Aerospace Group Conveyance Systems Division Carter Brand Ground Fueling Equipment IN64102 August 1997 Applicable additional manuals: IN64035 Installation Instruction IN64702 Installation Instruction Installation Instructions Solenoid Valve Manifold for use with Digital Pressure Control Coupler Model 64102 NOTE: OEM/CUSTOMER - PLEASE FILL OUT AND MAIL IN THE REGISTRATION CARD PROVIDED WITH THE INSTALLATION INSTRUCTIONS, IN64035 OR IN64235. SEE LAST PAGE OF THAT INSTRUCTION MANUAL FOR FURTHER INSTRUCTIONS.
TABLE OF CONTENTS Para. Description Page 1.0 Scope -------------------------------------------------------3 2.0 Equipment Supplied by Customer-------------------3 3.0 General Description-------------------------------------3 4.0 Installation -------------------------------------------------3 5.0 Orifice Changes------------------------------------------6-2 -
1.0 SCOPE August 15, 1997 IN64102 These installation instructions have been developed for use in mounting Model 64102 Solenoid Manifold Assembly on any hydrant servicer vehicle for use in controlling Eaton's Carter brand 64702 Hydrant Coupler. These instructions do not cover all requirements for such an installation which might be dictated by other authorities which have jurisdiction over the use of the vehicle. The responsibility for proper final installation configuration is yours. Consult with the local airport authority or corporate authority for further information. 2.0 EQUIPMENT SUPPLIED BY CUSTOMER The following is a listing of the required equipment supplied by the customer on the refueling vehicle. The digital valve system needs to interface with all of the items below: Mounting hardware needed to affix the 64102 to the vehicle. Hose and fittings to connect between the 64102 and hydrant coupler being operated by the 64102. Accumulator to be utilized as the fluid power source for the 64102. It is recommended that an accumulator with a minimum volume of 2.5 cubic feet be utilized. An accumulator of lesser volume can be used, expecially if the hydrant system pressure is never lower than 90 psi. The amount of volume used provides a capability to operate longer at lower pressures. Testing of smaller volume accumulators is on-going at Eaton and if a smaller one is desired, contact Eaton prior to proceeding. 3.0 GENERAL DESCRIPTION 3.1 The 64102 is an assembly of two solenoid valves mounted to a manifold block in such a way as to constitute a pilot to operate a pressure control coupler such as the 64702 Digital Coupler. One solenoid valve is a normally closed (NC) valve and one is normally open (NO). The NC valve is the shorter of the two, the NO the taller. 3.2 The manifold block onto which the two solenoid valves are assembled is also fitted with flared tube fittings. Two of these fittings, located next to each other on one side of the manifold, have factory installed orifices within them which are critical to the function of the Digital Valve system. DO NOT TAMPER WITH THESE TWO FITTINGS, OR THE ORIFICES WITH IN THEM, IN ANY WAY OTHER THAN AS STATED WITHIN THIS DOCUMENT. TAKE GREAT CARE TO KEEP THESE ORIFICES CLEAN AT ALL TIMES, ESPECIALLY DURING FIRST WETTING OF THE SYSTEM. If these orifices become blocked, it will adversely effect performance of the pressure control valve. The other fittings on the opposite ends of the manifold may be utilized or replaced at the option of the installer. All such ports on the manifold are 1/8 female NPT. 3.3 One hose, or other suitable conduit, will be utilized to connect the center passage of the manifold to the control cavity of the pressure control coupler. 3.4 Two wires will be connected to each of the two solenoid valves of the manifold assembly (four (4) wires total) to connect them to the 64035 Digital Control Module. 3.5 The 64102 can be mounted at any convenient location on the refueling vehicle in any orientation. However, it is best, if possible, to mount the assembly with the valves upright and the manifold on the bottom. 3.6 An accumulator must be used to store fluid power to be utilized as the source of inlet pressure for the 64102 manifold block. 4.0 INSTALLATION 4.1 Mounting 64102 on the Vehicle - 3 -
