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C-5108 - Operation and Maintenance Services Agreement for Newport Terrace Landfill Gas Control System
CID AMENDMENT NO. TWO TO p OPERATION AND MAINTENANCE SERVICES AGREEMENT WITH ES ENGINEERING SERVICES, LLC FOR V7 NEWPORT TERRACE LANDFILL GAS CONTROL SYSTEM THIS AMENDMENT NO. TWO TO OPERATION AND MAINTENANCE SERVICES AGREEMENT ("Amendment No. Two") is made and entered into as of this 1st day of April, 2017 ("Effective Date"), by and between the CITY OF NEWPORT BEACH, a California municipal corporation and charter city ("City"), and ES ENGINEERING SERVICES, LLC, a Delaware limited liability company ("Contractor"), whose address is 1036 W. Taft Ave, Orange, CA 92865, and is made with reference to the following: RECITALS A. On April 10, 2012, City and GC Environmental, Inc., a California corporation, entered into an Operation and Maintenance Services Agreement ("Agreement') for Contractor to perform the Operations and Maintenance ("O&M") services related to the Newport Terrace Landfill Gas Control System (`Project'). B. On January 6, 2016, GC Environmental, Inc. requested that the City assign its rights and obligations under the Agreement to Contractor. C. On March 31, 2016, City and Contractor entered into Amendment No. One for City to accept the sale of the Agreement to Contractor, to memorialize the assignment of the Agreement to Contractor, to update Insurance Requirements, and to update the Notice provisions of the Agreement. D. The parties desire to enter into this Amendment No. Two to extend the term of the Agreement to June 30, 2017. NOW, THEREFORE, it is mutually agreed by and between the undersigned parties as follows: TERM Section 1 of the Agreement is amended in its entirety and replaced with the following: "The term of this Agreement shall commence on the Effective Date, and shall terminate on June 30, 2017, unless terminated earlier as set forth herein." 2. INTEGRATED CONTRACT Except as expressly modified herein, all other provisions, terms, and covenants set forth in the Agreement shall remain unchanged and shall be in full force and effect. [SIGNATURES ON NEXT PAGE] IN WITNESS WHEREOF, the parties have caused this Amendment No. Two to be executed on the dates written below. APPROVED AS TO FORM: CITY ATTORNEY'S OFFICE Date: U//7 By: Aaron C. Harp 3� City Attorney ATTEST: Date: a;'�zLe r1i 1. rown C evc, I e I CITY OF NEWPORT BEACH, a California municipal corporation Date: !fl 111. Ian By: _ -A—� — Dave Kiff City Manager CONTRACTOR: ES ENGINEERING SERVICES, LLC, a Delaware limited liability company Date: titittA By: Vijay Manthripragada President Date:�j By: J uelta easurer [END OF SIGNATURES] ES Engineering Services, LLC Page 2 0% J —0 AMENDMENT NO. ONE TO ' OPERATION AND MAINTENANCE SERVICES AGREEMENT U WITH ES ENGINEERING SERVICES, LLC. FOR NEWPORT TERRACE LANDFILL GAS CONTROL SYSTEM THIS AMENDMENT NO. ONE TO OPERATION AND MAINTENANCE SERVICES AGREEMENT ("Amendment No. One") is made and entered into as of this 31st day of March, 2016 ("Effective Date"), by and between the CITY OF NEWPORT BEACH, a California municipal corporation and charter city ("City"), and ES ENGINEERING SERVICES, LLC., a Delaware limited liability company ("Contractor'), whose address is 1036 W. Taft Ave, Orange CA 92865, and is made with reference to the following: RECITALS A. On April 10, 2012, City and GC Environmental, Inc., a California corporation, entered into an Operation and Maintenance Services Agreement ("Agreement") for Contractor to perform the Operations and Maintenance ("O&M") services related to the Newport Terrace Landfill Gas Control System ("Project"). B. On January 6, 2016, GC Environmental, Inc. requested that the City assign its rights and obligations under the Agreement to Contractor. C. The parties desire to enter into this Amendment No. One for City to accept the sale of the Agreement to Contractor, to memorialize the assignment of the Agreement to Contractor, to update Insurance Requirements, and to update the Notice provisions of the Agreement. NOW, THEREFORE, it is mutually agreed by and between the undersigned parties as follows: 1. ASSIGNMENT As of the Effective Date, GC Environmental, Inc. hereby assigns to Contractor all of the rights, title and interest in and obligations under the Agreement. Contractor hereby accepts such assignment and hereby assumes, agrees and undertakes to perform all obligations of GC Environmental, Inc., pursuant to the Agreement as of the Effective Date. Any reference to GC Environmental, Inc., in the Agreement, shall be deemed to be a reference to Contractor. As of the Effective Date, GC Environmental, Inc., shall have no further rights of any kind whatsoever under the Agreement. 2. INSURANCE Section 10 of the Agreement is deleted in its entirety and replaced with the following: "Without limiting Contractor's indemnification of City, and prior to commencement of Work, Contractor shall obtain, provide and maintain at its own expense during the term of this Agreement or for other periods as specified in this Agreement, policies of insurance of the type, amounts, terms and conditions described in the Insurance Requirements attached hereto as Exhibit C, and incorporated herein by reference." 3. NOTICES Section 14 of the Agreement is amended in its entirety and replaced with the following: "14.1 All notices, demands, requests or approvals, including any change in mailing address, to be given under the terms of this Agreement shall be given in writing, and conclusively shall be deemed served when delivered personally, or on the third business day after the deposit thereof in the United States mail, postage prepaid, first- class mail, addressed as hereinafter provided. 14.2 All notices, demands, requests or approvals from Contractor to City shall be addressed to City at: Attn: Director Municipal Operations Department City of Newport Beach 100 Civic Center Drive PO Box 1768 Newport Beach, CA 92658 14.3 All notices, demands, requests or approvals from City to Contractor shall be addressed to Contractor at: Attn: Farideh Kia ES Engineering Services, LLC. 1036 W. Taft Ave Orange CA 92865" 4. INTEGRATED CONTRACT Except as expressly modified herein, all other provisions, terms, and covenants set forth in the Agreement shall remain unchanged and shall be in full force and effect. [SIGNATURES ON NEXT PAGE] ES Engineering Services, LLC. Page 2 IN WITNESS WHEREOF, the parties have caused this Agreement to be executed on the dates written below. APPROVED AS TO FORM: CITY ATTO IEY'S OFFICE Date: VAN CITY OF NEWPORT BEACH, a California municipal corporation Date: Wk k -- By: W� By: Z �� Aaron C. Harper Dave i City Attorney City Manager ATTEST: / `� v to Date: V �/ By: olt� ,bw, Leilani I. Brown City Clerk CONTRACTOR: ES ENGINEERING SERVICES, LLC., a Delaware limited liability company Date: igFM - Vijay Manth President Date: By: Jo e e uel Treasurer AGREED: GC Environmental, Inc., a California Corporation By. f L�-- Richard W. Prosser Chief Executive Officer Date: 5 S 20 1 By: Farideh Kia Chief Financial Officer [END OF SIGNATURES] Attachments: Exhibit C — Insurance Requirements ES Engineering Services, LLC. Page 3 EXHIBIT C INSURANCE REQUIREMENTS 1. Provision of Insurance. Without limiting Contractor's indemnification of City, and prior to commencement of Work, Contractor shall obtain, provide and maintain at its own expense during the term of this Agreement, policies of insurance of the type and amounts described below and in a form satisfactory to City. Contractor agrees to provide insurance in accordance with requirements set forth here. If Contractor uses existing coverage to comply and that coverage does not meet these requirements, Contractor agrees to amend, supplement or endorse the existing coverage. 2. Acceptable Insurers. All insurance policies shall be issued by an insurance company currently authorized by the Insurance Commissioner to transact business of insurance in the State of California, with an assigned policyholders' Rating of A- (or higher) and Financial Size Category Class VII (or larger) in accordance with the latest edition of Best's Key Rating Guide, unless otherwise approved by the City's Risk Manager. 3. Coverage Requirements. A. Workers' Compensation Insurance. Contractor shall maintain Workers' Compensation Insurance, statutory limits, and Employer's Liability Insurance with limits of at least one million dollars ($1,000,000) each accident for bodily injury by accident and each employee for bodily injury by disease in accordance with the laws of the State of California, Section 3700 of the Labor Code. Contractor shall submit to City, along with the certificate of insurance, a Waiver of Subrogation endorsement in favor of City, its City Council, boards and commissions, officers, agents, volunteers, employees, and any person or entity owning or otherwise in legal control of the property upon which Contractor performs the Project and/or Services contemplated by this Agreement. B. General Liability Insurance. Contractor shall maintain commercial general liability insurance and, if necessary, umbrella liability insurance, with coverage at least as broad as provided by Insurance Services Office form CG 00 01, in an amount not less than one million dollars ($1,000,000) per occurrence, two million dollars ($2,000,000) general aggregate. The policy shall cover liability arising from premises, operations, products - completed operations, personal and advertising injury, and liability assumed under an insured contract (including the tort liability of another assumed in a business contract). C. Automobile Liability Insurance. Contractor shall maintain automobile insurance at least as broad as Insurance Services Office form CA 00 01 ES Engineering Services, LLC. Page C-1 covering bodily injury and property damage for all activities of Contractor arising out of or in connection with Work to be performed under this Agreement, including coverage for any owned, hired, non -owned or rented vehicles, in an amount not less than one million dollars ($1,000,000) combined single limit each accident. D. Professional Liability (Errors & Omissions) Insurance. Contractor shall maintain professional liability insurance that covers the Services to be performed in connection with this Agreement, in the minimum amount of one million dollars ($1,000,000) per claim and two million dollars ($2,000,000) in the aggregate. Any policy inception date, continuity date, or retroactive date must be before the Effective Date of this Agreement and Contractor agrees to maintain continuous coverage through a period no less than three years after completion of the Services required by this Agreement. E. Builder's Risk Insurance. For Contracts with property exposures during construction, Contractor shall maintain Builders Risk insurance or an installation floater as directed by City, covering damages to the Work for "all risk" or special causes of loss form with limits equal to 100% of the completed value of contract, with coverage to continue until final acceptance of the Work by City. At the discretion of City, the requirement for such coverage may include additional protection for Earthquake and/or Flood. City shall be included as an insured on such policy, and Contractor shall provide City with a copy of the policy. F. Pollution Liability Insurance. If required, Contractor shall maintain a policy providing contractor's pollution liability ("CPL") coverage with a total limit of liability of no less than one million dollars ($1,000,000) per loss and two million dollars ($2,000,000) in the aggregate per policy period. Claims - made policies require a 5 -year extended reporting period. The CPL policy shall include coverage for cleanup costs, third -party bodily injury and property damage, including loss of use of damaged property or of property that has not been physically injured or destroyed, resulting from pollution conditions caused by contracting operations. Coverage as required in this paragraph shall apply to sudden and non -sudden pollution conditions resulting from the escape or release of smoke, vapors, fumes, acids, alkalis, toxic chemicals, liquids, or gases, waste materials, or other irritants, contaminants, or pollutants. The CPL shall also provide coverage for transportation and off -Site disposal of materials. The policy shall not contain any provision or exclusion (including any so-called "insured versus insured" exclusion or "cross -liability" exclusion) the effect of which would be to prevent, bar, or otherwise preclude any insured or additional insured under the policy from making a claim which would otherwise be covered by such policy on the grounds that the claim is brought by an insured or additional insured against an insured or additional insured under the policy. ES Engineering Services, LLC. Page C-2 4. Other Insurance Requirements. The policies are to contain, or be endorsed to contain, the following provisions: A. Waiver of Subrogation. All insurance coverage maintained or procured pursuant to this Agreement shall be endorsed to waive subrogation against City, its City Council, boards and commissions, officers, agents, volunteers, employees, and any person or entity owning or otherwise in legal control of the property upon which Contractor performs the Project and/or Services contemplated by this Agreement or shall specifically allow Contractor or others providing insurance evidence in compliance with these requirements to waive their right of recovery prior to a loss. Contractor hereby waives its own right of recovery against City, and shall require similar written express waivers from each of its subContractors. B. Additional Insured Status. All liability policies including general liability, products and completed operations, excess liability, pollution liability, and automobile liability, if required, shall provide or be endorsed to provide that City, its City Council, boards and commissions, officers, agents, volunteers, employees, and any person or entity owning or otherwise in legal control of the property upon which Contractor performs the Project and/or Services contemplated by this Agreement shall be included as insureds under such policies. C. Primary and Non Contributory. All liability coverage shall apply on a primary basis and shall not require contribution from any insurance or self- insurance maintained by City. D. Notice of Cancellation. All policies shall provide City with thirty (30) calendar days notice of cancellation (except for nonpayment for which ten (10) calendar days notice is required) or nonrenewal of coverage for each required coverage. 5. Additional Agreements Between the Parties. The parties hereby agree to the following: A. Evidence of Insurance. Contractor shall provide certificates of insurance to City as evidence of the insurance coverage required herein, along with a waiver of subrogation endorsement for workers' compensation and other endorsements as specified herein for each coverage. Insurance certificates and endorsement must be approved by City's Risk Manager prior to commencement of performance. Current certification of insurance shall be kept on file with City at all times during the term of this Agreement. City reserves the right to require complete, certified copies of all required insurance policies, at any time. B. City's Right to Revise Requirements. City reserves the right at any time during the term of the Agreement to change the amounts and types of ES Engineering Services, LLC. Page C-3 insurance required by giving Contractor sixty (60) calendar days advance written notice of such change. If such change results in substantial additional cost to Contractor, City and Contractor may renegotiate Contractor's compensation. C. Right to Review Subcontracts. Contractor agrees that upon request, all agreements with subcontractors or others with whom Contractor enters into contracts with on behalf of City will be submitted to City for review. Failure of City to request copies of such agreements will not impose any liability on City, or its employees. Contractor shall require and verify that all subcontractors maintain insurance meeting all the requirements stated herein, and Contractor shall ensure that City is an additional insured on insurance required from subcontractors. For CGL coverage, subcontractors shall provide coverage with a format at least as broad as CG 20 38 04 13. D. Enforcement of Agreement Provisions. Contractor acknowledges and agrees that any actual or alleged failure on the part of City to inform Contractor of non-compliance with any requirement imposes no additional obligations on City nor does it waive any rights hereunder. E. Requirements not Limiting. Requirements of specific coverage features or limits contained in this Section are not intended as a limitation on coverage, limits or other requirements, or a waiver of any coverage normally provided by any insurance. Specific reference to a given coverage feature is for purposes of clarification only as it pertains to a given issue and is not intended by any party or insured to be all inclusive, or to the exclusion of other coverage, or a waiver of any type. If the Contractor maintains higher limits than the minimums shown above, the City requires and shall be entitled to coverage for higher limits maintained by the Contractor. Any available insurance proceeds in excess of the specified minimum limits of insurance and coverage shall be available to the City. F. Self-insured Retentions. Any self-insured retentions must be declared to and approved by City. City reserves the right to require that self-insured retentions be eliminated, lowered, or replaced by a deductible. Self- insurance will not be considered to comply with these requirements unless approved by City. G. City Remedies for Non -Compliance If Contractor or any sub - Contractor fails to provide and maintain insurance as required herein, then City shall have the right but not the obligation, to purchase such insurance, to terminate this Agreement, or to suspend Contractor's right to proceed until proper evidence of insurance is provided. Any amounts paid by City shall, at City's sole option, be deducted from amounts payable to Contractor or reimbursed by Contractor upon demand. ES Engineering Services, LLC. Page C-4 H. Timely Notice of Claims. Contractor shall give City prompt and timely notice of claims made or suits instituted that arise out of or result from Contractor's performance under this Contract, and that involve or may involve coverage under any of the required liability policies. City assumes no obligation or liability by such notice, but has the right (but not the duty) to monitor the handling of any such claim or claims if they are likely to involve City. Contractor's Insurance. Contractor shall also procure and maintain, at its own cost and expense, any additional kinds of insurance, which in its own judgment may be necessary for its proper protection and prosecution of the Work. ES Engineering Services, LLC. Page C-5 ES Engineering Services, LLC. CERTIFICATE OF INSURANCE CHECKLIST City of Newport Beach This checklist is comprised of requirements as outlined by the City of Newport Beach. * Date Received: 6/10/16 Date Completed: 6/10/16 Sent to Company/Person required to have certificate: Type of contract: Dept./Contact Received From: Rachell Rachell By: Alicia Montrose Environmental Group/ES Engineering All Others I. GENERAL LIABILITY EFFECTIVE/EXPIRATION DATE: 12/31/15-12/31/16 A. INSURANCE COMPANY: Homeland Insurance Company of New York B. AM BEST RATING (A-: VII or greater): A:X AM BEST RATING (A-: VII or greater) A:XV C. ADMITTED Company (Must be California Admitted): ADMITTED COMPANY (Must be California Admitted): Is Company admitted in California? ❑ Yes ® No D. LIMITS (Must be $1 M or greater): What is limit provided? 1,000,000/2,000,000 E. ADDITIONAL INSURED ENDORSEMENT — please attach ® Yes ❑ No F. PRODUCTS AND COMPLETED OPERATIONS (Must LIMITS Waiver of Auto Insurance / Proof of coverage (if individual) include): Is it included? (completed Operations status does (What is limits provided?) N/A not apply to Waste Haulers or Recreation) ® Yes ❑ No G. ADDITIONAL INSURED FOR PRODUCTS AND Haulers only): ® N/A ❑ Yes ❑ No COMPLETED OPERATIONS ENDORSEMENT (completed HIRED AND NON -OWNED AUTO ONLY: ❑ N/A ® Yes ® No Operations status does not apply to Waste Haulers) ® Yes ❑ No H. ADDITIONAL INSURED WORDING TO INCLUDE (The City its officers, officials, employees and volunteers): Is it included? ® Yes ❑ No I. PRIMARY & NON-CONTRIBUTORY WORDING (Must be included): Is it included? ® Yes ❑ No J. CAUTION! (Confirm that loss or liability of the named insured is not limited solely by their negligence) Does endorsement include "solely by negligence" wording? ❑ Yes ® No K. ELECTED SCMAF COVERAGE (RECREATION ONLY): ® N/A ❑ Yes ❑ No L. NOTICE OF CANCELLATION: ❑ N/A ® Yes ❑ No H. AUTOMOBILE LIABILITY EFFECTIVE/EXPIRATION DATE: 12/31/15-12/31/16 A. INSURANCE COMPANY: National Union Fire Insurance Company B. AM BEST RATING (A-: VII or greater) A:XV C. ADMITTED COMPANY (Must be California Admitted): Is Company admitted in California? ® Yes ❑ No D. LIMITS - If Employees (Must be $1 M min. BI & PD and $500,000 UM, $21M min for Waste Haulers): What is limits provided? 1,000,000 E LIMITS Waiver of Auto Insurance / Proof of coverage (if individual) (What is limits provided?) N/A F. PRIMARY & NON-CONTRIBUTORY WORDING (For Waste Haulers only): ® N/A ❑ Yes ❑ No G. HIRED AND NON -OWNED AUTO ONLY: ❑ N/A ® Yes ® No H. NOTICE OF CANCELLATION: ❑ N/A ® Yes 0 No III. WORKERS' COMPENSATION EFFECTIVE/EXPIRATION DATE: 12/31/15-12/31/16 A. INSURANCE COMPANY: Commerce and Industry Insurance Company B. AM BEST RATING (A-: VII or greater): A:XV C. ADMITTED Company (Must be California Admitted): ® Yes ❑ No D. WORKERS' COMPENSATION LIMIT: Statutory ® Yes ❑ No E. EMPLOYERS' LIABILITY LIMIT (Must be $1M or greater) 1,000,000 F. WAIVER OF SUBROGATION (To include): Is it included? ® Yes ❑ No G. SIGNED WORKERS' COMPENSATION EXEMPTION FORM: ® N/A ❑ Yes ❑ No H. NOTICE OF CANCELLATION: ❑ N/A ® Yes ❑ No ADDITIONAL COVERAGE'S THAT MAYBE REQUIRED IV. PROFESSIONAL LIABILITY V POLLUTION LIABILITY V BUILDERS RISK HAVE ALL ABOVE REQUIREMENTS BEEN MET? IF NO, WHICH ITEMS NEED TO BE COMPLETED? Approved: 6/10/16 Agent of Alliant Insurance Services Date Broker of record for the City of Newport Beach ❑ N/A ® Yes ❑ No ® N/A ❑ Yes ❑ No ® N/A ❑ Yes ❑ No ® Yes ❑ No RISK MANAGEMENT APPROVAL REQUIRED (Non -admitted carrier rated less than _ Self Insured Retention or Deductible greater than $ ) ❑ N/A ❑ Yes ❑ No Reason for Risk Management approval/exception/waiver: Risk Management approval needed for the non -admitted status of the GL carrier. Sheri approved 2/16/16. Approved: Risk Management Date * Subject to the terms of the contract. ACORO® CERTIFICATE OF LIABILITY INSURANCE ih� DATE(MMIDDIYYYY) 3/7!2016 THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AFFIRMATIVELY OR NEGATIVELY AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. THIS CERTIFICATE OF INSURANCE DOES NOT CONSTITUTE A CONTRACT BETWEEN THE ISSUING INSURER(S), AUTHORIZED REPRESENTATIVE OR PRODUCER, AND THE CERTIFICATE HOLDER. IMPORTANT: If the certificate holder is an ADDITIONAL INSURED, the policy(ies) must have ADDITIONAL INSURED provisions or be endorsed. If SUBROGATION IS WAIVED, subject to the terms and conditions of the policy, certain policies may require an endorsement. A statement on this certificate does not confer rights to the certificate holder in lieu of such endorsement(s). PRODUCER Beecher Carlson Insurance Services 6 Concourse Parkway, Suite 2300 Atlanta, GA 30328 CONTACT ATL Alfredo Jenkins PHONE PAX Ac No: 770-870-3031 E DRESS: a enkinsCcilbeechercarlson.com INSURE 8 AFFORDING COVERAGE NAIc# 12131/2015 INSURER A: Homeland Insurance Company Of New York 34452 www.beechercadson.com INSURED Montrose Environmental Corporation GO Montrose Environmental Group, Inc. "See Attached Named Insured List" INSURERS: National Union Fire Insurance Company 19445 INSURERC: Commerce and Industry Insurance Company 19410 INSURERD: MED EXP (Arty one person) $ 5,000 1 Park Plaza, Suite 1000 Irvine CA 92614 INSURERS: INSURER F: COVERAGES CERTIFICATE NUMBER: 28868138 REVISION NUMBER: THIS IS TO CERTIFY THAT THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TO THE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWITHSTANDING ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOCUMENT WITH RESPECT TO WHICH THIS CERTIFICATE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEREIN IS SUBJECT TO ALL THE TERMS, EXCLUSIONS AND CONDITIONS OF SUCH POLICIES. LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CLAIMS. LTR TYPE OF INSURANCE INSR$V/Pcoolllution AWL BURR POLICY NUMBER MOMIIDDYEPP IYYYY POLICY EXP LIMITS A MERCIAL GENERAL LIABILITY 7930041020000 12131/2015 12/31/2016 EACH OCCURRENCE $ 1,000,000 CLAIMS -MADE � OCCUR DAMAGE TO PR MISES Eeo e$100,000 MED EXP (Arty one person) $ 5,000 (occurrence) PERSONAL B ADV INJURY $ 1,000.000 GENERALAGGREGATE $ 2,000.000 3EN'L AGGREGATE LIMIT APPLIES PER: POLICY ✓❑ JET � LDC PRODUCTS AGO $ 2,000,000 $ OTHER: B AUT ONIOBILELIABILITY CA 7196009 (AOS) 12131/2015 12/31/2016 Ee BINEDtsINGLE LIMIT $ 1 000 000 BODILY INJURY (Per person) $ ✓ancl ANYAUTO CA 7196010 (MA) 3/3112016 12/31/2016 BODILY INJURY (Per acddenp $ ✓ OWNED✓ AU OS ONLY AUTHIRED OSUNED LED AUTOS ONLY ✓ AUTOS ONLYY Physical Damage PaO d DAMAGE $ $ Com (Coll. Ded $1,000 A UMBRELLALUIB �/ OCCUR 7930041030000 12/31/2015 12/31/2016 EACHOCCURRENCE $ 5000000 AGGREGATE $ 5,000,000 ✓ EXCESS LIAR CLAIMS -MADE `Professional Excess is Claims MadeD OERETENTION E C WORKERSCOMPENSATION AND EMPLOYERS' LIABILITY YIN ANYPROPRIETORIPARTNERUEXECUTNEE.L. OFFICERIMMBER EXCLUDED'! FN (Mamlatay in NH) NIA WC 17705228 (AOS)' WC 17705229 (CA) 12/31/2015 12/31/2015 12/3112016 12/31/2016 STATUTE Eli"' EACH ACCIDENT $ 1,000,000 E.L. DISEASE - EA EMPLOYEE $ 1,000,000 E.L. DISEASE- POLICY LIMIT 5 1,000,000 If yes, describe under DESCRIPTION OF OPERATIONS below A Professional Liability 793004102 0000 12!3112015 12/31/2016 Per Occurrence 1,000,000 (Claims Made) Per Aggregate 1,000,000 DESCRIPTION OF OPERATIONS I LOCATIONS I VEHICLES (ACORD 101, Additional Remarks Schedule, may be aeached if mora space is rpuired) The City of Newport Beach, its officers, officials, employees and volunteers are named as additional insured a primary and non-contributory basis as respects the general liability, but only if required by written Contract with the named insured prior to an occurrence. General Liability includes Completed operations. Waiver of Subrogation applies in favor of the certificate holder. Umbrella coverage follows form to underlying, including General, Auto, Employers' and Professional liability. "See Attached Named Insured List*' CERTIFICATE HOLDER CANCELLATION CI of New ort Beach, its officers,a encies, P 9 O ICIals, employees and volunteers SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, NOTICE WILL BE DELIVERED IN ACCORDANCE WITH THE POLICY PROVISIONS. Attn: Utilities Dept 100 Civic Center Drive Newport Beach CA 92660 AUTHORIZED REPRESENTATIVE Sharon D. Brainard ©1988.2015 ACORD CORPORATION. All rights reserved. ACORD 25 (2016103) The ACORD name and logo are registered marks of ACORD 28868138 115.16 Montrose ALL ENT. SEP PROP Liab I ATL) Alfreda Jenkins 13/7/0016 9:28:29 AM (EST) I Page 1 of 9 3/7/2016 The following are included as Named Insured: Air/Compliance Consultants, Inc. Air/Compliance Consultants, Inc. dba Montrose Air Quality Services, LLC Air Compliance Testing, Inc. The Air Compliance Group, LLC AmTest Air Quality, LLC AmTest Air Quality, LLC dba AmTest Horizon, LLC ARI Environmental, Inc. Avanti Environmental, Inc. Avogadro Environmental Corporation The Avogadro Group, LLC Class One Technical Services, Inc. DePar, Inc., dba Associated Laboratories; DePar, Inc ("Associated Laboratories"); De Par, Inc. dba Enthalpy Analytical Delta Air Quality Services, Inc. Delta Air Quality Services, Inc. dba PES, Inc. Eastmount Environmental Services, LLC EDM Consulting, L.L.C. EDM Consulting, L.L.C., dba Enviroplan Consulting Emission Testing Services, Inc. Enthalpy Analytical, Inc. Enthalpy Analytical, Inc. dba Arista Laboratories Enthalpy Analytical, Inc. dba Curtis & Tompkins, Ltd. Environmental Rentals, Inc. ES Engineering Services, LLC ES Engineering Services, LLC dba Environ Strategy Consultants ES Engineering Services, LLC dba ES Engineering Horizon Engineering, LLC Montrose Air Quality Services, LLC MEC Entec Services, LLC Montrose Environmental Corporation dba SCEC Montrose Environmental Laboratory Services, LLC Montrose Services, LLC South Florida Environmental Services, LLC dba South Florida Environmental 28868138 1 15.16 Montrose ALL ENT. SEP PROF Ll so I (AnAl frade Jenkin 1 3/1/2016 9:20:29 AM (EST) I Page 2 of 9 3/7/2016 Montrose Environmental Corporation Policy Number: 793-00-41-02-0000 Wo Montrose Environmental Group, Inc. THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFULLY. ADDITIONAL INSURED - OWNERS, LESSEES OR CONTRACTORS - COMPLETED OPERATIONS This endorsement only modifies coverage provided under the following: COMMERCIAL GENERAL LIABILITY COVERAGE PART CONTRACTORS ENVIRONMENTAL LIABILITY COVERAGE PART SCHEDULE Name Of Additional Insured Person(s) Or Organization(s): Location And Description Of Completed Operations: Any person or organization for which the Named Any location or completed operation, but Insured has agreed to provide insurance prior to loss as only to the scope of insurance agreed to provided by this policy but only to the scope of by the Named Insured. insurance agreed to by the Named Insured. (If no entry appears above, information required to complete this endorsement will be shown in the Declarations as applicable to this endorsement.) SECTION II — WHO IS AN INSURED is amended to include as an additional insured the person(s) or organization(s) shown in the SCHEDULE above, but only with respect to liability for bodily injury, property damage or environmental damage caused, in whole or in part, by your work at the location designated and described in the SCHEDULE above performed for that additional insured and included in the products - completed operations hazard. All other terms and conditions remain the same. OBENV GE 304 (02 11) Includes copyrighted material of Insurance Services Office, Inc. 1 of 1 Copyright, OneBeacon Insurance Group, 2011 26868130 115.16 Montrose ALL M. SEP PROF Liab I (ATLI Alfreda Jenkins 1 3/7/2016 9:20:29 AM !ESTI I Page 3 of 9 3/712016 Montrose Environmental Corporation Policy Number: 793-00-41-02-0000 c/o Montrose Environmental Group, Inc. THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFULLY. PRIMARY AND NON-CONTRIBUTORY ENDORSEMENT This endorsement modifies coverage provided under the following: COMMERCIAL GENERAL LIABILITY COVERAGE PART CONTRACTORS ENVIRONMENTAL LIABILITY COVERAGE PART SECTION IV - CONDITIONS, 8. Other Insurance, is amended by adding the following paragraph: This insurance will be considered primary to, and non-contributory with any other insurance issued directly to a person or organization added as an additional insured under this policy, only if you specifically agree, in a written contract or agreement, that this insurance must be primary to, and non-contributory with, such other insurance. All other terms and conditions remain the same. OBENV GE 319 (02 11) Includes copyrighted material of Insurance services Office, Inc. 1 of 1 Copyright, OneBeacon Insurance Group, 2011 28068138 1 15.16 Montmae ALL E 7r. SEP PROP Liab I (ATL) Alfieda JoOkino 1 3/7/2016 3:20:29 AM (EST) I Page 4 of 9 3/7/2016 Montrose Environmental Corporation Policy Number: c/o Montrose Environmental Group, Inc. THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFULLY. ADDITIONAL INSURED - OWNERS, LESSEES OR CONTRACTORS - SCHEDULED PERSON OR ORGANIZATION - FORM I This endorsement only modifies coverage provided under the following: COMMERCIAL GENERAL LIABILITY COVERAGE PART CONTRACTORS ENVIRONMENTAL LIABILITY COVERAGE PART SCHEDULE Name of Person or Organization: Any person or organization for which the Named Insured has agreed to provide insurance prior to loss as provided by this policy but only to the scope of insurance agreed to by the Named Insured. (If no entry appears above, information required to complete this endorsement will be shown as applicable to this endorsement.) A. SECTION II — WHO IS AN INSURED is amended to include as an insured the person or organization shown in the SCHEDULE above, but only with respect to liability arising out of your ongoing operations performed for that insured. B. With respect to the insurance afforded to these additional insureds, the following exclusion is added: 2. Exclusions This insurance does not apply to bodily injury, property damage or environmental damage occurring after: (a) All work, including materials, parts or equipment furnished in connection with such work, on the project (other than service, maintenance or repairs) to be performed by or on behalf of the additional insured(s) at the site of the covered operations has been completed; or (b) That portion of your work out of which the injury or damage arises has been put to its intended use by any person or organization other than another contractor or subcontractor engaged in performing operations for a principal as a part of the same project. All other terms and conditions remain the same. OBENV GE 301 (02 11) Includes copyrighted material of Insurance services Office, Inc. 1 of 1 Copyright, OneBeacon Insurance Group, 2011 28868138 1 15.16 Montrose ALL EXT. SEP PROF Liab I (AM) A1`_zeda Jenkins 13/7/2016 9:20:29 AM (EST) I Page 5 of 9 Mt/frTr1G: POLICY NUMBER: CA 7196009 (AOS)_ - ,. COMMERCIAL AUTO __ _ _ CA 20 46 02 99 THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFULLY. DESIGNATED INSURED This endorsement modifies insurance provided under the following: BUSINESS AUTO COVERAGE FORM GARAGE COVERAGE FORM MOTOR CARRIER COVERAGE FORM TRUCKERS COVERAGE FORM With respect to coverage provided by this endorsement, the provisions of the Coverage Form apply unless modified by this endorsement - This endorsement identifies personis) or organization(s) who are "insureds" under the Who Is An Insured Provision of the Coverage Form This endorsement does not alter coverage provided in the Coverage Form This endorsement changes the policy effective on the inception date of the policy unless another date is indicated below Endorsement Effective* 12/31/2015 Countersigned By Named Insured: Montrose Environmental Corporation ____LL9.MOaVose_Environmental Group, Inc. (Authorized Representative) SCHEDULE Name of Person(s) or Organization(s): AS REQUIRED BY WRITTEN CONTRACT OR AGREEMENT CA 20 48 02 99 Copyright, Insurance Services Office, Inc , 1998 Page 1 of 2 28860138 1 15.16 Montooee ALL BMf. SEP PROP Liab (ATL) Alf.da JaN ire 1 3/7/2016 9:20:29 AM (EST) I Page 6 of 9 (If no entry appears above, information required to complete this endorsement will be shown in the Declara- tions as applicable to the endorsement.) Each person or organization shown in the Schedule is an "insured" for Liability Coverage, but only to the extent that person or organization qualifies as an "insured" under the Who Is An Insured Provision contained in Section 11 of the Coverage Form Page 2 of 2 Copyright, Insurance Services Office, Inc , 1998 CA 20 48 02 99 28868138 1 15.16 Montrose ALJ. ENT. SEP PROF Liab I (ATL) Alfredo Jex ins j 3/7/2016 9:20:29 M (EST) I Page 7 of 9 3/7/2016 WAIVER OF OUR RIGHT TO RECOVER FROM OTHERS ENDORSEMENT This endorsement changes the policy to which it is attached effective on inception date of the policy unless a different date is indicated below. (The following "attaching clause" need be completed only when this endorsement is issued subsequent to preparation of the policy), This endorsement, effective 12:01 AM 12/31/2015 forms a part of Policy No. WC 17705228 (AOS)' Issued to Montrose Environmental Corporation By c/o Montrose Environmental Group, Inc. We have the right to recover our payments from anyone liable for an injury covered by this policy. We will not enforce our right against the person or organization named in the Schedule. This agreement applies only to the extent that you perform work under a written contract that requires you to obtain this agreement from us. This agreement shall not operate directly or indirectly to benefit any one not named in the Schedule Schedule This form is not applicable in California, Kentucky, New Hampshire, New Jersey, North Dakota, Ohio, Tennessee, Texas, Utah, or Washington. WC 00 03 13 Countersigned by (Ed. 04/84) Authorized Representative 28868138 1 15.16 Montrose ALL EN . SEP PROP Liab I (ATL) Alfred. Se.k... 1 3/7/2016 9:20:29 AM (EST) I Page 6 of 9 317/2016 BLANKET WAIVER OF OUR RIGHT TO RECOVER FROM OTHERS ENDORSEMENT This endorsement changes the policy to which it is attached effective on the inception date of the policy unless a different date is Indicated below (The following "attaching clause" need be completed only when this endorsement is issued subsequent to preparation of the policy). This endorsement, effective 1201 AM 12/31/2015 forms a part of Policy No. WC 17705229 (CA) Issued to Montrose Environmental Corporation By c/o Montrose Environmental Group, Inc. We have a right to recover our payments from anyone liable for an injury covered by this policy. We will not enforce our right against any person or organization with whom you have a written contract that requires you to obtain this agreement from us, as regards any work you perform for such person or organization. The additional premium for this endorsement shall be % of the total estimated workers compensation premium for this policy WC 04 03 61 Countersigned by _ _ _ _ _ _ _ _ _ _ _ _ (Ed. 11/90) Authorized Representative 28868138 1 15.16 Montrose ALL EMT. SSP PROF Liab I (ATL) Alfieda Senki� 1 3/7/2016 9:20:29 AM (EST) I Page 9 of 9 AGREEMENT FOR OPERATION AND MAINTENANCE SERVICES WITH GC ENVIRONMENTAL, INC. FOR NEWPORT TERRACE LANDFILL GAS CONTROL SYSTEM THIS AGREEMENT FOR OPERATION AND MAINTENANCE SERVICES ( "Agreement') is made and entered into as of this 10th day of April, 2012 ( "Commencement Date ") by and between the CITY OF NEWPORT BEACH, a California municipal corporation and charter city ( "City "), and GC ENVIRONMENTAL, INC., a California corporation ( "Contractor "), whose principal place of business is 1230 N. Jefferson Street, Suite J, Anaheim, California 92807 and is made with reference to the following: RECITALS A. City is a municipal corporation duly organized and validly existing under the laws of the State of California with the power to carry on its business as it is now being conducted under the statutes of the State of California and the Charter of City. B. City requires operation and maintenance ( "O &M ") service related to the Newport Terrace Landfill Gas Control System ( "System "), as described and depicted in the Operation and Maintenance Manual, dated March 13, 2009 and revised by the City November 8, 2011, attached hereto as Exhibit "A" and incorporated herein by this reference. C. City desires to engage Contractor to perform the O &M for the System, as described in Exhibits "A" and "B ", attached hereto and incorporated herein by this reference (`Project'). D. Contractor has examined the location of all proposed work, carefully reviewed and evaluated the specifications set forth by the City for the Project, and is familiar with all conditions relevant to the performance of services and has committed to perform all work required for the price specified in this Agreement. NOW, THEREFORE, it is mutually agreed by and between the undersigned parties as follows: 1. TERM The term of this Agreement shall be for a period of five (5) years and shall commence on the Commencement Date, and shall terminate on March 31, 2017, unless terminated earlier as set forth herein. 2. SCOPE OF WORK 2.1. City and Contractor acknowledge that the above Recitals are true and correct and are hereby incorporated by reference. Contractor shall perform all the work described in the Scope of Work attached hereto as Exhibit A and incorporated herein by this reference ( "Services" or "Work "). As a material inducement to the City entering into GC ENVIRONMENTAL, INC. Page 1 this Agreement, Contractor represents and warrants that Contractor is a provider of first class work and Contractor is experienced in performing the Work contemplated herein and, in light of such status and experience, Contractor covenants that it shall follow the highest professional standards in performing the Work required hereunder and that all materials will be of good quality. For purposes of this Agreement, the phrase "highest professional standards" shall mean those standards of practice recognized by one or more first -class firms performing similar work under similar circumstances. 2.2. Contractor shall perform everything required to be performed, and shall provide and furnish all the labor, materials, necessary tools, expendable equipment and all utility and transportation services necessary for the Project. 3. TIME OF PERFORMANCE 3.1. Routine O & M Services. Time is of the essence in the performance of Services under this Agreement. Contractor shall perform the Routine O & M Services, identified in items 1 thru 3 in Exhibit B, in accordance with the schedule included in Exhibit A. The failure by Contractor to strictly adhere to the schedule may result in termination of this Agreement by City. 3.1.1. Notwithstanding the foregoing, Contractor shall not be responsible for delays due to causes beyond Consultant's reasonable control. However, in the case of any such delay in the Services to be provided for the Project, each party hereby agrees to provide notice to the other party so that all delays can be addressed. 3.1.2. Contractor shall submit all requests for extensions of time for performance in writing to the Project Administrator not later than two (2) calendar days after the start of the condition that purportedly causes a delay. The Project Administrator shall review all such requests and may grant reasonable time extensions for unforeseeable delays that are beyond Consultant's control. 3.1.3. For all time periods not specifically set forth herein, Consultant shall respond in the most expedient and appropriate manner under the circumstances, by telephone, fax, hand - delivery or mail. 3.2. On -Call Services. Upon verbal or written request from the Project Administrator (as defined below in Section 5), Contractor shall provide a letter proposal for on -call Services requested by the City including, the Services identified as items 4 thru 7 in Exhibit B (hereinafter referred to as the "Letter Proposal "). The Letter Proposal shall include the following: 3.2.1. A detailed description of the Services to be provided; 3.2.2. The position of each person to be assigned to perform the Services, and the name of the individuals to be assigned, if available; 3.2.3. The estimated number of hours and cost to complete the Services; and 3.2.4. The time needed to finish the specific Project. GC ENVIRONMENTAL, INC. Page 2 3.3. No on -call Services shall be provided until the Project Administrator has provided written acceptance of the Letter Proposal. Once authorized to proceed, Contractor shall diligently perform the duties in the approved Letter Proposal. 4. COMPENSATION 4.1. City shall pay Contractor for the Services on a time and expense not -to- exceed basis, in accordance with the provisions of this Section and the Schedule of Billing Rates attached hereto as Exhibit B and incorporated herein by reference. No rate changes shall be made during the term of this Agreement without the prior written approval of the City. Contractor's total annual compensation per calendar year from the Commencement Date of the Agreement for Services performed in accordance with this Agreement, including all reimbursable items, shall not exceed Eighty Eight Thousand Eighty Dollars and 00/100 ($88,080.00) without written amendment to the Agreement. The total compensation over the full term of the Agreement shall not exceed Four Hundred Forty Thousand Four Hundred Dollars and 00 1100 ($440,400.000) without written amendment to the Agreement. 4.1.1. Routine O & M Services. As full compensation for the performance and completion of the Routine O & M Services as identified as items 1 thru 3 on Exhibit B, City shall pay Contractor and Contractor accepts as full payment the sum of Fifty Two Thousand Nine Hundred and Eighty Dollars and 001100 ($52,980.00) per calendar year from the Commencement Date of the Agreement, subject to the annual adjustment in proportion to changes in the Consumer Price Index more particularly described in Section 4.2 below. Compensation for the Routine O & M Services, identified as items 1 and 2 on Exhibit B shall be paid in twelve (12) equal monthly installments. Services identified in item 3 of Exhibit B shall be paid on a Unit Price rate as outlined in Exhibit B, with written approval from the City and upon completion of work. 4.1.2. On -Call Services. For all other Services the City shall pay Contractor on a time and expense not -to- exceed basis, in accordance with the provisions of this Section and the Schedule of Billing Rates attached hereto as Exhibit B and incorporated herein by reference. 4.2. Consumer Price Index. Upon the first anniversary of the Commencement Date and upon each anniversary of the Commencement Date thereafter, the rates to be paid by the City as set forth in Exhibit B items 1 thru 3 shall be adjusted in proportion to changes in the Consumer Price Index, subject to the 3.0% maximum adjustment increase set forth below. Such adjustment shall be made by multiplying the original rate by a fraction, the numerator of which is the value of the Consumer Price Index for the calendar month three (3) months preceding the calendar month for which such adjustment is to be made and the denominator of which is the value of the Consumer Price Index for the same calendar month one (1) year prior. For example, if the adjustment is to occur effective June 1, 2011, the index to be used for the numerator is the index for the month of March 2011 and the index to be used for the denominator is March 2010. The "Consumer Price Index" to be used in such calculation is the Consumer Price Index, All Urban Consumers (All Items) for the Los Angeles Anaheim Riverside Metropolitan Area, published by the United States Department of Labor, GC ENVIRONMENTAL, INC. Page 3 Bureau of Labor Statistics (1982 84 = 100). If both an official index and one or more unofficial indices are published, the official index shall be used. If said Consumer Price Index is no longer published at the adjustment date, it shall be constructed by conversion tables included in such new index. In no event, however, shall the amount payable under this agreement be reduced below the Rate in effect immediately preceding such adjustment. The maximum increase to the Rate, for any year where an adjustment is made in proportion to changes in the Consumer Price Index, shall not exceed 3.0% of the Rate in effect immediately preceding such adjustment. 4.3. Contractor shall submit monthly invoices to City describing the Work performed the preceding month. Contractor's bills shall include the name of the person and /or classification of employee who performed the Work, a brief description of the Services performed and /or the specific task from the Scope Services attached hereto which it relates, the date the Services were performed, the number of hours spent on all Work billed on an hourly basis, and a description of any reimbursable expenditures. City shall pay Contractor no later than thirty (30) days after approval of the monthly invoice by City staff. 4.4. City shall reimburse Contractor only for those costs or expenses specifically approved in the Scope of Services attached hereto. Unless otherwise approved, such costs shall be limited and include nothing more than the actual costs and /or other costs and /or payments specifically authorized in advance in writing and incurred by Contractor in the performance of this Agreement. 4.5. Contractor shall not receive any compensation for Extra Work without the prior written authorization of City. As used herein, "Extra Work" means any work that is determined by the Project Administrator (as defined in Section 5 below) to be necessary for the proper completion of the Project, but which is not included within the Scope of Work and which the City and Contractor did not reasonably anticipate would be necessary. Compensation for any authorized Extra Work shall be paid in accordance with the Schedule of Billing Rates set forth in Exhibit B. 5. ADMINISTRATION This Agreement will be administered by the Municipal Operations Department. George Murdoch, Utilities General Manager, or his designee shall be the Project Administrator and shall have the authority to act for City under this Agreement. The Project Administrator or his authorized representative shall represent City in all matters pertaining to the Services to be rendered pursuant to this Agreement. 6. TYPE AND INSTALLATION OF MATERIALS /STANDARD OF CARE 6.1. Contractor shall use only the standard materials described in Exhibit A in performing Services under this Agreement. Any deviation from the materials described in Exhibit A shall not be installed unless approved in advance by the Project Administrator. 6.2. All of the Services shall be performed by Contractor or under Contractor's supervision. Contractor represents that it possesses the personnel required to perform GC ENVIRONMENTAL, INC. Page 4 the Services required by this Agreement, and that it will perform all Services in a manner commensurate with highest professional standards. All Services shall be performed by qualified and experienced personnel who are not employed by City, nor have any contractual relationship with City. 7. RESPONSIBILITY FOR DAMAGES OR INJURY 7.1. City and all officers, employees and representatives thereof shall not be responsible in any manner for any loss or damage to any of the materials or other things used or employed in performing the Project or for injury to or death of any person as a result of Contractor's performance of the Services required hereunder; or for damage to property from any cause arising from the performance of the Project by Contractor, or its subcontractors, or its workers, or anyone employed by either of them. 7.2. Contractor shall be responsible for any liability imposed by law and for injuries to or death of any person or damage to property resulting from defects, obstructions or from any cause arising from Contractor's Work on the Project, or the Work of any subcontractor or supplier selected by the Contractor. 7.3. To the fullest extent permitted by law, Contractor shall indemnify, defend and hold harmless City, its City Council, boards and commissions, officers, agents, volunteers, and employees (collectively, the "Indemnified Parties ") from and against any and all claims (including, without limitation, claims for bodily injury, death or damage to property), demands, obligations, damages, actions, causes of action, suits, losses, judgments, fines, penalties, liabilities, costs and expenses (including, without limitation, attorney's fees, disbursements and court costs) of every kind and nature whatsoever (individually, a Claim; collectively, "Claims'), which may arise from or in any manner relate (directly or indirectly) to any breach of the terms and conditions of this Agreement, any Work performed or Services provided under this Agreement including, without limitation, defects in workmanship or materials or Contractor's presence or activities conducted on the Project (including the negligent and /or willful acts, errors and /or omissions of Contractor, its principals, officers, agents, employees, vendors, suppliers, consultants, subcontractors, anyone employed directly or indirectly by any of them or for whose acts they may be liable or any or all of them). 7.4. Notwithstanding the foregoing, nothing herein shall be construed to require Contractor to indemnify the Indemnified Parties from any Claim arising from the sole negligence or willful misconduct of the Indemnified Parties. Nothing in this indemnity shall be construed as authorizing any award of attorney's fees in any action on or to enforce the terms of this Agreement. This indemnity shall apply to all claims and liability regardless of whether any insurance policies are applicable. The policy limits do not act as a limitation upon the amount of indemnification to be provided by the Consultant. 7.5. Contractor shall perform all Project Work in a manner to minimize public inconvenience and possible hazard, to restore other work areas to their original condition and former usefulness as soon as possible, and to protect public and private property. Contractor shall be liable for any private or public property damaged during the performance of the Project Work. GC ENVIRONMENTAL, INC. Page 5 7.6. To the extent authorized by law, as much of the money due Contractor under and by virtue of the Agreement as shall be considered necessary by City may be retained by it until disposition has been made of such suits or claims for damages as aforesaid. 7.7. The rights and obligations set forth in this Section shall survive the termination of this Agreement. 8. INDEPENDENT CONTRACTOR City has retained Contractor as an independent contractor and neither Contractor nor its employees are to be considered employees of the City. The manner and means of conducting the Work are under the control of Contractor, except to the extent they are limited by statute, rule or regulation and the express terms of this Agreement. No civil service status or other right of employment shall accrue to Contractor or its employees. Contractor shall have the responsibility for and control over the means of performing the Work, provided that Contractor is in compliance with the terms of this Agreement. Anything in this Agreement that may appear to give City the right to direct Contractor as to the details of the performance or to exercise a measure of control over Contractor shall mean only that Contractor shall follow the desires of City with respect to the results of the Services. 9. COOPERATION Contractor agrees to work closely and cooperate fully with City's designated Project Administrator and any other agencies that may have jurisdiction or interest in the Work to be performed. City agrees to cooperate with the Contractor on the Project. 10. INSURANCE 10.1. Without limiting Contractor's indemnification of City, and prior to commencement of Work. Contractor shall obtain, provide and maintain at its own expense during the term of this Agreement, policies of insurance of the type and amounts described below and in a form satisfactory to City. The cost of such insurance shall be included in Contractor's bid. 10.2. Coverage and Limit Requirements. 10.2.1. Workers' Compensation. Contractor shall maintain Workers' Compensation Insurance providing statutory benefits and employer's liability insurance with limits of at least one million dollars ($1,000,000) each type for Contractor's employees in accordance with the laws of the State of California, Section 3700 of the Labor Code. In addition, Contractor shall require each subcontractor to similarly maintain Workers' Compensation Insurance and Employer's Liability Insurance in accordance with the laws of the State of California, Section 3700 for all of the subcontractor's employees. The insurer issuing the Workers' Compensation insurance shall amend its policy by endorsement to waive all rights of subrogation against City, its elected or appointed officers, agents, officials, employees and volunteers. Contractor GC ENVIRONMENTAL, INC. Page 6 shall submit to City, along with the required certificate of insurance, a copy of such waiver of subrogation endorsement. 10.2.2. General Liability. Contractor shall maintain commercial general liability insurance in an amount not less than one million dollars ($1,000,000) per occurrence, two million dollars ($2,000,000) General Aggregate and two million dollars ($2,000,000) Products and Completed Operations Aggregate for bodily injury, personal injury, and property damage, including without limitation, blanket contractual liability. Coverage shall be at least as broad as that provided by Insurance Services Office form CG 00 01. None of the policies required herein shall be in compliance with these requirements if they include any limiting endorsement that has not been first submitted to City and approved in writing. 10.2.3. Automobile Liability. Contractor shall maintain automobile insurance covering bodily injury and property damage for all activities of the Contractor arising out of or in connection with Work to be performed under this Agreement, including coverage for any owned, hired, non -owned or rented vehicles, in an amount not less than one million dollars ($1,000,000) combined single limit for each accident. 10.2.4. Builders Risk. For Agreements or Contracts with Construction /Builders Risk property exposures, Contractor shall maintain Builders Risk insurance or an installation floater as directed by City, covering damages to the Work for "all risk" or special form causes of loss with limits equal to one hundred percent (100 %) of the completed value of contract, with coverage to continue until final acceptance of the Work by City. At the discretion of City, the requirement for such coverage may include additional protection for Earthquake and /or Flood. City shall be included as an insured on such policy, and Contractor shall provide the City with a copy of the policy. 10.3. Other Insurance Provisions or Requirements. 10.3.1. Evidence of Insurance. Contractor shall provide certificates of insurance to City as evidence of the insurance coverage required herein, along with a waiver of subrogation endorsement for workers' compensation and an additional insured endorsement for general liability. Insurance certificates and endorsements must be approved by City's Risk Manager prior to commencement of performance or issuance of any permit. Current evidence of insurance shall be kept on file with City at all times during the term of this Agreement. All of the executed documents referenced in this Agreement must be returned within ten (10) working days after the date on the "Notification of Award," so that the City may review and approve all insurance and bond documentation. City reserves the right to require complete, certified copies of all required insurance policies, at anytime. 10.3.2. General liability insurance provisions. Primary and excess or umbrella liability policies are to contain, or be endorsed to contain, the following provisions: 10.3.2.1. City and the Newport Condominium Association ( "NCA "), their elected or appointed officers, agents, officials, employees, and volunteers GC ENVIRONMENTAL, INC. Page 7 are to be covered as additional insureds as respects: liability arising out of activities performed by or on behalf of Contractor, including the insured's general supervision of Contractor; products and completed operations of Contractor; premises owned, occupied or used by Contractor. The coverage shall contain no special limitations on the scope of protection afforded to City, its elected or appointed officers, officials, employees, agents or volunteers. Contractor shall submit to City a copy of the additional insured endorsement along with the required certificates of insurance. 10.3.2.2. Contractor's insurance coverage shall be primary insurance and /or primary source of recovery as respects to City and the Newport Condominium Association ( "NCA "), their elected or appointed officers, agents, officials, employees and volunteers as respects to all claims, losses, or liability arising directly or indirectly from the Contractor's operations or services provided to the City. Any insurance or self- insurance maintained by City and the Newport Condominium Association ( "NCA "), their officers, officials, employees and volunteers shall be excess of the Contractor's insurance and shall not contribute with it. 10.3.2.3. Contractor's insurance shall apply separately to each insured against whom claim is made or suit is brought, except with respect to the limits of the insurer's liability. 10.4. Acceptable Insurers. All insurance policies shall be issued by an insurance company currently authorized by the Insurance Commissioner to transact business of insurance in the State of California, with an assigned policyholders' Rating of A- (or higher) and Financial Size Category Class VII (or larger) in accordance with the latest edition of Best's Key Rating Guide, unless otherwise approved by the City's Risk Manager. 10.5. Notice of Cancellation. Contractor agrees to oblige its insurance broker and insurers to provide to City with 30 days notice of cancellation (except for nonpayment for which 10 days notice is required) or nonrenewal of coverage for each required coverage except for builder's risk insurance. The builder's risk policy will contain or be endorsed to contain a provision providing for 30 days written notice to City of cancellation or nonrenewal, except for nonpayment for which 10 days notice is required. 10.6. Self- Insured Retentions. Contractor agrees not to self- insure or to use any self- insured retentions on any portion of the insurance required herein and further agrees that it will not allow any indemnifying party to self- insure its obligations to City. If contractor's existing coverage includes a self- insured retention, the self- insured retention must be declared to City. City may review options with the contractor, which may include reduction or elimination of the self - insured retention, substitution of other coverage, or other solutions. Contractor agrees to be responsible for payment of any deductibles on their policies. 10.7. Timely Notice of Claims Contractor shall give City prompt and timely notice of any claim made or suit instituted arising out of or resulting from Contractor's performance under this agreement. GC ENVIRONMENTAL, INC. Page 8 10.8. Waiver. All insurance coverage maintained or procured pursuant to this agreement shall be endorsed to waive subrogation against City, its elected or appointed officers, agents, officials, employees and volunteers, or shall specifically allow Contractor or others providing insurance evidence in compliance with these requirements to waive their right of recovery prior to a loss. Contractor hereby waives its own right of recovery against City, and shall require similar written express waivers and insurance clauses from each of its subcontractors. 10.9. Enforcement of Aqreement Provisions. Contractor acknowledges and agrees that any actual or alleged failure on the part of the City to inform Contractor of non - compliance with any requirement imposes no additional obligations on the City nor does it waive any rights hereunder. 10.10. Requirements not Limiting. Requirements of specific coverage features or limits contained in this Section are not intended as a limitation on coverage, limits or other requirements, or a waiver of any coverage normally provided by any insurance. Specific reference to a given coverage feature is for purposes of clarification only as it pertains to a given issue and is not intended by any party or insured to be all inclusive, or to the exclusion of other coverage, or a waiver of any type. 10.11. City's Remedies. City shall have the right to order the Contractor to stop Work under this Agreement and /or withhold any payment(s) that become due to Contractor hereunder until Contractor demonstrates compliance with the requirements of this article. In the alternative, City may purchase the required coverage and charge Contractor the cost of the premiums or deduct the cost from Contractor's payments. 10.12. Coverage not Limited. All insurance coverage and limits provided by contractor and available or applicable to this agreement are intended to apply to the full extent of the policies. Nothing contained in this agreement or any other agreement relating to the city or its operations limits the application of such insurance coverage. 10.13. Coverage Renewal. Contractor will renew the coverage required here annually as long as Contractor continues to provide any Services under this or any other contract or agreement with the City. Contractor shall provide proof that policies of insurance required herein expiring during the term of this Agreement have been renewed or replaced with other policies providing at least the same coverage. Proof that such coverage has been ordered shall be submitted prior to expiration. A coverage binder or letter from Contractor's insurance agent to this effect is acceptable. A certificate of insurance and /or additional insured endorsement as required in these specifications applicable to the renewing or new coverage must be provided to City within five days of the expiration of the coverages. 11. SUBCONTRACTING City and Contractor agree that subcontractors may be used to complete the Work outlined in the Scope of Work provided the Contractor obtains City approval prior to the subcontractor performing any work. Contractor shall be fully responsible to City for all acts and omissions of the subcontractors. Nothing in this Agreement shall create any contractual relationship between City and subcontractor nor shall it create any obligation GC ENVIRONMENTAL, INC. Page 9 on the part of City to pay or to see to the payment of any monies due to any such subcontractor other than as otherwise required by law. 12. WITHHOLDINGS City may withhold payment to Contractor of any disputed sums until satisfaction of the dispute with respect to such payment. Such withholding shall not be deemed to constitute a failure to pay according to the terms of this Agreement. Contractor shall not discontinue Work as a result of such withholding. Contractor shall have an immediate right to appeal to the City Manager or his /her designee with respect to such disputed sums. Contractor shall be entitled to receive interest on any withheld sums at the rate of return that City earned on its investments during the time period, from the date of withholding of any amounts found to have been improperly withheld. 13. CONFLICTS OF INTEREST 13.1. The Contractor or its employees may be subject to the provisions of the California Political Reform Act of 1974 (the "Act "), which (1) requires such persons to disclose any financial interest that may foreseeably be materially affected by the Work performed under this Agreement, and (2) prohibits such persons from making, or participating in making, decisions that will foreseeably financially affect such interest. 13.2. If subject to the Act, Contractor shall conform to all requirements of the Act. Failure to do so constitutes a material breach and is grounds for immediate termination of this Agreement by City. Contractor shall indemnify and hold harmless City for any and all claims for damages resulting from Contractor's violation of this Section. 14. NOTICES 14.1. All notices, demands, requests or approvals to be given under the terms of this Agreement shall be given in writing, to City by Contractor and conclusively shall be deemed served when delivered personally, or on the third business day after the deposit thereof in the United States mail, postage prepaid, first -class mail, addressed as hereinafter provided. All notices, demands, requests or approvals from Contractor to City shall be addressed to City at: Attn: George Murdoch Municipal Operations Department City of Newport Beach 3300 Newport Blvd. PO Box 1768 Newport Beach, CA 92658 Phone: 949 - 644 -3011 Fax: 949 - 646 -1509 14.2. With a courtesy copy to: John Van Vlear, Esq., R.E.A. GC ENVIRONMENTAL, INC. Page 10 Voss Cook & Thel LLP 895 Dove Street, #450 Newport Beach, CA 92660 E -Mail: vv @vctlaw.com Phone: (949) 435 -4338 Fax: (949) 435 -0226 14.3. All notices, demands, requests or approvals from City to Contractor shall be addressed to Contractor at: Attn: Farideh Kia GC ENVIRONMENTAL, INC. 1230 N. Jefferson Street, Suite J Anaheim, California 92807 Phone: 714 - 632 -9969 Fax: 714 - 632 -9968 15. NOTICE OF CLAIMS 15.1. Unless a shorter time is specified elsewhere in this Agreement, before making its final request for payment under the Agreement, Contractor shall submit to City, in writing, all claims for compensation under or arising out of this Agreement. Contractor's acceptance of the final payment shall constitute a waiver of all claims for compensation under or arising out of this Agreement except those previously made in writing and identified by Contractor in writing as unsettled at the time of its final request for payment. The Contractor and the City expressly agree that in addition to all claims filing requirements set forth in the Agreement, the Contractor shall be required to file any claim the Contractor may have against the City in strict conformance with the Tort Claims Act (Govt. Code §§ 900 et seq.). 16. TERMINATION 16.1. In the event that either party fails or refuses to perform any of the provisions of this Agreement at the time and in the manner required, that party shall be deemed in default in the performance of this Agreement. If such default is not cured within a period of two (2) calendar days, or if more than two (2) calendar days are reasonably required to cure the default and the defaulting party fails to give adequate assurance of due performance within two (2) calendar days after receipt of written notice of default, specifying the nature of such default and the steps necessary to cure such default, the non - defaulting party may terminate the Agreement forthwith by giving to the defaulting party written notice thereof. 16.2. Notwithstanding the above provisions, City shall have the right, at its sole discretion and without cause, of terminating this Agreement at any time by giving seven (7) calendar days prior written notice to Contractor. In the event of termination under this Section, City shall pay Contractor for Services satisfactorily performed and costs incurred up to the effective date of termination for which Contractor has not been previously paid. On the effective date of termination, Contractor shall deliver to City all materials purchased in performance of this Agreement. GC ENVIRONMENTAL, INC. Page 11 17. STANDARD PROVISIONS 17.1. Compliance with all Laws. Contractor shall at its own cost and expense comply with all statutes, ordinances, regulations and requirements of all governmental entities, including federal, state, county or municipal, whether now in force or hereinafter enacted. 17.2. Waiver. A waiver by City of any term, covenant, or condition in the Agreement shall not be deemed to be a waiver of any subsequent breach of the same or any other term, covenant or condition. 17.3. Integrated Contract. This Agreement represents the full and complete understanding of every kind or nature whatsoever between the parties hereto, and all preliminary negotiations and Agreements of whatsoever kind or nature are merged herein. No verbal Contract or implied covenant shall be held to vary the provisions herein. 17.4. Conflicts or Inconsistencies. In the event there are any conflicts or inconsistencies between this Agreement and the Exhibits attached hereto, the terms of this Agreement shall govern. 17.5. Amendments. This Agreement may be modified or amended only by a written document executed by both Contractor and City and approved as to form by the City Attorney. 17.6. Effect of Contractor's Execution. Execution of this Agreement by Contractor is a representation that Contractor has visited the Project Site, has become familiar with the local conditions under which the Work is to be performed, and has taken into consideration these factors in submitting its Project Proposal and Scope of Work. 17.7. Controlling Law and Venue. The laws of the State of California shall govern this Agreement and all matters relating to it and any action brought relating to this Agreement shall be adjudicated in a court of competent jurisdiction in the County of Orange. 17.8. Equal Opportunity Employment. Contractor represents that it is an equal opportunity employer and it shall not discriminate against any subcontractor, employee or applicant for employment because of race, religion, color, national origin, handicap, ancestry, sex or age. 17.9. Interpretation. The terms of this Agreement shall be construed in accordance with the meaning of the language used and shall not be construed for or against either party by reason of the authorship of the Agreement or any other rule of construction which might otherwise apply. 17.10. Severability. If any term or portion of this Agreement is held to be invalid, illegal, or otherwise unenforceable by a court of competent jurisdiction, the remaining provisions of this Agreement shall continue in full force and effect. GC ENVIRONMENTAL, INC. Page 12 17.11. No Attorney's Fees. In the event of any dispute or legal action arising under this Agreement, the prevailing party shall not be entitled to attorney's fees. 17.12. Counterparts. This Agreement may be executed in two or more counterparts, each of which shall be deemed an original and all of which together shall constitute one and the same instrument. [SIGNATURES ON NEXT PAGE] GC ENVIRONMENTAL, INC. Page 13 IN WITNESS WHEREOF, the parties have caused this Agreement to be executed on the dates written below. APPROVED AS TO FORM: CITY ATTORNEY'S OFFICE Date: jh -/fL By: l Aaron C. Harp City Attorney City Clerk o � ��t CITY OF NEWPORT BEACH, A California corporation Date: L %i Tunicipal t2. By: Nancy Gardner Mayor CONTRACTOR: GC ENVIRONMENTAL, INC., a California corporation Date: By. Richard W. Prosser .P/giq,e ypXd'Chief Executive Officer Date: By: Farideh Kia Vice President and Chief Financial Officer [END OF SIGNATURES] Attachments: Exhibit A - Operation and Maintenance Manual Exhibit B - Schedule of Billing Rates GC ENVIRONMENTAL, INC. Page 14 OPERATIONS AND MAINTENANCE MANUAL (CD) GC ENVIRONMENTAL, INC. Page A -1 EXHIBIT B SCHEDULE OF BILLING RATES Routine O eration & Maintenance Services Item No. Carbon Change -Out Quantities Total Price Provide lump sum costs for replacement of carbon M 4. Routine O &M Services LS Monitoring Pursuant to Regulations and as described in the b) $6,750 1 OM &M Plan, Other Monitoring and Maintenance LS 5 Parameters, and Reporting (as specified in RFP Section 1 -F (Annual) $37,300 and attached O &M Manual), exclusive of laboratory Unit Price $8,350 analyses. 6. Laboratory Analyses See Rate Provide rate schedule for T &M work, including labor and Provide unit cost for laboratory analyses of air /gas samples, a) $90 2. including Unit price 7. a) Total Gaseous Non - Methane Organics (TGNMOs) (12 /yr) T &M See Rate b Rule 1150.1 Toxic Air Contaminants TACs 28/ r b) $275 3. Landfill Gas Source Test Unit Price $6,900 On -Call Services • The GC Environmental, Inc. will obtain three bids or proposals from qualified subcontractors for any on- call services- requested. GC Environmental, Inc. will provide the bids to the City for final approval before any work is started. • GC Environmental, Inc. shall use the lowest qualified bid received. GC ENVIRONMENTAL, INC. Page B -1 Carbon Change -Out Provide lump sum costs for replacement of carbon a) $4,900 4. adsorption media: LS a) for a single vessel b) $6,750 b for two vessels simultaneous) 5 Sulfa -Treat Change -Out Provide unit cost for replacement of Sulfa -Treat media. Unit Price $8,350 Non- Routine Services and Emergency Response 6. T &M See Rate Provide rate schedule for T &M work, including labor and equipment rates. Schedule Engineering Services 7. Provide rate schedule for T &M work, including labor and T &M See Rate equipment rates. Schedule GC ENVIRONMENTAL, INC. Page B -1 GC ENVIRONMENTAL, INC. - BASIS OF CHARGES Effective January 1, 2012 1. Listed herein are typical prices for services most frequently performed by GC Environmental, Inc. Prices for other services not listed will be given upon request. 2. Invoices will be issued on a monthly basis, or upon completion of a project, whichever is sooner. The net cash amount of [his invoice is payable within 30 days of receipt and approval of the invoice. 3. For hourly workers, time worked in excess of eight hours per day and weekend work will be charged at 1.5 times the hourly rate. 4. Per Diem will be charged at a rate of $75 per day per person or expenses plus 15 %, whichever is greater. Per Diem will be charged for all projects in excess of 50 miles from the GC Environmental, Inc. office. 5. Outside services will include a 15% markup unless otherwise noted. 6. We are protected by Worker's Compensation Insurance, and will furnish certificates thereof upon request. We assume the risk of damage to our own supplies and equipment. If your contract or purchase order places greater responsibilities upon us or requires further insurance coverage, GCE will, when specifically directed by you, take out additional insurance (if procurable) to protect us at your expense, but we shall not be responsible for property damage from any cause, including fire and explosion, beyond the amounts of coverage of our insurance. 7. All environmental samples may be returned to clients at GC Environmental, Inc.'s discretion 30 days after submission of final report, . unless prior arrangements are made. 8. Proper disposal or handling of soil boring cuttings, well development and purge waters, decontamination solutions, and other contaminated/potentially contaminated materials is the responsibility of the client. GC Environmental, Inc. can provide containers for on -site containment and can advise the client regarding proper handling procedures. 9. Expert witness, depositions and testimony at two times the regular fee. FEE SCHEDULE ............................... $150 /day PrincipalProfessional ........................................................................................ ............................... ...........................$151 Senior Professional/Project Manager ................................................................. ............................... ............................138 RegisteredProject Professional .......................................................................... ............................... ............................123 ProjectProf essional ...........................................................................:................. ............................... ............................114 StaffProfessional ................................................................................................ ............................... ............................103 Professional......................................................................................................................................... .............................91 AssistantProfessional ......................................................................................................................... .............................79 Senior Technician/Field Engineer ............................... Technician..................................... ............................... Word Processing / Clerical ............. ............................... Engineering Assistant ................... ............................... Mileage.......................................... ............................... Insurance — Waiver of Subrogation ............................. Drawing Copies ........ ............................... Communication & Computer Fee at 2% Equipment ....................................................................... .............................70 ....................................................................... .............................62 ....................................................................... .............................54 Standard Federal Rate for Business ........................... 3% of Project Cost ......... ............................... $0.10 each ......... ............................... $2.50 each ..................... ............................... 2% GEM 500 Gas Monitoring Equipment ................................................................................. ............................... $150 /day RIQEagle Equipment ................................................................................................................. ............................$85 /day OVAEquipment ......................................................................................................................... ............................$85 /day PIDEquipment ............................................................................................................... ............................... $125 /day Pump Tray /Sampling Equipment ..................................................................................... ............................... $50 /day TSIEquipment ...................................................................................................................... ............................... $100 /day WaterLevel Meter ...................................................................................................................... ............................$25 /day DraegerHandheld ...................................................................................................................... ............................$55 /day WeatherStation ..................................................................................................................... ............................... $125 /day Ambient Air Sampling Equipment ( upgradient/ downgmdient) .......................................... ............................... $100 /day Truck........................................................................................................................................... ............................$45 /day. Truck& Tools ............................................................................................................................. ............................