Download Viking Pump Technical Service Manual UDF 400 For Duplex Fuel
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VIKING PUMP Duplex Fuel Oil Packages Field Start-Up Guide Bulletin: UDF400 Issued: 2-Oct-06 Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 1 Before arriving on job site, make sure you have: A copy of the approved drawing or certified print of the Duplex Fuel Oil Pump Package A copy of the approved drawing of the Control Panel. Read all of the instructions, notes, and suggestions in this bulletin to become familiar with the start-up procedures. If you have any questions or require clarification please contact our systems specialist, Humberto Da Silva, P.Eng. at (905) 542-8906 ext. 204 (or North America toll free at 1-888-845-7867 ext. 0 and asked to be transferred) When you arrive at the site confirm the following: Check the name plate rating on the Control Panel and compare with the incoming voltage and motor ratings. The compound gauge should be located on the pump suction or in the suction header (depending on pump size and duplex package configuration layout). The pressure gauge should be on the discharge of the pump or in the discharge header (depending on pump size and duplex package configuration layout). Examine the suction header and confirm that the arrow cast into suction strainer points toward the pump suction. Confirm the sales order number stamped on the serial number plate matches the packing slip. The serial number plate is typically located on the base plate of the unit. On the control panel confirm the voltage, phase, horsepower, certifications and part number stamped on the serial number plate located on the door of the panel match the specifications. Do not open the panel door. Observations to be made on site: General Installation The package should be anchor to the ground to prevent movement. If the unit is mounted on a shelf it should be properly bolted. All piping (suction, discharge and relief return lines) should be externally supported to prevent pipe stresses being transferred to the unit. Ideally flexible connections should be used. Suction Piping If possible follow the suction pipe to the supply tank. The suction line should go around obstacles instead of over them. This is to prevent air lock (the system will not prime if the suction line is air locked). If there are any valves on the suction line they should be in the open position. With long suction pipe there should be a hand operated pump to evacuate the air from the suction line. This pump should be piped parallel to the duplex package. The relief valves piping can not be piped back into the suction piping. Both valves can be piped to a common pipe. But that pipe has to be piped back to the supply tank. There should not be any other valves in this line. If there is any they should be always in the open position. Discharge Piping The discharge will be piped into a day tank or directly into the diesel generator or boiler depending on the installation. If possible follow the discharge pipe. If there are any valves on the discharge line they should be in the open position. Take a look at the day tank. There should be the line from the duplex pump unit, overflow and floats. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 2 Fig. 1 – Typical F-432 & FH-432 Layout Fig. 2 – Typical Series 4195 & Spur Gear Layout VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 3 Main Disconnect Switches “ON-OFF” “POWER ON” White Pilot Light “LEAD PUMP FAILURE” Red Pilot Light Manual “RESET” Button “RUN” Green Pilot Light “RUN” Green Pilot Light “P1-AUTO-P2” “HAND-OFF-AUTO” Switch for P1 “HAND-OFF-AUTO” Switch for P2 Fig. 3 – Typical Control Panel Cover Priming the Duplex Fuel Oil Package: 1. On the Control Panel make sure both the Main Disconnect “ON-OFF” switches are in the “OFF” position (power off). 