Operating and Maintenance Manual

Transcription

1 Ace Heaters, LLC Packaged Unfired Steam Generator Steam-to-Steam System Operating and Maintenance Manual Designed and Manufactured in Accordance with ASME Code Section VIII Div. I Clean Steam. Pure Steam. Process U

2 AJAX BOILER INC. Page 2 Table of Contents Page 3 Operating and Installation Instruction 4 The Packaged Unfired Steam Boiler Name Plate and Model Number 5 The Parts of the Packaged Unfired Steam Boiler 7 Receiving your Packaged Unfired Steam Boiler General Installation Instruction Feed water treatment and Blow Down Permissible Solids Concentration in Boiler Water 10 Start-up Instruction Shut down instruction Emergency Safety features Disassembly Instruction Tube Bundle and Cap Installation 13 Trouble-shooting Guide 14 Maintenance Instruction Preventive maintenance Replacement parts Material Safety Data Sheet Contact Us Warranty Manufacturers Cut-Sheets (Disclaimer: Some parts may vary from actual model)

3 AJAX BOILER INC. Page 3 Operating and Installation Instructions Congratulations on on your purchase of of a a new new Ace, Ajax Packaged Boiler, Packaged Unfired Steam Unfired Boiler. Steam In Boiler. this book, In this we book, we have included installation and and maintenance instructions that, that, if if followed, will will provide you you with with many many years years of of service from your your new new unit. unit. Also Also included included are are instruction instruction manuals manuals for each for each of the of controls the controls furnished furnished with the the generator. Please Please read read them them carefully. carefully. They should They should be helpful be in helpful both the in both installation the installation and and service of of this unit. Keep these instructions with the the unit unit for for future reference. The Ace Ajax unfired steam boiler is is of of rugged construction, yet yet of of simple simple design. The The generator uses uses steam steam from a boiler to to produce process, clean, or or pure steam, whichever the unit is is designed for. The unfired steam boiler construction and design provides a high quality, low maintenance and an extremely The unfired cost steam effective boiler steam construction generating and system. design provides a high quality, low maintenance and an extremely cost effective steam generating system. The heat exchanger tubes are rolled and expanded into a tube sheet. Each unfired steam boiler is constructed The heat exchanger and stamped tubes in accordance are rolled and with expanded Section VIII into Div-1 a tube of the sheet. ASME Code, Each unfired which is steam stamped boiler on is the constructed nameplate and with stamped applicable in accordance markings. with Section VIII Div-1 of the ASME Code, which is stamped on the nameplate with applicable markings. Experience in the field has proven that the Ace Unfired Steam Boiler, if properly applied and maintained, Experience in the field has proven that the Ajax Unfired Steam Boiler, if properly applied and maintained, will give many years of efficient, dependable and economical service. will give many years of efficient, dependable and economical service. Ajax Boiler Inc. February 2006

4 AJAX BOILER INC. Page 4 The Unfired Steam Boiler Nameplate And Model Number The Unfired Steam Boiler Nameplate The following illustration is an accurate depiction of the nameplate found on the boiler. A. NB or serial number B. Shell pressure C. Shell temperature D. Tube pressure E. Tube temperature F. Min. Atmospheric Pressure G. Atmospheric temperature H. Serial number I. Year built J. Model number K. Capacity L. Square feet M. Job number The Unfired Steam Boiler Model Number PSB V B7 S P 200 PSB = Packaged Unfired Steam Boiler V = Type (H = Horizontal, V = Vertical, M = Mini-pack style) 36 = Tank Style or Mini-Pack Style Vessel Diameter 05 = Shell Length B7 = Steam Quality (A6 = Pure Steam, B7 = Clean Steam, C5 = Process Steam) S = Steam P = Control Valve (A = Pneumatic Warren, E = Electric, P = Pilot-operated Spence ) 200 = Control Valve size (200 = 2, etc.)

5 AJAX BOILER INC. Page 5 Parts of the Packaged Unfired Steam Boiler (See Attached Diagrams) Diagram may vary from actual model

6 AJAX BOILER INC. Page 6 Receiving Your Packaged Unfired Steam Boiler Check Equipment Received. Inspect the the unit unit for for any any shipping damage. Make Make sure sure you you have have received received all loose parts, such as as listed listed on on the the Bill Bill of Lading. of Lading. Larger Larger strainers strainers and valves, and valves, usually usually 2-1/2 and 2-1/2 and above, are shipped loose. Note Note any any damages or or shortages on on the the bill bill of of lading lading prior prior to signing to signing it. If it. the If the unit is received damaged or missing parts, it it is is your responsibility to to notify the the shipping company and and file file a freight claim. Ace Ajax Heaters, Boiler cannot LLC cannot send send replacement replacement parts parts for freight for freight damaged damaged or missing or missing equipment as warranty equipment items. as warranty Permission items. to Permission return goods to return must be goods received must be from received the factory from prior the factory shipping. prior to Goods returned shipping. without Goods returned a Returned without Goods a Returned Authorization Goods number Authorization will not number be accepted. will not be Purchased accepted. Purchased parts are subject parts are to subject replacement to replacement only under only the under manufacturer s the manufacturer s warranty. warranty. The warranty The warranty does not does include not include the cost the for labor, removal, or installation of the warranted part. cost for labor, removal, or installation of the warranted part. General Installation Instruction NOTE: All electrical and piping installation should only be accomplished by qualified personnel following all applicable local, and state codes required for their installation. Code Requirements: It is very important that your installation comply with all federal, state and local codes as well as meet good industry practices as shown in publications issued by ASME, UL, ASHRAE, ABMA, etc. Placement: The steam generator was either fabricated as a vertical or horizontal unit. It should be installed on a solid foundation, preferably a concrete pad. Provide adequate clearance for normal inspection and maintenance purposes and allow tube pull clearance to remove the exchanger for servicing. A minimum clearance of 24 is recommended from all accessories for ease of maintenance. Make sure the unit is level, from side to side and front to back, to assure proper operation and draining. Use metal shims if necessary. Piping: All piping to and from the heater must be provided with adequate supports and expansion compensation so that pipe stresses are not transmitted to the unit. The relief valve should be piped to a safe drain. Stud Nuts: During shipment, the bonnet and shell flange nuts may loosen and should be re-tightened before start-up. Tighten these nuts to the torques specified later in this manual. After the unit has been in operation for a few days, check and retighten. Note: Bolting is independent on the bonnet and shellside flanges through the use of a threaded tube-sheet flange. Therefore, stud bolt nuts must be retightened on both sides. See Figure 1.1 for bolting arrangement.

7 AJAX BOILER INC. Page 7 Torque s: The following are recommended bolt torque requirements Bolt Size Min Torque Max Torque 1/2" 45 ft-lbf. 60 ft-lbf. 5/8" 90 ft-lbf. 120 ft-lbf. 3/4" 150 ft-lbf. 200 ft-lbf. 7/8" 240 ft-lbf. 320 ft-lbf. 1" 368 ft-lbf. 490 ft-lbf. 1 1/8" 533 ft-lbf. 710 ft-lbf. 1 1/4" 750 ft-lbf ft-lbf. 1 1/2" 1200 ft-lbf ft-lbf. Notes: * Spray each stud bolt and nut generously with penetrating oil before re-torque. ** Gasket thickness before compression. All partition gaskets are in width before compression. All gaskets expand twice their width after compression. *** These are recommended torque values. Stud bolts must not be stressed above 60% of their yield strength. Stud bolt torque (T) & Bolt diameter (Y) Gap between flanges approx. (X) after torque Figure 1.2 Shell flange to bonnet flange joint DW Tube Bundle 360º Leak detection area Figure 1.1 Shell flange to bonnet flange joint SW Tube Bundle

8 AJAX BOILER INC. Page 8 Water Connections: Pipe make-up water line to water make-up solenoid assembly. Pipe surface and bottom blow-off connections to drain. Steam Piping: Check the steam supply pressure. The steam supply pressure should not exceed design pressure stated on List of Materials, which include design parameters. Connect steam supply line to control valve strainer. Connect product steam outlet of generator to system steam header. Condensate: The condensate outlet of the steam trap is to be connected to condensate return line. Relief Valve: The relief valve discharge must be piped to a floor drain to eliminate the potential of scalding burns. The drain line must be the same size as the relief valve outlet and have a downward slope to insure proper drainage. The drain line termination should be visible to see discharge. The unit's operating pressure cannot exceed that listed on the relief valve nameplate. Electrical: Verify the electrical supply using a voltmeter. The voltage tie-in leads are indicated on the wiring diagram. Electrical power supplied through remote mounted electrical disconnect, supplied by others. This unit contains sensitive control components and it is recommended that a suitable commercial grade surge protection device be installed. The unit must be installed in accordance with the National Electric Code and in accordance with all state and local codes. Water Treatment: We, the manufacturer of your Packaged Unfired Steam Boiler, wish to call to your attention the necessity for a sound approach to proper water treatment. The unit uses boiler steam as its heating medium. On steam systems, boiler makeup water continuously introduces contaminants; scale forming solids, corrosive minerals and oxygen, which can cause corrosion or scale formation inside the tube bundle. Whenever appreciable amounts of raw makeup water are continuously added to your system, we recommend that the problem be brought to the attention of a qualified water consultant. Proper treatment will insure longer product life and reduced maintenance. Also, note that proper and adequate blow down of unit effects quality of produced steam. Feed Water Treatment and Blow Down Water treatment in the Unfired Steam Boiler is not as critical as in direct-fired boilers from the standpoint of generator failure. It must, however, be considered in every installation. Though water treatment frequently is unnecessary, it depends on the makeup water quality and its total solids content weighed against the percentage of makeup water added per pound of steam generated. One situation that would require water treatment is the use of an unfired steam boiler for humidification only in a hard water region. Hard water is usually considered any water containing 200 ppm total hardness. It may have additional mineral and organic solid content, however, that may boost its total solids content beyond 250 ppm. In humidifier applications, there is 100 percent makeup to the unfired steam boiler. Every pound of water fed to the generator leaves its solids content concentrated in the generator boiler water. If the solids reach a concentration of 5,000 ppm or higher, moisture and solids maybe carried over with the steam, making it extremely difficult to control the humidifying equipment. Often a suggested first treatment step is to soften the water. This converts insoluble calcium and magnesium salts to soluble salts. The soluble salts do not form hard scale on the tubes. They remain in solution in soft form to be discharged proportionately in the surface and bottom blow off. One cautionary note, over-treatment can cause more harm than good. The treatment must be compatible with the tubing used in the steam generator. In addition, if the steam is to be used directly in food preparation or for sterilization and some water treatment is necessary, the water must be nontoxic.

9 AJAX BOILER INC. Page 9 It is possible for makeup water to be so hard and so high in total solids that complete demineralization would be the most economical approach. To determine the best type of treatment required for your system, call in a water treatment specialist. Despite its value, water treatment alone is not sufficient. The key factor in effectively controlling solids concentration in the unfired steam boiler is a regular batch or continuous blow down from the generator shell. This should be combined with routine sample testing of the boiler water for total solids content. A formula for calculating rate of blow down follows: Permissible Solids Concentration in Boiler Water Operating pressure (psig) Solids (ppm) Zero to 5 2,500 5 to 10 2, to 25 1, and up 1,000 CAUTION: Prior to start-up, be certain that safety valve discharge and blow down valves are piped to a safe area to avoid possibility of injury to personnel or damage to property.

10 AJAX BOILER INC. Page 10 Start-up Instruction It is assumed that installation is complete and that all connections have been made, including: electrical, steam, water, instrument air, vents, drains and safety valve discharge lines. 1. Make sure all adjustable settings are observed: a) Steam control valve is to be set for the desired output. See pressure control manual within this booklet for fine-tuning. (Example: 15 psi) b) Steam Safety High Pressure Limit Switch (MERCOID) is to be set 10 psi above control valve set pressure. (Example: 25 psi) c) Pressure relief valves are factory set at 10 psi above high-pressure limit switch. (Example: 35 psi) 2. Turn power on: Turn on electrical system at manual Power-On switch on control panel. The On light (green), high-pressure light (red), feed water light (amber), and low water level light (red) should come on. 3. Supply water to system: The operator shall familiarize themselves with the valving and by-pass lines involved in the feed water lines. It will be observed that the feed water can be valved to bypass the feed water valve by use of a three-valve by-pass around the feed water valve (not provided with unit). This is recommended for initial fill of tank. The valving in the feed water circuit shall be set to allow the passage of feed water through the feed water valve and into the shell of the steam generator. The Low Water (red) and Feed Water (amber) lights will be on. If feed water is now introduced to the unit, it will continue to fill the generator shell until the water level control de-energizes the feed water solenoid (on initial fill of tank operator will have to manually shut off by-pass). At this point, the gauge glass on the steam generator shell will indicate water at approximately the quarter point of the sight glass, the feed water low water alarm and light will be off. At the same time, open the top tri-cock (or isolation ball valve) to bleed the air out. Leave the tri-cock open until the feed water level starts to stabilize. 4. Supplying plant steam to generator: A. For Warren Pneumatic: 1) Turn on the pneumatic system to the control making sure that 35 psi supply air is not exceeded. 2) Slowly open the manual shut-off valve to the control valve that passes the heating steam. Open this valve slightly and wait for the metal parts to heat up, then allow the control valve to slightly open to allow the coil and exchanger head to get hot. This is to ensure that the valve body and seat are not shocked, and that all connections to the valve are proved tight. 3) Then open the control valve completely; this will take about 15 to 30 seconds. You should notice the required steam pressure on the cap gauge. This pressure should not be higher than system design pressure noted in design parameters section. 4) Fine-tune Pressure Controller. Refer to Manual within this booklet.

11 AJAX BOILER INC. Page 11 B. For Spence P14 and P15 pilot: 1) Adjust the pilot wheel to the down position (zero pressure on spring). 2) Slowly open the manual shut-off valve to the control valve that passes the heating steam. Open this valve slightly and wait for the metal parts to heat up. This is to ensure that the valve body and seat are not shocked, and that all connections to the valve are proved tight. 3) Slowly turn the Spence pilot adjustment wheel until steam enters tube bundle. Let stabilize for one (1) minute, or until steam is observed exiting the tri-cock on the float assembly. If no steam is observed, turn pilot adjustment wheel in one quarter (1/4) turn increments with one (1) minute pauses until steam is observed. Close tri-cock, and observe steam pressure on shell pressure gauge. 4) Continue adjusting pilot adjustment wheel with one (1) minute pauses until desired pressure output from generator is observed. 5) Fine tune pilot. Refer to Manual within this booklet. 5. Open product steam valve on steam outlet of unit. 6. Test all safety controls to ensure they are operable. 7. The steam generator will now function automatically under designed load. Shut Down Instruction 1. Close off plant steam to generator: 2. De-energize all electrical power sources to the steam generator 3. Close air line supplying instrument air to generator (if applicable) 4. Shut valve for product steam 5. Drain water out of unit: Open drain valve on unit. Pull lever on relief valve and leave open until unit has drained and cooled. Also, drain water out of sight glass assembly. 6. Allow unit to cool down: Approximately hours. Emergency Safety Features 1. Control valve system: The steam control valve system is designed to fail closed in the event of a power failure. 2. Relief valve: The relief valve is designed to relieve the pressure in the vessel in the event the pressure gets too high. 3. Level controls: Shell water level controls will shut off the steam control valve in case of low feed water level in the shell. At the same time, the low level alarm(s) will be triggered (red light) (audible or remote alarm). 4. Mercoid pressure switch: This high-pressure limit switch will shut off the steam control valve activating the high-pressure (red light) alarm.

12 AJAX BOILER INC. Page 12 Disassembly Instructions 1. Controls and instrumentation: Refer to the individual "Maintenance Instructions" sections for these components. 2. Bundle removal: 1. Shut down unit. (See shut down instructions). 2. Drain steam generator to sewer (after cool down period). 3. Be certain plant steam is closed off completely. 4. Disconnect flanged lines to tube bundle bonnet (stream inlet and condensate outlet). 5. Remove nuts from the steam bonnet and shell nozzle. 6. Steam bonnet can now be removed and tube bundle can be pulled out directly. Note: Tube bundle is supported inside the steam generator by a full length steel, or stainless steel, track. Care should be taken to remove bundle without damaging the tubes. Tube Bundle and Cap Installation 1. Flange and tube sheet preparation: Gasket surfaces must be clean and even. 2. Apply gaskets: Install gasket material on stationary flange with adhesive side down. 1. Overlap material at top of flange. 2. Overlapped ends should protrude out of flange, with one end on each side of top bolt. 3. Make sure gasket does not extend into bore. Gasket Material 3. Install heat exchanger bundle: Bundle should be lifted or jacked to proper height before being pushed into gasket. Bundle should be left supported until installation is complete. 4. Apply gasket material on channel cap: Overlap gasket material around bolt hole as above. Apply gasket on divider sections as well. Overlap the divider gasket strips over the main gasket.

13 AJAX BOILER INC. Page Bolting cap and flange: Place at least four (4) bolts thru stationary flange, double nut and thread thru tube sheet. Using jack or overhead support to lift cap into position, align with the bolts that are in place, level and slide cap against tube sheet. Remove second nut from tank side of bolt. Install nuts on bolts in place and tighten finger tight. Install remaining bolts and nuts, equal out bolts on tanks side and cap side, again tightening finger tight. 6. Torque: Unless otherwise specified, when using Goretex or spiral wound gaskets, use the following table to find recommended bolt tightening torque. Bolt Size Min Torque Max Torque 5/8" 90 ft-lbf. 120 ft-lbf. 3/4" 150 ft-lbf. 200 ft-lbf. 7/8" 240 ft-lbf. 320 ft-lbf. 1" 368 ft-lbf. 490 ft-lbf. 1 1/8" 533 ft-lbf. 710 ft-lbf. 1 1/4" 750 ft-lbf ft-lbf. 1 1/2" 1200 ft-lbf ft-lbf. 7. Torque bolts: Set torque wrench to half of recommended torque rating. Tighten bolts according to alternating crossover pattern. Do not over tighten any one bolt initially as this could crimp the gasket. The sequence is to lightly tighten the first bolt then move directly across the circle for the second bolt. Continue as illustrated below. Tighten each bolt in increments repeating the cycle until half torque ratings are reached. Reset torque wrench to full torque rating, and repeat tightening sequence in increments until full torque ratings are reached. Remember, for the gaskets to work properly, the flange faces must be kept parallel and the bolts tightened uniformly. Completion: When bolt-tightening sequence is complete, remove the support from the tube sheet and the channel cap.

14 AJAX BOILER INC. Page 14 Trouble-shooting Guide a Banging or pinging: 1. Check for proper condensate drainage. Clean out all dirt and debris. 2. Check for backpressure in the condensate line. 3. Check steam trap(s) for proper operation. b Erratic temperature control: 1. Check for condensate lift. 2. Check for proper steam pressure. Make sure it is not more than what the steam generator is designed for. 3. Check steam trap(s) for proper operation. 4. On pneumatic valves, check control pressure to the actuator. Make sure it is not fluctuating. 5. Check for debris in valve or strainer. 6. Sticking valve stem. This can be caused by a bent valve stem or a valve stem not properly lubricated. A sticking valve stem can also be caused by the packing gland assembly being too tight. Loosen the packing gland assembly and lubricate. 7. Regulator is controlling at incorrect set point. 8. The sensitivity screw or wheel on the controller needs adjustment. c Poor recovery: 1. Shut unit down, remove bonnet and inspect coil for scale or fouling, restricting heat transfer. Clean with an approved chemical treatment. 2. Make sure the steam generator is not trying to supply more steam than it is designed for. 3. Check for fouling of steam pilot on pilot operated valves. 4. Check for proper air pressure to control valve on pneumatic valves. d Control Valve not closing: 1. The valve seat is worn or there is debris in the seat. 2. The packing gland assembly is too tight, locking the valve stem. 3. The temperature adjusting nut assembly is raised too high. 4. Increase the valve spring tension.

15 AJAX BOILER INC. Page 15 Maintenance Instruction KEEP TUBES CLEAN: In order to maintain high efficiency, the steam generator tubes should be cleaned periodically. The frequency of cleaning the tubes depends on the characteristics of the water and the type of installation. Contact your local water treatment company for evaluation and recommendations. GASKETS: Tighten gaskets during start up and periodically thereafter. Leaky gaskets can cause corrosion of the stud bolts. It is good practice to use a new gasket each time the tube bundle or cap is removed. STUDS: Keep studs protected from corrosion with paint or oil. Keep stud bolts tight to prevent leaky gaskets. Stud bolts will not corrode if they are kept dry and protected. Use caution in removing and reinstalling the bonnet. The steam generator must be shut down and drained before attempting removal. Before removing the nuts, apply penetrating oil and allow it to set for a few minutes. Forcing the nut off could cause breakage. Use a torch to heat the nut and it will come off easier. If a torch is not available, take a cold chisel, place it across the flat of the nut, and strike several sharp blows with a heavy hammer. This should loosen the nut. If necessary, it is better to split the nut open and replace it than to break the stud off. CONTROLS: Under normal conditions, controls furnished with the steam generator require very little service. It is important, however, that the controls be protected from moisture. All controls should be checked frequently to make sure that they are working properly. RELIEF VALVE: The steam generator is equipped with a lever type relief valve of ASME rated capacity. To maintain the valve in good working condition, it should be manually opened once a month. The relief valve outlet should be piped directly to an open drain and the drain checked frequently for discharge. If the relief valve is leaking or does not operate freely, it should be replaced. Preventive Maintenance Every 3 months: 1. Visually check for leaks from the valve body joints, piping, packing and stem areas. 2. Visually check for excessive corrosion on the regulator, bellows, capillary, bulb, bridge, and yoke. 3. Check for full valve travel. Less than full valve travel may indicate a leak in the bellows, capillary, or bulb. 4. Test the temperature adjusting nut assembly for freedom of movement. 5. Remove bulb from the steam generator and check for excessive corrosion or erosion. 6. Strainers should be inspected and cleaned. Damaged screens should be replaced. Annual Maintenance 1. The relief valve must be tripped to insure proper operation as a safety device. 2. Pull the tube bundle and clean the inside and outside of the tube bundle of scale. The frequency of tube cleaning will be determined after inspection. (Heavy scale will indicate more frequent cleaning is necessary). A light sludge or scale coating on the tube greatly reduces its effectiveness. A marked increase in pressure drop and/or reduction in performance usually indicate cleaning is necessary. The tube bundle should be cleaned with a tube brush and/or a muriatic pool acid solution. Replacement Parts Ajax Ace Heaters Boiler maintains a a complete equipment list list for for each Unfired Steam Boiler, filed by serial number. In order In order for for us us to to give give prompt service and to ensure that correct parts parts are are supplied, please please be be sure sure and and supply the model and serial number.

16 AJAX BOILER INC. Page 16 Material Safety Safety Data Data Sheets Sheets Some of of Ace Ajax Heaters, Boiler products LLC products contain contain materials materials that that have have been been recognized recognized as as posing health health risks. Material risks. Material Safety Safety Data Sheets Data Sheets for these for these materials materials are available are available from from your your local local Manufacturer s Manufacturer s rep. rep. When When requesting this information, be sure to to have the model number and serial number available. If you do not know who your local Manufacturer s Rep is, you can find out by logging into the If you do not know who website, your and local clicking Manufacturer s on the Representative is, you tab can found find in out the table by logging of contents. into the website, and clicking on the Representative tab found in the table of contents. Ace Ajax Heaters, Boiler Inc. LLC S. Harbor Blvd. Santa Ana, CA Parts: info@ajaxboiler.com

17 FACTORY LIMITED WARRANTY POLICY The Ajax Ace Ace Boiler Factory Factory limited limited warranty warranty provides provides assurance assurance that all that products all products are free are free from from manufacteres manufacuteres defects defects at the at time the time of of shipment and meet specifications cations and and performance described in in the the product product literature. literature. It is important to understand the difference between a factory warranty and an installed warranty. There are many factors that can occur to the products after they are shipped that the company has no control over and can not fully verify. These includes: 1. Hidden damage during the shipping. 2. Handling damage. 3. Damage during storage. 4. Installation conditions. 5. Other unknown variables in the system design: maintenance, pulsation and vibrations. The installed warranty is the responsibility of the architech, specifying engineer, contractor and/or owner who jointly have control over the application, installation, location, operating and maintenance conditions. The The Ace Ajax Heaters, Boiler Inc. LLC warranty warranty excludes excludes extended extended liabilities. liabilities. Extended Extended liability liability typically typically occurs occurs when when products products are installed are without proper installed drainage, without fl ooding proper containment drainage, or when flooding safety containment devices are or not when tested safety and devices repaired are or not replaced tested when and repaired needed. or replaced when needed. Product problems are often caused by the condition of the water, the lack of water treatment and/or the improper treatment of the water, insuffi cient combustion air, improper draft conditions, bolts not re-tightened, pipes not fl ushed and cleaned of oil, metal chips, rags, vibration and pulsation etc. These are installation, operating and/or maintenance conditions that are beyond the seller s responsibility and are not covered by the factory warranty, but may be covered by the installer s warranty. The factory warranty covering company products is based upon extensive product development and testing. Combustion products under go certifi cation testing and approvals to Underwriters Laboratory (UL) standards. Auditing of the production of combustion products is conducted by a nationally recognized testing laboratory. Pressure vessel products are designed and manufactured to American Society of Mechanical Engineering (ASME) and National Board (NB) Design standards. Design reviews, factory product manufacturing quality inspections and testing are carried out by a third party National Board authorized inspection agency. Ajax Ace Boiler Heaters, Inc. LLC products products have have proven proven themselves themselves in service in service for over for 85 over years 85 years which which indicates indicates that the that company the company products perform exceedingly products perform well when exceedingly normal installation, well when operating normal installation, and maintenance operating conditions and maintenance exist. conditions exist. The following is a review from the the terms and and conditions of of sale. sale. Also included in in paragraph two, two, below, is the is the Ajax Ace Boiler Heaters Inc. nonconformance nonconformance policy. LLC policy. 1. Ace Heaters, 1. Ajax LLC Boiler warrants Inc. warrants its products its products against against defective defective material material and/or and/or workmanship workmanship only. The only. warranty The warranty does not does not apply to apply to operational operational failures, failures, electrical electrical failures, failures, gasket gasket leaks, leaks, and/or and/or other other malfunctions caused by by improper application, installation and/or maintenance. and/or maintenance. 2. It is the 2. buyer s It is the responsibility buyer s responsibility to inspect to and inspect accept and the accept product, the when product, received, when received, as conforming as conforming to their purchase to their purchase order, order, specifications specifi and approved cations and drawings. approved All drawings. claims for All non-conformance, claims non-conformance, errors, shortages, errors, etc. shortages, must be etc. made must within be made 10 within 10 days after receipt days of after the receipt shipment. of the shipment. 3. Ace Heaters, 3. Ajax LLC Boiler do not Inc. provide do not provide a warranty a warranty or guarantee, or guarantee, express express or implied, or implied, in any in manner, any manner, form, form, usage usage of trade, of trade, merchant merchantability -ability or fitness or tness which which extend extend beyond beyond the product the product description description and and quotation. quotation. 4. Ace Heaters, 4. Ajax LLC Boiler liability Inc. is liability limited is limited to the factory the factory repair or repair replacement or replacement of warranty of warranty failures, failures, or non-conformance, or upon upon the the return of the return product of the to product the factory. the factory. 5. Ace Heaters, 5. Ajax LLC Boiler is not Inc. liable is not for liable any for direct any or direct consequential or consequential damages. damages. 6. Ace Heaters, 6. The LLC Ajax warranty Boiler Inc. is based warranty upon is based section upon 23161(2) section of 23161(2) the uniform of the commercial uniform commercial code and code is printed and in is printed the termin the terms s and conditions and of sale conditions which of is sale referenced which is in referenced every quotation, in every on quotation, the back on of the sales back order of sales acknowledgements order acknowledgements and invoices. and invoices. It is legally correct It is legally and is correct an industry and is standard industry policy. standard policy. February 2017 ace

18 WARRANTY Limited Ace Heaters, LLC provides a limited warranty on its products against defective material and/or workmanship Ajax Boiler Inc. provides a limited warranty on its products against defective material and/or workmanship only. This only. This limited warranty is not applicable to operational failures, electrical failures, gasket leaks, wear or malfunctions limited warranty is not applicable to operational failures, electrical failures, gasket leaks, wear or malfunctions caused by caused by improper application, storage, installation, and/or maintenance. improper application, installation, and/or maintenance. Product Period - The following Limited Warranty period are from date of shipment: Tanks Product Period - The following Limited Warranty period are from date of shipment: Tanks - Carbon Boiler Steel: Pressure One Year Vessels: One year. Tanks - Stainless Carbon Steel: Steel Three Tank Years Storage Water Heaters Single-wall and Heat or Double-wall Exchanger Tank/Exchanger Pressure Vessels: Coils: One One year. Year Clean Steam Stainless Generators: Steel One Tanks: YearThree years. Linings: (Pro-rated Boiler Copper Warranty) Fin Coils: Three years. Magnesium Single-wall Anodes must or be Double-wall used at all Tank/Exchanger times to maintain the Coils: Limit One Warranty year. Section VIII Tanks: Epoxy: 30" Single-wall dia. and above or Double-wall (Three years) Mini-Packs : One year. Glass: 24" Atlas dia. and Series under Condensing (One year). Boiler: One year. LIMITED Glass: 30" Linings: dia. and above (Pro-rated (Five Warranty) years). Cement: (Five years). In Section VIII Tanks: Glass 30" dia. and above (Five years). Pre-Krete: (Ten years). Section IV Tanks: SW Model Only Glass 24" dia. and under (One year). Glass (One year) & Epoxy (Three years). Cement (Five years). Minipacks Single-wall or Double-wall: Pre-Krete One Year(Ten years). Shell & Tube Heat Exchangers In Section IV Single-wall Tanks: Glass or (One Double-wall: year). One Year Atlas Series Controls: Condensing Components Boiler manufactured (Heat Exchanger): by other One than Year Tanks Ajax Boiler Inc. such as controls, instruments, forced draft Triton Series Near Condensing burner, etc., provided Boiler (Heat with Exchanger): Twelve Years the boilers and packaged products are not covered by the Ajax Boiler Inc. Liberty Series Condensing Warranty. Boiler However, (Heat Ajax Exchanger): Boiler Inc. extends Ten Years to the customer the same warranty provided by the B-Series Copper Fin Boiler: Three Years manufacturer to Ajax Boiler Inc. The customer shall receive the full benefi ts of adjustments made to Ajax Boiler Inc. by the manufacturer. Controls: Components manufactured by other than Ace Heaters, LLC such as controls, instruments, forced draft burner, etc., provided with the boilers and packaged products are not covered by the Ace Heaters, LLC Any claim for adjustment under this limited warranty must be made within the warranty period. Ajax Boiler Inc. s liability shall Warranty. However, Ace Heaters, LLC extends to the customer the same warranty provided by the be limited to factory repair or, at Ajax Boiler Inc. s option, replacement of all parts which, upon test and examination by Ajax manufacturer to Ace Heaters, LLC. The customer shall receive the full benefits of adjustments made to Boiler Inc., prove to be defective material and/or workmanship and within the above limited warranty. If required by Ajax Ace Heaters, LLC by the manufacturer. Boiler Inc., parts which are claimed to be defective must be promptly delivered to the Ajax Boiler Inc. facility, transportation Any claim for adjustment under this limited warranty must be made within the warranty period. Ace Heaters, LLC s charges prepaid. This warranty does not cover the cost of labor, removal, or installation of the warranted item during the liability shall be limited to factory repair or, at Ace Heaters, LLC s option, replacement of all parts which, upon t est limited period. and examination by Ace Heaters, LLC, prove to be defective material and/or workmanship and within the above limited warranty. If required by Ace Heaters, LLC, parts which are claimed to be defective must be promptly This warranty is limited to the above and applies only for the period set forth. Ajax Boiler Inc. will not be liable for any loss delivered to the Ace Heaters, LLC facility, transportation charges prepaid. This warranty does not cover the cost damage, direct, incidental or consequential damages of any kind, whether based upon warranty, contract, negligence or of labor, removal, or installation of the warranted item during the strict liability and arising in connection with the sale, use or repair of the products. Ajax Boiler Inc. s maximum liability shall limited period. This warranty is limited to the above and applies only for the period set forth. Ace Heaters, LLC will exceed the contract price for the product s merchantability or fitness for any particular purpose and in no event shall be held not be liable for any loss damage, direct, incidental or consequential damages of any kind, whether based upon warranty, responsible for any consequential damages. contract, negligence or strict liability and arising in connection with the sale, use or repair of the products. Ace heaters's maximum liability shall exceed the contract price for the product s merchantability or fitness for any particular purpose and For complete Limited Warranty conditions see Section G and H under terms and condition of sale. in no event shall be held responsible for any consequential damages. For complete Limited Warranty conditions see Section G and H under terms and condition of sale. Ajax Boiler Inc., also doing business as Ace Boiler Inc., is referred to herein as Ajax Boiler Inc. Ace Heaters, LLC, also doing business as Ace Heaters, LLC, is referred to herein as Ace Heaters, LLC Ace Heater, LLC 130 Klug Circle, Corona CA PHONE: (951) FAX: (951) February 2017 ace

19 Ace Heaters, LLC WARNING PRODUCT SAFETY NOTICE ACE BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES AJAX BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES Before using this product, read and understand instructions. Save these instructions for future use. Before Before servicing, using to this prevent product, serious read burns and or understand injury, the boiler instructions. and water Save heater these products instructions must for be cooled future use. to less than 80 F (27 C) Before and servicing, the pressure to prevent must be serious 0 psi (0 burns bar). or injury, the boiler and water heater products must be cooled to less than Turn off 80 F the (27 C) electrical and power the pressure before making must be electrical 0 psi (0 connections bar). to prevent electrical shock. These products must be placed in a controlled location where untrained or unqualified personnel cannot access the Turn off the electrical power before making electrical connections to prevent electrical shock. operating or safety controls, must not be able to come in contact with high temperature or high pressure parts and must not perform These maintenance products must or demolition be placed work. in a controlled location where untrained or unqualifi ed personnel cannot access the All work operating performed safety must be controls, by qualified must properly not be able equipped to come personnel in contact trained with high in the temperature proper application, or high installation, pressure parts and and must maintenance not perform demolition maintenance of plumbing, or demolition steam, work. and electrical equipment and/or systems in accordance with all applicable All work codes performed and ordinances. must be by qualifi ed properly equipped personnel trained in the proper application, installation, and ACE Boilers maintenance and Water or demolition Heaters are of complete plumbing, package steam, units and with electrical safety equipment and operating and/or controls systems and in are accordance constructed with with all non ASBESTOS applicable materials. codes and Any ordinances. replacement gaskets, refractory, insulation, etc used must not contain Asbestos. No additional insulation is required on the Boilers and Water Heaters. Ajax Boilers and Water Heaters are complete package units with safety and operating controls and are constructed with Additions or replacement of insulation on any connecting pipes or accessories to the Boilers and/or Water Heaters must be of NON-ASBESTOS non ASBESTOS and materials. contain only Any replacement non-hazardous gaskets, materials. refractory, insulation, etc used must not contain Asbestos. Crystalline No additional Silica, a material insulation known is required to cause on cancer, the Boilers may be and encapsulated Water Heaters. in some refractory or insulation materials and must Additions be handled or replacement only by authorized of insulation trained on personnel. any connecting Crystalline pipes Silica or accessories as used is encapsulated to the Boilers and and/or is not Water harm Heaters must full in this be form. of NON-ASBESTOS Care must be taken and during contain removal only non-hazardous or replacement materials. of refractory or insulation to remove it in bulk form and Crystalline avoid generation Silica, a material or inhalation known of dust. to cause Removal cancer, must may be be properly encapsulated performed in some by trained, refractory qualified or insulation and materials equipped and personnel. must be handled This is also only true by of authorized Asbestos not trained contained personnel. in ACE Crystalline products but Silica may as be used otherwise is encapsulated contained and in is not harm replacement materials or parts, in connecting piping or other nearby products. full in this form. Care must be taken during removal or replacement of refractory or insulation to remove it in bulk All safety and operating controls must be set within the specified operating limits and tested periodically to assure proper operation. form All and limit avoid and generation operating controls or inhalation must of be dust. installed Removal in series must on the be boiler. properly performed by trained, qualifi ed and Connect equipped drain pipes personnel. to a safe This drain is to also prevent true of serious Asbestos personal not contained injury from in relief Ajax valve products discharge but may and be or from otherwise boiler contained blow in down discharge. replacement materials or parts, in connecting piping or other nearby products. After installation, All safety and check operating for proper controls operation must of be all set limit within and the operating specifi ed controls operating before limits leaving and the tested site. periodically to assure proper Perform operation. scheduled All and limit annual and operating inspections controls including must checking be installed Controls in series for proper on the calibration boiler. and performance. Connect drain pipes to a safe drain to prevent serious personal injury from relief valve discharge and or from boiler blow down discharge. Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and equipped After personnel installation, in check the operation, for proper service, operation modification, of all limit and removal operating or demolition controls before of these leaving products the site. or replacement of parts Perform with non-authorized scheduled and factory annual inspections non-asbestos including materials checking could cause Controls damage, for proper personal calibration injury and or death. performance. Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and equipped personnel in the operation, service, modification, removal or demolition of these products or replacement of parts with non-authorized factory non-asbestos materials could cause damage, personal injury or death. Ace Heaters. LLC February 2017 ace