$75 /day 0se er\0PR0P09AIS \City of Nmport Beadi U012\13asis of Chargs NewpmLdoc Copyright 02012 —G Environmmtnt, Ins. All Rights Reserved GC ENVIRONMENTAL, INC. Page B -2 = CITY OF: NEWN �CJFOANP City Council Agenda April 10, 2012 TO: HONORABLE MAYOR AND MEMBERS OF THE CITY COUNCIL FROM: Municipal Operations Department Mark Harmon, Municipal Operations Department Director 949 644 -3055, mharmon @newportbeachca.gov PREPARED BY: Kathryne Cho APPROVED:, O, �JW TITLE: Newport Terrace Landfill Gas Collection and Control System — Award of Contract and Budget Amendment ABSTRACT: Award of contract to GC Environmental, Inc. (GCE) for perform operation, maintenance and monitoring (OM &M) services on the Newport Terrace Landfill Gas Control System (System) and budget amendment to fund the remaining OM &M services for Fiscal Year 2011 -2012 (FYI 1-12). RECOMMENDATION: Approve an annual contract for $88,080.00 with (GCE) for the OM &M services of the (System) and authorize the City Manager and City Clerk to execute the Contract on behalf of the City. 2. Approve a Budget Amendment transferring a total of $21,180.00 from Environmental Liability unappropriated fund balance, 292 -3605, to Environmental Liability, Maintenance and Repair, 3155 -8030, to fund the remaining OM &M services, possible carbon /sulfa -treat change -outs and emergency repair costs for FY11 -12. Budget Amendment No. BA12 -031 FUNDING REQUIREMENTS: The Budget Amendment records and appropriates $21,180.00 in increased expenditure appropriations from Environmental Liability unappropriated fund balance. A breakdown of the budget amendment is as follows: Newport Terrace Landfill Gas Collection and Control System — Award of Contract and Budget Amendment April 10, 2012 Page 2 Purpose Vendor Account Account Amount Description Number Routine OM &M GCE Environmental $15,530.00 Routine Testing & GCE $2,560.00 Lab Analyses Liability, Carbon /Sulfa -treat GCE Maintenance and 3155 -8030 $13,250.00 Change-Out Repair Emergency GCE $7,000.00 Repairs T &M FY 11 -12 Estimated Remainin Cost $38,340.00 Available Fund Balance $17,160.00 FY11 -12 Bud etAmendment $21,180.00 BACKGROUND: The Newport Terrace residential community is located at the northeasterly corner of 19th Street and Balboa Boulevard along the westerly boundary of Costa Mesa. The property was acquired by the City of Newport Beach and used as a solid waste disposal site (landfill) in the 1950s and early 1960s. It was sold to a private company in the early 1970s and developed with residential condominium units along both sides of the landfill area. A gas collection system was installed as part of the residential project's construction and the homeowner's community association (Newport Condominium Association, or NCA) was responsible for the system's operation and maintenance. By October 2004, that responsibility evolved into litigation between the NCA and the City which culminated in a Settlement and License Agreement in November 2006. The Agreement established that the City was responsible for: (1) the design and construction of an up- graded System, and (2) the ongoing OM &M of the System after completion of construction. The Agreement also provided that the construction costs and OM &M costs are to be shared equally between the City and the NCA. The firm of SCS was hired by the City to prepare plans and specifications for construction of the System, as well as to provide support during the bidding and construction phases. Construction of the System was performed by Innovative Construction Solutions (ICS) under Contract No. 3651. Construction work began in September 2007 and was completed in May 2008, with formal acceptance by the City Council on May 27, 2008. On June 9, 2009, Council approved an award of contract to GCE. Since that date, GCE has provided OM &M services for the System. Due to the expiration of GCE's contract, f Newport Terrace Landfill Gas Collection and Control System — Award of Contract and Budget Amendment April 10, 2012 Page 3 staff was advised to re -bid the contract and now another award of contract is recommended. DISCUSSION: Five firms attended a mandatory on -site pre - proposal meeting on December 8, 2011 and submitted complete proposals on January 4, 2012. The proposals were ranked based on a two -step evaluation process. The first step involved the review of proposals with scores based on the following: 1.) Qualifications of the firm and the proposed personnel; 2.) Operational experience of the proposing firm; 3.) Operational methodology of LFG system maintenance and operation; and 4.) Responsiveness of the proposal. The second step of the evaluation process involved a ratio of costs analysis performed on all proposals. In the end, GCE was rated as the highest qualified firm for this project based on receiving the highest rated proposal and having the lowest proposed cost. A summary of the proposal evaluation process may be found in Attachment B. A Notice of Intent to Award was mailed to all firms on February 11, 2012. On March 1, 2012, GCE met with City and NCA to discuss contract procedures and basis of cost. GCE evaluated the cost for in -house Source Testing which resulted in a reduction of $1,000.00 from the specific line item cost. With the concurrence of the NCA, Staff recommends award of the OM &M service contract to GCE for a period of five (5) years with an annual budget of $88,080.00. A breakdown of the annual budget is as follows: Purpose Vendor Account Account Amount Descripion Number Routine OM &M GCE Environmental $37,300.00 Routine Testing & GCE $15,680.00 Lab Analyses Liability, Carbon /Sulfa -treat GCE Maintenance and 3155 -8030 $15,100.00 Change-Out Repair Emergency GCE $20,000.00 Repairs (T &M OM &M Annual Budget $88,080.00 Under the terms of the Settlement and License Agreement, the NCA is obligated to reimburse the City for 50% of the actual costs incurred. Reimbursement will be accomplished by submittal of a City invoice which is expected to be done on a monthly basis. Newport Terrace Landfill Gas Collection and Control System — Award of Contract and Budget Amendment April 10, 2012 Page 4 ENVIRONMENTAL REVIEW: Staff recommends the City Council find this action is not subject to the California Environmental Quality Act ( "CEQA ") pursuant to Sections 15060(c)(2) (the activity will not result in a direct or reasonably foreseeable indirect physical change in the environment) and 15060(c)(3) (the activity is not a project as defined in Section 15378) of the CEQA Guidelines, California Code of Regulations, Title 14, Chapter 3, because it has no potential for resulting in physical change to the environment, directly or indirectly. NOTICING: The agenda item has been noticed according to the Brown Act (72 hours in advance of the meeting at which the City Council considers the item). Mark Harmon � Municipal Operations Department Director Attachments: A. Project Site Location B. Request for Proposal Memo (Proposal Packets Available Upon Request) C. GC Environmental Inc. Contract (Complete OM &M Manual Available Upon Request) { u T T 1 71� I --7f i r—` Attachment A Newport Terrace Landfill PROJECT SITE vmxd a ';L 1r ST W� j r 1W+ 0 i 000 2,000 4,000 Feel FARAD ST HSTW Attachment B CITY OF NEWPORT BEACH FINANCE DEPARTMENT Accounting • Finance • OMB • Revenue March 28, 2012 TO: Mark Harmon, Municipal Operations Director FROM: Anthony Nguyen, Senior Buyer SUBJECT: Newport Terrace Landfill Gas System Operation and Maintenance On Thursday, February 2nd, 2012 the evaluation panel for the Newport Terrace Landfill Gas (LFG) System project convened to evaluate and discuss the responses to the City's Request for Proposal (RFP). The purpose of this memorandum is to provide you with a synopsis of the panel's ratings as well as a summary of the RFP process thus far. Evaluation Panel The evaluation panel for this project consisted of the following individuals: George Murdoch, Utilities General Manager (Municipal Operations Department), Kathryne Cho, Junior Civil Engineer (Municipal Operations Department) and Anthony Silva, representing the Newport Terrace Condominium Association. Proposal Evaluation This solicitation yielded proposals from the following firms: Environ Strategy, GC Environmental, G.E.O. Inc., SCS Field Services and Shaw Environmental. This project entailed a two -step evaluation process, with an optional third step. The first step involved the evaluation panel reviewing and scoring the proposals based on the following criteria: 1. Qualifications of the firm and the proposed personnel; 2. Operational experience of the proposing firm; 3. Operational methodology of LFG system maintenance and operation; and 4. Responsiveness of the proposal. Each of the aforementioned categories was assigned a weighted multiplier based on significance and relevance to the project, resulting in a possible score of 100 points for each proposal. Exhibit A is a summary of the results from the proposal evaluations: EXHIBIT A: PROPOSAL EVALUATION RESULTS The second step of the evaluation process involved a ratio of costs analysis performed on all of the proposals. Because of their recurring, constant and necessary nature, three costs were isolated for this analysis: (1) Routine Operations and Maintenance Services; (2) Laboratory Analyses; and (3) Landfill Gas Source Testing. The lowest cost proposal was awarded 100 points and subsequent cost proposals were awarded a percentage of points in direct relation to the percentage difference of cost from the lowest cost proposal. Exhibit B is a summary of the results from the ratio of costs analysis: EXHIBIT B: RATIO OF COSTS ANALYSIS Environ Strategy GC Environmental G .E.O., Inc. SCS Field Services Shaw Environmental Panelist Strategy Environmental 45.00 Services Environmental Kathryne Cho 72 83 29 gg 83 George Murdoch 75 80 40 80 72 Anthony Silva 63 91 66 57 86 TOTAL 1 210 1254 97.99 135 225 241 AVERAGE 70.00 184.67 145.00 175.00 80.33 The second step of the evaluation process involved a ratio of costs analysis performed on all of the proposals. Because of their recurring, constant and necessary nature, three costs were isolated for this analysis: (1) Routine Operations and Maintenance Services; (2) Laboratory Analyses; and (3) Landfill Gas Source Testing. The lowest cost proposal was awarded 100 points and subsequent cost proposals were awarded a percentage of points in direct relation to the percentage difference of cost from the lowest cost proposal. Exhibit B is a summary of the results from the ratio of costs analysis: EXHIBIT B: RATIO OF COSTS ANALYSIS Evaluation Results The scores from the first two steps were then tabulated to quantitatively rank the proposals. The evaluation panel was advised that a third optional step, which involved interviewing the top - qualified firms, could be initiated upon the panel's request if none of the top - qualified firms distinguished themselves and further information or clarification was needed. Exhibit C is a summary of the aggregate scores of all five (5) proposing firms (overall rank in parenthesis): EXHIBIT C: AGGREGATE SCORES OF PROPOSALS Environ GC G.E.O., Inc. SCS Field Shaw Proposal Average Score Strategy Environmental 45.00 Services Environmental Operation and 94.45 97.99 68.85 100 86.71 Maintenance Annual Cost $47,275.00 $45,565.00 $64,850.00 $44,650.00 $51,495.25 Proposed Ratio of Costs 94.45 97.99 68.85 100 86.71 Evaluation Results The scores from the first two steps were then tabulated to quantitatively rank the proposals. The evaluation panel was advised that a third optional step, which involved interviewing the top - qualified firms, could be initiated upon the panel's request if none of the top - qualified firms distinguished themselves and further information or clarification was needed. Exhibit C is a summary of the aggregate scores of all five (5) proposing firms (overall rank in parenthesis): EXHIBIT C: AGGREGATE SCORES OF PROPOSALS GC Environmental was rated as the highest qualified firm for this project by virtue of having the highest rated proposal and lowest proposed cost. The panel was impressed with the experience Environ Strategy GC Environmental G.E.O., Inc. SCS Field Services Shaw Environmental Proposal Average Score 70.00 84.67 45.00 75.00 80.33 Ratio of Costs Score 94.45 97.99 68.85 100 86.71 Aggregate Score 164.45(4) 182.66(l) 113.85(5) 175.00 (2) 1 167.04 (3) GC Environmental was rated as the highest qualified firm for this project by virtue of having the highest rated proposal and lowest proposed cost. The panel was impressed with the experience and operational knowledge demonstrated by GC Environmental in their proposal. Since there was a significant difference between GC Environmental and the second highest qualified firm (SCS Engineers) and there were no points of clarification needed, the panel deemed that interviews were not necessary and recommends the City negotiate with GC Environmental toward a contract for this project. Attachment C AGREEMENT FOR OPERATION ARID MAINTENANCE SERVICES WITH GC ENVIRONMENTAL, INC. FOR NEWPORT TERRACE LANDFILL GAS CONTROL SYSTEM THIS AGREEMENT FOR OPERATION AND MAINTENANCE SERVICES ( "Agreement") is made and entered into as of this 10th day of April, 2012 ( "Commencement Date ") by and between the CITY OF NEWPORT BEACH, a California municipal corporation and charter city ( "City"), and GC ENVIRONMENTAL, INC., a Califomia corporation ( "Contractor"), whose principal place of business is 1230 N. Jefferson Street, Suite J, Anaheim, California 92807 and is made with reference to the following: RECITALS A. City Is a municipal corporation duly organized and validly existing under the laws of the State of California with the power to carry on its business as it is now being conducted under the statutes of the State of California and the Charter of City. B. City requires operation and maintenance ( "O &M ") service related to the Newport Terrace Landfill Gas Control System ("System "), as described and depicted in the Operation and Maintenance Manual, dated March 13, 2009 and revised by the City November 8, 2011, • attached hereto as Exhibit "A" and incorporated herein by this reference. C. City desires to engage Contractor to perform the O &M for the System, as described In Exhibits "A" and "B ", attached hereto and Incorporated herein by this reference ( "Project "). D. Contractor has examined the location of all proposed work, carefully reviewed and evaluated the specifications set forth by the City for the Project, and is familiar with all conditions relevant to the performance of services and has committed to perform all work required for the price specified In this Agreement. NOW, THEREFORE, it is mutually agreed by and between the undersigned parties as follows: 1. TERM The tern of this Agreement shall be for a period of five (5) years and shall commence on the Commencement Date, and shall terminate on March 31, 2017, unless terminated earlier as set forth herein. 2. SCOPE OF WORK 2.1. City and Contractor acknowledge that the above Recitals are true and correct and are hereby incorporated by reference. Contractor shall perform all the work described In the Scope of Work attached hereto as Exhibit A and incorporated herein by this reference ("Services" or uWork"). As a material inducement to the City entering Into GC ENVIRONMENTAL, INC. Page 1 this Agreement; Contractor represents and warrants that Contractor is a provider of first class work and Contractor is experienced in performing the Work contemplated herein and, In light of such status and experience, Contractor covenants that it shall follow the highest professional standards in performing the Work required hereunder and that all materials will be of good quality. For purposes of this Agreement, the phrase "highest professional standards" shall mean those standards of practice recognized by one or more first -class firms performing similar worts under similar circumstances. 2.2. Contractor shall perform everything required to be performed, and shall provide and furnish all the labor, materials, necessary tools, expendable equipment and all utility and transportation services necessary for the Project. 3. TIME OF PERFORMANCE 3.9. Routine O &, M Services. Time is of the essence In the performance of Services under this Agreement. Contractor shall perform the Routine O &, M Services, Identified in items 9 thru 3 In Exhibit B, in accordance with the schedule included in Exhibit A. The failure by Contractor to strictly adhere to the schedule may result in termination of this Agreement by City. 3.9.9. Notwithstanding the foregoing, Contractor shall not be responsible for delays due to causes beyond Consultant's reasonable control. However, in the case of any such delay in the Services to be provided for the Project, each party hereby agrees to provide notice to the other party so that all delays can be addressed. 3.9.2. Contractor shall submit all requests for extensions of time for performance in writing to the Project Administrator not later than two (2) calendar days after the start of the condition that purportedly causes a delay. The Project Administrator shall review all such requests and may grant reasonable time extensions for unforeseeable delays that are beyond Consultant's control. 3.9.3. For all time periods not specifically set forth herein, Consultant shall respond in the most expedient and appropriate manner under the circumstances, by telephone, fax, hand - delivery or mail. 3.2. On -Cali Services, Upon verbal or written request from the Project Administrator (as defined below in Section 5), Contractor shall provide a letter proposal for on -call Services requested by the City Including, the Services Identified as items 4 thru 7 in Exhibit B (hereinafter referred to as the "Letter Proposal "). The Letter Proposal shall include the following: 3.2.9. A detailed description of the Services to be provided; 3.2.2. The position of each person to be assigned to perform the Services, and the name of the individuals to be assigned, if available; 3.2.3. The estimated number of hours and cost to complete the Services; and 3.2.4. The time needed to finish the specific Project. GC ENVIRONMENTAL, INC. Page 2 3.3. No on-call Services shall be provided until the Project Administrator has provided written acceptance of the Letter Proposal. Once authorized to proceed, Contractor shall diligently perform the duties in the approved Letter Proposal. 4. COMPENSATION 4.1. City shall pay Contractor for the Services on a time and expense not -to- exceed basis, In accordance with the provisions of this Section and the Schedule of Billing Rates attached hereto as Exhibit B and incorporated herein by reference. No rate changes shall be made during the term of this Agreement without the prior written approval of the City. Contractor's total annual compensation per calendar year from the Commencement Date of the Agreement for Services performed in accordance with this Agreement, including all reimbursable hems, shall not exceed Eighty Eight Thousand Eighty Dollars and 001100 ($88,080.00) without written amendment to the Agreement. The total compensation over the full term of the Agreement shall not exceed Four Hundred Forty Thousand Four Hundred Dollars and 00/100 ($440,400.000) without written amendment to the Agreement. 4.1.1. Routine O & M Services. As full compensation for the performance and completion of the Routine O & M Services as identified as items 1 thru 3 on Exhibit B, City shall pay Contractor and Contractor accepts as full payment the sum of Fifty Two Thousand Nine Hundred and Eighty Dollars and 00/100 ($52,980.00) per calendar year from the Commencement Date of the Agreement, subject to the annual adjustment in proportion to changes in the Consumer Price Index more particularly described in Section 4.2 below. Compensation for the Routine O & M Services, identified as Items 1 and 2 on Exhibit B shall be paid in twelve (12) equal monthly installments. Services Identified in item 3 of Exhibit B shall be paid on a Unit Price rate as outlined in Exhibit B, with written approval from the City and upon completion of work. 4.1.2. On -Call Services. For all other Services the City shall pay Contractor on a time and expense not -to -exceed basis, in accordance with the provisions of this Section and the Schedule of Billing Rates attached hereto as Exhibit B and Incorporated herein by reference. 4.2. Consumer Price Index. Upon the first anniversary of the Commencement Date and upon each anniversary of the Commencement Date thereafter, the rates to be paid by the City as set forth in Exhibit B Items 1 thru 3 shall be adjusted in proportion to changes in the Consumer Price Index, subject to the 3.0% maximum adjustment Increase set forth below. Such adjustment shall be made by multiplying the original rate by a fraction, the numerator of which Is the value of the Consumer Price Index for the calendar month three (3) months preceding the calendar month for which such adjustment is to be made and the denominator of which is the value of the Consumer Price Index for the same calendar month one (1) year prior.. For example, If the adjustment is to occur effective June 1, 2011, the Index to be used for the numerator is the Index for the month of March 2011 and the index to be used for the denominator Is March 2010. The "Consumer Price Index" to be used in such calculation is the Consumer Price Index, All Urban Consumers (All Items) for the Los Angeles Anaheim Riverside Metropolitan Area, published by the United States Department of Labor, GC ENVIRONMENTAL, INC. Page 3 Bureau of Labor Statistics (1982 84 = 100). If both an official index and one or more unofficial indices are published, the official index shall be used. If said Consumer Price Index is no longer published at the adjustment date, it shall be constructed by conversion tables included in such new index. In no event, however, shall the amount payable under this agreement be reduced below the Rate In effect Immediately preceding such adjustment. The maximum increase to the Rate, for any year where an adjustment is made in proportion to changes in the Consumer Price Index, shall not exceed 3.0% of the Rate in effect immediately preceding such adjustment. 4.3. Contractor shall submit monthly invoices to City describing the Work perfomned the preceding month. Contractors bills shall include the name of the person and/or classification of employee who performed the Work, a brief description of the Services performed and /or the specific task from the Scope Services attached hereto which it relates, the date the Services were performed, the number of hours spent on all Work billed on an hourly basis, and a description of any reimbursable expenditures. City shall pay Contractor no later than thirty (30) days after approval of the monthly invoice by City staff. 4.4. City shall reimburse Contractor only for those costs or expenses specifically approved in the Scope of Services attached hereto. Unless otherwise approved, such costs shall be limited and include nothing more than the actual costs and/or other costs and /or payments specifically authorized In advance in writing and Incurred by Contractor in the performance of this Agreement. 4.5. Contractor shall not receive any compensation for Extra Work without the prior written authorization of City. As used herein, °Extra Work" means any work that is determined by the Project Administrator (as defined in Section 5 below) to be necessary for the proper completion of the Project, but which is not included within the Scope of Work and which the City and Contractor did not reasonably anticipate would be necessary. Compensation for any.authorized Extra Work shall be paid in accordance with the Schedule of Billing Rates set forth in Exhibit B. 5. ADMINISTRATION This Agreement will be administered by the Municipal Operations Department. George Murdoch, Utilities General Manager, or his designee shall be the Project Administrator and shall have the authority to act for City under this Agreement. The Project Administrator or his authorized representative shall represent City in all matters pertaining to the Services to be rendered pursuant to this Agreement. 6. TYPE AND INSTALLATION OF MATERIALS /STANDARD OF CARE 6.1. Contractor shall use only the standard materials described in Exhibit A in performing Services under this Agreement. Any deviation from the materials described In Exhibit A shall not be Installed unless approved in advance by the Project Administrator. 6.2. All of the Services shall be performed by Contractor or under Contractor's supervision. Contractor represents that It possesses the personnel required to perform GC ENVIRONMENTAL, INC. Page 4 the Services required by this Agreement, and that it will perform all Services in a manner commensurate with highest professional standards. All Services shall be performed by qualified and experienced personnel who are not employed by City, nor have any contractual relationship with City. 7. RESPONSIBILITY FOR DAi!liAGES OR INJURY 7.9. City and all officers, employees and representatives thereof shall not be responsible in any manner for any loss or damage to any of the materials or other things used or employed in performing the Project or for injury to or death of any person as a result of Contractors performance of the Services required hereunder, or for damage to property from any cause arising from the performance of the Project by Contractor, or its subcontractors, or its workers, or anyone employed by either of them. 7.2. Contractor shall be responsible for any liability imposed by law and for injuries to or death of any person or damage to property resulting from defects, obstructions or from any cause arising from Contractors Work on the Project, or the Work of any subcontractor or supplier selected by the Contractor. 7.3. To the fullest extent permitted by law, Contractor shall indemnify, defend and hold harmless City, its City Council, boards and commissions, officers, agents, volunteers, and employees (collectively, the "Indemnified Parties ") from and against any and all claims (Including, without limitation, claims for bodily injury, death or damage to property), demands, obligations, damages; actions, causes of action, suits, losses, judgments, fines, penalties, liabilities, costs and expenses (including, without limitation, attorney's fees, disbursements and court costs) of every kind and nature whatsoever (individually, a Claim; collectively, "Claims "), which may arise from or in any manner relate (directly or indirectly) to any breach of the terms and conditions of this Agreement, any Work performed or Services provided under this Agreement including, without limitation, defects in workmanship or materials or Contractors presence or activities conducted on the Project (including the negligent and /or willful acts, errors and /or omissions of Contractor, its principals, officers, agents, employees, vendors, suppliers, consultants, subcontractors, anyone employed directly or indirectly by any of them or for whose acts they may be liable or any or all of them). 7.4. Notwithstanding the foregoing, nothing herein shall be construed to require Contractor to indemnify the Indemnified Parties from any Claim arising from the sole negligence or willful misconduct of the Indemnified Parties. Nothing in this Indemnity shall be construed as authorizing any award of attorney's fees In any action on or to enforce the terms of this Agreement. This indemnity shall apply to all claims and liability regardless of whether any insurance policies are applicable. The policy limits do not act as a limitation upon the amount of indemnification to be provided by the Consultant. 7.5. Contractor shall perform all Project Work in a manner to minimize public Inconvenience and possible hazard, to restore other work areas to their original condition and former usefulness as soon as possible, and to protect public and private property. Contractor shall be liable for any private or public property damaged during the performance of the Project Work. GC ENVIRONMENTAL, INC. Page 5 7.6. To the extent authorized by lava, as much of the money due Contractor under and by virtue of the Agreement as shall be considered necessary by City may be retained by It until disposition has been made of such suits or claims for damages as aforesaid. 7.7. The rights and obligations set forth in this Section shall survive the termination of this Agreement. 8. INDEPENDENT CONTRACTOR City has retained Contractor as an independent contractor and neither Contractor nor its employees are to be considered employees of the City. The manner and means of conducting the Work are under the control of Contractor, except to the extent they are limited by statute, rule or regulation and the express terms of this Agreement. No civil service status or other right of employment shall accrue to Contractor or its employees. Contractor shall have the responsibility for and control over the means of performing the Work, provided that Contractor Is In compliance with the terms of this Agreement. Anything in this Agreement that may appear to give City the right to direct Contractor as to the details, of the performance or to exercise a measure of control over Contractor shall mean only that Contractor shall follow the desires of City with respect to the results of the Services. Contractor agrees to work closely and cooperate fully with City's designated Project Administrator and any other agencies that may have jurisdiction or interest in the Work to be performed. City agrees to cooperate with the Contractor on the Project. 10. INSURANCE 10.1. Without fiat ing Contractors indemnification of City, and prior to commencement of Work. Contractor shall obtain, provide and maintain at its own expense during the term of this Agreement, policies of insurance of the type and amounts described below and in a form satisfactory to City. The cost of such insurance shall be included in Contractors bid. 10.2. Coverage and Limit Requirements. 10.2.1. Workers' Compensation. Contractor shall maintain Workers' Compensation Insurance providing statutory benefits and employers liability insurance with limits of at least one million dollars ($1,000,000) each type for Contractors employees in accordance with the laws of the State of California, Section 3700 of the Labor Code. In addition, Contractor shall require each subcontractor to similarly maintain Workers' Compensation Insurance and Employers Liability Insurance in accordance with the laws of the State of California, Section 3700 for all of the subcontractors employees. The insurer issuing the Workers' Compensation insurance shall amend its policy by endorsement to waive all rights of subrogation against City, its elected or appointed officers, agents, officials, employees and volunteers. Contractor GC ENVIRONMENTAL, INC. Page 6 shall submit to City, along with the required certificate of insurance, a copy of such waiver of subrogation endorsement. 10.2.2. General Liability. Contractor shall maintain commercial general liability insurance In an amount not less than one million dollars ($1,000,000) per occurrence, two million dollars ($2,000,000) General Aggregate and two million dollars ($2,000,000) Products and Completed Operations Aggregate for bodily injury, personal injury, and property damage, Including without limitation, blanket contractual liability. Coverage shall be at least as broad as that provided by Insurance Services Office form CG 00 01. None of the policies required herein shall be in compliance with these requirements if they include any limiting endorsement that has not been first submitted to City and approved in writing. 10.2.3. Automobile Liability. Contractor shall maintain automobile Insurance covering bodily injury and property damage for all activities of the Contractor arising out of or in connection with Work to be performed under this Agreement, Including coverage for any owned, hired, non -owned or rented vehicles, in an amount not less than one million dollars ($1,000,000) combined single limit for each accident. 10.2.4. Builders Risk. For Agreements or Contracts with Construction/Builders Risk property exposures, Contractor shall maintain Builders Risk Insurance or an Installation floater as directed by City, covering damages to the Work for "all risk" or special form causes of loss with limits equal to one hundred percent (100 %) of the completed value of contract, with coverage to continue until final acceptance of the Work by City. At the discretion of City, the requirement for such coverage may include additional protection for Earthquake and /or Flood. City shall be Included as an insured on such policy, and Contractor shall provide the Cily with a copy of the policy. 10.3. Other Insurance Provisions or Requirements 10.3.1. Evidence of Insurance. Contractor shall provide certificates of insurance to City as evidence of the insurance coverage required herein, along with a waiver of subrogation endorsement for workers' compensation and an additional Insured endorsement for general liability. Insurance certificates and endorsements must be approved by Citys Risk Manager prior to commencement of performance or Issuance of any permit. Current evidence of Insurance shall be kept on file with City at all times during the term of this Agreement. All of the executed documents referenced In this Agreement must be returned within ten (10) working days after the date on the "Notification of Award; so that the City may review and approve all insurance and bond documentation. City reserves the right to require complete, certified copies of all required insurance policies, at anytime. 10.3.2. General liability Insurance orovislons Primary and excess or umbrella liability policies are to contain, or be endorsed to contain, the following provisions: 10.3.2.1. City and the Newport Condominium Association ( "NCA "), their elected or appointed officers, agents, officials, employees, and volunteers GC ENVIRONMENTAL, INC. page 7 are to be covered as additional Insureds as respects: liability arising out of activities performed by or on behalf of Contractor, including the Insured's general supervision of Contractor, products and completed operations of Contractor, premises owned, occupied or used by Contractor. The coverage shall contain no special limitations on the scope of protection afforded to City, Its elected or appointed officers, officials, employees, agents or volunteers. Contractor shall submit to City a copy of the additional insured endorsement along with the required certificates of insurance. 10.3.2.2. Contractor's insurance coverage shall be primary insurance and /or primary source of recovery as respects to City and the Newport Condominium Association ( "INCA "), their elected or appointed officers, agents, officials, employees and volunteers as respects to all claims, losses, or liability arising directly or Indirectly from the Contractor's operations or services provided to the City. Any Insurance or self- insurance maintained by City and the Newport Condominium Association ( "NCA "), their officers, officials, employees and volunteers shall be excess of the Contractors insurance and shall not contribute with it. 10.3.2.3. Contractors insurance shall apply separately to each insured against whom claim is made or suit is brought, except with respect to the limits of the Insurers liability. 10.4. Acceptable Insurers. All Insurance policies shall be issued by an insurance company currently authorized by the Insurance Commissioner to transact business of insurance in the State of California, with an assigned policyholders' Rating of A- (or higher) and Financial Size Category Class VII (or larger) in accordance with the latest edition of Best's Key Rating Guide, unless otherwise approved by the City's Risk Manager. 10.5. Notice of Cancellation. Contractor agrees to oblige its insurance broker and insurers to provide to City with 30 days notice of cancellation (except for nonpayment for which 10 days notice is required) or nonrenewal of coverage for each required coverage except for builders risk Insurance. The builders dsk policy will contain or be endorsed to contain a provision providing for 30 days written notice to City of cancellation or nonrenewal, except for nonpayment for which 10 days notice is required. 10.6. Self - Insured Retentions: Contractor agrees not to self - insure or to use any self - Insured retentions on any portion of the insurance required herein and further agrees that it will not allow any indemnifying party to self-Insure its obligations to City. If contractors existing coverage Includes a self- insured retention, the self- insured retention must be declared to City. City may review options with the contractor, which may include reduction or elimination of the self - insured retention, substitution of other coverage, or other solutions. Contractor agrees to be responsible for payment of any deductibles on their policies. 10.7. Timely Notice of Claims. Contractor shall give City prompt and timely notice of any claim made or suit instituted arising out of or resulting from Contractors performance under this agreement. GC ENVIRONMENTAL, INC. Page 8 10.8. Waiver. All insurance coverage maintained or procured pursuant to this agreement shall be endorsed to waive subrogation against City, its elected or appointed officers, agents, officials, employees and volunteers, or shall specifically allow Contractor or others providing insurance evidence in compliance with these requirements to waive their right of recovery prior to a loss. Contractor hereby waives its own right of recovery against City, and shall require similar written express waivers and Insurance clauses from each of its subcontractors. 10.9. Enforcement of Agreement Provisions Contractor acknowledges and agrees that any actual or alleged failure on the part of the City to Inform Contractor of non - compliance with any requirement Imposes no additional obligations on the City nor does it waive any rights hereunder. 10.10. Requirements not Limiting Requirements of specific coverage features or limits contained in this Section are not intended as a limitation on coverage, limits or other requirements, or a waiver of any coverage normally provided by any insurance. Specific reference to a given coverage feature is for purposes of clarification only as it pertains to a given issue and is not intended by any party or insured to be all Inclusive, or to the exclusion of other coverage, or a waiver of any type. 10.11..CitVs Remedies. City shall have the right to order the Contractor to stop Work under this Agreement and /or withhold any payment(s) that become due to Contractor hereunder until Contractor demonstrates compliance with the requirements of this article. In the alternative, City may purchase the required coverage and charge Contractor the cost of the premiums or deduct the cost from Contractors payments. 10.12. Coverage not Limited. All insurance coverage and limits provided by contractor and available or applicable to this agreement are intended to apply to the full extent of the policies. Nothing contained in this agreement or any other agreement relating to the city or its operations limits the application of such insurance coverage. 10.13. Coverage Renewal. Contractor will renew the coverage required here annually as long as Contractor continues to provide any Services under this or any other contract or agreement with the City. Contractor shall provide proof that policies of Insurance required herein expiring during the term of this Agreement have been renewed or replaced with other policies providing at least the same coverage. Proof that such coverage has been ordered shall be submitted prior to expiration. A coverage binder or letter from Contractor's insurance agent to this effect is acceptable. A certificate of insurance and /or additional insured endorsement as required in these specifications applicable to the renewing or new coverage must be provided to City within five days of the expiration of the coverages. 11. SUBCONTRACTING City and Contractor agree that subcontractors may be used to complete the Work outlined in the Scope of Work provided the Contractor obtains City approval prior to the subcontractor performing any work. Contractor shall be fully responsible to City for all acts and omissions of the subcontractors. Nothing in this Agreement shall create any contractual relationship between City and subcontractor nor shall it create any obligation GC ENVIRONMENTAL, INC. Page 9 on the part of City to pay or to see to the payment of any monies due to any such subcontractor other than as otherwise required by law. 12. WITHHOLDINGS City may withhold payment to Contractor of any disputed sums until satisfaction of the dispute with respect to such payment. Such withholding shall not be deemed to constitute a failure to pay according to the terms of this Agreement. Contractor shall not discontinue Work as a result of such withholding. Contractor shall have an Immediate right to appeal to the City Manager or his/her designee with respect to such disputed sums. Contractor shall be entitled to receive interest on any withheld sums at the rate of return that City earned on its investments during the time period, from the date of withholding of any amounts found to have been improperly withheld. 13. CONFLICTS OF INTEREST 13.1. The Contractor or its employees may be subject to the provisions of the California Political Reform Act of 1974 (the "AcY'), which (1) requires such persons to disclose any financial Interest that may foreseeably be materially affected by the Work performed under this Agreement, and (2) prohibits such persons from making, or participating in making, decisions that will foreseeably financially affect such Interest. 13.2. If subject to the Act, Contractor shall conform to all requirements of the Act. Failure to do so constitutes a material breach and is grounds for immediate termination of this Agreement by City. Contractor shall indemnify and hold harmless City for any and all claims for damages resulting from Contractors violation of this Section. 14.1. All notices, demands, requests or approvals to be given under the terms of this Agreement shall be given in writing, to City by Contractor and conclusively shall be deemed served when delivered personally, or on the third business day after the deposit thereof In the United States mail, postage prepaid, first -class mail, addressed as hereinafter provided. All notices, demands, requests or approvals from Contractor to City shall be addressed to City at: Attn: George Murdoch Municipal Operations Department City of Newport Beach 3300 Newport Blvd. PO Box 1768 Newport Beach, CA 92658 Phone: 949 - 644 -3011 Fax: 949646 -1509 14.2. With a courtesy copy to: John Van Vlear, Esq., R.E.A. GC ENVIRONMENTAL, INC. Page 10 Voss Cook & Thai LLP 895 move Street, #450 Newport Beach, CA 92660 E -Mail: vv @vctlaw.com Phone: (949) 435 -4338 Fax: (949) 435 -0226 14.3. All notices, demands, requests or approvals from City to Contractor shall be addressed to Contractor at: Attn: Farideh Kla GC ENVIRONMENTAL, INC. 1230 N. Jefferson Street, Suite J Anaheim, California 92807 Phone: 714 -632 -9969 Fax: 714 -632 -9968 15. NOTICE OF CLAIMS 15.1. Unless a shorter time Is specified elsewhere in this Agreement, before making its final request for payment under the Agreement, Contractor shall submit to City, in writing, all claims for compensation under or arising out of this Agreement. Contractor's acceptance of the final payment shall constitute a waiver of all claims for compensation under or arising out of this Agreement except those previously made in writing and identified by Contractor in writing as unsettled at the time of its final request for payment. The Contractor and the City expressly agree that in addition to all claims tiling requirements set forth in the Agreement, the Contractor shall be required to file any claim the Contractor may have against the City in strict conformance with the Tort Claims Act (Govt. Code §§ 900 et seq.). 16. TERMINATION 16.1. In the event that either party fails or refuses to perform any of the provisions of this Agreement at the time and in the manner required, that party shall be deemed in default in the performance of this Agreement. If such default is not cured within a .period of two (2) calendar days, or if more than two (2) calendar days are reasonably required to cure the default and the defaulting party fails to give adequate assurance of due performance within two (2) calendar days after receipt of written notice of default, specifying the nature of such default and the steps necessary to cure such default, the non - defaulting party may terminate the Agreement forthwith by giving to the defaulting party written notice thereof. 16.2. Notwithstanding the above provisions, City shall have the right, at its sole discretion and without cause, of terminating this Agreement at any time by giving seven (7) calendar days prior written notice to Contractor. In the event of termination under this Section, City shall pay Contractor for Services satisfactorily performed and costs Incurred up to the effective date of termination for which Contractor has not been previously. paid. On the effective date of termination, Contractor shall deliver to City all materials purchased in performance of this Agreement. GC ENVIRONMENTAL, INC. Page 11 d i�x1t'aIF1 4 r.`.�i,,�0 ",�, 17.1. Compliance with all Laws. Contractor shall at Its oven cost and expense comply with all statutes, ordinances, regulations and requirements of all governmental entities, including federal, state, county or municipal, whether now in force or hereinafter enacted. 17.2. Waiver. A waiver by City of any term, covenant, or condition In the Agreement shall not be deemed to be a waiver of any subsequent breach of the same or any other term, covenant or condition. 17.3. Intecrated Contract. This Agreement represents the full and complete understanding of every kind or nature whatsoever between the parties hereto, and all preliminary negotiations and Agreements of whatsoever kind or nature are merged herein. No verbal Contract or Implied covenant shall be held to vary the provisions herein. 17.4. Conflicts or Inconsistencies. In the event there are any conflicts or inconsistencies between this Agreement and the Exhibits attached hereto, the terms of this Agreement shall govern. 17.5. Amendments. This Agreement may be modified or amended only by a written document executed by both Contractor and City and approved as to form by the City Attorney. 17.5. Effect of Contractoes Execution. Execution of this Agreement by Contractor Is a representation that Contractor has visited the Project Site, has become familiar with the local conditions under which the Work is to be performed, and has taken into consideration these factors in submitting its Project Proposal and Scope of Work. 17.7. Controlling Law and Venue. The laws of the State of California shall govern this Agreement and all matters relating to it and any action brought relating to this Agreement shall be adjudicated In a court of competent jurisdiction in the County of Orange. 17.8. Ewa ual Opportunity Employment. Contractor represents that it is an equal opportunity employer and it shall not discriminate against any subcontractor, employee or applicant for employment because of race, religion, color, national origin, handicap, ancestry, sex or age. 17.9. Interpretation. The terms of this Agreement shall be construed in accordance with the meaning of the language used and shall not be construed for or against either party by reason of the authorship of the Agreement or any other rule of construction which might otherwise apply. 17.10. Severability. If any term or portion of this Agreement is held to be invalid, Illegal, or otherwise unenforceable by a court of competent jurisdiction, the remaining provisions of this Agreement shall continue in full force and effect. GC ENVIRONMENTAL, INC. Page 12 17.11. No AttomeVs Fees In the event of any dispute or legal action arising under this Agreement, the prevailing party shall not be entitled to attorney's fees. 17.12. Counteroarts. This Agreement may be executed in two or more counterparts, each of which shall be deemed an original and all of which together shall constitute one and the same Instrument. QSIGNATt1RES ON NEXT PAGE) GC ENVIRONMENTAL, INC. Page 13 p ;er�yegyp� �,j 6 .�y� '{ ltlje fitl C�y( y y ~6, }�{}�ftYt �a��y .r "U�j� 'a Ki I. �. y_ � X43 w�'� 'XBCl�t6CI;¢Ot3. ii6 G u lYtW be 10, 0 AP�P�' 0C".�Mx•F atta +mO � u ����b���Y,) { t' iffie¢atitBroM,°x °` "F�iartl�PirsSe (itY Clerk P; rA z_ a s Attacia�ie #s E Fiibrt A per iqr �F*W -1 Schedule v. fill rid �� ♦tY ' a .... „ s f , �4 E x! v� �2x Fa f2 Y i Iq f� ry ti l � h i 6 ° f e % 4 ,Cir;ATtO,RiEYSt7F IG. Ii.AGaa a lcin- .0"SH`�afp s r£t�xipa (A�r ®re l 4 t/ N 'ice �6 i• h�I %�fll �,Tsd r rr t; yyN/A %fEVt , f AJ 3 1>0 v t' iffie¢atitBroM,°x °` "F�iartl�PirsSe (itY Clerk P; rA z_ a s Attacia�ie #s E Fiibrt A per iqr �F*W -1 Schedule v. fill rid �� ♦tY ' a .... „ s f , �4 E x! v� �2x Fa f2 Y i Iq f� ry ti l � h i 6 ° f e % i:l,,: OPERATIONS AND MAINTENANCE MANUAL (C ®) GC ENVIRONMENTAL, INC. Page A -1 EXHIBIT B SCHEDULE OF BILLING RATES Routine Operation & iWaintenance Services Item NO. Carbon Change -Out Quantities Total Price Provide lump sum costs for replacement of carbon M 4. Routine O &M Services LS Monitoring Pursuant to Regulations and as described in the b) $6,750 �' OM &M Plan, Other Monitoring and Maintenance LS $37,300 5. Parameters, and Reporting (as specified in RFP Section I -F (Annual) $8,350 and attached O &M Manual), exclusive of laboratory anal es. See Rate 6. Laboratont Analyses T &M a) Provide unit cost for laboratory analyses of air/gas samples, Unit price --$20— 2. Including: See Rate 7. a) Total Gaseous Peon- Methane Organics (TGNMOs) (12/yr) T &M b) 275 b Rule 1150.1 Toxic AIr Contaminants ACs 2 3. Landfill Gas Source Test Unit Price $6,900 On -Call services • The GC Environmental, Inc. will obtain three bids or proposals from qualified subcontractors for any on -call services requested. GC Environmental, Inc. will provide the bids to the City for final approval before any work is started. • GC Environmental, Inc. shall use the lowest qualified bid received. GC ENVIRONMENTAL, INC. Page B -1 Carbon Change -Out Provide lump sum costs for replacement of carbon a) $4,900 4. adsorption media: LS a) for a single vessel b) $6,750 b for two vessels simultaneous) 5. Sulfa-Treat Change -Out Unit Price $8,350 Provide unit cost for replacement of SuKa Treat media. Non- Routine Services and Emergency Response See Rate 6. Provide rate schedule for T &M work, Including labor and T &M Schedule equipment rates. Engineering Services See Rate 7. Provide rate schedule for T &M work, including labor and T &M Schedule equipment rates. GC ENVIRONMENTAL, INC. Page B -1 GC EN VIROMAENI'AI., INC. - ISASIS OF CHARGES Effective January 9, 2092 I. Laud herein are typical prices far OWAM most 5equmdy pedonncd by (1C Emiturns 1, Ine, Priaafmodwaavieeenot Batedwill begivcaupon request. 2. 1mrole" will be iswed at a mcaddy basis, or upon completion of a project, whichever is aeons. The act cash amount of this invoice is payable within 30 days ofteeeipt and approval of the invoice. 3. For hourly wo*Am time worked in emcee of eight boas per day and wcekend work: will be charged at 1.5 times the hourly rate. 4. Per Diem will be charged at a rue of $75 pa day per person or erpeenot plus 1494 whichever is greacr. per Diem will be dwaged for all projcets in exams of 50 mike from the GC EwArramnemal, Inc. office. A Outdde services wiU kdudo a 1Sok morkua unless othetwiise noted. ti. WO are protected by Worker's Compenandon buuranee, and wig famish mocates thereof upon rcqueat. We assume the risk of damage to our own supplies and equipment. If your contract or 9mehme order Places greater responsibilities upon us or requires briber insurance coverage, GCE Will, when specifically directed by yoq take am additional inatamazo Cif procurable) to protect us at your expense, but we shall not be responsible for property damage from any cause, including fire and erosion, beyond dw amauote ofeoverage of am fitsurance. 7. All envirotmreaW Samples may be schemed to clients at GC Envimmnonul, roe's discretion 30 days otter submission orfivai repor4 unless prior ananli menu arc reads. 0. Proper dupasal or handling of sail boring cuttings, well development and purge waters, daonremimffioa soludom and odor eontaroimatedrpotentiaity contra mated materials is dire responedli ry of the effect. GC EaWroomenul, Inc. can provide cmainers for oasite containment and can advise the client regatditug pmperka procedures. 9. EVed wimew, depmidons and tearimmry as two dares the regain, fur. Pnmfeaeiaal Mileage___......______..._.......__......_. .._..»..._,_____............___ Standard Insurance— Waiver of conu_ a adersi..rt.n .. .t »_ C..o._m_p.u_te»r .. F._e.e _ at .2..% _.. �.»._x......_... ._..._.___.._.... __.._..__.".."..".___..... ...... .» .»...._ _».......»....... »_._ ...».._.»........_.._.... _»..5..2..3..0 .» a.2% Equipment GEMS00 Gs Madta fte Equipment _..._......_.»._...._._...____».......__ »..»..__..._......»...._...____ SI50/day OVEagle me ntment......»..»._..„_..._ .............___._........._....__ ��..._..»__._.._ .»_...__...__.........._Sg5/day OVAEquipmem......____.__»._...»..»_......_..._.....»..._.__...._.__......._.._.__._ ..._..._»_..._......�__»SSS/day PID EqudPmaa.__....» .......... ........_......_._.»_......._»........._.»__......._... _.....__...__..... » »........ »._ 5125 /day Pump Tray/Sampling Equipment .................. _.......__.__........».......».........._._. ..._..._._.........._. »........ S30/day TS[ E9wimmat..,......_...»..-_._...._...._......_.............. «._.... »_...___....__.... »..... 5100! Wale Tr Aare.. ..- _.........»._...____..» day an.xNw re+.wucw .......»_ .............».__.....«..._«....__».__._._.»_...__. �_..._.__._..... ......._......__....__..535/day Armck .__..._..._......_...._..._._...__._....»_.»_..._.._..._ w»._.»_._ ...._..._ ......_........SiOaday mblent AU SamPg EymPmad ( upgradieaudawngmdkaQ - 4451day Truck & Tools........._.__....»_..._........_..._..«..,.__ ......._..»..._._._......_...__ .__._ .............____.._...575 /day wavaWPaOPOSALT40ay'prraapat tlead,V USHIS r!(7wan NmpmW, cgyriauo2a12- OC6nk=Mmat,1ea Aawsma GC ENVIRONMENTAL, INC. Page B -2 ity ®f Newport Bead NO. BA- 12BA -031 BUDGET AMENDMENT i 2011 -12 AMOUNT:1 $21,180.00 EFFECT ON BUDGETARY FUND BALANCE: Increase Revenue Estimates Increase in Budgetary Fund Balance Increase Expenditure Appropriations AND X Decrease in Budgetary Fund Balance Transfer Budget Appropriations No effect on Budgetary Fund Balance SOURCE: from existing budget appropriations from additional estimated revenues X from unappropriated fund balance ff -IML97 •il This budget amendment is requested to provide for the following: To increase expenditure appropriations from unappropriated Environmental Liability fund balance for the balance of FY11 -12 operation maintnenance and monitoring services on the Newport Terrace Landfill Gas Control System. ACCOUNTING ENTRY: BUDGETARY FUND BALANCE Amount Fund Account Description Debit Credit 292 3605 Environmental Liability - Fund Balance $21,180.00 * REVENUE ESTIMATES (3601) Fund /Division Account Description EXPENDITURE APPROPRIATIONS (3603) Signed: Financial Appro all Finance Director Signed: Administ tive Approval: City Ma * Automatic $21,180.00 Date Date Signed: City Council Approval: City Clerk Date Description Division Number 3155 Environmental Liability Account Number 8030 Maintenance &Repair - Equipment Division Number Account Number Division Number Account Number Division Number Account Number Signed: Financial Appro all Finance Director Signed: Administ tive Approval: City Ma * Automatic $21,180.00 Date Date Signed: City Council Approval: City Clerk Date Newport Terrace Landfill Operation and Maintenance Manual Landfill Gas Control System Prepared for: City of Newport Beach Utilities Department 3300 Newport Boulevard P.O. Box 1768 Newport Beach, CA 92658-8915 and Newport Condominium Association Action Community Management 29B Technology Drive, Suite 100 Irvine, CA 92618 Prepared by: SCS ENGINEERS 3900 Kilroy Airport Way Suite 100 Long Beach, CA 90806-6816 (562) 426-9544 * File No. 01 201 221.08 March 13, 2009 Revised by: City of Newport Beach November 8, 2011 Offices Nationwide www.scsengineers.com Newport Terrace Landfill — O&M Manual Newport Terrace Landfill Operation and Maintenance Manual Landfill Gas Control System Prepared for: City of Newport Beach Utilities Department 3300 Newport Boulevard P.O. Box 1768 Newport Beach, CA 92658-8915 and Newport Condominium Association Action Community Management 29B Technology Drive, Suite 100 Irvine, CA 92618 Prepared by: SCS ENGINEERS 3900 Kilroy Airport Way Suite 100 Long Beach, CA 90806-6816 (562) 426-9544 File No. 01 201221.08 March 13, 2009 Revised by: City of Newport Beach November 8, 201 1 Newport Terrace Landfill — O&M Manual Table of Contents Section Page Introduction.............................................................................................................................................. 1 1.1 Operation and Maintenance Manual Objectives..................................................................1 1.2 Applicable Permits and Regulations........................................................................................1 1.2.1 No. F8501 1, Issued November 6, 2006 (Appendix C) ........................................1 1.2.2 No. F85012, Issued November 2, 2006 (Appendix D) ........................................2 1.2.3 Rule 1150.1 Compliance Plan, Issued December 17, 1999 (Appendix G)......2 1.2.4 California Code of Regulations (CCR), Title 27 .....................................................2 1.3 Site Location and Physical Description.....................................................................................3 1.4 Site Owner/Operator................................................................................................................6 1.5 Landfill Gas Hazards..................................................................................................................6 1.5.1 Landfill Gas Levels at Newport Terrace.................................................................8 2 Description of LFG Control System...................................................................................................10 2.1 System Objectives and General Description....................................................................... 10 2.2 Monitoring Probes.....................................................................................................................1 1 2.3 Extraction Wells........................................................................................................................ 15 2.4 Blower Station........................................................................................................................... 16 2.4.1 Moisture Separating Tank....................................................................................... 16 2.4.2 Blowers........................................................................................................................16 2.4.3 Activated Carbon Adsorption Units....................................................................... 16 2.4.4 Sulfatreat System......................................................................................................17 2.5 Site Security...............................................................................................................................17 3 LFG Condensate Handling System...................................................................................................18 3.1 LFG Condensate........................................................................................................................ 18 3.2 Gas Condensate Handling System Description...................................................................18 3.3 Handling LFG Condensate......................................................................................................18 4 System Operation................................................................................................................................19 4.1 Operational Criteria................................................................................................................19 4.2 System Start-up......................................................................................................................... 19 4.3 System Shutdown...................................................................................................................... 20 4.4 Operation Schedule................................................................................................................. 20 4.5 Remote Monitoring by City.....................................................................................................21 5 System Monitoring...............................................................................................................................22 5.1 Monitoring Criteria................................................................................................................... 22 5.2 Monitoring Equipment.............................................................................................................. 22 5.2.1 Combustible Gas Monitoring Instrument............................................................... 22 5.2.2 Photo Ionization Detector (PID)...............................................................................22 5.2.3 Hydrogen Sulfide Measurement............................................................................ 23 5.2.4 Pressure/Vacuum Gauges.......................................................................................23 5.2.5 Miscellaneous.............................................................................................................23 5.3 Monitoring Procedures.............................................................................................................23 Newport Terrace Landfill — O&M Manual 5.3.1 Carbon Adsorption Units (Each)..............................................................................25 6.2.1 5.3.2 Sulfatreat System......................................................................................................25 6.2.2 5.3.3 Extraction Wells (Each)............................................................................................ 26 Flame Arrestor...........................................................................................................33 5.3.3.1 Pressure/Vacuum......................................................................................26 6.2.4 Moisture Separator...................................................................................................33 5.3.3.2 Gas Composition......................................................................................26 6.2.5 5.3.4 Monitoring Probes (Each).........................................................................................26 6.2.12 5.3.4.1 Pressure/Vacuum......................................................................................26 6.2.13 5.3.4.2 Methane Concentration...........................................................................26 6.3 Maintenance Records and Schedule..................................................................................... 5.3.4.3 Methane Concentration Exceedance....................................................27 5.4 Monitoring Records and Schedule......................................................................................... 28 5.5 Reporting to Regulatory Agencies.........................................................................................29 6 System Maintenance...........................................................................................................................32 6.1 Maintenance Criteria............................................................................................................... 32 6.2 Maintenance Procedures......................................................................................................... 32 6.2.1 Compressor.................................................................................................................32 Piping, Valves, and Fittings.....................................................................................33 6.2.2 Blowers........................................................................................................................32 Extraction Wells........................................................................................................ 6.2.3 Flame Arrestor...........................................................................................................33 Monitoring Probes.....................................................................................................33 6.2.4 Moisture Separator...................................................................................................33 Carbon Adsorption Units..........................................................................................34 6.2.5 Electrical Controls......................................................................................................33 Sulfatreat System......................................................................................................34 6.2.6 Gauges and Sampling Ports...................................................................................33 6.2.7 Piping, Valves, and Fittings.....................................................................................33 6.2.8 Extraction Wells........................................................................................................ 33 6.2.9 Monitoring Probes.....................................................................................................33 6.2.10 Carbon Adsorption Units..........................................................................................34 6.2.1 1 Sulfatreat System......................................................................................................34 6.2.12 In -Line Flow Meter.....................................................................................................34 6.2.13 Automated Condensate Sumps...............................................................................34 6.3 Maintenance Records and Schedule..................................................................................... 34 7 Data Management and Evaluation..................................................................................................36 7.1 The Data — Collection, Assessment, and Management...................................................... 36 7.2 Data Collection..........................................................................................................................36 8 Safety.................................................................................................................................................... 38 8.1 Contact Information.................................................................................................................. 38 9 Listing of Permits..................................................................................................................................39 Newport Terrace Landfill — O&M Manual List of Figures No. 1 Project Site Location............................................................................................................................4 2 Probe Locations and Outline of Fill Areas.......................................................................................5 List of Tables No. 1 Typical Landfill Gas Components.....................................................................................................7 2 Non -Methane Organic Compounds Detected at Newport Terrace...........................................8 3 Monitoring Probe Data....................................................................................................................1 1 4 Extraction Well Casing Depths....................................................................................................... 16 5aMonitoring Schedule.........................................................................................................................27 5b Summary of Regulatory Reporting Requirements.......................................................................29 6a Summary of Routine Maintenance of Equipment.........................................................................34 6b Preventative Maintenance Schedule for GX4.............................................................................34 Appendices A System Drawings B Gas Extraction Well Boring Logs C SCAQMD Permit To Construct/Operate — Collection System D SCAQMD Permit to Construct/Operate — Treatment System E Monitoring Forms F Contact Information G Rule 1150.1 Compliance Plan H Instrumentation and Equipment Literature on CD: DXA120 DAQSTANDARD DXAdvanced Electronic Manual Operation Guide User's Manual Communication Interface Manual User's Manual for DAQSTANDARD for DXAdvanced Series 454FT User's Guide Flow Units Conversion Table Quick Start Guide Series 454FT — Insertion Mass Flow Transmitter User's Guide State Diagram Newport Terrace Landfill — O&M Manual INTRODUCTION 1.1 OPERATION AND MAINTENANCE MANUAL OBJECTIVES The City of Newport Beach (City) has entered into an agreement with Newport Condominium Association, Inc. (NCA) to operate and maintain the LFG collection and control system at the Newport Terrace Landfill. The purpose of this manual is to familiarize the reader with and to provide step-by-step instructions for the operation, maintenance, and monitoring of the Landfill Gas (LFG) control system at the Newport Terrace site. It is recommended that qualified, experienced professionals operate, maintain, and monitor the system, especially if LFG is detected at or outside the property boundary or if the system is modified significantly. It is further recommended that this manual be updated periodically to reflect the current operating conditions, such as for a change in operation, when extensive reconstruction or modifications have been made, when maintenance or monitoring events provide new information, changes in regulations, or other important events occur that may affect the monitoring regime. At a minimum, the manual should be reviewed annually to determine if modifications are needed. 1.2 APPLICABLE PERMITS AND REGULATIONS The LFG system at Newport Terrace operates under the following permits issued by the South Coast Air Quality Management District (AQMD): 1.2.1 No. F85011, Issued November 6, 2006 (Appendix C) This "Permit to Construct/Operate" principally addresses the LFG treatment (carbon adsorption and system, setting requirements for operation, monitoring and reporting). A summary of requirements follows. • LFG flow through the treatment system shall not exceed 375 standard cubic feet per minute (scfm). • Concentration of total non -methane organic compounds (TNMOC) in inlet gas (before treatment) shall not exceed 250 parts per million by volume (ppmv) measured as hexane. • Concentration of TNMOC after treatment shall not exceed 20 ppmv measured as hexane at 3 percent oxygen, or shall be reduced by at least 98 percent by weight (relative to inlet concentration). • Annual source test required (see Item #10 in Permit, Appendix C). • Monthly sampling of inlet and treated gas for volatile organic compounds (methane and TNMOC) and Toxic Air Contaminants (TACs). Newport Terrace Landfill — O&M Manual • Monthly sampling of Sulfa -Treat system exhaust for sulfur compounds (as hydrogen sulfide). • Emissions at the treatment exhaust shall not exceed the following concentrations: - Chloroform 0.10 ppmv - Vinyl Chloride 0.17 ppmv - Hydrogen Sulfide 0.1 ppmv • If TNMOC concentration at the outlet of the primary (lead) adsorber exceeds 20 ppmv, the carbon in the primary adsorber shall be replaced or the vessels rotated (see Item #16 in Permit). 1.2.2 No. F85012, Issued November 2, 2006 (Appendix D) This "Permit to Construct/Operate" principally addresses the LFG collection. It sets conditions for the construction/installation of extraction wells and collection piping, principally to prevent nuisances and air quality impacts during underground construction (drilling and trenching). The Permit allows for a control system of up to 75 vertical extraction wells (the newly installed system has 15). The future construction of additional wells (if needed for additional control and/or replacement of failed wells) would need to conform to this Permit. 1.2.3 Rule 1150.1 Compliance Plan, Issued December 17, 1999 (Appendix G) AQMD Rule 1150.1 addresses surface emissions and lateral (subsurface) migration of LFG. All of the surface emissions monitoring requirements contained in Rule 1150.1 have been waived by the AQMD for the Newport Terrace site (see Appendix G). Monthly perimeter probe monitoring is required, which is duplicative of requirements under CCR Title 27 (see next section). However, the Rule 115 0. 1 Plan does add these requirements to the routine probe monitoring: • Obtain laboratory analyses of a gas sample from a monitoring probe: - Toxic air contaminants (TAC) from the probe with the highest concentration during any one of the monthly monitoring events during the quarter. - Total Organic Compounds (TOCs) — if the TOC concentration measured with a Flame Ionization Device or approved alternative instrument exceeds 5 percent by volume in any of the probes, a single sample from the probe with the highest concentration (from the monthly monitoring events during the quarter). 1.2.4 California Code of Regulations (CCR), Title 27 These regulations govern subsurface lateral gas migration, and are administered by the local enforcement agency (LEA), in this case the Orange County Environmental Health. 2 Newport Terrace Landfill — O&M Manual Conformance requires monthly monitoring and reporting of perimeter gas migration probes. Methane concentrations in the probes may not exceed 5 percent by volume. 1.3 SITE LOCATION AND PHYSICAL DESCRIPTION The Newport Terrace Landfill (Newport Terrace) is located at corner of Balboa Boulevard and 19th Street in the City of Newport Beach, CA (see Figure 1). The site contains the Newport Terrace Condominium complex that consists of 62 residential buildings containing between two to eight condominium units each, parking garages and ancillary buildings. All units are residential use and many families live in them. It is assumed that most are owner -occupied; however, some are rental units. The condominium complex was constructed at the site in 1972; prior to that, it was vacant land partially used for aggregate mining and land -filling (until 1967). A portion of the condominium complex overlies an inactive municipal solid waste (MSW) landfill, operated in the 1960's and 1970's. The landfill actually has two distinct areas: (1) the main landfill, and (2) the "rubble fill," which received principally inert waste. The areas are delineated on Figure 2. An LFG system was installed in landfill areas in the early 1980's to protect the surrounding residential improvements. A substantial reconstruction/replacement of the LFG system was initiated in September 2007 and completed in May 2008. The new system consists of 15 gas extraction wells, associated underground collection piping, four pneumatic condensate traps, and an indoor treatment facility consisting of blowers, hydrogen sulfide removal and carbon adsorption equipment. The system also contains cross -connections to allow extraction from portions of the previously existing gas control system. In addition, about 40 gas migration monitoring wells (including about 80 probes) exist at the site. A complete set of as -built drawings of the reconstructed LFG system is contained in Appendix A. The new system was constructed pursuant to corrective action ordered by the Orange County Local Enforcement Agency (LEA), the California Integrated Waste Management Board (CIWMB), and permits from the South Coast Air Quality Management District (SCAQMD) Newport Terrace Landfill — O&M Manual MAP NEWPOR: PHOTOREVISE X A J 1�1 ir T) IL TF z Soh L L J —Vur. Fire Ets • Res- Ilk LI 0: J FA I IRvr iF-W STATE HOSPITAL Ll z rr. f1 P3 CC i Jr r Liz, wlu., PROJrCT SITE inn wJ6' FIX, Figure 1. Project Site Location. 4 ST II 0(A K"rcf 2.000 RCX- SCALE IN FEET S�: 5r L!, mr N669� Newport Terrace Landfill — O&M Manual mmm►= GRAPHIC SCALE G 200 400 SCALE IN FEET BOUNDARY UNE ewxvx sranora 0 � � _�_ =_ Figure 2. Probe Locations and Outline of Fill Areas. 5 0 D 0 Newport Terrace Landfill — O&M Manual 1.4 SITE OWNER/OPERATOR The City of Newport Beach both owns and operates the LFG control system, although the NCA owns the property. The contact person for the City is: George Murdoch City of Newport Beach Municipal Operations Department 3300 Newport Boulevard P.O. Box 1768 Newport Beach, CA 92658-8915 (949) 644-3011 1.5 LANDFILL GAS HAZARDS LFG is produced as part of the decomposition processes that occur following the burial of organic refuse materials. LFG contains methane which is a flammable gas — if exposed to an ignition source, methane is explosive at concentrations between 5 and 15 percent v/v, the so- called lower and upper explosive limits (LEL and UEL). An LFG mixture is flammable at higher methane concentrations. Production of LFG can create pressure within the landfill which acts as a driving force, pushing LFG into surrounding soils, which can result in off-site subsurface movement (migration). The placement of cover soil or other means of capping (i.e., pavement or landscaping) over the landfill site or adjacent areas reduces free venting of LFG to the atmosphere and promotes lateral LFG migration toward off-site locations. Methane migrating through soils from landfill sites may pose a safety threat if it is allowed to infiltrate into an enclosed space, and is ignited by a spark or other ignition source. Methane can accumulate in buildings above the ground surface, particularly in wall spaces. The distance and speed of LFG migration are functions of the rate of gas generation, characteristics of the landfill cover (which regulates internal pressure buildup), the elevation of groundwater, and the permeability of adjacent soils. The composition of the waste and the availability of moisture are the principle factors determining the amount of LFG generated. Construction debris with low organic content produces a small volume of gas, whereas municipal wastes with a high organic content can produce substantial volumes of LFG. The age of the landfill also affects the rate of gas generation. Decomposition of refuse, and the resulting gas generation, will slow over time as the organic fraction of the waste is consumed. It has been observed that significant gas production and the potential for a migration problem may proceed for 20 to 50 years after the placement of refuse in the landfill site. The LFG system at Newport Terrace was installed to control potential off-site subsurface migration. As generated, LFG is primarily composed of 45 to 60 percent methane and 40 to 55 percent carbon dioxide. In older landfills, such as Newport Terrace, the LFG is often naturally diluted 0 Newport Terrace Landfill — O&M Manual with nitrogen and oxygen due to air intrusion into the waste mass. LFG also includes small amounts of ammonia, sulfides, hydrogen, carbon monoxide, and non -methane organic compounds (NMOCs) such as trichloroethylene, benzene, and vinyl chloride. Table 1 lists typical landfill gases, their percent by volume, and their characteristics. NMOCs consist of hazardous air pollutants (HAPs) and volatile organic compounds (VOCs), which can react with sunlight to form ground -level ozone (smog) if uncontrolled. Some of the NMOCs also are odorous. Rule 1150.1 identifies a list of specific Toxic Air Contaminants (TACs) which must be sampled for within collected and treated gas, as well as at probes (see Section 1.2.1 and 1.2.3). Table 1. Typical Landfill Gas Components Component Percent by Characteristics Volume Methane 45-60 Methane is a naturally occurring gas. It is colorless odorless, and can be explosive. Landfills are the single largest source of U.S. man-made methane emissions. Carbon Dioxide 40-55 Carbon dioxide is naturally found at small concentrations in the atmosphere (0.03%). It is colorless, odorless, and slightly acidic. Nitrogen 2-5 Nitrogen comprises approximately 79% of the atmosphere. It is odorless, tasteless, and colorless. Oxygen 0.1-1 Oxygen comprises approximately 21 % of the atmosphere. It is odorless, tasteless, and colorless. Ammonia 0.1-1 Ammonia is a colorless gas with a pungent odor. Non -Methane Organic 0.01-0.6 NMOCs are organic compounds (i.e., compounds Compounds (NMOCs) that contain carbon). (Methane is an organic compound but is not considered an NMOC.) NMOCs may occur naturally or be formed by synthetic chemical processes. NMOCs most commonly found in landfills include acrylonitrile, benzene, 1,1-dichloroethane, 1,2 -cis dichloroethylene, dichloromethane, carbonyl sulfide, ethyl -benzene, hexane, methyl ethyl ketone, tetrachloroethylene, toluene, trichloroethylene, vinyl chloride, and xylenes. Hydrogen Sulfide 0-1 Hydrogen sulfide and other sulfur compounds (e.g., dimethyl sulfide, mercaptans) are commonly found in landfills that give the landfill gas mixture its rotten -egg smell. Sulfides can cause unpleasant odors even at very low concentrations. 7 Newport Terrace Landfill — O&M Manual Table 1. Typical Landfill Gas Components Component Percent by Characteristics 10.0 Volume 2.0 Hydrogen 0-0.2 Hydrogen is an odorless, colorless gas. Carbon Monoxide 0-0.2 Carbon monoxide is an odorless, colorless gas. Source: Tchobangolous, Theisen, and Vigil 1993; EPA 1995. 