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Zoltec BELTOMATIC Operator's Manual

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OPERATORS MANUAL

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  • Page 1 OPERATORS MANUAL...
  • Page 2 60" width belt w/ 2" tall side plates & 6" pitch mild steel roller chain www.belt-o-matic.com Belt wiper product spreader, two 1-Hp drives Mild steel construction, insulated, Zoltec Blue Auto fines clean out in bottom plenum of dryer, 1-Hp drive High temperature limit switches & dial temperature thermometers...

  • Page 5: Table Of Contents

    Table of Contents Introduction pg. 1 A. Warnings B. Equipment ID C. Warranty D. Disclaimer Safety pg. 2 A. Fire Safety B. Fire Safety Equipment on all New Belt-o-matic Dryers 1. Burner control power interlock 2. Airflow switch 3. High limit safety switches C.
  • Page 6 Controlling Capacity F. Controlling Efficiency VII. Maintenance pg. 12 A. Housekeeping B. Bearing Service C. Gearboxes D. Chain Adjustments E. Maintaining Woven Wire Conveyor Belt 1. Belt maintenance 2. Belt traction 3. Belt adjustments 4. Belt removal and replacement F. Maintaining Solid Tray Conveyor Belt 1.
  • Page 7 Gun Style Burner Foot per Minute Web Travel Chart O-1-6 Lesson Motors Technical Information O-8-9 Leeson VFD Quick Reference Guide P-1-8 Gear Speed Reducers Q-1-2 Gas pressure gauge, and thermometers R-1-4 High Limits S-1-2 Pressure Switch T-1-2 Parts List Parts Order Form...

  • Page 8: Introduction

    INTRODUCTION A. Warnings When drying combustible material with heated air, there is a fire hazard. Warning. Avoid pulling particles through the burner or heat exchanger. The heat source can ignite the particles and send sparks into the drying chamber. Warning. Product left in and around the machine can ignite and start a fire.

  • Page 9: Safety

    SAFETY A. Fire Safety When drying combustible product with heated air there is a threat of fire. With certain products that are flammable and have a high amount of fines, the fines material can be ignited as it passes through the burner.

  • Page 10: Emergency Fire Shut Down Procedure

    in the air chamber are wired in series with the burner controller. If these switches overheat, they will automatically shut the burner off. The fan will remain running. Once the switches cool and reset, the burner controller will once again light the burner. These switches are usually set at 250°F, but may vary.

  • Page 11: Servicing Statement

    Ph # -574-353-7855 Fax # -574-353-8152 Email – sales@belt-o-matic.com Web page – www.belt-o-matic.com B. Servicing Statement It is the customer's responsibility to maintain the equipment as written in this manual. C. Using the Manual Due to B.N.W. Industries involvement with different applications and customizations, parts of this manual may or may not apply to your specific machine.

  • Page 12: Installation

    INSTALLATION A. Installation Site Place the machine on a level concrete pad with supports at each corner of the bottom frame. Additional supports are recommended every 10' along the frame of machines 20' or longer, but may vary. The machine should be supported at least one foot off the floor for maintenance purposes. Machines with auto fines clean out need space under the frame to discharge fines material.

  • Page 13: Assembly Of Parts

    Liquid LP models: Connect to the provided 1/2" inch liquid LP line with tank pressure. Frost may be seen before the internal vaporizer. If frost appears after the internal vaporizer, loss in heat will occur. You must reduce the flow or pressure into the vaporizer to eliminate this frost. Alternate fuel sources: (i.e.

  • Page 14: Rotations And Alignments

    F. Rotations and Alignments Check the rotation of all motors. Check and clean the fan housing of any debris before operating the fans and conveyors. Check the air chamber and the conveyors for any parts stowed there. The fan should rotate counter clockwise. With multiple fans, the rotation should alternate, with the fan next to the burner rotating counter clockwise.

  • Page 15: Shut Down Procedure

    On newer systems, the burner controller readout gives a signal reading from the inferred or UV eye. This signal reading must be five or stronger for the Fireye and 3.5 to 7.5 for the Honeywell to run the burner. Older Fireye models have a run check switch. When placed in the check mode, the burner will stay lit and a DC volt tester can check the voltage at the test ports.

  • Page 16: Adjustments And Controls

    Be sure to spread all fine material evenly throughout the layer of product for even drying and/or cooling. The product depth can change between levels on multiple pass machines. As the product dries and/or cools, the depth may be increased. This will help accommodate for product shrinkage. The speed ratio between the top and lower passes will determine the depth thickness.

  • Page 17: Flame Adjustment

    machines conveyor belt. To have a consistent bed depth the spreader needs to be fed evenly at a metered rate. It will control the evenness in the machine but not the volume or depth. The machine's conveyor belt speed will control the depth. The cross belt of the spreader is one speed whereas the wiper is variable speed.
  • Page 18 The Partlow minimum setting is set at the factory. If this needs to be changed, or adjusted, refer to the Partlow manual provided. The orifice valve is the last ball valve downstream of the gas controller. This valve has a small hole drilled in the ball to act like an adjustable orifice.

  • Page 19: Controlling Capacity

    coolers use the same air intake. Control the airflow by increasing or decreasing the fan pitch, motor hertz, or horsepower of the cooling fan. E. Controlling Capacity Capacity is adjusted through the product depth, airflow, and conveyor belt speed. The amount of time each process requires depends on the product temperature, moisture, size, and drying characteristics.

  • Page 20: Housekeeping

    A. Housekeeping As covered in various sections of this manual, it is very important to perform housekeeping functions daily, if not more often. The machine must be kept free of debris. Belt-o-matic machines have specific built-in features that promote cleanliness. It is important to maintain these features. Most units have an auger style idle roller.

  • Page 21: Belt Maintenance

    1. Belt maintenance. Cleaning the belt is important in many drying applications. A continuous wash down area or high-pressure washer works well. Work at the face of the tail pulley when cleaning the belt. Particles that are stuck in the belt are usually not a factor in reducing airflow. These particles will often fall out on the return portion of the belt or as the belt flexes around the rollers.

  • Page 22: Maintaining Solid Tray Conveyor Belt

    If the belt is being completely replaced, attach the new belt to the old belt. As you pull the old belt out, the new belt will be installed. A long cable tied to the belt and a vehicle of some sort will help with this process.

  • Page 23: Optional Equipment

    The lagging consists of a rubber compound that will need replaced after time. An indication that the lagging need replaced is a loss of traction. Pre-lagged drive rollers are available at B.N.W. Industries for purchase. To replace the lagging the conveyor belt and drive roller will need to be removed. Remove the old lagging from the roller and scrape the roller clean.

  • Page 24: Stirring Equipment

    paddle wheel is driven by a shaft mounted gearbox and a c-face motor. Be sure to frequently inspect the fines opening in the air chamber for blockage of the opening. B. Stirring Equipment Rotating stirrers help mix the product at various locations as the product travels on the conveyor belt. Mixing the product will provide better consistency in the moisture level of the product as well as reestablish the airflow.

  • Page 25: Ac Inverters

    The amount of BTU's needed determine whether one or two coils will be mounted at the air intake on the vacuum side of the fan. If there are two steam coils, the inlets will be plumbed together and the outlets separated. An air snorkel is used to prevent heat damage to the motor.

