10851186-MAN - Rev 01 - 10851186-MAN - Rev01 [PDF]

Zitiervorschau

User Manual

Hydraulic Power Unit/Blowout Preventer Control System

Customer References Customer: National Oilwell Varco Rig / Hull: Rig #141

National Oilwell Varco References: SO Number: 831049 Document Number: 10851186-MAN Revision: 01 Volume:1

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User’s Manual HPU/BOP Control System Rig #141

Customer Name

National Oilwell Varco Rig Name

Rig #141 Sales Order Number

831049

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Reference

Reference Description

HPU/BOP Control System This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell Varco. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned. © National Oilwell Varco

National Oilwell Varco 6390 Eldridge Pkwy Houston, TX 77041 Phone: 832-424-6000 Fax: 832-424-6700

Document Number

Rev.

10851186-MAN

01

Revision History

01

03.10.2013

Issued for implementation

MS

RH

RH

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

Change Description Revision 01

Change Description First issue

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Table of Contents Chapter 1: General Information Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Transporting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Electric Circuit Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Hydraulic Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Cable and Hose Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Work Area Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Use Correct Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Mailing Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Shipping Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 NOV Repair Center Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 NOV Technical Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Chapter 2: Introduction Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Major Components, Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 HPU Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Operating Fluid and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Junction Box (P/N 10656624-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Gauge Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Emergency Battery Back-up System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Control Panel Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

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Table of Contents Chapter 3: Installation and Operation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Pre-Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Triplex Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 BOP Line Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Pre-Operational/Commissioning Testing Procedures . . . . . . . . . . . . . . . . . . . . . 3-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hydraulic Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Control Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Remote Control Panels and HPU Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Emergency Battery Back-up/Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Remote Control Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 General System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Remote Operated Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Conditions Requiring Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Chapter 4: Maintenance Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Checking Nitrogen Precharge Pressure in Accumulator Bottles . . . . . . . . . . . . . 4-2 Filters, Strainers, Air Lubricators, Air Regulators . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Triplex Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Low Accumulator Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Fluid Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-Way Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Motor Starter Junction Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Alarm Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 MKR and AMKR Pressure Regulating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Emergency Battery Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Conditions Requiring Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 System Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Electric Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 HPU J-Box, Driller’s Control Panel, and Toolpusher’s Control Panel . . . . . . . . 4-14 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Significant Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Repairable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Triplex BD-30 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Precharging Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 11-Gallon, 3,000 psi Top Loading Accumulator Bottles . . . . . . . . . . . . . . . . . . 4-19 Replacing Accumulator Bladder (Top Loading) . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4-Way Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 1” MKR Pressure Reducing and Regulating Valve (P/N 1000149) . . . . . . . . . . 4-32 1” AMKR Pressure Reducing and Regulating Valve (P/N 1000539) . . . . . . . . 4-42

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Table of Contents Chapter 5: Parts Lists Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Charging and Gauging Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Chapter 6: Drawings and Bills of Materials Engineering Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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General Information This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco (NOV) will not be held liable for errors in this material, or for consequences arising from misuse of this material.

Conventions Notes, Cautions, and Warnings Notes, cautions, and warnings provide readers with additional information, and also advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note:

ii The note symbol indicates that additional information is provided about the current topics.

Caution:

The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning:

Wa r n

in g

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.

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General Information

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Illustrations Illustrations (figures) provide a typical and graphical representation of equipment, its components, or screen snapshots for use in identifying parts, establishing nomenclature, or calling out notes and procedures. Illustrations may or may not show all current aspects of the equipment nor be drawn to scale. Illustrations will not reflect any changes made after publication. For component information specific to the product purchased, see the technical drawings included with your National Oilwell Varco documentation.

Weights and Dimensions Some weights and dimensions of the equipment and components within the manual are typical and subject to change. Refer to the Engineering drawings and Bills of Material when provided for more specific data.

Transporting Equipment Transporting precharged accumulator bottles within the United States is covered by HAZMAT rules and DOT regulations. Consult the proper authorities’ regulations outside the United States.

Safety Requirements National Oilwell Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in NOV manuals are the recommended methods of performing operations and maintenance.

To avoid injury to personnel or equipment damage, carefully observe requirements outlined in this section.

Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.

Personnel should wear protective gear during installation, maintenance, and certain operations.

Contact the National Oilwell Varco Equipment training department for more information about equipment operation and maintenance training.

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General Information

1

Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. NOV recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures or using tools not specifically recommended by National Oilwell Varco.

General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water.

Read and follow the guidelines below before installing equipment or performing maintenance to avoid endangering exposed persons or damaging equipment.



Isolate energy sources before beginning work.



Avoid performing maintenance or repairs while the equipment is in operation.



Wear proper protective equipment during equipment installation, maintenance, or repair.

Replacing Components 

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during assembly and disassembly of equipment to ensure correct installment.



Replace failed or damaged components with NOV certified parts. Failure to do so could result in equipment damage or injury to personnel.

Routine Maintenance Equipment must be maintained on a routine basis. See the service manual for maintenance recommendations.

Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Proper Use of Equipment National Oilwell Varco equipment is designed for specific functions and applications and should be used only for its intended purpose.

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General Information

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General Safety Precautions Operation of the control systems may present certain hazards that require the attention and caution of operators and technicians. Normally, many hazards are avoided by observing and exercising standard safety precautions.

Electric Circuit Safety Precautions Certain safety precautions must be exercised regarding the electric circuits of the control system. The precautions will prevent damage to equipment and injury to personnel that might result from electric power. Personnel engaged in electrical work should receive proper instruction in accident prevention and first aid procedures. 

An electric power source must be supplied at correct voltage, current, and phase to enable safe and correct operation of equipment.



Exercise caution when working around exposed electrical conductors, terminals, and remotely activated equipment.



Ensure flashproof integrity of explosion-proof electrical junction boxes, connections, and circuit breakers. This will prevent fires or explosion that might result from a spark during electrical switching.



Do not override or tamper with electrical or mechanical interlocks and safety devices.



Before attempting any corrective action on the electrical circuit, verify that all electric power sources have been removed from the circuit. Ensure that all electrical switches are set to “Off” and the appropriate breakers are set to “Open”.



Do not service or adjust the electrical circuits alone. Always verify that a qualified person is present who can render aid in case of accident and who is familiar with emergency shutdown procedures.



Appropriate warning tags labeled “Requiring Open Circuit Condition” shall be placed on all necessary switches and circuit breakers to prevent accidental application of power to units of the system during maintenance procedures.



Wear suitable protective clothing while working within 4 feet of exposed electrical equipment. Do not wear rings, wristwatches, or clothing with exposed metal buttons, zippers, or fasteners.



Metal handles of hand-held tools should be insulated by an approved taping, coating, or sleeve method.



Whenever it is necessary to work on electrical circuits or equipment in wet or damp locations, dry, wooden (or similar non-conducting material) platforms should be provided to prevent the possibility of contact between the wet floor and workers’ shoes.

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General Information

1

Hydraulic Safety Precautions Hydraulic power source produced by the accumulator control/pump unit is at sufficiently high pressures and volumes to present a hazard if required safety practices are not followed. Exercise the following precautions to aid in preventing damage to equipment and injury to personnel that might result from hydraulic power related accidents: 

Mop up spilled hydraulic fluid immediately. Immediately investigate and correct the cause of any leakage of hydraulic fluid.



If clothing becomes drenched with hydraulic fluid, change immediately to dry clothing. The fluid is severely irritating to eyes and skin. Prolonged contact with hydraulic fluid may cause dermatitis, which may progress to allergic sensitization.



Ensure that only correct hydraulic fluid is supplied and used for safe and correct operation of the control systems unit.



Hydraulic fluid must be filtered to prevent any dirt or debris from entering the hydraulic circuit.



Ensure that the pressure relief valves are in working condition, and that the valves are set to relieve at their designated pressure levels.



Should there be a rupture or break in the hydraulic circuit (when pressurized), do not place hands, face, or any part of the body over the escaping jet stream of fluid. Severe bodily injury will result.



Never torque leaking connections or fittings while lines are pressurized. Application of torque to fitting or connections while lines are pressurized may cause lines to rupture and result in injury to personnel.



Before attempting any corrective action on the hydraulic circuit, verify that:





The electric power source is turned off.



The pneumatic power source is turned off.



All hydraulic pressure is completely vented. Verify that all hydraulic gauges read 0 psi (0 bar).

When precharging accumulators, use only dry nitrogen gas. The use of another gas may cause unit failure or explosion.

Cable and Hose Safety Precautions 

Protect all hydraulic hoses from cutting, scraping, pinching, abrasion or any physical damage. Route all cables and hoses outside of the crew’s traffic patterns and away from mechanical equipment.



Welding or acetylene cutting must not be done near unprotected cables or hoses, as this may result in damage to cables or hoses.



Consideration must always be given to the prescribed minimum bend radius for cables and hoses. Twisting or bending cables or hoses beyond the minimum bend radius can damage the insulation, conductors, or reinforcing wire shield.

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Work Area Safety Precautions The following safety precautions should be observed in the work area: 

Work in an area free of any dangerous obstructions, chemicals, or hazards.



If any dangerous obstruction is located overhead, to the side, or on the surrounding floor of the work area, the hazard must be removed as safely and quickly as possible by appropriate personnel.



If any flammable materials are located or are spilled within or in proximity to the work area, the hazardous material must be removed and cleaned from the work area. Flammable materials include but are not limited to those listed below: 

Oily rags, paper products, or any combustible solid.



Kerosene, gasoline, or any combustible liquid.



Oxygen tanks, acetylene tanks, or any combustible gas.

Should any condition, situation, or circumstance occur that may pose serious hazard(s), appropriate action must be taken to correct or remove the hazard(s) from the work area and to return to a safe working environment.

Use Correct Replacement Parts Many NOV system components are specially manufactured to system design and specifications, although apparently similar to commercial available hardware. To avoid possible hazardous failures, use only NOV replacement parts, components, and assemblies.

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General Information

1

Customer Service Direct all correspondence to one of the addresses provided below.

Mailing Address National Oilwell Varco (NOV) P.O. Box 1473 Houston, Texas 77251, U.S.A.

Shipping Address 12950 West Little York Houston, Texas 77041 Phone: (832) 424-6000 Fax: (832) 424-6700

NOV Repair Center Address 5100 N. Sam Houston Parkway West Houston, Texas 77086 Tel. (281) 569-3000

NOV Technical Support Services Tel. (281) 569-3050, Houston TX Email: houstonservice [email protected]

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Introduction This manual provides procedures for installation, operation, and maintenance of the National Oilwell Varco (NOV) Koomey® Blowout Preventer (BOP) control system. The BOP control system consists of an accumulator Hydraulic Power Unit (HPU), Driller's remote control panel, Toolpusher's remote control panel, and a constant-power battery charger power supply. This chapter provides a general description of the control system.

Description All NOV Koomey® BOP control systems incorporate, as a minimum, an accumulator unit with a volume adequate to close all preventers (with pumps inoperative) while retaining a 50% reserve of fluid above minimal system pressure. The HPU is equipped with two 30 HP electric motor-driven triplex hydraulic pumps. Each electric-driven triplex pump is capable of maintaining the 3,000 psi (207 bar) system working pressure. The electric-driven triplex hydraulic pumps provide 3,000 psi (207 bar) pressurized hydraulic fluid to the HPU accumulator bottle racks (see Figure 2-1).

Accumulators

Triplex Pumps Figure 2-1. Hydraulic Power Unit

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Introduction

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Major Components, Hydraulic Power Unit Figure 2-2 on page 2-3 shows a typical hydraulic power unit (HPU) and the location of the components on the unit. These figures are used as an example ONLY; the customer’s equipment may vary in components and quantities used. Item numbers refer to the figures. 1. Electric Motor-Driven Triplex Pump Assemblies – Primary pressure source; horsepower rating can vary. 2. Check Valve – High pressure fluid. 3. Automatic Pressure Switch – Pressure switch is set at 3,000 psi (207 bar) cutout and 300 to 400 psi (21 to 28 bar) cut-in differential. Adjustable. See the hydraulic flow diagram. 4. Electric Motor Starter (Automatic) – Automatically starts or stops the electric motor driving the triplex pump. Works in conjunction with the automatic pressure switch and has a manual on/off/auto switch. 5. 4-Way Valves – With air or hydraulic cylinder actuators for remote operation from the control panels. Keep in standard operating mode (“Open” or “Close”), never in the center position. 6. Bypass Valve – With air or hydraulic cylinder actuators for remote operation from the control panels. In “Low” position, 1,500 psi (103 bar), it allows regulated pressure on control valve manifold, and in “High” position, 3,000 psi (207 bar), it allows full accumulator pressure on the control valve manifold. Keep in “Low” position, 1,500 psi (103 bar), unless 3,000 psi (207 bar) or more is required on ram-type BOPs. 7. Pressure Reducing and Regulating Valve – Manually operated. Adjust to the required continuous operating pressure of ram type BOPs. Typically 1,500 psi (130 bar). 8. Pressure Reducing and Regulating Valve, Air or Hydraulically Operated – Reduces the accumulator pressure to the required annular BOP operating pressure. Pressure can be varied for stripping operations. Maximum recommended operating pressure of the annular preventer should not be exceeded. 9. Pressure Gauges – Panel of 6” gauges providing typical readings of: 

Annular Pressure



Accumulator Pressure



Manifold Pressure

10. Control Valve Manifold – 3,000 psi (207 bar) working pressure; 2” (5 mm). 11. Junction Box (J-Box) – Component housing for electric remote panels. Houses the system pressure switches, pressure transmitters, and solenoids. 12. Suction Strainer – Located in the suction line of the electric pump. Clean every 30 days.

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5 6

7

10

9

8 11

4

3

2 1

12 (Not Shown) Figure 2-2. Hydraulic Power Unit (Front View)

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Introduction

System Components The following describes the components of the BOP control system.

HPU Accumulator Bottles Wa r n

in g

The accumulator bottles within this control system are nitrogen gas precharged to high pressure and are not protected by an overpressure-relieving device. Steps should be taken to prevent over-pressuring and possible failure of these bottles due to the excessive heat associated with fire. Consideration should be given to the hazards associated with these bottles and provisions taken for adequate fire protection measures.

When transporting precharged accumulator bottles, the recommended precharge pressure is 35 psi (2.4 bar) maximum. Refer to the section titled “Transporting Equipment” on page 1-2.

Use nitrogen when adding the precharge. Other gases and air may cause fire and/or explosion.

The accumulator bottle racks (see Figure 2-3) store the volume of pressurized control fluid necessary to support the control system operational requirements. The accumulator bottles should only be serviced during periods when rig activities do not require the control system and blowout preventers to be operational. The entire HPU accumulator system should be bled down to 0 psi (0 bar) pressure prior to working on the accumulator bottles.

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Figure 2-3. Accumulator Bottle Rack Assembly

The HPU skid-mounted accumulator bottle rack assembly consists of twenty top loading 11-gallon accumulator bottles with 3,000 psi (307 bar) working pressure dedicated to the Blowout Preventer (BOP) control system. The HPU accumulators are equipped with gauges to monitor system pressure, isolation ball valves to isolate system pressure, block and bleed valves to vent system pressure, and a relief valve [set at 3,300 psi (228 bar)] to prevent over-pressuring the accumulator bottles (see Figure 2-4 on page 2-6).

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Introduction

HPU/BOP Control System Page 2-6 of 24

Pressure Switch

HP Filter

Accumulator Gauges

Bleed Valve

Figure 2-4. Accumulator Rack Gauges and Valves

Each accumulator bottle contains nitrogen. The nitrogen pressure in the accumulator bottles is charged to 1,500 psi (103 bar) through the cap at the top of the bottle. The hydraulic fluid is then pumped into the bottle cavity through the lower end, and the nitrogen is compressed until the maximum working pressure is reached.

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The shutoff valves control the flow of hydraulic fluid to and from each header. In normal operation, the shutoff valve is open and allows fluid to enter the accumulator banks and pressurize the system. For repair operations of any equipment on the hydraulic control manifold, the accumulator bottle rack shutoff valves are closed, thus maintaining system pressure in the four accumulator header banks. Pressure in the manifold piping is then bled off, and the maintenance operation is performed. After repairs to the control manifold are completed, the shutoff valves to the pressurized accumulator banks are reopened, and the system is back on line, fully pressurized. The bleeder valve on each header enables the pressurized fluid in the bank to be vented into the reservoir. In normal operation, the bleeder valve is closed. Prior to maintenance operations on an accumulator bank, the bleeder valve is opened and the fluid in the accumulator banks is vented into the reservoir. The pressure gauge reads the manifold supply pressure, which is normally 3,000 psi (207 bar). Prior to starting maintenance operations, the header should be vented, and the gauge pressure should read 0 psi (0 bar). The relief valves, set at 3,300 psi (228 bar), relieve any over-pressure condition.

Pumps The BOP control system is provided with two independent pumping systems mounted on the HPU skid. The pumping system consists of two 30 HP electric motor/triplex pump assemblies. Either triplex pump is capable of supplying fluid to the accumulators at full operating pressure.

Electrically Operated Hydraulic Pump The electrically operated hydraulic pump pressurizes the system accumulator bottle racks. The triplex pump (see Figure 2-5) is complete with a 460 VAC, 3-phase, 60 Hz explosionproof motor. The triplex pump generates hydraulic pressure for the BOP control system. Each pump is fitted with an On/Off pressure switch assembly. One pump is set to turn on when the system pressure falls to 2,800 psi (193 bar) and turn off when the system pressure reaches 3,000 psi (206.84 bar). The other pump is set to turn on when the system pressure falls below 2,750 psi (190 bar) and turn off when the system pressure is greater than 2,900 psi (200 bar). This lead/lag design minimizes pump duty cycles for maximum pump life.

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Introduction

Triplex Pump

Strainer

Figure 2-5. Triplex Pump Assembly

Motor Starter Junction Box (P/N 10656625-001) The triplex pumps are controlled by the motor starter junction box (see Figure 2-6), which is provided with an On/Off breaker switch, a Hand/Off/Auto selector switch, and a Motor Run Indicator Lamp. During normal operation, the selector switch is placed in the “Auto” position. The selector switch is spring return from the “Hand” position to the “Off” position. The selector switch “Hand” position may be used to jog the motor to verify proper rotation of the triplex pumps. Also located on the motor starter Junction Box is an emergency stop mushroom button. In an emergency, hitting the emergency stop button with the palm of the hand immediately stops the triplex pumps. To restart the triplex pump, requires the mushroom button to be rotated clockwise.

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Motor Starter J-boxes

Figure 2-6. Motor Starter Junction Box

Relief Valves (P/N 1550111) The relief valves are installed on the hydraulic power unit to protect the system from being over pressured (see Figure 2-18 on page 2-22). The relief valves are shear seal-type and are designed to relieve excess pressure and reseal when the pressure drops below its setpoint. If these valves do not reseal, replace them.

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HPU/BOP Control System Page 2-10 of 24

HPU Pneumatic Circuit The air receiver system integral to the HPU (see Figure 2-7) has a 30-gallon (113.5-liter) tank with a relief valve set at 200 psi (13.8 bar) to prevent over pressuring of the tank. Prior to entering the tank, air passes through a filter and a 1" inline check valve. The tank is also supplied with a drain valve to vent the system and remove any water that may have accumulated in the tank. Air from the receiver is used to supply air to the solenoid pressure switches located in the HPU junction box and to operate the AMKR valve that regulates hydraulic pressure to the annular open/close function. The air from the receiver to the AMKR valve is reduced to 90 psi (6 bar) by an inline air regulator.

Air Receiver

Figure 2-7. Air Receiver

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Operating Fluid and Reservoir Hydraulic Fluid A clean, lightweight high-quality hydraulic control fluid, or fluid concentrate, which is capable of being mixed with potable water, should be used as the operating fluid. Do not use motor oil, kerosene, diesel fuel, chain oil, or petroleum products containing aromatics that can damage rubber components and seals. Reservoir capacity equals approximately twice the usable fluid capacity of the accumulator system. Access ports of 4” ID (102 mm) are at each end of the reservoir to allow detection of any leaking components on the manifold. Internal baffles in the reservoir restrict fluid movement should the unit be transported. Hydraulic fluid should have the following properties: 

No freezing in cold climates



Lubricity to reduce wear



Chemical compatibility with the elastomer seals



Corrosion inhibitors for metal surfaces

Where pollution due to accidental spillage of hydraulic fluid is a problem, use environmentally safe water-based fluid or pre-mixed fluids.

ii To prevent freezing at temperatures below 35F (2C), ethylene glycol without any additives is recommended.

Do not use commercial antifreeze mixes.

Low Fluid Level Alarm Float Switch Located on the fluid reservoir is a low-level alarm float switch (see Figure 2-8 on page 2-12). If the fluid level in the reservoir drops below the low-level float switch, it closes the switch, which energizes the audible alarm on the HPU junction box and illuminates the red “Low Reservoir Fluid Level” indicator lamp (see Figure 2-8 on page 2-12). The switch also routes an electric signal to the Driller’s and Toolpusher's control panels to illuminate the red “Low Reservoir Fluid Level” indicator lamp on the panels. Pressing the “Alarm Acknowledge” pushbutton on the HPU junction box will silence the audible alarm; however, the lamp will remain illuminated red until the proper fluid level is restored.

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HPU/BOP Control System Page 2-12 of 24

Alarm Float Switch

Figure 2-8. Alarm Float Switch

Low Accumulator Pressure Alarm Switch Located on the HPU is a low-pressure accumulator alarm switch. If the HPU accumulator pressure drops below 2,000 psi (138 bar), the switch closes, energizing the audible alarm on the HPU junction box and illuminating the red "Low Accumulator Pressure" indicator lamp (see Figure 2-11 on page 2-16). The switch also routes an electric signal to the Driller's control panel and Toolpusher's control panel, to illuminate the red "Low Accumulator Pressure" indicator lamp on the panels. Pressing the Alarm Acknowledge pushbutton will silence the audible alarm; however, the lamp will remain illuminated red until the proper accumulator pressure is restored.

Low Air Pressure Alarm Switch Located on the HPU is a low air pressure alarm switch. If the HPU instrument air supply drops below 60 psi (4 bar), the switch closes, energizing the audible alarm on the HPU junction box and illuminating the red "Low Rig Air Pressure" indicator lamp (see Figure 2-11 on page 2-16). The switch also routes an electric signal to the Driller's control panel and Toolpusher's control panel, to illuminate the red "Low Rig Air Pressure" indicator lamp on the panels. Pressing the Alarm Acknowledge pushbutton will silence the audible alarm; however, the lamp will remain illuminated red until the proper instrument air supply pressure is restored.

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Introduction

Pressure Reducing and Regulating Valves (P/N 1000149 and 1000539)

ii The AMKR valve can be remotely adjusted from the Driller's control panel or Toolpusher's control panel and manually adjusted at the HPU hydraulic control manifold. However, the MKR valve can only be manually operated at the HPU hydraulic control manifold.

There are two pressure reducing and regulating valves (see Figure 2-10) on the hydraulic power unit: 

Manual Koomey® Regulator (MKR) valve (P/N 1000149) - Reduces the 3,000 psi (207 bar) pressure to 1,500 psi (103 bar) manifold pressure, to the ram and choke/kill valves.



Air Motor Koomey® Regulator (AMKR) valve (P/N 1000539) - Supplies regulated hydraulic pressure to open and close the annular packer.

MKR Valve

HMKR Valve

Figure 2-9. Pressure Reducing and Regulating Valves

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Introduction

HPU/BOP Control System Page 2-14 of 24

Control Manifold The master hydraulic control manifold is integral with the HPU. The hydraulic control manifold should be located at a safe distance from the wellbore and controlled by a panel near the driller. If a blowout occurs, controls on the drill floor might be destroyed or become inaccessible. The hydraulic control manifold should be located at a safe distance so that the well can be closed in safely. The HPU has two separate hydraulic supply manifold circuits for BOP stack control and annular control. The HPU master hydraulic control manifold circuit supplies regulated hydraulic manifold pressure to the 4-way control valves that operate the ram-type preventers and stack-mounted gate valves. The annular hydraulic control manifold circuit supplies regulated hydraulic manifold pressure to the annular control valve to operate the open/close functions of the annular element. An MKR pressure regulator is installed upstream of the BOP ram control manifold (see Figure 2-10 on page 2-15). This regulator is factory preset at 1,500 psi (103 bar), the hydraulic operator’s normal working pressure for BOP ram preventers. A quick-opening regulator bypass valve, capable of being remotely operated, is fitted to allow the full 3,000 psi (207 bar) accumulator pressure to the ram preventers for fast, positive closure in emergency situations. A high-pressure strainer is installed upstream of the regulator and the 4-way valves to reduce the possibility of foreign matter affecting the sealing capacity of the valves. A remotely controlled Air Motor Koomey Regulator (AMKR) valve (see Figure 2-10 on page 2-15) is also provided upstream of the valve that controls the open and close function of the annular element packer. The AMKR valve is capable of regulating and maintaining pressures from 500 psi (35 bar) to 1,500 psi (103 bar). It is also capable of relieving pressure in excess of its set operating pressure to minimize build-up during annular stripping operations. A high-pressure hydraulic filter is located upstream of the annular AMKR valve to prevent foreign material from damaging the regulator. Clearly marked nameplates on the HPU master hydraulic control manifold identify which ram preventer or hydraulic valve each 4-way control valve operates and indicates its position. During drilling operations, valves should be placed in either the “Open” or “Close” position, never in the center (block) position.

When manually operating the four-way valves on the HPU from left to right or from right to left, move the valve handle rapidly. Failure to heed this caution will cause excessive wear of the valve rotor and shear seal rings.

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AMKR MKR

Figure 2-10. HPU Control Manifold

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Introduction

Junction Box (P/N 10656624-001) The HPU is provided with a junction box (see Figure 2-11) mounted on the HPU skid. Inside the junction box are the solenoid valves (see Figure 2-12 on page 2-17) for remote operation of the annular AMKR valve and 4-way control valves. The AMKR valve has two solenoids, one for the increase function and one for the decrease function. Each 4-way control valve has two solenoids, one for each operating position (e.g., close, open).

LOW ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

EMERGENCY POWER ON

LAMP TEST

ALARM ACKNOWLEDGE

DP COMM ERROR

TP COMM ERROR

Alarm Panel LOW ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

EMERGENCY POWER ON

LAMP TEST

ALARM ACKNOWLEDGE

DP COMM ERROR

TP COMM ERROR

J-Box Assembly

Figure 2-11. HPU Junction Box

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PLC

Solenoids

Figure 2-12. Interior of HPU Junction Box

Figure 2-13. Pressure Switches and Pressure Transmitters

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Introduction

LOW ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

EMERGENCY POWER ON

LAMP TEST

ALARM ACKNOWLEDGE

DP COMM ERROR

TP COMM ERROR

Figure 2-14. J-Box Alarms

The junction box houses the pressure switches that operate the indicator lights on the remote control panel and pressure transmitters (see Figure 2-13 on page 2-17). The pressure transmitters convert the fluid pressure at the HPU gauges to electrical signals to register the pressures on the electric meters on the Driller’s and Toolpusher’s control panels. The HPU junction box has the following alarm indicators and buttons installed on the front cover (see Figure 2-14 on page 2-18): 





Red Alarm Indicators: 

LOW ACCUMULATOR PRESSURE



LOW RESERVOIR FLUID PRESSURE



LOW INSTRUMENT AIR PRESSURE



EMERGENCY POWER ON

Green Alarm Indicators: 

DRILLER’S PANEL COMMUNICATION ERROR



TOOLPUSHER’S PANEL COMMUNICATION ERROR

Pushbuttons: 

LAMP TEST



ALARM ACKNOWLEDGE

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Pressing the “Alarm Acknowledge” button will silence the alarm horn. However, the alarm indicator lamp will remain illuminated until the fault is corrected. The “Lamp Test” button is used to verify there are no fused lamps and the horn is audible. The lamp test button should be pressed at the beginning of each shift to verify all lamps illuminate and the alarm horn sounds.

Gauge Panel The HPU is fitted with a number of gauges for monitoring of critical parameters. The HPU gauge panel (see Figure 2-15) has the following indicators: 

MANIFOLD PRESSURE (BOP)



ACCUMULATOR PRESSURE (BOP)



ANNULAR PRESSURE

Figure 2-15. HPU Gauge Panel Assembly

Bypass Valve The HPU/hydraulic control manifold bypass valve (see Figure 2-16) is intended for emergency use only. The bypass valve can be operated at the control panel or remotely from the Driller’s or Toolpusher’s control panel. During the drilling operation, the bypass valve remains in the normal “low” position, which allows 1,500 psi (103 bar) regulated pressure to flow to all functions in the hydraulic control manifold. In an emergency, the valve can be moved to the bypass “high” position, which allows the full 3,000 psi (207 bar) accumulator pressure to flow to all functions in the hydraulic control manifold.

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Introduction

Bypass Valve

MKR

Figure 2-16. Bypass Valve Assembly

In addition to the above, the accumulator bottles may be isolated and the electric pumps used to pump the rams closed.

4-Way Valves The HPU control manifold has manual and air-operated 4-way function valves and an Air Motor Koomey® Regular (AMKR) valve (see Figure 2-17). All BOP control functions can be activated from the HPU control manifold and can also be operated from the Driller’s or Toolpusher’s control panel.

AMKR

Figure 2-17. Four-Way Valves and AMKR Valve

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Air Cylinders On the HPU control manifold, functions that require remote operation are provided with air cylinders connected to the 4-way control valves. These functions can be operated from the Driller’s or Toolpusher’s control panel. When a function pushbutton is pressed on either of these control panels, an electric signal is sent to the appropriate solenoid-operated valve in the HPU control system junction box. The energized solenoid sends an air pilot signal to the selected air cylinder. The air pilot pressure shifts a piston inside the cylinder, and the piston shifts the valve handle.

Remote Control Panels In addition to the preceding, there are two remote control panels (see Figure 2-18): the Driller’s control panel and the Toolpusher’s control panel. The Driller’s control panel is enclosed in a stainless steel cabinet with buttons mounted on the front of the panel arranged to mimic the BOP system. The Toolpusher’s control panel is also enclosed in a stainless steel cabinet and duplicates the arrangement on the Driller’s control panel. The Driller’s and Toolpusher’s control panels are identical in operation and remotely operate the annular, pipe rams, blind rams, and choke/kill valves on the hydraulic control manifold on the HPU.

ii The remote control panels do not interfere with the manual operation of the control valves at the HPU hydraulic control manifold. The HPU valves may be remotely operated at the Driller’s or Toolpusher’s control panel or manually at the HPU.

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HPU/BOP Control System Page 2-22 of 24

Introduction

LOW ACCUMULATOR PRESSURE

ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

MANIFOLD PRESSURE

EMERGENCY POWER ON

COMMUNICATION ERROR

ANNULAR PRESSURE

PRESSURE INCREASE

ALARM ACKNOWLEDGE

RIG AIR PRESSURE

PRESSURE DECREASE

BYPASS

LOW

HIGH

PUMP 1 RUNNING

PUMP 2 RUNNING

ANNULAR

OPEN

CLOSE

UPPER PIPE RAM

OPEN

CLOSE

BLIND SHEAR

OPEN

CLOSE

CHOKE

OPEN

KILL

CLOSE

OPEN

CLOSE

LOWER PIPE RAM

PUSH & HOLD TO OPERATE

OPEN

CLOSE

LAMP TEST

Figure 2-18. Remote Control Panels

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Emergency Battery Back-up System

The emergency battery backup system is only used for the remote control of the BOPs. It does not supply power to run the triplex pumps.

The emergency battery backup system supplies 24 VDC power to the hydraulic power unit PLC junction box and the PLC in the Driller's and Toolpusher's control panel. In this manner the remote control panels and the HPU will remain operational until the main electric power is restored. Provided the battery packs are properly maintained, the emergency battery backup system can power the control system for approximately two hours duration. Before the battery power is depleted, the main electric power supply must be restored or the blowout preventer must be closed. For more information on the emergency battery backup system, refer to the component documentation section of this manual.

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Introduction

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Control Panel Theory of Operation A Programmable Logic Controller (PLC) system operates the HPU from the remote control panels. Commands from the remote control panels are encoded by the PLC's located in the remote control panels, and sent via fiber optic cables, for decoding and action by the PLC located in the HPU junction box. For example, while holding the “Push and Hold” to operate button, the driller initiates a function such as upper annular close, by pushing the “Upper Annular Close” button. This sends an encoded light signal via fiber optic cable to the PLC input block in the HPU junction box. The input block sends an encoded digital message to the Central Processing Unit (CPU) of the PLC’s Fiber Optic Communication (F.O. Comm.) modem. After the CPU agrees that the message is correct, the CPU sends it to the output block. The F.O. Comm. modem receives the message and sends an encoded signal through the fiber optic cable to the F.O. Comm. modem located in the hydraulic power unit Junction Box. The F.O. Comm. modem receives the signal and sends an encoded digital message to the CPU of the PLCs. The PLCs will read and identify the message. After the CPU agrees that the message is correct, the CPU sends it to the output block. At the output block, the message is found and a contact is closed. The closed contact then sends an electric signal to energize the solenoid, which is dedicated for the specific function, in this case “Upper Annular Close.” When the solenoid energizes, it sends air pressure to the actuator on the 4-way control valve on the HPU manifold. This moves the 4-way valve lever to the right. This allows regulated hydraulic pressure to flow through the 4-way valve and close the upper annular. The indicating lamps on the remote control panel are activated by the use of normally open pressure switches activated by the hydraulic pilot fluid sent to open or close the annular. The annular open close data is encoded by the PLC in the HPU junction box and sent via fiber optic cables, to the remote control panel PLC's for decoding and display. In this example, the green lamp was illuminated for the annular open function. However, when the annular “close” function was activated by the driller, this vented the pilot signal for the annular “open” function, which allowed the pressure switch to return to its normally open position, breaking the electric circuit to turn off the green indicator lamp. Conversely, the pilot signal for the annular “close” function also closes the pressure switch for that function. This completes the electric circuit, which turns the red indicator lamp on for the annular close function.

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HPU/BOP Control System Page 3-1 of 16

Installation and Operation Introduction This section describes the recommended installation and commissioning of the HPU/BOP control system and remote control panels. The following procedures are provided to ensure all equipment components are carefully inspected, correctly installed, and connected with the appropriate power supply before attempting operation. Prior to installation, the equipment should be visually inspected for any physical damage. Any item with physical damage should be replaced before attempting operational procedures.

Installation

The Driller's control panel (P/N 10658761-001), Toolpusher's control panel (P/N 10658763-001) and hydraulic power unit (P/N 10644181-001) are acceptable for installation in a Class 1 Division 2 area. However, the emergency Battery Backup (P/N 10659507-001) must be installed in a Safe Area.

1. Locate the HPU/BOP control system a safe distance from the wellbore. 2. Assemble the HPU/BOP control system as shown in the hydraulic/electrical block diagrams. 3. Install the uninterruptible power supply battery charger in a safe area that is convenient to the HPU/BOP control system and remote control panels. 4. Install the Driller’s control panel in an appropriate location on the drill floor. 5. Install the Toolpusher’s control panel in an appropriate location. 6. Install all hydraulic, pneumatic, and electrical supplies and interconnections as per the hydraulic and electrical block diagrams, general arrangement diagram, and hydraulic/pneumatic schematic located in Chapter 6, titled “Drawings and Bills of Materials”.

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Pre-Startup Procedures 1. Fill the reservoir to within six inches of the top with a pre-mixed fluid or concentrate and potable water. 2. Confirm that all pneumatic line lubricators have proper oil levels and all triplex pumps have been filled and checked in accordance with the following steps: a. Read the instructions located in the component documentation section of this manual. b.

Fill the power frame with the proper oil. See the Component Documentation titled “National Oilwell Varco BD-30 Pump” for lubricant specifications.

ii When changing the oil, remove the crankcase cover and clean the crankcase. Change crankcase oil more frequently under adverse conditions. Clean the crankcase at least once per year. See the Component Documentation titled “National Oilwell Varco BD-30 Pump” for oil types and temperatures.

c.

Check the plunger connections. The connections should be snug but not over-tight.

d. Check all cylinder bolting. e. Check the stuffing box for 360 contact with the cylinder. f.

Check all suction and discharge line valves for open position.

g. Clean the plunger rod, and then clear the drain hole. 3. Confirm that 460 VAC, 3 phase, 60 Hz electrical service is connected to the pump motor starter. Confirm that the motor overload setting is selected on each motor starter. Momentarily apply electric power to each motor, and then confirm correct rotational direction of the pumps. 4. Confirm that the nitrogen precharge in all accumulators is as shown in the hydraulic/pneumatic schematic. If the precharge is not correct, see the section titled “Checking Nitrogen Precharge Pressure in Accumulator Bottles” on page 4-2 for precharge instructions.

Triplex Pump Rotation For proper rotation, refer to the Component Documentation section titled “National Oilwell Varco BD-30 Pump”.

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BOP Line Flushing The following procedures require flushing of the supply and return line piping between the HPU and accumulator racks to be completed, the accumulator racks nitrogen precharge verified, and the interconnecting piping pressure tested and connected.

Wa r n

in g

Hydraulic fluid, air, and any particles in the lines will be blown free at high pressure when flushing the lines. All personnel must stay clear of the area of flow.

Fill the HPU mixed fluid reservoir to within six inches of the top with 2% Hydraulic Concentrate and fresh potable water. Start the triplex pump, and then allow the accumulator racks to be pressured to approximately 1,500 psi (103 bar).

When flushing is in process, check the reservoir fluid level on a regular basis.

Before connecting the HPU/BOP control manifold to the BOP system, follow this flushing procedure: 1. At the HPU control manifold, move all 4-way valves to the center (handle vertical) position, except the bypass (low) 4-way control valve. 2. At the HPU control manifold, adjust the annular and manifold regulators to approximately 300 psi (20 bar). 3. Secure all lines and hoses to be flushed. 4. At the HPU control manifold, move one 4-way valve handle from the center position to the left (open) position. 5. Flush the line for approximately five seconds, and then move the valve handle to the right (close) position. 6. After approximately five seconds, return the valve handle to the center position. 7. Repeat steps 4 through 6 for all remaining 4-way valves on the HPU control manifold. 8. When all flushing procedures are completed, check the HPU mixed fluid reservoir level, and then refill to the proper level with 2% hydraulic concentrate and potable water. 9. Connect all lines to the BOP stack. 10. To remove entrapped air open/close/open the BOP Rams and choke/kill valves three to four times.

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Installation and Operation

HPU/BOP Control System Page 3-4 of 16

Startup Procedure 1. Open the isolator valve on one 11-gallon accumulator header to 3,000 psi (206.84 bar). Leave all remaining accumulator headers closed off. Place all control valves in the center position. Place the manifold regulator bypass valve in the “low/regulated position.” 2. Prime the triplex pump by removing the plug in the cylinder head and then pouring control fluid mixture into the hole until full. Reinstall the plug. Each pump must be individually primed. 3. Start primary electric pump, and then allow it to charge the accumulator bank. Monitor and verify that the pump pressure switches turn pump on at 2,800 psi (193 bar) and off at 3,000 psi (206.84 bar). Check the system for leaks, and then correct as needed. Turn off the pump, and then bleed the pressure down to 2,400 psi (165 bar). 4. Start the secondary electric pump, and then verify its pressure switches turn the pump on at 2,750 psi (190 bar) and off at 2,900 (200 bar). Turn off the electric pumps. Adjust the pressure switches to achieve the desired operating (on/off) pressure. After adjustments are made on the pumps, complete the following steps: a. Check all gasketed joints for leakage. b.

Check for excessive stuffing box leakage. The stuffing box should leak approximately 5 or 6 drops per minute.

c.

Check the oil seals for leakage.

d. Check the power frame for overheating. e. If the stuffing box lubricator is furnished, adjust the rate of injection. The normal rate is approximately five drops per minute per plunger. f.

Schedule the power frame oil changes.

5. Adjust the manifold regulator to 1,500 psi (103 bar) and the annular regulator to 1,500 psi (103 bar). 6. Confirm that the system is free of leaks. 7. Confirm that all lines are properly connected to the BOP stack from the end of the control system piping. 8. Verify each function operated from the driller’s and toolpusher’s control panel matches the 4-way valve name tag on the HPU manifold.

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Installation and Operation

3

Pre-Operational/Commissioning Testing Procedures 1. Turn on 24 VDC to energize the remote control panels. Confirm that the panels turn on and indicate “no faults” or “alarms.” 2. Turn on the electric pumps, and then pressure the system to 3,000 psi (206.84 bar) (it may be necessary to bleed the system down in order for the pumps to start). Verify the pressures at the remote control panels. Accumulator pressure should read 3,000 psi (206.84 bar), and both manifold and annular pressures should read 1,500 psi (103 bar). Turn the electric pumps off, and then slowly bleed the system down. As system pressure drops below 2,000 psi (138 bar), confirm that the low accumulator pressure light begins blinking and the horn sounds. 3. Ensure the instrument air supply to the HPU is open. Verify the air pressure at the remote control panels. Close off the air supply, and then slowly bleed the air from the system. Verify that as the system air pressure drops below 60 psi (4 bar), the low instrument air light begins blinking and the horn sounds

In the following step 4, do not allow the reservoir fluid level to drop below the triplex pump’s suction line.

4. Open all remaining accumulator bottles on the main system. Turn on the electric pump, and then confirm that the low fluid level light begins blinking and the horn sounds. Turn the pumps off, and then fill the reservoir with fluid mix. Monitor the system for the remainder of pressure-up to ensure that the proper level of fluid is maintained in the reservoir. 5. Install the test pipe in the BOP stack (ensure that the pipe size is correct for the rams installed). From the HPU, operate the annular, upper and lower pipe rams close and open. Confirm proper operation of the BOP after each function. Confirm proper illumination of the lamps on the remote control panels after each function. 6. From the remote control panels, increase and decrease the manifold pressure and annular pressure output two times. Reset to 1,500 psi (103 bar). Confirm proper operation of each valve on the HPU after each function. Confirm proper illumination of the lights on the remote control panels after each function. 7. Confirm the Driller’s and Toolpusher’s control panels open/close the proper 4-way valve on the HPU manifold and that the BOP open/close/open the proper rams and valves.

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Installation and Operation

Operation The BOP is ready for operation upon completion of pre-operational/commissioning function testing procedures. If the unit has been shut down for an extended period of time, ensure the recommended checks have been made as per the table titled “Operational Check List” prior to operating. Be sure to observe the safety precautions in the section titled “General Safety Precautions” on page 1-4.

Operational Check List Electrohydraulic Pumping Unit

Check OK

Check nitrogen precharge: set per sizing calculation (see "Checking Nitrogen Precharge Pressure in Accumulator Bottles" on page 4-2). Check oil level electric pump (see "Pre-Startup Procedures" on page 3-2). Check air lubricator; fill with SAE-10W oil. Check reservoir fluid level (see "Pre-Startup Procedures" on page 3-2). Set bypass in “low” position. Open electric pump suction valve. Open all accumulator valves. Verify hydraulic filter supply valve is open and vent valve is closed. Function Driller’s control panel. Verify function at HPU. Function Toolpusher’s control panel. Verify function at HPU. Verify pump #1 stops at 3,000 psi (206.84 bar). Verify pump #2 stops at 2,900 psi (200 bar). Function Driller’s control panel. Verify function at BOP equipment. Function Toolpusher’s control panel. Verify function at BOP equipment.

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Installation and Operation

3

Hydraulic Pump Unit The HPU provides the necessary high-pressure hydraulic fluid for control of the blowout preventer stack. The HPU is equipped with two electric-driven hydraulic pumps. These pumps discharge high-pressure hydraulic fluid into storage vessels called accumulator bottles. These bottles are precharged with compressible inert nitrogen gas. When fluid is introduced into the accumulator bottles, the nitrogen is compressed and stores a tremendous amount of potential energy. Accumulator bottles are bladder-type bottles. All NOV Koomey® accumulator units operate on the same principle. The electric-operated hydraulic pumps are supplied with fluid from the reservoir through suction strainers. These pumps produce high-pressure hydraulic fluid, which is stored in the accumulator bottles.

Keep the accumulator nitrogen precharge at the recommended pressure. Failure to do so will aerate the fluid and reduce the nitrogen volume. This will reduce the usable fluid stored in the accumulators.

Each electric-operated pump is equipped with a hydroelectric pressure switch, which shuts off and restarts the pump at specific levels (see Figure 3-1).

Motor Starter J-boxes

Figure 3-1. Motor Starter Junction Box

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Installation and Operation

Control Manifolds The control manifolds direct the flow of the high-pressure hydraulic fluid produced by the triplex pumps through two high-flow, shear-seal regulators (see Figure 3-2): 

One AMKR valve to regulate pressure to the BOP annular preventer.



One MKR valve to regulate pressure to the valve manifold.



The manifold MKR is equipped with a bypass valve, which bypasses the regulator and supplies 3,000 psi (207 bar) hydraulic pressure directly to the ram preventers or choke/kill valves.

The regulated pressure from the MKR valve is directed through 4-way shear-seal control valves. The “Open” and “Close” ports of these valves are connected to the “Open” and “Close” side of the preventers. Each manifold provides independent supply to each regulator, which is essential for safe and dependable operation. Each control valve is supplied with nameplates to indicate “Open” and “Close” positions. The valves should always be in either the left or right position. Never center the control valve handle because this will block both control ports. The control valves are equipped with pneumatic cylinders for remote operation. The bypass valve is used to direct regulated pressure or unregulated hydraulic pressure to the ram and gate valve control manifold. In the left (low) position, this valve directs fluid from the MKR manifold regulator to the welded supply header. In the right (high) position, this valve directs fluid from the pump discharge to the welded supply header and shuts off the regulated pressure. The bypass valve should only be used in the “High” position for emergencies.

Manifold Valves Bypass Valve MKR

Figure 3-2. Manifold Pressure Reducing and Regulating MKR Valve, Bypass Valve, and Manifold Valves

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Installation and Operation

3

Remote Control Panels and HPU Junction Box The remote control panels are connected to the pilot control manifold through fiber optic control cables. The control cables are terminated from the HPU J-Box to each of the two remote control panels. Also, an emergency battery back-up system is connected to each of these panels (see block diagram in Chapter 6, titled “Drawings and Bills of Materials”). The operation of the remote control panels are similar. pushbuttons located on the control panels are used to generate the signals to the pilot solenoid valves located in the HPU junction box (see Figure 3-3 on page 3-10). Each 4-way valve mounted on the pilot control manifold has an associated pilot actuator, which is tubed to the pilot control manifold junction box. These pilot actuators are connected to the 4-way valves by means of linkage. When a pushbutton on the control panel is activated, the pilot solenoid valve permits air pressure to flow to the control valve pilot actuator. This causes the actuator to extend or retract, and the 4-way valve handle is then moved to the selected open/close position. When a function is selected, the pressure switch, located on the junction box on the HPU, senses the hydraulic pressure and illuminates a lamp on the control panel, which corresponds to the pushbutton activated. Manifolds, which have an air-operated regulator, incorporate Increase/Decrease pushbuttons on the control panel. Activation of the Increase pushbutton will cause the pressure to increase. Activation of the Decrease pushbutton will cause the pressure to decrease. Electric pressure transmitters/switches on the junction box (see Figure 3-3 on page 3-10) send a signal to the remote control panel to activate the appropriate pressure readback meter in the panel. These meters mimic the hydraulic pressure reading on the HPU panel gauges. Readback pressure is provided for the following: 

Rig Air Pressure



Manifold Pressure



Accumulator Pressure



Annular Pressure

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Installation and Operation

PLC

Solenoids

24VDC Power Supply

Fiber Optic Connection

Figure 3-3. Junction Box

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Installation and Operation

3

Emergency Battery Back-up/Battery Charger

ii The emergency battery charger back-up system must be installed in a safe area.

ii The emergency charger battery back-up system does not supply power to run the triplex pumps.

If the main electric power supply is unavailable, the emergency charger battery back-up system (P/N 10659507-001) supplies 24 VDC power to the hydraulic power unit PLC junction box and to the remote control PLC panels. Provided the batteries are properly maintained, the emergency battery back-up will supply 24 VDC power to the HPU and remote control panels for two hours. In this manner, the HPU will remain operational until the electric power stored in the battery back-up system is depleted. Before this occurs, the main electric power supply must be restored or the blowout preventer closed. For more information on the emergency battery back-up system/battery charger, refer to the 24DC battery charger user’s manual in the component documentation section of this manual.

Remote Control Panel Operation The Driller’s control panel is enclosed in an explosion-proof box with buttons mounted on the front of the panel arranged to mimic the BOP system. The Toolpusher’s control panel is also enclosed in a stainless steel cabinet and duplicates the arrangement on the Driller’s control panel. Although the Driller’s control panel and the Toolpusher’s control panel are two separate units, they are functionally identical in operation. The Driller’s control panel and Toolpusher’s control panel are suitable for installation in a Class 1, Division 2 area. The Driller’s control panel and the Toolpusher’s control panel provide two options for control and monitoring of the BOP control system. Usually, the BOP stack control system is operated from the Driller’s control panel. However, if the Driller’s control panel is disabled or inaccessible, BOP functions can be controlled from the Toolpusher’s control panel. In an emergency where both control panels are inaccessible, the BOP can be operated from the hydraulic power unit (HPU).

Controls and Functions The Driller’s control panel (see Figure 3-4 on page 3-12) is supplied with the following controls: 

Illuminated pushbuttons to activate functions



Pushbuttons to activate functions

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HPU/BOP Control System Page 3-12 of 16

Installation and Operation



Pressure meters to monitor system pressure



Indicator lamps to monitor system operation



Increase/Decrease pushbuttons to adjust annular pressure



Alarm panel to alert rig personnel of system faults



HPU triplex pump status indication lamp

LOW ACCUMULATOR PRESSURE

ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

MANIFOLD PRESSURE

EMERGENCY POWER ON

COMMUNICATION ERROR

ANNULAR PRESSURE

PRESSURE INCREASE

ALARM ACKNOWLEDGE

RIG AIR PRESSURE

PRESSURE DECREASE

BYPASS

LOW

HIGH

PUMP 1 RUNNING

PUMP 2 RUNNING

ANNULAR

OPEN

CLOSE

UPPER PIPE RAM

OPEN

CLOSE

BLIND SHEAR

OPEN

CLOSE

CHOKE

OPEN

KILL

CLOSE

OPEN

CLOSE

LOWER PIPE RAM

PUSH & HOLD TO OPERATE

OPEN

CLOSE

LAMP TEST

Figure 3-4. Driller’s Control Panel

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Installation and Operation

3

The Toolpusher’s control panel (see Figure 3-5) is supplied with the following controls: 

Illuminated pushbuttons to activate functions



Pushbuttons to activate functions



Pressure meters to monitor system pressure



Indicator lamps to monitor system operation



Increase/Decrease pushbuttons to adjust annular pressure



Alarm panel to alert rig personnel of system faults



HPU triplex pump status indication lamp

LOW ACCUMULATOR PRESSURE

ACCUMULATOR PRESSURE

LOW FLUID LEVEL

LOW RIG AIR PRESSURE

MANIFOLD PRESSURE

EMERGENCY POWER ON

COMMUNICATION ERROR

ANNULAR PRESSURE

PRESSURE INCREASE

ALARM ACKNOWLEDGE

RIG AIR PRESSURE

PRESSURE DECREASE

BYPASS

LOW

HIGH

PUMP 1 RUNNING

PUMP 2 RUNNING

ANNULAR

OPEN

CLOSE

UPPER PIPE RAM

OPEN

CLOSE

BLIND SHEAR

OPEN

CLOSE

CHOKE

OPEN

KILL

CLOSE

OPEN

CLOSE

LOWER PIPE RAM

PUSH & HOLD TO OPERATE

OPEN

CLOSE

LAMP TEST

Figure 3-5. Toolpusher’s Control Panel

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Installation and Operation

HPU/BOP Control System Page 3-14 of 16

Button Safety Features There are two safety features on the control panels that are designed to prevent accidental operation of critical BOP functions. These are as follows (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13): 

PUSH/HOLD TO OPERATE button — The PUSH/HOLD TO OPERATE pushbutton is located on the lower left side of each control panel. Each panel requires this button to be held down continuously with one hand while the appropriate function button is operated with the other hand. This two-handed operation prevents accidental operation of any function.