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21 Kunkle Safety and Relief Products Series 6000 and Models 6933, 6934, 6935 ASME Section I and VIII, Steam, V and UV, ASME Section VIII, Air/Gas UV National Board Certified. Models 6933, 6934, and 6935 are ASME Section IV, Steam, HV National Board Certified Features O-ring seats available for exceptional leakfree performance, reduced maintenance cost, multiple cycles with tight shutoff, improved seating integrity. Wide hex on valve nozzle provides wrenching service clearance for easy installation. Dual control rings offer easy adjustability for precise opening with minimum preopen or simmer and exact blowdown control. Pivot between disc and spring corrects misalignment and compensates for spring side thrust. Grooved piston model disc reduces sliding area and friction. Model Descriptions Model 6010: Side outlet. Full nozzle design with bronze/brass trim. Available with O-ring seats. For exceptional leak-free performance. Model 6021: Same as Model 6010 with Teflon (PFA) disc insert. For exceptional leak-free performance (use on steam only). Model 6030: Same as Model 6010 except SS trim (nozzle and disc). Available with O-ring seats for exceptional leak-free performance. Model 6182: Top outlet. Full nozzle design with bronze/brass trim. O-ring seat available for exceptional leak-free performance. Model 6121: Same as Model 6182 with Teflon (PFA) disc insert. For exceptional non-leak performance (use on steam only). Model 6130: Same as Model 6182 except SS trim (nozzle and disc). O-ring seat available for exceptional leak-free performance. Model 6186: Top outlet. Full nozzle design with bronze/brass trim. 150 psig [10.3 barg] maximum set pressure. Replaces Model 86 (original equipment only). Model 6283: Over-sized side outlet. Full nozzle design bronze/brass trim. Model 6221: Same as Model 6283 with Teflon (PFA) disc insert. For exceptional leak-free performance (use on steam only). Model 6230: Same as Model 6283 except SS trim (nozzle and disc). Model 6933: Same as Model 6010 except certified for ASME code Section IV. Low pressure steam heating boilers set at 15 psig [1.0 barg] only. Model 6934: Same as Model 6021 except certified for ASME code Section IV. Low pressure steam heating boilers set at 15 psig [1.0 barg] only. Model 6935: Same as Model 6030 except certified for ASME code Section IV. Low pressure steam heating boilers set at 15 psig [1.0 barg] only. Applications Steam Boilers and Generators. Air/Gas Compressors - reciprocating or rotary - portable or stationary, intercoolers and aftercoolers. Pressure Vessels - containing steam, air or non-hazardous gas. Including tanks, receivers, sterilizers and autoclaves. Pressure Reducing Stations - protection of the discharge or low pressure side of system. Model 6010 Pressure and Temperature Limits Models 6010, 6021, 6182, 6283, 6221 Steam Service 3 to 250 psig [0.2 to 17.2 barg] -60 to 406 F [-51 to 208 C] Air/Gas Service 3 to 300 psig [0.2 to 20.7 barg] -60 to 406 F [-51 to 208 C] Models 6030, 6130, 6230 Steam and Air/Gas Service 3 to 300 psig [0.2 to 20.7 barg] -60 to 425 F [-51 to 218 C] Note 1. Resilient seats determine temperature range. (see page 11) Total Flow Control Solutions Tyco reserves the right to change product design and specifications KUKMC-0394-US-0207 without notice. Copyright 2002 by Tyco International Ltd. Kunkle Safety and Relief Products Series 6000 and Models 6933, 6934, 6935 Parts and Materials Models 6010, 6021, 6030, 6221, 6230, 6283, 6933, 6934 and 6935 No. Part Name Materials Materials 6010, 6021, 6221, 6030, 6230, , 6933, Nozzle Bronze SS 2 Body Set Screw SS SS 3 Warn Ring Set Screw SS SS 4 Disc B21 Alloy 485, SS 5 Wire and Seal SS Wire and Lead seal SS/Lead 6 Guide Set Screw SS SS 7 Retainer Nut Brass, B16 Brass 8 Stem SS, A SS 9 Body Bronze Bronze 10 Lever Steel Steel 11 Jam Nut Brass, B16 Brass 12 Lift Nut Steel Steel 13 Cap Brass Brass 14 Lever Pin Steel Steel 15 Cap Set Screw SS, Commercial 18-8 SS 16 Compression Screw Brass, B16 Brass 17 Spring SS SS 18 Spring Step Brass, B16 Brass 19 Stem Retainer Brass, B16 Brass 20 Guide Brass/Bronze Brass/Bronze 21 Warn Ring Brass/Bronze Brass/Bronze 22 Seat 1 1, 2 1, 2 Note 1. Models 6021, 6121, 6221 and 6934 Teflon, optional O-ring seat available for all others except Models 6933 and Tyco reserves the right to change product design and specifications KUKMC-0394 without notice. Copyright 2002 by Tyco International Ltd Model 6010 Model 6021 Seat Retainer Disc O-ring Model 6010V (Optional Soft Seat)

22 Models 6130, 6182 and 6186 Model 6121 Seat Retainer Disc O-ring Model 6010V (Optional Soft Seat) Kunkle Safety and Relief Products Series 6000 and Models 6933, 6934, 6935 Parts and Materials Models 6121, 6130, 6182 and 6186 No. Part Name 6121, 6182, Nozzle Bronze SS 2 Body Screw Steel Steel 3 Warn Ring Set Screw Steel Steel 4 Disc Brass, B21 Alloy 485 SS 5 Wire and Seal SS Wire and Lead seal SS Wire and Lead seal 6 Guide Set Screw Steel Steel 7 Retainer Nut Brass, B16 Brass, B16 8 Stem SS SS 9 Body Bronze, B584 Alloy Bronze, B584 Alloy Lever Steel Steel 11 Jam Nut Brass Brass 12 Lift Nut Steel Steel 13 Cap Brass Brass 14 Rivet Steel Steel 15 Cap Screw Steel Steel 16 Compression Screw Brass Brass 17 Spring SS, A SS, A Spring Step Brass, B16 Brass, B16 19 Stem Retainer Brass, B16 Brass, B16 20 Guide Brass/Bronze Brass/Bronze 21 Warn Ring Brass/Bronze Brass/Bronze 22 Warn Ring Spring 1 SS SS 23 Seat Notes 1. Item 22 available as an option. 2. Item 23 is Teflon for Model Viton O-ring seat available on Models 6182, 6186, and Tyco reserves the right to change product design and specifications KUKMC-0394 without notice. Copyright 2002 by Tyco International Ltd. 3 Kunkle Safety and Relief Products Series 6000 and Models 6933, 6934, 6935 Series 6000 and Models ASME Section I and VIII, Steam, ASME Section VIII, Air/Gas National Board Certified. Models are ASME Section IV, Steam, National Board Certified Specifications Model Orifice Connections Valve Dimensions Approximate Number 1 ANSI Standard in [mm] Weight Inlet Outlet A B C lb [kg] in [mm] in [mm] 60**DC# D 1/2 [12.7] 3/4 [19.0] 2 1 /8 [54] 1 5 /8 [41] 6 1 /2 [165] 1 1 /2 [0.7] 60**DD# 2 D 3/4 [19.0] 3/4 [19.0] 2 1 /8 [54] 1 5 /8 [41] 6 1 /2 [165] 1 3 /4 [0.8] 61**DC# D 1/2 [12.7] 6 1 /2 [165] 1 1 /4 [0.6] 60**ED# E 3/4 [19.0] 1 [25.4] 2 3 /8 [60] 1 3 /4 [44] 7 1 /2 [191] 2 1 /2 [1.1] 60**EE# 2 E 1 [25.4] 1 [25.4] 2 1 /2 [64] 1 3 /4 [44] 7 5 /8 [194] 2 3 /4 [1.2] 61**ED# E 3/4 [19.0] 7 1 /2 [191] 2 1 /4 [1.0] 62**ED# E 3/4 [19.0] 1 1 /4 [31.75] 2 7 /8 [73] 1 3 /4 [44] 7 1 /2 [191] 2 3 /4 [1.2] 60**FE# F 1 [25.4] 1 1 /4 [31.8] 2 5 /8 [67] 2 [51] 8 1 /2 [216] 3 1 /2 [1.6] 60**FF# 2 F 1 1 /4 [31.8] 1 1 /4 [31.8] 2 7 /8 [73] 2 [51] 8 3 /4 [222] 3 3 /4 [1.7] 61**FE# F 1 [25.4] 8 1 /2 [222] 3 1 /4 [1.5] 62**FE# F 1 [25.4] 1 1 /2 [38.0] 2 7 /8 [73] 2 [51] 8 1 /2 [222] 3 3 /4 [1.7] 60**GF# G 1 1 /4 [31.8] 1 1 /2 [38.0] 3 1 /8 [79] 2 3 /8 [60] 9 5 /8 [244] 5 1 /2 [2.5] 60**GG# 2 G 1 1 /2 [38.0] 1 1 /2 [38.0] 3 3 /8 [86] 2 3 /8 [60] 10 [254] 5 3 /4 [2.6] 61**GF# G 1 1 /4 [31.8] 9 5 /8 [244] 5 [2.3] 62**GF# G 1 1 /4 [31.8] 2 [51.0] 3 3 /8 [86] 2 1 /4 [57] 9 5 /8 [244] 5 3 /4 [2.6] 60**HG# H 1 1 /2 [38.0] 2 [51.0] 3 5 /8 [92] 2 3 /4 [70] 10 5 /8 [270] 7 3 /4 [3.5] 60**HH# 2 H 2 [51.0] 2 [51.0] 4 1 /8 [105] 2 3 /4 [70] 11 1 /8 [283] 8 [3.6] 61**HG# H 1 1 /2 [38.0] 10 5 /8 [270] 7 1 /4 [3.3] 62**HG# H 1 1 /2 [38.0] 2 1 /2 [64.0] 3 7 /8 [98] 3 [76] 10 5 /8 [270] 8 [3.6] 60**JH# J 2 [51.0] 2 1 /2 [64.0] 4 1 /4 [108] 3 3 /8 [86] 13 5 /8 [346] 15 1 /2 [7.0] 60**JJ# 2 J 2 1 /2 [64.0] 2 1 /2 [64.0] 4 1 /2 [114] 3 3 /8 [86] 14 [356] 15 3 /4 [7.2] 61**JH# J 2 [51.0] 13 5 /8 [346] 15 [6.8] 62**JH# J 2 [51.0] 3 [76.0] 4 5 /8 [117] 3 3 /8 [86] 13 5 /8 [345] 15 1 /2 [7.0] Notes 1. Replace asterisks with desired model number. Replace # with desired seat material. 2. Model 6030 available only 1 /2 x 3 /4-inch [12.7 x 19 mm], 3 /4 x 1-inch [19 x 25.4 mm], 1 x 1 1 /4-inch [25.4 x 31.8 mm], 1 1 /4 x 1 1 /2-inch [31.8 x 38 mm], 1 1 /2 x 2-inch [38 x 51 mm] and 2 x 2 1 /2-inch [51 x 64 mm]. 3. Models 6933, 6934 and 6935 have same dimensions as Model C A B Tyco reserves the right to change product design and specifications KUKMC-0394 without notice. Copyright 2002 by Tyco International Ltd. 4

23 Kunkle Safety and Relief Products Series 6000 and Models 6933, 6934, 6935 Service Recommendations for Resilient Seat/Seal Materials Seat/Seal Materials Service Recommendation Viton A (-10 to 406 F) [-23 to 208 C] Air and Gas Ethylene Propylene (-70 to 400 F) [-57 to 205 C] Steam ASME Section I and VIII, Steam, ASME Section VIII, Air/Gas National Board Certified. Models 6930, 6933, 6935 ASME Section IV, National Board Certified Model Number/Order Guide Model Number Position Example H G M 0 1 A M Model Orifice D G E H F J Inlet Size C - 1 /2-inch [12.7] G /2-inch [38.1] D - 3 /4-inch [19.0] H - 2-inch [50.8] E - 1-inch [25.4] J /2-inch [63.5] F /4-inch [31.8] Seat Material M - Metal E - EPR V - Viton Variation (01 through 99) 01 - Plain lever 02 - Plain lever with vibration dampener 03 - Plain lever with gag 60 - BSP Threads Design Revision Indicates non-interchangeable revision. Dash (-) if original design. Valve Service A - Steam ASME Section I K - Air/Gas ASME Section VIII L - Steam ASME Section VIII G - Steam ASME Section IV (Models 6933, 6934, 6935 only) P - Steam, Non-code N - Air, Non-code Spring Material M-SS Set Pressure psig [1.0 barg] only for Models 6933, 6934, 6935 Tyco reserves the right to change product design and specifications KUKMC-0394 without notice. Copyright 2002 by Tyco International Ltd. 11 Kunkle Safety and Relief Products Facility Phone: Valves & Controls The data presented in this bulletin is for general information only. Manufacturer is not responsible for acceptability of these products in relation to system requirements. Patents and Patents Pending in U.S. and foreign countries. All rights reserved. Printed in U.S.A. Tyco reserves the right to change product design and specifications without notice. Copyright Tyco reserves the right to change product design and specifications KUKMC-0394 without notice. Copyright 2002 by Tyco International Ltd. 12

24 yp, Commercial Gauges Product Specifications Ashcroft Model Number: 1000, 2071A Size: Case: Black painted steel 2071A- Black painted aluminum with back flange Ring: Black painted steel, friction fit 2071A- Chrome plated steel, friction fit Window: Glass Dial: Black figures on white background, steel Pointer: Black, Aluminum 2071A- Adjustable, Black, Aluminum Bourdon Tube: Bronze 2071A- Bronze, soldered, siphon required for steam service Movement: PowerFlex with polyester segment Socket: Brass Connection: 1/4" NPT lower Ranges: Vacuum psi and compound Accuracy: ASME B40.1, Grade B, ± 3-2-3% Optional Features 2071A- ASME B40.1, Grade A, ± 2-1-2% Case: Case color (other than black) Window: Plastic Pointer: Adjustable (Type 1000) Socket: Nickel Plated Throttle plugs _ 0.007, 0.013, 0.020, orifices Others: Customized dials Chrome ring (Type 1000) Black ring (Type 2071A) Non-standard ranges Special calibration on application F A B Dimensions D T-1000 C E 1/4 N.P.T. G B I D A H T-2071A C E Commercial Gauges Type 1000, 2071A F 1/4 N.P.T. 3 HOLES.218 (ø 5.5) EQUALLY SPACED ON ø 5 3/8 (137) BOLT CIRCLE. G Wrench T-1000 A B C D E F Flats Weight G Inches /16 12 oz. mm (121) (29) (60) (119) (86) (9) (14) Wrench T-2071A A B C D E F Flats H I Weight G The tradition of providing accurate, distinctive, reliable pressure instruments continues in Ashcroft Type 1000 and type 2071A commercial gauges. Inches / oz. mm (121) (36) (60) (148) (86) (12) (14) (11) (6) How to Order 45 W 1000 H 02L X(AP) 100# Dial Size: PowerFlex Movement Case type number: 1000 Socket material: Brass Connection size/location: 1/4 Lower Option: Adjustable Pointer Range: 100 psi Ashcroft Type 1000 gauges utilize a black steel case and ring, with a glass window. These gauges are appropriate for general industrial applications and can be customized to complement your equipment. Ashcroft Type 2071A, Contractor gauges, are constructed with a back flanged aluminum case, painted black, and a chrome ring with glass window. These gauges are designed to meet the needs of heating, ventilating, plumbing and air conditioning contractors. The accuracy of these gauges is ASME B40.1, Grade A, ± 2-1-2%. Sales Offices Domestic Headquarters Houston, Texas 3838 N. Sam Houston Parkway East, Suite 120 Houston, TX Tel: (281) FAX: (281) Chicago, Illinois 400 W. Lake Street, Suite 318 Roselle, IL Tel: (630) FAX: (630) Berea, Kentucky Harrison Road Berea, KY Tel: (606) FAX BEREA ( ) dresser-berea-mkt@dspn.com Incorporated in both, Type 1000 gauges and Type 2071A gauges, is the PowerFlex movement. This movement provides superior resistance to shock, vibration, and pulsation; thereby assuring longer life for your pressure instrument. Los Angeles, California 3931 Mac Arthur Blvd., Suite 202 Newport Beach, CA Tel: (714) FAX: (714) International Headquarters Specifications subject to change without notice. Subject to standard terms and conditions of sale. Copyright Instrument Division, Dresser Industries Inc., 5/95 Stratford, Connecticut 250 E. Main Street Stratford, CT Tel: (203) FAX: (203) Printed In-House DresserInstrumentDivision,Stratford CG 10/21 20M HG rev 10/97 Hartford, Connecticut 1501 East Main St. Meriden, CT Tel: (203) Fax: (203) Mobile, Alabama 851 South Beltline Hwy., Suite 402, Mobile, AL Tel: (334) Fax: (334) True Zero indication, a standard feature on these gauges, reduces the potential risk of installing a damaged gauge on your equipment. Other benefits of this unique safety feature include reduced manufacturing and inspection costs. As in all Ashcroft commercial instruments, the dial artwork is designed to provide gauges that are consistent in appearance, attractive, and easy to read. BEREA OPERATIONS BULLETIN CG - 10/21 AVAILABL FROM STOCK MADE IN THE Visit our

25 Gauges Type 1000, Grade B, (3-2-3%) Type 2071A, Grade A, (2-1-2%) Type 2071A contractor gauge offers aluminum-back flange case (black), with attractive chromeplated steel ring Type 1000 gauge offers black steel case with black ring and glass window Adjustable pointer is standard on contractor gauges Patented PowerFlex movement with polyester segment True Zero indication, a unique safety feature Ashcroft Type 1000 gauges have a black steel case and ring with a glass window. These gauges are appropriate for general industrial applications and can be customized to complement your equipment. Ashcroft contractor gauges (Type 2071A) are lightweight, highly sensitive and accurate. These gauges are designed to meet the needs of HVAC and plumbing contractors, and are tested against strict industry specifications. The aluminum case provides corrosion resistance. The patented PowerFlex movement, in both Types 1000 and 2071A, provides the shock resistance needed for rough treatment. True Zero indication reduces the potential risk of installing a damaged Type 2071A Contractor gauge shown gauge on your equipment. FlutterGuard is available to eliminate pointer flutter and extend gauge life. GAUGE SPECIFICATIONS TYPE 1000 TYPE 2071A Size: Case: Black-painted steel Aluminum with back flange, painted black. Ring: Black-painted steel, friction fit Chrome-plated steel, friction fit Window: Glass Glass Dial: Black figures on white background Black figures on white background Pointer: Black, aluminum Adjustable, black, aluminum Bourdon tube: Bronze, soldered Bronze, soldered (siphon required for steam service) Movement: Patented PowerFlex with polyester segment Patented PowerFlex with polyester segment Socket: Brass Brass Connection: 1 4 NPT lower 1 4 NPT lower Ranges: Vacuum through 600 psi and compound Vacuum through 600 psi and compound Operating temperature: 40 F to 150 F 40 F to 150 F Options: Case color other than black Plastic window (PD) Chrome ring (13) FlutterGuard (SF) Adjustable pointer (AP) Nickel-plated socket (NP) Customized dials Throttle plugs: 0.007, 0.013, 0.020, orifices Special calibration on application Case color other than black Plastic window (PD) Nickel-plated socket (NP) FlutterGuard (SF) Black steel ring Customized dials Throttle plugs: 0.007, 0.013, 0.020, orifices Special calibration on application TO ORDER THESE TYPE 1000/2071A GAUGES: Select: 45 W 2071A 02L 300 # 1.Dial Size: Patented PowerFlex Movement 3.Case Type Number: 2071A 4.Connection Size/Location: 1 4 NPT lower 5.Range: 300 psi Reference Bulletin CG-10/21 MADE IN U.S.A. Consult factory for guidance in product selection Phone (859) , FAX or visit our web site at a Halliburton company

26 DESCRIPTION C24, C25, Boiler and Water Column Liquid Level Switches are single or multi-switch units that offer versatility and reliable operation in a variety of applications. Available with up to three switch mechanisms for level alarm, control, and shutdown functions, the boiler and water column controls are designed for use in steam boiler applications while the Models C24 & C25 are for general industrial use. FEATURES Easy inspection of float chamber through removable head Cast iron or fabricated steel float chambers 316 and 316L stainless steel floats Brass chamber liner standard in B24, B25, W24, and W25 models Right or left hand water column mounting Try cock tappings and sight glass tappings available Process temperature to +750 F (+399 C) Multiple switch capability Working steam pressure to 600 pounds Choice of switch mechanisms: Mercury Hermetically sealed Dry contact Pneumatic Choice of switch mechanism enclosures: NEMA 1 carbon steel for pneumatic NEMA 4X/7/9 Class I, Div. 1, Groups C & D, polymer coated aluminum NEMA 4X/7/9 Class I, Div. 1, Group B, polymer coated aluminum C24, C25, Boiler and Water Column Liquid Level Switches APPLICATIONS Condensate receiver control Flash tank high level alarm Water tube boiler low water cutoff Boiler steam chest high level alarm Boiler feedwater pump control Day tanks Boiler low water cutoff Holding tanks TECHNOLOGY A permanent magnet (1) is attached to a pivoted switch mechanism (2). As the float (3) rises, following the liquid level, it raises the attraction sleeve (4) into the field of the magnet, which then snaps against the non-magnetic enclosing tube (5), actuating the switch mechanism. The enclosing tube provides a static pressure boundary between the switch mechanism and the process. On falling level, a spring retracts the magnet deactivating the switch mechanism. 4 Process Liquid Pivot Return Spring 1 Process Liquid Rising Level Falling Level MOUNTING WATER COLUMN LEVEL SWITCHES The right and left hand mounting arrangement refers to the position of the try cock tappings in relation to the gauge glass connections. Model W24 Right hand mounting Model W25 Right hand mounting Model W29 Left hand mounting To determine whether the control mounting is right or Model W60 Left hand mounting left hand, position the control with the gauge glass connections facing you. If the try cock tappings are to the right, it is a right hand control, if they are to the left, it is a left hand control. Refer to illustrations below. Left hand control Right hand control 2

27 SPECIFICATIONS SWITCH MECHANISMS AND ENCLOSURES SERIES 2 & 3 HIGH TEMPERATURE MERCURY SWITCHES SERIES B & C DRY CONTACT SWITCHES Quick visual inspection of contact conditions Dry contact for applications where mercury must be avoided Series 3 are heavy duty units with high load carrying capability Designed for AC and DC current applications Series 2 designed to provide vibration resistance Process temperatures to +450 F (+232 C) Process temperatures to +750 F (+399 C) SERIES HS & H1 HERMETICALLY SEALED SWITCHES Ideal for use in salt and other corrosive atmospheres SERIES J & K PNEUMATIC SWITCHES Suited for applications where electrical power is not available Positively pressurized capsule for entire mechanism and contacts Process temperatures to +750 F (+399 C) Bleed and non-bleed designs Process temperatures to +400 F (+204 C) SWITCH ENCLOSURES BASIC ELECTRICAL RATINGS Voltage Switch Series and Non-Inductive Ampere Rating B C HS H Vac Vac Vdc Vdc Vdc NEMA 4X/7/9 aluminum enclosures Designed to meet Class I, Div. 1, Groups C & D and Class I, Div. 1 Group B Optional housing heaters and drains available for some enclosures Pneumatic switch mechanisms available with a NEMA 1 enclosure 3 AGENCY APPROVALS AGENCY MODEL APPROVED APPROVAL CLASSES FM All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as NEMA 4X/7/9 Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as NEMA 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G CSA All with a Series HS, H1, 2 or 3 electric switch Class I, Div 2, Groups B, C & D mechanism and a housing listed as CSA TYPE 4X All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as NEMA 4X/7/9 Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as NEMA 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G CENELEC All with an electric switch mechanism and a EEx d IIC T6 CENELEC housing SAA All with an electric switch mechanism and a housing Ex d IIC T6 IP65 listed as NEMA 4X/7/9 Class I, Div 1, Group B 4

28 M M DIMENSIONAL SPECIFICATIONS INCHES (mm) P N N P N P R Q M plugged Gauge glass tappings L K Q M plugged Drum connections M R Q M plugged K LL HL Low water cutoff point A K K G T Try cock tappings R HL LL LL HL K C Models B24, C24 A C S Models B25, C25 B J A Allow (254) overhead clearance for cover removal. Conduit Connections M Electrical Switches: NEMA 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches: 1 NEMA 1: 4" NPT All housings rotatable 360 L E B D C Models W24, W25, W29, W60 K S ACTUATION LEVELS * Min. S.G. 1.0 Model HL LL HL LL B24/C24 (18) (40) (24) (42) B25/C25 (94) (114) (105) (124) W24 (289) (311) (302) (321) W25 (240) (260) (251) (270) W29 (279) (302) (292) (311) W60 (267) (281) (284) (297) * Single switch mechanism only. Consult factory for multiple switches. DIMENSIONS Model A B C D E G I J K L N P Q R S T " B24/C24 (141) n/a (71) n/a n/a n/a n/a n/a NPT n/a (150) (96) (158) (412) n/a n/a " " B25/C25 (177) (51) (66) n/a n/a n/a n/a n/a NPT n/a (150) (96) (214) (561) NPT n/a " 3 4" " 3 4" W24 (405) (76) (66) (77) (88) (381) (88) (101) NPT NPT (150) (96) (214) (850) NPT NPT " 1 2" " 1 2" W25 (343) (51) (66) (77) (51) (343) (76) (76) NPT NPT (150) (96) (214) (726) NPT NPT " 3 4" " 3 4" W29 (381) (114) (71) (73) (114) (381) (88) (101) NPT NPT (150) (96) (214) (850) NPT NPT W60 3 4" 4" " 3 ➀ 4" (381) (106) (91) (92) (106) (381) (88) (101) NPT NPT (150) (96) (214) (872) NPT NPT ➀ Model W60 also available per customer specifications 5 MODEL NUMBER Models available for quick shipment, usually within one week after factory receipt of a purchase order, through the Expedite Ship Plan (ESP) MODEL NUMBER CODE, MATERIALS OF CONSTRUCTION AND TANK CONNECTION Model Minimum Maximum Chamber Attraction Float Trim Max. WSP Max. Pressure Try Cock Code S.G. WSP ➁ Material Sleeve Material Material 100 F (38 C) Mounting B24-1B10 ➂ 0.85 C24-1B10 ➃ ➀ 400 Series 250 psig Cast Iron B25-1B10 ➂ SS F 400 psi C25-1B10 ➃ 316L SS 316 SS N/A ( C) (28 bar) C25-2B10 ➃ psig Cast Iron ➀ 316 SS W24-1B10 ➂ psig Cast Iron ➀ 400 Series Right W25-1B10 ➂ SS Hand F 500 psi W29-1B psig Fabricated 400 Series ( C) (34 bar) Left 316L SS 316 SS Steel SS F 900 psi Hand W60-1B psig ( C) (62 bar) ELECTRIC SWITCH MECHANISM AND ENCLOSURE ➆ Max. ➄ B24 & C24 only Process NEMA 4X/7/9 Aluminum Enclosure ➅ Switch Temp. Set Class I, Div. 1, Class I, Div. 1, Description ➇ F ( C) Contacts Points Groups C & D Group B Series SPDT 1 3KP 3KT Mercury Switch w/beaded Leads (399) DPDT 1 3NP 3NT Series B 250 Snap Switch (121) SPDT 1 BKP BKT DPDT 1 BNP BNT Series C 450 Snap Switch (232) SPDT 1 CKP CKT DPDT 1 CNP CNT Series 2 SPDT 1 2KP 2KT Vibration Resistant 750 Mercury Switch (399) w/beaded Leads DPDT 1 2NP 2NT ➀ Cast iron models limited to maximum service temperature of +406 F (+207 C) or switch mechanism temperature rating if lower. ➁ Saturated steam service rating ➂ Models B24, B25, W24, and W25 contain brass inner liners. ➃ Models C24 & C25 are intended for non-boiler service as they do not contain a chamber liner. ➄ Process temperature based on +100 F (+38 C) ambient ➅ Uncontrolled housing heater or drain available in NEMA 4X/7/9. Consult factory for standard part numbers. ➆ Consult factory for NEMA 4X/7/9 cast iron housings. ➇ Consult factory for manual reset switches. complete order code for Flanged External Cage Liquid Level Switch I I 6

29 MODEL NUMBER CONTINUED ELECTRIC SWITCH MECHANISM AND ENCLOSURE ➆ Max. ➄ All except B24, C24, C25-2B10 C25-2B10 only Process NEMA 4X/7/9 Aluminum Enclosure ➅ Switch Temp. Set Class I, Div. 1, Class I, Div. 1, Class I, Div. 1, Class I, Div. 1, Description ➇ F ( C) Contacts Points Groups C & D Group B Groups C & D Group B Series Mercury Switch (399) w/beaded Leads Series B 250 Snap Switch (121) Series C 450 Snap Switch (232) 1 3KA 3KJ 3KB 3KK SPDT 2 3LE 3LG 3LB 3LK 3 3ME 3MG 3MB 3MK DPDT 1 3NA 3NJ 3NB 3NK 2 3OA 3OJ 3OB 3OK 1 BKA BKJ BKB BKK SPDT 2 BLA BLJ BLB BLK 3 BMA BMJ BMB BMK 1 BNA BNJ BNB BNK DPDT 2 BOA BOJ BOB BOK 1 CKA CKJ CKB CKK SPDT 2 CLA CLJ CLB CL 3 CMA CMJ CMB CMK 1 CNA CNJ CNB CNK DPDT 2 COA COJ COB COK Series 2 1 2KA 2KJ 2KB 2KK Vibration 750 SPDT 2 2LE 2LG 2LB 2LK Resistant (399) 3 2ME 2MG 2MB 2MK Mercury Switch 1 2NA 2NJ 2NB 2NK w/beaded Leads DPDT 2 2OA 2OJ 2OB 2OK Series HS 5 amp Hermetically 1 HMJ HMK SPDT HMN HMP Sealed Snap Switch (204) 1 HMS HMT w/wiring Leads DPDT 2 HMY HMZ Series HS 5 amp Hermetically 400 SPDT 1 HM3 HM4 Sealed Snap Switch (204) w/terminal Block DPDT 1 HM7 HM8 Series H1 1 amp Hermetically 750 SPDT 1 Sealed Snap Switch (399) 2 HKP w/wiring Leads HKJ HKK PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Maximum Maximum Bleed Orifice All except Code Switch Description Supply Pressure Process Temp. Diameter B24, C24 B24, C24 psig bar F C Inches mm NEMA 1 Series J Bleed Type Series K Non-Bleed Type JDE JEE JEG KOE KOG KOG 7 QUALITY The quality assurance system in place at Magnetrol guarantees the highest level of quality throughout the company. Magnetrol is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. ESP Expedite Ship Plan Several Level Switches are available for quick shipment, usually within one week after factory receipt of a purchase order, through the Expedite Ship Plan (ESP). To take advantage of ESP, match the color coded model number codes in the selection charts (standard dimensions apply). ESP service may not apply to orders of ten units or more. Contact your local representative for lead times on larger volume orders, as well as other products and options. WARRANTY All Magnetrol mechanical level and flow controls are warranted free of defects in materials or workmanship for five full years from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied except special written warranties covering some Magnetrol products Belmont Road Downers Grove, Illinois Fax Jardin Drive, Units 1 & 2 Concord, Ontario Canada L4K 1X Fax Heikenstraat 6 B 9240 Zele, Belgium Telex Fax Regent Business Ctr., Jubilee Rd. Burgess Hill, Sussex RH15 9TL U.K Fax Copyright 2003 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. Performance specifications are effective with date of issue and are subject to change without notice. The brand and product names contained within this document are trademarks or registered trademarks of their respective holders. BULLETIN: EFFECTIVE: November 2001 SUPERSEDES: March 2001

30 Installation and Operating Manual Boiler Controls External Cage Float Actuated Liquid Level Switches Read this Manual Before Installing This manual provides information on the Boiler Controls External Cage Liquid Level Switches. It is important that all instructions are read carefully and followed in sequence. Detailed instructions are included in the Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. Notes Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Warnings Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Low Voltage Directive For use in Installation Category II, Pollution Degree 2. If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Notice of Copyright and Limitations Copyright 2002 by Magnetrol International. All rights reserved. Magnetrol reserves the right to make changes to the products described in this manual at any time without notice. Magnetrol makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol/STI mechanical level and flow controls are warranted free of defects in materials or workmanship for five full years from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol/STI shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol/STI products. Quality assurance The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available.