1.5.1 Landfill Gas Levels at Newport Terrace At Newport Terrace, with the installation of the new vertical wells and collection piping, the concentration of methane in the collected gas is averaging about 4 to 5 percent. (Before the 2007-08 modification of the system, the gas collected usually contained methane concentrations under 1.0 percent by volume, because (a) the collection piping had deteriorated over the years, allowing air intrusion; and (b) the original trench collectors were very shallow, and the system was located at the margins of refuse burial, possibly in native soil.) At Newport Terrace, based on monitoring performed since start-up of the new system, total NMOCs have been detected in the area of 40 ppmv (after carbon adsorption the concentrations have been reduced to under 10 ppmv). TACs in the collected gas have been consistently been detected at the levels (parts per billion, ppbv) shown in Table 2. Table 2. Non -Methane Organic Compounds Detected at Newport Terrace Compound Average Level Detected (ppbv) Benzene 10.0 Chlorobenzene 2.0 Dichlorobenzenes 15.0 Dichloromethane 1.5 Perchloroethylene 3.0 Toluene 50.0 Tricholorothene 3.0 Chloroform 10.0 Vinyl Chloride 5.0 m+p xylenes 90.0 o -xylene 30.0 8 Newport Terrace Landfill — O&M Manual After treatment, all levels decline to single -digit ppbv or non-detectable, with the exception of Vinyl Chloride, which remains at the 5.0 ppbv level, but well below the AQMD permit standard of 170 ppbv (0.17 ppmv). Hydrogen sulfide has not been detected in significant amounts. Title 27 of the California Code of Regulations (27 CCR), Section 20917, requires all municipal solid waste landfill operators to ensure that the concentration of methane gas generated from their landfill does not exceed 1.25 percent (by volume in air) in all on-site enclosed structures, excluding LFG control structures, nor 5 percent (by volume in air) in soils at the property boundary. Further, air quality regulations have been adopted which limit the amount of LFG that can be released into the atmosphere. SCAQMD Rule 1150.1 supports Title 27 by requiring subsurface monitoring, but also addresses surface emissions monitoring (although Newport Terrace is largely exempt due to its age.) 0 Newport Terrace Landfill — O&M Manual 2 DESCRIPTION OF LFG CONTROL SYSTEM 2.1 SYSTEM OBJECTIVES AND GENERAL DESCRIPTION The primary objective of the Newport Terrace LFG system is to maintain methane concentrations of no more than 5 percent at the property boundary. The secondary objective of the system is to reduce emissions of non -methane organic compounds (NMOCs) of the collected LFG to less than 20 parts per million by volume (ppmv) (measured as hexane at 3 percent oxygen) or 98 percent destruction, thereby protecting air quality. The reduction of NMOC emissions is accomplished via the newly installed carbon adsorption units. These objectives meet the goals of regulations which govern the site, primarily those summarized below: • California Code of Regulations (CCR) Title 27, Section 20917 et seq. This code requires the site owner to monitor for the presence or movement of subsurface LFG toward off-site locations. The monitoring is typically accomplished through installation of probes at the property boundary. This code also requires the owner to maintain a methane concentration of 5 percent or less at the property boundary and a methane concentration of 25 percent or less within on-site structures. The Local Enforcement Agency (LEA) administers the above regulation for the state. The LEA for the Newport Terrace site is the: Orange County Health Care Agency Environmental Health Division 1241 East Dyer Road, Suite 120 Santa Ana, CA 92705 (714) 433-6000 • South Coast Air Quality Management District (AOMD) Rule 1150.1 Compliance Plan. The Newport Terrace site applied for a Rule 1150.1 Compliance Plan (Application #355993) which was approved on December 17, 1999. This plan describes compliance procedures for control of gaseous emissions from municipal solid waste landfills. The plan may be referenced in Appendix G. South Coast Air Quality Management District 21865 Copley Drive Diamond Bar, CA 91765 (909) 396-2000 IE Newport Terrace Landfill — O&M Manual The Newport Terrace LFG Control System consists of three major components: • Monitoring Probes. Thirty-nine multi -depth monitoring wells, three containing three nested probes and the rest containing two probes, have been installed around the site boundary. (Note: These probes were all in place prior to the 2007-08 system upgrade.) • Extraction Wells. Seventeen vertical extraction wells have been installed at the landfill. Fifteen of the extraction wells were constructed in 2008 and two shallow extractions wells were constructed in 2011. The previously installed horizontal collectors are connected to the new system, and can be utilized in conjunction with the new wells, although their condition is not known. • Blower Station. A blower station is located in the Northwest corner and contains blower equipment, activated carbon adsorption units, a Sulfatreat system, and condensate separation equipment, all installed as part of the 2007-08 construction. Record drawings for the system installed in 2008 are attached in Appendix A. 2.2 MONITORING PROBES Monitoring probes are located outside of refuse around the site perimeter. (These probes were part of the original LFG system and pre -date the 2008 construction). All the probes are multi - depth and contain casings which are capable of providing readings for different subsurface zones. Five of the probes contain three casings. The data that is known about the probes, including depth where available, is listed in Table 3. Probe locations are shown on Figure 2. Table 3. Monitoring Probe Data Probe Material Depth (ft) Notes CP -01A 1/2 PVC 8.51 CP -01 B 1/2 PVC 25.3 CP -01 C 40.23 PVC CP -02A Tubing CP -02B Tubing CP -03A Tubing CP -03B Tubing CP -04A Tubing CP -05A Tubing CP -05B Tubing Newport Terrace Landfill — O&M Manual Table 3. Monitoring Probe Data Probe Material Depth (ft) Notes CP -06A Tubing Vault cover broken, not marked CP -06B Tubing Vault cover broken, not marked CP -07A 3/4 PVC 9.31 CP -07B 3/4 PVC 25.25 CP -07C 3/4 PVC 40.26 CP -08A 3/4 PVC 10.23 CP -08B 3/4 PVC 25.26 CP -08C 3/4 PVC 39.92 CP -09A 3/4 PVC CP -09B 3/4 PVC 21.2 CP -09C 3/4 PVC 38.95 CP -1 OA Tubing CP -10B Tubing CP -1 1 A Tubing CP -1 1 B Tubing CP -12A - CP -12B - CP -13A Tubing CP -13B Tubing CP -14A Tubing CP -14B Tubing CP -15A Tubing No Valves CP -16A Tubing CP -16B Tubing CP -17A Tubing CP -17B Tubing CP -18A 1/2 PVC 15 CP -1 8B 1/2 PVC 23 12 Newport Terrace Landfill — O&M Manual Table 3. Monitoring Probe Data Probe Material Depth (ft) Notes CP -19A Tubing CP -19B Tubing CP -20A Tubing CP -20B Tubing CP -21 A 3/4 PVC CP -21 B 3/4 PVC CP -22A - CP -22B - CP -23A 1/2 PVC CP -23B 1/2 PVC CP -23C 1/2 PVC CP -1C Tubing CP -4B Tubing CP -7C 3/4 PVC CP -8C 3/4 PVC CP -9C 3/4 PVC P-1 A Tubing P-1 B Tubing P -7A Tubing P-713 Tubing P -8A Tubing P-813 Tubing P -9A Tubing P-913 Tubing P -14A Tubing P -14B Tubing P -15A Tubing P -15B Tubing 13 Newport Terrace Landfill — O&M Manual Table 3. Monitoring Probe Data Probe Material Depth (ft) Notes P-1 6A Tubing P-1 6B Tubing P-21 A Tubing P-21 B Tubing P -25A Tubing P -25B Tubing P -27A Tubing Plugged P -26A Tubing P -26B Tubing P -27B Tubing P -28A Tubing P -28B Tubing Water Blocked P -30A 5 P -30B 15 P-31 A 3/4 PVC 5 P-31 B 3/4 PVC 15 P -32A 3/4 PVC 5 P -32B 3/4 PVC 15 P -33A 1/2 PVC 5 P -33B 1/2 PVC 15 14 Newport Terrace Landfill — O&M Manual 2.3 EXTRACTION WELLS The vertical extraction wells (EW) numbers 1, 2, 3, 4, and 5 are located within the refuse footprint (boring logs confirm intercepting refuse). EW 6 through 11 are in soils outside the perimeter of refuse placement. EW 12, 13, 14 and 15 were completed in the rubble fill area. The wells depths are shown in Table 4, and each contains a casing perforated in the lower 1/3 zone, approximately (see boring logs, Appendix B). Table 4. Extraction Well Casing Depths Well No. Depth (ft) EW -1 30 EW -2 30 EW -3 20 EW -4 29 EW -5 29 EW -6 29 EW -7 29 EW -8 29 EW -9 29 EW -10 29 EW -1 1 29 EW -12 29 EW -1 3 20 EW -13S 12 EW -14 23 EW -15 20 EW -15S 12 With the exception of EW -13S and EW -15S, the remaining extraction well casings are made of 3 -inch -diameter solid Schedule 80 PVC pipe, with the bottom third made of 3 -inch -diameter slotted Schedule 80 PVC pipe (a detail is shown in the system drawings, Appendix A). The casings for extraction wells EW -13S and EW -15S are made of 4 -inch -diameter solid Schedule 40 PVC pipe, with the bottom 4 feet made of 4 -inch -diameter slotted Schedule 40 PVC pipe. The well casing is installed straight and plumb in the center of the borehole. Wells EW -13S and EW -15S have 8 -inch diameter boreholes; wells EW -12 through EW -15 have 12 -inch boreholes; and, remaining wells have 18 -inch diameter boreholes. The annular space surrounding the slotted well casing is filled with specified filter pack consisting of clean gravel backfill 1 foot above the top of the slotted casing. The gravel backfill is then covered with a 1 -foot layer of clean soil, followed by a 3 -foot bentonite plug. The casing is backfilled with soil up to 4 feet 6 inches below ground surface, and an additional 2 -foot bentonite plug is then placed. The well is Newport Terrace Landfill — O&M Manual completed by installing a valve box with concrete surround and a gravel base. A control valve and monitoring tubing with labcock valves are also installed with a valve box. 2.4 BLOWER STATION The blower station is located within a building with locking doors. Four blowers, a moisture separating tank, two activated carbon adsorber units, a sulfatreat system, and electrical controls are located within the blower station. Highlights of the major blower station components are given below. 2.4.1 Moisture Separating Tank The first equipment LFG reaches in the station is the moisture separator (knockout) vessel. The LFG is introduced into the knockout near the midpoint and exhausted at the top. While rising through the tank, condensate and particulates are removed from the gas stream through a filter (demister). This condensate drains from the knockout bottom to a pipe and flows by gravity to the condensate sump (CS -1). 2.4.2 Blowers Four blowers are installed in the station. There are two CP404M HZS blowers and two CP808 LFG blowers. Information on the blowers is provided below. Motor Model Numbers: HsS blowers: Rotron; Saugerties, NY 12477 CP-404FQ58MLR - 1.0 hp 115/230 V, 60 Hz, 1 Phase 107 cfm capacity each Type: Sealed Regenerative w/Explosion-Proof Motor LFG Blower #1: Airtech; Englewood, NJ 07631 3BA1630 - 5 hp 208-230/460 V, 60 Hz, 3 Phase 225 cfin capacity LFG Blower #2: Rotron; Saugerties, NY 12477 CP-808FX5MWLR - 5.5 hp 230 V, 60 Hz, 1 Phase 300 cfin capacity 2.4.3 Activated Carbon Adsorption Units VFD Direct Drives & Controls, Orange, CA 92865 Hitachi X200-075LFU2 - 10 hp 230 V input Single Phase/ 230 V output 3 Phase Two skid mounted activated carbon adsorption units (vessels), installed in series, are located within the blower station, each containing 2,000 lbs of material. The carbon is R 4X8 series granular activated carbon (GAC) from Baker Filtration. The purpose of the activated carbon is W. Newport Terrace Landfill — O&M Manual to remove the non -methane organic compounds (NMOCs) of the LFG by adsorption. A sampling port is provided at the exhaust side of each unit to monitor the carbon performance. Upon detection of unacceptable levels of NMOCs at the first vessel exhaust which is specified in the AQMD permit as 20 ppm as hexane (see Appendix D), the material is considered exhausted and the unit contents must be removed and reloaded with fresh (regenerated) GAC. The LFG passes through each adsorption unit in series, and the units are intended to operate as a primary unit and secondary unit. When carbon in the primary becomes "saturated," i.e., can no longer adsorb NMOCs, "breakthrough" will be detected and the secondary unit becomes the principal adsorber. At that point, fresh carbon should be ordered for the primary unit; and after it has been replaced, the flow should be reversed (using the available valves), so that the secondary unit becomes the primary. (For example, if the system is running with gas flowing from Vessel A to Vessel B, when the gas exiting Vessel A exceeds 20 ppm NMOCs, replacement carbon should be ordered and put into Vessel A, then the system should be reversed such that the gas flows from Vessel B to Vessel A.) The LFG control system must be shut down during unloading and reloading of carbon. 2.4.4 Sulfatreat System One skid mounted sulfur absorber is located within the blower station, containing 2,000 lbs of material ("Sulfatreat"). The purpose of the Sulfatreat system is to remove the sulfur compounds of the LFG collected in header line `B". A sampling port is provided at the exhaust and intake sides to monitor the Sulfatreat performance. The discharge of the Sulfatreat system is into the carbon adsorption units. Upon detection of unacceptable levels of sulfur measured as H2S at the Sulfatreat exhaust ("breakthrough") which is specified in the AQMD permit — a maximum of 0.1 ppmv sulfur at the exhaust of the carbon system (see Appendix D) — the material is considered exhausted and the unit contents must be removed and reloaded with fresh Sulfatreat material. The LFG control system serving Line B is shut down during unloading and reloading of Sulfatreat material in the unit. 2.5 SITE SECURITY The blower facility is contained within a lockable building — keys are maintained by the city staff and its contractors. The building doors are connected to an alarm system — entry sends a signal to the city Utilities Department. Authorized personnel are issued two keys — one to enter the building and a second to suppress the alarm. The operations contractor is be responsible for ensuring appropriate signage is placed on the exterior of the blower facility (e.g. "Keep Out"). Well control valves, monitoring probes, condensate sumps are contained in valve/utility boxes as illustrated on the as-builts (see Appendix A), and require a lifting tool and wrench to access. 17 Newport Terrace Landfill — O&M Manual 3 LFG CONDENSATE HANDLING SYSTEM 3.1 LFG CONDENSATE LFG condensate is a liquid which develops as LFG cools while flowing in the collection system. It is mostly water but contains some dissolved organics and often is acidic (due to carbon dioxide in the LFG). LFG condensate must be removed from the collection piping system or it could collect in low points and cause gas flow blockage. Condensate shall be disposed of as hazardous waste unless otherwise determined by laboratory tests. 3.2 GAS CONDENSATE HANDLING SYSTEM DESCRIPTION Condensate collection facilities are shown on Sheets 3 (location) and 5 (details) of the system drawings (Appendix A). To collect and remove LFG condensate, four sumps (CS -1 through -4) are incorporated into the collection header (Line A), and a moisture knockout is located in the blower station. The sumps are pneumatic in operation — air is supplied from a compressor in the blower station and via HDPE pipes in the collection header trenches. When the liquid level in the sump reaches a certain point, a float -control valve activates the air supply to the pneumatic pump, and liquid is pumped back into the header to continue flowing downhill to the next sump/low point, where the process is repeated. At the downhill end of the header system (past EW 11), the liquid is pumped out of the last trap to a discharge line which runs north into an existing city sewer manhole in the condominium development in Seabird Court. For Line B, condensate is allowed to drain back into EW 14. In the blower station, all gas travels through the condensate knockouts (one each for Line A and B). The condensate flows by gravity to CS -1 where it is pumped into the header to ultimately flow to the city sewer. 3.3 HANDLING LFG CONDENSATE LFG condensate may contain many trace chemicals and be highly biologically active. Appropriate protective gloves and splash protection equipment should always be employed when working with LFG condensate. Operating personnel should always avoid direct skin contact. 18 Newport Terrace Landfill — O&M Manual 4 SYSTEM OPERATION 4.1 OPERATIONAL CRITERIA The Newport Terrace LFG Control System operational criteria are based on the system design, regulatory requirements, and past experience with other LFG extraction systems. The criteria summarized below follow the AQMD Permit to Construct/Operate (PTO) (see Appendices C and D): • Methane concentration shall be maintained at less than 5 percent by volume at all perimeter probes. • The concentration of total NMOCs at the final outlet of the carbon adsorption units shall not exceed 20 ppmv or achieve 98 percent destruction removal efficiency. • The sulfur concentration, measured as HZS at the final outlet of the carbon adsorption unit shall be below 0.1 ppmv. A more extensive discussion of permitting requirements is presented in Section 1.2. 4.2 SYSTEM START-UP The system requires start up upon power shutdown, carbon adsorption unit replacement, blower maintenance, or other operation interruption. Only qualified, experienced staff is recommended as operators to start the system using the following guidelines: Check for alarms before entering blower house. 2. Check the system instrumentation for malfunctions (Yokogawa recorder, Kurz flowmeter, Raco autodialer, General Monitors gas detectors), which are indicated by trouble -lights on the control panel. 3. Check air compressor pressure (normal operating pressure is 100 psig). 4. Confirm main gas inlet valve HV -1 is open. 5. Confirm inlet and outlet valves (HV -2 and 3 or HV -4 and 5) are open for the selected blower. 6. Confirm valves for the Carbon vessels are set correctly (for V-1 primary and V-2 secondary, valve position is as follows: HV -6, 9, 10, and 13 open; valves HV -7, 8, 11, and 12 closed). 7. Confirm hydrogen sulfide gas inlet valve HV -14 is open. IM Newport Terrace Landfill — O&M Manual 8. Confirm inlet and outlet valves (HV -15 and 16 or HV -17 and l 8) are open for the selected Sulfatreat blower. 9. Confirm Sulfatreat outlet valve HV -19 is open. 10. Select Blower No. 1 or Blower No. 2 for the methane system and select Blower No. 3 or Blower No. 4 for the hydrogen sulfide system. (Note: Use hours meters on blowers to balance long-term usage.) 11. Turn the blower control selector switches to "AUTO." 12. Confirm that selected blowers are operating. 13. Confirm that operating parameters are within acceptable limits. For the initially installed equipment, the following should apply: - Main system —vacuum maximum 60 inches; flow between 200 scfm and 300 scfm (maximum under SCAQMD Permit). - H2S system — vacuum maximum 45 inches; flow between 40 to 80 scfin. - Inlet gas temperature maximum below 140°F. Use the following procedure to shutdown the treatment system: 14. Turn blowers I through 4 to the "OFF" position. 15. Close inlet valves HV -1 and HV -14. 4.3 SYSTEM SHUTDOWN It will be necessary to periodically shut the system down for repair or service. Use the following procedure to shutdown the treatment system: 1. Turn blowers 1 through 4 to the "OFF" position (on control panels). 2. Close inlet valves HV -1 and HV -14. 3. Additional steps may be required for extensive maintenance or repair activities. 4.4 OPERATION SCHEDULE The blower station is equipped with a timer for an automatic start up and shutdown to allow the system to operate a minimal amount of hours while still preventing methane concentrations above 5 percent at the perimeter. 20 Newport Terrace Landfill — O&M Manual The operating schedule (as of October 2008) is 10 hours per day, 7 days per week. It may be possible over time to reduce these hours to minimize operating costs and system wear, while meeting regulatory performance goals. Iteratively, the system flow should be reduced while watching probe methane concentrations — until monitoring data suggest that further reductions in operating times could result in methane exceeding the 5 percent limit. Changes to the operating schedule should be discussed with and approved by city staff. 4.5 REMOTE MONITORING BY CITY Remote monitoring of the on-site alarm systems within the equipment building will be handled by the Utilities Department. Such monitoring will be accomplished by wireless means with a telephone land -line connection as backup. Information relative to power outage, blower failure, gas detection, and unauthorized building entry is transmitted to the city's SCADA system on a real-time basis which is continuously monitored. Operation and maintenance of remote monitoring equipment are the responsibility of the Utilities Department. Operation and maintenance of the on-site alarm system within the equipment building are the responsibility of the O&M contractor. The O&M contractor shall provide contact information to the Utilities Department so that alarms detected by the remote monitoring can be relayed to the O&M contractor for response on a "24/7" basis. The contact information must be kept current during the O&M contract term. 21 Newport Terrace Landfill — O&M Manual 5 SYSTEM MONITORING 5.1 MONITORING CRITERIA Routine monitoring is scheduled at the Newport Terrace LFG Control System to check its conformance with the regulatory criteria and permits described in Section 3 of this report, as follows: • Methane concentration shall be maintained at less than 5 percent by volume at all perimeter probes. • The concentration of total NMOCs at the final outlet of the carbon units shall not exceed 20 ppmv or achieve 98 percent destruction removal efficiency. • Sulfur concentration measured as H2S at the final outlet of the carbon adsorption system shall not exceed 0.1 ppm. In addition, monitoring is performed to keep the system running at its optimum efficiency. Experienced, qualified LFG technical staff is recommended to perform the monitoring tasks. 5.2 MONITORING EQUIPMENT Monitoring techniques described in this manual involve commonly used battery-operated instruments which have proven to be easy to use and provide reliable results. The following monitoring equipment is needed to perform recommended monitoring. Alternative equipment may be utilized if it can provide suitable, dependable data. 5.2.1 Combustible Gas Monitoring Instrument For monitoring methane at the extraction wells, monitoring probes, and the blower station, a portable combustible gas analyzer is necessary. At a minimum, the gas analyzer must be capable of measuring methane in percent by volume and percent LEL. Instruments are available which measure methane as well as oxygen, carbon dioxide, pressure, vacuum, and temperature, but these are more expensive. Measurement of carbon monoxide and temperature may be considered optional and warranted under special conditions, such as suspicion of subsurface combustion. Gas instruments are to be calibrated in accordance with the manufacturer's procedures and schedules. There are numerous portable gas instruments available. However, the preferred instrument is the Landtec GEM -2000. This instrument is recommended and detects methane, oxygen, carbon dioxide, and nitrogen, as well as static pressure and flow rate. 5.2.2 Photo Ionization Detector (PID) A PID is recommended (referred to as an organic vapor analyzer in the SCAQMD Permit to Operate) to measure the emission at the carbon adsorption unit exhaust. A PID measures all organic components in the gas stream, except methane. 22 Newport Terrace Landfill — O&M Manual Either of the following instruments may be considered appropriate for this site: Thermo Electron TVA 100013 Vapor Analyzer www.thermo.com MiniRAE 2000 RAESales@raesystems.com 5.2.3 Hydrogen Sulfide Measurement Drager tubes or H2S detectors are used to measure the sulfur emissions as H2S. A bag sample needs to be taken from the outlet of the Sulfatreat system for testing for H2S. A Drager tube or other instrument is used to determine if the sulfur emissions are above 0.2 ppmv. A bag sample can be taken using a sampling box. SCS recommends taking bag samples to measure the sulfur emissions at the rubble fill wells (EW -12, EW -13, EW -14, and EW -15). 5.2.4 Pressure/Vacuum Gauges Portable pressure/vacuum gauges are required for field measurements at the extraction wells and monitoring probes. Appropriate, permanent gauges are installed on-line at the blower station piping. (Note: The GEM 2000 allows direct reading of static and differential pressures and so can service this purpose.) The ranges of pressure/vacuum typically encountered at sites such as Newport Terrace would be from 0 to 30 inches -water column. Magnehelics or a digital manometer may also be used for pressure measurements. 5.2.5 Miscellaneous Tedlar bags will be required for LFG samples taken at the carbon adsorption unit inlets and emission sample at the outlet of the final carbon adsorption unit. Tedlar bag and Drager Tube that can measure down to 0.2 ppmv H2S or equivalent equipment is necessary to measure the inlet and exhaust of the Sulfatreat system. Gas samples from the inlet are analyzed for VOCs and speciated for Toxic Air Contaminants (YACs, as defined in SCAQMD Rule 1150.1) and the gas samples from the exhaust of the carbon system are analyzed for chloroform, vinyl chloride, and hydrogen sulfide in the laboratory in accordance with the AQMD permit. 5.3 MONITORING PROCEDURES Monitoring procedures include visual inspection, meter reading, and testing with field instruments. Monitoring results should be recorded directly into the instrument (if capable) or onto an inspection form (Appendix E). 23 Newport Terrace Landfill — O&M Manual The system is monitored for the following items: 24 Subject Method Methane Inlet System Inlet separator Differential pressure, in H2O Gauge reading Inlet gas temperature Temperature, °F Gauge reading Inlet gas pressure Pressure, in H2O Gauge reading Blower discharge temperature Temperature, °F Gauge reading 1-12S Inlet System Inlet Separator Differential pressure, in H2O Gauge reading Sulfatreat discharge temperature Temperature, °F Gauge reading Sulfatreat discharge pressure Pressure, in H2O Gauge reading Blower discharge pressure Pressure, in H2O Gauge reading Instrumentation - Operating System Gas flowrate Flowrate, SUM Kurz meter Total gas flow Volume, SCF Kurz meter Major gases (CH4, CO2, N2, 02) Percent by volume GEM 2000 (inst. test) H2S concentration ppm Drager Tube (inst. test) Air compressor pressure Pressure, psi Gauge reading Air compressor hours Elapsed time, hr Gauge reading Blowers (H -O -A) Lead blowers Note switch position Blower hours (each) Elapsed time, hr Gauge reading Blower Station Automated Safety Monitoring Percent combustibles - percent LEL - General Monitors Sensor/Alarm 1-12S concentration- ppm 1-12S - General Monitors Sensor/Alarm Carbon Adsorbers Vessel No. 1 inlet NMOC Concentration PID Instrument test Vessel No. 1 outlet NMOC Concentration PID Instrument test Vessel No. 2 outlet NMOC Concentration PID Instrument test Sulfatreat System outlet Sulfur Concentration (as H2S) Drager Tube or other inst. 24 Newport Terrace Landfill — O&M Manual Extraction Wells (each) Pressure/Vacuum Instrument test Temperature Instrument test Methane Instrument test Oxygen Instrument test Carbon Dioxide Instrument test Monitoring Probes (each) Pressure/Vacuum Instrument test Methane Instrument test Oxygen Instrument test Carbon Dioxide Instrument test All instrument readings are taken at cock valve hose fittings under the procedures noted below. 5.3.1 Carbon Adsorption Units (Each) 1. Connect Tedlar bag to V-1 inlet (SP -3) and fill bag. 2. Connect PID to Tedlar bag. 3. Open sample valve and record instrument reading upon stabilization (i.e., when gauge reading holds steady for several seconds). 4. Repeat for V-1 outlet (SP -8) and V-2 outlet (SP -9). 5.3.2 Sulfatreat System 1. Connect sample box with Tedlar bag inside to Sulfatreat vessel outlet (SP -6). 2. Start sample pump and fill Tedlar bag. 3. Connect Tedlar bag to H2S monitoring instrument to Drager tube. 4. For instrument: open sample valve and record instrument reading upon stabilization (i.e., when gauge reading holds steady for several seconds). 5. For Drager tube: break off the tip of Drager tube using the Drager tool. 6. Insert the Drager tube into the Drager pump. 7. Attach the Drager pump to the Tedlar bag. 25 Newport Terrace Landfill — O&M Manual 8. Open the Tedlar bag and slowly pump the gas out of the Tedlar bag using the Drager tube, making sure the pump counter clicks over. 9. Record the number of pumps. 10. Record the reading on the Drager tube and calculate the HZS concentration. 5.3.3 Extraction Wells (Each) It is important to take vacuum/pressure readings before methane or other gas chemistry readings. 5.3.3.1 Pressure/Vacuum 11. Connect pressure gauge hose to the sampling port fittings on the well side of flow control valve. 12. Record instrument reading upon stabilization (i.e., when gauge reading holds steady for several seconds). 13. Repeat pressure/vacuum reading Steps 1 and 2 for sampling port on header side of gate valve. 5.3.3.2 Gas Composition 14. Follow instrument manufacturer's procedure for startup and calibration of combustible gas monitoring equipment. 15. Record instrument reading for methane, carbon dioxide, oxygen and balance gas, if included, upon stabilization (i.e., when gauge reading holds steady for several seconds). 5.3.4 Monitoring Probes (Each) It is important to take vacuum/pressure readings before methane or other gas chemistry readings. 5.3.4.1 Pressure/Vacuum 1. Connect pressure gauge hose to shallowest cock valve hose fitting. 2. Open cock valve and record instrument reading upon stabilization (i.e., when gauge reading holds steady for several seconds). Close cock valve. 3. Repeat pressure/vacuum reading Steps 1 and 2 for all subsurface zone cock valves. 5.3.4.2 Methane Concentration 4. Follow instrument manufacturer's procedure for startup and calibration of combustible gas monitoring equipment. 5. Record instrument reading for methane, carbon dioxide, oxygen and balance gas, if included, upon stabilization. 26 Newport Terrace Landfill — O&M Manual 6. Close cock valve. 7. Remove hose and instrument. 8. Repeat Steps 4 through 8 for all subsurface zone cock valves. 5.3.4.3 Methane Concentration Exceedance When gas monitoring indicate concentrations of methane in excess of the compliance level, do some combination of the following to bring the probe back into compliance with the requirements of CCR Title 27: 1. If a probe has more than 5% methane, notify the Landfill owner and LEA within 1 business day of the monitoring event. 2. Within 7 days of the detection of exceedance verify the result by performing the following: • Monitor probe weekly. • Verify that the blower is running properly and that there are no water restrictions or air leaks in the pipe. • Increase and optimize landfill gas collection using the existing gas collection wells. This may require increasing the blower speed using the variable frequency drive. • Improve gas collection by improving Landfill surface cover to decrease air infiltration. • Evaluate the effects of barometric pressure. • Verify the probe(s) measurements. • Inform LEA of actions taken to control LFG by e-mail or letter. 3. If the initial verification indicates exceedance, continue monitoring on a weekly to allow the methane concentration drop to below 5% in response to the system adjustments/ optimization. 4. Within 21 days of first methane exceedance, submit to the LEA a letter workplan which describes the nature and extent of the problem, all operational actions taken, and recommended corrective actions needed to protect public health and safety and the environment. The letter should: • Evaluate the problem. • State actions taken to date. • Evaluate appropriate alternatives. Alternatives may include some combination of the following: — Install additional interior landfill gas extraction well(s) — Replace the blower with a larger unit. 27 Newport Terrace Landfill — O&M Manual — Other control alternatives - the purpose of this category is to acknowledge that new technologies are continually being developed and that a new technology may be the preferred approach. • Bar hole punch (3 foot depth) and monitor by all homes within 25 feet of probe weekly. • An implementation schedule of the selected alternative and anticipated schedule to bring the probe into compliance. 5. After probe readings decrease to below compliance levels, continue weekly monitoring for four (4) consecutive weeks. After four (4) consecutive weeks of readings below compliance levels, the monitoring frequency may revert to monthly or as otherwise approved by the LEA. 6. If exceedances return, increase monitoring frequency to weekly and reinitiate evaluation, and implementation of control measures. 5.4 MONITORING RECORDS AND SCHEDULE The probes are monitored monthly for TOCs (reported as methane) and lab analyzed quarterly for TACs. A Tedlar bag sample needs to be lab analyzed for TOCs quarterly. All other monitoring events happen monthly except the source test which is performed annually (see Table 5b). Table 5a. Monitoring Schedule 28 Monthly Quarterly Annually Collect and lab analyze sample from inlet and outlet of carbon x system for VOCs and TACs Monitor Sulfatreat exhaust for H2S with Drager Tubes x Monitor TNMOC concentration at each carbon adsorber outlet x with PID Monitor boundary probes for TOCs (as methane) using x portable instrument Collect sample(s) from boundary probe(s) for lab x analysis of TACs and TOC Source Test x 28 Newport Terrace Landfill — O&M Manual Field measurements should be recorded directly either directly into monitoring instruments that have data logging capability (e.g., GEM), or onto paper monitoring forms (see example forms, Appendix E). If monitoring data is recorded on the instrument, that data should be uploaded to a data management system which can be queried for trends and reporting. Original records shall be saved for a minimum of 2 years in accordance with the SCAQMD Permits and 3 years per LEA requirements. In practice however, all data should be securely stored electronically for future use, which may be assumed to be for 20 years or more. In addition to the reporting required by regulatory agencies (LEA and SCAQMD), monitoring and maintenance data should always be sent to the City of Newport Beach and the Newport Condominium Association. 5.5 REPORTING TO REGULATORY AGENCIES Monitoring results are required to be reported to two regulatory agencies, the solid waste local enforcement agency (LEA) within five days of monitoring event, and the South Coast Air Quality Management District. The following table summarizes reporting requirements to the SCAQMD and LEA: 29 Newport Terrace Landfill — O&M Manual TASLE 613_ SUMMARY OF REGULATORY REPORTING REQUIREMENTS Rec;ulred Test Test Regulatory Regulatory Agency Regulatory IVI tnitoring Evont Procedure Frequency Agency Notification Report Agency Permit No. and Date Source Test Tait lniat gas (before Annual South Coast 1) Written NotlCe - 10 ouo 30 pays alter testing to No. Fa5orl i Carbon Adsorbers) and AQMD days prior to test- AQMD 11/2/2006 Final outlet Gas for 2) Agency Approval - following compounds: Prior appre-.vel to [vesting FxMpUrt the f4oIlvwFrxg: A- Methane and analysis methods 30 1) Operational flours of 8. 7-NMC)Cs days prior to testing- carbon C. TACa (Rule 'I 1 50-1) 2) Final outlet gas conc- D. total Sulfur (Hydrogen 3) Calculations to Sulfide) demonstrate that outlet gas E_ Moisture Content did not cxccod 20 ppm- -- F- Temperature measured as hexane at 3% G_ Flow Rate oxygen or reduced by 981 H. Oxygen by weight. • Volatile Organic Test Inlet and Outlet of Monthly South Coast Report thr Fmt-l- 1150-1 TIa- F850.11 Compounds and Carbon Adsorbers- AQMD speciated TAC5 11/2/2006 Speciated Toxic Conform with CARE Method Air Contaminants 422 or equivalent. Utilize (TAC) EPA Method TO 14 or other method approved by South Coast AQMD. Total Non- Outlet Of Cal'17Or1 Aduor tours Monthly Soutn Coast No- Fa5011 Methane Organic (2)- AQMn 11/2,12006 Compounds Use CVA or other approved (TNMOC) Instrument.. Emissions at outlet shalt not exceed the following - 1) Chloroform 010 ppmv 2) Vinyl Chloride 0.17 ppmv 3) Hydrogen SuSfidg 0-1 ppmv Sulfatreat Systom Sulfur Campunds Monthly South Coast No. F85011 Exhaust I1 dry en Sulfide AQMD 71/2/2006 Gas Collection As Needed South Coast One weak In advance for Wr}tten with entire gas No- FB5012 Waits 8. AQmr-) additional wells and collection system drawings- 11/212006 Associated Piping associated piping- Proposed wolf depths, pipe lengths, diameter, layouts - prior to notificationEt ..... .. .. ........ . 7 ...-. .. - Subsurface Refuse Utilize FID - If FID readings Monthly South Coast Send data to LEA monthly. Rule 1ISO, 1 Boundary Probes are below SIX. volume, then AQMD and Data to be included in Compliance Plan TOC no Tedlar bag sample is LEA quarterly 1150.1 reports to 12/17/1099 collected. SCAQMD- S rlbsul facie Refuse Collect Ted laf bang sample quarterly South Coast Analyze and report the Rule 1150,1 Boundary Probes at probe with highest TdC AQMD TACs (Core Group) Compliance Plan TAC measured concentration provided in TaWe 1 of 1 211 711 9 99 during the previous 3 Attachment A- months - Use TQ -14 Analysis Method - Records Retention Monthly South Coast Maintained at Action Rule 1150.1 AQMD Property Management Compliance Plan 1) Most recent year: 12J17/1999 available within 4 hours of request - 2) 2 to 5 years aid: available within 48 hours of r- st 30 Newport Terrace Landfill — O&M Manual The operator (contractor) should copy the LEA on all reports sent to the SCAQMD. In the event that any test result indicates that the regulatory agency would be agreeable to reducing the frequency of that test, the operator (contractor), with the approval of the city and the NCA, will assist the city to petition the agency for an appropriate reduction. If the reduction is granted, this manual will be immediately updated to reflect the reduction. 31 Newport Terrace Landfill — O&M Manual 6 SYSTEM MAINTENANCE 6.1 MAINTENANCE CRITERIA The purpose of a scheduled maintenance program is to provide safe and efficient operation of the system and to prevent equipment breakdowns (unscheduled maintenance). The maintenance program consists of the observation and servicing of mechanical equipment and other components. Most of the equipment at the blower station is to be maintained according to manufacturer's criteria. This equipment includes the blowers, electrical controls, activated carbon canisters, Sulfatreat system, and moisture separating tank. The remainder of the system components is to be maintained by field staff. These components include the header/lateral/blower station piping, cock valves, check valves, in-line meters, and valve boxes. The safety and orderliness of the blower building, as well as the accessible wellfield facilities (well and probe vaults) are the responsibility of the system operator. This includes preventing and repairing damage from vermin. 6.2 MAINTENANCE PROCEDURES Visual inspection is the typical maintenance procedure, as described below, to be performed outside of the manufacturer's requirements. In general, the operator should do a visual inspection each time they enter the blower building and/or open well -field or probe vaults. Signs of unusual deterioration, damage (including from animals) shall be noted on a monthly log, included in Appendix E, and addressed as necessary. Equipment literature, including maintenance details, are included in Appendix H. 6.2.1 Compressor An Atlas Copco GX-4 air compressor provides pressurized air for the pneumatic pumps in the condensate sumps. Maintenance principally involves checking and maintaining the oil level, and cleaning air and oil filters. However, it is important that the operator respond to signs of incipient failure (unusual wear, or sounds or smells) in order to anticipate or react quickly to equipment failure, to allow planning for equipment replacement and minimize system downtime. 6.2.2 Blowers The manufacturer requires periodic inspection and service typically based on hours of service as measured by the elapsed time meter. 32 Newport Terrace Landfill — O&M Manual 6.2.3 Flame Arrestor The flame arrestor will require disassembly and cleaning if the differential pressure exceeds two inches water -column. 6.2.4 Moisture Separator The moisture separator should be visually inspected for corrosion, weathering, leaks, seals, and pressure drop. An increase in pressure drop, measured at the sampling ports, one on each of the tank inlet and outlet pipes, indicates the unit is clogged and should be cleaned. Accumulated moisture in the separator, indicated also by an increase in pressure drop across the unit, should be drained by opening the drainage valve at the base of the unit. 6.2.5 Electrical Controls The system should be start-up tested monthly. The electrical controls should be visually inspected monthly or more frequently. 6.2.6 Gauges and Sampling Ports Permanent station gauges and sampling ports should be visually inspected for damage, proper seating and fit, and accuracy. Gauges need to be zeroed prior to recording readings. 6.2.7 Piping, Valves, and Fittings Piping, valves, and fittings within the station should be visually inspected for damage, corrosion, weathering, seal, and leaks. 6.2.8 Extraction Wells Visually inspect the wells at least once a month as follows: 1. Check inside the vaults and look for damage and proper operation of the well head, later tie in (flex hose) and condensate drain. 2. Check the sampling ports and gate valve for damage, leaks, workability, and seating. 3. Check the lateral piping for damage and leaks. 4. Check the modified condensate drains for damage or leaks. 6.2.9 Monitoring Probes Visually inspect the probes as follows: 1. Check the valve box, valve box cover, and identification tags for damage. 2. Check the cock valves for damage, leaks, workability, and seating. 33 Newport Terrace Landfill — O&M Manual 6.2.10 Carbon Adsorption Units Upon detection of "breakthrough" (exceedance of NMOCs at the carbon units' final exhaust, as measured by PID), the carbon shall be replaced and/or reactivated by an approved carbon provider as necessary. The sequence of carbon change -out is discussed in Section 2.4.3. 6.2.11 Sulfatreat System When breakthrough of HZS is detected (Drager Tube reading of 0.1 ppmv), the Sulfatreat media needs to be replaced, by contacting the Sulfa -treat vendor. 6.2.12 In -Line Flow Meter The Kurz flow transmitter uses thermal conductivity to measure the rate of flow of gas passing through the pipe. The heated sensor should be removed and cleaned annually. 6.2.13 Automated Condensate Sumps The four automated sumps should be visually inspected during routine monthly monitoring. 6.3 MAINTENANCE RECORDS AND SCHEDULE Routine maintenance activities at the blower station should be performed weekly, monthly, quarterly or annually, as described above and summarized in Table 6a 1. Monitoring forms for these maintenance activities are included in Appendix E. All maintenance work should be promptly and neatly recorded and retained as a permanent record to track long-term changes or trends in the equipment performance. This record is used for planning future preventive maintenance or in diagnosing equipment breakdowns. Section 7 discusses data management. An annual maintenance and monitoring report shall be submitted by the owner to the solid waste local enforcement agency (LEA) by March 1St of every year. Report shall include all maintenance performed on the system. 1 Monitoring Forms are included in Appendix E. 34 Newport Terrace Landfill — O&M Manual TABLE 6a. SUMMARY OF ROUTINE MAINTENANCE OF EQUIPMENT Equipment Mode[ Appendix Warranty Scheduled Maintenance Activity Frequency Thresholds LFG system Ametek (Rotron) App H - One year Visual Observation Monthly For Full -Feature versions: clean the condensor of the dryer. blowers CP808M Section 2 For compressors with PDX filter: check the service indicator. replace the filter if necessary. 2000 Replace the air filter. If Atlas Copco Roto -Inject Fluid is used, change the oil. Replace the oil filter. For compressors with PDX filter: replace the filter. 4000 Clean the finned surface of the oil cooler - H2S system Ametek (Rotron) App H - One year Visual Observation Monthly blowers CP404M Section 2 Rotary Screw Atlas Capco GSC -4 App H - One year See Table 61; below. See Table 5b below - Compressor Section 2 Carbon Baker Corp. Kleen App H - One year None. Replace Carbon As needed Carbon Vessels Air 2000 S Section 3 in sequence as replaced when described in Section exhaust 2.4,3 of O&M Manual NMOCs exceed 20 ppm Flame Groth Corp. No. App. H Section One year Remove and inspect Annually or when 2 inches water Arrestor 7628-04-11-F00 6 elements pressure drop column exceeds thresshold In-line Flow Kurz 454 FT App, H Section One year Remove sensor and Annually meter 7 clean Methane General Monitors App, H Section One year Calibrate with certified Quarterly sensor and 480A controller; 10 gas controls 10001-1 Sensor Hydrogen General Monitors App. H Section One year Calibrate with certified {Quarterly Sulfide sensor 2180A con rolIer; 8 gas and controls 50445-1 sensor Condensate Real Environmental App. H Section Five year Visual Observation Monthly sumps Products, AutoSump 09 7000; Auto Pump A4 TABLE 61b. PREVENTATIVE MAINTENANCE SCHEDULE FOR GX4 COMPRESSOR Maintenance Frequency - Running Hours Operation 50 Drain the condensate from the receiver. Check the oil level - For Floor -mounted versions: clean the prefilter an the rear side of the compressor. 500 Clean the air filter. For Full -Feature versions: check that condensate from the dryer is drained automatically. For Full -Feature versions: clean the condensor of the dryer. Check the belt tension. For compressors with PDX filter: check the service indicator. replace the filter if necessary. 2000 Replace the air filter. If Atlas Copco Roto -Inject Fluid is used, change the oil. Replace the oil filter. For compressors with PDX filter: replace the filter. 4000 Clean the finned surface of the oil cooler - Replace the oil separator. Have the safety valve tested. 35 Newport Terrace Landfill — O&M Manual 7 DATA MANAGEMENT AND EVALUATION 7.1 THE DATA — COLLECTION, ASSESSMENT, AND MANAGEMENT Much of the work of collecting and controlling LFG involves the collection, evaluation, and management of LFG data. This process of collecting, evaluating, and managing data may be relatively simple or very complex. The level of complexity depends on the problems that a site presents, the evaluation or control objectives, resources available, and budget constraints. The process may be as simple as measuring and recording several key parameters on a reading sheet and making immediate on the spot adjustments in the field, or as detailed as performing systematic analysis using sophisticated software employing graphing or plotting data in multiple dimensions. 7.2 DATA COLLECTION The data required by the SCAQMD Permits to Operate are as follows: • The quantity of LFG in standard cubic feet per minute being treated by the carbon adsorbers. • The concentration of TNMOCs at the combined inlet to the carbon adsorption system. • The concentration of TNMOCs at the final outlet of the carbon adsorber. • Annual source tests of the carbon adsorber system inlet and final outlet. • VOC and TAC samples collected from the inlet and outlet of the carbon adsorbers. • Sulfur compounds (measured as H2S) concentration at the exhaust of the Sulfatreat system. • Emissions at the exhaust of the carbon adsorbers sent to a lab to determine concentration of chloroform, vinyl chloride, and hydrogen sulfide. • Test results. • Monitoring data. • Dates of carbon replacement. Data is collected routinely using monitoring forms (either manual or electronic) for the blower facility, the wellfield, migration monitoring probes, onsite structures, etc. These data readings become a part of the facility operating record. A retention period of at least three years is required by the solid waste local enforcement agency (LEA). 36 Newport Terrace Landfill — O&M Manual The system operator (contractor) will retain all monitoring and maintenance records, as well as providing digital copies to the City of Newport Beach and the NCA. Contact information for the city and NCA are listed in Appendix F. The city and NCA will each be responsible for archiving monitoring and maintenance records. A contractor working for the city or NCA should retain data for 10 years. The city and NCA should retain data for at least as long as the landfill and LFG system are subject to regulatory oversight (i.e., indefinitely). 37 Newport Terrace Landfill — O&M Manual 8 SAFETY The principle components of LFG are methane and carbon dioxide; other gases which may be found in lesser amounts are hydrogen sulfide, organic acids and gases, and nitrogen. Hydrogen sulfide is HIGHLY TOXIC; the other acidic gases and organic vapors should also be treated as toxic and hazardous. In concentrations of 5 to 15 percent by volume in air, methane may explode when ignited by a spark or other ignition source. In addition, LFG can displace oxygen in confined spaces. Confined spaces within which oxygen levels are below 19 percent by volume should not be entered. This manual does not contain a Health and Safety Plan (HASP), nor does it contain lock -out, tag - out procedures. The LFG system operator needs to develop a site-specific HASP (including lock -out, tag -out procedures) based on analysis of the existing site conditions. 8.1 CONTACT INFORMATION Appendix F lists major stakeholder and regulatory parties contact information. 38 Newport Terrace Landfill — O&M Manual 9 LISTING OF PERMITS South Coast Air Quality Management District, Permit to Construct/Operate, No. F85011, issued November 6, 2006 (Appendix C) — no specific expiration date. South Coast Air Quality Management District, Permit to Construct/Operate, No. F85012, issued November 6, 2006 (Appendix D) — no specific expiration date. Rule 1150.1 Compliance Plan, issued December 17, 1999 (Appendix G) — no specific expiration date. As of February 2009, an application has been submitted to the AQMD to modify the Compliance Plan to indicate the change in ownership of the site and the LFG system. California Code of Regulations (CCR), Title 27 — this is not a specific permit, but rather the owner/operator is required to perform monthly monitoring and submit quarterly reports to the LEA. 39 Newport Terrace Landfill — O&M Manual Appendix A System Drawings Newport Terrace Landfill — O&M Manual Appendix B Gas Extraction Well Boring Logs Newport Terrace Landfill — O&M Manual Appendix C SCAQMD Permit to Construct/Operate — Collection System Newport Terrace Landfill — O&M Manual Appendix D SCAQMD Permit to Construct/Operate — Treatment System Newport Terrace Landfill — O&M Manual Appendix E Well Field Monitoring Form Newport Terrace Landfill — O&M Manual Appendix F Contact Information Newport Terrace Landfill — O&M Manual Appendix G Rule 1 150.1 Compliance Plan Newport Terrace Landfill — O&M Manual Appendix H Instrumentation and Equipment Literature (on CD) Newport Terrace Landfill — O&M Manual Appendix A System Drawings mirmell COSTA MESA VICTORIA ST 0 a m Q � , a 19TH ST kd 17TH ST w 15TH ST ELMIL 11 LOCATION =� PACIFIC JOHN WAYNE >� AIRPORT 0 UPPER NE ORT o 1 BAY S� CITY OF IRVINE UNIVERSITY ;AVE 4 1 0-�, �,; GENERAL NOTES 1 . ALL WORK DETAILED ON THESE PLANS TO BE PERFORMED UNDER CONTRACT SHALL BE CONSTRUCTED IN ACCORDANCE WITH THE "STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION," 2003 EDITION AND SUPPLEMENTS TO DATE, EXCEPT AS OTHERWISE STATED IN THE CITY'S STANDARD SPECIAL PROVISIONS, OR IN THIS CONTRACT'S SPECIAL PROVISIONS. 2. EXISTING UNDERGROUND UTILITIES ARE SHOWN AS PER AVAILABLE RECORDS. THE CONTRACTOR SHALL BE RESPONSIBLE FOR VERIFYING THE ACTUAL LOCATION AND ELEVATION IN THE FIELD PRIOR TO BEGINNING CONSTRUCTION. 3. P.C.C. SHALL BE CLASS 560-C-3250. 4. CONTRACTOR SHALL ADJUST CITY UTILITY (e.g. WATER VALVES, SCO, SURVEY MONUMENTS, SEWER AND STORM DRAIN MANHOLES) FRAMES AND COVERS TO FINISHED GRADE. NEWPORT TERRACE LANDFILL GAS COLLECTION AND CONTROL SYSTEM CONTRACT N0. 3651 INDEX OF SHEETS 1. TITLE SHEET 2. SITE PLAN - EXISTING AND PROPOSED LFG COLLECTION SYSTEM CALL TOLL FREE 1-800-422-4133 BEFORE YOU DIG EMERGENCY TELEPHONE NUMBERS DAY NIGHT SOUTHERN CALIFORNIA GAS COMPANY (800)-624-8153 ��E�N � FAS (800)-624-8153 SOUTHERN CALIFORNIA EDISON COMPANY 3. PROPOSED LFG COLLECTION SYSTEM -NOTES LOCATION MAP � PACIFIC TELEPHONE COMPANY 611 611 NOT TO SCALE CITY OF NEWPORT BEACH (UTILITIES DEPARTMENT) (949)-644-3011 (949)-644-3717 4. WELL SCHEDULE AND MISCELLANEOUS DETAILS ORANGE COUNTY SANITATION DISTRICT (714)-962-2411 ADELPHIA CABLE APPROVED: 5. CONDENSATE SUMP AND PIPE TRENCH DETAILS UNDERGROUND SERVICE ALERT (800)-422-4133 DATE: MCWD SYMBOL LEGEND SIGN DIRECTOR OF PUBLIC WORKS R.C.E. NO. 36106 6. SCHEMATIC FLOW DIAGRAM - LFG TREATMENT AND DISPOSAL SYSTEM GARAGE OPENING � POWER POLE WINDOW 7. PLAN - EXISTING BLOWER BUILDING, AND DEMOLITION, PRESERVATION AND RE -HABILITATION NOTES O SCO SANITARY SEWER CLEANOUT APPROVED: DATE: =;}SMH SANITARY SEWER MANHOLE * SPRINKLER GENERAL SERVICES DIRECTOR 8. PLAN - NEW LFG COLLECTION, TREATMENT AND DISPOSAL SYSTEM v FIRE HYDRANT WM--- WATER METER BOX & SERVICE ABBREVIATIONS 9. SECTIONS nGM GAS METER AC ASPHALT CONCRETE 10. MISCELLANEOUS DETAILS VALVE DIP DUCTILE IRON PIPE VCP VITRIFIED CLAY PIPE ; 11. ARCHITECTURAL - PLOT PLAN AND GENERAL NOTES POWER POLE ANCHOR RWV RESILIENT WEDGE VALVE $��� A pI Qyp rn o r St N` MONUMENT ri c a Ilk 12. ARCHITECTURAL - SITE PLAN FE FLANGED END 1 xxx FENCE MJ MECHANICAL JOINT_ P 13. ARCHITECTURAL - DEMOLITION PLAN AND ROOF PLAN BLOCKWALL NTS NOT TO SCALE �d �rBluff g a co TREE RT RING TIGHT 14. ARCHITECTURAL - ROOF FRAMING PLAN AND EXTERIOR ELEVATION Q C3 SHRUBBERY STL STEEL leneRple 0 ak EA � 9 15. ARCHITECTURAL - REFLECTED CEILING PLAN ,,, ,,, ,,, ,,, ASPHALT PAVEMENT ABAND ABANDONED BRICKWALK IP&T IRON PIPE AND TAG f #� Tove PI n 16. ARCHITECTURAL - WALKWAY PLAN MON MONUMENT U m CONCRETE CATV CABLE TV 17. ELECTRICAL - GENERAL NOTES BUILDING DWY DRIVEWAY EXISTING CONSTRUCTION CO CLEANOUT (SEWER) Canyon Everprern 18. ELECTRICAL - PLAN — - - PROPERTY LINE ARV AIR RELIEF VALVE � �� oo s NEW CONSTRUCTION B/APPR BACK OF ALLEY APPROACH pd 19. ELECTRICAL - SINGLE LINE DIAGRAM CENTERLINE EV ELECTRICAL VALVE ' 20. ELECTRICAL - SENSOR SYSTEM AND WIRING DIAGRAM SW SIDEWALK t ---S-__- SEWER LINE WWF WELDED WIRE FABRIC w1'` st 21. ELECTRICAL - MOTOR STARTER WIRING DIAGRAM AND DETAILS - -W- -- WATER LINE MLCCSP MORTAR LPIPE ED CEMENT COATEDSTEE _ PROJECT LOCATION - --G- - - GAS LINE RCSCP REINFORCED CONCRETE STEEL CYLINDER PIPE r E POWER LINE O 4"A.C. CORING INFORMATION iti Towne !3t AS -BUILT T TELEPHONE LINE MCWD MESA CONSOLIDATED WATER DISTRICT zi 2 BASED ON SURVEY INFORMATION RECEIVED FROM CATV CABLEVISION LINE w i% { INNOVATIVE CONSTRUCTION SP SPRINKLER SYSTEM SOLUTION, I N C STREET LIGHT DATE: 05-05-08 CALL TOLL FREE 1-800-422-4133 BEFORE YOU DIG EMERGENCY TELEPHONE NUMBERS DAY NIGHT SOUTHERN CALIFORNIA GAS COMPANY (800)-624-8153 (800)-624-8153 SOUTHERN CALIFORNIA EDISON COMPANY (800)-611-1911 (800)-611-1911 PACIFIC TELEPHONE COMPANY 611 611 CITY OF NEWPORT BEACH (UTILITIES DEPARTMENT) (949)-644-3011 (949)-644-3717 ORANGE COUNTY SANITATION DISTRICT (714)-962-2411 ADELPHIA CABLE (714)-338-2000 (714)-644-6222 UNDERGROUND SERVICE ALERT (800)-422-4133 (800)-422-4133 MCWD (949)-574-1000 (949)-631-1200 VICINITY MAP_ NOT TO SCALE PREPARED BY: APPROVED SCS ENGINEERS CITY ENGINEER R.C.E. NO. 24967 ENVIRONMENTAL CONSULTANTS DATE 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED DRAWN LONG BEACH, CA 90806 S. KOTHARY L. FUENTES PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATE M. GEYER SEP 19 200! REF: TRACT 7989 LANDFILL GAS COLLECTION AND CONTROL SYSTEM NEWPORT TERRACE LANDFILL CITY OF NEWPORT BEACH M -5374-S PUBLIC WORKS DEPARTMENT SHEET 1 OF 21 1 D 0 161 I I I I I I i i I I I I I I I I I Lu 0 0 I I I I �P-23 C i NT2 0 NT1 0 SITE PLAN - EXISTING AND PROPOSED LFG SYSTEM HEADER -LINE G -LINE A N__- GRAPHIC SCALE 80 0 80 160 APPROXIMATE SCALE IN FEET I FrFmn EW -01 NEW LFG EXTRACTION WELL 65 EXISTING VERTICAL GAS EXTRACTION WELL CP -4 EXISTING COMPLIANCE GAS MONITORING PROBE P-15 • EXISTING NON-COMPLIANCE GAS MONITORING PROBE NEW H.D.P.E. HEADER LINE EXISTING P.V.C. HEADER LINE -c—c—c—c- BELOW GRADE 2" DIA. HDPE SDR 9 CONDENSATE LINE NOTE: 2 PROVIDE TRENCH DAM AT EVERY 300'-0" O.C. ALONG THE PROPOSED HEADER/ LATERALS, AND AT LOCATIONS SHOWN, PER DETAIL. 3 25 FOR EXACT LOCATION OF EXISTING SEWER LINE AND MANHOLES, REFER TO CITY DRAWINGS. NEWPORT CONDOMINIUMS 19TH STREET PLAN AND PROFILE TRACT NO. 7989 NOTE: FOR CONDENSATE AND AIR LINE, SEE SHEET 3R. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 O I I I I M. ULTLN I uu1. 2, zuui I . --- - . - -. -. -- _ ....... I - .__ . - -- -- I u 11 o �2 11 0 Q Z! 0 0 0 0 0 0 0 SITE PLAN - PROPOSED LFG COLLECTION SYSTEM N__- GRAPHIC SCALE 80 0 80 160 SCALE IN FEET LEGEND EW -06 LFG EXTRACTION WELL 8"0 BELOW GRADE 8" DIA. HDPE SDR 17 LFG HEADER w. CONDENSATE FLOW DIRECTION —AAAA— BELOW GRADE 2" DIA. HDPE SDR 9 AIR LINE BELOW GRADE 2" DIA. HDPE SDR 9 CONDENSATE LINE C.SA 0 CONDENSATE SUMP/PUMP NOTES 1. THE CONTRACTOR SHALL MAINTAIN A MINIMUM SLOPE OF 2% ALONG THE BELOW GRADE LFG HEADER/ LATERALS 2. LOCATIONS OF LFG EXTRACTION WELLS SHALL BE STAKED OUT IN THE FIELD BY THE CONTRACTOR AND SHALL BE APPROVED BY THE ENGINEER PRIOR TO START OF ANY DRILLING WORK FOR THE WELLS. 3. THE LFG HEADER/LATERAL ALIGNMENT SHALL BE STAKED OUT BY THE CONTRACTOR AND APPROVED BY THE ENGINEER. ADJUSTMENTS TO THE ALIGNMENT MAY BE REQUIRED TO SUIT THE FIELD CONDITIONS. 4. ALL LFG HEADERS/LATERALS SHALL BE HDPE SDR 17, UNLESS SHOWN OTHERWISE. 5. AUTOMATIC PNEUMATIC CONDENSATE SUMPS SHALL BE CONSTRUCTED AND LOCATED AT THE LOWEST POINTS ALONG THE HEADERS. LOCATIONS SHOWN ON THE DRAWINGS MAY NEED TO BE ADJUSTED IN FIELD TO SUIT THE SITE CONDITIONS. SEE DETAIL 1 55 6. CONDENSATE AND AIR LINES SHALL BE 2" HDPE SDR 11 AND SDR 9 RESPECTIVELY. 7. WHENEVER POSSIBLE, CONDENSATE AND COMPRESSED AIR CONVEYANCE LINES SHALL BE INSTALLED IN THE COMMON TRENCH WITH THE LFG HEADER OR LATERAL PIPING. 8. NO SIDEWALK, CURB & GUTTER, STREET, LANDSCAPING SHOWN. THEREFORE THE CONTRACTOR TO ESTIMATE QUANTITIES AFTER THE FIELD REVIEWS, AND HIS BID WILL INCLUDE REPLACING SIDEWALK, CURB & GUTTER, STREET, LANDSCAPING TO THE SATISFACTION OF THE CITY. 9. REFER TO GENERAL CONSTRUCTION NOTES ON SHEET 5 NOTE: THE STRIP TOPOGRAPHIC MAP, ALONG THE PROPOSED ROUTES FOR LFG HEADERS AND LATERALS, PREPARED BY DULIN AND BOYTON, LICENSED SURVEYORS, INC. BASED ON THE FIELD SURVEY CONDUCTED BY THEM ON DECEMBER 28th 2005. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 o I I I I M. btTLM I JtF' I`J, LUUb I . - - -.- .. -. ". -- --. . -. -.... ....I --• --. - _. __ I �1 n I 0 W 1/4" PVC COCK VALVE 4" MIN 0 N cn w Q E 0 I z 0 U w cn 0 w 0 cn N 0�0�0 � 00000 00000 00000 00000 00000 00000 00000 00000 0 0 0 00000c C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED EQUAL (TYP) CONCRETE SURROUND (f'c = 2,500psi) FINISHED GRADE IDENTIFICATION TAG 000000 SEE DETAIL 2 0000°° 4 4 o°o°o° o°o°o° o°o°o° o°o°o° °0°00 ° BENTONITE PLUG 0000°° 3'-0" MIN 12" OR 18" BORE HOLE SEE WELL SCHEDULE SOIL BACKFILL BENTONITE PLUG 3" SCH 80 PVC SOLID PIPE SOIL BACKFILL Y4" TO 1 )/2" CLEAN GRAVEL (TYP) 3"0 PVC FLOW CONTROL GATE VALVE d.. 12" 8"o PVC SCH 80 PIPE (TYP) d .. .d 8"0 HDPE SDR 17 PIPE 4" IMIN 4" IMIN 1/4" PVC COCK VALVE (TYP) 3/8" CLEAN GRAVEL (TYP.) HDPE FLANGE ADAPTER SEE DETAIL 3 44 4"x3" SCH 80 PVC REDUCER 1 1/4"0 x 1/16" THK BRASS TAG W/1/8"O HANGING HOLE �-- LFG EXTRACTION WELL NO. S.S. TIE WIRE—\ EW -01 30' ,/— WELL DEPTH DETAIL - IDENTIFICATION TAG N.T.S. IAlNLLS. BOLTS AN PVC SC FLANGED PV( ni inTii F ionni 71 nn1nE PIPE 1 IUr L I LPIINUL nuAPTER DETAIL - FLANGE ADAPTER N.T.S. 8"12" 12" TYP. 90° P. TYP. TYP. r"4 �� �0) 3" SCH 80 PVC SLOTTED PIPE SEE DETAIL 4 3"0 SCH 80 4 4 PVC PIPE SAW—CUT 2 — 1,/4"x 8" LONG SLOTS PER ROW AT 12' O.C. 3" SCH 80 PVC CAP ADJACENT ROW SHALL BE STAGGERED AT 90° DETAIL - SLOTTED PVC PIPE 4 N.T.S. 4 4 DETAIL - LFG EXTRACTION WELL N.T.S. C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED 2D FINISHED GRADE EQUAL (TYP) 4" 3"0 PVC FLOW CONTROL GATE VALVE MIN CONCRETE SURROUND (f'c = 2,500psi) NA ° 1 ° .d °. . '4 .° n .. 12„ [7 . A � 8" 0 HDPE SDR 17 PIPE PVC COUPLING CUT AND REMOVE THE EXISTING PVC LATERAL EXISTING PVC WELL CASING 3'-0" MIN 4" MIN 1/4" PVC COCK VALVE (TYP) 3/8" CLEAN GRAVEL (TYP.) DETAIL - CONNECTION TO EXISTING WELL N.T.S. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 DETAIL - LFG LATERAL CROSSING EXISTING DRAINAGE DITCH rsE N.T.S. HDPE FLANGE ADAPTER SEE DETAIL g 44 4"x3" SCH 80 PVC REDUCER LFG EXTRACTION WELL SCHEDULE WELL No. LOCATION COORDINATES ° w. WELL CASING SLOTTED DEPTH 'D 1' FT. BORE HOLE DIAMETER NORTH EAST EW -1 9 6,046,745 33 10 18" EW -2 2,182,934 I 33 10 18" EW -3 d 0 N cn w Q E 0 I z 0 U w cn 0 w 0 cn N 0�0�0 � 00000 00000 00000 00000 00000 00000 00000 00000 0 0 0 00000c C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED EQUAL (TYP) CONCRETE SURROUND (f'c = 2,500psi) FINISHED GRADE IDENTIFICATION TAG 000000 SEE DETAIL 2 0000°° 4 4 o°o°o° o°o°o° o°o°o° o°o°o° °0°00 ° BENTONITE PLUG 0000°° 3'-0" MIN 12" OR 18" BORE HOLE SEE WELL SCHEDULE SOIL BACKFILL BENTONITE PLUG 3" SCH 80 PVC SOLID PIPE SOIL BACKFILL Y4" TO 1 )/2" CLEAN GRAVEL (TYP) 3"0 PVC FLOW CONTROL GATE VALVE d.. 12" 8"o PVC SCH 80 PIPE (TYP) d .. .d 8"0 HDPE SDR 17 PIPE 4" IMIN 4" IMIN 1/4" PVC COCK VALVE (TYP) 3/8" CLEAN GRAVEL (TYP.) HDPE FLANGE ADAPTER SEE DETAIL 3 44 4"x3" SCH 80 PVC REDUCER 1 1/4"0 x 1/16" THK BRASS TAG W/1/8"O HANGING HOLE �-- LFG EXTRACTION WELL NO. S.S. TIE WIRE—\ EW -01 30' ,/— WELL DEPTH DETAIL - IDENTIFICATION TAG N.T.S. IAlNLLS. BOLTS AN PVC SC FLANGED PV( ni inTii F ionni 71 nn1nE PIPE 1 IUr L I LPIINUL nuAPTER DETAIL - FLANGE ADAPTER N.T.S. 8"12" 12" TYP. 90° P. TYP. TYP. r"4 �� �0) 3" SCH 80 PVC SLOTTED PIPE SEE DETAIL 4 3"0 SCH 80 4 4 PVC PIPE SAW—CUT 2 — 1,/4"x 8" LONG SLOTS PER ROW AT 12' O.C. 3" SCH 80 PVC CAP ADJACENT ROW SHALL BE STAGGERED AT 90° DETAIL - SLOTTED PVC PIPE 4 N.T.S. 4 4 DETAIL - LFG EXTRACTION WELL N.T.S. C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED 2D FINISHED GRADE EQUAL (TYP) 4" 3"0 PVC FLOW CONTROL GATE VALVE MIN CONCRETE SURROUND (f'c = 2,500psi) NA ° 1 ° .d °. . '4 .° n .. 12„ [7 . A � 8" 0 HDPE SDR 17 PIPE PVC COUPLING CUT AND REMOVE THE EXISTING PVC LATERAL EXISTING PVC WELL CASING 3'-0" MIN 4" MIN 1/4" PVC COCK VALVE (TYP) 3/8" CLEAN GRAVEL (TYP.) DETAIL - CONNECTION TO EXISTING WELL N.T.S. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 DETAIL - LFG LATERAL CROSSING EXISTING DRAINAGE DITCH rsE N.T.S. HDPE FLANGE ADAPTER SEE DETAIL g 44 4"x3" SCH 80 PVC REDUCER LFG EXTRACTION WELL SCHEDULE WELL No. LOCATION COORDINATES WELL DEPTH `D' FT. WELL CASING SLOTTED DEPTH 'D 1' FT. BORE HOLE DIAMETER NORTH EAST EW -1 2,183,042 6,046,745 33 10 18" EW -2 2,182,934 6,046,752 33 10 18" EW -3 2,182,747 6,046,744 30 10 18" EW -4 2,182,651 6,046,752 30 9 18" EW -5 2,182,590 6,046,745 30 9 18" EW -6 2,181,924 6,046,340 30 10 18" EW -7 2,181,931 6,046,255 30 10 18" EW -8 2,181,937 6,046,156 30 10 18" EW -9 2,181,939 6,046,053 30 10 18" EW -10 2,181,943 6,045,978 30 10 18" EW -11 2,181,939 6,045,893 30 10 18" EW -12 2,182,968 6,045,944 30 10 12" EW -13 2,182,992 6,045,941 21 10 12" EW -14 2,182,947 6,045,892 23 10 12" EW -15 2,182,971 6,045,959 20 10 12" NOTE: THE CONTRACTOR IS ADVISED THAT THE DEPTH OF THE WELL AND THE LENGTH OF PERFORATION MAY BE ADJUSTED IN THE FIELD ON THE CONDITIONS ENCOUNTERED, PARTICULARLY THE THICKNESS OF COVER MATERIAL AND DEPTH OF REFUSE. IN THE CASE OF WELLS PENETRATING NATIVE SOIL BENEATH REFUSE, IF DIRECTED BY THE ENGINEER, THE CONTRACTOR SHALL CEASE DRILLING AND FILL THE LOWER PORTION OF THE WELL PENETRATING NATIVE SOIL WITH BENTONITE PLUG. THE DEPTH OF THE PLUG SHALL BE SUCH THAT THE TOP OF THE PLUG SHALL BE AT LEAST TWO (2) FEET ABOVE THE UNDISTRUBED NATIVE SOIL LAYER, IN REFUSE. C-3651 6" PVC SCH 80 BLIND FLANGE HDPE FLANGE ADAPTER 6" MIN 6 HDPE SDR 17 PIPE HDPE LEG HEADER AUTOMATIC CONDENSATE SUMP SERIES 7000 MANUFACTURED GALVANIZED NUTS AND BOLTS BY REAL ENVIRONMENTAL PRODUCTS OR APPROVED EQUAL I SOIL BACKFILL SLOPE 1/2"0 HDPE VACUUM BALANCE LINE 8" HDPE SDR 17 CROS 8"X4" HDPE REDUCER 3/8" CLEAN GRAVEL BACKFILL 4"0 HDPE SDR 17 DRAIN LINE 10"0 DOUBLE WALL HDPE SDR 17 SUMP con I � VAULT SUBMERSIBLE PUMP 0'-6" TO 1'-0" (TYP.) 4" MIN 3/8" CLEAN GRAVEL (TYP.) 3/8" CLEAN GRAVEL BACKFILL APPROX. LIMITS OF EXCAVATION /,REFUSE DETAIL - AUTOMATIC PNEUMATIC CONDENSATE SUMP AND PUMP N.T.S. C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED EQUAL (TYP) 0 I N CONDENSATE DISCHARGE LINE Cl, C2, AND C3=CONNECTED TO LINE—A AT LOCATION PER THES DRAWINGS, PER DETAIL C4= CONNECTED TO EXISTING SEWER AND NEW MANHOLE UNDER 19TH STREET, PER THESE DRAWINGS 1 COMPRESSED AIR INLET CONNECTED TO 2" COMPRESSED AIR LINE FROM AIR COMPRESSOR IN BLOWER BUILDING z METALLIC MARKER TAP E w 0 U 0 V) w J 0 w w cn cn w .24 w 2"0 HDPE SDR 11 CONDENSATE LINE WHERE APPLICABLE STANDARD MANHOLE COVER REFER TO CITY OF NEWPORT BEACH FINISHED GRADE DRAWING NO. STD -401—L 18" MIN. TRENCH WIDTH DETAILS - PIPE TRENCH ninr Tnrnini i AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 F9 , k 2" HDPE SDR 9 COMPRESSED AIR LINE WHERE APPLICABLE HDPE SDR 17 LFG HEADER/ LATERAL SAND OR SELECTED GRANULAR BEDDING AND BACKFILL COMPACTED TO 95% DENSITY AT OPTIMUM MOISTURE CONTENT WHEN PIPE IS LAID IN NATIVE SOIL AND 90% DENSITY WHEN PIPE IS OVER REFUSE FI EL iEADER/LATERAL �hT 10- 11-1 DETAIL - MANHOLE COVER nNiicUEn r'oAnE- 18" MIN. TRENCH WIDTH SECTION A 55 DETAIL - TRENCH DAM 3 25 PREPARED BY: APPROVED SCS ENGINEERS CITY ENGINEER R.C.E. NO. 24967 ENVIRONMENTAL CONSULTANTS DATE 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED DRAWN LONG BEACH, CA 90806 S. KOTHARY L. FUENTES PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATE M. GEYER SEP 19, 2006 EI LL PIPE C-3651 LANDFILL GAS COLLECTION AND CONTROL SYSTEM NEWPORT TERRACE LANDFILL CITY OF NEWPORT BEACH M -5374-S PUBLIC WORKS DEPARTMENT SHEET 5 of 21 X SOIL BACKFILL COMPACTED TO 95% DENSITY AT OPTIMUM MOISTURE _ i���i�� CONTENT WHEN PIPE IS LAID IN NATIVE SOIL AND 90% DENSITY WHEN PIPE IS OVER REFUSE FILL 18" MIN. TRENCH WIDTH DETAILS - PIPE TRENCH ninr Tnrnini i AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 F9 , k 2" HDPE SDR 9 COMPRESSED AIR LINE WHERE APPLICABLE HDPE SDR 17 LFG HEADER/ LATERAL SAND OR SELECTED GRANULAR BEDDING AND BACKFILL COMPACTED TO 95% DENSITY AT OPTIMUM MOISTURE CONTENT WHEN PIPE IS LAID IN NATIVE SOIL AND 90% DENSITY WHEN PIPE IS OVER REFUSE FI EL iEADER/LATERAL �hT 10- 11-1 DETAIL - MANHOLE COVER nNiicUEn r'oAnE- 18" MIN. TRENCH WIDTH SECTION A 55 DETAIL - TRENCH DAM 3 25 PREPARED BY: APPROVED SCS ENGINEERS CITY ENGINEER R.C.E. NO. 24967 ENVIRONMENTAL CONSULTANTS DATE 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED DRAWN LONG BEACH, CA 90806 S. KOTHARY L. FUENTES PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATE M. GEYER SEP 19, 2006 EI LL PIPE C-3651 LANDFILL GAS COLLECTION AND CONTROL SYSTEM NEWPORT TERRACE LANDFILL CITY OF NEWPORT BEACH M -5374-S PUBLIC WORKS DEPARTMENT SHEET 5 of 21 E 4� CHECK VALVE P,"ur) 1i-" (TYP) I IL/1VL1\ — LIINL_ U MOISTURE SEPARATOR VI VACUUM INDICATOR P PRESSURE INDICATOR SCHEMATIC FLOW DIAGRAM - LFG TREATMENT AND DISPOSAL SYSTEM XPi DIFFERENTIAL PRESSURE INDICATOR N.T.S. EG LIQUID GAUGE �11L FLEX CONNECTOR E a ECT TO ING 8" QED BARGE IT STACK AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 O I I I I M. bt T LM I JtF' I `J, LUUb I . - - -. - .. -. ". -- - -. . -. - ........ I --.. _ _ . - - . _ _ I EXISTING BLOWER - VENT SYSTEM 1" = 15-0" :XISTING BLOWER BUILDING - DEMOLITION, PRESERVATION AND REHABILITATION NOTES 1. REFER TO ELECTRICAL NOTES (E1) FOR REMOVAL, PRESERVATION AND RE—HABILITATION OF ELECTRICAL SYSTEMS. 2. REMOVE ALL EXISTING EQUIPMENT INSIDE THE BUILDING; FOR EXAMPLE: MOTORS, BLOWERS, CANISTERS, PIPING. 3. PRESERVE ALL PIPE PENETRATING THE FLOOR TO CONNECT TO NEW EQUIPMENT PER THE PROJECT DRAWINGS AND SPECIFICATIONS. 4. REMOVE DOORS AND DOOR FRAMES. 5. REMOVE ALL VEGETATION WITHIN 12—INCHES OF ALL EXTERIOR WALLS. 6. CUT (BORE) A 6—INCH HOLE IN WALL FOR LATERAL LINE—B (PER DRAWINGS) AND A 2—INCH HOLE IN WALL FOR DRAIN PIPE (PER DRAWINGS) 7. REMOVE CHAIN—LINK CEILNG. 8. PRESSURE WASH WALLS, BOTH INSIDE SURFACES AND OUTSIDE SURFACES, AND PREPARE SURFACES FOR NEW PAINT SYSTEM. 9. INSTALL NEW DOORS AND DOOR FRAMES AS SHOWN ON DRAWINGS EXISTING CMU WALL AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 o I I I I M. bt T LM I JtF' I `J, LUUb I . - - -. - .. - . ". -- - -. . -. ' ........I - . _ _ . - - . _ _ I o Q a� 0 0 0 Q Z! I 0 0 0 0 0 N 2"0 BURRIED SDR 9 HDPE AIR LINE CONDENSATE SUMP NO.1 TRANSITION FITTINC EXISTING CMU WALL AIR COMPRESSER FU[ FEATURE MODEL GX AS MANUFACTURED E ATLAS COPCO C STOCKTC BLOWER BUILDING PLAN SCALE: 1 " = 15-0" PIPE SUPPORTS SHOWN ON THE DRAWINGS ARE INTENDED TO BE DEPICTIVE AND MAY NOT REPRESENT THE EXACT NUMBER REQUIRED TO SUPPORT THE PIPING AND APPURTENANCES IN A FIRM SUBSTANTIAL MANNER FROM THE SLAB/FINISH GRADE AT THE REQUIRED ELEVATIONS. IT IS THE CONTRACTOR'S RESPONSIBILITY TO PROVIDE SUFFICIENT NUMBER OF PIPE SUPPORTS WHERE REQUIRED OR AS RECOMMENDED BY THE PIPE MANUFACTURER. URE SEPARATOE E DETAIL ( --2-) 8 10 DVC SCH 80 90° BEND (TYP) =THANE GAS SENSOR REGENERATING BLOWER MODEL CP-808FX5MWLR -----� 4" HDPE LFG LATERAL — LINE B NOTES: 1. THE PLAN SHOWS THE BASIC LOCATIONS OF THE MAJOR COMPONENTS OF THE LFG TREATMENT AND DISPOSAL SYSTEM. THE PIPING AND VALVES ARE JUST THE REPRESENTATIONS AND SHALL BE INSTALLED AS CLOSE AS POSSIBLE TO THE EQUIPMENT THEY ARE SERVING. THE ACTUAL EQUIPMENT, PIPING AND VALVES SHALL BE INSTALLED SUCH THAT THERE IS AN ADEQUATE ROOM ALL AROUND THE EQUIPMENT AND PIPING FOR EASY OPERATION AND MAINTENANCE OF THE SYSTEM. 2. ALL PIPING WITHIN THE BUILDING SHALL BE CPVC SCH 80 3. THE CONTRACTOR SHALL MAKE AN EFFORT TO INSTALL ALL THE HORIZONTAL RUNS OF THE PIPING AT A MAXIMUM ELEVATION OF 2'-0" WITHIN THE BUILDING. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 O I I I I M. bt TtK I JtF' l y, LUUb I . - - -. - .. - � - -- - — . .. - ...-... I -- -- • - - -- I 4" CPVC SCH 90° BEND (T) 4" CPVC SCH TEE (T) 4" TRUE UNI BALL VALVE (T) EXISTING BELOW GRADE 8"6 PIPE I DJ SECTION a N.T.S. " —' " SCH 80 (TYP) EXISTING BELOW 8U DRAIN LINE GRADE 8"0 PIPE SECTION c N.T.S. 8 U9 :TE SLAB 4'-6"X4" HIGH) XISTING BUDDING LOOR SLAB i u) �,rvu purl 80 DRAIN LINE 4"0 CPVC SCH 80 PIPE n" A /- n\ i r- c- r- i 1 0 rl\ 1"0 CPVC SCH 80 EXIS- FLOC 1 1/2" CPVC SCH 80 TRUE UNION BALL VALVE 3"X1 1/2" CPVC SCH 80 REDUCER SECTION e N.T.S. 8 9 1 1/2" CPVC SCH 80 CHECK VALVE m a, N. 6" 'AD. ff`t rCCDMr\ I L U. l,. 4" EMBEDMENT, EXPDXY INTO EXISTING SLAB REGENERATIVE BLOWER MODEL CP-404FQ58MLR AS MANUFACTURED BY AMETEK TECHNICAL AND INDUSTRIAL PRODUCTS OF KENT, OHIO OR APPROVED EQUAL SCH 80 3" CPVC SCH 80 PIPE (TYP) 3/8" RED HEAD—MIN. 6" EMBEDMENT INTO PAD 1 1/2" FLEX H OSE EXISTING BUILDING (TYP) 2'-0"X1'3"X4" HIGH FLOOR SLAB ° CONCRETE PAD ° .a 41. ° DVC SCH 80 a ° a ° a ° a a ° as ° ° a a a ° ° a s ° ° a s a P a TYP) a °a d a ° ° a NG BUILDING � SLAB D/ c r«u MEAD MIN. 6" EMBEDMENT INTO EXISTING SLAB (TYP.) AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 SECTION —_—(& N.T.S. 8 9 #4 REBAR 12" O.C. EPDXY 4" EMBEDMENT INTO EXISTING SLAB C-3651 CN cc E Q N I 0 0 o 0 Q) Q) 0 0 U 0 0 ti w J m i Q U 0 i L 0 Q z i 0 CN 0 0 0 0 N 2"0 unn� cno 1 1 CON FROM CONDENSATE S EXISTING GRADE ADDLE 8"DIA. HDPE SDR 17 LFG HEADER DETAIL - CONNECTION OF CONDENSATE LINE TO LFG HEADER N.T.S. PVC SCH 80 COUPLING EXISTING P.V.0 HEADER/LATERAL PVC SCH 80 RE HDPE F HDPE HEADER/LA- SEE PL/ I In lr r`17r n\/n f -`n I nn TrE EXISTING PVC HEADER/LATERAL =CTION TO BE WRAPPED dIL PVC SHEETING AND D WITH S.S. STRAPS S.S. BOLTS AND BOLTS VALVE BOX PER DETAIL 7� 1 DETAIL - CONNECTION TO EXISTING LFG LATERAL N.T.S. 9 12"X8" S.S. NUTS AND BOl CONNECTION TO BE WRAPPED IN 6 MIL PVC SHEETING AND BANDED W/S.S. STRAPS LINE 8" HDPE FLANGE P.V.0 BU1 8" PVC Sun OU FL/-uvUL JrUUL VALVE BOX PER DETAIL 7 101 MOISTUR EXISTING CONCRETE SLAE 19"�- VALVE BOX PER DETAIL 7� 1 DETAIL - MOISTURE SEPARATOR N.T.S. EXISTING 12" PVC HEADER/LATERAL ALVE DETAIL - CONNECTION BETWEEN 8" LFG HEADER TO EXISTING 12" HEADER N.T.S. PROVIDE STEEL CRADLE— W/ NEOPRENE PAD PER PIPE REQUIREMENTS (TOLCO OF CORONA, CA OR APPROVED EQUAL) 2" EXISTING CONCRETE MIN. SLAB T ' RED HEAD MIN. 4" EMBEDMENT (TYP.) INTO EXISTING SLAB FAI L' MOISTUR EXISTING CONCRETE S LAE DOUBLE NUTTED U—BOLTS PER MFR'S RECOMMENDATIONS. DO NOT TIGHTEN U—BOLT ON FRP PIPING. 2 1/2"0 SCH.4O STEEL PIPE (HEIGHT VARIES) STD. PIPE FLANGE ATTACHED TO CONCRETE W/ 4 S.S. 5/8" MIN. 4" EMBEDDED STUD TYPE WEDGE ANCHORS. 2" MIN. NEW CONCRETE PAD #4 REBAR DOWELS MIN. 4 DOWELS EACH 4" EMBEDMENT INTO EXISTING SLAB W/EXPDXY DETAIL - PIPE SUPPORT ITYP.I N.T.S. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 �19 DETAIL - MOISTURE SEPARATOR N.T.S. CONCRETE SURROUND (f'c = 2,500psi) 'TION INLET AUGE )/u L -t -\D MIN. 4" EMBEDMENT (TYP.) INTO EXISTING SLAB C.I. HEAVY DUTY VALVE BOX W/LOCKING TRAFFIC COVER MODEL NO. A-2989 AS MANUFACTURED BY ALHAMBRA FOUNDRY CO., OF ALHAMBRA, CALIFORNIA OR APPROVED EQUAL (TYP) 14" VARIES MIN. FINISHED GRADE L 12 d. •'d .3 d a e d 0 d d%' 4" IMIN VARIES DETAIL -VALVE BOX � N.T.S. 01 C-3651 BEST PRACTICES FOR FIRE NOTES ARCHITECTURAL NOTES GENERAL NOTES PROJECT ADDRESS: CONSTRUCTION ACTIVITIES I. BUILDINGS UNDERGOING CONSTRUCTION, ALTERATION OR DEMOLITION SHALL BE IN ACCORDANCE WITH CFL ARTICLE 07 (UFC,/GFG SEG. g p I. ALL REQUIRED APPROVALS MUST BE OBTAINED FROM THE FIRE AND HAZARD PREVENTION SERVICES BEFORE THE BUILDING IS OCCUPIED. 1. ALL WORK SHALL BE IN ACCORDANCE WITH THE 2001 EDITION OF THE CALIFORNIA BUILDING CODE, TITLE 24, AND ALL LOCAL ORDINANCES AND NE�NFORT TERRAr.E r.ONDO5 NFNFORT 5EAGH GA ADD 2. RESS SHALL BE PROVIDED FOR ALL NEW AND EXISTING BUILDINGS IN A POSITION AS TO BE PLAINLY VISIBLE AND LEGIBLE 2. EXIT DOORS TO BE OPERABLE FROM THE INSIDE WITHOUT THE USE O REGULATIONS BY AUTHORITIES HAVING JURISDICTION OVER THE PROJECT I. ERODED SEDIMENTS AND OTHER POLLUTANTS MUST BE RETAINED ON SITE AND MAY NOT BE TRANSPORTED FROM THE SITE VIA FROM THE STREET OR ROAD FRONTING THE PROPERTY (UFC,/CFC. SEC. A KEY OR ANY SPECIAL KNOWLEDGE OR EFFORT. 2. IT SHALL BE THE BUILDERS RESPONSIBILITY TO INVESTIGATE THE EXISTING SHEETFLOW, SWALES, AREA DRAINS, NATURAL DRAINAGE COURSES 3. DECOR?FHFS FOLIC, -i - AT RIALS°OHALL BE MAINTAINED IN A FLAME 3. FIRE AND/OR SMOKE DAMPER ASSEMBLIES, INCLUDING SLEEVES, AN INSTALLATION PROCEDURES SHALL BE APPROVED BY THE INSPECTIO CONDITIONS OF THE PROPOSED SITE. ANY UNUSUAL OR SPECIAL CONDITIONS SHALL BE BROUGHT TO ATTENTION OF THE DESIGNER IN WRITING. OR WIND. RETARDANT CONDITION. (GAL LODE REQS., TIT. 1-1, SEG. 8.08, 8.21, SERIGES 1:;)I\,/1510N PRIOR TO INSTALLATION. 8. THE BUILDER SHALL FURNISH ALL LABOR, MATERIALS, SUPERVISION, TOOLS, DEFERRED SUBMITTAL 2. STOCKPILES OF EARTH AND OTHER CONSTRUCTION RELATED 4. AFT LEA�NI= FIRE EXTINGUISHER WITH A MINIMUM RATING OF 2AIOBG SHALL BE PROVIDED WITHIN 75' MAXIMUM TRAVEL DISTANCE FOR EQUIPMENT, WAREHOUSING, TRANSPIRATION, TEMPORARY FACILITIES AND MATERIALS MUST BE PROTECTED FROM BEING TRANSPORTED FROM THE SITE BY THE FORGES OF WIND OR WATER. EACH 1000 50. FT. OR PORTION THEREOF ON EACH FLOOR. (UFC/GFG OTHER NECESSARY ITEMS AS REQUIRED TO COMPLETE THE WORK DETAILED, SHOWN OR REQUIRED. DB1`BRRBD SUBMIfifiAL(S) SHALL �B PROVIDBD FOR fiHfB 5. SEC. 1002 PLGANS AN°DASPEG°I F I C AT ONS®F°OR FIRE ATLARM SYSTEMS; FOL=L=OV I N& BUILDING COMPONENTS/F_L F_MENTS: 8. FUELS, OILS SOLVENTS AND OTHER TOXIC MATERIALS MUST BE FIRE -EXTINGUISHING SYSTEMS, INCLUDING AUTOMATIC SPRINKLERS 4. THE BUILDER SHALL PROVIDE ADEQUATE SUPERVISION FOR ALL JOB SITE STORED IN ACCORDANCE WITH THEIR L I STING AND ARE NOT TO AND WET $ DRY STANDP I PES; HALON SYSTEMS AND OTHER SPECIAL OPERATION. THE SUPERVISION SHALL HAVE THE NECESSARY KNOWLEDGE, CONTAMINATE THE SOIL AND SURFACE WATERS. ALL APPROVED TYPES OF AUTOMATIC FIRE -EXTINGUISHING SYSTEMS; BASEMENT PIPE EXPERIENCE AND AUTHORITY TO CONDUCT THE REQUIRED ACTIVITIES IN STORAGE CONTAINERS ARE TO BE PROTECTED FROM THE INLETS; AND OTHER FIRE -PROTECTION SYSTEMS AND APPURTENANCES COMPLIANCE WITH THESE NOTES. BUILDING CODE DATA WEATHER. SPILLS MUST BE GLEANED UP IMMEDIATELY AND DISPOSED OF IN A PROPER MANNER. SPILLS MAY NOT BE WASHED THERETO SHALL BE SUBMITTED TO FIRE AND HAZARD PREVENTION SERVICES FOR REVIEW AND APPROVAL PRIOR TO INSTALLATION. 5. THE BUILDER SHALL AT ALL TIMES KEEP THE PREMISES GLEAN AND FREE TYPE OF CONSTRUCTION: V -N SPRINKLERED: ❑YES INTO THE DRAINAGE SYSTEM. 6. �IErIIS +YSTEMS SHALL BE INSTALLED IN ACCORDANCE WITH UBC/CBC SEG. c104 AND COMPLY WITH UBG STANDARDS 11-1 AND FROM AN ACCUMULATION OF WASTE MATERIAL AND RUBBISH. AT THE END OF EACH WORK DAY THE BUILDER SHALL REMOVE ALL DEBRIS FROM Z NO 4. EXCESS OR WASTE CONCRETE MAY NOT BE WASHED INTO THE PROPERTY AND LEAVE THE WORK AREA IN A BROOM GLEAN CONDITION. THE BUILDER SHALL SUPPLY THE TRASH BINS. OCCUPANCY CLASSIFICATION: H-7 NUMBER OF STORIES: 1 7• ALL ROLLING THE WATER SUPPLY FO PUBLIC WAY OR ANY OTHER DRAINAGE SYSTEM. PROVISIONS NKLER SPRINKLER SYSTEMS AN TCHES ON ALL�THE SHALL BE MADE TO RETAIN CONCRETE WASTES ON SITE UNTIL SYSTEMS S CTRONICALLY MONIT UMBS 6. DAILY CONSTRUCTION ACTIVITIES AND MATERIAL STORAGE SHALL BE BUILDING HEIGHT: 16 +/- FEET THEY GAN BE DISPOSED OF AS SOLID WASTE. 5. R ALAR SYSTE S ALL G DA G T G/GFG SEC. CONDUCTED SO AS TO PROVIDE FOR SAFETY OF PERSONNEL WORKING IN GOVERNING CODES: 2001 CALIFORNIA BUILDING CODE (CBC) q. IS�C�T"7USED THE AREA. 5. TRASH AND CONSTRUCTION RELATED SOLID WASTES MUST BE DEPOSITED INTO A COVERED RECEPTACLE TO PREVENT 7. THE BUILDER SHALL PROVIDE A TOILET, JOB PHONE, ALL TEMPORARY FACILITIES REQUIRED FOR A SAFE CONSTRUCTION OPERATION. CARE SHALL FLOOR AREA ANALYSIS CONTAMINATION of RAINWATER AND DISPERSAL BY WIND. 10. FIRE PROTECTION, INCLUDING FIRE APPARATUS ACCESS ROADS AND BE TAKEN TO PROJECT EXISTING GONSTRUGTI ON, EQUIPMENT, FURNITURE AND 4 41 100 0 OPEN YARDS: SIDES, MIN. WIDTH ft, /a INCREASE 1. SEDIMENTS AND OTHER MATERIALS MAY NOT BE TRACKED WATER SUPPLIES FOR FIRE PROTECTION, SHALL BE INSTALLED AND MADE SERVICEABLE PRIOR TO AND DURING TIME OF CONSTRUCTION. PERSONNEL IN THE AREA OF CONSTRUCTION. THE BUILDER WILL BE ALLOWED TO USE WATER a POWER AVAILABLE ON THE SITE a AT NO COST. FROM THE SITE BY VEHICLE TRAFFIC. THE CONSTRUCTION ENTRANCE ROADWAY MUST BE STABILIZED SO AS TO INHIBIT 11. I I R' �1TS��IH LL7�U1�IP' I + FHPS POLICY F -16-0I FOR 8. PROPOSED SUBSTITUTIONS OF MATERIALS, COMPONENTS AND SPECIFIED NOTE: OPEN YARDS USED FOR FLOOR AREA INCREASE SHALL BE MAINTAINED THROUGHOUT SEDIMENTS FROM BEING DEPOSITED INTO THE PUBLIC WAY. 12 �IL-ESI�T��ilY�i�AI�ITS SHALL BE IDENTIFIED BY THE EQUIPMENT OTHER THAN THOSE INDICATED IN THIS DRAWING OR THE LIFE OF THE BUILDING. OCCUPANCIES H-7 ACCIDENTAL DEPOSITIONS MUST BE SWEPT UP IMMEDIATELY AND INSTALLATION OF REFLECTIVE MARKERS. (UFC,/GFG SEG. 1�10L4.8) SPEGIFICATION OR ALTERNATE METHODS OF PERFORMING THE WORK WHICH MY NOT BE WASHED DOWN BY RAIN OR OTHER MEANS. WILL RESULT IN OVERALL COST SAVINGS WITHOUT IMPAIRING THE UTILITY OR BASIC AREA, ft' 13. PROVID 0\/El::)ILLUMINATED DIRECTOR CTED IN FUNCTION, WILL BE CONSIDERED FOR EVALUATION IF SUBMITTED IN WRITING (a) PER TABLE 5-13 2500 SF - - i. ANY SLOPES WITH DISTURBED SOILS OR DENUDED OF ACCORDANCE WITH FH - OMPLETE, FULLY FOR APPROVAL BEFORE TIME OF BID. AFTER CONSTRUCTION HAS STARTED AREA INCREASE VEGETATION MUST BE STABILIZED AS TO INHIBIT EROSION BY WIND DIMENSIONED PLA G MATERI D OF CONSTRUCTION SUBSTITUTIONS APPROVAL MUST BE AUTHORIZED BY THE DESIGNER. AND WATER AND OF INSTALLATION SHALL BE SUBMITTE AND MULTIPLIER FOR (b) - - - - I ION 01. PRIOR TO FINAL INSPECTION, A CERTIFICATE OF CONSTRUCTION OPEN YARDS 2 (UFC/CFC SEG. cTOI.4.4) COMPLIANCE SHALL BE MADE READY FOR THE DESIGNER. THE CERTIFICATE PER SEC. 505.1 SHALL STATE THE "BASED UPON PERSONAL KNOWLEDGE, THAT THE WORK AREA INCREASE APPEARS TO HAVE BEEN PERFORMED AND MATERIALS USED AND INSTALLED MULTIPLIER FOR APPEAR IN EVERY MATERIAL RESPECT IN COMPLIANCE WITH THE PLANS, SPRINKLERS (c) 1 - - - - DRAWINGS AND SPECIFICATIONS." THE CERTIFICATE MUST BE SIGNED BY THE ONE-STORY BUILDER. PER SEC. 505.3 AREA INCREASE MULTIPLIER FOR - 10. IT IS THE INTENT OF THE DRAWINGS THAT ALL NEW WORK SHALL MATCH EXISTING WORK IN PLACE. ANY CONFLICT WITH INTENT OF DRAWINGS AND SPRINKLERS (d) 1 - BOUNDARY LINE OR SPECIFICATIONS SHALL BE BROUGHT TO THE DESIGNER'S ATTENTION. MULTI -STORY PER SEC. 505.3 - - - _ _ - - -LO 11. THE BUILDER AND ALL SUBCONTRACTORS SHALL VERIFY ALL DIMENSIONS AND CONDITION ON THE JOB SITE PRIOR TO BEGINNING OF CONSTRUCTION AREA INCREASE } 0 �W AND REPORT ANY DISCREPANCIES TO THE DESIGNER. MULTIPLIER FOR 101♦0 RECOVERY ♦___ ______i ____.�_--__---- O0BUILDINGS W-103 MULTI-STORYVAPOR (e) - FACILITY IW -102 COURT 12. THE BUILDER, AT HIS/HER OWN EXPENSE, SHALL KEEP THE PROJECT AREAS AND SURROUNDING AREA FREE FROM DUST AND OTHER NUISANCES. PER SEC. 504.2 ____ ---_ THE WORK SHALL BE IN CONFORMANCE WITH THE AIR POLLUTION CONTROL ALLOWABLE AREA ONE-STORY, ft 5000 SF - ' 1 I SUNpANCE`' I STANDARDS AND REGULATIONS OF AUTHORITIES HAVING JURISDICTION OVER (a)x(b)x(c) 1 1 WINDSONG CT. 1 VENT STACK I I 1D 31 THE WORK. B 5. THE BUILDER SHALL FURNISH ADEQUATE SCAFFOLDING, RACING, ALLOWABLE AREA MULTI -STORY ftZ 1 BARRICADES AND PROTECTIVE MEASURES AS REQUIRED TO SAFELY (a)x(b)x(d)x(e) w w I o I NJ's? EXECUTE ALL WORK AND SHALL BE FULLY RESPONSIBLE FOR SAME. ♦ 32 ~ o LL' 1 1 2 1 14. CONSTRUCTION DEBRIS AND WASTES SHALL BE DEPOSITED AT AN FLOOR AREAS PER OCCUPANCY: > I -- - g J 4 o ��------------------------ II � APPROPRIATE SITE AND IN APPROPRIATE MANNER. OCCUPANCIES SUM / FLOOR CT. I "T 33! I - -------------� 15. ALL REQUIRED PERMITS SHALL BE OBTAINED BY THE BUILDER FROM AUTHORITIES HAVING JURISDICTION OVER THE WORK. PLAN CHECK FEES, FLOORS ft ft ft ft2 1 SANpFLOwER `�` 3% ENTITLEMENTS AND DISCRETIONARY PERMITS MAY BE REQUIRED AND SHALL 27 I BIGDIPPER CT. : l` 28 �.