Button covers — These acrylic covers are mounted over certain critical BOP stack functions and must be lifted before the function buttons can be operated. The covers prevent accidental activation of any of the critical BOP functions.

LAMP TEST Pushbutton The LAMP TEST pushbutton on the Driller’s and Toolpusher’s control panels (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13) enables rig personnel to quickly locate any burned-out lamps. The LAMP TEST pushbutton should be pressed at the beginning of each work shift to confirm that all lamps are operational. All panel lamps will remain illuminated and the alarm horn will sound until the LAMP TEST pushbutton is released.

ii The LAMP TEST pushbutton does not require the PUSH /HOLD TO OPERATE pushbutton to be activated.

INCREASE/DECREASE Pushbutton The INCREASE/DECREASE pushbutton on the Driller’s and Toolpusher’s control panels (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13) is used to alter the Annular and Diverter hydraulic system pressure. Adjusting the pressure requires the PUSH/HOLD TO OPERATE pushbutton to be pressed and maintained while the INCREASE/DECREASE pushbuttons are operated. The pushbuttons must be held until the required pressure is reached as indicated on the control panel pressure meter.

Pressure Indicators There are four pressure indicators on the Driller’s and Toolpusher’s control panels as follows (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13): 

MANIFOLD PRESSURE – 0 to 5,000 psi (345 bar)



INSTRUMENT AIR PRESSURE – 0 to 300 psi (21 bar)



ACCUMULATOR PRESSURE – 0 to 5,000 psi (345 bar)



ANNULAR PACKER PRESSURE – 0 to 3,000 psi (207 bar)

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Installation and Operation

3

ALARMS Located on the upper-left side of the Driller’s and Toolpusher’s control panels (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13) is a group of red indicator lights/alarms. These are the warning–low/fault lamps, which signal low system pressure, low air pressure, low fluid level, and emergency power on. Should an abnormal condition occur, a horn will sound and a flashing red lamp will illuminate on the control panels and HPU hydraulic control manifold junction box to identify the problem.

ALARM ACKNOWLEDGE The driller may silence the audible horn by pressing the ALARM ACK (“alarm acknowledge”) button (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13). This will silence the horn alarm, and the flashing red lamp will stop flashing. However, the lamp will continue to be illuminated until the problem is corrected. The alarm will reset when the problem is corrected.

BYPASS Valve Pushbuttons The BYPASS valve pushbuttons can be operated from the Driller’s or Toolpusher’s control panel (see Figure 3-4 on page 3-12 and Figure 3-5 on page 3-13), or they may be manually operated from the HPU/hydraulic control manifold. The HPU/hydraulic control manifold bypass valve is intended for emergency use only. During the drilling program, it remains in the normal “low” position, green lamp illuminated. In an emergency, this valve can be moved to the bypass “high” position, red lamp illuminated. When in the “high” bypass position, it allows the full 3,000 psi (307 bar) accumulator pressure to flow to all functions on the HPU/hydraulic control manifold. The driller should consider using this function before shearing pipe in the BOP stack. In addition to the above, in an emergency when accumulator bottle rack pressure is low, the bypass valve should be placed in the “high” position and the accumulator bottle racks isolated. Then the electric pump can be used to pump the rams closed.

System Testing General System Testing The entire blowout preventer control system should be tested at least once a week. Testing should include operating all functions from the remote control panels to ensure all functions operate as intended. The steps outlined below should be a part of the testing: 1. Operate all the 4-way valves to both “Close” and “Open” position. 2. Operate the regulators through the entire operating range, normally 0 to 1,500 psi (0 to 103 bar). Be careful not to overpressure the annular. The annular blowout preventer should never be completely closed over an open hole during testing because this shortens the element life considerably. 3. Observe all hydraulic gauges for correct operation. 4. Bleed the system completely down, and allow the pumps to recharge the system to operating pressure. Observe the pumps for normal operation.

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Installation and Operation

HPU/BOP Control System Page 3-16 of 16

Remote Operated Panels Operate all buttons and make sure that each function on the panel is operating the corresponding 4-way valve on the master hydraulic manifold to the proper position. When controlling the annular pressure by remote, push the Increase/Decrease buttons and make sure that the panel meter pressure reading corresponds to the annular pressure gauge located on the HPU gauge panel.

Conditions Requiring Investigation Any of the following conditions should be investigated to determine their root cause and establish if any maintenance or repair to system components is required maintenance or repair to system components is required: 

Unusual noise or vibration



Electrical arcing, smoke, or fire



Unexplained reduction of fluid flow or pressure, system jerkiness, or erratic operation



Unexplained stoppage of components



Excessive motor or pump drive or component vibration or overheating



Hot pressure-containing surfaces



Fluid leakage, seepage, or high-pressure fluid spray from components or piping

Wa r n

in g

High-pressure fluid spray can cause serious injury. Do not attempt to cover or restrict high-pressure fluid spray with hands or other body parts, with or without protective clothing or gear. Do not attempt to tighten leaking pressurized connections. Failure to heed this warning can cause severe bodily injury.

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HPU/BOP Control System Page 4-1 of 50

Maintenance Preventive Maintenance The table below shows the preventive maintenance program for components of the HPU/BOP control system. Recommended frequencies are given. However, the user may revise the maintenance schedule based on how frequently the equipment is operated. Throughout the Maintenance chapter, numbers in parentheses correspond to the item numbers on the engineering drawing for the component. The preventive maintenance procedures in this table should be used as a quick reference to accompany the detailed preventive maintenance procedures beginning on page 4-2. Preventive Maintenance Schedule Check Daily

7 Days

14 Days

Item

Procedure

Accumulator bottles

Check precharge (see “Checking Nitrogen Precharge Pressure in Accumulator Bottles” on page 4-2).

Air Filter

Drain filter (see “Filters, Strainers, Air Lubricators, Air Regulators” on page 4-3).

Y-Type Strainer

Clean element (see “Filters, Strainers, Air Lubricators, Air Regulators” on page 4-3).

Air Lubricator

Check oil level (see “Filters, Strainers, Air Lubricators, Air Regulators” on page 4-3).

Electric Pump

Check packing glands. Check crankcase oil. Check V-belt drive.

4-Way Control Valves

Oil detent. Grease body (see “4-Way Hydraulic Control Valves” on page 4-9).

Air-Motor Driven/Manual Regulating Valves

Operate through range of pressures. See “1” AMKR Pressure Reducing and Regulating Valve (P/N 1000539)” on page 4-42.



Check fluid levels. Refill if necessary. Check for sludge. Flush if necessary (see “Fluid Reservoirs” on page 4-8).



Fluid Reservoir

Electrical Junction Box

Open and inspect for corrosion and dampness; replace desiccant pellets (see “Motor Starter Junction Boxes” on page 4-9).

30 Days

90 Days

   





  



 

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HPU/BOP Control System Page 4-2 of 50

Maintenance

Checking Nitrogen Precharge Pressure in Accumulator Bottles

When transporting pre-charged accumulator bottles, it is recommended that the pre-charge pressure be 35 psi (2.4 bar) max. Refer to the section titled “Transporting Equipment” on page 1-2.

Check the nitrogen precharge in all accumulator bottles every 30 days. The accumulator bottle rack assemblies should be charged per the sizing calculation (see Chapter 6, titled “Drawings and Bills of Materials”). 1. Shut off the electric triplex pumps. 2. Bleed the pressure from all accumulator bottles, and then check the nitrogen precharge. The precharge pressure should be as specified.

ii If precharging is required, use only dry nitrogen gas.

If precharging is necessary, perform the following steps: a. On the HPU, open the accumulator bleed valve to bleed the system. The accumulator bank pressure gauge should read 0 psi (0 bar). Close the bleed valve.

ii If the system is to continue operating during precharging procedures, close the accumulator isolator valve and operate the system with the pump.

b.

Remove the guard from the top of the accumulator bottle. Connect the gauging head assembly to the precharging valve at the top of the accumulator bottle. For an exploded view of the charging and gauging assembly, see Figure 5-1 on page 5-2.

c.

Screw down the T-handle of the gauging head assembly to check the nitrogen precharge pressure in the accumulator bottle.

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Maintenance

4

d. If the precharge pressure is low, attach the swivel connector and hose of the charging and gauging assembly to the gauging head assembly. Connect the gland of the charging assembly to the nitrogen bottle. Open the valve on the nitrogen bottle slowly to prevent damage to the valve core. Charge the accumulator bottle until the gauge reads the desired pressure. Close the valve on the nitrogen bottle. Wa r n

in g

Always use inert nitrogen gas for precharging. Do not use compressed air. Air is highly explosive, and serious injury or death to personnel could occur.

e. Remove the charging and gauging assembly from the accumulator bottle. 3. After checking the precharge, apply one drop of light oil to the charge valve stem to check for nitrogen leakage. Do not use saliva because it is corrosive. 4. Lightly grease the threads of the bottle caps before replacing the caps.

Filters, Strainers, Air Lubricators, Air Regulators Air Filter Drain the air filter at least once per work shift to keep the liquid level in the bowl below the filter baffle. If the liquid level rises above the baffle, the liquid will re-enter the air stream and be carried downstream. 1. To drain the air filter, back off the manual drain cock at the bottom of the filter and let the air blow all accumulated liquids and solids out of the filter. Tighten the drain cock. 2. Remove and clean the filter element periodically. Wash the filter element with kerosene or a similar cleaner compatible with polycarbonate. Blow the filter element dry with compressed air.

Y-Type Strainer 1. Ensure there is no hydraulic pressure to the strainer. 2. Remove the pipe plug from the lower arm of the Y-body. 3. Remove and clean the strainer element. 4. Reinsert the strainer element into the Y-body. 5. Replace the pipe plug. 6. When the system is pressurized, check for leaks around the pipe plug.

Air Lubricators 1. Check the air lubricators daily, and then refill with SAE-10W lightweight oil as required. 2. Drain the water trap daily.

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Maintenance

High Pressure Hydraulic Filter (P/N 10649451-001) Wa r n

in g

Vent all hydraulic pressure to 0 psi (0 bar) before attempting to remove the filter bowl to clean or replace the filter element. Failure to heed this caution may cause severe injury or death to personnel.

The 25-micron hydraulic filter element should be inspected periodically to establish a timeframe on when to clean or replace the filter element. The element should be immersed in an ultrasonic cleaner tank using Cavi-clean or Varisol liquid cleaner and Safety Clean rinse. Prior to installing the filter bowl, coat the threads on the bowl with aluminum paste or a quality anti-seize lubricant such as Sweeney 503 Moly Paste (P/N 7403582).

Hydraulic Filter (P/N 10649451-001) Qty.

Description

Part No.

1

25-Micron Filter

10649615-001

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Maintenance

4

Junction Box Pressure Switch The pressure switches are located on the HPU junction box. The pressure switches are factory preset. To adjust the pressure switch, refer to the document titled “Barksdale Adjustment Instructions” located in the component documentation section of this manual.

Figure 4-1. Pressure Switch

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Maintenance

HPU/BOP Control System Page 4-6 of 50

Triplex Pumps For triplex pump preventive maintenance, see the section titled “National Oil Varco BD-30 Pump” in the component documentation section of this manual.

Triplex Pump Pressure Switch (P/N 20086694) For adjustment of the triplex pump pressure switch, see the section titled “Barksdale UDS7-BX Operating Instructions” located in the component documentation section of this manual.

Tensioning Banded Belts The electric motor that drives the triplex hydraulic pump uses multi-band belts. The tension on new belts must be verified and readjusted after the first 24 hours of operation. After being re-tensioned, the belts should be visually inspected weekly for general condition and then re-tensioned every two months if necessary.

Alignment of V-Belt Drives All V-belt drives must be in proper alignment to prevent excessive wear. The driver and driven shafts must be parallel and the V-belts at right angles to these shafts. Misalignment will cause belts to wear or turn over in the sheave grooves. Check alignment by placing a straightedge evenly across the rims of both sheaves. If the faces of the sheaves are not of equal width, check the alignment by resting the straightedge across the wider sheave and measuring the distance from the straightedge to the nearest belt groove with a scale. Adjust either sheave on the shaft to equalize these dimensions.

Tensioning V-Belt Drives During the first few days of operation, the belts will seat themselves into the grooves. Therefore, the drive must be retightened to take up the slack and prevent the belts from slipping. Keep the belts clean and free from oil. Use a cloth dampened with soap and water to clean oily belts. Squealing belts are often, but not always, the clue to slipping belts. Use a tachometer to check the pump speed. Pump speed should equal driver speed multiplied by driver sheave pitch diameter divided by pump sheave pitch diameter.

Do not pry, twist, or force the belts over the sheave grooves. Shorten the drive enough to permit fitting the belts into the grooves without using force. Failure to heed this caution may damage the belts and reduce their life.

Never install new belts on the same drive with used belts. Replace belts in sets.

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4

Maintenance

Establishing proper tension in single and multiple V-belt drives requires the use of a small spring scale, applied at the center of the belt span (see Figure 4-2).

Deflection

Belt Span

Figure 4-2. V-Belt Span and Deflection

Apply spring tension to the tightest belt of the set, and then compare belt force and deflections in the table titled “Belt Tensioning USA” on page 4-7 (or the table titled “Belt Tensioning Metric” on page 4-8). Then read the applied scale force and adjust as required; tighten or slacken the belt until the proper force and belt deflection are achieved.

Belt Tensioning USA

Belt Size Section

Force Normal Tension (lb)

Force New Belts (lb)

Approximate Belt Span (in.)

Belt Deflection (in.)

A

1.5 to 2.25

2.25 to 3.0

20

5 16

B

3.25 to 5.0

5 to 6

24

3 8

C

6.5 to 9.75

9.75 to 13

28

7 16

D

11 to 16.5

16.5 to 22

32

1 2

3V

4 to 5.5

5 to 7

40

5 8

5V

9.5 to 11.5

11.5 to 14.5

48

3 4

8V

22 to 29

29 to 35

60

15 16

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Maintenance

Belt Tensioning Metric

Belt Size Section

Force Normal Tension (kg)

Force New Belts (kg)

Approximate Belt Span (mm)

Belt Deflection (mm)

A

0.68 to 1.02

1.02 to 1.36

508.0

7.9

B

1.47 to 2.27

2.27 to 2.72

609.6

9.5

C

2.95 to 4.42

4.42 to 5.9

711.2

11.1

D

4.99 to 7.48

7.48 to 9.98

812.2

12.7

3V

1.81 to 2.49

2.27 to 3.18

1016.0

15.9

5V

4.31 to 5.22

5.22 to 6.58

1219.2

19.1

8V

9.98 to 13.15

13.15 to 15.88

1524.0

23.8

Low Accumulator Pressure Switch Every 90 days or between rig moves, check the operation of the low accumulator pressure switch. The low accumulator pressure alarm will activate when the accumulator pressure drops below 2,000 psi (137.89 bar). Verify pressure switch operation as follows: 1. Stop the triplex pumps. 2. Isolate the accumulator bottle racks. 3. Open the HPU vent needle valve. 4. Monitor the accumulator pressure gauge. 5. When the alarm activates, close the HPU vent needle valve. 6. Open the accumulator bottle racks. 7. Start the triplex pumps. If the low accumulator pressure alarm does not activate, readjust or replace the pressure switch (see the section titled “Junction Box Pressure Switch” on page 4-5).

Fluid Reservoirs It is recommended that fluid samples be taken from the reservoirs every 60 days or at the maximum timeframe of three months. These fluid samples should be sent to an approved test facility for evaluation. If the samples indicate bacteria growth, the contaminated reservoir should be drained into suitable containers and disposed of in an approved manner. The reservoir should be flushed with potable water, steam cleaned, and air dried. The contamination must also be removed from the hydraulic control system. Refer to the fluid concentrate supplier for the appropriate system cleaner product and procedures to sterilize the control system fluid.

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Maintenance

4

Low-Level Alarm Float Switch (P/N 4550004) Located on the fluid reservoir is a low-level alarm float switch (P/N 4550004). If the fluid level in the reservoir drops below the low-level float switch, the switch closes, energizing the audible alarm on the HPU junction box and illuminating the red “Low Fluid Level” indicator lamp. It is recommended to check the reservoir low-level alarm every 30 days by allowing fluid to be drained to verify that the low fluid level alarm system functions properly.

4-Way Hydraulic Control Valves The 4-Way control valves should be serviced as recommended in the table titled “Preventive Maintenance Schedule” on page 4-1. Periodically dismantle the valves for inspection and cleaning. Wash all metal parts with kerosene or a solvent with similar characteristics. Wash all seals with soap and water, and then examine the seals for cracks or signs of wear. Dry all parts with a low-pressure air jet. Replace all worn or defective parts.

Motor Starter Junction Boxes Inspect the junction boxes every 90 days as follows: 1. Turn electric power off. Lock or remove the breaker. 2. Open and inspect the interior of the junction box for corrosion or dampness. Replace the desiccant each time the box is opened. 3. Keep the box closed except when servicing.

Alarm Junction Box The alarm system PLC is inside the junction box. On the left of the junction box are the pressure switches and pressure transmitters. Located on the front of the junction box are the alarm indicator lamps, Lamp Test pushbutton, and Alarm Acknowledge pushbutton. All the components in the junction box are not repairable; see Chapter 6, titled “Drawings and Bills of Materials” for component part numbers. The only required routine maintenance is to push the Lamp Test pushbutton on the junction box and replace any fused lamp bulbs.

MKR and AMKR Pressure Regulating Valves The internal seals of the valves can lose their effective sealing if not operated on a regular interval. It is recommended that MKR and AMKR valve hydraulic pressure be reduced by 21 to 34 bar (300 to 500 psi) and returned to the original pressure setting on a daily basis. This will assist in maintaining smooth valve operation and preventing premature valve seal leakage. The MKR and AMKR valves should be operated on regular intervals and serviced on a yearly basis or whenever seal leakage is evident (see the section titled “Corrective Maintenance” on page 4-11 for repair procedures).

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Maintenance

Remote Control Panels The components on the remote control panels are not repairable; see Chapter 6, titled “Drawings and Bills of Materials” for component part numbers. The only required routine maintenance is to push the Lamp Test pushbutton on the control panel and replace any fused lamp bulbs. Use a damp cloth to clean the panel face, and then lightly lubricate the pushbuttons using a food-degradable silicone spray (P/N 1877044). On a daily basis, verify that the pressure meters on the control panels match the pressure indicated on the HPU pressure gauges. If the pressure meter readings are in error, refer to the configuration procedures in the document titled “Beka Meter Manual”, located in the component documentation section of this manual.

Emergency Battery Back-up Refer to the document titled “Falcon Operating Manual”, located in the component documentation section of this manual.

Conditions Requiring Investigation Any of the following conditions should be investigated to determine the root cause and establish whether any maintenance or repair to system components is required: 

Unusual noise or vibration



Electrical arcing, smoke, or fire



Unexplained reduction of fluid flow or pressure, system jerkiness, or erratic operation



Unexplained stoppage of components



Excessive motor or pump drive or component vibration or overheating



Hot pressure-containing surfaces



Fluid leakage, seepage, or high-pressure fluid spray from components or piping

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High-pressure fluid spray can cause serious injury. Do not attempt to cover or restrict high-pressure fluid spray with hands or other body parts, with or without protective clothing or gear. Do not attempt to tighten leaking pressurized connections. Failure to heed this warning can cause injury to personnel.

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Maintenance

4

Corrective Maintenance The following sections provide troubleshooting information for specific equipment at the HPU. Troubleshooting should be done only when it is safe to disconnect the hydraulic power unit from the BOP stack, or when it is safe to operate the control system and BOP stack. The following troubleshooting recommendations should determine the more common malfunctions of the BOP control unit and associated manifold. Due to the complexity of the hydraulic circuitry and its components, not every possibility can be covered. If a problem has not been located after following these basic troubleshooting procedures, or if the system is custom designed and unique, contact the nearest NOV service office or distributor of NOV equipment.

System Leaks The most normal indication of a malfunction in a BOP control unit and control manifold is the continuous running of the air-operated pump (if installed). This suggests there is a leak in the system. If the unit is equipped with only electric pumps and these pumps periodically turn on without any operation having been performed, this also suggests a leak in the system. If either of these conditions occurs, the following inspections should be performed.

Piping 1. Check all external piping on the unit for visible leaks. The open and close line piping from the BOP control unit to the BOP stack should also be inspected. If no visible leaks are present, continue as follows. 2. Remove the 4” (102 mm) plugs from the ends of the reservoir, and then inspect the return lines from the components on the manifold. If a leak is detected, determine which component on the manifold is venting into the reservoir. By centering the 4-way valves one-by-one while looking into the reservoir, if the leak stops when a particular valve is centered, then that valve is associated with the problem. If the leak is from a component other than the 4-way valves, by estimating visually where the leaking return line enters the reservoir, a determination can be made as to which component is leaking. If there is no fluid returning to the reservoir indicating a leak, disregard the section titled “4-Way Valve” on page 4-11 through the the section titled “Bleeder Valve on the Manifold” on page 4-12, and go to the section titled “Miscellaneous Leak Causes” on page 4-13.

4-Way Valve 1. One of the 4-way valves could be leaking internally. Turn off the electric-operated pump, and then shut off the air valve to the air-operated pump (if installed). 2. Close the accumulator shutoff valves. 3. Open the manifold bleeder valve to vent the entire system, and then open and close the function valve to vent pressure from the line going to the preventer. 4. Disconnect the open and close BOP lines coming from the valve in question, and then put high-pressure plugs in their place. 5. Turn on the electric pump, and then place the valve in the position in which it was when a leak was detected. If the leak continues, the valve should be repaired. If no leak occurs, test the valve in all three positions (open, center and close). If there still is no visible leak, then the leak may be in the preventer.

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Maintenance

6. Bleed down pressure, remove the plugs, and reconnect the open and close lines to the preventer. Pressure up, place the valve in the position in which it had leaked before (open or close), and check the inside of the reservoir to see whether the leak has resumed. If the valve is again venting into the reservoir, then the preventer is leaking internally, either from the open chamber into the close chamber, or from close to open, then returning to the reservoir.

Pressure Reducing and Regulating Valve for the Annular Preventer Remove the 4” plug located near the top of the reservoir, and then observe the return lines for fluid leaks. The annular regulator may be adjusted manually at the HPU or by remote operation from the Driller’s or Toolpusher’s control panel. The remote operation is achieved by an air-driven motor on the regulator.

ii Leaking seals in the annular preventer itself are often the cause of the short working life of the regulator that controls pressure to the annular. Check the 4-way valve as per the section titled “4-Way Valve” on page 4-11 to determine whether the leak stays in the preventer and returns to the reservoir through the 4-way valve that controls the preventer. In addition, fluid can frequently leak into the wellbore undetected. If a regulator operates only a short time before it begins to leak through its seals, perform a hydrostatic test on both the open and close side of the annular to determine whether the leak is actually through the preventer and into the wellbore, thereby causing the regulator to operate continuously and wear out more rapidly.

Pressure Reducing and Regulating Valve for the HPU Control Manifold Remove the 4” (102 mm) plug near the top of the reservoir, and then observe the return lines for leaks. If a leak is detected, remove and replace the valve.

Accumulator Relief Valve Remove the 4” (102 mm) plug near the top of the reservoir, and then observe the return lines for leaks. If the valve is leaking, replace the complete valve.

Bleeder Valve on the Manifold Remove the 4” (102 mm) plug near the top of the reservoir, and then observe the return lines for leaks. If this valve is leaking, replace it.

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Maintenance

4

Miscellaneous Leak Causes If no leaks have been detected in the previous steps, then the problem may be in the pumping system, or it may be that the system is losing operating pressure downstream of the BOP control unit (the lines to the BOPs or the BOPs themselves may be leaking). Center all of the 4-way valves on the manifold. If the pumps stop running, there is a strong possibility that the leakage is occurring downstream of the BOP control unit and manifold. Any pumps that continue to run should be checked individually for a malfunction or other problem.

Electric Pumps The procedure listed below indicates the proper method for troubleshooting the electric pumps: 1. Check the fluid reservoir level to ensure that the hydraulic fluid is sufficiently above the pump suction lines tied into the reservoir. If the level is too low, the pumps will continue to run but will not produce any pressure. After adding more fluid to the reservoir, the pumps may need to be primed by removing the pipe plug on the discharge side of the pump and filling with fluid. Replace and tighten the plug.

When starting the electric pumps, always make sure that the shutoff valves to the accumulators are open. Failure to heed this caution can cause damage to equipment and injury to personnel.

2. Check the suction strainers, and then remove any trapped material. Note that when the suction to the pumps is restricted, the pumps will continue to operate but will produce little pressure, if any. 3. If the pumps continue to run without building pressure, disassemble the fluid cylinder, and then inspect all valves and seals on both the suction and the discharge sides. Replace as necessary. For additional information on troubleshooting and corrective actions, refer to the NOV BD30 Pump manual located in the component documentation section of this manual.

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Maintenance

HPU/BOP Control System Page 4-14 of 50

HPU J-Box, Driller’s Control Panel, and Toolpusher’s Control Panel To troubleshoot these panels, refer to the electrical block diagrams and hydraulic schematics located in Chapter 6, titled “Drawings and Bills of Materials”. Using the block diagram/schematic, isolate where the problems exist. Carefully inspect the following: 

Control panel



Interconnecting electric power cables



Internal cable connections



HPU junction box



UPS

Do not open the control panels and HPU junction box until all other obvious problems have been eliminated.

Accumulators Drain all fluid from accumulators before moving them. Leave only the nitrogen precharge when moving accumulators. Check the nitrogen precharge regularly to maintain the desired level. See the hydraulic schematic in Chapter 6, titled “Drawings and Bills of Materials”.

Significant Do’s and Don’ts There is important information relative to the operation of BOP control units that should be known by those responsible for the operation of blowout preventers: 

Never leave the shutoff valves to the accumulators in the closed position.



Never use diesel fuel oil or kerosene in the system as a control fluid. Always use good, clean lightweight hydraulic oil or fluid concentrate properly mixed with potable water or water and glycol.



Never allow oxygen to be stored in the vicinity of an accumulator unit. Always precharge accumulator bottles with nitrogen gas, which is inert. Accept no substitutes.



Never leave the vent valve for the air pilot valve switch assembly in the open position.



Never put any locking mechanism on the handles of the 4-way hydraulic control valves. A cover made of expanded metal, clear plastic, or other will serve the same purpose without hampering the operation of the valve. Be sure the cover is large enough to allow the valve handle to operate freely for remote control operation.



Keep a charging and gauging assembly near the unit at all times.



Maintain and test the system periodically, and operate it at its designed working pressure.



Size the accumulator system for each different blowout preventer stack it is to operate.

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Maintenance



Leave the 4-way control valves in normal operating position (normally annular and rams in open, choke in closed position). Never leave the valve handle in the vertical position during drilling operations.



Do not leave cable connectors unprotected. Install protective covers when not in use.



Always store cables on a storage rack when not in use.

Repairable Components The table below lists some of the major repairable components of the BOP control unit. The table also lists part numbers, repair kit numbers, and seal kit numbers (where applicable). HPU Hydraulic Control Manifold/Diverter Control Component

Part Number

Repair Kit Number

Seal Kit Number

Regulator, Air Motor-Driven

1000539

9910182

9910181

Regulator, Manually Operated

1000149

9910001

9910050

Valve, 4-Way, 1”, NPT (bypass valve)

10648646-001

10659654-001

10659676-001

Valve, 4-Way, 1”, NPT

10647335-001

10659669-001

10659676-001

0000204

0000378

Bladder Kit

11-Gallon Accumulator Bottle, 3,000 psi (207 bar)

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It is recommended that the following corrective maintenance procedures not be done while the well is active. These corrective maintenance procedures are best done between drilling activities or when the well is safe.

Triplex BD-30 Hydraulic Pump The triplex pump typically is found on the hydraulic power unit. The pump is designed to provide as little maintenance as possible. For repair procedures, see the NOV BD-30 manual located in the component documentation section of this manual.

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Maintenance

Precharging Accumulator Bottles Wa r n

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NEVER USE OXYGEN OR SHOP AIR! This can be extremely dangerous and will void your warranty. Precharge with safe DRY NITROGEN GAS.

If the accumulator is already installed on a system: 1. Pump a small amount of system fluid (10% of accumulator capacity) into the accumulator at low pressure; do not exceed 35 psi (2.4 bar). 2. Turn off all power to the system and release all hydraulic pressure from the accumulator.

If the accumulator is not yet installed: 1. Place a small amount of fluid (10% of accumulator capacity) into the accumulator. Lubricate as much of the bladder surface area as possible. 2. Remove the protective cap (gas valve guard) and the valve cap (if there is one). 3. Attach the gland and nut portion of the charging assembly to a dry nitrogen gas bottle and tighten securely.

ii If the gland and nut do not fit, you are using the wrong gas or wrong pressure!

4. Attach the gas chuck to the accumulator bladder gas valve by hand-tightening its swivel hex connection (for top-repairable models, use a TR valve extension). 5. Open the valve by turning its top (small) hex nut counterclockwise. 6. Set the nitrogen bottle gas regulator (if attached) to 35 psig (2.4 bar).

The use of a nitrogen gas regulator is strongly recommended!

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Maintenance

4

7. Open the nitrogen bottle gas valve.

If you are not using a nitrogen gas regulator, care should be taken to slowly “crack” the valve open. With a regulator, the valve can be opened fully.

8. Precharge slowly at 35 psig (2.4 bar) with dry nitrogen gas until the bladder is fully inflated.

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Initial precharging at a rate above 35 psig (2.4 bar) will cause the bladder to burst.

9. Close the valve by turning its top (small) hex nut clockwise. 10. Remove the charging assembly. Check for gas leakage.

ii When checking for gas leakage, gas leak detection fluid or soapy water should be used.

11. Tighten the hex jam nut and lock nut fully. 12. Replace the valve cap, protective cap, and nameplate; hand tighten. 13. Install the accumulator on the system. Check for leakage. 14. Pressurize the system and operate.

ii Failure to follow proper service and installation instructions will void product warranty.

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Maintenance

Accumulator Precharge Maintenance 1. Check the precharge weekly.

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Operation of accumulator without sufficient precharge (minimum of 25% of maximum working pressure) can cause bladder “pick-out.”

2. Release system pressure. Do not release gas precharge. 3. Remove the gas protective cap (valve guard) and valve cap. 4. Install the gauging device on the gas valve stem. 5. Open the gas valve hex fitting (do not loosen from bladder). Check the pressure. 6. Add additional dry nitrogen gas (if necessary) using the above procedures. 7. To release excess nitrogen gas (if any), open up the bleeder valve, located at the bottom of the gauging device, until the desired pressure is achieved.

Gas Safety Cap The yellow plastic safety cap, located at the top of the protective cap, is designed to “blow-off” if there is a valve stem gas leak. If the cap is missing, check the precharge immediately.

Cleaning and Inspecting Use the following guidelines when cleaning and inspecting the accumulator bottles: 

Clean all the metallic parts of the accumulator with an organic solvent. Avoid exposing the rubber parts to the solvent to prevent any attack on the rubber.



Inspect the condition or the metallic components of the fluid port (poppet, spring, stop nut, and piston), and replace the complete fluid port assembly if any of the components are damaged.



Push the poppet valve head to make sure it slides freely through the guide in the fluid port.



Clean the bladder with isopropyl alcohol or equivalent. Inspect the bladder for any visible damages. Replace if necessary.



Check that there is no corrosion inside or outside of the shell.



Replace all parts considered defective. The O-rings and back-up rings must be replaced.

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Maintenance

11-Gallon, 3,000 psi Top Loading Accumulator Bottles This section provides repair procedures for the following accumulator bottle: o

11-Gallon Top Loading Bladder-Type Accumulator Bottle (P/N 0000204) located on the HPU Accumulator Bottle Racks.

ii See Figure 4-3 on page 4-22 for exploded view of the 11-gallon accumulator bottle. For 11-gallon bladder repair kit information, see table titled “Common Parts – 3,000 psi (307 bar) Accumulator Bottle (Top-Loading)” on page 4-23.

Replacing Accumulator Bladder (Top Loading) For a list of tools required to replace the accumulator bladder, see the table below. Tools for Replacing Accumulator Bladders Tool

P/N

Core Tool (all sizes)

9000019

Bladder Pull Rod

9001001

Charging and Gauging Assembly (3,000 psi)

1700001

Charging and Gauging Assembly (5,000 psi)

1700071

Valve Extension

1700042

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Maintenance

Preparing to Remove Accumulator Bladder (Top Loading) Replacing the accumulator bladder requires all hydraulic pressure to be vented from the accumulator in accordance with the following steps:

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Do not attempt to replace the accumulator bladder until all hydraulic pressure is vented to atmosphere and all gauges show 0 psi (0 bar).

1. Isolate accumulator bottles from the main hydraulic supply by closing the appropriate ball valve. 2. Vent the residual nitrogen precharge pressure from the bottle to atmosphere using the charging and gauging assembly. 3. Drain the fluid from the accumulator by opening the vent ball valve.

ii Top loading accumulator bottles do not need to be removed from the unit to replace the bladder.

Removing Accumulator Bladder (Top Loading) 1. Remove the gas protective cap and valve cap from the accumulator (see Figure 4-3 on page 4-22). 2. Install the proper charging and gauging assembly on the gas valve stem. Attach the gas chuck to the accumulator bladder gas valve by hand-tightening the swivel hex connection. 3. Open the valve by turning its top (small) hex nut counterclockwise.

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HIGH PRESSURE GAS IS DANGEROUS! Wear proper eye protection. Take proper safety precautions.

4. Bleed off all nitrogen gas pressure by opening the bleed valve completely. Remove the gas valve. 5. Remove the gauging device from the gas valve stem. 6. Attach a bladder pull rod to the bladder by carefully threading over the Schrader connection. 7. Remove the hex jam nut from the bladder stem. 8. Attach two more pull rods and push the bladder into the shell.

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Maintenance

4

9. Remove the lock nut from the top of the unit using a spanner wrench. 10. Remove the spacer and rings. 11. Push the top load adapter into the accumulator and through the anti-extrusion ring. Remove the anti-extrusion ring by folding it and pulling it through the hole. 12. Remove the top load adapter, and pull the old bladder from the top of the accumulator.

Installing Accumulator Bladder (Top Loading) 1. Remove the valve core and the gas valve from the new bladder and squeeze all air from the bladder. Replace the valve core. 2. Unfold the bladder completely. 3. Lubricate the bladder and shell with system fluid. 4. Attach a bladder pull rod to the bladder by carefully threading over the Schrader connection. 5. Roll the vertical length of the bladder, and insert into the top of the accumulator. Push the bladder down into the shell.

Verify the bladder is not bent, twisted or folded in the shell, as this will cause the bladder to burst.

6. Push the top load adapter assembly and then the anti-extrusion ring into the shell. 7. Pull the top load adapter assembly through the anti-extrusion ring. Seat the ring in the hole, metal side down. 8. Pull the bladder through the top load adapter. 9. Attach the hex nut onto the exposed gas valve stem hand tight. 10. Remove the pull rod. 11. Install a new metal back-up ring and a new O-ring, making sure not to pinch the O-ring. Install a new rubber back-up ring, spacer, and lock nut. Hand-tighten the lock nut. 12. Precharge the accumulator (see instructions in the section titled “Precharging Accumulator Bottles” on page 4-16). 13. Tighten the jam nut, making sure the gas valve stem does not rotate. 14. Tighten the lock nut.

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Maintenance

Safety Cap Valve Cap Hex Jam Nut Rubber Back-up Ring

Gas Valve Bladder Kit

O-Ring

Top-Load Adapter

Metal Back-up Ring

Lock Nut Spacer

Anti-Extrusion Ring

Shell Bladder Kit

Anti-Extrusion Ring

Poppet Spring

Metal Back-up Ring O-Ring Spacer Piston Stop Nut

Rubber Back-up Ring Lock Nut Special Seal Sub Oil Port

Figure 4-3. Top-Loading Accumulator Bottle

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Maintenance

Common Parts – 3,000 psi (307 bar) Accumulator Bottle (TopLoading) Item # Assembly

Description 11-gallon

1*

Safety Cap

1*

Protective Cap

2*

Valve Cap

3*

High Pressure Gas Valve

4

Bladder Kit

5*

Hex Jam Nut

6

Nameplate

7*

Anti-extrusion Ring

8*

Lock Nut

9*

Oil Port

10*

Stop Nut

11*

Piston

12*

Spacer

13*

Spring

14*

Poppet

15

Shell

16*

Metal Back-up Ring

17*

O-ring

18*

Rubber Back-up Ring

19*

Not Used

20*

Top Load Adapter

P/N 0000204

0000378

*Parts may be ordered by referencing the item number, description, accumulator size, accumulator pressure rating and accumulator bottle part number.

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Maintenance

4-Way Hydraulic Control Valves This section outlines the disassembly and reassembly procedures for the 4-way hydraulic control valves. These valves are typically found on the hydraulic control manifold, diverter master panel, hose reels, and standby hose reels. Note that the manipulator-type valves, typically found on the hydraulic control manifold and diverter master panel, are not interchangeable with the outwardly similar selector-type valves typically found on the hose reels. Differences in reassembling the manipulator-type valves and selector-type valves are pointed out in the procedures below. In all other steps, both types of valves—and valves of all sizes—use the same procedures. The numbers in parentheses correspond to the item numbers shown in Figure 4-5 on page 4-28 and the associated parts table. Assembly and kit part numbers are also listed in the table.

Disassembly 1. Disconnect all fittings from the valve body (4).

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Isolate the 4-way valves from all system pressure before performing any disassembly procedures. Also, place the valve handles fully in the left and right position before disassembly or removal from the system equipment. This action releases any pressure that may be trapped in the valve body.

2. Remove the shaft nut (19), shaft washer (18), handle (21), retainer ring (14), and spacer (17) from the front of the control panel. 3. Remove the four body screws (1), nuts (2), and washers (3). 4. Lift the valve out of the bracket and move the valve to a clean work area, free of dirt, dust, grit, etc. 5. Carefully remove the housing (25) from the body (4). Exercise caution so that the rotor does not fall out of the housing. 6. Remove the housing O-ring (10) and rotor (11) from the housing (25). 7. Remove the thrust bearing assembly (29, 28, 27) from the housing (25). 8. Remove the three shear seal seats (9) from the three cavities in the body (4).

ii The O-ring (8) and back-up rings (7) are assembled on the shear seal seats (9).

9. Remove the shear seal seat spring washers (6) from the body (4).

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Maintenance

4

10. Reinstall the nut (19) on the shaft (12). Using a nonmetallic mallet or a block of wood between the nut and the mallet, drive the shaft sufficiently out the back of the housing (25) to make complete removal easy (see Figure 4-4).

Do not strike the nut with a metal hammer because this could strip the threads on the nut and/or shaft.

Figure 4-4. Drive Shaft out of Housing

11. Remove the nut (19) and pull the shaft (12) completely out the back of the housing. 12. Remove the O-rings (26, 13) from the shaft (12). 13. Remove disc detent (22), detent ball (16), detent spring (23) and the stop pin (15).

Cleaning and Inspection 1. Thoroughly clean and inspect the body (4). Pay particular attention to the areas around the three ports for signs of washout. If washout in these areas is severe, the entire valve assembly should be replaced. 2. Thoroughly clean the body (4), rotor (11), shaft (12), and thrust bearing assembly (27, 28, 29). 3. Clean the disc detent (22).

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Maintenance

HPU/BOP Control System Page 4-26 of 50

Reassembly 1. Prior to reassembly of the valve, discard the following parts removed during disassembly: 

All shear seal seats with all O-rings and backup rings



Shear seal seat spring washers



O-rings



Thrust bearing



Retainer ring



Rotor

2. Install the new shear seal seat spring washers (6) into the body (4). 3. Grease the area around the ports on the body (4). 4. New O-rings (8) and backup rings (7) are assembled on the new shear seal seats (9) from the repair kit. Thoroughly grease with a good quality bearing grease and install the shear seal seats with the beveled edges facing outward, toward the surface of the body.

Do not use any metal object to push the seal ring into the seal container. The seal rings are manufactured to a very specific tolerance. These tolerances would be damaged by contact with metal tools. Use fingers, preferably protected with clean gloves. Avoid contacting the beveled edges of the seal rings directly with the fingers. The beveled edges of the seal rings are sealing surfaces, which will corrode if contacted by the natural acids on fingers. If it is necessary to push the seal rings in with the fingers apply a sufficient coating of oil to the seal rings. The oil acts as a barrier between the acids and the metal.

5. Install a new dirt seal O-ring (13) and shaft O-ring (26) on the shaft (12). 6. Thoroughly grease the inside of the housing (25). 7. Lightly grease the shaft (12) and install it into the housing (25). 8. Grease the thrust bearing assembly (27, 28, 29) and install into the housing (25). Again, apply a generous amount of grease. 9. Lightly grease the new rotor (11). Do not touch the face of the rotor with the fingers because the natural acidity of fingers can corrode the sealing surface of the rotor. 10. Install the rotor into the housing. The rotor must be installed so that the vent hole in the rotor will match the vent port in the valve body when the housing is made up to the body (see Figure 4-5 on page 4-28). 11. When the rotor is in position, rotate the shaft (12) until the two alignment pins in the shaft engage to two alignment holes in the back of the rotor. 12. Lightly grease and install the housing O-ring (10) into the housing (25).

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Maintenance

4

13. Assemble the housing assembly onto the body. Check to confirm that the vent hole in the rotor is aligned with the vent port in the valve body. The housing and body can be installed in only one position due to special alignment pins and holes (see Figure 4-5 on page 4-28). 14. Install the detent spring (23), detent ball (16), and stop pin (15). 15. Lightly grease and install the detent disc (22). 16. Install the retainer ring (14) and handle spacer (17) onto the threads of the shaft (12). 17. Set the valve back into the bracket in the unit. 18. Install the four body screws (24), nuts (2), and washers (3). 19. Install the handle (21), shaft washer (18), and shaft nut (19) on the front of the control panel.

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Maintenance

20

Item 1 (Stud) not shown. Use only for panel mounting. Item 30 (Anti-velocity Ring) not shown. Integral to item 25. Items 30 and 31 (Grease Fitting) not used on all valves. Manipulator Bypass

21 24

29

28

27

14

31 15 19 18 17

10

22

5 3 2

26 13

23

16

25

12 11

Selector

9

4

7 6

7

8

Figure 4-5. 4-Way Control Valve - Exploded View

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Maintenance

Parts List – 4-Way Control Valve, Selector Type (P/N 10647335-001) Item #

Repair Kit

Seal Kit

Assy Kit Kit



Description

1” Valve P/N*

Qty.

4-Way Control Valve

10647335-001

–

Repair Kit

10659669-001

–

Seal Kit

10659676-001

–

1

Stud (Panel Mounting Only)

–

4

2

Nut, Body Screw

–

4

3

Lock Washer, Body Screw

–

4

4

Body

–

1

5

Dowel Pin

–

2

6



Washer, Shear Seal Seat Spring

–

7



Back-up Ring, Shear Seal Seat

–

6

8



O-ring, Shear Seal Seat

–

3

9



Shear Seal Seat

–

3

10



O-ring, Housing Rotor

–

1

Rotor

–

1

Shaft

–

1

O-ring, Shaft (Dirt Seal)

–

1

14

Retainer Ring

–

1

15

Pin, Stop

–

1

16

Ball, Detent

–

1

17

Handle Spacer

–

1

18

Washer, Shaft

–

1

19

Nut, Shaft

–

1

20

Rubber Grip

–

1

21

Handle

–

1

22

Disc, Detent

–

1

23

Spring, Detent

–

1

24

Screw, Body, Panel-Mounting

–

4

11



12 13



3

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Maintenance

Parts List – 4-Way Control Valve, Selector Type (P/N 10647335-001) Item #

Repair Kit

Seal Kit

Description

1” Valve P/N*

Qty.

24

Screw, Body, Regular Mount

–

4

25

Housing

–

1

O-ring, Shaft

–

1

–

2

Not Used

–



26 27



Thrust Washer

28



Retainer, Ball Bearing

29



Bearing, Ball

–

26

30

Anti-Velocity Ring

–

1

31

Grease Fitting

–

1

*Parts may be ordered by description and by referencing the valve part number and item number.

Parts List – 1” 4-Way Control Valve, Bypass Type (P/N 10648646-001) Item #

Description

Assy.

Repair Kit

Seal Kit

1” Valve P/N*

Qty.

4-Way Control Valve

10648646-001

-

Kit

Repair Kit

10659654-001

-

Kit

Seal Kit

10659676-001

-

1

Stud (Panel Mount Only)

–

-

2

Nut

–

4

3

Lock Washer

–

4

4

Body

–

1

5

Dowel Pin

–

2

6

Washer



–

3

7

Back-up Ring



–

6

8

O-ring



–

3

9

Shear Seal Seat



–

3

10

O-ring



–

1

11

Rotor

–

1

12

Shaft

–

1

13

O-ring

–

1







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Maintenance

Parts List – 1” 4-Way Control Valve, Bypass Type (P/N 10648646-001) Item #

Description

Repair Kit

Seal Kit

14

Retainer Ring

–

1

15

Pin, Stop

–

4

16

Ball, Detent

–

4

17

Spacer

–

1

18

Washer, Shaft

–

1

19

Nut, Shaft

–

1

20

Rubber Grip

–

1

21

Handle

–

1

22

Disc, Detent

–

4

23

Spring, Detent

–

1

24

Screw, Panel Mount

–

1

24

Screw, Regular Mount

–

4

25

Housing

–

1

26

O-ring

–

1

27

Thrust Washer

–

1

28

Retainer, Ball Bearing

29

Ball Bearing

30 31

 

1” Valve P/N*

Qty.

Not Used 

–

1

Anti-Velocity Ring

–

1

Grease Fitting

–

1

*Parts may be ordered by description and by referencing the valve part number and item number.

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Maintenance

1” MKR Pressure Reducing and Regulating Valve (P/N 1000149) This section provides the disassembly and reassembly procedures for the 1 MKR valve (P/N 1000149), which is used for reducing the 3,000 psi (207 bar) triplex pump supply pressure to 1,500 psi (103 bar). These procedures are for field repair operations and involve the total replacement of all valve O-rings, backup rings, seals, and certain other components. The valve must be removed from the system equipment for this total overhaul procedure. For a list of recommended tools and supplies, see the table titled “Recommended Tools/Supplies — 1” MKR Valve (P/N 1000149)” on page 4-33.

Figure 4-6. 1” MKR Valve

Wa r n

in g

Isolate the MKR valve from all system pressure before performing any disassembly procedures or removing the valve from the panel.

ii Numbers in parentheses correspond to Figure 4-7 on page 4-34, Figure 4-8 on page 4-35, and the table titled “Parts List — 1” MKR Valve (P/N 1000149)” on page 4-36. Refer to this table for assembly and kit part numbers.

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Maintenance

Recommended Tools/Supplies — 1” MKR Valve (P/N 1000149) Description

Purpose

Torque wrench with 50 ft-lb range

Tightening valve components

Torque wrench with 150 in-lb range

Tightening valve components

12-inch adjustable wrench

Installing valve components

5  16

allen wrench

Installing 38-16 socket head cap screws

3  16

allen wrench

Installing 14-20 socket head cap screw

Latex gloves (optional)

Pushing seal ring into seal container

Clean, dry compressed air

Removing loose dirt and grit

Ultrasonic cleaner tank

Cleaning valve components

Cavi-clean liquid detergent and additive or Varisol cleaner and Safety clean rinse

Cleaning valve components

Lubriplate grease (P/N 20026730)

Lubricating components during reassembly

Moly Paste Lube 503 (P/N 7403582) or Fastorq A/G s.s. Anti-seize Compound

Lubricating threads

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Maintenance

41 42 40 39 38

37 10

36 35 33 34 32

31 30

13

29 5

26

3

27

18

28 14

25 10

1 4

6

8

20

9

21

19 2

15

16

5

17 22

11

24 23

13 12 10

7

4

10

Figure 4-7. 1” MKR Valve (P/N 1000149) — Exploded View

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Maintenance

41 42 39

23

21 20

24 25

40 38 36 35

22 26

34 37

19

33 25 24

20 21

Seal Orientation

15

1

17

12

10

13

18

7

16

5 30

15

3

Figure 4-8. 1” MKR Valve (P/N 1000149) — Cross Section

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Maintenance

Parts List — 1” MKR Valve (P/N 1000149)

Item #

In Repair Kit

In Seal Kit

Assembly Kit Kit



Description

P/N

Qty.

Hyd. Pressure Reducing and Regulating Valve

1000149

–

Repair Kit

9910001

–

Seal Kit

9910050

–

1

Body

*

1

2

Plunger Guide

*

1

O-Ring

*

1

4

Plunger Stem

*

1

5

O-ring

*

1

Backup Ring

*

1

7

Seal Container

*

1

8

Dowel Pin

*

1

Retainer Sleeve

*

1

Flow Port

*

1

O-Ring

*

2

Plate

*

1

Flange

*

1

Socket Head Cap Screw

*

4

15

Socket Head Cap Screw

*

32

16

Flange

*

1

3

6





9



10



11



12







 

13 14





17





O-Ring

*

2

18





O-ring

*

1

19



Seal Ring

*

2

20





O-Ring

*

2

21





Backup Ring

*

2

22



Wave Spring

*

1

23



Seal Ring

*

4

24





O-Ring

*

4

25





Backup Ring

*

4

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Maintenance

Parts List — 1” MKR Valve (P/N 1000149)

Item #

In Repair Kit

26



In Seal Kit

P/N

Qty.

Compression Spring

*

2

Flange

*

1

O-Ring

*

2

29

Socket Head Cap Screw

*

6

30

Flange

*

1

31

Pipe Plug

*

2

32

Spring Guide

*

1

39

Adjusting Screw

*

1

40

Lock Handle

*

1

41

Ball Handle

*

1

42

Set Screw

*

2

Anti-Seize

*

1

27 28

43









Description

* Parts may be ordered by reference assembly, part number, item number, and description

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Maintenance

HPU/BOP Control System Page 4-38 of 50

Disassembly – 1” MKR Valve (P/N 1000149)

Do not attempt to disassemble this regulator valve without the correct repair kit or seal kit. Use the proper tools and work in a clean, dry environment.

