Algas SDI QM 28 Operation & Maintenance Manual

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Operations & Maintenance

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FILE: MANUAL PN 52644 REV 07-30-04 QM.doc

...Innovative liquid vaporizing and gas mixing solutions

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1140 NW 46 Street, Seattle, Washington, USA 98107

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Page 1 ...Innovative liquid vaporizing and gas mixing solutions Operations & Maintenance Operations & Maintenance Operations & Maintenance Operations & Maintenance Manual Manual Manual Manual 1140 NW 46 Street, Seattle, Washington, USA 98107 Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com FILE: MANUAL PN 52644 REV 07-30-04 QM.doc...
Page 2 WARNING Read the OPERATION MANUAL before operating this equipment. ■ NOTE: Algas-SDI reserves the right to use alternate manufacturers’ components as vendor delivery applicability dictates. Literature contained in the Operation Manual has been supplied by vendors. Please check to be sure supplied data matches your configuration.
Page 3 DISCLAIMER and WARNING DISCLAIMER and WARNING DISCLAIMER and WARNING DISCLAIMER and WARNING Read this Operation and Maintenance Manual before operating the QM system. DISCLAIMER DISCLAIMER DISCLAIMER DISCLAIMER Algas-SDI International, LLC (ASDI) shall not be liable for technical and/or editorial errors or omissions in this manual. ASDI makes no warranties, express or implied, including the implied warranties of merchantability and fitness for a particular purpose with respect to this manual.
Page 4 WARRANTY REGISTRATION WARRANTY REGISTRATION WARRANTY REGISTRATION WARRANTY REGISTRATION To Register your new equipment: Visit Algas-SDI's web site at: algas-sdi.com, then click on the "Tech Support" button. Select online Registration or print out the Acrobat Warranty Registration. Fill out the Warranty Registration information on the last page of this manual. Then make a photocopy and mail to the address shown at the bottom.
Page 5 SYMBOLS AND CONVENTIONS SYMBOLS AND CONVENTIONS SYMBOLS AND CONVENTIONS SYMBOLS AND CONVENTIONS Special symbols are used to denote hazardous or important information. You should familiarize yourself with their meaning and take special notice of the indicated information. Please read the following explanations thoroughly. GENERAL WARNING OR CAUTION GENERAL WARNING OR CAUTION GENERAL WARNING OR CAUTION...
Page 6 TABLE of CONTENTS TABLE of CONTENTS TABLE of CONTENTS TABLE of CONTENTS 1 1 1 1 Introduction Introduction Introduction Introduction Description/Overview QM System Basic Features Figure 1 — QM Vaporizer-LPG/Air Mixer System, Basic Features Figure 2 — QM System Dynamics 2 2 2 2 Major Components or Components...
Page 7 4 4 4 4 Startup Startup Startup Startup General Warnings 4-25 Initial Startup Instructions 4-26 Initial Vaporizer Startup 4-26 Initial LPG/Air Mixer Startup 4-27 5 5 5 5 Operation Operation Operation Operation Overview 5-29 Vaporizer/Mixer Modes of Operation 5-29 Start/Stop and Standby Sequence 5-30 Operator Panel Menu Levels 5-31...
Page 8 Alarm Screen 5-43 Figure 18 — Alarm Screen, Control Panel, General Help and Alarm Screen 5-43 Alarm Messages 5-43 Event Log 5-43 Panel Command Modes 5-44 Special Components Operation 5-44 PLC Sequencer 5-44 CPU Module 5-45 Analog Input Module 5-45 AC Input Module 5-45 AC Output Module...
Page 9 Spark Plug Gap 5-55 Figure 23 — Spark Plug Gap 5-55 Flame Monitoring System 5-55 Safeguard LED Indicator Light 5-55 Resetting Flame Safeguard 5-55 Flame Rod 5-55 UV Scanner (Q1650V models) 5-56 Airflow Switch Adjustment 5-56 Waterbath Circulation System 5-56 Waterbath 5-56 Watertrain...
Page 10 To Remove CPU Battery 6-75 Figure 31 — CPU Battery Removal 6-75 To Install CPU Battery 6-75 Control Box Heater 6-75 Testing the Control Box Heater 6-76 7 7 7 7 Troubleshooting Troubleshooting Troubleshooting Troubleshooting General Warnings and Cautions 7-79 Table 6 -- Troubleshooting, Causes and Solutions 7-80 Options...
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Page 13 1 1 1 1 Introduction Introduction Introduction Introduction Description/Overview Description/Overview Description/Overview Description/Overview natural gas replacement system is a combination gas fired Algas-SDI QM waterbath LPG vaporizer and an atmospheric venturi LPG/Air mixer. The QM system first vaporizes the Liquid Propane Gas (LPG fed from a storage tank, by passing it through a heat exchanger immersed in a heated water/glycol mixture.
Page 14 Introduction Introduction Introduction Introduction Figure1 — QM Vaporizer - LPG/Air Mixer System Basic Features QM Vaporizer.wmf 1. LPG vaporizer 3. Operator panel ! ! ! ! Operator interface 2. LPG/air mixer ! ! ! ! PLC sequencer 4. Flame safeguard Algas-SDI Operations &...
Page 15 Introduction Introduction Introduction Introduction ______________________________________________________________________________________ Figure 2 — QM System Dynamics QM System Dynamics.wmf 1. Fire tubes (typical) 7. Venturi solenoid valve 2. LPG heat exchanger 8. Pressure control regulator 3. Burner / blower assembly 9. Venturi nozzle 4. Combustion chamber 10.
Page 16 Introduction Introduction Introduction Introduction Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 17 2 2 2 2 Major Component Drawings Major Component Drawings Major Component Drawings Major Component Drawings Figure 3 — QM Component Diagram - Front View, Door Open QM Comp Diag.wmf 1. Flue gas outlet 11. Water train isolation valve 2. Control box, See also Figure 6. 12.
Page 18 Major Component Drawings Major Component Drawings Major Component Drawings Major Component Drawings Figure 4 — QM Component Diagram - Side View QM Comp Diag-side.wmf 1. Vapor pressure gauge 6. Mixed gas outlet header 2. Venturi solenoid valve 7. Air inlet header 3.
Page 19 Major Component Diagrams Major Component Diagrams Major Component Diagrams Major Component Diagrams Figure 5 — QM Component Diagram - Back View QM Comp Diag-back.wmf 1. Vapor outlet temperature gauge 6. Burner train drip leg 2. Waterbath drain 7. Burner regulator 3.
Page 20 Major Component Drawings Major Component Drawings Major Component Drawings Major Component Drawings Figure 6 — QM Component Diagram - Inside Control Box QM Control Box.wmf 1. Operator interface panel 8. Fuse blocks 2. Master control switch 9. Ground buss 3. Control panel heater 10.
Page 21 Major Component Diagrams Major Component Diagrams Major Component Diagrams Major Component Diagrams Figure 7 – Burner Train Component Layout Standard Q320V through Q1650V Models and Minnesota Q320V or Q800V QM Burner Train.wmf 1. Main gas supply hand valve 8. Flame rod / UV scanner (on Q1650 only) 2.
Page 22 Major Component Drawings Major Component Drawings Major Component Drawings Major Component Drawings Figure 8 — Burner Train Component Layout Q1120V & Q1650V, Minnesota Option QM Minnesota Burner.wmf 1. 2nd stage regulator relief vent 9. Air flow switch 2. Main gas supply hand valve 10.
Page 23 3 3 3 3 Installation Installation Installation Installation QM SYSTEM INSTALLATION QM SYSTEM INSTALLATION QM SYSTEM INSTALLATION QM SYSTEM INSTALLATION PROCEDURE Installation of the QM system begins with the physical placement of your unit on a concrete base. Second, connect all required liquid piping from the LPG storage tank to the QM system.
Page 24 Installation Installation Installation Installation Figure 9 — Typical QM System Installation with External Components ___________________________________________________________________________ QM Installation.wmf 1. Packaged QM vaporizer/mixer system *8. Accumulator tank drain *2. Electrical service required *9. Accumulator tank *3. Isolation valve with hydrostatic relief *10. Mixed gas outlet valve *4.
Page 25 Installation Installation Installation Installation Liquid Piping Installation Liquid Piping Installation Liquid Piping Installation Liquid Piping Installation Size the liquid line from the storage tank to the vaporizer to supply the vaporizer at full capacity with a minimal pressure drop. CAUTION CAUTION CAUTION CAUTION...
Page 26 Installation Installation Installation Installation Figure 10 – Installation Position of Plugged Drain at LPG Contaminants Drain ___________________________________________________________________________ LPG Contaminants Drain.wmf 1. LPG contaminants drain 2. Plugged drain valve Clean all foreign material from all pipe lines prior to making final connections. All joints require a pipe sealant suitable for Liquid Propane Gas.
Page 27 Installation Installation Installation Installation Mixed Gas Outlet Installation Mixed Gas Outlet Installation Mixed Gas Outlet Installation Mixed Gas Outlet Installation ACCUMULATOR SIZE ! Provide a correctly sized , Figure 9, MIXED GAS ACCUMULATOR SURGE TANK Item 9) suitable for the intended service and pressure. The tank must have a relief valve, drain, pressure gauge, mixed gas inlet and outlet (the same size), pressure sensing port and gas sampling port.
Page 28 Installation Installation Installation Installation Figure 11 - Accumulator Tank Piping Arrangements Accumulator Arrangments.wmf Clean all prior to making final connections. Welding slag can jam PIPELINES piston-type solenoid valves. All joints require a pipe sealant for LPG. Test for leaks using an inert gas such as carbon dioxide or nitrogen at 150 PSIG (10.5 kg.cm 3-16 Algas-SDI Operations &...
Page 29 Installation Installation Installation Installation Install Flare Stack Install Flare Stack Install Flare Stack Install Flare Stack ASDI recommends that a be installed so the QM system can FLARE STACK be operated for a short initial period to permit setting the desired mixed gas pressure (system delivery), to confirm adjustments to the motive pressure regulators and check the BTU valve of mixed gas.
Page 30 Installation Installation Installation Installation Optional Outputs Optional Outputs Optional Outputs Optional Outputs , for information on operation and wiring for system status See Operation section indication, alarm indication and LPG pump control. 3-18 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 31 Installation Installation Installation Installation Freeze and Corrosion Protection Freeze and Corrosion Protection Freeze and Corrosion Protection Freeze and Corrosion Protection The QM consists of an open system waterbath vaporizer, meaning it is vented to atmosphere and requires a little greater corrosion protection than closed systems.
Page 32 Installation Installation Installation Installation Freeze and Corrosion Product Calculation Freeze and Corrosion Product Calculation Freeze and Corrosion Product Calculation Freeze and Corrosion Product Calculation FREEZE PROTECTION To calculate gallons of pure glycol or Dow products to add for freeze protection: Determine freeze protection required.
Page 33 Installation Installation Installation Installation CORROSION PROTECTION Freeze protection that requires less than 50%, by volume, or DOWTHERM will need inhibitor adjustment equivalent to a 50/50 mix. Contact DOWFROST Dow for further information on inhibitor adjustment. When using pure glycol or 100% water, use Table #3 to determine the required amount of to add.
Page 34 Installation Installation Installation Installation Table 2 – Anti-Freeze Products ETHYLENE PRODUCTS PROPYLENE PRODUCTS FREEZE BOILING FREEZE BOILING % VOL %VOL %VOL % VOL. %VOL. %VOL. POINT POINT ETHYLENE DOWTHERM DOWTHERM POINT POINT PROPYLENE DOWFROS DOWFROST GLYCOL. SR-1 4000 GLYCOL T HD 10.3 12.7 13.2...
Page 35 Installation Installation Installation Installation ORDERING INFORMATION ORDERING INFORMATION ORDERING INFORMATION ORDERING INFORMATION Phone: 1-800-447-4369 DOW ANALYSIS KITS Phone: 1-800-447-4369 The Dow Chemical Company Larkin Lab C/O Thermal Fluids Testing Lab 1691 North Swede Road Midland, Michigan 48674 ! CH20 Phone: 1-800-562-6184 Fax: 1-360-352-4813 Web Site:...
Page 36 Installation Installation Installation Installation 3-24 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 37 4 4 4 4 Startup Startup Startup Startup WARNING WARNING WARNING WARNING LPG is explosive and extremely flammable. Appropriate safety procedures must be observed when installing, starting, and operating the system. Any leak anywhere in the system is extremely dangerous and should not be tolerated. If any leak is detected the entire system must be shut down, power turned off, lines bled to zero.
Page 38 Startup Startup Startup Startup Initial Startup Instructions Initial Startup Instructions Initial Startup Instructions Initial Startup Instructions NOTE NOTE NOTE NOTE All initial settings were made at the ASDI factory. However, some settings may need adjustment upon setup. Refer to the QM Data Sheet for all control settings.
Page 39 Startup Startup Startup Startup Initial LPG/Air Mixer Startup Initial LPG/Air Mixer Startup Initial LPG/Air Mixer Startup Initial LPG/Air Mixer Startup Before beginning the startup procedure, allow the vaporizer to warm up to MIXER the standby setpoint temperature 100° F ( 37.8° C ). When the vaporizer is up to temperature, the burner will shut off and the operator indicator interface will indicate STANDBY...