31 Boiler Controls External Cage Float Actuated Liquid Level Switches Table of Contents 1.0 Installation 4.0 Preventive Maintenance 1.1 Unpacking What To Do Every 6 Months Critical Alarm Function Switch Corrosion Inspection Piping Switch and Wiring Inspection Shutoff Valves for Boiler Controls Functional Test Mounting What To Do Every 12 Months Wiring Switch Corrosion Inspection Reference Information Switch and Wiring Inspection Description Control Head Removal and Installation Theory of Operation Functional Test Operating Cycle Specifications 2.4 Switch Differential Adjustment Agency Approvals Low Level Controls Physical High Level Controls Replacement Parts 2.5 Replacement of Standard Float and Stem Assembly Replacement of Chamber Liner Tandem Float Models Installation, Preventive Maintenance, and Troubleshooting Differential Adjustment Replacement of Float and Stem Assembly Troubleshooting 3.1 Check Switch Mechanism Standard Boiler Control Models Parts Identification Switch and Housing Reference Model B24, B25, C24, C Model W24, W25, W29, W Tandem Boiler Control Models Parts Identification Switch and Housing Reference Model W24, W25, W29, W Model Numbers Check Sensing Unit Installation Caution: If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. 1.1 Unpacking Unpack the instrument carefully. Inspect all units for damage. Report any concealed damage to carrier within 24 hours. Check the contents against the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. Caution: Do not discard the shipping container until all parts are accounted for. 1.2 Critical alarm function NOTE: Confirm that the installed unit meets the criteria of the intended application. The most critical parameters are the pressure, temperature, and specific gravity. If there is a question or conflict between actual parameters and the Magnetrol switch nameplate, contact Magnetrol for information on the level control (please have the serial number available). Conduit outlet Shutoff valve (if used) It is recommended that for critical alarm functions, an additional level switch be installed as a high high or low low level alarm for maximum protection. 1.3 Piping Switch actuating level reference mark Optional liquid leg connection to vessel Shutoff valve (if used) An instruction tag secured to the control gives dimensional data on switch actuating levels referenced from center line of upper side tank connection. Position control so that actuating levels correspond with the desired liquid level trip points in the boiler. Figure 1 Typical Piping Arrangement Optional blow-down or drain valve Caution: Refer to boiler manufacturer s specifications regarding control levels for piping alignment requirements. Use pipe of sufficient strength to support the control. If necessary, provide a stand or hanger to help support its weight. All piping should be straight and free of low spots or pockets so that lower liquid line will drain towards the boiler and upper vapor line will drain toward the control. Shut-off valves are recommended for installation between the boiler and the control. Refer to Figure 1. If control is to be used with a low temperature liquid (one which will boil in the float chamber if outside heat is absorbed), Boiler External Cage Liquid Level Switches

32 Boiler External Cage Liquid Level Switches the chamber and piping should be insulated. Such boiling in the chamber will cause false level indications. Caution: DO NOT INSULATE SWITCH MECHANISM HOUSING. For controls equipped with pneumatic switch assemblies, consult bulletin on mechanism furnished for air (or gas) piping instructions. See Switch and Housing Reference, Section If the liquid to be controlled has a tendency to leave deposits in the piping, right angle turns should be made with cross type fittings equipped with plugs in unused openings. Removal of plugs will permit pipe line to be rodded clean. Blow-down connection on boiler installations should be piped in such a manner that the operator will not scald himself when blowing down control. 1.4 Shutoff Valves for Boiler Controls When shutoffs are used in pipe connections between boiler and water column or boiler and shutoff valves (required for the gauge glass), they should be either outside-screwand-yoke, level-lifting type gate valves, or stop cocks with levers permanently fastened; or another type through-flow shutoff valve that prevents blockage by sediment. Shutoff valves should be locked or sealed in the open position. When stop cocks are used, they should be the type with the plug held in place by a guard or gland. 1.5 Mounting Caution: This instrument is intended for use in Installation Category II, Pollution Degree 2 locations. Controls used on boiler applications should be mounted as close to the boiler as possible. This will result in a more responsive and accurate level change in the control. Water in a long line, will be cooler and more dense than the boiler water, causing lower level indication in the control than actual level in the boiler. Adjust piping as required to bring control to a vertical position. Magnetrol controls must be mounted within three degrees (3 ) of vertical in all directions. A three degree slant is noticeable by eye, but installation should be checked with a spirit level on top and/or sides of float chamber. Caution: Never insulate the switch housing of the level control. 2 Installation and maintenance of tandem float models are accomplished in much the same manner as described for standard models. Additional consideration must be given to the piping arrangement to allow for alignment of the two switch actuating level marks on the float chamber with the desired levels in the vessel. 1.6 Wiring Caution: All Boiler Controls are shipped from the factory with the enclosing tube tightened and the switch housing set screw locked to the enclosing tube. Failure to loosen the set screw prior to repositioning the conduit connections may cause the enclosing tube to loosen, resulting in possible leakage of the process liquid or vapor. Boiler controls are shipped with the conduit entry of the switch housing placed 180 opposite the tank connections to simplify most installations. If this configuration is appropriate to the installation, proceed to Step 4 to begin wiring the unit. If another configuration is desired, the switch housing can be easily rotated by first following Steps 1, 2, and 3. NOTE: A switch or circuit breaker shall be installed in close proximity to equipment and within easy reach of operator. It shall be marked as the disconnecting device for equipment. Screw Set screw Screw Figure 2 Switch Housing Base Set Screws 1. Loosen set screw(s) at base of switch housing. Refer to Figure Switch housing may be rotated 360 to allow correct positioning of conduit outlet. 3. Tighten set screw(s) at base of switch housing. 4. Unscrew and remove switch housing cover. The threads have been lubricated to facilitate removal. NOTE: For supply connections, use wire with a minimum rating of +167 F (+75 C) as required by process conditions. Use a minimum of 14 AWG wire for power and ground field wires. NOTE: Housing must be grounded via protective ground screw in the base of the housing. NOTE: On high temperature applications (above +250 F [+121 C] in float chamber), high temperature wire should be used between control and first junction box located in a cooler area. On non-hazardous applications, flexible conduit may be used between the control and the first junction box. 5. The switch terminals are located next to the conduit outlet to facilitate wiring. Bring supply wires through conduit outlet. Route extra wire around enclosing tube under the Boiler External Cage Liquid Level Switches

33 Mercury switch Pivot 2.3 Operating Cycle As the liquid level rises in the chamber the float moves the magnetic attraction sleeve up, within the enclosing tube and into the field of the switch mechanism magnet. As a result, the magnet is drawn in tightly to the enclosing tube, causing the switch to trip making or breaking an electrical circuit. Refer to Figure Enclosing tube (non-magnetic) Sleeve (magnetic) Float Tension spring Magnet Swing in position Normal operating level Figure 5 "Swing In" Magnet Position As the liquid level falls, the float drops and moves the attraction sleeve out of the magnetic field, releasing the switch mechanism magnet. The tension spring ensures the return of the switch in a snap action. Refer to Figure Switch Differential Adjustment The standard differential of Boiler Control float models with one switch may be field adjusted. Adjustment may be necessary if a wider differential needs to be set to overcome switch chatter caused by the process Baffle plate Run wires under baffle plate to terminal block. Line Internal circuit (left) switch Close on high level Common Close on low level Terminal block assembly Figure 3 Placement of Supply Wires Load Load Load Load Figure 4 Terminal Connections DPDT Switch Mechanism Series A, B, C, D, and E Switch mechanism Notches in baffle plate Conduit entry Internal circuit (right) switch Close on high level Common Close on low level Line baffle plate. Refer to Figure 3. Connect the supply wires to the proper terminals. Refer to Figure 4 or your switch bulletin for this information. See Switch and Housing Reference, Section Dress wiring to ensure no interference or contact with tilt of switch, or replacement of switch housing cover. NOTE: It is the responsibility of the customer to comply with applicable installation codes and practices. Class I, Division 1 locations may contain explosive gas mixtures. Appropriate precautions must be taken. Installation should be performed by qualified personnel. 7. Replace housing cover. 8. If control has been furnished with an explosion proof or moisture proof switch housing, it must be sealed at the conduit outlet with a suitable compound or non-hardening sealant to prevent entrance of air. 9. Test switch action by varying liquid level in float chamber. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin for additional wiring information on switch mechanism furnished. See Switch and Housing Reference, Section Check cover to base fit to be certain gasketed joint is tight. A positive seal is necessary to prevent infiltration of moisture laden air or corrosive gasses into switch housings. Caution: In hazardous areas, do not power the unit until the conduit is sealed and the enclosure cover is screwed down securely. 2.0 Reference Information 2.1 Description Boiler controls are completely self-contained units, designed for side mounting to a vessel or tank with threaded or flanged pipe connections. 2.2 Theory of Operation The design of float operated level switches is based upon the principle that a magnetic field will not be affected by non-magnetic materials such as 316 stainless steel. In this case, the float moves a magnetic attraction sleeve within a non-magnetic enclosing tube and actuates a magnetic switch mechanism. The enclosing tube provides a pressure seal to the chamber and therefore to the process Boiler External Cage Liquid Level Switches 4 Swing out position Low level Figure 6 "Swing Out" Magnet Position NOTE: This procedure may be applied to single switch models only. The differential, or the amount of level travel between switch-on and switch-off, may be adjusted by repositioning the lower jam nuts on the float stem. This adjustment is different for high level and low level controls. Please refer to the appropriate section below for adjustment instructions. NOTE: Maximum differential adjustment is 1 inch. Caution: Differential adjustments should NOT be made in the field on tandem float models. Switch actuation levels have been set at the factory to meet customer specifications. Variations in actual conditions from design conditions, usually require special control modifications. Consult the factory or your local representative for assistance Boiler External Cage Liquid Level Switches

34 2.4.1 Low level controls Slight play (gap) must be allowed (.03" [.8 mm] typical) Position of bottom jam nuts (normal factory setting) Replace in same position Drop bottom jam nuts to increase gap setting Float Sleeve stop strap Figure 7 Normal Factory Setting (minimum differential) D 1.00 (25 mm) Figure 8 Differential Adjustment For access to bottom jam nuts, remove top jam nuts, washer, and attracting sleeve Sleeve stop strap Float Max gap setting (Applies to models having a single switch mechanism with a single magnet actuator only) On low level controls the switch trips on the lower actuation point and resets on the higher actuation point. Widening the differential will allow the switch to trip on the original actuation point and reset at a later or higher point. The differential on low level controls may be adjusted by repositioning the lower jam nuts on the float stem. The standard factory setting is for a minimum amount of play (gap) between the top jam nuts and the attraction sleeve. Refer to Figure Determine what change in differential is necessary. NOTE: To widen the differential by one inch, the lower jam nuts must be set proportionately lower on the stem (i.e. in this example by 1 inch). 2. Make sure power source is turned off. 3. Unscrew and remove switch housing cover. 4. Disconnect power supply wires from switch mechanism. Pull wires out of conduit connection opening in housing base. Refer to Figure 9 on page Perform system shut-down procedures as required to relieve pressure from float chamber of control. Allow unit to cool. 6. Close shut-off valves (if so equipped) to isolate control from tank. Drain off liquid in float chamber. 7. On installations without shut-off valves, relieve pressure from the tank. Drain liquid in tank to a level below the connections of the float chamber. NOTE: Level control, connections and pipe lines need not be removed from the tank. 8. Loosen enclosing tube nut with a 15 16" wrench. Unscrew enclosing tube counterclockwise (switch and housing base will rotate also), until it is free. Refer to Figure 9 on page Lift enclosing tube, switch, and base off float chamber. Jam nuts and attraction sleeve are now accessible. 10. Measure the distance D from the top edge of the upper jam nuts to the top of the float stem. Refer to Figure 8. Record this measurement. 11. Loosen and remove upper jam nuts, guide washer and attraction sleeve. 12. Loosen and adjust lower jam nuts to the desired position. Tighten lower jam nuts securely. Refer to Figure Replace attraction sleeve on stem Boiler External Cage Liquid Level Switches 6 Switch housing cover Conduit connection Enclosing tube nut Enclosing tube Refer to Figures 6 and 7 Housing base 14. Replace upper jam nuts and guide washer on the stem in the position previously noted. Tighten upper jam nuts securely. Refer to Figure 8 on page 6. NOTE: Use a new enclosing tube gasket when reassembling enclosing tube to the chamber. Make certain that all gasket surfaces are thoroughly cleaned to allow proper gasket seating. Coat enclosing tube threads with anti-seizing compound. 15. Replace enclosing tube, switch, and base on chamber. Rotate e-tube clockwise until tightened to foot-pounds of torque. 16. Loosen the set screws at the base of the switch housing. Rotate switch housing to correct position and tighten set screws. Refer to Figure 2 on page 3. Chamber Float Figure 9 Caution: After increasing gap setting, be certain to check for proper operation of switch mechanism by raising and lowering float assembly. Magnet must snap cleanly, with additional float movement available after magnet snaps. 17. Bring supply wires through conduit outlet. Follow Steps 5 through 10 in Wiring, Section Test switch action by varying liquid level in float chamber. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism. If the unit still fails to function properly, consult the factory High level controls On high level controls, the switch trips on the higher actuation point and resets on the lower actuation point. Caution: On high level controls, widening the differential requires raising the trip point a proportional amount. The reset point will remain the same. To widen the differential by raising the trip point, follow Steps 1 through 16 in Low Level Controls, Section Replacement of Standard Float and Stem Assembly 1. Disconnect wiring or medium lines from control and perform system shutdown. See Low level controls, Section 2.4.1, steps 2 through Remove switch housing assembly from float chamber at head flange by loosening flange bolting Boiler External Cage Liquid Level Switches

35 3. Remove sleeve stop strap from the underside of the head flange and slide the float stem assembly out of the enclosing tube. Retaining screws Dim. A 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Head flange (ref.) Stop tube Sleeve stop strap NOTE: New float and stem kits are supplied unassembled. For standard jam nut settings (dimension A) refer to Figure 10 and Table 1. Table 1 Model "A" Dimension B24, C (19) B25, C (22) W24, W25, W29, W60 4. Check new float and stem assembly to be certain it is the correct replacement unit: 4.1 Float should be of same physical size and shape. 4.2 Stem length should match closely. 4.3 Set attraction sleeve per dimension A as shown in Figure 10. NOTE: If differential adjustment has been altered in the field, disregard dimension A and readjust new assembly to the previously determined level differential settings. See Switch Differential Adjustment, Section 2.4. Figure 10 Float and stem assembly 5. Replace new float and stem assembly into head flange and install new stop strap with screws included. 6. Remount head flange on float chamber, using new gasket provided. Tighten flange nuts evenly, using an alternating pattern typical of standard industry practice. NOTE: Care must be taken during installation to be certain float stem does not become bent. 7. With control assembly in place, test switch actuation by varying liquid level in float chamber. NOTE: When reassembling the enclosing tube or the upper flange assembly to the control, tighten according to the following torque values in Table 2. Table 2 Model Flange Bolting Enclosing Tube B24, B25, C24, C ft-lbs ft-lbs W24, W25, W29, W Boiler External Cage Liquid Level Switches Replacement of Chamber Liner Chamber wall recess A Chamber liner Models B24, B25, W24, and W25 cast float cage level controls, specified for boiler water service, are equipped with self-cleaning brass liners to prevent scale growth in the chambers. Since brass has a different coefficient of expansion than scale, any deposits that form will flake off the liners with temperature change and be removed during routine blow-down. Brass liners are designed to snap into a special recess provided in the wall of the chambers. Replacement liners are designed with a temper to spring out against chamber wall for secure positioning. Chamber projections Try-cock openings 1. Perform system shut down as required to relieve pressure from float chamber of control and allow unit to cool. B Caution: Failure to disconnect electrical power to the unit during maintenance may result in shock or serious injury 2. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit of operating medium line connections to switch housing. 3. Remove switch housing, along with float and stem assembly, by unbolting unit at head flange. Figure 11 Chamber Liner Position NOTE: Old liners are nearly always damaged during removal. Do not attempt to reuse old liner. 4. With old liner removed, scrape chamber walls thoroughly to remove all rust and scale deposits. NOTE: New liner must fit snugly against chamber wall. Any foreign particles between new liner and chamber will prevent a good fit. 5. Check positioning of liner carefully before attempting to insert into chamber Try-cock openings on certain water column models are equidistant from both top and bottom of recess in chamber wall, as indicated by reference dimensions A and B. Refer to Figure 11. If wrong end of liner is inserted first, try-cock openings will not line up with holes in liner. 5.2 Liner should be rotated to correct position before inserting as it is best to avoid having to turn liner inside the chamber Boiler External Cage Liquid Level Switches

36 6. To install new liner, hold with both hands and carefully squeeze it to a diameter slightly less than the chamber opening, with edges overlapped slightly. 7. When properly inserted, liner will spring out to fit into recess of chamber wall. 8. Check edges of liner, which were overlapped during installation, to be certain they now butt firmly together over entire length of liner. 9. Water column models have two projections into recess of chamber wall. Projections must engage in notches provided in top and bottom of liner to prevent rotation while in service. Caution: Unless liner edges are butted entire length, holes aligned with chamber openings and ends engaged correctly in chamber wall recess, liner may prevent proper float operation or obstruct water flow. 10. Reassemble control and return to service in reverse order of steps 1 through 3. Refer to Table 2 on page 8 for flange bolting torque specifications Boiler External Cage Liquid Level Switches Tandem Float Models Models with tandem floats are used on applications where it is advantageous to have two widely spaced high and low switching functions using a single control. The units incorporate two floats which operate independently, and are arranged so that the lower float actuates the upper switch mechanism, and the upper float actuates the lower switch mechanism. The upper float is attached to the lower attraction sleeve by means of a hollow stem. The lower float attaches to the upper attraction sleeve with a solid stem that extends upward, through the upper float and stem assembly Installation, Preventive Maintenance, and Troubleshooting Installation and maintenance of tandem float models is accomplished in much the same manner as for standard models previously described. Some additional consideration must be given to the piping arrangement to allow for alignment of the two switch actuating level marks on the float chamber with the desired levels in the vessel. When troubleshooting the level sensing portion of the control, additional checks may be made of the following: 1. Inspect for binding of solid (lower) float stem within hollow (upper) float stem due to corrosion or possible damage incurred during shipment or blowdown. 2. Make certain that retaining (snap) rings, used to locate lower attraction sleeve, are locked in place. An extreme shock or hammer, such as during blow-down on a water column boiler control, may damage a ring causing it to snap out of its retaining groove in the hollow (upper) float stem Differential Adjustment Figure 12 Typical Tandem Float Control Caution: No differential adjustment should be made on tandem float models in the field. Switch actuation levels have been set at the factory to meet customer specifications. Variations in actual conditions, from design conditions, usually require special control modifications Boiler External Cage Liquid Level Switches

37 2.7.3 Replacement of Float and Stem Assemblies Retaining screws Dim. A 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Head flange (ref.) Stop tube Sleeve stop strap Should replacement of either upper or lower float and stem assembly be required, see Replacement of Standard Float and Stem Assembly, Section New float and stem assemblies are available in separate replacement kits with attraction sleeve parts furnished loose, to allow for field assembly with existing serviceable components. See Replacement Parts, Section Dimension A, shown in Figure 13 must be determined by direct measurement from old assembly. NOTE: Disregard dimension A shown in Table 1 on page 8. If in doubt, or unable to get an accurate measurement from old assembly, consult factory or local representative for assistance. 3. Lower attraction sleeve locks in place on hollow (upper) float stem with external type snap rings. NOTE: Care must be taken to be certain rings are properly installed. If available, use the correct type external snap ring pliers. Figure 13 Float and stem assembly 3.0 Troubleshooting Usually the first indication of improper operation is failure of the controlled equipment to function, i.e.: pump will not start (or stop), signal lamps fail to light, etc. When these symptoms occur, whether at time of installation or during routine service thereafter, check the following potential external causes first. Fuses may be blown. Reset button(s) may need resetting. Power switch may be open. Controlled equipment may be faulty. Wiring leading to control may be defective. If a thorough inspection of these possible conditions fails to locate the trouble, proceed next to a check of the control's switch mechanism Boiler External Cage Liquid Level Switches Check Switch Mechanism 1. Pull switch or otherwise disconnect power to the control. 2. Remove switch housing cover. 3. Disconnect power wiring from switch assembly. 4. Swing magnet assembly in and out by hand to check carefully for any sign of binding. Assembly should require minimal force to move it through its full swing. 5. If binding exists, magnet may be rubbing enclosing tube. If magnet is rubbing, loosen magnet clamp screw and shift magnet position. Retighten magnet clamp screw. 6. If switch magnet assembly swings freely and mechanism still fails to actuate, check installation of control to be certain it is within the specified three (3 ) degrees of vertical. 7. If mechanism is equipped with a mercury switch, examine glass mercury tube closely as described in Preventive Maintenance, Section 4.1.1, step 3. If switch is damaged, replace it immediately. If microswitch, check continuity with ohmmeter. 8. If switch mechanism is operating satisfactorily, proceed to check sensing unit. NOTE: As a matter of good practice spare switches should be kept on hand at all times. 3.2 Check Sensing Unit Conduit outlet Shutoff valve (if used) 1. Reconnect power supply and carefully, manually actuate switch mechanism (use a non-conductive tool on electrical switch mechanisms) to determine whether controlled equipment will operate. Switch actuating level reference mark Figure 14 Optional liquid leg connection to vessel Shutoff valve (if used) Optional blow-down or drain valve Caution: With electrical power on, care should be taken to avoid contact with switch leads and connections at terminal block. 2. If controlled equipment responds to manual actuation test, trouble may be located in the level sensing portion of the control, float(s), stem(s), and magnetic attraction sleeve(s). 3. Check to be certain liquid is entering float chamber. A valve may be closed or piping plugged. Caution: Be certain to pull disconnect switch or otherwise ensure that electrical circuit(s) through control is deactivated. Close operating medium supply valve on controls equipped with pneumatic switch mechanisms Boiler External Cage Liquid Level Switches

38 4. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit or operating medium line connections to switch housing. 5. Perform system shutdown to relieve pressure from float chamber of control, and allow unit to cool. 6. Close shutoff valves (if equipped) to isolate control from vessel. Drain off liquid in chamber if necessary 7. On installations without shutoff valves, relieve pressure from vessel and drain off liquid head above control mounting level. NOTE: Control chamber, connections, and pipe lines need not be removed from vessel or boiler. 8. Remove switch housing assembly by loosening enclosing tube hex nut, which is located immediately below housing base. Refer to Figure 9 on page With switch housing assembly removed, inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids buildup, which could restrict movement, preventing sleeve(s) from reaching field of switch magnet(s). 10. If differential has been changed in the field by repositioning the lower jam nuts on the float stem, check tightness and position of the jam nuts. 11. Check float to be certain it is buoyant in the liquid (float chamber or vessel must have adequate liquid level). If float is determined to be filled with liquid, or it is collapsed, it must be replaced immediately. Caution: Do not attempt to repair a float. See Replacement of Standard Float and Stem Assembly, Section 2.5. If all components in the control are in operating condition, the trouble must be (and should be) located external to the control. Repeat inspection of external conditions previously described. NOTE: If difficulties are encountered which cannot be identified, consult the factory or your local representative for assistance. A complete description of the trouble should be provided along with information concerning your piping and mounting arrangement, plus a description of your operating sequence. Sketches or photographs showing the installation are also beneficial. When communicating about your control, be certain to always specify the complete Model and Serial numbers Boiler External Cage Liquid Level Switches Preventive Maintenance Periodic inspections are a necessary means to keep your level control in good working order. This control is a safety device to protect the valuable equipment it serves. Therefore, a systematic program of preventive maintenance must be implemented when the control is placed into service. If the following sections on what to do and what to avoid are observed, your control will provide reliable protection of your equipment for many years. 4.1 What to do every 6 months (minimum) Switch Corrosion Inspection For every 6 months in service, conduct the following maintenance and inspection checks. NOTE: For applications where the switches are exposed to corrosive environments this inspection should be conducted every 3 months. Some environments may cause accelerated corrosion on the switch mechanism. In order to identify switch corrosion prior to failure, use the following procedures: 1. Disconnect power to the switch. 2. Remove switch housing cover to inspect switch mechanisms for visible signs of corrosion on terminals and wires. NOTE: If cover is difficult to remove, secure base to prevent it from moving while loosening it. Loosen set screws securing the base to the enclosing tube prior to using a cross-bar or hammer to loosen cover. Loosening the set screws will prevent the enclosing tube from loosening resulting in possible leaks. 3. Mercury switches may be visually inspected for short circuit damage. Check for small cracks in the glass tube containing the mercury. Such cracks can allow entrance of air into the tube causing the mercury to oxidize. This is noticeable as the mercury will appear dirty or dull, and will not break into clean, round pools. If these conditions exist, replace the mercury switch immediately. 4. Dry contact switches should be inspected for excessive wear on actuating lever or misalignment of adjustment screw at point of contact between screw and lever. Such wear can cause false switch actuating levels. Adjust switch mechanism to compensate (if possible) or replace switch Boiler External Cage Liquid Level Switches

39 Mercury switch Terminal screws Switch wires Supply wires Switch mechanism clamping screw Figure 16 Mercury switch Terminal screws Supply wires Switch wires Switch mechanism clamping screw Figure Boiler External Cage Liquid Level Switches 5. Controls may sometimes be exposed to excessive heat or moisture. Under such conditions, insulation on electrical wiring may become brittle, eventually breaking or peeling away. The resulting bare wires can cause short circuits. Check wiring carefully and replace at the first sign of brittle insulation. 6. Vibration may sometimes cause terminal screws to work loose. Check all terminal connections to be certain that screws are tight. 7. Conduct a continuity test for switch contacts, using a low voltage DC circuit with an indicator. 8. Switches that are corroded or that failed the contact continuity test should be replaced. DO NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms furnished for service instructions.) 9. Verify that switch housing cover and conduit seal are properly closed after each inspection of the switch mechanism(s). NOTE: In applications with presence of salt laden air or corrosive vapors, contact Magnetrol for possible alternate switch mechanisms Switch and Wiring Inspection The switch mechanism and supply wiring need to be in proper position to assure correct switch operation. 1. Remove switch housing cover to inspect the supply wires. 2. Check that the supply wires are attached to the terminal block and run under the baffle plate. Be certain that excess wire does not interfere with the tilt of the switch and that adequate clearance exists for replacement of switch housing cover. 3. Manually push on the magnet of the switch mechanism to confirm that the mechanism pivots freely. If it does not, the switch mechanism should be replaced. 16 Housing base casting hub Figure 18 Figure 19 Switch mechanism Baffle plate Enclosing tube Mechanism Clamping Screw Housing base 4. Make sure the switch mechanism is seated all the way down on the baffle plate. Refer to Figure 18. Additionally, check that the mechanism clamping screw is tightened to assure that the mechanism is secured to the enclosing tube and in proper position on the baffle plate. Refer to Figure 19. The baffle plate should rest on the housing base casting hub. NOTE: HS series switches use a cylindrical spacer in place of the baffle plate. Refer to Figure If the above wiring conditions are not met the unit should be rewired. Proceed to step 6. NOTE: When wiring units with mercury switches, care must be taken to ensure that the control wires do not interfere with the movement of the switch. 6. Disconnect power to the switch. 7. The baffle plate is notched at the front and rear for control wires to pass through. Control wires should enter through the conduit entry, pass under the baffle plate to the notch, then proceed through to the terminal block. Refer to Figure 3 on page Switch mechanism wires move as the switch pivots; control wires must not touch or interfere with mechanism wires. Refer to Figures 16 and 17 on page 16 for wiring with two different terminal block configurations. 9. Control wires should not touch moving parts in any way. 10. The control wires should be attached to the terminal block so that they run from the terminal block, down through the notch, and under the baffle plate. Enclosing Tube Housing Base Casting Hub Figure 20 Switch Spacer Switch Washer HS Switch Mechanism Housing Base NOTE: The control wires must not interfere with the switch mechanism wires. 11. Connect power supply to the control and conduct functional test of unit as described below. 12. Replace switch housing cover and place control into service Functional Test of Unit This procedure will assure that the complete unit is functioning properly. This test should be conducted after switch and wiring inspections have been completed. 1. Adjust piping as required to bring control to a vertical position. Control must be mounted within 3 degrees of vertical. Installation should be checked with an indicating level on top or sides of float chamber Boiler External Cage Liquid Level Switches

40 2. Check the chamber mounting within 3 degrees of vertical after the boiler installation. 3. Raise level in the vessel sufficient to raise the float and trip the switch. Lower level in the vessel sufficient to lower float and reset the switch. Confirm switch trips and resets at expected levels (contact Magnetrol for specific information on trip points; please have the serial number of the unit). 4.2 What to do every 12 months (minimum) Switch Corrosion Inspection For every 12 months in service, conduct the following maintenance and inspection checks in addition to customer specific or code requirements. NOTE: For applications where the switches are exposed to corrosive environments this inspection should be conducted every 3 months. 1. Disconnect power to the switch. 2. Remove switch housing cover to inspect switch mechanisms for visible signs of corrosion on terminals and wires. NOTE: If cover is difficult to remove, secure base to prevent it from moving while loosening it. Loosen set screws securing the base to the enclosing tube prior to using a cross-bar or hammer to loosen cover. Loosening the set screws will prevent the enclosing tube from loosening resulting in possible leaks. 3. Mercury switches may be visually inspected for short circuit damage. Check for small cracks in the glass tube containing the mercury. Such cracks can allow entrance of air into the tube causing the mercury to oxidize. This is noticeable as the mercury will appear dirty or dull, and will not break into clean, round pools. If these conditions exist, replace the mercury switch immediately. 4. Dry contact switches should be inspected for excessive wear on actuating lever or misalignment of adjustment screw at point of contact between screw and lever. Such wear can cause false switch actuating levels. Adjust switch mechanism to compensate (if possible) or replace switch Boiler External Cage Liquid Level Switches Controls may sometimes be exposed to excessive heat or moisture. Under such conditions, insulation on electrical wiring may become brittle, eventually breaking or peeling away. The resulting bare wires can cause short circuits. Check wiring carefully and replace at the first sign of brittle insulation. 6. Vibration may sometimes cause terminal screws to work loose. Check all terminal connections to be certain that screws are tight. Refer to Figure Conduct a continuity test for switch contacts, using a low voltage DC circuit with an indicator. 8. Switches that are corroded or that failed the contact continuity test should be replaced. DO NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms furnished for service instructions.) 9. Verify that switch housing cover and conduit seal are properly closed after each inspection of the switch mechanism(s). NOTE: In applications with presence of salt laden air or corrosive vapors, contact Magnetrol for possible alternate switch mechanisms. Terminal screws Mechanism clamping screw Switch and Wiring Inspection Figure 21 The switch mechanism and supply wiring need to be in proper position to assure correct switch operation. 1. Remove switch housing cover to inspect the supply wires. 2. Check that the supply wires are attached to the terminal block and run under the baffle plate. Refer to Figure 3 on page 4. Be certain that excess wire does not interfere with the tilt of the switch and that adequate clearance exists for replacement of switch housing cover. 3. Manually push on the magnet of the switch mechanism to confirm that the mechanism pivots freely. If it does not, the switch mechanism should be replaced. 4. Make sure the switch mechanism is seated down on the baffle plate. Refer to Figure 18 on page 17. Additionally, check that the mechanism clamping screw is tightened to assure that the mechanism is secured to the enclosing tube and in proper position on the baffle plate. Refer to Figure 21. The baffle plate should rest on the housing base casting hub. Note: HS series switches use a cylindrical spacer in place of the baffle plate. Refer to Figure Boiler External Cage Liquid Level Switches

41 5. If the above wiring conditions are not met the unit should be rewired. Proceed to step 6. NOTE: When wiring units with mercury switches, care must be taken to ensure that the control wires do not interfere with the movement of the switch. Terminal screws Supply wires Switch wires Figure 22 Mercury switch Switch mechanism clamping screw 6. Disconnect power to the switch. 7. The baffle plate is notched at the front and rear for control wires to pass through. Control wires should enter through the conduit entry, pass under the baffle plate to the notch, then proceed through to the terminal block. Refer to Figure 3 on page Switch mechanism wires move as the switch pivots; control wires must not touch or interfere with mechanism wires. Refer to Figures 22 and Control wires should not touch moving parts in any way. 10. The control wires should be attached to the terminal block so that they run from the terminal block, down through the notch, and under the baffle plate. NOTE: The control wires must not interfere with the switch mechanism wires. 11. Connect power supply to the control and conduct functional test of unit as described below. 12. Replace switch housing cover and place control into service. Mercury switch Control Head Removal and Installation Terminal screws Supply wires Switch wires Figure 23 Switch mechanism clamping screw When inspection of the chamber is required the control head must be removed to provide proper access to the chamber. This procedure will assure that the head assembly is removed and reinstalled properly. 1. Allow vessel to get to safe temperature and pressure before opening the pressure boundary. 2. Power down all wiring to the unit. 3. Remove all wiring and conduit from the unit. 4. Remove flange bolts Boiler External Cage Liquid Level Switches Prepare an area where the head assembly can be placed such that it rests on the flange in it's normal orientation (two 2x4 boards placed across an open drum work well). Refer to Figure Carefully lift the head assembly by holding the sides of the flange. Maintain the head assembly as much as possible in the vertical position. NOTE: Care must be taken not to place side force on the float which could bend the stem. 7. With the unit resting in its temporary fixture in an upright position, it can now be inspected or repaired. Caution: Do not place the unit on its side this could result in damage to the stem. 8. Conduct a check for float stem straightness as follows: 8.1 Remove the stem assembly including attraction sleeve from the head assembly by removing the two screws holding the stop strap to the bottom of the flange. Refer to Figure 13 on page 12 for assembly schematic. 8.2 Check the stem straightness by aligning the stem against a strait edge. Stems that are bent in excess of 1 8 inch over any 6 inch length should not be used in this condition. Replace any bent stems. See Replacement Parts, Section 6.0. Figure Boiler External Cage Liquid Level Switches

42 Retaining screws Dim. A 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Head flange (ref.) Stop tube Sleeve stop strap 8.3 Ensure that the components in the stem assembly are in good condition and surfaces are clear of potential obstructions. The stem assembly is reinstalled by securing the stop strap to the flange. Ensure that the attraction sleeve moves freely through the enclosing tube and that the stem assembly surfaces are smooth. Note: Care must be taken during the straightness check to be certain that the attraction sleeve is not removed from the stem and jam nuts settings are not changed. 9. Raise the liquid level in the container that the unit is set on sufficient to lift the float and trip the switch mechanism. Inspect inside of chamber for any obstructions or scale build up. If excessive build up is present, the interval between inspections should be shortened. Remove old gasket such that mating flange surfaces are completely clean. Position new gasket on chamber flange before replacing the head assembly. Note: The float is restricted from moving laterally by the chamber, in the test configuration the float and stem can move further off center than possible under normal operation. Avoid excess movement in this lateral direction during the test. If switch trips, the unit may be reassembled. If not, follow the procedure in Troubleshooting, Section 3.0. Figure 25 Float and stem assembly 10. Replace the assembly keeping it as vertical as possible. Carefully lower the assembly into the chamber making sure that the stem does not become bent during installation. Refer to Figure Tighten flange bolts per torque values in Table 2 on page Attach wiring and connect power supply as described in Switch and Wiring Inspection, Section Functional Test of Unit This procedure will assure that the complete unit is functioning properly. This test should be conducted after switch and wiring inspections have been completed. 1. Adjust piping as required to bring control to a vertical position. Control must be mounted within 3 degrees of vertical. Installation should be checked with an indicating level on top or sides of float chamber. 2. Check the chamber mounting within 3 degrees of vertical after the boiler installation. 3. Raise level in the vessel sufficient to raise the float and trip the switch. Lower level in the vessel sufficient to lower float and reset the switch. Confirm switch trips and resets at expected levels (contact Magnetrol for specific information on trip points; please have the serial number of the unit) Boiler External Cage Liquid Level Switches Specifications 5.1 Agency Approvals AGENCY MODEL APPROVED APPROVAL CLASSES FM All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as NEMA 4X/7/9 Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as NEMA 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G CSA All with a Series HS, H1, 2 or 3 electric switch Class I, Div 2, Groups B, C & D mechanism and a housing listed as CSA TYPE 4X All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as NEMA 4X/7/9 Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as NEMA 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G CENELEC All with an electric switch mechanism and a EEx d IIC T6 CENELEC housing SAA All with an electric switch mechanism and a housing Ex d IIC T6 IP65 listed as NEMA 4X/7/9 Class I, Div 1, Group B CE Low Voltage Directives 73/23/EEC & 93/68/EEC Installation Category II Per Harmonized Standard: Pollution Degree 2 EN /1993 & Amendment No Boiler External Cage Liquid Level Switches

