0808 133 M200J 01

Dollinger Power Systems
4647 SW 40th Ave

Ocala, Fl 34470
Tel: +1-352-237-1220
Fax: +1-352-873-5773
www.SPXFT.com
INSTALLATION, OPERATING
AND MAINTENANCE
INSTRUCTIONS
DOLLINGER NO. : 3257674-IOM
MODEL : DPS-C20060C6-SKID-LLPTFVPSVFA
CUSTOMER : Pratt and Whitney Power
ORDER No. : 4501799329
DOLLINGER SO No. : SO1394941
DOLLINGER SERIAL : 164495001
Homepage Previous Document

INDEX
1.0 SEQUENCE OF OPERATION

1.1 Introduction
1.2 Pre Start-up
1.3 Normal Operation
1.4 Change-over & Maintenance
2.0 INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS
2.1 Description
2.2 Specification
2.2.1 Skid Vessel
2.2.2 Filter Element
2.3 Installation
2.4 Operation
2.4.1 Start up procedure
2.4.2 Operation
2.4.3 Shut Down Procedure
2.5 Maintenance
2.5.1 Filter Service
2.6 Spare Parts Data
3.0 G.A. DRAWING
4.0 PART MANUALS AND CATLOG CUT SHEETS

4.1 Ball Valve (BAV)
4.2 Block and Bleed Valve (BB)
4.3 Level Indicator (LI)
4.4 Level Switch (LS)
4.5 Level Control Valve- Auto (LCV)
4.6 Pressure Switch (PS)
4.7 Actuator (TSV)
4.8 Solenoid Valve (SOV)
4.9 Position Switch (ZS)
4.10 Relief Valve (PSV)
4.11 Pressure Diff. Indicator (PDI)
4.12 Pressure Diff. Transmitter (PDT)
4.13 Flame Arrestor (FA)
4.14 Heater (H)
4.15 Enclosure

1.0 SEQUENCE OF OPERATION
1.1 INTRODUCTION
The Dollinger Fuel Gas Scrubber skid comes complete with 1No. C20060C6
Filter vessel fitted with 12 No. filter elements (Cat #: 3507525). The filtration
package is mounted on a skid base frame to allow securing to concrete base.
The skid comes complete with isolation valves, trip safety valve, level gauge,
level switches, pressure relief valve, auto drain valve, differential pressure
transmitter, differential pressure gauge, flame arrestors, and vessel heater.
1.2 PRE START-UP

Prior to the system start-up please ensure that the skid base is securely bolted
using 4 No. 5/8” anchor bolts through the ¾” bolt-holes provided on the base
frame. The skid must be earthed through the connection provided.
1.3 NORMAL OPERATION BRIEF

During normal operation fuel gas will enter the vessel via the inlet nozzle (G50).
The fuel gas will pass through the filter elements. Fluid is collected on the outer
surface of the element.
The Fluid is then allowed to drain naturally to where it is collected in the bottom
of the vessel until the level reaches the opening point for the automatic float
valve. Then the valve opens and allows the fluid to be exited through the drain
(G52).
The vessel is fitted with a Differential Pressure transmitter and a Differential
Pressure indicator that allows the operator to monitor the increase in differential
pressure across the inlet (G50) and outlet nozzle (G51).

1.4 CHANGE-OVER & MAINTENANCE
When the differential pressure across the filter reaches a high (10 psi), as
indicated by the differential pressure gauge or transmitter, this will indicate the
need for maintenance of the Filter. To allow continuous operation of the turbine
it is recommended that a secondary filter or bypass be installed.
The dirty filter will still have gas pressure contained within the vessel and this
will need to be vented prior to removing the access flange at the top of the filter
for element replacement. This can be vented by opening BAV1152 and BAV
1153.
Pressure equalisation must be verified prior to opening of access flange.
The Filter Vessel contains 12 No. elements. Once the vessel is isolated and the
closure opened, the elements are removed and replaced with new elements
(see 2.5.1)
The access flange should be secured in accordance with the Installation,

Operations & Maintenance Instructions and the filter can be returned to stand-
by mode. This process will be repeated once the filter separator differential
pressure reaches 10 PSI.

2.0 INSTALLATION, OPERATIONS & MAINTENANCE
INSTRUCTIONS.
2.1 DESCRIPTION
The Dollinger Filter has been engineered and designed to efficiently remove
virtually all water, oil and solid contaminants from air and other gases used in
compressed gas systems.
The filter should not be operated at temperatures above 240°F.
You should become familiar with the design, operating, installation and
maintenance characteristics of the filter prior to use. The information contained
in these instructions will allow you to achieve optimum operation of not only your
Dollinger filter, but your entire system and equipment.
To maintain product warranty, performance and reliability, use only

®
genuine DOLLINGER replacement parts.
2.2 SPECIFICATION
2.2.1 Vessel
The pressure vessel is fabricated from carbon steel and is designed to

ASME VIII Div.1, 2007 Add. 2009
2.2.2 Filter Element
12 No. filter element Part No. 3507525 are installed, with a total effective
filtration area of 36 ft².
The filter medium is Borosilicate Microglass with an efficiency of 100% at

0.3µ (solids and liquids).
The element support structure is manufactured from perforated Stainless

Steel.
The element cannot be cleaned.

2.3 INSTALLATION
(a) For best results, the filters should be installed as near as possible
to the point of usage of the filtrate or to the location of the
equipment being protected.
(b) It is important that the gas flow is in the direction indicated by the
arrows on the inlet and outlet nozzles.
(c) Care should be taken to ensure that the filter is installed with
sufficient free space around it for servicing.
(d) Remove all flange blanking covers and clean flange faces before
connecting into the pipework.
(e) Install connecting pipework and valves.
(f) Connect the filter electrically to earth using earth grounding pad
provided on the skid.
2.4 OPERATION
(a) Ensure that the maximum rated Design Pressure and

Temperature of 670 psig & 240°F respectively are no t exceeded.
(b) Avoid flow rates above the design capacity, or else the filter
efficiency may be affected. (28,000 SCFM)
(c) When out of service the filter should be isolated and vented.
2.4.1 Start-Up Procedure

* denotes carried out by Dollinger for newly supplied units
(a) Ensure that the filter vessel interior has been thoroughly cleaned.*
(b) Ensure that the elements are securely held in place by the cluster
hold down plates.*
(c) Ensure that the cover gasket and bolting hardware have been
correctly installed and that the vessel closure is secure.
(d) Ensure that all connecting pipe work has been correctly installed.
(e) Ensure the drain and vent connections are closed.
(f) Open the inlet valve. In order to protect the element, pressurise
the filter as gradually as is practical.
(g) Open the outlet valve slowly to bring the filter on stream.

2.4.2 Operation
All filtration systems have a maximum recommended pressure

drop at which the filter element should be cleaned or replaced. The
recommended maximum pressure drop for cleaning or replacing
elements in the Filter is 10 psig, subject to any lower limit set by the
process conditions. The ultimate strength of each of the elements
installed in the filter greatly exceeds this maximum recommended
pressure drop - the maximum allowable differential pressure to ensure
element integrity is 20 psig. However, routine maintenance should be
carried out to ensure that the optimum performance is available from the
elements.
It is difficult to accurately determine the life of an element in a

given environment. The variance of element life is due primarily to the
many types of conditions that exist. It is therefore advisable and highly
recommended that the pressure drop across the filter be monitored
weekly to determine the element life. In order to prevent long downtimes,
it is suggested that spare elements and gaskets be kept on hand.
2.4.3 Shut Down Procedure
(a) Close the isolating valves to filter (BAV1150 & BAV1151)
(b) Allow release of pressure by slowly opening the vent valves

(BAV1152 & BAV 1153).
IMPORTANT: For safety reasons, pressure relief must be verified before

opening the vessel.
2.5 MAINTENANCE
Maintenance is necessary once the differential pressure reaches 10 psig

or the limit set by the process conditions.
2.5.1 Filter Service
(a) Open up the vessel closure using davit provided on access blind
flange.
(b) Remove the retaining Hex Nut and washers on the element cluster
retaining plate
(c) Remove the element cluster hold-down plate to expose the

elements

(d) Remove the elements by pulling straight upwards, using care
(e) Apply a light film of oil to the O-ring of the new Dollinger
replacement element
(f) When all used elements have been replaced, replace the element
cluster plate
(g) Replace the retaining nut and washers on each element cluster
hold down plate
(h) Check the vessel closure gasket for signs of deterioration. If it is

cut or otherwise damaged, it should be removed completely, and a
new gasket installed. All bolts and nuts should be well lubricated
with any common thread lubricant. Bolts should be torqued in a
sequence that will ensure even gasket loading.
(i) Follow Start-Up Procedure as detailed in Section 2.4.1.
2.6 SPARE PARTS DATA
Recommended Maintenance spares considered necessary for use during

normal operation are as follows:-
(a) Element Part No. 3507525

12 No. required per filter
(b) Cover Gasket Part No. 3508031

1 No. required per filter

3.0 Drawings (Drawings follow this page in this order)
3.1 General Arrangement
3.2 Grounding lug Detail
3.3 Process and Instrumentation Diagram
3.4 Conduit
3.5 Electrical Schematic

CAUTION
Although Dollinger products are manufactured to the highest standards and are
constantly being reviewed and improved, these products, as with any product,
may react in ways which cannot be predicted or anticipated when subjected to
unusual forces or uses. Therefore, whenever a Dollinger product is used either
in a system or independently, the following steps are urged:
1. All available information regarding the product's potential use should be

conveyed to Dollinger sales and technical personnel.
2. Standards and criteria for the use of a Dollinger product, as set forth in
the specification and operating manual, should be carefully respected.
3. The purchaser should, when a Dollinger product is being or may be

subjected to conditions other than design conditions, contact Dollinger
personnel immediately.
4. Any Dollinger product should be maintained, operated, inspected and

serviced at regular intervals and in accordance with the operating manual
provided.
ANY QUESTIONS ABOUT THE OPERATION OR USE OF DOLLINGER

PRODUCTS SHOULD BE PROMPTLY CONVEYED TO DOLLINGER
INTERNATIONAL.

4.0 PART MANUALS and CATALOG CUT SHEETS
4.1 Ball Valve (BAV)
4.2 Block and Bleed Valve (BB)
4.3 Level Indicator (LI)
4.4 Level Switch (LS)
4.5 Level Control Valve – Auto (LCV)
4.6 Pressure Switch (PS)
4.7 Actuator (TSV)
4.8 Solenoid Valve (SOV)
4.9 Position Switch (ZS)
4.10 Relief Valve (PSV)
4.11 Pressure Diff. Indicator (PDI)
4.12 Pressure Diff. Transmitter (PDT)
4.13 Flame Arrestor (FA)
4.14 Heater (H)
4.15 Enclosure

4.1 Ball Valve
(BAV)

INSTALLATION, OPERATION
&
MAINTENANCE MANUAL
FLOATING AND TRUNNION MOUNTED BALL VALVE
VIRGO ENGINEERS LIMITED VIRGO VALVES & CONTROLS LIMITED

(An ISO 9001, PED, API Certified Company) (An ISO 9001, PED, API Certified Company)
Regd. Office: Works:

277, Hinjewadi Phase II, Maan (Mulshi), 277, Hinjewadi Phase II, Maan (Mulshi),
Pune – 411 057, INDIA. Pune – 411 057, INDIA
Phone: +91-20-66744000. Phone: +91-20-66744000.
Fax: +91-20-66744021. Fax: +91-20-66744021.
E-mail: sales@virgoengineers.com E-mail: sales@virgoengineers.com
Website: www.virgoengineers.com Website: www.virgoengineers.com
Page 1 of 24

Table of Contents
Sr. No. General Instructions Page No.
1. Introduction 3
2. Transportation, Reception and Storage 3
3. Do’s and Don’ts 4
4. Installation 5
5. Operation of the valve(s) 7
6. Preventive Maintenance 8
7. Trouble Shooting 9
8. Ordering the Spares 9
9. General Disassembly and Assembly Instructions for: 10

I) Trunnion Mounted Ball Valves.
II) Floating ball valve
9.I.A Disassembly For Trunnion Mounted Ball Valves 10
(Two Piece Design/Three Piece Design)-Trunnion Ball Valve
9.I.B Reassembly For Trunnion Mounted Ball Valves 11
(Two Piece Design/Three Piece Design)-Trunnion Ball Valve
9.I.C Exploded View- Trunnion Ball Valve - Two & Three Piece 13
Design
9.I.D Disassembly For Trunnion Mounted Ball Valves 14
(Two Piece Design/Three Piece Design)-Trunnion Plate Valve
9.I.E Reassembly For Trunnion Mounted Ball Valves 14
(Two Piece Design/Three Piece Design)-Trunnion Plate Valve
9.I.F Exploded View- Trunnion Ball Valve – Two & Three Piece 16
Design-Trunnion Plate Ball Valve
9.II.A Disassembly for Floating Ball Valve 18
(Two Piece Design/Three Piece Design)
9.II.B Reassembly for Floating Ball Valve 18
(Two Piece Design/Three Piece Design)
9.II.C Exploded Views For Floating Ball Valves-Two Piece Design- 19
Lever Operated.
9.II.D Exploded Views For Floating Ball Valves-Three Piece Design 20
9.II.E Exploded Views For Floating Ball Valves-Two Piece Design- 21
Gear Operated
Table: A Recommended Tightening Torque 22
10.0 Address for correspondence : Works 23
10.I Address for correspondence : Branch offices 24
Page 2 of 24

Installation, Operation & Maintenance Manual
1.0 INTRODUCTION:
Scope -
The manual is provided to ensure proper installation, operation & maintenance for the Ball valves
manufactured and supplied by Virgo Group of Companies. The valves are identified by marking
on the body or on a nameplate or both.
VIRGO ENGINEERS LTD

VIRGO ENGINEERS LTD
PUNE, (INDIA)
PUNE, (INDIA)
1.1 Identification of Valve
2.0 TRANSPORTATION, RECEPTION AND STORAGE:

• While loading & unloading check for any “arrow” mark on packing box as indicating upward
position.
• Always place the valve preferably on rubber sheets layed on ground.
• Ensure that all valves ends are covered with protective end caps.
• Always store the valve under roof, in a dry and clean atmosphere, protected from rain & storm.
• Before installation of stock valves, it is advisable to conduct hydrostatic/pneumatic test.
• Do not remove any protection from the equipment during storage period.
• Please refer also to actuator instruction for long storage of the equipment.
2.1 INSPECTION AND HANDLING OF THE EQUIPMENT
• Identify the equipment contained using the copy of the packing list fixed to the case.
• If a tag number is specified by the customer, identify the valves using tag number stamped on
the manufacturer plate.
• Visually inspect all the valves to assure that they have not been damaged during the transport.
• In case of paint damaging, touch-up the damaged painted surface.
• Do not remove any protection from the valve (end flanges, stem connection, etc.), until just
before the installation in order to assure maximum protection to valve internal parts and coupling
surfaces.
• If the valve is supplied with an operator ( gearbox or actuator ) already installed, always use
valve lifting lugs to lift the complete equipment; do not use operator lifting points to handle the
valve.
• The valves are shipped in the fully open position (with exception of a fail spring close actuator
installed).
• Always keep the valves in fully open or fully closed position (0°- 90°).
• If the valve is supplied with an actuator, please keep plugged every pneumatic, electrical or
hydraulic connection until just before the installation (refer to specific actuator instructions for
further information).
Page 3 of 24
• During handling pay particular attention to the valve ends in order to avoid any mechanical
damage of sealing surfaces or butt weld faces (as applicable).
• For valve handling always use straps sized to the weight that has to be lifted; do not use chains
or hooks in contact with the machined surfaces.
3.0 DO’s AND DON’ts :

Do’s -
• It is recommended always to use the Installation, Operation & Maintenance Manual before
installing, operating or repairing of any Ball Valve(s).
• Use specified / recommended MOC (Material of construction) for specified application.
• Before installation of “Virgo Made” standard valve, it is advised for user to ascertain the
compatibility of the material.
• Periodically ensure the tightness of Body-Adapter joint bolting, operatability & the electrical
continuity of the valve.
• Always use dry, moisture free air while opening the valve with pneumatic actuator or for cleaning
purposes.
• Always wear warm clothes while working with cryogenic liquids.
• Ensure that thorough ventilation is provided while working on the close equipment for oxygen
transfer.
• Ensure that the end protections are removed before installation of valve in line.
Don’ts -
• Do not drag the valve on bare floor.
• Do not try to rectify the valve leakage by reworking of seats. Leaking seats have to be replaced
with the new Virgo genuine seats.
• Do not allow any such process, which may generate spark, particularly working in H2 or O2 service
line or any such inflammable fluids.
• Do not allow dirt, scales, oil or grease to flow through valve & pipeline for oxygen service.
• Do not allow to replace (even temporarily) the pressure-relieving device, which is installed, for its
intended use by a threaded blind plug.
• Do not inhale the cold gases / fumes for long duration while working with cryogenic liquids.
• Following figures indicate do’s & don’t for special valve (stem extension) :
3.1 Stem extension valve - lifting precautions.
Page 4 of 24
4.0 INSTALLATION :
• Before installation, ensure that the valve end protectors are removed & gasket is
placed for Flanged end valves. Clean the valve ends & bore using methylene chloride
or trichloroethylene or as per the Customer’s specification.
• Clean the pipeline to avoid damage of the soft seat due to debris, scaling, etc.
• Keep the valve in fully open condition.
• Never install the Valve with the Actuator on the underneath side in the pipeline.
• It is recommended to support pipeline at distance of 2 X D (where D is nominal
diameter of pipeline in mm) from valve ends.
4.1 Avoid this mounting position 4.2 Supporting of the valve
While Installing for :

I. Flanged End Valves -
• Don’t over tighten the joint bolting.
• Refer Table : A on page no.18 for recommended tightening torque for bolts,
nuts.
II. Weld End Valves -

• Don’t allow temperature of the valve body seat area to exceed 200°F (94°C).
To check the temperature, use thermal chalks. (Ref. Fig.4.6 & 4.7)
a) Butt Weld End Valves -
• A proper alignment & a gap ‘g’ as shown in figure 4.3 to get full penetration of
weld upto root.
b) Socket-Weld End Valves -
• Ensure for proper alignment & a minimum gap of 1.6 mm between the pipe end
face and the socket weld ends as shown in Figure 4.4.
• While installing unidirectional valve in pipeline, check for the flow direction mark
on valve body.
4.3 Minimum gap for butt weld end
Page 5 of 24
• Figures 4.5,4.6, 4.7 are of three-piece socket weld end valves showing
typical exploded view, it’s welding to the pipeline & in line maintenance
when the pipeline is shut down respectively.
0.06" TO 0.08" GAP (APPROX)
X min. = 1.25T
PIPE LINE FILLET WELDING
SOCKET WELD END

BODY ADAPTER
4.4 welding socket weld end valve to pipe line 4.5 Three piece socket weld end valve exploded view
4.6 Virgo make 3-piece ball valve supplied 4.7 In line maintenance of 3-piece socket weld
with pup piece (welding procedure) end valve
Page 6 of 24
5.0 OPERATION OF THE VALVE (S) :
5.1 For lever operated valves, the hand lever is either assembled with the valve or shipped
loose depending upon the size of the valve / hand lever.
5.2 For gear operated valves, THE GEAR OPERATOR OPEN / CLOSE ADJUSTMENT HAS
BEEN DONE PRIOR TO SHIPMENT AND MUST NOT BE CHANGED. Rotation of hand
wheel in the clockwise direction closes the valve and counter clockwise rotation opens it.
(Looking from hand wheel end) The details of gear operator are shown in the fig. 4.8. The
internal details/construction of gear operator may vary as per manufacturers standard
5.3 Ball valve always closes in a clockwise direction. Valve should always be rotated through
90º to the fully opened or fully closed position.
5.4 Valve should be opened and closed slowly to avoid hammering effect on the valve and
pipeline.
5.5 Once the flushing is complete, valve should be operated 3-4 times and then kept in the
fully open position.
5.6 If the valve is not operating to fully open or fully closed position, and/or leaking, do not
apply excessive force to operate the valve. This can damage the seats or stem.
• Apply gradual force on the handwheel of the gear operator and do not give impacts.
• Do not apply extra leverage (using pipe / bar), when the end stops of the gear operator
are reached.
Fig 5.0 Gearbox drive arrangement
5.7 Lubrication of Worm Gear operator -
a. Worm gear operators are packed with grease. Normally the grease is suitable for -
20oC (-40F) to 80oC (1760F). For other applications, consult the nearest branch office /
factory.
b. Grease should be changed as following:
If operated frequently, after approx. 3 years.
If operated rarely, after approx. 5 years.
c. Recommended Greases-
• Servogem EP2 (Extreme Pressure),
• Mobilux EP3,
• Valvoline EP3,
• Castrol EP3.
Page 7 of 24
6.0 PREVENTIVE MAINTENANCE :

i. In order to avoid valve failure during operation, all valves in a process plant should
be periodically inspected thoroughly to detect the wear of ball, seats, and seals. It
is recommended that on such occasion seats, soft seals should be replaced.
ii. The type of process, fluids involved, working conditions and location of the valves
in the process plants, will determine the frequency of periodic inspection /
maintenance which in fact will be made at the time of partial or total shutdown of
the plant. Preventive maintenance is absolutely essential as the failure due to lack
of the same may cause an emergency shut down of the plant.
iii. Section 9 describes the procedure for disassembly, repair and assembly of the
valve. The procedure will be the same for a valve failing during operation due to
lack of preventive maintenance.
iv. Once a valve is repaired, it should undergo a complete set of tests to make sure
that the valve is adequate for the original working conditions. Hydro/Pneumatic
tests should be carried out as per the specifications relevant to the valve (Refer
General Arrangement Drawing).
6.1 Emergency Sealant Injection System in Trunnion Ball Valves:

• Sealant injection system is provided on valve seat or stem packing area to carryout
temporary shut off for maintenance or other purpose.
• This secondary sealant injection system is to be used only when damage has been caused
to the seats & seals by the hard particles or dirt in the process media.
• Always flush the sealant port with suitable valve cleaner, before injecting sealant.
• Refer sealant injection fitting arrangement is shown in Figure No. 6.1
CONNECT TO THE HOSE

OF SEALANT GUN.
END CAP W ITH
VENT HOLE
DOUBLE CHECK W ITH

TW O PIECE FITTING.
GIANT BUTTON HEAD COUPLER
SEALANT PORT ON BODY/

STEM HOUSING/BODY ADAPTER
6.1 Sealant Injection Fitting Arrangement

( For Information Only )
Page 8 of 24
7.0 TROUBLE SHOOTING :

The following table lists the possible malfunctions that might occur after prolonged use :
Symptom Possible fault Actions

Leakage through a Damaged ball surface Replace the ball.
closed Valve Damaged seats Replace seats.
Ball might not be closed Check ball Open/Close
fully settings.
Irregular ball movement Impurities between the Flush the ball from inside.
ball and seats or ball – Clean the sealing surfaces
body cavity and ball and seats.
Seats.
Valve too hard to Damaged seats Replace the seats.
operate / valve torque High application pressure Confirm the application
too high / temperature pressure /temperature
rating.
Foreign particles in Valve Clean the internals.
Water hammer or noisy Error in valve sizing or Confirm valve sizing with
operation flow of fluid with high respect to flow.
velocity.
Leakage through stem Gland nut loose Tighten gland nut.
Damaged stem, stem Replace the stem.
sealing surface
Damaged stem seal Replace the stem seal.
Leakage through body- Damaged ‘O’ ring or Replace ‘O’ ring/ gasket.
adaptor joint breakage of gasket
Relaxation of studs due Retighten the studs evenly
to gasket creep in criss-cross manner
8.0 ORDERING THE SPARES :

When ordering for spare parts, always convey the following information :
Size of the valve

Valve rating
Available on name plate or body of the valve
Sr. No. / Batch No.
Mfg. Date
Part No.
Name of the part
Available on general arrangement drawing
Number of pieces required.
P. O. Number
Note: Selection and use of the valve for a specific application requires close consideration of
detailed aspects. Due to the nature of the product, this manual cannot cover all the individual
situations that may occur when installing, using or servicing the valve.
Page 9 of 24
9.0 GENERAL INSTRUCTIONS FOR DISASSEMBLY & RE-ASSEMBLY OF