Page 40 Startup Startup Startup Startup 4-28 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 41 5 5 5 5 Operation Operation Operation Operation OVERVIEW OVERVIEW OVERVIEW OVERVIEW The Operations section includes: Start/stop sequence steps for the vaporizer and LPG/air mixer. Complete QM operation details, including operator interface panel, key and page definitions. Special component control procedures. Burner and flame safeguard operation for all standard models, plus Minnesota options Q1120V through Q1650V.
Page 42 Operation Operation Operation Operation Start/Stop and Standby Sequence Start/Stop and Standby Sequence Start/Stop and Standby Sequence Start/Stop and Standby Sequence Turn power switch . Display panel reads SYSTEM OFF VAPORIZER START PROCEDURE (Vaporizer Standby) Press once on the OPERATOR INTERFACE PANEL Watch for the green LED to illuminate over The vaporizer begins the warm-up sequence.
Page 43 Operation Operation Operation Operation 5-31 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 44 Operation Operation Operation Operation 5-32 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 45 Operation Operation Operation Operation QM Operation Details QM Operation Details QM Operation Details QM Operation Details OPERATOR PANEL gathers various kinds of data and information OPERATOR INTERFACE PANEL from the PLC Sequencer. The display panel has the following capabilities: Displays system parameters in real-time. Monitors system for shutdown conditions and faults.
Page 46 Operation Operation Operation Operation VAPORIZER START SEQUENCE Figure 13 — F 1 Screen, Vaporizer Start/Stop Key, Annunciated Messages and Settings. ___________________________________________________________________________ F1 Screen – Vap Start.wmf Press to start . The burner will start if the waterbath standby VAPORIZER setpoint is higher than the actual waterbath temperature. When the vaporizer standby mode is enabled and running the green LED will illuminate.
Page 47 Operation Operation Operation Operation NOTE NOTE NOTE NOTE Standby operation is used to expedite quick changeover when the vaporizer is required to produce gas on short notice. By keeping the waterbath up to standby temperature 100° F ( 37.8 ° ° ° ° C ), the changeover can occur rapidly.
Page 48 Operation Operation Operation Operation LPG/AIR MIXER START SEQUENCE Figure 14 — F2 Screen, Mixer Start and Stop Key, Annunciated Messages and Settings F2.DXF / f2_scrn.cdr F2 Screen – Mixer Start.wmf Press to start . When the vaporizer is not running, it will start and the MIXER green will light.
Page 49 Operation Operation Operation Operation STATUS SCREEN Figure 15 — F3 Screen, QM Status Page for Real-Time Data ___________________________________________________________________________ F3 Screen – Status.wmf Press to transfer to the for the QM system real-time MIXER STATUS SCREEN data display, including on/off status of the LPG/Air mixer. While you are viewing in the status screen the F3 LED will flash.
Page 50 Operation Operation Operation Operation SETPOINTS SETUP SCREEN Figure 16 – F4 Screen, Setup Page for Displaying and Entering Setpoints ___________________________________________________________________________ F4 Screen – Setpoints Setup.wmf is the QM mixer setup screen where the following setpoints are displayed and set. While viewing in the setup screen will flash.
Page 51 Operation Operation Operation Operation is used to turn on all trains at the same time for SETUP MODE adjustments. To enter go to and select SETUP MODE ALLOW SETUP This is a test mode only and must be off for operation. * * SDI –...
Page 52 Operation Operation Operation Operation HELP PAGE SCREEN Figure 17 — Main Screen, General Instructions and Help Keys Mini-Screen.wmf GENERAL HELP Help is available from the by pressing the key. Basic MAIN SCREEN HELP instructions and definitions of operator interface panel components is discussed. The up and down arrow keys allow the operator to scroll through the text line by line.
Page 53 Operation Operation Operation Operation UP / DOWN FAULT HELP PAGES keys are used scroll through real-time data line by UP AND DOWN ARROW line. They are also used increment or decrement setpoint values while in the data entry mode on the page.
Page 54 Operation Operation Operation Operation ALARM SCREEN is displayed automatically upon receiving an alarm. The “ ” ALARM SCREEN on line one indicates the operator is looking at the alarm list. The next character fields on line one are the current state of the alarm, .
Page 55 Operation Operation Operation Operation ALARM SCREEN Figure 18 — Control Panel General Help and Alarm Screen ___________________________________________________________________________ Alarm Screen.wmf ALARM MESSAGES Help with alarms can be viewed by pressing during the alarm message. HELP Possible alarm messages are outlined as below: HIGH LPG LEVEL Burner Safety Circuit LOW WATER CUTOFF...
Page 56 Operation Operation Operation Operation PANEL COMMAND MODES uses an operating system similar to other OPERATOR INTERFACE PANEL computers used to execute applications. When the key is pressed for two ENTER seconds the main menu will appear displaying the following commands. Use the arrow keys to highlight the command and the key to select or execute the ENTER...
Page 57 Operation Operation Operation Operation CPU MODULE When the system is operating normally the following PLC LEDs are lit: is normally off. It will only come on if the fails. The system CPU LED does not have a battery, so the battery indicator light is , there is a battery failure.
Page 58 Operation Operation Operation Operation Optional Outputs Optional Outputs Optional Outputs Optional Outputs SYSTEM STATUS INDICATION Terminals 38 and 39 can be wired for a or system SYSTEM STATUS INDICATOR device by the customer. When the LPG/air mixer is running the output is turned on and the contacts close.
Page 59 Operation Operation Operation Operation LPG/Air Venturi Type Mixers LPG/Air Venturi Type Mixers LPG/Air Venturi Type Mixers LPG/Air Venturi Type Mixers Mixed gas is produced by the . High pressure LPG vapor is VENTURI ASSEMBLY introduced into the venturi nozzle. It accelerates through the venturi nozzle forming a vacuum as it exits the nozzle.
Page 60 Operation Operation Operation Operation Pressure Adjustments Pressure Adjustments Pressure Adjustments Pressure Adjustments The following subsections discuss to the mixing PRESSURE ADJUSTMENTS system. With the LPG vaporizer at operating temperature, put a load or flare stack on the system so at least one venturi is cycling. Note the number of venturis that are not cycling.
Page 61 Operation Operation Operation Operation ADJUSTING THE MOTIVE PRESSURE ON SYSTEMS WITH A SINGLE REGULATING STATION: Close all venturi shutoff valves. Close the shutoff valve on the pilot supply line to the pilot operator for the main reactor. on the operator panel, put the unit in setup mode. SETUP (F4) Press the mixer to start the LPG/air mixer.
Page 62 Operation Operation Operation Operation Detailing Venturi Performance Detailing Venturi Performance Detailing Venturi Performance Detailing Venturi Performance Figure 20 - Typical Venturi Performance Curve Venturi Performance Curve.wmf The factory set is the point at which the venturi performance MOTIVE PRESSURE yields the leanest mixture at rated output and discharge pressure, when installed at elevations up to 2000 ft.
Page 63 Operation Operation Operation Operation Additional Safety and Operation Switches Additional Safety and Operation Switches Additional Safety and Operation Switches Additional Safety and Operation Switches NOTE NOTE NOTE NOTE All switches are preset at the factory. You should only have to adjust them after replacement.
Page 64 Operation Operation Operation Operation TIME DELAY RELAY ( See Figure 6, #6 ) allows the system to remain operating if there is a short TIME DELAY RELAY temporary power loss or if any safety switch trips for less than 3 seconds. The time delay relay is fixed at 3 seconds and will not allow a shutdown of the vaporizer if the safety was open for less than that time.
Page 65 Operation Operation Operation Operation The regulator pressure can be set by measuring either the differential pressure across the gas inlet orifice, taps “ ” and “ ”, See Figure 21, or the inlet pressure to the inlet orifice, tap “ ”.
Page 66 Operation Operation Operation Operation DUNGS DUAL MULTI-VALVE AND VISUAL INDICATORS Both safety shutoff gas valves, one quick opening and one slow opening, are combined in the Dungs Dual Multi-Valve (DMV) used on all standard and Minnesota units through Q960V. On the side of the valve are two visual indicators.
Page 67 Operation Operation Operation Operation SPARK PLUG GAP A recommended monthly maintenance practice is to clean the spark plug and check the electrode gap. The gap should be approximately 0.100 as measured in the diagram. Figure 23 - Spark Plug Gap ___________________________________________________________________________ Spark Plug Gap.wmf FLAME MONITORING SYSTEM...
Page 68 Operation Operation Operation Operation UV SCANNER (Q1650V models) The UV scanner detects the radiant energy from the flame. The current passing through the detector is amplified by the combustion safeguard and interlocks the safeguard safety circuit. The UV scanner lens must be clear of debris to properly view flame.
Page 69 Operation Operation Operation Operation Optional Equipment Optional Equipment Optional Equipment Optional Equipment ACCUMULATOR TANK Algas-SDI can provide a mixed gas accumulator tank. The tank comes with all the necessary hardware for field installation. See Installation, Section 3 for mounting and sizing criteria. STANDBY ELECTRIC BATH HEATER The standby electric bath heater is typically recommended when the ambient...
Page 70 Operation Operation Operation Operation QM REMOTE CONTROL AND MONITOR PACKAGE SYSTEM ELECTRONIC INTERFACE FOR REMOTE OPERATION REQUIRED OPERATING SYSTEM: Personal computer running Windows 95, 98, or NT Procomm Version 3.0 or better (provided with the option) OPTIONS FOR CONNECTING TO A PC: 1.
Page 71 Operation Operation Operation Operation Figure 26 – Electronic Interface – Side View EL Side.gif Figure 27 – Electronic Interface – Pump View EL Pump.gif 5-59 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 72 Operation Operation Operation Operation 5-60 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 73 6 6 6 6 Maintenance Maintenance Maintenance Maintenance MAINTENANCE CHECKLIST Check these items weekly to ensure safe proper operation: The presence of LPG vapor. Glycol/water level. Verify water pump operation. Gas valve operation. Flame safeguard status. Smooth lightoff and smooth burner operation. Venturi motive pressure.
Page 74 Maintenance Maintenance Maintenance Maintenance Table 5 - Maintenance Schedule. DESCRIPTION WEEKLY EVERY MONTH EVERY SIX MONTHS EVERY YEAR Blower wheel Check that wheel is tight on shaft . Check for dirt. Blower air flow Check adjustment. switch Test shutdown. Burner fuel supply Pressurize and lines check for leaks.
Page 75 Maintenance Maintenance Maintenance Maintenance Maintenance Schedule continued... DESCRIPTION WEEKLY EVERY MONTH EVERY SIX MONTHS EVERY YEAR Unit connections Leak test w/soap (all). solution. CPU battery From operator condition screen check battery status. It will indicate “CPU battery ” or “replace CPU battery”...
Page 76 Maintenance Maintenance Maintenance Maintenance Safety Shutoff Valve Leak Test Procedure Safety Shutoff Valve Leak Test Procedure Safety Shutoff Valve Leak Test Procedure Safety Shutoff Valve Leak Test Procedure FOR DUNGS DMV The burner must be to perform a leak test on the safety gas valves. Remove power connection at valve by loosening hold down screw and pulling off connector.
Page 77 Maintenance Maintenance Maintenance Maintenance Immerse the hose end just below the surface of a container of water. If bubbles appear, the valve is leaking. Follow manufacturer’s instructions for corrective action. Reinstall plug after testing. Leak Testing the Pilot Train Leak Testing the Pilot Train Leak Testing the Pilot Train Leak Testing the Pilot Train The burner must be off to perform a leak test on the safety gas pilot solenoid...
Page 78 Maintenance Maintenance Maintenance Maintenance Water/Glycol Maintenance Water/Glycol Maintenance Water/Glycol Maintenance Water/Glycol Maintenance In addition to maintaining proper coolant level, PH and corrosion inhibitor control are also necessary. Water loss by evaporation is natural and depends on system use and ambient conditions.
Page 79 Maintenance Maintenance Maintenance Maintenance A rigorous PH and inhibitor monitoring and maintenance schedule is essential but not always easy to establish, as the rate of change is dependent on system use. A good method to establish a pattern for a schedule is to analyze PH an inhibitor level (for Hydro-treat) immediately after installation, after 2 months or 200 hours use, whichever occurs first, and after 6 months or 500 hours use, whichever comes first.
Page 80 Maintenance Maintenance Maintenance Maintenance Venturi Check Valve Replacement Instructions Venturi Check Valve Replacement Instructions Venturi Check Valve Replacement Instructions Venturi Check Valve Replacement Instructions This instruction set is to be used for the Venturi Check Valve Kit- P/N - 40490. A.
Page 81 Maintenance Maintenance Maintenance Maintenance 2) Screw the Clevis ( I ) into the Venturi Housing, until 1 – 2 threads are left inside of the housing ( D ). Do not use a screwdriver or other prying device to install the clevis. 3) Insert the Check Valve Arm ( K ) into the slot of the Clevis ( I ) and connect the two pieces with the clevis/arm Pivot Screw ( L ) through the aligned holes.
Page 82 Maintenance Maintenance Maintenance Maintenance b) With the Check Valve ( M ) rotated to the other extreme position around the valve/arm pivot, lowering the Check Valve Arm ( K ) should cause only the upper part of the Check Valve ( M ) to contact the Seating Surface ( F ). c) Lower the arm ( K ) a third time, allowing free rotation of the Check Valve (M).
