bytes readlnghefflting <variable received, transmitter fault, invalid response code, invalid response label> command, invalid reply data field, or failed pre* or post-read method; or a response code of any class other than SUCCESS is returned reading a particular variable. <variable label> has an A variable related to this variable has been edited. Send related unknown value. Unit must variable to the device before editing this variable, be sent before editing, or invalid data will be sent. -.~,.. A-12 t Appendix Model 268 Communicator INTRODUCTION This appendix provides basic communicator information on the Rosemount Model 268 SMART FAMILY Interface when used with a Model 1151 Smart Pressure Transmitter. Included'in this appendix are a menu tree, a table of fast key sequences, and information on using the Rosemount Model 268 SMART FAMILY Interface. B~I HosemourlT MOOel 1101 bmaF[ rressure i rarlsrlllt~efs - FIGURE B-1. 268 Menu Tree. F3 XMTR Revs · M~I, U~, O~ ~im~, F1 ~ Tm _ F4 E~ D , e ~ ~, Tag, ~, Me~, Daa, Meter, ': ~ B ~ I' ~n~R~, ~ ~L, ~ng, Horn Menu ~ ~4/~ F~i- m, m ~u~ ~ ~d . ......: ~:~: I~l~r~r F3 F~ue~ F1 R~ F1 ~. Tag F3 ~11 F4E~ ~ Tm ~ ~ F4 P~ H T~ ~d ~ ~ T~ _ F3 XffiR R~s F2 Tffi - F2 X~R T~ F4 E~ F14~ F3 R~II - ~Tffi ~F4P~] F2~mA ~ P~ F3 ~er ~le F4 ~ F1 ~ F4 E~ F1 ~i~ ~ _ F2 R~I F3 ~ F2 Change Output t Units, 4/20 mA pts, Output/I Lin.-sqRT, Damping F3Configure - Tag, Descriptor, Message, Date, Meter, I F3 XMTR Info - Range '1~ , Flan Mat., O-d , Vents, F4 Send Data F1 Other Functions --{ Burst Mode I F2 Other Scale F3 Digital Trim _ F1 Output Trim -- F3 Abort F2 Sensor Trim -- F1 Full Trim F4 End F4 End F2 Zero Trim F3 Abort " I TABLE B-2. Model 268 Fast Key Equivalents. Function Model 26~ Fast Ke'/Sequences Analog Output F3, F2 Analog Output Alarm Not Applicable Burst Mode Control F4, F4, F1 Burst Operation Not Applicable Calibration Not Applicable Characterization F4, F4, F2 Damping F3, F2, F2 Date F3, F3, (F1 x 3) Descriptor F3, F3, F1 Digital To Analog Trim (4-20 mA Output) F4, F4, F3 Disable Local Span/Zero Adjustment F4, F4, F1 Field Device Information F3, F3 Full Trim F4, F4, F3, F2, F1 Keypad Input (Trim Points) F3, F2, F1 Loop Test F2, F3 Lower Range Value Process Variable Key, F2 Lower Sensor Trim F4, F4, F3, F2, F1, F2 Message F3, F3, F1, F1 Meter Type F3, F3, (F1 x 4) Number Of Requested Preambles Not Applicable Percent Range Not Applicable Poll Address F1, F4, F4, F2, F3 Pressure Process Variable Key Range Values F3, F2, F1 Rerange F4, F4, F3, F1, F1 Scaled D/A Trim (4-20 mA Output) F4, F4, F3, F1, F2 Self Test (Transmitter) F2, F2 Ser~sor Information F3, F3 Sensor Temperature Process Variable Key, F3 Sensor Trim Points F3, F2, F1 Status Not Applicable ' Tag F3, F3 Transfer Function (Setting Output Type) F3, F2, F1, F1 Transmitter Security (Write Protect) Not Applicable Trim Analog Output F4, F4, F3, F1 Units (Process Variable) F3, F2 Upper Range Value Process Variable Key, F2 Upper Sensor Trim F4, F4, F3, F2. F1, F3 Zero Trim F4, F4. F3, F2, F2 B-3 CONNECTIONS AND The Model 268 can communicate with a transmitter from the control HARDWARE room, the transmitter site, or any other wiring termination point in the loop. To communicate, it must be connected in parallel with the transmitter; the connections are non-polarized. FIGURE B-3. Bench Hook-up (Smart Transmitters). F[ 24 V dc ~ -- Power ~ Supply ~ ~,_,~ ~ RL _ 250 ~ Dr'ID FIGURE B-4. Field Hook-up (Smart Transmitters). Optional Chart Recorder '~' RL>'250fi ' .~ 'F L~ ~ ;;? -- Power Supply ~li~r'~ Optional _ DJ'I[~ Indicator ° ............ CO MMUNICATOR KEYS The keys of the Model 268 include the dedicated, alphanumeric and shift, and function keys that vary depending on the task being performed. The dedicated key functions are always the same. Dedicated Keys On/Off Use this key to turn the unit on and off. When the Model 268 is turned ON, it searches for a transmitter in the 4-20 mA loop. If no transmitter is found, the Model 268 offers the opportunity to try again, select "MULT DROP" or "OFF-LINE". Process Variable Use the Process Variable key to disp]ay up-to-date process variable readings from the transmitter in engineering units, milliamps, pulse rate, and shedding rate. It also displays'totalized flow. Review The Review key allows you to step through all the information currently held in the four memory locations of the transmitter and Model 268 -- SAFE MEM, OFLN MEM, WORK REG, and XMTR MEM. FIGURE B-5. Model 268 Comrnunicator. r · (Green) ' . Dedicated Keys U, Alphanumeric Keypad (White) Help Use the Help key to explain the software-defined key functions (F1-F4) in detail. Restart Use the Restart key to initiate communication with a transmitter while the Model 268 is still turned on. Upon connection to a new transmitter, pressing this key loads information from the new transmitter into the Model 268 working register. Previous Function The Previous Function key returns you to the previous decision level and allows you to select a different software-defined key function. t I I S T T ! rtUljtllilUUIIt I¥1UfJt~l I I 0 I Olllkll t r'lt$~U!~ I Alphanumeric and Shift Some menus require data entry. Use the alphanumeric and shift keys to Keys enter all alphanumeric information into the Model 268. FIGURE B-6. Model 268 Communicator Alphanumeric and Shift Keys. If you press an alphanumeric key alone from within an edit menu, the bold character in the center of the key appears. These characters include the numbers 0 through 9, the decimal point (.), and the dash symbol (-). To enter an alphabetic character, first press the shift key that corresponds to the position of the letter you want on the alphanumeric key. Then press the alphanumeric key. For example, to enter the letter R, first press the right shift key, then the "6" key (see Figure B-7). Do not press these keys simultaneously, but one after the other. FIGURE B-7. Data Entry Key Sequence. PQR 6 Function Keys Use the four software-defined function keys, located below the LCD, to perform software functions. On any given menu, the label appearing above a function key indicates the function of that key for the current menu. As you move among menus, different function key labels appear over the four keys. I 1 I' " i I FAST KEY SEQUENCES The Model 268 fast key sequences provide quick on-line access to transmitter variables and functions. Instead of stepping your way through the menu structure, you can press a fast key sequence to move from the Home Menu to the desired variable or function. On-screen instructions guide you through the rest of the screens. Fast Key Sequence The fast key sequences for the Model 268 use the following conventions Conventions for their identification: F1, F2, F3, F4-Refer to each function key located directly below the LCD on the Model 268. (F2 x 7)-Means to push the F2 key seven consecutive times. Process Variable-Refers to the dedicated key located below the function keys on the Model 268. To return to the Home Menu, use the function keys to exit the current task and press the PREVIOUS FUNCTION (dedicated key) as many times as necessary. The fast key sequences are applicable only from the Home Menu. The Home Menu lists the model and tag, and labels the four function keys Offiine, Test, Configure and Format (see Figure B-8). After completing a task, return to the Home Menu if you intend to use the fast key sequences. Fast key sequences will not work from any other Model 268 screen. NOTE Certain tasks require that you set the control loop to manual control before completing them. Fast key sequences often include a warning to' return the loop to manual. FIGURE B-8. Model 268 Home Screen. rModel: Model 1151 "~ Tag: XXXXXXXX Off- T Test For To return to the Home Menu, use the function keys to exit the current task and press PREVIOUS FUNCTION as many times as necessary. When the Home Menu appears, you can use another fast key sequence to reach a desired task. NOTE Certain tasks require that you set the control loop to manual control before completing them. Fast key sequence steps often include the warning to return the loop to manual. If the loop is not in manual control, be sure to watch for this screen. If it comes up during the fast key sequence, set the loop to manual before continuing with the task. Fast Key Sequence Date Examples To change the date following the menu structure, you would start at the Home Menu and press F3 for Configure, F3 for XMTR Info, and F1 three times in a row to reach the Date function. The fast key sequence is F3, F3, [F1 x 3]. Loop Test To perform the Loop Test, start at the Home Menu and press F2 for Test, F3 for Loop Test, and F4 for Proceed (after the loop is set to manual). The Function Key Sequence is F2, F3, F4. B-7 DIAGNOSTICS MESSAGES T~e following table provides a guide to diagnostic messages of the Model 268. Message Description CAUTION.- Off-line Memory is cleared for new information. Progressing will clear Ofln Mem Data saved in OFLN Off-line configuration data are saved in the Off-line Memory and can Mere for downloading be downloaded or sent to the flowmeter at an appropriate time. DIfferent XMTR type The flowmeter did not accept data sent because the data is meant for connected-XMTR a different type of transmitter. Mem not changed End of list ERR-filter auto adjust The low pass filter auto-adjust sequence error occurs under the following conditions: · no flow in pipe · erratic flowrote · filter tracking disabled Remedy conditions and repeat function. ERR-Hard/software is not compatible ERR-Not in output mode ERR-Not XMTR The flowmeter does not understand the command sent by the Model command 268. Press F4, RESTART to restart the flowmeter, or press F3 to suppress the error message and REVIEW the software revision level. You may need to contact the Rosemount Service Center. ERR-Out of range ERR-PV out of limits ERR-Update failure ERR-Value was too hi ERR-Value was too Io ERR-XMTR fault ERR-XMTR will not The flowmeter does not understand the Model 268 command. Press support command F4, RESTART or press F3, REVIEW to review the software revision level of the flowmeter. Check compatibility. ERR-268 Date err Errors Dotected-XMTR The flowmeter did not accept data because it contained Mem not changed nonpermissible values. Data errors must be corrected and the data sent again. FAILURE. Electronics Gen failure-No. 1 Making changes Data is being sent to the flowmeter and the flowmeter is accepting permanent-PLEASE the data. WAIT No date modified to Data with no changes is being sent. Press F4 to continue. send No data saved in OFLN There are no data in the Off-line Memory to review. Mem ! 'l' [ I Message Description No data saved in SAFE There are no d~ta in ~t~ Safe Memory to review. of In Mem not The data stored in Off-line Memory and Working Register are from compatible with WORK different kinds of transmitters, or the Off-line Memory is empty. Press REGS-Data not F4, REVIEW, F2 to see the data in Off-line Memory and connect the transferred Model 268 to similar transmitter. SAFE Mem from diff Data in the Safe Memory and Working Register are from different XMTR than WORK transmitters. Press F4, REVIEW, F1 and find the flowmeter serial REGS-Data not number. Connect the Model 268 to the flowmeter with that serial transferred number and press RESTART. SAFE Mem not The unique identifier in the Safe Memory and the transmitter are compatible with WORK different. Press F4, REVIEW, F1 to see the data in the Safe Memory. REGS-Deta not Connect the Model 268 to the matching transmitter and press transferred RESTART. The XMTR has returned an error WARN-Used nearest The value entered has too many decimal places. The Model 8800 legal table value defaults to the closest value available. WARN-Value at limit The entered value is beyond the upper or lower limit. Adjust to a value reverse direction within the limits. WARN--Value entered The Model 268 will not accept the entered value. Enter an acceptable is illegal, re-enter value (see relevant section in manual). WARN-Value out of The Model 268 could not store the entered value so it changed to the limits, altered by 268, maximum allowable value. Check the new value. re-check data WARNING-Analog output outside range points WARNING-Control Before sending the data that could affect the 4-20 mA output signal, loop should be in set the loop to manual control. After it is set, press F4. manual WARNING-DSta Previous communication between Model 268 and the flowmeter was transmission error not successful. If this message appears repeatedly, check the loop for a source of noise that could corrupt the signal. WARNING-Loop may After completing a communication that required the loop to be set in be returned to auto manual, you may return the loop to automatic control, WARNING-Match xmtr Cheek to be sure that the entered flowmeter serial number is the S/N to nameplate S/N same as that on the flowmeter nameplate. WARNING-Not on line The key you have pressed is not applicable for off-line configuration tasks. WARNING-Process Indicates that the self-test has been aborted by pressing any key. has been aborted WARNING-PV out of range WARNIN~me of Flowmeter did not receive all configuration changes. Note differences the changes were not in configuration data and reconfigure the flowmeter accordingly. saved in the xmtr mem WARNING-This Another transmitter is already using the entered multi-drop address. address already being Enter a new address. used Message Description WARNING-This will DIlls in lhe Working Register will be replaced with data from a erase work rag another location. WARNING-XMTR/268 Model 268 did not get answer from flowmeter: not in con~munication · Check connections · Check that power is reaching flowmeter · Check for minimum 250 ohms resistance in loop WARNING-XMTR in During start-up and restart, the transmitter milliamp output does not output mode reflect the process variable. Press F4. WARNING-XMTR is Model 268 did not get answer from flowmeter: not communioeting · Check connections · Check that power is reaching flowmeter · Check for minimum 250 ohms resistance in loop WARNING-268 does Model 268 recognizes a Rosemount transmitter in the loop but not know this XMTR cennct communicate with it. The message usually indicates a software revision level incompatibility between the Model 268 and*the transmitter. XMTR Mem dlff than Data in the Working Register and in the flowmeter have different WORK Regs-XMTR unique identifiem. The Model 268 was probably connected to not changed different flowmeter without RESTART or power-off/power-on sequence. Press RESTART to erase the Working Register or save the Working Register to the Off-line Memory and download to the pmpor flowmeter at a later time. XMTR Security: On- XMTR will not accept changes to Memory XMTR still busy Flowmeter is running a computational or diagnostic routine and cannot respond to the Model 268 instructions. Press the PREVIOUS FUNCTION key to cancel. XXXX=YYYY ERR- Illegal value XXXX=YYYY ERR-Out of range XXXX=YYYY ERR- Span too small XXXX=YYYY ERR-Valu was too hi XXXX=YYYY ERR-Valu was too Io XXXX=YYYY ERR-LRV too hi XXXX--YYYY ERR-LRV too Io XXXX=YYYY ERR-LRV & URV out limits XXXX=YYYY ERR-URV too hi XXXX=YYYY ERR-URV tOO IO XXXX=YYYY ERR-268 data err 268 Failure-No. 1 268 Failure-No. 2 268 Test: FAIL B-10 I i I I ' I "' I r I Appendix Retrofitting the Model 1151 Transmitter INTRODUCTION This section describes how the Rosemount Smart Retrofit Kit can be used to retrofit a Model 1151AP, DP, GP, HP, or LT transmitter with 4-20 mA dc linear or square root output. NOTE The Model 1151DR (Draf~ Range) Transmitter cannot be retrofitted with the 1151-0935-0001 Retrofit Kit. In addition, Model 1151 transmitters with serial numbers below 10,000 and approximately 2,000 Model 1151 AP Range Code 4 Transmitters with serial numbers between 1,318,500 and 1,690,000 may experience some degradation in performance from temperature effect if retrofitted. Therefore, retro~tting of these transmitters is not recommended. SAFETY MESSAGES Warnings (j~) Procedures and instructions in this section that raise potential safety issues are indicated by a warning symbol (A). Refer to the following warning messages before performing an operation preceded by this symbol. ~'~WARNING · Explosions can result in serious injury or death. Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendiary field wiring practices. · Toxic processas can result in serious injury or death. Transmitter can contain residue process. Use appropriate safety precautions when opening drain vents or disconnecting a transmitter from a process. · DO NOT attempt to loosen drain vent valves or disconnect the transmitter from the process without taking precautionary measures. ° Install and tighten all four process adapter bolts or drain vent valves before applying pressure. · Both transmitter covers must be fully engaged to meet explosion-proof requirements. 'I I i T I i RETROFITTING OVERVIEW The procedure for retro~tting a transmitter is divided into three parts: 1. Removing the analog electronics assembly. 2. Installing the smart electronics kit. 3. Characterizing the retrofitted transmitter. Two tools are required to remove the analog electronics and to install the smart electronics: · Flat-bladed screwdriver - · ¼-in. nut driver or wrench The following equipment is needed to characterize the retrofitted · A Rosemount Model 275 or Model 268 HART Communicator with SMART FAMILY~ Interface · An accurate pressure source, preferably 0.025% accuracy or better · A 250 ohm resister The Smart Retrofit Kit, P/N 01151-0935-0001, contains the following items: Quantity Description I Smart electronic assembly i Electronics cover I Cover O-ring 2 Terminal eyelets 2 Board spacers 2 Standoffs REMOVING THE ANALOG ELECTRONICS ASSEMBLY _~CAUTION Use proper earth grounding techniques when handling the smart electronics assembly. The smart electronics assembly is potentially sensitive to electric static discharge. The vast majority of installed Model 1151 Transmitters have either "E' (4-20 mA linear) or "J' (4-20 mA square root) output codes. The transmitter output code is part of the model number on the transmitter nameplate. It is the eighth character from the left for AP, DP, GP, and HP, and LT transmitters. Example: (1151DP4 E 12M1) The following steps describe how to remove the analog electronics assembly from transmitters with "E' or "J~ output codes for smart retrofitting. However, they can also be used as guidelines for retrofitting transmitters with "A' or "C' output codes. This process requires opening the electronics compartment on the circuit side of the transmitter and removing the amplifier or amplifier/squaring assembly, standoffs, and the calibration board. NOTE Numbers in parentheses indicate parts shown in Figure C-1. C-2 FIGURE C-1. Model 1151 Analog Electronics. Ref, Part No. Description I Retainer Screws (Linear) IP ' 2 Amplifier Board (Linear) LINEAR OUTPUT 3 Header Board Assembly 4 Standoff Screws (Linear) 5 Calibration Board (Linear) 6 Bayonet Connector Pins 7 Standoff Screws (Linear) 8 Sensor Module Electronics 9 Wiring 10 Zero and Span Adjust Screws 11 Housing Cover 12 Retainer Screws (Square Root) 13 Two-board Amplifier/Squaring Assembly (Square Root) 14 Calibration Board (Square Root) o IJJ SQUARE ROOT OUTPUT ~., 1. Ensure that power is removed from the transmitter before beginning the retrofit procedure. 2. Remove the cover from the circuit side of the transmitter. 3. Remove the three retainer screws (1 or 12). See "Safety Messages" on page C-1 for complete warning information. J I " I '1' 1 I I · Appena~x ~ 4. Pull the amplifier board (2) or amplifier/squaring assembly (13) directly off the bayonet connectors (6). C-5 5. Pull the header board assembly (3) off the bayonet connectors. The header board must be reinserted. Do not cut the wires (9) or remove the header board. t , ,:.,: ,. 6. If the transmitter has Linear output electronics, remove ~e three standoffs (4). Use a ~-~. nut ~ver or wrench. 7. Align the zero and span adjust screws (10) so that the potentiometer blades are perpendicular to the board. C-7 I 1 '!' l' " [' " 8. For linear output models, grip the calibration board (5) by the interface pin. For square root output modes insert a retainer screw into the threaded rivet for use as a handle. Pull out the calibration board. (Removing the calibration board disables the conventional zero and span screws.) [ I ':" I l~ I I I' , Appena:x Insert the standoffs (7), if necessary. The transmitter is now ready to receive the plug-in smart electronics assembly. Rosemount MOOel 11 ~}1 ~milrt yressure I ransmlHers , INSTALLING Installing the smart retrofit electronics kit in the transmitter requires f installing plastic spacers to accommodate the retrofit kit and securing THE SMART RETROFIT KIT the retrofit electronics. After the retrofit kit has been installed, it is necessary to attach eyelets to the terminal side of the transmitter. The eyelets enable hook-up with a HART-based communicator (see Figure ~ C-2). "~ _'~CAUTION Use proper earth grounding techniques when handling the smart electronics assembly. The smart electronics assembly is potentially sensitive to electdc static discharge. FIGURE C-2. Spacer Assembly. This side faces bottom _~ ~ This side faces toward of electronics assembly O // O electronics housing cover O ~ _[]~;~ O 0 0I 0 k 0 connectors. Then repeat the procedure for the other row. / C-10 { '~t '! ' I '11 IT I I I 2. Align the header board with the bayonet connector pins, and slide the header board halfway down the pins. / 3. Align the tops of both spacers with the bayonet connector pins, and slide them down the pins, pushing firmly on both the spacers and the header board to seat the board. C-11 I i ! i T' i T I 4. Align the smart electronics assembly with the bayonet connector pins, making sure all pins line up with the proper receptacles. Next, push the assembly slowly inward until it is fully seated. i 5. Tighten the three captive screws on the smart electronics assembly to secure it in place. 6. Attach the electronics cover provided in the smart retrofit kit, and tighten securely. 7. Remove the cover from the terminal side of the transmitter. Two eyelets that fit under the + and - signal terminal screws are provided to facilitate connections to HART-based communicator. The signal terminal is the upper block as indicated on the transmitter housing. 8. Remove the signal terminal + and - screws. Attach an eyelet to each screw, and reinsert the screws. 9. Reattach the cover on the terminal side, and tighten securely. See 'Safety Messages" on page C-1 for complete warning information. CHARACTERIZATION The transmitter is now ready to be characterized. Characterization is a one-time calibration of the sensor in the Model 1151 Transmitter. During characterization, known pressures are applied to the sensor, and corresponding digital values are stored in the EEPROM located in the smart transmitter electronics. The microprocessor uses these values to make linearization corrections. The digital-to-analog converter then converts the corrected digital signal into a 4-20 znA dc output. The Model 1151 Transmitter will stay in high alarm (approximately 22 mA output) until the characterization sequence is completed. NOTE The transmitter must be re-characterized if either the sensor module or the smart transmitter electronics are repaired or replaced. Before Characterizing the 1. Be prepared to answer the following questions: Transmitter · Module type (AD, DP, HP, LT) on the transmitter S/N tag? · Module range on the transmitter module tag? · Pressure units on your pressure source? · Serial number on the transmitter S/N tag? Ak 2. Connect the pressure source. ~k 3. Remove the terminal side cover of the Model 1151 Smart Pressure Transmitter. Ak 4. Connect power supply leads to the terminal block. Apply power to the transmitter. NOTE Failure to use accurate equipment may result in a transmitter that cannot meet its accuracy specification. Characterizing with a /~ 1. Connect the Rosemount Model 275 HART communicator Model 275 Comrnunicator electrical connections to the SIGNAL terminal block. The Model 275 connections are not polarity sensitive. 2. Turn the Model 275 on by pushing the I/O butten. 3. Follow the Model 275 menus to characterize: · Device setup · Detailed setup · Sensor · Pressure sensor · Sensor service · Characterize 4. Follow the instructions on the screen. 5. Verify the new transmitter configuration: · Tag · Range points · Linear/square root · Damping 6. Verify that the Fail Safe Mode Switch and the Transmitter Security Switch on the smart electronics circuit board are correct. 7. Attach the electronics cover and tighten. 8. Put the transmitter back in service. ~ See "Safety Messages" on page C-1 for complete warning information, C-13 Characterization with a /A, 1. Connect the Rosemount Model 268 HART Communicator Model 268 Communicator electrical connections to the SIGNAL terminal block. The Model 268 connections are not polarity sensitive. 2. Turn the Model 268 on by pushing the I/O button. 3. Follow the Model 268 menus to characterize: · Proceed · Format · Proceed · Charize 4. Follow the instructions on the screen. 5. Verify the new transmitter configuration: · Tag · Range points · Linear/square root · Damping 6. Verify that the Fail Safe Mode Switch and the Transmitter Security Switch on the smart electronics circuit board are correct. 7. Attach the electronics cover and tighten. 8. Put the transmitter back in service. See "Safety Messages" on page C-1 tot complete warning information. Appendix Approval Drawings Index of intrinsically safe barrier systems and entity parameters for Models 444, 1135, 1144, 1151, and 2051 transmitters and Model 751 Field Indicators (Drawing Number 01151-0214, Rev. U), pages D-2 through D-7. Index of intrinsically safe C.S.A. barrier systems for Model 1151 transmitters (Drawing Number 01151-2575, Rev. C), pages D-8 through D-10. Index of intrinsically safe barrier systems and entity parameters for the Model 268 SMART FAMILY Interface (Drawing Number 00268-0031, Rev M), pages Doll through D-17. Index of intrinsically safe barrier systems and entity parameters for the Model 275 HART Communicator (Drawing Number 00275-0081, Rev B), pages D-18 through D-23. Index of intrinsically safe C.S.A. barrier systems for the Model 275 HART Communicator (Drawing Number 00275-0082, Rev A), page D-24. D-1 I=IOSEI!IOUII'I, II/II,)UI~I I I~ I OliRlll I"IUIiliUIU IlilllbllllLLt:llb CONTENTS ENTITY APPROVALS S~ETS 2 THRU 4 APPROVED PARAMETERS SHEETS 2 THRU 3 CONNECTION DIAGRAMS SHEET 4 MASTER APPROVED SOURCES OF SUPPLY Material purchosecl to this Rosemount Specification Control Drawlrig shall be required to meet oll the MFG MFG PART NO specifications of this drawing. Any mention of monufocturer's port number within this drawing is for reference only. This is necessary to ensure design control of Rosemount'$ end product. It is Rosemount's intent to purcttose your standard material whenever possible. SPECIFICATION CONTROL bRAWINC 'rOl,~3bleC~$: TITLr Ar,,~4wr. ort o.c. INDEX OF ]I~]]NISICA/iY SAFE BARRIER SYSTEMS o~c~mz.s r~cr,oNS ~"'~'~ ~: E.NTITY PAR,AJvt~RS FOR 444, 1 ]35, 1144, 115 I, .xt.1 st/32 .xx · .o2 sw, LSs Jf ~, & 2051TKA/qSMITTERS AND 751 RBLD INDICATORS A 01151-0214 C I I I !l 1i I I I Appendix D ENTI~ CONCEPT APPROVALS The entity concept atllows interconnection of intrinsically safe apparatus to associated apparatus not spe. cifically enmined in combination as a system. The approved values of maximum open circuit voltage (V or V ) and maximum short circuit current (ISC or IT) (VMAX~' and input current MAX) of the ~ sa~e apparatus, In addition, the appro~F~! ~um ~o~b~ connected ca citancc (CA) and inductance (LA) of the associated a ms musx b~ ~a2r fi2n ~e msmmum an cted imernal eapacitance ~CL) and ~~e I) of the inuinsically safe apparatus. ~e;pproved entity concep~ parameters are as Model 444 Class I, Div. 1, Cu'oups Aand B V~fAX = 40V VOC or VT is less than or equal m 40V IMAX" 1~ mA ISC or IT is less than or equal to 1~ mA CI = 0.0~ssF CA is greater than 0.0441F LI - 0 LA is ~.a~er than 0 Class I. Div. 1, Groups C and D VMAX = 40V VOC or VT is less than or equal to 40V 1MAX - 2~. mA lSC or lT is less than orequa1 to 225 mA CI = 0.044~F CA is greater than 0..044F LI = 0 LA is greater than 0 Model 751 Class I, Div. 1, Groups A and B VMAX - 40V VOC or VT is less than or equal to 40V IMAX - 165 mA ISC or IT is less than or equal to 16S mA CI = 0 CA is greater than 0 LI = 0 LA is greater than 0 Class I, Div. 1, Groups C and D VMAX = 40V VOC or VT is less than or equal to 40V IMAX -' 22S mA ISC or IT is less than or equal to 225 mA cI = 0 CA is greater than 0 LI = 0 LA is greater than 0 .. !:lomm~ount Inc. MNIf,/MoOLI~ MINNI~OTA "" I Xi "" I"""" 0-,',5',..02-,4 ISSUE ScN.E NONE !wT. D-3 t 't si T I Model mud 11Sl Clan l, I:)h,. 