  • Page 26: Troubleshooting

    TROUBLESHOOTING The burner will not stay lit. (B.N.W. Industries manufactured gas burners) 1. If the burner lights but goes out before it enters continuous operation, the infrared or UV eye is not sending a good signal to the burner controller. Clean the lens of the infrared or UV eye then check the signal of the eye.
  • Page 27 Check the exhaust air duct for restriction. If the exhaust duct size is too small or restricted, a high amount of pressure will be evident in the top cover of the machine. This will cause product to blow out of the hopper and the discharge. Also, check the hinge plate air locks at the discharge of the conveyor or at the separation of the heat and cool section.
  • Page 28 The burner controller signal from the scanner is too low. The scanner eye is either dirty or has moisture on it. Remove the scanner eye from the mounting pipe. Clean and dry the eye. If the photo lens is cracked, a poor signal will result. If this does not improve the signal, check the mounting pipe for proper alignment.
  • Page 29 Exhibit A-2 Roller Adjustment for Discharge Drive most units frame # 500 or higher Discharge End of Conveyor (Drive Roller) ADJUSTING NUT FOR WRAP ROLLER TENSION DRIVE ROLLER SHAFT COIL SPRING SNUB ROLLER SHAFT Inlet End of Conveyor (Idle Roller) ADJUSTING NUT TO MOVE IDLE ROLLER IDLE ROLLER SHAFT...
  • Page 30 Exhibit B Fines Conveyor Adjustment FINES RETURN CONVEYOR ADJUSTING SLOTS SHAFT PILLOW BLOCK BEARINGS SPROCKET THREADED FRAME ADJUSTING NUTS (TIGHTEN TO STRETCH FINES BELT) Top View * Note - Idle End of Conveyor is Diagrammed...
  • Page 31 Exhibit D-1 Web Disassembly UNIT SIDEWALL PULL SLACK WOODEN 4X4 WIRED TO WEB HERE DRIVE ROLL SPROCKET FACE OF DRIVE ROLLER WOODEN 4X4 JACK (CLAMP 4X4 TO WEB AND DRIVE ROLLER) Side View PRODUCT WEB OUT IDLE PULLEY WEB IN RETURN DRIVE ROLLER Measure distance between web and sidewall at point A &...
  • Page 32 Exhibit D-2 Heavy duty clinched selvage belts are available in two different mesh sizes and four different materials: low carbon galvanized steel, C-1045 bright high carbon steel, T- 304 stainless steel and T-316L stainless steel. Clinched selvage belts can be ordered in any width from 10"...
  • Page 33 Exhibit E Roller Lagging Vulcanized Style Lagging CUT OUT FOR VULCANIZED WELDING TYPE LAGGING HALVES TO ROLLER Vulcanized type lagging is in halves which weld to the roller at the cutouts. Stagger the splits in the halves. Asphalt Belt Lagging TAPER LAGGING AT END START LAGGING OF ROLLER SO THE...
  • Page 34 Exhibit F-1...
  • Page 35 Exhibit F-1a Gas Train Layout 1. Main-gas regulator evens out fluctuations in the incoming gas pressure and provides the down-stream pressure required by the combustion system being used. 2. Main-gas cock gives positive shut-off for overnight or extended periods of shut-down.
  • Page 36 51-52-03-36 10/04 UDC2500 Page 1 of 13 Universal Digital Controller Specification Overview The UDC2500 Universal Digital Controller is a new, low-priced addition to Honeywell’s Controller family. This controller introduces new features in the popular low priced ¼ DIN size while retaining all the reliability, cost effectiveness, simplicity, and popular HMI of Honeywell’s UDC 2300.
  • Page 37 51-52-03-36 Page 2 • either high or low alarm. The alarm type Time Proportional Duplex - Digital Inputs can be selected to be either of the Depending on which control inputs, the Process Variable, Deviation, algorithm you select, this duplex Two isolated digital inputs are provided Output, Shed from communications, PV output algorithm can provide On-Off...
  • Page 38 51-52-03-36 Page 3 Miscellaneous (continued) Quality/Support - The UDC2500 is Displays— During normal operation, the upper display is dedicated to the covered by a 18-month warranty and Moisture Protection - The NEMA4X process variable (4-digits) and special backed up by a toll-free phone number and IP66 rated front face permits use in annunciator features.
  • Page 39 51-52-03-36 Page 4 Operator Interface See Display Indicators below See Keys and Functions below Figure 2—Operator Interface (all display indicators shown) Display Indicators Upper display with 4 larger digits shows Process Indicates either degrees Fahrenheit or Centigrade. Variable value (normal operation) or parameter value (configuration).
  • Page 40 51-52-03-36 Page 5 PC & Pocket PC Software Features Infrared Communications • The infrared connection provides a non-intrusive wireless Create configurations with intuitive software program connection with the instrument and maintains NEMA4X and running on either a Pocket PC, a Desktop or a laptop IP66 integrity.
  • Page 41 51-52-03-36 Page 6 Specifications Design CE Conformity (Europe) This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed.
  • Page 42 51-52-03-36 Page 7 Specifications Design Digital Inputs (Two) (Optional) +30 Vdc source for external dry contacts or isolated solid state contacts. Digital Inputs are isolated from line power, earth ground, analog inputs and all outputs except for the Second Current Output. On contact closure the controller will respond according to how each digital input is configured.
  • Page 43 51-52-03-36 Page 8 Specifications Design RS422/485 Modbus RTU Baud Rate: 4800, 9600,19,200 or 38,400 baud selectable Communications Interface Data Format: Floating point or integer (Optional) Length of Link: 2000 ft (600 m) max. with Belden 9271 Twinax Cable and 120 ohm termination resistors 4000 ft.
  • Page 44 51-52-03-36 Page 9 Specifications Design Power Inrush Current 10A maximum for 4 ms (under operating conditions), reducing to a maximum of 225 mA (90 to 264 Vac operation) or 750 mA (24 Vac/dc operation) after one second. CAUTION When applying power to more than one instrument, make sure that sufficient power is supplied.
  • Page 45 51-52-03-23 Page 10 Table 1—Input Actuations Range Range Input 1 Actuation °F °C Input 1 Actuation °F °C Thermocouples (Per ITS-90) Per IEC-60751 (1995) IEC Alpha = 0.00385 0 to 3300 –18 to 1816 –454 to 1832 –270 to 1000 100 ohms –300 to 1200...
  • Page 46 51-52-03-36 Page 11 General Reference Data Isolation Analog Inputs : are isolated from all other circuits at 850Vdc for 2 seconds, but not from each other. (Functional) Analog Outputs : are isolated from all other circuits at 850Vdc for 2 seconds. AC Power : is electrically isolated from all other inputs and outputs to withstand a HIPOT potential of 1900Vdc for 2 seconds per Annex K of EN61010-1.
  • Page 47 51-52-03-36 Page 12 Dimensions The controller is housed in a 4.5-inch (114 mm) deep, black plastic case with a dark gray elastomer bezel, that can be panel mounted in a 1/4 DIN cutout. The plug-in chassis allows easy access to the controller board and its various option boards. All power, input, and output wiring are connected to screw terminals on the rear panel.