VALVES ( LEVER / HANDLE OR GEAR OPERATED ) :
GENERAL NOTES :
1. Before any valve disassembly make sure that all necessary original spare parts are
available.
2. Please note that in case of disassembly:
• Fire-safe graphite gaskets shall be always replaced with new ones.
• O-rings could be re-used, but it is recommended to replace them with new ones in any
case to extend the valve life.
3. Before disassembling the valve it is essential to mark, in a lasting way all the parts in
order to make a correct reassembly (make a reference sign to all the external surfaces of
the flanged joints).
4. A lifting facility may be necessary to handle the valve or its components.
5. During handling always use soft-straps to avoid any damage of machined components.
6. A particular attention shall be paid to the valve flanges ends.
7. Protect every sealing surface.
8. Exploded view drawing shows the standard O-ring configuration but can be considered
as reference for lip-seal configuration too. To remove an actuator from the valve, refer to
specific actuator instructions.
9. After having disassembled a valve it is recommended to replace all the O-rings / Lip-seals
and the gaskets.
10. O-Rings require a certain tension to be inserted in their shoulders, be careful not to cause
cutting during re-assembling (Apply light grease compatible with working fluid).
9.I) TRUNNION MOUNTED BALL VALVES -
Pipeline and valve must be depressurized by shutting off the valves & the bleed line. Then cycling the
valve once & leaving it half open to relieve the pressure from the body cavity.
9.I.A. Disassembly – Trunnion Mounted Ball Valves (Trunnion ball valve) :
1. Valve shall be positioned vertically by resting body side flanges on clean ground surface
(preferably covered with rubber sheet). Ensuring no damage to the bottom/ end face/threads
as applicable)
2. Loosen safely the vent/drain plug (37) to relieve any residual pressure from the body cavity.
Rotate the ball (03) to fully open position.
Page 10 of 24
3. Remove the locking screw (38) lift the handle (39) off the stem (04). Be careful not to damage
the stem key (30). (Remove the operator handle, lever or gearbox as applicable)
4. Open the body adapter joint by loosening the nuts in criss-cross pattern.
Always tighten / loosen the bolts in criss-cross pattern
5. Remove body adapter (02) use puller holes provided on body adapter for easy removing.
6. Remove the ‘O’-ring (body adapter) (07) & gaskets (body) (08) from the body adapter.
7. Remove seat (05), seat springs (28).
8. Remove Seat ‘O’-ring (06) from the seat.
9. Remove the ISOPAD (20) & stem housing (09) by loosening cap screws. Remove dowel pins.
10. Pull the stem (04). Loosen the cap screws of trunnion (25) and remove trunnion (22).
11. Remove the ball (03) from the body & the seats (05) from body & body adapter.
12. All the components should be stored in a clean place.
13. Remove the antistatic spring (27), the thrust washer (19) (trunnion & stem), the gasket (trunnion)
(23) & the ‘O’-ring (trunnion)(24).
14. Remove bush bearing (10) from ball & stem housing (10).
15. Where applicable, the sealant injection fittings [(stem) & (seat)] & drain/vent plugs (37) may be
removed for cleaning.
9.I.B. Re-assembly – Trunnion Mounted Ball Valves (Trunnion ball valve) :
Before reassembly, inspect the valve for any damage on Body-Adapter & all internals.
Wipe all the metal part with a petroleum solvent, using a soft cloth.
Ensure cleaning of valve.
Damaged internals to be replaced by genuine & with recommended parts only.
Before assembling the flanged joints check the reference sign applied before disassembly.
1. Body (02) shall be positioned vertically by resting body side flanges on clean ground
surface (preferably covered with rubber sheet).
2. Apply suitable industrial grease to bolting to prevent corrosion.
Page 11 of 24
3. Put the respective o-rings & gaskets in to body (01), body adapter (02), seat (05), stem
housing (09), and trunnion (22).
4. Tighten the studs (17) to body.
5. Place the springs (28) into the seat (05) & insert seat (05) into the body recess (02)
6. Insert the bearing (10) in the ball (03) on trunnion side recess.
7. Lift the ball (03) & lower it into the body (01) so that ball bore is perpendicular to body
bore.
8. Place thrust washer (26) in ball trunnion recess. Locate the trunnion (22) with bearing into
the ball recess. Then tighten it with the cap screws (25) or hex bolts.
9. Insert stem (04) along with thrust washer (19) and align its key slot parallel to the body
bore.
10. For lever-operated valve align stem A/F parallel with the body bore.
11. Insert the bush bearings (10) in to the stem housing (09).
12. Insert dowel pin (15) in the dowel hole provided on body.
13. Insert stem housing (09); locate its dowel hole on body.
14. Tighten stem housing (09) with cap screws (16).
15. Insert ISOPAD (20); locate its dowel hole on stem housing (09).
16. Tighten the ISOPAD (20) to the stem housing with cap screws (20).
17. Put another seat (05) with springs (28) on the ball followed body adapter (02).
18. Tighten the body nuts (18) in a crisscross pattern. (refer Table : A for recommended
tightening torque)
19. Fit the stem key (30) in stem keyway.
20. Lift the valve & place it so that the direction of the flow axis is horizontal.
21. Put the operating member i.e. lever/ handle or G.O. in position into body & tighten them.
22. Ensure proper locking of stem with lock nut, washer or mounting plate as applicable.
23. Ensure open and close smooth operation of valve.
24. For lever operated valves, place the hand coupler (not shown) with lock & stop plate (not
shown) on the stem & tighten the hex bolt/grub screw.
25. For gear operated valves, place the coupling on the stem, place the bracket on the stem
housing, fit the studs & tighten the nuts. Place the gear operator on the coupling & the
bracket, fit the studs & tighten the nuts.
26. Where applicable, fit sealant injection fittings [(stem) & (seat)] & the drain/vent plugs.
27. Rotate the ball slowly back & forth to a full quarter turn. This will allow the seat to assume
its permanent position & shape against ball & body. A fast turning motion may damage the
seat before it has a chance to form a proper seal.
Note: For three-piece design ball valves there are two-body adapter & one body. In this
case the assembly procedure remains the same as explained above for two-piece ball
valve except that the body adapter side flange is to be positioned on clean ground side as
mentioned in clause 9.I.A-1.
Page 12 of 24
9.I.C. Exploded view : Two Piece & Three Piece Design - Trunnion Mounted Ball Valves
- ( Trunnion ball valve ) :
E
LV
VA
LL
BA
E
LV
E
EC
VA
PI
LL
E
BA
RE
E
TH
EC
PI
O
TW
Note: Always use the genuine spare parts to make sure that the valve functions as intended.
Page 13 of 24
9.I.D. Disassembly – Trunnion Mounted Ball Valves ( Trunnion plate ball valve ) :
1. Valve shall be positioned vertically by resting body side flanges on clean ground
surface (preferably covered with rubber sheet). Ensuring no damage to the bottom/
end face/threads as applicable)
2. Loosen safely the vent/drain plug (37) to relieve any residual pressure from the
body cavity.
3. Rotate the ball (03) to fully open position.
4. Remove the locking screw (38) lift the wrench (39) off the stem (04)(Not shown). Be
careful not to damage the stem key (30). (Remove the operator handle, lever or
gearbox as applicable).
5. Open the body adapter joint by loosening the nuts in criss-cross pattern.
6. Remove body adapter (02). Use puller holes provided on body adapter for easy
removing.
7. Remove the ‘O’-ring (body adapter) (07) & gaskets (body) (08) from the body
adapter.
8. Remove seat (05), seat springs (28).
10. Remove the ISO PAD (20) & stem housing (09) by loosening cap screws. Remove
dowel pins.
11. Remove the stem (04).
12. Remove the ball & trunnion plate assembly from the body & then seat (05) from body
& body adapter.
14. Remove trunnion plates (22) from ball and trunnion plate assembly, and then remove
the trunnion plate bush bearings (10).
15. Remove the dowels (23) in the trunnion plate.
17. Remove the thrust washers (trunnion plate) (26).
18. Remove all stem housing & trunnion seals.
19. Where applicable the sealant injection fittings [(stem) & (seat)] & drain/vent plugs
may be removed for cleaning.
9.I.E. Reassembly – Trunnion Mounted Ball Valves ( Trunnion plate ball valve ) :
Before reassembly, inspect the valve for any damage on Body-Adapter & all internals.
Ensure cleaning of valve.
Page 14 of 24
1. Body (02) shall be positioned vertically by resting body side flanges on clean ground
surface (preferably covered with rubber sheet).
2. Apply suitable industrial grease to bolting to prevent corrosion.
3. Put the respective o-rings & gaskets in to body (01), body adapter (02), seat (05), stem
housing (09), and trunnion (22).
4. Tighten the studs (17) to body.
5. Place the springs (28) into the seat (05) & insert seat (05) into the body recess (02)
6. Insert the dowel pins (23) in the trunnion plate.
7. Press bush bearing (26) into the trunnion plate recess then insert the thrust washer on
the ball.
8. Insert the trunnion plates (22) on the ball.
9. Lift the ball & trunnion plate assembly (03) & lower it into the body so that ball bore is
perpendicular to body bore.
10. Match the dowel pin (23) to the dowel hole on body or body adapter (in case of 3-pc
trunnion plate ball valve.)
11. Insert stem along with thrust washer and align its key slot parallel to the body bore.
12. For lever-operated valve align stem A/F parallel with the body bore.
13. Insert dowel pin (15) in the dowel hole provided on body.
14. Insert stem housing (09); locate its dowel hole on body.
15. Tighten stem housing (09) with cap screws (16).
16. Insert ISOPAD (20); locate its dowel hole on stem housing (09).
17. Tighten the ISOPAD (20) to the stem housing with cap screws (20).
18. Put another seat (05) with springs (28) on the ball followed body adapter (02).
19. Tighten the body nuts (18) in a crisscross pattern. (refer Table : A for recommended
tightening torque)
20. Fit the stem key (30) in stem keyway.
21. Fit the stem key in stem key way.
22. Put another seat (05) with springs (28) on the ball followed by body adapter (02).
23. Tighten the nuts (18) in a crisscross pattern.
24. Lift the valve & place it so that the direction of the flow axis is horizontal.
25. Put the operating member i.e. lever/ handle or G. O. in position into body & tighten them.
26. Ensure proper locking of stem with lock nut, washer or mounting plate (not shown) as
applicable.
27. Ensure smooth open and close operation of valve.
28. For lever operated valves, place the hand coupler with lock & stop plate on the stem &
tighten the hex bolt / grub screw.
Page 15 of 24
29. For gear operated valves, place the coupling on the stem, place the bracket on the stem
housing, fit the studs & tighten the nuts. Place the gear operator on the coupling & the
bracket, fit the studs & tighten the nuts.
30. Where applicable, fit sealant injection fittings [(stem) & (seat)] & the drain/vent plugs.
31. Rotate the ball slowly back & forth to a full quarter turn. This will allow the seat to assume
its permanent position & shape against ball & body. A fast turning motion may damage
the seat before it has a chance to form a proper seal.
Note: For three-piece design ball valves there are two-body adapter & one body. In
this case the assembly procedure remains the same as explained above for two-piece
ball valve except that the body adapter side flange is to be positioned on clean
ground side as mentioned in clause 9.I.E.1
Page 16 of 24
9.I.F. Exploded view : Three Piece & Two piece Design – Trunnion Ball Valve –
( Trunnion plate Ball valve ) :
Page 17 of 24
9.II) FLOATING BALL VALVE :

9.II.A. Disassembly – Floating Ball Valves :
1. Valve shall be positioned vertically by resting body side flanges on clean ground surface
(preferably covered with rubber sheet).
2. Remove the handle, lever or gearbox.
3. Open the body adapter joint by loosening the Nuts in crisscross pattern
4. Remove the body seal from the body adapter and body gasket from the body.
5. Remove the ball from the body & the seats from body & body adapter.
6. Remove the stem by removing stem-holding devices as applicable.
7. Push stem into Body cavity & take it out.
8. Remove all stem seals.
9.II.B. Reassembly – Floating Ball Valves :
Before reassembly, inspect the valve for any damage on Body-Adaptor & all internals.
1. Follow the same step as mentioned in 9.II. A.1.

2. Apply suitable coat to bolting to prevent from corrosion.
3. Insert body seats in position.
4. Insert the stem seal bottom & the stem ‘O’ rings on the stem & install the stem from inside the
body.
5. Insert the top stem seal, the spacer, the disc springs or stem bush into the stem as applicable.
6. Ensure proper locking of stem with lock nut, washer or mounting plate as applicable.
7. Align stem A/F parallel with the body bore.
8. Gently slide the ball over the stem A/F.
9. Place seal & seat in body adaptor.
10. Position the gasket with the body & position studs.
11. Assemble the valve by putting adapter on the body & tighten the body nuts in a crisscross
pattern. (Refer Table : A for recommended tightening torque)
12. Put the operating member i.e. lever/ handle or G.O. in position into body & tighten them.
13. Ensure smooth operation of valve during opening and closing.
Page 18 of 24
9.II.C. Exploded view: Two Piece Design – Floating Ball Valves : Lever Operated :
Parts List
ITEM PART NAME ITEM PART NAME

01 Body 11 Spacer Ring
02 Body Adapter 12 Disc Spring
03 Ball 13 Stem Nut
04 Stem 14 Stud
* 05 Seat 15 Nut
* 06 Body Seal 16 Stop Pin
* 07 Body Gasket 17 Lock Washer
* 08 Stem Seal Bottom 18 Handle
* 09 Stem ‘O’ Ring 19 Handle Lock Nut
* 10 Stem Seal Top
* Marked are recommended spare parts.
Page 19 of 24

9.II.D. Exploded view: Three Piece Design – Floating Ball Valves :
Parts List
ITEM PART NAME QTY

01 Body * 09 Stem Seal Top
02 Pipe End 10 Spacer Ring
03 Ball 11 Disc Spring
04 Stem 12 Stem Nut
* 05 Seat 13 Stop Pin
06 Seat Ring 14 Handle
* 07 Body Gasket 15 Studs
* 08 Stem Seal Bottom 16 Nuts
Page 20 of 24

9.II.E. Exploded view: Two Piece Design – Floating Ball Valves - Gear Operated :
Parts List
ITEM PART NAME

01 Body 10 Stem Bush
02 Body Adapter 11 Body Stud
03 Ball 12 Body Nut
04 Stem 13 Stem Key
* 05 Seat 14 ISOPAD
* 06 Body ‘O’ Ring 15 Cap screw for ISOPAD
* 07 Body Gasket 16 Gearbox
* 08 Stem Seal Bottom 17 Stud for Gear box
* 09 Stem ‘O’ Ring 18 Nut for gearbox.
Page 21 of 24

TABLE: A - RCOMMENDED TIGHTENING TORQUES, N-m

( For Information Only )
FOR METRIC SERIES TORQUE (N-m) FOR INCH SERIES. TORQUE (N-m)
Thread Size Thread
(Metric) Pitch LOW RES.* HIGH RES** Size (INCH) TPI LOW RES.* HIGH RES**
M10 1.5 20 40 1/2 13 40 80
M12 1.75 35 69 5/8 11 78 155
M14 2 54 108 3/4 10 135 270
M16 2 83 165 7/8 9 215 429
M18 2.5 114 228 1 8 320 639
M20 2.5 159 318 1-1/8 8 463 925
M22 2.5 214 428 1-1/4 8 643 1285
M24 3 272 544 1-3/8 8 864 1727
M27 3 394 787 1-1/2 8 1131 2261
M30 3.5 533 1066 1-5/8 8 1447 2894
M33 3.5 718 1436 1-3/4 8 1818 3636
M36 4 923 1845 1-7/8 8 2247 4493
M39 4 1185 2370 2 8 2738 5476
M42 4.5 1467 2934
M45 4.5 1820 3639
M48 5 2192 4383
M52 5 2813 5626
M56 5.5 3498 6995 Note: ensure that all the nuts/bolts are tightened
M60 5.5 4336 8671 to the torque values as specified in this Table.
*Low resistance Bolting: Material Grade B7, B7M, L7, L7M
**High resistance Bolting: Material Grade B8, B8M, Class12.9
Use above value for normally lubricated surface ( UNCOATED ) only machining oil
For coated bolts multiply for reduction factor: 0.65- PTFE COATED
Page 22 of 24

Customer
Project
Consultant
P. O. No. And Date
Work Order No.
Date of Last Dispatch
Date of Commissioning
Warranty:
“Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury or damage
attributable thereto is limited to making goods by replacement or repair defects which under proper use
appear therein and arise solely from faulty materials and workmanship within a period of 18 calendar
months after the original goods shall have been first dispatched or 12 calendar months from the date of
commissioning, whichever is earlier provided that such defective parts are returned free to our works
for examination. The undertaking shall exclude any and every other obligation.”
Virgo does not assume responsibilities for any liabilities/damages arriving out of wrong
application of its valves, or imprudent operations carried out by inexperienced operators, or
which does not comply with this manual, or instructions provided by Virgo.
The valves shall be appropriately used for the purpose they are built, or applications they are
supplied. Use of standard valves for special applications is not recommended unless it has
been communicated and agreed to by Virgo.
Valves shall be operated and maintained strictly in accordance with the procedures. Operation
or maintenance outside these procedures constitutes abuse of the product and voids all
warranty and claims.
10.0 ADDRESSES FOR CORRESPONDENCE :

In case of service / repair, please contact our nearest Branch Office / Factory.
Head Office: Works:
VIRGO ENGINEERS LIMITED VIRGO ENGINEERS LIMITED

277, Raisoni Industrial Park, (Ball Valve Division)
Phase II, Hinjewadi, Maan (Mulshi), 277, Hinjewadi Phase II, Maan
Pune – 411 057, INDIA. (Mulshi),
Phone: +91-20-66744000. Pune – 411057 INDIA.
Fax: +91-20-66744021. Phone: +91-20-66744000.
E-mail : sales@virgoengineers.com Fax: +91-20- 66744021.
Website: www.virgoengineers.com
Page 23 of 24

10.I ADDRESSES FOR CORRESPONDENCE : Branch offices India and

overseas :
Mumbai Kolkata
Unit No. 103, First Floor, 2-B, Haralal Das Street
A - Wing, Building No. 1, 2nd Floor, Entally
Kailash Industrial Complex, Behind Godrej Kolkata 700 014
Colony, Off. L.B.S.Marg, Parksite, Tel: (033) 22272269 / 22272533
Vikhroli (E ) Mumbai - 400 079 Fax: (033) 22272279
Phone - 022 40100700 E-mail: virgoccu@cal2.vsnl.net.in
Fax - 022 40110701
E-mail: virgobom@virgoengineers.com
Baroda Chennai
14, Guruprasad Society, Behind Akota No. 59, Ground Floor, Teacher’s Colony,
Stadium, Karma Avenue, Ayer,
Baroda-390 015. INDIA Chennai-600 020. INDIA
Phone: +91-265-2342837, 2355133, 2341053 Phone: +91-44- 24404119
Fax: +91-265- 2314449 Fax: +91-44-24410664
E-mail: virgobrd@virgoengineers.com E-mail: virgomds@md4.vsnl.net.in
Delhi MALAYSIA
7/39, 2nd Floor, 1 B, Virgo Valves and Controls Ltd.
Vikram Vihar, Lajapat Nagar, Suite 1904, 19th Floor, Kenanga
New Delhi – 110 024. INDIA International
Phone: +91-11- 51729161/2/3/4 Jalan Sultan Ismail,50250 Kuala Lumpur,
Fax: +91-11- 51729164 Malaysia
E-mail: virgodel@virgoengineers.com Ph: +60 3 21618260
Fax : +60 3 21666489
E-mail : ajagnade@virgoengineers.com
Virgo Engineers Inc. Virgo Valves & Controls Limited

13219, N.Promenade Blvd, (Warehouse and Valve Automation
Stafford, Center)
Texas – 77477. USA. Unit - Fzs1 AH07,Jebel Ali Free Zone
Phone: 001-281-491-0400 (South),
Fax: 001-281-491-0444 P.O. Box – 18478, Dubai-UAE
E-mail: mmalkarnekar@virgoengineers.com Phone : +971-4-8860980
Fax : +971-4-8860981
Virgo Europe Spa

Via Torino 3/5-20039,
Varedo Milano
Italy.
Phone: +39 0362 589711
Fax: +39 0362 554439
E-mail : scalciolari@virgoeurope.com
Document Path: P:\USERS\SPECS\ISO\IOM\IOM08.doc Rev No.: 8 Published On: 14.03.2009
Page 24 of 24

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4.3 Level Indicator
(LI)

SureSite®
Magnetic Liquid Level Indicator
Instruction Bulletin No. 177664-1 (Rev. E)
Section 1: Weldments
Thank you for purchasing the GEMS SureSite Magnetic Level Indicator. Please read this document prior to
installing your SureSite and store it where it may be readily referred to for familiarization and maintenance
purposes. If you require any additional information, you are welcome to call GEMS at the number shown below.
1-800-321-6070
(Outside of the Continental U.S., call 860-747-3000)
Record the Part Number of your SureSite here to use when ordering spare or replacement parts:
Part Number:____________________
SureSite Operating Principle
The liquid level of a tank is made visible, even at great distances,

through the use of a shock and vibration-proof magnetic level indica- Flag Channel Magnetic Flags
tor that employs “flags” arranged within a specially constructed exter- (Plain Side Out)
nal housing: the flag assembly. The two sides of each pivoting flag
Liquid
are marked with contrasting colors. A permanent magnet is encapsu- Magnetic
lated inside each flag and forms a secure magnetic interlock with the Float
adjacent flags. As the liquid level rises, a float equipped with a per-
manent magnet causes each of the flags to begin rotating in turn.
This action exposes the contrasting (fluid level indicating) color on
the other side of the flag. As the float and liquid level rise, each flag
below the level of the float completes a 180 degree rotation, while
remaining magnetically interlocked with the other lower flags. Together, Magnetic Flags
the rotated flags display a band or column of color, the height of which (Colored
corresponds with the liquid level within the tank. An exclusive feature Side Out)
of the SureSite is the patented magnetic guide1 that is integrated into
the flag assembly. This magnetic attraction ensures that the float is
always aligned for optimum performance and exactness, regardless W eldment
of any shock, vibration, or rapid change to the level of fluid in the
tank.
Standard and Mini-SureSites are supplied with the floats packed

either separately, or securely strapped to the unit. Top-mounted
SureSites are typically supplied with the floats installed and secured
by a support tube. The float supplied with each unit has been de-
signed to the specific gravity of the fluid being monitored, so that the Tank
permanent bar magnet will always seek and indicate the fluid surface.
Because of the attraction of the permanent bar magnet in the float
and the patented magnetic guide, the SureSite flag assembly can be
rotated to a position which will allow for optimum viewing.
(See the Maintenance Section on page 5 for instructions on how to rotate your
SureSite flag assembly.)
_____________________________
1
Patent No. 4,457,171. The patented magnetic guide is singularly magnetized on each side and attracts
the proper pole of the permanent bar magnet in the float.
-1-

Important!
Read the following instructions completely - BEFORE installing the SureSite.
Installation Precautions and Preparation
Failure to observe these precautions could affect the operation of your unit.
1. When locating the tank ports for the SureSite, make sure that no strong magnetic fields or magnetic materials
(such as railings, protective cages, I-beams, etc.) will be any closer than 6 inches (153 mm) from the SureSite.
2. Make necessary efforts to ensure that all tank-side modifications and equipment; i.e., the mating flanges, NPT
ports or shut-off valves (if used) will align properly with the SureSite connections. Improper alignment could
cause distortion and may damage welds and compromise the integrity of the SureSite and/or the tank.
3. After any necessary tank modifications are completed, the tank should be cleaned to remove contaminants. This
will ensure that the installation is free of foreign particles; especially those which could be magnetic and which
could impair the performance of the SureSite.
4. Do not begin the installation of the SureSite until all necessary tools and materials are obtained. (Such as
mating flange gaskets, bolting hardware, etc. )
5. Gasket material typically supplied with the standard SureSite unit is either Viton or nitrile rubber, Garlock 3000
style. Higher pressure units are typically supplied with FlexitallicTM gaskets. For replacement gaskets, please
consult GEMS Sensors for your specific material type.
6. All supplied flag assembly clamps are intended to be installed with a torque on the clamp screw not to exceed
5 lb.-inches.
Installation
Caution
Handle the SureSite with care to avoid damaging the threaded areas, flange surfaces, etc.
Note
If you have a top-mounted alloy or top-mounted plastic SureSite, skip to Page 4 for instructions.
For Standard SureSites (Alloy, Mini and Plastic)
1. Remove the protective packing materials from your SureSite.
2. Position the unit horizontally on a level surface.
3. Unpack the float assembly or, with the aid of a wire-cutter or similar device, remove the strapping that secures
the float to the exterior of the SureSite Unit.
-2-

Warning
D0 NOT: 1) Hold the SureSite in a vertical position or 2) Drop the float assembly into the unit. Avoid this or
any action which could damage or dent the float. Such damage could cause the float to crush under normal
working pressures.
TOP
Float Float
TOP Float
W eldment W eldment
TOP
Flange
Flange
W eldment
Threaded
Remove Bolts Remove Bolts End Cap
Standard SureSite Mini SureSite Plastic SureSite
4. Remove the end cap or flange attaching bolts, as indicated in the appropriate drawing. Then remove
the end cap or flange.
5. With the unit still in a horizontal position, insert the float assembly into the weldment, with the “TOP” indication
on the float assembly moving in the same direction as the “UP” arrows that are located on each side of the
externally mounted flag assembly.
6. With the gasket or O-ring properly positioned, reassemble the end cap or flange to the weldment. Tighten the
end cap or flange bolts securely, using the proper recommended torque value as supplied in Figure A, page 5.
7. Slowly raise the top end of the SureSite, while the bottom end remains on the level surface, permitting the float
to slowly slide to the bottom, avoiding any sudden impact damage to the float assembly.
8. Move the SureSite to the tank and position the unit with the end marked “TOP” pointing upwards. Install any
necessary mounting gaskets or seals 2, and align the mating port flanges, NPT’s or connections of the tank with
those of the SureSite. DO NOT ATTEMPT TO FORCE ALIGNMENT. To do so may damage the welds or
compromise the integrity of the SureSite. While following standard practices and procedures, tighten the flange
bolts, NPT’s or connections. Recommended torque values are supplied in Figure A, page 5.
9. Before Filling the Tank . . . . Be sure that the installation is free of foreign particles, especially any that are
magnetic. Check that all connections are secure. A hydrostatic pressure test of the complete assembly
is recommended.
NOTE
GEMS recommends that you include at least one support bracket in your installation for SureSite units greater than
10 feet (120 inches, 3048 mm) in length. Depending on the specific installation, a load-bearing support at the base
of the SureSite may be beneficial.
______________________________________
2
Gaskets or seals for the port flanges are not supplied with the SureSite.
-3-

Installation for Top-Mounted Alloy SureSites
1. After removing any protective packing materials from your Float

top-mounted SureSite and positioning it horizontally on a level
surface, remove and discard the protective cap from the bottom of
the SureSite and carefully withdraw the cardboard support tube. Float
Chamber
2. Slowly raise the top end of the SureSite, while the bottom end
remains on the level surface; permitting the float to slowly slide to
the bottom and avoiding any sudden impact damage to the float
assembly.
Cardboard
3
3. Position the necessary gasket or O-ring seal on the tank mounting Support Tube
flange and align the unit so that the bolt holes of the mating flange
match. The indicating face of the flag assembly should be directed
towards your desired point of observation. Do not attempt to force
alignment. To do so may damage the welds or compromise the
integrity of the SureSite.
Protective
4. While following standard practices and procedures, tighten the
Cap
flange bolts with the recommended torque values as supplied in
Figure A, page 5.
Installation for Top-Mounted Plastic SureSites Float
1. Remove the threaded stop pin from the bottom of the top-mounted
SureSite and slowly withdraw the support tube. Reinstall the stop Float
pin. Chamber
2. Slowly raise the top end of the SureSite, while the bottom end
remains on the level surface; permitting the float to slowly slide to
the bottom and avoiding any sudden impact damage to the float
assembly.
Cardboard
3. Position the necessary gasket or O-ring seal 3 on the tank mounting Support Tube
flange and align the unit so that the bolt holes of the mating flange
match. The indicating face of the flag assembly should be directed
towards your desired point of observation. Do not attempt to force
alignment. To do so may damage the welds or compromise the Stop
integrity of the SureSite. Pin
4. While following standard practices and procedures, tighten the

flange bolts with the recommended torque values as supplied in
Figure A, page 5.
_____________________________
3
Gaskets or seals for the port flanges are not supplied with the SureSite.
-4-