1, Crrou~ A and B VMAX - 40V VOC or VT is ~, than or equal to 40V IMAX - 16S mA ISC or IT is less than or equal to 165 mA CI(~LS~ Sut) - 0 CA is Sreater man 0 CKSman nS~) - 0.02~F CA is greater than 0.024uF Ci(1151 Sui w/R Option)- 0.01QuF CA is greater than 0.01QuF Ci(11~1 Smart w/R_Option) = 0.03~uF CA is greater than 0.034~F Li(1151 5td) = 0 LA/s greater than 0 Li(1151 w/R_ Option) - 2QuH LA is greater than Class I, Div. 1, Groups C and D VMAX -, 40V VOC or VT is less than or equal to 40V IMAX - 225 mA ISC or IT is less than or equal to 225 mA q(us~ sta) - 0 CA is greater man 0 Ci(5man 1151) - 0.024~F CA is greater than 0.024~F Ci(1151 $td W/R Option) - 0.010psF CA is greater than 0.01quF Ci(11~1 Smart w/R_Option) = 0.034~F CA is greater :han 0.034~F Li(1151 5td) - 0 LA is greater than 0 Li(1151 w/R_ Option) - 2QuH LAis greater than 20/~H Model 20Sl Class I, Div. 1, Groups A and B VMAX = 40v vOc or vT is less than or equal to 40V IMAX = 165 mA ISC or IT is le.~ than or equal to 165 mA CI = 0.012/~F CA is greater than 0.012IF LI = 480juH LA is greater than 480lH Class I, Div. 1, Gwups C and D VMAX = 40V VOC or VT is less than or equal to 40V IMAX = 225 mA ISC or IT is less than or equal to 225 mA CI = 0.012~F CA is Ereater than 0.012IF LI =, 480~H LA is liTeater than 4801H Rossmounl I Xl "" ! DR. ISSUIE sasa~ so~ Jwt. Jss~zr ~ o, l~ C Appenmx u Model 1135 Class I, Div. 1, Group~ A and B VM, AX = 40V VOC or VT is less than or equal to 40V IMAX = 165 mA ISC or IT is les~ than or equal to 165 mA CI = 0.00~F CA is greater than 0.{:)081F LI = 0 LA is greater than 0 Class I, Div. 1, Groups C and D VlV~ = 40V VOC or VT is less than or equal to 40V IMAX = 225 mA ISC or IT is less than or equal to 225 mA CI = 0.00~F CA is greater than 0.00~LF LI = 0 LA is greater than 0 Model 1144 Class I, Div. 1, Groups A and B V]VfAX = 40V VOC or VT is less than or equal to 40V IMAX = 165 mA ISC or IT is less than or equal to 165 mA CI = 0 CA is greater than 0 LI -= 0 LA is gr~ater than 0 Class I, Div. 1, Groups C and D V~VLA, X = 40V VOC or VT is less than or equal to 40V IMAX = 225 mA ISC or IT is less than or equal to 29...5 mA CI = 0 CA is greater than 0 LI = 0 LA is greater than 0 Rosemount Inc. MNNENa0L~, M~A SSSUE scN. r~.c~,a~l~. _ I~ ~ D-5 T I ! s~ " I ! ! &PItAIIATUI ! 1144 011 1111 I I I ' 4 I- I I AIIOCtR!III I I I I I I I , I SIZE CODE IOENT NC)DRAWINC NO sc, t~c None I.f., U I ~ ~ ~ i I '1 '1' i I' I I · Appendix D 1151 -- L & M CIICUIT CONNECTION WITH INTRNSIC SAFETY BARRF. RS HAZARDOUS AREA NON-HAZARDOUS AREA ! I I I ~ ~ _ P/S ' 'A/D i i +"i F F -cony I - ! I Two Single Channel CIICIilT lli61il I kr0NLY FOF, USE Wl-r'H E:,/,~JEE~5 A,PPF-oVEb IN 'T'HI5 CONFIr..t~'TiON) HAZARDOUS AREA NON-HAZARDOUS AREA I I I t I 41 J 'J"' &"* * ' "'A/D .j, _ I P/s I 'C, Je ~ F -.cony I -- I ' I One Dual Channel Daffier I CiSCI!IT DrAGBAIl 2 SIZE COOE IDENT NO DRAWING NO ',c,,..: .0.E l ,,E,, UI~. 0' e D-7 Rosemount Model 1151 Smart Pressure Transmitters PROPRIETARY INFORMATION IS REVISIONS CONTAINED HEREIN AND MUST BE HANDLED ACCORDINGLY REV DESCRIPTION CHG. NO. APP'D DATE BY DATE A NEW RELEASE G4GGG6 w.c.R..4/.v~2 B ]50 ohms was 120 ohms 650816 JJ.B..n3x,2 C 15B ohms ~s 12~ ohms (SHT 3) 6521~5 ~.~. v~x,a CSA INTRINSICALLY SAFE APPROVAL Exia intrinsically Safe/Seour te Intrinseque THE ROSEMOUNT MODEL 1151 PRESSURE TRANSMITFER IS APPROVED BY CSA AS iNTRINSiCALLY SAFE FOR THE CLASS I. DIVISION 1 GROUPS AS INDICATED WHEN USED WITH THE BARRIERS AND CONVERTERS LISTED BELOW AND CONNECTED AS SHOWN IN THE ACCOMPANYING DIAGRAMS. APPROVFI) FOR DEVICE PARAMETERS CLASS !. DtV. 1 30 V or Ices 330 ohms or more pc,~ Approvad Safer, Barrier 28 V or loss Groups A, B, C, D 22 V or less 18C ohrns or more F.,'>Xt.';C~!'C Cc'.,hv~!Ter 2.AZ--I3'.-C_GB. 3AL'N3~A C~E/CGB-At. 2A;43V--CGB. 3A.?.-13D CSE / CGB.-A. 2Aj-!2V-CGB. 3A242D C,c~E/CGB-A. Grc~ups P,, C. D ~,S-i2 ;-CGE 3A4-i2DA Qc--E / CGB-A. 3F~j2DAi CS-E/CG~A 30 t; or less """ Approved Safety Barrier t50 ohms or moro ~,, ' Groups C, D THIS DRAWING WAS CREATED ON CAD. DRAWING IS ARCHIVED ON MAGNETIC TAPE FOR EC0 CHANGES. ROSEMOUNT' ..... "°""' "' UNLESS OTHERWISE SPECIFIED CONTRACT NO. Control 12001 Technology Drove ~..1~u:.3 Eden Prairie, MN 55344 USA REMOVE ALL BURRS AND SHARP EDOES. UACHINE DR. S. CAP.&UI, 03"8'92 TITLE INDEX OF CSA INTRINSICALLY -~oL~RA.~E~-CH~'~..C..^UT. .4,.,,~ SAFE' BARRIER SYSTEMS FOR DEC]MALe FRACTIONS APP'D-W.C.RAUTH 04/01,'t2 MODEL 1151 TRANSMITTERS .xx_+.e2 ~NGLES SIZE I FSCM NO DWG NO. · :' A 01151-2575 APP'D. GOVT. DO NOT SCALE PRINT SCALE N/P) wT. SHEET I OF 3 REVISIONS REV DESCRIPTION CHG. NO. APP'D ~ DATE C 652195 MODEL 11~I CiRCUiT CONNECTION WITH BARRIER OR CONVERTER + BARRIER OR ' = CONVERTER ~ - HAZARDOUS AREA NON-HAZARDOUS AREA MODEL 1!51___L, M CIRCUIT CONNECTION WITH BARRIER(S) ,__ + ~ Jr- POWER : + A/O - HAHH!~H -- SUI~PLY : + A/D HAZARDOUS ~REA NON-H{ARDOUS ~REA Rosemount inc. 12001Toc:~noiogy Drivo THIS DRAWING WAS CREATED ON CAD. DRAWING IS ;-det, Prairie. MN 55344 USA ARCHWED ON MAGNETIC TAPE FOR EGO CHANGES. s,~ ~,~. No~o .o.01151-2575 DR. S. CAPAULO3/18/92 A ISSUED SCA.E NONE ~w'r. I S"EET 20P 3 D-9 I '! ! ml f ' T I HOSe1110Urlt MOOel I REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE C 652195 MODEL 1151 L, M CIRCUIT CONNECTION WITH BARRiER(S) (CONTINUED) APPROVED FOR CLASS i, DIVISION I, GROUPS A, B, C, D WHEN USED iN CIRCUIT WITH TWO CSA APPROVED SINGLE Ci iANNEL SAFETY BARRIERS; ONE WITI! APPROVED SAFETY PARAMETERS OF 28 VOLTS OR LESS AND 3',:}0 OHMS OR MORE IN +POWER LINE, AND THE OTHER WiTH APPROVED SAFETY PARAMETERS OF 10 VOLTS OR LESS AND 47 OHMS OR MORE IN +OUTPUT LINE, -OR- ONE CSA APPROVED DUAL CHANNEL SAFE'Pf BARRIER WITH IDENTIC, AL APPROVED SAFE]D( PARAMP ! ERS CONNbC I b.D IN LIKb MANNFR. APPROVED FOR CI_ASS I, DIVISION 1. GROUPS C. D WHEN USED IN CIRCUIT WITH ,'D, NO ,,":.SA APPROVED SINGLE r'~4ANNE SAFETY P-ARmoRq- ONE WITH APPROVED SAFETY PARAMETERS OF 30 VOLTS OR LESS AND 150 OHMS OR MORE IN +POWER LINE AND THE OTHER WITH APPROVF[:} SAFFrY PARAMFTFRS OF 10 VOI TS OR I FSS AND 47 OHMS OR MORF IN + OUTPUT LINE. C Rosemount Inc. 12001 Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Edel~ P:'airie. MN 55344 U,SA ARCHIVED ON MAGNETIC TAPE FOR EGO CHANGES. SIZE FSCM NO DWG NO. D~. s.c.,.u,.,3,3.,~2 A 01151-2575 ISSUED SCALE N/A I wT. I S"EET 3 OF 3 D-IO I 1 I II ' I: ] I I . Rppena,x u PROPRIETARY INFORMATION IS REVIS]0NS CONTAINED HEREIN AND MUST BE HANDLED ACCORDINGLY REV DESCRIPTION CHG, N0. APP'D DATE BY DATE G ADD SHT 4&5, DELETE CLASS I] &I]I. 636328 H ADD 305] P/L/H. 3081C CL/CH 636904 K.D.V. J ADD SHT. 6, FIX TBL. l. 638723 KSJ. 01/B2~ K ADD 3044C 641710 W~I:. L ADD 300]S & SHT 7 FOR 3051C-LP 642380 M ADD 3095 653145 K~).V. THE ROSEMOUNT MODEL 268 SMART FAMILY INTERFACE IS APPROVED BY FACTORY MUTUAL AS INTRINSICALLY SAFE FOR THE CLASS I, DIVISION 1 GROUPS INDICATED WHEN USED IN CIRCUIT WITH THE BARRIERS AND CONVERTERS LISTED BELOW AND THE ROSE- MOUNT SMART FAMILY TRANSMITTERS DEPICTED IN THE ACCOMPANYING CIRCUIT DIAGRAMS. APPROVED FOR BARRIER CLASS I MANUFACTURER MODEL DIVISION 1. GROUPS FOXBORO 2AI -I2V-FGB A,B,C,D 2AI-I3V-FGB 2AS-I3I-FGB 3A2-I2D-CS-E/FGB-A 3A2-I3D-CS-E/FGB-A HONEYWELL 38545-000-0110-113-F505 38545-000-0110-111/]12-F505 C,D MTL 115 A,B,C,D 122 322 715 722 R. STAHL 8901/3]-:199/100/7 8901/30-199/100/7 · 8901/31-280/165/7 C,D 8901/30-280/165/7 C,D 8903/5>200/050/7 A,B,C,D 8901/31-086/150/7 A,B,C,D E8901/3]-280/165/7 C,D 8901/31-086/150/7 C,D 9005/01-245/060 A,B,C,D 9005/01-252/100 A,B,C,D TAYLOR 5850FL81200 C,D 5851FL81200 1130FF21000 1130FF22000 1135FF21000 1135FF22000 · THIS DRAWING WAS CREATED ON CAD. DRAWING IS ARCHWED ON MAGNETIC TAPE FOR EGO CHANGES. ROSEMOUNT' ""'* "°'"°"" C~-.I 12001 Technologg Drive UNLESS OTHER'~.'rSE SPECiFIEG CONTRACT NO. ~I~u~el Eden P,'air~e. ~ 55344 USA DIMENSIONS IN INCHES. YaIve~ REMOVE .ALL BURRS AND s.A,,,.E,~oEs. M,,c..,,EDR. INDEX OF I.S. BARRIER SURFACE FINISH 125 MIKE DOBE 2/7/90 TITLE -~DLE.A,c~-c.,<'~ SYSTEMS FOR HOD. 268 .E~,.~L~.RA¢,o.sA~P'D.,,:..:,....~.0~,,~,~0SMARTFAMILYINTERFACE .xt.l +.1/32 ,xXt.02 ANGLES SIZE L FSCM NO ] DWG NO. -×××'--""' " A 00268-0031 APP'u. COVT. I I DO NOT SCALE pRINT SCALE WT. SHEET i OF 7 FORM NO 60651A-1 REV, C D-11 ' ' · ml T' I I HO~ITIOUfll. MOgUl I I0 I ol!ltlrt r'reBI~ure I r~ln8mluer~ REVISIONS REV DESCRIPTION CHG. NO. APP'D [ DATE H 653145 ENT]TY CONCEPT APPROVALS THE ENTITY CONCEPT ALLOWS INTERCONNECTION OF INTRINSICALLY SAFE APPARATUS TO ASSOCIATED APPARATUS NOT SPECIFICALLY EXAM]NED IN COMBINATION ~S ~ SYSTEM. THE APPROVED V~LUES 0F M~XIMUM OPEN CIRCUIT VOLTAGE (VT O~Vo~O~ ~ND MAXIMUM SAFE ZNPUT VOLTRGE (VN~x), H~X~HUN S~FE INPUT CURRENT (~N~x)~ND HAX~HUH S~FE ZNPUT POWER (PN~x)OF THE ]NTRZNS]C~LLY S~FE APPARATUS, ZN ~DD]TZON, THE ~PPROVED H~X]HUN ~LLOW~BLE CONNECTED CAP~CZT~NCE (C~)~ND ~NDUCT~NCE (L~) OF THE ASSOCZ~TED APPARATUS HUST BE GRE~TER TH~N THE N~XZNUN UNPROTECTED ZNTERNAL C~PACZTANCE (Cz)~ND ZNDUCTANCE (L~)OF THE ZNTRZNS]CALLY S~FE ~PP~R~TUS. THE ~PPROVED ENTITY CONCEPT P~R~METERS ~RE ~S FOLLOWS: ~RE ~S FOLLOWS: NOTE: ENTITY P~R~METERS LISTED ~PPLY ONLY TO ASSOCIATED ~PP~R~TUS WITH LINEAR OUTPUT. INPUT PARAMETERS (CLASS I. DIV. 1, GROUPS A, B, C, D) Vmax: 32 Vdc VT or Voc of beltPier must be < 32 Vdc Imax: 186 mA IT or Isc of barrier must be < 186 C1 = 0.B1 ~[F CA Of be)Prier must be > 0.01 L1 = 1.1 mH LA OF harPlet must be I 1.1 mH Pmax: 1.1W 0.8W 0.6W Voc x ]sc of barrier must be _< specified 4 v~lue. Temp code T4A T5 T6 OUTPUT PARAMETERS Voe: 1.5 Vd.c. Isc = 27 mA CA: 10,000 ~F LA: 46 mH Rosemount Inc. 12001Technology Drive THIS DRAWING *WAS CREATED ON CAD. DRAWING IS Eden Prairie. MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR EgO CHANGES. SIZE: FSCM NO I DWG NO, DR. D.P.A.~ A 0 0 2 G 8 - 0 0 3 1 ISSUED SCALE N/A [wT. [SHEET 2 OF 7 FORM NO. 60651A-1REV. C D-12 I" i ~r' i' I I I Appendix D ~J~ REVISIONS REV DESCRTPT]ON CHG. NO. APP'D DATE M 653]45 HAZARDOUS AREA NON-HAZARDOUS AREA BARRIER POWER OR CONVERTER SUPPLY ROSEMOUNT SMART TRANSMITTER ~ ~ i · - MODEL 288 ROSEMOUNT SMART TRANSMITTERS MODEL 1151 SMART MODEL 3051 MODEL 3051C, 3051P, 3051L, 3051H, 3051CA MODEL 3044 MODEL 3044C MODEL 3001C, 3001CL, 3001CH MODEL 3311 MODEL 3001S, 3001SL, 3001SH MODEL 3095 UP TO FOUR MODEL 751 INDICATORS MAY BE WIRED IN SERIES WITH THE TRANSMITTERS SHOWN ABOVE AND MAY BE LOCATED IN EITHER THE HAZARDOUS OR NON-HAZARDOUS AREA Rosemount Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden Prairie, MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. SIZE FSCM NO DWG NO. DR. ..,,,...,so~ A 0 0 2 6 8 ' ~ 0 3 1 ISSUED SCALE N/(~ IWT. [SHEET 3 OF 7 D-13 I ! I II [ T I Rosemount MOOel 1101 bmBrl rressure lensmillers REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE M 653145 THE MAXIUH ALLOWABLE CONNECTED INDUCTANCE (La)OF THE ASSOCIATED APPARATUS IS DETERMINED BY ADDING 27 mA TO THE Isc OF THE BARRIER (Im=Isc + 27mA AND ENTERING TABLE 1 (SHT 5) AT THE RESULTING VALUE, Ira, OR THE NEXT HIGHER VALUE OF Ira, TO DETERMINE THE Le~, (THE La MUST INCLUDE THE Lz OF THE MODEL 268, WHICH IS 1.1mH). EXAMPLE ~1: Isc OF BARRIER = 100mA. Im = 100mA + 27mA = t27mA ENTER TABLE AT Im = 130ma; L~ = 2.0mH --WARNING-- BEFORE CONNECTING THE MODEL 268 INTO THE LOOP, DETERMINE THE CONNECTED INDUCTANCE OF THE SYSTEM BY ADDING THE L~ OF THE TRANSMITTER, CABLE, AND MODEL 268. THE SUM MUST BE LESS THAN THE Le DETERMINED FROM THE TABLE IN ORDER FOR THE MODEL 268 TO BE CONNECTED INTO THE LOOP. IF THE CONNECTED INDUCTANCE IS GREATER THAN THE VALUE DETERMINED FROM THE TABLE, A BARRIER WITH A LOWER Isc MUST BE CHOSEN. EXAMPLE ~2: BARRIER ISC = 41.8ma; BARRIER LA = 20.0mH IM = 41.BmA + 27mA = GB.Bmm; ENTER TABLE AT 70mA AND READ La = 7.5mH ADD CONNECTED INDUCTANCE OF SYSTEM: MODEL 268 L~ = 1.1mH MODEL 3051 TRANSMITTER Lz = 0.48mH INDUCTANCE OF LOOP WIRING 1.0mH TOTAL CONNECTED INDUCTANCE = 2.58mH TOTAL CONNECTED INDUCTANCE IS LESS THAN Le = 7.5 mH AS DETERMINED ABOVE AND IS ALSO LESS THAN THE BARRIER L,~. THE MODEL 268 MAY SAFELY BE CONNECTED INTO THE LOOP. IF THE MODEL 751 INDICATORS ARE USED, THEIR TOTAL INDUCTANCE (LABEL VALUE '" NUMBER OF INDICATORS)MUST ALSO BE INCLUDED. SIZE FSCM NO DWC NO. ...A.Du.oN A 00268-0031 SCALE N/A WT, ]SHEET 4 OF 7 ¢ fORM NO. 60651A-1REV, C D-14 I , Appencl~x D ~*~ REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE N 653145 Im (mA) Le, ()mH) 150 1.3 145 1.5 140 1.6 130 2.0 120 2.5 110 3.0 100 4.0 c~0 5.0 85 5.5 80 6,0 75 6.7 70 7.5 65 8.8 62 9.5 60 10.0 57 11.0 55 12.0 50 15.0 45 lc~.0 40 23.0 35 31.0 T ABLE 1 Rosemount Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden Prairie. MN 55344 USA ARCHtVED ON MAGNETIC TAPE FOR ECO CHANGES. SIZE F'SCM NO t DWG NO. DR. S..AR,~USO~ 3~J.L .. A, 0 0 2 CO 8 ' 0 0 3 1 ISSUED SCALE N/A wT. SHEET- 5 OF 7 FORM NO. 60651A-1 RFV, C REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE HAZARDOUS AREA NON-HAZARDOUS AREA TAYLOR POWER 1152FZ81110 SUPPLY ROSENOUNT 3044A TRANSHITTER NODEL 2G8 ROSEMOUNT 3044A SMART TRANSMITTERS MAY BE PLACED IN A CLASS I. DIVISION I, GROUP A, B, C, D HAZARDOUS LOCATION AS SHOWN ABOVE. THE LOOP POWER IS LIMITED BY A TAYLOR 1152FZ81110 INTRINSIC SAFETY BARRIER. THE ROSEMOUNT 268 MAY ALSO BE CONNECTED IN THE LOOP AS SHOWN. FOR CABLE WITH CAPACITANCE OF GO pF/ft OR LESS ANO INDUCTANCE OF .2 uH/f~: OR LESS; CABLE LENGTHS OF UP TO 1600 FEET ARE ALLOWED. TRANSMITTER: ROSEMOUNT 3044A BARRIER: TAYLOR 1152FZ81110 COMMUNICATOR: ROSEMOUNT 268 CABLE: Cmax = 68 pF/Ft Lmax = ,2 uH/Ft MAX, LENGTH = 1600 ~t Rosemount Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden Prairie. MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. SiZE FSCM NO DWC NO. D~. C. SCR,.~.R ,~,~,,'~. A 00268-1ZIIZI31 foRM NO. SOSSlA-, REV. C ISSUED SCALE N/A i wT- J SHEET 6 OF 7 D-16 1 ! "' I: I I · )~pptlllui&u REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE N 853145 HAZARDOUS AREA NON-HAZARDOUS AREA T IBARTIER · OR · POWER · · CONVERTER · SUPPLY SYSTEM ! ! ! MODEL 268 CONNECTION FOR LOW POWER VERSIONS OF THE FOLLOWING ROSEMOUNT SMART TRANSMITTERS MODEL 3051C, 3051P, 3051L, 3051H, 3051CA MODEL 3001C, 3001CL, 3001CH MODEL 3001S, 3001SL, 3001SH Rosemount Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden Prairie. MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR EGO CHANGES. *- SIZE FSCM NO ]DW"'G NO, ISSUED SCALE N/A wT. SHEET 7 OF 7 FORM NO. 60651A-1 REV. C D-17 I I i ii l' I I t-'I~OHHIIc_ I ANY INF L)NMA 11UN 15 REVISIONS ~ CONTAINED HEREIN AND MUST BE HANDLED ACCORDINGLY REV DESCRIPTION CHG. NO. 4PP'D DATE BY' _ _ _ DATE _ A NEW RELEASE 654533 e.u. ,n.x.3 B CHG Vmax & C~ 657178 ~.s.L ~,,~s t THIS DRAWING WAS CREATED ON CAD. DRAWING IS ARCHIVED ON MAGNETIC TAPE FOR EGO CHANGES. ROSEMOUNT' -"-"' ,o..mo.n, c~-vo] i2001 Technology ~lve ~L~SS OTHERWISE SPECIFIED CONTRACT NO. ~.~c.~ Eden P~a~r~e, NN 55344 USA DIMENSIONS IN INC~S, REMOVE ALL BURR5 AND ~"""~'~'~"'~ ~- INDEX OF [.S. BARRIER SURFACE FINISH 125 C. SC~]BNE~ 6/2/93 TITLE -~"~- ~'~' SYSTENS FOR HOD. 275 o~,.~ ~.~,o~~,.o.,~-,~,'~"'~HART e COMMUNICATOR .xf.l .xxbeZ ANGLES SIZE ~ FSCM NO [ DWG NO, .,-,.,,, ,,. 88275-8881 DO NOT SCALE PRINT SCALE Wl. SHEET D-18 i ' 'i ! ..... 1' I I ! HEV[SIUNb REV DESCRIPTION CHG. NO. APP'D I DATE B 657178 FM ENTITY CONCEPT APPROVALS THE ENTITY CONCEPT ALLOWS INTERCONNECTION OF INTRINSICALLY SAFE APPARATUS TO ASSOCIATED APPRATUS NOT SPECIFICALLY EXAMINE0 IN COMBINATION AS A SYSTEM. THE APPROVED VALUES OF MAXIMUM OPEN CIRCUIT VOLTAGE (VTOR rOE)AND MAXIMUM SHORT CIRCUIT CURRENT (ITOR ISC)FOR THE ASSOCIATED APPARATUS MUST BE LESS THAN OR EQUAL TO THE MAXIMUM SAFE INPUT VOLTAGE (VMAX)AND MAXIMUM SAFE INPUT CURRENT (IMAX)OF THE INTRINSICALLY SAFE APPARATUS, IN ADDITION, THE APPROVED MAXIMUM ALLOWABLE CONNECTED CAPACITANCE (CA)AND INDUCTANCE (LA)OF THE ASSOCIATED APPARATUS MUST BE GREATER THAN THE MAXIMUM UNPROTECTED INTERNAL CAPACITANCE (C])AND INDUCTANCE (Li)OF THE INTRINSICALLY SAFE APPARATUS. THE APPROVED ENTITY CONCEPT PARAMETERS ARE AS FOLLOWS' NOTE: ENTITY PARAMETERS LISTED APPLY ONLY TO ASSOCIATED APPARATUS WITH LINEAR OUTPUT. INPUT PARAMETERS (CLASS I, DIV. 1, GROUPS A, B. C. D) Vm~x = 3~ Vdc VT or Voc o~ barrier must be (_ 30 Vdc Im~x = 30B mA IT or Isc o~c barrier must be (_ 300 mA Cz: 0.07/~F CA of b~rrLer must be Z 0.07/~ F Lz: 0 mH LA o~ barr~er must be Z 0 mH OUTPUT PARAMETERS Voc = 1.7 Vd.c. Isc = 32 mA Rosemount Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD, DRAWING IS Eden Prairie, MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES, s,zE I "°' 00275-0081 DR. C. SCRIBNER A msuEo so~,E N/A J~. I~"EE~ 2 o~ G D-19 i m 'm ml l' I i Rosemount Model 1151 Smart Pressure Transmitters · REVISIONS REV DESCRIPTION J CHG. NO. APP'D J D(~TE ~iL ' B 657178 HAZARDOUS AREA NON-HAZ(~RDOUS AREA BARRIER POWER OR SUPPLY CONVERTER SMART ~___~ ' TRANSHITTER HODEL 275 Rosenlounl: Inc, 12001 Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden Prairie, MN 5534~ USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. SIZE ~ FSCM NO [ DWG NO. c. A 00275-0081 ISSUED scALE N/A iw~. IswEET 3 OF G D-20 I '1 II TT I T I REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE B 657178 7HE MAXIMUM ALLOWABLE CONNECTED INDUCTANCE (La)OF THE ASSOCIATED APPARATUS IS DETERMINED BY ADDING 32 ma TO THE isc OF THE BARRIER (Im=Isc + 32mA)AND ENTERING TABLE 1 (SHT 5) AT THE RESULTING VALUE, Ira, OR THE NEXT HIGHER VALUE OF Ira, TO DETERMINE THE L~o EXAMPLE ~1: Isc OF BARRIER : 180ma. (GROUP A) Im : 188mA + 32mA: 132m~ ENTER TABLE AT Im = 140mA; La: 1.68mH --WARNING-- BEFORE CONNECTING THE MODEL 275 INTO THE LOOP, DETERMINE THE CONNECTED INDUCTANCE OF THE SYSTEM BY aDDING THE Lz OF THE TRANSMITTER AND CABLE. THE SUM MUST BE LESS THAN THE La DETERMINED FROM THE TABLE IN ORDER FOR THE MODEL 275 TO BE CONNECTED INTO THE LOOP. IF THE CONNECTED INDUCTANCE IS GREATER THAN THE VALUE DETERMINED FROM THE TABLE, A BARRIER WITH A LOWER Isc MUST BE CHOSEN. EXAMPLE ~2: BARRIER ISC = 41.8ma; BARRIER LA: 28.8mH ]M = 41.8ma + 32mA = 73.8ma; ENTER TABLE aT 88mA AND REaD La = 6.BmH aDD CONNECTED INDUCTANCE OF SYSTEM: MODEL 3851 TRANSMITTER Lz = 0.48mH INDUCTANCE OF LOOP WIRING 1.GmH TOTAL CONNECTED INDUCTANCE = 1.48mH TOTAL CONNECTED INDUCTANCE IS LESS THaN La = mH AS DETERMINED ABOVE AND IS ALSO LESS THAN THE BARRIER La. THE MODEL 275 MAY SAFELY BE CONNECTED INTO THE LOOP. IF THE MODEL 751 INDICATORS ARE USED, THEIR TOTAL INDUCTANCE (LABEL VALUE ,' NUMBER OF INDICATORS)MUST ALSO BE INCLUDED. Rosemourn Inc. 12001Technology D~e THIS DRAWING WAS CREATED ON CAD. DRAWING IS Eden PrBirie, MN 55344 USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. SIZE FSCM NO I DWG NO. DR. - 00275-0081 ~SSOEO SCALE N/A [wT. S.EET 4 OF 6 D-21 '1 '!" T T' I REVISIONS REV DESCRIPTION CHG. NO. APP'D DATE B 657178 Im L~ (mH) (mA) GROUPS A & B GROUP C GROUP D 300 0.20 t.80 3.20 280 0.21 2.00 3.70 270 0.23 2,20 3,90 260 0.25 2.50 4.30 Z50 0.27 2.7~ 2~ ~.5~ 4.~ 7,2~ 12e 2.58 1~.~ 19.8B lee ~.~8 15.~ 28.5B 85 5,58 2~,88 39,3~ 75 6.78 25.B8 5D.5~ 7D 7,5~ 65 8.8~ 34,~ 67.18 62 9.58 37.DB 73.78 57 ll. BB 43.~8 87.18 55 12.BB 48,DD 93.5B 45 lq.8~ 70.~B 13q.4~ 4~ 23.00 87.~ 176.3B 32 36.8~ 135.8~ 274.8~ 28 46.~ 17~.B~ 358.4~ 1 Rosen~ount Inc. 12001TechnologV Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS 5dcn Prairic, MN 5~ USA ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. SIZE ] FSCM NO DWG NO. ~ssu~o D-22 I ':" i' I T I' tl~ REV DESCRIPTION CHG. NO. APP'D DATE B 657178 HAZARDOUS AREA NON-HAZARDOUS AREA BARRIER · ~R · POWER · · CONVERTER · SUPPLY SYSTEM T /=-~- ,j MODEL 275 Rosefl~oul~ Inc. 12001Technology Drive THIS DRAWING WAS CREATED ON CAD. DRAWING IS Edcn Prairic. MN 55344 USA ARCHNED ON MACNETIC TAPE FOR EGO CHANGES. SIZE L FSCM NODWC NO. ~' ~. ~,.,,~,, ~ ~ ~ A ~ ~ 2 7 5 - ~ ~ 8 1 D-23 PROPRIETARY INFORMATION IS REVISIONS ~ CONTAINED HEREIN AND MUST', BE HANDLED ACCORDINGLY REV DESCRIPTION CHG. NO. APP'D [ DATE BY DATE --., a NEW RELEASE 654533 CSA INTRINSIC SAFETY APPROVALS HODEL 275 CIRCUIT CONNECTION WITH INTRINSIC SAFETY BARRIERS "Exla" INTRINSICALLY SAFE/SECURITE :INTR]:NSEOUE HAZARDOUS AREA NON-HAZARDOUS AREA I I.S. LOAD POWER L__,,BARRIER SUPPLY CSA CERTIFIED INTRINSICALLY \ SAFE MODEL 3844 OR 3851 38446 38516 ~ \ 3851CA 3881C \ 7581 3851L T~ 275 \ 3851H 3851P INTRINSICALLY SAFE F R USE IN CLASS 1, D]VISON 1, GROUPS A,B,C AND D HAZARDOU~ LOCATIONS WHEN CONNECTED TO ESA CERTIFIED INTRINSIC SAFETY BARRIERS AS [NDICATED IN THE ABOVE CONNECTION DIAGRAM. CERTIFIED INTRINSIC SAFETY BARRIERS ARE LISTED BELOW, 30V MAX, 330 OHMS MIN 28V MAX, 308 OHMS MIN 22V MAX. 180 OHMS M]N THIS DRAWING WAS CREATED ON CAD. DRAWING tS ARCHIVED ON MAGNETIC TAPE FOR ECO CHANGES. ROSEMOUNT' "' ESS OTHERWISE SPECIF CONTRACT NO. C,,,t,-o] 12001 Techno]ogg Dr~ve ~,lgt~c~l Eden Prairie, NN 55344 USA RE VE ALL BURRS NO Slit, EDGES. U INE DR. C. SC:P~IBI"'~T:~,iE{ e/2/'~3 TITLE R s. cE.,,, ,2~ 275 CSA INTRINSICALLY - TOL CES - CHK'D GEe,,.,,, -,,o,,,s~,Pp'o. SAFE CONFIGURATION · SIZE FSCM NO DWG NO. A eez75-ee82 APP'D, COVT. oo .o'~ sc..E P.,.'r SCALENONEI~'L J S.E~T 10~ I D -24 Glossary Some of the terms used in this manual relate specifically to the operation of Rosemount transmitters, hand-held communicators, and other Rosemount products. The following list provides brief definitions. See the sections listed for additional information. Analog Output Trim Digital trim operation that allows adjustment of the output electronics to conform to the plant standard of current. Three types of analog output trim are available: 4-20 mA output trim, 4-20 mA other scale, and low power. Cloning Off-line operation that uses a HART-based communicator to copy configuration data from one transmitter to one or more other transmitters that require the same data. Commissioning Functions performed with the HART-based communicator and the transmitter that test the transmitter and test the loop, and verify transmitter configuration data. Configuration Process of setting parameters that determine how the transmitter operates. Damping Output function that increases the response time of the transmitter to smooth the output when there are rapid input variations. Descriptor Sixteen-character field for additional identification of the transmitter, its use, or location. The descriptor is stored in the transmitter and can be changed using the HART-based communicator. Digital Trim Format function that allows you to adjust the transmitter characterization for purposes of digital calibration to plant standards. Digital trim includes two separate operations: sensor trim and analog output trim. Failure Mode Alarm Transmitter function that drives the analog output to ajumper- selectable high or low value in the event of an electronics failure. Factory Characterization Factory process during which each sensor module is subjected to pressures and temperatures covering the full operating range. The sensor module memory stores data generated from this process for use by the microprocessor in correcting the transmitter output during operation. Full Trim Sensor trim function in which two accurate, end-point pressures are applied and all output is linearized between them. The selected end points should always be equal to or outside the LRV and URV. HART (Highway Communications standard that provides simultaneous analog and Addressable Remote digital signal transmission between control rooms and field devices Transducer) Protocol such as transmitters. All Rosemount SMART FAMILY products communicate using the HART protocol. Lower Range Limit (LRL) Lowest value of the measured variable that the transmitter can be configured to measure. G-1 Rosemount Model 1151 Smart Pressure Transmitters · Lower Range Value (LRV) Lowest value of the measured variable that the analog output of the transmitter is currently configured to measure. Multidropping The connection of several transmitters to a single communications transmission line. Communication between the host and the transmitters takes place digitally with the analog output of the transmitters deactivated. Reranging Configuration function that changes the transmitter 4 and 20 mA settings. Send Data HART-based communicater command that transfers configuration data from the hand-held communicater's memory to the transmitter memory. Sensor Trim Digital trim function that allows you to adjust the digital process variable reading to a precise pressure input. Zero trim and full trim are the two sensor trim functions. Smart Term used to describe instruments that are microprocessor-based and feature advanced communications capabilities. SMART FAMILY Rosemount pressure, temperature, level, and flow instruments with microprocessor-based digital electronics. Span Algebraic difference between the upper and lower range values. Tag Eight-character field for identifying the transmitter. The tag is stored in the transmitter and can be changed using the Model 268 Commanicator and the transmitter information function. Transmitter Address Unique number (1-15) used to identify a multidropped transmitter. Transmitters that are not multidropped have 0 as an address. Transmitter Security Jumper-selectable feature that prevents accidental or deliberate changes to configuration data. Upper Range Limit (URL) Highest value of the measured variable that the transmitter can be configured to measure. Upper Range Value (URV) Highest value of the measured variable that the analog output of the transmitter is currently configured to measure. Zero Trim A zero-based, one-point adjustment used in differential pressure applications to compensate for mounting position effects or zero shifts caused by static pressure. G-2 I '! i !l ] ] I Index A I= Board Spacers C-10 Access Requirements Electrical Housing 4-7, 4-8 Electrical Considerations 3-11 Circuit Side of Electronics Electrical Installation Environmental Housing 3-4 Considerations 3-11 Considerations 3-15 Exterior of Electronics Grounding 3-12 General Considerations 3-3 Housing 3-4 Power Supply 3-11 Hazardous Locations 3-15 Process Flange Orientation 3-3 Signal and Test Terminals 3-12 Mechanical Considerations 3-3 Terminal Side of Electronics Wiring 3-12 Mounting Bracket Options 3-10 Housing 3-4 Entity Approvals 5-2, 5-4 Mounting Considerations 3-10 Action Keys Environmental Considerations 3-15 Power Supply Load Hot Key A-6 Environmental Requirements Limitations 3-11 ON/OFF Key A-6 Mounting Requirements 3-7 Process Considerations 3-9 Up Arrow Key A-6 Exterior of Electronics Housing 3-4 Signal Wiring Grounding 3-13 Alphanumeric and Shift Keys B-6 Smart Retrofit Kit C-10 Amplifier Board Standoffs C-5 F Installation Diagrams Analog Electronics (Figure 12-1) C-3 Filter Terminal Blocks Impulse Piping 3-7 .Analog Electronics Assembly C-2 Installation 3-19 Integral Span and Zero Buttons 2-10 Approvals 5-2, 5-4 Full Trim 2-12 K 8 Function Keys Help Key A-7 Keypad Board Spacers C-10 Home Key A-7 Action Keys A-6 Brackets Functional Specifications 5-1 Hot Key A-6 Mounting Options 3-10 LCD Meter 3-16 C Gas Assembly 3-17 Calibrate the Sensor 2-12 Mounting Requirements 3-7 Certifications 5-2, 5-4 Grounding 3-12 Configuration 3-16 Characterization Effects on Accuracy for Fast Specifications 5-30 Before Characterizing the Sample Computers 3-14 Liquid Transmitter C-13 Transmitter Case 3-13 Mounting Requirements 3-7 Characterizing with a Model 275 Communicator C-13 H M Checking the Transmitter Maintenance Output 2-4 HART Communicater Circuit Side of Electronics Data Entry A-7, B-6 Reassembly Procedure 4-8 Housing 3-4 Hazardous Locations 3-15 Return of Material 4-11 Commissioning the Model 3051 with Header Board Connections Sensor Module Checkout 4-10 a HART-Based Communicator 2-3 (Figure 9-4) 4-11 Troubleshooting Symptoms and Commissioning the Transmitter on Housing Corrective Action (Table · the Bench 2-1 Electrical 4-7, 4-8 9-2) 4-3 Mechanical Installation Configuration Connecting Sensor 4-8 Considerations 3-3 LCD ,Meter 3-16 Sensor Removal 4-7 Model 1151 Analog Electronics Standard 5-8 Electronic (Figure 12-1) C-3 Connections Circuit Side 3-4 Mounting Bracket Options Electrical Housing to the Exterior 3-4 (Figure 4-2) 3-10 Sensor 4-8 Terminal Side 3-4 Mounting Considerations 3-10 Header Board (Figure 9-4) 4-11 Rotation 3-4 Mounting Requirements 3-7 Drain/Vent Valves 3-8 D I Impulse Piping 3-8 Dedicated Keys B-5 Impulse Piping 3-8 Taps 3-7 Digital Trim (Analog Output Trim Installation Diagrams 3-7 and Sensor Trim) 2-12 Installation 3-19 Drain/Vent Valves 3-8 I-1 I"It, IHIIII=I'LIIIL IVIIelLaI~I I I.