  • Page 48 51-52-03-36 Page 13 Wiring Diagram Digital Input #1 Digital Input #1 Digital Input #2 Digital Input #2 Current Output Current Output 10 + 10 + 12 + 12 + 12 + 12 + 11 – 11 – 13 – 13 – 13 - 13 - Earth Ground...
  • Page 49 51-52-03-36 Page 14 Warranty/Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose .
  • Page 50 DMA & DMK/6 Assembly Installation Instructions SPECIFICATIONS The DMA actuator drives from 0 to 90 degrees via 4-20 The DMK/6 butterfly control valve actuates from 0 to 90 mA input signal. It can move in any direction and stop degrees in either direction; it is not a tight shut-off valve. anywhere over the entire 90 degree stroke.
  • Page 51 Mounting the DMA to the DMK/6 Note: Y min (Zero) must be no more than 75 % of Y max 1. Remove the clear cover from the DMA (Span) (reference: 90˚ = 100%). E.g. if the maximum 2. Insert the shaft from the DMA into the linkage of the position is set at 85˚, the minimum position can be set at DMK/6until the motor is flush on the DMK/6 mounting 64˚...
  • Page 52 DMV-D(LE)/622 Installation Instructions SPECIFICATIONS DMV-D/622 Two normally closed safety shut off valves in one housing. Fast opening, fast closing. Valve 2 features adjustable max. flow and proof of closure. DMV-DLE/622 Two normally closed safety shut off valves in one housing. Valve 1 fast opening, fast closing. Valve 2 slow opening, fast closing.
  • Page 53 MOUNTING • Use a 5mm Allen wrench for the DMV-D(LE) 701. • Examine the DMV-D(LE)/622 for shipping damage. • Use a 6mm Allen wrench for the DMV-D(LE) 702/703. • The main gas supply must be shut off before • Tighten the screws in a crisscross pattern starting the installation.
  • Page 54 PROOF OF CLOSURE Location Annual Testing The proof of closure switch is factory installed on valve 2 • Perform a switch continuity test at least annually to verify of the DMV, it visually and electrically indicates valve that the proof of closure switch is working properly. position.
  • Page 55 VALVE ADJUSTMENT Flow Setting • Loosen the pan head screw until you can freely rotate • The valves are factory set with the flow adjustment fully the flow adjustment. open. • Turn clockwise for less gas or counterclockwise • CAUTION: Make sure the flow of gas does not create a for more gas.
  • Page 56 VALVE LEAKAGE TEST This test checks the sealing capabilities of the DMV-D(LE)/ 5) Fill a glass of water at least 1 inch from the bottom, 6 automatic shutoff valves. This test requires test nipples Connect a 1/4” flexible hose to a rigid tube. The rigid installed in the downstream accessory port of both auto- tube shall be 1/4 in.
  • Page 57 FLOW CURVE Based on 60 °F, 14.65 psia, dry 1,000 2,000 4,000 6,000 10,000 20,000 Flow (CFH) of natural gas s.g. 0.65 at 60 °F 20 in W.C. ° ° Type of gas Density gas used Natural Gas [kg/m f = correction factor to determine flow through valves with other 0.81 0.65...
  • Page 58 Exhibit F-41 GAO/GMH/GML AA-… Pressure switches for gas and air Differential pressure switches for air Pressostats pour gaz et air Pressostats différentiel pour air Interruptor automático caída de presión de gas y aire Interruptor diferencial automático caída de presión de aire Pressostato diferencial para ar Pressostato para gás e ar UL / FM / CSA approved versions...
  • Page 59 Pressure switch Exhibit F-42 for gas and air GAO-A4… GMH-A4… GML-A4… UL Listed • UL 353 • File # MH 16628 CSA Certified • CSA C22.2 No. LR 53222 • Certification # 201527 FM Approved • Class 3510, 3530 • File # J.I. 1T7A8.AF Description Application European models tested to EN1854...
  • Page 60 Exhibit F-43 GAO-A4… SPDT pressure switch requires no auxiliary power. The GAO-A4… is suitable for making and/or breaking a circuit when the set point is exceeded or undershot. A tripped switch is indicated by a neon light after set point is exceeded or undershot.
  • Page 61 Exhibit F-44 Dimensions inch (mm) GAO-, GMH-, GML-A4… Integrated test nipple 1/4” NPT pressure connection 3 (76) 2.1 (53,7) Reset button GMH-A4… GML-A4… Made in Germany que 65 in. Lbs M. torq NPT 1/2” conduit connection 4 X Ø 0.16 (4.2) for M4 screws Replacement parts / Accessories Order No.
  • Page 62 Exhibit F-45 ∆ Definition of switching hysteresis The pressure difference between the upper and lower switching pressures Pressure at meter Setpoint tolerance Upper switching pressure Lower switching pressure 4 … 6...
  • Page 63 Exhibit F-46 Installation position Standard installation position When installed horizontally, the pressure switch switches at a pressure higher by approximately 0.2 in wc (0.5 mbar). When installed upside down, the pressure switch switches at a pressure lower by approximately 0.2 in wc (0.5 mbar). When installed in other position the pressure switch switches at pressure deviating from the set reference value by max.
  • Page 64 Pressure switch Exhibit F-47 for gas and air GAO-A4… GMH-A4… GML-A4… Technical data Version Setting range Switching hysteresis Type Order No. In. W.C. In. W.C. (calibrated at) GAO-A4-4-2 0.16 - 1.20“ ≤ 0.12“ GAO-A4… 46014-2 GAO-A4-4-3 0.40 - 4.00“ ≤ 0.20“ pressure switch 46014-3 GAO-A4-4-5...
  • Page 65 Exhibit F-48 Valve position indication CPI 400 Visual Indicator UL Listed • Covered under file # MH 16727 CSA Certified • Covered under file # 157406 FM Approved • Covered under report # J.I. 3007653 Description Application DUNGS is an ISO 9001 manufac- The CPI 400 (closed position indicator) The DUNGS CPI 400 is recommended turing facility.
  • Page 66 Exhibit F-49 CPI 400 SPDT switch requires no auxiliary power. The CPI is suitable for making and/or breaking a circuit when the valve is opened or closed. An open valve is indicated by a green neon light. A closed valve is indicated by an orange neon light.
  • Page 67 Exhibit F-50 Dimensions inch (mm) CPI 400 Plunger Plunger 9/16” (~14) Set screw Plunger connection 3 (76) 2.8 (72) Made in Germany torq que 65 in. Lbs M. NPT 1/2” conduit connection Dimensions inch (mm) Visual Indicator 5/8” (~16) 0.6 (14.5) 3 …...
  • Page 68 Exhibit F-51 Valve position indication CPI 400 Visual Indicator Technical data Type Order No. CPI 400 D224 253 Visual Indicator 46000-6 We reserve the right to make any changes in the interest of technical progress. Karl Dungs Inc. Karl Dungs GmbH & Co. KG 524 Apollo Drive, Suite 10 P.O.
  • Page 69 Exhibit F-79 Legend Ball Valves are available in forged brass, bronze, carbon, or stainless steel. The stems are a bottom loaded-blowout proof design. Each series is available in full port or conventional port styles. Many are offered in F.I.P. x F.I.P., M.I.P. x F.I.P., Barb x Barb, F.I.P.
  • Page 70 Exhibit F-80...
  • Page 71 Exhibit F-81...
  • Page 72 Exhibit F-82...
  • Page 73 Exhibit F-83...
  • Page 74 Exhibit F-84...