2. Take a look at the suction gauge to see if there is any pressure on the suction line. If there is pressure and the application is not a flooded suction the suction line is pressurized. Carefully remove the drain plug from the basket strainer to release the compressed air. 3. Turn the four ball valves connected to the pressure gauges (suction & discharge gauges) to closed position. 4. Remove the thumbscrew from top of the lid of the basket strainers, rotate the lid counter clockwise until the pin hits and stops, and then remove lid. 5. Open the suction valves. 6. Fill the strainers with diesel (the suction valves should be in open position, as you fill one strainer the liquid level will flow in the other strainer). 7. Reinstall the lid with the tab of the lid just to the left of the boss with the body, rotate the lid clockwise until the holes line up, and reinsert the thumbscrew. 8. Both the suction and discharge ball valves should be in open position. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 4 9. On the Control Panel, turn the “Hand-Off-Auto” selector switches to “Off” position for both P1 and P2. 10. Turn both the Main Disconnect “On-Off” switches to “ON” position (power on). 11. Turn the “P1-Auto-P2” switch to “P1” position. 12. Have some one observe the motor fan for the next operation. 13. For P1 turn “Hand-Off-Auto” selector switch to “Hand” position and P1 will start. 14. After approximate 3 seconds turn the “Hand-Off-Auto” selector switch for P1 back to “Off” position. 15. Confirm that the motor fan had spun in the proper rotation. If the motors are not rotating properly have an electrician switch the motor leads and check again the rotation of the motors. 16. Repeat steps 11 to 15 for P2. 17. Turn the four ball valves connected to the pressure gauges (suction & discharge gauges) to the open position. 18. For P1 turn “Hand-Off-Auto” selector switch to “Hand” position and P1 will start. 19. Observe the suction compound gauge; it should start pulling a vacuum. The discharge gauge will read 0 psi. Run P1 for no more than 2 minutes then turn it off. Place you hand on the pump (around the seal area) and if it starts heating up, turn off the pump to prevent mechanical seal failure. 20. When the pumps are primed and pumping the discharge gauge will show a positive pressure. NOTE: If the suction line is long you may have to refill the basket strainer again. Before this is done the suction valves will have to be in the closed position, other wise the vacuum will be lost. Then alternate running P1 and P2 in manual mode. NOTE: Some local codes specify a anti-siphon valve to be installed on the suction line. It is usually installed close to the main supply tank. In some cases this valve will prevent the pumps from priming. If the pumps don’t prime after a few attempts ask the contractor to loosen the spring in the anti-siphon valve and then after the pumps are primed the spring can be set in order to meet local codes. NOTE: If the installation has a flooded suction, turn the suction and discharge valves to the open position. The suction pressure gauge should show a positive pressure. If it doesn’t follow the suction line to the supply tank and see if all the valves are open. If all the valves are open and the pressure gauges don’t read a positive pressure there a blockage in the line. The blockage will have to be cleaned before running the pumps. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 5 CONTROL PANEL Check the name plate rating of the Control Panel and compare with the incoming line voltage and the motors ratings. Adjust overload relay setting to full current rating Check that motor protector push actuator(s) is (are) in start position. Check that float switches are adjusted to the desired levels Check that the controller is properly connected to the pump motors If motors are rotating in the proper direction (as checked in steps 10 to 16 under Priming section), and all the above checks out correctly, turn the “Hand-Off-Auto” switches for both P1 and P2 to the “Auto” position. Activate float switches manually and test if the pumps start and stop at desired levels. Once the level falls below the