~s I .__~1114:11 I. I"'llC~.b,:~lall~. Illlll.blllltl. lCfib, 0 S V ON/OFF Key A-6 Sending Data to the Transmitter 2-7 Vent/Drain Valves 3-8 On-line Configuration Sensor Transmitter Security 2-2 Connecting to the Electrical W Optional Plug-in Meter 4-10 Housing 4-8 Wiring 3-12 Options Removal from Electrical Signal Terminals 3-12 LCD Meter 3-16 Housing 4-7 Test Terminals 3-12 Sensor Module Checkout 4-10 p Header Board Connections (Figure 9-4) 4-11 7 Performance Specifications 5-7 Sensor Trim 2-12 Zero and Integral Span Buttens 2-10 Physical Specifications Standard Setting Output Units 2-5 Zero Trim 2-13 Configuration 5-8 Piping Setting the Loop to Manual 2-7 Impulse Piping 3-8 Signal Terminals 3-12 Power Supply 3-11 Signal Wiring Grounding 3-13 Smart Retrofit Kit C-10 Load Limitations 3-11 Software Defined Function Keys B-6 Process Considerations 3-9 Specifications and Reference Process Flange Orientation 3-3 Data 5-1 Process Sensor Body 4-6, 4-8 Functional Specifications 5-1 Process Variable 2-4 Model 1151.Transmitter Range Availability 5-1 · Fi Performance Specifications 5-7 Rangeability 5-1 Physical Specifications Standard Reassembly Procedure 4-8 Configuration 5-8 Connecting the Electrical Rangeability (Table 10-1) 5-1 Housing to the Sensor 4-8 Startup Electrical Housing 4-8 Testing Equipment and Loop 2-4 Optional Plug-in Meter 4-10 Steam Process Sensor Body 4-8 Mounting Requirements 3-7 Removing Power C-3 Removin-g the Amplifier Board T Standoffs C-5 Taps 3-7 Removing the Analog Electronics Terminal Block Assembly C-2 Removing the Sensor from the Elec- Specifications 5-31 trical Housing 4-7 Terminal Side of Electronics Reranging the Transmitter Housing 3-4 Terminals 3-12 Using the Integral Span and Zero Buttons 2-10 Signal 3-12 Retrofit Kit C-10 Test 3-12 Retro~tting the Model 1151 Trans- Test Terminals 3-12 mltter Transient Protection Installing the Board Installation 3-19 Spacers C-10 Transmitter Installing the Smart Retrofit Disassembly Kit C-10 Electrical Housing 4-7 Model 1151 Analog Electronics Process Sensor Body 4-6 (Figure 12-1) C-3 Removing the Sensor from Removing Power C-3 the Electrical Housing 4-7 Removing the Analog Electronics Transmitter Exploded Assembly C-2 View 4-6 Return of Material 4-11 Range Availability (1151) 5-1 ReviewingTransmitterConfiguration Security 2-2 Data 2-4 Transmitter Case 3-13 Rotating Housing 3-4 Troubleshooting Symptoms and Cor- rective Action (Table 9-2) 4-3 Rosemount Inc. Fisher-Rosemount Limited Fisher-Rosemount 8200 Market Boulevard Heath Place Singapore Pte Ltd. Chanhassen, MN 55317 USA Bognor Regis 1 Pandan Crescent Tel 1-800-999-9307 West Sussex P022 9SH Singapore 128461 Telex 4310012 England Tel (65) 777-B211 Fax (612) 949-7001 ~ Tel 44 (1243) 863 121 Fax (65) 777-0947 © 1999 Rosemount Inc. Fax 44 (1243) 867 5541 TIx RS 61117 FRSPL http://www. rosernoun t. Corn It IIIIIIllllBllffillilllltlllll Ill ilROSEMOUNT' 00809-0100-4593 Rev. BA 3/99 FISHER-ROSEIIIIINT,MaBagingTbe Process Better: I ] '1" 17' [i' [' [ DATA SHEET 320.015 ISSUED 6/1/86 Stahc Pressure Transmitters. Switches, or Gages Consolidates multiple actions MODEL and fittings ~nto one, compact umt Again PRESSURE TRANSMITTER MANIFOLD D/A has combined ruggedness, durability, simplicity, and usabiHty into another superior product. ......... ,.: ~"' · .-' ......L,~~"~ %, ~ LARGE, RODDABLE -"' ......... ~.,.-,. .F 1/4" process po~s. ':' PVC COATED ARROW : '~ 3/16" inst., test and HANDLE with spring-loaded : ~ bleed po~s. locking device to ELIMINATE :l~l.~k ~ -~ switching from normal position. This comfortable handle allows switching ~....~ to block or calibrate positions with a '- ""' simple 90 degree turn. .~ ALL PARTS :~ ..... &~..:~=~ Replaceable in-line. ~ - ~ ~ ~ _ ,,,~:~ 9/32" MOUNTING HOLES with '- convenient '3/4" spacing enables '- '~. you to mount the PTM6 to most ' standard mounting brackets. '" ~:' ...... :,~ ~ .... ~ ., ~ ~'L / :' ' ' ~, ,.~:~ ~:;:.:,~.:' INTEGRAL BLEED VALVE .... ' .... ' allows venting with , ..~. ': :.~,, handle in any position. 3/8" HEX ~;-:., ~: ,~..~ ~, ~ STANDARD 1/2" NPT .~, ......... connections adapt to most "' , ' "~,~':,~ ~.,..~..~"' '~.--......-, ,,., ........~'-' existing systems. :%.: .,>~-'~':"~'.:.%~,. c~':r~'> ",' ~-~'~ Neatly BEVELED CORNERS /-,- help give your installation '~' ........... ~ the PROFESSIONAL look. ~',~,~ ~ ..... ~ .-~ ~.-.~ ~ .... ~ ~, .... ~ ~ ..... ~,.-m~~~.~-~.,r. . ~.,,.-.~,...~,~..f ....~- BODY: 316SS or nickel plated ' . '~"::' *~':'*:.~. . WETTED PLUG: 316S. S.R C f ':~,~ PLUG LINER: Teflon or yton rein orced Teflon" FACE SEALS: Ryton reinforced Teflon ,:~ NON-WETTED TRIM: 303S.S. ' 3azs" HANDLE: PVC coated with spring loaded locking device~ INTEGRAL BLEED VALVE: 303 S.S. NAMEPLATE: S.S. embossed ~"'- Consult your D/A representative for exotic ::~. PROCESS ~ ~ ~ INSTRUMENT ,.~ materials Of construction Or special requirements /~' .~ MAX. PRESSUREREMPERATURE RATINGS , ~ TEFLON: 15~ PSI ~ 22~ F :'~ manifold operating temp. exc~ds 10~ F) ~' MOUNTING OPTIONAL HOLES Ratings are for main process block valve ~ ~ ~f CONNECTIONS 1/2" fnpt process, inst. and test OPTIONS ~.~ AFI Adaptor Flange connector converts 1/2" fnpt inst. connection to flanged connection. 1/2" fnpt Additional Outlet for pressure gauge, ~ Mounting Bracket for field mounting to 2" pipe. '~ · ~ 1/4" fnpt Side Purge connection at process. e 3.500" ~ :~% OPERATION ~; -.- O NORMAL MODE TEST/CALIBRATE MODE ISOLATION MODE ORDERING ........... ,'j Shipping weight: 3 IbS. PTM6 - T - SS - MODEL [ PLUG LINER .~.~ Rylon relnlor~ Tell~ ...........R ~DY .. :~. s~s s.s. s C.S. C PLUG 16 S.S. S AFI ~.:, AO . . ............................................... i I I WHAT IS SADDLEpAK ? SADDLEPAK is a modular support system for fie/d- mounted . : instrumentation. It " is easily assembled i ' WHY USE SADDLEPAK? duplicate any REDUCE ENGINEERING TIME mounting deta~. :. ; · Cataloged components eliminate design details. ~ -- . . · Consistentqualityproduct. The system is ' ' · Engineered and tested modules. SADDLEPAK is a comprised of components which tested product. are combined to construct a :, · Fault tolerant. support. ff you do not find a standard component to meet your -; REDUCE FIELD TIME specific needs, we can fabricate,, · A vailable from stock. one to fit your appficafion. , · Modular construction permits changes to accommodate field conditions. · Eliminate field welding. · Minimize field installation time. EXCELLENT CORROSION RESISTANCE · lOyearreplacementguarantee. ·Sealed components eliminate tt)e potential of corroding from the inside out. HIGH QUALITY PRODUCTS ·/SO 9000. · SADDLEPAK is a technically superior product. Eve~ O'Bden SADDLEPAK has been Mounting slots are more tolerant of Compression washers keep the cables tight designed and tested right down to the set misplaced concrete anchors. Eve~ aspect during temperature shifts. Grooved seat screws. The reverse knuded cup point set of SADDLEPAK design creates a technically wire rope clips secure the cable to the screw pro vides more biting sudace and superior product. base. Base plates are ~" steel sheared and acts as its own lock washer. ~' formed into a channel to provide gripping edges on the process line. HOW TO ORDER SADDLEPAK DETERMINE HOW YOU WILL MOUNT THE SUPPORT · Choose from floor, wall, cable or U-bolt mounts. SELECT A PRIMARY MOUNT · Primary mounts may be used individually or in comb/nation with Secondary Modules. SELECT SECONDARY MODULES · Secondary modules are often added to the Primary Mount to build more complex instrument supports. SPECIALS SIZES AND LENGTHS Sizes and lengths shown in the catalog are for standard components. We can also create nonstandard components to meet your specific needs. FINISHES All the products shown in this catalog have been protected with our standard Zinc Arc Spray Metallizing. We also offer most products on special order with a zinc plated yellow dichromate dip, aluminum metallized, galvanized or painted finish. SADDLEPAK can also be supplied in stainless steel and in design~ to meet sanitary application requirements. ; i !: FLOORSTANDS All floor mounts have a ~A" thick steel 10" X 10" base plate and are slotted to accept up - to W' mounting bolts on 8" to 6" centers. Two 8" gussets are welded to the base plate and extension, significantly increasing the bending moment of SADDLEPAK floorstands. WALL MOUNTS Wall mounts have a W' thick steel base .~-~, plate to clamp, bolt or weld to a vertical surface. The KM and K24M Hand Rail Clamp can be used with a wall mount to eliminate drilling or welding in the field. U-BOLT MOUNTS The U-bolt mounts secure the instrument support to process lines from 1" through -' 36" in diameter. Restrictions against welding onto process lines make U-bolt mounts an alternative solution. The prefix to the model number designates the required process line size in inches. CABLE MOUNTS Similar in application to the U-bolt mounts, cable mounts use a pair of high-tensile strength cables to secure the instrument support to process lines from 3" through 36" in diameter. Each strand of the cable is individually galvanized to provide maximum corrosion protection. The cables are secured to the base plate with grooved seat wire rope clips. The 5,~,, NC fitting swaged to the end of the cable is used to tighten the ....... cable around the process line. AISI 6150 calibrated compression washers insure that Models FP40, FP52, 3FP52, F$52 and 32FP52 the cable stays tight during ambient and Standard heights are 40" and 52" as designated in the model number. Nonstandard sizes process line temperature shifts. can be ordered by designating a different length in the model number. Two cable lengths are available: FP40 and FP52 50" for 3" to 14" line sizes is standard Standard 2" pipe mounts. The 40" high Standard is ideal for mounting VIPAK instrument 120" for 3" to 36" line sizes enclosures. The 40" floorstand is normally used as the base for dual or triple mount Type 300 Series stainless steel cables are stands. The. 52" floorstand is recommended for typical instrument mounting or when a also available for additional corrosion partial enclosure such as a HEATPAK, HEATPAK II or FLEXIBLE HEATPAK is used. protection. 3FP52 A 3" pipe stand. It provides added support for very large and heavy equipment. FS52 Has a 2" square extension. Use with "A" series Secondary Support Modules to mount a group of instruments on one pedestal with complete vertical adjustability. 32FP52 Combines the added strength of the 3" pipe stand and the versatility of a 2" pipe mount. Reusable Flexible Insulation for Industrial Equipment Requiring Periodic Access and Maintenance Save TIME, Save ENERGY, Save MONEY, Specify FLEXPAK Here are 10 Good Reasons why! · Winterization Withstands · · Prevents Temperature Freezing Extremes · Reusable Craftsmanship · · Retrofit Custom · Applications ;. Tailored ;.. Appearance · Reduce Heat Loss ~. Chemical · Resistance · Increase Energy Savings ~. ~. Acoustical · · Standard Deadening and Designs are Easy Vibration to Order Resistance · Lightweight Personnel * · Easy Installation Protection Applications 1 Pressure Transmitters ' 2 Level Controllers 4 Vodex Flowmeters Transmitters - Transmitters ?;": " 9 Level Gages 10 Gage Pressure 11 Pressure Gauges 12 F l a n g e s 13 Rotometers ~ 8 ~ ' ~ · :. ~=~.~- ....' 14 Flanged Level 15 Site Flow Indicators~""' 17 Controllers ::-. · .... 18 Level Switches"' 19 Steam Traps For more details refer to O'Brien bulletin APBR-6 for a list af over 400 specific applications, each referenced by individual manufacturer - and model number. Features Specifications MATERIAL OPTIONS MISCELLANEOUS OPTIONS ~ LINER &JACKET (inner &outer layers of fabdc) Drain grommets, wind flaps with drawstrings and ~- Si icone impregnated fiberglass (to 500°F), Teflon windows are just a few of the many options un,tmated woven fiberglass (to 1000°F), and available with Flexpak enclosures. FREEZE WITHSTANDS TEMPERATURE stainless steel wire mesh (to 1200°F). PROTECTION EXTREMES i INSULATION Choice of thickness from 1/2", 1", Flexpaks protect critical Flexpaks withstand equipment or ambient 2" or 3". Available materials include SUPPORT EQUIPMENT a non- process instrumentation temperatures ranging from -65°F(-54oC) to hygroscopic low temperature insulation (to 250°F), . O'Brien's line of Saddlepak® _~ from freezing. Flexpak 1000°F (534°C). Quality and durability are Type E glass fiber fabricated in mat form with low enclosures are excellent available in a choice of materials to handle your chioride level and no resinous or organic binders (to ~ are available to complement I weather barriers, and will needs. 1200°F). needled ceramic glass mat with no organic I · lji' Flexpak enclosures by pro- maintain proper heat for specific operating condi- binders (to 1400°F), elevated temperature fiberglass viding strong modular sup- tions when combined with steam and electric blanket (to 500°F). All insulation is asbestos free. ~ ports for a wide variety of heating systems available from O'Brien. REDUCED HEAT LOSS industrial equipment. Flexpaks prevent exces- ~ ~ ~ ~- FASTENING TECHNIQUES sive heat loss from high ,~~~ Three basic methods are available including hook SERVICE TEMPERATURE CRAFTSMANSHIP I I I I I I I I temperature equipment. "/,//~'~,~~ and loop, stainless steel lacing hooks, and cinch Design combinations are available to Withstand Flexpak's quality appear- ~ ance, fit and performance ["~1 The resultant energy j; ~ ~ b~ts. temperatures from -65°F(-54°C) to 1000°F(534°C). are beyond equal. Each savings can typically , In certain situations, the use of any insulation can Flexpak enclosure is pro- generate a payback of ENGINEERED HEATING SYSTEMS increase equipment body temperature which could duced from computer gen- several months. As a Steam and electric heating systems are available possibly result in equipment failure or leakage at erated patterns providing ~ customer service, O'Brien fQ~ a wide variety of industrial equipment. These flange connections. an exact fit for each application. can provide a detailed s~stems are thoroughly designed to meet all codes Consideration should therefore be given to the heat loss analysis for specific site conditions. and are tested in O'Brien's environmental chamber maximum operating temperature of equipment, the to insure proper heat for specific operating proper metallurgy of bolts, sufficient pretorqueing of CHEMICAL RESISTANCE conditions. bolts and nuts, and possible retorqueing when at Flexpak insures instrument protection in even theRETROFIT APPLICATIONS operating temperature. most corrosive industrial environments. A choice Flexpak is an ideal solution for enclosing and Proper installation procedures will make it possible of materials is available depending on the protecting existing field mounted equipment. Its to use Flexpak insulation without the inconvenience requirements for your particular application. flexible construction enables installation around and expense of equipment failure and resultant existing pipes, conduit and accessory items. down time. EASY TO ORDER How To Order Flexpaks are easy to order. An extensive list ofPERSONNEL PROTECTION Tefion is a registered trademark of the E.I, DupontCompany. standard designs for common applications saves ordering time. Off the shelf, quick delivery at an ~ Flexpaks provide added personnel safety in high economical price make Flexpak a truly competitive ' · Specify the device to be covered, giving the areas because traffic insulation method. ' manufacturer and model number. ..___. ,---- exposed high temper- ature surfaces can be Specify what portion of the device is to be covered or enclosed. covered and any special requirements or EASY conditions. INSTALLATION ~ Specify the operating temperature, the insula- tion thickness and the materials of construction easy to install, and that ACOUSTICAL DEADENING and required for the Flexpak. saves installation time. In VIBRATION RESISTANCE most cases a Flexpak can Flexpak enclosures provide a significant decrease be installed by one man in in noise level. Due to its flexible, pliable design, Maj~ufactured under license in: Bulle~n FPBR-3-5 Canada/CB Engineering Lid No 1 - 6320 - 11 lh St S E CalgaW Alberta T2H 2L7 403-259-6220 October 5, 1988 minutes compared to the hours required for Flexpak can be used on vibrating equipment where UnWed Kingdom/O'Brien Pr~:l~-t;s Limited Forcom'H~u~,L= Maryl~r~d Road. London E15 1JW 0-1-555-5437 Replaces FPBR-3-4 conventional rigid insulation. other types of insulation will break down. WestGermany/Synlhetica Wilhelm Muller'~mbH & Co KG', Posffach 258, D-5990 Altena 1(0 23 52)2 50 14/15 dated May 5, 1987 O'Bden Corporation · 1900 Crystal Industrial Ct. · St. Louis, MO 63114 · Phone 314/423-4444. Fax 314/423-1144 Pfices/Specifr,,ations subject to change without notice. ASHCROFF' Pressure, Temperature, Control Instrument Ordering Handbook General Service Gauge Meeting the requirements of many industrial applica- tions, General Service Gauges may be used on steam boilers or other pressurized vessels; on pumps and '~" ' '~"" compressors; on many types of industrial machinery; in the chemical, petrochemical and allied process indus- tries; in power plants; in pulp and paper mills. For low pressure applications gauges with a bellows pressure element are available. Two distinctly different pressure elements comprise the Ashcroft General Service Gauge line. First is the stand- ard Bourdon tube, engineered to precise tolerances, for consistent repeatability and response to pressure ___~ fluctuations. The choice of metals includes: bronze, alloy .... \ ....... steel, AISI 316 stainless steel, and Monel, for ranges up ----___ to 20,000 psi. ; .... self-draining bellows. Gauges with bellows pressure / '~ Type 1189 elements are used for air, gas or liquid service, in pressure ranges from 10" water to 10 psi and vacuum ! ranges from 10" water to 20" mercury. Bellows mate- rials include brass, monel, and AISI 316 stainless steel. Case styles are described below. All are open front /. construction '., Type 1009 - , .- -,~. Polished stainless steel case and bayonet lock ring in ""\-- -~' ......... 21/2'', 31/2'', 4V2" and 6" sizes. Maximum corrosion Type 1017/1187 resistance. Available for stem, surface, or flush Black, phenolic turret cases in 4V2", 6", 8V2" sizes, with stainless steel snap ring. Lightweight, offers high resist- ance to corrosion. Stem or surface mounted; can be flush panel mounted with an accessory ring. Type 1189 Aluminum case with threaded aluminum ring. Case and ring are black epoxy coated. 41/2" and 6" sizes. Stem, surface, or flush mounted. ': Type 1010 , Type 1188/1220 Aluminum in 41/2'' and 6" sizes; cast iron in 81/2" and 12", friction steel ring. Black epoxy coated. Stem, surface, or flush mounting: lower and back connection. Type 1017/1187 Aluminum case in 41/2'', 6" and 81/2'' sizes, with steel ring hinged at top, retained by a clamp screw at the bottom ..... Case and ring are black epoxy coated. Flush mounted, . I back connection only. IL.- ~ 150 II" :'. , All cases are provided with pressure relief discs as Type 1010 5 5 standard construction. ' For additional information refer to Bulletin GS-1 L50~0,5~_.....:::. ~, :IS 275 ;' '.' . General Service Gauge (Bourdon Tube Type) To Order A Gauge: 41/2" 1009 S 1/;NPT BackConn, w/"U'Clamp 0/2000psi Select: I ~ 1, Dial Size -- Table A 2, Case Type Number- Table A 3, Boutdon System Selection (ordering code) -- Table B 4. Connection: Location -- Table A: Size ~ Table B 5, Mounting Accessory or Variation (if required) -- Table A 6. Range -- Table C 7. Accessories and Optional Feature -- pages Table A -- Case Selectjoe Style Ceee Type DIal Size Case: Mateebl Ring: Materhal Mouedktg and Number (IN:bee) Firdab ~ Comectkm 1009(*)'~ 2'~,, 3'& 4,& 6 Stainless Steel Bayonet lock Slem--lowerorback Polished Stainless Steel Surface- lower Polished wall mounting bracket: specify XBF back flange (2V2' & 3V2"): specify XFW Surface-- back wall mounting braket (4i/2"): specify XBF back flange (21/2'' & 31/2"): specify XFW Flush -- back front flange :specify XFF U-clamp: specify XUC 1010(*) 41/2, 6. 81/2. 12 Aluminum: 41/2.6 Slip Stem- lower or back Cast iron: 81/2 12 Steel Surface -- lower or back Black Epoxy Coated Black epoxy Flush- back: specify X20 1017(*) 41/2, 6 Aluminum: 41/2.6 Hinged Flush -- back connection only Black epoxy coated Steel Black epoxy coated 1220(*) 41/2, 6, 81/2 Phenol Snap Stem --lower or back Black Stainless Steel Surface -- lower or back Flush-back: order e 1278 mounting ring (*) Bourdon tube ordering code from Table B. ' ~available liquid filled -- see liquid filled gauge section page 12. Table B -- Bourdon System Selection (Ordering Code) Bourdon Tube and Tip Material Range Ordering (all joints TIG Socket Tube Selection NFT Code welded except "A") Material Type Limits (psi) Connection® A Grade A Phosphor Bronze Brass Drawn 12/1000 Tube -- Brass Tip, Silver Brazed C-Tube B AISI 4130 alloy steel AISI1019 steel Drawn 15/1500 C-Tube Drawn 2000/5000 Helical R AISI 316 stainless steel AIS11019 steel Drawn 15/1500 C-Tube Drawn 2000/20,000 Helical S AISI 316 stainless steel AISI 316 stainless steel Drawn 15/1500 C-Tube Drawn 2000/20,000 Helical SW'3' AISI 316 stainless steel AISI 316 stainless steel Drawn 15/600 '/. C-Tube Drawn 800/15,000 Helical P"~ K Monel Monel 400 Drawn 15/1500 C-Tube Drawn 2000/20,000 Helical (1) For selection of the correct Bourdon System material. see Media Application Table on page 8, Bul. GS-1. (2) Optional connections available: 1/2 NPT where 'A NPT is standard, Y, NPT where ~,5 NPT is standard · (Not applicable to 2~,5'' and 3'/~" 1009: only available with % NPT.). (3) Available for 2~/5 and 3% 1009 SW only. (4) Use for applications where NACE standard MR-01-75 is specified. General Service Gauge (Bourdon Tube Type) TableC-- Standard Psi Ranges pressure (psi) compound figure minor figure minor range interval graduation range interval graduation 0/15 1 0.2 inches inches 0/30 5 0.5 mercury psi mercury psi 30" Hg Vac/0/15 psi 5 3 I 0.5 0/60 5 1 30" Hg Vac/0/30 psi 10 5 1 1 0/100 10 1 30" Hg Vac/0/60 psi 10 10 2 1 30" Hg Vac/0/100 psi 10 10 2 1 0/160 20 2 30' Hg Vac/0/150 psi 10 20 5 2 0/200 20 2 30" Hg Vac/O/300 psi 30 25 5 5 0/300 30 5 0/400 50 5 combination 0/600 50 10 0/800 100 10 range figure interval minor graduations 0/1000 100 10 inner outer 0/1500 200 20 scale scale feet feet 0/2000 200 20 psi feet water psi water psi water 0/3000 300 50 0/15 0/34 3 5 0.5 1 0/30 0/70 5 10 0.5 1 0/5000 500 50 0/60 0/140 5 20 I 2 0/6000 1000 1 O0 0/100 - 0/230 10 20 1 5 0/7500 1000 100 0/160 0/370 20 50 2 5 0/200 0/460 20 50 5 5 0/10,000 1000 100 0/300 0/690 25 50 5 10 0/15,000 2000 200 0/20,000'~ 2000 200 retard '~> Not available in 21/2'' and 31/2'' sizes. dial size (inches) range vacuum I figure minor 41/2 0/15 psi retard to 30 psi 10" hg Vac/5 psi retard to 30" Hg range interval graduation 0/30 psi retard to 60 psi and to 15 psi 30-0 5 0.5 Accuracy-- Grade A (ANSI B40.1 ) --2/1/2% inches inches inch Mercury Standard Metric Ranges RANGE DIAL GRADUATIONS RANGE DIAL GRADUATIONS Outer Scale kg/cm~ when dual (Kilograms per figure minor kPa figure minor range specifiec sq. cm.) bar interval graduation (kilopascal) interval graduation psi pressure 0/1 0/1 0.1 0.01 0/100 10 1 0/14 0/1.6 0/1.6 0.2 0.02 0/160 20 2 0/22 0/2.5 0/2.5 0.5 0.05 0/250 50 5 0/35 0/4 0/4 0.5 0.05 0/400 50 5 0/55 0/6 0/6 0.5 0.1 0/600 50 10 0/85 0/10 0/10 1 0.1 0/1000 100 10 0/140 0/16 0/16 2 0.2 0/1600 200 20 0/220 0/25 0/25 5 0.5 0/2500 500 50 0/350 0/40 0/40 5 0.5 0/4000 500 50 0/550 0/60 0/60 5 1 0/6000 500 100 0/850 0/100 0/100 10 1 0/10 000 1000 100 0/1400 0/1 GO 0/1 GO 20 2 0/16 000 2000 200 0/2200 0/250 0/250 50 5 0/25 000 5000 200 0/3500 0/400 0/400 50 5 0/40 000 5000 500 0/5500 0/600 0/600 50 10 0/60 000 5000 500 0/8500 0/1000 0/1000 100 10 0/100000 10000 1000 0/14000 _ vBcuum -1/0 -1/0 0.1 0.01 -100/0 k Pa 10 1 30/0' Hg _ compound -1/0/1.5 -1/0/1.5 0.5 0.05 -100/0/150 kPa 50 5 30" Hg/0/20 -1/0/3 -1/0/3 0.5 0.05 -100/0/300 kPa 50 5 30" Hg/0/40 -1/0/5 -1/0/5 0.5 0.1 -100/0/500 kPa 50 10 30" Hg/0/70 -1/0/9 -1/0/9 1 0.1 -100/0/900 k Pa 100 10 30" Hg/O/125 -100/0/1500 kPa 200 20 30' Hg/0/215 -100/0/2400 kPa 500 20 30' Hg/0/340 Thermazip Insulation Systems - . Thermazip is a unique concept in pipe insulation , design. It incorporates a protective outer jacket, -' -- , insulation and a locking closure into a one-piece ; \-. - ......... system which can be simply snapped around a pipe. '""'- ._ This locking trac is then permanently sealed with the '. ........ . ~ ~ . .~ ,. use of our "Fastener Weld" sealant. ~r high-tempera- Y --: '.._ . .-~_~ :~ .- ture, sanitary, or other special applications, an adhesive flap is incorporated into the jacket design. ' The Thermazip and Acoustazip insulation system is available in many standard jacket and insulation configurations to cover a wide range of insulation '--.. needs. Thermazip and Acoustazip insulation systems '- have been designed to provide you many years of our new TechLite® Hi-Temperature foam. Thermazip is available in maintenance free service. Each of our standard sheets for covering tanks and vessels. In addition, Thermazip pipe jackets is available with 3 different choices of insulation is shipped in convenient 40 fbot kits (104' sections) which insulation material; fiberglass, polyurethane foam, or include accessories at no extra charge. 1 O0 Series '- For Light Duty Applications on Hot and Cold Surfaces TMZ 150 Jacketed Flexlble Fiberglass Use on Temperatures to +400°F TMZ 175 Jacketed Flexible Polyurethane Foam Use on Temperatures from -65°F to +220°F TMZ 179 Jacketed Rigid or Flexible TechLIte Hi-Temp Foam Use on Temperatures from -320°F to +400°F Uses and Applicallons: Suitable for light duty indoor applications on both hot and cold sudaces. Chemical resistance, plus ability to withstand repeated cleaning with detergents, makes this an excellent product for use where a clean appearance is important. Thermazip 100 is used to insulate hot and cold pipes; control sweating and dripping pipes; protect personnel from burns; color code pipes, and control temperature of process liquids. Typical end users are: laundries, hospitals, schools, offices and commercial buildings. Available Forms: Available in standard 4-foot lengths or pre-cut to your specific""' Description: Thermazip 100 Series consists of foam or requirements up to 25 feet to fit pipe and tube sizes up to S inches. Polyurethane fiberglass insulation laminated to a lightweight reinforcedfoam insulation is standard in '/2, 1 and 1 '/2 inch thicknesses; fiberglass in 3/,, 1 and jacket. A patented locking trac. factory applied to the 1~ inches; flexible TechLite in '/2 and 1 inch; rigid TechLite in '/2, 1, 1'/2.2 and 3 iacket, is used to snap Thermazip on the pipe. inches and only in 4 foot lengths. Thermazip Jacket Specifications Series 400 JEkel De~:rlplion zn~ Sp~:lfi,--ali~n: ThermaziC, 400 jackal, is made ol a fiber,21ass ./: ~,~,. fabric imgregnated with nan-combustible, lully cured Hypa~on~. A white Tedlarf film is laminated lc one side. The [alat thickness Is .0]7 in:has. J Jacket I~at~rizl an~ Properti~ V~lu~ While Polyvinyl Fluoride Film .............................. 