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HomeMy WebLinkAboutChester Lake O and M Manual 1988-.. SECTION NUMBER I II III IV v VI TABLE OF CONTENTS CIVIL FEATURES . .OPERATION , ME~HANICAL SYSTEMS ELECTRICAL SYSTEMS BUILDING SYSTEMS CONTRACT SPECIFICATIONS '," '' CONTRACT D~~INGS 'I OPERATIONS MANUAL CHESTER LAKE HYDROPOWER STATION CIVIL CONTRACT CL02 CIVIL CONTRACT FEATURES civil features constructed under the Civil Contract for the Chester Lake Hydropower Station include the lower Penstock, the Pumping System, and the Valve Vault. The Penstock brings water from the dam to the turbine located in the powerhouse andjor the water treatment plant located adjacent to the powerhouse. The Pumping System pumps water from the turbine tailrace to the water treatment plant. The Valve Vault houses 'the valves regulating flows entering. the water treatment plant. The civil features described in this manual are depicted on Drawings Cl through C23 of the Chester Lake Hydropower station "Record Drawings". Specific operation and maintenance items for each of these features are discussed in the following three sections. -1- ( 1.0 PENSTOCK FEATURES The Penstock carries water from the dam, elevation 855 feet, to the turbine, centerline elevation 33 feet, located in the powerhouse. The 3 1 521 foot long penstock is 2 0 inches in diameter. The lower 273 feet of penstock was constructed under this contract. The upper 3 1 248 feet of penstock was previously constructed at the same time the dam was built in 1986. Water from Chester Lake passes through a trashrack located in the face of the dam prior to entering the penstock. A 20-inch butterfly valve is located 108 feet downstream of the dam. A 4-inch pipe with a 4-inch gate valve is located 3 1 466 feet downstream of the dam at the low point on the penstock, 55 feet from the powerhouse. A 12-inch pipe with a 12-inch butterfly valve tees off the penstock 28 feet from the powerhouse. The 12~inch pipe provides water directly to the water treatment plant via ~he Valve Vault. 1 . 1 TRASHRACK The trashrack has 1/4-inch bars spaced (center to center) to prevent entry of penstock which could damage the turbine. at 1 1/4 inches debris into the The rack should be checked for a build up of debris annually or if a noticeable drop in pressure or flow indicates a flow restriction. Significant buildup of debris is not expected on the trashrack based on past operation of the water supply system from Chester Lake. However, if debris becomes a frequent problem at the trashrack, then a trashrake suitable for the bar spacing of the rack should be constructed and used to regularly clean debris from the rack. Any debris removed from the rack should be removed to the downstream side of the dam. l---~-----2-_______ j ( 1.2 20-INCH BUTTERFLY VALVE The 20-inch butterfly valve requires eithe'r a h~~dwheel or large crescent wrench to operate . it. The valve is useful for isolating the penstock for dewatering arid t6r filling the . ··- penstock upon return to operation. This valve must always remain in the full open _position during normal operation of the penstock. During filling of the penstock the valve must be opened 12 turns for 20 minutes allowing water to slowly fill the pipe to prevent potentially damaging surge pressures. This valve can be used to stop flow to either the turbine or the water treatment plant in the event of an emergency. The valve should only be used to stop flow if both the turbine needle valves and the turbine ball valve are inoperable. 1.3 4-INCH DRAIN The 4-inch gate valve allows draining of the penstock, as well as flushing of any debris accumulated at_the low point. This valve should be operated slowly to avoid the potential for damaging surge pressures. When flushing debris, open the valve completely to prevent jamming of the valve by debris. 1.4 12-INCH BUTTERFLY VALVE The 12-inch butterfly valve allows isolation of the 12-inch pipe and valve vault from the penstock. The 12-inch pipe allows water to travel to the water treatment plant without passing through the turbine and pumping system. Water will flow through the 12-inch water line to the treatment plant whenever sufficient water is not flowing through the turbine and pump to the water treatment plant. Therefore, this valve must always remain in the full open position during normal operation of the water treatment plant. L -3-l ---------------------------~-·~--~~---_) ( 2.0 PUMP SYSTEM FEATURES The Pumping System lifts water from a wetwell connected directly to the turbine tailrace and delivers water to the water treatment plant via an a-inch pipe running through the Valve vault. An a-inch check valve is located immediately downstream of the pump. 2.1 VERTICAL TURBINE PUMP The vertical turbine pump is capable of pumping 1.45 cfs (650 gpm) at 2a5 feet (123 psi) to the water treatment plant. The pump is driven by a 60 HP electric motor. The pump has a basket strainer on the bellmouth suction intake located in the wetwell. This basket protects the pump impellers from damaging debris and may become plugged if a build up of debris occurs on the basket. The basket should be checked ·monthly for (!ebris buildup or any time a buildup of debris is suspected since this will directly impact the performance and power requirements of the pump. Routine maintenance of the pump is required as indicated in this manual. 2.2 8-INCH CHECK VALVE The a-inch check valve prevents damaging reverse flow of water through the pump. This valve is self actuating and need only be maintained as indicated in this manual. -4- 3.0 VALVE VAULT FEATURES Piping from both the Penstock and .the P~mping, sy~S?tem enter the Valve Vault prior to enter.ing th~ .w.ater t,reatment plant. The vault houses 3 wye strainers., a.6-inch pressure reducing valve, and associated valving. 3.1 8-INCH WYE STRAINERS Three wye strainers are located in the vault. These strainers prevent any small debris from entering into the water treatment plant. Two of the strainers serve the incoming 12-inch line from the penstock, and one serves the incoming 8-inch line from the vertical turbine pump. The two parallel strainers serving the 12-inch pipe are set in this configuration so that one will remain operable even if the other is plugged by debris. Both of the butterfly valves serving each of these strainers must remain i~ the full open position during operation of the water treatment plant. -The strainer serving the a-inch line has only one butterfly valve serving it, this valve must also remain in the full position during operation of the water treatment plant. open Each wye strainer can be blown clean by opening the 2-inch. gate valve serving it. If a wye strainer cannot be cleaned by this method, then the strainer basket should be removed after the wye strainer has been isolated using the adjacent butterfly valve(s). 3.2 8-INCH BUTTERFLY VALVES There are five 8-inch butterfly valves located in the valve vault. These valves are useful for isolating the individual wye strainers for removal and cleaning of the basket strainers if the strainers can not be cleaned via the 2-inch blowoff lines. The a-inch butterfly valves should not be used to regulate flow. If removal of a basket strainer is required during flow of water to the treatment plant, then -5- valves must be closed slowly to avoid potentially damaging surge pressures. Closure of butterfly valves to isolate only one· wye str.:iirl:er at a time can be performed on the parallel wye strainers during operation of the water treatment plant. 3.3 2-INCH GATE VALVES There are three 2-inch gate valves located in the valve vault, one serving each wye strainer. These valves allow the wye strainers to be blown clean during the flow of water to the treatment plant. To blow the wye strainers clean, slowly open the 2-inch gate valve, one at a time, not simultaneously, to the full open position and allow water to discharge for a full minute. Slowly close the valve after blowoff. 3.4 6-INCH PRESSURE REDUCING VALVE There is one 6-inch pressure reducing valve in the valve vault. This valve reduces the approximately 800 feet {350 psi) of dynamic head in the 12-inch line from the penstock to an acceptable 277 feet (120 psi) of head for delivery of water to the water treatment plant. This valve must be set in the field according to the manufacturers recommendations and should be checked monthly to ensure that only 120 psi is present on the downstream side of the valve. If servicing of the pressure reducing valve becomes neces- sary, then the valve can be isolated by closing two upstream butterfly valves, one on each wye strainer, and the down- stream a-inch gate valve. When the pressure reducing valve is isolated in this way the only source of water for the water treatment plant is from the pumping system located in the powerhouse. If either the turbine or the pump is not operating, then no water is available for supply to the water treatment plant. l __ ·---6-___ ) The isolating valves must not be used to regulate flow through the pressure reducing valve. The isolation valves must remain in the full open position during operation of the water treatment plant. 3.5 8-INCH GATE VALVE There is one a-inch gate valve located in the valve vault. This valve is useful for isolating the pressure reducing valve from the water treatment plant. This valve must remain in the full open position whenever water is flowing to the water treatment plant in the 12-inch pipe directly from the penstock. -7- .. ~ _ .... t . ~ ·~ .. .... . .. ' .. ' .. . 1 .... -:o~ t- r ~ t"< d ; ... : .. ~ """ t• ' .. ~.(~. • • ··..lr.l " • .. I ~ "" ~ c American Mechanical Inc. P.O. Box 72991 • Fairbanks. ,-\Iaska 99707 • (907) 479-5754 Operation & Maintenance Information for Chester Lake Hydroelectric Project • License :--.:o. A-11468 • Chester Lake Hvdropower Project Metlakatla, AK. Item ~o. ---- 1. '1 ... 3. 4. s. 6. 7. 8. 9. 10. 11. 12. Operation & Maintenance Information Index Description Gate Valves Strainers Butterfly Valve Check Valve Vertical Turbine Water Resupply Pump Link Seal and Wall Sleeve Ventilator Pipe Certification Shop Drawings Thermostat Ventilator Fan Pressure Reducing Valve .~ • I OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 l. 2. 3 • 4. 5. 6. 7 • Item No. Specification Paragraph Drawing No. Name of Article Manufacturer Size, Capacity or Rating Catalog No. one 15001 page 5 C-9, C-19 Gate valve Grinnell 2". 4", 8" Fig. 6100A 8. Spare Parts are Available from Western Utilities 9. Guarantee to be Provided by Contractor Subcontractor Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone Name Address Phone 907-479-5754 ( ITT GRINNELL ITT Bronze & Iron Valves Catalog CBIV-84 ITT GRINNELL Figure No. 6100A 250# Iron Wedge Gate Valve, 2"-12" 250 PSI Saturated Steam, 500 PSI Non-Shock Cold Water, Oil, or Gas Bolted Bonnet • Outside Screw and Yoke • Solid Wedge Conforms to Federal Specification: WW-V-58 Class 2, Type I & MSS SP-70 21 /a 9 1/2 3 11 1/e 4 12 5 15 6 151/e 8 161/z ;,:~-18 ~~~ ;~ --~~~ -'?! ·,J; -•';># . _..,.( -·'1' .. :1 ... -~ t4 -~ 34 187 /u 8 7'1: 20'12 10 81{4 27 12 10 31 1/z 12 11 33 16 121/z 45 1 12 16 15 56 20 17'/z 55.0 75.0 1'ie 119.0 ·-.:,: 1'/• 192.0 . ·i P/e 295.0 j • 411.0 I "\ : i ~ .. -·~ ,. 'f .• ., ' ~ ;; ., ·; ·.· •! .. ·.· 1.3 DETAILED DESCRIPTION The gate valves listed above and covered in these instructions are ductile iron, cast iron, ductile iron, alloy iron, bolted bonnet, outside screw and yoke - rising stem and inside screw -non rising stem valve types. The valve is operated with the handwheel and is used to start or stop the flow of fluids in piping system. Clockwise rotation of the handwheel closes the valve. The body and bonnet are bolted together with bolts and nuts; and the joint is sealed with a non-asbestos gasket. Flow through the valve is stopped by forcing the wedge down between the seat rings which are screwed into the body. The wedge is the solid type and is guided through its entire travel by guides in the body. The head of the stem screws into the wedge and these are prevented from unscrew- ing with a wedge pin. In sizes 14"-24" some designs have an interlocking type stem-wedge connection. This is shown in the appropriate catalog for the specific valve. The stuffing box is formed by the circular space between the stem ~~d bonnet and is filled with non-asbestos packing. The packing is compressed in the stuffing box by the pack gland bushing and packing gland follower, which are drawn do~~ against the packing by two gland bolts and nuts. The stem threads engage the yoke bushing which is held in the top of the bonnet yoke by the bonnet cap in rising stem O.S.&Y. valves.------ In non-rising stem valves the stem is one piece but has a shoulder on it of a larger diameter than the operating diameter. This shoulder is held in a pocket in the bonnet when the stuffing box is placed in on top of it. The stem is ,_ operated by the turning of the handwheel. The threads on the bottom of the stem engage the threads inside the wedge raising it up and down when the stem is turned. The handwheel fits onto the hex end of the yoke bushing on the rising stem valves. The handwheel is held on by the handwheel nut which is threaded onto the yoke bush- ing. For non-rising stem valves, the handwheels fit onto a tapered squa~ end of the stem. The handwheel is held on by a bolt screwed into the end of the stem. 88.140-4 ~ J l I I ~ ~ j 1 ' ~ ~ ~ ~ 4 ' .-~ -~ h ~ -• . ~ ~ ~ • 2.0 INSTALLATION c--2.1 PRELIMINARY INFORMATION c (_ The gate valves should preferably be installed with the stem pointed vertically upward. However, it is normally acceptable to have the valve stem pointed in a horizontal position either in vertical or horizontal piping. Although a gate valve will function satisfactorily in an inverted position it is not qenerally recommended because it allows fluids to become trapped in the bonnet cavity resulting in contami- nation and inability to fully drain the system. Valves are shipped in the closed position to prevent damage to the seating surfaces. There is no internal blocking used for shipment. 2.2 HANDLING AND INSTALLATION Each valve should be handled only with apparatus that will safely support the valve weight. Slings should never be placed around the handwheel, stem, or gland adjustment parts. First raise the valve to the vertical position and block it. Reposition the slings and lift the valve vertically. Remove the expendable end protectors if present and install the valve according to the piping layout. For installation of valves into pipelines, flange bolting~gaskets, are governed by the applicable code for pipeline specification. While the valve is being installed, it shou~d be kept in the closed position, and care should be taken to prevent foreign material from entering the valve. For flange bolting data, refer to appendix. After installation and during system testing, the gland nuts should be tightened uniformly, if necessary, until leakage through the packing is stopped. Tighten the nuts just enough to prevent leakage. Excessive tightening may cause diffi- cult operation of the valve, damage the stem, and shorten packing life. 98.140-S CAUTION Care should be taken during handling, installation, and operation to prevent damage to valve seating surfaces. ,I . , ~ ' - ' - .•, . 3.0 OPERATION Gate valves should never be used for throttling purposes. They should be fully opened or fully closed. If the valves were only slightly opened, wire drawing and erosion of the wedge and seats would result. Valves should not be tightly backseated as line contamination over a long period of time may lock up the valve causing problems when the valve has to be closed. 88.140-6 ( ( ,. ., ,. 4 ·~ ' <· J.i ~ -~ ! , ·~ "i ... .. "' .... l ~ :-~ . , ~ j { .; :~ ·J u -·~ ·~ ·!> .i --~ ~ 11.; .-s ' { ., ::· .;r _,_ : '~ ·~ ,, ""·· ., .. t· ~ ·t~ ,. o!J .t '-\'1 .,i/: ""· ~-. ~ -·:\.: !~ ':.~ c· ( 4.0 TROUBLESHOOTING 4.1 LEAKAGE THROUGH THE BONNET JOINT 1. Remove the handwheel from the stem. 2. Mark the body -bonnet flanges with a piece of chalk so they can be matched up later. 3. Remove body-bonnet nuts and bolts. 4. Carefully remove the bonnet assembly. Be careful no to nick or scratch the wedge seats. 5. Thoroughly clean the body and bonnet surfaces. 6. Check the body and bonnet gasket surfaces for any scratches gouges or other irregularities. 7. In the event the surfaces are marred they must be filed.or machined flat again • If the damage is considerable the body or bonnet may have to be replaced. A competent valve shop or machine shop may have to be consulted or contact NIBCO Technical Services or your nearest NIBCO representative for help. In many cases it is less costly to replace the entire valve rather than have it repaired. B. With the surfaces now clean and flat again place the gasket on the body and replace the· bonnet. Be careful to use the chalk ma•ks to put everything back together the same way it came apaz-t.. Always use a : .ew clean fresh gasket. It does not pay to take a chance using the old gasket over again. - 9. Reinstall the body-bonnet nuts and bolts then carefully check to see that the body and bonnet are in the same position as when they were separated. Follow the bolt torquing procedure in the Appendix I • 10. Pressure test the valve for leakage to see if a good joint has been make. 4. 2 LEAKAGE THROUGH THE VALVE SEAT Leakage across the valve seat most of the time is generally due to foreign matter lodged in the seat. Occasionally, such foreign material can be washed away by allowing flow through the valve. In valves that are used with fluids that are contaminated and known to cause buildup a drain can be installed at the bottom of valves so the seats can then be flushed prior to closing. At times the leakage may be overcome by tightening the valve further. If the leakage persists, ~isassemble the valve and examine the seat surface on the wedge and the seat surfaces within the body. (See section 4.1) Minor scratches can be corrected by polishing the wedge face, but generally if there are deep· scratches in the body seats, the valve should be removed from the line and replaced or repaired by a competent valve shop. If the wedge does have scratches it is generally acceptable to take a piece of 400 grit sandpaper, lie it upon a flat plate, such as an inspectors table (granite slab) and slightly polish the surface of the wedge. This will remove some of the scratches and possibly reduce the amount of leakage. Critical to good valve performance is to keep the surfaces flat and not to change the angle of the wedge or body seats. 88.140-7 I . j "l . j . . 1 .,j ' ·: ' j ] < } 1 j .. j . ' .. \ ~ :~ ~ ' ., J ~ '!: .0.: t 4.3 LEAKAGE THROUGH THE STUFFING BOX Leakage through the stuffing box packing may be stopped by tightening the packing steel iron only, nuts. Excessive tightening may cause difficult operation of the valve and could cause damage to the stem or packing nut. so do not over tighten. They should be just tigh~ enough to stop the leak. If the pack gland follower has run out of travel, isolate and depressurize the valve for repacking or the addition of more packing. Repacking of valves under pressure is ~ a recommended practice. This is dangerous and could result in serious injury even if the valve appears to back-seated. Foreign matter may have accumulated on the back seat, or by accident the stem could be knocked off the back seat position thereby allowing dangerous fluids to injure maintenance personnel. Remove the handwheel, packing nuts, pack gland follower and gland to remove the old packing. If the packing is removed, discard and do not try to put it back once it has been removed. Clean the stem and examine it for damage. Rope packing is some- times spiral wound around the stem and pushed into the stuffing box. Install the new packing which may either be rope packing or cut rings. If rope is used make sure there is enough put into the packing chamber so a little bit will stick up over the top. When the packing is compressed by the gland it should then be slightly lower than the top. If rings are used, install one ring at a time with the diagonal cut in each ring being staggered 90° away from the cut in the ring below. Each ring should be firmly compressed in the stuffing box after it is placed in position before the next ring is added. Install the giarid bushing and packing nut ·nd tiqtl"ten down. The packing nut should be-tightened only enough to prevent leakage. Pressurize the valve and check the packing for leakage. Retighten as required. 6 88.140-8 . . -. ... r .. c C. 5.0 MAINTENANCE 5.1 TOOLS AND EQUIPMENT Standard wrenches and tools are suitable for servicing valves as follows: A. For removing the bonnet-body nuts and bolts a full set of 1/2" and 3/4" drive sockets is normally used or the appropriate socket that will fit the bonnet union nut. For screw in type bonnets -generally a socket wrench or open end wrench may be used if extreme caution is used. Pipe wrenches on nuts or bolts have a definite crushing action which will deform them and are not recommended. B. Standard packing tool can be used and/or a blunt hook is generally used to remove packing rings. A screwdriver to raise the packing gland if it is in the fully down position and generally combination box -open end wrenches are used to tighten the packing nuts. c. Combination oil stone and flat plate glass course with fine 400 grit sandpaper to polish the wedge. Flat plates to check high spots on flat surfaces such as bonnet, seal surface and wedge in conjunction with machinist blueing. D. Punches, hammer, pliers, files, wire brush, putty knife, chalk and other tools generally contained in a good set of mechanics tools will be needed for things like cleaning up the gasket surfaces,-removtng pins from stem-wedge connections • 6.0 SPARE PARTS Normal spare parts to be maintained on hand are listed on the NIBCO spare parts list. If the bonnet or body are damaged it is normally less expensive to remove the entire valve from the line and install a new one. When placing an order for spare parts it is necessary to give the size, the valve figure number found on the aluminum identification plate and also heat numbers, part numbers, and date code numbers which are generally cast into the valve body on its side. Designs have had modifications over the years which could render the parts useless if they are of a different configuration, so proper· identification is very important. B8.140-9 ! I . 1 7.0 MAJOR REPAIRS For other repairs or replacement not covered in the above description, contact the Technical Services Department of NIBCO INC. for special instructions. Always give the figure number and size shown on the identification plate affixed to the valve along with the general serial letter. 88.140-10 j ) ~ ~ ~ l . ~ ' ~ ' 1 ' ~-' .l ' • ; ~ ; J ~ ~ ~ . . ~ ' ~ , i ~ ~ 1 1 ~ ~ ' . ' ~ I J ! 1 & ~ i ~ . ( ~ ~ A ~ ~ ~ ~ ~ ~ APPENDIX I BODY TO BONNET BOLT INSTALLATION PROCEDURE FOR NIBCO CAST IRON, ALLOY IRON AND DUCTILE IRON VALVES The following procedure outlines the methods to be used in the assembly of and field installation of the body to bonnet bolts and nuts in order to assure the proper clamping stresses. The correct sequence and torque for tightening the body to bonnet bolts and nuts is also identified. These instructions apply for ASTM-A-307 Grade B high tensile strength bolting material used on NIBCO cast iron, alloy iron, and ductile iron bolting material used on N!BCO valve body and bonnet flange joints. 1. Visually inspect all threads and remove all foreign matter such as rust, dirt, corrosion and any lubricant. 2. Clean the body gasket and bonnet gasket seating area thoroughly. The gasket seating area must be clean prior to assembly as the area becomes_ inaccessibi~ after assembly. The area is to be cleaned with a suit~~ solvent or cleanser that will remove all dirt, grime and gasket particles. 3.0 The threads of the bolts and the surfaces under the bolt heads and nuts to be coated with an antiseize compound such as Felpro, type C5A Hi-Temp Antiseize compound or equal. The threads of the nuts should also be lubricated. Clean off excess lubricant with solvent as noted in Item 2 • 4.0 Clean off the gasket. Make sure that no foreign particles are stuck to it that might cause a leak. Make sure the gasket is the correct size. It should fit inside the bonnet-body bolt holes. 5.0 Place the bonnet in position; insert the bolts and hand tighten the nuts against the body. A minimum of 2-1/2 threads is to extend beyond each nut • 6.0 After the nuts are hand tight, follow the tightening sequence shown in the table. The sequence shown is an illustrated method only and the actual sequence is dependant upon the total number of bolts. ' 7.0 The use of an air impact device which does~ have a direct torque control is prohibited for the torquing of body to bonnet bolts. The use of a hand torque wrench, electronic torquing system or power wrench with direct torque control is recommended. If such equipment is not available, the following standard wrenches may be used: 1/2" bolts 6" wrench 5/8" bolts 12" wrench 3/4" bolts 18" wrench 7/8" bolts 24" wrench 1" bolts 36" wrench .• . ·> IRON VALVE BOLT TORQL~ Before tightening make sure all surfaces that the fastener will contact are clean ana dry. The torque tightening table listed below applies to clean, undamaged, well lubricated threaded fasteners. When tightening use the sequence chart below. Tighten in two steps. 1. Tighten fastener using about 1/2 the final torque figure. 2. Final tighten using the full torque figure. ASTM A-307 Grade-"B" only. Fastener Size 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 Torque in Ft. Lbs. 47 69 103 145 234 372 551 872 1211 1624 1943 BOLT TIGHTENING SEQUENCE LARGE VALVES SMALL VALVES ' f . I 5 It;. \ 9 '/ II /)\- /13 ~ \ I : J-+ !-I + . . ~5 ~t \':):_4 2. 6 3---:"-a \4-/ ';( I l' \-\' 12 Ia If.:. 6 G 2---1----+--+-- 3 4-2. ( ( i ' OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 1. ') .... 3. 4. 5 • 6. Item No. Specification Paragraph Drawing ~o. Name of Article Manufacturer Size. Capacity or Rating two 15001 page 4 C-19 "Y" Strainer Mueller Steam Specialty 8" 7. Catalog No. Muessco No. 752M 8. Spare Parts are Available from Western Utilities 9. Guarantee to be Provided by Contractor Subcontractor Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone Name Address Phone 907-479-5754 ~ • i II ~ l -) CAt)f lMUl\i fLi-\:\il'i::U IIY" TYPE SlHAINERS SE~VICE PECOMMENOATIONS: UuJ to .. tor:a:ve:y tu f>l'll 'll fo:O !ii n matter from pip9 1!"9' e,d provioe ,.,8'1(· p.Jr.sl·.-o ~·o!ect•cr. for CC:it'y ;)•.Jmps, r."tt'.urt. va'vt,, anc s !:r.l iar m8Ch$1'llCel O::IVI;lmont. SCREEN~· !\Oc,r,..·,st:y furnished rna -:!& frn'TI heavy Qli ·.:Ct! t-~·forAtr.d Hain'fl•ll• ijl~l·l ehoot. re-infcucAd in l~'ll"' ••ltrll for liov~ urvrce. 3 ;6~ •• l)arforationa "''~·tlly f:_.:niahed for steam &9rvlce in :~!Z\'ll through ·, 0 "; 1 i1 6" vutfo•atic.n' for ltilfOr s:zns !'l stum aer· vic e. St~a1ners for l;qutd ser.,ice uauat!y turnrsh•CS w•th 1 -' 16·' perforation :n alzru throu~h 4" and 1/8" per- to~llt:c~.s a•c ova•ldtllt!. For sr.r...-'ces rtQui~ing extrema· !y f!,, s~rsini"';] w<!l SUC'J~&I 513:1" perforated metal .,:,~el'\5 l•ned w•th <~n appro~rie4t~ wire rr.or.h. Site ~ttgtt &-3. COP~STRUCTior~: All 7 51 type atrail'lerl feature m~chinad seats in both the b0\1y tnd c:lvar fla~a for ~a.:urot !;Creln reter.tion. Cover flor•Qtfl for the I 751 · SW are !lght enough fOf eaty h~,dliniJ •• the hln~t arrl'naement Or\ the I 7 51·HC mir~lmi7et thw in· C')~'vtn 1 '!'rtC'l of se"'ielng lerg~t 1trainera. O·nng ao&led cov~· fl1ngns "'e av~i!llblt. SELF CLtA!'liNQ Is don• by open~no tt-o v!'ll ... e or plug co:.n.-c:wJ •~ the blowoff outlet. Advi11o w"'on ----}. -----strainers ••e to be mounted in vartn:ei piping: we can rototo tne cover brln<ling the blowoff to the loweat ~oint. • I I L--- BlOWOF~ OUTLETS: f11pped NPT, aize1 apeelfitd b1t!.Jw. Not no;ma!ly {urniahed ploggttd. Cf.PACITV: These etralnere t\ave acre•.,• with open ereas many times ~reeter l;,a!l \ht1 c:one&pond•ng pipe t•re lt"d thttr.lby re.:iuo:e pnusure lou ~o • mlnrmum . Dependant l.ll)'ln the •ele~tlon of ~rloretiont, ratio• •• greet •• ••x to one ere ,.., alloble. PHESSUAE DROP: See cherts, page C· 1. GALVANIZED STRAINERS evallablt Crom atock In ell lt%411. INCUVlOUALl V HVDROSTATICALLV TESTED _ .• ~ .' ~.'' •.. --t :, ,;_-:-, __ .• , MATERiAL: Cast lro~ ~~!~A 126·~.;- 01't1E~S10NS AND W~'"101-4TS APPROXIMAlE ••A?PLY FOn CfRTIFIEO OAAWINOS '' . r .. . ~··"··· ._,.. . .... '" lo·• J. 11''" r. U'l -·1.-:.ca·• -1-.u••. ·Mt•.;. , .... ' . . . . I' . . _-,.. ,_, '3 " ..!" •• : ••. . .. .. ... .~ . . -. ;~ ... -.. 2.::.:1 ' i•J '.'2 -.!1_ _,l:c l=!.~t. . ,~_ :0.1 _ • ~· r-"f•-~-!..:'' 1 u•• I ""--~1-w-;r M.lL"-~.H ..D. ·:','"f~ -~1!: II,.-~~~ 1-JlltL 1J ~t. 1--1! ~'L r-J~it:~t.:~--~111 ~ -ll · D~ .. I.»J.• I M !All "' 3.&--w-_ ~u;r. · :;?ltilo!!;y; .l.I.L'--~~ ~ _1.1. ,.-.-,& ~._,, __ Ll.f_;!l!.. Cjt_ · i1~ r -.,.:.~ it~ .. ~~ .:21._ T-.A,., ";-:-., ~b :J.• '~~' ~e· J' .'71.:['711~ ..!r---/-I-~-::!-· ..t..l.L r---L. ~\~ tt. I]\~ ..!.!...!,'~ -l!t t-4 71 7A ;;t !/2. b!.111lltJ.~·4I01_ 4UlA... ~tl·!N ~~· ., n -~& ,, n\ot ,.-,, -·· ' \-) \? I ':~ I,., I 17 Z ! 2 7 2. l 1 I z 7& . ..JL ~) _.JL_I-~--:-.-.t:._t--:-le. -;-~-1-170 ..,:. ~~t ,, ~ l)i' 12 " -;~--. .lJI~;¥ . t=a=.. fL. ~ -.JL 1i ., -·~ •. . .\.?L )'!D I u I _me I ·uall~~ . ·-%1 -~ t-li--::.-u '-~ -.-·-~~ • --~-~ ' ~-I. t~L_ • ut_ it.'-l\" . •lO I ~ I 160 I ,;)(\) f -,,;o I Y.-i; l ·~ (l;--n•-A'ot . IQ io. J il) J ~ I 61 l~L.!' ~· l71 I »7 ~~7 I :"Jft I I.MJ I ••-lf I •••u '·"'I ..... . MUELLER STEAM SPECIAL TV · ...... .-~··_ .~ .. · -....... ; ... ~ ,_ P.O. Box 1~i901 Caroline Avt., Luf'\Otrtol\, NC ~ Tei:91&-73S-8241 . ,:.·. ,. -TWX610-~f .~ ;.:.. .... _=·.:.-.. ... • .. · .··, .. · ·.·.· •••. . .• ·. ~·, .... · .. ~ · .... .~ •. r..' '!'. --.., ~ -,. ~... . ·. _ ..... _·.·.~.·-_··:__,,·~-·-·• . . . . ,:·~ .. :c..··.. ..,. ·~.-· _... . ...... ... ~' ' .. + . ,., ..... ..., .... ~' ~ ~ -· .. c c OPERATION & MAINTENANCE INFORMATION ProJect: Chester Lake Hydropower Project Contract No.CL-02 1. 2. 3 • 4. 5 • 6. .., I • 8. 9. Item ~o. three Speciflcation Paragraph 15001 page 5 Drawing ~o. Name of Article Manufacturer Size, Capacity Catalog No. Spare Parts are Guarantee to be Contractor Subcontractor C-9, C-10, C-19 Butterfly valve Keystone or Rating 8", 12" Fig. 370 Available from Unit Process Company Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone Name Address Phone 907-479-5754 Umque packing materials and geometry---------- Integral flange bolt seat retaining ring locator----+' Tangential taper pins Double-offset stems------ Full l 1!2 diameter stem en~1Qg.ement-------...s..-- Choice of TFE. R1FE. UHMWPE. elastomer. 316 SS. or Rresafe seart-----'"\ ---Flatted body bore at hubs '-------Press-fit inboard bushing .-----Disc locating shoulder Static gasket seal--------- Sremmrostwashe•rn---------------------- The "extended-service" K-LOK valve complements the high performance characteristics of Keystone resilient- seated butterfly valves. It incorporates unique seat designs within an inno- vative valve structure. The result is a design which emphasizes the total valve. The K-LOK is designed for ease of actuation by utilizing an integrally-cast actuator mounting pad. This aHows for direct-mounting of aH Keystone actuators, ehminating the need for costly brackets and adapters, and their associated misalignment problems. The extended neck permits adequate clearance for pipehne insulation, and aHows 180" accessibility to the packing gland adjustment assembly that may be readily adjusted without having to remove the directly- mounted actuator. Two types of packing rings are used. Sohd TFE "V' rings and braided TFE. The braided TFE seals the stem, and the sohd TFE seals the braided material. Graphite packing material in a similar arrangement is available for high temperature apphcations. Range bolt ahgnment plates on the • • The inverted packing gland design puts the adjusting screws in a location where they are within immediate access. The result is a packing gland wafer-style valve assure accurate valve • positioning between mating flanges conforming to ANSI. ISO. JIS. DIN. and BS standards. • The unique seat designs of the K-LOK ture ratings: UHMWPE. 200°F; TFE, The K-LOK Firesafe seat design 300°F; and RTFE. 450°F. employs an RTFE member fitted to 1 valve allow positive bi-directional shutoff K-LOK elastomer seats offer an eco-a 316 stainless steel seat UnUke some p throughout the full pressure/temperature nomical alternative to polymer seats up competitive designs the K-LOK F'll'e-c range. to a maximum pressure of 740 psi, and safe seat does not rely on Une pressure c maximum temperature of 250°F. The to activate the seal. More importantly, K-LOK polymer and metal seat designs Buna-N or EPDM member is moulded the valve will seal in both a partial or 1 employ a unique stainless steel wire-around a 360° reinforcement ring complete bum situation. I. winding concept which provides abso-in a U-shape fashion, as with the All seats are held in place between r lute seat rigidity when the disc is closed. polymer seats. the serrated body face and a one-piece c When the disc is open, the wire wind-The K-LOK metal seat offers an retaining ring. A gasket is provided ing does not impose a load on the seat -· alternative to polymer seats for use with between the retaining ring and body • This allows for radial flexure of the seat, abrasive Une media and elevated tern-to prevent atmospheric contaminants assuring minimal seat wear. The rigidity peralure service. The design employs from entering the valve. • in the closed position provides consis-a 316 stainless steel seat of convoluted The retaining ring is positioned by • tent seat interference for tight shut-off shape, reinforced by windings of 316 the flange adapters rather than a valve against high and low pressures and stainless steel wire. The convoluted sec-body counterbore, eUminating corro-• vacuum. Polymer seats are available in tion compensates for any difference in sion-caused disassembly problems. TFE. reinforced TFE, and UHMWPE. expansion or contraction by tempera-It is secured by tabs which are external • Each incorporates an inserted metal ture differences. The wire windings to the flange mating face, making the reinforcement ring and nylon covered provide closure rigidity and open valve ideal for spiral-wound gaskets. 302 non-wetted stainless steel wire flexibili~ Metal seats are rated at a The retaining ring can be provided in winding, providing bubble-tight shut-off maximum 285 psig pressure and lOOO"F a variety of thicknesses to comply with in either flow direction. maximum temperature. The allow-the standard MSS SP-67laying length, Polymer seats are rated from full able leakage rate for the metal seat is as well as other worldwide standards. vacuum to 7 40 psi. Maximum tempera-5 rnl/min/nps at full rated pressure. il' • LEGEND t Seat 2. Seat backing wire 3. Seat backing ring 4. Seat retaining ring 5. Seat retaming gasket 6. Flat head screw 7. Locating plate 8. RTFE member The K-LOK Equalinearr" disc design provides maximum flow area, high capadty and desirable flow control characteristics. The 2-piece stem design of the K-LOK valve alloiAIS a disc configuration which maximizes flow capacity and provides a characteristic that is approximately midway between linear and equal percentage. Reduced disc deflections are obtained by: • Press fit bushings • Tangential stem taper pins • Disc geometry • One and one-half times diameter stem penetration into disc • Close tolerance stem holes • Minimum unsupported stem area. The Equalinearr" disc is located within the seat at the time of assembl\,t An assembly-positioned disc locating shoulder secures disc concentricity with relation to the seat This assures perfect disc-seat alignment. unaffected by machining tolerances. The posi- tion. once set. remains positive and permanent even if the seat is changed. The sterns of the K-LOK valve are double-offset The first offset isolates the seating area from the stem. allowing 360° of uninterrupted spherical seating in the closed position. The second offset displaces the center of rotation of the disc from the vertical axis of the seat This alloiAIS a caroming action at the closure end of travel. redudng seat- ing torque and wear As the disc opens. disc/seat contact ceases at about 15°. depending on valve size. No disc/ seat contact exists from 15 o to the fully open position, eliminating seat wear and deformation in the modulating and full open range of travel. The K-LOK valve functions weU for control where normally a linear chOJUCtl!rlstic is more suited than equal percentnge. It also functions well where an equal percentage characteristic IS more desirable than linear • • • Integrally-cast actuator mounting pad-------~ Easily-accessed packing adjustments-------- ~-----Full ANSI rated. cast body Seat retaining ring suitable for spiral wound gaskets------ Integrally-cast internal travel stop---~ Lugs are tapped and drilled to ANSI Class 150 and 300 standards -------..1! The double-offset stem design reduces seating torque and seat wear. Press-fit bushings enswe positive retention and high cycle life. langentially-drilled taper pins provide an optimum strength disc/shaft connection. A disc locating shoulder keeps the disc concentric with the seat The seat retaining ring is externally located giving an undrilled flange face suitable for spiral-type metallic gaskets. This also allo\AIS easy removal for main- tenance. The K-LOK valve is available in TFE. reinforced TFE, UHMWPE, elastomer, 316 SS and Firesafe seat alternatives. Cast body construction fully conforms to ANSI 816.34 design standards without the excess weight penalty of flame cut designs. The upper neck am:111gement of the K-LOK valve allows direct mounting of standard Keystone actuators, with no requirement for standoff brockets or external adapters. High capadty EqualinearTM disc ) KEYSTONE VALVE USA K·LOK BUTTERFLY VALVES Installation and Maintenance Manual , Keystone K-LOK Extended Service Butterfly Valve INSTALlATION Disc dosed (unlike resilient seated valves). While supporting valve, install two flange bolts through opposite sides of flange. Valve may be supported or may be rested against these flange bolts while remainder are installed. Tighten flange bolts using standard alternating sequence. NOTE: The Key- stone K-LOK flange adaptors serve to accurately align the valve with the flanges. Flanges with less than sched- ule 80 inside diameters may not dear the K-LOK disc as it opens. To obtain maximum clearance, center the valve as accurately as possible within the flange. Fig. I Fig. 3 f-.--Disc closed Flange Bolt--- MAINTENANCE Packing Leakage The K-LOK uses a superior packing arrangement and materials. Leakage will seldom occur despite high cycle opera- tion and maximum pressures. Any leakage can be stopped by tightening the packing gland nuts located below the valve top plate. These are standard right hand threaded fasteners which pull doiNTI on the packing follower to tighten the packing. Note that packing leakage cannot force line pressure into the actuator as the valve body casting provides openings through which the packing fasteners attach to the follower plate. Packing Replacement In the unlikely event that packing is to be replaced. the following procedure should be followed: Remove all pipeline pressure and fluid from the valve. Remove actuator. Remove packing fasteners and follower plate. Remove packing follower. Remove packing. Install new packing set. [nstall packing follower. Install existing packing follower plate and fasteners. Tighten packing until leakage stops. Follower-------= Plate Packing------- Follower Pocking------~ Gland Nuts Packing--------- Fig. 4 Access for remoual of (XJCking follower ( n Seat Replacement The K-LOK seats can be replaced without removal of the valve disc or stems. The procedure folloVJS: Remove the socket head screws which SocketHD. secure the stamped flange adaptors Screws (or the retaining clips on lugged style valves). Remove the stamped adaptors and the Gasket retaining ring. Remove the seat and external gasket Retaining Check and clean the disc edge and seat Ring pocket With the disc dosed, replace the seat and external gasket Seot (Polymer) lnstall the retaining ring using the stamped adaptor to align the ring with the~ ~ lnstall and tighten the socket head screws. lnstall the valve into the pipeline with Fig. 5 disc in dosed position. Disc or Stem Replacement Replacing the disc or stem requires replacement of both components as they are pre-pinned at the factory as matched sets. Remove the stem packing as per fle packing replacement instructions. Remove the valve seat as per the seat replacement instructions. Remove the valve body bottom cover and gasket Tap pins on welded side to remove TIG weld. Knock out disc/stem tangential pins. Remove both sterns. The bottom shoulder is fixed to the bottom ·stem and is withdrawn as part of the lower stem assembi)L This shoulder does not detach. Check and clean ~ Check inboard bushings. If worn remove and replace. Bushings are press fit into place. New bushings are to be positioned immediately adjacent to the body bore for maximum stem support Hold new disc in place and insert top and bottom sterns. Align tangential taper pin holes and insert the taper pins lightly. Center the disc in the ~ Place the seat and external gasket in position. Use the seat to confinn that the disc is centered In 1he body and seat Install the seat retaining ring and stamped adaptors to secure the seat Pin Pfn Press Frt lnbocm:l Buthings Bottom Couer and Gasket • • • Slide the new, unaffixed. bottom shoul- der into the bottom stem with the body- side thrust washer in place with anti- friction side against the shoulder surface. Hold the shoulder against the thrust washer and the valve body. Insert the shoulder taper pin. driving it into the shouldered part until flush or slightly below flush with the surface. (Body must be secured during driving of pin to prevent dislocation in respect to the disc.) The shoulder is now affixed to the bottom stem and need not be disassembled for future valve service. (Note that the locatable shoulder alloVJS factory pinning of the valve disc and stem thereby eliminating the need to drill and ream pin holes in the field despite body tolerances etc. ) Place the cover plate thrust washer and gasket into the bottom cover and install the cover into the body. Install the upper stem packing and rotate the valve disc to assure smooth operation with the seat Tighten stem packing. Firmly seat the disc/stem tangential taper pins and TIG weld small end if possible -otherwise centerpunch the disc material to prevent accidental loosening of the taper pins. Re-install the valve in the pipeline with disc in the closed position. Lower Stem Mr-r----~-----rn~ -"'bshe?S fig.8 .. ! • . .. OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 1. 2. 3 • 4. 5. 6. 7. 8. 9. Item No. four Specification Paragraph 15001 page 4 Drawing ~o. ~arne of Article Manufacturer Size, Capacity Catalog No. Spare Parts are Guarantee to be Contractor C-10 Check valve Gulf Valve Company or Rating 8" Model 30MB Available from Unit Process Company Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks. AK 99707 Phone 907-479-5754 Subcontractor Name Address Phone :...::-. - No . 594-7 . .2" . PO. BOX 262157/HOUSTON, TEXAS 77207·2157 PHONE 713-644·7333 TELEX NO. 762944 ""Pnnted "' U S.A." ..... " :. " }1· ... - .. ·~-­ ""' ~ ·.· "'· ... j· .... ,':: .. 1 THE GULF VALVE WAR lANTY All Gulf Valve Company products are guaranteed against defects in materia' ':'lnd workmanship. No claims are allowed for unau;norized r~ . rs, labor, or material. No guarantee is made against corrosion or chemical attack. All metals and resilient synthetics are guaranteed to be of the material specified. This is the only warranty and no other is :;xpress::d or implied. This warranty does not apply to products manufactured by others. Warranty is for a period of J year after being placed in service, but not exceed- ing 18 months after shipment. ~------· ;; j if'· .,....,.,...,...,.,..-~~· """~' -~· ... \-··" -~~ ... :~·=·,-;, -. .. ' ~~~ ·. ..,·.;··< ~:_.·• t ·,··r · ---.~:.. .<·2li:s·ftw ... ..,,._;... INDEX GULF VALVE WARRANTY .............. PAGE 1 MB DESIGN FEATURES ................ PAGE2 MB DIMENSION DRAWING ............. PAGE3 MB 2"-48" INSTALLATION DIMENSIONS .................... PAGES4&5 THREADED VALVE DESIGN FEATURE .. ~" :;:;: i. THREADED VALVE 2u·42" INSTALL.A.-:>• QtMEr ... .S.QNS .... PAGES7&8 ORDERING INSTRUCTIONS ............ PAGE9 • RB DESIGN FEATURES ............... PAGE 10 R3 DIMENSION DRAWING ............ PAGE 11 RB 4"-48" INSTAL- LATION DIMENSIONS ............... PAGE 12 RB '"'RDE.RING .: TRUCTIOt.:; ..................... PAGE 13 rEW WAFER CHECK APPLICATIONS ..................... PAGE 14 ENGINEERING DATA ............. PAGES 15-18 rl\~ , ..... . ~ }~,:,U · . ..._..,r ..,;' _,_ L GULFVAYE MODEL MB !I 'l!. ~'( ,.-~ ~ . ..-:-·· --.--·-~.-:::~-~-r.·:::~: -:·~·" :···-~ : ~: -~ .. :?f:'t \f ~:~':~X ~.: .. """--~ .. _.. -~-: . -·•• I ~ ', • •' ·.• """---·· .. -; . ;.._. .. -~ - ·-~ -· .J "WAFER CHECK" valves ore fur- .t nished for all check valve applications and in suitable materials of construc- . = ' ... . ~ tion for all services. i "WAFER CHECK" valves with resi- lient seats ore positive sealing in gas or liquid service. Resilient seats, avail- able in a wide selection of materials, ore vulcanized into the body. !his fea- ture assures much longer service life than with valves having their seat e x posed to the erosive line of flow. Metal to metal sealing available for high temperatures and special services. . .. f "WAFER CHECK" short face to face Y and over all compactness simplifies installation without additional pipe fittings or expensive line supports. ""WAFER CHECK" disc closure is by spring action to assure silent, non - slam operation . t/ "WAFER CHECK" will i~creose your profits and eliminate costly mainte- nance.~ GULF VALVE ~~~. ... .. -~ .. :• ... ..~. '· -·· .... '~ ,_,..,. ... '! ~ .. f Coost Guard Approved for Morine W Application • .. f "WAFER CHECK " valves are manufac- W tured and tested in accordance wit h API 594. 2 -..... ~ ---..,.---~'7--'---~--. -~ -· © t ® @ I I I I t MODEL MB MONOBODY METAL SEATED 1 ® MODEL MB MONO BODY RESILIENT SEA TED STUDS REQUIRED FOR INSTALLATION ® NO. REQUIRED @SIZE <8) LENGTH f r I MODEL ANSI 125 150 300 400 600 900 1500 2500 M B INSTALLATION DIMENSIONS Valves made to DIN 8'1t1sh and other standards ava1lab'e TYPE SIZE SERIES FACING ®';) @ ©' @ (§.;/ ® © (H) Q) SOMM 125 Flat Face 4' • 2', 1 !'2 2 11e P'n 4 % 5% lS:t,e; !50 RF RJ-22 4',~ 2ltiJ fJi,6 2% 1 "'' 4 ~~~ s:v, r;l!l 250 RF 4J.'. 2'. I 'lz 2'\'a 1'1n 8 ''e 511, '5-,6 2" 300-400-600 RFRJ-23 4:La 2:lla Pl,6 2'1• 1 !,~2 6 ''• 6''• ·:, 900 RF RJ-24 S'·a 2'·· 0 2'1• , 5,12 8 .,. a•·, 13/,5 1500 RF RJ-24 5'·· 23'• 0 2'1a 1 s/:1 2 8 ··• 8"? P•., 2500 RF RJ-26 5''• 2''• 0 2'1• , ~1)2 8 1 9:L, 1'··· SSMM 125 Flat Face 4' ' 2'!• 2n,, 2'·8 , ·~')2 4 ''• 6 1 150 RF RJ-25 4' 2'1• 2'8 2'1• 1'5'12 4 '·· s··, ,., ' ' . 250 RF s· • 2:!., 2'!12 27-~ 1 '5132 8 ll, 6'1, 1 21 2"' 300 RF RJ-26 5'. 2'·· 2" ·• 2% 115/n 8 3i . 6'1• , .. .. 400 RF RJ-23 5''a 2'' 2 1/s 2" .. 11 ~'32 8 3!, 7l;2 , . • 600 RF RJ-26 5"a 2'• 2" ,, 2'~ 1 ''1,, 8 l/. ]1/2 1' • 900-1500 AF RJ-27 6'·, 3L~ 2 2" ., 1'5/32 8 1 9'1, 1]/16 2500 AF RJ-28 6 51a Jl;. 2 2'1• 1 15/)2 8 1 1'8 11 1J!H) 75MM 125 Flat Face 5'•, 2''• 2''''' 3% 131, 4 % 6'•, 1''11) 150 RF RJ-29 53/. 2" .. 2'1• 3'1. 131, 4 s;a 7 1 :!/~ 8 250 RF 5'1• 2 5·s 2''1" 3% 1 Jt~ 8 ''· 7 1 lJ,~ 3" 300-400-600 RF RJ-31 511, 2", 23!,, 3% Ill, 8· 'I, 8 p,. 900 RF RJ-31 6'1• Ji.'. 2'.'• 3% 1'1, 8 'le 9 1"., 1500 RFRJ-35 6'·• 3'1, 21.~ 3% 131, 8 1'1a 10'1, 17/lfl 2500 RF RJ-32 7'1, :p;, 2'/a 3% Pr4 8 , tt,. 12.;4 1 i/16 100MM 125 Flat Face 611, 2% J23fJ2 4% 2~/16 8 ~'e 61;< pt. 150 RF 6''• 2'1• 31111t 4% 211,. 8 5/8 7 1 !i16 250 RF 7'/s 2% 3~, 4% 2~1,. 8 ll, 7'1. p~ 4" 300 RF 7 11, 2~18 :)111,& 4% 251,. 8 ¥, 71/, , ;,,6 400 RF RJ-37 7 J'la J11/l2 4% 251,, 8 1!8 8 31, 1"• 600 RF RJ-37 71'3 3'1• 3"132 45fs 21/,. 8 '/a 9 1"• 900 RF RJ-37 8'1, 4 3 1/,s 4''• 25/,. 8 1'/s 1 o:v, p,. 1500 RFRJ-39 8ftj 4 3'!,, 4% 2'1,. 8 1'1, 11lf, H, 2500 RFRJ-38 9'1• 4 1/a 3'1,, 4% -251,. 8 1 '1, 14'·· 1ll, 125MM 125 Flat Face ('Jj .. 3'/• 45ft 5% 211116 8 ~~. 7" .. P/8 5" 150 RFAJ-40 73!, 3 1r4 4"fo 5% 2'1l,$ 8 "• 7r/,. P~o 250 RF 8•1, 3•!, 45ft 5% 2"/,. 8 lf, 8 Ilia 300 RF RJ-41 8'12 3 11, 4r¥, 5% 2111Hs 8 :y, 8 PI, 150MM 125 Flat Face ~. 3Jf, 5,.,, 5118 3%, 6 '¥, 7'¥, 1 ., .. 150 AF 83(, 371, 59,1,, 6"'a 39fn 8 'I. 8 1 11,,6 250 RF 9'/s 3'1, 5'¥,, 6% 39fn 12 '1, 8>1, 1"' .. 300 RF 9'1• 311, 59116 6% 3•1,, 12 ll, 9 1'' .. 6" 400 RF RJ-45 9314 531, 4~1 .. 6% 3%, 12 'I, 11 '1, 2')1lf5 600 RFRJ-45 lO'!i 5Jf, 4'1, 6% 3•1,, 12 1 12 11, 2'··· 900 RFAJ-45 11% 6'1. 3% 651, 3•!,, 12 1'/a 14 2'~ •• 1500 AFRJ-46 11 1/8 6 1/, 351, tW8 3%, 12 He 16'1, 2')!16 2500 RFRJ-47 12'1, 6'!, 419/32 6"'• 3'¥,, 8 2 20 2"• 200MM 125 Flat Face 11 5 7'1, 8% 4" ,, 8 '1, 91/ ... 2:11,. 150 RF 11 5 7'1, as;, 4V4 8 :v, 9''• 2"·• 250-300 RF 12", 5 7'12 8¥, 4'/._ 12 'I, 10'1, 211. 8" 400 AFRJ-49 12 6'/, 7'1, 85fe 4'1• 12 1 13'/, 2'' 600 AF RJ-49 121/s 6'12 6 25/32 8% 4'1, 12 1 '/a 14L( zq/,6 . 1~. 900 AFRJ-49 14 1/8 8'/s 6 1/2 8% 4'/._ 12 Ills 17 •. I 1500 RFRJ-50 13'1• 81fe 6'/z 8% 4'1 12 15/e 19'1, 2'·, . 2500 AF RJ-51 15'1, 8" ·• 6lf12 85/s 4" '• 12 2 23'/, J 250MM 125 Flat Face 13% 5'1, 9 7/,. 10'!, 51!32 12 11. 10 11,. 2' .• 150 RF 133/s 53/, 97/,e 1 03(, 5'h2 12 'I• 10'12 2". 250 RF 14'1, 5'1, 9'/•e 10'/, 5'132 16 1 11 :v. 2"· • 10" 300 RFRJ-53 14'/, s:v, 9 71,. 103/, 5'132 16 1 12 2'\.,4 400 RFRJ·53 14 'i• 8% 8'!, 1()3/, 571,, 16 1 ''e 16 3 600 RF RJ-53 15'·• 8% 8'1, 10'1, 5'132 16 1 ''• 17 i J:. 900 AFRJ-53 177Jo 9 11, a:y •• 10ll, 5 7/oz 16 T lfe 183·, I ]·!_ 1500 RFAJ-54 17'l• 9'1, 8 10'1, 5'/32 12 , '·a 23'. ; -- 2500 RF RJ-55 18"~ 10 6'/z 1031, 5'132 12 2'•z 29 • ' 'Minomum flange bore 4 Continued MODEL •A•N•S•I •1•2•s-1.so_3•o•o-4.oo_.sa.o_g.o.o_,s.o.o.2.s_oo M B INSTALLATION DIMENSIONS Valves made •o DIN Bnt>sh and other stanoards ava•iable TYPE SIZE SERIES FACING I'A)D ® (C)' @ (§:/ ® © (H) (]) 300MM 125 Flat Face 16118 7', 11'. 12", 6li8 12 ,, , 13l. 3'1, 150 RF 16';8 7'·8 11 '/, 12'/e 6~, 12 .. 113!, 3'/, 250-300 RF 16'1• 7'·e 11 1/c 121/8 6"'e 16 1' 8 14 3'' ,, 12" 400 RF RJ-57 16'12 9 10''·• 12% 63,. 16 1 ~,, 17 3'·• 600 RF RJ-57 18 9 to•;,, 12'·e 63/a 20 1'1 ,, 1 7'3/. ~·. 900 RF RJ-57 19% 11 ··, 93f, 12'·11 631, 20 , 3;8 21 1t2 4~.'. 1500 RF RJ-58 20 11, 12 9'/, 12';8 6 3/e 16 2 27 41/2 2500 RF RJ-60 21% 12 9 11, 121/e 63!. 12 23!" 33'/• 41r( 350MM 125 Flat Face 17ll, rJ., 12% 14 6''e 12 1 12'', 3 150 RF 17lf, 7•: ,, 12% 14 6''e 12 1 12'·, 3 14" 250-300 At= 19•;8 8J;' 12'/,g 14 s·, 20 1 •;8 15>1; 33;,. 400 RF RJ-61 19 1 ()3;, 11 ''!,. 14 615;~6 20 1'' '• 19 3% 600 RF RJ..Q1 1931e 1 ()3;, 111~/16 14 6 15'16 20 p;l 20 3% 400MM 125 Flat Face 20'1, 7'·2 14111,6 16 723(32 16 1 13 2';, 150 RF RJ-65 20 1/, 7'i, 1411/16 16 7<'3132 16 1 13 2'/;? 16" 250 RF 21 '1, 9'/• 14'h 16 72~/Jl 20 1'/• 163f, 3 300 RF RJ-65 21 1/, 9'1, 14% 16 723(32 20 1 '/. 163f, 3 400 RFRJ-65 21'/8 12 13 1/z 16 72%2 20 1% 203f, 4 1/, 600 RF RJ·65 22'/, 12 13% 16 7'fu. 20 1'1, 22 4'/, 450MM 125 F'at Face 21'\-8 8 16•;,8 18':,, 8", 16 1 '/e 14 3'-'z 150 RF 21% 8 16•;,. 18~1,. 8'' ,, 16 1 'Ia 14 3',7 18" 250 RF 231/, 10% 16JI, 18'11• 8',8 24 ,,i. 18'/, 3lf, 300 RF RJ-69 23% 10% 16% 18'\-'•• 8~ft 24 , '1.-18 1/, 3lf.-,, 400 RFRJ·69 23% 14'/, 133f, 18¥ •• 8"¥,. 24 1% 23'/, 57/! 600 RFRJ·69 24'/a 14'/, 133f, 18¥,. 8•5!,. 20 Ws 25 5';• SOOMM 125 F!a1 Face 23 7/a 83fa 18o/,. 20 93/, 20 1 'Ia 143,, 3l!a 150 RF 231fe 8% 181/,. 20 9'1. 20 1 '/a 15 3'/;? 20" 250 RF 25lf. 11 '12 18"1,. 20 9'1. 24 1'/, 193,, 3~1. 300 RF RJ-73 253/, 11'1, 18'1,. 20 93/, 24 1 '/, 193~ 3'1. 400 RF RJ-73 25';, 14% 16 15{,. 20 92'/n 24 1 '/, 24';, 5•:, 600 RFRJ-73 26% 14'1, 161¥,. 20 921/n 24 1% 26 5" ,, 600MM 125 Flat Face 28'/, 83f. 21% 24 11~; •• 20 1 .,, 15''• 3l!, 150 RF RJ-76 28'/, e:v, 21% 24 1151,. 20 1 v. 153!, 3";, 24" 250 RF 30'!, 12'/, 2011/,. 24 11%6 24 1'h 213f, 4'/a 300 RF RJ-77 30'/, 12'/, 20"1,. 24 11 Sf,. 24 1 '12 21l/, 4'fa 400 RF RJ·77 30'1• 15% • 2(W,, 24 11 '1'32 24 P/, 26'1. 5';, ,. 600 AFRJ-77 31 •;. 11'1, 20'/, 24 11'%, 24 F/a 301/, 5'!, 750MM 125 Flat Face 34:Y, 12 287/1& =i 143/, 28 1 '/, 19'!2 3''1,. 150 RF 34o/, 12 287118 14o/, 28 1 1J. 19'1? 3'¥,. 30" 250 RF 37'1; 14'-'z 275fa 143f, 28 1lf, 26 5% 300 RFRJ-95 37112 14'1? 275fa 3034 143,1, 28 13f, 26 5'12 400 RFRJ-95 37'/1 18'/1 26% 30% 14'4 28 2 31 '12 6';• 600 RFRJ-95 38'!, 19'/, ~ I 30% 141/, 28 2 34'1, 7 900MM 125 Flat Face 41 v. 14',7 36 •• 32 1'12 23 4'\', 31. 150 RF 41'/, 14'/, 343fa 36 17'¥16 32 1 •;, 23 43/, 250 RF 44 181/a 33',7 36 17"3f,, 32 2 32 6'/e 300 RF 44 187/, 33% 36 17':Y,, 32 2 32 6'/a 1050MM 125 Flat Face 48 17 4()tf,. 42 2021/u 36 1',1: 26 5'/• 42. 150 RF 48 17 4Qtf,1 1 42 202'1:!2 36 1'1, 26 5'!, 250 RF 50¥, 22~ 39% 42 202'~2 36 2 35 7 300 RF SO¥, 22~ 39'h 42 202'/32 36 2 35 7 1200MM 125 Flat Face 54'12 20% 44¥,, 48 23'"/u 44 1'/2 29'1, 8o/a 48" 150 RF 54'!, 2(W, 443f,, 48 23'"/u 44 1 •;, 29'1, 8% 250 RF 58¥, 243f, 42'1. 48 23'"132 40 2 37'1. 10'1, 300 RF 58¥, 24¥, 42'/, 48 23'"1:!2 40 2 37 1/, 10'1, Larger s1zes ava1lable on application ·Mm1mum llange bore G~~!~VE ~ PO eox u 21 snHOU~N. TE~ m~·"" • PHONE 713·644-7333 TELEX NO. 762944 Threaded Flange Available 18" and Larger Threaded Lug Availabfe2" to 16" -~-...;-. -· --· -_, --___ .... __ - -· THREADED WAFER CHECK VAL VE .S . -.~.- The purpose of the Threaded Wafer Check is to allow the valve to rema i n in position when one flange is removed. This is accomplished by bolting the Threaded Wafer Check directly to the mating flange . This feature allows the upstream flange to be disconnected while maintaining pressure on the down- stream side. The Threaded Wafer Check minimizes and makes easier routine mai nte- nance. Therefore, we recommend the Threaded Wafer Checks in all applica- tions where it is essential to maintain pressure on the downstream side while disconnecting the upstream flange. P.O. BOX 262157/HOUSTON, TEXAS 77207-215. PHONE 713-644-7333 TELEX NO. 762944 7 ...... --®---j ..... i ---~ ... ....; ---· Otmenstons shown tn mches SIZE SERIES 2" 125 250 125 2'11" 250 3" 125 250 12$ 4" 250 125 s· 250 125 6" 250 • 125 ANSI Installation Dimensions THREADED LUG WAFER CHECK VALVES SOLTS REQUIRED FOR INSTALLATION <!:) NO REQUIRED @SIZE (8) LENGTH r ·-:-~:; . ~-~:..~----.... ~ •'. ~ ~,,:. ._ -. i / ... ,_,,_~ ~--1.1..--~<'-...... ___ _;;_ __ ,_ ... ~_,.-~-_ ...... .....:..;..,. .. _ -.s" .. ~ .. l.ec·+• ~., ·J •. ,-..:-........,_._.~_. -- TYPE FACING Ao B c· D ER F G H .J FlatFac:e 4'/a 2'/3 1'1:! 23/e 1'/" 8 'feUNC H', ·~'16 RF 43/. 2'1. 11/2 2"• 1'1"' 16 >•,UNC 2 ·~,-.-:; Flat Face 4% 2lfo 2)',2 2 7;f 1'h• 8 %UNC 2 1 RF 5'/o 2% 2 71,. 2'/e 1'1" 16 3/,UNC 2'/, 1 Flat Face 5% 2St8 22%2 3o/a 1 :v. 8 %UNC 2 , .... RF 5 7/e 2% 22%2 3% 1 :y, 16 3/, UNC 2% 11 ·~ Flat Fac:e 6'/s 2% 323!,, 4"1o 2"f,. 16 SfeUNC 2 1'. RF 7'/a ~Ia 32~ 4% 2!1'!1 16 3f4 UNC 2% p •• Flat Face 731. 3'1. 4"fe 5% 2"/•e 16 3/,UNC 2'1. 1'\1 RF 8'1:! 3'l• 4% 5% 2"/,, 16 ~:.UNC 2'1:! 1lfa FlatFac:e 83f, 331, so;,, 6% 3%2 16 '\14 UNC 2'1. 111/,. RF 9'/e 3lf, 59/,e 6% 3'1Y32 24 :y, UNC 2lf. 1" " Fiat Face 1 1 5 7'1? 85ft 4'/• 16 _ _j lf,UNC ~-8" 250 ~"" 5 7'1, 8% 4'/• 24 7/8 UNC 3 - 125 13l/a 5•;, B1:±f 5'132 24 7/8 UNC 23{, •. 2-10" 250 14 1/, 5'~ 9 Olf, 57/n_ 32 1 UNC 3'1, 2' '6 ~25 16'/e 7'!, · 1 '/, 27/8 6o/t 24 '/8 UNC 2:Y. 3'1, 12" 250 RF 165/, 7'1• •11(4 1271. 63!, 32 I 1'/8 UNC 4 3'1. 125 FlatFac:e 173f. 7'/, 12!>18 14 6% 24 1 UNC 3 3 14" 250 AF 19'/, Blf. 12'1·• 14 6% 40 1'/1 UNC 4 Jlf,. 125 Flat Face 20'1. 7'12 14"/18 16 7>ll32 32 1 UNC 3'/, 2'/, 16" 250 RF 21 v. 9'1• 14'"' 16 72¥,2 40 1'/,UNC 4'/• 3 • M.n•mum flange bore I • L,. tl "--~_./ '~ r-- 1 i ! ·-ANSI Installation Dimensions. THREADED FULL FLANGE WAFER CHECK VALVES ® BOLTS REQUIRED FOR INSTALLATION ! ® NO REQUIRED @SIZE @ LENGTH ·-............ ~ ·-,._ )CP.~ ·~ -· 3:~~; -; -~r·*"'--..-~· ·--_..::.,; .... _ -·----·--~--~~-~-................ ~~· .... llf!kq,_ ....... __ ..,.J;. -··"""'~-... ~-·~ ~.;""'X '5 ........... ~ .. --. TYPE SIZE SERIES FACING Ao B c· D ER F G H J 125 Flat Face 25 a 169/16 185/,e B1fa 32 1'/8 UNC 3'/z 3'/z 18" 250 AF 28 10% 15SSf64 1 85,1,6 8% 48 1'/4 UNC 4% 4 125 Flat Face 27',7 8% 18 1 ~. 20 93/, 40 11feUNC 3'/z 3'/z 20" 250 RF 30'/z 1 1 'lz 177/H; 20 g:v. 48 1 1/4 UNC 4'/z 4% 24" 125 Flat Face 32 av. 213/. 24 ns;,e 40 1 1/.UNC 4 3'/s 30" 125 Flat Face 38¥. 12 28 11, 303/s 143/, 56 1'/4 UNC 4'!. 4 3/s 36" 125 Flat Face 46 14 1/2 343/,6 36 1713/16 64 1llzUNC 43f. 5 42" 125 Flat Face 53 17 409/,6 42 20 2 ~~2 72 1'/2 UNC 5 5'1, ., 8 ORDERING INSTRUCTIONS ~-:-: ?-. ..,~·7·. .. ~~ -~. -~ . . •;-''-.'\: . .,... ..... ~'~-.: -~~.; ·~ .::-i: ~---: . .. .,.,.~-H-.~ ; ~-... , .,__ ...... :.. •• -c_· ... ..:.. ....... ~·.....:......._...;:_ .• MODEL MB (Monobody) When ordering Gulf Wafer Check Valves, use the following example to select size, model , series and materials of construction. EXAMPLE: Specifications call for 6" ANSI 300 Wafer Check. Carbon Steel Body, Monel Disc. Teflon Seat and lnconei-X Spring . 6" MB30-2073XR 6" MB 30 Modol~los O"I"Body MB 125 12 LCB Steel 1 None Required 2 R L (·XXX MOdification Number) 3 X 0 7 Disc Seal Spring Ends RJ LCBSteel 1 Bun a-N 1 316St.Stl. s Ra1secrFace Inner Body Monobody 150 15 2 Oes1gnate With WCBSteel 2 Neap. 2 lnconel w Flat Fa c e F 300 30 3 Alum mum 3 Teflon 3 lnconei-X X RmgJt J 400 40 Alummum 4 0 316St.Stl. 4 Vi ton 4 Monel M Threaoed 600 60 Cast Iron 5 410St. 511. 6 Silicone 5 Lug T .L 900 90 316St.Stl. 6 Monel 7 316St. Stl . 6 Threaded 1500 150 410St.Stl. 7 Alum. Bronze 8 Metal 7 Flng . T.F . 2500 250 ALBronze 9 Cast iron 9 4105 s 8 Ductile 0 NOTE: Shaft. Disc Stop and Thrust-Bushings are 316 St. Stl. as Standard Materials of Construction. Valves furnished of other materials of construction will be furnished with shaft and thrust bushings of a compatible material. 1. -01 Outer Body 2. -03 Disc (2) : ~· -:.-! 3 . -04 Shaft • 9 4. -05 Thrust Bushings 5. -06 Spring (1, 2 or 3) 6. -08 Disc Stop 7.-10 Shaft&Stop Retainers P.O. BOX 262157/HOUSlON, TEXAS 77207-2157 PHONE 713-644-7333 TELEX NO. 762944 u \.) ------· -------------- -~~: .!.'t);~ ... ~· ~:Jd~!!i~~~ MODEL RB • "WAFER !2t'I\J!2n,,...~, .... var~e -co · ~i~~~~~~:~~~·!~i!]~,~~-~~f~~~~;~w~~~ 1 · .. 1 cti~k . . . J~ ... in any other esign .-. ~- ..-:~ :.:: . ,· '.-~·-....:· . When ·you buy ¢heck v ves . formance to meet the unusual cesses . Requirements· and restri ing and economy as well as ov_er:a portant effect on design. Heavy:•·sla parts and erratic sealing action have gi tive and fast closures. Some check valves ay have ad-V .:· · vanced far beyond the conventional designs few years ago.' They weigh much less, r~quire lin e~:.~~;.· support and have no connecting flang~s. But on ··'"!~ "WAFER . CHECK" has all these big advantages .. in regular production models plus·patimtea tea-:~_. . tures which give you peak efficiency and ext'ra·· '~: r . long ~i~e ~:! ~~~.J-~s~ ~~OJ~'-~::P-~~s.~ .. ·;;· f;·: { ;-~~ ·-.. ·• · -~· ·. ~, ·:f.~.~:}:::tf. ·::~-::>-.z~r ·: :;:.-: , .. 1 ~·~:l · · -"'-...;.r ......... x.-.~.:~ · cle··· -=;; . .;;. _ ....., • ..;o .. .........,....,.....;,..,..;.;t;!lj~-"""~•·: Available 4" thru 48" -ANSI 150 thru 300 F / I ~ .. _;~:: • I ~~I : .' ;;~:~ 2-~--~--~ T7 I r NO EXTERNAL PJRTS OR PACKING y AEPLACEABL"NNEA BODY y SEAT YUL~IZED INTD INNER BDDV ./ UNIVER~L OPERATING POSITIONS "7 > _,>" STANDARD NON-SLAM .. Y LOW PRESSURE DROP ,";. ~ ~j-" WIDE RANGE OF MATERIALS I ·:/PROVEN IN SERVICE '~ .. ,.--NO EXTRA LINE SUPPORTS ' . j / LOW MAINTENANCE LESS EXPENSIVE P.O. BOX 262157/HOUSTON , T EXAS 77207·21 57 PHONE 713·644·7333 TEL EX NO. 762944 10 © I t ( .,J -· • I I I I © ' t . ' ® @ I I I I I MODEL RB REPLACEABLE INNER BODY METAL SEATED r I· ®. @ I ~ MODEL RB REPLACEABLE INNER BODY RESILIENT SEATED 1 -~ f~-~ '_' 0 STUDS REQUIRED FOR INSTALlATION ·tl NO REQUIRED "'' ~·~:....S:_IZ:;_E _______ ~ @LENGTH 11 - ' ... SIZE SERIES 4'' 150 250-300 6" 150 250-300 8" 150 250-300 10" 150 250-300 12" 150 250-300 14" 150 250-300 150 16" 250 300 150 18" 250 300 150 20" 250 300 150 24" 250 300 150 30" 250 300 125 36" 150 250 300 125 42" 150 250 300 125 48" 150 250 300 "M1n1mum flange bore MODEL RB TYPE (f:f FACING RF 67ia RF 7"a RF 83/4 RF 97·8 RF 11 RF 12'8 RF 133'a RF 14 14 RF 16';8 RF 165/8 RF 17 3/4 RF 19 118 RF 20'14 RF -21 1/4 RF 21 1/4 RF 21% RF 23% RF 23 1h RF 23 7/a RF 25314 RF 25 314 RF 28 1•4 RF 30% RF 30112 RF 34314 RF 37% RF 37 112 Flat Face 41 '1. RF 41 1/4 RF 44 RF 44 Flat Face 48 RF 48 RF 50314 RF 503/4 Flat Face 54% RF 54% RF 583/4 RF 58% ANSI 150 300 400 600 900 1500 2500 INSTALLATION DIMENSIONS @ ©" @ ©" ® © ® Q) 25/a 353/64 4% 2'1 .a 8 % 6'h 13',6 25/a 353164 45/a 2'ia 8 3(4 71/2 1 Jl,.l 33·4 549164 6% 33/32 8 3/4 7'h 1 Q; -16 33/J 5 49 ~4 6% 33/32 12 3/4 8 31. 19/16 5 7% 8% 4'h2 8 32 91/2 2''·6 5 7% 8% 4'/32 12 T!a 11 112 231,6 51;2 99/,6 103/4 431iJ2 12 7/a 10 15/16 5'12 99/,6 103/4 431/32 16 1 12 15/,6 7'1 •a 113/a 12 3/. 531/32 12 7/a 11 1/2 2 3/4 71/e 113/e 12 3/4 53'/32 16 ~ 'Ia 14 1/4 2 314 7 12 1/2 14 613/,6 12 1 12 3 5/16 8 314 12 1/2 14 67/e 20 1 1/8 16'/4 3 1/2 6'4 15 16 717/32 16 1 12 2 7116 9'/e 145/,s 16 7% 20 1'1. 163/4 39/16 9'/a 145/,6 16 7% 20 1'/4 163/4 39f,6 7'' Ia 167/a 185/16 8"/16 16 11/a 13 2' 1/ '16 103/a 167/a 18 - 8 3/4 24 11/4 19 4 103/8 167/a 18 8% 24 1% 19 4 8 31a 183/16 20 9 1/2 20 11/e 14 1/4 3'/4 11 1/4 17'5/16 20 93/4 24 1'/ ·4 20 4% 11 1/4 1715/16 20 93/4 24 1'!. 20 45fe 8 3/4 22% 24 11 '!. 20 11/4 163/4 3'/a 121/2 219/,s 24 11"h2 24 1'h 22% 47/e 12112 219f,a 4 11"/32 24 1'/2 22 112 4-' 'Ia 11"a 29'!. 303/8 14 3/4 28 1'/. 18'12 3 1/2 14 1/2 283/4 303/8 145/16 28 P/4 25'/4 671 ·a 14 1/2 28% 303/8 145/16 28 P/4 25 114 6:/a 14 35 36 17'/4 32 11/2 22% 4 1/2 14 35 36 17'!. 32 11/2 22'/2 4 112 187/a 35 36 173/a 32 2 32 53/4 187/a 35 36 173/a 32 2 32 5 3/4 17 41 42 203/4 36 11/2 25% 5 1/4 17 41 42 203/4 36 1112 25 1/2 5 1/4 21 'Ia 41 42 209/16 36 2 35 5 '3/16 21 1/8 41 42 209/,s 36 2 35 5 :3;,6 20% 47 48 233/4 44 11/2 29112 7 20% 47 48 233/4 44 1% 29112 7 243/4 47 48 239h2 40 2 37 1/4 6'3116 243!. 47 48 239h2 40 2 37 1/4 6'3!,6 Larger s1zes available on app11cat1l 12 ORDERING INSTRUCTIONS -·~ .......... ,..-... ...,...._ _ .... ~.~--~....,.,.,. ~.--:::~::lZZ;Iif:S.:;::t:: . ~~·-. --· .. MODEL RB (Replaceable Inner Body ) When ordering Gulf Wafer Check Valves, use the following example to select size, model. series and materials of construction . EXAMPLE: Specifications call for 6" ANSI 300 Wafer Check. Carbon Steel Outer Body, 316 St. Stl. Inner Body, Monel Disc. Teflon Seat and lnconei-X Spring. 6" R830·2473XR 6" RB 30 2 4 7 3 X R (·XXX Modification Number) Mo~l~iH t: J , ... ,~ Disc: Seat Spring Ends RB 150 15 1 316St.Stl. 4 316St. Stl. 4 Bun a-N 1 316St.Stl. s Ra1sedFace Replaceable 300 30 2 410St.Stl. 6 410St. Stl. 6 Neop. 2 lnconel w Flat Face F Inner Body 400 40 Ductile 3 Monel 7 Monel 7 Teflon 3 lnconei-X X RingJt. J 600 60 Alum1num 4 AI. Bronze 8 Alum . Bronze 8 Vi ton 4 Monel M Spec1al s 900 90 Cast Iron 5 Aluminum 9 Silicone 5 1500 150 316St. Stl. 6 2500 250 Metal 7 410S s. 8 NOTE: Shaft and Thrust Plates are 316 St. Stl. as Standard Materials of Construction. Valves furnished of other materials of construction will be lurnished with shaft and thrust plates of a compatible material. . ·. ORDERING INSTRUCTIONS: When ordering spare parts for a Wafer Check simply use the complete valve · ·' description and include after it the dash number of the part desired. Example: RB 15-3441-SR-01 Outer Body. ' .. 1. -01 Outer Body 4.-04 Shaft 2. -02 Inner Body 5. -05 Thrust Bushings 3. ;-03 Disc (2) 6. -06 Spring (1 or2) 7. -07 Seal Ring 8. -08 Disc Stop 9. -11 Shaft & Disc Stop Retainers• 13 PO. BOX 262157/HOUSTON. TEXAS 77207·2157 PHONE 713-644·7333 TELEX NO. 762944 t : t • ; i -~~·1 \ ..._; MATERIAL SPECIFICATIO ,NS Aluminum Aluminum Bronze Cast Iron Monel (A-Monel) 316 Stainless Steel Carbon Steel Low Carbon Steel Ductile Iron 410 Stainless Steel ASTM 8-26 ASTM 8-148 ASTM A-278 ASTM QQN-288 ASTM A-351 ASTM A-216 ASTM A-352 ASTM A-395-61 ASTM A-217 Alloy 355-T6 Grade 9-A Class 40 Composition A Grade CF8M Grade WCB Grade LCB 60-45-10 Grade CA-15 Special coating, rubber lined and other material available upon request. SEAT MATERIAL AND SPRING MATERIAL OPERATING TEMPERATURES (°F) Buna-N -60° +200° !spring Material Maximum Recommended Operating Temperature Viton -_10° +400° Type 316SS 550° Neoprene oo +212° Monel 450°- Teflon -40° +300° Silicone -40° +300° In cone I 700F. lnconel X (Heat Treated) I 1100F . APPLICATIONS A 4" "WAFER CHECK'' replaced a conventional valve which was slamming. WAFER CHECK's non-slam feature solved the problem. The ""WAFER CHECK'' bolts directly to the gate valve and requires a spool piece to make up space formerly occupied by the conventional valve. This 24" ANSI Series 125 "WAFER CHECK" is used in a municipal water system. requires no extra line supports, and weighs 571 lb. compared to 3,010 lb. for conventional valve. 14 ENGINEERING DATA HIGH A LLOY BODY MATERIALS COST LESS WITH "WAFER CHECK" If the product to be handled is cor- rosive or erosive it is not necessary to construct the entire valve of expensive materials suitable only for that particular service . Only parts exposed to line flow need be compatible to the service. The outer body not in contact with the product is made of much less ex- pensive material while the removable inner body, re- presenting less than one half of the total weight. ef- fectively protects the entire unit. LIGHT WEIGHT MOVING PARTS "WAFER CHECK" discs are identical members without seals. Since the seals are in the inner body, discs seldom need to be replaced . Smooth surfaces of any kind. offer very lit- tle restrictive force to the line of flow. NON-SLAM AT NO EXTRA COST. All Standard pro- duction models of the "WAFER CHECK" employ a very light torsion spring on the shaft to return the discs to a tight sealing position instantly before re- versal of the flow. This feature effectively eliminates all slam and water-hammer so typical of many valves offered today . EVEN FREIGHT COSTS ARE LESS WITH "WAFER CHECK." The slender "WAFER CHECK" design is 75% less in face-to-face dimensions and 80% less in weight than the average conventional check valve. Savings are passed on to the customer.· "WAFER CHECK" uses less material in manufacture. they ar e easier to install , require no support-even cost less to ship. EXTRA LONG LIFE WITH THE PROTECTED , RE- SILIENT SEAT The "WAFER CHECK" has a protected resilient seat which gives long, trouble-free service because it is out of the erosive line of flow. This is a real saving in parts and labor costs when total oper- ation expenses are evaluated. A DISTANCE OF TEN (10) PIPE diameters should be maintained between the "WAFER CHECK" and pump. GULF VALVE ( .,. ~t,.t;~J_/ __ /_ ... .f -.7 __ ..,.; 15 ,...~r.-...,....,..,..,....._ __ •,;~ .: .-~ ~~~· ··'· ~; 1t:'' ~: : J .. PRESSURE DROP DATA WATER STANDARD CONDITIONS 1,000,000 700,000 600,000 500,000 400,000 300,000 200,000 20,000 1,000 700 600 500 400 300 200 100 70 60 so 40 30 20 10 _L I _L ~ I 1 I' l V :1 I t---+--+-+-+--+-+-t-H-+1-+!-~l-~-t--t----t-+-+1 +l+-1. -I_ 1"-'--._J~-'~"-'V-+--+----! -i-+-1 -;-.' ,..:.:.A-':y : r,:r jl!.~ v:l I i ' 0 I 02 ' I I 1 i I• I ;lj...V V li:.A" ' I 1 l--(1 I ! : V ./ J..---r,r v v I U- ~vt:ll 1.-i"'l ~ ~ , ~ :,..a:'x4--+-+l-++-+--::::t-"/H+H v I v I y .!!! !IV I VI I r--I .,. .. .v, ,.v / I v ......r I~ I I ' I / v I I I ' v v I i ! / I-"" I I I I i I I I i i I I i I I : i I i I ! i I I i I I I i I i I I I I I I I 0.3 0 .. 0 5 0.7 1.0 20 3.0 .. 05.0 70 10 20 30 40 50 6070 I 00 06 60 HEAD LOSS IN FEET OF WATER 16 PRESSURE DROP DATA -~---~~_y.~._.,.,~ " w~ ' .......... 1,000,000 500,000 400,000 300,000 ! 200,000 :::::1 ··~ "' ··r..,.....-. "' ! 100,000 A. • "' :e 50,000 :E • ..... • '-' 0 = ...... =c ;r: 9 ..... all: -c 40,000 30,000 20,000 10,000 5,000 4,000 3,000 2,000 1,000 500 400 300 200 100 I I ! ' ,.... I -.,~X:. v ' . i -..,!!>':"-/ ~~ ' I t.~L v-: I Iii/ i / l ""'· """ r-·;~, K K"lk I . I I • . . b y'/11\~j/ ,..,. /rfj11 1- / 'v VI k-fl·~ t::~~~ ~ 0lJ-hl ... t:::: / I : ,IJ.-.. V y~ I ./ A ....-1 '),.\j / / .Y / 1 v z~ ,, ...-: I' I ,.. I ./ / . ' / I ' . I /\~/ / v A 1 /'( A I .rl Ll:)' .,/ / ·:..- /1/ :yw \ .. ~/ v y ,.. v / ./~!..-'·...-~\b; v v i""'J •' L l v v vv kJ:::~ \'/:-v .....,:.-/ 1.-- ~ v ~ v l., ).-" ..... £ v-·,........ ~ v / !..- ~ v v f."' v vv i"" v ).-" v v v ~ v ~~--v v [,..,.( l,..- / v / ""' / / ./ ..... 1:)' ./ / ..,. /' / i./ ./ / I-"" I L / ; ~·/ v / v L L v / v v~--' / "" / / v l..--'v Y" l.--' L v / / ,v / v ,..,~ / ..... f."' / v ,/ / v / , ~ / , v / L / ..... ~ ....~ ,.., ... ,/ ..,. / / g / ..... v ,.... L / v v / L v ')!' v / / y r-/ ..... v ,...I', v v 1-/ / v v _l I I I t 0.1 0.2 0.3 0.4 0.5 1.0 2.0 3.0 4.0 5.0 10 PRESSURE DROP · P .S.I. L . ~· 'i .... ::--....=-. '.-J --~ 1 i TEMPERATURE PRESSURE RATIO NON·SHOCK SERVICE PRESSURE (P.S.I.) I 150 ' 300 i 400 600 900 I Tempen~ture I 1 ! I Degrees Series Series Series Series Series Fahrenheit Ste>JI :316 ss Steel 316 ss Steel . 316 ss: SIHI ' 316 SS ; Steel 316 ss 1500 I Series I Steel I 316 SS I I i ' I I I 1480 i 1440 1 2220 i I I I 100 I 285 275 740 720 990 960 216o ; 3705 I 3ooo : I I I i I i ' 272 . I i ' 892 ! 1415 i I I 150 I 257 707 670 I 945 I 1340 2122 ! 2010 3540 1 3347. ' I . i I ' I I I ' 200 260 240 675 620 900 825 1350 1240 i 2025 1860 3375; 3095 250 245 227 665 590 887 785 ' 1332 1180 1997 1770 3327 I 2945 ' 300 230 215 655 560 875 745 l 1315 I 1120 I 1970 : 1680 3280. 2795 ' I ' ' i I 350 215 I 205 645 i 537 ' 860 i 715 ; 1292. 1075 . 1935 i 1610 3225 i 2682 I l I ' ' ' ! i I 3170 1 i 1000 I 400 200 195 I 635 515 845 685 i 1270 1030 1540 2570. I I : ! i i i • i 30821 I 450 185 182 617 I 497 ! 822 i 660 I 1235 ' 992 1847 1487 2480' ' i I ' I 170 .. c 170 i i I i ' I 2995! 2390 I 500 600 480 I 800 635 I 1200 955 i 1795 I 1435 : I I 575 I 465 ! I i I i I 2865 1 i I 550 155 155 i 765 617 1147 ! 930: 1717 i 1395 I 2322 I I I 140 1 I ' i I i I 27351 2255 1 600 140 i 550 450 I 730 600 1095 i 905 : 1640 1 1355 . I i I I I I I i I ! i 890 i I I 125 1 I 715 I 1330: 650 125 535 I 445 590 1075 1610 • 2685; 2220 I : I I 575 11065 : i I 110 1 535 I 700 110 I i 430 710 I 865 : 1600 I 1295 ; 2665 i 2160 : I ' I i 95 I I I I l i ' 750 95 ! 505 425 1 67o I 565 I 1010 i 845 ! 1510 I 1270 : 2520 2110 ; ' I I ' i ' 80 I I 415 I 550 ! 555 I 825 i 83o I 1235 1245 2060: 2075 800 80 I 410 I I I i I I i I I 535: 810 I 8051 1215 i 1340 i 2030 I 850 65 i 65 I 270 : 405 355 540 i I I I 57 l I I 292 I 440 l 8oo I ! I ·, 875 57 220 I 400 532 660 1 1197 I 11oo 1 2000: I I I i I 110 I 395 ! 230 1 525 I 345! I 515 I I 860 1 900 I 50 ! 50 i 790 1180 i 1970 . • : I 42 ! I l 390 1185 : I ! I 1170! I 925 ! 42 137 I 520 275 782 412 1 687! 1950 I I I I I ! I ' 515 1 775 1 I I 950 I 35 l 35 I 105 i 385 i 140 205 310 1160 i 515! 1930 1 I I I 27 ! I I I I 750 1 I 11251 18751 975 I 27 77 I 375 105 500 15s 1 232,1 387 ' I I I I I l 1051 7251 I 1000 I 20 l 20 I so 365 ! 70 485 155 1090 l 260 1820 I ! ' I I ! i 816.5-1977 2500 Senes Steel 316 ss 6170 i 6000 I 5897 5580 5625 516C 5547 4910 5470 4660 5375 4470 I 5280. 4280 ' 5135 i 4130 i 4990 I 3980 4775: 3870 ' 4560. 3760 4475 3700 4440' 3600 4200 3520 3430 3460 2230 3380 1830 3330 1430 3280 1145 3250 860; 3220 645. 3125 430 3030 PO. BOX 262157/HOUSTON, TEXAS 77207·2157 PHONE 713·644·7333 TELEX NO. 762944 18 ... ·' . L ' .. OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 l. 2. 3. 4. 5. 6. 7. 8. 9. Item No. Specification Paragraph Drawing No. ~ame of Article Manufacturer Size, Capacity or Rating Catalog ~o. five 11030 C-10 Vertical turbine resupply pump Simmons Pumps 650 gpm with 285'tdh Model SD12C-4 Spare Parts are Available from Simmons Pump Guarantee to be Provided by water Contractor Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks. AK 99707 Phone Subcontractor Name Address Phone 907-479-5754 I .. I I I l I (: I l f: I ,.~ ' I ~, l' • -------··-······ -·· .. ·····-..... KaiUTBNAHCI PYKNAIX 1. EQUIPMENT ITEM: Vertical Turbine Pump 2. MANUFACTURER: ··--5-im~,~T~o~n~s~P~u~m~p~C~o~rp~o~f~A~Z~-------------------------- ~. ~~UIPMENT ID~NTI~ICATION NUMbE~(O)I Repump Water Supply Pump 4, NAMEPLATE DATA (HP 1 VOLTAGE, $f'Et;D, ETC.): 60HP, 460V, 3D, 60HZ 1800 RPM o. MANUFACTURER'S LOCAL R&PRE~~NTATlV~: Name: Unit Process Company A~~.t·tuis: 420 - 6 tb Street South I Kirkl§gg. W A 9§Q33 Telephone Noa (2061 827-0433 6, KAIMTEN~NCE REQUIREMENTS Fr9Q.Yjtncy (It Ap.sJ.is;able) C0111p1nts M4intenanee opcratipn Ltat briefly each ~•intenQn~• operation required and reter to specific information in mon~tocturer'a standard maintananc• ~anual, it applicable. Ltet r•C"~Uired. frequency ot each. rnainte• nance opera- tion. Reter by aymbol·· ----------to lubricant Re!fu.·ence ti.YJDDOJ. List symbols used 1n ltel'll o 1 a.bove. e. .SPARE PARTS 6nell liat os re- quired.. .SEE 0 & M MANUAL St~t.nd.ard pil rr ------- Gult .· -----. or Eqyol L1a~ •qu1va1ent lubricants, •• a1•~r1buted bf each manutecturer ror ~h• ap•citic use recomm•n~ea. P!JMPS ARE PROQUCT LUBR.U:6TfD._ __ • IncluOe your recommen~ationa re9ara1n9 wna~,spare part¥, it Any, 1 shou 1<1 be kept on the jOb. No spare parts are recommended. ...., 01001 -10• 0 & M MANUAL AMERICAN MECHANICAL CHESTER LAKE HYDRO s~Mgo~§UPLED PUMP WITH CAST DISCHARGE HEAD 35-9116" 20" 1" 6-5/8 134-112" 197" 67-1/4" 20-7/8" 4 -3/4" HOLES ON!8-3/4~ B.C. DISCHARGE FLANGE 6" 150# ~ ----~~~------------- MOTOR 67..:li4"MAKE----.;,;USE;.;;;M;.;... __ _ ENCLOSURE---•Iif;,:;.-l~o...--­ ........ au. H.P. 60 R.P.M. 1800 DHASE CYCLE-..o~o61111o0_ VOLTAGE 460 62-112" \IIIII-. v.s.s. _J ~ 11-112" PAGE 1102.130 OAT E 5/25/85 SUPERSEDES 7/1/83 1102.70 DATE 9-21-87 DISTRIBUTOR UNIT PROCESS co. JOB At-t::RICAN I<E:CHANICAL CHESTER LAKE HYDRO JOB•---------------- QTY. 1 GPM----~65~0~·------------ TOH 285' -----------------STRAINER TYPE CLIP-Ol"l GALVANIZED BASKET BOWl MODEL# SD12C-4 WITH SUCTION BELL COLUMN ASSY 1-3/16" X 6" PRODUCT LI..BE FOUNDATION PLATE FP-300 FABRICATED STEEL DISCHARGE HEAD S-350 CAST IRQN WITH SAFETY GUARDS SEAL TYPE PACKING Q..ANO 9.000" IMP. DIA.-------- IWP. TYPE ENCLOSED SPECIAl ALLfo1INUM BRONZE IMPELLER WEAR RING OTHER SIZE 3 NON-SPACER TYPE MOTOR CClPL ING PRODUCT SECTION: PAGE: CUSTOMERNAME --------------------------------------------------------- CUSTOMER ORDER NO. ___________________________________________________ _ U.S. E.M. 0 R DE R NO. ----------QUANTITY ____ 1 ______ H.P. _ ___;;.60.;..._ _____ _ FRAME _____ 36_4f_P __________ TYPE ______ R_u ________ PHASE __ 3 ___ HERTZ ___ 6_o ______ __ R.P.M. ___ l_ao_o ____ VOLTS ____ 460 ______ ASSY. POS. ______ v_s_s --------- MARKS: TAG NOS.: _____________ __ EXCEPTIONS & CLARIFICATIONS (IF ANY): IF PROPERLY ENDORSED THIS PRINT IS CORRECT FOR FRAME 8t ASSEMBLY POSITIONS INDICATED. BY DATE ------ It! u.s. ELECTRICAL MOTORS DIVISION EMERSON ELECTRIC ca . """'•o "' u.S.A. ........... Q 'Z "'" 0 JJIL U\ ~ U.S. ELECTRICAL MOTORS CUSTOMER _______ _ P.O. NBR-------- USEM REF. NBR ________ _ TYPICAL JOB ____________________ _ PERFORMANCE DATA MARKS------------------- Performance Data Based on Standard Rules of IEEE, ASA and NEMA · HP NO LOAD FUll lOAD FRAME NBR. TYPE ENCLOSURE SPEED RPM SPEED RPM 60 1800 1770 .364VP RU WP-1 CURRENT • AMPERES MAX. TEMP. I PHASE/HERTZ VOLTS INSULATION RISE SERVICE FUll lOAD LOCKED ROTOR CLASS D (RESIST.) fACTOR D (THERM.) 3/60 460 75 454.5 r l05°C , 1.15 TORQUE AT FULL VOLT AGE % EFFICIENCY % POWER FACTOR DIRECTLY MEASURED NEMA NEMA FUll 3/4 1/2 LOAD LOAD LOAD 90 91 91 II IIMiiR5DN U.S. ElECTRICAl MOTORS DIVISION EMERSON ELECTRIC CO. OlD GA Tl lANE MilfORD, CONNECTICUT 06460 TEL 203·111·9311 FULL 3/A LOAD LOAD 86 83 FULL LOAD 1/2 (LB. FT.) LOAD 75 178 LOCKED PULL-OUT (STARTING) (BREAKDOWN) KVA/HP DESIGN CODE LETIER PERCENT OF FULL LOAD 140 200 G 8 BY ------------ DATE------------------ VERTICAL MOTORS DIMENSIONS HIGH THRUST SOLID SHAFT--TYPE RV-4 (OPEN DRIPPROOF) BASIC v FRAME c p MIN. 284.286 25·3/4 16 4·112 324.: J6 37·118 18·311 4·112 364, 365 40·1/11 18·311 4·1/2 404,405 46-1/B 20·112 4·1/2 444,445 li3·7111 22-7/1 4-112 u FRAME -.001 AJ AK 284, 286VPZ 1-6/1 1·1/1 1·114 284 286VPAZ t.fi/8 1·111 1·114 284, 286VPHZ 1-6/1 14·314 13-112 324 326VP 1-518 14-314 13·112 324, 326VPH 1-5/1 f.111 1-1/4 I 364 .. vP 1-6/1 1~ 13·112 364 365VPA 1-518 .. ,,. 