4.1.1 There are two ways in which the Manifold Assembly can be mounted to the refueling vehicle. This first is by utilizing the two threaded holes available in the bottom of the black manifold block. These threaded holes are metric, 5 mm fine thread, and are ½ inch in thread depth. (5 mm is very close in size to 3/16 inch. A 3/16-32 screw will fit, but the thread fit will be loose to a very small degree. Use good judgment in determining if this screw results in an acceptable mounting.) 4.1.2 The alternative method of mounting involves using the same holes, but utilizing 2 of #8-32 socket head cap screws and inserting them from the other side of these same holes. The #8-32 screws will pass through these threaded holes. Select a length of these screws as required for your installation. HOWEVER, you must first remove the Solenoid Valves from the Manifold Block to access these holes. This must be done by REMOVING THE CORRECT TWO SCREWS from the Solenoid Valves, as described below: 4.1.2.1 Note that there are four (4) screw heads visible on the top of each Solenoid Valve. Two of these hold the Solenoid Valve onto the Manifold Block. The other two hold each Solenoid Valve together. To determine which two screws to loosen, orient the Solenoid Valve with the electrical connections up or down, as opposed to left or right. In this orientation, the correct screws to loosen to remove the Solenoid Valve from the Manifold Block are at the upper left and lower right. HAZARDOUS NOTE! THE OTHER TWO SCREWS RETAIN SPRING LOADED PARTS WITHIN THE SOLENOID VALVE AND SHOULD NOT BE TAMPERED WITH. 4.1.2.2 Make special note of the orientation of each solenoid valve on the manifold block. This orientation is critical to the operation of the 64102. If this orientation is not correct when the valves are re-installed, then the 64102 will not perform properly. The NC valve should be mounted with the electrical connection located over one of the two side ports on the manifold block. The NO valve should be mounted in the opposite direction, with the electrical connection on the blank side of the manifold block. 4.1.2.3 Also note that, when removing the Solenoid Valves from the Manifold Block, there are two small O-rings which seal the ports on the bottom of the Solenoid Valve. Make certain that these two O- rings are correctly installed when re-fitting the Solenoid Valves to the Manifold Block or fuel leakage will occur. 4.2 Accumulator 4.2.1 Any 2.5 gallon bladder accumulator can be utilized for the fluid power source for the Manifold Block used to control the Digital Coupler (such as the 64702). Follow the manufacturer s instructions for mounting the accumulator on your vehicle. 4.2.2 Connect a line to the fuel resevoir portion of the accumulator from a high pressure source on the vehicle. This line will be used to charge the accumulator with fuel pressure. 4.2.3 Install a check valve in this line which will allow flow from the vehicle plumbing into the accumulator but not allow flow from the accumulator back into the plumbing. The result is that fuel pressure will be applied to the inlet of the Manifold Block from the accumulator and it will become re-charged whenever the pressure in the vehicle is greater than the pressure within the accumulator. 4.2.4 Also connect the fuel resevoir portion of the accumulator to the inlet of the Manifold Block used to control the Digital Coupler. Follow the installation instructions, IN64702, for the 64702 regarding this connection. 4.2.5 Pre-charge the gas end of the accumulator with 60 psi of air (or nitrogen) pressure. 4.3 Manifold Fluid Connections 4.3.1 There are four ports on the manifold block, each a female 1/8 NPT. Two ports are on one side of the manifold block. The other two are on opposite ends of the manifold block. These end two are connected by a large through hole in the manifold block. The other two feed to the underside of the two solenoid valves. - 4 -
4.3.2 The two fittings located next to each other on one side of the manifold have factory installed orifices within them which are critical to the function of the Digital Valve system. DO NOT TAMPER WITH THESE TWO FITTINGS, OR THE ORIFICES WITH IN THEM, IN ANY WAY OTHER THAN AS STATED WITHIN THIS DOCUMENT. TAKE GREAT CARE TO KEEP THESE ORIFICES CLEAN AT ALL TIMES, INCLUDING DURING FIRST WETTING OF THE SYSTEM. These two fittings will be connected to a high pressure source and to a low pressure point of a collection tank. 4.3.3 Connect the high pressure source, such as an accumulator (see 4.5 below) used in conjunction with the 64702, to the fitting adjacent to the NC (shorter) solenoid valve. Use a 1/4 or 3/8 inch inside diameter hose, tube or pipe for this application. Make sure the connection is made to the fitting on the side of the manifold block which contains an orifice and not to the fitting on the end of the manifold block. 