1. Place the valve on a clean area, free of dust sand, grease, grit, etc. 2. Relieve the pressure on the compression springs (33, 34) by releasing the lock handle (40) and rotating the ball handle (41) counterclockwise until it moves freely. 3. Loosen and remove the eight socket head cap screws (15) using a 516 allen wrench. Remove the adjustment head (37) from the body. 4. Slowly tighten down on the ball handle (41) until both compression springs force the plunger guide (2) out the lower end of the adjustment head. 5. Loosen and remove the six socket head cap screws (29) on the outlet flange (27). Slowly remove the flange so as not to damage the O-ring (28). 6. Loosen and remove the eight socket head cap screws (15) on the inlet flange (16). Remove the inlet flange by rotating it slowly back and forth. 7. Loosen and remove the eight socket head cap screws (15) from the flange (13). Remove the flange by rotating it slowly back and forth. 8. Loosen and remove the eight socket head cap screws (15) from the bottom flange (30). Remove the flange.

In the following Step 9, be careful not to damage the lapped surfaces of the vent and supply seal rings (19, 23) while removing the seal container (7).

9. Tap lightly with a rubber mallet on the plunger stem (4). The seal container (7) and its components will fall out the lower end of the body (1).

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Maintenance

Reassembly — 1” MKR Valve (P/N 1000149) For torque values used in this procedure, see the following table.

Torque Values — 1” MKR Valve (P/N 1000149) Torque Value  Valve P/N

1000149

Item #

Qty.

Description

15

32

SHCS 38–16 – 112

14

4

SHCS 14–20 – 78

29

6

SHCS 38–16 – 114

ft-lb

in-lb

18 (24 Nm) 59 (612 Nm) 18 (24 Nm)

 Torque values are based on using Fastorq RS anti-seize. The factor for Fastorq RS 18 is: K=0.18. 1. Prior to reassembly wash all metal parts with a cleaning solvent Thoroughly wash inside the valve body (1). Check all valve parts for scarring and washout. Replace parts that are badly scarred or damaged by washout. 2. Replace the following items in the seal container (7): four seal rings (23), two compression springs (26), two seal rings (19) one wave spring (22). The seal container items, with the following O-rings and backup rings (24, 25, 20, 21), are provided in the repair kit.

Do not use any metal object to push the seal rings into the seal container. The seal rings are manufactured to a very specific tolerance, which would be damaged by contact with metal tools. Use fingers, preferably protected with clean gloves. Avoid contacting the beveled edges of the seal rings directly with the fingers. The beveled edges of the seal rings are sealing surfaces which will corrode if contacted by natural acids from fingers. If it is necessary to use fingers to push the seal rings in, apply a sufficient coating of oil to the seal rings. The oil acts as a barrier between the acids and the metal.

3. Apply a light coating of Lubriplate (P/N 20026730) or other equivalent seal lubricant to the O-rings prior to the replacement Install the seal rings with the beveled edges facing outward toward the surface of the seal container.

4. Install the new O-ring (5) and backup ring (6) on the stem(4). 5. Install the Dowel Pin (8) through the seal container (7) and plunger stem (4) and install the retainer sleeve (9).

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Maintenance

6. Gently replace the seal container assembly back into the body (1) with the indentations in the upper end of the seal container facing toward the inlet flange (16) (see Figure 4-9).

ii It may be necessary to lubricate the outer diameter of the flanges with a lightweight lubricant prior to reassembly.

Inlet Port

Seal Cartridge Indentions

Figure 4-9. Installing Seal Container

7. Install a new O-ring (3) onto the bottom flange (30). Mount the bottom flange onto the body (1). Install and tighten the eight socket head cap screws (15). 8. Replace the O-ring (11), the plate (12) and the two socket head cap screws (14) on the flange (13). Reassemble the new plate to the flange using the new socket head cap screws.

ii It may be necessary to lubricate the outer diameter of the flanges with a lightweight lubricant prior to reassembly.

9. Mount the flange onto the body (1). Align the “X” on the flange with the “X” on the body (see Figure 4-10 on page 4-41). Install and tighten the eight socket head cap screws (15).

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Maintenance

4

XX Z Z

Figure 4-10. Installing Flanges

10. Replace the O-rings (11, 17, 3, 18), the socket head cap screws (14), and the flow port (10) on the inlet flange (16). Reassemble the new flow port to the inlet flange using the new socket head cap screws. 11. Mount the inlet flange onto the body. Align the “Z” on the flange with the “Z” on the body (see Figure 4-10 on page 4-41). Install and tighten the eight socket head cap screws (15). 12. Replace the O-ring (28) on the outlet flange (27). Mount the outlet flange onto the body (1). Install and tighten the six socket head cap screws (29). 13. Replace the O-ring (3) on the plunger guide (2). Place the plunger guide (2) onto the plunger stem (4) which protrudes from the top of the body (1). 14. Set the adjustment head assembly (37) down over the plunger guide and onto the top of the body. Align the holes and install the socket head cap screws (15). 15. Move the ball handle (41) down to its original position and set the lock handle (40). The valve is now ready for operation.

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Maintenance

1” AMKR Pressure Reducing and Regulating Valve (P/N 1000539) This section provides disassembly and reassembly procedures for the 1” AMKR valve (P/N 1000539) (see Figure 4-11). These procedures are for field depot repair operations and involve total replacement of all valve O-rings, back-up rings, seals, and certain other components. The valve must be removed from system equipment for this total overhaul procedure.

Figure 4-11. 1” AMKR Valve

Wa r n

in g

Isolate the AMKR valve from all system pressure before performing any disassembly procedures or removing the valve from the panel.

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Maintenance

Do not attempt to disassemble this regulator valve without the correct repair kit or seal kit. Use the proper tools and work in a clean, dry atmosphere. For a list of recommended tools and supplies, see the table titled “Recommended Tools/Supplies — 1” AMKR (P/N 1000539)”.

ii Numbers in parentheses correspond to Figure 4-13 on page 4-47 and the table titled “Parts List — 1” AMKR Valve (P/N 1000539)” on page 4-44. See this table for assembly and kit part numbers.

Recommended Tools/Supplies — 1” AMKR (P/N 1000539) Description

Purpose

Torque wrench with 50 ft-lb range

Tightening valve components

Torque wrench with 150 in-lb range

Tightening valve components

12 adjustable wrench

Installing valve components

5/ ” 16

hex wrench

Installing 3/8”-16 socket head cap screws

3/ ” 16

hex wrench

Installing 1/4”-20 socket head cap screw

Latex gloves (optional)

Pushing seal ring into seal container

Clean, dry compressed air

Removing loose dirt and grit

Ultrasonic cleaner tank

Cleaning valve components

Cavi-clean liquid detergent and additive or Varisol cleaner and Safety clean rinse

Cleaning valve components

Lubriplate grease (P/N 20026730)

Lubricating components during reassembly

Sweeney 503 Moly Paste Lube (P/N 7403582) or Fastorq A/G s.s. Anti-Seize Compound

Lubricating threads

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Maintenance

Parts List — 1” AMKR Valve (P/N 1000539)

Item #

In Repair Kit

In Seal Kit

P/N

Qty.

Pressure Reducing and Regulating Valve

1000539

–

Kit

Repair Kit

9910182

–

Kit

Seal Kit

9910181

–

Body

1000204

1

Assy

1

Description

2



Plate

1000139

1

3



Flow Port

1000135

1

4





Socket Head Cap Screw

20016241

4

5





O-Ring

20016210

2

6

Flange

1000133

1

7

Flange

1000140

1

8





O-Ring

20016185

1

9





O-Ring

20016189

1

10

Socket Head Cap Screw

20016237

32

11

3  8

20041847

2

12

Flange

20016177

1

O-Ring

20016214

1

Seal Container

1000203

1

Seal Ring

1000143

2

13





14

NPT Pipe Plug

15



16





O-Ring

20016191

2

17





Backup Ring, 1316 x 1116

20016225

2

18



Wave Spring

1000147

1

19



Seal Ring

1000134

4

20





O-Ring

20016186

4

21





Backup Ring, 1 x 78

20016223

4

Flange

1000141

1

O-Ring

20016215

1

Socket Head Cap Screw

20016235

6

Compression Spring

1000138

2

22 23



24 25





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Maintenance

Parts List — 1” AMKR Valve (P/N 1000539) (Continued)

Item #

In Repair Kit

In Seal Kit

Description

P/N

Qty.

26

Plunger

1000555

1

27

Spring Pin

20016448

1

28





O-Ring

5020028

1

29





Backup Ring

20016228

1

30

Plunger Guide

1000554

1

31

Spring Plate

1000553

1

32

Compression Spring

1000548

1

33

Compression Spring

1000119

1

34

Spring Guide

1000542

1

35

Adjustment Head

1000158

1

36

Actuator Assembly, Motor-driven

1000209

1

37

Name Tag

20007449

1

38

Screw, Drive

20007471

2

39

Anti-Seize

20007472

A/R

Anti-Seize

20007473

1

40



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Maintenance

40 39 36

34 35 32 33

10 39 40

1 8 2 3

9

7

6

5

14 12 40 39 10

13

Figure 4-12. 1” AMKR Valve (P/N 1000539) — Cross Section

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Maintenance

19

20 21

14

25

36

35 10

Supply Seal Ring

34 32 33 31

18

15

2 3

30 13 5

28

3

26

18

25 1 10

4

6

20 8

29

27 14

Vent Seal Ring

21

19

9 15

2

16

16 17

14

5

17 22 24

11 23

13 12 10

7

4

10

Figure 4-13. 1” AMKR Valve (P/N 1000539) — Exploded View

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HPU/BOP Control System Page 4-48 of 50

Maintenance

Disassembly — 1” AMKR Valve (P/N 1000539) 1. Place the valve on a clean area, free of dust, sand, grease, grit, etc. 2. Relieve the pressure on the compression springs (32, 33) by releasing the lock nut and rotating the ball handle on the valve actuator assembly (36) counterclockwise until it moves freely. 3. Loosen and remove the eight socket head cap screws (10) using a 516 allen wrench. Remove the adjustment head (35) from the body. 4. Slowly tighten down on the ball handle on the valve actuator assembly (36) until both compression springs force the plunger guide (30) out the lower end of the adjustment head. 5. Loosen and remove the six socket head cap screws (24) on the outlet flange (22). Slowly remove the flange so as not to damage the O-ring (23). 6. Loosen and remove the eight socket head cap screws (10) on the inlet flange (6). Remove the inlet flange by rotating it slowly back and forth. 7. Loosen and remove the eight socket head cap screws (10 from the flange (7). Remove the flange by rotating it slowly back and forth. 8. Loosen and remove the eight socket head cap screws (10) from the bottom flange (12). Remove the flange. 9. Tap lightly with a rubber mallet on the plunger (26). The seal container (14) and its components will fall out the lower end of the body (1).

Cleaning and Inspecting — 1” AMKR Valve (P/N 1000539) Prior to reassembly, wash all metal parts with a cleaning solvent. Thoroughly wash inside the valve body (1). Check all valve parts for scarring and washout. Replace parts which are badly scarred or damaged by washout.

Reassembly — 1” AMKR Valve (P/N 1000539) For torque values used in this procedure, see the table titled “Torque Values — 1” AMKR (P/N 1000539)” below.

Torque Values — 1” AMKR (P/N 1000539) Torque Value * Valve P/N

1000539

Item #

Qty.

Description

10

32

SHCS 38–16 – 112

4

4

SHCS 12–20 – 78

24

6

SHCS 38–16 – 134

ft-lb

in-lb

18 (24 Nm) 59 (612 Nm) 18 (24 Nm)

* Torque values are based on using Fastorq RS anti-seize. The factor for Fastorq RS 18 is: K=0.18.

4-48 www.nov.com

HPU/BOP Control System Page 4-49 of 50

Maintenance

4

1. Replace the items below in the seal container (14), along with O-rings and backup rings (20, 21, 16, 17), which are all provided in the repair kit: 

four seal rings (19)



two compression springs (25)



two seal rings (15)



one wave spring (18)

Prior to replacement, apply a light coating of Lubriplate (P/N 20026730) or other equivalent seal lubricant to the O-rings. Install the seal rings with the beveled edges facing outward toward the surface of the seal container. 2. Install the new O-ring (28) and backup rings (29) on the plunger (26). 3. Gently replace the seal container assembly back into the body (1) with the indentations in the upper end of the seal cartridge facing toward the inlet flange (6) (see Figure 4-14).

Inlet Port

Seal Cartridge Indentions

Figure 4-14. Installing Seal Cartridge

4. Install a new O-ring (13) onto the bottom flange (12). Mount the bottom flange onto the body (1). Install and tighten the eight socket head caps crews (10). 5. Replace the O-ring (5), plate (2), and two socket head cap screws (4) on the flange (7). Reassemble the new plate to the flange using the new socket head cap screws.

ii It may be necessary to lubricate the inside of the flanges with SAE 10W lubricant prior to reassembly.

4-49 www.nov.com

4

HPU/BOP Control System Page 4-50 of 50

Maintenance

6. Mount the flange onto the body (1). Align the “X” on the flange with the “X” on the body (see Figure 4-15). Install and tighten the eight socket head cap screws (10).

XX Z Z

Figure 4-15. Installing Seal Flanges

7. Replace the O-rings (8, 5, 13, 9), the socket head cap screws (4), and the flow port on the inlet flange (6). Reassemble the new flow port to the inlet flange using the new socket head cap screws.

Do not use any metal object to push the seal ring into the seal container. The seal rings are manufactured to a very specific tolerance, which would be damaged by contact with metal tools. Use fingers, preferably protected with clean gloves. Avoid contacting the beveled edges of the seal rings directly with the fingers. The beveled edges of the seal rings are sealing surfaces which will corrode if contacted by natural acids from fingers. If it is necessary to use fingers to push the seal rings in, apply a sufficient coating of oil to the seal rings. The oil acts as a barrier between the acids and the metal.

8. Mount the inlet flange onto the body. Align the “Z” on the flange with the “Z” on the body (see Figure 4-15). Install and tighten the eight socket head cap screws (10). 9. Replace the O-ring (23) on the outlet flange (22). Mount the outlet flange onto the body (1). Install and tighten the six socket head cap screws (24). 10. Replace the O-rings (13) on the plunger guide (30). Place the plunger guide (30) onto the plunger (26) which protrudes from the top of the body (1). 11. Set the adjustment head assembly (35) down over the plunger guide and onto the top of the body. Align the eight holes for the socket head cap screws. 12. Move the ball handle on the valve actuator assembly (36) down to its original position and set the lock nut. The valve is now ready for operation.

4-50 www.nov.com

HPU/BOP Control System Page 5-1 of 4

Parts Lists Parts Identification All parts required for maintenance or repair are available from NOV. Assembly drawings and exploded views correspond to the parts list, which identifies each part by number. Using this part number and part name will ensure procurement of the proper part when ordering.

Ordering Replacement Parts When ordering replacement parts, please specify the following information: 

Part name – part name as called out on applicable drawing



Part number – part number as called out on applicable drawing



Drawing number – engineering drawing number and item number for drawing



Quantity – quantity needed



Serial number – serial number (if applicable) as shown on nameplate

Recommended Spare Parts The following table lists the recommended spare parts for two years of service on the BOP control system. Spare Parts Kits for Two Years of Service Qty.

Part #

Description

1

10684068-001

Spare Parts Kit for Hydraulic Power Unit

1

10721000-001

Spare Parts Kit for Upper-level J-box Assembly

1

10710987-001

Spare Parts Kit for HPU J-box Assembly

1

10729811-001

Spare PArts Kit for Motor Starter

1

10715084-001

Spare Parts Kit for Driller’s Control Panel

1

10715087-001

Spare Parts Kit for Toolpusher’s Control Panel

1

10729874-001

Spare Parts Kit for Battery Charger

5-1 www.nov.com

5

HPU/BOP Control System Page 5-2 of 4

Parts Lists

Charging and Gauging Assembly Figure 5-1 shows an exploded view of the charging and gauging assembly. The table lists corresponding parts for the exploded view.

1 3 5 6

2 Sub Assy

4

7 9

8

10

Figure 5-1. 3,000 psi (207 bar) Charging and Gauging Assembly

Parts List – 3000 psi Charging and Gauging Assembly Item #

Qty.

Description

P/N

Assembly

Complete Charging and Gauging Assembly

1700001

Subassembly

Gauging and Head Assembly (1, 2, 3, 4, 5)

20006400

Head Assembly (2, 3, 4, 5)

1700062

Tool Kit

20003420

1

1

Gauge

4002000

2

1

Gas Chuck

1700003

3

1

Adapter

1700004

4

1

Bleeder Valve

1700007

5

1

Tank Valve

1700005

6

1

Swivel Connector

1700006

7

1

Hose with End Fitting

2565001

5-2 www.nov.com

HPU/BOP Control System Page 5-3 of 4

5

Parts Lists

Parts List – 3000 psi Charging and Gauging Assembly (Continued) Item #

Qty.

Description

P/N

8

1

Coupler

2022002

9

1

Nut

1700054

10

1

Gland

1700053

5-3 www.nov.com

5

HPU/BOP Control System Page 5-4 of 4

Parts Lists

This page intentionally left blank

5-4 www.nov.com

HPU/BOP Control System Page 6-1 of 2

Drawings and Bills of Materials Engineering Drawings and Parts Lists The following table lists the engineering drawings and parts lists for the HPU/BOP Control System.

Engineering Drawings and Parts Lists Drawing #

Parts List

Description

10648661-DIA

–

Electrical Block Diagram

10642541-GAD

–

General Arrangement, Hydraulic Power Unit

10644181-ASM

10644181-001

10641447-SCH

–

–

*10645953-001

D-5616043D

5616043

Gauge Panel Assembly

–

*10648646-001

Bypass Valve Assembly

10653700-ASM

10653700-001

4-Way Valve Assembly with Air Cylinder

10656456-ASM

10656456-001

Electrical Assembly, Hydraulic Power Unit

–

10647804-001

J-box Upper Level Assembly, Hydraulic Power Unit

10680243-GAD

–

General Arrangement, Motor Starter Junction Box

10656625-ASM

10656625-001

10680245-DIA

–

Wiring Diagram, Motor Starter Junction Box

10668096-GAD

–

General Arrangement, HPU Junction Box

10656624-ASM

10656624-001

10679345-DIA

–

10658761-ASM

*10658761-001

10667736-DIA

–

Wiring Diagram, Driller’s Control Panel

10658763-ASM

*10658763-001

Toolpusher’s Control Panel Assembly

10678681-DIA

–

–

*10659507-001

–

*0000204

–

10684068-001

Hydraulic Power Unit and Flow Diagram Hydraulic/Pneumatic Schematic, Hydraulic Power Unit Pump and Motor Assembly, 30 HP

Motor Starter J-box Assembly

HPU Junction Box Wiring Diagram, HPU Junction Box Driller’s Control Panel Assembly

Wiring Diagram, Toolpusher’s Control Panel UPS Battery Charger BOP Bottle Rack Assembly (20 - 11-Gallon Top Load) Spare Parts Kit, Hydraulic Power Assembly

6-1 www.nov.com

6

Drawings and Bills of Materials

HPU/BOP Control System Page 6-2 of 2

Engineering Drawings and Parts Lists (Continued) Drawing #

Parts List

Description

–

10721000-001

Spare Parts Kit, Upper-level Junction Box Assembly

–

10710987-001

Spare Parts Kit, HPU Junction Box Assembly

–

10729811-001

Spare Parts Kit, Motor Starter Assembly

–

10715084-001

Spare Parts Kit, Driller’s Panel Electric Assembly

–

10715087-001

Spare Parts Kit, Toolpusher’s Panel Electric Assembly

–

10729874-001

Spare Parts Kit, Battery Charger Assembly

*Part number for reference only

6-2 www.nov.com

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:08:05 AM Page: 1 of 2

Bill of Material for Item 10644181-001 Description: ACCUM UNIT ASSY,W/ 20 ACCUM BTLS, W/ ELECT REMOTE, Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

10641447-SCH

04

DWG:SCHEM, HYD,ACCUM UNIT ASSY,W/20 BTLS,IDEAL RIG

EA

0.0000 09/01/2012

10642541-GAD

02

DWG:GA,ACCUM UNIT ASSY,W/20 BTLS,2 ELECTRIC PUMP,

EA

0.0000 09/05/2012

10644181-ASM

03

DWG: ACCUM UNIT ASSY, W/ 20 ACCUM BTLS, W/ ELECT,

EA

0.0000 09/05/2012

10684068-001

SPARE PARTS KIT F/ 10640281-001

EA

1.0000 09/05/2012

AX040014

STS: SURFACE TREATMENT, PAINT

EA

0.0000 08/15/2012

SPEC: TP HYDRAULIC POWER UNIT ASSY, IDEAL RIGS

AZ061529

AA

EA

0.0000 10/23/2012

1

10651010-001

B

STRUCT, HPU,184" LGX72" WDX59" HIGH

EA

1.0000 05/15/2012

2

10645953-001

PUMP ASSY, TRIPLEX 30HP, HORZ MT

EA

2.0000 05/15/2012

3

1500255

VLV, CHK, 1", 5000 PSI, STL, FULL FLOW

EA

2.0000 05/15/2012

4

1112939

VLV, BALL, 1-1/2", 150#, BRNZ

EA

2.0000 05/15/2012

5

0510005

STRAINER, Y-TYPE, 1-1/2", 250 PSI, MI, 20 MESH SC

EA

2.0000 05/15/2012

6

1112414

VLV, BALL, 1"NPT, 316SS

EA

2.0000 05/15/2012

7

0500215

FLTR, AIR

EA

1.0000 05/15/2012

8

1500350

VLV, CHK, FREE FLOW, 1"FPTxFPT 3000#, ZERO LEAKAGE

EA

1.0000 05/15/2012

9

0112002

RCVR, AIR, 30 GAL, HORIZ MT W/ LEGS, 200 PSI, ASME

EA

1.0000 05/15/2012

10

10640775-001

VLV, RELIEF, 1/4"MNPTxFNPT, SET @200PSI, S.S.

EA

1.0000 05/15/2012

11

10653700-001

VLV ASSY, FUNC, 1” 4-WAY VLV, W/AIR CYL, STD HPU

EA

6.0000 05/15/2012

12

10648646-001

VLV, CNTL, 1"NPT, 3K, 3POS, ACTUATED, BYPASS

EA

1.0000 05/15/2012

13

1000149

RGLTR, MKR, 1", 3000#

EA

1.0000 05/15/2012

14

1000539

RGLTR, HYD, 0-1500 OUTPUT, SPG-LOADED, AIR MTR DRV

EA

1.0000 05/15/2012

15

10649792-001

LEG PIPE ASSY, HPU

EA

12.0000 05/15/2012

16

5616043

PNL ASSY, GAUGE, (3) 6" GAUGES FLUID-FLD, W/FAILS

EA

1.0000 05/15/2012

17

10647137-001

VLV, BALL,1" NPT, 5000 PSI

EA

5.0000 05/15/2012

18

1550111

VLV, RELIEF, 5/16"ORIFICE, 3/4"MPT INLT x 3/4"FPT

EA

2.0000 05/15/2012

19

6553041

VLV, NEEDLE, 1/2"FNPT-FNPT, SS, 10,000PSI, METAL T

EA

10.0000 05/15/2012

20

20002331

MNFD ASSY, 2 VLV, 1/2"NPT, 6000 PSI, 316L SS +NN

EA

4.0000 05/15/2012

21

4005074

GAUGE, 4"FACE, DIAL TO READ IN BAR & 0-5000#, 1/4"

EA

4.0000 05/15/2012

22

9800405

MNFD, CNTL VLV, MACH, 5-STA,69"LG

EA

1.0000 05/15/2012

23

0000204

ACCUM ASSY, 11 GAL, TOP LOAD, OIL SVC, 3M PSI, -2

EA

20.0000 05/15/2012

24

9800305

MNFD, ACCUM, MACH, 54"LG

EA

4.0000 05/15/2012

25

2034345

NIPPLE, 1-1/4"x3"LG, XXH, A106 SMLS

EA

20.0000 05/15/2012

26

8030026

U-BOLT W/NUTS, 9-1/2"IDx 11-1/2"INSIDE LNGTH, 1/2"

EA

20.0000 05/15/2012

27

70000514

U-BOLT, 4"PIPE, 1/2"DIAx4-5/8" IDx8-5/16"LG

EA

8.0000 05/15/2012

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:08:05 AM Page: 2 of 2

Bill of Material for Item 10644181-001 Description: ACCUM UNIT ASSY,W/ 20 ACCUM BTLS, W/ ELECT REMOTE, Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

28

10649451-001

FLTR, 1"NPT, 25 MICRON, 5K PSI, 50GPM

EA

1.0000 05/15/2012

30

4005095

GAUGE, 2-1/2"FACE, 1/4"NPT, BM, 0-300 PSI/BAR, TEM

EA

1.0000 09/05/2012

31

1112417

VLV, BALL, 1/2"NPT, 316 SS, 2000 PSI

EA

2.0000 05/15/2012

32

1877208

HSG, GAUGE, WA, (2) 4"GAUGES

EA

2.0000 05/15/2012

33

0500012

BREATHER, FLTR, 3/4"NPT, HI IMPACT TECHNOPOLYMER C

EA

5.0000 05/15/2012

34

10656090-001

TUBE FTG AND TUBING KIT F/ STD LAND UNIT

EA

1.0000 05/15/2012

35

207267

WSHR, SPLIT, 1/2", SS

EA

60.0000 05/15/2012

36

8020456

WSHR, 1-3/8"OD, 9/16"ID, SS, FOR 1/2" BOLT

EA

48.0000 05/15/2012

37

8020263

NUT, HX, 1/2"-13UNC, SS

EA

52.0000 05/15/2012

38

20016423

GAUGE, SIGHT LEVEL, LIQUID, CTRS 24", FLOAT 316SS

EA

1.0000 05/15/2012

39

10654521-001

PIPING KIT, LAND RIG

EA

1.0000 05/15/2012

40

9107830

LABEL, DANGER- HIGH PRESSURE, W/ GRAPHIC

EA

20.0000 05/15/2012

41

20018051

TAG SET, HPU

EA

1.0000 05/15/2012

42

8638128

BRKT, TBG, 16- LINE

EA

7.0000 05/15/2012

43

8638120

PLT, BASE, 1"x1"x1/4" F/TBG CLAMP

EA

14.0000 05/15/2012

44

06020673

FL BAR 304SS 1/4 X 1"

FT

10.0000 05/15/2012

45

10656456-001

ELECT ASSY, HPU, BOP CNTL SYS, IDEAL LAND RIG

EA

1.0000 05/15/2012

46

8641472

GUARD, RAM, SHR

EA

1.0000 05/15/2012

47

9200011

ANGLE, 00.50"x03.00"x03.00", A36

FT

40.0000 05/15/2012

48

9200007

ANGLE, 00.25"x02.00"x02.00", A36

FT

20.0000 05/15/2012

49

10657062-001

BRKT, MTG PRESS REGULATOR ASSY, ACCUM. UNIT, ASSY.

EA

1.0000 05/15/2012

50

10656111-001

BRKT, ANNULAR REGULATOR ASSY

EA

1.0000 05/15/2012

51

20005210

SCREW, HHC, 3/8"-16UNC x 1" LG, 316 SS

EA

10.0000 05/15/2012

52

8020261

NUT, HX, 3/8"-16UNC, SS

EA

10.0000 05/15/2012

53

8020960

WSHR, LK, 3/8", HELICAL SPG, SS

EA

10.0000 05/15/2012

54

8020454

WSHR, FL, 3/8", SS

EA

10.0000 05/15/2012

55

10665290-001

OIL,HYDRAULIC,CHEVRON RANDO HD 32, 330 GAL TOTE

EA

1.0000 06/20/2012

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:29:06 AM Page: 1 of 1

Bill of Material for Item 5616043 Description: PNL ASSY, GAUGE, (3) 6" GAUGES FLUID-FLD, W/FAILS Balloon Number

Part Number

Rev

5616043D

B

Description

U M

Quantity Per

Eff Begin

DWG: PNL ASSY, GAUGE, (3) 6" G

EA

0.0000 06/12/2003

1

8638212

PLT, MTG, GAUGE HSG (SPECIAL)

EA

1.0000

2

1050513

VLV, CNTL, AIR, 1/2"NPT, 4-WAY 3-POS, AIR PILOT, W

EA

1.0000

3

4005091

GAUGE, 6" FACE, GLYCERIN FILL, 1/4" LBM TO READ IN

EA

2.0000

4

4005092

GAUGE, 6"FACE, GLY-FLD, 1/4" LBM, TO READ 0-3000 P

EA

1.0000

5

9106171

NMPLT, "INCREASE"

EA

1.0000

6

9106170

NMPLT, "DEC"

EA

1.0000

7

9100537

NMPLT, "ANNULAR PRSSR" 1"x2"

EA

1.0000

8

9100536

NMPLT, "ACCUM PRSSR" 1"x2"

EA

1.0000

9

9100535

NMPLT, "MNFD PRSSR" LYNN PLY, 1"x2"

EA

1.0000

10

8007710

SCREW, RD HD, 10-32x3/4", SS

EA

9.0000

11

8020293

NUT, HX, #10-32UNF, SS

EA

9.0000

12

2115437

CONN, TUBE, 1/4"Tx1/4"FPT, SS

EA

3.0000

13

1705101

GAUGE,SNUB, POROUS METAL,1/4"MPTx1/4"FPT,OIL,316SS

EA

3.0000

14

8002828

SCREW, SHC, 1/4"UNCx1-1/4"LG, SS

EA

3.0000

15

8020526

WSHR, FL, 1/4", SS

EA

3.0000

16

8020958

WSHR, LK, 1/4", HELICAL SPG, SS

EA

3.0000

17

8020259

NUT, HX, 1/4"-20UNC, SS

EA

3.0000

18

2115054

CONN, TUBE, 1/2"Tx1/2"MPT, SS

EA

1.0000 06/11/2003

19

2115248

ELBOW, TUBE, 3/8"Tx1/2"MPT, SS

EA

2.0000

20

2302059

TBG, 00.38"x0.035"WALL, 316SS, SMLS SEE SLC TEXT

IN

120.0000 06/11/2003

21

2115048

CONN, TUBE, 3/8"Tx1/4"MPT, SS

EA

2.0000 06/11/2003

23

2040034

ELBOW, 90DEG, 1/2", SS, FPTxFPT

EA

1.0000 06/11/2003

24

2040307

NIPPLE, HX, 1/2"MPTx1/2"MPT, SS

EA

3.0000 06/11/2003

25

4600013

LUBRICATOR, AIR, 1/2"NPT, W/ METAL BOWL

EA

1.0000

26

1200013

RGLTR, RELIEVING, AIR, 1/2"NPT W/GAUGE, 0-250#

EA

1.0000

27

2040047

ELBOW, STREET, 90 DEG, 1/2", MPTxFPT, SS

EA

1.0000 06/11/2003

28

2115041

CONN, TUBE, 1/4"Tx1/8"MPT, SS

EA

1.0000

29

2115239

ELBOW, TUBE, 1/4"Tx1/8"MPT, SS

EA

1.0000

30

8030017

U-BOLT W/NUTS, 3"PIPE, 3-1/2" IDx4-5/8"INSIDE LNG

EA

2.0000

31

8020981

WSHR, LK, 3/8", HI COLLAR, HELICAL SPG, SS

EA

4.0000

32

8020528

WSHR, FL, 3/8", SS

EA

4.0000

End of Publication

NMPLT,

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:30:06 AM Page: 1 of 1

Bill of Material for Item 10653700-001 Description: VLV ASSY, FUNC, 1” 4-WAY VLV, W/AIR CYL, STD HPU Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

10653700-ASM

01

DWG: VLV ASSY, FUNC,1” 4-WAY VLV,W/AIR CYL,STD HPU

EA

0.0000 04/17/2012

AX040014

AA

STS: SURFACE TREATMENT, PAINT

EA

0.0000 08/15/2012

1

10647335-001

VLV, CNTL, 1"NPT, 3KPSI, 3POS, 4WAY, ACTUATED

EA

1.0000 04/17/2012

2

2022099

ELBOW, 90 DEG, 1"NPT, STREET, 3000#, FCS, A105

EA

2.0000 04/17/2012

3

2031546

UNION, 1"NPT, 3000# INTEGRAL

EA

3.0000 04/17/2012

4

2033985

NIPPLE, 1"x8"LG, SCH160, SMLS, A106

EA

2.0000 04/17/2012

6

2033982

NIPPLE, 1"x3"LG, SCH160, SMLS, A106

EA

1.0000 04/17/2012

7

2033983

NIPPLE, 1"x4"LG, SCH160, SMLS, A106

EA

3.0000 04/17/2012

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:30:36 AM Page: 1 of 1

Bill of Material for Item 10656456-001 Description: ELECT ASSY, HPU, BOP CNTL SYS, IDEAL LAND RIG Balloon Number

Part Number 10656456-ASM

Rev

03

Description

U M

Quantity Per

Eff Begin

DWG: ELECT ASSY, HPU, BOP CNTL SYS, IDEAL LAND RIG

EA

0.0000 11/05/2012

1

10647804-001

J-BOX UPR LVL ASSY, HPU, IDEAL LAND RIG

EA

1.0000 05/01/2012

2

10656625-001

J-BOX ASSY, MOTOR STARTER, IDEAL LAND RIG

EA

2.0000 05/01/2012

3

20086694

SOLID STATE PRSS SWITCH, 0-7500 PSI, ZON

EA

2.0000 05/14/2012

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:31:06 AM Page: 1 of 1

Bill of Material for Item 10647804-001 Description: J-BOX UPR LVL ASSY, HPU, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

10656624-001

J-BOX ASSY, HPU, IDEAL LAND RIG

EA

1.0000 05/14/2012

2

4520255

TRNSMTR, PRSSR, 0-3000 PSI, 4-20MA, 24VDC

EA

1.0000 07/20/2012

3

4520256

TRNSMTR, PRSSR, 0-5K, 4-20mA, 24VDC

EA

2.0000 07/20/2012

4

4520253

TRNSMTR, PRSSR, 0-300 PSI, 4-20MA, 24VDC

EA

1.0000 07/20/2012

5

20004323

ADPTR, 1/2" NPT(F) TO M20 (M) BRASS,E EX E +NN

EA

30.0000 10/29/2012

6

10663774-001

SWITCH, PRSSR, 150-1000 PSI, ADJ, E EX D

EA

12.0000 07/20/2012

7

10663787-001

SWITCH, PRSSR, 400-3000 PSI, ADJ, E EX D

EA

2.0000 07/20/2012

8

10663790-001

SWITCH, PRSSR, 5-150 PSI, ADJ, E EX D

EA

1.0000 07/20/2012

9

4550017

SWITCH, FLOAT, LIQUID LEVEL, EX-PRF, SPST, 1500 PS

EA

1.0000 07/20/2012

10

2040216

BUSHING, REDUCER, 2"MPTx 1-1/2"FPT, SS

EA

1.0000 07/09/2012

11

6560003-00

CABLE, BFOU, 250V, 1X2X1.5, ARMORED, W/INDVIDUAL,

FT

150.0000 07/20/2012

12

6560003-01

CABLE, BFOU, 250V, 2X2X1.5, ARMORED, W/INDIVIDUAL,

FT

100.0000 07/20/2012

13

6560005-14

CABLE, BFOU, 1KV, ARMORED, PWR'D CABLE

FT

100.0000 07/20/2012

14

20035871-057

GLAND, CABLE, EEXD/E,1/2"NPT, 6.5-13.9MM CABLE OD

EA

5.0000 10/29/2012

15

20035874-057

GLAND, CABLE, EEXD/E, 1/2"NPT,0.512-0.823"CABLE OD

EA

2.0000 07/20/2012

16

20035874-061

GLAND, CABLE, EEXD/E, 3/4"NPT,0.709-1.031"CABLE OD

EA

8.0000 07/20/2012

17

339572

PLUG, STOPPING, 3/4" NPT

EA

4.0000 07/20/2012

18

340175

PLUG, STOPPING, 1-1/2" NPT

EA

1.0000 07/20/2012

20

6200606

ELBOW, 90 DEG, 1/2"NPT, MALE

EA

1.0000 07/20/2012

21

20012770

OTLT BDY, CONDUIT, 1/2"HUB, WCVR

EA

1.0000 07/20/2012

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Aug 13, 2013 Time: 1:41:01 PM Page: 1 of 1

Bill of Material for Item 10656625-001 Description: MTR STARTER, HPU, 480V, 30HP, 60HZ, 3PH, Balloon Number

Part Number 10656625-ASM

Rev

02

Description

U M

Quantity Per

Eff Begin

DWG: MTR STARTER, HPU, 480V, 30HP, 60HZ, 3PH,

EA

0.0000 03/11/2013

1

10729462-001

ENCL, CLASS 1/DIVISION 1/2

EA

1.0000 03/11/2013

2

10704920-001

BACKPAN, ENCLOSURE EXB-12246 N34

EA

1.0000 03/11/2013

3

10537294-001

PUSH BUTTON, E-STOP

EA

1.0000 03/11/2013

4

10704872-001

SWITCH, 3 POSITION, HOA, SPRING FROM LEFT

EA

1.0000 03/11/2013

5

10729476-001

LIGHT, IND, 24VDC, GRN, CLASS 1/DIVISION 1/2, ATEX

EA

1.0000 03/11/2013

6

10729490-001

PROTECTOR, MTR CIRCUIT, 50 A, 3 PH, 480 V

EA

1.0000 03/11/2013

7

10729529-001

PWR SPLY, 460:24VDC, 10A

EA

1.0000 03/11/2013

8

10729530-001

CONTACTOR, 3 PH, 40HP, 24VDC COIL

EA

1.0000 03/11/2013

9

10729533-001

OVERLOAD, FRAME SIZE D, 40-57 A, ADJ

EA

1.0000 03/11/2013

10

10729535-001

CONTACT, AUX, CONTACTOR, 2a/2b

EA

1.0000 03/11/2013

11

10729539-001

LIGHT, IND, 24VDC, CLR, CLASS 1/DIVISION 1/2, ATEX

EA

1.0000 03/11/2013

12

10537292-001

SWITCH, PUSH BUTTON, RESET

EA

1.0000 03/11/2013

13

10729544-001

DRAIN, ENCL, 1/2NPT GRP, A ATEX, IEC EX

EA

1.0000 03/11/2013

14

10634511-001

GENERAL PURPOSE CNTL RELAY, 24 VDC COIL,10A, 4POLE

EA

1.0000 03/11/2013

15

10667240-001

CNTL RELAY, BASE, 4PDT

EA

1.0000 03/11/2013

16

10667241-001

TERM BLK, FEED THRU

EA

6.0000 03/11/2013

17

20005066

PLT, END, SAK 2.5

EA

1.0000 03/11/2013

18

6552755

BRKT, END, BLK, TERM, DIODE

EA

5.0000 03/11/2013

19

0000-6987-57

TERMINAL GROUND TS 35 RAIL

EA

1.0000 03/11/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jul 30, 2013 Time: 12:39:07 PM Page: 1 of 2

Bill of Material for Item 10656624-001 Description: PNL ASSY, HPU ELECT, BOP CNTL SYS, IDEAL LAND RIG Balloon Number

Part Number 10656624-ASM

Rev

02

Description

U M

Quantity Per

Eff Begin

DWG: PNL ASSY, HPU ELECT, BOP CNTL SYS, IDEAL LAND

EA

0.0000 07/25/2013

1

10721373-001

POWER SPLY, 24VDC INPUT, 4A@5V DC OUTPUT

EA

1.0000 07/25/2013

2

10721404-001

CONTROLLER, PROGRAMMABLE AUTOMATION, 1MB

EA

1.0000 07/25/2013

3

9151960370

PLC, MODULE, AB #1769-IQ16 (FOR MICROLOGIX 1500)

EA

2.0000 07/25/2013

4

10721427-001

MODULE, OUTPUT, 32POINT, 24VDC, COMPACTLOGIX

EA

1.0000 07/25/2013

5

10721436-001

MODULE, INPUT, ANALOG, 8 CHANNEL, COMPACTLOGIX

EA

1.0000 07/25/2013

6

9151960380

END CAP, PLC TERMINATOR , AB #1769-ECR

EA

1.0000 07/25/2013

7

10705057-001

ENCLOSURE, 316 SS, EEx e, IP66, 25.6X37.4X12

EA

1.0000 07/25/2013

8

97288

MISC ALARM, AUDIBLE IS +NN

EA

1.0000 07/25/2013

9

20070966

PILOT LIGHT, LED, 24 VDC, RED

EA

4.0000 07/25/2013

10

20080660

CONTACT BLK, RED, ATEX

EA

4.0000 07/25/2013

11

20072805

PILOT LIGHT, LED, 24 VDC, YELLOW

EA

2.0000 07/25/2013

12

20080661

CONTACT BLK, AMBER, ATEX

EA

2.0000 07/25/2013

13

P250002-0002-35

SWITCH, PUSHBUTTON NON-ILLUM; FLUSH

EA

2.0000 07/25/2013

14

10692456-001

CONTACT BLK, 1 N.O.-1 N.C., LATCH MT, BLK

EA

2.0000 07/25/2013

15

10721454-001

CONN, MALE, NP BRASS 1/4 IN

EA

16.0000 07/25/2013

16

7804320

MALE, CONN-PRESTOLOK,1/4"

EA

16.0000 07/25/2013

17

10721511-001

CONN, FEMALE, BULKHEAD, PNEU, 1/4" FNPT, 316SS

EA

16.0000 07/25/2013

18

10721515-001

CONN, FEMALE, BULKHEAD, PNEU, 3/8" FNPT, 316SS

EA

1.0000 07/25/2013

19

10721521-001

MUFFLER/FILTER, 3/8" NPT MALE, 11/16" HEX, 250 PSI

EA

2.0000 07/25/2013

20

10722669-001

CONN, FEMALE BULKHEAD, 3/8 IN, 300 PSI

EA

2.0000 07/25/2013

21

10722670-001

CONN, ELBOW, TUBE TO MAIL NPT, 3/8 IN

EA

4.0000 07/25/2013

22

10722671-001

PLUG, SOCKET HEAD, MALE, 3/8 IN, 1000 PSI

EA

3.0000 07/25/2013

23

9111962940

POWER SUPPLY, SOLA/HEVIDUTY #SDN10-24-100P,

EA

1.0000 07/25/2013

24

10722672-001

CONN, FIBER CABLE, MULTIMODE

EA

2.0000 07/25/2013

25

10722673-001

BUR, GROUND, PANELBOARD, 12 TERMINAL

EA

1.0000 07/25/2013

26

10715177-001

SWITCH, ETHERNET, 8-PORT, FULLY MANAGED

EA

2.0000 07/25/2013

27

10704322-001

HUB, GROUND, BASIC SCRU-TITE, ZINC, 1/2" NEMA

EA

2.0000 07/25/2013

28

10667241-001

TERM BLK, FEED THRU

EA

157.0000 07/25/2013

29

20005066

PLT, END, SAK 2.5

EA

5.0000 07/25/2013

30

6552755

BRKT, END, BLK, TERM, DIODE

EA

7.0000 07/25/2013

31

P250002-0019-35

JUMPER-CROSS-CONNECTOR/LINKFOR M

EA

11.0000 07/25/2013

32

0000-9634-85

TB-TAG CARRIER,TS32 & TS35

EA

5.0000 07/25/2013

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jul 30, 2013 Time: 12:39:07 PM Page: 2 of 2

Bill of Material for Item 10656624-001 Description: PNL ASSY, HPU ELECT, BOP CNTL SYS, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

33

10723411-001

HOLE SEAL, FOR MICRO- 0.56IN DIA., SS TYPE 304

EA

2.0000 07/25/2013

34

10723413-001

HOLE SEAL, F/0.5-IN CONDUIT, SS

EA

3.0000 07/25/2013

35

948513-068

TERM BLK, GROUNDING, 6.0MM

EA

6.0000 07/25/2013

36

20072818

SWITCH, SLCTR, 2 POS, 2 N/O CONTACT

EA

1.0000 07/25/2013

37

20080663

CONTACT BLK, BLK, ATEX

EA

1.0000 07/25/2013

38

10723419-001

O-RING, 1/4", IP66

EA

16.0000 07/25/2013

39

10723421-001

O-RING, 3/8 ", IP66

EA

1.0000 07/25/2013

40

10723424-001

O-RING, 3/8" NTP, IP66

EA

2.0000 07/25/2013

41

10723428-001

MNFD SYS, CLASS 1, DIV 2, 10- STA

EA

1.0000 07/25/2013

42

10699867-001

RELAY, PLC, 24 VDC, HAZARDOUS LOCATION

EA

1.0000 07/25/2013

43

10726009-001

CONDUIT, RIGIT, 1/2"X3", ELECT

EA

1.0000 07/25/2013

44

10726004-001

HUB, CONDUIT, 1/2" NPT, HAZARDOUS LOC.

EA

2.0000 07/25/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jan 21, 2013 Time: 8:31:55 AM Page: 1 of 1

Bill of Material for Item 10684068-001 Description: SPARE PARTS KIT F/ 10640281-001 Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

1500255

VLV, CHK, 1", 5000 PSI, STL, FULL FLOW

EA

1.0000 09/01/2012

2

0500215

FLTR, AIR

EA

1.0000 09/01/2012

3

1500350

VLV, CHK, FREE FLOW, 1"FPTxFPT 3000#, ZERO LEAKAGE

EA

1.0000 09/01/2012

4

10640775-001

VLV, RELIEF, 1/4"MNPTxFNPT, SET @200PSI, S.S.

EA

1.0000 09/01/2012

5

10659669-001

RPR KIT, VLV, CNTL F/1" NPT VLV P/N: 10647335-001

EA

3.0000 09/01/2012

6

10659654-001

RPR KIT, VLV, CNTL F/1" NPT VLV P/N: 10648646-001

EA

1.0000 09/01/2012

7

9910001

RPR KIT, VLV, HKR **SEE TEXT**

EA

1.0000 09/01/2012

8

9910050

SEAL KIT, SOH=0, WHEN OBS R/B P/N 10564140-001

EA

1.0000 09/01/2012

9

9910182

RPR KIT, F/#1000539

EA

1.0000 09/01/2012

10

9910181

SEAL KIT, F/#1000539

EA

1.0000 09/01/2012

11

4005091

GAUGE, 6" FACE, GLYCERIN FILL, 1/4" LBM TO READ IN

EA

1.0000 09/01/2012

12

4005092

GAUGE, 6"FACE, GLY-FLD, 1/4" LBM, TO READ 0-3000 P

EA

1.0000 09/01/2012

13

1050513

VLV, CNTL, AIR, 1/2"NPT, 4-WAY 3-POS, AIR PILOT, W

EA

1.0000 09/01/2012

14

4600013

LUBRICATOR, AIR, 1/2"NPT, W/ METAL BOWL

EA

1.0000 09/01/2012

15

1200013

RGLTR, RELIEVING, AIR, 1/2"NPT W/GAUGE, 0-250#

EA

1.0000 09/01/2012

16

10647137-001

VLV, BALL,1" NPT, 5000 PSI

EA

1.0000 09/01/2012

17

1550111

VLV, RELIEF, 5/16"ORIFICE, 3/4"MPT INLT x 3/4"FPT

EA

1.0000 09/01/2012

18

6553041

VLV, NEEDLE, 1/2"FNPT-FNPT, SS, 10,000PSI, METAL T

EA

3.0000 09/01/2012

19

4005074

GAUGE, 4"FACE, DIAL TO READ IN BAR & 0-5000#, 1/4"

EA

2.0000 09/01/2012

20

0000378

BLADDER KIT, ACCUM, 11 GAL, 3000# PSI, 1-1/4" & 2"

EA

5.0000 09/01/2012

21

10649615-001

FLTR, ELEM, 25 MICRON, 300# GLASS FIBER

EA

1.0000 09/01/2012

22

4005095

GAUGE, 2-1/2"FACE, 1/4"NPT, BM, 0-300 PSI/BAR, TEM

EA

1.0000 09/01/2012

23

0500012

BREATHER, FLTR, 3/4"NPT, HI IMPACT TECHNOPOLYMER C

EA

2.0000 09/01/2012

24

1112417

VLV, BALL, 1/2"NPT, 316 SS, 2000 PSI

EA

1.0000 09/01/2012

25

10659676-001

SEAL KIT, VLVS, CNTL, PACSEAL HYDRAULICS

EA

4.0000 09/01/2012

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Mar 20, 2013 Time: 7:35:07 AM Page: 1 of 1

Bill of Material for Item 10721000-001 Description: SPARE PARTS KIT, HPU ELECT PNL UPR LVL,IDEAL RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

2040216

BUSHING, REDUCER, 2"MPTx 1-1/2"FPT, SS

EA

1.0000 02/09/2013

2

4520255

TRNSMTR, PRSSR, 0-3000 PSI, 4-20MA, 24VDC

EA

1.0000 02/09/2013

3

4520256

TRNSMTR, PRSSR, 0-5K, 4-20mA, 24VDC

EA

1.0000 02/09/2013

4

4520253

TRNSMTR, PRSSR, 0-300 PSI, 4-20MA, 24VDC

EA

1.0000 02/09/2013

5

10663774-001

SWITCH, PRSSR, 150-1000 PSI, ADJ, E EX D

EA

2.0000 02/09/2013

6

10663787-001

SWITCH, PRSSR, 400-3000 PSI, ADJ, E EX D

EA

1.0000 02/09/2013

7

10663790-001

SWITCH, PRSSR, 5-150 PSI, ADJ, E EX D

EA

1.0000 02/09/2013

8

4550017

SWITCH, FLOAT, LIQUID LEVEL, EX-PRF, SPST, 1500 PS

EA

1.0000 02/09/2013

9

20035874-057

GLAND, CABLE, EEXD/E, 1/2"NPT,0.512-0.823"CABLE OD

EA

1.0000 02/09/2013

10

20035874-061

GLAND, CABLE, EEXD/E, 3/4"NPT,0.709-1.031"CABLE OD

EA

1.0000 02/09/2013

11

339572

PLUG, STOPPING, 3/4" NPT

EA

1.0000 02/09/2013

12

340175

PLUG, STOPPING, 1-1/2" NPT

EA

1.0000 02/09/2013

13

6200606

ELBOW, 90 DEG, 1/2"NPT, MALE

EA

1.0000 02/09/2013

14

20012770

OTLT BDY, CONDUIT, 1/2"HUB, WCVR

EA

1.0000 02/09/2013

15

20004323

ADPTR, 1/2" NPT(F) TO M20 (M) BRASS,E EX E +NN

EA

3.0000 02/09/2013

16

20035871-057

GLAND, CABLE, EEXD/E,1/2"NPT, 6.5-13.9MM CABLE OD

EA

1.0000 02/09/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Aug 13, 2013 Time: 1:20:56 PM Page: 1 of 2

Bill of Material for Item 10710987-001 Description: SPARE PARTS KIT, HPU ELECT PNL, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

10721373-001

POWER SPLY, 24VDC INPUT, 4A@5V DC OUTPUT

EA

1.0000 08/05/2013

2

10721404-001

CONTROLLER, PROGRAMMABLE AUTOMATION, 1MB

EA

1.0000 08/05/2013

3

9151960370

PLC, MODULE, AB #1769-IQ16 (FOR MICROLOGIX 1500)

EA

1.0000 08/05/2013

4

10721427-001

MODULE, OUTPUT, 32POINT, 24VDC, COMPACTLOGIX

EA

1.0000 08/05/2013

5

10721436-001

MODULE, INPUT, ANALOG, 8 CHANNEL, COMPACTLOGIX

EA

1.0000 08/05/2013

6

9151960380

END CAP, PLC TERMINATOR , AB #1769-ECR

EA

1.0000 08/05/2013

8

97288

MISC ALARM, AUDIBLE IS +NN

EA

1.0000 08/05/2013

9

20070966

PILOT LIGHT, LED, 24 VDC, RED

EA

1.0000 08/05/2013

10

20080660

CONTACT BLK, RED, ATEX

EA

1.0000 08/05/2013

11

20072805

PILOT LIGHT, LED, 24 VDC, YELLOW

EA

1.0000 08/05/2013

12

20080661

CONTACT BLK, AMBER, ATEX

EA

1.0000 08/05/2013

13

P250002-0002-35

SWITCH, PUSHBUTTON NON-ILLUM; FLUSH

EA

1.0000 08/05/2013

14

10692456-001

CONTACT BLK, 1 N.O.-1 N.C., LATCH MT, BLK

EA

1.0000 08/05/2013

15

10721454-001

CONN, MALE, NP BRASS 1/4 IN

EA

2.0000 08/05/2013

16

7804320

MALE, CONN-PRESTOLOK,1/4"

EA

2.0000 08/05/2013

17

10721511-001

CONN, FEMALE, BULKHEAD, PNEU, 1/4" FNPT, 316SS

EA

2.0000 08/05/2013

18

10721515-001

CONN, FEMALE, BULKHEAD, PNEU, 3/8" FNPT, 316SS

EA

1.0000 08/05/2013

19

10721521-001

MUFFLER/FILTER, 3/8" NPT MALE, 11/16" HEX, 250 PSI

EA

1.0000 08/05/2013

20

10722669-001

CONN, FEMALE BULKHEAD, 3/8 IN, 300 PSI

EA

1.0000 08/05/2013

21

10722670-001

CONN, ELBOW, TUBE TO MAIL NPT, 3/8 IN

EA

1.0000 08/05/2013

22

10722671-001

PLUG, SOCKET HEAD, MALE, 3/8 IN, 1000 PSI

EA

1.0000 08/05/2013

23

9111962940

POWER SUPPLY, SOLA/HEVIDUTY #SDN10-24-100P,

EA

1.0000 08/05/2013

24

10722672-001

CONN, FIBER CABLE, MULTIMODE

EA

1.0000 08/05/2013

25

10722673-001

BUR, GROUND, PANELBOARD, 12 TERMINAL

EA

1.0000 08/05/2013

26

10715177-001

SWITCH, ETHERNET, 8-PORT, FULLY MANAGED

EA

1.0000 08/05/2013

27

10704322-001

HUB, GROUND, BASIC SCRU-TITE, ZINC, 1/2" NEMA

EA

1.0000 08/01/2013

28

10667241-001

TERM BLK, FEED THRU

EA

15.0000 08/05/2013

29

20005066

PLT, END, SAK 2.5

EA

1.0000 08/05/2013

30

6552755

BRKT, END, BLK, TERM, DIODE

EA

1.0000 08/05/2013

31

P250002-0019-35

JUMPER-CROSS-CONNECTOR/LINKFOR M

EA

1.0000 08/05/2013

32

0000-9634-85

TB-TAG CARRIER,TS32 & TS35

EA

1.0000 08/05/2013

33

10723411-001

HOLE SEAL, FOR MICRO- 0.56IN DIA., SS TYPE 304

EA

1.0000 08/05/2013

34

10723413-001

HOLE SEAL, F/0.5-IN CONDUIT, SS

EA

1.0000 08/05/2013

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Aug 13, 2013 Time: 1:20:56 PM Page: 2 of 2

Bill of Material for Item 10710987-001 Description: SPARE PARTS KIT, HPU ELECT PNL, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

35

948513-068

TERM BLK, GROUNDING, 6.0MM

EA

1.0000 08/05/2013

36

20072818

SWITCH, SLCTR, 2 POS, 2 N/O CONTACT

EA

1.0000 08/05/2013

37

20080663

CONTACT BLK, BLK, ATEX

EA

1.0000 08/05/2013

38

10723419-001

O-RING, 1/4", IP66

EA

2.0000 08/05/2013

39

10723421-001

O-RING, 3/8 ", IP66

EA

1.0000 08/05/2013

40

10723424-001

O-RING, 3/8" NTP, IP66

EA

1.0000 08/05/2013

41

10723428-001

MNFD SYS, CLASS 1, DIV 2, 10- STA

EA

1.0000 08/05/2013

42

10699867-001

RELAY, PLC, 24 VDC, HAZARDOUS LOCATION

EA

1.0000 08/05/2013

43

10726009-001

CONDUIT, RIGIT, 1/2"X3", ELECT

EA

1.0000 08/05/2013

44

10726004-001

HUB, CONDUIT, 1/2" NPT, HAZARDOUS LOC.