start lead pump level float switch FL2 (as shown in diagram under Float Controls), the pump motor is energized and the lead pump starts pumping fuel into the tank. If the lead pump has failed and the level falls below FL2 start lead pump level float switch, the “Lead Pump Failure” red pilot light is turned on and the lag pump motor is energized so that the lag pump keeps pumping fuel into the fuel tank. In order to turn off the “Lead Pump Failure” red pilot light, the manual “Reset” red pushbutton must be pressed. Once the level reaches the stop all pumps level float switch FL3, the pump motors are deenergized and the pumps stop. If the alternation selector switch “P1-Auto-P2” is in the “Auto” position, the stop all pumps float switch FL3 triggers the alternator and reverses the order of the lead and lag pumps. For example, if P1 was the lead pump before the trigger, P2 will become the lead pump after the trigger. RELIEF VALVES Checking Relief Valves Current Setting 1. 2. 3. 4. 5. With the pump running notice the reading on the discharge pressure gauge. Slowly close the discharge ball valve. Operate only one pump at a time in manual mode. The reading on the discharge pressure gauge will increase. Make a note of the pressure reading when the valve is fully closed; this value is the pressure relief valve setting. It should be approximate 15 to 20 psi greater than the specified pump discharge pressure. 6. Open the discharge valve and turn the pump off. 7. If the pressure relief setting in satisfactory, repeat for the other pump. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 6 Setting the Pressure Relief Valves 1. Turn the “Hand-Off-Auto” switches to “OFF” for both P1 and P2. 2. Remove the cap (item J) of the pressure relief valve for pump P1. 3. Loosen the lock nut (item F) 4. Turn the adjusting screw (item C) clockwise to increase the pressure setting or counterclockwise to decrease the pressure setting 5. Tighten the lock nut (item J) 6. Reinstall the cap (item B) onto the valve. 7. Turn the “Hand-Off-Auto” switch for P1 to “HAND” position. 8. Slowly close the discharge ball valve for P1. If the pressure relief setting is not satisfactory repeat the operation to adjust the adjusting screw. 9. Repeat steps 1 to 8 for pump P2. FLOAT CONTROLS The standard duplex control panel contains NC relays to operate three float switches (switches supplied by others) for the day tank. If more than three floats are required, the control panel would have to be ordered with optional NC relays. The top float (FL3) stops both pumps, the middle float (FL2) starts the lead pump and the bottom float (FL1) starts the lag pump. It may not be practical to fill the day tank to test the operation of the panel. A simpler way is to have the electrician simulate the open and closing contacts of the floats to check the operation sequence. This procedure can be used to check the high and low level alarms (if supplied) in the panel. The electrician can check the conductivity of the float (normally open or normally closed) to see if they are the same as specified. In some cases there is no day tank and the pump duplex unit pumps directly into the diesel generator or boiler. The panel will receive the signal from the generator and start the lead pump. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved Viking Duplex Fuel Oil Package Field Start-Up Guide Bulletin: Issue: Page: UDF400 2-Oct-06 7 PRESSURE SWITCHES If the duplex unit is supplied with pressure switches (either single or dual stage) they will be installed on the discharge line. The pressure setting will be factory set, but they are field adjustable. To simulate a low pressure condition on the discharge line, have the control panel on automatic mode and then close the discharge valve of the pump running. The relief valve will open and the pumping liquid will return to the supply tank. The pump will shut down and a red light will come on the panel, the time will be that is set on the timer. It is difficult to simulate an actual