0015 inches · Hypalon® Coated Fiberglass Fabric ......................... I2 oz/sq yd : Total Weight ........................................... 18 oz/sq yd L.~ ........ Ambient Temperature Range ............................. -40°F to <-250°F Jacket with self*sealing lap Jacket with hook trak closure Tensile Strength ................................. Warp: 350 Ibs/in. rain . . ............ (cut strip method) Fill: 2500 Ibs/in. rain Tear Strength .......................................... Warp: 1600G Puncture Resistance (ASTM-D-1424-63) .................... 300 scale units Permeability (ASTM-E-96-A) (WVTR) ........................ 02 maximum Cold Crack ................................................. -50°F Flame Spread ................................................ 25 J~ckEI Description ~nd Specification: Thermazip 100 jacket is made of a strong . Fuel Contribute~ .............................................. 25 polyester scrim laminated between 2 layers of PVC which provides excellent Smoke Dovelope." ............................................. 50 resistance to chemicals. The total thickness is .016 inches. Standard color is white, but red, blue, yellow or green is available. Polyvinylchloride ......................................... 016 inches Polyester fabric ....................................... 11 x 11 scrim Jacket Description and Speclli:ation: Thermazip 500 jacket is made of a heavy Total weight ........................................... 10 oz/sq yd fiberglass fabric coated with a specially formulated temperature resistant Ambient Temperature Range ............................ +40°F to +150°F compound. It is aluminized on one side to reflect radiant heat and to serve as a T~.nsile Strength ..................................... Warp: 120 Ibslin vapor barrier. The to~al thickness is .025 inches. (Fed. Method 191, 5100) Fill: 80 Ibs/in Tear Strength .......................................... Warp: 24 Ibs Jacket M~terial and Properti,'~ Valu ""' (Fed. Method 191,5134) Fill: 25 Ibs High Tamp Coatin,3 ........................................ 003 inch , .old Crack (Fed. Method 191, 5204J .............................. +IO°F Aluminum ............................................... 002 inch~ Fire Hazard Classification ........................... Self Extinguishing Fiberglass Fabric ...................................... 18.5 oz/sq yd (Fed. Method 191, 59032) 2 sac. max Ambient Temperature Range (continuous) ...................... to +500"F Tensile Strength ..................................... Warp: 900 Ibs/in (MIL-C-20079E) · Fill: 780 Ibs/in 2 0 0 Fire Hazard ClassitS:arSon Flame Spread ................................................. 0 Jacket Description and Specifl:alion: Thermazip 200 jacket' is made of white Fuel Contributed ............................................... 0 poiyvinylchloride. Its smooth outer coating prevents harboring of germs or fungus. Smoke Developed .............................................. 0 Steam or chemical cleaning will not harm the material when properly used. The to~al thickness is .040 inches. J~cket Material ~nd Properties Values 600 Potyvinylchloride ......................................... 040 inches. Ambient Temperature Range ............................ +5[PFto+lSO°E JacketDe=criptjonandSpecificatiorcAcoustazipeOOjacketismadeofamass-loaded Tensile Strength ...................................... Warp; 3500 psi PVC compound with ultraviolet and flame retardant addStires. The white PVC Fill: 3100 psi exter or provides excellent chemical resistance. The tota! thickness is .095 inches. Tear Strength ....................................... Warp: 440 Ibs/in Fill: 395 Ibs/in Jacket Material and PrepcriSes Values. Cold Crack ................................................. +30°F Barium loaded polyvinylchloride ............................ 16 oz/sq ft Fire Hazard Classification ........................... Self Extinguishing Ambient Temperature Range .............................. O°F to ',200°F ASTM-D-2963 .............................................. Pass Tensile Strength ...................................... Warp: 79 Ibs/in CC-191 .................................................... Pass (FS-191 Method 5102) Fill: 83 Ibs/in Tear Strength .............................................. Warp: 8 (FS-191 Method 5134) Fill: 8 3 O 0 Fi re Hazard Classification ASTM 162 ................................................. Pass Jacket Description and Specification: Thermazip 300 jacket is made of a strong Federal Spec 191, Method 5903 ...................... Self-extinguishing polyester fabric impregnated with polyvinylchloride. Standard color is white, however 300 Series jacket is available in colors at no extra charge for color coding of piping. Colors are black, brown, red. orange, yellow, green, blue and gray. 800 Jacket Material and Properlies Values Polyvinylchloride ......................................... 030 inches Jacket Description and Specifi;alion: ThermazipeO0 jacket is made of white, rigid PVC. Polyester fabric ......................................... 5 oz/sq yd Its shiny, hard surface resists accumulation of foreign material that may Total weight ..................................... 28 oz/sq yd contaminate sanitary processes. The total thickness is .020 inches. It is washable__ Ambient Temperature Range ............................. ,-40°F to ..160°F and never needs painting. 'r:nsile Strength ..................................... Warp: 400 Ibs/in . ~S 191 Method 5100 & 5102) Fill: 350 Ibs/in Jacket Material and Properties Value~ ar Strength ......................................... Warp~ 190 Ibs High Impact Polyvinylchloride ............................... 020 inches (FS 191 Method 5134 & 5136) Fill: 66 Ibs Ambient Temperature Range .............................. O°F to +150°F Cold Crack ................................................. -40°F Tensile Strength (D-882) ..................................... 6500 [psi Fire Hazard Classification Cold Crack ............................................. : ..... O°F CaIi/ornia Fire Marshall Coae ................................... Pass Fire Hazard Classification (ASTM-E-8.4) U'.214 Method 5903 ........................................... Pass Flame Spread ................................................ 25 R.F. EA,-701-1966 ........................................ - ..... Pass Smoke Developed ......... · .................................... 50 L. EL & EL-MC product specifications T-201-E 6/91 APPLICATIONS: Econotrace® EL parallel resistance, constant watt heating cables are for water freeze protection and process temperature maintenance up to 90°F (32°C). EL-MC cables include an additional conductor for monitoring the voltage and continuity of the heating cable. CONSTRUCTION: ~ 16 AWG COPPER BUS WIRE NICHROME WIRE HEATING ELEMENT i -~ SOLDERED PARALLEL BUS CONNECTION 4,-::!:' ?'~ THERMOPLASTIC RUBBER ~'i~;-'~ ''~, JACKET ~' '~' OPTIONAL METALLIC BRAID* ] . ..~ OPTioNAL OVER JACKET* - ;E-;:.. OPTIONAL MONITOR WIRE* ;,..ii~ :~..~. *OPTIONS: MC Monitor wire. EL cables with MC option must also include either the BC, BS or OJ option. BC Tinned copper braid for Division 2 hazardous areas, or where traced equipment does not provide adequate grounding (stainless steel, plastic or coated piping). BS Stainless steel braid for Division 2 hazardous areas where corrosives may be present.. Also used when added tensile strength is required. OJ Thermoplastic rubber overjacket (includes tinned copper braid). Provides mechanical and chemical protection for braid where corrosive chemical solutions or vapors may be present. Not available with "BS" option. NOTE: The 1987 National Electrical Code, Article 427-22, states: "Ground-fault protection of equipment shall be provided for branch circuits supplying electric heating equipment not having a metal covering:' RATINGS: EL and EL-MC Maximum maintenance temperature 90°F (32°C) Maximum exposure temperature 250°F (121°C) (cable de-energized) Minimum installation temperature -60°F (-51°C) Earth leakage .48 mAper 100 ft. @ 240 VAC .24 mA per 100 ft. @ 120 VAC NOMINAL CABLE DIMENSIONS .18" .20~" ! . ~ .25' .25 L__ .28' ---= L___ .30' -- ~ .35 .... ,475' EL EL-BC, BS EL-OJ EL-MC-OJ MINIMUM BENDING RADIUS: EL, EL-BC, ELUBS: 0.56 in. (14.2 mm) EL-BC-MC, EL-BS-MC, EL-O J, EL-MC-OJ: 0.75 in. (19.1 mm) MAXIMUM HEATING COLOR OUTPUT CIRCUIT ZONE *CATALOG OF IDENTIFYING SERVICE W/Ft. LENGTH LENGTH CURRENT DRAW NUMBER THREAD VOLTAGE (W/m) Ft. (m) in. (cm) AMPSIFt. (AMPSIm) EL-2.5 Black 115 2.5 (8.2). 330 (116) 24 (61) 0.020 (0.072) EL-4 Blue 115 4 (13) 285 (91) 24 (61) 0.032 (0.115) EL-6 Brown 115 6 (20) 225 (75) 24 (61) 0.048 (0.171) EL-13 Yellow 220 4 (13) 550 (175) 40 (102) 0.017 (0.059) 240 4.8 (16) 0.020 (0.065) EL-20 Orange 220 6 (20) 435 (143) 40 (102) 0.025 (0.089) 240 7.1 (23) 0.030 (0.098) APPROVALS I LISTINGS: --- FACTORY MUTUAL RESEARCH (~ UNDERWRITERS LABORATORIES, INC. Ordinary Locations Component Recognition Hazardous Locations: Listed for Non-hazardous Locations Class I, Division 2, Groups B, C and D Class II, Division 2, Group G Class III, Division 2 ACCESSORIES A complete electric heat tracing package includes: 1. Econotrace EL heating cable 2. Power connectors 3. End terminations 4. Adhesive tape for cable attachment to pipe 5. Splice kits 6. Temperature controls 7. Caution labels 8. installation instructions THERMON supplies a complete line of these materials. See "Accessory Specifications;' Form T-207-E See "Estimating Bill of Materials;' For T-208-E, Section D See "Installation Procedures;' Form T-210-E THI:I:tMr'~N MANIIFACTURING COMPANY DRAW'rNGS TABLE OF CONTENTS 98051-01 RTU AUXZiLZARY PANEL 98051-02 POWER WIRING 98051-03 MAIN VALVE VVZRZNG 98051-04 MISCELLANEOUS AC WIRING 98051-05 ANALOG WIRING 98051-06 ANALOG WIRING 98051-07 ANALOG WIRING ) 2 X 3 WIREDUCT TB-PWR CR~ I. OR2 CR3 TB-;"~ C;R~ CR5 1 CR6 CR7 CR8 UPS HOFFMAN ENCLOSURE HOFFMAN SUBPANEL A-302zt-12LP A-30P2zl- 1. TERMINAL BLOCKS ENTRELEC 115 116,07 HID-TEX CONTROLS, INC, 2. USP TRIPP LITE BC~00 INSTRUMENTATION SYSTEMS 3. 2~VDC POWER SUPPLY MOORE INDUSTRIES fPS/2~DC/llZAC[STD] ,~u. =,~ i~,,m,,ma, I~Dm,. ~ ~. RELAYS POTTER BRUMFIELD KRP-IIAG-120 ~ ~- ~ 5. [5 AMP DUPLEX OUTLET WAGONWHEEL ELEVATED STORAGE TANK RTU AUXILIARY PANE, CITY OF COPfELL, TX ~l-SJ ) ) FIELD SUB PANEL FRONT PwR~ZN UPS 128V AC I ....H lQ FROM ....'N1- ~QQ ~sA CKT ( .....6 1.~ KV A BRKR I CKT ~ 3 7 2 TB-PWR -H __~ ---6 - H 2~ + ~'} TO TBA- 1 + --N VBC --- 6 P.S. ! ~'l TO TBA-2- - H ) TO TB1-1,13,25 HIB-TEX CONTROLS, INC, - N )TO CR-1 THRU 8 INSTRUMENTATION SYSTEMS i~l.~, ~ I ~ ~ ~'I, I~ WAGONWHEEL ELEVATED STORAGE TANK POWER WIRINO -- CITY OF COPPELL, TX 98~51-02 ) L') FZELE) SUB PANEL FLD RTU HAIN. VALVETB 1H N SEL. "-- '2 """ SW. H N ;MEMC~'FG ....] "'°'/' ' D'J I ; SWITCH 7~ 2 ' ......'~F~ ....2 " l'iR~?"' 3 'OP, ', SCADA ED · L_SWITCH 7~ 2 ..... '~N ....~ RENOTEED [ CR2 ........ 5 ',CL. LIPlIT [__S__W_Z_T__C_H_ ....67~ 2 SCADA RTU btu The Setectbr Switch F bpn 3-2 '~R%Fd~t~ ....7i1 is on th~ Vatve I DZ~ [F~__T_O__~T_U_ ....8--F3 CR2 btk 3-3 ~ VAL'9~"Oi~'" 9I 1 CR3 DZ2 F~__T_O__~_T_U_ ....10 F~ b tu MZD-TEX CONTROLS, ZNC, CR~ '""' I"" B 13 _ T 0 R TU:]. 213 WAGONWHEEL ELEVATEO STOP, AOE TANK t, IA[N VALVE W'[I~]NO CITY OF COPPELL, TX geesi-o3 FTELB SUB PANEL FRONT ,,..I OBSTRUCTTON H N LIGHT "'T' ~ -i'A'C~RM1 ....13 SC ADA R l~[k " 3 8~Z~ ~'[ ARM "' 15~ 1 POWER FAILUREbpn 3-1[]~]'AiZAR'F1 ....17 - ~ T R __ :~CR1 [~_O___TU _ 18 ~ MID-TEX CONTROLS, INC. INSTRUMENTATION SYSTEMS WAOON~/HEEL ELEVATED SIORAOE TANK MISCF. LLANEOUS AO ~/IRINO OIlY OF COPPELL, TX ~l-e~ ) ) } FTELD SUB PANEL TEA + 2zl- VDC- ET LEVEL e .....~ - ~ + INDICATING TRANSHITTER e ...............1-y , Y SC ADA R TU 1 S r['~ 19 a ~ 3- '~:r"E~P~E'F .............2+ 2 ............2- Y 2_S~ SPARE ........................... 3- 3S SPARE MID-TEX CONTROLS, INC, ........................... z~-_ INSTRUMENTATION SYSTEMS WAOONWHEEL ELEVATED STORAGE TANK ANAL00 WIRINO CITY OF COPfELL, TX 9885[-85 ) ~) ) FIELD SUB PANFL RTU '['B'A RTU SCADA "tS'~aAi~"?XFVG ..................... RT ................................POSITION CONHAND POSZTZON CONHAND 5- - .................................... n n 28 68 ............................POSITION COHMAND POSITION COMMANO ....7 ...................................... " Y .. 78 Y Con t lnued on dwg. q~9805 1-(37 MID-TEX CONTROLS, iNC. INSTRUMENTATION SYSTEMS WAGONWHEEL ELEVATED STORAGE TANK ANALOG WI~NG CITY OF COPPELL, TX 98851-86 . FIELD SUB PANEL RTU Continued From dwg, ~9805 1-86 TBA RTU SCADA .,, P__O_S_~_T__Z_O_N___Z_N..O_~_C__&T__Z_O_N_ ........S-- .........-P-O-S-!-T-Z-O-N---Z-N-D--Z-C-A-T-Z-O-N----F'] ~ n 21 _R_E_S__ZD_U__A_L___A__N_A_L__Y_Z_E__R_ ........9 .........-R--E-S-I--D-U-A-L--Z-N-qZ-C--A-T-Z-g-N----F7] MID-TEX CONTROLS, INC. INSTRUMENTATION SYSTEMS V/AGONWHEEL ELEVATED STORAOE TANK ANALOG WIRING CITY OF COPPELL, TX 9ees~-e? WAGON WHEEL RANCH 2.0 MG ELEVATED STORAGE TANK C'rTy OF COPPELL~ TEXAS PRO3ECT NO. WA-96-01 OPERA TZON & IV[A2'NTENANCE MANUAL CATHODIC PROTECTION SUPPL'rER HARCO/CPS WATERWORKS 581 SZGMAN ROADs, SUZTE 300 CONYERS~ GEORGZA 30208 (770) 761-5400 TABLE OF CONTENTS SECTION I INTRODUCTION SECTION II SERVICE REPORT AND FINAL TEST RESULTS SECTION III LAYOUT DRAWINGS & CATHODIC PROTECTION PRODUCT DATA SHEETS SECTION IV WARRANTY SECTION V UNDERSTANDING CATHODIC PROTECTION SECTION VI RECTIFIER SURVEILLANCE SECTION VII RECTIFIER TROUBLESHOOTING SECTION VIII INSTRUCTIONS FOR TASC VII RECTIFIERS SECTION IX SAMPLE - SERVICE AGREEMENT SECTION X MONTHLY MONITORING LOG SECTZON Z 1NTRODUCTZON SECTION i iNTROaUCTION TO CATHODIC ?ROTECTION OBJECT!VrS !- To acquaint mainuenance personnel ~;ith the fundamenuals of cathodic protection. 2. Tc enable maintenance personnel to conduct Fericdic x~s*~ng cathodic orotec~ion svstems tc assess testing on e .... . their effecuiveness. t~ETHODS Moniuor structure-to-water potenzia! measuremenus and ~=~-~.fier uniu outputs Uc ensure effective levels cf ca~hodic Drozec~ion are mainuained. SECTZON II SERVZCE REPORT AND FZNAL TEST RESULTS 1055W. Smith Road 581 Sigman Rd., Ste. 300 2421 Icr,oStreet 5643 N. 52ndAve. ww,.v,3orrCrcj.. C: "' Fax 33O 723-6065 Fax 770/761-5410 Fax 908 686-1704 Fax 602/842-9697 t/'"pISTOMER: Ship To: Customer Contact Name and Number: Schedule Customer P.O. Customer No. Job No. Region Tank Capacity and Type Type of System __ Type of Service Tank Address: County Rectifier Mfg. No. System No. Rating Anode Configuration Measurements prior to testing, evaluation and adjustments "OFF" "ON" a) Rectifier Tap Setting at: Auto [] Manual [] Water Level b) Rectifier Operating at: Bowl Volts Amps Pot. Set Potential Level Riser Volts Amps Pot. Set Potential Level Reference Cell- Bowl Riser Aux. No. d) Independent Tank-to-Water Potential Profile Within Tank: Tank Bottom ON Instant OFF e) Rectifier Operation Adjusted To: Tap Setting: Auto [] Manual [] Bowl Volts Amps Pot. Set Potential Level Riser Volts Amps Pot. Set Potential Level WORK ORDER ['~ Installation [] Startup [] Service [] Other 1 ) Electrical' 2) Anode System 3) Rectifier Evaluation - Overall System Performance for Corrosion Control: Recommendations: Operator Instructions provided to: Do NOT adjust recti~er in automatically controlled mode of oCeration. Record voltage, current and potential meter readings at intervals not to exceed sixty (60) days, ,,r"r" HARCO/CPS WATERWORKS a corrpro company SUBSCRIBER'S ACCEPTANCE By: Date: By: Date: CLE";'ELANT_, ,~.TLANTA NE',;':' './OR,~ f 'T I $t SECTTON 1'1'1' LAYOUT DRAWINGS AND PRODUCT DATA SHEETS - /""""~"'~- 12 - 5"¢ HANDHOLES CUT INTO THE TANK ROOF a"f ~ "" LANDMARK STRUCTURES ON A RADIUS OF 24', EVENLY /' " · SPACED EVERY 30 DEGREES J: SIX INCHES. I t _F_A · 97'5" e. ANY QUESTIONS REGARDING THE PLACEMENT OF THE HANDHOLES SHOULD BE DIRECTED TO MILES STEELE · WITH HARCO/CPS WATERWORKS AT 770-761-5400 OR (800)-554-9077. · FOR HANDHOLE AND SUSPENSION DETAIL, SEE HARCO DRAWING NO. HHC-CUT. //if/_, ,/," ' "",,~/-- 12 - TITANIUM MIXED METAL OXIDE ANODE STRINGS, EACH _ ( CONTAINING 38' OF ANODE MATERIAL, SUSPENDED 8' l OFF THE TANK FLOOR. 1 - HARCO/CPS WATERWORKS CATALOG #IHRP-801 PERMACELL 46't' 88'7~ 1 - 1/2"~ GALVANIZED RIGID CONDUIT CONTAINING 2 - 7 ~12- STRAND THHN AND 1 - #18-2C ~ WIRES. , ,MODIFICATIONS MAY BE MADE TO MEET FIELD CONDITIONS. ' LANDMARK STRUCTURES NEEDS TO ALLOW FOR AN ~ AREA OF 3 SQUARE FEET NEAR THE ELECTRICAL PANEL TO lO0'tO" ~ FACILITATE MOUNTING OF THE RECTIFIER. //,//,//,,z,,/ 1 - HARCO/CPS WATERWORKS TASC VII AUTOMATIC - RECTIFIER RATED @ 30 VOLTS & 8 AMPS. - ' C_ _ ....... ~ 115V/60Hz/l~ A.C. SUPPLY BY OTHERS NO DATE BY REVISION ="*"" "Y M. STEELE °Es'°NE°"Y M. STEELECATHODIC PROTECTION SYSTEM ,~ WA TERWOFeKS; C.P. oAT 3/18/99 ki m ,~ COreRPRo COMP,~N~'sc,,~2MMG COMPOSITE ELEVATED TANK AR,~ONA . ~A~,,~N,A . ~O,O~00 . ,L,,~O,S . LO~,~,ANA~ CITY OF COPPELL TEXAS MONTANA · OHIO · PENNSYLVANIA · TEXAS · WASHINGTON DWG. .o. LM-MM012 I '1 I II i CATHODIC PROTECTION CALCULATIONS 2,000,000 Gallon Composite Elevated Tank City of Coppell Coppell, Texas COMPUTATIONS: A. WATER RESISTIVITY: B. MAXIMUM DESIGN CURRENT FOR TANK BOWL: K R= .......... I=AxCdxC~ T I = total current required (amps) A = total surface area (ft2) R = Water Resistivity (ohm'cm) C~ = cun'ent density (A/ft2) K = Conductance Constant = 625,000 Cf = coating factor (25%) T = Total Dissolved Solids I = 21,550 x .001 x 25% 625,000 R = ......... = 3,360 ohm'cm* I = 5.4 amps 186 ( *The Industrial Utility of Public Water Supplies in the U.S.) C. MIN. LENGTH OF ANODE MATR. FOR TANK BOWL: D. RECTIFIER VOLTAGE RATING: L= I/IA R= (In{4~tL1) where: (0.062) (_LJ L = Minimum Bowl Anode Wire Legnth (feet) where: "'T' I = Total Current Required In Bowl (amps) R = Anode-to-water Resistance IA = Anode Rated Output (amps/ft.) P = Water Resistivity (3,360 ohm-cm) L = Anode Lengt~ (5,472 inches) L = 5.4~0.10 - This is for 100mNft anode r = Anode Radius (0.031inches) L = 54 feet R = (In (0.031) (5472) The actual anode length used will be 456 feet = (13.46 -1) x 0.04 to ensure even current distribution w/i the tank. = 0.5 ohms E. LIFE OF BOWL ANODE MATERIAL: Rectifier Voltage Anode Life '~" L = Cdr x 20 E = U_) LR_)(1.5) Cda where: where: L = Anode Life E = IRSF Cdr = Rated Anode Output = lOOrnNft E = Rectifier Voltage (volts) Cda = Actual Anode Output (mA/ft) I = Required Current (5.4) R = Anode Resistance (0.5 ohms) Cda = IlL Sf = Safety Factor (50%) where: I = maximum current output in mA E = (5.4) (0.5) (1.5) L = total length of anode material E -- 4.05 D.C. Volts Cda = (5400)/(456) = (11.8) mA/ft ~""7~ 00) (20~ l~1.8) L = 169 years 1 1 ! II ! HARCO / CPS WATERWORKS CATHODiC PROTECTION a Corrpro Company CORROSION CONTROL T.A.S.C. VII AUTOMATIC RECTIFIER FOR WATER STORAGE TANKS AND WATER / WASTEWATER TREATMENT EQUIPMENT RECTIFIER OPE~TION ! DESCRIPTION The HARCO / CPS T.AS.C. VII r~fier is sp~fi~lly design~ ~ pm~de a~m~, ~nomi~l ~osion ~n~ol ~r ~e submerged su~ces of st~l ~ter s~mge ~nks a~ ~r / ~~ter ~eatment units. The T.A.S.C. VII is d~ign~ by ~CE a~r~it~ ~ic prot~ engin~m' ~r .~otimum peffo~an~ in a~an~ ~th ANSUA~A D104, Ty~ k IR Dr~ F~ ~n~i s~rds. 'he T.A.S.C. VII automa~lly monitom and adjus~ ~ DC o~ut ~ui~ ~r ~mum ~sion ~n~el. The T.A.S.C. VII ~n~l unit is ~uip~ ~ an automarc ~ten~al limit ~i~ is adju~ to maintain A~A D1~-97 a~ NACE ~eda ~r optmum ~ffi~ic pmt~on ~on ~n~ ~ile preventing over or under prot~on of ~e coat~ su~. Supedor d~ign, engin~d~ and ~m~on provide owner / ppemtom ~ long life, low maintenm pe~an~. ~e s~n~ffi digi~ d~play metera ~cilitate ease of monitoring, ~ ~do~an~ indi~tor ligh~ on ~e ~nt ~bin~ available ~ an optional e~m feature. Each T.kS.C. VII is bo~ ~o~ a~ job site ~t~ to insure q~i~ wo~ship and pe~o~ance. ' ' STANDARD F~TURES: · Totally Automatic Control · Eliminates "IR' Drop Error · Controls from 0 to 100% of Rated Output · Automatic Current Limiting · Silicon Recti~er Stacks · Upgraded Ughtning Protection (AC and DC) · Plug In Automatic Control Circuit Board · Manual Operation Mode · NEMA 4X Enclosure · High Intensity LED Digital Meters · Individual Circuit Shunts CSA (Canadian Standards Association) Approved · Full Height Silkscreened Instrument Panel A- TRANSFORMER FI- AC DIODE BRIDGE /o °\/-® c- .c L~o..N,~ ~RR~STOR J:~ ~"~ D- DC OUTPUT TERMINAL RLOCK '~' /" ~ E AC ,NeUT ~Er~M~NAL aLOC~ · o 6- TASC V CONTROL PC ~OARf) O tl- -I-5 VOI.T SUPPLY PC 13OARD Q ~p~ o I - DC METERING SIIUNTS " ®'X "/ ~:D I I ..... ~ o O XO ec r,,,,,, ~ A CORIIf'IIII CIIIJI'AIII ~::l,,, BACK PANEL PAR|S LAYOUI fOR IASC VII CON1ROL-1YPE RECIIFIER (|)UAL POSIIIV[') ~".-.~~..'. """""~- I""" ''" "DRAWl'I: [R AlE: O~/:Ji/g& I., I 'n i, ,N~/,z-N,,,x,xx MOUNTING DIMENSIONS: (CENIER TO CEI',iIER) .s~,\ ~6.0o~ WII)'III I 2.{)()" i'IEICI I! - 18. ===~ 17.37 ' HOLE SIZE - 0.34" ( 11/32) OVERALL CI..LAI,~ANCL DIMENSIONS: WID II I -- 18 .O0" FIEICHT - 19.50" 19 .so" 8.50" ~L80" WATERWORKS C.P. J~ A R C D.. ,, ,:o..,.,o co,,,..,,,~ !~:;~,.. CAtllN[I I AYOUI FOR [ASC VII CONIROL-IYP[ R[CIII'I[t~ ~2"'~""~ """ "" I °""~"'"°i' "''' ,P' DRAWhf: ER ~ 0,5/2,1/96,'[ASC I 0A --- ., .-.-. ,~p..:. .......... TYPICAL HANDHOE AND ANOOE SU SP EN Sl ON D ETAI L TECHNOLOGIES r""' CORPORA T'70N ~ NC~E .4R,rZGNA , C,4L.SFC~IA · C:LGR.;,CC' - ~:R~A iULLNCI.~ . L~..q..,'/~NA o ~G'V. TANA · Cffia· Q(L~CUA1 I I ! 'L I WATERWORKS WIRE ANODE APPUCATIONS ANODE UFE · Water Storage Tanks Due to the extremely low consumption rates and · Water Treatment Equipment dimensional stability of mixed metal oxide anodes, the electri~ resistance of the ELGARD Water-works ELGARD Waterworks Wire Anode is a copper cored tit. a- Wire Anode remains essentially cor~tant with time. nium wire with a mixed metal oxide coating. The mixed metal oxide is a crystalline, electrically-conductive coat- The high current density capability of mixed metal ing that activates the titanium and enables it to function oxide anodes have the added advantage of allowing overloads The F[C~ARD wire anode delivers reliable, long-life for initial - ,-____.,__ - . current necessary to uniformly protect wa~ storage polarization tanks and assorted water treatment equipment from inter- without nal corrosion. causin9 harm to , TITANIUM .- ,~....::,~;__,_----/co.g CORE Arxx~e life projections am accurately made using ..... derksdfmmacceler- ated life tests and Lqw~nmeCOa~Ne , ~-:c__,C:Z,:;3~ sive field FEATURES BENEFITS · High Current Output , Lower cost per ampere year · Low Coming Wear Rate · Constant electrical resistance · Highly Conductive Copper Core · Minimizes voltage drop · ' ANSI/AVVWA St~idan:J D 104.91 TECHNICAL SPECIRCATIONS ~ Rating for 20 year life (mAJft) 100 ELGRRI3 Corporation r"~neter (inches) 0.062 A Subsiciary of ELTECH SysTems CorD. Maximum continuous length (feet) 1000 L1.10 Incustnal BIrd. Resistance (milliohms/ft) 7 Sugar Lan0. Texas 77,~78 l-8(:X)-4~2-5432 · ( 7 ~-3) 2408686 · Fax: (713) 240-8779 Weight (ounces/ffl 0.138 ELGARD s a ,,'fa~ernar~ ct ELGARD CCrOCraUCp. T I I II I CELLS Permace!P 801 Permanent Reference Cell For Accurate Readings in Fresh Water Environments Routine monitoring is an important paF, of any ........ · ........ ..... cathodic protection maintenance progran~ To - ~_ ~. ,~,~. -... . simplify this tasting procedure, differen~ types of perrr~nent reference ce/ls can be usecL For sUuc- made using a 99.99% puzs copper coiled elem~-nt ';~ which ~ surrounded by a super satum~d sck~on of copper sulfate. To ensure a low resistance cormecCioD. a lead wize is soldered and rneCh~ni- '" c~ly bonded to the copper element. This electrical , junction is then encapsulated by a moisture r~-~- rant material for a lnzly sealed connection. Electri- "' cal ccntac~ to the electrolyte m accomplished tllrough a filtering plug at the end of the reference elec=ode. The plug allows accurate potential ' measuzem~m to be obtained while preve_~ng cell con~rnination the PemmceZi 801 a lO-yeaz design life In order for a reference to be effective, it must remain elecUicaIly stable over time. Harco's 801 the abl]it]F to nl:~inmin a.D elecRic~d poteDti~ of w/tkin plu~ or minus 5 minivolts. re{erence cell delivem unsuz'pa,~ sr~ility due to -~,-"~ quali~ comzol pmceduzes ~ple.~enu~ Typical Appfications du,r~g the rn_~anRf~cRz!~g process, The ceD is coz~tructed in a con|zolled environment. tor~y fzee The Pemmcell 801 is ideal {o~ use in c~thodic Of coIll~minAntS. The vaziD~ cornpODel:ItS ased in protection systm~ opem~ in fzesJz wate~ the ceil aze also puzifi~ Dioniy-ed wru~ is used to czeate the super saturated solution of copper storage tanks, clazffie~. =avelLug soreens, suIate, and the coppe~ element is ueated wiffi a dock mzucu=es. ~ ce, l] can be operated spec~ cleans~g agent befc~ it is iz~-,aJ]ed ~to the cell's plastic housing. Each cell is also ~esed ~or in tempemtuzes of up to 135°F. not be used in waters containing high obtained are recorded and umrked on shipping tags concentrations of chloxide ions. attached to the ceIts. These extra quality steps give II T t " ' I IT z""" "' /""i ~,,, :5" :AMETER -ANDHOLE //// "" '1 / //' ,~, ,,,: -- / - :. / i= 6" DIAMETER ! ER PL~?TcJ E // i x GASKET i ~. ..// ,// t,~(:~~ ~ PORC-'LAIN PRODUCTS PIN i . INSULATOR CAT. NO. 211 9 " .:':.:....,,... · '.-':E.. ' ANODE HEADER WIRE ! I !1 " --2-LAYERS OF HALF LAPPED VINYL TAPE SCOTCH 88 OR EQUAL , .. --2-LAYERS OF HALF LAPPED RUBBER TAPE SCOTCH C130 , OR EQUAl_ """""'~--ANODE LEAD WIRE ' ~ I~a, li [rf REVISION """'"" "' M. STEELE ................ ~ TECHNOLOGIES ~'~ "' ~. stme CORPORATION *"' sl~oi~z COMPRESSION CONNECTOR SPIICE At~'IZONA · CALIFORNIA · COLORADO · GEORGIA sc,~e NONE II,IlN()IS · LOUISIANA · MONTANA · OHIO · OKLAHOMA~et 1 ~ 1 PENNSYLVANIA · TEXAS · INTERNATIONAL n~. ........... .. SPLICE4 ,,,,-,,,,o,,.-..-Conductor UNSHIELDED Two Conductor Twisted Pair Jacketed ~ / Gray PVC jacket, (Un shielded) ;~ ~.~~ Copolene ~,,~ insulated ' '~'~~:~~~~:7~4;L:' ::~-:::~;'~-: ~lor coded BlackRed. Catalog numD~s ~6 and 227: Bl~hite pdm~ies. 220, 221, Standard sDool size: 1~0 feet. 222, 223, and 224 ~e Available in Following Jacket C~alq N~ber A~. ~a Ins~ation ~_~ ~ { Ors: Nm~ Gray White ~0 2 22 Solid ,010 ,0~ ,I 32 ~0 B town ~1 2 22 (7 x 30) .010 -~0 , ~ 42 350 ~ 2 20 (7 x 28) ,010 ,020 J52 ~0 ~""' ~3 2 19 Solid ,015 ,~ ,;72 ~0 ~ ~ ~8' 2 18 Solid ,015 ,~5 ,220 4B ..- ~..~ ~4 2 18 (7 x 26) .015 ,025 ,~5 450 ~ ---- ' ~'~- ~5 2 16 ( 19 x 29) ~22 ,025 -255 ~00 w~RES ': .... 226 2 14 (19X27) ,032 -~2 ,~25 750 ~7 2 12 (19X25) ,~2 -~2 .3e5 750 *Red anC W~te primaries S~cial Pr~u~s l~SD, l~SD, ~7~ - Grange an~ ~wn Primaries. I I I DATA SEC~ON 3 05 9-81 Anaconda-Ericsson Type THHN or THWN Copper Conductor 6430 Volts 90C De.scdption Features and Benefits How to 43rder Type l*HHN-11-rWN AP(]6201 UL listeel as Type THHN or 11,tWN. for Ctc~r from your local AuthOrtZeCl Annecle~l t3are cooper conclucl~' per general power or conrol wiring in oc- Anaconcla~-s__f,n StocVjng 0islr~u~r ANSI/ASTM83. coralonce will~ the NCIIioncII e, eCtrtcal ~yAP06201orTypeTI-IHN, Solicl ~4AWGr--10AWG CoCo. ~;nn;;~;sc ..AWC---.OAwG UL ILS,e~ as Typ. MTW ~ ~. in Alternative Products 8AWG--500MC~M mac,~ine rCol winng. sizes ~4. ~12cncl ~0 Type USe~HH~HW 0a~Sectlon3C<~ Polyvinvl OhiohOe. rnermoplcs~c PVC AWG. Tyl~e XHHW Cutasneam -e Cc~ Sectlon 40~ insulation. UL lis~'ecl as Type AWM for use in aD- un,c~nr-REP O(~l~3Seclion4133 Cle~r nyion jacket aver the insulation. pik=nce wiring Accel~ta=le for use in OSHA re~uk;:ll'ect THHN Tray Cable Specifications ins~llallons. MulliDle ~l~r Type TC consm4c- UL 8.1 Sranc~ora for Safety for ~'herma- UL ILstecl cs VWd. Passes all flame tesls .lone ~'e plastic ~nsuk~leci Wires anal Cccles. requirecl ~y UL 8..1. AP 0620'1 Anaconca-eic.~.son General Annexteal cocker concuc:ots tar easy pro<3uc.' specifical'icn. insl~lla~on cncl Iroucle tree con- JC-30A 7--ecleral $pec~cat~on. nec.*tons. Please c"dll your Ar~3C. Oncta-eriC.sson I~/C insuk'_.tion aaheres tignlty ro i~epresenrative tot L'Z~_~t(~'~Ce in pie- perconcluc~tsyetecsdvsmOsc~ean. pann~ sCeci~cations or selec.'