43 M M 5.2 Physical Inches (mm) P N N P N P Q Q M Q plugged R M plugged Gauge glass tappings L Drum connections K M R M plugged K LL HL Low water cutoff point A K K G T Try cock tappings R HL LL LL HL K C Models B24, C24 A C S Models B25, C25 B J A Allow (254) overhead clearance for cover removal. Conduit Connections M Electrical Switches: NEMA 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches: 1 NEMA 1: 4" NPT All housings rotatable 360 L E B D C Models W24, W25, W29, W60 K S ACTUATION LEVELS * Min. S.G. 1.0 Model HL LL HL LL B24/C24 (18) (40) (24) (42) B25/C25 (94) (114) (105) (124) W24 (289) (311) (302) (321) W25 (240) (260) (251) (270) W29 (279) (302) (292) (311) W60 (267) (281) (284) (297) * Single switch mechanism only. Consult factory for multiple switches. DIMENSIONS Model A B C D E G I J K L N P Q R S T " B24/C24 (141) n/a (71) n/a n/a n/a n/a n/a NPT n/a (150) (96) (158) (412) n/a n/a " " B25/C25 (177) (51) (66) n/a n/a n/a n/a n/a NPT n/a (150) (96) (214) (561) NPT n/a " 3 4" " 3 4" W24 (405) (76) (66) (77) (88) (381) (88) (101) NPT NPT (150) (96) (214) (850) NPT NPT " 1 2" " 1 2" W25 (343) (51) (66) (77) (51) (343) (76) (76) NPT NPT (150) (96) (214) (726) NPT NPT " 3 4" " 3 4" W29 (381) (114) (71) (73) (114) (381) (88) (101) NPT NPT (150) (96) (214) (850) NPT NPT W60 3 4" 4" " 3 ➀ 4" (381) (106) (91) (92) (106) (381) (88) (101) NPT NPT (150) (96) (214) (872) NPT NPT ➀ Model W60 also available per customer specifications Boiler External Cage Liquid Level Switches Replacement Parts 6.1 Standard Boiler Control Models Parts Identification Housing cover 2 Housing base 3 Switch mechanism 4 Enclosing tube 5 Enclosing tube gasket 6 Head flange 7 Studs and bolts 8 Hex nuts 9 Flange gasket 10 Float chamber 11 Stop strap 12 Screws 13 Float and stem assembly 14 Jam nuts 15 Guide washer 16 Attraction sleeve 17 Stop tube 18 Chamber liner 13 IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number Switch and housing reference Series Type Bulletin# Mercury A Anti-vibration mercury E Dry contact B, C, D Hermetically sealed F Hermetically sealed HS Bleed type pneumatic J Non-bleed type pneumatic K Boiler External Cage Liquid Level Switches I I

44 6.1.3 Models B24, C24, B25, and C25 ➀ B24 ➁ C24 B25 ➁ C25 ➂ Housing cover See at left See at left Housing base See at left See at left Switch mechanism See at left See at left Enclosing tube kit ➂ includes items 4 and 5 Enclosing tube gasket Head flange kit includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit ➁ includes items 7, 8, 9, 10, and 18 Float and stem assembly ➃ ➂ includes items 9, 11, 12, 13, 14, 15, 16, and 17 Chamber liner ➁ not required not required Complete control ➃ ➄ ➂➃ less float chamber (10), bolts (7), nuts (8), and liner (18) Models W24, W25, W29 and W60 W24 ➁ W25 ➁ W29 W60 Housing cover See at left See at left Housing base See at left See at left Switch mechanism See at left See at left Enclosing tube kit includes items 4 and 5 Enclosing tube gasket Head flange kit includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit ➁ includes items 7, 8, 9, 10, and 18 Float and stem assembly includes items 9, 11, 12, 13, 14, 15, 16, and 17 Chamber liner ➁ not required Complete control ➄ ➄ ➄ not available less float chamber (10), bolts (7), nuts (8), and liner (18) Notes: ➀ All replacement assemblies listed are furnished in kit form for standard base models. Consult local representative for ordering assistance on all special model replacement parts or accessories not included in above listing. Model and serial numbers required. ➁ Cast float cage models used on boiler service require brass chamber liner. ➂ Consult factory for replacement parts for models with material of construction code -2. ➃ Furnished with one Series 3 SPDT mercury switch and standard switch housing. ➄ Furnished with two Series 3 SPDT mercury switch and standard switch housing. Flanged External Cage Liquid Level Switches Tandem Boiler Control Models Parts Identification Housing cover 2 Housing base 3 Switch mechanism 4 Enclosing tube 5 Enclosing tube gasket 6 Head flange 7 Studs and bolts 8 Hex nuts 9 Flange gasket 10 Stop strap 11 Screws 12 Upper float and stem assembly 13 Lower attraction sleeve 14 Spacer washer 15 Retaining ring 16 Jam nuts 17 Upper attraction sleeve 18 Lower float and stem assembly 19 Safety stop washer 20 Float chamber 21 Chamber liner (not shown) IMPORTANT: 19 When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number Boiler External Cage Liquid Level Switches

45 6.2.2 Switch and housing reference Series Type Bulletin# Mercury A Anti-vibration mercury E Dry contact B, C, D Hermetically sealed F Hermetically sealed HS Bleed type pneumatic J Non-bleed type pneumatic K Models W24, W25, W29 and W60 W24 ➁ W25 ➁ W29 W60 Housing cover See above See above Housing base See above See above Switch mechanism See above See above Enclosing tube kit ➁ ➃ includes items 4 and 5 Enclosing tube gasket Head flange kit includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit includes items 7, 8, 9, 20, and 21 Upper float and stem assembly ➃ see note ➂ includes items 9, 10, 11, 12, 13, 14, and 15 Lower float and stem assembly ➃ see note ➂ includes items 9, 16, 17, 18, and 19 Chamber liner not required Notes: ➀ All replacement assemblies listed are furnished in kit form for standard base models. Consult local representative for ordering assistance on all special model replacement parts or accessories not included in above listing. Model and serial numbers required. ➁ Cast float cage models used on boiler service require brass chamber liner. ➂ Special order item. Specify model and serial number when ordering Boiler External Cage Liquid Level Switches Model Numbers MODEL NUMBER CODE, MATERIALS OF CONSTRUCTION AND TANK CONNECTION Model Minimum Maximum Chamber Attraction Float Trim Max. WSP Max. Pressure Try Cock Code S.G. WSP ➁ Material Sleeve Material Material 100 F (38 C) Mounting B24-1B10 ➂ 0.85 C24-1B10 ➃ 250 psig Cast Iron ➀ 400 Series B25-1B10 ➂ SS 0.84 C25-1B10 ➃ 316L SS 316 SS C25-2B10 ➃ psig Cast Iron ➀ 316 SS F 400 psi ( C) (28 bar) W24-1B10 ➂ psig Cast Iron ➀ 400 Series Right W25-1B10 ➂ SS Hand N/A F 500 psi W29-1B psig Fabricated 400 Series ( C) (34 bar) Left 316L SS 316 SS Steel SS F 900 psi Hand W60-1B psig ( C) (62 bar) ELECTRIC SWITCH MECHANISM AND ENCLOSURE ➆ Max. ➄ B24 & C24 only Process NEMA 4X/7/9 Aluminum Enclosure ➅ Switch Temp. Set Class I, Div. 1, Class I, Div. 1, Description ➇ F ( C) Contacts Points Groups C & D Group B Series SPDT 1 3KP 3KT Mercury Switch w/beaded Leads (399) DPDT 1 3NP 3NT Series B 250 Snap Switch (121) SPDT 1 BKP BKT DPDT 1 BNP BNT Series C 450 Snap Switch (232) SPDT 1 CKP CKT DPDT 1 CNP CNT Series 2 SPDT 1 2KP 2KT Vibration Resistant 750 Mercury Switch (399) w/beaded Leads DPDT 1 2NP 2NT ➀ Cast iron models limited to maximum service temperature of +406 F (+207 C) or switch mechanism temperature rating if lower. ➁ Saturated steam service rating ➂ Models B24, B25, W24, and W25 contain brass inner liners. ➃ Models C24 & C25 are intended for non-boiler service as they do not contain a chamber liner. ➄ Process temperature based on +100 F (+38 C) ambient ➅ Uncontrolled housing heater or drain available in NEMA 4X/7/9. Consult factory for standard part numbers. ➆ Consult factory for NEMA 4X/7/9 cast iron housings. ➇ Consult factory for manual reset switches Boiler External Cage Liquid Level Switches

46 ELECTRIC SWITCH MECHANISM AND ENCLOSURE ➆ Max. ➄ All except B24, C24, C25-2B10 C25-2B10 only Process NEMA 4X/7/9 Aluminum Enclosure ➅ Switch Temp. Set Class I, Div. 1, Class I, Div. 1, Class I, Div. 1, Class I, Div. 1, Description ➇ F ( C) Contacts Points Groups C & D Group B Groups C & D Group B Series Mercury Switch (399) w/beaded Leads Series B 250 Snap Switch (121) Series C 450 Snap Switch (232) 1 3KA 3KJ 3KB 3KK SPDT 2 3LE 3LG 3LB 3LK 3 3ME 3MG 3MB 3MK DPDT 1 3NA 3NJ 3NB 3NK 2 3OA 3OJ 3OB 3OK 1 BKA BKJ BKB BKK SPDT 2 BLA BLJ BLB BLK 3 BMA BMJ BMB BMK 1 BNA BNJ BNB BNK DPDT 2 BOA BOJ BOB BOK 1 CKA CKJ CKB CKK SPDT 2 CLA CLJ CLB CL 3 CMA CMJ CMB CMK 1 CNA CNJ CNB CNK DPDT 2 COA COJ COB COK Series 2 1 2KA 2KJ 2KB 2KK Vibration 750 SPDT 2 2LE 2LG 2LB 2LK Resistant (399) 3 2ME 2MG 2MB 2MK Mercury Switch 1 2NA 2NJ 2NB 2NK w/beaded Leads DPDT 2 2OA 2OJ 2OB 2OK Series HS 1 HMJ HMK SPDT 5 amp Hermetically HMN HMP Sealed Snap Switch (204) 1 HMS HMT w/wiring Leads DPDT 2 HMY HMZ Series HS 5 amp Hermetically 400 Sealed Snap Switch (204) w/terminal Block SPDT 1 HM3 HM4 DPDT 1 HM7 HM8 Series H1 1 amp Hermetically 750 SPDT 1 Sealed Snap Switch (399) 2 HKP w/wiring Leads HKJ HKK PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Maximum Maximum Bleed Orifice All except Code Switch Description Supply Pressure Process Temp. Diameter B24, C24 B24, C24 psig bar F C Inches mm NEMA 1 Series J Bleed Type Series K Non-Bleed Type JDE JEE JEG KOE KOG KOG Boiler External Cage Liquid Level Switches 30 Customer Notes Page Boiler External Cage Liquid Level Switches

47 Customer Notes Page Boiler External Cage Liquid Level Switches 32 ASSURED QUALITY & SERVICE COST LESS Service Policy Owners of Magnetrol/STI controls may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequential damage will be allowed. Return Material Procedure So that we may efficiently process any materials that are returned, it is essential that a Return Material Authorization (RMA) number be obtained from the factory, prior to the material's return. This is available through Magnetrol s or STI s local representative or by contacting the factory. Please supply the following information: 1. Company Name 2. Description of Material 3. Serial Number 4. Reason for Return 5. Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory Belmont Road Downers Grove, Illinois Fax Dorman Road Mississauga, Ontario L4V-1H Fax Heikensstraat 6 B 9240 Zele, Belgium Fax Regent Business Ctr., Jubilee Rd. Burgess Hill, Sussex RH15 9TL U.K Fax Belmont Road Downers Grove, Illinois Fax Copyright 2002 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. STI and STI logotype are registered trademarks of Magnetrol International. Performance specifications are effective with date of issue and are subject to change without notice. The brand and product names contained within this document are trademarks or registered trademarks of their respective holders. BULLETIN: EFFECTIVE: August 2002

48 Installation & Maintenance Instructions MM-221(C) Model 157-RBP-MD (Mercury Switch) Model 157S-RBP-MD (Snap Switch) Low Water Cut-Off/Pump Controller Applications: For bi-level pump control applications such as multiple boiler level operation. Model 157-RBP-MD Model 157S-RBP-MD! WARNING Before using this product read and understand instructions. Save these instructions for future reference All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of plumbing, steam, and electrical equipment and/or systems in accordance with all applicable codes and ordinances. To prevent serious burns, the boiler must be cooled to 80 F (27 C) and the pressure must be 0 psi (0 bar) before servicing. To prevent electrical shock, turn off the electrical power before making electrical connections. This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler. After installation, check for proper operation of all of the limit and operating controls before leaving the site. We recommend that secondary (redundant) Low Water Cut-Off controls be installed on all steam boilers with heat input greater than 400,000 BTU/hour or operating above 15 psi of steam pressure. At least two controls should be connected in series with the burner control circuit to provide safety redundancy protection should the boiler experience a low water condition. Moreover, at each annual outage, the low water cut-offs should be dismantled, inspected, cleaned, and checked for proper calibration and performance. To prevent serious personal injury from steam blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge. To prevent a fire, do not use this low water cut-off to switch currents over 7.4A, 1/3 Hp at 120 VAC or 3.7A, 1/3 Hp at 240 VAC, unless a starter or relay is used in conjunction with it. Failure to follow this warning could cause property damage, personal injury or death. OPERATION Maximum Pressure: 150 psi (10.5 kg/cm 2 ) Electrical Ratings Float Control Pump or Motorized Valve Circuit Rating (Amperes) Voltage Full Load Locked Rotor Pilot Duty 120 VAC VA at 240 VAC or 240 VAC Probe Control Pump or Motorized Valve Circuit Rating (Amperes) Voltage Full Load Locked Rotor Pilot Duty 120 VAC VA at 240 VAC or 240 VAC Probe Sensitivity: - 4,000 ohms Probe Input Power volts Settings and Differential Pressures: * Values are ± 8 (3.2mm). 157-RBP-MD/157S-RBP-MD Pressure Probes Any Pressure Approximate Distance Above Cast Line Differential Setting In. (mm) In. (mm) Pump Off 5 1 /2 (140) Pump On 4 (102) 11/2 (38) Float 0 psi (0 kg/cm 2 ) Pump Off 15 /16 (24) 3/8 (16) Pump On 9/16 (14) Burner Off 0 N/A Float 150 psi (10.5 kg/cm 2 ) Pump Off 1 7 /16 (37) 3/4 (19) Pump On 11/16 (17) Burner Off - 3 /8 (-16) N/A 2 Alarm Circuit Rating Voltage Amps 120 VAC VAC 1/2 Probe Settings PUMP OFF PUMP ON CASTING LINE 4" (102mm) Float Settings (0 psi) 9/16" (16mm) PUMP OFF PUMP ON BURNER OFF 3/8" (35mm) Motor Horsepower Voltage Amps 120 VAC 1/3 240 VAC 1/3 11/2" (38mm) CAST LINE WARNING CAUTION

49 STEP 3 - Electrical Wiring! WARNING To prevent electrical shock, turn off the electrical power before making electrical connections. This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler. After installation, check for proper operation of all of the limit and operating controls, before leaving the site. Boiler manufacturer schematics should always be followed. In the event that the boiler manufacturer s schematic does not exist, or is not available from the boiler manufacturer, refer to the schematics provided in this document. Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in property damage, personal injury or death. Switch Operation - Float Control Boiler feed pump off, burner on, alarm off. Boiler feed pump on, burner on, alarm off. Boiler feed pump on, burner off, alarm on Switch Operation - Probe Control WATER "ON" HIGH PROBE WATER "OFF" LOW PROBE a. Using a flathead screwdriver, remove the junction box cover (K) by unscrewing the four (4) cover screws. 4 K Chassis Ground Chassis Ground INSTALLATION TOOLS NEEDED: Two (2) pipe wrenches, one (1) flathead screw driver, and pipe sealing compound. IMPORTANT: Follow the boiler manufacturer's instructions along with all applicable codes and ordinances for piping, blow down valve and water gauge glass requirements. STEP 1 - Determine the Elevation at Which the Low Water Cut-Off/Pump Controller Must be Installed Size the steam (top) and water (bottom) horizontal equalizing pipe lengths so that the horizontal cast line on the body is 12 (38mm) below the boiler s normal water level, but not lower than the minimum safe water level, as determined by the boiler manufacturer. 1 1 /2" (38mm) NORMAL BOILER WATER LINE MINIMUM SAFE WATER LEVEL CUT-OFF LEVEL AT CAST LINE BLOW DOWN VALVE BLOW DOWN VALVE STEP 2 - Installing the Low Water Cut-Off a. Using a pipe wrench, unscrew the plastic float blocking plug (A) from the float block tapping of the low water cut-off body (B). B Install pipe plug (provided) to seal port. A b. Mount and pipe the low water cut-off (C) on a vertical equalizing pipe (D) at the required elevation level, as determined in Step 1. D Install full ported blow down valves directly below the lower cross of the water equalizing pipe (F). NORMAL BOILER WATER LINE C F BLOW DOWN VALVE BLOW DOWN VALVE

50 L L b. Following the appropriate wiring diagram, (refer to page 6) based on your application requirements, and using BX armored cable or Thinwall electrical metal tubing connector fittings, make electrical connections to the junction box (L). IMPORTANT: There must be a minimum space of 1/2 (13mm) between connector fittings and electrical live metal parts. Snap Switches (Series 150S) Mercury Switches (Series 150) PUMP ALARM LOW WATER PUMP ALARM LOW WATER CIRCUIT CIRCUIT CUT-OFF CIRCUIT CIRCUIT CUT-OFF TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS PUMP SWITCH LOW WATER CUT-OFF AND ALARM SWITCH CUT-OFF PUMP AND ALARM SWITCH SWITCH Mount Control Box in a suitable location near the boiler s main electrical panel. NOTE Boiler sight glass must be visible from location of Control Box and must be within 25 feet of Control Body. Install electrical conduit between Probe Housing and Control Box. NOTE Wire must be 18 AWG stranded with glass braided silicone jacket (UL 3071) suitable for high temperature (200 C) service. NOTE Refer to and follow local codes and standards when selecting conduit and electrical fittings. Wires from Probe Housing and Control Box must be in their own conduit. If they are run in conduit with other wires, there may be interference that can affect the performance of the control. Pull three (3) wires through conduit. 5 6 WIRING DIAGRAMS Low Water Cut-Off Only 1. Main Line Switch - For burner circuits within the switch s electrical rating. 2. Pilot Switch - To holding coil of a starter when the burner circuit exceeds the switch s electrical rating. LINE LINE LOAD OR LOAD Pump Control Only 1. Main Line Switch - For pump motors within the switch s electrical rating. 2. Pilot Switch-To holding coil of a starter when the pump circuit exceeds the switch s electrical rating. LINE LINE LOAD OR LOAD Alarm Circuit Only 1. Low Water Alarm 2. High Water Alarm ALARM ALARM NEUTRAL HOT OR NEUTRAL HOT Combination Pump Control, Low Water Cut-Off and Alarm 1. Main Line Switch - For burner circuits within the switch s electrical rating. 2. Pilot Switch-To holding coil of a starter when the burner circuit exceeds the switch s electrical rating. SEE PUMP SEE PUMP ALARM LINE (3 PHASE) CONTROL HOT CONTROL CIRCUIT ALARM CIRCUIT TO NEUTRAL TO BURNER CONTROL CIRCUIT OR LOAD ELECTRONIC PROBES: Securely tighten all electrical conductors to terminals.

51 STEP 4 - Testing This control is factory calibrated for specific level settings as shown on page 2 in the "Operation" section. The following testing procedure is only meant to serve as a verification of proper operating sequence. IMPORTANT: Follow the boiler manufacturer s start-up and operating instructions along with all applicable codes and ordinances. Standby Range Operation: a. Turn on the electric power to the boiler. The pump should go on and the burner must remain off. 7 MAINTENANCE SCHEDULE: Blow down control as follows when boiler is in operation. Daily if operating pressure is above 15 psi. Weekly if operating pressure is below 15 psi. NOTE More frequent blow-down may be necessary due to dirty boiler water and/or local codes. Disassemble and inspect annually. Remove sediment or debris from float chamber. Inspect and clean probes. Use a non-abrasive cloth to clean probes. NOTE The probes may need to be inspected and cleaned more frequently on systems with high raw water make-up. This includes systems with no condensate return or untreated boiler water. Replace head mechanism every 5 years. More frequent replacement may be required when severe conditions exist such as rapid switch cycling, surging water levels and use of water treatment chemicals. Replacement parts are available from your local authorized McDonnell & Miller Distributor. The use of parts or components other than those manufactured by McDonnell & Miller will void all warranties and may affect the units compliance with listing or regulating agencies. BLOW DOWN PROCEDURE:! CAUTION To prevent serious personal injury from steam pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge. Failure to follow this caution could cause personal injury. Blow down the control when the water in the boiler is at its normal level and the burner is on. NOTE: Refer to page 2 for switch operating points. Open upper valve (#1). Slowly open the lower valve (#2). Water level in the sight glass should lower. As the water level in the sight glass lowers, the pump should turn on. As water continues to lower in the sight glass, the burner should turn off. Slowly close the lower valve (#2). Close the upper valve (#1). The water level in the sight glass should rise, first turning on the burner and then turning off the pump. NOTE: On manual reset models, the reset button will need to be pressed after the water level has been restored before the burner will operate. Valve #1 Valve # N. Spaulding Avenue Chicago, Illinois tel: fax: ITT Industries, Inc. Printed in U.S.A ON! WARNING If the burner comes on, immediately turn the boiler off and make the necessary corrections. OFF Failure to follow this warning could cause an explosion or fire and result in property damage, personal injury or death. b. The boiler should begin to fill with water. As the water level rises in the sight glass, the burner should turn on and then the pump should turn off. If the burner does not turn on or pump turn off at appropriate levels, immediately turn off the boiler and make the necessary corrections.! CAUTION To prevent serious personal injury from steam pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge. Failure to follow this caution could cause personal injury. c. Blow down the control when the water in the boiler is at its normal level and the burner is on. Slowly open the upper then the lower blow-down valves and observe the water level fall in the sight glass. Close the valves (lower first then upper) after verifying that the pump contacts have closed and the burner shuts off. If this does not happen, immediately shut off the boiler, correct the problem and retest. INSTALLATION COMPLETE

52 STEP 1 - Preparation 2 ON a. To prevent electrical shock turn off all electrical power to the boiler. CAUTION: There may be more than one source of power to the boiler. OFF Replacement Instructions MM-711 Series 150, 150S, 157, 157S Bellows Replacement Series 150S Series 150! WARNING Before using product, read and understand instructions. Save these instructions for future reference. All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of plumbing, steam, and electrical equipment and/or systems in accordance with all applicable codes and ordinances. To prevent electrical shock, turn off the electrical power before making electrical connections. To prevent serious burns release all pressure and let boiler cool down to 80 F (27 C). Drain water level down below the float bowl chamber before taking the head mechanism out of the body. Failure to follow this warning could cause property damage, personal injury or death. b. Release all pressure from the boiler and let it cool down to 80 F (27 C). Drain the water level down below the float chamber. c. Remove the four screws that hold the cover on the switch housing (A) and remove the cover. Mark all electrical supply wires so they can be returned to the proper terminals. Remove the wires and conduit connections from switch housing (A). Four Cover Screws A d. Remove eight hex head bolts holding head mechanism (B) to float chamber. Carefully remove head mechanism (B) from float chamber and place in a vise. B Eight Hex Head Bolts e. Holding float (C) firmly, unscrew Allen or Torx fastener (D). (Units with date codes of E99 or earlier will have Allen head fasteners. Those with codes of F99 or later will have Torx fastener). Unscrew float and float rod (C). For snap switch units see Step 3a. For mercury switch units remove the two mercury switches. Remove six (6) Allen or Torx screws (E). D E A f. Remove switch housing (A) from head casting (B). The bellows assembly (F) may stick to the switch housing (A). Remove bellow assembly (F) and clean gasket surfaces on both head casting (B) and switch housing (A). F B C WARNING CAUTION

53 STEP 2 - Changing the Bellows for Mercury Switch Units (For Snap Switch See STEP 3) a. NOTE: On units that have Allen head screws they should be replaced with Torx screws (furnished). b. Take the new bellow assembly (F) and disassemble it noting the order of the parts. Put sealing washer (J) on top of float arm (K) and insert into inside of bellows (F). Place gasket (L) over bellows (F). Insert this assembly into switch housing (A) and bracket (H). If the screw (D) was an Allen screw, the spacer washer (G) will have to be put in the top hole of bracket (H). Take Torx screw (D) (furnished) and insert it into hole on top of bracket (H) and spacer washer (G) (if needed) and screw into float arm (K). Hand tighten only. K D H G J E D A c. Make sure tapped hole on float arm (K) is facing the correct way, so the float and float rod (C) can be screwed into it when bellows assembly is assembled on the head casting. Place gasket (M) on casting (B). Center the gasket and place the bellows assembly (F) and switch housing (A) on head casting (B). Insert and tighten six (6) Torx screws (E) to 125 in. lbs. (14 N m). d. Screw float and float rod (C) into float arm (K) and hand tighten. Center the float rod in the float rod guide (not shown) and tighten Torx screw (D) to 125 in. lbs. (14 N m). Make sure you hold the float in place while tightening screw (D). Move the float up and down, making sure there is no binding and that the float rod is still centered. C H M J K B L F Step 3 - Changing the Bellows for Snap Switch Units a. Clean out sealant and remove two (2) screws (N) and bracket (P). Remove (6) Allen or Torx screws (E). Remove switch housing (A) from head casting (B). The switch bracket (R) will come out with the switch housing (A). The bellows assembly (F) may stick to the switch housing (A). Remove bellow assembly (F) and clean gasket surfaces on both head casting (B) and switch housing (A). E D R G N P A F J B C 3 Step 3 - Changing the Bellows for Snap Switch Units (cont d) b. NOTE: On units that have Allen head screws they will be replaced with Torx screws (furnished). c. Take the new bellows assembly (F) and disassemble it noting the order of parts. Put sealing washer (J) on top of float arm (K) and insert into inside of bellows (F). Place gasket (L) over bellows (F). Insert this assembly into switch housing (A) and bracket (H). If the screw (D) was an Allen screw, the spacer washer (G) will have to be put in the top hole of bracket (H). Take Torx screw (D) (furnished) and insert it into hole on top of bracket (H) and spacer washer (G) (if needed) and screw into float arm (K). Hand tighten only. d. Make sure the tapped hole on float arm (K) is facing the correct way, so the float and float rod (C) can be screwed into it when bellows assembly is assembled on the head casting. Place gasket (M) on head casting (B). Center the gasket and place the bellows assembly (F) and the switch housing (A) on head casting (B). Insert and tighten the six (6) Torx screws (E) to 125 in. lbs. (14N m). Make sure that two (2) of the screws capture the switch bracket (R). e. Screw float and float rod (C) into float arm (K) and hand tighten. Center the float rod in the float rod guide (not shown) and tighten Torx screw (D) to 125 in. lbs. (14N m). Make sure you hold the float in place while tightening screw (D). Move the float up and down, making sure there is no binding and that the float rod is still centered. Install bracket (P) using screws (N), tighten to 40 in. lbs. (4.5 N m). C K D H G J B E D J H R A P N M K L F STEP 4 - Assembling the Head to the Body and Test for Proper Operation a. Clean the gasket surface on head casting (B) and the body casting. Using a new gasket (furnished) mount the head mechanism to the body casting. Tighten the eight (8) bolts to 18 ft. lbs. (24N m). Reattach conduit connectors and connect wires to the proper terminals. Turn on electrical power to the boiler. b. Run the unit through several cycles of operation, noting the operating points. On the snap switch controls it may be necessary to readjust the switches. If this is necessary follow the enclosed instructions. (See attached for reference only, MM-235) N. Spaulding Avenue Chicago, Illinois tel: fax: ITT Industries Inc. Printed in U.S.A

54 Installation & Maintenance Instructions MM-416 Wiring connections for a Series 150E/157E when used as a replacement for a Series 150/157 (mercury) or 150S/157S (snap) switch unit. NOTE Read and follow installation instructions included with 150E/157E control. A. Connect 'Hot' (L1) wire from power supply to Terminal 'H'. B. Connect 'Neutral' (L2) wire from power supply to Terminal 'N'. NOTE: Power wires connected to Terminals 'H' and 'N' on 150E should be from the boiler's control transformer connections which are usually designated 'L1' and 'L2'. The 150E SHOULD NOT be powered as part of any operating or safety circuit. C. Remove wire from Terminal '1' and connect to Terminal 'PCOM'. D. Remove wire from Terminal '2' and connect to Terminal 'PNO'. E. Remove wire from Terminal '4' and connect to Terminal 'BNO'. F. Remove wire from Terminal '5' and connect to Terminal 'BCOM'. G. Remove wire from Terminal '6' and connect to Terminal 'BNO'. Snap Switches (Series 150S and 157S) PUMP ALARM LOW WATER CIRCUIT CIRCUIT CUT-OFF TERMINALS TERMINALS TERMINALS PUMP SWITCH LOW WATER CUT-OFF AND ALARM SWITCH Mercury Switches (Series 150 and 157) PUMP CIRCUIT TERMINALS ALARM CIRCUIT TERMINALS LOW WATER CUT-OFF TERMINALS PUMP SWITCH CUT-OFF AND ALARM SWITCH Electronic Relays (Series 150E and 157E) Probe Connections Top Blue Middle Yellow Bottom Red Burner Terminals BCOM BNC BNO 0-60 Second Adjustable Burner Off Delay PCOM PNC PNO 3500 N. Spaulding Avenue Chicago, Illinois tel: fax: ITT Industries Inc. Printed in U.S.A N H Secs. Pump Terminals Probe LED's 110 Volt Input from Boiler Test Circuit Manual Reset Switch (If applicable) Power Low Water LED LED Green Red

55 APPLICATIONS Unit Heaters & other Space Heating Equipment Heat Exchangers/Reboilers Steam Heating Coils Steam Main Drips Air Compressor Receivers Air Line Drips Air Powered Process Equipment OPTIONS Repair Kits SIZING INFO OPERATION Air entering trap is immediately discharged through the high capacity integral air vent. The thermostatic vent will close just prior to saturation temperature. The balanced design will allow venting of non-condensibles that collect in the float chamber when operating at design pressure. When steam enters the trap, the thermostatic air vent closes to prevent steam loss. FTN SERIES FLOAT & THERMOSTATIC STEAM TRAPS Pressures To 125 PSIG (8.6 barg) Temperatures to 450 F (232 C) Universal Four-port Design Four possible hookup combinations of the H pattern body and piping dimensions similar to other major manufacturers allow maximum installation flexibility for easy replacement of other traps. Inlet and outlet taps on larger sized traps located in the cover to permit larger capacities. All Stainless Steel Internal Components Hardened valves and seats. Extra long life and dependable service. Resists water hammer. Protects against erosion and corrosion. Balanced Pressure Thermostatic Element allows venting of non-condensibles while operating at design pressure. Rugged Welded Stainless Steel Element Increases service life. Wide Selection of Differential Pressures Sizes 3/4" to 2" available with 15, 30, 75 and 125 psig differential pressures. Air Line Water Removal Special configuration FTNA optimized for compressed air service. Repairable In-line Can be serviced without disturbing system piping. MODELS FTN-15 Steam pressures to 15 PSIG FTN-30 Steam pressures to 30 PSIG FTN-75 Steam pressures to 75 PSIG FTN-125 Steam pressures to 125 PSIG FTNA-75 Air pressures to 75 PSIG FTNA-125 Air pressures to 125 PSIG Installation Tip: Always install STV Test & Block Valve as part of trap station Installation Tip: Add Uniflex Pipe Coupling for ease of maintenance When steam gives up it s latent heat, it becomes condensate. This condensate enters the trap and causes the stainless steel ball float to rise. Raising of the float opens the discharge valve, allowing condensate to be continuously discharged as it enters the trap. The condensate level in the trap body is maintained above the discharge seat, providing a positive seal against the loss of steam. FTN SERIES FLOAT & THERMOSTATIC STEAM TRAPS SPECIFICATION Steam trap shall be of float and thermostatic design. Float shall actuate the valve via a hinged lever and linkage. Air vent shall be of balanced pressure design with stainless steel welded encapsulated bellows capable of discharging air and noncondensable gases continuously within 15 F of saturated temperature. Traps through 1-1/4" shall employ H pattern connections to accommodate multiple piping configurations. Trap shall be cast iron bodied suitable for pressures to 125 psi and available in 3/4" through 2" NPT. 3 /4", 1" - All 1 1 /4" - FTN-15, FTN /2", 2" - All * 1 1 /4" - FTN-75, FTN-125, FTNA-75*, FTNA-125* *1/8" NPT tap at top boss for balancing line. MAXIMUM OPERATING CONDITIONS PMO: Max. Operating Pressure ORIFICE PMO psig (1.03 barg) psig (2.07 barg) psig (5.17 barg) psig (8.62 barg) PMA: Max. Allowable Pressure 250 psig (17.2 barg) TMA: Max. Allowable Temperature 450 F (232 C) MATERIALS OF CONSTRUCTION Body & Cover..Cast Iron ASTMA126B All Internal Stainless Steel Air Vent (FTN only)....balanced Pressure, Welded Stainless Steel Dimensions Connections: 3/4"-2" NPT Inches (mm) Weight Model No. Size A B C D E E1 lbs (kg) 3 / (159) (140) (84) (76) (146) (4.1) (159) (140) (84) (76) (146) (4.1) FTN-15, FTN / /2 (159) (146) (76) (97) (146) (4.3) 1 1 / (216) (108) (76) (18) (213) (8.2) (249) (123) (123) (3) (232) (11.8) 3 / (159) (140) (84) (76) (146) (4.1) (159) (140) (84) (76) (146) (4.1) FTN-75, FTN / FTNA-75,FTNA-125 (216) (108) (76) (18) (213) (8.2) 1 1 / (216) (108) (76) (18) (213) (8.2) (249) (123) (123) (3) (232) (11.8) Maximum Capacity lbs/hr (10 F Below Saturation) Size Differential PSIG (barg) Trap NPT Orifice 1/4 1/ (in.) (.017) (.034) (.069) (.138) (.345) (.690) (1.03) (1.38) (1.72) (2.07) (2.76) (3.45) (5.17) (6.90) (8.62) FTN-15 3/4" FTN-15 1" FTN /4" FTN /2" FTN-15 2" FTN-30 3/4" FTN-30 1" FTN /4" FTN /2" FTN-30 2" FTN-75 3/4" FTN-75 1" FTN /4" FTN /2" FTN FTN-125 3/4" FTN-125 1" FTN /4" FTN /2" FTN-125 2" For Kg/Hr Multiply by.454 For FTNA capacities, multiply by 1.33.