Page 83 Maintenance Maintenance Maintenance Maintenance d) If the valve does not contact the seat as described above, reposition the Clevis ( I ) in the Housing ( D ). At least three threads must be exposed for proper installation of the acorn nut ( G ). 5.
Page 84 Maintenance Maintenance Maintenance Maintenance LEAK CHECK PROCEDURE FOR VENTURI CHECK VALVES Remove from venturi. AIR INLET HEADER ( See Figure 4, Item 7 ) Build-up pressure in accumulator to the system operating pressure, shut off the system, close the , and disconnect all power. INLET VALVE Use either a gas detector or a soapy solution applied to the check valve and seat to determine if there is a leak.
Page 85 Maintenance Maintenance Maintenance Maintenance PLC Sequencer PLC Sequencer PLC Sequencer PLC Sequencer The ASDI sequencer is accessed by opening the door of the control cabinet. NOTE NOTE NOTE NOTE Do not attempt to repair the sequencer modules. If the module is defective, the entire module should be replaced.
Page 86 Maintenance Maintenance Maintenance Maintenance REPLACING AC INPUT AND OUTPUT MODULES (SLOT 1 AND 2): Turn off power at the disconnect. Modules must not be removed with power applied to the sequencer. Squeeze the tabs on the top and bottom of the terminal block and pull it out. Pull outward on the retaining clips, located at the top and bottom, to unlock the module.
Page 87 Maintenance Maintenance Maintenance Maintenance TO REMOVE CPU BATTERY Remove the battery terminal clip from the circuit board connector. Gently remove the battery from the battery holder. Figure 31 – CPU Battery Removal CPU Battery Removal.wmf 1. CPU module 3. CPU battery 2.
Page 88 Maintenance Maintenance Maintenance Maintenance TESTING THE CONTROL BOX HEATER If the heater is not on due to ambient temperature being higher than the thermostat settings, the heater can be checked by the following procedure: The operating thermostat is on at 45° F and off at 60° F. The high temperature limit thermostat opens at 150°...
Page 89 Maintenance Maintenance Maintenance Maintenance 6-77 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 90 Maintenance Maintenance Maintenance Maintenance 6-78 Algas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 91 7 7 7 7 Troubleshooting Troubleshooting Troubleshooting Troubleshooting WARNING WARNING WARNING WARNING At all times make absolutely sure that no LPG vapor is present around the electric enclosure. The electrical arcing that occurs when the various switches and relays within the enclosure operate is a possible source of explosive ignition.
Page 92 Troubleshooting Troubleshooting Troubleshooting Troubleshooting Table 6 – Troubleshooting, Causes and Solutions TROUBLE PROBABLE CAUSE SOLUTION ANNUNCIATED OPERATOR PANEL HIGH LPG LEVEL HIGH LPG LEVEL Float chamber filled with LPG or Drain LPG or contaminants. contaminants. See Figure 4. LPG pump pressure set too high. Lower LPG pump pressure.
Page 93 Troubleshooting Troubleshooting Troubleshooting Troubleshooting TROUBLE PROBABLE CAUSE SOLUTION MOTOR RUNS, GAS PILOT Manual valve closed. Open valve. ESTABLISHES, MAIN GAS Manifold gas pressure too low. Adjust pressure regulator to valve at FLAME DOES NOT IGNITE setting shown on Data Sheet, Main and/or secondary gas valve Check voltage to coil or gas valve.
Page 94 Troubleshooting Troubleshooting Troubleshooting Troubleshooting TROUBLE PROBABLE CAUSE SOLUTION RESET/POWER FAILURE RESET/POWER FAILURE Power switch off. Turn switch on and start system. Power outages longer than three Restart system. seconds. Blown fuse. Check cause of problem, replace fuse. BURNER BLOWER AIR FLOW FAILURE ON Lockout reset tripped on flame Reset flame safeguard.
Page 95 Troubleshooting Troubleshooting Troubleshooting Troubleshooting TROUBLE PROBABLE CAUSE SOLUTION PWR INDICATOR OFF Incorrect voltage to sequencer. Perform basic power checks - check voltage, disconnect power and check wiring for loose connections, check all connections in panels. Measure voltage at the base Faulty power supply or CPU terminal strip.
Page 96 Troubleshooting Troubleshooting Troubleshooting Troubleshooting 7-84 lgas-SDI Operations & Maintenance – QM Models – P/N: 52644...
Page 99 OPTIONS...
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Page 101 ACCUMULATOR / SURGE TANK ACCUMULATOR / SURGE TANK ACCUMULATOR / SURGE TANK ACCUMULATOR / SURGE TANK Contact Algas-SDI international for Accumulator Surge Tank Packages. FLARE STACK FLARE STACK FLARE STACK FLARE STACK Contact Algas-SDI international for Flare Stack Packages. LIQUID PUMP LIQUID PUMP LIQUID PUMP LIQUID PUMP...
Page 102 Figure 32 – Filtaire Operation BYPASS VALVE (NORMALLY CLOSED) 1ST STAGE REGULATOR OUTLET VALVE “FILTAIRE” OIL DEMISTER VAPOR FROM VAPORIZER VAPOR LINE INLET VALVE PIPE 5 DRAIN STAND VALVE VAPOR TO LOAD Filtaire.wmf LEAK TEST CAUTION CAUTION CAUTION CAUTION The entire installation must be leak tested prior to operating the system.
Page 103 APPENDIX A TECHNICAL INFORMATION...
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Page 105 Figure 20 - ASCO Valve used by Algas-SDI 2.9.98 WARNING: TURN OFF ELECTRICAL POWER AND DE-PRESSURIZE VALVE BEFORE MAKING ANY REPAIRS. TORQUE CRISSCROSS TO 110 in-Lbs [ 12.4 N-m ] TORQUE TO 175 in-Lbs [ 19.7 N-m ] Algas-SDI ASCO Valve Draw.wmf...
Page 106 SOLENOID NOISE SOLENOID NOISE SOLENOID NOISE SOLENOID NOISE Solenoid valves emit a sound when operated. When energized, they emit a clicking sound. Also, accompanying the operation of most AC valves, is AC hum. Whether or not AC hum is objectionable actually depends on the requirements and opinion of the user.
Page 123 Provisions for Pressure and Seat Leakage Testing V710 Series valves are provided with four 1/4I NPT tapped and plugged holes (pressure taps). Each side of the valve body is provided with an upstream and downstream pressure tap for testing. The taps closest to the valve bonnet are upstream, while the taps closest to the bottom of the valve body are downstream.
Page 124 Maximum Operating Pressure Differentials: S 3/4I, 1I, 1 1/4I and 1 1/2I NPT - 15 psi S 2I, 2 1/2I and 3I NPT - 10 psi INSTALLATION Check nameplate for correct catalog number, pressure, and Testing for External Leakage service. Check the catalog number against Table 1 to ensure that the valve meets the requirements of the application.
Page 125 4. Shut off the upstream manual gas cock and NOTE: The leakage rate above recognizes that some wear de-energize valve. Remove the plug from the leak test and contamination from use can result in a slight amount of tap or downstream pressure tap in the valve body. leakage.
Page 126 T T T T T ransducers and T ransducers and T ransducers and T ransducers and Transmitters ransmitters ransmitters ransmitters T T T T T ransmitter ransmitter ransducers and T ransmitter ransmitters ransmitter ransmitter Current Output Series 425 Shown with standard 1/4" NPT 425 Series 4-20 mA with built-in snubber 4-20 mA...
Page 131 PUMP BODY DIAGRAM 1AA, 1 "AA, 1 "AA and 2"AA Discharge Gage Tapping (on side opposite) Seal Assembly Volute Gasket Coupler Assembly Impeller (Enclosed) Shaft Sleeve Impeller Key Impeller Lock Nut Pump Shaft Volute Impeller Lock Washer Motor Bracket Assembly Face Plate Rear Bearing Front Bearing...
Page 132 For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053, Phone (847) 966-3700 – Facsimile (847) 966-9052. Bell & Gossett Morton Grove, IL, U.S.A. PRINTED IN U.S.A. 2-95...
Page 137 Shaft Slinger Bracket Cover Plate Shaft Sleeve Seal Assembly Impeller Washer Impeller Key Volute Gasket Volute Cap Screw Impeller Impeller Lock Washer Volute Impeller Cap Screw FIG. 7 SERIES 80 WITH STANDARD MECHANICAL SEAL Slinger Shaft Bracket Shaft Sleeve Gland Bolt Flush Line Packing Gland Packing...
Page 138 O-RING COVERPLATE FOR 1 " SEAL " MOTOR FOR 1 " SEAL O-RING " SEAL LOCKING COLLAR SEAL CAP SEAL CAP BOLTS MOTOR O-RING O-RING...
Page 140 For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053, Phone (847) 966-3700 – Facsimile (847) 966-9052. Bell & Gossett Morton Grove, IL, U.S.A. PRINTED IN U.S.A. 12-92...
Page 145 SHAFT SLINGER SHAFT SLEEVE BRACKET COVER PLATE SEAL ASSEMBLY VOLUTE CAP SCREW VOLUTE GASKET SUCTION DISCHARGE GAUGE TAPPING IMPELLER COMPANION FLANGE VOLUTE IMPELLER CAP SCREW SHAFT SHAFT SLEEVE SLINGER SEAL ASSEMBLY BRACKET COVER PLATE VOLUTE CAP SCREW VOLUTE GASKET SUCTION DISCHARGE GAUGE TAPPING IMPELLER...
Page 146 For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053, Phone (847) 966-3700 – Facsimile (847) 966-9052. Bell & Gossett Morton Grove, IL, U.S.A. PRINTED IN U.S.A. 1-94...
Page 147 Dual Safety Shutoff Valves DMV-D/6, DMV-DLE/6 Two normally closed safety shutoff valves in one housing; each with the following approvals. UL Recognized • UL 429 • File # MH16727 CSA Certified • ANSI Z21.21 • CSA 6.5 • C/I Automatic Valves •...
Page 148 DMV-D…/6 Two normally closed safety shutoff valves in one housing. V1 and V2 are fast opening, fast closing. Adjustable max flow with V2. DMV-DLE…/6 Two normally closed safety shutoff valves in one housing. V1 fast opening, fast closing. V2 is slow opening, fast closing. Adjustable max flow and Adjustable initial lift with V2. Specifications Body sizes DMV 701...
Page 149 DMV dual safety shutoff valve modular system Optional mounting system shown, other configurations possible Port 1 Port 2 Port 3 = 7 PSI max. Pressure switch can be mounted on flange DMV dual safety shutoff valve with upstream FRI pressure regulator High gas Port 3 pressure switch...
Page 150 Dimensions inch (mm) Port 2 Port 1 Port 3 Type 110-120 VAC 24 VAC 24 VDC Dimensions [inch] Weight Power* [lbs] 50-60 Hz 50-60 Hz [VA] Dimensions [mm] c**** [kg] Order No. Order No. Order No. DMV-D 701/6 D224 842 D228 220 D226 990 6.9 / 8.1...
Page 151 DMV-D(LE)…/6 sectional drawing Strainer Flange Valve V1 Housing Closing spring V1 Plunger V1 Solenoid V1 Electrical connection Max flow adjustment Initial lift adjustment (DMV-DLE) Hydraulic brake (DMV-DLE) Valve V2 Closing spring V2 Plunger V2 Solenoid V2 Solenoid housing Visual indicator (VI) CPI 400 interlock switch CPI 400 can be used in place of one...
Page 152 Dual Safety Shutoff Valves DMV-D/6, DMV-DLE/6 Flow diagram 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. We reserve the right to make any changes in the interest of technical progress. Karl Dungs Inc.
Page 153 Pressure switch for dual modular valves GAO-A2… GMH-A2… GML-A2… 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 European models tested to EN1854 Description Application...
Page 154 GAO-A2… SPDT pressure switch requires no auxiliary power. The GAO-A2… 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. Automatic reset when pressure returns below or above set point. GMH-A2…...
Page 155 Dimensions inch (mm) GAO-, GMH-, GML-A2… .4 (10) Through hole for M4 Screw 2.1 (53,7) 2.8 (72) Reset button • GMH-A2… • GML-A2… Slot for O ring (10.5 x 2.25) Made in Germany que 65 in. Lbs M. torq Adapters / replacement parts / Order No.
Page 156 A2 mounting options FRI gas pressure regulator Pressure tap mounting possible… = 7 PSI max. A2 mounting options 3 p a 2 p e MB 053-403 GasMultiBloc Pressure tap mounting possible… yes, with #D221 630 3 p a 2 p e yes, with #D221 630 A2 mounting options p Br...
Page 157 A2 mounting options DMV 300/500 Dual modular valve DMV 500 p = 5 PSI Pressure tap max. DMV 300 p = 3 PSI max. mounting possible… yes, with # D214 975 yes, horizontal yes, with # D221 630 A2 mounting options DMV 701-703 Dual modular valve DMV 700 p = 7 PSI...
Page 158 Pressure switch for dual modular valves GAO-A2… GMH-A2… GML-A2… Technical data Version Setting range Switching hysteresis Type Order No. ∆ In. W.C p In. W.C (calibrated at) GAO-A2-4-2 0.16 - 1.20“ ≤ 0.12“ D217 085 GAO-A2… GAO-A2-4-3 0.40 - 4.00“ ≤...