!ng wire Sm~orn nylon j~3cllel aiC$ in ec~er pull- for your aoloticafion. ing. Application str,=,er overall ~lameter results in greater concuit fib in olcl wax or new Anacc. nCa-I='tics.son Type THHN or THWN rn~y ice used for C~3wer or conlrot cir- cuits. in recogizea raceways. in wet or ReILSl= oils. c~emic~ls. ~;~::~es czncl city I~.."~.ns anal in me presence of oil. gasoline. gases. <g~soline <=ncl chemicals. in corclc~nce with the Nalion~l Etec~ic~t Stocke(l na~onwicle 13y levicling Auli'~dze~l l~[e~tric~l l~i.strii~ul~rl for Coae (NEC]. Quick oilivory. Also suitcDle as switc~l::x;x~a wiring. Maximum cOncluc*,cr t~mpetc~lure: Type Oil Wet I:~ THHN--..'HWN 75C 75C MTW _ -- AWM -- -- ~ NC:tioncl Electrical C,.,~cle t~eferences: Genercs Wiring Article 3 ~ 0 Amf:>cclv Article 3 Concu~t Fill TaDlos ChaPter 9 Switch ccarcl Wirin(~ Anic~ 384 ConsuJt your Ioc,.,_,t eiec~'icat insDocTor for c~,ce interprerc:ton anc lOCal rulings. =,~CC:rCC-::'rC::Sr' r'c . .'~ire CnC C.:-=~e .:n.'~S~cr- E-reer".,,,;c."' Efface ;cr'~: ~.ee,"".,.,.c- i' :: e 2':- 2:-:'. :2'2'_-":':: i i II SERVIT--TYPE KS For Copper Cable or Wire Type KS designed for making service connections quickly and surety. Units for accommodating wire sizes up to and including 500 Mcm. are made of forged Durium, a high-copC~er alloy, which eliminate danger of corrosion and insures good contact between conductors. Each size of Servit is designed to accommodate at least two conductors of maximum diameter, but it will close down on a single maximum conductor or its equiva|ent. Nos. KS15 thru KS28 listed by U.Lo Inc. Cat. No. 2-Piece- Our Pert Maximum Retainer Type KS No. Conductor Size KS90 527-947 10 Sol. 12 Str. KS15 661-341 8 SoL 8 Str. KS17 699-985 6 Sol. 7 Str. KS17-3 527-955 6 SoL 7 Str. KS20 673-854 4 SoL S Str. KS20-3 521-963 4 Sol, 5 Str. SCOTCH TAPES SCOTCH* VINYL PLASTIC ELECTRICAL TAPE ~ NO. 33+ ~e industry's premium all-purpose vinyl plastic electrical tape. Excellent for ost plastic tape applications in all types ofweather conditions. No. 33+ is a 7rail ~ck tape and is available in various convenient lengths and withe. Size P~cking Our Pert No. "~" x 66' Can 561-185 UNITED RUBBER TAPE Excellent For All Insulating Jobs That Require Extra Protection Cat. No. Our Pert No. Size Std. Pkg. UT-13 632-068 ~" x 22ft. 100 PORCELAIN PRODUCTS CO. HOUSE BRACKETS Insulators House Bracket Insulators are the same aS regular wireholders except have stud bolts for fastening to straps or back ban. 5pedal stud lengths available on special order. Wt. Std. Per Cat, No. Style Stud Use With Strap Pkg. 100 3111 193 1 } ~ "x3A" 2200--2300 50 96 ana I 933 z4oo-z o m as 2116 1986 j ½ "x~" 2200--2300 50 72 2119- 2119 19~j ',5~"x3A.'' 2200--2300 50 65 Galvanized Rigid Steel Conduit Furnished in I O flit lengths w,m coupling screwed on one end. R C CLAM P Thremie~l on e}otn er~s. Our Wt. Lbs. ~l Wall Pa~ Size .,. Per Per ~ickn~s No. Ins. 100 Ft. In. In. 50N03 ~ 80.3 14 .109 ~r mound~ pi~ or ~uit at ~ht angle m 50~Oll ~ 106.4 14 .113 50~038 1 154.4 11 ~ .133 Our Pan 500-046 1% 203.7 11 '~ .1 ~ No. 0~ 50~O54 1 ~ 251.0 11 '~ .145 ~ S~ ~. ~ S~ $~ 500-062 2 338.0 11 '/t .154 No. In. Per 1 ~ QW In. Oz-GNne 500-070 2~ 541.0 8 .203 RC-~ ~ 25 89~17 ~ - 50~089 3 706.0 8 .2I 6 RC-~ ~ 41 1420 ~ 81 500-097 3'~ 849.0 8 .226 RC-~ ~ 46 5a~9 ~ 815-538 500-100 4 1 ~3.0 8 .237 RC-1 I 51 58~7 1 739-413 5 1343.0 8 .258 RC-1% 1% 54 1~19 1% 815-551 RC-1~ 1~ 58 ~3 1~ 815-~ -- 6 1918.0 8 .280 RC-2 2 86 Si6471 2 All dimensions and weigh~ are nominal. RC-2~ ~ 109 5~8498 ~ ~ RC-3 3 118 M6-501 3 ~1~8 RC -3~ ~ 13~ 5M-528 3'~ 81541 RC4 4 I~ 696~25 4 815-~4 ': : e: i NEGATIVE WIRE FROM RECllFIER GROUNDING !2j. ~ NUT THREADED HOLE l! Z l 1/4 .-,. 20 BOLT SOLDERLESS CRIMP CONNECTOR NEGATIVE CONNECTION FROM THE RECTIFIER TO THE STRUCTURE IS MADE BY DRILL.'-NG AND TAPPING A 1/,$" HOLE INTO THE TANK, AT A SUITABLE GROUND CONNECTION POINT, AND THEN BOLT1NG TF.'E WIRE Tg ,THE STRUCTURE USING A SOLDERLESS CRIMP CONNECTOR AND A 1/~-" BOLT AND NUT. AFFER THE CONNECTION IS COM PL~D, BOTH SIDES ARE COATED WITH · 3M-SCOTCHKOTE [OR EQUAL) TO :REVENT OXIDATION OF THE CONNECTION. - NO. DATE BY REVISION o;,,,,, e~ L. L!JZADDER ARIZONA · CALIFC:'NIA · COLORADO · GEORGIA LLJNOIS i'2UISIANA 'JONTANA OHIO · OKLA~CMA SHEET SECTTON IV WARRANTY r'- SECTION IV HARCO/CPS WATERWORKS CATHODIC PROTECTION SYSTEM WARRANTY All workmanship, materials, and equipment shall be guaranteed for a pedod of one (1) year from the date of the final acceptance of the system. Harco/CPS Waterworks shail guarantee that the cathodic protection system, when maintained in operation in accordance with the manufacturers instructions, shall provide protection against corrosicn of the submerged surface inside the tank. In the event corrosion is not prevented. Harco/CPS Waterworks shall, at their own expense, make whatever changes are necessary in the cathodic protection system to prevent corrosion. As a condition of this warranty, the Owner warrants that the cathodic protection system shall be maintained in continuous operation at all times in accordance with the recommended operating parameters and that written records of the operation shall be maintained on a monthly basis. Upon prompt receipt of notice, from Owners of an installation in the United States, of failure of any part of the system during the one year pedod, new replacement parts shall be provided and installed by Harco/CPS Waterworks at no additional expense. For Owners of an installation outside the United States, such new replacement will be provided f.o.b. Medina, Ohio U.S.A. NOTICE: This warranty does not extend beyond the one year pedod and excludes damage caused by vandalism, act of God (lightning, etc.), or unauthorized modifications or adjustments to the system by the Owner. Moreover, in the event the system installed is not a Harco system, this warranty does not extend to ice formation damage. Harco shall in no event be responsible for any loss of business or profits, downtime, or delay, labor repair or material costs, or any similar consequential loss or damage incurred by Owner. No other warranty, whether expressed or implied, including any warranty cf merchantabilit-/ or fitness, shall exist in connection with the sale or use of any Harco prcduct. -. SECTION V UNDERSTANDING CATHODIC PROTECTION SECTION V UNDERSTANDING CATHODIC PROTECTION To have an effective cathodic protection maintenance program, it is important that personnel responsible for monitoring understand the basic principles on how the systems ~ork. This section of the manual is devoted to giving these persons a better understanding of why metals corrode and hew cathodic protection achieves corrosion control. When metals are made they must first be recovered from the environment in their natural state. An example of this is that iron is mined in the form of iron-oxide or rust. This oxide is then processed through refining and heating to form steel. The steel is then molded into plates and other structural configurations. When this steel is placed in the environment, however, it immediately wants to revert back to itts original state or, rust. The process by which the steel reverts to rust is known as corrosion. When steel corrodes it releases the energy it acquired when it was refined. This energy is released in the form of electrical current discharged into the water. The release of energy is the result of reactions the steel has with the surrounding environment. For instance a steel tank may corrode due to differences in water resistivity or temperature because of varying oxygen levels, or when it is connected to other metals such as cooper. Each small amount of energy released causes iron particles to leave the tankts surface. These ~articles accumulate and eventually form visible rust nodules. To control corrosion, the release of e!ec~rical energy from the metals surface must be stopped. This can be accomplished in a number of ways which includes coatings and cathodic protection. Coatings are commonly used to, in essence, separate the metal from the environment. ~hus, the metal cannot react or corrode. However, no coating is perfect and small flaws develop. These flaws, commonly called holidays, are the result of damage during transportation, installation and o~her work being performed on the tank, as well as imperfection applications. Since the metal is exposed, corrosion will be initiated at each of these flaws. To control corrosion at coating flaws and on bare structures cathodic protection is commonly applied. Cathodic protection is a method in which current is applied to the metal surface from the water. When this applied current equals or exceeds the current leaving the metals surface, corrosion is stopped. The current is applied from an expendable anode placed in the water in the proximity of the structure protected. All cazhodic protection systems pass current through I I II I the water from anodes connected to the s~ructure that is to be protected. Twc basic means are employed. Sacrificial anode material, such as magnesium or zinc, ~s used to create a galvanic cell. Such ancdes are self-energized and are connected directly t~ the s~ructure to be protected. These anodes are usually used where it is desirable to apply small amounts of curren~ to achieve corrosion control. The other basic method employs anodes energized by a direct current power supply known as a rectifier. This method, ccmmonly referred to an "impressed current", employs relatively inert anodes (usually titanium, platinum, or high-silicon cast iron) connected directly to the positive terminal of the rectifier, with the structure being protected connected to the negative terminal. D.C. current is then forced from the anodes to the structure. These systems are generally used where large amounts of current are required, such as storage tanks, and water treatment vessels. The cathodic protection equipment to be used in any given cathodic protection system is also of utmost importance. A wide selection of rectifiers are available, including air-cooled, oil-immersed, and automatic units. The range of voltage and amperage outpu~ is almost infinite. Selection should be based on the particular requirements of the "project", as determined by thorough engineering. Anodes which serve to distribute the direct current into the earth or water are manufactured from various metals. Graphite, High-silicon cast iron, platinum, titanium, magnesium, aluminum, and zinc alloys are commonly used. Each has its cwn particular application, and the engineering of their usage is a determining faczor in the success or failure of the cathodic protection system. Through proper engineering practices, material and system. selection, and installation and maintenance procedures, cathodic protection can extend the useful life of any structure being protected. I I II I SECTION VI RECTIFIER SURVEILLANCE SECTION VI RECTiFIER SURVE_IT.L~CE A. CRITERIA Ensure the rectifier are operab!e and =ha~ cu~put levels are wlzhin accepted taFget values. B. EDU!PMENT !. High-input impedance vo!~meter wi~h I to !O0 VAC and ~o !00 ~C scales. The following meter is approved. a. BecKman Model HD-!0O C. SEOUENCE Da~a shall be obtained on a monthiv basis to ensure proper cperating status. A written record cf ~he monthly operating s~atus shall be maintained. A mon~h!y log sheet is provided within this manual for your use. D. RrCORDiNG All pertinent recEifier da~a shall be recorded on a "Rectifier Maintenance" sheet on a mon~h!y basis. These forms shall be da~ed and s~c~=~ and any changes or unusual circumstances tha~ may have had an influence on the readings shall be noted. E. t4ArFUNCTION A malfunc~ion is indicted when OUtOut levels are outside the target values given on the rectifier maintenance sheets. In the event an abrupt change in rec~ifier output level occurs cr the rectifier becomes inoperable, utilize the rec=ifier troubleshooting information contained within this manual. i~ the problem persisns, nonify Harco Waterworks C.P. F. SD~MMARY The rectifier unit converts AC Dower to DC Dower which is supplied to the impressed current anodes situated inside the water tank. This curren~ is then discharged from anodes, travels through the water to ~he me~a!!ic zank, and then returns to the rectifier via ~he negative cables attached to the tank. Rectifier surveillance is required to ensure that the rectifier unit operates on a continuous basis aZ desired OutDut levels. '! ' I IT [] PROCEDURE !. Reczifier Surveillance a. Record the reczifier vzl~age and amperage values as indicated by the corresponding me=or. These meters are mounted on the panel hoard within the rect==~ ca~ine~. b. Open all rectifier doors and ensure the unit is relatively clean and free of debris. c. The re!rage output is measured directly by reading across the output lugs with a standard vc!tmezer. Current output is measured indirectly by reading across the calibrated shunts provided withi~ each rectifier with the same oorta~!e voltmeter. The raEing of each shunt is embossed cn the shunt bar. d. Record any adjustment zo the r=~-{~iar output in terms of the final transform =ap settings or Dotenzia! set point. 'These changes should only be made ~t the direction cf a qualified corrosion engineer. WATER TANK POTEnTiAL MONITORING CRITERIA Tank-~o-water potentials between -0.85 volts (-850 mi!livolts) and -i. !0 { I!00 mi!iivo!ts) with respec~ .~o a copper-copper su!p_hate reference e!ec~rode a.-- all pcints tested. EQUIPMENT !. High-input impedance 20 mega-ohm minimum DC vzi=meter with a 0-2 volt full scale meter ~d~g=.t=] or analog acceptable). The following meters are approved: a. M.C. Miller Model LC-'~ b. Beckman Model HD-!00 c. Fluke DVM 2. A freshly-charged copper-copper su!pha~e reference electrode wi~h a 56' (rain.) lead wire. The following are approved: a. M.C. M~ 1 ~ =~ Pcr,-_ace!! - Model iEHR8 b. Tinker & Rascr - Model 8B or 6A 3. ~o (2) five foot long tesz leads, one end ecuipped with. "banana" plugs for connection zo the vof.~me~er and the other end with "a!liga-_or" clips- C. SEQUENCE Tes=ing shall be conducted quarterly by =he facility maintenance personnel ~o ensure the effectiveness of the cathodic pro~ection systems afforded the water tanks. Annually a survey should be performed by a qualified corrosion engineer. D. RFCORDING Test measurements are to be recorded. This form must be dated, and any activities that may have ~ad an influence cn any of the measurements shall be noted on t~is sheet. Quar~er!y readings are to be obtained at the surface, middle and bottom from each of ~he tank manways. E. TEST FAirURE in ~he even~ the test measurements do no~ mee~ the acceo~ed cri=eria, investigate to deter-mine the cause. Pos~i'c!e reasons for =est failures would include inoperable rectifiers, severed ancde cables or daD!e~ed anodes Chezk ~= -=~-{~=- asscciazed wizh the zank eva!ua~ed. '1 .- attempts to correc~ these deficiencies fail, notify Earco waterworks C.P. F. SUMMARY Cathodic Drc-_ecticn curran~ shifts The zank-~o-wa-zer potentials in a mole negative dlrecticn, this zest is to verify that sufficien~ current is bein~ received by internal submerged tank walls. G. PROCEDURE !. Water Tank uar~er!v a. Locate the ~ank as noted on ~he q . sur~ey sheets. b. Climb the hank ladder and c=en the manway atop the tank. c. Connec~ ~he copper su!fate reference cell 50' lead wire. Ta~e the connection to ensure the threaded copper portion of ~he cell does contact Zhe water. d. Lower the reference cell into uhe water to the bcuuom cf the ~ank. Cor~nec% ~he negative lead cf the volume~er to the lead wire on the reference f'~ cell. e. Connect the positive zest lead of the voltmeter directly =o the ri~ of the manway. Clean the meza! ~o ensure good contact is made. f. Turn the voltmeter "ON" and zo the 2 vc!z D.C. scale. Record the pcten=ia! at the bottom of the tank, halfway to the surface, and az ~he water surface. g. This procedure is to be repea~ed at each of the wa~er storage tanks on a quarterly basis. 2. Special Notes a. Copper-copper sulphaze reference electrodes are usually received in a dr_v' ccndltion from the supplier. it will be necessal7 to fill the cell with diszi!ied water before using. (Fill to within a~proximateiy one inch of the top). ~. Examine the cell regularly, keeping ~he liquid level full. when =he copper rod becomes ~ad!y discolored, discard =ks solution, sand =he cop~er f-~ rod zo bright cop~er, and add new Cu/CuSC_ ; cr;sta!s and distilled water. Su~==~~= ..... ,'CuSC. '1 IT ' ' " I c~;stais should be added To obtain a sa:ura:ed scluticn. c. wken ncz in use, keep the cel!'s ~orcus tip cc-;ered. T '1 IT "' I SECTZON VII RECTZFZER TROUBLESHOOTZNG SECTION VIZ .WZCT!FIER TROUBLESHOOTING Adherence ~o a maintenance and periodic testing orocram as previous!v described will c-=a~]v reduce the =csslbi!izv of u!Zimate rectifier failure. However, failures may occur. The following procedures are reco~numended tc enable maintenance persenne! to find and repair zrcub!es rapidly in order ~o maintain cathodic pre~ec~ion cn the water s~orage tank. !. Precaution: following D~eca~,~on= should be observed when troub!eshcoZing rectifiers: a. Turn the rcc.~e~ off when '.-~nd~{nc comoonents ~:;ithin the reczifier. Turn off the circuit breaker at the AC oanelboard and at ~he reczifier cabinet. b. Check the recUifier w~ ~ ~c diacram before starting to troubleshoot. c. Make certain than meters used in troubleshooting are properly connected. The voltmeter should be · connected across the ~oints where the voltage is to be measures while the ammeter should be placed in series with the circuit being tested. A mi!!ivc!tmeter should be connected across the terminals on uhe recZifier shunt. Correct po!ariu~ mus~ be observed when using DC instruments. I '1' IT I 2, Procedures: Most rectifier troubles are simple and do not require extensive denailed troub!eshoozing procedures. Most coma. on pro~iems are: b!owT. fuses, faulty me=or, loose terminals open anode leads, and ~ah~c strike d~mage. Tkese troubles are usua!iv found hy a simple visual inszoo=ion of Ehe rectifier. For more difficul= troubles, however, it is usually better ~- systematica!lv isolate the rectifier components until the defective part is found. This may be done as follows: a. Check zo see whether voltage is being applied to the rectifier by placing the leads from an AC voltmeter across the line side of the circui~ breaker. b. Check across =he load side of the circuit breaker zo determ. ine whether it is defective. The volEage should be the same as tha= of the line side. c. With an AC voltmeter, check the =tansformer seconda_~f windings to determine whether voltage is present. If the circuit breaker trips, indicating a short circuit, ~he transformer may be isc!a~ed from the DC circuit by removing the secondary tap changing link bars or wires. if the circuit breaker continues ~o zriu, check for possi~!e shorts within the transformer. r~ {~ no longer trips, the shcr~ is no: in the zransf=rmer, but either in the recz.~~=- stack or in tke DC circuit. 2 d. ~.aasuring :he A~' voltage sup.~!ied rec'_ifier stack. T~.is vc'_~age s as ~ha-_ measured a~_ the =ransform..er se_-onda~. Z f AC voltage is present at t~.e transformer ~- stack ~C ~enina!s, seconc_'ary but nc~ az ~.= .. check ~-he leads from ~he zransfc~m.~er tc the stack as follows: Place -_he AC vo!r. mazer leads between -_he transformer secondar; and the stack. If nc voltage is present, =he lead be-_ween the two is probably eden. Verif!; by measuring the AC vc!tage. a. if the circuit breaker trips, -_he stack may be isolated from the rest of the DC circuit b~I removing one or hc~h of the DC leads, If the breaker continues to zrip~ the s=ack is defective and should be re=laced. /'~ = ~= the circuit breaker does no~ ~rip when a DC lead cn the stack is removed but does trip when i= is connec=ed, ~he shon circuit is prcb~_b!y in -_he anode circuit or structure leads. This may be verified by removing one of the exte~ leads from the rectifier and turning ~he rectifier on again. g. If DC voltage is present at the stack but not at the rectifier outout terT...ina!s, check for loose conneczions or ODe~ leads between the stack and the positive te_'T..~ina! or between the stack and the negative tarm. ina!. This may be done ~v measuring the DC vc!tage ~etween the positive and ~=gat~v= at ~he s~ack and between the and necative cuzzu-_ te_~r...ina!s. h. if DC voltage is present a= the rec:~=~ output zemina!s but nc curren~ is flowing, =here is an ouen circuit in one of the exzerna! DC leads. i. Fau!t~ meters ma-; cause the rectifier to appear defective when iz is actually operating. The me=ors may be checked with portable meters known ZG be accurate. 3. Troubleshoot~ng Techniques: Many rectifier problems have s.vmuEoms which are obviousf however, the obvious should never be overlooked. Loose connections, signs of arcing, s~range odors, etc., indicate trouble which do not re~u~= e!a~oraze test procedures zo uncover. Some helpful ~roub!eshooting techniques are: r~ no output voltace or current {~ present, the nroub!e and remedy may be: a. Breaker tripped for fuse b!own): (i) if apparently due to steady overload, reduce the outpu= s!igh=ly. (2) If the breaker trips repeatedly even with the cutout reduced, the cause may be a sho~ circuit in some component. isolate ~he component as described before and repair or replace. (3) r~ -~- breaker trips cccasiona!!y for no obvious reason, -_he cause mav ~e: (a) r{.= voltaa= surges (b) intermittent short circuits. isolate the component as described before. Check for loose brackets or connections. Check wi~h ohm~eter while moving leads, etc. (Make ce_~cain Dower is turned off when using =he ob~nme~er ) . b. No AC line voltage. Check zhe AC breaker. Dc not overlook the possibility tha~ the AC panelboard circuit breaker may have tripped. c. Open circuiu in some ccmDonenu or connection: (l) Check all connecuions~ fine and coarse transfo_rmer tap adjusumenus, and stack ~'~ connections. (2) Rec~ifier slacks. Use an AC vc!~meter to see if voltage is applied to the suacks. if so, ~hey may be open-ciru,_ii~ed and should be checked wiuh an ohnuneter and possibly replaced. d. Defective meters. Check the wires between the meters and the calibrated shunt and ouupu: lugs. If the wires are intact but ~he problem persists reoiace the me~er. e. Defecuive uransformer. if AC line voltage is applied uc the prima_--.¢ but none is presenu at the secondary, check to see wkeuher ~here is an audible h~'_m coming from Zhe uransform. er. if so, 'I ' I li I ~.e primary is coera=ing bu= ~ha saconda~; is probably open. f Circui~ breaker. ~-' -~.e contacts do not close, ~hev should be repaired or the breaker replaced- 't ' I"' IT' SECTTON VIII INSTRUCTZONS FOR TASC V'r'r RECTZFZERS E'~'STRUCTION MANUAL TASC-VII IR DROP FREE R E CT~'~RS H,-h~CO/CPS WATERWORKS el DIVISION OF CORRPRO CO.'~IP,.IzVIES, I:VC. NORTH SOUTI-IE.~ST Vv'EST OHIO GEORGIA :~...~IZON.-'. 1055 W. Smith Rd. 581 Sigman Road. #300 5643 Nor.h 52nd Ave. Medina. OH 44256 Conyers, Ga 30013 Glendale. -~2 853C~! (330~ '25-668 l (770) 761-5400 (602) 26~-'641 Fax: {.'-30) 723-6065 Fax: (770) 761-5410 Fax: (602: S-'2-969' I I i" ! [ INSTRUCTION MANUAL FOR TASC VII CATHODIC PROTECTION RECTIFIERS INDEX INTRODUCTION PAGE A DELIVERY INSPECTION PAGE A THE I.R. DROP ERROR PROBLE.~ PAGE A PRINCIPLES OF OPEP,.ATION PAGE A SPECIFICATIONS PAGE A GENERAL INSTALLATION PAGE A TASC INSTALLATION PAGE A OPER. ATION PAGF. A MAINTENANCE PAGF_.. A TROUBLESHOOTING PAGe. A SCHEMATIC AND OTHER CUSTOMER DATA IN BACK OF MANUAL INTRODUCTION f...T,Corrosion cf submar.cod surfaces in water treatment facilities and other areas is a process .,~hich is continuous 24 hours per day, 365 days per year; and protection must also be csntinuous to effectiveiy combat corrosion. Correct selection, installation and operation of a cathcdEc protecticn system is [reportant, as severe corrosion could result from interruptions in protection. The TASC VII rectifier is a reliable, cost effective device which has been specifically designed fcF this purpose. The TASC VII rectifier is an improved version of the latest generation of a patented, proprietary controller used to automatically control the structure-to-reference potential of a cathodicaily protected structure. All TASC systems have featured the unique abili~ to monitor the instant~ff structure potential and make use of it to control the cathodic protection current. Early TASC units achieved this by turning off the rec'tifier output for several half cyc!es of the AC waveform on a pedodic basis (approximately ever,/haif second). The TASC VIi units monitor the structure potential every half cycle of the AC input waveform (120 times a second) and thereby provide an output which appears to be continuous. This achieves a reasonably stable output meter display as well as a .Greater degree of pctential control. All units are marketed excfusive!y by the Harco Corporation of Medina, Ohio. Additional technical infc,n'nation cutside the scope of this manual is available from Harco Waten,vcrks CPTM, Cc,,-T'pro Companies Inc., located in convenient areas across the U.S.A., ---.Canada and overseas. When reouesting information or crdedng parts for this rectifier unit, please specify the serial number ~nd model number. Rectifiers manufactured by Harco Wate.,,,vorks CP"".,tCorrpro Companies Inc. are .cuaranteed against defe~,s in design, workmanship or material for a pedod of one year as described in our catalog. in any event, the obligation of HarcolCorrpro is limited to the repair, adjustment or replacement at our ~.,ctory of any rec:~fier or part, thereof, which shall be found defective upon examination. DEi IVORY INSP;CT1ON Rectifiers received in damaged condition should be accepted, a noted<an made on the freight bill and a claim made to the carrier. Always check rectifier th~aroughly after receipt (regardless of expected installation date) as external andor internal damage must be reported to the carrier immediately. When making a claim to a carrier, all cartons and/or crates should be saved in odginal condition for inspection by ',.he carrier. Permission must ~e granted by Hams WaterworKs CPTM, Corrpro Companies Inc., befcre the return of any rectifiers for repairs. (A I) I t ! I THE i.R. DROP ERROR PROBLEM "T. real problem exists in ir:.cressed current cathodic protection systems in w~'.ich st~-ucture- -.:o-reference ce!l potential !s used to continuously control the out._-ut of the rectifier. The desired structure-to-referer. ce potential is electronically compared to the ac:ual structure- ~o-reference poter, tial generated by the cathodic protection current. An error exists in the structure-to-reference poter, tiai as normally measured and is proportional to the produg of the current and the resista:ce through the e!ectrolyte, be~,veen the structure and reference cell. The only method which completely eliminates this IR drop error in the potential measurement is one which momentarily turns the cathodic protection c::n'ent off and measures the reference ce!l potential while the current is zero. The sb'ucture~to-reference potential is thus sampled at the "instant-oH' level. This instant-off potential is that which is compared with the preset desired value, to control the recti~er. The TASC VII controller, like the earlier TASC mode!s, accomplishes the above described sampling of the structure- to-reference potential to provide IR drop flee automatic control. PRINCIPLES OF OPERATION The basic concept of the TASC VII system controller is to "sample" the structure-to- reference potential at a time when the output current is zero thus eiiminating IR drop on"or. The TASC VII controller samples the structure-to-reference potential even/half-c',tde at a "e immediately after the zero crossing of the AC input voltage. T:.~.e rapid sampling of the ~tructure-to-reference potential e!iminates "bouncing" cf the OL.