56 APPLICATIONS Very High Condensate Loads Continuous Drainage With High Air Venting Capacity Requirements Industrial And Commercial Applications Absorption Systems Air Handling Coils Heat Exchangers Dryers Evaporators Hot water Generators Rendering Machines Steam Process Equipment Air Make-up Coils Unit Heaters And Cooking Kettles SIZING INFO OPERATION During startup, air and non-condensible gases enter the trap and are automatically vented through an accurate balanced pressure internal thermostatic air vent. As condensate enters the trap, the float and lever mechanism is raised, lifting the valve off MAX-FLO SUPER HIGH CAPACITY FLOAT & THERMOSTATIC STEAM TRAPS Pressures to 175 PSIG (12.1 barg) Temperatures to 377ºF (260ºC) High Capacities Rugged cast iron body and cover Stainless steel thermostatic element eliminates air binding Stainless steel float and lever mechanism Below condensate level seat design prevents steam leakage Resistant to water hammer and corrosion In-Line repairable MODELS HC-15 - Steam pressures to 15 PSIG HC-30 - Steam pressures to 30 PSIG HC-75 - Steam pressures to 75 PSIG HC Steam pressures to 125 PSIG HC Steam pressures to 175 PSIG Installation Tip: Always install STV Test & Block Valve as part of trap station Installation Tip: Add Uniflex Pipe Coupling for ease of maintenance the seat, discharging the condensate. Condensate will continue to be discharged at the same rate at which it is entering. Any air or non-condensible gas that may accumulate will be continually and efficiently passed by the thermostatic air vent. MAX-FLO SUPER HIGH CAPACITY FLOAT & THERMOSTATIC STEAM TRAPS SPECIFICATION Steam trap shall be of float and thermostatic design. Float shall actuate the valve via a hinged lever and linkage. Air vent shall be of balanced pressure design with stainless steel welded encapsulated bellows capable of discharging air and noncondensable gases continuously. Trap shall be cast iron bodied suitable for pressures to 175 PSI and shall be a NPT connection. MAXIMUM OPERATING CONDITIONS PMO: Max. Operating Pressure see orifice selection TMO: Max. Operating Temperature saturated at pressure PMA: Max. Allowable Pressure 175 PSIG (12.1 barg) PMA: Max. Allowable Pressure 377ºF (192ºC) 1 1 4" & 1 1 2" 2" E F E C Drain C Thermostatic Vent C B E D F J H A A A B D MATERIALS OF CONSTRUCTION Body & Cover Cast Iron 30,000 psi tensile Valve Pin and Seat......Stainless Steel (Hardened) Float Stainless Steel Lever Assembly Stainless Steel Thermostatic Air Vent Stainless Steel Cage & Thermal Element Cover Bolts Grade 5 Baffle......Stainless Steel (2-1/2 (65mm) units only) Inlet 2 1 2" Discharge J K L 4-Holes, 17/32" Dia. D F G G H B Dimensions NPT Size Weight MODEL in. (mm) A B C D E F G H J K L lbs (kg) HC & (32 & 40) (108) (211) (217) (76) (86) (51) (17.8) (35) (8) ALL (50) (254) (381) (394) (168) (121) (89) (49) ALL (65) (368) (514) (441) (241) (379) (159) (127) (305) (41) (114) (178) (79) Maximum Capacity-lbs/hr Differential - PSIG (barg) Trap Orifice 1/4 1/ Max ΔP (0.017) (0.035) (0.07) (0.14) (0.35) (0.69) (1.0) (1.4) (1.69) (2.1) (2.8) (3.5) (4.2) (5.2) (6.9) (8.6) (10.4) (12.1) HC-15, 2" HC-15, 2 1 2" HC-30, 2" HC-30, 2 1 2" HC-75, 2" HC-75, 2 1 2" HC-125, 2" HC-125, 2 1 2" HC-175, 1 1 4" HC-175, 1 1 2" HC-175, 2" HC-175, 2 1 2" For Kg/Hr Multiply by.454

57 STOCKED MODELS in bold High Current Capacity or Extra Low Deadband Mercury Switches (SPST) MERCURY SWITCH SPST HIGH CURRENT MERCURY SWITCH SPST LOW DEADBAND BOURDON ADJUSTABLE 120V., 240V. AC/DC 120VAC., 240VAC., 120VDC TUBE OPERATING MINIMUM OPEN ON INC. CLOSE ON INC. MINIMUM OPEN ON INC. CLOSE ON INC. MATERIAL RANGE (PSIG) DEADBAND PSIG MODEL NUMBER MODEL NUMBER DEADBAND PSIG MODEL NUMBER MODEL NUMBER 0-30 Hg. Vac. 2 Hg. Vac. DA * DA * 1 Hg. Vac. DA * DA * 1/ DA DA DA DA / DA A DA A 0.5 DA A DA A DA DA DA DA BRASS DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA S DA S 2.5 DA S DA S DA S DA S 3.0 DA S DA S DA S DA S 4.0 DA S DA S 403SS DA S DA S 7 DA S DA S DA S DA S 15 DA S DA S DA S DA S 50 DA S DA S DA S* DA S* 200 DA S* DA S* 316SS DA E DA E 3.0 DA E DA E DA E DA E 5.0 DA E DA E Also available in Weather-proof (DAW-33) or Explosion-proof (DAH-31) Housings. *Range 2 and 15S not FM approved. Other ranges FM approved. For FM approved models specify DAF or DSF. Example DAF STOCKED MODELS in bold Weather-proof Models SNAP ACTION SWITCH SPDT SNAP ACTION SWITCH SPDT MERCURY SWITCH SPDT Bourdon Adjustable 120/240 VAC 120/240 VAC 120V., 240V. AC/DC Tube Operating Fixed Minimum Minimum Material Range (PSIG) Deadband PSIG Model Number Deadband PSIG Model Number Deadband PSIG Model Number 0-30 Hg. Vac. 3 Hg. Vac. DSW * 9 Hg. Vac. DAW * 2 Hg. Vac. DAW * 1/ DSW DAW DAW / DSW A 4 DAW A 1 DAW A DSW DAW DAW BRASS DSW DAW DAW DSW DAW DAW DSW DAW DAW DSW DAW DAW DSW DAW DAW DSW S 9 DAW S 4 DAW S DSW S 13 DAW S 6 DAW S DSW S 15 DAW S 8 DAW S 403SS DSW S 19 DAW S 14 DAW S DSW S 45 DAW S 25 DAW S DSW S 130 DAW S 90 DAW S DSW S* 900 DAW S* 450 DAW S* 316SS DSW E 11 DAW E 6 DAW E DSW E 28 DAW E 18 DAW E *Range 2 and 15S not FM approved. All other DAW ranges are FM approved. POPULAR MODELS Explosion-proof Models SNAP ACTION SWITCH SPDT SNAP ACTION SWITCH SPDT MERCURY SWITCH SPDT BOURDON ADJUSTABLE 120/240 VAC 120/240 VAC 120V., 240V. AC/DC TUBE OPERATING FIXED MINIMUM MINIMUM MATERIAL RANGE (PSIG) DEADBAND PSIG MODEL NUMBER DEADBAND PSIG MODEL NUMBER DEADBAND PSIG MODEL NUMBER 0-30 Hg. Vac. 3 Hg. Vac. DSH * 9 Hg. Vac. DAH * 2 Hg. Vac. DAH * 1/ DSH DAH DAH / DSH A 4 DAH A 1 DAH A DSH DAH DAH BRASS DSH DAH DAH DSH DAH DAH DSH DAH DAH DSH DAH DAH DSH DAH DAH DSH S 9 DAH S 4 DAH S DSH S 13 DAH S 6 DAH S DSH S 15 DAH S 8 DAH S 403SS DSH S 19 DAH S 14 DAH S DSH S 45 DAH S 25 DAH S DSH S 130 DAH S 90 DAH S DSH S* 900 DAH S* 450 DAH S* DSH E 11 DAH E 6 DAH E 316SS DSH E 28 DAH E 18 DAH E *Range 2 and 15S not FM approved. Other ranges FM approved. For FM approved models specify DAHF or DSHF. Example DAHF Dwyer Instruments, Inc. P.O. Box 373/Michigan City, Indiana 46361/Phone /Fax U.K. Phone (01494) Australia Phone (02) Pressure Pressure Series DA/DS Bourdon Tube Pressure Switches Visible setpoint, adjustable deadband, snap action switch pressure ranges to 5000 psi 2-1/4 [57.15] Weather-Proof Types DAW, DSW, DRW F M REAR MOUNTING 4-3/16 FLANGE (3).203 DIA. 2-13/16 HOLES AT 120 ON 6-1/2 DIA. BOLT CIRCLE 1-5/8 [41.28] Ø6-1/64 [152.8] 1/4 NPT 5/8 OPERATING ADJUSTMENTS GASKETED COVER FOR ADJUSTMENTS GASKET 15/16 1-5/8 DIA. 1/2 CONDUIT HUB ADJUSTMENT SCREWS 1/2 CONDUIT HOLE 5/8 [15.88] 7/8 [22.23] Customers tell us that this is the best pressure switch made. Our most popular, Model DA combines extremely high sensitivity and repeatability with easily adjustable set and reset points through non-interactive external adjustments. Visible calibrated dial for setpoints and on/off indicator to indicate switch actuation are included. Choose either high current snap-switch or hermetically sealed contact mercury switch. The DS Model has a fixed deadband. FEATURES DA Series is equipped with two external adjustments. One sets high pressure operating point, the other sets reset point. Deadband, or the difference between set and reset points is adjustable over the full scale. DS Series has a single external adjustment and fixed deadband. Visible calibrated dial, on/off indication. SPDT snap-action or sealed mercury switches. Minimum deadband obtainable at any point in range. Pressure Ranges vacuum to 5000 psig. U.L. and C.S.A. listed. Many models FM listed. STOCKED MODELS in bold PHYSICAL DATA Max. Temperature: 180 F. For higher temperature media applications, a remote connection or siphon (pigtail) should be used. Pressure Connection: 1/4 NPT. (1/2 on range 15S). Housing: pressed steel with transparent cover. Wiring Connections: 3 screw type. Wetted Parts: same as Bourdon tube material. Weight: 4 lb. (std); 6 lb. (wea-proof); 8 lb. (exp-proof). Max. Press.: Max. adjustment operating range. Suggested Specification Pressure switch shall be Mercoid Series DA operated by a (brass) (type 316 stainless steel) (type 403 stainless steel) Bourdon tube actuating a (mercury switch) (snap-switch). Switch shall have deadband fixed or adjustable up to a maximum of 100% of switch range. Switch shall have calibrated dial and one or two pointers indicating set and reset points. Switch shall have visible on/off indication. Setpoints shall be adjustable without removing switch cover or shutting down process. Explosion-Proof Types DAH, DRH, DSH SNAP ACTION SWITCH SPDT SNAP ACTION SWITCH SPDT MERCURY SWITCH SPDT BOURDON ADJUSTABLE 120/240 VAC 120/240 VAC 120V., 240V. AC/DC TUBE OPERATING FIXED MINIMUM MINIMUM MATERIAL RANGE (PSIG) DEADBAND PSIG MODEL NUMBER DEADBAND PSIG MODEL NUMBER DEADBAND PSIG MODEL NUMBER 0-30 Hg. Vac. 3 Hg. Vac. DS * 9 Hg. Vac. DA * 2 Hg. Vac. DA * 1/ DS DA DA / DS A 4 DA A 1 DA A DS DA DA BRASS DS DA DA DS DA DA DS DA DA DS DA DA DS DA DA DS S 9 DA S 4 DA S DS S 13 DA S 6 DA S DS S 15 DA S 8 DA S 403SS DS S 19 DA S 14 DA S DS S 45 DA S 25 DA S DS S 130 DA S 90 DA S DS S* 900 DA S* 450 DA S* 316SS DS E 11 DA E 6 DA E DS E 28 DA E 18 DA E Additional features available on special order, include other electrical ratings and circuits, lower minimum differentials, special housings, diaphragm seals and manual reset. For severe vibration, a special Delrin Bushed Movement is available. *Range 2 and 15S not FM approved. Other ranges FM approved. For FM approved models specify DAF or DSF. Example DAF /8 1-3/4 U Dwyer Instruments, Inc. P.O. Box 373/Michigan City, Indiana 46361/Phone /Fax U.K. Phone (01494) Australia Phone (02) /4 CONDUIT TH D 3-1/2 7-3/4 3-1/2 (2) STD. 13/32 DIA. MOUNTING HOLES L CONTROL ADJUSTMENTS 1/2 NPT 3/4 PIPE THD. CONDUIT HOLE 2-9/16 1-1/4

58 Series DA FEATURES External Setpoints Deadband Adjustable (over 100% of scale) or Fixed Visible Calibrated Dial, PSI/kg Visible Operation On/Off Indication Repeatability 1% of full scale Minimum Deadband Obtainable at any Point in Range Welded Stainless Steel Bourdon Tubes Provide Reduced Chance of Leakage in Case of Fire Pressure Ranges to 8000 psig UL, CSA Listed (most models, features) Bourdon Tube Pressure Switches General Data and Accessories PHYSICAL DATA Max. Temp.: 180 F. For higher media applications, a remote connection or siphon (pigtail) should be used. Pressure Connection: 1/4 NPT std. 1/2 NPT on range 15S, 16S Wetted Parts: Same as bourdon tube material except range 23K, 24K, 9K. Weight: 4 lb. std., 6 lb. weatherproof 8 lb. exp. proof Max. Press.: Max. adjustment operating range. Use of a surge tank, snubber of capillary tubing connection is recommended where pulsation, pressure surge or water hammer may occur. Suggested Specification Pressure switch shall be Mercoid Series DA operated by a (brass) (type 316 stainless steel) (type 403 stainless steel) Bourdon tube actuating a (mercury switch) (snap-switch). Switch shall have deadband adjustable up to a maximum of 100% of switch range. Switch shall have calibrated dial and two pointers indicating set and reset points. Switch shall have visible on/off indication. Setpoints shall be adjustable without removing switch cover or shutting down process. Mounting Flange For Surface Mounting (Field Installation) For DA, DAF, DS, DSF, DR, DRF and DL controls only. May be ordered separately for field installation. Part No (except on 15S, 16S) Part No (for range 15S, 16S only) Mounting Bracket For use with standard NEMA 1 enclosure general purpose controls only: Series DA, DAF, DS, DSF, DR, DRF, DL. Note: not adaptable for Range 15S and 16S. Part No Conduit Hub For 1/2 rigid conduit. Mercury switch type controls with standard general purpose NEMA-1 or optional weather-resistant NEMA-3 or NEMA-4 enclosures are suitable for Class 1, Div. 2 applications when ordered with this hub. Available for DA Series. Part No Breathers & Drains STANDARD BREATHER STANDARD DRAIN For Class I, Groups C, D and Class II, Groups E, F, G (water only). Mercoid s.s. drains are flame-tight, but not watertight which permits water to escape continuously. Mercoid s.s. breathers include a water shedding cap and provide effective case ventilation. For Series DAH, DAHF, DRH, DRHF, DSH, DSHF. Part No Standard drain. Part No Standard breather. For Series DAE, DRE. Part No Drain with 1/4 connection. *Part No Standard breather with 1/2 connection. *Part No Reducer (3/4 to 1/2 ) for breather. *Breather and reducer must be ordered together. Miscellaneous Oxygen & Acetylene Service Spec Fungus Proof Spec FM Approval DAF, DRF, DSF DELRIN* Bushed Movement B *Registered Trademark of E.I. DuPont de Nemours & Co. PIVOT POINT BEARINGS, TOP & BOTTOM, BUSHED WITH DELRIN SWITCH CARRIER STOP POST SLEEVED WITH DELRIN DELRIN PIN Factory Mutual Approved Series D Pressure Switches F M Cover Over External Adjustments DELRIN PIN BAR LINK DELRIN BRUSHED PIVOTAL END BEARING & CONNECTION BAR PIN OF DELRIN Remote Connections Pigtail Siphon Part No HP 6 ft. copper remote connection, 2500 psig max. Part No ft. 316 s.s. connection with 303 s.s. fittings, 3000 psig max. 1/4 NPT Recommended for steam applications 35 psig or higher. For Series D-30, D-530, D-230, D-7030, D-7230 pressure controls. Please specify. Part No psig max. Provides longer service life for Series D pressure and temperature controls. Vibration and pulsation are the prime causes of control wear. Almost all types of vibration will have some effect on the life and continued accuracy of controls. To offset the wearing of metal surfaces found in bearings and pivot points, the control mechanism is designed to incorporate Delrin bushed movements at each possible wear point. Also for environments where corrosion may be a factor. Add Letter B After Type and Suffix Nos. Example: DS-221-2B, DA-31-3B, DAH-41-3B. 7 Dwyer Instruments, Inc. P.O. Box 373/Michigan City, Indiana 46361/Phone /Fax U.K. Phone (01494) Australia Phone (02) Pressure Pressure Series DA/DS Bourdon Tube Pressure Switches Type DA Adjustable Deadband, Fully Automatic, Double Adjustments Type DR Semi-Automatic, Manual Reset, Single Adjustment VISIBLE CALIBRATED DIAL DOUBLE EXTERNAL ADJUSTMENTS Snap Action Switch VISIBLE CALIBRATED DIAL RESET SINGLE ADJUSTMENT Manual Reset ( 2 or 3 circuits only) SWITCH INDICATOR VISIBLE CALIBRATED DIAL DOUBLE EXTERNAL ADJUSTMENTS Mercury Switch Contact Equipped with a single adjustment for setting operating point to operate the circuit automatically upon a pressure increase or decrease. Pushbutton reset must be operated manually to restore the circuit to original position after automatic operation. Suffix L, i.e. DR L denotes control will operate automatically on increase; suffix U denotes control will operate automatically on decrease. Equipped with two external adjustments, one for setting high pressure operating point, the other for setting low pressure operating point. Deadband, or the difference between high and low setpoints, is adjustable over full scale. Mercoid s most popular operating mode, available on most Series D pressure and temperature controls. Type DS Fixed Deadband, Fully Automatic, Single Adjustment VISIBLE CALIBRATED DIAL SINGLE EXTERNAL ADJUSTMENT Snap Action Switch Type DL Semi-Automatic, Manual Lock Reset, Single Adjustment VISIBLE CALIBRATED DIAL RESET SINGLE EXTERNAL ADJUSTMENT Manual Lock Reset ( 2 or 3 circuits only) Equipped with a single adjustment for setting operating point. Control will operate at setpoint only upon a decrease in pressure. Manual lock feature permits circuit to be reset and locked in position. Lock remains in effect until pressure rises above control setting. Lock then releases and circuit is held in reset position until further automatic operation upon pressure decrease. SWITCH INDICATOR VISIBLE CALIBRATED DIAL SINGLE EXTERNAL ADJUSTMENT Mercury Switch Contact Equipped with single adjustment for setting operating point only. A single pointer on scale sets pressure point at which switch action occurs. Fixed deadband is factory set and cannot be altered in the field. Available on series D-200, D-7200 and D-9200 only. Type D-400, DA-7400 Two-Stage, Fully Automatic, 2 Set Pts. Provides two stage control by actuating one circuit upon a rise or fall in pressure and a second circuit on a further rise or fall. Each setpoint has a fixed deadband. Dwyer Instruments, Inc. P.O. Box 373/Michigan City, Indiana 46361/Phone /Fax U.K. Phone (01494) Australia Phone (02)

59 Pressure General Purpose Types DA, DS, DR, DL Drawing No. 1000B Series DA Bourdon Tube Pressure Switches Control Dimensions Weather-Proof Types DAW, DSW, DRW Drawing No Explosion-Proof Types DAH, DRH, DSH Drawing No HOLES FOR FLANGE SCREWS DA21 DA31 DA41 REAR FLANGE MOUNTING HOLES (3) 2-13/16 3-1/2 BREATHER (OPTIONAL) MOUNTING HOLES (OPTIONAL) 13/32 DIA. 5 1/2 CONDUIT CONNECTION 5-3/4 DIA. DA24 DA34 DA /16 DIA. 7-5/8 6-9/ /16 CONDUIT CONNECTIONS 6-1/2 DIA. 1/4 NPT 1/4 NPT 1-1/2 7 DIA. 3/4 CONDUIT CONNECTION 9-7/8 [«\«1 DA22 DA32 DA42 1-1/8 1/4 NPT [\««1 ADJUSTMENTS GASKETED COVER 1/2 CONDUIT HUB 7-3/4 1/2 NPT 1/4 NPT *Consult factory for Cenelec approved DAH models. Diaphragm Seal Types MSAG Drawing No Flange for Surface Mounting Drawing No. 1000F PN (2) BACK CONNECTION Explosion-Proof Types DAE, DRE, DSE Drawing No. 98D 13/64 DIA. DA23 DA33 DA43 BOTTOM CONNECTION 1/4 NPT 7/8 MOUNTING HOLES (4) 2-5/16 9-1/8 4 DIA. 1/4 NPT FLUSHING CONNECTION PROCESS CONNECTION 1/4, 1/2, 1, 1-1/2 NPT (1.) 1/2 NPT Connection for ranges 15S, 16S (2.) Use PN for ranges 15S, 16S General Purpose NEMA 1 Enclosure For indoor use and other general purpose applications under normal atmospheric conditions. Provides protection against dust and light splashing. Heavy gauge plain steel case. Flanged case available. Transparent cover for visible on-off operation. Locking device prevents tampering. Pressure connection, 1/4 NPT. Electrical connection back of case for 1/2 conduit or BX. Shipping wt. 4 lbs. See above for dimensions. Furnished as standard unless otherwise specified. Watertight, Dust-tight/ Type W NEMA 3S, 4, & 4X Enclosure For outdoor or indoor applications. Complies with hose test and requirements for watertight, dust-tight, drip-tight weatherproof, weather-resistant, splash-proof, sleet-proof, and moisture-resistant. Flanged, heavy gauge steel case with transparent cover for visible on-off operation. External adjustments protected by cover. Bottom pressure connection. 1/4 NPT. Electrical connection back of case for 1/2 conduit, removable 1/2 hub. Shipping wt. 6 lbs. See above for dimensions. Optional, add W to prefix, i.e. DAW, DRW, DSW, when ordering. Explosion- Proof Type H Hazardous Area Enclosure suitable for Class I, Groups C & D, Class II, Groups E, F & G; NEMA 7 & 9 applications. Control mechanism is an integral part of enclosure and cannot be replaced in the field. For surface, panel or pipe mounting. Aluminum case with glass window in cover for visible on-off operation. Bottom pressure connection, 1/2 NPT male 1/4 NPT female. External adjustments. Available with breather and drain. Shipping wt. 8 lbs. (3.6 kg.). See above for dimensions. Optional housing, to order add H to prefix. Example: DAH, DRH, or DSH. Not available on D80 Series. NOTE: Standard general purpose NEMA 1 and NEMA 4 enclosures are suitable for Class I, Division 2 applications with addition of conduit hub (mercury switch models only). Dwyer Instruments, Inc. P.O. Box 373/Michigan City, Indiana 46361/Phone /Fax U.K. Phone (01494) Australia Phone (02)

60 TYPE E MAIN VALVE SIZES 3 /8" 12" PRESSURES to 600 PSIG at 750 F TYPE E MAIN VALVE APPLICATION DATA Pressure Regulating for Steam Distribution Regulating for Process Control (Temperature or Pressure) Maintain Back Pressure or Differential Pressure For use with Self-contained, Pneumatic or Electronic Pilots Single Point or Multiple Use Applications Slow Start-up or Shutdown SIZING INFO VALVE RATINGS Valve Ends Pressure Temperature ASME/ANSI PSIG (bar) F ( C) CAST IRON Class 250 NPT (232) B16.1 Class 125 Flanged (232) B16.1 Class 250 Flanged (232) CAST STEEL B16.34 Class 300 NPT (315) B16.34 Class 150 Flanged (260) B16.34 Class 300 Flanged (315) B16.34 Class 600 Flanged (315) 750 F (400 C) construction available on request. Other pressure/temperature ratings available; consult factory. Maximum downstream pressure is 300 psi. Canadian Registration # OC C Installation Tip: Add EZ Connections for ease of maintenance Normally Closed Single Seat Balanced Metal Diaphragms Protected Main Spring Fluid, Gas & Vapor Applications Accurate Regulation Unaffected by Service Conditions ANSI/FCI 70-2 Class IV Shutoff Virtually Frictionless for Long Service Life Packless Construction Easy In-line Maintenance Wide Variety of Pilots for Many Applications Minimum Operating ΔP 10 psi (.7 bar) Lifetime Warranty against Wiredrawing of Seat & Disc* OPTIONS Composition Disc Parabolic Disc Balanced Construction Integral Mount Pilot Insulcap Insulating Jacket Secoweld High Temperature Construction Dashpot Low ΔP (LP) Main Spring EZ Connections TYPICAL CONFIGURATIONS PRESSURE REDUCING TYPE ED SERIES AIR ADJUSTED TYPE EA SERIES BACK PRESSURE TYPE EQ SERIES PUMP GOVERNOR TYPE EP SERIES LOAD ALLOCATING TYPE EFD AIR CONTROLLED TYPE EAP60 ELECTRONIC SLOW START TYPE ED208D SOLENOID CONTROLLED TYPE EMD SOLENOID ACTUATED TYPE EM DIFFERENTIAL TYPE EN TEMPERATURE CONTROL TYPE ET SERIES RATED FLOW COEFFICIENTS (Cv) SEAT REGULATOR SIZE FACTOR 1 / /2 3/8 1 /2 3 / / Full Full 75 % Full 50 % Normal Normal 75 % Normal 50 % * When installed according to factory specifications. TYPE E MAIN VALVE SPECIFICATION A The valve shall be self-operated, external pilot type, single seated, metal diaphragm actuated, normally closed design. The valve will function quickly and shut tight on dead end service. Internal parts including seats, discs, stems and diaphragms shall be of stainless steel. There shall be no springs in the steam space and no stuffing box. The valve shall be easy to maintain with all parts accessible without removal from the line. C MATERIALS OF CONSTRUCTION Body, Cast Iron ASTM A126 Cl. B Body, Cast Bronze ASTM B61 UNS C92200 Body, Cast Steel ASTM A216 WCB Stem 303 St. Stl. ASTM A582 Disc 3/4-5" 420 St. Stl. ASTM A743 CA-40 Disc 6-12" 304 St. Stl. ASTM A167/A240 Seat 3/4-5" 420 St. Stl. ASTM A743 CA-40 Seat 6-12" 316 St. Stl. ASTM A CF-8M Gasket Non-asbestos Diaphragm Stainless Steel MIL-S-5059C Spring Steel B TYPE E MAIN VALVE D FITTINGS DIMENSIONS inches (mm) AND WEIGHTS pounds (kg) FACE TO FACE DIMENSIONS C A B Std. Mount Integral Mount D* APPROX. WT. SIZE ANSI ANSI ANSI ANSI ANSI ANSI CI & Brz. Steel Steel ANSI ANSI ANSI ANSI NPT 125, All 600 NPT 125, , /8 4 3 /8 5 7 /8 2 3 /4 3 1 /2 3 1 /2 5 1 /4 14 (10) (111) (149) (70) (89) (89) (133) (6) 1 /2 4 3 / /8 2 3 /4 2 3 /4 3 1 /2 3 1 /2 3 5 /8 5 1 / (12) (111) (152) (149) (70) (70) (89) (89) (92) (133) (6) (9.1) 3 /4 4 3 /8 6 3 /8 6 1 /2 2 7 /8 3 7 /8 3 5 /8 3 3 /4 4 1 /2 5 1 / (19) (111) (162) (165) (73) (98) (92) (95) (114) (140) (8) (13) /8 5 1 / /2 6 1 / /8 4 1 /4 4 3 /8 4 3 /8 4 3 /4 6 1 / (25) (137) (140) (152) (165) (165) (178) (92) (108) (111) (111) (121) (159) (10) (12) (14) (15) 1 1 /4 6 1 /2 6 3 /4 7 1 /4 7 7 /8 7 7 /8 7 7 /8 4 1 /8 4 5 / / / (32) (165) (171) (184) (200) (200) (200) (105) (117) (102) (117) (127) (165) (15) (17) (19) (20) 1 1 /2 7 1 /4 6 7 /8 7 3 / /4 4 3 /8 5 1 /8 4 3 / / (38) (184) (175) (187) (203) (203) (222) (111) (130) (111) (127) (181) (20) (21) (25) (26) /2 8 1 / / /4 9 7 /8 5 1 /4 5 3 / /8 5 3 /4 7 5 / (51) (191) (216) (229) (260) (260) (251) (133) (146) (127) (143) (146) (194) (28) (33) (35) (38) 2 1 /2 9 3 / / / /8 5 3 /4 7 7 /8 5 1 / /4 8 3 / (64) (238) (254) (286) (286) (276) (146) (200) (140) (152) (210) (213) (43) (45) (59) / / / /4 6 5 /8 9 1 /8 6 3 /8 7 1 /8 9 1 / (76) (254) (273) (311) (311) (298) (168) (232) (162) (181) (235) (57) (64) (80) / / / / /4 7 5 / /8 7 1 / / (102) (302) (318) (318) (368) (375) (194) (270) (184) (203) (302) (95) (105) (141) / / / / /8 8 1 / /2 8 1 /8 8 1 / / (127) (346) (368) (368) (419) (429) (216) (318) (206) (216) (318) (134) (141) (223) / / / /4 9 1 /2 9 1 / / / (152) (384) (406) (406) (441) (502) (254) (349) (241 (241) (346) (359) (191) (214) (298) / / / / / / / (203) (483) (508) (508) (549) (572) (292) (391) (286) (298) (438) (318) (323) (486) / / / (254) (600) (635) (635) (711) (349) (594) (563) (591) / / / (305) (673) (711) (711) (838) (403) (641) (936) (972) *Add 65% to D dimension for stem removal clearance.

61

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63 TYPE P14 PILOT APPLICATION DATA Steam Driven Pump Control RATINGS (Maximum Inlet Conditions) Pressure Temperature Construction PSIG (bar) F ( C) Cast Iron (232) Cast Bronze (204) Cast Steel (400) SPRING PRESSURE RANGES (PSIG) P P P P Canadian Registration # OC C SIZING INFO TYPE P PUMP GOVERNOR PILOT CONTROLS 3 to 2000 PSIG Self Contained Spring Operated Normally Open ANSI/FCI 70-2 Class IV Shutoff Packless Construction Accurate to ±1 psi Three Adjustable Spring Ranges Steam Applications Constant Average Discharge Pressure Accurate Regulation Unaffected by Service Conditions Easy In-line Maintenance OPTIONS Adjustment Indicator Integral Mount MODELS TYPE P13 features a spring for controlling pressures 100 to 300 PSI. TYPE P14 features three spring ranges for controlling pressures 5 to 150 PSI. TYPE P15 features two spring ranges for controlling pressures 3 to 25 PSI. TYPE P32 is piston driven and features three spring ranges for controlling pressures 200 to 2000 PSI. TYPICAL CONFIGURATIONS STEAM PUMP CONTROL TYPE EP STEAM PUMP CONTROL TYPE E2P STEAM PUMP CONTROL TYPE E5P TYPE P PUMP GOVERNOR PILOT SPECIFICATION 5 7 /8 (149) The Pilot shall be separate from the main valve and connected to it with a male union. The Pilot shall be normally closed design with packless construction. A strainer screen shall be built into the Pilot inlet. The Pilot shall be interchangeable on all sizes of main valves. The pilot shall automatically adjust pump discharge pressures within the spring range to maintain a constant average pressure. MATERIALS OF CONSTRUCTION Body, Cast Iron ASTM A126 Cl B Body, Cast Bronze ASTM B61 UNS C92200 Body, Cast Steel ASTM A216 GR. WCB Stem 2024-T4 ASTM B Disc 440 St. St. ASTM A COND A Seat 420 St. Stl ASTM A276 COND A Gasket Non-Asbestos Diaphragm 301 St. Stl. MIL C Spring Steel ASTM A (280) 2 (51) TYPE P14 PILOT 13 LBS. (5.9 KG) 4 1 /2 (114) 3 1 /2 (89) 4 1 /2 (114) 6 3 /4 (171) 11 3 /8 (289) 10 7 /8 (276) 11 (280) 2 (51) 2 (51) 2 (51) TYPE P32 PILOT 10 LBS. (4.5 KG) TYPE P13 PILOT 11 LBS. (5 KG) TYPE P15 PILOT 15 LBS. (6.8 KG) For Integral Mount Pilot, this dimension is 1 1 /16" (27).