Figure A
(Recommended Torque V
Torque alues are for Lubricated Threads, Only)
Values
Fastener Nominal
Indicator Type
Type Torque Value
Value
Description Size
70 - 80 Lb.-Inches NTE
3/8 Inch (Not to Exceed) 120 Lb.-Inches
1/2 Inch 30 Lb-Feet
Standard Alloy,
Alloy, Bolt, Nut 5/8 Inch 60 Lb-Feet
Top-Mount Alloy 3/4 Inch 100 Lb-Feet
7/8 Inch 150 Lb-Feet
1 Inch 250 Lb-Feet
1-1/8 Inch 350 Lb-Feet
15-20 Lb-Feed (Valid for bolts
Standard Plastic, Bolt, Nut with flat washers under both bolt-
Top-Mount Plastic heads and nuts)
Mini Bolt, Nut 5/16 Inch 70 - 80 Lb-Inches
Flag Installation
General Notes
Under normal circumstances, it should not be necessary to reposition the flag assembly on your SureSite. However, if
you find it desirable or necessary to reposition the flag assembly, we strongly recommend that you first mark the
distance from the top of the weldment to the top of the flag assembly. Before securing the flag assembly in a new radial
position, ensure that the distance from the top of the flag assembly to the top of the weldment is the same as the
previously noted dimension. Making a temporary or permanent mark on the weldment can ease the process.
Maintenance
The only maintenance typically required is to ensure that the internal walls of the weldment and the float are free of
foreign matter. This may be accomplished by removing the float assembly from the unit and wiping both the float and
the inside wall of the float chamber or weldment. Any maintenance interval is to be established by the user of the
SureSite and would depend upon the characteristics of the application. Maintenance could coincide with tank cleaning
or flushing.
Float Installation
Mini SureSite Float: (To set magnet position, please go to page 8.)
To accomplish the removal and subsequent reinstallation of the float assembly, follow the appropriate instructions
provided on page 6 for the SureSite type and mounting configuration you have selected.
Caution
Make sure that the tank is depressurized and that liquid
has been emptied prior to removal of the float assembly.
-5-

SureSite with Side Connections (Alloy, Mini and Plastic)
The float assembly can be removed without disturbing the mounting of the SureSite unit to the tank.
1. Carefully remove the end cap (access to the float assembly) which may be retained by bolts, NPT threads
or held in place by setscrews. The float assembly should be resting on the end cap as it is being lowered.
Support the float assembly while setting the end cap aside.
Note: For units supplied with top float access, the float assembly must be
extracted from the top of the weldment by engaging the hooking ring
provided on the top of the float.
2. Withdraw the float assembly from the unit, exercising caution not to damage the float. Note the “TOP”
indication marking on the float assembly.
3. Wipe down the weldment and the float assembly with a clean, lint-free cloth.
4. Carefully reinsert the float assembly into the weldment, ensuring that the “TOP” indication marking on the
float assembly is positioned in the same manner as when it was removed.
5. Remove the old gasket or O-ring from the end cap assembly and replace it with a new gasket or O-ring.
6. With the new gasket or O-ring properly positioned, reassemble the end cap assembly to the weldment.
Tighten the end cap or secure flange fasteners, using the proper recommended torque value, as supplied
in Figure A -page 5.
SureSite with Top and Bottom Connections (Alloy, Mini and Plastic)
The SureSite unit should be adequately supported when removing it from the tank.
1. Disconnect the top and bottom flange/socket or NPT connections.
2. Remove any other fasteners that retain the unit and/or support bracket(s) to the tank.
3. Remove the SureSite unit from the tank, while avoiding any motion that will cause damage to the float assembly.
4. With the SureSite placed in a horizontal position on a level surface, remove the end cap or flange and withdraw
the float assembly from the unit; noting the relative position of the portion of the float assembly marked “TOP”.
5. Wipe down the weldment and the float assembly with a clean, lint-free cloth.
6. Carefully reinsert the float assembly into the bottom of the float chamber or weldment, ensuring that the “TOP”
indication marking on the float assembly is positioned the same as when it was removed.
7. Remove the old gasket or O-ring from the end cap assembly and replace it with a new gasket or O-ring.
8. With the new gasket or O-ring properly positioned, reassemble the end cap assembly to the bottom of the
weldment. Tighten the end cap or flange bolts securely, using the proper recommended torque value, as
supplied in Figure A, page 5.
9. Complete installation of the unit by following the Installation Instructions for Standard SureSites (Page 3,
Steps 7, 8 and 9).
-6-

SureSites Mounted on Top of Tank
The construction of top-mounted SureSites varies with the material selected, and each requires a slightly different
procedure than those preceding for “wipe-down”. It is advisable to mark or index mating flanges and other parts
so that the relative positions of the components are maintained upon reassembly.
Alloy
1. Remove the attaching bolts that secure the SureSite unit to the top of the
tank. Lift the SureSite vertically from the tank and set it aside on a
level work area, in horizontal position. Exercise caution so that the
float assembly will not be dented or damaged. Remove any gasket
material from the tank and SureSite mounting flanges. Flag
External
W eldment Assembly
2. Remove the attaching bolts securing the external weldment (with the
attached flag assembly) to the mounting flange that was secured to your
tank, and carefully remove the weldment and gasket from the float
chamber, taking care not to damage the sphere-shaped magnet carrier.
3. While lightly supporting the magnet carrier, remove the upper (first)
cotter pin attaching it to the float rod. Set the magnet carrier and
cotter pin aside. Attaching
Bolts
4. Remove the lower (second) cotter pin from the float rod and set it aside.
Gasket
5. Withdraw the float and float rod from the bottom of the float chamber.
6. Wipe the inside of the float chamber and the exposed float assembly with
a clean, lint-free cloth.
Magnet
Carrier
7. After completing the “wipe-down” cleaning, the unit can be reassembled. Cotter
Pins Float Rod
8. Obtain new gaskets for: a) Installation between the weldment and float
chamber1, and b) Installation between the mounting flange2 of your tank
and that of the unit. Obtain new cotter pins for the float rod.
9. Insert the float assembly and rod into the float chamber, passing the float Mounting
rod up through the opening in the mounting flange. Secure the rod to the Flange
float chamber by installing a cotter pin in the lower (second) hole and
securing it. Reinstall the magnet carrier to the float rod. Insert and Float
secure a cotter pin in the upper (first) hole to retain it. Chamber Float
10. Complete the remainder of the reassembly and installation by reversing

the process described in Steps 1 and 2. Refer to Figure A, page 5 for
recommended torque values for bolts. Use a new gasket: a) Between Protective
the weldment and mounting flange of the float chamber, and b) Between Cap
the mounting flange of your tank and that of the SureSite unit.
_____________________________________________
1
Contact Gems Sensors for spare or replacement parts
2
Customer-Supplied
-7-

Plastic
1. Remove the attaching bolts that secure the SureSite
Flag
unit to the top of the tank and lift the indicator unit
Assembly
External (with its float chamber) vertically from the tank. Set
W eldment it aside on a level work area, horizontally. Handle
the float assembly with care to prevent damage.
Magnet Remove any gasket material from the tank and
Carrier SureSite mounting flanges.
2. Unscrew and remove the stop pin from the bottom of

Mounting the float chamber.
Flange
3. Carefully withdraw the float, float rod, and attached
magnet assembly from the bottom of the float
chamber.
4. Wipe the inside of the float chamber and the exposed

Float
float assembly with a clean, lint-free cloth.
Chamber
5. After completing the “wipe-down” cleaning, the unit
Float
can be reassembled. Obtain a new gasket for
installation between the mounting flange of your tank
Stop Pin and that of the SureSite unit. Prepare the mating
surfaces for reassembly.
6. Insert the float assembly and rod into the float

chamber, passing the magnet assembly and float rod
Hold the float vertical. A paper clip will attach to the up through the bottom of the float chamber. Secure
magnet to show its position. Adjust the magnet the float assembly and rod to the float chamber by
position by gently tapping the end of the float. reinstalling the stop pin.
Basic Float Part No. 807100 Basic Float Part No. 807200
(Liquid Specific Gravity Range: 0.8 to 1.2) (Liquid Specific Gravity Range: 1.5 to 3.8)
Liquid Liquid
Float Specific “X” Float Part No. Float Specific “X” Float Part No.
Part Number Gravity Dimension W/Lift Ring Part Number Gravity Dimension W/Lift Ring
85206 0.8 5” 810919 88111 1.9 2” 810928

83453 0.9 4.5” 810917 801708 1.5 2.6875” 810927
85208 1 4” 810916
85209 1.2 3.312” 810915
84158 0.85 4.75” 810918
TO P
807200
“X” à
à
Dimension
TO P
807100
à
“X” Dimension à
-8-

Troubleshooting
Condition Possible Cause Solution
No Float Install float
Float sticking, due to contamina- Clean the float and weldment

No change in Media tion in the fluid level
Level Indication
Float attracted, due to external Remove the ferrous materials
ferrous materials within close from close proximity
proximity.
The float is damaged Replace the float
Port is blocked Remove blockage
Float attracted, due to contami- Clean the float and weldment

nation in the media
Float sticking, due to external Remove the ferrous materials

Incorrect Fluid Level ferrous materials within close from close proximity
Indication proximity
The float is damaged Replace the float
The float is upside down Invert the float
Flag assembly is upside-down. Rotate the flag assembly 180

Incorrect Color (The wrong color is indicating the degrees (with the end marked
Indicating Fluid Level liquid level) “TOP” uppermost)
Note: Increased viscosity increases the response time of the SureSite indicator
Warnings/Cautions
1. The SureSite Magnetic Level Indicator must be maintained and installed in strict accordance with
this Instruction Bulletin. Failure to observe this warning could result in serious injuries or damages.
2. The liquids to be monitored must be compatible with the materials of construction. Specifications
of these materials will be provided upon request.
-9-

High Performance Versions – Ordering is Easy! See Page C-40.
Easy online ordering too!
Standard Size
LEVEL SENSORS – CONTINUOUS
 Designed to meet the requirements of ASME B31.1/B31.3*

 Temperatures to 750°F (399°C)
 Pressures to 4200 PSI (290 bar)
For your most demanding applications, these SureSite® Indicators
feature ANSI flanges and fittings and construction to rigorous ASME
standards. You can’t specify a better visual level indicator.
1. Mounting Configuration Types
To choose the best configuration for your application, focus on the process
connections (connections where the liquid typically enters/leaves the SureSite).
Type AA Type BA Type CA Type DA

Top and Bottom Side and Side Top and Side Side and Bottom
Process Connections Process Connections Process Connections Process Connections
T
Sa
T
Sa
L = Length of L L L
Visual C to C L & C to C C to C C to C
Indication
B B
Sb Sb
Typical C to C = C to C = C to C =
C to C = L
Lengths† L + 10-1/4˝ (260.4 mm) L + 3-3/4˝ (95.2 mm) L + 6-1/2˝ (165.1 mm)
Flag Material Plastic (300°F/148.9°C) or Aluminum (750°F/399°C)
Length of Indication
240˝ (610 cm)
(Uninterrupted)
Minimum
0.39
Specific Gravity
† Dimensions vary due to connections, material and specific gravity.
2. Material 4200
(290)
Consult
Select desired material from those tabulated below. 4000 Factory
(276)
Mark the Code Number on your OrderIt! Check List.
PRESSURE PSI (BAR)
3800
The pressure/temperature performance parameters are (262)
specified in the chart at right. Consult the factory with
3600
pressure/temperature requirements that fall outside the (248)
parameters shown here. These units are manufactured 3400
in Schedule 40, 80 or 160 pipe accordingly. (234)
3200
= Stock Material (Best economy and delivery). (221)
High
3000
Materials (207)
Performance
Code
Housing Float 2800
(193)
316L Stainless Steel
316L Stainless Steel 2 0
600 psi – 0 100 200 300 400 500 600 700 800 °F
-18 +38 +93 +149 +204 +260 +316 +371 +427 °C
Titanium (Ti-6AI-4V) TEMPERATURE
316L Stainless Steel 9
600 psi+
Note: Additional materials, floats, connections and manufacturing
techniques are available to extend lengths and operational
capabilities. Please contact GEMS Sensors if the parameters
above do not meet your requirements.
*Units are not ASME rated/certified.
C-38 www.gemssensors.com
SURESITE® LEVEL INDICATORS
3. Connection Codes
All connections comprised of ANSI fittings (See complete descriptions below)
NPT Flange Weld
LEVEL SENSORS – CONTINUOUS

Blind
Fixed Removable Fixed Removable
Fixed Removable
Fixed Removable Female Male Female Male Socket Butt Socket Butt
T15 T16 T17 T19 T20 T22 T23 T24 T25 T26 T27 T28
T29 T30 T32 T33 T34 T35

T
TOP
SIDE
Sa Connection Codes and

NPT Weld Materials background-
Blind Flange
Male Female Socket Butt shaded in this color are
S1 S2 S3 S4 S5 S6 S7
readily available from Gems.
Select these connections
where possible to obtain
the most economical
Sb
SIDE
SureSite Indicators.
NPT Flange Weld

Blind
BOTTOM
Fixed Removable Fixed Removable

B Fixed Removable Female Male Female Male
Fixed Removable
Socket Butt Socket Butt
B15 B16 B17 B19 B20 B22 B23 B24 B25 B26 B27 B28
B29 B30 B32 B33 B34 B35
Note: Gems recommends a removable top and/or bottom connection for float access.
Connection Code Descriptions

Please provide all connections when completing the OrderIt! Product Check List (located in the back of this catalog).
Note: Before selecting your connections, consider incorporating your vent and drain requirements.
T & B (Top and Bottom) Sa & Sb (Sides)

T/B 15. ANSI welded pipe cap S1. No connection
T/B 16. ANSI fixed slip-on flange/blind mating flange S2. MNPT nipple
T/B 17. ANSI welded pipe cap with FNPT S3. FNPT coupling
T/B 19. ANSI welded pipe cap with MNPT nipple S4. ANSI flange
T/B 20. ANSI fixed slip-on flange/mating FNPT reducing flange S5. Weldneck flange
T/B 22. ANSI fixed slip-on flange/mating flange w/MNPT nipple S6. Socketweld coupling
T/B 23. ANSI welded pipe cap with ANSI flange S7. Buttweld nipple
T/B 24. ANSI fixed slip-on flange/mating reducing ANSI flange spool
T/B 25. ANSI welded pipe cap with socketweld coupling Accessories – Pages C-44 to C-46
T/B 26. ANSI welded pipe cap with buttweld nipple Make more of your SureSite® Indicator with the
T/B 27. ANSI fixed slip-on flange/mating flange with socketweld coupling productivity-enhancing accessories found at the end of
T/B 28. ANSI fixed slip-on flange/mating flange with buttweld nipple this section.
T/B 29. ANSI fixed weldneck flange/blind mating flange • Indicating Scales
T/B 30. ANSI fixed weldneck flange/mating FNPT reducing flange Add graduations to your flag indication.
T/B 32. ANSI fixed weldneck flange/mating flange w/MNPT nipple • Switch Modules
T/B 33. ANSI fixed weldneck flange/mating reducing flange spool Control pumps, valves, alarms, etc. Mount externally
T/B 34. ANSI fixed weldneck flange/mating flange with socketweld coupling on housing for infinite positioning.
T/B 35. ANSI fixed weldneck flange/mating flange with buttweld nipple • Continuous Output Transmitters
Signal conditioned for compatibility with most
electronic instruments.
www.gemssensors.com C-39
SURESITE® VISUAL INDICATORS – HIGH PERFORMANCE Product Check List

This is a  Request for a Quote Name __________________________________________
 Order P.O.# ______
Company ________________________________________
Quantity Needed ____________
Street __________________________________________
Photocopy This Form Date Required ____/____/_____

City_______________________ State ____ Zip__________
Use one form for each product Shipping Method:____________
type you are selecting. Phone ( _____ ) __________________________________
Partials Accepted:  Yes
 No Fax ( _____ ) _____________________________________
SureSite Indicators, High Performance Versions

Process Conditions
This information is essential to the accurate and proper operation of your Use this page for high performance units only.
SureSite® Visual Level Indicators. Please complete fully and accurately.
1. Pressure: Operating __________ psig Maximum ________ psig 4. Specific Gravity @ Operating Condition: ____________________
2. Temperature: Operating ________ °F Maximum __________°F 5. Viscosity: _________________ SSU
3. Liquid Media: _________________________________________ 6. Application Location:  Indoors  Outdoors
Physical Configuration
1. Mounting Configuration Types: 2. Housing and Float Material – Housing: 316L/SS
 Type AA  Type BA  Type CA  Type DA  Code 2 – 316L SS Float  Code 9 – Titanium Float
3. Connection Codes – Complete all 4 connection code lines. Check off NPT or Flange size where appropriate.
 Connection Code Number Goes Here. Connection Code Numbers and their descriptions are on Page C-39.
Top T NPT or Weld Flange
 1/2˝  1˝  1.5˝  1/2˝  1˝  2˝  150# (RF)  600# (RF)  900# (RF)
 Other ____________  Other ____________  Other ______________________________
Side Sa NPT or Weld Flange

 1/2˝  1˝  1.5˝  1/2˝  1˝  2˝  150# (RF)  600# (RF)  900# (RF)
Side Sb NPT or Weld Flange

 1/2˝  1˝  1.5˝  1/2˝  1˝  2˝  150# (RF)  600# (RF)  900# (RF)
 Other ____________  Other____________  Other ______________________________
Bottom B NPT or Weld Flange

 1/2˝  1˝  1.5˝  1/2˝  1˝  2˝  150# (RF)  600# (RF)  900# (RF)
4. Length of Visual Indication – L: _____ inches (240˝, Max.). Special Instructions (Materials, Connections, etc.)
Connection to Connection Dimension – C to C: ________ inches.
5. Flag Type
Plastic flags available to 300°F. Aluminum flags only
for temperatures to 750°F.
 Plastic (Orange and White)  Aluminum (Black and Silver)
 Non-Standard; Specify:_____________________ consult factory.
Accessories (Pages C-44 to C-46) 4. Switch Modules (Single Point): _______ Quantity (only if required)
a.  SPST  SPDT  DPDT 120 VAC  DPDT 24 VDC
1. Transmitters (Continuous Electrical Indication):
b.  Standard – 300°F  High Temperature – 750°F
 Low Temperature – 300°F  High Temperature – 750°F
 Explosion-Proof  Explosion Proof
2. J-Box/Signal Conditioners Accessories: 5. Indicating Scales:
 Terminal Strip  4-20 mA Output  Feet and Inches  Inches  Metric  Blank
 0-12 VDC Output  0-5 VDC Output  Custom Graduations; specify: _______________________
3. Power Supply:  115 VAC (Input) /24 VDC (Output) Gems Sensors Inc.
(Optional)  230 VAC (Input) /24 VDC (Output) One Cowles Road
Plainville, CT
Please contact GEMS Sensors Inc. for any configuration or special 06062-1198
requirements not covered on this form. 800-378-1600 tel 860.747.3000
fax 860.747.4244
Quote: $ _______________ Date Quoted:____/____/____ www.gemssensors.com
C-40
4.4 Level Switch
(LS)

SureSiteâ
Magnetic Liquid Level Indicator
Installation, Operation and Maintenance
Bulletin No. 177664-2 (Rev. B)
Section 2: Switches
Operation
The SureSite Switch Module, available for use with the SureSite Magnetic Liquid Level Indicator, is a sealed assembly
containing a magnetically actuated “latching-reed” switch assembly. The reed switch is actuated by the movement of
the magnet contained in the SureSite float. The design of the reed switch permits the switch module to perform as
either a “normally open” or “normally closed” switch. When installed with the lead wires (or junction box) installed at
the top, the switch module is “normally open” and the reed switch will close with the rising fluid level in the tank;
remaining closed until a falling fluid level in the tank causes the float to drop below the indicating position, opening the
reed switch. When installed with the lead wires (or junction box) at the bottom, the switch module is “normally
closed” and the reed switch will open with the rising fluid level in the tank, and remain open until a falling fluid level
in the tank causes the float to drop below the indicating position, closing the reed switch. (See sketches below)
For electrical schematics of the switch module, please refer to the Wiring Diagrams, located on pages 5 and 6.
- Normally Open Operation - - Normally Closed Operation -
Lead W ires and Junction Box Positioned at T

Wires op
Top Lead W ires and Junction Box Positioned at Bottom
Wires
Installation
o
General: The SureSite switch module must be mounted 180 opposite the flag assembly of the SureSite Magnetic
Level Indicator and within its operating range. The installation of the switch module varies, depending on the switch
module housing and the type of SureSite Magnetic Level Indicator. The chart on the next page is intended to provide
an overview of the various switch modules and to indicate which diagram(s) should be referred to for installation
instructions.
1 of 6

Installation (Cont.)
If it is necessary to locate two switch-points close together, two switch modules can be positioned
o
side-by-side and located 180 opposite of the flag assembly, as shown.
Flag
Assembly
Top V iew
View
Switch Modules
Mounting Hardware Switch
Part SureSite Switch Rating / Max. Fluid
Housing
Number Type Configuration Temp (°F / °C) Bracket / Spacer Clamp J-Box
Block Material
Standard
85350 Standard 20 VA SPST, N.O. or N.C. 300 / 148 N/A N/A N/A Polysulfone
86435 Standard 20 VA SPST, N.O. or N.C. 300 / 148 N/A Incl. N/A Polysulfone
86567 Mini 20 VA SPST, N.O. or N.C. 300 / 148 N/A Incl. N/A Polysulfone
87480 Mini / Plastic 20 VA SPST, N.O. or N.C. 300 / 148 N/A N/A N/A Polysulfone
80469 Plastic 20 VA SPST, N.O. or N.C. 300 / 148 N/A N/A N/A Polysulfone
High Temperature
Temperature
83140 All 20 VA SPST, N.O. or N.C. 750 / 398 Incl. N/A N/A 316 SS
83150 All 20 VA SPST, N.O. or N.C. 750 / 398 Incl. N/A N/A 316 SS
84320 All 20 VA SPDT, N.O. or N.C. 750 / 398 Incl. N/A N/A 316 SS
803430 All 220 VDC, 5 Amp 750 / 398 Incl. Incl. Incl. 316 SS
Explosion-Proof / High Temperature
Temperature
83100* All 120 VDC, 10 Amp 750 / 398 Incl. Incl. Incl. 316 SS
83110* All 24 VDC, 10 Amp 750 / 398 Incl. Incl. Incl. 316 SS
83120* All 20 VA SPST, N.O. or N.C. 750 / 398 Incl. Incl. Incl. 316 SS
83130* All 20 VA SPST, N.O. or N.C. 750 / 398 Incl. Incl. Incl. 316 SS
84330 All 20 VA SPDT, N.O. or N.C. 750 / 398 Incl. Incl. Incl. 316 SS
* Factory Mutual approved for:
Explosion-proof for Class 1, Division 1, Groups C & D and Class 1, Division 2, Groups B, C & D; Dust ignition proof per Class
2, Division 1, Groups E, F & G and suitable for Class 3, Division 1, Hazardous Location, Indoors (Ref. File #J.I. 0A8A3.AE).
Also CSA certified for Class 1, Division 1, Groups B, C & D (Ref. Files LR22666-22 and LR22666-24).
Note
For Standard Unit installation instructions, see Mounting Diagram “A”
For all other part numbers listed above, see Mounting diagram “B”, “C” or “D”
2 of 6

- Mounting Diagrams -
Diagram A
Standard SureSite®
Switch Part Numbers
80469, 85350, 86435, 86567, 87480
1. Position the switch module 180° from

the flag assembly and within indicating
range.
2. Slide the switch clamp between the

flag assembly and the weldment of your
SureSite Magnetic Level Indicator.
3. With the switch module located at the

desired fluid level, tighten the clamp
screw securely; not to exceed a torque of
10 lb-inches.
4. Connect the switch module leads to the load

circuit.
Mini SureSite®
Diagram B J-Box Not

Included
1-1/4”
1. Position the switch module 180° from Switch O.D.
On Type
the flag assembly and within indicating Part Numbers Tubing
83140
range. 83100, 83110, Flag
83120, 83130. Assembly
2. Slide the tabs of the switch clamps 83140, 83150,
between the flag assembly and the
Õ
84320, 84330
weldment of the Mini SureSite Magnetic 2-1/2”
Level Indicator; wrapping the retaining Ref. Switch
screw-end around the upper and lower
Õ
Module
stem of the switch, as shown. #24 Clamp
(P/N 85576)
3. With the switch module located at the -2 Required
desired fluid level, tighten the clamp
1-1/4”
screw securely; not to exceed a torque of O.D.
120 lb-inches. Tubing
Flag
4. Connect the switch module leads to the Assembly
Switch
Module
load circuit. Switch
Part Numbers
Õ
83150, 84320
2-1/2”
Ref.
Õ
#24 Clamp
(P/N 85576)
-2 Required
3 of 6

Mounting Diagrams (Cont.) Alloy SureSite®
J-Box Not
Included
On Type
Tubing
83140
or
Diagram C Switch Flag Pipe
Part Numbers Assembly
1. Slide the switch into the support 83100, 83110,
bracket. 83120, 83130.
83140, 83150,
2. Position the switch module 180° from 84320, 84330
the flag assembly and within indicating Switch
range. Module
3. Slide the switch clamp between the #48 Clamp

(P/N 85577)
switch bracket and the stem of the
switch, then between the flag assembly
and the weldment of your SureSite
Magnetic Level Indicator.
Tubing
or
4. With the switch module located at Pipe
Flag
the desired fluid level, tighten this Assembly
clamp screw securely, not to exceed a
torque of 120 lb-inches. Switch
Part Numbers
5. Connect the switch module leads to 83150, 84320
the load circuit. Switch
Module
#48 Clamp
(P/N 85577)
Plastic SureSite®
J-Box Not
Diagram D Included
Tubing On Type
1. Slide the switch into the plastic spacer Switch
or 83140
Pipe
block. Part Numbers Flag
Assembly
83100, 83110,
2. Position the switch module 180° from 83120, 83130.
the flag assembly. 83140, 83150,
84320, 84330
3. Slide the tabs of the switch clamps Switch
between the flag assembly and the Module
weldment of your SureSite Magnetic
Level Indicator, wrapping the retaining P/N 802265
screw-ends around the stem of the switch, #48 Clamp
Spacer Block
(P/N 85577)
above and below the spacer block and the
desired indication/activation level, as
shown.
4. With the switch module located at the

desired fluid level, tighten both clamp Tubing
or
screws securely, not to exceed a torque of Switch Pipe
120 lb-inches. Part Numbers
83150, 84320
5. Connect the switch module leads to the
load circuit.
Switch
Flag Module
Assembly
P/N 802265
#48 Clamp Spacer Block
(P/N 85577)
4 of 6

Wiring Diagrams
Part Numbers Part Number 83100

80469, 87480, 85350, 86435, 86567 - Dry Condition -
120 VA C
_
RED +
YELLOW
RED GREEN
SPST, N.O. or N.C. (Dry) BLUE
ORANGE
BROWN
WHITE
Part Number 831 10

83110 Part Numbers
- Dry Condition - 83120, 83140, 83150
- Dry Condition - 2-COND.
24 VDC CABLE
_
+
YELLOW
GREEN
BLUE
ORANGE
BROWN
WHITE
Part Number 83130 Part Numbers

- Dry Condition - 84320, 84330 DPDT
- Dry Condition / J-Box at Top -
3-PIN 3-PIN
TERM TERM.
3-COND.
CABLE
5 of 6

Wiring Diagrams (Cont.)
Part Numbers
84320, 84330
- Dry Condition / J-Box at BTM -
3-PIN
TERM.
3-COND.
CABLE
Switch Module Troubleshooting

Condition Possible Cause Solution
Positioned Incorrectly Reposition Switch Modules
Switch not in Indicating Range Reposition Switch Modules

Intermittent Switching
or Incorrect Mounting Hardware See Appropriate Mounting Diagram
Not Latching
Incorrect Wiring Between Correct Wiring
Switch & Load (See Wiring Diagrams)
Positioned Incorrectly Reposition Switch Modules
Switch Not in Indicating Range Reposition Switch Modules

Switch Not Switching
Incorrect Mounting Hardware See Appropriate Mounting Diagram
Switch Remains Open Incorrect Wiring Between Correct Wiring

or Switch & Load (See Wiring Diagrams)
Closed At All times
Switch Rating Exceeded Replace Switch
(See Appropriate Rating Diagram)
6 of 6

4.5 Level Control Valve - Auto
(LCV)

Installation and Maintenance
Armstrong 2313 HLS -- 2416 HLS Drainers
This bulletin should be used by experienced personnel as a quide

to the installation of 2313 HLS -- 2416 HLS drainers and their
repair parts. Selection or installation of equipment should
always be accompanied by competent technical assistance. We
encourage you to contact Armstrong or its local representative
for complete details.
INSTALLATION OF DRAINER
Make sure you have received the correct drainer. The model
number, orifice size, liquid discharge, capacity, maximum working
pressure, and serial number are all stamped on a yellow metal
plate screwed to the drainer body.
Remove the wire from the drainer body connection. This wire
holds the float in position during Leave wire in place
as long as possible.
On medium and heavy loads, and where there is horizontal
drain piping, install the drainer with a vent line as shown in
Fig. 1. In order for liquid to enter the drainer in this piping
configuration, noncondensible gases must be backvented Without
the vent line, these gases would not be displaced and liquid
would back up in the inlet piping. Install a strainer if scale
or grit are present, as they may prevent proper seating of the
valve. valve C and test valve F are important for
checking drainer operation.
On light loads a vent line is not required unless there is
horizontal drain piping. Plug the side inlet and provide a
single inlet pipe connection as shown in Fig. 2. The following
conditions must be met if this procedure is followed:
pipe minimum is used for drainer inlet;
A gate valve rather than a globe valve is used as a stop
valve;
The liquid is free from grit or scale.
When the drainer is installed. the float will be down and the
valve closed. To place in operation, open the liquid inlet valve
to the drainer and the vent line valve if a vent line is used.