EA

1.0000 08/05/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Mar 20, 2013 Time: 7:36:19 AM Page: 1 of 1

Bill of Material for Item 10729811-001 Description: SPARE PARTS KIT, MTR STARTER J-BOX, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

10704920-001

BACKPAN, ENCLOSURE EXB-12246 N34

EA

1.0000 03/11/2013

2

10537294-001

PUSH BUTTON, E-STOP

EA

1.0000 03/11/2013

3

10704872-001

SWITCH, 3 POSITION, HOA, SPRING FROM LEFT

EA

1.0000 03/11/2013

4

10729476-001

LIGHT, IND, 24VDC, GRN, CLASS 1/DIVISION 1/2, ATEX

EA

1.0000 03/11/2013

5

10729490-001

PROTECTOR, MTR CIRCUIT, 50 A, 3 PH, 480 V

EA

1.0000 03/11/2013

6

10729529-001

PWR SPLY, 460:24VDC, 10A

EA

1.0000 03/11/2013

7

10729530-001

CONTACTOR, 3 PH, 40HP, 24VDC COIL

EA

1.0000 03/11/2013

8

10729533-001

OVERLOAD, FRAME SIZE D, 40-57 A, ADJ

EA

1.0000 03/11/2013

9

10729535-001

CONTACT, AUX, CONTACTOR, 2a/2b

EA

1.0000 03/11/2013

10

10729539-001

LIGHT, IND, 24VDC, CLR, CLASS 1/DIVISION 1/2, ATEX

EA

1.0000 03/11/2013

11

10537292-001

SWITCH, PUSH BUTTON, RESET

EA

1.0000 03/11/2013

12

10729544-001

DRAIN, ENCL, 1/2NPT GRP, A ATEX, IEC EX

EA

1.0000 03/11/2013

13

10634511-001

GENERAL PURPOSE CNTL RELAY, 24 VDC COIL,10A, 4POLE

EA

1.0000 03/11/2013

14

10667240-001

CNTL RELAY, BASE, 4PDT

EA

1.0000 03/11/2013

15

10667241-001

TERM BLK, FEED THRU

EA

1.0000 03/11/2013

16

20005066

PLT, END, SAK 2.5

EA

1.0000 03/11/2013

17

6552755

BRKT, END, BLK, TERM, DIODE

EA

1.0000 03/11/2013

18

0000-6987-57

TERMINAL GROUND TS 35 RAIL

EA

1.0000 03/11/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Mar 20, 2013 Time: 7:36:42 AM Page: 1 of 1

Bill of Material for Item 10715084-001 Description: SPARE PARTS KIT, DRLR'S PNL, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

9151961280

PLC, AB #1794-AENT FLEX I/O COMMUNICATION &

EA

1.0000 03/08/2013

2

9151961370

PLC, AB #1794-IB32, FLEX I/O (32) SINKING INPUT

EA

1.0000 03/08/2013

3

9151961380

PLC, AB #1794-OB32P, FLEX I/O (32) SOURCING OUTPU

EA

1.0000 03/08/2013

4

10715165-001

ANALOG OUTPUT MODULE, 4 CHANNEL, FLEX I/O

EA

1.0000 03/08/2013

5

9151961390

PLC, AB #1794-TB32S, FLEX I/O (32) TERMINAL BLOCK,

EA

1.0000 03/08/2013

6

9151961310

PLC, AB #1794-TB3 FLEX I/O TERMINAL BLOCK

EA

1.0000 03/08/2013

7

10679195-001

INDICATOR, DIGITAL, 5 DIGIT, 4-20MA IN

EA

1.0000 03/08/2013

8

20070966

PILOT LIGHT, LED, 24 VDC, RED

EA

1.0000 03/08/2013

9

20080660

CONTACT BLK, RED, ATEX

EA

1.0000 03/08/2013

10

20072805

PILOT LIGHT, LED, 24 VDC, YELLOW

EA

1.0000 03/08/2013

11

20080661

CONTACT BLK, AMBER, ATEX

EA

1.0000 03/08/2013

12

20072806

PILOT LIGHT, LED, 24 VDC, GREEN

EA

1.0000 03/08/2013

13

20080662

CONTACT BLK, GREEN, ATEX

EA

1.0000 03/08/2013

14

20070964

PUSHBUTTON, NON-ILLUM, BLACK, 2 NO, 30 MM

EA

1.0000 03/08/2013

15

10692456-001

CONTACT BLK, 1 N.O.-1 N.C., LATCH MT, BLK

EA

1.0000 03/08/2013

16

20077263

OPER, PUSHBUTTON, FLUSH, ILLUMINATED, 30MM, GREEN

EA

1.0000 03/08/2013

17

10705049-001

MDL PWR, 24 VDC, 1 NO CONTACT, HAZ LOC, GREEN

EA

1.0000 03/08/2013

18

20072816

OPER, PUSHBUTTON, FLUSH, ILLUMINATED, 30MM, RED

EA

1.0000 03/08/2013

19

20079164

PUSHBUTTON, LED, 1 N/O CONTACT, 24 VDC, RED

EA

1.0000 03/08/2013

20

P250002-0008-39

PWR SPLY- 24V, 5. A,INPUT,OBS,R/B P/N 10066883-001

EA

1.0000 03/08/2013

21

10715184-001

ALARM, BUZZER, 24VDC, EX

EA

1.0000 03/08/2013

23

10715170-001

CABLE, FIBER, FLANGE MT, 62.5, MULTIMODE, ST CONN

EA

1.0000 03/08/2013

24

10715177-001

SWITCH, ETHERNET, 8-PORT, FULLY MANAGED

EA

1.0000 03/08/2013

25

10667241-001

TERM BLK, FEED THRU

EA

11.0000 03/08/2013

26

10537299-001

END PLATE-TB, ELEC

EA

1.0000 03/08/2013

27

948513-068

TERM BLK, GROUNDING, 6.0MM

EA

1.0000 03/08/2013

28

10537298-001

END STOP-TB, ELEC

EA

1.0000 03/08/2013

29

0000-9634-85

TB-TAG CARRIER,TS32 & TS35

EA

1.0000 03/08/2013

30

P250002-0019-35

JUMPER-CROSS-CONNECTOR/LINKFOR M

EA

1.0000 03/08/2013

31

10699867-001

RELAY, PLC, 24 VDC, HAZARDOUS LOCATION

EA

1.0000 03/08/2013

32

20072818

SWITCH, SLCTR, 2 POS, 2 N/O CONTACT

EA

1.0000 03/08/2013

33

20080663

CONTACT BLK, BLK, ATEX

EA

1.0000 03/08/2013

End of Publication

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Mar 20, 2013 Time: 7:37:06 AM Page: 1 of 2

Bill of Material for Item 10715087-001 Description: SPARE PARTS KIT, TLPSHR'S PNL, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

9151961280

PLC, AB #1794-AENT FLEX I/O COMMUNICATION &

EA

1.0000 01/22/2013

2

9151961370

PLC, AB #1794-IB32, FLEX I/O (32) SINKING INPUT

EA

1.0000 01/22/2013

3

9151961380

PLC, AB #1794-OB32P, FLEX I/O (32) SOURCING OUTPU

EA

1.0000 01/22/2013

4

10715165-001

ANALOG OUTPUT MODULE, 4 CHANNEL, FLEX I/O

EA

1.0000 01/22/2013

5

9151961390

PLC, AB #1794-TB32S, FLEX I/O (32) TERMINAL BLOCK,

EA

1.0000 01/22/2013

6

9151961310

PLC, AB #1794-TB3 FLEX I/O TERMINAL BLOCK

EA

1.0000 01/22/2013

7

10679195-001

INDICATOR, DIGITAL, 5 DIGIT, 4-20MA IN

EA

1.0000 01/22/2013

8

20070966

PILOT LIGHT, LED, 24 VDC, RED

EA

1.0000 01/22/2013

9

20080660

CONTACT BLK, RED, ATEX

EA

1.0000 01/22/2013

10

20072805

PILOT LIGHT, LED, 24 VDC, YELLOW

EA

1.0000 01/22/2013

11

20080661

CONTACT BLK, AMBER, ATEX

EA

1.0000 01/22/2013

12

20072806

PILOT LIGHT, LED, 24 VDC, GREEN

EA

1.0000 01/22/2013

13

20080662

CONTACT BLK, GREEN, ATEX

EA

1.0000 01/22/2013

14

20070964

PUSHBUTTON, NON-ILLUM, BLACK, 2 NO, 30 MM

EA

1.0000 01/22/2013

15

10692456-001

CONTACT BLK, 1 N.O.-1 N.C., LATCH MT, BLK

EA

1.0000 01/22/2013

16

20077263

OPER, PUSHBUTTON, FLUSH, ILLUMINATED, 30MM, GREEN

EA

1.0000 01/22/2013

17

10705049-001

MDL PWR, 24 VDC, 1 NO CONTACT, HAZ LOC, GREEN

EA

1.0000 01/22/2013

18

20072816

OPER, PUSHBUTTON, FLUSH, ILLUMINATED, 30MM, RED

EA

1.0000 01/22/2013

19

20079164

PUSHBUTTON, LED, 1 N/O CONTACT, 24 VDC, RED

EA

1.0000 01/22/2013

20

P250002-0008-39

PWR SPLY- 24V, 5. A,INPUT,OBS,R/B P/N 10066883-001

EA

1.0000 01/22/2013

21

10715184-001

ALARM, BUZZER, 24VDC, EX

EA

1.0000 01/22/2013

22

10679188-001

ENCLOSURE, 650X200X950, SS, EE XE, IP66

EA

1.0000 01/22/2013

23

10715170-001

CABLE, FIBER, FLANGE MT, 62.5, MULTIMODE, ST CONN

EA

1.0000 01/22/2013

24

10715177-001

SWITCH, ETHERNET, 8-PORT, FULLY MANAGED

EA

1.0000 01/22/2013

25

10667241-001

TERM BLK, FEED THRU

EA

11.0000 01/22/2013

26

10537299-001

END PLATE-TB, ELEC

EA

1.0000 01/22/2013

27

948513-068

TERM BLK, GROUNDING, 6.0MM

EA

1.0000 01/22/2013

28

10537298-001

END STOP-TB, ELEC

EA

1.0000 01/22/2013

29

0000-9634-85

TB-TAG CARRIER,TS32 & TS35

EA

1.0000 01/22/2013

30

P250002-0019-35

JUMPER-CROSS-CONNECTOR/LINKFOR M

EA

1.0000 01/22/2013

31

10699867-001

RELAY, PLC, 24 VDC, HAZARDOUS LOCATION

EA

1.0000 01/22/2013

32

20072818

SWITCH, SLCTR, 2 POS, 2 N/O CONTACT

EA

1.0000 01/22/2013

33

20080663

CONTACT BLK, BLK, ATEX

EA

1.0000 01/22/2013

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Mar 20, 2013 Time: 7:37:06 AM Page: 2 of 2

Bill of Material for Item 10715087-001 Description: SPARE PARTS KIT, TLPSHR'S PNL, IDEAL LAND RIG Balloon Number

Part Number

End of Publication

Rev

Description

U M

Quantity Per

Eff Begin

Eff End

Ccn: 200 - NATIONAL OILWELL VARCO, L.P. Date: Jul 30, 2013 Time: 12:42:17 PM Page: 1 of 1

Bill of Material for Item 10729874-001 Description: SPARE PARTS KIT, UPS J-BOX, IDEAL LAND RIG Balloon Number

Part Number

Rev

Description

U M

Quantity Per

Eff Begin

1

10727125-001

ECLIPSE, MTG FOOT KIT, ENCL

EA

1.0000 06/29/2013

2

10727127-001

RACK, MTG KIT, 19" F/30" x 24" ENCL

EA

1.0000 06/29/2013

3

10727137-001

FILTERFAN, 16-506 CFM, EXAUST, 120 VAC

EA

1.0000 06/29/2013

4

40955270-002

FILTER, EXHAUST, IP54,

EA

1.0000 06/29/2013

5

10727132-001

HOOD, VENTILATION, NEMA 3R, ANSI 61, GRAY

EA

1.0000 06/29/2013

6

10727138-001

HEATER, W/FAN & TERMOSTAT, 125 W, 120 VAC

EA

1.0000 06/29/2013

7

10727140-001

KIT, WINDOW, 5 x 3, NEMA 4, MS & SS

EA

1.0000 06/29/2013

8

10727142-001

UPS, 1500 W, 120 VAC IN/OUT

EA

1.0000 06/29/2013

9

10727156-001

MODULE, EXT BATTERY, 10 YEARS VRLA BATTERIES

EA

1.0000 06/29/2013

10

10727233-001

CNTL TRNSFMR, 1500VA XFMR, 240VAC TO 120VAC

EA

1.0000 06/29/2013

11

10727234-001

BRKR, CIRCUIT, 20A, 1 POLE, TERMAL MAG

EA

1.0000 06/29/2013

12

10727235-001

BRKR, CIRCUIT, 10A, 1 POLE, TERMAL MAG

EA

1.0000 06/29/2013

13

10727236-001

BRKR, CIRCUIT, 15A, 2 POLE, TERMAL MAG

EA

1.0000 06/29/2013

14

0000-9638-80

FUSE-HOLDER,1P,30A, 600VAC, W/INDICATOR

EA

1.0000 06/29/2013

15

10727237-001

FUSE, 2A, TRI-ONIC, UL MIDGET

EA

1.0000 06/29/2013

16

10667241-001

TERM BLK, FEED THRU

EA

1.0000 06/29/2013

17

948513-068

TERM BLK, GROUNDING, 6.0MM

EA

1.0000 06/29/2013

18

10537298-001

END STOP-TB, ELEC

EA

1.0000 06/29/2013

19

10537299-001

END PLATE-TB, ELEC

EA

1.0000 06/29/2013

20

10727238-001

RELAY CPLR, SPDT, 120VAC/DC, 6A, DIN RAIL

EA

1.0000 06/29/2013

End of Publication

Eff End

ADJUSTMENT INSTRUCTIONS Differential/Pressure/Vacuum Switch General: 1. Check proof pressure of switch on name plate or catalog. NEVER EXCEED THIS PROOF PRESSURE. 2. Note the adjustable range of switch (increasing or decreasing pressure) as listed in the catalog or on the name plate. 3. Check the catalog listing for actuation value of the switch. To set the switch you need: 1. A pressure/vacuum source 2. A pressure/vacuum gauge 3. An electric continuity tester CAUTION! -ALWAYS CHANGE PRESSURE SETTING GRADUALLY. -ALWAYS check switch setting before making any adjustments. Step 1. Determine if the pressure/vacuum set point is on increasing or decreasing pressure. Step 2. If the set point is on increasing pressure, then decrease the pressure/vacuum of the source starting at a point lower than the set point. Use maximum 1/4 turn on adjustment screw. If the set point is on decreasing pressure, then increase the pressure/vacuum of the source starting at a point higher than the set point. Step 3. Using the continuity tester and the pressure/vacuum gauge determine the actuation point of the switch. Step 4. If the actuation point is above the desired value, turn the adjustment screw or knob per instructions in the pressure switch catalog to increase the actuation point, and if it is below, turn the adjustment screw or knob in the opposite direction to decrease it. Step 5. For exact pressure/vacuum setting, cycle pressure/vacuum switch and make fine adjustments by repeating steps 2 through 4 (trial and error process) until the desired setting is obtained. Note 1. For proper electrical connection follow colors of wire insulation or instructions on terminal code tag attached to switch. Note 2. Dual control switches should be set one side at a time. Recheck both sides after final setting.

CAUTION! -DO NOT force adjustment screw when it becomes difficult to turn.

Dialog item

Value

Description (continued)

V 7.X

Lev0... Lev2

Programming lock:

Operating Instructions Dual Pressure Switch UDS 7 Dual Temperature Switch UTS 7

Version display with current input level: 0:

only display of operating parameters, no changes possible

1:

only switching points can be set and “max” and “min” memories

2:

release user level (all operating parameters for customer)

LITH

20... 100

Change display brightness 20... 100% (only for units with dot-matrix display)

AOZS (only V 7.X)

0... 9999

Scale the analog output - start value (e. g. 0 bar = 4 mA)

AOFS

0... 9999

Scale the analog output - end value (e. g. 400 bar = 20 mA) ((output signal start value always corresponds to the display initial value, e. g. 0 bar = 4 mA), max. turn-down 4: 1, i. e. at values below 25 % of the measuring range the analog output is switched off

Code

OPT (only V 7.X)

000... 999

-----

Enter the code level:

Changes:

Lev1:

471

(up + down 5 seconds) Lev1 - Lev0

Lev2:

740

(up + down + M 5 seconds) Lev2 - Lev0

Lev0:

999

Display of the unit options stored by the manufacturer Barksdale.

1

Intended Applications ................................................................................................. 2

2

Safety Instructions ...................................................................................................... 2

3

Standards..................................................................................................................... 3

4

Warranty/Guaranty ...................................................................................................... 3

5

Installation/Commissioning ........................................................................................ 4

6

Maintenance/Cleaning ................................................................................................. 5

7

Technical Data ............................................................................................................. 6

8

Operation ..................................................................................................................... 8

9

Programming ............................................................................................................... 9

10

User Level Dialog ...................................................................................................... 10

Barksdale GmbH Dorn-Assenheimer Straße 27 D-61203 Reichelsheim +49 (6035) 949-0

Index E, 19.08.2009

Fax:

+49 (6035) 949-111 and 949-113

Software version: from V 1.X

email:

[email protected]

Specifications are subject to changes without notice!

Internet: www.barksdale.de

12

Art. no. 923-1724

Phone:

1

1

Intended Applications

Disposal

The dual pressure switch monitors system pressures and has up to two switching outputs and one analog output.

The sensor must be disposed of correctly in accordance with the local regulations for electric/electronic equipment.

The dual temperature switch monitors the temperature of the medium into which the probe is immersed and has up to two switching outputs and one analog output. DANGER

The switch must not be disposed of with the household garbage!

3

The standards applied during development, manufacture and configuration are listed in the CE conformity and manufacturer's declaration.

The switch may only be used in the specified fields of application. The temperature must be within the specified ranges, the pressure values and the electrical rating must not exceed the values specified. Observe also the applicable national safety instructions for assembly, commissioning and operation of the switch. The switch is not designed to be used as the only safety relevant element in pressurized systems according to DGR 97/23/EC.

2

Safety Instructions The safety instructions are intended to protect the user from dangerous situations and/or material damage. In the operating instructions the seriousness of the potential risk is designated by the following signal words:

Standards

4

Warranty/Guaranty Warranty Our scope of delivery and services is governed by the legal warranties and warranty periods. Terms of guaranty We guaranty for function and material of the dual pressure and temperature switch under normal operating and maintenance conditions in accordance with the statutory provisions. Loss of guaranty The agreed guaranty period will expire in case of: • • •

incorrect use, incorrect installation or incorrect handling or operation contrary to the provisions of these operating instructions.

No liability is assumed for any damage resulting therefrom, or any consequential damage.

DANGER Refers to imminent danger to men. Nonobservance may result in fatal injuries. WARNING Refers to a recognizable danger. Nonobservance may result in fatal injuries, and destroy the equipment or plant parts. CAUTION Refers to a danger. Nonobservance may result in light injuries and material damage to the sensor and/or to the plant. IMPORTANT Refers to important information essential to the user.

2

3

5

Installation/Commissioning

6

Maintenance/Cleaning Maintenance

DANGER Only install or uninstall the switch when deenergized (electrically and hydraulically/pneumatically). Pressure connection and electrical connection must be carried out by trained or instructed personnel according to state-of-the-art standards. The switch must only be installed in systems where the maximum pressure Pmax or the maximum temperature Tmax is not exceeded (see type label).

The pressure/temperature switch requires no maintenance. Cleaning CAUTION The membrane keys may be damaged by the use of unsuitable cleaning agents. Do not use any cleaning agents containing solvents or abrasive additives.

WARNING Be aware of the fact that in case of operation with higher temperatures the casing surface may become very hot! CAUTION Mount the pressure switch from bottom to the fitting with a wrench SW 36 (1/4“) resp. 19 with 45 Nm torque. Do not operate the switch if the switch itself or the connection cable is damaged. Impact and heavy vibrations during transportation should be avoided. Even if the switch casing remains undamaged, inside parts may be damaged and cause malfunctions. Electrical connection depends on the type of pressure switch (see type label) according to the chart below. Wrong assignment of the connections may cause malfunctions or incorrect switch outputs. Connection Chart Plug M 12x1 4-pin / 5-pin

Model with 2 switching outputs

Model with 2 switching outputs and 1 analog output

Pin 1

+Ub: 18... 32 V DC

+Ub: 18... 32 V DC

Pin 2

SP2 0.5 A max.

analog: 4… 20 mA / 0... 10 V DC

Pin 3

0V

0V

Pin 4

SP1 0.5 A max.

SP1 0.5 A max.

Pin 5

4

SP2 0.5 A max.

5

Operating and display elements/Dimensions

Measuring element

Piezoresistive pressure sensor with internal stainless steel diaphragm

Pt100 (class B) according to DIN IEC 751

Measuring ranges

0… 1 bar to 0… 10 bar 0… 15 psi to 0… 150 psi absolute pressure

0 ... +100 °C to -30 ... +150 °C +32 ... +212 °F to -22 ... +302 °F

Dual pressure switch UDS7 approx 35

120

LEDs (1)

0 ... 10 bar to 0 ... 600 bar 0 ... 150 psi to 0 ... 9000 psi relative pressure 4-digit dot-matrix display, green, digit height 5 mm 2 x transistor switching output, pnp NO/NC function (programmable), adjustable switching time delay 0... 9.9 s

G ¼, G ½ front flush 1/4" – 18 NPT 7/16 – 20 SAE

G ¼, 1/4" – 18 NPT

120

Change dialog items/functions, change numerical values

Dual temperature switch UTS7 approx 35

131

17 12

Protection system/class

Nema 4X, IP65/III

Electrical connection

Plug 5-pin, M 12x1

Auxiliary power

(green) – switching point 2 Dialog item "change to value/to function", acknowledge inputs

G1/4

Process connection (fitting "A" without adapter)

-30 ... +150°C / -22 ... +302 °F

(green) – switching point 1

S2

12

-10 ... +70°C / +14 ... +158 °F -25 ... +100°C / -13 ... +212 °F

(yellow) – alarm

S1

18...  32 V DC

2 approx 48

*L0

6

For further technical data and options please refer to the data sheets

32

Operating temperature range

approx 48

2

AL

Membrane keys (2)

HXN27

Switching outputs

Media temperature range

1

G1/4

Display

14

32

UTS 7

G1/2

UDS 7

Dimensions in mm

HXN19

Technical Data

HXN27 32

7

6

7

8

Operation

9

Programming

The switch may be installed and operated only by authorized persons. Do not use any hard objects for

1

In case of first commissioning a self-test is performed. The device is menu-operated via three membrane keys, which must not be touched with any hard objects.

2

If an error is detected during the self-test or normal operation, this error is signaled by a (yellow) flashing alarm LED (AL). The error can be read out in the menu ERRC .

3

Activate dialog item Value input/function selection

4

Change value

making entries.

change to the first dialog item.

After switching on with Change dialog item

Select the desired dialog item with

(see chapter 10 „User Level Dialog)

The green LEDs S1 and S2 signal the activity of the two switching points.

or

. to change the corresponding value or

Activate the desired dialog item with the desired function. .

Select the individual digits with Change the numerical value with

or

and acknowledge with

.

If the entered value is within the permissible range, the system changes to the dialog item after input of the last digit, otherwise the 1st digit will flash again. 5

Change function

Change the function with

Activate key lock

Simultaneously press

or +

during this time. On activation,

and acknowledge with

.

for at least 5 s. The display must not change * appear in succession. and e. g.

Key lock active

Values or functions will be displayed but cannot be changed. LOCK will be displayed when attempting a change.

Deactivate key lock

+ for at least 5 s. Simultaneously press (siehe Kapitel 10 „User Level Dialog, dialog item: CODE)

Return to measuring mode

If no entry is made for 2 minutes, the switch automatically returns to the measuring mode without accepting the entries.

Terminate programming

Press

for at least 5 s to change to the measuring mode.

* Software version no.

8

9

10

User Level Dialog (xxxx = 125% v. f. s.) Dialog item

Value

Value

ON-2

-1... xxxx

Description

Description (continued) Switch-on point for SP2 NOTE: if the ON-value is set smaller than the OFF-value you receive a decreasing switch point evaluation.

MENU

-1... 9999

Primary display, e.g. the value selected in the DISP menu

OFF-2

-1... xxxx

Switch-off point for SP2

DISP

-----

Display value which should be permanently in the display:

DLY2

0.0... 9.9 s

Switch-on / switch-off delay for SP2 in seconds

act

actually measured value

INV-2

-----

Inversion of switching output SP2

sp1

switching point SP1

hlfs

high-level-fail-save (normally open function)

SP2

switching point SP2

llfs

low-level-fail-save (normally closed function)

ACT.

-1... 9999

UNIT (only V 7.X)

SP.1

ON-1

-----

-1... xxxx

max

maximum peak value

MAX -1

min

minimum peak value

CLRH

Display of the peak value "max“

-----

Delete the maximum value memory -----

no deletion

Fixing the unit (The unit is shown in the display appr. every 30 sec for appr. 5 sec)

clr

delete value

CDLY

0.0... 9.9 s

Time setting to delete the maximum value memory after switching point SP1 is reached (manual deletion is still possible)

= psi x 10

MIN

-1... xxxx

Display of the peak value "min“

= psi

CLRL

-----

bar

bar

= bar

psi

psi x

psi

psi

hPa

hPa

= Hekto-Pascal

mbar

mbar

= millibar

Delete the minimum value memory -----

no deletion

clr

delete value

NOTE: no choice of the unit possible at UTS 7. Only °C possible!

OFFS

-9.9... +xx

Measured value offset in bar

none

switching output SP1 deactivated

CUT

0.0... +xx

Cut-off i.e. signal suppression at measuring range start in bar

wind

window technology

DLDS

0.0... 9.9 s

Time delay for currently displayed value in seconds

stnd

standard evaluation SP1

ERRC

-----

Error display:

erro

error output

0:

-ok-

no error

Switch-on point for SP1;

1:

max

exceeding pos. meas. range

NOTE: if the ON-value is set smaller than the OFF-value you receive a decreasing switch point evaluation.

2:

min

exceeding neg. meas. range

3:

dig1

switching output 1 error

4:

dig2

switching output 2 error

5:

anao

analog output error

6:

sens

sensor error

7:

data

data error (EEProm)

8:

prog

program error

9:

cal

calibration error

-1... xxxx

Switch-off point for SP1

DLY1

0.0... 9.9 s

Switch-on / switch-off delay for SP2 in seconds

INV-1

-----

Inversion of switching output SP1

-----

... xxxx

Display of actually measured value in bar

OFF-1

SP.2

10

Dialog item

hlfs

high-level-fail-save (normally open function)

Ilfs

low-level-fail-save (normally closed function)

none

Switching output deactivated

wind

window technology

stnd

standard evaluation SP2

erro

error output

11

Pressure

Explosion Proof Compact Switch

Series 9671X, 9681X, 9692X

Features ATEX approved NEMA 4X, 7 & 9 NACE compliant SPDT and DPDT switch Safe to adjust during operation Dia-seal/piston sensor Hazardous location dual seal approved for Canada

Applications BOP closing units Safety panels Pipelines Chemical and petrochemical plants Pulp and paper mills Pump and gas compressors Turbines Oil & gas applications

General Specifications* Accuracy:

±2% of full scale

Pressure Connection:

1/4” NPT female

Typical Life:

2.5 million cycles

Approvals:

Switch:

SPDT, snap action, Class CC simulated DPDT (optional)

CE 0081, LCIE 08 ATEX 6074X II 2 G, Ex d IIC T6

UL # E37043 CSA # LR22354

UL&CSA Approved for use in hazardous locations Class I, Groups A,B,C,& D; Class II, Groups E,F,& G (Group A, UL Only)

Ambient Temperature:

-4° to +104°F (-20° to +40°C)

EMI/RFI:

EN55011

Vibration:

10g’s 10-500 Hz, MIL-STD-202F

Shock:

50g’s, 11 mS, MIL-S-901C

Wetted Parts: Process Fitting:

316 stainless steel

Seals:

Viton® Diaphragm (9671X & 9681X) Viton® O-ring and Teflon® backup ring (9692X)

Piston:

Stainless steel (on 9692X)

Enclosure:

316 stainless steel or aluminum

Electrical Connection:

1/2” NPT male conduit connection, 18 AWG, 18” (300 mm) free leads

Adjustment:

Internal adjustment wheel with built in locking set-screws (#6)1

Electrical Rating:

11 amps @ 125/250VAC 5 amps @ 30 VDC (CC Class)

Shipping Weight:

Approximately 1.85 lbs.

Enclosure Ratings:

NEMA 4X, 7 & 9 (SS) NEMA 4, 7, & 9 (AL)

1

* See product configurator for additional options.

Need to loosen set screw (#6) at all times when resetting adjustment.

Wiring Diagram (9681X/9692X models)

Wiring Code 9692X/9681X (Pressure) Lead Normally Open Common Normally Closed Ground

(SPDT)

9671X (Vacuum)

(DPDT) NO1 (Red)

Circuit #1

Circuit #2

Circuit #1

Circuit #2

NO (Red)

Red

Yellow

Blue

Orange

C (Purple)

NC1 (Blue)

NC (Blue)

NO2 (Yellow)

Purple

Brown

Purple

Brown

Blue

Orange

Red

Yellow

Green

Green

Ground (Green)

C1 (Purple)

P

INCR

C2 (Brown) NC2 (Orange) Ground (Green)

P INCR

1

Explosion Proof Compact Switch

Series 9671X, 9681X, 9692X

Technical Drawings 9681X

9692X

1/2 NPT CONDUIT CONNECTION

1/2 NPT CONDUIT CONNECTION

22.2

HEX

25

ADJ U S T M E N T WHE E L

19.1

PRESSURE PORT FITTING

(1.0 .88

LOCKING SET SCREW SIZE #6

6.04 153.3

FLATS

38.1

4.13 [105]

6.38 162.1

(F O R 1 /2 N P T F IT T IN G )

.75 1.50

ADJUSTMENT WHEEL

PRESSURE PORT FITTING

0.88 [22.2] WRENCH FLATS

ADJUSTMENT WHEEL

PRESSURE PORT FITTING

VACUUM PORT FITTING

(FOR 1/2 NPT FITTING)

1/2 NPT CONDUIT CONNECTION

9692X-K*

FOR -7 RANGE)

WRENCH FLATS

28.6

Dimensions in inches (mm)

Product Configurator

17.1

2X

9671X 9681X

Top View

.68

. 2 0 0 [5 . 1 ]

1.125

#8-32 EXTERNAL GROUND SCREW

1 23/32 [45.2]

* K option also available with 9671X and 9681X See sales drawing for more details

Bottom View

Example:

9681X

-1CC

0.73 18.4

M O U N T IN G H O L E S

9671X

-2

-AL

-K

-W036

Base Model 9671X

Vacuum switch, 1 - 30 in. Hg.

9681X

Pressure switch, 2 - 500 psi

9692X

Pressure switch, 100 - 10000 psi

Options

Limit Switch -1CC

SPDT Switch, 11 amps @ 125/250 VAC; 5 amps @ 30 VDC

-2CC

DPDT Switch, 11 amps @ 125/250 VAC; 5 amps @ 30 VDC

-1GH

SPDT gold contact switch, 1 amp @ 125 VAC

-2GH

DPDT gold contact switch, 1 amp @ 125 VAC

-K

Adjustable Range

9671X Blank -1

Increasing - psi (bar)

Factory preset (consult factory)

Mounting holes and conduit wrench flats

Proof

Blank

316 stainless steel housing

(Actuation Value)

Pressure

-AL

Aluminum housing (-K only)

psi-(bar)

psi (bar)

Max

Min

Max

1” Hg

21” Hg

5” Hg

30” Hg

4 - 9” Hg

30” Hg

2 (.1)

12 (.8)

3 (.2)

15 (1)

1 - 3 (.07 - .2)

1000 (69)

Process Connection2

-2

5 (.3)

125 (8.6)

7 (.5)

150 (10.3)

2 - 25 (.1 - 1.7)

1000 (69)

Blank

-3

25 (1.7)

260 (17.9)

32 (2.2)

300 (20.6)

7 - 40 (.5 - 2.8)

1000 (69)

-P1

-4

50 (3.4)

440 (30.3)

65 (4.5)

500 (34.4)

15 - 60 (1 - 4.1)

1000 (69)

9681X

Pressure Range for 9692X 9692X

-Sxxx

Approx. Deadband1

Min

Adjustable Range

Extra wire length (XXX = inches)

Housing Option

Pressure Ranges for 9681X & Vacuum Ranges for 9671X Decreasing - psi (bar)

-Wxxx

Approx. Deadband1

Proof

1/4” NPT Female (standard) 7/16-20 SAE female process connection

Wetted Material

(Actuation Value)

Pressure

Blank

Min

Max

Min

Max

psi-(bar)

psi (bar)

-B

Buna-N diaphragm/O-rings

-1

100 (6.9)

600 (41.4)

150 (10.3)

750 (51.7)

50 - 150 (3.4 - 10.3)

15000 (1034)

-2

150 (10.3)

800 (55.2)

220 (15.2)

1000 (69)

70 - 200 (4.7 - 13.8)

15000 (1034)

-E

EPR diaphragm/O-rings (UL, CSA, and ATEX not available for this option)

-3

400 (27.6)

2600 (179)

500 (34.5)

3000 (207)

100 - 400 (6.7 - 27.6)

15000 (1034)

-4

700 (48.2)

4400 (303)

840 (57.9)

5000 (345)

140-600 (9.6 - 41.4)

15000 (1034)

-5

1000 (69)

6700 (462)

1200 (82.8)

7500 (517)

140-800 (9.6 - 55.2)

15000 (1034)

Decreasing - psi (bar)

Increasing - psi (bar)

-6

150 (10.3)

800 (55.2)

220 (15.2)

3000 (207)

50-1000 (3.4-68.9)

15000 (1034)

-7

5000 (344.8)

8800 (606.9)

5200 (358.6)

10000 (689.7)

200-2000 (13.8-137.9)

15000 (1034)

Viton® diaphragm/O-rings (standard)

NOTES: 1 Deadband values indicated when used with the “CC” limit switch 2 Contact factory for other possible connection options

3211 Fruitland Avenue • Los Angeles, CA 90058 •  800-835-1060 • Fax: 323-589-3463 • www.barksdale.com See Barksdale’s Standard Conditions of Sale • Specifications are subject to modification at any time • Bulletin #S0049-i • 09/11 • ©2011 • Printed in the U.S.A.

2

Operating Instructions Solid State Dual Switch UDS7-BX Operation:

Dimensions (in)

UDS7-BX

The pressure switch should be installed and operated only by authorized persons. After being switched on the UDS7-BX runs through a self-test. The device is menu operated and configured with three keys on the front. With the “M“ key (= mode) you change between the dialog values and the adjusted/actual values. With the keys “ “ = up and “ “= down you change between the dialog values in the menu or change the values/functions in the menus (see below: “List of functions“). If the dialog is not continued within two minutes the device automatically returns to the measuring mode. When the programming lock is entered, “LOCK“ appears in the display when an attempt is made to change values.

Programming: The setting menu is activated with the mode key. The dialog items are selected with the “ “ and “ “ keys. If the mode key is pressed again the corresponding value for the dialog item is shown and can be altered with the “ “ and “ “ keys. If the dialog with the unit is not continued within two minutes the device auto-matically returns to the measuring mode without accepting the new values. To terminate programming more quickly, you can switch back to the measuring mode (primary menu) from any item in the menu by pressing and holding the M-key for five seconds. If the programming lock has been activated, the values can be shown, but no changes made, i.e. when Level 0 is active (“LOCK“ appears in the display when an attempt is made to change values).

Agency Approvals: CE 0081 ISSeP 09 ATEX 034X II 2 G D Ex d IIC T6 Ex tD A21 IP65 T80°C -40°C ≤Tamb ≤ +60°C

1. Product description Intended Applications - This dual pressure switch is a device to monitor system pressure and has up to two switching outputs and one analog output. - This instrument should only be installed in systems where the maximum pressure (Pmax) is not exceeded, according to the values on the type label. - Attention: This device is not designed to be used as the only safety relevant element in a pressurized system according to PED 97/23/EC.

2. Starting operations Caution: To reduce the risk of ignition of hazardous atmospheres, disconnect the device from the supply circuit before opening. Keep assembly tightly closed when in operation.

Only assemble or disassemble the device with no pressure applied!

Barksdale Inc. 3211 Fruitland Avenue Los Angeles, CA 90058-0843 U.S.A. Phone: (323) 589 - 6181 Fax: (323) 589 - 3463 E-mail: [email protected] www.barksdale.com

See Barksdale’s Standard Conditions of Sale • Specifications are subject to modification at any time Bulletin #272280 A.1 • 07/09 • ©2009 • Printed in the U.S.A.

4

Connecting the switch - Mount the pressure switch from bottom to the fitting with a wrench and no more than 45 Nm torque. - Electrical connection: 3/4“ NPT female. Seal with certified junction box. - Process connection: 1/4“ NPT female (std).

Electrical connections Terminal Description Connection 6-Position Pin 1

Voltage (Ub): 15-28 VDC

Pin 2

Analog: 4-20 mA or 0-10 voltage

Pin 3

Common (-)

Pin 4

SP1: 0.4 A Max

Pin 5

SP2: 0.4 A Max

Pin 6

Internal Ground

4-20 mA/0-10V 1

List of functions: Dialog item

(xxxx = 125% f. s.)

Value

MENÜ

-1...9999

DISP

.....

Description Primary display, e.g. the value selected in the DISP menu appears here Display value which should be permanently in the display: act

actual measured value

sp1

switching point SP1

sp2

switching point SP2

max

maximum peak value

min

minimum peak value

ACT.

-1...9999 Display of actual measured value in bar

UNIT

Fixing the unit bar

bar = bar

The unit is shown in the display appr.

psi

psi x = psi x 10

every 30 sec. for appr. 5 sec.

psi

psi = psi

HPa

HPa = Hekto-Pascal

mbar

mbar = millibar

UND SP.1

ON-1

-1 ... xxxx

none

switching output deactivated

wind

window technology

stnd

standard evaluation SP2

erro

error output

Value 0,0s...9,9s

Switch-on point for SP1; if the ON value is smaller than the OFF

-1 ... xxxx

Switch-off point for SP1

DLY1

0,0s...9,9s

Switch-on / switch-off delay for SP1 in seconds

INV-1

.....

Inversion of switching output SP1

.....

-1 ... xxxx

hlfs

high-level-fail-save (normally open function)

Ilfs

low-level-fail-save (normally closed function)

none

switching output deactivated

wind

window technology

stnd

standard evaluation SP2

erro

error output

MIN

-1 ... xxxx

Display of peak value “Min“

CLRL

-----

Delete the minimum value memory

-1 ... xxxx

Switch-off point for SP2

DLY2

0,0s...9,9s

Switch-on / switch-off delay for SP2 in seconds

INV-2

-----

Inversion of switching output SP2 hlfs

high-level-fail-save (normally open function)

Ilfs

low-level-fail-save (normally closed function)

MAX

-1 ... xxxx

Display of peak value “Max“ (xxxx: = max. 125 % f. s.)

CLRH

-----

Delete the maximum value memory

2

-----

no deletion

clr

delete value

no deletion

clr

delete value

-9,9 ...+xx

Measured value offset in bar

CUT

0,0 ... +xx

Cut-off. e.g. signal suppression at measuring range start in bar

DLDS

0,0 ... 9,9s

Time delay for currently displayed value in seconds

ERRC

-----

Error messages:

V7.X

Lev0...Lev2

0:

-ok-

no error

1:

max

exceeding pos. measuring range

2:

min

exceeding neg. measuring range

3:

dig1

switching output 1 error

4:

dig2

switching output 2 error

5:

anao

analog output error

6:

sens

sensor error

7:

data

data error (EEProm)

8:

prog

program error

9:

cal

calibration error

Programming lock indication (see code) Version display with actual input level:

LITH

20 ... 100

AOZS

0 ... 9999

AOFS

0 ... 9999

0:

only display of operating parameters, no changes possible

1:

only switching points can be set (“max” and “min” memories)

2:

release user level (all operating parameters for customer)

Change display brightness 20...100% (only for units with Dot-Matrix display) Scale the analog output - start value (e. g. 0 bar = 4 mA) Scale the analog output - end value (e. g. 400 bar = 20 mA) (output signal start value always corresponds to the display initial value, e. g. 0 bar = 4mA) Maximum turn-down 4 : 1, i.e. at values below 25 % of the

if the ON value is smaller than the OFF value OFF-2

----OFFS

Switch-on point for SP2; the switching point evaluation is falling

Description Time setting to delete the maximum value memory after switching point SP1 is reached (manual deletion is still possible)

the switching point evaluation is falling

OFF-1

ON-2

CDLY

Unit display “on” or “off” .....

value

SP.2

Dialog item

measuring range the analog output is switched off CODE

OPT

000...999

-----

Security Sequence Lev1: 471

Allow to change switching point parameters only

Lev2: 740

Able to reconfigure all allowable parameters

Lev0: 999

All parameters will be lock

For internal use only

(onlyV7.X)

3

BD-30

TM

BEAR Reciprocating Plunger Pump

S/N:

Installation, Operation, and Maintenance Manual

2 www.nov.com

Installation, Operation, and Maintenance Manual

Foreword… This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment. Because of the many factors, which contribute to the function or malfunction of this machinery, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this presentation and when situations encountered are not fully encompassed by complete, understandable instructions, these situations must be referred to the manufacturer. When other than routine servicing is necessary, it can be most efficiently performed if the unit is removed to an area of adequate space where an over-head crane, hydraulic lift, bearing pullers, impact tools, etc., are accessible. The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible or economically feasible to reestablish such strict alignment and correct all dimensional deviations. Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these products and result in inconsistencies between the content of this publication and the physical equipment. We reserve the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the purchase contract. The pictures, photographs, charts, diagrams, drawings, verbal contents and specifications are not to be construed as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. National Oilwell Varco makes no warranty, either expressed or implied beyond that which is stipulated in the purchase contract. TM

BEAR pumps are manufactured by National Oilwell Varco in Houston, Texas. A serial number is stamped on each pump, fluid end and power end. Please refer to this serial number when ordering parts. The right and left sides of the pump are determined by viewing the pump from the back of the power end, looking toward the fluid end. This position is also used to identify the plungers and their related parts as being number one, two and three, beginning at the left side of the pump.

! CAUTION ! CAUTION ! CAUTION ! EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS; USE ONLY APPROVED METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF QUESTIONABLE SAFETY; ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY IS YOUR BUSINESS AND YOU ARE INVOLVED.

! WARNING ! WARNING ! WARNING ! BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE COMPRESSOR/AIR SYSTEM, ETC.

! WARNING ! WARNING ! WARNING ! FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.

3 www.nov.com

Installation, Operation, and Maintenance Manual

! ATTENTION - NOTICE - IMPORTANT ! THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP, COMPONENTS OR ATTACHMENTS.

! WARNING ! WARNING ! WARNING ! BEFORE SERVICING PUMPS: 1.

SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE.

2.

SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.

3.

RELIEVE OR "BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S).

FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE.

4 www.nov.com

Installation, Operation, and Maintenance Manual

TABLE OF CONTENTS 1.0 SYSTEM DESIGN CONSIDERATIONS AND GUIDELINES 1.1

DESIGN CHECKLIST ............................................................................................................................ 8

1.2

PUMP MOUNTING ............................................................................................................................... 9

1.3

PRIME MOVER ALIGNMENT .................................................................................................................. 9

1.4

SUCTION SYSTEM GUIDELINES .......................................................................................................... 10

1.4.1

Suction Pressure Considerations ................................................................................................................10

1.4.2

Acceleration Head .......................................................................................................................................10

1.4.3

Suction Piping Design .................................................................................................................................11

1.5

DISCHARGE LINE .............................................................................................................................. 12

2.0 INSTALLATION, START UP, & OPERATION 2.1

LIFTING ............................................................................................................................................ 13

2.2

INSTALLATION................................................................................................................................... 13

2.3

LUBRICATION ................................................................................................................................... 14

2.3.1

Power End ...................................................................................................................................................14

2.3.2

Packing Lubricator ......................................................................................................................................14

2.4

OPERATIONAL CHECK POINTS ........................................................................................................... 15

2.5

STARTUP ......................................................................................................................................... 15

2.6

MAINTENANCE .................................................................................................................................. 16

2.6.1

Daily Maintenance.......................................................................................................................................16

2.6.2

Monthly Maintenance ..................................................................................................................................17

2.6.3

Storage ........................................................................................................................................................17

2.6.4

Start-Up After Storage.................................................................................................................................17

2.7

TROUBLESHOOTING GUIDE ............................................................................................................... 18

5 www.nov.com

Installation, Operation, and Maintenance Manual 3.0 PARTS LIST 3.1

POWER END EXPLODED VIEW & BOM ............................................................................................... 20

4.0 DISASSEMBLY AND REASSEMBLY 4.1

GENERAL ......................................................................................................................................... 22

4.2

POWER END DISASSEMBLY ............................................................................................................... 22

4.2.1

Plunger Disconnection And Removal ......................................................................................................... 22

4.2.2

General ....................................................................................................................................................... 23

4.2.3

Crankshaft Removal ................................................................................................................................... 23

4.3

FLUID END ....................................................................................................................................... 23

4.3.1

Fluid End Removal...................................................................................................................................... 23

4.3.2

Stuffing Boxes Removal.............................................................................................................................. 24

4.3.3.

Stuffing Box Disassembly ........................................................................................................................... 24

4.3.4

Standard Valve And Seat Removal/Inspection ........................................................................................... 24

4.4

CHECK POINTS AND ADJUSTMENTS ................................................................................................... 25

4.5

POWER END ASSEMBLY .................................................................................................................... 26

4.5.1

Connecting Rod/Crosshead Assembly ....................................................................................................... 26

4.5.2

Crankshaft Main Bearings (If replacement is required) .............................................................................. 27

4.5.3

Crankshaft Installation ................................................................................................................................ 27

4.5.4

Connecting Rod To Crankshaft Assembly .................................................................................................. 28

4.5.5

General ....................................................................................................................................................... 28

4.6

FLUID END ASSEMBLY ...................................................................................................................... 29

4.6.1

Installation of Valve Seats .......................................................................................................................... 29

4.6.2.