64 APPLICATIONS Steam Tracing Drips Heating Canadian Registration # OE0591.9C OPERATION Incoming air and condensate flow through the trap body and into the control chamber. Line pressure raises the disc off the seat allowing complete discharge. When flashing condensate enters the cartridge, flow velocity increases, creating low pressure underneath the disc. Flashing condensate at high velocity strikes the inside wall of the disc chamber and is deflected to the top of the disc causing a NTD600 SERIES THERMO-ACTIVE STEAM TRAPS Pressures To 600 PSIG (41.3 barg) Temperatures to 800 F (426 C) Compact Design Hardened stainless steel disc is the only moving part. Inexpensive Low initial cost is less expensive than repairable technologies. Simplifies Installation Works in any position. Rugged Handles water hammer and superheat. Reliable, Efficient Operation Blast discharge helps to eliminate dirt buildup and provides tight shutoff Freeze resistant Self draining design prevents freezing. All Stainless Steel Construction Resists both internal and external corrosion. Easy to Monitor Audible discharge cycle makes checking operation simple. MODELS NTD600 Thermodynamic Disc Trap Installation Tip: Always install STV Test & Block Valve as part of trap station Installation Tip: Add Uniflex Pipe Coupling for ease of maintenance SIZING INFO pressure buildup. The disc is forced down onto the seat by this pressure imbalance. The trap remains closed as flashed vapor in the control chamber keeps the disc seated. Pressure inside the cap is not lowered until the trapped flash vapor condenses due to body radiation. Condensing steam lowers the pressure above the disc. Disc is then lifted and the cycle repeated. NTD600 SERIES THERMO-ACTIVE STEAM TRAPS SPECIFICATION C Steam trap shall be of thermodynamic design. Body shall be of all stainless construction and hardened throughout. Seat shall be integral to body. Cover shall seal to body without gaskets or seals. Trap shall be suitable for pressures through 600 psi and available in 3/8" through 1". A MAXIMUM OPERATING CONDITIONS B PMO: Max. Operating Pressure 600 psig (41.3 barg) TMO: Max. Operating Temperature 800 F (426 C) PMA: Max. Allowable Pressure 600 psig (41.3 barg) TMA: Max. Allowable Temperature 800 F (426 F) MATERIALS OF CONSTRUCTION Body 420F SS ASTM A743 CA40F Cap & Disc 416 SS ASTM A582 Connections: 3 8" 1" NPT Dimensions in inches (mm) Weight in Lbs. (kg) Size A B C 3 /8" /4 1 3 /4.8 (51) (44) (44) (.36) 1/2" 2 11 / / (68) (44) (51) (.55) 3/4" 213 / / / (71) (59) (62) (.86) 1" 35 / /2 2 7 /8 3.1 (84) (64) (73) (1.8) Maximum Capacity lbs/hr 10 F Below Saturation Differential PSIG (barg) NPT Connection (0.24) (0.34) (0.7) (1.4) (2.1) (3.4) (5.2) (6.9) (10.3) (13.8) (20.7) (27.6) (34.5) (41.3) 3/8" /2" /4" " For Kg/Hr Multiply by.454

65 8 Industrial Gauge 500X Series with Dial Sizes through12" A ø D 3 HOLES EQUALLY SPACED J 0.06 [1.5] All dimensions are nominal. Dimensions in [ ] are in millimeters. K C G B E F H N/A = Not Available Dial Size A B C D E F G H J K 4 1 /2" [149.7] [60.7] [121.7] [5.6] [97.2] [23.8] [41.3] [35.7] [52.4] [136.5] 6" [193.6] [79.8] [159.8] [7.1] [119.5] [23.8] [41.3] [35.7] [53] [177.8] 8 1 /2" [260.4] [111.1] [223.4] [7.1] [147.5] [24.6] [41.3] [35.7] [56.8] [244.5] 12" N/A [362] [321.5] [7.1] [200.7] [24.6] [41.3] [35.7] [56.8] [244.5] Standard Available Ranges psi Ranges (PSI) kpa Ranges (KPA) kg/cm Ranges (KG) Range Specific Figure Minor Range Specific Figure Minor Range Specific Figure Minor Code Range Intervals Divisions Code Range Intervals Divisions Code Range Intervals Divisio " Hg to to 0 kpa cm Hg to " Hg to 15 psi 10/5 0.5/ to 100 kpa cm Hg to 1 kg/cm 2 20/0.5 5/ " Hg to 30 psi 10/5 1/ to 200 kpa cm Hg to 2 kg/cm 2 20/0.5 5/ " Hg to 60 psi 10/10 1/ to 400 kpa cm Hg to 4 kg/cm 2 25/1 5/ " Hg to 100 psi 30/10 2/ to 600 kpa cm Hg to 7 kg/cm 2 76/1 5/ " Hg to 150 psi 30/25 5/ to 1000 kpa cm Hg to 10 kg/cm 2 76/1 15/ " Hg to 300 psi 30/50 5/ to 2000 kpa cm Hg to 21 kg/cm 2 76/3 38/ to 15 psi to 100 kpa to 1 kg/cm to 30 psi to 200 kpa to 2 kg/cm to 60 psi to 400 kpa to 4.2 kg/cm to 100 psi to 700 kpa to 7 kg/cm to 160 psi to 1200 kpa to 11 kg/cm to 200 psi to 1500 kpa to 14 kg/cm to 300 psi to 2000 kpa to 21 kg/cm to 400 psi to 3000 kpa to 28 kg/cm to 600 psi to 4000 kpa to 42 kg/cm to 1000 psi to 7000 kpa to 70 kg/cm Ranges over 1000 psi are not available on 500XB to 1500 psi to 10,000 kpa to 100 kg/cm to 2000 psi to 14,000 kpa to 140 kg/cm to 3000 psi to 20,000 kpa to 210 kg/cm to 5000 psi to 35,000 kpa to 350 kg/cm to 10,000 psi to 60,000 kpa 10, to 700 kg/cm to 15,000 psi to 100,000 kpa 10, to 1000 kg/cm to 20,000 psi to 140,000 kpa 20, to 1400 kg/cm Dual scale (psi/kpa and psi & kg/cm 2 ) ranges are available. Specify the PSI Range Code required along with the appropriate Units of Measure code (PSI/KPA or PSI/KG). Other pressure measurement ranges available, including Altitude, Ammonia, Refrigerant and Receiver ranges. Consult Special Application Ranges section or factory for availability. 1/1/ W.Eight Mile Road Oak Park,MI / FAX:248/ Industrial Gauges Industrial Gauge 500X Series with Dial Sizes through12" The Trerice Series 500X Industrial Gauge is designed to withstand the most demanding applications of a variety of industries. This pressure gauge has a back flanged, cast aluminum case and stainless steel ring. Wetted parts are either bronze tube with brass socket or stainless steel tube and socket. 41/2", 6", 1/2" & 12" Dial Sizes 8 ±0.5% Accuracy Cast Aluminum Case Industrial Gauges Case style variations and optional features are also available. Please consult the Options Section for details. For correct use and application of all pressure gauges, please refer to Pressure Gauge Standard ASME B XB, 41/2" pictured Accuracy ±0.5% Full Scale, ASME B Grade 2A Window Clear glass Connection Lower male or lower back male, 1/4 or 1 /2 NPT Specifications Models 500XB, 500XSS Maximum Temperature 250 F (121 C) Pointer 4 1 /2", 6", 8 1 /2" Dial Size: Micro adjustable, black finished Case Cast aluminum, black finished, surface mounted back flanged Size 4 1 /2", 6", 8 1 /2", 12" Approximate Shipping Weight 4 1 /2" Dial Size: 2.0 lbs [0.91 kg] 12" Dial Size: Plain, black finished Wetted Parts 500XB: Bronze tube, brass socket Ring 4 1 /2", 6", 8 1 /2" Dial Size: Friction type, 304 stainless steel 6" Dial Size: 2.8 lbs [1.27 kg] 8 1 /2" Dial Size: 5.8 lbs [2.63 kg] 12" Dial Size: 14.6 lbs [6.62 kg] Dialface Aluminum, white background with black graduations and markings 500XSS: 316 stainless steel tube and socket.* 12" Dial Size: Friction type, steel, black finished Movement Stainless steel *403 stainless steel tube and 316 stainless steel socket furnished above 10,000 psi How to Order Sample Order Number: 500XB45SML250PSI XB 45 SML 250 PSI 110 Model Dial Size Case Type & Connection Units of Measure Range Connection Location Size Code 500XB /2" SMB Surface Mount Back /4 NPT PSI psi See Standard 500XSS 60 6" SML Surface Mount Lower /2 NPT KPA kpa Available /2" FSB Flangeless Back KG kg/cm 2 Ranges (over) 12 12" FSL Flangeless Lower PSI/KPA psi/kpa HRB Hinged Ring Back PSI/KG psi & kg/cm 2 HRL Hinged Ring Lower 1/1/ W.Eight Mile Road Oak Park,MI / FAX:248/

66 VACUUM BREAKERS Johnson Vacuum Breakers provide a simple, dependable way to relieve unwanted vacuum which may develop in a closed vessel or pipeline. They can be used to prevent contamination from back siphonage in fluid handling systems, and to protect equipment against collapse or implosion. They combine tight closing with instant response, provide large air venting capacity, and are designed for easy installation and long service life. OPERATING PARAMETERS 5 Temperature Up to 365 F 4 Pressure Up to 300 psig Note: Maximum limits vary in relation to changes in pressure, and temperature. Consult Johnson for safe limitations under your specific application conditions. Assembly dimensions are +/- 1/8. 1 Body 2 Retainer Tube 3 Ball 4 O-Ring 5 Spring SERIES VB8 VACUUM BREAKERS Catalog Number Pipe Thread Size Outlet Pipe Size Total Length L Engaged Length E O.D. of Tube D Hex Body Size Diameter of Orifice VB8-38-BR-P-S-E 3/8 1/ 4 1-1/ 2 1-1/ 8 9/16 3/4 1/ 4 VB8-51-BR-P-S-E 1/ 2 3/8 1-3/4 1-3/8 11/16 1 9/32 VB8-76-BR-P-S-E 3/4 1/ 2 2-1/8 1-5/8 13 /16 1-1/ 4 13/32 VB8-101-BR-P-S-E 1 3/4 2-3/8 1-7/ 8 1-1/16 1-1/ 2 19/32 VB8-126-BR-P-S-E 1-1/ /16 2-5/16 1-5/16 1-3/4 3/4 VB8-151-BR-P-S-E 1-1/ 2 1-1/ 4 3-1/16 2-1/2 1-9/16 2 7/ 8 Explanation of Catalog Numbers Vacuum Required to Open VB8 38 BR P S E Horizontal Top Outlet Vertical Bottom Outlet Series VB8 Vacuum Breakers Size Body Outlet Ball Seal 38 = 3/8 51 = 1/2 76 = 3/4 101 = 1 126= 1-1/4 151= 1-1/2 BR = Brass SS = Stainless Steel P = Plain T = Threaded S = Stainless Steel E = EPR (Specify alternate by name) VB8-38 3/8 VB8-51 1/2 VB8-76 3/4 VB VB /4 VB /2 In. H 2 0 In. Hg PSI In. H 2 0 In. Hg PSI In. H 2 0 In. Hg PSI In. H 2 0 In. Hg PSI In. H 2 0 In. Hg PSI In. H 2 0 In. Hg PSI Note: Stainless Steel Ball was used to arrive at all figures.values given are averages of test results and may vary slightly. Dimensions are in inches and for reference only. Certified drawings are available on request. Vacuum Breakers - page 2 Diameter of Ball 3/8 1/ 2 5/8 7/ 8 1-1/16 1-3/16 No Spring

67 VACUUM BREAKERS Approximate Series VB8 Air Handling Capacities The air handling capacity curves were plotted from calculations using the C v factors of the vacuum breaker units. The C v factor is a flow coefficient determined by actual test which mathematically gives the relationship between the rate of flow and the pressure drop. The flow formula used was recommended by the Fluid Controls Institute. INCHES HG VACUUM NOTE: Capacities will vary slightly due to position of installation or kind of ball. SCFM-AIR SCFM-AIR VACUUM BREAKERS Dimensions are in inches and for reference only. Certified drawings are available on request. Vacuum Breakers - page 3 VB8-151 VB8-126 VB8-101 VB8-76 VB8-51 VB8-38

68 VACUUM BREAKERS Typical Installations of Johnson Vacuum Breakers MODULATING CONTROL VALVE JOHNSON VACUUM BREAKER HEATING COIL Johnson Vacuum Breaker installed on heating coil. When the modulating control valve closes, the steam in the coil will condense. Actually, a vacuum can exist in the coil with the control valve partly open and positive pressure between the control valve and the coil. Dimensions are in inches and for reference only. Certified drawings are available on request. Vacuum Breakers - page 2 THE JOHNSON CORPORATION 805 Wood Street, Three Rivers, Michigan USA tel: fax: VACUUM BREAKER INSTALLATION Figure 1 Standard Vertical Installation Pipe as shown if possible for a preventative measure. If the outlet is exposed it can become fouled with dust and dirt. Upon operation this contamination can prevent the vacuum breaker from resealing. Figure 2 High Temperature or Hazardous Chemical Service Pipe as shown for safety reasons. After undeterminable amount of time the vacuum breaker will fail. Having the outlet piped to a safe location eliminates a safety hazard. Although the installation shown is vertical with outlet on the bottom, this should be done regardless of the installation orientation. Figure 3 High Temperature Installation Piping the vacuum breaker as shown can eliminate the need for special high temperature seals. The temperature at the vacuum breaker varies depending the steam line temperature. The pigtail should be sized to have a flow area equal or greater than that of the vacuum breaker used. Figure 4 - Engaged Length When piping in the vacuum breaker, attention should be given to the engaged length E. 1. The vacuum breaker should never be installed such that the screen is in the flow path. In instances of high velocities the correct operation can be disrupted as well as damage to the vacuum breaker. 2. Vacuum breakers should be installed in pipe couplings to prevent damage on installation. An example of this would be installation in the short side of a pipe tee where the screen could be crushed.

69 PRODUCT SPECIFICATION March 2005 PNEUMATIC ACTUATED INDUSTRIAL VALVES SERIES: SIZES 1/2 to 2 INCHES 2800 Precision Globe Control Valves Two-Way and Three-Way, Reciprocating, Bronze or Stainless Steel Body Valves for Process and Utility Applications Table of Contents Body Style Versus Application Body Pressure-Temperature Rating Flowing Differential Pressure Limits Flow Coefficients (Cv) Versus Travel Sizing Reference and Load Sizing Calculations Shut-Off ΔP Ratings Dimensions and Weights Actuators, Positioners, and Accessories Factory Default Settings Configurations Two-Way Single Seat Unbalanced Valve Flexible Design Options provide optimum performance and extended reliability in a cost effective, application specific package. Dual Point PEEK Bearing Stem Guiding provides both stability and low friction, yielding reduced hysterisis and optimum control. Trim available in 316SS, 17-4 ph, Alloy 6, PEEK, and PTFE. Port Guided Plug Assembly provides stability and desired equal percentage flow characteristic. Lower Plug offers easy access for inspection and clean out. Rugged Body with a selection of port reductions.

70 SERIES: 2800 Precision Globe Control Valves 2830 Three-Way Mixing Valve Bronze Body 2832 Three-Way Diverting/Mixing Valve Bronze Body Fluoraz O-Ring Upper and Lower Body Seals in Stainless Steel Body Valves Guided Low-Friction TFE V-Ring Packing Spring Loaded Adjustable Graphite Packing Description Warren Controls Series 2800 Precision Globe Control Valves feature rugged bronze or stainless steel bodies with a variety of trim materials and port sizes. The equal percentage and linear plugs in the 2-way valves and linear plugs in the 3-way valves provide excellent modulating control of a wide variety of fluids for pressure, temperature, level, and flow applications from 20 to 500ºF. The Series 2800 is ideally suited where value and long life are important objectives for applications including but not limited to the Chemical, Food & Beverage, General Service, Refining, and Pharmaceutical Industries Emrick Blvd., Bethlehem, PA Tel: or Fax: Body Style Versus Application 2-Way Valves (Control of Liquids, Gases, and Steam) 3-Way Valves (Control of Liquids) 2820 Two-Way Single Seat Unbalanced Valve The most commonly applied solution with ANSI Class IV and VI shut-off. Sizes: 1/2, 3/4, 1, 1-1/4, 1-1/2, 2 inch Body: ANSI B16.15 Bronze 250LB Threaded (NPT) or 316 Stainless Steel 300LB Threaded (NPT) Trim: EQ% or Linear, 316 Stainless Steel, Alloy 6, TFE, PEEK, or 17-4 PH Hardened Stainless Steel Shut-off: ANSI Class IV (Stainless Steel and Alloy 6 Trim), ANSI Class VI (TFE and PEEK Trim) Packing: Guided Low-Friction TFE V-Ring, Spring Loaded (+32 to 450 F), Adjustable Graphite Packing (+32 to 500 F) Temperature: +32 to 400 F (Bronze 250LB Threaded Body) +32 to 450 F (316 Stainless Steel 300LB Threaded Body w/ TFE or PEEK Trim) +32 to 500 F (316 Stainless Steel 300LB Threaded Body w/ Stainless Steel or Alloy 6 Trim) Rangeability: 50: Three-Way Mixing Valve This valve has two inlets and one outlet, and is the simplest solution for mixing or bypass applications with ANSI Class IV shut-off. In normal applications the inlet pressures are near equal and control is possible from 5% to 95% of travel with inlet pressures up to 100 PSI. Sizes: 1/2, 3/4, 1, 1-1/4, 1-1/2, 2 inch Body: ANSI B16.15 Bronze 250LB Threaded (NPT) or 316 Stainless Steel 300LB Threaded (NPT) Trim: Linear, 316 Stainless Steel Packing: Guided Low-Friction TFE V-Ring, Spring Loaded (+32 to 450 F), Adjustable Graphite Packing (+32 to 500 F) Temperature: +32 to 400 F (Bronze 250LB Threaded) +32 to 500 F (316 Stainless Steel 300LB Threaded) Rangeability: 50:1 Stem Down Stem Up Upper Port Common Port Flow Flow Upper Port Common Port Stem Down Stem Up Flow Flow Lower Port Lower Port Flow Flow The upper port opens The upper port closes and the lower port closes and the lower port opens The valve closes The valve opens Body Pressure-Temperature Ratings: Temperature (F) 250 THD 300 THD Bronze SS +32 To 150 F Flowing Differential Trim Materials Pressure Limit Bronze 50 PSID 316 Stainless Steel 100 PSID TFE 100 PSID PEEK 100 PSID 17-4 ph Hardened Steel 200 PSID Alloy PSID Pressure ratings are PSIG For applications below 32º consult factory. For applications above 375º, 300 THD Stainless Steel Body is recommended Three-Way Diverting/Mixing Valve Designed as a diverting valve with one inlet and two outlets with ANSI Class III shut-off. However, flow can be reversed for mixing if this port configuration is desirable. The difference between the upper port and lower port pressure must not exceed 50 PSID. Sizes: 1, 1-1/2, 2 inch Body: ANSI B16.15 Bronze 250LB Threaded (NPT) or 316 Stainless Steel 300LB Threaded (NPT) Trim: Linear, Bronze (Bronze 250LB Threaded), or 316 Stainless Steel (316 Stainless Steel 300LB Threaded) Packing: Guided Low-Friction TFE V-Ring, Spring Loaded (+32 to 450 F), Adjustable Graphite Packing (+32 to 500 F) O-Ring: EPR (Bronze 250LB Threaded), Fluoraz 797 (316 Stainless Steel 300LB Threaded) Temperature: +32 to 300 F (Bronze 250LB Threaded) +32 to 500 F (316 Stainless Steel 300LB Threaded) Rangeability: 50:1 Stem Down Stem Up Upper Port Lower Port Upper Port Lower Port Flow Common Port Common Port The upper port opens The upper port closes and the lower port closes and the lower port opens 3 For additional applications, and/or products call: or visit: PS 2800 C

71 Sizing Reference Steam Table Steam Temp. Temp. Sensible Latent Total Pressure F C Heat Heat Heat PSIG BTU/Lb. BTU/Lb. BTU/Lb Rectangular Tank Capacity in Gallons Height x Width x Length (inches) Gallons = 230 or Gallons = H x W x L (Ft.) x 7.5 Circular Tank Storage Capacity in Gallons Storage = 6D 2 x L (Gallons) Where: D = Tank Diameter in Feet L = Length in Feet Load Sizing Calculations Glossary of Terms t = Time in Hours Cp = Specific Heat of Liquid S = Specific Gravity of Fluid W = Weight in Lbs. ΔT = Temperature Rise or Fall in F h fg = Latent Heat of Steam Conversion Factors 1 Lb. Steam / Hr. = 1000 BTU / Hr. 1 Cubic Meter = 264 U.S. Gallons 1 Cubic Foot Water = 62.4 Lbs. 1 PSI = 2.04 Inches of Mercury 1 PSI = 2.3 Feet of Water 1 PSI = 27.7 Inches of Water 1 U.S. Gallon Water = 231 Cubic Inches 1 U.S. Gallon Water = 8.33 Lbs. Heating Water with Steam Quick Method GPM Lbs./Hr. = x ΔT 2 Accurate Method Lbs./Hr. = GPM x 500 x ΔT h fg Heating or Cooling Water with Water F water 2 temp. rise or drop GPM 1 = GPM 2 x F water 1 temp. rise or drop Heating or Cooling Water BTU / Hr. GPM = ( F water temp. rise or drop ) x 500 Heating Oil with Steam GPM Lbs./Hr. = x ( F oil temp. rise) 4 Heating Air with Water CFM x ( F air temp. rise) GPM = 2.16 x 1000 x ( F water temp. drop) Heating Liquids with Steam GPM x 60 x Cp x W Lbs./Hr. = x ΔT h fg Heating Liquids in Steam Jacketed Kettles GPM x Cp x S x 8.33 Lbs./Hr. = x ΔT h fg x t General Liquid Heating W x Cp Lbs./Hr. = x ΔT h fg x t Heating Air with Steam CFM Lbs./Hr. = x ΔT For additional applications, and/or products call: or visit: PS 2800 C Flow Coefficients (Cv) Versus Travel 0 0 Valve 2820 Flow Coefficients (Cv) Two-Way Single Seat Unbalanced Valve 2-WAY VALVE TYPICAL FLOW CURVE Valve Trim Trim Port %Travel Size(IN) Style Size(IN) Size 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 1/2 EQ% FULL % CV % TRAVEL 2-Way Valves (Control of Liquids, Gases, and Steam) 2830 TYPICAL FLOW CURVE SR SR LINEAR FULL /4 EQ% FULL SR SR SR LINEAR FULL EQ% FULL SR SR SR SR LINEAR FULL /4 EQ% FULL SR SR SR SR LINEAR FULL /2 EQ% FULL SR SR SR SR LINEAR FULL EQ% FULL SR SR SR SR LINEAR FULL UPPER 60 LOWER 50 % CV COMBINED 40 Valve 2830 Flow Coefficients (Cv) Three-Way Mixing Valve Valve Trim Trim Port Travel Valve Trim Trim Port Travel Size(IN) Style Size(IN) Size 100% Size(IN) Style Size(IN) Size 100% /2 LINEAR FULL /4 LINEAR FULL SR SR 10.0 % TRAVEL FULL SR /2 LINEAR SR SR /4 LINEAR FULL LINEAR FULL TYPICAL FLOW CURVE SR SR SR SR FULL LINEAR SR SR SR 1.00 UPPER 70 LOWER 60 % CV COMBINED 3-Way Valves (Control of Liquids) Flow Coefficients (Cv) Three-Way Diverting/Mixing Valve Valve % TRAVEL 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Valve Trim Travel 100% Size(IN) Style Upper Lower 1 LINEAR /2 LINEAR LINEAR 40 47

72 Shut-Off ΔP Ratings Valve Actuator Shut-Off ΔP Three-Way Mixing 2830 Valve Actuator Shut-Off ΔP Three-Way Diverting/Mixing 2832 Shut-Off ΔP Ratings NOTES: Maximum Shut-off ΔP in PSI Upper Port Closed Lower Port Closed Trim Valve Plug Direct Acting Direct Acting Size Size Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) (IN) (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI /2 9/16 DL49 Low N/A thru Full N/A N/A High /2 9/16 DL49 Low N/A thru Full N/A N/A High /2 9/16 DL49 Low N/A N/A thru Full N/A N/A High N/A /4 3/4 DL49 Low N/A N/A thru Full N/A 2 24 N/A High N/A DL84 Low N/A Full N/A N/A N/A 486 High N/A N/A /4 DL49 Low N/A N/A N/A Full N/A N/A N/A N/A N/A 174 High N/A DL84 Low N/A N/A Full N/A N/A 23 N/A N/A Shut-Off ΔP Two-Way, Single Seat Unbalanced Valve Actuator NOTES: 1) 2820 Seat closure ANSI Class IV (Stainless Steel and Alloy 6 Trim), ANSI Class VI (TFE and PEEK Trim). 2) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 3) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 4) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure. Maximum air pressure DL49 30 PSIG DL84 & 84XR 30 PSIG 5) See Actuators, Positioners, and Accessories section for explanation of spring ranges. 6 1) 2830 Mixing Valves have two inlets and one outlet. Published shut-off values are with respect to worst case conditions with zero downstream pressure on the outlet port and zero upstream pressure on the opposing inlet port. Pneumatic Actuators used with the 2930 are direct acting. The upper port fails closed on loss of air pressure to the actuator. N/A Exceeds DL49 and DL84 Actuator s Maximum Air Pressure N/A Exceeds DL49 and DL84 Actuator s Maximum Air Pressure 2) 2830 Seat closure ANSI Class IV. 3) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 4) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. High N/A N/A 294 DL84XR Xtra-High N/A N/A 294 5) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure. 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges. Maximum air pressure DL49 30PSIG DL84 & 84XR 30PSIG Maximum Shut-off ΔP in PSI Upper Port Closed Lower Port Closed Direct Acting Direct Acting N/A Exceeds Actuator Rating Valve Plug Size Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 1 3/4 DL49 High N/A N/A 115 DL84 High N/A N/A /2 3/4 DL49 High N/A N/A N/A 113 DL84 High N/A N/A /4 DL49 High N/A N/A 110 N/A N/A 111 DL84 High N/A N/A 115 N/A Exceeds Actuator Rating 5) N/A indicates that the air signal is not capable of providing any shut-off or it exceeds the actuator s maximum air pressure. 1) Published shut-off values are for diverting applications. The values are worst case and based on the pressure difference between the inlet and the outlet that is closed. Consult the factory if the required shut-off exceeds the published value and the pressure at the inlet and both outlets is known. For proper operation in diverting applications, the pressure difference between both outlets must not exceed 50 PSI. Consult the factory for shut-off values for 2832 mixing applications. Pneumatic Actuators used with the 2832 are direct acting. The upper port fails closed on loss of air pressure to the actuator. Maximum Shut-off ΔP in PSI Fail Closed Fail Open Trim Valve Plug Reverse Acting Direct Acting Size Size Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) (IN) (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI /2 3/4 DL49 Low N/A thru Full /4 High /2 3/4 DL49 Low N/A thru Full High /4 DL49 Low N/A thru Full N/A N/A High DL84 Low N/A Full N/A N/A High N/A /4 3/4 DL49 Low N/A thru Full N/A N/A High DL84 Low N/A Full N/A N/A High N/A DL84XR Xtra-High N/A N/A N/A /4 3/4 DL49 Low N/A N/A thru Full N/A N/A High N/A DL84 Low N/A Full N/A N/A High N/A Maximum air pressure DL49 30 PSIG DL84 30 PSIG 4) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 2) 2832 Seat closure ANSI Class III. 3) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges. 7 For additional applications, and/or products call: or visit: PS 2800 C 0305 DL84XR Xtra-High N/A N/A N/A /4 DL49 Low N/A N/A Full N/A 7 21 N/A High N/A DL84 Low N/A N/A Full N/A N/A 23 N/A N/A 307 High N/A N/A 307 DL84XR Xtra-High N/A N/A N/A N/A Exceeds DL49 and DL84 Actuator s Maximum Air Pressure 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: N/A Exceeds DL49 and DL84 Actuator s Maximum Air Pressure

73 Dimensions & Weights Component 2820 Variable 1/2, 3/4, 1 1-1/4 & 1-1/2 2 A 250THD 4-7/8 5-3/4 6-1/2 300THD 5 6-1/8 6-1/2 B 250THD 2-3/4 3-1/4 3-5/8 300THD 3 3-1/2 3-7/8 C DL49 Direct* 15-1/4 15-7/8 16-1/8 DL49 Reverse 14-5/8 15-1/4 15-1/2 DL84 Direct* 19-1/4 19-7/8 20-1/8 DL84 or 84XR Reverse 18-5/8 19-1/4 19-1/2 H DL49 1-3/4 2-3/8 2-3/4 (W/760) DL84 or 84XR 3-5/8 4-1/4 4-1/2 Item Weight (LB) by Valve Size (IN) Variable 1/2, 3/4, 1 1-1/4 & 1-1/ THD 8-1/2 14-1/2 18-1/2 300THD /2 19 Component 2830 Dimension (IN) by Valve Size (IN) Dimension (IN) by Valve Size (IN) Variable 1/2, 3/4, 1 1-1/4 & 1-1/2 2 A 250THD 4-7/8 5-3/4 6-1/2 300THD 5 6-1/8 6-1/2 B 250THD 2-3/4 3-3/ THD 2-3/4 3-3/8 3-3/4 C DL49 Direct* 15-1/4 15-7/8 16-1/8 DL84 or 84XR Direct* N/A 19-7/8 20-1/8 H DL49 1-3/4 2-3/8 2-3/4 (W/760) DL84 or 84XR N/A 4-1/4 4-1/2 Item Weight (LB) by Valve Size (IN) Variable 1/2, 3/4, 1 1-1/4 & 1-1/ THD / THD /2 Component 2832 * Includes 1-3/8 inch for air fitting H = Centerline of pipe to bottom of positioner CF = Consult factory N/A = Not Available Dimension (IN) by Valve Size (IN) Variable 1 1-1/2 2 A 250THD 4-7/8 5-3/4 6-1/2 300THD 5 6-1/8 6-1/2 B 250THD 3-1/2 3-3/ THD 2-3/4 3-3/8 3-3/4 C DL49 Direct* 15-1/4 15-7/8 16-1/8 DL84 Direct* 19-1/4 19-7/8 20-1/8 H DL49 1-3/4 2-3/8 2-3/4 (W/760) DL84 3-5/8 4-1/4 4-1/2 Item Weight (LB) by Valve Size (IN) Variable 1 1-1/ THD / THD /2 Allow 4-7/8 inch clearance above actuator for removal. Actual shipping weights may vary. Actuator Weight (LB) DL /2 DL84 84XR 48-1/2 Positioner Weight (LB) Consult factory for drawings, weights, and dimensions of configurations not shown. Face to face dimensions conform to historical Warren Controls standard and are NOT ANSI/ISA compatible. Dimension (IN) D Radius (W/760) DL49 11 DL84 or 84XR 13-7/8 DL49 7-7/8 DL84 or 84XR 8-1/8 RADIUS is from centerline of actuator to outside edge of positioner. Positioner Removal Clearance Allow 3-1/4 Inch beyond 760 for cover removal/service. 2-WAY or 3-Way w/dl49 & 760 Positioner 2-WAY or 3-Way w/dl84 or 84XR & 760 Positioner 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Actuators, Positioners, & Accessories Actuators Positioners Actuator Spring Range (PSI) Size Action Low Full High Xtra-High DL49 Direct N/A DL49 Reverse N/A DL84 Direct N/A DL84 Reverse N/A DL84XR Direct N/A N/A N/A See Note DL84XR Reverse N/A N/A N/A See Note Note: The spring range of XR (extended Range) actuators varies with travel. These actuators require positioners or I/P s for modulating control Effective Area: DL49 (49 Sq In), DL84 & 84XR (84 Sq In) Springs: Multiple Max Air Supply: 30PSIG Air Connections: 1/4 NPT Diaphragm: Buna-N Fabric Reinforced Diaphragm Chambers: Steel Yoke: Ductile Iron Stem: 300 Series Stainless Steel Finish: DL49 Epoxy-Coated DL84, 84XR Acrylic Enamel Ambient Temperature: DL49-20 to 160 F DL84, 84XR -40 to 180 F Mounting: Vertical Above or Below Valve Handwheel: Available on DL84 & 84XR Not available on DL49 Split Ranging with Positioners Positioners are sometimes used to Split-Range two control valves in a parallel configuration within a piping scheme. This technique is used to obtain higher rangeability than could otherwise be achieved with a single control valve. Typically one smaller valve supplying 15% to 35% of total flow is mated with a larger valve supplying 65% to 85% of total flow. The best-matched pair will each be providing similar rangeability for each respective flow contribution to the manifold. Calculated as maximum flow /minimum controllable flow, the smaller valve should not be attempting to control flow below 5% of stroke. Estimate Cv from Cv tables vs. stroke to calculate this. The chosen positioners would then have a Low Range signal for the smaller valve and a High Range Signal for the larger valve. With this, a single control signal can be sequentially applied to each valve. At mid-signal range, the little valve is completely open while the larger valve is just starting to open. Controllability for wide process set point ranges is dramatically improved. BLX Models: BLX Pneumatic Models: BFP_: Full Range Signal (3-15 PSIG) BLP_: Low Range Signal (3-9 PSIG) BHP_: High Range Signal (9-15 PSIG) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: Pneumatic 145 PSIG Max Not to exceed actuator rating Air Consumption: 0.19 SCFM at 30 PSIG BLX Electro-Pneumatic Models: BFE_: Full Range Signal (4-20 ma) BLE_: Low Range Signal (4-12 ma) BHE_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: 21.8 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG BLX Electro-Pneumatic Intrinsically Safe Models: BFI_: Full Range Signal (4-20 ma) BLI_: Low Range Signal (4-12 ma) BHI_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Approvals & Ratings: FM Intrinsically Safe: Class I II III, Div 1, Groups A,B,C,D,E,F,G. CSA Intrinsically Safe: Class I, Div 1, Groups A, B, C, D. Class II, Div 1, Groups E, F, G. Class III. Class I, Div 2, Groups A, B, C, D. Class II, Div 2, Groups E, F, G. Supply Pressure: 30 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG 9 For additional applications, and/or products call: or visit: PS 2800 C 0305

74 Actuators, Positioners, & Accessories Positioners (Continued) BLX Electro-Pneumatic Explosion Proof Models: BFX_: Full Range Signal (4-20 ma) BLX_: Low Range Signal (4-12 ma) BHX_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Approvals & Ratings: FM Intrinsically Safe: Class I II III, Div 1, Groups A,B,C,D,E,F,G. Non-Incendive: Class I, Div 2, Groups A,B,C. Explosion Proof: Class I, Div 1, Groups B,C,D. Class I II III, Div 1, Groups E,F,G. CSA Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III. Class I, Div 2, Groups A,B,C,D. Class II, Div 2, Groups E,F,G. Explosion Proof: Class I, Div 1, Groups B,C,D. Class II, Div 1, Groups E,F,G. Supply Pressure: 30 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG BLX Electro-Pneumatic Fail Freeze Models: BFF_: Full Range Signal (4-20 ma) BLF_: Low Range Signal (4-12 ma) BHF_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: 20 to 100 PSIG Max Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG 760E Electro-Pneumatic (Continued) CSA Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III, Div 1. Suitable for: Class I, Div 2, Groups A,B,C,D. Class II, Div 2, Groups E,F,G. Class III, Div 2. All Models: Construction: Aluminum Housing with Epoxy/Polyester Powder Coat Ingress & Corrosion Protection: NEMA 4, 4X, IP65 Action: Direct or Reverse Supply Pressure: 150 PSIG Max Not to exceed actuator rating Media: Clean Dry Oil Free Air Filtered to 3 micron Flow Capacity: 9.0 SCFM Air Consumption: 0.5 SCFM Typical Air Connections: 1/4 NPT Electrical Connection: 3/4 NPT Gauges: Input 0-30 PSIG, Output 0-60 PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: 760P -40 to 180 F, 760E 40 to 167 F Mounting: Yoke Mounted Westlock ICoT Models: All Models: Construction: Aluminum Housing with Polyester Powder Coat Action: Direct or Reverse Media: Clean Dry Oil Free Air Filtered to 5 micron Air Connections: 1/4 NPT Flow Capacity: 9.8 SCFM at 30 PSIG Electrical Connection: 1/2 NPT Gauges: Input 0-30 PSIG, Output 0-60 PSIG, Supply 0-60 PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: -40 to 185 F (Except Fail Freeze 4 to 158 F) Mounting: Yoke Mounted Limit Switches and Feedback Options are NEMA 4X, IP66 only, and are not suitable for hazardous locations. Moore 760 Models: Electro-Pneumatic Models: 510_: Full Range Signal (4-20 ma) Options 2SPDT Limit Switches Intelligent with Keypad Models: 520_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad Options 2SPDT Limit Switches, 4-20 ma Feedback Intelligent with HART Models: 530_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad & HART Options 2SPDT Limit Switches, 4-20 ma Feedback Intelligent with Foundation Fieldbus Models: 540_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad & Foundation Fieldbus Options 2SPDT Limit Switches, 4-20 ma Feedback 760P Pneumatic Models: 76P_: Full Range Signal (3-15 PSIG) Options Limit Switches, 4-20 ma Feedback (Reduced feedback span for valves with less than 1 inch travel Call factory for details) 760E Electro-Pneumatic Models: 76E_: Full Range Signal (4-20 ma) Options Limit Switches, 4-20 ma Feedback (Reduced feedback span for valves with less than 1 inch travel Call factory for details) Approvals & Ratings: FM Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III, Div 1. Non-Incendive: Class I, Div 2, Groups A,B,C,D. Suitable for: Class II, Div 2, Groups F,G. Class III, Div 2. All Models: Construction: Engineered Resin Housing Ingress & Corrosion Protection: NEMA 4, 4X Approvals & Ratings: Non-Incendive Groups A-G, Div 2 Action: Direct or Reverse Supply Pressure: 15 to 45 PSIG Not to exceed actuator rating Media: Clean Dry Oil Free Air Filtered to 40 micron Flow Capacity: 8.0 SCFM at 25 PSIG Air Consumption: SCFM at 20 PSIG Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT Gauges: Supply 0-60 PSIG, Output PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: -40 to 180 F Mounting: Yoke Mounted 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Actuators, Positioners, & Accessories Position Indication Switches Proximity Mark 1 Models: 2 SPDT Switches 4 SPDT Switches 6 SPDT Switches 2 SPDT Switches w/ 2K Potentiometer 2 SPDT Switches w/ 4-20 ma Feedback Construction: Aluminum Housing, Hard Anodized Locations: NEMA 1, 2, 3, 3R, 3S Ambient Temperature: -40 to 180 F Electrical Connection: 3/4 NPT, Terminal Strip Mounting: Yoke Mounted I/P s Type 500X Locations: NEMA 3 Construction: Zinc Alloy Base with Aluminum Bonnet, Epoxy Painted Ranges: 3-9, 9-15, 3-15, 1-17, or 6-30 PSI Supply Pressure: Minimum 3 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 4.5 SCFM at 25 PSIG Air Consumption: 0.05 SCFM Midrange Typical Ambient Temperature: -20 to 140 F I/P s (Continued) All Models: Input: 4-20 ma Field Reversible Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT, Pigtail Leads Media: Clean Dry Oil Free Air Filtered to 40 micron Mounting: Yoke Mounted Air Filter Regulators Models: Type 300, Type 350SS Output Ranges: Type 300, 0-30, 0-60 PSIG Type 350SS, PSIG Supply Pressure: Type 300, 250 PSIG Maximum Type 350SS, 290 PSIG Maximum Construction: Type 300, Die-Cast Aluminum with Irridite and Baked Epoxy Paint Type 350SS, 316 Stainless Steel Gauge: Type 300, Output, Housing Steel Painted Type 350SS,Output, Housing Stainless Steel Air Connections: 1/4 NPT Filter: Type 300, 40 micron. Type 350SS, 25 micron Mounting: Chamber Mounted Solenoids Type 550X Locations: NEMA 4X (IP65) Construction: Chromate-treated Aluminum with Epoxy Paint Ranges: 0-30 PSI Supply Pressure: Minimum 5 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 12 SCFM at 100 PSIG Air Consumption: 6.0 SCFH Midrange Typical Ambient Temperature: -20 to 150 F Type 950X Models: 8320G184, EF8320G184, 8320G202, EF8320G202 Construction: (EF)8320G184, 3-Way Brass (EF)8320G202, 3-Way Stainless Steel Locations: 83206G184 & 8320G202, Watertight, Types 1, 2, 3, 3S, 4 & 4X EF8320G184 & EF8320G202, Explosion proof and Watertight, Types 3, 3S, 4, 4X 6, 6P, 7 & 9 Supply: 120VAC Ambient Temperature: +32 to 125 F Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT, Pigtail Leads Approvals: CSA, UL, CE Mounting: Chamber Mounted Air Tubing Standard: Copper Optional: Stainless Steel Locations: NEMA 4X (IP65), Explosion proof Construction: Chromate-treated Aluminum with Epoxy Paint Ranges: 3-15 PSI Supply Pressure: Minimum 5 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 4.5 SCFM at 25 PSIG Air Consumption: 3.0 SCFH Midrange Typical. Ambient Temperature: -40 to 160 F 11 For additional applications, and/or products call: or visit: PS 2800 C 0305