  • Page 75 Exhibit F-85...
  • Page 76 Exhibit F-86 Model 243-8HP ILL. PART ILL. PART DESCRIPTION NUMBER DESCRIPTION NUMBER Seal Disc Assembly - Monitor 143-16-508-00 Seal Cap and Spring Adjustment 18a Seal Disc, CRS cad. plated 143-16-008-00 Assembly 18b Inner O-ring 934007 Seal Cap 121-10-005-52 18c Outer O-ring 905809 Adjustment Screw 906537...
  • Page 77 Exhibit H-1 Electrical Control Box...
  • Page 78 Exhibit H-2 Power Hook Up SWITCH OUTSIDE TWO LINES TO REVERSE MOTOR POWER IN ROTATIONS PLACE OVER WIRE TERMINALS SAFETY SHIELD MAIN DISCONNECT WIRE LUGS FUSE BLOCK CARTRIDGE TYPE FUSE POWER OUT...
  • Page 79 Honeywell Exhibit H-3 7800 SERIES RM7895A,B,C,D Relay Module The Honeywell RM7895 is a microprocessor based inte- grated burner control for automatically fired gas, oil, or combination fuel single burner applications. The RM7895 consists of the Relay Module. Subbase, Amplifier and Purge Card are required to complete the system.
  • Page 80 Exhibit H-4 RM7895A,B,C,D SPECIFICATIONS • ORDERING INFORMATION Specifications ELECTRICAL RATINGS, see Table 1: Maximum Total Connected Load: 2000 VA. Voltage and Frequency: 120 Vac (+10/-15%), 50 or Fusing Total Connected Load: 20A maximum, type 60 Hz (+/- 10%). FRN or equivalent. Power Dissipation: RM7895: 10W maximum.
  • Page 81 Exhibit H-5 RM7895A,B,C,D SPECIFICATIONS ENVIRONMENTAL RATINGS: WEIGHT: RM7895 with Dust Cover: 1 pound 15 ounces, Ambient Temperature: unpacked. Operating: -40° F to 140° F. Storage: -60° F to 150° F. IMPORTANT: Flame Detection System available for Humidity: 85% RH continuous, noncondensing. use with RM7895.
  • Page 82 Exhibit H-6 RM7895A,B,C,D SPECIFICATIONS SEQUENCE TIMING FOR NORMAL OPERATION: Flame Establishing Period Device Initiate Standby Purge Pilot Main AFSC RM7895A 10 sec. 4 or 10 sec. RM7895B 10 sec. 4 or 10 sec. RM7895C 10 sec. 4 or10 sec. 10 sec. RM7895D 10 sec.
  • Page 83 Exhibit H- 7 RM7895A,B,C,D SPECIFICATIONS Fig. 2—Mounting dimensions of RM7895 Relay Module and Q7800B Subbase in inches [millimeters]. BURNER CONTROL [127] POWER PILOT FLAME MAIN ALARM RESET [155] 5 [127] REMOVE ONLY FOR TERMINAL TEST ACCESS. M5004B Fig. 3—Rectification detectors. IGNITION ELECTRODE FLAME ROD...
  • Page 84 Exhibit H- 8 RM7895A,B,C,D SPECIFICATIONS Fig. 4—Ultraviolet detectors. [105] 2 [51] 1/2-14 NPSM 4 [102] COLLAR WITH 6 FOOT [1.83 METER] 1–11-1/2 NPSM INTERNAL THREADS LEADWIRES (2) [89] INTERNAL THREADS [30] [27] [25] [38] 6 FOOT COLLAR WITH 1/2-14 NPSM [67] [1.83 METER] INTERNAL THREADS...
  • Page 85 Exhibit H-9 RM7895A,B,C,D SPECIFICATIONS Fig. 4—Ultraviolet detectors (Continued). [300] 1 INCH NPT [198] [147] 15/16 [24] DIA. [55] [47] [158] [147] [64] [168] 1 [25] 15/16–18 UNC (2 EACH) 2 [51] C7076D M5084 Fig. 5—Infrared detector. CELL MOUNT HEAT BLOCK [41] [27] [70]...
  • Page 86 Exhibit H-10 RM7895A,B,C,D PRINCIPAL TECHNICAL FEATURES Principal Technical Features The RM7895 provides all customary flame safeguard 4. PILOT FLAME ESTABLISHING PERIOD (PFEP) functions while providing significant advancements in the a. Airflow lockout feature is enabled and the air- areas of safety, annunciation and system diagnostics. flow switch opens.
  • Page 87 Exhibit H-11 RM7895A,B,C,D SAFETY PROVISIONS Safety Provisions INTERNAL HARDWARE STATUS MONITORING EXPANDED SAFE-START CHECK The RM7895 checks the purge card for correct parity to The conventional safe-start check, which prevents burner prevent purge timing shifts and circuitry failures. It also start-up if flame is indicated at start-up, is expanded to include analyzes the integrity of the configuration jumpers and a flame signal check during STANDBY, an airflow switch...
  • Page 88 Exhibit H-12 RM7895A,B,C,D SAFETY PROVISIONS • INSTALLATION Self-Diagnostics add to the First-out Annunciation by Airflow Switch Interlock allowing the RM7895 to distinguish between field (external This interlock is typically connected to an airflow device) and internal (system related) problems. Faults asso- switch.
  • Page 89 Exhibit H-13 RM7895A,B,C,D INSTALLATION Fig. 6—Internal block diagram of the RM7895 (see Figs. 7 and 8 for detailed wiring instructions). (HOT) 120 Vac PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY...
  • Page 90 Exhibit H-14 RM7895A,B,C,D INSTALLATION • WIRING MOUNTING WIRING SUBBASE sure to allow adequate clearance for servicing, instal-lation, access and removal of the RM7895, Dust Cover, flame NOTE: For installation dimensions, see Figs. 1 or 2. amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field 1.
  • Page 91 Exhibit H-15 RM7895A,B,C,D WIRING Fig. 7—Wiring the RM7895A,B. Q7800 120V ALARM BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK INTERMITTENT PILOT/IGNITION MAIN FUEL VALVE(S) IGNITION RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) MASTER FLAME DETECTOR SWITCH C7027A, C7035A, OR FOR DIRECT SPARK IGNITION (OIL WHITE BLUE...
  • Page 92 Exhibit H-16 RM7895A,B,C,D WIRING Fig. 8—Wiring the RM7895C,D. Q7800 120V ALARM BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK 10 SEC. INTERRUPTED PILOT/IGNITION MAIN FUEL VALVE(S) DELAYED IGNITION MAIN VALVE RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) MASTER FLAME DETECTOR SWITCH...
  • Page 93 Exhibit H-17 RM7895A,B,C,D ASSEMBLY Assembly MOUNTING RM7895 Fig. 10—Wall or burner installation. NOTE: For installation dimensions, see Figs. 1 or 2. RELAY MODULE MOUNTING 1. Mount the RM7895 vertically, see Figs. 9 or 10, or mount horizontally with the knife blade terminals pointing downward.
  • Page 94 Exhibit H-18 RM7895A,B,C,D ASSEMBLY 5. Reinstall the Dust Cover, Keyboard Display Module, DATA CONTROLBUS MODULE™ or Extension Cable Fig. 13—Flame signal amplifier mounting. Assembly onto the RM7895 and restore power to the device. Run the burner system through at least one complete cycle to verify the system is operating as desired.
  • Page 95 Exhibit H-19 RM7895A,B,C,D ASSEMBLY Fig. 14—Flame detector wiring. C7076A,D ULTRAVIOLET DETECTOR INFRARED (C7015) REMOTE SENSOR WHITE EARTH GROUND BROWN SHUTTER C7076A C7076D SHUTTER TERMINAL BLOCK ULTRAVIOLET (C7027/C7035/C7044) L1 (HOT) L2 (COMMON) BLUE 7800 SERIES WHITE SOLID STATE SELF-CHECKING SOLID STATE ULTRAVIOLET (C7012E,F) ULTRAVIOLET (C7012A,C) BLUE...
  • Page 96 Exhibit H-20 RM7895A,B,C,D OPERATION Operation Sequence of Operation NORMAL START-UP The RM7895 has the following operating sequences, PREPURGE see Figs. 15, 16 and 18. The RM7895 provides a selectable PREPURGE timing from two seconds to 30 minutes with power applied and INITIATE the RM7895 operating control indicating a call for heat.
  • Page 97 Exhibit H-21 RM7895A,B,C,D OPERATION Fig. 16—RM7895C,D sequence. TIMED PFEP PURGE 4 OR 10 SEC INITIATE STANDBY START MFEP STANDBY POWER POWER POWER POWER POWER POWER POWER POWER DISPLAY PILOT PILOT PILOT PILOT FLAME FLAME FLAME FLAME MAIN MAIN MAIN MAIN ALARM ALARM ALARM...