1·114 364 365VPZ 2·118 1~ 13-112 364 365VPAZ 2·111 .. ,/1 1·114 404 405VP 1-6/8 1~4 13-112 404, 405\IPA 1-5/8 14-3/4 13·112 404, 405\IPZ 2·118 14-314 13-112 404, 405VPAZ 2·111 14·314 13·112 444, 445VP 2·111 14-3/4 13·112 444, 445VPA 2·118 14-3/4 13·112 L TOLERANCES I "AK" Oomen,oon Foc.o Runout Ptrmiuoble Eccentricity of Mountinv RIIXMt 'ermouibl• Sh•h Runoul ALL DIMENSIOHS ARE IN INCHES AA A8 AC AF 2 12-7/11 f.1/11 3-1/4 3 16-3/11 11-6/1 4 3 15-3/11 11-6/1 4 3 16-3/1 12-3/4 4 3-112 11·1/4 14·7111 &.e/32 •• MIN. 80 afl 3/11 10 7/11 3/11 12 7/11 1/4 11-112 11/16 1/4 16-112 11/18 3111 12 7/18 1/4 18-112 11/16 3/11 12 7/11 1/4 16-112 11/16 3111 12 7116 1/4 18-112 11111 114 20 11116 1/4 18-112 11111 1/4 20 11/18 1/4 18-112 11/11 114 20 11111 8·114 AK 13-112AI( +.003 +.005 .004 f.I.R. .007 f.I.R. .004 F.I.R. .007 F.I.R. .W2 f.I.R. .002 f.I.R. , f I 10 j AG 21·1/4 32-6/1 36.e/11 41-618 AH 4-1/2 4·1/2 4·112 4·112 41-11/11 4-112 ES MIN. WIDTH LENGTH 3/1 3-5/32 3/1 3·6132 3/1 3-5132 3/1 3-5132 3/1 3-5132 318 3-6/32 318 3-5/32 112 3·3132 112 3-3/32 3/1 3·3132 318 3-3/32 112 3-3/32 112 3-3/32 112 3·3/32 1/2 3-3/32 ~ \ --rt,--t--r- AH I v BE BV xo 13/11 10·114 11·314 11/16 11·1116 21 11/16 14 21 3/4 18·118 23·311 3/4o 21-3/16 25·718 EU BASIC BRACKET -.005 PART NO. 1·1/4 148270 1·114 1o&8317 1·114 148306 1·118 19216i 1·1/8 1i2163 1·118 192169 1·111 192163 1-3/4 192169 1·3/4 192163 1-1/4 11181>62 1·114 188664 1·3/4 1881>62 1-3/4 188664 1·3/4 188762 1-3/4 1811764 All rOUIIh e~~tine dimtnaionl mey VfiiY by 114" d~ie to CMtinv variation&. I!:! U.S. ELECTRICAL MOTORS DIVISION EMERSON ELECTRIC CO • EFFECTIVE: DECEMBER 15, 1811 SUPERSEDES: SEPTEMBER 1, 1811 ........ SECTION : 505 PAGE: 38 DO NOT USE FOR CONSTRUCTIO.. PUA..OSES UNLESS CERTIFtt 0 - A-C 1M MONS FLANGED COUPLINGS FOR SOLID SHAFT MOTORS .,_ __ F --'" t-----G----.1 B D _j PAGE DATE 1102.90 5/25/85 SUPERSEDES 7/1/83 1102.41 ~ADJUSTABLE FLANGED COUPLING .,._---G----....1 ~ ADcJUS'l':ABLB SPAC:SR PLAtmSD COUPLING a.: MAX. lUX. H.P. RATING BOLT BOLTS ::111.1 THRUST F~ u A B C• D E F G o!:::! IN LIS. 1800 1800 1200 tOO SIZE ucn 1 2,400 3 l 4 7 6:!. ll 2 1 1 11 21 -----------8 4 2 4 2 4 2 4,500 25 20 10 7~ .!. 4 1 i ~ 2 2.! 1 .! 1 .! 11 3 4 2 4 4 4 4 ~ 3 11,000 150 125 75 60 rl 4 1 ! 8~ 2.! 4 2~ 1 ~ 1 l. 4 2~ 3ij- 4 20,000 700 JOO 200 150 ~ 6 2 i 10yt 2# 2ft 1 i 21 4 3j 5 5 28,000 ---400 JOO 200 ~ 6 2 i lli ~ 3f;-2~ 2i 3i 5£- 6 31,000 ---800 600 350 1 6 2 5 lJi. 3-2. Jl 3 21 41 &l 2 i 8 16 4 4 8 4 7 41,000 -----------500 ' 8 3 k 15 i 4 4i 3t Jl 4i 61 4 4 8 73,000 ---1000 BOO 600 1 6 3 !.. n.! 41 41 4 4 5!.. a.:.2 4 8 2 8 4 8 16 * DIMENSION C MAY BE INCREASED TO ALLOW FOR PACKING BOX ASSEMBLY OR MECHANICAL SEAL ASSEMBLY REMOVAL NOTE -THIS MAY REQUIRE A TALLER DISCHARGE HEAD. H l 4 3 A" Ti i I 3 4 1 4 .!2. 16 IMMONS. ' _rrw•~ HI STANDARD DISCHARGE HEAD ~ ·-WITH PRODUCT LUBE PACKING GLAND PAGE llOJ.JJ OAT E 5/9/S6 SUPERSEDES 027 02~ 012 014 0 SAFETY GUARDS SHALL BE PROVIDED. CATALOG PART NAME NUMBER 001 t£AD, OISCHARCE 002 OOJ .-~ I r ... •- 008 SHAF'T I t£AO 009 SLEEVE I SHAF'T 012 f ITTI~ I CREASE ou BOX, PACKING 014 O-R INC 017 RING, LANTERN 018 RINGS, PACKING 019 BEARING, PACKING BOX 020 ~.-. I" II'>. 025 CAP, SCREW 027 S TUl IW:J NUT 028 O..IW:J, SPLIT PACKING 0~0 PLL£ PH£-U . .ef lUI ' DATE 9-21-87 DISTRIBUTOR UNIT PROCESS co. 002 020 003 JOB A"'ERICAN "'ECHANICAL CHESTER LAKE HYDRO 001 MOOEL# ____ s_-3-50---------- 102 JOB~----------------- 001 027 021 CATALOG QUAN• PART NUMBER TITY NUMBER 011 001 1 002 0 N/A 017 011 003 0 N/A 008 1 013 '009 l 011 012 1 Cl3 l 014 l 017 l 018 6 019 1 020 ' 0 N/A 025 4 027 2 028 1 050 1 10:! 0 N/A MATERIAL STANDARD A.S.T.M. DESIGNATION OPTIONAL CAST IRON A-48 CLS 3U .......... N/A N/A STEEL A-108 CR 1045 ST. STEEL A-582 CR 416 CO+ERCIAL CAST IRON A-48 CLS 30 t.£~t.£ BRONZE B-144-JB GRAPHITE BRONZE B-144-JB "'' N/A CC»++£RC IAL BRASS MONZE B-144-JB Cll-M:RC IAL - N/1\ s~M~~~NDARD DISCHARGE HEAD DIMENSIONS PAGE DATE 1102.30 5/25/85 SUPERSEDES 7/1/83 1102.11 X 4-M HOLES ON N-BC. l E ~~~~-----------~~---------~&-~~ S-THREADED COLUMN-NPS I-DEEP ---------D-----------~ 2-J-HOLES ON K-B.C. ..a:£L. 1-(), 5-150 ~ 5-350 5-550 5-750 t«Xn h(). 5-150 ~ 5-350 5-550 5-750 NO'i'B NOTE - F IS 150# FLANGE. OU£NSII)..S ( HCI-£5) A B c 0 E F' c X 16 1/2 10 9 1/8 16 6 4 X 9 13/16 9112 20 16 1/2 11112 20 7/8 7 6 X 11 1 11 9/16 22 5/16 16 1/2 13 23 7/8 81/2 8 X 13 112 1 12 1/8 26 20 15 27 1/4 11 10 X 16 1 1/8 13 1/4 M N 5 T 0 p H J K 4 -3/4 14 1/4 4 1 3/8 5 3/4 11 1/4 18 1/2 1/2 7 112 4 -3/4 18 3/4 6 1 3/4 81/2 14 1/2 20 3/4 11 1/4 4 -7/8 21 l/4 8 1 3/4 10 1/2 16 1/2 20 1 13 4 -7/8 25 10 2112 12 1/2 201/2 24 1 16 3/4 WUf!l4 CAH MOUl4Tf!f), "ftl'' & "W' COl~PORM 'fO AWWA - CLASS 0 SPDCIPICA'i'IONS DISC. SIZE 4 6 8 10 s~M~c~!E HEAD FOUNDATION PLATE 0 / / / ~' c 8 ~~~~======~~~~_L Lo----.~.J ~STANDARD fOUNDATION PLATE IO:U N..M£R A B c FP-100 16 13112 5/8 FP-200 19 16 7/8 ~ FP-300 21 18 718 FP-400 24 20 7/8 FP-500 26 22 1 1/8 FP-600 28 24 1 1/8 FP-700 32 28 1 1/8 FP-800 J4 1/4 30 1/4 1 1/8 FP-900 36 1/2 32 1/4 1 1/8 -,- F [)it E 11 12 12 13 112 1.5 1.5 3/4 16 18 18 19 112 21 21 23 24 25 25 1/2 27 28 F 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 1 112 PAGE DATE 1102.80 5/25/85 SUPERSEDES 7 I 1/83 1102.30 8PTI8NAL F8~N9Ali8N P~AlE WHII SIIEJl.R I(E¥5 SIIEAR ltE'i' BETAit lJ«RGRClUl DISCHARGE G H J K L•• 15 1 3/4 10 18 1 3/4 12 20 1 3/4 l l ,.., 23 1 3/4 14 1/2 25 1 3/4 17 27 1 3/4 20 31 1 3/4 20 33 1/4 . 1 3/4 24 112 35 112 1 3/4 26 112 •O DIMENSION MUST BE GREATER THAN LARGEST DIAMETER OF PUMP TO ALLOW INSTALLATION. **L CONSULT FACTORY FOR SIZES NOT SHOWN. IMMONS PRODUCT LUBE THREADED COLUMN e--11!5 u CATALOG PART NAME NUMBER 101 SHAF'T Lit£ 102 COUPLING LINE SHAFT 103 SLEEVE, SHAFT 107 RETAINER, BEARING (T~O) lOB BEARING Lit£ SHAFT (co..PLEO) 109 LOCK RING, BEARING 110 PIPE CCL~ ( Ttft:AC£0 6 COUPLED) 115 .... -"',_,.,.. IT>....,..A~\ ..... PAGE 1101.140 OAT E 5/25/&5 SUPERSEDES 7/l/&~ 1101.&1 DATE 9-21-87 DISTRIBUTOR UNIT PROCESS co. JOB AI-ERICAN 1-ECHAN!CAL ----------~-------CHESTER LAKE HYDRO JOB~----------------- CATALOG QUAN· PART NUMBER TITY NUMBER 101 1 102 1 10.3 1 107 1 108 1 109 1 110 2 115 a N/A MATERIAL STANDARD OPTIONAL A.S.TM. DESIGNATION STEEL A-lOB OR 1045 STEEL A-lOB OR 1018 SS A-582 OR 416 BROOE B-145 I£CPREI£ SS A-582 OR 416 STEEL A-538 NlA 1M MONS PAGE 1101.160 PRODUCT LUBE BOWL ASSEMBLY OAT E 5/25/85 CATALOG PART NAME NUMBER 201 BCW.. Dtsc::HMCE HOUSINC 202 80iol. t(P tOJSll(; 20) 80iol. IHTEAMEDIATE HOUSJI(; 2o. 80iol. Sl.CTIC).I HOUS11(; 205 llof'ELLER (Q.OSEO) ~ 207 BELL SU::TlC).I 208 SHAF' T' BIJol.. 209 co.J'I..INC 80iol. SHAF' T 211 BEAR II(; TI:P 8011.. 216. BEAR II(; INTERKOIATE BCW.. (RI.III!Eil) 211 218 CO..LET Ilf'ELLER 219 CO..LAR, SAl() 220 CO..LAR LOCI< SCA£1i 221 BEAR II(;, SLCT 10. 8011.. 222 Pl.t..C CREASE 22} C/IP SCA£1i 224 225 SCRffN, BASI<E T ( CL 1 P Qol) 226 Rll(; WEAR ( llf'ELLER) 227 228 BEAR 1 t.C, 0 1 SCHAf!CE tOJS 1t.C SUPERSEDES 7/1/83 1101.110 DATE 9-21-87 DISTRIBUTOR UNIT PROCESS co. JOB~----~A~~~Rl~C~A~N~~~CH~A~N~IC~A~L~ CHESTER LAKE HYDRO MODEL~#~--~SD~l~2C~-~4------­ J0BM#---------------- CATALOG QUAN· PART NUMBER TITY NUMBER 201 1 202 1 201 3 204 1 205 4 207 1 208 1 209 1 2ll 1 216 3 217 0 N/A 218 4 219 2 220 .. 221 1 ~2 I 22) 60 '2214 0 N/A 225 l 226 4 227 0 N/A na 1 MATERIAL •!lTJTtr:".~~pTtnN OPTIONAL CAST 110 A-48 O.S lD CAST IRON A-48 O..S lD CAST IA().I A-48 O..S ~0 CJU T IA().I A-48 0.. S lD 8fOaE B-1-..-38 CAST 1RC).I A-48 0.5 lD SS A·582 CR 1416 STEEL A·l08 CR 1018 l"lROaE 8·1144-38 II[CFR£11[ N/A STEEL A·108 CR 1020 ~~ACNE 8-1144·38 8fOaE 8-1144-)8 l"lROaE B-1411· 38 CCMERCIM. CCM4ERC1*- N/A fillflth SofEEI: r.Al VANIZED l!ltttcf l!i tu Je PL.-BRGm:E N/A ~~ACNE. B-1144-Ja ONE STAGE ~ ~ ~ ~ ~ 90 80 70 60 50 15 10 5 1M MONS SD12C 1770 RPM SERIAL 112125 0 200 400 U.S. GALLONS 600 PER MINUTE PAGE OAT E 3-25-88 SUPERSEDES 800 1000 fT1 ., ., ;::; -fT1 ~ < 1M MONS PUMP CORPORATION ~ 7&4 iAST looiAUY P.O. BOX 5.20 WILLCOX, ARIZONA 85643 VERTICAL TURBINE OPERATION & MAINTENANCE MANUAL TABLE OF CONTENTS PAGE• INSTALLATION ................ -............................................................................................... I - 1 3 I Receiving, lJncrDting, and lnspecting ....................................................... l II lnstaiJation Equipment and Tools ................................................................ 1 Ill Special Precautions ............................................................................................... 2 IV Preperatioo afld Cleaning ................................................................................... 2 V lrastalletion_ ...................... _ .................. --··············-···············--································3 STORAGE .......... ~~ ............................................... -............................................................... 14-1 S I Considerations ... -····-············ .. ····--··-··--·····························································1 ~ II ~rte'ral Hints ................... : ... : ..... -.. ·-·············-···············-········-·······························1 ~ Ill Short Coupled Pt.rrlps ........................................................................................... l 41 IV Misce11arteOUS ltems .................. -...................................................................... 1 41 BOWL DISASSEt1BL Y AND ASSEtiBL Y ......................................... ~ ............... 16-18 I Bowl Disassenlbly .;..·-·······--····--··-................................................................. 16 II Bowl AsseiTlt>Jy --................... _;_, __ ................... _ ............... _ ..... -............... 17 OPERATION·-··-··-··-·-----······--······-··--······-·········-·-··············-·-···-········-··········-19 I Pri a' to Stal't ~ ········-····-···-·-······-····-··-··-····---······-····-·······-·-··-······-······ 19 II Initial S'tri ~--·-······ .. ···········-·--·-······ ................................ _ ............................. 19 FIELD TESTS ............... -·-···········-····-··-·-·------··-················-·-·-···---········-······--· 20 ENGitE'ERING ....... -........ -·-···-···················-·············-······-····················-···-···-············ 21--2-4 HA: I NTENANC:E -·-··············-············-··-· .. ···---··-······-·················-·······-·······-············ 25-29 I 6e:Mra1 .............................. -·······-···-·-······-···-·······-················---··-·····-··················25 II Be-arirlg Replacement ........... _ ........................................................................... 25 Ill Wear Ring Replacement ··-·----.................................................................. 25 IV PackirJg Reptacetllent ..................................... :.. ................................................... 26 V Preventive t1eintenartee .................................................................................... 29 TROUBLE SHOOTING ............................... -.................. _ ............... _ ...................... 30-34 I. R£CEIVII6, u•tRATII& AID IISPECTII& 1. A phystcel chedc of on equip- ment should be mode wtth the packing list and inspected for obYtous damage tncwred during shtpment. 2. lmmedtotely report ony damoge· to~er. 3. Uncrete end loy out on the equipment t n the order of tnsto11atton on clean boards or floor. II. liST ALLATIOI EQUIPHEIT MD TOOLS 1. A portable or permanent derrick of sufficient strengta .to safely ltft the total weight of the pump should be used. A conservattw wetght of the pump . meu be obtotned from the freight btU. Tbe mtntmum · travel of the derr1dc should be at least 6" WNter thin the longest ptece of pump equjpmellt. Hotst must how swivel hoot. 2. One or two cable sltngs of sufftctent strength to lift the enure pwnp end long enough to cleer greatest shaft projectton. 3. one .-ector allng for urung the m-lva". 4. Dtel Indicator calibrated In .00 a· d1Ytstons wtth a stand. 5. SA£ 10 vtacoatty, low cold pow potnt mineral oil If pump Is to be o11 lubricated. 6. wtra brush, patnt brush, tine- cornered file .. flat ftle end emery cloth. 1 IIISTALLATIOI 7. Set Of mecnentc•s tools tnclude- tng en assortment of socket wrenches. 8. Bucket of solvent, cool oil or nophthl .. etc. 9. t'lechtntst's level 10. Steel tape measure. 1 t. Two ptpe wrencheS of sufftc1ent size to handle shaft end coupltngs. (Alwoys requtred for ho11ow shaft drive). 12. One set of steel clamps to ftt the pump bowl. 13. Two sets of steel clomps to ftt the column ptpe. NOTE: One set ts requtred tf only one secuon of colutm ts furntshed wtth the pump assembly. 14. Two 4 x 4 timbers or "H. beams (tf the untt ts extra 1~ and heavy), long enough to spon the tnstelloUon opentng. 15. Two ·v· blocks for checking shaft stretghtness. 16. Two chotn tongs of sufftctent stze to hendle column pjpe. 17. 1s· of 3/~ rope. 18. Tined compound and gasket compound wttb thtnner. 19. Two ptpe wrenctaes of sufftctent stze to handle on tubing tf pump ts to be on 1ubr1coted). 20. SUfftctent quenttty of wedgeS to level discharge heed or foundation plate (tf eppltclble). 21. SUfflctent quantity of top qualtty non-shrink grout. 22. AnU-setze compound for statnless to stainless threads. 23. Bli'Mile of cleaning regs. 24. Putty kntf e. GPEU!IOII & tMIIITEMJICl ttUIM1. Ill. SPECIAL PIECAUTIOIIS 1. t1eke certain thet no regs, wood scraps, etc., ore lodged In ony exposed openings. Chectc pit depth end enchor bolt spacing w1th pwnp dimensions. Lift end hlndle untt cenfully to pt'lrM'at dlmege ceused by eppllcaUon of blAding strain. Do not 11ft ony item by the &heft. Take extre precautions wben handling a mechanical seal or pocking gland assembly, since this Is a most delicate and precision com- pooent. 2. Do not allow ptpe compound, solvent or any petroleum products to _get on rubber beerlngs. 3. NEYER USE THREAD COMPOUND ON SHAIT JOINTS. 4. Shaft threads are usuelly lift hind.-column thneds an r1ght ....... IV. PREPARATIOI AID Q.EAIIII& 1. CJeen an ttnods end flenge faces wtth a w1ra IW'ulh or paint brush end solvent. Clan thrnds .. tf requtnd, with • three- cornend file. The protective coot lng on thrlods end flanges Is o rust prwenttYe end not e tined compound or gostet motertal. 2. Clean ell shafts ond coupltngs W1th • ret soelced tn solvent. ttete certain thlt ell ~ngs ere cleon. 2 IISTALLATIOI 0 $ 3. (If oppltcable) Remove pro- tective cops from ends of oil tubing and clean ell tUbtng lhreeds ond sheft beor1ngs thoroughly In solvent. t1oke certain thet tubing feces erv free of nicks, dents or burn. 4. Remove gland assembly from cUscherge heed. Remember to be very careful wtth this item. 5. Melee a physical check of the discharge heed or f oundot 1 on plate for proper fit to foundation. 6. Checlc pipe and ol1 tube ends end couplings to be sure there ore no dents, nicks or burrs. 7. Ch8clc shaft end for nicks, burrs, etc. The shoft oltgrment Is dependent on the point of the shaft ends. 8. Checlc ell boxed shafting for straightness using V blocks and dlel tndtcator os fo11ows: A. Start with V blocks os close to the thr8eds IS possible. Chedc lwew.-...atrabetween ·v· blocks . w :~eo. ·•n to wtthtn .oo3· to .oos· of the Total Indicated run-out. Stratghlentng moy be performed by mechentcel or htgh pressure on the htgh point. B. MoYe one V block about 201 of shaft length Inward from the end. Chedc bet ween the ·v- blocts end the overhanging ends; straighten as In Step A. above. C. If stnlghtentng· was required In Step 8., repeat Step A. Repeat the eboYe · steps unt11 shoft Chicks w1tllta tolerance In both positions. wtpe the Shoft clean after chedctng. 9. Check nil-out on bOwl sfteft extension by plectng dtal Indicator town the end of the shaft end turntAg slowly moking certotn that the shoft stoys to one st de of the upper most bowl beortng. Totol Indicated Run-Out should not exceed .oos·. 1 o. Cbedc end record the total bowl latenl or end ploy. If pnme oover ts soltd sheft, this Information wtn be requ1nd for flanged coupling assembly.. V. IISTALLATIOA A. FOUNDATION PlATE (IF SUPPLIED) 1. Ploce foundaUon plate OYer enchor bolts end allow to rest on fow.deUon. 2. If the ftnel elevaUon of the plate is cr1Ucel, thts should be taken 1Dto constdlratton end checked at thts Ume. 3. Attech hex nuts to anchor belts enct snug agel nat fooodeUoa plate to protect anchor bolt threlds. 4. The foundation plate serves as a good SW'fece for the elevators end c...,.,. to rest upon-end as IX'Qtectten for the r....aeuon. see tnustretton 1.1 B. PliPBOWL 1. Piece the two bMms on the fOWMietton plete or foundetton op .. tng. 2. Secure the proper clamp to the ._,..,. end of the bowl blneeth • convenient shoulder. (If only one 3 IIISTALLATIOI sUng ts used). Altoch the sltng to the clomps fer enough out on the eors to allow tts removal after setting down on beoms. 3. Holst the bowl to o verttcel position ustng the derr1ck. If the bowl Is equipped wtth o streiner, be careful not to dreg the stntner across the floor. ILLUST. 1.1 4. If tber8 ts ~ euxtUory piping to the boWl belrtng or the thermo- wens make cartotn that the bowl portion of the ptplng ts essembled to the bowl at thts Ume. 5. Centw the bowl over tnstelletton opening then carefully lower untn the clamp eers ere resting SQUeRIU on the beems. Remove the sUng. 6. Clean the following ttems: shift tbrleds, discharge threads, flange foce (if eppltceble), threads end fece of on tubing (If eppltcablet. ltghtly on the sheft Unads end screw tt• coupl-tng on bllf way. Piece a reg over the coupling to prevent entrance of OPfiMTI-a ttAIIT!IMICf ttUtMl fentgn metter dwing the next step in assembly. C. COLUNN lPEN LINESHAFT Refer to instenotton pion or overon dtmenston sheet of the submtttol to det.ermtoe CGfl'Kt sequence of instonouon of colwm lengths. 1. Secure ptpe cl.np immediately beneath eolwnn coupltng. If co Jurm is f1ongad insert bolts end secure cllfnP below bottom of tllftll. ClaMP llle11d k_, .. bolts tn posttton. see Ulustnuon 1.2 COUPLING THREADED COLUMN FL.ANGEO COLUMN IL.LUST. 1.2 2. SUde the Unesblft tnto bottom of coltl'lll ptpe end enow tt to extend epproxtmetely 15· below tbe bottom end of the ptpe. t1ake certetn that the s188Yt ne of the ltnnheft (tf eppltceDle) ts town the top of the ptpe. Tte e sertes of hllf llttcbll to uae column ptpe IRd 11RIIhlft W1th 31-r rope. (A chotn ptpe YtM meu 4 be used· on the Uneshoft to Ue the rope to). Attach the sling to the clamp ears os descr1bed under Section 8, Step 2. 3. Holst column ond 1tR8SMft to the verttcol pos1t1on wtth the derr1ck. Do not drag shoft across the floor. Before centering cokmn over bowl, tap side of coii.IM to remove ony loose metter. 4. Post Uon the column end Jtneshoft OYer the bowl. A11gn the 11neshoft, and remo¥1 the reg front the bewlslllltt· coup11D4 •. _LiFt11(o11 the Uteods. . Lo~· untn the Jtneshoft contocts CO'CJUng, tMII rtmOY8 the rope. tmld coupl1ng end turn the ltneshoft (left hond threads) e.ntn the &heft ends butt up. Piece one pipe wnmch on the CO'C»ltng end one on the Lit£ SHAFT. Ttghten securely. ReiDOYt the wrench morts from t.Ae shaft end coupUng with o not fUt end emery cloth. 5o. If the bowl to colwnn connecUOA. ta thraoded, apply ttnod compowad to the pipe threads. Attach chetn tongs to bow1 end to col.., for support. Lower the COIUIM ptpe end ot the some Ume twn tbe ptpe · unUI tt seats ogatnst the mottng shoulder on the bowl. Tighten ptpe tnto bowl seanly. 5b. If bowl to colurm connection ts flenged, spreod e thin, 8Y8n ftlm of gasket compuwJ on the bow1 dtsehlrge flange. Lower ptpe, end ellgn stUds tn the bowl wtth holes tn flange. Slot the column GPfiATIOtl & tMIITEUKf ttAIIU&l. flange ogotnst bOWl nonge. Iuten Met ttghten heX nuts evenly. 6. Hoist aaemb1y eoough to remove the clomp on the bowl oasambly. 7. It there is ony owdltary ptptng to bowl beor1ng or thermo-wen being used., thot portion corresponding to the colwm sectton shoUld now be installed. Also., if the bowl end COIWM are coated with ony special coottng, •v required potch wort should be done before lowem.g untt. 8. Sltde beoms tn close to coh.mn. Lower the assembly end rest the clamp ears on the beoms. Remove the sUng. 9e. If there ts more then one secUon of threaded co).wnn, a centertng spider moy be used is used. SUp U. spider over the ltnesboft w1 th lode ring on top (1f rubber FIG. I a..-.. ... ·used). Screw the centering spider Into the column coupttng· unttl tt butts ega1nst the colurm p1pe. see tnustratton 1.3, ftgwe 1. 5 IISTALI.ATIOI 9b. If co1wnn ts nonged., clean flange end the 0.0. of the sptder. Sltp the spider over the ltneshoft wtth lack r1ng on top (1f rubber beer1ngs are used) ond seot into spider recess. See 111ustroUon 1.3., figure 2. 1 o. Clean on Uneshoft threods and foces thOroUghly. screw the coupUng on helf of trs length. Cover the coupHng wtth a rog to prevent entrence of foreign metter. 11. If there is more then one secuon of column, repeat Section C, steps 1 through 1 0 for eoch addtttonel sectton untn an of the colwnn 1s assembled. Cleon the threods/flange face of the colwm pipe and the Jtneshoft projection thoroughly. DO not assemble the shaft coupling to the top piece of shaft. FIG. 2 ILLUST 1.3 D. CDlut1N ENCLOSED LINESHAFT 1. sean ptpe clamp tmmed1ate1y beneath column coupUng. If celwm ts flanged tnsert. bolts ciKI secure clamp below bOttom of ftonge. Clamp should keep bolts tn posttlon. 2. Sltde the correct tubtng sectton wt th shift Into the column pipe. Allow the tubing to extet'Mt stx tncbes below the bottom end of tbe pipe. Allow the sheft1ng to extend about she tnches beyorMI u.e bottom end of the on tube assembly. T1e e sertes of half hitches to the ptpe, to the tubing end then to the lheft wltft.· u. 3/4 lncft rope. A thaift pipe Y188 IMIJ be used on the shaft. Attach · tM sung to the clamp. Leove room for remoYil of the sung while the cl.nps on resting on the beams tn the following steps. J. Hoist column -to the Y&rttcaJ postttOft w1th the-rope end denick. Do not dreg the sheft ecross the floor. Before cantering column over bowl, tep s1de of colwm to remove any loose matter. 4. Posttton the column end llnesheft over the bowJ. Align tile linesheft, end remove the rag from the bowllhoft coupUng. Lightly on the ttnlds. Lower lltttl tbl Uneshlrt contacts coqJltng. thaD remove the rope. Hold ceupllng end tum the Jlneaboft (left hMd threads) mU1 the nft ends butt up. P1ece one ptpe wrench on the QM4)11ng end one on the LINESHAFT. Tighten securely. Remove tbl wrench marts fro~~ u.e &Mft end coupling wtth a net rue .a emery cloth. 6 s. Low.-ossembly unu 1 tubtng contects the linesheft beortng# then remove the rope. Apply a smon ornow.t of threed compound to the upper bearing threods. Hake· certain not to get any threod compound on the f oces of the on tubes. Place one p1pe wrench OR Uw· suet-up tUbe of the bowl assembly and one wrench on the on tube usemb\V 1n the column ptpe. Align verUcelly end tighten. If the on tublftl ts coated· wa.ut any special application, fD.1 · · touch-up requtred resuiUng from uetng the PIJI wrench shoUld be done now. 6a. If the bowl to column connecuon ts tlnaded. apply lhreod compound to the ptpe t,.,.... Attedl chein tongs to bowl end to colwnn for support. Lower the colwnn ptpe lftd ot the same Ume tll'ft the pipe unttl it seats egeinst the mating shoulder on the boWl. Tighten .ptpe 1nto bowl 18CU1'81y. 6b. If bowl to coiWM connection ts flanged, spreed. o thtn. even fUm of gasket compound on the bowl dtscherge flange. Lower pipe, end align studs tn the bowl wlth holes in nenge. Seet the column flange egoinst bowl flange. lnsten and Ughten heX nuts evenly. 7. Hoist assembly enough to remove the cllml) on the bowl assembly. 8. If there is eny euxntery ptptng to boWl be.-tng or thermo-wen betng used, that port1on corresponding to thl column sectton should now be tnstelled. Also, 1f the bowl end column are coot ad w1 th any spedel coottng, any required potch wort should be done before lowenng unit. 9. SUde beems tn close to colwnn. lower the assembly end rest the c1snp ears on the beems. Remove the sUng. 10. After the colwnn l.aa been lowered end ts resttng on. the setUng beems pour ebout helf o cup of SAE 1 o on tnto the on tubing. AIPIY joint compcM.Ri to the leodtng threods of the LINESHAFT beertn~ on bore lightly, slide over the shaft end thnad tnto the o11 tubing for hltf or 1 rs length. It should not be necessary to exert eny stde pressure on the .shaft to stert the beertng. The need for such pressure tndtcates mts- eU gnment, bent shaft, or bent ot 1 tube tn ttats or precedtng sect tons end must be corracted before proceedtng. 11 a. If the coJwm is tln8ded end the setting ts deep enough to requtre e rubber center1ng spider, sUp the sptder OYtr the on tutnng end foRe tnto the colwnn ptpe lbout en Inch er two below the top end. Spectne of thl sptdln ts genanny 20 feet from tbe boWl end from tbe beod llld 410 feet. tn between. 1tb. If tbe colunn ts O•ll'l•. c.._ . .;.. the ngtsten tn the flanges Mel tnsert the e11gmng ling. Sltde the· rubber centertng spider over the on tUbtng end tnto the column. 12. C1een en 1tneshaft tJneds ond 1 IISTALI.ATIO. feces thonKighly. Screw the coupltng on helf of trs length. Cover the coup ling wtth o nsg to prevent entnnce of foreign metter. 13. If there is more than one section of colurm, repeet Secuon D, steps 1 through 12 for eech lddUtonel secuon unt11 all of the colwnn ts assembled. Note thot the top end of the top piece of on tubing~ coned the stretch tube, ts chemfered end filed smooth on the o.d. and hos extra Jong threeds for the tension assembly. E. PliF HEAD 1. Wipe o thin Ioyer of joint compound on the top column ttneds (or, tf connection ts flanged~ on the top flonge f oce). Remove the pecking glend assembly from the dtschorge heed· or motor stend. Cleen en mectnned feces of· the dtsctwge head/mot« stand thoroughly. Attech o sltng to the dtschorge heod/motor stond, hoist discblrge heodlmotor stend ond center over the colUIM. Lower the dtsct.ge head/motor stand · being careful not to damoge the top sectton of shefttng. known es the t.e.1 shift, or the strelch tube (tf eppltceble). 2e. Altgn the holes of the dtsct.ge hHdlmotor stond wtth the holes of the colwnn ptpe f1enge, then lower &.l\tt1 held · ts resting SQUW~ly on flenge. Install bolts end Ughten. 2b. Set the d1scherge heed on the top OPfMTIOII & tMIITEIAICE MIIUAL sect ton of threaded columA pipe. Screw the dtsehlrge heed onto the column ptpe 3. If thera ia ., ~ outlet, . place the held In relation to tbe outlet as closely os posstble to the finol pos1Uon. 4a. If en adjustable top flange or thneded · held ts V&ld, the heed· con be readily t..-ned to place it to the underground outlet. In eddltton, the heed should be turned os needed to ottotn the proper shaft projection end the correct distance from the outlet cent.-line to llw bottcn of the heed. Beck the pocttno nng off to onow omple worttng room. fUl the chomfer on the lower end of the flange _ with lompwlck pedctng thot his been precooted wtth jotnt compo&I'Mt. Use a generous amount of pocking end wtnd the pocktngorOURd tn such o manner that 1t 1s screwed tnto piece. screw the pectctng nng egcnnst the flange or bottom of uae heod end tighten. •· If the adjustable flange ts being l.8ed tn conj..w:tton wtth on tubing., thl top of the tUbing should be IPP'QXimetely 1-1/4 iacMI below tbl tenston boX mounting face of the heed after the flange ts adjusted. 5. Hotst head slightly. Recnon the clamp from Ute top piece. of colut'M. Remev.-setting beams end clean surf oce of the foc.mdiUon ttself. If thlrl ts en euxntery line to thl boWl be«''ng or thermo-well., that portton tmmedtotely below n attochtng 8 I liST AliA TIOI to t.he hlod should now be tnstolled. Properly piece d1scharge outlet end aHgn mow\Ung holes wtth anchor bolts end lower unttl heed ts resting squerely on the foundation. 6e. If heed is resting on f oundatton plate, oltgn mounting holes of the heed wtth tepped holes in the foW'Kiotton plate. Install and tighten cop screws. 6b. Mtx up o sufftctent quonttty of rather dry non-shrink grout. Force os much grout under the foundotton plate as possible. If grout holes are provtded~ grout con be presU"e · fed through the grout holes untn an cevtues are filled. 6c. As the heed ts resting on the fOCildation. dr1Ye wedges Under heed until proper eleYatlon 1s achieved end continue working wtth wedges until head 1s wtthin .005 tncnn of the Total Indicated Run-Out· wtth respect to top or heed shaft. Install and tighten hex nuts to anchor bolla. Grout \IMler the outer perimeter of the bead and form the grout to cover the wedges. 6d. If o motc:r stand ts used~ as tn an ~ dtsehlrge applt- cetton. 1t shoUld ftrst be determined that the outlet in the column oltgna wttb the discharge ptplng so that no stroin wt n be placed on the pump. Qo not rnakt tbts correction ot this ttmt. boweyer. Aft• checlctng the ptpe aUgnnnt follow Step 4a for leveling and grouting. 68. Step 6d should be foJiowed tf OPfUTIOI & ttAIUfiiAII:£ twiiMl. F. there 1s • sucuon connecthMl to tile heeder. It ts recommended that o flexible joint of some descr1ptton be employed bet ween the suctton flange end beoder to compensate for aUght mts- eUgrwnent. · If there ere no pro- vtstOM for one~ the header flonge must be perfectly eltgned 80 thlt oo misalignment ts tnnsferred to the pump. PACKING GLAND OR tECHANIC.Al SEAL 1. PACKING GLAND CPEN llf!ESHAFT a. Remove the split pecttng gJend. pocktng rings Md lontem r1ng from the gland assembly. C1eon the pecking box thoroughly end apply e copper gestet te the lower fece of the pecttng box. b. Sltde lhl peclctng boX over the heed shaft. Properly odJust mounting holes 80 that the . rrease ports of the pecttng gland ere directed toward the access windows of t•d1scherge heed or motor stand. Seet the pecking glond ogetnst the dtsct."ge head/mater stand then tnatan end tlfaten cep screws. It ShoUld not be necesserv to exert any stde prnaun on the lheft tn crder to seat the packing box prop.-ly. c. Reseet the first ttne· rings of poclc1ng using o spUt bushing. Seat thllMtem nng on the first three nnga of peclctng end follow 1 t with tine more rings of 9 I liST AllA TIOII pecktng. d. Insert the-studs 1nto the pock1ng gllnd. Place the split pock1ng glond on top of the packing nngs. Screw nuts onto studs but do not Ughten down on the poctcing. This w111 be done only during start-up operation. 2. MECHANICAL SEAL f.P£N llNEStWT a. Due to the rnony different 1'18Chenico1 see1 types.. it ts necessary to refer to the proper mecbentcol seat Instruction· book fer complete li88n$ly detons. 3. PACKING GLAND ClOS£0 LIN£ SHAfT e. If a motor stand 1s employed. go to Section F .• step 3b. Screw the oi J tube 1oclc nut onto the extension tUbe. b. Ploce the pocktng box gosket erot.md the pecking gland seat of the dtacherge heed/motor stond. Screw the packing box onto the extenston tube until 1t seots agatnst the gasket. Tighten the pectctng box one-quorter tW"Il more for short or close coupled eppltcottons. Ttghten the peclclng box enough to telce up 3/16. per every hundred feet 1n deep well applicattons. c. If a motor stand ts employed, go to Sectton F ... step 3d. Insert e shOrt pteca of shafttng or a boord throUgh the discherge opentng of the dtschorge head. Ploce tt IPEIL\T181 & ttiiiTEIAIIC£ tMIHIAl ogatnst the ot 1 tUbe lock nut ond Ughten the lock nut ogatnst the pecktng box. d. Seot three rtng.s of packtng tnto the pecking box and around the extension tube. Screw on the pocking follower ond ttghten securely against the pocktng rtngs. Postt1on the dust cover on the pocktng box and align the ho las or the dust cover wtth the to~ed holes tn the d1schorge t.od/motor stond. lnstoH end t1ghten cap screws. G. VERTICAL MOTORS 1. HOLLOW StWT MOTOR a. Clean thrleds ond face of hlocJ shaft projecting above pecttng gland thoroughly, then on ttnods Hghtly. Thread coup1tng on shaft for half of tt"s length. Stuff o ng 1nto open end of the shift coupltng. b. Remove the top cover from the motor. Unbolt the coupling (clutch or drive block) from the motor ..S remove the ceupltng. c. Run e ftne nat tne ovw the rnotar mounting u1ece of the t.ed to remove any ntcks or burn.. Thoroughlg Clllft fOCI end rtglst ... wttll solvent Wtpe e t.b1a Ioyer of Ught on over surfece. Tbts wtn help prevent rvst ond wtn also foctlttate _ aUght *fvw shtfUng · ckring coupling oltgnment. d. Attach the erect• SltAf to the motor 11fttng lugs. Hotst motor suff1c1enUy to enow eesy eccess 10 IISTAI.LATIOI to mounung nonge. Remove n1cks end bun's on the mounting flange wUh e rtne not rne, onc:1 thoroughly cteon With solvent. e. If there ts surttctent heod room to tnstall the motor shaft after placing the motor on the head, prepare the short os described tn Step g. below* then lower the motor shaft through the motor wtth t.be keywoy end up. Install the held nut end threod it on 4 or 5 Unods, then allow the short to suspend tnstde the motor. 1. Holst motor sufftctently to cleer the st.d, end swtng It OY8f" untU ootor ts resung on MCMI\Ung rtng. Properly place conduit box, altgn moonUng holes end tnstoll but do not ttgbten cep sere~. g. Clean the head shoft thoroughly end dress the threads end keywey wtth a 3-comered rne, tf necessary. Ltft the motor shoft onc1 carefully lower tt thrOugh the QUtll or hollow shaft (end wttb keyway · goes towerd the top) end onow shoft to contact heed coupling. Remove the rog tn the coup1tng. Screw the motor shaft tnto the motor coupling on the heed shaft end tighten. h. t1eke ternporory electrical connectton to motor. IUDil starter to detenntne correct rototton (coc.r.ter clodcwtse os viewed from above). Install end ttghten cop screws to the motor end dtscbarge head/motor stand. If POWK ts not mtlable. DO NOT mokt ttnol dc1D Shott coooecttons <steos t.J & t> untn oower ts oyoUobJe pod comet OPERATIOII &. NlfifMICf ttUUAI. rotatton ts detenntned. 1. Piece the gtb key on the drive plete OYer tile ho11ow sheft egeinst the drive sheft. T..-n the rotor observ1ng the cl...-..nce between key and sheft, shttt <iiver untn the key touches ell eround. Tighten the CIP screws. j. Slide clutch OY8f drive sheft, seet egainst drive plate, Install end Ughten belts. k. Tum clutch untn keywoys tn &heft end clutch o11gn, install and seet gtb key. Ttread head nut onto sheft until it seats egetnst top of the clutch. Hold the clutch from turnlnt end un head nut weUl Impellers clear the bottom by .125• for enclosed Impellers .w .o 15· for semt-open tmpe11ers, allowing the rotor to turn freely. ConUnue to ttghten head nut untn tmpelltn ore elevoted 1 sufficient dtstence to accommoctete pwnp fVYauUc thrust end essocteted shift stretch (see the ENGINEERING section of lhts menuol for detetls). Align holes tn heed nut wtth tops In clutch, tnston end tighten mechtne screws. Place top COYer on dr1ver end sean. 2. 5(1..10 SHAFT 110TOR o. Cleen the thraedl of the heed shaft thoroughly end dnss them wUh 1 3-cornered file If necessery. b. SlIde the pump hub of the edjustlble mot.-coupltng ·onto the heed-shaft end tns«t the gtb key. Screw the edjust.-nut onto 11 liST ALLA TIOII the head shaft. c. Attech the erector sling to the motor lifting lugs. Hoist motor sufftc1enUy to on ow eosy eccess to mounUng flange. Remove nicks end burrs on the mounting flange w1th a ftne not f11e, ond thoroughly clean wtth solvent. d. Wh1le the motor 1s suspended from the erector sling., slide the motor hub of the adjustable motor coup11ng onto the motor shoft. Insert the g1b key into the keyway of the motor shaft end motor hub. Slide the motor hub f • enough up the motor shaft to expose the keeper key seat on the motor Shaft. Seot the keeper key onto the motor shaft. Pull the motor hub down over the keeper key. e. Piece the spacer on top of the adjuster nut tf appUcoble. f. Hoist motor suff1ctent1y to clear the stond, end lower 1t until the motor 1s resung· on d1schorge heed. Properly piece conduit box, e11gn mounung holes and install but do not \Umten cep screws. g. Adjust the adjuster nut unU1 there ts .125· between the spocer/adjuster nut ond the motor hub for enclosed impellers or .ots· fer sem1-open Impellers. Allow enough-room odded to the ebo.Ye adjustments to eccom- modete pwnp hydreUHc thrust end assoc1eted shaft stretCh (see the ENGINEERING secUon of this manuo1 fer deteUs). h. Mike t......,.,..., e1ectr1ce1 COMICUen to motor. fHml sterter to determine correct DlfRATIII a tMIIITEIIIICf ttAIIIAL rotottoa (coooter cloctw1se os Yfewtd from above). Install Olld t\glatiR cep.screws to the motor ond cHschorge head/motor stond. If power Is not oyoUoble . .QQ tm mote flool drive short COOOICUQOI (SliD 1) UQUI DOWI[ is oyo118ble and CO[IICt retattoo ls d8tarmtoed. 1. AJtgn holes end taps of the motor t..tb, pump bub, odjustar nut end spoc.-Of oppllceble). lnston and tighten cap screws. H. tt1SC£LLAHEWS ASS£11BLIES I I LUBRICATOR o. lnston the on pot on the discharge heed. Install necessarg ptpe fttUngs In on pot to connect the on dripper 1 f there ts a solenoid oner, tnstall tt betw.n on pot and on dr1pper. Connect the I /4 Inch copper line from on dr1pper to the padctng gland Inlet port. 2. DISCHARGE PIPING o. Above floor ptptng should be tnstellld tn SUCh a monner as to eltmtnate the posstbl11ty of the clschergt bead being strained. Gete vtlves, chick veJ¥88 and other ptplng ttems must not depend upon the pump head for support. b. lftterground dtschlrgl con- nect tons should be made In such o manner u.t .. no stnatn or 12 IIISTALI.ATII. mtsaltgnment ts imposed ori the colwm ptpe. Allgrvnent between the purRJ discharge and the outstde shoUld hove olreody been achteved es Instructed under secuon E, step 6d. c. If a flexible joint such os o dresser coupltng ts to be used, the Ue bolts ones lugs used to spon the flexible jotnt should be of sufficient strength to restst the force creoted by the cHscherge pressure ot the pump head. None of this force should be imposed on the heed ond the fOI.I\dotton bolts. The tension should be telcen carefully on these Ue bolts so that q .,....t of forwon:l movement Induced to the heod wt U be counteracted during operation so thot oltgnment ts metntotned thrpugbout OD8I'JIUOn. 3. AIR RELEASE VALVE a. Install the air releose volw on the pump head or. just beyond on the dischorgl piping. It ts suggested that If a throttling YOIYe Is not furnished, o threttltng dMce be used to restr1ct the dtschorge of atr to trmn that a cusnton of otr ts ovotlobJe in the d1schorge heod. P1acament . of the throttling deYtce should be such that the otr raleese Yelve ts bet ween the dtscMrge heed end throttling valve. Note: Exheusting the otr from a bead too quickly often causes breakage. OPfRATIOI & twDEMICE KUI8AI. 4. GAUGES AND MISC£LLANEWS PIPE CONNECTIONS e. Connect the pressure gauge to the top in the d1scharge and 1f required In the suction flange. Position dial face to fecUttote nodlng. b. Mete pre-lube .. drain .. greose Une to ton beortng, etc., pipe connections. Route piping so that 1t w11J not interfere with normol 13 maintenance procedUres. 6. ELECTRICAL CONNECT IONS o. All connections to the motor such es metn leeds, space heater leeds .. winding pretecUon Jeods, etc.. should be mode in occordence wlth prevoi11ng spectftcouons. b. Hoke necessary connections to Jubr1cotor solenoid. IPfiATIOIA. tiAIIITEMIICf KAIUM. I. COftSIDERAT lOftS When o pwnp Is mode for use by an tAdustry or rruatctpoltt~ it ts usually o short coupled or close coupled pump assembly. A short or close coupled pump ts stmply o short pump assembly for use tn o sump or booster oppltcoUon. Short coupled pump ossemb11es ore usuony sn1PP8d completely ossembled less the c:rtYer. Storege for such pwnps ts on eosy metter when ustng o Ultle convnon sense. Pumps used for agrtcultwel p.erposes on the other bond~ tend to be deep setUnt pwnps. These ore shipped unossembled. The un- essembled p1eces generally being the driver, the dtschorge or motor stend 1 COili'M ptpe~ tube end shefl assernbltes, end the bowl ossembly ttseJf. AgotnJO common sense ts the best tool for determtntng storege teCMtques. The following ts just o generol Hsttng of some thtngs one might constder. II. &EIERAL HID'S As stated In the INSTALLATION chapter of thts monuol, tt 1s o very good tdee to mek8 sure on ot the necessary tt.,. ordered 11"8 ncetved tn good order. 1. After e.mcreUng/unpokogtng end checking that· ell ttems were ncetved tn good order, recrete and pectoge on ttems 1n the same manner that they wen received. Cleerly 1obel eoctl poctege es to 14 STOAAG£ the contents end use In the ossembly. 2. If more than one stze and/or model of pump is ordered, tote spectol cere not to confuse ltke t terns for the two or more pumps. Items such os valves, gouge, bolts end hordwore, or spore ports. 3. Group ports occon:ling to the1r stage of assembly. Example: bowls first~ column end shofUng second~ dtschorge thtn:l, end so on. Thts will seve searching for the proper ports end hardware ot ony gtven potnt of assemblage. Ill. SHORT COUPLED PUitPS 1. Cover suction ond dtschorge ports to prevent entrance of ony foreign metertols. 2. Cover on other mtsceHoneous holes~ t.e. pressure rettef # pre lube end pnSS&n gouge holes, etc. 3. Avotd exposure to weether end elements. Thts can be occompltshed. by either storing indoors or covertng wtth o terp. 4. Apply support so thot no stele press&n ts 8)Cirted on the pump when p1oced in storage. IV. niSCELLAIEOUSITEnS The best odvlce for most ports ts to cover any openings end keep ttems from exposure to adverse condtUons such os provtdtng level support of on tubes end shafts# protect ony threads, end store in o momer so that the 1tem mtght not fell or be knocked over. GPfiMTIOII A KAIITfiiAKE HAIIIMl These things ere listed merely es gu1deUnes to proper storage. When stonng anything tt ts necessary to osk the quesUons of ·where· end 15 STOMGE ·how·. The answers wtll depend on the opplicetlon. materiels of constructton. ond the duratton of the storage to nome e few. I. BOWL DISASSEtull.Y 1. Remove the bowl assembly from the column assembly. 2. RemoYe the bell suction from the bowl assembly (U oppUcoble). 3. Remove the grease plug from the suction bowl. 4. Insert e ratatntng bolt through the greese plug hole end screw Into the bottom of the bowl shaft to retain the shaft end the tmpeUer(s) cleor of the bottom seot. See t11ustrat1on 2.1 BRACKET TO SUIT BOWL SIZE. IBY CUSTOMER I 5. Remove the cap acnws connecting the cHscharge bowl to the top bowl end sltde the cHscherge bowl from the pump shaft. DO NOT ALLOW THE WEIGHT OF THE BOWLS TO RESf I* THE BOWL SHAFT· WHILE REt10YING.. 16 .WL DISASSEHILY & ASSEHBl Y 6. Remove the cop screws connect1ng the top bowl to the suction bowl If single staged or the tntermedtote bowl if multiple staged. Slide the top bowl from the bowl shaft. 7. SHde the femole end of o collet knocker (see tllustrotton below) toward the Impeller collet. Sit de the collet bock end forth on the bowl shaft knocking the Impeller wt th enough force to jor the impeller loose from the collar. Remove the collet knocker. See tll~trlttt~ 2.2 ILLUST. 2.2 TO REMOVE COLLET 8. Use a screwdr1ver to spreod the collel Remove the collet end the tmpeller from the bowl shaft. 9. Repeat Steps 6 through 8 untt 1 ell trnpellan are removed. 10. Remove the retotntng bolt from the bowl Shaft. 11. Pull the bowl shaft from the suction bowl. 12. Loosen the set-screw on the sand con.-end sUde off of the bowl shaft. •ruTNIII & tiAIITEIAICE ttiiiUAI. II. BOWL ASSEIUJL Y Before assembly., check the cleoronces of the bowl beorings ond the tmpe11er skirts. Check the bowl shaft for excesstYe weer. BOWL BEARING DIAMETER CLEARANCE SHAFT DIA. CLEARANCE 1.000 .007-.010 1.187 .0075-.0105 1.500 .009-.012 1.667 .0095-.013 1.937 .0105-.014 2.187 .0115-.015 2.687 .0125-.0165 1. Sltde the bowl short tnto the suctton boWl. Altgn the end of tbe shift wtth the bottom of the bowl beoring. 2. Slide the sand collor on the bowl shoft ond seat tt OYW' the bowl beering. TemporerUy ttghten the set-screw. 3. The shoft side-up must be sat It thts ume. Slide the cftsehlrge bowl ov .. the bowl shaft leeYIRQ. enough spece for the tep bowl end the tntennedtete. bowl(s) (tf oppUceble). Sltde the bowl shift tn or out to anow for the proper st 1ctc-up. See tllustratton 2.3. The suet-. ts tb8 distenee from the top end of the bowl·lhlft to where the COlUIM pipe butts up to the bowl ossembly. Attecb I ntotner plate os shown tn 111ustntton 2.1 Tight• the sand collor setscrew. 4. Insert the ntaintng bolt ttnugh uae sucuon bowl and· Ughten the . ' 17 BOWl DISASSEMil Y & .ASSEJUl Y locknut (f1nger Ught>. 5. Slide the dtscb«ge bowl off of the-bowlsheft. Be careful not to domoge the bowlshaft threads. ILLUST. 2.3 6. Slide the 1mpe11er on the pump shift and follow wtth the collet knocker (men stde towonl the 1mpe41er). Hold the tmpe11er oil the way to the bot tom of the bowl with one bond end. sUde the collet 1nto the impeller wtth the collet knocker. The conet should be ot 1eest flush with the tmpen.-. Remove the collet tnocter. See u tustrauon 2.4. TWO THIN (.030"'1 WIDE LINES OF LOCTITE RUNNING LONGITUDINAL ON COLLET ILLUST• 2.4 7. Sltde the intermediate bowl housing onto the pump shaft. Use cauuon to ovoid putttng the bowl weight on the bowl shoft. Bolt the 1ntermedtete bowl to the suction bowl wtth eepscrews. e. Continue Steps 6 to 1 untn the assembly ts complete. CIPfRATIM& twiTEMICf tMIIIMl q RemoYe reto&ner bolt from the bowl shaft. Chedc the bowl shoft for rototton and lotent movement. Loterol should be os stoled on poge 20. 18 10. F111 the beor1ng cevuy tn ·the sucuon bowl wUh o non-soluble grease ond insert the pipe plug In the bottom of the suction bowl. A. PRIOR TO START-UP 1. Perform Initial servicing on the dr1 ver as recommended by the driver manufacturer. Also perform initial servicing on an oux11iery assemblies 1f required. 2. Recheck all fasteners and fttUngs for tightness. 3. If the air releose is menuol or 1f o1r vent is oulomatic but equipped wtth a valve, melee certotn thot the valve is opened oort1aJJy but no alJ of the way. 4. If there ts a control velva on the discharge stde of the pump. moke certain that 1t ts porttelly open so thot the pump will not be damaged if normal bact pressure ts not avatleble until long ltne, etc. is filled. 5. If un1t ts on lubricated, fiH lubricator with a good grade SAE to viscosity rau~ low cold po..-point mtnenl on. f1MUIHV open needle valve end anew about a cup of on to dretn 1nto tubtng. REFILL LUBRICATCR. 6. If untt 1s open LINESHAFT and equipped wtth pn-1ubr1catton, turn on the pre-lubr1cation system some Ume before start- up end onow tt to nm a short ume ef'ter st.-.-up. 7. If untt ts force water klbrtcated. t..-n on end regulate flow from 1 o to 1 s PSI above normal dtscherge pressure. Lubricauon should conunue dlrlng enure pump operetton ume. 1 f the tan beortng 1s olso lUbrtcotld by outside water, presan need 19 only be about 5 to 10 PSI. 6. .esmm starter to insure that the untt has correct rotation. B. INITIAL START-UP 1. Energize starter. After pump has come up to the reted speed and oil a1r hos been exhousted, regulate control volve to ochteva desired pressura. 2. If the air release is monuol, close tt off after air ts exhausted. If air release ts automatic, determine whether atr was exheusted · too quictcly, ceus1ng the pump to jer1c violently when the. valve closed. or too slowly end regulate monuel valve or throttling ®vtce to correct thts. 3. Regulate lubricator to allow 5 drops of on per m1nute for each 50 feet of setting. 4. Check an Joints for leakage ond correct 1f evident. · 5. 11oke certeln that the driver ts operating satisfactorily as to temperature, beoring tem- perature, etc . ., as prescr1bed by the driver manuf octurer. 6. Check for excessive vtbretton. If thts ts evident shUt doWn untt tmmecltate1y end beg1n chect1ng for cause. 7. AdJust peck1ng glend to onow some leotege post the packing. After nm1ng un1t for a number of hours, chectc gland end if tt is hot to the touch loosen ..-.ul tt b8comes no more than warm to the touch. When e f1eld test of the pump's performance ts requtred. make the following reedings: Vohme. Total Heed end Horsepower Heosurernents. Rotating Speed end Liquid Tempenture. Compere the results of tbe field test wfth the performonce curve for your pump. All volume. totol head end efficiency guarwltees ere based on shop test when handling c1eor. cold. fresh woter at 1 tempenbn not exceeding as• F. end under specified suct1on conditions. (1) VOIIIDI etooocttyl neosurement- Measure the rote of flow from th& pump d1schorge tn gallons per minute. Tbe volume meosurement lniY be IMd8 · using eny one of the following pieces ot equipment: A coUbrated Venturi meter. 1 thln-p1ote caUbroted or1flce, e calibrated pilot tube. or en accurately rneestnd resewlr. · (2) Total tteod 111oswJmeol . -The total pumping heed consfsts of: dlstonce from the weter level In \he sump (when pumptng) to the center of the dischorge pressun gauge. plus the discharge gouge reod1ng nt the veloctty hied· et the dlschlrge. Convert ....-.. gauge nodtng to feet of ltqutd by multiplying the noding ttmes 2.31 times the Specific 20 f1RD TESTS Grav1ty of L1QUid. (3) tforseoower Measurement - Meosure horsepower consumption of the pump by o d1rect reeding of a wattmeter ond applying the reading to the following formula. ttersepowar-Formula: Bhp : KW lnoot x Eff l 0.746 Where: KW Input Eff1 Eff2 Sg =brake horsepower delivered = reel input power (KW) = motor efficiency = pump efficiency = specific grw1ty of Uquld The motor efficiency cen be determined from dynamometer tests. P1mp Efftcteacy F.,.....la: Pwnp Eff. = TDH X GPM X Sg 3960 X Bhp TDH = total dynom1c head 6Pt1 = gallons per minute Sg = spectf1c gnwtty of Uquld Bhp = brake horsepower IPEMTIOII & IMIUEMICE IMIUAl DOWITHRUST Downthrust ts the total tlnlst lood exa:ressed tn pounds corr1ed by the thrust beoring tn the motor. gear dive or pump head. It is the un of the weight of the rotating elements end the hydraUltc downthrust of the bowl untt. The shaft length ts the Slln of the setUng (column lengtht the length of tbe discharge heed end the drtver (from dimension sheet) and the length of the bowl assembly ·(from the pump curve). Exomp1e: Given • 6 stoge SRIOC bowl assembly. 75 HP. 1770 RPt1 rwotor. 5600 dischirge heed. 200· setting. 1 112· shift. 6. colwm. end 31 X total dynemtc head. For K fectors. Jetenl. end shaft weights see pege 18. For 1mpelltr wetflt see per- fonnence cwve. ( 1) 200' (setting) + 6.5' (bowl shoft) + s· (heed shift) = 211.s· feet of shafting. (2) 211.5 x 6.011bs. (&heft weight per foot) = 1271 Jba. of shift. (3) 312' Til) x 4.7 (K foetor) = 1 «J6 1bl.. bydnu11c thrust. (4) 6 (rulber of tmpel1en) x 11 1bs. CwetFt of one tmpel1er) = 66 1bs. Add (2). (3) end (.-) end get 2803 lbs. of total thrUst loed. Tbe motor date sheet shows· e 75 1-P motor at 1800 RPI1 to heYe o nennaJ thrUst capetMJttv of 4800 1bs .• so no edd1Uone1 thrust lood capoci ty Is required. 21 fEIIEERIE NOTE: CoupHng weight moy be odded for deep aetttng pumps. SHAn STRETCH The hydraulic thrust when the pump js operating 1mposes on extol tensile loed on the shoft which ceuses the shaft end column pipe to stretctt 1 t ts necessary. therefore. to detenn1ne the magnitude of the net elongation end whether or not the elongoUon exceeds the cleorence prov1ded in the pump bowls. If there ts Insufficient c1eorence, the impeHer skirts wn1 nab on the bowl seal rings. resulting tn excessive weor end power conswnpUon. From the example ot the rtght we hove 1«.6 lbs. of hydrlulic thrust. -From the. shaft elongation chert (poge 19) tt ts found bg tntwpoleUon that the elongation for 1 1/T shaft ot 1466 lbs. hydriUltc thrust is .034' per 'oo· of wft- ElongeUon for 200'' of shaft = (200/100) x .o34· = .068· Column elongation ts found by the same method ustng the column el.,..uon chart (page 20)- ElongeUon for 200· of colt.mn = (200/100) X .006 = .01T Shott elongotton . minus colurM e1ongetton equals net elongot1on- .06tr-.01T = .056· Chect the chart on page 20 under bowl date to see if the standard lateral. provided is odeQUOte. tf not extra letenl meu be moch1ned tf required. BOWL t100EL SN6C SP6C S67C SP7C SF6S S66C SH6C SJ6S Sl8C SRBC SC10C S010C SE10C SF10C SGIOS SH10C SI10C SJ10C Sl.10C SP10S SR10C SUIOC SV10C SW10C SC12C SD12C SG12C SH12C SJ12C Sl12C SP12C SRI2C fMGIIffRIE HYDRAULIC THRUST TECH .. CAL DATA BOWL DATA IMPELLER K LATERAL WEIGHT FACTOR 2.75 1.6 9/16. 2.25 1.8 9/16. 5.25 5.3 t-1/a· 5.25 5.3 1-1/&- 5.00 2.9 11/16. 5.00 2.7 13/4"' 5.00 2.8 9/16. 5.00 5.2 11/16. 6.75 3.6 3/4. 7.50 4.5 1-1/4. 9.50 3.4 3/4f' 9.00. 3.5 1-513T 9.50 3.4 3/4. 9.50 -·3.6 1-513T 7.00 5.3 11/16. 8.25 5.3 3/4f' 9.25 4.2 15116. 11.00 4.8 13/16. 9.75 4. 1 3/4. 7.00 7.8 15116. 11.00 4.7 13/16. 12.75 3.9 13/16. 15.25 7.6 1-9/16. 13.00 5.5 15/16. 14.75 4.8 11/16. 17.75 4.8 11/16. 12.25 3.8 7/e- 14.75 6.2 11/16. 16.25 6.1 11/16. 15.00 5.3 15/16. 16.00 11.7 15116. 16.00 11.7 15/16. 22 BOWL DATA BOWl IMPELLER K LATERAL MODEL WEIGHT FACTOR SS12C 16.25 6.0 716. ST12S 8.75 11.2 11/16. SU12C 15.00 7.9 11a· SV12C 16.25 11.7 15/16. S014C 34.00 19.4 1-3/16. SG14C 34.00 19.4 1. SJ14C 35.00 19.4 1. SR14C 32.75 19.4 1. SG16C 40.00 34.9 ,. SP16C 40.00 34.9 1. K fectors ere et peek efftctency, everege K factors ere about 501 higher. SHAFT WEIGHTS SHAFT WEIGHT DIAMETER (LBS. PER FOOT) 3/cf' 1.50 ,. 2.67 1-3/16. 3.77 1-1/4. 4.17 1-7/16. 5.52 1-1/T 6.01 1-11/16. 7.60 1-15/16. 10.02 2-3/16. 12.78 2-7/16. 15.87 2-11/16. 19.29 OPEMTIOI &. t'IAIITEUICf HA•IML IIVOIMUliC THRUST 3/4 500 .047 600 .056 800 .075 1 800 .0941 1 200 .112 1 .o400 .131 1.600 .150 '800 .169 2 000 .187 2 «)() .225 2 800 .262 3 200 3.600 4000 4.400 4.800 5 200 5.600 - 6.000 6.500 7 000 7.500 8.000 9.000 10.000 12.000 14000 16.000 18 000 20.000 22.000 24.000 26.000 28.000 30.000 SHAFT ELOI&AT 101 CHART (InCheS per hundred feet of shafUng) StWT DWtfTER t..c•> 1 1-3116 1-1/2 1-11116 1-1511_6 .026 .018 .012 .009 .007 .032 .022 .014 .011 .008 .042 .030 .019 .015 .011 .053 .037 .024 .019 .014 .063 .045 .028 .022 .017 .074 .052 .033 .026 .020 .084 .060 .038 .030 .022 .095 .067 .042 .033 .025 .105 .075 JW7 .037 .028 .127 .090 .056 .044 .0341 .1. .105 .066 .052 .039 .169 .119 .075 .059 .045 .190 .135 .085 .067 .051 .211 .150 .094 .074 .056 .240 .164 .103 .081 .062 .253 .179 .113 .089 .061 .274 .194 .122 .096 .073 .209 .131 .107 .019 .224 .141 .111 .084 .243 .153 .120 .091 .260 .164 .129 .098 .176 .139 .105 .188 .1G .112 .211 .167 .126 .2:W .185 .140 .281 .222 .168 .259 .196 .296 .224 .252 .280 23 f11iiiEERIIG 2-3116 2-7116 IZ-11116 .006 .009 .011 .009 .013 .011 .015 .012 .010 .018 .014 .012 .020 .016 .013 .022 .018 .015 .026 .021 .018 .030 .025 .020 .035 .028 .023 .0410 .032 .026 .0+1 .036 .029 .o.a .039 .032 .053 .043 .035 .057 .046 .038 .062 .050 Jl41 .066 .053 .044 .071 .058 .047 .077 .062 .051 .082 .067 .055 .088 .071 .058 .098 .080 .066 .110 .089 .073 .132 .106 .088 .154 .124 .102 .176 .142 .117 .198 .160 .131 220 .176 .146 .242 .195 .160 .264 .213 .175 .286 .230 .190 .2. .204 .266 .219 OPfiATIOI a HAIITEIIHC£ tMIHMl lft'DIWI.IC THRUST 3 500 .007 600 .008 800 .011 1.000 .013 1200 .016 1 400 .019 L600 .021 I 800 .1)2-4 2~100 .027 2 410 .032 2.800 .03? 3.200 .&43 3 600 .048 4000 44)0 4 .. 800 5.200 5 .. 600 6.000 6 .. 500 l.OOO 7 500 8 .. 000 9 .. 000 10.000 12 .. 100 1-4000 16 .. 000 18J)OO 20 .. 000 22 800 24000 26 .. 000 28 .. 000 30.000 COLun• ELOI&ATIOI CHART (Inches per hUAdred feet of colurM) JD11W.l COLIHI DIAtETER (inches) • 5 6 8 10 12 .005 .004 .003 .006 .005 .OG4 .008 .006 .005 .010 .008 .006 .004 .012 .009 .007 .005 .014 .011 .008 .006 .016 .012 .009 .007 .005 .018 .014 .011 .008 .006 .020 .015 .012 .009 .007 .023 .019 .014 .010 .008 .006 .027 .022 .016 .012 .010 .00? .031 .025 .019 .01-4 .011 .008 .035 .028 .021 .016 .012 .009 .039 .031 .023 .01? .014 .010 .043 .034 .026 .019 .015 .011 .047 .037 .028 .021 .016 .013 .051 .040 .030 .02! .018 .014 ·.oss .043 .033 .024 .019 .015 .0. .035 .026 .020 .016 .050 .038 .028 .022 .017 .054 .041 .030 .024 .018 .058 .044 .033 .025 .020 .062 .047 .035 .027 .021 .053 .039 .030 .023 .059 .043 .034 .026 .070 .052 .041 .031 .082 .061 .fMI .036 .094 .070 .054 .042 .078 .861 JW7 .087 .068 .052 .096 .075 .057 .104 .082 .063 .113 .088 .068 .095 .073 .102 .078 24 EKI.EERIE 14 16 .008 .008 .009 .010 .009 .011 .010 .012 .9t1 .013 .011 .014 .012 .015 .013 .016 .014 .017 .015 .019 .017 .021 .019 .025 .023 . .029 .026 .034 .030 .038 .034 .0<42 .037 .046 .041 .050 .045 .055 .049 .059 .052 .063 .056 OPEIMTIOII & tMID'EMIEE tMIUAL I. 6EI£RAL 1. For nonnol operation end meintenence of driver, foHow the instrucUons of the drtver menuf ecturer. 2. Check the oil level tn the lubricator end refHl on e regular scheWle. If pwnp is otl lubr1cated. 3. If the wnt requ1res pre- Jubriceuon, meke certein thot tbis process ts started tn emple Ume pr1or to pump start-up to tnsun thet ell beenngs ere properly wetted. 4. Apply greoae to the pecttng gland essembly at the nte of one ttn of e greese cut for eech 24 hours of openUon. -- 5. If force water lubricauon ts employed, this system should be twned on prior to eoch stert -up and proper presswe should be motnte1ned. 6. The poctctng glend should seldom requint adjustment but tn the event thot the leokoge becomes- excessive, tighten the gland sufficiently to throttle leekege bllt not to pnyeot on Jeokoge. _ Remember thlt OYer ttghtentng wean out the pecttng rtngs prematurely end ceuses sconng and demage to the shaft. Always odjust the glend wtth the untt rvnntng. 7. If the bowl beertngs ere pr8SSW'8 grease lubricated apply about one turn of a greose cup for each 24 ho..-s of operauon. 6. Refer to ortginol equ1pment raaoufactunrs melntenence 25 HAIITEMK£ monuels for detetls. II. BEARIN& REPLACEI1£NT 1. Metal beenngs such es bronze can be readHy pressed tn with and arbor or screw press. If this is not evetleble, they cen be dr1ven In very cerefuHy wtth e block of wood end e hemmer. t1eke certain. that beenng projections ore metnteined. 2. Grephtte end metal compostUon beor1ngs do not possess greet tensne or compressive strength end camot be driven In es metal beer1ngs cen. They must be pressed tn w1th e slow, continuous end even mouon ottelned wtth end .-bor or screw press w1th a mondrel to ftt the bearing properly. The hub bore end the beer1ng should be lubricated wtth weter to aid the pnsstng opentton. DO NOT LUBRICATE WITH OIL OR GREASE. Ill. WEAR Rl•& REPLACEI1EIT 1. Weer rings cen be removed by cutting the cross sectton wtth a chtsel and prying one end inwerd untn tt 1s loose tn the bore. To tnstan. make a mandrel to ftt the weer rings end press In wtth on arbor or screw press. In en ~ the weer rings con be tnstelled by gently end evenly tapping around the top edge with a wood bloctc and • ~emmer or o rubber hammer. 2. If tmpeller sttrts ere equipped with wear rings, cut the wear GPEIMTIOI a. ttAIITEMICE tWIIMl push the pecking to the bottom of the boX. The O.D. of thts sp11t bushing should be opproxtmotely .005 inch smeller then the bore of the pecking box to preyent the formeuon of e Up on the pocldng tbet ts being seoted. Seet th1s bottom rtng herd because 1t must seol on the rece· of the pocldng box beer1ng es wen es ogotnst the shift end the bore. See 111ustretton 6.1. 5. Repeat th1s operation with eoch nng tnelctng s..-e to stegger the gaps formed by tM ends or the ring et 90 degrees tntervols. See t nustrotton 6.2 TOP VIEW SIDE VIEW ILLUST. 6.2 6. If o lentem rtng Is used, be U'8 It ts properly positioned so that 1t ts centered with the dr111tng tn tAe pectctng box. see tnuatntton 6.3 7. Pos1tton the split pocking gln 27 tiAI ITEIIAII:E Tighten tt down evenly. The split poddng glend must not be cocted wtthln the pocking box. An unsquore spHt pocking ghmd couses untYen compression of GREASE LINE f:ll:llll.--"''~" ER LANTERN RING WITH GREASE LINE 1LLUST 6.3 the pecking rings ond more importantly, damoge to the shofl Good practice Js to ell ow ot least 1/4 tnch from the top of the top pecttng rtng to the top foce of tbe pecking box.· Thts helps center the gland end mtntmlzes cocting. See UlustnUon 6.4 ILLUST 6.4 CIPfiMTICIIA tiAIIfTEIAICE ttAIIUAL a Permtt sufftctent leakage to keep the pecktng boX runntng cool. Adequate 1eokoge at thts Ume ts a necessity. Check the temperetn of the lnkoge os wen es the pump housing. If the pump runs hot end the leakage bag1ns to choke off, tt ts edvtsobte to stop the PtJft1' end permit 1t to cool down. After the pump hes cooled sufftttently., re- start ond repeat Step 6. 9. Allow the pump to run 15 mtN.~tes and tf leakage rete 1s more then dlstreble, tighten the glond nuts 1/8 of a turn . Thts pocttng adjustment ts made wtth the pwnp runntng. Before making another adjustment, allow the 26 ttAIIfTEUIICE pecking to equoHze egatnst the tncreesed pressure ond the leakage to gradUally decrease to o steady rote. PUMP PACKING MUST AJ.WAVS LEAK SLIGHTLY. Mote: 1. Chences ere the pecking will run e ltttle wormer for the f1rst few days ooUl the pocking nngs hove bumtshed tn. Often the leakage rete wtll reduce by itself at this ttme. 2. Remember that metelHc end plosUc pect1ngs ore good for temperatures of ot least ~F. So, even tf the leakage ts wenner then the nutd betng pumped, It doesn"t meon thot the pecktng ts betng domoged. OPERATIOI &. tiAIITEIAIEf NIUM.l I'IAIITEUICE Y. PREYEKTIYE HAIITEIIANCE QMRM.-Preper ,nwattw _.,.,... ceMjstJ tll.tl&llaieg ncenla If opuetion Mun41 OfeRtiAt .... IMit reldlags..., •Mc:e perforlnld 11 the pump. UtiliziDO tlds tnforlllltion in c:enjuactiH vtt• tlll141111fStell pnwattw aiall•a acllldule llelw wm r..-. downtime end pr8¥8nt c:estlv b~•- PlfYliiTIYf ltA.IITfiiAIIC£ IITfiYAt 115Pa:TI81 CHAIT fREQU(IEY Of COI1POII£NT INSPfCTION AND ttt.tNTftW££ U6PECTION Weet1t Drtwr MltDr Cl•n en, .a.t, ... rt, wkr and cMmicals from till IXtlrior t1 IDDCor. Hate Hn DJtDr li r tAtab lftd eutleb (tea ceoled motor) art ~uctld. HDnt~a~v Driver t1ot8r Cblct ...,. llelriDO te...,.rature vtU. te11- ,.,... ... tlldlatlr (.t 'ltll' lui). If ....nop en rYDDtag W, eo~~ult .tor IDIDUflctunr'a t.truca-. Plett na Glud Gr.. ~u-IDOdat •moult of DICtiaalubricant. fwrt31D111t• · PlctiAGGIIDII I Mild •ttaa •• nDia tf ~.:easar~. (2ooo.,.r-,.....,. Chlct till Mlft. Sc:enag eccelerates war 11 IHIOMin) -pcttng. Rl,.tr .,. npla abaft tf ICOiing---is m.at. S.ni-MIUIIlt Punp Ca.ct .,.,..ttag vik"ltioo If U. pwnp and (4000 ... -..,.,.. t1 vtbrltiea.a.t tabl durtng tmttel lttlg .... ) i..,.ctioft. If vtw.ttoa Ml c.,.., ab..t *-'n ,.... .... flllll&..,. ....... , ......... .,. clealiiRI. .,.,, ....... Clllct ,......_·for aettltat. It •·ce• •-lltta•lt tl pulaP lid lln6n oo dlacblr91 .. ..... ....... Cernct fer 181 ..... .......... p_,Perflr~~~~a Ct.ct •ac~~~rtt 1M Mtioa ,....,. .._..,. ..... tllltlel fteN tat .... c:wnct Itt .. jtDtiag tiiPIIlentf ............. dnppM 11 txCIII If lOS ,.. ...... ., Plctt11JG11111 Rl.w .. -........... ,_ ,.cttag ......... cMct flraltlllllddl,.t. ta.t ratrict flow. -. .. ..... .... [fftcttlq t1111we tiW "IUic ._ anll1 ow . Tea PIIWV .......... Conapen vttla tldU.I ncord of ,., lftlcltaq . If lftlcincV Ma ceaed ..,. U.. SS, nedjllt hapelltn. If ,.,.,.,._ ... -taprove, npl• t.,.11tr or wer rill • nalind. 54dtoallwl Alpect ..u.. ... Merill vitla .,._ tf ,...., lllr111 tt MPPIW Yitll ,,... lubrtcltld llelriiQ. Cllttel-..... .,.., .... 29 OPEMTI811 & tw.ITEIIAII!f tMIIUAl INSUFFICIENT PRESSURE 1. Speed too slow (Check voltage). 2. Impeller trtmmed incorrectly. 3. Impeller loose. 4. Impeller plugged. 5. Weer r1ngs worn. 6. Entrained air In pump. 7. leek1ng joints or bowl casings. 8. Wrong rotaUon. 9. Incorrect tmpener odjustment. NO LIQUID DELIVERED J. Pump suctton broken (woter level below Inlet). 2. Suction valve cJosed~ 3. Impeller plugged. 4. Strainer clogged. 5. Wrong rotation. 6. Shott broken or un screwed. 7. lmpeHer loose. a BerreJ or discharge not vented. 9. Drtver inoperative. VIBRATION 1. 11otor lmbel~~a (electr1ca1). 2. 11otor beortng ts not properly seated or Is wom. 3. Motor dr1ve coupling out of balance or oHgrvnent. 4. 11tsaUgrment of pwnp, caatng., dtseherge heed, colwm, end/or bOwls. 5. Dtschll"g8 heed . misaligned by Improper mounting or pipe strain. 6. Bent shifting. 7. Worn pwnp belrtngs. 8. Clogged Impeller or foreign materto1 tn IUI'Il 9. Improper Impeller adJUStment. 10. Vortex problems In sump. 1 1. Resonance (system fr'ICI'*lCY at or ..,. pump speed.) 12. Covttotton. 13. Impeller out of bel once. 30 TROUBLE SHOOTIIG INSUFFICIENT CAPACITY 1. Speed too slow. 2. Impeller tr1mmed incorrectly. 3. Impeller loose. 4. Impeller or bowl portially plugged. 5. leaking joints. 6. StraSner or suct1on p1pe clogged. 7. SUction YOI¥8 throttled. 6. Low woter level. 9. Wrong rotot ton. 10. Insufficient submergence. 11. Insufficient N.P.S.H. 12. Incorrect impeller adjustment. 13. Worn pump. 14. PressW"e higher then design. USING TOO MUCH POWER I. Speed too htgh. 2. Improper impeller adjustment. 3. Improper impe11er tnm. 4. Pump out of eltgnment. 5. Coup11ng out of oUgnment. 6. Pumping foreign moter1ol. 7. lubrication on too heovy. 8. Bent shofl , 9. Tight beonng or pecking. 10. Spectftc gravity or vtscostty of flutd higher then design. 11. Worn pump. 12. Damaged pump. 13. Parttal freezing of pump Hqutd. ABNORIW.. NOISE 1. 11otor notse. 2. Pump beering running dry. 3. Brok• column beor1ng retotners. 4. Broken shift or on tub1ng. s. Impeller dnlgg1ng on bowl cose. 6. CIY1totton, due to 1nsuffictent N.P .S.H.A. ond/or submergence. 7. Foreign motlfiol tn pump. 8. Excessive flutd veloctty In pipe system. TROUBLE SIDJTIE 111PEllERS TROU8LE SOURCE PR08ABLE CAUSE REMEDY Weor on extt YCIIl8'S end Abnl6tw acttOtt -RlpJK& tmpeller If excessive. shrouds. COnsider coottng or up- gredjng motenol. Pitting on entrance CovttoUon Correct condt t ton or upgrade venes of 1mpe11er. moteriol to extend Ufe. Pitting on impellers Corroston/Eroston Investigate cost of different Mel bowl costtngs. materiels vs. frequency of rep1ocements. Wear on impeller skirts 1. Abrasive octton or 1. Install new beertngs end nil or bowl seol r1ng excess weer anow-weer r1ngs. Upgrade mot- ne. tng tmpeller Sktrts ertot u abrestve actton. to fWtettoo as beer-2. Re-r1ng end odjust tng journal impellers correctly. 2. Impellers set too htah. lr\1)eJler loose on shaft 1. Repeated shock I oad 1. Re-f1t impellers. If collet (extremely nn occur-by surge tn suctton mounted, consider changing ence) or dischorge ltne. key mounttng. (cen loosen rtrst or 2. Remove cause of jommi ng. lost stage Impellers). 3. If collet mounted. con- 2. Foreign motenol stder changing to key jamming .impeller. mounted. Avotd a.dden (l1oy 1ne1c shaft or thennol shock. tr1p 0\W' loacil be-4. Cornet ports 1f necessary rcntfnl)811er end refit. becomes loose). 5. Add keyway to collet 3. Dtrr.-..ttal expan-mounting. ston dUe to tam- perature. 4. Pwts improperly mochtned .. dlor assembled. 5. Torsion loodtng on submersible m""'ne. 31 TROUBLES TROUII.E SOURCE PROBABLE CAUSE REMEDY Premature bearing weor. Abrasive ectlon. Consider conversion to water flushing on ell beerings, pressure grease or oi 1 lubrication. Bearing set zed or gal-Rwvatng dry without Check lubrication, look ling on shaft. lubrtcatton. for plugged suction or evidence of flashing. Bearing fatlure or High temperature Check pump menuf ac- beor1ng seized. fetlun. tanr for beering tern- perature Umits. Excessive shaft weer Rubber beer1ngs w111 Change beer1ng moter1e1. under rubber bearings. swell tn hydro-carbon, H~ & htgh temperature. Uneven weer on beer-Pump's non-rotating Check mounting end dis- 1ngs, waiform weer on parts mtae11gned. chorge pipe connection, _ shift. dtrt bet ween column jotnts. Correct mts- eUgr.ment, replace beer- tngs end repoir or re- place shaft. Uniform wear on bear-Abrasive ocuon. Replace ports, consider ings and shaft. chang1ng matenals or means of lubrication. Uniform weer on beer-1. Shaft rwa-out 1. Straighten shaft or tngs, uneven weer en ciU88d by bent replace, clean and shaft. shafts, shafts not assemble correctly. butted on coup-2. Face panJiel end lings, dtrt or grease concentric. bet ween the shafts. 2. Sheft ends not prop- perlg faced. . ' / 32 .fRATIOI & ttAimiAIIC£ ttAIIMl t•Uilf SIIDOTIIG SHAFT AND COUPLINGS TROU8lE SOURCE PRD8A8l.E CAUSE REMEDY Bent shaft. t11shandllng tn tnnstt Check straightness. Correct or assembly. to .005./fl total N'l-out or replece. Shaft coupling un-Pump started tn re-Shifts may be bent, check screwed. Y8f'Se rotation. shafts end coupUngs. Correct rotation. Shaft coupling elon-1. Motor ts started 1.look for faulty check valve. geted,(neclc down). while pump,.._ Could also be momentery ntng tn reverse. power tenure or Improper 2. Corrosion. sterttng timers. 3. Ptpe wrench fatigue 2. Replace coupltngs. on reused coupl lngs. 3. Replace coupl1ngs. 4. Power betng eppl1ed 4. Check for gelltng on to shafts that ere shoft ends. not butted In ~Ung. Broken shaft or COUI)ltng 1. Can be caused by I. Same IS above. same reasons Usted 2. s.ne es above for beortng for coupl1ng elon-S8IN"8. getton. 3. Add strainers or screens. 2. can also be coused 4. Check eltgrvnent of the by beertngs seized pwnp compon,ents to due to 1fiCic of lub-eJtmtnote vibration. ncetton. 5. See Engineering Section 3. Foretgn metutaJ for cornctton. Joct1ng tmpellws.,.. gelling .... rings. 4.1'1etal fattp due to vtbriUons. 5. Improper Impeller adjustment or con-unuous upthrust cond1Uons, causing tmpe11er to draa. 33 T_,UBLE SIIDOTIIIi IJlWLS TROU8LE SOURCE PROBABLE CAUSE REMEDY Weer on. bowl vones. Abrastveectton. Coot bowls, upgn~de mater1o1 or rubber ltne. PACKING BOX Extesstveleakege. I. Improper packtng 1. Repactc correctly. 2.1ncornct type or 2. Repeck wtth the correct defective pocking. grade for sarvlce. 3. Worn shaft or 3. Remochtne or reploce sleeve. scored ports. Pecldng box OYer-1. Improper pocking 1. Repeck correetly. heating. procedln. 2. Release gland pressure. 2. Pecking too ttght. 3. Repock corncUy. 3. Insufficient lubrt-4. Repack with the correct cat ton. gnc1e for service. 4. lncomct type of - Dacttna. Pecking weors pre-I. Improper packing I. Repock correctly. ~nattnly. properly. 2. Repock eorrectly. 2. lnsuffictent lubrl-3. Remochine or replace cation. scored ports. 3. Shoft or sleeve 4. Repock with the correct scored. grade for service. 4. Incorrect typt of 5. Remove source of pecking. ebrastves. 5. Abnsives tn 1tau1d. INtERCOLI.IIt Water in i...-colwm.. 1. Bypass ports plugged. 1. Remove cause. 2. Badly worn bypeSS 2. Replace worn ports. seal· or b8or1ftg8. 3. Enstn tubtng Joint facets 3. Tub1ng jotnt leelctng. clean and 1s butted 4. erect or hole In squarely. tub1ng. 4. Replace sectton effected. 34 ... .. - ... . .... lla .. 8 INSTALLATION AND MAINTENANCE MANUAL U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO. 12$ OLD GATE LANE MILFORD, CONNECTICUT 064410 Printed in U. S. A . Part Number 835172 TABLE OF CONTENTS SECTION SAFETY ........................................................... ii SHIPMENT ......................................................... 1 II HANDLING ..................................................... · ... 1 Ill STORAGE ......................................................... 2 IV INSTALLATION LOCATION ........................................ 2, 3 v INITIAL INSTALLATION .......................................... 3-7 1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. HOLLOSHAFT Motors ...................................•......... 3 3. Water Cooling for Bearing Oil Reservoir ................................. 5 4. Electrical Connection ............................................... 6 5. Direction of Rotation ............................................... 6 6. Initial Start ..............................................•...... 6, 7 VI NORMAL OPERATION ............................................ 7-8 1. General Maintenance . . . . . . . . . . • . . . . . . . . . . • . . . . . . . • . . . . . . . . • . • . . . . . . 7 2. Inspection and Cleaning ................•.......................... ~. 7 3. Insulation Resistance . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VII NON-REVERSE RATCHET ........................................... 9 VIII END PLAY ADJUSTMENT ...........................•••.......... 9-13 IX X 1. Ball Thrust Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . 9 2. Spherical Roller Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 Vertical Motor Cross Section -Type RU. • • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Vertical Motor Cross Section· Types HU, HV-4. . . . . • . . . . . . . • . . . . • • . . . . . . . . 12 Vertical Motor Cross Section· Types TU,LU,TV-4,LV-4 ..................... 13 LUBRICATION . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • 14-17 1. Oil Lubricated Bearings ....•....................................... 14 2. Grease Lubricated Bearings ........•................................ 14 Recommended Oils. . . . . • . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Recommended Greases . . . . . . . . . . . . . . . . . . . • . . . • • . . • . . . . . . . • . . . . . . . . . . . 16 Suggested Regreasing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUNDAMENTAL TROUBLE SHOOTING- PROBLEM ANALYSIS ..................•..........•.•............ 17, 18 RENEWAL PARTS AND SERVICE ...•................................. 18 INSTALLATION RECORD ..........•.•....•...•...•..............•.. 19 1-U.S. ELECTRICAL MOTORS ~ DIVISION OF EMERSON ELECTRIC CO -1(5 OLD GATE LANE lfMII ... DN MILFORD. CONNECTICUT ~460 SAFETY SAFETY FIRST High voltage and rotating parts can cause serious or fatal injury. Safe installation, operation and main· tenance must be performed by qualified personnel. Familiarization with and adherence to NEMA MG2, the National Electrical Code, and local codes is recommended. It is important to observe safety pre· cautions to protect personnel from possible injury. Personnel should be instructed to: 1. DISCONNECT ALL POWER TO MOTOR PRIOR TO INITIATING ANY MAINTENANCE OR REPAIRS. 2. AVOID CONTACT WITH ROTATING PARTS. 3. ACT WITH CARE IN ACCORDANCE WITH PRESCRIBED PROCEDURES IN HANDLING AND LIFTING THIS EQUIPMENT. 4. BE SURE UNIT IS ELECTRICALLY GROUNDED AND PROPER ELECTRICAL INSTAL- LATION WIRING AND CONTROLS ARE USED CONSISTENT WITH LOCAL AND NATIONAL ELECTRICAL CODES. REFER TO "NATIONAL ELECTRICAL CODE HANDBOOK" -NFPA NO. 70. EMPLOY QUALIFIED ELECTRICIANS. 5. BE SURE EQUIPMENT IS PROPERLY ENCLOSED TO PREVENT ACCESS BY CHILDREN OR OTHER UNAUTHORIZED PERSONNEL IN ORDER TO PREVENT POSSIBLE ACCIDENTS. 6. BE SURE SHAFT KEY IS FULLY CAPTIVE BEFORE UNIT IS ENERGIZED. 7. ALWAYS BE SURE OIL LUBRICATED UNITS ARE FILLED WITH CORRECT OIL TO PRO· PER LEVEL BEFORE OPERATING. 8. PROVIDE PROPER SAFEGUARDS FOR PERSONNEL AGAINST ROTATING PARTS AND APPLICATIONS INVOLVING HIGH INERTIA LOADS WHICH CAN CAUSE OVERSPEED. 9. AVOID EXTENDED EXPOSURE TO EQUIPMENT WITH HIGH NOISE LEVELS. 10. OBSERVE GOOD SAFETY HABITS AT ALL TIMES AND USE CARE TO AVOID INJURY TO YOURSELF OR DAMAGE TO YOUR EQUIPMENT. 11. BE FAMILIAR WITH THE EQUIPMENT AND READ ALL INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR WORKING ON EQUIPMENT. 1-U.S. ELECTRICAL MOTORS la!:i :J:VISION 0~ EMEPSON ELECTRIC CO -1i5 :JLD GATE LANE IIMIIIII•DN ""'L':l"<O C:l'<,.,ECTICUT O(>•sc jj SHIPMENT SHIPMENT HANDLING Prior to shipment, all motors undergo extensive electrical and mechanical testing, and are thor- oughly inspected. Upon receipt of the motor, carefully inspect the unit for any signs of damage that may have occured during shipment. Should such damage be evident, unpack the motor at once in the presence of a claim adjuster and immediately report all damage and breakage to the transportation com- pany. When wr1tmg to U. S. Electrical Motors concerning the motor, be sure to include the complete motor identification number, frame and type which appears on the nameplate. II HANDLING The equipment needed to handle the motor includes a hoist and spreader bar arrangement (See Figure 1.) of sufficient strength to lift the motor safely. The spreader bar should have the lifting rings or hooks positioned to equal the span of the lifting lugs or eyebolts. The lifting lugs or eyebolts are intended to lift the motor weight only. CAUTION Lifting the motor by other means may result in damage to the motor or injury to personnel. U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO 125 OLD GATE LANE MILFORD CONNECTICUT 06•60 FIGURE 1 r------u------. ~SPREADER BAR 0 STORAGE INSTALLATION LOCATION Ill STORAGE If the motor(s) is not put into immediate service (1 to 6 months depending upon environmental conditions) or is taken out of service and put into storage, the following precautions should be taken: Preparation- 1. Store indoors, if possible. 2. Motors should not be stored on vibrating bases or floors. Any motor so stored should be disas- sembled and inspected for bearing damage prior to service. If bearing damage is evident, replace bearing. 