75 Factory Default Settings Positioners Input Signal Failure Modes Actuator Electro- Increasing Loss of Signal 1 Loss of Supply Valve Type Action Pneumatic Pneumatic Signal Valve Fails Valve Fails 2820 Direct 3-15 PSI 4-20 ma Closes Valve Open Open Reverse 3-15 PSI 4-20 ma Opens Valve Closed Closed 2830 & 32 Direct 3-15 PSI 4-20 ma Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open 1 Valves with Fail Freeze Positioners Fail in Last Position on Loss of Signal. Positioner Feedback Actuator Feedback Signal Valve Type Action Signal 2 Increases as 2820 Direct 4-20 ma Valve Closes Reverse 4-20 ma Valve Opens 2830 & 32 Direct 4-20 ma Lower Port Closes/ Upper Port Opens 2 Reduced feedback span for valves with 760 and less than 1 inch travel. Positioner Limit Switches Settings Valve Type Position Switch 1 Switch Valve Closed Closed Open Valve Open Open Closed 2830 & 32 Upper Port Closed Closed Open Lower Port Closed Open Closed I/P s Failure Modes Actuator Increasing Loss of Signal Loss of Air Supply Valve Type Action Input Signal Signal Valve Fails Valve Fails 2820 Direct As Required For Shut-off Closes Valve Open Open Reverse As Required For Shut-off Opens Valve Closed Closed 2830 & 32 Direct As Required For Shut-off Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open SOLENOIDS (without Positioners or I/P s) Failure Modes Actuator Solenoid Loss of Signal Loss of Air Supply Solenoid De-energized Valve Type Action Energized Valve Fails Valve Fails Valve Fails 2820 Direct Closes Valve Open Open Open Reverse Opens Valve Closed Closed Closed 2830 & 32 Direct Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open Lower Port Open If the Solenoid is used with a Positioner or an I/P, refer to the Positioner or I/P listings for factory default settings and failure modes with the solenoid not failed. Proximity MARK 1 Position Limit Switches Indication Switches Feedback Settings Valve Type Position Switch 1, 3, 5 Switch 2, 4, 6 Actuator Feedback Signal Feedback Signal Valve Type Action Potentiometer 3 ma Increases as 2820 Direct ohm 4-20 ma Valve Closes Reverse ohm 4-20 ma Valve Opens 2830 & 32 Direct ohm 4-20 ma Lower Port Closes/ Upper Port Opens 3 Span varies from approx 155 to 350 ohm depending on actuator and travel Valve Closed Closed Open Valve Open Open Closed 2830 & 32 Upper Port Closed Closed Open Lower Port Closed Open Closed Air Filter Regulators Actuator Output Pressure DL49, 84 & 84XR 30 PSIG 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Configurations 1. SELECTIONS Please make a selection from each table of OPTIONS below to make a complete model number string. 28N 2. OPTIONS Valve Type Size Body Material VALVE BODY Model Trim Style Trim Material Trim Cv Packing Type End Connection 20 2-Way Single Seat 30 3-Way Mixing 32 3-Way Diverting 050 1/2 inch 075 3/4 inch inch /4 inch /2 inch inch B Bronze F CF8M S Screwed NOTE : Additional end connections are available check with the factory. E Equal % L Linear Types 30/32, Linear Only S 316SS B Bronze 6 Alloy 6 H 17-4 PH T Teflon P PEEK F Full Port 1 1st Port Reduction 2 2nd Port Reduction 3 3rd Port Reduction 4 4th Port Reduction NOTE : Port reductions only available on Type 20/30. Check factory for availability. T Teflon G Graphite Stainless Steel, Type 20 Bodies come standard w/peek bearings. Used for Temp. up to 500 F. VALVE TYPE/TRIM MATERIAL COMBINATIONS: VALVE TYPE/ACTUATOR COMPATIBILITY: SIZE TRIM MATERIAL S B 6 H T P 316 SS Bronze Alloy PH Teflon PEEK 050 1/2 inch 20, 30 N/A /4 inch 20, 30 N/A inch 20, 30, 32SS 32 BRZ /4 inch 20, 30 N/A /2 inch 20, 30, 32SS 32 BRZ inch 20, 30, 32SS 32 BRZ VALVE STYLE VALVE SIZES ACTUATORS Type 20 1/2-2 DL49 Type DL84 Type /4-2 DL84XR Type 30 1/2-2 DL49 Type /4-2 DL84 Type 30 2 DL84XR Type 32 1/2-2 DL49 & DL84 See Shut-Off ΔP Ratings for details. 13 For additional applications, and/or products call: or visit: PS 2800 C 0305

76 Actuator Series ACTUATOR ACCESSORIES Action Spring Range Handwheel Positioners, I/P s & Limit Switches Air Filter Regulators ASCO Solenoids Special Options 00 None DIAPHRAGMS: 49 DL49 (49 Sq.In.) 84 DL84 (84 Sq.In.) 8X DL84XR (84 Ext. Rng.) NOTE : 8X Only in Xtra-High Spring Range FAILURE MODES: 0 None R Reverse Stem Fail Down D Direct Stem Fail Up 0 None L Low 4-10 PSI 49R ; 3-9 PSI 49D, 84R/D F Full 5-14 PSI 49R ; 4-13 PSI 49D; 3-15 PSI 84R/D H High 9-15 PSI PSI 49R 8-12 PSI 49D X Xtra-High DL84XR MODE VALVE TYPE ACTUATOR ACTION Closed 20 Reverse Open 20 Direct Upper Closed* 30/32 Direct Upper Open 30/32 Reverse *Standard 0 None R Reverse D Direct NOTE : DL84 or DL84XR only - Must match action None POSITIONERS: BxP_ BLX Pneumatic BxE_ BLX ElectroPneumatic BxI_ BLX ElectroPneu. Intrn. Safe BxX_ BLX ElectroPneu. Exp. Proof BxF_ BLX ElectroPneu. Fail Freeze 76P_ Moore 760 Pneumatic 76E_ Moore 760 Electro-Pneumatic 510_ Westlock ICoT Electro-Pneumatic 520_ Westlock ICoT Intelligent-Keypad 530_ Westlock ICoT Intelligent-Hart 540_ Westlock ICoT Found.Fieldbus PROXIMITY SWITCHES: PX11 Mark 1 Series - 2 ea. SPDT PX12 Mark 1 Series - 2 ea. SPDT w/2k Pot. PX13 Mark 1 Series - 2 ea. SPDT w/4-20 Feedback PX14 Mark 1 Series - 4 ea. SPDT PX15 Mark 1 Series - 6 ea. SPDT I/P s Use with Diaphragm Only MAP1 Type 500X I/P, 3-9 PSI MAP2 Type 500X I/P, 9-15 PSI MAP3 Type 500X I/P, 3-15 PSI MAP4 Type 500X I/P, 1-17 PSI MAP5 Type 500X I/P, 6-30 PSI MAP6 Type 550X I/P, 0-30 PSI MAP9 Type 950X I/P, 3-15 EXP x digit spec. F Full Range Signal, 3-15 PSI or 4-20mA L Low of Split Range, 3-9 PSI or 4-12mA HHigh of Split Range, 9-15 PSI or 12-20mA 4th digit spec. 0 No Additions L w/mech. Lmt Swtch s F w/4-20 Feedback B w/swtch s & Feedbck 0 None A Type 300, 0-30 PSI B Type 300, 0-60 PSI D Type 350SS, PSI 0 None A 8320G184 3-Way Brass B 8320G202 3-Way SS L EF8320G184 3-Way EXP Br. MEF8320G202 3-Way EXP SS 120 VAC Coils 0 None S Special Opts or Set-up T SS Tubing G SS Tagging B SS Tubing and Tagging Note: Standard pneumatic tubing is copper. SS tubing T is optional. SS tagging G (Two lines, 24 characters/line) is optional. SS tubing and tagging together B is optional. ACTUATOR/BODY COMPATIBILITY: DIAPHRAGMS BODY Sq.In. (DL49) For 28N Bodies Sq.In. (DL84) For 28N Bodies 8X (DL84XR) For 28N Bodies Warren Controls does not assume responsibility for the selection, use, or maintenance of any product. Responsibility for proper selection, use, and maintenance of any Warren Controls product remains solely with the purchaser and end-user Emrick Blvd., Bethlehem, PA Tel: or Fax: ACTUATED INDUSTIRAL VALVES 1800 SERIES Heavy Globe Control Valves 2800 SERIES Precision Globe Control Valves 2900 SERIES High Capacity General Purpose Globe Control Valves 3800 SERIES E-Ball Rotary Control Valves styles: 2-way balanced 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way balanced 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way rotary - flow to open - flow to close sizes 2-1/2 to 12 in. class 300 ends 150,300 RF flg body Cast Iron, WCB,CF8M trim 316 SST, Alloy 6 Cv up to 1649 temp. -20 to 800 F body limitto 740 psi shutoff class III, IV rangeability 50:1 sizes 1/2 to 2 in. class 250 & 300 ends Buttweld, NPT body Bronze, CF8M trim Bronze, 316SST 17-4pH, Alloy 6, TFE, PEEK Cv up to 40 temp. -20 to 500 F body limitto 720 psi shutoff class III, IV, VI rangeability 50:1 sizes 2-1/2 to 10 in. class 125 & 250 ends Flange body Cast Iron trim Bronze, 300SS, 17-4pH, Alloy 6 Cv up to 960 temp. -20 to 400 F body limitto 400 psi shutoff class II, III, IV rangeability 50:1 sizes 1 to 8 in. class 300 ends 150,300 RF flg body WCB, CF8M trim 316 SST, Alloy 6, Ceramic, TFE, PEEK Cv up to 1420 temp. -20 to 800 F body limitto 740 psi shutoff class IV, VI rangeability 100:1 Heavy Duty Severe Service High Pressure Differentials Corrosive Materials, Liquids, Gases & Steam Modulating or On/Off Control Economical Precision Control Suited for Gases, Steam, or Liquids that are Not Viscous or Solids Bearing High Capacity General Purpose Moderate Pressure Drops Compatible Liquids and Gas, Steam & Water Modulating or On/Off Control Eccentric, Segmented Ball Well Suited for Erosive Service Various Trim Options Include Ceramic for Slurries or Gritty Materials & Teflon for Class VI Shutoff 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: SERIES Compact Globe Control Valves styles: 2-way cageretained seat sizes 1 to 4 in. class 300 ends 150,300 RF flg body WCB, CF8M trim 316 SST, Alloy 6, TFE, PEEK Cv up to 170 temp. -20 to 800 F body limitto 740 psi shutoff class IV, VI rangeability 50:1 Highly Efficient, Compact Design High Pressure Drops Typically Suited for High Force Piston Actuators for Steam, Chemicals & Dirty Fluids Minimizes Cavitation or Flashing Effects PS.2800.C.0305

77 A IR P REPARATION M ODULAR T YPE F ILTER R EGULATOR S ERIES AW Port Size M5 3 /4 Differential or float type autodrain Quick release bowl. High flow 5μm filter element Bowl guard standard (Models 3000 & 4000) T ECHNICAL SPECIFICATIONS Model AW1000 AW2000 AW3000 AW4000 Port size M5x /8 /4 1 3 /4 / /8 /2 /4 D IMENSIONS AW Flow rate Nl/min Max. supply pressure kpa 1500 Max. operating pressure kpa 1000 Pressure regulating range kpa 50~700 50~850 Port size for pressure gauge Ambient and media temperatur e Filtration 1 /16 1 /8 1 /8 1 / 4 5 ~ 60 C Standard: 5μm Bowl capacity cm Bowl material Construction/regulator Accessory (standard) Bowl guard Polycarbonate Relieving type - - D IMENSIONS H O W T O O R D E R F ILTER R EGULATOR AW B ODY S IZE 1000 M /8 1 / /4 3 / /8 1 /2 3 /4 BG A UTODRAIN Nil Without D With P ORT S IZE M5 M kpa 2 Metal bowl C AL2000 only 01 1 / / / / /4 ACCESSORIES F ILTER R EGULATOR S Y M B O L S Filter Element 5μ AW AW AW AW4000 With Auto Drain Differential Float Type Port Size A B C D E F G H J K L M ØN P pressure type Model N.O B B M5x AW /8 1 / AW /4 3 / AW /4 3 /8 1 / AW / Bracket B120 AW1000 B220 AW2000 B320 AW3000 B420 AW4000 Auto Drain AD61 AW1000 AD62-C AW2000 AD43 AW3000 AD44 AW4000

78 PRODUCT SPECIFICATION March 2005 PNEUMATIC ACTUATED INDUSTRIAL VALVES SERIES: SIZES 2-1/2 to 10 INCHES 2900 High Capacity, General Purpose, Globe Control Valves Two-Way and Three-Way, Reciprocating, Iron Body Valves for Process and Utility Applications 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Table of Contents Body Style Versus Application Body Pressure-Temperature Rating Flowing Differential Pressure Limits Flow Coefficients (Cv) Versus Travel Sizing Reference and Load Sizing Calculations Shut-Off ΔP and Cv Ratings Dimensions and Weights Actuators, Positioners, and Accessories Factory Default Settings Configurations Two-Way Cylinder Balanced Valve Peek Bearing for low friction provides stem guiding and protects packing box from external debris. Robust Spring-Loaded PTFE V-Ring Packing has low friction and is self adjusting for zero maintenance. Peek Bearing in Lower Bonnet Assembly provides stem guiding and protects packing box from entrained solids for longer packing life. Thick Balancing Chamber in bronze, 300 SS, or 17-4pH. EPDM O-Ring or Fluoraz O-Ring (for higher temperatures) maintains pressure balance seal. Plug and Seat in choice of Bronze, 300 SS, 17-4pH, or Alloy 6 provide Class IV shut off. Bottom Post Guide for additional stability, allowing higher pressure drop.

79 SERIES: 2900 High Capacity General Purpose Globe Control Valves 2920 Two-Way Single Seat Unbalanced Valve 2922 Two-Way Double Seat Balanced Valve 2930 Three-Way Mixing Valve 2932 Three-Way Diverting/Mixing Valve Guided Low-Friction TFE V-Ring Packing Spring-Loaded Description Warren Controls Series 2900 High Capacity General Purpose Globe Control Valves feature rugged iron bodies with a variety of trim materials. The equal percentage plugs in the 2-way valves and linear plugs in the 3-way valves provide excellent modulating control of a wide variety of fluids. The Series 2900 is ideally suited where value and long life are important objectives for applications including but not limited to: Food & Beverage, Packaged Water Heaters, Pharmaceutical, General Service, and Waste Water having moderate pressure drops and temperatures from -20 to 400 F Emrick Blvd., Bethlehem, PA Tel: or Fax: Body Style Versus Application 2-Way Valves (Control of Liquids, Gases, and Steam) 3-Way Valves (Control of Liquids) 2920 Two-Way Single Seat Unbalanced Valve The most commonly applied solution for sizes 3" and under with ANSI Class IV shut-off. Sizes: 2-1/2, 3, 4, 5, 6, 8, 10 inch Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange Trim: EQ%, Bronze (2-1/2 thru 6), 300 Series Stainless Steel (2-1/2 thru 10), or 17-4 PH Hardened Stainless Steel (2-1/2 thru 6) Packing: Guided Low-Friction TFE V-Ring, Spring Loaded Temperature: +32 to 350 F (125 FLG) +32 to 400 F (250 FLG) Rangeability: 50:1 Stem Down Stem Up 2930 Three-Way Mixing Valve This valve has two inlets and one outlet, and is the simplest solution for mixing or bypass applications with ANSI Class IV shut-off. In normal applications the inlet pressures are near equal and control is possible from 5% to 95% of travel with inlet pressures up to 100 PSI. Sizes: 2-1/2, 3, 4, 5, 6, 8 inch Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange Trim: Linear, Bronze (2-1/2 thru 6) or 300 Series Stainless Steel (2-1/2 thru 8) Packing: Guided Low-Friction TFE V-Ring, Spring Loaded Temperature: +32 to 350 F (125 FLG) +32 to 400 F (250 FLG) Rangeability: 50:1 Flow Flow Stem Down Stem Up 2922 Two-Way Double Seat Balanced Valve A balanced valve that is an effective solution for sizes over 3" and for higher pressures. Its double seat design allows for dirtier fluids and requires less force to operate than unbalanced valves so smaller actuators can be used. It is limited to ANSI Class III shut-off. Sizes: 2-1/2, 3, 4, 5, 6, 8, 10 inch Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange Trim: EQ%, Bronze or 300 Series Stainless Steel Packing: Guided Low-Friction TFE V-Ring, Spring Loaded Temperature: +32 to 350 F (125 FLG) +32 to 400 F (250 FLG) Rangeability: 50:1 Stem Down The valve closes Flow Flow The valve opens 2923 Two-Way Cylinder Balanced Valve A balanced valve that is an effective solution for sizes over 3" and for higher pressures. It requires less force to operate than unbalanced valves so smaller actuators can be used. Its single seat o-ring seal design facilitates ANSI Class IV shut-off. It is limited to cleaner fluids. Sizes: 2-1/2, 3, 4, 5, 6 inch Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange Trim: EQ%, Bronze, 300 Series Stainless Steel, 17-4 PH Hardened Stainless Steel, or Alloy 6. Packing: Guided Low-Friction TFE V-Ring, Spring Loaded O-Ring: EPDM (BRZ) Fluoraz 797 (300 SSTrim, 17-4 ph or Alloy 6 Trim) Temperature: +32 to 300 F (BRZ) +32 to 350 F (125 FLG w/ 300 SSTrim, 17-4 PH or Alloy 6 Trim) +32 to 400 F (250 FLG w/ 300 SSTrim, 17-4 PH or Alloy 6 Trim) Rangeability: 50:1 Stem Down The valve closes Flow Flow The valve closes Stem Up Stem Up The valve opens The valve opens Upper Port Common Port Flow Flow The upper port opens and the lower port closes 2932 Three-Way Diverting/Mixing Valve Designed as a diverting valve with one inlet and two outlets with ANSI Class II shutoff. However, flow can be reversed for mixing if this port configuration is desirable. The difference between the upper port and lower port pressure must not exceed 50PSID. Sizes: 2-1/2, 3, 4, 5, 6, 8 inch Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange Trim: Linear, Bronze or 300 Series Stainless Steel Packing: Guided Low-Friction TFE V-Ring, Spring Loaded O-Ring: EPR Temperature: +32 to 300 F (2-1/2 through 6) +32 to 150 F (6 & 8) Rangeability: 50:1 Stem Down Flow Lower Port Upper Port Lower Port Common Port The upper port opens and the lower port closes Body Pressure-Temperature Ratings: Temperature (F) 125 FLG 250 FLG +32 To Pressure ratings are PSIG For applications below 32 consult factory Upper Port Common Port Flow Lower Port The upper port closes and the lower port opens Stem Up Upper Port Lower Port Flow Common Port The upper port closes and the lower port opens Flowing Differential Trim Materials Pressure Limit Bronze 50 PSID 300 Series Stainless Steel 100 PSID 17-4 ph Hardened Steel 200 PSID Alloy PSID 3 For additional applications, and/or products call: or visit: PS 2900 C

80 4 Flow Coefficients (Cv) Versus Travel 2-WAY VALVE TYPICAL FLOW CURVE 2920 Flow Coefficients (Cv) Two-Way Single Seat Unbalanced Valve Valve % CV Valve Trim %Travel Size (IN) Style 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 2-1/2 EQ% EQ% EQ% EQ% EQ% EQ% EQ% Flow Coefficients (Cv) Two-Way Double Seat Balanced Valve Valve % TRAVEL Valve Trim %Travel Size (IN) Style 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 2-1/2 EQ% EQ% EQ% EQ% EQ% EQ% EQ% Flow Coefficients (Cv) Two-Way Cylinder Balanced Valve Valve 2930 TYPICAL FLOW CURVE 2-Way Valves (Control of Liquids, Gases, and Steam) Sizing Reference 80 Steam Table Steam Temp. Temp. Sensible Latent Total Pressure F C Heat Heat Heat PSIG BTU/Lb. BTU/Lb. BTU/Lb Rectangular Tank Capacity in Gallons Height x Width x Length (inches) Gallons = 230 or Gallons = H x W x L (Ft.) x 7.5 Circular Tank Storage Capacity in Gallons Storage = 6D 2 x L (Gallons) Where: D = Tank Diameter in Feet L = Length in Feet Load Sizing Calculations Glossary of Terms t = Time in Hours Cp = Specific Heat of Liquid S = Specific Gravity of Fluid W = Weight in Lbs. ΔT = Temperature Rise or Fall in F h fg = Latent Heat of Steam Conversion Factors 1 Lb. Steam / Hr. = 1000 BTU / Hr. 1 Cubic Meter = 264 U.S. Gallons 1 Cubic Foot Water = 62.4 Lbs. 1 PSI = 2.04 Inches of Mercury 1 PSI = 2.3 Feet of Water 1 PSI = 27.7 Inches of Water 1 U.S. Gallon Water = 231 Cubic Inches 1 U.S. Gallon Water = 8.33 Lbs. Heating Water with Steam Quick Method GPM Lbs./Hr. = x ΔT 2 Accurate Method Lbs./Hr. = GPM x 500 x ΔT h fg Heating or Cooling Water with Water F water 2 temp. rise or drop GPM 1 = GPM 2 x F water 1 temp. rise or drop Heating or Cooling Water BTU / Hr. GPM = ( F water temp. rise or drop ) x 500 Heating Oil with Steam GPM Lbs./Hr. = x ( F oil temp. rise) 4 Heating Air with Water CFM x ( F air temp. rise) GPM = 2.16 x 1000 x ( F water temp. drop) Heating Liquids with Steam GPM x 60 x Cp x W Lbs./Hr. = x ΔT h fg Heating Liquids in Steam Jacketed Kettles GPM x Cp x S x 8.33 Lbs./Hr. = x ΔT h fg x t General Liquid Heating W x Cp Lbs./Hr. = x ΔT h fg x t Heating Air with Steam CFM Lbs./Hr. = x ΔT For additional applications, and/or products call: or visit: PS 2900 C UPPER 60 LOWER 50 % CV Valve Trim %Travel Size (IN) Style 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 2-1/2 EQ% EQ% EQ% EQ% EQ% COMBINED Flow Coefficients (Cv) Three-Way Mixing Valve Valve % TRAVEL 2932 TYPICAL FLOW CURVE Valve Trim Travel Size (IN) Style 100% 2-1/2 LINEAR 69 3 LINEAR 86 4 LINEAR LINEAR LINEAR LINEAR Flow Coefficients (Cv) Three-Way Diverting/Mixing Valve Valve 80 UPPER 70 LOWER 60 % CV COMBINED 3-Way Valves (Control of Liquids) Emrick Blvd., Bethlehem, PA Tel: or Fax: Valve Trim Travel 100% Size (IN) Style Upper Lower 2-1/2 LINEAR LINEAR LINEAR LINEAR LINEAR LINEAR

81 Shut-Off ΔP and Cv Ratings 2922 Valve Actuator NOTES: 1) 2922 Seat closure ANSI Class III. Maximum Shut-off ΔP in PSI Fail Closed Fail Open Valve Plug Reverse Acting Direct Acting Size Cv Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) Rating (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 2 1/2 70 3/4" DL49 Low N/A N/A Full N/A N/A High N/A DL84 Low N/A Full N/A N/A High N/A /4" DL49 Low N/A N/A Full N/A N/A High N/A DL84 Low N/A N/A Full N/A N/A 169 N/A N/A 400 High N/A N/A /4" DL49 Low N/A N/A N/A Full N/A N/A 32 N/A N/A 400 High N/A DL84 Low N/A N/A Full N/A N/A 44 N/A N/A 400 High N/A N/A /4" DL84 Low N/A N/A N/A Full N/A N/A N/A N/A N/A 400 High N/A N/A /4" DL84 Low N/A N/A N/A Full N/A N/A N/A N/A N/A 400 High N/A N/A 400 2) Inlet pressure cannot exceed Body Pressure-Temperature Rating. Valve Actuator Shut-Off ΔP Two-Way Double Seat Balanced 3) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. Shut-Off ΔP Two-Way Single Seat Unbalanced Maximum Shut-off ΔP in PSI Fail Closed Fail Open Valve Plug Reverse Acting Direct Acting Size Cv Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) Rating (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 2 1/2 65 3/4 DL49 Low N/A N/A N/A N/A N/A Full N/A N/A 10 N/A N/A N/A 130 N/A High N/A N/A N/A DL84 Low N/A N/A 12 N/A N/A Full N/A N/A 12 N/A N/A N/A 217 N/A High N/A N/A N/A 217 N/A DL84XR Xtra-High N/A N/A N/A N/A N/A DL115 Low N/A Full N/A N/A High N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A /4 DL49 Low N/A N/A N/A N/A N/A Full N/A N/A 3 N/A N/A N/A 86 N/A High N/A N/A 3 93 N/A DL84 Low N/A N/A 4 N/A N/A Full N/A N/A 4 N/A N/A N/A 146 N/A High N/A N/A N/A 146 N/A DL84XR Xtra-High N/A N/A N/A N/A N/A DL115 Low N/A N/A Full N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A /4 DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 77 N/A High N/A N/A N/A 77 N/A DL115 Low N/A N/A Full N/A N/A 3 3 N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A /2 DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 46 N/A High N/A N/A N/A 46 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A /2 DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 30 N/A High N/A N/A N/A 30 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A /2 DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A Shut-Off ΔP and Cv Ratings 4) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure NOTES: 1) 2920 Seat closure ANSI Class IV. 2) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 3) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 4) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure. Maximum air pressure DL49 30PSIG DL84 & 84XR 30PSIG DL115 & 115XR 40PSIG 5) Do Not Use DL115 OR 115XR Actuators on Valves With Bronze Trim. 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges Emrick Blvd., Bethlehem, PA Tel: or Fax: N/A EXCEEDS DL49 AND DL84 ACTUATORS MAXIMUM AIR PRESSURE Maximum air pressure DL49 30PSIG DL84 30PSIG 5) Do Not Use DL115 Actuators on Valves With Bronze Trim. 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges /2" DL84 Low N/A N/A N/A Full N/A N/A N/A N/A N/A 400 High N/A N/A /2" DL84 Low N/A N/A N/A Full N/A N/A N/A N/A N/A 400 High N/A N/A 400 PS 2900 C 0305 For additional applications, and/or products call: or visit: 7 N/A EXCEEDS DL49 AND DL84 ACTUATORS MAXIMUM AIR PRESSURE

82 Valve Actuator Shut-Off ΔP Two-Way Cylinder Balanced 2923 Maximum Shut-off ΔP in PSI Fail Closed Fail Open Valve Plug Reverse Acting Direct Acting Size Cv Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) Rating (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 2 1/2 65 3/4 DL49 Low N/A N/A N/A N/A N/A Full N/A N/A 42 N/A N/A N/A High N/A N/A N/A N/A N/A DL84 Low N/A N/A 53 N/A N/A Full N/A N/A 53 N/A N/A N/A 400 N/A High N/A N/A N/A 400 N/A /4 DL49 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 400 N/A High N/A N/A N/A 400 N/A DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 400 N/A High N/A N/A N/A 400 N/A /4 DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 400 N/A High N/A N/A N/A 400 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A /2 DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 400 N/A High N/A N/A N/A 400 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A /2 DL84 Low N/A N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 400 N/A High N/A N/A N/A N/A 400 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A N/A N/A Shut-Off ΔP and Cv Ratings NOTES: 1) 2923 Seat closure ANSI Class IV. 2) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 3) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 4) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure. Maximum air pressure DL49 30PSIG DL84 30PSIG DL115 & 115XR 40PSIG 5) Do Not Use DL115 OR 115XR Actuators on Valves With Bronze Trim. 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges Emrick Blvd., Bethlehem, PA Tel: or Fax: Shut-Off ΔP and Cv Ratings NOTES: 1) 2930 Mixing Valves have two inlets and one outlet. Published shut-off values are with respect to worst case conditions with zero downstream pressure on the outlet port and zero upstream pressure on the opposing inlet port. Pneumatic Actuators used with the 2930 are direct acting. The upper port fails closed on loss of air pressure to the actuator. 2) 2930 Seat closure ANSI Class IV. 3) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 4) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 5) N/A indicates that the air signal is not capable of providing any shut-off or it exceeds the actuator s maximum air pressure. Maximum air pressure DL49 30PSIG DL84 & 84XR 30PSIG DL115 & 115XR 40PSIG 6) Do Not Use DL115 OR 115XR Actuators on Valves With Bronze Trim. 7) See Actuators, Positioners, and Accessories section for explanation of spring ranges. Valve Actuator Shut-Off ΔP Three-Way Mixing 2930 Maximum Shut-off ΔP in PSI Upper Port Closed Lower Port Closed Valve Plug Direct Acting Direct Acting Size Cv Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) Rating (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 2 1/2 69 3/4" DL49 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 121 N/A High N/A N/A N/A 131 N/A DL84 Low N/A N/A 12 N/A N/A Full N/A N/A 12 N/A N/A N/A 208 N/A High N/A N/A N/A 208 N/A DL84XR Xtra-High N/A N/A N/A 208 N/A DL115 Low N/A Full N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A /4" DL49 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 79 N/A High N/A N/A N/A 86 N/A DL84 Low N/A N/A 4 N/A N/A Full N/A N/A 4 N/A N/A N/A 140 N/A High N/A N/A N/A 140 N/A DL84XR Xtra-High N/A N/A N/A 140 N/A DL115 Low N/A N/A Full N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A /8" DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 74 N/A High N/A N/A N/A 74 N/A DL115 Low N/A N/A Full N/A N/A 3 3 N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A /8" DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 44 N/A High N/A N/A N/A 44 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A /8" DL84 Low N/A N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A 28 N/A High N/A N/A N/A 28 N/A DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A /2" DL115 Low N/A N/A N/A N/A Full N/A N/A N/A N/A N/A N/A High N/A N/A DL115XR Xtra-High N/A N/A N/A N/A For additional applications, and/or products call: or visit: PS 2900 C

83 Shut-Off ΔP and Cv Ratings Dimensions & Weights NOTES: Valve Actuator Shut-Off ΔP Component 2920 Dimension (IN) by Valve Size (IN) Variable 2-1/ Three-Way Diverting/Mixing 2932 Maximum Shut-off ΔP in PSI Upper Port Closed Lower Port Closed Direct Acting Direct Acting Valve Plug Size Cv Travel Pneumatic Spring Air Signal to Actuator Air Signal to Actuator (IN) Rating (IN) Actuator Range 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 3-15 PSI 1-17 PSI 0-30 PSI 0-40 PSI 2 1/2 68/75 3/4" DL49 HIGH N/A N/A N/A N/A 110 N/A DL84 HIGH N/A N/A N/A 115 N/A 3 85/95 3/4 DL49 HIGH N/A N/A N/A N/A 108 N/A DL84 HIGH N/A N/A N/A 113 N/A 4 160/180 3/4 DL49 HIGH N/A N/A 104 N/A N/A N/A 106 N/A DL84 HIGH N/A N/A N/A 111 N/A DL115 HIGH N/A N/A / /4 DL84 HIGH N/A N/A N/A 108 N/A DL115 HIGH N/A N/A / /8 DL84 HIGH N/A N/A N/A 106 N/A DL115 HIGH N/A N/A / /5 DL115 HIGH N/A N/A ) Published shut-off values are for diverting applications. The values are worst case and based on the pressure difference between the inlet and the outlet that is closed. Consult the factory if the required shut-off exceeds the published value and the pressure at the inlet and both outlets is known. For proper operation in diverting applications, the pressure difference between both outlets must not exceed 50 psi. Consult the factory for shut-off values for 2932 mixing applications. Pneumatic Acuators used with the 2932 are direct acting. The upper port fails closed on loss of air pressure to the actuator. 2) 2932 Seat closure ANSI Class II. 3) Inlet pressure cannot exceed Body Pressure-Temperature Rating. 4) The 3-15 and 1-17 columns of the table apply to valves with control signals coming directly from I/P transducers with matching ranges. The 0-30 and 0-40 columns apply to valves with a positioner or an I/P transducer of suitable range. 5) N/A indicates that the air signal is not capable of providing any shutoff or it exceeds the actuator s maximum air pressure. Maximum air pressure DL49 30PSIG DL84 30PSIG DL115 40PSIG A 125FLG /4 17-3/4 16-1/ FLG 9-5/8 10-3/4 13-5/8 16-5/8 18-5/8 16-1/4 21-3/8 B 4-3/4 5-3/8 6-3/8 7-3/ /8 9-7/8 C DL49 Direct* 17-5/8 18-1/2 N/A N/A N/A N/A N/A DL49 Reverse /8 N/A N/A N/A N/A N/A DL84 Direct* 21-5/8 22-1/2 23-1/2 24-1/8 24-3/4 N/A N/A DL84 or 84XR Reverse /8 22-7/8 23-1/2 24-1/8 N/A N/A DL115 or 115XR Direct* /8 35-7/8 36-1/2 37-1/8 38-3/8 39-1/8 DL115 or 115XR Reverse CF CF CF CF CF CF CF H DL49 4-1/4 5 N/A N/A N/A N/A N/A W/760 DL84 or 84XR 6 6-7/8 7-7/8 8-1/2 9 N/A N/A DL115 or 115XR Direct 11-1/8 11-7/ /8 14-1/4 15-1/2 16 DL115 or 115XR Reverse CF CF CF CF CF CF CF Item Weight (LB) by Valve Size (IN) Variable 2-1/ FLG FLG Component 2922 Dimension (IN) by Valve Size (IN) Variable 2-1/ A 125FLG 7-3/ / /8 16-1/ FLG 8-3/8 9-3/ /8 14-1/2 16-1/4 21-3/8 B 4-1/8 4-3/ /8 7-5/8 8-7/8 9-7/8 C DL49 Direct* 17-1/4 17-1/2 19 N/A N/A N/A N/A DL49 Reverse 16-5/8 16-7/8 18-3/8 N/A N/A N/A N/A DL84 Direct* 21-1/4 21-1/ / /4 DL84 Reverse 20-5/8 20-7/8 22-3/8 23-3/8 24-1/4 25-3/8 26-1/8 H DL49 3-3/ /8 N/A N/A N/A N/A W/760 DL84 5-5/8 5-7/8 7-3/8 8-3/8 9-1/4 10-3/8 10-7/8 Item Weight (LB) by Valve Size (IN) Variable 2-1/ FLG FLG * Includes 1-3/8 inch for air fitting H = Centerline of pipe to bottom of positioner CF = Consult factory N/A = Not Available RADIUS D Consult factory for drawings, weights, and dimensions of configurations not shown. RADIUS D Component 2923 Dimension (IN) by Valve Size (IN) Variable 2-1/ A 125FLG /4 17-3/4 250FLG 9-5/8 10-3/4 13-5/8 16-5/8 18-5/8 B 4-3/4 5-3/8 6-7/8 7-7/8 8-1/2 C DL49 Direct* 18-1/8 19 N/A N/A N/A DL49 Reverse 17-1/2 18-3/8 N/A N/A N/A DL84 Direct* 22-1/ /8 24-5/8 25-1/4 DL84 Reverse 21-1/2 22-3/8 23-1/ /8 DL115 or 115XR Direct* N/A N/A 36-1/ /8 DL115 or 115XR Reverse N/A N/A CF CF CF H DL49 4-3/4 5-1/2 N/A N/A N/A W/760 DL84 6-1/2 7-3/8 8-1/ /8 DL115 or 115XR Direct N/A N/A 13-1/2 14-1/8 14-3/4 DL115 or 115XR Reverse N/A N/A CF CF CF Item Weight (LB) by Valve Size (IN) Variable 2-1/ FLG FLG Face to face dimensions conform to historical Warren Controls standard and are NOT ANSI/ISA compatible. 8 3/4 RADIUS is from centerline of actuator to outside edge of positioner. Positioner Removal Clearance Allow 3-1/4 Inch beyond 760 for cover removal/service. D 8 1/16 RADIUS 6) See Actuators, Positioners, and Accessories section for explanation of spring ranges. 7 1/8 7 1/8 H H H 2-WAY w/dl49 & 760 Positioner 2-WAY w/dl84 or 84XR & 760 Positioner 2-WAY w/dl115 or 115XR & 760 Positioner 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: For additional applications, and/or products call: or visit: PS 2900 C A C B 9 A C B A C B