�o--� I_ ♦- -. • �` 29 ___+_- ` ` �` 4 �` BE PAID FOR BY OWNER. I1. PROVIDE ALL NECESSARY BLOCKING, BACKING, BACK-UP FRAMING FOR 4th 34`� �� �'� `•` �`�` . `� �`�5 26�� Go LIGHT FIXTURES, TOILET FIXTURES, ELECTRICAL UNITS AND A/C EQUIPMENT. 3rd 2nd 1st 500 •I i'� .XI I i � .�`�, �. 25 6 10 1 R IOTO THE ISSUANCE'S OF A BUILD 7. PR35 BUILDING PERMIT, THE BUILDER SHALL SUM /OCCUPANCY 500 It � �`,;��,-� 7 .' I ------- -� 30 ` I �' - %`� I I � . I-1'�,,,`�., 8 ��'' � J I �.• 24 I '`�J'`�1w g HAVE EVIDENCE OF CURRENT WORKMAN'S' COMPENSATION INSURANCE COVERAGE ON FILE WITH THE BUILDING DEPARTMENT AND IN A FORM IN COMPLIANCE WITH SECTION 8800 OF THE CALIFORNIA LABOR CODE. G� 3611 POOL AREA �� 1 O I I w i 1 I 0J `` 23 I 0 SUMMERWALK CT. I I Q� • I 8. DIMENSIONS: ALL DIMENSIONS ARE TO THE ROUGH CONSTRUCTION UNLESS OTHERWISE 1st BASEMENT 2nd BASEMENT ------------ v_vi � I _- ---- I 37 NOTED. w ALL DIMENSIONS SHALL HAVE PREFERENCE OVER SCALE ALL DIMENSIONS OF CONCRETE OR MASONRY ARE TO THE FACE OF G� 1I W CONSTRUCTION. VICINITY MAP W- �5� I --�� DRIVE �� 22 I r - p1SCOVERY DO I q. NOT USED a ' ] ' 21co ; 20. SPECIAL NOTE TO BUILDER: IF YOU DISCOVER A CONFLICT BETWEEN DRAWINGS OR SPECIFICATIONS AND DRAWINGS, THE HIGHER PRICED ; J y�L! i �` 20 ' PRODUCT OR PROCESS SHALL GOVERN (SHALL BE CHOSEN). 21. SUBMITTAL DOCUMENTS FOR DEFERRED SUBMITTAL ITEMS SHALL BE SUBMITTED TO THE TSU I LD I NO OFF 1 C I AL FOR REVIEW AND APPROVAL e = ucsc�iss Ta,6er,. �cgwnal Park i ANO 19 1 1 5 = 14 BY THE PROJECT ARCH I TELT, AND NOT BY THE I ND I V I DUAL SUB -CONTRACTOR /CONSULTANT. •'Y�� � � i SAS, _ g tlenPi G� •--+---♦- --------t- • �I 16 __----Z_-� 39 ---- O� 17 ,._--- -- •-- 40 41 COU�T 42 43 44 Q��� X18 _---- __--•-- II �� `�-- __•_-- , II w I r J I� ! k 1 3 00i 22. DEFERRED SUBMITTAL DOCUMENTS IN ADDITION TO THE SEAL OF THE RESPONSIBLE ENGINEER, SHALL BEAR THE SHOP DRAWINGI� APPROVAL STAMPS OF THE PROJECT ARGHITEGT, ENGINEER OF RECORD, AND THE GENERAL GONTRAGTOR ON ALL SHEETS OF PLANS X30 -E ; � s'� I, e'er ]t- E .� C w s: �' U a w 2wn Ss Sem & . BLOCK WALL �J ' ` II `� ICammu 49 45 •-----_♦__----+------+____-� � AND DOVER OF THE CALCULATIONS. 25. SUBMITTAL DOCUMENTS FOR DEFERRED SUBMITTAL ITEMS SHALL BE w Genymn ' � � SI� ge Park, 0 . 46 I 47 48 O T 1 2 mQ COUR SUBMITTED IN A TIMELY MANNER THAT ALLOWS A MINIMUM OF THIRTY CALENDAR DAYS FOR THE INITIAL PLAN REVIEW TURN -AROUND.-` I I =n w,en� LJe wlsln - r I pB�Rp I 0 SE Q 0 RFSM� STARFIS ♦----------•---------♦ SO 24. DEFERRED SUBMITTAL ITEMS SHALL NOT E3E FABRICATED / INSTALLED UNTIL THEIR DESIGN AND SUBMITTAL DOCUMENTS HAVE BEEN APPROVED BY THE BUILDING OFFICIAL. Mem vi�'�� �� � 0 0 P3 ❑eaM SS I c ss n caMerss ; rast - weamo. a _ ♦CO -N � ��5 455 01 25. PROVIDE TWO COPIES OF DEFERRED SUBMITTAL DOCUMENTS FOR KID' �/''�l �/ 0 W - - - - FINAL APPROVAL. W19tl�9k - PROJECT r^'s� - a f LOCATION D `'z= Jae P -M �qf _ - - -B L V D UNDEVELOPED LAND BALBOA -- to 1 F � m. � ��'�� I � ' � TS 1,90 PLOT PLAN- NTS A-1 C-3651 A -B ILT APPROVED PREPARED BY: Fax -(562)421-2055 Phone(562)421-3100SCS THE USE OF THESE PIANS & SPECIFICATIONS SHALL DE 4195 N. VIKING WAY BASED ON SURVEY INFORMATION RECEIVED FROM RESTRICTED TO THE ORIGINALSIiEFORWHICHTHEYWERE Suite 130 PREPARED & PUBLICATION THEREOF IS D1(PRESSLY UNITED TO Long Beach ENC31NEERS LANDFILL GAS COLLECTION CITY ENGINEER R.C.E. NO. 24967 SUCH USE WHOLEORIREPRODUCTION PUBLICATION OR RE -USE TO TANYHE California 90808 NEIHOD, IN WHOLE OR IN PART IS PROHIBITED. RTL TO THE INNOVATIVE CONSTRUCTION BANS & SPECIFICATIONS RENIN IN THE JON SUMMERS, NA E-MMoil: jon.sommers®verizon.net AND CONTROL SYSTEM THESE PIANS & SPESPECIFlCATIOETS SHALLCONSTITUTE PRIMA FACIE ENDENCE OF ME ACCEPTANCE OF THESE RESTRICTIONS. SOLUTION, INC ARCHITECT WHHPREJUDICE VISUALCONTACT WDA JONS"ERS ENVIRONMENTAL CONSULTANTS DATE NEWPORT TERRACE LANDFILL Design ArchitPlannecture DATE.- 05-05-08 AKARCHITCIS 3900 KILROY AIRPORT WAY, SUITE 100 LONG BEACH, CA 90806 DESIGNED J. SOMMERS DRAWN J. SOMMERS CITY OF NEWPORT BEACH M -5374-S Engineering PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATEPUBLIC WORKS DEPARTMENT SHEET 11 OF 21 SEP 19, 2006 .......... .................. .................... ...................... ........................ ......................... ........................... ............................. .............................. ................................ .................................. .................................... ...................................... .......................................... ■INEINEENiESEE■ WMINE /%INEINE ■MM - EINEINE■ INEENINEINEENINE ANN 01001 EE L 0 EN MZE I NE INE INE INEINEEN■ ANNINEEN 1 DEMOL T ON N07ES DEMOL T ON NOTES RDMO\/E WOOD S 1 D I NCS, WOOD PURRI NCS, REMOVE WOOD S D NCS, WOOD FURRI NCS, WOOD FAG I A, WOOD TRIM, $ WOOD PARAPET WOOD FAG I A, WOOD TRIM, $ WOOD PARAPET GUT EXIST10 GONG SLAB AS SHOWN ON MEGHIANIGA GUT EXIST'C� GONG SLAB AS SHfOWN ON MEGH#ANIGA DRAWINGS FOR GONG PEDESTAL FOUNDATIONS FOX DRAW I NGS FOR GONG FFDF_STAL FOUNDATIONS FOf NEW EOU I PMENT NEW EOU I PMENT REMOVE EXIT'G WOOD DOORS REMOVE F-XIT'G WOOD DOORS EXIST'G ELEGTRIG SER\/I(f E $ METER EXIST'G ELE(f, TRIGMETER � I I DI EXIST'& GONG BLOCK WALLS EXIST'& GONG BLOCK WALLS TO REMAINI \\\\ / I TO REMAIN � I I REMOVE EXIST'G CHAIN LINK MATERIAL ALL SUPPORTS FROM ROOF EXIST�I�� FLOOR DRA I 4 1 TO REMAIN [E] FLOOR DRAIN REMOVE EXIST'NEW VAPO EGOVERY EOU I PMENT. SEE EOU PM T. S MEGH 2 MEGH DRAW I NGS _ . \ x E e N $� Z�)E�0 T ON FLAN N 1:7_/ SCALE: 1/4" = 1'-0" OOF PROP LINE I � I IR O E STalr� IN LI ATERIAL & P TS I I EXIST T \ I FLOO E] FLOOR LE E D EXIST'O CONSTRUCTION TO REMAIN NEW GONSTRUGTION EXIST'0 GONSTRUGfiION TO EE REMOVED DOOR SCHEDULE 4195 N. VIKING WAY NO. W I DTH HE I OHT TH I GK. CORE T1'PF_ I°A0E FRAME � 0 yLd o v O - Engineering REMARKS 5'=0" =7'-O" =�/�" INSULATED HOI�I�OI�I METAL MST I� METAL [51 USE SE0URIT`` HINGES V / NON-REMOVAE3I=E SINS PR -3'-0" -7'=011 INSULATED HOLLOVW METAL METAL METAL [S] USE SECURITY HIN&ES N1 NON=REMOVAE3LE FINS AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 ON THE USE OF THESE PUNS & SPECIFICATIONS SHALL BE RESTRICTED TO THE ORIGINAL SITE FOR WHICH THEY WERE PREPARED & PUBUCATION THEREOF IS UPRESSLY UI TO SUCH USE. REPRODUCTION, PUBLICATION OR RE -USE BY ANY METHOD IN WHOLE OR IN PART IS PROHIBITED. TITLE TO THE AARCHITECT WITHOUT PREJUDICE. NSUALNCONACCTT Alk Wfiil THESE PIANS & SPECIFICATIONS SHALL CONSTITUTE EMMA FACE EMENCE OF THE ACCEPTANCE OF THESE RESTRICTIONS. TC STEEL U'� ` 1111111111► ■■■■■■■■■■■■ 25'-5"5/g TLOO FLAB S(f,ALE: 1/4" -1'-0" 5E T TN SCALE: I/4" -_ 1'-0" Phone(562)421-3100 Fax(562)421-2055 E_ ail: jon.sommers@verizon.net 1V:1= 12e1:1= 101*9 k. � 1 rTUT11' � I1NJ I I I1ri1IJ%T' rm7r ,iiil I I� �'W I � 7TTM rm rr[ � ■ • h • � 3900 KILROY AIRPORT WAY, SUITE 100 LONG BEACH, CA 90806 PH. (562) 426-9544 FAX. (562) 427-0805 OOF PROP LINE LE(S)END EXIST'C� CONSTRUCTION TO REMAIN NEW CONSTRUCTION EXIST'C� GONS7RUG7ION 70 5E REMOVED ACCESSIBILITY REQUIREMENTS FOR EXISTING BUILDINGS / PORTIONS I. 1 AM THE DESIGNER/OWNER IN RESPONSIBLE CHARGE OF THIS ADDITION/ALTERATION PROJECT; I HAVE INSPECTED THE SITE/PREMISES AND DETERMINED THAT EXISTING CONDITIONS, ❑ ARE ❑ AS IMPROVEID PER THESE PLANS, WILL BE IN FULL COMPLIANCE WITH CURRENT SITE ACCESSIBILITY REOU I REMENTS TO THE EXTENT REQU I RED BY LAW. ❑ DESIGNER NAME SIGNATURE DATE ❑ OWNER (PRINT) 2. 1 AM THE DESIGNER/OWNER IN RESPONSIBLE CHARGE OF THIS ADDITION / ALTERATION PROJECT; I HAVE INSPECTED THE SITE/PREMISES AND DETERMINED THAT EXISTING RESTROOM(S) SERVING AREA(S) OF A _ATERiEATION, L[I AS IMPROVED PER THESE PLANS, WILL BE FULLY ACGESSIBL.E ACCORDING TO CURRENT REQU I REMENTS. ❑ DESIGNER NAME SIGNATURE DATE ❑ OWNER (PRINT) 3. IF THE BUILDING INSPECTOR DETERMINES NONCOMPLIANCE WITH ANY CURRENT ACCESSIBILITY PROVISIONS OF THE LAW, HE/SHE SHALL REQUIRE SUBMITTAL OF COMPLETE AND DETAILED PLANS TO THE BUILDING DEVELOPMENT REVIEW DIVISION OF THE DEVELOPMENT SERVICES DEPARTMENT FOR FURTHER REVIEW. PLANS MUST CLEARLY SHOW ALL EXISTING NON -COMPLYING CONDITIONS AFFECTED BY THE REMODEL (INCLUDING SITE PLAN, FLOOR PLAN, DETAILS, ETC.) AND PROPOSED MODIFICATIONS OF DEFICIENCIES TO MEET CURRENT ACCESSIBILITY PROVISIONS. THE PLANS MUST BE STAMPED BY THE FIELD INSPECTOR PRIOR TO SUBMITTAL FOR PLAN REVIEW. A2,00 C-3651 A-3 APPROVED LANDFILL GAS COLLECTION CITY ENGINEER AND CONTROL SYSTEM R.C.E. NO. 24967 DATE NEWPORT TERRACE LANDFILL DESJ.ED AWN SOMMERS DR J. SOMMERS CITY OF NEWPORT BEACH M -5374-S CHECKED DATE PUBLIC WORKS DEPARTMENT SHEET 13 OF 21 SEP 19, 2006 4195 N. VIKING WAY Suite 130 Long Beach California 90808 JONSMERS Design Architecture Interiors AmikARCHIIECIS Planning Engineering SCALE: I/4" -_ 1'-0" Phone(562)421-3100 Fax(562)421-2055 E_ ail: jon.sommers@verizon.net 1V:1= 12e1:1= 101*9 k. � 1 rTUT11' � I1NJ I I I1ri1IJ%T' rm7r ,iiil I I� �'W I � 7TTM rm rr[ � ■ • h • � 3900 KILROY AIRPORT WAY, SUITE 100 LONG BEACH, CA 90806 PH. (562) 426-9544 FAX. (562) 427-0805 OOF PROP LINE LE(S)END EXIST'C� CONSTRUCTION TO REMAIN NEW CONSTRUCTION EXIST'C� GONS7RUG7ION 70 5E REMOVED ACCESSIBILITY REQUIREMENTS FOR EXISTING BUILDINGS / PORTIONS I. 1 AM THE DESIGNER/OWNER IN RESPONSIBLE CHARGE OF THIS ADDITION/ALTERATION PROJECT; I HAVE INSPECTED THE SITE/PREMISES AND DETERMINED THAT EXISTING CONDITIONS, ❑ ARE ❑ AS IMPROVEID PER THESE PLANS, WILL BE IN FULL COMPLIANCE WITH CURRENT SITE ACCESSIBILITY REOU I REMENTS TO THE EXTENT REQU I RED BY LAW. ❑ DESIGNER NAME SIGNATURE DATE ❑ OWNER (PRINT) 2. 1 AM THE DESIGNER/OWNER IN RESPONSIBLE CHARGE OF THIS ADDITION / ALTERATION PROJECT; I HAVE INSPECTED THE SITE/PREMISES AND DETERMINED THAT EXISTING RESTROOM(S) SERVING AREA(S) OF A _ATERiEATION, L[I AS IMPROVED PER THESE PLANS, WILL BE FULLY ACGESSIBL.E ACCORDING TO CURRENT REQU I REMENTS. ❑ DESIGNER NAME SIGNATURE DATE ❑ OWNER (PRINT) 3. IF THE BUILDING INSPECTOR DETERMINES NONCOMPLIANCE WITH ANY CURRENT ACCESSIBILITY PROVISIONS OF THE LAW, HE/SHE SHALL REQUIRE SUBMITTAL OF COMPLETE AND DETAILED PLANS TO THE BUILDING DEVELOPMENT REVIEW DIVISION OF THE DEVELOPMENT SERVICES DEPARTMENT FOR FURTHER REVIEW. PLANS MUST CLEARLY SHOW ALL EXISTING NON -COMPLYING CONDITIONS AFFECTED BY THE REMODEL (INCLUDING SITE PLAN, FLOOR PLAN, DETAILS, ETC.) AND PROPOSED MODIFICATIONS OF DEFICIENCIES TO MEET CURRENT ACCESSIBILITY PROVISIONS. THE PLANS MUST BE STAMPED BY THE FIELD INSPECTOR PRIOR TO SUBMITTAL FOR PLAN REVIEW. A2,00 C-3651 A-3 APPROVED LANDFILL GAS COLLECTION CITY ENGINEER AND CONTROL SYSTEM R.C.E. NO. 24967 DATE NEWPORT TERRACE LANDFILL DESJ.ED AWN SOMMERS DR J. SOMMERS CITY OF NEWPORT BEACH M -5374-S CHECKED DATE PUBLIC WORKS DEPARTMENT SHEET 13 OF 21 SEP 19, 2006 N C E Q N I 0 O N o 0 0 cc I W Z m I Q 0 0 Q z I O N N O N O i O O N M METAL FASG I A - .4 RIDGE \/ENT A�.O DORMER TOP OF A4.0 /ENT RI DCBE GONG SHINGLES 1 I� I-2 L -- -- - -- TS B X X 4 - TS5X5X2 TS5X2X4 l_ -I FIBRE GEMENT F BRE -GEMENT TRIM SIDING I \ TS B X B X I '� WOOD GRAIN LAP - 4 +� i+ TS B X B X SIDING PATTERN 4 + _ EXI5T'G \/ENT -- T 1 GONG — Z / �� BLOCK —Int—It —ICY—It / X X TS B X X 4 i X x I --- -- -- TS5XSX4 I I I TRA FLAN SCALE: /4" -11-0' _ \_ [E] GONG BLOCK I SCALE: I/4" = I' -O" ALTEI SATE DEDUC,,T IN LIEU OF FIBRE GEMENT SIDINO I, REMOVE ALL EXIST'O EXTERIOR MOOD SIDING, FURRING TRIM $ PARAPETS. FRESSURE WASH $ DE -GREASE EX I ST'O GONGRETE BLOCK WALLS. PATCH, REPAIR $ PAINT EXTER ORTR�/���� NAME SFE I F I OAT 10 N MODEL FINISH DOLOR DETAIL(S) RIDGE A4.O AND NOTES GONG SHINGLES I I2 12 F 15RE GEMENT +ARD I FLAN 5/16, TI=I I (f,K CEDAR =__ FACTORY =__ ATTAOI-I TO �MU'S �N/ AFRI OO :�O FC, ASM -144-0125F. S 1 Z.) I NO I UL 144 X 1=1/4 SMOOTH PINS AS SUFFL I E� 5Y ET � F TOP I�� L IG�O NSR=4O _UIjII MAS FASTENING SYSTEI-IS, SOLON, OH0. 440=24E5=,5&55 [E] CMU =__ ___ FAINT =__ FRESSURE lNASH �$ DE=GREASE. SIDING I O FATC,H AS NECESSARY $ FAINT. CONCRETE SIS I NCLES I DURAL 17E SKATE 5Y 1-IONIERI IFETILE G50 ER. 2656 METAL PANED V�ILDTI-� 12" CLASS A EASG I A I FIRE RAT I NO. 22 OA STEEL AS SUFPL I EL-,) 5Y 1- IETALS, ADELANTO, GA. / _760=246=5545 MAROUEE I/2" (fDX FL"r1NOOD OVER 1- FETAL DECD ___ AFFL i" I40RIZONTALL`T". USE SUISSTRUCTURE SUFFORT GOMFONENTS 5Y 1�I�ELROY. TOP O MASO RY P I �' S 4.0 �' _O w ollo O �.O O /ENT FIN. FLO R METAL FASCIA I FIBRE GEMENT TRIM EXIST'G GONG BLOCK FIBRE GEMENT TRIM - EXIS RIDGE VENT GONG NC TOP OF BLOCK V i ^EST ELFT ON _ EAST ELE\/T ON K R SCALE: 1/4'' = I' -O" 12 2 �a RIDGE \/ENT A4.0 DORMER TOP OF 0 \/ENT RIDGE GONG SHINGLES 12 L 42 ■ww■I� ■ww■I■ ■ww■I■-------------- ■ww■I■ • r - - - ■� \/ENT / \ O / O /ENT \ / FIN. \ / FLO( SOUTH ELF\/TON SCALE: I/4" = I' -O" AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 TOP MAS P A3.0 C-3651 A-4- PREPARED BY: APPROVED THE USE OF THESE PIANS & SPECIFICATIONS SHALL DE 4195 N. VIKING WAY ENC31NEERS LANDFILL GAS COLLECTION RESTRICTED TO THE ORIGINAL SIZE FOR WHICH THEY WERE Suite 130 Phone 562 421-3100IPREPARED & PUBUCATION THEREOF IS EXPRESSLY UNTTD TO Long Beach Fax_(562)421-2055aM ( ) SUCHUSEREPRODUCTIONPUBLICATIONORREANY E- ail:CSAND CONTROL SYSTEM NEMOD, IN WHOLE OR IN AART IS PROHIBRTD. TTLE TO'HE California 90808 jon.sommers®verizon.net CITY ENGINEER PLANS & SPECIFICATIONS RENIN IN THE JON SONNERS, Alk R.C.E. NO. 24967 THESEARCHITECT WTHOUT PREJUDICE VISUAL CONTACT WITH JONS"ERS ENVIRONMENTAL CONSULTANTS DATE THESE PIANS & SPECIFICATIONS SHALL CONSTITUTE PRIMA NEWPORT TERRACE LANDFILL FACIE ENDENCE OF THE ACCEPTANCE OF THESE RESTRICTIONS. Design 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED DRAWN nterioesture AKARCHITCIS LONG BEACH, CA 90806 J. SONNETS J. SONNETS CITY OF NEWPORT BEACH M -5374-S EnginePlanniering PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATE PUBLIC WORKS DEPARTMENT SHEET 14 OF 21 SEP 19, 2006 RIDGE VENT DORMER TOP OF VENT RIDGE A4.O GONG SHINGLES I I2 12 42 -42 UL TOP _UIjII MAS SIDING I O WOOD G � SID V i ^EST ELFT ON _ EAST ELE\/T ON K R SCALE: 1/4'' = I' -O" 12 2 �a RIDGE \/ENT A4.0 DORMER TOP OF 0 \/ENT RIDGE GONG SHINGLES 12 L 42 ■ww■I� ■ww■I■ ■ww■I■-------------- ■ww■I■ • r - - - ■� \/ENT / \ O / O /ENT \ / FIN. \ / FLO( SOUTH ELF\/TON SCALE: I/4" = I' -O" AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 TOP MAS P A3.0 C-3651 A-4- PREPARED BY: APPROVED THE USE OF THESE PIANS & SPECIFICATIONS SHALL DE 4195 N. VIKING WAY ENC31NEERS LANDFILL GAS COLLECTION RESTRICTED TO THE ORIGINAL SIZE FOR WHICH THEY WERE Suite 130 Phone 562 421-3100IPREPARED & PUBUCATION THEREOF IS EXPRESSLY UNTTD TO Long Beach Fax_(562)421-2055aM ( ) SUCHUSEREPRODUCTIONPUBLICATIONORREANY E- ail:CSAND CONTROL SYSTEM NEMOD, IN WHOLE OR IN AART IS PROHIBRTD. TTLE TO'HE California 90808 jon.sommers®verizon.net CITY ENGINEER PLANS & SPECIFICATIONS RENIN IN THE JON SONNERS, Alk R.C.E. NO. 24967 THESEARCHITECT WTHOUT PREJUDICE VISUAL CONTACT WITH JONS"ERS ENVIRONMENTAL CONSULTANTS DATE THESE PIANS & SPECIFICATIONS SHALL CONSTITUTE PRIMA NEWPORT TERRACE LANDFILL FACIE ENDENCE OF THE ACCEPTANCE OF THESE RESTRICTIONS. Design 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED DRAWN nterioesture AKARCHITCIS LONG BEACH, CA 90806 J. SONNETS J. SONNETS CITY OF NEWPORT BEACH M -5374-S EnginePlanniering PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED DATE PUBLIC WORKS DEPARTMENT SHEET 14 OF 21 SEP 19, 2006 ON (P) NOTE: I. a. NEW FLASHING METAL SHALL BE MIN 22GA GI b. FLASH ALL ROOF, ROOF TO WALL INTERSECTIONS A5 WELL A5 ROOF PENETRATIONS 2. GUTTERS 4 DOWN5POUT5 SHALL BE ALUMINUM. SEE EXTER. WALL ELEVATIONS FOR DS LOCATIONS F�TTT FLAN LINE OF BLr,)O E3ELO^ SCALE: Val' =l' -O" FIBRE GEMENT SIDING [SHIP LAP. 12' LONG BLANKS] MET'L FL SH'G - m FIBRE =MENT TRIM 2 U FIBRE GEMENT — — TRIM TEAR, MATTE Tv D DOOR TRATE ��' i SCALE: S - 1'-0'' EXIST'G BLOCK WALL FABRICATE FLANGE $ SLEAVE FROMi 1' STEEL. ATTACH STEEL SCREEN TO INSIDE OF FLANGE W A i T '2 v STEEL SCREEN EXISVO GONG SLAB EXIST'G BLOCK WALL TO REMAIN CAULKING METAL DOOR FRAME SHOT PIN OR RED HEAD METAL RETAINER CLIP PER FRAME MANU. /ENT 507H O 11-I LIAR I DES OF lNAL. SC,ALE : 1 1/2'' = 1 -0 R I DOE VENT FLASH I NCS W/ "E" CLOSURES PEREORA7ED "E" rON� SHINGLES I l-1- 1 Y`L-1C/L-1 1." F__C_1i__�IIVC_7 GORRI GATED METAL DECK FEW TUBE STEEL. SEE FRAMING PLAN Fi�ET LET�TED T E D T c� FLAT rF) SCALE: 1/4" AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 C-3651 A4.0 i N 44 Q N SUGGESTED BOMANITE/BOMACRON SPECIFICATIONS BOMANI TE CORPORATION 10 05 2p PA VING & WALKS Following are the suggested Bomanite/Bomacron specifications to assist you in the preparation of project documents. The Bomanite/Bomacron portion of the project should be separated from the balance of the concrete work in Division 3, since the work will be performed by specifically trained Bomanite contractors. Depending on the project, the Bomanite/Bomacron portion of the work may also be included in Division 2, Paving and Walks, Division 7, Roof Decks, or Division 9, Special Flooring. Additional assistance on specifications and technical service are available from your local Bomanite contractor or Bomanite Corporation. 1.00 GENERAL 1.01 Description — Bomanite/Bomacron Imprinted Concrete includes: a. Materials: Forming materials, reinforcement, concrete, dry—shake color hardener, curing compound, release agent and sealer. b. Special imprinting and texturing tools. c. Concrete placement and finish. d. Color hardener and release agent placement. e. Pressure washing to remove excess release agent. f. Curing compound application (Bomanite only). g. Sealer application. 1.02 References and Standards a. Bomanite/Bomacron Imprinted Concrete: Install in accordance with the standards and specifications of Bomanite Corporation and the American Concrete Institute (ACI). b. The contractor for this work shall be the following Bomanite licensed contractor who has been trained and equipped by Bomanite Corporation: Name of Bomanite contractor ----------------------------------- Address ----------------------------------------------------- Telephone--------------------------------------------------- Fax --------------------------------------------------------- 1.03 Definitions Bomanite: a cast—in—place concrete slab, having the surface colored and imprinted with a pattern. The work is performed on the job site by trained and experienced workmen. Bomacron: A cast—in—place concrete slab, having the surface colored, imprinted with a pattern and texture. The work is performed on the job site by trained and experienced workmen. 1.04 Related Work — to be completed by a licensed Bomanite contractor except where noted. a. Preparation work, including sub—grade preparation, finish grading, constructing formwork, placing and setting screeds, and furnishing and placement of reinforcement shall be done by a licensed Bomanite contractor or other qualified contractor. b. Provide and place concrete. c. For all pedestrian and light traffic applications, provide and apply regular grade Bomanite Color Hardener. For heavy pedestrian and vehicular traffic, provide and apply heavy duty grade Bomanite Co/or Hardener. d. Provide and apply all Bomacron release agents. Release agent is a dry powdered, colored agent used to facilitate release of the imprinting tools from concrete surface, and to provide moderate color variations to the textured surface. e. Provide and apply Bomanite and/or Bomacron imprinting tools. f. (Bomanite only) Provide and apply curing compound. g. (Optional) Provide and apply grout for imprinted joints. (Grouting option applies to Bomanite patterns only, except in special cases. Consult your local Bomanite Contractor.) h. Provide and apply sealer. i. Outside edges of all imprinted slabs shall be left uncolored unless otherwise specified in the drawings. J (Optional) Provide and apply Bomanite Con—Shield per manufacturer's recommendations. Con—Shield will prevent deterioration and spolling from deicing salts used in freeze/thaw conditions. Con—Shield will also increase the abrasion resistance of Bomanite/Bomacron. 1.05 Quality Assurance a. All Bomanite/Bomacron work shall be installed by a licensed Bomanite contractor. The Bomanite contractor shall provide a qualified foreman or supervisor who has a minimum of three years experience with imprinted and textured concrete, and who has successfully completed at least five Bomanite/Bomacron imprinted concrete installations of high quality and similar in scope to that specified herein, and located within a 100 mile radius of the proposed project. Evidence that the contractor is qualified to complete the project in a workmanlike manner as specified herein shall be submitted to, and approved by, the architect/engineer. b. All Bomanite work shall comply with the current specifications and quality standards issued by Bomanite Corporation. c. The Bomanite contractor shall provide a job site sample (referee sample) of 100 square feet minimum to be approved by the architect/engineer prior to the start of construction. Said sample shall be the standard for the balance of the work installed, and shall be protected against damage until final approval from the architect/engineer. 2.00 PRODUCTS AND MATERIALS 2.01 Concrete Mix Design a. The concrete shall have a minimum compressive strength of 3000 psi in non—freeze areas, 3500 psi in moderate freeze—thaw areas and 4000 psi in severe freeze—thaw areas. Portland cement shall conform to ASTM C 150 Type I, ll, or V, depending on soil conditions. Aggregates shall conform to ASTM C 33. Mixing water shall be fresh, clean and potable. In freeze—thaw areas only, an air—entraining admixture complying to ASTM C 260 shall be used to achieve an entrained air content for the particular mix used in accordance with the published recommendations of the Portland Cement Association and the American Concrete Institute. No admixtures containing calcium chloride shall be permitted. 2.02 Coloring, Imprinting, Curing and Sealing Materials a. Bomanite Color Hardener: The concrete shall be colored with the following Bomanite Color Hardener color(s): -------------------------------------------- The grade of the hardener shall be: (choose one) Regular Grade or Heavy Duty Grade. b. (Optional) Bomacron Release Agent: The fol/owing Bomacron Re/ease Agent color(s) shall be applied to all concrete surfaces to be imprinted and textured:-------------------------------- Bulletin ------------------------------- Bulletin 200.6 c. Pattern: The following Bomanite (Bomacron) pattern shall be used: ------------------------------------- All imprinting tools used in the execution of this project shall be manufactured by Bomanite Corporation. d. (Optional) Reinforcement: All imprinted slabs shall conform to the guidelines and recommendations of the American Concrete Institute for reinforcement of cast—in—place concrete slabs. e. Curing: All Bomanite imprinted concrete slabs shall be cured with Bomanite Color Cure, Clear Cure or approved equal. Bomacron imprinted concrete slabs are not compatible with curing compounds, and do not typically require membrane or mechanical curing. Bomacron imprinted/textured concrete may be cured using nonstaining reinforced curing paper when necessary. f. Sealer: All Bomanite/Bomacron slabs shall be sealed in accordance with the manufacturer's recommendations. 3.00 EXECUTION 3.01 Installation Procedures a. The area to receive Bomanite/Bomacron imprinted concrete shall have the sub—grade prepared and compacted as required by local governing authority and conditions. b. The formwork shall be installed in accordance with the drawings. The slab thickness shall be consistent with that of ordinary concrete slabs under the some conditions. (Note to specifier: Bomanite/Bomacron is most often a 4" thick or greater monolithic slab on grade. However, Bomanite may also be installed as a 2" or thicker topping over a base slab.) c. Provide reinforcement as specified. d. Control joints and/or expansion joints shall be provided in accordance with the drawings and the guidelines established by the American Concrete Institute. As with any concrete slab, Bomanite/Bomacron imprinted concrete usually contains construction joints, control joints and expansion joints. The contractor shall advise and work with the architect/engineer to determine the best location for these joints to minimize the visibility of the joints and to minimize unsightly cracking. e. The concrete shall be placed and screeded to the finished grade, and floated to a uniform surface using standard finishing techniques. f. Bomanite Color Hardener shall be applied evenly to the surface of the fresh concrete by the dry—shake method using a minimum of 60 pounds per 100 square feet. It shall be applied in two or more shakes, floated after each shake and troweled only after the final floating. g. (Optional) Bomacron Release Agent shall be applied evenly to the troweled surface prior to imprinting. (Note to the specifier: this product should be specified only if imprinted slab is Bomacron.) h. While the concrete is still in its plastic stage of set, the Bomanite/Bomacron imprinting tools shall be applied to the surface. i. Approved curing method shall be applied in accordance with the manufacturer's recommendations immediately after completing the imprinting process for Bomanite slabs only. Reference section 2.02. J (Optional) After initial curing period, the imprinted joints shall be grouted using a sand/cement/water mixture. k. After the initial curing period (and grouting operation, if applicable), the surface of the slab shall be sealed. CODES, CERTIFICATION All materials manufactured by Bomanite Corporation are warranted to be of uniform quality within manufacturing tolerances. Since control is not exercised over their use, no warranty, expressed or implied, is made as to the effects of such use. Bomanite Corporation's obligation under this warranty shall be limited to refunding the purchase price of that portion of the material proven to be defective. Please contact your local Bomanite contractor for available warranties on workmanship. Bomanite Corporation makes no warranty, expressed or implied, as to the quality of the workmanship by local Bomanite con tractors. OPERATION, MAINTENANCE All Bomanite/Bomacron installations should be regularly maintained by a licensed Bomanite contractor in order to maintain a top quality appearance. Every 18 to 36 months, installations should be inspected by your local Bomanite contractor, and should be cleaned and resealed as required by volume and intensity of traffic. Contact your local Bomanite contractor for the proper maintenance program in your area. The Bomanite International Society of licensed contractors is a worldwide network of specially trained and equipped professionals. Through constant exchange of new ideas, re—education and development programs, members of the Bomanite International Society continue to increase already high standards of quality and service. The activities of the Bomanite International Society are coordinated by Bomanite Corporation. The Corporation also provides services and technical assistance to its member licensees, and to architects, designers and engineers specifying Bomanite products. For more information, including a list of members of the Bomanite International Society, contact: Bomanite Corporation P.O. Box 599 Madera, California 93639-0599 Tel: (559) 673-2411 Fax: (559) 673-8246 Web site: www.bomanite.com ©Copyright 2005 Bomanite Corporation. Bomanite® and Bomacron® are registered trademarks and servicemarks with the U.S. Patent Office and other countries. All Bomanite Concrete GrophicsO patterns are copyrighted and are the property of Bomanite Corporation and cannot be copied for any purpose. IMPORTANT NOTICE: This specification guideline supersedes all Bomanite/Bomacron specifications published prior to October 2005. THE USE OF THESE PLANS & SPECIFICATIONS SHALL BE RMCTED TO THE ORIGINAL SITE FOR WHICH THEY WERE PREPARED & PUBLICATION THEREOF IS EXPRESSLY LIMITED TO SUCH USE REPRODUCTION, PUBLICATION OR RE -USE BY ANY MERE, IN WHOLE OR IN PART IS PROHIBITED. TRIP TO THE PLANS & SPECIFICATIONS RENAIN IN THE JON SOMMERS, Alk ARCHITECT WITHOUT PREJUDICE VISUAL CONTACT WITH THESE PIANS & SPECIFICATIONS SHALL CONSRRTIE PRIMA FACIE ENDENCE OF THE ACCEPTANCE OF THESE RESTRICTIONS. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 4195 N. VIKING WAY Suite 130 Long Beach California 90808 Phone(562)421-3100 Fax(562)421-2055 E—Mail: jon.sommers®verizon.net IZJ;1=I:7_1:1;;101*9 CHAMFER EDGE NIDTH \/ARES. SEE PLAN I/a" X " SCORE W/ CHAMFERED EDGES SUSC�RADE PREPARED a COMPACTED PER GEOTECHNICAL REPORT, 1�10516 MIN. COMPACTION OV�ALK�NAT` FAV N(� SCALE: 3/4" = I'C" APPROVED 4-1/2" COLORED I$ ST r MPED P.G. CONCRETE, 4,000 PSI PATTERN TO MATCH EXIST'(� all �WT,�i� II=11-11 S C EN S111 GNIINEERS CITY ENGINEER ENVIRONMENTAL CONSULTANTS DATE R.C.E. NO. 24967 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED LONG BEACH, CA 90806 J. SOMMERS PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED 6" THK. TYPE 2 CL"13 A&GREGATE 5ASF_ T COMPACTED TO 1�15 A5,00 C-3651 A-6 LANDFILL GAS COLLECTION AND CONTROL SYSTEM NEWPORT TERRACE LANDFILL DRAWNJ. SOMMERS CITY OF NEWPORT BEACH M -5374-S DATE PUBLIC WORKS DEPARTMENT SHEET 16 OF 21 SEP 19, 2006 JONSMERS Design Architecture Interiors AmIkARCHITICIS Planning Fnaineenno Phone(562)421-3100 Fax(562)421-2055 E—Mail: jon.sommers®verizon.net IZJ;1=I:7_1:1;;101*9 CHAMFER EDGE NIDTH \/ARES. SEE PLAN I/a" X " SCORE W/ CHAMFERED EDGES SUSC�RADE PREPARED a COMPACTED PER GEOTECHNICAL REPORT, 1�10516 MIN. COMPACTION OV�ALK�NAT` FAV N(� SCALE: 3/4" = I'C" APPROVED 4-1/2" COLORED I$ ST r MPED P.G. CONCRETE, 4,000 PSI PATTERN TO MATCH EXIST'(� all �WT,�i� II=11-11 S C EN S111 GNIINEERS CITY ENGINEER ENVIRONMENTAL CONSULTANTS DATE R.C.E. NO. 24967 3900 KILROY AIRPORT WAY, SUITE 100 DESIGNED LONG BEACH, CA 90806 J. SOMMERS PH. (562) 426-9544 FAX. (562) 427-0805 CHECKED 6" THK. TYPE 2 CL"13 A&GREGATE 5ASF_ T COMPACTED TO 1�15 A5,00 C-3651 A-6 LANDFILL GAS COLLECTION AND CONTROL SYSTEM NEWPORT TERRACE LANDFILL DRAWNJ. SOMMERS CITY OF NEWPORT BEACH M -5374-S DATE PUBLIC WORKS DEPARTMENT SHEET 16 OF 21 SEP 19, 2006 GAS MONITORING SYSTEM SPECIFICATIONS GENERAL NOTES: LEGEND: 1. GAS MONITORING SYSTEM 3. SYSTEM DESCRIPTION CONTINUED (CONTINUED) 1. ALL WORK AND MATERIALS SHALL BE IN FULL COMPLIANCE TO NATIONAL ELECTRICAL A AMPERE CODE 2002 EDITION AND CITY OF NEWPORT BEACH REGULATIONS. AFF. ABOVE FINISHED FLOOR A. GENERAL: A. GAS MONITORING SYSTEM CONTINUED (CONTINUED) 2. ALL MATERIALS SHALL BE NEW AND SHALL BE LISTED BY UNDERWRITERS A.I.C. C AMPERE INTERRUPTING CAPACITY CONDUIT LABORATORY. CB CIRCUIT BREAKER CONTRACTOR SHALL FURNISH, INSTALL AND PLACE IN OPERATING CONDITION A GAS MONITORING SYSTEM 3) METHANE GAS CONTROLLER: CH4 METHANE SUITABLE FOR CONTINUOUSLY DETECT METHANE (CH4) AND HYDROGEN SULFIDE (H2S) GASES. THE SYSTEM 3. RACEWAYS: D DEPTH SHALL BE MANUFACTURED AND INSTALLED AS INDICATED ON THE DRAWINGS AND AS SPECIFIED HEREIN, METHANE GAS CONTROLLER SHALL BE CAPABLE OF CONTINUOUSLY MONITORING COMBUSTIBLE GAS DISC. DISCONNECT COMPLETE WITH ALL ACCESSORIES NECESSARY FOR PROPER OPERATION. CONCENTRATION IN A REMOTE LOCATION. THE CONTROLLER SHALL CONSIST OF A REMOTE SENSING a) ABOVEGROUND CONDUIT SHALL BE ELECTRICAL METALLIC TUBING (EMT). (E) EXISTING ASSEMBLY AND A SOLID STATE CONTROLLER. THE CONTROLLER SHALL CONSIST OF AN INDEPENDENT WHERE EXPOSED TO PHYSICAL DAMAGE, ABOVEGROUND CONDUIT SHALL BE EMT ELECTRICAL METALLIC TUBING THE SYSTEM SHALL BE DESIGNED TO MINIMIZE THE RISK TO PERSONAL AND EXPOSED FACILITIES TO CHANNEL WITH CONTROL CIRCUITRY. GALVANIZED RIGID STEEL CONDUIT. GND GROUND DANGEROUSLY HIGH CONCENTRATION OF METHANE AND H2S GASES. INHERENT IN THE SYSTEM DESIGN SHALL GRS GALVANIZED RIGID STEEL BE INTERNAL, CONTINUOUS SELF -DIAGNOSTICS TO INSURE THE SYSTEM BEING OPERATING PROPERLY. THE CONTROLLER SHALL FEATURE A DIGITAL DISPLAY OF GAS CONCENTRATION IN % LEL (0-99% LOWER b) UNDERGROUND CONDUIT SHALL BE PVC SCHEDULE 40. H HEIGHT EXPLOSIVE LIMIT) FOR CHANNEL. CALIBRATION SHALL BE DONE INDEPENDENTLY WITH ALARM RELAYS H2S HYDROGEN SULFIDE THE GAS MONITORING SYSTEM SHALL BE MANUFACTURED AS AN INTEGRATED SYSTEM BY GENERAL MONITORS DISABLED WHILE IN THIS MODE. c) FINAL CONNECTION TO VIBRATING EQUIPMENT SHALL BE WEATHER PROOF HP HORSEPOWER SYSTEMS, INC. OR APPROVED EQUAL. FLEXIBLE METAL CONDUIT. PROVIDE THE FLEXIBLE CONDUIT LENGTH NOT J -BOX JUNCTION BOX THE CONTROLLER SHALL HAVE A VARIETY OF RELAY OPTIONS, SUCH AS NORMALLY ENERGIZED OR TO EXCEED 6 FEET. KWH KILOWATT-HOURS B. SYSTEM OVERVIEW: DE -ENERGIZED HIGH AND LOW ALARMS AND LATCHING OR NON -LATCHING HIGH AND LOW ALARMS. THE d) EXPOSED CONDUITS SHALL BE INSTALLED PERPENDICULAR TO WALL, LTG LIGHTING FAULT RELAY CIRCUITRY SHALL NORMALLY BE ENERGIZED. THESE RELAYS SHALL BE EITHER DISCRETE FOR MAX MAXIMUM A GAS MONITORING PANEL SHALL BE LOCATED IN BLOWER ROOM. THE PANEL SHALL BE EQUIPPED WITH ONE SINGLE CHANNEL OR COMMON TO THE CHANNEL. ALSO THE CONTROLLER SHALL BE ABLE TO PROVIDE AN CEILING AND STRUCTURAL MEMBERS. MIN MINIMUM (1) COMBUSTIBLE GAS CONTROLLER AND ONE (1) HYDROGEN SULFIDE GAS CONTROLLER. EACH CONTROLLER ANALOG OUTPUT. THE CONTROLLER MODULE MUST BE APPROVED BY THE CANADIAN STANDARDS (N) NEW SHALL BE CONNECTED WITH EACH TYPE OF GAS SENSOR ASSEMBLIES LOCATED REMOTELY INSIDE THE ROOM. ASSOCIATION (CSA) AND MUST MEET THE CSA PERFORMANCE STANDARD FOR COMBUSTIBLE GAS DETECTION. e) CONDUIT SUPPORTS INCLUDING CONDUIT HANGERS, CONDUIT STRAPS AND NEMA NATIONAL ELECTRIC MANUFACTURE ASSOCIATION THE SENSOR ASSEMBLIES SHALL DETECT GAS CONCENTRATION IN THOSE REMOTE AREAS AND TRANSMIT ANALOG THE COMBUSTIBLE GAS CONTROLLER MODULE SHALL BE SINGLE -CHANNEL COMBUSTIBLE GAS MONITOR CHANNELS SHALL BE GALVANIZED STEEL. N.T.S. NOT TO SCALE SIGNAL PROPORTIONAL TO THE DETECTED GAS CONCENTRATION IN PERCENT OF LOWER EXPLOSIVE LIMIT (% LEL) MODEL 480A MANUFACTURED BY GENERAL MONITORS, INC. OR APPROVED EQUAL. f) P POLE FOR METHANE GAS AND IN MEASURED LEVEL OF PART PER MILLION (PPM) FOR H2S GAS TO THE GAS CONDUIT SUPPORT SHALL BE WELL DESIGNED TO HAVE SUFFICIENT SCE SOUTHERN CALIFORNIA EDISON CONTROLLERS. THE GAS MONITORING PANEL SHALL EQUIP AN AUTOMATIC TELEPHONE DIALING SYSTEM TO 4) HYDROGEN SULFIDE (H2S) GAS CONTROLLER: STRENGTH TO CARRY THE WEIGHT OF CONDUITS, ENCLOSED WIRING, SW. SWITCH PROVIDE REMOTE NOTIFICATION FOR THE SYSTEM STATUS. VISUAL ALARM INSTALLED IN FRONT OF THE BLOWER FITTINGS AND PULLING FORCE DURING WIRING INSTALLATION. TC TIME CLOCK ROOM SHALL INDICATE THE GAS ALARM STATUS OF THE PRESET MONITORED GAS LEVELS. THE SYSTEM ALARM HYDROGEN SULFIDE GAS CONTROLLER SHALL BE CAPABLE OF CONTINUOUSLY MONITORING H2S GAS ABOVEGROUND PULLBOX SHALL BE NEMA -3R, ZINC -COATED SHEET STEEL TYP. TYPICAL INDICATION SHALL CONTINUELY OPERATE UNTIL THE SYSTEM RESET IS EXECUTED. CONCENTRATION IN A REMOTE LOCATION. THE CONTROLLER SHALL CONSIST OF A REMOTE SENSING g) V VOLT ASSEMBLY AND A SOLID STATE CONTROLLER. THE CONTROLLER SHALL CONSIST OF AN INDEPENDENT WITH GASKET SCREW FASTENED COVER. W WIRE 2. SUBMITTAL CHANNEL WITH CONTROL CIRCUITRY. h) PROVIDE VERTICAL EYS TYPE SEAL FITTING FOR TRANSITION OF RACEWAYS W. P. WEATHER PROOF A. GENERAL: IN AMPLE TIME FOR EACH TO SERVE ITS PURPOSE AND FUNCTIONS, THE CONTRACTOR SHALL SUBMIT THE CONTROLLER SHALL FEATURE A DIGITAL DISPLAY OF GAS CONCENTRATION IN RANGES OF PART PER FROM UNDERGROUND TO ABOVEGROUND. THE SEAL FITTING SHALL NOT BE TO THE ENGINEER SUCH SCHEDULES, SHOP DRAWINGS, LITERATURE SAMPLES, INSTRUCTIONS, OPERATION AND MILLION (PPM). CALIBRATION SHALL BE DONE INDEPENDENTLY WITH ALARM RELAYS DISABLED WHILE IN THIS INSTALLED NO MORE THAN 18" ABOVE FINISHED GRADE.KWH UTILITY METER MAINTENANCE MANUALS, AND GUARANTEES AS ARE SPECIFIED OR REASONABLY REQUIRED FOR CONSTRUCTION, MODE. OPERATION AND MAINTENANCE OF THE GAS MONITORING SYSTEM. 4. WIRING: THE CONTROLLER SHALL HAVE A VARIETY OF RELAY OPTIONS, SUCH AS NORMALLY ENERGIZED OR B. SHOP DRAWINGS: SHOP DRAWINGS, LAYOUT DIAGRAMS, CATALOG DATA, TEST REPORTS, AND INFORMATION IN DE -ENERGIZED HIGH AND LOW ALARMS AND LATCHING OR NON -LATCHING HIGH AND LOW ALARMS. THE70A a) POWER AND CONTROL CONDUCTORS SHALL BE 600V COPPER STRANDED 2P MOLDED CASE CIRCUIT BREAKER SUFFICIENT DETAIL TO SHOW COMPLETE COMPLIANCE WITH ALL SPECIFIED REQUIREMENTS SHALL BE FURNISHED FAULT RELAY CIRCUITRY SHALL NORMALLY BE ENERGIZED. THESE RELAYS SHALL BE EITHER DISCRETE FOR CONDUCTOR THWN INSULATION. GROUND CONDUCTOR SHALL BE IN GREEN n RATING AS INDICATED TO THE ENGINEER, COVERING BUT NOT LIMITED TO, THE ITEMS UNDER MATERIALS AND EQUIPMENT LIST. SINGLE CHANNEL OR COMMON TO THE CHANNEL. ALSO THE CONTROLLER SHALL BE ABLE TO PROVIDE AN COLOR. ANALOG OUTPUT. THE CONTROLLER MODULE MUST BE APPROVED BY THE CANADIAN STANDARDS 1. MATERIAL AND EQUIPMENT LIST: ASSOCIATION (CSA) AND FACTORY MUTUAL (FM). THE HYDROGEN SULFIDE GAS CONTROLLER MODULE SHALL b) SIGNAL CABLE INSTALLED FROM METHANE/H2S GAS MONITORING PANEL TO 5A DISCONNECT FUSE BE SINGLE -CHANNEL HYDROGEN SULFIDE GAS MONITOR MODEL 2180A MANUFACTURED BY GENERAL METHANE GAS SENSOR SHALL BE THREE -CONDUCTOR AWG NO.20 RATING AS INDICATED (a) GAS MONITORING PANEL: MONITORS, INC. OR APPROVED EQUAL. SHIELDED CABLE WITH COLOR CODES OF WHITE, RED AND BLACK. - COMBUSTIBLE GAS CONTROLLER - HYDROGEN SULFIDE GAS CONTROLLER 5) ENCLOSURE: c) SIGNAL CABLE INSTALLED FROM METHANE/H2S GAS MONITORING PANEL TO 30A 2P - COMBUSTIBLE GAS SENSOR ASSEMBLY - HYDROGEN SULFIDE GAS SENSOR ASSEMBLY H2S GAS SENSOR SHALL BE FOUR -CONDUCTOR AWG NO.20 SHIELDED DISCONNECT SWITCH THE ENCLOSURE SHALL BE WALL MOUNTED, NEMA -4X, KEY LOCKABLE WINDOWED DOOR WITH MOUNTING CABLE WITH COLOR CODES OF WHITE, RED, BLACK AND GREEN. — RATING AS INDICATED - INDICATING LIGHTS AND KEY OPERATED SELECTOR SWITCH BACK PANEL. APPROXIMATE DIMENSION OF THE ENCLOSURE SHALL BE 24"H x 24"W x 12"D. - STROBE LIGHT AND HORN d) TELEPHONE WIRING SHALL AWG. N0. 24 TINNED COPPER SOLID - ENCLOSURE AND COMPONENT LAYOUT A LABEL SHALL PROVIDED ON THE CONTROL PANEL WHICH PROVIDES A PHONE NUMBER OF A - WIRING DIAGRAM RESPONSIBLE CONTACT PERSON WHO WILL RESPOND IN EVENT OF A SYSTEM MALFUNCTION OR SENSOR PAIRS PVC INSULATION CABLE. r)cTWISTED MOTOR STARTER - CONNECTION DIAGRAM (b) 24VDC SYSTEM ALARM. e) ALL SIGNAL CABLES SHALL BE INSTALLED CONTINUOUSLY FROM THE GAS l SIZE AS INDICATED - 24VDC POWER SUPPLY MONITORING PANEL TO THE SENSORS WITHOUT SPLICING. - BACKUP BATTERY B. VISUAL ALARM: f) 3/4 MOTOR - FUSE AND TERMINATION BLOCK ALL WIRING SHALL BE ENCLOSED IN METAL RACEWAYS OR CONDUITS SIZE AS INDICATED - WIRING AND CONNECTION DIAGRAMS A VISUAL COMPONENT SHALL BE 24VDC SINGLE FLASHING DEVICE WEATHERPROOF STROBE LIGHT WITH RED - BACKUP BATTERY COMPUTATION DURING SWITCHING OVER TIME COLOR LENS. PROVIDE NEMA -3R J -BOX AS REQUIRED FOR MOUNTING THE COMPONENTS ON WALL. 5. CONDUIT ROUTINGS SHOWN ON THE DRAWINGS ARE SCHEMATIC ONLY. THE FROM BUILDING NORMAL AC POWER TO EMERGENCY GENERATOR POWER) C. BATTER BACKUP: DRAWINGS ARE SCHEMATIC TO THE EXTENT THAT BENDING, HEIGHTS AND EXACT LOCATIONS ARE NOT INDICATED. INSTALL OF EXPOSED CONDUIT SHALL BE WELL OFF C. SUBMITTAL PROCEDURE: A QUANTITY OF FIVE (5) SHOP DRAWINGS AND DATA SHALL BE SUBMITTED TO THE A BATTERY BACKUP SYSTEM SHALL HAVE CAPACITY TO PROVIDE EMERGENCY POWER TO THE GAS MONITORING COORDINATED TO OTHER EQUIPMENT SUCH AS PIPES BOXES FITTINGS ETC. IN HAND AUTO � ENGINEER. THE SUBMITTAL SHALL CLEARLY INDICATE THE SPECIFIC AREA OF THE CONTRACT DOCUMENTS FOR SYSTEM CONTROLLER, SENSOR ASSEMBLIES AND AUTOMATIC TELEPHONE DIALING DEVICE IN THE EVENT OF ORDER TO ACHIEVE GOOD INSTALLATION APPEARANCE. 3 -POSITION SELECTOR SWITCH WHICH THE SUBMITTAL IS MADE. TWO (2) COPIES WILL BE RETURNED TO THE CONTRACTOR'S REPRESENTATIVE. POWER OUTAGE FOR A PERIOD OF 24 HOURS SUPERVISORY AND 5 MINUTES ALARM. THE BATTERY BACKUP THE ENGINEER'S NOTATIONS OF THE ACTION WHICH HE/SHE HAS TAKEN WILL BE NOTED ON ALL RETURNED SHALL HAVE MINIMUM OF 1IO AMPERE -HOUR. THE 24VDC POWER FROM THE BATTERY BACKUP SHALL BE 6. ALL EQUIPMENT PANELS SHALL BE WALL MOUNTED. THE CONTRACTOR SHALL COPIES. AUTOMATICALLY ACCESSED BY THE CONTROLLER IF 120VAC POWER INPUT DROPS BELOW 90VAC. WHEN AC PROVIDE MOUNTING SUPPORTS ON WALL THAT SUFFICIENTLY CARRY THE MINIMUM POWER RETURNS ABOVE 90VAC THE BATTERY BACKUP SYSTEM SHALL RETURN TO STANDBY STATUS AND THE OF 200 PERCENT OF TOTAL WEIGHT OF THE PANELS. TYPES OF SUPPORTS SUCH IF, AFTER REVIEWING A SUBMITTAL FOR AN ITEM, THE ENGINEER FINDS THAT SUCH SUBMITTAL IS BATTERY SHALL BE RECHARGED. THE SYSTEM SHALL CONSIST OFA 24VDC BATTERY, CONVERTER, AND A DUAL AS SCREWS, ANCHOR BOLTS, CHANNELS, ETC., SHALL BE PROVIDED AND NORMALLY CLOSED CONTACTOR UNACCEPTABLE, THE CONTRACTOR SHALL MAKE THE NECESSARY CORRECTION AND SHALL RESUBMIT THE MODE CHARGING CIRCUIT. THE TWO CHARGING MODES SHALL BE A FLOAT MODE AND A FAST CHARGING MODE. CONSTRUCTED TO SUIT THE WALL CONDITION, AND TO HAVE GOOD INSTALLATION PACKAGE FOR SUCH ITEM. THE ENGINEER WILL REVIEW THE FIRST RE -SUBMITTAL FOR AN ITEM WITHOUT THE 24VDC CIRCUITS PROVIDING POWER TO THE GAS MONITORING SYSTEM SHALL BE EQUIPPED WITH 10A APPEARANCE. CHARGE TO THE CONTRACTOR, HOWEVER; IF THE ENGINEER FINDS THAT THE FIRST RE -SUBMITTAL UNACCEPTABLE, THE CONTRACTOR SHALL BEAR COSTS OF ALL SUBSEQUENT REVIEWS BY THE ENGINEER. SUCH 24VDC FUSES AS SHOWN ON THE DRAWINGS. NORMALLY OPEN CONTACTOR COSTS WILL BE DEDUCTED BY THE ENGINEER FROM ANY MONEY DUE TO THE CONTRACTOR. D. WIRING AND CONTACT TERMINATION: D. TECHNICAL MANUALS: THE CONTRACTOR SHALL FURNISH THE ENGINEER FIVE (5) IDENTICAL SETS OF TECHNICAL ALL PANELS SHALL BE PROVIDED WITH FIELD TERMINAL STRIP AND SHALL BE COMPLETELY PRE -WIRED, DEMOLITION NOTES: M 1 RELAY MANUALS FULLY DESCRIBING THE EQUIPMENT BEING FURNISHED. EACH SET SHALL BE BOUND IN A STANDARD TESTED AND INSPECTED BY THE MANUFACTURER. PROVIDE SPARE OUTPUT CONTACTS FOR GAS ALARM AND SIZE, THREE-RING, LOOSE LEAF, VINYL PLASTIC HARD COVER BINDER SUITABLE FOR BOOKSHELF STORAGE. SENSOR FAULT SIGNALS. PROVIDE LABELS FOR ALL FIELD TERMINALS. BINDER RING SIZE SHALL NOT EXCEED 1.5 INCHES. THE TECHNICAL MANUALS SHALL INCLUDE OPERATING AND 1. EXISTING METER INCLUDING UNDERGROUND SERVICE CONDUCTORS AND CONDUIT MAINTENANCE INSTRUCTIONS AS APPLICABLE FOR EACH ITEM OF THE EQUIPMENT. E. AUTOMATIC TELEPHONE DIALER: INTERIOR LIGHTING, RECEPTACLES TO REMAIN AND TO BE PROTECTED IN PLACE G INDICATING LIGHT DURING CONSTRUCTION. PROVIDE CIRCUIT BREAKER PANEL AND CIRCUIT BREAKERS R -RED AUTOMATIC TELEPHONE DIALER SHALL BE A SOLID STATE COMPONENT CAPABLE OF DIALING UP TO 16 AS SHOWN ON SINGLE LINE DIAGRAM. A -AMBER 3. SYSTEM DESCRIPTION TELEPHONE NUMBERS WITH EACH NUMBER UP TO 60 DIGITS IN LENGTH. THE DIALER SHALL BE ABLE TO DIAL PHONE NUMBERS IN BOTH STANDARD PULSE DIALING AND TOUCH TONE DTMF DIALING. ALL PHONE NUMBERS 2. ALL WIRING AND CONDUITS: FROM EXISTING METER/CB PANEL TO EXISTING BLOWER A. GAS MONITORING SYSTEM AND THE DIALER OPERATIONS SHALL BE PROGRAMMABLE. THE DIALER SHALL HAVE SPEECH MESSAGE STARTER PANELS; FROM EXISTING BLOWER STARTER PANELS TO BLOWERS; AND OFF CAPABILITY. THE DIALER SHALL HAVE OPTIONS FOR MESSAGE RECORDING FROM BOTH REMOTE TELEPHONE AND FROM EXISTING METER/CB PANEL TO EXISTING AUTO DIALER PANEL, SHALL BE A GAS MONITORING PANEL SHALL BE DESIGNED TO DETECT GAS CONCENTRATION LEVEL OF METHANE AND THE DIALER FRONT PANEL. THERE SHALL NO BE LIMIT ON THE LENGTH OF ANY PARTICULAR MESSAGE. THE REMOVED. AUTO TEST HYDROGEN SULFIDE (H2S) GASES IN REMOTE AREA. THE SYSTEM SHALL BE SERVED FROM 120VAC AND DIALER SHALL HAVE MINIMUM OF FOUR (4) INPUT CHANNEL CONTACTS. THE DIALER SHALL HAVE FUNCTION TO OPERATED ON 24VDC POWER SUPPLY AND BATTERY BACKUP SYSTEM. THE SYSTEM PANEL SHALL BE CONTAINED ACKNOWLEDGE FOR RECEIVED CALL. CONNECTION TO TELEPHONE LINE SHALL BE THROUGH A 4 -PIN RJ11 3. EXISTING BLOWER STARTER PANELS AND AUTO DIALER PANELS TO BE REMOVED. K IN NEMA -4X ENCLOSURE DESIGNED FOR WALL MOUNT AND PROVIDED WITH A KEY LOCKABLE WINDOWED DOOR. MODULAR JACK. THE AUTOMATIC TELEPHONE DIALER SHALL BE INSTALLED INSIDE THE GAS MONITORING PANEL. 3 -POSITION KEY OPERATED THE MINIMUM REQUIREMENT OF THE SYSTEM SHALL CONSIST OF THE FOLLOWING MAIN COMPONENTS: THE DEVICE SHALL BE POWERED BY 120VAC FROM POWER SUPPLY OF THE GAS MONITORING PANEL. DURING 4. EXISTING LIGHTING FIXTURES AND LIGHTING SWITCHES IN BLOWER ROOM SHALL - - SELECTOR SWITCH NORMAL POWER OUTAGE, THE DIALER SHALL BE POWERED BY 24VDC BATTERY BACKUP INSIDE THE GAS REMAIN. CONTRACTOR SHALL INSTALL WIRING AND RACEWAYS TO NEW INSTALLED 1) METHANE GAS SENSOR ASSEMBLY MONITORING PANEL. THE AUTOMATIC TELEPHONE DIALER SHALL HAVE EXPANDABLE OPTIONS FOR RECORDED CIRCUIT BREAKER PANEL TO COMPLETE THE CIRCUITS. TELEPHONE NUMBERS, MESSAGE CAPACITIES, AND INPUT CHANNEL CONTACTS. DETAIL AND SECTION CROSS REFERENCING CONVENTION: METHANE GAS SENSOR SHALL BE A LOW TEMPERATURE, CATALYTIC COATED, CONTINUOUS DIFFUSION TYPE, WITH DUAL MATCHED SENSOR BEADS. A WHEATSTONE BRIDGE CIRCUIT SHALL PROVIDE COMPENSATION FOR AMBIENT TEMPERATURE, PRESSURE AND HUMIDITY VARIATIONS. THE SENSOR SHALL BE CAPABLE OF MEASURING THE COMBUSTIBLE GAS CONCENTRATION IN A RANGE OF 0 TO 100 PERCENT LOWER EXPLOSIVE LIMIT (% LEL). THE SENSOR SHALL HAVE 6 -SECOND TIME CONSTANT WHEN EXPOSED TO 50 % LEL OF COMBUSTIBLE GAS. THE SENSOR SHALL HAVE ZERO DRIFT OF LESS THAN 5 PERCENT OF FULL SCALE PER YEAR. THE SENSOR MUST BE APPROVED BY CANADIAN STANDARD ASSOCIATION (CSA). SENSOR ASSEMBLY SHALL BE EXPLOSION PROOF HOUSING. THE SENSOR ASSEMBLY SHALL BE CAPABLE OF OPERATING IN CLASS 1, DIVISION 1, GROUP B, C AND D HAZARDOUS CLASSIFIED LOCATIONS. THE SENSOR SHALL BE GENERAL PURPOSE, POISON RESISTANT, STAINLESS STEEL BODY. THE SENSOR SHALL BE MODEL NO.10058-1 R MANUFACTURED BY GENERAL MONITORS, INC. OR APPROVED EQUAL. 2) HYDROGEN SULFIDE (H2S) GAS SENSOR ASSEMBLY HYDROGEN SULFIDE GAS SENSOR SHALL BE A METAL OXIDE SEMICONDUCTOR, ABSORPTION, CONTINUOUS DIFFUSION TYPE SENSOR DEVICE. THE OPERATING PRINCIPLE OF THE SENSOR SHALL BE BASED ON REDUCING OF RESISTANCE ACROSS SURFACE OF SEMICONDUCTOR AT A RATE PROPORTIONAL TO THE PRESENT OF H2S GAS CONCENTRATION. THE SENSOR SHALL BE CAPABLE OF MEASURING THE H2S GAS CONCENTRATION IN A RANGE OF 0-20, 0-50 AND 0-100 PART PER MILLION (PPM). THE SENSOR SHALL BE MANUFACTURED TO BE SENSITIVE TO H2S GAS AND BE UNAFFECTED BY HIGH CONCENTRATION OF OTHER GASES. THE SENSOR MUST BE APPROVED BY CSA AND MEET ISA S92.0.01 PART1-1998 REQUIREMENTS AS VERIFIED BY FACTORY MUTUAL (FM). SENSOR ASSEMBLY SHALL BE EXPLOSION PROOF HOUSING. THE SENSOR ASSEMBLY SHALL BE CAPABLE OF OPERATING IN CLASS 1 DIVISION 1 GROUP B, C AND D HAZARDOUS CLASSIFIED LOCATIONS. THE SENSOR SHALL BE MODEL 50448-9HT 0-20 PPM STAINLESS STEEL BODY MANUFACTURED BY GENERAL MONITORS, INC. OR APPROVED EQUAL. PROVIDE NEMA -0 ENCLOSURE WITH MESH PROTECTED BOTTOM OPENING AND DIMENSION OF 10"H X 8"W X 6"D FOR HOUSING THE SENSOR ASSEMBLY. 4. CALIBRATION: CALIBRATION SHALL BE PERFORMED IN THE FIELD AFTER COMPLETION OF SYSTEM INSTALLATION BY A CERTIFIED FACTORY -TRAINED INDIVIDUAL. THE CALIBRATION SYSTEM SHALL CONSIST OF A PRESSURE AND FLOW REGULATION SYSTEM FOR DELIVERY OF CALIBRATION GAS TO THE SENSOR. A REFILLABLE, PRESSURIZED GAS CYLINDER SHALL BE PROVIDED. A COPY OF THE MANUFACTURER'S CURRENT WRITTEN SET OF INSTRUCTIONS ON TESTING, MAINTENANCE AND SERVICE INCLUDING CALIBRATION SHALL BE SUBMITTED TO THE ENGINEER. CERTIFICATION BY ATTESTING TO THE PERFORMANCE AND CALIBRATION OF EACH SENSOR SHALL BE SUBMITTED TO THE ENGINEER. 5. GUARANTEE: ALL COMPONENTS OF THE GAS MONITORING SYSTEM AND INSTALLATION SHALL BE GUARANTEED IN WRITING AGAINST FAULTY WORKMANSHIP AND/OR MATERIAL FOR A PERIOD OF ONE (1) YEAR FROM THE DATE OF ACCEPTANCE BY THE OWNER. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 'SECTION' IDENTIFICATION LETTER 'DETAIL' IDENTIFICATION NUMBER SHEET NUMBER WHICH 'SECTION' OR 'DETAIL' IS DRAWN. SHEET NUMBER WHICH 'SECTION' OR 'DETAIL' IS TAKEN MAY BY MORE THAN ONE SHEET. C-3651 I I I I I I I I EXISTING BLOWER BUILDING --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- LJ --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- I I I I \ --------------- LANDFILL LANDFLL SCALE: 3/4"=l'—O" CAS COLLECTION AND CONTROL SYSTEM - ELECTRICAL PLAN AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 '10 GND '10 GND 3 5 8 20 18 20 :XIBLE (TYP.) '#8+#8 GND (10 GND ?#8+#8 GND X10 GND X10 GND EQUIPMENT LIST: ITEM DESCRIPTION REMARKS ITEM DESCRIPTION REMARKS O EXISTING METER AND CIRCUIT BREAKER PANEL SEE NOTES 1 AND 2 THIS SHEET O METHANE/H2S GAS MONITORING PANEL SEE NOTE 4 THIS SHEET. O LANDFILL GAS DUPLEX BLOWER STARTER PANEL SEE NOTE 5 THIS SHEET. O H2S GAS SENSOR SEE NOTE 4 THIS SHEET. O H2S GAS DUPLEX BLOWER STARTER PANEL SEE NOTE 5 THIS SHEET. 10 METHANE GAS SENSOR SEE NOTE 4 THIS SHEET. O4 5.5HP LANDFILL GAS BLOWER MOTORS TYPICAL FOR 2 BLOWERS 12 WEATHER PROOF 24VDC STROBE LIGHT MOUNTED ABOVE DOOR LEVEL, SEE NOTES 3 AND 4 THIS SHEET. O 1HP H2S GAS TYPICAL FOR 2 BLOWER MOTORS BLOWERS WEATHER PROOF 120VAC TYPICAL FOR 2 O STROBE LIGHT PLACES. MOUNTED ABOVE DOOR LEVEL, SEE NOTES 3 AND 5 THIS SHEET. CONDUIT TRANSITION INSTALLATION DETAIL 1 N.T.S. 18 18 UNDERGROUND CONDUIT INSTALLATION DETAIL A N.T.S. 18 18 NOTES: 1. SEE DWG. E-1 SHEET 17 FOR DEMOLITION NOTES FOR EXISTING METER AND CB PANEL. 3+#8 GND 2. SEE DWG. E-3 SHEET 19 FOR SINGLE LINE DIAGRAM AND EQUIPMENT SCHEDULE. ?#12+#12 GND 3. PROVIDE 6-1/2"WX2"H FOR EACH BLOWER SYSTEM STROBE LIGHT AND PROVIDE 6-1/2"WX2"H FOR GAS ALARM. SIGN SHALL BE AFFIXED 3" BELOW STROBE LIGHTS. SIGNS SHALL BE IN RED LETTER ON WHITE BACKGROUND. PROVIDE SIGN AS FOLLOWS: ?#14 a) FOR LANDFILL AND H2S GAS BLOWER SYSTEM; LANDFILL GAS H2S GAS BLOWER FAIL BLOWER FAIL 1 18 18 b) FOR LANDFILL/H2S GAS ALARM; METHANE/H2S GAS ALARM 4. SEE DWG. E-4 SHEET 20 FOR SENSOR ASSEMBLY AND INSTALLATION DETAILS, GAS A MONITORING PANEL CONTROL AND WIRING DIAGRAMS INCLUDING PANEL DETAILS. 18 18 5. SEE DWG. E-5 SHEET 21 FOR LANDFILL GAS AND H2S GAS DUPLEX BLOWER STARTER PANEL CONTROL DIAGRAM AND PANEL DETAILS INCLUDING BLOWER SYSTEM FAIL 1 "C—TELEPHONE NOTIFICATION. WIRING, SEE NOTE 6. TERMINATED LOCATION OF WIRING AND RACEWAYS FOR AIR COMPRESSOR TO BE 7 THIS SHEET REFERRED TO THE AIR COMPRESSOR MANUFACTURER AND TO BE VERIFIEED IN FIELD BY THE CONTRACTOR. X10 GND 7. THE CONTRACTOR SHALL COORDINATE WITH TELEPHONE COMPANY FOR TELEPHONE #12 GND SERVICE. INSTALLATION OF ALL WIRING AND RACEWAYS INCLUDING UNDERGROUND INSTALLATION FROM POINT OF TERMINATION OF TELEPHONE UTILITY TO LANDFILL/H2S GAS MONITORING PANEL SHALL BE RESPONDED BY THE CONTRACTOR. C-3651 o I I I I M. ULILLK I JtF' I`J, 2UUb I . - - - - .. _. - __ - -. . " -.... .... I _..__ . __ _. __ I I (E) METER AND (N) CB PANEL (SEE DEMOLITION NOTES ON DWG. E-1)1 (E) 100A 120/240 10 3W SCE METER (E) UNDEGROUND SERVICE NOTES: i. \ /A)), � nA„ . nA„ . k I r METHANE/H2S GAS MONITORING PANEL NGLE LINE DIAGRAM. N.T.S. 1. SEE DWG. E-1 SHEET 17 FOR DEMOLITION NOTES FOR THE EXISTING UTILITY METER AND EXISTING CIRCUIT BREAKER PANEL. 2. SEE DWG. E-2 SHEET 18 FOR ELECTRICAL PLAN. 3. SEE DWG. E-4 SHEET 20 FOR METHANE/H2S GAS MONITORING PANEL WIRING DIAGRAMS AND DETAILS, SENSOR ASSEMBLY AND INSTALLATION DETAILS. 4. SEE DWG. E-5 SHEET 21 FOR DUPLEX BLOWER STARTER PANEL WIRING DIAGRAMS AND DETAILS. 1HP 1HP BLOWER BLOWER NO.3 NO.4 0 0 EQUIPMENT SCHEDULE ITEM DESCRIPTION QUANTITY REMARK ITEM DESCRIPTION QUANTITY REMARK O EXISTING 100A 120/240V 10 3W METER AND 1 (IN FRONT OF BLOWER ROOM) O STROBE LIGHTS FOR BLOWER SYSTEM FAIL 2 INSTALLED ABOVE QUANTITY NEW 100A 120/240V CIRCUIT BREAKER PANEL MODE FLASHING ALARM NOTIFICATION SHALL BE WEATHERPROOF 120VAC METHANE (CH4) THE DOOR IN 15 WATTS 1 0.63 A @ 24VDC (HI ALARM) SINGLE FLASH STROBE LIGHT WITH AMBER COLOR LEN. PROVIDE NEMA -3R J -BOX AS REQUIRED FOR A FRONT OF BLOWER ROOM. GAS CONTROLLER EQUIPMENT SEQUENCE OF OPERATION PROCEDURE H2S GAS LEVEL O DUPLEX BLOWER STARTER PANEL FOR LANDFILL 2 ITEM '2' FOR (PPM) MOUNTING ON WALL. HYDROGEN SULFIDE (H2S) (IN FRONT OF BLOWER ROOM) 15 WATTS GAS BLOWERS SHALL BE NEMA SIZE 2, FULL 0.63 A @ LANDFILL GAS 0.63 A @24VDC O VOLTAGE, NON REVERSED, 240V 10 IN NEMA -3R BLOWERS AND HIGH INDICATING LIGHT ALARM INDICATING LIGHT 2 (HI ALARM) ENCLOSURE. DUPLEX BLOWER STARTER PANEL AUTOMATIC TELEPHONE ITEM '3' FOR H2S Cj TIME CLOCK CONTROL SHALL BE 120VAC, 15A 2 INSTALLED IN FOR H2S GAS BLOWERS SHALL BE NEMA SIZE 0, A GAS BLOWERS DIALER DPST CONTACTS, DIN RAIL MOUNTING TYPE, 7 DUPLEX BLOWER FULL VOLTAGE, NON REVERSED, 240V 10 IN DAY SCHEDULE WITH OVERRIDE SWTICH GAS ALARM PANEL 10 WATTS NEMA -3R ENCLOSURE. OVERLOAD RELAY SHALL - 1.25 A @24VDC RED STROBE LIGHT BE SET FOR 115% OF MOTOR NAMEPLATE FULL LOAD CURRENT. CONTROL COMPONENTS O METHANE/1-12S GAS MONITORING PANEL 1 24VDC COMPONENTS AND CONTROL DIAGRAM AS SHOWN A @24VDC TOTAL REQUIRED LOAD 4.59 A @ 24VDC ON DUPLEX AIR BLOWER CONTROL DIAGRAM THIS A @24VDC O H2S GAS SENSOR 1 MOUNTED ON = SHEET. BLOWER CONTROLS SHALL BE X (5 MIN) CALCULATION = 110.16 AH WALL AT 18" AFF. INTERLOCKED TO ALLOW ONLY ONE BLOWER (60 MIN) = 0.49 AH TOTAL REQUIRED BACKUP BATTERY FOR OPERATED AT A TIME. 110.65 AH SUPERVISORY AND ALARM MODES 10 METHANE GAS SENSOR 1 MOUNTED ON MOUNTED ON COVER - DISCONNECT SWITCHES, BATTER WITH 20% SAFETY FACTOR 132.78 AH WALL AT 84" AFF. HAND -OFF -AUTO SELECTOR SWITCHES, ELAPSED 145 AH TIMER, BLOWER RUN AND BLOWER FAIL INDICATING LIGHTS, AND OVERLOAD RESET PUSH 11 AUTO DIALER, TO BE INSTALLED IN THE 1 BUTTON. METHANE/1-12S GAS MONITORING PANEL 12 O STROBE LIGHT FOR METHANE/1-12S GAS ALARM 1 INSTALLED ABOVE O 5.5HP 240V 10 LANDFILL GAS BLOWER MOTORS 2 NOTIFICATION SHALL BE WEATHERPROOF 24VDC THE DOOR IN SINGLE FLASH STROBE LIGHT WITH RED COLOR LEN. PROVIDE NEMA -3R J -BOX AS REQUIRED FOR FRONT OF BLOWER ROOM. O 1HP 240V 10 H2S GAS BLOWER MOTORS 2 MOUNTING ON WALL. _7 5 z HP OV WER + ).2 zlizz 00 c� z 0 AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 METHANE GAS MONITORING METHANE/1-12S GAS MONITORING SYSTEM PROCEDURE METHANE GAS LEVEL METHANE GAS METHANE/1-12S GAS STROBE LIGHT BATTERY BACKUP CALCULATION CONTROLLER MONITORING PANEL (IN FRONT OF BLOWER ROOM) COMPONENT FAULT INDICATING LIGHT POWER/MODULE QUANTITY SUPERVISORY MODE FLASHING ALARM MODE METHANE (CH4) 20 % LEL AND ABOVE 15 WATTS 1 0.63 A @ 24VDC (HI ALARM) 0.63 A @24VDC GAS CONTROLLER EQUIPMENT SEQUENCE OF OPERATION PROCEDURE H2S GAS LEVEL H2S GAS METHANE/1-12S GAS STROBE LIGHT STEP (PPM) CONTROLLER HYDROGEN SULFIDE (H2S) (IN FRONT OF BLOWER ROOM) 15 WATTS 1 0.63 A @ 24VDC 0.63 A @24VDC GAS CONTROLLER - 2 PPM AND ABOVE HIGH INDICATING LIGHT ALARM INDICATING LIGHT 2 (HI ALARM) FLASHING AUTOMATIC TELEPHONE RED STROBE FLASHING 30 WATTS 1 1.25 A @ 24VDC 1.25 A @24VDC DIALER GAS ALARM 10 WATTS 1 - 1.25 A @24VDC RED STROBE LIGHT CONTROL COMPONENTS 50 WATTS - 2.08 A @ 24VDC 2.08 A @24VDC TOTAL REQUIRED LOAD 4.59 A @ 24VDC 5.84 A @24VDC REQUIRED BACKUP BATTER = (4.59 A) X (24 HR) = (5.84A) X (5 MIN) CALCULATION = 110.16 AH (60 MIN) = 0.49 AH TOTAL REQUIRED BACKUP BATTERY FOR 110.65 AH SUPERVISORY AND ALARM MODES REQUIRED BACKUP BATTER WITH 20% SAFETY FACTOR 132.78 AH MANUFATURER TO PROVIDE 145 AH METHANE GAS MONITORING EQUIPMENT SEQUENCE OF OPERATION PROCEDURE METHANE GAS LEVEL METHANE GAS METHANE/1-12S GAS STROBE LIGHT STEP (% LEL) CONTROLLER MONITORING PANEL (IN FRONT OF BLOWER ROOM) ALL % LEL FAULT INDICATING LIGHT FAULT INDICATING LIGHT 1 (SENSOR FAULT) FLASHING FLASHING (AMBER COLOR) - 20 % LEL AND ABOVE HIGH INDICATING LIGHT ALARM INDICATING LIGHT 2 (HI ALARM) FLASHING FLASHING (RED COLOR) RED STROBE FLASHING HYDROGEN SULFIDE (H2S) GAS MONITORING EQUIPMENT SEQUENCE OF OPERATION PROCEDURE H2S GAS LEVEL H2S GAS METHANE/1-12S GAS STROBE LIGHT STEP (PPM) CONTROLLER MONITORING PANEL (IN FRONT OF BLOWER ROOM) ALL RANGE FAULT INDICATING LIGHT FAULT INDICATING LIGHT 1 (SENSOR FAULT) FLASHING FLASHING (AMBER COLOR) - 2 PPM AND ABOVE HIGH INDICATING LIGHT ALARM INDICATING LIGHT 2 (HI ALARM) FLASHING FLASHING (RED COLOR) RED STROBE FLASHING C-3651 o I I I I M. ULILLK I JtF' I`J, 2UUb I . - - — - .. -. - -- --. . " -.... .... _..__ . -- _. -- I 24" 24" METHANEZH2S GAS MONITORING PANEL_ DETAIL_ 1 18 20 N.T.S. NOTES: qLL H2S GAS SENSOR 2 18 20 SENSOR ASSEMBLY N.T.S. METHANE GAS SENSOR 3 18 20 N S TA L LAT I O N DETAILS 1. SEE DWG. E-2 SHEET 18 FOR ELECTRICAL PLAN. 2. SEE DWG. E-3 SHEET 19 FOR SINGLE LINE DIAGRAM, EQUIPMENT SCHEDULE, GAS MONITORING SYSTEM BATTERY BACKUP CALCULATION AND GAS MONITOR EQUIPMENT SEQUENCE OF OPERATIONS. 3. MANUFACTURE TO UTILIZE LATCH HI -ALARM OUTPUT CONTACTS OF THE GAS CONTROLLERS FOR PROVIDING HI -ALARM SIGNAL FOR THE GAS MONITORING SYSTEM CONTROL. ALL L------------- L 120VAC - 5A METHANE GAS RA1-4 HI ALARM (SPARE) H2S GAS RA2-4 T HI ALARM (SPARE) IINJIHLLLU IN IjHJ MONITORING PANEL METHANE GAS RF1-2 SENSOR FAULT (SPARE) H2S GAS RF2-2 SENSOR FAULT (SPARE) PANEL POWER ON INDICATING LIGHT METHANE GAS HI ALARM AUX. CONTACT METHANE GAS SENSOR FAULT AUX. CONTACT H2S GAS HI ALARM AUX. CONTACT H2S GAS SENSOR FAULT AUX. CONTACT METHANE GAS SENSOR FAULT INDICATING LIGHT H2S GAS SENSOR FAULT INDICATING LIGHT METHANE GAS HI ALARM INDICATING LIGHT H2S GAS HI ALARM INDICATING LIGHT METHANE/H2S GAS ALARM FLASHING STROBE LIGHT CONTROL METHANE GAS ALARM AUTO DIALER CH1 INTERLOCKED H2S GAS ALARM AUTO DIALER CH2 INTERLOCKED (N) 3/4"C -3/C #20 SHIELDED CABLE METHANE GAS SENSOR CH4 - - - - ASSEMBLY (N) 3/4"C -4/C #20 SHIELDED CABLE H2S GAS SENSOR H2S - - - - ASSEMBLY METHANE/H2S GAS MONITORING PANEL � CH4 CONTROLLER � I I L J I I H2S CONTROLLER I I I I I I i L J i (N) 3/4"C-214 I GAS ALARM S -_-- ----_ STROBE LIGHT 1_111jto] 11111aI I TEL LINE I METHANE GAS tc H1 HI ALARM—� ❑o H2S GASH 2 HI ALARM _ SPARE CH3 I I SPARE T I CH4 (N) 3/4°C TELEPHONE I WIRING GAS MONITORING PANEL_ WIRING DIAGRAM N.T.S. (N) 3/4"C-2#10+#12 GND METHANE/H2S GAS MONITORING PANEL IVILII IrIIVL/IILJ VI"lJ IVIVIVII VI\IIVV IrIIVLL CB PANEL 20A 1P � POWER SUPPLY I -------� I IN Ll - - - - - - - - - - -- IL - - - - - - - PANEL WIRING BY MANUFACTURER PER CODE i GAS MONITORING PANEL CONTROL DIAGRAM N.T.S. AUTO DIALER ------- + i - L- - - - - - - - BATTERY BACKUP I + I 24VDC I - L— — — — — — — I PANEL WIRING BY MANUFACTURER PER CODE GAS MONITORING PANEL_ POWER SUPPLY WIRING DIAGRAM r� T_ y �l T IIII O N.T.S. IIII I O I IIII 0 0 -------- AS -BUILT 10" IIII I O I o BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION IIII `-��-J IIII 6 I I I I III IIII I I A 11 I I SOLUTION, INC IF - �� �L - i METHANE GAS SENSOR DETAIL 5 DATE. 05-05-08 LMa�__---�J -� --- J 18 20 N.T.S. 8 C-3651 PREPARED BY: APPROVED LANDFILL GAS C( FRONT VIEW TOP VIEW e% ^ � """ ®i ® ®i n "'Olt H2S GAS SENSOR ASSEMBLY DETAIL 4 18 20 N.T.S. (N) I)l"C-5#8+#8 CND (N) 3/4"C-2#8+#8 GND (E) CB PANEL 0 (N) COMBINATION DUPLEX MOTOR STARTER O (N) 3/4"C W.P. 70A 2P 100A 2P M1 FLEXIBLE CONDUIT :05 5.5HP 240V 10 4 LANDFILL GAS O BLOWER NO.1 (N) 3/4"C W.P. 70A 2P 100A 2P M2 FLEXIBLE CONDUIT 5.5HP 240V 1 O y _ _____� � ___ ___� LANDFILL GAS I 'T' BLOWER NO.2 N------ --I I 10A OFF BLOWER#1 '*.-, �l �BLOWER#2 OFF HAND �\�", AUTO TC1-'I TIME CLOCK (N) 3/4"C-2#8+#8 GND -TIME CLOCK TERMINAL BLOCK (TYP.) BLOWER PANEL L BLOCK (TYP.) M1-2 C1-1 M1 RUN R ELAPSED TIMER FAIL A 0L'S BLOWER NO.1 RUN INDICATING LIGHT BLOWER NO.1 ELAPSED TIMER BLOWER NO.1 FAIL 1 INDICATING LIGHT BLOWER NO.1 MOTOR RELAY 3'-10" 2,-8„ s LANDFILL GAS DUPLEX BLOWER STARTER PANEL DETAIL 1 N.T.S. 18 21 3'-10" 2,-8„ _ � " ,\e H2S GAS DUPLEX BLOWER STARTER PANEL DETAIL 2 18 21 N.T.S. I c1 BLOWER NO.1 AUXILIARY RELAY I (N) 3/4"C-2#12+#12 GND I _ O M1-3 C1-2 O CB PANEL (N) TIME CLOCK#1 I --- s -- BLOWER FAIL STROBE 7 O _ LIGHT WITH AMBER 15A1 P 1 0 STROBE LIGHT COLOR LEN, MOUNTEDn _ 1 _ _ _ _ _ _ IN FRONT OF ABOVE DOOR IN FRONT r —r — — - 4 14 1 I M2-3 C2-3 BLOWER ROOM OF BLOWER ROOM N----- I OFF HAND � AUTO RUN I I — — TO DUPLEX LANDFILL `�,Ix M2-1 R BLOWER NO.2 RUN 1 I I TC1-1 _ — GAS BLOWER F_TC1--- INDICATING LIGHT -- STARTER PANEL, SEE DUPLEX BLOWER -� -I ELAPSED TIMER BLOWER NO.2 I TC1-2 — CONTROL DIAGRAM I - TIME CLOCK ELAPSED TIMER I I — THIS SHEET I I I L J I M2-2 C2-1 FAIL A BLOWER NO.2 FAIL INDICATING LIGHT (N) 3/4"C-2#12+#12 GND 0L'S M2 BLOWER NO.2 MOTOR RELAY I (N) TIME CLOCK#2 O c2 BLOWER NO.2 AUXILIARY RELAY i I O 1 I I I L-- ------- I 4#14 I -_T I TO DUPLEX H2S TC2-1 GAS BLOWER 1 — — STARTER PANEL, SEE I — — DUPLEX BLOWER I TC2-2 CONTROL DIAGRAM DUPLEX BLOWER STARTER CONTROL DIAGRAM FOR LANDFILL GAS BLOWERS #1  1 -- THIS SHEET (TYPICAL FOR H2S GAS BOWERS #3) NOTES: 1. SEE DWG. E-2 SHEET 18 FOR ELECTRICAL PLAN. 2. SEE DWG. E-3 SHEET 19 SINGLE LINE DIAGRAM AND EQUIPMENT SCHEDULE FOR SIZES OF STARTER PANEL, MOTORS, CIRCUIT PROTECTIONS AND CONDUCTOR SIZES. AS -BUILT BASED ON SURVEY INFORMATION RECEIVED FROM INNOVATIVE CONSTRUCTION SOLUTION, INC DATE 05-05-08 TIME COCK CONTROL DIAGRAM N.T.S. C-3651 Newport Terrace Landfill — O&M Manual Appendix B Gas Extraction Well Boring Logs SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -1 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? _—_—_7—f Organic Topsoil 1 ti ti Yellow -Orange Sand, Poorly Graded 11/12/07 Boring Diameter: 18 in. Well Diameter: 3 in. 5 �^ ti ti Bentonite Seal 2 ti ti ti ti ti Refuse Encountered, Containing Plastic, Paper 3" dia. PVC blank 3 10 and Other Small Debris 1 o v o v 0 0 v v 4 �.. ti.. °0 °0 �..-.. v v 15 1 0 ° ° °0 0 ° ° °0 Gravel pack 10 ft. to 33 ft. v v 5 �.. ti.. °0 °0 �..-.. v v 0 0 v v 6 20 �^ 2 0 °o 0 °o °o °o 7 o 0 o ° o ° 0 ov 0 3" dia. PVC screen 25 ti 2 °o °o 8 0 0 0 o 0 O o ° ° o ° ° A � 'n O 0 O 0 9 30 3 0 0 Endcap j � °o poop ° 0°0 o° �o nDark Grey, Inorganic Silt or Clay With Some p 0 p ° Gravel Pack n 10 Plasticity L 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Date Started: 11/12/07 Date Ended: 11/12/07 Boring Diameter: 18 in. Well Diameter: 3 in. Total Depth: 33.0 ft. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -2 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? _—_—_7—f Organic Topsoil Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Date Started: ti ti Yellow -Orange Sandy Silt, Poorly Graded 11/12/07 Boring Diameter: 18 in. Well Diameter: 3 in. 5 �^ ti ti Bentonite Seal 2 ti ti ti ti ti Refuse Encountered, Containing Plastic, Paper 3" dia. PVC blank 3 10 and Other Debris 1 o v o v 0 0 v v 4 �.. ti.. °0 °0 �..-.. v v 15 1 0 ° ° °0 0 ° ° °0 Gravel pack 10 ft. to 33 ft. v v 5 �.. ti.. °0 °0 �..-.. v v 0 0 v v 6 20 �^ 2 0 °o 0 °o °o °o 7 o 0 o ° o ° 0 ov 0 3" dia. PVC screen 25 ti 2 °o °o 8 0 0 0 o 0 O o ° ° o ° ° A � 'n O 0 O 0 9 30 3 0 0 Endcap j � °o poop ° 0°0 o° �o nDark Grey, Inorganic Silt or Clay With Some p 0 p ° Gravel Pack n 10 Plasticity L 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Date Started: 11/12/07 Date Ended: 11/12/07 Boring Diameter: 18 in. Well Diameter: 3 in. Total Depth: 33.0 ft. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -3 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? 0 0 — Organic Topsoil Yellowish -Orange Refuse encountered at 3 feet 30 End of Bore Hole L J 10 L 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No soil samples or drive tubes obtained Date Started: 9/21/07 ti ti 9/21/07 Boring Diameter: 18 in. ti ti 3 in. 2 ti ti v v ti ti ti ti Refuse 3 10 v v 4 1 ti ti 1 -Inch Gravel pack 15 5 ^� °0 6 20 v v 0 0 o a o a °0 °0 ti ti v v 8 2 J V 30 End of Bore Hole L J 10 L 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No soil samples or drive tubes obtained Date Started: 9/21/07 Date Ended: 9/21/07 Boring Diameter: 18 in. Well Diameter: 3 in. Bentonite Seal Total Depth: 30.0 ft. °0 °0 3" dia. PVC blank 1 0 0 0 o v v 0 0 o a o a °o °o v v 0 0 °a °a °0 °o v v 1 ° ° ° ° °0 °0 1 -Inch Gravel pack v v 0 0 °a °a °0 3" dia. PVC screen v v 0 0 o a o a °0 °0 v v Endcap 2 0°00 0° 0°00 0° 0°00 0° °,°o° 2 o° ° o° o°o Gravel Pack o°moo o° o°moo o° Total Depth: 30.0 ft. :9 SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -4 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? 0 0 — Organic Topsoil Yellowish -Orange g Dark -Grey Inorganic Silt or Clay with Some 30 Plasticity 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No Soil Samples Obtained Date Started: ti ti Date Ended: 5- ti ti 18 in. 2 ti ti ti ti ti ti Refuse ti ti 4 ^�^� 15- 5 ^� 0 o a °O 6 20- 0 0 7 7 ti 25 ti 0 o a °O 1 g Dark -Grey Inorganic Silt or Clay with Some 30 Plasticity 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No Soil Samples Obtained Date Started: 9/21/07 Date Ended: 9/21/07 Boring Diameter: 18 in. Well Diameter: 3 in. Bentonite Seal Total Depth: 30.0 ft. °o °o 3" dia. PVC blank 10- °O 0 0 0 0 o a °O 0 o a °O 0 0 0 o a °O 0 o a °O 1 0 ° 9 Ft to 30 Ft 1 -Inch o a °o ° a °o Gravel pack v v 0 o a °O 0 o a °O O O 0 o a °O 0 o a °O 2 0 2 °O 0 d °O O O O O °O O O O °O ° a °O a °O 3" dia. PVC screen o v 2 0 °a °o 0 °a °o o °a °O °a °O o v 0 o a 0 o a Endcap Gravel Total Depth: 30.0 ft. :9 SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -5 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? 0 0 — Organic Topsoil Yellowish -Orange 8 g Dark -Grey Inorganic Silt or Clay with Some 30 Plasticity 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No Soil Samples Obtained Date Started: ti ti Date Ended: 5- ti ti 18 in. 2 ti ti ti ti ti ti Refuse ti ti 4 ^�^� 15- 5 ^� 0 o a °O 6 20- 0 0 7 7 ti 8 g Dark -Grey Inorganic Silt or Clay with Some 30 Plasticity 35 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No Soil Samples Obtained Date Started: 9/21/07 Date Ended: 9/21/07 Boring Diameter: 18 in. Well Diameter: 3 in. Bentonite Seal Total Depth: 30.0 ft. °o °o 3" dia. PVC blank 10- °O 0 0 0 0 o a °O 0 o a °O 0 0 0 o a °O 0 o a °O 1 ° 1 -Inch Gravel pack o0 a °O oa °O v v 0 o a °O 0 o a °O O O 0 o a °O 0 o a °O 20- °O O o=, O O O °O O O O °O o a °O a °O 3" dia. PVC screen o v 2 0 °a °O 0 °a °O O O 0 o a °O 0 o a °O O O 0 o a 0 o a Endcap °o a� °o Gravel Total Depth: 30.0 ft. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -6 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. sch. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/19/07 Date Ended: 9/19/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -7 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. sch. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/19/07 Date Ended: 9/19/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -8 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. sch. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/18/07 Date Ended: 9/18/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -9 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. sch. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/20/07 Date Ended: 9/20/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -10 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. SCH. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. SCH. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/20/07 Date Ended: 9/20/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -11 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Organic topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish orange sand, poorly graded Bentonite plug 1-2 L73 1 F 1 5 1-6 H7 1-8 Light brown, silty sand Olive gray, clayey sand Dark gray, inorganic silt, or clayey, fine sand with some plasticity Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered. 3" dia. sch. 80 PVC blank 10- - — — Soil backfill E Bentonite plug Soil backfill o R, 0 2 Date Ended: °o 0 °o 0 Total Depth: 30.0 ft. 0 0 0 0 0 0 Well Diameter: °o O °o O ° o 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0= 0 0 0 °o 0 0 °o 0 0 3/4 to 1/2 -in. clean °gravel °o °o 0 0 0 0 0 0 0 0 °o O °o O 0 ° e 0 ° a Endcap Date Started: 9/20/07 Date Ended: 9/20/07 Total Depth: 30.0 ft. Boring Diameter: 18 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -12 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0 = Grass, Organic Topsoil — F Concrete °o °o F3/4 to 1/2 -in. clean 0 o gravel 1 Yellowish Orange Sandy Silt Bentonite plug �-2 Light Brown, Silty Sand [7-3 1 Olive Grey Clayey Sand k 1 5 1-6 F7 Olive Gray Clayey Sand, Wet F8 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker No refuse encountered 3" dia. sch. 80 PVC blank 1 — — Soil backfill Date Started: 1 Date Ended: 9/24/07 Total Depth: 30.0 ft. Boring Diameter: 12 in. Well Diameter: Bentonite plug Soil backfill °o °o °o °o y o o 0 0 0 °o 0 0 0 °o O ° o O 0 3" dia. sch. 80 PVC °o °o slot 0 0 0 0 0 °o 0 0 0 °o Water encountered at 21 feet after 2 0 ° o 0 ° o 3/4 to 1/2 -in. clean gravel drilling and construction °o°o completed olo v 00 °oo °o°o 00 00 ° e a Endcap Date Started: 9/24/07 Date Ended: 9/24/07 Total Depth: 30.0 ft. Boring Diameter: 12 in. Well Diameter: 3 in. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -13 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments -2 Log E 4? 0 0 — - — - — — Grass, Organic Topsoil 0 —7 -7 -- Yellowish -Orange Silty Sand 3" dia. PVC blank 2 3 4 5 6 2 7 2 8 L9 Rubble, Concrete Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Rubble Encountered at 21 feet Date Started: 9/25/07 Date Ended: 9/25/07 Boring Diameter: 12 in. Well Diameter: 3 in. Bentonite Seal Total Depth: 21.0 ft. 10- o=, 0 0=, o o o 15- % 3" dia. PVC screen o=, o o=, o o=' 0 o 0, Endcap 2� 0 '0 1 1/2 -inch Gravel Pack Total Depth: 21.0 ft. 15 20 25 30 35 40 45 50 RIM ELEVATION (feet): GROUND SURFACE ELEVATION: TOTAL DEPTH (feet): 12.7 DATE DRILLED: 10/19/11 GC Environmental, Inc. California Contractor's License #709413 Anaheim, CA PROJECT NUMBER 1379-14 LOGGED BY: Jerry Ren DRILL RIG: Limited Access Rig (BC2 Environmental) DIAMETER OF BORING (inches): 8" WATER ENCOUNTERED AT DEPTH (feet): Not Encountered City of Newport Beach PLATE Newport Terrace, Newport Beach, CA LOG OF BORING EW -13S PAGE 1 of 1 SAMPLE ° o ° N w �+ vi WELL CONSTRUCTION 0 U y 0 SOIL DESCRIPTION A � o aai � � ° a 0 : - Connect to LFG System FILL, CLAY -SILTY FINE SAND Brown CL Bentonite Seal FILL, SILTY CLAY 4" Sch 40 PVC Blank CasingL-M #1 Sand 5 CLAYEY SILTY SAND,with rocks, (small) less CLG than 1/2" =- #3 SandCL SILTY SANDY CLAY = : - 4" Sch 40 PVC = .= Screen Casing 10 CLAYEY SILTY SAND,with rocks, (small) less .=- 4" Sch 40 PVC CLG than 1/2" Bottom Cap CL SILTY SANDY CLAY 15 20 25 30 35 40 45 50 RIM ELEVATION (feet): GROUND SURFACE ELEVATION: TOTAL DEPTH (feet): 12.7 DATE DRILLED: 10/19/11 GC Environmental, Inc. California Contractor's License #709413 Anaheim, CA PROJECT NUMBER 1379-14 LOGGED BY: Jerry Ren DRILL RIG: Limited Access Rig (BC2 Environmental) DIAMETER OF BORING (inches): 8" WATER ENCOUNTERED AT DEPTH (feet): Not Encountered City of Newport Beach PLATE Newport Terrace, Newport Beach, CA LOG OF BORING EW -13S PAGE 1 of 1 SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -14 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: Newport Beach, CA Depth Completion Detail E Graphical Description Comments a� a� Log E ? 0 0 —_—_—_— Grass, Organic Topsoil 3" dia. PVC blank 1 Yellowish -Orange Sandy Silt 5 ... Bentonite Seal 1-2 �3 10j'::::;;::'::;.I::;;::� Light Brown Silty Sand F 1 5 1-6 H7 1-8 Olive Gray Clayey Sand Rubble Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Rubble and other debris encountered at 23 feet Unable to achieve required depth Date Started: 9/24/07 Date Ended: 9/24/07 Boring Diameter: 12 in. Well Diameter: 3 in. 0 o aJ la a Gravel Pack o 0 0 0 oa oa 1 °o Flo 3" dia. PVC screen o oa oa o v 0 0 oa oa 0=, °o o v 0 0 o a o a o 2 ° °o o v 0 0 o a o a o ° °o O O 0 0 o o „ Total Depth: 23.0 ft. SCS ENGINEER'S BORING LOG 3900 Kilroy Airport Way, Suite 100 BORING NUMBER: EW -15 Page 1 of 1 Long Beach, California 90806-6816 Landfill Gas Collection System JOB NUMBER: 01201221.07 Task 2 Newport Terrace Landfill REMARKS: No refuse encountered Newport Beach, CA Depth Completion Detail E Graphical Description Comments Flush -Mount, Traffic -Rated Log a Well Box 1/4" Labcock Valve I.D. Tag 0 0— __7 Grass, Organic Topsoil 777 777 7777 7= Yellowish -Orange Silty Sand 3" dia. PVC blank 1 5 ... Bentonite Seal 1-2 L73 1 1-7 1-8 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker 9/25/07 00 0 00 0 Boring Diameter: 12 in. Well Diameter: 0 0 s 1 v 1-7 1-8 Drilling Company: BC2 Environmental Drilling Method: Hollow Stem Auger Logged By: B. Baker Date Started: 9/25/07 00 0 00 0 Boring Diameter: 12 in. Well Diameter: 0 0 1 v Water detected at 21 feet with o=, 0 water sounder v 0 o° 00 0 o° 0o v v 0 0o 0 0o v v 1 � ° � ° �o 3" dia. PVC screen o v v 0 o° �o 0 o° �0 v v Date Started: 9/25/07 Date Ended: 9/25/07 Boring Diameter: 12 in. Well Diameter: 3 in. Endcap Total Depth: 20.0 ft. 15 20 25 30 35 40 45 50 RIM ELEVATION (feet): GROUND SURFACE ELEVATION: TOTAL DEPTH (feet): 12.8 DATE DRILLED: 10/19/11 GC Environmental, Inc. California Contractor's License #709413 Anaheim, CA PROJECT NUMBER 1379-14 LOGGED BY: Jerry Ren DRILL RIG: Limited Access Rig (BC2 Environmental) DIAMETER OF BORING (inches): 8" WATER ENCOUNTERED AT DEPTH (feet): Not Encountered City of Newport Beach PLATE Newport Terrace, Newport Beach, CA LOG OF BORING EW -15S PAGE 1 of 1 SAMPLE ° o ° N w �+ vi WELL CONSTRUCTION 0 U y 0 SOIL DESCRIPTION A � o aai � � ° a 0 : - Connect to LFG System FILL, CLAY -SILTY FINE SAND Brown CL Bentonite Seal SILTY CLAY 4" Sch 40 PVC Blank Casing CL -Ml =_ #1 Sand 5 FILL, SILTY SANDY CLAY =- #3 Sand SILTY SANDY CLAY 4" Sch 40 PVC .=- =- Screen Casing CL 10 SILTY SANDY CLAY =- =- 4" Sch 40 PVC Bottom Cap 15 20 25 30 35 40 45 50 RIM ELEVATION (feet): GROUND SURFACE ELEVATION: TOTAL DEPTH (feet): 12.8 DATE DRILLED: 10/19/11 GC Environmental, Inc. California Contractor's License #709413 Anaheim, CA PROJECT NUMBER 1379-14 LOGGED BY: Jerry Ren DRILL RIG: Limited Access Rig (BC2 Environmental) DIAMETER OF BORING (inches): 8" WATER ENCOUNTERED AT DEPTH (feet): Not Encountered City of Newport Beach PLATE Newport Terrace, Newport Beach, CA LOG OF BORING EW -15S PAGE 1 of 1 Newport Terrace Landfill — O&M Manual Appendix C SCAQMD Permit to Construct/Operate — Collection System From: 6443139 Page: 1/4 Date: 1/29/20072: 05: 52 PM SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865 Copley Drive, Diamond Bar, CA 91765 PERMIT TO CONSTRUCT/OPERATE Page 1 Permit No. F85012 AN 460099 This initial permit must be renewed ANNUALLY unless the equipment is moved, or changes ownership. If the billing for the annual renewal fee (Rule 30 Lf) is not received by the expiration date, contact the District. Legal Owner ID 119098 or Operator: CITY OF NEWPORT BCH CITY HALL, CTY ATTY 3300 NEWPORT BLVD, P O BOX 1769 NEWPORT BEACH, CA 92658 R ECEIVED V 13 'G6 Equipment Location: END OF W 19TH ST, NEWPORT BEACH, CA 92663 [CITY OFFICE Equipment Description : LANDFILL GAS COLLECTION SYSTEM CONSISTING OF: 1. SEVENTY FIVE (75) VERTICAL LANDFILL GAS COLLECTION WELLS AND ASSOCIATED PIPING. 2. UP TO FIVE (5) LANDFILL GAS COLLECTION WELLS AND ASSOCIATED PIPING, TO BE INSTALLED AS NEEDED. 3. SIX LATERAL GAS COLLECTION LINES "B" THROUGH "F", HDPE, 0'-4" DIA. 4. TWO HEADER LINES "A" AND "B", HDPE, UP TO 0'-6" DIA. AND 0'-10" DIA, CONNECTING TO A LANDFILL GAS CONTROL SYSTEM. 5. CONDENSATE COLLECTION SUMPS, ASSOCIATED PIPING (COMMON TO A LANDFILL GAS CONTROL SYSTEM) AND A BELOW -GRADE SEWER DISCHARGE CONNECTION. 6. LANDFILL GAS BLOWERS, COMMON TO A LANDFILL GAS CONTROL SYSTEM Conditions: 1. OPERATION OF THIS EQUIPMENT SHALL BE CONDUCTED IN ACCORDANCE WITH ALL DATA AND SPECIFICATIONS SUBMITTED WITH THE APPLICATION UNDER WHICH THIS PERMIT IS ISSUED UNLESS OTHERWISE NOTED BELOW. 2. THIS EQUIPMENT SHALL BE PROPERLY MAINTAINED AND KEPT IN GOOD OPERATING CONDITION AT ALL TIMES. 3. THIS EQUIPMENT SHALL BE OPERATED AND MAINTAINED BY PERSONNEL PROPERLY TRAINED IN ITS OPERATION. 4. WELL DRILLING, DRIVING AND/OR TRENCHING SHALL NOT BE CONDUCTED BETWEEN THE HOURS OF 6 P.M. AND 7 A.M. OR ON SATURDAYS, SUNDAYS OR LEGAL HOLIDAYS, UNLESS OTHERWISE APPROVED BY THE AQMD. ORIGINAL This fax was received by FAX -CNB on Line 2 from 6443139 From: 6443139 Page: 2/4 Date: 1/29/2007 2:05:53 PM SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT Paget I 21865 Copley Drive, Diamond Bar, CA 91765 Permit No. F85012 PERMIT TO CONSTRUCTIOPERATE AIN 460099 5. WELL DRILLING, DRIVING AND/OR TRENCHING SHALL NOT BE CONDUCTED ON DAYS WHEN THE AQMD FORECASTS SECOND OR THIRD STAGE EPISODES FOR AREA NO. 18 OR WHEN THE AQMD REQUIRES COMPANIES IN AREA NO. 18 TO IMPLEMENT THEIR SECOND OR THIRD STAGE EPISODE PLANS, EPISODE FORECASTS FOR THE FOLLOWING DAY CAN BE OBTAINED BY CALLING (800) 288-7664. 6. WELL DRILLING, DRIVING AND/OR TRENCHING SHALL NOT BE CONDUCTED WHEN THE WIND SPEED IS GREATER THAN 15 M.P.H. AVERAGE (OVER 15 MINUTES) OR THE WIND SPEED INSTANTANEOUSLY EXCEEDS 25 M.P.H. 7. EACH WELL SHALL BE COMPLETED AND CAPPED THE SAME DAY ITS CONSTRUCTION COMMENCES UNLESS THE WELL HOLE IS COMPLETELY SEALED AND THE WELL CASING IS CONNECTED TO THE GAS COLLECTION HEADER TO PREVENT ANY LANDFILL GAS FROM ESCAPING INTO THE ATMOSPHERE. 8. THE CONSTRUCTION OF ANY PIPING OR WELL TRENCH WHICH EXPOSES LANDFILL TRASH TO THE ATMOSPHERE SHALL BE STAGED SUCH THAT NO MORE THAN ONE HUNDRED (100) LINEAR FEET OF TRENCH IS EXPOSED AT ANY TIME PRIOR TO BACKFILLING. 9. WELL HOLES, TRENCHES AND EXPOSED LANDFILL TRASH SHALL BE COMPLETELY COVERED TO PREVENT ANY EMISSIONS OF LANDFILL GAS TO THE ATMOSPHERE WHENEVER WORK ON THE WELL IS NOT ACTUALLY IN PROGRESS. THE COVER SHALL INCLUDE, BUT MAY NOT BE LIMITED TO A MINIMUM OF 6 INCHES OF CLEAN DIRT, APPROVED FOAM OR HEAVY DUTY PLASTIC SHEETING. FOAM BY ITSELF SHALL NOT BE USED AS A NIGHT COVER IF IT IS RAINING OR RAIN IS PREDICTED BY THE NATIONAL WEATHER SERVICE PRIOR TO THE NEXT SCHEDULED WORKING DAY. 10. EACH VERTICAL WELL OR LATERAL SHALL BE EQUIPPED WITH A SHUT-OFF VALVE AND A SAMPLING PORT. 11. UNTIL CONNECTED TO AN OPERATING LANDFILL GAS COLLECTION SYSTEM, EACH COMPLETED WELL SHALL BE CAPPED AND ITS GAS CONTROL VALVE CLOSED TO AVOID VENTING LANDFILL GAS TO THE ATMOSPHERE. 12. EACH WELL SHALL BE SECURELY SEALED TO PREVENT ANY EMISSIONS OF LANDFILL GAS FROM AROUND THE WELL CASING. 13. FOR THE PURPOSE OF THIS PERMIT, CONSTRUCTION SPOILS ARE LANDFILL TRASH, MATERIAL THAT IS MIXED WITH LANDFILL TRASH, MATERIAL THAT HAS BEEN IN CONTACT WITH LANDFILL TRASH, OR ODOROUS MATERIAL THAT IS REMOVED FROM WELL HOLES OR TRENCHES. 14. CONSTRUCTION SPOILS AND ALL WORKING AREAS BEING ACTIVELY USED FOR TRUCK AND CONSTRUCTION EQUIPMENT TRAFFICKING SHALL BE MAINTAINED IN A MOIST CONDITION TO MINIMIZE DUST AND EMISSIONS. [I]N1"10011 This fax was received by FAX -CNB on Line 2 from 6443139 From: 6443139 Page: 3/4 Date: 1/29/2007 2:05:54 PM SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865 Copley Drive, Diamond Bar, CA 91765 PERMIT TO CONSTRUCT/OPERATE Page 3 Permit No. FS5012 AIN 460099 15. ALL CONSTRUCTION SPOILS SHALL BE PROPERLY DISPOSED BY THE END OF THE WORKING DAY OR AS DEEMED NECESSARY BY AQMD PERSONNEL. 16. DURING TRANSPORT OF THE CONSTRUCTION SPOILS, NO MATERIAL SHALL EXTEND ABOVE THE SIDES OR REAR OF THE VEHICLE HAULING THE MATERIAL. 17. THE EXTERIOR OF THE VEHICLE (INCLUDING THE TIRES) HAULING THE CONSTRUCTION SPOILS SHALL BE CLEANED OFF PRIOR TO LEAVING THE WORKING SITE. 18. IF A DISTINCT ODOR LEVEL (LEVEL III OR GREATER) RESULTING FROM THE CONSTRUCTION IS DETECTED AT OR BEYOND THE PROPERTY LINE, ALL WORK SHALL CEASE UNTIL THE ODOR SOURCES ARE DETERMINED AND ELIMINATED. ODOR LEVELS SHALL BE DETERMINED BY AQMD PERSONNEL OR ON-SITE SAFETY COORDINATOR IN THE ABSENCE OF AQMD PERSONNEL. 19. DURING CONSTRUCTION, IF A CONSIDERABLE NUMBER OF COMPLAINTS ARE RECEIVED, ALL WORK SHALL CEASE AND APPROVED MITIGATION MEASURES SHALL BE IMPLEMENTED IMMEDIATELY. WORK SHALL NOT RESUME UNTIL THE EMISSIONS CAUSING THE COMPLAINTS ARE MITIGATED AND THE APPROVAL TO RESUME WORK IS RECEIVED FROM THE AQMD. 20. MITIGATION MEASURES, OTHER THAN THOSE INDICATED IN THESE CONDITIONS, WHICH ARE DEEMED APPROPRIATE BY AQMD PERSONNEL AS NECESSARY TO PROTECT THE COMFORT, REPOSE, HEALTH OR SAFETY OF THE PUBLIC SHALL BE IMPLEMENTED UPON REQUEST. 21. ALL GASES COLLECTED BY THIS SYSTEM SHALL BE VENTED TO A CONTROL SYSTEM WHICH IS IN FULL USE, CAN ADEQUATELY PROCESS THE VOLUME OF GAS COLLECTED, AND HAS BEEN ISSUED A VALID PERMIT TO CONSTRUCT OR OPERATE BY THE AQMD. 22. THE OPERATION OF THIS EQUIPMENT SHALL NOT RESULT IN THE RELEASE OF ANY RAW LANDFILL GAS INTO THE ATMOSPHERE. 23. LANDFILL GAS CONDENSATE SHALL BE COLLECTED AND CONVEYED IN AN ENCLOSED MANNER AND SHALL BE DISPOSED OF PROPERLY. THE OPERATION OF THIS EQUIPMENT SHALL NOT RESULT IN THE DISCHARGE OF ODOROUS LIQUIDS/VAPORS TO THE ATMOSPHERE. 24. THE AQMD SHALL BE NOTIFIED IN WRITING AT LEAST ONE WEEK IN ADVANCE WHEN ADDITIONAL WELLS AND THEIR ASSOCIATED PIPING WILL BE INSTALLED. THE PROPOSED WELL LOCATIONS AND ASSOCIATED PIPING SHALL BE IDENTIFIED ON A DRAWING WHICH SHOWS THE ENTIRE GAS COLLECTION SYSTEM. THE PROPOSED WELL DEPTHS, PIPE LENGTHS, DIAMETERS, AND LAYOUTS SHALL BE SUPPLIED TO THE AQMD IN THIS ADVANCE NOTIFICATION. 25. WITHIN 90 DAYS AFTER CONSTRUCTION OF A GROUP OF WELLS AND THEIR ASSOCIATED PIPING IS COMPLETE, THE PERMITTEE SHALL KEEP ON FILE AND SUBMIT UPON REQUEST, AS BUILT DRAWINGS TO THE AQMD. This fax was received by FAX -CNB on Line 2 from 6443139 From: 6443139 Page: 4/4 Date: 1/29/2007 2:05:54 PM SOUTH .COAST AIR QUALITY MANAGEMENT DISTRICT Page 21855 Copley Drive, Diamond Bar, CA 91765 Permit No. F85012 PERMIT TO CONSTRUCT/OPERATE AIN 460099 NOTICE IN ACCORDANCE WITH RULE 206, THIS PERMIT TO OPERATE OR COPY SHALL BE POSTED ON OR WITHIN 8 METERS OF THE EQUIPMENT. THIS PERMIT DOES NOT AUTHORIZE THE EMISSION OF AIR CONTAMINANTS IN EXCESS OF THOSE ALLOWED BY DIVISION 26 OF THE HEALTH AND SAFETY CODE OF THE STATE OF CALIFORNIA OR THE RULES OF THE AIR QUALITY MANAGEMENT DISTRICT. THIS PERMIT CANNOT BE CONSIDERED AS PERMISSION TO VIOLATE EXISTING LAWS, ORDINANCES, REGULATIONS OR STATUTES OF OTHER GOVERNMENT AGENCIES. EXECUTIVE OFFICER By Dorris M.Bailey/TKOI 11/2/2006 ORIGINAL This fax was received by FAX -CNB on Line 2 from 6443139 Newport Terrace Landfill — O&M Manual Appendix D SCAQMD Permit to Construct/Operate — Treatment System From: 9496443139 Page: 1/4 Date: 11/14/20061:14:00 PM r SOUTH COAST AIR QUALITY MANAGEMENT DISIRICT Page t rj 21865 Copley Drive, Diamond Bar, CA 91765 Permit No. F85Dt1 PERMIT TO CONSTRUCTIOPERATE A/N 460102 This initial permit must he renewed. ANNUALLY unless the equipment is moved, or changes ownership. If the billing for the annual renewal Fee (Rule 301 J) is not received by the expiration date, contact the District. Legal Owner ID 119098 or Operator: CITY OF NEWPORT BCH CITY HALL, CTY ATTY 3300 NEWPORT BLVD, P O BOX 1768 NEWPORT BEACH, CA 92658 Equipment Location: END OF W 19TH ST, NEWPORT BEACH, CA 92663 Equipment Description : LANDFILL GAS CONTROL SYSTEM CONSISTING OF: 1. TWO KNOCKOUT VESSELS, ACS INDUSTRIES WITH DEMISTER PAD. 2. ADSORBER, SULFATREAT410 HP, WITH 2000 LBS OF GRANULAR MATERIAL, 7-8" H. X T-10" DIA., REMOVING SULFUR COMPOUNDS FROM LANDFILL GAS COLLECTED IN HEADER LINE B. 3. TWO BLOWERS, ONE SPARE, EACH 75 SCFM, VENTING TREATED LANDFILL GAS COLLECTED IN HEADER LINE "B" TO THE CARBON ADSORPTION SYSTEM. 