~:--ut volt and aremeters. The TASC VII controller aiso has an output current limit feature which prevents the cutput current from reaching a vaiue sufficient to cause failure of the output SCR"s. The sampling gate is actu'ated by and synchronized to the AC input voltage via the sample time generator. These c~rcuits cause the structure-tc-reference potential to be "sampled" for approximately 0.11 miilise,'..onds, shortly after the zero crossing c~f the AC input wave form. This sample is taken every half-cycle of the input wave farm,,; thus 120 samples are taken every' second with a 80 HZ input. When the out"put c, zrrent of ,the recti~er is be!ow the current limit the sampled structure-to-reference potential is compared with the set potential and controls the SCR ~dng point. When the reCj~er current required to satisfy, the "potential" is greater than the current limit, then it wiil be limited to a safe value and the "potential" demand within the controller will not be satisfied, i.e. the sampled structure-to- reference potential will not be equal to the set potential. (A2) Normally, a TASC Vll controlled rectifier will operate as follows when turned cn after initial setup. Assume, for example, that the set potential is 0.9 vctts. Before cathcdic protect[on /,~c ac~olied, the actual st,mcture-tc-reference potential will be less than this amount (0.6 volts r ~'xample). V~en the rectifier is turned on, the cutput voltage will immedia~.e!y dee to its full rating for the particular tap setting. This may be less than the rated voltage cf the rectifier if the taps are at less than full setting. The structure-to-reference potential as measured by the sampling circuit (indicated on the potential meter) will increase smoothly from zero to a value greater than~he set pctential value. After a few seconds the structure- to-reference ce!l potential will decrease slcwiy to the set potential value. The structure-to- reference potential measured by the meter will increase from zero even through the actual potentiaf begins at about 0.6 volts. This [s because the capacitor where the "sample'" is '"stored" discharges to zero when the power is off. When the sampled structure-to- reference potential becomes equal to the set potential, the output voltage and current will decrease to a level necessary to maintain the sampled structure-to-reference potential at the set potential value. The rate of the measured (sampled) structure-to-reference potential when the unit is turned on will depend greatly upon the tap se.Fdng. As mentioned in the operation section, the tap setting should be no higher than necessary to provide the desired protection for all conditions which are anticipated between se,,,lice checks on the rectifier. If the structur~to-reference potential takes more than 20 seconds to reach the set potential value, then the tap set~jng could be increased unless it is known that t;:e particular structure will polarize slowly. The current limit characteristic was explained bdefiy in the operating section. The principle /~;its operation is such that the OUtDut Of the unit is controlled to maintain the structure-to- ference potential at the set potential level providing the current required dces not exceed a safe value. Once the limit value of current is achieved, command signals fcr additional current from the reference ceil circuit are ignored. The current limit value is constant from 100% conduction time of the SCR down tca 50% conduction time. If the Iced resistance decreases further the current limit value decreased. it is approximately 10% of the rated output current under a sho~--circuit condition. T'ne current limit has been designed in this fashion so that peak instantaneous currents through the SCR's will not exceed safe limits. One feature. of the input circuit is that opening the reference cell input lead causes the rectifier to react, just as though the structure-to-reference potential were ver,t high. Thus the rectifier will turn off. SPECIFICATIONS The TASC VII controller can be used to control virtually any level of cutput power. Typically, cathodic protection rectifiers utilizing the TASC VIi system are r,.ot required above 100 V at 100 amps, atthcugh lar.cer units are possible. The controller itsoil can therefore be used on a wide range of rectifier sizes. i'ne contrciler has :~e following specifications: j. A3) Input power: 115 VAC, 60 HZ Set desired ;otentia[ range: 0 to -1.5 volts Reference Ceil Input Current: Less than 0.3 ua Reference Ceil Input Impedance: Greater than 20 megchins Set potential stability: Better than 0.01% / degrees C I n put voitage offset vo liege: (Difference between re foronce and soL) Less than 5MV Current Limit: ' Voltage from 50 to 200 mV Sample time per cycle: 0.11 milliseconds Operating Temperature Range: -25 degrees C to + 55 degrees C Operating Humidity Range: 0-100% GENERAl INSTALLATION Before going into the specific installation procedures for the TASC VII rectifier, here are some general rectifier installation tips which may be useful: 1. The site of the installation is import. ant !t should be at a location which is easily accessible so the rectifier can be inspected and adjusted regularly. and yet not near residential districts, play grounds, etc., where vandalism may be a problem. [f the rectifier is mounted around livestock, it should be fenced in or mounted high enough so they cannot scratch on it. If installed in remote rT" areas open to hunting, it should be made as inconspicuous as possible. Avoid placing bdght symbols or madKings on the redtier which would make good targets. 2. Adequate ventilation is impor'ant Install the rec~fier away from building ventilator shaft, s, diesel exhausts, etc. and keep an adequate distance from buildings or other devices. Air cooled re~d~fiers are cooled by ccnve~on (air moving over the components) and should not be located near other heat radiating sources. Keep the cabinet at least one foot away from the other objects. Nothing of an insulating nature should be applied to the case such as mastic, tar, etc. If possible, place the unit in the shade. Mounting it an the north side cf the pole or structure will help. If the ambient tempera~re is extremely high, a sunshade is a good investment. 3. Most codes require a fused, visible disconnect switch ahead cf the recktier. When working on the reC, ifier, make certain this switch is c.cen (o~, since voltage is present on the line side of the circuit breaker even when it is ~r,,,ed off. (A4) i ! i ! 4. Lighting arrestors are cheap insurance when the rectifier is Iccated in areas of frequent thunder storms. The AC arrestor is best placed at the top cf the '""T service pete; but is effective even when placed inside the unit. AC and DC lighting arrestors shcuid be standard equipment cn all recti~ers with silicon bridges. 5. The following precautiens should be observed cn ait recti~er installations: (A) The recti~er chassis should be connected to a ground rod driven at the location of the unit. Most manufacturers provide a grounding lug or terminal connection on the cabinet for this purpose. (B) Make ce~ain before energizing the unit that the input volta_co available is that for which the recti~er is designed. (C) Check the output connections for correct pcladzation. (D) Do not install other equipment in the recti~er cabinet. This invalidates the recti~er guarantee, since the manufacturer has no control over the qualit'/of the equipment added. The additional equipment might also interfere with the cooling and/or operation cf the rectj~er. (E) If there are screens on the recti~er cabinet, ensure that they are not obstructed. Do not place the Service Manual on the bottom air screen to store. Future ground-bed changes should to be consic:ered when a convention~ recti~er is adjusted at near maximum voltage cr current. When initially adjusting the rectffier, start on the low adjusting tacs and bdng ua the desired rating slowly. T'nis keeps the power re!atively low if a fault should occur. TASC VII INSTALLATION Tne TASC VII controller is designed to be used in conjunction with a single phase full wave bddge, rectifier assembly having t';~o diodes and two silicon controlled rectffi, ers (SCR'S). The rectifier assembly should also contain a current shunt in the negative D.C. power c~rcuit to provide an output current signal to the cantroilem current limiting drcuitry. Tne proper connection of the TASC Vtl controller is shown in the schematic at the end ef this manual. This connecticn diagram shows a manual-auto switch. it allows t;-.e rectifier to operate manually without the controller. It also shcws the potential meter connections and the general physical arrangement cf terminal blocks and other compcnents connected to ~, .~ controller. (AS) Wh. en the TASC VIi con:.-ctler is factory installed in a recti~er, all interconnections are made, and only the three feZ!owing areas are to be ccnne~ed in the fie!d: f""T' (1) The AC input: must be properly connected to the correct input vaitage following local codes and goad installation practices. (2) The DC out= ut must be connected cbserving proper pciadt, t cf the output leads with adequate'sized wire. (3) The structure to be protected must be connected to the black combination binding post / banana plug terminal cn the inner hinged pane! of the uniL This is usu~-ily done with a wire of sufficient size to prevent accidental breaking. The last wire ta connect to the unit is the reference cell lead (a maximum af t';~o independent cells and lead connections can be used). The red cambina.t~cn binding post I banana plug terminal on the inner hinged panel is provided for this purpose. If the positive lead is placed in the same conduit as the reference cell lead, the structure sense lead (connected ta the black binding post) must also be placed in the conduit It is good practice to mist the structure sense lead and the reference cell leads together in the conduit. The negative cutput power !ead can also ~,e placed in the conduit so that the four leads associated with the output are in the same conduit. Oil connecting widng should be checked to be sure that it is secure and propedy dressed. The unit is now ready to be energized. OPEF~TION After the rectifier with TASC VII controller has been properb! installed and connected, it is ready to be placed in operation. Rrst, set the taps at their lowest set'ring(A-I); switch the auto-manu,~',-switch to manual, and turn the rectifier on. The reference cell potential will then be measured by the controller. The tap se.~dngs should be increased until the measured structure-to-reference potential is greater than the desired value by a small amount. (Note: T'ne measured sb'ucture--to-reference potential will indic=te IR drop or "on" potential when operating in manual mode because them may be scme output ~jrrent flowing when the sample is taken). The Auto-Manual switch can now be switched to Auto. (A6) At this point the sat or "desired" structure-to-reference potential indicated on the potential meter when the Potential-Set switch is held in the Set position. If the set potential is not at the correct leve!, it sheuid be changed to the exact desired level by adjusting the set /""T~otentiaZ adjustment potentiometer. VVith the unit operating in Auto mcde, the str'.-'cture-tc- reference potential should be identical to ',.he set potential (within 5MV). If the st.p.:c:ure-to- reference potential indicates less protection than the set potential, the tag setting will have '-' be increased to achieve more output. The tad setting will not have to be increased ;,,,, , beyond a point where the reference potential is equal to the set potential unless changes in the system are anticipated which wilt require a greater output voltage from the reCjfier to maintain the desired (set) potential. Proper setting cf the TASC VII unit's taps will result in the following observed operation when the unit is turned on. The output will immediately go to ~11 output fcr the established tap setting and remain there until the desired structure-to-reference potential is equal to the set potential. The controller has an automatic current limit circuit which prevents the cu.tput current from reaching a value sufficient to damage the components of the recfjfier. MAINTENANCE The maintenance of a rec,fifier using the IR DROP FREE controller is cniy slighfJy more r]"'involved than that of a manual re~jfier. it should begin by keeping pro,cot records. These records should indicate the following: (A) AC input volts and amps; (B) AC volts at the bridge; (C) Output DC volts and amps; (D) Rectifier tap set~jngs; Records ar.e usually kept of these parameters for manual rockers. It is all the more important to keep records of these for IR DROP FREE units, In addition the following items should be recorded. (E) "Set" potential; (F) Reference potential; It is also quite helpful to record any known changes in the system which might effe~ the output. Such notes might include water level of a system on a stora_ce tank, ccr. dition of the coating, or impurity content of the water. Records indicating changes can be ve.,,t hetpfui in finding rectifier performance and operatichal problems. (A7) , ', s ! , TROUBLESHOOTING ShcL:ld it be determined that the TASC VII rectifier is not operating prc:erly, the contrcl card of the :nit can be removed and replaced with a control card known :c be good. First, turn cff the main power breaker on the unit Turn the t~vo quarter-turn fasteners on the front hinc~ed pane! counter-c~ockwise and swing open the panel. The circuit card is located cn the !eft side cf the back panel and is easily removed by pulling it straight cut from the unit. Slide the new card into the unit'~nd turn on the rectifier. If the new card does not produce proper operation (after being sure to establish the desired set potentiai), then the prcbtem could be in the remainder of the unit The autc-manual switch on the unit shculd then be switched to the manual position. When the rectffier is switched to manual mode, the SCR's are circuitsHi in a continuous "on" state, to act as diodes. Thus the unit should perform like any manually adjusted single phase recti~er. (Note: If it is desirable to measure the structure-to-reference potential while in manual mode, the measured potential will not then be IR drop free! This is .b'ue even though the structure-to-reference potential is being sampled 120 times a second just aft, eft he zero crossing of the AC wave form. There will be some current through the elec='olyte which is prevented from ticwinG when the unit is operating in automatic mode.) The simples.*. way to approach a trouble shooting procedure is to go thrc,.:gh the unit in step by step manner to ensure all components are checked. Therefore, in this discussion, · the components which are used (excluding the previously discussed TASC VII controller) ""will be studie~, starting from the output of the unit and carrying it back thrc,,:gh to the input. 1. The meters in the rectifer should be checked using a portable DVM (Digital Voltmeter), which is known to be accurate. An assumption t~hat a rec+j~er is inoperative or has no cutput may come as a resuit cf nc reading cn the voltmeter cr aremeter. However, one should nct cvedcck the fact the voltmeter or aremeter itse!f could be at fault The accuracy of the TASC VII voltmeter can be checked by connecting the DVM leads across across the test points on the front panel labeled VOLTS '+" and "-' The TASC VII aremeter can then be checked by c-~nnecting your DVM leads across the test points on the front panel labeled TOTAL AMPS "+" and"-'. (it should be noted that the "-" test point for the above two measurements is identical.) The potential meter can also be ve.~ed by connecting the DVM negative lead to the front panel connector labeled 'STR." and the positive lead to the connectcr labeled "REF. 1". T'ne above test points are cjearfy shown cn drawing "TASCO" which appears later in this manual. 2. Ensure that the cutput circuit and ccnne~icns are .cocoa. If there is DC voltage at the cutput cf a unit but no current, it is ~ikeiy that the anode cr structure connec~cn and/or cabling is ~.ulty and should be (AS) 3. The DC output circuit fuse protects the unit from a possible 'current overload" condition. If this device continually operates (blows open c!rcuit), the cutput circuit may be "shoRed" (or has significantly lowered in resistance) and should '---e investigated. 4. The DC surge arrestor acts as a by-pass far high voltage surges entering the recti~er as a result of lightning and/or transients. When the DC arrestcr in a unit fails, generally Sere are quite visible signs of this failure. If, however, the DC output fuse continually operates, disconnect the arrastot, replace the fuse and try to turn the breaker on. If the fuse now remains continuous, then the DC arrestor may have "shorted" on the last surge into the unit. 5. The SCR I Diode bridge is the device that converts the aitemating current (AC) from the secondary of the transformer to direct current (DC) far use in cathodic protection. T'nis device can fail due to a voltage surge into the AC or DC side of the unit (generally protected by the surge arrestors and fusing in the unit). The SCR / Diode bddge can fail to a "short circuit" ar an "open circuit" condition. If the secondary AC fuse in the unit operates (and the above five points have been checked), the bddge in the unit could be "shorted" and may need replacement. Altemateiy, if rated current ~nnat be achieved from the unit, part of the bddge in the unit could have "opened" and it may again, need replacement. -,, 6. The AC secondary fuse is another form of protectj'on for the unit against surges and overloads. If the recti~er is set to operate abcve ifs rating, this fuse may operate. (Also refer to step 6 above for alternate cause of this fuse to operate.) 7. The transformer provides three important qualities to the rectifier. It isolates the AC utilit, t ~om the cathodic system, it steps the input AC voltEgo up or down as needed, and provides a form of output adjustre, ant. To ensure a transformer is operating correctly, measure the AC voltage between each of '- the "coarse" and 'fine" terminals on the transformer secondary (A-8, B-C, C- D, D-E (COARSE))(1-2, 2-3, 3-4, 4-5 (FINE)). From A to E and I to 5, the voltages should be in equal steps and the 'fine" te.,-minais should be approxim,~tety llSth the value of a 'coarse" terminal. (Fcr exam pie, an a transformer with a 50VAC secondary; A-B should equal 10 VAC, B-C should equal 10 VAC, etc. Consequently, 1-2 should equal 2 VAC, 2-3 should equal 2 VAC, etc.) The rn~irnurn secondary AC voltage af ~e transformer should appear between the terminals labe!ed as "E' and "5'. The value of the transfcn'ner secondary should be approximately 1.1 to 1.2 *jmes the rated DC output voltage of the unit (Ag) 8. The circuit breaker is a magnetic type of breaker which serves three func~ons. It protects the unit from overloads, short c~rcuits, and is used as an "ofT" and "on" switch for the unit. Circuit breakers can some:~rnes deve!cp bad contacts; therefore, if the unit is completely inoperative, use a DVM to ensure if there is AC voltage on the load side (as well as line side) cf the breaker when in the "on" position. 9. The AC surge arre~'tor acts as a by-pass for high voltage surges entedng the rectffiers AC input as a result of lightning and/or transients. When the AC arrestor in a unit fails, generally there are quite visible signs of this failure. If, however, the input breaker c,?,ntinuatly operates, disconnect, the arrestcr, and try to turn the breaker on. If the breaker now remains on, then the DC arrestor may have "shorted" on the last surge into the unit. 10. A yen/irnpo~ant (and many times forgotten) item to check is the AC input terminals. F:nsure that there is in fact AC voltage to the unit and at a correct level for the unifs rating. Do this with ,the unit's breaker in the "cn" pos~ion. Many special feature may be inco.rporated in the recti~er, such as seccr, dary breaker protection, alarm circuits, etc. The best sources of circuit information are the c';rcuit diagram and specfficaticn sheet at the end of this manual. (Al0) ,,~ A- TRANSFOI~MER /o o\/_® t~- ^c ~,o,,~ C- DC LIGIIINING ARI:{ESIOR [ - AC INPUT I[RMINAL BLOCK C- TASC V CONiROL PC BOARD w o 14- +5 VOLT SUPPLY PC BOARD I O ..... ~ O O ~AR C~ w,TC..o. Ks c.P. ((, m A CORNPRO COMPANY *";"'. PARIS !.AYOU I FOIl OACI( PANEt. FOR IASC VII CON1ROL-IIP[ RECI~FIER .- M'P,: ~T IASC9 II MOUNTIN(; DIMENSIONS: (C[NIER I0 C[NIER) S<////2>""'x~ ~~"X.,,,.~ WIDTII - 12.00" HEIGHI'- 18.75" /~~7.~7 HOLE SIZE - 0.34" ( 11/32) , '/ OVERALL CLEARANCE DIMENSIONS: -t " IWIDIH - 18 .O0" I.IEIGI-IT - 19.50" Ig.5o" 19,50' \ . R.50' ',,,.\ I IIi!; WATERWORKS C,P, /ASC VII CONIROL-IYP[ R[CflFIER DIIAVlIt: In ~AI[: oS/;!,/,il [ASC I 0 , LED DPM CONNECTIONS """ f O-PIN DPM REAR VIEW _.. ' 1OK SE-' NOT=, 1 NOTES: 1. IF T"HE SIGN~. IS ISOLATED F.-'.QM THE FOHrr_R SCURC~ CONNECT INFUT (-) TO GNC _-'fFt4ER OIF~EC ~'L Y GR ~'HROUGH ~"HE fGK .=.~.SISTCR NETt/QFU< AS SHOWN TO REDUCe. C~MMCN MGCE 2. CtS~,LA Y HCLDS .-'.EAQING WHEN ~'OCG°IS HIGH (,SV]. REA~JNGS A~E U~ATED ~SV LOWO~ ~LOA~G. 3. INPUT COMMON MQQE R~GE iS ,A fV ~. TERMINAL DESCRIPTIONS PIN OESCRIPTION v+ +5v DPM POWER SUPPLY~EE~ f. GNO DPM POWER SUPPLY GROUND DP COM DECIMAL POINT R~RN DP 1 1AX ~ CONNECT TO DP2 1X.~- *DPCOM'TO DP3 1 ,~ / TURN ON INPUT(-,-) PCSITIVE INPUT SIGNAL INPUT(-) NEGATIVE INPUT SIGNAL NC NO CONNECTION REQUIRED HOLD HOLD ~ST OISP~Y ~TES: I 1. ~XCE~C~NG ~'/ ~R REVERSZt~G rH~ ~R SU~.Y MAY CAUSE CORKPRO C,~N'ADA INC., RTS MFG. DIV. KECTIFIER SPECIFICATIONS CUSTOM2ER: I--t.-LRCO WATERWORKS CP (ATL.~NTA) P.O.: 3206-~NT DATE: A.PRIL 01,1996 6.73 ~ QTY.: ITE~I P.-~RT N'U,.'~IBER DESCRiFrlO,N [ [ ENCLOSURE vJIal6HW._PL2~ VYNC'..GER, NEMA 4X, GREY F[BERGL&SS t TI~-~NSFOR.MER T-3016-AT RT~, (TASC SPECIAL) 5-COARSEtS-F~'~ TAPS i VOLTMETER 15146914, SUMNIIT !99.9 VOLTS, 3.5 DIGIT LED, RED I AMMETER SI~691Dt-, SUMMIT 19.99 AMPliKES, 3.5 DIGIT LED, RED 1 POTENTL-kL METER SI-469!-,', SU~I.MIT 1999 MILLIVOLTS, 3.5 DIGIT LED, RED t METER PW'R BOARD B3-P-0It0, RTS DUAL +SVDC METER SUPPLY, IISVAC I i SCR/D[ODE MOD. B612-2T, CRYDOM 40 &MP, 400 VOLTS I HEATSIN~K #423-K W.~ded!FltiLD EXTRUSION, BLAC< ANOD[ZED 1 HEATSINX BKT. 6I-T-0160, C.T.&D. T~d~-MINAL BLOCK/SWTFCH MTG. | i CIRCUIT BEAKER IA1SD3ABOIDAW-7.5 HEtNE.M.laN'N. 7.5 AMP., I-POLF, [ SHUNT 20 .-~._MP. 1C0 MV. HOLLOWAY, C/W MOUNT~'G BASE I 1 CONTROLLER 0CtGOIi7-A, TASC-V RTS,MODIFIED FOR l0 MViA2,,IP ~N"PUT I B[ND~xtG POST 01-!032-i-32!0 CONCORD, SINGLE 5-WAY, 'STKUCTU'R.F.' 2 BINDING POST 01-i032-!-92!2 iCONCOP, D, SINGLE Z-WAY, 'KEFF_?~NCE' (1' TEST JACK 09-9!24-[-D2!0102!2 0.093 DIA. PHONE T~ JAG<, 2-RED/I-BL~CK 1 A.C. SURGE LPC-l!785 LIGHTNB~G PROTECT[ON CORP. M.O.V. I I D.C. SURGE 1...PC-!189.~-100 LIGHTNING PROTECTION COIL~. M.O.V. I FUSEHOLDER HKP, BUSSMAN 30 .~MPEKI~, !~0VAC (I/,t x i-ii'-,') i 2 FUSEHOLDER HPF, BUSSMAN 30 AblPERE, (xX)VAC (Ii/i! x t.~') I CONTROLLER FUSE MDL-I/8 AMPERE BUSSMAN, I/8 A~MPE,;LE 2 AC SEC.FUSE MI!N-20, EDISON 20 A.~MP[~., ~0VAC. 11132' x 1.5' I DC OUTPUT FUSE SFI3X20, EDISON 20 .~M. PERE, 130 V SE.MICONDUCTOR b"USE 2 SWITCH S--331/EQUIV., NrKK DPDT,'REF i/KEF 2'/'M. ANUAiJAUTOMATIC [ S'WITCH S-335/EQUIv., NICK DPDT, 'IK)TENTIAI. SET/ACTUAL' t 1 POTENTIOMETER 35905-1-103, BOUILNS 20K0, 20--TUIL'~ WlRR.,m~/OUND l/l ACtDC TE.::LMINAL B--03, F_-XGLE 85 ..~'vlP[~d!, 6G0 VAC I TERMINAL BLOCK 8-t.~t, JONES SCR BRIDGE HOOK-UP STRIP I CHASSIS 61-T--01t~3, C.T.&D. I4 GA. GALV. STEEL. WHITE 2 PHENOLIC BKTS 61-T-.0ti0/6I-T-0120 t'-. GA. GALV. STEEL. WHITE I FRONT PANEL 6t-T-.0t80. C.T.&D. .I00 ALUMINUM. BLACK & S,U_2,C~C.~LEENED NOTES: t. REC~T:F!ER EOUIPPED WITH SINGLE ANODE CIRCUIT. TASC-V Cb'~'~+.'ROELE.~ DIGITAL . t-_'Ei'ERS. & UI~-GRADED L!GI4TNING ROTECT~O;'. . , P N A.C. WIRE SIZE: # ~-* TEW SEC./D.C. WIRE SIZE: #I-' '~W SECTTON TX SAMPLE SERVZCE AGREEHENT \ ..... ~j ,., ~_,aa,a North Sourheas: West WATERWORKS CP P.O, Box 72: 58t Sigman Rd, 5643 N, 52nc Ave. .:~::..~ "':~ a di~sion of CCRRPRO COMPANIES, INC. Medina, OH ~258 Sus;e 30Q Glendale, AZ S5301 ' '~'J 3301725-6~8 ~ ~ax 330172~-~065 ~01761-5~00 Fax 5021842-~697 F ~x 770175 t - 5410 , Harco engineering and maintenance services for effective and economical corrosion control in accordance with AWWA D 104-91, Appendix "C", STRUCTURE LOCA~ON RECTIRER NO. Stan~srd Service Inc-'udes: 1. Tanl<-to-water pote.,;aal 0ro~le wittUn .'~jnk to monitor and verify e~.-c,--veness of system on sz.~.,merGed_ melal surface --t ,'artk. 2. :_!ec~nc~ meam.rem.,,eftts to test ancce and reference Gels. 3. Inspect..'..-st. anc~ ~ean rec:ifief. con~'ols, meters. c~,nTac:a. w~'m;. ~qc ..onnec~ans. Reolac~ .':Jses as reG~red. ~ 4, Adjust system for ~ctimta~ corrosion control On $u,'merged metal sLY, lee of 5. SuDmit re~ort w~rrt al dam oOtained. mlk)n of data. and reccmmsftc'a~onm ~r cOn~uec ;erfotrnarrj. J~ ; S,'andar~ Serlfc~. ~,nd Se~sanai A~o~s J... ~ Addit!cn-'=i Ser/ic3 Requirsm~-'t.~.s Harco agrees =o furnish all ~ersonneL ec~iOment. and instTuments to Dm Itte ser~cg alescuttled in ~ AGreement f~' trte lump sum price of -'- (S }. Payment is due at me start of t~he contact 13eno¢ Additional refers or reOiacements of sy~em c~mOonents w~uld the suDject to SUDSGn~et'$ aoc~rovaJ, This agreement ~aes not effec: in any .Nay the original -Nan'anty on the sy~em(sl desc, foed aloove. Harco agrees ~o maintain Puolic Liamlty Instrance, PrcOert'y Oa/rta{;e tl'tsll'dm:e. ~ Wk)t'kfflett$* COmDefl,~a~3rl Inaura/',ce ckjring me annual se~ice Dertod. The Suoscnl~et a{3rees m irtdemmfy and hOld herroles HarCo for darne;es arising out ot me perhormance of mis cottract which is not covered ,~y ~t~e fore(Joing jI"Leel/I1C8, The ~erm of C~s annual Agreement t3e<3:ns Please return on or before ACCEPTED BY HARCO WATERWORKS C,P. SUBSCRIBER'S ACCEPTANCE By 8y T~e Suom~tlec .n ,~ucfic;~..ce - Subscriber '.c .."ned one s~nec -~rtan.,-_-. -'_dhnGs. Ch~C_~,;...-. C;e,e:,~md. Genver. Hcus.'cn. Los Athletes_. Ne,.v ! !' .... f il SECTZON X MONTHLY MONITORING LOG HARCO/CPS WATERWORKS CATHODIC PROTECTION SYSTEM MONTHLY MONITORING LOG T 8 P,i~w n e r: Locat~orl: Tank Capacity: Tank Name/Location: :~ecti~er Mfg. &Model No.: - Rectifier Serial No.: Type of Anode System: No. of Permanent Ref. Electrodes: L/pan completion and final testing of the cathodic protection system the rectifier was left operating 9t the following values. POTENTIAL .TAP DATE METER D.C. VOLTS D.C. AMPS #1 D.C. AMPS ~r2 SETTING POTENTIAL TAP }ATE METER D.C. VOLTS D.C. AMPS #1 D.C. AMPS #2 SETTING ~me & Daytime Ph. # of Person Monitorinq System: a c it/on of the warrant,/the above info. is to be documented on a monthly basis with ~ copy sent to !rco:~7~S Wate,~vvor'~cs monthly for review and evaluation of system opeiation. Ma/i reports to: rco/CPS Waterworks @ 581 Sigman Rd. - Suite 300 Conyers, Ga. 30013 Attn: Miles Steele WAGON WHEEL RANCH 2.0 HG ELEVATED STORAGE TANK CZTY OF COPPELL~, TEXAS PRO3ECT NO, WA-96-0'~ OPERA T2'ON & M AZNTENANCE MANUAL IRRIGATION IRRIGATION CONTRACTOR TRAVIS LANDSCAPZNG 1605 S, 1-35E CARROLLTON~. TEXAS 75006 (972) 323-1878 r I r' W~ ,d ESP. LX+ and ESP. LXi+ /ns~a//a~/on, Programm/ng, & OperaS/on Gu/de o o~ ~ Indoor / Outdoor Indoor DAY~/¢If ~ ol Fo ' ,E/~ ESP-8LX+ ESP-12LXi + ~"""" ESP-12LX+ ESP-16LXi + ~"~ ,~ ~ ' ESP-16LX+ ~ F' ESP-2OLX+ Rain Bird Sales, Inc. -- Contractor DIvision P/N 6344 15 145 Norffi Grand Ave, Glendora, California 91740 USA Contents ~,1 Introduction ,, .....................................................................................2Set Rain Delay ...........