3. Check the rust preventative coating on external machined surfaces (including shaft extension on Solid Shaft Motors) for damage. If necessary, recoat the surfaces with Rust Veto No. 342 (Manu- factured by E. F. Houghton Co.) or equivalent. The condition of the rust preventative coating should be checked periodically and surfaces should be recoated as recommended by the coating manufacturer. 4. Oil lubricated bearings -drain oil from bearing housing and refill, to maximum level, with a circulating type oil such as Mobil Vaprotec Concentrate or equivalent. Oil should be changed every 12 months while motor is in storage. 5. Grease lubricated bearings · once a month, inject a small quantity of grease (use grease from table 2) into the grease fill such that grease is purged from the drain. Inspect purged grease for water condensation or oxidation. If water condensation or oxidation is evident, the motor should be disas- sembled and contaminated grease removed, and replaced with new grease. 6. Take precautions as necessary to prevent rodents, snakes or other small animals from nesting inside motor. 7. Prevent moisture or condensation from accumulating by energizing space heaters if provided, or applying reduced voltage to one phase of motor windings (trickle-voltage-heating). Request % of rated voltage and transformer capacity to be used from U. S. Electrical Motors. The winding should be maintained 5 Degrees C Minimum above ambient temperature (some locations require a higher temper- ature above ambient) to prevent condensation. 8. If motor is to be covered by plastic or similar material, additional precautions such as heated or circulating air and silica gel may be necessary to protect against moisture or condensation. 9. Rotate motor shaft several revolutions once every two weeks while in storage to insure a pro· tective oil film on bearing surfaces. 10. Start-up preparation after storage: A. Thoroughly clean and inspect motor. B. Change oil or grease in bearing housings using lubricant recommended in Table 1 or 2. Secure all plugs, fittings, etc.,to prevent leakage. C. Check insulation resistance as described in Section VI "Normal Operation" Part 3. IV INSTALLATION LOCATION When selecting a location for the motor and driven unit, keep the following items in mind: 1. The location should be clean, dry, well ventilated, properly drained, and provide accessibility for inspection, lubrication, and maintenance. Outdoor installations on Open Dripproof Motors require protection from the elements. U.S. ELECTRICAL MOTORS DIVI510'1 0~ EME'ISON ElECT!>IC CO 125 ClO GATE lANE Mil fORO C J""ECTICUT 06A60 2 --- U.S. INSTALLATION AND MAINTENANCE MANUAL 2. The location should also provide adequate space for motor removal without shifting the driven unit. 3. The temperature rise of a standard motor is based on operation at an altitude not higher than 3,300 feet or 1000 meters above sea level. 4. The motor should not be installed in close proximity to any combustible material or where flam· mable gases may be present, unless motor is specifically built for that environment and is U.L. labeled accordingly. V INITIALINSTALLATION 1. General Reliable trouble free operation of a motor and driven unit depends on a properly designed found- ation and base plus good alignment. If the motor and driven unit are not installed properly the following may result: a. Noisy Operation b. Excessive Vibration c. Bearing Damage or Failure d. Motor Failure 2. Holloshaft Motors A. Pump Shaft Alignment and Adjustment -· The pump shaft should be aligned such that it is concentric to the motor shaft within .030 T.I.R. To facilitate axial pump shaft adjustment, a locking feature (See figure 2) is provided to lock the motor shaft against rotation. The type of locking feature varies with the size of motor supplied. Two types are as follows: 1. locking arm (Figure 2) • The locking arm is bolted to a stationary part and is pinned (for best results use arm in tension) or interferes with a rotating part (when locking arm is not in use it should be moved out of the way and bolted in 'place). · 2. Pinning thru mating holes· holes are provlaed in a stationary and rotating part which line up and allow insertion of a pin. CAUTION locking device must be disengaged prior to starting motor or motor damage and or injury to personnel may result. LOCKING ARM LOCKS MOTOR SHAFT AGAINST ROTATIO II .... ,..aN U.S. ELECTRICAL MOTORS DIVISION 0~ EMERSON ELECTRIC CO. 125 OLD GATE lANE MILFORD. CONNECTICUT ()6q() FIGURE 2 3 Pf;tnted in U S A NITI AL INSTALLATION CAUTION Care should be exercised when lowering the motor over the pump shaft so that the oil retaining tube in the lower bracket is not damaged (applies only to motors with oil lubricated lower bearing). B. Drive Coupling The Drive Coupling may be utilized in one of the two following ways: 1. Bolted type (Figure 3) -hold down bolts are installed (some size motors require removal of driving pins to allow installation of hold down bolts) in the drive coupling to prevent upward movement of the pump shaft. This will allow momentary upthrust from the pump to be taken by the lower bearing of the motor. 2. Self -release type (Figure 4) -driving pins are used to engage the drive coupling with the rotor. A power reversal may unscrew the joints of the pump shafting, causing the shafting to lengthen and buckle or break if the shafting is restrained. The self-release coupling will lift out of engagement with partial unscrewing of the shafting, thus stopping further rotation of the pump. The following items must be followed for proper functioning of the self-release coupling: a. The pump shaft adjusting nut must be properly secured to the drive coupling (use locking screwt b . The drive coupling should not bind on the driving pins (driving pins are to engage coupling in drilled holes). c. The drive coupling must not be bolted down. d. The pump shaft must be concentric to the motor shaft to prevent rubbing and further rotation of the pump shafting. U.S. ELECTRICAL MOTORS DI VISION OF EMERSON ELECTRIC CO. 1 2 ~ OLD GATE LANE .. I LF O RD CONN EC TIC UT ~ FIGURE 3 HOLD DOWN BOLTS · 4 Pt l"tld '" U $ A --fi! .. , U.S. INSTALLATION AND ~ MAINTENANCE MANUAL NITIAL INSTALLATION 'I ADJUSTING NUT LOCKING SCREW DRILLED HOLES TO ENGAGE DRIVING PINS FIGURE 4 DRIVE COUPLING DRIVING PINS DRIVE COUPLING ENGAGED DRIVE COUPLING DISENGAGED 3. Water Cooling for Bearing Oil Reservoir If the motor is equipped with cooling coilo; in the oil reservoir, a minimum water supply of 4 G.P.M. must be maintained at a maximum of 125 P.S.I. with a 90 degree F. maximum inlet temper- ature. External water connections must be self draining to prevent cooling coil rupture at freezing temp- eratures. Use clean non-corrosive water only. If corrosive conditions exist, and are specified at time of motor order, special corrosion resistant fittings can be supplied. During freezing weather the oil reservoir will not normally require water cooling to keep the oil reservoir below 90 degrees C. (194 Degree F.). If it is determined that water cooling is not required during freezing weather, the water lines and motor cooling coils should be completely drained. '~------------------------------------------------------~ Ill U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO. 125 OLD GATE LANE ....... aN MILFORD. CONNECTICUT O&..a 5 ,. ........ \ . INITIAL INSTALLATION 4. Electrical Connection Refer to the motor nameplate for power supply requirements and to the connection dia- gram on the motor. Be sure connections are tight. Check carefully and assure that they agree with the connection diagram, then carefully tape all connections with electrical tape to be sure that they will not short against each other or to ground. Be sure the motor is grounded to guard against possible electrical shock. Refer to the National Electrical Code Handbook (NFPA No. 70) and to local electrical codes for proper wiring, protection, and wire sizing. BE SURE proper starting equipment and protec- tive devices are used for every motor. For assistance contact the local sales office of the motor starter manufacturer for the particular brand of equipment you are using. Part Winding Starters: Part winding starters used with part winding start motors should have the timer set at a minimum time consistent with the power company requirements. Two seconds is the recommended maximum time on part winding. Setting the timer for longer periods can cause permanent damage to the motor and may void the warranty. 5. Direction of Rotation As standard, motors that are equipped with a non-reverse ratchet are designed to operate in a counter-clockwise direction as viewed from the top of the motor. Also, some high speed motors have unidirectional ventilating fans. When the motor has a unidirectional ventilating fan 'the direction of rotation is noted by an arrow mounted on the motor and by a warning plate mounted near the main nameplate. CAUTION Apply power momentarily to observe the direction of rotation for which the leads are connected. If power is applied for more than 5 seconds with motor stalled, motor damage may occur. The motor should be uncoupled from the driven equipment during this procedure, to assure driven equipment is not damaged by reverse rotation. To reverse the direction of rotation (if motor is not operating in the correct direction) interchange any two of the three power leads to the motor leads. Be sure the power is off, and steps are taken to prevent accidental restarting of the motor. before attempting to change any electrical connection. 6. Initial Start After installation is completed, but before motor is put in regular service, make an initial start as follows: A. Assure that motor and control device connections agree with wiring diagrams. B. Assure that voltage, phase, and frequency of line circuit (power supply) agree with motor nameplate. C. Check insulation resistance according to Section VI "Normal Operation" Part 3. D. Check all foundation, base and coupling bolts to assure they are tight. 1-U.S. ELECTRICAL MOTORS 11::!1 OfV~SION OF EMERSON ELECTRIC CO -125 OLD GATE LANE 6 IIIUIII ... DN MiL<ORO CONNECTICUT 06•60 U.S. INSTALLATION AND MAINTENANCE MANUAL INITIAL INSTALLATION NORMAL OPERATION E. If motor has been in storage, either before or after installation, refer to Section Ill "Storage" Part 10 for preparations. F. Check oil lubricated bearings to be certain that bearing housings have been filled to the "Max" leve: with the correct lubricant. See Table 1. G. Check for proper or desired rotation. See Section V "Initial Installation" Part 5. H. Assure that all protective devices are connected and operating properly. I. Start motor and monitor to assure no unusual condition develops. VI NORMAL OPERATION Start the motor in accordance with standard instructions for the starting equipment used. 1. General Maintenance Regular, routine maintenance is the best assurance of trouble-free, long-life motor operation. It prevents costly shutdown and repairs. Major elements of a controlled maintenance program are: A. Trained personnel who KNOW the work. B. Systematic records, which contain at least the following 1. Complete nameplate data. 2. Prints (wiring diagrams, certified outline dimensions). 3. Alignment data. 4. Results of regular inspection. 5. Repairs. 6. Lubrication data: a. Method of application. b. Types of lubricants for wet, dry, hot or adverse locations. c. Maintenance cycle by locations (some require more frequent lubrication). 2. Inspection & Cleaning Stop the motor before cleaning. (CAUTION: ASSURE AGAINST ACCIDENTAL STARTING OF MOTOR). Clean the motor, inside and outside, regularly. The frequency depends upon actual condi· tions existing around the motor. Use the following procedures, as they apply: A. Wipe off dirt, dust, oil, water or other liquids from external surfaces of motor. These mat· erials can work into, or be carried into, the motor windings and may cause overheating or insulation breakdown. B. Remove dirt, dust, or debris from ventilating air inlets. Never allow dirt to accumulate near air inlets. Never operate motor with air passages blocked. CAUTION When using compressed air always use proper eye protection to prevent accidental eye injury. C. Clean motors internally by blowing with clean, dry compressed air at 40 to 60 psi. If the conditions warrant, use a vacuum cleaner. U.S. ELECTRICAL MOTORS 01'!/ISION OF EI.IERSO"' ElECTRIC CO. 125 OLO GATE LA"'E "'ILFORO. CONNECTICUT 064t0 7 NORMAL OPERATION U.S. INSTALLATION AND MAINTENANCE MANUAL D. When dirt and dust are solidly packed, or windings are coated with oil or greasy grime, disassemble the motor and clean with solvent. Use only high-flash naphtha, mineral spirits, or Stoddard solvent. Wipe with solvent-dampened cloth, or use suitable soft bristle brush. DO NOT SOAK. Oven dry (150 -175 Degrees F.) solvent-cleaned windings thoroughly before reassembly. E. After cleaning and drying the windings, check the insulation resistance (see the foliowing section). 3. Insulation Resistance Measurements should be taken at time of initial motor installation and periodically thereafter. Mea- surements are also important when repairs are made or after moisture is dried from winding. A. Insulation History: The only accurate way to predict insulation failure is to maintain a history of the insulation resistance readings. Over a period of months or years these readings will tend to in- dicate a trend. If a downward trend develops or if the resistance drops too low, thoroughly clean and dry the windings as described in Section VI "Normal Operation" Part 2. The recommended insulation resistance test is as follows: 1. Using a megohmmeter, with winding at ambient temperature, apply DC voltage (noted below) for 60 seconds and take reading. Rated Motor Voltage 600 and less 601 to 1000 incl. 1001 and up Recommended DC Test Voltage 500 VDC 500 to 1000 VDC 500 to 2500 VDC (2500 VDC optimum) 2. For comparison the reading should be corrected to a 40 degree C. base temperature. This may be done by utilizing the following: R40C = KtX Rt Where R40C = insulation resistance (in megohms) corrected to 40 degree C. Rt =measured insulation resistance (in megohms) Kt =temperature coefficient from Graph 1 GRAPH 1 W'INJING TE~RATURE. °C -10 0 10 20 30 40 50 60 70 80 90 100 110 U.S. ELECTRICAL MOTORS DIVISIQ"; 0' EME~SON ELECT~IC CO 125 OLD GATE LANE MILFJ~O CJ~NECT1CUT 0646C ""' ~ I ~ ~ '""' I ' I I ! I l ,I I I I I I I !!,1 I I i ""'-' I i I ' I : 'i I I I ! IIIIi I I i t!i' I"' i :: I ' . I :! < ! ,: I I :I i ' !l i " ,, I I !I : ~ I' ' Y! I ! I i I I 'H I ':I I i 0.05 C.1 IJ.S 1.0 10 50 100 fNSUl.A TION RESISTANCE TEMPERATURE COEFFICIENT. 1<.1 8 (ADAPTED FROM IEEE 43) U.S. INSTALLATION AND MAINTENANCE MANUAL NORMAL OPERATION NON-REVERSE RATCHET END PLAY ADJUSTMENT B. INDIVIDUAL READINGS: If an insulation history is not available and it bes:omes necessary to determine the acceptability of the winding, the following formula can be used. However, it must be realized that it is only a guide line and that operator and equipment safety must also be considered. The test and voltage should be the same as outlined in Section VII "Normal Operation" Part 3, Item A. Rm = Kv +1 Where Rm = Recommended minimum insulation resistance in megohms at 40 degree C. Kv =rated motor voltage in kilovolts C. DIELECTRIC ABSORPTION RATIO: In addition to the individual test reading a dielectric absorption ratio may be required. The dielectric absorption ratio is obtained by taking megohmmeter readings at a one minute and ten minute interval or when hand powered megohm meters are used. at thirty second and sixty second interval, with megohmmeter power applied continuously. The voltage should be the same as outlined in Section VII "Normal Operation" Part 3, Item A. The ratio is obtained by dividing the second reading by the first reading and is based on a good insulation system increasing its resistance when subjected to a test voltage for a period of time. The ratings are as follows: 10 minute : 1 minute Dangerous = less than 1.0 Poor = 1.0 to 1.4 Questionable = 1.5 to 1.9 Fair = 2.0 to 2.9 Good = 3.0 to 4.0 Excellent = Over 4.0 60 second : 30 second Poor = less than 1.1 Questionable = 1.1 to 1.24 Fair = 1.25 to 1.3 Good = 1.4 to 1.6 Excellent = Over 1.6 If a lower insulation resistance reading is obtained in either the individual test or dielectric absorp- tion ratio test, thoroughly clean and dry the windings as described in Section V Ill "Normal Operation" Part 2. Recheck insulation resistance and dielectric absorption ratio. For additional information on insulation testing, refer to IEEE Transaction Number 43. VIII NON-REVERSE RATCHET NON-REVERSE RATCHETS are refine balanced by using washers of different sizes on the rotating ratchet. If the ratchet is removed it should be marked and reassembled in the same position to retain a fine balanced motor. VIII END PLAY ADJUSTMENT Should the motor be disassembled for any reason, the rotor end play must be readjusted. Use one of the following procedures, depending upon the type of thrust bearing. 1. Ball Thrust Bearing The best way to position the nut is by using a dial indicator and limiting the end play between .005 and .010 inches. The nut should then be locked with the lockwasher. U.S. ELECTRICAL MOTORS 01\/ISION OF EMERSON ELECTRIC CO 125 OlD GATE LANE MILFORD. CONNECTICUT 06450 9 END PLAY ADJUSTMENT 2. Spherical Roller Thrust Bearings 't':l ,.. Adjust the end play by positioning the motor shaft nut. Place a dial indicator poinfid of the bearing mount then tighten the shaft nut until the bearing mount reaches the limit of its travel: The springs should be completely compressed at this point and the lower bearing up against the bearing cap. Reverse the shaft nut until bearing mount raises .005 to .010 inches. This process should be re- peated a few times to insure that the bearings are properly seated. Motors built with spherical roller thrust bearing construction require a minimum external thrust load sufficient to compress upper die springs and unload lower guide bearing from axial spring thrust. Refer to motors spring thrust plate for required minimum thrust. Do not run motor no load for more than 15 minutes as lower bearing damage may occur, and improper seating of thrust bearing may cause vibration. li 1-U.S. ELECTRICAL MOTORS -~ O·vrSIO" 0~ EMERSON HECTRIC CO 125 OLO GATE LANE 10 IIMII ... DN M 1 cf:JRO C:lNNECTrCUT 06•60 VERTICAL MOTOR TYPE RU VERTICAL MOTOR TYPE RU STATOR SCREEN GREASE FITT UPTHRUST GUIDE BEARING SLINGER ·--- U.S. ELECTRICAL MOTORS 01\II$10N Of EMERSON ElECTRIC CO. 125 OLO GATE LAN£ MllfORO. CONNECTICUT 06460 11 EY BOLTED COUPLING KNUT & WASHER DUST COVER FILL HOLE PORT WINDOW DRAIN CAP SHAFT IRING CAP FITTING SNAP RING VERTICAL MOTOR TYPES HU, HV-4 U.S. INSTALLATION AND MAINTENANCE MANUAL I!! VERTICAL MOTOR TYPES HU, HV-4 BEARING SPHERICAL CANOPY LIFTING LUGS LIGHT WEIGHT CANOPY LOCKING DRIVE DUST OIL OIL VISOLUBE OIL OIL OIL COOLING HOLLOW SHAFT ---4-~~='!+--++ ROTOR------+-~~~~ STAT 0 R ----J--iii~ BEARING CAP Locked VISOLUBE SNAP OIL RETAINING TUBE U.S. ELECTRICAL MOTORS 12 DRIVE COUPLING COUPLING ROTOR LOCKNUT & WASHER THRUST HOUSING ""'~DENT SCREEN "" AIR INTAKE LIFTING LUGS SPLIT --CONDUIT BOX SCREEN Note: For high thrust vertical solid shaft, construction except: solid shaft, remove drive coupling & locking arm INTAKE u IIMII,.SDN DIVISION OF E"'ERSON ELECTRIC CO 125 OLD GATE LANE "'IL'ORD C:JNNECTICUT 0646C U.S. INSTALLATION AND MAINTENANCE MANUAL VERTICAL MOTOR TYPES TU, LU TV-4 LV-4 , VERTICAL MOTOR TYPES TU, LU, TV-4 & LV-4 PUMP SHAFT ADJUSTING NUT AND LOCKING SCREWS ARE FURNISHED BY CUSTOMER SELF RELEASE LOCKNUT SELF RELEASE PIN OIL FILL 320 & ABOVE ROTOR FANS • U.S. ELECTRICAL MOTORS OIVISIO"' OF EMEASOH ELECTRIC CO. 1Z5 OLO GATE LANE .M Dll MIL FORO. CO,..,_.ECTICUT 08460 13 CONDUIT BOX CONDENSATE DRAIN WHEN SPECIFIED VERTICAL SOLID SHAFT IS IDENTICAL WITH EXCEPTION OF SELF RELEASE COUPLING LUBRICATION IX LUBRICATION Motor must be at rest and electrical controls should be locked open to prevent energizing while being serviced. If motor is being taken out of storage refer to Section Ill "Storage" Part 10 for preparation instruc· tions. 1. Oil Lubricated Bearings Change oil once a year with normal service conditions. Frequent starting and stopping, damp or dusty environment, extreme temperature, or any other severe service conditions, will warrant more frequent oil changes. If there is any question consult U.S. Electrical Motors Engineering for recommended oil change intervals regarding your particular situation. Use a premium quality Turbine Oil from Table 1, or an equivalent oil, which is fully inhibited against oxidation and corrosion. Add oil at oil fill hole, at each bearing housing until the oil level reaches the "Maximum" mark located on the oil sight gauge window. See the motor nameplate for the approximate quantity of oil required. 2. Grease Lubricated Bearings Units with grease lubricated bearings are prelubricated at the factory and normally do not require initial lubrication. Refer to Table 2 and 3 for recommended greases and suggested regreasing intervals for longest bearing life. To relubricate bearings, remove the drain plug and add new grease until clean grease appears at the drain. Run the motor for approximately ten minutes, with the drain plug removed to allow purging of the excess grease. After the excess grease has been purged, replace the drain plug. CAUTION Over greasing can cause excessive bearing temperatures, premature lubricant breakdown, and bearing failure. Care should be exercised to insure against over greasing. If old grease cannot be readily purged from drain hole, immediately cease to add new grease. Investigate cause of grease exit blockage. A mechanical probe or scavenger may be required to dislodge blockage (caked grease or foreign particles) from grease drain (care should be exercised to prevent dam· age to bearing with probe or scavenger). Under no circumstances should a mechanical probe or scav· enger be used while motor is in operation. As new grease appears at the drain hole, the bearing grease cavity should be completely full. The grease cavity must be purged to approximately 60 to 70% full. Start the motor and run for approx- imately ten minutes, as mentioned above, with drain plug removed. This will allow the excess grease to purge itself from the grease cavity. II U.S. ELECTRICAL MOTORS 01\IISION OF Et,4ER50N ELECTRIC CO 12S OLO GATE LANE .U1 .... DN MILFORD CONNECTICUT 06480 14 ,.tnted !PI U S A LUBRICATION TABLE 1 RECOMMENDED 01 LS ANGULAR CONTACT SPHERICAL ROLLER THRUST BEARINGS THRUST BEARINGS AMBIENT UP TO 100°F ABOVE 100°F TO UPT040°F ABOVE 40° F TO TEMPERATURE A MAX OF 140° A MAX OF 140° RANGE ISO GRADE 32 68 68 150 OIL 130 TO 165 SUS 284 TO 347 SUS 284 TO 347 SUS 620 TO 765 SUS VISCOSITY AT 100°F AT 100° F AT 100°F AT 100° F MANUFACTURERS SPECIFICATIONS CONOCO INC. CONOCO DECTOL 15R&OOIL EXXON COMPANY TERRESSTIC U.S.A. 33 MOBIL OIL CO. DTE OIL LIGHT PENNZOI L COMPANY AW HYD. OIL 32 INC. SHELL OIL CO. TELLUS 32 CHEVRON U.S.A. INC. CHEVRON OC TURBINE OIL 32 TEXACO, INC. REGAL 32 UNION OIL CO. UNAX AW32 OF CALIF. II U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO 125 Ol.D GATE LANE ...... SDN MILFORD. CONNECTICUT 0t..o CONOCO DECTOL CONOCO DECTOL CONOCO DECTOL 33 R & 0 OIL 33 R & 0 OIL 51R&OOIL TERRESSTIC TERRESSTIC TERRESSTIC 68 68 150 DTE OIL DTE OIL DTE OIL HEAVY MEDIUM HEAVY MEDIUM HEAVY AW HYD. OIL 68 AW HYD. OIL 68 AW HYD. OIL 150 TELLUS 68 TELLUS 68 TELLUS 150 CHEVRON OC CHEVRON OC CHEVRON OC TURBINE OIL 68 TURBINE OIL 68 TURBINE OIL 150 REGAL 68 REGAL68 REGAL 150 UNAX AW68 UNAX AW 68 UNAX AW 150 15 LUBRICATION MANUFACTURER CHEVRON U.S.A. INC. EXXON COMPANY U.S.A. PENNZOIL COMPANY, INC. UNION OIL CO. OF CALIFORNIA TABLE 2 RECOMMENDED GREASES GREASE (NLGI NO.2) CHEVRON SRI GREASE NO.2 UNIREX N 2 OR RONEX MP MULTIPURPOSE LUBE NO. 705 UNOBA EP NO. 2 VALVOLINE DIV. OF ASHLAND OIL INC. VALVOLINE VAL-LITH NO.2 EP MOBIL OIL CORP. MOBILUX 2 SHELL 01 L CO. ALVANIA NO.2 TEXACO, INC. PREMIUM RB NO.2 TABLE 3 SUGGESTED REGREASING INTERVALS INTERVAL 1-2 YEARS 1 YEAR 6 MONTHS 3 MONTHS TYPES OF SERVICE INFREQUENT OPERATION OR LIGHT DUTY 8-16 HAS/DAY IN CLEAN, RELATIVELY DRY ATM PHERE. 12-24 HAS/DAY, HEAVY DUTY OR IF MOISTURE ISPR HEAVY DUTY IN Dl RTY, DUSTY LOCATIONS; HIGH AMBIENTS: MOISTURE LADEN ATMOS- PHERE; VIBRATION. CAUTION Greases of different soap bases (lithium, sodium, etc.) may not be compa- tible when mixed. Prevent such intermixing by completely purging the bearing of old greases. (See Section X Ill "Lubrication"). NOTE: Use regreasing intervals and grease as noted in tables 3 and grease noted in table 2, unless a lubrication plate on motor indicates otherwise. • U.S. ELECTRICAL MOTORS OIVISION OF E"'ERSON ELECTRIC CO -t2S OLD GATE LANE ........ CIJit "''LFORO CONNECTICUT ~60 16 ........ " .. MOTOR ANALYSIS X FUNDAMENTAL TROUBLE SHOOTING-PROBLEM ANA LYSIS This chart can reduce work and time spent on motor analysis. Always check the chart first before starting pump motor disassembly, as what appears to be a motor problem may often be located elsewhere. SYMPTOM PROBABLE CAUSE Motor fails to start Motor fails to come up to speed Motor runs hot Motor vibrates Loose or poor connections Incorrect connection at motor Overload -Mechanical Inadequate ventilation Hydraulic disturbance in d Motor noisy Electrical n U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO 125 OLD G.t.TE L.t.NE MILFORD. CONNECTICUT Oli480 17 ANALYSIS Push reset button. start and allow sufficient time for operation of time delay, if used, then check voltage across magnetic holding coil. If correct voltage is measured, coil is de- fective. If no voltage is measured, control Make visual inspection of all connections in control circuit. Open manual disconnect switch, close mag- netic switch by hand and examine contactors Assure adequate supply of fresh air. Check air blast through motor by feeling air dis- gn- on Check isolation joint in discharge piping head. cover, rotate rotor by hand and make visual examination of balls and races. (Brg. noise is usually accompanied by a h vibration). ost motors are electr y noisy during the starting period. This noise should diminish as motor reaches full speed. MOTOR LOAD TEST RENEWAL PARTS & SERVICE U.S. INSTALLATION AND MAINTENANCE MANUAL ELECTRICAL MOTOR LOAD TEST USING THE WATT HOUR METER In the motor analysis of Electrical Motors, it is sometimes desirable to conduct an accurate load check on a particular installation to determine whether the motor is operating within the rating and horsepower it was designed for. Since most pump installations have their own watt hour power meters, accurate read- ings and calculations will permit a load check by the following formula: K = Disc constant (watt for one revolution of disc per hour). This disc constant is found on the face of the meter. R = Revolutions of disc in watt meter within the time of the test. Established by counting, from visual observation. T = Time of test, in seconds. Transformer Ratio = stated on meter face, must be included where current transformers are used with watt meters. TO OBTAIN INPUT KILOWATTS: KW = K x B x 3.6 T TO OBTAIN INPUT HORSEPOWER: Input HP = K x R x 4.83 x Transformer Ratio* T (*If any shown) The watt hour meter measures power consumed over a period of time. It is necessary for us to establish the rate at which power is being consumed by the work being done. We establish this rate by counting the revolutions of the disc in a given time. Here is a typical example of a load check: GIVEN: 1. Pump motor to be load checked is rated 100 HP, 1800 RPM, 3-phase, SO-cycle U.S. HOLLOSHAFT motor. 2. Disc constant (K) found on face of meter-40. 3. Transformer ratio found on face of meter= 3. DATA FOUND FROM TEstS: With stop watch or a watch with an accurate sweep second hand, disc was observed to revolve 10 times in exactly 49 seconds. For this test, therefore, R = 10; T = 49. THUS: Input HP = 40 x 10 x 4.83 x 3 49 = 118.29 Output HP = Input HP x Motor Efficiency Output HP = 118.29 x 91 = 107.54 THUS: The output HP (107.54) is over nameplate (100 HP) of the motor, but well within the 1.15 Service Factor load which applies to this motor. The following values of full load efficiency are represent,tive of the average 2,4, or 6 Pole Motor, and may be used in the formulas: RENEWAL PARTS & SERVICE HP: 1 to 3 5 to 15 20 to 200 EFFICIENCY: 78-82 83-87 88-92 A parts list is available for your unit and will be furnished upon request. Parts may be obtained from local U. S. MOTORS distributors and authorized service shops, or through U.S. MOTORS distribubion centers located at •.... U.S. ELECTRICAL MOTORS 125 OLD GATE LANE MILFORD, CONNECTICUT ZIP 06460 PHONE AREA CODE 203 783-5200 • U.S. ELECTRICAL MOTORS DIVISION OF EMERSON ELECTRIC CO 125 OLO GATE LA"'E .... ._.DN Mll~ORO CON"'ECTICUT 06•60 18 ""'* lft U 5 A INSTALLATION RECORD NAMEPLATE & INSTALLATION INFORMATION SERIAL NUMBER OR MODEL NUMBER ................................................ _________ _ HORSEPOWER .......................................................................................... .._.--------- MOTOR RPM ............................................................................................. ._.--------- PHASE ........................................................................................................ _________ _ FREQUENCY ............................................................................................ ________ -:--- AMPS ........................................................................................ AT _________ VOL TS DESIGN ..................................................................................................... .:....--------- FRAME ...................................................................................................... .:.... --------- TYPE ........................................................................................................ ~ .. --------- DATEPURCHASED P.O.NUMBE~-------------- DATE INSTALLED ................................................................................... .:...--------- LOCATION OF JOB SITE .......................................................................... :___ _______ _ MACHINE OR INSTALLATION NUMBER ............................................... ~.--------- PURCHASED FROM ................................................................................. .:....--------- MOTOR RESISTANCE LINE TO LINE AT TIME OF INSTALLATION~--------­ INSULATION TO GROUND READING AT TIME OF INSTALLATION=----------- RECORD OF MAINTENANCE GRADE & TYPE OF LUBRICANT USEDL------------------- DATE OF LAST INSULATION OVERHAUL OR REPAIR RELUBRICATION RESISTANCE DATE MEGOHMS DATE ACTION . ~-U.S. ELECTRICAL MOTORS ~ DIVISION Of £a.!EASON ElECTRIC CO 19 -125 OlD GATE lANE ,.,1ftted '" U S A ....... aN a.IILfORO. CONNECTICUT O&oiOO INSTALLATION RECORD U.S. INSTALLATION AND MAINTENANCE MANUAL NAMEPLATE & INSTALLATION INFORMATION SERIAL NUMBER OR MODEL NUMBER ............................................... _________ _ HORSEPOWER ......................................................................................... .._.--------- MOTOR RPM ............................................................................................ ,....__ ________ _ PHASE ........................................................................................................ _________ _ FREQUENCY ............................................................................................ , ________ _ AMPS ........................................................................................ AT _________ VOL TS DESIGN .................................................................................................... :....--------- FRAME ...................................................................................................... .:...---------- TYPE ........................................................................................................ ..._ .. ________ _ DATEPURCHASED P.O.NUMBE~------------ DATE INSTALLED ................................................................................... ,:....--------- LOCATION OF JOB SITE .......................................................................... :...__ _______ _ MACHINE OR INSTALLATION NUMBER ............................................... ~.--------- PURCHASED FROM ................................................................................. ,:....---------- MOTOR RESISTANCE LINE TO LINE AT TIME OF INSTALLATION:__ ________ _ INSULATION TO GROUND READING AT TIME OF INSTALLATION:__ ____ _:__ ___ _ RECORD OF MAINTENANCE GRADE & TYPE OF LUBRICANT USEDL------------------- DATE OF LAST OIL DATE LAST DATE OF LAST CHANGE REGREASED OVERHAUL OR REPAIR I! U.S. ELECTRICAL MOTORS 20 OIVISIO'-OF EMERSON ELECTRIC CO :25 OLD GATE LANE IIUII ... DN VIL~ORC C::>~NEC'TICL:T 06460 ''·"ted " .. . ,. . ' I L ,. OPERATION & MAINTENANCE INFORMATION ProJect: Chester Lake Hydropower Project Contract No.CL-02 1 Item No. l • ') Specification Paragraph -. 3 • Drawing No. 4. Name of Article 5. Manufacturer 6. Size, Capacity or Rating 7. Catalog No. six C-13 C-13 Link Seal Sleeves and Wall Thunderline Corporation 8" link sleeve LS-475-C, seal for 12" WS-12-37 -30", WS-12-37-54" 8. Spare Parts are Available from C.M. Hoskins Co., Inc. 9. Guarantee to be Provided by Contractor Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone Subcontractor Name Address Phone 907-479-5754 -· '--- '--- -C. M. HOSK INS COMPANY , l~l~. L.. 73 ~3 -15th N.W. SEATILE, W .~ 98117 (206) 789-lfC :: ' --- - '--.-J IPE TO WALL PENETRATION SEAI9 LINK·SEAL . . . the fast, modern way to seal wall pipe penetrations and pipeline casings at road crossings. Economical, easy -to-install LINK- SEAL is fast becoming the standard method for positive, hydrostatic sealing of the annular space between pipes and the holes or casings through which they pass. Patented in seven countries and-sold world-wide by 98 stocking distributors, ~hese unique, interlocking, modular seals ~ave gained widespread acceptance among leading architects, engineers, contractors and pipeliners. Many years of rugged on-the-job use have proven LINK-SEAL to be far superior to old-fashioned lead-oakum joints, expensive hand-fitted flashings, messy, non-pressure sealing, non-support- ing mastics or leak and damage suscep- tible casing boots. Extremely versatile and available in an almost infinite range of sizes, Ll N K- SEAL can be found on such diverse applications as a pipeline in Arabia, a pneumatic drug-distributing system in a modern New York hospital, or a fire protection system in a British nuclear power plant. The modular link design permits easy assembly in the field and enables users to maintain a complete stock of seals with a minimum of inventory. "While -ry ~Sible effort hu been mede by Thund.,ine CorpOration to insura that all Linii·Seal model numb!Hs and their corrasponding specifications have bean 1ccurately set forth in this catalog, no rasponsibility is anum~ by Thunderline CorpOration for any loss incurred by reason of any saia errors or omi:ssions ." 3 ,-.:Si ',_,. :1 1) Identical links •• mohf. · > ed of solid synthetic rullblr, , spacially compounded to ,.. ' sist aging, ozone, sunlieht. >"! wntw, ch~mats ..-..._. , ·-"~ • ......,.~---".,··."r·. ··'i . . .'. ."'· .... ·~ ••• a I . ,I LINK-SEAL POSITIVE HYDROSTATIC SEALING When properly installed, Link-Seal is rated for 40 feet of head or 20 psig ... pressures much greater than normally encountered in wall and casing seal applica- tions. They effectively withstand radiation levels up to 5 x 108 AADS often encountered in nuclear power plants, and prevent tracking or corona resistance created by high energy underground electrical cables. EASY INSTALLATI ON CUTS LABOR COSTS As shown in the step-by-step photos on the preced- ing page, Link-Seal can be installed in minutes. Time consuming caulking, leading, flashing, taping and messy mastics are eliminated, and installation time and costs are reduced by as much as 50%. SEALS ANY TYPE CON DU IT Link-Seal is ideal for use with API steel pipe, soil pipe, copper and steel tubing, cast iron pipe, concrete pipe, electrical conduit, PVC and other type plastic pipes. Since plastic pipes can't tolerate the heat required for lead-oakum joints, Link-Seal is a natural. On thinwall conduit the expanded links provide excellent sealing with no danger of damaging or rupturing the pipe wall. 6) Cut-away of completed installation. Link-Seal not only helps support the carrier pipe, but absorbs shock and dampens vibration. Metal-to-metal contact is eliminated, thus preventing any damaging cathodic reaction. 4 FEATURES CATHO DIC PRO TECTI ON Where insulation against cathodic reaction (electro- lysis -is required, Link-Seal is supplied with special high strength, non-creep glass-reinforced nylon pressure plates. Since all metal parts are encased either in solid rubber sealing elements or dielectric plastic pressure plates, metal-to-metal contact is impossible. FI RE AND HIGH T EMPERA TU RE PRO TECTION For firewalls or applications where extreme heat may be encountered, Link-Seals can be supplied with metal pressure plates and special high temperature-resistant . elastomer sealing elements. See page 9 for details. EIGHT BASIC LINK SIZES Link-Seal comes in eight different thicknesses to fit various size annular spaces. They have been used to effectively seal pipes from 1/4" to 121" in diameter, though there is no maximum limit to the diameter that can be handled. Select the exact model you require from the charts on pages 10-19. SUPPOR T FOR CARRIER PIP E Link-Seal's solid rubber links and sturdy pressure plates resist radial loading which helps the floor or ceiling brackets support the carrier pipe. In cased cross- ings the Model PL Link-Seal installed at each end (see pages 20 & 21) effectively centers the carrier pipe in the • casing and helps the cradles, end supports or insulators resist the loads from back-filling. Although Link-Seal does not anchor the pipe, it does provide the pipe good axial support on vertical floor and ceiling applications. SHOCK, SOUND AND VIBRATION ABSORPTION An inherent feature of Link-Seal's flexible rubber body is its ability to absorb shock, sound or vibration created either by changes in internal pipe pressures or ground disturbances such as earthquakes or shock waves at railway crossings. Failures due to fatigue are greatly reduced at welds, flanges and threaded connections. PRO TECTION AGAINST DAMAGE Unlike exposed pipeline boots, Link-Seal's position inside the casing or sleeve prevents any damage from sharp aggregate, tools or backfilling equipment. , LONG SEAL LIFE Link-Seal's thick section design provides excellent protection against rotting, tearing, aging, punctures and other hazards of direct ground burial. SEALS ARE SHIPPED ASSEMBLED To save you time and facilitate field assembly, Link- Seal are shipped pre-assembled from our factory or local distributor in ten ( 1 0) link sections -with complete installation instructions. Simply add or remove the necessary number of links to make up a seal that fits your specific pipe diameter. MINIMUM INVENTORY The modular, interchangeable nature of Link-Seal requires stocking only the desired number of each size link from which seals can be assembled for particular jobc;. OFF-CENTER COMPENSATION Since the rubber sealing elements expand when the bolts are tightened, Link-Seal will compensate for a considerable amount of both angular misalignment and eccentricity while still forming an efficient seal. CASINGS AT ROAD CROSS- INGS • COMPRESSOR STATION WALLS REGULATOR PIT WALLS HVAC SYSTEMS • STEAM TUNNELS • POWER HOUSE PIPING • TOTAL ENERGY PLANTS • UNDERGROUND HEATING PII'E SYSTEMS • WATERPROOFING FLOOR PENETRATIONS • FIRE PROTECTION PIPING • SOUND- WASTE TREATMENT PLANTS • SANI - TARY SEWER MANHOLES LIFT STATIONS • CHEMICAL FILTRATION PIPING • FIL TEA BED WALLS AND PIPE GALLERIES PROOFING APPLICATIONS ··- NUCLEAR AND FOSSIL FUEL PLANTS INTERIOR AND EXTERIOR WALL PENETRATIONS • ASSURES NEGATIVE PRESSURE WITHIN BUILDING • CONTROL AND INSTRUMENTATION PIPING • FIRE PROTECTION SYSTEMS • POWER PROCESS PIPING • COOLING TOWERS • ELECTRICAL CONDUIT • CIA· CULATING WATER LINES • CONDENSATE DIS· CHARGE LINES • TURBINE OIL FILTER LINES • DRAIN AND COOLER LINES 6 · . • , -corpo r at.i o,...., LINK-SEAL WALL SLEEVES LINK-SEAL WALL SLEEVES LINK·SEAL WALL SLEEVES are specially designed to mate w ith LINK·SEAL MODULAR WALL & CASING SEALS for a lifetime of leak-free performance. They offer the user the advantage of "one stop shopping" coupled with the as· surance of correct size selection. Proper WALL SLEEVE sizes are shown in the selection charts on pages 10-14. Each LINK -SEAL WALL SLEEVE is manufactured from heavy wall welded or seamless steel pipe. A full circle continuously welded water stop plate assures positive water sealing on the sleeve O .D. and acts as a sleeve anchor to prevent any thrust movement. Sleeves are protected by a coating of enriched red primer and are shipped con- veniently tagged for location as per ordering instructions. This avoids possible confusion on long term projects. HOW TO ORDER Specify order numbers as follows : WS-~- Sieeve pipe OD (nominal size in inches) Sleeve wall thickness (in inches). -er-1 LS4~-5-10 I Length in inches (Wall structure thickness) Steel. (Other materials avail - able upon request. contact factory) ENGINEERING DECALS Link·Sea l model number- (lf complete wall sleeve and seal assembly desired) These LINK-SEAL design decals (shown actual size) are yours for the asking. They s implify your drawings and assure proper ordering procedure. L l •a -IIAL. WALL ILII't'l LIHIC-SfAL PIPE THIIU WALL Pt:Hf:TIIATIOH ASUII8L Y ~TA IL THUNDERUNE CORPORATION • BELLE VILLE. MICHIGAN 48117 *SEE PAGES 10-14 FOR SPECIFIC MODEL NUMBERS AND DIMENSIONS. 6 **CUSTOMER MUST SPECIFY AT TIME OF ORDERING. -corporat i on L LINK-SEAL FIRE-RATED SEALS PYRO-PAC ~M WALL & FLOOR SEAL ... for 3-hour fire · resistance LINK-SEAL has developed a new family of seals which pro- vides three-hour protection against flames, smoke , gases and water even when exposed to temperatures up to 1900°F (1038°C). E-119-76 fire and hose stream criteria. This allows the seal to be accepted by American Nuclear Insurers (ANI -formerly NEL-PIA) of Farmington, Conn., for use in nuclear power plants. PYRO-PAC seals incorporate nearly all the features of stand- ard LINK-SEAL, but are constructed of completely inorganic ma- terials -with steel pressure plates and fire resistant silicone rubber sealing elements. PYRO-PAC fits all pipes and conduits from 1/2" to 120" diameter and can be used with standard LINK-SEAL wall sleeves core-bit drilled openings or fabricated sleeves. Completely factory assembled, they can be easily installed by your own personnel with regular tools and minimal instructions. Normal operating conditions in absence of fire : up to 20 psi and 450°F (232°C). See page 23 for ORDERING INFOR- MATION . A prominent, independent fire technology laboratory has thoroughly tested PYRO-PAC in accordance with ASTM HOW PYRO-PAC WORKS The PYRO-PAC seal is made up of two individual ,_. .• ._. sealing units, either of which can be sacrificed to P"~-• the fire, depending on which side of the penetra- tion is attacked. ~;....;.;:l:i:-~~~;;.;.;..::~:.D~-_.;;;;~-1 MODEL FD PYRO-PAC • When both sides of the wall or floor entry '-===~§§§g;;~~?===~ hole are accessible, PYRO-PAC Model FD f which consists of two independent LINK- SEAL units can be used. Certified test fumiCI with pipe and cable penetrations and PYRO-PAC seals installed in concrete floor slab. 27 thermo couples were used per slab. MODEL FS PYRO-PAC • For entry holes accessible from only one side, use PYRO-PAC Model FS. A unique tie rod connects both sets of sealing ele- ments, permitting the assembly to be in- serted and tightened from one side. (FS PYRO-PAC can also be used for holes ac- cessible from both sides). TESTING PROCEDURE Test slab being rli11d from fumaat comple- tion of 3-hour tnt (Slab w• next positioned vertically for hose stream test.) 7 LINK-SEAL MODEL LS-200-FD or FS LS-300-FO or FS LS-325-FD or FS LS-400-FD or FS LS-425-FD or FS LS-475-FO or FS LS-500-FO or FS LS-525-FO or FS -MINIMUM THICKNESS 4" 6" 7" 8" 8" 8" 8" 8" Test sllla lfW t.e 111'11111 twt Cold watar ltrikint dae 20Cid'F slab caused spelling of concrete but left PYRO-PAC seals intact Un- up-.1 side thowed no evidence of water. lFHUNDre~lb.DN~ corporat i on LINK·SEAL & WAll OP£NING SELECTION DATA The charts on page 21 and pages 10-14 $how which LINK-SEAL models are best suited for use with the most popular sizes of pipe, tubing or conduit -based on common sizes of sleeves or wall openings . If your sperific pipe and wall opening do not appear on a chart, turn to page 16 _ Ordering information is on page 23. STEP BY STEP PROCEDURE FOR SELECTING LINI<·SEAL ASSEMBLIES 1) FIND THE PROPER CHART Your particular type of pipe, tubing or conduit should appear in one of the charts on pages 10-14 _ See "Index to Charts." 2) LOCATE PIPE SIZE Find your pipe size in column one of the chart. Note that for most pipe sizes two LINK-SEAL models are available. Your choice of models may be based on economics (small links are usually less expensive), fixed I.D. of sleeve or wall opening, architectural codes (requiring a specific pipe-to-sleeve size rela- tionship), or clearance (larger links allow more eccentricity between pipe and wall opening). If the chart does not include your specific pipe and wall opening, see page 16. "" &Cl¥al 1&11 OUJIIOI ' .o•IMl OWIITIIII t •• D. I 3) DETERMINE TYPE OF WALL OPENING The following four types of wall opening are shown on each chart. (AWWA Cast and Ductile Iron Pipe Chart also lists Cast Iron Sleeves as available from foundry pipe manufacturers.) ANCHDI1 & WATER STOP PLATE CORE BIT J_AS REQUIRED f-.--5 "~ :---r 2-1/2" ":; ~ :£: :::;:._;_~:~;::: OUT _!_l___rSIOE I.Oi. DIM ENSION FRu M CHAR T ANCHOR & WATER STOP PLATE a.) STEEL PIPE SLEEVE This is the most common method of con- structing a wall opening. Sleeves are of standard weight unless otherwise noted , and inside surface conditions should be of "mill specification" where possible. Thunderl ine also manufactures a complete line of wall sleeves. See page 6 for details. b.) CORE BIT DRILL This method of constructing wall open- ings is ideally suited for LINK-SEAL. Core bit drills produce an excellent sealing sur- face. The I.D.s shown in this column are preferred but not necessarily fixed . If the particular bit listed is not available, you can calculate minimum and maximum 1.0. limits from the figures shown in LINK-SEAL DIMENSIONAL CHART (1) on page 16. c.) PRECAST CONCRETE Holes formed in a poured concrete wall by plugs, plastic knock-out sleeves or tapered metal forms usually provide a satisfactory sealing surface for LINK-SEAL. Any "pop- corn" surfaces or score marks, however, should be "buttered" in the field to assure a good seal. If a tapered plug is used, the taper of the diameter should not exceed 1/2" per 5" of wall thickness. Since LINK- SEAL assemblies are usually installed from inside a wall, the I.D. of a tapered hole should be measured 2-1 /2" from the inside surface of a wall. d.) ROLLED OR FABRICATED SLEEVES Sleeves c an easily be rolled from steel plate (usually 1/4") to the recommended I.D. Light gauge sheet metal sleeves may also be used, providing they have the strength to withstand the concre te pouring and forming process. This method is also used by Thun- derline for non-standard diameters in their wall sleeve line . See page 6. 4) DETERMINE LINK-SEAL MODEL AND REQUIRED NUMBER OF LINKS The last two columns in each chart show model number and the number of links required per _seal or assembly . NOTE: All model numbers are shown with a "C" designation for simplifica- tion purposes. When ordering be sure to replace the "C" w ith the letter designation for the type of service you require. (See SERVICE DESIGNATION on page !:1.) MINIMUM WALL THICKNESS Shown in the following chart is the minimum wall thickness (or recommended seating area) required to assure a proper seal with each LINK-SEAL modeL The dimensions shown are liberal, and can be reduced if necessary . Consult factory for "absolute minimums". SERVICE DESIGNATION The letter at the end of each LINK-SEAL model number designates the materials from which the pressure plates, bolts and sealing elements are made ... based-1>n the type of service or conditions under which LINK-SEAL assemblies wilt be used. For simplification purposes, all model numbers in the charts are shown with a "C" designation. Check the following service descriptions and substitute the correct letter (if other than C) when ordering. C STANDARD SERVICE-(INSULATING TYPE) -40° F to +250° F PRESSURE-PLATE : Glass reinforced nylon plastic for elec- trical insulation and cathodic protection. BOLT AND NUT*: Low carbon steel, zinc galvanized plated to resist normal corrosion. SEALING ELEMENT: EPDM rubber for general service in water, moist environments and normal atmospheric con- ditions. M STANDARD SERVICE-(NON-INSULATING TYPE) -40° F to +250° F PRESSURE PLATE : Low carbon steel zinc galvanized plated for use where cathodic protection is not required. BOLT AND NUT*: Low carbon steel, zinc galvanized plated to resist normal corrosion . SEALING ELEMENT: EPDM rubber for service in water, moist environments and normal atmospheric conditions. S CORROSIVE SERVICE-(CHEMICAL PLANTS, FOOD PROCESSING, PAPER MILLS) -40° F to +250° F PRESSURE PLATE : Glass reinforced nylon plastic for good resistance to organic compounds, many weak acids and related chemicals. BOLT AND NUT: 18 -8 stainless steel (304). SEALING ELEMENT: EPDM rubber which has high resis- tance to most inorganic materials (water, acids, alkalis) as well as most organic materials (acetic, acetone, anatine, etc.) 9 THlYNDERLINE corporat.i OI""\ -u UNK·SEAL MODEL DESIGNATION (Q) OIL RESISTANT SERVICE -40° F to +250° F PRESSURE PLATE : Glass reinforced nylon plastic for cathodic protection and electrical insulation. BOLT AND NUT*: Low carbon steel, zinc galvanized plated to resist normal corrosion . SEALING ELEMENT: Nitrile rubber which offers good resistance to o ils, aromatic fuels, solvents and other petroleum-base products. T HIGH OR LOW TEMPERATURE SERVICE -67° F to +450° F PRESSURE PLATE : Low carbon steel , zinc galvanized plated. Insulating features cannot be offered in this model due to temperature limitations of plastic. BOLT AND -NUT*: Low carbon steel, zinc galvanized plated to resist normal corrosion. SEALING ELEMENT: Silicone rubber for temperatures from -67°F to +450°F. This seat may also be used as a fire barrier for service up to one hour. To determine if this model meets your fire rated criteria, send for bulletin LS-150. FD-IFS FIRE RATED SERVICE-3 HOURS -PRESSURE PLATE : Low carbon steel, zinc galvanized plated. Insulating features cannot be offered in this model due to temperature limitations of plastic. BOLT AND NUT*: Low carbon steel, zinc galvanized plated to resist normal corrosion. · SEALING ELEMENT: Silicone rubber for temperatures from -67°F to +450°F in absence of fire . See page 7 for details as to actual fire rating performance and how to order. NOTE: The above service designations represent only the most popUlar options. Many additional variations are available such as, different elastomer for the sealing element (neoprene, SBR, natural rubber) or different surface treatments for the low carbon •steel bolt and nut (cadmium plating). Please consult factory if the above service designations do not meet your requirements. Types C, M and T are ideal for nuclear power plant applications. Details will be provided on request. ENGINEERING DECALS See page 6 for actual size ver- sion of our WALL SEAL and WALL SLEEVE decals avail- able for your engineering drawings. *ASA-NC Series are standard offering -metric series DIN 558-6.8 available upon request. ~...-rHIIIJ--...~natf...,.rOfTAI. ,.,....,.,..c::tJIWIICRirDI ·~ ..,.,.......,,, ~ :!f'~~~p~~~;D~~ ·-STEEL PIPE DATA ALSO PLASTIC PIPE HAVING SAME 0.0. AS STEEL PIPE RECOMMENDED I.D. AND STEEL PIPE SLEEVE LINK·SEA L LI NK-SEAL MODELS FOR WALL SLEEVE LINK CORE BIT DRI LLED AND PIPE ACTUAL ~ LINKS PRE-CAST WALL SIZE OUTSIDE ~ SEAL PER OP£N INGS ~ NOMINAL DIAMETER MODEL SEAL o:> c ·. (0.0.) NO . NOTE: Before specifying or ordering LINK -SEAL, see SERVICE DESIGNATION section on page 9. NOTE : The above chart may not include ALL the possible pipe-to-wall opening sizes . Consult pages 16-19 for calculating other combinations. "' This is the preferred factory recommendation for this combination ... based on a better fit, economics, sleeve material availability, etc. * Specify sleeve length required (8 •, 1 0 •, 12 •, etc.). All lengths plus or minus 1/1 6 •. See WALL SLEEVES on page 6 for details. A Caution: Wall sleeve does not have SCH . 40 or STO WT wall thickness. 10 CAST IRON SOIL PIPE (EXTRA HEAVY) PIPE SIZE NOMINAL ACTUAL OUTSIDE DIAMETER (D.O.) STEEL PIPE SLEEVE TD=IUNDIERILDNIE -co,..po,..at.i on PIPE SIZE CAST IRON SOIL PIPE (SERVICE WEIGHT) STEEL PIPE SLEEVE ACTUAL OUTSIDE ~ NOMINAL DIAMETER (0 .0.) LINK-SEAL WALL SLEEVE LINK-SEAL WALL SLE"EVE ~ LINK SEAL MODEL NO . LINK SEAL -MODEL NO. NOTE: Before specifying or ordering LINK-SEAL, see SERVICE DESIGNATION section on page 9. LINKS PER SEAL LINKS PER SEAL RECOMMENDED I.D. AND LINK-SEAL MODELS FOR CORE BIT DRILLED AND PRE-CAST WALL OPENINGS ~ o:> ~ I. D. I. D. NOTE : The above chart may not include ALL the possible pipe-to-wall opening sizes. Consult pages 16-19 for calculating other combinations . ~This is the preferred factory recommendation for this combination ... based on a better fit, economics, sleeve material availability, etc . * Specify sleeve length required (8 •, 1 0 •, 1 2 •, etc.l. All lengths plus or minus 1 /1 6 •. See WALL SLEEVES on page 6 for details . A Caution : Wall sleeve does not have SCH. 40 or STD WT wall thickness. 12 THUNro>~RILON~ -LJ c 0 r p 0 r a t j 0 '"' STEEL PIPE DATA (cont'd) PIPE SIZE NOMINAL ACTUAL OUTSIDE DIAMETER (0.0.) STEEL PIPE SLEEVE LINK·SEAL WALL SLEEVE eb LINK LINKS SEAL PER MODEL SEAL NO. 1.0. NOTE : Before specifying or ordering LINK-SEAL, see SERVICE DESIGNATION section on page 9. NOTE: The above chart may not include ALL the possible pipe-to-wall opening sizes. Consult pages 16-19 for calculating other combinations. fil" This is the preferred factory recommendation for this combination ... based on a better fit, economics, sleeve material availability, etc. * Specify sleeve length required (8 •, 1()•, 12 •, etc.). All lengths plus or minus 1/16 •. See WALL SLEEVES on page 6 for details. A Caution: Wall sleeve does not have SCH. 40 or STD WT waH thickness. PIPE SIZE NOMINAL ACTUAL OUTSIDE DIAMETER (0.0.) LINK·~AL WALL SLEEVE THUND~RLDN~ corporatio LINK SEAL MODEL NO. LINKS PER SEAL NOTE: Before specifying or ordering LINK-SEAL, see SERVICE DESIGNATION section on page 9. . NOTE: The above chart may not include ALL the possible pipe-to-wall opening sizes. Consult pages 16-19for calculating other combinatiOns fl' This is the preferred factory recommendation for this combination ... based on a better fit, economics, sleeve material availability. etc * Specify sleeve length required (8 •, 1 0 •, 1 2 •, etc.). All lengths plus or minus 1/1 6 •. See WALL SLEEVES on page 6 for details . A Caution : Wall sleeve does not have SCH . 40 or STD WT wall thickness. 11 -co .-po .-a t i o,..... L CAST AND DUCTILE IRON PIPE PIPE SIZE NOMINAL ACTUAL OUTSIDE DIAMETER (0 .0.) STEEL PIPE SLEEVE LINK-SEAL WALL SLEEVE LINK SEAL MODEL NO . NOTE: Before specifying or ordering LINK-SEAL, see SERVICE DESIGNATION section on page 9. LINKS PER SEAL AWWA TYPE RECOMMENDED LD. AND LINK-SEAL MODELS FOR CORE BIT DRILLED AND PRE·CAST WALL . OPENINGS ~ ~ ~ I. D. NOTE: The above chart may not inclu~ ALL the possible pipe-to-waH opening sizea. Conault pages 16-19 for calculating other combinations . ...,. This is the preferred factory recornmeno ... tion for this combination ... baaed on a better fit, economics, sleeve material availability, etc . * Specify sleeve length required 18 •. 1 o·. 12 •• etc.). AI lengths plus or minus 1116•. See WALL SLEEVES on page 6 for detaHs . • Caution: Wall sleeve does not have SCH. 40 or STD WT wall thickness. FIND YOUR APPLICATION MANHOLES ~ft a SEWER MAl~ UNDERGROUND HEATING CONDUIT This catalog shows the most frequently used types of pipe, tubing and conduit. Link-Seal, however, has been used on many other type pipes including the following. Rubber jacketed electrical transmission Vitrified clay pipe -in sanitary sewers cable -in tunnel penetration Steel tubing -in hydraulic piping Lead jacketed coaxial cable -in service Polyethylene pipe -for sewer renewal entrances PVC pipe -for electrical conduit Plastic jacketed telephone cable -in pull R FP pipe -in chemical processing vaults Steel conduit -for underground heating Concrete pipe -all series ..• wet walls Thinwall tubes -in air transfer systems Asbestos cement pipe -all series . . • Sheet metal ducts -in air conditioning potable water mains 13 SHIPPING WEIGHT OF LINK-SEAL MODELN().t WEIGHT FOR 10 LINk SECTION LS-200-C .75 LS-300-C 2.00 LS-325-C 5 .50 LS-400-C 12.00 LS-425-C 10.00 LS-475-C 10.00 LS -500-C 27 .00 LS-525-C 25 .25 +The "C" service designation m•v be used in calculating weights tor other · service designations . I!~~~?~~~~~~ -COPPER TUBING DATA STEEL PIPE SLEEVE LINK ·SEAL ACTUAL WALL SLEEVE LINK 1 LINKS PIPE O?P SIZE OUTSIDE ~"'-SEAL ! PER NOMINAL ! DIAMETER -MODEL SEAL (0 .0.) '::tl' NO . I. D. NOTE : Before specifying or ordering LINK-SEAL, see SERVICE DESIGNATION section on page 9. NOTE: The above chart may not include ALL the possible pipe-to-wall opening sizes. Consult pages 16-19 for calculating other combinations. fl" This is the preferred factory recommendation for this combination ... based on a better fit, economics, sleeve material availability, etc. • Specify sleeve length required (8 •, 1 o•, 12 ~, etc.). All lengths plus or minus 1 /16•. See WALL SLEEVES on page 6 for details . .A Caution: Wall sleeve does not have SCH. 40 or STD WT wall thickness. INSTALLATION NOTES TOOLS The Link-Seal bolt heads are usually re- cessed below the wall opening or the edge of casing pipe and therefore a socket or offset wrench mtJst ~e used. • • "'! .. , 0 LINK-SEAL LS-200 LS-300 LS-325 LS-400 LS-425 LS-475 LS-500 LS-525 5/16" hex head slotted 1/2" HEX 1/2" HEX 9/16" HEX 9/16" HEX 9/16" HEX 3/4" HEX 3/4" HEX HAND TOOLS: Use 5/16" hex or #6 screwdriver for LS-200. 1/2" hex re- quires 3/8" drive socket wrench. 9/16" and 3/4" hex requires 1/2" drive socket wrench. POWER TOOLS: Recommended if Link-Seal is used on continuous basis. Cuts labor cost approximately 75%. Use 1/2" air or electric impact wrench. FIELD INSTRUCTIONS Like most construction type products the perfor- mance of Link-Sal is billed in pert on the quality of workmanship at the time of installation. To help guarantee proper procedures ant followed an easy to reed step by step illustrated instruction bulletin is pecked with each carton of seals. For those designers and engineers wishing to formalize field ir-.tallstion procedures to the contractor please see Semple Written Specification on page 2. LARGER STEEL PIPE SIZES SHOWN ON NEXT PAGE 14 . -COrporat•o.-, u PIPE DIAMETER & SLEEVE REFERENCE CHART DIMENSIONS OF SEAMLESS AND WELDED PIPE-API TYPE, IPS, BLACK STEEL & RIGID CONDUIT Nom mal Pipe Actual Standard 10 20 30 40 60 80 100 120 140 160 S•ze 0.0 Wall LO. Wall 1.0. Walli 1.0. Wall' 1.0. Wall! 1.0. Wall 1.0. Wall 1.0. Wall 1.0. Wall 1.0. Wall 1.0. Wall 1.0. J!B" 405 0681 269 ---.068 .269 --.095 .215 ----- 1!4" 540 .0881 364 ---.088 .364 --.119 .302 -------- 3/8" 675 .091[ 493 ·--.091 .493 -.126 .423 ----- - 112" 840 109j 622 ----.109 .622 --'147 546 ------.188 .464 3 4' 1 050 1! 3 32-l 1 1 3 824 154 742 l -219 612 1' I 3' 5 1 J-19 '33 ~ 049 -179 957 ----2501 815 1·1 4' 1 660 1-10 1 1 380 140 1 380 -191 1 278 I --250 1 160 1-1 2" 1 900 145 1 610 -145 1 610 --200 1 500 -----281 i 1.338 2" 2375 154 2.067 ---.154 2.067 --.218 1.939 ---.344 1.887 2-1 /2" 2.875 203 2469 ---.203 2469 --.276 2.323 ------.375 2.125 3" 3.500 .216 3.068 --.216 3.068 .300 2.900 -.438 2.624 3-1/2" 4.000 .226 3 548 ------226 3 548 --318 3.364 ------ 4" 4 500 237 4 026 ---237 4 026 -337 3826 438 3.624 531 3.438 5" 5.563 258 5 047 ·----258 5 047 - -375 4 813 --500 4 563 -= .625 4.313 6' 6 625 280 6 065 --280 6 065 .432 5.761 .562 5.501 -.719 5.187 8" 8 625 322 7 981 -250 8 125 277 8.071 322 7 981 .406 7 813 500 7 625 594 7.437 719 7.187 .812 7 001 906 6 813 10" 10750 .365 1002C -.250 1025( .307 10.136 .365 10020 .500 9.750 .594 9.582 .719 9.312 .844 9.062 1.000 8.750 1.125 8.500 12"' 12750 375 12.000 -.250 12.25C 330 12.090 406 11.938 .562 11.626 .888 11.374 .844 11.062 1.000 10.750 1.125 10.500 1.312 10 126 14" 14 000 .375 13.250 .250 13.500 .312 13.376 .375 13.256 438 13.124 .594 12.812 .750 12.500 .938 12.124 1.094 11.812 1.250 11.500 1.406 11.188 16" 16 000 .375 15 250 .250 15.500 .312 15.37e .375 15.250 .500 15.000 858 14.888 .844 14.312 1.031 13.938 1.219 13.582 1.438 13.124 1.594 12.812 . 1 8" 18.000 375 17 250 250 17 500 312 17 376 .438 17 124 562 16.876 .750 16.500 938 16.124 1.156 15.688 1.375 15 250 1.562 14 876 1781 14438 20" 20 000 375 19 250 250 19 500 375 19 250 500 19.000 .594 18 612 812 18.376 1 031 17 938 1281 17 438 1500 17.000 1.750 16 500 1969 16.062 22" 22 000 375 21.250 250 21500 375 21250 .500 21000 - -.875 20.250 1.125 19.750 1 375 19.250 1.625 18 750 1875 18250 2 125 17.750 24" 24 000 375 23.250 .250 23500 .375 23.250 .562 22.876 688 ~2.624 .969 22.062 1219 21 562 1.531 20938 1812 20376 2.062 19 876 2344 19 312 26" 26000 .375 25.250 [.3t2 ~5.376 .500 25.000 --------- 28"' 28000 375 27.250 .312 27.376 .500 27.000 .625 26.750 --- -- ------- 30" 30000 .375 29.250 .312 29.376 500 29.000 .825 28.750 ----------- 32" 32.000 .375 31.250 .312 31.376 500 31.000 .625 30.750 .688 30.624 ------------ 34" 34000 375 33.250 .312 33.376 .500 33000 625 32750 688 32.624 --- 36" 36.000 .375 35 250 .312 35.376 .500 35.000 .625 34 750 .750 34 500 --- --------- 38'" 38000 .375 37.250 .312 37.376 .500 37.000 .625 36.750 .750 36.500 ---- 40" ~0 000 375 39.250 312 39.376 .500 39000 .625 38.750 .750 38.500 -- -- - - ------ 42" ~2.000 375 ~1.250 .312 41.376 500 ~1000 .825 40.750 .750 40.500 ----- 48" 48.000 .375 47.250 --.500 47.000 --------------- 54" 54.000 .375 53.250 --.500 53.000 --.750 52.500 ---------- &0" 60.000 .375 59.250 --.500 59.000 --.750 58 .. ~00 ----- - - '---- 1 I lfiHllUJ~(Q)~~lLUIN1~ co~oorat.'o~ -LINK·SEAL FOR NON-STANDARD DIAMETERS Due to the limitless vanety of LINK-SEAL applications, space does not allow the charting of every possible pipe diameter in relation to every size casing, sleeve or wall open1ng. By using the nformation on pages 16-19, you can quickly calculate and select the proper SIZe LINK-SEAL assembly for any applicat:on. Initial- ly, however, it is •mportant to understand SEALING RANGE, a basic LINK-SEAL feature. LINK-SEAL DIMENSIONAL CHART (1) SEALING RANGE* MODEL FREE STATE EXPANDED STATE CHORD LENGTH THICKNESS THICKNESS LS-200 LS-300 LS-325 LS-400 LS-425 LS-475 LS-500 LS-525 .500" .625" 1.125" 1.510" 3.100" 3.625" 3.625" 2.625" 3.860" 3.860" .687" .875" .935" 1.187" 1.437" 1.812" 1.125" 1.500" 1.625" 2.000" 2.375" 2.812" 2. 187" 2.500" .. •These dimensions have been adjusted to assure clearance for insertion and to compensate for extreme eccentricity between pipe and wall opening. Select the LINK-SEAL model whose SEALING RANGE encompasses your available annular space. SEALING RANGE As shown in LINK-SEAL DIMENSIONAL CHART 1 each LINK-SEAL model has a sealing range (between its free state and its expanded state thickness). The free state thickness is the minimum annulus (space between pipe and wall opening) that will permit that particular LINK-SEAL model assembly to be easily inserted into position for tightening. The expanded state thickness is the maximum annulus into which that particular LINK-SEAL model assembly can be expanded and still provide a satisfactory hydrostatic seal. For example the sealing range for a model LS-400 is between the free state thickness ( 1.437") and the expanded state thickness ( 1.812"). MODEL. LINK-SEAL MODEL SELECTIOI CHART d) (FOR NON- STANDARD PIPE D.O.'S) SMALL D.O. LARGE 0.0. RECOMMEND- ED F 0 R .250'' to 2.875" O.D. PIPE WHERE WALL OPEN- ING IS FROM 1.00'' to 1.25" LARGER.* For pipes larger than 5.00" with nar- row annulus, consult factory. .250" . 2.875" 3.00" . 5.00" RECOMMENDED FOR 1.90" to 4.50" O.D. PIPE WHERE WALL OPENING IS FROM 1.4" to 1.8" LARGER." Though LS-300 can be used for .625" to 10. 750" pipe, pipes smaller than 1.90" should use LS-200 and pipes larger than 4.50" should use LS-400, LS-425 or LS-475 if possible. For pipes larger than 10.750" whose annu- lar space requires LS-300, consult factory. .625". 4.750" 4.875" . 1 0.750" In most applications the annular space will dictate wh1ch LINK-SEAL model you use, since annular space is directly related to the sealing range. A quick and easy method of calcu- lating your annular space IS shown below. 17 .386" . WALL OPENING ""'-....,...-c~~-_j_ 1 7.386" -14.250" 1.568"__, -1 4 250 .. ~ DIFFERENCE 3.136"= ANNULAR PIP.E O.D. DIVIDE BY 2 -' SPACE ANNULAR SPACE 1.568" _/ ---------SAMPLEANNULARSPACEPROBLEM--------~ SMALL OR LARGE PIPES? The first step in selecting LINK-SEAL assemblies for non- standard diameters is to determine whether your pipe is con- sidered SMALL or LARGE in relation to the sleeve or wall opening through which it will pass. SMALL PIPE links don't form a true circle LARGE PIPE LINK-SEAL assemblies, when used with small diameter pipes, do no: form a true circle. The smaller number of links simply cannot be forced, in their "free" state, to conform as closely to the curved annular space between pipe and sleeve as can a larger assembly with a larger number of links. Consequently, it is neces- sary to use different methods to calculate LINK-SEAL assemblies for large and small pipes. This model fits the same pipe sizes as LS400 & LS425, but is thinner to permit use with nar- rower annulus. If at all possible, however, the LS400-or LS425· should be used to provide more leeway for out-of-roundness and misalignment. Wall opening tol- erances and elliptical conditions mu~t be closely controlled with large pipes, and LS-500 or LS· 525 should be used if possible. 3.00" . 11.00" 12.00" · 20.00" or larger RECOMMENDED FOR 8.50" to 28.00" O.D. PIPE WHERE WALL OPENING IS FROM 2.90" to 3.60" LARGER.* CJa be used for pipes as small as 2.875" and larger than 28.00", but only if fixed annulus requires. On large diameter (over 28.00") pipes, wall openings must be carefully prepared to assure a uniform annular space, since the limited sealing range of this model cannot compensate well for irregular shapes. Best use LS-500 or LS-525 if possible. 2.875" . 16. 750" 16.875" · 28.00" or larger *These wall opening figures are approximate. To be absolutely sure that the LINK-SEAL model you have selected will work with your particular pipe and wall opening or sleeve, check free state and expanded state thickness in DIM ENS I ON A l CHART ( 1). 16 !~~~~~~~~..,.~~ L UNK·SEAL FOR NON-STANDARD DIAMETER~ ~-To determine whether your particular pipe application falls EXAMPLE (B): KNOWN PIPE O.D., UNKNOWN WALL into the SMALL or LARGE category, read the bold type in the OPENING I.D. .-· ~ box below for directions. EXAMPLE (A): KNOWN PIPE O.D. AND WALL OPENING I. D. Assuming that your pipe O.D. is 10.375" and your sleeve I.D. is 13.125" ... Step 1) DETERMINE ANNULAR SPACE Annular Space = 13 ·125 " ~ 10.375 " = 1.375" Step 2) SELECT PROPER LINK-SEAL MODEL Refer to LINK-SEAL DIMENSIONAL CHART ( 1) and select the LINK-SEAL model whose SEALING RANGE encompasses a 1.375" annular space. LS-425 is selected because 1.375" falls between its 1.125" free state and 1.500" expanded state thicknesses. Step 1) DETERMINE PROPER LINK-SEAL MODEL Carefully study LINK-SEAL MODEL SELECTION CHART ( 2) and select the model that seems to best fit your requirements. For a 24.00" O.D. pipe. two LINK- SEAL models are "recommended"-LS-400 and LS-425. However, since you're not "locked in" to a specific wall opening J.D .. LS-400 is the better choice. The price is identical to LS-425. and you'// have much more leeway for mis-alignment and out-of-roundness. Step 2) CALCULATE MINIMUM AND MAXIMUM WALL OPENING I.D. The selection chart shows that for LS-400, the wall opening J.D. can be 2.90" to 3.60" larger than your actual ( 24.00 ") pipe 0. D. (This is double the sealing range for model LS-400 ). MINiMUM WALL OPENING J.D. = 24.00" + 2.90" = 26.90" MAXIMUM WALL OPENING /.D. = 24.00" + 3.60" = 27.60" b: LINK-SEAL DIMENSIONAL CHART (1) =:::==::;::==::_ -J Step 3) SELECT EXACT SIZE OF SLEEVE OR WALL ..,.., OPENING . SEAliNG RANGE• MODEL FREE STATE I EXPANDED STATE THICKNESS THICKNESS ~ ..l't'VV' I -~· Step 3) SMALL OR LARGE PIPE? CHORD LENGTH 'L..S.!IIII." As shown on page 8. you have several J.Ypes of wall openings from which to choose. The most common wall opening is a standard weight pipe sleeve. The chart on page 15 shows that a standard weight 28.00" O.D. pipe has a 27.250" /.D. which falls nicely between the 26. 90" minimum J.D. and 27.60" maximum J.D. If a core bit drill or pre-cast hole is to be used, be sure that the lD. of the resulting hole falls within the same limit ( 26. 90" to 27.60"). Locate model LS-425 in LINK-SEAL MODEL SELEC· TION CHART (2) and see whether your actual pipe O.D. (] 0 375") falls in the "S " category. Since 7" en2.500"andl6.875' thepipe is considered SMALL. a ed directly to section on page 18 entitled "SIZING LINK-SEAL ASSEMBLIES FOR SMALL DIAMETER PIPES". If your actual pipe OD. had [allen in the "LARGE" category (over 1700" O.D.). you would proceed directly to the section on page 18 entitled "SIZING LINK-SEAL ASSEM- BLIES FOR LARGE DIAMETER PIPES': LS-425 i;;.-. · I.S-471 ~ RECOMMENDED FOR 8.50" to 28.00" RECOMMENDED FOR RECOMMENDED FOR 0.0. PIPE WHERE WALL OPENING 2.375" to 8.625" 0.0. 30.00" 0.0. PIPE (OR IS FROM 2.25" to 3.00" LARGER.• WHERE WALL OPEN· LARGER) WHERE WALL This model fits the same pipe sizes as lNG IS FROM 3.25" to OPENING OR CASING J.D. LS-400, but is thinner to permit use 4.00" LARGER.• Can IS FROM 4.70" to 5.60" with narrower annulus. If at all possible, be used for pipes from LARGER.* Can be used for pipes as small as 2.00" however, the LS-400 should be used 1.250" to 20.00" if if large fixed annulus re· to provide more leeway for out-of· large annulus requires. quires, though smaller roundness and mis-alignment. like the If possible, however, use ll N K-SEA L models are pre-LS-400, this model can be used on LS-200 or LS-300 for ferable where possible. This pipes as small as 2.51f"or larger than pipes smaller than model's liberal expansion 28.00" but only if a fixed annulus 4.500" and LS.400 or range makes it ideal to requires. Wall opening tolerances and LS-425 for pipes larger compensate for out-of- elliptical conditions must be closely than 8.625" roundness, pipe mis-align- controlled with large pipes, and LS-500 ment, pass-through-wall or LS-525 should be used if possible. clearances, etc. 2.50" ·16.875" 1.250" . 11.879" 2.00" • 17 .250" 17 .00" -28.00" or larger 12.00". 20.00" 17 .375" · 84.00" or larger lS-621 • MODEL RECOMMENDED FOR 30.00" O.D. PIPE (OR LARGER) WHERE WALL OPENING OR CASING 1.0. IS FROM 4.40" to 5.00" LAR· USE AND GER. • This model is DESCRIPTION basically the sa me as OF LS-500, but is thinner to permit use with a LINK-SEAL narrower annulus. like the LS-500, this model compensates well for out-of-roundness, mis· alignment and pass· through clearances. 2.250" -17 .375" t SMALL 0.0. 17 .50"·84.00" or I~ • LARGE O.D. *These wall openmg f1gures are approximate. To be absolutely sure that the LINK-SEAL model you have selected w1ll work w1th your particular pipe and wall opening or sleeve, check free state and expanded state thickness in DIMENSIONAL CHART Ill THUNDERLDN~ cor-por-ation LINK·SEAL FOR NON-STANDARD DIAMETERS (cont'd) Step 4) SMALL OR LARGE PIPE? Read down in the LS-400 section of SELECT/0,\' CHART ( :J) and you'll find that a ::4 fJO" pipe IS considerr::d LARGE (over 16 875"). Turn rmmediatr::lv ro the section below entitled "S!ZI:VG LI.VK-SEAL ASSE.\1BL!ES FOR LARGE DIAMETER PIPES" If your actual pipe O.D. had fallen in thr:: SAI.4LL cate- gory (less than 16. 750 "),you would then proceed directly to the section on rhis page entitled "SIZI.VG L/.V K-SEA L ASSEMBLIES FOR SMALL DIAMETER PIPES" SIZING LINK-SEAL ASSEMBLIES FOR "LARGE" DIAMETER PIPES At this point you have read either EXAMPLE (A) or EXAMPLE (B) and now know four things; 1) Pipe O.D., 2) Wall opening I.D., 3) LINK-SEAL model number and 4) the fact that your pipe is considered LARGE in relation to the wall opening. Here's how to figure how many links you'll need per seal. Step 1) DETERMINE "BOLT CIRCLE" CIRCUMFERENCE. BOLT CIRCLE The bolt circle is the imaginary circle that lies halfway between the pipe O.D. and wall opening /.D. WALL OPENING The length or circumference of the bolt circle can be quickly calculated by using the following formula. {We'll assume that the pipe is 24.00" and the wall opening I.D. is 27.250"). PIPE O.D. +WALL OPENING I.D. BOLT CIRCLE"' 2 x 3.14 or 24.00" + 27.25" 2 X 3.14 = 80.46" Step 2) CHECK CHORD LENGTH Each LINK-SEAL model has a specific bolt to bolt length or "chord length". Refer to LINK-SEAL DIMEN· SIONAL CHART (1) and locate chord length for model LS-400 ... which is 3.625" Step 3) FIGURE REQUIRED LINKS PER SEAL Divide bolt circle length (80.46") by chord length (3.625") LINKS PER SEAL 80.46.::_' = 22.2 3.625" NOTE: This calculation will almost never come out even so always round off to the next lower whole number. (In this case, 22 lmks.) -- SIZING LINK-SEAL ASSEMBLIES FOR "SMALL" DIAMETER PIPES At this point you have read either EXAMPLE (A) or EXAMPLE (B) and you now know four things; 1) Pipe O.D., 2) Wall opening I.D .• 3) LINK·SEAL model number and 4) the fact that your pipe is considered SMALL in relation to its wall opening. The sizing charts (3·10) on page 19 are designed to help you quickly pinpoint the required number of links per seal and also check to be sure that the LINK-SEAL model you have selected will actually work with your particular pipe and sleeve sizes. HOW TO USE SIZING CHARTS Assuming that your pipe O.D. is 14.625", your wall opening I.D. is 17.700", and you have settled on LINK·SEAL model LS-400 Step 1) Go to LS·400SIZING CHART (6) and locate your actual pipe O.D. between the figures in column A and column C. Step 2) If your actual pipe O.D. falls between the figures in column A and column B. your minimum sleeve or wall opening size will be the figure in column D. LS-400 SIZING CHART -(6) Minimum wall opening I.D. L----14.625" falls between A & B Step 2allf your actual pipe O.D. had been 14.800", it would have fallen between the figures in column B and column C. The minimum wall opening I.D. would then be the sum of your actual pipe O.D. and the figure in column E. LS·400 SIZING CHART -(6) -tep 31 To determine the max1mum wall opening I.D, locate your p;pe O.D. between column A and column C and add the f,gure ,n column F to your actual pipe O.D. .500 .500 .687 1.750 3 1.25 1.25 .687 .937 1.125 1.937 4 1.00 1.25 1.125 1.375 1.500 2.375 5 1.00 1.25 1.625 1.875 1.937 2.875 6 1.00 1.25 2.000 2.125 2.375 3.125 7 1.00 1.25 2.375 2.500 2.812 3.500 8 1.00 1.25 2.687 2.812 3.125 3.812 9 1.00 1.25 3.125 3.375 3.625 4.375 10 1.00 1.25 LS-300 SIZING CHART-(4) .625 .687 .875 2.375 3 1.687 1.750 ~ 1.125 1.312 1.437 2.875 4 1.562 1.750 1.562 1.875 2.000 3.312 5 1.437 1.750 2.062 2.375 2.687 3.812 6 1.437 1.750 2.562 2.875 3.125 4.312 7 1.437 1.750 3.062 3.375 3.812 4.812 8 1.437 1.750 3.562 3.937 4.125 5.312 9 1.374 1.750 4.000 4.375 4.750 5.750 10 1.374 1.750 LS-325 SIZING CHART-(5) 1.625 1.875 2.000 4.000 3 2.125 2.375 2.875 2.875 3.125 5.250 4 2.375 2.375 3.625 4.000 4.250 6.000 5 2.000 2.375 4.625 5.000 5.250 7.000 6 2.000 2.375 5.625 6.000 6.500 8.000 7 2.000 2.375 6.625 7.000 7.625 9.000 8 2.000 2.375 7.625 8.000 8.625 10.000 9 2.000 2.375 8.625 9.000 9.625 11.000 10 2.000 2.375 LS-400 SIZING CHART-(6) 2.875 2.875 3.500 6.500 4 3.625 3.625 3.875 4.250 4.750 7.500 5 3.250 3.625 5.000 5.250 6.125 8.625 6 3.375 3.625 6.125 6.500 7.250 9.750 7 3.250 3.625 7.250 7.875 8.500 10.875 8 3.000 3.625 8.375 9.125 9.750 12.000 9 2.875 3.625 9.500 10.250 11.250 13.125 10 2.875 3.625 10.625 11.370 12.125 14.250 11 2.875 3.625 11.750 12.500 13.375 15.375 12 2.875 3.625 12.937 13.687 14.437 16.562 13 2.875 3.625 14.00 14.750 15.525 17.625 14 2.875 3.625 15.250 16.000 16.750 18.875 15 2.875 3.625 NOTE: The SIZING CHARTS llboH mq maw tMI yow WGlJ opening or sleepe u too illrre OT too llffllll/or u. with the particultu UNK-5EAL model you lrtne ~lected.. IPI tlrb aue, you can either go back to SELECTION CHART (2) on pages 16-17 and choose another LINK-5EAL model, or clumge the I. D. of your wall opePiing. If either clumge appean to be a problem, contact factory. 