4. TWO BLOWERS, ONE SPARE, EACH 300 SCFM, VENTING LANDFILL GAS COLLECTED IN HEADER LINE "A" TO THE CARBON ADSORPTION SYSTEM. 5. FLAME ARRESTOR. 6. CARBON ADSORPTION SYSTEM CONSISTING OF TWO CARBON ADSORBERS, IN SERIES, BAKER FILTRATION, MODEL NO. KLEEN AIR 20005, EACH 2000 LBS OF ACTIVATED CARBON, REMOVING TNMOCS FROM LANDFILL GAS COLLECT ED IN HEADER LINES "A" AND "B". 7. EXHAUST STACK, MINIMUM 32'-0" H. X 0'4" DIA. WITH NO RAIN CAP. Conditions : OPERATION OF THIS EQUIPMENT SHALL BE CONDUCTED IN ACCORDANCE WITH ALL DATA AND SPECIFICATIONS SUBMITTED WITH THE APPLICATION UNDER WHICH THIS PERMIT IS ISSUED UNLESS OTHERWISE NOTED BELOW. 2. THIS EQUIPMENT SHALL BE PROPERLY MAINTAINED AND KEPT IN GOOD OPERATING CONDITION AT ALL TIMES. THIS EQUIPMENT SHALL BE OPERATED AND MAINTAINED BY PERSONNEL PROPERLY TRAINED IN ITS OPERATION. IIII7;7TRYLTa" This fax was received by FAX -CNB on Line 3 from 9496443139 From: 9496443139 Page: 2/4 Date: 11/14/20061:14:01 PM auu I H L�UA,'i I AIH UVALI I Y MANA LMEN I UIS I HICT 21865 Copley Drive, Diamond Bar, CA 91765 PERMIT TO CONSTRUCT/OPERATE C MKC L Permit No - F85011 AIN 460102 4. A FLOW INDICATING AND RECORDING DEVICE SHALL. BE INSTALLED IN THE LANDFILL GAS SUPPLY LINE TO TIIE CARBON ADSORBERS TO MEASURE AND RECORD THE QUANTITY OF LANDFILL GAS (IN STANDARD CUBIC FEET PER MINUTE (SCFM) BEING TREATED BY THE CARBON ADSORBERS- 5. THE BLOWERS IN THIS EQUIPMENT SHALL NOT BE OPERATED UNLESS GASES ARE VENTED THROUGH TWO CARBON ADSORBERS CONTAINING A TOTAL OF AT LEAST 4000 LBS OF GRANULAR ACTIVATED CARBON. 6. RAW LANDFILL GAS SHALL NOT BE RELEASE TO THE ATMOSPHERE FROM THIS EQUIPMENT. 7. THE TOTAL VOLUME OF LANDFILL GAS TREATED BY THE CARBON ADSORBERS SHALL NOT EXCEED 375 SCFM. S. THE CONCENTRATION OF TOTAL NON METHANE ORGANIC COMPOUNDS (TNMOC) AT THE COMBINED INLET TO THE CARBON ADSORPTION SYSTEM SHALL NOT EXCEED 250 PPMV, MEASURED AS HEXANE. 9, THE CONCENTRATION OF TNMOC AT THE FINAL OU -1 LET OF THE CARBON ADSORBERS SHALL NOT EXCEED 20 PPMV MEASURED AS HEXANE AT 3 PERCENT OXYGEN OR SHALL BE REDUCED BY AT LEAST 98 PERCENT BY WEIGHT BY THE CARBON ADSORBERS. 10. OWNER/OPERATOR SHALL CONDUCT ANNUAL SOURCE TESTS IN ACCORDANCE WITH AQMD APPROVED TEST PROCEDURES AND FURNISH WRITTEN RESULTS OF SUCIi SOURCE TESTS TO THE AQMD WITHIN 30 DAYS AFTER TESTING. WRITTEN NOTICE OF THE SOURCE TESTS SHALL BE PROVIDED TO THE AQMD 10 DAYS PRIOR TO TESTING SO THAT AN OBSERVER MAY BE PRESENT. ALL SOURCE TESTING AND ANALYTICAL METHODS SHALL BE SUBMITTED TO THE AQMD FOR APPROVAL AT LEAST 30 DAYS PRIOR TO TIIE START OF TESTS. THE TESTS SHALL INCLUDE, BUT MAY NOT BE LIMITED TO, A TESTOF THE INLET GAS TO THE CARBON ADSORBER SYSTEM AND FINAL OUTLET OF THE CARBON ADSORBER SYSTEM FOR: A. METHANE B. TNMOC C. TAC'S (AS SPECIFIED IN RULE 1150.1) D. TOTAL SULFUR, AS 1425 E. MOISTURE CONTENT F. TEMPERATURE G. FLOW RATE H. OXYGEN FINAL REPORT SHALL INCLUDE AGE (IN OPERATIONAL IIOURS) OF THE CARBON AT TIME OF SOURCE TEST, AND CALCULATIONS TO DEMONSTRATE COMPLIANCE WITH THE REQUIRMENTS IN CONDITION NO -9 - ORIGINAL This fax was received by FAX -CNB on Line 3 from 9496443139 From: 9496443139 Page: 3/4 Date: 11/14/20061:14:01 PM uvu i n lJVHO I /11r1 VUHLI I Y IVI/ilNHlatIVItIN I UIS I -tIU I 21865 Copley Drive, Diamond Bar, CA 91765 PERMIT TO CONSTRUCT/OPERATE rage a Permit Na. F85011 AM 460102 11. SAMPLES SHALL BE COLLECTED AND ANALYZED ONCE EACH MONTH OF OPERATION FOR VOLATILE ORGANIC COMPOUNDS AND SPECTATED FOR TAC'S AS SPECIFIED IN RULE 1150.1 AS FOLLOWS: A. SAMPLES SHALL BE COLLECTED AT THE INLET AND OUTLET OF CARBON ADSOR.BERS, B. SAMPLING SHALL CONFORM TO CARB METHOD 422 OR EQUIVALENT. SAMPLES WITH HIGH MOISTURE SHALL BE COLLECTED USING AN APPROPRIATE METHOD SUCH AS SCAQMD METHOD 25.1/25.3 OR OTHER METHODS APPROVED BY SCAQMD. C. ANALYSIS SHALL BE CONDUCTED USING EPA METHOD TO 14 OR OTHER METHOD APPROVED BY SCAQMD. 12. THIS EQUIPMENT SHALL COMPLY WITH RULE 1150.1. 13. THE EXHAUST OE THE SULFATREAT SYSTEM SHALL BE MONITORED FOR SULFUR COMPOUNDS (AS H2S) USING AN APPROVED METHOD ON A MONTHLY BASIS. WHENEVER MONITORING RESULTS INDICATE AN II2S BREAKTHROUGH, THE ADSORBER SHALL BE REPLACED ACCORDING TO MANUFACTURERS SPECIFICATIONS. MONITORING RESULTS AND ADSORBER. REPLACEMENTS SHALL BE RECORDED. 14. THE CONCENTRATION OF TOTAL NON -METHANE HYDROCARBONS SHALL BE MEASURED AND RECORDED AT THE OUTLET OF THE CARBON ADSORBERS MONTHLY USING AN ORGANIC VAPOR ANALYZER OR OTHER APPROVED METHOD. THE MONITOR SHALL BE CALIBRATED WITH OR RESULTS CORRELATED TO HEXANE, AND MAINTAINED AND CALIBRATED PER EPA METHOD 21. CALIBRATION SHALL BE PERFORMED PRIOR TO EACH MONITORING VISIT. 15, THE EMISSIONS AT THE EXHAUST OF THE CARBON ADSOR13ERS SHALL NOT EXCEED THE FOLLOWING: COMPOUND CHLOROFORM VINYL CHLORIDE HYDROGEN SULFIDE CONCEN'T'RATION (PPMV) 0.10 0-1.7 0.1 16. WHENEVER THE TNMOC CONCENTRATION AT THE OUTLET OF TIIE PRIMARY CARBON ADSORBER SYSTEM IS 20 PPMV OR GREATER, AS HEXANE, THE GRANULAR ACTIVATED CARBON IN THE CARBON ADSORBERS SHALL BE ROTATED/REPLACED AS FOLLOWS: A. PRIMARY ADSORBER REPLACED WITH EITHER FRESH CARBON OR CARBON IN SECONDARY ADSORBER, B. SECONDARY ADSORBER REPLACED WITH FRE S14 CARBON. u3.:1r�� This fax was received by FAX -CNB on Line 3 from 9496443139 From: 9496443139 Page: 4/4 Date: 11/14/20061:14:01 PM M TUU I H UUAS I AN UUALI I Y MANAGEMENT DISTRICT 21865 Copley Drive, Diamond Bar, CA 91765 PERMIT TO CONSTRUCT/OPERATE rage 4 Permit No - F85011 AIN 460102 17. ALL RECORDS, SUCH AS TEST RESULTS, MONITORING DATA AND DATES OF CARSON REPLACEMENTS SHALL BE KEPTAND MAINTAINED FOR AT LEAST TWO 'YEARS AND MADE AVAILABLE TO AQMD PERSONNEL UPON REQUEST, 18. THIS PERMIT SHALL EXPIRE IF CONSTRUCTION OF THIS EQUIPMENT IS NOT COMPLETE WITHIN ONE YEAR FROM THE DATE OF ISSUANCE OF THIS PERMIT UNLESS AN EXTENSION IS GRANTED BY THE AQMD. I`Te➢Y (N A IN ACCORDANCE WITH RULE 206, THIS PERMIT TO OPERATE OR COPY SHALL 13F POSTED ON OR WITHIN 8 METERS OF THE EQUIPMENT. THIS PERMIT DOES NOT AUTHORIZE THE EMISSION OF AIR CONTAMINANTS IN EXCESS OF THOSE ALLOWED BY DIVISION 26 OF THE HEALTH AND SAFETY CODE OF THE STATE OF CALIFORNIA OR THE RULES OF THE AIR QUALITY MANAGEMENT DISTRICT. THIS PERMIT CANNOT BE CONSIDERED AS PERMISSION - TO VIOLATE EXISTING LAWS, ORDINANCES, REGULA2IONS OP. STATUTES OF OTHER GOVERNMENT AGENCIES. EXECUTIVE OFFICER Ey Dorris M.Eailey/TKOI 11/2/2006 ORIGINAL This fax was received by FAX -CNB on Line 3 from 9496443139 Newport Terrace Landfill — O&M Manual Appendix E Well Field Monitoring Form Gas Treatment System Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA Date and Time Temperature Personnel Baro. Press. Wind Speed & Dir. Weather Methane Inlet System Process Conditions Inlet Separator dP in. H2O Gas Flow rate SCFM Inlet Temp °F Total Gas Flow SCF Inlet Pressure in. H2O Percent Combustibles %LEL Blower Disch Temp °F H2S Concentation PPM Air Compressor Press PSI Sulfatreat Inlet System Air Compressor Hours Hrs Inlet Separator dP in. H2O Lead Methane Blower #2 Sulfatreat Disch Temp OF Lead Sulfatreat Blower #4 Sulfatreat Disch Press in. H2O Blower 1 Hours Hrs Blower Disch Press in. H2O Blower 2 Hours Hrs Blower 3 Hours Hrs Inlet Gas Composition Blower 4 Hours Hrs CH4 % CO2 % SUlfatreat Inlet Gas Composition 02 % CH4 % Bal % CO2 % 02 % Activated Carbon Tanks ppm TNMOC Bal % Inlet to First Carbon Unit Between Carbon Units Sulfatreat Vessel Outlet of Final Carbon Unit Vessel Outlet Valve Positions No. Description Size %Open No. Description Size %Open HV -1 Main Gas Inlet 6" HV -10 CU 1 Outlet 4" HV -2 BlowerInlet 2 1/2" HV -11 CU 2 Inlet 4" .1 HV -3 Blower 1 Outlet 2 1/2" HV -12 CU 2 Inlet Bypass 4" HV -4 Blower 2 Inlet 2 1/2" HV -13 CU 2 Outlet Bypass 4" HV -5 Blower 2 Outlet 2 1/2" HV -14 Sulfatreat System 4" HV -6 CU 1 Outlet Bypass 4" HV -15 Blower 3 Inlet 1 1/2" HV -7 CU 1 Outlet 4" HV -16 Blower 3 Outlet 1 1/2" HV -8 ICU 2 Inlet 1 4" 1 HV -17 Blower 4 Inlet 1 1/2" HV -9 ICU 2 Inlet Bypass 4" HV -18 Blower 4 Outlet 1 1/2" HV -19 Discharge to Vent Y Comments / Actions: DATE MONITORING: TECHNICIAN: GCE PROJECT NUMBERS: Extraction Well Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA EQUIPMENT USED: WEATHER / TEMPERATURE: BAROMETRIC PRESSURE: Gas Composition % Init Static Temp Init Flow Probe Date Time CH4 CO2 02 BALANCE Press De F) (scfm) Comments/Actions/Visual Inspection EW -01 EW -02 EW -03 EW -04 EW -05 EW -06 EW -07 EW -08 EW -09 EW -10 EW -11 EW -12 EW -13 EW -13S EW -14 EW -15 EW -15S * Flow cannot be measured for there is no sample port for TSI DATE MONITORING: TECHNICIAN: GCE PROJECT NUMBERS: Probe Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA EQUIPMENT USED: WEATHER/TEMPERATURE: BAROMETRIC PRESSURE: Gas Composition (%) .• �. ���"T"T Imm Comments Actions Visual Inspection DATE MONITORING: TECHNICIAN: GCE PROJECT NUMBERS: Probe Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA EQUIPMENT USED: WEATHER/TEMPERATURE: BAROMETRIC PRESSURE: Gas Composition . • �����Comments Actions Visual Inspection DATE MONITORING: TECHNICIAN: GCE PROJECT NUMBERS: Probe Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA EQUIPMENT USED: WEATHER/TEMPERATURE: BAROMETRIC PRESSURE: Gas Composition (%) RELATIVE Probe Date Time CH4 CO2 02 BALANCE PRESSURE Comments / Actions / Visual Inspection P -28A P -28B P -30A P -30B P-31 A P-31 B P -32A P -32B P -33A P -33B Blower Station Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA DATE MONITORING: TECHNICIAN: GCE PROJECT NUMBERS: Monthly Visual Equipment Test Inspection Check Item Comments / Actions 1 NA - Discharge Temperature 2 NA - Excessive Vibration Blowers 3 NA - Unusual Sound 4 NA - Extremely Hot Unit Flame Arrestor NA Differential Pressure Moisture 1 NA - Water Level, Leak Separators -Pressure Drop (<1" W.C.) 2 NA Electrical Controls Start-up Test, Broken Wires Gauges and Sampling Ports NA Damage, Alarm Light Piping, Valves, and NA Damage Fittings Carbon Adsorption Units NA Spill, Drain Liquid Sulfatreat System NA Spill, Drain Liquid Blower Station Monitoring / Maintenance Log Newport Terrace Landfill, Newport Beach, CA NA = Not Applicable Monthly Visual Equipment Test Inspection Check Item Comments I Actions Oil Level, Pressure (>80 psi), Alarm Light, Check Valves 1500 Hr - Clean Air Filter, Belt Tension Air Compressor NA 2000 Hr - Replace Air/Oil Filter, Change Oil 4000 Hr - Clean Oil Cooler, Replace Oil Separator, Test Safety Valve Strip Chart Recorder NA Alarm Light, Download Data Autodialer NA Alarm Light, Check Panel Gas Detectors NA Alarm, Quarterly Calibration NA = Not Applicable Newport Terrace Landfill — O&M Manual Appendix F Contact Information Newport Terrace Landfill — O&M Manual APPENDIX F LIST OF CONTACTS CITY OF NEWPORT BEACH: George Murdoch General Manager Municipal Operations Department gmurdoch@newportbeachca.gov City of Newport Beach 3300 Newport Blvd. PO Box 1768 Newport Beach, CA 92658-8915 Ph: 949-644-3011 Fax: 949-646-5204 NEWPORT CONDOMINIUM ASSOCIATION (NCA): Todd Borland, CCAM Community Manager tborland@actionlife.com Action Community Management 2603 Main Street, Suite 500 Irvine, CA 92614 p 949.450.0202 f 949.450.4366 info@actionlife.com www.actionlife.com Newport Terrace Landfill — O&M Manual Appendix G Rule 1 150.1 Compliance Plan South Coast Air Quality Management 21865 E. Copley Drive, Diamond Bar, CA 91765-4182 (909) 396-2000 • http://www.agmd.gov h D 1 --- r,� District December 17, 1999 NEWPORT TERRACE CONDOMINIUM ASSOC., INC. P.O. BOX 4708 IRVINE, CA 92716 Attention: VICKY HARMON (Villageway Management) RULE 1150.1 COMPLIANCE PLAN Reference is made to your Application for a Rule 1150.1 Compliance Plan for the following landfill. Facility ID: 119098 Sector: RH Application No: 355993 Phone No: (949) 754-3242 Common Name: Newport Terrace Condominium Assoc., Inc. Location Address: END OF 19TH STREET City: NEWPORT BEACH CA 92663 South Coast Air Quality Management District (AQMD) has reviewed your application and approved the following alternatives to Rule 1150.1 requirements for your landfill. Rule 1150.1 Compliance Plans may be submitted by each owner or operator responsible for that section of the rule directly under their control, or by the owner or operator responsible for the entire landfill. Compliance under the alternative provision is achieved if only one owner or operator with responsibility submits a compliance plan for the applicable section of the rule. Only one alternative to each rule requirement shall be allowed for multiple Compliance Plans issued to one landfill. The approved alternative shall be written into each Compliance Plan. The AQMD reserves the right to deny any or all of these alternatives if it is determined that the altemative(s) allow emissions from the landfill that would not have occurred if the owner or operator was complying with the rule requirements. The Municipal Solid Waste (MSW) landfill owner or operator shall comply with this approved Compliance Plan no later than March 1, 2000. Where no Rule 1150.1 alternatives are specified below, compliance with provisions of Rule 1150.1 is required. You are further advised that other governmental agencies may require approval for the operation of this landfill and it is the responsibility of the applicant to obtain approval from each agency. This compliance plan will remain in force until either a new plan is filed and approved or the applicant is notified by the Executive Officer of revisions to this plan. The AQMD shall not be responsible or liable I(0 2000 for any losses resulting from measures required or taken pursuant to the requirements of this approved Rule 1150.1 Compliance Plan. If you have any questions regarding this matter, please phone Ted Kowalczyk, Air Quality Engineer at (909) 396-2592. cc: Dan Russell Air Quality Inspector Issue Number: 0 1-7 Sincerely, Larry M. Bowen Senior Manager (Adopted April 5, 1985)(Amended April 10, 1998) RULE 1150.1. CONTROL OF GASEOUS EMISSIONS FROM MUNICIPAL SOLID WASTE LANDFILLS TABLE OF CONTENTS (a) Purpose (b) Applicability (c) Definitions (d) Active Landfill Design and Operation Requirements (e) Active Landfill Sampling and Monitoring Requirements (f) Active Landfill Recordkeeping and Reporting Requirements (g) Active Landfill Compliance Schedule (h) Inactive Landfill Requirements (i) Alternatives 0) Test Methods (k) Exemptions (1) Loss of Exemption Attachment A 1.0 Subsurface Refuse Boundary Sampling Probes 2.0 Integrated Landfill Surface Sampling 3.0 Instantaneous Landfill Surface Monitoring 4.0 Landfill Gas Sample From Gas Collection System 5.0 Ambient Air Samples At The Landfill Property Boundary Figure I Portable Integrated Bag Sampler Figure 2 Typical Landfill Walk Pattern Figure 3 Quality Control Sheet Figure 4 Bag Sample Custody Form Table 1 Carcinogenic and Toxic Air Contaminants (Core Group) Table 2 Carcinogenic and Toxic Air Contaminants (Supplemental Group) The reference numbers in the left hand margin of the rule refer to sections of 40 CFR, Part 60, Subpart WWW (HSPS) . (Adopted April 5, 1985)(Amended April 10, 1998) RULE 1150.1. CONTROL OF GASEOUS EMISSIONS FROM MUNICIPAL SOLID WASTE LANDFILLS (a) Purpose The rule is intended to limit Municipal Solid Waste (MSW) landfill emissions to prevent public nuisance and possible detriment to public health caused by exposure to such emissions. (b) Applicability This rule applies to each active and inactive MSW landfill. (c) Definitions Terms used but not defined in this rule have the meaning given them in 40 CFR, Part 60, Section 60.751 (Definitions): (1) ADMINISTRATOR means the Executive Officer of the South Coast Air Quality Management District (District). (2) ACTIVE LANDFILL means an MSW landfill that has received waste on or after November 8, 1987. (3) BACKGROUND means the local ambient concentration of total organic compounds (TOC) measured as methane determined by holding the instrument probe approximately 5 to 6 feet above the landfill surface. (4) CLOSED LANDFILL means a disposal facility that has ceased accepting waste and was closed in accordance with all applicable federal, state and local statutes, regulations, and ordinances in effect at the time of closure. (5) INACTIVE LANDFILL means an MSW landfill where solid waste had been disposed of before November 8, 1987 and no more subsequent solid waste disposal activity has been conducted within the disposal facility. (6) MSW LANDFILL means an entire disposal facility in a contiguous geographical space where solid waste is placed in or on land. An MSW landfill may be either active or inactive. (7) OPERATOR means the person: (A) Operating the MSW landfill, or (B) Operating the MSW landfill gas collection or control system. (8) OWNER means the person holding Title to the property. 1150.1 - 1 1 C' Rule 1150.1 (Amended April 10, 1993 (9) PERIMETER means the outer boundary of the entire waste disposal property. (10) PROFESSIONAL ENGINEER means an engineer holding a valid certificate issued by the State of California Board of Registration for Professional Engineers and Land Surveyors or a state offering reciprocity with California. (11) TOXIC AIR CONTAMINANT (TAC) means an air contaminant which has been identified as a hazardous air pollutant pursuant to Section 7412 of Title 42 of the United States Code; or has been identified as a TAC by the Air Resources Board pursuant to Health and Safety Code Section 39655 through 39662, or which may cause or contribute to an increase in mortality or an increase in serious illness, or potential hazard to human health. (d) Active Landfill Design and Operation Requirements The MSW landfill owner or operator shall comply with the provisions of paragraphs (d)(1) through (d)(9): (1) If a valid Permit to Construct or Permit to Operate for the collection and control system that meets the requirements of subparagraphs (d)(1)(A) 752(b)(2)(i) through (d)(1)(C) has not been issued by the District by the adoption date 752(b)(2)(i)(D) of this rule, submit a site-specific collection and control system design plan. The design plan shall be prepared by a Professional Engineer and sent to the Executive Officer with applications for Permits to Construct or Permits to Operate no later than one year after the adoption of this rule. The Executive Officer shall review the collection and control system design and either approve it, disapprove it, or request that additional information be submitted. (A) The collection and control system shall be designed to handle the maximum expected gas flow rate from the entire area of the 52(b)(2)(ii)(A)(I), (3), (a) landfill that requires control, to minimize migration of subsurface 755(a)(1) gas to comply with paragraph (d)(4), and to collect gas at an 758(b)(1)(i) extraction rate to comply with paragraphs (d)(5) and (d)(6). For the purposes of calculating the maximum expected gas generation flow rate from the landfill, one of the equations in 40 CFR, Part 60, Section 60.755(a)(1) shall be used. Another method may be used 1150.1 -2 Rule 1150.1 (B) 752(b)(2)(i)(C) 756(e) (C) 752(b)(2)(iii) n (Amended April 10, 1998 to determine the maximum gas generation flow rate, if the method has been approved by the Executive Officer. If a valid Permit to Construct or Permit to Operate has not been issued by the District for the collection and control system, the collection and control system design plan shall either conform with specifications for active collection systems in 40 CFR, Part 60, Section 60.759 or include a demonstration to the Executive Officer's satisfaction of the sufficiency of the alternative provisions describing the design and operation of the collection system, the operating parameters that would indicate proper performance, and appropriate monitoring procedures. Alternatives to this rule shall be submitted as specified in subdivision (i). The design plan shall provide for the control of collected MSW landfill emissions through the use of a collection and control system meeting the applicable requirements in clauses (d)(1)(C)(i) and (d)(1)(C)(ii): (i) Route all the collected gas to a control system designed and operated to either reduce NMOC by at least 98 percent by weight or reduce the outlet NMOC concentration to less than 20 parts per million by volume (ppmv), dry basis as hexane at 3 percent oxygen. The required reduction efficiency or ppmv shall be established by an initial source test, required under 40 CFR, Part 60, Section 60.8 and annually thereafter using the test methods specified in paragraph 0)(1). The annual source test shall be conducted no later than 45 days after the anniversary date of the initial source test. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE AS LONG AS THE COLLECTED LANDFILL GAS EMITS LESS THAN ONE POUND PER DAY OF NMOC AND MEETS RULE 1150.1 EXEMPTIONS (K)(3) AND (K)(4). THE OWNER/OPERATOR SHALL SAMPLE AND ANALYZE THE VENTED LANDFILL GAS FOR NMOC AND TAC ONCE PER YEAR. SHOULD THE VENTED GAS EXCEED ONE POUND PER DAY, 1150.1 -3 I Rule 1150.1 (Amended April 10, 1998 ONE IN ONE MILLION CANCER RISK, (K)(3) OR CAUSE A NUISANCE THE OWNER/OPERATOR SHALL BE REQUIRED TO CONTROL THE COLLECTED LANDFILL GAS. (I) If a boiler or process heater is used as the control device, the landfill gas stream shall be introduced into the flame zone. Where the landfill gas is the primary fuel for the boiler or process heater, introduction of the landfill gas stream into the flame zone is not required. (II) The control device shall be operated within the operating parameter ranges established during the initial or most recent compliant source test. The operating parameters to be monitored are specified under paragraph (e)(6). (ii) Route the collected gas to a treatment system that processes the collected gas for subsequent sale or use. All emissions from any atmospheric vent from the gas treatment system shall be subject to the requirements of clause (d)(1)(C)(i). (2) Install and operate the collection and control system no later than 18 752(b)(2)(ii) months after the submittal of the design plan. (3) If the District has not issued prior written approval for subsurface refuse boundary sampling probes, design and install subsurface refuse boundary sampling probes as specified in Section 1.1, Attachment A, to determine whether landfill gas migration exists. Installation of the refuse boundary probes shall be no later than 18 months after the submittal of the collection and control design plan as specified in paragraph (d)(1). ALTERNATIVE: THE SUBSURFACE REFUSE BOUNDARY PROBES APPROVED IN THE PAST OR SUBMITTED WITH THIS APPLICATION, ARE APPROVED. ALL FUTURE DESIGNS AND INSTALLATIONS NOT MEETING THE RULE REQUIREMENTS, SHALL BE SUBMITTED FOR AQMD PRE - CONSTRUCTION APPROVAL WITH A COMPLIANCE PLAN APPLICATION. (4) Operate the collection system to prevent the concentration of TOC measured as methane from exceeding live percent by volume in the 1150.1-4 Rule 1150.1 (Amended April 10, 1998 subsurface refuse boundary sampling probes constructed for the purposes of detecting lateral migration of landfill gas away from the waste mass, as determined from collected samples. (5) Operate the collection system to prevent the concentration of TOC measured as methane from exceeding 50 ppmv as determined by integrated samples taken on numbered 50,000 square foot landfill grids. (6) Operate the collection system to prevent the concentration of TOC 753(d) measured as methane from exceeding 500 ppmv above background as determined by instantaneous monitoring at any location on the landfill, except at the outlet of any control device. (7) Operate the control or treatment system at all times when the collected gas is routed to the system. In the event the collection, treatment or control 753(e) system is inoperable, the gas conveying system shall be shut down and all valves in the collection, treatment and control system contributing to venting of the gas to the atmosphere shall be closed no later than one hour after such breakdown or no later than one hour after the time the owner or operator knew or reasonably should have known of its occurrence. (8) Operate the collection, treatment and control system until all the ff 52(b)(2)(v) exemption criteria under subdivision (k) has been met and the reports specified in subparagraph (f)(2)(D) have been submitted to the Executive Officer. (9) Design, install and operate a wind speed and direction monitoring system with a continuous recorder of the requirements in subparagraphs (d)(9)(A) and (d)(9)(B), at a site which is representative of the wind speed and direction in the areas being sampled. The wind velocity shall be recorded throughout the sampling period. The wind direction transmitter shall be oriented to true north using a compass. The monitor shall be installed according to the criteria set forth in 40 CFR, Part 50. (A) For wind speed use a 3 cup assembly, with a range of 0 to 50 miles per hour, with a threshold of 0.75 mile per hour or less. (B) For wind direction use a vane, with a range of 0 to 540 degrees azimuth, with a threshold of plus-minus 2 degrees. ALTERNATIVE: NO PERMANENT METEOROLOGICAL STATION REQUIRED. THE WIND SPEED SHALL BE MEASURED WITH AN APPROVED HAND-HELD 1150.1 - 5 7 ( Rule 1150.1 (Amended April 10, 1998 ANEMOMETER DURING INTEGRATED SURFACE MONITORING. (e) Active Landfill Sampling and Monitoring Requirements The MSW landfill owner or operator shall comply with the provisions of paragraphs (e)(1) through (e)(6), after installation of the landfill gas control system: (1) Monitor and collect samples for analysis as specified in Section 1.0, Attachment A, to determine the concentrations of TOC and TAC each month from the subsurface refuse boundary sampling probes, to assure continued compliance. Any measurement of 5 percent TOC by volume or greater shall be recorded as an exceedance and the actions specified in subparagraphs (e)(1)(A) through (e)(1)(C) shall be taken. ALTERNATIVE: TOC MONTHLY/TAC QUARTERLY (A) The probe shall be identified and the location recorded as specified in Section 1.6, Attachment A. (B) Adjustments to the vacuum of adjacent wells to increase the gas collection in the vicinity of the probe with the exceedance shall be made and the probe resampled no later than 10 calendar days after detecting the exceedance. (C) If the resampling of the probe shows a second exceedance, additional corrective action shall be taken and the probe shall be resampled again no later than 10 calendar days after the second exceedance. If the resampling shows a third exceedance, it is a violation unless the owner or operator determines that a new or replacement gas collection well is needed. The owner or operator must install and operate the new or replacement well no later than 45 days after detecting the third exceedance. (2) Collect monthly integrated samples for analysis as specified in Section 2.0, Attachment A, to determine the concentrations of TOC and TAC from the landfill surface, to assure continued compliance. Any reading of 50 ppmv or greater shall be recorded as an exceedance and the actions specified in subparagraphs (e)(2)(A) through (e)(2)(C) shall be taken. ALTERNATIVE: NOT REQUIRED (A) The and shall be identified and the location recorded as specified in Section 2.8, Attachment A. 1150.1 -6 (%% 4 Rule 1150.1 (Amended April 10, 1998 (B) Cover maintenance or adjustments to the vacuum of adjacent wells to increase the gas collection in the vicinity of the grid with the exceedance shall be made and the grid resampled no later than 10 calendar days after detecting the exceedance. If measurable precipitation occurs within the 10 calendar days, all resampling and analysis shall comply with Section 2.2.2, Attachment A. (C) If the resampling of the grid shows a second exceedance, additional corrective action shall be taken and the grid shall be resampled again no later than 10 calendar days after the second exceedance. If the resampling shows a third exceedance, it is a violation unless the owner or operator determines that a new or replacement gas collection well is needed. The owner or operator must install and operate the new or replacement well no later than 45 days after detecting the third exceedance. (3) Monitor instantaneously as specified in Section 3.0, Attachment A, to determine the concentration of TOC each calendar quarter, to assure 755(c) continued compliance. Any reading of 500 ppmv TOC or greater shall be 756(f) recorded as an exceedance and the actions specified in subparagraphs (e)(3)(A) through (e)(3)(C) shall be taken. Any closed landfill that has no monitored exceedances of the 500 ppmv standard in three consecutive quarterly monitoring periods may monitor annually. Any reading of 500 ppmv TOC or more above background detected during the annual monitoring or compliance inspections shall result in a return to quarterly monitoring for that landfill. ALTERNATIVE: NOT REQUIRED (A) The location of each monitored exceedance shall be marked on the landfill or identified by using a global positioning system and the location recorded as specified in Section 3.4, Attachment A. (B) Cover maintenance or adjustments to the vacuum of adjacent wells to increase the gas collection in the vicinity of each exceedance shall be made and the location shall be remonitored no later than 10 calendar days after detecting the exceedance. (C) If the remonitoring of the location shows a second exceedance, additional corrective action shall be taken and the location shall be remonitored again no later than 10 days after the second exceedance. If the remonitoring shows a third exceedance, it is a 1150.1 - 7 Rule 1150.1 (Amended April 10, 1998 violation unless the owner or operator determines that a new or replacement gas collection well is needed. The owner or operator must install and operate the new or replacement well no later than 45 days after detecting the third exceedance. (4) Collect a monthly landfill gas sample for analysis as specified in Section 4.0, Attachment A, to determine the concentrations of TOC and TAC from the main gas collection header line entering the gas treatment and/or gas control systems. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE (5) Collect monthly ambient air samples for analysis as specified in Section 5.0, Attachment A, to determine the concentrations of TOC and TAC from the landfill property boundary. ALTERNATIVE: NOT REQUIRED (6) Monitor the collection and control system equipment specified under subparagraphs (e)(6)(A) and (e)(6)(B) in order to comply with subparagraph (d)(1)(C). ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE (A) For an enclosed combustor install, calibrate, maintain, and operate 756(b) 1 according to the manufacturer's specifications, the following equipment: (ii) A temperature monitoring device equipped with a continuous recorder and having an accuracy of plus-minus 1 percent of the temperature being measured expressed in degrees Celsius or Fahrenheit. A temperature monitoring device is not required for boilers or process heaters with design heat input capacity greater than 44 megawatts. (iii) At least one gas flow rate measuring device that shall record the flow to the control device(s) at least every 15 minutes. (B) For a device other than an enclosed combustor, demonstrate compliance with subparagraph (d)(1)(C) by providing information 756(d) satisfactory to the Executive Officer describing the operation of the control device, the operating parameters that would indicate proper performance, and appropriate monitoring procedures. Alternatives to this rule shall be submitted as specified in subdivision (i). The 1150.1 - 8 x% Rule 1150.1 (Amended April 10, 1998 Executive Officer may specify additional appropriate monitoring procedures. (f) Active Landfill Recordkeeping and Reporting Requirements The MSW landfill owner or operator shall keep all records up-to-date, readily accessible and maintained for at least a period of 5 years and made available to 758(a District staff upon request. Records older than 2 years may be maintained off- site, if they are retrievable no later than 4 hours after request. ALTERtNATIVE: RECORDS SHALL BE MAINTAINED AT VILLAGEWAY MGMT. AND THE MOST RECENT TWO YEARS OF RECORDS MADE AVAILABLE WITHIN 4 HOURS AFTER REQUEST. RECORDS BETWEEN 2 AND 5 YEARS OLD SHALL BE MADE AVAILABLE WITHIN 48 HOURS AFTER REQUEST. (1) The records required in subparagraphs (f)(1)(A) through (f)(1)(H) shall be maintained at the facility. (A) For the life of the control equipment as measured during the initial 758(6) source test or compliance determination: (i) The control device vendor specifications. (ii) The maximum expected gas generation flow rate as calculated in subparagraph (d)(1)(A). (iii) When seeking to demonstrate compliance with subparagraph (d)(1)(C) through the use of an enclosed combustion device other than a boiler or process heater with a design heat input capacity greater than 44 megawatts: (I) The average combustion temperature measured at least every 15 minutes and averaged over the same time period of the source test. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE (II) The reduction of NMOC determined as specified in clause (d)(1)(C)(i) achieved by the control device. (iv) When seeking to demonstrate compliance with subclause (d)(I)(C)(i)(I) through the use of a boiler or process heater of any size: a description of the location at which the collected gas vent stream is introduced into the boiler or 1150.1 - 9 ?�% Rule 1150.1 (Amended April 10, 1998 process heater over the same time period of the source testing. (B) The data required to be recorded under Section 1.6, Attachment A, for subsurface refuse boundary sampling probes and all remedial actions taken for exceedances of the 5 percent TOC standard required in paragraph (d)(4). (C) The data required to be recorded under Section 2.8, Attachment A, for integrated samples and all remedial actions taken for exceedances of the 50 ppmv TOC standard required in paragraph (d)(5). (D) The data required to be recorded under Section 3.4, Attachment A, 758(e) for instantaneous monitoring and all remedial actions taken for exceedances of the 500 ppmv TOC standard required in paragraph (d)(6)• (E) The data required to be recorded under Section 4.5, Attachment A, for landfill gas samples collected from the main gas collection header line entering the gas treatment and/or gas control systems. (F) The data required to be recorded under Section 5.7, Attachment A, from ambient air collected at the landfill property boundary. (G) A description and the duration of all periods when the collection, 757(f)(3) treatment or control device was not operating for a period exceeding one hour and the length of time the system was not operating. (H) Continuous records of the equipment operating parameters specified to be monitored under paragraph (e)(6) as well as records 758(c) for periods of operation during which the parameter boundaries established during the most recent source test are exceeded. (i) The following constitute exceedances that shall be recorded: (I) For enclosed combustors except for boilers and process heaters with design heat' input capacity of 44 megawatts (150 million British thermal unit per hour) or greater, all 3 -hour periods of operation during which the average combustion temperature was more than 28° C (82° F) below the average combustion temperature during the most recent 11e0.1 - 10 Rule 1150.1 (Amended April 10, 1998 source test at which compliance with subparagraph (d)(1)(C) was determined. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE (II) For boilers or process heaters, whenever there is a change in the location at which the vent stream is introduced into the flame zone as required under clause (f)(1)(A)(iv). (ii) Records of the indication of flow to the control device specified under paragraph (e)(6)(A)(ii). (iii) Each owner or operator who uses a boiler or process heater with a design heat input capacity of 44 megawatts or greater to comply with subparagraph (d)(1)(C) shall keep records of all periods of operation of the boiler or process heater. (Examples of such records could include records of steam use, fuel use, or monitoring data collected pursuant to other State, local, Tribal, or Federal regulatory requirements.) (2) The reports required in subparagraphs (f)(2)(A) through (f)(2)(D) shall be submitted to the Executive Officer (Either paper copy or electronic formats are acceptable). (A) The initial source test report no later than 180 days after start-up and each succeeding complete annual source test report no later than 45 days after the anniversary date of the initial source test, for all control systems required in subparagraph (d)(1)(C). ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE (B) A report no later than 45 days after the last day of each calendar quarter with the information required in clauses (f)(2)(13)(i) and (i) All exceedances of the emission standards required in paragraphs (d)(4), (d)(5) and (d)(6) in the format required under Sections 1.6, 2.8 and 3.4, Attachment A. All exceedance resampling/remonitoring and each corrective action required under paragraphs (e)(1), (e)(2) and (e)(3). 1150.1 - 11 � I Rule 1150.1 (Amended April 10, 1998 If there are no exceedances, submit a letter stating there were no exceedances for that quarter. (ii) All TAC analyses required in paragraphs (e)(1) through (e)(5). (C) A closure report to the Executive Officer no later than 30 days after waste acceptance cessation. The Executive Officer may request F75 -7(d—)] additional information as may be necessary to verify that permanent closure has taken place in accordance with the requirements of 40 CFR, Part 60, Section 258.60 or the applicable federal, state and local statutes, regulations, and ordinances in effect at the time of closure. If a closure report has been submitted to the Executive Officer, no additional wastes shall be placed into the landfill without filing a notification of modification as described under 40 CFR, Part 60, Section 60.7(a)(4). (C) A decommissioning report to the Executive Officer 30 days prior 757(e) to well capping, removal or cessation of operation of the collection, treatment or control equipment. The decommissioning report shall contain all of the items as specified in clauses (f)(2)(D)(i) through (f)(2)(D)(iii): (i) A copy of the closure report submitted in accordance with subparagraph (f)(2)(C). (ii) A copy of the initial source test report demonstrating that the collection and control system has been installed a minimum of 15 years. (iii) All records needed to verify the landfill meets the exemption criteria under subdivision (k). (g) Active Landfill Compliance Schedule The MSW landfill owner or operator shall comply with the active landfill requirements of this rule or submit alternatives to this rule as specified in subdivision (i) no later than 90 days after the adoption of this rule. Rule T 150.1 Compliance Plans previously submitted to the District shall remain in effect during the 90 days after the adoption of this rule, or until the owner or operator has received an approved alternative Rule 1150.1 Compliance Plan submitted as specified in subdivision (i). 1150.1 - 12 6 Rule 1150.1 (Amended April 10, 1998 (h) Inactive Landfill Requirements The MSW landfill owner or operator shall comply with either the applicable requirements in paragraphs (h)(1) and (h)(2) or submit alternatives to this rule as specified in subdivision (i). (1) Inactive landfills that have a landfill gas collection system shall meet all of the active landfill requirements. For those inactive landfills without a gas collection system and determined to need one, meet all of the active landfill requirements, except the collection and control system design plan and applications for permits shall be submitted no later than one year after notification by the Executive Officer. (2) Inactive landfills without a gas collection system: (A) Upon discovery of TOC measured as methane exceeding 500 ppmv at any location on the landfill surface, apply mitigation measures such as compaction, additional cover, and/or watering to reduce the emissions to less than 500 ppmv. The procedure used for measurement of TOC shall meet the requirements of Section 3.0, Attachment A. (B) Submit the following Data and/or meet the required action in paragraph (h)(1): (i) At any time after the adoption of this rule, but not later than 30 days after the receipt of a request, submit to the Executive Officer a screening questionnaire pursuant to California Air Resources Board Health and Safety Code (H & S) 41805.5. (ii) No later than 90 days after the date of a second request, submit to the Executive Officer a solid waste air quality assessment test (SWAT) report pursuant to H & S 41805.5, to determine whether or not a landfill gas collection and control system and/or a subsurface refuse boundary probe sampling system shall be required to be installed. (iii) If additional time is needed to provide the information' required in clauses (h)(2)(B)(i) and (h)(2)(B)(ii), a written request for an extension may be submitted in writing to the Executive Officer, indicating the amount of time that is needed to obtain such information. Such a request for an extension may be submitted to the Executive Officer no 1150.1 - 13 ; I Rule 1150.1 (i) Alternatives: (Amended April 10, 1998 later than 30 days after the receipt of the Executive Officer's requests as specified in clauses (h)(2)(13)(i) and (h)(2)(13)(ii)• (iv) Upon notification by the Executive Officer that a landfill gas collection and control system and/or a subsurface refuse boundary probe sampling system shall be required, comply with paragraph (h)(1). Because of the many site-specific factors involved in the design and operation of landfill gas systems, alternatives to the requirements, test methods, procedures, compliance measures, monitoring, recordkeeping or reporting provisions of this rule may be necessary. All alternatives to the requirements of this rule shall be submitted to the Executive Officer in a Rule 1150.1 Compliance Plan. The Executive Officer shall review the Rule 1150.1 Compliance Plan and either approve it, disapprove it, or request that additional information be submitted. The Executive Officer shall deny the plan unless he determines that it will provide equivalent levels of emission control and enforceability, as would compliance with the requirements of this rule. (j) Test Methods (1) Methods of Analysis (A) Either U.S. EPA Reference Method 25 or U.S. EPA Reference Method 18, 40 CFR, Part 60, Appendix A shall be used to 754(d) determine the efficiency of the control system in reducing NMOC by at least 98 percent by weight. If using Method 18, the minimum list of compounds to be tested shall be those published in the most recent Compilation of Air Pollutant Emission Factors (AP -42). The equation in subparagraph 0)(1)(B) shall be used to calculate efficiency. (B) U.S. EPA Reference Method 25, 40 CFR, Part 60, Appendix A shall be used to determine the efficiency of the control system in reducing the outlet NMOC concentration to less than 20 ppmv, dry basis as hexane at 3 percent oxygen. Until, but not after District Method 25.3 has met equivalency as specified in paragraph 6)(2), U.S. EPA Reference Method 18, 40 CFR, Part 60, Appendix A 1150.1 - 14 3D_ Rule 1150.1 (Amended April 10, 1998 may be used for this source test. If using Method 18, the minimum list of compounds to be tested shall be those published in the most recent Compilation of Air Pollutant Emission Factors (AP -42). The following equation shall be used to calculate efficiency: Control Efficiency = (NMOCi� - NMOCoJ/(NMOCiJ where, NMOL;,, = mass of NMOC entering control device NMOC.�' = mass of NMOC exiting control device (2) Equivalent Test Methods Any other method demonstrated to be equivalent and approved in writing by the Executive Officers of the District, the California Air Resources Board (CARB), and the Regional Administrator of the United States Environmental Protection Agency (U.S. EPA), Region IX, or their designees, may be used to determine compliance with this rule. (k) Exemptions An MSW landfill may be temporarily exempt from all or any portion of the requirements of this rule if the owner or operator can demonstrate to the Executive Officer that the MSW landfill emissions meet the requirements of paragraphs (k)(1) through (k)(4). Temporary exemption may be independently determined by the Executive Officer, if the MSW landfill emissions meet the requirements of paragraphs (k)(1) through (k)(4). MSW landfills issued temporary exemption letters by the Executive Officer shall remain exempt, subject to periodic review, provided: (1) The MSW landfill complies with the requirements of paragraphs (d)(4), (d)(5) and (d)(6)- (2) The MSW landfill emits less than 55 tons per year of NMOC as specified in 40 CFR, Part 60, Section 60.752(b) or, for a closed landfill, as specified in 40 CFR, Part 60, Section 60.752(b)(2)(v)(C). (3) The MSW landfill constitutes an insignificant health risk. In making this determination the Executive Officer shall consider the listed factors in subparagraphs (k)(3)(A) through (k)(3)(G). Where not specified, in evaluating the cancer risks and hazard indexes, the Executive Officer shall be guided by the definitions in District Rule 1401 - New Source Review of Carcinogenic Air Contaminants, and Rule 1402 - Control of Toxic Air Contaminants From Existing Sources. 1150-1- 15 �� Rule 1150.1 (1) (Amended April 10, 1998 (A) The proximity to, and any adverse impacts on, residences, schools, hospitals or other locations or structures which have children, or elderly or sick persons. (B) The emission migration beyond the landfill property boundary. (C) The complaint history. (D) The age and closure date. (E) The amount and type of waste deposited. (F) That the emissions of carcinogenic air contaminants, specified in Table 1, Attachment A, from the landfill will not result in a maximum individual cancer risk greater than one in one million (1 x 10-') at any receptor location. (G) That the emissions of TAC, specified in Table 1, Attachment A, from the landfill will not result in a total acute or chronic Hazard Index of greater than 1. (4) The MSW landfill is in compliance with District Nuisance Rule 402. Such temporary exemption shall be reviewed periodically by the Executive Officer, to consider the land use surrounding the landfill and gaseous emissions, and the impact on the public. Depending upon the results of the review, the Executive Officer may extend or terminate the exemption. Loss of Exemption If an MSW landfill should have its temporary exemption terminated, the owner or operator shall comply with the active landfill requirements of this rule. 1150.1 - 16 �� Rule 1150.1 (Cont.) ATTACHMENT A (Amended April 10, 1998) 1.0 SUBSURFACE REFUSE BOUNDARY SAMPLING PROBES Paragraph (d)(4) and (e)(1) Requirements of Rule 1150.1 1.1 Subsurface Probe Design and Installation Landfills which are subject to Rule 1150.1 must install and maintain a subsurface refuse boundary probe sampling system of adequate design to determine if gas migration exists for the ultimate purpose of preventing surface emissions. The California Integrated Waste Management Board also requires the installation of refuse boundary probes for purposes of detecting and ultimately preventing subsurface migration of landfill gas past the permitted property boundary of the landfill/disposal site as well as the prevention of the accumulation of landfill gas in on-site structures. It is the District's intent that the subsurface refuse boundary probes required by paragraph (d)(3) of Rule 1150.1 be designed and installed in such a manner as to comply with the requirements of the California Integrated Waste Management Board (whenever possible) and Sections 1.1.1 through 1.1.4. 1.1.1 The probes shall be installed within the landfill property line and outside the refuse disposal area. 1.1.2 Wherever accessible, the probes shall be located no further than 100 feet from the refuse boundary. ALTERNATIVE: WHEREVER ACCESSIBLE AND THE PROBES ARE GREATER THAN 100 FEET FROM THE REFUSE, MONITOR INSTANTANEOUSLY FROM THE REFUSE BOUNDARY TO THE PROBE, USING THE GRID METHOD EVERY QUARTER AND WHEN PROBES EXCEED 2% TOC. 1.1.3 The spacing between probes shall be based on the adjacent land use no further than 1320 feet (1/4 mile) from the refuse boundary and shall be determined as follows: LAND USE Residential/Commercial Public Access Undeveloped Open Space, (No Public Access) Landfill with Liners 1150.1 - 17 �� SPACING 100 feet 500 feet 650 feet 1000 feet Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) 1.1.4 Each probe shall be capped, sealed, have a sampling valve and be of multiple -depth design for which the depth shall be determined based on the depth of refuse no further than 500 feet from the probe as follows: First Depth 10 feet below surface. Second Depth 25% of refuse depth or 25 feet below surface, whichever is deeper. Third Depth 50% of refuse depth or 50 feet below surface, whichever is deeper. Fourth Depth 75% of refuse depth or 75 feet below surface, whichever is deeper. Second, third, or fourth depth probes may be deleted if the required depth of such probe is deeper than the depth of the refuse. 1.2 Number of Samples All refuse boundary gas probes at each depth shall be monitored monthly for TOC measured as methane using a portable flame ionization detector (FID) meeting the requirements of Section 3.2 and with a tube connected to the probe sampling valve. In addition, samples shall be taken as specified in Section 1.2.1 or 1.2.2 to determine the concentration of both TOC and TAC. The Executive Officer may require additional probes to be sampled upon written request. 1.2.1 If the TOC concentration measured with the FID does not exceed 5% by volume in any of the probes, collect one bag sample from one probe with the highest concentration, or ALTERNATIVE: IF THE TOC CONCENTRATION MEASURED WITH THE FID OR APPROVED ALTERNATIVE DOES NOT EXCEED 5% BY VOLUME IN ANY OF THE PROBES, NO BAG SAMPLES ARE REQUIRED FOR TOC ANALYSIS. HOWEVER, EACH QUARTER COLLECT ONE BAG SAMPLE FOR TAC ANALYSIS FROM THE PROBE WITH THE HIGHEST CONCENTRATION DURING ANY ONE OF THE MONTHLY MONITORING PERIODS, OR 1.2.2 If the TOC concentration measured with the FID for any of the probes exceeds 5% by volume, collect one bag sample per probe from the probes with the highest concentrations above 5% by volume, from at least five probes. 1150.1 -18 ) n Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) ALTERNATIVE: IF THE TOC CONCENTRATION MEASURED WITH THE FID OR APPROVED ALTERNATIVE EXCEEDS 5% BY VOLUME IN ANY OF THE PROBES, EACH QUARTER COLLECT ONE BAG SAMPLE FOR TOC/TAC ANALYSIS FROM THE PROBE WITH THE HIGHEST CONCENTRATION DURING ANY ONE OF THE MONTHLY MONITORING PERIODS. 1.3 Subsurface Refuse Boundary Probe Sampling Procedure 1.3.1 Prior to collecting gas samples, evacuate the probe (the probes must be sealed during evacuation) until the TOC concentration remains constant for at least 30 seconds. 1.3.2 The constant TOC concentration shall be measured using an FID that meets the requirements in Section 3.2. ALTERNATIVE: PORTABLE ANALYZERS ON AN APPROVED LIST OF EQUIPMENT MAINTAINED BY THE AQMD MAY BE USED AS ALTERNATIVES FOR THE SAMPLER/INSTRUMENT REQUIREMENTS OF THIS RULE. 1.3.3 Collect approximately a 10 -liter gas sample in a Tedlar (Dupont trade name for polyvinyl) bag or equivalent container over a continuous ten- minute period using the evacuated container sampling procedure described in Section 7.1.1 of EPA Method 18 or direct pump sampling procedure described in Section 7.1.2 of EPA Method 18. The container shall be LIGHT -SEALED. 1.4 Subsurface Refuse Boundary Probe Analytical Procedures All samples collected shall be analyzed no later than 72 hours after collection for TOC using U.S. EPA Method 25, 40 CFR, Part 60, Appendix A analysis or a portable FID that meets the requirements in Section 3.2 and for the TAC specified in Table 1 and upon written request, Table II, using U.S. EPA Compendium Method TO -14. 1.5 Chain of Custody (Required for samples sent to the lab) A custody sheet shall accompany the bag samples. Each time a bag changes hands, it shall be logged on the custody sheet with the time of custody transfer recorded. Laboratory personnel shall record the condition of the sample (full, 1150.1 - 19 �_7 Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) three-fourths full, one-half full, one-fourth full, or empty). An example of a custody sheet is shown in Figure 4. 1.6 Recording the Results 1.6.1 Record the volume concentration of TOC measured as methane for each individually identified refuse boundary probe (at each depth) and the volume concentration of TAC for selected probes on a quality control sheet as shown in Figure 3. Include a topographic map drawn to scale with the location of both the refuse boundary probes and the gas collection system clearly marked and identified. 1.6.2 Maintain and submit the results as specified in subdivision (f) of Rule 1150.1. 2.0 INTEGRATED LANDFILL SURFACE SAMPLING Paragraph (d)(5) and (e)(2) Requirements of Rule 1150.1 2.1 Number of Samples The number of samples collected will depend on the area of the landfill surface. The entire landfill disposal area shall be divided into individually identified 50,000 square foot grids. One monthly sample shall be collected from each grid for analysis. Any area that the Executive Officer deems inaccessible or dangerous for a technician to enter may be excluded from the sampling grids monitored by the landfill owner or operator. To exclude an area from monitoring, the landfill owner or operator shall file a written request with the Executive Officer. Such a request shall include an explanation of the requested exclusion and photographs of the area. The Executive Officer shall notify the landfill owner or operator in writing of the decision. Any exclusion granted shall apply only to the monitoring requirement. The 50 ppmv limit specified in paragraph (d)(5) of Rule 1150.1 applies to all areas. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 2.2 Integrated Surface Sampling Conditions , 2.2.1. The average wind speed during this sampling procedure shall be five miles per hour or less. Surface sampling shall be terminated when the average wind speed exceeds five miles per hour or the instantaneous wind speed exceeds ten miles per hour. Average wind speed is determined on a 15 -minute average. 1150.1 - 2r;� Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) 2.2.2. Surface sampling shall be conducted when the landfill is dry. The landfill is considered dry when there has been no measurable precipitation for the preceding 72 hours prior to sampling. Most major newspapers report the amount of precipitation that has fallen in a 24-hour period throughout the Southern California area. Select the nearest reporting station that represents the landfill location or provide for measurable precipitation collection at the MSW landfill wind monitoring station. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 2.3 Integrated Surface Sampler Equipment Description An integrated surface sampler is a portable self-contained unit with its own internal power source. The integrated sampler consists of a stainless steel collection probe, a rotameter, a pump, and a 10 -liter Tedlar bag enclosed in a LIGHT -SEALED CONTAINER to prevent photochemical reactions from occurring during sampling and transportation. The physical layout of the sampler is shown in Figure 1. An alternate integrated surface sampler may be used, provided that the landfill owner or operator can show an equivalency with the sampler specifications in Section 2.4 and shown in Figure 1. All alternatives shall be submitted as specified in subdivision (i) of Rule 1150.1. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 2.4 Integrated Surface Sampler Equipment Specifications 2.4.1 Power: Batteries or any other power source. 2.4.2 Pump: The diaphragm shall be made of non -lubricated Viton (Dupont trade name for co -polymer of hexafluoropropylene and vinylidene fluoride) rubber. 2.4.3 Bag: One 10 -liter Tedlar bag with a valve. The Tedlar bag shall be contained in a LIGHT -SEALED CONTAINER. The valve shall be leak free and constructed of aluminum, stainless steel, or non-reactive plastic with a Viton or Buna-N (butadiene acrylonitrile co -polymer) o -ring seal. 2.4.4 Rotameter: The rotameter shall be made of borosilicate glass or other non-reactive material and have a flow range of approximately 0 -to -1 liter per minute. The scale shall be in milliliters or an equivalent unit. The graduations shall be spaced to facilitate accurate flow readings. 1150.1 -21 �(/ I Rule 1150.1 (Cont.) (Amended April 10, 1998) (Attachment A Continued) 2.4.5 Air Flow Control Orifice: Needle valve in the rotameter. 2.4.6 Funnel: 316 stainless steel. 2.4.7 Fittings, Tubing and Connectors: 316 stainless steel or Teflon. 2.5 Integrated Surface Sampling Procedure 2.5.1 An integrated surface sampler as described in Section 2.4 shall be used to collect a surface sample approximately 8 -to -10 liters from each grid. 2.5.2 During sampling, the probe shall be placed 0 -to -3 inches above the landfill surface. 2.5.3 The sampler shall be set at a flow rate of approximately 333 cubic centimeters per minute 2.5.4 Walk through a course of approximately 2,600 linear feet over a continuous 25 -minute period. Figure 2 shows a walk pattern for the 50,000 square foot grid. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 2.6 Integrated Surface Sample Analytical Procedures All samples collected shall be analyzed no later than 72 hours after collection for TOC using U.S. EPA Method 25, 40 CFR, Part 60, Appendix A analysis or a portable FID that meets the requirements in Section 3.2. In addition, the samples specified in Section 2.6.1 or 2.6.2 must be analyzed no later than 72 hours after collection for the TAC specified in Table 1 and upon written request, Table II, using U.S. EPA Compendium Method TO -14. 2.6.1 Ten percent of all samples which have a concentration of TOC greater than 50 ppmv as methane, or 2.6.2 Two samples if all samples are 50 ppmv or less of TOC or two samples if there are less than 20 samples above 50 ppmv. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE The Executive Officer may require more samples to be tested for TAC if he determines there is a potential nuisance or public health problem. 2.7 Chain of Custody (Required for samples sent to the lab) A custody sheet shall accompany the bag samples. Each time a bag changes hands, it shall be logged on the custody sheet with the time of custody transfer recorded. Laboratory personnel shall record the condition of the sample (full, three-fourths full, one-half full, one-fourth full, or empty). An example of a custody sheet is shown in Figure 4. 1150.1 -22 q 0 Rule 1150.1 (Cont.) (Amended April 10, 1998) (Attachment A Continued) 2.8 Recording the Results 2.8.1 Record the volume concentration of both TOC measured as methane for each grid and the volume concentration for the required TAC on a quality control sheet as shown in Figure 3. Include a topographic map drawn to scale with the location of the grids and the gas collection system clearly marked and identified. 2.8.2 Record the wind speed during the sampling period using the wind speed and direction monitoring system required in paragraph (d)(9) of Rule 1150.1. 2.8.3 Maintain and submit the results as specified in subdivision (f) of Rule 1150.1. 3.0 INSTANTANEOUS LANDFILL SURFACE MONITORING Subparagraph (d)(6) and (e)(3) Requirements of Rule 1150.1 3.1 Monitoring Area The entire landfill disposal area shall be monitored once each calendar quarter. Any area of the landfill that the Executive Officer deems as inaccessible or dangerous for a technician to enter may be excluded from the area to be monitored by the landfill owner or operator. To exclude an area from monitoring, the landfill owner or operator shall file a petition with the Executive Officer. Such a request shall include an explanation of why the area should be excluded and photographs of the area. Any excluded area granted shall only apply to the monitoring requirement. The 500 ppmv limit specified in paragraph (d)(6) of Rule 1150.1 applies to all areas. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 3.2 Equipment Description and Specifications A portable FID shall be used to instantaneously measure the concentration of TOC measured as methane at any location on the landfill. The FID shall meet the specifications listed in Sections 3.2.1 through 3.2.4 and shall be kept in good operating condition. 3.2.1 The portable analyzer shall meet the instrument specifications provided in Section 3 of U.S. EPA Method 21, except that: 3.2.1.1 "Methane" shall replace all references to VOC. 1150.1-23 L4 Rule 1150.1 (Cont.) (Amended April 10, 1998) (Attachment A Continued) 3.2.1.2 A response time of 15 seconds or shorter shall be used instead 33 3.4 of 30 seconds. 3.2.1.3 A precision of 3% or better shall be used instead of 10%. In addition the instrument shall meet the specifications in Sections 3.2.1.4 through 3.2.1.6. 3.2.1.4 A minimum detectable limit of 5 ppmv (or lower). 3,2.1.5 A flame -out indicator, audible and visual. 3.2.1.6 Operate at an ambient temperature of 0 - 50° C. 3.2.2 The calibration gas shall be methane, diluted to a nominal concentration of 10,000 ppmv in air for subsurface refuse boundary probe monitoring and sample analysis to comply with paragraph (e)(1) of Rule 1150.1, 50 ppmv in air for integrated sample analyses to comply with paragraph (e)(2) of Rule 1150.1 and 500 ppmv in air for instantaneous monitoring to comply with paragraph (e)(3) of Rule 1150.1. 3.2.3 To meet the performance evaluation requirements in Section 3.1.3 of U.S. EPA Method 21, the instrument evaluation procedures of Section 4.4 of U.S. EPA Method 21 shall be used. 3.2.4 The calibration procedures provided in Section 4.2 of U.S. EPA Method 21 shall be followed at the beginning of each day before commencing a surface monitoring survey. Monitoring Procedures 3.3.1 The owner or operator shall monitor the landfill disposal area for TOC measured as methane using the described portable equipment. 3.3 .2 The sampling probe shall be placed at a distance of 0-3 inches above any location of the landfill to take the readings. 3.3.3 At a minimum, an individually identified 50,000 square foot grid shall be used and a walk pattern as illustrated in Figure 2 shall be implemented including areas where visual observations indicate elevated concentrations of landfill gas, such as distressed vegetation and cracks or seeps in the cover. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE Recording the Results 1150.1-24 �� Rule 1150.1 (Cont.) (Amended April 10, 1998) (Attachment A Continued) 3.4.1 Record the location and concentration of TOC measured as methane for any instantaneous reading of 500 ppmv or greater on a topographic map of the landfill, drawn to scale with the location of both the grids and the gas collection system clearly marked and identified. 3.4.2 Maintain and submit the results as specified in subdivision (f) of Rule 1150.1. 4.0 LANDFILL GAS SAMPLE FROM GAS COLLECTION SYSTEM Subparagraph (e)(4) Requirement of Rule 1150.1 4.1 Number of Samples Collect one monthly sample of landfill gas for analysis from the main gas collection header line entering the gas treatment and/or gas control system(s). 4.2 Sampling Procedure Collect approximately a 10 -liter sample in a Tedlar bag or equivalent container over a continuous ten-minute period. 4.3 Analytical Procedures Samples collected shall be analyzed no later than 72 hours after collection for TOC using U.S. EPA Method 25, 40 CFR, Part 60, Appendix A analysis and for the TAC specified in Table 1 and upon written request, Table II, using U.S. EPA Compendium Method TO -14. 4.4 Chain of Custody (Required for samples sent to the lab) A custody sheet shall accompany the bag samples. Each time a bag changes hands, it shall be logged on the custody sheet with the time of custody transfer recorded. Laboratory personnel shall record the condition of the sample (full, three-fourths full, one-half full, one-fourth full, or empty). An example of a custody sheet is shown in Figure 4. 4.5 Recording the Results 4.5.1 Record the volume concentration of both TOC measured as methane and the volume concentration for the required TAC on a quality control sheet as shown in Figure 3. Include a topographic map drawn to scale with the location of the gas collection and control system clearly marked and identified. 4.5.2 Maintain and submit the results as specified in subdivision (f) of Rule 1150.1. 1150.1 - 25 q Rule 1150.1 (Cont.) (Attachment A Continued) 5.0 AMBIENT AIR SAMPLES BOUNDARY (Amended April 10, 1998) AT THE LANDFILL PROPERTY Subparagraph (e)(5) Requirement of Rule 1150.1 5.1 Number of Samples Monthly ambient air samples shall be collected for analysis at the landfill property boundary from both an upwind and downwind sampler sited to provide good meteorological exposure to the predominant offshore (drainage land breeze) and onshore (sea breeze) wind flow patterns. The upwind and downwind samples shall be collected simultaneously over two 12 hour periods beginning between 9:00 a.m. and 10:00 a.m., and 9:00 p.m. and 10:00 p.m. on the same day or different days. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 5.2 Ambient Air Sampling Conditions Ambient air sampling shall be conducted on days when stable (offshore drainage) and unstable (onshore sea breeze) meteorological conditions are representative for the season. Preferable sampling conditions are characterized by the following meteorological conditions: 5.2.1 Clear cool nights with wind speeds of two miles per hour or less, and 5.2.2 Onshore sea breezes with wind speeds ten miles per hour or less. No sampling will be conducted if the following adverse meteorological conditions exist: 5.2.3 Rain, 5.2.4 Average wind speeds greater than 15 miles per hour for any 30 -minute period, or 5.2.5 Instantaneous wind speeds greater than 25 miles per hour. Continuously recorded on-site wind speed and direction measurements required in paragraph (d)(9) of Rule 1150.1 will characterize the micrometeorology of the site and serve to verify that the meteorological criteria have been met during sampling. 5.3 Ambient Air Sampler Equipment Description An ambient air sampling unit consists of a 10 -liter Tedlar bag, a DC -operated pump, stainless steel capillary tubing to control the sample rate to the bag, a bypass valve to control the sample flow rate (and minimize back pressure on the pump), a Rotameter for flow indication to aid in setting the flow, a 24-hour clock 1150.1 -26 q Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) timer to shut off the sampler at the end of the 24-hour sampling period, and associated tubing and connections (made of stainless steel, Teflon, or borosilicate glass to minimize contamination and reactivity). The physical layout of the sampler is shown in Figure 5. An alternate ambient air sampler may used, provided that the landfill owner or operator can show an equivalency with the sampler specifications in Section 5.3 and shown in Figure 5. All alternatives shall be submitted as specified in subdivision (i) of Rule 1150.1. 5.4 Ambient Air Sampler Equipment Specifications The equipment used when conducting air samples at any landfill property boundary shall meet the following specifications: 5.4.1 Power: one 12V DC marine battery. The marine battery provides 12V DC to the pump and the clock. 5.4.2 Pump: one 12V DC pump. The diaphragm shall be made of non- lubricated Viton rubber. The maximum pump unloaded flow rate shall be 4.5 liters per minute. 5.4.3 Bag: One 10 -liter Tedlar bag with a valve. The Tedlar bag shall be enclosed in a LIGHT -SEALED CONTAINER. The valve is a push-pull type constructed of aluminum and stainless steel, with a Viton or Buna-N (butadiene acrylonitrile co -polymer) o -ring seal. ALTERNATIVE: THIS REQUIREMENT IS NOT APPLICABLE 5.4.4 Rotameter - made of borosilicate glass and has a flow range of 3 -to -50 cubic centimeters per minute. The scale is in millimeters (nun) with major graduations (labeled) every 5 mm and minor graduations every 1 mm. 5.4.5 Air flow control orifice: 316 stainless steel capillary tubing. 5.4.6 Bypass valve. 5.4.7 Fittings, tubing, and connectors -- 315 stainless steel or Teflon. 5.4.8 Clock timer with an accuracy of better than I%. 5.5 Ambient Air Sample Analytical Procedures ' Samples collected must be analyzed no later than 72 hours after collection for TOC using U.S. EPA Method 25, 40 CFR, Part 60, Appendix A analysis or a portable FID that meets the requirements in Section 3.2 and for the TAC specified 1150.1-27 4v) Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) - in Table 1 and upon written request, Table II, using U.S. EPA Compendium Method TO -14. 5.6 Chain of Custody (Required for samples sent to the lab) A custody sheet shall accompany the bag samples. Each time a bag changes hands, it shall be logged on the custody sheet with the time of custody transfer recorded. Laboratory personnel shall record the condition of the sample (full, three-fourths full, one-half full, one-fourth full, or empty). An example of a custody sheet is shown in Figure 4. 5.7 Recording the Results 5.7.1 Record the volume concentration of TOC measured as methane and the volume concentration of TAC for each sample on a quality control sheet as shown in Figure 3. Include a topographic map drawn to scale with the location of both the upwind and downwind samplers and the gas collection and control system clearly marked and identified. 5.7.2 Record the wind speed and direction during the 24-hour sampling period using the wind speed and direction monitoring system required in paragraph (d)(9) of Rule 1150.1. 5.7.3 Maintain and submit the results as specified in subdivision (f) of Rule 1150.1. a 1150.1 -28 14((? Rule 1150.1 (Cont.) ( (Attachment A Continued) Amended April 10, 1998) rnysiCai Layout Figure 1 1150.1-29 5001 Rule 1150.1 (Cont.) (Attachment A Continued) Typical Landfill Walk Pattern for a 50,000 Square Foot Grid (Amended April 10, 1998) Figure 2 1150.1-30 1� Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) QUALITY CONTROL SHEET • Prior to use, the Tedlar bag system shall be leak checked, evacuated and filled with purified nitrogen three times to flush out the old sample. • All samples must be kept in LIGHT -SEALED CONTAINERS to avoid photochemical reactions. „rOPERATIOlrCp TS Grid or Date Wind Time Time I.D.# Valve Rotameter Pump probe tl Speed On Off Open Reading (On/Off) Signature: Figure 3 1150.1-31 Rule 1150.1 (Cont.) (Attachment A Continued) BAG SAMPLE CUSTODY FORM Project Date: (Amended April 10, 1998) Bags Prepared By: Bags Taken Out By: Bags Taken to Lab By Bags Received In Lab By: * P = 1/2 full to full, 0 = Overfull (Bulging), L = 1/4 to 1/2 full, G = Less than 1/4 full but contains some sample, N = No sample at all. Figure 4 1150.1-32 Time: Date: Time: Time Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) 1150.1-33 Sample Bag .IR SAMPLER i,y-n.ai "ayOUt Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) TABLE 1 - CARCINOGENIC AND TOXIC AIR CONTAMINANTS (Core Group) Paragraph (e)(2), Subparagraphs (k)(3)(F) and (k)(3)(G) Requirements of Rule 1150.1 1. Benzene CA 2. Benzyl Chloride C6HSH2CI 3. Chlorobenzene C6H5C1 4. 1,2 Dibromoethane (Ethylene Dibromide) BrCH2CH2Br 5. Dichlorobenzene C6H4Cl2 6. 1,1 Dichloroethane (Ethylidene Chloride) CH3CHCl2 7. 1,2 Dichloroethane (Ethylene Dichloride) CIHZHZCI 8. 1,1 Dichloroethene (Vinylidene Chloride) CHZ: CC12 9. Dichloromethane (Methylene Chloride) CH2Cl2 10. Hydrogen Sulfide HZS 11. Tetrachloroethylene (Perchloroethylene) C12C : CC12 12. Tetrachloromethane (Carbon Tetrachloride) CC14 13. Toluene C6HSCH3 14. 1,1,1 Trichloroethane (Methyl Chloroform) CH3CC13 15. Trichloroethylene CHC1 : CC12 16. Trichloromethane (Chloroform) CHC13 17. Vinyl Chloride CHZ: CHC1 18. Xylene C6H4(CH3)2 1150.1 - 34 ("' Rule 1150.1 (Cont.) (Attachment A Continued) (Amended April 10, 1998) TABLE 2 - CARCINOGENIC AND TOXIC AIR CONTAMINANTS (Supplemental Group) Paragraph (e)(2), Subparagraphs (k)(3)(F) and (k)(3)(G) Requirements of Rule 1150.1 1. Acetaldehyde CH3CHO 2. Acrolein CH2CHCHO 3. Acrylonitrile H2C : CHCN 4. Allyl Chloride H2C : CHCH2C1 5. Bromomethane (Methyl Bromide) CH313r 6. Chlorinated Phenols 7. Chloroprene H2C : CHCC1 : CH2 8. Cresol CH3C6H4OH 9. Dialkyl Nitrosamines 10. 1,4 - Dioxane OCH2CH2OCH2CH2 11. Epichlorohydrin CH2OCHCH2C1 12. Ethylene Oxide CH2CH2O 13. Formaldehyde HCHO 14. Hexachlorocyclopentadiene C5C16 15. Nitrobenzene C6H5NO2 16. Phenol C6H5OH 17. Phosgene COC12 18. Polychlorinated Dibenzo-P-Dioxin 19. Polychlorinated Dibenzo Furan 20. Polychlorinated Biphenols 21. Polynuclear Aromatic Hydrocarbons 22. Propylene Oxide CH2-CH-CH3 23. Tetrahydrothiophene CH2CH2CH2CH2S 24. Thiophene CHCHCHCHS 1� 1150.1-35 A Division of 4306 West 190th Street, Torrance, CA 90504 Activated Carbon and Specialty Media Tel: 310.303-3700 ♦ Fax: 310.406-3001 Pollution Control Systems and Filtration Equipment Rental MATERIAL SAFETY DATA SHEET I. PRODUCT IDENTIFICATION TRADE NAME: SulfaTreat® 410 HMIS Hazard Ratings H: 0 MANUFACTURER'S NAME & ADDRESS: F: 0 The SulfaTreat Company R: 0 17998 Chesterfield Airport Rd. Suite 215 P: Chesterfield, MO. 63005 EMERGENCY PHONE: 1-800-726-7687 or 1-314-532-2189 FAX: 1-314-532-2764 II. HAZARDOUS INGREDIENTS Chemical Names CAS Numbers % Exposure Limits in Air (Units) None N/A, Proprietary N/A N/A III. CHEMICAL & PHYSICAL PROPERTIES Vapor Density (Air = 1) N/A Melting Point or Range OF N/A Specific Gravity 1.1 Boiling Point or Range OF N/A Solubility in Water Nil Evaporation Rate (BuAcetate=l) N/A Vapor Pressure, mmHg @20 °C 0 VOC (EPA Method 24) 0 pH N/A Appearance & Odor Black, Granular, Odorless Solid IV. SHIPPING REGULATIONS DOT Proper Shipping Name: N/A DOT Hazard Class: N/A DOT I.D. Number: N/A DOT Hazardous Substance: N/A V. FLAMMABILITY & EXPLOSIVE PROPERTIES Flash Point °F: N/A Auto Ignition Temperature °F: N/A Flammability limits in Air, Volume %: LEL (Lower): N/A UEL (Upper): N/A Fire Extinguishing Materials: N/A Special Fire fighting Procedures: None Unusual Fire & Explosion Hazards:None Hazardous Products formed by Fire: None VI. HEALTH HAZARD INFORMATION SYMPTOMS OF OVEREXPOSURE (for each potential route of exposure) Inhalation: Overexposure to dust may irritate the nasal passage, Eyes: May cause eye irritation similar to dust. Skin: Contact with skin has no effect. Absorbed through skin: None Swallowed: No significant effect under normal exposure. Significant ingestion may require purging. HEALTH EFFECTS OR RISKS FROM EXPOSURE: Acute: No acute effects to health are known. Not toxic. LD50 greater than 3990 mg/kg (Highest practical test level). Chronic: No chronic effects to health known. FIRST AID: EMERGENCY PROCEDURES Eye Contact: Flush with water Skin Contact: Wash with soap and water Ingestion: Purge if necessary Inhalation: Remove to fresh air SUSPECTED CANCER AGENT: NO - The product ingredients are. not found in the following lists: ACGIH, NIOSH, OSHA, NTP or IARC. MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: None Known. VII. REACTIVITY DATA Stability: Stable: X Unstable: Conditions to Avoid: N/A Incompatibility (Materials to avoid): Strong oxidizers Hazardous decomposition products (Including combustion products): Irritating gases Hazardous polymerization: Will not occur. VIII. SPILL, LEAK & DISPOSAL PROCEDURES Spill Response Procedures (include employee protection measures): No special procedures required. Preparing Waste for Disposal (container types, neutralization, etc.) No special procedures required. Recommended Methods of Disposal: Dispose of all wastes in accordance with Federal, State & Local regulations. Not listed as a material banned from land disposal according to RCRA. IX. SPECIAL HANDLING INFORMATION Ventilation & Engineering Controls: No Special Requirements. Respiratory Protection (type): NIOSH/MSHA approved dust mask (TC -21C-132). Eye Protection: None required. Gloves (specify material): None required. Other Clothing & Equipment: No special requirements. Work Practices, Hygienic Practices: No special requirements, avoid excessive dust inhalation. Other Handling & Storage Requirements: No special requirements. Protective measures during maintenance of contaminated equipment: N/A X. REGULATORY INFORMATION US EPA - TSCA Chemicals in this product are listed on the TSCA inventory. Chemicals in this product are not on the Health & Safety Reporting List, are not under a Chemical Test Rule or listed in TSCA Section 12b, or have SNRU under TSCA. USA EPA- SARA This product has no RQ or TPQ under Section 302 and are not reportable under Section 313. US EPA - Clean Air Act This product does not contain any hazardous air pollutants or Class 1 and Class 2 Ozone depletors. US EPA - Clean Water Act None of the chemicals in this product are listed as Hazardous Substances, Priority Pollutants or Toxic Pollutants under the CWA. Canada This product is not listed on Canada's Ingredient Disclosure List. X. PREPARATION INFORMATION Revision Date: November 25, 1998 Baker Filtration Corporate Offices 4306 W. 190`h Street, Torrance, California 90504 Phone: 310.303.3 700 ♦ Fax: 310.406.3001 %G'06 BAKER Technical Information Manual � GENERAL INFORAM77ON WEIC7H7SAND MEASURES �» Max Flowrate IOOOS: 600 cfm 2000S: 600 cfm » Max. Pressure: I' 15 psi •Specialty Media r e Volume » Max Temp 150'F ... 20005: 67 cu ft __ » Height 10005 66" 20005 . ...__.�_... _..._..__..__ 92" _ _...,._ _-_ __ ----- .._ r777 ��� - Diameter. __ » Inlet a - _ Shipping Wt*: .... 1000S: ...._... �.,_:-..�... 1800 Ibs. - 2800 Ibs (drum+media) 2000S: 3050 Ibs. - 5050 Ibs. Outlet (*Media dependenlJ FILTER MEDIA ..... .............. » Types: ..._ Activated Carbon ............................... •Specialty Media Volume IOOOS: 34 cu ft ... 20005: 67 cu ft 'Weight* r IOOOS: 1000 Ibs 2000 Ibs. L�i(-Meda dependen4. a 20005: 2000 Ibs 4000 tbs. A41SCELLANEOLIS DATA » Inlet 4 4' FNPT .........�' Outlet 4 FNPT y>! Interior ; Double -layered epoxy coating Coating » Internals: ....€ PVC inlet diffuser a d.�..ws 3 ...... » Media Top manway (neoprene gasket( Access PRESSURE DROP DA TA 0 25 ❑ 20 w (D r 15 L7 C 10 U) W 5 af n EN.AI R-20005 NAR -1 100 200 300 400 500 600 FLOW (CFM) ANOTES: I. In the presence of activated carbon, some contaminants may oxidize, polymerize or otherwise react resulting in the release of heat and become a potential fire hazard. Extreme care should be taken in the design and operation of such applications. 2. Wet activated carbon preferentially removes oxygen from air. In closed or partially closed containers and vessels, oxygen depletion may reach hazardous levels. If workers are to enter a vessel containing carbon, appropriate procedures for potentially low oxygen spaces must be followed, including all federal and state requirements. 3020 Old Ranch Parkway • Suite 220 • Seal Beach, CA • 562-430-6262 A Division of 4306 West 190th Street, Torrance, CA 90504 Activated Carbon and Specialty Media Tel: 310.303-3700 ♦ Fax: 310.406-3001 Pollution Control Systems and Filtration Equipment Rental MATERIAL SAFETY DATA SHEET DATE OF ISSUE: June 6, 2005 SECTION I- GENERAL INFORMATION MANUFACTURER NAME: Baker Filtration 310.303.3700 4306 West 190th Street, Torrance, CA 90504 CHEMICAL NAMES & SYNONYMS: Activated Carbon, Activated Coconut, Activated Charcoal, Char TRADE NAMES & SYNONYMS: Activated Carbon CHEMICAL FAMILY: Amorphous Carbon, Activated Coconut FORMULA: Carbon atom in a crystallite structure has an infinite molecular weight, Anthracite Coal, Sub -Bituminous Coal, Bituminous Coal CAS NO. 7440-440 SECTION II- HAZARDOUS INGREDIENTS CHEMICAL NAME (Ingredients) [% TLV (Units)]: No Hazardous Ingredients HAZARDOUS MIXTURES OF OTHER LIQUIDS, SOLIDS, OR GASSES [% TLV (Units)]: LIQUIDS Activated Carbons that have adsorbed other carbon or non -carbon liquids or gasses may lower or raise the ignition point and must be laboratory checked for ignition point when expended. SECTION III- PHYSICAL DATA BOILING POINT (DEG F): 4200 SPECIFIC GRAVITY (H20-1):1.8-2.1 VAPOR PRESSURE (MM HG) N/A PERCENT VOLATILE BY VOLUME: none VAPOR DENSITY (AIR= 1): N/A EVAPORATION RATE: none SOLUBILITY IN WATER: insoluble IGNITION TEMPERATURE: 600 deg C APPEARANCE & ODOR: Odorless, black granular solid SECTION IV- FIRE HAZARD & EXPLOSIVE DATA FLASH POINT (method used): none FLAMMABLE LIMITS: Lower Explosive Limit: N/A Upper Explosive Limit: N/A EXTINGUISHED MEDIA: Use media for class A fires: Foam, multipurpose dry chemical and water type extinguishers. SPECIAL FIRE FIGHTING PROCEDURES: none UNUSUAL FIRE & EXPLOSION HAZARDS: Provide for the handling of dry flowing solids in grounded equipment to prevent build up of static electric charge especially when explosive dust or vapor mixtures may exist in confined areas. Also provide for pressure relief devices following the principles set forth in the National Fire Protection Association Explosion Preventing Guide NFPS68-1854. SECTION V- HEALTH HAZARD DATA THRESHOLD LIMIT VALUE: Avoid exposure to dust levels 15 mg per cubic meter. (Federal), 10 mg per cubic meter (California State). EFFECTS OF OVEREXPOSURE: Temporary dryness to mucous membrane causing coughing and minor nose and throat irritation. EMERGENCY AND FIRST AID PROCEDURES: Wash mouth with water -no other treatment required. Use protective respiratory equipment to avoid inhaling carbon dust. SECTION VI- REACTIVITY DATA STABILITY: UNSTABLE STABLE-> X CONDITIONS TO AVOID: Activated Carbon is chemically inert INCOMPATABILITY (Materials to avoid): none HAZARDOUS DECOMPOSITION PRODUCTS: none HAZARDOUS POLYMERIZATION: MAY OCCUR—> WILL NOT OCCUR—>X SECTION VII- SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED: Spills can create nuisance dust and house keeping problems. Vacuuming is best clean up procedure. WASTE DISPOSAL METHOD: Wet or dry activated carbon is best disposed of by landfill. SECTION VIII -PROTECTION INFORMATION RESPIRATORY PROTECTION (Specify Type): Respiratory classifications table G-2 part 1910.93 (OESHA) Rules & Regulations. VENTILATION: LOCAL EXHAUST: Vacuum to control dust PROTECTIVE GLOVES: None required EYE PROTECTION: For airborne dust OTHER PROTECTIVE EQUIPMENT: Protective clothing should be worn during handling to protect against airborne dust. SECTION IX- SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING: Packaged activated carbon is not resistant to weather or outside storage and requires indoor Type I and Type II storage facilities. OTHER PRECAUTIONS: Check oxygen content of atmosphere of any vessel containing activated carbon before allowing entry of personnel. SECTION X- TRANSPORTATION DATA PROPER SHIPPING (Article) NAME: Steam Activated Carbon, Non -Regulated OR Carbon, Activated, Non -Regulated DOT CLASSIFICATION: NMFC 40560 / DOT MARKING: N/A / DOT PLACARD: N/A EMERGENCY ACCIDENT PRECAUTIONS AND PROCEDURES: Contact: Baker Filtration Phone: 310.303.3700 PRECAUTIONS TO BE TAKEN IN TRANSPORTATION: N/A The information contained herein is based on data considered accurate in light of current formulation. However, no warranty is expressed or implied regarding the accuracy of this data or the results to be obtained from the use thereof. Baker Filtration Corporate Offices 4306 W. 190`h Street, Torrance, California 90504 Phone: 310.303.3700 0 Fax: 310.406.3001 Instruction Book GX 2, GX 3, GX 4, GX 5 Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Date Printed .................... 