~ ................. ......: .............: ........................28 IX+ and LXi+ Series Controllers ..............................................2 Set Calendar Days OFF ...........................................................29 Controller Stations .............................................................2Set Sensor System and Bypass Switch ..................................31 Station Layout ....................................................................3Run Test Program .................................: .................................33 Controls, Switches, and Indicators ........................................:...4Operating the Controller ...................................................................34 Programming the Controller ...............................................................6Operate Controller Antomatically ............................................34 Definitions ..................................................................................6Run Program(s) Manually ........................................................35 Programming Under Battery Power ..........................................6 .Run Station(s) Manually ...........................................................36 Programming Checklist ................................: ............................7Installing the Controller ......................................................., ...........37 Fill out Programming Chart .......................................................8Installation Checklist ................................................................37 Clear all Program Information .................................................10Select Location ............... .........................................................38 Set Time ...................................................................................11Remove Door and Face Panel ................................................40 Set Date ..................................................................~ ................12Mount Controller on Wall .........................................................42 Select Program ........................................................................13Connect Main Power Wires .....................................................44 Set Watering Day Cycle ...........................................................14 ESP-IX+ (Outdoor / Indoor Controller) ...........................44 Custom ............................................................................14ESP-LXi+ (Indoor-Only Controller) ..................................48 Cyclical ............................................................................16Connect Field Wires ................................................................50 Odd/Even Cycle ..............................................................18 Field Wire Entrances ........................................................50 Set Station Watering Times ......' ...............................................19Station Valve Wiring .........................................................51. Set Program Start Times ........... ...............................................21Master Valve Wiring .........................................................51 Set Water Budget ....................,: ...............................................23Sensor System Wiring .....................................................52 Set Station Delays ...................................................................24Install Battery .................................: .........................................53 Set MV / Pump Starts ..............................................................26Troubleshooting ................................................................................55 © 1998 Rain Bird Sprinkler Mfg. Co~p Questions? Call Rain Bird Technical Assistance ar 800-2473782, ® Registered Trademark of Rain Bird Sprinkler Mfg. Corp. \ WARNING: A CIRCUIT BREAKER OR CUTOFF SWITCH IS TO ATTENTION: UN DISJONCTEUR OU UN INTERRUPTEUR DOlT BE PROVIDED IN THE FIXED WIRING TO ISOLATE THE ETRE INSTALLE SUR LE PRIMAlRE POUR ISOLER LE CONTROLLER." PROGRAMMATEUR. I1~ MEMORY IS RETAINED BY A BATTERY WHIC, H IS TO BE LA MEMOIRE EST MAINTENUE GR~,CE A UNE BATTERIE DISPOSED OF IN ACCORDANCE WITH LOCAL REGULATIONS. RECHARGEABLE A DISPOSER SELON LA REGLEMENTATION CAUTION ICONS LOCALE. //~ The lightning flash with arrowhead symbol, within an L'(~clair avec le symbole de la fl~,che, plac~ darts les equilateral triangle, is intended to alert the user to the limites d'un triangle ~quilat~ral est pr~vu pour avertir presence of uninsulated "dangerous voltage" within I'utilisateur de la pr(~sence de "tension dangereuse" the product's enclosure that may be of sufficient non isoi~ da'ns I'enceinte du produit qui pourrait ~tre magnitude to constitute a risk of electronic shock to d'une importance suffisante pour pr(~senter un risque d'~lectrocution aux personnes. .. persons. /~ The exclamation point within an equilateral triangle isz~ . Le point d'exclamation dans un triangle ~quilat(~ral intended to alert the user to the presence of -est pr~vu pour avertir I'utilisateur de ia presence important operating and maintenance (servicing) d'instructions importantes pour les opt, rations et instructions in the literature accompanying the I'entretien (service) dans les manuels fourhis avec product. I'appareil. ESP-LX+ & LXi+ Installation. Programming &Operation Guide Page 1 ,/ INTRODUCTION LX + and LXi + Series Controllers I1~ The ESP (Extra 'Simple Programming) -LX+, -LXi+ Serie~The ESP-LX+ comes in 6~, 8-, 12-, 16-, 20-, or 2.4-station models, Controller is an irrigation timing system for residential and light.designed for either indoor or outdoor use. The ESP-LXi+ comes commercial use. in 8-, 12-, or 16-station models, for indoor use only. Controller Stations Your ESP-LX+, LXi+ Series controller is an electronic clock that//~NOTE: ESP-LX+ and -LXi+ controllers let you set a controls when your sprinkler system turns on/and how long the delay between stations. For example, if you set a sprinklers run. The controller has sdveral stations connected to it,one-minute delay, station 1 will run until finished, as shown in the illustration .on the following page. Each station isfollowed by a one-minute delay. Then station 2 will connected to a remote control sprinkler valve. operate, followed by a one-minute delay. The valve opens when it 'receives power from the controller, and the sprinklers connected to that valve turn' on. When these sprinklers have run for their programmed time, the controller shuts off the valve and opens the next valve in sequence. For example, the illustration shows that station 1 is currently watering. When station 1 is finished, the controller will shut it off and start station 2. In the same way, station 3 will begin watering when station 2 is finished. Page 2 ESP-LX+ & LXi+ Installation, Programming &Operation Guide Station Layout Controller Remote Control Valves Sprinklers Y' ~ Station 1 Common ~~ ires Wire '1~ - Station 2 Station 3 ESP-I,X+ & LXi+ Installation, Programming &Operation Guide Page 3 ContrOls, SwitcheS, and:. Indicators The illustration shows the controls, switches, and indicators onr~~~.Dl '~~_ ,.1 the ESP-LX+ controller, including: 0 Fault LED -- flashes when the controller senses a station '~' "" short circuit. '0 \ ~rER BUDGET ~ ' e) Reset Button -- used to turn off the Fault LED after the fault~Sr~'AOC, a~' CUS has been corrected. 6 LCD Display -- during normal operation, displays the time of ~.o~f o day; during programming, shows the result of your ~/u~, commands; during watering, shows the station that is 0 · _ running and the minutes remaining in its run time. .,, WATERING TIME~ 0 Manual Staff/Advance Button --used to start a program ~,,, PERSTATION manually or to manually advance watering from one station O STARONS to the next. Also used to make program changes. """'"' Oflr ACTIVE 6) PGM Button -- used to select watering program A, B, C, or D-drip. :. ~ ' = 6Arrow ! ON-OFF Buttons -- used to set times and days, and to make program changes. 0Programming Dial -- used to turn the controller off and on, and for programming. Page 4 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Watering Suspended by Sensor LED -- glows when watering is r prevented by a sensor. o 0 · Sensor Bypass Switcb-- used to tell the controller to obey or ignore input from a sensor system. (Sensor systems are z~z~ll> ,., ~ optional.) Stations Slide Switch- used to select one of the station rows around the' Programming Dial. For 12-, 16-, 20-. and 24-station models only. ~ , WATERING TIME PER STATION W,4~IIW~ ""O SENSOR STATIONS 2- O0 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 5 PROGRAMMING THE CONTROLLER Definitions ' "' Programming is the process of telling the controller exactly when and how long you want to water. The controller opens and closes· Start time(s) <~ - the time(s) of day that the program begins; the remote control valves according to the program you set.this is the time that the first station in the program begins watering; all other stations in the program then follow in Each program contains: sequence. ~/~ /~ NOTE: The term "start time" refers to the time that a · Waterinll days - the specific days of the week on which program starts -- not to the time that each individual watering takes place (for example; Monday, Wednesday, station begins to run. Friday), or the watering interval (for example, every third day, or only on even or odd numbered days of the month). · Run time ~ - the number of minutes (or hours and minutes) that each station runs. Programming Under Battery Power ' If you wish, you can remove the front face panel of the controllerTo program the ESP-LX+ or ESP-LXi+ controller under battery and program the unit under battery power. This feature can bepower, you will need to install the battery as described on page useful if the controller is installed in an area that is not readily53. To remove the face panel, see the instructions on page 40. accessible. This feature also allows you to enter program information before installing the controller at the job site. Page 6 ' ESP-LX+ & LXi+ Installation, Programming &Operation Guide Programming Checklist ,_ To program the ESP-LX+ controller for the first time, we recommend that you complete the following steps in order. For your convenience, a check-off box (C3) is provided for each step. El Fill out Programming Chart .......................................:: ......................Page 8 El Clear all program information ...........................................................Page 10 El Set time and date ..............................................................................Page 11 For each program: A B C D El El El El Select program (A. B. C, or D-drip) ......Page 13 El El El El Set watering schedule.: ........................Page 14 El El El El Set station run times .............................Page 19 El El El El Set program start time(s) .....................Page 21 El El El El Set water budgel (optional) ..................Page 23 El El El El Set station delays (optional) .................Page 24 El Set master valve / pump starts for each station (optional) ...............Page 26 El Set rain delay (optional) ....................................................................Page 28 El Set calendar day(s) ON/OFF (optional) ............................................Page 29 El Set sensor system and switch (optional) ..........................................Page 31 El Run test program (optional) ..............................................................Page 33 ' El Set con!roller to automatic operation ..................... ............................Page 34 ,, ESP-LX+ & LXi+ Installation, Programming &Operation Guide Page 7 Fill out Programming Chart Before you begin programming, fill out the Programming Chart(~ Enter the watering run time (in hours and minutes) for each and attach it to the inside of the controller door. A sample station assigned to Program A. Programming Chart is on the next page. (]) Enter the water budget percentage. The water budget in the 0 Describe the sprinklers or plant zones covered by each sample is set to 80% station on the controller. 0 Enter the station delays for Program A. A station delay is the e Indicate which stations drive a master valve or booster pump. time between the end of one station's operation and the relay by checking "ON" in the MV / Pump column. beginning of the ne. xt. Station delays can be used to allow a ~) In the Program "A" column, for Custom cycle, circle the water well tc~ recover or slow-closing valves to turn off specific days of the week; for Cyclical schedule, write thecompletely. If neither of these situations applies to your site, cycle period (e.g., "3 - day cycle" means every third day); forleave the station delay set to 0. A station delay setting - ODD/EVEN-day watering, check ODD or EVEN. applies to all stations on the program. (:) Enter the start time for Program A. You may enter up to sixIn the sample chart, Program A has a one-minute delay start times for each program, but only one is needed to run between stations. When Station 1 ends, the controller waits the program. one minute before starting Station 2. There will also be a t/~ NOTE: Start times apply to the program, not to the one-minute delay between Station 2 and Station 3, etc. individual stations assigned to the program. In this 0 Make any special notes in the space provided. example, Program A begins watering at 8:00 a.m. on (])Repeat steps 2 through 7 for Programs B, C, and D. Mondays, Tuesdays, Thursdays, and Saturdays. Sta- /,~ NOTE: Stations assigned to Program D cannot be tion 1 runs for ten minutes, followed by Station 2 for 20 used in any other programs. See page 19 for more minutes, Station 3 for 20 minutes, and Station 4 for information. 5 minutes. The entire program will take about an hour. 'Page 8 ESP-I,X+ & LXi+ Installation, Programming & Operation Guide / · S~W~FS SMTWTFS GMTWTFB SMIWTFS' PROGRAMMING CHART o ~ o ~ o ~ ~ ~-~. 0 ~m~g O ~.~le 0 ~mild O ~m31~ 2 __~lm_ 2 ~lm 2 9:~1~ 2 mira · T~~:~47~ ~ / 1 rain./' ~ R~ ~m R~ ~ Run ~N ~ ~ 10 rain./ 2 L ~m~ ~ 20 4 5hinge ~ .... 5 ~ln. IO rain. 6 ~ ~ack ~ / 10 rain. 7 ~ack 5p~e Q~ 10 rain. .... a M~'e ~ Q ~ .... 5 rain. '' 9 Dsa'e ~F=dm=~ om ~ rain. 10 .~, ESP-~+ & ~i+ Instabtion, Programmin~ & Ope~tion Guide PaOe 9 Clear all Program Information To ensure you begin with a "clean" set up, clear the controller of ,.e all existing program settings. O Turn the dial to "OFF." ~ Hold down "ON" and "MAN. START/ADV." for about seven seconds until the display reads INITSYS.and then begins to scroll. ~) When the minutes in "SUN 12:00" flash in the display, the existing program se~ings have been cleared. Page 10 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ,.I Before you can program the controller, you must set its internal clock to the correct time and date. 0 Turn the dial to "TIME/CALENDAR." e) The hour digits in the display flash. WA~R~u~r ~ CSUC~ 0 Press 9 or ~ to set the current hour. .,, {) Press "MAN. START/ADV." T~/C,~,.~\ RAiN D~LAY ~) The minutes digits in the display flash. ·Press t3' or ,5 to set the current minute. ' I O SENSOR STATIONS ESP-LX+ & LXi+ Installation, Programming &Operation Guide ' Page 11 Press "MAN. START/ADV." A new display appears, showing the day, month, and year. r The month flashes. ,,-, · o Press '~ or ~ to set the Current month. wArERBuDeEr Press "MAN. START/ADV." DAY CYCLE ~) The day number flashes in the display. RAIN DELAY f o Press t~ or. a, to set the current day of the month. ~/~u~P SELECt Pre~s.,.MAN. START/ADV." w~N~ . The year flashes in the display. WATERING Press ~ or ~ to set the current year. 0 SENSOR srA~To~vs You are finished setting the time and date. Turn the dial to """=' "AUTO." oft ~cr~ ca:> cz~ Page 12 ESP-LX+ & LXi+ Installation, Programming &Operation Guide Select Program Four programs are available in the ESP-LX+, LXi+ Series Programs A, B, and C are not allowed to overlap each other. If controller: A, B, C, and D-ddp. Multiple independent programs letthey are programmed to overlap, programs A, B, or C will "stack" you enter schedules to meet the requirements of different types(run in consecutive order upon the completion of the program in of plant materials, soils, slopes, shady or sunny areas, etc.progress). The D-drip program is designed for drip irrigation equipment.Program "stac._king" prevents excessive flow demand and low Stations assigned to the D-drip program cannot be assigned towater pressure caused by having too many valves running at one any other program. The D-drip program can overlap, or run time. concurrently, with programs A, B, or C. .~ NOTE: It is easier to .select a program and program it completely, Jumping from program to program can be confusing. O Turn the dial to "AUTO." ~ · e) Press "PGM" 'to cycle through the available programs. The which program is currently selected... : . ESP-LX+ & LXi+ Installation, Programming &Operation Guide '~ Page 13 Set Watering Day Cycle Each program can operate in one of four watering day cycles:3. ODD waters only on odd-numbered days of the month. See f: CUSTOM waters on the days of the week you select. See thepage 18. instructions below. . 4. EVEN waters only on even-numbered days of the month. See 2, CYCLICAL waters on a selected daily interval (for example,page 18. every other day, or every third day). See page 16. CUStOITI To set a custom cycle: r 0 Turn the dial to "DAY CYCLE." o e) The display shows the currently selected program. If the program you want is not displayed, press "PGM" until it appears. ~) Press t~ or ~ until "CUSTOM" appears in the display. WAF~PJN~ PER STATION O SEttSOR ~SP- Page 14 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Turn the dial to "MON." The display shows the selected day and either "ON" or "OFF." ON means the selected day is a watering day. OFF means watering doesn't take place on that day. Press ~ or ~ to set the day ON or OFF. Turn the dial to the ne~ day of the week. Repeat steps 6 until you have set each day of the week ON or OFF. Turn the dial to "AUTO." ESP-LX+ & LXi+ Installation, Programming &. Operation Guide Page 15 ,/ To set a cyclical schedule: .d 0 Turn the dial to "DAY CYCLE." .,,,.~. ~.'.. !- E O The display shows the currently selected program. If the program you want is not displayed, press "PGM" until it appears. O Press t3' or ~ until "CYCLIC" appears in the display. e Press "MAN. START/ADV." "" 'D'2~" ~-zx 6) The display shows the number of days remaining until a ~ ' watering day and the number of days in the cycle. The "DAY CYCLE" digit flashes. O Press ~ or ~ to set the number of days in the cycle. For example, if you want to water every other day, set the day cycle to "2." If you want to water every third day, set the day .. cycle to "3." ""~'~'~,~ " "" """"' "' "'" Page 16 ESP-LX+ & LXi+ Installation, Programming & Operation Guide l) Press "MAN. START/ADV." 0 The DAYS REMAINING digit flashes. ,e (D Press t~ or 8 to set the number of days remaining before the next watering day. "0" means that today is a watering day. So if youwant'watering to begin tomorrow, set the days remaining to "1 ." ~ Turn the dial to "AUTO." ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 17 it Odd/Even Cycle To set an odd/even cycle: 0 Turn the dial to "DAY CYCLE." r · o 0 0 The display shows the currently selected program. If the program you want is not displayed, press "PGM" until it. appears. ~Y~,~ 0 Press ~ or ~, until "ODD" or"EVEN" appears in the display. 0 Turn the dial to "AUTO." /~ NOTE: If you do not want to water on the 31 st of any WATERING TIME, PER STATION month (a restriction imposed in some local areas), you must set the 31 st day OFF. Sei9 page 29 for o instructions. ,,_ ESP- 12-L~__ '~(~f~ Page 18 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Set Station Watering Times You can set any station to run from 0 to 12 hours. For the first two hours, you can set the watering time in one-minute increments. For the remaining 10 hours, you can set the watering time in 1 O? minute increments. OOn 12-, 16-, 20-. and 24-station models, set the "STATIONS" slide switch to the block of stations you want to set. e Turn the dial to the station number'you want in the "WATERING TIME PER STATION" section of the dial. · ~) The display showS the program, the station number, and the currently set watering time. If the station has been included in another program. "USED" appears in the display. A NOTE: If "USED" appears, you can-still set a watering previously assigned to the D-drip program. Stations assigned to the D-drip program cannot be used by any other program. ESP-LX+ & LXi+ Installation, Programming &Operation Guide Page 19 ,I 0 If the program you want is not displayed, press "PGM" until it appears. · Press t~ or 8. to set th'e length of time you want the station '~' O me to run. Repeat steps 2 - 5 for all stations. If you do not want ~ After you have set the run time for the last station turn the dial to "AUTO." ' R/dN DEL4Y /NOTE: You can use the Water Budgeting feature to ~ ', set watering times of less than one minute. For example, if you set a station watering time of one ~,~ minute and adjust Water Budgeting to 50 percent, , the station will run for 30 seconds. See page 23 for instructions on setting the Water Budget. 0~ ~c~ <z~ Page 20 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Set Program Start Times You may.assign up to six start times to a program per day. A program may start on any quarter hour. Multiple start times allow you to run a program more than once on each watering, day. For example if you are growing new lawn seed, you may want tO water several times a day to keep the seedbed or top dressing damp. //~ NOTE: Start times apply to the entire program, not to an individual station. O Turn the dial to "WATERING START TIMES." 0The display shows the program, the number of the start time, and the start time itself. The start time number .. flashes. 6If the program you want is not displayed, press "PGM" until it appears. 0 Press t~ or 8 to select one of the six start time numbers for the program. 6) Press "MAN. START/ADV." 6 The ,Starting time flashes. ESP-LX+ & LXi+ Installation, Programming &Operation Guide Page 21 ,/ Press t3' or 8, to set the start time. Start times are available in 15-minute intervals throughout the day. To eliminate a start time, select the OFF setting between r 11:45 p.m. and 12:00 a.m., or between 23:45 and 24:00. o //~ NOTE: Start times appear in chronological order. If you delete a start time by setting it to OFF, all later ~mc~ll> start times are automatically moved down one start time number. ,~,/pu,~ SELECt' When you set a start time for any start time number, the controller automatically reorganizes the start times so they appear in chronological order. The earliest start time will be number 1 and the latest o start time will be number 6. This reorganizing only occurs after you move the dial off the "WATERING START TIMES" position. k. If you want to set additional start times, press "MAN. START/ADV ." Repeat steps 2 - 7 to set the next start time. Turn the dial to "AUTO." Page 22 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Set Water Budget The water budget feature lets you increase or decrease the runIn addition, you can use the 0% setting to shut off a program times of all stations on a program by a selected percentage. Youtemporarily. can set the percentage from 0% to 300%, in increments of oneWater budget percentages are calculated on the normal percent. Each program can have a different water budget programmed run times for each station. For example, if a station percentage. is programmed to run for 10 minutes, and you set the water You can use the water budget feature to cut back watering duringbudget to 80%, the station will run for 8 minutes (80% of 10). If cool winter months, or to increase watering during periods ofyou set the water budget to 120%, that same station will run for unusual heat. 12 minutes (120% of 10). 0 Turn the dial to "WATER BUDGET." 1]) The display shows the selected program and its current r water budget percentage. The default is 100%. ~ ~'A '~ · ~ If the program you want is not displayed. press "PGM" until it ~',,",.,.~-,,~' appears. 0 Press t~ or 8 to set the percentage. ;;" 6) To set water budgeting for another program, press "PGM" until the program appears. Then repeat step 4. ~ Turn the dial to "AUTO." When the water budget for a ~ ~ OFF program is set higher or lower than 100%. "WATER . ./.~ , BUDGET" appears in the display whenever the program is '- selected. , ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 23 Set Station Delays The station delay feature lets you program a pause between theYou can set a different station delay for each program. A station end of one station's watering operation and the beginning of thedelay applies to all stations on a given program. next station's operation. You may set a delay from one second toBecause the station delay feature is not used very often, it has nine hours. · ' been "hidden" behind the "TEST PROGRAM" position on the You can use station delays to allow a water well to recover ordial. slow-closing valves to turn off completely. If neither of these situations applies to your site, leave the station delay set to O. 0 Turn the dial to "TEST PROGRAM." ~ The display shows "TEST" and the standard two-minute run r time for the test program. o ~) Press t~ AND ~, at the same time. 0ArCI~ R/JNO(Z/J'le' WA~EAW6 Page 24 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ~) "DELAY" appears in the display momentarily, followed by the delay time. f - · 0 If the program you want is not displayed, press "PGM" until it appears. 5E O Press 9 or ~, to set the delay time. To cancel station DAYCIf, t,E~ w~a . delay, set the delay time to zero. lIME CA~ND4R /f NOTE: The display initially shows the delay time in seconds ("SEC"). When you advance past 59 seconds. the display changes to "MIN" for minutes and seconds. When you advance past 60 minutes, the display changes to "HOUR" for hours and minutes. ,,~o,.0, ~ ~:~:~ OFF ACT/VE i) To set delays for additional programs, press "PGM" until the ESP-12-LX':~'~' program you want appears. Repeat step 6. O' Turn the dial to "AUTO." /F',, NOTE: During the delay between stations, the master valve / pump relay is not. active. See page 26 for instructions on selecting the master valve / pump relay. ESP-LX+ & LXi+ Installation, Programming & Operation Guide , Page 25 / Set MV / Pump Starts You can assign a master valve relay or a pump start relay to eachThe MV / Pump start setting affects the station in all programs to ,.d station. This means that any time the station operates, the relaywhich it is assigned. assigned to it will also turn on. For example, if a specific station needs additional water pressure, you may want to activate a,~ CAUTION: If an unused station is turned on and booster pump whenever that station turns on. activates a pump start relay, the pump may overhear //~ or cause a pipe to burst. To prevent operating a NOTE: Stations that have a master valve / pump relay pump with no flow (deadheading), make sure all assigned to them must be wired properly to activate unused stations have a zero run time. the relay. See page 51 for instructions. 0 Turn the dial to "MV / PUMP SELECT." .. ~ The display shows the station number and "MV ON" or "MV r ~'~ 6) Press ~ or ,~ to select the station number you want to set. ~ Press "MAN. START/ADV." ~,,..~ "] ~.,o~ Page 26 ESP-LX+ & LXi+ Installation, Programming & Opsration Guide ,! 6) The "ON" or "OFF" flashes in the display. 6 Press t} for ON or 8 for OFF. i) To set another station. press "MAN. START/ADV." Repeat steps 2 - 6 for each station you want to set. 6 Turn the dial to "AUTO." I ESP-L)(+ & LXi+ Installation, Programming &Operation Guide Page 27 ,/ Set Rain Delay : ,~1 ESP-LX+ and -LXi+ controllers let you manually delay watering for up to 14 days. For example, if rainy weather lasts for 2 or 3 period manually. If you have an automatic rain sensor days, you can set a Rain Delay of 5 or 6 days to let the attached to your system, see the instructions on landscape dry out before resuming normal watering schedules. page 31. The Rain Delay setting applies to all programs. You can run programs manually during the Rain Delay period. O Turn the dial to "RAIN DELAY." r , O The display shows "RAIN DELAY" and the number of days Delay set, zero will appear in the display above the words .