Page 159 Safety Shutoff Valves MVD/6, MVDLE/6 ® Normally closed safety shutoff valve with the following approvals. UL Listed • UL 429 • File # MH16727 AGA / CGA Certified • ANSI Z21.21 • CGA 6.5 • CGA 3.9 • File # LM112901-04 FM Approved •...
Page 160 Normally closed automatic safety shutoff valve, fast opening, fast closing. Adjustable max. flow. MVDLE Normally closed automatic safety shutoff valve, slow opening, fast closing. Adjustable initial lift. Adjustable max. flow. Specifications Pipe thread (NPT) 1/2" 3/4" 1" 1 1/4" 1 1/2" 2"...
Page 161 Approvals Model Temperature Rating MOPD Max. Close Off Electrical Ratings (PSI) (PSI) (Volts / Hz) -20 °F to 120 °F 120/60 (-10% +15%) -20 °F to 120 °F 120/60 (-10% +15%) -20 °F to 120 °F 24/60 (-10% +15%)* -20 °F to 120 °F 24/60 (-10% +15%)* UL 429 -30 °F to 140 °F...
Page 162 Type Sole- Order Opening time Dimensions [inch] Weight max. noid Dimensions [mm] [lbs] [VA] to max flow [kg] Inrush and Full Load MVDLE 205/6* 1/2" 46030-2 approx. 10 s 1.97 2.95 5.31 2.76 6.10 2.43 46031-2* 1,10 MVDLE 207/6* 3/4" 46030-3 approx.
Page 163 Type MVD Type MVDLE sectional drawing sectional drawing 120 VAC 60 Hz 120 VAC 60 Hz Housing Solenoid CPI 400 position Strainer Electrical connection interlock switch Valve disc Max flow adjustment Visual indicator (VI) Closing spring Initial lift adjustment MVDLE Plunger Hydraulic brake MVDLE On the MVDLE, the hydraulic brake 10...
Page 164 Safety Shutoff Valves MVD/6, MVDLE/6 Flow diagram Recommended operating range Based on 60 °F, 14.65 psia, dry 40,000 300 400 600 800 1,000 2,000 4,000 6,000 10,000 20,000 Flow (CFH) of natural gas; s.p. 0.65 at 60 °F We reserve the right to make any changes in the interest of technical progress. Karl Dungs GmbH &...
Page 165 Instruction Manual 818 2/02 VeriFlame Single Burner Monitoring System Model 5600 Version 1.21 Modulation Model No Purge Model Purge Model...
Page 166 Copyright 1997 by Eclipse Combustion, Inc. All rights reserved worldwide. This OPYRIGHT publication is protected by federal regulation and shall not be copied, distributed, transmitted, transcribed or translated into any human or computer language, in any form or by any means, to any third parties, without the express written consent of Eclipse Combustion, Inc., Rockford, Illinois, U.S.A.
Page 167 About this manual This manual has been written for the people who select and install the product UDIENCE and the technicians who work on it. They are expected to have previous expe- rience with this kind of equipment. This manual contains essential information for the proper installation and op- COPE eration of the Eclipse Veri-Flame Burner Monitoring System.
Page 168 If you need help, you can contact your local Eclipse Combustion sales office. OW TO GET HELP You can also contact Eclipse Combustion, Inc. at: 1665 Elmwood Road Rockford, Illinois 61103 USA Phone: 815-877-3031 Fax: 815-877-3336 E-mail: eclipse eclipsenet.com http://www.eclipsenet.com Eclipse Veri-Flame Instruction Manual 818 -2/02...
Page 169 Table of Contents About this manual ..................Table of contents ..................Introduction ....................Product Description ................... Specifications ....................Introduction ......................Specifications ......................Dimensions ......................DIP Switch Selection ................Introduction ......................DIP Switch Location ..................... DIP Switch Access ....................No Purge DIP Switch Settings ................Modulation &...
Page 170 Optional Features ....................Pilot Test Mode Sequence ................Air Switch Input Hold ..................Remote Display & Power Supply ..............Status Lights & Push-buttons ................Interlocks Closed ..................... Air Failure ......................System Error ..................... Burner On ......................Flame Failure ..................... Low Fire ......................High Fire ......................
Page 171 Maintenance & Troubleshooting ............ Introduction ......................Maintenance ......................Monthly Checklist ....................Yearly Checklist ..................... Troubleshooting ..................... LED Status ......................LED Status & Conditions for No Purge Models (Table 8.1) ...... LED Status & Conditions for Purge Models (Table 8.2) ......LED Status &...
Page 172 Introduction The Eclipse Combustion Veri-Flame Single Burner Monitoring System controls RODUCT the start-up sequence and monitors the flame of single gas, oil, or combination ESCRIPTION gas/oil burners. There are three different models to the Veri-Flame line: the no purge, the purge and the modulation models. Each model features field select- able trial for ignition (TFI).
Page 173 Specifications This section gives a detailed overview of Veri-Flame specifications and dimensions. NTRODUCTION Specifications ARAMETER ESCRIPTION • Series 5602 & 5605: 120 VAC ( + 10%, - 15%), 50/60 Hz standard. Supply Series 5603: 240 VAC ( + 10%, - 15%), 50/60 Hz standard. Internal power consumption: 12 VA (excluding external connected loads).
Page 174 Specifications (continued) ARAMETER ESCRIPTION Approvals • No Purge & Purge Models: (See chart below.) Series 5602: UL listed, CSA certified, FM approved and IRI acceptable. Series 5603: No approvals. Series 5605: UL listed, FM approved and IRI acceptable. • Modulating Models: Series 5602: UL recognized (must be mounted in panel), CSA certified, FM approved and IRI acceptable.
Page 175 Dimensions (continued) Veri-Flame/Modulating Model with Base Model Number 5602-40 24mm (15/16") 171mm (6-3/4") 25mm (1") 1 2 3 4 5 6 7 8 A D S2 S1 11 12 13 40mm (1-9/16") 10mm (3/8") 5mm (3/16") 213mm (8-3/8") 116mm (4-9/16") Remote Display Model Number 5602-DB 89mm 102mm...
Page 176 DIP Switch Selection This section details the location, selection and description of the Veri-Flame NTRODUCTION DIP switches, which allow for sequence and timing functions as well as sys- tem configuration. Caution To avoid electric shock, shut off the power supply when installing or removing any control device.
Page 177 Figure 3.1 DIP Switch Location Close-up of DIP switches on back side of all Veri-Flame models. Figure 3.2 DIP Switch Labels with Selections No Purge Models Modulation Models Purge Models Eclipse Veri-Flame Instruction Manual 818 -2/02...
Page 178 Function Summary This section describes the features of the Veri-Flame. It is broken into three categories: NTRODUCTION Standard features, Optional features and the LED Indicator Lights on the front cover. Refer to Figure 5.5 for sequence diagrams. The following function features are standard on the Veri-Flame models as noted: TANDARD FEATURES Interlocks and Limit This input is considered the normal operation control or run input to the Veri-...
Page 179 For modulation models: This feature is enabled when the jumper on the Main Fuel Valve Closed/ base is cut. The system checks that the high fire position switch and the High Fire Purge Check main valve closed switch are both made at the end of the high fire purge. (Terminal D) For all models: when selected, the Veri-Flame will restart the sequence after Recycle Mode...
Page 180 System Errors & 4) Low fire fail (for modulating model)–low fire switch open prior to trial Lockout Conditions for ignition. (Continued) 5) High fire fail (for modulating model)–high fire switch is not closed at the end of high fire purge. The following situations will result in a lockout condition: 6) Air failure (for purge and modulation models) –...
Page 181 The following features are available on select models, or when optional equipment PTIONAL FEATURES is purchased. Air Switch Input Hold For purge/modulation models: holds the sequence indefinitely until air switch input is confirmed without affecting the air failure function and causing a lockout. Remote Display &...
Page 182 System Installation In this section, the necessary procedures are detailed to integrate a Veri-Flame into a NTRODUCTION burner system; Figures 5.1 and 5.2 illustrate the various terminal strips mentioned. Note: Shut off the power supply before the Veri-Flame is removed or replaced from the base. Caution: Installation and maintenance must conform with the National Electrical Code and all other national and local codes and authorities having jurisdiction.
Page 183 Ignition Wiring Route ignition wiring a sufficient distance from all sensors and other low volt- age wiring to avoid electrical interference, which may cause erratic operation of the Veri-Flame system. Keep the high voltage wire run from the ignition trans- former as short as possible.
Page 184 Figure 5.1 No Purge and Purge Wiring Diagrams Purge Models No Purge Models 5602/5605: 5603: 5602/5605: 5603: 120 VAC 240 VAC 120 VAC 240 VAC 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 15 A On/Off 15 A On/Off Fuse Fuse Piloted Burner Piloted Burner...
Page 185 Figure 5.3 Typical Connections For All Models Model 5602 DBP Model 5602 DB 24 VDC Remote Display 120 VAC Remote Display 120V 120V 24V G Tx Rx To 1 Cable to 120 VAC Flame Signal PLUG Cable Flame Signal PLUG #20318 Test Jack #20318...
Page 186 Figure 5.4 Purge and No Purge Bases Internal Diagram Model Number 5602-10 Model Number 5602-10-1 Purge & No-purge Alarm Pilot P3 Fault Jumper Main Jumper Supervisor Jack Flame Signal 5 6 S2 S1 7 8 A 1 2 V 4 3 Amplifier NOTE: Ground Terminal Note: No purge models do not use 6 &...
Page 187 Figure 5.5 Sequence Diagrams Terminal Function Control Power Pilot Valve Outputs Ignition Main Valve Interlocks Inputs POVC Flame Recycle 35 Seconds Check Permitted Main Pilot Firing Trial Trial Cycle 10 Sec Terminal Function Control Power Pilot Valve Ignition Outputs Main Valve Air Switch Inputs Interlocks...
Page 188 Sensor Installation This section describes the proper wiring, installation and sighting considerations for NTRODUCTION all sensors that can be used with a Veri-Flame. Warning Incorrect sensor installation may cause the sensor to generate a false flame signal, possibly resulting in the collection of unburned fuel in the combustion chamber.
Page 189 1) Keep the flame rod as short as possible and at least 13 mm (1/2") away from any refractory. 2) Position the rod into the side of both the pilot and main flames, preferably at a descending angle to minimize drooping of the flame rod against burner Figure 6.1 Flame Rod Position parts, as shown in Figure 6.1.
Page 190 Test Procedures This section describes the test procedures that must be performed after instal- NTRODUCTION lation to insure that the Veri-Flame is operating properly; these procedures are mandatory. a 0-15 VDC, digital volt meter Insert the positive probe of into the test Flame Signal Strength point on the front cover of the Veri-Flame;...
Page 191 Pilot Flame Failure Test 1) Manually shut off the fuel supply to the pilot and the main burner. 2) Place system in pilot test mode (please refer to page 15). 3) Start the system normally. The controller should lock out*; if it doesn’t, then the controller is detecting a false flame signal (see Section 6).
Page 192 Maintenance & Troubleshooting This section is divided into two parts: NTRODUCTION • The first part describes the maintenance procedures. • The second part describes troubleshooting procedures, from identifying prob- lems to interpreting the operating conditions by the lit LEDs on the front cover. Preventative maintenance is the key to a reliable, safe and efficient system.
Page 193 ROUBLESHOOTING ROBLEM OSSIBLE AUSE OLUTION Check main valve closed switch. Cannot initiate start sequence Main valve is not closed. No voltage on V (or D). Check air pressure switch adjustment. Check air filter. Air pressure switch has not made Check blower rotation. contact.
Page 194 LED S This section describes the status of operating conditions based on the LED or TATUS combination of LEDs which are lit on the front cover of each Veri-Flame model. Table 8.1 LED Status & Conditions for Veri-Flame No Purge Models LED( OSSIBLE AUSES...
Page 195 Table 8.2 LED Status & Conditions for Veri-Flame Purge Models LED( OSSIBLE AUSES INTERLOCKS CLOSED 1) The interlocks are closed (normal operation), power on terminal 7. SYSTEM ERROR 1) The flame detected is out of sequence, flame signal light is on. 2) The sensor is “runaway”, flame signal light is on.
Page 196 Table 8.3 LED Status & Conditions for Veri-Flame Modulation Models LED( OSSIBLE AUSES INTERLOCKS CLOSED 1) The interlocks are closed (normal operation), power on terminal 7. SYSTEM ERROR 1) The flame detected is out of sequence, flame signal light is on. 2) The sensor is “runaway”, flame signal light is on.
Page 197 Remote Display Messages This section covers how the optional remote display is used with the Veri-Flame. NTRODUCTION The remote display provides LCD messages which monitor the status of the Veri- Flame’s functions as well as any lockout conditions. This section is divided into two parts or tables: •...
Page 198 Table 9.1 Veri-Flame Operating Sequence POWER ON Was internal safe start check successful? NORMAL MESSAGE REMOTE DISPLAY Various lockout messages REVISION X.X EXTERNAL INTERLOCK CHECKS Is flame signal present? ERROR MESSAGE #1 UNSAFE FLAME ON Is main valve closed switch made?* Fan is energized.