Installation of Valves and Covers ............................................................................................................... 29

4.6.3

Installation of Stuffing Boxes and Plungers ................................................................................................ 30

4.7

Connection of Fluid End to Power End ....................................................................................................... 30

5.0 PACKING ASSEMBLIES 5.1

GENERAL ......................................................................................................................................... 31 6 www.nov.com

Installation, Operation, and Maintenance Manual 5.2

INSTRUCTION FOR SQUARE RING TYPE PACKING ............................................................................... 31

5.3

INSTRUCTIONS FOR MOLDED ‘V’ RING TYPE PACKING ........................................................................ 33

5.4

INSTRUCTIONS FOR SPRING LOADED "V" PACKING ............................................................................ 35

5.5

INSTRUCTIONS FOR NON-ADJUSTABLE "J" PACKING ........................................................................... 37

6.0 ENGINEERING DATA 6.1

SUCTION PRESSURE REQUIREMENTS ................................................................................................ 39

6.2

RECIPROCATING PUMP FLOW CURVES .............................................................................................. 41

6.3

PUMP SPEED VS. TORQUE ................................................................................................................ 42

6.4

STANDARD MATERIALS OF CONSTRUCTION ........................................................................................ 43

6.4.1

Power End ...................................................................................................................................................43

6.4.2

Fluid End .....................................................................................................................................................43

7 www.nov.com

Installation, Operation, and Maintenance Manual 1.0 SYSTEM DESIGN CONSIDERATIONS AND GUIDELINES Careful planning of the plant layout will save considerable time and expense, both initially when the installation is made and later during the operation of the unit. The design guidelines provided for in this section are Hydraulic Institute recommendations and criteria established by experienced designers of systems containing reciprocating pumps. The pump manufacturer cannot assume responsibility of system design into which the pump is installed. That responsibility must lie with the system designer. The guidelines that follow are offered only as an aid to those involved in the system design.

1.1

DESIGN CHECKLIST

The following outlines the basic requirements for an installation 1.1.1

Insure there is enough suction pressure to overcome all acceleration and friction losses and still provide the pressure needed for the pump.

1.1.2

Has a weir/baffle plate been utilized to help release trapped gases?

1.1.3

Has a vortex breaker mechanism been utilized in the system?

1.1.4

Is suction velocity within recommended limits? If marginal, is a larger suction line within system limit? (see hydraulic institute standards)

1.1.5

Have all unnecessary piping bends been minimized? (use long radius bends where possible)

1.1.6

Are suction valves the full open type?

1.1.7

Is there a suction stabilizer (or at least provision for one) near pump suction?

1.1.8

Is there a pulsation dampener (or at least provision for one) near pump discharge?

1.1.9

Is the relief valve sized to pass total pump flow at relief valve pressure setting?

1.1.10 Is there a capacity control valve in a bypass loop? 1.1.11 Are the inlets below minimum fluid levels? 1.1.12 Is there a check valve in the discharge piping? 1.1.13 Is discharge velocity limited to 3 times section? supported?

Is the number of turns limited, and is the line fully

Reservoir Vent 1.1.11 Elevation of Reservoir 1.1.1

Tank Inlet

1.1.7

1.1.2

1.1.13

1.1.5

1.1.8 1.1.10 1.1.9

1.1.3

1.1.12

Discharge 1.1.4 1.1.13

1.1.5 1.1.6

Suction

Pump Fluid End

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Installation, Operation, and Maintenance Manual 1.2

PUMP MOUNTING 1. Consideration should be given to the location of the equipment with its proximity to the associated equipment, fluid supply, environmental contamination, ease of maintenance, etc. 2. Ensure that crankshaft rotation is over the top, towards the Fluid End. Note: Fluid will be pumped regardless of pump rotation; however, Power End lubrication will be insufficient and component life will be reduced. 3. The pump must be mounted level and should be grouted in and be free of strain. This applies to a skidmounted pump or a pump mounted directly on a concrete base. Use shims if necessary. 4. The skid or foundation must be of sufficient size and design to maintain the equipment free of strain. 5. The equipment must be adequately secured to the foundation. High strength bolts or cap screws with locking devices are generally employed. 6. Avoid environmental contamination by providing the proper disposition of drainage from the crankcase, gear case, chain case, sludge sump and any other lubrication reservoirs as well as from the flushing media sump, the pump cradle, the suction line and the discharge line.

1.3

PRIME MOVER ALIGNMENT 1. The prime mover foundation should follow the same guidelines described in Section 1.2. 2. The sheave of a belt driven pump must be correctly aligned with the prime mover sheave. Care must be used to prevent over-tightening as this will shorten belt life, place the pump in a strain, and cause undue additional loads on the crankshaft and bearings. Sheave sizes should not be smaller than the minimum approved diameter. 3. When connecting a direct-driven pump, the shafts must be correctly aligned. Couplings should not be expected to compensate for avoidable misalignment. With Thomas Flexible Couplings, angular misalignment should not exceed one-half degree. Offset misalignment of the centerlines of the two shafts should not exceed .010" (.254 mm) and should be as small as practical. 4. Follow the recommended alignment procedures provided by the manufacturer of the belts and sheaves or couplings.

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Installation, Operation, and Maintenance Manual 1.4

SUCTION SYSTEM GUIDELINES

1.4.1

Suction Pressure Considerations

The inlet pressure required by the pump is a function of pump type, pump speed, fluid end valve springs, viscosity of the fluid being pumped and the vapor pressure of the fluid at the expected temperature. Failure to provide this required pressure will cause cavitation, reduced output and, eventually, complete failure of the system and pump. The minimum suction pressure required by the pump is published in Section 6.2. This information is based on water at 100°C. A correction factor for viscosity and the addition of the vapor pressure relevant to your application will need to be applied. Following equation is offered as an aid to the system designer for calculating the amount of suction pressure available at the pump inlet.
   
 
 
 
 
 Where:


=

Absolute Pressure at surface of liquid in Tank, in psia (kPa abs)




=

Pressure due to level of fluid above (+) of below (-) pump inlet, in psi (kPa)




=

Friction losses in line, valves, and fittings, in psi (kPa)




=

Fluid vapor pressure at pumping temperature, in psia (kPa abs)


 =

Pressure loss due to acceleration head, (see Section 1.4.2) converted to psi (kPa)

The pressure available should exceed the pressure required by at least 1 psi (6.9 kPa) to compensate for variations in temperature, atmospheric pressure, and other variables 1.4.2

Acceleration Head

Suction system design for a reciprocating pump requires more consideration than for a centrifugal pump. Based on the fluid in the suction line pulsation (accelerating and decelerating), a certain amount of energy is required to produce the required acceleration. This energy is in addition to the friction loss and is usually referred to as “Acceleration Head”. If sufficient energy is not available to accelerate the liquid in the suction line, the liquid will flash, the suction and discharge lines may shake, and the pump will operate loudly and less efficiently. In extreme cases, it can fracture a fluid cylinder with the high pressure surges that occur in the cylinder when the fluid flashes. To calculate the head required to accelerate the fluid in a short, non-elastic suction line, the following equation is offered as an aid in system design. 

 

Where: 

=

Acceleration Head, in feet, (meters)



=

Length of suction pipe, in feet (meters)



=

Mean velocity of flow in suction line, in ft/sec (m/s)



=

RPM of pump 10 www.nov.com

Installation, Operation, and Maintenance Manual =



0.400 for Simplex, single-acting 0.200 for Duplex, single-acting 0.066 for Triplex 0.040 for Quintuplex

=



1.4 for liquid with almost no compressibility (de-aerated water) 1.5 for amine, glycol, water 2.0 for most hydrocarbons 2.5 for relatively compressible liquid (hot oil)

=



2

2

Gravitational Constant, 32.2 ft/s (9.81 m/s )

It should be noted that as the pump speed is increased, both n and V increase. Therefore,  varies as the square of pump speed.  also varies directly with . Installation of a suitable suction stabilizer near the pump is highly recommended to dampen the effects of acceleration head. Doing so will increase the life of the system and the pump and reduce unnecessary down time. 1.4.3

Suction Piping Design

While designing the piping layout for your BEAR™ reciprocating pump, consideration should be given to the fact that positive suction head at the pump inlet contributes toward pump efficiency; however, the layout of the piping, the arrangement of the fittings, and restrictions in the suction and discharge lines have an even greater effect. For this reason, all fittings and valves should be full opening; all bends should be of long radius or should be eliminated where possible. Long radius 45° ells should be used, particularly if installed near the fluid cylinder. 1. The suction line should be at least one or two pipe sizes larger than pump suction connections. Use the following for selection of effective pipe size. 2. A triplex pump should have a velocity less than 2 ft/sec for speeds up to 250 RPM, 1-1/2 ft/sec for speeds up to 330 RPM and 1 ft/sec for speeds above 330 RPM. 3. For a quintuplex, these velocities may be increased 70% or as determined by the system design 4. Eliminate any rise or summit in the suction line where air or vapor can collect.. (No high points unless vented) Air pockets in the line will cause erratic pump operation and may cause a complete loss of prime. 5. Use eccentric reducer at pump cylinder with flat side up.) 6. All systems should contain a minimum number of turns. Necessary turns should be accomplished with longradius elbows or laterals. 7. Do not use meters or other restrictions in the suction line. 8. Provide a full opening gate valve in the suction line adjacent to the supply tank to permit the line to be drained when necessary. Do not use any type of restricting valve. 9. When necessary to manifold a number of pumps to a common suction, the diameter of the manifold and suction pipe leading from the supply tank must be such that it has a cross sectional area equal to or greater than the area of combined individual suction pipes. 11 www.nov.com

Installation, Operation, and Maintenance Manual 10. When a charging or booster pump is used in the suction line it must have a capacity equal to twice that of the pump output. This is necessary to provide a charging pump with an output great enough to meet the peak volume requirements of the pump during the suction stroke and not act as a restriction in the line. 11. All piping, both suction and discharge, must be solidly and independently supported. The first support must be as close to the pump as practical. This is necessary to prevent placing the pump in a strain and to keep any vibration in the system from acting directly on the pump. 12. Make sure all pipe connections are sealed. Air entering the lines will reduce capacity and cause cavitation 13. It is highly recommended that unions or flanges be installed close to the pump to facilitate fluid cylinder removal and maintenance. 14. A flexible section of hose should be installed between the pump and the rigid section of piping to isolate vibrations as well as allow for ease of maintenance.

1.5

DISCHARGE LINE

! WARNING ! WARNING ! WARNING ! ONLY USE PIPE OR HOSE INSIDE OF ITS STATED MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) RATING. EXCEEDING THIS LIMIT CAN CAUSE THE LINE TO BURST RESULTING IN PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH. 1. Use a pulsation dampener in the discharge line. It should be placed in the line as near the fluid cylinder as possible and ahead of any bend in the line. 2. Discharge line velocity should not exceed three times the suction velocity. Do not reduce the size of the discharge line below that of the pump outlet until the line has passed through the dampener, and is away from the pump approximately 20 feet (6m). 3. Any bend in the discharge line should be made with long radius 45°ells. Do not use a bend directly adjacent to the fluid cylinder. Avoid using any 90° bends if at all possible. 4. A pressure relief valve must be installed in the discharge line. The relief valve should be set to operate at a pressure no greater than 25% above the maximum rated pressure for the plunger size being used. It should be installed in the line ahead of any valve and be piped so that any flow is returned to the supply tank rather than the suction line. This will prevent possible damage to the suction line and suction dampener. Note: The return line size should not be smaller than the relief valve port. Do not install any valves between the relief valve and suction tank 5. All piping, both suction and discharge, must be solidly and independently supported. The first support must be as close to the pump as practical. This is necessary to prevent placing the pump in a strain and to keep any vibration in the system from acting directly on the pump. 6. A by-pass line should be installed to permit the pump to be started without load. This allows oil to circulate and reach all parts in the power end before they are loaded. Note: It is recommended that the oil temperature be above 30˚F (0˚C) before load is applied 7. It is highly recommended that unions or flanges be installed close to the pump to facilitate fluid cylinder removal and maintenance. 8. A flexible section of hose should be installed between the pump and the rigid section of piping to isolate vibrations as well as allow for ease of maintenance. 12 www.nov.com

Installation, Operation, and Maintenance Manual 2.0 INSTALLATION, START UP, & OPERATION 2.1

LIFTING

! WARNING ! WARNING ! WARNING ! EXTREME CARE MUST BE MADE WHEN LIFTING THIS PUMP TO AVOID PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH 3/4 – 10UNC

1. Use a properly rated strap or chain. 2. Attach a heavy duty forged eye bolt to the threaded port identified in the illustration. 3. Attach a properly rated lifting hook.

2.2

INSTALLATION 1. Inspect the exterior of the unit for any damage that may have occurred during shipment. 2. Remove inspection doors and covers – check the interior of the pump for dirt, rust, water, and foreign objects, particularly if the pump has been in storage. If necessary, clean and wash out the power end with non-toxic, non-explosive solvent. 3. Replace Inspection doors and covers. 4. All studs and nuts of the fluid end should be checked for tightness prior to start-up. Refer to “Assembly Section” for correct torque. 5. Fill the power end with the correct amount of the proper lubricant as detailed in the Lubrication section of this manual. 6. If the pump is equipped with a packing lubricator, assure that the reservoir has an adequate supply of lubricant. Add if necessary and fill the pump lines. Check by breaking connection at stuffing box, working lubricator plunger until oil appears. 7. Mount pump and connect to prime mover (see Sections 1.2 &1.3). 8. Connect suction and discharge piping. Make certain the Fluid End is completely purged of air before attempting to operate under pressure. 9. Inspect all fittings and fasteners for tightness. Check all piping for leaks. Tighten or repair as necessary. 10. Check rotation. Direction of rotation must always be such that the crankshaft extension rotates with the top of the shaft moving towards the fluid end of the pump. The direction of crankshaft rotation is also indicated by rotation arrow. Note: The pump will not lubricate if direction of rotation is reversed. Incorrect hookup of the pump will damage the pumping unit.

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Installation, Operation, and Maintenance Manual 2.3

LUBRICATION

NATIONAL OILWELL VARCO models BD-30 triplex pumps are "splash-gravity" lubricated. The main bearings and crankshaft bearings are fed by splash. Crossheads and crosshead pin bushings are fed through holes in the crossheads and crosshead reservoir. Intermediate rods are lubricated from the splash they receive from the crosshead. If equipped, the packing lubricator is run on an auxiliary pump and is force fed into the stuffing boxes 2.3.1

Power End

Use industrial-type (mild) extreme pressure gear oil. The recommended AGMA numbers for various temperatures of air surrounding the pumps are shown in the following table. The oil should contain a good rust inhibitor. U.S. UNITS OF MEASURE Temperature

AGMA Industrial EP Gear Oil

Capacity

+50ºF to +155ºF

AGMA No. 6 EP or ASTM/ISO Grade No. 320

1.5 gal

+20ºF to +100ºF

AGMA No. 5 EP or ASTM/ISO Grade No. 220

1.5 gal

-20ºF to + 60ºF

AGMA No. 2 EP or ASTM/ISO Grade No. 68

1.5 gal

U.S. UNITS OF MEASURE Temperature

AGMA Industrial EP Gear Oil

Capacity

+10ºC to +68ºC

AGMA No. 6 EP or ASTM/ISO Grade No. 320

5.7 L

-7ºC to +38ºC

AGMA No. 5 EP or ASTM/ISO Grade No. 220

5.7 L

-29ºC to +16ºC

AGMA No. 2 EP or ASTM/ISO Grade No. 68

5.7 L

Oil must pour freely at minimum operating temperature. Change oil every six months or as frequently as operating conditions require maintaining a clean, sludge-free oil of proper viscosity 2.3.2

Packing Lubricator

When an automatic lubricator is used in water or oil service, use Rock Drill (Air Drill) oil or steam cylinder oil of proper viscosity. For butane-propane service, use NATURAL castor oil. Set lubricator to feed 5 to 7 drops per minute.

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Installation, Operation, and Maintenance Manual 2.4

OPERATIONAL CHECK POINTS

! WARNING ! WARNING ! WARNING ! FAILURE TO ADHERE TO THE FOLLOWING POINTS CAN CAUSE DAMAGE TO PUMP, DAMAGE TO THE SYSTEM, DAMAGE TO PROPERTY, SERIOUS BODILY INJURY, OR DEATH 1. Pump must be a set level for proper lubrication. 2. Make sure pump is filled with clean oil of the proper viscosity. A lubrication chart is provided in Section 2.3.1. 3. Do not over-speed the pump. 4. Do not use a smaller diameter sheave than is recommended for the pump. 5. Make sure all safety shutdown switches are operating properly. 6. Keep all suction and discharge line valves fully open. 7. If a bypass is used to regulate output, make sure it is set properly. 8. Make sure the pressure relief valve is set properly. 9. Do not exceed the pressure rating of the pump for the particular plunger size. 10. Make sure the suction line is tight, as air entering the suction line will cause severe hammering and knocking of the pump. 11. Make sure plunger and intermediate rod connections are tight and locked. 12. Check the plunger packing for correct adjustment as defined in Section 5.0. 13. Check the suction and discharge dampeners for proper charge, as this is very important for long life and good pump operation. 14. Make sure the hex nuts holding the cylinder in place are tight.

2.5

STARTUP 1. Open bypass valve. 2. Open valve at pump suction. Note: During operation the valve must be fully open. Never throttle the suction line

! WARNING ! WARNING ! WARNING ! BEFORE ATTEMPTING TO ROTATE EQUIPMENT MANUALLY, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY FROM ENTERING THE EQUIPMENT. 3. Assure power to unit is locked out. Remove any necessary guards and rotate the pump one full revolution by hand to be certain all moving parts are free and can move unrestricted. 15 www.nov.com

Installation, Operation, and Maintenance Manual 4. Reattach power supply and apply power slowly and control at low rpm to prime the pump fluid chambers. Check that the direction of rotation 5. Run the pump under no load for a period of time to assure that the Power End is being properly lubricated. Pump should run at no load until oil temperature reaches 30°F. Check gasket joints for leakage 6. Open the valve in the discharge line, increase power, close the bypass valve and observe the following:

2.6

•

Check for excessive stuffing box leakage. Some leakage is desirable to insure the packing is lubricated.

•

Check oil seals for leakage.

•

Check power frame for overheating.

•

Check for fluid leaks at valves.

•

If a stuffing box lubricator is equipped on the pump, adjust rate of injection. Normal rate about 5-8 drops per minute per plunger.

MAINTENANCE

The following points are intended as a guide to be used in setting up a maintenance program. Good preventive maintenance will pay big dividends in the form of reliable service with a minimum of trouble. 2.6.1

Daily Maintenance

1. Check power end oil level daily. Do not attempt to check the oil with the pump running. Inspect the oil for dirt or contamination and change if necessary. An increase in oil level indicates fluid end leakage into power end. Change oil immediately and check intermediate rod wipers and surface smoothness of rod. Check for plunger packing leakage. 2. Lubricate plunger packing frequently. Packing life can be greatly increased by greasing every four (4) hours with a small amount of grease. Grease is not recommended at pressures above 1200 psi. Use an alternate packing lubricator to drip the proper oil on the plunger for lubrication. (See page 10 for further details). 3. Check lubricator for proper level and operation. 4. Check plunger packing for excessive leakage. Replace packing as required. 5. Check stuffing box adjusting nuts for tightness. 6. Drain plunger leakage sump tanks if required. 7. Flush plunger chamber drain lines with kerosene on power oil pumps and fresh water on salt pumps. This may be done weekly unless salt and paraffin accumulation is severe. 8. Make sure suction and discharge line valves are fully open. 9. Check for leakage between the fluid cylinder and frame or stuffing box to fluid cylinder packing if required. 10. Check all seals for leakage. 11. Check belts or clutch for slippage. If either condition exists, correct immediately.

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Installation, Operation, and Maintenance Manual 2.6.2

Monthly Maintenance

1. Drain and refill crankcase a minimum of every six (6) months or as often as required to maintain a clean, sludgefree oil of the proper viscosity. 2. Pull crankcase cover to inspect inside power frame. 3. Clean crankcase air breather with a non-explosive solvent. 4. Check all studs, nuts and cap screws for tightness. Inspect gaskets for leaks; tighten or replace as required. 5. Clean pump. Good housekeeping is a prerequisite to good maintenance. 2.6.3

Storage

If the pump is to be idle for longer than one (1) week, it should be prepared for storage as follows: 1. Drain and clean crankcase thoroughly. Leave drain open and install 90° elbow, pointing downward, to permit air circulation and prevent condensation build-up. 2. Coat all bearings, finished surfaces, and entire inside surface of crankcase with a rust inhibiting oil. 3. Remove plungers and packing, clean and coat with rust inhibiting oil. 4. Remove fluid cylinder valves allowing cylinder to be thoroughly cleaned and drained. 5. Coat entire cylinder, valves and parts, with a rust inhibiting oil. 6. Thoroughly inspect pump and rotate crankcase once each month. Re-coat with rust inhibiting oil where necessary. 2.6.4

Start-Up After Storage

Any pump that has been in storage after field use will need a thorough inspection to make sure it has not been damaged in any way and that all parts are properly in place.

! ATTENTION ! ATTENTION ! ATTENTION ! FAILURE TO OBSERVE THE FOLLOWING POINTS CAN RESULT IN SERIOUS DAMAGE. 1. Remove all covers on both power end and fluid end; thoroughly clean and inspect all parts and finished surfaces. 2. Check all bearings to make sure they are clean and in good condition. 3. Make sure valves, plungers and packing are properly installed and in good condition. 4. Carefully tighten all bolts, nuts, studs and working connections. 5. Fill power end to the proper level with clean oil of the proper viscosity. Make sure oil is poured into the crosshead reservoir and is worked into all bearings. 6. Fill packing lubricator and pump lines full. Check by breaking connection at stuffing box, working lubricator plunger until oil appears. 17 www.nov.com

Installation, Operation, and Maintenance Manual 2.7

TROUBLESHOOTING GUIDE

PROBLEM

POSSIBLE CAUSE

CORRECTION

SUCTION LINE RESTRICTED BY:

(1, 2, 3, 4) 1. TRASH, SCALE BUILD UP, ETC. LOCATE AND REMOVE 2. PARTIALLY CLOSED VALVE IN SUCTION

LOCATE AND CORRECT LINE 3. METERS, FILTERS, CHECK VALVES, NON-FULL-OPENING, CUT-OFF VALVE OR RE-WORK SUCTION LINE TO ELIMINATE OTHER RESTRICTIONS.

4. SHARP 90°BENDS OR 90º BLIND TEES.

RE-WORK SUCTION LINE TO ELIMINATE.

AIR ENTERING SUCTION LINE THROUGH TIGHTEN OR REPACK VALVE STEM PACKING CUT-OFF VALVE AIR ENTERING SUCTION LINE THROUGH LOCATE AND CORRECT LOOSE CONNECTION OR FAULTY PIPE AIR OR VAPOR TRAPPED IN SUCTION LINE

LOW FLUID LEVEL KNOCKING OR POUNDING IN FLUID END AND PIPING SUCTION DAMPENER NOT OPERATING

LOCATE RISE OR TRAP AND CORRECT BY STRAIGHTENING LINE, PROVIDING ENOUGH SLOPE TO PERMIT ESCAPE AND PREVENT BUILD-UP INCREASE SUPPLY AND INSTALL AUTOMATIC LOW LEVEL SHUT-DOWN SWITCH INSPECT AND REPAIR AS REQUIRED

WORN VALVES

INSPECT AND REPAIR AS REQUIRED

ENTRAINED GAS IN FLUID

PROVIDE GAS BOOT OR SCRUBBER FOR FLUID

INLET TO BE AT TOP OF TANK AND BAFFLED TO POOR INLET AND OUTLET ARRANGEMENT BREAKOUT GAS AND PREVENT CHANNELING. OUTLET AT SUPPLY TANK TO BE 12" FROM BOTTOM OF TANK AND AS FAR FROM INLET AS POSSIBLE, NEVER CLOSER THAN 90º. LOOSE PACKING ADJUSTING NUT

TIGHTEN AND/OR REPLACE PACKING

REPLACE WITH INDIVIDUAL SUCTION LINE OF NEXT SIZE LARGER THAN INLET PUMP LEAKAGE PRESSURE RELIEF VALVE THAT REPAIR VALVE AND RE-WORK PIPING TO RETURN TO HAS BEEN PIPED BACK INTO SUCTION LINE SUPPLY TANK - NOT SUCTION LINE. BY-PASS PIPED BACK TO SUCTION REWORK TO RETURN BY-PASSED FLUID BACK TO SUPPLY TANK - NOT SUPPLY LINE INSPECT WHEN ROTATING PUMP BY HAND AND BROKEN PLUNGER REPLACE AS REQUIRED INADEQUATE SIZED SUCTION LINE

VALVE WEAR OR DAMAGE

CHECK FLUID END FOR BAD VALVES

WORN MAIN BEARINGS

REPLACE AS REQUIRED

KNOCK IN POWER END LOOSE PLUNGER - INTERMEDIATE ROD INSPECT FOR DAMAGE CROSSHEAD CONNECTION TIGHTEN

- REPLACE AS REQUIRED AND

WORN CROSSHEAD PIN, OR CONNECTING LOCATE AND REPLACE AS REQUIRED ROD

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Installation, Operation, and Maintenance Manual PROBLEM

RAPID VALVE FAILURE

WEAR

OR

POSSIBLE CAUSE

CORRECTION

CORROSION

TREAT FLUID AS REQUIRED

ABRASIVES IN FLUID

FILTER AS REQUIRED

IMPROPER INSTALLATION

INSPECT AND INSTALL PER INSTRUCTION SHEET IN PACKING BOX

IMPROPER LUBRICATION (EITHER CHECK INSTRUCTIONS IN MANUAL AND CORRECT AS INSUFFICIENT OR EXCESSIVE OR REQUIRED. INCORRECT TYPE) LUBRICATOR NOT OPERATING

INSPECT AND CORRECT AS REQUIRED

ADJUSTING NUT LOOSE

INSPECT AND REPACK PER INSTRUCTIONS

SCALE OR BUILD UP ON PLUNGER

TREAT FLUID AS REQUIRED

WORN OR PITTED PLUNGERS AND/OR REPLACE AS REQUIRED STUFFING BOX

SHORT PACKING LIFE

ABRASIVES IN FLUID

FILTER AS REQUIRED

PUMP OPERATED WITHOUT FLUID

CHECK SYSTEM FOR FAULTY LOW-LEVEL SHUTDOWN CONTROLS OR CLOSED VALVES AND CORRECT AS REQUIRED.

ABNORMALLY HIGH FLUID TEMPERATURES

CHECK WITH MANUFACTURER RECOMMENDATIONS ON TYPE OF PACKING

FOR

FOR CHECK WITH MANUFACTURER RECOMMENDATIONS ON TYPE OF PACKING

FOR

WRONG TYPE OF PACKING PARTICULAR FLUID BEING HANDLED

CAVITATION (KNOCKING AND POUNDING IN REFER TO CORRECTION OF FLUID CYLINDER AND PIPING) PIPING" ABOVE

BROKEN OR PITTED PLUNGER

"KNOCK IN END AND

ADJUSTMENT NUT TOO TIGHT

ADJUST AND REPLACE PACKING AS REQUIRED

PLUNGER CRACKED AT INSTALLATION.

INSTALL NEW PLUNGER USING CARE TO AVOID ANY SHARP BLOW OR FORCE ON PLUNGER.

PLUNGER SHOCK.

CRACKED

FROM

CHECK SYSTEM TO ELIMINATE ANY SHARP OR SUDDEN TEMPERATURE DIFFERENCES. THERMAL TEMPERATURE EXTREMES ON THE PLUNGER CAN OCCUR FROM PACKING AS DISCUSSED UNDER “SHORT PACKING LIFE” PROBLEM FROM TEMPERATURE CHANGES IN THE FLUID ITSELF.

PLUNGER PITTED FROM IMPLOSIONS CHANGE SUCTION SYSTEM TO ELIMINATE OR CHECK CAUSED BY EXCESSIVE GAS OR AIR WITH MANUFACTURING REGARDING USE OF SPECIAL ENTRAINED IN FLUID. PACKING ARRANGEMENT.

RAPID WEAR OF COATED PLUNGER

HARD-

CHECK AND CORRECT PER RECOMMENDATIONS UNDER “SHORT PACKING LIFE” PROBLEM.

PACKING FAILURE.

PLUNGER NOT SUITABLE FOR PARTICULAR CHECK WITH MANUF. FOR RECOMMENDATION. SERVICE. PUMP NOT LEVEL.

OIL SEAL LEAKS

CHECK AND CORRECT AS REQUIRED.

WORN, CORRODED, PITTED, OR CHECK AND CORRECT AS REQUIRED. OTHERWISE DAMAGED SEALING SURFACE. WORN OR DAMAGED SEALS.

CHECK AND CORRECT AS REQUIRED.

OIL LEVEL TOO HIGH.

CHECK AND CORRECT AS REQUIRED.

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Installation, Operation, and Maintenance Manual 3.0 PARTS LIST 3.1

POWER END EXPLODED VIEW & BOM

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Power End Cylinder Tie Stud Hex head Cap Screw Crosshead Stub Crosshead Wrist Pin Set Screw Wrist Pin Bushing Connecting Rod Connecting Rod Bearing Connecting Rod Bolt Lock Washer Bearing Cone Bearing Cup Inboard Frame Cap Oil Seal, Crankshaft

Item 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Description Key Shim, .005" Shim, .007" Shim, .010" Shim, .020" Crankshaft Crankcase Cover Gasket Crankcase Cover Nipple Tee Hex head Cap Screw Oil Drain Plug Oil Sight Gauge Hex head Cap Screw Oil Fill Hex head Cap Screw Hex head Cap Screw

Item 33 34 35 36 37 38 39 40 41 42 43

Description Inspection Cover Inspection Cover Gasket Outboard Frame Cap Hex Head Cap Screw Plunger Cover Thumb Screw Crosshead Seal Cap Oil Seal, Crosshead Stub Hex head Cap Screw Deflector O-Ring

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Installation, Operation, and Maintenance Manual 3.2

Fluid End Exploded View & BOM

Item 1 2 3 4 5 6 7 8

Description Fluid Cylinder Stuffing Box Gasket Throat Bushing Stuffing Box Flange Stud Valve Seat Valve Valve Spring

Item 9 10 11 12 13 14 15

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Description Valve Cover Gasket Discharge Valve Stop Cylinder Head Extension Dowel Pin Valve Cover Flange Stud Hex Nut

Installation, Operation, and Maintenance Manual 4.0 DISASSEMBLY AND REASSEMBLY 4.1

GENERAL

The bearings and other working parts in the power end have been designed for continuous duty, and if properly lubricated, will provide years of trouble-free service. However, after the pump has been in service for a long period of time, the bearings and other working parts will gradually loosen, and if not corrected, will lead to more serious trouble. The time to overhaul the pump will vary; depending on the operating conditions, and is therefore a matter that must be left to the good judgment of the operator. Complete disassembly and assembly procedures are discussed in their respective sections. The crankshaft main bearings for the BD-30 are single row; shim adjusted, tapered roller bearings. They have been assembled and adjusted at the factory with proper clearance and will give long trouble-free service. The proper clearance is found by adjusting the amount of shims until the crankshaft has .001" to .003" endplay and will rotate freely. Tools Required Most of the tools required to overhaul the pump will be found in an ordinary set of mechanics hand tools. The special tools and equipment required and not furnished with the pump include a torque wrench, valve seat puller, bearing puller and a hydraulic press.

4.2

POWER END DISASSEMBLY

It is not necessary to remove the fluid end when disassembling the power end. However, the plungers should be removed through the fluid end cylinder head ports. If you intend to remove the Fluid Cylinder, replace the instructions in Section 4.2.1 with those found in Section 4.3.1. All fluid cylinders have separate intermediate rods (Crosshead Stubs) These are threaded into the crosshead and retained with thread locking compound and a nylon insert and should only be removed if necessary. If while removing the plungers the crosshead stubs break loose, these methods of retention will need to be replaced/reapplied

! ATTENTION ! WARNING ! ATTENTION ! POWER END DISASSEMBLY AND OVERHAUL IS BEST PERFORMED IN A WELL EQUIPPED SHOP ENVIROMENT. IF THE PUMP IS DISASSEMBLED AT LOCATION ENSURE THE PRESSURE HAS BEEN REMOVED FROM THE FLUID END AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES. ENSURE THE FLUID END IS DRAINED AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE PROCEEDING! 4.2.1

Plunger Disconnection And Removal

1. Remove the Drain Plug and empty the oil from the crankcase. NOTE: Dispose of used oil according to local laws and regulations. Remove oil level indicator. 2. Remove Thumb Screws and Plunger Cover. 3. Remove Cylinder Head Extensions and their Valve Covers. You may have to rotate the pump by hand to move the Plungers away from the Cylinder Head Extensions to facilitate removal. Remove the valve springs from the top of the valves loosen Stuffing Box Glands. 4. The Plungers and Crosshead Stubs separate at the knurl area interface. Using a pipe wrench on the knurled area on the plunger and another pipe wrench in the reverse direction on the Crosshead Stub, break the plunger loose and unscrew from the Crosshead Stub 5. Remove the Plungers through the fluid cylinder opening.

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Installation, Operation, and Maintenance Manual 4.2.2

General

1. Remove the Crosshead Stub Deflectors and the Crosshead Stub seal caps. Discard the Crosshead Seal Cap Gaskets 2. Remove the crankcase cover and discard the Crankcase Cover Gasket. 3. Remove the outboard frame cap, the inboard frame cap and all Shims. Take care to avoid damaging the Oil Seal when removing the frame caps. NOTE: keep the Shim Sets together with the corresponding cap These should be kept together for reassembly at their original location. 4. Remove connecting rod bolts and caps. NOTE: Connecting rods and caps are matched sets and must be kept together. Do not mix caps and rods. 4.2.3

Crankshaft Removal

1. Push Crosshead/Connecting Rod Assemblies to the full forward position. Place a block of wood on the non drive side of the crankshaft and, with a hammer, tap the Crankshaft until the opposite side Bearing Cup is removed from the Power Frame (1). Repeat on the drive side to remove the remaining Bearing Cup. NOTE: Bearing Cups and Cones are matched sets. When reusing the Crankshaft Bearings, it is important to mark from which side each cup was removed and must be correctly assembled as a unit. 2. Carefully remove the crankshaft out either side of the power frame. Thoroughly clean and inspect the crankshaft and Main Bearings. Examine the journals, where the Connecting Rods attach. These should be smooth and free of dings, gouges, or excessive wear. NOTE: The crankshaft main bearings may be inspected while on the crankshaft and should not be removed unless necessary. A puller is required when replacement is necessary. Always replace the Bearing Cup when replacing Bearing Roller Cone. 3. Remove the each Crosshead/Connecting Rod out the rear of the Power Frame and tag each to identify the bore from which it was removed. It is good practice to reattach the matched connecting rod caps at this point. 4. Remove one Set Screw from the underside of each Crosshead and back out the second Set Screw.5-6 turns. Remove the Crosshead Wrist Pin to release the Connecting Rods from the Crossheads. Reinstall the removed Set Screw into the Crosshead. 5. Clean and inspect all components and sub-assemblies. Discard all gaskets and worn components. 6. Thoroughly clean out the crankcase. Take care to remove any sludge and residue that may have collected in the bottom.

4.3

FLUID END

! ATTENTION ! WARNING ! ATTENTION ! BEFORE WORKING ON THE FLUID END ENSURE THE PRESSURE HAS BEEN REMOVED FROM THE FLUID END AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES. ENSURE THE FLUID END IS DRAINED AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE PROCEEDING! 4.3.1

Fluid End Removal

1. Remove suction and discharge piping connections from the Fluid Cylinder. 2. Remove Thumb Screws and Plunger Cover. If the pump is equipped with a lubricator, disconnect the lines at the Stuffing Boxes.

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Installation, Operation, and Maintenance Manual 3. The Plungers and Crosshead Stubs separate at the knurl area interface. Using a pipe wrench on the knurled area on the plunger and another pipe wrench in the reverse direction on the Crosshead Stub, break the plunger loose and unscrew from the Crosshead Stub. 4. Remove the four Cylinder Tie Stud Nuts which secure the Fluid End to the Power End. 5. Attach a sling and use a power lift to separate the Fluid End from the Power End. Gentle prying may be required to separate the two assemblies. Care should be exercised to avoid shearing the two Alignment Pins located on the front of the Power Frame. 4.3.2

Stuffing Boxes Removal

1. Loosen the packing gland nuts and remove Plungers 2. Remove the nuts holding the Stuffing Box Flange onto the Fluid Cylinder. Lift off the Stuffing Box Flange with the Stuffing Boxes 3. Carefully remove each Stuffing Box Assembly and set to the side. Remove and discard all Stuffing Box Gaskets Note: Exercise care when removing these gaskets to avoid damaging the gasket sealing area. Any time the stuffing box is removed, new gaskets should be installed to assure a positive seal. 4.3.3.

Stuffing Box Disassembly

National Oilwell Varco supplies a variety of packing solutions. The most common configurations are described in this manual. For support on non-standard packing assemblies, please contact National Oilwell Varco using the contact information on the last page of this manual. 1. Remove the Stuffing Box Gland Nut. Remove all internals from the Stuffing Boxes 2. Clean and inspect the Stuffing Box bore to assure there is no pitting in the packing area. 3. All packing assemblies contain a Throat Bushing which is a slight press fit into the Fluid Cylinder. Clean and inspect the inside of the Throat Bushing for excessive wear or pitting. Replace as necessary. 4. Clean and inspect all stuffing box internals to assure there is no pitting or wear areas which could lead to premature packing failure and replace as necessary. Inspect the plungers for pitting or longitudinal scoring lines and replace as required. For spring loaded packing assemblies, examine the Packing Spring for any pitting or wear and replace as necessary. Note: For more information on packing setups, see Section 5 4.3.4

Standard Valve And Seat Removal/Inspection

1. Remove the Cylinder Head and Discharge Valve Covers Flanges, Cylinder Head Extensions, and Discharge Valve Stops. Examine them for wear. These parts can be reused if found to be in acceptable condition. Discard the Cylinder Head and Discharge Valve Cover Gaskets. Note: carefully remove the Cylinder Head and Discharge Valve Cover Gaskets to avoid damaging the gasket seal decks. 2. If this is an inspection only, remove the Springs. and mark and remove each Valve to be matched with the Seat from which it was removed. Note: Marking is essential during inspection if the Valves are to be reused. In the case of a complete rebuild, discard the Valves, Seats and Springs. 3. Removal of the Valve Seats requires the use of a Valve Seat Puller. All valve seats are a press-fit and require a mechanism for applying upward force from below the valve seat. A Valve Seat Puller is available for each fluid cylinder size and valve type . Following the instructions with the valve seat puller, remove the upper discharge Valve Seats first, and then remove the lower suction Valve Seats from the fluid cylinder. Note: The suction valve seats must be removed through the cylinder head ports where each cylinder head extension attaches. They cannot be removed through the discharge ports on top. 24 www.nov.com

Installation, Operation, and Maintenance Manual 4.4

CHECK POINTS AND ADJUSTMENTS •

The connecting rod shell bearings or inserts are precision automotive type. A proper torque of 32ft-lb is required.

•

The factory clearance between the crosshead and crosshead bore is .004” (.102 mm) to .007” (.178 mm). The maximum allowable clearance, including wear, is .010” (.254 mm).

•

The replacement wrist pin bushings must be pressed into the connecting rods and then reamed and honed to size. The allowable clearance between the pin and bushing is listed below. FITS AND TOLERANCES CLEARANCE (in) Min Max .000 .002 .001 .003 .003 .005 .0005 .0012 .0010 .0022 .004 .007

BD-30 POWER END Crankshaft Main Bearing Fit In Power Frame Crankshaft End Play (Without Preload) Connecting Rod Bearing Clearance Over Crankshaft Wrist Pin Clearance In Crosshead Wrist Pin Clearance In Connecting Rod Pin Bearing Crosshead Clearance In Power Frame

CLEARANCE (mm) Min Max .000 .051 .025 .076 .76 .127 .013 .030 .025 .056 .102 .178

TORQUE SPECIFICATION CHART BD-30 POWER END Recommended Torque (Lubricated) Part Description Thread Size ft-lbs N-m Connecting Rod Bolts 3/8-24UNF 32 43 Frame Cap Bolts 3/8-16UNC 15 20 Crankcase and Inspection Cover Bolts 3/8-16UNC 15 20 Stub Seal Cap Bolts 3/8-16UNC 15 20 Plunger to Stub 5/8-11UNC 50 68 Cylinder Tie Stud Nuts 1/2-13UNC 55 75

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Installation, Operation, and Maintenance Manual 4.5

POWER END ASSEMBLY

4.5.1

Connecting Rod/Crosshead Assembly

The Crosshead Wrist Pin is a slip fit into the Connecting Rod and is locked into the Crosshead with two Set Screws. Properly installed, the Connecting Rod should slide inside the Crosshead. This allows for alignment of the Connecting Rod after attachment to the Crankshaft. 1. Clean and inspect the Crosshead Assembly. Examine the Crosshead Stub for any nicks, dings, or longitudinal scoring. Replace if necessary. 2. Clean and inspect the Connecting Rod and install new Connecting Rod Bearings into the rod and caps. Note: Connecting rods and caps are matched sets. Do not mix caps and rods. Check the Wrist Pin Bushing for excessive wear as well as fit tolerance with the Crosshead Wrist Pin. When replacement of the Wrist Pin Bushing you must machine and hone the wrist pin bearing to 1.0532" / 1.0538" NOTE: This can be done only after the Bushing is installed into the Connection Rod and is best done by a competent machine shop. 3. Connect the Crosshead to the Connecting Rod by first applying a thin film of lubricant and inserting the Wrist Pin into one end of the Crosshead and through the small end of the Connecting Rod. Secure the Wrist Pin by threading one Set Screw into the threaded port on rear of the Crosshead making sure that the Set Screw bottoms out on the machined relief of the Wrist Pin. Apply a thread locking compound on a second Set Screw and install into the same threaded port as the first. 4. Lubricate the crosshead bore and slide the Connecting Rod/Crosshead Assembly into the Power Frame bore from which it was removed. Push the assemblies to the full forward. The big end of the connecting rod and caps are stamped with matching numbers. This stamping should face up when installed

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Installation, Operation, and Maintenance Manual 4.5.2

Crankshaft Main Bearings (If replacement is required)

! WARNING ! WARNING ! WARNING ! EXERCISE CARE IN THE ACTIONS DESCRIBED BELOW. ALWAYS WEAR THE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT WHEN HANDLING HEATED COMPONENTS. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN SEVERE BODILY INJURY. 1. Thoroughly clean and remove all burrs from the bearing seating surfaces on the crankshaft. 2. Heat the roller cone assembly in an electric oven to no more than 300°F (149°C). Do Not Overheat. 3. After the bearings have been brought up to temperature and with the crankshaft firmly supported, install the cone and roller assemblies on the crankshaft. Note: Make sure the cone and roller assemblies are firmly against the shoulders on the crankshaft. 4. Allow the crankshaft and bearing assembly to cool before installing in the power end. 4.5.3

Crankshaft Installation

1. Make sure the main bearing openings in the frame are clean and free of burrs. 2. Tap one Crankshaft Bearing Cup into one side of the Power Frame until flush with the outside of the power frame. If necessary, remove the Connecting Rod caps and set on top of crankcase over its corresponding assembly 3. Carefully insert the Crankshaft through the side of the Power Frame past the Connecting Rods until it rests in the Crankshaft Bearing Cup on the opposite side, then tap in the opposite side Crankshaft Bearing Cup. 4. Install a Oil Seal into the Inboard Frame Cap If new main bearings are installed: • When first installing shims, add enough that the Crankshaft will rotate freely. Install the Frame Caps with the proper torque. • Tap Crankshaft on each end sufficient enough to ensure that the Bearing Cups seat firmly against the Frame Caps. . • Mount a dial indicator with a magnetic base onto the Power frame and set the indicator perpendicular to the end of the shaft. • With a large screwdriver and using the inside of the Power Frame as a base, carefully pry the Crankshaft to each side measuring the total indicator reading. • The proper clearance is found by adjusting the amount of shims until the crankshaft has .003" to .005" endplay and will rotate freely. If the used main bearings are reinstalled: • Replace the Inboard and Outboard Frame Caps using the same Shim Stack that was removed with each cap. • Torque the hex head bolts to the proper load and check that the Crankshaft rotates freely. 27 www.nov.com

Installation, Operation, and Maintenance Manual 4.5.4

Connecting Rod To Crankshaft Assembly

1. Thoroughly clean and remove all burrs and nicks from the Connecting Rods, Caps, and Crankshaft journals. 2. Install a Bearing half into each Connecting Rod and Cap by aligning the tang on the Bearing with the groove in the rods and caps 3. Apply a thin film of lubricant to the Crankshaft journals and Connecting Rod Bearings. 4. Position the first crankshaft throw to the rear. 5. Slide the connecting rod back over the crankshaft throw using caution so the outer surface of the insert is not damaged. Note the match numbers of the cap and rod to be certain the rod is assembled correctly. 6. Torque the Connecting Rod Bolts to 43 ft-lbs. 7. Repeat for the remaining Connecting Rods. 4.5.5

General

1. Install two new Oil Seals into each Crosshead Seal Cap. Seals with the solid metal faces against each other and the spring side facing out 2. Lubricate each Crosshead stub. Install new O-rings on the Seal Caps and carefully slide the seals over each Crosshead Stub. 3. Slide the Crosshead Seal Caps into the crosshead bores of the Power Frame and secure with the Washers and Hex head bolts. 4. Install Crosshead Stub Deflectors onto the Crosshead Stub just after the knurled surface. 5. Replace the Oil Level Indicator, Drain Plug and Crankcase Breather. Note: It is recommended that the Crankcase Breather be cleaned during each oil change to insure adequate air flow to the crankcase 6. Remove the Oil Fill Plug, fill with the amount and recommended type of oil based on ambient temperature conditions, and replace the oil fill plug. See the chart on page 13 for oil requirements. 7. Reconnect the plunger to the crosshead assembly (10). Tighten according to the Torque Specification Chart in Section 4.4.

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Installation, Operation, and Maintenance Manual 4.6

FLUID END ASSEMBLY

! ATTENTION ! PRECAUTIONS SHOULD BE TAKEN TO PREVENT FOREIGN MATERIAL FROM ENTERING THE ASSEMBLY WHEN INSPECTING OR REPLACING COMPONENTS OF THE FLUID CYLINDER. SOLID FOREIGN DEBRIS CONTAMINATING THE ASSEMBLY WILL LEAD TO PREMATURE FAILURE OF THE PACKING, PLUNGERS, VALVES AND SEATS 4.6.1

Installation of Valve Seats

1. You must install the lower Suction Valve Seats before installing the upper Discharge Valve Seats. 2. Install the new Valve Seats by setting the new valve seat with the radius edge to the seat pocket. Then, place on top a round disc larger than the Seat and press into place. 3. Do not hammer Valve Seats into the fluid cylinder – press into place. Also, check to insure that the valve seat is going in straight and not cocked at an angle. Shrinking the seats with dry ice will make the installation process easier 4.6.2.

Installation of Valves and Covers

1. Insert the Valves into the upper Seats and check to see that each moves freely. Place a Valve Spring on top of each valve. 2. Inspect the gasket sealing deck areas of the Fluid Cylinder for any gouges, dings, or pits and remove any burrs. Install the new Cylinder Head and Discharge Valve Cover Gaskets. 3. If reusing the Discharge Valve Stops, clean and inspect for any gouges, dings, or pits that would prevent the parts from properly sealing. Place the Discharge Valve Stop over each Valve Spring with the small end down and the threaded hole up. 4. Replace the Discharge Valve Cover. Torque the Nuts using the procedure described below a. Hand tighten all nuts. b. ‘M’ Cylinder: Pre-torque all nuts to 55 ft-lbs (75 N-m) ‘L’ Cylinder: Pre-torque all nuts to 28 ft-lbs (38 N-m) c. ‘M’ Cylinder: Final torque to 110 ft-lbs (149 N-m) ‘L’ Cylinder: Final torque to 55 ft-lbs (75 N-m) Note: Torque values provided are based on lubricated threads Use torque sequence shown for all Pre and Final torque values Always Re-torque final torque value

5. Insert the Valves in the lower Seats and check to see that each Valve moves freely. Place a Valve Spring on top of each Valve. 6. Inspect the cylinder head gasket sealing deck area for any gouges, dings, or pits and remove any burrs; Install the new Cylinder Head Gaskets. 7. If reusing the Cylinder Head Extensions, clean and inspect for any cracks or excessive wear. Install the cylinder head extensions by first entering the port at a slight upward angle in order to clear the top of the valve spring.

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Installation, Operation, and Maintenance Manual 8. Replace the Cylinder Head Valve Cover. Torque the Nuts using the procedure described below. a. Hand tighten all nuts. b. ‘M’ Cylinder: Pre-torque all nuts to 55 ft-lbs (75 N-m) ‘L’ Cylinder: Pre-torque all nuts to 28 ft-lbs (38 N-m) c. ‘M’ Cylinder: Final torque to 110 ft-lbs (149 N-m) ‘L’ Cylinder: Final torque to 55 ft-lbs (75 N-m) Note: Torque values provided are based on lubricated threads Use torque sequence shown for all Pre and Final torque values Always Re-torque final torque value

4.6.3

Installation of Stuffing Boxes and Plungers

1. Inspect the stuffing box gasket sealing deck area for any gouges, dings, or pits and remove any burrs; carefully tap in each Throat Bushing install the new Stuffing Box Gaskets. Note: The Throat Bushing is a slight press fit in the Fluid Cylinder and may have to be driven into position. As an alternative you can chill the Throat Bushings in a freezer or with CO2.