high pressure shut down. Have the electrician simulate by open or closing the contacts in the control panel. Field adjustment of the pressure setting can be done by the following: Single Stage Pressure Switch – Square D – 9012-GNG2 See UDF400-1 Single Stage Pressure Switch.pdf Dual Stage Pressure Switch – ASCO – SC10D-TG10A21 See UDF400-2 Dual Stage Pressure Switch.pdf FLOW SWITCHES If the duplex unit is supplied with a flow switch it will be installed on the discharge line. To simulate a low flow condition on the discharge line, have the control panel on automatic mode and then close the discharge valve of the pump running (either P1 or P2). The relief valve will open and the pumping liquid will return to the supply tank. Within a few minutes (usually 1 to 3 minutes) based on the time set on the timer, the control panel will start the other pump and the “Low Flow” Signal red lights (optional equipment required for installation of low flow switch) will light up on the panel. VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA ©2006 VIKING PUMP, INC., All Rights Reserved UDF4001 Si ngl e St age Pr essur e Swi t ch B u l l e t i nN o .6 5 0 13 - 10 1- 3 5 C A u g u s t ,1 9 9 2 et 9t € R r F.:$ Ssw Ns o--.-(D @- t ; J W {W W A wARNING HAZARDOUS VOLTAGE CAN CAUSE SEVERE INJURY OR DEATH To reduce the hazardof electricalshock always disconnect power from the circuit beforeinstallingthe pressureswitch or exposing the electricalterminalsfor maintenance. Per ridurre il pericolodi infortunida shock elettrico,prima di installarel'interuttorea pressioneo primi di accedereai terminali per manutenzionetoglieresempretensionedal circuito. Um die Gefahrvon stromschlagenzu mindern,vor Einbaudas Druckwachtersoder Offnen das Klemmendackelszu Wartungszweckendie Versorgungspannungabschalten. Avant toute interventionsur ce material,couper I'alimentation electriquede I'appareilafin d'evitertout risque d'electrocution. ANTESde instalarel interruptora presion o ANTESde exponer las terminaleselectricaspara daries maintenimiento,DEScoNECTELA ENERTIAy reduzeael peligro de una sobrecargaelectrica. MOUNTING It is not recontmended to mountthe switchby its pressure connectiononly. The holes "M" "N" andslotsidentifiedas or arefor surfacemountingtheswitch.Whenconnecting theswitchto thepressure systempiping,tum theswitchontothepipeusinga wrench bodyof theactuator. on thehexagonal Do notapplyleverage throughtheswitchhousing. pressure FortypeGxO,G*G thestandard connectionis I 14-18 NPTF.thedrysealthread shouldsealagainsta new extemall/4 NFrf threadwithoutthe uscof sealingtapeor compounds. Altematepressure connections include:Fonn Z fc>rGNO, GNG, GRO, GRGonly whichis l/4-l8 NFrfexternalthread,FormZ16forGNO,GNG,GRO,GRG only is ll2-14 NFrf externaland ll4-18 NFrfF intemalthread.FonnZl8 for all G*O. G*G isl 116-20 UNF-2A. O 1992SquareD All RightsReserved Page2 B u l l e t i nN o .6 5 0 13 - 10 1- 3 5 C August,1992 ( - c r162 - 1 ?.t2 .T I t38 3t I t l-..- N ?r9 55 I I I t03 l i*ze+ r/4 - TSNPTF-= I N TT H R E A D 2 -520 6 --l i r u R NR A D t u s = $ lr 2A J 275 70 c 65080- 26I Dual Dimensions NOTE M O U N T I N GH O L E S , ' N A ' 'N D '' M O U N T I N GS L O T S M " A R E SIZEDFOR #IO MOUNTING SCREWS lXcH€s MailameleI NOTE Do not plug the 1/4 inch diameterholes on types GPO,GPG,GSO, GSG. WIRING Class9012TypeG pressure switchesaresuitablefor #12,14,16AWG or 1.0-2.5mm solidor strandedcopperwire. Tightenterminalscrewsto 6-9 in-lbf (0.7-I Nm). They are not suitablefor use with aluminumwire. For enclosedtypesG*G grounding (eanhing)provisionis locatedabovethe snapswitchon theenclosure backplateandis marked@. The singlepole,doublethrow snapswitchcontainssinglebreakcontactsofferingone normallyopencircuitand one normallyclosedcircuit.Thesecircuitsare electrically separatebut arenot for useon circuitsof oppositepolarity.For properwiring, refer to thewiringdiagramonthesnapswitchnottheterminalidentification on thesnapswitch. SET POINT ADJUSTMENTS Range Adjustment The pressure switchis setat the factoryto