  • Page 98 Exhibit H-22 RM7895A,B,C,D OPERATION See Table 6 for further details of Hold conditions. NOTE: When the RM7895C,D is switched to the TEST mode, it stops and holds at the next Run/Test Switch RUN/TEST SWITCH FUNCTIONS point in the operating sequence. MAKE SURE THAT The Run/Test Switch is located on the top side of the THE RUN/TEST SWITCH IS IN THE RUN POSITION RM7895C,D, see Fig.
  • Page 99 Exhibit H-23 RM7895A,B,C,D OPERATION GENERAL INSTRUCTIONS 8. If there is no voltage or the operation is abnormal, 1. Perform all applicable tests listed in Static Checkout, check the circuits and external devices as described in the Table 5, in the order listed. last column.
  • Page 100 Exhibit H-24 RM7895A,B,C,D CHECKOUT Checkout WARNING CHECKOUT SUMMARY • Preliminary inspection—all installations. Do not allow fuel to accumulate in the combus- • Flame signal measurement—all installations. tion chamber. If fuel is allowed to enter the • Initial lightoff check for proved pilot—all installa- chamber for longer than a few seconds without tions using a pilot.
  • Page 101 Exhibit H-25 RM7895A,B,C,D CHECKOUT FLAME SIGNAL MEASUREMENT (Fig. 20 and Table 5) TABLE 5—FLAME SIGNAL. Minimum Flame Acceptable Maximum Detector Flame Signal Amplifier Steady DC Voltage Expected DC Voltage Flame Rod R7847A,B 1.25 Vdc 5.0 Vdc at the Keyboard Photocell Display Module C7012A,C C7012E,F...
  • Page 102 Exhibit H-26 RM7895A,B,C,D CHECKOUT INITIAL LIGHTOFF CHECK FOR PROVED PILOT l. Reinstall the RM7895 on the subbase and close Perform this check on all installations that use a pilot. the master switch, then return to step 4. It should immediately follow the preliminary inspection. 7.
  • Page 103 Exhibit H-27 RM7840E,G,L,M CHECKOUT 21. Return the system to normal operation. sure the burner flame goes out and make sure all automatic 22. Make sure all readings are in the required ranges be- fuel valve(s) close. fore proceeding. 17. If used, remove the bypass jumpers from the low fuel pressure limit and subbase.
  • Page 104 Exhibit H-28 RM7895A,B,C,D CHECKOUT NOTE: INTERMITTENT PILOT MODELS should con- 9. Repeat step 8 to verify the pilot gas pressure reading tinue with step 6. INTERRUPTED PILOT MODELS at the exact point the FLAME LED light goes out. should proceed to step 7. 10.
  • Page 105 Exhibit H-29 RM7895A,B,C,D CHECKOUT 4. Make sure the leadwires from the flame rod and burner flame or FLAME LED goes out. If this takes ignition electrode are not too close together. more than three seconds, the infrared detector is sens- 5.
  • Page 106 Exhibit H-30 RM7895A,B,C,D CHECKOUT • TROUBLESHOOTING 4. Failure to ignite pilot. FLAME SIGNAL WITH HOT COMBUSTION a. Close the pilot and main fuel manual shutoff valve(s). CHAMBER (All Installations) b. Depress the reset push button. After all initial start-up tests and burner adjustments are c.
  • Page 107 Exhibit H-31 RM7895A,B,C,D TROUBLESHOOTING Total Hours, Fault History, Diagnostic Information and when the fault occurred, and the fault message and burner Expanded Annunciator Terminal Status (if used). With status when the fault occurred. The Historical Informa- this information most problems can be diagnosed without tion can be viewed by the optional S7800A1001 Keyboard extensive trial and error testing.
  • Page 108 Exhibit H-32 RM795A,B,C,D TROUBLESHOOTING TABLE 6—SEQUENCE AND STATUS HOLD MESSAGES (Continued) NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type. Sequence Status STANDBY The LED indicates the burner status, POWER. The burner can be placed in STANDBY by opening the burner switch or if the operating controller indicates its set point has been satisfied.
  • Page 109 Exhibit H-33 RM7895A,B,C,D TROUBLESHOOTING TABLE 6—SEQUENCE AND STATUS HOLD MESSAGES (Continued) Sequence Status The LEDs indicate the burner status, POWER, FLAME and MAIN, which is the period of time after the Ignition Trials and before the operating controller set point is reached. During this time, the burner is firing under the control of the operating control- ler (RM7895C,D).
  • Page 110 Exhibit H-34 For replacement parts information or an application guide, visit our website at www.sea.siemens.com or contact your local Siemens sales office. Instructions 49-HACRO IMPORTANT THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT, NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE.
  • Page 111 Exhibit H-36 Overview Bussmann ® for Non-Fusible Disconnect Switches CDNF16 – CDNF160 CDNF16 CDNF25 CDNF32 CDNF30 CDNF60 CDNF100 CDNF160 Catalog number 3 pole CDNF16 CDNF25 CDNF32 CDNF45 CDNF63 CDNF30 CDNF60 CDNF100 CDNF160 General purpose amp rating Approvals 2 pole UL98 3 pole UL508 UL508...
  • Page 112 Exhibit H-37 Overview Bussmann ® for Non-Fusible Disconnect Switches BDNF200A – BDNF3150 BDNF175A BDNF200A BDNF400A BDNF600A BDNF800A BDNF1200 BDNF1600 BDNF2000 BDNF3150 Catalog number 3 pole BDNF175A BDNF200A BDNF400 BDNF600A BDNF800A BDNF1200 BDNF1600 BDNF2000 BDNF3150 General purpose 1200 1600 2000 3150 amp rating Approvals 2 pole...
  • Page 113 Exhibit H-38 16A – 100A Bussmann ® for Non-Fusible Disconnect Switches Base & DIN Rail Mounted For a complete assembly, please select one of each: 1 switch 1 handle 1 shaft CDNF63 CDS85S CDH3S 16 – 100 Amp switches, 600V, 3 pole general AC21 Maximum horsepower rating...
  • Page 114 Exhibit H-39 Handles & Shafts Bussmann ® for 16A – 100A Non-Fusible Disconnect Switches Base & DIN Rail Mounted Pistol handles — for use with shafts .20 x .20" ( 5 x 5 NEMA Length Weight Catalog Color Marking Defeatable Padlockable type type...
  • Page 115 Exhibit H-40 Accessories Bussmann ® for 16A – 100A Non-Fusible Disconnect Switches Base & DIN Rail Mounted Base and DIN rail mounted switches (N)7 (N)8 OT 16 E3 OF F Auxiliary contacts — snap-on mounting Weight Catalog Description For use on: thermal rated (lbs.)
  • Page 116 Exhibit H-41 Accessories Bussmann ® for 16A – 100A Non-Fusible Disconnect Switches Base & DIN Rail Mounted Terminal shrouds* — snap on mounting for line or load side Weight Catalog Description For use on: (lbs.) number 3 pole CDNF16, CDNF25, CDNF32, 0.02 CDTS32T3 includes one shroud...
  • Page 117 Exhibit H-42 Accessories Bussmann ® for 16A – 100A Non-Fusible Disconnect Switches Base & DIN Rail Mounted Conversion mechanisms • For use with Base and DIN rail mounted switches only • Switches are not included Weight Catalog Description For use on: (lbs.) number 6 or 8 pole...
  • Page 118 Exhibit H-43 125A Bussmann ® Non-Fusible Disconnect Switches For a complete assembly, please select one of each: 1 switch 1 handle 1 shaft CDNF160 BDS210 BDH60 125 Amp Base & DIN rail mounted switches , 600V Maximum horsepower rating general AC21 Terminal lugs Catalog...