-..,.g--, "DAYS REMAINING." '"'~"~ ~) Press t~ or ~ to set the number of days to wait until the next watering day. To cancel a Rain Delay, set the number of days to zero. (:) Turn the dial to "AUTO." Page 28 .,ESP-LX+ & LXi+ Installation, Programming & Operation Guide , i Set Calendar Days OFF .d The Calendar Day OFF feature lets you: · Permanently set the 31 st day Of any month OFF. This setting : · Temporarily suspend watering on a specific day of the monthcomplies with local watering ordinances that prohibit watering - on the 31 st. Unlike settings for other days of the month, this i (selected up to 30 days in advance). For example, if you are' planning an Independence Day picnic, you can set July 4th setting remains in effect until you ~hange it. OFF, so no watering will occur. After July 4th passes, theA Calendar Day OFF setting applies to all programs. fourth of each month will be automatically reset to ON. 0 Turn the dial to "TIME/CALENDAR." 0 e Press "MAN. START/ADV" five times. r ,., ~) The display shows the day of the month and its ON or OFF setting. The day of the month flashes. '"I e Press ~ or ~ to select the day of the month you want to set. ESP-LX+ & LXi+ Installation, Programming &Operation Guide Page 29 ,/ (]) Press "MAN. START/ADV." ~) The ON or OFF setting flashes. ~ml 0 Press t3' to set the day ON or ,g, to set the day OFF. o O 0 Turn the dial to "AUTO." When an OFF day occurs, the display shows "NON" (for non-watering day), and no watering occurs. The next time the date occurs, normal RA/N ~)EMY watering schedules will resume (except for the 31 st of the month, which remains OFF until you reset it manually). SE~cr WArg'!/NG PER SENSOR SI'ArlONS Page 30 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Set Sensor System and Bypass Switch ESP-LX+ and -LXi+ controllers let you connect a sensor systemz~ NOTE: For this feature to operate properly, the that interrupts watering when a "wet" condition is detected. For sensor must be connected according to the example, if you have a Rain Bird Rain Check'" sensor connected instructions on page 52. to the controller, it will be prevented from watering when rainfall ' reaches the shutoff level in the sensor's collector cup. O To activate the sensor system, set the sensor bypass switch r '~' .,. · to "ACTIVE." The controller will operate normally until a wet W,4I'ER BUDCa' condition is detected by the sensor. r~.r~.o~ \ · ~ S/.~'rl la:os,. /~ NOTE: If no sensor is attached to the controller, ~'~i~ ' · ~MEICALENG4R make sure the supplied jumper connects the two o SENSOR terminals on the controller's circuit board. If Sh~V~C you set the sensor.bypass switch to "ACTIVE" ,,~ without a sensor or jumper connected to these ' terminals, the valves will not operate, and no watering will occur. See page 52 for instructions. ~ When the sensor detects a wet condition, power to the cm valves will be interrupted, and no watering will occur ESP-12-LX (including manual program or station op.eration.) The ~- ' = "WATERING SUSPENDED BY SENSOR" indicator will light up. ESP-I-X+ & LXi+ Installation, Programming & Operation Guide ' Page 31 / To bypass the sensor, set the sensor bypass switch to r ~' ,,~, ~ "OFF." The controller will ignore any sensor signals, and normal watering schedules will resume. This setting also lets wr~.~r. rr~ c~,~ I 5~"'J'f fa:EI 5,.1 you run programs and stations manually. ~,~ ~. ~ PER S TA~ON ~ 0 ~ S~S ~S~-]2-~ Page 32 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Run Test Program The controller's built-in test program will run each station.that has a 0 non-zero watering time assigned to it, When you run the test program, the controller will operate each station in numerical ~,.,.~.~ \\ ~ :. sequence, from lowest to highest, You can use this program to. .,,=, . ~ . check out the operation of all the sprinklers in the system. ~,~,~' ' .~~~.~EE]I~ ' 0 Turn the dial to "TEST PROGRAM," (~ The display shows "TEST" and the amount of time each station will run. The run time flashes. The default run time is two minutes per station. "' ~) Press l:r or ~ to increase or decrease the run times for the TEST PROGRAM. The maximum run time is 10 minutes. 0 Press "MAN. START/ADV." to start the test program. , (;) Turn the dial to "AUTO." · The display shows the number of the station that is running, ..o,~o~ . ~ . along with its remaining run time. The controller runs each station in sequence, from lowest number to highest. The test program skips any stations that have zero watering times assigned to them. When the test program is finished, the controller returns to automatic operation. 'i) To cancel a test program after it has started, turn the dial to "OFF" for three seconds. Then turn the dial back to "AUTO." ESP-L.X+ & LXi+ Installation, Programming &Operation Guide Page 33 ,/ OPERATING THE CONTROLLER , After you have programmed the controller, you will normally set itYou can also manually, run one or more programs, and you can ~.1 to operate automatically. manually operate a single station or several stations. ~ I I Operate Controller Automatically 0 Turn the dial to "AUTO." The controller runs the sprinklers according to the programs you have set. 6~l//~.~r/ · cO D~,~ .~ [~ -- --- ~ ~sP-~-~{~ Page 34 ESP-LX+ & LXi+ Installation, Programming & Operation Guide RUn Program(s) Manually ,~ NOTE: To run a program manually, please foliow the instructions below carefully. Unlike other ESP controllers, ESP-LX+ and -LXi+ controllers have must select a program before you press the MAN. START / ADV. huron. : O Turn the dial to "AUTO." ~ ~e display ~hows t~e da~ of the wee~ and ti~e of ~a~. ~ Press "P~" ~ntil the ~ro~ra~ you want i~ ~i~la~e~. G ~re~s "~N. 8TART /~DV." to sta~ the seleGte~ If you want to run additional ~ro~ram~. re~eat ~te~ ~aGh ~rogram you select will run when t~e has ended. You Gan "sta~k" all four pro~ra~ to ru~ sequence. 9 To cancel all programs currently seiected to run, turn the dial to "OFF" for three seconds. Then turn the dial back to "AUTO." ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 35 ,i Run Station(s) Manually O On 12-, 16-, 20-. and 24-station models, set the "STATIONS" ~"" slide switch to the block of stations containing the one you want to run. r o0~ (~ Turn the dial to the station number you want in the WATER BUDGET "WATERING TIME PER STATION" section of the dial. ~) The display shows the currently selected program. the station number, and the station's run time. If the station is not~,,~,~. used in the current program but is used in another program, $EECT the word "USED" will appear in the display instead of the run time. " 0 Press "'PGM" until the display shows a run time for the station. o 0 Press "MAN. START / ADV." to operate the selected station. ~ ~c~ If you want to run additional stations, repeat steps 3 to 5. J~SP-]2-Z,Z Each station you select will run when the previous station "- "" has ended. (]) After selecting all the stations you want to run, turn the dial to "AUTO." The stations you have selected will operate for their programmed run times and then shut off automatically. O To cancel the manual operation of all selected stations, turn the dial to "OFF" for three seconds. Then turn the dial back to "AUTO." .. Page 36 ESP-LX+ & LXi+ Installation, Programming & Operation Guide INSTALLING THE CONTROLLER This section of the manual explains how to mount the controllerThe ESP-LXi+ controller must be installed .indoors only. The "i" in on the wall and connect the wiring. the model number stands for "indoors." //~ NOTE.' This controller must be installed in The ESP-LX+ controller may be installed either indoors or compliance with local electrical codes. outdoors. Installation Checklist - To install the ESP-LX+ controller, we recommend that you ~omplete the following steps in order. For your convenience, a check-off box (C3) is provided ~or each step. 1211 Select location. · , ................................................ Page 38 1211 Remove door and face panel ..........................Page 40 1211 Mount controller on wall ...................................Page 42 123 Connect main power wires ..............................Page 44 t2]1 Connect field wires... ............ Page 50 1231 Connect sensor system (optional) ..................Page 52 1211 Install battery ...................................................Page 53 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 37 Select Location ~..I Follow these guidelines to select a location for the controller:~ Choose a flat, stable. vertical sudace. Allow enough 0 Select an area protected from vandalism. where the user can clearance for electrical conduit and connections at the easily reach the controller. We recommend mounting the bottom of the pla,stic cabinet. controller at eye level in a utility room. Q Allow at least 91/2" (24,2 cm) of horizontal clearance so the //~ NOTE: To minimize electromagnetic intederence, hinged cabinet door can swing fully open to the left. select a location at least 15 feet (4,6 m) away from (~ Allow at least 63A" (17,2 cm) of clearance above the cabinet high-draw motors such as air conditioners, door so the hinge pin can be removed to service the refrigerators, or pool pumps. controller. ~) Select a location that has access to 120-Volt AC electrical power or 230-Volt AC electrical power (as required). //~ WARNING: A circuit breaker or cutoff switch is to be provided in the fixed wiring to isolate the controller. Page 38 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ( 17,2 cm) P ESP-LX+ & I, Xi+ Installation, Programming & Operation Guide Page 39 '! Remove Door and Face Panel Before you mount the controller, we recommend that you remove~ Disconnect the ribbon cable by grasping it along its two flat ~.~ the door and face panel. Although these steps are not absolutelysides. Then pull the cable gently out of its connector. necessary, they will make installation more convenient. 6 Unplug the two-wire harness by releasing the latch on the O Open the door and swing it to the left. If necessary, unlockside of the connector. Then pull the connector away from the the door with the supplied key. terminal board. e Flip the upper tip of the hinge pin out of the groove in thel)Press down on the upper flexible hinge to release the hinge door so it is pointing at you. knob from its hole in the cabinet. 6) Support the door and slide the hinge pin upward until it~) Pull the lower hinge knob out of its hole and remove the clears the hinges. Then remove the door. panel. 0 Open the face panel by grasping its lower right corner and swinging it to the left. Page 40 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ......... __,,,~~.y · ~ I ' "' o0 p,·~ .o P L ,,- . _:, ',,._ ..,, . ESP-LX+ & LXi+ Inslalla.lion, Programming & Operalion Guide Page ,/ Mount Controller on Wall The ESP-LX+ has four mounting holes on the back of the cabinet(]) Use the keyhole slot(s) to hang the controller cabinet on the ~ee -- three "keyhole" slots at the top of the cabinet and one circularfasteners. Make sure the shafts of the fasteners are well up hole at the bottom of the cabinet. in the narrow part of the keyholes. O To install the controller on a flat wall surface, use the left and~ Drive the last fastener through the lower mounting hole. right keyhole slots at the top of the cabinet. Verify that the cabinet is secure. If necessary, tighten the 1~1 To install the controller on a narrow stud, use the centerfasteners in the upp'er keyhole Slot(s). keyhole slot. 6) For all installations, use the small round hole at the 15otto.rp of the cabinet. .. ~) Hold the controller (at eye level) against the mounting surface. Use a pencil to mark the position of the holes on the mounting surface. Then remove the controller cabinet. ~ On flat wall surfaces, drive an appropriate fastener for the type of wall into the two outside keyhole marks. ~ For narrow stud installations, drive an appropriate fastener for the type of wall into the middle keyhole mark. I) Use a nail to tap a small pilot hole on the mark for the lower mounting hole. However, DO NOT drive a fastener into this location yet. Page 42 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ESP-LX+ & LXi+ Installation, Programming &Operation Guide Page 43 ,m Connect Main Power Wires ESP-I.X:+ (Outdoor / Indoor Controller) //~ NOTE: To connect main power wires on the ESP- ~ WARNING: To prevent electrical shock, make sure all LXi+ indoor-only controller. see the instructions on supply power is OFF before connecting these wires. page 48. The ESP-LX+ controller has an internal transformer that reduces Electrical shock can cause severe injury or death. standard supply voltage (11 7 VAC in U.So models; 230 VAC in All electrical connections and wiring runs must be international models) to 24 VAC to operate the valves connected made according to local building codes. to the controller. You will need to connect power Supply wires to the transformer's three wires. 0 With the door and face panel removed, locate the high- voltage compartment in the lower left corner of the controller cabinet. e Remove the screw on the right edge of the compartment ~.' ,~(i~ ~[iIlfiji'~ ~.- cover. Then swing the cover open to expose the transformer's primary input wires CAUTION ' VO Page 44 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ~) If You wish to bring the Power supply wires through the wall on which you mount the controller, use the W' (1.3 cm) ' knockout in the rear of the cabinet. A/so remove the circular cutout in the flame~retardant fiberboard liner at the rear of the high-voltage compartment. For safety Purposes, be sure to seal th~ unused entry at the bottom of th · Attach a ~ the high-voltage compartment. Then attach conduit to the f/ffing. ~' (1,3 cm) conduit fiffing to thee cab/net. . bottom entrance of ESP-LA', & L,~'i, Insla!lalion, prograrnrnh9 & OPera/ion Guide ' Page45 ,m e Bring three supply wires from the power source through the conduit into the high-voltage compartment. Strip the O Using a code-approved wire connector, connect the wires as follows: On 117-120 VAC models (U.S.), connect the black supply wire ("hot") to the black transformer wire. On 230 VAC models (international), connect the brown supply wire ("hot") to the brown transformer wire. 0 On 117-120 VAC models (U.S.), connect the white supply wire ("neutral") to the white transformer wire. On 230 VAC models (international), connect the blue supply wire ("neutral") to the blue transformer wire. ~ On 117-120 VAC models (U.S.), connect the green supply wire ("'ground") to the green transformer wire. On 230 VAC models (international), connect the green-with- yellow-stripe supply wire ("ground") to the green-with-yellow- stripe transformer wire. ./~ NOTE: The ground wires MUST be connected to provide electrical surge protection. Page 46 ESP-LX+ & LXi+ Installation, Programming & Operation Guide ,m of the high-voltage compartment and secure it with.the 000000 ,CAUTION HIGH V LTAGE ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 47 ESP-LXi+(Indoor-OnlyController) The ESP-LXi+ controller (117 VAC model only) has an external transformer that reduces standard supply voltage to 24 VAC to operate the valves connected to the controller. the vertical terminal strip in the controller cabinet. //~ CAU,TI ON: To avoid electrical shock, do NOT plug in the transformer until you have connected its cable to the controller. If the transformer is plugged in while the cable is not attached, any contact between the three forked connectors will blow the transformer's internal fuse. A blown transformer fuse cannot be ' repaired. All electrical connections and wiring runs must be made according to local building codes. 0 Make sure the transformer is HOT plugged in. ~ Feed the three forked transformer wires through the bottom left hole in the cabinet. Then pull about 12 inches of the cable up into the controller cabinet. ~) Tie a loose overhand knot in the cable just inside the controller to prevent any strain on the connector terminals. Page 48 ESP.LX+ & LXi+ Installation, Programming & Operation Guide On the vertical terminal strip, connect the green forked wire to the terminal labeled "GND." //~ NOTE: The green ground wire MUST be connected properly to provide electrical surge protection, Connect one of the remaining ~o forked wires to one of the terminals labeled "24 VAC."" (In some units, these ~o IA~~ ~" ' "'.. ' - terminals are labeled "ORN.") Connect the last forked wire to wires is not impo~ant. You may connect either wire to either transformer into any standard three-prong grounded 117 VAC electrical outlet. blade of plug to wide slot, fully inse~ed. C0M ESP-I_X+ & LXi+ Installation, Programming &Operation Guide Page 4~ Connect Field Wires Field Wire Entrances The ESP-LX+ cabinet has three entrances for routing field wires and the third is located on the back of the cabinet. O ~e underside of the cabinet has a hole sized for a 1" (2,6 cm) PVC male adapter so you can easily install a 1" (2,6 cm) PVC pipe or conduit for the valve wires. ~ A larger knockout for a 1 ~A" (3,2 cm) PVC male adapter is molded into the underside of the cabinet, surrounding the 1" (2,6 cm) hole. You may need this larger hole if you are using ~14 gauge wire or larger. To use the larger hole, turn the cabinet upside down. Place the blade of a slot-head screwdriver in the groove around the knockout. Then firmly tap the handle of the screwdriver to punch in the knockout. You may need to punch the groove in ~o places. ~ If you wish to route the field wires through the wall on which the controller is mounted, use the 1" (2,6 cm) knockout on the back of the controller cabinet. Use a screwdriver to punch out the knockout, as described in step 2. Page 50 ESP-LX+ & LXi+ Installation, Programming & Operation Guide Station Valve Wiring Connect each valve by its own separate power wire to one of the '=i~'LL:i% ~[('i ~ ~ t ~ ~ i i ~ [ numbered terminals on the ESP-LX+ terminal strip, as shown in ~ ~. ,, :/.~ ............, ........~, ..' ,, , ,.. , the illustration. You may connect up to ~o 24 VAC, 7VA solenoid · .~..~, ,. · . _ valves per station. You may use the special Valve Test position to help identi~ valve stations BUT NOT for permanent connections: To speed up installation, slide the stripped end of the valve wire E '~ :' ' , . "" ". -'F under the "'pinch plate" at each terminal. The pinch plate eliminates the need to wrap the wire around the screw head. ~j,~2~'~~~ NOTE= The ESP -20 and -24 station models have a special scre~ess terminal strip for valve wire i~ ;.~ ~ + ~' connections. Connect a common wire to one of the leads on each valve. Connect the other end of the common wire to the COM terminal % ~ ~ Power on the flip strip. Wire used to connect the valves must be code- ~Wire approved for underground installation, Master Valve Wiring requires a master valve (an automatic valve installed on the mainline pipe upstream from the station valves) or a pump relay. ~e controller does NOT provide main power for a pump. Connect the master valve wiring to the MV terminal and COM MASTER STATION VALVES ~Common terminal as shown in the illustration. VALVE Wire , ESP-~+ a LXi+ Installation, Programming & Operation Guide , Page Sensor System Wiring ,NOTE: Complete this section .only if your system i ' ' '~'" .m. has an automatic r. ain sensor. ,"i ~:. .': :,, If you are not connecting a sensor to the controller,. ,._, , ,, ~~. '. - make sure the supplied jumper is installed on the ~".,' .". '~ ~;. ~ ,' ~" '/~' '~:L )':[ ~,~"( ~E,'~ . ."---: ~o SENSOR terminals on the contrGIler's vedical -" ' " terminal strip. ~, . 0 Most sensors have ~o wires or ~o terminals designed to be connected to the valve common wire. Instead of ' · ~oR ~- , ' .., ' or terminals to the "SENSOR" terminals on the ESP-~+ or - sensor system. ~ Follow the Sensor system's ,directions for placing and connecting moisture probes, seffing the rain shutoff level. ~'~ .~~~ and making final adjustments, Sen , Page 52 ESP-LX+ & LXi+ Installation,. Programming & Operation Guide ,1 ,m Install Battery ~...The 9-Volt rechargeable nickel metal hydride (NiMH) battery~NOTE: Memory is retained by a battery which supplied with the controller provides power to maintain the is to be disposed of in accordance with local current time and date during a power outage. Program regulations. information is maintained independently of battery power. So if a The battery also lets you program the controller with the face prolonged power outage outlasts the life of the battery, you willpanel detached from the cabinet power supply. only have to update the time and date after power is restored. 0 If you have removed the face panel and cabinet door for a new installation, reinstall them now. Be sure to connect the ribbon cable and two-wire harness from the face panel to the controller's circuit board. as described on page 40. 1~1 Loosen the screw on the battery cover, and slide the battery out of its bompartment. If you are replacing a used battery, - -' . , ', ':;.' :. discard the old battery properly. The replacement battery must be a 9-Volt rechargeable NiMH battery. ~:~. 0 If the battery has a protective cover installed over its terminals, remove the cover. Then connect the two-wire battery clip to the terminals. ~t,"~-~,.f · (222) ., Page 53 ESP-LX+ & I_Xi+ Installation, Programming & Operation Guide Slide the battery back into its compartment, and tighten the r"' I I I "~ screw. The controller will fully charge the supplied NiMH battery in approximately 48 hours. The controller will continue to trickle- charge the battery whenever the controller is supplied with electrical power. Page 54 ESP-LX+ & !,Xi+ Installation, Programming & Operation Guide TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE CORRECTION , Program does not come on 1. Dial' is set to OFF position. Set the dial to AUTO. automatically. 2. Start time has not been entered for the program.Turn the dial to WATERING START TIMES and check the start times entered for the program. If the start time is missing, enter it as described on page 21. 3. Rain Delay feature is preventing watering. (Displayif the Rain Delay feature has been set properly, no shows "RAIN DELAY" and "DAYS REMAINING.") correction is needed. To cancel the Rain Delay, see page 28. 4. Today may not be a watering day for the program.Press the PGM key to check the days remaining until the (Display shows "DAYS REMAINING" to the nextnext watering day for each program. watering day.) 5. Day Off feature is preventing watering. (DisplayIf the Day Off feature has been set properly, no correction is shows "NON," followed by the time of day.) needed. To run a program manually (even on a Day Off), see page 35. To change the Day Off feature, see page 29. 6. Program's Water Budget is set to 0%. Set the Water Budget above 0%. See page 23. Display sho~s a station 7. Sensor system is preventing irdgatjon. (WATERINGTurn the sensor bypass switch to OFF. If watering resumes, operating, but no watering SUSPENDED BY SENSOR light is lit.) the sensor is operating properly, and no correction is occurs. necessary. 8. No sensor or jumper is connected to the controller'sTurn the sensor bypass switch to OFF. To prevent future SENSOR terminals, and the SENSOR BYPASS switchoccurrences, install the supplied jumper on the controller's has been set to ACTIVE. SENSOR terminals. See page 52. ESP-LX+ & LXi+ Installation, Programming & Operation Guide Page 55 SYMPTOM POSSIBLE CAUSE CORRECTION Station does not come on. 9. No run time has been set for the station.Turn the dial to the station number, and press the PGM key to check the mn times set for the station. To add a mn time, see page 19. 10. A short circuit in the solenoid or valve wiring hasIdentify and repair the fault in the circuit. Then press the disabled the station, (Display shows "FAULT" and aRESET button, and start the station manually. See page 36 station number, and the FAULT light in the upper leftfor instructions. comer of the face panel is lit.) 11. Sensor system is preventing irrigation, (WATERINGSee correction for Cause #7. SUSPENDED BY SENSOR light is lit.) 12, Start time has not been entered for the program toSee correction for Cause #2. which the station is assigned. 13. Water Budget for the station's program is set to 0%.See correction for Cause #6. Display shows "PWR OFF." 14, No power is being supplied to the controller.Vedfy that the controller is plugged into a working outlet. Check the main power supply to the controller. Display shows "FUSE." 15, Fuse has blown. Disconnect the controller from its power source. Identify and repair the circuit fault that caused the fuse. to blow. Then replace the fuse with the spare fuse supplied on the inside of the face panel, just above the 9-Volt battery. For the ESP-LX+, use a 1.5A SLO-BLO fuse. Forthe ESP-LXi+, use a 1.25A SLO-BLO fuse. Reconnect power to the .controller and reset the time and date, Page 56 ESP-LX+ & LXi+ Installation, Programming & Operatioh Guide SYMPTOM POSSIBLE CAUSE CORRECTION Display shows "MVFAULT." 16. An electrical fault has occurred in the master valve orIdentify and repair the fault in the master valve or pump start pump start relay circuit. relay circuit. Then press the RESET button in the-upper left comer of the face panel. To vedfy that the probte. m has been corrected, ,manually start a program (see page 35) or run the TEST program (page 33). Display is partially or 17. An electrical surge or lightning strike has damagedTurn off the controller and disconnect the 9-Volt battery, Let completely blank. the controller's electronics. the controller sit for two or three minutes. Then reconnect the battery and restore power to the controller. Reset the time and date as described on page 11. If the electrical surge did no permanent damage, the controller will accept programming commands and function normally. If the controller does not operate properly, contact Rain Bird Technical Assistance at 800-247-3782. Watedng starts when it 18. MAN START / ADV. key has been pressed. To cancel a program that has been manually started, set the dial to OFF for three seconds, Then set the dial back to should noL AUTO. 19. An unwanted start time may have been entered.Turn the dial to WATERING START TIMES and check to see if any programs have an unwanted start time. See page 21 for instructions on setting and eliminating start times. 20. The programs may be stacked. Programs A, B, and C will sta~k behind each other if they are scheduled to start while another program (other than D) is running. Check to make sure Programs A, B, and C are not scheduled to start when any program other than D is scheduled. Refer to page 13. Page 57 ESP-LX+ & LXi+ Installation, Programming & Operation Guide This controller generates radio frequency energy and may 1. Reorient the receiving antenna. cause interference to radio and television reception. It has 2. Move the controller away from the receiver. been type tested and found to comply with the limits for a Class B computing device in accordance with the 3. Plug the controller into a different outlet so that the controller and receiver are on different branch circuits. specifications in Subpart J of Part 15 of FCC Rules, which are. designed to provide reasonable protection against such If necessary, the user should consult the dealer or experienced interference in a residential installation. However, there is noradio / television technician for additional suggestions. The guarantee that intederence will not occur in a particular user may find the following booklet prepared by t~e~fal installation. Communications Commission helpful: If this equipment does cause interference to radio or television"How to Identify and Resolve Radio-TV Interference Problems." reception, which can be determined by turning the equipment This booklet is available from the U.S. Government Printing off and on, the user is encouraged to try to correct the Office, Washington, D.C. 20402, Stock No. 004-000-00345-4. interference by one or more of the following measures: ,RAIN" ,BIRD RAIN BIRD SALES, ING, -- Oontractor Division 145 North Grand Avenue, Glendora, California 91740, U.S.A. 626-963-9311 © 1998 Rain Bird Sprinkler Mfg. Corp. ® Registered trademark of Rain Bird Sprinkler Mfg. Corp. ,. Technical Services: 800-24'7-3782