19 LINK·SEAL FOR NON-STANDARD DIAMETER: Step 41 DETERMINE NUMBER OF LINKS PER SEAL Assuming that your wall opening or sleeve size fall w1thin the minimum and maximum I.D. limits as deter mined 1n steps 1, 2, and 3, the requ1red number of link per seal are shown in the fifth column. F G5:1iE~ 1:rnrr:rsppru e Links per seal----.....1 F 3.000 3.500 3.500 6.000 4 2.500 3.000 4.125 4.500 4.875 7.125 5 2.625 3.000 5.250 5.750 6.250 8.250 6 2.500 3.000 6.500 7.000 7.500 9.500 7 2.500 3.000 7.625 8.250 8.750 10.750 8 2.500 3.000 8.750 9.250 10.000 11.750 9 2.500 3.000 9.875 10.500 11.000 12.875 10 2.375 3.000 10.937 11.562 12.187 13.937 11 2.375 3.000 12.125 12.875 13.500 15.125 12 2.375 3.000 13.375 14.125 14.625 16.375 13 2.250 3.000 14.375 15.125 15.750 17.375 14 2.250 3.000 15.625 16.375 16.875 18.625 15 2.250 3.000 LS-475 SIZING CHART-(8) 1.375 1.687 2.000 5.375 4 3.688 4.000 2.250 2.562 2.812 6.250 5 3.688 4.000 3.125 3.562 3.875 7.125 6 3.563 4.000 3.875 4.375 4.750 7.875 7 3.500 4.000 4.875 5.375 5.750 8.875 8 3.500 4.000 5.625 6.125 6.500 9.625 9 3.500 4.000 6.375 6.875 7.375 10.375 10 3.500 4.000 7.250 7.750 8.375 11.250 11 3.500 4.000 8.000 8.625 9.250 12.000 12 3.375 4.000 8.750 9.500 10.250 12.750 13 3.250 4.000 9.625 10.375 11.125 13.625 14 3.250 4.000 10.375 11.125 11.875 14.375 15 3.250 4.000 2.375 2.375 2.500 8.000 4 5.625 5.625 3.375 3.625 4.000 9.000 5 5.375 5.625 4.375 4.812 5.375 10.000 6 5.188 5.625 5.625 6.250 7.000 11.250 7 5.000 5.625 6.750 7.500 8.375 12.375 8 4.875 5.625 8.000 8.750 9.500 13.625 9 4.875 5.625 9.125 10.000 10.750 14.750 10 4.750 5.625 10.500 11.375 12.250 16.125 11 4.750 5.625 11.750 12.625 13.500 17.375 12 4.750 5.625 12.937 13.815 14.875 18.565 13 4.750 5.625 14.500 15.375 16.125 20.125 14 4.750 5.625 15.625 16.500 17.250 21.250 15 4.750 5.625 LS-525 SIZING CHART-(10) 2.750 2.750 2.875 7.750 4 5.000 5.000 3.750 3.750 4.250 8.750 5 5.000 5.000 5.000 5.000 5.625 10.000 6 5.000 5.000 6.000 6.250 7.062 11.000 7 4.750 5.000 7.125 7.625 8.250 12.125 8 4.500 5.000 8.562 9.062 9.750 13.562 9 4.500 5.000 9.750 10.375 10.875 14.750 10 4.375 5.000 10.811 11.437 12.312 15.811 11 4.374 5.000 12.124 12.750 13.625 17.125 12 4.374 5.000 13.436 14.062 14.937 18.436 13 4.374 5.000 14.874 15.500 16.250 19.874 14 4.374 5.000 16.000 16.625 17.375 21.000 15 4.374 5.000 I i I . I ' .. • -co..-po..-at.o o,...., THIS PAGf FOR PIPELINE CASED CROSSING TYPICAL ROAD CROSSING CASING PIPE LINK-SEAL MODEL PL for sealing pipe casings at highway and railroad crossings A LINK-SEAL assembly installed at each end of pipeline cas· ings at highway and railroad crossings provides positive, hydro· static protection against the entry of water, soil or other backfill material and eliminates corrosion and ice dam~ in the annular space between pipeline and casing. Unlike exposed pipeline boots, LINK-SEAL is positioned in· side the casing, which protects it from being damaged by sharp Plain ru bber •li ng al• .,ent wi th mat in g non -c on- rctive pressu11 platiS and rrosion resistant bolt. Lin k-Sea l assembly ~~low­ in g th e PL model. 2S (Of' th e botto m 90°) is com- posed of "CB" block links. aggregate, tools or backfilling equipment. LINK·SEAL'S metal parts are completely encased either in solid rubber sealing ele· ments or dielectric glass reinforced nylon pressure plates, prevent· ing any metal·to·metal contact which cciuld cause a cathodic re· action. Starting with some 10" diameter models, we supply LINK· SEAL assemblies with "centering blocks" in 25% of the links. These centering blocks, made of strong, non-creep reinforced plastic, fit into molded openings in the links which will occupy the lower 90° of each seal assembly. Since the centering blocks are slightly thicker than the free· state (unexpanded) thickness of the rubber links, they position the pipe higher during initial stages of installation and prevent any pinching of the lower links or scraping of the pipe coating by the pressure plates. In addition, they give auxiliary support to any cradles, insulators, sand bags, etc. used to resist the loads created by back·fill. • For ordering information on Model PL, see page 23. Rullllerlil* wiltl...Worced ..... " ....... lllloct. ---·~-drict­• -U.JII ,ru!JUnk. Cut--. af PL11..._ ,_ tic CIMII'ilt blocks (one is visible in '-IWd -• thlt .... will ... ill ... cen1ric and ..,_. aaxil~ .., IIIPPOft ......... from blck-fll. 20 • SIZING CHARTS FOR LINK-SEAL PL IMPORTANT NOTE If carrier pipe coating or cas i ng wall thickness varies consider· ably from the standard limits shown under each SIZING CHART, please consult factory , 300 For Casing One Pipe Size L•ger Than Cam. Pipe IMoxomum cooting .080 -C81ing pipe wall should be -• 40 or ._ SERIES except for sizn 8 " a 10" whicti should haW wall thick,... of llcl'iecklle 30 or leu. When 17' ,.,;ng ;,.-, ..,..;ty sctiedulo 20 well or 1-.1 Comptete Cnine Seal C arner AUimbtv '' Complete Casing • Composed of .... Basic S.al Order No . c .. ;ng P;p. l onk-S.ol Links Modo I !For API & IPS IAPI & IPS Total Pla1n w ith Used Pipe Sizft Only) Pipe S izel} L•nks L•nks Centertng * Blocks• 1/2" X 2·1/2" 3 0 LS-300 -C Link-Seal No. 525 3/4" X 3" 4 4 0 lS-300-C link·Seal No. 753 1" X 3" 4 4 0 lS-300-C link-Seal No. 13 1-1/4" X 3-1/2" 5 5 0 LS·300 ·C link·Seal No. 12535 1-1/2" X 3-1/2 " 5 5 0 lS-300-C link·Seal No. 1535 1·1/2" X 4" 3 3 0 lS-325-C. Link-Seal No. 154 2" X 4" 6 6 0 lS-300-C link·Seal No. 24 2·1 /2"x5" 4 4 0 LS-325-C• Link-Seal No. 255 3" X 5" 8 8 0 lS-300 -C link-Seal No. 35 3·1/2 " X 6" 5 5 0 LS-325-C• link·Seal No. 356 4" X 6" 10 10 0 lS-300 -C Link·Seal No. 46 { 6" X 8" 15 15 0 lS-300-C link·Saal No . 68 8" X 10 " 19 19 0 lS-300-C link-Seal No. 810 10 " X 12" 22 22 0 lS-300-C link-Seal No. 1012 • When ordering links separately, use Baa•c L ink·Seal Model Number. • Cent ering block links are not necessary in 300 Series. . . . _.These models may be used in place of LS·42S·C in cases where annular space •• hm1ted due to heavy coa t ing on c arrie r pipe or e xtra-thick c aeing wall. NON-STANDARD APPLICATIONS -Though 99% of all pipeline si ze combinati ons can be found in the charts on this page, vour job mav be the exception. If so, please contact our factory for advice . Campletad inallltiaa • lhowiftt•.,.....ru'*- linb and ........ .... did ....... ,_. pldn .......... . --· 21 [J For c.ing Two Pipe Siz• ......, Than Carr* Pipe IMoximum co.tong 3118" tllicll -caing ptpe walls ol>ould not ex~ .500'' oxeept lor-17', 14" •nd 18" ""'""' "'ould not •-• _, thoc:k .................. 317'.1 Complete Cn•ne Seal c.,, ... Auembly '' Complet• C.lltnt . Compos.t of ... 8UIC' Se•l Order No . Cu•neP•pe L mk ·S.•I Ltnk s Model !For API & IPS !API & IPS Tot11 l Platn with Used P •SM s,u, Onl y I Ptpe Stztsl L tnks Ltnks Center•ne .. 81odn .. 2" X 6" 5 5 0 LS-475 -C Link-Sea l No. 26 3" X 6" 4 4 0 lS-425-C link-Seal No. 36 4" X 8" 7 7 0 LS -475-C link·Seal No. 48 6" X 10" 10 10 0 lS·475-C Link-Sea l No. 610 8" X 12" 12 12 0 lS·475·C Lin k-Sea l No . 812 10" X 14" 10 10 0 LS-425-C....._ l in k·Seal No. 1014 12" X 16" 12 12 0 lS-425 -C....._ Link -Seal No. 1216 ~--.. ,r· ~ .. .t~.- 14 " X 18" 13 9 4 LS -400-C Link-Sea l No . 14 18 16 " X 20 " 15 11 4 LS -400-C l ink-Sea l No. 1620 18" X 22" 17 13 4 LS-400 -C link-Seal No. 1822 20 " X 24 " 18 13 5 lS-400 -C Link-Seal No. 2024 22" X 26" 21 16 5 LS -400-C l ink-Seal No . 2226 24" X 28 " 22 17 5 LS-400 -C link-Sea l No. 2428 26 " X 30 " 23 17 6 lS-400 -C Link-Seal No. 2630 28" X 32 " 25 18 lS-400-C link·Seal No. 2832 JO " X 34" 27 20 7 lS-400-C l ink-Seal No. 3034 32 " X 36" 29 21 8 LS-400-C Link·Saal No. 3236 34 " X 38" 30 22 8 LS-400 -C link·Seal No. 3438 36" X 40 " 32 24 8 LS-400-C link·Seal No. 3640 •• When ordering Plain Linke separately, uae Baste L•nk-Seal Model Number . .. When ordering l in k s wit h Centeri ng 81ocko oeporately, use Model No . l S-400-C B. M These models may be used in place of LS-400-C in cases where annular space is limited due t o heavy coat ing o n carrier pipe or extra-t hick casing wall. 500 ,., a..-... ....... ~ n.. c.rier Pipe , ___ --2/lr ..... -..... ,.. ...... "'-1111 ftOt ·- IERIEa.· ...................... ,..._-'d ____ ...,_ __. ._ .3fT.~ Complete CHing S..l c ... , .... A-blY II Complete Ca11n1 • Com_..tof .•. a .... S.ol Ordor No . lonk·S.ol c • ..,.P;po L1nk1 M~l I For API & IPS IAPI & IPS Total Platn wrth UJOd Pipe Sizn OnJyl P;po Sizoll Links Links Cent•,,.. ••• B lodl• ••• 4". 10" 6 6 0 LS-500 -C link·Seal No. 410 6" X 12" 8 8 0 lS-500·C lin k-Sea l No . 612 8" X 14" 9 9 0 lS-500-C Lin k-Sea l No . 814 ~ ..... )!...>,:,._. ..... ;:;_:i.~ . . -~-. . ... ·-:· . ..... -;·"..; 10" X 16 " 10 7 3 LS·525C<~.M Link-Sea l No. 1016 12" X 18" 12 9 3 lS-525-C<~.M link·Seal No . 1218 14" X 20" 13 9 4 lS-500 -C link-Sea l No. 1420 16 " X 22 " 15 11 4 lS-500 -C link ·Seal No . 1622 18" X 24 " 16 12 4 lS-500·C l ink·Saa l No. 1824 20" X 26 " 18 13 5 LS-500 -C lin k·Sea l No . 2026 22 " X 28" 19 14 5 lS-500 -C lin k-Sea l No . 2228 24" X 30" 21 15 6 LS -500 -C link·Sea l No . 2430 26 " X 32" 23 17 6 lS-500-C l ink -Seal No. 2632 28 " X 34" 24 18 6 lS-500·C l in k·Sea l No . 2834 30" X 36 " 26 19 7 lS·SOO ·C Link -Sea l No . 3036 32" X 38" 27 20 7 lS-500-C l ink-Sea l No . 3238 34" X 40" 29 21 8 lS-500-C link ·Seal No . 3440 36" X 42 " 30 22 8 lS-500-C Link -Seal No . 3642 42 " X 48 " 36 27 9 LS ·500-C Lin k ·Sea l No . 4248 48" X 54" 41 30 11 lS-500 -C l in k-Seal No . 4854 54" X 60 " 45 33 12 lS-500 -C . link ·Seal No . 5460 ••• When ordering Platn Ltnkl sep arately, uae Baste Ltnk ·Seal Model Nu"'o~, -When orderong l inkl w ith-Centering Block1 teplrately . u se ModoJ '-o l S 500 CB .AM These models m ay be used in place of LS-500-C in c ases where a nl'lu•d' '" .. ' ~ ·s 11 m,tt due t o heavy coating on _c arrier ptpe o r e•tra·thick cas.ng wall 11 Y~~!4P~~~~~~ -APPLICATIONS ... . - Effects of corrosion from iJnPFOPW t'MihGd of •aline ••H open- ing. Pipe ~In 8XC1tlent .... untitpedcint ~ Ml re- moved from annulus and ct.p pits obiiMd. Lil*.s.t etlmt.mas this c:onditiGn . :6" lf1d 2cr --~ -~1111!· ,gai ~ downward lad . ..., --:--r-~~7+.:' ~#~~\t:t:·:;_~~~:'.t View of pipe from inside tlnk. Since pipe -•nn~NM ll tldt point, engineer preferred to use l"'ltrri~t type tie-rod dft!c-· 22 lf'IHJUINID~RLON~ Corporat.i ol""""l -L ORDERING INFORMATION HOW TO ORDER LINK-SEAL BUILDING CONSTRUCTION MODEL LINK-SEAL----- Each LINK-SEAL link consists of a rubber sealing efement, two pressure plates and a connecting bolt and nut. Standard models of LINK-SEAL are pre-assembled and pack· aged in ten-link sections. When ordering, try to keep quantities in multiples of ten. State quantity of links, model number and service designation. SAMPLE ORDER 1) REQUIREMENT: To seal 20 wall openings where 4" PVC plastic pipe passes through a 6" steel pipe sleeve, standard weight. 2) First see pages 8 and 9 for selection procedure. 3) Chart on page 10 (segment shqwn above right) shows that this combination of pipe and sleeve requires 10 links of Model LS-300. LINK-SEAL MODEL PL -Pipe Line Unlike building construction LINK-SEAL models, LINK-SEAL ~odel PL (Pipe Line) is pre-assembled at the factory and shipped ~~ complete casing seal assemblies ... to fit your actual size car· rier pipe and casing pipe combination. To order, simply locate your carrier and casing pipe sizes in the charts on page 21. Specify the quantity of complete LINK-SEAL assemblies you need and the LINK-SEAL casing seal order number from the right hand column. SAMPLE ORDER 1) REQUIREMENT: To seal 18 cased crossings where 16" API carrier pipe passes through 20" API casing pipe. (Cased cross· ings require a seal at BOTH ENOS.) · 2) Chart on page 21 shows that 16" x 20" crossings take LINK· SEAL No. 1620 Casing Seals. 3) 18 crossings x 2 ends= 36 LINK-SEAL assemblies. 400 .. I .-f.-::..,. ~ ..,..., • ~-~; SERIES c., .... . Casu'l P.pe ·' Complete c.inl Seel ... _.,. Com--of ... Order should read .... 36 T Quantity of complete assemblies :; .. ~' "-··r l.-.:::., -~ """:-~. LINK SEAL No. 1620 Complete casing seal order number 1'-lOTE: It mav be advantageous to atock certain aizea of Lll'lK-SEAL Pl. in large q1111ntitin for on-tht-tob assembly. These seals will be shipped to vou pre-assembled in ten-link aection1 fOt easy handling. Each section will contain all plain Iinke or all "CB" link1. You mav then rntke up vour own complete casing seals as outlined in the chartl, with the proper number of Plain and "CB" links. 23 4) Now select the proper "SERVICE DESIGNATION" letter, . based on the type of service to which the LINK-SEAL assem- blies will be subjected. (See page 9) "M" designation is selected because LINK-SEAL assemblies will be used to seal plastic water pipe entering sub-basement of building, and cathodic protection is not required. 5) Total links required ... 20 wall openings x 10 links per seal = 200. Order should read . . . . 200 ...:: LS-300 - M T Quantity I \ Model Service Designation PYRO-PAC LINK SEAL -Fire Rated To select the proper PYRO·PAC unit, use the LINK-SEAL charts on pages 10-14. PYRO-PAC is pre-assembled at the factory in complete assemblies, to fit the actual 0.0. of the pipe and the ac- tual 1.0. of the wall or floor opening. State quantity of complete assemblies, model number, service designation and number of links per seal. SAMPLE ORDER 1) REQUIREMENT: Seal 15 wall openings of 4" EMT conduit through a 6" thick fire-rated wall. 1.0. of the wall sleeves is 6". ' { " . ~ 'THUIIIDERLINE L-·- -~11.1. rnu,.. ... ••• .. WALL ..... WML&IIVI .TW: •• TNII -ICTML @ g; ..... I ... . .. _ -· ...... Cllti«T -=--•. IJ a:> . ..,, ''' --... , 1.1. .. LH . ,.-c.uT ---. 1/2 100 2 '" 2) Chart for Electrical Mechanica onduit on page 11 shows that 4" pipe x6" sleeve requires 10 links of LS-300-C. 3) If wall is accessible from both sides, you can use either model FS or FD. One side accessibility requires model FS. Order should read .... 15 -LS-300 FO 10 Quantil:of T Pvro-"C ul complete assemblies Model Service per Designation Seal NOTE: By ordering ONE of Model FD, you will receive TWO in· dependent Ul8mblies of 10 links each. LINK-SEAL WALL SLEEVES Ordering instructions for LINK-SEAL WALL SLEEVES c.,-, be found on page 6. COPYRIGHT 1985 CATALOG NO. LS-119-G. LOCAL LINK-SEAL OFFICE THUNDIERILDNE corporat on 87rJl SAMUEL BARTON DRIVE • BELLEVILLE, MICHIGAN 48111 PHONE 3131397-5000 • TELEX NO. 23-0711 "While eVflry possitJie effort has been made tJy Thundllt'linfl Corpora/ion to insurfl that all Link-SHI model numllllfs and their corrflsponding SfJ«;ifications haVfl tJHn accurately set forth in this a.talog, no rflsponsitlilily is assumtld tJy Tlfundflrlinfl Corporation lor any loss incurrtld tJy reason of any said errors or omiss1ons. " PRINTED tN l.. S ·' OPERATION & MAINTENANCE INFORMATION .I Project: Chester Lake Hydropo~er Project Contract No.CL-02 1. 2. 3. 4. 5. 6. 7. 8. 9. Item No. seven Specification Paragraph 15240 Drawing No. Name of Article Manufacturer Size, Capacity Catalog No. Spare Parts are Guarantee to be Contractor C-14 Ventilator Loren Cook or Rating 9000 cfm 30SP6B Available from Alaska Winter Inc. Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks. AK 99707 Phone 907-479-5754 Subcontractor Name Address Phone I ........... . ..... ] LOREN COOK COMPANY MAINTENANCE AND OPE RAT lNG DATA We are supplying the attached data to be used as a guide for proper installation and ~aintenance of your COOK Yentilators. With proper installation. these ventilators wi II give you years of trouble- free service. The attached data includes literature in the following categories: 'ALASKA W1NTER INC. ~ :!901 SPENAAD ROAD r..-..:::.-:s;;,,,;:::,. ~'<A 99SC3 CATALOG NO. SERIES SWD. SPO, SWB, SPB, AWD, AWB, ADD, ADS, SSWB, APD, APE INSTALLATION AND OPERATING INSTRUCTIONS SERVICING INSTRUCTIONS ' MOTOR WIRING DIAGRAMS DIMENSION DRAWINGS PARTS LISTS • P•rts Lists as such are not av•ilable for COOK ventilators. Our units •re of all-aluminum construction •nd would require none of the m.jor component parts to be replaced under normal conditions. In the event • part is needed, we suggest you indicate the appropriate part on the attached drawing and forward It to us along with the Catalog Number and Serial Number of the f•n. We can then Identify the part and size re1ufred •nd meke the necessary arrangements for replace- -. ment In the field. . - I LOREN COOK COMPANY ..... PtiLD.~IIII I INSTALL A Tl ON AND OPERATING INSTRUCTIONS (PROPELLER WALL UNITS} 1. When louvers are required, place the louver into the wall opening. Then operate the dampers manually to be sure the blades operate freely. 2. All units are shipped completely assembled, ready for installation, except where motor horsepower exceeds 2 H.P. Three horsepower motors and above are shipped loose and must be field mounted. Place the ventilator in the wall opening. 3. If APD unit or APB unit is being installed, fasten the louver to the unit with sheet metal screws. 4. Secure ventilator to the wall by means of lag screws, anchor bolts or other suitable fastener. 5. When disconnects are used, follow the wiring diagram in the disco~~ect switch and the wiring diagram with the motor. 6. Test unit after it has been wired to be sur~ the rotat:on i~ thP ~ame as indicated by the arrow marked "ROTATION.11 7. 8. 9. 1 0. .. .. IMPORTANT: Hake sure unit is not running in the wrong cirection. The wrong rotation will cause air flow in opposite direction of that desired. If the unit is running in the wrong direction, c,~r~ the =on:-~; switc~. It is possible to merely interchange the leads at :.r-i~ lc.:ation to De certain the unit is operating in the correct direction. All belt drive units are set in the plant for tne prooer RPM and belt tension. Check the belt tension after six months' operation and be sure that 1/2" play is allowed at'atl times. All motors furnished have pre-lubricated bearings, and, under normal conditions, will not require a":· further maintenance for a cc:-io::! of ten years. Should the unit be subjected to greater usa~e. :t is a~visable to remove the motor after three years' operation, and have vour maintenance department re-lubricate the bearings with fresh grease, ........ U.S.. A. I M-35-A I [ II•IA. OHIO J LOREN COOK COMPANY SERVICING COOK PROPELLER VENTILATORS 1. CHECK ROTATION OF FAN PROPELLER A common difficulty with propeller fans is encountered when they are not wired to run in the right direction. The rotation of many types of motors is determined by the electrician at the time of installation and cannot be controlled by the Loren Cook Company. A unit running backwards will deliver air but in the wrong direction. In order to safeguard against this, all COOK units are fur~ished with rotation arrows on the motors and belt drive assemblies. All units should be checked at the time of installation to make certain that they are running in the right direction. In the case of three phase motors, the direction can be changed by interchanging any two of the three motor leads. In the case of single phase motors, the reversing instructions will appear on the wiring diagram. -2. CHECK VOlTAGE AT THE FAN Tn SEE IF IT CORRESPONDS WITH THE MOTOR NAMEPLATE. Many motor failures are caused by connecting the motor to the improper voltagP This is especially true when buildings have both 115 and 230 volt single phas current. Motors wired to the wrong voltage will run excessively hot, and, if not properly fused, they will eventually ''bake out" until a short occurs in the windings causing them to burn out completely. Hany complaints of motors drawing more than nameplate amperage are solved by connecting the motor to the proper voltage. 3. CHECK PUllEY ALIGNMENT AND BELT TENS,ION. lt. All belt driven ventilators are equipped with variable pitch pulleys. To change fan speed, loosen set screw on driver (motor) pulley and either open or close the gr~ove facing to change the pitch diameter. When groove facing is opened, belt will pull down into the groove and speed will be reduced. To increase speed, close groove facing allowing belt to come up to the outside edge of the groove. It may be necessary to slide the motor on its mounting base to maintain belt tension. Loosen bolts on the motor mounting plate and slide motor until the proper tension is reached. Tighten bolts to maintain this new setting. A belt play of 1/2 11 is recommended for proper operation and minimum belt w~1 Care must be taken to not get the be 1 ts too tight. . t!¥}.. ~\N\E.R \1 v. NJ..'-' _.-~AS.t> ~o,.::> ••. 390\ ~";;-;u.:.~-\ 99~""" ... -~~;-P-t CHECK BEARINGS, SHEAVES, PROPELLER, ETC. ~ Units may be improperly h•ndled during· shipment causing d•mege sufficient to sh.orten fan I ife. Units. should be checked for visible:s igns of d.,.ge or mishandling. Check such items as propeller, motor, s~ves, and shaft for such dam~ge or misalignment due to handling. · '··~47" I LOREN COOK COMPANY I ftUA.,OMIO WIRING DIAORAMS FOR ALL UNITS li£Nf:!W. ELECTft!C 0111 UIIIU!:!QN lfljl.g P£C:Q • IIHGLE P'145£ i.i.!'i[!!AL ELECTRIC. 2 SPEEQ, z w 'NO lNG. SINGLE ~>MAS£ GRWNO A WHEN GRD AEOOIIIIED.ATTACH TO GRO Aor8 WITH NO I THRE_AD FOMIING SCMWS. TO REVERSE, INTERCHANGE IIUJE AHO WHITE LEADS. WH£N GRD. I'IEOUitEQ, ATTACH TO GRD A or I WITH NO.I THREAD FORMING SCREW$. TO REVERSE, INTEI'IC:HAHG£ lUCK AND ltED U:AOS. St!t\DCR PQ!.E MO!Q!! WITH SPE[Q CO!!TitO!. ~ p;:;J--:>-L, :- MOTOR t---o------------L.t ~ EXP!!.DSIQN mfF, JrGI.E V'UQ. 51'!__ P_,£ -I. CHIC« LINE \101.1&11:. I CM[Cit ROT.t.TICIH WITM "''"* ~ UNIT. 1 ...._.'IS CHECK J "'""• UIIIT1 ~ ROTATION. AU I 3 .. HAS£ I ' !,[A Q WOTOIII $ LOW YOLTM& 201 1 no YOLTI ~ TOGETHER I J z 3 J J LINE ANY Z LINE LEADS. 2 SPEED, I WIHOIIIG, 3 PHASfi HIGH SPEED LOW SPEED B §~rootTHDt R 4<lt_, L 5<>~..tl 6~N E 8 1--:-L, L z-:-l..tr 3--o-LJ N 4<:-E 5<:-OPEN 6-o-- TO R[V(It$(, INTERCHAHGE ANY 2 LIN[ LEADS. MOTORS REOUJIItE MAGNETIC CONTROL. Z SI"UD, 2 WINDING, 3 PHASE MOTOR TO REVEIIISE:: HIGH SPEED: INTEitCHANGE LEADS -· AND T~&. LOW SPU.DrltfTEJIICHtt.NGE: LEADS • 4N0 Ta. tiOTH SP££0Sa NTEitCHAHGE AHY ~ LINE LEADS. , ..... IIIOTOR OAIIIIPI• IIOTOIII ....... TYPICAL fAI MOIO!/DAMt!ft IIOTQ!II SCHEMATIC ~ i--- ;--..___!,1 ;--..___Lz --._, L:s .· 'Oit J !'MAll, OAIIiiPIIt IIOTOit VOLT All SHOU..O II TMI a.a•l .TWU• L1 MIO Lz. L N E 'Otl II•IU "'*II Ufll\.ICATIC*, DIIMUJtO LJ• • M.L OAWU •OTCNtl MAVI 0.1 .... UTili ANO &ttl tTOCaiO II 111, no A .. 410 VOLT MOOlL.I. 4. CNICII IOTM waDI 0' I 111£1:0. S llltlll UllfT1 I'O't R01aT-UTU ..... CICllfT1IOU,. I. ..... ¥CX.TMI 01' tMOtll ~TaTOI .._.. ... OUT IIOT<M 11110 ~D ~ t ] AMPERE RATING TABLE I /• Phase 3 Phase ~5 220 440 230 208 230 <460 480 HP RPM Volts Volts Volts Volts Volts Volts 1/30 1050 1.90 .95 1/25 1550 2.00 1.00 1/20 1550 2.30 1.15 1050 3.10 1.55 1/12 1725 3.20 1.60 1140 3.20 1.60 860 3.00 1.50 1/8 1725 3.00 1.50 1140 2.40 1.20 860 3.90 2.00 1/6 1725 3.40 1.70 1140 4.00 2.00 860 5.80 2.90 1/4 1725 4.40 2.20 1 • 1 1.0 .5 .46 1140 4.20 2.10 1.5 1.4 .7 .64 860 5.40 2.70 1.9 1.8 .9 .83 1/3 1725 5.40 2.70 1.8 1.6 .8 .73 1140 4.60 2.30 1.7 1.6 .8 .73 860 7.40 3.70 2.5 2.4 1.2 1.10 1/2 1725 7.60 3.80 2.1 2.0 1.0 .92 1140 6.20 3.10 2.5 2.4 1.2 1.10 860 9.80 4.90 2.8 2.6 1.3 1.20 / , 1725 ~.8g) 5.40 3.2 3.0 1.5 1.38 1140 -s-.4Q 4.20 2.6 2.4 1.2 1.10 860 14.20 7.10 3.8 3.6 1.8 1.65 1 1725 13.20 6.60 ' 3.6 3.4 1. 7 1.56 1140 4.0 3.8 1.9 1.74 860 4.9 4.6 2.3 2.11 1-1/2 1725 5.0 4.8 2.4 2.20 1140 5.1 4.8 2.4 2.20 860 7.2 6.8 3.4 3.12 .2 1725 5.9 5.6 2.8 2.57 1140 7.2 6.8 3.4 3.12 860 8.5 8.0 4.0 3.67 3 1725 8.4 8.0 4.0 3.67 1140 9.3 8.8 4.4 4.03 860 10.0 9.4 4.7 4.31 5 1725 14.0 13.0 6.5 5.96 , 1140 15.2 14.4 7.2 6.60 860 17.4 16.4 8.2 7.52 7-1/2 1725 22.0 20.8 10.4 10.80 1140 21.2 20.0 10.0 9.17 IIIIAM CATALII. • ... F·l 11tJSf(8 I .. ' - TYPE SPB &TIEL 'ROPELLIER 'AC WALL fAN 8EL T DRIVE M11: 9-J4-t7-M..,t-P.I.: .-CIE$1ER fll•IW ollt'IIOUn: ____________ gJ nan:_-...A.:..W:;....:r=-. _______ _ .... '"" Sf I -T'IC~IT- 1 .............. . !ISZIL ,.., ··'-""'· ~m •1IPI fftOIOf" .. "* 011 too or bOtt'Oift-ftOI on IH3el. DtMENSION DATA IIIIE A I c D ~ 32·13nl 30-H »13nl 30-112 .. 30 3f.1311t ... 33-13nt 31-314 31 ·~11 42-all 3f.13nl ,. ~ 51·13nl ... .. ,3nt 17-314 41 .,3nt M-7MI .13nl 6112 ,.. G13nt .7,. 57·13nl ~ Nl .,. CN • .. • ,. C'f'U t&11 ,,()0 .nr '2" -¥4-I ~ WNIIIPT D, II DUll "" S11L :"""I '-" . ~ . . - LEGEND ACCDSOIUES 1o ii8Eft 11!188 8eilc?ll4es 2. ENif¥ 8e:lt.,.148 • M8'8fUEI 14 MII'RER 4. 'ttte n• "eMP"I"ilcete • geiQONNK;.T SWfiCu liiiOTOI' TYH STO·STANDARO ! W ! Wll!l ""'"'I el'Lelfe14 fi~F l£,.8 .. , • va-s t SPI-2·A . ' ,. 00 OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 1. 2. 3 • 4. 5. 6. 7. 8. 9. Item No. eight Specification Paragraph 15001 Drawing No. Name of Article Manufacturer Size, Capacity Catalog No. Spare Parts are Guarantee to be Contractor Subcontractor C-3, C-8, C-9, C-10, C-1 1. C-12, C-13, C-17, C-18, C-19 Pipe certification Inland Pipe Fabricators or Rating 1 II t 2", 4" , 6", 8", 12" 20" N/A Available from Inland Pipe Fabricators Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone Name Address Phone 907-479-5754 . lgj ~~JI~~~1110Jfj'l' ~J I , '• lJA N 2 5 19b ' ,, ,! .... NORTHWEST PIPE & CASING CO. CERTIFIED TEST REPORT CU.JOMIR PIP£ 51'1: Clf ICA T ION DATI /t:; fr 11571'1 /-s- ~ ... NATI:RUU. SPI:CWICATION 541..1:5 OfiOlR NUMlllA 7 ASTh /1-~ CUSJOMlR PO NUM8[R PA00 ONIXR NUNlii:A 7 /00~1 -00 ttJOAO fl:lil f'ftl:l>SUAI: -.?CJ ~~ ;r If'S II g'Q MECHANICAL PROPERTIES CHEMICAl ANAlYSIS '1. HAn[NING RI:PlAINCI ON BEND USJ -•u• RI~IUS . ILONGAIIOH c ,. s IN 2"1" -;/ .a.?J .tJI -- • - I Ci:RTif'Y THE ABOVE FIGURES TO BE CORRECT tZr -1-=n. AS CON f AIN£0 IN f tt[ RECOHOS OF THE COMPANY. a· LESIGN C.h.LCULATIONS FOn CONNECTION OF 40.FT PIPE LENGTH FOR CHESTER LhKE HYDROFOWER PROJECT ;__L'lf-,~·1J""~t'., t/ .. 12 .t o/l' .7 Prepared by I I·ate ~-~~-;8/ November 198 7 . : : : rva-CJ!pe S~,~bs1aia'y o= 7y1er Ccrporotion GROOVE~ IPS Pipe NUMBER 105 LIGHTWEIGHT •werklnt Olm•.,•lona Nom. ,,... .. u,. kit lncnea W• foro lighter pal Qty. A I c ~~ wtught. more economical mg. the 105is recommended lor piping ication1 involving law A.12 1.81 1.5~ pressures and low 5treu.es such as fire A.37 1.81 2.&:1 sprinkler system a. It !table for many applications 500 2 5.12 1.75 3.:La 1 0 in industrial plants. and conuoctor utility piping 2'1, 500 2 5.75 1.75 3.75 2.4 system$, 3 500 2 6.50 1.75 ~ 39 -2.6 2'h 500 2 7.A.7 1.7$ A.94 3.2 !"----_ _. ___________ .... "-' ____ ... _.; 4 500 2 8.00 1.87 5.6:2 3.8 NUMBER 110 HIGH PRESSURE 5 500 2 9.53 2.00 •. 66 5.6 COUPLING {See page 14) 6 500 2 10.87 2.00 7.7-: 6.3 • 500 2 13.87 2.37 10' '':' l3.4 --~-· ·-- ~· A •worldnt Dt.,...,..,lont H-. , ....... u .. lolt ,.,.,., .. Wt. Oeu:riptlon and Application 'lpe Slae ptl Oty. A • c lbt. Toggle type Gruvagr1p;! couplings ore the ultimate Number 11$ in simplicity and speed. They ore ·deal for low• 1 500 3.:31 1.69 2.75 .9 preuurtt lines where frequent moke-up and br•okout 1'4 500 S.75 1.69 3.12 1.3 it. required. such os temporary lines. proceu piptng. c~n1tru<:Jion and mining ... any condition where u 500 4.25 1.69 3.50 1.6 t••qvent di,anembly. ac:ceu or Inspection is -2. soo 4.69 1.81 4.00 2.0 2" ~')() 5.4.4 1.69 .4.62 2.2 ·equired. ..., CAUTION: When u•ed In COI"'Crete pulftpiftg ...... liS c:ouplingt 3 500 4.03 1.69 5.25 2.9 mu•• be l.•pt w1thin th• rt<ommended rounss .• Aa11imum joint • 500 7.50 1.94 6.69 5.4 worl.in; prenur• mull include thocl. lood. pllp• groow•l !...,. ond Qa•ket c:ov•tl•• must bel••• e~l conc:r••• 01\d oth., +or•ign mall••· It ' 500 10.12 1.94 8.25 1.2 1hould nof b• neceuory to clot• coupling by hommeung. Tl\•115 co..rphn; it not det•gn.d lor •u:entttC lood•n;L It thOI.IId ,., b. uud • Wor\lnt ,,. •• UN I.,.. IHI•..t an hprott•fic t•· ta with ftO ••'•'"•I 01 m• end of Cor'!Crt'f• oumpln9 lx>om• orO" -lito I tia•"' oboo.• 30 loa4_. C•upll"l ond flttlnt _,.,,.., pntn~o~••• ohan YOry. Al,.ayw. '-~~· ~... -.... --....1..-----. ~ • • '-- • \ • .. CAlCULATION SHEET JOB HO. _____________________________________ SHT__£_0F r CUSTOHE:R BY k,!.) DATE /1-ICJ-d7 SUBJECT CH2S'Tt--t< L fiJ.-Z' J./y@t7Q/?=QtAJ~~ ~t:"l CHK_DATE: /. Vt"f('CUUn · c;:rl~Cj)p -11i17t/JutiJI ;r'?e t!>/ 6e// al Jj,.R t>.Jrd t.u_1 40 It 1~·1;'-1;..!, I T I f .f e/., c t <7"/1 t/ 6 e ( ( L ~~d.P dr)t:u,e"/Pr .2CJ.Y!" · (JC/ftcV ckamPif'r .2 IJlO ,, ,.. CALCULATION SHEET JOB NO. _________________ SHT_{_OF 5""" CUSTOMER BY i-.J DATE 11-/? .j "} J. Vt/eldt d~s'tyl1 1/ r c:; LJ.)-elc/ .. l&fp J.:;,'h 1-( 1,;1-(#1-t-vd tl') ;, -L -7!"5:'1 ltj·j,, -Tel --12o 71 (.zo) - 12 :. ~-''-JtJ63 31 lt/;4 -- rrcl - 7Tx2d /w -(j/+ ;,) ~ I~ /w .= (l2o 2 -f .21 <) j}lloc,v~t.f< :/.r.gf'f tj w-e/ d Ftv ::: J 6tto·a _ '2..)( 2. . -'{o-cnJ f?.S~ /1;h.tillltH f/1/-el f"l., a -:: ----- l:~t::j~,C~:, -;/<N'7 tAJ-dd 11 IZS -- Jot:! Fuller Hnlartel Ohtr1butors P.O. Box 4410 Spokone WA 99202 Mr. Fuller. Jonuary 2B, 19BB Tt.. letter is in regcrd to the working pressure of the Rorp'lc FC400 flanged coupling edapters w1th AWWA Ctess F flanges per·your P 0. •209~~· I i ! The body, end ring, enchor loops, end gesket of the flanged coupling adopter wt11 pr.trform sottsfectorny el 360 pst • If you nove any further questions .. pleose cal1 us ot Romoc. Industries. We would be heppy to help. Sincerely, ROHAC IND. INC. Del bert H. Eeton Engineering -ROMAC ~ INDUSTRIES, INC. ~ 1064 4~h ~>we. S. Seattle. WA 98134 -PO. Box 3212. Seattle. WA 98114 (206! 624-6491 Telex 32·8765 1·800·426·9341 STYLE "FCA501" FLANGED COUPLING ADAPTER NOM. PIPE SIZE 3" 4"x3" FLG 4" 8" 10" 12" 16" NOM. PIPE SIZE 4" 6" 8" 10" 12" 16rl 24 I I COLOR CODE RED REO BLACK RED BLACK YELLOW RED BLACK YELLOW RED BLACK YELLOW RED BLACK YELLOW RED BLACK YELLOW RED BLACK FLANGED BODY Through Bolt wiNuts MATERIAL SPECIFICATIONS GASKET RANGE 348-, 3.64 3804 405 3.80-t 4.05 406....1 4.31 4.50-{ 4.70 4 50-I 481 4 80-t 500 4 74-l 5.10 511-t530 3.80-, 4 05 4.06-; 431 450] 4.70 4 50 4.81 480-t 5.00 4 74-, 5.10 5.11-1 5.30 511 -1 5.40 5.80-t 6.10 6.05-f 6.30 6.55-; 6.76 6.60....1 6.91 690-t 7.10 686-1 720 7 15 735 7 15 7 45 7.80 8.10 8.50-1 8.30 ass-; 8.75 860-t 9.06 9.05..., 9.30 8.99-; 9.40 9.31 -1 9.50 931-, 9.70 9.80 10.10A 10 70 411.00A 10 70-110.808 10.89 11.408 11.35-111.758 11.80-,12.128 11.81 12.10A 1~.6S-t12.95A 12.70-,12.808 13.15-t13.55B 13.85...,14.108 14.20...114.408 16.00 FLANGED BODY: Ductile (nodular) iron. meeting or exceedtng ASTM AS26-80. Grade 65-45-12. Standard 150 lb. flange. Ye!lovv shop coat. END RING: Ductile (nodular) 1ron. meetmg or exceedtng ASTM AS36-80. Grade 65-45-12. Color coded Red tor O.D. and STD. ST., Black and Yellovv for cast iron and A/C. GASKETS: Virgm SBR compounded tor water & sewer servtce. Meets ASTM D2000 3 8A715. Flanged 0-nng gasKet ts neoprene rubber. Other compounds available tor oil. etc. BOLTS and NUTS: High strength, low alloy steel. with heavy hex nuts. The steel used follows AWWA C-111-80 compoSition spectficattons. Threads protected wtth plastic caps on e13ch bolt end. The 10" and 12" flange bolts and nuts are mild steel. electro-galvantzed w1th a hex head. APPROXIMATE use Sta Stl C.L & 0 D Stl O.D Stl Aiv Stl. Std. Stl Std Stl. & D I Cast Iron C I & AIC M.E. AIC A B O.D Sti Rtv Stl Std Stl. Std. Stl & D.l Cast Iron . C.l & AIC ME. AIC R.B AIC A 8. CL200 O.D Stl. AIV. Stl. Std Sll. Std. Stl & D.L Cast Iron C.L & AIC ME. AIC R.B AIC RB CL200 O.D. SU. Atv. S1J. Std. St! Sid Stl. & 01. Cast Iron C. I & AIC M.E. AIC RB. AIC R.B Cl200 0.0. su. Std Stl Std. Stl. Cast Iron AIC M.E. AIC R.B O.D. SU. Std. Stl. Std. Sd. Cast Iron AIC ME. AIC RB. .0. Stl. CATALOG ~ NUMBER F A501-3.65 FCA501-4.05-3 FCAS01-4.05-3 FCA501-431-3 FCA50 1-4. 7Q-3 FCA501-4.81-3 FCA501-S.OQ-3 FCA501·5.10-3 FCA501 -5.30·3 FCA501-405 FAC501-4 31 FCA501-4.70 FCA501-481 FCA501·5.00 FCA501-5.10 FCA501·5.30 FCA501·5.40 CA50Hi.10 FCA50 1.S.30 FCA501.S.76 FCA501-6.91 FCA501-7.10 FCA501-7.20 FCA501-7 35 FCA501-7.4S FCA501.S. 10 FCA501.S30 FCA501-8.7S FCA501-9.06 FCA501·930 FCA501·9.40 FCA501·9.:JO FCA501-9.70 A501-10.10 FCA501-11 00 FCA501-10.BO FCA501·11 40 FCA501-11 75 FCA501-12.12 FCA501-12. 10 FCA501-12.95 FCA501-12.80 FCA501-13.55 FCA501-14.10 FCASOHHO FCA501·16.00 FCA501-17 40 * 12 o•ns) NA *(2 pms) *(2 pms) *(2 pms) *(3 ptns) *(3 pms) POA APPRO X.. WEIGHT & OVERALL LENGTH 161 411•" 191 4•1•" 17.51 4" 281 33.51 4V4' 701 A-5v.-· 8-5•1," STYLE "FCA501" PARTS LIST **Less Flange Bolts/nuts *Submit pressure data wllen SPeCifying ptns ANCHOR PIN END FLANGE BOLTS W/NUTS THROUGH BOLTS WINUTS GASKET RINGS NO.Sr SIZE I t 4-5/8 X 3" t 4-3/4 )( 3'1.." T 4-3/4 X 3'1.." t 6·7/8x4" T 6-7/8 X 4" 16-1" X 4'h'' PAICEU NO.Sr SIZE 4-5/8 )( 7%'' 4-3/4 X 8". 4-3/4 )( 8" 6-~ X "'X 9'h" 6-7/8 X 9" N.A. 12-518 X 8H PRICE EA. TO ORDER: Specify catalog number for com- plete FCAS01, lldd the letter "P" to end of catalog number for FCA501 w1th anchor p,n,. Example: FCA501·SOOP. For FCA501 w1thout flange bolts add the letter "X" to end of catatov number. t Thts symbol denotel those parts wfltch are interchangeable with the 501 couplings Ex•mple: FCASOl-SOOX r--------------------------------------------------------------------------------------------------- m fl.F ~~s ~ cc..-s. aoo- SC. !P ·Oft F kANG£ r ~ A. e I I ANCHOR LOOP A.STM A3G 5TE£L I ,.--ENO R.ING / ovcnL£. IRON t /-TRACK. H£A0 ~ T WlTH C OIA. / AM. STO. HEAVY HE.X NUT EYI!fc:a'5 '"' DE".oam• I hNA~ CLS. F 2 I AD0£0 I).S'S PIPE. 0.0. '1-70 6.91 9..0. A ...... s.t:S 8.'\.J~ I B 11).1'4 liO.lf! 10.?0 I MTI I Mf¥ 12·tH? I'-~ ..... 12-17-87 1&.+&.~ c 1iOLTs- DIAJ LG. ~«). IC • .S.S .C3 '$'.0 '!. •a. !IS .82 s.o s 15'-2'1 .C3 5'.() ' Fl...ANUE. SIZ.E .. IN. .., 6 8 ft. IRON !Pftt::.s-:a. jw;T. PSol t#« I. 8 ~- 300 I !HJ.o aoo 1-"Jo.o 300 11)0.0 100 ANO WASHER tPJPE 0.0. GASKET RUBBER COATING P£~ CU5TON'IEA Q~OE:R 18l..O ~.98 n.l'-1 rt.82. "~ S'.O '7 (!] II!!!!IIOMAC IIDISTIUES -I I I I : f I I I I I I lwl?!!;J l!r!:::,r;::_~_L~ \'3.-ss lll~r·u FC400 COUPUNG L -f Wtl&i ----- - i ... B i ANCHOR LOOP ASTM A3G STE.E.L ..... A •j ITJ I P, F t:.J.A SS j:" C L 'S. 300 \ I ~END RING SUP.·Ott f:L.ANGE / DUCTILE. l~ [ \ \ /-TRACK HE.A0 eat.. T W&TH C OIA. ~ ·F' -1---L~~/ ::..~· ~~VY HE:X NUT ~ _g ~Y///ff///,0~ >//.· /'"''-"'" ¥' tPlPE. 0.0. ~vI . \ 'I OUCllt.E IR.ON i 1£ 'fJSICIG GA.SX.ET l£f -~mcn Mit "'" RUBBER . , lf~f\'S. CL.'S. F 12-lp..e? '\..k.td:;;.. 2 ADDED 1).55 ~-tl-87 s.u.e;,;.... . Co..t\~f"tG PER CUSTONIEA QP.OE.R PIPE. A 8 c BOLTS FLAI\IGE. rsu:~s. W<;T. 0.0. DIA. LG. ~-SIZE IN. F'r-1 t{ll:ll. L8S. "1.70 ..... ...... I0.4S .C3 '$'.0 '& " 300 !Hl,o j 6.91 9.!$ 10..&! 12..95' • C2 s.o s 6 aoo ·1'0.0 . ~-0· .. , ... 10.70 IS.2't .C:t 15.0 c. 8 300 11)0.0 I ' 13.~S "· ''1 [i] ~ IOMAC IIDISTIIlS 1ft( IUU> I '!t.&e I'T.8 2. 1.1 ~.o -, It, lOO •• ,.0 FC400 COUPLING I . sc:..._•N.T..S. 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OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 1. 2. 3. 4. 5. 6. 7. 8. 9. Item No. ten Specification Paragraph 15240 Drawing No. Name of Article Manufacturer Size. Capacity Catalog No. Spare Parts are Guarantee to be Contractor M-14 Thermostat Johnson Controls or Rating N/A · T26 Available from Johnson Controls Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks, AK 99707 Phone 907-479-5754 Subcontractor Name Address Phone .·~ I Catalog Sec:1on T Senes T26 Bul letin No. 4054-C Supersedes 4054-B -- · ~NSON . . . ·.: ·~ -·.. • .ft ' . .,. EGNT lS · . · . . · ; -·! ·-~ "{ -~J Johnson Controls, Inc. Control Products Division 2221 Camden Court Oak Brook. IL 60521 Application T26 line voltage thermostats control heating, cooling, or year 'round air conditioning units in commercial, industrial or residential installations. Typical uses are for unit heaters, fan coils, blast coils, refrigerated storage rooms, electric heat, duct furnaces, greenhouses, etc. Models are available with SPST or SPOT contact action and for standard duty (nominal Y4 hp; 10 amps. non-inductive) or heavy duty (nominal1 hp; 22 amps. no.,_ inductive) applications. These --- thermostats are also suitable for low voltage applications. All Series T28 thermostats are designed for use only as sbrli• 1"28 Line Voltage Thermostat Heating, Cooling, Combination Heating and Cooling Standard Duty and Heavy Duty operating controls. An operating control is not authorized for use where its failure in any mode can result in personal injury and/or loss of property. It is the responsibility of the user to add those necessary devices that protect against undesirable system failure modes. For line voltage thermostats with integral selector switches refer to T22 Bulletin 3233. Features -ene~_coi}Servation models available featuring fixed limited ranges. -Enclosed Pennswitch contact unit -dependable, dustproof, and field proven. Specifications Fig. 1 -T21 Thermostat with horizontal faceplate (top) or vertical faceplate (bottom). Type Number Differential Finish Matera.l MounUnt Range · Sensing Element Shipping Weight • T26A T26B T26J T26S Faceplate BaM Cover Thermostat Thermometer Individual .. --.. Pack Ove'l)tck of 1.0 lb. (.45 kg) .. 22 lbt. (1 0 kg) .. -.. ... ··-...... ... -Field adaptable t~verticall horizontal mounting and for knob, key, or concealed adjustment -Locking cover with Allen-head screws is standard. _ -Close differential without need tor anticipator. · :o Units . Thennometer .. ·-"' . .... :·· - Wiring --· .•. ------· . . Bimetal Type for Accuracy and Clarity, May Be Field Calibrated .: ·. • .. Laroe Screw Type Terminals, Terminal Identification Markings Stamped on Back of Case -Internal dual Celsius and Fahrenheit ~cale Is ~tandar~ -Separable mounting plate ConnecUone .. .. -- allows easy mounting and 1 T26 ...- ~-HK:iH ~~~ .• __.,TlMI'fllAT\JIIf ~ ~ --STOI' LOW •:I_•' TtMPE!lAT\Jit! . _ ~~, STOI' l\1·/:-1 i ·j\·1-INSID! SCALI CAlltlATJNG 0 i ._ Ar1llll/ t(-_ . ~>-t<;?!l CELSIUS ....... I.\ -~; llir o~~~:N~~~TL! STO' ~~~t.~}ll I : ---d::/-SENSING , · ~ fLLIO.ENT ~ Fig. 2 -Interior of T28. Note how element is wrapped around inside of thermostat for maximum sensitivity. Integral adjustable high and low temperature stops. wiring without removing thermostat cover. -Switch mechanism and wiring terminals (#8 screws) go into switch box for ~afety and isolation of load from sensing element. Matching humidistat is available. (See W43A Bulletin 3391 .) General Description T26 thermostats are extremely versatile. Using different field- installable faceplates, combinations of (1) vertical/ horizontal mounting, (2) knob, key, or concealed adjustment and 13) with or without thermometer indication are possible. These thermostats have metal locking covers with Allen-head screws to discourage unauthorized tampering. The standard models are supplied with a faceplate installed for vertical mounting with knob adjustment and thermometer. A field installable faceplate for horizontal mounting is also included on wholesaler models. (See Figs. 1 and 6.) Standard models are SPOT for heating, cooling, or heating and cooling applications. · _ "'tandard models can be changed the field as follows: - 1. To convert to key adJustment, loosen the screw in the center 2 of the knob, remove the knob, and the knob becomes the key. 2. To convert to other configurations, for example concealed adjustment, select the faceplate kit that meets the desired requirements from the "Faceplate Selection Table" on Page 3. The cover and faceplate design makes the thermostats adaptable to any decor. The thermostats have a sturdy steel cover with "tawny silver'' finish. The faceplate is dark brown and light brown with aluminum numbers and graduation marks. The internal dial on these thermostats has a dual Fahrenheit-Celsius scale. (See Fig. 2.) When a faceplate with Celsius . thermometer ~d set point scale is used the thermostat is totally Celsius. The liquid charged sensing element is formed to achieve maximum sensitivity to surrounding air temperature changes. (See Fig. 2.) Coupled with a highly efficient diaphragm and leverage mechanism, the element operates a totally enclosed Pennswitch contact unit for close differ~ntial and dependable sv.1tching action without the use of "heat or cool" anticipators. Elimination of anticipators increases versatility of these thermostats, which may be used on heating and/or cooling over a wide range of current loads, either on 24 V., 120 V. or 240 V. systems. Operating Differential The operating temperature differential of any self-contained thermostat depends on: the current flowing through the thermostat (amperage load); the velocity of air over the thermostat; the rate of temperature change to which the thermostat is subjected; and, whether the thermostat is operating heating or cooling equipment. Electrical Ratings T26A, T26S Motor Ratings 120V. 208V. 240V. 2nv. A. C. Full Load Amps. 6.0 3.5 3.0 A. C. Locked Rotor Amps. . 36.0 21.0 18.0 A. C. Non-Inductive Amps. 10.0 10.0 10.0 10.0 Pilot Duty-125 VA. 24 to 2n V. A.C. T26B and Heating Side of T26T Motor Ratings 120 V. 208 V. 240 V. 2nv. A. C. Full Load Amps. 18.0 9.2 8.0 A. C. Locked Rotor Amps. 96.0 55.2 48.0 A. C. Non-Inductive Amps, 22.0 22.0 22.0 22.0 Pilot Duty-125 VA. 24 to 277 V. A.C. . -··-·· 240V. A. C. Full Load Amps. 8.0 8.0 8.0 A. C. Locked Rotor Amps. 48.0 48.0 48.0 Pilot Duty-125 VA. 24 to 277 V. A. C. T26J -. __ ·-· Motor Ratlnc• 120 Y. 208 Y. 240V. A. C. Full Load Amps. 8.0 3.5 3.0 A. C. Locked Rotor Amps. 36.0 21.0 18.0 ?ilot Duty-125 VA. 24 to 2n V. A. C. ..... i ') T26 .,.. s ~I ----,.-------,---___,-....,....___,--i ~ -l--~-+-.....____.2.2 ~ ~_,.51 "1 ~ .<..> T26T COOLING : < 4 . "' ;i ! ! I ~ T26B, T26~.. J ~ "Q'oo-iNQ l ffi CNLT I tt I 1,1 Q ~ ,_ ~ .... a.. ~ ~·~· i.•iilf"" 12.2 ~ ~ 3 1 1 I ~. ~ I ~ i3 2 .• . ' ~ 1,1 Q ~ f. I I I I _u ~ ~ I '-. _.;,..___,__ T26J, T26S COOLING I I : L------~~~~-~~-....._~-~~ 0 0 1t I I I I ' ' 1t 0 0 0 0 :2 14 16 18 20 22 0 2 4 6 8 AMPERAGE l.OAO AMP4i:RAGE l.OAO Fig. 3 -Operating differential f()r T26A and heating side of T26S (lower graph line). Upper graph line illustrates differential tor T26B and heating side of T26T. Fig. 4 -Operating differential lor T26J and CO<lllng side of T26S (lower graph line). Upper graph line illustrates differential for eo<~ling aide of T26T. The heavy line in each or the above figures is the nominal operating temperature differential. Production thermostats may vary from the norm as indicated by the shaded areas. Faceplate Selection Table Kit Mounting Position Type of Adjustment Thermometer Number Vertical Horizontal Knob Concealed Yes No PLT213·5 X X X PLT213·6 X -X-· X PLT213-9* X X X PLT213·11• X X X PLT213·15 X X X PLT213-18 X X X PLT213·17 X X X PLT213·18 X X X PLT213-19** X X X Pll.ll1:~··. x_ X X • Supplied with standard wholesaler models (vertical is factory installed). • • Celsius Scales. Faceplates must be ordered in multiples of ten. Graphs (Figs. 3 and 4) show the operating temperature differentials of these thermostats under various load conditions. These curves are based on tests made in a NEMA standard test box according to NEMA standard DC3-1959. The air velocity was 2.5 feet per minute (.127 m/ sec.) and the rate of temperature change was 8°F {3.3°C) per hour. For air velocities greater than 25 feet per minute and/or for rates of temperature change less than 6°F per hour, the operating differentials will be less than shown In Figures 3 and 4. Optional Constructions Brand Nameplates Available on quantity orders. Contact Customer Service. Concealed AdJustment Available on factory order at no extra cost. For field changeover use the concealed faceplate kit and install directly over the faceplate on the cover. Double Control Trim Plates For vertical mounting of T26 thermostats side-by-side on a three gang electrical box. May also be used with T22, T25, Tao, W43 and W45 controls. Overall dimensions are SVz" high by 9~" long. Order Part No. PLT231·1R. Energy Conservation Models Thermostats are available with limited heating or limited cooling ranges. The standard heating models are set at a maximum of 75°F (24°C) or 65°F {18°C). The cooling models are set at a minimum of 75°F (24°C) or 78°F J26°C). Other limit setting$ are avaitable on quantity orders. Faceplates Available in separate kits for on the-job installation. All plates have peel-off backing strips. Faceplates are available in all combinations shown in the "Faceplate Selection Table." Key Adjustment Remove the knob and keep for key adjustment when set point change is desired. Thermostat Guards Plastic, wire or cast aluminum guards are available at extra cost. See Control Products Catalog or "GAO" Bulletin No. 3860. Ordering Information To order, specify: 1. Product Number, if available. 2. Faceplate kit, if other than standard is required. Order In multiples of ten. 3 !6 • of F st. 3 4 T26 3. Other optional contruction features, if required (quantity orders only). a. Faceplate required if other than standard vertical. b. SPST contact action. c. Brand nameplate. Repairs and Replacement Field repairs must not be made except for the knob, cover, and mounting plate. For replacement thermostat or repair parts, contact the nearest Johnson Controls wholesaler. Part Number CVR48A-600R CVR48A·602R KNB20A·600R PLT51A·602R PLT61A·600 PLT231·1R Replacement Parts Description Cover Assembly lor Knob Adjustment Models with Thermometer, • F Scale. Vertical Faceplate Assembled, Horizontal Faceplate Supplied Unassembled Cover Assembly for Knob Adjustment Models with Thermometer. •c Scale. Vertical Faceplate Plastic Knob Conduit Box Mounting Plate Mounting Plate tor Thermostat a~d Selector Sw•tch Double Gang Box Mounting Plate ~ZOIJTAL '&Cri'UTt. wrr• .. ,.o• .tlltO ·-·-, ... -t Fig. 5 -Line drawing illustrating method of mounting ;; - vertical thermostat to a horizontal outlet box and installing a horizontal faceplate. - Fig. e -Line drawing Illustrating method of mounting 1 vertical thermostat to outlet box. Also shown is 1 solid vertical faceplate for concealed adjustment when desired. Typical Application Diagrams HEATING 'll' HOT ___:::_:1---• t.:..:--TQ NEUTRAL 1-iEATING Fig. 7 -Internal diagram of T26A and T26B. HEATING HOT : __ C~] _ _J TO COOLiNG :---rt- --.. --------... ·---HOT ---' '--TO NEUTRAL COOLiNG Fig. 8 -Internal diagram of T26J. COOLiNG :' :---....l-...~. :I ~·u: ; ':3 I 2 : HOT A----·-___________ .' TO NEUTRAL HEATING NEUTRAL COOLING Fig. 9 -T26S, T26T wired for neating application. HEATING AND COOLING EXTERNAL MANUAL OR AUTOMATIC CHANGEOVER SWITCH ~--~---4==---TO .----HEATING TO 1..---------lo----COOLING Fig. 10 -T26S, T26T wired for cooling application. HEATING AND COOLING , ... ---· ·------------... l HOT----+---+----1----, NEUTIUL--r-------~~~ CHANGEOVER CONTROL F'AN VALVE Fig. 11 -T26S, T26T wired for Fig. 12 -T2BS, T26T on fan-coil unit with cycling valve continuous fan. healing and cooling with manual or automatic changeover switch. HEATING AND COOLING H:IT---t----' ~~------~~~ Terminal markings shown for A19CAC changeover control. VALVE R ~1--~r----J CHANGEOVER FAN SPEED CONTRot.. CONTROL \if uucl) Fig. 13-T26S, T26T on fan-coli unit with cycling fan and valve. Terminal markings shown for A 19CAC changeover controL T26 5 T26 r qr ll J ---~----72 ,-, T I -~ I I 4"y I ' I I 4.57 ~ ~ I I __L I L i i I ' NO 6 THREAO 2 PLACE:S I T26 Dimension• ___!!!__ mm Performance specifications appearing herein are nt>minal and are subject to accepted manufacturing tolerances and application variables. Utho In U.S.A. 1182 •, • .. ... .... ~ .. OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 1. 2. 3. 4. 5. 6. 7. B. 9. Item No. eleven Specification Paragraph none Drawing No. Narr.e of Article Manufacturer Size. Capacity Catalog No. Spare Parts are Guarantee to be Contractor C-19 Exhaust Fan Loren Cook or Rating 834 cfm lOCV17D Available from Alaska Winter Provided by Name American Mechanical Inc. Address P.O. Box 72991 Fairbanks. AK 99707 Phone 907-479-5754 Subcontractor Name Address Phone LOREN COOK COMPANY •fiiiNQfiiLO. ~·· IUIA. OHIO MAINTENANCE AND OPERATING DATA P.-...U.LA. We are supplying the attached data to be used as a guide for proper installation and maintenance of your COOK ventilators. With proper installation, these ventilators will give you years of trouble- free service. The attached data includes literature in the following categories: CATALOG NO. ftJ t:, J/ 11 ]) s ER 'Es __ cv_-_u_cv_, ;..__ INSTALLATION AND OPERATING INSTRUCT IONS SERVICING INSTRUCTIONS . MOTOR WIRING DIAGRAMS DIMENSION DRAWINGS PARTS LISTS • Parts lists as such are not available for COOK ventilators. Our units are of all-aluminum construction and would require none of the major component parts to be replaced under norm.! conditions. In the event a part is needed. we suggest you indicate the appropriate part on the attached drawing and fo~ard it to us along with.the Catalog Number and Serial Number of the fan. We can then identify the part and size required and .-ke the necessary arrangements for replace• .. nt In the field • .. Revised 10-4·72 I ri1-42-A I [ LOREN COOK COMPANY •IIIlA. ONIO J CENTRI-VANE INSTALLATION AND OPERATING INSTRUCTIONS 1. The cook univers~l mounting bracket is recommended for in- stallation of al ~ ~entri-vane units. The bracket should he fastened securely to the wall, ceiling, or floor. The bracket has integral rubber mounting, and additional vibration iso- lators are not required under most conditions. 2. The centri-Vane unit is shipped ready for installation. It may be rotated in the mounting bracket to facilitate wiring. Loosen the four clamp holts on the mounting bracket and rotate the unit to tl1e-desired position. Be sure the clamp holts are- tightened again to assure quiet operation. 3. Run the electrical wiring into the external junction box. The centri-Vane is pre-wired to this point and need not he disassembled for wiring. 4. CHECK ROTATION CAREFULLY. The wrong rotation will burn out the motor and void the warranty on this equipment. A rotation arrow is provided to show the proper direction. 5. Connect the ductwork to the unit ·using companion flanges. This will allow the unit to be removed from the system should cleaning or servicing he required. We recommend using canvas or other flexible duct connectors on both sides of the Centri- Vane to minimize noise transmission and to assure quiet operation. 6. All motors furnished have sealed hearings and, under normal conditions, will not require any further maintenance for a period of ten years. Should the centri-Vane be subjected to continuous usage, it is advisable to-remove the motor after three years usage and take it to the local motor service sta- tion to have the bearings repacked with fresh grease. 7. Cantri-Vanes operating at above no.rmal aJ'I\bient temperature• require special motors. consult the factory for specific reoc:x.endations. r 1 I LOREN ~IC C:OWANY ............ liD"* ..... GMtO 1 BEARING LUBRICATION INSTRUCTIONS The Loren Cook Company will uae only ehe fineat bearinca available. Each Sealmaater bearing comes faceory prelubricated with grease chosen for iea general mechanical aeability. In caaea where a grease tube is required, the tubing is also filled at our factory to avoid unnecessary and harmful over-lubrication. None of our Loren Cook equipment should require any lubrication for a mintmum of two weeks after operation begins in extreme duty cases; or six months in average to light duty cases. (Refer to Conditions chart on reverse side.) Loren Cook Colapany uses Mobil Mobilux 2 grease. Other types of grease should not be uaed unless the bearings and lines have been flushed clean and then, use a lithium base grease conforming to a NLGI grade two consistency. This light viscosity, low torque grease is rust inhibited and water resistant, has a temperature range-JOO F. to +200° F. vieh intermittent higha of +250° F. BLOWER LUBRICATION: For beat results, bearings ahould be re-lubricated while unit is running. Puap grease in slowly_ until a slight bead foriU around the:: bearing seals. This is aii tne greaae that is required. Over- greasing can burst seals and aid tR reducing bearing life consider• ably. Refer to Conditions chart vben determining your lubrication schedule. INLINE VENn LA noN ( CV, UCV TCV: UTCV) : Cases where bearing cannoe te seen !or lubrication. In order to supply the bearing with an adequate ..aunt of grease, refer to ehe Re-lubricaeion chart on ehe reverae aide. The unit should be running for even grease distribution. PwBp grease slowly and do not over-lubricate. Sn>RAGE: If equi,_mt ia atored for an ezteaded period of t!ae, bearina• ahou1d be covered with aruae to help aul out aoiature. It is alao a ~ practice to rotate the wbael aeveral rll'ftlutioraa every tbr .. to ft.. da1•· 'ftlia keepa a coatina of area•• oa all internal beariaa perta. !he entire unit abould be covered. with __. type of ••Idler cover, plaatic, etc •• ·.li:.. I M-31·A I CONDinONS . Tempera-Cleanli-! Greas!:f Speed ture ness Interva 100 ltPM Up to 120° F. Clean 6 to 12 Hontha 500 RPM Up to 150° F. Clean 2 to 6 Months 1000 RPM Up to 210° F. Clean 2 Weeks to 2 Months 1500 RPM OVer 210° F. Clean Weekly Any Speed Up to 150° F. Dirty 1 Week to 1 Month Any Speed ~yer 150° F. Dirty Daily to 2 Weeks Any Speed Any Temp. Very Dirty Daily to 2 Weeks Any Speed Any Temp. Extreme Daily to 2 Weeks Conditions I RE-LUBRICATION OF SEALMASTER BEARINGS Shaft Size Hand Operated Grease Gun Injections 1/2" to 3/4" 7/8" to 1-3/16" 1 Injection 1-1/4" to 1-1/2" l·ll/16"to 1-15/16" 2" to 2-7/16" 2 Inject ions 2-1/2" to 2-15/16" 3" to 3-7/16" 3·1/2" to 4" 3 Injections 4-3/16" to 4-15/16" -.... I LOREN COOK COMPANY ] UltiA, OHtO ASSEMBLY AND DISASSEMBLY INSTRUCTIONS FOR CENTRI•VANE BLOWER REWOVE MACHINE SCR!WS TO HPAIIATE HOQIIMG I!WOV£ UACMINI SCUWS AT UOTOR HOt:SING AND UUQVI WQTOI ASUMILT p.-..U.I.A. IEWOV£ MACHIN£ SCREWS AT WHEEL AND Jt!WOV£ WHUL FltOt.l HUI PLATE • Pl.ATE SET SCREW LOOSUI SIT SCI£W AND UMOVE HUI PLATE flOW MOTOI SHAri. REMOVE HOTOI! UOM MOIOI PLAT£ TO UASUHIL£ • PIOCEED IN II· V!ISI OIIDU • ..IUU..I· HATCH t.IAII:I All! PIOVIDtD nrlilATING PAITI, WHEN II£ASSEWILING, HUI PLATE SHOULD II LOCATED A5 FOLLOWS: lJt' Clnr&acc Dlacanoa ( 1" Cla&laaca D1 fllaauoa cv-114-A : LOREN COOK COMPANY ] .... A. OHIO - WIRING DIAGRAMS FOR ALL UNITS LECTR 1C OR !!!A"! THO!! q;p I SltfGL£ PHASE ! LINE ~~--------~---L& ' / WHEN GRO REOUIRED, ATTACH ...L/ TO GI'IO. A or 8 WITH NO.6 THREAD FORMING SCREWS. TERCHAHGE BLUE ,'fl ANO YELLOW,T-4. WHEN GRD REOIJIREO. ATTACH TO GRO A or 8 WITH NO 6 THREAD F'OAM~ SCREWS. SE 'I!CHAHGE 8UJ£ AHO WHIT£ LEADS, ~ GRD REOVIREO. AT TACH TO GRO. I WITH NO 6 THREAD FORWING SCREWS. RSE. INTERCHANGE BUGK AHO REO U:~ SI1AOEQ f'QLE MOTOR WITH SPEED CQIIITRO!, l ~ ~----<-LL JR~'I ~ LaN __j E EXPLOSION PROOf, SINGLE SPEEP, SING!,.E PHAS[ -r-y~L,L IIIOTOII r lUI( : -_j:: IIUQI ::::L-... £\ I. CHECIC LIN[ VO\.TAG[, 2 CH[Cll ROTAT!Oft WITH ARROW 111110( UNIT. 1 Al.IIA'IS CH[CIC 3 "'"AS[ UNIT'S F'Otl IIIOTATION. A\.1,, 3 I"MA$[,9 J.EAO WO~$ LOW VOLTI!GE 201 I Z30 VOU'S HIGH~~ 41 5 rYl TOGETHER ;z !~ ~ TOGETHER I z 3 ~ r ~r ;r L. 4 ... J J J LINE LINE TO REVERSE, INTERCHANGE ANY Z LINE LEADS. 2 SPEED. I WINOieG, 3 PHASE HIGH SPEED LOW SPEED B i~TOGETHER -1-:-L, L I ..... 2 --::>-L., I I MOTOR ~ :='· ~ 4<lL, L S<lt..l 6 <lt.. N E Cs<!--OPEN 6<!-- TO REVERSE, INTERCHANGE AltY 2 LINE LEADS. MOTORS REQUIRE WAGNE TIC COfiTROL. 2 SPEED, 2 WINOING, 3 PHASE r------r---~ -1.01:=-1 . ~:=::~!-t'[!u 7 . I '~4N , MOTOR i '<1 La E I :r. .-.-a~-~ I . h1t--MGH:::J--; ~1a IIIGM TO REVERSE: HIGH SPEED: INTERCH!&HGI[ LEAOS T11 ANO T11. LOW SPEEOtiNTERCHAHG£ L.£AOS T, AND Tr. lOTH SPEEDS& INTEitCMAHG£ 11M'( 2 LIN[ LEAO$, F'AN MOTOJII OAIIIHJII IIOTOR .lAW. • TT~ICAL FAI MOTO,/Q&MPE! MOTQ!! SCHEMATIC t--- t--- :---_,_LI :---_,_b2 --.... LJ F'OJII J PMAII, OAIIHII MOTOJII VOLTUI SMOUI.D II THI IAMC H TWI. Lt Alii \.1 · L I N ' F'OJII IINILI P~ ~ICATIOII, DIIJIICUAO Ll· • ALL DAII~I· MOTOitl MAVI 0.1 A .. JIIATINI AND AM STOCKI:O Ill 111, 110 AIIO <MO VOLT MOOI:LI. 4. CHI:C.: 80TM SIUDI 0' Z Sfii([D, J ~ .... TI 'Oit ... TOll .VTU ...... ~ !. W~ vot.T..C 01t W~ ROTAfQI W"-L ._ OUT 110~ MO ~0 t - !as{':f :erva .2 Montha 6 Months s to 2 Months io1eekly to 1 Month :o 2 Weeks :o 2 Weeks 0 2 Weeks J AMPERE RATING TABLE 1 Phase 3 Phase 115~ 220 440 230 208 230 460 480 HP RPM Volts Volts Volts Volts Volts Volts 1/30 1050 1.90 .95 1/25 1550 2.00 1.00 1/20 1550 2.30 1.15 1050 3.10 1.55 1/12 1725 3.20 1.60 1140 3.20 1.60 860 3.00 1.50 1/8 1725 3.00 1.50 1140 2.40 1.20 860 3.90 2.00 -, t/6 1725 Q.40.) 1.70 / 1140 4.00 2.00 860 5.80 2.90 1/4 1725 4.40 2.20 1.1 1.0 .5 .46 1140 4.20 2. tO 1.5 t .4 .1 .64 860 5.40 2.70 1.9 1.8 .9 .83 1/3 1125 5.40 2.10 1.8 1.6 .. 8 .13 1140-. 4.60 2.30 1.7 1.6 .8 .13 860 7.40 3.10 2.5 2.4 1.2 1.10 1/2 1725 1.60 3.80 2.1 2.0 t .0 .92 1140 6.20 3.10 2.5 2.4 1.2 1.10 860 9.80 4.90 2.8 2.6 1.3 1.20 3/4 1725 10.80 5.40 3.2 3.0 1.5 1.38 1140 8.40 4.20 2.6 2.4 1.2 1.10 860 14.20 7.10 3.8 3.6 1.8 1.65 1 1725 13.20 6.60 3.6 3.4 1.7 1.56 1140 4.0 3.8 1.9 1.74 860 4.9 4.6 2.3 2.11 1-1/2 1725 5.0 4.8 2.4 2.20 1140 5.1 4.8 2.4 2.20 860 7.2 6.8 3.4 3.12 2 1725 5.9 5.6 2.8 2.57 1140 7.2 6.8 3.4 3.12 860 8.5 8.0 4.0 3.67 3 1725 8.4 8.0 4.0 3.67 1140 9.3 8.8 4.4 4.03 860 10.0 9.4 4.7 4.31 5 1725 14.0 13.0 6.5 5.96 1140 . 15.2 14.4 7.2 6.60 860 17.4 16.4 8.2 7.52 7-1/2 1725 22.0 20.8 10.4 10.80 1140 21.2 20.0 10.0 9.17 ..... !EF•I - CVD DIRECT DRIVE CENTRI·VANP CENTRIFUGAL BLOWER CUITIIEI I'.D.: ________ B-EEIII:I: ------------- ~---------------------------------------------------------- AI'PWOY£DIT: _____________ ~DIT: ;IUStrl'l WI~/~ --------F-------·' -----8----~ .,.._ T HOU! WIOTH • ~ CM. A I c .... IICV • 1).1/4 1 3-lllt !OCV 10 15 11-311 12CV 12 11·111 , .. ,. l<ICV 14 '"'-'I 22 1&CV ,. 21-1111 :14·74 !IICV " 2•·112 21·31• 20CV 20 a.J/1 )1).112 ACCDIOIIIIEI •. llt1AIItf48tl lltr;ll D 1-711 .. ,12 t-:114 !1-114 11·1.2 ,. 1$-112 2. WOtttM! OOif.,.,.Ot 8,_111,1!!111 3. flti!M18tl! I!MHW eeffNI!ITM ... IUtft VM .. ! ILWIII!fll I , G ...... .... 1-114 tl·114 1o-611 10.114 1-114 ,,.,. 12 ... U-1!1111 ,.,,. ''"'" ,...,. ,,..,. ,_,,. 17·3111 16-M , .. ,,. ,.,. ,.!liS 1~4 20oHI111 1·114 22·112 20-314 ~~· 1·ll• 2-.:n 2J.3I.6 3-11• LEGEND 5. 88Mfll:ti18U P'IIAfUii I. ,,..., MMEtt P. 8'*":Ef 18 .. EEU 8. EIIBt Ill-88.C:'fiiUI I. ENM¥ 88A'fllf48 a.-.. .. SLJBM:TT:.l.LS ?~: :-_, :--o.~ AL .. A/5 :~...,'), · .. \• : 1'~ :.. \. I. ' -. Anc!"'t~.~~·..l£::.. ""';c · ·<.:; fhcr.z: 2'-::.-;;·_·; :;J ........_ .0111 100 IIIOTOit TYN STO • STANOA .. O 'I IP 2 &PE!I ..... ...,. CATAUI• .. -Cllll • .. .. .. C'fCU ·" "" ACCIIII.I .... "" [Jo&V"P ~I ~VJ') SJ+ .zr nzr 1t. I "' /ZIJ 'mJ . .. • .. ' ~ ' ,. .. •" I • • r OPERATION & MAINTENANCE INFORMATION Project: Chester Lake Hydropower Project Contract No.CL-02 l. 2. 3. 4. 5. 6. 7. Item No. Specificat1on Paragraph Drawing No. ~arre of Article Manufacturer Size, Capacity or Rating Catalog No. twelve none C-19 Pressure Reducing Valve Bailey 6" tt9010 6" 8. Spare Parts are Available from CMB Industries 9. Guarantee to be Provided by Contractor Subcontractor Name Address Phone Name Address Phone American Mechanical Inc. P.O. Box 72991 Fairbanks, AK 99707 907-479-5754 6" NO. 9010 PRESSURE REDUCING VALVE METLAKATLA WATER TREATMENT PLANT ALASKA POWER AND LIGHT MANUFACTURED BY: . BAILEY DIVISION OF CMB INDUSTRIES P.O. BOX 8070 1550 N. PEACH AVE. FRESNO, CA 93747 \ :aailey SPECIFICATION SHEET CONTROL VALVES • STRAINEI'!S • POLY JETS Model305 Polyjet Valve (2" through 12,) "Y" Pattern DESCRIPTION The Model 305 Control Valve is designed for conventional control valve applications when other models of the potyjet may not be applicable. The Model305 is designed to control flow or pressure in systems where high inlet pressure and severe throttling conditions are encountered. The inner valve is of the Poly jet design and may be arranged to suit the most severe applications. Control systems are available for the Model 305 which make the valve particularly suited for pressure reducing, pressure relief, rate of flow, and surge relief applications. • SIZES: 2 to 12 inches with 150#, 300#, 400#, or 600# flanges as required. • CAPACITIES: To 10,600 GPM. • MAXIMUM PRESSURE DIFFERENTIAL: 1 ,000 PSI. TYPICAL APPLICATION MAINTAINING LEVEL OF RESERVOIR STORAGE T AHK LOW PRESSURE TO SYSTEM OPERATING PRINCIPLE The Model 305 operates on throttling pressure across multiple orifices that are specially sized, tapered, and positioned around a circular valve port. The valve opening characteristics are normally linear throughout the stroke but can be characterized for special applications. Control of the valve is normally hydraulically operated with incoming fluid used as the control medium. Other types of control include pneumatic, manual, motor operated, or hydraulically actuated with oil used as the control medium. The operator can be made compatible with any standard control system. APPLICATION OAT A SIZES I Flanged Connections 2"to 12" MAXIMUM WORKING PRESSURE (Cast Steel) 150# Flange 300#Fiange 400#Fiange 600#Fiange TEMPERATURE RANGE I Water CAPACITIES SIZE MAX. (INCHES) GPM 2 290 2'At 460 3 660 4 1,180 285PSI 740PSI 960PSI 1,480PSI SIZE (INCHES) 6 8 I 10 12 MAX. GPM 2,650 4,700 7.300 10.600 \ I NO. 9010 PRESSURE REDUCING VALVE (REF. Drawing A -3795) OPERATION, MAINTENANCE AND INSTALLATION INSTRUCTIONS INSTALLATION The installation of shut-off or isolating valves is recommended on the inlet and outlet of the main valve. A line strainer on the inlet of the valve is also recommended. Pressure gauges should be installed at the inlet and outlet of the valve. Sufficient room should be provided around the valve for maintenance and disassembly. OPERATION AND INITIAL START-UP 1. Close shut-off valves on inlet and outlet of main valve. 2. Inlet needle valve (9A) should be open 3/4 to 1 turn. 3. Remove all tension from spring in pilot valve (2) by turning adjusting screw counter clock-wise. Close outlet shut-off valve (4) in pilot piping. 4. Open inlet shut-off valve to main valve. 5. Bleed all air from diaphragm assembly by opening air cock (19). Close a~r cock when all air is removed. 6. Open outlet shut-off valve to main valve partially. Make certain there is a demand on the system. Open drain line downstream if necessary 7. When main valve is closed, open outlet shut-off valve (4) in pilot piping slowly. 8. Turn adjusting screw on pilot valve (2) slowly in a clockwise direction. This will increase the pressure on the downstream side of the valve to the required setting. 9. If valve has a tendency to hunt or pulsate, close down slightly (turn clockwise) needle valve (9A). 10. Needle Valve (9B) should be 3/4 to 1 turn open. NOTES.· rtEM NUMBERS REFLECT P/L #9010R002 MISCELLANEOUS FJmNGS NOT SHOWN. ITEM DESCR/PnON 1 #305 MAIN VAL \IE 2 #400P PRESSURE REDUCING PILOT 4 1/2• IPS BALL VAL \IE 6 #1008 STRAINER 9 NEEDLE VAL YES 16 CHECKVAL \IE 19 AIR VENT 300, flANGE PRESSURE REDUCING IDA TE 8/!!f/j VAL~ D~ BY DRA~ NUYS£R FRESNO. CA SCALE: ..........__., A3795 ) / 'V''t' /,~"'~ / f '~ 22~ 3~ 4 40 ' ~' ~" ~ ------1--< / 25 •• 1 o-n lllllf'O ITEM I z .,. -' 4 5 10 B q 11 I'Z. 14- 1'5 IB 19 22. 24 25 2fr, 2.1 2B 30 31 'PAOII'fAfl' OJ Clol8 IHUU:i>TAti:~ Al.f'MOOve110H PA(..o!oot-'nO illlrtl,..WI fkE (APRUoS WM!TlE ... {.ON!si.HI OJ CUM tNOUS. 1 A If:$ " PARTS UST NAME ·lon MATERIAL EDD't I SiEEL SEAT RING I Slt.\N STL O·RING I ewr.A"N' SLEEVE I I STAIN S1L SEAT SEt..L I BUNA "N" .. SEAT 140..DER I S1.t.iN P1':>TON LINER I E.RCNZE. Q-RtNG I ,-BUNA "N" . CYLINDER 1 STA-IN S1L- 0-RING 2 WNt>. ~N~ COVER I S1EEL ':>TUD ~~ 3TsrfEl. ---·- O·RING I I BUNA "N· INDICA-TOR STEM AC:.S't I -t~-~~-~_RS ~C 1-\D CAPSCREW ~ SiAIN STL CAP'E:.CRE.'N E S1t.IN '::.TL 50C HD CP.P5CREW 8 :'_'fr...IN STL SPACER I 3_;<;DN!E CH<'ING I BUNA "N' 0·'1\NC:. I BUN.!. "N" :.Jt-.OALANCE!<t CYLINDER I ! 20NZE··- UNBA.LANCER CAP ~texwzE-- 32. , O·l".!ING I r·&J~~·w 33 o-RiN"G I ··cc· ''i;,~" 34 UNMLANCER PISTON I E:f.ONZE .... 35 UNBALA.NCER SIEM I STAIN C:.TL 3'1 O·RING I Bl.JIJA "tJ' 40 0-RING I 1--- 15.1 NUT l(o ' tJ01E5: EHO CONNEC1\0N5 ARE ~·-=oo• RF. FLANGE.':> FER AN 51 13 II..>. 5 2. .t-LL INTERIOR FERROUS '::LJRFACES ARE COklE.D WITH 3M • 301D EPOX'( UHtfS.SOlr-lklNISE $P£ClFIED ....,Ooolllt~-~ ~-··t-&ga .......... ..,...._«.DQf.._ .,....,.......,_~L...,nt: ~o.....,...:.u ,_·if .......... ,, .... ~~\l~foQioUt,&"""" ........ .... lllfU.UI)rooot~ ·--....._ ............. • ut• ~!loU -.,u -loaGMql~flll ......... 'ttM ASSEMBLY •"1:XXJ •N• .. . ID' I ) \~ -~ '~' DESCRIPTION The 400P pilot valve is the standard pilot valve for all No. 400 series pressure reducing valves. It is a direct act· ing, spring loaded, diaphragm control valve that is hyd· raulically controlled. The valve is normally opf.!n, depend· ing on the tension of the main spring, and closes when the reduced pressure exerts force on the underside of the dia- phragm. The valve is of all bronze construction with stainless steel seat ring and disc holder. Inlet and outlet connections are 3/8" NPT. Pressure ranges: 5 · 20 psig 20 • 60 psig 50· 100 psig NO. 400P PILOT VALVE 90 · 200 psig 150 · 300 psig PV-1 To change ranges, it is only necessary to change the spring Part No. 10. The valve is adjustable and will control downstream pres· sure within the above ranges. To increase pressure, loosen locknut Part No. 13, and turn • adjusting screw Part No. 12, in a clockwise direction. To decrease pressure, loosen locknut Part No .. 13 and turn adjusting screw Part No. 12 in a counter-clockwise direction. When decreasing pressure, make certain there is a flow in the system. This valve has an atmospheric vent drilled in the spring chamber Part No. 9. It water flows from this vent, it is an indication that the diaphragm Part No. 7 is damaged or the diaphragm locknut is loose. CHAS. M. BAILEY CO., lNC. P. o. Box 8070 Fresno, CA 93747 TO DISASSEMBLE PILOT VALVE 1. Loosen locknut Part No. 13 and turn adjusting screw Part No. 12, counter clockwise until all tension is removed from spring. 2. Remove all capscrews Part No. 20, from spring chamber. 3. Remove spring chamber Part No. 9, spring button part No. 11, and spring Part No. 10. 4. Remove locknut Part No. 8 by turning in a counter· clockwise direction. 5. Remove and inspect diaphragm Part No. 7. Replace if necessary. 6. Remove bottom nut, Part No. 2 and spring Part No. 25. 7. Remove disc holder Part No. 3 and seat disc Part No. 4. The disc holder may be removed by using a Ya" 12 point deep socket. The disc is molded into the disc holder. Inspect disc and replace if necessary. DISASSEMBLY, ASSEMBLY AND PARTS LIST NO. 400P PILOT VALVE PV-1 4~ ITEM NAME MATERIAL 1 Body Bronze 2 Bottom Nut Bronze 3 Disc Holder Monel 4 Seat Disc Bvna uN.u 5 Yoke Bronze 7 Diaphragm Buna "N" 8 D1aphragm Lock Nut Brass 9 Spring Chamber Bronze 10 Spring Steel 11 Spring Button Brass 12 Adjusting Screw Brass 13 Lock Nut Brass 2t 15 Seat Ring Monel 16 Cap Screws Brass I 17 Diaphragm i Button Bras1 25 Auxiliary Spring Stain. Steel 8. Remove yoke Part No. 5. 9. Remove seat ring removed by using a Replace if necessary. Part No. 15. This may be '!:!" 12 point deep socket. To reassemble valve, reverse this procedure. Care 'should be taken to make certain yoke moves freely when pressure is applied to diaphragm area. RECOMMENDED SPARE PARTS 1 Part No.3 disc holder 1 Part No. 4 seat disc 1 Part No. 7 diaphragm When ordering replacement parts, please give size and catalog number of valve and all information on the name- plate. CHAS. M. BAILEY·CO., INC. r- P. o. Box 8070 Fresno, CA 93747 I ~ NUPRD. "C" & "CA" SERIES CHECK & ADJUSTABLE IN-LINE RELIEF VALVES [ __ p'~~t~~~3Dtls~:-~;~ '-;?;t ·~-;~~TI~'FII~G.~~~::, --~:,_~:-:;S . ·:-t~:!~,~~~U>2 f .. :. NUPRO "C;; Series Check ·and ·~cA"·:· ;::·~ .. Soft, resili.ent 0-Ring gently stops poppet • Large seating' areas provide '::·~ ; ... Series In-line Adjustable Relief ~-~. sensitive open!ng pressures and leak-tight sealing • .0-Ring easily replaced _ ... ~ k Valves are available with integral ·: · · . • ~~o~th floatmg poppet allows chatter-tree operat1on • Smooth flow p~th :.. · .. : . SWAGELOK Tube Fittings for safe,::~·. m1n1m1zes pressure drop • Back stopped poppet prevents overstressmg ·: 1;:: reliable connection direct I}' to tubing;' ... · spri.ng • Fixed . spring ("C" Series) and adjustable m_odels ("CA" Series) ·. · L · eliminating the need tor additional fit-~· . available • Vanety of SWAGELOK. male and female p1pe connections and .... j': : ti':lgs !lnd connections. The soft 0-~:::;( combi~atio~s .".'.i.~!~iz~s t~e need lor additional fittings and reduces instal-.;· r : .. Rmg seat ~nd smo<?th flow _poppet.~· .. :·,:.•.:.la.t ~on tl~e :~~:; . .,_.: .j·~·· ~: ·:.::-. .'· . .. • -~ . • • .• ..... ~ ·: •• ·, ·"' . ,.. · i'.::· ~;~·~nfr:;~v·~:~:~~t·~~t :e~~~;a"c~ .. ·:\~·,·;.ojus·-r·MENT :~~\~~ ,,~·,:... . -?~ .. ~7:. _..::;· .. <· · .... : ~;$:t~)1f:7t:~7~:~·.:;~·- } .. val_v~ • ._.._. ·:· ·.: · ·:· ~ . ··. ·To adjust "CA" Series R~liet v~tve~: ··· .. · :· ·-.._ ) ·. · · · · · · ~: · .: ·: .. ·. · • .. -: .. : ... , · .' ...... ~ lnse~ ·standard _513~." hex . key wrench into the·." ( .J L APPLICATIONS .-: .. · .... ·.,:'·; IOCk1ngscrew. c·~·.·. · ... ·. . · .. ~.: · : · ' · ' · ·:· .:· . • Break locking screw counter-clockwise until the · · · N~P.RO 9heck Valves are _us~d for . . . ··: hex wrench slides into the adjusting screw . ·· · ... • un1d1rect1onal flow and as m-Ime or -, ·· ••· • · · · · , · · ; . · t·.· popoff relief valves. They can be ·~~:_:.;"~·· Tum bOth sere~ to the desir~ cracking pr~: .. :. ~~ · used in gas or liquid service of all ·. ·;-... sure. (Clockwise 1ncreases openmg pressure.> ...... (. types. as det~rmined by the 0-Ring .·~.-: • .• ':'etracrhex key wrench into the locking screw. :;. :::. L . ch~m•cal res1stance and metal prop-.. : .. _::;·. • Lock against adjusting screw by tuming clock~· : ~·· .. -·~.7:~~~~ :.~::· .. <> ::::~~ .· .·.{ : ·~ ~·· · .. :.-:·· ··?:~~~~::_-:: w~~-,~::~:;.:;.~~;.:~~:.~/ ·:·. \~:~~~::·: :: -. .::,~~~-:- . ·· --... . .. · -· -· ,~. TECHNICAL 0 hTA . '· .. . .. . .. .. '~:. ·. ;·: ':··-.~~:.~?.-_::..::_:.~.:.:~_~L.-~_: .. · .. ~: ~.: .. _._;_._::-_:_:.:.. :.:-.·> ~. :·. . ... ~:;._,_·-:-....... ~.···:"' _;.· .... ·:·: __ ... -.:,.. "' ,.4·... ... . .. . .· _,. -• . '. i.; i-: !··· ' ... .~ NUPRO COMPANY • 4800 E. 345th Street • Willoughby, Ohio 44094 ... .-:- -- ~·-.. , \J NUPRCJ . "C" & "CA" SERIES CHECK & ADJUSTABLE IN-LINE RELIEF VALVES :~FLOW CAPACITY t' --\ \ I :--·.. . . . . -~ ~:-.. . . ~ . :: . . . . --.:-~ . . -. ' :· . :~F-~ :;_-~· ~ : • ~ • • ~ .·;~ .. -.•:;;. • ·.-:; r~ , .. , .. 10 .. ,,. ~ , .. 2.21 0.51 ... ,.,-.. so •-.-• .-·.· ·-6.12 . 1 1.13 ; ... 100 . :·-:·. · 10.85 . 1 1.60 ...... ·~·· 10 ... • .... ;.·• 6.50 '1.49 . · .... 50 17.98 3.32 .... ~,:-. 100 :-: .. ·· 31.87 .... 4.70 . 10 .J 2033 4.65 50 ·-56 .23 10.39 100 99 .68 14.70 50 63 .49 11.74 100 112.56 16.60 I 10 I 5.14 1.17 I 50 I 14.01 2.62 I 100 I 24 .84 3.70 MATERIALS Body, Poppet, Nuts & Ferrules-Brass, 316 sta inless steel, Monel, and anodized al um.num. Spring-Type 302 stainless steel in an valves, except Monel valves use Monel springs. Gasket ("CA" Series only)-TFE O·Ring-Buna "N" is standard in brass and aluminum valves. Viton is standard in sta.nless steel and Monel valves. Many dil· ferent types of elastomer ().Rings are stocked by NUPRO Company for special· ized applications. Oue to the hardness of TFE, O·Rings of this material will not seal leak-tight except with very high back pres- sure. TFE ().Rings are useful on cycling pump applications where gas tight sealing is not required and pressure surges are common. Adjusting Screw, Lock Screw ("CA" Sertes Onty)-brass, aluminum, and 31 6 stainless steel valves use 316 sta•nless steel. Monel valves use Monel. ' . •• -...... . r . :.-.· ;....:: %Male NPT ·2C4· •.. ·".187 'J, Female NPT ·4C·-· .187 'L SWAGELOK ·4C1· .. '.187 '1. Male NPT . ·4C2· . 187 . 'J. Male NPT .. ·4C4· _ ,: .· .187 .~· % Female NPT ·4CA· · • 156 : '1. SWAGELOK -4CA1· __ ;.· ~-._156 Y. Male NPT · % SWAGELOK ·6C2· · _ _:.';-. . 359 '· %Male N~: %Male NPT . ·. % NPT % SWAGELOK, . 'L ~AGELOK Y. Male NPT _:: 'L Fema!e NPT 'L SWAGELOK 'L SWAGELOK % SWAGELOK % Male NPT .. :. % Female NPT 1"\, -~ '% •. " 1¥. . " 2"/u '%a ., %' , .. 2j.' ::. ... ~ ·. ,,, ~· . 2%. ,_ .... " 2'/u .. ~~-:.;. .. ¥. 3'/u 11%. .. '" ., .... 3~~ 1'%. .. %· no 3%. 1'%.· -·~~ % 2•"' 41 :·1'%··· . % 3 -~ ·:· . .... : -_.359 '::·· % Female_ NPJ' ·-.359 •·. % SWAGELOK ~:~--6~-.... ~~­ :.:.~:~ l-......;..---1----+-----"---..;...-+--------+-...;_...;_+---+--l :; , ·8C· ,;-· .. ':. -.. % SWAGELOK .; ... , . 1'%·. ... : . %· ~:-:_ ·8C2_.. i:.~_. .. %Male NPT .·. % Male NP(.z . 3'/,. 11" .. : .... -.'7. .. 359 % Female NPT -t ··· f : ·8C4:", :-~-~·· ',1, Female NPT 3~. : .. 1%. ·;·:-- ··. ;359 % SWAGELOK % SWAGELOK 3~. 1'" •. 1 ,., ' Ill ,.. t -:- : .. .. , ,, ~ " ... •. . ' . ·:· :: 1'· ... . ' :--.... . . . -' .,. _. i/?::;/~~ :~~?)~A~-:~~;--.~~r:~\;:_:!~~ •~~;::-~_)T~~~1:zt~?!/~!~~t~-~ ~-: :_~:::·.: ~ ~: .. il'=.f. '1' For a complete ordenng number..-· -:-J _;,..,.s.=~;:>':-,~.::.-_,_. ·~<:-~.;~-.-·:.·;., :w-,: :. ·.. . ~. \.!.J' ... .. . . J •• ..,~,,-~.-.·---·t. ···· .. ·--'": -~-.... · ... t . ; :-'!-: i: Add B for-brass. ss for 316 stainleSs stHI: ·A tor-aluminum ·and M for t~;)•·.~::~. Monel as a ·prefix to the -catalog nu'mber~ ~ample: SS-2C:~~-.:-::·, .. ~·;_-.: : ' .. ..... -~ ••••. f . -:. . . . -~.--·-•. • 0 ....... -~..... •· ~ ... • • .... •• -• ... •• (:;:-::.-: ....... b~.-for ;"C':. Series valves, ~dd ~. 1. 1 ~ o.~ 25 as_ a ~uf!ix to the catalog :::.~:.~ · _-. number for the desired cracking pressure. Special springs toJOO psi ·. ;. _.: :: · : ·cracking pressures are available. Example: B-4C-1 · :.-· · · .· .. · · · -' -~ ~ i ·:·c.·. For ."CA" Series valves, add 3 for 3 to 50 psi cracking pressures. 50 . · I , . .. . . ·• • lF '. : .. .;...;_. for 50 to 150 psi, 150 for 150 to 350 psi, or 350 f9r 350 to 600 pst as a t·;:;·~:. ·>·"suffix to the catalog number for the desired Cr-acking range •... : .. · .. _( :}, ::_ . . :_ §:xa_mP.Ie :_ S~-4CA:-3::·. ~ •. : ~: · ";~: --~·.:.;~;:..: ·:·:~ ;_::f ~--'::;~~~:.-~\-:-:-. . · · .. · .·.... . . L-~-~~.~~~;0."~ ~~~~ j'!!~~~~?:.LP~.~~ ~n~~[l,.~~~'"7Lap~!o~b-~; ••• ft;I~J~--~lli~~f:J;:~:.-~}~l~~~~~~f.:-~i'?,·:r· .-: NUPRO COMPANY • 4800 E. 345th Street • Willoughby, Ohio 44094 ••HII~T ~ U I \IIU I \1 tjUJ\ll\lt:l Kt:l:iULAIINt:i & SHUT-OFF VALVES PURPOSE WHITEY Union Bonnet Valves provide safe, reli· able operation with pressures .up to 5000 psi. The heavy duty, three-piece union bonnet construc- tion is an important safety feature when working with high pressure systems. The union bonnet design prevents accidental disassembly of the valve while in service. Vee stems are used for shut-off service with self-lubricating fluids. A TFE tip stem for positive, repetitive shut-off, is especially useful with thin gases, solvents, etc. A TFE ring is press -fitted and mechanically rolled into the stem on the inside and outside diameters of the ring. The result is a permanent assembly which will not come apart in service. Regulating stems are used for fine con· trol and shut-off throughout a Q,r:oad flow range. OPERATION \ WHITEY Union Bonnet Valves with TFE and Vee stems are opened to full flow with 2 to 3 turns of the handle. Regulating stem valves open 7 to 12 turns, dependinl on the orifice size. · APPLICATIONS High pressure hydraulic and pneumatic systems. Shut-off valves for pumps, compressors and gauges • Natural gas lines. Feed lines in refiner· ies and chemical plants. Sampling lines • Power plants • Laboratory and research applications. SPECIAL FEATURES l Machined, pure TFE cylinder packing. fully con-J J. ... _,_ . . . \ ·.' ~ . tained by metal • Packing adjustable and can be replaced without removing valve from system • Prec-ision machined barstock body • Metal-to- Metal, non-rotating bonnet seal • Pressures to 5000 psi. Straight and angle patterns • Universal mounting nut standard • SWAGELOK end connec· tions • Female pipe connections • 100% factory. tested. TECHNICAL DATA ORIFICE!' ~FLOW~,.Q ; PRESSURE !~ IIAXIMUMb.; ~SIZE~ ~ICIENTt ~R~TINia.i , TEMPERATURE} (J.