Page 199 Table 9.1 Veri-Flame Operating Sequence (continued) BURNER START-UP Is voltage present at air flow switch within ten seconds? NO PURGE MODELS MODULATION MODELS Is voltage present at air switch . . . PURGE MODELS NORMAL MESSAGE AIR PROVEN Is voltage present at air switch . . . ERROR MESSAGE NORMAL MESSAGE AIR NOT PROVEN...
Page 200 Table 9.1 Veri-Flame Operating Sequence (continued) BURNER START-UP (continued) Is flame signal present? ERROR MESSAGE MAIN FLAME FAIL XX:XX:XX LOCKOUT NORMAL MESSAGE MAIN FLAME ON NORMAL MESSAGE NORMAL MESSAGE IF Interrupted Pilot is selected IF Intermittent Pilot Is Selected MAIN FLAME ON MAIN FLAME ON PILOT OFF Pilot will shut off 10 seconds...
Page 201 Table 9.1 Veri-Flame Operating Sequence (continued) BURNER SHUTDOWN Shutdown is started by opening the operating interlock circuit. Is voltage present at interlocks? Continued operation. Is post purge selected? NORMAL MESSAGE POST PURGE Fuel valves de-energized; fan energized for 15 seconds. Is main valve closed switch made?* ERROR MESSAGE MAIN VALVE FAIL...
Page 202 Table 9.2 Remote Display Diagnostic Messages (Listed Alphabetically) ESSAGE XPLANATION AIR FAILURE Lockout For purge & modulation models: Combustion air flow limit XX:XX:XX LOCKOUT switch opened for more than two seconds once initially proven. AIR FAILURE Status For purge & modulation models: Combustion air flow limit switch RECYCLING opened;...
Page 203 Table 9.2 Remote Display Diagnostic Messages (continued) ESSAGE XPLANATION Lockout Main valve has been energized and main flame proven during trial MAIN FLAME ON for ignition. MAIN FLAME ON Status Pilot valve is de-energized and main flame is on. PILOT OFF MAIN VALVE FAIL Lockout For purge and no purge models: Main valve closed switch is...
Page 204 Table 9.2 Remote Display Diagnostic Messages (continued) ESSAGE XPLANATION UNSAFE FLAME ON Hold Flame signal—actual, induced, or runaway scanner—is detected be- fore start-up or after shutdown. The fan is energized. If the cause is corrected within 30 seconds, as in afterburn, the control will turn off the fan and continue the sequence.
Page 205 Appendix Metric to English. ONVERSION ULTIPLY BY ACTORS cubic meter (m cubic foot (ft 35.31 cubic meter/hour (m cubic foot/hour (cfh) 35.31 degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 1.8) + 32 kilogram (kg) pound (lb) 2.205 kilowatt (kW) Btu/hr 3414 meter (m)
Page 206 LLUSTRATED ARTS Pos. Model Part Description Number Number Category Straight U.V. scanner 5600-91 49600-91 NEMA 4 U.V. scanner 5600-91N4 20898 90˚ U.V. scanner 5600-90A 49600-90 I.R. scanner 5600-92B 49600-92 Self-check scanner 5602-91 49602-91 Solid-state U.V./I.R. scanner 5600-92SC 21349 10-foot cable for self-check scanner 5602-91-7 49602-91-7 Scanner support (max.
Page 207 Data 114-4 12/02 ThermAir Burners Model TA075 Version 1.10 Main Specification – TA075 BLOWER SIZE PARAMETER 3"w.c. Packaged 6"w.c. Packaged Maximum input (Btu/hr) Frequency Capacity at Chamber Pressure Capacity at Chamber Pressure (To maintain 15% excess air BTU/hr "w.c. mbar BTU/hr "w.c.
Page 208 Performance Graphs ThermAir TA075 Air Flow vs. Chamber Pressure Control & Operation Zone 10,000 Typical Fixed 1,000 Air Control -1.0 -2.5 -2.0 7000 7500 8000 8500 9000 9500 Input (x 1000 BTU/hr) Air Flow (scfh) Input (kW) Air Flow (Nm /hr) Burner Flame Length - 3"Blower Burner Flame Length - 6"Blower...
Page 209 Performance Graphs (Continued) ThermAir TA075 NOx Emission Data Notes on emission data Natural Gas NOx emission data is given for: Propane • Ambient combustion air ~70° F (20° C) Butane • Minimal process air velocity • ppm volume dry at 3% O •...
Page 210 Piping Orientation Piping Options Upright Inverted With ratio regulator and control BV Right Hand Piping Right Hand Piping (24.0) LeftHand Piping With control BV only Left Hand Piping (16.6) No Piping Less ratio regulator and control BV No Piping 114-4 Data 12/2002 Litho in U.S.A.
Page 211 Data 114-6 12/02 ThermAir Burners Model TA200 Version 1.10 Main Specifications - TA200 PARAMETER SPECIFICATIONS Frequency Btu/hr mbar "w.c. 2,071,000 -1.0 -2,5 60 Hz Maximum input packaged 2,000,000 blower (To maintain 15% excess air with 1,871,000 the standard air orifice and 2,235,000 -1.0 -2,5...
Page 212 Performance Graphs ThermAir TA200 NOx Emission Data Control & Operation Zone 10000 Natural Gas Propane Butane Typical Fixed Air Control 1000 1000 1500 2000 1000 1500 2000 Input (x 1000 BTU/hr) Input (x 1000 BTU/hr) Input (kW) Input (kW) Burner Flame Length Notes on emission data 1500 Natural Gas...
Page 213 Dimensions-TA200 mm (in) (28.5) (1.2) Tap "A" Tap "C" Optional Filter/Silencer and Pressure Switch shown in gray Tap "D" Tap "B" (0.35) 1.5" N.P.T (8.9) or 1.5" B.S.P Port Connection Sparkplug 14mm Blower 10" w.c. Flamerod or scanner 0.5" N.P.T. Peepsight 0.75"...
Page 214 Piping Orientation Piping Options Upright Inverted With ratio regulator and control BV Right Hand Piping Right Hand Piping (27.1) LeftHand Piping With control BV only Left Hand Piping (17.0) No Piping Less ratio regulator and control BV No Piping 114-6 Data 12/2002 Litho in U.S.A.
Page 215 Installation Guide 114 05/03 ThermAir Burners TA Series version 1.10...
Page 216 Copyright 1998 by Eclipse Combustion, Inc. All rights OPYRIGHT reserved worldwide. This publication is protected by federal regulation and shall not be copied, distributed, transmitted, transcribed or translated into any human or computer language, in any form or by any means, to any third parties, without the express written consent of Eclipse Combustion, Inc., Rockford, Illinois, U.S.A.
Page 217 About this manual This manual has been written for people who are already UDIENCE familiar with all aspects of a nozzle-mix burner and its add-on components, also referred to as “the burner system.” These aspects are: • installation • use •...
Page 218 There are several special symbols in this document. You OCUMENT must know their meaning and importance. ONVENTIONS The explanation of these symbols follows below. Please read it thoroughly. Danger: Indicates hazards or unsafe practices which WILL result in severe personal injury or even death. Only qualified and well trained personnel are allowed to carry out these instructions or procedures.
Page 219 Table of contents About this manual ......3 Audience ........3 ThermAir Documents .
Page 220 Adjustment, Start & Stop (Cont.) ... . . 21 System 2 Burner adjustment without a ratio regulator ..21 Step 1 Reset the system ..... 22 Step 2 Verify the system .
Page 221 Introduction The ThermAir burner (TA Series) is a nozzle-mix burner with a RODUCT packaged combustion air blower that is designed to fire with ESCRIPTION fixed combustion air over a wide gas turndown range. An integral gas orifice is provided to ease burner setup. The burner is designed to facilitate: •...
Page 222 Blank page. Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03...
Page 223 Safety This section is provided as a guide for the safe operation of NTRODUCTION the ThermAir burner system. All involved personnel should read this section carefully before operating this system. AFETY Danger: The ThermAir burners, described herein, are designed to mix fuel with air and burn the resulting mixture.
Page 224 Only qualified personnel, with good mechanical aptitude and APABILITIES experience on combustion equipment, should adjust, maintain, or troubleshoot any mechanical or electrical part of this system. The best safety precaution is an alert and trained operator. PERATOR RAINING Train new operators thoroughly and have them demonstrate an adequate understanding of the equipment and its operation.
Page 225 Installation In this section you will find important notices about safe NTRODUCTION operation of the burner: Handling: ANDLING AND 1. Make sure that the components are clean and free of TORAGE damage. 2. Protect the components from weather, damage, dirt and moisture.
Page 226 Electrical wiring All electrical wiring must comply with one of these standards: • NFPA Standard 70 • ANSI-C11981 • EN 746-2 • the electrical wiring must be acceptable to the local authority having jurisdiction All gas piping must comply with one of these standards: Gas Piping •...
Page 227 Air Supply INSTALLATION Provide an opening in the burner room of at least one square HECKLIST inch per 4000 BTU/hr (6 cm per 1 kW) to supply the burner intake with fresh, outdoor, combustion air. If there are corrosive fumes or materials in the surrounding air, find an uncontaminated source to supply air to the burner.
Page 228 Chamber Wall NSTALLATION Make sure the chamber wall ! is strong enough to support the CONTINUED weight of the burner ". If necessary, reinforce the mounting area. Burner Mounting Mount burner to chamber wall using four (4) customer supplied nuts and lock washers. 1.
Page 229 Piping Support Use brackets or hangers to support the gas piping. If you have questions, consult your local gas company. Control Motor Install a control motor to modulate the gas control valve if not previously installed on the burner. Installing the flame sensor There are two different types of flame sensors: U.V.
Page 230 After installation of the burner system components is REPARE FOR complete, the following steps should be followed in order to DJUSTMENT prepare for adjustment: 1. Set the air flow switch so that it drops out at 20% below the maximum pressure of the combustion air blower. 2.
Page 231 Adjustment, Start & Stop In this chapter you will find instructions on how to start and NTRODUCTION stop a burner. The chapter begins with general instructions that are useful for adjustment. Danger: The ThermAir burners, described herein, are designed to mix fuel with air and burn the resulting mixture.
Page 232 Step 2: Verify air flow TA 015, 025, 040, 075, 100, 200 1. Make sure that the pressure tap located on the chamber is open. Chamber 2. Connect the manometer to the chamber pressure tap. Wall 3. Measure the chamber air pressure. 4.
Page 233 1. Drive the gas control valve to low fire. Note: All ThermAir burners are limited to ignition at inputs below 40% of maximum unless the control circuit on page 15 of Design Guide 114 is followed. 2. Make sure the combustion air blower is running. 3.
Page 234 If the burner has ignited: a) Adjust the bypass flow adjusting valve such that the burner is able to maintain a stable flame and an adequate flame signal. b) Open all remaining manual gas valves feeding the burner. 1. If the burner has and is ignited, drive the main gas control Step 4: Set high fire gas valve to high fire (full open).
Page 235 10. Remove the manometer. 11. Close the pressure taps. 1. Drive the main gas control valve to low fire. Step 5: Set low fire gas 2. Adjust the control valve linkage to provide the desired low fire gas flow. Note: It is very difficult to measure the very low gas pressures experienced at low fire, and it may be necessary to rely on visual inspection of the flame.
Page 236 TA 015, 025, 040, 075, 100, 200 Step 2: Verify the system 1. Make sure that the pressure tap located on the chamber is open. Chamber 2. Connect the manometer to the chamber pressure tap. Wall 3. Measure the chamber air pressure. 4.
Page 237 2. Make sure the combustion air blower is running. 3. Open all manual gas valves feeding the burner. 4. Initiate the ignition sequence through the flame monitoring control system. 5. Verify that the burner has ignited. If the burner does not ignite: a) Try to ignite again to purge the air out of the gas piping.
Page 238 Step 4: Set high fire gas 1. If the burner has and is ignited, set the main gas pressure regulator for 7” w.c. outlet pressure. 2. Drive the main gas control valve to high fire (full open). 3. Verify air flow with the burner firing, repeat Step 2 “Verify air flow”.
Page 239 Maintenance & Troubleshooting This chapter is divided into two sections: NTRODUCTION • Maintenance procedures • Troubleshooting guide Preventive maintenance is the key to a reliable, safe and efficient system. The core of any preventive maintenance system is a list of periodic tasks. AINTENANCE Note: These are guidelines only.
Page 240 Yearly Checklist 1. Leak test the safety shut-off valves for tightness of closure. 2. Test the pressure switch settings by checking the switch movements against pressure settings and comparing these with the actual impulse pressure. 3. Visually check igniter cable and connectors. 4.
Page 241 ROUBLESHOOTING ROCEDURES PROBLEM POSSIBLE CAUSE SOLUTION Reduce start point gas flow. No ignition: Verify control circuit. • Attempting to ignite at inputs greater than 40%. Verify ignition transformer is a No ignition: 6,000 - 8,000 volt transformer. • Weak or non-existent spark. (Not half-wave) Start-up sequence runs but No ignition:...
Page 242 PROBLEM POSSIBLE CAUSE SOLUTION Start-up sequence runs but No flame signal: Inspect and clean sensor burner does not light. • Broken flamerod Replace if necessary (continued) • Dirty UV scanner lens Verify that the flamerod is No flame signal: installed correctly and is the •...