06/06/2006 Atlas Copco www.afascopco.com Table of contents 1 Safety precautions......................................................................................... 4 1.1 SAFETY ICONS........................................................................................................................ 4 1.2 SAFETY PRECAUTIONS DURING INSTALLATION.................................................................................. 4 1.3 SAFETY PRECAUTIONS DURING OPERATION...................................................................................... 6 1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR..................................................................... 7 2 General description...................................................................................... 10 2.1 INTRODUCTION....................................................................................................................... 10 2.2 AIR FLOW............................................................................................................................. 14 2.3 OIL SYSTEM.......................................................................................................................... 17 2.4 REGULATING SYSTEM...............................................................................................................18 2.5 CONTROL PANEL....................................................................................................................19 2.6 PROTECTION OF COMPRESSOR....................................................................................................20 2.7 AIR DRYER............................................................................................................................ 21 3 Installation.................................................................................................. 22 3.1 INSTALLATION PROPOSAL..........................................................................................................22 3.2 DIMENSION DRAWINGS.............................................................................................................25 3.3 ELECTRIC CABLE SIZE...............................................................................................................27 3.4 ELECTRICAL CONNECTIONS........................................................................................................28 3.5 ELECTRICAL DIAGRAMS.............................................................................................................29 3.6 PICTOGRAPHS........................................................................................................................ 31 4 Operating instructions.................................................................................. 33 4.1 INITIAL START-UP....................................................................................................................33 4.2 STARTING.............................................................................................................................35 4.3 STOPPING.............................................................................................................................38 4.4 TAKING OUT OF OPERATION.......................................................................................................39 2 7 Problem solving............................................................................................ 50 7.1 PROBLEM SOLVING.................................................................................................................. 50 8 Technical data.............................................................................................53 8.1 READINGS ON CONTROL PANEL................................................................................................... 53 8.2 SETTINGS FOR OVERLOAD RELAY AND FUSES.................................................................................. 54 8.3 REFERENCE CONDITIONS AND LIMITATIONS..................................................................................... 55 8.4 COMPRESSOR DATA................................................................................................................ 55 9 Instructions for use of air receiver..................................................................58 9.1 INSTRUCTIONS FOR USE............................................................................................................ 58 10 PED............................................................................................................59 10.1 PRESSURE EQUIPMENT DIRECTIVES............................................................................................... 59 3 5 Maintenance................................................................................................41 5.1 PREVENTIVE MAINTENANCE SCHEDULE.......................................................................................... 41 5.2 DRIVE MOTOR....................................................................................................................... 42 5.3 OIL SPECIFICATIONS................................................................................................................ 42 5.4 OIL, FILTER AND SEPARATOR CHANGE.......................................................................................... 42 5.5 PDX FILTER CHANGE............................................................................................................... 44 5.6 STORAGE AFTER INSTALLATION................................................................................................... 45 5.7 SERVICE KITS........................................................................................................................ 45 6 Adjustments and servicing procedures............................................................46 6.1 AIR FILTER............................................................................................................................ 46 6.2 COOLERS..............................................................................................................................47 6.3 SAFETY VALVE...................................................................................................................... 47 6.4 BELT SET EXCHANGE AND TENSIONING......................................................................................... 48 7 Problem solving............................................................................................ 50 7.1 PROBLEM SOLVING.................................................................................................................. 50 8 Technical data.............................................................................................53 8.1 READINGS ON CONTROL PANEL................................................................................................... 53 8.2 SETTINGS FOR OVERLOAD RELAY AND FUSES.................................................................................. 54 8.3 REFERENCE CONDITIONS AND LIMITATIONS..................................................................................... 55 8.4 COMPRESSOR DATA................................................................................................................ 55 9 Instructions for use of air receiver..................................................................58 9.1 INSTRUCTIONS FOR USE............................................................................................................ 58 10 PED............................................................................................................59 10.1 PRESSURE EQUIPMENT DIRECTIVES............................................................................................... 59 3 Instruction manual 1 Safety precautions 1.1 Safety icons Explanation 1.2 Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non -observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. General precautions 1 . The operator must employ safe working practices and observe all related local work safety requirements and regulations. 2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply. 3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised personnel. 4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to local legislation and standards. 5. Before any maintenance, repair work, adjustment or any other non -routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch must be opened and locked. 6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection. 4 Instruction manual Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with local safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment. 2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air. 3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes. 4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure. 5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to internal fire or explosion. 6. Arrange the air intake so that loose clothing worn by people cannot be sucked in. 7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials. 8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain. 9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is remotely controlled and may start without warning. The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment. 10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet. 11. The electrical connections must correspond to the local codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor. 12. On machines with automatic start -stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning" must be affixed near the instrument panel. 13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non - return valves (check valves) must not be relied upon for isolating pressure systems. 14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure -relieving device or devices as required. 15. Pipework or other parts with a temperature in excess of 80°C (176°F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high- temperature pipework must be clearly marked. 16. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. 5 Instruction manual 17. If the ground is not level or can be subject to variable inclination, consult the manufacturer. Also consult following safety precautions: Safety precautions during operation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 1.3 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non -observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. General precautions 1. The operator must employ safe working practices and observe all related local work safety requirements and regulations. 2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply. 3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised personnel. 4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to local legislation and standards. 5. Before any maintenance, repair work, adjustment or any other non -routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch must be opened and locked. 6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection. Precautions during operation 1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it. 2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. 3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or particles. 6 Instruction manual 4. Never operate the machine below or in excess of its limit ratings. 5. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door. 6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear protectors. 7. Periodically check that: • All guards are in place and securely fastened • All hoses and/or pipes inside the machine are in good condition, secure and not rubbing • There are no leaks • All fasteners are tight • All electrical leads are secure and in good order • Safety valves and other pressure -relief devices are not obstructed by dirt or paint • Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse 8. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 9. Do not remove any of, or tamper with, the sound -damping material. 10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure -relieving device or devices as required. Also consult following safety precautions: Safety precautions during installation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 1.4 Safety precautions during maintenance or repair All responsibility for any damage or injury resulting from neglecting these precautions, or non -observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. General precautions 1. The operator must employ safe working practices and observe all related local work safety requirements and regulations. 7 Instruction manual 2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply. 3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised personnel. 4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to local legislation and standards. 5. Before any maintenance, repair work, adjustment or any other non -routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch must be opened and locked. 6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection. Precautions during maintenance or repair 1 . Always wear safety glasses. 2. Use only the correct tools for maintenance and repair work. 3. Use only genuine spare parts. 4. All maintenance work shall only be undertaken when the machine has cooled down. 5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting equipment. 6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. 7. Close the compressor air outlet valve before connecting or disconnecting a pipe. 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids. 10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape. 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam -cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted. 13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc. 14. Make sure that no tools, loose parts or rags are left in or on the machine. 15. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. 8 Instruction manual 16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures and time settings are correct. Check that all control and shut -down devices are fitted and that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled. 17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits; if excessive, the deposits should be removed. 18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g. when steam -cleaning. 19. Make sure that all sound -damping material, e.g. on the bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing. 20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls. 21. The following safety precautions are stressed when handling refrigerant: • Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use breathing protection. • Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid. 22. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil. Also consult following safety precautions: Safety precautions during installation and Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 9 Instruction manual 2 General description 2.1 Introduction Introduction GX2 up to GX5 are single -stage, oil -injected screw compressors. The compressor is air-cooled and belt -driven by an electric motor. The compressor is enclosed in sound - insulated bodywork. An easy -to -operate control panel (1) is provided, including the start/stop switch and the emergency stop button. A cabinet housing the regulator, pressure switch and motor starter is integrated into the bodywork. Floor -mounted model 10 1 Front view, GX2 up to GX5 Floor -mounted The compressor is installed directly on the floor. The compressor should always be installed with a suitable air receiver. Instruction manual Tank -mounted model Front view, GX2 up to GX5 Ref. Name 1 Control panel AO Air outlet AR Air receiver Dm2 Automatic condensate drain, air receiver SV Safety valve Instruction manual Co OF 1 DR n2 hR Front view, GX2 up to GX5 Full -Feature 12 Instruction manual OF OS AF Rear view, GX2 up to GX5 Full -Feature GX2 up to GX5 are mounted on a large air receiver (AR) of 200 1 (52.80 US gal / 44 Imp gal / 7 cu.ft). Ref. Name 1 Control panel AF Air filter AO Air outlet AR Air receiver Co Oil cooler Dm2 Manual condensate drain, air receiver DR Dryer E Compressor element OF Oil filter OS Oil separator OT Oil separator tank 13 GX Pack The compressor is not fitted with a dryer. 2.2 Air flow Flow diagram 14 Instruction manual Instruction manual Air flow, GX2 up to GX5 Tank -mounted Pack Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed. The air is discharged via minimum pressure valve (Vp) towards the air outlet (AO). 15 Instruction manual Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed. The air is discharged via minimum pressure valve (Vp), air receiver (AR) and dryer (DR) towards the air outlet (AO). Instruction manual 2.3 Oil system A 4�6 121 LE L a® I g 17 Instruction manual Air pressure forces the oil from oil separator/tank (OT) through oil cooler (Co) and filter (OF) to compressor element (E) and the lubrication points. In oil separator/tank (OT), most of the oil is removed centrifugally; the rest is removed by separator (OS). The oil system has a thermostatic by-pass valve (BV). The oil cooler is by-passed until the oil reaches the correct operating temperature. 2.4 Regulating system Main components PSR11 52879F View on regulating system 10 10 Y1 Instruction manual The main components of the regulating system are: • Pressure switch (PSR1 1) which opens and closes at preset pressure limits. • Blow -off valve (Y1) Pressure switch (PSR1 1) opens and closes its contacts at pre-set pressures. During loaded operation, the contacts are closed: the motor is running. If the working pressure reaches the maximum limit, the contacts of the pressure switch open: the motor will stop. The blow -off valve (Y1) opens and the pressure in the air/oil separator is released. When the working pressure decreases to the pre-set minimum pressure, the contacts of the pressure switch close and the motor restarts. The blow -off valve closes and compressed air is supplied to the receiver again. 2.5 Control panel 55638F Controlpanel, GX2 up to GX5 19 Instruction manual Reference Designation Function 1 Start/stop switch - Starts and stops the compressor. Also used to stop emergency switch the compressor in the event of an emergency and to reset the thermal overload of the electric motor by switching it to 0 and back to I. 2 Dryer on/off button Button to switch on/off the dryer Not installed on Pack versions 3 Reset button Reset button (after unscrewing cover) for high oil temperature shut -down. Hm Hour meter Indicates the total running time. Gpa Working pressure The white pointer indicates the actual working pressure. H1 Alarm lamp Lights up in the event of high oil temperature shut- down. 2.6 Protection of compressor SV Safety valve of the vessel Safety valve on the compressor Instruction manual Reference Designation Function Q21 Motor overload relay To shut down the compressor in case the motor Also see the current is too high. Electrical diagrams section TSHH11 Temperature shut -down To shut down the compressor if the temperature at Also see the switch the outlet of the compressor element is too high. Electrical diagrams section Sv Safety valve To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve. After tripping of the temperature protection: switch off the voltage and depressurise. See Maintenance remarks. Check and remedy. See Problem solving. Wait a few minutes to let the machine cool down. To reset and restart, switch on the voltage and press the red reset button after unscrewing its cover: the machine will restart. 2.7 Air dryer 55648F Air dryer Wet compressed air (B) enters the dryer. The air then flows through a heat exchanger (2) where refrigerant evaporates, withdrawing heat from the air. The cold air then flows through a condensate trap (1) which separates condensate from the air. The condensate is automatically drained and this is regulated by a timer. The dried air is then discharged from the dryer. 21 Instruction manual 3 Installation 3.1 Installation proposal Important 1 Transport by a pallet truck 22 To prevent a Tank -mounted model from falling over during transport by a pallet truck: push the forks underneath the air receiver and place a wooden beam (1) (cross-section approx. 4 x 6 cm / 1.6 x 2.4 in) through the supports on both sides of the receiver. While holding the compressor, slowly lift the forks until the receiver is secured between the beams. Move the compressor gently. 22 Instruction manual Proposal \ Vj s 6 :��57192D Installation proposal, Floor -mounted GX2 up to GX5 Ref. Description/recommendation (6) Outlet valve 1 2 1 i MINIMUM J' Y MUM 1.5 m (1 j ' SPACE FOR MAINTENANCE` ` 3: MINIMUM 2m POWER CABLE SHOULDy' (2) BE PROTECTED SO THAT IT COMPLIES LOCAL CODE SINGLE PHASE DRYER SUPPLY 52869D THREE PHASE SCREW -COMPRESSOR SUPPLY J I (<) Installation proposal, Tank -mounted GX2 up to GX5 23 Instruction manual Ref. Description/recommendation 1 Isolating switch, compressor 2 Isolating switch, dryer 3 Front panel, compressor 4 Dryer (1) Minimum 1.5 m (2) Space for maintenance, minimum 2 m (3) Single-phase dryer supply (4) Three-phase screw compressor supply (5) The power cable should be protected so that it complies with local codes Step Action 1 Install the compressor on a solid, level floor suitable for taking the weight. The recommended minimum distance between the top of the unit and the ceiling is 1.5 m (58.5 in). The minimum distance between the wall and the back of the compressor must be 200 mm (7.8 in). Floor -mounted versions must be installed with suitable air receiver. The pipes between a Floor -mounted compressor and air receiver are hot. 2 Position of the compressed air outlet valve. Close the valve. Connect the air net to the valve. 3 The pressure drop over the delivery pipe can be calculated from the following formula: dp= (L x 450 x Qc1-85) / (d5 x P) • dp = pressure drop (recommended maximum = 0.1 bar / 1.5 psi) • L=length of delivery pipe in m • d = inner diameter of the delivery pipe in mm • P=absolute pressure at the compressor outlet in bar(a) • Qc=free air delivery of the compressor in I/s 4 Ventilation: the inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor or dryer is avoided. 5 Lay out the condensate drain flexible from timer (T) as well as the flexible from condensate drain valve (4) towards a drain collector. The drain flexibles to the drain collector must not dip into the water of the drain collector. See the Starting section for the location of the components. Instruction manual 3.2 Dimension drawings Dimension drawings, GX2 up to GX5 Floor -mounted GX2 up to GX5, Pack 605 620 CODLING RIR EXIT (2) 25 550 30 V" Otn 'v o ® C" p- o • 0 Lu (3) _ U-) J u -i RLn M1 p LnJ O Y �.Q (5) ti COMPRESSED RIR CUTLET B0 3/4' 2202260960` (4) 57191 D COOLING RIR ENTRY . u (2) m m ZDOLIKC RIR IXIT ii 118 25 (3) ELECTRICfL CRBLE ENTRY Floor -mounted GX2 up to GX5, Pack 620 IL❑ O a o v O i 240 s20M^T" ^- -240 Instruction manual COOLING AIR , (2) OUTLET 25 se N o W (4) _06— //C T (4) 0) so G 112" wVLuv 3 mr, I,Vv Ml MIN COMPRESSED IPLET INLET AIR OUTLET 0 450 175 750 175 (5) 386 132 1 1100 732 4450 1420.. 55 25 118 v? 8 2202 2609 59/3 66690D Tank -mounted GX2 up to GX5, Pack 26 m (� COOLING AIR OUTLET (2) 2202 2609 59/3 66690D Tank -mounted GX2 up to GX5, Pack 26 Instruction manual COOLING RIR 1015 55 (2) OUTLET 25 395 � o G112' zes ❑ q COMPRESSED {5)` RIR OUTLET M1 OW® N O 100 1015 {4) 7Q,\{4) CONDENSRTE DRAIN PIPE 3/8'F, valve included so COOLING RIR COOLING RIR {7) INLET I INLET 0'. 6450 1717155�. 750 175 1_ 3e6 L: 732 1.100. L32 440 1420.' {3) 25 ]le EIECTRCCFL CR&E ENTRY N COOLING RIR (2) OUTLET7 220226D9 58/3 55691D 101s Tank -mounted GX2 up to GX5, Full -Feature Ref. Name 1 Condensate drain pipe, valve included (only on Tank -mounted units) 2 Cooling air outlet 3 Electrical cable entry 4 Cooling air inlet 5 Compressed air outlet 3.3 Electric cable size Attention Local regulations remain applicable if they are stricter than the values proposed below. The voltage drop must not exceed 5% of the nominal voltage. It may be necessary to use cables of a larger size than those stated to comply with this requirement. Instruction manual 3.4 Electrical connections Step Action GX2 GX3 GX4 GX5 Frequency (Hz) Voltage (V) Cable size Cable size Cable size Cable size IEC (mm2) (mm2) (mm2) (mm2) 50 230 2.5 2.5 4 4 50 400 1 1 1.5 1.5 60 230, 1 -ph 2.5 4 4 6 60 380 1.5 - 1.5 1.5 CSA/UL AWG AWG AWG AWG 60 230, 1 -ph 2.5 4 4 6 60 208 1.5 - 2.5 4 60 230 1.5 - 2.5 4 60 460 1.5 - 1.5 1.5 60 575 1.5 11.5 11.5 3.4 Electrical connections Step Action 1 Ensure that the supply voltage matches the voltage on the data plate. 2 Fit an isolating switch near the compressor. For Full -Feature compressors: fit an isolating switch near the dryer. 3 Fit fuses in the incoming wiring. Check the condition of all incoming wiring and make connections. See Electrical diagrams. Instruction manual 3.5 Electrical diagrams Customer's Installation (1) Customer's Installation (1 } 3phase 230-400V 50-60Hz (2) I i (phase 230V 50-60Hz (3) LI _-___--t__-----__ LI -------- __ 12 _______yt -___ ___L2 __ -_ _ __ ___ — __ I U _______J_FY ________ PE PE— _ _* I I MRX. FUSE [a] 1 I I I I I IEL Llass G lw� a s ImI�, 10 R - — - — - -�z- — — — — — — — I - — - — - — — -� Compressor 1 2 3 1 - -.Dryer D 0 L 1 E - (4) Fl (�� C OV Ti 24V - SETTIN6 23OV u S1 E- - - - - - - - v -------v OV You T Ps213 : Q2 L 400V I P r I L -PGRI I(2I 1. PSp2 i I I H2 %I I I P K21 e is IQt: Y1 1 _ — — Cb] _' H1 PI h M � i M ICM � Ht 3'�. 3 14 Iti PB 1'�. I 9820 3888 01 52849D Electrical diagram, GX2 up to GX5 with DOL starter L.7 Instruction manual Customer's Installation (1) Name Customer's installation (2) 3-phase 230-400 V 50-60 Hz Customsis Instal lat on 3phase 230-400V 50-60Hz (2) (4) Compressor (5) Dryer - _ ]phase 230Y 50-BOHz (3) u. ------- -- ------a--- -- --- ---------- --t ?— ----- MM. FUSE [a] _ _ ..}-� . — . _ - — - _ — _ . _ _ _ — . — _ . _ _ _ _ — . }� _— -— - —- —-— �_ SETTING 021 Its -Compressor. ^— _ �. Dryer (FJ} _ --- (4) F1 rsmu '1 s' E Si I v n oV TI 24V� M° ' 230Y i I rse.a -:400Y sal '. Nei ` s I(ti M2e. K24 s RM a Q1 IE �a I K21 IQ3 Y7 Ismm K72 k2P � - — — 1 x' P1 h nl a1. t M PE i4 11 to Imo. 9820 3888 02 52850D Electrical diagram, GX2 up to GX5 with YID starter Ref, Name (1) Customer's installation (2) 3-phase 230-400 V 50-60 Hz (3) 1 -phase 230 V 50-60 Hz (4) Compressor (5) Dryer 30 Instruction manual 3.6 Pictographs I rn (0 LO LO 1&,' AV— 6 2 Ar Ax. 7_ 3 /4.\X— 8 4 9 � e 5 10 52871 P Pictographs, GX2 up to GX5 Pictographs, GX2 up to GX5 Instruction manual Ref. Description 1 Warning: possible air/fluid discharge 2 Warning: voltage 3 Warning: air must not be inhaled 4 Warning: wear ear protectors 5 Warning: machine may start automatically 6 Warning: pressure 7 Warning: hot parts 8 Warning: moving parts 9 Warning: rotating fan 10 Drain condensate weekly 11 Read the instruction manual 12 Working pressure 13 Hour meter 14 Reset of temperature protection 15 High temperature outlet of the compressor element 16 Read instruction manual before carrying out maintenance or repair work 17 Lightly oil gasket of oil filter, screw filter on and tighten by hand 32 Instruction manual 4 Operating instructions 4.1 Initial start-up Safety The operator must apply all relevant Safety precautions. Moving To safely move a Tank -mounted model, see Installation. General preparation 55617F Air outlet valve 2 Step Action 1 Consult the installation instructions (see Installation). 2 Check that the electrical connections correspond to the local codes. The installation must be earthed and protected against short circuits by fuses in all phases. An isolating switch must be installed near the compressor. 3 Fit outlet valve (2), close it and connect the air net to the valve. Connect condensate drain valve (4) of the air receiver to a drain collector. Close the valve. Oil system OS 1 SG 7 AF 55675F Oil level sightg/ass, GX2 up to GX5 Instruction manual Step Action If more than 3 months have passed between assembly and installation, be sure to lubricate the compressor before starting up: • Remove the front panel. • Unscrew the fixing bolts in the top and remove the panel. • Unscrew the cover of the air filter (AF) and remove the filter element. • Open valve (7) and drain approx. 0.2 1 (0.05 US gal / 0.04 Imp gal) of oil into a clean receptacle. Carefully pour this oil through the filter housing into the compressor element. • Fit the air filter and screw on the filter cover. • Refit the top and front panels. Check the oil level. The oil level sight -glass (SG) must be above the minimum level. If the oil level is below the minimum level, top up to the middle. Do not overfill. Always use the same type of oil. n A J'+ Instruction manual Start-up Label on the top Step Action 1 Check that all panels of the compressor housing are fitted. Check that sheet (5) (explaining the procedure for checking the motor rotation direction) is affixed to the cooling air outlet of the compressor (grating on the compressor top). Consult Dimension drawings. Switch on the voltage. Run the compressor for 1 second by briefly toggling switch (1) to position I and stop after 1 second by turning the switch to position O. Check the rotation direction of the motor. If the motor rotation direction is correct, the label on the top grating will be blown upwards. If the sheet remains in place, the rotation direction is incorrect. If the rotation direction is incorrect, switch off the voltage, open the isolating switch and reverse two incoming electric lines. All electrical work should be carried out by professionally qualified people. 2 Start and run the compressor for a few minutes. Check that the compressor operates normally. 4.2 Starting 55617F Air outlet valve 2 Instruction manual Pressure gauge Starting the air dyer on GX2 up to GX5 Full -Feature Gpa Dryer onloff switch Step Action 1 Switch on the voltage to the dryer and start it by moving switch (3) to I. A• Switch on the dryer before turning on the compressor • The dryer must be kept running while the air compressor is operating to ensure that the air piping remains condensate -free. • If the dryer is switched off, wait at least 5 minutes before restarting the dryer; this allows for balancing of the internal pressure in the dryer. 36 Instruction manual Starting the compressor T Timer drain (Rear side of the dryer) F1 Compressor switches Step Action 1 Check the oil level sight -glass (SG). The oil level should be in the middle. If it is below the minimum level, top up to the middle. Do not overfill. 2 Switch on the voltage. 3 Open air outlet valve (2). 4 Move start/stop switch (1) to position I. If the compressor has been exposed to low temperatures (below 01C/321F), it may have difficulty starting due to high oil viscosity. In this case, depress yellow button (5) while starting using button (1). Button (5) should only be depressed for a few seconds while starting. Button (5) should only be used if experiencing difficulty due to low temperatures. 5 Regularly check the working pressure (Gpa). 6 For Full -Feature compressors, regularly check that condensate is drained (T) during running. 4.3 Stopping 55617F` Air outlet valve 2 Dryer on/off switch 3 5560OF Dryer on/off switch Instruction manual Instruction manual Step Action 1 Move start/stop switch (1) to position 0. On Full -Feature units: move switch (3) of the dryer to position 0. 2 Close air outlet valve (2) and switch off the voltage to the compressor. On Full -Feature units: switch off the voltage to the dryer. 3 Open condensate drain valve (4) of the air receiver for a few seconds to drain any condensate and then close the valve. The air dryer and the air receiver remain under pressure. The PDX filter (if installed) remains under pressure. If maintenance or repair work is necessary, consult the Problem solving section for all relevant safety precautions. 4 Wait at least 30 seconds before restarting the machine. 4.4 Taking out of operation 55617F Air outlet valve 2 Condensate drain valve In ou Instruction manual 3 Filler plug, GX2 up to GX5 This procedure should be carried out at the end of the compressor's service life. Step Action 1 Stop the compressor and close the air outlet valve (2). 2 Switch off the voltage and disconnect the compressor from the mains. 3 Depressurise the compressor by opening plug (3) one turn. Open condensate drain valve (4). 4 Shut off and depressurise the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet valve from the air net. 5 Drain the oil and condensate circuits. 6 Disconnect the compressor condensate outlet and valve from the condensate net. Instruction manual 5 Maintenance 5.1 Preventive maintenance schedule Warning Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Switch off the voltage and open the isolating switch. • Close the air outlet valve and open the manual condensate drain valves. • Depressurise the compressor. For detailed instructions, see Problem solving. The operator must apply all relevant Safety precautions. Warranty -Product Liability Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. General When servicing, replace all removed gaskets, 0 -rings and washers. Intervals Carry out maintenance at the interval which comes first. The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor. The "longer interval" checks must also include the "shorter interval" checks. Preventive maintenance schedule for GX2 up to GX5 Running hours Operation 50 Drain the condensate from the receiver. Check the oil level. For Floor -mounted versions: clean the prefilter on the rear side of the compressor. 500 Clean the air filter. " For Full -Feature versions: check that condensate from the dryer is drained automatically. " For Full -Feature versions: clean the condenser of the dryer. Check the belt tension. For compressors with PDX filter: check the service indicator, replace the filter if necessary. 2000 Replace the air filter. If Atlas Copco Roto -Inject Fluid is used, change the oil. 41 Instruction manual Running hours Operation Replace the oil filter. For compressors with PDX filter: replace the filter. 4000 Clean the finned surface of the oil cooler. Replace the oil separator. Have the safety valve tested. 5.2 Drive motor Description The motor bearings are greased for life. 5.3 Oil specifications ANever mix oils of different brands or types. It is strongly recommended to use Atlas Copco Fluid (see Preventive maintenance schedule). Atlas Copco Roto -Inject Fluid Atlas Copco Roto -Inject Fluid is special oil for oil -injected scroll and screw compressors which keeps the compressor in excellent condition. Roto -Inject Fluid can be used for compressors operating at ambient temperatures between 0°C (32°F) and 40°C (1040F)(see Service kits). 5.4 Oil, filter and separator change Important Never mix oils of different brands or types. If the compressor is exposed to external pollutants, is being used at high temperatures (oil temperature above 90°C / 194°F) or is being used under severe conditions, it is advisable to change the oil more frequently. Consult Atlas Copco. 42 Instruction manual GX2 up to GX5 8 7 6 5 Step Action 1 Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. 2 Remove the front and top panels. 3 Depressurise the compressor by unscrewing filler plug (8) one turn to permit any pressure in the system to escape. 4 Depressurise the air receiver by opening drain valve (4). 5 Drain the oil by opening drain valve (5). Close the valve after draining. Deliver the spent oil to the local oil collection service. 6 Remove oil filter (3) and separator (2). Clean the seats on the manifold. 7 Oil the gaskets of the new filter and separator and screw them into place. Tighten firmly by hand. 8 Remove filler plug (8) and fill oil tank (7) with oil until the level reaches the middle of sight -glass (6). Ensure no dirt gets into the system. Refit and tighten filler plug (8). 9 Unscrew the air filter cover (1), remove the filter element and carefully pour approx. 0.1 1 (0.03 US gal / 0.02 Imp gal) of oil into the compressor element. Do not overfill. 10 Re -assemble the inlet filter 11 Fit the bodywork panels. 12 Close drain valve (4) of the air receiver. 13 Run the compressor for a few minutes. Check the oil level. AO `+J 5.5 PDX filter change Oil filler plug Instruction manual GX2 up to GX5 Drain valve, air receiver 3 f4 55699F GX2 up to GX5 Step Action 1 Stop the compressor, close the air outlet valve, switch off the voltage and depressurise by unscrewing oil filler plug (3) one turn to permit any pressure in the system to escape. Depressurise the air receiver by opening condensate drain valve (4). 2 Unscrew the vessel. A whistling noise will warn you if the vessel is not fully depressurised. If this occurs, the vessel should be screwed back and the venting should be repeated. 3 Discard the filter element. 4 Clean the vessel and replace its O-ring. 5 Fit the new filter element. 6 Refit the vessel. 7 Tighten oil filler plug (3). 8 Close condensate drain valve (4). A A YY Instruction manual 5.6 Storage after installation If the compressor is stored without running from time to time, consult Atlas Copco as protective measures may be necessary. 5.7 Service kits Service kits Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. The kits comprise all parts needed for servicing. Service kits Content Ordering number Filter kit Air filter, oil filter and oil separator 2901 0865 01 Air filter kit Filter cartridge 1622 0658 00 Oil filter kit Filter cartridge 2903 0337 01 Oil separator kit Filter cartridge 1622 0623 01 PDX kit Filter cartridge 2901 0867 00 Roto -Inject Fluid 5 -litre (1.32 US gal / 1.10 Imp gal / 0.18 cu.ft) can 2901 0245 01 Roto -Inject Fluid 20 -litre (5.28 US gal / 4.40 Imp gal / 0.70 cu.ft) can 2901 0522 00 Roto -Inject Fluid 209 -litre (55.18 US gal / 45.98 Imp gal / 7.32 cu.ft) can 2901 0045 01 45 Instruction manual 6 Adjustments and servicing procedures 6.1 Air filter Changing the air filter 55665'F Position of air filter for GX2 up to GX5 Air filter change on GX2 up to GX22 Step Action 1 Stop the compressor, close the air outlet valve and switch off the voltage. 2 Remove the front panel and the top panel of the compressor housing. 3 Unscrew the filter cover (1) and remove the filter element. Discard the air filter element. 4 Fit the new element and screw on the filter cover. 5 Refit the top and front panels. A C �tv Instruction manual 6.2 Coolers 55683F GX2 up to GX5 Co Step Action 1 Keep oil cooler (Co) clean to maintain the cooling efficiency. 2 Stop the compressor, close the air outlet valve and switch off the voltage. Remove any dirt from the cooler with a fibre brush. Never use a wire brush or metal objects. Then clean using an air jet. 6.3 Safety valve 47 Instruction manual 55605F' 3 Filler plug, GX2 up to GX5 Testing The valve can be tested on a separate compressed air line. Before removing the valve: stop the compressor; on a Full -Feature unit also stop the dryer. Close the air outlet valve, switch off the voltage, open drain valves (4 if fitted) and unscrew filler plug (3) one turn to permit any pressure in the system to escape. If the valve does not open at the set pressure stamped on the valve, replace the valve. No adjustments are allowed. Never run the compressor without a safety valve. 6.4 Belt set exchange and tensioning GX2 up to GX5 48 5288OF Instruction manual Read the warning in the Preventive maintenance schedule section. Adjusting the tension of the drive belt for GX2 up to GX5 Step Action 1 Stop the compressor, close the air outlet valve and switch off the voltage. For Full -Feature versions: also stop the dryer. 2 Remove the front panel of the compressor housing. 3 Remove the side, back and top panels of the compressor housing. 4 Loosen the 4 bolts (2) by one turn. 5 Adjust the belt tension by turning tensioning nut (1). 6 The tension is correct when a force of 50 N (11.25 Ibf) applied at the midpoint of the belt causes a deflection of 6 mm (0.23 in). 7 Retighten bolts (2). 8 Refit the bodywork panels. Replacing the drive belt on GX2 up to GX5 Step Action 1 Stop the compressor, close the air outlet valve and switch off the voltage. For Full -Feature versions: also stop the dryer. 2 Remove the front panel of the compressor housing. 3 Remove the side, back and top panels of the compressor housing. 4 Loosen the 4 bolts (2) by one turn. 5 Release the belt tension by loosening tensioning nut (1). 6 Remove the fan cowl. 7 Remove the belt via the fan cowl opening. Install the new belt via the same opening. 8 Tension belt (3) as described above. 9 Re -assemble the fan cowl. 10 Refit the bodywork panels. 11 Check the belt tension after 50 running hours. A n .+V 7 Problem solving 7.1 Problem solving Start/stop switch Air outlet valve Oil filler plug 55600 F GX2 up to GX5 55617F GX2 up to GX37 1 2 55605E GX2 up to GX5 Instruction manual Instruction manual Drain valve, air receiver Dryer on/off switch 55604F GX2 up to GX5 Attention Faults and remedies For all references given hereafter, see Air flow diagram, Initial start-up or Regulating system. .71 Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions. Before carrying out any maintenance or repair work on the compressor: move start/ stop switch (1) to position 0. Move dryer on/off switch (6) to position 0. Wait until the compressor has stopped and switch off the voltage. See Stopping section. Open the isolating switch to prevent an accidental start. Close air outlet valve (2) and depressurise the compressor by opening plug (3) one turn. Open manual condensate drain valves (4 and/or 5). The air outlet valve (2) can be locked during maintenance or repair as follows: • Close the valve. • Remove the screw fixing the handle with the wrench delivered with the compressor. • Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body. • Fit the screw. Faults and remedies For all references given hereafter, see Air flow diagram, Initial start-up or Regulating system. .71 Instruction manual Compressor of GX2 up to GX5 Air dryer of GX2 up to GX5 Condition Fault Remedy 1 The machine does not start No power Check power supply through the dryer Fuse (F1) blown Replace fuse The main motor thermal Check and let motor cool down; to 2 Condensate in the piping protection has tripped reset/restart, move compressor The dryer is working outside start/stop switch to 0, then to 1 2 The machine does not start, Oil cooler is dirty Clean cooler high oil temperature lamp is condenser and check operation of on (temperature switch fan 3 tripped) The dryer is working outside Check room temperature - air hot (above 55°C / 1310F) - Ambient temperature too Improve ventilation in compressor motor overload high room Oil level too low Top up oil tank 3 The compressor does not Blow -off solenoid valve (Y1) Check; replace valve if necessary reach working pressure remains open refilled 4 Excess oil consumption Oil separator (OS) clogged Replace oil separator not start Oil level too high Drain to correct level Air dryer of GX2 up to GX5 Condition Fault Remedy 1 No compressed air passes Pipes are frozen inside Hot -gas by-pass valve through the dryer malfunctioning; consult Atlas Copco 2 Condensate in the piping Insufficient condensate drain Check the operation of timer (T) The dryer is working outside Check room temperature - air its rating temperature at dryer. Clean the condenser and check operation of fan 3 The compressor head is very The dryer is working outside Check room temperature - air hot (above 55°C / 1310F) - its rating temperature at dryer. Clean the motor overload condenser and check operation of fan Insufficient refrigerant in Have system checked for leaks or dryer refilled 4 The motor hums and does Line voltage too low Check power supply not start The machine was switched Wait a few minutes before starting off and on again too rapidly the machine again (not enough time for the pressure equalization) Instruction manual 8 Technical data 8.1 Readings on control panel GX2 up to GX5 ff s Hm 55630F The readings mentioned below are valid under the reference conditions (see Reference conditions and limitations). Ref. Name Gpa Air outlet pressure Reading: Modulates between preset unloading/stopping pressure and loading pressure Hm Hour meter Reading: Total running time 53 Instruction manual 8.2 Settings for overload relay and fuses GX2 and GX3 Frequency (Hz) Voltage (V) Overload relay Q21 (A) of GX2 Main fuses, compressor supply (A) of GX2 Overload relay Q21 (A) of GX3 Main fuses, compressor supply (A) of GX3 Main fuses, dryer supply (A) IEC DOL gL/gG gL/gG gL/gG 50 230 13.9 16 17.4 16 10 50 400 8 10 10 10 10 60 230, 1 -ph 18.4 32 22 32 10 60 380 6.4 20 11.8 - 10 CSA/UL DOL CSA -UL CSA -UL CSA -UL 60 208 11.6 20 - - 10 60 230, 1 -ph 18.4 32 22 32 10 60 220/230 10.7 20 - - 10 60 440/460 5.4 20 - - 10 60 575 4.3 20 - - 10 GX4 and GX5 Frequency (Hz) Voltage (V) Overload relay 021 (A) of GX4 Main fuses, compressor supply (A) of GX4 Overload relay Q21 (A) of GX5 Main fuses, compressor supply (A) of GX5 Main fuses, dryer supply (A) IEC DOL gL/gG gL/gG gL/gG 50 230 19.1 20 23.5 25 10 50 400 11 16 13.5 16 10 60 230, 1 -ph 24.6 50 33.9 50 10 60 380 10.6 20 11.8 20 10 IEC Star -delta gL/gG gL/gG gL/gG 50 230 19.1 20 23.5 25 10 50 400 11 16 13.5 16 10 CSA/UL DOL CSA -UL CSA -UL CSA -UL 60 208 15 20 21.5 32 10 60 230, 1 -ph 24.6 50 33.9 50 10 60 220/230 13.8 20 19.6 32 10 60 440/460 6.9 20 9.8 32 10 60 575 5.5 20 7.8 20 10 GA J "t' Instruction manual 8.3 Reference conditions and limitations Reference conditions Air inlet pressure (absolute) bar 1 Air inlet pressure (absolute) psi 14.5 Air inlet temperature °C 20 Air inlet temperature OF 68 Relative humidity % 0 Working pressure bar(e) See Compressor data Working pressure psi See Compressor data Limitations Maximum working pressure bar(e) See Compressor data Maximum working pressure psig See Compressor data Minimum working pressure bar(e) 4 Minimum working pressure psig 58 Maximum air inlet temperature °C 46 Maximum air inlet temperature OF 115 Minimum ambient temperature °C 0 Minimum ambient temperature OF 32 8.4 Compressor data 50 Hz 10 bar (under reference conditions) Compressor type GX2 GX3 GX4 GX5 Frequency Hz 50 50 50 50 Maximum (unloading) pressure, Pack bar(e) 10 10 10 10 Maximum (unloading) pressure, Pack psig 145 145 145 145 Maximum (unloading) pressure, Full -Feature bar(e) 9.75 9.75 9.75 9.75 Maximum (unloading) pressure, Full -Feature psig 141 141 141 141 Nominal working pressure bar(e) 9.5 9.5 9.5 9.5 Nominal working pressure psig 138 138 138 138 Pressure drop over dryer bar(e) 0.15 0.15 0.15 0.15 Pressure drop over dryer psig 2.18 2.18 2.18 2.18 Motor shaft speed rpm 3000 3000 3000 3000 Set -point, thermostatic valve °C 71 71 71 71 55 Instruction manual Compressor type GX2 GX3 GX4 GX5 Set -point, thermostatic valve OF 160 160 160 160 Temperature of air leaving receiver (approx.), Pack °C 33 33 33 33 Temperature of air leaving receiver (approx.), Pack OF 91 91 91 91 Pressure dew -point, Full- Feature °C 3 3 3 3 Pressure dew -point, Full- Feature OF 37 37 37 37 Power input, Pack at maximum working pressure kW 3.8 4.1 4.9 6.6 Power input, Pack at maximum working pressure hp 5.1 5.5 6.57 8.85 Power input, Full -Feature at maximum working pressure kW 4.1 4.4 5.2 6.9 Power input, Full -Feature at maximum working pressure hp 5.5 5.9 6.97 9.25 Power consumption, dryer at full load kW 0.3 0.3 0.3 0.3 Power consumption, dryer at full load hp 0.4 0.4 0.4 0.4 Power consumption, dryer at no load kW 0.2 0.2 0.2 0.2 Power consumption, dryer at no load hp 0.27 0.27 0.27 0.27 Refrigerant type R134a R134a R134a R134a Total amount, refrigerant kg 0.4 0.4 0.4 0.4 Total amount, refrigerant Ib .0.88 0.88 0.88 0.88 Oil capacity 1 2.5 2.5 2.5 2.5 Oil capacity US gal 0.66 0.66 0.66 0.66 Oil capacity Imp gal 0.55 0.55 0.55 0.55 Oil capacity cu.ft 0.09 0.09 0.09 0.09 Sound pressure level (according to ISO 2151 (2004)) dB(A) 61 61 62 64 60 Hz 10 bar (under reference conditions) Compressor type GX2 GX4 GX5 Frequency Hz 60 60 60 Maximum (unloading) pressure, Pack bar(e) 10 10 10 Maximum (unloading) pressure, Pack psig 145 145 145 Maximum (unloading) pressure, Full -Feature bar(e) 9.75 9.75 9.75 Maximum (unloading) pressure, Full -Feature psig 141 141 141 Nominal working pressure bar(e) 9.5 9.5 9.5 Nominal working pressure psig 138 138 138 Instruction manual Compressor type GX2 GX4 GX5 Pressure drop over dryer bar(e) 0.15 0.15 0.15 Pressure drop over dryer psig 2.18 2.18 2.18 Motor shaft speed rpm 3495 3490 3495 Set -point, thermostatic valve °c 71 71 71 Set -point, thermostatic valve OF 160 160 160 Temperature of air leaving receiver (approx.), Pack °c 33 33 33 Temperature of air leaving receiver (approx.), Pack OF 91 91 91 Pressure dew -point, Full -Feature °c 3 3 3 Pressure dew -point, Full -Feature OF 37 37 37 Power input, Pack at maximum working pressure kW 3.7 4.7 6.3 Power input, Pack at maximum working pressure hp 4.96 6.3 8.45 Power input, Full -Feature at maximum working pressure kW 4 5 6.6 Power input, Full -Feature at maximum working pressure hp 5.36 6.71 8.85 Power consumption, dryer at full load kW 0.3 0.3 0.3 Power consumption, dryer at full load hp 0.4 0.4 0.4 Power consumption, dryer at no load kW 0.2 0.2 0.2 Power consumption, dryer at no load hp 0.27 0.27 0.27 Refrigerant type R1 34a R134a R1 34a Total amount, refrigerant kg 0.4 0.4 0.4 Total amount, refrigerant Ib 0.88 0.88 0.88 Oil capacity 1 2.5 2.5 2.5 Oil capacity US gal 0.66 0.66 0.66 Oil capacity Imp gal 0.55 0.55 0.55 Oil capacity cu.ft 0.09 0.09 0.09 Sound pressure level (according to ISO 2151 (2004)) dB(A) 61 62 64 57 Instruction manual 9 Instructions for use of air receiver 9.1 Instructions for use 1 This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. 2 This vessel must only be used as compressed air/oil separator and must be operated within the limits specified on the data plate. 3 No alterations must be made to this vessel by welding, drilling or other mechanical methods without the written permission of the manufacturer. 4 The pressure and temperature of this vessel must be clearly indicated. 5 There is no intrinsic need for service inspection of the vessel when used within the design limits for its intended application. 6 Corrosion must be prevented under the conditions of use. Condensation may accumulate inside the tank and this must be drained every day. This may be done manually, by opening the drain valve, or by means of the automatic drain, if fitted to the tank. =0 UO Instruction manual 10 PED 10.1 Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category II Compressor type Part number Description PED Class GX2 up to GX5 2200 9507 74 Safety valve IV 2200 9507 75 Safety valve IV Overall rating The compressors conform to PED smaller than category 1. 59 GX 2, GX 3, GX 4, GX 5 Instruction Book What sets Atlas Copco apart as a company is our conviction that we can only excel in what we do if we provide the best possible know-how and technology to really help our customers produce, grow and succeed. There is a unique way of achieving that - we simply call it the Atlas Copco way. It builds on interaction, on long-term relationships and involvement in the customers' process, needs and objectives. It means having the flexibility to adapt to the diverse demands of the people we cater for. It's the commitment to our customers' business that drives our effort towards increasing their productivity through better solutions. It starts with fully supporting existing products and continuously doing things better, but it goes much further, creating advances in technology through innovation. Not for the sake of technology, but for the sake of our customer's bottom line and peace -of -mind. That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and to maintain our position as the industry leader. Document: GX 2-5 PD001 Page: 1 of 2 Date: 3/29/2005 AML: 9820405701 GX2-5 Oil Injected Screw Compressors Air Cooled 3 thru 7.5 Horsepower MODEL Unit GX 2 GX4 GX5 General Horsepower HP 3 5 7.5 Capacity-FAD CFM 8.5 16.5 21.2 Operating Pressure 2 PSIG 145 145 145 Min Operating Pressure PSIG 58 58 58 Max Operating Pressure 2 PSIG 145 145 145 Drive System V -Belt V -Belt V -Belt Power Requirements Compressor (Shaft) BHP 4.2 5.5 7.5 Total Package Input (Pack Unit) BHP 4.2 5.5 7.5 Cooling Cooling Medium Maximum Ambient Temperature OF 104 104 104 Minimum Ambient Temperature OF 32 32 32 Package BTU Rejection Pack BTU/hr 12,131 15,409 20,654 Full Feature BTU/hr 13,114 16,392 21,638 Outlet Temperature above ambient Pack OF 17 24 27 Full Feature OF 2 12 18 Oil Capacity Gal 0.66 0.66 0.66 Cooling Air Flow Pack CFM 339 424 636 Noise Level 3 Pack dB(A) 61 62 64 Full Feature dB(A) 61 62 64 Drive Motor Data Manufacturer WEG WEG WEG Enclosure TEFC TEFC TEFC Insulation Class F, B rise Class F, B rise Class F, B rise RPM 3495 3490 3495 Notes: 1. FAD (Free Air Delivery) measured according to ISO1217, Ed. 3, Annex C-1996 2. On Full Feature units, dryer module air pressure drops must be included 3. Noise level measured according to ISO 2151 iWascopeo Document: GX 2-5 PD001 Page: 2 of 2 Date: 3/29/2005 AML: 9820405701 GX2-5 Oil Injected Screw Compressors Air Cooled 3 thru 7.5 Horsepower wf-- M DEL Unit GX 2 GX4 GX5 Dimensions 4 Tank Mtd 60 Gal. (LxWxH) in 56x22x50 56x22x50 56x22x50 Discharge Valve Connection in NPT 1/2 1/2 1/2 Condensate Drain Connections in NPT 3/8 3/8 3/8 Weights (approximate) Tank Mtd 60 Gal. (Pack / Full Feature) Net lbs 3371412 351/425 362/437 Shipping lbs 513/588 527/601 538/613 Refrigerated Dryer (Full Feature only) Dryer module DLX1 DLX1 DLX1 Compressor rating (nominal) HP 0.4 0.4 0.4 Pressure dewpoint 5 °F 35-39 35-39 35-39 Pressure drop at nominal capacity PSIG 2.2 2.2 2.2 Cooling air flow CFM 318 318 318 Refrigerant type R134A R134A R134A Refrigerant charge lbs 0.88 0.88 0.88 Input power Compressor KW 0.3 0.3 0.3 Fan Motor KW 0.1 0.1 0.1 Recommended Filter 6 1.0 micron DDp 9 9 9 0.01 micron / 0.01 PPM liquid DD 9 9 9 0.01 micron / 0.01 PPM liquid PD 9 9 9 0.01 micron / 0.01 PPM liquid QD 9 9 9 Notes: 4. Discharge valve adds approximately 3 inches to installed length 5. Dewpoint at standard Atlas Copco ref. Conditions 6. At 145 psig (Ref. Filter Price Book Section correction factors for other pressures) Atlas Copco Oil -injected Rotary Screw Compressors GX 2-11 2-11 kW/3-15 hp 101 compact screw compressors built to last Atlas Copco screw compressors have always set the standard for reliability and performance in the compressed air industry. With the new GX 2-11, Atlas Copco brings the power and reliability of an industrial screw compressor to small and medium sized industry. The advanced sound dampening of these units ensures silent power while simple reliability is guaranteed as the GX is suitable for 100% continuous duty. COMPLETE COMPRESSED AIR INSTALLATION The GX 2-11 is delivered with all of the components required for a complete installation. Suitable for customers who have limited space, the package has a minimum footprint. The GX is also available with a built-in dryer to reduce the space requirements even further. In addition, all air connections have been optimized to minimize pressure drop and potential air leaks. SIMPLE AND QUICK MAINTENANCE • Service points are grouped together and accessible through the removable front panel. • Spin -on oil separator and filter for quick maintenance. o • • • • ' • Oil level display. o Set to meet your specific requirements and tackle your daily challenges, Atlas Copco offers you the GX, by far the most powerful and reliable compressed air solution. Immediately ready to supply high quality air, this solution provides you with the exceptional power and reliability you are looking for. BUILT-IN RELIABILITY • Rugged screw compressor technology allows for a 100% continuous duty cycle. • Maximum mechanical simplicity providing increased dependability. • All oil lines are rigid pipe or high temperature hose. • No plastic oil tubing is used. • All electrical wiring is done with heavy-duty cable and high quality connectors. • Low operating temperature insures long life and eliminates the necessity for an aftercooler. • The GX package includes the main switch with integrated circuit breaker to protect the compressor. High-quality clean and dry air Moisture, dirt particles and aerosols in plant air can damage your piping,, compressed air tools and machinery as Well your end products. To keep production operations running smoothly, you are in need of clean and dry: compressed air. The GX 2-11 compressors can be equipped with an integrated dryer, an in-line air filter - and electronic drain option. o FULL FEATURE AIR DRYER The GX 2-11 is available with an advanced built-in refrigerant air dryer. This dryer cools the compressed air and removes water vapor before it can enter your compressed air network preventing rust in your compressed air piping and avoiding damage to your air tools. p l� ................... K;11. o ELECTRONICRECEIVER Compressed air receivers drainage to remove any With the electronic drain automatically and efficiently. t DRAIN PDX HIGH EFFICIENCY AIR FILTER always require periodic All oil -lubricated compressors expose your condensate that may accumulate. vapors. These oil vapors, combined with option, this operation is handled can create an abrasive oil sludge. The best tools and machinery is to install an in-line o ' compressed air to oil atmospheric pollutants, way to protect, your PDx air filter. FLOW CHART AIR FLOW REFRIGERANT FLOW Intake air 1. Inlet air filter 12. Evaporator ® A-': 2. Inlet check valve 13. Refrigerant compressor � l " r -= '; - Air/oil mixture 3. Compression element _ \a 14. Condenser u I Oil 4. Oil separator element 15. Capillary tube 5. Minimum pressure valve 16. Water separator - -i, ®,. ® Wet air 6. Aftercooler Dry air 7. Air receiver A - Full Feature B - PDx high efficiency air filter Water OIL FLOW C - Electronic receiver drain 4 ANY Refrigerant gas 11. Oil reservoir - ®� 0 '.: ®` _ Refrigerant liquid 12. Oil cooler - 13. Thermostatic valve block 14. Oil filter ,? r Typical flowchart forthe GXTIT FF -------------------- Technical specifications Mean noise level measured according measured according to ISO standard. Standard air receiver size, GX 2-5: 2001/60 gal, GX 7-77:270 U72 gal. w GX 7-11 FF Floor Mounted GX 7-11 FFTank Mounted r H In order to be First in Mind—First in Choice' for all your compressed air needs, Atlas Copco delivers the products and services that help increase your business' efficiency and profitability. Atlas Copco's pursuit of innovation never ceases, driven by your need for reliability and efficiency. Always working with you, we are committed to providing you the customized quality air solution that is the driving force behind your business. 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A. oy Pajv— a Buurq�v�ruw m1 P.- papm 'Pa+aliv 1 w ssaua0 .nv i�43� iau IIN4 W .lS�atloA . s S—P sol roa.y p uovvaE as Nu 6Na — BWNPap. J. a4va.pvl .+mn lw qg 'Px4-8 �rwe � o. a�.aay:aoy aap,oz f:�, laz �a .�p,acw azw s. aaawiw an — _I C CO Q T U / \ - T W O N N N M c c a z w a u-� R' d z _ o Li 3 6m Mw In -�. N Z J 3 d Q U Cu V In Z .-C w> o n t z ZD > MI LL) W Z J 9'9Z E'9 z - ED U --An y I N M n Z J 8 J z O O 4Y , .n ..M a . A. oy Pajv— a Buurq�v�ruw m1 P.- papm 'Pa+aliv 1 w ssaua0 .nv i�43� iau IIN4 W .lS�atloA . s S—P sol roa.y p uovvaE as Nu 6Na — BWNPap. J. a4va.pvl .+mn lw qg 'Px4-8 �rwe � o. a�.aay:aoy aap,oz f:�, laz �a .�p,acw azw s. aaawiw an — _I AIRT=CH'R 3BA1630 Vacuum/Pressure da7wWb&V Regenerative Blower Features: • Cooler running, outboard bearing provides maintenance -free operation • Environmentally friendly oil -free technology • Extremely quiet operation Performance curve for Vacuum pump 350 300 so H E / 250 A 241 / T A 243 / a 200 x / A 240 C / g 150 A 245 .� A 242 100 A 247 / A 244 • 50 A 246 0 140 120 100 80 60 40 20 0 ch Hz0 *nA p total pressure difference (vacuum) 7.5 A 2477 6.0 a � � A 245 d2 �y 4.5 A 246 - �\ a m A 243 a) n 3.0 A 244 `w A 241 a E A 242 a) A 240 \ a 1.5 s o c CL 0.0 140 120 100 80 60 40 20 0 nch Hz0 + A p total pressure difference (vacuum) 300 LL A 246 250 A 247 200 a, A 244 c 150 a� @ z Z� \ A 242 E2 'm 100 A 245 A 240 at 0 50 A 243 -- — A 241 0 140 120 100 80 60 40 20 f inch H 0 A total pressure difference vacuum P P (vacuum) AIRT=CH° ENGLEWOOD, NJ 07631 "'777ko *All motors are standard TEFC with Class F insulation, UL recognized, CE Compliant Explosion -Proof motors available • Custom construction blowers are available • Rugged die cast aluminum construction Performance curve for Compressor 350 - - so H� so H� 300 v \ A 241 250 A 243 U \� a 200 A 240 A 245 U \ oA 242\^ \ v 150 A 247 A 244 100 A 246 50 0 0 20 40 60 80 100 120 140 total pressure difference (gauge) Ap inch } 7.5 I , .A 247 6.0 IL i o_ = A 245 A 246 aci 4.5 '✓ L A243 i A 241 -✓ A 244 3.0 A a a / A 242 3.r�.. 1.5 �A240 a o 0.0 0 20 40 60 80 100 120 140 total pressure difference (gauge) Ap inches 300 LL c 250 ~ 200 A 246 a c 150 � m � L A 245 i A 247 100 A 243 d a) A 241 - A 244 ns _ _ E o 50 — - — A 242 A 240 0 0 20 40 60 80 100 120 140 total pressure difference (gauge) A inches WWW.AIRTECHUSA.COM TEL: (888) 222-9940 FAX: (201) 569-1696 3BA1630-062408 %d IRT= C H" 3BA1630 Vacuum/Pressure daCMu,gu=55,,v Regenerative Blower Specifications subject to change without notice. Please contact factory for specification updates. Recommended Accessories: Relief valve: VC61Z (Vacuum) PC61Z (Pressure) Filter: ATF -200-15124/1 (Vacuum) AF -S30-200-10 (Pressure) Selection & Ordering Data - Type 3BA1630 Curve Order No. Fre- Rated nil Input 0401 Sound Weight No. quency power current differential pressure pressure O Specifications subject to change without notice. Please contact factory for specification updates. Recommended Accessories: Relief valve: VC61Z (Vacuum) PC61Z (Pressure) Filter: ATF -200-15124/1 (Vacuum) AF -S30-200-10 (Pressure) Selection & Ordering Data - Type 3BA1630 Curve Order No. Fre- Rated Input voltage Input Permissible total Sound Weight No. quency power current differential pressure pressure level Vacuum Compressor Hz HP V A inch H2O inch H2O dB(A) lbs 3-- 50/60 Hz IP55 insulation material class F A 240 3BA1630-7AT06 50 2.14 200D ... 240D 345Y ... 415Y 8.5D 4.9Y -40 36 70 59 A 241 3BA1630-7AT06 60 2.75 220D ... 250D 415Y ... 460Y 7.51D 4AY -32 32 73 59 A 242 3BA1630-7AT16 50 2.95 200D ... 240D 345Y ... 415Y 9.71D 5.6Y -64 60 70 66 A 243 3BA1630-7AT16 60 3.42 220D ... 250D 415Y ... 460Y 9.01D 5.3Y -52 48 73 66 A 244 3BA1630-7AT26 50 4.02 200D ... 240D 345Y ... 415Y 12.51D 7.2Y -92 88 70 77 A 245 3BA1630-7AT26 60 4.62 220D ... 250D 415Y ... 460Y 12.01D 6.5Y -84 76 73 77 A 246 3BA1630-7AT36 50 5.36 200D ... 240D 345Y ... 415Y 15.61D 9.OY -116 124 70 95 A 247 3BA1630-7AT36 160 16.17 1 220D ... 250D 415Y ... 460Y 15.21D I 8.5Y 1 -120 1 112 173 195 Suitable for 208 Volt Operation AIRT=CH° ENGLEWOOD, NJ 07631 WWW.AIRTECHUSA.COM TEL: (888) 222-9940 FAX: (201) 569-1696 MGQC�77"w 3BA1630-042208 Eni, I �, FASI�:: PIS r� Max. Flow 13 gpm (49 Ipm) O.D. 3.5 in (8.9 cm) ottom Inlet, Short Description. The AP4 Bottom Inlet Short. AutoPump provides maximum capabilities and flow in a bottom inlet pump for 4" (100 mm) diameter and larger wells with shorter water columns and/or - the need to pump down to lower water levels, compared to full-length pumps. It offered in optional versions to handle even the most severe remediation and landfill pumping applications, and delivers flow rates up to 13 gpm (49'lpm)* The AP4 Short Bottom Inlet AutoPump is I ` complemented by the most comprehensive selection of accessories to provide a complete system to meet site specific requirements. Call QED for prompt, no -obligation - assistance on your pumping project needs: The AutoPump Heritage The AP4 Bottom Inlet Short AutoPump ispartof the famous AutoPump family, of original automatic air -powered pumps, developed in the mid 1980s specifically to handle unique pumping needs at remediation and ;landfill sites. - - Over the years they've proven their durability at thousands of sites worldwide. AutoPumps are designed to handle difficult pumping challenges that other pumps can't, such as hydrocarbons, solvents, suspended solids, corrosives, Advantages temperature extremes, viscous fluids and frequent start/ stop cycles. Beyond just the. pump, AutoPump systems 1. The original automatic air- offer the most complete range of tubing, hose, connectors, powered well pump, proven wellhead caps and accessories to help your installation go worldwide over 18 years smoothly. This superior pumping heritage, application experience and support back up every AutoPump you put 2. The highest flow rates and to work on your project. deepest pumping capabilities in the industry 3. Patented, proven design for superior reliability and durability, even in severe applications 4. Handles solids, solvents, hydrocarbons corrosive conditions, viscous fluids and high temperatures beyond the limits of electric pumps 5. Five-year warranty *Consult QED for higher flow requirements VQED 10 Pump Dimensions Specifications & Operating Requirements pllodel.. -47:--„ Liquid Liquid Inlet Locatton Bottom Length Overall (pump & fittings) 41 in (104 cm) Length0ye�all, w /.Extendel.Scleen< Weight 13 lbs (5.9 kg) Liquid Discharge Pump Volume /Cycle 0.22 0.36 gal (83 1.36L) M Air Supply a .. Exhaust Max Depth .. 250 ft (16 m) Air Pressure Range 5. 1.20 psl,(0 4 .$.4 kg/crri2), , . r - AIF Usage Q.4-1.5 scf / gal (1.5 51 Iter of air a _ y tf igh Pressure Ptyrnp Max Depth 425 ft (130 m) _ . , < ... Air �essure Range t , 5. 2DO.,psi (tl 4 x:41 �g�cro2) �_.• .,...: m a S _ . C N m Mm Lrqurd pensrty ' 0 7 SpG (O '7-g/cm3) u, � m Standard Coitstiucfion'(gatenals'k. `o � Pump Body Fiberglass or Stainless Steel - m rump Ergs � Stainless Steel UItNVVPE�, Blass Internal Components Stainless Steel, Viton, Acetal, PVDF1 r Fitting Type, Barbs or Quick Connects Inlet Tube & Hose Options O.D. 3.5" (as mm) Sizes Liquid Discharge 1 in (25 mm) or 1-1/4 in (32 mm) OD Air Exhaust 5/8 in; (16 mm)`OD Hose��Natenal , N�rile Sizes Discharge 1 -'Liquid m (25 mm) ID PumpG' up Y �8 �� X19 mm) or Air Exhaust 1/2 in. (13 mm) ID ' Material upgrades available 3 UHMWPE - Ultra High Molecular Weight Polyethylene z Applies to QED supplied tubing; ° PUDF,- Polyumylidene Fluoride other tubing sources'may not conform to QED filtings.. Application Limits Long and short AP -4 AutoPumps are warranted for five (Base model) (5) years: 100% materials and workmanship first three AP4 AutoPumps are designed to handle . (3) years; 50% materials and workmanship for the fourth the application ranges described below. (4th) and fifth (5th) years. For applications outside these ranges, consult QED about AN upgrades.: Low -Drawdown for the AutoPumps are,warranted for one (1) Year. Maximum Temperature: 150°F (650C) pH Range: 4-9 Solvents 'sand 'Fuels: diesel, gasoline, JP1-JP6, #2 heating oils, BTEX, MTBE, landfill liquids *Consult QED for higher flow requirements 11 P.O. Box 3726 -Ann Arbor, MI 48106.3726- USA 1 S00 62Q_2026 F --1134M-5.1170 mfnanorlonv rnm - wunu.no —j—.corn Am P4B i 1 1 1 Flow Rates' 3/4 inch (19 mm) 1 inch (25.4 mm) Inside Diameter Discharge Hose Inside Diameter Discharge Hose (Equivalent. to 1 -Inch O.D. Tubing) (Equivilant to 1.25 -Inch O.D__Tubing) 6INCH (i 5 cm) SUBMERGENCE OF PUMP HEAD 6 INCH (15 cm) . SUBMERGENCE OF PUMP HEAD 18 - 68.1, 18 . 68.1 16 60.6`. 16 60.6 . GALLONS 14 - _, 53 , APPROXIMATE - GALLONS14 -,.. ; .. 53 -.: APPROXIMATE - ... PER 12 AIR INLET PRESSURES 45.4 LITERS PER 12 AIR INLET PRESSURES 45.4 LITERS+ MINUTE 37.9:.. 37 MINUTE -,ap ... .. ? 37.9. ..... _... WITH MINUTE' _. Wfili - MINUTE. 3/4 -INCH _8 30.3' WITH S 1 -INCH 8 30.3 WITH I.D.19 HOSE-...� �.. 22.71 MM I.D. HOSE '4 25.4 mm .. 1 15 1 I.D.OSE 7100 Kg/cmlz 15J. I.D. HOSE'. 710 Kg/CM 2 2 40 PSI 70 PSI 7.6 2 40 PSI 0 SI 7.6; p 3Kg/cm2 5Kg/cm2 p `. 3Kg/an2 Ljlkm2 0 0 20 40 60 8 140 160 180 200 FT. ` DEPTH 0 p 20 40 60 80 100 120 140 160 180 200 FT. DEPTH 6.1 12.218.324.430.536.642.748.854.9 61 Meters IN WELL 6.1 12.2 18.3 24A 30.5 36.6 42.7 48.8 54,9 61 Meters INWELL 2 FT. (60 cm} SUBMERGENCE OF PUMP HEAD 2 FT.(60 cm) SUBMERGENCE OF PUMP HEAD 18 68.1 18 68.1 _ 16 60.6 16 .; 60.6; GALLONS �, _ 53 APPROXIMATE - .... GALLONS 14 ; , , - -, 53 APPROXIMATE -... -. PER _ 12AIR INLET PRESSURES 45.4 LITERS PER 12AIR INLET PRESSURES 45.4 LITERS MINUTE 1037.9' _ _ _, PER MINUTE 10 _ . , - 37.9 PER .., WITH MINUTE - . ..WITH .. MINUTE .. 3/4 -INCH 8 :. 30.3... WITH ! 1 -INCH 8 30.3' WITH I.D. HOSE 6 _ 22.7 19mm I.D. HOSE 6 : - 22.7 25.4 mm ` 4 I� 12 15.1: I.D. HOSE - :, 7K I.D.HOSE' ,. .... _. _.-. 4 - /- 15.1. , _.. ,.. 2 Pml 7.6 3 KO 2 70 P51 2 40 PSI 70 P51 7.6 0 5 km 2 0 3 cm 2 2 0 20 40 60 8 140 160 180 200 FT. DEPTH 0 S K cm 0 6.1 2.2 18.3 24A 30.5 36.6 42.7 48.8 54.9 61 Meters IN WELL 0 20 40 60 80 100 120 140 1 200 FT. DEPTH 6.1 12.2 18.3 24.4 30.S16 6 42.7 48.8 54:9 61 Meters IN WELL 10 FT. (300 cm) SUBMERGENCE OF PUMP HEAD 18 68.1 10 FT. (300 cm) SUBMERGENCE OF PUMP HEAD 18 68.1; 16 60.6, 16 60.6:_ GALLONS 14 53 APPROXIMATE 14 53 PER 12 AIR INLET PRESSURES 45.4: LITERS '.. .GALLONS . , , ; , APPROXIMATE MINUTE . - .. PER PER 12 AIR INLET PRESSURES 45.4 LITERS -10 ,. 37.9-. MINUTE :. MINUTE ip 37.9: 3/41NCH - $ 30.3- yylT}I- WITH ` .. s s MINUTE. I.D. HOSE 6 22.7 19 mm 1 -INCH "8 309 WITH; 100 PSI 7K LD.HOSE LD. HOSE 6 - 100 PSI 22.7 25.4 mm 4 cm2 15.1:. 7 Kg/cm 2 I.D. HOSE 2 40 PSI 70 PSI 7.6 4 15.1 - 0 3 Kg/cm 2 S K cm 2 0 2 40 P512 70 PSI 7.6 0 20 40 60 80 100 120 140 160 180 200 FT. DEPTH 0 3 K 5 K cm 2 p 6.1 12218324.430.536.642.748.8 54.9 61 Meters IN WELL 0 20 40 60 80 100 120 140 160 180 200 FT. DEPTH 6.1 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters IN WELL 'FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE. ® VQEU 12 v � Fs "' n v„w w y $ y �• 1 'p 1 •ti �, t Bottom Inlet, Short ® . .rM 1 g 1 _y M ®/ d' M MMMMMMMM MMMMMMMMM• 1 I .1 / ® I 1 1 M :1-1- AUTO SUMP 7000 0 & M MANUAL 0 -,"i-OWER -E KE REAL ENVIRONMENTAL PRODUCTS 19550 BERRY STREET - BLDG B - UNIT A PINE GROVE, CA 9566 PHONE: 209-296-7900 FAX: 209-296-7944 1 CYCLE COUNTER f` ! 3/4' FPT CONDENSATE DISCHARGE 1 F FPT AIR IN I I Jill 1/2' FPT BALANCE LINE Jill I I I 1 I I 8' S/S BACKING RING I I I I I I AUTO DRAIN FILTER REGULATOR I 1 I 1 I I 1 I I I I 1 4' ISO WELL Q I I I I I I 1 I I I I I I 8' SDR 17 HDPE CASING DRAIN PLUG I I 1 1 I I i SHEATHED TUBING BUNDLE 11' i I I r I Fh III I 4% 1 41 11 `111 lyi i QED AP -4 SHORT PUMP I ii�11i I (PUMP NOT INCLUDED) 1I'�1 I I 7r� I \\—SS I E�9 I BOLTS WELDED TO BACKING RING Fid 1 �uq �4' INLET 300COOd Real t+ o o �+ EnvironmentO fl V. q J 12' Products 7"Sw�s AUTO SUMP 7000 7605 - DRAWN BY: T. CORSON I. Is FIGURE #1 2. 3. .9 10. n, eal rcts-k T.:,;�rrAmnmental 't 1products AUTO SUMP 7000 '07 .x� Vault: All operating components of the condensate pump and control assembly are located in a polyethylene vault that is integrally mounted on top of condensate liquid sump. Service connections, including the liquid discharge, pressure balance line, and high-pressure air inlet are grommet or bulkhead mounted on a common wall of the vault. Connec#ions: The AUTO -SUMP 7000 has the following sizes and types: Service Size Connections Furnished Compressed Air Inlet 12 - inch FNPT Condensate Liquid Discharge %- inch FNPT Pressure Equalization Line %2 -inch FNPT The condensate liquid inlet to the sump is 3 -inch diameter rated for at least 29.8 inches mercury vacuum. No PVC Pipe is used in the Auto -Sump assembly. The compressed air, liquid and equalizing tube inside the sump is constructed of nylon tube. Liquid Pump: A pneumatic, submersible, AP -4 short body pump manufactured by QED is used to transfer liquids from the sump. Pump seals, which contact liquid, shall be Vicon or Teflon_ Level Control: Internal switches in the submersible pump accomplish level control. Compressed Air System: The compressed air system includes an inlet block valve, filter with automatic drain valve, and regulator with removable seat. All components are rated for 150 PSIG. Bolts: All bolts, nuts, and washers in contact with LFG are stainless steel type 304. 1. Stainless Steel Bail Valve, Air Inlet. 2. Condensate Discharge Stainless Steel Ball Valve. 3. Isolation Well Balance Line Shut Off. 4. Sunup Balance Line Shut Off. 5. Stainless Steel Locking Latch (Typ.2) 6. Threaded Plug for Sounding. 7. Auto Drain Filter Regulator. �. Air Quick Disconnect. 9. Drain Plug (into sump). 10. Stainless Steel Hydraulic quick disconnect (condensate discharge). 1 w9 Step 1. 1. Turn the Air Shut Off valve to the off position. See # 1 Fig. 1 Step 2. 2. Turn the Condensate Discharge valve to the off position. See # 2 Fig. 1 3. Turn the Isolation Well Balance valve to the off position. See # 3 Fig. 9 4. Turn the Sump Balance valve to the off position. See #4Fig. 1 Note' Turning the Sump Balance Line to the off position may prevent condensate from draining into the sump from the header and may cause condensate in the sump to be drawn back into the header. This condition will occur if the negative pressure of the header is greater than the distance from the flow line of the header to the top of the water level in the sump. This valve can be left open while servicing the pump and not allow oxygen to enter the system if the water levet is higher than the drain holes in the isolation weIL Disconnect5. Quick Step 5. 6. Disconnect the Condensate Quick Disconnect. See # 10 Fig. 1 7. Release the stainless steel quick latches. ,See # 5 Fig. 1 R . Carefully pull the Well Head off the Isolation well, and pull the pump from the isolation Installation of Backup lump 1 . Follow Steps 6. —1. 13 gprn (49 Ipm) 3.5 in (8.9 cm) 41 in. (104 cm) j 1. The original automatic air- { powered well pump, proven worldwide over 18 years u_ 2. The highest flow rates and deepest pumping capabilities in l the industry 3. Patented, proven design for. superior reliability and durability, even in severe applications 4. Handles solids, solvents, hydrocarbons corrosive conditions, viscous fluids and high temperatures beyond the limits of electric pumps 5. Five-year warranty *Consult QED for higher flow requirements The AM Bottom Inlet Short AutoPump provides maximum capabilities and flow in a bottom inlet pump for 4' (100 mm) diameter and larger wells with shorter water columns and/or the need to pump down to lower water levels, compared to full-length pumps. It is offered in optional versions to handle even the most severe remediation and landfill pumping applications, and delivers flow rates up to 13 gpm (49 Ipm)* The AP4 Short Bottom Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site specific requirements. Call QED for prompt, no -obligation assistance on your pumping project needs. The AM Bottom Inlet Short AutoPump is part of the famous AutoPump family of original automatic air -powered pumps, developed in the mid 1980s specifically to handle unique pumping needs at remediation and landfill sites. Over the years they've proven their durability at thousands of sites worldwide. AutoPumps are designed to handle difficult pumping challenges that other pumps can't, such as hydrocarbons, solvents, suspended solids, corrosives, temperature extremes, viscous fluids and frequent start/ stop cycles. Beyond just the pump, AutoPump systems offer the most complete range of tubing, hose, connectors, wellhead caps and accessories to help your installation go smoothly. This superior pumping heritage, application experience and support back up every AutoPump you put to work on your project. m AP4 AutoPumps are designed to handle the application ranges described below. For applications outside these ranges, consult QED about AP4 upgrades. Maximum Temperature:150°F (65°C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1 JP6, #2 heating oils, BTEX, MTBE, landfill liquids *Consu6t QED for higher flow requirements Model Liauld Inlet Location OD Length Overall (pump & fittings) Length Overall, w/Extended Screen Weight Max. Flow Rate Pump Volume / Cycle Min. Actuation Level Standard Pump Max. Depth Air Pressure Range Air Usage High Pressure Pump Max. Depth Air Pressure Range 4" - Short AP4 Bottom Inlet Bottom 3.5 in. (8.9 cm) 41 in. (104 cm) 44 in. 1112 cm) 13 lbs. (5.9 kg) 13 gpm (49 Ipm)* - See Flow Rate Chart 0.22 - 0.36 gal (.83 -1.36L ) 27 in. (69 cm) 250 ft.176 m) 5 -120 psi (0:4 - 8.4 kg/cm2) 0.4-1.5 scf / gal. (1.5 - 5.7 liter of air / fluid liter) - See air usage chart 425 ft. (130 m) 5 - 200 psi (0.4 -14.1 kg/cm2) Min. Liquid Density 0.7 SpG (0.7 g/cm3) Standard Construction Materials' Pump Body Pump Ends Internal Components Tube &'Hose Fittings Fitting Type Tube & Hose. Options Tubing Matedal2 Sizes - Liquid Discharge Pump Air Supply Air Exhaust Hose Material Sizes - Liquid Discharge Pump Air Supply Air Exhaust ' Material upgrades available 2 Applies to QED supplied tubing; other tubing sources may not conform to QED fittings. Fiberglass or Stainless Steel Stainless Steel, UHMWPE', Brass Stainless Steel', Viton, Acetal, PVDF1 Brass or Stainless Steel Barbs or Quick Connects Nylon 1 in. (25 mm) or 1-1/4 in. (32 mm) OD 1/2 in. (13 mm) OD 5/8 in. (16 mm) OD Nitrile 3/4 in. (19 mm) or 1 in. (25 mm) ID 3/8 in. (9.5 mm) ID 1/2 in. (13 mm) ID '-UHMWPE - Ultra'High Molecular Weight Polyethylene PVDF - Polyvinylidene Fluoride Long and short AP -4 AutoPumps are warranted for five (5) years: 100% materials and workmanship first three (3) years; 50% materials and workmanship for the fourth (4th) and fifth (5th) years. Low -Drawdown for the AutoPumps are warranted for one (1) year. P.O. Box 3726 Ann Arbor, Mr 48106-3726 USA 1.800.624.2026 F 1.734.995.1170 info@gedenv.com www.gedenv.com 3/4 inch (19 mm) I inch (25.4 marl Inside Diameter Discharge Hose (Equivilant to 1.25 -Inch O -D. Tubing) 77�_ Y Inside Diameter Discharge Hose (Equivalent to 1 -Inch O.D. Tubing) 16 F 68.1 60.6 16 60.6 53 14- 53 12 -45.4 12 37.9 10 8 303 -77i t 311_ 1. r., 6 22.7 8 4 30-3 27.6 0 0 20 40 60 SO IOU 120 140 160 180 200 FT.DEPTH 6 6.1 12.218.324.430536.642.748.8 54.9 61 Meters IN WELL f 22.7 18 68.1 16 60.6 15.1 14 53 2 12- 45.4 o iE 10 37.9 6.1 12.2 183 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters -J IN WELL 303 78 68.7 22.7 16 4 15.1 '4 53 2 7.6 45.4 10 1 1 1 1 20 40 15. 181- 140 160 180 200 FT, 60 DEPTH I WELL 6.1 12.218324.430536.642.748.8 54.9 61 Meters IN 18 68.1 16 60.6 4 53 .0 12 45.4 1:' 0 37.9 30.3 1-3T.'i 622.7 415.1 2 7.6 a . 0 0 20 40 60 s6 100 120 140 160 150 200 FT. DEPTH 6.1 12.218-324.430-536.642.748.854.9 61 Meters -J IN WELL I inch (25.4 marl Inside Diameter Discharge Hose (Equivilant to 1.25 -Inch O -D. Tubing) 77�_ Y 8 6 4 2 0 30.3 22.7 7.6 0 20 40 60 80 100 120 140 160 IdU -200 FT. DEPTH 6.1 12.2 183 24.4 30.5 36,6 42.7 48.8 54.9 61 Meters J IN WELL 18 68.1 6 60.6 14 53 12 45.4 0HL 37.9 � 6 22.7 4 I J -L 2 7.6 0_ 0 20 40 60 80 100 120 140 160 180 200 FT. DEPTH 6.1 122 18.3 24.4 305 36.6 42.7 48.8 54.9 61 Meters IN WELL 'FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE. 18 68.1 16 60.6 14 53 12 45.4 10 T -I 1 37.9 8 30-3 6 22.7 4 15.1 2 7.6 o FT77U 0 20 40 60 80 100 120 140 160 180 200 F1% DEPTH 6.1 12.2 183 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters -J IN WELL 78 68.7 16 6D.6 '4 53 12 111 E 1',`: L" L, I-3 45.4 10 1 1 1 37, 8 6 4 2 0 30.3 22.7 7.6 0 20 40 60 80 100 120 140 160 IdU -200 FT. DEPTH 6.1 12.2 183 24.4 30.5 36,6 42.7 48.8 54.9 61 Meters J IN WELL 18 68.1 6 60.6 14 53 12 45.4 0HL 37.9 � 6 22.7 4 I J -L 2 7.6 0_ 0 20 40 60 80 100 120 140 160 180 200 FT. DEPTH 6.1 122 18.3 24.4 305 36.6 42.7 48.8 54.9 61 Meters IN WELL 'FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE. 1.6 1.5 1.4 1.3 1.2 1.1 1.0 .9 .8 .7 .6 .5 .4 .3 .2 1.6 1.5 1.4 1.3 1.2 1.0 .9 .8 .7 .6 .5 .4 .3 .2 iz 3/4 incn wj mm) 11.2 Inside Diameter Discharge Hose (Equivalent to 1 -Inch O.D. Tubing) 10.5 9.7 9.0 7-5 6 -7* .7 6.0 5.2 4.5 3.7 3.0 2.2 1.5 20 40 60 80 100 120 140 160 180 200 FT. -1 DEPTH 6.1 12.2 183 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters I IN WELL 12 1 inch (25.4 mm) 112 Inside Diameter Discharge Hose (Equivalent to 1.254nch OD. Tubing) 10.5 9.7 9.0 7.5 6.7 6.0 5,2 4-5 3.7 3.0 2.2 1S 20 40 60 80 100 120 140 160 180 200 FT. --I DEPTH 6.1 12.2 183 24.4 30.5 36.6 42.7 48S 54.9 61 Meters _j IN WELL PCI, Box 3726 .Ann Arbor; Ml 48106-3726 USA 1.800.624.2026 IF 1.734.995.1170 info@qedenv.com www.qedenv.com EN r+ 1160 Nicole Cour Glendora. CA 91740 800-735-5566 a 909-592-6272 I N D U S T R I E S L L C Fax. 909-592-7971 www.carsonind.com �15-3/8" 24-5/8" 2-1/4" L -Bolt Option M Bolt Down Loc-IGtTm (Patent Pending) Included d I t D" FLUSH COVER a Models: 1) - 1324 -3B Bolt Down Calif i� F 1324-3L Captive L -Bolt Lock 12" 1324-5B Bolt Down with Plastic Reader 28-15/16" 1324-5L L Bolt with Plastic Reader Optional water Meter Header 1324-613 Bolt Down with Cast Iron Reader (575 mm) 1324-6L L -Bolt with Cast Iron Reader M Bolt Down Loc-IGtTm (Patent Pending) Included d I t D" Models: 1324-4B Bolt Down 1324-41- Captive L -Bolt Lock GRADE RIND Model: 1324**2RH Green/Gray 130DRE5 Models: 1324-12 1324-15 COLORS AVAILABLE: Green, Gray, Black, Tan or Violet/Lavender Note: For use in non -vehicular traffic situations only. We do not recommend installation in concrete or asphalt. Weights and dimensions may vary slightly. All information contained In this brochure was current at the time of printing. Because of Carson Industries' policy of ongoing research and development, the Company reserves the right to discontinue or update product information without notice. A a c 1) E F G 25-3/8" 15-15/16" 12" 22-5/8"^ 32-1116" 28-15/16" 19-1/2" 1324-12 (645 mm) (405 mm) .