theoperatingpoint(s)markedon theoutside of the mechanismhousing.It is good practiceto cyclethe switchto determineactual operatingpointsbeforeproceedingwith readjustment. Referto the illustrationon page 2 for locationof adjustment. Fornon-adjustable differential typesGRo,GRG,GSo,GSG,GTo, GTG The rangeadjustment may be usedto seteithersetpointandcompletesthe adjustmcnt To increase sequence. the operatingpoints;with the switchmountedas shownin the illustrationon page2 andfacingthe switch,placea flat bladedscrewdriverin the slots of rangeadjustmentnut (A) androtatefrom right to left. Foradjustable differential typesGNO,GNG,GPO,GpG,GeO,GOG Therangeadjustment is usedto setthedecreasing setpointandmustbemadefirst.This adjustmentis madein the samemannerasfor non-adjustable differentialtypes. O 1 9 92S quareD A l l R i ghtsR eserved Page3 B u l l e t i nN o .6 5 0 13 - 10 1- 3 5 C August1 , 992 Differential Adiustment REPLACEMENT PARTS For types GNO, GNG, GPO, GPG, GQO, GQG of the set point on increasingpressureis available.This adjustment An inclependent pressure setpointhasbeenadjusted. afterthedecreasing must be perfonned adjustment The point on increasingpressure. raise set to the screw clockwise (B) Tum adjusting pressure adjustrnent. not this is affected by point decreasing set parts.Class,Typ", andForlr of srvitch Note:Whenorderingany of thesereplacement on whichthereplacement is to be usedmustbe spccifiedwith theorder. Table 2 Item Description 2 Class Order Type Form Used On 9998 PC 265 G N O ,G N G ,G R O ,G R G - 1 DiaphragmAssembly 9998 9998 PC 266 PC 267 G N O ,G N G ,G R O ,G R G - 3 G N O ,G N G ,G R O ,G R G - 4 DiaphragmAssembly 9998 9998 PC 268 PC 269 G N O ,G N G ,G R O ,G R G - s G N O ,G N G ,G R O ,G R G - 6 DiaphragmActuatorAssy 9 9 9 8 9998 PC177 P C 178 G P O ,G P G ,G S O ,G S G - 1 G P O ,G P G ,G S O ,G S G - 2 PistonActuatorAssv 9998 9998 9998 9998 PC 270 PC271 PC 272 P C 273 GQO,GOG ,G TO ,G TG - 1 GQO,GQG ,G TO ,G TG - 2 GQO,GQG,GTO,GTG-3 GQO.GQG,GTO.GTG.4 EnclosureAssemblv 9049 U E -1 ConvertsType G.O to G.G DiaphragmAssembly COPYRIGHT NOTICE @ 1 9 9 2b y S q u a r eD C o m p a n ya, l l r i g h t sr e s e r v e dT. h i s b u l l c t i nm a y n o t b e c o p i e di n w h o l eo r i n to any other media without thc writtcn perntissionof SquareD Contpany. part,or transf'erred PLEASE NOTE: o n l y b y q u a l i f i e del c c t r i c aIl n a i n t e n a n cpec r s o n r l c al .n dt h i s E l e c t r i c a l e q u i p m esnht o u l db e s e r v i c e d d o c u m e n st h o u l dn o t b e v i e w e da s s u f f i c i e n ti n s t r u c t i o nt o r t l i o s ew h o a r en o t o t h e r w i s eq u a l i f i e c l t i s c u s s e dA. l t h c l u g hr e a s o n a b lcca r ch a sb e en t a k c n t o o p e r a t es, e r v i c eo r n t a i n t a i nt h ee q u i p m c n d a n da u t h o r i t a t i vien f o r m a t i o ni n t h i sd o c u m c n tn, o r e s p o n s i b i l i tiys a s s L r r n cbdy t o p r o v i d ea c c u r a t e a sr i s i n go u t o f t h e u s eo f t h i s m a t c r i a l . S q u a r eD f o r a n y c o n s e q u e n c e e 1 992S quareD A l l R i ghtsR eserved Page4 UDF4002 DualSt age Pr essur e Swi t ch Wiring Winng must comply rrth loc-l codcs end thc Natkroal EhctricalCode. All snrrtchenclsurer arc prcrrdcd witb two 3/,t' NPT conduit hubswith one pluggedrhcn not in r.rsc.It is recommendedthat a flexibleconduit connection bc urd. If ngid conduit is used,do not considerit or use it as a means of supportlmounting). For generalpurpoceandwalertighlconstruction,the s*'itch cover is remored by looseningtwo screpsthen tvristingslightlyand lifting. For exploeionprmfconstruction,the cover unscrews.When explosionproofcoveris replaced,torque coverlo 135 + 10 in-lbs [10,7 r- 1,1 Nml. Use No. 14 AWG copperwire raled for 60oC minimum. All switches havea groundingscrewand clamp in lhe enclosure. For factorywiredswitch, black leadiscommon,red leadis normallyopen,blue leadis normallyclosed, and the green lead wire is a ground. IMPORTA\iT: Electrical load must be within rang€statedon nameplate. F a i l u r et o s l a y* i t h i n t h e e l e c t r i c arl a n g eo f t h es * i t c h r a t i n gm a vr e s u l ti n dt-ra" !o or poematurr failurt of electrkal sritch. rll CAUTION: IlordcrrrcrcsCwscrwffrrfrrlr-E A vien making terminal connections. Vyhenconncc{ionserc medc, be surc th€re is no stnesson the wirc leads. Either condition mey caus€malfunction ol switch. ELECTRICAL RATINGS Standald slMlch Ratlng Ratlngs for Induslrlal Conlrols and Temp€ralur€ lndlcalhg and Begulatlng Equlpment Ratlngs tor Llmll Controls and Pressure OD€rat9d S\Mtches SY/ltch Unlt 15Amp6Res.,125 VAC 10AmpsRes, 25OVAC l/4 HP 125VAC 1/2 HP 250 VAC 112AmpRes.,125VDC 1/4Amp B€s.,250vOC 5 Amps Ros.,I 251250VAC 1/8HP 125VAC 1/4 HP 250 vAc 0.4AmDRes..125VDC Schematic SPDT N.O. Thermal Well (Optional Feature) A thermalwell may be usedfor capillarl and bulb (remote)or direct probe 1.aal) lemperalure transducen.The thermalwell affordsprolection for the snsing bulb and allowsremovalof the rnsing bulb while maintaininga Fressuretight vessel.When installingrnsrng bulb in lhermal well, be sure riratit is fully inserted. Where a thermal rcll alreadyexists,jam nuts may bc obtainedlo adaptthe capillaryand bulb to the existingthermal well. The enstingthermalwell musl be for a 3 8' dramelerrnsing bulb. Union Connector (Optional Feature) A u n i o nc o n n e c l o*rr l l a l l o * d i r e c lm o u n t i n go f t h er n s i n g b u l b i n t h ef l u i d b e i n gc o n t r o l l e d . I n s l a l lu n i o n i n t o p i p i n gc o n n e c t i o nb e f o r et i g h t e n i n g uniononlo bulb. For maxrmumprrformance, the bulb shouldbe inserted in the union conneclionso lhal the end of the sensingbulb is evenwith the torquewhentighlenendof the union conneclornut. Do not applyexcessive ing union connectornul. Adjustment (Signal Setting) of Tlvo-Stage Dual A{iust' ment Switch 'Io (signalsetting) a 7116" wrench and a pressureor make adjustments, lemperalure gage (within suitable range) are required. If electrical conneclion(lo line of final application)of the swrtchis not desirable,a batlery powered tesl lamp or ohm meler may be used. hessure or temperalure rangescalesshouldbe usedfor initial signalsetting. Thesewill be accuratewithin 5%. l,rn .:rn lock ring and lurn adjustingnul until red line is evenwilh the desiredrange. For exact signalsetting,proceedas follows: WARNING: To prevent the possibility of personal A iqiury or property damage, turn ofT electrical power when making permanent electrical connections to switch. Adjustrnent (Signal Setting) of Normally Closed or Normally Open S*itch, Increasing Signal (Refer to Figure 2) (signal whenadjuslment isin thelineof finalapplication 1. If the swrtch setting)is made,be sureswilchcan be lesl operatedwithoul affecting o l h e re q u i p m e n t . 2. l-oosen lock nng on adjuslmenlnul andlurn low signaladjustmentnul adiuslment fu! down using a 7/16" , full uprrards and high sig,oa-l \/ wlcnch. CAUTION: Adjusting nut wilt turn easily until it hits a stop. Do not A over torque; over torquing may caus€ internal damage resulting in malfunction. 3. Remove switch cover to gain access lo snap switch. l4/iing for cover removal. See seclion on 4. Follow the step in the chart below lo make signal setling: NORMALLY CLOSED Adlustment Procedur€ INSTALI.-{TIONOF TEMPERATURE TRANSDUCERS Direct Probe The directprobe(local)temperalurelransduceris providedwith 1/2" NPT conneclion.When inslalling,do nol useswilchunit asa leverfor lightening. Use wrenchingflats provided at baseof transducerfor tighlening. and Bulb are providedwilh The capillaryand bulb (remole)temperalurelransducers " gulb. a l e n g t ho f c a p i l l a r ya n d a 3 / 8 d i a m e t e rs e n s i n b Capillary CALTIOIi: Do not bend capillary at sharp angles.For properoperA ation,be suresensin3bulb is completelyimmersedin fluid and not in contact with heatingelementor anythint that would directly affect the temp€rature of the fluid being scnsed. 