! ATTENTION ! NOTICE ! IMPORTANT ! PREVENT DAMAGE BY PLACING A BLOCK OF WOOD OVER THE THROAT BUSHING FACE. 2. Inspect the sealing face of the Stuffing Boxes to insure there are no gouges, dings, or pits to prevent proper sealing. Place the Stuffing Boxes over the Throat Bushings. 3. Install the Stuffing Box Flange over the Stuffing Boxes. Torque the Nuts using the procedure described below

a. Hand tighten all nuts. b. ‘M’ Cylinder: Pre-torque all nuts to 100 ft-lbs (136 N-m) ‘L’ Cylinder: Pre-torque all nuts to 55 ft-lbs (75 N-m) c. ‘M’ Cylinder: Final torque to 200 ft-lbs (271 N-m) ‘L’ Cylinder: Final torque to 110 ft-lbs (149 N-m) Note: Torque values provided are based on lubricated threads Always Re-Torque Final Torque Value

4. Follow the instructions provided in Section 5 for packing installation 4.7

Connection of Fluid End to Power End 1. Attach a sling and use a power lift to return the Fluid End assembly to the Power End. Insert the Cylinder Tie Studs on the Power Frame, through the holes provided on the Stuffing Box Flange and carefully guide, but do not force, the Fluid End assembly onto the Dowel Pins located on the front of the Power Frame. 2. Use the Hex Nuts to secure the Stuffing Box Flange to the power frame. Note: Be sure to pull the sides of the fluid cylinder up to the power frame equally; avoid cocking at an angle as this could shear the alignment pins. 3. Pull the Plunger to Crosshead Stub and tighten securely, but avoid over tightening. Refer to the torque specifications in Section 4.4 for the proper load. 4. Attach plunger lubrication lines if applicable. Install the Plunger Cover

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Installation, Operation, and Maintenance Manual 5.0 PACKING ASSEMBLIES 5.1

GENERAL

Plunger packing replacement is best accomplished after removal of the Fluid Cylinder from the Power Frame. See instructions for Fluid Cylinder removal in Section 4.3.1. The following instructions are for the four most common types of packing assemblies. Review the Illustrations in the following sections as well as the exploded view in Section 3.2 to identify the appropriate parts and their descriptive names. It is important to adhere to the following instructions in order to maximize the life of both the Packing and the Plunger. Note: Any system which insures a dependable drip or flow of oil on the plunger either internally or on the outside of the stuffing box is desirable. The correct type and amount of oil needed for lubrication can be found in Section 2.3.2.

5.2

INSTRUCTION FOR SQUARE RING TYPE PACKING

Item 1 4 7

Description Plunger Throat Bushing Lantern Ring

Item 2 5

Description Stuffing Box Gland Packing

Item 3 6

Description Stuffing Box Gland Follower

1. Clean all stuffing box internals and the inside bore of the Stuffing Boxes. 2. Inspect all parts for pitting, excessive wear, and longitudinal scoring lines. These items can often be reused, but if they are worn, replace them. Reusing worn trim will cause premature packing failure. 3. Refer to the stuffing box assembly illustrations above for the proper arrangement of packing and components. Note: for non-lubricated assemblies, the number of packing rings vary with plunger size. Lubricated assemblies using rope packing will always have three packing rings before the lantern ring and two after as shown above 4. Apply a film of light oil to the inside of each Stuffing Box 5. Apply a film of light oil to each Packing Ring. 6. Install the packing rings individually into each Stuffing Box. Seat each ring firmly into place. It may be helpful to use the Gland Follower to push the individual packing rings to the bottom. DO NOT BEND, TEAR, OR COMPRESS THE PACKING RINGS. Split ring type packing should be installed with the splits located 120° apart. 31 www.nov.com

Installation, Operation, and Maintenance Manual 7. If assembling a lubricated stuffing box, apply a film of light oil to each Lantern Ring and install between the third and forth Packing Rings of each Stuffing Box. Be sure the Lantern Rings align with the lubrication ports of the Stuffing Boxes. 8. Install each Gland Follower after the last Packing Ring. 9. Apply an anti-seize thread compound to the threads of the Stuffing Boxes and install each Stuffing Box Gland until FINGER TIGHT ONLY. 10. Apply a film of light oil to the Plunger and carefully install it through the Stuffing Box 11. Follow the procedure for connection of Fluid End defined in Section 4.7. 12. Rotate the crankshaft in the proper direction about 10 times. Unscrew the Stuffing Box Gland and re-tighten to finger tight again. Be sure the gland is only finger tight. 13. The pump is now ready to run to “seat-in” the Packing. Start the pump and allow it to run idle with little or no pressure. Do not be alarmed if the packing leaks. Leakage will decrease as pressure is applied to the pump and as the Packing begins to heat up. During the first 15 minutes of operation, allow each Packing Set to leak at about 60-120 drops per minute. If necessary, loosen the Stuffing Box Gland to maintain the desired leak rate, but only if there is a reduction in the leak rate during the first 15 minutes. As the Plunger travels through the Packing, the Packing may begin to heat up and it will need room to expand. Increasing temperature due to inadequate lubrication or over-tightening of the Stuffing Box Gland will cause the Packing to bind on the Plunger and result in premature failure of the packing. To assure proper seating of the Packing, it is recommended that a light oil be squirted on to the Plunger outside of the Stuffing Box during this process. Closely monitor the temperature, carefully by touch, of the Plunger and the Stuffing Box. 14. Slowly tighten the Stuffing Box Gland Nuts about 1/8 to 1/6 turn every 4-5 minutes until the leak rate per plunger falls into the range defined in the chart below. If the Plunger or Stuffing Box temperature increases due to the tightening, loosen the glands and repeat this step. Continue this process until the temperature remains constant after re-tightening the Stuffing Box Glands.

! ATTENTION - NOTICE - IMPORTANT ! DURING NORMAL OPERATION, THIS TYPE OF PACKING MUST MAINTAIN A SLIGHT LEAKAGE OF. THIS WILL ALLOW THE PLUNGER TO BE LUBRICATED AND INCREASE THE LIFE OF BOTH THE PLUNGER AND PACKING. WHEN READJUSTING THE PACKING, DO NOT OVER TIGHTEN. TIGHTEN ONLY AS NEEDED TO COMPENSATE FOR EXCESSIVE LEAKAGE.

DRIP RATE CHART Plunger Size Up to 1-1/2” 1-1/2” to 2-1/2” 2-1/2” to 3-1/2” 3-1/2” to 4-1/2”

Drips Per Minute 8-10 12-14 16-18 20-22

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Installation, Operation, and Maintenance Manual

5.3

INSTRUCTIONS FOR MOLDED ‘V’ RING TYPE PACKING

Item 1 4 7

Description Plunger Throat Bushing Lantern Ring

Item 2 5

Description Stuffing Box Gland Packing

Item 3 6

Description Stuffing Box Gland Follower

1. Clean all stuffing box internals and the inside bore of the Stuffing Boxes. 2. Inspect all parts for pitting, excessive wear, and longitudinal scoring lines. These items can often be reused, but if they are worn, replace them. Reusing worn trim will cause premature packing failure. 3. Refer to the stuffing box assembly illustrations above for the proper arrangement of packing and components. Note: for non-lubricated assemblies, the number of pressure rings vary with plunger size. Lubricated assemblies using "V" type packing will always have three pressure rings in the packing set before the lantern ring and two pressure rings in the packing set after as shown above 4. Apply a film of light oil to the inside of each Stuffing Box 5. Apply a film of light oil to each Packing Ring. Install each pressure ring with the open end of the "V" facing toward the fluid end. 6. Install the packing rings individually into each Stuffing Box. Seat each ring firmly into place. It may be helpful to use the Gland Follower to push the individual packing rings to the bottom. DO NOT BEND, TEAR, OR COMPRESS THE PACKING RINGS. Split ring type packing should be installed with the splits located 120° apart. 7. If assembling a lubricated stuffing box, apply a film of light oil to each Lantern Ring and install between the two sets of packing in each Stuffing Box. Be sure the Lantern Rings align with the lubrication ports of the Stuffing Boxes. 8. Install each Gland Follower after the last Packing Set. 9. Apply an anti-seize thread compound to the threads of the Stuffing Boxes and install each Stuffing Box Gland until FINGER TIGHT ONLY. 10. Apply a film of light oil to the Plunger and carefully install it through the Stuffing Box 33 www.nov.com

Installation, Operation, and Maintenance Manual 11. Follow the procedure for connection of Fluid End defined in Section 4.7. 12. The pump is now ready to run to “seat-in” the Packing. Start the pump and allow it to run idle with little or no pressure for fifteen. Do not be alarmed if the packing leaks. Leakage will decrease as pressure is applied to the pump and as the Packing begins to heat up. As the Plunger travels through the Packing, the Packing may begin to heat up and it will need room to expand. Increasing temperature due to inadequate lubrication or overtightening of the Stuffing Box Gland will cause the Packing to bind on the Plunger and result in premature failure of the packing. To assure proper seating of the Packing, it is recommended that a light oil be squirted on to the Plunger outside of the Stuffing Box during this process. Closely monitor the temperature, carefully by touch, of the Plunger and the Stuffing Box. 13. Slowly tighten the Stuffing Box Gland Nuts about 1/8 to 1/6 turn every 4-5 minutes until a leak rate of 2-8 drops per minute per Plunger is attained. If the Plunger or Stuffing Box temperature increases due to the tightening, loosen the glands and repeat this step. Continue this process until the temperature remains constant after retightening the Stuffing Box Glands.

! ATTENTION - NOTICE - IMPORTANT ! IT IS ESSENTIAL WHEN INSTALLING THE "V" TYPE PACKING TO NOT OVER COMPRESS THE SET. THE SET SHOULD BE ALLOWED SUFFICIENT LOADING TO INITIALLY SEAL WHILE STILL BEING ABLE TO RELAX ON THE STROKE RETURN.

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Installation, Operation, and Maintenance Manual 5.4

INSTRUCTIONS FOR SPRING LOADED "V" PACKING

Item 1 4 7

Description Plunger Throat Bushing Lantern Ring

Item 2 5 8

Description Stuffing Box Gland Packing Male Adapter

Item 3 6 9

Description Stuffing Box Female Adapter Packing Spring

1. Clean all stuffing box internals and the inside bore of the Stuffing Boxes. 2. Inspect all parts for pitting, excessive wear, and longitudinal scoring lines. These items can often be reused, but if they are worn, replace them. Reusing worn trim will cause premature packing failure. 3. Refer to the stuffing box assembly illustrations above for the proper arrangement of packing and components. Note: All stuffing box assemblies of this style use three pressure rings with integral adapter rings 4. Apply a film of light oil to the inside of each Stuffing Box and all internal parts. Install a Packing Spring and Male Adapter into each Stuffing Box. 5. Apply a film of light oil to each Packing Ring. Install each pressure ring with the open end of the "V" facing toward the fluid end. 6. Install the packing rings individually into each Stuffing Box. Seat each ring firmly into place. It may be helpful to use the Gland Follower to push the individual packing rings to the bottom. DO NOT BEND OR TEAR THE PACKING RINGS. 7. If assembling a lubricated stuffing box, apply a film of light oil to each Lantern Ring and install between the second and third pressure ring sets of packing in each Stuffing Box. Be sure the Lantern Rings align with the lubrication ports of the Stuffing Boxes. 8. Install each Female Adapter after the last Packing Set. 9. Apply an anti-seize thread compound to the threads of the Stuffing Boxes and install each Stuffing Box Gland just a few turns. Do not fully tighten the Stuffing Box Gland at this time. 10. Apply a film of light oil to the Plunger and carefully install it through the Stuffing Box 11. Follow the procedure for connection of Fluid End defined in Section 4.7.

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Installation, Operation, and Maintenance Manual 12. Fully tighten the Stuffing Box Glands. This packing style is spring-loaded and once the Stuffing Box Glands are properly pulled up there is no more adjustment. 13. Start the pump and bring up to pressure.

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Installation, Operation, and Maintenance Manual 5.5

INSTRUCTIONS FOR NON-ADJUSTABLE "J" PACKING

Item 1 4 7

Description Plunger Throat Bushing Lantern Ring

Item 2 5

Description Stuffing Box Gland Packing

Item 3 6

Description Stuffing Box Gland Follower

1. Clean all stuffing box internals and the inside bore of the Stuffing Boxes. 2. Inspect all parts for pitting, excessive wear, and longitudinal scoring lines. These items can often be reused, but if they are worn, replace them. Reusing worn trim will cause premature packing failure. 3. Refer to the stuffing box assembly illustrations above for the proper arrangement of packing and components. Note: All stuffing box assemblies of this style use three pressure rings each with special adapter rings 4. Apply a film of light oil to the inside of each Stuffing Box and all internal parts. 5. Apply a film of light oil to each Packing Ring. Install each pressure ring with the open end of the "V" facing toward the fluid end. 6. Install the first two packing rings with their respective adapters individually into each Stuffing Box. Seat each ring firmly into place. It may be helpful to use the Gland Follower to push the individual packing rings to the bottom. DO NOT BEND, TEAR, OR COMPRESS THE PACKING RINGS. 7. Apply a film of light oil to each Lantern Ring and install between the second and third pressure ring sets of packing in each Stuffing Box. Be sure the Lantern Rings align with the lubrication ports of the Stuffing Boxes. 8. Install each Gland Follower after the last Packing Set. 9. Apply an anti-seize thread compound to the threads of the Stuffing Boxes and install each Stuffing Box Gland just a few turns. Do not fully tighten the Stuffing Box Gland at this time. 10. Apply a film of light oil to the Plunger and carefully install it through the Stuffing Box 11. Follow the procedure for connection of Fluid End defined in Section 4.7. 12. Fully tighten the Stuffing Box Glands with a gland nut wrench be hand DO NOT USE A CHEATER 37 www.nov.com

Installation, Operation, and Maintenance Manual 13. Start the pump and operate at pressure for two to three hours while observing for excessive leakage. If leakage is excessive, stop the pump and readjust. After the two or three hours, stop the pump and readjust. Again, DO NOT USE A CHEATER.

14. This style packing is considered non-adjustable and should be ready to go at this point. However, it may take as much as one or two days to fully seat. After a couple of days, stop the pump and check the packing again. After this adjustment the pump should be ready to run without further adjustment.

38 www.nov.com

Installation, Operation, and Maintenance Manual 6.0 ENGINEERING DATA 6.1

SUCTION PRESSURE REQUIREMENTS

Label

Plunger Size

Suction Springs

A

1"

No

B

1-1/2"

No

C

1"

Standard

D

1-1/2"

Standard

39 www.nov.com

Installation, Operation, and Maintenance Manual

Label

Plunger Size

Suction Springs

A

1-5/8"

No

B

2-1/4"

No

C

1-5/8"

Standard

D

2-1/4"

Standard

40 www.nov.com

Installation, Operation, and Maintenance Manual 6.2

RECIPROCATING PUMP FLOW CURVES 160% 150%

PERCENT OF AVERAGE FLOW RATE (VELOCITY) IN DISCHARGE LINE

140% 130% 120% 110% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% DUPLEX, SINGLE-ACTING 107% 100% 90% 82% TRIPLEX, SINGLE-ACTING 102% 95%

100% QUINTUPLEX, SINGLE-ACTING 0°

45°

90°

180°

135°

225°

270°

315°

360°

DEGREES OF CRANKSHAFT ROTATION NOTE:

THE ABOVE CURVES ARE APPROXIMATE AND REPRESENT RECIPROCATING PUMPS WITH A CONNECTING ROD LENGTH EQUAL TO FIVE TIMES THE CRANK THROW. 41

www.nov.com

Installation, Operation, and Maintenance Manual PUMP SPEED VS. TORQUE 160 150 140 130 % OF FULL-LOAD TORQUE

6.3

120 (A) FULL-LOAD TORQUE

110 100 90 80 70 60 50 40 30

(B) NO-LOAD TORQUE

20 10 0 0

10

20

30

40

50

60

70

80

90

100

% OF FULL-LOAD SPEED

(A) FULL-LOAD TORQUE This represents start-up against the designed discharge pressure of the pump.

(B) NO-LOAD TORQUE This represents start-up with an open by-pass valve to the pump suction.

42 www.nov.com

Installation, Operation, and Maintenance Manual 6.4

STANDARD MATERIALS OF CONSTRUCTION

6.4.1

Power End COMPONENT

6.4.2

MATERIAL

Power Frame

ASTM A536 Grade 65-45-12 Ductile Iron

Crankshaft

ASTM A536 Grade 80-55-06 Ductile Iron

Connecting Rod

ASTM A536 Grade 80-55-06 Ductile Iron

Crosshead

ASTM A48 Class 30 Cast Iron HT501

Crosshead Stub

ASTM A564 Type 630 Annealed

Main Bearing

Timken Tapered Roller

Connecting Rod Bearing

Babbitt Lined Steel--Precision Automotive Type

Crosshead Wrist Pin

ASTM A534 Grade 8620 CHT 203

Crosshead Wrist Pin Bearing

SAE #600 Bearing Bronze/ASTM B438 Gr. 1 Type II

Crankcase Cover

Commercial Quality Steel

Plunger Cover

Commercial Quality Steel

Crosshead Stub Cap

ASTM A48 Class 30 Cast Iron

Crankshaft Cap

ASTM A48 Class 30 Cast Iron

Lubrication

Splash & Gravity

Fluid End COMPONENT

Fluid Cylinder Stuffing Box Throat Bushing Lantern Ring Gland Follower Gland Nut Plunger Valve Valve Seat Valve Spring Valve Stops Flanges Bolting Packing & Gaskets

MATERIAL

ASTM A516 Grade 70 Pressure Vessel Plate ASTM A108-1215 C.F. Carbon Steel ASTM A108-1117 C.F. Carbon Steel ASTM A108-1117 C.F. Carbon Steel ASTM A108-1117 C.F. Carbon Steel ASTM A108-1215 C.F. Carbon Steel ASTM A108-1018 C.F. Coated Colmonoy #6 ASTM A564 Type 630 Condition H1025 ASTM A564 Type 630 Condition H900 ASTM A313 Type 302 HT 303 Spring Wire ASTM A108-1215 C.F. Carbon Steel ASTM A108-1018 C.F. Carbon Steel ASTM A193-79A Grade B7 Per Application

43 www.nov.com

Installation, Operation, and Maintenance Manual

BEAR PRODUCT LINE - MISSION PRODUCTS

http://www.nov.com/bearpumps 9616 Telge Road, Houston, Texas 77095 Phone: 281-200-1000

Fax: 281-200-1005

Email: [email protected]

44 www.nov.com

NATIONAL OILWELL VARCO

BD‐30 PN# A041250304A05 Level 2nd Item  Number

Description  

1 .2 .2 .2 .2 1 1 1 1 1 1 1 1 1 1 1 1 .2 ..3 ..3 ..3 ..3 .2 .2 .2 .2 1 1 1 1 1 .2 ..3 ..3 ...4 ...4 ...4 ...4 ..3 ...4 ....5 ...4

Pump Base Assy, BD‐30, Standar  Flat Washer, Steel,  Pump Base, BD‐30, St  Hex Nut, Nylock, Pla  HEX HEAD CAP SCREW, Hex Head Cap Screw, Hex Nut, Nylock, Pla HEX NUT, CYL TIE/VAL Flat Washer, Steel, Bushing, E, 1‐7/8 BO QD Bushing Motor Sheave Pump Sheave V‐Belt PUMP SKID, BD‐30 Brace, Belt Guard Back Plate Belt Guard Assy, BD‐30  Belt Guard, BD‐30 (23.6")   Hex Head Cap Screw,   Nut, Trip Spring Ret   Belt Guard, BD‐30 (23.6") Ta   Flatwasher, Plated  Belt Guard Back Plate, BD‐30  Hex Head Bolt, Plate  Hex Nut, Nylock, Pla  Flatwasher, Plated Motor Base, Adjustable 286T Hex Head Bolt, Grade 8 Riser, Motor Base Motor/30HP/1800/EXP/ BD‐30, 1.250 COL/CS/CS/CU/NON  POWER END ASSY, BD‐30 2.75 ST   Nipple 1/2" NPT X 1.   SHIM SET, BD‐30    Shim, .020 BD‐30 (Ye    Shim, .010 BD‐30 (Br    Shim, .007 BD‐30 (Cl    Shim, .005 BD‐30 (Li   CROSSHEAD ASSY, BD‐30    Crosshead, BD‐30 (Th     Casting, Crosshead BD‐30    Crosshead Stub, BD‐3

B642A0000030A B911008106A1 B642A0000030 B9108A080NY1 B9101A0810A1 B9101A0610A1 B9108A060NY1 B9108A081DF1 B911008106A1 B96180E187B7 B9618SDS0187 B96190350490 B96190352360 B96205VX0900 B900A0030‐00 B900A0030‐03 B640A0302362U B640D0392361A 80204 AP32219 B640D0392361A‐4 B911006100A1 B641D0302362 B9101A0660A1 B9108A060NY1 B911006100A1 B900A0030‐01 B9101A0824A2 B900A0030‐02 M03018EH3FJT‐F2 B04A125A01N0ABA B100410 70113103 B010967 B134B0625501 B134B0625502 B134B0625503 B134B0625504 B100407 B117C0652600 B100407‐1 B122B0342600

Quantity   UM   1 8 1 4 0 2 2 12 24 1 1 1 1 4 1 1 1 1 2 2 1 10 1 5 5 10 1 12 2 1 1 1 1 1 3 2 2 2 3 1 1 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

NATIONAL OILWELL VARCO

BD‐30 PN# A041250304A05 Level 2nd Item  Number

Description  

...4 ..3 ...4 ....5 ....5 ....5 ....5 ...4 ..3 ..3 ...4 ..3 ..3 ..3 ..3 ..3 ...4 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 .2 ..3

   SET SCREW, BD‐30/60, CROSSH   CONNECTING ROD ASSY, BD‐30    CONNECTING ROD, BD‐30     Casting, Connecting Rod BD     BOLT, CONNECTING ROD, BD‐3     LOCKWASHER, BD‐30 CONN. RO     WRIST PIN BEARING, BD‐30 (    BEARING, CONNECTING ROD BD‐   Power Frame, BD‐30   CRANKSHAFT, BD‐30 2.75 STROK    Casting, Crankshaft BD‐30 2   WRIST PIN, CROSSHEAD BD‐30   DEFLECTOR, CROSSHEAD STUB BD   CRANKSHAFT FRAME CAP, OUTBOA   CRANKSHAFT FRAME CAP, INBOAR   Seal Cap, Crosshead    Casting, Crosshead Stub Sea   COVER, PLUNGER, BD‐30   COVER, INSPECTION, BD‐30   Cover, Crankcase BD‐30   GASKET, CRANKCASE COVER BD‐3   GASKET, INSPECTION COVER BD‐   GASKET, CROSSHEAD STUB SEAL   Stud, Cylinder Tie,   Key, BD‐30   Hex Head Cap Screw,   Hex Head Cap Screw,   HEX NUT, CYL TIE/VAL   Hardend Steel Pin   Thumb Screw   Reducing Tee, Black,   PLUG, 1/2" NPT, SQUARE HEAD   PLUG, 3/4" NPT, SQUARE HEAD   PLUG, 1/2" NPT, SOCKET HEAD   CROSSHEAD STUB OIL SEAL, MX‐   CRANKSAHFT OIL SEAL, BD‐30   OIL LEVEL INDICATOR   CRANKCASE BREATHER, 3/8" MNP   CONE, CRANKSHAFT BEARING, BD   CUP, CRANKSHAFT BEARING, BD‐  FLUID END, BD‐30 1.250 COL/CS   BARE FLUID END, BD‐30 1.500

B9137B0610A1 B100408 B100408‐3 B100408‐1 B9102F0620A1 B9111AD600A2 B9604W00030A B116B1017400 B100E0365000 B103D0611400 B103D0611400‐1 B119A0616800 B123A0617800 B132B0623800 B133B0623700 B141B0624200 B141B0624200‐1 B152C0638600 B153C1366900 B154B0624400 B620B0625400 B621C1367000 B623A0619502 B643A0617900 B811B0323120 B9101A0605A1 B9101A0610A1 B9108A081DF1 B912137510A2 B9135A0404A1 B9205BAA4ED8 B9214DA04JD5 B9214DA06JD5 B9214FA04JD5 B94111000103 B94111000134 B9513ECAB0BB B9514B1D0000 B9610BETA041 B9610CETA001 F04A125A01N0ABA B300E0603700

Quantity   UM   2 3 1 1 2 2 1 1 1 1 1 3 3 1 1 3 1 1 1 1 1 1 3 4 1 20 18 4 2 2 1 1 1 2 6 1 1 1 2 2 1 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

NATIONAL OILWELL VARCO

BD‐30 PN# A041250304A05 Level 2nd Item  Number

Description  

...4 ...4 ....5 ...4 ...4 ...4 ...4 ...4 ...4 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ..3 ...4 ...4 ..3 ..3 ..3 ..3

   Fluid Cylinder, BD‐30 1.500    VALVE, SUC/DIS, 1.5 CYL MX‐     CASTING, 1.5 CYL BD‐30/BX‐    SEAT, SUC/DIS, BD‐30 1.5 CY    SPRING, SUC/DIS, BD‐30/BX‐1    Stud, Valve Cover, B    Stud, Stuffing Box F    Heavy Hex Nut    Hex Nut, BD‐60/BD‐85   VALVE COVER, BD‐30 1.500   STUFFING BOX, BD‐30 1.250‐1.   GLAND NUT, BD‐30 1.250‐1.500   GLAND FOLLOWER, BD‐30 1.250   THROAT BUSHING, BD‐30 1.250,   PLUNGER, BD‐30 1.250, COLMON   Stuffing Box Flange,   CYLINDER HEAD EXTENSION, BD‐    Cylinder Head Extension    Hardend Steel Pin   DISCHARGE VALVE STOP, BD‐30   VALVE COVER GASKET, BD‐30 1.   STUFFING BOX GASKET, BD‐30 1   PACKING SET, 1.250 X 2.000 X

B300E0603700‐1 B320B0792300 B320B0792300‐1 B322B0824400 B334B0634701 B824A0154911 B824A0155022 B9108A101DF1 B9108A121DF1 B317B0727600 B337B0644300 B338B0624802 B339B0720703 B341B0720503 B353B0657603 B366C0625800 B368A0625700 B368A0625700‐3 B912125006A2 B370B0727700 B619B0608403‐1 B622B0647503 BP01203225

Quantity   UM   1 6 1 6 6 24 8 24 8 6 3 3 3 3 3 1 3 1 1 3 6 3 3

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

BA307E, BA327E, BA308E & BA328E intrinsically safe loop-powered panel mounting indicators Issue 3

Issue: 3 17th April 2012

2

CONTENTS

1. 2.

Description Operation 2.1 Controls

3. 3.1 3.2 3.3 3.4 3.5 4.

System Design for Gas Hazardous Areas 4.1 Transmitter loops 4.2 Remote indication

5. 5.1 5.2 5.3 5.4 6.

7.

Intrinsic safety certification ATEX gas certificate Zones, gas groups & T rating Special conditions for safe use 4/20mA input Certification label information

Installation Location EMC Installation procedure Scale card

Configuration and Calibration 6.1 Summary of configuration functions. 6.2 Indicator function 6.3 Resolution 6.4 Position of decimal point 6.5 Calibration using an external current source. 6.6 Calibration using internal reference. 6.7 Bargraph format and calibration 6.8 Function of the P push-button 6.9 Tare function 6.10 Security code 6.11 Under and over-range Lineariser 7.1 Lineariser calibration using an external current source. 7.2 Lineariser calibration using internal reference. 7.3 Lineariser error message 7.4 Lineariser under and over-range 7.5 Lineariser default configuration

8. Maintenance 8.1 Fault finding during commissioning 8.2 Fault finding after commissioning 8.3 Servicing 8.4 Routine maintenance 8.5 Guarantee 8.6 Customer comments 9. Accessories 9.1 Scale card 9.2 Tag strip 9.3 Alarms 9.3.1 Solid state output 9.3.2 Intrinsic safety 9.3.3 Configuration and adjustment. 9.3.4 Alarm enable 9.3.5 Setpoint adjustment 9.3.6 Alarm function 9.3.7 Alarm output status 9.3.8 Hysteresis 9.3.9 Alarm delay 9.3.10 Alarm silence time 9.3.11 Flash display when alarm occurs. 9.3.12 Access setpoint in display mode. 9.3.13 Adjusting alarm setpoint from the display mode. 9.4 Display backlight 9.4.1 Loop powering the backlight 9.4.2 Separately powering the backlight.

Appendix 1 ATEX dust certification Appendix 2 IECEx gas and dust certification Appendix 3 FM and cFM certification

The BA307E, BA327E, BA308E & BA328E are CE marked to show compliance with the European Explosive Atmospheres Directive 94/9/EC and the European EMC Directive 2004/108/EC

3 1. DESCRIPTION These panel mounting, intrinsically safe digital indicators display the current flowing in a 4/20mA loop in engineering units. They are loop powered but only introduce a 1.2V drop, which allows them to be installed into almost any 4/20mA current loop. No additional power supply or battery is required. The four models are electrically similar, but have different size displays and enclosures. Model

Display

Bezel size

BA307E

4 digits 15mm high

96 x 48mm

BA327E

5 digits 11mm high and bargraph.

96 x 48mm

BA308E

4 digits 34mm high

144 x 72mm

BA328E

5 digits 29mm high and bargraph.

144 x 72mm

2. OPERATION Fig 1 shows a simplified block diagram of all the models. The 4/20mA input current flows through resistor R1 and forward biased diode D1. The voltage developed across D1, which is relatively constant, is multiplied by a switch mode power supply and used to power the instrument. The voltage developed across R1, which is proportional to the 4/20mA input current, provides the input signal for the analogue to digital converter. Each time a 4/20mA current is applied to the instrument, initialisation is performed during which all segments of the display are activated, after five seconds the instrument displays the input current using the calibration information stored in the instrument memory. If the loop current is too low to power the instrument the indicator will display the error message ‘LPLo’.

This instruction manual supplements the instruction sheet supplied with each instrument. The main application of all the models is to display a measured variable or control signal in a hazardous process area. The zero and span of the display are independently adjustable so that the indicator can be calibrated to display any variable represented by the 4/20mA current, e.g. temperature, flow, pressure or level. All the models have been certified intrinsically safe for use in gas and dust hazardous areas by Notified Body Intertek Testing and Certification Ltd and comply with the European ATEX Directive 94/9/EC. The EC-Type Examination certificate specifies that under fault conditions the output voltage, current and power at the 4/20mA input terminals will not exceed those specified for simple apparatus in Clause 5.7 of EN 60079-11, which simplifies installation and documentation. For international applications all models have IECEx certification which is described in Appendix 2. For applications in the USA and Canada all models have FM and cFM certification, see Appendix 3.

Fig 1 Indicator block diagram

4 2.1 Controls The indicators are controlled and calibrated via four front panel push-buttons located below the display. In the display mode i.e. when the indicator is displaying a process variable, these push-buttons have the following functions: P

▼

▲

While this button is pushed the indicator will display the input current in mA, or as a percentage of the instrument span depending upon how the indicator has been conditioned. When the button is released the normal display in engineering units will return. The function of this push-button is modified when optional alarms are fitted to the indicator. While this button is pushed the indicator will display the numerical value and analogue bargraph* the indicator has been calibrated to display with a 4mAΦ input. When released the normal display in engineering units will return. While this button is pushed the indicator will display the numerical value and analogue bargraph* the indicator has been calibrated to display with a 20mAΦ input. When released the normal display in engineering units will return.

E

No function in the display mode unless the tare function is being used.

P+▼

Firmware number followed by version.

P+▲

Direct access to the alarm setpoints when optional alarms are fitted to the indicator and the ‘ACSP’ access setpoints in display mode function has been enabled.

P+E Note:

Access to configuration optional security code.

menu

via

* BA327E and BA328E only If the indicator has been calibrated using the CAL function, calibration points may not be 4 and 20mA.

Φ

3. INTRINSIC SAFETY CERTIFICATION All models have ATEX and IECEx gas and dust certification. This section of the instruction manual describes ATEX gas certification. ATEX dust and IECEx approvals are described in Appendixes 1 and 2.

3.1 ATEX gas certification All the models have been issued with a common EC-Type Examination Certificate number ITS11ATEX27254X by Notified Body Intertek Testing and Certification Ltd. This confirms compliance with harmonised European standards and it has been used to confirm compliance with the European ATEX Directive for Group II, Category 1G equipment, Ex ia IIC T5 Ta = -40 to +70ºC. The indicators bear the community mark and subject to local codes of practice may be installed in any of the European Economic Area (EEA) member countries. ATEX certificates are also acceptable for installations in Switzerland. This section of the instruction manual describes ATEX installations in explosive gas atmospheres conforming with EN60079-14 Electrical Installations design, selection and erection. When designing systems for installation outside the UK the local Code of Practice should be consulted. 3.2 Zones, gas groups and T rating The indicators have been certified Ex ia IIC T5. When connected to a suitable system the indicator may be installed in: Zone 0 explosive gas air mixture continuously present. Zone 1 explosive gas air mixture likely to occur in normal operation. Zone 2 explosive gas air mixture not likely to occur, and if it does will only exist for a short time. Be used with gases in groups: Group A propane Group B ethylene Group C hydrogen Having a temperature classification of: T1 450oC T2 300oC T3 200oC T4 135oC T5 100oC At ambient temperatures between -40 and +70oC. This allows the indicators to be installed in all gas Zones and to be used with most common industrial gases. 3.3 Special conditions for safe use The ATEX certificate has an ‘X’ suffix indicating that special conditions apply for installations in IIIC conductive dust atmospheres. No special conditions apply to installations in gas or in IIIA and IIIB dust atmospheres. See Appendix 1 for information about use in dust atmospheres.

5 3.4 4/20mA input The input safety parameters for the 4/20mA input, terminals 1 and 3 are: Ui Ii Pi

= = =

30V dc 200mA 0.84W

The maximum equivalent capacitance and inductance between the two 4/20mA input terminals 1 and 3 is: Ci Li

= =

13nF 8µH (Effectively 0)

The maximum permitted loop cable parameters can be calculated by adding these figures to Ci and Li of other instruments in the loop and subtracting the totals from the maximum cable capacitance Co and cable inductance Lo permitted for the Zener barrier or galvanic isolator powering the loop. Although the indicators do not themselves comply with the requirements for simple apparatus, the EC-Type Examination Certificate states that for intrinsic safety considerations, under fault conditions the output voltage, current and power at terminals 1 & 3 will not exceed those specified by clause 5.7 of EN 60079-11 for simple apparatus. This simplifies the application and intrinsic safety documentation for a loop into which an indicator is connected. Apart from Ci, the effect of the indicator’s may be ignored when assessing the loop safety. 3.5 Certification label information The certification label is fitted in a recess on the top outer surface of the instrument enclosure. It shows the ATEX certification information, instrument serial number, year of manufacture plus BEKA associates' name and location. Non European certification information may also be included, a typical label is shown below.

4. SYSTEM DESIGN FOR GAS HAZARDOUS AREAS 4.1 Transmitter loops All indicator models may be connected in series with almost any intrinsically safe 4/20mA current loop and calibrated to display the measured variable or control signal in engineering units. There are three basic design requirements: 1. The intrinsic safety output parameters of the 4/20mA loop, which are defined by the Zener barrier or galvanic isolator powering the loop, must be equal to or less than: Uo Io Po

= = =

30V dc 200mA 0.84W

2. The maximum permitted cable capacitance of the loop must be reduced by 13nF. The maximum permitted cable inductance is not reduced by the inclusion of an indicator. 3. The loop must be able to tolerate the additional 1.2V required to operate the indicator. When fitted with an optional backlight this increases to 5.0V if the backlight is loop powered. See 9.4.1 Figs 2a and 2b illustrate typical applications in which an indicator is connected in series with a 2-wire transmitter powered by a Zener barrier and alternatively by a galvanic isolator.

Fig 2a Loop powered by a Zener barrier

BA328E certification label

6

Fig 2b Loop powered by a galvanic isolator

4.2 Remote indication The indicators may be driven via an intrinsically safe interface from a 4/20mA safe area signal to provide a remote display within a hazardous area. The type of intrinsically safe interface is not critical, either a Zener barrier or a galvanic isolator may be used, providing that Ui, Li and Pi of the indicator are not exceeded and the voltage capability of the 4/20mA signal is sufficient to drive the indicator plus the interface. When a high integrity earth connection is already available, a Zener barrier is usually the least expensive option. If an earth connection is not available or isolation is required, a galvanic isolator is the correct choice. If one side of the 4/20mA current loop may be earthed, a single channel Zener barrier provides the lowest cost protection. If the 4/20mA signal is not isolated, then two Zener barriers, a two channel Zener barrier or a galvanic isolator must be used. Fig 3 shows the alternative circuits which may be used.

Fig 3 Alternative circuits for remote indication in a hazardous area

7 5. INSTALLATION 5.1 Location All the models have a robust glass reinforced modified PPO enclosure with a toughened glass window. The front of the indicator has IP66 protection and a gasket seals the joint between the instrument enclosure and the panel. The rear of the indicator has IP20 protection. The indicators may be installed in any panel providing that the operating temperature is between –40ºC and +70ºC and intrinsic safety requirements are complied with. Figs 4A and 4B show the overall dimensions of the 96 x 48mm and the 144 x 72mm instruments together with the recommended panel cut-out dimensions. To achieve an IP66 seal between the instrument enclosure and the instrument panel the smaller tolerance aperture must be used, and the 144 x 72mm models must be secured with four panel mounting clamps. Although the indicator front panel provides IP66 protection it should be shielded from direct sunlight and severe weather conditions.

Fig 4B BA308E and BA328E dimensions

5.2 EMC The indicators comply with the requirements of the European EMC Directive 2004/108/EC. For specified immunity all wiring should be in screened twisted pairs, with the screens earthed at one point within the safe area.

Fig 4A BA307E and BA327E dimensions

8 5.3 Installation Procedure a. Cut the specified aperture in the panel. To achieve an IP66 seal between the instrument enclosure and the instrument panel the aperture must have the tighter tolerances specified in Fig 4A and 4B. b. Slide the gasket over the body of the indicator before inserting the instrument into the panel aperture. c.

Firstly ensure that all the panel mounting clamps are closed by turning the knurled screws fully anti clockwise until the two pips in the clamp foot align with holes in the clamp body.

d. Place a clamp in the recess on each side of the indicator, pulling gently to slide it onto the dovetail as shown in Fig 5. Push the knurled screw slightly forward to engage the thread and tighten by turning clockwise until it is just finger tight. When both clamps are fitted ensure that the gasket behind the front panel bezel is correctly positioned before fully tightening the clamps to secure the instrument. The maximum recommended clamp tightening torque is 22cNm (1.95 lbf in) which is approximately equvalent to fingertight plus one half turn. Do not over tighten. e. Four panel mounting clamps are required to achieve an IP66 seal between a BA308E and BA328E indicator and the instrument panel. f.

Connect the panel wiring to the rear terminal block(s) as shown in Figs 4A and 4B. To simplify installation, the terminals are removable so that the panel wiring can be completed before the instrument is installed.

Fig 5 Fitting panel mounting clamps

5.4 Scale card The indicator’s units of measurement are shown on a printed scale card in a window at the right hand side of the display. The scale card is mounted on a flexible strip that is inserted into a slot at the rear of the instrument as shown in Fig 6. Thus the scale card can easily be changed without removing the indicator from the panel or opening the instrument enclosure. New indicators are supplied with a printed scale card showing the requested units of measurement, if this information is not supplied when the indicator is ordered a blank card will be fitted. A pack of self-adhesive scale cards printed with common units of measurement is available as an accessory from BEKA associates. Custom printed scale cards can also be supplied. To change a scale card, unclip the protruding end of the flexible strip by gently pushing it upwards and pulling it out of the enclosure. Peel the existing scale card from the flexible strip and replace it with a new printed card, which should be aligned as shown below. Do not fit a new scale card on top of an existing card. Install the new scale card by gently pushing the flexible strip into the slot at the rear of the indicator, when it reaches the internal end-stop secure it by pushing the end of the flexible strip downwards so that the tapered section is held by the rear panel.

Align the selfadhesive printed scale card onto the flexible strip and insert the strip into the indicator as shown below.

Fig 6 Inserting flexible strip carrying scale card into slot at the rear of indicator.

9 6. CONFIGURATION AND CALIBRATION Indicators are configured and calibrated via the four front panel push-buttons. All the configuration functions are contained in an easy to use intuitive menu that is shown diagrammatically in Fig 7. Each menu function is summarised in section 6.1 and includes a reference to more detailed information. When the indicator is fitted with alarms additional functions are added to the menu which are described in section 9.3

6.1 Summary of configuration functions This section summarises each of the main configuration functions and includes a cross reference to a more detailed description. Fig 7 illustrates the location of each function within the configuration menu. The lineariser and the optional factory fitted alarms are described separately in sections 7 and 9.3 of this manual. Display

Summary of function

'FunC'

Indicator function Defines the relationship between the 4/20mA input current and the indicator display. May be set to: ‘Std’ Standard linear relationship ‘root’ Square root extraction ‘Lin’ 16 segment adjustable lineariser – see section 7. See section 6.2

'rESn'

Display resolution Defines the resolution of the least significant display digit. May be set to ‘1’, ‘2’, ‘5’ or ‘10’ digits. See section 6.3

'dP'

Decimal point Positions a dummy decimal point between any of the digits or turns it off. See section 6.4

'CAL'

Calibration of the digital display using an external current source. Enables the zero and span of the indicator to be adjusted using an external current source such as a calibrator. When used with an accurate traceable current source this is the preferred method of calibration. See section 6.5

'SEt'

Calibration of display using internal references. Enables the zero and span of the indicator to be adjusted without the need for an accurate input current or disconnection from the 4/20mA loop. See section 6.6

'bAr'

Bargraph format and calibration Only BA327E & BA328E have bargraph The bargraph may be conditioned to start from left, right or centre of the display, or it may be disabled. When optional alarms are fitted it can also display both alarm setpoints and the measured value. The bargraph may be calibrated to start and finish at any value within the indicator’s calibrated digital display. See section 6.7

Throughout this manual push-buttons are shown as P, E, ▼ or ▲, and legends displayed by the indicator are shown within inverted commas e.g. 'CAL' and ' ALr2'. Access to the configuration menu is obtained by operating the P and E push-buttons simultaneously. If the indicator security code is set to the default 0000 the first parameter 'FunC' will be displayed. If a security code other than the default code 0000 has already been entered, the indicator will display 'CodE'. Pressing the P button will clear this prompt allowing each digit of the code to be entered using the ▲ and ▼ pushbuttons and the P button to move control to the next digit. When the correct four digit code has been entered pressing E will cause the first parameter 'FunC' to be displayed. If the code is incorrect, or a button is not pressed within twenty seconds, the indicator will automatically return to the display mode. Once within the configuration menu the required parameter can be reached by scrolling through the menu using the ▲ and ▼ push-buttons as shown in Fig 6. When returning to the display mode following recalibration or a change to any function, the indicator will display ‘dAtA’ followed by ‘SAVE’ while the new information is stored in non-volatile memory. All new indicators are supplied calibrated as requested at the time of ordering. If calibration is not requested, indicators will be configured as follows: BA307E BA327E BA308E BA328E

Access code ‘CodE’ 0000 Function ‘FunC’ Std Display at 4mA ‘Zero’ 0.0 Display at 20mA ‘SPAn’ 100.0 Resolution ‘rESn’ 1 digit Bargraph start ‘BarLo’ ----Bargraph finish ‘BarHi’ ----P button in display mode ‘C—P’ % Tare ‘tArE’ Off

0000 Std 0.00 100.00 1 digit 0.00 100.00 % Off

Default configuration can easily be changed onsite.

10

11 Display

Summary of function

'C - - P' Function of P push-button The indicator may be configured to display the input current in milliamps, or the input current as a percentage of the 4/20mA input when the P push-button is operated in the display mode. See section 6.8

6.2 Indicator function: ‘FunC’ This configuration function defines the relationship between the indicator’s 4/20mA input current and the indicator’s display. Three alternatives are available: ‘Std’ Standard linear relationship ‘root’ Square root extraction ‘Lin’ 16 segment adjustable lineariser.

'tArE'

Tare function When enabled the tare function sets the indicator display to zero when the E push-button is operated in the display mode. See section 6.9

To reveal the existing indicator function select 'FunC' from the configuration menu and press P. If the function is set as required, press E to return to the menu, or press the ▲ or ▼ button to change the setting, followed by the E button to return to the configuration menu.

'CodE'

Security code Defines a four digit numeric code that must be entered to gain access to the configuration menu. Default code 0000 disables this security function and allows unrestricted access to all conditioning functions. See section 6.10

‘Std’

'rSEt'

Linear Provides a linear relationship between the 4/20mA indicator input current and the indicator display.

‘root’ Square root extraction Primarily intended to linearise the square law 4/20mA output from differential flowmeters.

Reset Contains two sub-functions, ‘ConF’ which returns the indicator to the default conditions and ‘LtAb’ which returns the lineariser to the default conditions. To prevent accidental use both resets must be confirmed by entering ‘5urE’ before they will be executed. See section 6.11

For reference, the following table shows the output current from a non-linearised differential flowmeter. % of full flow Current output mA 2.5 4.01 10.0 4.16 25.0 5.00 50.0 8.00 75.0 13.00 100.0 20.00 When the root function is selected the indicator will display flow in linear units. ‘Lin’

16 segment adjustable lineariser Enables non linear variables to be displayed by the indicator in linear engineering units. Use of the lineariser is described in section 7 of this instruction manual.

6.3 Resolution: rESn This function defines the resolution of the least significant display digit. Decreasing the display resolution can improve the readability of a noisy signal. Select ''rESn' from the menu and press P which will reveal the current display resolution. To change the resolution press the ▲ or ▼ button to select 1, 2, 5 or 10 digits, followed by the E button to enter the selection and return to the configuration menu.

12 6.4 Position of the decimal point: ‘dP’ A dummy decimal point can be positioned between any of the digits or it may be absent. To position the decimal point select 'dP' from the menu and press P. The decimal point can be moved by pressing the ▲ or ▼ push-button. If a decimal point is not required it should be positioned beyond the most or least significant digit. When positioned as required press the E button to enter the selection and return to the configuration menu. 6.5 Calibration using an external current source: ‘CAL’ This function enables the zero and span of the indicator to be adjusted using an external calibrated current source. When used with an accurate traceable current source this is the preferred method of calibration. Zero is the indicator display with 4mA input Span is the indicator display with 20mA input To calibrate the indicator select 'CAL' from the configuration menu and press P. The indicator will display 'ZEro' which is a request for a 4mA input current. Adjust the external current calibrator to 4.000mA and again press P which will reveal the current zero display. The flashing digit of the indicator display can be changed by pressing the ▲ or ▼ buttons, when set as required pressing P will transfer control to the next digit. When all the digits have been adjusted, press E to enter the new zero and return to the 'ZEro' prompt . Pressing the ▲ button will cause the indicator to display 'SPAn' which is a request for a 20mA input current. Adjust the external current calibrator to 20.000mA and again press P which will reveal the existing span display. The flashing digit of the indicator display can be changed by pressing the ▲ or ▼ buttons, when set s required pressing P will transfer control to the next digit. When all the digits have been adjusted press E to enter the new span and return to the 'SPAn' prompt. Finally press E again to return to the configuration menu. Notes: a. The indicator input current must be adjusted to the required value before the zero and span functions are entered by pressing the P button. b. Indicators may be calibrated at currents other than 4 and 20mA, withiin the range 3.8 to 21.0mA providing the difference between the two currents is greater than 4mA. If these conditions are not complied with, the indicator displays ‘FaiL’ and aborts the calibration. c.

If the zero current is greater than the span current the instrument will be reverse acting i.e. an increasing input current will cause the display to decrease.

6.6 Calibration using internal reference: ‘SEt’ Using the ‘SEt’ function the indicator can be calibrated without the need for an accurate external current source and without the need to disconnect the indicator from the 4/20mA measuring loop. The indicator’s internal reference is used to simulate a 4mA and 20mA input current, so the actual indicator input input current does not have to be known during calibration. Zero is the display with a simulated 4mA input Span is the idisplay with a simulated 20mA input To calibrate the indicator display select 'SEt' from the configuration menu and press P. The indicator will display 'ZEro', pressing P again will reveal the current display at 4mA. The flashing digit can be adjusted by pressing the ▲ or ▼ buttons, when the flashing digit is correct pressing P will transfer control to the next digit. When all the digits have been adjusted, press E to return to the 'ZEro' prompt. To adjust the display at 20mA, press the ▲ button which will cause the indicator to display 'SPAn', pressing P will then reveal the indicator’s exisitng display at 20mA. The flashing digit can be adjusted by pressing the ▲ or ▼ buttons, when the flashing digit is correct pressing P will transfer control to the next digit. When all the digits have been adjusted press E to return to the 'SPAn' prompt followed by E to return to the ‘SEt’ prompt in the configuration menu. 6.7 Bargraph format and calibration: ‘bAr’ Only BA327E & BA328E have a bargraph In addition to a five digit numerical display the two BA327E and BA328E indicators have a 31 segment analogue bargraph which may be configured to start and finish anywhere within the indicators numerical display range. To configure the bargraph select 'bAr' from the configuration menu and press P. The indicator will display 'tYPE', pressing P again will reveal the existing bargraph justification which can be changed to one of the following four or five options using the ▲ or ▼ button: Bargraph starts from

‘LEFt’ ‘CEntr’ ‘riGHT’ ‘AlrSP’ ‘oFF’

Left end of display Centre of display Right end of display Only with alarms – see section 9.3.14 Bargraph disabled

When set as required press E to return to the ‘tYPE’ sub-function prompt.

13 The indicator’s digital display at which the bargraph starts is defined by the ‘bArLo’ subfunction which is selected by pressing the ▲ button followed by the P button which will reveal the current indicator display at which the bargraph starts. The flashing digit can be adjusted by pressing the ▲ or ▼ buttons, when set as required pressing P will transfer control to the next digit. When all the digits have been adjusted, press E to return to the 'bArLo' prompt from which ‘bArHi’ which defines the finishing point of the bargraph can be selected by pressing the ▲ button. ‘bArHi’ is adjusted in the same way as ‘bArLo’. When set as required, pressing E twice will return the display to the ‘bAr’ prompt in the configuration menu. Note: ‘bArLo’ must be set lower than ‘bArHi’, incorrect setting is indicated by the bargraph scale flashing with a single bargraph segment activated. 6.8 Function of the P push-button: ‘C - - P’ When the indicator is in the display mode, operating the P push-button will display the input current in milliamps, or the displayed value as a percentage of the difference between the displayed values at 4mA and 20mA inputs. To check or change the function of the P pushbutton select 'C - -P' from the configuration menu and press P to reveal the current setting. Pressing the ▲ or ▼ button will toggle the setting between '4-20' the current display in milliamps and 'PC' the percentage display. When set as required press E to return to the ‘C - - P’ prompt in the configuration menu. 6.9 Tare function: ‘tArE’ The tare function is primarily intended for use with weighing system. When the indicator is in the display mode and the tare function is activated, pressing the E button for more than three seconds will zero the indicator’s digital display and activate the tare annunciator. On models with a bargraph, the bargraph remains linked to the digital display when the tare function is activated. Subsequent operation of the E push-button for less than 3 seconds will return the indicator to the gross display and deactivate the tare annunciator. To check or change the tare function select 'tARE' from the configuration menu and press P to reveal the current setting. Pressing the ▲ or ▼ button will toggle the setting between 'on' and 'oFF'. When set as required press E to return to the ‘tARE’ prompt in the configuration menu. 6.10 Security code: ‘CodE’ Access to the instrument configuration menu may be protected by a four digit security code which must be entered to gain access. New instruments

are configured with the default security code 0000 which allows unrestricted access to all configuration functions. To enter a new security code select 'CodE' from the configuration menu and press P which will cause the indicator to display the existing security code with one digit flashing. The flashing digit can be adjusted using the ▲ and ▼ push-buttons, when set as required operating the P button will transfer control to the next digit. When all the digits have been adjusted press E to return to the ‘CodE’ prompt. The revised security code will be activated when the indicator is returned to the display mode. Please contact BEKA associates sales department if the security code is lost. 6.11 Reset to factory defaults: ‘rSEt’ This function enables the indicator and the lineariser to be quickly returned to the factory default configurations shown in sections 6 and 7. To reset the indicator or lineariser select ‘rSEt’ from the configuration menu and press P, the indicator will display one of the reset options ‘ConF’ or ‘LtAb’. ‘ConF’ ‘LtAb’

Resets the indicator to defaults Resets the lineariser to defaults

Using the ▲ or ▼ push-button select the required sub-function and press P. To prevent accidental resetting the request must be confirmed by entering ‘5urE’. Using the ▲ button set the first flashing digit to ‘5’ and press P to transfer control to the second digit which should be set to ‘u’. When ‘5urE’ has been entered pressing the E button will reset the selected configuration menus and return the display to the ‘rSEt’ function in the configuration menu. 6.12 Under and over-range If the numerical display range of the indicator is exceeded, all the decimal points will flash as shown below: Underrange Overrange

BA307E BA308E -9.9.9.9 9.9.9.9

BA327E BA328E -9.9.9.9.9 9.9.9.9.9

Although not guaranteed, most indicators will continue to function normally with an input current between 1.8mA and 4mA, at lower currents the instrument will display ‘LPLo’ before it stops functioning. Under or overrange of the BA327E and BA328E bargraph is indicated by an activated arrow at the appropriate end of the bargraph and a flashing bargraph scale.