84 Dimensions & Weights Component 2930 Dimension (IN) by Valve Size (IN) Variable 2-1/ A 125FLG /4 17-3/4 16-1/4 250FLG 9-5/8 10-3/4 13-5/8 16-5/8 18-5/8 16-1/4 B 125FLG 7-1/ /8 9-1/4 9-7/8 11-7/8 250FLG 7-3/8 8-3/8 10-1/4 10-3/ /8 C DL49 Direct* 17-5/8 18-1/2 N/A N/A N/A N/A DL84 or 84XR Direct* 21-5/8 22-1/2 23-1/2 22-3/8 23-1/8 N/A DL115 or 115XR Direct* /8 35-7/8 34-3/4 35-1/2 38-3/8 H DL49 4-1/4 5 N/A N/A N/A N/A W/760 DL84 or 84XR 6 6-7/8 7-7/8 6-3/4 7-1/2 N/A DL115 or 115XR Direct 11-1/8 11-7/ /8 12-5/8 15-1/2 Item Weight (LB) by Valve Size (IN) Variable 2-1/ FLG FLG Component 2932 Dimension (IN) by Valve Size (IN) Variable 2-1/ A 125FLG /8 16-1/4 250FLG 9-5/8 10-3/4 13-5/8 12-7/8 14-1/2 16-1/4 B 125FLG 7-1/ /8 10-1/2 11-1/8 11-7/8 250FLG 7-3/8 8-3/8 10-1/ /2 12-3/8 C DL49 Direct* 17-5/8 18-1/2 19-1/4 N/A N/A N/A DL84 or 84XR Direct* 21-5/8 22-1/2 23-1/4 23-7/8 N/A N/A DL115 or 115XR Direct* N/A N/A 35-5/8 36-1/4 36-7/8 38 H DL49 4-1/ /8 N/A N/A N/A W/760 DL84 or 84XR 6 6-7/8 7-7/8 8-1/4 8-7/8 10 DL115 or 115XR Direct N/A N/A 12-3/4 13-5/ Item Weight (LB) by Valve Size (IN) Variable 2-1/ FLG FLG * Includes 1-3/8 inch for air fitting H = Centerline of pipe to bottom of positioner CF = Consult factory N/A = Not Available Actuator Dimension (IN) D DL49 11 DL84 or 84XR 13-7/8 DL115 or 115XR 16-3/4 RADIUS DL49 7-7/8 W/760 DL84 or 84XR 8-1/8 DL115 or 115XR Direct 10-5/8 DL115 or 115XR Reverse CF Actuator Weight (LB) DL /2 DL84 or 84XR 48-1/2 DL115 Direct 84 DL115XR Direct 92 DL115 Reverse CF DL115XR Reverse CF Positioner Weight (LB) Actuator Removal Clearance Above DL49, 84, or 84XR allow 5-5/8 IN Above DL115 or 115XR allow 6-1/8 IN Consult factory for drawings, weights, and dimensions of configurations not shown. Actual shipping weights may vary. Face to face dimensions conform to historical Warren Controls standard and are NOT ANSI/ISA compatible. D RADIUS is from centerline of actuator to outside edge of positioner. Positioner Removal Clearance Allow 3-1/4 Inch beyond 760 for cover removal/service. D 8 1/16 RADIUS /4 D RADIUS 7 1/8 H 7 1/8 H H 3-WAY w/dl49 & 760 Positioner 3-WAY w/dl84 or 84XR & 760 Positioner 3-WAY w/dl115 or 115XR & 760 Positioner 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Actuators, Positioners, & Accessories Actuators Positioners Actuator Spring Range (PSI) Size Action Low Full High Xtra-High DL49 Direct N/A DL49 Reverse N/A DL84 & DL115 Direct N/A DL84 & DL115 Reverse N/A DL84XR &DL115XR Direct N/A N/A N/A See Note DL84XR & DL115XR Reverse N/A N/A N/A See Note Note: The spring range of XR (extended Range) actuators varies with travel. These actuators require positioners or I/P s for modulating control Effective Area: DL49 (49 Sq In), DL84 & 84XR (84 Sq In) DL115 & 115XR (115 Sq In) Springs: DL49, 84 & 84XR Multiple DL115 & 115XR Single Max Air Supply: DL49, 84 & 84XR 30PSIG DL115 & 115XR 40PSIG Air Connections: 1/4 NPT Diaphragm: Buna-N Fabric Reinforced Diaphragm Chambers: Steel Yoke: DL49, 84 & 84XR Ductile Iron DL115 & 115XR Aluminum Stem: 300 Series Stainless Steel Finish: DL49 Epoxy-Coated DL84, 84XR, 115, & 115XR Acrylic Enamel Ambient Temperature: DL49-20 to 160 F DL84, 84XR, 115 & 115XR -40 to 180 F Mounting: Vertical Above or Below Valve Handwheel: Available on DL84, 84XR, 115 & 115XR Not Available on DL49 Split Ranging with Positioners Positioners are sometimes used to Split-Range two control valves in a parallel configuration within a piping scheme. This technique is used to obtain higher rangeability than could otherwise be achieved with a single control valve. Typically one smaller valve supplying 15% to 35% of total flow is mated with a larger valve supplying 65% to 85% of total flow. The best-matched pair will each be providing similar rangeability for each respective flow contribution to the manifold. Calculated as maximum flow /minimum controllable flow, the smaller valve should not be attempting to control flow below 5% of stroke. Estimate Cv from Cv tables vs. stroke to calculate this. The chosen positioners would then have a Low Range signal for the smaller valve and a High Range Signal for the larger valve. With this, a single control signal can be used and serially applied to each valve. At mid-signal range, the little valve is completely open while the larger valve is just starting to open. Controllability for wide process set point ranges is dramatically improved. BLX Models: BLX Pneumatic Models: BFP_: Full Range Signal (3-15 PSIG) BLP_: Low Range Signal (3-9 PSIG) BHP_: High Range Signal (9-15 PSIG) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: Pneumatic 145 PSIG Max Not to exceed actuator rating Air Consumption: 0.19 SCFM at 30 PSIG, 0.25 SCFM at 40 PSIG BLX Electro-Pneumatic Models: BFE_: Full Range Signal (4-20 ma) BLE_: Low Range Signal (4-12 ma) BHE_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: 21.8 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG, 0.28 SCFM at 40 PSIG BLX Electro-Pneumatic Intrinsically Safe Models: BFI_: Full Range Signal (4-20 ma) BLI_: Low Range Signal (4-12 ma) BHI_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Approvals & Ratings: FM Intrinsically Safe: Class I II III, Div 1, Groups A,B,C,D,E,F,G. CSA Intrinsically Safe: Class I, Div 1, Groups A, B, C, D. Class II, Div 1, Groups E, F, G. Class III. Class I, Div 2, Groups A, B, C, D. Class II, Div 2, Groups E, F, G. Supply Pressure: 30 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG, 0.28 SCFM at 40 PSIG 13 For additional applications, and/or products call: or visit: PS 2900 C A C B 9 A C B A C B

85 Actuators, Positioners, & Accessories Positioners (Continued) BLX Electro-Pneumatic Explosion Proof Models: BFX_: Full Range Signal (4-20 ma) BLX_: Low Range Signal (4-12 ma) BHX_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Approvals & Ratings: FM Intrinsically Safe: Class I II III, Div 1, Groups A,B,C,D,E,F,G. Non-Incendive: Class I, Div 2, Groups A,B,C. Explosion Proof: Class I, Div 1, Groups B,C,D. Class I II III, Div 1, Groups E,F,G. CSA Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III. Class I, Div 2, Groups A,B,C,D. Class II, Div 2, Groups E,F,G. Explosion Proof: Class I, Div 1, Groups B,C,D. Class II, Div 1, Groups E,F,G. Supply Pressure: 30 to 145 PSIG Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG, 0.28 SCFM at 40 PSIG BLX Electro-Pneumatic Fail Freeze Models: BFF_: Full Range Signal (4-20 ma) BLF_: Low Range Signal (4-12 ma) BHF_: High Range Signal (12-20 ma) Options 2SPDT Limit Switches, 4-20 ma Feedback Ingress & Corrosion Protection: NEMA 4X, IP66 Supply Pressure: 20 to 100 PSIG Max Not to exceed actuator rating Air Consumption: 0.21 SCFM at 30 PSIG, 0.28 SCFM at 40 PSIG 760E Electro-Pneumatic (Continued) CSA Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III, Div 1. Suitable for: Class I, Div 2, Groups A,B,C,D. Class II, Div 2, Groups E,F,G. Class III, Div 2. All Models: Construction: Aluminum Housing with Epoxy/Polyester Powder Coat Ingress & Corrosion Protection: NEMA 4, 4X, IP65 Action: Direct or Reverse Supply Pressure: 150 PSIG Max Not to exceed actuator rating Media: Clean Dry Oil Free Air Filtered to 3 micron Flow Capacity: 9.0 SCFM Air Consumption: 0.5 SCFM Typical Air Connections: 1/4 NPT Electrical Connection: 3/4 NPT Gauges: Input 0-30 PSIG, Output 0-60 PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: 760P -40 to 180 F, 760E 40 to 167 F Mounting: Yoke Mounted Westlock ICoT Models: All Models: Construction: Aluminum Housing with Polyester Powder Coat Action: Direct or Reverse Media: Clean Dry Oil Free Air Filtered to 5 micron Air Connections: 1/4 NPT Flow Capacity: 9.8 SCFM at 30 PSIG, 13.1 SCFM at 40 PSIG Electrical Connection: 1/2 NPT Gauges: Input 0-30 PSIG, Output 0-60 PSIG, Supply 0-60 PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: -40 to 185 F (Except Fail Freeze 4 to 158 F) Mounting: Yoke Mounted Limit Switches and Feedback Options are NEMA 4X, IP66 only, and are not suitable for hazardous locations. Moore 760 Models: Electro-Pneumatic Models: 510_: Full Range Signal (4-20 ma) Options 2SPDT Limit Switches Intelligent with Keypad Models: 520_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad Options 2SPDT Limit Switches, 4-20 ma Feedback Intelligent with HART Models: 530_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad & HART Options 2SPDT Limit Switches, 4-20 ma Feedback Intelligent with Foundation Fieldbus Models: 540_: Full Range Signal (4-20 ma) Calibration 3 Button Keypad & Foundation Fieldbus Options 2SPDT Limit Switches, 4-20 ma Feedback 760P Pneumatic Models: 76P_: Full Range Signal (3-15 PSIG) Options Limit Switches, 4-20 ma Feedback (Reduced feedback span for valves with less than 1 inch travel Call factory for details) 760E Electro-Pneumatic Models: 76E_: Full Range Signal (4-20 ma) Options Limit Switches, 4-20 ma Feedback (Reduced feedback span for valves with less than 1 inch travel Call factory for details) Approvals & Ratings: FM Intrinsically Safe: Class I, Div 1, Groups A,B,C,D. Class II, Div 1, Groups E,F,G. Class III, Div 1. Non-Incendive: Class I, Div 2, Groups A,B,C,D. Suitable for: Class II, Div 2, Groups F,G. Class III, Div 2. All Models: Construction: Engineered Resin Housing Ingress & Corrosion Protection: NEMA 4, 4X Approvals & Ratings: Non-Incendive Groups A-G, Div 2 Action: Direct or Reverse Supply Pressure: 15 to 45 PSIG Not to exceed actuator rating Media: Clean Dry Oil Free Air Filtered to 40 micron Flow Capacity: 8.0 SCFM at 25 PSIG Air Consumption: SCFM at 20 PSIG Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT Gauges: Supply 0-60 PSIG, Output PSIG, Housing Black Steel Case with Chrome Ring Ambient Temperature: -40 to 180 F Mounting: Yoke Mounted 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Actuators, Positioners, & Accessories Position Indication Switches Proximity Mark 1 Models: 2 SPDT Switches 4 SPDT Switches 6 SPDT Switches 2 SPDT Switches w/ 2K Potentiometer 2 SPDT Switches w/ 4-20 ma Feedback Construction: Aluminum Housing, Hard Anodized Locations: NEMA 1, 2, 3, 3R, 3S Ambient Temperature: -40 to 180 F Electrical Connection: 3/4 NPT, Terminal Strip Mounting: Yoke Mounted I/P s Type 500X Locations: NEMA 3 Construction: Zinc Alloy Base with Aluminum Bonnet, Epoxy Painted Ranges: 3-9, 9-15, 3-15, 1-17, or 6-30 PSI Supply Pressure: Minimum 3 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 4.5 SCFM at 25 PSIG,12 SCFM at 100 PSIG Air Consumption: 0.05 SCFM Midrange Typical Ambient Temperature: -20 to 140 F I/P s (Continued) All Models: Input: 4-20 ma Field Reversible Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT, Pigtail Leads Media: Clean Dry Oil Free Air Filtered to 40 micron Mounting: Yoke Mounted Air Filter Regulators Models: Type 300, Type 350SS Output Ranges: Type 300, 0-30 or 0-60 PSIG Type 350SS, PSIG Supply Pressure: Type 300, 250 PSIG Maximum Type 350SS, 290 PSIG Maximum Construction: Type 300, Die-Cast Aluminum with Irridite and Baked Epoxy Paint Type 350SS, 316 Stainless Steel Gauge: Type 300, Output, Housing Steel Painted Type 350SS,Output, Housing Stainless Steel Air Connections: 1/4 NPT Filter: Type 300, 40 micron. Type 350SS, 25 micron Mounting: Chamber Mounted Solenoids Type 550X Locations: NEMA 4X (IP65) Construction: Chromate-treated Aluminum with Epoxy Paint Ranges: 0-30, or 0-60 PSI Supply Pressure: Minimum 5 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 12 SCFM at 100 PSIG Air Consumption: 6.0 SCFH Midrange Typical Ambient Temperature: -20 to 150 F Type 950X Models: 8320G184, EF8320G184, 8320G202, EF8320G202 Construction: (EF)8320G184, 3-Way Brass (EF)8320G202, 3-Way Stainless Steel Locations: 83206G184 & 8320G202, Watertight, Types 1, 2, 3, 3S, 4 & 4X EF8320G184 & EF8320G202, Explosion proof and Watertight, Types 3, 3S, 4, 4X 6, 6P, 7 & 9 Supply: 120VAC Ambient Temperature: +32 to 125 F Air Connections: 1/4 NPT Electrical Connection: 1/2 NPT, Pigtail Leads Approvals: CSA, UL, CE Mounting: Chamber Mounted Air Tubing Standard: Copper Optional: Stainless Steel Locations: NEMA 4X (IP65), Explosion proof Construction: Chromate-treated Aluminum with Epoxy Paint Ranges: 3-15 PSI Supply Pressure: Minimum 5 PSIG Above Maximum Output Maximum 100 PSIG Not to Exceed Actuator Rating Flow Capacity: 4.5 SCFM at 25 PSIG Air Consumption: 3.0 SCFH Midrange Typical. Ambient Temperature: -40 to 160 F 15 For additional applications, and/or products call: or visit: PS 2900 C 0305

86 Factory Default Settings Positioners Input Signal Failure Modes Actuator Electro- Increasing Loss of Signal 1 Loss of Supply Valve Type Action Pneumatic Pneumatic Signal Valve Fails Valve Fails 2920, 22 & 23 Direct 3-15 PSI 4-20 ma Closes Valve Open Open Reverse 3-15 PSI 4-20 ma Opens Valve Closed Closed 2930 & 32 Direct 3-15 PSI 4-20 ma Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open 1 Valves with Fail Freeze Positioners Fail in Last Position on Loss of Signal. Positioner Feedback Actuator Feedback Signal Valve Type Action Signal 2 Increases as 2920, 22 & 23 Direct 4-20 ma Valve Closes Reverse 4-20 ma Valve Opens 2930 & 32 Direct 4-20 ma Lower Port Closes/ Upper Port Opens 2 Reduced feedback span for valves with 760 and less than 1 inch travel. Positioner Limit Switches Settings Valve Type Position Switch 1 Switch , 22 & 23 Valve Closed Closed Open Valve Open Open Closed 2930 & 32 Upper Port Closed Closed Open Lower Port Closed Open Closed I/P s Failure Modes Actuator Increasing Loss of Signal Loss of Air Supply Valve Type Action Input Signal Signal Valve Fails Valve Fails 2920, 22 & 23 Direct As Required For Shut-off Closes Valve Open Open Reverse As Required For Shut-off Opens Valve Closed Closed 2930 & 32 Direct As Required For Shut-off Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open SOLENOIDS (without Positioners or I/P s) Failure Modes Actuator Solenoid Loss of Signal Loss of Air Supply Solenoid De-energized Valve Type Action Energized Valve Fails Valve Fails Valve Fails 2920, 22 & 23 Direct Closes Valve Open Open Open Reverse Opens Valve Closed Closed Closed 2930 & 32 Direct Closes Lower Port/ Upper Port Closed/ Upper Port Closed/ Upper Port Closed/ Opens Upper Port Lower Port Open Lower Port Open Lower Port Open If the Solenoid is used with a Positioner or an I/P, refer to the Positioner or I/P listings for factory default settings and failure modes with the solenoid not failed. Proximity MARK 1 Position Limit Switches Indication Switches Feedback Settings Valve Type Position Switch 1, 3, 5 Switch 2, 4, 6 Actuator Feedback Signal Feedback Signal Valve Type Action Potentiometer 3 ma Increases as 2920, 22 & 23 Direct ohm 4-20 ma Valve Closes Reverse ohm 4-20 ma Valve Opens 2930 & 32 Direct ohm 4-20 ma Lower Port Closes/ Upper Port Opens 3 Span varies from approx 155 to 350 ohm depending on actuator and travel. 2920, 22 & 23 Valve Closed Closed Open Valve Open Open Closed 2930 & 32 Upper Port Closed Closed Open Lower Port Closed Open Closed Air Filter Regulators Actuator Output Pressure DL49, 84 & 84XR 30PSIG DL115 & 115XR 40PSIG 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: Configurations 1. SELECTIONS Please make a selection from each table of OPTIONS below to make a complete model number string. 29 R 2. OPTIONS Valve Type Size Body Material VALVE BODY Model Trim Style Trim Material Trim Cv Packing Type End Connection 29N 49 or 84 Pneumatic Pneumatic 20 2-Way Single Seat 22 2-Way Double Seated 23 2-Way Cylinder Bal Way Mixing 32 3-Way Diverting /2 inch inch inch inch inch inch inch R Cast Iron F 125 lb. Flanged G 250 lb. Flanged E Equal % Types 20/22/23 L Linear Types 30/32 B Bronze S 300 SS H 17-4 PH 6 Alloy 6 Wrapped F Full Port NOTE : Valve Type 22 is Only Used with 29N Body & DL49/DL84 Actuators. T Teflon G Graphite Graphite Packing Used for Temp up to 500F where Body Pressure/Temp is not Violated! VALVE TYPE / TRIM MATERIAL COMBINATIONS: VALVE TYPE / ACTUATOR COMPATIBILITY: SIZE TRIM MATERIAL B S H 6 Bronze 300SS 17-4 PH Alloy 6 Wrapped /2 in. 20, 22, 23, 30, 32 20, 22, 23, 30, 32 20, inch 20, 22, 23, 30, 32 20, 22, 23, 30, 32 20, inch 20, 22, 23, 30, 32 20, 22, 23, 30, 32 20, inch 20, 22, 23, 30, 32 20, 22, 23, 30, 32 20, inch 20, 22, 23, 30, 32 20, 22, 23, 30, 32 20, inch 22, 32 20, 22, 30, 32 N/A N/A inch 22 20, 22 N/A N/A VALVE STYLE VALVE SIZES ACTUATORS Type /2 & 3 DL49 & DL84XR Type /2 6 DL84 Type /2 10 DL115 & DL115XR Type /2 4 DL49 & DL84 Type DL84 Type /2 & 3 DL49 Type /2 6 DL84 Type DL115 Type 23 6 DL115XR Type /2 & 3 DL49 & DL84XR Type /2 6 DL84 Type /2 8 DL115 DL115XR Type /2 4 DL49 Type /2 6 DL84 Type DL For additional applications, and/or products call: or visit: PS 2900 C 0305

87 Actuator Series ACTUATOR ACCESSORIES Action Spring Range Handwheel Positioners, I/P s & Limit Switches Air Filter Regulators ASCO Solenoids Special Options 00 None DIAPHRAGMS: 49 DL49 (49 Sq.In.) 84 DL84 (84 Sq.In.) 8X DL84XR (84 Ext. Rng.) 15 DL115 (115 Sq.In.) 5X DL115XR NOTE : 5X & 8X Only in Xtra-High Spring Range, Reverse Acting 0 None R Reverse Stem Fail Down D Direct Stem Fail Up 0 None L Low 4-10psi 49R ; 3-9psi 49D, 84R/D, 115R/D F Full 5-14psi 49R ; 4-13psi 49D; 3-15psi 84R/D, 115R/D H High 9-15 psi 84; psi 49R 8-12 psi 49D X Xtra-High DL84XR & DL115XR 0 None R Reverse D Direct NOTE : DL84; DL115; DL84XR & DL115XR only - Must match action. FAILURE MODES: MODE VALVE TYPE ACTUATOR ACTION Closed 20/22 Reverse Open 20/22 Direct Upper Closed* 30/32 Direct Upper Open 30/32 Reverse *Standard ACTUATOR / BODY COMPATIBILITY: 0000 None POSITIONERS: BxP_ BLX Pneumatic BxE_ BLX ElectroPneumatic BxI_ BLX ElectroPneu. Intrn. Safe BxX_ BLX ElectroPneu. Exp. Proof BxF_ BLX ElectroPneu. Fail Freeze 76P_ Moore760 Pneumatic 76E_ Moore760 Electro-Pneumatic 510_ Westlock ICoT Electro-Pneumatic 520_ Westlock ICoT Intelligent-Keypad 530_ Westlock ICoT Intelligent-Hart 540_ Westlock ICot Found.Fieldbus PROXIMITY SWITCHES: PX11 Mark 1 Series - 2 ea. SPDT PX12 Mark 1 Series - 2 ea. SPDT w/2k Pot. PX13 Mark 1 Series - 2 ea. SPDT w/4-20 Feedback PX14 Mark 1 Series - 4 ea. SPDT PX15 Mark 1 Series - 6 ea. SPDT I/P s Use with Diaphragm Only MAP1 Type 500X I/P, 3-9 PSI MAP2 Type 500X I/P, 9-15 PSI MAP3 Type 500X I/P, 3-15 PSI MAP4 Type 500X I/P, 1-17 PSI MAP5 Type 500X I/P, 6-30 PSI MAP6 Type 550X I/P, 0-30 PSI MAP7 Type 550X I/P, 0-60 PSI-For 15 or 5X only MAP9 Type 950X I/P, 3-15 EXP x digit spec. F Full Range Signal, 3-15 PSI or 4-20mA L Low of Split Range, 3-9 PSI or 4-12mA HHigh of Split Range, 9-15 PSI or 12-20mA 4th digit spec. 0 No Additions L w/mech. Lmt Swtch s F w/4-20 Feedback B w/swtch s & Feedbck 0 None A Type 300, 0-30 PSI B Type 300, 0-60 PSI D Type 350SS, PSI 0 None A 8320G184 3-Way Brass B 8320G202 3-Way SS L EF8320G184 3-Way EXP Br. MEF8320G202 3-Way EXP SS 120 VAC Coils 0 None S Special Opts or Set-up T SS Tubing G SS Tagging B SS Tubing and Tagging Note: Standard pneumatic tubing is copper. SS tubing T is optional. SS tagging G (Two lines, 24 characters/line) is optional. SS tubing and tagging together B is optional. DIAPHRAGM BODY Sq.In. (DL49) For 29N Bodies Sq.In. (DL84) For 29N Bodies 8X DL84XR For 29N Bodies Sq.In. (DL115) For 291 Bodies 5X DL115XR For 291 Bodies Warren Controls does not assume responsibility for the selection, use, or maintenance of any product. Responsibility for proper selection, use, and maintenance of any Warren Controls product remains solely with the purchaser and end-user Emrick Blvd., Bethlehem, PA Tel: or Fax: ACTUATED INDUSTRIAL VALVES 1800 SERIES Heavy Globe Control Valves 2800 SERIES Precision Globe Control Valves 2900 SERIES High Capacity General Purpose Globe Control Valves 3800 SERIES E-Ball Rotary Control Valves styles: 2-way balanced 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way balanced 2-way unbalanced 3-way mixing 3-way diverting styles: 2-way rotary - flow to open - flow to close sizes 2-1/2 to 12 in. class 300 ends 150,300 RF flg body Cast Iron, WCB,CF8M trim 316 SST, Alloy 6 Cv up to 1649 temp. -20 to 800 F body limitto 740 psi shutoff class III, IV rangeability 50:1 sizes 1/2 to 2 in. class 250 & 300 ends Buttweld, NPT body Bronze, CF8M trim Bronze, 316SST 17-4pH, Alloy 6, TFE, PEEK Cv up to 40 temp. -20 to 500 F body limitto 720 psi shutoff class III, IV, VI rangeability 50:1 sizes 2-1/2 to 10 in. class 125 & 250 ends Flange body Cast Iron trim Bronze, 300SS, 17-4pH, Alloy 6 Cv up to 960 temp. -20 to 400 F body limitto 400 psi shutoff class II, III, IV rangeability 50:1 sizes 1 to 8 in. class 300 ends 150,300 RF flg body WCB, CF8M trim 316 SST, Alloy 6, Ceramic, TFE, PEEK Cv up to 1420 temp. -20 to 800 F body limitto 740 psi shutoff class IV, VI rangeability 100:1 Heavy Duty Severe Service High Pressure Differentials Corrosive Materials, Liquids, Gases & Steam Modulating or On/Off Control Economical Precision Control Suited for Gases, Steam, or Liquids that are Not Viscous or Solids Bearing High Capacity General Purpose Moderate Pressure Drops Compatible Liquids and Gas, Steam & Water Modulating or On/Off Control Eccentric, Segmented Ball Well Suited for Erosive Service Various Trim Options Include Ceramic for Slurries or Gritty Materials & Teflon for Class VI Shutoff 2600 Emrick Blvd., Bethlehem, PA Tel: or Fax: SERIES Compact Globe Control Valves styles: 2-way cageretained seat sizes 1 to 4 in. class 300 ends 150,300 RF flg body WCB, CF8M trim 316 SST, Alloy 6, TFE, PEEK Cv up to 170 temp. -20 to 800 F body limitto 740 psi shutoff class IV, VI rangeability 50:1 Highly Efficient, Compact Design High Pressure Drops Typically Suited for High Force Piston Actuators for Steam, Chemicals & Dirty Fluids Minimizes Cavitation or Flashing Effects PS.2900.C.0305

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97 Form 166 Sheet P/N Rev. H Warrick Series 16 General Purpose Controls Installation and Operation Bulletin This bulletin should be used by experienced personnel as a guide to the installation of Series 16 controls. Selection or installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact Gems Sensors Inc. or its local representative if further information is required. Installation 1. Drill three.187 dia. holes in customer supplied backplate using stick on template supplied with control. Standard standoffs are designed for backplate thickness of.062 (1/ 16 ). Standoffs are available for backplates of.125 (1/8 ) nominal thickness. If retrofit plate standoffs are used, drill three.250 dia. holes in proper location. 2. Install three standoffs onto backplate. Install circuit board onto standoffs by pushing down on circuit board at outer edges of all four corners. Use both hands to slide board onto standoffs until standoffs lock. CAUTION: Do not overflex circuit board during installation. Do not push down on transformer or relays during installation. See sketch for proper installation. Install control in appropriate enclosure. 3. Wire control per diagram, following N.E.C. and local codes. Use appropriately sized spade terminals. Standoffs We have four different types of standoffs, designed to connect cirucit boards to panels Specifications Control Design: Open circuit board design Contact Design: SPDT (1 form C): one normally open (N.O.) and one normally closed (N.C.), non-powered contacts. Contact Ratings: 120 or 240 VAC resistive (120 F), 1 120, 240 VAC resistive (150 F), 1/3 120, 240 VAC (120 F) Contact Life: Mechanical: 5 million operations. Electrical: 100,000 operations minimum at rated load. Supply Voltage: 120, 240 or 24 VAC models: +10% - 15%, 50/60 Hz. 208/240 Model: 187 Vmin to 255 Vmax. VAC 50/60 Hz Supply Current: Relay energized 4.4 VA. Secondary Circuit: 12 VAC RMS voltage on probes, 1.5 milliamp current. Sensitivity: Models operate from 0 to 1,000,000 Ohm maximum specific resistance Temperature: -40 to 150 F. ambient. Terminals: Probe connections 3/16 spade: Line and power connections 1/4 space Time Delays: Standard H probe, 0.5 seconds on rising level Listing: U.L. recognized, Industrial Motor Control (508) Top View Side View Wiring Diagram A. C. Supply Dimensions L1 L2 Transformer G L Backplate Supplied by Others Reference Probe H NC C NO For single level service, use H and G connections. 1/16 1/8 High Probe Low Probe If metallic, the tank may be used in place of the reference probe. Bottom View Operation Direct Mode- Single Level Service: When the liquid rises to the electrode on terminal H, the control energizes, changing state of the load contacts. (LED will be lit) The control remains energized until the liquid level recedes below electrode on terminal H. The control then de-energizes, (LED will not be lit) returning load to original state. Inverse Mode- Single Level Service: Control energizes with power, changing state of the load contacts. (LED will be lit) When the liquid rises to the electrode on terminal H, the control de-energizes, returning the load contacts to shelf state. (LED will not be lit) The control remains de-energized until liquid level recedes below the electrode connected to terminal H. The control then energizes. Direct Mode- Differential Service: When the liquid rises to the electrode on terminal H, the control energizes, changing state of the load contacts. (LED will be lit) The control remains energized until the liquid level recedes below electrode on terminal L. The control then de-energizes, (LED will not be lit) returning the load contacts to original state. Inverse Mode- Differential Service: Control energizes with power, (LED will be lit) changing state of the load contacts. When the liquid rises to the electrode on terminal H, the control de-energizes, returning load contacts to shelf state. (LED will not be lit) The control remains de-energized until the liquid level recedes below the electrode on terminal L. The control then energizes. Optional Time Delays: With time delay on increasing level, the liquid must be in contact with the short electrode for the full duration of the time delay before control will operate. With delay on decreasing level, the liquid must be below long electrode for the full duration of the time delay before control will operate. In single level service, terminals H and L must be jumpered together to achieve time delays on both increasing and decreasing levels or just decreasing level. Dirty Electrode Detection: The LED will flash every half-second once the probe resistance reaches a value greater than the nominal control sensitivity rating. The relay state will not change until it exceeds the nominal sensitivity by more than 25% (typically) at nominal input voltage. At which time the LED and relay contact return to the dry state. Such a condition may suggest electrode maintance is required. Time Out Option: The latching circuit for the high and low electrode has an optional timer. In some applications the High or Low electrode may become short circuited or disconnected. Such an occurrence may potentially over fill in fill applications, or cause the pump to run dry in pump down applications. The time option is custom programmed up to 3 minutes. When a fault condition occurs, the fill LED will have a blink sequence of.5 seconds on 2 seconds off. See Chart A-1 for time delay options. 16 X X X X XX XX X Chart A-1 Dirty Probe/Timeout Timer Option: (See Chart A-1) Time Delay Decreasing Level: H/L function 0-90 seconds, blank = 0 seconds Time Delay Increasing Level: H/L function 0-90 seconds, blank = 0 seconds Optional Character: R = Retrofit plate or blank Enclosure: 0-None,1-Nema 1,4-Nema 4 Standoff Style/Socket Type: A - 1/16 Panel C - Screw Mount B - 1/8 Panel D - Retrofit Supply Voltage: VAC 3-24 VAC VAC 8-208/240 VAC Mode/Sensitivity: Direct Inverse A - 4.7K K - 4.7K B - 10K L - 10K C - 26K M - 26K D - 50K N - 50K E - 100K P - 100K F - 470K R - 470K G - 1M S - 1M Gems Sensors Inc. One Cowles Road Plainville, CT Tel: Fax: /16 (5.55 cm) 1-3/4 (4.45 cm) 3/16 (.48 cm) REF Transformer Screw Mount Standoff Circuit Board Standoff Retrofit Standoff 1/8 Standoff 1/16 Standoff 1-1/16 (2.70 cm) REF Sensitivities vs Maximum Probe Wire Distance* 1/2 (1.27 cm) 1-5/8 (4.13 cm) 2-1/2 (6.35 cm) Distance (Ft) Sensitivity (K Ohms) Sensitivity Character A or K ,000 B or L 10 5,700 C or M 26 2,200 D or N 50 1,075 E or P F or R G or S 1, * Based on type MTW or THHN wire, #14 or #16 AWG 1-7/8 (4.76 cm) 1 (2.54 cm) Mounting template supplied with all open circuit board controls. Notes If panel mount stand-off is to be used, thru-holes to be drilled in back plate should be.187 Dia. If retrofit stand-off is to be used, thru-holes to be drilled in back plate should be.250 Dia.

98 N O T I C E This owners & operation manual provides warnings of risk of harm from improper installation, operation and/or maintenance of Ace Products. Ace Heaters, LLC used ordinary care and complied with UL and ASME Standards in the design and manufacture of Ace Products. Proper installation, operation and maintenance are covered in the manual supplied with the product. All equipment must comply with local codes. Ace Heaters, LLC SO # Serial No. Model No. Ace Heaters, LLC. All rights reserved. Printed in the USA Performance specifications are effective with date of issue and are subject to change without prior notice. The brand and product names contained within this document are trademarks or registered of their respective holders.