1 Slarthg at zsro slgnal, conn€ctlest lamp lo common. 2 Apply deslred acluatlon slgnal. Then oft slgnal back untll adlustlng nul swltch acluales. NORMALLY OPEN Tesl Lamp On-Ofl SrMlch Tormlnal Tesl Lamp On-Olt NC On (Clo6€d Clrcun) NO Olf (Open Clfcutl) NC Oll (Open Clrcult) NO SrMtch Termlnal : -ow€f srgna lo roetualixl d€dreo slgnal. Cn iclo's€c Clrcun) |lo Form No. V5736F2 On (Clo€ed Clrcull) dl tooen Clrcutl) 5 . Cyclebetween signalsetlings and make minor adjustmentsto adjusling nuts as required lo achievethe exactsignalsetting. Afler selling hasbeen made,make permanenleleclricalconnections. A S C O Valves Page 2 o{ 4 V ASCOLECTRIC limited B R A N T F O R DO . NTARIO Adustment (Signal Setting) of Normally Closcd or Normafly Open Switch, Decreasing Signal (Referto Figure 2) wiring and pipe conneclion should be made so that svrlch can b€ lesl operated withoul affecting olher equipment. 1. If the wnlch is in the line of final applicationwhenad;ustnrntlsignal selting)is made,be sureswitchcan be lest operated rrthout affecting other equipment. J 2. Loosen lock ring on adjustmentnuts and lurn lory signalad;ustmenl nut fullupwardsand high signaladjustmentnul slighttybeyonddesired actuationsettingusinga 7/16" wrench. CAUTION: Adjustmentnut will turn easilyuntil it hits a stop. Do A not over torque;over torquing may causeinternal damageresultingin nalfu nction. ] RemOVC$i:.'h i|'"nng C a r r c r' \ i i r i n 3iCcr. l,'.::rl .rr:lCh Sce:t'Ctr()nOn . Periodic inspeclion of the switch, externalsur{aces only, should r*- carried out. Swilch should be kept clean and free from painl. forergn matler, corrosion, icing, and freezing conditions. . K e e p t h e m e d i u m e n l e n n g t h e l r a n s d u c e r a s f r e e a s f x - n s i b l ef r o m d r r l a n d f o r e i g n m a l en a l Causesof Improper Operation S * i t c h * r l l n t - r al c l u s l e ( ) r a c l u 3 1 e 5a n d r e : i i u - i t c s u n J ( \ i i - 3 t ' l c . (lreck lca.Js to srrtch [Je surr' ther Inco<rtct Elcctrkd C6o.cti(r: are prope rly connecled. S*rtch rs marked .\O for \ormalh Oprn..\(for Normalty Clced and C for Common. . Check electrical power supply to switch. Control Circuic fbultl Check for loose or blown fuses, open-circuiled or grounded wires, i t x r s cc t r n n e c t i o n sa t t e r m i n a l h i o e ' ko r s q ' i t c h S t ' e t r a n r t : p l a l cf o r c ' l e c t r i c a l r a t r n ga n d r a n q c . . ('heck pressure In s\slem *rth surlable pressure Incorrtct Prcsurt: gaRe. hessure musl br srlhrn range sprcrfiedon nameplale . A d j o s r r n t : C h e c k a d j u s t m en l n u t f ( t r p r ( ) f r r s r l l r n q R e f e r lrqrtct t o a d ; u s t m en l t n s t r u c l i o n s . . Er&ynrl lrakage: Check lo re that bolts r{tholdrng tranvlucer to p r e s s u r es w i l c h a r e p r o p e r l y t o r q u e d l o 8 0 * 1 [ )r n - l b s [ 9 . l t * 1 . 1 \ m ] I f b o i t s a r e l i g h l a n d l e a k a g ei s s l i l l e v i d e n t , r e p l a c el r a n v l u c er . R e f e r to paragraph on Assembly'of Switch Unit and Transducer L'nit . Ercessive Vibration or Surges Causing Switch to Actuak and R.eectua t e : C h e c k f o r f l u c t u a l r o n si n q r s l e ma n d i n s t a l lp r e s s u r es u r g es u p p r e s s o r . C h e c k s l r l c h m o u n t i n g a n d b e s u r e l h e r e i s n o e x c e s s r vver b r a l r o n . . Incorrtrt T?mprraiurc: Check lemfEralure in qstem *rth surlable lhermometer. Temprrature musl be *rth;n rance spcrfied on nameplate. Check locatron of capillary and bulb for rncorrect mountlng,. Refer to pnragraphs on Insullation Of Temperature Transducen. fur COv€r re rotrral 4. Follo* stcpsin charr bclo* to makc signalrtting. NORMALLYCLOSED Adluslm€nt Procedure Swllch T€rmlnal 1. Startlngwilh Inltlalslgnal above deslred actuatlon s€ttlng, connect t€sl lamp lo common. NC 2. D€crease slgnal lo d€slred acluatlon slgnal. Th6n advanc€ adJustlng nul untll swltch acluales. NC 3. Incraas€ slgnal locheck roacluallon slgnal. NC ToslLamp On-Ofi t{c)RMALtY Cp€\ S\./tlch Termlnal ofl (Open Clrcull) ^to On (Closed Clrcull) NO otf (Open Clrcun) NO T6l i_.Jng Cn-Clt Or tfu.d CrqJn) dl rOgcn Qtrattl) O;t (Clo3€d Clrcun) 5. Clcle between actuation and reactuation signals and make minor adjustment to adjusling nuls as required to achieve the exact signal seltinqs. 