INSTALLATION AND MAINTENANCE OF ARMSTRONG
2313 HLS -- 2416 HLS DRAINERS
Fig.
INSTALLATION OF VALVE AND SEAT MECHANISM

Check the stamped orifice size to insure you have received the
correct mechanism.
Remove the spring but do NOT disturb the spring calibration
screw.
Remove the float and float link by taking out the
pivot pin.
3) Remove float stop screw (2315 HLS, 2415 HLS, 2316 HLS, 2416
HLS only).
4) Remove hex head screw.
5) Remove the valve seat from the mechanism by folding back the
lever and unscrewing the valve seat clamp nut.
Place cap, machined side up, in vise.
Clean all valve seat contact surfaces, especially chamfer in
bottom of seat hole, and screw in new valve seat firmly.
Assure that good contact is made between the cap and the
valve seat.
Place the mechanism in the cap and center it before
tightening the clamp nut. The frame assembly should be on a
line from the valve seat to the webbing of the cap. After
tightening the clamp nut, fold the valve lever to its
original position.
Center the valve lever with the pivot clip and hold the
valve firmly on the seat while tightening the hex head screw
(IMPORTANT: Be careful to protect the valve and valve seat.
Raking the valve over the valve seat will cause scratches on
the ground surface of the valve.)*
2
*The lever should remain parallel to the valve lever

assembly. However, should the adjustment be thrown off
installation of a new mechanism, loosen the hex head
adjust the jack screw assembly until the parts are
parallel. NOTE: During this adjustment, hold the valve
firmly in the orifice of the valve seat to assure that no
damage occurs to these surfaces. When the float lever is
parallel with the valve lever assembly and there is
clearance between the pivot clip and valve lever, then hold
the jack screw firmly with a wrench and tighten the hex head
screw.
Replace the spring, small end first, making sure not to
disturb the spring calibration screw.
Replace float stop (2315 HLS. 2415 HLS. 2316 HLS,
and 2416 HLS only.)
Replace the float and float link with the pivot pin.
TROUBLESHOOTING
I. DRAINER DOES NOT DISCHARGE
1. The line pressure may be higher than that stamped on the
drainer.
2. The specific gravity of the liquid being used may be
lower than the specific gravity of the liquid for which
the drainer was ordered.
3. There may be no flow of liquid to the drainer due to:
a) Plugged strainer. Blow down the strainer.
After a few minutes the drainer should start
to discharge.
b) The vent valve may be closed.
4. If liquid is present, the strainer is clean. and the
vent valve is open, but the drainer will not
discharge, check the float for leaks:
3
Close the inlet, return, and vent valves.

Blow down the drainer. Immediately open the
drainer. Remove the float and shake it. If
the float is leaking you should be able to
hear liquid sloshing. Do not delay between
blowing down the drainer and shaking the
float.
b The float may have collapsed. Leaky or
collapsed floats must be replaced. When
ordering, specify drainer figure number and
serial number.
Inspect for mechanical trouble such as disconnected
float or broken valve. The spring may need to be
replaced or adjusted.
II. VALVE LEAKS
The drainer discharge is normally continuous, making it hard
to tell if the valve leaks.
With valve D closed and valve F open, open drain valve
which will lower thelevelof liquid in the drainer.
The valve should contact the seat and shut off. If it
does not, either the valve is leaking or it is being
held open by scale or grit.
Close the inlet valve for a few minutes to accumulate
liquid. Open the inlet valve quickly. The float
should rise high enough to blow out grit. Repeat the
procedure in 1 to check the valve for leaks. If the
valve continues to leak, new parts are required.
III. DRAINER DISCHARGES -- WIDE OPEN CONTINUOUSLY
If there is a build up of liquid in the unit to be
drained then,
Pressure may be too low;
the load may be higher than anticipated;
a larger orifice or a larger drainer may be
needed.
If the continuous discharge is a mixture of liquid and
gas there may be scale in the drainer or mechanical
trouble.
Check that the mechanism is free to open and
close without friction.
Check all parts, particularly valve and seat.
Check the unbalanced float Too much
tension on the spring could keep the valve
from closing.
Clean the drainer mechanism and cap.
4
SPRING ADJUST- , \
*Model Shown
‘OUTLET
Fig. 3
Should the spring or float require replacement. the loading of

the spring will have to be adjusted to the correct unbalanced
float weight as given below:
UNBALANCED
DRAINER SIZE FLOAT WEIGHT
2313 HLS or 2413 HLS 4 oz.
2314 HLS or 2414 HLS 4 oz.
2315 HLS or 2415 HLS 4 oz.
2316 HLS or 2416 HLS 6 oz.
Replace the spring. Place the cap and mechanism on a flat
surface. Hook a spring scale to the float hanger as shown in
Fig. 3. The required unbalanced float weight should be just
enough to move the valve off the seat. Tighten the spring pad to
decrease the unbalanced weight and back off the spring pad to
increase the unbalanced weight. When the valve lifts off the
seatatthe correct weight, take a screwdriver to hold the spring
pad and tighten the lock nut.
5
4.6 Pressure Switch
(PS)

229
Pressure and Differential
Pressure Switches, Explosion-Proof
Enclosure, Type 700, B-Series
This broad Ashcroft® switch series • Readily available

is ideal for use in virtually all pro- • Standard pressure connection
cess and industrial applications. materials:
• Explosion-proof NEMA 7/9, IP66 Pressure psi ranges
enclosure (explosion-proof enclo- - 316L SS
sure Class I, Div. 1 & 2, Groups Differential psid ranges
B, C, & D and Class II, Div. 1 & 2, - Nickel plated brass(9)
Groups E, F & G) Pressure and differential inches
• Choice of switch elements for all of water ranges
applications, including hermeti- - Epoxy coated carbon steel
cally sealed • ATEX models available(8)
• Wide choice of wetted materials, • IECEx models available(10)
including all-welded Monel or • CSA models available(8)
stainless steel
• FM models available(8)
• Fixed or limited adjustable
deadband • Setpoints adjustable from 15-100% LOOK FOR THIS AGENCY
MARK ON OUR PRODUCTS
of range
• UL listed ATEX model shown
• Dual Seal Rating models available(8)
• Various actuators available
• Belleville actuator(8)
1 - ENCLOSURE 3 - ACTUATOR SEAL(7) ATEX APPROVAL FOR HAZARDOUS LOCATIONS
ATEX is a European designation that deals with standards for
B7 - Pressure switch, type 700, explosion-proof Code Process Range
equipment and protective systems intended for use in poten-
enclosure meets Div.1 & 2, NEMA 7/9, IP66 & Temp.(6) Vac 0-600 1000 2000- tially explosive atmospheres. This approval is required for
requirements Material Limits in.H2O psi psi 3000 switches intended for use in hazardous locations, especially
°F psi important to OEMs who export to Europe and contractors
D7 - Differential pressure switch, type 700, specifying or purchasing products for European applications.
B-Buna N 0 to 150     XCN option adds special features to Ashcroft 700-Series
explosion-proof enclosure meets Div. 1 & 2,
V-Viton 20 to 300  switch enclosures that meet the requirements for the highest
NEMA 7/9, IP66 requirements   
levels of security and danger, such as:
T-Teflon 0 to 150     • Special locking device requiring an Allen wrench to remove
2 - SWITCH ELEMENTS S-SS(5)(10) 0 to 300   cover
Order Description/Maximum Electrical Ratings • Special vents that blow out should the diaphragm rupture,
P-Monel(5) 0 to 300  
Code UL/CSA Listed SPDT thus preventing pressure build-up in the enclosure
• Special conduit plug requiring an Allen wrench for removal
  20(4) Narrow deadband 15A, 125/250 Vac 4 - OPTIONS • Available on pressure, temperature and differential
  21(9) Ammonia service 5A, 125/250 Vac pressure models
(See pages 238-239) • Meets Explosion Class EEx d IIC T6
Hermetically sealed
  22(3) switch, narrow 5A, 125/250 Vac 5 - STANDARD PRESSURE RANGES
deadband
(See page 235)
23 Heavy duty ac 20A,125/250 Vac
15A,125/250/480 Vac NOTES:
24(1) General purpose 1/2A, 125 Vdc 1. Standard switch.
1/4A, 250 Vdc LOOK FOR THIS AGENCY
2. Dual switches are 2 SPDT snap-action switches not MARK ON OUR PRODUCTS
25 Heavy duty dc 10A,125/ Vac or dc
independently adjustable.
1/8HP 125/ Vac or dc
3. Estimated dc rating, 2.5A, 28 Vdc (not UL listed).
26(4) Sealed environment 15A, 125/250 Vac
proof
4. Estimated dc rating, .4A, 120 Vdc (not UL listed).
5. Available on pressure only.
27 High temp. 300°F 15A, 125/250 Vac
6. Ambient operating temperature limits –20 to 150°F,
31 Low level (gold) 1A,125/250 Vac
all styles. Setpoint shift of ±1% of range per 50°F
contacts
is normal. Switch calibrated at 70°F reference.
Hermetically sealed
32 switch, general 11A, 125/250 Vac
7. Items are wetted by process fluid.
purpose 5A, 30 Vdc 8. Refer to Option Table.
50 Variable deadband 15A,125/250 Vac 9. Order Option XUD, stainless steel process connection.
10. On differential switches, stainless steel is
UL/CSA Listed Dual SPDT(2)
available in 15, 30, 60 and 90 psid ranges only.
61(4) Dual narrow deadband 15A, 125/250 Vac
Includes Teflon O-ring and 316 SS connection.
62(4) Dual narrow environ- 15A, 125/250 Vac
ment proof
63 Dual high temp. 300°F 15A, 125/250 Vac
15A,125/250/480 Vac TO ORDER THIS B-SERIES PRESSURE SWITCH:
64 Dual general purpose 1/2A, 125 Vdc
1/4A, 250 Vdc Select: B7 20 B X06 600#
65 Dual ammonia service 5A,125/250/480 Vac 1. Enclosure:
Hermetically sealed
67(3) switch, narrow 5A, 125/250 Vac 2. Switch Element:
deadband 3. Actuator Seal:
Dual hermetically 4. Options (see pages 238-239):
68 sealed switch, 11A,125/250 Vac
general purpose 5A, 30 Vdc 5. Pressure Range (see page 235):
Consult factory for guidance in product selection

Phone (203) 378-8281 or visit our web site at
www.ashcroft.com
Installation and Maintenance Instructions for
B400 & B700 ASHCROFT® Snap Action
Switches for Pressure Control
Ø 0.28 X 3 HOLES
B400 (7)
4.03
Ø 0.28 X 3 HOLES 2.27 (102) 2.27
(7) (58) 0.22 (58)
0.22 4.03 (6)
(6) (102) 1.25
1.25
(32) (32)
0.25 0.25
(6) (6)
3.32 2.77 3.32 2.77
(84) 3.26 (70) (84) (70)
(83) 5.68 5.11
(144) (130)
5.95
(151)
2.84 2.50
1.25 (64)
(32) 3/4 NPT (72)
3/4 NPT
Ø 0.34
2 HOLES
0.36 Ø 2.31
(9) (59)
3.26
0.14 1.39 3.06 (83)
(4) (35) (78)
2.78 5.62
0.50 (71) (143)
(13) STANDARD RANGES 1.8 lb
3.50
(89) BRACKET WHEN 15, 30, 60, 100, 200, 400, 600 psi
1/4 NPT (.81 kg)
Ø 5.12 FEMALE REQURIED “XBP” 1000, 3000 psi
VARIATION
(130) 30˝Hg vac.-0
STANDARD RANGES 2.7 lb

10, 30, 60, 100, 150 ˝H2O
15˝H2O vac.-15˝H2O (1.2 kg)
B700
Ø 0.28 x 3 HOLES
(7) 5.20 3.58
3.58 (132) (91)
Ø 0.28 x 3 HOLES 5.20 (91)
(7) (132)
1.22
2.18 (31)
2.18 1.22 (31) (55) 0.03
(55) 0.03 (1)
(1)
0.32 0.32
(8) (8)
3.62 1.37
(92) (35) 3.62
(92) Ø 3.90
Ø 3.90
(99) (99)
5.73
6.43 (146)
163 0.31
1.93 0.31 (8) (8)
1.11 4.37 (49)
(111) 1.37
(28) (35)
3/4 NPT
2 HOLES 3/4 NPT 2 HOLES
Ø 0.34 X 2 HOLES
(9) 1.93
(49) 2.31
1.39 0.36 1/4 NPT FEMALE (59)
(35) (9)
0.36 4.37
(9) 3.06
0.50 2.78 (78) (111)
(13) 5.62
(71) (143)
3.50
(89) 1/4 NPT FEMALE BRACKET WHEN
REQUIRED "XBP" 2.7 lb
Ø 5.12 VARIATION
(130)
(1.2 kg)
3.6 lb
(1.6 kg)
INTRODUCTION available with various electrical characteristics. Two SPDT switch

The Ashcroft pressure switch is a precision built agency elements mounted together are available except on variable
approved control device which features a mechanical snap Deadband and manual reset types. Various wetted material con-
action switch. Controllers are available for operation on pressure structions for compatibility with a range of pressure media may
or vacuum with fixed or variable differential. Also manual reset be obtained.
types for operation on increasing or decreasing pressure. The The Ashcroft snap action pressure switch is furnished in the
manual reset types remain tripped until reset by pressing a but- standard NEMA 4 and explosion-proof NEMA 7 & 9 enclosure
ton on top of the enclosure. Standard electrical switch is SPDT, styles. Both enclosures are epoxy coated aluminum castings.
© 2007 Ashcroft Inc., 250 East Main Street, Stratford, CT 06614-5145, USA, Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M009-10008-10/00 (250-2246E) AMR 12/07

Installation and Maintenance Instructions for
B400 & B700 ASHCROFT® Snap Action
Switches for Pressure Control
INSTALLATION When hermetically sealed switch elements(s) are supplied, the

These controls are precision instruments and should never be lead color coding is as follows:
left with internal components exposed. During installation insure Common – White
that covers are in place and conduit openings are closed except Normally Closed – Red
when actually working on the control. Normally Open – Blue
MOUNTING B400 AND B700 SERIES B700 SERIES

Three holes external to the enclosure for surface mounting. SPDT – Wire directly to the switch according to circuit requirements.
Location of these holes is shown on the general dimension 2 SPDT – Wire to front switch terminal block (left) and rear
drawing. They may also be mounted directly on pressure line switch terminal block (right) as marked. Strip insulation 5⁄16˝,
using the pressure connection. When tightening control to pres- insert in proper terminal connector and tighten clamping screw
sure line, always use the wrench flats or hex on the lower housing. to secure.
ELECTRICAL CONNECTIONS ADJUSTMENT OF SETPOINT

Remove cover B400 & B700 Series – A single setpoint adjustment nut (7⁄8˝) is
B400 Series – two screws hold cover to enclosure located centrally at the bottom on the inside of the enclosure.
B700 Series – cover unscrews For accurate setpoint calibration, mount the switch on a cali-
bration stand, a pump or catalog No.1305 deadweight gauge
TERMINAL BLOCK tester. A suitable reference standard such as an Ashcroft
SWITCH A Duragauge or Test Gauge is necessary to observe convenient
3
2 TERMINAL BLOCK
changes in pressure.
As received, the pressure switch will normally be set to
1
SWITCH B
approximately 90% of the indicated range. Pressurize the
1
2 system to required setpoint and turn the adjustment nut until

C
3
switch changes mode. Direction of turning is indicated on a label

NO
affixed to the inside of the control enclosure. When setpoint has
NC
NC been achieved raise and lower pressure to insure that setpoint
NO
is correct.
C After installation of the control replace cover to insure electri-
cal safety and to protect internal parts from the environment.
CONDUIT CONNECTIONS
Note – It is recommended that Teflon tape or other sealant be B450 and B750 VARIABLE DEADBAND SWITCHES
used on conduit, bushing or plug threads to ensure integrity of Deadband is varied by rotating the wheel on the precision
the enclosure. switch. When viewed from the front of the enclosure, rotation to
the left increases deadband – rotation to the right decreases
B400 Series standard – one 3⁄4˝ NPT conduit hole right side. deadband. Letters on the wheel may be used as a reference.
B700 Series standard – two 3⁄4˝ N PT conduit holes with one Deadbands obtainable will vary from 0.5% to 9% of pressure
permanent plug. NEMA 7 & 9 enclosures require proper conduit range depending on range segment and type of diaphragm.
seals and breathers as per the National Electrical Code.
ADJUSTMENT OF SETPOINT
B400 & B700 Series – XJL variation – two 3⁄4˝ NPT conduit As received, the pressure switch will normally be set to approxi-
holes with two 3⁄4˝ to 1⁄2˝ NPT reducing bushings. mately 90% of range. Rotate the wheel on the MICRO SWITCH
B400 Series – XJK variation – two 3⁄4˝ NPT conduit holes. all the way to the right; this will provide smallest deadband.
Pressurize the system to the required setpoint and turn the
B400 SERIES adjustment nut until the switch changes mode. Lower the
SPDT – Wire directly to the switch according to circuit require- pressure to reset the switch. Rotate the wheel on the MICRO
ments. On controls with pilot lights wire lights according to circuit SWITCH until the desired deadband is obtained. The upper
diagram on inside of cover. See special wiring instruction tag for setpoint will be changing upward with this adjustment. Lower the
single switches with two pilot lights and dual switches with one pressure to reset the switch. Then increase the pressure to the
or more lights. desired setpoint and turn the adjusting nut until the switch
changes mode. Lower the pressure and check resetpoint and
2 SPDT – Dual switching elements consist of two SPDT switches deadband.
mounted together in a bracket. Switches are calibrated to have
simultaneous operation within 1% of range either on increasing Note – As indicated above, adjustment of setpoint is made by
or decreasing pressure but not in both directions. Wire directly to use of 7⁄8˝ nut. Precision switch element mounting screws
the front and rear switch according to circuit requirements. and bracket adjusting screw are factory sealed and
Leads are provided on rear switch color coded as follows: should not be tampered with.
Common – White Note – Since vacuum models are already above setpoint at
Normally Closed – Red atmosphere, the Normally Open (NO) circuit will be
Normally Open – Blue closed as received.
See SPDT instructions for pilot light hook-up.
© 2007 Ashcroft Inc., 250 East Main Street, Stratford, CT 06614-5145, USA, Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M009-10008-10/00 (250-2246E) AMR 1/07

4.7 Actuator
(TSV)

Bulletin OMI 0506
110 COMMERCE DRIVE

VALLEY COMMERCIAL CENTER
PELHAM, AL 35124
PHONE (205) 663-0533

FAX (205) 663-0703
OPERATION
And
MAINTENANCE INSTRUCTIONS
For
Models B, C & S
INTRODUCTION
General Application
Morin Actuators are designed for “on-off ” or modulating control of any quarter-turn ball, butterfly, rotary plug or damper style valve
application.
Technical Data
Supply pressure: 40-160 psig, See Product Nameplate.
Supply medium: Any pneumatic fluid compatible with materials of construction.
Temperature rating: Standard Range: -20°F to 210°F
Optional Range: -65°F to 300°F
Angular rotation: 90 degrees ± 8 degrees
Note: language translations of this document available on the internet at http://www.tycovalves-eu.com/

1. Installation
The actuator can be mounted parallel or perpendicular to pipeline. The actuator can be installed in any convenient position
including vertical, horizontal or upside down.
A. Bolt mounting bracket to actuator hand tight. DO NOT tighten yet.
B. Install coupling on valve. Be sure rotary stops on valve are removed or adjusted to allow actuator stops to do the
stopping.
C. Install actuator and bracket to valve being sure to leave all fastener connections hand tight. If possible, stroke valve and
actuator to a half open position 45° and physically shift actuator back and forth until coupling and all fasteners are
relaxed then tighten all bolts and nuts. This procedure will accurately align valve stem to actuator output shaft and
prolong valve stem seal life.
D. Cycle valve / actuator assembly and observe for smooth operation.
E. Adjust travel stops for perfect alignment in both open and closed positions.
Note: If jackscrew override is installed, please refer to section 2B for stroke adjustment.
F. Tubing Connections – some models utilize two pistons for added power. Spring return (single acting) dual cylinders
designs require one “jumper” to make the supply port common on both pistons. Double acting (air to air) dual cylinder
designs require two “jumpers.” See FIGURE 1 for typical arrangement.
2. Maintenance
Morin actuators are factory lubricated and in general do not require periodic lubrication or maintenance while in service.
Actuators should be visually inspected periodically for corrosion damage and promptly repaired. Actuators should be
operated at least annually to assure proper operation.
Models: B, C & S
SINGLE ACTING ACTUATOR DOUBLE ACTING ACTUATOR
TWO CYLINDERS WITH JUMPER TWO CYLINDERS WITH JUMPER
SUPPLY SUPPLY
SOLENOID SOLENOID
OR
EXHAUST OR
EXHAUST
POSITIONER POSITIONER
FIGURE 1
2. Jackscrew Override
The jackscrew option is intended for infrequent or emergency on-site operation of the automated valve.
Note: Jackscrew override is not available on HP actuators.
A. Jackscrew Operating Instructions:
1. Disengage power supply and vent air from actuator.
2. Operate the handwheel to drive the actuator into the desired position. Valve position can be verified by checking
the actuator position indicator. For models 006 through 270, the jackscrew must be returned to the fully retracted
position before actuator can resume normal operation. Back the jackscrew out until it stops. Air will leak from
the jackscrew unless it has been fully retracted against its internal seal.
B. Actuator Stroke Adjustment: (The jackscrew has a built-in actuator stroke adjustment.)
Models 006 through 270 (See FIGURE 2)
1. Retract the jackscrew override completely by rotating counter clockwise.
2. Loosen the lock nut and turn the brass adjusting screw to the desired position. The handwheel will rotate with the
adjusting screw. Never make stroke adjustments by turning the handwheel only.
3. Tighten lock nut.
Models 370, 740 & 575 (See FIGURE 3)
1. Retract the jackscrew override completely by rotating clockwise.
2. Loosen the stroke adjusting screw and lock nut.
3. Using the handwheel, turn the jackscrew to adjust the actuator to the desired position.
4. Screw the adjusting screw until it stops and tighten lock nut.
2
JACKSCREW OVERRIDE - MODELS 006 through 270
ACTUATOR STROKE
ADJUSTING SCREW
NOTE: AIR ESCAPES UNLESS

JACKSCREW IS FULLY
RETRACTED
STROKE ADJUSTING SCREW
JACKSCREW
LOCK NUT
SEAL
JACKSCREW SEAL
JACKSCREW JACKSCREW
FULLY RETRACTED EXTENDED
FIGURE 2
JACKSCREW OVERRIDE - MODELS 370, 575 & 740

HANDWHEEL
LOCK NUT LOCK NUT

SHUT
STROKE ADJUSTING SCREW STROKE ADJUSTING SCREW

OPEN
OPEN
SHUT
SEALED JACKSCREW ASSEMBLY
FIGURE 3
HYDRAULIC OVERRIDE
RESERVOIR
HANDLE
Manual hanpump specifications:

SELECTOR VALVE
1. Maximum reservoir fill volume = 75 cu. in.
2. Pump relief pressure = 1500 psi
3. Pump volume/stroke = 0.66 cu. in.
4. Handle length = 24 in.
FIGURE 4
3
4
Materials of Construction
S MATERIAL B MATERIAL C MATERIAL
ITEM 003-100 135-1150 006-100 135-1150 575 & 1150