(305 mm) (575 mm) (814 mm) (735 mm) (495 mm) 25-114" 15-314" 15.1/4" 23.5/16" 32-3/4" 29-518" 20-3/16" 1324-15 (641 mm) (400 mm) (387 mm) (592 mm) (832 mm) (752 mm) (513 mm) Models: 1324-4B Bolt Down 1324-41- Captive L -Bolt Lock GRADE RIND Model: 1324**2RH Green/Gray 130DRE5 Models: 1324-12 1324-15 COLORS AVAILABLE: Green, Gray, Black, Tan or Violet/Lavender Note: For use in non -vehicular traffic situations only. We do not recommend installation in concrete or asphalt. Weights and dimensions may vary slightly. All information contained In this brochure was current at the time of printing. Because of Carson Industries' policy of ongoing research and development, the Company reserves the right to discontinue or update product information without notice. Carson industries, LLC 1160 Nicole Court Glendora. CA 91740 800-735-5566 0 909-592-6272 Fax: 909-592-7971 www.carsonind.com HDPE Structural Foam RAW 61411ATEROAL ASTlltal Test SHIPPING INFOdtMATOON SPECIFICATIONS Material Property Method Typical Value' Type, Class, Category D 1248 IA, A, 3 Density, g/ cm3 D 1505 0.950 min., not to exceed 0.965 Tensile Strength, at break, psi D 638 3,000 to 4,400 Elongation, at break, % D 638 400 Tensile Impact, ft-Ib/n2 D 1822 27 Flexural Modulus, psi D 790 120,000 min., not to exceed 1324-12: Unit, 16 assemblies = 42.6 cu. ft.; 413.0 lbs. reserves the right to discontinue or update 240,000 Low Temperature Brittleness. D 746 <-76 F50. at°C Hardness. Shore D D 2240 66 Deflection Temperature. at D 648 1501, min., not to exceed 2000 66 Dsi Electrical Dielectric Strength, D 149 V/mi l 400 min., not to exceed 600 Molded Product -- Chemical Resistance D 543 Very Resistant Water Absorption D 570 Less than I% weight change 'The values listed for physical property measurements are nominal values only. Certain physical property measurements are subject to variations consistent with the test methods and are within a generally accepted range for such values. 2 est reports available on request. 12/18/02 SHIPPING INFOdtMATOON Weigh 1324 -3B, -3L, -4B, -4L Covers 6 lbs. 1324**2RH Grade Ring 4 lbs. 1324-12 Body 16 lbs. All information contained in this brochure 1324-15 Body 20 lbs. was current at the time of printing. Because of Carson Industries' policy of ongoing Shipping Configuration research and development, the Company 1324-12: Unit, 16 assemblies = 42.6 cu. ft.; 413.0 lbs. reserves the right to discontinue or update 1324-15: Unit, 16 assemblies = 49.75 cu. ft.; 430.0 lbs. product information without notice. Auto Sump 7000 Specifications and Special Features Model # 7000-8 Auto Sump OVERVIEW Many automatic condensate systems have been utilized in landfill service over the years and most work satisfactorily. Real Environmental Products set out to design a new system that will challenge the status quo in terms of simplicity, cost, and reliability. The Auto Sump system was designed with the LFG system operator in mind. This design enables the operator to utilize the submersible pumping system of his choice in a user friendly environment. REP has designed in special features that allow servicing of the pump without influencing 02 into the gas system. It also has a quick disconnect design which allows removal and replacement of the pump utilizing minimal tools and can be accomplished in less than 3 minutes. Real Environmental Products, is pleased to submit the following design specifications and special features for our Auto Sump 7000. We believe our Auto Sump 7000 to be unequaled in the Landfill Gas industry due to the following features. • The Auto Sump 7000 features the unique isolation well design. • Our isolation well design allows the pumping system to be serviced while the Landfill Gas System is being operated, preventing the introduction of oxygen into the system. • With the isolation well there is no need for an external drain line valve that can be problematic from an operations standpoint. • The isolation well also acts as a pre filter for the pump by preventing shavings from collecting on the pump screen. • Our isolation well, vault box bottom, and vault box are all manufactured of HDPE and are completely seal welded together. • The isolation well is also removable to allow cleaning of the sump of debris etc. if it ever becomes necessary. • All welding is accomplished by hot air, extrusion, and butt fusion. • It has been demonstrated that the pump in the Auto Sump 7000 can be removed and replaced with a spare in 3 minutes elapsed time. • The air inlet and condensate discharge hoses inside the HDPE containment vault are high pressure with stainless steel quick disconnects. • All fittings inside the HDPE containment vault are stainless steel, HDPE, or polypropylene. • The vault wall penetrations are stainless steel with neoprene grommets. 19550 Berry Street B/dg B UnitAl Pine Grove, CA 95665/ Ph:209 296-7900/ Fax., 209-296-7944 Env. ironmental Summary: In summary the Auto Sump 7000 was developed with long term 0&M and the Landfill Gas System operator in mind. The Auto Sump 7000 was designed to withstand the harsh environment associated with Landfill Gas Systems. The Auto Sump 7000 was designed for long term operation with no maintenance necessary. If maintenance on the pumping system should ever be required we designed in quick disconnects and to enable the operator to remove and replace the pump quickly and easily. • The Auto Sump 7000-8 will be supplied as a complete manufactured unit. • All equipment in the Auto Sump is rated for harsh and potentially explosive environments. • No PVC pipe or fittings are utilized in the Auto -Sump 7000 due to possible failures in solvent welded joints over long periods of service. • All HDPE pipe and fittings as well as integral sump bottom are manufactured of ASTM D-1248 pipe grade materials. • The filter/regulator is located in a HDPE vault assembly that is integrally mounted to the top of the condensate liquid sump, the HDPE vault bottom is attached to the vault by continuous HDPE weld. The vault will withstand temperatures up 180 deg F with excellent chemical resistance and nil water absorption. • The simplicity of the Auto -Sump design allows for ease of accessibility for operation and maintenance. • Service connections are mounted with stainless steel fittings and neoprene grommets to a common wall of the vault. • The liquid submersible pump shall be a Short AP4 BL as manufactured by Clean Environment Equipment Oakland, CA. • The filter/regulator enclosure shall have zinc housing and zinc bowl. • The filter/regulator is an Auto -Drain type. 19550 Berry Street Bldg B Unit A Pine Grove, CA 95665/ Ph; 209 296-7900/ Fax,, 209-296-7944 Real f_. Environmen a.1-, h 1 u • The filter/regulator is rated for 150 psig. • The filter/regulator is capable of controlling air pressure from 10 to 120 psig. • The filter regulator includes a 0-160 psi gauge. • All hoses used in the Auto Sump Assembly are Hercules or Gorilla Hose with a working pressure of 500 psi and burst pressure of 2000 psi. • Stainless steel block valves with Teflon seats are standard on all Auto Sumps for air inlet and condensate discharge. • Stainless steel bolts are welded to a stainless steel backing ring as one complete unit for total corrosion protection. • This Auto Sump 7000-8 is a single contained unit consisting of an 8" SDR 17 HDPE primary containment sump. 19550 Berry Street Bldg B UnitA Pine Grove, CA 95665/ Ph; 209 296-7900/ Fax, 209-296-7944 3✓4' FPT CONDENSATE DISD [/2' FPT AIR IN 1/2' FPT BALANCE LINE L QPE CASING I CONDENSATE DISCHARGE ENVIROPLUG® MEDIUM & COARSE were the FIRST bentonite chips developed and marketed. They are pure Wyoming Bentonite, designed for use as sealants for hole abandonment, casing seals or any vertical seal to prevent water movement up or down a bore hole. When absorbing water, ENVIROPLUG® MEDIUM and COARSE swell to fill voids, exerting pressure against all surfaces to create a flexible low permeability seal. Since ENVIROPLUG® is introduced in a "dry" state, shrinkage cannot occur and there is a reserve expansion capacity. Generally hydration takes 1 to 2 hours. PRODUCT SPECIFICATIONS Sizing Bulk Density Moisture Content Permeability ENVIROPLUG® MEDIUM -3/8" + 1/4" 68 lb/ft3 15%::L 2 1 x 10-9 cm/sec ENVIROPLUG® COARSE -3/4" + 3/8" 641b/ft3 15% ±2 1 x 10-9 cm/sec HOLE ABANDONMENT AND APPLICATION GUIDELINES ENVIROPLUG® COARSE has been used for abandoning drill holes since 1983. It easily falls through standing water and thin drilling fluids filling the column from the bottom upward. A fall rate of 1 foot/second through water can be expected and has been successfully applied through water to depths of over 1600 feet. Consult local regulations before beginning any abandonment procedure. Hole abandonment should be done by "Groundwater Professionals Only." I CASED HOLES OR UNCASED HOLES I For decommissioning cased or uncased holes larger than 3" diameter, use ENVIROPLUG° COARSE. If static water is present, pour chips from the bag at a rate of 1 1/2 to 2 minutes per 50 pounds. A funneling device with a 2" opening can be used to insure a constant flow of material into the hole. Should the water level be quite low - a screen can be used to drop out "fines" from the material before entering the hole. For holes less than 3" in diameter use ENVIROPLUG® MEDIUM. The technique is the same but a funnel with a V to 1 1/2" opening is recommended to regulate the flow. Holes with less than a 1" diameter should be plugged with a pumpable material such as ENVIROPLUG° GROUT. I ABANDONING DUG WELLS I Completely filling dug wells with bentonite chips can be very expensive and unnecessary. To economically decommission and stabilize dug wells, ENVIROPLUG° COARSE should be placed from the bottom section upward to 3 feet above the water bearing zone. Alternate sections of sand, fine gravel, or clay upward with a 12" layer of ENVIROPLUG® COARSE or MEDIUM every 5 to 6 feet. Any of the above methods should be finished off approximately 3 feet below the surface, then filled with native soil or cement depending upon local regulatory requirements. Page I of 2 SEALING CASING Slowly pour ENVIROPLUG° MEDIUM into annulus and allow to drop to the gravel pack. For bentonite grouting, continue to pour ENVIROPLUG° MEDIUM directly into annulus, alternating from one side of the casing to the other. This aids in even distribution of particles around the casing. To avoid bridging problems pour at a rate of 1'/2 to 2 minutes per bag. If available, a funnel -type device with a 1'h" bottom opening has proven very successful in regulating the flow into the hole and thus reducing the chances for bridging. When used in conjunction with pumpable grouts, ENVIROPLUG® MEDIUM can be used immediately above the sand or gravel pack and at the top of the hole for a more rigid seal. I GROUNDING ROD AND HEAT PUMP CONDUCTOR HOLES I After drilling a 41/2" to 5" diameter hole to the desired depth, simply center the grounding rod with the ground wire attached or the circulating loop from the heat pump in the bore hole. In the case of a wet hole condition, pour hole ENVIROPLUG° MEDIUM slowly (11/2 - 2 minutes per bag) down the bore alternating each bag from one side of the hole to the other. In dry hole conditions, fill the hole with water, then add the ENVIROPLUG° MEDIUM displacing the water upward. If the water dissipates into formations while filling the hole, continue to add water while adding ENVIROPLUG° MEDIUM until the hole is sealed. Adding 5 gallons of water per 50 pound bag is usually adequate to provide hydration. Expected values for hydrated chips: Thermal Conductivity 0.50 Btu/hr-ft-'F Resistance < 0.3 ohms -meter. SEISMIC SHOT H After the hole is drilled and charge is placed, pour ENVIROPLUG° COARSE slowly into the hole (1%2 -2 minutes per bag). In wet hole conditions add enough ENVIROPLUG° COARSE to fill up to the static water level. In a dry hole, add 2 to 4 bags directly over the charge. Where auger drills are used or where water is injected, pour 2 bags per 50 feet of hole depth. TYPICAL E.P. TOXICITY ANALYSIS Standard m Set Grout m Arsenic 5.0 <0.10 Barium 100.0 0.50 Cadmium 1.0 <0.05 Chromium 5.0 <0.10 Lead 5.0 <0.10 Mercury 0.2 <0.02 Selenium 1.0 <0.05 Silver 5.0 <0.10 TYPICAL CHEMICAL ANALYSIS % Si02 61.40 MgO 1.70 A1203 18.10 Ca03 0.40 Fe203 3.50 Ti02 0.20 K20 0.10 Na20 2.30 H2O 7.80 Other 0.07 L.O.I. * 4.40 *Loss on Ignition ENVIROPLUG° MEDIUM and COARSE are available in 50 pound bags and 3,000 pound bulk bags. Page 2 of 2 ENVIROPLUG MEDIUM / ENVIROPLUG #8 DESCRIPTION Enviroplug Medium and Enviroplug #8 are granular Wyoming bentonite chips, which can absorb 5 times their weight in water and swell to 12-16 times their dry bulk size. PROPERTIES APPLICATION Enviroplug #8 and Enviroplug Medium are designed to seal surface and upper intermediate hole sections experiencing. severe lost circulation. Enviroplug is poured directly down the hole where it rapidly swells and seals areas of severe lost circulation. It is not advisable to attempt to circulate an Enviroplug pill down the hole as rapid hydration will occur when the granules come in contact with water creating the potential of plugging even open-ended drill -pipe. MIXING AND HANDLING Add directly down the annulus. Avoid breathing dust. It is advisable to use a dust mask and eye protection while mixing all powdered products. WHMIS: Controlled (see MSDS) TDG: Not regulated PACKAGING: 50 lb sack Physical Chemical Appearance: Grey to tan granules Type: Sodium Montmorillonite Specific Gravity: 2.45-2.55 Solubility: Not soluble (colloidal Moisture Content: Not available suspension) Flash Point: Not applicable pH: 8.0-10.0 (5% suspension) Grind Size: Medium (100% passing Microtox: Not applicable 3/8 inch mesh) #8 97% passing 4 mesh) APPLICATION Enviroplug #8 and Enviroplug Medium are designed to seal surface and upper intermediate hole sections experiencing. severe lost circulation. Enviroplug is poured directly down the hole where it rapidly swells and seals areas of severe lost circulation. It is not advisable to attempt to circulate an Enviroplug pill down the hole as rapid hydration will occur when the granules come in contact with water creating the potential of plugging even open-ended drill -pipe. MIXING AND HANDLING Add directly down the annulus. Avoid breathing dust. It is advisable to use a dust mask and eye protection while mixing all powdered products. WHMIS: Controlled (see MSDS) TDG: Not regulated PACKAGING: 50 lb sack R TH CORPORATION a Continental Disc Company ■ Sizes 2" through 60" ■ Available in, carbon steel, stainless steel aluminum (type 356) and other materials ■ Wafer design for quick and easy maintenance ■ Unique recessed seating for superior protection ■ Factory Mutual approval for most sizes and materials ■ Proven spiral wound, crimped ribbon, flame element FLAME ARRESTER Both models are designed to inhibit flame propa- gation in gas piping systems and to protect low pressure tanks containing flammable liquids. Arresters protect low flash point liquids from exter- nally caused sources of heat and ignition. This provides increased fire protection and safety. SPECIAL FEATURES Both models are built of corrosion resistant materi- als throughout. Wafer design construction affords easy accessibility to the flame bank. Additionally, jack screws aid in the removal from the shell assembly. All Groth flame arrester flame banks utilize spiral wound, crimped ribbon constructed flame elements. These proven, Factory Mutual approved elements have been reported, by NTIS of the Dept. of Commerce, to provide the best flame quenching performance for the least pres- sure drop. Groth's special recessed flame bank seating construction uniquely provides an extra measure of protection against leakage and possi- ble flame propagation. GROTH, THE CAPABILITY COMPANY As with all Groth products, every Flame Arrester is factory inspected and tested to meet all critical requirements and special needs. Inventory is maintained to insure rapid delivery. FLAME ARRESTERS Models 7618 / 7628 MODEL 7628 (HORIZONTAL) Note: All Groth Flame Arresters are Bi-directional. Factory Mutual regulates that Flame arresters be installed less than 10 pipe diameters from the source of ignition. Section 2:200-263.gxd, June, 2002, 2.5m Groth Corporation, a Continental Disc company, Stafford, TX, USA 200 Spedfirations subject to change without notice. Certified dimensions available upon request. ' 7618 Vertical t MRWP Zs618 � ` � MAWP 7628 Approk h A B AA BB MAWP 7618 Carbon , MAWP 7628 Carbon Shlp Srze' NCrdtl1 Height n Length Hetgitt Allimttwm " orSS Nummum- orSS Wi lbs {mm) tmrtt?'mm) (mdt� Emmy (mm) (mm} fu1m� (Alummtml) 2" 8 314 " 14" 13- " 9 1/2 " 50 PSIG 100 PSIG 150 PSIG 350 PSIG 18 (51 mm) (221) (356) (349) (241) (345 kPa) (690 kPa) (1035 kPa) (2415 kPa) (Bkg) 3" 91/2 " 16" 15- " 11" 50 PSIG 100 PSIG 140 PSIG 325 PSIG 25 (76 mm) (241) (406) (400) (279) (345 kPa) (690 kPa) (966 kPa) (2242 kPa) (11 kg) 4" 11 112 " 18 tr^ " 18" 121M " 50 PSIG 100 PSIG 140 PSIG 325 PSIG 40 (102 mm) (292) (464) (457) (318) (345 kPa) (690 kPa) (966 kPa) (2242 kPa) (18 kg) 6" 16,12 " 21" 21" 16,12 " 50 PSIG 100 PSIG 140 PSIG 325 PSIG 70 (152 mm) (419) (533) (533) (419) (345 kPa) (690 kPa) (966 kPa) (2242 kPa) (32 kg) 8" 21" 25" 25" 20,12 " 50 PSIG 100 PSIG 90 PSIG 200 PSIG 135 (203 mm) (533) (635) (635) (521) (345 kPa) (690 kPa) (621 kPa) (1380 kPa) (61 kg) 10" 24- " 30" 30" 24,12 " 50 PSIG 100 PSIG 75 PSIG 150 PSIG 235 (254 mm) (629) (762) (762) (622) (345 kPa) (690 kPa) (517 kPa) (1035 kPa) (107 kg) 12" 28- " 321,2 " 32- " 281/2 " 50 PSIG 100 PSIG 75 PSIG 150 PSIG 345 (305 mm) (727) (826) (826) (724) (345 kPa) (690 kPa) (517 kPa) (1035 kPa) (156 kg) * Larger sizes available on special application. '150# )LN.S.I. drilling compatibility, F.F. on aluminum and RF. on carbon steel and stainless steel alloys. Pneumatic tested to 15 PSI as standard For easy ordering, select proper model numbers MODEL # SIZE MATERIAL Y Y Y Y - ---------- 7618 Vertical 7628 Horizontal 02" Thru 60" h Include model member when ordering. For special options, consult factory. G When ordering steamjacket, include steam pressure/temperature. Z OPTIONS LO = No Options Flame element winding Z = Special Options 0 = No Jacket Body Material J = Steam Jacket 1 = Aluminum F = Hanged outlet (in-line design) 3 = Carbon Steel W = Weatherhood (replaces 5 = 316 SS Flanged outlet) Z = Special 201 Groth Corporation, a Continental Disc company, Statrord, TX, USA Model 7618 / 7628 Flow Capacity End of Line 1 0.6 2.89 5.05 8.98 20.2 34.7 54,7 79.1 2 1.2 4.40 8.03 14.3 32.1 55.9 87.8 127 3 1.7 5.58 10.4 18.5 41.5 72.7 114 164 12 6.9 12.0 23.5 41.7 93.8 166 260 375 14 8.1 13.1 25.6 45.5 102 182 284 409 16 9.2 14.0 27.5 49.0 110 196 306 441 26 15.0 18.1 35.9 63.9 144 256400 576 28 16.2 18.9 37.4 66.5 150 267 416 599 30 17.3 19.6 38.8 69.0 155 277 432 622 1. Flow facility and equipment comply with API 2000. 2. Flow measurement accuracy verified by an independant research organization. 3. Flow capacity is based on actual tests and certified by Groth Corporation. 1,000 w 0 1 ' 0 4. Flow data are for tank mounting or end of line and includes flame arrester entran loss, exit loss, and internal losses. 10" 6" 4" 3" 2" 5 10 15 20 25 30 Tank Pressure - inches W.C. Grolh Corporation, a Continental Disc company, Stafford, TX, USA 202 Model 7618 / 7628 Flow Capacity End of Line 25 2.45 0.08 0.14 0.25 0.57 0.98 1.55 2.24 50 4.90 0.12 0.23 0.40 0.91 1.58 2.49 3.59 75 7.35 0.16 0.29 0.52 1.18 2.06 3.23 4.66 10Q 9.80 019 0.35 0.62 1.40 2.46 3.86 5.57 150 14.7 0.23 0:45 0.79 1.79, 3.15 i 4.93 200 19.6 0:27 0.53 = 0:94 "` 2.11 3.73 5.84 �" 8.42i " 250 24.5 "0.31 1.07 2.40 4.25 - 6.64 9.57 " 300 29.4 0.34 0.66 1.18 2.66 4.72 7.37 10.6 350 34.3 0.37 0.72 1.29 2.90 5.15 8.04 11.6 400 39.2 0.40 0.78 1.39 3.12 5.55 8.67 12.5 450 44.1 " i 0.42: 0.83 1:48 3.33, 5:92 9.25 , 13.3' . 5,00 49.0 0.45 0,88 1.7 553 3: 6.28, ° 9 81�" 14:1 . 550 X53.9 0.47".' 0.93 1.65 , 3:72 �, 6.62 10.314:9 600 59 0.49 0.97 1:73 3.90 6.94 ' 10.8 15.6 650 64 0.51 1.02 1.81 4.07 7.25 11.3 16.3 700 69 0.53 1.06 1.88 4.24 7.55 11.8 17.0 750 74 0.55 1.10 1.95 4.40 7.84 12.2 17.6 1. Flow facility and equipment comply with AN 2000. 2. Flow measurement accuracy verified by an independant research organization. 3. Flow capacity is based on actual tests and certified by Groth Corporation. 100 0 0 O O O 0.1 0.01 0 4. Flow data are for tank mounting or end of line and includes flame arrester entran loss, exit loss, and internal losses. 125 250 375 500 Tank Pressure - millimeters HZO 203 Groth Corporation, a Continental Disc company, Stafford, DX USA 625 750 12" 10" 8„ 6" 4" 3" 2" Model 7628 / 7618 Flow Capacity In -Line 1 0.6 3.32 5.58 9.92 23.640.2 63.4 91.8 2 1.2 5.27 9.44 16.8 40.0 69.1 109 157 3 1.7 6.79 12.6 22.4 53.3 93.0 146 211 12 6.9 15.3 30.7 54.5130 232 363 522 14 8.1 16.6 33.6 59.8 142 255 398 573 16 9.2 17.9 36.4 64.7 154 277 431 620 26 15.0 23.346.6 82.9 198 348 545 786 28 16.2 24.3 48.4 86.0 205 362 566 816 30 17.3 25.2 50.1 89.1 212 374 586 845 1. Flow facility and equipment comply with AN 2000. 3. Flow capacity is based on actual tests and certified by Groth Corporation. 2. Flow measurement accuracy verified by an independant research organization. 4. Flow data are for in-line mounting and does not include entrance losses or exit losses. 1,000 1 ' 0 12" 10" $„ 6" 4„ 3" 2" 5 10 15 20 25 30 Pressure Drop - inches W.C. Grath Corporation, a Continental Disc company, Stafford, TX, USA 204 Model 7628 / 7618 Flow Capacity In -Line 25 2.45 0.09 0.16 0.28 0.67 1.14 1.80 2.60 50 4.90 0.15 0.27 0.48 1.13 1.96 3.08 4.45 75 7.35 0.19 0.36 0.63 1.51 2.63 4.13 5.97 100 `9:80 0.23 0.43., = 0:77;=184 3.22: 5.05 Z29 150. - 14.7 ; 0.29 0.57 1.00 - 2.39 4:24, , 6.63 9.55 200= 19.6 0:34 0.68 :111 2:87 5.10 7:98 11.5 250 24.5 - 0.39 0.78 , 1.38 1. 588 ' 9:18. 13.2 300 29.4 0.43 0.87 1.54 3.68 6.58 10.3 14.8 350 34.3 0.47 0.95 1.69 4.04 7.23 11.3 16.2 400 39.2 0.51 1.03 1.83 4.37 7.84 12.2 17.6 450 44.1 :0:54 1.1.0 1.96 4:68; 8.41 = 13.1 18.8'' 500 49.0 0.57 1.17 2.09 4:97, 8.66. 13.6 19.9 X550 53.9_ X0.60 1.24 2:21 5:26 9.08 14.2 20.5 600 59 .0:63 1.27. :_2.26: 5;38 ' ;-9.48 , _ 14.8 � 21.4 650 64 0.66 1.32 2.35 5.60 9.87 15.5 22.3 700 69 0.69 1.37 2.44 5.81 10.2 16.0 23.1 750 74 0.71 1.42 2.52 6.01 10.6 16.6 23.9 1. Flow facility and equipment comply with AN 2000. 3. Flow capacity is based on actual tests and certified by Groth Corporation. 2. Flow measurement accuracy verified by an independant research organization. 4. Flow data are for inline mounting and does not include entrance losses or exit losses. 100 O 0 0 0 0 0.1 0.01 0 125 250 375 500 Pressure Drop - millimeters H2O 205 Grath Corporation, a Continental Disc company, Stafford, TX, USA 625 750 12" 10" $„ 6° 4" 3" 2° E�m��s�iple Gas .: Z � W= GENERAL MONITORS Protection for Life. Single -Channel Combustible Gas Monitor Description • Continuous diffusion, electro - catalytic sensor • High visibility LED status indicators Benefits • Stable operation over wide ambient temperature and humidity ranges • Provides visual indication of fault and alarm status at the detector location • Adjustment -free calibration • Lower calibration costs • Low power consumption -7 watts • Lower operating costs • Wide variety of relay options • Two year warranty The General Monitors Model 480A is a single -channel system specifically designed for continuous monitoring of combustible gas concentrations. The system consists of a remote sensing assembly and solid-state controller. The controller can be wall, panel or rack mounted in a non -hazardous area. The system operates in the range of 0-100% LEL (Lower Explosive Limit) and is calibrated to a particular gas or vapor. User interfaces are provided so that the operator may interpret and direct the Model 480A in the performance of its various functions. User interfaces consist of a digital display, status indicators, a mode button, and a reset button. The system operates on 117 VAC, 50-60 Hz (optional 220 VAC, 50-60 Hz), or 24 VDC primary input power with the capability of 24 VDC battery backup. Nominal power consumption is 7 watts. • Provides choice to meet specific customer requirements • User protection • Fuel Loading Facilities • Compressor Stations • LNG Processing and Storage • Oil Well Logging • Sewage Plants • Gas Turbines • Drilling Platforms and Rigs • Gas and Oil Production Platforms • Solvent Vapors System Specifications Digital Readout: 0-99% LEL Accuracy: ±3% LEL:5 50% LEL gas 5% LEL> 50% LEL gas Electrical Classification: General purpose for mounting in non -hazardous areas, indoors. Warranty: Two years Approvals: CSA Environmental Specifications Temperature Range: 32°F to 140°F (0°C to 60°C) Storage Temperature: -4°F to 149°F (-20°C to 65°C) Humidity: 15-95%, non -condensing Mechanical Specifications Mounting: Panel or wall Dimensions: 2.1" W x 6.9" H x 11.5" D (53mmW x 175mmH x 292mmD) Weight: 3.8 lbs. (1.8 kg) Electrical Specifications Power: 105-130 VAC (205-255 VAC optional), 50-60 Hz, 22-30 VDC, 7 watts nominal (117 VAC) Output: Analog 4-20mA (300 ohm load max.) Accuracy ±5%, 1.5-20mA Alarm Circuits: 4A/117 VAC, resistive LED Status Indicators: AO - Analog output malfunction SE - Sensor malfunction HI - High line voltage LO - Low line voltage Standard Configuration: 480A-1-1-01-1 (110 VAC / 24 VDC, latch alarm, non -latch warn, de -energized, standard sensor, 1 -active channel) Sensor Elements General Monitors' sensors are designed for reliable performance and long life. Each sensor must undergo extensive burn -in and rigid quality control procedures before shipment. The sensors consist of two catalytic bead elements in a balanced Wheatstone bridge circuit. These low temperature catalytic bead -sensing elements require minimal sensor excitation current, greatly increasing sensor life. Sensor Specifications Type: Continuous diffusion, low temperature catalytic bead. Standard Industrial Hydrocarbon Sensor. High Temperature Standard Industrial Hydrocarbon Sensor. Temperature Range: -65°F to +200°F (-55°C to +93°C) High Temperature Sensor to 400°F (200°C) Response Time: Tw typical 6 seconds Zero Drift: Less than 5% per year Life: 3 to 5 years, normal service Electrical Classification: Class I, Division 1 and 2, Groups B, C and D Cable Length: Three conductor cable. Maximum length of cable between controller and sensor assembly with loop resistance of 20 ohms NOTE: Shielded cable is recommended Wire Size Length AV1 Qz (Meters) F t 14 2,320 7,600 16 1,460 4,800 18 910 3,000 20 580 1,900 Warranty: Two years Approvals: CSA and/or FM Specifications subject to change without notice. Represented by: Publication #: DS-48OA-BO806 � A A o;;=- GENERAL MONITORS Protection for life. Single -Channel 1-12S Gas Monitor esc i io • Continuous diffusion, solid-state sensor • High visibility LED status indicators • Stable operation over wide ambient temperature and humidity ranges • Provides visual indication of fault and alarm status at the detector location • Adjustment -free calibration • Lower calibration costs • Low power consumption -7 watts • Lower operating costs • Wide variety of relay options • Two year warranty The Model 2180A is a single -channel system specifically designed for continuous monitoring of Hydrogen Sulfide (H2S) gas in the ppm (parts -per - million) range. The 2180A controller is a microprocessor -based instrument, which features recent advancements in electronic circuitry and packaging techniques. User interfaces are provided so that the operator may interpret and direct the Model 2180A in the performance of its various functions. User interfaces consist of a digital display, status indicators, a mode button and a reset button. The digital display provides the user with the gas concentration at the sensor site, fault diagnostic codes, calibration prompts and setup parameters. The controller should be mounted in a weather protected non -hazardous area. Several GMI accessories are available for panel, wall or 19 -inch rack installation. For hazardous areas an explosion proof housing is available for Class I, Division 1, Groups C and D. • Provides choice to meet specific customer requirements • User protection • Compressor Stations • Drilling Platforms and Rigs • Gas and Oil Production Platforms • Fuel Loading Facilities • Gas Turbines • LNG Processing and Storage • Oil Well Logging • Solvent Vapors • Wastewater Treatment Plants DragerSensor® H2S LC - 68 09 610 Data Sheet This data sheet is a sensor specific supplement to the "Instructions for Use" of the respective transmitter. Please consult in any event the "Instructions for Use" of the Transmitter. Intended Use The DragerSensor® H2S LC is an electrochemical three electrode sensor for the continuous real-time monitoring of hydrogen sulfide (1-12S), tetra- hydrothiophene (THT), methyl mercaptane (MeM), ethyl mercaptane (EtM), n -propyl mercaptane (nPM), i -propyl mercaptane (iPM), t -butyl mercap- tane (tBM), dimethyl sulfide (DMS) and dimetyl disulfide (DMDS) in ambient air. The sensor is designed to be used only in conjunction with an appropriate Drager transmitter. Technical Data Electrode reactions (shown for H2S) Measuring electrode: H2S + 4 H2O —> H2SO4 + 8 H+ + 8 e Counter electrode: 2 02 + 8 H+ + 8 e- —> 41-120 Display: H2S THT MeM EtM nPM iPM tBM DMS DMDS Measuring gases: H2S C4H8S CH3SHC2H5SH CH3CH2CH2SH (CHs)2CHSH (CHs)sCSH (CH3)2S (CHs)2S2 Measuring ranges: minimum [ppm] ul 0...20 0...20 0...20 0...20 0...20 0...20 0...20 0...20 default [ppm] 0 54 0...50 0...50 0...50 0...50 0...50 0...50 0...50 0...50 maximum [ppm] 0100 0...100 0...100 0...100 0...100 0...100 0...100 0...100 0...100 Relative sensitivities 0.3 0.6 0.5 0.3 0.5 0.5 0.3 0.5 Calibration interval: minimum 1 day default 6 months maximum 12 months Ambient conditions: Operation H2S, THT, nPM, tBM –40 °C to 65 'C (-40 °F to 150 °F) MeM, EtM, iPM, DMS, DMDS 0'C to 40'C (30'F to 105 °F) 700 hPa to 1300 hPa (20.7" Hg to 38.4" Hg at 32 °F) 5 % r.h. to 95 % r.h., non condensating 0 'C to 40 °C (30 °F to 105 °F) Storage (in original container) Expected sensor life > 36 months Lower detection limit'* 1 ppm Linearity tolerance s ± 4 % of measured value Repeatability / accuracy: zero s � 0.5 ppm sensitivity s ± 3 % of measured value Effect of temperature: zero s �t 0.1 ppm / K sensitivity s ± 0.2 % of measured value / K Effect of pressure: zero no effect sensitivity s t 0.1 % of measured value / hPa Effect of humidity: zero s � 0.05 ppm / % r.h. sensitivity s ± 0.1 % of measured value / % r.h. Effect of flow between 0 and 6 m/s (0 and 1180 ft/min): zero no effect sensitivity s ± 5 % of measured value Long-term drift: zero s ± 0.5 ppm / month sensitivity s 3 % of measured value / year Response time to go with dust filter ** s 40 seconds Warm-up time: Sensor ready for operation after *** s 30 minutes Sensor ready for calibration after **** s 6 hours ® DragerSensor is a trademark of Drager, registered in Germany. * Only applicable when used in conjunction with an appropriate Polytron transmitter. At 25 °C (77 °F), 1013 hPa (29.2" Hg at 32 °F), 50 % r.h. *** At this time, the actual zero point error of the sensor is less than 4 times the value stated in this data sheet. *" At this time, the sensor has reached its specific accuracy. Cross Sensitivities The table on the next page shows the response of the sensor to other gases than target gas (cross sensitivities). The values are typical and apply to new sensors. The table does not claim to be complete. Gas mixtures can be displayed as the sum of all components. Gases with negative cross sensitivities may displace a positive reading of the sensor. Gas / Vapor Chemical Symbol Gas concentration Displayed value in ppm H2S Acetaldehyde CH3CHO 50 ppm s 8 Acetone CH3COCH3 1.25 % by vol. s 5 Ammonia NH3 500 ppm s 1 Benzene CeHe 0.6 % by vol. s 1 Butadiene CH2CHCHCH2 50 ppm s 20 Carbon dioxide CO2 30 % by vol. no effect Carbon monoxide CO 1 000 ppm s 7 Chlorine Cl2 5 ppm s 1 H* Diethylamine (C2H5)2NH 100 ppm no effect Ethanol C,H50H 200 ppm s 2 Ethene C2H4 1 % by vol. s 10 Ethine C2H2 0.6 % by vol. s 10 Ethylene oxide C2H40 30 ppm s 1 FAM -petrol / (DIN 51635, DIN 51557) 0.55 % by vol. s 1 Formaldehyde HCHO 50 ppm s 15 Hexane C8H14 0.6 % by vol. s 1 Hydrogen H2 1 % by vol. s 10 Hydrogen chloride HCI 40 ppm s 1 Hydrogen cyanide HCN 25 ppm s 4 Hydrogen peroxide H2O2 40 ppm s 8 Hydrogen selenide SeH2 5 ppm s 3 Methanol CH30H 2 000 ppm s 5 Methylmethacrylate CH2C(CH3)COOCH3 60 ppm s 1 Nitrogen dioxide NO2 20 ppm Nitrogen oxide NO 20 ppm s 10 Octane C8H18 0.4 % by vol. s 1 Phosgene COCl2 5 ppm s 1 Phosphine PH3 5 ppm s 5 Propane C31-18 1 % by vol. s 1 i -Propanol (CH3)2CHOH 500 ppm s 7 Propene C3H8 0.5 % by vol. s 50 Styrene CeHSCHCH2 30 ppm s 10 Sulfur dioxide SO2 20 ppm s 4 Tetrahydrofurane CAO 60 ppm s 10 Toluene CeH5CH3 0.6 % by vol. s 1 Vinyl acetate CH3COOCHCH2 30 ppm s 6 Vinyl chloride C2H3CI 50 ppm no effect Xylene C6H4(CH3)2 0.5 % by vol. s 4 negative display. Order List DragerSensoro H2S LC ...................................................... 68 09 610 Dustfilter............................................................................. 68 09 595 For calibration: Calibration adapter V ........................................................... 68 10 536 Calibration bottle for calibration with ampoules .................... 68 03 407 Test gas ampoule 10 ppm H2S.......................................... 68 08 140 Test gas ampoule 20 ppm H2S.......................................... 68 08 141 Test gas ampoule 40 ppm H2S.......................................... 68 08 142 Test gas ampoule 100 ppm H2S.......................................... 68 08 143 Drager Safety AG & Co. KGaA — ® Revalstra6e 1, D-23560 Lubeck, Germany — E +49 451 8 82 - 27 94 — FAX +49 451 8 82 - 49 91 9 http://www.draeger.com/gds 9th edition - January 2003 90 23 456 - TD 4681.320 en/de Subject to alteration © Drager Safety AG & Co. KGaA IR; The explosion proof transmitter for combustible gases and vapors. The Polytron FX is an economical, microprocessor -based gas detector for continuous monitoring of combustible gases and vapors in ambient air. Non -intrusive calibration and mainte- nance is performed using a magnetic wand to access the software through the enclosure window — no need to open the enclosure (and obtain special area permits) to perform routine calibra- tions. With only seven software menu choices to work with, the Polytron FX is easy to use. The heart of the Polytron FX is the new DragerSensor PR. The interior of the sensor has been redesigned to almost double the sensitivity. Higher sensitivity also means shorter response time, higher accuracy and improved stability of the sensor signal. The advanced poison resistant DragerSensor PR has a significantly increased sensor life. Features and Benefits: • Economical • Non -intrusive calibration • DragerSensor technology • Simple software menu Technical Data Order List DETECTION PERSONAL PROTECTION DIVING TECHNOLJuY S'STEi1 TECHNOLOGY SERVICES Polytron TX: Electrochemical sensor to detect toxic gases and Oxygen. The Polytron TX is an economical, microprocessor -based gas detector for continuous monitoring of toxic gases and oxygen in ambient air. Non -intrusive calibration and mainte- nance is performed using a magnetic wand to access the software through the enclosure window – no need to open the enclosure (and obtain special area permits) to perform routine calibrations. Easy to install The enclosure provides two mounting holes. For easy wiring, bezel and electro- nics is one unit, and can be pulled out. The two wire cable, fed through a sealed conduit, is terminated in a pluggable connector at the printed circuit board. One man calibration All setup and maintenance is performed without opening the transmitter or declassifying the hazardous area. Tapping a magnetic wand at the three buttons through the window gives full access to the menu and the calibration procedure. No reed for an additional handheld terminal. ORDER INFORMATION DraegerSensor technology High sensitivity, long term stability and no false alarms are the hallmark of the new and improved third generation of sensors. Sensors are the keystones of any gas detection system. Fastest response to the target gas combined with minimal inter- ference by other gases or environmental influences (no false alarms) as well as the sensor life -time determine the reliability and the operating cost of a system,. Features and Benefits: Economical Non -intrusive calibration DraegerSensor technology Simple software menu TX without sensor; UL, CSA, ATEX, suitable for CO, H2S2 02 45 43 405 Polytron TX without sensor, general purpose; suitable for Cl.,, H.,, NH.,; N01, S02 45 43 435 DraegerSensor CO 68 09 605 DraegerSensor H2S –......--- 68 09 610 ---- ---- ---- — DraegerSensor Oz ----- --......... _._....... ------ 68 09 630 DraegerSensor CIz 680966.5 DraegerSensor H2 68 09 685 DraegerSer.sor NH, LC DraegerSensor NH, HC 68 09 680 68 09 645 DraegerSensor NO, 68 09 655 DraegerSensor SO, Maenetic wand for menu access 68 09 660 45 43 428 TECHNICAL DATA Type Explosion proof transmitter Gases and Ranges Toxic gases and Oxygen in pre-set, user selectable ranges CO 0 to 100 1/ 300 / 500 ppm H,,S 0 to 20 50 1 100 ppm 0, 0 to 25 Vol% C11, 0 to,5 porn *) H2 0 to 500 Ppm NH, 0 to 100 / 300 500 pprn NO, 0 to 20 ppm SO,; 0 to 20 ppm Display 3 digit LCD, resolution varies with the range Signal 002PUt Normal operation 4 to 20 mA Maintenance 4 mA ± 1 mA 1 Hz modulation, or steady 3 mA: user selectable Fault < 2 mA Supply Voltage 16 to 30 V DC, 2 -wire Ambient Conditions Temperature 40 to + 150'F 40 to + 65'C Pressure 20.7 to 38.4 inch Hg / 700 to 1300 mbar Humidity 0 to 100 %RH (see also sensor data sheet) Enclosure lowder-coated aluminum transmitter housing, Stainless steel sensor housing Enclosure rating NEMA 4X & 7, IP 66; 3/4" NPT female conduit entry Size (h x w x d, approx) 9.5' x 4.511 x 4" 246 x-115 x 100 rnm VVeight (approx.) 5.7 lbs / 2.6 kg Approvals UL, CSA Class 1, Div 1, Group C, D ATEX 1! 2GD ELx d 1113 + H2 T6/-51 40 s T s < + 50 65'C CE -mark electromagnetic compatibility (directive 89/336/EEC) . ... ..... .. . ... . general purpose only Digital Readout: 0-20, 0-50, 0-99 ppm Accuracy: 2 ppm or 10% of applied gas, whichever is greater Electrical Classification: General purpose for mounting in non -hazardous areas, indoors. Warranty: Two years Approvals: CSA Temperature Range: 32°F to 140°F (0°C to 60°C) Storage Temperature: -4°F to 149°F (-20°C to 65°C) Humidity: 15-95%, non -condensing Mounting: Panel or wall Dimensions: 2.1" W x 6.9" H x 11.5" D (53mmW x 175mmH x 292mmD) Weight: 3.8 lbs. (1.8 kg) Power: 105-130 VAC (205-255 VAC optional), 50-60 Hz, 22-30 VDC, 7 watts nominal (117 VAC) Output: Analog 4-20mA (300 ohm load max.) Accuracy ±5%, 1.5-20mA Alarm Circuits: 4A/117 VAC, resistive Status Indicators: AO - Analog output malfunction SE - Sensor malfunction HI - High line voltage LO - Low line voltage Standard Configuration: 2180A-1-1-01-1-1 (110 VAC / 24 VDC, latch alarm, non -latch warn, de -energized, 100 ppm standard sensor, 99 ppm meter scale, 1 -active channel) Type: Continuous diffusion, adsorption type Temperature Range: Standard Sensor: -65°F to +167°F (-55°C to +75°C) High Temperature Sensor to +195°F (90°C) FM Approved: -40°F to +140°F (-40°C to +60°C) Response Time: T5o < 1 minute with full-scale gas applied (screen) Tw < 2 minutes with full-scale gas applied (sintered) Zero Drift: Less than 5% per year Repeatability: 2 ppm or 10% of reading, whichever is greater Life: 3 to 5 years, normal service Electrical Classification: FM and CSA, Class I, Division 1, Groups B, C and D; ATEX and GOST, Ex ds I IC T6 Specificity: H2S specific Warranty: Two years Cable Length: Four conductor cable. Maximum length of cable between controller and sensor assembly with loop resistance of 20 ohms NOTE: Shielded cable is recommended Wire Size Length AS (Meter F t 14 1,029 3,375 16 686 2,250 18 411 1,350 20 274 900 Specifications subject to change without notice. Represented by: Publication #: DS-218OA-BO806 RACO Verbatim, the long-standing first choice of the industry, offers pace- setting functionality and expandability— It's an autodialer alarm system, a remote monitoring system, a supervisory control system, a SCADA system, and a PLC net- work interface4n one compact package. With an expandable, modular bus architecture and up to 32 digital inputs, 16 analog inputs, and 8 digital control outputs, the system can monitor flow, level, pressure, temperature, pH, and other types of sensors, as well as control remote electrical devices. AlarmIII The system is designed to continu- ously monitor preset alarm points. If an alarm. condition is sensed at a moni- tored point, the Verbatim System will automatically dial a list of 16 pre-pro- grammed emergency telephone num- bers, calling until it gets an answer. When the call is answered and acknowl- edged, the system reports the alarm location and status via pre-recorded voice messages. Communicating over standard land- line or wireless telephone networks, the Verbatim delivers alarm messages to standard. phones, cell phones, numeric or voice pagers, and voice mail systems, and talks just as easily with computers. The voice messages are digitally pre-recorded by the user. Anything that can be spoken is accurately stored in memory—from names and numbers to technical terms and detailed instruc- tions. Messages are delivered with maxi- mum clarity, lessening the chance for misunderstanding or error. And, you can easily enter or change your messages over the phone or at the front panel. Fully Interactive With Verbatim, you're never out of touch with your monitoring system. With any standard touch-tone phone, you can call in for a status report, review and change programming, or control a re- mote device. With the touch of a key, you can listen to local sounds or talk to per- sonnel using the unit's built-in speaker- phone. When calling for status report, you hear a comprehensive suiummy of all conditions monitored by the system, in- cluding internal power. Hard copies of event data—alarms, acknowledgements, inquiries, and programming changes— can be printed out at any time using the system's data logging capabilities. Controls and indicators are provided on the Verbatim's front panel for on-site pro- gramming and review of system opera- tion, alarm status, and battery condition. Supervisory Control System A Verbatim System can be equipped with up to b digital control outputs to remotely actuate HVAC systems, pumps, compressors, and other electrical devices from a standard phone, the Verbatim front panel, or a PC. RACO MMIISCADA Systems provide monitoring and control of up to 200 RACO Verbatim Remote Terminal Units (RTUs) over the standard dial-up tele- phone network. Each RTU has full alarm monitoring, reporting, and autodialing capabilities, and because Verbatim sys- tems report by exception, they do not need to be polled. When an alarm is sensed, the RTU reports to the central computer. If the computer operator does not acknowledge the alarm, the RTU will commence autodialing. Offering alarm and monitoring for as many as 96 remote channels, the Verbatim can use RS232 commu- nications to work with any PLC or other device using Modicon's Modbus protocol. Take Control EquipmentRemote A Verbatim System can be used with a RACO Responder or another Verbatim to actuate pumps, compres- sors, gates, or other electrically oper- ated equipment over the dial-up tele- phone network. Upon receipt of an alarm signal—low water level, for exam- ple—the Verbatim issues a command to activate an output relay in the Res- ponder or other Verbatim unit, which initiates an action such as turning on a pump motor. E MI E liF r'I'll Verbatim systems incorporate a non-volatile memory. Recorded alarm messages and user -entered program- ming is retained indefinitely in the event of a power loss. A rechargeable gel -cell battery pro- vides up to 20 hours of continuous oper- ation in the event of power loss. And because the system uses a precision regulated charger instead of the tradi- tional `trickle" charger, the time re- quired for charging is minimized and battery life is significantly extended. Built for tI► Term lil in the Toughest Envii Verbatim is designed and built for superior performance -year after year. The system's rugged durability is evi- dent in its heavy-duty metal enclosure, carefully selected and proven solid- state components, and sealed mem- brane keyboard. Heavy-duty solid state and gas tube surge protection is pro- vided on all power, phone, and signal lines. Features: • Monitors 4 channels plus internal AC power • Solid-state message recording • Expandable modular design • Superior surge protection on all inputs • Alarm call grouping • Low cost Remote programming Nonvolatile memory 20 hour battery backup 5 year warranty Typical Monitoring Applications: 11 Boilers • Chemical Plants • Computer Rooms • Facility Security • Fish Hatcheries • Frozen Food Storage 13 HVAC Systems • Hydroelectric Power Stations • Pipeline & Compressor Stations • Remote Pump Stations • Storage Tanks • Telephone Sivitchgear • Unattended SCADA Systems • Water & Wastewater Treatment Plants I , i 11 Flow M Power Leak N Pressure Level E Temperature Motion E Vacuum pH Standard Specifications: ELECTRICAL IJ Power requirement: 105-135 NAC, 50/60 Hz, 15 watts maximum or 8-14 VDC at 500 mA maximum. CI Battery charging: Precision voltage controlled, including automatic rapid recharge after drain. Battery backup: 20 hours • Input sensing: Four unpowered con- tact inputs standard. Open contacts see 5 volts DC; closed contacts see 10 ma DC. • Standard Centronics parallel printer port. Literature Code #118 PHYSICAL Surge protection: Integral gas tube and solid-state protectors on all phone, power, and signal lines. Accommodates field -installed upgrades. Rugged metal indoor enclosure. ..1 Weight. 8lbs. (3.6 kg). „I Dimensions: 11-7/8" H x 9-3/4" W x 5" D. Mounting Centers: 113/8" vertical x 6" horizontal. ENVIRONMENTAL Temperature range: 20' to INE 'i Humidity: 0 to 95%, noncondensing. TEI,EPHONE Rotary pulse or tone dialing, keyboard selectable .3 Dials up to 16 different numbers, each up to 60 digits long. Allows programming of PBX delays in 1 second increments. • FCC Registered Part 68, "Ringer Equivalence": 0.3A. i Mann Acknowledgement. is by TouchTone key or by calling back. Built-in speaker phone allows two-way conversation Compatible with most cellular telephone systems. SPEECH MESSAGES Users record their own messages. Also includes resident vocabulary for program- ming guidance and for default "alarm/ normal" speech if no user messages are recorded. UL STANDARD J Verbatim complies with UL Standards: 1459,1950. WARRANTY Five year parts and labor warranty. See our separate warranty card for details. MODULAR OPTIONS Channels. Upgradeable to 8,16; 24 or 32 contact channels. Analog. Custom scaled in the units of measurement required for your job. Analog alarms on a high and a low alarm setpoint. Upgradeable to 1, 4, 8 or 16 analog channels. J Remote Supen4sory Control. The operator can turn equipment, on or off via any telephone. Upgradeable to 4 or 8 outputs. Modbus Interface. In addition to physi- cal inputs, the unit is upgradeable to 32, 64 or 96 additional alarms of any type via RS232 and Modbus RTU master protocol. J Cellular Telephone. Our CellularmT1 System provides temporary or permanent alarm autodialing over the cellular tele- phone network when conventional tele- phone lines are disabled or unavailable. Furnished in a rugged, weather -resistant housing that's easy to transport and set up. FACTORY OPTIONS J Enclosure. System available in NEMA 4X enclosure, which is corrosion proof and sealed against 12 feet of water. J Environmental. Thermostatically con- trolled heater available, suggested for operation below 20'F or where condensa- tion may occur. J Local Alarm Relay Output. Relay activates during unacknowledged alarm conditions. Secure Front Panel. Verbatim System furnished without front panel program- ming controls and indicators. Restricts access to unsupervised or remotely located units, as well as reducing the initial purchase price. ,j Solar Electric Generator Systems. Ideal for remote location applications where conventional power and telephone services are not available or too costly. Provides steady, clean power and has sufficient storage capacity for overcast and inclement weather conditions. RACO MANUFACTURING AND ENGINEERING CO. 1400 -62nd Street, Emeryville, CA 94608 - (510) 658-6713 - FAX: (510) 658-3153 1-800-722-6999 • www.racoman.com Represented in your area by: vCopyright 4,989 Race Manufacturing and Engineering Co. Specifications subject to change witho tit notice. Touch Tone is a registered trademark of At& is • Printed in U.S.A. 3M 10;04 RACO Manufacturing and Engineering Co., 1400 62nd St., Emeryville, CA 94608 (510) 658-6713 800-722-6999 FAX (510) 658-3153 Description and Phone Number Dialing: 1. The dialer shall be a solid state component capable of dialing up to 16 telephone numbers, each up to 60 digits in length. Phone numbers and Standard pulse dialing or Touch Tone DTMF dialing are user programmable via the system's keyboard or remotely via Touch Tone telephone. In addition, the dialer shall: ** Group Alarm Calls - On alarm, system shall selectively call the correct phone number according to the specific alarm(s). ** Detect Telephone Line Fault and indicate condition with Front Panel LED. ** Automatically select Tone versus Pulse Dialing. ** Monitor Call Progress - Detect Busy and Ringing Signals, Abandon Call if Busy, Wait until phone is answered to Annunciate Voice Reports. ** Provide Numeric Pager Support ** Provide PBX Support Solid State Voice Message Recording & Playback: 2. The unit shall have two different categories of speech message capability, all implemented with permanent non-volatile solid state circuitry with no mechanical mechanisms. The unit shall allow for message recording from a remote telephone as well as from the front panel. * * User Field Recorded Messaees: The user may record and re-record his own voice messages for each input channel and for the Station ID. a. There shall be no limit on the leneth of any particular message within the overall available message recording time, which shall vary from 26 to 635 seconds, depending upon the number of input channels selected, and the recording rate used. b. The unit shall allow selective recording of both Normal and Alarm advisory messages for each input channel. c. The unit shall provide for automatic setting of the optimum speech recording rate for the total set of messages recorder, in order'to achieve optimum recording sound quality. d. Circuit board switches or jumper straps shall not bean acceptable means of manipulating message length or recording rates. ** Permanent Resident Non -Recorded Messaees: Permanent built-in messages shall be included to support user programming operations, to provide supplemental warning messages such as advising that the alarms have been disabled, and to allow the unit to be fully functional even when the installer has not recorded any messages of his own. Input Monitoring Function: 3. The basic unit shall continuously monitor the presence of AC power and the status of four (4) contact closure inputs. AC power failure, or violation of the alarm criteria at any input shall cause the unit to go into alarm status and begin dial -outs. The unit shall, upon a single program entry, automatically accept all input states as the normal non -alarm state, eliminating possible confusion about Normal Open versus Normally Closed inputs. Further, as a diagnostic aid, unit shall have the capability of directly announcing the state of any given input as currently "Closed Circuit" or "Open Circuit" without disturbing any message programming. Each input channel shall also be independently programmable, without the need to manipulate circuit board switches or jumpers, to any of the following: ** Normally Open, Normally Closed, or for No Alarm (Status Only). ** Run Time Meter - to accumulate and report the number of hours a particular input circuit has been closed. Any channel so configured will never cause an alarm call, rather, on inquiry will recite it's message according to the status of the input and then report the closed circuit time to the tenth of an hour. The input will accumulate and report in tenths of hours up to a total accumulated running time of 99,999.9 hours. The initial value of the Run Time Meter shall be programmable in order to agree with existing electromechanical Run Time Meters. Up to a total of 8 Run Time Meters may be programmed. ** Pulse Totalizer - to count the accumulated number of pulses (momentary contact closures) occurring at the input so programmed. Any input channel may be programmed for a Totalizer Function, up to a maximum of 8. Maximum Input pulse rate is 100 Hz, with a 50% Duty Cycle. The spoken scaled value will not "roll-over" to zero until a value of 4,294,967,294. has been exceeded. Input/Output Expansion Capability: 4. The standard unit shall be modular in design, permitting it, therefore, to accept "plug-in" expansion circuit boards to incorporate any of the following: ** Contact Closure Expansion Capability to a total of 8, 16, 24, or 32 total dry contact inputs. ** Analog Input Capability to a total of 1, 4, 8, or 16 total analog inputs. * * Remote Supervisory Control Outputs to manipulate 4 or 8 output relays. Modbus Communications: 5. The unit shall accept an expansion card which enables it to communicate directly with devices utilizing Modbus RTU Protocol. A unit so configured shall be capable of "reading" and "writing" to 32, 64, or 96 data registers via Touch Tone Telephone. No modem or host computer shall be required. Interface shall consist of a single RS -232 Serial Cable. Printer/Computer Communications: 6. The unit shall be equipped with a centronics parallel printer port, enabling the user to print alarm reports, download programming data, and generate scheduled status reports as required. Alternatively, the unit shall be able to accept an optional modular, plug-in asychronous communications card to permit any of the following: ** Local Data Logging - Permits a single dialer to communicate with a local Serial printer to log routine status reports, alarm reports, and programming data. ** Central Data Logging - Permits one or more dialers to communicate with a single centrally located Serial printer equipped with a suitable modem to log routine status reports, alarm reports, and programming data. ** Data Acquisition and Control - Permits one or more dialers to communicate with a centrally located Computer/Printer System equipped with a SCADA software package, thereby functioning as a stand alone SCADA system. Alarm and Inquiry Messages: 7. Upon initiating an alarm call, the system is to "speak" only those channels which are currently in "alarm status". Inquiry phone calls can be made directly to the unit at any time, for a complete status report. Acknowledgement: 8. Alarms are acknowledged either by pressing a Touch Tone "9" as the call is being received, or by calling the unit back after having received an alarm call. Nonvolatile Program Memory Retention: 9. User -entered programming and voice messages shall be kept intact, even during power failures or when all power has been removed, for up to ten (10) years. This shall be accomplished through inclusion in the system of a lithium battery separate from the unit's backup rechargeable gel cell battery. Local and Remote Programming Capabilities: 10. The user may optionally elect to alter the following parameters from their standard normal default values via keyboard entry or remotely from any Touch Tone telephone. ** Alarm Response Delay: 0.1 to 999.9 seconds, with different delays being assignable to different alarms. ** Delay Between Alarm Call outs: 0.1 to 99.9 minutes. ** Alarm Reset Time: 0.1 to 99 hours, or "No Reset". ** Incoming Ring Response (Answer) Delay: 1 to 20 Rings. ** Number Of Message Repetitions: 1 to 20 Repetitions. * * Autocall Test: When enabled, the unit shall place a single round of test calls, both at the time this function is enabled, and also at regular subsequent intervals until this function is disabled. ** Remote System Microphone Activation. * Remote Arming and Disarming of System. Phone Line: 11. The dialer is to use a standard "dial-up" telephone line (direct leased line is not required), and is to be F.C.C. approved. Connection to the telephone is through a 4 -pin modular jack (RJ 11). Speakerphone: 12. The unit shall be capable of dialing any phone number on command and functioning as a speakerphone. Real Time Clock: 13. The unit shall be equipped with a real time clock thereby making it possible to: ** Alarm Ready Schedule - The dialer shall be user programmable to follow a specific schedule of operations. This shall include the flexibility to set a weekday, weekend, and holiday schedule. With this feature the dialer shall arm and disarm itself according to the schedule programmed. * * In the event any of the printer configurations outlined in Section 6, are utilized, all alarm reports will be time and date stamped. Routine scheduled status reports can also be programmed. PowerBattea Backup: 14. Normal power shall be 105-135 VAC, 15 watts nominal. The product is to contain its own gel cell rechargeable battery which is automatically kept charged when AC power is present. The system shall operate on battery power for a minimum of 20 continuous hours in the event of AC power failure. A shorter backup time shall not be acceptable. The built -m charger shall be precision voltage controlled, not a "trickle charger", in order to minimize recharge time and to maximize battery life available. Inte rag 1 Surge Protection: 15. All power,�nhone line, dry contact. and analog signal inputs shall be protected at the circuit board to IEEE Standard 587. cate,goU B(6,000 volts open circuit/3,000 amps closed circuit). Gas tubes followed by solid state protectors shall be integral to the circuit board for each line. Technical/Customer Support: 16. All users shall be provided and/or shall have access to the following support resources. ** Each autodialer shall be shipped with a VHS Format Video Tape which details all features of the product and provides an in-depth step-by-step programming: wide. A superficial marketing overview will not be acceptable. ** A Fax -on -Demand System which allows any user to call the manufacturer and retrieve copies of all technical information available directly into his own fax system. This service shall be available on a 24 hour basis. ** A toll free 800 number shall be available during manufacturer's normal working day to permit users to talk directly with technical service personnel and resolve problems not solved by either the Video Instruction Tape or the information provided via Fax -on -Demand. Warran : 17. The dialer shall be covered by a FIVE (5) YEAR warranty covering parts and labor performed at the Factory. Additional Features: Sealed Switches. LED Indicators. Alarm Disable Warning, Talkthrough: 18. All keyboard and front panel switches shall be sealed to prevent contamination. Front panel LED's shall indicate: Normal Operation, Program Mode, Call in Progress, Status for each Channel, AC Power present, AC Power failure, and Low, Discharging, or Recharging Battery. On any inquiry telephone call, or On -Site status check, the voice shall provide specific warning if no dialout phone numbers are entered, or if the unit is in "alarm disabled" mode, or if AC power is off or has been off since last reset. A built-in microphone shall allow anyone at a remote site to listen to Local sounds and to have a two-way conversation with personnel at the dialer. Miscellaneous Special Order Items: 19. The following options shall be available on specific order: ** Radio Communications Interface ** Various NEMA 4X (sealed) Enclosures ** Thermostatically Controlled Heater ** UL Approved Power Supply ** Cellularm Communications Systems FORM 116 2.1 2.2 Installation This section describes how to install the Verbatim autodialer and how to install a parallel printer to use the Parallel Printer Local Data Logging feature. Location and Mounting Choose a mounting location which is not exposed to condensing humidity or temperatures beyond the limits of 20°-130°F. This location should ideally be within 5 feet of a standard RJ -11 phone jack and a grounded 120 VAC power outlet. 1. Mount the Verbatim autodialer on centers of 6" x 11 3/8" using the external mounting ears on the enclosure. #10 or 3/16" bolt sizes are best. 2. Install the NEMA 4X weatherproof outer enclosure, (optional purchase). This allows the Verbatim autodialer to be mounted outdoors as long as temperature limits are not violated. It is best to provide at least an over- head shelter to minimize direct precipitation and solar heating effects. 3. Install the heater/thermostat for cold or humid environments, (optional purchase). The 120 VAC heater dissipates 75 watts, providing a temperature rise of approximately 30 degrees, or 60 degrees when enclosed in the optional NEMA 4X enclosure. Wiring Refer to the diagram on page 2-3 for an example of the wiring connections. 1. Inspect and remove any foreign materials which might create short circuits. Connect the red (positive) battery lead to the positive terminal on the gel - cell battery. 3. Plug the power cord into a grounded 120 VAC outlet. Or, remove the power cord from the Verbatim autodialer and install well- grounded 120 VAC power to terminal strip TS3, located on the lower right of the main circuit board. Verbatim Owner's Manual 2-1 Installation If there are any green grounding wires in place on TS3 originating from plug-in expansion cards, leave those green grounding wires in place on the terminal marked GRN (Green). If the Verbatim autodialer turns on when power is applied, turn it off with the red POWER ON/OFF key. 4. Connect dry (unpowered) contacts to the terminal strip connection points. The connection point for basic four -channel units is terminal strip TSI, located on the lower left of the main circuit board. Note that there are four common return terminals marked "C"; any combination of these internally grounded terminals may be used. Terminal strip TS 1 may be unplugged for convenience. All terminal points are screw clamp type, eliminating the need for wire termination lugs. The contact input wires should ideally be light (18 to 24 gauge) signal wire rather than heavy power wire. This reduces problems of bulk and stiffness. 5. If your unit has 8 or more inputs, the VX32 Channel Expansion Card should be plugged into connector J4. If your unit has this card installed, then use TS 1 for common return connections only, and connect one side of each contact to the appropri- ately marked channel input number on the VX32 card. Leave TS 1 terminals 1,2,3 and 4 disconnected. Notes: ♦ The common return side of the contacts will need to be consolidated into not more than four wires coming into the TSI terminals marked "C". ♦ Route the wires to the VX32 card so that they do not protrude above the top of the card, other wise they will interfere with the front panel board when the door is closed. ♦ Terminal strip TS 1, and the terminal strips on the VX32 card if any, are not removable terminal blocks. Be sure that the terminal strips do not become unplugged due to wires being stressed when the door is closed. Caution: NO 120 VAC INPUT CIRCUITS! Please verify that the circuits you connect to these inputs are "dry" (unpowered) and are not directly connected to 120 VAC power. Connecting such circuits will damage the unit. ♦ Exception: If your inputs are coming from a logic controller with TTL, CMOS or 5 -volt DC logic outputs, direct connection may be made as long as the controller has the same electrical ground as the Verbatim autodialer. 2-2 Verbatim Owner's Manual Installation Electrical Connection Diagram For Dry Contact Inputs VSP SPEECH CARD 0 O O O O re QO = SPEAIE2 no VOLUME m m 7 ' M This connection is not �m H 11 12 13 14 132 wn 5 U U Z_ Q \� VX 32 CHANNEL EXPANSION CARD / O�NMVNtO f�ODOO�C,10 MID lh-WO 0 N Nmvv or -w Ot �� NNNNN NNM MP9 X", ffi .�:..ux• sates cz Expansion Input Slot VX 32 Jew GROUND (WIRE Connect Grounded 120 VAC Power T S 3 Connect common return of all contacts to point(s) "C" on TS1. The common returns for all inputs are connected to TSI terminals marked "C". These four "C" terminals are connected together and to electrical ground. 4 Channel Verbatim: Connect one side of each contact to the corresponding numbered terminals on TS1. The other side of each contact connects to the common return (the "C" 'terminals on TSI). 8 Or More Channel Verbatim: Connect one side of each contact to the corresponding numbered terminals on the VX32 expansion card. Connect the other side of each contact to the common return (the "C" terminals on TS 1 of the main board). Note that TS I terminals 1 through 4 are not used in this case. Verbatim Owner's Manual 2-3 O O O O T12341CCCR G Y B = m 7 ' , This connection is not made if a VX32 card is resent. 11 12 13 14 132 _______ Connect common return of all contacts to point(s) "C" on TS1. The common returns for all inputs are connected to TSI terminals marked "C". These four "C" terminals are connected together and to electrical ground. 4 Channel Verbatim: Connect one side of each contact to the corresponding numbered terminals on TS1. The other side of each contact connects to the common return (the "C" 'terminals on TSI). 8 Or More Channel Verbatim: Connect one side of each contact to the corresponding numbered terminals on the VX32 expansion card. Connect the other side of each contact to the common return (the "C" terminals on TS 1 of the main board). Note that TS I terminals 1 through 4 are not used in this case. Verbatim Owner's Manual 2-3 re Verbatim Floobydust Verbatim Enclosure Diagram 6„ 0 0 Verbatim 11-3/8" o O 9-3/4" 11-7/8" RECTANGULAR MOUNTING CENTERS: 6" W x 11-3/8" H OVERALL DIMENSIONS: 9-3/4" W x 11 7/8" H x 5" D H-24 Verbatim Owner's Manual 12.5" Verbatim Floobydust NEMA 4X Enclosure Diagram 11.5" 99 RECTANGULAR MOUNTING CENTERS: 8" W x 12.5" F OVERALL DIMENSIONS 11.5" W x 13.5" H x 5.5" D Verbatim Owner's Manual 13.5" H-25 M-=""5 k w wi HTA Rugged, Industrial Design The 1609 can be mounted to a DIN rail or to the back of the panel. Elevated Temperature Performance A high temperature battery option allows operation up to 50°C. Comprehensive Network Management The optional Network Management Card (NMC) is monitored via RSView ' or via the on -board web browser, and provides alarms that indicate the status of the UPS. "Dry contact" 1/0 The 1609 has standard relay outputs to signal "Battery On." The optional NN1C allows additional UPS data to be communicated. Rockwell Monitor via Serial Cable / PowerChute'' Monitor via Ethernet Web Browser/RSView' (Requires NMC) The optional networking capabilities of the 1609 UPS allow the end user to remotely configure and monitor the status of individual or multiple UPS devices. f 11 500 '< H C I Rated Output Power Input/Output Voltage Special Functions 500 = 500VA (325W) N = 115V AC S = Standard Battery E = 230V AC H = High Temp Battery Power Supply Type U= Uninterruptable Power Supply Network Management C = NMC included Can be left blank Characteristic 115V Model 230V Model Input voltage (default) (Widen selectable range transfer points) 81V AC ... 143V AC 75V AC. ..153V AC 160V AC ... 287V AC 150V AC ... 300V AC Nominal Current 4.12 A 2.2 A Ouput voltage (default) (Widen selectable range transfer points) 106V AC ... 127V AC 97V AC ... 136V AC 208V AC ... 253V AC 196V AC ... 265V AC Overload Protection Alarm/Shutdown 107% Alarm/Shutdown 107% Battery Run Time Full Load: 9 Minutes Full Load: 9 Minutes Charge Time < 3hrs to 90% capacity < 3hrsto 90% capacity Operating Temperature: Standard Battery High Temp Battery 0...40'C 0...50°C 0...40°C 0...50"C Dimensions/Weight (HxWxD) 6 x 14.25 x 6" 26 lbs www.rockwellautomation.com Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, M;I ^Jaukee, wl, 532172-5302 USA, lei: (1) 414.212.5200, Fax: 0) 414.212.5201 Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Mi vvaukee, Wl 533204-2496 USA, Tel: 11l 414.3822000, Fax: (1) 414.382.4444 Europe: Rockwell Automation SA/NV VorstlaaniBoulevard du Souverain 38 BP 3A/B, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, 27/r' Citicorp Centre, 18 Whitfield Read, Causeway Bay, Hong Kong, Tel: 18521 -1,887 4788, Fax: (852) 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (11864297.4800, Fax: i1) 864.281.2433 Europe: Rockwell Automation, BriihistraRe 22. D-74834 Elztai-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 1774 Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733 Publication 1609-PP001A-EN-P--- October 2004 ridil w 2004 Roc u H A-1 atiw. hoc :V. richt, ies—A P6,11 ,1 :r is;. M&WMAPE A A'rvoslox of lift nx Pkttttrs d` &that CnMrar 1P IPS Size and Dimension Data PE3608 (PE3408) DriscoPlexe Municipal & Industrial & Energy Series/IPS Pipe Data Pressure Ratings are calculated using 0.50 design factor for HDS at 73°F as listed in PPI TR -4 for PE 3608 materials. Temperature, Chemical, and Environmental use considerations may require use of additional design factors. will vary. When designing components to fit the pipe ID, refer to pipe dimensions and tolerances in the applicable pipe manufacturing specification. v September 2006 Supercedes all previous publications Bulletin: PP 152-3608 © 2001-2006 Chevron Phillips Chemical Company LP a I�rrMANWPIPE A DIVISION OF CREVRO'N MUMS &EMICAL COMPANY CP IPS Size and Dimension Data PE3608 (PE3408) DriscoPlexe Municipal & Industrial & Energy Series/IPS Pipe Data Pressure Ratings are cslculated using 0.50 design factor for HDS at 73°F as listed in PPI TR -4 for PE 3608 materials. Temperature, Chemical, and Environmental use considerations may require use of additional design factors. re 100 psi DR 17.0 80 psi DR 21.0 65 psi DR 26.0 50 psi DR 32.5 NominalAehage IDF Weight quer%age �D Weight Avef ge{ID Weight Ave rage"'IA Weight OD (in) id 1Il Yom, lbs/ft th"`.!n lbs/ft, inky ,; lbs/ft NSF to z lbs/ft 1.660 1.900 JENNIM 2.375 2 07$ , € 0.43 8412; 3.500 1n yx 3 063 �� ; 0.93 _ ,.. x� IRISH 4.5003.9$ F.: 1.544 _ Q46 1.26 ,. NEREM 6.6255 798 3.34 2.73 2.73tD84w 2.23 1.80 1.80 8.625 W!,58 5.65 X 7 754 4.64 1VON7 92 3.79 9 8 06 3 3.05 10.7509, ... 41_Q 8.78 665 7.219?x,8,i,4 5.870404 n 4.75 12.750 1118.0005,5, :160 12.36 �,t3 10.13117ea1 8.2611x9,19, , 6.67 14.00025: 14.91125$6 12.22,12$59 9.96hp 1086.7`' 8.05 16.000 19.46 19.46 1,385 15.96 --T3.01 14957 10.50 24.6416.8„3 20.19 6$3Ek 16.47f 15 86k> 13.30 20.00017x507, 30.411798 24.93183<0 20.34.1696x" 16.41 22.000 19257 36.80 77$ 30.18 2d 2060. 24.6128565; 19.86 24.0001x0`7 43.81 215. 35.91 29.30x122,435;, 23.62 26.00072759: 51.3923375 42.1423 880 34.39 g1§2 27.74 27.74 28.000 24 50$s 59.62 2517 '.; 48.86 X25 7, ,1 39.88 ,a ,26x1,73* K 32.19 30.000 68.45,26971n 56.12 27554r 45.78 '�z$ 04 36.93 32.0002$0 10� 77.862.7f8 63.8429'3904 52.10 t29 912; 42.04 34.000.°9760 87.91OA568 72.06 327 58.81 31',782 47.43 36.000 �31t�v10 98.57 �32z366;F 4 80.78 X33„U64kk 65.94 3 61 53.20 42.000 36%61; 134.16 37 76Q 109.97 X38 57t,;> 89.71 3961 72.37 48.000 42 Q 13 175.23 43,w1F54 143.65 44 9 6 117.18 44 59 94.56 54.000 ,_48W5¢9 181.75 49597 148.33^5,477 119.70 Performance Pipe can produce to specialized pipe dimensions. Check with your Performance Pipe contact for availability of dimensions not listed. and PERFORMANCE PIPE are trademarks of Chevron Phillips Chemical Company LP September 2006 Supercedes all previous publications Bulletin: PP 152-3608 © 2001-2006 Chevron Phillips Chemical Company LP For more information and technical assistance contact: Performance Pipe, a division of Chevron Phillips Chemical Company LP P.O. Box 269006 Plano, TX 75026-9006 800.527.0662 DriscoPlex° PE3608 / (PE3408) Pipe Pipe and Fittings Data Sheet Typical material Physical Properties of DriscoPlekO PE3608 / (PE3408) High Density Polyethylene Materials A&vxwtr(mmayAwaq%mrtto mAP Bulletin: PP 109 Revision Date September, 2006 r�li Typical Value Material Designation -- PPI TR -4 PE3608 Cell Classification -- ASTM D3350 345464C Pipe Properties Density gms / cm3 ASTM D1505 0.955 (black) Melt Index Condition 190 / 2.16 gms / 10 minutes ASTM D1238 0.08 Hydrostatic Design Basis 73-F 23 C psi ASTM D2837 1600 Hydrostatic Design Basis 140-F (60-C) psi ASTM D2837 800 Color: UV Stabilizer [C] [E] ASTM D3350 Min 2% carbon Black Color UV Stabilizer Material Properties Flexural Modulus 2% Secant - 16:1 span; depth, 0.5 in / min psi ASTM D790 >110,000 Tensile Strength at Yield psi ASTM D638 Type IV 3200 Elongation at Break 2 in / min., Type IV bar % ASTM D638 >700 Elastic Modulus psi ASTM D638 >150,000 Hardness Shore D ASTM D2240 62 PENT hrs ASTM F1473 >100 Thermal Properties Vicat Softening Temperature °F ASTM D1525 256 Brittleness Temperature °F ASTM D746 -103 Thermal Expansion in / in / °F ASTM D696 1.0 x 10-4 Bulletin: PP 109 Revision Date September, 2006 AmJa�yp�duilE�m' Before using the piping product, the user is advised and cautioned to make its own determination and assessment of the safety and suitability of the piping product for the specific use in question and is further advised against relying on the information contained hereir �-^ as it may relate to any specific use or application. It Is the ultimate responsibility of the user to ensure that the piping product is suited and the information is applicable to the user's specific application. This data sheet provides typical physical property information for i� polyethylene resins used to manufacture the piping product. It is intended for comparing polyethylene piping resins. It is not a product + ® I specification, and it does not establish minimum or maximum values or manufacturing tolerances for resins or for the piping product. These typical physical property values were determined using compression -molded plaques prepared from resin. Values obtained from L t3 NP daR tests of specimens taken from the piping product can vary from these typical values. Performance Pipe does not make, and expressly Do (t* disclaims, all warranties, of merchantability or fitness for a particular purpose, regardless of whether oral or written, express or implied, allegedly arising from any usage of trade or from any course of dealing in connection with the use of information contained herein or tht piping product itself. The user expressly assumes all risk and liability, whether based in contract, tort or otherwise, in connection with th For more information and technical assistance contact: Performance Pipe, a division of Chevron Phillips Chemical Company LP P.O. Box 269006 Plano, TX 75026-9006 800.527.0662 SUGGESTED INDUSTRIES AND APPLICATIONS Potable Water Mains Horizontal Directional Drilling (HDD) Marine Service Sliplining : Water transmission Lines Pipe Bursting .Industrial Water Mains MunicipalWater Utilities Ash, Tailings & Abrasives Open -cut and Bury Mining- iningMunicipal Culverts 4500, 4600, 4700 River Crossings 0.63 Rural Water Distribution 4000, 4100, 4200, 4300, 4400, Plow -in Mun. & Ind. Sewer Trenchless Technologies Crude oil Fire Main Piping Rural Water Distribution Plow -in Butt Fusion Conditions 60-90 psig (4.14-6.21 bar) interfacial fusion pressure. • 400-450° (204-232°C) heater surface temperature range. • Please refer to Performance Pipe's PE3608 (PE3408) fusion procedure, Bulletin PP 750. Available Sizes • W through 54" IPS • 4" through 36" DIPS Specification Data The resin, pipe and fitting listed may comply with one or more of the standards below. Applicable Standards® DriscoPlex Pipe Series PE3608 (PE3408) PE4710 (df) ASTM F714, NSF 61, ASTM 4000, 4100, 4200, 4300, 4400, ` as it may relate to any specific use or application. It is the ultimate responsibility of the user to ensure that the piping product is suited D3035 4500, 4600, 4700 0.5 0.63 r 4000, 4100, 4200, 4300, 4400, i R tests of specimens taken from the piping product can vary from these typical values. Performance Pipe does not make, and expressly AWWA C906, AWWA C901 45 00, 4600, 4700 [0-5 0.63 FMA, AWWA, F714 1500, 1600 0.5�� API 15LE, ASTM D2513 [64-00 0.5 Ron— A ftor QrLi'iPXbA Man &MA9CMRLVliP'� Bulletin: PP 109 Revision Date September, 2006 Ax>v�wAdypt7fern Before using the piping product, the user is advised and cautioned to make its own determination and assessment of the safety and suitability of the piping product for the specific use in question and is further advised against relying on the information contained hereir as it may relate to any specific use or application. It is the ultimate responsibility of the user to ensure that the piping product is suited and the information is applicable to the user's specific application. This data sheet provides typical physical property information for polyethylene resins used to manufacture the piping product. It is intended for comparing polyethylene piping resins. It is not a product specification, and it does not establish minimum or maximum values or manufacturing tolerances for resins or for the piping product. r These typical physical property values were determined using compression -molded plaques prepared from resin. Values obtained from i R tests of specimens taken from the piping product can vary from these typical values. Performance Pipe does not make, and expressly f disclaims, all warranties, of merchantability or fitness for a particular purpose, regardless of whether oral or written, express or implied, allegedly arising from any usage of trade or from any course of dealing in connection with the use of information contained herein or the piping product itself. The user expressly assumes all risk and liability, whether based in contract, tort or otherwise, in connection with th For more information and technical assistance contact: Performance Pipe, a division of Chevron Phillips Chemical Company LP P.O. Box 269006 Plano, TX 75026-9006 800.527.0662 Members Of:@ PLASTICS -PI PF -1 NTS 'ITi TE NOTICE: This data sheet provides tpical physical property information for polyethylene resins used to manufacture PERFORMANCE PIPE polyethylene piping products. It is intended for comparing polyethylene piping resins. It is not a product specification, and it does not establish minimum or maximum values or manufacturing tolerances for resins or for piping products. Some of these typical physical property values were determined using compression molded plaques. Values obtained from tests of specimens taken from piping product can vary from these typical values. Performance Pipe has made every reasonable effort to ensure the accuracy of this data sheet, but this data sheet may not provide all necessary information, particularly with respect to special or unusual applications. The data sheet may be changed from time to time without notice. Contact Performance Pipe to determine if you have the most recent edition. Bulletin: PP 109 Revision Date September, 2006 AsGtlervHyJ�¢th�m Before using the piping product, the user is advised and cautioned to make its own determination and assessment of the safety and suitability of the piping product for the specific use in question and is further advised against relying on the information contained hereir as it may relate to any specific use or application. It is the ultimate responsibility of the user to ensure that the piping product is suited and the information is applicable to the user's specific application. This data sheet provides typical physical property information for polyethylene resins used to manufacture the piping product. it is intended for comparing polyethylene piping resins. It is not a product ■ ■ specification, and it does not establish minimum or maximum values or manufacturing tolerances for resins or for the piping product. ! i These typical physical property values were determined using compression -molded plaques prepared from resin. Values obtained from C#ai1t�LP tests of specimens taken from the piping product can vary from these typical values. Performance Pipe does not make, and expressly disclaims, all warranties, of merchantability or fitness for a particular purpose, regardless of whether oral or written, express or implied, allegedly arising from any usage of trade or from any course of dealing in connection with the use of information contained herein or the piping product itself. The user expressly assumes all risk and liability, whether based in contract, tort or otherwise, in connection with th Brie l 1LLLciI.LC�!'LL LCL PSE/PV C I V,(, ' I PS Nda.4I130 Nominal Poly -Cam- Coupling Coupling HDPE HDPE PVC PVC Size IJIDPE/P.V 'Diameter Length I,en th, Diameter Length Diameter "Inches Mater11a1 finches) (inches) (inches) (inch l (inches)(inches) B C D E C' Ea coated .7 eri�n,Ae�l '104, nd 416 1-250 `2, 50 4.1 1.050 4.75 1.050 Epoxy coated 1: rlxew t l 30 . 1 1 F 15 3.00 4.50 1-315 .50 1,315 Epoxy coated, 1, `'' C arlS�tc4l 314, ,d 31 1,660 3 4,25 1-660 4.2.E 1:660 ,Stalkless Steel FpD?W c MtCd, 1 304, and 31 1,900 4.40 4.00 1,900 4,00 ' 1.900 Stainless Steel Epoxy coated , 2 �' rla r� t l moi , and $1 _-7S 4. 10: . 2.375 _ .00 x'.375 Stainless Steel Epoxy coated onStetel 16 3. )00 5-00 5.50 .500 5.50 3.500 E coated - e.rl va 't el 104, and 3 1 45 00 6,00 5M 4,500 5.00 4,500 I, tWh- vxt'al . SIRMiItIl SM, 44LO , 7,. Q, 1 I. l Manufactured I U046 "W iL slert-d Tr drinark PtaEVA, IMM', lnv. US Niew 0 ,114,429 rage l f 2 Phone, 763-786-6682 , Fax! 76,3-786-2167 Transition for HI)P,EIPV,C PVC v IPS Sch.40/8 13 linless Steel, ox,v coated arbonStcol 8.625 9,00 10,50 8.6-5 10. 