~c~~~r -~ ~·~ 7_1!1:~ ~R~n~c;~..e 0.156 0.37 mss ·o.zso D.BS 5000psi 45Q•F with Brass• TFE packin& 0.312 u 3000 psi •Special ordat ontr . Mt. TERIALS Body-Type 316 stainless steel. Stem-Type 316 stainless steel on all valves. TFE tip stems can be furnished in all valves. Packing-Pure high-density, TFE cylinder ma- chined from extruded solid rod. Handle-Black anodized aluminum bar handle on 0.312• orifice valve. On other orifice sizes, molded phenolic knobs are available in black (standard), blue, green, red, yellow. orange, gray, maroon and brown. Handle extensions can be supplied on special order. All other Parh-Type 316 stainless steel. WHITEY COMPANY • 5679 Landregan Street • Oakland, California 94662 ( J'. • I u WN1IEY1; UNION BONNET REGULATING & SHUT-OFF VALVES l . I r ' I I •, ) -- " -~---p:=-::=r -· -·-·----•---' TABLE OF DIMENSIONS ~6.@lojf,!? .. ~~EJ:~!\LV~~~ :1!~ !~~~~T~ ~~~-Mf~;.-,.,, ~ ;..,,,.,, .-~.._ .... .....,.~11.1:, . . . l:!~~$'i-!Gt£,~b~·M(,:: '=',....,... ·~;:oo:' . ....<.'!_ C~T~i~~·~! :~~;!E_~tF j OR~Jff,~ ~~~~~ H~ ~~-tm. ~~: ~~~~c~ -~~ ~-:~. I&::M ~~~·~ f~_H_··;:: NUMB , TYPE · (I NCI I~G. .CLOSED -3LRF2 Re&ulatm& -3TF2 TFETip 0.156 Y1 Female NPT 2 1 Ya n;" 1\4 1%z ¥. 1% l'fu 3l-l 3\ol -3VF2 Vee ·3LRF4 Regulatm& ·3TF4 TFE Tip 0.156 \4 Female NPT 2Via 11hz n;" ISf!l 1% Phz(l) %,]) 1% 11/u 3l-l 3\ol -3VF4 Vee ·3LRS4 Regulatln& ..-1TS4 TFE Tip 0.156 \4 SWAGELOK 2%a l'hz Pill -1.,. 1'A• 11/u ••· ·¥. w. l'hz 3l-l 3\7 ·3VS4 Vee -. - ·6LRF4 Regulatin& -6TF4 TFE Tip 0.250 % Female NPT 2\4 1Y1 1V!. 1 l% 1''hz ~® 1~ J~ 41'111 411hz ·6VF4 Vee ·6LRS6 Regulatin& ·6TS6 TFE Tip 0.250 ¥. SWAGELOK 2Ya 1%. PAt 1'/a• 11%. 1''1Jz lh lYa n~sz 4111!1 411hz ·6VS6 Vee ·8RF6 Regulatin& -8TF6 TFE Tip 0.312 %Female NPT 2% lVJ, 1% 1% 2 1% % 2\7 Z~iz 4l-l 4%z -8VF6 Vee -8Rr8 Regulating -8TF8 TFE Tip 0.312 ~Female NPT 2% 1% 1~ 1% 2 1% !'1 2\7 Zl;iz 4l-l 4J;iz -8VF8 Vee ·SRSS Re&ulatin& ·STSS TFE Tip 0.312 ~ SWAGELOK 3%, ll%z }Zihz 117hz 2'hz 1%(!) ~'a 2\7 n,~z 4lq) 4%z11 -SVS! Vee (i_.Far I COftll>ltlt OtGetlft(IUIIIDer . tGG I lor llltll Ot SS lor 116 llttnltsS SIHI IS I DrllfiiiO tile UIIIOt IUIIIDer . AGG ·A IS I sutl11 lor IOIIt Dlllllrl nlwft . {it111111: SS·llRFc, SS-6VU.A. '!•Ot_R_ SROwo wtln SWACELO!Iouts ltnret·lllftl, WIIIO III>UCIDit . (!.AGG •~~o•tor anrtelllllerA "'-· '.!.-SuDtriCI V.. • ler ••&II t~anero ••-· FLOW CAPACITY CURVES ;~ £':·-r'.-..;9; ~ ,_,_,_ ~~~·;;;. ~;o:: / 10 ' '. • •· ....,..._...,.__F ~~ ,. ~~Jin~~-~c:n~ -,.:.:;."~-~ '/..v;;:. r ' -~--~-"'"·-_... ·-. -..;. .. .-.• -0 • __ ............ -~ ..... --~ ....... ~ z-~ "*",;.:u..,.r. ~ 7 -~·<~i'•ol.oiiii~.:i.-;: """~· • • ! • ~""'~""t·~--A · ,...,.~t.'!'lt.~ ~J.c ;:; ' :.l..~ ~f'o.-':.1>~~ --,. -. ~ . ; • ~; ~./~-41~---~~ I , ~~ ~ ~~"~ ~ . ~~ ~~A"-~fn ··~· J ~.l"./--• ~ wu.'mJil.."T;I!(;;;T...rc :>'~,P.. I _,_, .,._ ... ·"' l . '--'i'Y-"':>'· II 0.11 UO G.lD 'LOW COC1f1Q[IIT tC:... T\111111 oP(II UQ.JO.•"O-'U rLOOO COl"CiliiT tC.o • T\IIINS ~ 100 tUI 1•.00 :~ ~.!'~·-.. -. --~-·--:-:-:~ 11 ij',_T....,_, . •. '!....,. ..__ ~--... ~.St2111.1:1Rif1Ct '-=' :/-'"+.·'"'--t>-' !'. alO ~. ;.-....,.~ ••: .. ~ ~ .. ,...-....... -:-.,; 5 ..... :~ .. ~... ... . .... """",_..,. 1"--'J'~ i • !;.1 ........ ~~ •JI'.A·. 41 .• .A--: !: ~·~.:· --~·=·.;._... -~~~,~-~---~;:=~: t· p;; ;:: :;~ -~--,_ ....... ~·" • , .<o;;':. ...... ~-.. ; ~-...o!"-""!"1~---- ~:·~~· ~~.um .. ,l~-~t -·~./ .. _ ....... -. " -J>-... - U 00 H D.l I D 12 • • Fl.lllf COO'ICllNT tC.. e T\llttS QP(N WHITEY COMPANY • 5679 Landre~an Street • O;.kl~nri . C•lif,.. .. ,..;. a,u:c:., \ J \ PILOT SYSTEM STRAINERS Strainers are used in Bailey control valves to protect the pilot system from foreign material that may lodge in needle valves or pilot valves. The No. 110A insert strainer with 90° ell. This strainer is inserted in the inlet connect- ion of the main valve. The screen element is soldered to a brass nipple which is screwed into the ell. The flow of fluid passing around and through the screen keeps foreign parti· cles from collecting on the strainer. The standard screen is 40 mesh stainless steel. No. 110-391 insert strainer with needle valve. This strainer is also inserted in the inlet con- nection of the main valve and is connected to a No. 391 needle valve. Parts List 71 ........... Body 72 .......... Needle 73 ............ Cap 74 . . . . . . . • Locknut 75 •......... Screen 76 ......... 0 Ring No. 1009 Y Strainer. This strainer is all bronze with 'l:t" NPT connections. The standard screen is 40 mesh stainless steel. Larger size strainers are available which may be bushed to 'l:t" NPT. All types of screens with finer mesh are available. Parts List 1 .....•...... Body ·2 •.........••. Cap 3 ........... Screen 4 ...•........ Plug 6 ....•••.... Gasket Regular maintenance schedules should be set up to clean these strainers. When or· dering replacement parts, please give size and catalog number of valve and all in· formation on the nameplate. OPERATION, MAINTENANCE AND INSTALLATION INSTRUCTIONS PILOT SYSTEM STRAINERS CHAS. M. BAILEY CO .• INC. 1301 59th Street Emeryville, CA 94608 S-1 I f .. , ,. t. ·. ·! .. . ' 1 ,. ,. .. .. •' ~~-' .. '' r • ~ t ..... l .. ... ,!, t ~.+ ... ·~· L • 'W' " " .. ~ .. .. • J . , ' ... , • " .. . ~ ' ' j' . . ~ ~;. ·'' 'f .~ ',.. ' ( ec::.cr: Sect lor. r J. :~·e ~er I I I l983 T8Jle of Ccntents LJ3~:::ec:tt=r ~lectric Uni~ Heaters Ventilating Fan Thermostat ;:J c; --:.: l •or-" is t n e _;_ o a c:.:. enter f o ::-the build in r; : L <:; r, t: : n:;; , H VA C and c c n v e "• i e n c e out l e t s • I t i s .::'"~ '' ~~ ,c;l t sin~le ;J~:ase and is Fee throu•:Jh a -a~r j~eaker wrich serves as its cisconnect. M3i~~erance arj operation shou_;_d be in scrict 3Cc~rdan:e ~it~ the manufactu:er's publication ~a ' -1986 attached to this section. is i~portant to rene~oer that there are ether sources cf power in this builaing and the main breaKer in Pane~ ~ ~ not a complete ~icc: D~scor:rlect! STANDARDS PUBLICAT;QN PB 1.1-1986 GENERAL INSTRUCTIONS FOR PROPER INSTALLATION, OPERATION AND MAINTENANCE OF PANELBOARDS RATED 600 VOLTS OR LESS S·,x.:E SECTION GENERAL SECTION 2 INS.,.At.cAT<Ct, OF PM;EU30"RD CABINE "J :"·:.'<ES· SECiiON t-JSTAl__A'!"-\JN UF COND~;:r ;lND ... v·c.r:s SECTION ~ •NSTALLAT•ON OF PA~lELBOM:;D SECTION 5 S7EPS '0 f-IE: TAI\EN 8EF0PE ENERGIZ r,G SECTION 5 iNSTALAT'U~ OF C:A&INE~ f'RQ"'T SECTION r ENERG ZING EQL<P'vlENT SECTION 8 CARE AND MAINTE'lANCE SECTION 9 °C:"lMISSI8lE ~OADI~iG CF PANE~8CM1SS GENERAL INSTRUCTIONS FOR THE PROPER INSTALLATION. OPERATION, AND MAINTENANCE OF PANELBOAROS RATED 600 VOLTS OR LESS FOREWORD ~":S :::-w~1 ti:ar~en <!3 a (')Uhie :J• ~ractte.al '"''r;rmatiOI' .:ur;latnlr,q nst·'~" ~.·T-S 'rJI t~ ;K':(;)er ,..,~,~a1..::r: · " I(~· .: .:· d"<l :1'131r.\~l"la:·ce :Jf pan~!bcaras rated 6CX) vo~!s or l€tSS ;hese ·eo-.c -rrenaa!·or's of .... t:J o~~ ~·:..-:-o.r! -!:'·: :::; .. ,, •• :t...~t·o~ Soaro Sectlcn ot ~~e 'iaHonal Elec~r·cJt Man\..fat:h...'ers 4.-:)s..;;.cl~ilt:r w11i ~ *:-. ~r-o Jo::ar ... ~ :::~·. v -"''1dc:s. t?'~r:l~iCll er:g1n•~ers 9l&ct~lcal t:"J'ltra._rcrs $1t:1cv:c an~. 'TlJ F':~··at~-~ "'-r.-J•"1HW;::. :,r.d .:...ners · s ~ec:t'f"'f"'1ent::ed ~'"'a~ wor• cte~nbM ,, th1s sat of ~~:str 1 1C~IC,...S ~e ~r'·:-r...,.,f'C ::;n'r bv ;'lva~1t ~J'C :~r<:~,·n,'•J 'dF' :1ar '#t1~n '"'·e ;,;crsrr.._C1. Jr. find ooera!!on ot ;Janetb08l'Os a,"'.Q mar -; ... cr ..._,,,r1( ~:::;~e ~lJ"f..,.,.OO ~,..,Y ~"!"'""' ·eJO "'g ·r1s :,;ITlple~f :et -.Jt 1rs~r JCll'~ns F-Jr~"'er "'"'iE-rToA.,fena-.ct: ;.>eriionnet have s~~~h,: que'i:,r.:rs "'lO!..: ~.,.,~ Dv '"'ese .;·~~· _-r;!,fH"<S :~~, ..:,rq "'rged :c ':'O,.,~'lC! 1 "'tl <"':'1arutac Jrer ot the pa,eiboard dl'e<:f!\ ;_""ese .""!s:tvCt:C'"'S wdl ~ rli..,,ewed D6''001C3II't-Oy tne S~:ux ror owr:,.ose of vCdat,rq-me-•c rtt!-,l .-u:t-..1\rc:,:'!g :ec,.,nr;-c.;;-1 P'ea!'fl aoljress tlny ':.omm&nts rn :':IJB'S!Jo:·,s yOu 'Tiaf r.a~ 'YI ·r-e ;9,. Manager Er'lg1n~nng ~oar.:,.....e->1 fMt,onal E!.ectocal Mar.;1ac! ... r~(:; As.::io.-::ar on 21C1 l Street N W Wasni"'Jton DC 2003' ',. 1r:: .L ,. e "'p··. ~ .l '; '~' .. .)! O· 'l.rJ.: , ;tt;. :_~r .. 'c"' iS • .. :r.~·• ,. ;::.~ ~-~ i-:'.., ;~ f l,.C ·i •· ~t.::•~,/d:"'lt --:t i'J:j ~. · "/t··,··~ ·r ···~!dt)l;. ··:.c :. 1(!(, -;r, ~ WARNiNG-·· tr!~· ... r~ ~ -1AL..:..::..t[ ~i; ~;_EC'?~C ;;.r<c:~.-<: '-.!=-,;;;.jt, 'hr•E:-,::_ .... r~ oV(;Fu• ~~, ,:..::.:c·, .. .:Nr C::..F·.·~-~!CA.L E:-l_·IPME;,T ..... ,....:."~ '=' J\\~.P St.:;lc' y·~.,j n-.r E_,:·r.; ·.~:-..~!<.-Bt:.= . .lr..\: -1\'GRK;.'I(J •t.,SIOE Seclion 2 iNSTALLATION OF PANELBOAAO CABINETS (BOXES) t ,,. ,.::'"/ ,, HruiJ; -~~ L<-'CafEf ~~e ·~dt:,ne 1 sc tt'Jtt \ ·s tead:'y acc.~5S 1 t"8 af"rd r"'Ot e'llposeo !O Ptlt·.J:cal .::lar1aq~ ~-"'~f~Wi S1 f"\1t't! C •r.dll ~ Do t'C~ lOCAte 'he CilDt'iet where ~ w••: DE O'lt)O$&d lO amb•t:mt t8f'J'l06fCit.Jft;5 .100ve 4.()0C {104~ c·:.r-t)s;· ... ~ or ·~:.:~OSI¥9 ~u,t!'s. oust. >'rlDOrs. c:-·::-·',)•ng or stardmg water abnor- ...,al v1bfauo11. :"!\eehal"·ca! ·JliOCA ..,:gf'; "'l:.,o;'lf'drf'"¥, t1.~111g \lr unus~~ed o~ratrng .:o!"dlf~ vnhst"i.S ·r:~ cab,net/panettx.arc: :;t.'m ~:nal1on I"' as ~n cie'!tgnec 1s.r ·nese conC'·11Cr'1S /n,..J,,.-u· Om'U: L."~·,a:u•u Loellte or sn~a~d •J"\e cabrnet w i:t! tv prf!>Yef'lt ~i'!OlSt1~·-;:;-aro :Nat~r •rc~ ~~'-"' 1:-:g and accumu•dt~~ H··~rem Mouro! the ca~>net ~ r~at !"';f:"rl'l sat ·qas: ~!4 1n~-... ·)~ s·· ->oact1 ::.e: wet:tn :r;e c.abii'\E"f a.'lQ tr-e ..... ai Ot ur~rer :lupc<:)ct•OQ 3..:rt1ce ~-~! /..· ;l{l,>"{j CaOine•!. O)hctJ!d toe S[)eClhcatty at:I'QfO'Ved !cf" WE'! k'.C<!IiMS M{H.r! me (:S,t•r,~: ~\}! .. a, tr-$.:-re •s at least •14 1n:.h of it!' sca.:e r.>e~ l.he ~atanet ard tt'e waH -y .:th.;r -; .... pp-:-r'''19 sv· t:e 6 (ir,; ..• n,·r _.•rom ("'I/! 'It' Do not lOCate th.e Cabti'Mtf aya1r\~1 1 i0"·1 H~JVOOi Cll•-·;~ e;lk,.'W a c.o~~-~ 1t J feet ~tween ~f'lE' CP.Ibrw_; and cab•fiet i..n~$ an arM.t<.ivd'e !,rctpfOOJ Sf\1eta :s ;Jrl".t O::f?'O 'J'~er :r;bld:l:'"';: 't~J~>::>rtJt ~~ ::;H('.":' 2"'3' :n~ ~J:'\ .,., 1 t ,.,, • ". r" ( t··e-~:·,·e·y. ~~s~ · ... r.,.;;.~c -~ . .:·· ,.r,:._", •s sues< ~n!.-,.,l·• a'.:JI\-oter.• ·a t"'_H a~ordpc; ::J"f tf'lt' ·\ :~e ,,,... s"'e·j $<..~.'-lC€1 1r .... 1 s ::,.r " ,._.,, ,-r O'O!ec~ :J.of?\ _:,-.,-: ·n,. '" >:<''!· ~ r: :...,fl ;;;.:; •. -. .:.>• ·,) ;.r(Jv ..;l :"''.:!' :.atJtnoP' ,, ... ..J,~.~t ., ;J .1r .... ,~.:, ·n~ :: \t; ,··-::· ·:~ ~ .. -x a~ s;::·t::"': ··~ ., .i.r C:B ;:.so Jf tr.B ".J ·a E:ec~·.ca C.1Ce .f¥¥->E>,., :".+:: c::!t'•"'··::q cr X-( -::or.ta.r":.> s.er.·~;~e ~~L.I;:J!TtJ:t'il ,. Nil. ::oe n~r.·~~~S.J,:'', :'::' :>.::;rc .... !? c:<·" ·-:~· Jr~·.1·0e.J -iieL.;tr.;:i )L..OC:It c---Tt .. L:--::0r Sect;or. 3 INSTALLATION OF CONDUIT AND .VIRES CcrcL.:s 'Sf''IOLf<l ':':If" ff'Sfailed :;o as TC C·f€!'ter.t 'TI•:as1...:re ::· 'ttl:l!er !r.·y·n eP'P"I'"l9 anv . __ .,..._~ .3' .-. ...-~•t-:f" '"'.e en<. JSwr•~ i:'ltov!SlOn S:""OUJC De made tO ;.JrOH:Vf r_rwauctors f"'('r"!" c::v 'lSH)r r :.1"' N'u· Ar;.c:e -3·~1 -,r ·ne Nahona: E:e-ctnc.11 (:ode P1aca screworP..-er ~>~aoe ac<w·"~st po.nt ~a"i'"'es; ~··-)rr t~ ar:o str-i(e !NW.A.~D ·,i='lg•Jre .2-i 1 Bt-r.'! Jo;.act-: af'ld 'or"h to orea~ ~~e b Pry first r1t<; CJTWARD w!l'"' s-crawd~· ... e• ,...,...,owa, :.e'we-en t>ei . ...as1ng Ol•ers *'a! aga,no;,: ~~ « ·..~~~der scr~cnver (F1g~.;re 3·21 Bef"''C r:ng seC:ilons OU'r"'¥iAPO wttn pherc; :1"1~ oa.; .... a 'y·"' to break · es (F gure 3-3; Remove sacnf'd nng p·..;WAA:J by s!Nung scr~f1rt•e.-·wrtt" hi.ll.d~ ;:tqa1ns• potr-' ~·ow·c~·. ~~. twtlen t1e~:~ :~e"' breaK:ng '-ng sec:.ol"5 1nwa:d a. ... ,d o.a.cj( and ft"'fth :o bre-dK ~ ~s &t sure tt'lat tf"\tto il..~ are suJtd.ole and a:QOfV'-00 for ~.;se •'lfi :ne c.at);e 0oe")'J i.."Q"n~:e-.: :-'J ~~ ':! pan-elboard Sdf t\I!:'M 7 of S$Ctll)n 4 fOf maKing proper \.:0'1'"!411JCt~ Becore ~:!, q )t'"ly CtlC•tt1 tne box_ :nake svre that the ~e,...,peralure ratmg of thew re conplltts.., tf' ..... ~ ::-t 3-0f'-'C :.~at•or<; .:;---: ~he oanetbcar~ :ntenor f'l"'ark.mg, •f ava!iabre • NFPA Pub ~o 70-198--4. avatlable ~rom the Nai,OOal c.-a 0 rot~~~,.. .&5s.oc ar,c~" ·~ctrf''""•''"',v: ... -='..t~~ Ou1ncy" M.essacr"luser!1 C22'S9 Fl9ut• l-1 Kl\OCI<out R_,l , Sle!) 1 Flgure J.l Knocl<out Re"""'af · St"o .) 444 = -· "-t~e:: -_·-~,·,~uc;::y r-·~·r.s •,: i1 ...... ,.., ...... ,,.~-<~<~• • ...,!,... :re..,. r.: ; .... ~~· :~:.;;-~;i•-•· .:cc ~ e-.J '"lS "J~ .. ,t'':-:--'J'C 21+" -d -?-,.., • ..... i '.-, ·;·;: :;__ ,~ :.'!-t:: ,··c t ,.. .:} '"3 ,-, ''"'.;:? ::;; 1~~-::r r;~.:,_,: t~..~ .... --~ -~ r,;_,_ .. "<; (. • ·1 ~ ~ J+:··! ;;r : e·.....,. ~-_: -ort.-.'""'f ~,_-.r;s :---· 11 >~c ~ 1 " •• --~~i'€C Section 4 INSTALLATION OF PANELBOAAO ·r!df"'l ._::r·, :>,:•.>':-·._ .1" :·~ _yJ t~">.j' nf>·,;t' •• ) ~1' j,jrr -,,J€' ... --·~ ... ac-oer ·~ '"•€:·::.~ h'; ;.:·~:~pu.·><:; --a,~-A.J~ ar(;. ,--.s· J :,,!:~ !'\ "' :f'le ..::-'lt ··-;-.•\ W . .1MtilNG-8E ::-~-;:f-r .; A.L_ .YCY..E=i 15 ;.jf--tNC: -:_·.t:F A',::.-. M{:\•A·"J~ (;["~-Q;_,p ·,.---:: · -·• ;".JC r'jS7 .:.!...; .-6. ''~(_,'"'J pq(_,C::D\...'RES · .:mr•~ C!ea~ ·~B .::abrret ot all ~Cl.Sign :-nateoa!s :;Ytor •c •'"'\S-d! attot: of ~'"'le pal'e':>C£\(a ;ar•· :11 C\lnr:ectiOf1 OC~'1tS are soattere-c Wtth cement Oi3Ete· !).11('11 or otrer tOter<:f"' .....,;;_:pr .: 'tY~r.> .. -:: ··•tt ·~-re-gn f'O)a!e ·a1s wtth graa[ cure to a-.r010 r:t.J.mag,r;"} ptated :J·,;rfacn Unless oth.lr.w1s.e !MSH..tC1ed by t""e -mnuf&eturer .s<JJuS! ;r-.e I)Clne!t<.l41.n:1., tf".at the retutf1 ftallQEr vt ~~e dea.Oftc"~nt sh1e1C ~s no f'T"Ore tn£H"l Jl, 6 tnch ''"Om 1 1 ~ tne ~ron1 of ~ t:Gx tor s.ur1'ace "r"Guf" ~1ng or :'2) tt'le ~urround1n{f wall su,..aces tor flush mounting C •11(/u,·:o,._l · UWt care :n !trlpptng msuiattOii tro~ conductor~ sou nor to n!dt f;)f rif'HJ tne :oo ductor ~o< atummum, C! .. ar. all OX<O. from tn" $tf•GC<I<J ~101" and IIWV A i(litlt compovnd o Dlstnbute aM arrange conductors neal~ •n the '""'"'i 11'>1!"" tSe. See11on J , Be sura that tl'te iug.s are su1table &"''d ap;lfO~~ •or .;~ w*'tt': t~ CADi• :>eto"tt Otti"<; :Q('In.-.ce;_ to tM oanelbOIIrd _,-... -l . ,_ ' • C' "'~-~ -~... ~. =... .. . :·;::. . ' dl1t.llb<:·3'·; :::~• ~rt. :v~C·1~1 ,·,· -t ~~ ~·t' t:'-Ji arV r :it~·: 3 :11~e .. .t __ .,r-;t-.--:.yc: "l"' ""€ !Jt.( ·' '"e ;: .s y-,:.:.~t:-:.~.,.,-,.... "·u -;.teas ,r Sec~:or ~ ~-c Tt" 1w;1a! ; .... ~ -.;, :··~cr ~ Secbon 5 STEPS TO BE TAKEN BEFORF.. ENERGIZING e. ~.':'!e;,•. -,1• v··'.-'t :-,·_;ct, (· ")r-,a;.~,.Y ·S >Of Jf( ·,w_:ea.,. ~~ :"e ~Gulpf'T"'e:'.t con~ .... H '",(! :~1;n:,.~.1.:t: .... 3r t},~l'-~ c.:.'"'.::~·· ·~.a· a O''Xk; ... sP'l 1:;: sr,·;:;fl"ent ~avt> t~: r'!,__ :;,~~J 1f 1J,... 3 i ~rv"',·,·. t•"~ ;..:. .. · >~~ ;~.! t>;e :;:a'1e:!" .·ar..; \~a~·:...a 1 ', ·?J<E'rC1S:" '!' ~w ..:re:L c rc.,>~! t::realt.fr~ -~-:! ::tr'le· ~,.;;r il··,~ .""l""·:t~:r• s·"'s · · ~,,.., :t: .,,.3,; ""':~y ~~~ att •· -~-r Tc m.3to:e s ..... -~ •r:a· :~,;;: s 1 re~ :.-~J<"'I sncn ts a:,(] ·.;;rct. . .t·-'tS. corouct 1r .rr:;u.a·.".,~ re:5 .s:a·-:c~ ~tJ~.t ::r-ose w grc Jl'"i.; ;-r;a<;e ·o ::;"'~asa w1~h ihe 'SN·tcre~ !')~ c;~: .... :t Dreat~~ars n o-.:!!"1 ;r'i' ~~ .n; ::·eseo ;JC5'!'r:;rs I! ~., nB;stance 'P-.lld'i ·t'':lS tha-· me.::"'.;, W ... J!i! !6S!1ng tvaf'Ct"l c:rc~1: Jo::~ q;s ·· ..... ~ t:,utr o...-::s~·~c·-·.,e s·t5~eP, mav Of!' ...Jn'ioate ar.a -:;ntJuld ne ;-... est,gared Sr·ec~ to ·je:f>'"'r·ii•• •r·l)f all grwr.dt<"1q' CfJfl''lBC71V11<i are ;.r JPt"l) :Tlade it tt"te Caf18tb0ard IS -..'$00 as ser.~1ce ~QviP,.....t"rlt "'1ak6 certal~ !"'at li"W!' roau1ra1 15 or':>iJE:'"ly OOilde-d ~n the etictosure t3 Fhrnove a!l jC~r <; iC"ac:; -..1re E-tc . •r0~ !1'\e paPelboard and ·.::aC>!nB! before ltiStttll!l''-;t th-e Cdbtnet tror:t Malo.~ cet1dP1 :t-1 .H ali dea<J'nnt sn1e!ds arE> pr )per:y P.t!!g·-·~ aPd • gt'l1er-9d If'\ stall the t:JoH··,et 'fOr~ 1K.:cr:Ja:1 c;:> '*"' th S~C!iCM 6 Section 6 INSTALLATION OF CABINET FRONT rlu,..i. ,, A ~UI!ab4e p.:!lnt or o~t;er 80ftO'SIOO·'&SiSta'1t fli"'•sn S!">C.vld t)e i:IPPIIec! !O :nose pia :es .... r~r~ ll'le IJntSh ,5 damage<: Frmt: Ah,J(FYmt'!ft fM catunet frct11 rr.ay p.:: PH."">'1decl -...:~t-3f" ad:'.J,tlf'lq rr~ea.rs :,..., a!l9f'llt ~:q. a.re1t ,..,~·h tt;e O~o . .HIO:ng even 1hoYgh the uo• ,,..,,.., :::e 1r.-gnt1 1 au~ ~t p!.,~I'T>C' '-'~'lr'". tne ~·; ~11ng t; ,, '•::-.: :"!·-~-: ..,l"',,c_ -~ ~·-... -,··.~ .;:.:'<-; •r ~~; .·' ,..,:·· nw:t·~.., ;t·;:;. -Odd .-:··c ,,.. C''"' -:' ..,-: · --er ~ .:.;;.. Sect•on 8 , .... r~ .):r :e-. J'·(' -'i('-i' CARE AND MAiNTENANCE c. '-<.trP. ar-c -1 n·<-?r·ar:.;e ~rc<;•B.....,_ ·~-, ,, a.:cor·.:ar.:e w.:t', tre :;lk.·wmg ,,-___._ •; .. ~r ,,....£, ree .. ;er ·;~-. ~ ~' :e-<;7 .. •: :-~• .BS l' ,:. paf"le!t'larc ""~.,;_ . ...,·-as ~~e,~ :.-~----r··.q -:~ •e-y~·ar f'c!·J •-:·r -l~ lt>:i.SI J --..::-vr, · ... "-'t yo ::.n·:L.i,1 •. .'e t1c C: -~s:ea by ~ae!tl"'lq :~~ -:le?tc'.-s.-: 0) .• -~.---J.Ci~S .:,1 ·:-......!. ::;.rt.: .. ~ '':J. ::;..-.,;..:;t'-:~ ·r ... , ... j :!OC-"S V'10 e·1c:-cs ,rP. staes ..,...~ ... !!'11:? : .. ctlr-· •rt:-1n.i"~d ·r :rH-" ·~·TP<~:··;nure -_t nes.t ~_.;-, .. es jr::es !C~ ~ff'll' vc-__. 'C ;r1l11nl:-l11'., C00l3:~ rn• a: ·~?a.;: -, ~t::-CG.--,()5 (>"1-~ ~,lfi ,· Jf: an nd:c:H or ~r--_· J\:••t• a'X; -... est.~a::o'1 :s ---~&r.:essarv WARNtNG-SEFORE PERFOF2M:N(.:: ANY OF Tr·:: rou..(.'..t..,,·JG .:Ps;.:_li.-+!ONS. TURN OFF AlL POWt:F< SU"P'. r 'NIJ THE PA~<E•.,:;Q!IRD CHEC><: ··;E v'X l AGE CF ALL <NCOMI"G LINE 7f'l· M<NAt.S TO POSITIVE:. r ASCERTA·N ~~'"' T Tr<E EQUIPMENT IS TO" ALLY :;;EENFRG,ZE::J !...VCk tor anv motslur~ cr s.gns '-'t ~'-~ev.•J!__.s w.a1nes; :)r :J"'IDP· rg .ns.ott lhe p3f'€-lboahl :()f"loo'an- 5attC" 1:1 c:onduil5 l)f dr·p~.an~ frcr_ J..;t-:;,de :-;..-Jvt.es of"-e ~nowf\ cause :)f m&Jfunc•l-Qn : •, J Sea: off a:~y c00dut1S _,.,h,,c~• r:a·.-e :jnqJe-G '"')d~'-'31€ ;;.;10 ;.rovl(je ":1: m~ans fOf "unMer C! f,.... dftOS-al~ !0 dratr a*ai 'rom ~r-e-P~W~lC.i-:.'" ( 2} Sea: otf any cracks or '.)C'•f:H·>.,gs t¥h.-,r. ... J'-le ailewftd "'~''t; sture tQ '9f'lt~· !f'e i?f'C'CSu:t EHtr '"'·"ce !he SOurce ol ai"'y Cf:;)plr.q :Jr 11"'e &flC1CSu'lli j('f: ~-:y ·'";W 'i.:(,f(;8 Jf r 01St' .. r~ 1 -~ R.ep-act-lt•rtnc·rrA.c;rny ;--{arc :_;tPo;r> :1r: ~~c-:..~.~:,r~'n>\fqr,.~ ... -,t(:~ ·Sd""-r.c ~-, <N~< _,rs~·v-:.""~s an 2 ::c J~'!!Jfahor' ~~~ ·t·'~o·;-1•)11 rr-atann. 1 r::~~-:;·r>'-"'--'-s w-qr "q! n 1t 1hera IS ar accl.mu.at1cr-ct ::.h .. s; ~nd '.!1rt :Jean out th€1 p.dr'le'ib4:..ard by .JS,rq a ,J-fuS.--, :dt,;t,· ,: clt:~ar:e-1 :)r ·:1ean hr.t·t ... ee r;tgs A-.,.JH.! t~ow·nu Just 1rto -~ ·"'.: j 1 ore-lX-e-rs /'if :.t .... ~r ..:·')r"lCCJret ~~ Do not 'J.-\8 6 olowef or ;0~ores<:;ed a1r 8 >-:P • .-.• L.> .;·' ~ .. :: 't· 'l ' ' ..... -~ ::. t<rT':.."" 11 l..,. ~~:-.~ 1 "~>,:, ~ ~ ,0 ! ·e:- r:, :I\ w•'" -~1:1 .'' -::;· ... ,;, .,.,~ Q,?.'":t."O\t<:l • ----: (~fC ~--;'I'd:"". 0Pi?'c'\li' j ~·,<-0 "'-~1"''':! -1' •; O::l'--· • ~:· H _ ~""::--cr r: -~ ....... "',. ~'"-t?>f vpe:dte ··e>?r" :,_,· 'r'llo! ~ ,:.-r ;::. ·~ p,;,, ':t;-., /.·re...,.:.-.;. f .ra,::•ca! c"'.·~c·. i·-~VIC':S •ur ·'!";j ·.s·r·: -;r free ~ C' ~" e."lt corrc<:>.:.-r -:i-·~ _j;·c: ':!• ·r.: ~-Ai·C.r t.• : :0-e\t"~t~ st Jrt c~r~.__. I. ~«CtN -,-? '!. :c-. lS r;:l. .. j;_.ore. ~ ~-~':i-r··:a:<:?:he(-Df a·nqo:F~so~·:·.,..,: .. "'~c"':Jr:'3"" ·~1c ~:rslo--~::-,:ne~.lr'.JTfi"'-...r~"t r-sff\J• "C~"'s Nf">,cr ar , ~-,.;.tlly .P'•r1AC m c.c~'-ii11S ::" .:30t?:s L.;t; Clean If ~r; lrs:,-L>..:t;-:P~-are g."en on tho •Jev••:e-! if :::l~'lg c-·-...:n~?( ::or.:,KtS cperJ; ng mecha,.,.•Sm'\ 1fl-! o("\f~r OCks ""·.lt toe lutnc.att:rj .\>-~"" ::·r-..:tn 'II.;~! qr"l'<h~ Operate eacn '5¥-tC'"' 1:.-r ':ltCu•l 'rea,.er H!>\•t1>r;:j/ ~ rr·~s e'"'.s., ..:-'"'a~:;;;! . ..,...,._ ... '"''ns--11€ ''-:': 1"'(] r-oru~f worl. ,rh., onjel' ;::;epla>.t' -1-J r~·~u•rt;\(J Cr;~ci!: c:rcu1t r-JrE·J~oolrs an<l •uses tc t!f'Sut8 :~., r-1a-.e ·• ~ ;:;·,;()f'!• arnoere ?.r·,_; •rne:•,Jc!:~J •,.r L~:c E11Sura tha~ none JfP;'r_,..ilffiltl!"19 C!E!VlC@'S are r>t=~ver uS&"l 'l"S re;:)laceme,.ts tor ~ .. ;~"Jf"t-· r.·:w~ 013'>1Ct' ~ever at~empf lo ;jeteat :er·3C1cn -rect'l.an·'Sms .... n1:;r d.rP ::r-:-v:ded i,~ ;;.,r~vt?r .,..e rs~ )l<ai nl •rt. n<;orrect class C1 fuse 9 ~·---------------------------------------------------------------------- '1 E 'lMISS,BLE LOA. DING CF OANfC\ .. i30AROS '···l"'l ., . ;.<1 ··r-·,.t;• ,s .;::.·· ··,.,J' ', . · .. s "' 10 ·----------·-------------· .• ·' •t 1 ·-:· ~ . ..: --~· ~,:· ... ,·~n ' ; _ ) ~,J ':-;e :'-w • --"Ia<:,':; J" ___: t• :"'!~ .j ~~ ;' ,-,~, i)l ·..:.h.· ,",J,'-1;<.~.1 '"''.:"J r <.--~'fhl:' ): ..1 '•d! .1.1.J; ~ie-~:· ;; \1J.- "'-.t: . ,-J! L--~ \!.J.'-' J-.. ,__, )~ :1' :; ', •. he-.... -¢ •j . ' · ... • ·I . !-' r\l: \f: P) ,., '\. H1 ~n .. : E :t· .. -,,, 1: \Lll1!1!a_·:ur<!"-.-~ A;,-;..:,__ Jlk:: St.u:'..!.trJ·, are :1: 1 ... ,·!«-;'~:" 'F\L\ ..;.i..LI'...:J·-.! • .-..t;l...:t'l re:a:es ~() J rr.•.:·;,.! .:~·~r,r-r~:llh •I .. .I'~JJ~.Lb::j ani! ,..~t;C\.: ;,"; ·:pe:-: .( T.;:' . .; ~,__.:.·~~~-:'~ '-;r,l.n..!.rd f.'~r Fu:;J~~ Oo!gr:. -.!1-_-: ~na, ::n: ';J~~-·r-~ .• darh. ar.olt~J :o a .<'HtFT'lt'.ti! p;.-.Ju.::. "'J~ .... r-.• h }ugge~t<.. a ~ou:nC ::ng n~:-ron~ .:.;::r!<Jdl:'h •.1 furur.: ,:c,-:.·.lpmenL .,.tJ,.;-t; ~~and.tr•; ~.~,.,<'en a; -:.J c•J ':1\ .l' -,.,ht ''-.fo:,~-'11::-j~ .. )f :ttf' mefi'l-::,_·p. or' ·n~ S-.Jodi\·~K'f: ~-..:_;~1~ .,..._}!C' :t:er~:or rH~:a.,~Atrt l-'. S.,..c }, S~.~buCI:t~~ 8! Authorized Engtn..,tng !ntormat10n -\u:hor•uJ £ng1neer>ng inform .. HIOf'. .:nn''"b of e'-rt.ma~·)r>' -Ji:d,t anJ n1h.er cngtn«rm& tnformat1on uf 4n 1r::Jtma~:'e .:t-<>ra.;:er not falltng wuh1n ttie ~!.l~lllll.a'!Or. ,,, '-f"-1 \ ~tanJ,uct 0r Suagt~ted Stanctara for fUI\Jf~ £k~-l~!". Offietai Stana.-rdt Propo11i A-n Off:\.·tal \:andard\ Propo<;.al 15. an ulfif,::al dra!! v! • pr···rw•-,t:d ~tand.aru l4;':,,;11 ~ f1·,,;1idlh ;('~>'·":~n:tn,k·~ to .1n outsfdc :Jrga.n;latiOtl('>J for .:on-;td.e•auoi c-ommtnl .t.rH..!. or aj:'pf!'' :l1 :8-.,lu•-~n V. S~t 4, SwlJSCCtiiJ'1 A; ICI!IIlllflcatlon ol Status Stand.trds U'l ~EM.~ Standards P·Jbl;cattor'l~ art !dt-nHfit'd m thr lwt:.,..ord or follo.,.,n, t:ach standard a~ "'tE\1A Standard" or "Su-untcd St.andard for fucu:(' Of51g_n ..• f:u·!tf :nd1.:ate tht 1t.Aha. of !he stanuard Thtt~t vrord~ ire follo•td by a date '*hlch Jndh:.lttl "'htn 1hr ~tan.,;LeJ •4\ adopttd 1n ~~~ pr~!ltnt form bv ~ ht 1\ SSOCiaUOn. Tht material idrntlfttd 11 ''Atuhor1tClJ Englntcnng lnformai:-On· and' Offt.:-1al S!i!h.l.ifdl Propos.,''~~ dn•&nltC'd s1 mtiar!., P.V-IELBOAi-!0 AND OfSTR!Bl.JT10N BOARD SECTIQ~t OF THE ~ATICNAL C:i.ECTRlCAL MANUFACTURERS ASSOCiATION \I -\; E:,·~~··rf-'k.~~ ,.~. 1\t-4~,, '"" ... ' .. ,, '' -~ ";..! '-' ·f"T" lf Jl \bn~._r'<.:~tl'r _ •,. '· ; , ':\ ~·.,~r;,o Hdt"'ht'!l •-" 1 h ,;nl!~. (:1' (~ • \Hf>..tni. M.ant..f.K't..:;,r:k: l. K.H'l"'-'L"-C1f) Ml) n.J!.ll '\i;~ Jnd ~~;lc. i:i .. BuL1r<t {:~ '0~ !( o,IEMBER COMPA~IES ,, ' k, ',',,; : (U' f!~ I I :Jl,,ll'• I f 1: l'..: · J: Pr•"tlth.h ~ .h ' I '4, f),\ : ';lf"'C',:Jff' ... .~:., lfh ·~n~ -'-1\"'H'.:' :; (. •p:pq,tto t) il.i.H,.. It ....Oil !f)~ 'u(">("rh•r • .... ,, __ r_h,~r· .• r<'\.l De'''"'• ... r.r,.,, r _'H .<.4 -~ .. : · r1..: Jl f'>·; 'Ili-A:~ { ·\ -.:;: .... ..., -~·:,a~~_.,.,-..,-~L-...rn.; ,· •li" F'·:t .~,.;:too p .t j ; .:.: ~ ----------------------------------------------- ·---!r ......... -··~-....... 1.-.....,;;,..1j·fi¢=~~._....~.-...~--.-. -· -~ --=-~--=-== ~-~..!.-:·E:_ I--/~/~ ~~-· 4.t-=> e:,:._E.;;:.._--;-R-,.. [Q] PANELBOARD SCHEDULE PAGE__L_QF__j_ PANEL ~ PANEL \ PANEL ~A ·~R K I,"< G ------'-":j______ MARKING_ MARKING---------- OUAN Tl T Y _____ _ I TYPE NQoD SEg'viCE VOLTAGE~~4L~ ,-60X DIMENSIONS I ,-;:;--; w I D ~ i_.±± 1-::z..o 17~ MOUNTING D FLUSH L SURF. I GUTTERS ----, [ TOP l BOT. I AOGHT I LEFT I EQUIPMENT D GROUND BAR QUANTITY _______ __ DWG. NO. TYPE ___ _ SERVICE , VOLTAGE I i --------~ I ' BOX DIMENSIONS lf--H-.--1-W----,/-D-----l I J I MOUNTING D D FLUSH SURF. GUTTERS TOP j BOT. I RIGHT l LEFT i I I I QUANTITY ____ _ DWG. NO. ________ _ TYPE _____________ _ SERVICE VOLTAGE-------·--- 1,1 -----------~ BOX DIMENSIONS L H r w 1 o I I J MOU~~~~ D SURF.[] I GUTTERS ' TOP I BOT. I RIGHT I ~ EQUIPMENT D EQUIPMENT D GROUNDBAR GROUNDBAR I MAINS I MAIN LUGS FUSIBLE BREAKER ONLY SWITCH I~ ,..----, :---: L-J I I I MAINS I I MAINS -------~------4. I ~-M-A_I_N ___ L_u~G~s--~F-u~s1~B~L~E-~~ ~~ -M-A-IN ____ L_U_G_s ___ F_v_SI_B_L_E-~ [ I 1 8REAI<ER ONLY SWITCH !BREAKER ONLY SWITCH I : I! ;----: I ·,, n, I i !l c: Lr---,1 I i : • I I i ··~ L__j AMPERE \50 RATING FRAME Q2L ' I ~ 'I , I,; AMPERE ------i : ! RATING I ------=====---===~-~ i j I --- AMPERE -i RATING I I FRAME I •u.L. AI~ I CONDUCTORS I MAX. SIZE _AiorCu 1 LOCATION D BOT.[] I I TOP i •u.L. AIC tO,-~ CONDUCTORS MAX. SIZE (\')~m:.tn AI or Cu LOCATIOND ~ TOP BOT. ~ I FRAME 1 •u.L. AIC CONDUCTORS MAX. SIZE AI or Cu LOCATION D BOT.D TOP BRANCHES I au.n. """" ,. F,.,... •U.L. AIC BRANCHES BRANCHES au.n .. A,.._ !Pole F..-•u.L.AIC I I I i I ! I i i I ' ! I _. i I ' : ---I I I I I i r I : ! ! i I i I I ----i I I I ' l I ' ·--- L----------------------------~----------------------------L-------------------- NOTES: P8A PS. :~·~:.LISTED INTERFIUPTING CAPACITY AT SERVICE VOLTAGE lAMS SYM. AMPEAESI 11 54 750 j rr~ · ~~·1 ·· ~r-n' "r11-·--1tt 11 =r ~·~~ Tolm ~II~, I II m ~ Soll•'-""'~11 ~ 11-~ -~- :: ~:11 I II A • c r r •• t -·--.. . '"' ,,.. ·.f Con.c.,..lr1r KO Du .. DuftHlltona ~ TYPICAl &o• WIJH INTERIOR 306 1 •t 7,!9 ] .. --. . J.Ofi 1 31 rl ... , '•I U lwo .., r 0 r , ~....-COftC""'Iflie KO --I t --.,.-L -g .. ··"~ u... ,..i. . .• ·/! · ...... '~ ' ·.· \ '"!' -~--­ '1' • , .. 2 2 .11 \ I COIV"'trll[ fifO t 1(1 , f , 2 )· ) l ,) Conc~lrtc: KO lYPICAL ENOWALL INCHES -~ ... Refer to DP Catalog Class 1630 lor addiiiOflal informatiOn. NO I I ~~y i '}Ill Ne .... l1~11ng RFVISIONS BY DATE: l r -===-==----o 0 H ~- ~5 75 I 141 .-j JYPICALBOX SIDE VIEW Ma11rmun1 Mr\ln Bre&Mttt Ampe1e Ratong ?25 102.02 H 02HI -- 225 1KA,KH.1KJ M;~rr111u1n Numi'H'I ol (•H"tr•IC. .10 42 ~· lO 4? ~-· PRA 11n: NO Tf <; I J I I I . t ' ', II ' I 1 I ' ' : ~' .I .. • r J! j( n ~ 1 ~: ,. "·II~~ •. 11. 1 . ~: 1 ,, ! 11 , 1 •. 1 11 tp 1 ·I tl. II· , •. •• l--t l I I MAINS r.~ .. , !•'l•,tn·l (J/1 ~ <\1 ~ill 1~.1 :'."•>\ I. I' ( 111flt't~ Still t!dt) 1111 1 llj)ilt'f 1JI ,tltJ/Itltl\:111 '/vi! I' ORANCIIFS·';.i'"'"'litol"'i''"l)ll. dn<IUI•I'. I ,,1 .. • uu .. nor.., I I ~ puh 1 lttt•ffiLti lti.•·j/tt!\11 ,·111 till hl!'d~t·ro.., All l'1 .111 I. dii\~H·rP .,,nqlt> 111d·· U()" tut•dkt•i'~ .\11' ltJ.Uhl·d '~:.1 • r~IHl ;He lJl ll',h~d ""' ~lWtld1111q d11ly ( ll('tH1 tl!t',tht·t flu<;.t\lodo, ---~M fi!~ BOX· ( Oilf' IJ.lll'l' ljdiV.llllll•<l •;11'!'1 ' ~-I ', ... , . ' . ' 1: "' c c ~ ~ <II -~ __ , l_"l TYPICAl FRONT 1 •--Flue~~ -ling 2:.~o ___ 1 ]•·S..toce-llng 2~;)2·jJ ~ • '~ w 'D J ~~ 7,, -I It I 6 08 . J r , . ., 'o.:;' ·i I 154 -11 d ·. ~ Coo<•••" ~ Door Htn~a I ¥PICAl MOUNTING Of 00, 008 BREAKERS --~~-1 A I A -T- (' ,., lllrll IN mm '"r IN fT\01 4-lr)t) 1 l IH 'HJG ~· .!9 R8 IOIJ J990 1(113 'JIJOO 1?70 15 00 11.:1 45 88 1165 44 75 11 J7 ">600 14?? 5100 ll9!1 51 1111 1318 ')() '~ 1~89 44 00 1118 J900 ~· 39 88 101] J9 !10 101 j ·,o ,.) I •no 4~ 00 1143 4588 1165 44 7~ 1137 "6 00 1427 5100 ll9!1 51 88 1318 !>() 75 1289 NOOD PANELBOARD L "' ! . . , .. ---· FRONT· ",J{ HJ() II/\('" {'l)ll'~lt\11 hill I ·NIIIl I Ill \I,.'" I lfllll '-;('lf•W'~ ,tf;(j d1,:11 llltHJf>~, f IUI\1 fHifl Ji'lllil\ d•l• •· .. 1' lht· diJUI lot kt~d 1 ir,,,. hdkf'd t'ttdfll"l lnll'.ll , ... ,. 11." PI JSIII~d I lVt!l ( It• 'II It'd pi\( ,.,pll.lltlt•d '-,It ·t-1 LOCK: f lto·,l< t, .. f ""111 '""·.l~t·tl •i.lllllo .. ,·, •.1•·.-1 ,. , t'tH~tJII f-J~;t{ /',1 kf•y I fl,liHjt' . T , . I,., ; ~ l I~ I >. f' > / '\ ) '. I ' _I \ -- > • , I \1(, (d \I u u I.' .!';o L'tJ .' 1~J • I . ' ;· ~'V ~) 1( i v I! ,, I' ' ' I j, I I I: I r I s I' i ( I c I 'N I I l L • .. 1 ( )\) () I I'.'J ,'! 1jl • I ,'1 I II.'J ''li•J (tt,,,r, fJ lo'J l,'t,'\iJJ 1 Yr'l( Al WIIU'li, DIAtiHI\M', I> (hml, ~flll'' •,r,r• "' C(\J I (IHllltl• ht•l' ,! (!It l .. p f o•e•l 11\<illo<" I,.,., I"L' f ,., ... ! Hnllo1111 I' • •' I ~. ~ ' . ' I . 1/.ioPII,I,Ij• IN 1 IIUH j If~ tlllll !IJ j 1!1"' !tl IIlii> I . l I I ' .. ~ 1 "' I"'" I ... [''I "' I~ 19 J:'', I ( 11•:' \(Mlf..-11 ~ t .l.o r'f''. ,lrU1 fh•or!•.l' ~~~ l_:_l'_~~j__:H !?~'l:_~ I '2 (l~, I '\i)f·, -_j - -~ ---- 10or 3v1 22~ Ampe1e Maximum Matn Breaker NEMA Type 1 ~~~~ 5~5~"~:'~"~" COMPRNY 2(r W1de Enclosure ()'w'Jt, t ~~ ) PBA-507 .... hould be re-la~pec 3s a l 2 ~: ~ ! r::: CJ hours GSage !r srder -~ 2ress~re s ~·u~ :amos ~ave a raced life cf ,vJC h~J!S. ~sling on ana aff ~ill Gs~aliy -~~ · -3 e :~c: ::'~d of ::he lamp's li f::. Re:< .. ace B'IJ ··· rrl """:~:;: C y ,., six In to ~revent ignitor liq~tin __ tG ~e tested for ooeration (o~ months ard a record ~ept of tnese orc~r :o te effe:tive, the test should removal Jf normal A.C. power to the to ll hours. (See attached information) TURRET INDUSTRIAL 20~ UPLJGHT • 2 OR 3 LAMPS • RAPID START I AF240/340 FEATURES /)~---_----,, Available in 4 · and tandem-w1red 8 · lengths / " -• 20% uplight; ~3"' sh1elding angle wtth T12lamps f/~ i /;::::, , • ------.___ • Cte-emoossec reflec~or construc:ec of heavy-gauge .~?:'/ v~ '\ ccld-rolled steel-white enamel nntsh standara. · · · '~ p:)rcetam fin1sh optional . '. :.:~. //' ~~.,., • Pressure-lock tampholders enclosed !r'l snap-<n //' /~-? / // I / turret hous:ng //>~ ~?" /// // • For unit or row tnstallation. surface or suspended . < ~;///;~ / \ / mounting .; ·-~;~"' ,/ \ • 6" lamp spacing standara on 2-tamp models . · .;.·/ ~ /~ • Reflector aligners and channel connectors fumLShed .. ~::: · .6 ~-" // \ • End plates available-order separately, one pair .. <:::::< ,.,_ ,1\/,. , per fixture or row ---:::.::_~.' / SPECIFICATIONS Ballasts ./ Thermally-protected. ~esettlng, Class P. HPF ballasts standard. Sm .. nd rattng A. CBM/ETL cer:1fied. UL listed. Advance. GE or Umversa1 :nstalled uniess otherwtse spec:fied. Wiring & Electrical A~•\1. iFN or THHN ,.,nre :..sed througnout. rated 'or required terr:oeratures. 3-lamp moaels: Center :ampfs) connected to se,::;arate oallast-facllitares sw•tcn w1ring for three-levei ligNing. Input watts (standard) (energy-saving): AF 240 (95) (71 ): AF 340 (748) (112). Materials Metal parts die-formed from code--gauge steel. Reflector sect.red by plated turn latches. Finish F;~~e-stage. iron-phosphate pretreatment ensures superior pamt adr.es1on and rust res1stance. Channel and reflector fimshed after taonca110n wtth electrostatically·applied polyester powder • ena;nel {85°/o gloss, 890!o reflectance). Salt spray test 500 hvu~s. hardness mtn1mum 2H. UL listed and labeled I.B.E. W-A.F of L Fi xrure guaranreed tor one year against mechanical aetects m manufacture. "t~~ OtA. a.o. m 1/a • ""'-'"• 0(21 2 • Ol.t.. ItO. /1~ · Dt.t.. l o. I --:--~ -~--·~·~4-;-1 '....-l t,;-= . " . -· .IQ -)!,,. -- 4'•--·---12-- 10 --------.. ----- '"'•" Ot.t.. K 0. '11o'OI.t.. K.O. r~'! ·-----r -13 ,,. -- 99••..,, J 11•' OIA l:) >;jo. OIA. ( 0 ·~ -J -J - 13) • MOUNTING DATA For unit or rttN tnstallanon. surface or suspended mounting UNIT INSTAllATION ROW INSTALLATION HC 2 hangtng devices 1 hang1ng devtce per ~xture required per fixture plus 1 per row required HRUN (~;;I ' . ' i " ' ' S~ ACCESSORIES on reverse stde *or other hangtng cev,ces Approval -----..... ~----information A v../ ~'-<,\ ;.....~A ;if t.le_ ~ . ---------~ -- f ~J./THDNIA. - AF240/340 TURRET INDUSTRIAL 20% UPLfGHT • 2 OR 3 LAMPS • RAPID STAAT PHOTOMETRIC$ AF 240• c;QEFf'!CIENTS OF UTILIZATION ZONAL CAVITY r""'c :.... 5lJ" : : _..,., ' I ::..._ I • Siaruard ballast(s), F40T12'C'N lamps 13200 lumens) Spac1ng cn:erion: 1 5 x mounting he:gl'1t Full •eourt available. c;equest ITL 1e288 For pl'1•;torr:etr:c.s on otner coniigurat1ons. see -:-~:1r . .;ai Data sect1on or LJthcn1a representative I t!""Z..l '-~ ' I A l. / 4IIIU I AUlllfl ; I :.n.~ •::.:."'1 :~7 I ~ I ·n, ''ffl ~ I !&' I ! ;;-· ~i ug ~s ?3' "l lO 95 /!) 105 ., ''5 ''i!l '?5 142 1JS .)25 1<.S 002 155 458 165 49() '75 51• ·so i2? ZONAL LUMEN SUMMARY .,. AC!IIIII ·~I •ni 'J:l' 1334 :: I 1345 tlool; 'l27 ! 'J10 I 'CliO I :14 8115 i!5.l 59'l ~ J7j :!7 I 3' ;!() JS ' l5 52 5:l 1)1 :11 1J) ;O? m 18J xs m ll5 m 415 J/4 J77 054 I Si3 510 ~27 517 ORDERING INFORMATION Example: BTAF i PO 277 is L /---..,~ I For tandem-wired double-lengttl AF I ,_4o II I unrt. add prefix 8T. For in-line winng on tandem 2-lamp models. add prefix ST and suffix TIL W Series 2 or 3 lamps (not included) Nominai40W (48") REFLECTOR FINISH S:andard f1n:sn s wn,te enamel. Insert PO lor :lPtiOnal wn1te porce1a1f' FIXTURE SCHEDULE TYPE I CATALOG NUMBER REMARKS -/4--·------. v..../ &xcQ (...Ui:_ .... ~ l~ SHEET AF 240/340 VOLTAGE 120 or 2n Otners ava11ao~ons-.~11 factory OPTIONS ES E oergy-savu>g ballast!> PI Pluq-ln lsongle<lrcudl PIRIP18 Pluq-ln (two-cltCUrt) PL P!vg-ln Plus (!!'lree-orcu•ll EL SelkontiiiMed emergency •oqn~u'Q GLR Internal faat-i*lw tuslng iGMF for Slow-()iawl TILW Tandem •n-ltne ww.ng SW Str~ch-Wrap (pelleltad '" ca"""") For uetaots and complele I~ of opctCns. -OPTIONS AND ACCESSOF!tE S sectoon ACCESSORIES 1028 MRUN HRUN1 sa s .... ~ stem nanqer I spec."< 'ltt"qtt: F~ delaus ~o :orr.pt81ellst ol ~essones. see QPT10NS ..:.NC ACCESSORIES sec1ocr, f~L/THDNIA :._·r·-.. ~~ .N ,_:, It_. ~HCII.,j-,~ ... __. ..... ,..,, "Sl_" A.-~ -,. ;{ i~:, ~E~~~-;-..i-~ -:;-.-::·:~7 • .16..: ~ 35 -Wallpackette · Wa!l-:nountej; HPS. merct_;ry anc 1rcandescent: wide-spread distributJ• How to construct a catalog number for Wallpackerte -Applications -:-r"s se•,es ts raeally sur:ec tor oewne:e-· ~ ... __ arcunc rnous:roa1 plants. wal~. ~;ays ;;a7,. ~; ~a'" 10adH'9 docks. cJnderpasses. tunne's or :o-ne: ,, w"'ere htgh per1ormances and m'""'~t.r:--n,.,,.;, are reqUired. ·- Advantages Lum,na11es are compact hea11y-dut1 and weatr-.~· reSIStant fixtures leaturu1g thermal snock •es s:a-- pnsmahc glass refractors n·,e refractor :ro·,,oe~ w::Jes;Jread l>gh! d>S!'IDutton proauctng ex ~e; e": co11erage allowmg spacmg up to 5 ;:mes ''le mounting hetght. Choice of lamps and wattages: ,15. 50. ~ow HP' 100, 17SW Mercury and 150W Incandescent. · EXAMPLE: t WP ~ ~-, 070HP, -~ -, BZ 1-,'---F;...;I_-....;P_,, 1 2 3 4 5 6 7 Step Catalog no. Description ----------~------~--------------1 lum;n<ure WP 2 s,ze of un1t 1 2 3. 'T ·;pe ot .tJ, er•t'Y 8 4 SGurce anc 035HP w,;::age ~ Lam., type Watts HPS 35 50 OSOHP 050HP '070HP 'tOOMV ~7SMV 1501N Wallpackette 150W .ncandescent, 35W and SOW HPS (120V. NPF only): med1um base only All other Nattages Standard entry over box Lett s•oe conduit entry 35W h1gh pressure sodtum uneo.um basel, ol'\ly ,, stze 1 (120V,NPF only) SOW high pressure SOdium (med•um base), only in size 1 (120V, NPF only) 50W high prnaure sodium (mogul base). only In &ze 2 (120V, only) 70W high pressure &Odium, only in size 2 100W mercury. only in size 2 175W men:ury. only in size 2 150W i~nt. only in lize 1 0 w (ins.J (ins.) 6-1/4 8-1/4 6-114 8-114 Step 5. Voltage Catalog no. 12 20 24 27 ·MT 120voll 2()8 voll 240 volt 277 volt Mutt1-voltage for 120 through 277'. available w1th wattages 1n::1:~a!ea aoove: also see opt,on pa~e 1 1 6. Color BZ Bronze patnt fin•sh GR Grey paint fin1sh 7. Options-See page 71 for availaOie options. .,-,;:,>:::- 1 1 •- £ 1 ·.:.-~:!.._-.... - ' ' \~' -·~ ·.·~_...~.,.. Fixture s ' nel Wl tr 8sJiat typtl lbs N p NPF 8 $ -8 -~ 50 70 .. ----- "Q" WP1A035HPt28Z1 ''Q'' WP1A050HP121JZ1 WP2A050HP 121JZ1 "Q''WP2A070HP128zt 8-718 8-718 10.112 10.112 6-1/2 , 4-114 /#IF 17 6-112 14-114 /#IF 18 MV 100 ~75 INC 150 ,Q WP2A 1 OOMV12Bzt "Q"WP2A175MV12Bzt "Q"WP1A1SOINBZ No tea 10-112 10-112 8-7/8 6-112 6-112 6-114 14-1/4 CWA 17 14-1/4 CWA 18 8-114 6 For options and acceuories, ... page 71; for replacement parts, ... pag. 179. "Q" Ct.•clo:Ship rtem. see page 4 for deta1ts Ava•lal:lle wrth 120V only. Ava1lable lOt 120, 203. 240 or 271V at !he sa~ pnce: tor 2:2CN 50Hz. cont8c1 HOiophane or yo;;r uJSl''t,;r·.'' F t vVa:1pack · and Underpass Luminaires ;-lt:av·: .:;w:y: hiJ and .ncandes:e'"l:: w•Ce-spr'=ad distribution grey ;Jaint fin. ..=i;..;l!ooo=""""~~"' T 11·7·8 Choice of lamps and wattages: 70. 100, 150W HPS, 175, 2SOW Metal HaltCe, ~75, 250W Mercury and 300W Incandescent Applications Wa:loac• :s a heavy-<juty. rugged "'a''·mc.,"''• lumo"'l3Jf€ 0es1gnea ~or the narsn I?~'¥ ... Qr ,T,~n; w t'1dustr;a, plants. parku.,g garages loao•nc c:x. roadway unoerpasses 0' fer any apphc.:;~.·cr, ,.. pe'manence ease of ma•ntenance and '"''<;"· ""' mance are requ~red. The :ntegral ballast nousmg <S anac~ec :o tne lum•na~re. but •solated from the lamp hous•ng 1: keep ballast temperature low. whtcn ma.,~1 zes ponent hie. Advantages Precise, w•de-soread IJght d:stnbulto., pr:Kl:.;c~. , ce!lent area coverage aHowmg spacu"g to mwn· height ratios ot up to 5 1 Fu;~ld adjustal:lte we~<e· results tn maxtmum output at etther 6{)0 or 7')" above nadir. Tne alum1rtum v•sor may be remove· d1rect light onto ce•lings .n covered areas, suet• a: parking garages. Underpns lighting An underpass version of Wallpack utilizes a priema1 refra.ctOI' deS•gned to. redirect glare producing 191 a-y from the .,driver's line of sigh1 wttile spreading the ltgh1 acrosS multiple lanes of traffic. How to construct a catalog number for Wallpack EXAMPLE: WL 1 K 070HP--; 12,--F1-U Step Catalog no. Lurrunatra WL 1 K 2. Source and '070HP watlage • 1 OOHP '15AHP ''58HP '175MH '250MH '175MV 1 2 3 4 Wallpack 70W high pressure sodium 100W high pressure sodium 150W-55V high pressure sodium tSOW-1 OOV high pressure sod1um 175W metal halide 250W metal halide 1 75W mercury 250W mercury 300W Incandescent Step 3 Voltage 250HP' 12 20 24 27 48 'MT 250W high pressure sodium lor use w1th remote ballast 120 volt 208 volt 240 vott 2n votl 480 volt Multt·vottage lor 120, through 2T!Y available with wattaQM indicated • In Step 2; a1IO ... optiOn pege 75. 250MY 3001N 250MH 1 175W or 254W mercury or metal halide, lor U8ll with remoce ballut ... OpltoM ... ,... 11 ... m' "* ....... •' ,"\-' Lamp type Watta Luminaint catalOg number HPS 70 WL1K070HP121 . .A==== ~ . 34 100 WL 1K100HP12ll ~ HPF · ·· ~-. ~"\.r, • ~ 34 · 150 WL1K11AHP1Jll ----·-. : i ~: ' .• ~.':.!.~' 38 ·. ·~ { --~.~tso _________ WL __ 1_K1_~ ____ 21_._:~·~-----__ · ______ ._H¥ ___ .4~·--·~;~~:~:~~~,·~:~ __ .~~-~~~-~-~~··_.;._._38 ____ ~!~j0~ MH ~ 175 WL1K1~121 · ,..,.I.MII 32 '250 WL1KHOIIH1Jll. ,....I.MIJ I '• 38 e MV INC 175 250 MVIMH ~ 75 250 HPS 250 WL1K17111V121 WL1K250MV121 WL1K3001N WL1K250MH2 WL1K250HP~ NotM CW-'1 32 CW-'1 32 18 IF<:¥_,_~ 18 11'<:¥-o-. 18 For options Md acceaone., -pave 75; for ~ petta, ... .,... 111; to# ~ .,...... ·~bly, -r-ge 75. FQ( remotl biiiUI units. Of'del' ballast separately and do not indicate \IIOI&IIgll in flidure part number. z Avattable !()( 120. 208. 240, 2n. or ~vet IN NI'IMt price; tot '120V 50Hz. cont.:1 Holophane ()( ~ O•S1riOJtelf ...... a .... -------- Cla$S I, Div. 2, Groups A,B,C.D Class II, Div. 2, Groups E,F,G Class 111• V-51 All Maileable Y·51 Enclosed and Gasketed Incandescent Fixtures. All Fixtures Surtable tor Use in Wet Locations. catalog Number· Size (Inches) V·St All Malleable All Aluminum 60-1 50 Watt A21 1!2 3/4 1·1.'4 150-300 Watt PS30 1/2 314 1-1.4 With Guard' VA1050G VA1075G VA1100G VA1125G VA2050G VA2075G VA2100G VA2125G Ceiling-Five Tapped Openings Four ctcse-up plugs. 60-1 50 Wart A21 1.:2 314 150-300 Wart PSJO 1/2 3;4 1 VXHA1050G VXHA1075G VXHA1100G VXHA.2050G VXHA2075G VXHA2100G Waii-JB Box Mountlnst Fit5 JB cast box. Order box lrom Cat. S.C. A. Screws and gasket lurntsned With fixture. • 60-150 wan A-21 150.300 Watt PS-30 JBWlOG JBW20G With Guard' With Guard' VA1050G-M VA1075G-M VA1100G-M VA1 125G·M VA.2050G-M VA2075G-M VA.2100G-M VA2125G-M VXHA1050G-M VXHA1075G·M VXHA1100G-M VXHA2050G·M VXHA2075G-M VXHA.2100G-M JBW10Q.M JBW20G-M VA10SOG-A VA1075G·A VA.2050G-A VA2075G·A VXHA1050G-A _ VXHA1075G·A VXHA10100G-A VXHA2050G-A VXHA2075G-A VXHA201 OOG-A JBW10G·A JBW20G-A j., ( (~· ( - t----:·~---· Ceillng-JB Box Mounting Fits JB cast outlet boll. Oroer box from Cat. Sec. A. Screws and gasket turmsnea w1th 'ill!ure. 60-150 Watt A21 JB10G 150-300 Watt PS30 J820G JBlOG·M JB10G-A J820G·M J820G-A 'See page 4 for :emoorature '•mtts Jn ;ndl'llduat V-51 fixtures To orcer fixtures WI!Motlt guards. om•t G sulb: trom catalog numoer. Orcer 'e!lectors ancl accessorres separate;·, pages '8. 19 and 201. t30' Anq;e rettec:or adaptaole ~or ~00 Wart fixture oniy. when mounted at :eas: .1. ~ 2" '"om wad Discount Schedule UD Refer 10 :::>-:c,n.;; tncl!n tor t=.r.ce "'e•gnt. and s:a,.,dara ;::adage PAQ£ 14. £:11!!<:'·•., :~8C 1701 W Ne11 ><gtcn -\•,tJ Cn:cago llllnc•s 6C65' -'le F-! CO emergency ligfit- '9 umt 1!; a reliable and r.1gged 1ndustrial grade :.. r:1t. The 6 volt LEC-36 ca 1- c um battery :s permanently sealed. maintenance-tree .1nd has a 7 5 year warranty. t,pplication ·~--e.=~·~(~~ S\NICe~y,.4·sed n·~c::."es '~:_.s: ... :cl [~·Jnf:::ie.'<~S. nL.c:ea~ = J'.v~r : ·~:·:s .li J ,.,~·iJ~ar'1 ,,.~s~cilat~crs l)peration ----------~-----~---------·--·--~~ ~~-~: n~ -------~;_____2P~Ji_ __ ~ ·---~~_?~7__- •' >>~· .•jlt<;: ........... ;J~ ./ .. , -----···---~------~ --------·----~-· ·- -'2~ .. 2-...~ '"='~ --~~---------~------=----~ ·----~---~ Case ·:~e 2C gauge steel conta1rer and 1 a ;ac_;ge steel door are coateC w1tn an :c:d-res1stant :;vay fln1sh Lamps •,,, • ,., ,.,...,~-::! Hour<, .... ·-~·-• r•,• -l . "ltaqe 115 . -·c.. '2W ':=---cease::J ·erro:::; .::aoat,, .,, usE- . :.:":: H 'am::.:; Charger --·~ s:d,,·j state ~e'Y':J~',J~·J:~ ~ ~r;;C'?'~­ ),;:,::d :-:h;~"'_Jer rest~res bnt~er,, ~c • .... :1 ~ r 1.'! r ~ '=' 'l_, · t ..... I rr • 2 ~"1 1 ~ lJ; ) (..1 t ~ t~· r j ~. ~ F-100 · .:c .va!~ ·'Jcc _:.·.·~ :a~:er/ \'C:.ItJge J~--c :L-: s ~:CJ'•Car::: ·: :::revent :je'?c: :CIS- .-=:t·\~r~-=-:.:Li'"~r.g ~-l\:C,..,·:es 00~'8'" ;J.'Gr.:: Br ~ NnGL.t :Jr::tec::c:· ·s stancarc~ r .:oc:er- ]enc. :1c;;:--:s c;re ::c::•iatec ~me" .:.c 1ne ;rJi:ac;;e :::rc;:;s :::e::;·:; 85 vc1tsJ Dimensions .ol.pprcx1mate assernbled .ve1ght 42 :bs. ( ~ 9 K_gl Note: ,\ !!h S-_:;~:: 'le1g!lt J1mens!cn s i 6 r..! ~ ~:M) Indicator Lights. Test Switches. and Voltmeter Thp u,.,,t has a-: r'ternal readytstandb·1 s.v,tc:7l. a fronr-r.::;_,n:ed press-to-:est S'o'lltc~ 1cr qu;C·, ·es·,ng r:;t lames :~nd :;:;r:e:-; 2 reaC, :,;~r :1 red i1gr: .'lOI- ~.Jt.r .; 'e:st -:~a·::;e •J:e anc a sra1~dar~ trr_:·l't ·1~Uur1~t~1~ .· ~ ~';·.l:!t~r Features Battery T~:a ., ~a ~·'?"2''C..c;-··ee 1Jr: ~ E''"~a: ·: :' ::.-..-, ..\.(= .r[J1_ -1;~~ =~e--,..~-·<;;·r:~ ·F.·;:~r­ ar~ ... e ·-.::r.·:c·~r·s:::.:~:CJ .. r--~rqe: L..::w .~'tee;;=: 0<:::<•: c:r~te,::!:·::· Tt-~ cr ~:: s 3 ~-·=t:1 1 rS -~-= ~ sealE<: IP2~:-~~-~:.~~ _.:.! = .... ·-~3·<~Y :;: r~ :-::-~:~erl n 1~ :1 _:s a ......... c-=-r..:-,...-' _<lC:>Y. ~-~ c..: ·>::~as .-·;a •,\,at::-· r·.r;; .=· ~2 . ..-..t~:-..... ar.~e d'w; :nc;; <tS ':IF Ordering information ~="m Jpt1ons a.ad sut1x rc: .,., -~de! ~ L.mbE as rec;u1red Examole F-' ·JG-2H (2H~ 2:S starcar:!! F-'OC-2S t2S2::6 cc:,cn21l See . .l..ccesscr:,· Sect1Gn lor _,cjCI: ona1 o:: t1ons \'/.'len order•nc; reCldCemer-t Oattenes tor the F-~GC .iSe ~~ty 1 -'-::·:-36 P ~. 2~ ., 12177-:Jc Warranty The=.: ~.:o s ,.,ar·a··rec · ~-.Pars T...,. L..E:-36 !Jatter.' r".as :.! • ~: • ~ .. -.: ... ·NJrr'3r"~~"' 3 ,e3r •·-Jil an:~:= ,':?.1r 2r----.. :!e~ --,_ L-- .;:::,1 f E~ectricc: Sales 215 S. fli';'J ~A Y SEATILE, WA. 98108 {206) 763-4010 L POWER CORPORATION A layman's guide TECHNICAl SERVICES BULLETIN IJ0765· B Aug. 1985 to emergency lighting battery maintenance Codes and common sense call tor the installation of emergency lighting. Equally important: The National Electrical Code and the Life Safety Code requtre pencd1c testing and maintenance. With a s1mple maintenance and testing program you can ensure you will have light wrH;n you need it. The battery IS the biggest variable in the emergency system and perhaps the most critical. It tS your power source in an emergency. Batteries are not immortal. they have a finite life !literally they begin to die the day they '!remade) but there are a few stmple actions you can take to lead them into a graceful and useful old age. WHAT CAN I DO? In a nutshell ... exercise them regularly! (We'll cover more on this later.) WHAT ARE THESE BATTERIES? There are five general types of batteries commonly used in emergency lights: 1. LEAD ACID 2. NICKEL CADMIUM A wet ::::ells A. wet cells B.· gelled" electrolyte cells B. sealed cylindrical cells C cylmdrical ·pure lead" cells Most of our d1scussion will be on the lead acid types, since they are the most popular These batteries are rechargeable storage batteries. They store chemical energy and release 1t m the form cf electrical energy during discharge. During chargtng the chem1c ' process that produced electrtcity is reversed. thus putting back into storage a new ·su~H ct electro·c hem teal energy ( Th1s 1s opposed to the common flashlight battery which tS n , rr<.h::Hgfable s,nr;e the electro·chemrcal actron cannot be reversed.) 8edu·= nc:; tr,e c::.:>'"'cc:;:t to Slrt;p!iS!IC te~ms: The stor3ge ::>atter; IS a bucket 1nto ,y1,ch nJJ pour eiectr,clty ltC],s IS charging; Later 'fOU can pour it out (this is dischargmgJ How fast you fill the bucket IS a funct1on cf 1 ne charger. Hm.v long it takes to err.ptv the bucket is a func:~~or. o 1 how fast you pour :t OLCt 1how m'JCh load ;ou put on). and how much you actually Pld '",·,vas 1t fully chargea to ava1lable caoacity'~l But there are a couple of JOKers in th1s deck: First. t~,e bucket leaks 1th1s IS natural sell-discharge ... which 1s what happens to your e:;ut·~ batter)! 1f you oor.·t run the car lor a iong time). To compensate for this leakage you r.eep tr1cr,lirtg 1n electricity (which 1s "float" charging). Second. the bucket actually gets smal!er. Suppose the inter1or of the bucket "corroded· anj serJm~ent from th1s corrosion fell to the bottom of the bucket. tak1ng up space that fcrmerlv held water. But you can do something about this: If at regular intervals (before the SP1j1ment so;idifiesl you dump out the "water" you will dump out sediment with it. thus regc.t~nmg capac1ty. (Th1s is not what is actually happenmg inside the battery battery chem1stry is much more complex than this ... but it gives you an 1dea of the net result.) For the more technically minded: During discharge the lead of the plates combines w1th the sulfates of the sulphuric acid electrolyte to form lead sulfate. During the charge cycle the sulfate is drawn out of the plates. This sulfate displaces active plate material and reduces the electro-chemical potential of the plate system. If left on the plates the sulfate eventually become~ chemically meversable, reducing active plate material. Batteries will loose capacity even while on float charge due to internal chemical action between parts of the plates themselves. The sulfation process can be reversed through penodic equalization charges. and since you don't want to over charge batteries you need to discharge them before recharging ... this is ··exercise". - Battery technology 1s complex and there can be many other factors affecting battery ide and capacity. but sulfation is a primary factor 1n loss of capac1ty in emergency l1ghting batteries. HOW LONG SHOULD A BATTERY LAST? Many factors affect battery life. such as depth of discharge, ambient conditions. number of discharges. But as a rule of thumb. in float serv;.ce you can expect the following: TYPE LIFE Wet Nickel Cadmium 25 years Sealed Nickel Cadmium 15 years Wet Lead Acid 10 years Cylindrical Lead Acid 8 years "Gelled" Lead Acid 4 years But this does not imply that you will retain 100% of capacity for that full period. One manufacturer of gelled (dry) lead acid batteries states his batteries "should last four or flvf; years before the capacity drops to 60% of its original rating.·· And only one manufacturer ,-,1 emergency lighting units (who provides over·stzed batteries) is willing to warrant that h1s un: ts wi II prov1de a full 90 m 1nutes of light for three years 1 WHY ALL THIS EMPHASIS ON CAPACITY? Because the codes mandate a run time requirement for emergency ltghting (usual 1 y ')rl rn1nutes). When the unit was certified by Underwriters Laboratories (with a new battery' 1' operated for 90 m1nutes or more. but willtt continue to give 90 minutes If the battery capac1ty is now 70° , ? HOW DO I KNOW HOW MUCH CAPACITY MY BATTERIES HAVE? This is a toughie. When you charqe a bat:er•t to fu!i voltage a ·;olt meter w:ii te!J .,.,..,!! · ':d yo•Jr bucket is full to the brim. but 11 doesn·t tell you how b1g that bucke' IS lt 'S pcss1ble but compl:cated. to make a test by a qu1cf.: burst ot d1schar9e at a very r1qh load and th<"'r' ,_,ompare voltage drop against known values tor that spec1flc batte~·. and th swill be an appro.; 1 mr1 t 10n. The s1m plest and most ace urate test IS to d1 scharqe the ba tter1•~ s for 90 rTnrutes .snd see w~1at happens . . do ynu stdl have l1ghP WHY NOT JUST USE THE TEST BUTTON? Virtually all emergency lighting units have a ··test button . which w~""'<en depressed put . ...,.: umt into battery operation. They are great for telling you if your unit is IJ',orking They are great for spotting a totally dead battery. But a brief push of this button will not tell you ho.v long that unit will operate. A battery that has lost virtually alt of 1ts capacity may st1ll ooerate the lights for 30 seconds or longer ... but this brief test does not show 1f you w1:1 have light an hour and a half later. CAN LRELY ON MY INDICATOR LIGHTS? The indicator lights on the face of the unit can have different functions depending on the brand. but none truly indicate the condition of battery capacity or life. Typically nne l1r,ht might simply indicate that AC power is going into the unit, one might indicate that the charger is working at high rate. and one might indicate the charger is at "float" level. And 1 1 there is a meter 1t may tell you the battery voltage at that moment. BUT MY BATTERIES ARE MI\INTENANCE FREE? Maintenance Free is a phrase loosely used by manufacturers of ··solid" electrolyte batteries. such as gelled cells. A more proper phrase is MAINTENANCE IMPOSSIBLE. The maintenance they are freeing you from is the act of adding distilled water to depleted cells Over a period of time the water content in the electrolyte can diminish through the natural charging and discharging action. You can replenish the water in wet batteries (lead acid rtnd nickel cadmium), but there is no way to top up a sealed battery (which is one of the reasons why maintenance free batteries have potentially shorter lives than wet batteries)_ WILL EXERCISING THE BATTERIES SHORTEN THEIR LIFE? On the contrary. it should prolong it. Batteries should be good for a minimum of sever.:;: hundred charge and discharge cycles. so a test every six months will not shorten lite. One caution: discharging a battery to less than 80 per cent of the initial rated voltage (for example about 5 volts is the cut-off point for a 6 volt battery) is considered deep discharge and can be damaging to the battery life. Most quality emergency lights have lo'.v voltaqe disconnects designed 1nto their electronic circuits. a feature des1gned to prevent deep discharge. If during the test the lights become extremely dim (barely visible) 1! IS a or,.tt, good bet that the low voltage disconnect has failed and you are 1nto deep d1scharqe th1s case immediately disconnect the unit and have the c1rcu1t board checKed. 'vVHAT KIND OF MAINTENArL:;E PROGRAM SHOULD I HAVE? I It should be regular S1x months IS 3 ~(JC:.J 1rter·Jal Na!1 nal Po.ver supplies rem1n•Jc:• st:r;.r 'S t~J te placed on your calendar .A. :,:cL:-to scheduie it IS !he end of the last :, Y • 'flQ 'lay ot the week. ensur:r:q an unoccup.ed buiidir.g '.\lhile the units are recharging ; : simplest way to conduct the 90 mm;... te exercise •s to pu' 1 the breaker on the -:--"r.enc 1 1r•:::u1t. nh1ch w1ll put a!i the units 1nto cperat1on at once. \\'r1G:: ycu are iO:J~,•:lQ for IS. a. Dr a vou have 90 m1 nu tes of opera t 1 on'~ n. if r '-'n1t has indirator lights for both h1gh and float ct1arge 1 \Nhen power was restored Old the tliQh charge l1ght ':orne .Jn? 2. 24 hours later was the float charge l1ght onr; If tt1e r11gh charg~': iiqnt remains on the battery IS probably being overcharged and is · drflnQ o,.Jt Th1s of water is irreversible rn "maintenance free" batter•es Iii Test1ng and rec::Jrd keeping are required by the National E!ectrrcal Code Art;cle 700.:1 .J• tne code states 1n part "b. Systems shall tested periodically on a schedule acceptable to the autnortty having ;urisdiction to assure their ma1ntenance in proper operattng condition · "c. Where oattery systems or unit equipment are mvolved ... the authority havrng Jurisdiction shall require periodic maintenance." ·d. A written record shall be kept of such tests and mamtenance.·· VI National Power suppltes inspection labels on which you can note the :nspection dates. Pc.Jt one ot the stickers inside each unit. ReqUire the maintenance staff to note the inspectton date on each sticker. Not only does this give a good record of the testing. but 1t also forces the maintenance staff to open each unit. which gives them a chance to make a visu..:;! inspection When the unit is open they can ensure that the terminals are clean ana trgnt And If the battery is a wet cell they can inspect the electrolyte level and add distillea water. if requtred. '. 1 . If dur1ng the test the unit failed to provide light for 90 minutes it is htghly probable that the battery has lost capacity and should be replaced. To make replacement simple. before •nsta!ling the inspection sticker note on the sticker (using the National Power Cross fereqce Guide) the National Power battery required for that unit. Also put on the st1cker the name and phone number of your National Power stocking representattve CORPORATION 1740 N. Marshfield Ave. • Chicago. IL 60622 • (312) 486-2776 ~t :;eaters Eac~ un t heat r is e~uip~ed w;th a ~ui! i~ th~:mc3 3t as specified. To heat the ou ldi~g .o ': desired tem8eratJre, tu::::r thermos 3t to tnr:: "high" settir.·~ a:,c let the unit run until the u~ ~res ·~~el of ~eat~ng is reac~ed. Tur~ thA th~=~~stat down unt!l tne Gnit shuts off, a0d le3~e tne thermostat in this position to ma~ntain ~~3: at ~his ~evel. unit shJuld be de-energized before working or it! I ~ EMERSON -Env1ronmental Products Type MUH Space ModTM Unit Heater Ooe un•t mounts either horizontally or vertically. -::::~ y .e·sa: e =)r ·accr es ,\ :=.:: -.:;-~:;.e ;:lra;es s:cres sr:.p:::;;ng ~s .:·J.ve o:a: ons a 'C'3": nan.;;a'S Car ~~·= ·~~ :r s ..... :.:Y:::~:r.er::a~'y se:ot or -:: __ a· ,s~e~: ~ea: ,....g • lv ::~ "3~ge :;~ oot or: a! C8;"'l~ro: i( 1ts are · ~ ~ a: e r:c:-eas r.g SP . .:.CE \1100 ..:.:::::;:_·~.::: ·• ·.-:: ·..-e s:::~: · -:~: C"'"' :ar¥e~ • =~·:e~ a· ~r· -ea'e' .v:-: 10 ::;ower ··:,..., 3 ".v :c 50 Kw "ea:·ng o:.;tnut "~J .::~-a-~.!.30\ 18230'o'70500 ;r---:-.J.:::: e I"T'cce~s \nc <Jee-::J ~c trv to •: " -e;;~ ~g syste: 'ror-7 8 or' 30 • -e;, . ~.L;e::; e-'')·;e::: s·ee -::;vs '~ :.~~·: -----.......,:;·-:; s~·. es • • • ::0 " • :: :-,..~ .... r.:-~e··. e~c: ~se-: Specifications Cot1101 .... ,., ll.tl-03-8 lillfj.G){ IIIIJ'.Oll _.Uii-0)-4 YU"'"l: ! ~L,;P'! ::.' ~ ,. .. ¥L~ -, ~ II.)M.;:~ 'ol\.t' :. : ijiL .. ·; .• ~- '" 30 ]2 3 0 30 lO "; J I .. i . r>~ i 'i, f; IT~ ~~ diDO! 10 2 7 ~ 10 2 10 2 10 l ., .. J . ' 2~ 6 :s l 2S 6 ?~ 6 ?~ 6 1-!_,_-_, Jces ELECTIIC&I. Olll Vlll!ap 2011 2011.((0 117 41!0 ... . " !!.() ;?08 20&740 217 481) Coii1Jtl Ill --2011 20111Z40 217 24 2C8 '08 '40 . ?') :• 24 i' 2' 24 ... ~&. .. :...· •. b.:~ .............. -... ...___,ll--~::. .. ..:.-:-:.--:-._ "''u~ .. ~~ ,;~-----~~ ~~ .... ~ • 1 or 3-ohase .v1rmg on 5 throug~ 10 Kw • 2-speec •an seiecto~ :;w,tc:-!25 :c 50 K.-.. 208 2.:tQV ar ;J 1 5 r\ w 208V JMS i fre1d mode! S · 'nterc!':angeacJe 1 • Ai.JI"'1il"lum-'•nnec copper claa steel sneatr '"'eetlf-:g e•erel"lt ,.,as onge' .JSe'ul :re :eca ... se or .:oc e .. sr"eatr :emceraL.re 3nc: ·aste~ ~eat ::·ss :a! or .,....,ocelS ~ .. ::, d ""'1,~ :: ::a·-:: .. :1r.~ --rt.;~e 3.:::-J· "'a~e r""'e3;s :i ~e,.......::--::·3·,....--= ::t ..... ,.~. ~ "':., ar.-=: 5 "'.v 205-2rv -a . .., . 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J! \1 c ?4 1-~ 11 lr.&C •.,. ~J :a z )l z 24 1• n 3 36 ; l6AO !l.l -~?l.L __ _;;;=-. __ _,?.::.'--·-'~"'•:...... __ :,a_,_a_+--''-'-"-----"'l&CO::::::.. __ ..u... _ _.___::.:__.--"=---..::_+-...I.L.-~-'----'"---+---'}3,.___ l,. '>ii :a6~ I! · :Ja : ){)() 1: fN J<~> ,, : 1e ~ :060 ·~ • I ;:;a.: •c : )liC " :; 1; s;; j• ~,. J ;:;t;J iS.~ ; !~ ;~CfJ .t~ ?J .. .• 24 1• )2 !iO a 2100: i'Oll ll' u• 201mo t&OOi!l 75 '' l• 30 ·~ ?100 2030 38' u• 4«l J&OO•!m . -~ .• 3• dt .~~ ~)" ... ... !l 93 l J .. " j . I . . ' ' .-~ i I( : i J• ,;; ·: ' ·~. \3' ~;.. • ,. ·~ "'· 1 J•.: -~ j~ -~ ,c.· ~3· 't ~.c~~J-,.-.• -.---.o-,-;~·-',J~~-,---i'O-!--?-~-.-----,,~----~l.~---~-4-.~~-,--~~~~--~,~~--~~~T-~=---~~~~--,~~+-~I~~--~2~&-r--~-- ~-~:--~~·:......-~~~----~2~~----~~~--~·•~o--~~~~~~~~~~~~~~--~~~~--·~~-+~~~--~~~--~~~--~--- ::1 :• J• :39 lOOC :.;,x il' ,;,-:31 .\(' :4~0 ., :: :1 . ,-;,. G~ .·:~ .'l ... a:: i ... , " ... _'"" :• J• .~1: ;:: 4 !('I)C :~~·; ~]· >l' ! :~8 :&O :~7~ .•20 ., I .~ :~ :• l• o;.c: JOG~ ~1).:-0 ~;" 5:6 • .:ac .:::~ :A;: "" -' : I '-'·;'"' ~{. ~ rc \il~~ ~'::-.! F~ .'.t·1'Jjtf. •·~1\ _,.,,If _'ai• ,. ...... ':'J' t<t J\4· J::!'f' 'J' ~ · ..tl~ ::r·~~ .,,. "'IOf ·c :vet~ l:· .:-·~ ... r.~~ ~·~·· ,,.,( ;r-If! ·:J .. I'!i•~ ~f.._, ·.:.tlf -~~~:""'\ '. ~ .. -/ -.1111"' <! .... ..-~-4 "'li~ "'' ;IW ""J~.:' ~""-* l" -~-~ J '!l'tf'' 1/0'' Jf! •• t I~EMERSON-CHROMALOX .... !!! Installation Instructions and RENEWAL PARTS IDENTIFICATION ~-~. ··~\ 'r ~·I .• . I '.C---....__~ .!;~-'1 ! : I \ . I 1-:' ~ · 1 I l ~~~· ~ .• ------' I ' I I I I I , ,c::::; I I L_·_,'--_"_' ._· ~_----__ ·_-_!_V_--1 HORIZONTAL MOUNTING Be sic MODULAR UNIT HEATERS CATALOG NUMBERsA LISTED BELOW "'Suffix "M" added after the basic Cittalog Number indicates that the Unit Heater is "made-to-order". • • Available with line voltage contactor Cat. No. MUH-05-2-MG Cat. No. MUH-05-8-MG t Available with built-in thermostat; Cat. No. MUH-05-2-T. Table 1. Specifications Phase Cct. No. Voltage (V) Wattage (KW) (¢) Amperage B.T.U. ML H 03 8 208 3 1 14.5 10,236 ML.H03·2 208/240 2.2/3 1 10.8/12.5 7506/10,236 MLH 03 7 277 3 1 11 10,236 MLH 03·4 480 3 . 3 3.7 MLH05·8 208 5 1·3 24. 17.060 MLH 05-2 208/240 3.7/5 1·3 18.1/21. 12,795/1 7.060 I\~ I. H 05· 7 277 5 1 18 17.060 ML H-05-4 480 5 3 6 MLH-07-8 208 7.5 1·3 36* 25.590 Ml H-07 2 208/240 5.6/7.5 1-3 27.4/31. 19.106/25.590 ML•H-07 7 277 7.5 1 27. 25.590 ~.1L: H-07 4 480 7.5 3 9 Ml'H'108 1 208 10 1·3 48* 34.120 ~~ L h i 0 2 202 '24C 7 5 10 1 3 36 114/' 25.590/34,120 'vii. H 10 7 277 10 1 36 J4,120 Dit!user Selector hbl" f~ Yer1ical Mounting •n~~Ul OIFFUSll 'tc. ~··• ... s.tr ~!f'G~:l ... ~t '!' J stra1ant oo•ntto,. l lf ::--ar~rm s PQu trMJ F01 m111m"m a1r !hro" :!- -no~~t .o uwm An-, or :tnee O•ffusers ..:Jft oe JCGt<l tCI :;)UiC 1tJ1ff AMUIOST&T DIFFUSU "of ·amtorf cnrlu!.tr F-rooucrs :1rat1 -'ree J•' ,ovement at low mounting ~e•ents floor covfl- age ~'-o"" '" til~le LOIA(R OlfFUSll ?er11uts du.cttOnal (strilt&nt unel au llo" as '" a11 •unatn appucatiGll ovfl ~oorwavs. R.ctan- eutar ·ov~o age ~OUVt'l CJn 0t tumt'l on .,tiler !N!Ctllln IWIIAl OlfFUSl.. • nrreases floor coverage Ad1ustable ions :n vtr· tiCJI moGe 1uect dowt~wara '" a t•ll'lf ;)anern CJnverse•Y . 4•tn t·ns are ttllec !o ~5· 1ng•e . 'IC.lr ");.friJt~ S. .:0 :o ~5°·o &ruttr at ·r ·J· ·;~~, . ., 1.-,'ftO..,nt ·~~ "~ftgr:ts Space Mod Dimension Data I U.OI ....... cata ...... ... ... '" 28 2~ 70 63 -•• • "':. .: • ' ~ -"' ~-,... ' • ".,_ Jj" "(~ ~ [<' . •• . 1' ~-• ~·~ r·.-·r . ')!-.i' -~ . i .. . . • MAO· II 'AAO·M 15 !7 35 £() • .. • - . -• ..j- '·• . .. •:~· . ' 11\J\-(0 111.1'-50 MAD·l IIAO-l ll.D·l 11..0 -l 22 20 24 22 88 I) 17 70 . ... . -~ .. .. ~; .--:-.r.~; .. :<~'--!'1-.. ;.:,. •. --·. :J:--'-~~-... w.zs M30 'oiU~JQ MU~-)0 -· IIRD-11 IIRD·M IIIRD·L IIIRD·l II ?O D zp Univerul Wall I Ceiling Mounting BrackM HOW TO ORDER ,'., oa.,;.r ':''':If-' r ':; : ,,.':t:':: '1 ~f;'? ·~'-'C A '/,":q 3 .;:; :.:-)•': -e-o.:t:• 40 45 • 10 :s 68 ·-!, ·-: ... r '.Jr: --.... -~ ...... !: --.,.., .. ;i .. ~- ·:r, ___ 1l 'Jr.-·- ..,_,,..,. . ... ., ~ 8 +++H 1~11:1~: 8 ~ (1----~A -B )· Bracket Size IMPORTANT!! FAILURE TO UNDERSTAND AND FOLLOW THESE INSTA- LLA TJON INSTRUCTIONS AND THE "CAUTION" NOTES THEREIN MAY RESULT IN SERIOUS PERSONAL INJURY FROM ELECTRICAL SHOCK, OR FROM THE HEATER FALLING DUE TO FAUL TV MOUNTING INSTALLATION. CAUTION TO AVOID POSSIBLE ELECTRICAL SHOCK, BE SURE ELECTRICITY IS TURNED OFF AT MAIN SWITCH FIRST BEFORE WIRING. ALL WIRING MUST BE IN ACCOR- DANCE WITH LOCAL ELECTRICAL CODES AND THE CAUTION-All BUll T-IN THERMOSTATS: IF THE HEATER IS USED TO PREVENT PIPING OR LIOU· IDS FROM FREEZING, AND IF THE THERMOSTAT IS SET BElOW •SO F., THE FAN MUST BE RUN CONTINU· OUSLY. SINGLE POLE THERMOSTATS (Available as a kit or factory installed option). Turn the knob clockwise to raise the temp- erature setting. The lowest temperature setting is 400 F., (full counterclockwise rotation). TWO-STAGE THERMOSTAT (AvaiiM>Ie as a kit or factory in· stalled option). Turn the knob clockwise to raise the tempera- ture setting. The lowest temperature setting is 40° F., (full counterclockwise rotation). This thlfmostat has two live oper- ating contacts. Two-pole thermostats han only one live oper· lti!li con1:11e1 and 1 hazmfou1 condition may exilt if used in piece of 1 two-stage thennostat. HEAT RECOVERY THERMOSTAT (Available as 1 kit or fac· tory installed option). Turn the knob clockwise to raise the t~mperature for the fan turn on. Full counterclockwise rota- tion of the knob is approximately 60° F. Full clockwise rota- tion at the knob is approx imat{:l) 120° F. The mid-point at the rotation should be approximately 90° F. POWER DISCONNECT SWITCH (Available as a kit or factory installed option). This swttch disconnects the oov.er to the power terminal block when the handle is turned to its full counterclockwise position. The power is on when th& r;y~Ji',ch handle 1s rotated clockwtse. If for any reason the knob is re- moved, 1t should be aligned with the "OFF" mark when the switch IS off i Full counterclockwi~e rotation). 1. Use copper conductor supply wire only when connect- mg lO the power line. (See F1gure 11.) 2 Connectton to the switch pigtails should be made with compress1on connectors and the jomt should be then well insulated. 3 Consult the local wir•ng code in your area. SUMMER FAN SWITCH (MOUNTED ON BACK OF HEAT ERI When the ~WitCh handle is pointing toward the "FAN ON'. pos•t:on. tt1e fan will run continuously. When the switch hand e IS po.nt,ng toward the "AUTO" pos1tion the fan will run only when the heating elements are hot. REMOTE FAN SWITCH (MANUAL SWITCH-LINE VOLT· AGEl. The wall switch is packed in the wrring compartment. 6/79 2 HEATER ~UST BE ~qJ,.J!\JDEl' .:>.5:... ?REC..\~. '"< A. GAINST POSSIBLE ELrCTRICAL SH:X., DO NOT MOUNT ~ERCURY TYPE THERMOSU1T 018 ECTLY ON UNIT VIBRATION COULD CALSE HEA7ER TO MALFUNCTIO:\ THE HEATER MUST BE MOUNTED AT LEAST 7' ABOVE THE FLOOR TO PREVENT ACCIDENTAL CONTACT WITH THE FAN BLADE 'w\HICH COULD CAUSE INJURY THE CEILING MOUNTING STRUCTURE AND THE AN- CHORING PROVISIONS MUST BE OF SUFFICIENT STRENGTH TO SUPPORT THE COMBINED WEIGHT OF THE HEATER AND MOUNTING BRACKET. (REFER TO TABLE 1 FOR WEIGHTS OF HEATER AND BRA:KET J The remote fan sw' tch is mounted ell ternal and remotP from the MUH unit heater. The voltage of the remote far, svlltch •s the same as the supply voltage to the MUH heater. 1. Use 14 gage copper, NEC Class 1. 600V rated 'mulated wire. Wiring must meet all Local and NEC reQUirt!ments for 480-volt service. 2. Install the remote fan switch in standard wall tox m any convenient location that is protected from traffic or other accidental damage. 3. Connect the 14 gage copper field wire to the sw1tch le<ld wires with suitable connectors. 4. A %-inch knockout is provided in the back of the 'lea~er adjacent to the control terminal ooard. Use a crimp-on terminal suitable for a No. 8 screw on the control termi- nal board. Connect one field wire terminated lfad to terminal F 1 and the other terminated lead to terminal F2. Refer to FigurelO for connecting to heaters wrthout built-in contactors. Refer to Figure 9 for conn-:ctmg to heaters equipped with built-m contactors. REMOTE FAN SWITCH (USED WITH 24-VOL T RELAY) (Available as a kit or factory installed option). The wall switch is packed in the wiring compartment. 1. Use 18 gage (min) NEC Class 1 600V wirrng that meets all Local and NEC requirements. 2. Install the wall switch in a standard wall box tn an, con· venient location that is protected from traffic o· Jther accidental damage. 3. Connect the field wire to the switch lead w•re> w•tr suit· able connectors. 4. A 'lz-inch knockout is prov1ded in the hack of the ~.-,?dtr.' •adjacent to the control terminal hoard Use<~ ;-:rrrr1p on terminal suitable for a No. 8 screw on the contrc,l errn ina! board. Connect one freld wire term ;nated ·e •d ro termmal "R" and the ot'ler term•nated f•ecd ·: "" 'e.rd r•:J terminal "G" Refer to F:gure 9 MANUAL RESET LIMIT 1 Factory rnstai!ed <'P'•() : n:, · The tim;t switch :s located nr.,,,-.,.,,,., CJn the r•':, ·)t '"" .,, .;'" On the MUH-03 and MUH-05 rT'Odels. '"'"ace-; ::: .,..,_ ., •• button is on the rtght side \when !ae<"g rear o' 11"a•~-· '"' ~ other models it is near the top •ear of the heate'. The manual reset l1mit IS in se~:es w,tb tre autom3'if ec, cling protector (l.mit). The manual reset !.m:: ,,.,.,, ·: • ,,. r until the button is pu~hed 'n r HEATER LOCATION INSTRUCTIONS ~·~ t~ :,c tr-.c:r CISCharg€ a:r s:reams: . ,_,r·t!'Li''U ,., o mtn,rnurn of i·lterfe:-ence from column:, if .;,_t 1 ·t''Y drld ;JdrtJtH.)ns 1. _ ,. •!';JrJseJ walls wtt'lout biow•ng directly at them. ,,~ d·•-cted away frorr 'JOtn occupcmts tn comfort heating: "' e dt ect.ed along the wtndward s1de when tnstalled •n a budd•ng exposed to a prevad1ng wtnd. L·xatE tnermostats on interior partition walls or posts away 'cc·rT• cic dratts, tnternal heat sources and away from heater c , :t,atge at r streams. Small rooms can be heated b·1 one untt heater. Where two .. ails are exposed, the heater shuuld be mounted like this. Large rooms require multi- ' r·t tnstallat;ons. Number and cc..)ac•ty of units will be deter- r•~:-•E:d by volume of building c nd squarr ft>et of floor area to t e heated. Arrange unm tc pov•de pertmeter air circula- t•cn where each unit supports t'"lt air stream from another_ MOUNTING THE HEATER CAUTION TO PREVENT AN UNSAFE CONDITION, KEEP AT LEAST 5' CLEARANCE IN FRONT OF HEATER. REFER TO TABLE 2 FOR SIDE, TOP, AND BACK CLEARANCE RE· C·.UIREMENTS. GENERAL T1~ heater may be mounted to discharge the heated air ~i tne• horizontally or vertically When the heater is mounted fc r ve•:ical discharge, it is recommended that the heater be P•'Stttoned so that the access door will open away from the wall t( provtde the greatest acces~ to the wiring and control com- p .. rtment. If the heater is to be mounted w1th the access dnor facing a wall, the heater must oe mounted far enough fr)m that wall to allow ful! opening of the access door (a dtstac.ce approximately equal :a the width of the heater ... ,~t .-c:k clearance before t"'Stall:ngl. Refer to Table 2 and Figure 1 •,, ,·,ali and ce·lrng c:lea•ances before mount·ng tne heater. 7> ·-r.:ate• may b~ moU'1terJ fur ~·t'let vertical or hor:zontal :1 ' 3rc;2 t•\' the'-''~ of •hr~ac>C rocJ' (Rete• to Tdble 3 for :1·· "J:Ied •od s:zes rcc ... med \ Observe !'le deta•led procedures ·, ··. fol1v._,.,,~ "~9 r"''.t:.I!Jtio~ .nstruct1ons. .... -... ·:_·;·:a,.·:; sv be sus~J":'r(~ed horn t~e v,al! c'r ced,ng bv ·:i .jr 1Jr:~·onai mount1ng br3cKet ftl·Pt.· ~J.'-v~B) whic~~ tlr~· ."ur1 (>: j'•' ... Jti·""'Q c! tht: r.ea!P' ThE moun~t:lq ;: ~')~''<~ Ql ;~./0 rn:.,1 '"' C0M,)0'12r'l .. S the •..~r.it 11l()U1'1!!,.,9 .; t· t • ~\i c.~ !'r.g b'dCk'-t A pi\·o: bc!t \".~th r.u: ,\--J:.t ·' Jr._) :11'.() ::l(:.ul1'~d. lrr.1o·ia;:,nn croceciures fc~ thPSP r....-,, • I~ ·'' JL"'.~~~ a:e c._:·,rlj'(j·~U 1~"\ i\• .. echar:ccl Ac.~essor'•'· 1~.. J' u-•·-·s:·ucr x''· sa"' r~t'· e.1c~ ~IUH 402. -:11. ~= L~H :::: :.·~-·J· ~~.:_-:l'.::·gt. :r·!.! 1:: .. 1.crs shou;u :J ~tl( • e ~~p· ·~·rz,./! d!'· ~ J 1r •1:..··:.-·· .. ·.:.J~~~ 0 ·:c: rg tht: a . :.c,•,., r~'CY C.:. ;2e i_r,~· o-t·r::•l 1J J • '"r· rem:;.P ..... ti:P CeiL,~g J. .,t, v~ J'>~·· er-:':j\· H)R1ZOi\ITAL DISCHARGE 1Rod-f.-1ount from Ct:,lt:.gl 1 f..: .• · ~..·~t:.-·) ,' b· •t. 1 '·.::·~, :t-.t' •: ·~c'.:•.'d ~ c1es .... 'lar·-ow) t~·.. • ·~.r ":.:atf' VERTICAL MOUNnNG Filln• 1. Will eM C ... C...,._. --- Teblt 2. Wall and CHino Cl....x:e Unchesl Unit Discharge Ceilint SideW .. I Horiz. 2 6 3 & 5 KW Vert. 6 18 7.5-10 K Horiz. 6 6 Vert. 6 24 15-20 KW Horiz. 6 9 Vert. 6 24 25-50 KW Horrz. 16 12 V~rt. 12 36 HORIZONTAL MOUNTI.G Back Wall 9-1/2 18 13 24 13 24 19 36 -- i. Install four t"re~ci'!d mounttng rods in the :hreoded :;:,:•,s and seCur"' ·n IJI~cE: us•ng 1(".:~ nt;ts a~ sho·Nr, in F,,~u·e-: ~Refer to T;;ble 3 for moun;tr:q rod thread 5•1~1 . 3. SK J! ( i y au dCI-1 !hP four rnot 1 ntrng rods to t~if' (" p• I i r;c 'Fi ,-~ to T~t·lr 2 f, .. v..~li at'o ce· '"-' clearanres.;, -d F ~·~·~ ':c rnr.)ur.tr.-\q SPdCI~Ig ~rmer's•OfiS.I r I I I I I ,· Cf!li~,;G ;-----------~-Tf'----"tf" -- • '.'] .'..; \~----~: 'I . ~. ': t; 'I LJ.!\ '.•jT~:--:fi . ' i VI A· l ~-----~ Frguf'! 2. Horizcnt31 Discharge Mounttng ______ ____J f1gure 3. Herizontll Disdiii'JI! Rod S!*i"' Table 3. Rod Thread Type and Spac1ng Dimensions (inches) for Horizontal Discharge Rod Unit Thread A 8 c D Type 35 KW 6 4-1/16 3/4 7510 KW 5116-18 6-1!16 !P/8 5· 1/8 3/4 15-20 KW 11·3/8 2530 KW 10.9,16 14·1 /2 6-3/16 5/8 3/8·16 15-15 16 14-1/2 6-3!16 5/8 40.50 KW VERTICAL DISCHARGE (R~·Mount from Ceiling) 1. Remove four bolts !if present) from the threaded holes m the back of the heater. 2. Install four th.-.ded mounting rods in the threaded holes and secure in place using lock nuts IS shown in Ftgure 4. (Refer to Table 3 for mounting rod ttl read size). 3. Securely attach the four mounting rods to the ceiling. (Refer to Table 2 for wall and ceiling clearances, and Figure 5 for mount1ng rod spacing dimensions.) Figure 4. \ltrtic:al Oisc:harve Mounting Figura !i Vertical Oischargt Rod Spacing ! Table 4. Rod Thread Tvpe and Spacing D•menstom !tnchf'5 for Vert1cat Drscharge I I Rod ! I I Unit Thread I E F G H i I Typp I !35K\(> l c j.J ·~ 2 I .. ' . ·-+·' 5 76-18 51 '9 : 7 5 :?0 nv E7 P 14 5 8 2 · 25 50 KW 3'816 14 I 21 1 4 2 3 lfi GJ 10 WIR ~G CAl'" ON ) j TO AVOID POSSIBLE ELECRICAL SHOCK. BE SUR£ ELECTRICITY IS TURNED C !=AT MAIN SWITCH FIRs~· BEFORE WIRING. ALL WI~ :NG MUST BE IN ACCOR DANCE WITH LOCAL ELECRICAL CODES AND THf HEATER MUST BE GROUNDED AS A PRECAUTiOrJ A GA!NST POSSIBLE ELECTRICAL SHOCK. BRANCH CIRCUIT (POWER) 1. CONNECT HEATER ONLY TO THE VOLTAGE -\'d) FREQUENCY SPECIFIED ON THE NAMEPLATE. 2. ALL WIRING TO BE 001\E IN ACCORDANCE V-'111·; LOCAL AND NATIONAL ELECTRICAL CODES 3. The access door is hinged. There are ei;her one or • ·:. J screws, accessible from the srde, that must be loose,•..cJ !"' gain access {Figure 71. These screws are the capttve ryp•:; do not try to remove them. 4. A knockout (Figure 7) is provided in the back of the heatl'r close to the power terminal block and the·control rermrn ll board. The control terminal board knockout is 1/2-inch conduit size. The power terminal block knockout is mult· iple drameter. Use the diameter that f;ts the required fO ,_ duit size. 5. A ground terminal is provided near the power terminal boar j The ground wire should be connected before other co~· nections are made. 6. The power terminal board is equipped With bo>< termtn. Is sized to accept the correct s•ze power supply wire. W re rated at 600 V and 60°C. ;s satisfactory lor the rea~.,r branch cirCUit. Either aluminum or copper wire is sat s- factory for connection to the heater power termmal boa•d box termrnats. Copper wire is recommended. 7. Ea~h heater has a winng d:agram fixed to the •nstde o' t w access door. Consult this d1dg• o'l'1 before mak•ng <JTJ f., ·c connectrons. 8. $,ngle Or three-phase power U.H'~Oectton; may De used''. !h heater models MUH-05 2, MUH 05·8. MUH 07·2. N1UH O:' Q MUH-10·2. MUH-10-8. and MUH 15·8 Thes~ heat'" :•~ factory-w11ed for smgle-phase power To con,f--t ;•. ·· heaters for use with three pnase power. reconnen 1"<' ::• ·'' as indtcated tn the winng d•agram a:tacred to thP ro.,· Add•t•onal rnformatton can he found bv 'oo'<•ng a: t•·--.· • tng .'lust• at.ons tn Figwes 6J dnd Gt; On models MUH-05·2. MUH 05 8, MUH·07 2. MUf-I . :: MUH·10·2, and MUH·10·8 (Figure 6al, move only thE,.,, wtres marked "A1" and "61"; do f'ot move or changf ·Jny other wtrrng. The element lead w.re marked "8 1 · , v:"' ch !S factory connected to the power term•nal block (;c ....., · ,, ;ocated closest to the elements! must be moved to :f''' "B" on the three·phase term,nal block The rrl:ry tact or\ lead w;re "A 1" must be moved from •'1e en" m•nai of the power terminal block (term.na' c··,se•t: , .. , contactor or control termrnai board) to the ".C.,"'"',.,.., •he lower term1nat block !center term,r.all Mode: MUH-15·8 (F·gure 6ol has two the.-P" as~ IPr • olocks located adjacent ~o the relays icon:actors ·J"i { tne twc wrres rr.a' k ~d "C 1 ·· af'lct "D 1" :Jr • . .<:: two three-phase termu1ai blocks. Do not move or ~· d ·;1e ;,r.y other wires. Move the wires marked "Cl" and ) 1: to term111al "B" on the three-pnase terminal block. 9 :C'ectr,cal Accessories, either k1ts or factorv·installed options, o'f' shown connected by a dash line on tne heater w1r.ng rLilgrarn HEATER FAOIIT \ ., .,. - ;.__-----\ CONT ACTOR <OR P2i POWER HRMIIIAl SlOC~ FACTORY-WIRED FOR SINGLE PHASE POWER 10. 708/240 VOLT HEATER. Interchange transformer red and black primary leads {see wiring diagram) when the heater is to be connected to 208 volt supply. FIELD-WIRED FOR THREE.PHASE POWER figure 61. Wiring Connections for Sintfe-PhiSI and Thrt..,hiSI Po11111r IMUH-05-2, MUH.OS.I, MUH-07-2, MUH-07-8, MUH-10-2 1nd MUH-10-81 FACTORY-WIRED FOR SINGLE PHASE POWER FIELD-WlRED FOR THREE. PHASE POWER Figure &b. Wiring Connections for Singlt.Phase end Thr,.Phfle Po~r •UH-15-8) BAC~ WAll \.li /~~ 0 / i\ ----. ... 0 / c ·:; II .w 'A CONTROL VOLTAGE WIRING -EXTERNAL THERMOSTATS AND FAN SWITCHES (Refer to Figure 8 for Wiring Diagrams) CAUTION LINE VOLTAGE !S PRESENT ON SOI\1£ OF THE TERMIN ALS ON THE CONTROL TERMINAL BOARD. ALWAYS DISCONNECT THE POWER FROM THE HEATER BEFORE MAKING ANY CONNECTIONS TO THE CONTROL TERM INAL BOARD. 1. Use 600 volt N::C Class 1 .nsJ "H'C ,, -~g""' Th "m10. rnu~· gcge of 18 for ther;nustat~. ina J 'T'•rnr.u;n gage cf 14 f;_~r l1ne 110ltage mck• sw,·c:h ''·'rlute 'a~" sw :c" w•t"1o :' r~lc.v l ... WIRING DIAGRAMS* 'Nl:lt I f11 '~·~fl•t",; , ; . 11dn·1 t•lrl; .-;.r ' '.'! f ( '! t I ' •• I'. • t: . 1 ~I) ll \ ' I I' I ,,;. ~--------------------------------------------~ ......... ~ ... ,.,. I'""'' -. .._.. ·~ 6- ~::~:~·;_,-;--~ , Ffrl -,. . L· ~ ~ ~.. -=---~j ..... q"i ' .. ,.)~' '.' =-- """"'"'!;) .! I '\ • .... _ .. ~ . r·_·. .. ~ ~ -~-r·~ . I - /~ ·-\__] ,_, C!llttllll""&l Cl.lfOUt -~ + -f.it ~~~·1. .. .::.:;:w-_-··w-f'dl0.0 ... 1~~=-·-=-=-=-= , .... f'0411111Mtll I .:$i_.,.··"' .......... fUIIJIIOfiiiAO. lkUC• ~UNwilH4i. (lolll;(;b """""'- 3 ELEMENT, SINGLE PHASE (Models MUH-07-7 and MUH-1D-71 ·r:nr -· - ~ J r 1~; "1 r--~:""')r-j '' I I -~ ~-.. ·~" vv-v~ I I 0\lfftMJA~ ,-rl\ hiW•Ilt •~ I ---, '"'~' -V\/V~VVv ..... I M-, r@--~ --~~--, . ---~ +--JJ-I _ .. d •• (' -1 I I ,, L . -~ ' t t ,,_._~ T ~-_j I i.~ •.• ~. ;-. :_( ' ' . I ., ....... , ...... :':.::,· f -'"~ ' - i f i :-.. i ~ I ::.=:·"' -' L± ' ---i j; ----=---.J__~=-:c -:-:'.>' __: i m "'"" ,... ..•.. -;;----+ii i'ft' ... .-.. J:T I .--' ,.u.,u.fo ~.,, •Ill 0 --.-~ --62" ~J.. . _ _j 19) -...... ,.;;;;;;;-. -= ..... -.. ' ... -»'·.: ~; ' f ........ , •• ......;:;;M<H"' "''"' ' C r:. -U ftlllllt Ollit.lool ' f'CMII. O.C-OM!tl(l "" 3 ELEMENT. THREE PHASE (Models MUH-03-4, \1UH·0&-4, MUH-07-4 and MUH-10-41 IIIIOfl I;•,..,H, POt. I l"l ......... l""l -~••~o·~ .. , • .,,., _,,,_,cao ••• •4• , .. ,., .. on•' ratuo"O ......... -.....~··tt(llfl ·-· OY ....... , t:vtuvt ----· _r----"~·N\t\J\i'--o---­ uu .... ,, -· --l JD.., y.. '\. V·-"-l ~J\A"-',·--...~ ............ ""--' ~ ~::.;."•·:·;· . . --:::·---------~ --=----.:::., r! ~~-~.1,, .k ---, I I b a.•u.q;. ,\j' ' ~~~~~~-.•• ,:;;: '\ ,..,. =::· "' ' -·~"'" ~ ••o ~~"':.''"'•"" Jj .. ,.. qrji:d ~~J) , "'""'' J,_~;J ~J '• ___ .J .J I { ... c_ __ L --""&-j It)• .. ....... t.,-.,,,.o___ _ ~ ---~--r..r ... I -~ .. ".-. ... ---+---1tt~----r--f-:: ~.-:::-::~.·.:-~::--• -L-~ ---·----/ 1._ ~) 1 ---------1 lji'Ooo!lt• , .... ,,, • ._....-;,l-AM J...~--~.::tJ ~~·tfl •VII , ... ~ .. --... C~(. t (< :'\ 1, \#..""\ .ol.llf(; • l'O (•) rtlllfiiii:A lf~Al ~ OLtt ; -. I -ltCt<~ • . I ~Y · \. *O«ua .,,l' .. ,o..j >311 .:, ~ l <OIIIIOUC:to"• ·- 3ELF .. , SINGlE AND THREE PHASE (Models MUH0&-2 and MUH-05-R\ -. ....... \ .,.,, "*'' ! I ~~.!."..~. L~.uo -~ ""' ~ fr!.lC!)IIIlA f"Ht....aofiU - ~ f.] i! ~--=-~ . .. .. , r (7 ~ II'?II ...... COkto!f(7tU -- Jt't(A.liCf~IIICU(,) ---- i#TIOIIIIAL ,OU....,tJt' ''""'' _ ,,,.u•o.u.u f..LI..:'(Uo"' ~liHtO 1 i'~U•lot 1'-JHI'IU""H.Utl;:t,!Nfll:ll..l ,":,\ !U ~<t ~· ,;.q fl. i "-I >"ttl\!