  • Page 119 Exhibit H-44 Accessories Bussmann ® for 125A Non-Fusible Disconnect Switches Auxiliary contacts, top mounted • Accepts four contacts maximum, mounting base always required Weight AC thermal AC rated Catalog Description For use on: (lbs) amp rating voltage number 1 N.O. 0.07 CDAUXCA10 CDNF160...
  • Page 120 Exhibit H-45 Accessories Bussmann ® for 125A Non-Fusible Disconnect Switches Conversion mechanisms • For use with Base and Din rail mounted switches only • Switches are not included Weight Catalog Description For use on: (lbs.) number 6 or 8 pole 1.52 BDZW2 Transfer (1, 3R, 12)
  • Page 121 Exhibit H-46 UL & CSA Technical Data Bussmann ® for Non-Fusible Disconnect Switches CDNF16 – CDNF160 UL & CSA Catalog number 3 pole CDNF16 CDNF25 CDNF32 CDNF45 CDNF63 CDNF30 CDNF60 CDNF100 CDNF160 Approvals 2 pole UL98 & IEC 3 pole UL508 &...
  • Page 122 Exhibit H-47 IEC Technical Data Bussmann ® for Non-Fusible Disconnect Switches CDNF16 – CDNF160 Catalog number 3 pole CDNF16 CDNF25 CDNF32 CDNF45 CDNF63 CDNF30 CDNF60 CDNF100 CDNF160 Rated insulation and operation 40°C voltage, AC20 and DC20 1 V Rated impulse withstand voltage Rated thermal current, I open 2 AC 20/DC 20...
  • Page 123 Exhibit H-48 IEC Technical Data Bussmann ® for Non-Fusible Disconnect Switches CDNF16 – CDNF160 Catalog number 3 pole CDNF16 CDNF25 CDNF32 CDNF45 CDNF63 CDNF30 CDNF60 CDNF100 CDNF160 Rated voltage, U e 415/690 Rated conditional short-circuit current 80/50 Max. allowed fuse size, type OFAA 160/250 Max.
  • Page 124 Exhibit H-49 Approximate Dimensions Bussmann ® for Non-Fusible Disconnect Switches CDNF16 — CDNF100 CDNF16, CDNF25, CDNF32 — base & DIN rail mounted switch 0.43 0.43 0.20 0.18 DIA. 0.47 1.38 2.13 2.36 2.68 0.87 1.77 0.43 1.38 0.51 2.20 CDNF45, CDNF63 — base & DIN rail mounted switch OT16,25,32 0.69 0.69...
  • Page 125 Exhibit H-50 Bussmann ® Class R Fuseblocks R600 Series 600 Volts Catalog Symbol: R600 Series Ampere Rating: ⁄Ω ¡ º to 600A Voltage Rating: 600V Agency Information: UL Listed, UL 512, Guide IZLT, File E14853 CSA Certified, C22.2 No. 39, Class 6225-01, File 47235 Withstand Rating: 200,000A RMS Sym.
  • Page 126 Exhibit H-51 Bussmann ® Class R Fuseblocks R600 Series 600 Volts Dimensional Data 600V, ⁄Ω ¡ º to 30A FIGURE 1. FIGURE 2. FIGURE 3. 600V, 31 to 60A 4.94" 3.38" 0.59" 0.59" 1.81" 1.56" 1.56" 1.56" 2.06" 0.25" 0.62" 0.62"...
  • Page 127 Exhibit H-52 Bussmann ® Class R Fuseblocks R600 Series 600 Volts 600V, 101 to 200A 600V, 101 to 600A 9.0" 3.15" 8.0" .75" 6.5" 0.34 DIAMETER 0.34 DIAMETER 9.58" 0.75" 0.75" DIA. C'BORE C'BORE 5.5" .50" Deep 3.0" 2.04" FIGURE 10. FIGURE 11.
  • Page 128 Exhibit H-53 Bussmann ® Fusetron FRS-R ® Dual-Element, Time-Delay Fuses ⁄Ω ¡ º-60A Class RK5 – 600 Volt General Information: Dimensional Data • Provides motor overload, ground fault and short-circuit pro- 5" (± 0.31) tection. When used in circuits subject to surge currents such .81"...
  • Page 129 Exhibit H-54 Bussmann ® Fusetron FRS-R ® Dual-Element, Time-Delay Fuses ⁄Ω ¡ º-60A Class RK5 – 600 Volt Time-Current Characteristic Curves–Average Melt AMPERE RATING AMPERE RATING CURRENT IN AMPERES Current-Limitation Curves 100,000 CURRENT IN AMPERES 10,000 1,000 PROSPECTIVE SHORT-CIRCUIT CURRENT SYMMETRICAL RMS AMPERES The only controlled copy of this Data Sheet is the electronic read-only version located on the Bussmann Network Drive.
  • Page 130 Exhibit H-55 Bussmann ® Fusetron ® FRS-R Dual-Element, Time-Delay Fuses 65-600A Class RK5 –– 600 Volt Dimensional Data Dimensions (inches) Ampere Ratings 65-100 7.88 (± 0.062) 1.11 (± 0.020) 110-200 9.63 (± 0.062) 1.61 (± 0.020) 225-400 11.63 (± 0.094) 2.34 (±...
  • Page 131 Exhibit H-56 Bussmann ® Fusetron ® FRS-R Dual-Element, Time-Delay Fuses 65-600A Class RK5 –– 600 Volt Time-Current Characteristic Curves–Average Melt Current-Limiting Effects FRS-R Apparent RMS Symmetrical Let-Through Current AMPERE Prospective RATING 100A 200A 400A 600A 5,000 1,400 2,000 2,900 3,950 5,000 5,000 10,000...
  • Page 132 Exhibit H-57 Bussmann ® Fusetron ® FRS-R Dual-Element, Time-Delay Fuses 65-600A Class RK5 –– 600 Volt Current-Limitation Curves 400,000 FRS-R (600V) 100,000 600A 400A 200A 100A 10,000 1,000 PROSPECTIVE SHORT CIRCUIT CURRENT SYMMETRICAL RMS AMPERES The only controlled copy of this Data Sheet is the electronic read-only version located on the Bussmann Network Drive. All other copies of this document are by definition uncontrolled. This bulletin is intended to clearly present comprehensive product data and provide technical information that will help the end user with design applications.
  • Page 133 Series 50 Industrial Control Transformers Domestic Series: Features •UL Listed, File E3210. •CSA Certified, File LR 560. • All copper windings. • All designs are rated 50 / 60 Hertz. • Rugged coil mounted screw terminals. • Primary fuse blocks and secondary fuse holders •...
  • Page 134 Series 50 Industrial Control Transformers Export Series: Features •UL Listed, File E3210. •CSA Certified, File LR 560. • All copper windings. • All designs are rated 50 / 60 Hertz. • Rugged coil mounted screw terminals. • Primary fuse blocks and secondary fuse holders •...
  • Page 135 Series 50 Industrial Control Transformers SUFFIX -054, 50 / 60 HZ Primary Volts 208, Secondary Volts 120 General Information Dimensions (inches) Primary Secondary Pri. Pri. Sec. Sec. Sec. Catalog Wgt. Height Width Depth Mounting Max. Amps Fuse Max. Fuse Fuse Number Cap.
  • Page 136 Series 50 Industrial Control Transformers SUFFIX -058, 50 / 60 HZ Primary Volts 220 / 380 / 415, Secondary Volts 95 / 115 General Information Dimensions (inches) Primary Secondary Pri. Pri. Sec. Sec. 115 V Catalog Wgt. Height Width Depth Mounting Max.
  • Page 137 Series 50 Industrial Control Transformers Connection Diagrams Suffix -052 Suffix -053 Suffix -054 Primary Secondary Primary Secondary Primary Secondary Connect Connect Connect Connect Connect Connect Voltage Jumper Incoming Voltage Voltage Jumper Incoming Voltage Voltage Jumper Incoming Voltage Load To LoadTo Load To Lines To Lines To...
  • Page 138 Series 50 Industrial Control Transformers SERIES 50 PRIMARY FUSE KIT Fuse Kit BR-734 •Meets UL 508 •Meets NEC Article 450 •Uses Class CC Fuses Installation Procedure • • • Note: Fuses are not • supplied in fuse kit. SERIES 50 SECONDARY FUSE KITS Fuse Kit GLF 1¼...
  • Page 139 Industrial Ignition Transformers...
  • Page 140 Exhibit J-1 Setting the Fan Blade Pitch 38” Fan Blade Setting with Steel Hub (Add 3/16” for Aluminum Hub) 30HP 3” CAUTION: Settings can vary under different conditions. Always check 25HP 2-7/8” motor amp. draw. 20HP 2-3/4” 15HP 2-5/8” 10HP 2-1/2”...
  • Page 141 Exhibit J-2 Installation of and Use of Special Fan Blade Washers (Note: Torque 3/4” Fan Bolts to 135 FT/LBS) Bolts are to be lubricated with SAE 30 non-detergent motor oil. THIS INFORMATION APPLIES TO: 12" & 16" DIAM HUBS Typical special washer, slightly deformed not tumbled.