1 Housing 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
2 Yoke 17-4 PH 17-4 PH 17-4 PH 17-4 PH 17-4 PH
3 Output shaft 17-4 SS 17-4 SS 4140 4140 4140
4 Piston rod 316 SS 316 SS CPO CPO CPO
5a Bushing - Output Shaft TEFLON - BRONZE - -
5b Needle Bearing - STEEL - STEEL STEEL
6a Yoke Pin 18-8 SS - STEEL - -
6b Key - Yoke - 17-4 PH - STEEL STEEL
7 Bushing - Piston Rod TEFLON TEFLON BRONZE BRONZE BRONZE
8 Retaining Ring - Output Shaft 15-7 MO 15-7 MO STEEL STEEL STEEL
9 Thrust Pin 440C SS 440C SS 440C SS 440C SS 440C SS
10 Roller Bearing 440C SS 440C SS 440C SS 440C SS 440C SS
11 Retaining Ring - Pin 15-7 MO 15-7 MO STEEL STEEL STEEL
12a Set Screw 18-8 SS - 18-8 SS - -
12b Retaing Ring - Lower Bearing - 18-8 SS - STEEL STEEL
13a Position Indicator 304 SS - 304 SS - -
13b Thrust Plate - 316 SS - DUCTILE IRON DUCTILE IRON
14 Hex Head Bolt 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
15 Lock Washer 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
16 Pointer SOFT PVC SOFT PVC SOFT PVC SOFT PVC SOFT PVC
17 Round Head Screw 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
18 Cover - Housing 316 SS 316 SS STEEL STEEL STEEL
19 Hex Head Bolt 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS
21 Pointer Washer 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
22 Thrust Washer - 18-8 SS - STEEL STEEL
23 Gasket - Cover FIBER FIBER FIBER FIBER FIBER
24 Cylinder 316 SS 316 SS 316 SS 316 SS CS, TFE
25 Piston 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
26 Adaptor 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
27 Endcap 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
28 Rod Cover 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
29 Seal - Piston Rod BUNA-N BUNA-N BUNA-N BUNA-N BUNA-N
30 Seal - Piston Bolt BUNA-N BUNA-N BUNA-N BUNA-N BUNA-N
31 Seal - Piston BUNA-N BUNA-N BUNA-N BUNA-N BUNA-N
32 Gasket - Housing FIBER FIBER FIBER FIBER FIBER
33 Piston Bolt 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
35 Bearing - Piston TEFLON TEFLON TEFLON TEFLON TEFLON
36 Thread Seal SS/EPDM SS/EPDM STEEL/EPDM STEEL/EPDM STEEL/EPDM
37 Travel Stop Bolt 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
38 Jam Nut 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
39 Socket Head Cap Screw 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
41 Tie Rod 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
42 Seal - Output Shaft - - BUNA-N - -
45 Stato-seal BUNA-N BUNA-N BUNA-N BUNA-N BUNA-N
46 Cylinder Gasket or O-ring TFE OR BUNA-N BUNA-N BUNA-N BUNA-N BUNA-N
47 Label - Nameplate MYLAR MYLAR MYLAR MYLAR MYLAR
48 Seal - Output Shaft Bushing - - BUNA-N - -
49 Cylinder - Spring Side 316 SS 316 SS 316 SS 316 SS CS, TFE
50 Tie Rod - Spring Side 316 SS 316 SS 316 SS STEEL STEEL
52 Travel Stop Bolt 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
53 Flat Washer 18-8 SS 18-8 SS 18-8 SS STEEL STEEL
54 Endcap - Spring Side 316 SS 316 SS DUCTILE IRON DUCTILE IRON DUCTILE IRON
55 Spring - Outer STEEL STEEL STEEL STEEL STEEL
56 Spring - Inner STEEL STEEL STEEL STEEL STEEL
57 Breather 18-8 SS 18-8 SS STEEL STEEL STEEL
58 Label - Spring LEXAN LEXAN LEXAN LEXAN LEXAN
5
Materials of Construction
S MATERIAL B MATERIAL C MATERIAL
ITEM 1480-2380 1480-2380 1480-2380

1 Housing 316 SS DUCTILE IRON DUCTILE IRON
2 Yoke 17-4 PH 17-4 PH 17-4 PH
4 Piston rod 316 SS CPO CPO

5 Bushing - Yoke BRONZE BRONZE BRONZE
7 Bushing - Piston Rod BRONZE BRONZE BRONZE
9 Thrust Pin 440C SS 440C SS 440C SS

10 Slide Block BRONZE BRONZE BRONZE
11 Retaining Ring - Pin 15-7 MO STEEL STEEL
12 Plug - Thrust Pin Access 18-8 SS STEEL STEEL
13 Accessory Drive NYLON NYLON NYLON
14 Drive Bar STEEL STEEL STEEL
15 Screw - Accessory Deive STEEL STEEL STEEL
16 Pointer SOFT PVC SOFT PVC SOFT PVC

17 Round Head Screw 18-8 SS 18-8 SS STEEL
18 Cover - Housing 316 SS STEEL STEEL
19 Hex Head Bolt- Cover 18-8 SS 18-8 SS STEEL
20 Lock Washer - Cover 18-8 SS 18-8 SS STEEL
21 Pointer Washer 18-8 SS 18-8 SS STEEL
22 Vent Valve Brass Brass Brass
24 Cylinder 316 SS 316 SS CS, ENP

25 Piston 316 SS DUCTILE IRON DUCTILE IRON
26 Adaptor 316 SS DUCTILE IRON DUCTILE IRON
27 Endcap 316 SS DUCTILE IRON DUCTILE IRON
28 Rod Cover 316 SS DUCTILE IRON DUCTILE IRON
29 Seal - Piston Rod BUNA-N BUNA-N BUNA-N
30 Seal - Piston Bolt BUNA-N BUNA-N BUNA-N
31 Seal - Piston BUNA-N BUNA-N BUNA-N
32 Gasket - Housing FIBER FIBER FIBER
33 Hex Head Bolt - Piston 18-8 SS STEEL STEEL
34 Lock Washer - Piston 18-8 SS STEEL STEEL
35 Bearing - Piston TEFLON TEFLON TEFLON
36 Thread Seal SS/EPDM STEEL/EPDM STEEL/EPDM
37 Travel Stop Bolt 18-8 SS STEEL STEEL
38 Jam Nut 18-8 SS STEEL STEEL
39 Socket Head Cap Screw 18-8 SS STEEL STEEL
41 Tie Rod 18-8 SS STEEL STEEL
42 Seal - Yoke BUNA-N BUNA-N BUNA-N
43 Lock Washer 18-8 SS STEEL STEEL
44 Hex Head Bolt 18-8 SS STEEL STEEL
45 Stato-seal BUNA-N BUNA-N BUNA-N
46 Cylinder O-ring BUNA-N BUNA-N BUNA-N
47 Label - Nameplate MYLAR MYLAR MYLAR
48 Seal - Output Shaft Bushing BUNA-N BUNA-N BUNA-N
49 Cylinder - Spring Side 316 SS 316 SS CS, ENP
50 Tie Rod - Spring Side 316 SS STEEL STEEL
51 Hex Head Bolt 18-8 SS STEEL STEEL
52 Travel Stop Bolt 18-8 SS STEEL STEEL
53 Flat Washer 18-8 SS STEEL STEEL
54 Endcap - Spring Side 316 SS DUCTILE IRON DUCTILE IRON
55 Spring - Outer STEEL STEEL STEEL
56 Spring - Inner STEEL STEEL STEEL
57 Breather 18-8 SS STEEL STEEL
58 Label - Spring LEXAN LEXAN LEXAN
6
3. Manual Handpump Override (see FIGURE 4)
A. Always vent the air supply to the cylinders before using the hydraulic override.
B. Maintain fluid level to fill line using ISO-22 hydraulic fluid. Use Chevron “Hydraulic Oil AW” or equal.
C. Open reservoir air vent when operating pump.
D. The selector control valve is set in center position for remote operation. Select left or right positions for manual open or
manual close as shown on pump label.
E. Store and lock handle to keep pump plunger closed. Do not remotely operate actuator with handle on plunger.
4. Proximity Switch Mounting

Morin actuators are available with drilled and tapped ports to accept any proximity switches with 5/8-18 UNF, 12-1mm and
18-1 mm threads. Mounting brackets are not required.
A. Remove plastic plugs from proximity ports located on the back of the actuator housing.
B. Insert switch and turn clockwise until switch touches ferrous activator on yoke, then back off approximately 1/16”.
C. Test switch by stroking actuator and verifying make and break of switch.
D. Repeat procedure for second switch if required.
5. Spring Conversion
Unless otherwise specified, all single acting actuators are shipped to distributor stock with an 80 PSI rated spring package.
The 80 PSI package consists of an inner and outer spring. Various spring packages are available upon request from the
factory.
CAUTION
Before attempting spring conversions always be sure that spring is in the “failed” or extended position. Remove any
accessory equipment that may cause the spring to be cocked (e.g.: declutchable override, jackscrew override, etc.).
A. Back off adjustable travel stop on end of actuator opposite spring end. This will allow maximum spring extension inside
the actuator.
(Models S-003 & B-006 only)
B. Remove tie rod bolts (41). Back off piston bolt (33) until spring is fully relaxed and piston (25) is free.
C. Remove 80 PSI spring package and replace with desired spring package.
D. Re-assemble piston, cylinder, endcap and tie rods, being sure to follow the tie rod tightening sequence (FIGURE 8). Do
not over tighten bolts. Refer to Assembly Torque Requirements Chart (FIGURE 9).
(All models except S-003 & B-006 only)
B. Alternately and uniformly remove bolts (51) from hollow tie rods. Back off each bolt approximately ¼”, following the
tie rod sequence (FIGURE 8). Repeat the sequence until spring(s) is/are totally relaxed and endcap is free.
C. Remove 80 PSI spring package and replace with desired spring package.
D. Re-assembly endcap with bolts (51). Use reverse procedure as shown in Step B, being sure to follow the tie rod
tightening sequence (FIGURE 8). Be sure each hollow tie rod slides into the counterbore in endcap. Do not over tighten
bolts. Refer to Assembly Torque Requirement Chart (FIGURE 9).
E. Remove nameplate from actuator and stamp or etch correct spring pressure rating accordingly.
6. Failure Mode Change
(Models 003-100 & 144)
Conversion from “fail close” to “fail open” is very simple and never requires actuator disassembly or special order. Simply
remove pointer and indicator plate and mount on opposite side of actuator.
(Models 135, 270-2380)
Requires disassembly to change failure mode and should be designated upon order entry.
7. Removal of Actuator from Valve
CAUTION
Do not attempt to remove mounting bolts between actuator and valve until supply pressure has been disconnected and vented.
If spring return, be sure that valve is completely in failed position. If valve is frozen in a position causing the spring to be
cocked, removal of bracket bolts would allow spring to stroke, resulting in the actuator rotating over bracket causing possible
injury or damage.
A. Loosen bracket to actuator bolts to hand tight position.
B. Physically shift actuator back and forth to be sure there is no strain (or shear stress) on the bracket bolts. Once it has
been determined that there is no pressure or spring coil remaining in the actuator, remove bolts and remove actuator and
coupling from valve.
C. In the event the valve is frozen or locked in place, resulting in spring energy remaining in the actuator, replace adjusting
screw (37) on end of actuator opposite spring end with length of “all thread” rod of sufficient length and turn clockwise
until it contacts the piston. This procedure will safely secure the piston and spring assembly and allow actuator removal.
Be sure to remove “all thread” rod prior to actuator disassembly.
7
FIGURE 5 FIGURE 6 FIGURE 7
8. Actuator Disassembly
A. Remove endcap(s) (27); tie rods (41) and cylinder (24). Remove rod cover (28) if applicable.
B. Remove piston bolts (33) and pistons (25).
C. Remove adaptor (26) and piston rod seals (29).
Note: S-003, B-006 & B-015 have one piece cast housing / adaptor.
D. Remove nameplate (18), pointer (16) and position indicator (13).
E. Disengage yoke (2) from roller bearing assembly by pulling piston rod to extreme right, as in FIGURE 5, and swing
yoke mechanism clear of roller bearing as in FIGURE 6.
F. Rotate piston rod 90° to allow access to retaining ring (11) as shown in FIGURE 7.
G. Remove retaining ring and bearing (10). Then rotate piston rod shaft 180° and remove remaining bearing and thrust pin
assembly.
H. Remove piston rod (4) and piston rod bushings (7).
(Models 003-100 & 144)
I. Remove plug (12) from back of housing.
J. Using a punch or suitable dowel pin, insert through clearance hole and press yoke pin (6) out.
K. Remove retaining ring (8) from output shaft. Remove output shaft and yoke.
L. Remove bushings (5) from housing.
(Models 135, 270-1150)
I. Remove retaining rings on both ends of output shaft.
J. Remove thrust plate and washers on top of actuator.
K. Using a soft hammer, drive output shaft out through top of housing.
L. Withdraw yoke from housing.
M. Remove both top and bottom bearings by striking the end of bearing with a blunt object.
(Models 1480-2380)
I. Remove the pointer (16) and accessory drive (13) from the actuator by removing the screw (14) from inside the yoke (2)
bore.
J. Remove all cover bolts (19). Three of these bolts occupy “jack bolts” holes and are threaded into the cover (18). Screw
three long cover bolts into these “jack bolt” holes and turn them sequentially ½ turn at a time to pry the cover off. See
figure 6A.
K. Remove the thrust pin access plug (12). (Figure 5A)
L. Push the yoke (2) using the piston rod (4) until the thrust pin(9) is centered over the thrust pin access hole (See Figure
5A). Remove the upper thrust pin retaining ring (11) from the thrust pin (9) (Figure 7A).
M. Push the thrust pin (9) and lower retaining ring (11) out through the thrust pin access hole allowing the slide blocks (10)
to fall free. Remove the slide blocks (10).
N. Remove the piston rod (4), piston rod bushings (7), yoke (2). Remove yoke bearings (5), and yoke seals (48) from the
housing (1) and cover (18). Remove the upper and lower vent valves (22) from the back of the housing.
8
9. Actuator Assembly
(Models 003-100 & 144)
A. Insert piston rod bushings (7) and output shaft bushings (5) in housing. (On models B-006 through 100 lube output shaft
bushings o-rings (48) with "Dow Corning #55" lubricant. Push one o-ring halfway on each bushing and install bushings
in housing.)
B. Place yoke (2) in position in housing. Lubricate with "WD40" or similar lubricant and install output shaft (3). (On
models B-006 through 100, lube output shaft o-rings (42) with "Dow Corning #55" lubricant. Install one o-ring on one
end of output shaft and insert through housing and yoke. Install second o-ring on opposite end of output shaft and push
output shaft back into housing.) Secure output shaft with retaining rings (8).
C. Lubricate and press yoke pin (6) into yoke and output shaft assembly from open side of housing. Be sure pin is pressed
flush in yoke to prevent interference with piston rod (4).
(Models 135, 270-1150)
A. Insert yoke key (6b) into output shaft (3).
B. Install yoke (2) in housing (1). Slide output shaft (3) through top of housing (1) into the yoke (2). Install lubricated
upper and lower bearings (5a).
C. Install lower thrust washer (22), thrust plate (13), upper thrust washer (22) and retaining ring (8). Install lower bearing
retaining ring (12b).
(Models 003-1150)
D. Lubricate with "WD40" and install piston rod (4) being careful not to scratch sealing surfaces when sliding through yoke
assembly.
E. Swing yoke clear toward left side of housing as shown in FIGURE 7.
F. Sub-assemble thrust pin (9) with one roller bearing (10) and one retaining ring (11). Pre-lubricate sub-assembly with
high temperature grease such as "Whitmore’s Omnitemp II".
G. Install roller bearing sub-assembly per FIGURE 7. Rotate piston rod 180° and assemble second roller bearing and
retaining ring. Place ample amount of high temperature grease on roller bearing and inside wear area of yoke.
H. Engage roller bearing in yoke assembly as shown in FIGURE 7, 6, & 5.
I. Install plug (12) in back of housing if applicable. Use "Loctite 222 Thread Locker".
(Models 1480-2380)
A. Install yoke seals (48) using o-ring lube and yoke bearings (5) using WD-40 into the cover (18) and housing (1).
B. Inspect the housing upper and lower vent passages and clear any blockage. Install new vent valves (22).
C. Lubricate the bearing surfaces of the yoke (2) with WD-40 and install the yoke (2) in the housing (1). Install the yoke
with the marking and the pointer drive bar visible through the cover hole.
D. Install the piston rod bushings (7) and the piston rod (4).
E. Install the lower retaining ring (11) on the thrust pin (9) and lubricate the pin with Whitmore grease. Lubricate the slide
blocks (10) with Whitmore grease inside and out and position them in the yoke (2) slots. Insert the thrust pin (9) through
the thrust pin access hole (Figure 6A) and slide it through the lower slide block (10), piston rod (4), and upper slide
block (10). Install the upper retaining ring (11) on the thrust pin (9).
F. Place joint compound on the sealing surface of the cover (18), install the cover on the housing (1), and torque the cover
bolts (19) to 30 ft-lb. Install the short cover bolts (19) into the jack bolt holes of the cover (18).
(Cylinder and Rod Cover Assembly-All Models)
J. Assemble bolt (33) on end of piston rod before installing rod cover when rod cover is required.
K. Install rod cover (28) if applicable. Actuators utilizing one piston only require a rod cover. Bolt rod cover and gasket in
place with socket head screws (39). Use “Locktite 222 Thread Locker.”
L. Assemble piston rod o-ring (29) on piston rod. Lubricate o-ring with "Dow Corning #55"
lubricant.
9
M. Assemble adaptor (26) to housing. A gasket (32) must be used between adaptor and housing. If actuator is spring return
model be sure to insert long tie rod bolts (51) with washer into adaptor prior to bolting adaptor to housing. Insert hex
head bolts (44) with stato-seals (45). Use “Locktite 262 Permanent Thread Locker”. Uniformly tighten bolts. Refer to
Assembly Torque Requirement (FIGURE 9) for proper bolt torque.
(Models S-003, B-006 & B-015 only)
N. Lubricate piston bolt o-ring (30) with "Dow Corning #55" lubricant and put on piston rod. Assemble piston (25) to
piston rod with bolt (33) and lock washer (34). Use "Locktite 262 Permanent Thread Locker"on bolt threads. Rotate
piston before tightening piston bolt to ensure proper seating of o-ring.
O. Install cylinder gasket or lubricated o-ring (46) in adaptor groove.
P. Lubricate piston seal (31) with "Dow Corning #55" lubricant and install on piston.
Q. Lubricate piston bearing (35) and cylinder (24) with "Dow Corning #55" lubricant. Hold piston bearing (35) in place on
piston (25) and slide cylinder (24) over piston and bearing until cylinder is in contact with gasket / o-ring (46) in adaptor
groove. On spring return models substitute one cylinder (24) with cylinder (49) on spring side.
R. Assemble tie rods (41) on adaptor.
S. Insert cylinder gasket / o-ring (46) in endcap (27) groove and place endcap over tie rods (41) and on cylinder (24).
T. Assemble lock washers (43) and hex nuts (HP Models) on tie rods and uniformly tighten. Do not exceed torque values
shown in Assembly Torque Requirement Table (FIGURE 9).
SPRING RETURN ONLY
(Models S-003 & B-006 only)
U. Place cylinder gasket / o-ring (46) in endcap (54).
V. Place springs in adaptor, being sure to nest in contours. Mount piston (25) over springs and fasten with piston bolt (33)
and lock washer (34). Do not over tighten bolts. Refer to Assembly Torque Requirement (FIGURE 9).
All Models (except S-003 & B-006)
U. On spring return models; hollow tie rods (50) must be screwed onto long bolts (51) protruding from adaptor (26).
V. Place cylinder gasket / o-ring (46) in endcap (54). Insert long bolts (51) with flat washer (53) in endcap.
W. Place spring(s) in cylinder, being sure to nest in piston contours. Mount endcap over extended spring(s) and fasten to
hollow tie rods (50) with bolts (51). To prevent galling, lubricate bolts (51) with "Whitmore’s Omnitemp II" grease or
equal. Alternately and uniformly tighten bolts (51) in hollow tie rods. Tighten each bolt approximately ¼” – ½”
following the sequence shown in Tie Rod Tightening Sequence (FIGURE 8) until spring is completely compressed. Be
sure that each hollow tie rod slides into the counterbore in the endcap. Do not over tighten bolts. Refer to Assembly
Torque Requirements Table (FIGURE 9).
All Models
X. Install position indicator (13) and pointer (16), where applicable. Assemble adjusting screws (37), thread seals (36) and
jam nuts (38). Lubricate the rubber face of the thread seal with Dow Corning #55 lubricant and install finger tight
against the endcap. Tighten the seal approximately one turn so that the rubber begins to bulge beyond the metal portion
of the seal.
Y. Stoke actuator with rated supply air and check for leaks. The thread seal may be tightened up to one additional turn if
there is any leakage at the adjusting bolt.
10. Operating instructions:
Operate the actuator in accordance with the pressure and temperature limits specified on the
nameplate. See the appropriate Morin Catalog for technical information.
10
IMPORTANT SAFEGUARDS
Caution: To reduce the risk of injury:
• Read the entire Operation and maintenance Instruction manual before installing,
operating, or servicing this actuator.
• Inspect the actuator regularly for signs of corrosion and repair immediately.
• Always remove pressure and disconnect power supply before servicing the actuator.
• Keep hands and feet clear of an actuator that is in service.
• Do not disassemble the actuator without reviewing the disassembly procedure in this
manual first. This is particularly important that the proper procedure be followed to avoid
injury from internal spring power.
• Before attempting to remove an actuator from the equipment it is assembled to, always be
sure that spring is in the “failed” or extended position. Remove any accessory equipment
that may cause the spring to be cocked. If there is any doubt that the actuator is in the
“failed” position, remove the air pressure from the actuator and install a long threaded bolt
(a bolt that exceeds the length of the cylinder) in place of both travel stops. Once the
actuator has been removed from the equipment the long bolts must be removed first before
the actuator can be disassembled.
• Repair or replace a damaged actuator immediately.
• Inspect the vent valves on models 1480 – 2380 during regular maintenance periods. The
valves should allow leaking fluids to escape but prevent contaminates from the surrounding
atmosphere from entering the actuator. Fluid leaking from the lower valve indicates a valve
stem seal leak. Fluid leaking from the upper valve indicates a leaking cylinder seal. If
leakage is observed from either valve disassemble and repair the source immediately.
Never replace the vent valves with plugs.
• Operate the actuators within the pressure and temperature ranges specified on the
nameplate. Otherwise the actuator life may be reduced or serious safety hazards may
develop.
Additional Safety Instructions for Actuators used in a Potentially Explosive

Atmosphere under ATEX 94/9/EC
Marking
• ATEX 94/9/EC , Group II , category (2), G
Selection
• Ensure that the equipment is marked with the correct equipment group, category and type of
atmosphere for the application and that the safety instructions are followed for each item of the
equipment.
• In particular, all items included in an actuator package, including valve, actuator and all
accessories should be CE marked to ATEX in the appropriate and / or requested category.
Installation
• The installer must only use tooling appropriate to the working area, see EN 1127-1 Annex A.
• Installation must be carried out at ambient temperature.
• During installation ensure that no metallic shocks / impacts are made to the equipment or the
adjacent piping.
• Ensure that the equipment is suitably earthed (grounded) through the pipe or individually.
• The installer should thoroughly follow the operating and safety instructions provided for each
individual item of equipment.
11
• When the valve is to handle hot fluids or fluids where exothermic reactions may take place,
the end user must take al the necessary measures to ensure that the hot surface of the valve
cannot provide a source of ignition to the surrounding gas, vapour, mist or dust atmosphere.
• Before putting into use or during operation with a dangerous fluid, ensure that no release of
the fluid to atmosphere can take place.
Maintenance
• The operator must ensure that only personnel qualified to work in a potentially hazardous area are
allowed to carry out maintenance appropriate to the category of the equipment in use.
• The end user must ensure that only tooling appropriate to the working area is used, see EN 1127-
1 Annex A.
• All equipment must only be fitted with manufacturer’s original spare parts.
Additional Safety Instructions for Actuators used in Emergency Shut-down

Service or IEC 61508 (SIL) Compliant Installations
1. Actuators should be inspected for proper functioning and signs of deterioration every
100,000 cycles or annually (whichever comes first) under normal operating conditions.
Inspect more frequently under severe operating conditions Defects should be repaired
promptly.
2. Normal operating conditions are: Air Quality within ISA-SP7.3S standards; operating
temperature and pressures consistent with the actuator nameplate and catalog limits;
environment free from excessive particulates; operating environment consistent with the
actuator materials of construction. Under these conditions, actuator life can exceed a
million cycles.
3. The recommended minimum operating interval is six months and a partial stroke is
acceptable to confirm that the installation is functioning.
4. When an actuator has been repaired or any maintenance is performed, check the
actuator for proper function (proof testing). Any failures affecting functional safety
should be reported to the Pelham facility.
5. IEC 61508 (SIL) installations should consult the Morin factory to obtain the assessment
and FMEDA report, which include failure data, PFDAVG, and other associated statistical
data to establish or satisfy SIL level or requirements. This information is available in
report MOR 05-10-19 R001 V1 R2 FMEDA B-series actuators.
6. Proof testing of the actuator shall be performed on the interval determined per IEC
61508 / IEC 61511 requirements. A suggested proof test is included in report MOR 05-
10-19 R001 V1 R2 FMEDA B-series actuators. No special tools are needed. The report
includes the achieved proof test coverage.
12
4.8 Solenoid Valve
(SOV)