Page 243 PROBLEM POSSIBLE CAUSE SOLUTION • Cannot initiate a start Air pressure switch has not Check air pressure switch sequence. made contact. adjustment. Check air filter. Check blower rotation. Check outlet pressure from blower. • High gas pressure switch has Check incoming gas pressure. activated.
Page 244 Appendix Metric to English. ONVERSION From Multiply By ACTORS cubic meter (m cubic foot (ft 35.31 cubic meter/hour (m cubic foot/hour (cfh) 35.31 degrees Celsius (ºC) degrees Fahrenheit (ºF) (ºC x 1.8) + 32 kilogram (kg) pound (lb) 2.205 kilowatt (kW) BTU/hr 3414 meter (m)
Page 245 These are the symbols used in the schematics. EY TO YSTEM CHEMATICS Symbol Appearance Name Remarks Bulletin/ Info Guide ThermAir Eclipse Combustion, Inc. Main Gas Shutoff strongly endorses NFPA as a Valve Train minimum Gas cocks are used to Gas Cock manually shut off the gas supply on both sides of the main gas shut-off valve train.
Page 246 ThermAir Parts Drawing Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03...
Page 247 ThermAir Parts List Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03...
Page 248 ThermAir Parts List (Continued) Litho in U.S.A Installation Guide 114 05/03...
Page 249 R400 & R500 Fisher Controls MCK-1177 03/99 Low Pressure Second-Stage & Reguladores de Baja Presión Para Gas-LP de Segunda Etapa y Dos Integral 2-Stage LP-Gas Regulators Etapas Integradas Tipo R400 y R500 Type R400 & R500 ADVERTENCIA Failure to follow these instructions or to properly El no cumplir con estas instrucciones o no instalar install and maintain this equipment could result in y dar mantenimiento apropiado a este equipo...
Page 250 R400 & R500 Fisher Controls Especifícaciones Specifications Table 1 lists the specifications for the regulator. Contact the factory La tabla 1 lista las especificaciones para este regulador. Contacte a la fábrica si al regulador va a darse un servicio distinto a gas LP, if the regulator is to be used on any service other than LP-gas, gas natural, o aire.
Page 251 R400 & R500 Fisher Controls Instale el regulador de tal manera que las descargas de gas a través Install the regulator so that any gas discharge through the vent or de la ventila o del ensamble de la ventila queden a más de 3 pies (1 vent assembly is over 3-feet horizontally from any building opening metro) de cualquier abertura que tenga el edificio abajo del nivel de la below the level of discharge.
Page 252 R400 & R500 Fisher Controls Los sistemas subterráneos requieren de una linea de venteo para from entering the regulator spring case, see figure 4. Remove the impedir que el agua entre al contenedor del resorte del regulador, ver vent screen and install a vent tube. The vent tube must be run from figura 4.
Page 253 R400 & R500 Fisher Controls Large volumes of gas may discharge through the una sobrepresión, el mismo deberá inspeccionarse regulator vent during internal relief valve operation para verificar que no este dañado. which can result in fire or explosion from accumu- Volúmenes grandes de gas pueden ser descargados lated gas.
Page 254 Fisher Controls R400 & R500 Asegúrese de que la ventila del regulador, el ensamble de la ventila corrosion may require complete removal of the adjusting screw o el tubo de la ventila nos encuentran obstruidos por mugre, insectos, and shut down of the gas system. Closely examine regulators hielo, nieve, pintura, etc.
Page 255 Type R522 Fisher Controls Fisher Controls Fisher Controls Fisher Controls Fisher Controls Installation Manual Type R522 and R522H Pressure Reducing Regulators October 1992 Form 5331 Introduction avoid such injury or damage, provide pres- sure-relieving or pressure-limiting devices (as required by Title 49, Part 192, of the U.S. This installation manual covers the installation, startup, Code of Federal Regulations, by the Na- and adjustment procedures for Type R522 and R522H pres-...
Page 256 Type R522 l t u . c . . c . o l l . c . . c . . c . . c . o l l Description Body 1/2-inch size 3/4-inch size Inlet Fitting 1/4-inch size 1/2-inch size 3/4-inch size Spring Case Assembly Vent Screen...
Page 257 Types 1098-EGR & 1098H-EGR Incorporates Erratas Dated 06/97, 08/99, and 07/02 Instruction Manual Fisher Controls Type 1098-EGR & 1098H-EGR Pilot-Operated Regulators May 1987 Form 5084 Contents Introduction ........Scope of Manual .
Page 258 Types 1098-EGR & 1098H-EGR Introduction such as gas distribution systems, heat-treating furnaces, and boiler plants. They are also used in plant air service and in liquid service where a slow stroking time (approximately 30 to 90 seconds) is desired on both opening and closing the main valve. Scope of Manual The Type 1098-EGR regulator is used with a Type 6351, 6352, 6353 or the 61 series pilot.
Page 259 Types 1098-EGR & 1098H-EGR Table 1. Specifications (Continued) ACTUATOR SIZES PORT DIAMETERS AND MAXIMUM AND TRAVELS ACTUATOR TRAVEL PORT PORT PRESSURES DIAMETER Standard Restricted Capacity BODY SIZE BODY SIZE INCH INCH Percentage of Inch Inch Inch mm OUTLET (CONTROL) EMERGENCY Flow Capacity ACTUATOR PRESSURE...
Page 260 Types 1098-EGR & 1098H-EGR Table 2. Maximum and Minimum Differential Pressures for Main Valve Spring Selection Low-differential boiler fuel installation Type 1098-EGR requiring CONSTRUCTION All Other Constructions quick-opening cage and limited to 20 psig (1.4 bar) max inlet pressure 400 psig (28 bar) MAXIMUM ALLOWABLE 20 psig (1.4 bar) 60 psi (4.1 bar)
Page 261 Types 1098-EGR & 1098H-EGR 48A6566-A B1622 Figure 3. Standard Single-Pilot Installation 2. Install a three-valve bypass around the regulator if into the 1/4-inch NPT vent tapping. The Type 61LD pilot is vented continuous operation is necessary during maintenance or by installing the vent piping in place of the pipe plug (key 22, inspection.
Page 262 Types 1098-EGR & 1098H-EGR Pilot Adjustment 6. If a quick acting solenoid is to be installed downstream of a regulator, the regulator and solenoid should be located To adjust standard 6350 Series pilots: loosen the locknut as far apart as practical. This will maximize the gas piping (key 11, figure 13, or key 10, figure 14), and turn the volume between the regulator and solenoid and improve adjusting screw (key 10, figure 13, or key 9, figure 14).
Page 263 Types 1098-EGR & 1098H-EGR 48A6564-B B1654-1 Figure 4. Typical Dual-Pilot Boiler Fuel Installation 3. Attach a 1/2-inch NPT downstream pressure control CAUTION line ten pipe diameters downstream of the regulator in a straight run of pipe. Connect the other end of the control line to the 1/4-inch NPT connection in the control line pipe tee Introduce pilot supply pressure into the reg- as shown in figure 4.
Page 264 Types 1098-EGR & 1098H-EGR Working Monitor the spring case increases the spring compression and pressure setting. Turning the adjusting screw counterclock- wise decreases the spring compression and pressure Installation setting. 1. For both the working monitor regulator and the working regulator, perform the Standard Single-Pilot Regulator Pilot Adjustment Installation section through step 6.
Page 265 Types 1098-EGR & 1098H-EGR Table 3. Standby Pilots for Boiler Fuel Control Applications MINIMUM PRESSURE AT STANDBY PILOT INFORMATION WHICH STANDBY PILOT WHICH STANDBY PILOT Construction Spring Range Spring Part Number CAN BE SET 3 to 8 inch wc (8 to 20 mbar) 1B6358 27052 1 inch wc (2.5 mbar) 5 to 15 inch wc (12 to 38 mbar)
Page 266 Types 1098-EGR & 1098H-EGR The only adjustment necessary on a Type 1098-EGR or 4. Adjust the setting of the monitoring pilot to establish the 1098H-EGR regulator is the pressure setting of the pilot desired emergency downstream pressure, which is to be control spring.
Page 267 Types 1098-EGR & 1098H-EGR 16A4297-A 16A4296-A Figure 6. Typical Wide-Open Monitor Installations Pilot Adjustment D Block valves isolate the regulator. To adjust all standard 6350 Series pilots: loosen the D Vent valves are closed. locknut (key 11, figure 13, or key 10, figure 14), and turn the adjusting screw (key 10, figure 13, or key 9, figure 14).
Page 268 Types 1098-EGR & 1098H-EGR Shutdown In operation, assume that outlet pressure is below the pilot control setting. Control spring force on the pilot diaphragm Installation arrangements vary, but in any installation it is thus opens the pilot valve plug (Type 6351 pilot) or relay important that the valves be opened or closed slowly and orifice (Type 61LD pilot), providing additional loading that the outlet pressure be vented before venting inlet...
Page 269 Types 1098-EGR & 1098H-EGR 16A4297-A 17A9161-A B1617 Figure 7. Principle of Operation Schematics the working monitor regulator actuator. This actuator will O-rings can be checked for damage during normal move the valve plug and control the downstream pressure operation by line pressure leakage or unexpected grease at the emergency level.
Page 270 Types 1098-EGR & 1098H-EGR BODY FLANGE CAGE SCREWS INTO BODY FLANGE SEAT RING SCREWS INTO CAGE W3012-1* Figure 8. Trim Package Removal Design EGR Main Valve Replacing Quick-Change Trim Package Perform this procedure if the entire trim package (figure 8) is replaced.
Page 271 Types 1098-EGR & 1098H-EGR 1. Remove the indicator fitting (key 5) and attached parts. Proceed to step 5 if only maintenance on the fitting or attached parts is performed. 2. Remove the cap screws (key 3) with a cast iron body, or remove the stud bolt nuts (key 29, not shown) with a steel body, and pry the body flange loose from the valve body (key 1).
Page 272 Types 1098-EGR & 1098H-EGR Upon reassembly, one of the flat washers must go between Note the filter element and filter head (key 3) and the other must The body (key 1) may remain on the pipe go between the filter element and gasket. Use a good grade nipple (key 23, figure 15 or key 39, figure 16) of pipe thread sealant on the filter head pipe threads as unless the entire pilot is replaced.
Page 273 Types 1098-EGR & 1098H-EGR 4. To inspect the two diaphragm (keys 14 and 15) Type 1098 and 1098H Actuator and Pilot thoroughly, remove the diaphragm nut (key 11), hex nut (key Mounting Parts 19), and the upper and lower diaphragm plates (key 16 and 17).
Page 274 Types 1098-EGR & 1098H-EGR Parts Ordering into the bonnet to prevent stem or O-ring damage, and secure the lower diaphragm case to the upper diaphragm case with the cap screws and nuts. Tighten the cap screws Each Type 1098-EGR or 1098H-EGR regulator is assigned and nuts evenly in a crisscross pattern to avoid crushing the a serial number or F.S.
Page 275 Types 1098-EGR & 1098H-EGR 25A3170-C 35A3167-D 26A3800-A Figure 11. Design EGR Main Valve Description Part Number Description Part Number Valve Body (Continued) Body Flange Class 600 RF Cast iron, ENC 6 inch 34A6997 X012 1 inch 24A6761 X012 6 inch (NACE) 34A6997 X022 2 inch 25A3168 X012...
Page 276 Types 1098-EGR & 1098H-EGR Description Part Number Description Part Number Indicator Stem (Continued) Cap Screw, zn pl steel (use w/cast iron body) 316 stainless steel (NACE) 1 inch (4 req’d) 1R2811 24052 1 inch (NACE) 14A6756 X022 2 inch (8 req’d) 1A4533 24052 2 inch (NACE) 14A6994 X022...
Page 277 Types 1098-EGR & 1098H-EGR Description Part Number Description Part Number Upper Seal Flange Nut, pl steel 14A5693 X012 Nitrile (standard) E-Ring 1 inch 14A6789 X012 stainless steel 14A8181 X012 2 inch 24A5674 X012 1577 steel, heat treated (NACE) 14A8181 X022 3 inch 24A5659 X012 Drive Screw, stainless steel (4 req’d)
Page 278 Types 1098-EGR & 1098H-EGR 34A6635-B 32A6985-A Figure 13. Type 6351 Pilot Assembly Description Part Number Description Part Number Body Plug Standard P590 Series Aluminum 1B7975 09032 Filter (figure 12) Brass 1B7975 14012 316 Stainless steel 1B7975 35072 Filter Body Stainless steel (NACE) 1B7975 09032 Type P594-1, brass 1E3124 14012...
Page 279 Types 1098-EGR & 1098H-EGR 35A6235-A 35A8889-A B1403 A2950 Figure 14. Type 6352 Through 6354M Pilot Assemblies Description Part Number Control Spring Zn pl steel Description Part Number Type 6352 2 inch wc to 2 psig (5 to 140 mbar), yellow 14A9672 X012 Type 6352 Through Type 6352...