\' I{ ,1\j ·\ . 1 .. , . ¥•••"'V H ........... , -~ ~ ~ ~-~ ,·, '1;. 3 ELEMENT, SINGLE AND THREE PHASE !Moueis MUll 07 2 .1/Hl MUll :o :'l ~------<>~\/l.f\1\1\. \ (i) ut ..... Nft. r:~~:~ . (.,j -ht--· ... r#l!l)( I li1Mo:1.41, iklA.fi.O -I~~ y:~-~ W.fitwl!t4~ !lin.•• ,.., .. , .. - ): C!1 •-•-i~· ·--l.l..-- lii•IIIT ""oontl'< UI'IJol<"'""' •lt)o..·._ I I'CTOaYMJi.---- Cli"''1GN•o.CQu ......... l--- f'fi1D w.IJ'f;&LLtO 0\ll.lllt-itAf fHU. lii!Ol ll1>fl'l '*l. 01\~o.u L rul'(IU1' l< ... f)t .......... I t 3 ELEMENT, SINGLE PHASE (Models MUH OJ 2, MUH-03 l, MUH OJ 8 aM MUH-05-7) r---ru--.............. I - ., I I ~ I (.J/'• -' ~/..,~v·vv···r (i (• •.roU•,ff; .;..-'"\,.'\,.c')/'1 ~... (} I L -""""' .... , lloiiiO '"'"''' "• '~~·.\~~ ... [, ~J ~ I , <l'Vllll .... t'*i tul~>r _.(~ l 1 ll "~'"'·•·l•h" J f .. (1o;!'il' n•••L !l"t•"U --- Ml ....... t l>JV-.tJito) f' . . ~ . -<II'' I j' t':' ' 1<-· ·+---" ~ ·-·~··,'\. "~rl~'--~~~·~'.-v i i .Vvv.h.rv y '11 l I J ~~ ' 6 ELEMENT, THREE PHASE (ModPis MIJH l5 2, MUH 1 S4. MliH :>o 2 .Jnn MUH-2041 ' '' ,, •· ~~ : :~. ;;i b-1, ... '·-·--,. tl ~'IWlM ~ .. J,(;.t)ro<o ... .l' ' ...... ,.: .. ~ ic ~· ! '. ~~ .. h ~~: ·NOT { Tlu· ~~~~JlW>t IHdnbf'r elenw111 .... I<H .lfl c1 I! 11·· WIRING QlliGRlii\IIS* ------------------~~ • .. . ' : ! l :-' ; ( ' . : • . ~ • _; j :;. j • r---------- ,·' ' ~:l :~~~~:~·-~~~~~: 1 ' ·--·-_: j '-'·-~ v,- ~-I I 4--__j -t-- :·' : ~ tJ ~ . --c l· • -~ ., v -· ... ' ' i .. ; ! , .,. _, r r ~j ,1-r. l , .. I. I l ·•' • (. 'I ' " i. ~ ''I ' --~-~-~'? -~~ ;--~-1 . l ~ ~ " --L---' l'1 ~:_:----=-.J~ I ' ---::-,,. ,,, ~:E: ---• -. -j-;-.. ·I: j -·-·------------------ 6 E LEivlfNT. 2 CONTACTOR, 3 PHASE j, :; (• I ..., : ~-".1 .,,,, I • : .. ~ ' ..... !, '' 1 1· ···~· 1';4 \ "' ..._,; ~ ..... -::"\ ..... \ -~:;:;;.;·.v-. \ . ..... ,,,. ...... , ,, ~ ... ~ ... , ..... ,, ........ , .. ,_ -I w:,.VN. -. I ..: <ll < '""'' .. !\ ',.~}.~~~~-·-I • . , ; I •: ! ; • ( ::: }• • .'~ , -.. I I C'>v-.vs""'-'? II '; ~ I I I : I. ' 1 I 1 I . ,, ' ' \_, 1. ' ••• , I• \-·~~~ 1"-c~'l~ I -~-[II ~. I :, ~ • f , -~ l rll ........ ·:.)~ ;._.,. : -~~ ~ .. ". -; -l"i] ••• --I l•f .. --. '•t t -. ---I · I .. tf,, ·ll~ I ,: ~ ·. .l ,., ' I' I ........ !OC ~ I \ \ ··J -~ -:.'. ' '-· r: f 1 -~ -r( 1 < I ,...,,, ............. ,)!. •OP '"-"'"·•• ... lt:l, 2 '~ ., ·--~ ,_ WI a• ~ci i 18 ~·· !). ... \~ .. ,a":_LJ -••. lJ .. ''-' .,_,. Ollol.._lCT -" ..... fi ELEMENT. 2 CONTACTOR. 3 PHASE I M"<t"'' MUH 25-<' Jru1 MUH 30 21 --~~~ :£:,---,>:...:::. '--w~c· !l '11-..r.;;,,o l\('0,::;-_:,;.:..:;.;~~- . I 1,' \ '::; ~··.' ·< · .. ·:. . ! I ;-+ _:.-.~·~·· ". ' I Q,__::,·~:", .. j d ""' .. :·,.-\ .·· .. ;,,;1 ·f··_"l 1 [lfw~rll~~ J·~:, .f~'-( ~. ~! ,~,: 1 1[ l llr.l~--j~ L.j, I :~ ... . ..... . I ;;.p , , .... ~lj.'i -o~111 ~ .. -w, ~-.. ~~::o· I :·~; .... ; ' ~ ~ 1 l! ..... ·~ . ttf' ·--~'"''~I~. ~;j. ·•-• '• -:;.1; ~ I' '·~""'~ ~ •>' •; ~I ( ' !J ""'"g I I ' ' I ..._ ' I f t I . I . ·-' I p ,~. 0 C1 . ' ' . t I I I •• ' ' • J. • • . , • I) i, ,, 6 J, . ,"', k,·-~0! ~~ :, f · 1-· l~·u-.... -ft~YI©l. ~·>'::.~~ :~--; ""' ,( ~(_j I I I;~~ I I~ -;l"'' . . lf+ ....... ~ ' ~ r~. •\ · .,. 1 --M.~~~':.."··, j .... -· .c'-:"~~~~-t>·~-I .. . , . , ~ .\-~-¢-~~~ I . ]. . ., . ~ ! ' -' l ' · ..... • ....... · ' ... · 'r 'r' ~ .,.:::-~·. ·'~ J ' ' ~ .... ' ... ,... .. ,,., -·I(>• 9 E.:LEMENT. 3 CONTACTOR. 3 PHASE -----------------·-~----~----------------, r ·· · ·l j c ·-::_! ·.'' .,,,1 ... 1'•"· ·:·I "'". '· .•. { c. I .:.~..,_·,· •. · ·-'-1 t· j ! ~ • ! ' -f . I (' J'_ . ;(', ·,:, ·i> ,, i ~, .. , ..... " ,. -, ..... . I .:. . 't . --.. ...... · ... _ . r-r __ ~ __ J._=:..--- ,,· ·-t-i ' +!.--~ ~-:;-I ~""')" '!' -.. ,... -"--~ -~ +-'1 '"'"' I...__. """ l--- -~ .. .,1. .. --:--,, 1 , ..... , '"" .. . J f ?"("! 1 ......... . ; I· I I ........ . .:::;...--t-~ -~-1 r -1•,..- 1 j I )< : 1!: ---~~--J --',.. _j i, --- -~t ! l· 'r \ : i I I I , .. C1'otll'f"'l•fDJ,...,AII 0 --- (IP1'10N ... li0UO-flol1 PlfiDI ... II .. ttfO PI-I• ,,,.._.., ... , t>t ~ o '•l• toll ...... "' ... fJ\ ,, o '""'l>UI ""'• 6 ELEMENT, 3 PHASE (Model~ MtJH 25 4 ""ci MUH 304r I ,, " ~-' ... rk;n ........ •fl"f l j_ J '"" M I OoOOIILIII\ ~,. .. ::.~~., 1 ,;> 1 ·~ .. "" : r~ ~~···!"'" "·" I ' '1. I ~ 0 \-1 It ~~ ,' '-!) "' ~~~~. I I !.) -: .. ': I ':= I~~ ~llq_: ,~~-, I' (,;,::::-::.~~.----1, (!~ -· < ; ; " '( I C' '"• < I < k· ~· 'I'?'"""< ""''" ~~: ~~ t·r -·~~;L,J'I,l'li rtj I I['~'NV<.··Iull a' I I ,_:;:;,• • l[il',..>r/ I I I I ~~,,-_,, .... ,.0 • ----1 I l I I I ' ' ,.,1 I ' < 8 . I '! I '-'-L "' ' ' • ,, •• ,,.. ' J """ -' '· ;. •, > . •••• ~· '(·'~-~0''""'"'1' [ J • '1 G-"----~T •• "''""'" • .. '"'~' = , ' I ,. --,.' ....... ' ..,.,_ ' ---' I "'t • T . I. -'"'Cf-:--'J\ _., ------lj I .... ; r ~ ·l '"' -\::-==: ----. • .l ·• -. -I --.,,., ' ' -· ---i I '' -,, ~.J..J.:. -----J • ,. .. +' ------·I ·-..... ··· · '· ·.J oP~ 0<111\'t"WtltfOJ,.... =-c... -r'C::-:·· _,j.Q..)_ . .-Jifl~fl.,~f,_;s.~ .0 ----~~~--.r ----~--.. "·· "'" ----..... 1, ·---~ - . . ... --~ ~~I .,', 9 ELEMENT, 2 CONTACTOR, J ,. L, - 1 ,........-~ -, ~} ~ « ·~ ol 101 ,"/I'VYV'./' I ."' v 'I ,_ ....... ,{' ' I' : ••• ~,Je-ll. -~ol ~•n• l:Gi'~,~-,' I ! cJI •''•. I ~~•JVVV'~ I""" ~ "":~'" I -~ )r ~""'"" 'u ... ~... I ('l '"-~'"" 1' ... , .... I • ' I ..... -~: ~.NVV-··' I'"'' v, I I IJ;l.. ...... , __ . I I .... f.' ' I ·--.:·fil~' II I ' -!'"' . i ~ _ .. ,. ' I L. I ' I I Ll I II I ' I , • 1 I 'i -0 I --1 )1.' J' _..J ~ I • I ~~l {.-( 'il. "\O)t·~ 'tli1'•'io'l1 ° ' I ~":'.;. '"'"' 3t .1. .! .. ~··""" [~, r ~"··~·"·1 ~.~.~I I ~ ; I ' : ~':;"":"'J. ~d T T .. -'T'fi ~ -'f I 1' ' I ··-4 ...:::-+_ -= ! t t ' J I ; I ..... ~ • ' ---~ I ~-• • " I ';.-' :.. --l 1 '"'' f) / rvu ;'t ~~~.w~ _" ----iJ+~~~ ,/ ++~ r-• I ~ _ .... -{~1 t i 1 / ·; _ _,.. -<w~~~ 1 I l ,; I '\,!/ .... ,._ ... t It]-t · -:::.:::: ..... ' : ', ~ : I · I I , l •" ---,\'\ .. ::... . ' tlll.....-o"'MIII ::LEMENT, 3 CONTACTOR, 3 PHASE 1 Mn.i .. t< MUH-40 2 and Ml , .. _,,,,.,,,,, ~ I ; .,., •, " 'I I 5 Install the remote fan swotch in any cotwenoent locatoon that os protected from traffic or likely accldentiiil dam•ge. 6. Internal optoonal controls are shOWT' on the ""'' heal!" worong diagrams by a da~h lone. AEIIOT£ SIIIGLE.STAGE HEATING THERMOSTAT t24V) WITH FAll SWITCH w, \ll p JUMPU WIRE FOR Z.STAG( HEATERS USIIIG 1 STAGE THEIIMOSTA TS to~cy~Gj TO w1 011 IIUH-~ 1 f L--TOG ON MUH TO w2 011 IIUH-....J L---TOR 0111 MUH IIUH COITROL TENIIIIALIOARD REIIOTE (LIIIE Y.) FAN SWITCH !MRFS-1) [frJ TOF 1 0IIIIUH-.J ~-TOF 2 0NMUH REIIOTE .IIILE.rTAII NUT116 THERMOSTAT C24Y) cw TO w1 1»1 MUH -~ ~-TO II OIIIIUH REMOTE TWO-STAGE HEATII6 THERMOSTAT !24Y) ~ REIIOTE (RELAY) FAI .. TCH (MRFS-2) ctB TOG 0111 MUH---J I..... -TO R 011 MUH TO w1 0111 IIUH-.J I ~-TO A 011 IIUH TO W2 011 IIUH - -j Filllrt I. Ty,al Exw.l Ce11tret Wiriltt r~ r-JLACI TO WI r'-----~,!D_-----, I ~~._ llliiOTE SUMIIU FAll I ILACI t 1 ltllrtTCH IIIRf'S. 11 1 r--------, ' , I r--4-, r--4-t-t I "FAII~HAY IT .L. I IT .L. .L.1 1 I : : lfOR II~FW AIID IIHRTI I 'V'T I I 'V'T Tl I I I r----,1 I IIT·t 1 I I I I 1 1 1 1 t:a ,... ~ , L--"t-J LilT 1 I IJ I 1 I ~ 1 1 1 I I 2~AGE-T'11 I J.. I I ~ .. ..--~~ I .l. nt., llrnUAL I I 0 ~ If() I 'tJ ' I I T Uj, I I THERIIOSTATI L~~!. ---G ,, I W2 I Fl '-'SU .. R L : ...JII '--'-------~ 11t \.. / FAll 'j-I I ~EO TO~ RED @., 'rJ I I '0 '0-_ _!II...!,T£!4 _ ...J I I IIH~T HEAT RECOVERY C 1 (i' 1 I IW1 F1 I I THUIIDSTAT OR~----'T-1------------.J I ~EIIOTE fAN I I I .ITCH!IIRFS-11 '-----t,::;:,~-----_ ---__ --.J Fipn I. Celltnll Ttrminal Boanl (for H11t1n W'rth Contacton) ~:J:RGNEAL REMOTE SUMMER THERMOSTAT FAN SWITCH lMRFS-11 OR SUMMER FAN j ,... ~q_~_r...._--------. SWITCH MCFS lMANUALI r---,""BLK ~ ~ Rf!q_,----~1 ""Tz,...-,..,--u.s-•~ ~ ~vr.::..l.: H1 I H2 F2 iS 1 1 T""':lf(p ~-1 M ~ L_Bl'A_((j' I~ 1 ,_--_I 1 I P2 ~--1 r---; ... ;~-;i I I /..l.l l : v ""':L_ ___ ..J I I L ____ .J ~DTES ' THIS STYLE CONTROL TERMINAL BOARD USED WITH MODELS MUHOJ 2. MUH.OJ 7 MUH·OJ.S. MUH.QS 2. MUH·05-7. AND IIUH.OS 8 2 WHEN UNIT IS WIRED FOR SINGLE PHASE. JUIIPER HI TO H2. IF SINGLE POLE THERMOSTAT IS USED WITH SINGLE PHASE UNIT, CONNECT THERMOSTAT LEADS TO PI AND H1. 1 EXTERNAL LI~E VOLTAGE THERMOSTATS SHOLJLO BE TREATED AS SINGLE STAGE ONLY TO POI"IER SUPPLY SEE NOTE 2 L1 L2 L3 IIOTES IIOTES: 1. THIS ST'!'LE CONTROL TERMINAL BOARD USH WITH ALL MOOELS EXCEPT "'UH.Q3·2, IIUH.O:l-7, MUH-G:I-l, IIUH.0~2.11UH~7. AND MUH.05-l. 2 REMOVE JUMPER WI TO W2 WHEN 1.STAGE THERMOSTAT IS USED. 3. "ONLY ONE OF THESE ACCESSORIES MAY BE INSTALLED IN A SINGLE HEATER 4. EXTERNAL LIIIE VOLTAGE THERMOSTATS SHOULD BE TREATED AS SINGLE STAGE ONLY POWER DISCONNECT SWITCf' TER~~I"oAl BLOCK 1 THISILLUSTRAT'C~ SHOWSWtRt"G MOO~ c'" FDA THAE~ PHASE SERVICE RE,Ciif lEAD WIRES MARKEe L: A!'10 Sl WHEN USING 0"£ PHASE POWER SEA'<tCE USE COPPEO SUPI'l '<WIRE 0!'1L r I'WI"'e T~'S SWITCH Fiqure 10. Control Terminal Board (for H•ten Without Contacton) ~F_i_g_ur_e_1_1_. __ P_o_~ __ r_D_i~_c_o_n_n_ec_t_S_w_lt_ch __ W_i_ri_n_g_D_i_a_gr_a_m _______ ____j 6 I <0 WIRING DIAGRAMS* ' \it ; 1 I''" . I ... p lit• •I<<! ·] , . --------------. i t l ~·· ! .. ~ 0' I .. J I I I' ...... i ;;_ ·--.:F 1\/ i:. ·r1' ::._\!!~;: ~:; ,. .. , ,, r, , .. 3 ELEMENT SINGLE AND THREE PHASE !Model~ MUH 05 2 MG ann MUH058-MGl --~A.A-".'.. -l --·-·· ~ I r ~"''"'"" ·-..... r:I]_ T -{j-~ r '\___" clli'l I--_-=~~,~~:' ~ ...... ~...... % I 1 1 ;,,.,.' o o' • ~' I ...._ <J I ...... ~ j ~-~--~--~ ·~-• --L i:;::.. ~ ' •,_ ---+ ,.., -1-~ 1 ~0 ~ '·~ 'I' < ...... r--=-+' I -~·-··· ~ l "' I I . '-. ", ;l ~ !2 il 5 ~~ .. ;2 · -• - -· · r· 1 f>1 • -6 '1 ~~---~;~:_~~ -~ ---lf-J l ~ ·>_-_~---=-iw __ :j ~61 ----~ -.. flhlli 1----_.;t; ' ' J ·;--, -. --::_-------F ,\ .. +-/ . ~·-\+-;! ' \._ --------=--------' l --····~.... -~-'-----I Jtt .-u.. • ,....,., .. ~. • - "" . T\ · e-n•• -12---,. ;:' _.. ••• ~ "" cu \ ~:1 ' ... ..:..~-....... • • ..,.,,_ _,_ '1< I . :-II,.. ~ ll ............... -::::~=~=·~c:.(_. ~·1· ... ,·~ .. ····• 3 ELEMENT SINGLE AND THREE PHASE tModel MUH 10-Bl I j'""·" ~ I J~_:__;j :::-·· ~!~ ') "'" .,. ... [ ...... "''*' -~ .:-::·~ ~-i ~ • .. !4lw.. ' .. ' ~ ~ ~ } I ....;._~------; ' ,_..,..~•u•--­ ,..,.. ..... ~.-tt'l!-. :::.~'7",•;1 l;GU...,.to> ''''' •( ~' ·•1 r,. --~ ' I J I ; . ----- ~~-:"·--~ ~~-.~~~· )li. h:•·u•H . \ ~ !. ..:~ .. '''""""-· ... ,." ;1 ;'/ : ,_;_ b. ·1"5 ¢ -~ ,:1 :3 EUMENT SINGLE AND THREE PHASE (Model MU1l07 8) ........ ·=~· .. j • i i i! l1 v3 ",j hi ~=~ .. , ....... ....... :.. ..... -II(" ""'""'"""' liiiH' I<U•I t·;, \' ' I'.F'"" . '{....:. ' ,_"';;~'" ·--*-I '(T!I I i ~.:)~"-,;A··_ ) 1 --t ; L j{._· ~ "-• , I . I -. l~{.) -.. ' i ~-·· ... , _J.-,~-··"'· t. •••• ..L'l \• \ ' f ..... -:'!~~~ffl \ ~ ---\ \ . . ~~.';~:~.:"·~~! .. ~~~:' ::' ~U.;t.(O IQA I><Atf !l'o•A:.1 ._,..,. ... , ,·, .. ,.,.. (>l H• <> H '""' '-. " I.;,,,..........,.., I I· ' .+ o f ? 0, . ' I 'i . ~ (f l ''. ,, t ' \..;.\ ,) ~I 1 }fl., .\ 4 ! : , l; )'-: '. ! t' ' • ' ; ':-~· : . ~ ,· : r·...... ' I """-"':"i, T I I I i I I I I ~-l ~ :-1 '--------------------~------ I ' " l ill :I .;. ; -~""li .. : "1'11 '' (. J.-t4~ i(" 6 ELEMENT 2 CONTACTOR SINGLE AND THnEE PHASE 11\lwtt1 r.1lJH ,.-------------------------... ~.::r~ ... ...... "'~'"'' •••r• "''-' .... ·• r----~~~-.. ~ ~~~·---,-=:~·~1 1 ,1~,:!~:( <b i I ' ;•:•'· •o ' l'lll"""Jl' .. . I I~--I k'·).t~~J .• • 1 'l -~~-. f'~ .. \ ------.... ,, 1 IU<.I'l,.ll ... I J:•; l~i~Uf ~ 1 _7- f..X. '""' •• ,.1.0J• .. "•t /(,. t#1!<JN.I.~ t~•-.tJroJ t<lllJ• IPG1'Attt0 l'. t . ..... ~ • ' ! ! : t f . ., .. & n . .... ~ ~ ~- ;:11 i i .# r I , L'" _· ./.. "' !.,~t· i. ~I !l : -. J c b ~~' """' '* 1 b 'l'i -J j ,;-~- 6 ELEMENT 2 CONTACTOR THHEl PHASI: (Modt:l MUll )I) H! r ----· , •• ••! ... .L I . I ,_.J ~·-· ... ' ' I ..,.., ... 1,, ... , ... lE la:,.. ll<fiA.: ~ ,..0 --·- )0; :•{ ,.\ . ' --· ••fj {.' . ·"·\ , . ..-t>,~ -"\---' ---' I ... ~, -= i' ' "\ t -,._~;:UVIaV I \ '';'_,.,., •.,;:.,'' \_ I . --- r',...u.t ..1, .... --- '""'•a-• -..;. J-~·.::=11111 ~ ~~ ""'' l .. I i ~ i , • ......,.nJf~" \'I "j t!J_J;JAr...hu ... -.., t. .......... .,. :""' i' ' -• II r{l ," , ... .-f ' I ' I .. • .• ' ...... ¥~ ... t.ooo. ........ :; ; ~I j' j j· • '--T ... !I' -' ' \ ·~ 'r - r, 1:, ·,' 'tt ·- :' • ~~ ~~~ ~;~ " " (rl!oo-lt ~ ... ·t: •• ---~ --------------~ 6 ELEMENT 2 CONTACTOR THHf:E: PHASE !Monel MUH :m Ui i WIRING DIAGRAMS* "NOTE: The hi9hest number element oslocated at the rear of th<t h .. ter nousin9. 9 ELEMENT 3 CONTACTOR THREE PHASE !Mooe1 ~. _H-5081 MANUFACTURER PART NUMBER BREAKDOWN FOA MADE-TO-ORDER UNITS LOCATED ON UNIT NAMEPLATE • MUH-A OODOODDO ODD Cllh ... 01 02 D3 1)1 05 06 07 08 011 10 11 12 13 14 15 16 11 Coit No~. 27 28 29 30 "-.._. 2.2 3.0 l.J u 5.& 7.5 10.0 11.2 !!i.O 18.7 20.0 22.5 25.0 30.0 37.5 40.0 ~0.0 II tat• Yo!tJp 20811, 1 Ot 3. 24011. 1 or 38 27111. 18 48011 3t c..tllo .... 40 4! 42 43 44 ·~ CIMit .... 00 61 67 68 69 70 Ce* ..... 00 79 00 &!I Ito Oiac:onntet Swttth Disc-I S..•tth No ~an S..mn S..mmtr Ftn Sw•tcn Romoto Fin Swttt!l !Retry! Heat Recowry Tht<moslil Remon ~on S...tcn liA•nuall llttt RICOWII'V T'M<mootf! and Rtmott F 11ft S..ttt> Rt!ay ThonniiStll 00 No Thtrmosm S5 1 St. Thruoollltlt 5.s 2 St.tq~ r~,. ... - c ........ CellfliV ..... No Contoctill"' 24 Volts :ntornol 120 VotnlnTtP•II 2081240 II oil! (nltfnli [4 \loin ~•ttri\OI 120 \lol!l t•tt<nli •NOTE: Made-to Order Humrs have 1 Suffix "M" IIi part of the Catalog Number. !t.e. MUH 10-A-MI 10 I I I I RENEWAL PARTS IDENTIFICATION (FOR BUILT-IN CONTROLS-MADE-TO-ORDER UNITS ONLY) 0 0 SINGLE~OLE THERMOSTAT TW~TAGETHER~AT HEAT RECOVERY THERMOSTAT . 10 ~ POWER DISCONNECT SWITCH SUMM~R FAN SWITCH Ref. No. Description Part No. 1 Thermostat, One Pole (MT-1 !' ...... 5813 0036 000 1 Thermostat, Two Stage (MT·2) ...... 5813 0035 000 2 Knob, Thermostat •••••• 0 • . . . . . . 3301 0060 000 3 Label, Thermostat .............. 3502 1 78 1 000 4 Screws, Fl. Hd., 6-32 X 1/4 ........ 5/02 7009 021 5 Clip, Ti1ermostat . . . . . . . . . . .... 1403 0041 000 6 Sw1tch. 25A. OEM .. . . . . . . ..... :.216 0132 000 6 Switct·,, 25A, K & N . . . . . . ..... 5216 0204 000 6 Sw1tch, 63A. OEM . . . . . .. . .. 5216 0131 000 6 Switch, 63A, K & N ... . .. 5216 0203 000 6 Swnch, 25A, Electro ... ' ...... . . 5216 0200 000 7 Screw, M4 x 10, Rd. Hd. (25A). .. . . ~ Screw. 63A, MS x 16. Rd. Hd. I . '. ' 8 Knob. 25A, OEM "T1" ......... OEM "T1" I 3 r~nctJ. 25A. K & iJ K & N Sl B 6001 8 Knoh. 63A OEM OEM "S4" FJ Knob. E3A. K & N K & N S28 G001 8 Knob. Electro ... El 14174 7 0 Sw,:ch, ;"(){lg'e. 600\' 5216 0130 000 j[" Rti,Jv. F;,,. 24V Co.t 5018 0008 000 1, Swire!-. As·.e:r~:y 5216 0199 000 12 Mdnu01i Rt!~!'! L rn t 4520 0012 000 11 5 .. 6,/7 .·1 n • VIEW I).D RENEWAL PARTS IDENTIFICATION TlltYINALD'OUkllt !IJSlO AS IIIE !)UtllfDI (MUH-25 THRU MUH-60 ONLY) ~ ~ VIEW A·A VIEW B·B VIEW D·D (MUH-01 THRU MUH-20 ONL Vl VIEW C-O IMUM-03 THRU MUH-05 ONL Yl \ I THESf P;<F.TS :. Rc USED I; . ' :;r E v, = ~\ 1\ on / I [ I ·: ,. ~ ~--~ I I i ~ '•-!·('' <: r- 1 :: I:· . L~\/~H~~- 1 •. '-. ' k:· ~. ,;_ I :." ~ ;-.., ' l" ! ' H); .. 4 1..:_ RENEWAL PARTS IDENTIFICATION 1402 0340 003 1402 034C 003 1402 0340 003 140 2 0340 003 1401 0340 003 FUM Bloc:lt •425 QX9 006 •4:5 OOOY 00\• 1<25 OOQ'; ;)()6 142'5 0009 006 14;>5 0009 001 ,.,~ 0009 007 1425 0009 009 1425 0012 003 1425 0012 OOJ 1425 0009 009 142? 001: 002 1425 0012 002 1425 0011001 14]0 0011 001 1-426 0012 002 @ Fuso ;"S,)4 QC I ; :)0 :, ,504 01) 1 1 100 1S04 t;~ ~ , 000 7504 00 1 1 000 ~4.:"J0110C0 l }~C4 onn ,y:':. \:'~~ "\(11 l :~04 COli t~;r., !;:~~;~~; 1802 0087 GJ 1 -,-80,-oos':''"'· --t:;:;c;::-c·;c.;;c:-=c +----- 1802 ooe' -; 1801 OOSi ~1r, 1 !102 00117 026 1!1020087 o:; 1802 0087 ~ 3 1!102 00117 031 '8020087 014 1!102 0087 G15 1802 0087 026 1802 0081 0'6 1802 0081 0'7 1802 0087 018 1802 0087 019 1802 0087 028 180:! 0081010 , 802 0087 01\ 1801 OOeJ 0:2 180:10081 023 1802 0087 030 (See following page for addctional Renewal Parts ldentificatton listing) 13 RENEWAL PARTS IDENTIFICATION (Cont.) Ret No. 1 1 2 3 4 5 6 7 8 14 15 15 17 17 17 20 20 22 25 26 27 18 18 28 29 32 32 33 D~riptron Spronq, ElPment (used on MUH-03 t"'ru MUH-20 0'11y) Spron\j, Element (used on MUH-25 thru MUH !)() 0"'"' Sprong, Cap11tarv Tube Sprong, Element Reta1ner Sw1tch lund on MUH-25 thru MUH-50 only) Insulator (used on MUH-25 thru MUH-SO only) Bracket Ex~tn11on {ul«< on MUH-15. MUH-20. MUH-40, and MUH-~0 only) .. Switch Brldtet . . . . . Fen Delay ProtKtor Speed 'Mil . . . . . . . ... lrecUt. c.pc,..,. Sc:r-(used on MUH~3 thru MUH-20 only) Brackfl, Captrw Scr-IUMCI on MUH-25 thru MUH-50 only) Protectcw. u-Limit I used on MUH~3 thru MUH~ only) Protector, Linear LJmot {used on MUH~7 thru MUH-20 only) Protector, Lrnear Lrmit {used on MUH -25 thru MUH -50 only I Ctemp luted on MUH-20 thru MUH-50 only) ..... Brackfl, Mounting. c.p.cjtor (UMd on MUH-20-8 only I ....•... Tarm1nal Luc;~ (used on MUH~7 thru MUH-50 only) Bushong lul«< c;,n MUH-20 thru MUH-SO only) W•her. Ground (used on MUH-03 and MUH-<15 only) Screw, Ground (used on MUH~3 and MUH~S only) Louver (used on MUH~3 thru MUH~5 only) Louver (used on MUH~7 thru MUH-20 only I Louver (used on MUH-25 thru MUH-50 only) Sprong, Louver . . . . . . . . . . . . . Terminal Block, 3 Ph-(used on MUH~5~2. MUH~7~2. and MUH-10-2 only). . . . . . . . . . . . . . . . .. TermiNI Block, 3 Ph-lYSed on MUH~. MUH-07-8, and MUH-1 !).8 only •..•...••.••...•.......•...•.•. Termonal Doublers {used where required) ...•.............. LIMITED WARRANTY Part No. 5208 0073 000 5208 0073 001 5208 0072 000 5208 0074 000 5716 7076 001 2900 003, 000 121 5 0282 000 1215 0256 000 4520 0010 000 4100 7036 026 121 5 0291 000 1215 0289 000 4520 0011 000 4520 0011 001 4520 001 1 002 1417 5004 000 1215 0314 000 3504 7002 001 121 3 7001 006 640, 0084 000 5202 0290 002 3503 0036 000 3503 0036 001 3503 0036 002 5208 7005 001 5823 0003 000 582 3 0003 000 5819 7012 005 t.ll ;:Jroducts covered by this Instruction Sheet are warranted against cefests ;., workmanshrp and materials for one year from date of sale. T h1s warranty does not apply to damage from acc1dent. misuse. or alteration. nor where the connected voltage is mere than 5% above :·,e nameplate voltage. nor to equipment improperly installed or .-med or ma1nta1ned m violatiOn of this Instruction Sheet. Th1s v<arranty :s va.•:J only tn the ftfty states of the United States. No c t~er Nritten or ural warranty applies. No employee. agent. dealer or other person IS autt10flzed to g1ve any warranties on behalf of Emerson Elect fie Co. Emerson. It is agreed that such repair or replace'TlE-nt 15 :~ .. · • '·''·'·, remedy avai!ab!e frofT' Emersor. Electr:c Co J'ld ·~<•' E~.F •'' </, ' NOT RESPONSIBLE FOR DAMAGES OF 41'oY KIN::l 1 ~C. INCIDENTAL AND CONSEQL' ENTlAL D~ v,,;GE Sc:"• · · ••- not allow the exclusiu;, or l:•n1tat1cn o' '"c dl nt:" , r r --r· The customer shall be respons1ble for all costs incurred in the removal or re1nstallat10n and shipp1ng of the product for repairs. With1n the limitations of th1s warranty, moperat1ve un1ts should be rl!turned to the nearest Emerson authorized service center. or the Emerson Electric Co. Service Center. and we will repair or replace. a: our opt1on, at no charge to you wrth return fre1ght pa1d by damar:;es, so the abov~ c>C'USIO'l .-.. li-n1ta; or n<2;' r 01 1: Th!S warranty g1ves you S:Jec.flc lc9ai 'Jght, a:cd >U-> -~ .• other nghts wh1ch 'ary frorn state to state For the address Gf your near(·5t author;zec! s~~rv·cc C·:·:rf:'r 'r,; f1l' Emerson Electflc Co. P :] Box 11 32 Ben-1E''s'-: S · Carolina 29512. 1803 479-9(16'3· Merc:1a:.J1se IC·tc:r , ... factory must be accornp~'1~e:; h. 1 returr· a•":hor,~J::orl ident1ftcat10n tan, bot~ dVCJJ1J~::e from tT;c-at.,·,. ,;.:_ .1 request1ng rerur·~ authcr~zaur·'l l'l':,.Jde a: -~~~tc on the product . .................................................................................. II I!MI!RSCN EMERSON ELECTRIC CO. SERVICE CENTER BOX 113:2 BENI\E--~s\··· .. ·~~-:..'""' ~~ Section IV ventilatin; F2n Thermostat There is a thermostat mounted on the east ~all for the operation of the ventilating fan. The thermostat will close on temperature increase and operate the fan until t~e desired temperature setting is reacned and will shut off . • T c:·,.s & PAR rs MANUAL SPOT TEMPEr~ A TURE CONTROLS MODELS 2E34 7 & 2E848 DAYTON ELECTRIC MANUF"ACTURING CO. CHICAGO 60648 _ .e.J l~,s~ '' :-:-1or.s CAP.EFULL Y E!EFORE ATIEMPTING TO INSTALL, OPERATE OR SERVICE DAYTON cr EMrt:~:.ruo;_;; ,~'GN:ROLS. FAILURE TO COMPLY WITH iNSTRUCTIONS COULD RESULT IN PER· )flAi. Ji' .. .Jt.;t; · AND OR .:>ROPER:-Y DAMAGE! . • ~ •14 .•,-rc: ,cr (. •JS ;;: )R FUTi.iFir: 'lEFE'qENCE . :---·,,~ ~ i t I ';~" ~ : i ' ., ., ' l ·• j ---------"' • 2t ~~.: Description f:·-:::•1 : • · ·-:e :: ::. :::ir-'0 T ~·'·~perature cor.trots wtm . , ' , (';;), .,;;;~".:>!·~ • cc·,ers anj 0-ring seals · • :r · ·~ ... -,:"c sr'3i•s Trs .ase has been tested by ''=' ~ .. J;•( :~•u.e:: .. JLl meet1ng the reQu;re- __ , 1 · r ~-i:M,\ -L<. •'nC!JW•as a:~d the reQwrements •' .. , .. 1 ~'ectc·: -:::-Gt: ~~-E:) }lrticle 547·4. when ': Y·~:-. ;a:e wi'!~p·-,.;;•n conduit connectiOn · .• ·: , " !•· · -,.., ·'''="'-" ,;::,:ed !emperature sens1ng ,-•::t : ~ :::: he oc•-:c.:.·., of ti"e CdSe on Model '-·•>:: ?=: -~ nas : ,,.ckel piatec cap1Uary and • . t;!l , ;.__·.,sc~~·J Th~~se C(lntrols operate by ·· ·: -=. ,r s ·;n "->rd contract1cn of liqwd 1n respanse to :· , :. \ .-:: -.:h.1'T' ; ::e l•ql •I! is conta111ed w1thin an •. , • :-:. :: .w.; ~apt:larv and a flexible d1aphragm :>;; '· , Yin occurs at :he diaphragm. Both are "' '. ,_. ~.. ~ ' -~ ' . level of accuracy aM sen- by heavy duty. prec,s·on adJuStment ;s accom- .. 1djust1ng knob ; tlnpecking l,L. ·-err~' r ·:le"'lt temperature sensing bl.llb Of' I'IQ :"', w 1 : J::;,nc; T~1s may render control Specifications (;ne :~ ~::T ~-: .. ten (Jce so:: cl :;8r.tacts cpo1s on tern- ~-~'<.! ,. w.; •. ;'· "'·' :::"~r :,.:.: c•::ses, f.~~ ,wtaole for h;·1l,.~' <\:'..;1 t• ["•': '!d \,~r.:~·r'3'E:'t-)"~- .. ~ ·' ~-.. , · ' '.CHi :;. tit·~ :•11 C .... J C3~-.lll3r) df· :· t€'·.: l .: :-!~~· MODEL 2E8J.8 c-;~·sP!JT·s-witcn 1one set of oon!acts opens on tem- 81' · ature rise as the other closes 1 ~Jot suttaole fOf' :oac! ;rarsfer" :::ldnge: D to 120°F (13sor: mal(1mum Nlthstand remperature). OiHerenttal: Appro,umatety 5°F. Sens1ng Element 3-3/16" x 3/8" nickel plated bulb with 5 ft. ruckel plated capillary. \100ELS 2E84 7 & 2E848 case and Cover: Meets NEMA Class 4X and National Electnc Code rNEC) Artide 547-4 requirements. When used with appropriate watertight conduit conneclk:ln (watertight condutt connection not included).·· UL LISTed.. • Swtable tor turning 10aa ON and OFF but not lor SwitChtng between loads; see Winng Diagram ELECT'FUCAL RATlNG$ --------·--;-----·-:;T-----------~----........, ~-, 120 VAC , 2~~E _ _.. 2n VAl: j ~ VA~ __ J =u~t Load 16.0 amps! 12 0 amps: 10.0 llfT1C'I !' - .. oe~cec~ Rofor : eo.o ampsJ 60 o lf1'lPS! so.o ImPS -1 Non-ln1uetMt 25.0 ~~ 25 0 IIITlPtl · 22 0 amps ! s.o an "> 1 • Pilot Duty I 125 VA • __ t2S ~~--,;, __ 125 VA~~~-_j • I ·aLACK POWER l. OR NEUTRAL SPOT f SWITCH I OR I THERMOS TArT ·NOT suPPUEDl L---1---t--' !"EO l£3-J I COOLING i..OAO 'lOTE. Heating or eooitng ecu·~11"1ent w~r: S;•QT sw.:ch opens ~;r ::loses one etrC:Jt: en temp. n~. t<. ..... ... ~· ., ::::·· t-· -,· . : . .::L~''"' .... ,.)US .. ~10~~~ .: ~tr~.: ·~: ~31 ~--~·J!at:cr::. t:..~~~---·:J ~r.e ~, ~·' ,·; ~::f ~~-~ ··:t.· r--~st:~~ src· .... ' t )I : ~pt ,-J t ,.:·, > ,:; \ -~; _.. ~J \. ~: r ,. ';"?' ,_. ' ''' '' 1 '~--... " i ~., ; ' ....-.~ 1! \_f._,;. 'f.':~':"l()€fl.t_.1 ~ ' •.• .., ,;_:qJ..,:~ :J'CX'.k.:--1-:; . ;·· . ·e ,; rt:!~ reriJ:•Jre '""' ! ~ '· ·.·. ~h :~if:',e th€•rlOS~.3:!S. 1,. . i S·:>cord :he< ncs1a1 v .. rtr-1 '"': tc orcv· .. "'!e ·ed:~'1C3f'·'/ In!: !ailation . t:-,·.·; .. ,, • ·~ nt::-r: '<' ·;·stai''lt10r !rt- t •·•· ·:J:1 e-. ··a '>ed. e(p€r:an·.:ec serv:ce ''·•,Jn: '--'1' ,.. JPC'~;cJr>a:" drea ,n .:;.rcBr tc olaCB as · ·,cr :,=,::: ;:,·, il':d ::-•J t ·· ied:um to t::-e ~ontrolled. : .•;.1\e :... -:::..:; ~ ~~o rna:; j,g ,, ,erj .., air. gases or most l . ...;u OS ,._. 'f or •• ·rhOt.;t t1Tifil2' StOn ·uelf. irnmersicn well r·' ~ j ~•<:' ''::!...; ,J '8C 1n a;::;pl•c ~ f>,:'lS Wtth htgr :y COfi')SIIIf' . ;12te'id•':': c.:;· ~ "qun~s ~'. ·. ,rq at rncre tran 5 t:. p.; ::e·~O"'C: OperaUon 'E'':.T M, :, · :0 OPER,; T .Jr< ·:; cht;,c~. tr • epee?!''"' o' hPattng s 1 ~~_r:-s. ~ D·sccn ... ,-2.:t .:c'.,., e; ?!.;; :e ~.· e "eat/COt,, ;;e,e:.:t:-r sw:tcn. 1l dDphc3tJII:l ,,.. me re.c:• ;:;os•tlon . Aj;us~ :he S8TPQ41"17 :en or ~ore de-,:;r<:>t?S beiO.,., lt"'!E: t~~mper ature of the cor:trol•t'd space. J Rest·:Jra ~·ower 5 S1c:w!y "dJ.;St tht: s;:;::~c)mt upward. When tre setpoto;: reacres the ~:::;proxrmate temperature ot the controllec soace. the heating equtpnl8nt shoulo start w;. ':NING B!::F·:·RE at:. 31NNING 1N ST ALLATlC N, Ct::.( : . .::Nt-.E:2T ;JQWER ~ 0 check :~e ~ratror. o' rr,e cooli~tems: o!sconnec! p()wer.· ----· ----- "'• . L ~ · J;::; :·! .. ::~ .'. ;rlf''J Diag· ar;· Wtr:r'g m~;::ot • •r y ' 1,.::! '·des re<Jula!icr:s. :~nd ordt· ·"" '/i.re·;;;: _:, .. ~eo .:unnector·-to orevent ·, .. ". h'' .;a::;<' ·Je .. >·•Kk 1nstailat'C<~ thorcugnly 2. Place :r~e t-,eat/coul :::e!ec:ur sw1tch. 1f applicable. •n tre CCCI pO~ltiOn 3. AdjuSt tt:e setpoim ten !:.r more degrees ~e the temperature of the conrrcdad space. · ~ Restore pc"'er c~ · TIOn Del"ting. cut'l:i:-JQ, tr damage to sensing buu• '"111 c~".ange tempe:crure calibration and damage ::~,·p~;oL ~.1ster: to w:!!l ~r panel with screws d'lrough me mount:ng holes m t,..·~ back of d'le case. 5. Slowly ao1us~ the setpc•nt downward. When the setpoint r'3acr.es tlie ar;,proximate temperature ot the controflec space. the cOOling eat.:tpmer.t snou10 start '0:: : ::L 2~84 ;· The operatiOn ot ttle control may be affected by heat from tne ha,..ds ot the installer and by the temperalure to wh1ch t! has been exposed prior to 'nstaliation. It therefore may not immedia!*"Y ooerate accurately. Allow one hour for the control and system to stabtl•ze for normal operation. '·' ·: a'r' ··'·' :·" ate-y t~ ~. aCvve fhJQr wr1ere >I Will be :. 'o·'.: ·c a-r·'1ge ter--:·eratwre of the space to be • ·:·H.-:; ·'Jo nor !'1St~'' ::::ontrol wrere 1t W!ll be ex- ... \.~ ·-~.JSL.a; t?xtrfr'~·'JS cf reat }f cold. tor exar~­ ,. ~:·~: <J""I;ct-t. .,., :'Cr"'NS. Goors or ar, outside wall. Troubleshooting Chert ___ .. _, ....... __ .... . -- ----+-----·-~IBLE CAUSE(S) +---~~AE~ ACTION , ·• , .. ·, •:r,,t••c; ,,-•P.v ... ,·.p ------~P!_~!.Wifi'!S_ __ . __ ,____ C~ Mrl':![. __ _ SYMPTOM "·c ,.• '19 •. •· : <:···,;,s not OC:·E' :~~e 1 Improper w•nng Q'le.;lt. o>Vtr!rtg i 2 Tl1ermostat 11a1 sot 'J':liOW 2. Set 1•al to nlQher temperaturw ~--·---·-·,· .. ! __ ~ace tfmPE'~!l~Ye ---·----·--------·-... ------_ ly . l 1. tmpoper wmng 1 ~ wmnq . . ,,...---f-! .. 9'~•_set~~~~-~2~!-=~ '~".:IP!f~!~~---~ 2. Set.~.~~ ~ature_. __ ..... _ ........ _ : D~~~c--~~s·rg_!:l~'~·-_______ R~ co~r~:_ ____ . _ -· ·- UIIIT£0 WARRANTY .,, .,. r-.. Ja .. · '· ,.,· .. -I" ........ .,..,.,.,,....\ .. 1 ... t,'!..,_ .. ,~-~-.,._,lllllid!:Jt_~, ... ~.....,..-.... eo ~~ .. , .......................... i'l__.. .................... j '""'"' ,, . • ..~ " ' ... ...,.,_...It ........... ~j tw ~ ~·-... ...,_.."' --~ ...... 'tftr-. .,. .._._ ...... ..w'ftC. ~ .. .Jipwo ~ .... ~ ........................... ' ' •••• J .. M ' '<JU ·""'" • If ..... .,~~,I'll ........... --=--1 XJIII .... i.' • ....,. -:Jill ,. ll'flll"'11ll'........,.,...,...., ~--............. ~ ·~ .. ·~--' ............. •• -4 ... , ". • ..... ., ...... o6(1i> .. ~··•11fr1i• ............ -""ffr!J ~_.,. .... _ .. ,.~~--...:!·"'~ ................. -..c ..... ~ • ._...,., ........... ..,.,., .. ..._,·~ .... • ........... ,.., ........... ·uN••·t~...,... .... ..,.'-'<., ........ ....,.fl//l!t.MI .......... .., ..... "'._, • ...,._.. .............. ..._., ..... ...,.~ • .q ........... . .,. .__. •ll._.,., .. ._ t<t.t:" .. y .,.~_...,.,....,.._ ..-.. ,..Gf'l:d..:'ft.---....,:-..-...:eN~-71'~ ......... ~ • ...,-• -t" .... <I~ •Vi~--,F , ..... ..,... ....... ~ .... l--·~::....,...>Uf~' ............. ,)ll~-........., ~:~· ~-.:~\~::-::.~::~~: ... ~·~~·~.::...~P'~::.~...::::-.-:.~,:.:-::.:.,~ .... ---=.=..~rr..~::.;.:.-:=,::;:-; ··•l .--' .... '--,... ·• ... ~ tiC\.. ....... , .11 .... ...,._ ....... ;,:;a»_· ............ V" .c: ..... ~O"';h ... i-.w'l ,"' .,....,., .... • . .,. •• ,..,_,-~._..,.,. ,.,._. H-Vrt •J • ~---,r u...-:.._.._.....,.tv -..,..._.,~Oil~_....,_ .... ~..-. .• --...aro...,•••• , , .. •. ..... . , ... *·; r ·"'t,..., .... .....,., .. , ~~.....,. .... ...,.... '*~~ .....-_.. _..., .rr. .• .,. .,. 't DW _. ~ ... ~-~ _., :'W ,_,....., _.,._ .....-...-..: ..,...,.,. • ·-.. ~<I/Jltll"'\:~ ........ , .............. "~·'":"~-~-, ..... "'',A.,,._,.~;-.~ -..,'f(,ltw-~'1/f~._......, .• _'"';· ·.;. 7:.. .. ·~ ~-," ·=::-:~..,..;:..· ~.:-~·.:::..-:...:( .. ~..;:-~;.:_ :.:::::~;:::. -:::~~ ;.: ... ~..:.7:...:..~ ;,.,._ ... _. ,,..,... • ..,. 'If•._ ·•• >"':aJt• _. ...-.... -r,,p •• l(_, .,. . ., l111/f1111.-"ffiD.,. _.....,...,....,..., .. l -a._..._,.._..,.... r :lytnn Electric Mfg. Co., 5959 W. Howard St. Chicago, ll ~ . , ., • 4' • . . .... DimtiAICI IJDIIIIX 1. tQUIPMSif'l' I'RM: -A.IA"'"''L!!.i.ML.U.alAa~~llit.ll..t.L .... --..,.,/#J'¥-lw.lc...$~L-------- 2. MANUFAC'l'URER: ...,..!J"O'f&aiii!i5i...-...f;8t.t4?5~.~·--------------­ l 3. EQUIPMBNT IDENTIFICATION NUMBU(S) I 1£/-tfW 111PM1'14•1 x 4. NAMEPLATE DATA (HP, VOLTAGI, SPEBD, lTC.) s ,'thO. 1.. A£ J() ""'J } ~ ~tre 1 (, t'l'lt1 1 ~ v~ 1 41CJ 6. MAINTENANCE RSQUIREMBMTS Maintenance Operation Lilt briefly each maintenance operation required and refer to specific information in manufacturer's •tandard maintenance manual, it applicable. F(eg:uncy Li•t required frequency of each Minta- nance opera- tion. lit A;plictbll) Refer by •YJlbol to lubricant lilt •• re- quired. CQilltgta 7. WSRICANT LIST ,. ~ ~ Reference SvaRol Standard Oil CjMlf' or 1&11 List symbols List equivalent lubricant., aa distributed by ••ch used in Itea aanufacturer for tbe •pecific u•• reco-.ended. 6, above. 8. SPARE PARTS Include your reco .. endation• •hould be kept o~ the ~ob. ' ,• . ,/ ... ,. I . I reqardinq vbat spare parte, {I) /WrJpiC. (l:;IM~i'l( 01001 c,, l~k* o~ •14- it any, l'jtJ .,_,' 1'/N itJO'I I ":I' . "<'' -. ·~· . ~.~· ·:· . ;I. ··~ . ; ...... ' MAINTENANCE REQUffiEMENTS Maintenance Operation Check all operating controls for proper operation Check limit switches for proper operation Check brake for proper operation Check load chain for wear, twists, distortion, nicks, gouges, corrosion Check hooks for cracks, deformation, elongation and twisting. If hook safety latch no longer contacts hook tip, then hook has been deformed and should be replaced Check that safety latch properly closes off hook Check that bottom hook swivels freely Inspect chain per page 16 of manual Inspect suspension lug for signs of wear Check chain guide for wear Check sheaves for excessive wear, cracks and incorrect wear Check motor brake adjustment per page 18 of manual Check bearings for noisy operation Check gear box lubrication Check for loose electrical connections Check all gaskets and seals between housings Hooks: Perform crack-detecting operation (dye penetrant, x-ray, magnetic particle, etc.) Support structure: Check for damage and continued ability to support load Frequency Daily Daily Daily Daily Daily Daily Daily Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Yearly Yearly WASHINGTON CRANE MAINTENANCE SUMMARY LUBRICANT LIST Item Load chain Hoist gear case Bottom block and idler sheave bearing Top hook Lubricant Beebe Lubri-Link Texaco Meropa 320 Shell Alvania EP 2 or equal Multi-purpose heavy grease lUILDERS HRRDWRRE TEL No. 206 281 3747 Mar 21.88 14:51 P.Ol Builden' Hard-ware (I Supply Co. 1s1e 1Stn .-.. w..t • ~a aox c 1VOOI5 Seanse. WA 91119-318.5 • Phone ZI1..J700 ~ACSIMI~l! ~HSMiiiAL RI~UIST II'AX NUMB£R OF RI!CIIVIK: c;:iCa~-f£'.1. :Oibk<ib NUMS!R O' PAG!S INCLUOINQ COVCA SHCIT ~ PLEASE OELIVEA THIS MESSAGE TO; NAME: MA][ f/EAW•M'? coMPANY: NoaH WEA"T 5Tt& r:tutss f'KOI't IU I LOERS" HA!\DWAA£ ' SUPPt.Y CQ. I'AX 106•ZB 1•37'7 TRAN SM 11'1!0 8V: tla I'AG 'U;::kl;.y QAT!; 3-/$-~ - I, VOU ~V£ ANY P~OBL£K ~ECIIVINC fMIS fRANSHlTTAL, PLIASE CA~ (206)281•3700 HGTES: .. ------- ~uiLOERS HARDWARE TEL No. 206 281 3747 Mar 21.88 14:52 P.02 •1 I I I I ' J~JU Serios Multi·Sized Spa:ilic.;atiuus Ill '" ltlilcull to mf• .rmcttlun nn I hill Jlillfl! itiiiiJMldfluillutUlllll rm ill~ Jltl!(l' I ·UU·: tl·:'{f'l~l'• c :tl\'llrll ancl Su~lod ~1)0(;)111 '"'Y It I lid" -..•tu•o. ( :ln'-ll'lr • Th111 110ri0!i ClOHr hu built·htftlhlrtl allowing spring powur •diu»tmttnt In tho fteln tn ec:cnmmndat~ virtually •lldc~ • (Jnn ~~.o Fila AU • UuiwrNI-NotllAndM • l.i'llncl l.y tJndr.rwrlter'l Labc:ntarJel • S Yuor Umited WIIII'IDI)' • J l~vy I luly ~·orsnct RIMI Main Ann • StmnmllnerC".ov11r Fumilhw Sl.lndard C'.ovon: Cover No. Slla 1UI.W8V u '1'1. l( 2'-4. •• 2t ,., •• Plat. 41iMI·'W ~%111". 2'""··· au,-..• PmJ. MuJU.~lzed 0UMI' Adt-tiiMDI: ,._, 1\ono lnolll~• ..... r .. C"' ...... N. ... a.nr-n... -···-··~ .. ' Dllc:riptloa R.cwuLv.Nnn- MllaWc Puii"K" C"..mmr, Naa-MitalUc su.,.....~ !llpedftcatlaa: AJtlbr c:Ja.n sheD be 390 Suriutii Clu.m u nwuaufactmtd by Cclbtn. eben m.ll u. nl r•11:k anti ptnlcm r.onstruc:dan. Svlndle tn bo IDIChlned trum one ptec:. hiHh h''""il\t illluy stwl. ,_ n.ttd md proctttan arouud. r' .. 'l'IC'I !!lwll htl t:aM aluminum, VIC'UUm md pre:aure lmflm· 1111t1ud with NJ .. ;iill ""'ill. Sprlop lh.n bo mualtr. wire IY)lO. hip)l tc.uulih:J. ull tempered and heaiiNitld. V~t~IV\:tt lllutlll~t' uuudlu lyJIU, •IUIKriliall with RunN "()" rln~& llt!CIIa. l..'losi"'C and lalc:hlftlipeeda lhall be controlled h)o'uou.,. :nhr.al, dual funt:tlnn VIIW!. All YIIVMIMI1 hr. • • .. --~-.. ~.~ .... _ -----.~:---................ Mn..........l ,,.u,. AU Multl.$17.0 Closers J.w Uw t.dory with lhe aprb~ pow.-adjuatmcnllnl at nticf..rtl9. The custcm. am tb11n lncrt~~~~t Ul d«:nNUe the pow. a needed to IUit door opon· In& r.nMitiMa. l'.xcellenl product eeltctloa &.r uadl· capped appUc:adoa. 6, _l!·~~--··--+----·--~--0--~--t~- 3'0' 2 2 ~· 3'8"' a·r a·o-• a TOPJAMI 4'0" :t'O" a·r 1 4 WOIIft'ID -· --!-";......-t__;;,..;;..-+-----tl--_...._ ••r l'l" .•• .,. 10 s s·cr 4'Cf ••r 12 e MUU.AJ. 2'0'" - - 2 2 AIM 1-;........;..--t---+---+--....,_--+--- _!~-. t-..:·: .. ·-+-•z;....;;·r;...._t--~• ---it----3;..__ 3'r 3'0" 1 c +--+-~-3'0. tO S 4'0" 4'8" 4'0" 12 e tlltllllii~Q.~pli~•\iona. Covtr rur ... 390 SliM aWl bt sur· · fam applkld wtlh mr.tansular cbiF and capAble of botnc epplled un HI'• • kip nil ur tup 11mb lor laYa'IMI mounttq. lM SMn~tn mix 'n • tNtr.h wtth 290 Scrtnl. Nan Mld~n dn110r1 ahAII bn rugulnrtt!:tlhr.d with a ftMIIibJe powor l.~t~t~l.ut "1 pruvide 15% in power. OMddnc fluid sh•ll be hiah lubtic:jty and low pour point. ll.dclu m.at be n~tCUluiy fumiab.d. NoP-IIaed c1n1an to be ( :ntbha 300 Sclrlftl wtth fully adjulltlble lll'iJW power In !IU 1 Mnmnlbtln I'll ;,ow , oU •nd tu ftldhtaiO r.ompbllw::o w\1 h handiCOIIIIJOd ft!Cilltft!monta. ( ( ( ( ( I IIAIJD'IlWICI SQJQIUX 1. EQUIPMENT ITDis t?!)~D Th-f>'l?6 2 • MANUFACTURER: 3<+ S M.AtJ U. rAc:rt,..t..&JbJ 62 ::!.#.1 C-· 3. EQUIPMENT IDENTIFICATION ~BER(S): tit-7°/ -93!/ l)Jc.., /O/..j. 4. NAMEPLATE DATA (HP, VOLTAGE, SPEED, ETC.): 5. MANUFACTURER'S LOCAL REPRESENTATIVE: ~ Name: 1"'e.Hr!t2.. Nf:PL~ -Ath, ('( f::9!\ sl;c;_ D Address: ""L -z...-l 0 \ 3:Z. -::;f: · B&tJ..e l}!.<....f , WA ''f?VO'l Telephone No: { 7-Db) tAl -7 b77.c 6. MAINTENANCE REQUIREMENTS Maintenance Operation List briefly each maintenance operation required and refer to specific information in manufacturer's standard maintenance manual, if applicable. Frequency List required frequency of each mainte- nance opera- tion. MlrlNUJ/It+J<I' (.Jif<K. p/CLA ~~~~ 7. LUBRICANT LIST Reference S'vmbol Shell Standard Oil (If Applicable) Refer by symbol to lubricant list as re- quired. Gulf Comments Or Eaual List symbols used in Item 6, above. List equivalent lubricants, as distributed by each manufacturer for the specific use recommended. 8. SPARE PARTS Include your recommendations should be kept on,. the job. ... . ~ ... / ...... __ ...... ---...~ ............... ···-·•""--~· .. reqardinq what spare parts, if any, 01001 -14- SERVl:CE DOOR XNSTALLATJ:ON l:NSTRUCTXONS MAKE IT EASY! READ INSTRUCTIONS COMPLETELY. SELECT GUIDE CONFIGURATION, THEN LAY OUT ~ACK-TO-~ACK ON JAMBS. SEE GUIDE ILLUSTRATIONS <FIGURE 1) FOR BIB MEASU~~MENT. CAUTION-BIB MEASUREMENT IS FOR ~RACkETS ON THE FLAT SIDE OF THE WALL ANGUE, THE SAME SIDE WHERE THE OUTSIDE GUIDE IS MOUNTED. SET WALL ANGLES ON WALL-LEVEL BOTH VERTICALLY AND HORIZONTALLY USING A LINE LEVEL, THEN ATTACH TO JAMBS. ASSEMBLE ~RAC~ETS ON .BARREL <AS SHOWN ON FIGURE 2) CAUTION-DO NOT INSERT TENSION PIN THRU TENSION CLIP INTO TENSION WHEEL. RAISE THE BARREL AND 9RACKET ASSEMBLY INTO POSITION AND ATTACH TO THE WALL ANGLES. USE 1/2" HEX HEAD BOLTS IN TOP HOLES OF THE ~RACKET AND A CARRIAGE ~OLT IN THE 90TTOM HOLE. ALL BOLTS SHOULD GO FROM INSIDE THE ~RACKET COMING OUT -WITH THE NUTS APPLIED OUTSIDE. ~E SURE TO PULL ~OTTOM OF THE &RACKET AWAY FROM THE WALL BEFORE TIGHTENING NUTS. RAISE CURTAIN AND SET IN INSTALLATION 9ELTS COR SLINGS> WITH TOP SLAT POINTING AWAY FROM WALL CFIGURE 3>. ATTACH TOF· SLAT TO SLINGS WITH VICE GRIP AND PULL HAND CHAIN CIN ORDER TO TURN ~ARREL> TO BRING CURTAIN OVER TOP OF BARREL AND HAMMER TOP SLAT FLAT ON THE BARREL. LEAVE VICE GRIPS ON IN ORDER'.TO AL,.IGN E«AF<REL WITH TOP SLAT. SPIN BARREL SLOWLY TO ALIGN TOP SLAT HOLES WITH BARREL HOLES AND SECURE WITH 3/8" X 1/2" EtOLTS.AND FENDER WASt;ERS. REMOVE VICE GRIPS. CAUTION-DO NOT USE BOLTS ANY LONGER THAN 1/2" LONG. LONGER BOLTS WILL INTERFERE WITH THE BARREL SPRING. WRAP CURTAIN ON BARREL UNTIL FOOTPIECE IS HANGING 6., BELOW HEADER HEIGHT. LOCK OFF CHAIN TO PREVENT CURTAIN FROM FALLING. CAUTION-LEAVE SLING ON AS A PRECAUTION. INSTALL GUIDES AS SHOWN <FIGURE U, USING 3/8 .. X 1-1/4'* BOLTS. BE SURE TO SPREAD GUIDES TO MAXIMUM SPACE ALLOWED BEFORE TIGHTENING NUTS. <WHEN FURNISHED, SECURE CHAIN LOCK ON ONE SUIDE BOLT) TURN TENSION WHEEL DOWNWARD CFIGURE 4) AT LEAST 1-3/4 REVOLUTIONS. CURTAIN SHOULD BEGIN TO PICK ITSELF UP SLIGHTLY AT THIS POINT. ') CHECK OPERATION OF DOOR AND ADJUST TENSION AS REQUIRED. CURJAIN SHOULD SPRING OFF THE FLOOR Co• TO 12") AND SPRING UP AT THE TOP SLIGHTLY. CAUTION-ONLY AO.JUST TENSION WITH THE DOOR IN THE FULLY OPEN F'OSITION. 11> INSTALL HOOD WITH 114•• SHEET METAL SCREWS. J 1J 12> ~HAT·s IT -EXCEPT FOR THOSE FINISHING TOUCHES THAT GUARANTEE ANOTHER SATISFIED CUSTOMER. 1. 2. ..,. ...>. 4. NOTEa WARRANTY VOIDED IF THE DOOR IS INSTALLED 8Y OTHER THAN AN R & S INSTALLER OR A DULY AUTHORIZED REPRESENTATIVE. • • • ' t ~ . "• -e::;> ~. c!? ~ • • • • p .. ' .. 'c>. ~. • • Z-GUIDES WALL ANGLE. .<::> ~ • & • • A -.. ~.,. ~. -· ,.!? • • • • ./'), tP • : p c.r • • ~ • rY e:J" 1:W'' I I .. INSIDE GUIDE : ... ~:lr 11. uz z" • OUTSIDE GUIDE -·o r BIB ~ CBAP.RE'L LENGTH + 2 3/4'') , U •GUIDES > > ~ > ~ ~ ~ ~ ,.~ ,. , , , '1 f · •y;»= 2 WALL ANGLES ~ INSIDE GUIDE ---~~~~ OUTSIDE GUIDE • ? Ill z I~ f• BIB f BARREL LENGTH+ 2 112.,) ., s. 6. 7. e. 9. 10 11 12 ;[ r- -.STALL BELT )R SUN l .T BARREL AND BRACKET ASSEM8LY TENSION 51 DE 1. BARREL ASSEMBLY -COMPLETE z. 1" SPACER -SLIDE ON POWER SHAFT PCWE~ StDE 3. POWER BRACKET CW/BEARING> -SLIDE ON END OF SHAFT 4. MAIN GEAR -ALIGN W/POWER BRACKET. SLIDE ON SHAFT 5. KEYSTOCK -DRIVE THROUGH KEYWAY IN I"''.AIN GEAR & SHAFT 6. WASHER -FIT ONTO SHAFT AS MANY AS t~EEOED FOR GEAR ENGAGEMENT 7. COTTER PIN -DRIVE THROUGH HOLE IN SHAFT 8. TENSION BRACKET <SPACER ATTACHED> 9. TENSION WHEEL -SLIDE ON END OF TENSION SHAFT 10. TENSION PIN & TENSION CLIP -SET TENSION AS REQUIRED &FTER CURTAIN IS INSTALLED ON BARREL. 11. NOTCHED TENSION SHAFT 12. KEYED POWER SHAFT NOTES: 1. CHAIN OPERATION SHOWN-OTHER OPERATION SIMILAR. Z. RIGHT-HAND OPERATION SHOWN. LEFT-HAND OPPOSITE. 4 T E,NS•ON PIN) TENSION SAR ;TALLATION :LT · SUNGJ BARP.EL • • • • c ® PULL OOWN MAINTENANCE SCHEDULE: ( CHECK ONCE A MONTH ) J. CHECK fOR DAMAGED SLAT, REPLACE OR REPAIR Jf fUNCTION Of DOOR JS IMPEDED. 2. CHECK FOOTPlECE FOR BENT ANGLE IRON, lOOSE BOLTS OR SCR£WS. REPLACE OR REPAIR IF FUNCTION OF DOOR JS IMPEDED. 3. CHECk GUIDES OR TRACK FOR BENT ANGl£ IRONS, lOOSE BOLTS OR. SCREWS. REPLACE DR REPAIR IF fUHCTlON OF QOOR IS IMPEDED. 4. RE·TlGHTEN ALL MOUNTING BOLTS. BRACKET BOLTS, GUIDE BOLTS, AND fOOTPl£C£ BOLTS. 5. CHECk CURTAIN fOR PROPER AL1GNV.£NT-TRU£, LEVEL, AND Pl~B. CORRECT BY LOOSENING TOP SLAT BOlTS AND SHIFTING. CURTAIN TO PROPER POSITION. SEE INSTRUCTIONS. 6. IF tHAI~ OPERATED, CHECK HAND CHAIN FOR DA~AGED LINKS. REPLACE OR REPAIR If FUNCTIO~ Of DOOR IS IMPEDED. 7. IF MOTOR OPERATED, CHECK DOOR OPERATING POWER SPROCKET ~~0 CHAIN, TIGHTEN A~D OIL AS NECESSARY. RE·ADJUST LIMITS AS t;ECESSARY. ' ! I ; lUBRICATION SCHEDULE: ( ~C£ A MOhTH ) 1. All BEARlhGS AR£ SE~lED AND PRE-LUBRICAi£0. CHECK FOR~~~ SEAlS OR SkAFT. REPAIR OR REPLACE BEARING If ~lSY OR ~SLY • . Z. CAST IRON GEARS AND DOOR GUIDES OR TRACKS CA~ IE lUSRlCAT£0 WITH A GRAPHITE BE~IHG DRY-TYPE LUBRICANT. DO lOT USE GREASE, GEAR MOVEMENT WJLL fllhG GREASE AWAY. 3. GREASE DOOR TRACKS OR 6UlDES lF OBJECTlO~ABLY -oJSY. t i l ~ l .. J I" I OPERATING INSTitUTIONS: CBAlN: (1) PlJLL BAND CHAIN OOWN TO RAISE DOOR. (2) PULL BAND CBAIN 1M OPPOSITE DiiECI'lON TO CLOSE DOOR. MOTOR: (1) PRESS "OPEN" BUTTON ON ~ONTROL lOX TO RAISE DOOR. • (2) PRESS "CLOSE" BUTTON ON CONTROL BOX TO LOWER DOOR. (3) PlESS "STOP" BUTTON TO STOP. NOTE: IN THE EVENT OF FAILURE OF A.\'Y OF THE ABOVE OPERATING PROCEDURES CON!ACI' REPAIR COMP~..e IMMEDIATELY. . . .. . . . . . . CHESTER LAKE HYDROELECTRIC PROJECT CONTRACT NO. CL 02 CIVIL CONSTRUCTION Prepared for: D'l'LAD'l'LA I:iDIU COJOIUBITY IDI'l'LAD'l'L& .ORR .'A1ID LIGHT Prepared by: 0'1"'1' WA'l'IIR DGIDIIRS 1 INC. 12310 N.JI. 8'l'B S'l'RBB'l' BIILLBVUB, WASHINGTON 98005 JULY 1987 TABLE OF CONTENTS DIVISION 0 -BIDDING AND CONTRACT DOCUMENTS Rural Electrification Form 200 DIVISION 1 01001 01310 DIVISION 2 02110 02220 02221 02240 DIVISION 3 03300 DIVISION 4 DIVISION 5 05500 DIVISION 6 DIVISION 7 DIVISION 8 DIVISION 9 09900 DIVISION 11 11010 11030 DIVISION 13 13121 DIVISION 15 15001 DIVISION 16 16000 -GENERAL REQUIREMENTS -General Requirements -Construction Schedule Metlakatla Indian Community Resolution No. 81-84 -SITE WORK -Clearing and Grubbing -Earthwork -Trench Excavation and Backfill -Sediment and Erosion Control -CONCRETE -Reinforced Concrete NOT USED -METALS -Miscellaneous Metals -NOT USED -NOT USED -NOT USED -FINISHES -Painting -EQUIPMENT -Hoist -Pump -SPECIAL CONSTRUCTION -Prefabricated Metal Buildings -MECHANICAL -Plumbing and Piping Systems -ELECTRICAL -Electrical GEOTECHNICAL INFORMATION REVISION SHEET REVISION DATE NUMBER ISSUED REVISION 1 8/28/87 Addenda 1 & 2 Incorporated SCHEDULE OF COSTS 1 MOBILIZATION (Includes but is not limited to mobiliza- tion, de-mobilization, construction, site office, bonds) 2 CARE OF WATER (Includes but is not limited to diversion andjor dewatering of excavation) 3 SITE WORK (Includes but is not limited to excavation, backfill, grading, surfacing, riprap, rock slope protection, and barriers) 4 INTAKE (Includes but is not limited to installation of air relief, butterfly valve, and plug in existing penstock; fabrication, and installa- tion of trashrack) 5 PENSTOCK dollars $ ________ __ dollars $ ---------- dollars $ ________ __ dollars $ ________ __ (Includes but is not limited to penstock pur- chase and installation; concrete encasement of penstock; 2 tees in penstock; 4-inch blow- off line and chamber) 6 POWERHOUSE FOUNDATION (Includes but is not limited to excavation, concrete, and backfill at the·Powerhouse) 7 POWERHOUSE BUILDING (Includes but is not limited to metal build- ing, building erection, lighting, heating, and ventilation) 8 PUMP. VALVES. VAULT, AND PIPING (Includes but is not limited to water pump, 8-and 12-inch pipe lines, valve vault with its drain, pipes, valves, fittings, lighting, and heating) dollars $ ________ _ dollars $ ---------- dollars $ ________ _ dollars $ ________ _ TOTAL BID $==== NOTE: The above items shall include all work under this contract. Therefore, the sum of these amounts must equal the total bid. PROJECT DESCRIPTION 01001 GENERAL REQUIREMENTS Metlakatla Power and Light company (MPL) is planning construction of a 1-MW hydropower project on Annette Island. The project is located at the head of Chester Bay, approximately 1-1/2 miles southeast of Metlakatla. Metlakatla Power and Light is owned by the Metlakatla Indian Community (MIC). Components of the project, which are to be constructed in late summer and early fall of 1987, are described below: 1. INTAKE The work at the intake is located at the new dam at Chester Lake at elevation 855, approximately 3,600 feet from the powerhouse site. This work includes the fabrications and installation of a 60-inch by 61-inch trashrack at the dam, a 20-inch butterfly valve, a 6- inch air valve, and 2-inch plug in the pipeline wall. The valves and plug are located approximately 100 feet downstream of the dam. The butterfly valve, air valve, and plug will be furnished by the owner. 2. PENSTOCK This work involves the installing of approximately 271 feet of 20-inch diameter steel penstock. The penstock will be buried and will be connected by means of welded bell and spigot joints. Two joints near the powerhouse will be connected by Dresser couplings. Work also includes the necessary ~hrust blocks and pipe protection at the relief channel. 3 . POWERHOUSE A 26-foot by 36-foot powerhouse is to be constructed at the head of Chester Bay. Work includes excavation and a foundation consisting of reinforced concrete. The foundation will form a combination wet well and tailrace. Also included are a steel building with a 10- ton overhead travelling crane, powerhouse lighting and electrical heating installation, and a small tailrace channel consisting of concrete and riprap lining. Part of this work is a single speed, 70-horsepower pump which will be installed to draw water from the tailrace wetwell and will discharge through approximately 150 feet of a-inch pipe to the nearby water treatment plant valve vault. 01001 -1- 4. SITE WORK Site work consists of a roadway ramp from the existing Walden Point Road to the powerhouse parking lot and a powerhouse parking lot. An overflow relief channel and bank protection are also included. 5. WATER SUPPLY In addition to the pump in the powerhouse and its 8-inch pipe, a valve vault is to be constructed on land across the creek. A 12-inch pipeline about 200 feet long will connect the valve vault to the penstock. To determine the full scope of the project or any particular part of the project, coordinate the applicable information in the several parts of these Contract Documents. PERMITS No state permits are required. The contract is to obtain all local permits. A Section 404 permit has been obtained from the Corps of Engineers. A copy of this permit may be obtained from MPL or the Engin~er. EMPLOYEES The Contractor will comply with the Alaska Wage and Hour Act, Alaska Statutes Section 23,10.050 et seq., and all Federal wage laws as though such acts or laws were the laws of the Metlakatla Indian Community and to comply with Resolution No. 81-84 of the Metlakatla Indian Community Council which establishes the Metlakatla Tribal Employment Rights Office and sets forth standards and procedures for hir~ng employees and subcontractors. A copy of Resolution No. 81-84 is included at the end of this Division. If subcontractors are required, the Contractor will employ subcontractors pursuant to the provision of Metlakatla Indian Community Council Resolution No. 81-84 and under agreements binding each subcontractor to the terms and conditions set forth in this Contract, and to be fully responsible for all acts or omissions of such subcontractors. COORDINATION Contractors shall cooperate in the coordination of their separate activities in a manner that will provide the least interference with the Owner's operations, with other contractors, with utility companies working in the area, and in the interfacing and con- nection of the separate elements of the overall project work. 01001 -2- MAINTENANCE DURING CONSTRUCTION All materials installed shall be maintained and operated by the Contractor until final acceptance; however, specific items meeting the requirements of Article IV, section 4 REA Form 2 00, at the Owner's discretion, can be operated and maintained by the owner. SYSTEM TESTING Functional (or run) testing, in the presence of the manufacturer's representative and/or Engineer, will be required following instal- lation. Functional testing is defined as that testing necessary to determine if installed systems will operate as intended. The Contractor shall furnish all equipment, instruments, and services functional and performance testing. OWNER FURNISHED MATERIAL labor, materials, tools, necessary to perform the The following material will be furnished by the Owner for the contractor to install and incorporate into the work. All inci- dental materials required to properly install this Owner-furnished material, and all materials, except as specifically list~d as owner-furnished, shall be furnished by the Contractor. MATERIAL 20" Butterfly valve 6 11 Air Relief valve APPROXIMATE WEIGHT (LBSl 1000 100 STORED City of Metlakatla City of Metlakatla The Contractor shall procure owner-furnished material which has been received by the Owner from the storage location and transport it to the jobsite. owner-furl}ished material designated to be received by the Contractor shall be received, unloaded, inspected, and transported to the jobsite by the Contractor. Owner-furnished materials that are damaged during Contractor's operations or damaged while in the Contractor's possession shall be replaced andjor repaired to the satisfaction of the Engineer at no additional cost to the owner. Payment for handling Owner-furnished material shall be included in the applicable items of the Bidder's lump sum Proposal for installing the material, or included in the Bidder's applicable unit prices for installing the material. 01001 -3- SITE CONDITIONS SITE INVESTIGATION AND REPRESENTATION The Contractor acknowledges that he has satisfied himself as to the nature and location of the work and local conditions, particu- larly those bearing upon availability of transportation, disposal, handling and storage of materials, labor, water, electric power, roads; uncertainties of weather, creek stages, or similar physical conditions at the site; the conformation and conditions of the ground; the character of equipment and facilities needed prelimi- nary to and during the prosecution of the work; and all other matters which can in any way affect the work or the cost thereof under this Contract. Typical temperature and weather conditions at Metlakatla during the year are summarized below: Temperature op Precipitation (inches) Month _!iL __1Q_ Total-Mean Snow-Mean Jan 38 28 9.8 14.6 Feb 41 32 9.7 11.3 Mar 44 33 8.8 9.7 Apr 49 -37 8.6 2.5 May 56 42 6.6 0.2 Jun 60 48 4.9 .0 Jul 64 52 4.9 . 0 Aug 64 52 7.4 . 0 Sep 60 48 9.8 . 0 Oct 52 42 16.9 0.2 Nov 44 35 12.8 3.2 Dec 40 31 12.0 12.0 ~ The Contractor further acknowledges that he has satisfied himself as to the character, quality, and quantity of surface and subsurface materials to be encountered from inspecting the site, from all exploratory work done by the owner as well as from information presented by the Drawings and Specifications made a part of this Contract. Any failure by the Contractor to acquaint himself with all the available information will not relieve him from responsibility for properly estimating the difficulty or cost of successfully performing the work. The contractor warrants that as a result of his examination and investigation of all the aforesaid data, that he can perform the work in a good and workmanlike manner and to the satisfaction of the Owner. The owner assumes no responsibility for any represen- tations made by any of its officers or agents during or prior to the execution of this contract, unless ( 1) such representations are expressly stated in the Contract, and (2) the Contract 01001 -4- expressly provides that the responsibility therefore is assumed by the Owner. INFORMATION ON SITE CONDITIONS Information regarding site conditions, subsurface information, existing construction of site facilities as applicable, and similar data may be available for inspection at the office of the Engineer upon request. Backhoe pit logs are provided in the Appendix to this specification. Such information is offered as supple-mentary information only. Neither the Engineer nor the Owner assumes any responsibility for the completeness or interpretation of such supplementary information. The contractor may make arrangements with the owner for permission to conduct such additional subsurface investigations as may be necessary to verify existing conditions. EARTHWORK BALANCE Bidders shall make their own estimate of earthwork materials and quantities. No special payment will be made for rock excavation, processing of rock materials as may be required to. be used in embankment sections, and borrow or excess material wasting. UTILITIES AND SERVICES It shall be the responsibility of the Contractor to locate all utilities and services and to protect and maintain such affected utilities during construction. The Contractor shall be solely and directly responsible to the Owner and operators of such properties for any damage, injury, expense, loss, inconvenience, delay, suits, actions, or claims of any character brought because of.any injuries or damage which may result from the construction operations under this Contract. Neither the Owner nor its officers or agents shall be responsible to the Contractor for damages as a result of the Contractor's failure to protect utilities encountered in the work. Notify all utility offices which are affected by the construction operation at least 48 hours in advance. Under no circumstances expose any utility without first obtaining permission from the appropriate agency. Once permission has been granted, locate, expose, and provide temporary support for all existing underground utilities. The Contractor shall replace at his own expense any and all existing utilities or structures removed or damaged during construction unless noted otherwise in these Contract Documents. 01001 -5- UTILITIES SERVING THE AREA Utility Water Line Address Metlakatla Indian Community Metlakatla, Alaska Telephone No. (907) 886-4441 overhead Electrical Line Attn: Delbert Dunn Metlakatla Power and Light P.O. Box 346 Metlakatla, Alaska 99926 INTERFERING STRUCTURES (907) 886-6661 Protect underground and aboveground existing structures from damage, whether or not they lie within the limits of the easements obtained by the owner. Where such existing fences, buildings, or any other structure must be removed in order to properly carry out the construction or are damaged during construction, restore to their original condition to the satisfaction of the property owner involved at the Contractor's own expense. Notify the Engineer of any damaged underground structure, and make repairs or replace- ments before backfilling. EASEMENTS AND RitHT-OF-WAY It is anticipated that the required easements and permits will be obtained by the owner before construction is started. However, should the procurement of any easement or permit be delayed, the Contractor shall schedule and perform the work around these areas until such a time as the easement or permit has been secured. The Contractor shall confine his construction operations to within the easement or right-of-way limits or make special arrangements with the property owners or apprQpriate public agency for the ad- ditional area required. Any damage to property, either inside or outside the limits of the easements provided by the Owner, shall be the responsibility of the Contractor as specified herein. TEMPORARY CONSTRUCTION FACILITIES TEMPORARY WATER Temporary water provided by the Owner is available near the site. The Contractor shall provide pumps and piping andjor trucking to transport the water to the point of use. TEMPORARY ELECTRIC POWER Temporary electric power is available from the power pole near the site. The costs of power and providing temporary wiring, 01001 -6- switching, and hookup to the Owner's system shall be borne by the Contractor. SANITARY FACILITIES The Contractor shall provide a chemical toilet of suitable type and maintain the facility in a sanitary condition at all times. The chemical toilet shall be of watertight construction so that no contamination of the area can result from its use. The facility shall conform to code requirements and be acceptable to the sanitary authorities. Upon completion of the work, the sanitary facility shall be removed and the area restored to its original condition. STORAGE OF MATERIALS Materials shall be so stored as to ensure the preservation of their quality and fitness for the work. When considered neces- sary, they shall be placed on wooden platforms or other hard, clean surfaces, and not on the ground. Stored materials shall be located so as to facilitate prompt inspection. Materials can be stored at the MPL diesel generating plant about 1 mile from the site. SAFETY AND CONV~NIENCE GENERAL The Contractor shall be solely and completely responsible for conducting his operations in a safe manner while conforming to all standards and regulations of governing safety authorities. COMPLIANCE WITH STATE SAFETY, OSHA, AND OTHER CODE REQUIREMENTS The completed work shall includ~ all necessary permanent safety devices, such as machinery guards and similar ordinary safety items required by the State and Federal OSHA industrial safety authorities and applicable local and national codes. Further, any features of the work subject to such safety regulations shall be fabricated, furnished, and installed in compliance with these requirements. One month prior to the plant COMPLETION OF CONSTRUCTION date, the Contractor shall request an inspection by a State and/or Federal Industrial Safety representative for the purpose of determining that the facilities provided are in compliance with the state and Federal safety requirements. TRAFFIC SAFETY AND MAINTENANCE Comply with all rules and regulations of the MIC authorities regarding closing or restricting the use of public streets or highways. No public or private road shall be closed, except by express permission of the governing agency or owner of the road. 01001 -7- ACCESS BY AUTHORIZED REPRESENTATIVES Authorized representatives of the Federal government, the Owner, and the Engineer shall at all times have access to the work and the Contractor shall provide proper facilities for such access and inspection. SNOW REMOVAL Snow removal at the construction site and access road as required for construction will be the Contractor's responsibility. USE OF EXPLOSIVES Obtain and pay for the cost of any permits and licenses required for blasting, and make arrangements for inspection if required by agencies having jurisdiction over such matters. The storage, handling, and use of explosives shall be performed in strict compliance with Federal, State, and local regulations that apply. Coordinate and perform blasting work to avoid interference with or danger to the operations and property of the owner and adjacent facilities. Take all precautions necessary to protect the safety of ail persons in the vicinity of the work. Adopt precautions which will prevent damage to landscape features and other surrounding objects, and which will prevent the scat- tering of rocks, stumps, or other debris outside the construction area. FIRE PREVENTION AND PROTECTION The Contractor shall perform all work in a fire-safe manner. He shall supply and maintain on ~he site adequate fire-fighting equipment capable of extinguishing incipient fires. The Contrac- tor shall comply with applicable Federal, State, and local fire prevention regulations and with applicable parts of the National Fire Prevention Standard. PRESERVATION, RESTORATION, AND CLEANUP SITE RESTORATION AND CLEANUP At all times during the work, keep the premises clean and orderly. Upon completion of the work, leave the project free of rubbish or excess materials of any kind. FINISHING OF SITE, BORROW, AND STORAGE AREAS Upon completion of the project, all areas used by the Contractor shall be properly cleared of all temporary structures, rubbish, 01001 -8- and waste materials and properly graded to drain and blend in with the abutting property. Areas used for the deposit of waste materials shall be finished to properly drain and blend with the surrounding terrai~. TREE REMOVAL No trees, except those required to be removed for construction and by the plans and these specifications, shall be removed without the approval of the Engineer. DISPOSAL OF TREES, BRUSH, AND ROOTS Trees, brush, and roots which are required to be removed for construction shall be hauled to the local landfill located approximately 2.5 miles from the construction site. 01001 -9- PROTECTION OF VEGETATION Trees and shrubbery not designated to be removed shall be protected from damage during construction operations. REVEGETATION Vegetated areas damaged during construction and those areas shown or specified to be revegetated shall be seeded with an approved grass using hydroseeding methods. DUST PREVENTION Unpaved roads and construction areas shall be periodically watered to prevent dust. WORK AROUND STREAMS Deleterious materials 1 such as dirt 1 silt, cement 1 or petroleum products shall not be allowed to enter stream channels, nor should such contaminants be placed where they may later enter these areas. Rubbish and construction debris, including cans, bottles, paper, stumps, and slash shall not be deposited within 50 feet of the high watermark of any stream. All rubbish shall ultimately be removed from the site. Water pumped out of excavations shall be discharged into settling/ percolation ponds or an area separated from the natural stream channel. Earthwork in the floodway shall be with minimum disturbance in compliance with requirements of all Federal, state, and local agencies. SUBMITTALS DORING CONSTRUCTION GENERAL Review of substitutions, schedules, shop drawings, lists of materials, and procedures submitted or requested by the Contractor shall not add to the Contract amount; and all additional costs which may result therefrom shall be solely the obligation of the Contractor. The Owner is not precluded, by virtue of review, from obtaining a credit for construction savings resulting from allowed concessions in the work or materials therefore. It shall not be the responsibility of the owner to provide engineering or other services to protect the Contractor fro~ additional costs accruing from such approvals. 01001 -10- No equipment or material for which listings, drawings, or descriptive material is required shall be installed until the Engineer has on hand copies of materials and the appropriately stamped final shop drawings. The review of drawings by the Engineer will be limited to general design requirements only, and shall in no way relieve the Contractor from responsibility for errors or omissions contained therein. Submittals will be acted upon by the Engineer as promptly as possible and returned to the Contractor not later than the time allowed for review in Shop Drawing Submittal Procedure. Delays caused by the need for resubmittals shall not constitute reason for an extension of Contract time. SHOP DRAWING SUBMITTAL PROCEDURE The Contractor shall submit four copies to the Engineer for his review, such shop drawings, electrical diagrams, and catalog cuts for fabricated items and manufactured items (including mechanical and electrical equipment) required for the construction. Shop drawings shall be submitted in sufficient time to allow the Engineer not less than ten regular working days for examining the shop drawings. Shop drawings shall be submitted by the Contractor who shall indicate by a signed stamp on the shop drawings, or other approved means, that he has checked and approved the shop drawings, and that the work shown is in accordance with Contract requirements and has been checked for dimensions and relationship with work of all other trades involved. Incomplete shop drawings which have not been checked and signed by the Contractor will be considered as not complying with the intent of the Contract Documents and will be returned to the Contractqr for resubmission. After the shop drawings have been reviewed by the Engineer, two stamped sets of submittals will be returned to the Contractor. If major changes or corrections are necessary, the shop drawing may be rejected and one set will be returned to the Contractor with such changes or corrections indicated, and the Contractor shall correct and resubmit the shop drawings in the same manner and quantity as specified for the original submittal, unless otherwise directed by the Engineer. If additional changes are made by the Contractor on the resubmitted shop drawings, such changes shall be clearly explained in a transmittal letter accompanying the resubmitted shop drawings. The review of such shop drawings and catalog cuts by the Engineer shall not relieve the contractor from responsibility for correct- ness of the shop drawings, dimensions, fabrication details, and space requirements, or for deviations from the Contract Drawings 01001 -1:- or Specifications, unless the Contractor has called attention to such deviations in writing by a letter accompanying the shop drawings and the Engineer approves the change or deviation in writing at the time of submission. Shop drawing submittals processed by the Engineer do not become Contract Documents and are not Change Orders. The purpose of the shop drawing review is to establish a reporting procedure, aid the Contractor in organizing his work, and permit the Engineer to monitor the Contractor's progress and understanding of the project. SHOP DRAWING REQUIREMENTS Shop drawings shall be accurate, distinct, and complete, and shall contain all required information, including satisfactory identifi- cation of items, units, and assemblies in relation to the Contract Drawings and Specifications. Shop drawings referred to herein shall include shop drawings and other submittals for both shop and field-fabricated items. The Contractor shall submit, as applicable, the following for all prefabricated or manufactured structural, mechanical, electrical, plumbing, process systems, and equipment: 0 Shop drawings dimensions, size, work. or equipment drawings, including and location of connections to other o Catalog information and cuts. o Installation or placing drawings for equipment, drives, and bases. 0 Supporting calculatioP~ for supports specified to be manufacturers or suppliers. equipment designed and by associated equipment o Wiring and control diagrams of systems and equipment. 0 Complete manufacturer's specifications, materials description and paint system. including o List of special motor features being provided such as space heaters, altitude corrections, thermal protectors, etc. o Complete motor rating for all motors 15 hp and larger, including motor no-load, starting, and full-load current at rated voltage; full-load speed and full-load current at 110 percent voltage; motor efficiency and power factor at 1/2, 3/4, and full load at rated voltage. 01001 -12- The submittals shall include satisfactory identification of items, units, and assemblies in relation to the Specification section number, and the system or equipment identification or tag number shown on the Drawings, or as provided in the applicable Specification section. Should the Contractor propose any item on his shop drawings, or incorporate an item into the work, and that item should sub- sequently prove to be defective or otherwise unsatisfactory, (regardless of the Engineer's preliminary review), the Contractor shall, at his own expense, replace the item with another item that will perform satisfactorily. SUBMITTAL OF INTERFACE INFORMATION The Contractor, all subcontractors, manufacturers, and equipment suppliers shall provide accurate interface information necessary for design and construction. All costs for interfacing and changes required for successful interfacing shall be borne by the Contractor and shall be included as part of the lump sum bid. SAMPLES AND TEST SPECIMENS Where required in the Specifications, and as requested hy the Engineer, test specimens or samples of materials and fittings to be used shall be submitted to the Engineer at the Contractor's expense. Submit samples in time to enable the Engineer to make any tests or examinations necessary, without delay to the work. Laboratory tests and examinations that the owner elects to make in his own laboratory will· be .made at no cost to the Contractor, except that, if a sample of any ~aterial or equipment proposed for use by the Contractor fails to meet the Specifications, the cost of testing subsequent samples shall be borne by the Contractor. All tests required by the Specifications to be performed by an independent laboratory shall be made at the sole expense of the Contractor. PREPARATION OF OPERATION AND MAINTENANCE MANUALS Written Operation and Maintenance Manuals will be prepared by the Engineer from equipment information furnished by the Contractor. This information shall cover all equipment and materials within the project which involve electrical or moving parts subject to failure and replacement of parts thereof. For all equipment which is subject to routine maintenance, such as lubrication, periodic inspection, replacement of wearable parts, 01001 -13- the Contractor shall furnish four copies of a completed Mainte- nance Summary form as included at the end of this Specification section. This form shall be completed by the manufacturer or supplier of the equipment furnished for this project. The Maintenance Summary may take as many pages as required. However, the order and format shown must be adhered to. Only 8-1/2-inch by 11-inch paper will be accepted. For all piping and appurtenances the Contractor shall include the manufacturer's recommendations for the repair of these items and the associated coatings and linings. All of the above information shall be furnished to the Engineer at least 40 days prior to final acceptance. The above information is required in addition to shop drawing submittals even though some information may be identical. At least 20 days prior to comple- tion of the project, the Engineer will provide the Contractor with a list of equipment items for which additional information is required. This additional required information shall be furnished by the Contractor prior to the Engineer's recommendation for project acceptance. PAYMENT All work specified in this section shall be included as part of the lump sum bid. 01001 -14- MAINTENANCE SUMMARY 1. EQUIPMENT ITEM: 2. MANUFACTURER: 3. EQUIPMENT IDENTIFICATION NUMBER(S): 4. NAMEPLATE DATA (HP, VOLTAGE, SPEED, ETC.): 5. MANUFACTURER'S LOCAL REPRESENTATIVE: Name: Address: Telephone No: 6. MAINTENANCE REQUIREMENTS Maintenance Operation List briefly each maintenance operation required and refer to specific information in manufacturer's standard maintenance manual, if applicable. Frequency (If Applicable) Comments List required Refer by symbol frequency of to lubricant each mainte-list as re- nance opera-quired. tion. 7. LUBRICANT LIST Reference Symbol List symbols used in Item 6, above. 8. SPARE PARTS Shell Standard Oil Gulf Or Equal List equivalent lubricants, as distributed by each manufacturer for the specific use recommended. Include your recommendations regarding what spare parts, if any, should be kept on the job. 01001 -15- GENERAL 01310 CONSTRUCTION SCHEDULES RELATED REQUIREMENTS SPECIFIED ELSEWHERE All specification sections. GRAPHIC SCHEDULE A. The Contractor shall submit within fifteen (15) days after notice of award, a schedule in graphic form showing proposed schedule of anticipated progress to include all major operations and teams and time of anticipated completion of major portions of the work. B. The Contractor shall revise schedule on basis and resubmit if there are any deviations from previously submitted data. CRITICAL PATH (CPM) (ALTERNATE) a bi-weekly substantial A. The Contractor may utilize a critical path (CPM) schedule instead of the graphic schedule specified herein providing it meets all applicable requirements specified herein. CONTRACTOR TO SCHEDULE WORK A. The Contractor shall keep the Engineer informed sufficiently in advance of the time and places at which he intends to work in order that lines and grades may be furnished and necessacy measurements for record may be made with the minimum of inconvenience and delay to both the Engineer and the Contractor. FORM OR SCHEDULE (GRAPHIC SCHEDULE) A. Prepare in form of horizontal bar chart. B. Provide separate horizontal bar column for each trade or work activity. c. order: chronological order of beginning of each item of work. D. Identify each column by distinct graphic delineation. 01310 -1- E. Horizontal time scale: Identify first work day of each half month. F. Scale and Spacing: to allow space for updating. SHEET SIZE A. Suitable for size and complexity of project. CONTENTS OF SCHEDULES A. Provide complete sequence of construction by activity. B. Shop Drawings, Project Data and Samples. c. Product procurement and delivery dates. D. Dates for beginning, and completion of, each element of construction. E. Identify work in phases, or other logically grouped activities. F. Show projected percentage of completion for each item of work as of first day of each month. G. Provide subschedules to define critical portions of entire schedule. UPDATING AND CHANGES A. Show all changes occurring since previous submission of updated schedule. B. Indicate progress of each activity, show completion dates. c. Include: 1. Major changes in scope 2. Activities modified since previous updating 3. Revised projects due to changes 4. Other identifiable changes D. Provide narrative report, including: 1. Discussion of problem areas, including current and anticipated delay factors, and their impact. 2. Corrective action taken, or proposed, and its effect. 3. Effect of change in schedules of other Contractors. 4. Description of revisions: a. Effect on schedule due to change of scope b. Revisions in duration of activities 01310 -2- c. Other changes that may affect schedule SUBMITTALS BY CONTRACTOR A. Submit initial schedules within 15 days after date of Notice to Proceed. 1. Engineer will review schedules and return review copy within 10 days after receipt. 2. If required, resubmit within 7 days after return of review copy. B. Submit periodically updated schedules accurately depicting progress to first day of each month. c. Submit the number of copies required by Contractor, plus 4 copies to be retained by Engineer. REPORTS -MISCELLANEOUS A. The Contractor and each subcontractor shall submit to the Owner such schedules of quantities and costs, progress schedules, payrolls, reports, estimates, records and miscellaneous data pertaining to the Contract as may be requested by the Owner andjor requir~d by the Contract. DISTRIBUTION BY CONTRACTOR A. Distribute copies of reviewed schedules to: 1. Job site file 2. Other Contractors 3. Subcontractors 4. Other concerned parties B. Instruct recipients to" report any inability to comply, and provide detailed explanation, with suggested remedies. LIQUIDATED DAMAGES completion Date The required completion date is the date which is 170 calendar days after receipt of the notice to commence construction. The completion of the contract is the date the Certificate of completion is executed. Liquidated Damages In case of failure on the part of the Contractor to meet the required completion Date, including any extension thereof, the 01310 -3- Contractor shall pay the owner as fixed/ agreed 1 and liquidated damages the sum of $250 for each calendar day that the completion of the Contract is delayed. However/ the total amount of liquidated damages to be assessed by the Owner in case of such delays 1 shall not exceed 25 percent of the original Contract price. 