4.3.4 Connect the low pressure point or collection (slop) tank to the fitting adjacent to the NO (taller) solenoid valve. Use a 1/4 or 3/8 inch inside diameter hose, tube or pipe for this application. Again, connect to the fitting on the side of the manifold block and not to the one on the end. NOTE: The hose or conduit selected for this purpose must be free flowing. Any major resistance to flow in this line will adversely affect the operation of the 64102. Free flow of fluid in this line is imperative. 4.3.5 Connect the hose or conduit which carries fluid to the pressure control coupler, such as a 64702, to one of the end ports of the manifold block. Either end for this connection may be selected. Make sure the port on the opposite end is plugged, capped, or otherwise sealed. HINT: As an option, one may wish to connect a pressure gauge to this opposite port. This gauge will be useful in observing when and how the solenoid valves are controlling pressure in the control cavity of the pressure control valve for diagnostic purposes. 4.4 Pressure Control Coupler Connection 4.4.1 The other end of the hose or conduit described in 4.2.5 above is connected to the control cavity of the pressure control coupler. Use a 1/4 or 3/8 inch inside diameter hose, tube or pipe for this application. If using hose, it must be a braid reinforced hose suitable for 300 psi service or some other very stiff conduit. For best results, use the stiffest (least inflatable) hose you can. (Good results have been accomplished with the ¼ DAYCO 6L2 hose.) The hoses can be no longer than 60 feet. 4.4.2 When making this connection, use free flowing fittings which will not restrict flow through this conduit. Any major resistance to flow in this line will adversely affect the operation of the 64702. Free flow of fluid in this line is imperative. 4.4.3 It is suggested that a valve of some sort be installed on a tee fitting at this location which can be used to bleed air out of this conduit and out of the control cavity of the pressure control coupler. 4.5 Air Bleeding 4.5.1 Once the physical installation is complete and the vehicle is filled with fuel, upon first pressurization, the hoses and/or tubes that connect to the 64102 Manifold Assembly to the 64702 Digital Coupler and the internal cavity of the 64702 must be bled of air. 4.5.2 Open the valve on top of the 64702 fitted for this purpose (or loosen a fitting on the top of the 64702) and activate the Deadman Control to apply pressure to this line. Catch the fuel emitting from the control line in a suitable container. 4.5.3 When most of the air is bled, slowly close the valve (or tighten the fitting) to build pressure within the control cavity of the 64702. This will cause the 64702 to open. After the 64702 has opened, re-open this valve (or fitting). If open enough, the 64702 will stroke closed and exhaust some trapped air from the internal control cavity. Repeat this step until you are satisfied that all the air is removed from the control line and from the control cavity of the 64702. - 5 -
5.0 Orifice Changes 5.1 It may be necessary to change one or both of the two orifices installed in the fittings in the side of the manifold block for reasons which are specific to the installation. See the Set-Up and Calibration instructions, SU64035, for the 64035 to verify and diagnose this need. 5.2 To change the orifice on either fitting, you will need a 3/32 inch hex key (Allen wrench). You will also need a new size orifice from Carter to install. These are not supplied with the 64102. Contact Carter before proceeding to change the orifices. 5.3 Remove the connection from the appropriate fitting supplied by Carter on the side of the manifold block. Insert the hex key into the orifice screw visible from the open end of the fitting. Remove the orifice screw. Inspect it for clogging. Any contamination might have been affecting the performance of the 64702. 5.4 Install the new orifice screw. It should go in far enough to stop when it is sub-flush with the outer edge of the fitting. - 6 -
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