14 7. LINEARISER A sixteen segment, seventeen breakpoint (0 to 16) lineariser may be selected in the ‘FunC’ section of the configuration menu. The starting point and slope of each straight line segment are fully adjustable allowing the indicator to display most non-linear process variables in linear engineering units. Each break-points must occur at a current greater than the preceeding break-point and less than the following break-point, in the range 3.8 to 21.0mA Fig 8 shows a typical linearised indicator characteristic.

level sensor in an irregular tank may be displayed in linear volumetric units by filling the tank with known incremental volumes and calibrating the indicator to display the sum of the increments at each break-point. The number of break-points required should first be entered using the 'Add' and 'dEL' functions. In both these sub-functions the indicator initially displays the current break-points and the total number of break-points being used as shown below.

Display

Fig 8 shows a typical linearising characteristic Selecting ‘Lin’ in the ‘FunC’ section of the configuration menu activates the lineariser, this does not change the configuration menu shown in Fig 7, but the 'CAL' and 'SEt' functions are extended as shown in Fig 9. As with a linear indicator, calibration may be performed with an external current source using the 'CAL' function, or with the internal reference using the 'SEt' function.

Description of function

'Add'

Add a break-point Adds a new break-point before the displayed break-point. The calibration of existing break-points is not changed, but the identification number of all subsequent break-points is increased by one.

'dEL'

Remove a break-point Removes the displayed break-point and joins the preceding break-point to the following break-point with a straight line. The identification number of all subsequent break-points is decreased by one.

The lineariser configuration is retained irrespective of how the the indicator function ‘FunC’ is subsequently changed. It is therefore possible to select and deselect the lineariser without having to reconfigure it each time.

To add a break-point using the ▲ or ▼ button select 'CAL' from the configuration menu and press P which will result in the 'Add' sub-function prompt being displayed. To enter the sub-function press P which will reveal the current break-point and the total number of break-point which have already been entered. Each subsequent operation of the P push-button will introduce an additional breakpoint up to the maximum of 17. When adding a break-point to a calibrated indicator, the insertion position for the new break-point can be selected using the ▲ and ▼ push-buttons.

7.1 Lineariser calibration using an external current source. This method allows direct calibration of the lineariser with an exteral current source and is the preferred method when traceability is required. If the exact system non-linearity is unknown, this method also allows direct calibration from the variable to be displayed. e.g. the output from a

The delete break-point sub-function 'dEL' operates in exactly the same way as the 'Add' sub-function described above. Once within the ‘dEL’ subfunction each time the P button is pressed a breakpoint is removed. When deleting a break-point from a calibrated indicator, the break-point to be deleted can be selected using the ▲ and ▼ pushbuttons. The minimum number of breakpoints is 2, break-points 0 and 1.

15

16 When the required number of break-points have been entered, return to the linearisation sub-menu by pressing E. The indicator will display the 'Add' or 'dEL' prompt depending upon the last function used. Now that the number of break-points has been entered, the input current at which each occurs and the corresponding indicator display can be defined by the ‘Pts’ sub-function. Using the ▲ or ▼ button select 'PtS' from the submenu and press P which will select the first breakpoint '0 : n', where n is the total number of breakpoints entered. The selected break-point can be changed using the ▲ and ▼ buttons. When the required break-point has been selected, set the indicator input current to the exact value at which the break-point is required and press P. Then using the ▲ and ▼ buttons and the P button to move between digits, enter the required indicator display at this break-point. When set as required, press the E push-button to enter the required indicator display at this breakpoint and return to the sub-menu from which the next beak-point can be selected.

'dEL'

Remove a break-point Removes the displayed break-point and joins the preceding break-point to the following break-point with a straight line. The identification number of all subsequent break-points is decreased by one.

'in'

Defines the current at which breakpoint occurs Enables the required current at each break-point to be defined without having to input an accurate input current to the indicator.

'diSP'

Defines indicator display at breakpoint Enables the indicator display at each break-point to be defined.

The number of break-points required should first be entered using the 'Add' and 'dEL' subfunctions. In both these sub-functions the indicator initially displays the current break-point and the total number of break-point being used as shown below.

When all the break-points have been calibrated pressing E twice will return the indicator to the ‘CAL’ function in the configuration menu. Note: The indicator input current must be adjusted to the required value before the P button is operated to enter the required indicator display. 7.2 Lineariser calibration using the internal reference. The ‘SEt’ function enables the lineariser to be calibrated without the need for an accurate external current source. Throughout the calibration the indicator input current may be any value between 4 and 20mA. The ‘SEt’ functions contains four sub-functions. Display 'Add'

Description of function Add a break-point Adds a new break-point before the displayed break-point. The calibration of existing break-points is not changed, but the identification number of all subsequent break-points is increased by one.

To add a break-point, using the ▲ or ▼ button select 'SEt' from the configuration menu and press P which will result in the 'Add' sub-function prompt being displayed. To enter the sub-function press P which will reveal the current break-point and the total number of break-points which have already been entered. Each subsequent operation of the P push-button will introduce an additional breakpoint up to the maximum of 17. When adding a break-point to a calibrated indicator, the insertion position for the new break-point can be selected using the ▲ and ▼ push-buttons. The delete segment sub-function 'dEL' operates in exactly the same way as the 'Add' sub-function described above. Once within the ‘dEL’ function each time the P button is pressed a break-point is removed. When deleting a break-point from a calibrated indicator, the break-point to be deleted can be selected using the ▲ and ▼ push-buttons. The minimum number of break-points is 2, breakpoints 0 and 1.

17 When the required number of break-points has been entered, return to the linearisation sub-menu by pressing E. The indicator will display the 'Add' or 'dEL' prompt depending upon the last subfunction used. The indicator input current and corresponding indicator display at each breakpoint, can now be entered using the ‘in’ and ‘diSP’ sub-functions. Using the ▲ or ▼ button select 'in' from the submenu and press P which will reveal the first breakpoint '0 : n', where n is the total number of breakpoints entered. Press P and use the ▲ and ▼ buttons and the P button to move between digits, to enter the input current at which the first breakpoint is required, usually 4.000mA. When set as required, press E to return to the ‘0 : n’ prompt from which the the next break-point can be selected using the ▲ and ▼ buttons. When the required break-point has been selected press P and enter the indicator input current at which this break-point is required. Repeat this procedure until the indicator input current at all the break-points has been defined and then return to the ‘in’ subfunction by pressing the E button. The corresponding indicator display at each of the break-points can now be defined with the ‘diSP’ sub-function Using the ▲ and ▼ buttons select the ‘diSP’ sub-function and press P which will reveal the first break-point '0 : n', where n is the total number of break-points entered. Press P and use the ▲ and ▼ buttons and the P button to move between digits, to enter the required indicator display at this first break-point. When set as required, press E to return to the ‘0 : n’ prompt from which the the next break-point can be selected using the ▲ or ▼ buttons. When the required break-point has been selected press P and set the required indicator display at this break-point. Repeat this procedure until the indicator display at all the break-points has been defined and then return to the ‘SEt’ function in the configuration menu by pressing the E button twice. 7.3 Lineariser error message If an attempt is made to position a break-point at a current which is not greater than the current of the preceeding break-point, or at a current which is not less than the current of the following break-point, the error message ‘FaiL’ will be displayed. This error message will also be displayed if an attempt is made to position a break-point outside the current range 3.8 to 21.0mA.

7.4 Under and over-range The lineariser does not change the under and over-range indication described in section 6.12. At input currents below that specified for the first break-point (0), the indicator will continue to use the specified slope of the first segment. Although not guaranteed, most indicators will continue to function normally with an input current between 1.8mA and 4mA, at lower currents the instrument will display ‘LPLo’ before it stops functioning. At input currents above that specified for the last break-point, the indicator will continue to use the slope specified for the last lineariser segment. 7.5 Lineariser default configuration When the lineariser is reset to the default conditions using the ‘rSEt’ reset function described in section 6.11, the defaults conditions are: BA307E BA327E BA308E BA328E

First break-point 4mA Second break-point 20mA

0.0 100.0

0.00 100.00

18 8. MAINTENANCE 8.1 Fault finding during commissioning If an indicator fails to function during commissioning the following procedure should be followed: Symptom No display

Cause Incorrect wiring

Solution Check wiring There should be 0.6 to 1.2V between terminals 1 & 3 with terminal 1 positive.

No display 0V between terminals 1 & 3.

Incorrect wiring or no power supply

All decimal points flashing.

Underrange if –ve sign displayed or overrange. 4/20mA input is noisy.

Unstable display

Unable to enter configuration menu.

Incorrect security code entered.

8.3 Servicing All BA307E, BA327E, BA308E and BA328E loop powered indicators are interchangeable if the required optional backlight and alarms are fitted. A single spare instrument may quickly be recalibrated to replace any instrument that is damaged or fails. No attempt should be made to repair instruments at component level.

With an optional loop powered backlight, there should be 3.4 to 5V between terminals 1 & 13 with terminal 1 positive. Check supply voltage and voltage drop caused by all the instruments in the loop. Recalibrate the numerical display. Eliminate ripple on 4/20mA power supply and/or decrease indicator resolution. Enter correct security code, or contact BEKA if the code has been lost.

8.2 Fault finding after commissioning ENSURE PLANT SAFETY BEFORE STARTING MAINTENANCE Live maintenance is permitted intrinsically safe equipment installed hazardous area, but only certified equipment should be used unless a clearance certificate is available.

on in a test gas

If an indicator fails after it has been functioning correctly follow the procedure shown in section 8.1. If this does not reveal the cause of the fault, it is recommended that the instrument is replaced. This can be done without disconnecting power, but while the indicator is disconnected the 4/20mA loop will be open circuit.

We recommend that faulty instruments are returned to BEKA associates or to your local BEKA agent for repair. 8.4 Routine maintenance The mechanical condition of the instrument and electrical calibration should be regularly checked. The interval between inspections depends upon environmental conditions. We recommend that initially instrument calibration should be checked annually. 8.5 Guarantee Indicators which fail within the guarantee period should be returned to BEKA associates or our local agent. It is helpful if a brief description of the fault symptoms is provided. 8.6 Customer comments BEKA associates is always pleased to receive comments from customers about our products and services. All communications are acknowledged and whenever possible, suggestions are implemented.

19 9. ACCESSORIES 9.1 Scale card All models have a window on the right hand side of the display through which to view a scale card showing the units of measurement such as oC, mBar, RPM. New indicators are fitted with a scale card showing the units of measurement specified when the indicator was ordered, if the units are not specified a blank scale card will be fitted. A pack of scale cards pre-printed with common units of measurement is available as an accessory. These can easily be fitted on-site to the indicator without opening the indicator enclosure or removing it from the panel, See section 5.3 of this instruction manual. Custom scale cards for applications requiring less common units of measurement are also available. 9.2 Tag information New indicators are supplied with tag or application information thermally printed onto the rear panel adjacent to the terminals, legend as specified when the indicator was ordered. This tag information is not visible from the front of the instrument after installation. 9.3 Alarms CAUTION These alarms outputs should not be used for critical safety applications such as an emergency shut down system.

All models can be supplied with factory fitted dual solid state, single pole alarm outputs. Each alarm output may be independently conditioned as a high or low alarm with a normally open or normally closed output in the non-alarm condition. When the 4/20mA current powering the indicator is removed both alarm outputs will open irrespective of configuration. The open circuit condition should therefore be chosen as the alarm condition when designing an alarm system. Fig 10 illustrates the conditions available and shows which are fail safe. When an alarm occurs an alarm annunciator on the indicator front panel is activated and if required the numerical display can alternate between the measured value and the alarm channel identification ‘ALr1’ or ‘ALr2’. CAUTION The alarms are activated by the indicator’s numerical display. Use of the Tare Function ‘tArE’ will change the numerical display, the alarms will continue to function at the original displayed value, but this will correspond to a different input current.

Fig 10 Alarm outputs Configurable functions for each alarm include adjustable setpoint, hysteresis, alarm delay and alarm accept. 9.3.1 Solid state output Each alarm has a galvanically isolated single pole solid state switch output which as shown in Fig 11. The output is polarised and current will only flow in one direction. Ron Roff

= =

less than 5Ω + 0.7V greater than 1MΩ

Fig 11 Equivalent circuit of each alarm output 9.3.2 Intrinsic safety Each alarm output is a separate galvanically isolated intrinsically safe circuit with output safety parameters complying with the requirements for simple apparatus. This allows the alarm output terminals 8 & 9 and 10 & 11 to be connected to almost any intrinsically safe circuit protected by a Zener barrier or galvanic isolator providing the output parameters of the circuit do not exceed: Uo = Io = Po =

30V dc 200mA 0.84W

20

21 The maximum equivalent capacitance and inductance between each set of alarm terminals is:

Summary of alarm configuration functions Display

Ci Li

= =

13nF 8µH (Effectively 0)

To determine the maximum permissible cable parameters Ci should be subtracted from the maximum permitted cable capacitance specified by the certificate powering the alarm circuit, such as the solenoid driver and switch transfer galvanic isolators shown in Fig 13.

Fig 13 Typical alarm application (Shown without recommended screen cables)

9.3.3 Configuration and adjustment When optional alarms are fitted to a loop powered indicator the configuration menu is extended as shown in Fig 12. The additional functions appear between the ‘SEt’ and the ‘C- - P’ functions for the BA307E and BA308E indicators, and between ‘bAr’ and ‘C- -P’ for the BA327E and BA328E indicators. For simplicity, Fig 12 only shows the additional functions for alarm 1, but alarm 2 has identical functions. The following table summaries each of the configuration functions and includes a reference to more detailed information. only the functions on alarm 1 are listed, but 2 has identical facilities

alarm cross Again alarm

Description of function

'EnbL’

Alarm enable Enables or disables the alarm without changing the alarm parameters. See section 9.3.4

'SP1'

Alarm setpoint 1 Adjusts the alarm setpoint. The alarm is activated when the indicator display equals the setpoint. See section 9.3.5

'Hi.Lo'

Alarm function Defines the alarm function as High or Low. See section 9.3.6

'no.nC'

Normally open or normally closed output Sets the alarm output open or closed in the non-alarm condition. See section 9.3.7

'HStr'

Hysteresis Adjusts the alarm hysteresis. See section 9.3.8

'dELA'

Alarm delay time Introduces adjustable delay between the display equalling the setpoint and the alarm output being activated. See section 9.3.9

'SiL'

Alarm silence time Defines the time that the alarm output remains in the non-alarm condition following acceptance of an alarm. See section 9.3.10

‘FLSH’

Flash display when alarm occurs When enabled, alternates the numerical display between process value and alarm reference, ‘ALr1’ or ‘ALr2’, when an alarm output is activated. See section 9.3.11

'ACSP'

Access setpoint Sub-menu which enables direct access to the alarm setpoints from the indicator display mode, and defines a separate security code. See section 9.3.12

22 9.3.4 Alarm enable: ‘EnbL’ This function allows each alarm to be enabled or disabled without altering any of the alarm parameters. To enable or disable the alarm select 'EnbL' from the alarm menu and press P which will reveal the current setting ‘on’ or ‘oFF’. The function can be changed by pressing the ▲ or ▼ button followed by the E button to return to the alarm menu. 9.3.5 Setpoint adjustment: ‘SP1’ and ‘SP2’ The setpoint of each alarm may be positioned anywhere in the numerical display of the indicator providing that this corresponds to an input current between 3.8 and 20.2mA. e.g. If the indicator has been calibrated to display 0 with 4mA input and 10000 with 20mA input, the two alarm setpoints may be positioned anywhere between -125 and 10125. To adjust the setpoint select 'SP1' or 'SP2' from the alarm configuration menu and press P which will reveal the existing alarm setpoint. The flashing digit of the setpoint can be adjusted using the ▲ and ▼ push-buttons, and the P button to move control to the next digit. When the required setpoint has been entered press E to return to the alarm configuration menu. The alarm setpoints may also be adjusted when the indicator is in the display mode, see section 9.3.12. 9.3.6 Alarm function: ‘Hi.Lo’ Each alarm can be independently conditioned as a high alarm or as a low alarm. To check or change the alarm function select 'Hi.Lo' from the alarm menu and press P to reveal the current setting. The function can be changed by pressing the ▲ or ▼ button followed by the E button to return to the alarm menu. 9.3.7 Alarm output status: ‘no.nC’ Configures the solid state alarm output to be open ‘no’ or to be closed ‘nC’ in the non-alarm condition. When deciding which is required, care should be taken to ensure that the alarm output is fail safe as illustrated in Fig 10. ‘no’ Alarm output open in non-alarm condition ‘nC’ Alarm output closed in non-alarm condition CAUTION When the 4/20mA supply is removed from the loop powered indicator, both alarm outputs will open irrespective of conditioning. Therefore for fail safe operation both alarm outputs should be conditioned to be open in the alarm condition ‘nC’.

To check or change the alarm output status, select 'no.nC' from the alarm configuration menu and press P to reveal the setting. The function may be changed by pressing the ▲ or ▼ button followed by the E button to return to the alarm configuration menu. 9.3.8 Hysteresis: HStr Hysteresis is shown in the units that the indicator has been calibrated to display. To adjust the hysteresis select 'HStr' from the alarm menu and press P which will reveal the existing figure. The flashing digit can be adjusted using the ▲ and ▼ push-buttons, and the P button will move control to the next digit. When the required hystersis has been entered press E to return to the alarm configuration menu. e.g. An indicator calibrated to display 0 to 10000, with a high alarm set at 9000 and hysteresis of 200 will perform as follows: The high alarm will be activated when increasing indicator display equals 9000, but will not reset until the indicator display falls below 8800. 9.3.9 Alarm delay: dELA This function delays activation of the alarm output for an adjustable time following the alarm condition occurring. The delay can be set in 1 second increments between 0 and 3600 seconds. If a delay is not required zero should be entered. To adjust the delay select 'dELA' from the alarm configuration menu and press P which will reveal the existing delay. The flashing digit of the delay can be adjusted using the ▲ and ▼ push-buttons, and the P button to move control to the other digits. When the required delay has been entered press E to return to the alarm menu. e.g. An indicator with a high alarm set at 9000 and an alarm delay of 30 seconds will perform as follows: The alarm annunciator will start to flash when an increasing indicator display equals 9000, but the alarm output will not be activated until the alarm condition has existed continuously for 30 seconds. When the alarm output is activated, the alarm annunciator will stop flashing and become permanently activated. If the ‘FLSH’ function, which flashes the indicator display when an alarm occurs, has been enabled, it will not start to function until the alarm output is activated. See section 9.3.11

23 9.3.10 Alarm silence time: SiL This function is primarily intended for use in small installations where the alarm output directly operates an alarm annunciator such as a sounder or beacon. When the alarm silence time, which is adjustable between 0 and 3600 seconds in 1 second increments, is set to any figure other than zero, the P push-button becomes an alarm accept button. After an alarm has occurred, operating the P button will cause the alarm output to revert to the non-alarm condition for the programmed alarm silence time. If the alarm condition still exists at the end of the silence time, the alarm output will be reactivated. During the silence time the indicator alarm annunciator will flash until the silence time expires or the alarm is cleared. If the ‘FLSH’ function, which flashes the indicator display when an alarm occurs has been enabled, it will only function when the alarm output is activated, not during the silence time. See section 9.3.11

indicator is in the display mode is provided by a separate security code. This direct setpoint access menu is enabled and the separate security code entered from the 'ACSP' function in the alarm configuration menu as shown in Fig 12. To change the menu parameters select 'ACSP' from the configuration menu and press P which will display the enable prompt 'EnbL'. Press P again to reveal if the direct access menu is 'on' or 'oFF'. The ▲ or ▼ button will toggle the display between the two conditions. If 'oFF' is selected, the operator will not have access to the setpoints from the display mode. Return to the 'ACSP' prompt in the main menu by pressing E twice.

To adjust the alarm silence time select 'SiL' from the alarm configuration menu and press P which will reveal the existing silence time. The flashing digit of the silence time can be adjusted using the ▲ and ▼ push-buttons, and the P button to move control to the other digits. When the required silence time has been entered press E to return to the alarm menu.

If 'on' is selected, the operator will have direct access to the alarm setpoints from the display mode via a separate optional security code. To define this four digit security code press P to return to the 'Enbl' prompt followed by the ▲ or ▼ button to select the access code prompt 'ACCd'. Pressing P will reveal the current security code. Each digit of the code may be changed by operating the ▲ and ▼ push-buttons, and the P button to move control to the next digit. When the required code has been entered, press E twice to return to the 'ACSP' prompt in the configuration menu.

9.3.11 Flash display when alarm occurs ‘FLSH’ In addition to the two alarm annunciators on the top left hand corner of the indicator display which show the status of both alarms, this function provides an even more conspicuous indication that an alarm condition has occurred.

Default code 0000 will disable the security code allowing direct access to the setpoints in the display mode by pressing the P and ▲ buttons simultaneously. Unless otherwise requested new instruments with alarms are supplied with this function disabled and the security code set to 0000.

When enabled, the function alternates the indicator display between the numerical value and the alarm reference, ‘ALr1’ or ‘ALr2’, when the alarm output is activated. If both alarm outputs are activated, the alarm references are displayed in sequence. To enable or disable the function select 'FLSH' from the alarm menu and press P which will reveal the current setting ‘on’ or ‘oFF’. The function can changed by pressing the ▲ or ▼ button followed by the E button to return to the alarm menu. 9.3.12 Access setpoint in display mode: ACSP This function enables a separate menu providing access to the alarm setpoints from the display mode by simultaneously operating the P and ▲ push-buttons. An operator can therefore adjust the alarm setpoints without having access to the indicator configuration menu. Protection against accidental adjustment of the setpoints when the

9.3.13 Adjusting alarm setpoints from the display mode Access to the alarm setpoints from the indicator display mode is obtained by operating the P and ▲ push-buttons simultaneously as shown in Fig 14. If the setpoints are not protected by a security code the alarm setpoint prompt 'SP1' will be displayed. If the setpoints are protected by a security code, 'Code' will be displayed first. Pressing P again will enable the alarm security code to be entered digit by digit using the ▲ and ▼ buttons to change the flashing digit, and the P push-button to move control to the next digit. If the correct code is entered pressing E will cause alarm setpoint prompt 'SP1' to be displayed. Pressing the ▲ or ▼ button will toggle the display between the two alarm setpoint prompts 'SP1' and 'SP2'. If an incorrect security code is entered, or a button is not pressed within twenty seconds, the indicator will automatically return to the display mode.

24 9.3.14 Displaying setpoints on bargraph One of the selectable bargraph formats ‘AlrSP’ allows a low or a high setpoint plus the displayed value to be represented, or a low and a high setpoint plus the displayed value to be represented by the bargraph as shown in Fig 15.

Fig 15 Displayed value and setpoints on bargraph The bargraph area below the low alarm setpoint and the area above the high alarm setpoint are activated. The displayed variable is represented by an activated bar which moves between these low and high alarm setpoints.

Fig 14 Setpoint adjustment from the display mode To adjust an alarm setpoint select 'SP1' or 'SP2' and press P which will reveal the current setting. Each digit of the setpoint may be adjusted using the ▲ and ▼ push-buttons, and the P button to move control to the next digit. When the required setpoint has been entered, pressing E will return the display to the 'SP1' or 'SP2' prompt from which the other setpoint may be selected, or the indicator may be returned to the display mode by pressing E again. Note: With the indicator in the display mode, direct access to the alarm setpoints is only available when the ACSP menu is enabled - see section 9.3.12

When the activated bar representing the displayed variable is adjacent to the area representing the low or high ararm setpoints, the bar flashes. When a displayed variable equals the low or high alarm the complete bargraph representing the activated alarm flashes irrespective of whether the alarm output has been delayed or cleared. For this function to operate SP1 must be conditioned as a low alarm and SP2 as a high alarm; SP1 must always be less than SP2. Incorrect configuration is shown by a flashing bargraph scale with no activated bars.

25 9.4 Display backlight The BA307E, BA327E, BA308E and BA328E loop powered indicators can be supplied with a factory fitted backlight that may be loop or separately powered.

9.4.2 Separately powering the backlight The optional backlight may also be powered from a separate safe area power supply via an intrinsically safe interface as shown in Fig 18.

When loop powered the backlight produces green background illumination enabling the display to be read at night or in poor lighting conditions. No additional power supply, intrinsic safety interface or field wiring are required, but the indicator voltage drop is increased. When separately powered the backlight is brighter, but an additional intrinsic safety interface and field wiring are required.

Fig 16 Terminals for optional backlight 9.4.1 Loop powering the backlight The backlight is loop powered by connecting it in series with the indicator 4/20mA input as shown in Fig 17, which increases the maximum indicator voltage drop from 1.2 to 5V.

Fig 18 Separately powered backlight When separately powered the backlight draws a constant current when supply is equal to or greater the minimum specified voltage. Below this supply voltage the backlight continues to function but with reduced brilliance. Current 22.5mA 34.7mA

BA307E & BA327E BA308E & BA328E

Minimum voltage 9.0V 11.0V

Any certified Zener barrier or galvanic isolator may be used, providing the output parameters do not exceed: Uo = 30V dc Io = 200mA Po = 0.84W

Fig 17 Loop powered backlight The input intrinsic safety parameters of the combined indicator and backlight are the same as for the indicator alone. The EC-Type Examination Certificate states that for intrinsic safety considerations, under fault conditions the output voltage, current and power of the combined indicator and backlight terminals 1 & 13 will not exceed those specified by clause 5.7 of EN 6007911 for simple apparatus, which simplifies system design and documentation. Providing the increased voltage drop can be tolerated, the intrinsic safety and system design described in sections 3 and 4 of this manual remain valid with the loop powered backlight.

The internal capacitance Ci between terminals 12 & 14 should be subtracted from Co of the intrinsically safe interface powering the backlight to determine the maximum permissible cable capacitance. Ci Li

= =

13nF 8µH (Effectively 0)

Two separately powered BA307E or BA327E indicator backlights may be connected in parallel to a single channel 28V, 93mA Zener barrier or galvanic isolator with no noticeable reduction in brilliance on a 24V dc supply.

26 Having a Minimum Ignition Temperature of:

Appendix 1 Dust certification A1.0 ATEX dust certification In addition to ATEX certification permitting installation in explosive gas atmospheres which is described in the main section of this instruction manual, all BA307E, BA327E, BA308E and BA328E indicators have ATEX certification permitting installation in combustible dust atmospheres. This appendix describes ATEX installations in explosive dust atmospheres conforming with EN 60079-14 Electrical installations design, selection and erection. When designing systems for installation outside the UK the local Code of Practice should be consulted. The indicator’s dust input and output safety parameters are identical to gas parameters, so all the electrical circuits shown in the main section of this manual may also be used for dust applications. A1.1

Zones, and Maximum Surface Temperature The BA307E, BA327E, BA308E and the BA328E have been ATEX certified as Group II, Category 1D Ex ia IIIC T80ºC Da IP20 apparatus, Ta -40 to 70°C. When connected to a suitable indicators may be installed in:

system

the

Zone 20

explosive atmosphere in the form of a cloud of combustible dust in air is continuously present, or for long periods or frequently.

Zone 21

explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur occasionally in normal operation.

Zone 22

explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation, but if it does occur, will only persist for a short period.

Be used with dust in subdivisions: IIIA

combustible flyings

IIIB

non-conductive dust

IIIC

conductive dust (For use with IIIC conductive dusts special conditions for safe use apply – see section A1.4)

Dust cloud

120°C

Dust layer on indicator up to 5mm thick

155°C

Dust layer on indicator over 5mm thick.

Refer to EN 60079-14

At an ambient temperature between -40 and +70°C A1.3 Maintenance ENSURE PLANT SAFETY BEFORE STARTING MAINTENANCE Live maintenance is permitted on intrinsically safe equipment installed in a hazardous area, but only certified test equipment should be used. All models have IP66 front of panel protection and a gasket is provided to seal the joint between the instrument and the mounting panel thus preventing dust ingress from the outside of the mounting panel. The rear of the instruments is not sealed, but ATEX dust certification is dependent on the internal conformal coating of the instrument, so dust ingress is acceptable except for use in IIIC conductive dusts – see A1.4. However, it is good practice to minimise the amount of dust accumulating on the rear of the instrument. A1.4 Special conditions for use in IIIC dusts The ATEX certificate for the loop powered indicators has an ‘X’ suffix indicating that special conditions for safe use are required for installion in IIIC dust atmospheres, the certificate states: ‘For use in Group IIIC conductive gas atmospheres, the indicator shall be mounted such that the instrument terminals have at least IP6X protection.’ To prevent the indicator terminals becoming contaminated by conductive dust: The indicator must be installed in a panel, cubicle or enclosure providing a minimum of IP6X protection. The gasket supplied to seal the joint between the indicator and the mounting panel must be used, and the 144 x 72mm BA308E and BA328E indicators must be secured with four panel mounting clamps. Note: These special installation conditions only apply for indicators exposed to IIIC conductive dust atmospheres.

27 Appendix 2 IECEx certification A2.0 The IECEx Certification Scheme IECEx is a global certification scheme for explosion protected products which aims to harmonise international certification standards. For additional information about the IECEx certification scheme and to view the BEKA associate certificates, please visit www.iecex.com A2.1 IECEx Certificate of Conformity The BA307E, BA327E, BA308E and the BA328E loop powered indicators and the optional accessories have been issued with an IECEx Certificate of Conformity number IECEx ITS 11.0015X which specifies the following certification codes: Ex ia IIC T5 Ga Ex ia IIIC T80ºC Da Ta = -40ºC to 70ºC The specified gas and dust intrinsic safety parameters are identical to the ATEX safety parameters described in this manual. The IECEx certificate may be downloaded from www.beka.co.uk, www.iecex.com or requested from the BEKA sales office. A2.2 Installation The IECEx and ATEX certificates specify identical safety parameters and installation requirements for both approvals as defined by IEC / EN 60079-14. The ATEX gas and dust installation requirements specified in section 5 and Appendix 1 of this manual may therefore be used for IECEx installations, but the local code of practice should also be consulted.

A2.3 Special conditions for use in IIIC dusts The IECEx certificate for the loop powered indicators has an ‘X’ suffix indicating that special conditions for safe use are required for installion in IIIC dust atmospheres, the certificate states: ‘For use in Group IIIC conductive gas atmospheres, the indicator shall be mounted such that the instrument terminals have at least IP6X protection.’ To prevent the indicator terminals becoming contaminated by conductive dust: The indicator must be installed in a panel, cubicle or enclosure providing a minimum of IP6X protection. The gasket supplied to seal the joint between the indicator and the mounting panel must be used, and the 144 x 72mm BA308E and BA328E indicators must be secured with four panel mounting clamps. Note: These special installation conditions only apply for indicators exposed to IIIC conductive dust atmospheres.

28 Appendix 3 FM Approval for use in the USA and cFM Approval for use in Canada A3.0 Factory Mutual Approval For installations in the USA and Canada, all models have FM and cFM intrinsic safety and nonincendive approval, project identifications 3041487 and 3041487C. Copies of the Certificates of Compliance are available from the BEKA associates sales office and www.beka.co.uk A3.1 Intrinsic safety approval The indicators are approved to FM Class 3610 intrinsic safety standard for use in Division 1 and 2 hazardous (classified) locatios. Installations must comply with BEKA associates Control Drawing CI300-72, which is attached to this appendix, ANSI/ISA RP12.06.01 ‘Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations’ and with the National Electrical Code ANSI/NFPA70. Installations in Canada must comply with the Canadian Electrical Code C22.2

A3.2 Nonincendive approval All the models are FM Class 3611 nonincendive approved allowing installation in Division 2 hazardous (classified) locations without the need for Zener barriers or galvanic isolators. US installations must comply with the BEKA associates Control Drawing CI300-73, which is attached to this appendix, and with the National Electrical Code ANSI/NFPA70. Canadian nonincendive installations must comply with the Canadian Electrical Code C22.2 and with BEKA associates Control Drawing CI300-73, which is attached to this appendix. The front of all the models have IP66 (Type 4X) protection. To obtain an IP66 seal between the indicator and the panel in which it is mounted, the installation must comply with note 6 of Control Drawing CI300-73. All the models have a T4 rating at ambient temperatures up to +70ºC and may be used with the following gases:

The front of all the models have IP66 (Type 4X) protection. To obtain an IP66 seal between the indicator and the panel in which it is mounted, the installation must comply with note 11 of Control Drawing CI300-72.

Nonincendive Division 2 Class I Group A & B Group C Group D

All the models have a T4 rating at ambient temperatures up to +70ºC and may be used with the following gases:

Class I

Intrinsic Safety Division 1 or 2 Class I Group A & B Group C Group D Zone 0, 1 or 2 Class 1 Group IIC Group IIB Group IIA

The FM and cFM entity parameters are similar to the ATEX and IECEx parameters and the systems shown in section 4 of this manual may therefore also be used for FM and cFM installations.

Zone 2 Group IIC Group IIB Group IIA

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OWNER'S OPERATING MANUAL SSG SeriesTM Rackmount Industrial-Grade UPS Plus®

Uninterruptible Power Supply Models: SSG1.5KRM-1 - 1.5kVA, 1050W, 120Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation SSG1.5KRM-2 - 1.5kVA, 1050W, 230Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation SSG2.2KRM-1 2.2kVA, 1540W, 120Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation SSG2.2KRM-HW 2.2kVA, 1540W, 120Vac, -20ºC - 40ºC (-4ºF to 104ºF) Operation SSG2.2KRM-2 - 2.2kVA, 1540W, 230Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation SSG3KRM-1 3kVA, 2100W, 120Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation SSG3KRM-HW 3kVA, 2100W, 120Vac, -20ºC - 40ºC (-4ºF to 104ºF) Operation SSG3KRM-2 - 3kVA, 2100W, 230Vac, -20ºC - 55ºC (-4ºF to 131ºF) Operation

SSG Rackmount Models

FALCON® Electric Inc., 5116 Azusa Canyon Rd., Irwindale, California 91706, 626.962.7770, Fax 626.962.7720, Email: [email protected] 2011 Falcon® Electric Inc. All rights reserved. All other brand names and trademarks are the property of their respective owners. The information stated in this document is subject to change without notice. 2011-08-13 Falcon®, Falcon® Electric and UPS Plus logos are registered trademarks of Falcon Electric, Inc.

TABLE OF CONTENTS

SSG UPS Features. . . . . SSG Series Double-Conversion On-line UPS Block Diagram. Important Safety Instructions (READ FIRST) .

. . .

. . .

3 3 4

Chapter 1. Introduction Manual Overview. . Brief SSG Overview.. Load Segment Control. . Remote Emergency Power Off RS-232 & USB . . Communications Expansion Slot.

. . . . . .

. . . . . .

. . . . . .

5 5 5 5 5 5

. .

. . .

. . . . . . . . .

6 6 6 6 6 6 9 9 9

. . . . . . . .

9 10 10 12 13 13 14 15

Chapter 2. SSG UPS Circuit Descriptions Input FIlter. . . Power Factor Correction. DC/DC converter. . . DC/AC inverter . . Battery packs . . Battery charger. . . Manual bypass function. . Automatic bypass function. . Output fIlter . . Chapter 3. Installation Unpacking . . Inspecting the equipment . Rackmount UPS setup . Free standing tower installation with LCD display repositioning . Battery bank installation . Extended battery bank information Battery bank installation procedure

. . . . . . . . .

. . . . . .

. . . . . . optional . . . .

. . . . .

.

. . . . mounting feet. . . . . . . . .

Chapter 4. Displays & Controls LCD & LED indicators & icons. . Function/Test button . Set/Alarm Silence button . . How to display the UPS Parameters .

. . . .

. . . .

. . . .

16 17 17 17

Chapter 5. UPS Operation Operating Modes . . Normal On-line Mode Battery Mode . Bypass Mode . How to turn on the UPS . How to DC start the UPS . How to turn off the UPS .

. . . . . . .

. . . . . . .

. . . . . . .

18 18 18 19 19 19 19

. . . .

. . . .

. . . .

20 20 21 22

. . . . .

24 25 25 26 27

. . . . . .

Chapter 6. UPS Setup, Configuration & Programming How to place the UPS into setup mode. Setting the Green Mode. . . Setting the UPS output voltage. . Setting the load segment options. .

Chapter 7. Communications RS-232 & USB . . . . . REPO . . . . . . SSG1.5KRM-1 rear panel layout . . . SSG2.2KRM-1 & SSG3KRM-1 rear panel layout.. . SSG2.2KRM-HW & SSG3KRM-HW rear panel layout & wiring. Chapter 8. Maintenance Storing the UPS . . . When to replace batteries . . SSG1.5KRM-X Internal Battery Replacement SSG2.2KRM-X, SSG3KRM-X, SSGR & SSGR-X Performing a manual battery test . Recycling used battery packs . Chapter 9. Troubleshooting . . . Chapter 10. Technical Support . . Warranty . . . . Specifications . . . .

2

. . . . . . . . . Battery Replacement. . . . . . . . . . . . . . . . . . .

28 29 29 30 30 32 33 37 38 39-40

SSG SeriesTM Industrial-Grade UPS Features True Double Conversion On-Line Sinewave Design High Temperature 550 C Operation LCD Display with Advanced Monitoring Output Load Segment Control Remote Emergency Power Off (REPO) Input Power Factor Correction Wide Input Voltage Window Precision Output Voltage Regulation Superior Brownout, Surge and Transient Protection Optional Frequency Converter Operation User Replaceable and Hot Swappable Battery Pack Optional Extended Battery Banks & Chargers RS-232C, USB & Optional SNMP/HTTP Communications UPSILON UPS Monitoring & Management Software RoHS Compliant Two-Year Warranty

SSG Series Double-Conversion On-line UPS Block Diagram

3

IMPORTANT SAFETY INSTRUCTIONS, SAVE THESE INSTRUCTIONS RETAIN THIS USER MANUAL! This manual contains important instructions which must be followed during the installation, operation and maintenance of the SSG Series UPS, battery banks, options and batteries. Please read all instructions before operating this equipment and save this manual for future reference. All of the models presented herein are designed for installation and use in a temperature controlled environment, free of contamination. This UPS operates from utility power and contains a number of high current back-up batteries; this information is important to all personnel involved. Please read this manual first before continuing to unpack, install or operate this UPS. STORAGE AND TRANSPORTATION This UPS must be handled with care and given special attention due to the high amount of energy stored within its internal sealed, lead acid batteries. Please retain the UPS shipping container in the event the UPS needs to be returned for service. It has been designed to ship the UPS safely, without shipping damage. INSTALLATION This UPS must be installed in a clean environment, free from moisture, flammable gases or fumes and corrosive substances. Operate the UPS in an indoor environment with an ambient temperature range specified by model number herein. This UPS is designed for use with industrial, scientific or data processing class equipment. DO NOT USE TO POWER LIFE SUPPORT EQUIPMENT, OR OTHER DESIGNATED “LIFE CRITICAL” APPLICATIONS. The maximum UPS output load (in watts) must never exceed that shown on the UPS rating label. NEVER CONNECT equipment that could overload the UPS or demand half-wave rectification from the UPS, for example: electric drills, vacuum cleaners or hair dryers. Storing magnetic media on top of the UPS may result in data loss or corruption. WARNING This UPS should be installed according to the instructions in this manual. Failure to do so could result in unsafe operation and could invalidate your warranty. WARNING Once batteries have reached the end of their life, ensure they are disposed of properly. PLEASE REFER TO YOUR LOCAL LAWS AND REGULATIONS FOR BATTERY RECYCLING REQUIREMENTS. NEVER DISPOSE OF BATTERIES IN A LAND FILL. Do not dispose of battery pack or batteries in a fire. The battery may explode. Do not open or mutilate the battery pack. Released electrolyte is harmful to skin and eyes. It may be toxic. CAUTION A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working on batteries: * *

Remove watches, rings, and other metal objects. Use tools with insulated handles. 4

1.0 INTRODUCTION Manual Overview This user manual has been written to provide basic information about the Falcon SSG Series Industrial Grade UPS Plus. SSG models are available in nominal power ratings of 1500, 2200 and 3000 VA . The SSG Series is a compact, rugged, double conversion, "on-line" UPS. It provides continuous power conditioning and accepts a wide range input voltage while providing tight output voltage regulation with a true sinewave output. The SSG Series UPS protects your sensitive electronics equipment against the widest range of power problems, including power failures, power sags, power surges, brownouts, line noise, high voltage spikes, frequency variations, switching transients, and harmonic distortion. This manual also describes unpacking, unit installation, the major features of the SSG Series UPS, as well as detailed operation, configuration and troubleshooting. The specifications section states all of the detailed parameters of operation for the SSG Series, and provides general information on approvals and certifications. Brief SSG Overview The Falcon SSG Series Industrial-Grade UPS may be positioned vertical for desktop or floor standing applications. Brackets are supplied to accommodate installation into a standard 19 inch equipment rack. The SSG Series front panel features a graphical LCD display, providing detailed operational information at a glance. The display enables the user or field service engineer to easily monitor and troubleshoot localized power problems, in addition to UPS operation. UPS control and programming is easily accomplished using the Standby, Function/Test and Set/Alarm Silence buttons. Two levels of audible alarms are also provided when the unit is operating on battery. The SSG Series rear panel supports the following: a. Load Segment Control - Multiple output receptacles are grouped into one continuous and two programmable load segments. The two programmable load segments may be set to “shed” or turn off the load segment at loss of utility voltage or when the low battery level has been reached. This allows non-essential loads to be turned off, extending the amount of battery runtime. b. Remote Emergency Power Off (REPO) - SSG models are equipped with a REPO connector that may be interfaced with a computer room’s isolated, normally closed REPO and meets NFPA 70, NEC645-11. c. RS-232 and USB Ports - These ports may be used to provide communications between the UPS and a network server or other computer systems. When used in conjunction with the supplied UPSILON software, they give the ability to remotely monitor and control the UPS. The software will automatically save all open computer files and initiate an unattended shutdown in the event of a loss of utility. It supports most MS Windows and Linux operating systems. An optional Unix version is available through Falcon at an additional cost. d. Communications Option Board Expansion Slot - The slot supports the installation of an optional SNMP/HTTP Agent board or contact closure interface board. The SNMP/HTTP Agent board is a TCP-IP addressable solution to remote UPS monitoring and management via LAN, WAN or the Internet. The agent board is supplied with client software that will remotely shutdown multiple servers or computers through the Ethernet LAN. A CD containing software clients and a SNMP MIB II compliant MIB is provided that supports most popular operations systems. 5

2.0 SSG UPS CIRCUIT DESCRIPTIONS Input Filter This portion of the circuit provides surge protection, certified to meet IEC 61000-4-5 and IEC 801-5. It also filters out both electro-magnetic interference (EMI) and radio frequency interference (RFI) and prevents excessive levels from being conducted back to the utility source. All SSG Series rackmount models have been tested and comply with FCC Class B requirements. Input Power Factor Correction While the UPS is operating from the utility source, this circuit converts utility AC power to regulated DC power for inverter use. It corrects the input current to maintain a sine waveform to minimize the amount of current distortion that will be reflected back to the utility. DC/DC Converter The DC/DC converter utilizes energy from batteries and boosts up the DC bus voltage to a level required by the inverter. This allows the inverter to operate continuously at optimum efficiency and voltage. The converter incorporates a patented circuit which reduces the amount of ripple current and EMI interference to the battery, increasing the overall battery life. DC/AC Inverter In utility mode operation, the inverter utilizes the regulated DC output to invert DC back into clean, regulated sinewave AC power. When utility power fails, the inverter will receive its energy from the battery through the DC/DC converter. In both modes of operation, the UPS inverter is on-line and continuously generating clean, regulated AC output power to the load. The IGBT, PWM inverter is of a very robust design and produces a pure sinewave output with a +/-2% voltage regulation. Having a very low output impedance, it can supply the high current demands of high inrush and non-linear loads. Battery Packs The SSG Series UPS utilizes a flame retardant battery pack comprised of four 12V, 7AH, valve-regulated, sealed lead acid (VRLA) batteries in each pack. All SSG battery packs are interchangeable between SSG 1.5kVA-3kVA models. They are easily replaced through the UPS front panel. See replacement instructions outlined in this manual. To maintain the optimum battery life, the user should operate the UPS in an ambient temperature of 68ºF to 77ºF (20ºC to 25ºC). Some SSG Series UPS models have batteries that may be rated operational at 0º C - 55º C (32º F to 131º F), at these temperatures, battery life will be substantially reduced. Optional extended battery modules are available through Falcon and will extend the amount of battery runtime. Please refer to the exact UPS model in the attached specificaitons for the specific battery option part number. Battery Charger The battery charger utilizes energy from the utility power to continuously charge the UPS batteries. The charger operates in "constant power" mode. The UPS batteries are being charged whenever the UPS is plugged in, turned on and operating from utility power. The internal UPS battery charger output is rated at 1 amp.

6

Lithium-Ion Batteries SSG1.5KRM-1-LI and SSG1.5KRM-2-Li models are equipped with optional internal Lithium-IonPhospate Batteries. In comparison with VRLA (valve regulated sealed lead-acid) batteries which weigh 6 lbs. each, the Lithium-ion batteries weigh 1.8 lbs each while supplying almost twice the battery runtime as the same model equipped with VRLA batteries. CAUTION: If not handeled or disposed of properly Lithium-Ion batteries are extremely dangerious. Lithium-Ion-Phosphate batteries must be recycled - never dispose of the batteries in a land-fill or trash. Caution: Should a model SSG1.5KRM-1-LI or SSG1.5KRM-2-LI UPS require shipment by air transporation the shipping instrucitons on the following page must be followed: IMPORTANT SHIPPING INSTRUCTIONS To ship by air you need to: 1) Shipper must declare Hazardous materials/dangerous Goods description and proper shipping name – Lithium batteries, contained in equipment. 2) Identification Number – 3481(international)/3091(USA) note: that 3481 will be recognized in the USA but the CFR still has 3091 since the US has not harmonized with the rest of the world at this time. 3) The 12V7 batteries have been tested to UN Manual of Tests and Criteria, Part III, subsection 38.3. 4) The 12V7 batteries are under 100Wh and are excepted from the regulations. 5) The UPS must be packed in strong outer packaging constructed of suitable material of adequate strength and design in relation to the packaging’s capacity and its intended use. SAVE THE ORIGINAL SHIPPING CARTON, INSERTS AND PACKING MATERIALS. 6) Each consignment with packages bearing the lithium battery handling label must be accompanied with a document with an indication that: • the package contains lithium ion cells or batteries; • the package must be handled with care and that a flammability hazard exists if the package is damaged; • special procedures must be followed in the event the package is damaged, to include inspection and repacking if necessary; and • a telephone number for additional information. 11) A Shipper’s Declaration for Dangerous Goods is not required. 12) The words “Lithium ion batteries”, “not restricted” and “PI 967” must be included on the air waybill, when an air waybill is used. The information should be shown in the “Nature and Quantity of Goods” box of the air waybill. IMPORTANT LITHIUM-ION BATTERY SAFETY INSTRUCTIONS 1) Always replace the external UPS battery fuse with one of the same type and rating. 2) Always replace batteries with A123 12V7 manufacturer and type. Never attempt to replace with VRLA batteries. 3) Never dispose of the UPS or its internal batteries in a land fill. The UPS and batteries must be recycled by a state registered recycler. 4) For emergency information concerning A123 Model 12V7 Lithium-Ion-Phosphate batteries call: US & Canada 1-800-232-9300 International +1-703627-3887 5) Never store a UPS containing Lithium-Ion batteries in temperatures above 65oC. 6) Never attempt to replace the internal battery fuses. Batteries Must Be Replaced if internal Battery Fuse is blown. 7

7) 8)

Never Apply a Short Circuit Across The Batteries as Personnel Injury, Fire or Explosion May Result. DANGER ---- NEVER ATTEMPT TO CONNECT AN EXTENDED BATTERY BANK CONTAINING VRLA LEAD-ACID BATTERIES TO A UPS CONTAINING INTERNAL LITHIUMION-PHOSPHATE BATTERY

8

Manual Bypass Function A manual bypass button is located on the SSG front panel. When the UPS is operating from utility in the normal on-line state, depressing this button will cause the UPS to transfer to bypass. Depressing the bypass button again will return the UPS to the normal on-line condition. Automatic Bypass Transfers The SSG Series UPS will automatically switch to bypass to energize the connected load when the UPS is first turned on, encounters an overload, encounters an over temperature condition, or upon a UPS failure condition. Should any of these events occur, the UPS will transfer to bypass mode, sound an audible alarm and provide a "bypass" indication on the LCD display. Output Filter As with the input filter stage, the output filter maintains conducted (EMC) and RFI levels below FCC Class B limits. 3. 0 INSTALLATION Unpacking The SSG Series UPS may be shipped in a number of boxes, depending on the model and configuration ordered. The number of boxes you have received should be as indicated: MODEL

BATTERY MODULE

SSG1.5KRM-X SSG2.2KRM-X SSG3KRM-X

NUMBER OF BOXES

n/a (internal battery pack) 1 battery module 1 battery module

1 box shipped 2 boxes shipped 2 boxes shipped

If you have not received the proper number of boxes, please contact Falcon Electric Customer Service at 1-800-842-6940. This UPS is shipped complete with all cables required for operation, including UPSILON software, and rackmount ears for 19" rackmount shelf mounting. A full list of the box contents is provided as follows: SSG1.5KRM-X Box 1 contains:

SSG2.2KRM-X / SSG3KRM-X Box 1 contains:

UPS module with fitted battery pack RS-232 cable Software CD Manual 19" rack ears (+ screws)

UPS module without battery RS-232 cable Software CD Manual 19" rack ears (+ screws)

Box 2 contains: Battery module Battery connection cable Keyhole hardware 19" rack ears (+ screws) 1 set of mounting plates & securing hardware

9

Inspecting The Equipment Visually inspect the UPS for freight damage. If any equipment has been damaged during shipment, keep the shipping cartons and packing materials for the carrier, and immediately file a claim for “shipping damage” with the carrier. If you discover damage after acceptance, file a claim for “concealed damage”. To file a claim for shipping damage or concealed damage: 1. YOU MUST file with the carrier within 15 days of receipt of the equipment; 2. YOU MUST send a copy of the damage claim within 15 days to Falcon Electric, Inc. CAUTION

The UPS and Battery Module are heavy. Take proper precautions when lifting or moving them. 1. Install the UPS indoors in a controlled environment. 2. Place the UPS in an area with unrestricted airflow around the unit, away from water, flammable liquids, gases, corrosives, and conductive contaminant. 3. Maintain a minimum clearance of 4 inches in the front and rear of the UPS. 4. Maintain an ambient temperature range specified in the model specificaiton. To maximize the life time of the batteries, an ambient temperature of 68ºF to 77ºF (20ºC to 25ºC) is recommended. OPERATION IN TEMPERATURES ABOVE 77ºF (25ºC) WILL REDUCE BATTERY LIFE. 5. The SSG Series UPS can be installed in either a free-standing mini-tower or into a 19 inch equipment rack. Follow the appropriate instructions in either Rackmount UPS Setup or Free-standing UPS Installation. Rackmount UPS Setup All SSG Series models are shipped with front panel mounting ears that allow the unit to be installed in a 19" equipment rack. Each UPS unit and external battery enclosure requires 2U (3.5 inches) of vertical rack space. NOTE ! The rack-mounting ears WILL NOT support the weight of the UPS or battery bank by themselves. They are only to be used to secure the UPS to the front rails of the rack. Mounting rails or an equipment shelf are required to support the weight of each UPS or battery module.