01310 -4- SCOPE 02110 CLEARING AND GRUBBING This section covers the work necessary to remove all interfering or objectionable material from the designated areas of work as shown on the Drawings and as approved by the Engineer. In no case shall clearing and grubbing be performed outside of the limits of the Owner's property boundaries as delineated on the Drawings without the prior written approval of the Owner and the Engineer. Review with the Engineer the location, limits, and methods to be used prior to commencing the work under this section. EXISTING UTILITIES AND OBJECTS Conform to the requirements of GENERAL REQUIREMENTS. This work shall also include the preservation from injury or defacement of all vegetation· and existing objects designated to remain, as shown on the Drawings or as specified herein. Existing facilities, adjacent property, and utility facilities that are not to be removed sha 11 be protected from injury or damage resulting f_rom the Contractor's operations. MATERIALS GENERAL Clearing and grubbing shall include, but not be limited to, trees, logs, stumps, roots of downed trees, shrubs, vines, brush, grass, weeds, or other growth, and all structures or material that must be removed to complete this projec~. OWNERSHIP AND DISPOSAL OF MATERIAL All materials or debris removed shall become the property of the Contractor and shall be removed from the area of work and disposed. WORKMANSHIP PRESERVATION OF TREES, SHRUBS, AND OTHER VEGETATION Protect from damage trees, shrubbery, and other vegetation not designated for removal. Cut and remove tree branches only where, in the opinion of the Engineer, such cutting is necessary to effect the construction operation. Remove additional branches to provide a balanced appearance of any tree, as approved by 02110 -1- Engineer. Scars resulting from the removal of branches shall be treated with an approved tree sealant. CLEARING Complete clearing prior to the start of embankment construction. Cut trees and brush as near to the surface of the ground as practical; remove all stumps, and pile for disposal. Do not permit excavated materials to cover brush or trees prior to disposal. No trees shall be cut on the hillside adjacent to the powerhouse site except those designated by the Engineer. About ten trees are anticipated to be removed from the hillside. GRUBBING Remove all wood, roots, vegetable matter, and other material remaining as a consequence of the clearing work. DISPOSAL OF WASTE MATERIAL All waste material shall be disposed of at the Metlakatla landfill located about ·2.5 miles from the construction site. PAYMENT Payment for the work in this section will be included as part of the lump sum bid. 02110 -2- SCOPE 02220 EARTHWORK This section includes the work necessary for earthwork. Trench excavation and backfill shall conform to Section TRENCH EXCAVATION AND BACKFILL. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this Specification. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. DEFINITIONS Relative Compaction Relative compaction is defined as the ratio, in percent, of the as-compacted in-place dry density to the maximum dry density as determined by ASTM D 1557. Optimum Moisture Content Optimum moisture content is that moisture content at which the maximum dry density is reached when the soil is tested in accordance with ASTM D 1557. Well Graded Well graded as used in this section defines a mixture of particle sizes that have no specific concentration or lack thereof of one or more sizes. Well graded is used to help define a material that, when compacted, produces a strong and relatively incompressible soil mass free from detrimental voids. Influence Area Influence area is defined as the area within planes sloped downward and outward at an angle of 60 degrees from the horizontal from two feet outside the outermost edge at the base of founda- tions, slabs, roadways, and pipe springlines. 02220 -1- Completed Course Completed course is defined as a course or layer that is ready for the next layer or phase of construction. MATERIALS UNCLASSIFIED EXCAVATION Excavation is unclassified. Complete all excavation required regardless of the type, nature, or condition of the materials encountered. The Contractor shall make his own estimate of the kind and extent of the various materials to be excavated in order to establish the work. FILL MATERIAL Provide all labor, materials, and equipment necessary to haul, process, spread, moisture condition and compact fill materials. Random Fill Random fill shall consist of excavated material, free or organic and deleterious material and particles larger than 15 inches in maximum dimension. Select Fill Select fill shall consist of excavated material from the jobsite, free of organic and deleterious material and particles larger than four inches. Before excavating, select fill, remove all top- soil and organics. Shot Rock Fill Shall consist of well graded pit run shot rock having a maximum particle size of 8 inches in maximum dimension. The top 2 inches lift in the parking area and road surfaces shall be constructed of select pit run or crushed rock having a maximum particle size of 2 inches in maximum dimension. As an alternate to Shot Rock Fill material meeting requirements may be substituted for Shot Rock Fill. and free of organic and deleterious material meeting gradation requirements. 02220 -2- the following Must be sound the following Cummulative Percent Passing 100 90 -100 75 -100 30 -70 0 -20 less than 3 Size* 3" 1" 3/8" No. 4 Sieve No. 40 Sieve No. 200 Sieve * Sieve sizes are U.S. Standard. Granular Fill Granular fill shall consist of excavated sand free of organic and deleterious materials. ROCK SLOPE PROTECTION Rock for slope protection shall consist of sound quarry rock graded so that 5-percent exceed 200 pounds, 50-percent exceed 75 pounds, and 1 o o -percent of the rock each exceed 2 5 pounds in weight. RIPRAP Riprap shall consist of sound angular quarry rock graded so the 80 percent shall exceed 85 pounds, 50 percent shall exceed 680 pounds, and none shall be greated than 4,000 pounds. The length of the longest side shall not exceed 3 times the length of the shortest side FILTER FABRIC Filter fabric shall be Mirafi 600X or approved equal. A rock filter material approved by the Engineer may be substituted. WATER FOR COMPACTION Provide water for compaction that is reasonably free of turbidity. MATERIAL APPROVAL All tests necessary for the Contractor to locate an approved source of each material shall be the responsibilitiy of the Contractor. Obtain representative samples of each material to be used and submitted to the Engineer. Samples shall be collected in accordance with ASTM D 75, shall be clearly marked to show the 02220 -3- source of the material and the intended use on the project, and shall be submitted to the Engineer for approval at least 14 days before the material is required for use. Tentative approval of the source shall be based on an inspection of the source by the Engineer and test results submitted by the Contractor to the Engineer. Final approval will be based on tests made by the Engineer on samples of material taken from the completed course. If tests conducted by the Engineer indicate that the material does not meet Specification requirements, material placement will be terminated until corrective measures are taken. Material which does not conform to the Specification requirements and is placed in the work shall be removed and replaced at the Contractor's expense. All initial sampling and testing required to be performed by the Contractor and resampling and retesting required for correction or replacement of inadequate material shall be paid for by the Contractor. 02220 -4- COMPACTION EQUIPMENT Compaction equipment shall be of smooth wheel vibratory type and of a size to obtain the specified relative compaction. Provide hand-operated vibrating compactors for compaction adjacent to walls, footings, in tight locations, and in trenches. WORKMANSHIP SAFETY REGULATIONS The Contractor shall comply with all Federal, state, and local safety regulations concerning earthwork and earthwork equipment. GENERAL Use caution when operating heavy equipment within five feet of walls of concrete structures. Compact backfill within one foot of the wall with handheld tampers. Between a distance of one foot and five feet from the wall, lightweight mechanized compaction equipment may be used. Do not operate heavy equipment over underground pipelines when less than four feet of cover is present over the pipelines. Com- pact or excavat~ material within four feet of the pipeline ~sing light mechanized equipment or hand tools. Damage to pipelines shall be repaired by the Contractor at no additional expense to the Owner. UNCLASSIFIED EXCAVATION Excavate to the lines and grades shown or as required to accom- plish the construction. Allow for forms, working space, fill material, and finish topsoil where required. Do not carry excava- tion for footings and slabs d~eper than the elevation shown. Excavation carried below the grade lines shown or established by the Engineer shall be replaced with an approved compacted material or lean concrete. Cuts below grade shall be corrected by simi- larly cutting adjoining areas and creating a smooth transition. The Contractor shall bear all costs for correcting overexcavated areas. Limits of excavation to safely accomplish the work shall be determined by the Contractor. Any minimum excavation limits shown on the Drawings are for the purpose of material identification only and do not necessarily represent required safe limits. All excavations for footings, slabs, and areas to receive compacted fill shall be to firm, clean, undisturbed surfaces. Remove all loose material before pouring concrete or placing fill. 02220 -5- REMOVAL OF WATER Provide and operate equipment adequate to keep all excavations and trenches free of water. If excavations are permitted to become saturated prior to placement of fill material or concrete, soft saturated soil shall be excavated and the area backfilled with material approved by the Engineer. Remove all water during periods of laying pipe, placing of back- fill and concrete, and at such other times as required for efficient and safe execution of the work. Avoid settlement or damage to adjacent property. Dispose of water in an approved manner that will not damage adjacent property. When dewatering open excavations, dewater from outside the structural limits and from a point below the bottom of the excavation. Concrete pour locations shall be kept free of standing water for a minimum of 24 hours after the pour was completed. FILL General Obtain the Engineer's approval of the surface to be filled and the fill material to be used prior to placing any fill. Before placing fill materials, the area to receive fill shall be stripped of all topsoil and organics. Stockpile topsoil to spread as a finish course in random fill areas. All surfaces shall be finished to provide adequate drainage. The finished surface shall be reasonably smooth, compacted, free from irregular surface changes, and comparable to the smoothness obtained by bladegrader operations. Fill around concrete structurP,s only after the concrete has attained two-thirds of the specified compressive strength. Where backfilling on both sides of a structure is required, place the backfill and compact simultaneously on opposite sites in even lifts. Moisture control During the compacting operations, maintain optimum practical moisture content required for compaction purposes in each lift. Maintain moisture content uniform throughout the lift. Insofar as practical, add water to or dry out the material at the site of excavation. Supplement, if required, by sprinkling or aerating the fill. 02220 -6- Compaction Testing Field density and moisture contents shall be determined in accord- ance with ASTM D 2922, D 1556, D 2216, and D 3017, as selected by the Engineer. Cooperate with this testing by leveling small areas as designated by the Engineer. Backfill testing areas as directed. The frequency of testing will be determined by the Engineer. Random Fill Place random fill in areas outside of the influence area of all structures, roadways, footings, slabs, and pipes. Place random fill in maximum 18-inch loose lifts and compact to at least 85 percent relative compaction. The last lift of random fill shall consist of stockpiled topsoil as available. Select Fill Place select fill where shown on the Drawings in maximum nine-inch loose lifts and compact to at least 90 percent relative compaction at optimum moisture content. Spread successive courses so as to produce a uniform distribution of material free from lenses pockets and streaks. After each lift has been compacted and prior to placement of additional filL, the Contractor shall scarify the surface to prevent laminations between lifts. Granular Fill Place granular fill where shown on the Drawings. Place granular fill in influence areas in maximum six-inch loose lifts compacted to 95 percent relative . compaction at optimum moisture content. Place granular fill as ·structural backfill adjacent to concrete structures in maximum nine-in~h loose lifts compacted to 90 percent relative compaction at optimum moisture content. Shot Rock Fill Place in maximum lifts of eight inches. Each lift shall be compacted by four passes of heavy dozer tred traffic or a vibratory grid compactor. Use liberal amounts of water. Compact the rock until a stable surface exists prior to placing the next lift. Shot rock fill placed within the limits of the powerhouse foundation shall be compacted using hand-held vibratory equipment. ROCK SLOPE PROTECTION A footing trench shall be excavated along the toe of the slope and edge of protection as shown on the Drawings. 02220 -7- Rocks shall be so placed as to provide a minimum of voids and the larger rocks shall be placed in the foundation course and on the outside surface of the slope protection. The rock may be placed by dumping and may be spread in layers by bulldozers or other similar equipment. Local surface irregularities of the slope protection shall not vary from the planned slopes by more than one-foot measured at right angles to the slope. FILTER FABRIC Place two layers of filter fabric where shown on the Drawings in accordance with manufacturer recommendations. Lap sheets a minimum of one foot. Take care not to damage fabric with backfill material. Repair any damaged areas with a patch that extends one- foot beyond the tear in all directions. SITE GRADING The site shall be graded to plus or minus 0.2 feet of the lines and grades shown and/or established by the Engineer, with proper allowance for topsoil where specified or shown. Shape, trim, and finish slopes of channels to conform with the lines, grades, and cross sections as shown or approved. Make slopes free of all exposed roots and stones exceeding four-inch diameter. Finished site grading shall be approved by the Engineer. DISPOSAL OF EXCESS EXCAVATION On-site disposal areas for excess excavation materials are shown on the Drawings. If nc;:me are shown or are at capacity, excess materials shall be disposed off-site by the Contractor at no additional cost to the Owner. Conform to all local ordinances and laws relating to transport and disposal of material. PAYMENT Payment for work in this section will be included as part of the lump sum bid. 02220 -8- 02221 TRENCH EXCAVATION AND BACKFILL SCOPE This section covers the work necessary for the trench excavation and backfill, complete. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this project. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. DEFINITIONS Relative Compaction Relative compact-ion is defined as the ratio, in percent, of the as-compacted in-place dry density to the maximum dry density as determined by ASTM D 1557. Optimum Moisture content Optimum moisture content is that moisture content at which the maximum dry density is reached when the soil is tested in accordance with ASTM D 1557. Well Graded Well graded as used in this section defines a mixture of particle sizes that have no specific concentration or lack thereof of one or more sizes. Well graded is used to help define a material that, when compacted, produces a strong and relatively incompressible soil mass free from detrimental voids. TRENCH EXCAVATION Trench excavation shall conform to Unclassified Excavation in section MATERIALS. MATERIALS UNCLASSIFIED EXCAVATION Excavation is unclassified. Complete all excavation required regardless of the type, nature, or condition of the materials 02221 -1- encountered. The Contractor shall make his own estimate of the kind and extent of the various materials to be excavated in order to establish the work. FILL MATERIAL General Provide all labor, materials, and equipment necessary to haul, process, spread, moisture condition, and compact fill materials. Native Material Native material shall consist trench area after stripping. For material shall be free of roots, of material larger than three material. Imported Granular Material of material excavated from the backfill above pipe zone, native organic debris, rocks or masses inches, and other deleterious The pipe zone material shall be imported granular m~terial which shall be of a granular, sandy nature, well graded, free of organic matter and deleterious material and particles larger than 1/2 inch in maximum dimension. Imported granular material shall be-well- graded with less than ten percent passing the No. 200 sieve. It shall contain no crushed rock or rock with sharp edges or corners. WATER FOR COMPACTION Provide water for compaction that is reasonably free of turbidity. MATERIAL APPROVAL All tests necessary for the Ctmtractor to locate an approved source of each material shall be made by the Contractor. Obtain representative samples of each material to be used and submit for approval by the Engineer. Samples shall be collected in accordance with ASTM D 75 and be clearly marked to show the source of the material and its intended use. Tentative approval of the source shall be based on an inspection of the source by the Engineer. Final approval will be based on tests made by the Engineer on samples of material taken from the completed course. If tests conducted by the Contractor or the Engineer indicate that the material does not meet Specification requirements, material placement will be terminated until corrective measures are taken. Material which does not conform to the Specification requirements and is placed in the work shall be removed and replaced at the contractor's expense. 02221 -2- All initial sampling and testing required to be performed by the Contractor and resampling and retesting required for correction or replacement of inadequate material shall be paid for by the Contractor. CONCRETE ENCASEMENT Concrete for encasement shall conform to section CONCRETE. COMPACTION EQUIPMENT Compaction equipment shall be of sui table type and adequate to obtain the specified relative compaction. Provide hand-operated vibrating compactors for use in trenches. Compaction equipment shall be operated in strict accordance with the manufacturer's instructions and recommendations and shall be maintained in such condition that will deliver the manufacturer's rated compactive effort. WORKMANSHIP SAFETY REGULATIONS The Contractor _shall comply with all Federal, state, and local safety regulations concerning trench excavation and backfil-l and trench excavation and backfill equipment. GRADE Excavate the trench to the lines and grades shown or as estab- lished by the Engineer with proper allowance for pipe thickness and pipe zone. Correct any part of the trench excavated below the grade at no additional cost to the Owner. If the trench is exca- vated below the required grade, place native material to the established grade of the bottom of the pipe zone. Material shall be compacted to a minimum of 90 percent of maximum dry density. SHORING, SHEETING, AND BRACING OF TRENCHES Sheet and brace the trench when necessary to prevent caving during excavation in unstable material, or to protect adjacent struc- tures, property, workmen, and the public. Increase trench widths accordingly by the thickness of the sheeting. Maintain sheeting in place until the pipe has been placed and backfilled at the pipe zone. Shoring and sheeting shall be removed, as the backfilling is done, in a manner that will not damage the pipe or permit voids in the backfill. All sheeting, shoring, and bracing of trenches shall conform to the safety requirements of the Federal, state, or local public agency having jurisdiction. The most stringent of these requirements shall apply. 02221 -3- REMOVAL OF WATER Provide and operate equipment adequate to keep all trenches free of water. If trenches are permitted to become saturated prior to placement of fill material or concrete, soft saturated soil shall be excavated and the area backfilled with material approved by the Engineer. Remove all water during periods of laying pipe, placing of backfill and concrete, and at such other times as required for efficient and safe execution of the work. Avoid settlement or damage to adjacent property. Dispose of water in an approved manner that will not damage adjacent property. When dewatering open excavations, dewater from outside the structural limits and from a point below the bottom of the excavation. Concrete pour locations shall be kept free of standing water for a minimum of 24 hours after the pour is completed. FOUNDATION STABILIZATION When, in the opinion of the Engineer, the existing material in the bottom of the trench is unsuitable for supporting the pipe, excavate below the bottom of the pipe zone as directed by the Engineer. Backfill the trench to bottom of the pipe zone with native material. Place the imported granular material over the full width of the trench and compact in six-inch lifts to 90 percent of maximum dry density to the required grade. BACKFILL IN PIPE ZONE Provide imported granular material for the full depth of pipe zone. Hand grade material to proper grade ahead of pipe laying. Material shall provide a firm unyielding support along the entire pipe length. Compact the materi~l in six-inch lifts to 90 percent of maximum dry density. Particular attention must be given to the area of the pipe zone from the flowline to the centerline of the pipe to ensure that firm support is obtained to prevent any lateral movement of the pipe during the final backfilling of the pipe zone. TRENCH BACKFILL ABOVE PIPE ZONE When backfill is placed mechanically, push the backfill material onto the slope of the backfill previously placed and allow to slide down into the trench. Do not push backfill into the trench in such a way as to permit free fall of the material until at least two feet of cover is provided over the top of the pipe. Under no circumstances allow sharp, heavy pieces of material to drop directly onto the pipe or the tamped material around the 02221 -4- pipe. Do not use backfill material of consolidated masses larger than three inches. Backfill the trench above the pipe zone with native material. Place in six-inch layers and compact each layer by means of mechanical tampers or vibratory compactors to a minimum of 85 percent of maximum dry density. MOISTURE CONTROL During the compacting operations, maintain optimum practical moisture content required for compaction purposes in each lift. Maintain moisture content uniform throughout the lift. Insofar as practical, add water to or dry out the material at the site of excavation. Supplement, if required, by sprinkling or aerating the fill. COMPACTION TESTING Field density and moisture contents shall be determined in accor- dance with ASTM D 2922, D 1556, D 2216, and D 3017, as selected by the Engineer. Cooperate with this testing by leveling small areas as designated by the Engineer. Backfill testing areas as directed. The frequency of testing will be determined by the Engineer. CONCRETE ENCASEMENT Place concrete backfill in such a manner that no dirt or foreign material becomes mixed with the concrete. Minimum thickness of concrete protection shall be as shown on the Drawings for concrete encasement. Concrete shall have sufficient time to reach initial set before any additional backfill material is placed in the trench. FINISH GRADING OF WORK AREA All work areas shall be finish graded to within 0.2 feet of its original grade unless otherwise shown on the Drawings. The finished grade shall be free of rocks, and other foreign material. The finished grade shall be free draining and free from holes and rough spots. SETTLEMENT Any settlement noted in backfill within one year will be consid- ered to be caused by faulty workmanship and shall be corrected by the contractor at no cost to the owner. DISPOSAL OF EXCESS EXCAVATION Excess excavated material not required or suitable for backfill shall be disposed of on-site as directed by the Engineer. Conform 02221 -s- to all local ordinances and laws relating to transport and disposal of material. The disposal area shall be uniformly graded to conform to existing contours, shall be sloped to drain, shall be left with a neat appearance, and shall be revegetated as specified in section GENERAL REQUIREMENTS. PAYMENT Payment for the work in this section shall be included as part of the lump sum bid. 02221 -6- 02240 SEDIMENT AND EROSION CONTROL SCOPE This section includes the methods necessary to control surface runoff, sediment production, and erosion in the project area. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this Specification. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. MATERIALS GENERAL Supply all quality materials required to accomplish the work specified herein. SEDIMENT CONTROL Filter Berm Filter berm is a temporary sediment trap and consists of a ridge of gravel or crushed rock constructed across unpaved, graded roadway slopes. Height is 1.5 to 2.0 feet along the uniform top elevation. Top width is 3 to 5 .feet. Side slopes are 3: 1 or flatter. Spacings are 100 to 300 feet for slopes between 2:1 and 6:1, respectively. Straw Bale Barrier straw bale barriers to retain sediment on-site at main drainage ways shall be bound and anchored to the ground. Vegetative Filter Strip Vegetative filter strips are areas of vegetative cover through which storm waters flow before entering streams. Along live streams, vegetative filter strips should be a minimum of 100 feet in width. 02240 -1- EROSION CONTROL Discharge Aprons Velocity of water flowing from points of discharge shall be dissi- pated with the use of hand placed rock, concrete, or prefabricated metal discharge aprons. Design and proper placement shall follow local governing specifications. Graded Slope Protectors Down drains will convey drainage from slopes to stable points of discharge below. The drains may be a flexible down drain, pipe, or a flume. Drains shall be installed immediately following final grading and before revegetation. Surface Protection Protective coverings and mulches shall be used to prevent erosion from rainfall impact, runoff, and wind act'ion on disturbed soil surfaces such as cut and fill slopes, soil stockpiles, and work areas. Straw and hay mulches shall be applied by machine or hand at a rate of approximately two to three tons/acre. Woodchips mulches shall be used only on flat slopes or scarified or serrated steep slopes. Use approximately five to ten pounds of nitrogen fertilizer per ton of woodchips. Woodchips shall be 1/2 to 3 inches in length, 1/2 to 1-1/2 inches in width, and 1/2-inch thick. VEGETATION Native vegetation will be ret~ined and protected wherever possible. Removal of vegetation shall be limited to the area required for immediate construction operations. Seeds and plants to be used for revegetation following construc- tion activities should be selected in advance of construction. Species selection shall include seeds, shrubs, and trees known to be adapted to the soils and climate of the area. Fertilize to promote growth. WORKMANSHIP GENERAL Sediment and erosion control practices shall conform to local governing standards and these Specifications. 02240 -2- SEDIMENT CONTROL Sediment shall be retained on the site. Install sediment traps, straw bale barriers, or other similar control measures prior to clearing or grading. PROTECTION OF VEGETATION Native vegetation shall be protected whenever possible. Trees to be removed shall be clearly marked. GRADING Grading operations shall not create damaging effects of sediment production and dust on the site or on adjacent properties. CONTROL OF RUNOFF Changes in the soil and surface conditions during and after development shall be provided with measures to control conditions which increase runoff. On site runoff shall be collected and disposed at non-erosive velocities to the point of discharge into the natural watercourse. Discharge aprons,· graded slope protectors and other surface protection measures shall be implemented. SLOPE CONSTRUCTION Both cut and fill slopes shall not be steeper than 2:1 unless steeper slopes are determined safe by geological and engineering analyses and erosion control measures are specified. SLOPE SURFACE STABILIZATION .. Mulching, seeding, and other stabilization measures shall be used to protect exposed cut and fill areas. PROTECTION OF WATERCOURSES Grading equipment shall not cross or disturb flowing stream channels. No excavated material shall be deposited or stored in or along side watercourses where high water or storm runoff may wash it away. NEW ROADS Make every effort to limit roadway longitudinal grades to a maximum of between two and ten percent. Sections of steeper grade required for construction shall be limited and include additional erosion control measures specified herein. 02240 -3- A transverse grade from the inside (up-slope) to the outside (down-slope) of the road shall not be less than two percent if: 1) slopes above the road are less than 100 feet; 2) general slopes in the area are less than 20 percent; 3) there is dense vegetation on stable soils, with no large fill areas down-slope of the road; and, 4) conditions exist which encourage rapid and adequate vegetation. A two percent transverse slope from the outside to the inside of the road shall occur if the previous conditions do not exist. Cross drains, drainage dips, and culverts shall be constructed as required to adequately carry drainage water away from the roadway without erosion in or adjacent to the road. TOPSOIL Suitable topsoil shall be stockpiled for use on areas to be vegetated. Topsoil shall be stockpiled away from streams and drainageways and protected from erosion. SEEDING FOR REVEGETATION Seeds shall be placed on mineral soil and covered by soil and mulch. Soil surface shall be roughened to a depth of two inches in clayey soil, seed must be 1/4-inch below ground surface. Seed must be distributed evenly. Seeding shall not be performed when, in the opinion of the inspector, weather or ground conditions are unsuitable for this operation. PAYMENT Payment for work in this ~ection will be included as part of the lump sum bid. 02240 -4- SCOPE 03300 REINFORCED CONCRETE This section includes the work necessary to furnish and place reinforced concrete. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this specification. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. In addition, the following specific information shall be provided: o Reinforcing steel shop drawings including bending lists and placing drawings o Concrete mix design o Manufacturers recommendations and information for all concrete admixtures and embedded items PLANT INSPECTION The Engineer shall have access to inspect the concrete batch plant and the facilities of all suppliers providing products included in these Specifications. Batch plants shall have current certifica- tion that all weighing scales have been tested and are within the tolerance in ACI 304. MATERIALS CONCRETE concrete shall be ready-mixed conforming to ASTM C94, Alternative 1 and these Specifications. A mix design pre-prepared or done at the site may be substituted with the Engineer's approval. CEMENT cement shall conform to ASTM Cl50, Type I or Type II. (high early strength) cement shall only be used for installations as approved by the Engineer. 03300 -1- Type III specific AGGREGATE Natural aggregates shall conform to ASTM C33 and these Specifica- tions. Aggregates shall be thoroughly washed before use and shall not be potentially reactive as defined in Appendix XI of ASTM C33. Fine aggregate shall conform to ASTM C33 with less than four percent of the material passing the No. 200 sieve. Coarse aggregates shall be natural gravels, crushed gravels, crushed stone, or combinations thereof containing no more than 15 percent elongated particles (long dimension more than five times the short dimension) . Materials finer than the No. 200 sieve shall not exceed 0.5 percent. CONCRETE ADMIXTURES All concrete shall contain air-entraining and water-reducing admixtures. Both admixtures shall be non-toxic after 3 0 days, contain no chlorides, and be compatible with each other. The air- entraining admixture shall conform to ASTM C260: and the water re- ducing admixture shall conform to ASTM C494, Type A. The amounts of admixture shall be in accordance with the manufacturers recom- mendations and these Specifications. Furnish a manufacturers compliance statement that the admixtures used satisfy these requirements. GROUT Horizontal Construction Joint and Rock Grout Grout shall be flowable and consist of the specified concrete mix with the coarse aggregate left out. The ratios between the sand, fine aggregate, and cement shall be maintained, resulting in a higher cement content than the concrete mix. Add water for a four-to five-inch slump. • Drypack Grout One part cement to two parts fine sand and water to form a damp formable consistency. Nonshrink Grout Nonshrink grout shall conform to the Corps of Engineers Specifi- cation CRD-C588-78 and to these Specifications. The grout shall be non-metallic fluid grout containing all inorganic components. The grout shall be a nongas liberating type, cement base, premixed product requiring only the addition of water for the required consistency. Examples of grouts which meet this specification are UPCON High Flow, The UPCO Co. 1 and Master Flow 713, The Master Builders Company. 03300 -2- The grout shall be cured with a curing compound as recommended by the grout manufacturer. Epoxy Grout Epoxy grout shall be two-part Unisorb Y-100 as manufactured by Unisorb Machinery Installation Systems, Jackson, Michigan, or approved equal. FORMS Forms shall be plywood, plastic finished form plywood, or steel of sufficient strength and surface smoothness to produce the speci- fied finish. Forms shall have positive spacers for the required width. All joints, gaps, and openings in forms shall be plugged and/or caulked so that the joint is watertight and will not bulge or allow the formation of surface patterns. Corner strips shall be nonabsorbent and shall be sealed against the forms to prevent the loss of paste between the two surfaces. Form Ties Form ties shall be uniformly located to withstand all pressures while limiting the deflection of the forms. Ties shall have conical inserts and shall be constructed so that no metal is within one-inch of the concrete surface when the inserts and tie ends are removed. Wire form ties will not be permitted. BONDING AGENT The bonding agent shall be a product recommended by the manu- facturer as suitable to meet job requirements with regard to surface, pot life, set time, vertical or horizontal application, and forming restrictions. Submit manufacturers specific instructions for the job application to the Engineer for review. Examples of acceptable suppliers are W.R. Grace and Company, Sika Chemical Corp., and Adhesive Engineering Company. BOND BREAKER The bond breaker shall be a nonstaining type, which will provide a positive bond prevention such as Williams Tilt-Up Compound, Williams Distributors, Inc.; Silcoseal 77, Superior Concrete Accessories; or equal. Submit copies of manufacturer's data, 03300 -3- recommendations, and instructions for specific use on this project to the Engineer for review. CURING COMPOUND The curing compound shall conform to ASTM C309 and shall be compatible with any finishes or coatings. The Contractor shall conform to manufacturer recommendations for the quantity and coverage required and method of application to meet these Speci- fications. Submit manufacturer certification and recommendations to the Engineer for review. REINFORCING STEEL Deformed billet-steel bars shall be of the sizes shown on the Drawings conforming to ASTM A615, Grade 4 0. Grade 60 may be substituted for Grade 40 with the approval of the Engineer. Provide concrete blocks for reinforcing placed on grade and galvanized metal chairs for formed surfaces. Tie wire shall be 16-gauge, black, soft-annealed wire. Fabrication shall be in accordance with the current edition of the Manual of Standard Practice for Reinforced Concrete Construction, published by the Concrete Reinforcing Steel Institute. Al~ bars shall be bent cold. WORKMANSHIP CONCRETE MIX DESIGN The concrete supplier shall furnish evidence that his current supply of cement, admixtures, aggregates, and water, and his established mix designs using these ingredients meet all strength, density, workability, and durabi~ity requirements of these Speci- fications. The reports must be complete and current. The mix design shall meet the following requirements: o Design strength shall be 3, 000 psi at 28 days unless otherwise shown on the Drawings or specified herein. o Maximum water-cement ratio = o. 49 by weight, unless otherwise approved in writing by the Engineer. o Minimum cement content required for performance and longevity, regardless of design strength, shall be 517 pounds per cubic yard for concrete with the 1-1/2-inch maximum size aggregate and 564 pounds per cubic yard for the one-inch maximum size aggregate. The use of pozzolan fly ash as a substitute for cement is not acceptable. 03300 -4- The Contractor shall increase the cement content as required to meet strength requirements. o Air content (ASTM C231); range four to six percent. o Slump Range: Slab on grade or heavy sections wider (in plan view) than 3 feet Footings, walls, suspended slabs, and beams. 1 - 3 inches 2 - 4 inches Verify that design mix test results reflect the slumps to be used. o Combined Aggregate Gradings: Aggregates for concrete shall be combined in proportions that will provide a mixture within the grading limits shown below unless otherwise approved in writing by the Engineer. Sieve Sizes 2" 1-1/2 11 1" 3/4 11 3/8 11 No. 4 No. 8 No. 16 No. 30 No. so No. 100 No. 200 Percentage Passing 1-1/2 11 Max 100 90-100 50-86 45-75 38-55 30-45 23-38 17-33 10-;22 4-10 1-3 0-2 1" Max 100 90-100 70-90 45-65 31-47 23-40 17-35 10-23 2-10 0-3 0-2 The l-inch maximum or 1-1/2-inch maximum combined aggregate grading shall be used for all concrete placed with a chute. The l-inch maximum grading may be used in lieu of the 1-1/2-inch with the specific approval of the Engineer when it is necessary to pump the concrete. o Use a water-reducing agent in all concrete. o All mixes shall be designed to break at or above a strength equal to 118 percent of the design strengths shown or specified. 03300 -5- CERTIFICATION Furnish a delivery ticket with information conforming to ASTM c 94 15.1 and 15.2 to the Engineer with each batch of concrete before placement. MEASUREMENT AND MIXING Conform to ACI 304 and these specifications for mix design, testing, and quality control. Place conc~ete only after completion of forms, placement of reinforcing steel, and notifying other trades affected. Before depositing concrete, remove debris from the space to be occupied by the concrete. Dampen gravel fill under slabs on ground, sand where vapor barrier is specified, and all wood forms prior to placement of concrete. Reinforcement and all anchor devices shall be secured in position and acceptable to the Engineer before concrete is placed. Unless the tremie method for placing concrete is specified, remove all water from the space to be occupied by the concrete. Notify the Engineer or his authorized representative at least two days in advance of placing concrete. Placement shall conform to ACI 304 and these specifications. Place concrete in lifts not over 1-1/2 feet deep while limiting the free fall of the concrete to six feet. Total vertical lifts in a single pour shall not exceed 14 feet in height. The use of aluminum pipe or other aluminum-conveying devices will not be permitted. Consolidation Concrete shall be consolidated with equipment and methods conform- ing to ACI 309. Consolidation shall be with internal vibrators having a frequency of at least 8, ooo vibrations per minute. At least one operable stand-by vibrator shall be on the job prior to placing the concrete. Either the vibrator operator or an observer shall be able to see the concrete being consolidated. Placing Concrete in Cold Weather Place and protect in accordance with the requirements of ACI 306- 66. No concrete shall be placed against frozen earth or ice, against forms with frost or ice present, or when the ambient temperature is below 4o•F or approaching 4o•F and falling. Any concrete damaged by freezing shall be removed and replaced at no additional cost to the Owner. 03300 -6- Bonding to New Concrete Horizontal Construction Joints Roughen the surface of the hardened concrete. Thoroughly clean and saturate with water, cover the horizontal surfaces only with at least two inches of grout, as hereinbefore specified, and immediately place concrete. New concrete is defined as less than 60 days old. Limit the concrete lift placed immediately on top of the grout to 12 inches thick and thoroughly vibrate to mix and consolidate the grout and concrete together. Provide positive measuring device such as a bucket or other device that will contain only enough grout for depositing in one place in the wall or column to ensure that that portion of the form does not receive too much grout. The depositing of grout from pump hoses or large concrete buckets will not be permitted unless in- spection windows close to the joint are available to allow visual measurement of grout thickness and means for grout removal are available for removal of excess grout. GROUTING Mix and install all types of grout in accordance with manufac- turer's recommendations. Use the type of grout shown on the Drawings. Volu~es to be grouted shall be filled completely with grout without voids or inconsistencies. Grouting Machinery Foundations Block out the original concrete or finish off a sufficient distance below the bottom of the machinery base to provide for the thickness of grout shown on the Drawings. After the machinery has been set in position and set to the proper elevation by steel wedges, the space between the bottom of the machinery base and the original pour of concrete shall be filled with nonshrink or epoxy grout as hereinbefore specified ~nd shown on the Drawings. FORMS Form Design, Windows, and Shop Drawings All forms shall be structurally designed by the Contractor or Contractor's Engineer and the design shop drawings shall comply with all applicable portions of ACI 347 and these specifications. Form Tolerances Forms shall be surfaced and constructed to meet ACI 347 and the following minimum requirements for the specified finishes. 03300 -7- Rough Wall Finish Surface smoothness shall be such that surface defects are smaller than 1/4-inch in diameter or depth. Limit surface deflections to 1/4-inch in 10 feet. Fins shall be less than 1/8-inch wide and deep. Ordinary Wall Finish Surface smoothness shall be such that there are no surface defects larger than 1/8-inch in depth or 1/4-inch in diameter, and there shall be not more than ten such surface defects in any 1-square-foot area. There shall be no depressions or fins in excess of 1/16-inch. Surface deflections shall be limited to 1/16-inch at any point, and the variation in wall deflection shall not exceed 1/8-inch per 10 feet. Form panels shall be arranged orderly and symmetrically with a minimum of seams. Reuse of wooden forms will be permitted only if maintained in good enough condition to provide the specified wall finish. Form surface Preparation All form surfaces in contact with concrete shall be cleaned of all previous concre~e, dirt, and other surface contaminants. Wood forms shall be coated with a release agent according to manufacturer recommendations prior to form installation. Steel forms shall be sandblasted to remove millscale and rust before treating with a release agent. The release agent shall be recommended for steel forms and shall prevent discoloration of the concrete from rust. Beveled Edges (Chamfers) Form 3/4-inch bevels at all concrete edges, except those on top of walls and elevated slabs and beams. Round other edges with a radius tool. Form Removal The Contractor shall be responsible for all damage resulting from removal of forms. Forms and shoring for elevated structural slabs or beams shall remain in place in accordance with ACI 347 and until the concrete has reached a compressive strength as determined by test cylinders. Removal of all supports and reshoring shall not be permitted. 03300 -a- BACKFILL AGAINST WALLS Do not place earth backfill against walls until the concrete has obtained a compressive strength equal to the specified 28-day com- pressive strength. Where backfill is to be placed on both sides of the wall, the backfill shall be placed uniformly on both sides. CONCRETE FINISHES SCHEDULE OF CONCRETE FINISHES Area Exterior Slabs, Sidewalks, and Pads Interior Slabs All Exposed Walls Backfilled Walls CONCRETE WALL FINISHES Rough Wall Finish Type of Finish Broomed Steel Trowelled Ordinary Rough (to 2 feet below finish grade) All rock pockets, form tie holes, and other irregularities_shall be patched as specified herein. Ordinary Wall Finish Immediately after removal of the forms, patch or point up all defects as specified under Patching and Repair and cure patches. After paintings have set sufficiently, grind or fill all form marks and paintings to give a smooth surface even with the flat wall surface. • Give all concrete surfaces poured against forms, and not shown or specified as receiving a particular finish, an ordinary wall finish. CONCRETE SLAB FINISHES The excessive use of jitterbugs or other special tools designed for the purpose of forcing the coarse aggregate away from the surface and allowing a layer of mortar to accumulate will not be permitted on any slab finish. The dusting of surfaces with dry materials will not be permitted. Slabs and floors shall be thoroughly compacted by vibration. All edges of slabs and tops of walls shall be rounded off with a steel edging tool, except where a cove finish is indicated on the Drawings. Steel edging tool radius shall be 1/4-inch for all slabs subject to wheeled traffic. 03300 -9- Steel Trowelled Finish Finish by screeding and floating with straightedges to bring the surfaces to the required finish elevation shown on the Drawings. While the concrete is still green, but sufficiently hardened to bear a man's weight without deep imprint, it shall be wood-floated to a true, even plane with no coarse aggregate visible. Sufficient pressure shall be used on the wood floats to bring moisture to the surface. After surface moisture has disappeared, the concrete shall be hand trowelled to produce a smooth, impervious surface, free from trowel marks. An additional troweling shall be given the surface for the purpose of burnishing. The final troweling shall produce a ringing sound from the trowel. Dry cement or ad- ditional water shall not be used in troweling, nor will excessive troweling be permitted. Wood Float Finish Finish by screeding with straightedges to bring the surface to the required line as shown on the Drawings. While the concrete is still green, but hardened sufficiently to bear the cement finisher's weight, the surface shall be wood-floated to a true and uniform plane with no coarse aggregate visible. Broomed Finish Finish concrete as specified for steel-troweled floor finish above, except the final troweling shall be omitted and the surface shall be finished by drawing a fine-hair broom lightly across the surface. All brooming shall be in the same direction and parallel to expansion joints, or, in the case of inclined slabs, perpendicular to the slope. Sidewalks shall slope 1/4-inch per foot away from structures unless shown otherwise. Broom the surface at right angles to the direction of traffic. Power Machine Finish In lieu of hand finishing, the Contractor may use an approved power machine for finishing concrete floors and slabs in accor- dance with the directions of the machine manufacturer and as approved by the Engineer. CURING OF CONCRETE cure concrete by keeping the surface continuously wet for seven days where normal portland cement is used, or 3 days where high- early strength Type III cement is used. Subject to approval by the Engineer, one of the following methods shall be followed: 03300 -10- Walls o Concrete forms shall be left in place and kept suffi- ciently damp at all time to prevent opening of the joints and drying of the concrete; or o A curing compound as hereinbefore specified shall be applied immediately after removal of forms, except where finishing is required. In this case, forms will be kept damp as required above until removed. Where rubbed finish is required or where an ordinary wall finish for a painted surface is required, curing compound shall be applied immediately upon completion of finishing, and the unfinished, exposed surfaces shall be kept wet by sprinkling until finishing begins. When ordinary wall finish that will not require painting is required, curing compound shall be applied immediately after removal of forms and the compound chipped off or other- wise removed where patching or pointing is required. Compound shall not be applied to surfaces which are to later be bonded to new concrete; or o Exposed surfaces shall be continuously sprinkled. Slabs and Curbs o Protect surface by pending; or o Cover with burla~ or cotton mats kept continuously wet; or o Cover with l-inch layer of wet sand, earth, or sawdust, and keep continuously wet; or o Continuously sprinkle t~e exposed surface; or o Spray surface with curing compound and when hard enough to sustain foot traffic on same day as pour, lay sprinkler hoses and cover with Visqueen sheets. Keep enough water from sprinkler hoses to keep surface of slab under Visqueen wet for full cure period; or o Other agreed upon method that will provide that moisture is present and uniform at all times on the entire surface of the slab. Curing and Protection in Cold Weather Conform to ACI 306. Repair or replace concrete damaged by cold weather. 03300 -11- EVALUATION AND ACCEPTANCE OF CONCRETE Conform to ACI standard Building Code requirements for reinforced concrete (ACI 318-77), Section 4.8, Evaluation and Acceptance of Concrete and to the following specifications: The owner's representative will make or have tests made to determine compliance with the specifications. The Contractor shall cooperate in the making of such tests by furnishing necessary labor to assist testing agencies andjor the Engineer in obtaining, handling, and protecting andjor curing samples at the jobsite. The Contractor shall provide adequate facilities for safe storage and proper curing of concrete test cylinders on the project site for the first 24 hours and for additional time as may be required before transporting to the test lab. Specimens will be made, cured, and tested in accordance with ASTM c 31 and ASTM c 39. The frequency of testing may be increased at the discretion of the Engineer. Where the term "building official" is used in Section 4. 8 of ACI 318-77, the term shall be redefined to "the owner's representative". PATCHING AND REPAIR General Prior to starting repair work, the Contractor shall obtain proposed techniques and mixes. except as specified hereinafter, the Engineer's approval of the The Contractor shall develop his patching and repair techniques and mixes on a portion of as-cast surface selected by the Engineer for this purpose. Dress surface of patches that will remain ex- posed to view to match the color and texture of adjacent surfaces . • Patching and repair of defective concrete will be done to the satisfaction of the Engineer at no additional cost to the Owner. Tie Holes All tie holes, except where sealant is indicated, shall be filled with nonshrink, nonmetallic grout. Color of grout after curing shall match color of adjacent concrete. Defective Areas Remove all defective concrete out to sound concrete. If chipping is required, the edges shall be perpendicular to the surface. Feather edges shall not be permitted. The defective area shall be filled with a nonshrink, nonmetallic grout. Use an approved bonding agent on horizontal patches prior to placing nonmetallic, nonshrink grout. Since some bonding agents may not be compatible 03300 -12- for some vertical surface patching techniques, the Contractor shall consult with representatives of the bonding agent manufac- turer and the nonshrink grout manufacturer and obtain their written recommendations. Submit this information for review prior to performing the work. REINFORCING STEEL Delivery and Storage Deliver steel with suitable hauling and handling equipment. Tag for easy identification and store to prevent contact with the ground. Placing Reinforcing Steel Conform to the design Drawings, the reviewed shop drawings, the current ACI standard Building Code Requirements for reinforced concrete, and the current Recommended Practice for Placing Reinforcing Bars, published by the Concrete Reinforcing Steel Institute. Clean the reinforcement of any oil, soil, or loose scale before placing. Do not rebend reinforcement. Splices shall conform to the Drawings and the current ACI 318 code. Stagger all adjacent bar splices. - Reinforcement Around Openings Place an equivalent area of steel around openings equivalent to that which was cut for the opening. See the Drawings for additional reinforcing required. Welding Reinforcement Welding of reinforcement shall not be permitted. PAYMENT Payment for the work in this section will be included as part of the lump sum bid. 03300 -13- 05500 MISCELLANEOUS METALS SCOPE This section includes the work necessary to furnish and install all miscellaneous metals. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this Specification. Like items of materials provided hereunder shall be the end products of one manufacturer in order to achieve standardization for appearance, maintenance, and replacement. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. MATERIALS GENERAL Unless otherwise indicated, all materials shall conform to the latest issue of the following ASTM Specifications: Item Steel Shapes & Plates Stainless steel Exterior and Submerged Bolts Aluminum, Structural Shapes and Plates Connection Bolts for Steel Members Anchor Bolts (Galvanized unless otherwise shown) Connection Bolts for Wood Item ASTM Specification ASTM Specification A 36 A 167, Type 316 Type 303 or 304 Alloy 606l-T6; conform to referenced Specs & ASTM Sections found in the Aluminum Association current Construction Manual Series A 325-F A 307 A 307 05500 -1- Item ASTM Specification Connection, anchor, and Stainless steel, Type 303 expansion anchor bolts for or 304 aluminum Cast Iron A 48, Class 30 The miscellaneous metal work and castings indicated on the Drawings or required to secure the various parts together and provide a complete installation shall be included under this section. The tabulation of items herein is not intended to be all-inclusive, and it shall be the Contractor's responsibility to provide all metalwork and castings shown, specified, and necessary to complete the project. WELDING ELECTRODES Welding electrodes, shall be compatible with and develop the full strength of the base metal. conform to the Structural Welding Code of the American Welding Society. ANCHOR BOLTS Anchor bolts shal1 be 1/2-inch minimum galvanized or stainless steel bolts with nuts and washers as shown on the Drawings and required by these Specifications. DRILLED-IN EXPANSION ANCHORS Expansion anchor bolts and expansion flush shells shall be 1/2-inch minimum diameter galvanized, cadmium plated or Type 303 stainless steel as shown on the Drawings and required by these Specifications. Anchors shall be Phillips Red Head, Wej-It, Hil ti, or approved equal. Provi.s:le International conference of Building Officials (ICBO) recommendations regarding safe allowable working loads. PIPE SLEEVES ASTM A 120 standard weight steel pipe. Fabricate seepage rings of 1/4-inch steel plate extending 2 inches from the pipe and weld continuously to pipe around complete circumference. Hot-dip galvanize after fabrication. MACHINE BOLTS Machine bolts and fasteners permanently embedded in concrete and those bolts located outdoors, connecting aluminum, and in wet and corrosive areas shall be stainless steel. 05500 -2- Machine bolts located indoors and in noncorrosive areas shall be galvanized. GRATING All grating on the project shall be of either galvanized steel or aluminum as shown on the Drawings. Grating shall be supplied by a reputable grating manufacturer and shall be either welded or mechanical lock-type of the minimum thickness shown on the Drawings. The bearing bars shall be 3/ 16-inch-thick on 1-3/16-inch centers. Cross bars spaced four inches on center shall be hex-shaped for welded grating and notched rectangular bars for mechanical lock grating. Grating for spans not shown on the Drawings shall be designed for a minimum load of 100 psf with a maximum live load deflection of the span divided by 360. Maximum width of grating panels shall be otherwise shown. Band all edges and cutouts. grating and accessories after fabrication. three feet unless Galvanize all steel Grating shall be provided with all frames, seat angles, fasteners, and other required accessories. Fasteners for anchoring grating to beam and channel flanges shall be saddle clips with 1/4-inch bolts and nuts. Fasteners shall be a minimum of four to each grating panel. ABRASIVE NOSINGS Concrete stairways shall have cast aluminum abrasive nosings with integrally cast aluminum oxide granules to provide a non-slip surface. The treads shall have integrally cast anchors and shall . . extend to three 1nches from the edge of each tread. LADDERS Fabricate ladders with rails and rungs as shown on the Drawings. Include all brackets and accessories necessary for the instal- lation of the ladder. Ladder geometry and material (aluminum or steel) shall be as shown on the Drawings. Rungs shall have a non-skid surface. Aluminum ladders shall be anodized and steel ladders shall be hot-dip galvanized after fabrication. Ladder strength, capacity, and geometry shall conform to appli- cable standards of OSHA and the State Basic Safety Code. 05500 -3- CHECKER PLATE COVER Checker plate shall be a minimum of 1/4-inch thick or as shown. Provide frame, gasket, and screws as shown. Materials and size shall be as shown on the Drawings. Steel plate shall conform to Federal Specification QQ-F-461, Class I, hot-dip galvanized after fabrication, with steel frame and accessories. Aluminum plate shall be 6061-T6 tread plate with aluminum frame and stainless steel accessories. HATCHES Hatches shall be Bilco Type J or JD or Babcock-Davis AM or GT, respectively, or equal. Clear opening, material, and type of hatch (single or double) shall be as shown on the Drawings. Hatches shall have checker plate covers and be designed to withstand a live load of 300 pounds per square foot. Aluminum hatches shall receive a mill finish. GASKETS Gaskets where shown for checker plate covers and hatches shall be 1/4-inch thick closed cell neoprene. WORKMANSHIP GENERAL The Contractor shall verify all dimensions for metalwork and make any field measurements necessary before fabrication of metalwork. Workmanship and finish of all metalwork shall be equal to the best practice available in modern shops. Surfaces shall have smooth finishes with sharp, well defined lines. Conceal fastenings where possible, and countersink holes , for flat-head screws. Weld connections except where bolting is shown or required. Grind all exposed edges smooth and remove all burrs and surface defects. All members shall be furnished full length without splices unless otherwise shown or approved. steel shall be fabricated and erected in accordance with the American Institute of Steel Construction, Steel Construction Manual. Bolted connections shall be AISC standard framed beam connections to develop the full strength of the member unless shown otherwise. Aluminum shall be fabricated and erected in accordance with the standards of Aluminum Association. 05500 -4- PRODUCT DELIVERY STORAGE AND HANDLING As far as is practical, fabricated metals shall be factory assembled. Items that are shipped unassembled, shall be tagged for assembly. Load, transport, and unload metalwork such that it is not deformed, scratched, or otherwise damaged. store all materials in dry ventilated areas and not in contact with the ground. Do not install materials in a manner that might cause distortion or damage to the metalwork or the supporting structure. WELDING Welding techniques, filler, and methods shall conform to appli- cable standards of the American Welding Society (AWS). Surfaces to be welded shall be clean and free of loose scale, rust, grease, and paint. All welders shall be certified in accordance with AWS standard Qualification Procedure for the type of welding being performed. Weld shall be free uniform and free of undercutting, spatter, and sharp projections. All welded materials shall be coated (galvanized, anodized, or painted) after fabrication. Repair-type welds shall be recoated to match the surrounding coating system in quality and appearance. INSTALLATION Install metals in accordance with the shop drawings, the Drawings, and these Specifications. Perform field welding and erection work by skilled mechanics. Install fabricated metalwork plumb or level as applicable. The completed installations shall, in all cases, be rigid, substantial, and neat in appearance. Install commer- cially manufactured products in accordance with manufacturer's recommendations as approved. Mill markings shall not be removed from concealed aluminum surfaces. Exposed aluminum surfaces shall have all identification marks removed after final material inspection by the Engineer. ANCHOR BOLTS Cast-in anchor bolts shall be accurately located and held in place with templates at the time the concrete is poured. Inserting anchors into poured concrete is not acceptable. Expansion anchors 05500 -5- shall not be substituted for cast-in anchors unless shown or approved by the Engineer. DRILLED-IN EXPANSION ANCHORS Where shown on the Drawings or approved, installation of anchors shall not begin until the concrete or masonry receiving the anchors has attained its design strength. An anchor shall not be installed closer than six times its diameter to either an edge of the concrete or masonry or to another anchor, unless specifically detailed otherwise. COVERS AND HATCHES Cover and hatches shall be accurately positioned prior to placing concrete, such that the covers are flushed with the floor surface. The covers shall be protected from damage resulting from concrete placement. Exposed surfaces shall be thoroughly cleaned of all concrete spillage such that a clean, uniform appearance is achieved. Neoprene gaskets shall be continuous and uniform and be cemented in place to either the cover or the frame. GALVANIZING AND REPAIR Galvanizing of steel plates, shapes, and bars and products fabri- cated from these i terns, and strips 1/8-inch thick or thicker, shall conform to the specifications of ASTM A 123. Pipe, welded or seamless steel, shall conform to the specification of ASTM A 120. Material thinner than 1/8-inch shall either be galvanized before fabrication in conformance with the requirements of ASTM A 525, Coating Designation C 210, or after fabrication, in conform- ance with the requirements of ASTM A 123, except that the weight of zinc coating shall average not ~ess than 2.3 ounces per square foot. Square footage shall be a measure of actual surface area of steel to be galvanized including all sides of each bar or section. Unless otherwise provided, galvanizing shall be done before or after fabrication, for material which is thinner than 1/8 inch, at the option of the Contractor. Galvanizing will not be required for stainless steel and similar corrosion-resistant parts. All welded areas shall be thoroughly cleaned prior to galvanizing to remove all slag or other material that would interfere with the adherence of the zinc. When it is necessary to straighten any sections after galvanizing, such work shall be performed without damage to the zinc coating. In like manner, galvanizing of iron and steel hardware, nuts, and bolts shall conform to the specifications of ASTM A 153, except that the weight of zinc coating shall average not less than 2.0 ounces per square foot. 05500 -6- Components of bolted assemblies shall be galvanized separately before assembly. All edges of tightly contacting surfaces, where galvanizing is required, shall be sealed by welding before galvanizing. Galvanized surfaces that are abraded or damaged at any time after the application of the zinc coating shall be repaired in accor- dance with Section PAINTING. ALUMINUM AND DISSIMILAR METAL PROTECTION Where aluminum is in contact with dissimilar metals or to be embedded in masonry or concrete, protect surfaces in accordance with section PAINTING. Allow paint to dry before installation of the material. Protect painted surfaces during installation; should coating become marred, prepare and touch up surface per paint manufacturer's instructions. PAINTING Painting shall conform to Section PAINTING. GROUT Grouting of baseplates shall conform to Section REINFORCED CONCRETE. PAYMENT Payment for the work in this section will be included as part of the lump sum bid. 05500 -7- SCOPE 09900 PAINTING This section includes the work necessary for surface preparation, furnishing, and application of paints and protective Coatings. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this Specification. All interior, exterior metal and submerged metal surfaces shall be painted, whether specifically mentioned or not, unless otherwise noted on the Drawings or these Specifications. SUBMITTALS DURING CONSTRUCTION Submittals during construction shall be made in accordance with the GENERAL REQUIREMENTS. In addition, the following specific information shall be provided: The Contractor shall submit complete coating information for all items to be coated including all mechanical and electrical equipment. The coating information shall include a Paint System Data Sheet and a Coating Preparation and Application Sheet. These sheets shall describe surface preparation, the paint manufacturer and catalog number, color chips of paint, the number of coats, and total dry film thickness. The colors will be chosen by the Engineer during the review of the submittals. MANUFACTURER COATED EQUIPMENT ANO MATERIALS All manufactured items including electrical and instrumentation equipment, electric motors and pumps shall be prepared and coated by the manufacturer. All prefabricated metal building components except side and roof panels shall be either shop primed and field finish coated or shop primed and finish coated with field touch up. Building siding and roof panels shall be shop primed and coated with the manufac- turer's baked on coating system. See Section PREFABRICATED METAL BUILDINGS. Coating systems shall be the manufacturer's standard provided the systems are equivalent to the system specified for the service environment of that equipment or material. 09900 -1- Submit complete information to the Engineer Section submittals During Construction for coating systems. SURFACES NOT REQUIRING PAINTING for review as per all manufacturer Unless otherwise specifically indicated on the Drawings or these Specifications, the following areas or i terns will not require painting: o Concrete surfaces. o Nonferrous metals and stainless steel except where: 1) required for electrical insulation between dissimilar metals; 2) aluminum is in contact with concrete or masonry 3) color coding is required. o Nonmetallic materials such as glass, polyvinyl chloride, and plastic except as required for architectural treatment and color coding. MATERIALS GENERAL Paint materials are identified by proprietary name to indicate the type and quality of material desired. Materials by other manufac- turers which have equivalent quality, color selection, and utility to the specified paint may be substituted subject to a review by the Engineer. All materials of a paint system, including primer and finish coats, shall be produced by the same paint manufacturer unless otherwise approved by the Engineer and the affected paint manufacturer. Thinners, cleaners, driers, and other additives shall be as recommended by the manufacturer. PAINT DELIVERY AND STORAGE All materials shall be delivered to the jobsite in unopened containers that plainly show at the time of use the designated name, color, date of manufacture, and name of manufacturer. Paints shall be stored in a suitably protected area that is heated or cooled as required to maintain temperatures within the range recommended by the paint manufacturer. Paint materials shall be kept sealed when not in use. PAINT MATERIALS Industrial paint manufacturers and acceptable paints are listed below: 09900 -2- Koppers Company, Inc. Pittsburgh, Pennsylvania Porter Coatings. Louisville, Kentucky Coal Tar Epoxy Primer--Porter Shipyard No. 7650 Epoxy Primer, Koppers 654 Epoxy Primer, or equal. Coal Tar Epoxy--Porter Tarset Maxi Build II 7080, Koppers Bitumastic No. 300-M, or equal. Alkyd Primer--Koppers 622 Rust Penetrating Primer, Porter 297 Alkyd Fast Dry Primer, or equal. Exposed Metal Enamels--Koppers Glamortex 501 Alkyd Enamel, Porter I.A.-24 Gloss Finish Alkyd Enamel, or equal. Metal Trim and structural Steel Enamels--Koppers Rustarmor 500 Alkyd Enamel, Porter l.A.-; 24 Gloss Finish Alklyd Enamel, or equal. Galvanizing Repair Paint--Koppers Organic Zinc, Porter Zinc Lock 308 Organic Zinc, or equal. Metal Conditioner--Koppers Bitumastic Mill Undercoat or equal. Bituminous Paint--Koppers Tarmastic 100, or equal. WORKMANSHIP GENERAL Bitumastic No. so, Porter Apply coatings in conformance with manufacturer recommendations and these Specifications, PROTECTION OF MATERIALS NOT TO BE PAINTED Remove, mask, or otherwise protect hardware, lighting fixtures, switchplates, aluminum surfaces, machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not intended to be painted. Provide drop cloths to prevent paint materials from falling on or marring any adjacent surfaces. Protect working parts of all mechanical and electrical equipment from damage during surface preparation and painting process. All openings in motors shall be masked to prevent paint and all other materials from entering the motors. ENVIRONMENTAL CONDITIONS Paint shall not be applied in temperatures below 40 • F, unless approved by the Engineer, dust, smoke-laden atmosphere, or damp or humid weather. 09900 -3- Abrasive blast cleaning shall not be performed whenever the relative humidity exceeds 85 percent, nor whenever the surface temperature is less than 5•F above the dew point of the ambient air. Coating manufacturer's recommendations are to be strictly adhered to. METAL SURFACE PREPARATION All workmanship for metal surface preparation shall be in con- formance with the current Steel Structures Painting Council (SSPC) Specifications as follows: Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning White Metal Blast Cleaning Commercial Blast Cleaning Brush-Off Blast Cleaning Pickling Near-White Blast Cleaning APPLICATION OF PAINT SP 1 SP 2 SP 3 SP 5 SP 6 SP 7 SP 8 SP 10 Manufacturer's written instructions for applying each type of paint or protective coating shall be furnished prior to application. Cleaned surfaces and intermediate coats shall be inspected by the Engineer prior to the succeeding coat. Apply all coating in strict accordance with the paint manufacturer's recom- mendations, as approved by the Engineer. Sufficient time shall be allowed between coats to assure thorough drying of previously applied paint. Units that are to be bolted together and items that are bolted to structures shall be painted prio~to assembly or installation. FILM THICKNESS Coverage is listed as either total m~n~mum dry film thickness (MDFT) in mils or the spreading rate in square feet per gallon (SFPG). Per coat determinations are listed as MDFTPC or SFPGPC. The number of coats is the minimum required irrespective of the coating thickness. Additional coats may be required to obtain the minimum required paint thickness, depending on method of appli- cation, differences in manufacturers' products, and atmospheric conditions. Maximum film build per coat shall not exceed the coating manufacturer's recommendations. Film thickness measurements and electrical inspection of the coated surfaces shall be performed with properly calibrated instruments. Recoat and repair as necessary for compliance with the Specifications. Primer and intermediate coats will be subject 09900 -4- to inspection by the Engineer and the coating manufacturer's representative. Particular attention should be given to edges, flanges. Where insufficient film thicknesses are present, ensure proper millage in these areas. angles, and likely to be After repaired and recoated areas have dried sufficiently, final tests will be conducted by the Engineer. Coating thickness specified in mils will be measured with a magnetic type dry film thickness gage. Discontinuities and the voids in the coatings (except zinc primer and galvanizing) will be determined with an electrical holiday detector, low voltage, wet sponge type. PAINT SYSTEMS AND LOCATIONS SYSTEM NO. 1--EXPOSED METAL All exposed metal surfaces not submerged except those surfaces included in System No. 3 shall be coated with this system. Surface Preparation SP 10- Abrasive Blast, or Centrifugal Wheel Blast Paint Material Alkyd Primer 1 coat, Exposed Metal Enamel SYSTEM NO. 2--METAL TRIM AND STRUCTURAL STEEL Minimum Coats & Coverage 2 MDFT 2 coats, 4 MDFT All metal doors and frames, vents, louvers, structural steel framing, metal decking, siding and roofing, interior metals, and miscellaneous architectural flaShings and trims shall be coated with this system. The surface preparation and primer shall be applied to all surfaces prior to installation. Finish coats need only be applied to the surfaces exposed after completion of construction. Surface Preparation SP 6- Abrasive Blast, or Centrifugal Wheel Blast Paint Material Alkyd Primer Metal Trim and Structural steel Enamel 09900 -5- Minimum Coats & Coverage 1 coat, 2 MDFT 2 coats, 4 MDFT SYSTEM NO. 3--GALVANIZED METAL REPAIR All galvanized surfaces which have been damaged shall be coated with this system. The surface shall be solvent cleaned and wire brushed (SP 2 or SP 3) followed by a minimum of one coat, 3 MDFT of galvanizing repair paint. The total coating repair shall provide an equivalent amount of zinc per square foot to the original galvanized surface. SYSTEM NO. 4--ALUMINUM AND DISSIMILAR METAL INSULATION All aluminum and other nonferrous metals in contact with concrete, or other dissimilar metals, shall be coated with this system. Surface Preparation SP 1 Solvent Clean INSPECTION Paint Material Metal Conditioner Bituminous Paint Minimum Coats & Coverage 1 coat 1 coat, 15 MDFT The Contractor shall give the Engineer a minimum of three days advance notice of the start of any surface preparation or coating application work. All such work shall be performed only in the presence of the Engineer unless the Engineer has granted prior approval to perform such work in his absence. Inspection by the Engineer or the waiver of inspection of any particular portion of the work, shall not be construed to relieve the Contractor of his responsibility to perform the work in accordance with these Specifications . DAMAGED COATINGS • Damaged coatings, pinholes, and holidays shall have the edges feathered and repaired in accordance with the recommendations of the paint manufacturer, as approved by the Engineer. All finish coats, including touch-up and damage-repair coats shall be applied in a manner which will present a uniform texture and color-matched appearance. UNSATISFACTORY APPLICATION If the item has an improper finish color or insufficient film thickness, the surface shall be cleaned and topcoated with the specified paint material to obtain the specified color and coverage. Specific surface preparation information shall be secured from the coating manufacturer and the Engineer. 