  • Page 142 Exhibit L Air Duct to Cyclone Transition Drawing INLET 30° SUGGESTED DUCT 30° EXHAUST DUCT DRYER ROTARY AIRLOCK FLOOR Drawing shows the suggested transition from dryer or cooler to cyclone. The dimension will be different with different size cyclones. The two fans that sit on top are counter rotating. Looking from the motor side the top one is L.H.
  • Page 143 Exhibit M Gun Style Burner...
  • Page 144 Exhibit N...
  • Page 145 Exhibit O-1 TECHNICAL INFORMATION MOTOR SELECTION NAMEPLATE DATA Electric motors are the workhorses of industry. Many applications exist where more than one motor can be used and/or the exact replacement is Nameplate data is the most important first step in determining motor not available.
  • Page 146 Exhibit O-2 TECHNICAL INFORMATION NEMA SERVICE FACTORS METRIC (IEC) DESIGNATIONS The International Electrotechnical Commission (IEC) is a European-based organization that publishes and promotes worldwide mechanical and ENCLOSURE 3600 1800 1200 electrical standards for motors, among other things. In simple terms, it can 1/4-1/3 Open 1.35...
  • Page 147 Exhibit O-3 TECHNICAL INFORMATION U.L., CSA, ISO AND OTHER STANDARDS MOTOR EFFICIENCY VERIFICATION Energy Efficiency Verification - Full load efficiency ratings of three phase, single & APPROVALS – MOTORS speed, NEMA/EEMAC Design A or B squirrel cage induction motors, 1 through UNDERWRITERS LABORATORIES INC.
  • Page 148 Exhibit O-4 TECHNICAL INFORMATION INVERTER CAPABILITIES OF LEESON MOTORS NEMA Variable Constant STEEL FRAME MOTORS Frame Torque** Torque** Notes Standard General Purpose TEFC 56-210 frame 10-90* Hz 20-90* Hz 56-210 frame 10-90* Hz 20-90* Hz WATTSAVER ® Premium Efficiency TEFC 56-210 frame 6-90* Hz 20-90* Hz...
  • Page 149 Exhibit O-5 TECHNICAL INFORMATION LEESON MOTOR MODEL NUMBER NOMENCLATURE All LEESON motors, both stock and custom, have a catalog number and a Odd frequencies other than 50 Hz show synchronous speed code. model number. The model number appears on the motor’s nameplate and DC and special motors may have one, two, or three digits indicating motor describes pertinent electrical and mechanical features of the motor.
  • Page 150 Exhibit O-6 Lubrication Instructions For Ball Bearing Motors Lubrication This motor is supplied with pre-lubrication ball bearings. No lubrication required before start up. Relubrication Intervals The following intervals are suggested as a guide: SUGGESTED RELUBRICATION INTERVALS HOURS OF SERVICE PER YEAR RELUBE INTERVAL H.P.
  • Page 151 Exhibit O-7 Installation Maintenance Instructions AC Induction Motors Installation After unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections, check for proper grounding of motor and application. All electrical contacts and connections must be properly insulated and enclosed.
  • Page 152 Exhibit O-8 MC3000 FAULT MESSAGES MICRO SERIES PARAMETERS LEESON FAULT DESCRIPTION PARAMETER FACTORY PARAMETER FACTORY NAME DEFAULT NAME DAFAULT OUTPUT Output Transistor fault. Output current exceeded 200%. LINE VOLTS AUTO MANUAL KEYPAD May be ground fault or short circuit. Variable Speed AC Motor Drives SPEED #1 20.00 Hz CONTROL...
  • Page 153 Exhibit O-9 MICRO SERIES KEYPAD MICRO SERIES KEYPAD FUNCTIONS MICRO SERIES DISPLAYS Press the START key to start the drive. The START key Shown below are examples of MICRO SERIES displays. To scroll START is only active in LOCAL mode. through the SPEED, LOAD, and MOTOR VOLTAGE displays, STOP 20.00 HZ...
  • Page 154 174194.00 - SM SERIES SM REMOTE KEYPAD TEMPLATE REMOTE KEYPAD INSTRUCTIONS Hold this page against the panel where the remote keypad is to be mounted, and use a center punch to mark the location of the holes. The dotted line is the The SM Series Remote Keypad option allows the SM Series drive to be outline of the remote keypad.
  • Page 155 SETTING UP THE SM DRIVE REMOTE KEYPAD FUNCTIONS To set up the SM drive to work with the Remote Keypad, the following The M key and the keys on the remote keypad function the same as parameters must be programmed: the Mode button and the buttons on the drive.
  • Page 156 SM TERMINAL STRIP DIAGNOSTIC AND DISPLAY MESSAGES STOP DISPLAY DESCRIPTION Speed Reference Codes SIGNAL COMMON CONTROL PAD: The drive speed is controlled by the buttons on the front of the drive. 0-10 VDC SPEED REFERENCE INPUT EXTERNAL CURRENT: The drive speed is controlled by a 4-20 mA signal between TB-25 and TB-2 EXTERNAL VOLTAGE: The drive speed is controlled by a 0-10 VDC signal between TB-5 and TB-2.
  • Page 157 CONFIGURING THE SM DRIVE SM PARAMETER MENU Entering Program Mode: 7R DFFHVV WKH SDUDPHWHUV SUHVV WKH Mode EXWWRQ 7KLV ZLOO DFWLYDWH Parameter Range of Factory Parameter Range of Factory WKH SDVVZRUG SURPSW 7KH GLVSOD\ ZLOO UHDG ´µ DQG WKH ULJKWKDQG Name Adjustment Default...
  • Page 158 174191.00 - SM-PLUS SERIES SM-PLUS REMOTE KEYPAD TEMPLATE REMOTE KEYPAD INSTRUCTIONS Hold this page against the panel where the remote keypad is to be mounted, and use a center punch to mark the location of the three holes. The dotted line is the The SM-Plus Series Remote Keypad option allows the SM-Plus Series outline of the remote keypad.
  • Page 159 SETTING UP THE SM-PLUS DRIVE There are three possible control scenarios when using the remote keypad: TOGGLE CONTROL BETWEEN REMOTE KEYPAD AND TERMINAL STRIP The remote keypad is used for Start/Stop control, Forward/Reverse selection, programming, and monitoring. Set Parameter 14 (CONTROL) to “03” (TERMINAL STRIP OR REMOTE KEYPAD).
  • Page 160 Exhibit P-1 TECHNICAL INFORMATION ™ CONDENSED GLOSSARY OF MOTOR Thrust Load - Force imposed on a shaft parallel to a shaft’s axis. Thrust loads are often induced by the driven machine. Take care to be sure the thrust load rating of the AND GEARING TERMS reducer is sufficient that it’s shafts and bearings can absorb the load without premature failure.
  • Page 161 Exhibit P-2 TECHNICAL INFORMATION ™ A.G.M.A. SERVICE FACTORS DOUBLE ACTING PUMPS METAL MILLS 2 or more Cylinders 1.25 1.50 Draw Bench Carriages & Single Cylinder Contact Factory Main Drives 1.25 1.50 Service Factor Pinch, Dryer and Scrubber Application 3-10 Over 10 DRAW BENCH (Metal Mills) Rolls Reversing Contact Factory...
  • Page 162 Exhibit P-3 ELECTRIC MOTORS, GEARMOTORS AND DRIVES Speed Reducers Installation, Lubrication and Maintenance Instructions Table of Contents WARNING/CAUTION INFORMATION ..........2 General Operation .
  • Page 163 Exhibit P-4 Instruction Manual Selection Information Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance or operation. Written authorization from LEESON ELECTRIC is required to operate or use reducers in man lift or people moving devices. Check to make certain application does not exceed the allowable load capacities published in the current catalog.