Installation & Maintenance Instructions SERIES
4-WAY DIRECT-ACTING SOLENOID VALVES
BRASS AND STAINLESS STEEL CONSTRUCTION
8342
1/4I AND 3/8I NPT - 3/16I ORIFICE
Form No. V6319R3
Manual Operation
NOTICE: See separate solenoid installation and maintenance Manual operator allows manual operation when desired or
instructions for information on: Wiring, Solenoid during an electrical power outage. Depending upon valve
Temperature, Causes of Improper Operation, Coil or Solenoid requirements, two types of manual operators are available:
Replacement.
Momentary Push Type (Suffix MO) Manual Operator
To engage push type manual operator, push stem at base of
DESCRIPTION valve body upward as far as possible. Valve will now be in the
Series 8342 valves are 4-way direct-acting solenoid valves same position as when the solenoid is energized. To disengage
manual operator, release stem. Manual operator will return to
that require no minimum operating pressure and no minimum
original position.
flow for operation. Valves are made of rugged brass or stainless
steel and have a sliding resilient seal for tight seating. Standard Maintained Screw Type (Suffix MS) Manual Operator
valves have a general purpose solenoid enclosure. Valves may To engage screw type manual operator, push red knob upward
be provided with a combination explosionproof/watertight towards valve body and turn it clockwise until flow from port is
solenoid enclosure. stopped. Valve will now be in the same position as when
Series 8342 valves with Suffix P in the catalog number are solenoid is energized.
designed specifically for dry inert gas or non-lubricated air
service. CAUTION: If manual operator is not turned clockwise
after pushing upward to engage, leakage at exhaust port
OPERATION may occur.
Solenoid de-energized: Flow is from Pressure P to Cylinder A To disengage manual operator and return valve to the
and from Cylinder B to Exhaust E. de-energized position, turn red knob counterclockwise
Solenoid energized: Flow is from Pressure P to Cylinder B and allowing stem to disengage and drop.
from Cylinder A to Exhaust E.
CAUTION: For valve to operate electrically, manual
NOTE: No minimum operating pressure required. operator must be fully disengaged.
Flow Diagrams INSTALLATION
Solenoid De-energized Solenoid Energized Check nameplate for correct catalog number, pressure,
voltage, frequency and service. Never apply incompatible
fluids or exceed pressure rating of the valve. Installation and
valve maintenance to be performed by qualified personnel.
SOL. SOL.
P P
PRESS. PRESS. Future Service Considerations
A A Provision should be made for performing seat leakage, external
EXH. B leakage, and operational tests on the valve with a
EXH. B
E E nonhazardous, noncombustible fluid after disassembly and
reassembly.
NOTE: For 3-way application, one cylinder port can be Temperature Limitations
plugged. Plug Cylinder A for normally closed operation or
For maximum valve ambient and fluid temperatures, refer to
Cylinder B for normally open operation. chart below. Check catalog number prefix and watt rating on
IMPORTANT: Flow controls or regulators may be placed at nameplate.
any of the port connection without adversely affecting valve
operation. Catalog Max. Max.
Watt Coil
Number Ambient Fluid
Metering Device (Optional feature) Rating Class
Prefix Temp. Temp.
Valves with suffix M in the catalog number are provided with a None, DP 77_F
built-in metering device (flow control) for each cylinder F
or KP (25_C) 160_F
160 F
connection. To adjust metering device, release locknut by 20
125_F (71_C)
turning it counterclockwise. To increase flow, turn metering HB or KB H
(51.7_C)
stem clockwise. To reduce flow, turn metering stem
counterclockwise. After adjusting to desired flow, hold None, KP, 125_F
F
SP or SD (51.7_C) 160_F
160 F
metering stem and tighten locknut. The metering stem closest 20 1
20.1
to the solenoid controls Cylinder A; the adjacent metering stem HB, KB, 140_F (71_C)
H
controls Cylinder B. SS or SV (60_C)
e MM All Rights Reserved. Printed in U.S.A. Page 1 of 4
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Positioning S Depending on the medium and service conditions, periodic
This valve is designed to perform properly when mounted in inspection of internal valve parts for damage or excessive
any position. However, for optimum life and performance, the wear is recommended. Thoroughly clean all parts. If parts
solenoid should be mounted vertically and upright to reduce are worn or damaged, install a complete ASCO Rebuild Kit.
the possibility of foreign matter accumulating in the solenoid Causes of Improper Operation
base sub-assembly area.
S Incorrect Pressure: Check valve pressure. Pressure to valve
Mounting must be within range specified on nameplate.
For body boss mounting dimensions, see Figure 1. below. S Excessive Leakage: Disassemble valve and clean all parts. If
parts are worn or damaged, install a complete ASCO
.250-20 UNC-2B Rebuild Kit.
.25 [6] deep Valve Disassembly (Refer to Figure 4)
2 mounting holes 1. Remove piping from Cylinders A and B and disassemble
[24] valve in an orderly fashion. Use exploded views provided
.94 for identification and placement of parts.
2. Remove solenoid enclosure. See separate instructions.
3. Unscrew solenoid base sub-assembly and remove core
[14] spring guide and core spring.
.56 4. Remove end cap screws (4), end cap and end cap gasket
from valve body.
5. Pull sleeve/disc/spring assembly containing disc
Figure 1. Mounting dimensions
assemblies, disc spring and sleeve from valve body. Then
remove sleeve spring, core and bonnet gasket.
Piping
Note: On suffix P valve constructions, the core contains
Connect piping to valve according to markings on valve body.
Apply pipe compound sparingly to male pipe threads only. If three rider rings.
applied to valve threads, the compound may enter the valve and 6. If cleaning is all that is required, do not remove body seat
cause operational difficulty. Avoid pipe strain by properly (exhaust), body seat gasket, end cap seat (cylinder), end
supporting and aligning piping. When tightening the pipe, do cap seat gasket, or orifice gaskets. Remove these only if
not use valve or solenoid as a lever. Locate wrenches applied replacement seats and gaskets are available.
to valve body or piping as close as possible to connection point. 7. To remove body seat (exhaust) and seat gasket, insert an
appropriate tool or a heavy gauge wire with a bent hook
CAUTION: To protect the solenoid valve install a on the end through the center hole in the seat. Pull to
strainer or filter suitable for the service involved in the dislodge seat. If seat will not dislodge easily, remove
inlet side as close to the valve as possible. Clean piping from exhaust port and push seat out with a thin rod
periodically depending on service conditions. See through the exhaust port.
ASCO Series 8600, 8601 and 8602 for strainers. To remove end cap seat (cylinder) and gaskets, push seat
from end cap, using thin blunt rod inserted through hole
MAINTENANCE between Cylinder Port A and Cylinder Port B. When the
end cap contains metering devices, apply compressed air
WARNING: To prevent the possibility of through either pipe connection or the small vent hole in
the end cap to force out the end cap seat with the gasket.
death, serious injury or property damage, turn off If this fails, use the appropriate tool or bent wire described
electrical power, depressurize valve, and vent above to dislodge the end cap seat with the gasket.
fluid to a safe area before servicing the valve. 8. All parts are now accessible for cleaning or replacement.
Note: For inspecting, cleaning or rebuilding, remove piping If parts are worn or damaged, install a complete ASCO
from Cylinder Ports A and B. Rebuild Kit.
Cleaning Valve Reassembly

All solenoid valves should be cleaned periodically. The time 1. Lubricate all gaskets with DOW CORNINGr 111
between cleaning will vary depending on the medium and Compound lubricant or an equivalent high-grade
service conditions. In general, if the voltage to the coil is silicone grease. Lubricate seating surface of end cap seat,
correct, sluggish valve operation, excessive noise or leakage will body seat and disc assemblies (including u-cups) with
indicate that cleaning is required. In the extreme case, faulty Dow Corning Corporation's MOLYKOTEr M-77 Paste
valve operation will occur and the valve may fail to shift. Clean lubricant supplied in ASCO Rebuild Kit. Note: On suffix
strainer or filter when cleaning the valve. P valve constructions, lubricate core spring with lubricant
supplied.
Preventive Maintenance 2. Replace body seat gasket on body seat and install seat with
S Keep the medium flowing through the valve as free from dirt gasket side first into valve body.
and foreign material as possible. 3. Preassemble disc assembly on disc spring and install into
sleeve. Install remaining disc assembly from the opposite
S While in service, the valve should be operated at least once
end. The disc assemblies will snap onto the disc spring if
a month to insure proper shifting.
pushed evenly and twisted slightly.
Page 2 of 4 Form No.V6319R3

4. Install sleeve/disc/spring assembly into the valve body and Manual Operator (Optional feature)
onto core simultaneously. No field maintenance need be performed on the manual
5. Install end cap assembly consisting of end cap, end cap operator. However, it may be removed and replaced for
gasket, end cap seat, seat gasket and orifice gaskets (2). general cleaning or inspection (Refer to Figure 3).
Install end cap screws (4) and torque in a crisscross
manner to 110 ± 10 in-lbs [12,4 ± 1,1 Nm]. ORDERING INFORMATION
6. Move the core up and down to see that it is properly FOR ASCO REBUILD KITS
engaged and there is no misalignment or binding of parts.
7. Replace bonnet gasket, sleeve spring, core spring and Parts marked with an asterisk (*) in the exploded view are
core spring guide. supplied in Rebuild Kits. When Ordering Rebuild Kits for
8. Replace solenoid base sub-assembly and torque to ASCO valves, order the Rebuild Kit number stamped on the
175 ± 25 in-lbs [19,8 ± 2,8 Nm]. valve nameplate. If the number of the kit is not visible, order
9. Install solenoid. See separate instructions. by indicating the number of kits required, and the Catalog
Number and Serial Number of the valve(s) for which they are
WARNING: To prevent the possibility of death, intended.
serious injury or property damage, check valve for
proper operation before returning to service. Also metering end cap
perform internal seat and external leakage tests with Indicates Parts Supplied
a nonhazardous, noncombustible fluid. in ASCO Rebuild Kits
10. Restore line pressure and electrical power supply to valve.
11. After maintenance is completed, operate the valve a few metering stem
times to be sure of proper operation. A metallic click
indicates the solenoid is operating.
Metering Device Disassembly (Refer to Figure 2) metering disc
1. Loosen and remove locknut.
2. Unscrew metering cap with gasket and remove disc spring
stem/disc/spring assembly intact. A special wrench is
available for metering cap removal or installation. Order
ASCO Wrench Kit No. K158477-001.
metering cap locknut
gasket
3. Unscrew metering stem from cap and remove disc spring,
metering disc and metering stem gasket.
4. If cleaning is all that is required, do not remove end cap metering stem gasket
seat with gaskets. Remove these only if replacement seat
and gaskets are available. If replacement is necessary, use
an appropriate tool or compressed air as previously metering cap
described in Valve Disassembly to dislodge end cap seat.
5. All parts are now accessible for cleaning or replacement.
If parts are worn or damaged, install a complete ASCO
Special wrench available for metering cap.
Rebuild Kit. Wrench Kit Order No. K158477-001
Metering Device Reassembly
1. Reassemble in reverse order of disassembly. Use Figure 2. Metering device (optional)
exploded views provided for identification and placement
of parts.
2. Lubricate metering cap and stem gaskets with DOW
Screw type shown
CORNINGr 111 Compound lubricant or an equivalent
high-grade silicone grease.
3. Replace metering stem gasket, metering disc and disc Partial view of Indicates Parts Supplied
spring on metering stem. valve body in ASCO Rebuild Kits
CAUTION: Metering disc must be assembled as
indicated in Figure 2.
4. Install cap on stem/disc/spring assembly.
5. Install stem/disc/spring assembly intact then torque manual operator
metering cap to 110 ± 10 in-lbs [12,4 ± 1,1 Nm]. gasket
6. Replace locknut (loosely) and make adjustments as
follows: To Increase Flow: Turn metering stem clockwise.
manual operator
To Reduce Flow: Turn metering stem counterclockwise.
assembly
7. After adjusting to desired flow, hold metering stem and
tighten locknut.
Figure 3. Manual operator (optional)
Form No.V6319R3 Page 3 of 4

Torque Chart
Part Name Torque Value Inch-Pounds Torque Value Newton-Meters
Solenoid base sub-assembly 175 ± 25 19,8 ± 2,8
End cap screws & Metering cap 110 ± 10 12,4 ± 1,1
Manual operator assembly 150 ± 10 17 ± 1,1
solenoid base
sub-assembly
core spring
guide
Suffix P" core spring

Construction
Indicates Parts Supplied
In ASCO Rebuild Kits
core
core sleeve spring

with rider rings
bonnet gasket
body seat gasket

body seat (exhaust)
sleeve/disc/spring assembly
end cap seat gasket
end cap seat (cylinder)
orifice gaskets
end cap gasket
disc assembly
sleeve
disc spring
disc assembly
end cap screw (4)
end cap
Figure 4. Series 8342 valve without solenoid.
Page 4 of 4 Form No.V6319R3

4.9 Position Switch
(ZS)

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(;3

Installation & Operating Instructions
AccuTrak Rotary
1000/2000/3000/4000/5000/9000 Product Families
With Mechanical Switches, Inductive Proximity Sensors, MAGNUM or MagPAC Proximity Switches.
7[MXGL%HNYWXQIRX
1. With the valve in the closed position, lift the bottom cam
and turn until the switch has activated and then release.
The spring will push the cam back onto the splined shaft.
Stroke the actuator to the open position and push down
on the top cam and turn until the switch has activated and
then release.
2. Operate actuator from one end of stroke to the other
several times to check switch operation.
3. Replace the enclosure cover ensuring that the position
of the valve has been noted, either fully open or fully
closed.
4. Operate actuator from one end of stroke to the other
several times to check switch operation.
280 Midland Ave., Saddle Brook, NJ 07663

Tech-385_r0.0 Phone: (201) 794-7650 Fax: (201) 794-0913 E-mail: info@westlockcontrols.com www.westlockcontrols.com
D.W.O. 17072 2

Installation & Operating Instructions
AccuTrak Rotary
1000/2000/3000/4000/5000/9000 Product Families
With Mechanical Switches, Inductive Proximity Sensors, MAGNUM or MagPAC Proximity Switches.
7[MXGL7IRWSV)PIGXVMGEP6EXMRKW
V3 SPDT mechanical switches and Magnum XT-
90 proximity switches are considered as simple
apparatus and can be replaced by inductive
proximity sensors.
Mechanical V3 SPDT Switch
15A @ 250VAC; 15A @ 125VAC; 0.5A @ 125VDC;
0.25A @ 250VDC or 6A @ 24VDC
Mechanical DPDT Switch
10A @ 250VAC; 10A @ 125VAC or 10A @ 28VDC
Mechanical V3 Gold Plated SPDT Switch
100mA (resistive) @ 12VDC or 100mA (resistive) @
24VDC
Magnum XT-90 Proximity Switch
Tungsten: 3A @ 120VAC; 1.5A @ 240VAC or 2A @
24VDC
Rhodium: 0.295A @ 120VAC; 0.15A @ 240VAC or 1A @
24/VDC
MagPAC Proximity Sensor Pack
750mA @ 12-120VAC/VDC
(min. 2mA required to light LEDs)
7TIGMEP'SRHMXMSRWJSV7EJI9WI
1. All installations to be made in accordance with the NEC
in the US and the CEC in Canada.
2. When installing the AccuTrak Position Monitor ensure
that best engineering/installation practices are followed.
280 Midland Ave., Saddle Brook, NJ 07663

Tech-385_r0.0 Phone: (201) 794-7650 Fax: (201) 794-0913 E-mail: info@westlockcontrols.com www.westlockcontrols.com
D.W.O. 17072 3

4.10 Relief Valve
(PSV)

Pressure Relief Valves
Installation and Operating Instructions
Pre-Installation Handling
Verification of Model and Service This pressure relief valve is designed to protect equipment from overpressure. The valve should be
Media/Capacity/Temperature/Pressure handled with care, not subjected to heavy shock loads, and protected to prevent contamination
Limits from getting inside. It should be installed correctly per A.S.M.E. Boiler & Pressure Vessel Code
(Reference attached Model requirements, where applicable. Failure to do so could result in property damage or serious injury
Description/Guide.) Verify the Model Number to personnel. When hoisting the valve into position for installation, care should be exercised so
on the tag against the Model Number of the that lifting straps do not contact the valve lift lever.
order. For European service, verify the "CE
Mark" tag is connected to the valve. Verify the Installation
Service Media, Capacity, and Temperature
Always wear proper safety equipment, including safety glasses and ear protection.
and Pressure Limits of the valve against the
1. Mount the valve in a vertical position so that the valve body is self-draining. If a body drain port
application. Please note the marked capacity
is provided, make sure it is open when required by the ASME code. Do not plug any bonnet
is based on Standard Temperature and
vent openings. The inlet piping should be as short as possible, with no elbows, and equal to or
Pressure conditions and is valid only for the
greater than the size of the pressure relief valve inlet connection. This will help to limit the inlet
service media noted on the catalog order
pressure drop to 3% or less when the valve is relieving.
guide. Adjustments to the capacity must be
2. When discharge piping is connected to valve outlet, make sure it is self-draining if a body drain
performed for different temperatures or
port is not used. The valve should not be connected to any discharge pipe that contains
service media, and are the responsibility of
pressure before the valve opens or to any pipe where the pressure build-up is greater than
the end user to determine.
10% of the set pressure when the valve is open and relieving.
Discharge piping, other than a short tailpipe, must be supported. For steam service, a drip pan
elbow or flexible connection between the valve and the pipe should be used to prevent
excessive pipe stress, due to thermal expansion, from being imposed on the valve body.
3. For threaded valves, to prevent sealing compound from entering and damaging the valve,
apply a small amount of pipe thread sealing compound to external threads only. Do not put
any sealing compound on the first thread or on any internal threads. To do so may cause the
sealing compound to enter the valve and cause seat leakage.
Do not use the valve body or bonnet for installing the valve in threaded connections. Use the
wrench flats provided to tighten the valve to the connecting pipe. Torque valve enough to
ensure a pressure-tight seal and do not overtighten. To do so may cause valve leakage.
4. For flanged valves, use new gaskets and tighten the mounting studs evenly.
5. Do not paint, lubricate or allow contaminates to enter or cover the interior or any working parts
of the valve.
6. Remove gag screw (if valve is so equipped) before system start up.
Operation
1. Maintain a system operating pressure at least 5 psig or 10% below the set pressure of the
valve, whichever is greater. Operating too close to the valve set pressure will cause seat
leakage and will shorten the time between valve maintenance.
2. Do not use the safety valve as a control valve to regulate system operating pressure. Excessive
operation will cause the seat to leak and will require more frequent valve maintenance.
3. ASME Section I and VIII valves equipped with lift levers are designed to be operated only when
the system pressure is 75% of set pressure or greater. ASME Section IV valves may be
operated at any set pressure. When hand operating the valve, hold it open long enough to
purge any foreign matter from the seat area. If a cable or wire is attached to the lift lever for
remote actuation, make sure the direction of pull is the same as it would be if the lever were
pulled directly by hand.
Maintenance
Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is
recommended. Depending on the service conditions and the condition of the valve, the
inspection interval may be decreased or increased. Use only Kunkle parts for repair. Depending on
the local jurisdictional requirements where the valve is installed, repairs may have to be made by a
repair facility holding a VR stamp.
Kunkle Valve Division

953 Old US 70, Black Mountain, NC 28711 WARNING!
Removal of the seal wires or any attempt to adjust, repair or modify this product by non-VR
Certified personnel voids the product guarantee and may cause serious damage to equipment,
personal injury, and death. Kunkle Valve is not liable for any damage resulting from misuse or
misapplication of its products.
www.kunklevalve.com We reserve the rights to change the contents without notice KUKMC-6302-EN-0705
Homepage Rev E 05/24/2007
Previous Document
4.11 Pressure Diff Indicator
(PDI)

BULLETIN NO. IM140-141/02
Mid-West
(Supersedes BULLETIN NO. IM140/01)
®
Instrument
Model 140/141 Series

Installation and Operating Instructions
INSPECTION magnet attached to an indicating pointer. The

rotation of the follower magnet causes the
Before installation check the nameplate on
pointer to track movement of internal magnet
each instrument against the receiving
and indicate the differential on the dial scale.
paperwork and the intended application for
correct part number, materials of construction, When equipped with switches, a contact is
working pressure, dial range, etc. If equipped made, or broken, by the magnetic field of the
with switches, check electrical rating, type of internal magnets.
enclosure, etc. Inspect for shipping damage
The diaphragm is totally supported upon
and, if damaged, report it immediately.
reaching full travel in either direction, providing
NOTE - Before attempting repairs contact full over-range protection to the rated working
your local Mid-West Representative pressure of the housing.
or our factory. Failure to do so will
INSTALLATION
void any warranty.
Model 140/141 “Series” is calibrated and tested
PRODUCT DESCRIPTION
prior to shipment and is ready for immediate
The Model 140/141 “Series” is a medium range installation. Use of the following installation
differential pressure instrument available as a procedures should eliminate potential damage
switch, a gauge, or both. See “Part Numbering and provide optimum trouble-free operation.
System”, (Fig. 6) for available options.
A flexible elastomer diaphragm and calibrated 1. CONNECTIONS
range spring are moved by differential 1/4" FNPT is provided as standard but check
pressure. A pair of magnets, coupled with the paperwork for connections ordered. There are
diaphragm, transmit this motion through the two connections on the housing identified as
wall of the pressure housing to a follower “hi” and “lo” for high pressure and low pressure.

Be sure these get plumbed to the proper mounting studs, finger tight, into the metal
connections on your system. Improper inserts located in the rear of the bezel. Insert
connection will not damage the instrument, but the gauge through the panel aligning the panel
it will not function properly. mounting studs with the holes in the panel.
Install the four (4) #8-32 nuts onto the studs
Flexible tubing is recommended to minimize
and tighten securely.
effect of any vibration that may exist.
4. PIPE MOUNTING
An optional pipe mounting kit is available for
2. INSTRUMENT LOCATION
mounting the gauge to a 2" vertical or
On liquid service, the instrument should be horizontal pipe.
mounted below the process connections to
facilitate self-bleeding. On gas service, it
should be located above the process 5. TROUBLE SHOOTING
connections to promote self-draining. If the A. Gauge does not indicate differential.
process contains particulates, a “pigtail” loop or
drop leg (manometer “U-tube” configuration) in i. Check for proper hook up, high to “hi” and
the tubing will minimize the possibility of it low to “lo” ports.
migrating into the instrument. ii. Make certain block valves are open and,
if using a 3-valve manifold, that the
equalizer (balance) valve is closed.
3. PANEL MOUNTING
iii. If i & ii check out correctly, verify that
Gauges with 2-1/2" dials can only be mounted there is pressure to the instrument.
through the rear of the panel. Make the proper
panel cutout as indicated in (Fig. 5). Remove iv. If there is pressure to the instrument,
the (4) bezel screws. Insert the gauge front check to determine that there is
through the rear of the panel and reinstall the differential across the unit being
bezel screws through the front of the panel and monitored. If so, contact the factory for
into the gauge bezel. Tighten the screws assistance and/or an “RGA” (Return
securely, alternating in a diagonal pattern. Goods Authorization) number to return
the instrument for repair or replacement.
B. Gauge accuracy and set point problems:
Gauges with 3-1/2" dial must be mounted from
the front of the panel. Contact factory for i Verify gauge is not in an
mounting information and dimensional data. electromagnetic/magnetic environment.
i.e.; close proximity to high current power
lines.
The Gauges with 4-1/2" dial must be mounted
from the front of the panel. Make the cutout as ii All others, contact the factory for
shown in (Fig. 5). Insert the four (4) panel assistance.

MODEL 140 - 2-1/2 INCH PLASTIC DIAL ASSY. (STANDARD)
MODEL 140 - 4-1/2 PLASTIC INCH DIAL ASSY. (OPTIONAL)
(Fig. 5)
NOTES: 1. Drawings show standard gauge nominal dimensions. (not to scale)

2. Dimensions shown in parentheses are in millimeters.
3. Mounting Dimensions for 3-1/2" & 4-1/2" Alum. Dial Assys. – Contact Factory
Manufacturer reserves the right to change specifications without prior notice. All dimensions in inches and millimeters.

STANDARD MODEL SPECIFICATIONS DIFFERENTIAL RANGE & ACCURACY
Model 141 0-50" H2O thru 0-25 PSID
Model 140 over 0-25 PSID thru 0-100 PSID 0-50 to 0-400" H2O 0-15 thru 0-100 PSID.
(125 mbar to 1 bar) (1 to 7 bar) or equivalent
140/141-AA-00-OO or equivalent
3000 P.S.I.G. Working Pressure Aluminum Body, Buna N
Diaphragm and Seals, 316 Stainless Steel Internal Metal Parts, ±5% Full Scale + 3-2-3% Full Scale
(Ascending) (Ascending)
Ceramic Magnets, Teflon Guide Bushings, 1/4" FNPT Back
Connections, 2-1/2" Round Dial in Corrosion Resistant Engineering
Plastic Case with Shatter-Resistant Acrylic Lens.
PART NUMBERING SYSTEM (Fig. 6)
– – – –
➅ OPTIONS (Up to four options)

0. None
➀ BASIC MODEL NUMBER A.
B.
Reversed High/Low Process Connections
DIN2353 12-S (12 mm) Steel Tube Fittings (2)
➁ MATERIAL
A. Aluminum (3000 P.S.I.G.)
F. Pipe Mounting Kit (Not Available with Both
Reversed Port and Switches)
L. Liquid Fill (not available with maximum follower pointer)
B. Brass (1500 P.S.I.G.)
(not available with 3-1/2" dial)
S. 316 S.S. (3000 P.S.I.G.)
M. Maximum Indicator Follower Pointer
Z. Special (Uncoded Options)
T. Oxygen Cleaning
U. S.S. Tag mounted w/S.S. Wire
➂ DIAL SIZE V. S.S. Tag mounted w/S.S. Screws
A. 2-1/2" Round Engrd. Plastic Housing Assy.
W. Wall mounting kit
C. 4-1/2" Round Engrd. Plastic Housing Assy.
X. Chemical Seals
E. 3-1/2" Round Anod. Alum. Housing Assy.
G. 4-1/2" Round Anod. Alum. Housing Assy.
T. Non-Indicating Differential Pressure Switch Only
(Select Appropriate Electrical Options) ➆ ELECTRICAL CONFIGURATIONS
(Switch Adjustable Range 10-90% except where stated below)
0. None
A. One (1) Reed Switch in NEMA 4X Enclosure
➃ SEALS & DIAPHRAGM
0. Buna N (Standard)
B. Two (2) Reed Switches in NEMA 4X Enclosure
C. One (1) Reed Switch in Explosion Proof Enclosure with
1. *Viton (60” H2O & Above)
(Up to three options)

C.S.A & U.L. Listing (1) (2)
2. Silicone D. Two (2) Switches in Explosion Proof Enclosure with
4. Neoprene (25 PSID & Below) C.S.A & U.L. Listing (1) (2)
5. Ethylene Propylene
E. One (1) Reed Switch in NEMA 4X Aluminum Enclosure;
9. Special (Uncoded Options)
C.S.A & U.L. Div 2 Listing (3)
F. Two (2) Reed Switches in Nema 4X Aluminum Enclosure;
➄ CONNECTIONS
0. 1/4" FNPT Back Connections (Standard)
C.S.A & U.L. Div 2 Listing (3)
2. Dual 1/4" FNPT Top and Bottom (1)
Complete Assembly Certified Class 1, Div. 1, Groups C & D,
Connections (Non-Switch Units Only) Class II, Div. I, Groups E, F & G.
(2)
4. 7/16"-20 Str. Thd. O-Ring (Back Connections) For Explosion-proof assemblies use the Model 140 (not 141) to build
Model Number. Unit is available for the ranges specified for 140 and 141.
5. 1/2" FNPT S.S. Adaptors
(3)
Complete Assembly Certified Class 1, Division 2, Groups A, B, C, & D;
9. Special (Uncoded Options)
Class II, Division 2, Groups F & G.
➇ ELECTRICAL SPECIFICATIONS
(For Resistive Loads)
* Viton® is a registered trademark of DuPoint Dow Elastomers
A. S.P.D.T., 3 Watts, 0.25 Amp, 125 VAC/VDC
B. S.P.S.T., 25 Watts, 0.5 Amp, 230 VAC/VDC
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.
Manufacturer reserves the right to change specifications without prior notice.