6. Alter scltrngs haw bccn ma&, trghten lock rings and make perrnanenl electrical conneclions. yl Testingof Installation If the adjustment of the switch has been made outside of the line of final applicalion, the swilch should be retesled when inslalled in lhe line of final application. Follow adjustment instructions. Be sure swilch can be test operated without affecting olher equipmenl. MAINTENANCE If lhe ope ration of the switch cannol be correcled by the above means, lhe enlire switch unit should be replaced or an aulhorized factory represenlalive consulted. Color Code ldentification W t r e n t h e s * i l c h c o v e r r s r e m o v e d . t h c s * r t c h u n r t m a v h e i d e n t i f i e db y t h e color of lhe sealanlused on the lmknuts of the snap s*itch. The color of l h e s e a l a n t* - i l l c o r r e s p r c n dd i r e c t l y t o t h e t h i r d d r g r l o f t h e s w r t c hc a t a l o g number. Third Digit In Catalog liumber Sealant Color Used On Snap Switch Locknuts Yellow I I Green WARNING: To prevent the possibility of personal A iqiury or property damage, turn off electrical power and depressurize switch unit b€fore inspection or removal. IMPORTANT: Switchis notfieldrepairable.Theswitchmustbereturned to the factory (Automatic Switch Company. Florham Parlq New Jersey) or serviced only by an authorizd factory repres€ntative. Address all service inquiries to Automatic Switch Company, 50-60 Hanover road, florham Park, New Jersey 07932, Valve Service D€partment. The only mainte nance which may be performed on the two stage dual adjustment switch is changing the setting of the adjusting nut and replacement of the transducer unit. Replacement of transducer should be done only if external leakage is evident. PreventiveMaintenance . Whilein service, at n desired signals) operalethes\r'itch tcyclebenree leasl once a month lo insure prop€r ope ralion. If necessary,electrical 3 Red 4 Blue Example:If lhe sealantcolor on lhe snapswilchwasred, thiswould mean thal the third digit in the pressureswitchcalalognumberwouldbe 3, possibly SC30D. It would not be, for example; SCA0D, SCtrOD,or SC@0D. T\)R, SERYICE REPI-ACEMf,NT OR NEW TRANSDUCER Consult Factory,or Aulhorized Faclory Represenlativeor Dislributors ORDERI\G I:iFf)RMATIO\ For TWo-StageDual AdjustmentSwitchor New Thansducer When Ordering, SpecifyCatalogNumbers, Fluid, PressureRange, TemperatureRange,Serial Numbers,and hoof hessure or Rated OverrangeTemperalure. NAMEPI-ATES ARE LOCATED ON SWITCH COVER AND BOTTOM OF TRANSDUCER. ASCOValves ASCOLECTRIClimited oNrARlo BRANTFoRD Form No. V5736R2 Page 3 of 4 EnlargedlsometricViewShowing AdjustingNutAnd LockRing Rightside, high signal adjustingnut set at 80 psig CAUTION Adjusting nutwill turn until it hitsa stop. easily DO NOTOVERTORQUE Left side, low signal adjustingnut set at 20 psig adjustingnut (7116" wrench) lock ring (tightedsecurely) FrontView LookingDirectlyat Two-StageDual AdjustmentSwitch (PressureScalesShown) Setting)of Two-StageDual Explosionproof SwitchEnclosure Shown IMPORTANT The thlrd dlgit in catalog No. on the switch unit and transducer unil must be identical. See examplebelow. switch cover Torqueswitch cover to 1 3 5 +1 0 i n - l b s[ 1 5 , 3+ 1 , 1N m ] two-stagedualadjustment switchunit example CatalogNo. SCB2D A T I A 314" NPTfor conduit bothends connection - l--1 .dj,illflJ$,;ou., \-J transducergasket (used on Watertightor C onstructi ononl y) E xpl osi onproof Torquebolts(4)in a crisscross mannerto 80 +10in-lbs[9,0+1,1Nm] transducerunit examPle Catalog No. TEE0A/+4 tI bolt 1+;Figure3. SwitchUnit and TransducerUnit to be Assembled. ASCOValves Page 4 of 4 Form No. V5736R2 PRINTEDIN CANADA ASCOLECTRIClimited BRANTFoRD, oNrARto t\}- rt