09900 -6- All visible areas of chipped, peeled, or abraded paint shall be hand-or power-sanded feathering the edges. The areas shall then be primed and finish coated in accordance with the Specifications. Depending on the extent of repair and its appearance, a finish sanding and topcoat may be required by the Engineer. Work shall be imperfections. rejection. free of runs, bridges, shiners, laps, or other Evidence of these conditions shall be cause for Any effects in the coating system shall be repaired by the Con- tractor per written recommendations of the coating manufacturer. All repair of damaged and unsatisfactory coatings shall be done by the Contractor to the satisfaction of the Engineer at no addi- tional cost to the Owner. CLEANUP All cloths and waste that might constitute a fire hazard shall be placed in closed metal containers or destroyed at the end of each day. Upon completion of the work, all staging, scaffolding, and containers shall be removed from the site or destroyed in an approved legal manner. Paint spots, oil, or stains upon adjacent surfaces and floors shall be completely removed and the entire job left clean and acceptable to the Engineer. WARRANTY The Contractor shall warrant to the Owner and guarantee the work under this section against all defective materials and workmanship for a minimum period of two years, unless a longer time is specified herein, from the date of final acceptance of the work. PAYMENT Payment for the work in this Section will be included as part of the lump sum bid. 09900 -7- SCOPE 11010 HOIST This section includes the work necessary to furnish and install a ten-ton capacity electric, geared trolley hoist, including the supporting beam. GENERAL See the CONTRACTOR'S additional information specification. PROPOSAL and GENERAL REQUIREMENTS for and requirements that apply to this The design of the hoist, monorail, and frame will be in accordance with the ACSC code and the Metal Building code. SUBMITTAL DURING CONSTRUCTION In addition to the shop drawings submitted under Section 13121- PREFABRICATED METAL BUILDING, the Contractor shall submit three sets of shop drawings to cover the design, fabrication, and installation of the electric trolley hoist, monorail, ~nd supporting structure. MATERIALS HOIST The hoist shall be made of high strength steel and shall be designed for a maximum cap,acity of ten tons. The hoist shall be electric with geared trolley and shall be a Wright Trolley Hoist with Geared Trolley, or equal. • MONORAIL BEAM The beam shall be designed to support the weight of the hoist and its design load capacity. The beam shall be constructed of either standard or wide-flange steel. Supporting structures shall also be constructed of steel. WORKMANSHIP All equipment shall be installed in strict accordance with the manufacturer's instructions. The monorail beam shall be constructed level and at the elevations shown. The steel supporting structure shall be constructed following the design as approved by the Engineer. 11010 -1- SCOPE 11030 PUMP This section covers the pump for the repump water supply system complete. All equipment, piping, panels, supports, etc., shall be designed as required in the item GENERAL REQUIREMENTS. DEFINITIONS Terminology pertaining to pumping unit performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards. SUBMITTAL DATA Complete descriptive information on pumps and drives shall be submitted for review and shall include: 1. Details of construction and materials 2. outline dimensions and weights 3. Performance data MATERIALS VERTICAL TURBINE PUMP, GENERAL The pump shall be installed as shown on the Plans. Unless otherwise specified, pump materials and construction shall conform to ANSI B58.1 and the following: Pump bowls shall be cast iron with vitrous enamel lining in the water passages. Impellers shali. be the enclosed type of bronze and shall be dynamically balanced. The impellers or bowls shall have replaceable, aluminum bronze seal rings. Each bowl stage shall have a single bearing of high-lead bronze. A basket strainer shall be furnished for connection to the suction bell. The strainer shall be galvanized steel and shall be of the manufacturer's standard size and construction. Discharge column shall be fabricated of standard weight steel pipe. The column shall have flanged joints with registered fits to ensure positive alignment. Lineshaft bearings shall be water-lubricated, fluted rubber type mounted in bronze bearing retainers supported and centered at the column joints. Bearing spacing shall be as required to prevent resonant vibrations of the shaft and not greater than five feet. 11030 -1- Discharge heads shall be surface discharge type, either cast iron or fabricated steel, designed and manufactured for a working pressure equal to 1-1/2 times the pump shutoff head. The discharge nozzle shall be flanged, drilled, and faced to ANSI 125- pound standards. The shaft seal shall be a packing box and shall contain a bronze bearing, no less than five rings of graphite- impregnated packing, and provision for grease lubrication. A bronze split-type gland shall be provided for adjustment of packing. A steel flanged head shaft coupling shall be furnished with provision for impeller adjustment. The coupling shall have registered fits to ensure positive alignment and be dynamically balanced and match-marked. The flanged head shaft coupling and packing box shall be readily accessible for servicing. If the heads are of the standard cast iron configuration of the manufacturer, a spacer shall be provided between the head and the motor to provide access. Coupling guards shall be provided. The pump shall be rated as specified and shall not overload the drive motor at any point on the performance curve. The motor to be-· furnished with the pump shall be vertical, solid shaft, high thrust, 460 volts, 3-phase, Type 1HT. In addftion, motor insulation shall be General Electric 1002, Westinghouse PMR, or equal. Motor horse-power and speed shall be as specified for the applicable pump. The vertical turbine pump shall have a standard running test performed at the factory in accordance with ANSI B58. 1, Section A6. Certified copies of test data sheets and performance curves shall be furnished to the Engineer for review. The test data sheets shall be certified and si~ned by a Registered Professional Engineer. The pump manufacturer shall maintain a full line of replacement parts and shall have an authorized factory service representa- tives. Vertical turbine pump shall be as manufactured by Johnston Pump Company; Peabody Floway, Inc.; Aurora Pumps; Peerless Pump Company; or equal. The pump for the water supply repump system shall be vertical turbine type as follows: Rated capacity Total pump head Rated pump speed Minimum shutoff head 650 gpm 285 feet 1,760 rpm 300 feet 11030 -2- Minimum pump efficiency 75 Motor horsepower 50 (estimated) WORKMANSHIP INSTALLATION All equipment shall be installed in strict accordance with the manufacturer's instructions. Pumps shall be set level and plumb. All strain from attached piping shall be eliminated from the sumps. Anchor bolts shall be accurately placed with templates, and shall be in accordance with the Plans and the manufacturer's recommendations. ELECTRICAL All electrical work shall be in accordance with Section 16000, ELECTRICAL. VIBRATION Vibration for the complete pump assembly shall limits recommended by the Hydraulics Institute operating in the completed installation. PAYMENT be within the Standards when Payment for the work included in this section shall be included as part of the lump sum. 11030 -3- 13121 PREFABRICATED METAL BUILDINGS SCOPE This section includes the work necessary to design, furnish, fabricate, and erect prefabricated metal buildings complete, in- cluding coordinating construction of the metal buildings with the concrete foundations, anchor locations, and other miscellaneous related work. GENERAL See CONTRACTOR'S PROPOSAL and GENERAL REQUIREMENTS for additional information and requirements that apply to this Specification. Materials and workmanship shall be in accordance with these Specifications and the latest edition of the Metal Building Manufacturer Association (MBMA) Low Rise Building Systems Manual. SUBMITTALS DURING CONSTRUCTION Shop Drawings and Calculations The Contractor shall submit three sets of coordinated shop-draw- ings showing all components, including doors and other accessories regardless of supplier, and structural calculations. The calcu- lations shall be specifically for this project. Should the building design proposed use bolted moment-resistant connections in the main frames, the prying action of the bolts shall be con- sidered in the design. Lateral load analysis shall include calculations considering stresses due to eccentricities and actual in-place connections of rod bracing and other structural components. The shop drawings shall include as a minimum the . . . ' follow1ng 1nformat1on: o Foundation anchor bolt plan with anchor bolt, shear angle, and baseplate details for this project. o The building roof plan showing sizes and locations of all structural members and bracing. o Detailed drawings of the rigid frame together with building elevations showing sizes and location of all wall structural members bolts and bracing. o structural framing details and locations of openings in wall panels. o Roof and wall covering including fastener type and spacing. 13121 -1- o Sealant, flashing, closures, and trim details. o Door and window details and hardware. o Skylight, ventilator, and louver details. o Insulation and interior finish, if required. o Manufacturer's paint system. Manufacturer's standard details that pertain to the building may be used in addition to these Drawings listed above provided that the portions that apply and where they apply are clearly marked and those parts that do not apply are clearly marked. Blanket submittal of all standard details, regardless of application to the specific project, will be returned for compliance with this Specification. This also applies to general structural calcu- lations that have not been specifically prepared or assembled for this project. The design calculations and shop drawings shall be stamped by a registered Professional Engineer. MATERIALS GENERAL The building manufacturer shall be a member of and conform to the standards of the MBMA. Furnish the metal building including foundation, anchors, all primary and secondary structural framing members, connection bolts, siding, roofing, skylights, windows, doors, hardware, flashing, fasteners, closures, sralants, interior finish, and any other miscellaneous items as shown on the Drawings or called for in these Specifications. All materials shall be new, the end product of one manufacturer, and consistent in final appearance. GEOMETRY Building Size The building length and width shall be measured to the inside face of wall covering (outside face of girts). Building Height The building eave and ridge height shall be measured from finish floor to structural steel, building soffit, or ceiling as shown on the Drawings. The roof slope shall be a minimum of 1 inch unless shown otherwise on the Drawings. 13121 -2- Column Locations Bay spacing and column location including columns required for equipment or hoist beam support, and allowable zones for interior columns shall be as shown on the Drawings or specified herein. DESIGN General The design of the steel building shall conform to the current editions of AISC Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings and the AISI Speci- fication for the Design of Light-Gauge Cold-Formed Steel Structural Member. Design Loads The buildings shall be designed for its own dead-load plus the following loads: o snow load -50 psf. o Earthquake load -Uniform Building Code (UBC) Seismic Zone 4. o Wind -100 mph and minimum uplift in accordance with Underwriters Laboratory standard UL580 Class 90. o Crane loads -see Drawings for vertical capacity (design for vertical, longitudinal, and lateral). The design of the building for wind horizontal and uplight forces and for earthquake forces shall be in accordance with the latest edition of the Uniform Building'code as modified herein, and the MBMA Low-Rise Building Systems Manual. STRUCTURAL FRAMING General All framing members shall be shop fabricated for bolted field assembly. Field drilling, welding, or cutting shall be kept to a minimum and, if required for assembly, shall be noted on the shop drawings. Primary structural members shall include rigid frames, girders, beams, columns, overhangs, and main diagonal bracing. 13121 -3- Secondary structural members shall include purlins, girts, struts, flange and purlin bracing, sill, clips, and other miscellaneous structural parts. The structural requirements: framing shall conform to the following o The minimum web thickness of primary members shall be 1/8-inch and the maximum web depth to thickness ratio shall be 200. o Primary member flanges shall be a minimum of 3/16-inch thick and the maximum width to thickness ratio for projecting elements shall be 16. o Deflections from distributed live loads for all members shall not exceed the span divided by 240. o Lateral deflections of frames due to wind or seismic loading shall not exceed the eave height divided by 180. o If roof purlins serve as the compression member of a cross bracing system, the two purlins closest to the diagonal connection shall be at least 12 gage and shall be laterally supported at least once near midspan. o The maximum spacing of roof purlins shall be four feet. Primary rigid frames, girders, and beams shall be symmetrical "I" shaped rolled or built up members with either a constant or uniformly tapered depth. Secondary purlins and girts shall be rolled or cold formed "C" or "Z" sections. Purl ins shall be laterally braced at a minimum of all supports and in accordance with AISI and AISC Specifications . .. Building wind and earthquake bracing shall be diagonal angle or rod bracing in the roof and walls as required to resist design loads. Use double roof purlins between rigid frames at all points of attachment of diagonal bracing. Wall bracing shall be placed such that it does not interfere with openings or process piping and equipment. Wall bracing locations in open-sided buildings shall be in areas shown on the Drawings or approved by the Engineer. Framing for openings shall be designed to resist all vertical and horizontal loads. Frames, columns, girders, and other affected members shall be designed to support miscellaneous equipment and crane beams, shown on the Drawings. Provide all framing, corbels and holes as required to support the equipment. Coordinate support location, 13121 -4- size, and capacity with the Contractor, equipment supplier, and crane manufacturer. Provide a continuous support member at the base of the wall for steel-sided buildings. Coordinate foundation and anchors with bui.ld.ing manufacturer foundation anchorage details and make all rev~s~ons necessary to adapt or support the building to be constructed. Any additional costs or savings for the final building foundation construction shall be borne by the Contractor. Steel All hot rolled structural steel shapes shall conform to ASTM A36. All hot rolled steel plate used in welded fabrication shall be ASTM A529; A572, Grade 42; or A570, Grade E, as applicable. Rod bracing shall be ASTM A572, Grade 60. Structural tube shall conform to ASTM ASOO, Grade B or A501. Steel pipe shall be ASTM A501. Bolts Bolts for structural connections shall be ASTM A325. Anchor bolts in the foundation shall be ASTM A307. All bolts shall be galvanized. ROOF AND WALL COVERINGS General Panel materials shall conform to ASTM A446 of the appropriate grade. Galvanizing shall be G-90 in accordance with ASTM A525. Roof and Wall Panels Roof and wall panels shall be self-contained and factory assembled insulated panels consisting of an exterior ribbed panel, and interior panel, a foamed in place polyurethane core and joiner members. Panels shall extend from the building ridge to the eave and from the eave to the foundation without end laps. 13121 -5- The panel faces shall be 26-gage minimum galvanized steel. Galvanizing shall conform to ASTM A525 G90. The interior and exterior of the panels shall be treated and roll coated with the manufacturer's standard baked on thermosetting silicone polyester finish. The exterior finish coat shall have a finish dry film thickness of 1 mil. The panels shall be guaranteed to resist cracking, checking, spotting, blistering, fading, and chalking for a period of five years after acceptance. The panel system assembly including panels, fasteners, and secondary structural members shall have an insulating U value of 0.10 or smaller. Panel system shall have been tested in accordance with ASTM C-236. The pane core shall be polyurethene and not support fungus growth nor animal life. Panel Fasteners Panel fasteners shall be manufacturer standard designed to resist specified lateral and uplift forces while maintaining a tempera- ture resistant weather tight building. Sealant and Closures Sealant shall be non-asphaltic, nonshrinking, and nondrying tape, gun grade polyurethane, or similar type sealant recommended by the manufacturer as appropriate for the building application. Submit manufacturer sealant information to the Engineer for review. Closed cell polyurethane foam closures cut to match the building panel corrugations shall be installed along the building eave, rake, and around all openings an~ accessories to provide a weather tight building. Where visible, these closures shall be covered by metal covers cut to match panel profiles. Flashing. Closures. and Trim Galvanized steel flashing and trim shall be furnished at the rake, corners, eaves, overhangs, framed openings, and as necessary to provide weather tightness and a finished appearance. Coating shall be as specified for roof and wall panels. BUILDING ACCESSORIES Doors Doors shall be 1-3/4-inch thick full fabricated from 20-gage, galvanized, 13121 -6- flush, hollow, metal-type mill-primed steel. Doors shall conform to steel Door Institute SDI 100, Type II, Style 2, and these Specifications. Door frames shall be heavy gage galvanized steel conforming to SDI 100 and these Specifications. Doors and frames shall be constructed and reinforced to receive hinges and door hardware in accordance with SDI 107. Each door shall be provided with the following hardware: o 1-1/2 pair of hinges o Auto closure o Lockset and strike {coordinate keying with owner) o Threshold o Raindrip o Door bottom o stop o Head and jamb weatherstripping Door frames and doors shall be conditioned and coated with rust inhibitive primer. Rolling Doors Overhead rolling-doors shall be of the size shown on the Drawings. Door shall be constructed of rolled interlocking slats formed in easy curves from open-hearth galvanized steel. Slats shall be of sufficient strength to resist a design wind load of 20 psf. Ends of slats shall be provided with windlock lugs to engage bars in door guides. Door curtain shall be coiled on a pipe large enough to carry the door load and be spring balanced. The door coil shall be housed with a sheet metal hood with internal weather stripping. Slotted guides shall be provided with anchors for windlocks and external . side weatherstripping. Door shall be chain-operated with a continuous smooth coil proof chain. # Hot-dip galvanize door and frame with 1.25 ounces per square foot. Phosphate coat and apply one shop coat of rust inhibitive primer. Provide all attachment and building accessories required to connect door to building. Provide keyed door lock and coordinate keying with the owner. Windows Windows shall be building manufacturer's standard window conform- ing to the Drawings and these Specifications. All windows shall be single-hung. steel surfaces shall be galvanized, conditioned, and factory painted. 13121 -7- Glass shall be double strength and vandal resistant. Use plate glass where required by code. Vandal resistant glass shall be 1/4-inch thick with incorporated twisted hexagonal wire mesh. Glass shall be factory installed embedded in mastic and retained by extruded vinyl splines. All sliding windows shall be provided with 18 to 16 mesh plastic coated fiberglass or aluminum screens. All window hardware shall be made of corrosion resistant materials. Weather stripping shall be woven pile together with vinyl extrusions. Windows shall be supplied with integral head and sill flashing with jamb fins designed to match the wall panel profile for complete weather tightness. Skylights Skylights shall be insulated structural fiber reinforced polyester of a size shown on the Drawings. Skylights shall be white with a three-inch deep clear acrylic pan to create an insulating space. Light transmission shall be a minimum of 66 percent~ Skylights shall have a frame with flashing and fins designed to match the roof panel profile for complete weather tightness. Ventilators and Louvers Ventilators will be provided as shown on the Drawings and as described in the section HEATING AND VENTILATING. PAINTING and other metal acces- or field painted. and prime coated as Conform to Section All building structural framing, doors, series shall be shop-primed _and shop Galvanized materials shall be conditioned recommended by the paint manufacturer. PAINTING. Submit paint system and colors chips to the Engineer for review and color selection. Separate colors may be chosen for exterior roof and siding, trim, and doors and interior exposed metal. LIGHTING AND ELECTRICAL Building lighting and electrical shall conform to the Drawings and the Section ELECTRICAL. 13121 -8- WORKMANSHIP GENERAL The building workmanship and quality shall be by experienced personnel in accordance with manufacturer recommendations and these Specifications. The final building size and appearance shall conform to the contract Drawings and reviewed manufacturer shop drawings. PRODUCT DELIVERY STORAGE AND HANDLING Load and ship all materials such that they may be transported and unloaded without being deformed or otherwise damaged. Store all materials such that they are protected from corrosion, deter- ioration, and weather damage. Store in a dry area not in direct contact with the ground. Any damaged materials shall be replaced or repaired to the satisfaction of the Engineer. STRUCTURAL FRAMING Structural framing shall be erected in accordance with the manufacturer's recommendations and to AISC and AISI tolerances. No field cutting of structural members will be permitted. Provide temporary braci)lg as required for safe building assembly. When complete, the building frames shall be plumb and square. Shop Welding All welding shall be shop welding by qualified welders in conform- ance with AWS Standard Code for Welding in Building Construction. All flange-to-web welds shall be continuous on both sides of the web. All butt welds shall be full penetration type. Bolting All structural field bolting to primary and secondary members shall be ASTM A325. Bolts shall be tightened using the turn-of- nut method as specified by the AISC. Bracing Rod bracing shall be installed and adjusted such that the bracing is tight when the building is square and plumb. Provide clevises or turnbuckles to provide for bracing adjustment. FOUNDATION AND ANCHOR BOLTS Conform to Section REINFORCED CONCRETE. All manufacturer embedded items (bolts, shear angles, etc.) shall be set in place before pouring the foundation concrete. 13121 -9- ROOF AND WALL COVERINGS General Furnish all roof, wall, fascia, and soffit panels as continuous lengths. Attach panels in accordance with manufacturer's recom- mendations. Sealant and Closures Install sealant and closures in accordance with manufacturer's recommendations to provide an attractive weathertight joint. Flashing Closures and Trim Install flashing and trim in accordance with manufacturer's recommendations. BUILDING ACCESSORIES General Install all doors, door hardware, windows, skylights, gutters, ventilators, and louvers in a workmanship-like manner in accor- dance with applicable standards, manufacturer recommendations, and these Specifications. All doors, windows, sticking or binding. weathertight. PAINTING and dampers shall operate smoothly without They shall open and close squarely and be Paint systems shall be applied in conformance with manufacturer's recommendations for industrial applications and these Specifica- tions. Those items not covered ~y manufacturer standards shall be applied in conformance with Section PAINTING. REPAIR All materials and coatings damaged during shipping, storage, or building erection shall be replaced or repaired. Replacement will be required unless repair renders the item in a "like new" condition. Repair or replacement shall be to the satisfaction of the Engineer at no additional cost to the Owner. FINAL ACCEPTANCE To be acceptable, the building shall be complete in every way. The building shall be weather tight, plumb, square, and have a uniformly finished appearance. The finish colors shall be consistent throughout. 13121 -10- GUARANTEE The building system shall be fully guaranteed against faulty material and workmanship for a period of two years from the date of final acceptance. Manufacture applied baked on coating systems shall be guaranteed for five years. PAYMENT Payment for work in this Section will be included as part of the lump sum bid. 13121 -11- 15001 PLUMBING AND PIPING SYSTEMS SCOPE This section covers the work necessary for all piping and plumbing, including all valves and appurtenances, complete. The work shall included the furnishing, fabricating, erecting, and coating of the welded pipe, furnishing and installing all necessary reducers, bends, bifurcation, flanged connections, and all mechanical couplings and miscellaneous appurtenances necessary to complete the installation in accordance with these Contract Documents. EXISTING 12-INCH WATER PIPE An existing 12-inch pipe presently supplies water to the City of Metlakatla. This pipe may not be excavated around or damaged prior to the installation and acceptance of the new water supply system piping. Upon acceptanceof the new water supply system, the existing 12- inch pipe shall be removed to allow complete excavation of the relief channel. GENERAL Material certifications shall be furnished to the Engineer by the Contractor for all pipe, fittings, and coating materials required within this section. SUBMITTALS DURING CONSTRUCTION Submittals shall be made REQUIREMENTS. In addition, shall be provided: in the 1. Complete shop drawings accordance with the GENERAL following specific information 2. Certificates and test reports on all steel components 3. Welding procedure specification 4. Hydrostatic test procedure Shop drawings shall be furnished by the Contractor in advance of fabrication according to the GENERAL CONDITIONS. The shop drawings shall include the grade of material, size, wall thickness of the pipe and fittings, type and location of fittings, and the type and limits of the lining and coating systems of the pipe and fittings. Shop drawing shall be approved by the Engineer prior to beginning fabrication of the pipe. 15001 -1- QUALIFICATIONS The steel pipe and fittings shall be fabricated by a pipe manufac- turer experienced in the manufacture of high pressure steel pipelines. All steel fabrication, welding, and heat treatment shall be performed by the fabricator or under his direct supervision. STANDARDS The pipe sections and fittings shall be fabricated in accordance with the applicable standards and codes of the American Society for Testing and Materials (ASTM), the American Water Work Associa- tion (AWWA), and the American Welding Society (AWS). INSPECTION The Engineer may inspect all work performed and material furnished under this contract by the manufacturer in accordance with AWWA Specification C200-86. PIPE MARKING All piping shal!. be clearly and permanently marked with a serial number or other identification by the manufacturer so as to clearly identify each pipe section. Such marking shall correspond with the markings on the shop drawings so as to facilitate assembly in the field. PRESSURE REQUIREMENTS All pipe, fittings, valves, and appurtenances will be required to operate under the following pressure conditions: Pressure Condition Static Working Surge • Head C feet) Cpsi) 825 357 780 338 880 381 No hydrostatic testing of pipe sections by the manufacturer will be required under this contract. MATERIALS PIPE Steel Pipe steel pipe shall be fabricated as shown on the drawings and in accordance with "AWWA Standard for Steel Water Pipe 6 Inches and 15001 -2- Larger (AWWA C200-86)". The pipe shall be in maximum lengths of 20 feet. Pipe shall be electric resistance welded pipe and shall conform to the material requirements of ASTM A36. Steel pipe shall have the following minimum thicknesses: 20 inch, 1/4 inch thick; 12-inch, 8 inch, and 6 inch; 3/16 inch thick. Black Steel Pipe Black steel pipe shall be all pipe less than 6-inch diameter and shall be Schedule 40, ASTM A 120 Grade A. PVC Pipe Pipe shall be Type 1, Grade 1, conforming to ASTM D 1784 and ASTM D 1785. Pipe shall be Schedule 80 with solvent welded fittings. Solvent welded fittings shall conform to the requirements of ASTM D 2466. Threaded fittings shall conform to the requirements of ASTM D 2464. Fittings shall be the same color as the pipe. FITTINGS All fittings, including elbows and tees, shall be A.N.S.I. Class 300 steel fittings conforming to the material requirements of ASTM A 234, Grade WPA, and to the dimensional requirements of ANSI B16.9, "Factory-Made Wrought Steel Butt Welding Fittings" and ANSI B16.5, "Steel Pipe Flanges, Flanged Valves, and Fittings." Fittings shall have a wall thickness sufficient to withstand the design and test pressures of the pipe. JOINTS Pipe with bell and spigot joint-shall be provided for lap joint welding in the field. Pipe with plain ends shall be furnished where jointing is with mechanical couplings or flanged coupling adapters. The hold-back on all joined pipe shall be 8 inches long. WELDED JOINTS Welded joints shall be designed and fabricated to withstand the design and test pressures of the pipe without leaking. Refer to the WORKMANSHIP portion of this Specification. BURIED PIPING COATING All buried and concrete thrust block encased piping shall be exterior coated with a shop applied tape system in accordance with AWWA Specification C214. All coatings shall be applied per 15001 -3- manufactures specification and AWWA Specification C214. The coating shall be applied over clean, bright metal only. All exterior coating shall be tested by means of the electric spark gap method and all holidays and defects shall be shop repaired. Areas of damage to the coating shall be cleaned down and repaired according to manufactures specifications and AWWA Specification C214 prior to shipment. Pipe coating shall be held back 8 inches from each end of the pipe section to facilitate field welding and coupling. The Contractor shall provide complete protection of the finished coating against damage resulting from his operation and shall repair any damage to the coating so caused. EXPOSED PIPING COATING All exposed steel pipe shall be painted in conformance with the Section 09900 PAINTING found in this Specification. MITERED BENDS All mitered bends on the 20-inch diameter penstock shall be made with a double miter. No single miter bend will be allowed. THRUST BLOCKING Contractor shall construct thrust blocks at all locations indicated on the plans. Thrust blocks are to be placed aqainst undisturbed earth or structural backfill only. PIPE SUPPORTS Contractor shall furnish and install pipe supports at the locations indicated on the plans. Pre-engineered supports are acceptable only if approved by the Engineer. VALVES AND APPURTENANCES WYE Strainers Wye strainers shall be 8-inch diameter and shall have stainless steel strainers with 1/8 inch screen perforations. Locate each stainer rotated 45 degrees from vertical with the blowoff located at the lowest point possible. A blowoff outlet shall be provided on the strainer. The wye strainers shall be Muessco No. 752M as supplied by Mueller Stream Specialty, Brooklyn, New York, or equal. Check Valve Check valve shall be an a-inch, 300-pound, double door, spring check valve with cast iron wafer body bronze doors, stainless steel hinge pin and spring, and Buna-N seat. The valves shall be Apco Series 9000 or equal. 15001 -4- Butterfly Valves Flanged ANSI Class 300, 8-and 12-inch butterfly valves shall have ductile iron wafer-style body, 17-4pH stainless steel shaft, EPDM seat on stainless steel support ring disc, Keystone Figure 370, or equal. Butterfly valves shall be provided with handwheel gear operators, 30: 1 ratios for a-inch valves and 50: 1 ratios on 12- inch valve. Pressure Reducing Valve The pressure reducing valve is required to reduce 850 feet of head down to 280 feet, at 800-1,000 gallons per minute. Valve will be a 6-inch body with 300-pound flanges and be Model No. 305 Polyjet Sleeve Valve as provided by Bailey, a Division of CHB Industries, Fresno, California, no substitutes allowed. Gate Valves Gate valves of 6-, 4-, and 2-inch diameter shall have non-rising stem, and be flanged gate valves designed for use with 400 psi water. The body and bonnet shall be cast iron, disc and seat rings shall be bronze. Flanged Coupling Adapters Flanged coupling adapters shall be cast iron bodies, 300-pound flanges Baker Series 601, Dresser Style 127, or equal. Flexible Couplings Smith-Blair No. 411, Dresser Style 38, or equal with standard length middle ring. A joint .harness for thrust protection meeting AWWA standards shall be used where indicated and shall conform to AWWA standard details. The si:~e and number of the thrust ties shall be as required for the test pressure of the pipe. WORKMANSHIP HANDLING AND SHIPMENT OF PIPING All piping shall be protected during loading, transport, and unloading in such a manner as to not damage it in any way. TAPE COATING FIELD TESTING All piping shall be field tested by means of the electric spark gap method prior to placement. All holidays and defects shall be cleaned down and repaired according to manufactures specifications and AWWA Specification C209 prior to placement and burial. Every 15001 -5- effort shall be made to ensure the integrity of the tape coating system prior to final burial. TAPE COATING OF WELDED JOINTS Upon completion and acceptance of welded joints in the pipeline, the pipe shall be cleaned back and sandblasted or cleaned to bright metal. All joints shall then be primed and tape coated according to the manufactures specifications and AWWA Specification C214. Tape coatings at joints shall be field tested by the electric spark gap method and repaired as required prior to final burial. SITE STORAGE AND CARE The contractor shall store all pipe, fittings, flanges, and appurtenant i terns in such a manner as to protect these from possible damage. The Contractor is responsible for the condition of such items up until the time they are installed, tested, and accepted by the Inspector. PIPE PREPARATION AND HANDLING Pipe and fittings installation. Clean matter and dirf from after installation. shall be carefully inspected before ends of pipe thoroughly. Remove foreign inside of pipe and keep clean during and Use proper implements, tools, and facilities for the safe and proper protection of the pipe. Carefully handle pipe in such a manner as to avoid any physical damage to the pipe. CUTTING PIPE As far as practicable, all steel pipe shall be furnished in the proper lengths in accordance with the reviewed shop drawings. If cutting of the steel pipe is required in the field, cut with wheel-type pipe cutter. Do not cut with flame or hacksaw. INSTALLATION OF PIPING All pipe, fittings, valves, and appurtenances within or attached to structures shall be provided with hangers and supports or other means that, in the opinion of the Engineer, are necessary to assure no undue strain at any joint, valve, or fitting. Hangers and supports shall be as shown, but the number shall be increased if necessary to provide adequate support as hereinbefore specified. 15001 -6- INSTALLATION OF FLEXIBLE COUPLINGS AND FLANGED COUPLING ADAPTERS Prior to installation, thoroughly clean oil, scale, rust, and dirt from the pipe to provide a clean seat for the gasket. care shall be taken that the gaskets are wiped clean before they are installed. If necessary, flexible coupling and flanged coupling adapter gaskets may be lubricated with the manufacturer's recommendations. Bolts shall be tightened progressively, drawing up bolts on opposite sides a little at a time until all bolts have a uniform tightness. Workmen tightening bolts shall be equipped with torque-limiting wrenches. Alignment and Spacing Align ends to be joined within existing commercial tolerances on diameters, wall thicknesses, and out-of-roundness. Root opening of the joint shall be as stated in the procedure specification. Welding Procedures The shielded metal-arc process shall be used for all field welding, unless otherwise approved. Shop fabrication shall be in accordance with the submitted welding procedure qualifications, as approved. No welding shall be performed if there is impingement of any_rain, snow, sleet, or high wind on the weld area or if the ambient temperature is below 37 degrees F. If the ambient is less than 32 degrees F, local preheating to a temperature warm to the hand is required. Tack welds, if not made by a qualified welder using the same procedure as for the completed weld, must be completely removed. Tack welds which are not removed shall be made with an electrode that is the same as or equivalent to the electrode to be used for the first weld pass. Tack weJ.ds which have cracked shall be removed. Each layer of deposited weld metal shall be thoroughly cleaned prior to the deposition of each additional layer of weld-metal, including the final pass, with a power-driven wire brush. surface defects which will affect the soundness of weld shall be chipped out or ground out. There shall be a minimum of three weld passes using the specified covered electrode. Cracks will not be permitted. joints will be incomplete excessive weld reinforcement, excess of the limits prescribed codes. Other reasons for rejecting welded penetration, weld undercutting, porosity and slag inclusions in in Chapter V of the specified ANSI 15001 -7- Branch connections shall be fitted and groove-welded in accordance with the details described and shown in Chapter V of the specified ANSI code. WELD TESTING Field welds shall be visually inspected and may be tested as required using nondestructive test methods such as vacuum lock box, or ultrasonic inspection, in accordance with AWWA C206. PRESSURE TESTING Upon completion of the pipeline and thrust block installation and before backfilling the pipe shall be hydrostatically tested by slowly filling the pipeline and visually checking for leaks. Leaks shall be repaired and retested at no additional cost to the owner. In order to pressure test the pipe, a temporary flanged coupling adaptor with a blind flange plate shall be installed at the location of the most upstream flexible coupling outside of the powerhouse. The flanged coupling adaptor shall be thrust anchored prior to filling and testing. THRUST BLOCKING Pour thrust blocks against undisturbed earth. After all water has been removed from the excavation, construct suitable forms to obtain shapes that will provide full bearing surfaces against undisturbed earth or structure backfill, as indicated. cure thrust blocks before conducting hydrostatic tests. Take care not to over-excavate in the areas where thrust blocks are to be so placed, unless specifically shown otherwise, so that the pipe and fitting joints will be accessible for repairs. ANCHOR BOLTS For floor stands, stern guides, etc., cast in place during concrete placement. Threads shall be protected and shall be cleaned before the nuts are attached and tightened. PLASTIC PIPE All rigid accordance approved. PVC pipe shall with the pipe be cut, made up, and installed manufacturer's recommendations, in as Pipe shall not be laid when the temperature is below 32 degrees F, and precautions shall be taken as recommended by the manufacturer when the temperature is below 40 degrees F. All PVC pipe shall be 15001 -a- protected from the rays of the sun by appropriate covering until the piping is complete in place. VALVES Before installation, carefully clean valves of all foreign material, adjust stuffing boxes, and inspect valves in open and closed positions. Install valves in accordance with the applicable portions of these Specifications. Unless otherwise indicated, install valves with the stern vertical. Mount horizontal valves in such a manner that adequate clearance is provided for operation. Installation practices shall conform to manufacturer's recommendations. Prior to installing flanged valves, the flange faces shall be thoroughly cleaned. After cleaning, insert the gasket and tighten the nuts progressively and uniformly. If flanges leak under pressure, loosen the nuts, reseat or replace the gasket, retighten the nuts, and retest the joint. Joints must be water tight at test pressures before acceptance. Thoroughly clean threads of screwed joints by wire brushing, swabbing, or other approved method. Apply approved joint compound to threads prior to making joint. Joints shall be watertight at test pressures before acceptance. VALVE TESTING Valves will be tested at the same time that the adjacent pipeline is tested. Joints shall show no visible leakage under test. Repair all joints that shown signs of leakage prior to final acceptance. If there are any special parts of control systems or operations that might be damaged by the pipeline test, they shall be properly protected. The Contractor will be held responsible for any damage caused by the testing. FINAL CLEANING Prior to final acceptance, all pipelines installed under this section shall be flushed out and all accumulated construction debris and other foreign matter removed. PAYMENT Payment for work in the section will be included as part of the lump sum bid. 15001 -9- 15240 HEATING AND VENTILATING SCOPE This section covers the work necessary for the heating and ventilating systems, complete. MATERIALS POWERHOUSE UNIT HEATER The unit heaters shall be a forced-draft horizontal discharge heater, 10, ooo-watt, 480-vol t, 3-phase. The element shall be provided with internal thermal overload protection and integral thermostat. The fan shall be an axial-flow propeller fan, factory balanced, with wire guard. The housing shall be steel with adjustable horizontal louvers and baked enamel finish. VENTILATOR The ventilator shall be a belt-driven propeller fan with steel frame, formed venturi; slide-rail motor mount, and rear guard. The wheel shall ~be welded steel with airfoil blades. The capacity shall be as shown on the plans. Ventilator shall be automatically operated by a thermostatic control adjustable between 6o•F through 90"F with a manual override located four feet above the finished floor. FILTERS Filters shall be l-inch thick glass fiber filters with fiberboard casings and metal grids, American Air Filter 5700, or equal. Provide steel holding frames of the sizes shown on the Drawings. LOUVERS AND DAMPERS Intake louvers shall be as indicated on the plans and shall be 4 inches deep, fabricated of minimum 20-gauge galvanized steel, 45 degree blades with 16 gauge frames, and with 1/2-inch mesh galvanized hardware cloth bird screens. The dampers shall be motor-operated. The damper blades shall pivot freely on shafts supported by ball bearings or nylon brushings. WORKMANSHIP All material and equipment shall be installed as shown and described herein and as may be required by the applicable loca 1 codes. 15240 -1- Thoroughly clean all parts of the installation at the completion of the work. Proper lubrication and adjustments of all devices shall be made and proper operation shall be demonstrated. PAYMENT Payment for work in this section will be included as part of the lump sum bid. 15240 -2- SCOPE 16000 ELECTRICAL This section covers electrical work, complete. Furnish material, labor, and equipment in accordance with these Specifications, the accompanying Plans, and the directions of the Engineer. The contractor shall be responsible for complete systems in accordance with the intent of these Contract Documents. The Contractor shall refer to all of the Plans, Specifications, and shop drawings for other trades for details of equipment and construction which affect the work covered under this section. GENERAL Intent of Plans Exact conduit locations are not shown unless so indicate or specifically dimensioned. Departures from Plans Submit to the Engineer, in writing for review, details or any necessary proposed departures from these Contract Documents, and the reasons therefore, as soon as practicable and within 30 days after the award of the Contract. Make no such departures without the prior written approval of the Engineer. Submittals Before any material is fabricated or shipped, furnish to the Engineer full details, shop drawings, dimensions, catalog cuts, schematic (elementary) diagrams/ and other descriptive matter as required to fully describe the equipment specified under this section. Should any item which deviates from these Specifications be included, the deviation shall be clearly indicated and explained at the time of submittal. Submittals shall be complete, neat, orderly, and indexed. The Contractor shall check submittals for number of copies, adequate identification, correctness, and compliance with the Plans and Specifications, and shall initial all copies. Revise and/or resubmit all submittal information until acceptable to the Engineer. Review of submittal information by the Engineer shall not relieve the Contractor of responsibility for meeting the requirements of 16000 -1- the Plans and Specifications or for errors and omissions in submittals. Codes, Permits, and Regulations Do all work and install materials and equipment in accordance with the requirements of the National Electric Code, applicable state and local laws and ordinances, and the power company. Conflicts, if any, that may exist among the above items will be resolved at the discretion of the Engineer. Wherever the requirements of the Specifications or Plans exceed those of the items above, the requirements of the Specifications or Plans shall govern. Operation and Maintenance Manuals Provide operation and maintenance manuals. Include the following: o Corrected submittals as required herein. 0 Record (as-builts) drawings. wiring diagrams and equipment o For all equipment suppliers, list of current names, addresses, and telephone numbers of those who should be contacted for service, information, and assistance. o Record (as-built) Contract Drawings marked with red indelible pencil to show electrical work revisions and underground raceway and cable where different from the original drawings. Prepare by obtaining new, clean sets of Contract drawings from the Engineer and pay all costs for same. o Interconnection diagrams showing connections between pieces of equipment. Show terminals, terminal blocks, and conductors on the diagrams with the same identification as on the actual terminals and conductors. Material shall be clean and filed under dividers with headings in accordance with the Specification item title. MATERIALS GENERAL Unless otherwise indicated, provide all first-quality new materials, free from any defects, and suitable for the intended 16000 -2- use and the space provided. Provide materials approved by UL wherever standards have been established by that organization. Furnish and install all incidental items not specifically shown or specified which are required by good practice to provide the complete systems specified herein. Where two or more units of the same class of material or equipment are required, provide products of a single manufacturer. Component parts of materials or equipment need not be products of the same manufacturer. STANDARD PRODUCTS Unless otherwise indicated, provide materials and equipment which are products of manufacturers regularly engaged in the production of such materials and equipment. Provide the manufacturer's latest design that conforms to these Specifications. EQUIPMENT FINISH Unless otherwise indicated, finish for electrical equipment shall be manufacturer's standard grey or ANSI 61 gray over a primer and rust inhibitor. CONDUIT Conduit, Galvanized Rigid Steel CGRSl Rigid steel conduit including couplings, elbows, nipples, and other fittings shall be galvanized after fabrication by hot- dipping, electroplating, sherardizing, or metallizing process, and shall meet the requirements of ANSI C80.1 and ANSI C80.4, NEMA FB 1, UL-6, and the NEC. Do not use setscrew-type couplings. Conduit bodies and covers shall be of cast malleable galvanized ferrous materials. Provide covers with gaskets. Conduit, Rigid PVC (PVC) Rigid polyvinyl chloride (PVC) conduit shall be Schedule 40 UL listed for concrete encased, direct burial underground, and exposed use. Rigid PVC conduit including couplings, elbows, nipples, and other fittings shall conform to the requirements of the latest edition of NEMA TC 2 and NEMA TC 3, UL, NEC, Federal specification WC-1094, and shall meet applicable ASTM test re- quirements for the intended use. PVC conduit shall be rated 90°C. Conduit, Flexible (FLEX) Flexible conduit shall be moistureproof flexible steel, polyvinyl chloride jacketed type, UL approved, with continuous copper ground 16000 -3- path in the flexible steel tube, and shall be Anaconda sealtite conduit, Anaconda Type CN, Triangle Tristeel, or equal. BACKFILL MATERIAL FOR CONDUIT TRENCHES Backfill of conduit trenches shall contain no particles larger than three inches in diameter. Backfill material shall be free from roots and debris. CONDUCTORS Conductors shall be copper unless aluminum is indicated. Conduc- tors, including insulation, cabling, jacket, filler, shielding, covering and testing, shall meet applicable requirements of IPCEA S-19-81 and S-61-402, the NEC, and UL. Unless noted otherwise, conductors shall have 600-volt Type THW insulation. TWISTED SHIELDED PAIR (TSP) Twisted shielded pairs shall be AWG-16, twisted, stranded copper, with PVC insulation rated 300 val ts. Shield shall be aluminum polyester. Outer jacket shall be PVC. The cable shall be rated gooc minimum. The cable shall be Okonite P-Os, or equal. TWISTED SHIELDEO TRIAD (TST) Multiple twisted shielded triads shall be AWG-16, twisted, stranded copper, with PVC insulation rated 300 volts. Shield shall be aluminum polyester. Outer jacket shall be PVC. The cable shall be rated 90°C minimum. The cable shall be Okonite P- os, or equal. CAST BOXES Cast boxes shall be galvanized malleable ferrous metal, gasketed and watertight, with threaded hubs and mounting lugs. Cast boxes for conduit below grade shall be heavy duty with sidewalk cover, 8 x 8 x 4 inches minimum. Use PVC-coated boxes with PVC-coated conduit. SINGLE AND DUPLEX CONVENIENCE RECEPTACLES Receptacles shall be of specification grade and of NEMA configura- tion rating 5-15 (2 pole, 3 wire ground, 15 amperes, 125 volts). Contact arrangement shall be such that contact is made on two sides of each inserted blade. Bases shall be of ivory phenolic composition. Wire terminals shall be suitable for 10 AWG wire and shall be screw type. Receptacles shall be UL listed. Corrosion- resistant receptacles shall have conducting parts of nickel-plated brass and other metal parts of stainless steel. 16000 -4- GFI RECEPTACLES Receptacles with ground fault circuit interrupters (GFI) shall be UL listed, be duplex, have NEMA 5-15 configuration and rating, fit standard-sized outlet boxes, and have 12 AWG Type TW pigtails. Interrupters shall trip on a 5-mA ground fault, not on overloads, shall be capable of interrupting 1,000 amperes without damage, and shall have provision for testing. GFI receptacles shall be Pass and Seymour Catalog Nos. 1591 or 1591F as indicated, Square D Catalog Nos. GFR-115 of GFR-115M as indicated, or equal. WALL SWITCHES Wall switches shall be of specification grade, totally enclosed, tumbler type. Operating handles shall be phenolic composition and be ivory. switches shall be rated 20 amperes at 120/277 volts ac and shall be sui table for the control of tungsten lamp loads. Wire terminals shall be screw type. Switches shall be UL listed. Corrosion-resistant switches shall have conducting parts of nickel-plated brass and other metal parts of stainless steel. DEVICE PLATES Cast plates sha_ll be of galvanized malleable ferrous metal with gasket and galvanized steel screws with oval heads. Weatherproof device plates shall be of galvanized malleable ferrous cast metal with gasket and cap and shall be suitable for the device. The cap shall be permanently attached to the cover plate by a short length of bead chain or provided with a spring- hinged flap with rubber gaskets and stainless steel springs. Plates covering duplex receptacles shall have a cap over each receptacle opening. Raised sheet metal plates shall be of 1/2-inch-high zinc or cadmium-plated steel designed for one-piece drawn-type sheet steel boxes. LUMINARES Fixtures Lighting fixtures shall be of the types and sizes shown on the Plans and shall be furnished and installed complete with mounting devices and junction boxes where required. Fluorescent fixtures hung in continuous rows shall have wiring channels approved for use as wireways. Chain-suspended fluorescent fixtures in industrial areas shall have galvanized steel chains. 16000 -5- Cord-connected fixtures shall have Type so cord with two 14-AWG and one 14-AWG ground conductors, locking-type nylon cap matching the receptacle, and gland-type fixture entrance. LIGHTING &~D POWER PANELBOARDS Panelboards shall be circuit breaker type as indicated and shall meet the standards established by UL, NEMA PB 1, and the NEX. Panels used as service entrance equipment shall have UL approval for that use. Circuit breakers shall be of the indicating type, providing ON, OFF, and TRIPPED positions of the operating handle. Circuit breakers shall be quick-made, quick-break, with a thermal-magnetic action, and shall be noninterchangeable in accordance with the NEC. The use of tandem or dual circuit breakers in a normal single-pole space to provide the number of poles or spaces speci- fied is not acceptable. All multiple-pole ~ircuit breakers shall be designed so that an overload on one pole automatically causes all poles to open. Circuit breakers shall meet the requirements of UL and NEMA AB 1. GFI (ground fault interrupter) breakers shall trip in approximately .025 second with a ground fault of 5 rnA. WORKMANSHIP GENERAL Work shall be performed in a workmanlike manner by craftsmen skilled in the particular trade. Work shall be performed in accordance with the Plans, Specifications, manufacturers' recom- mendations, and the best practice of the trade. Completed work shall present a neat and finished appearance. Coordinate electrical work with the Owner and the work of other trades to avoid conflicts, error~, delays, and unnecessary inter- ference during construction. PROTECTION DURING CONSTRUCTION Throughout this Contract, provide protection for materials and equipment against loss or damage. Protect materials and equipment from the effects of weather. Prior to installation, store items to be installed in indoor locations, items subject to corrosion under damp conditions, and items containing insulation such as transformers, motors, and control, in indoor, heated, dry locations. Following corrosion, insulation. installation, protect materials and equipment from physical damage, and the effects of moisture on Cap conduit runs during construction with manu- 16000 -6- factured seals. Keep openings in boxes or equipment closed during construction. MATERIAL AND EQUIPMENT INSTALLATION Follow the manufacturer's installation instructions unless other- wise indicated. Follow the Engineer's decision, at no additional cost to the Owner, wherever any conflict arises between the manu- facturer's instructions, codes and regulations, and these Contract Documents. Keep a copy of the manufacturer's installation instructions on the jobsite available for review at all times. CUTTING AND PATCHING Do not cut or notch any structural member or building surface without specific approval of the Engineer. Carefully carry out any cutting, channeling, chasing, or drilling of floors, walls, partitions, ceilings, paving, or other surfaces required for the installation, support, or anchorage of conduit, raceways, or other electrical materials and equipment. Following such work, restore surfaces neatly to new condition using skilled craftsmen of the trades involved at no additional cost to the owner. CLEANING AND TOUCHUP PAINTING Keep the premises free from accumulation of waste materi-al or rubbish. Upon completion of work, remove materials,, scraps, and debris from the premises and from the interior and exterior of all devices and equipment. Refinish damaged surfaces to new condition using skilled craftsmen of the trades involved at no additional cost to the Owner. WIRING METHODS Generally, and unless otherwise specified or indicated, w1r1ng shall consist of insulated conductors installed in raceways of types indicated. CONDUITS Type to be Used Minimum size conduit shall be 1/2 inch, except 3/4 inch for under- ground and embedded conduit for the locations listed unless indicated otherwise: 0 Use galvanized rigid steel conduit (GRS) outdoors, in wet locations, and for exposed locations above the floor. o Use rigid polyvinyl chloride (PVC) conduit . and for buried and embedded conduit, except use galvanized rigid 16000 -7- steel (GRS) at least five feet on both sides of penetrations through footings and outside walls, under equipment mounting pads, where embedded in exterior light pole foundations, and where conduit changes from underground to exposed or from embedded to exposed. o GRS may be used as a substitute in any location. General Conduit system installation shall meet or exceed the requirements of the NEC. Raceways shall be concealed or exposed, as indicated, and shall be at least six inches away from parallel runs of flues and steam or hot water pipes. Group raceways in same area together. Raceways shall be supported at intervals required by the NEC and shall have exposed runs installed parallel or perpen- icular to walls, structural members, or intersections of vertical planes and ceilings. Avoid field-made bends and offsets where possible, but where necessary, make with an approved hickey or conduit bending machine. Heating of conduit to facilitate bending will not be acceptable, except as noted hereinafter. Changes in direction of runs shall be made with symmetrical bends or cast metal fittings. Do not install crushed or deformed raceways. Avoid traps in raceways where possible. Take care to prevent the lodgement of plaster, dirt, or trash in raceways, boxes, fittings, and equipment during the course of construction. Raceways-shall be entirely free of obstructions or shall be replaced. All conduit shall be reamed, burrs removed, and cleaned for proper introduction of wires and cables. Immediately after installation, plug or cap all conduit ends with watertight and dusttight conduit seals until the time for pulling wires. In block walls, do not run conduit in the same horizontal course with reinforcing steel. Install insulated bushings on the ends of all conduits, except where conduits terminate in threaded hubs on cast boxes or cabinets. Use insulating throat connectors where tubing terminates in boxes or cabinets. Provide suitable expansion fittings for raceways crossing expansion joints in structures or concrete slabs, or provide other suitable means to compensate for expansion and contraction. Wooden plugs inserted in concrete or masonry are not acceptable as a base for raceway fastenings, nor shall raceways or pipe straps be welded to steel structures. Support multiple raceways adjacent to each other by ceiling trapeze. Support individual raceways by wall brackets, strap hangers, or ceiling trapeze, fastened by toggle bolts or expansion shields on hollow masonry units, expansion shields on concrete or bricks, and clamp-type fasteners approved for the type of installation on steelwork. Threaded studs driven in by a powder charge and provided with lock washers and nuts are acceptable in lieu of expansion shields. Use PVC-coated fasteners and supports in PVC-coated conduit systems. 16000 -a- Conduit shall be of , greatest practical single length between joints. Joints shall be made up with approved jointing compound. Compound used with aluminum conduit shall contain graphite or powdered zinc. Do not use red lead as a joint compound. Do not use nails to fasten conduit. Do not use wire in·lieu of straps or hangers, and do not notch structural members for the passage of raceways except with prior approval of the Engineer. Install and equip conduit, boxes, and fittings installed outdoors or in other wet locations so as to prevent water from entering the conduit. Do not run conduit in equipment foundation pads. Empty ducts and conduits shall be identified at both ends and shall be capped and provided with a copper pull wire, AWG 14 minimum, or 1/8 inch minimum nylon cord, unless noted otherwise. For PVC conduit, use factory-made ells where applicable. Use approved heating methods for forming all other bends. Provide ex- pansion joints as required or as recommended by the manufacturer. When joining PVC conduit to metallic fittings, use approved PVC terminal adapters. When joining PVC conduit to rigid steel conduit, u~e an approved PVC female adapter. PVC conduit joints shall be solvent welded with solvent recommended by the conduit manufacturer. Where PVC conduit is used, a separate grounding conductor shall be run with the conductors. Concealed, embedded, and buried conduits shall emerge at right angles and shall have none of the curved portions of a bend exposed, unless otherwise approved by the Engineer. Where slabs are on grade, install conduit beneath the slab and not in the slab. Where ells are required to penetrate floor slabs, the ells shall be rigid steel conduit. Final connection to motors, motor heaters, wall or ceiling mounted fans and unit heaters, dry transformers, and to other equipment where flexible connection is desired or required to minimize vibration or to facilitate maintenance or removal of equipment, shall be made with short lengths of flexible conduit where the required conduit size is three inches or less. Length shall be 18 to 36 inches unless otherwise approved by the Engineer. Flexible conduit shall not be used as a ground. Flexible conduit shall be secured with conduit clamps or equivalent means except where the flexible conduit is fished and where sections less the four feet in length are used in concealed areas for lighting fixtures. Underground and Embedded Conduit On steel conduit installed underground, coat couplings arid joints or wrap couplings and joints with tape using 1/2-inch overlap. Use Kippers Bitumastic No. 505, Scotchwrap No. 51, or equal. 16000 -9- Separate parallel runs of four or more conduits in a single trench or embedded duct bank with preformed, nonmetallic spacers designed for the purpose. Install spacers at six feet or at intervals not greater than that specified in the NEC for support of the type conduit used. Support conduits installed in fill areas suitably to prevent accidental bending until backfilling is complete. Multiple conduit runs shall be arranged substantially as shown on Plans, but minor changes in location or cross sectional arrange- ment shall be made as necessary to avoid obstructions, etc. Where conduit runs cannot be installed substantially as shown because of conditions not discoverable prior to digging of trenches, the condition shall be referred to the Engineer for instructions before further work is done. Underground conduit work shall be coordinated with other outside construction work. Existing outside services shall be maintained in operation unless otherwise directed by the Engineer. Envelopes may be poured directly against the sides of the trenches if the cut is clean, even, and free of loose material. Loose material shall be removed from the trenches before and during pouring of concrete to ensure sound envelopes. Concrete shall be carefully spaded during pouring to eliminate voids under and between the conduits and honeycombing of the exterior surfaces. Power-driven tampers or agitators shall not be used, unless specifically designed for the application, in order to ensure that the watertightness of the conduits is not destroyed. To the extent practical, each duct bank shall be poured in one continuous operation. Where more than one pour is necessary, each joint shall have steel reinforcing bars designed and placed to prevent differential settlement or damage to the conduit. Where an envelope is installed over an extensive area of disturbed earth, such as that within tht! periphery of the building, a separate concrete base, satisfactory to the Engineer, shall be provided to ensure stability of the conduits during installation. The base shall be allowed to set before the conduit bank is installed. Trenches shall not be backfilled until envelopes have set sufficiently, as decided by the Engineer. After the envelope has set, a mandrel of diameter approximately 1/4 inch less than the inside diameter of the conduit shall be pulled through each conduit, after which a brush with bristles shall be pulled through. 16000 -10- Penetrations Penetrations may be cast in place or run through: bloc-kouts or holes, except where waterproof penetrations are ·,indicated. Dry pack with nonshrink grout• around conduits run through· -blackouts or holes. "· . , · • ·· Where a waterproof penetration is indicated, an approved malleable-iron watertight entrance sealing device_ shall be provided. Each end of the device shall have a gland-type sealing assembly with pressure bushings which may be tightened at any time, except where a concrete envelope is specified or shown on the Plans. Where there is a concrete envelope specified or shown on the Plans, a sealing gland assembly may be on the more acces- sible side only. The device shall be securely anchored .into the masonry construction with one or more integral flanges. The membrane waterproofing· shall be secured to the device in a permanently watertight manner. CONDUCTORS 600 VOLTS AND BELOW General Wire shall be continuous from outlet to outlet. Conductors shall not be smaller than No. 12 AWG for lighting or power circuits or No. 14 AWG for con~rol circuits, unless otherwise indicated.- conductors shall be stranded except solid· conductors No. 10 AWG and No. 12 AWG may be used for branch circuit power wiring and for lighting and receptacle circuits. Where conductors will be connected by. others, provide adequate length pigtails. Arrange wiring in enclosures neatly cut to proper length. Apply terminals to control wiring for connection to terminals, and bridle and secure in an approved manner. List all circuits emanating from power, distribution, and lighting panelboards by function on the directory card. Identify conductors at all splices and terminations. Raceways entering structures shall be sealed inside the conduit at the first box or outlet with oakum or suitable plastic expansible compound to prevent the entrance into the structure of rodents, gases, and liquids.· Splices and Terminations Preferably, conductors shall be run between pieces of equipment without splices. Splices, where required, shall be made in 16000 -11- accessible boxes only. Splices shall not be made below finish grade unless indicated on the Plans or approved by the Engineer. Make splices and terminations of stranded conductors using crimp- type or mechanical devices suitable for the type and size of conductor used. For control wiring, use preinsulated ring-tongue crimp-type devices except where terminals of factory-supplied equipment do not so allow. Use terminals, connectors, and installation tools as recommended by the manufacturer. Crimp-type lugs shall be applied with a tool so designed that once the crimping action is started, the tool cannot be removed until the crimping action is completed. Do not use wire nuts or solder for splices or terminations, except wire nuts may be used with solid wires as indicated below. For solid conductors No. 12 AWG and smaller, make splices and terminations using wire nuts or threaded mechanical devices suitable for the type and size of the conductor used. Wire nuts shall be the coiled, spring-loaded type. Do not use wire nuts constructed of one solid piece (not spring loaded) . For solid conductors No. 10 AWG and larger, make splices and terminations using threaded mechanical devices suitable for the type and size of conductor used. Shielded Wire and Cable Maintaining the integrity of shielding is essential. Shield grounding shall occur at one point, and at one point only. Take special care in cable installation to ensure that unwanted grounds do not occur because of careless terminations or damage to the jacket over the shield. Take special care to ensure that random contact of shields of adjacent cAbles does not occur. Provide crimp-type (solderless) lugs, connectors, and ferrule-ring assemblies of the proper s1.ze for the conductor used. Crimp devices using the tool recommended by the device manufacturer. The tool shall be designed such that once the crimping action is started, the tool cannot be removed until its jaws "bottom." Leave no shields bare. Where shields have been stripped, reinsulate with shrink tubing. Where a shield branches off from a parent conductor, leave no bare wire or shield exposed. To dead- end shields, strip back outer jacket and shield. Insulate shield end with shrink tubing. To ground shields, strip outer jacket back and unwrap shield. Splice shield to a length of green insulated conductor or cover with shrink tubing. In either case, insulate with shrink tubing the length of conductor near where the shield branches off. As an 16000 -12- alternate shield ,gro'l.lnaing . method, use manufactured. crimp-type ferrules and rings ,to, splice a length of ground~ conduGtor to the shield. Use devices manufactured by Burridy, Amp, or equal. Device size, type, :and: ,installation procedure shalL be _in accor- dance with the device manufacturer's recommenda1::_ionsfot.~the type of conductor used. Do not loop ground conductors ,from ;o,he shield to another. Ground each shield separately. ·-·· Testing After installation, termination, and identification 9-f conductors, perform continuity check and' 500-volt megger test on all wiring to demonstrate that · wil!',ing , has been properly installed. and · identi- fied, and that there are no shorts among wires, shielcts, and ground. Perform tests to demonstrate that shields a're · isolated from ground except __ at.: the grounding point. correct improper grounds. Tests shall be perfo~ed in the presence of the Engineer. BOXES './ . Provide each outle:t in the w~r~ng or raceway systems with an outlet box to suit the conditions encountered. Each box shall have sufficient volume to accommodate the number of conductors entering the box in. :accordance with the requirements of the-NEC. Provide flush or recessed fixtures with separate· junction boxes when required by the fixture terminal temperature requirements. Boxes used with concealed conduits shall be f~ush-~ounted, unless otherwise indicated. ·· · · . . . Use cast boxes outdoors I in wet 1ocati9nS I with rexposed conduit less than ten feet above tpe_ floor, and· with embe.dded aru;t buried conduit. Unless otherwise shown on the Plans, install boxes in a rigid and satisfactory manner and support independently of conduit by bar hangers in frame construction or fasten directly with bolts and expansion shield on concrete or brick, toggle bolts or expansion shields on hollow masonry units and machine screws on steelwork. Threaded studs driven in by a powder charge and provided with lock washers and nuts are acceptable in lieu of expansion shields. Where boxes are .flush mounted in walls, if not embedded in concrete, the hole shall be no larger than required to receive the box. Mounting hardware in industrial areas shall be galvanized. LUMINARES -. :., :-' Deliver lamps to the project . in their original c;arj:.,ons~ After construction of the total project is completed.~ wash 'J''ixtures, clean lamps, touch up any paint .. scratches or chip,f:?, re_move labels from fixture lenses, and replace ..noisy. ballasts,. · · " . ' ' ... 16000 -13- GROUNDING Unless otherwise indicated, ground all exposed noncurrent-carrying metallic parts of electrical equipment, raceway systems, and the neutral of all wiring systems in accordance with the NEC, state, and other applicable laws and regulations. Provide grounding points (foundation ground points) at each building and structure. Ground electrode shall be No. 4 minimum size attached to a twenty-foot minimum length piece of reinforcing steel located within and near the bottom of the concrete foundation. Attach the ground wires to the reinforcing steel by thermite welding. Where ground rods are indicated or used, they shall be copper clad not less than 3/4 inch in diameter, 10 feet long, driven full length into the earth. Make ground connections by brazing, thermi te welding, or with approved pressure terminals or mechanical grounding devices, except inaccessible connections shall be made by thermite welding. THERMITE WELDING The point of contact of the thermite weld shall be wire brushed or filed to a bare metal surface. Thermite welding cartridges and molds shall be used in accordance with the manufacturer's recom- mendations. After the welds have been made and cooled, slag shall be brushed from the welded area and the joint thoroughly cleaned. INSULATION TEST After the visual inspection of terminations and connections and the application of tape and other insulating materials, all . -. . sect1ons of the complete system of w1r1ng shall be thoroughly tested for shorts and grounds. The Contractor shall correct all defects. Each motor shall have its insulation resistance to ground measured with 500-volt megger prior to connection, in the presence of the Engineer. The Contractor shall make a record of these values and submit it to the Engineer. Values of resistance of less than one megohm will not be acceptable. Insulation resistance measurements of each branch power circuit shall be made with loads connected and contactors, if any, blocked closed to give complete circuits. Insulation resistance of the complete circuit shall be measured from the circuit breaker load terminals with the breaker open. The Contractor shall witness and make a record of these values and submit it to the Engineer. Values of resistance of less than megohm will not be acceptable. 16000 -14- OPERATING TEST After the electrical system installation is compl:eteQ., and at such time as the Eng irteer may direct, conduct an· operat.i.ng. test for approval. Demonstrate the equipment operating in~a9cor~ance with the requirements of· the Specifications. Perform the test in the presence of the Engineer. Furnish all instruments and personnel required for the tests. GUARANTEE All equipment to be furnished under this item shal:L be .. guaranteed for a period of one year from the date of acceptance thereof against defective materials, design, and workmanship. · PAYMENT Payment for this section shall be included as part of the lump sum bid. 16000 -15- -' . - ... I ~ 4 ., ... . , .. ' ...... ~ ,~ .. . ........ ~~ .. ,·.~., ~ .~t ~ :.y. ~ ' ~-t .~ t"" ~.) \ ~ CONTRACT DRAWINGS A set of "Record Drawings" have been produced for reference of constructed dimensions and information. The titles and drawing numbers for each civil contract drawing are presented below. DRAWING NUMBER Cl C2 C3 C4 cs C6 C7 ca C9 ClO Cll Cl2 Cl3 Cl4 Cl5 Cl6 Cl7 Cl8 Cl9 C20 C21 C22 C23 TITLE TITLE SHEET SYMBOLS AND ABBREVIATIONS SITE PLAN RELIEF CHANNEL -PROFILE AND SECTIONS SITE WORK -DIKE & PARKING LOT INTAKE -TRASHRACK AND DETAILS INTAKE -EQUIPMENT INSTALLATION PENSTOCK -PLAN AND PROFILE PENSTOCK -SECTIONS AND DETAILS POWERHOUSE -PLAN POWERHOUSE -FOUNDATION PLAN POWERHOUSE -SECTIONS POWERHOUSE -SECTIONS POWERHOUSE -ELEVATIONS POWERHOUSE -DETAILS POWERHOUSE -DETAILS POWERHOUSE -DETAILS WATER SUPPLY SYSTEM -PLAN AND DETAILS WATER SUPPLY SYSTEM -VALVE VAULT POWERHOUSE -GROUNDING GRID POWERHOUSE -GROUNDING GRID DETAILS POWERHOUSE -ELECTRICAL SYSTEMS POWERHOUSE -ELECTRICAL SYSTEMS