PROOF PRESSURE: Two times rated working pressure.
TEMPERATURE LIMITATIONS: -40°F(-40°C) to +200°F (+93°C). These limits are based on the entire instrument being saturated
to these temperatures. System (process) temperatures may exceed these limitations with proper installation.
STANDARDS: All Model 140/141 Series differential pressure gauges either conform to and/or are designed to the requirements of
the following standards:
ASME B1.20.1 NACE MR0175

ASME B40.1 NEMA Std. No. 250
CSA-C22.2 No. 14.25 and 30 SAE J514
EN-61010-1 UL Std. No. 50,508 and 1203
R E P R E S E N T E D B Y:
Mid-West
Instrument
®
6500 Dobry Dr. ■ Sterling Heights, MI 48314 U.S.A.

(586) 254-6500 ■ FAX (586) 254-6509
E-mail: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.
4.12 Pressure Diff Transmitter
(PDT)

http://www2.emersonprocess.com/siteadmincenter/PM%20Rosemount%20Documents/00809-0100-
4001.pdf

4.13 Flame Arrestor
(FA)

The Kemp Company
4647 S.W. 40th Avenue
Ocala, Florida 34474-5799 USA
(352) 873-5123 - Telephone
(352) 873-5187 - Fax
INSTRUCTIONS
KEMP FLAME ARRESTER
MODEL FA70
SCREEN CLEANING PROCEDURE:

a. To clean the insert pack, the flame arrester must
first be removed from the pipeline.
b. Unscrew inlet body half.
c. Remove laminated screen pack. Note relative
positions of gauze discs and perforated discs.
d. Clean individual gauze and perforated disc by
brushing off and/or washing in a non-film solvent.
Unit sizes 1” and larger have a center bolt
supporting the screen pack assembly that must be
removed to clean the insert pack assembly.
e. Replace any warped or damaged discs with new
ones.
f. Reassemble screen pack, having screens in the
same relative position as before. Unit sizes 1/4” to
3/4”: one perforated disc, ten gauze discs and one
perforated disc. Unit sizes 1” to 2”: one perforated
disc, five gauze discs, one perforated disc, five
PURPOSE: gauze discs and one perforated disc with a center
bolt tightly holding the screen pack together.
Kemp flame arresters are designed to stop flame
propagation in piping carrying combustible gas g. Inspect “O” ring. If damaged or brittle, it should be
mixtures. replaced.
h. Place screen pack back into outlet body half and
INSTALLATION: reassemble body.
The flame arresters can be mounted in any position with
the flow in either direction. It must be installed, however, WARNING:
so that the arrow on the body pionts toward the
potential flame source. It should be arranged so it can 1. Kemp single barrier flame arresters should not be
be removed from the line to permit access to the insert used if the mixture flame speed is in excess of five
screen pack assembly. feet per second.
The arrester should be installed as close as possible to 2. Do not use Kemp flame arresters with pure oxygen-
the known ignition source. The length of pipe between flammable mixtures.
the flame arrester and the potential source of ignition 3. Proper installation and location of flame arrester is
should not exceed 30 feet, however, the shortest essential to effective operation.
practical length is desirable. 4. Inserts taken apart for cleaning must be
If the arrester is to be installed in a location subject to reassembled properly as noted above in “SCREEN
freezing, the arrester must be heat traced to prevent CLEANING PROCEDURE". ALL GAUZE DISCS,
condensate from freezing and blocking the inserts. PERFORATED DISCS AND BOLT,(unit sizes 1”
and larger have a center bolt supporting the screen
MAINTENANCE: pack assembly), MUST BE IN PLACE OR THE
FLAME ARRESTER INSERT COULD FAIL TO
To insure proper functioning at all times, it is necessary STOP A FLAME.
that the flame arrester be given correct maintenance.
Dirty inserts will cause excessive pressure drop and 5. Failure of the flame arrester to stop a flashback due
could result in damage to the storage tank. to missing components or improper installation
could result in property damage, serious personal
When the pressure drop reaches the maximum allowed injury or death.
for the installation, the insert screens must be cleaned.
F-87 / 7-00

4.14 Heater
(H)

Chromalox
®
Installation, Operation SERVICE REFERENCE

DIVISION 4 SECTION RT
and SALES
REFERENCE (Supersedes PJ438-13) PJ438-14
MAINTENANCE INSTRUCTIONS 161-057884-001
DATE NOVEMBER, 2006
Industrial Heating Cable Products
IMPORTANT GENERAL INSTRUCTIONS

These instructions are to be followed when installing teristics. These characteristics may make one type of cable more
Chromalox Heating cables on pipes in ordinary locations. Consult suitable for a particular application than another. This manual,
factory for installation of braided cable in hazardous locations. however, is not intended as a product selection manual. Refer to
Chromalox has three basic types of heating cables: Self-Regulating, bulletin PJ304 “Chromalox Design for Heat Tracing Products” for
Constant Wattage and Mineral Insulated. Although they are all product selection guidelines. Below is a chart highlighting certain
resistance type cables, they each have different operating charac- characteristics for Chromalox heating cables.
Self-Regulating Constant Wattage Mineral Insulated

Hazardous ratings available Yes Yes Yes
Usable on plastic pipe Yes* No No
Can be cut to length in field Yes Yes No
Can be single over lapped Yes No No
* Low temperature cables only. UL listing only applies to 3W/Ft. cables
Jacket
Heavy-Duty
Metal Sheath
Overcoat Over Braid
(Optional) Resistance Wire
Densely Compacted
Binder Mineral Insulation
Buss Wires Module Point

Buss Wires
Tinned Copper Braid

(Optional) Primary Insulation
Jacket
Tinned Copper Braid (Optional)
Conductive Matrix Twin (Shown) or Single
Overcoat Over Braid (Optional)
Resistance Wires
Self-Regulating Constant Wattage Mineral Insulated
INCOMING INSPECTION
1. Open package and visually check for breaks or nicks in the
cable jacket. File claim with carrier if any damage is found.
2. Never energize the cable when it’s coiled or on a reel. Test ELECTRIC SHOCK HAZARD. Any cable with an insu-
only when it is laid out straight. lation resistance reading less than 10 megohms
3. After removing the cable from the carton or wrapping, check before installation should not be installed. Contact
the resistance of the unit from buss wires to braid or metal your local Chromalox representative.
sheath with a 500VDC megger to assure the cables have not
been damaged during shipping and handling. If the cable has 4. The heating cables should be stored in their shipping cartons or
no braid or metal sheath, uncoil the cable onto a metal surface on reels in a dry atmosphere until they are ready to be installed.
and check resistance between the buss wires and the metal sur-
face.
© 2006 Chromalox, Inc.
INSTALLATION
A. IMPORTANT — GENERAL NOTES REGARDING with the piping on the inflow end. The cable on the pump or
INSTALLATION OF HEAT TRACING SYSTEMS. vessel should be physically separate to permit disconnection
during maintenance or removal.
16. Use aluminum foil tape to cover the heating cable whenever the
cable is not in good contact with the pipe (i.e. at supports,
FIRE HAZARD. Failure to follow these guidelines valves, pumps, etc.) or whenever its use is specified by the
could result in property damage or personal injury. Chromalox Design Guide PJ304.
17. Separately controlled circuits should be provided on dead end
1. Read this instruction sheet and those enclosed with the acces- legs and closed bypasses.
sories to familiarize yourself with the products. 18. No heat tracing circuit should extend more than two feet beyond
2. Selection of heating cable type and rating should be in accor- a point where two or more pipes join when such junctions per-
dance with the procedures located in the “Chromalox Design mit optional flow paths. In such cases, separately controlled
Guide for Heat Tracing Products” (PJ304). traces should be used.
3. Ensure all pipes, tanks etc. have been hydrostatically tested 19. The minimum installation temperature for all Chromalox heat-
prior to the installation of the heating cable. ing cables is -40˚F (-40˚C).
4. Always install tracing at the 5 or 7 o’clock position on a pipe. 20. Chromalox Type SRL heating cables are well suited for heat
5. Installation Guidelines for fire protection systems: tracing plastic pipes. Consult bulletin PJ304 “Chromalox
a. For use on insulated UL listed steel schedules 5, 10, 20 and Design Guide for Heat Tracing Products” for design recom-
40 standpipe and sprinkler system pipe up to and including mendations. Installation details AD1 through AD17 apply for
6 in. size. Includes use on elbows, tees, flanges, hangers plastic pipe only when Type SRL heating cable is used. Consult
and valves as shown. (show figures of heating cable factory for applications involving other products.
installed to various equipment as mentioned above). UL
listed fiberglass insulation with a minimum k-factor of B. INSTALLING A SINGLE RUN OF CABLE ON A PIPE.
0.25 BTU/hr -˚F-ft2 -in with weatherproof cladding must 1. Mount the reel of cable on a holder and place near one end of
be used. the pipe run to be traced. Choose the end from which it will be
b. For systems having piping which connects between build- the easiest to pay out the cable.
ings in unheated areas, coolers and freezers. 2. Pay out the cable from the reel and loosely string along the pip-
c. For systems having sprinkler piping that is installed in ing, making sure the cable is always next to the pipe when
coolers or freezers where the temperature is -40˚F or crossing obstacles. For example, if the heater is on the wrong
greater. side of a crossing pipe, you will have to restring the cable or cut
and splice it.
Not intended to be used as the means to prevent freezing of
sprinkler branch lines including all accessories for these lines
and automatic (deluge, preaction, dry pipe, alarm, etc.) valves
as referenced in NFPA 13. To prevent damage to cable, avoid such things as:
For use in Ordinary Hazard Occupancies only as specified in — Pulling the cable over sharp edges.
NFPA 13 the standard for the installation of sprinkler sys- — Forcibly pulling the cable free if it snags while
tems. being paid out.
— Allowing the cable to be walked on or subjec-
Fire suppression system heater circuits must be connected to ed to other abuse which could cause mechan-
monitoring equipment. A listed power supply relay with the ical damage.
appropriate voltage coil shall be connected in parallel prior to 3. When you reach the end of the circuit, secure the heater cable
the heat tracing (should show figure with typical installation). to the pipe using glass tape or plastic cable tie with a tempera-
The output contacts of the listed power supervisory relay ture rating compatible with the heater cable.
should be connected to a listed fire control panel which has
provisions for supervisory circuits. If this end is to have an end seal installed, remember to leave
6. Do not attempt to heat trace any piece of about a foot of extra cable. If it is a power connection, leave
equipment which will not be insulated. about two feet of extra heater cable.
7. Do not install heating cable on equipment 4. (If the heater cable is to be spiralled, go to step 4A.)
which could become hotter than the heating Begin attaching the cable to the pipe about every foot (.3
cable’s maximum exposure temperature. meters).
8. Do not install heating cable in an area or on Place the cable on the bottom half of the pipe at the 5 or 7
equipment which contains potentially corro- o’clock position. Refer to installation detail ADI. Go to step 5.
sive materials without having a suitable pro- a. Note the path of the heater cable and the spiral factor of the
tective jacket on the cable. design. A simple way to think about spiral factor is: A1.1
9. The minimum bending radius for all Chromalox spiral factor means install 11 feet of heating cable on every
heating cables is six times the minor diameter. 10 feet of pipe, etc. At about every 10 feet of pipe, pull the
10. Allow a minimum of 2” between cable runs. required amount of cable and let hang in a loop, and attach
11. Always install heat tracing on the outside the cable to the pipe.
radius of elbows. b. Rotate the loops around the pipe until all the slack has been
12. Never install heat tracing over expansion taken up. Even out the spirals of the heater cable and secure
joints without leaving slack in the cable. to the pipe as necessary to obtain good contact. The entire
13. Never use tie-wire or pipe straps to secure circuit can be installed with hanging loops with the spi-
Self-Regulating Maximum Circuit length or ralling on the pipe being done when you trace the heat sinks.
Constant Wattage heating cables. Refer to installation detail AD3.
14. Observe all published specifications. Do not 5. At a heat sink (pipe supports, valves, pumps, reducers, gauges,
expose cables to temperatures above their bucket strainers, etc.), attach the heater cable to the pipe just
specified maximums. Do not run cables longer before the heat sink. Refer to the design specs to determine the
than specified maximum circuit lengths. See amount of heater cable you need to install on the heat sink. Pull
table 3 for details. this amount of cable into a loop, attach the heater cable on the
15. Pumps and small vessels should be heat traced and controlled other side of the heat sink and continue attaching the cable
down the pipe as before.
2
INSTALLATION
6. When you reach the heater cable reel, you should have the i. At each heat sink, the easiest thing to do is supply the
heater cable attached all along the pipe, with the correct amount extra heater called for by the design drawing from only
of heater cable pulled in loops at all heat sinks. Attach the cable one heater cable. This avoids having to measure out half
to the pipe, (leave an extra foot if at an end seal, two feet if at a of the requirement from each cable.
power connection) and cut the heater cable from the reel. ii. When doing the previous step, leave a small loop other
7. Install the heater cable loops on the heat sinks. Refer to the cable at equipment which may be serviced, such as
proper installation detail (AD5-AD12) for a general idea of how pumps, valves, instruments, etc. This is so both heater
to install the cable, but remember: cables may be removed enough for future access.
• It is important to get the proper amount of heater cable on b. Supply heater cables from one reel.
the heat sink, rather than exactly as the detail shows. The The general procedure is the same as given earlier, but there
detail is just a guide. are a few things to do to make sure the system is correctly
• Self-Regulating heater cables are very flexible and can be done.
single overlapped for installation ease. Feel free to use this i. With this method, a loop is pulled for the entire circuit.
feature when you can. To do this, attach the end of the heater cable to the pipe
near the heater cable reel. Remember to leave enough
extra cable for the type of connection to be installed.
ii. Begin pulling the cable off the reel in a large loop down
FIRE HAZARD. Do not overlap constant wattage the piping run. Be sure to keep the cable next to the pipe.
or mineral insulated heating cables. Moving down the run, continue attaching the cable to the
• By having the cable installed this way, it can be removed pipe, leaving the side of the loop going back to the reel
easily from the heat sink without cutting if access to, or unattached.
removal of the heat sink is required. iii.You will want both sides of the loop to be about the
same length to avoid future problems. Also, it is easier to
Note: If a tee is designed into the system, or if you are using two or
install the extra cable required at each heat sink from only
more short cable lengths to complete a circuit, allow two or three
one cable. Therefore, pull the right amount of extra heater
feet of each cable to overlap. This will allow flexibility in assem-
cable needed at every second heat sink from the side of
bling the connection kit and locating it on the pipe.
the loop you are attaching to the pipe. At the remaining
C. INSTALLING MORE THAN ONE HEATING CABLE serviceable heat sinks (pumps, valves, instruments, etc.)
ON A PIPE. don’t forget to leave a short loop of cable for slack when
There are two cases where you will need to install more than access to the equipment is needed.
one heater cable on a pipe: iv. When the end of the piping run is reached, pull the prop-
• When the design calls for more than one cable. er amount of extra cable for the connection to be installed.
• When the lines being heat traced are considered important v. Now, begin working the remaining side of the loop back
enough to install a backup (redundant) heat tracing system. toward the reel, installing it on the pipe and heat sinks as
required.
The installation requirements are different for these cases. 2. Installation for Backup (Redundant) Systems.
1. Installing multiple heater cables for design requirements. The purpose of a backup system is to provide the proper amount
The most common multiple cable requirement is two cables of heat from the second heater cable if there are problems with
on a pipe. Below are the recommended techniques for the two the first. Therefore, each cable must be installed so it can do the
cable systems. They also apply to installations where three or job alone. The simplest way to do this is to install the first heater
more cables are to be installed on a pipe. cable as given in Section B. Then, go back and install the back-
up heater cable the same way.
There are two ways of paying out two heater cables along a
pipe. The first is to locate two reels of heater cable and supply There are several things to keep in mind:
one cab from each. This method works for all types of piping • The power connections and end seals for the two cables are
runs. often designed to be at opposite ends of the run in a redun-
However, it may increase material waste by leaving unusable dant system. Remember to leave the proper amount of extra
lengths from two reels. The second way is to supply both cables cable for the connection to be installed on each cable at that
from one reel. This method is generally the easiest for relative- end.
ly straight, simple piping runs. For each circuit, decide which • On piping one inch IPS or smaller, it can be difficult to
method to use and then go to the appropriate part below. apply both heater cables with good contact at all places. The
a. Supplying cable from two reels. main thing is to get the correct amount of cable installed.
The general procedure here is the same as given earlier, but However, try to get as much contact with the piping and heat
there are a few things to do to make sure the system is cor- sinks from both cables as possible.
rectly done.
3
SUPPLEMENTAL INSTRUCTIONS FOR ATEX APPLICATIONS
1. Do not bend the cable for a length of 300mm from cable gland 3. The supply circuit to the heating cables must be protected by a
inlet. safety differential device or equivalent ground fault protection.
2. Connection and termination of Chromalox cable must be 4. Chromalox cable minimum installation temp is -30˚C.
installed using cable glands and type ‘e’ connection kits as
provided by Chromalox, Inc.
TYPICAL INSTALLATION DETAIL
Heating Cable Heating Cable

Self Regulating Self Regulating
Constant Wattage Constant Wattage
Mineral Insulated Tape or Banding Mineral Insulated Tape or Banding
Metallic Pipe Metallic Pipe
Top Top
45˚ 45˚ 45˚
12”
12”
Typical Weatherproof Jacket Typical
Weatherproof Jacket
Note: Cable located at nominal Note: Cable located at nominal 45˚ below Thermal Insulation
45˚ below horizontal centerline. Thermal Insulation horizontal centerline on either side.
AD1 - One Run of Cable AD2 - Two Runs of Cable

Heating Cable Heating Cable
Note: Tape or
Self Regulating, Constant Wattage, Self Regulating
1. Do not spiral if ratio Banding
Mineral Insulated Constant Wattage
of heater length to pipe
Mineral Insulated
length is greater than 12”
1.5. Instead, use two Typical
cables or choose a high-
er wattage heater. Note: Heating cable is
applied to the outside (long) Metallic Pipe
radius of the pipe elbow.
Tape or Banding
Metallic Pipe Pitch Weatherproof Jacket
Thermal Insulation
Note:
2. Refer to pitch chart in design Weatherproof
data section on circuit drawing Jacket
Thermal Insulation
for proper pitch length.
AD3 - One Cable-Spiralling Method AD4 - One Run of Cable at Pipe Elbow
Flange Position with Pipe Expanded

Expansion Joint
Orifice Plate Tape or Banding

Metallic Pipe
Metallic Pipe
Heating Cable
Heating Cable Self Regulating
Self Regulating Tape or Banding Constant Wattage
Constant Wattage Mineral Insulated Flexible conduit junction box may be
Mineral Insulated required if a splice is necessary
Conduit connection fitting to be suitable for area clas-
sification. Heating cable may be run continuously
Note: Insulate over flanges & orifice plate and through the conduit.
weatherseal. All piping must be fully insulated
and weathersealed. Note: All piping must be fully insulated and weathersealed.
AD5 - Orifice Flange AD6 - Expansion Joint
4
Metallic Pipe Tape or Banding

Tape or Banding
Metallic Pipe
A A
Support Shoe
3”
Heating Cable
Self Regulating Typical 3 inches (Typical)
Constant Wattage Pipe Support
Mineral Insulated
Section A-A
Heating Cable
Note: Pipe Support to be insulated two feet Self Regulating
below pipe and weathersealed. All piping Constant Wattage
must be fully insulated and weathersealed. Mineral Insulated Note: Insulate and weatherseal support. All pip-
ing must be fully insulated and weathersealed.
AD7 - Welded Support AD8 - Shoe Support
Pressure Gauge
Tape or Banding
Shut-Off
Valve
Front View Rear View
Heating Cable
Heating Cable Self Regulating
Self Regulating Constant Wattage
Constant Wattage Mineral Insulated
Mineral Insulated
Tape or Banding
Note: All piping must be fully insulated and Note: Completely insulate & weatherseal line and Metallic Pipe
weathersealed. gauge. All piping must be fully insulated and
weathersealed.
AD9 - Valve AD10 - Pressure Gauge
5
Heating Cable
Pressure Gauge Self Regulating, Constant Wattage,
Mineral Insulated
A
Diaphragm
Housing
Shut-Off
Valve
Level
Gauge
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Tape or Banding A
Tape or Banding
Metallic Pipe
Note: Completely insulate & weatherseal line. All
piping must be fully insulated and weathersealed.
Note: All piping must be fully insulated and weathersealed.
AD11 - Diaphragm Pressure Gauge AD12 - Level Gauge
Junction Box Connection

(See Instruction Sheets PJ442 or
PJ444 for Installation Instructions)
Conduit Connection
Hub (not included) Tape or Banding Splice Connection
Junction Box (See Instruction Sheets
(not included) PJ445 or PJ446 for
Installation Instructions)
Grounded Braid
Connect to bracket with
grounding screw
Metallic Pipe
Heating Cable
Self Regulating
Pipe Strap Constant Wattage
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage Tape or Banding
Note: All piping must be fully insulated and weathersealed. Note: All piping must be fully insulated and weathersealed.
AD13 - EL Series Power Connection AD14 - EL Series Splice & Tee Connection
Conduit Connection
Hub (not included) RTPC Power Connection Kit
End Seal Kit (See Instruction Sheet PJ451 for
(See Instruction Sheets Installation Instructions)
Metallic Pipe PJ441, PJ443 or PJ450 for
Installation Instructions) Heating Cable
Self Regulating
Constant Wattage
Heating Cable
Self Regulating Tape or Banding
Constant Wattage
Metallic Pipe Pipe Strap Tape or Banding
AD15 - End Seal AD16 - DL Series Power Connection
6
Junction Box Connection

(See Instruction Sheets PJ442 or
PJ444 for Installation Instructions)
Conduit Connection
Hub (not included) Tape or Banding Splice Connection
Junction Box (See Instruction Sheets
(not included) PJ445 or PJ446 for
Installation Instructions)
Grounded Braid
Connect to bracket with
grounding screw
Metallic Pipe
Heating Cable
Self Regulating
Pipe Strap Constant Wattage
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage Tape or Banding
AD13 - EL Series Power Connection AD14 - EL Series Splice & Tee Connection
Conduit Connection
Hub (not included) RTPC Power Connection Kit
End Seal Kit (See Instruction Sheet PJ451 for
(See Instruction Sheets Installation Instructions)
Metallic Pipe PJ441, PJ443 or PJ450 for
Installation Instructions) Heating Cable
Self Regulating
Constant Wattage
Heating Cable
Self Regulating Tape or Banding
Constant Wattage
Metallic Pipe Pipe Strap Tape or Banding
AD15 - End Seal AD16 - DL Series Power Connection

Note: Thermal Insulating
1. For multiple heaters place
Tape or Banding control sensor 90˚ from nearest Heating Cable
RTST Splice and Tee Kit
(See Instruction Sheet PJ452 heater or centered between Self Regulating
for Installation Instructions) equally spaced heaters. Constant Wattage
2. Place high-limit sensor Mineral Insulated
approximately 15” from heater
Pipe Strap and mount in the same manner
as shown below. 90˚ Control Sensor
Section A-A
Weatherproof
Jacket
Metallic Pipe
Metallic Pipe
Heating Cable
Self Regulating Tape or Banding to hold
Constant Wattage heating cable
3 Foot
Minimum Tape Bulb
tight against pipe
Nearest pipe support
Note: All piping must be fully insulated and weathersealed. or other heat sink
AD17 - DL Series Splice & Tee Connection AD18 - Sensor Placement
7
WIRING
ELECTRIC SHOCK HAZARD. Disconnect all power To prevent equipment damage, Circuits fed from
before installing or servicing heating cable. Failure overhead lines should be protected by secondary
to do so could result in personal injury or property lighting arrestors.
damage. Heater must be installed by a qualified CONTROLS:
person in accordance with the National Electrical 1. All heating circuits should have temperature controls. Temper-
Code, NFPA 70. ature control of the pipeline can be obtained through various
Chromalox temperature controls. Refer to Chromalox bulletins
PJ304 and PJ310 for recommendations.
2. Contactors must be used when load currents exceed the rating of
ELECTRIC SHOCK HAZARD. Any installation involv- the thermostat contacts. Equipment protection ground fault (30
ing electric heating cables must be performed by a mA EPD) thermal breakers are recommended with type SRL.
qualified person and must be effectively grounded 3. The temperature control should be mounted in a location where
in accordance with the National Electrical Code to it will not be subjected to excessive shock or vibration.
eliminate shock hazard. 4. Line sensing temperature sensors should be mounted in accor-
ACCESSORIES: dance with Installation Detail AD18 (see Detail on previous
1. Selection of Installation Accessories should be in accordance page).
with Chromalox bulletin PJ309 and PJ304. 5. Ambient sensing temperature sensors should be located at a
2. Only use Chromalox installation kits and use them only for the point where the lowest ambient temperature is expected.
operations for which they are designed.
3. The instructions included in the Chromalox installation acces-
sories must be followed in order for the third party approvals
(UL, FM, CSA, etc.) to apply. To prevent equipment damage, handle and secure
4. Junction boxes must be in accordance with the requirements of temperature sensors, especially thermostat bulbs
the area classification. and capillaries with care to avoid distortion or
5. All outdoor junction boxes must be located above grade level. crimping which might impair control accuracy.
Covers should be kept on the boxes at all time when not being 6. Exposed thermostat capillaries should have mechanical protec-
worked in. tion.
6. All terminations must be protected from the weather and from
physical damage by locating them either under the weatherproof
insulation or inside an appropriate junction box.
7. All equipment must be properly grounded.
8. Install installation accessories according to the instructions
included in the kits and per installation details AD13 through
AD17.
End Cap End Cap

Heat Generating Matrix Heat Resistance Wire
L2
L2
Power Supply
Power Supply
L1
L1 Buss Wire
Buss Wire Thermostat
Thermostat
Contactor Contactor
Heat Generating Matrix Heat Resistance Wire
L2 Power L2 Power
L1 Supply L1 Supply
Buss Wire End Cap Buss Wire