Page 280 Types 1098-EGR & 1098H-EGR Description Part Number Description Part Number Relief Valve Assembly O-ring, nitrile 1B8855 06992 Aluminum/stainless steel Relay Spring, 302 stainless steel 1E6436 37022 25 psi (1.7 bar) differential 16A5929 X052 Upper Diaphragm, Nitrile 1B8852 02052 Aluminum/302 stainless Lower Diaphragm, Nitrile 1B8860 02052 steel for 25 psi (1.7 bar) differential (NACE)
Page 281 Types 1098-EGR & 1098H-EGR 47A7118-B 47A7119-A C0513 Figure 16. Dual-Pilot Mounting Parts for Boiler Fuel Installations...
Page 282 Types 1098-EGR & 1098H-EGR 37A0565-C A2949-1 Figure 17. Dual-Mounting Parts for Working Monitor Regulator Description Part Number Description Part Number Loading Tube (Continued) Tee Fitting Copper Brass 14A9056 X012 Size 30 or 40 actuator 14A9458 X012 Steel 14A9056 X032 Size 70 actuator 050021 1701W Stainless steel 14A9056 X042...
Page 283 Types 1098-EGR & 1098H-EGR Description Part Number Description Part Number Cap Screw (for Type 1098 only) Zinc plated steel 1D5287 24952 Pipe Nipple, galvanized zn pl steel 1F7315 26012 B7M zinc plated steel (NACE) 1D5298 X0012 Pipe Nipple, galvanized zn pl steel Casing O-Ring (5 req’d for Type Y600P;...
Page 284 Types 1098-EGR & 1098H-EGR AD5586 A2131 20A6328-C 20A6326-C Figure 18. Type 61LD Pilot Assembly 14A5705-A Figure 19. Type 61LD Pilot and Type1806 Relief Valve Mounting 34A5692-A 36A8540-A Figure 20. Type 1098 and 1098H Actuator Assemblies While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent.
Page 285 Types 1098-EGR & 1098H-EGR May 1997 Errata Sheet Type 1098-EGR & 1098H-EGR Pilot-Operated Regulators, Form 5084, May 1987 This errata sheet covers updated information on the Type 1098-EGR Pilot Operated Regulators. Each bullet on this errata sheet refers to the Type 1098 and 1098H Actuator and Pilot Mounting Parts section on page 17 and figure 20 on page 28 of the Type 1098-EGR &...
Page 286 Types 1098-EGR & 1098H-EGR A6968 TYPE 1098 ORIGINAL DESIGN TYPE 1098 REDESIGN Description Part Number Description Part Number Bonnet, Steel 24A5681X012 Bonnet, Steel 33B0301X012 Casing O-ring, Nitrile 1F914106992 Casing O-ring, Nitrile 1F358106992 Stem O-ring (2 req’d) Stem O-ring (2 req’d) Nitrile 1C782206992 Nitrile...
Page 289 Types 1098-EGR and 1098H-EGR July 2002 Errata Sheet Type 1098-EGR and 1098H-EGR Pilot-Operated Regulators Form 5084, May 1987 This errata sheet covers the redesign of the Type 1098-EGR and 1098H-EGR travel indicator assemblies. This redesign has been incorporated into all body sizes, regardless of actuator size. The Type 1098-EGR and 1098H- EGR travel indicator assemblies now incorporate a redesigned O-ring retainer (key 6), TFE back-up rings (key 36), and an additional indicator fitting (key 35).
Page 290 Types 1098-EGR and 1098H-EGR • Insert the following steps after “Replacing Quick-Change Trim Package” section on page 14. Replacing Travel Indicator Assembly 1. Remove the travel indicator assembly by removing lower indicator fitting (key 5) from body flange (key 2). 2.
Page 291 Instruction Manual 627 Series Form 5252 Incorporates Errata dated January 2001 07/89 627 Series Pressure Reducing Regulators Description Introduction The 627 Series self-operated pressure reducing regula- Scope of Manual tors (figure 1) are for high and low pressure systems. These regulators can be used with natural gas, air, or a This manual provides instructions for the installation, variety of other gases.
Page 292 627 Series Table 1. Specifications Available Constructions Maximum Body Outlet Pressure(1) (Type 627M, 627MR, and 627HM Only) Type 627: Self-operated pressure reducing regulator equipped with a pitot tube for greater regulated 2000 psig (138 bar) for screwed steel, 1480 psig capacities (figure 7) (102 bar) for RF flanged steel, or 1000 psig (69 bar) for ductile iron.
Page 293 627 Series Table 2. Maximum Inlet Pressures, Differential Pressures, and Outlet Pressure Ranges o l l o l l l n i c i f . e l , ) r l n i i t c c i f...
Page 294 627 Series Table 3. Maximum Spring and Diaphragm Casing Pressure(1) a l i a l i a l i a l i a l i i l e a l i a l i a l i e l i a l i v i t Like most regulators, 627 Series regulators have outlet...
Page 295 627 Series Figure 3. Schematic of De-Icer System connected to a straight section of outlet piping 10 diameters downstream of the regulator. 9. A hand valve should be installed in the control line. A regulator may vent some gas to the This hand valve can be used to throttle down and atmosphere.
Page 296 627 Series Table 4. Type 627R Internal Relief Performance f i r o l l form with in this regulator. The formation of ice de- Startup and Adjustment creases the size of the port opening, so the regulator is unable to supply enough flow to satisfy the downstream Startup demand.
Page 297 627 Series Table 4. Type 627R Internal Relief Performance (continued) f i r i l e . y l l n i c i f . e l , ) r l n i l n i o l l .
Page 298 627 Series Table 5. Maximum Torque Values • e l i e l i Note 3. Open the vent valve between the regulator and the downstream shutoff valve nearest to it. Always use a pressure gauge to monitor pressure when making adjustments. 4.
Page 299 627 Series Problem Indication for Type 627R and 627MR Regulators RELIEF INDICATOR CAP (KEY 49) Isolate the regulator from all pressure to avoid personal injury and equipment damage due to explosion or sudden release of process pressure. Cautiously release pressure from the regulator before attempting disassembly.
Page 300 627 Series HAIR PIN CLIP LEVER STEM (KEY 10) DIAPHRAGM CASING (KEY 13) (KEY 15) O-RING (KEY 4) BODY DISK STEM BACKUP (KEY 1) ASSEMBLY RINGS (KEY 9) STEM GUIDE (KEY 12) (KEY 8) CAP SCREW (KEY 3) DIAPHRAGM CASING (KEY 5) STEM O-RING PITOT TUBE SEAT RING...
Page 301 627 Series DIAPHRAGM (KEY 23) DIAPHRAGM RELIEF VALVE O-RING HEAD (KEY 24) (KEY 28) DIAPHRAGM CONNECTOR PUSTHER POST NUT (KEY 22) (KEY 19) RELIEF VALVE GUIDE RETAINER SPRING (KEY 27) O-RING (KEY 48) W4668* GUIDE RETAINER RELIEF SEAL UPPER SPRING LOWER SPRING DIAPHRAGM CONNECTOR (KEY 26)
Page 302 627 Series Perform steps 12 through 19 for Type 627R and 24. Using a crisscross pattern, finish tightening the 627MR Regulators only: spring case cap screws (key 37) to 7 foot-pounds (9 N•m) of torque. 12. For Type 627R and 627MR regulators (figure 6), use steps 13 through 19 to disassemble and reas- 25.
Page 303 627 Series Description Part Number Description Part Number Seat ring (continued) Diaphragm, nitrile (continued) 316 Stainless steel, NACE construction only For Type 627 or 627M w/steel 3/32-inch (2.4 mm) port diameter 0R0441X0012 diaphragm case 10B8735X012 1/8-inch (3.2 mm) port diameter 1A9367X0022 For Type 627R or 627MR w/aluminum 3/16-inch (4.8 mm) port diameter...
Page 304 627 Series 30B3092-D Figure 7. Type 627 Regulator Components...
Page 305 627 Series 30B3089-D Figure 8. Type 627R Regulator Components...
Page 306 627 Series 30B6433-C 1/4-INCH NPT CONNECTION Figure 9. Type 627M Regulator Components...
Page 307 627 Series 1/4-INCH NPT CONNECTION 30B6434-D Figure 10. Type 627MR Regulator Components...
Page 308 627 Series 31B5374-B Figure 11. Type 627H Regulator Components...
Page 309 627 Series 31B9872-B Figure 12. Type 627HM Regulator Components...
Page 310 627 Series January 2001 Errata Sheet 627 Series Form 5252, July 1989 This errata sheet includes information covering the Type 627LB extended body regulator. This new body style is available on all 627 Series configurations and will be an addition to key 1 in the Parts List. The pressure ratings on the Type 627LB bodies will be identical to the existing specifications stated in the current 627 Series Instruction Manual.
Page 313 L4081A,B and L6081A,C ® Multiple Aquastat Controllers ® The L4081, L6081 Aquastat Controllers pro- vide boiler water regulation in gas- or oil-fired hydronic heating systems. An immersion type liquid-filled sensing element Differential adjustment on low limit or circulator actuates two snap switches. switch.
Page 314 L4081A,B/L6081A,C SPECIFICATIONS • ORDERING INFORMATION Specifications ® IMPORTANT: The specifications given in this publication ADDITIONAL FEATURES: TRADELINE pack with do not include normal manufacturing tolerances. cross reference label and special instruction sheet, well Therefore, this unit may not exactly match the listed adapter, tube of heat-conductive compound, and setting specifications.
Page 315 L4081A,B/L6081A,C SPECIFICATIONS SCALE MARKINGS: MAXIMUM AMBIENT TEMPERATURE: For Fahrenheit Models: At Switches: 150°F (65.5°C). High Limit:160, 180, 200, 220°F. At Sensing Element: 265°F (129.5°C). Low Limit or Circulator: 120, 140, 160, 180, 200°F. JUMPER: The 128975 Push-in Field Addable Jumper (in- For Celsius Models: cluded) can be inserted in slot between R-R terminals to High Limit: 55, 65, 75, 85, 95, 105°C.
Page 316 L4081A,B/L6081A,C SPECIFICATIONS • INSTALLATION ELECTRICAL RATING (A): See Table 2. Fig. 2—L6081C mounting dimensions in in. (mm). TABLE 2—ELECTRICAL RATINGS. 120 Vac 240 Vac Full Load Locked Rotor 48.0 30.6 Millivoltage 0.25A at 1/4 to 12 Vdc 3-5/8 (92) Plus ignition transformer load of 360 VA. Maximum con- nected load 2000 VA.
Page 317 L4081A,B/L6081A,C INSTALLATION • WIRING 7. Loosen the wall clamp screw three or four turns; move Fig. 3—Adjusting the capillary length. the screw in and out and note how it moves the well clamp. See Fig. 4. Loosen the screw enough so that when the screw is pushed inward, the T-shaped clamp guide is at the far end of the slot in the case.
Page 318 L4081A,B/L6081A,C WIRING Fig. 5—L4081A used with gas burner (line Fig. 6—L4081B used to prevent circulator voltage limit). operation with boiler water temperature below low limit setting. (HOT) L4081A CIRCULATOR (HOT) VR8300 VOLTAGE CIRCULATOR RELAY VALVE L4081B BURNER CIRCULATOR THERMOSTAT CONTROL MOTOR RA832A SWITCHING...
Page 319 L4081A,B/L6081A,C WIRING Fig. 8—L4081A used with oil burner. (HOT) (HOT) BLACK WHITE CIRCULATOR JUNCTION THERMOSTAT OIL PRIMARY CONTROL L4081A RA832A SWITCHING RELAY POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M8786 B TERMINALS ARE TAB TERMINALS. Fig. 9—L6081A used with oil burner. JUNCTION BOX R4184D PROTECTORELAY™...
Page 320 L4081A,B/L6081A,C OPERATION • SETTINGS Operation HIGH LIMIT temperature plus the difference between the differential The high limit opens and turns off the burner when the setting and 10°F (5.5°C). water temperature reaches the set point. The high limit automatically resets after the water temperature drops past EXAMPLES: the set point and through the 10°F (5.5°C) differential.
Page 321 L4081A,B/L6081A,C SETTINGS • CHECKOUT Fig. 10—Charts showing switching response Fig. 11—Setting stop shown in position to limit to temperature changes. high limit setting to 180°F (82°C). 240°F (116°C) KNOB SET AT 180°F (82°C) HIGH LIMIT SWITCH BREAKS ON RISE. SETTING BURNER TURNS OFF.
Page 322 L4081A,B/L6081A,C MATERIAL SAFETY DATA SHEET Material Safety Data Sheet (MSDS) for heat-conductive compound, which is included with the ® TRADELINE Aquastat Relay models. 60-2105—5...
Page 323 L4081A,B/L6081A,C MATERIAL SAFETY DATA SHEET Material Safety Data Sheet (MSDS) for heat-conductive compound, which is included with the ® TRADELINE Aquastat Relay models. 60-2105—5...
Page 324 Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc. Honeywell Limited—Honeywell Limitée 1985 Douglas Drive North 740 Ellesmere Road Golden Valley, MN 55422 Scarborough, Ontario M1P 2V9 QUALITY IS KEY 60-2105—5 Printed in U.S.A.
Page 325 DL205 User Manual Automationdirect.com...
Page 326 WARNING Thank you for purchasing automation equipment from Automationdirect.com. We want your new DirectLOGIC automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment. To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your equipment.