Use the following procedure to install the UPS in an standard 19” equipment rack: 1. Place the UPS on a flat, stable surface with the front of the UPS facing you. 2. Align the mounting ears with screw holes on the side of the UPS and secure with the supplied screws. 3. If installing the Battery Module, repeat above STEPS. 4. For slide rail installations, fasten the inner parts of the slide rails to the UPS on both sides with the screws provided.

10

5. 6.

** Securing hardware, slide rails and rail extensions are sold separately. Contact Falcon Electric for these additional options and any assistance needed.** Attach the two mounting brackets to the rack's mounting rails. The brackets allow adjustment of up to eight inches of the slide assembly mounting position, front-to-back, on the rack-mounting rails. Determine which adjustment holes to use on the bracket, and attach it to the slide assembly on the stationary outer slide.

11

7.

8. 9.

10.

11.

Install the slide assemblies, with brackets into the rack enclosure. The return flanges on the mounting brackets and outer parts fit to the inside of the rack-mounting rails. Verify the slide assemblies are in the same alignment position on all four rack-mounting rails. After checking alignment, TIGHTEN ALL SCREWS. Insert the UPS, with inner parts attached, into the slide assemblies. You may need to depress the locking mechanisms on the inner and outer parts of the slide assemblies to allow the slides to retract. The UPS should move smoothly forward and backward on the slide assemblies. If not, recheck alignment. Once the UPS is installed in the rack, the load may be connected to the output of the UPS. Ensure the equipment being connected is turned off. Plug all loads into the output receptacles on the rear of the UPS. Plug the UPS into a dedicated wall receptacle that is protected by a circuit breaker or fuse in accordance with national and local electrical codes. Use a 15 amp rated device for 1500 VA units, 20 amp for the 2200VA, and 30 amp for 3000VA. The wall receptacle must be grounded. To turn on the UPS, switch on the input circuit breaker; wait for the UPS to switch from bypass to inverter mode and then turn on the connected equipment.

Free-standing (tower) Installation (mounting feet to be purchased seperately) When installing the SSG Series UPS in a free-standing configuration, mounting feet for the SSG1.5KRM-1 model may be purchased seperately to stableize the UPS provided with mounting feet (shown below, left) to stabilize the UPS. The SSG2.2KRM-1 and SSG3KRM-1 models are provided with keyhole hardware to "lock" the UPS and battery bank units together. This key lock is also required if additional battery packs are added.

X

Mounting feet for additional battery banks

Mounting feet

SSG1.5KRM-X Free Standing

SSG2.2KRM-X & SSG3KRM-X Free Standing 12

LCD Display Repositioning WARNING: Refer the repositioning of the LCD display to a qualified electronic technician or the Falcon Service Department. LIVE COMPONENTS ARE INSIDE THIS UPS AND  RISK OF ELECTRICAL SHOCK. Prior to anyone starting to attempt the repositioning of the LCD display, SERVICE PERSONNEL MUST FIRST disconnect the UPS line cord and power plug, remove the battery fuse located on the UPS rear panel, disconnect any external battery banks and let the UPS discharge for one hour. The default LCD display mounting is for horizontal (Rackmount) viewing. To reorient the LCD display for vertical (Free Standing) viewing, remove the left half of the front plastic bezel by unscrewing the screws to the far left of the chassis. Next, remove the four screws securing the right plastic panel and pull the right panel forward evenly. Refer to the following figure, unscrew the LCD board and rotate it 90 degrees, to the correct position for viewing. Use care when handling the LCD display and associated cabling. Mount the front covers back and reinstall the screws.

SSG & HW Battery Bank Installation (SSG1.5KRM-X internal battery, SSG2.2KRM-X & SSG3KRM-X standard battery bank and all SSG extended battery banks) Note: Additional battery banks can be connected to the UPS to provide additional battery run time. There are two models of extended battery banks available for the SSG Series. Falcon model number SSGR is a universal battery bank without an internal charger. It may be added to any SSG 1.5-3kVA models. For 2.2-3kVA models, the addition of this type of extended battery bank will cause the stated recharge time to multiply by the number of battery banks added. The addition of more than three SSGR battery banks is not recommended. Use the SSGR-1 model universal extended battery models instead, as it incorporates internal battery chargers to assure proper battery recharging and greatly reduces the amount of battery recharge time. 13

SSG Extended Battery Bank Information EXTENDED BATTERY BANK (EBM) OPTIONS UPS Model

SSG1.5KRM -1 &HW SSG1.5KRM -2 & HW

SSG2.2KRM -1 & HW SSG2.2KRM -2 & HW

SSG3KRM-1 & HW SSG3KRM-2 & HW

Extended # Of Recharge Battery Battery Time in Bank Banks Hours Model (to 90%) Number (2)

SSGR

Weight (lbs.)

1

18

40.5

3

30

1

6

2

35

81

5

56

2

7

3

56

121.5

7

87

4

64

162

9

5

80

202.5

43.5 87 -1 120Vac 2A 130.5 54Vdc 3A (2 -2 Chargers 230Vac @1A each 174 1.5A

3

7

118

4

8

11

148

5

8

217.5

243

13

184

6

8

261

48Vdc

SSGR-1 SSGR-2

7

150

283.5

15

221

7

8

304.5

1

12

40.5

2

24

1

7

43.5

2

18

81

3

42

2

7

3

25

121.5

SSGR

SSGR

Number BACKUP EXTENDED BATTERY BANK (EBM) OPTIONS of parallel TIME (1) (With Internal Battery Charger) UPS BATTERY battery Extended # Of Recharge Charger Charger Recharge Weight Battery strings (Models BANK Battery Battery Time in Input Output Current (lbs.) Bus DIMENSIONS With & Bank Banks Hours Voltage & Voltage Voltage (Inches) Without Model (to 90%) Current Charger Number

4

63

96Vdc

SSGR-1 SSGR-2

3

8

4

8

87 -1 120Vac 2A 130.5 3A 109Vdc (2 (2 x -2 Chargers 230Vac 54Vdc) @1A each 174 1.5A

4

35

162

5

83

5

46

202.5

6

104

5

8

217.5

6

56

243

7

125

6

8

261

7

68

283.5

8

146

7

8

304.5

1

12

40.5

2

14

1

6

43.5

2

18

81

3

27

2

7

3

25

121.5

4

41

8

4

35

162

5

56

4

9

5

35

202.5

6

71

5

8

217.5

6

56

243

7

87

6

8

261

7

68

283.5

8

103

7

8

304.5

SSGR-1 SSGR-2

3.5 x 16.8 x 21.5 (each battery bank)

87 -1 120Vac 2A 130.5 109Vdc 3A (2 (2 x -2 Chargers 230Vac 54Vdc) @1A each 174 1.5A

3

96Vdc

3.5 x 16.8 x 21.5 (each battery bank)

3.5 x 16.8 x 21.5 (each battery bank

1. BATTERY TIMES ARE IN MINUTES @ FULL LOAD AND INCLUDE UNITS INTERNAL BATTERIES ON 1KVA UNIT. (TIMES ARE APPROXIMATE AND SUBJECT TO TEMPERATURE, CONDITION AND TYPE OF LOAD). 2. RECHARGE TIME WITH INTERNAL UPS CHARGER ONLY

14

Battery Bank Installation Procedure The battery modules have been designed to be placed on one side of the UPS as shown below.

1. 2. 3.

4.

Visually inspect the battery module for any freight damage. Report damage to the carrier and Falcon Electric immediately. Use the mounting feet to secure the unit and to prevent them from tipping over. One additional set of mounting feet base extensions ships with each battery bank. Turn off the battery disconnect switch and connect the supplied battery bank cable to the UPS connector located on the rear of the battery bank. Next connect the other end of the cable to the battery bank connector located on the rear of the UPS as shown. Turn on the battery disconnect switches located on the back on the rear of the battery bank(s).

15

4.0 DISPLAY & CONTROLS The diagram below shows the basic functions of the front panel for all SSG Series 1.5-3kVA UPS models.

Indicators and Icons located on the LCD models LED display: Green Mode: The bulb icon is displayed continuously when the Green Mode function is enabled. It will be flashing when the UPS has switched to Green Mode due to the UPS output load decreasing to less than 3% of the total UPS output rating. The UPS is shipped with the Green Mode disabled. See Green Mode setting instructions. Audible Alarm: The speaker icon will be displayed during an alarm condition. It will be flashing when the audible alarm has been silenced. UPS Fault Condition: This icon will be displayed when an alarm condition exists. Refer to page 29 of this manual and attempt to correct the alarm condition. Test: The Test icon will be displayed and flash whenever the UPS is conducting a Self/Battery Test. Not on LED models. Output Load %: The greater the load, up to three vertical bars will be illuminated at the ends of the icon. Each bar represents 25% of the UPS output rating. Inverter Status: This icon will be displayed when the UPS is in Inverter mode. PFC Status: This icon will be displayed with PFC is functioning. Utility Power Status: The Line Cord icon will be displayed when utility power is present. Charger Status: When the battery charger is operating, the gas pump icon will be displayed. Battery Mode: When the UPS is in battery mode this icon will be displayed. Battery Level: The battery icon or LED indicates the battery capacity. The more battery capacity available, the more bars that will be illuminated. Each bar represents 25%. Fan in high speed mode: The HS Fan icon is displayed when the UPS cooling fan is in high speed mode, typically during battery mode operation. Fan in medium speed mode: The MS Fan icon is displayed when the UPS cooling fan is in medium speed mode, typically when utility is present. Fan in low speed mode: The LS Fan icon is displayed when the UPS cooling fan is in low speed mode, typically when the UPS is in bypass. 16

Controls (all models): The primary front panel user controls consist of one input circuit breaker and three push-buttons: The switch located to the right of display is the main input circuit breaker and controls the connection of utility power to the UPS and its internal battery charger. .

The three buttons located to the left of the LCD display are for primary manual control and programming of the UPS. From top to bottom they are designated "Function/TEST", "Set/Alarm Silence", and "Bypass". Function/Test Button This button has two functions: 1 Initiates internal UPS Setup mode to allow for configuration changes. Setup mode is initiated by pressing both the "Function/Test" and Set/Alarm buttons down and holding them for one second. 2 Manual Battery Test - If depressed for less than three seconds, it initiates an immediate battery test. Manual Battery Test Description - When the UPS is operating normally from utility power, pressing the test button will cause the UPS to test the voltage status of the batteries for 10 seconds. During that period, the battery, if first determined to be good, will supply power to the UPS. Should defective batteries be detected, the audible alarm will sound one long tone, and the UPS will continue to operate from the utility voltage, without going to battery mode. During the battery test, the output of the UPS will not be adversely affected. Set/Alarm Silence Button This button has three functions: 1 Disables the audible alarm buzzer 2 Scrolls the display through the various UPS parameters. 3 Sets configuration changes (when pressed in setup mode only). Disable the Audible Alarm - Pressing the button for one second will turn off the audible alarm. This will cause future notification of minor alarms to be silenced. NOTE! THE FOLLOWING ALARMS CANNOT BE SILENCED: OVER TEMPERATURE, PFC OVER CURRENT, INVERTER OUTPUT OVER LOAD, LOW BATTERY AND UPS OR CHARGER FAILURE. How to Display The UPS Parameters - Repeat pressing of the Set/Alarm button will cause UPS input and output parameters to be displayed on the lower portion LCD display in the following order. The input voltage, output voltage, output frequency, battery voltage, percentage of output load, input current, internal UPS temperature and the output current. 17

CAUTION When the UPS is in Normal On-line mode, pressing the bypass button once will put the UPS into Bypass Mode. While in bypass, should the utility power become unavailable, the UPS output will turn off and the UPS will shut down. Once the unit is in Bypass Mode operation, pressing this button again will force UPS back to on-line mode operation. 5.0 UPS OPERATION OPERATING MODES (LCD models only, LED models are self-explanatory) The following outlines the UPS status for each mode of operation as displayed by the LCD. NORMAL ON-LINE MODE OPERATION During normal on-line operation, utility power provides energy to the UPS. The filters, power factor corrector and the inverter process the power to provide computer grade power to connected loads. The UPS maintains the batteries in a fully charged state. The LCD display icon configuration on the left indicates on-line mode operation, indicating the percent of load, inverter, PFC, line, charger and battery operation and status. The fan is shown at medium speed. The dark, solid line on the MIMIC portion of the display indicates the normal mode power flow from input, through the inverter, to load and from the input, to the charger and into the battery. BATTERY MODE OPERATION The battery mode icon configuration is displayed during a loss of utility power or during excessively high line voltage conditions. When in battery mode, the UPS battery supplies energy to the DC to DC converter, and then on to the inverter, which powers the connected load. During the battery discharging, the audible alarm will beep. The rate of the beeping will increase as the battery runs low (low battery), prior to UPS shut down. Once the low battery warning is sounded, there will be about one minute of battery runtime remaining. After the UPS has shut down, when utility power has been restored, the UPS will automatically restart. For approximate battery run times, refer to the specifications and extended battery runtime chart in this manual. The runtime is based on a resistive load being connected to the UPS output, and an ambient temperature of 77ºF (25ºC). The LCD display icon configuration on the left indicates the UPS is in Battery Mode. The dark solid line indicates battery power flow to the DC to DC converter and on to the inverter. The fan is shown in high speed mode. The bars inside the battery icon indicate the amount of battery capacity remaining; each bar represents a 25% capacity increment. As capacity decreases, fewer bars will remain illuminated. The charger icon is turned off. 18

BYPASS MODE OPERATION The UPS will automatically transfer to Bypass Mode in the event it is overloaded, experiences an internal failure and for the conditions listed below. When in bypass, the UPS will transfer the connected load directly to the incoming utility power. When in bypass mode, Battery Mode will not be available. However, the utility power will continue to be passively filtered by the UPS. Additionally, the UPS will sound an audible alarm and switch to Bypass Mode automatically upon the following conditions: * The UPS has experienced an over temperature condition. * The UPS has experienced an overload condition of 101 to 110% for over 120 seconds. * The UPS has experienced an overload condition of 111 to 150% for over 20 seconds. * The UPS has experienced an overload condition of over 150%. * The UPS detects a fault in the battery or UPS electronics. The LCD display icon configuration on the left indicates the UPS is in Bypass Mode. The dark solid line shows the input connected directly to the connected load. Another dark solid line shows the input power to the battery charger icon, then to the battery. The Fan is shown in low speed mode. GREEN MODE OPERATION When Green Mode is turned on using the UPS programming interface, the SSG unit will automatically switch to "Green Mode" (Bypass Mode), once the connected load drops to less than 3% of the UPS’s rated output. The load will operate directly from utility power, similar to Bypass Mode. The LCD display will indicate the UPS is in Bypass Mode, the Green Mode bulb icon will be flashing. If the load is increased to over 3% of the UPS output rating, the UPS will automatically switch back to normal on-line operation. All SSG models are shipped from the factory with Green Mode turned off. To enable Green Mode, refer to the section on UPS Setup, Configuration & Programming. See the green mode configuration section for further details and cautions. How to Turn On the UPS (with utility power) Once installation has been complete, the UPS can be powered up. With utility power present, turn on the UPS input circuit breaker located on the front panel. The UPS will enter an Auto-Test state and all of the LCD indicators will be illuminated flashing for ten seconds and then return to a normal state. The UPS will start up in bypass mode and after several seconds, should transfer to the normal on-line mode. How to DC Start the UPS (without utility power) In the event utility power is not available, the UPS may be started up in battery mode. To turn on the UPS without utility power available, press and hold the "BYPASS" button. The UPS will start on battery and supply power to the connected loads until the batteries are depleted. Always recharge the batteries immediately by connecting the UPS to utility power and turning on the UPS input circuit breaker after any full battery discharge. For DC start operation the load segment control must be set to Continuous Mode operation. How to Turn Off the UPS To turn off the UPS: While in normal on-line mode, press the Bypass button for one second. The UPS will go into Bypass Mode. Next, turn off the input circuit breaker. The unit will shut down after about 30 seconds. While in battery mode: Press the Bypass button for one second. The unit will shut down after about 30 seconds. 19

NOTE! DURING SHUT DOWN, DO NOT PRESS ANY BUTTON SINCE UPS MIGHT BE RE-ENERGIZED AND DELIVER POWER TO ITS OUTPUT UNEXPECTEDLY. 6.0 UPS SETUP, CONFIGURATION & PROGRAMMING The following section describes how to reconfigure the internal UPS setup options, by using the Setup, Configuration & Programming Mode. The setup options include: The UPS output voltage, enabling or disabling Green Mode and output Segment Control operational mode settings.

CAUTION Never change the voltage settings when the UPS is ON and powering any connected loads. How To Place the UPS Into Setup/Configuration Mode To place the UPS into configuration mode: press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will emit one audible beep and display function and status bit window at the bottom of the LCD display, entering Configuration Mode. Note on the bottom of the display panel, you will see a single row, 8 BIT column located at the bottom of the display. The right most bit is function BIT 0, with the remaining seven bits to the left, function bits 1 through 6. The last BIT 7 is the Status Bit and will indicate the setting status of the other Function bits. Repeat pressing of the "Function/Test" button will move the dot from function BIT 0 (far right) to function BIT 6. When selecting function BIT 0 through BIT 6, observe whether status BIT 7 has a (Dot) or (No Dot) displayed for the function bit selected. To select a dot or no dot for the function you are presently in, press the "Set/Alarm Silence" button to turn on (Dot) or turn off (No Dot) in status BIT 7. Next, press the “Set/Alarm Silence" and “Function/Test" buttons at same time, and hold for one second. The audible alarm will sound one short beep to acknowledge the UPS has stored the selected settings. Setting the Green Mode Function (set to disabled from factory) Green Mode is a power saving feature that should only be used in non-critical applications when the connected computer or equipment is the only device being protected by the UPS and when turned off, UPS battery backup is no longer necessary. When the Green Mode is enabled and the connected load decreases to less than 3% of the full rated UPS output capacity, the UPS will automatically switch from on-line to Bypass Mode, 30 seconds after the drop in load has been detected. After the UPS has switched to Bypass Mode, the Green Mode bulb icon will flash to indicate the UPS is in the energy saving Green Mode. While in Green Mode, should the load increase to greater than 3% of the UPS's full output rating, the UPS will automatically return to normal On-line Mode operation. CAUTION- When Green Mode is enabled, and the UPS has switched to Bypass Mode due to a reduction in load, THE UPS WILL NOT GO TO BATTERY MODE IN THE EVENT OF A UTILITY FAILURE. THE CONNECTED LOAD WILL BE TURNED OFF. Turning Green Mode off in configuration mode will restore normal UPS operation.

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Green Mode Setup

How to Enable or Disable Green Mode (Function Bit 2) To Enable: 1. Press the "Function/Test" and “Set/Alarm Silence" buttons at same time and hold them for one second. The unit will sound one beep and then enter the Configuration Mode. 2. Press the "Function/Test" button two times to move the dot from function BIT 0 to function BIT 2 (The Green Mode function). 3. Press the "Set/Alarm Silence" button to enable (NO DOT) BIT 7. (The reverse of other feature enable settings) 4. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm will sound one short beep to acknowledge the UPS has stored the setting. To Disable: (Factory Default) 1. Press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will sound one beep and then enter the Configuration Mode. 2. Press the "Function/Test" button two times to move the dot from function BIT 0 to function BIT 2 (Green Mode function). 3. Press the "Set/Alarm Silence" button to turn off (DOT) BIT 7. (The reverse of other feature disable settings) 4. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm buzzer will sound one short beep to acknowledge the UPS has stored the setting. How to Set the UPS Output Voltage (Function Bits 0 & 1) The SSG Series UPS is shipped configured from the factory with its output voltage set to 120Vac. For most North American applications, the UPS output voltage will not have to be changed. CAUTION: NEVER CHANGE THE UPS OUTPUT VOLTAGE WHILE IT HAS EQUIPMENT CONNECTED TO ITS OUTPUT RECEPTACLES. Make output voltage configuration changes and verify the desired output voltage is present at the UPS output using the UPS output voltage display function. Next, verify that all of the equipment to be connected to the UPS will operate satisfactorily on the newly selected output voltage. CAUTION:

When the UPS output voltage is set to 100Vac, the maximum amount of load that can be connected to the UPS must be derated (reduced) by 15%.

Output Voltage

Function BIT(s)

Status Bit (BIT 7)

120Vac 115Vac 110Vac 100Vac

BIT 0 BIT 0 BIT 0 BIT 0

For Fro For For

& & & &

BIT 1 BIT 1 BIT 1 BIT 1

BIT 0, BIT 0, BIT 0, BIT 0,

set set set set

bit 7 On (Dot), For BIT 1, set bit 7 On (Dot) (default) bit 7 Off (No Dot), For BIT 1, set bit 7 On (Dot) bit 7 On (Dot), For BIT 1, set bit 7 Off (No Dot) bit 7 Off (No Dot), For BIT 1, set bit 7 Off (No Dot) 21

Output Voltage Select Setup

Example - How to Set the UPS Output Voltage to 115Vac (-1 models) or 230Vac (-2 Models) 1. Press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will emit one alarm beep and then enter the Configuration Mode. 2. Press the "Function/Test" button eight times to move the dot to function BIT 0. 3. Press the "Set/Alarm Silence" button turn off (no dot) Status BIT 7. 4. Press the "Function/Test" button one time and move the dot to function BIT 1. 5. Press the "Set/Alarm Silence" button to turn on (dot) Status BIT 7. 6. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm buzzer will sound one short beep to acknowledge the UPS has stored the settings. 7. You must now restart the UPS before the new voltage setting will be in effect. How to Set the UPS Load Segment Control Options (Function Bits 3, 4, 5 & 6) Three conditions of automatic load segment control may be programmed for two separate output load segments. Additionally, one continuous load segment is provided. Per the model-specific rear panel pictures that follow, the two programmable and one continuous load segments are assigned to specific output receptacles located on the UPS rear panel. For each programmable load segment, the following conditional states may be selected: 1. Turn off the assigned load segment when utility power is lost (bits 3 & 5) 2. Turn off the assigned load segment whenever low battery is reached (bits 4 & 6). 3. Load segment bits are turned off making the load segment continuous. Load Segment Control Setup

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Making Load Segment Settings A. Setting load segments to automatically turn off the load segment when utility power is lost 1. Press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will emit one alarm beep and then enter the Configuration Mode. 2. Press the "Function/Test" button repeatedly and move the dot to function BIT 3 (for load segment 1), or BIT 5 (for load segment 2). 3. Press the "Set/Alarm Silence" button once to turn on (dot) Status BIT 7. 4. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm buzzer will sound one short beep to acknowledge the UPS has stored the settings. B. Setting load segments to automatically turn off the load segment at low battery 1. Press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will emit one alarm beep and then enter the Configuration Mode. 2. Press the "Function/Test" button repeatedly and move the dot to function BIT 4 (for load segment 1), or BIT 6 (for load segment 2). 3. Press the "Set/Alarm Silence" button once to turn on (dot) Status BIT 7. 4. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm buzzer will sound one short beep to acknowledge the UPS has stored the settings. C. Setting load segments for continuous mode operation 1. Press the "Function/Test" and "Set/Alarm Silence" buttons at same time and hold them for one second. The unit will emit one alarm beep and then enter the Configuration Mode. 2. Press the "Function/Test" button repeatedly and move the dot to function BIT 3 (for load segment 1), or BIT 5 (for load segment 2). 3. Press the "Set/Alarm Silence" button once to turn off (no dot) Status BIT 7. 4. Press the "Function/Test" button repeatedly and move the dot to function BIT 4 (for load segment 1), or BIT 6 (for load segment 2). 5. Press the "Set/Alarm Silence" button once to turn off (no dot) Status BIT 7. 6. Press the "Set/Alarm Silence" and "Function/Test" buttons at same time again and hold for one second. The alarm buzzer will sound one short beep to acknowledge the UPS has stored the settings.

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7.0 COMMUNICATIONS All SSG Series UPSs are provided with the following communication ports: * RS-232 port with standard DB-9F serial port connector. * USB port supporting the connection of a standard USB interface cable. * One advanced communications option slot is provided on the rear panel of the UPS. Unless an advanced communications option board has been previously purchased and installed, the port will be covered with a small cover plate. This plate will be secured with screws. CAUTION:

NEVER INSTALL OPTION CARDS THAT HAVE NOT BEEN SUPPLIED BY FALCON ELECTRIC OR ARE FOR ANOTHER FALCON MODEL WITHOUT  CONSULTING WITH FALCON SERVICE.

Advanced communications option cards available from Falcon are: Internal SNMP/HTTP Agent Board Standard Dry Contact Interface Board Note: A special external SNMP/HTTP Agent device is available that may be connected to the UPS's RS-232 port. This allows for one dry contact interface board to be installed into the Advanced Communications Option Slot concurrently. CAUTION:

When an internal SNMP/HTTP AGENT device is installed into the Advanced Communications Option Slot, the RS-232 port and UPSilon software may not be used. The USB port may be used in conjunction with UPSilon  software concurrently with the SNMP/HTTP agent.

RS-232 & USB Ports This UPS is equipped with (1) RS-232 and (1) USB port located on the UPS rear panel. A standard RS-232C interface cable is provided to allow for the connection of the UPS to another RS-232 port found on most computers. The USB port interfaces with a standard USB cable to be supplied by the end-user. The USB cable required is a - 4 Pin USB Type A (M) connector - 4 PIN USB Type B (M) connector. The USB and RS-232 ports cannot be used concurrently. When an RS-232 or USB cable has been connected, and the supplied UPSilon Computer Shutdown and Management software has been properly installed on the connected computer, a high level of UPS management and protection against lost or corrupted files is in effect. Please follow the installation and setup instructions supplied on the UPSilon software CD. The UPSilon users manual is also located on the UPSilon CD supplied with this unit. UPSilon supports most popular operating systems. Should you have special UNIX requirements, please contact Falcon Sales for information and pricing of UPSilon for UNIX.

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The supplied Falcon RS-232 interface cable pin designations are as follows:

The computer RS-232 Port settings should be set to the following:

Remote Emergency Power Off (REPO) A two-pin REPO connector is located on the rear panel of the UPS. The connector is shipped with a jumper wire installed, to facilitate the normal operation of the UPS in the event an REPO connection is not used. The REPO function provides an interface for a NFPA 70, NEC 645-11 compliant Remote Emergency Power Off (REPO) switch. The switch must have a normally-closed contact state that opens when the REPO button is depressed (REPO ACTIVE). When the REPO switch contacts are opened, which also turns the equipment room power and UPS power off, the UPS output will immediately turn off all connected loads and then will shut down within one minute. When the REPO switch contacts are closed, restoring the equipment room’s power, the UPS will restart.

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SSG2.2KRM-1 & SSG3KRM-1 Rear Panel Layout

Contact Closure Interface Card Option (New UA88374-SSG) Replaces UA88374-SSG Note: This card installs into the Communicaitons Option Slot

JUMPER SETTINGS J1 through J7 = 1-2 DB-9 configured for Green cable (Default) J1 through J7 = 2-3 DB-9 configured for standard RS-232 cable Note: J1-J7 must be all configured 1-2 or 2-3, or UPS and PC may be damaged. J9 Summery Alarm - 1-2 Normally Closed (Default), 2-3 Normally Open J10 Low Battery = 1-2 Normally Closed, 2-3 Normally Open (Default) J12 Model Selection = 1-2 XG & SSG Models, 2-3 IG & SVR-Pro-2 Models J13 On-Bypass = 1-2 Disable, 2-3 Enable (Default)

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DB-9 PIN ASSIGNMENTS 1 2 3 4 5 6 7 8 9

= Not Used = Utility Loss, Normally Open = Utility Loss, Normally Closed = Common (tied to pin 7) = Low Battery = Remote Shutdown (5-12Vdc) = Common (tied to pin 4) = Alarm / Bypass = Not Used

SSG2.2KRM-HW & SSG3KRM-HW Rear Panel Layout

OUTPUT WIRING DETAILS LS1 Line

GND

LS1 Neutral

LS2 Line

27

LS2 Neutral

8.0 MAINTENANCE All SSG Series UPS requires very little maintenance. The batteries are located inside user replaceable packs containing (4) CSB XTV1272 or equivalent, sealed, VRLA, maintenance-free,lead-acid batteries. Batteries must be kept recharged to prevent excessive self-discharging, which may result in their premature failure. The UPS will continuously recharge the batteries when plugged in and turned on. 1. The UPS and Battery Care Keep the area around the UPS clean and dust free. If the area around the UPS becomes very dusty, clean the area and the UPS with a vacuum cleaner. To assure the full 3-5 year battery life, keep the UPS at an ambient temperature of 25ºC (77ºF). 2. Storing the UPS and Batteries When storing the UPS for any length of time, it is recommended to plug and turn on the UPS for at least 24 hours, every four to six months to ensure full recharging of the batteries. This will prevent excessive battery self-discharge. 3. When to Replace Batteries We suggest the battery pack(s) containing 10-12 year batteries, have the batteries replaced every 810 years for SSG units that are operated and maintained in a 25ºC environment. Higher temperature operating environments will decrease the battery life. For 10-12 year batteries installed in a 50ºC enviroments, they will need to be replaced about every four years. In order to assure the performance of the SSG Series UPS, check the battery every two to three months by pressing "Function/Test" button and conducting a battery test. If the UPS goes back to normal On-line Mode in less than 10 seconds with one long beep, the batteries need replacing. Contact Falcon Electric Service Department to order replacement battery packs. 4. Battery Pack Replacement With the hot-swappable battery pack feature, the SSG Series UPS battery pack is easily replaced, without having to turn the UPS off or disconnecting the load. Refer to the battery replacement section of this manual for replacement instructions.

NOTE! NEVER ATTEMPT TO DISCONNECT THE BATTERIES OR REMOVE THE  BATTERY FUSE OR TURN OFF THE BATTERY DISCONNECT WHILE THE UPS IS IN BATTERY MODE.

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SSG1.5KRM-X Internal Battery Pack Replacement

1. 2. 3. 4. 5.

6. 7. 8. 9.

Loosen and remove the screws on the left hand front panel. Remove the panel from the unit. Lay the panel aside for reassembly. Loosen and remove the screws of battery stop plate. Lay them aside for reassembly. Grasp the battery pack, and pull it out of the front of the unit. Mark the top of the pack. Unpack the new battery pack. Take care not to destroy the packaging. Compare new and old battery packs and verify that they are the same type. If so, proceed with the next step, otherwise stop and contact Falcon Service. Line up and slide in the new replacement battery pack in the correct orientation, by referring to the mark on the original battery pack. Gently push the battery pack back into the cabinet. Ensure it is tightly seated into the unit. Reinstall the battery stop plate with the screws originally removed. Reinstall the front panel to the unit with the screws originally removed.

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SSG2.2KRM-X, SSG3KRM-X Standard and SSGR, SSGR-1 Extended Battery Module

Replacements 1. To replace the battery packs inside an extended battery module, unplug the connected battery cable from UPS and battery module. 2. Loosen and remove the screws from the battery module front panels. Remove both front panels from the module as shown above. 3. Lay the panels and screws aside for reassembly. 4. Loosen and remove the screws of battery stop plates. Lay them aside for reassembly. 5. Grasp the battery pack(s), and pull them out of the front of each side of the module. Mark the top of each pack. 6. Unpack the new battery packs. Taking care not to destroy the packing. Compare new and old battery packs to verify that they are same type. If so, proceed with next the step, otherwise stop and contact Falcon Service. 7. Line up and slide in the new replacement battery packs with right polarity by verifying against the marked battery pack. 8. Reinstall the battery stop plates with the screws previously removed. 9. Reinstall the front panels to the unit with the screws previously removed. 10. Re-connect the cable to the battery connector of UPS to that of the module. Performing a Manual Battery Test Pressing the "Function/Test" button for three seconds while the UPS is operating in Normal Mode will initiate a manual battery test. If the UPS goes to Battery Mode and returns to Normal On-line Mode after 10 seconds, the batteries are good. If a single, long audible tone is sounded and the unit does not switch to Battery Mode, this indicates that either the batteries are defective, installed incorrectly, the battery pack is not installed, the battery bank interconnect cable is not installed, or the battery fuse is missing or defective. If the problem cannot be resolved, contact Falcon Service. 30

Battery Module Installation: 1. Mount the battery module directly above or below the UPS or battery module in the equipment rack. 2. Verify the battery disconnect is in the off postion. 3. Remove the battery inteconnect connector cover plate located on the module rear panel. 4. Connect the battery cable to the newly installed battery module. Next, connect the other end of the cable to the UPS. 5. If the an extended module is being installed, verify all battery module battery disconnect switches are turned to the “off” position. Two battery interconnect connectors are provided on each battery module to allow for a daisy chain connection to all modules and the UPS. Performing a Manual Battery Test: Pressing the "Function/Test" button for three seconds while the UPS is operating in Normal Mode will initiate a manual battery test. If the UPS goes to Battery Mode and returns to Normal On-line Mode after 10 seconds, the batteries are good. If a single, long audible tone is sounded and the unit does not switch to battery mode, this indicates that either the batteries are defective, installed incorrectly, the battery pack is not installed, the battery bank interconnect cable is not installed, or the battery doscpnnect(s) are not in the “on” position. If the problem cannot be resolved, contact Falcon Service.

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Recycling the Used Battery Packs NEVER discard the UPS, the UPS battery pack, or batteries in the trash. Contact your local recycling or hazardous waste center for information on proper disposal of the used battery pack and batteries. The entire spent battery packs may be returned to the Falcon Service Center at the end user’s expense for recycling. Prior to returning the spent battery pack(s), please call the Falcon Service Center and obtain a Return Materials Authorization (RMA) number. NEVER dispose of batteries in a fire, as batteries will explode. NEVER dispose of used batteries or the UPS in the trash or a landfill as it is a violation of federal and state laws. The UPS and batteries must be recycled. For UPS and battery recycling information, please contact Falcon Service for the name and address of the nearest battery recycling facility. NEVER open or mutilate the battery or batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. A battery can present a risk of electrical shock and burns due to high short circuit current.

CAUTION Observe all warnings, cautions, and notes before replacing batteries. Batteries can present a risk of electrical shock and burns due to high short circuit current. The following precautions should be observed when working on batteries: * * * * * *

Remove watches, rings, and other metal objects. Use tools with insulated handles. Do not lay tools or metal parts on top of batteries. Do not attempt to alter any battery wiring or connectors. Attempting to alter wiring can cause injury. Do not dispose of batteries in a fire. The batteries may explode. Refer to your local codes for disposal requirements. Do not open or mutilate the battery packs or batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic.

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9.0 TROUBLESHOOTING Audible Alarms The SSG Series UPS features audible alarm codes to alert the user of potential problems. Please refer to the following table to identify and resolve alarms and the conditions causing the alarms.

33

UPS Alarm Status Display Upon the UPS sounding a continious alarm condition, the alarm status bit will be displayed on the LCD display located on the UPS front panel. Please note the status bit number displayed and contact the Falcon service department immedately. To assist please inform them of the bit(s) displayed.

BIT 0 ;DC BUS voltage over high flag BIT 1 ;soft start fault flag BIT 2 ;inverter voltage over high flag BIT 3 ;inverter voltage over low flag BIT 4 ;output current over high flag BIT 5 ;battery voltage over high flag BIT 6 ;low DC bus voltage flag BIT 7 ;inverter voltage feedback error flag

Warning: Upon experiancing errors Bit, 0, Bit 1, Bit, 2, Bit 3, Bit 6 and Bit 7 errors the UPS must be immediately turned off and the Falcon service department contacted. Attempting to turn the UPS back on may result in furter damage to its internal electronics.

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Troubleshooting Guide Prior to attempting any troubleshooting, always verify the UPS battery fuse is installed and the input voltage, input plug and wiring are correct. Please refer to the table below and attempt to solve the problem prior to contacting Falcon Service.

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FCC Considerations Note:

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: * * * *

Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/TV technician for help.

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10.0 Technical Support In the event your SSG Series UPS requires service or should any other technical support be required, write, call, fax or email Falcon Service. Falcon Electric Inc. 5106 Azusa Canyon Road Irwindale, CA. 91706 Service 800.842.6940 Voice 626.962.7770 Fax 626.962.7720 Email: [email protected] WWW.FALCONUPS.COM

Please have your UPS model, serial number and date of purchase on hand prior to your call. This information is located on the identification label on the rear panel of the UPS. This information is essential in retrieving your unit’s historical records. Should our service department determine service is required, you will be given a Return Material Authorization number (RMA) along with return shipping instructions. The RMA number issued must appear on the outside of the shipping carton. The original shipping container must be used when returning any SSG Series product. Failure to use the original shipping container and packing materials will likely result in the unit being received by Falcon with shipping damage. Falcon® Electric will not assume any responsibility for shipping damage. In the event shipping damage is found, you will be notified of the damage and be instructed to file a claim with the freight carrier. You will be billed for all required repairs due to the shipping damage. You must submit a copy of our repair invoice to the carrier for reimbursement. All units must be returned prepaid. The address and shipping instructions will be given to you at the time the RMA is issued. Requesting Technical Information or Support You may request technical information or support by email or telephone. Please send your technical or support questions by email to: [email protected] You may contact a FALCON support engineer directly by calling the FALCON support line between 9:00 am and 4:00 pm PST. 800.842.6940 FALCON Web Support Product data sheets, specifications and owner’s manuals are available in Adobe® Acrobat .PDF format on our corporate website at: WWW.FALCONUPS.COM

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FALCON ELECTRIC, INC. NEW PRODUCT LIMITED WARRANTY Limited Warranty: Falcon warrants that this product will be free from defects in materials and workmanship for a period of two years from the date of shipment by Falcon. Procedures: Any defective product must be returned to Falcon. No product can be returned without first obtaining a Return Material Authorization (RMA) number from Falcon. Falcon will repair, replace or refund the purchaser price, at Falcon’s sole discretion, for any defective product that is returned to Falcon with an RMA number. For defective product returned within 30 days of shipment, Falcon will pay for shipping costs to and from its service center. For defective product returned after 30 days but within 90 days of shipment, Falcon will only pay for shipping costs in sending the new or repaired product back to the end-user. For defective product returned more than 90 days after shipment, all shipping costs will be borne by the end-user. Exclusions: This limited warranty does not cover damage caused by: (i) improper installation, misuse or neglect; (ii) unauthorized repairs or modifications or use of unauthorized parts; (iii) acts or events outside of Falcon’s control, such as fire, accidents, impacts; (iv) normal wear and tear, such as cleaning and replacement of batteries. The warranty is null and void if: (i) the product is used in conjunction with life support equipment; (ii) the factory seal is broken or shows signs of tampering; or (iii) the battery is allowed to discharge below the minimum battery cutoff point. To prevent this discharge, remove the battery fuse, or switch the battery disconnect to the “off” position when the unit is to be stored without the AC power being supplied to the UPS for more than two days. The battery must be recharged every four to six months when not in use. This limited warranty is not transferable. Limitations: IN NO EVENT IS FALCON RESPONSIBLE FOR ANY SPECIAL, INDIRECT, SECONDARY OR CONSEQUENTIAL DAMAGES, SUCH AS PERSONAL INJURY, DAMAGE TO PROPERTY, LOSS OF DATA, LOST PROFITS, ETC. IN NO EVENT WILL FALCON’S LIABILITY UNDER THIS LIMITED WARRANTY EXCEED THE PURCHASE PRICE PAID FOR THE PRODUCT IN QUESTION. Disclaimers: The limited warranties set forth in this document are the only warranties that apply to Falcon’s products. ALL OTHER WARRANTIES ARE EXPRESSLY DISCLAIMED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY HAVE OTHER LEGAL RIGHTS THAT VARY FROM STATE TO STATE. 2007-04 Rev. C

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SSG SeriesTM Industrial-Grade UPS PLUS® Model Number

SSG1.5KRM-1 SSG1.5KRM-2 1500

Nominal VA Electrical Input

1.5kVA - 3kVA

SSG2.2KRM-1 SSG2.2KRM-2 2200

Nominal AC Voltage

SSG3KRM-1 SSG3KRM-2 3000

-1 Models 120Vac -2 Models 208-240Vac -1 Models 80-138Vac -2 Models 160-276Vac 50/60 Hz ± 5% (Auto Tracking) > 0.97 (at full load) IEEE/ANSI C62.41

AC Voltage Range Frequency Power Factor Correction Surge Suppression Efficiency (Typ.)

> 87%

Electrical Output Watts AC Voltage

1050 (User Programmable)

Frequency Frequency Stability

1540 -1 Models = 100, 110, 115 or 120Vac (sinewave) -2 Models = 208, 220, 230 or 240Vac (sinewave) 50/60 Hz (Auto Tracking or user programmable fixed 50 or 60Hz modes)

2100

± 0.3% (Battery Mode), ±5% Synchronized to the input frequency in utility mode ± 2% ± 7% for 100% load variation, recovery in 5ms < 3% Linear Load, < 5% Non-Linear Load

Voltage Regulation Step Load Change Harmonic Distortion Overload Crest Ratio Battery

150% for 10 seconds, 110% for 20 seconds, 105% for 50 seconds 3:1

DC Bus Voltage (nominal) Battery Pack Type

48Vdc

Battery Type (With standard VRLA Type) SSGLi-4 Ten-Year Lithium-Ion Battery Option Back Up Time (With standard VRLA Type) SSGLi-4 Ten-Year Lithium-Ion Battery Option SSGLi-8 2U External Lithium-Ion Bank

96Vdc User-Replaceable, Hot-Swappable (Batteries are replaceable through the front panel) (Battery packs are replaceable through the front panel without removing the UPS, battery bank or EBM from the equipment rack) 10-Year Rated, VRLA Batteries, 12Vdc, 7AH 10-Year Rated, Maintenance-Free, Sealed VRLA Batteries, 12Vdc, 7AH (4) 10-Year Rated, Lithium-Ion 12Vdc, 4.6AH N/A 5 minutes / 16 minutes 9.5 minutes / 20 minutes 28.5 minutes / 60 minutes

Recharge Time Transfer Time

8 minutes / 20 minutes N/A N/A

6 minutes / 18 minutes N/A N/A

8 Hours to 90%

Line Fails/Recovers UPS to Bypass or Reverse After Overload With Frequency Converter Options Electrical Connections Input

Zero < 4ms Auto Transfer to UPS Bypass Disabled -1 Models = 6’ Cord with 5-15P Plug -2 Models = 6’ Cord with Schuko Plug (8) 5-15R (4) IEC320

Output

-1 Models = 6’ Cord with 5-20P Plug -2 Models = 6’ Cord with Schuko Plug (4) 5-15R & (1) L5-20R (4) IEC320

-1 Models = 6’ Cord with L5-30P Plug -2 Models = 6’ Cord with Schuko Plug (4) 5-15R & (1) L5-30R (4) IEC320

Environmental Temperature

Operational Storage

-20ºC - 55ºC (-4ºF to 131ºF) (Extended operation in temperatures above 25ºC will shorten the battery life) -15ºC - 50ºC (5ºF to 122ºF) (Extended storage in temperatures above 25ºC will shorten the battery life)

Humidity Altitude

10% to 95% Non – Condensing 10,000 Feet (3000 meters) without derating

Cooling Heat Dissipation Audible Noise Controls & Indicators

(BTU/Hour) (@ 1 Meter)

LCD Display Audible Alarms Load Segment Control Remote Emergency Power Off (or) Remote Output Receptacle Control Communications Mechanical Dimensions HxWxD SSGH-B Battery Module

inches (mm)

Weight lb. (kg) Ten-Year VRLA Batteries (Standard) SSGLi-4 Ten-Year Lithium-Ion Battery Option SSGLi-8 2U Lithium-Ion Extended Bank Agency Approvals

Low Velocity Forced Air Fans 784 0.97 IEEE/ANSI C62.41 > 87%

AC Voltage Range Frequency Power Factor Correction Surge Suppression Efficiency (Typical) Electrical Output Watts AC Voltage

1540 (User Programmable)

Frequency Frequency Stability Voltage Regulation Step Load Change Harmonic Distortion

2100 -1 Models = 100, 110, 115 or 120Vac (sinewave) -2 Models = 208, 220, 230, 240Vac (Sinewave)

50/60 Hz (Auto Tracking or user programmable fixed 50 or 60Hz modes) ± 0.3% (Battery Mode), ±5% Synchronized to the input frequency in utility mode Voltage Regulation ± 7% for 100% load variation, recovery in 5ms < 3% Linear Load, < 5% Non-Linear Load

Overload Crest Ratio

150% for 10 seconds, 110% for 20 seconds, 105% for 50 seconds 3:1

Battery DC Bus Voltage Back Up Time

96Vdc @Full Load @1/2 Load

Battery Pack Type

8 minutes 20 minutes

6 minutes 18 minutes

User-Replaceable, Hot-Swappable individual 48Vdc packs Battery packs are replaceable through the front panel without removing the UPS, battery bank or EBM from the rack Long-life, 8 to 10 Year, Maintenance-Free, Sealed VRLA Batteries, 12Vdc, 7AH

Number of Battery Packs (48Vdc)

(2)

Recharge Time

8 Hours to 90%

Transfer Time Line Fails/Recovers UPS to Bypass or Reverse After Overload

Zero < 4ms Auto Transfer to UPS

With Frequency Converter Options Electrical Connections Input

Environmental Temperature

Bypass Disabled

-1 Models = 6’ line cord with 5-20P -1 Models = 6’ line cord with L5-30P -2 Models = 6’ line cord with Schuko -2 Models = 6’ line cord with Schuko The plug may be removed and cord used to hardwire The plug may be removed and cord used to hardwire Hardwire Terminal Block

Output

Humidity

-20ºC to +40º C (-4ºF to 104ºF) -15ºC to +50ºC (5ºF to 122ºF) 10% to 95% Non – Condensing

Altitude

Operational Storage

10,000 Feet (3000 meters) without derating

Cooling Heat Dissipation Audible Noise

Low Velocity Forced Air Fans (BTU/Hour) @ 1 Meter

Controls & Indicators LCD Display Audible Alarms

Communications Mechanical Dimensions UPS HxWxD

lb. (kg)

Agency Listing

784

1071 0.97 (at full load) IEEE/ANSI C62.41

AC Voltage Range Frequency Power Factor Correction Surge Suppression Efficiency (Typ.)

> 87%

Electrical Output Watts AC Voltage

1050 (User Programmable)

Frequency Frequency Stability

1540 -1 Models = 100, 110, 115 or 120Vac (sinewave) -2 Models = 208, 220, 230 or 240Vac (sinewave) 50/60 Hz (Auto Tracking or user programmable fixed 50 or 60Hz modes)

2100

± 0.3% (Battery Mode), ±5% Synchronized to the input frequency in utility mode ± 2% ± 7% for 100% load variation, recovery in 5ms < 3% Linear Load, < 5% Non-Linear Load

Voltage Regulation Step Load Change Harmonic Distortion Overload Crest Ratio Battery

150% for 10 seconds, 110% for 20 seconds, 105% for 50 seconds 3:1

DC Bus Voltage (nominal) Battery Pack Type

48Vdc

Battery Type (With standard VRLA Type) SSGLi-4 Ten-Year Lithium-Ion Battery Option Back Up Time (With standard VRLA Type) SSGLi-4 Ten-Year Lithium-Ion Battery Option SSGLi-8 2U External Lithium-Ion Bank

96Vdc User-Replaceable, Hot-Swappable (Batteries are replaceable through the front panel) (Battery packs are replaceable through the front panel without removing the UPS, battery bank or EBM from the equipment rack) 10-Year Rated, VRLA Batteries, 12Vdc, 7AH 10-Year Rated, Maintenance-Free, Sealed VRLA Batteries, 12Vdc, 7AH (4) 10-Year Rated, Lithium-Ion 12Vdc, 4.6AH N/A 5 minutes / 16 minutes 9.5 minutes / 20 minutes 28.5 minutes / 60 minutes

Recharge Time Transfer Time

8 minutes / 20 minutes N/A N/A

6 minutes / 18 minutes N/A N/A

8 Hours to 90%

Line Fails/Recovers UPS to Bypass or Reverse After Overload With Frequency Converter Options Electrical Connections Input

Zero < 4ms Auto Transfer to UPS Bypass Disabled -1 Models = 6’ Cord with 5-15P Plug -2 Models = 6’ Cord with Schuko Plug (8) 5-15R (4) IEC320

Output

-1 Models = 6’ Cord with 5-20P Plug -2 Models = 6’ Cord with Schuko Plug (4) 5-15R & (1) L5-20R (4) IEC320

-1 Models = 6’ Cord with L5-30P Plug -2 Models = 6’ Cord with Schuko Plug (4) 5-15R & (1) L5-30R (4) IEC320

Environmental Temperature

Operational Storage

-20ºC - 55ºC (-4ºF to 131ºF) (Extended operation in temperatures above 25ºC will shorten the battery life) -15ºC - 50ºC (5ºF to 122ºF) (Extended storage in temperatures above 25ºC will shorten the battery life)

Humidity Altitude

10% to 95% Non – Condensing 10,000 Feet (3000 meters) without derating

Cooling Heat Dissipation Audible Noise Controls & Indicators

(BTU/Hour) (@ 1 Meter)

LCD Display Audible Alarms Load Segment Control Remote Emergency Power Off (or) Remote Output Receptacle Control Communications Mechanical Dimensions HxWxD SSGH-B Battery Module

inches (mm)

Weight lb. (kg) Ten-Year VRLA Batteries (Standard) SSGLi-4 Ten-Year Lithium-Ion Battery Option SSGLi-8 2U Lithium-Ion Extended Bank Agency Approvals

Low Velocity Forced Air Fans 784