End Cap
Control Control
Circuit Circuit
Thermostat Thermostat
I. Self-Regulating Typical Wiring Diagrams II. Constant Wattage Typical Wiring Diagrams
Contactor
End Cap Heat Resistance Wire
Heat Resistance Wire
L2 L2 Power
Power Supply L1 Supply
L1
Cold Lead Thermostat End Cap
Control
OR Circuit
L2 L1 Thermostat
Thermostat
III. Mineral Insulated Typical Wiring Diagrams
8
INSTALLATION TESTING
When the heater cable and connections for a circuit have been 3. Inspect the insulation resistance of the circuit using a 500VDC
completed, immediately perform the following checks. megger. Always perform this test at the power connection. Any
cable with an insulation resistance of less than 10 megohms
1. Visually inspect the heater cable and temperature controls for
should be removed and discarded.
signs of mechanical damage. If damage is seen, either replace the
4. Check voltage at end of circuit and record in log.
complete heater cable, or cut out the damaged section and
replace using the proper splice connection for the area and cable
you are using.
2. Inspect all connections to be sure they are correctly assembled.
Be sure each heater cable entry to a connection has a grommet
and the compression plates and caps are properly tightened.
THERMAL INSULATION
An installed heating circuit should be thermally insulated imme- 7. Insulation must be covered by a weatherproof barrier, such as an
diately to provide protection from damage from ongoing work. aluminum jacket.
Things to remember about insulating: 8. If you are using metal jacketing and sheet metal screws, be sure
the screws are not long enough to penetrate the thermal insula-
1. Insulate the equipment being heat traced as soon as possible after
tion and damage the heater cable.
the heating cable is installed. This will protect the cable from
9. Again, perform the megger test on the circuit immediately after
possible physical damage.
the thermal insulation is installed to detect if any mechanical
2. The type and thickness of thermal insulation specified on the
damage may have occurred.
design drawing must be used. If you use another type or thick-
10. When the insulation and the weatherproofing is complete, attach
ness, the heater cable type or amount may have to be changed.
“Electric Traced” labels on the outside of the insulation. These
3. Never install wet insulation. Both the piping and the insulation
should be installed where they are visible from normal opera-
must be dry when thermally insulating a circuit. Wet insulation
tions, usually on alternating sides about every 10 feet. It is also
may cause start-up or operational problems.
useful to mark the location of any connections buried under the
4. Properly weatherproof the thermal insulation. All places where
insulation.
valve stems, conduits, pipe supports, connection housing, ther-
mal capillary tubes, etc. extend outside the insulation jacketing Additional requirements for rigid thermal insulations:
must be sealed with a suitable compound to keep water out. 1. In the standard single heater cable installation, rigid insulations
5. Insulate valves fully up to, and including, the packing gland. do not need to be oversized. However, they should be carved so
6. Heat trace and fully insulate the face of all non-diaphragm pres- there is no gap in the insulation.
sure instruments. 2. In case of redundant or multiple heater cables, rigid insulations
which are .500 inches oversized should be used.
COMMISSION TESTING
1. Again, visually inspect the piping, insulation and connections for For systems controlled by line-sensing thermostats:
the heater cable to make sure no physical damage has occurred 1. Set the thermostat to the desired control temperature.
if some time period has elapsed since the installation and start- 2. Turn the main circuit breaker ON.
up. 3. Turn ON the branch circuit breakers controlled by the thermo-
2. Megger the system again to determine if damage not readily vis- stat.
ible has occurred. 4. Allow the pipe temperatures to be raised to the control point.
3. Turn all branch circuit breakers to the OFF position. This may take up to four hours for most circuits (large full pipes
may take longer).
For systems controlled by ambient-sensing thermostats:
5. Measure the amperage draw. ambient temperature, and pipe tem-
1. If the actual ambient temperature is higher than the desired ther-
perature for each circuit and record in the installation log. This
mostat setting, turn the thermostat setting up high enough to turn
information may be needed for future maintenance and trou-
the system ON or (some models) turn the selector switch to the
bleshooting.
ON position.
2. Turn the main circuit breaker ON. For redundant systems:
3. Turn the branch breakers ON one-by-one until all are on. Follow the procedure above for the type of control system you
4. Allow system to run at least four hours in order to let all pipes have, but commission the systems one at a time. Start up the pri-
reach steady-state. mary system, qualify it and shut it down. Then start up the back-
5. Measure the amperage draw, ambient temperature and pipe tem- up system, qualify it and shut it down.
perature for each circuit and record in the installation log. This
information may be needed for future maintenance and trou-
bleshooting.
6. When the system is completely checked out, reset the thermostat
to the proper temperature.
9
SPECIFICATIONS
Table 1 – Maximum Temperatures
CABLE TYPE MAX. MAINTAIN (POWER ON) MAX EXPOSURE (POWER OFF)
SRL / HSRL 150˚F 185˚F
SRM/E / HSRM 302˚F 420˚F
CWM See table below See table below
SRF 150˚F 185˚F
Table 2 – Maximum Maintenance Temperatures
Temperatures (°F)
Output(W/Ft.) 3 4 6 6.7 8 9 10.1 10.6 12
w/o AT-1 Tape 340 325 293 282 262 246 229 222 200
w/ AT-1 Tape 350 344 332 328 320 314 307 304 296
Table 3 – Maximum Circuit Lengths

SRL / HSRL Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
50°F Start-Up (Ft.) 0°F Start-Up (Ft.) -20°F Start-Up (Ft.)
Cable Rating 10A 15A 20A 25A 30A 40A 10A 15A 20A 25A 30A 40A 10A 15A 20A 25A 30A 40A
SRL / HSRL3-1C 205 305 360 NR NR NR 135 200 270 330 360 NR 120 185 245 300 360 NR
SRL / HSRL3-2C 400 600 660 NR NR NR 275 415 555 660 NR NR 245 370 495 600 660 NR
SRL / HSRL5-1C 125 185 250 270 NR NR 90 135 180 225 270 NR 80 120 160 205 245 270
SRL / HSRL5-2C 250 375 505 540 NR NR 180 270 360 450 540 NR 160 245 325 405 490 540
SRL / HSRL8-1C 100 150 200 215 NR NR 70 110 145 180 215 NR 65 100 130 165 200 210
SRL / HSRL8-2C 185 285 375 420 NR NR 135 200 265 335 395 420 120 175 235 300 350 420
SRL / HSRL10-1C 60 95 130 160 180 NR 50 80 105 130 155 180 45 70 95 120 140 180
SRL / HSRL10-2C 100 160 210 260 315 360 80 125 170 210 255 340 75 120 160 195 240 320
SRM/E / HSRM Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
50°F Start-Up (Ft.) 0°F Start-Up (Ft.) -20°F Start-Up (Ft.)
Cable Rating 15A 20A 30A 40A 50A 15A 20A 30A 40A 50A 15A 20A 30A 40A 50A
SRM/E / HSRM 3-1 285 385 NR NR NR 275 375 385 NR NR 265 365 385 NR NR
SRM/E / HSRM 3-2 575 770 780 NR NR 540 750 780 NR NR 525 740 780 NR NR
SRM/E / HSRM 5-1 180 240 360 375 NR 165 220 330 375 NR 155 210 310 375 NR
SRM/E / HSRM 5-2 360 480 720 750 NR 325 430 645 750 NR 310 415 620 750 NR
SRM/E / HSRM 8-1 145 190 285 325 NR 135 175 265 325 NR 130 165 250 325 NR
SRM/E / HSRM 8-2 285 380 575 650 NR 255 345 520 650 NR 245 335 490 650 NR
SRM/E / HSRM 10-1 95 125 190 250 NR 90 110 175 250 NR 85 100 170 245 250
SRM/E / HSRM 10-2 190 255 385 490 NR 165 225 345 490 NR 155 215 330 470 490
SRM/E / HSRM 15-1 70 95 145 190 210 65 85 125 165 210 60 80 120 150 210
SRM/E / HSRM 15-2 145 190 290 385 420 120 175 270 360 420 115 165 260 340 420
SRM/E / HSRM 20-1 60 75 115 155 160 50 65 105 140 160 45 65 100 135 160
SRM/E / HSRM 20-2 115 155 230 305 350 100 135 200 270 350 90 130 195 255 335
CWM Specifications SRF Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
Circuit Load Max. Circuit Length 40°F Start-Up (Ft.) 0°F Start-Up (Ft.)
Model (Amps/Ft.) (Ft.) Cable Rating 20A 30A 40A 20A 30A 40A
CWM 4-1CT 0.033 350 SRF 3-1C 350 360 NR 270 360 NR
CWM 8-1CT 0.067 240 SRF 3-2C 660 NR NR 555 660 NR
CWM 12-1CT 0.100 200 SRF 5-1C 230 270 NR 180 270 NR
CWM 4-2CT 0.017 700 SRF 5-2C 450 540 NR 360 540 NR
CWM 8-2CT 0.033 480 SRF 8-1C 180 215 NR 145 215 NR
CWM 12-2CT 0.050 400 SRF 8-2C 330 420 420 265 395 420
CWM 12-4CT 0.025 780
NR = Not Required. Maximum circuit length has been reached in a smaller breaker size.
Note — Thermal magnetic circuit breakers are recommended since magnetic circuit breakers could "nuisance trip" at low temperature.
10
MAINTENANCE
Recommended maintenance for Chromalox heat tracing systems Repair or replace all damaged heater cable, connections, thermal
consists of performing the steps involved in the commission testing insulation and weatherproofing using only Chromalox connections
on a regular basis. For those systems controlled by line sensing ther- and methods before testing the system.
mostats, Chromalox recommends checking the system at least twice Record all repairs made and measurements taken in the installa-
per year. Systems controlled by an ambient-sensing thermostat tion and maintenance log.
should be checked when the season requiring their use is approach-
ing.
INSTALLATION AND MAINTENANCE LOG

Reference Information
Circuit Number
Circuit Breaker Number
Drawing Number
Circuit Length
Heat Tracing Visual Checks
Initial
No Signs of Moisture, Corrosion or Damage
Date
Initial
Proper Electrical Connection
Date
Initial
Proper Grounding of the Braid
Date
Heat Tracing Electrical Checks
Megger Test (500 VDC) Meg Ohms
(Bypass Controls) Date
Amperage
Amperage Draw Test
Amb. Temp.
Compare to design Amperage Draw
Date
Voltage
Voltage at end of Circuit*
Date
Accessories/Control Checks
Set Point
Temperature Control Properly Set
Date
Initial
Sensors Protected and Undamaged
Date
Initial
All Enclosures and Kits Closed and Sealed
Date
Thermal Insulation Checks
Location of Kits Visible on Initial
Outside of Insulation Date
Initial
Insulation is Complete, Dry and Weatherproof
Date
* This test must be performed at installation or at any time the cable is cut or damaged in any way.
11
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, indemnifies Chromalox against any liability to Chromalox's vendors arising out of such litigation.
and the work performed by Chromalox when performed, will meet all applicable specification and Upon Buyer's submission of a claim as provided above and its substantiation, Chromalox shall at
other specific product and work requirements (including those of performance), if any, and will be its option either (i) repair or replace its Products, parts or work at the original f.o.b. point of deliv-
free from defects in material and workmanship under normal conditions of use. All claims for defec- ery or (ii) refund an equitable portion of the purchase price.
tive or nonconforming (both hereinafter called defective) Products, parts or work under this war- THE FOREGOING IS CHROMALOX'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY
ranty must be made in writing immediately upon discovery, and in any event, within one (1) year FOR BREACH OF WARRANTY, AND IS BUYER'S EXCLUSIVE REMEDY AGAINST CHROMALOX FOR
from delivery, provided, however all claims for defective Products and parts must be made in writ- ALL CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED
ing no later than eighteen (18) months after shipment by Chromalox. Defective and nonconforming ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER
items must be held for Chromalox's inspections and returned to the original f.o.b. point upon THEORIES, BUYER'S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY
request. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING BUT NOT LIMITED TO
EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WAR- CLAIMS BASED ON LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL
RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. OR CONSEQUENTIAL DAMAGES AND BUYER SHALL HOLD CHROMALOX HARMLESS THERE-
Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause, it is specifically FROM. ANY ACTION BY BUYER ARISING HEREUNDER OR RELATING HERETO, WHETHER BASED
understood that Products and parts not manufactured and work not performed by Chromalox are ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER
warranted only to the extent and in the manner that the same are warranted to Chromalox by THEORIES, MUST BE COMMENCED WITHIN ONE (1) YEAR AFTER THE DATE OF SHIPMENT OR IT
Chromalox's vendors, and then only to the extent that Chromalox is reasonably able to enforce such SHALL BE BARRED.
warranty, it being understood Chromalox shall have no obligation to initiate litigation unless Buyer W2008M
undertakes to pay all cost and expenses therefor, including but not limited to attorney's fees, and
103 GAMMA DRIVE, PITTSBURGH, PA 15238

Phone: 800-443-2640 www.chromalox.com TA - Y6 - EF
Litho in U.S.A.
Chromalox
®
Installation Instructions
NOTICE: These thermostats are designed for temperature control service only.
SERVICE REFERENCE
DIVISION 4 SECTION RT
Because they may not fail safe, they should not be used for temperature limiting duty. SALES
WARNING: Users should install adequate back-up controls and REFERENCE (Supersedes PJ454-5) PJ454-6
safety devices with their electric heating equipment. Where the
consequences of failure may be severe, back-up controls are 161-562765-001
essential. Although the safety of the installation is the respon- DATE OCTOBER, 1998
sibility of the user, Chromalox will be glad to make equipment
recommendations.
RTBC and RTBC-EP

Power Connection Kit With Integral Thermostat
RTBC RTBC-EP
RTBC Kit Parts:

1 — Molded Enclosure consisting of Base — Box — Lid 1 — Ring Connector (RTBC Only)
1 — Three Position Terminal Block 1 — Thermostat with Mounting Screws (2)
1 — Mounting Screw for Terminal Block 1 — Capillary Grommet
1 — Uninsulated Barrel Connector (RTBC-EP Only) 1 — Cover Gasket
1 — Eight Inch Length of 14AWG Insulated Wire with 4 — Cover Screws, 5/8” Long
Connector (RTBC Only) 4 — Box Screws, 1” Long
GENERAL
WARNING: Hazard of Electric Shock. Disconnect all GR3 for CWM-C
power before starting. All installations must be GR4 for CWM-CT
effectively grounded in accordance with the GR5 for SRL-MC
National Electrical Code to eliminate shock hazard. GR6 for SRL-MCR or SRL-MCT
GR7 for SRM/E-C
Note: All electrical wiring, including GFCI (Ground Fault Circuit GR8 for SRM/E-CT
Interrupters), must be done according to National Electrical or local
codes by a qualified person. Each kit contains enough material to make one power connec-
tion. Materials required for installation include: Standard electri-
These kits are designed to provide temperature control as well as cal cutters, sharp utility knife, screwdriver and a pipestrap
power termination for one run of Rapid Trace Heating Cable. Select (Chromalox PS type or equal).
and purchase one grommet for terminating the cable. Please refer to
the list below to insure that you purchase the proper grommet for the Wipe inside lip of cover with a clean cloth. Removing protec-
cable you are installing. tive backing from the gasket and affix it to the cover lip. Press
GR1 for SRL-C firmly all around for proper adhesion.
GR2 for SRL-CR or SRL-CT
INSTALLATION
Note: These instructions are for all Self-Regulating and Constant
Wattage Heating Cables in ordinary locations. Consult factory for Module Point
installation of braided cable in hazardous locations. Not all
instructions, however, are for all cases. Each step of the instruc-
tions will have a heading in boldface stating which type of cable
or connection each instruction is intended for. 12”
1. FOR CONSTANT WATTAGE CABLE:
Cut the cable 12 inches past the last module point (indentation Figure 1
in cable). Note: Cutting the cable between module points cre-
ates a non-heating cold lead. See Figure 1.
© 1998 Wiegand Industrial Division, Emerson Electric Co.
INSTALLATION
2. FOR CABLE WITH EXPOSED METAL BRAID (-C): 7. FOR ALL CABLE:
Push the braid back 12 inches on the cable. See Figure 2. Feed the capillary of thermostat through the side hole of the box
and side hole of the base. Slip the grommet over the capillary
between the box and the base. See Figure 7.
12”
Figure 2
3. FOR ALL CABLE:

Feed the end of the cable through the appropriate hole in
the base. Allow 8 inches of cable to extend above the top of
the base. See Figure 3.
4. FOR ALL CABLE:
Slide cable grommet over the end of the cable and insert it into
the opening in the base. Attach the base to the pipe by threading
the appropriate sized pipestrap through the slot in the mounting
plate. Tighten the pipestrap until the base is loosely attached to
the pipe. See Figure 4.
8”
Figure 6 Figure 7
8. FOR ALL CABLE:

Feed the cable through the end hole in the box. Allow 3/4 inch-
es of stainless steel capillary to extend above the bottom of the
box. Secure box to base using all four large (8-32) screws. See
Figure 8.
9. FOR OVERCOATED CABLE:
Starting from the end of the cable. unravel 1-1/2 inches of the
braid. Twist the strands together to form a pigtail. See Figure 9.
1-1/2”
Figure 3 Figure 4
5. FOR OVERCOATED CABLES (-CR or -CT):

Score the outer insulation 1-1/2 inches from the end of
the cable. Remove the jacket to expose the metal braid. See
Figure 5. WARNING: Do not damage the braid or the base
cable insulation. Figure 8 Figure 9
10. FOR SELF-REGULATING CABLE:

Using standard electrical cutters, cut a 3/4 inch long notch out
/2”
1-1 of the cable between the conductor wires. Bare a 3/8 inch
length of each conductor by stripping off the outside insula-
tion and the inner black core material. See Figure 10.
11. FOR CONSTANT WATTAGE CABLE:
Score the outer jacket 3/4 inch from the end of the cable and
remove the jacket. Cut off the exposed nichrome wire, pushing
any remainder back under the jacket. Constant Wattage cables
have an inner layer of insulation which is also to be removed
as described above. Separate the buss wires and strip off the
Figure 5
last 3/8 inch of insulation from both buss wires. See Figure 11.
6. FOR ALL CABLE: 3/4”
Punch out the knockouts on the bottom of the box which cor-
respond to the openings in the base through which the heating 3/8” 1-1/2”
cable passes. For these kits, the openings to be knocked out 3/4”
are the ones opposite the conduit entry and the one by the side
of the box. Be careful to punch out only those knockouts to be
used. If one is mistakenly punched, blank grommets can be
ordered to re-establish the watertight seal. See Figure 6.
Figure 10 Figure 11

INSTALLATION
12. FOR OVERCOATED CABLE (RTBC ONLY):
Insert the end of the braid pigtail into the opening in the terminal
block which will be nearest the center of the box. Tighten the
screw firmly to hold the braid in place. See Figure 12.
Figure 16 Figure 17
Figure 12
18. FOR RTBC ONLY:
13. FOR ALL CABLE: Insert the bared end of the ground wire into the opening of the
Insert the bared ends of the conductors into two adjacent terminal block which is opposite of the braid (or is empty).
openings in the terminal block. Tighten screws firmly to hold Insert the ends of the other hot (or neutral) and the 8 inch long
conductors in place. See Figure 13. wire into the two remaining openings in the terminal block.
Tighten screws firmly to hold conductors in place. See Figure
18.
19. FOR RTBC-EP ONLY:
Slide the bared end of the hot power lead into the opening in the
terminal block which is opposite of the empty terminal. Slide the
bared end of the other hot or the neutral power lead into the mid-
dle opening of the terminal block. Tighten the screws firmly to
hold the wires in place. See Figure 19.
Figure 13
14. FOR RTBC ONLY:

Remove the screw and collar from the NORMALLY
CLOSED terminal of the thermostat. Discard the collar. Push
the screw through the opening in the connector attached to the
insulated wire and screw it back into the normally closed ter-
minal. See Figure 14.
15. FOR ALL CABLE:
Connect conduit hub (Chromalox CCH-1 or equal) to the box.
Attach conduit to hub and bring 8 inches of power leads into Figure 18 Figure 19
the box. See Figure 15.
20. FOR RTBC-EP ONLY:
A. Slide the bared end of the black (NORMALLY CLOSED)
thermostat wire into the opening of the terminal block which
is next to the incoming power leads.
B. Slide the bared end of the purple (COMMON) thermostat
wire into the opening opposite of the hot power lead.
Tighten the screws firmly to hold the wires in place. See
Figures 20A and 20B.
Figure 14 Figure 15
16. FOR ALL CABLE:

Strip a 3/8 inch length of each conductor of the power wiring.
See Figure 16.
17. FOR RTBC ONLY:
Crimp the ring connector onto the end of the “HOT” conduc-
tor. Remove the screw and collar from the COMMON termi-
nal. Discard the collar. Push the screw through the opening in
the ring connector. Drive the screw back into the COMMON
terminal. See Figure 17.
Figure 20A Figure 20B

INSTALLATION
21. FOR RTBC-EP ONLY: 25. FOR ALL CABLE:
Trim the blue (NORMALLY OPEN) thermostat wire so that it Push the knob onto the shaft of the thermostat. Adjust thermo-
is only 2 inches long. Tape over the end of the wire using stat to desired temperature setting. See Figure 25.
fiberglass tape. See Figure 21. 26. FOR ALL CABLE:
22. FOR RTBC-EP WITH OVERCOATED CABLE ONLY: Carefully push wires into the box. Secure lid to box. See
Slide the bared end of the ground wire into the end of the Figure 26.
uninsulated barrel connector. Crimp it on using a crimping
tool. Slide the end of the braid pigtail into the other end of the
uninsulated barrel connector and crimp it on. See Figure 22.
Figure 25 Figure 26
27. FOR CABLE WITH EXPOSED METAL BRAID:

Figure 21 Figure 22 Unravel four inches of braid from the cable and twist into a pig-
tail. Connect to appropriate grounding source. See Figure 27.
23. FOR ALL CABLE:
Mount terminal block to bottom of the box by driving the 6-32
self-tapping screw into the mounting hole as shown. See
Figure 23.
24. FOR ALL CABLE:
Thread the screws into the outside pair of mounting holes of
the thermostat leaving approximately 1/8 inch of thread. Slide
the screws into the slots in the mounting bracket. Push the
thermostat down as far as it will go and tighten the screws
firmly. See Figure 24.
6-32 Screw
Figure 27
28. FOR ALL CABLE:

Extend capillary to allow bulb to be placed in desired location.
The bulb should be placed on the bottom half of the pipe
spaced 90˚ from the nearest heating cable or centered between
equally spaced heaters. Do not locate the bulb within 3feet of
a pipe support or other heat sink.
Figure 23 Figure 24
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY

Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and es therefor, including but not limited to attorney's fees, and indemnifies Chromalox against any liability to
the work performed by Chromalox when performed, will meet all applicable specification and other specific Chromalox's vendors arising out of such litigation.
product and work requirements (including those of performance), if any, and will be free from defects in Upon Buyer's submission of a claim as provided above and its substantiation, Chromalox shall at its
material and workmanship under normal conditions of use. All claims for defective or nonconforming option either (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii)
(both hereinafter called defective) Products, parts or work under this warranty must be made in writing refund an equitable portion of the purchase price.
immediately upon discovery, and in any event, within one (1) year from delivery, provided, however all THE FOREGOING IS CHROMALOX'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY FOR
claims for defective Products and parts must be made in writing no later than eighteen (18) months after BREACH OF WARRANTY, AND IS BUYER'S EXCLUSIVE REMEDY AGAINST CHROMALOX FOR ALL
shipment by Chromalox. Defective and nonconforming items must be held for Chromalox's inspections CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON
and returned to the original f.o.b. point upon request. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES,
OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT BUYER'S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL
LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR CLAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON
PURPOSE. LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL OR CONSEQUENTIAL
Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause, it is specifically under- DAMAGES AND BUYER SHALL HOLD CHROMALOX HARMLESS THEREFROM. ANY ACTION BY BUYER
stood that Products and parts not manufactured and work not performed by Chromalox are warranted only ARISING HEREUNDER OR RELATING HERETO, WHETHER BASED ON BREACH OF CONTRACT, TORT
to the extent and in the manner that the same are warranted to Chromalox by Chromalox's vendors, and (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, MUST BE COMMENCED
then only to the extent that Chromalox is reasonably able to enforce such warranty, it being understood WITHIN ONE (1) YEAR AFTER THE DATE OF SHIPMENT OR IT SHALL BE BARRED.
Chromalox shall have no obligation to initiate litigation unless Buyer undertakes to pay all cost and expens- W2008M
Chromalox
®
PRODUCT SERV ICE

600 RIDGELY ROAD, MURFREESBORO, TN 37129 98 - 083
PHONE: (615) 848-2565 FAX: (615) 848-2181 TA - X8 - 5K
Litho in U.S.A.
4.6 Enclosure


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Dollinger Power Systems

4647 SW 40th Ave

DOLLINGER NO. : 3257674-IOM

CUSTOMER : Pratt and Whitney Power

ORDER No. : 4501799329

DOLLINGER SO No. : SO1394941

DOLLINGER SERIAL : 164495001

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1.0 SEQUENCE OF OPERATION

2.0 INSTALLATION, OPERATION & MAINTENANCE

3.0 G.A. DRAWING

4.0 PART MANUALS AND CATLOG CUT SHEETS

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1.2 PRE START-UP

1.3 NORMAL OPERATION BRIEF

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The access flange should be secured in accordance with the Installation,

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The filter should not be operated at temperatures above 240°F.

To maintain product warranty, performance and reliability, use only

The pressure vessel is fabricated from carbon steel and is designed to

2.2.2 Filter Element

The filter medium is Borosilicate Microglass with an efficiency of 100% at

The element support structure is manufactured from perforated Stainless

The element cannot be cleaned.

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(e) Install connecting pipework and valves.

(a) Ensure that the maximum rated Design Pressure and

2.4.1 Start-Up Procedure

(e) Ensure the drain and vent connections are closed.

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All filtration systems have a maximum recommended pressure

It is difficult to accurately determine the life of an element in a

2.4.3 Shut Down Procedure

(a) Close the isolating valves to filter (BAV1150 & BAV1151)

(b) Allow release of pressure by slowly opening the vent valves

IMPORTANT: For safety reasons, pressure relief must be verified before

Maintenance is necessary once the differential pressure reaches 10 psig

2.5.1 Filter Service

(c) Remove the element cluster hold-down plate to expose the

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(h) Check the vessel closure gasket for signs of deterioration. If it is

(i) Follow Start-Up Procedure as detailed in Section 2.4.1.

2.6 SPARE PARTS DATA

Recommended Maintenance spares considered necessary for use during

(a) Element Part No. 3507525

(b) Cover Gasket Part No. 3508031

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1. All available information regarding the product's potential use should be

3. The purchaser should, when a Dollinger product is being or may be

4. Any Dollinger product should be maintained, operated, inspected and

ANY QUESTIONS ABOUT THE OPERATION OR USE OF DOLLINGER

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FLOATING AND TRUNNION MOUNTED BALL VALVE

VIRGO ENGINEERS LIMITED VIRGO VALVES & CONTROLS LIMITED

Regd. Office: Works:

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