Page 327 2–7 Installation, Wiring, and Specifications Environmental The following table lists the environmental specifications that generally apply to the Specifications DL205 system (CPU, Bases, I/O Modules). The ranges that vary for the Handheld Programmer are noted at the bottom of this chart. I/O module operation may fluctuate depending on the ambient temperature and your application.
Page 328 2–10 Installation, Wiring, and Specifications Using Mounting The DL205 bases can also be secured to the cabinet by using mounting rails. You Rails should use rails that conform to DIN EN standard 50 022. Refer to our catalog for a complete line of DIN rail, DINnectors and DIN rail mounted apparatus.
Page 329 2–11 Installation, Wiring, and Specifications Installing Components in the Base To insert components into the base: first slide the module retaining clips to the out position and align the PC board(s) of the module with the grooves on the top and bottom of the base.
Page 330 2–12 Installation, Wiring, and Specifications Base Wiring Guidelines Base Wiring diagrams show terminal connections located on the power supply of the DL205 bases. The base terminals 110/220 VAC Base Terminal Strip can accept up to 16 AWG. You may be able to use larger wiring depending on the type of wire used, but 16 AWG is the 85 –...
Page 331 2–14 Installation, Wiring, and Specifications In some cases, using the built-in auxiliary +24VDC supply can result in a cost savings for your control system. It can power combined loads up to 300mA. Be careful not to exceed the current rating of the supply. If you are the system designer for your application, you may be able to select and design in field devices which can use the +24VDC auxiliary supply.
Page 332 2–15 Installation, Wiring, and Specifications Powering I/O In most applications it will be necessary to power the input devices from one power Circuits Using source, and to power output loads from another source. Loads often require Separate Supplies high-energy AC power, while input sensors use low-energy DC. If a machine operator is likely to come in close contact with input wiring, then safety reasons also require isolation from high-energy output circuits.
Page 333 2–16 Installation, Wiring, and Specifications Sinking / Sourcing Before going further in the study of wiring strategies, you must have a solid Concepts understanding of “sinking” and “sourcing” concepts. Use of these terms occurs frequently in input or output circuit discussions. It is the goal of this section to make these concepts easy to understand, further ensuring your success in installation.
Page 334 2–17 Installation, Wiring, and Specifications I/O “Common” In order for a PLC I/O circuit to operate, Terminal Concepts current must enter at one terminal and exit Main Path Field Device at another. Therefore, at least two (I/O Point) Circuit terminals are associated with every I/O point.
Page 335 2–25 Installation, Wiring, and Specifications Special Placement In most cases, the analog modules can be placed in any slot. However, the placement can also depend on the type of CPU you are using and the other types of Considerations for modules installed to the left of the analog modules.
Page 336 2–26 Installation, Wiring, and Specifications Wiring the Different There are two types of module connectors for the DL205 I/O. Some modules have Module normal screw terminal connectors. Other modules have connectors with recessed Connectors screws. The recessed screws help minimize the risk of someone accidentally touching active wiring.
Page 337 2–27 Installation, Wiring, and Specifications I/O Wiring Use the following guidelines when wiring the I/O modules in your system. Checklist 1. There is a limit to the size of wire the modules can accept. The table below lists the suggested AWG for each module type. When making terminal connections, follow the suggested torque values.
Page 338 2–33 Installation, Wiring, and Specifications D2–08NA-1 AC Input D2–08NA–2 AC Input Inputs per module Inputs per module Commons per module 1 (2 I/O terminal points) Commons per module 2 (internally connected) Input voltage range 80–132 VAC Input voltage range 170–265 VAC Peak voltage 132 VAC Peak voltage...
Page 339 2–34 Installation, Wiring, and Specifications D2–16NA AC Input F2–08SIM Input Simulator Inputs per module Inputs per module Commons per module 2 (isolated) Base power required 50 mA Max Input voltage range 80–132 VAC Terminal type None Peak voltage 132 VAC Status indicator Switch side AC frequency...
Page 340 2–40 Installation, Wiring, and Specifications D2–12TA AC Output Outputs per module Max leakage current 2mA (132VAC, 60Hz) Output Points Consumed 16 (4 unused, see chart below) Max inrush current 10A for 10 ms Commons per module 2 (isolated) Minimum load 10 mA Operating voltage 15–132 VAC...
Page 341 3–2 CPU Specifications and Operation Overview The CPU is the heart of the control system. Almost all system operations are controlled by the CPU, so it is important that it is set-up and installed correctly. This chapter provides the information needed to understand: the differences between the different models of CPUs...
Page 342 3–3 CPU Specifications and Operation DL250–1 CPU The DL250–1 replaces the DL250 CPU. It offers all the DL240 features, plus more Features program instructions, a built–in Remote I/O Master port. It offers all the features of the DL250 CPU with the addition of supporting Local expansion I/O. It has a maximum of 14.8K of program memory comprised of 7.6K of ladder memory and 7.2K of V-memory (data registers).
Page 343 3–6 CPU Specifications and Operation CPU Hardware Features Status Indicators DL260 DL250-1 Mode Switch Port 1 Port 2 Battery Slot Status Indicators Mode Switch BATT BATT DL240 Port 1 DL230 TERM Analog Adjustments PORT 1 PORT 1 Port 2 PORT2 DL205 User Manual, 3rd Ed., Rev.
Page 344 3–7 CPU Specifications and Operation The mode switch on the DL240, DL250–1 and DL260 CPUs provide positions for Mode Switch enabling and disabling program changes in the CPU. Unless the mode switch is in Functions the TERM position, RUN and STOP mode changes will not be allowed by any interface device, (handheld programmer, DirectSOFT32 programing package or operator interface).
Page 345 3–8 CPU Specifications and Operation Adjusting the There are 4 analog potentiometers (pots) on the face plate of the DL240 CPU. Analog These pots can be used to change timer Potentiometers BATT constants, frequency of pulse train DL240 TERM output, etc. Each analog channel has 250–1 corresponding V-memory locations for setting lower and upper limits for each...
Page 346 3–9 CPU Specifications and Operation The operating parameters for Port 1 on the DL230 and DL240 CPUs are fixed. Port 1 Specifications 6 Pin female modular (RJ12 phone jack) type connector K–sequence protocol (slave only) 250–1 RS232C, 9600 baud Connect to DirectSOFT32, D2–HPP, DV–1000, OI panels Fixed station address of 1 8 data bits, one stop Asynchronous, Half–duplex, DTE...
Page 347 3–10 CPU Specifications and Operation The operating parameters for Port 2 on the DL240 CPU is configurable using Aux Port 2 functions on a programming device. Specifications 6 Pin female modular (RJ12 phone jack) type connector K–sequence protocol, DirectNet (slave), 250–1 RS232C, Up to 19.2K baud Address selectable (1–90)
Page 348 3–11 CPU Specifications and Operation Using Battery Backup An optional lithium battery is available to maintain the system RAM retentive memory when the DL205 system is without external power. Typical CPU battery life is five years, which includes PLC runtime and normal shutdown periods. However, consider installing a fresh battery if your battery has not been changed recently and the system will be shutdown for a period of more than ten days.
Page 349 3–12 CPU Specifications and Operation Selecting the Program Storage Media Built-in EEPROM The DL230 and DL240 CPUs provide built-in EEPROM storage. This type of memory is non-volatile and is not dependent on battery backup to retain the program. The EEPROM can be electrically reprogrammed without being removed 250–1 from the CPU.
Page 350 3–16 CPU Specifications and Operation Setting the CPU The DL240, DL250–1 and DL260 CPUs have built in DirectNet ports. You can use Network Address the Handheld Programmer to set the network address for the port and the port communication parameters. The default settings are: Station Address 1 250–1 Hex Mode...
Page 351 4–23 System Design and Configuration Network Connections to MODBUS and DirectNet Configuring Port 2 This section describes how to configure the CPU’s built-in networking ports for either For DirectNet MODBUS or DirectNET. This will allow you to connect the DL205 PLC system directly to MODBUS networks using the RTU protocol, or to other devices on a DirectNET network.
Page 352 9–2 Maintenance and Troubleshooting Hardware Maintenance Standard The DL205 is a low maintenance system requiring only a few periodic checks to help reduce the risks of problems. Routine maintenance checks should be made Maintenance regarding two key items. Air quality (cabinet temperature, airflow, etc.) CPU battery Air Quality The quality of the air your system is exposed to can affect system performance.
Page 353 9–10 Maintenance and Troubleshooting CPU Indicators The DL205 CPUs have indicators on the front to help you diagnose problems with the system. The table below gives a quick reference of potential problems associated with each status indicator. Following the table will be a detailed analysis of each of these indicator problems.
Page 354 9–11 Maintenance and Troubleshooting PWR Indicator There are four general reasons for the CPU power status LED (PWR) to be OFF: 1. Power to the base is incorrect or is not applied. 2. Base power supply is faulty. 3. Other component(s) have the power supply shut down. 4.
Page 355 9–12 Maintenance and Troubleshooting Device or Module It is possible a faulty module or external device using the system 5V can shut down causing the Power the power supply. This 5V can be coming from the base or from the CPU Supply to communication ports.
Page 356 9–13 Maintenance and Troubleshooting RUN Indicator If the CPU will not enter the Run mode (the RUN indicator is off), the problem is usually in the application program, unless the CPU has a fatal error. If a fatal error has occurred, the CPU LED should be on. (You can use a programming device to determine the cause of the error.) If you are using a DL240, DL250–1 or DL260 and you are trying to change the modes with a programming device, make sure the mode switch is in the TERM position.
Page 357 9–17 Maintenance and Troubleshooting Noise Troubleshooting Electrical Noise Noise is one of the most difficult problems to diagnose. Electrical noise can enter a Problems system in many different ways and falls into one of two categories, conducted or radiated. It may be difficult to determine how the noise is entering the system but the corrective actions for either of the types of noise problems are similar.
Page 365 BULLETIN MI2030-11/00 SAFETY WARNING INSTRUCTIONS SAFETY WARNING INSTRUCTIONS SAFETY WARNING INSTRUCTIONS SAFETY WARNING INSTRUCTIONS SAFETY WARNING INSTRUCTIONS INSTRUCCIONES PARA PRECAUCIONES DE INSTRUCCIONES PARA PRECAUCIONES DE INSTRUCCIONES PARA PRECAUCIONES DE INSTRUCCIONES PARA PRECAUCIONES DE INSTRUCCIONES PARA PRECAUCIONES DE SEGURIDAD SEGURIDAD SEGURIDAD SEGURIDAD SEGURIDAD FOR MAXITROL GAS PRESSURE REGULATORS...
Page 366 6. La ventilación deberá deberá deberá deberá deberá estar controlada de acuerdo con los códigos y reglamentos 6. Venting must be controlled in accordance with government and plumbing gubernamentales de plomería para evitar el peligro de que se escape el gas en caso codes and regulations to avoid the danger of escaping gas should there be de una fuga interna.
Page 371 Safety Warning — LP-Gas Pressure Relief Valves Purpose In its continuing quest for safety, Engineered Controls International, Inc. is publishing safety warning bulletins explaining the hazards asso- ciated with the use, misuse and aging of ECII ® / RegO ® Products.
Page 372 Inspect Regularly 4. Physical damage. Ice accumulations and improper installation A pressure relief valve discharges when some extraordinary cir- could cause mechanical damage. IF THERE ARE ANY INDICA- cumstance causes an over pressure condition in the container. If a TIONS OF DAMAGE, REPLACE THE VALVE. pressure relief valve is known to have discharged, the relief valve, 5.
Page 373 RegO Pressure Relief Valves ® Requirements for Pressure Relief Valves The reasons for this are two-fold: Every container used for storing or hauling LP-Gas and anhydrous • If the relief valve is called upon to open, the resulting discharge ammonia must be protected by a pressure relief valve. These valves produces an increased vaporization of the product in the con- must guard against the development of hazardous conditions which tainer with the result that the liquid cools to a certain extent and...
Page 374 in the catalog. This information will give the maximum size (pounds Part Number Explanation water capacity) DOT container for which the relief valve has been Products carrying an “A” or “AA” prefix contain no brass parts and approved. are suitable for NH .
Page 375 Safety Information — Relief Valves Don’t Last Forever Use of Protective Caps Debris on valve seats which prevents reseating can occur whenever the valve collects material in the relief valve opening which is not blown out when the relief valve opens. Many of the problems that cause inoperative relief valves could be prevented if proper protective caps were kept in place at all times.
Page 376 Chart A — Minimum Required Rate of Discharge for LP-Gas Pressure Relief Valves Used on ASME Containers Minimum required rate of discharge in cubic feet per minute of air at 120% of the maximum permitted start-to-discharge pressure for pressure relief valves to be used on containers other than those constructed in accordance with Interstate Commerce Commission specification.
Page 383 Innovative Liquid Vaporizing and Gas Mixing Solutions WARRANTY REGISTRATION Type of Equipment: Serial Number: ASDI Sales Order #: Order Date: Purchased By: To help us give you better service, please fill out this warranty registration form and return it to ASDI to register your purchase and for follow up on the performance of ASDI equipment.
Page 386 Algas-SDI International, LLC 1140 NW 46 Street Seattle, Washington 98107 Ph.: 1.206.789.5410 Fax.: 1.206.789.5414 www.algas-sdi.com...

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