  • Page 164: General Operation

    Exhibit P-5 Instruction Manual General Operation Run the motor which drives the reducer and check the direction of reducer output rotation. Consult motor nameplate for instructions to reverse the direction of rotation. Attaching the load: On direct coupled installations, check shaft and coupling alignment between speed reducer and loading mechanism.

  • Page 165: Lubrication

    Exhibit P-6 Instruction Manual Lubrication The reducer is properly filled at the factory with sufficient lubricant per customer specified mounting position. If position is not specified by customer, reducer will be filled to level in mounting position 1 (worm over) Reducer ordered with a "MOD" will be filled based on the factory assumed mounting position, mounting position should be specified with order to assure proper lubrication.
  • Page 166 Exhibit P-7 Instruction Manual Standard Speed Reducer Mounting Positions & Vent Plug, Level and Drain Locations VENT VENT INSPECTION PLUG *OIL INSPECTION INSPECTION PLUG VENT VENT PLUG DRAIN DRAIN INSPECTION PLUG (All primary units have their own oil inspection plug.) DRAIN VENT VENT...

  • Page 167: Maintenance

    Exhibit P-8 Instruction Manual Rotate input shaft of reducer to position the set screw (ref. 113) in line with access hole provided in the “C” flange adapter, tighten set screw (make sure key is properly in place under set screw). Slide plastic sleeve (ref.
  • Page 168 Mobil SHC 600 Series Supreme Performance Gear and Bearing Oils Product Description Mobil SHC 600 Series lubricants are supreme performance gear and bearing oils designed to provide outstanding service in terms of equipment protection, oil life and problem-free operation. They are formulated from synthesised, wax-free hydrocarbon base fluids. The combination of a naturally high viscosity index and a unique, proprietary, additive system enables these products to provide outstanding performance in extreme service applications at high and low temperatures, well beyond the capabilities of mineral oils.
  • Page 169 benefits of the base oils to provide exceptional oil life and deposit control and resistance to thermal/oxidative and chemical degradation, as well as the balance of the performance features. The wax-free nature of the base oil also provides low temperature fluidity characteristcs unmatched by mineral products and is a key benefit for remote, low ambient temperature applications.
  • Page 170 Specifications & Approvals Mobil SHC 600 Series has the following builder approvals Cone Drive (US) Boston Gear (US) Typical Properties Mobil SHC 600 Series ISO Viscosity Grade 1000 Viscosity, ASTM D 445 cSt @ 40 º C 32.4 48.0 69.9 99.1 cSt @ 100 º...
  • Page 171 Health & Safety Based on available information, this product is not expected to produce adverse effects on health when used for the intended application and the recommendations provided in the Material Safety Data Sheet (MSDS) are followed. MSDS's are available upon request through your sales contract office, or via the Internet.
  • Page 172 -------------------------------------------------------------------------- 602912-00 MOBIL SHC 634 MATERIAL SAFETY DATA BULLETIN -------------------------------------------------------------------------- -------------------------------------------------------------------------- 1. PRODUCT AND COMPANY IDENTIFICATION -------------------------------------------------------------------------- PRODUCT NAME: MOBIL SHC 634 SUPPLIER: EXXONMOBIL OIL CORPORATION 3225 GALLOWS RD. FAIRFAX, 22037 24 - Hour Health and Safety Emergency (call collect): 609-737-4411 24 - Hour Transportation Emergency: CHEMTREC: 800-424-9300...
  • Page 173 For further health effects/toxicological data, see Section 11. -------------------------------------------------------------------------- 4. FIRST AID MEASURES -------------------------------------------------------------------------- EYE CONTACT: Flush thoroughly with water. If irritation occurs, call a physician. SKIN CONTACT: Wash contact areas with soap and water. Remove and clean oil soaked clothing daily and wash affected area. (See Section 16 - Injection Injury) INHALATION: Not expected to be a problem.
  • Page 174 permitted by regulatory authorities the use of suitable dispersants should be considered where recommended in local oil spill procedures. ENVIRONMENTAL PRECAUTIONS: Prevent material from entering sewers, water sources or low lying areas; advise the relevant authorities if it has, or if it contaminates soil/vegetation. PERSONAL PRECAUTIONS: See Section 8 -------------------------------------------------------------------------- 7.
  • Page 175 for specific details. APPEARANCE: Liquid COLOR: Orange ODOR: Mild ODOR THRESHOLD-ppm: NE pH: NA BOILING POINT C(F): > 316(600) MELTING POINT C(F): NA FLASH POINT C(F): > 93(200) (ASTM D-93) FLAMMABILITY (solids): NE AUTO FLAMMABILITY C(F): NA EXPLOSIVE PROPERTIES: NA OXIDIZING PROPERTIES: NA VAPOR PRESSURE-mmHg 20 C: <...
  • Page 176 Irritation Index: greater than 0.5 but less than 3). ---Based on testing of similar products and/or the components. OTHER ACUTE TOXICITY DATA: Although an acute inhalation study was not performed with this product, a variety of mineral and synthetic oils, such as those in this product, have been tested. These samples had virtually no effect other than a nonspecific inflammatory response in the lung to the aerosolized mineral oil.
  • Page 177 MOBILITY: When released into the environment, adsorption to sediment and soil will be the predominant behavior. PERSISTENCE AND DEGRADABILITY: This product is expected to be inherently biodegradable. BIOACCUMULATIVE POTENTIAL: Bioaccumulation is unlikely due to the very low water solubility of this product, therefore bioavailability to aquatic organisms is minimal.
  • Page 178 Governmental Inventory Status: All components comply with TSCA, EINECS/ELINCS, and DSL. U.S. Superfund Amendments and Reauthorization Act (SARA) Title III: This product contains no "EXTREMELY HAZARDOUS SUBSTANCES". SARA (311/312) REPORTABLE HAZARD CATEGORIES: None. This product contains no chemicals subject to the supplier notification requirements of SARA (313) toxic release program.
  • Page 179 INJECTION INJURY WARNING: If product is injected into or under the skin, or into any part of the body, regardless of the appearance of the wound or its size, the individual should be evaluated immediately by a physician as a surgical emergency. Even though initial symptoms from high pressure injection may be minimal or absent, early surgical treatment within the first few hours may significantly reduce the...
  • Page 180 Exhibit Q-1...
  • Page 181 Exhibit Q-2 REOTEMP PRESSURE GAUGES ERIES ENERAL URPOSE AUGES • Black Steel or Stainless Cases • Copper Alloy Wetted Parts • Cost Effective Design • Standard 3-2-3% Accuracy Specifications Case: Black Painted Steel or Stainless Steel Ring: Snap-In Window, Push-On Bezel, or Bayonet Lens: Snap-In Plastic or Glass...
  • Page 182 Exhibit R-2 WARM AIR CONTROLS FLUSH MOUNT FAN OR LIMIT CONTROLS/ ATTIC FAN CONTROL Ideal for Replacement of Similar Type Controls 757-1 FEATURES • For use where space is limited. • Small bimetal sensing element. • Snap-Action switch. • Fan control has adjustable range with direct reading temperature dial. •...
  • Page 183 Exhibit S-1 Series Compact Low 1900 Differential Pressure Switches Set Points from 0.07" to 20" w.c., Repetitive Accuracy within 3% Series 1910 pressure switch. All pressure and electrical connections and set point adjustments are on one side for easy installation. Series 1910 switch with conduit enclosure off.
  • Page 184 Exhibit S-2 CAUTION: FOR USE ONLY WITH AIR OR COMPATIBLE GASES. Weatherproof Housing 16-ga. steel enclosure with gasketed cover POPULAR MODELS (NEMA 4) for wet or oily conditions. Withstands 200 hour salt spray test. Wt. 5 lbs. Operating Approximate Approximate (2.3 kg).
  • Page 185 Exhibit T-1 Burner Controls: Mfg. Number BNW Ind. Number Partlow Gas Valve 3/4" PA GC00101 GVL-01PAGV34 Partlow Gas Valve 1 1/4" PA GC00103 GVL-01PAGV114 Partlow Sensor 5' PA PA 106560516 GVL-01PAS05 Partlow Sensor 15' PA PA 106561516 GVL-01PAS15 Partlow Sensor 25' PA PA 106562516 GVL-01PAS25 ASCO Solenoid Valve 1/2"...
  • Page 186 Exhibit T-2 Power Drive: Mfg. Number BNW Ind. Number 1 15/16" Insert Bearing 210-31 BSC-01PEB1.94 1 15/16" Pillow Block Bearing P210-31 BSC-01PEPBB156 1 15/16" Slot Take-Up Bearing T210-31 BSC-01PEBM.69 1" Pillow Block Bearing P205-16 BSC-01PEBPB1 1" Slot Take-Up Bearing T205-16 BSC-01PESTU1 Gearbox Multiplier 5:1 TXQ1-5-56C-56C...
  • Page 187 Exhibit T-3 Parts Order Form From: Date: Address: Serial No. Model No. Part Description: BNW Number: Amount: Part Description: BNW Number: Amount: Part Description: BNW Number: Amount: Part Description: BNW Number: Amount: Date Needed All parts shipped FOB Factory Tippecanoe, IN 46570 Fax: 219-353-8152 Mail: BNW Industries Phone: 219-353-7855...

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