5, 0 8,625 =4, and 31-6 iinleo Steel Oxy coated qt r ]' 10,750 9,00, 10,50 1 �7 0 ' 10,50 10,75 =4, and 316 inless Steel 4, a� i ts and 6 12-75 13,00 10.510 12.750 10,50 12.750 inless. Steel Fully [ %sur- va . '"WtavWmrfl NI )k aeras 7, 4, 11, V 'lanufac urc ! t I . L 1 . ld i 1 :1�=• B VUO V RfeOs® m- 1 Tradenuwk 10tal -f7mm„ Ince - US Pal'oni 0 5,29.14420 Page`2 of 2 Nominal Poly -Cam Coupling CouplingHDPE HDPE PVC PVC 1-M I. DPF/P'VC Dia mc#cr ixngtb length D3aanete T,,.en l)ia melter, I.nc,hes, 1' t t (inches) (inches) (inches) (nchu.-I Onches) Onches .. 67 6215 &00 9, 0,0 6.625 9.00 6.625 13 linless Steel, ox,v coated arbonStcol 8.625 9,00 10,50 8.6-5 10. 5, 0 8,625 =4, and 31-6 iinleo Steel Oxy coated qt r ]' 10,750 9,00, 10,50 1 �7 0 ' 10,50 10,75 =4, and 316 inless Steel 4, a� i ts and 6 12-75 13,00 10.510 12.750 10,50 12.750 inless. Steel Fully [ %sur- va . '"WtavWmrfl NI )k aeras 7, 4, 11, V 'lanufac urc ! t I . L 1 . ld i 1 :1�=• B VUO V RfeOs® m- 1 Tradenuwk 10tal -f7mm„ Ince - US Pal'oni 0 5,29.14420 Page`2 of 2 HITACHI Inspire the Next VA"LE FREQ UENff DRIVE Sif 200 Series SJ200 ������ �!■4�i_ iNxAr OH 5 r��il =rP P7" -Pi! 3}I i�h#R1D•JW-rp f -ori YI9!lWG�C�IYl bl■►,. {reF 3.5-t. .1Q3. ■V17�-. 1lM CiP:T��ti7�4=t. SJ200 81� eiec oN•L ruuN• CH Kri rid iwsTMq Pr+rSi bti7 'v rm • R�R�'L bliOA �MQ Iq�l Jnr 7R �tl�RJI C. ■!L'18=t . S J 200 ih121.Rr�NI a t r,r�irti 4�.+wr awry L'4�1 aati P.. ik � Lir+'r•rr. 7 0 J J 1 1 4 rII] �0 •me High starting torque of 200% or greater at 1 Hz Newly developed technology - Intelligent Sensorless Vector Control - cope provides optimal high torque without motor tuning. Trip avoidance function Advanced over -current trip avoidance function for acceleration, and over -voltage trip avoidance function for deceleration. Reduced trip likelihood means improved drive system reliability and availability. 40* • f Removable Control Terminal Connector type control terminal minimizes control terminal wiring when performing field maintenance. �r Input logic is selectable from Sink or Source to match external device (PLCs, etc.). r Removable Keypad Keypad (digital operator) can be connected via a cable. Remote operation ready. - Three LEDs (power, alarm, run) ldnlh� on the inverter display drive's status. Operation Source Switch Run command/frequency source are easy to select with a DIP switch Default is keypad settings. Sliding the switch changes the sources to the control terminals. Applicable Motor 1 -/3-phase 200V class 3-phase 400V class US version European version kW (HP) US version European version JP version 0.2(1/4) J200-002NFU SJ200-002NFEF SJ200-002LFR SJ200-004HFU SJ200-004HFEF jJ20 0.4(1/2) 0-004NFU SJ200-004NFEF SJ200-004LFR 0.55(3/4) SJ200-005N FEF 0.75(1) J200 007NFU SJ200 007NFEF SJ200 007LFR SJ200 007HFU SJ200 007HFEF 1.1(1.5) SJ200-011 NFEF 1.5(2) SJ200-015NFU SJ200-015NFEF SJ200-015LFR SJ200-015HFU SJ200-015HFEF 2.2(3) SJ200-022NFU SJ200-022NFEF SJ200-022LFR SJ200-022HFU SJ200-022HFEF 3.0(4) SJ200-030HFEF 3.7(5) SJ200-037LFU SJ200-037LFR 4.0(5) SJ200-040HFU SJ200-040HFEF 5.5(7.5) SJ200-055LFU SJ200 055LFR SJ200 055HFU SJ200-055HFEF 7.5(10) SJ200-075LFU SJ200-075LFR I SJ200-075HFU I SJ200-075HFEF CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net R � JJLLiJ � �a •�•' MV ..._ i r SJ200-****EF Type Improved PID control F r Versatile Functions • Reverse PID function changes the sign of • Pure analog monitor output (8-bit, 0-10V DC) the deviation value which is the difference • External thermistor terminal (PTC) between target and feedback values. -Cooling-fan on/off Upper and lower limits from a target value can be • Side-by-side installation • Regenerative braking circuit imposed on the inverter output frequency. • Instantaneous power failure recovery • Second motor setting r• Over -voltage suppression at deceleration Output Timing • 3 -wire control and Logic functions • RS -485 Serial port with Modbus°-RTU Output terminals can be assigned logical operators • Analog input selection AND, OR and XOR with RUN, AL and so on. • Second acceleration/deceleration setting ON and OFF dela times are settable or each output • Jogging y fh p •Auto -carrier frequency reduction terminal. Allows for more flexible system design. • Unattended start protection (USP) • Analog input wire -break detection Analog setpoint Global Performance calculate functions Conformity to global standards. CE, UL, c -UL An offset frequency can be added to or subtracted and c -Tick approvals. from the output frequency when ADD terminal is ON. For example, if output frequency setting is 40Hz and C E C&US offset frequency is 5Hz, output frequency becomes LISTED 45Hz (or 35Hz) when ADD terminal is ON. I c6 UL,c-Ub E I c-TickG A Integrated EMC Reduces electromagnetic noise. (on European -Version units only) Filter ISO 14001 EC97J109 Hitachi variable frequency drives (inverters) in this brochure are produced at the factory registered under the ISO 14001 standard for environmental management system and the ISO 9001 standard for inverter quality management system. CT Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net 143 -phase 200V class ModelSJ200- European Version 004HFEF European Version 002NFEF 004NFEF 005NFEF 007NFEF 011NFEF 015NFEF 022NFEF - - - USVersion 002NFU 004NFU - 007NFU - 015NFU 022NFU 037LFU 055LFU 075LFU 0.75(l) Applicable motor size, 4 -pole kW(HP) *1 0.2(1/4) 0.4(1/2) 0.55(3/4) 0.75(1) 1.1(1.5) 1.5(2) 2.2(3) 3.7(5) 5.5(7.5) 7.5(10) Output Ratings Rated capacity 1200V0.5 7.5 0.9 1.0 1.4 1.7 2.8 3.8 6.0 7.5 11 240V 0.6 1.2 1.3 2.0 2.1 3.3 4.5 7.2 9.9 13.3 8.6 Rated output current (A) *2 1.6 2.6 3.0 4.0 5.0 8.0 11.0 17.5 24 32 Weight (kg) Overload capacity(output current) 1.8 1.9 1.9 1.9 1.9 3.8 3.8 150% for 60 sec. 1.7 1.8 1.8 1.8 3.5 3.5 1c output 250V AC/30V DC 2.5A relay (ALO, AL1, AL2 terminals) Rated output voltage (V) RUN(run signal), FA1(Frequency arrival type 1 - constant speed), FA2(Frequency arrival type 2 - over -frequency), OL(overload advance Output signal 3-phase 3 -wire 200 to 240V (corresponding to input voltage) Input Rating Rated input voltage (V) Analog output terminal S ecification 1 -/3-phase 200 to 240V±10%, 50/6OHz±5 Function Analog voltage monitor, analog current monitor Enclosure *4 Specification 4 -digits 7 segment LEDs Function IP20 NEMA 1 Display Operator Cooling method input power, output voltage Status LED Self -cooling Power, Alarm, Run, Prg, Hz and A Interface Force ventilation Potentiometer, RUN, STOP/RESET, UP, DOWN, FUN and STR keys Weight (kg) Operator keypad -NFEF 0.8 0.95 0.95 1.4 1.4 1.9 1.9 - - - NFU/LFU 0.7 0.85 1.3 1.8 1.8 1.9 3.5 1 3.5 3-phase 400V class ModelSJ200- European Version 004HFEF 007HFEF 015HFEF 022HFEF 030HFEF 040HFEF 055HFEF 075HFEF US Version 004HFU 007HFU 015HFU 022HFU - 040HFU 055HFU 075HFU Applicable motor size, 4 -pole kW HP) *1 0.4(1/2) 0.75(l) 1.5(2) 2.2(3) 3 4 3.7(5) 5.5(7.5) 7.5(10) Rated capacity 400V 1.0 1.7 2.6 3.8 5.4 5.9 7.5 11 480V 1.2 2.0 3.1 4.5 6.5 7.1 10.8 13.3 Output Ratings Rated output current (A) *2 1.5 2.5 3.8 5.5 7.8 8.6 13 16 setting), 2CH(Second accel./decel.), FRS(Free-run stop), EXT(External trip), USP(Unattended start protection), SFT(Software lock), Overload capacity(output current) 150% for 60 sec. Functions Rated output voltage (V) 3-phase (3 -wire) 380 to 480V (corresponding to input voltage) Input Rating Rated input voltage (V) 3-phase 380 to 480V±10%, 50/6OHz±5% Enclosure *4 IP20 (NEMA 1) Cooling method Self -cooling Force ventilation Weight (kg) -NFEF 1.4 1.8 1.9 1.9 1.9 1.9 3.8 3.8 NFU 1.3 1.7 1.8 1.8 1.8 3.5 3.5 General Specifications Note 1: The applicable motor refers to Hitachi standard 3-phase motor (4 -pole). When using other motors, care must be taken to prevent the rated motor current (50/60 Hz) from exceeding the rated output current of the inverter. Note 2: The output voltage decreases as the main supply voltage decreases (except when using the AVR function). In any case, the output voltage cannot exceed the input power supply voltage. Note 3: The braking torque via capacitive feedback is the average deceleration torque at the shortest deceleration (stopping from 50/60 Hz as indicated). It is not continuous regenerative braking torque. The average decal torque varies with motor loss. This value decreases when operating beyond 50 Hz. If a large regenerative torque is required, the optional regenerative braking resistor should be used. Note 4: The protection method conforms to JEM 1030. Note 5: To operate the motor beyond 50/60 Hz, consult the motor manufacturer for the maximum allowable rotation speed. Note 6: The output frequency may exceed the maximum frequency setting (AO04 or A024) for automatic stabilization control. Note 7: Automatic torque boost adjustment shall be required. Note 8: Only terminal 6 is assignable the PTC (thermistor) function. CT Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Item General Specifications Control method Line -to -line sine wave pulse -width modulation (PWM) control Output frequency ran a *5 0.5 to 40OHz Frequent accuracy*6 Digital command ±-0.01%, Analog command±0.2% (25±10°C) Frequency setting resolution Digital: 0.1 Hz, Analog: (max frequency)/1000 Voltage/Frequency Characteristic V/f control,V/f variable (constant torque, reduced torque) Control Acceleration/deceleration time 0.01 to 3000 sec. (linear, sigmoid), two-stage accel./decel. Starting torque *7 200%11 Hz Carrier frequency range 2.0 to 14.OkHz Protective functions Over -current, over -voltage, under -voltage, overload, overheat, ground fault at power -on, overload limit, input over -voltage, external trip, EEPROM error, CPU error, USP error, braking resistor overload, LAD stop at over -voltage, over -current suppression Specification 10kohm input impedance, sink/source logic selectable FW(Forward), RV(Reverse), CF1-CF4(Multispeed command), JG(Jogging), DB(Extemal DC braking), SET(Second motor constants Input terminal setting), 2CH(Second accel./decel.), FRS(Free-run stop), EXT(External trip), USP(Unattended start protection), SFT(Software lock), Functions AT(Analog input selection), RS(Reset), PTC(Thermistor input) *8, STA(3-wire start), STP(3-wire stop), F/R(3-wire fwd./rev.), PID(PID On/Off), PIDC(PID reset), UP/DWN(Remote-controlled accel./decel.) , UDC(Remote-controlled data clearing), OPE(Operator control), NO(Not selected) Specification 27V DC 50mA max open collector output, 2 terminals Intelligent output 1c output 250V AC/30V DC 2.5A relay (ALO, AL1, AL2 terminals) Function RUN(run signal), FA1(Frequency arrival type 1 - constant speed), FA2(Frequency arrival type 2 - over -frequency), OL(overload advance Output signal terminal notice signal), OD(Output deviation for PID control), AL(alarm signal), DC(Wire brake detect on analog input) Analog output terminal S ecification 0 to 1 OV DC 8-bit resolution Function Analog voltage monitor, analog current monitor Specification 4 -digits 7 segment LEDs Function Parameter setting, output frequency, output current, motor torque, scaled value of output frequency, trip history, 1/0 terminal condition, Display Operator input power, output voltage Status LED Power, Alarm, Run, Prg, Hz and A Interface Potentiometer, RUN, STOP/RESET, UP, DOWN, FUN and STR keys Operator keypad Up and Down keys / Value settings or analog setting via potentiometer on operator keypad External signal 0 to 10 V DC, 4 to 20 mA Frequency setting Serial port RS485 interface Modbus RTU Operation Operator Keypad Run key / Stop key (change FW/RV by function command FW/RV Run External signal FW Run/Stop (NO contact), RV set by terminal assignment (NC/NO), 3 -wire input available Serial port RS485 interface (Modbus RTU) Operating temperature -10 to 40°C(carrier frequency 012kHz) -10 to 50'C(derating for carrier frequency and output current required) Storage temperature -20 to 65°C Environment Humidity 20 to 90% RH Vibration 5.9mm/s20.6G 10 to 55Hz Location Altitude 1,000 m or less, indoors no corrosive gasses or dust AVR (Automatic Voltage Regulation), V/f characteristic selection, accel./ Other functions decal. curve selection, frequency upper/lower limit, 16 stage multispeed, PID control, frequency jump, external frequency input bias start/end, jogging, automatic torque boost, cooling fan On/Off, trip history etc. Coating color Gray (Munsell 8.5YR6.2/0.2) Options Remote operator with copy function (SRW-OEX), EMI filters, input/output reactors, DC reactors, radio noise filters, braking resistors, braking units, LCR filter, communication cables (ICS -1, 3), programming software (being planned) Note 1: The applicable motor refers to Hitachi standard 3-phase motor (4 -pole). When using other motors, care must be taken to prevent the rated motor current (50/60 Hz) from exceeding the rated output current of the inverter. Note 2: The output voltage decreases as the main supply voltage decreases (except when using the AVR function). In any case, the output voltage cannot exceed the input power supply voltage. Note 3: The braking torque via capacitive feedback is the average deceleration torque at the shortest deceleration (stopping from 50/60 Hz as indicated). It is not continuous regenerative braking torque. The average decal torque varies with motor loss. This value decreases when operating beyond 50 Hz. If a large regenerative torque is required, the optional regenerative braking resistor should be used. Note 4: The protection method conforms to JEM 1030. Note 5: To operate the motor beyond 50/60 Hz, consult the motor manufacturer for the maximum allowable rotation speed. Note 6: The output frequency may exceed the maximum frequency setting (AO04 or A024) for automatic stabilization control. Note 7: Automatic torque boost adjustment shall be required. Note 8: Only terminal 6 is assignable the PTC (thermistor) function. CT Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net •SJ200-002 - 004NFU •SJ200-007 - 022NFU •SJ200-030 - 037LFU •SJ200-004 - 040HFU •SJ200-055,075LFU •SJ200-055,075HFU s_10 201 ®o: , 5(0.20) 67 (2.64) 80 3.15 n 000000000 N � 2-05 4 L6 b®wg ©®®o a 98 (3.86 5(0.20) 0 4.33 0000000000000 000 0 0 DODODOOODOOD a model D 002NFU 103(4.06) 004NFU 117(4.61) model D 007NFU 139(5.47) 004HFU 015,022NFU 166(6.54) 037LFU 007-040HFU 004HFU and 007HFU : without FAN lr�==R§ �-11IIWW1 II � ; I�1�Illdl�i��llllllh ll�llilt]��II Keypad (digital operator), provided as standard -OPE - SRmini •SJ200-002 - 005NFEF o 5(0.20) o®oo 5(0.20) 67 2.64 80 (3.15 000000000 0 0 •SJ200-007 - 022NFEF 2-05 •SJ200-004 - 040HFEF b o� ®® 5 0.20) 98 (3.86) 110 (4.33) c 0000000000000 000 0 0 •SJ200-055,075HFEF 2-06 model D 002NFEF 103(4.06) 004NFEF 117(4.61) 005NFEF model D 007,011NFEF 139(5.47) 004HFEF 015,022NFEF 166(6.54) 007-040HFEF 007NFEF, 004HFEF and 007HFEF : without FAN * Potentiometer knob can be removed. IIW WII Ili It�'11,llllllllllllllrl�l�1lIIII1�� - 70 (2.76) 3'r 10 2.7 2-04 20.5 (0.83) 18 0.73) POWERO ALARM O =OA N ioJ -f- o O ai �c RUN _Q OPR6 }� M I �o FUNC O STR �- i I ] 2-M3 depth 5 Reverse side Mounting holes [Unit: mm(inch)] Inches for reference only. [Unit: mm (inch)] Inches for reference only. CT Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net SJ200 Series can be easily operated with the digital operator (OPE-SRmini) provided as standard. The digital operator can also be detached and used for remote -control. An operator with copy function is also available as an option. Displays frequency, motor current, rotational speed of the motor, and an alarm code. Press to run the motor. Press to stop the L drive or reset an alarm. Press to set or monitor a parameter value. Press up or down to sequence through parameters and functions shown on the display, and increment/decrement values. Lights when the power input to the drive is ON Indicates the unit associated with the parameter display. Shows drive's status. Press to write the new value to the EEPROM. 4X-KlTmini Qap;u N_I cj Cvrc0 _j 11 E_qi cr0 Dpd rAnt cp7 _ E_qi c /❑ Qc p tbrco _j I] E_qi cr0❑ Pc_pArrt cp 1 You can mount the keypad with the potentiometer for a NEMA1 rated installation. The kit also provides for removing the potentiometer knob to meet NEMA 4X requirements,as shown (part no.4X-KITmini). 1. Setting the maximum output frequency (4) f?LOtj ; or the code (1) QO or the value previously number set in the end of monitored is displayed. (2)Function code appears. (3) R — — — appears. last setting is displayed. POWER.POWER. POWER. POWER. PLARMO ALARM. ALARM. ALARM. n n GOA Hz ® OHz ® OH ME 01, I, IJ OOA OA A Power o ORUN ° .RUN ° ORUN ° .RUN on RUN STOP .PRG ° RUN SGP °ERG ' RUN $TOR .PRG ° RUN STOR oPRG ° Press FUN key. Press Q Press FUN key. FUNC OQ O O NNC O O O OO FUNC OQ O O NNC O O SiR until 9 - - - appears. (8)Returnsto C?nnLf and (5) fi^0'l appears. (6)Preset value is displayed. (7)Newly set value is displayed. the setting is complete. POWER. POWER. POWER. POWER. A_RRMOAlARMO A_ARMO ALARMO @ ORz ® "I® "I® OHi OA OA OA oA ° .RUN ! ORUN .RUN .RUN OO RUN STS .PRG ° RUN STS .PRG ° �O RUN STS .PRG ° O y RUN STOP .PRG ° Press z Press FUN key. Press : Press srR ke to set desired °" to store N until ROOLs value. the value. appears. 'To run the motor, go back to monitor mode or basic setting mode. Pressing FUN key 2. Running the motor(by potentiometer) for a while and back to ciOLo i (1)00 or the value previously (2)The motor runs at the frequency monitored is displayed. set by the potentiometer. (3)The motor stops. POWERO POWER. POWER ALARM A fflo ALARM. nn 0A ®oH nn.A 1_1,11 O A O A IJ, LI o A Power O ORUN 0 .RUN • ORUN on RUN STOP oPRc ° RUN sTOP °PRG ° RUN ST0 °PRG ° OO O O Press RUN key and turn the O O O O Press key to stop the motor. O O O O DN �" potentiometer clockwise. G ON � 51R °N S N \ (Output frequency monitor) 3. Monitoring output current value (1) "10 or the value previously (4)Output current value monitored is displayed. (2)Function code appears. (3) d002 appears. is displayed. POWER. POWER. POWER. POWER. ALARM ®° A ALARM O ®° A ALARM ®° A ALARMO Power x'11 OA ° •RUN ° .RUN ° .RUN • .RUN OnRUN 5To 'PRG ° RUN STG oPRc ° RUN 5To oPRc ° RUN sTo oPac ° T Press FUN key.' Press 0 �Er Press FUN key. Fuxc Op O sm FNxc O O sm until d002 Fuxc Op O sm FNNC Op O srR appears. CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Hardware switches Terminal Description Terminal Svmbol RS -485 communication/ operator selection switch Frequency/RUN command source selection switch Terminal Symbol Terminal Name L1,L2,N/L3 Main power supply input terminals U/T1,V/T2,W/T3 Inverter output terminals +1,+ DC reactor connection terminals +,RB External braking resistor connection terminals + + External braking unit connection terminals SR [default] Ground connection terminal Screw Diameter and Terminal Width Model Screw diameter (mm) Terminal width W (mm) 002 - 004NFUI005NFEF M3.5 7.6 007- 022NFEF, 037LFU M4 10 004 - 040HFU/HFEF l)L 055-075LFU/HFU/HFEF M5 13 ATF Control circuit terminals Terminal arrangement L61432 I I I I 1 PCSI AL2 AL1 ALO H O OI L I AM CM2 12 1 11 Removable terminals, Upper/Lower independent. Terminal function Switch symbol Switch Name Switch Name Description Ranges and Notes Select input logic of intelligent input terminals from sink or SR/SK Input logic selection source. *1 SR [default] Source logic switch SK Sink logic 24V DC, 100mA max. Input/monitor 6 RS -485 Select communication connector distination. *2 485/OPE communication/key 485 RS485 communicaiton via Modbus protocol OPE [default] I Keypad (option) constants setting), 2CH(Second accel./decel.), FRS(Free-run stop), EXT(Extemal trip), USP(Unattended start protection), pad selection switch 3 Select frequency and run command input source. 2 Input from control terminal wire fwd./rev.), PID(PID On/Off), PIDC(PID reset), UP/DWN(Remote-controlled accel./decel.), UDC(Remote-controlled data 1 clearing), OPE O erator control), ADD Fre uenc set oint , F -TM Force terminal enable or NO Not selected). Frequency source: Analog input (0, OI) Frequency/RUN TM Run command source: FW and/or RV terminal TM/PRG command input T (FW and/or RV must be assigned to input Analog input, voltageO switch Freqency terminal) Input from source defined with keypad input impedance10kohm setting (1 k V IR DCO-10V DC4-20mA PRG [default] program OI Analog input, current Frequency source: Potentiometer (default) input impedance 250ohm If no input termilal is assigned to [AT](analog input selection),the inverter outputs Run command source: RUN key onkeypad Note 1: Polarity of the PCS terminal is changed by setting the input logic selection switch. Note 2: The standard keypad (OPE-SRmini) can be used either the switch is set to 485 or OPE. Terminal arran SJ200 002-007LFR,002-OO5NFEF,002-004NFU Jumper R/1-1 I S/1_2 I T/1_3 I U/T1 I V/T2 I W/T3 SJ200 015-037LFR,004-037HFR,007-022NFEF, 004-040HFEF,007-022NFU,037LFU,004-040HFU Jumper l�lll�® R/1-1 S/1_2 T/L3 U/T1 Vlf2 W/T3 SJ200 055.075LFR,LFU 055.075HFR,HFU,HFEF R/1-1 S/1_2 T/1_3 U/T1 V/T2 W/T3 • M® - - - . 11011111® Jumper CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Terminal name Descri tion Ranges and Notes AM Voltage analog out ut 0 to10V DC, 1 mA max. L Common for inputs PCS +24V power for inputs 24V DC, 100mA max. Input/monitor 6 Intelligent (programable) input terminals, selection from: FW(Forward), RV(Reverse), CF1-CF4(Multispeed JG(Jogging), DB(External DC braking), SET(Second 0 ated b y p 5 si signals 9 command), motor PCS . closermg switch. 4 constants setting), 2CH(Second accel./decel.), FRS(Free-run stop), EXT(Extemal trip), USP(Unattended start protection), SWI logic is 3 SFT(Software lock), AT(Analog input selection), RS(Reset), PTC(Thermistor input), STA(3-wire start), STP(3-wire stop), F/R(3- (Input 1-6 selectable) 2 wire fwd./rev.), PID(PID On/Off), PIDC(PID reset), UP/DWN(Remote-controlled accel./decel.), UDC(Remote-controlled data 1 clearing), OPE O erator control), ADD Fre uenc set oint , F -TM Force terminal enable or NO Not selected). H +10V analog reference H 1 O 1 OI 1 L H 1 O 1 OI 1 L H 1 O 1 OI L IOV DC, 10mA max T O Analog input, voltageO to 10V DC, Freqency _ input impedance10kohm setting (1 k V IR DCO-10V DC4-20mA 4 to 20mA DC, OI Analog input, current Input inpedance 101<0 Input inpedance 250ko input impedance 250ohm If no input termilal is assigned to [AT](analog input selection),the inverter outputs sum of O(voltage) and O1(current) frequency. L Common for inputs Assign [AT] for input terminal to selecting frequency source from voltage or current. — 12 Intelligent (programable) output terminals, selection from: Open collector output Output RUN(run signal), FA1(Frequency arrival type 1 -constant speed), FA2(Frequency arrival type 2 -over-frequency), L level operation 11 signals OL(overtoad advance notice signal), OD(Output deviation for PID control), AL(alarm signal), DC(Wire brake detect on 27V DC,,50mA max.. analog input), FBV Feedback voltage comparison), NDc Network Disconnection), LOG Lo isoperation result), CM2 Common for intelligent output terminals AL2 AC250V 2.OA (Resistive load) Relay contact (alarm output) 0.2A (cosrp =0.4) AL1 Relay terminals (programable, <Initial setting> DC30V 3.OA (Resistive load) output function is selectable same as Normal: AL0-AL1 closed AL2 AL1 ALO 0.6A(cosrP=0.4) intelligent output terminals). Trip/Power OFF: ALO -AL2 closed (minimum) AC100V 10mA ALO DC 5V 100mA CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Monitoring and main profile parameters Function Code Name d001 Output frequency monitor IM Range 0.0 to 400.0 Default lb - Unit Hz ,,/: Allowed j I X: Not allowed Run mode edit - d002 Output current monitor 0.0 to 999.9 - A - d003 Rotation direction monitor F Forward /o Sto /r Reverse - - - d004 Process variable, PID feedback monitor 0.00 to 99.99/100.0 to 999.9/1000. to 9999. - - - d005 Intelligent input terminal status 1 I r ION e.g. :1,2 : ON i i 1 11-1 OFF 3,4,5,6: OFF 6 54 32 1 - - - d006 Intelligent output terminal status 1 1 11 11 1-1 ON e.g. :11,12 : ON 111111111 I OFF AL : OFF AL12 11 - - - Monitor 4007 Scaled output frequency monitor O.00to99.99/100.Oto999.9/1000.to9999J1000to999910000t099999 - - - d013 Output voltage monitor 0.0 to 600.0 - V - d016 Cumulative operation RUN time monitor 0. to 9999./1000 to 9999/10000 to 99990 - hr - d017 Cumulative power -on time monitor 0. to 9999./1000 to 9999/10000 to 99991 - hr - d080 Trip counter 0. to 9999. - times - d081 d082 d083 Trip monitor 1 Trip monitor 2 Trip monitor 3 Displays trip event information - - - - - - - - - F001 Output frequency setting 0.0/start freq. to 400.0 0.0 Hz V F002 Acceleration time 1 setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 10.0 sec V Main Profile F202 Acceleration time 2 setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 10.0 sec V Parameters F003 Deceleration time 1 setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 10.0 sec V F203 Deceleration time 2 setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 10.0 sec V F004 Keypad Run key routing 00(Forward)/01 Reverse 00 - X A-- A Group: Standard functions I/ A020 - A035 Multi -speed frequency setting (0-15) Expanded b-- b Group: Fine-tuning functions 0.0 Hz V Multi -speed and functions C-- C Group: Intelligent terminal functions 0.0/start freq. to maximum freq. 0.0 0.0 Hz H-- TH Group: Motor constants functions A038 Jog frequency setting 0.00/start freq. to 9.99 1.00 A Group: Standard functions Hz V A039 Function CodeDefault EF CE -U UL Unit Run mode edit A001 I Frequency source setting 00(Keypad potentiometer)/01(Control terminal)/ 02(Function F001 setting)/03(RS485)/10(Calculation result) 01 00 - X A002 Run command source setting 01 (Control terminal)/02(Run key on keypad)/03(RS485) 01 02 - X Basic setting A003 Base frequency setting 30 to maximum freq. 50. 60. Hz X A203 Base frequency setting, 2nd motor 30 to maximum freq. 50. 60. Hz X A004 Maximum frequency setting 30 to 400 50. 60. Hz X A204 Maximum frequency setting, 2nd motor 30 to 400 50. 60. Hz X A005 [AT] selection 00(0/0I)/01(disable)/02(ONR)/03(OINR) 0.0 0.0 - X A011 [O] -[L] input active range start frequency 0.0 to maximum freq. 0.0 0.0 Hz X A012 [O] -[L] input active range end frequency 0.0 to maximum freq. 0. 0. Hz X Analog input A013 [O] -[L] input active range start voltage 0 to 100 0.0 0.0 /a X setting A014 [O] -[L] input active range end voltage 0 to 100 100. 100. % X A015 [O] -[L] input start frequency enable 00(use set value)/01(use 0 Hz) 01 01 - X A016 External frequency filter time constant 1 to 8 2. 8. - I/ A020 - A035 Multi -speed frequency setting (0-15) 0.0/start freq. to maximum freq. 0.0 0.0 Hz V Multi -speed and A220 Multi -speed frequency (2nd), 0 0.0/start freq. to maximum freq. 0.0 0.0 Hz V jogging A038 Jog frequency setting 0.00/start freq. to 9.99 1.00 1.00 Hz V A039 Jog stop mode 00(free-run stop)/01(deceleration and stopu02(DC braking) 00 00 - X A042 Manual torque boost value 0.0 to 20.0 5.0 5.0 % V A242 Manual torque boost value, 2nd motor 0.0 to 20.0 0.0 0.0 % J A043 Manual torque boost frequency adjustment 0.0 to 50.0 3.0 3.0 % V A243 Manual torque boost frequency adjustment, 2nd motor 0.0 to 50.0 0.0 0.0 % V A044 V/f characteristic curve selection 00(VC)/01(Reduced torque)/02(1-SLV) 02 02 - X V/f A244 V/f characteristic curve selection, 2nd motor 00(VC)/01(Reduced torque)/02(1-SLV) 02 02 - X Characteristic A045 V/f gain setting 20 to 100 100. 100. % V A046 iSLV voltage compensation gain 0 to 255 100. 100. % V A246 iSLV voltage compensation gain,2nd motor 0 to 255 100. 100. % V A047 iSLV slip compensation gain 0 to 255 100. 100. % V A247 iSLV slip compensation gain, 2nd motor 0 to 255 100. 100. % V A051 DC braking enable 00(Disable)/01(Enable) 00 00 - X A052 DC braking frequency setting Start freq. to 60.0 0.5 0.5 Hz X A053 DC braking wait time 0.0 to 5.0 0.0 0.0 sec X DC braking A054 DC brakingforce duringdeceleration 0. to 100. 0. 0. /6 X A055 DC braking time for deceleration 0.0 to 60.0 0.0 0.0 sec X A056 DC braking / edge or level detection for [DB] input 00(Edge)/01(Level) 01 01 - X A061 Frequency upper limit setting 0.0/Freq. lower limit setting to maximum freq. 0.0 0.0 Hz X A261 Frequency upper limit setting, 2nd motor 0.0/Freq. lower limit setting (2nd) to maximum freq. (2nd) 0.0 0.0 Hz X A062 Frequency lower limit setting 0.0/Start freq. to freq. upper limit setting 0.0 0.0 Hz X A262 Frequency lower limit setting, 2nd motor 0.0/Start freq. (2nd) to freq. upper limit setting (2nd) 0.0 0.0 Hz X Frequency limit Jump (center) frequency setting 1 0.0 to 400. 0.0 0.0 Hz X and jumpA063 A064 Jump (hysteresis) frequency setting 1 0.0 to 10.0 0.5 0.5 Hz X frequency A065 Jump (center) frequency setting 2 0.0 to 400. 0.0 0.0 Hz X A066 Jump (hysteresis) frequency setting 2 0.0 to 10.0 0.5 0.5 Hz X A067 Jump (center) frequency setting 3 0.0 to 400. 0.0 0.0 Hz X A068 Jump (hysteresis) frequency setting 3 0.0 to 10.0 0.5 0.5 Hz X CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net A Group: Standard functions IX:Not allllowed1 Function Code Name Range Default -EF CE -U(UL) Unit Run mode edit A071 PID Enable 00(Disable)/01 (Enable) 00 00 - X A072 PID proportional gain 0.2 to 5.0 1.0 1.0 - ./ A073 PID integral time constant 0.0 to 150.0 1.0 1.0 sec V A074 PID derivative time constant 0.00 to 100.0 0.0 0.0 sec V PID Control A075 PV scale conversion 0.01 to 99.99 1.00 1.00 - X A076 PV source setting 00([011 terminal)/01([O] terminal /02 RS485 /10 Calculation result 00 00 - X Restart after instantaneous A077 Reverse PID action OO(OFF)/01(ON) 00 00 - X A078 PID output limit 0.0 to 100.0 0.0 0.0 % X power failure A081 AVR function select 00 Enable 01 Disable /02 Enabled except during deceleration 00 00 - X AVR function A082 AVR voltage select 200V class: 200/215/220/230/240 400V class: 380/400/415/440/460/480 230/400 230/460 V X b212 A092 Acceleration 2 time setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 15.00 15.00 sec A292 Acceleration 2 time setting, 2nd motor 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 15.00 15.00 sec V Electronic thermal characteristic A093 Deceleration 2 time setting 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 15.00 15.00 sec V torque 2) A293 Deceleration (2) time setting, 2nd motor 0.01 to 99.99/100.0 to 999.9/1000. to 3000. 15.00 15.00 sec V Overload restriction operation mode A094 Select method to switch to Acc2/Dec2 profile 00 2CH from input terminal /01 transition freq.) 00 00 - X Operation mode A294 Select method tosuitchtoAoQ/Dec2 profile, 2nd motor 00 2CH from input terminal/01 transition freq.)00 A 00 - X and acc./dec. A095 Acct to Acc2 frequency transition point 0.0 to 400.0 0.0 0.0 Hz X function A295 Acct to Acc2 *uency transition point, 2nd motor 0.0 to 400.0 0.0 0.0 Hz X A096 Dec1 to Dec2 frequency transition point 0.0 to 400.0 0.0 0.0 Hz X Software lock mode selection A296 Dec1 to Dec2 frequency transition point, 2nd motor 0.0 to 400.0 0.0 0.0 Hz X A097 Acceleration curve selection 00(Linear)/01 (Sigmoid) 00 00 - X [AM] terminal analog meter adjustment A098 Deceleration curve selection 00(Linear)/01 (Sigmoid) 00 00 - X Start frequency adjustment A101 [Ol]-[1-1 input active range start frequency 0.0 to maximum freq. 0.0 0.0 Hz X Carrier frequency setting A102 [OI] -[Ll input active range end frequency 0.0 to maximum freq. 0.0 0.0 Hz X External freq. A103[011-[L]input active range start current 0. to 100. 0. 0. /o X tuning A104 [OI] -[L] input active range end current 0. to 100. 100. 100. % X Country code for initialization A105 [011-[L] input start frequency enable 00 Use setting value /01 OHz 01 01 - X Frequency scaling conversion factor A141 A input select for calculate function B input select for calculate function 01 (Keypad potentiometer) 02 (0 input)/03(01 in ut /04 RS485 02 03 02 - X A142 03 - X Frequency A143 Calculation symbol 00 A141+A142 /01 A141 -A142 /02 A141*A142 00 00 - X caluculation A145 ADD frequency 0.0 to 400.0 0.0 0.0 Hz V 0.0 A146 ADD direction select 00 Plus ,01 Minus 00 00 00(Deceleration and stop)/01(Free-run stop) X b Group: Fine-tuning functions Function Code Name Range Default -EF CE -U UL Unit Run mode edit b001 Selection of automatic restart mode 00(Alarm output)/01(Restart at OHz)/02(Resume after 00 00 - X freq. matching)103(Resume freq. matching then trip) b002 Allowable under -voltage power failure time 0.3 to 25.0 1.0 1.0 sec X b003 Retry wait time before motor restart 0.3 to 100.0 1.0 1.0 sec X b004 Instantaneous power failure / under- 00(Disable)/01(Enable) 00 00 - X voltage trip alarm enable Restart after instantaneous b005 Number of restarts on power failure / 00(Restart 16 times)/01(Always restart) 00 00 - X under -voltage trip events power failure b012 Electronic thermal setting Rated Rated A X 0.2*Rated current to 1.2*Rated current current current b212 Rated A X Electronic thermal setting, 2nd motor Rated current current b013 Electronic thermal characteristic 00(Reduced torque)/01(Constant torque)/02(Reduced 01 01 - X Electronic thermal characteristic, 2nd motor torque 2) 01 b213 01 - X b021 Overload restriction operation mode 00(Disable)/01(Enable)/02(Enable for during acceleration) 01 01 - X Overload b022 Overload restriction setting 0.2*Rated current to 1.5*Rated current 1.5*Rated 1.5*Rated A X restriction current current b023 Deceleration rate at overload restriction 0.1 to 30.0 1.0 30.0 sec X 00([SFT] input blocks all edits)/01([SFT] input blocks edits except Lock b031 Software lock mode selection F001 and Multispeed parameters/02(No access to edits)/03(No 01 01 - X access to edits except F001 and Multi -speed parameters) b080 [AM] terminal analog meter adjustment 0. to 255. 100. 100. - b082 Start frequency adjustment 0.5 to 9.9 0.5 0.5 Hz X b083 Carrier frequency setting 2.0 to 14.0 5.0 5.0 kHz X b084 Initialization mode (parameters or trip 00(Trip history clear)/01(Parameter initialization)/ 00 00 - X history) 02(Trip history clear and parameter initialization) b085 Country code for initialization 00(JP)/01(CE)/02(US) 01 02 - X b086 Frequency scaling conversion factor 0.1--99.9 1.0 1.0 - V b087 STOP key enable 00(Enable)/01(Disable) 00 00 - X Others b088 Restart mode after FRS 00(Restart from 0Hz)/01(Restart with frequency detection) 00 00 - X b090 Dynamic braking usage ratio 0.0 to 100.0 0.0 0.0 % X b091 Stop mode selection 00(Deceleration and stop)/01(Free-run stop) 00 00 - X b092 Cooling fan control (see note below) 00(Always ON)/01(ON during RUN, OFF during 00 00 - X STOP)/02(Depend on fin temperature) b095 Dynamic braking control 00(Disable)/01(Enable during RUN only)/02(Enable) 00 00 - X b096 Dynamic braking activation level 330-380/660-760 360/720 360/720 V X b130 Over -voltage LADSTOP enable 00(Disable)/01(Enable) 00 00 - X b140 Over -current trip suppression 00(Disable)/01(Enable) 00 00 - X b150 Carrier mode 00 Disable /01 Enable) 00 00 X CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net C Group: Intelligent terminal functions �/: Allowed X: Not allowed 1 Function Code Intelligent input terminal C001 C002 C003 C004 C005 C006 Name Terminal [1] to [6] function Range Default -EF(CE) -U(UL) Unit Run mode edit 00(FW:Forward), 01(RV:Reverse), 00 00 02-05(CF1-CF4:Multispeed command), 06(JG:Jogging), 07(DB:External DC braking), 08(SET:Second motor constants setting), 01 01 09(2CH:Second accel./decel.), l l(FRS:Free-run stop), 12(EXT:External trip), 13(USP:Unattended start protection), 02 16 15(SFT:Software lock), 16(AT:Analog input selection), 18(RS:Reset), 19(PTC:Thermistor input), 20(STA:3-wire start), 21(STP:3-wire stop), 22(F/R:3-wire fwd./rev.), 23(PID:PID On/Off), 24(PIDC:PID reset), 03 13 27(UP:Remote-controlled accel.), 28(DWN:Remote-controlled decel.), 29(UDC:Remote-controlled data clearing), 31(OPE:Operatorcontrol), 18 09 50(ADD: Frequency setpoint), 51(F -TM: Force terminal enable), 255(NO:Not selected) 09 18 - X - X - X - X - X - X H2O4 C16 CO 1 6 Terminal [1] to [6] active state 00(NO)/01(NC) 00` 00 - X 100 100 - 0O21 CO22 Terminal [11] and [12] function 00(RUN:run signal), 01(FA1:Frequency arrival type 1 - constant speed), 02(FA2:Frequency arrival type 2 - over- frequency), 03(OL:overload advance notice signal), 04(OD:Output deviation for PID control), 05(AL:alarm signal), 06(DC:Wire brake detect on analog input), 07(FBV: Feedback voltage comparison), 08(NDc: Network Disconnection), 09(LOG: Logic operation result) 01 00 05 01 00 05 - - X X CO26 Alarm relay function - X H -2 -07 - motor CO28 [AM] signal selection 00(Output frequency)/01(Output current) 00 1 00 - X Intelligent input terminal C031, C032 Terminal [11] and [12] active state 00(NO)/01(NC) 00 00 - X C036 Alarm relay active state 00(NO)/01(NC) 01 01 - X C041 Overload level setting 0.0'Rated current to 2.0'Rated current Rated current Rated current A X C042 Frequency arrival setting for acceleration 0.0 to 400.0 0.0 0.0 Hz X C043 Frequency arrival setting for deceleration 0.0 to 400.0 0.0 0.0 Hz X C044 PID deviation level setting 0.0 to 100.0 3.0 3.0 % X C052 Feedback comparison upper level 0.0 to 100.0 100 100 % X C053 Feedback comparison lower level 0.0 to 100.0 0 0 % X C071 Communicationspeed selection 04 4800b s /OS 9600b s /06 19200b s 06 04 - X C072 Node allocation 1. to 32. 1. 1. - X C074 Communication parity selection 00 No parity)/01 Even arit /02 Oddparity) 00 00 - X C075 Communication stop bit selection 1 1 -bit /2 2 -bit 1 1 bit X Serial communication C076 Communication error mode 00(Trip)/01(Trip after deceleration stop)/02(Disable)/ 03(FRS)/04(D celeration stop) 02 02 - X C077 Communication error time 0.00-99.99 0.00 0.00 sec X C078 Communication wait time 0. to 1000. 0. 0. msec X C081 [O] input span calibration 0. to 200. 100. 100. % I/ Analog meter C082 [OI] input span calibration 0. to 200. 100. 100. % V setting C085 Thermistor input tuning 0.0 to 200.0 100.0 100.0 % V C086 AM terminal offset tuning 0.0 to 10.0 0.0 1 0.0 V V C091 Reserved for factory adjustment 00 must not be changed) 00 00 - V C101 Up/Down memory mode selection 0O(Clear last frequency)/01(Keep last frequency adjusted b UP/DWN)00 00 - X C102 Reset mode selection 00(Cancel trip state at input signal ON transition)/ 01 (Cancel trip state at signal OFF transition)/ 02 Cancel trip state at input signal ON transition 00 00 - X Others C141 Input A select for logic output 1 00(RUN)/01(FA1)/02(FA2)/03(OL)/04(OD) 05 AL /06 Dc /07 FBV /O8 NDc 0 1 0 1 - X C142 Input A select for logic output 2 - X C143 Logic function select OO(AND)/01(0 /02 XOR 0 0 - X C144 ON delay time, output terminal 11 0.0 to 100.0 0.0 0.0 sec X C145 OFF delay time, output terminal 11 0.0 to 100.0 0.0 0.0 sec X C146 ON delay time, output terminal 12 0.0 to 100.0 0.0 0.0 sec X C147 OFF delay time, output terminal 12 0.0 to 100.0 0.0 0.0 sec X C148 ON delay time, relay 0.0 to 100.0 0.0 0.0 sec X C149 OFF delay time, relay 0.0 to 100.0 0.0 0.0 sec X vote: CO 4: 01 for CE version. H Group: Motor constants functions Function Code Name Range Default Unit -EF(CE) -U(UL) Run mode edit H003 Motor capacity, 1st motor JP, US: 0.2/0.4/0.75/1.5/2.2/3.7/5.5/7.5/11.0 CE: 0.2/0.4/0.55/0.75/1.1/1.5/2.2/3.0/4.0/5.5/7.5/11.0 Factory Factory kW set set kW X H2O3 Motor capacity, 2nd motor X Motor constants H004 Motor poles setting, 1st motor 2/4/6/8 4 4 poles X H2O4 Motor poles setting, 2nd motor 4 4 poles X and gain H006 Motor stabilization constant, list motor 0. to 255. 100 100 - H2O6 Motor stabilization constant, 2nd motor 100 100 - H007 Motor voltage class select, 1 st motor 00(200V class)/01(400V class) Factory Factory V set set V X H -2 -07 - motor voltage class select 2nd motor X CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Error Codes Name Cause(s) Display on digital operator Display on remote operator/copy unit Error code Output frequency at trip point While at constantspeed u OC.Drive During deceleration 2 OC.Decel The inverter output was short-circuited, or the motor shaft is locked or has a heavy Over current load. These conditions cause excessive current for the inverter, so the inverter output is turned OFF. During acceleration OC.Accel Others Li Over.0 Overload *1 When a motor overload is detected by the electronic thermal function, the inverter trips and turns OFF Over.L protection its output. Braking resistor overload When the regenerative braking resistor exceeds the usage time allowance or sage ratio, the inverter E OL.BRD trips and turns OFF its output to the motor. Over voltage protection When the DC bus voltage exceeds a threshold, due to regenerative energy from the motor. C u 0 Over.V EEPROM error *2,3 When the built-in EEPROM memory has problems due to noise or excessive temperature, the inverter u 8 EEPROM trips and turns OFF its output to the motor. Under -voltage error A decrease of internal DC bus voltage below a threshold results in a control circuit fault. This condition can also generate excessive motor heat or cause low torque. The inverter trips and turns OFF its g Under.V output. IL 1 i CPU CPU error A malfunction in the built-in CPU has occurred, so the inverter trips and turns OFF its output to the 22 COMM.ERR motor. External trip A signal on an intelligent input terminal configured as EXT has occurred. The inverter trips and turns 2 EXTERNAL OFF the output to the motor. USP *4 When the Unattended Start Protection (USP) is enabled, an error occurred when power is applied while a Run signal is present. The inverter trips and does not go into Run Mode until the error is USP cleared. Ground fault *5 The inverter is protected by the detection of ground faults between the inverter output and the motor 1 ` GND.FIt during powerup tests. This feature protects the inverter, and does not protect humans. Input over -voltage When the input voltage is higher than the specified value, it is detected 100 seconds after powerup CJ OV.SRC and the inverter trips and turns OFF its output. Inverter thermal trip When the inverter internal temperature is above the threshold, the thermal sensor in the inverter module detects the excessive temperature of the power devices and trips, turning the inverter output E OH FIN OFF. Gate array error An internal inverter error has occurred in communications between the CPU and gate array IC. 2 GA Thermistor When a thermistor is connected to terminals [PTC] and [CMI] and the inverter has sensed the 3 S TH temperature is too high, the inverter trips and turns OFF the output. Communications error The inverter's watchdog timer for the communications network has timed out. C0 COMM Note 1: Reset operations acceptable 10 seconds after the trip. Note 2: If an EEPROM error (E08) occurs, be sure to confirm the parameter data values are still correct. Note 3: EEPROM error may occer at power -on after shutting down the power while copying data with remote operator or initializing data. Shut down the power after completing copy or initialization. Note 4: USP error occures at reseting trip after under -voltage error (E09) if USP is enabled. Reset once more to recover. Note 5: Ground fault error (E14) cannot be released with resetting. Shut the power and check wiring. How to access the details about the present fault ►'L ii i (&'* i�i i%%i �* iii ST i �� i�� (I'* (51T �i (51T1077711 ii Error code Output frequency at trip point Motor current at trip point Voltage between Cumulative inverter Cumulative power -on P(+) and N(-) at trip point RUN time at trip point time at trip point CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Source type logic Powersou 143 -phase 200-24OV-1 3-phase 380-48OV-1 50/60Hz- Intelligent input terminals (6 terminals) Source type DC 0-10V(8bit) Frequency setting 1 kD-2kQ Current input 4mA-20mA Note 1: Common terminals are depend on logic. Terminal 1,2,3,4,5,6 H2O,OI 11,12 Common Sink logic: L L CM2 Source logic: PCS Note 2: Choose proper inverter input volotage rating. CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Power Supply Input p Voltage Applicable Motor (kW(HP)) Wireing Model Power Lines Signal Lines AWG mm2 Fuse (Class J) 200V 0.2(1/4) SJ200-002NFU/NFEF 16 1.25 0.14 to 0.75mm2 shelded wire 10 0.4(1/2) SJ200-004NFU/NFEF 16 1.25 10 0.55(3/4) SJ200-005NFEF 16 1.25 10 0.75(1) SJ200-007NFU/NFEF 14 2.0 15 1.1(1.5) SJ200-011 NFEF 14 2.0 15 1.5(2) SJ200-015NFU/NFEF 12 2.0 20(single ph.) 15(three-ph.) 2.2(3) SJ200-022NFU/NFEF 10 2.0 30(single ph.) 20(three-ph.) 3.7(5) SJ200-037LFU 12 3.5 30 5.5(7.5) SJ200-055LFU 10 5.5 40 7.5(10) SJ200-075LFU 8 8.4 50 400V 0.4(1/2) SJ200-004HFU/NFEF 16 1.25 0 714 to shelded wire 3 0.75(1) SJ200-007HFU/NFEF 16 1.25 6 1.5(2) SJ200-015HFU/HFEF 16 1.25 10 2'2(3) SJ200-022HFU/HFEF 16 1.25 10 3(4) SJ200-030HFEF 14 2.0 15 4.0(5) SJ200-040HFU/HFEF 14 2.0 15 5.5(7.5) SJ200-055HFU/HFEF 12 3.5 20 7.5(10) SJ200-075HFU/HFEF 12 3.5 25 Note 1: Field wiring connection must be made by a UL and c -UL listed closed-loop terminal connector sized for the wire gauge involved. Connector must be fixed using the crimping tool specified by the connector manufacturer. Note 2: Be sure to use large wire gauges for power wiring if the distance exceeds 20m (66ft). Note 3: Use 0.75mm2 wire for the relay terminals (ALO, AL1 and AL2) signal wire. Name Function This is useful in suppressing harmonics induced on the power supplylines, Input side AC reactor or when the main power voltage imbalance exceeds 3% (and power source capacity is more than 500kVA), or to smooth out line fluctuations. It also improves the power factor. Electrical noise interference may occur on nearby equipment such as a radio Radio noise filter receiver. This magnetic choke filter helps reduce radiat-ed noise (can also be used on output). EMC filter Reduces the conducted noise on the power supply wiring generated by the inverter. Connect to the inverter input side. Radio noise filter (Capacitor filter) This capacitor filter reduces radiated noise from the main power wires in the inverter input side. DC link choke Suppresses harmonics generated by the inverter. Braking resistor This is useful for increasing the inverter's control torque for high duty -cycle (on-off) applications, and improving the decelerating capability. Braking unit Output side noise filter Reduces radiated noise from wiring in the inverter output side. Electrical noise interference may occur on nearby equipment such as a radio Radio noise filter receiver. This magnetic choke filter helps reduce radiated noise (can also be used on input). This reactor reduces the vibration in the motor caused by the inver-ter's switching AC reactor waveforms, by smoothing the waveforms to approximate commercial power quality. It is also useful when wiring from the inverter to the motor is more than 10m in length, to reduce harmonics. LCR filter Sine wave shaping filter for the output side. Note: An EMI filter is required for European EMC directive and C -Tick, but the others are not for this purpose. CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net Application to Motors Application to general-purpose motors The overspeed endurance of a general-purpose motor is 120% of the rated speed for 2 minutes (JIS C4,004). For operation at higher Operating frequency than 60Hz, it is required to examine the allowable torque of the motor, useful life of bearings, noise, vibration, etc. In this case, be sure to consult the motor manufacturer as the maximum allowable rpm differs depending on the motor capacity, etc. The torque characteristics of driving a general-purpose motor with an inverter differ from those of driving it using commercial power Torque characteristics (starting torque decreases in particular). Carefully check the load torque characteristic of a connected machine and the driving torque characteristic of the motor. Motor loss and The torque characteristics of driving a general-purpose motor with an inverter differ from those of driving it using commercial power temperature increase Noise When run by an inverter, a general-purpose motor generates noise slightly greater than with commercial power. When run by an inverter at variable speeds, the motor may generate vibration, especially because of (a) unbalance of the rotor including a connected machine, or (b) resonance caused by the natural vibration frequency of a mechanical system. Particularly, be Vibration careful of (b) when operating at variable speeds a machine previously fitted with a constant speed motor. Vibration can be minimized by (1) avoiding resonance points using the frequency jump function of the inverter, (2) using a tire -shaped coupling, or (3) placing a rubber shock absorber beneath the motor base. Power transmission Under continued, low -speed operation, oil lubrication can deteriorate in a power transmission mechanism with an oil -type gear box mechanism (gear motor) or reducer. Check with the motor manufacturer for the permissible range of continuous speed. To operate at more than 60 Hz, confirm the machine , s ability to withstand the centrifugal force generated. n To SDecial motors Gear motor The allowable rotation range of continuous drive varies depending on the lubrication method or motor manufacturer. (Particularly in case of oil lubrication, pay attention to the low frequency range.) Brake -equipped motor For use of a brake -equipped motor, be sure to connect the braking power supply from the primary side of the inverter. There are different kinds of pole -change motors (constant output characteristic type, constant torque characteristic type, etc.), with Pole -change motor different rated current values. In motor selection, check the maximum allowable current for each motor of a different pole count. At the time of pole changing, be sure to stop the motor. Also see: Application to the 400V -class motor. Submersible motor The rated current of a submersible motor is significantly larger than that of the general-purpose motor. In inverter selection, be sure to check the rated current of the motor. Inverter drive is not suitable for a safety -enhanced explosion -proof type motor. The inverter should be used in combination with a Explosion -proof motor pressure -proof explosion -proof type of motor. `Explosion -proof verification is not available for SJ200 Series. Synchronous (MS) motor In most cases, the synchronous (MS) motor and the high-speed (HFM) motor are designed and manufactured to meet the High-speed (HFM) motor specifications suitable for a connected machine. As to proper inverter selection, consult the manufacturer. Single-phase motor I A single-phase motor is not suitable for variable -speed operation by an inverter drive. Therefore, use a three-phase motor. Application to the 400V -class motor A system applying a voltage -type PWM inverter with IGBT may have surge voltage at the motor terminals resulting from the cable constants including the cable length and the cable laying method. Depending on the surge current magnification, the motor coil insulation may be degraded. In particular, when a 400V -class motor is used, a longer cable is used, and critical loss can occur, take the following countermeasures: (1) install the LCR filter between the inverter and the motor, (2) install the AC reactor between the inverter and the motor, or (3) enhance the insulation of the motor coil. Notes on Use Drive Run/Stop Run or stop of the inverter must be done with the keys on the operator panel or through the control circuit terminal. Do not operate by installing a electromagnetic contactor (MC) in the main circuit. Emergency motor stop When the protective function is operating or the power supply stops, the motor enters the free run stop state. When an emergency stop is required or when the motor should be kept stopped, use of a mechanical brake should be considered. A max. 400Hz can be selected on the SJ200 Series. However, a two -pole motor can attain up to approx. 24,000 rpm, which is High -frequency run extremely dangerous. Therefore, carefully make selection and settings by checking the mechanical strength of the motor and connected machines. Consult the motor manufacturer when it is necessary to drive a standard (general-purpose) motor above 60 Hz. A full line of high-speed motors is available from Hitachi. Installation location and operating environment Avoid installation in areas of high temperature, excessive humidity, or where moisture can easily collect, as well as areas that are dusty, subject to corrosive gasses, mist of liquid for grinding, or salt. Install the inverter away from direct sunlight in a well -ventilated room that is free of vibration. The inverter can be operated in the ambient temperature range from -10 to 50°C.(Carrier frequency and output current must be reduced in the range of 40 to 50°C.) CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net main power su Notes on Peripheral Equipment Selection In the following examples involving a general-purpose inverter, a large peak current flows on the main power supply side, and is able Wiring connections to destroy the converter module. Where such situations are foreseen or the connected equipment must be highly reliable, install an AC reactor between the power supply and the inverter. Also, where influence of indirect lightning strike is possible, install a lightning conductor. When an electromagnetic contactor is installed between the inverter and the motor, do not perform on-off switching during running (A) The unbalance factor of the power supply is 3% or higher. (Note) contactor (B) The power supply capacity is at least 10 times greater than the inverter capacity (the power supply capacity is 500 kVA or more). Wiring (C) Abrupt power supply changes are expected. When used with standard applicable output motors (standard three-phase squirrel -cage four -pole motors), the SJ200 Series does not Examples: Installation of an (1) Several inverters are interconnected with a short bus. AC reactor on the (2) A thyristor converter and an inverter are interconnected with a short bus. input side (3) An installed phase advance capacitor opens and closes. Thermal relay In cases (A), (B) and (C), it is recommended to install an AC reactor on the main power supply side. motor Note: Example calculation with VRS = 205V, VST = 201V, VTR = 200V • for motors exceeding the range of electronic thermal adjustment (rated current). VRS : R -S line voltage, VST: S -T line voltage, Via: T -R line voltage Unbalance factor of voltage = Max. line voltage (min.) - Mean line voltage x100 Mean line voltage • The RC value of the thermal relay should be more than 1.1 times the rated current of the motor. Where the wiring length is 10 m or -_ VRS-(VRS) VST+VTR)/3 205-202 0 x100 = x100=1.5(/o) (V.) V.T+VTR)/3 202 Using a private power An inverter run by a private power generator may overheat the generator or suffer from a deformed output voltage waveform of the generator generator. Generally, the generator capacity should be five times that of the inverter (kVA) in a PWM control system, or six times greater in a PAM control system. Notes on Peripheral Equipment Selection High -frequency Noise and Leakage Current (1) High -f y components Included in the input/output of the inverter main circuit, and they may cause interference in a transmitter, radio, or sensor if used near the inverter. The interference can be minimized by attaching noise filters (option) in the inverter circuitry. (2) The switching action of an inverter causes an increase in leakage current. Be sure to ground the inverter and the motor. Lifetime of Primary Parts Because a DC bus capacitor deteriorates as it undergoes internal chemical reaction, it should normally be replaced every five years. Be aware, however, that its life expectancy is considerably shorter when the 50 inverter is subjected to such adverse factors as high temperatures or heavy loads exceeding the rated current --i-- of the inverter.The approximate lifetime of the capacitor is as shown in the figure at the right when it is used E 40 I 12 hours daily (according to the " Instructions for Periodic Inspection of General -Purpose Inverter--T--�---- (JEMA).)Also, such moving parts as a cooling fan should be replaced. Maintenance inspection and parts replacement must beperformed by only specified trained personnel. E 2.5 a 10 Capacitor lifetime(years) 1L3S l!U 011■OJ ELR-J■l3Ri-J • Before use, be sure to read through the Instruction Manual to insure proper use of the inverter. • Note that the inverter requires electrical wiring; a trained specialist should carry out the wiring. • The inverter in this catalog is designed for general industrial applications. For special applications in fields such as aircraft, outer space, nuclear power, electrical power, transport vehicles, clinics, and underwater equipment, please consult with us in advance. • For application in a facility where human life is involved or serious losses may occur, make sure to provide safety devices to avoid a serious accident. • The inverter is intended for use with a three-phase AC motor. For use with a load other than this, please consult with us. Information in this brochure is subject to change without notice. CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net (1) Be sure to connect main power wires with R(L1), S(L2), and T(L3) terminals (input) and motor wires to U(T1), V(T2), and W(T3) Wiring connections terminals (output). (Incorrect connection will cause an immediate failure.) (2) Be sure to provide a grounding connection with the ground terminal (0 ). Electromagnetic When an electromagnetic contactor is installed between the inverter and the motor, do not perform on-off switching during running contactor operation. Wiring When used with standard applicable output motors (standard three-phase squirrel -cage four -pole motors), the SJ200 Series does not between need a thermal relay for motor protection due to the internal electronic protective circuit. A thermal relay, however, should be used: inverter and Thermal relay ' during continuous running outside a range of 30 to 60 Hz. motor • for motors exceeding the range of electronic thermal adjustment (rated current). • when several motors are driven by the same inverter; install a thermal relay for each motor. • The RC value of the thermal relay should be more than 1.1 times the rated current of the motor. Where the wiring length is 10 m or more, the thermal relay tends to turn off readily. In this case, provide an AC reactor on the output side or use a current sensor. Install a circuit breaker on the main power input side to protect inverter wiring and ensure personal safety. Choose an inverter - Installing a circuit breaker compatible circuit breaker. The conventional type may malfunction due to harmonics from the inverter. For more information, consult the circuit breaker manufacturer. The wiring distance between the inverter and the remote operator panel should be 20 meters or less. When this distance (Wiring distance isexceeded, use CVD -E (current -voltage converter) or RCD -E (remote control device). Shielded cable should be used on thewiring. Beware of voltage drops on main circuit wires. (A large voltage drop reduces torque.) Earth leakage relay If the earth leakage relay (or earth leakage breaker) is used, it should have a sensitivity level of 15 mA or more (per inverter). Phase advance capacitor Do not use a capacitor for power factor improvement between the inverter and the motor because the high -frequency components of the inverter output may overheat or damage the capacitor. High -frequency Noise and Leakage Current (1) High -f y components Included in the input/output of the inverter main circuit, and they may cause interference in a transmitter, radio, or sensor if used near the inverter. The interference can be minimized by attaching noise filters (option) in the inverter circuitry. (2) The switching action of an inverter causes an increase in leakage current. Be sure to ground the inverter and the motor. Lifetime of Primary Parts Because a DC bus capacitor deteriorates as it undergoes internal chemical reaction, it should normally be replaced every five years. Be aware, however, that its life expectancy is considerably shorter when the 50 inverter is subjected to such adverse factors as high temperatures or heavy loads exceeding the rated current --i-- of the inverter.The approximate lifetime of the capacitor is as shown in the figure at the right when it is used E 40 I 12 hours daily (according to the " Instructions for Periodic Inspection of General -Purpose Inverter--T--�---- (JEMA).)Also, such moving parts as a cooling fan should be replaced. Maintenance inspection and parts replacement must beperformed by only specified trained personnel. E 2.5 a 10 Capacitor lifetime(years) 1L3S l!U 011■OJ ELR-J■l3Ri-J • Before use, be sure to read through the Instruction Manual to insure proper use of the inverter. • Note that the inverter requires electrical wiring; a trained specialist should carry out the wiring. • The inverter in this catalog is designed for general industrial applications. For special applications in fields such as aircraft, outer space, nuclear power, electrical power, transport vehicles, clinics, and underwater equipment, please consult with us in advance. • For application in a facility where human life is involved or serious losses may occur, make sure to provide safety devices to avoid a serious accident. • The inverter is intended for use with a three-phase AC motor. For use with a load other than this, please consult with us. Information in this brochure is subject to change without notice. CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net ■ Easy-to-use menu for display and set-up with HELP screens. ■ Two-line 16 character, back -lit LCD with twenty button keypad (optional). ■ User selectable scrolling display. ■ Adjustable LCD/Keypad orientation allowing ease of reading the display for horizontal or vertical installations. ■ Twenty-four hour clock/calendar. ■ Two optically isolated loop -powered 4-20 mA outputs, one for mass flow rate, one for process temperature (optional). ■ 4-20 mA outputs meet NAMUR NE43 recommendations. ■ Two optically isolated solid-state alarm/relays (optional). ■ Pulsed output for use as a remote flow totalizer (optional). ■ User selected English or Metric units (SFPM, SCFM, SCFH, PPM, PPH,'F; SMPS, SLPM, SCMH, KGM, KGH, 'C). ■ Multi -Point calibration correction factors for Flow and Temperature. ■ User -entered METER ID Number. ■ User -entered flow area. ■ Programmable sensor out -of -tolerance indication and alarm functions. ■ User may change STP reference condition. ■ User -selectable digital filtering for each METER. ■ Built-in flow totalizers and elapsed time. ■ UserAccess Code. ■ Selectable RS -232C or RS -485 Serial port for terminal operation. ■ Modbus ASCII or RTU communications ■ NEMA 4X/7 dual chamber epoxy painted electronics enclosure. ■ CE Compliance, including the current EMC, ATEX, LVD and PED Directives. ■ Configuration upload/download software using a PC. ■ Velocity/Temperature/Mapping (VTM) for wide ranging velocity and temperature. ■ Input power options of 115VAC or 230VAC 50/60 Hz or 24VDC. ■ Flash EEPROM program memory for user firmware upgrades. ■ Remote Electronics Enclosure option. ■ Velocity range of 0-24,000 SFPM. ■ Optional Hot -Air Purge Sensor Cleaning System ■ Process Temperature Rating of —40'C to 200'C (MT) or —40'C to +500'C (HHT). ■ Process Pressure Rating of 150 PSIG for MT temperature range and Class 150 mounting flanges; 300 PSIG for MT and HHT temperature ranges for no flange connection and Class 300 flanges. ■ Electronics operating temperature range of —25'C to +65'C, non -condensing, and —40'C to +65`C without the LCD/Keypad option. ■ All -welded sensor construction. ■ Fastest response to temperature and velocity changes in the industry. ■ Attitude insensitive. ■ Sensor lead length independent circuitry. ■ Non-Incendive, Flameproof/Explosion-Proof Safety Approvals (ATEX, CSA). ■ All components pass an extensive burn -in test for high reliability. ■ Optional Modbus local area network with a read- only control set (Trademark of Square D Company). ■ Canadian Registration Number (CRN) available for all listed gases, except Chlorine, and all Models except 454PFT-HHT. M\ WATIONS' ■ Industrial and process gas mass flows ■ Combustion air flow measurements ■ EPA Flow Monitors ■ Flare stack metering ■ Aeration air flow and digester off -gas flow ■ Landfill vapor recovery ■ Incinerator stack mass flow ■ Solvent recovery system mass flow ■ VOC mass flow ■ Cement plants ■ Coal-fired boiler combustion air ■ Compressed air ■ Natural gas ■ Semi -conductor processing gas metering ■ O.E.M. applications Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax w,-vz I., a vnnr*.n zinst u ..ents.com - c -man: sales@wpm uuxruuvcuu.w�n NCIPLE111 OPERATION The Series 454FT uses the well-recognized Kurz thermal convection mass flow measurement method by detecting the heat transfer from the heated RTD sensor (Rp) referenced to the temperature of the ambient gas stream RTD sensor (Rt).A constant temperature difference between the heated sensor and the temperature sensor is maintained by a modified Wheatstone Bridge circuit in which the heated sensor is the controlled element.This provides unexcelled speed of response and the many other advantages of constant temperature thermal anemome- try.The microprocessor -based electronics measures the heat transfer, computes the standard velocity and ambient gas temperature, and allows the user- to configure and set-up the 454FT to fit all flow require- ments. Display screens are easy-to-use and provide all the flow and temperature and diagnostic information. For a more detailed description of Kurz technology, please see Document Number 364003,"Theory and Application of Kurz Thermal Convection Mass Flow Meters", by contact- ing the Kurz Factory, or by visiting our web site. Figure I -Series 454FT LCD/Keypad with Lid Removed. VE Figure 3 -The flow calibration curve is non-linear, having a non- zero output (live zero) at zero flow and a nearly constant per- cent of reading accuracy. Zero is a E valid data point for a Kurz meter. Figure 2 -Fast Dual (FD) Sensor. 0 2000 4000 6000 8000 10,000 17,000 VELOCITY (SFPM) Figure 3 -Calibration Curve. E5�'O1ttSE TO FLOW AND #ATt1R-E' CHANGES Figure 4 -Shows the response of a Kurz Fast Dual (FD) MetalClad" sensor to a step change in veloci- ty. Kurz manufactures the fastest industrial quality sensors available. Figure 5 -Shows a typical response to a step change in temperature for a Kurz Fast Dual (FD) MetalClad" sensor. it is exceptional and allows use of the sensor for combustion air flow measurements in boilers that mix hot and cold air for tempera- ture control in coal pulverizers, for example. IN 90 so 70 0 y ao 0 so 0 40 30 20 10 FLOW OUTPUT SIGNAL RATE FLOW 2SI 201 S Ifl Y f 101 0 1 2 3 4 S 6 7 .8 9 10 TIMEtSEC. Figure 4 -Sensor Flow Response. 2 VOLTS @ 3000 SFPM Ali fON EFFECTS Figure 6 -Shows a typical output response to changes in the incom- ing velocity direction. Data is shown for rotation and yaw, as defined by Figure 7. Note that the effect is small for angles up to ±20 degrees. This is extremely important for flow applications having severe turbulence and a non -axial velocity direction. 0 2 4 6 TIMEtSEC. . Figure 5 -Sensor Temperature Response. 8 10 12 14 16 18 20 -SO -40 -30 -20 -10 0 10 20 30 40 SO DEGREESROTATIONIYAW Figure 6 -Sensor Measurement Error Versus RotationlYaw Angles. Figure 7 -Sensor Rotation and Yaw Description. Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Faxua 1 _xA�_non 1 . 1,.. .:..r, .. :1. 1 -r -A1,.. _:__�.... ___�- - .............-..,-.+>... - .. rr r..nu. �.ux. uu.c.. as.ivei, e-7ilau. aa7c��wnu7 unotT UI I Ic1Ita4.vlit YFIGt 3 INSERTIONtTRANSMITTERS SENSOR DESIGN Series 454FT Insertion Mass Flow Transmitters use the Kurz MetalClad" FD all -welded Alloy C276 sensor. In this design, the temperature sensor and velocity sensor are mounted in separate tubes (or "stings."), providing exceptional thermal isolation from the sensor- support structure and fast response to process temperature changes. SENSOR MATERIALS AND CONSTRUCTION The standard sensor material for all Kurz metal sen- sors is Alloy C-276.This material is far superior to 316 Stainless Steel in high temperature and corrosive applications. Kurz offers Chromium Nitride coating for abrasive, dirty applications, such as in boiler coal pulverizers. Kurz exclusively uses Inconel sheathed mineral -insulated cable (MI cable) for temperatures above 200°C. PROCESS TEMPERATURE RATING Kurz offers sensor process temperature ratings of 20WC and 500°C. Field data verifies that the lifetime at 500°C is at least five years and the lifetime at 200`C is many decades. TRANSMITTER CONFIGURATIONS Two configurations are available; Directly Attached Electronics Enclosure (TA) and Remotely Attached Electronic Enclosure (TS). PROCESS TEMPERATURE COMPENSATION The influence of temperature on the thermal proper- ties of gases requires temperature compensation for repeatable and accurate measurements. Standard Temperature Compensation (STC) is used for applica- tions in which the process temperature is below 125'C,over a moderate velocity range or below 20WC over more limited velocity range. If the process tem- perature and gas velocity vary widely,Velocity/ Temperature/Mapping (VTM) is recommended.VTM includes taking velocity calibrations at two or three process temperatures and using the microprocessor to calculate the velocity based on the built-in process temperature measurement. GAS CALIBRATION The customer has a choice of a laboratory calibration or a gas correlation calibration.Air calibrations are performed in the Kurz Model 400D NIST traceable wind tunnel. SENSOR PROTECTION The 454FT circuitry includes circuitry to prevent an over -temperature condition caused by a sensor, wiring or component failure. Our sensors will not overheat at zero flow, unlike most competitive devices because of our constant temperature sensor control method and the power limiting design. HOT-AIR PURGE SENSOR CLEANING SYSTEM The Model 454PFT-16-HHT has a special nozzle in the sensor window for use with the Model 146 or 148 Hot -Air Purge Sensor Cleaning System.The sensor cleaning is accomplished by a short, high pressure blast of hot air (sonic velocity) directed at the velocity and temperature sensors. Kurz offers a programmable timer, air heaters, solenoid valves and air blow -down tanks to allow periodic or on -demand cleaning.The air blow -down tank uses customer supplied compressed air (instrument quality) at 60 to 125PSIG.The average cleaning air consumption is less than 0.125 SCFM.The Model 454PFT is designed to measure air flow only at ambient pressure. Canadian Registration (CRN) is not available for the Model 454PFT.The primary application is for extremely dirty stacks and ducts having dry particulate matter that may build up on the sensor. Applications include fossil -fueled power boilers, municipal waste incinerators and combustion air flow situations in which fly ash is entrained. SENSOR ELECTRONICS The Series 454FT has several innovations which improve performance, reduce cost and provide extra- ordinary flexibility.A new constant temperature bridge circuit includes an efficient switching power supply and allows the microprocessor to calculate the process gas temperature directly using the temperature compensa- tion sensor.The bridge PCB has an EEPROM loaded with the PCB serial number, calibration coefficients, and component values which insures the safety of the data.The sensor electronics includes a sensor lead resistance compensation circuit which is extremely important for long sensor wires, rapid gas temperature changes and large temperature gradients between the sensor and the ambient air. ANALOG -TO -DIGITAL CONVERTER A serial 16-bitADC provides excellent resolution and noise rejection.To minimize noise the user can select the ADC sample rate for 50 Hz or 60 Hz to provide the best noise rejection. Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 43940 ■ Tel 800-424-7356 PAGE .r Fax 83 1446a 8901 ®,,.,,.,.. I.....�:..�a.....-,�....�,a,.......-, a.._..�..,:1.....l..r/13...,,...:....a............. a........... PAGE .».. ,++. r.rv�v. .•..n..�u. urw�. urncrraa.avnr-c-n rau. anres�nur mnau wucuw.a.vnr Cont'd. FIRMWARE The Display, Executive and Programming menus are very easy-to-use and are largely self-explanatory.The functions and instructions for the Series 454FT are nearly the same as those used for the Series 155 Mass Flow Computers, which are widely accepted.The flow and temperature data may be scrolled so it can be seen through the window in the cover.The user may press "D" and see the flow and temperature data, as well as the raw flow data. Pressing "H" holds the dis- play screen (but not the readings).A user access code is required for programming, seeing data and entering configuration and other user data. HELP SCREENS By pressing "HH" the user can obtain important infor- mation on the use of the Series 454FT, including the firmware version, Kurz telephone and fax numbers and the web site address, etc. FLASH EEPROM PROGRAM MEMORY The program may be updated in the field by the user using the RS -232 port.This new feature will allow our customers to upgrade to the latest firmware. SELF -DIAGNOSTICS The 454FT performs an extensive check-out upon power -up, and continuously monitors the sensor inputs/outputs and verifies the integrity of the sensor wiring and the measurements.The Sensor Kick -Out feature is used to set the fault limits. PROGRAMMABLE CORRECTION FACTORS A multi -point Variable Correction Factor (VCF) may be used to correct the flow calibration data to meet in-situ flow tests over the entire velocity range such as done for EPA Stack Flow Monitors. If VCF is not used, a Sensor Blockage Correction Factor (SBCF) can be used to correct for the area reduction caused by the sensor support.The user enters the area of the flow passage and the sensor center line distance from the inside of the flow passage and the Series 454FT auto- matically calculates the SBCF METER FILTERTIME CONSTANT A digital filter time constant may be set for each METER which affects the display readings and the 4-20 mA outputs.The time constant maybe set from 0 to 600 seconds. COMPATIBILITY WITH SERIES ISS MASS FLOW COMPUTERS A "Blind" Series 454FT (ordered with the two 4-20 mA Outputs and the +24VDC power- supply; but with- out the LCD/Keypad and Alarm/Relay/Pulsed Outputs) is fully compatible with the inputs and features of the Series 155 Mass Flow Computers. Thus, the user may obtain the advantages of flow and temperature mea- surements,Velocity/Temperature/Mapping (VTM), with a rugged, remote, easy-to-use electronics enclosure with LCD/Keypad, power supply, and all of the other features of the Series 155 Mass Flow Computer. (Please see the Series 155 brochure). SELECTABLE STP CONDITIONS The mass flow calibration data is referenced to the Kurz laboratory standard of 77` F/14.69 PSIA (25` C/760 mmHg).The user may change the STP conditions to suit his requirement. 4-20 mA OUTPUTS These loop -powered outputs are optically isolated, and include the NAMUR NE43 recommendation regarding fault detection.The fault conditions are set at the Kurz Factory, but may be set by the user.The user may easily calibrate the 4-20 mA outputs by entering the Output Calibration menu, measuring the output and adjusting it using the LCD/Keypad. NAMUR NE43 COMPLIANCE Kurz meets the NAMUR NE43 recommendation for the 4-20 mA outputs, under a fault defined by the sensor Kick -Out menu.A low flow or temperature condition will be transmitted as a 3.6 mA or -less sig- nal; a high flow or high temperature condition will be transmitted as a 21.0 mA or greater signal.This feature also frees up the alarm/relays so that the user can set- up the flow and temperature alarms for other needs. ALARM/RELAYS/PULSED TOTALIZER OUTPUT The customer may order 0 or 2 solid-state optically isolated relays. If no relays are ordered, the alarm func- tions are displayed on the LCD. Both relays may be used for alarms (LO, HI and HOL) or for the Sensor Kick -Out feature; or one relay may be used for an alarm function and one may be used as a pulsed output for use as a remote flow totalizer, or both relays may be used as pulsed outputs. Totalizers may be automati- cally reset at a specific total quantity (i.e., 10,000 SCF). Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax 831-646-8901 • vwv.,.kurz;nstruments.com - e=mail: salesVkurz;nstrurnents.CoM aauc s SERIES 454FT INSERTION MASS G VfORNIATION Note I: CRN Registration for all listed gases except Chlorine, and all Models except the Model 454PFT-16-HHT NOMENCLATURE: of �ttrfier `. Dei¢tion ` Range W MT Medium Temperature -40°F to 392'F (-40`C to 200'C) HHT Very High Temperature -40'F to 932'F (-40`C to 500°C) e fdentfl er' r esrrt{atiarr r��l�i N1 Non-Incendive,ATEX and CSA Approvals FPiXP Flame-Proof/Explosion-Proof,ATEX and CSAApprovals' CRN Canadian Registration Number PART NUMBER GENERATION PROCEDURE With the selected Parent Number, specify the entire Part Number by selecting an Option for each Feature as shown in the example below. Feature options in Bold type are more readily available. 756004 13 20 11 0520 21 14 01 28 21 II 12 Parent No. FI F2 F3 F4 F5 F6 F7 F8 F9 FIO Fill I Sensor Type/Sensor Material 2 Sensor Support Material/Length 3 Optional Flange Connection Size and Rating 4 Optional Flange U Dimension 5 Electronics Enclosure Configuration/Input Power 6 Gas Velocity Calibration Data Range 7 Specialty Gas Velocity Calibration 8 Process Temperature Compensation 9 4.20 mA Outputs/LCD/Keypad feat 10 Alarms, Relays, Pulsed Outputsrrerminal Communication & Data Ports MadW Posen r tensor Su Proc ss '-. - 0 Sojety� 3 �/ Num 6e Num6er rrrt Dla. T mR/ Rtin „Avr. !ip#ro„vats r .. . 48" 2 '1%%!' Purge I" 454FT-08-MT 756001 ;n" MT No NI,FP/XP,CRN 454FT-08-HHT 756002 1/2 Special No NI, CRN 454FT 12 -MT 756003 " MT No NI, FP,'XP, CRN 454FT-12-HHT 756004 '/V HHT No N1, CRN 454FT-16-MT 756005 1" MT No Nl, FP;xP, CRN 454FT 16-HHT 756006 I" HHT No N1. CRN 454PFT-16-HHT 756007 1" HHT Yes NI Note I: CRN Registration for all listed gases except Chlorine, and all Models except the Model 454PFT-16-HHT NOMENCLATURE: of �ttrfier `. Dei¢tion ` Range W MT Medium Temperature -40°F to 392'F (-40`C to 200'C) HHT Very High Temperature -40'F to 932'F (-40`C to 500°C) e fdentfl er' r esrrt{atiarr r��l�i N1 Non-Incendive,ATEX and CSA Approvals FPiXP Flame-Proof/Explosion-Proof,ATEX and CSAApprovals' CRN Canadian Registration Number PART NUMBER GENERATION PROCEDURE With the selected Parent Number, specify the entire Part Number by selecting an Option for each Feature as shown in the example below. Feature options in Bold type are more readily available. 756004 13 20 11 0520 21 14 01 28 21 II 12 Parent No. FI F2 F3 F4 F5 F6 F7 F8 F9 FIO Fill I Sensor Type/Sensor Material 2 Sensor Support Material/Length 3 Optional Flange Connection Size and Rating 4 Optional Flange U Dimension 5 Electronics Enclosure Configuration/Input Power 6 Gas Velocity Calibration Data Range 7 Specialty Gas Velocity Calibration 8 Process Temperature Compensation 9 4.20 mA Outputs/LCD/Keypad Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 RAGE 6 Fax 83I-646-8901 ■ r e-mail, sales@kuvzinstv..ments feat 10 Alarms, Relays, Pulsed Outputsrrerminal Communication & Data Ports II Safety Approvals Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 RAGE 6 Fax 83I-646-8901 ■ r e-mail, sales@kuvzinstv..ments f on Serfi¢cnct '- etrgch t ;" 1.70Wo ` Su ert ikrr3 h L 0 All 18" 5 -'/<" I" 36" I 4",'%d' 4" (MT Only) 6 1" 48" 2 '1%%!' 6" (MT Only) 7 I" 60" 3 All 12" 8 3X4"'1" 30" 4 All 24" 9 Special Special. Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 RAGE 6 Fax 83I-646-8901 ■ r e-mail, sales@kuvzinstv..ments D{ttran j DetcrifrtTbn� yOlbt own/ /%KrtptlQn Not"es 00 No flange 02 h" Class 300 Process Pressure Rating of 01 re" Class 150 12 /a', Class 300 150 PSIG for MT temperature range and Class 150 mounting 11 %s', Class 150 22 1'; Class 300 flanges; 300 PSIG for MT and 21 I", Class 150 26 1 "A", Class 300 HHT temperature ranges for 25 I'A', Class ISO 32 1 F", Class 300 no flange connection and 31 1:4",Class I50 42 Class 300 Class 300 flanges. Flange and __2" sensor materials must match. 41 2" Class 150 62 3" Class 300 Flange mounting dimensions 61 3" Class 150 conform to ANSI B16,5 Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 RAGE 6 Fax 83I-646-8901 ■ r e-mail, sales@kuvzinstv..ments E. �`&1:11 i a i a 01 1 Air at0PSIG 07 I Air to 150 PSIA - - opilGd% 56 08 02 300 (1.5) 14 6.000 (30) 04 600 (3) 16 9,000 (45) 06 1,000 (5) 18 12,000 (60) 08 2,000 (10) 20 15,000 (7S) 10 3,000 (15) 22 18,000 (90) 12 4,000 (20) 24 24,000 (120) 01 1 Air at0PSIG 07 I Air to 150 PSIA - - Dry Ammonia 56 08 Argon to 100 PSIA 58 14 Carbon Dioxide to 50 PSIA 64 — Dry Chlorine (Note 2) 68 20 Ethane to 100 PSIA 70 22 Ethylene to 100 PSIA 72 26 Helium to 100 PSIA 76 28 Hydrogen to 100 PSIA 78 32 Methane to 100 PSIA 82 34 Natural Gas (Simulated with Methane) to 100 PSIA 84 35 "Digester Gas" 50% Cho, 50% CO2 to 50 PSIA 85 36 "Digester Gas" 60% Cho, 40% CO2 to 50 PSIA 87 37 "Digester Gas" 70% Cho, 30% CO2 to 50 PSIA 87 40 Nitrogen to 100 PSIA 90 44 Oxygen to 100 PSIA 94 46 Propane to 50 PSIA 96 99 Special Gas calibration (including mixed gases)—Specify Note I: Laboratory calibrations can be ordered between 0 PSIG and the pressures noted. Correlated calibrations are performed at 0 PSI G.The customers is responsible for cleaning oxygen flow elemenmAdd ±5% of reading at correlated calibrations. The cost of calibrations is dependent on the types of gas and the velocity range. Contact Kurz for details. Note 2: CRN Not available 01 Standard Temperature Compensation (STC) over process temperature range of -40'C to +125'C. Accuracy: ± [(I%+,025%/`C) reading+(20 SFPM +.25 SFPM1'C)] Above or below 25°C, all gases. 13 Standard Temperature Compensation (STC) over process temperature range of 0°C to 200°C. Accuracy: ± [(2% + .025%!°C) reading +(20 SFPM + .25 SFPM/'C)] Above or below 100'C; Air. 02 and N, only. 23 VelocityrTemperature!Mapping (VTM) with three calibration data sets over process temperature range of 0"C up to 20T Accuracy: ±(2% reading + 20 SFPM), Specify Process Temperature Range, Air, 02 and N2 only. 0 No Solid -State Relay or Pulsed outputs, alarm functions dis- played on LCD. I Two Optically Isolated Solid -State Alarm Relays 2 Two Optically Isolated Solid -State pulsed outputs for remote flow totalizers. 3 One Optically Isolated Solid -State Alarm Relay and one pulsed output for a remote flow totalizer. RS -232C or RS -48S Qumper Selected) serial port; echoes the display and permits remote keypad entry for use with a PC running a terminal emulator program, supports configuration Upload/Download. 2 Option I plus a read-only command set for all METERS, including the log (L) or summary command. 30 ption I with RS -485 Multi -Point ModbusASClI or RTU protocol with read-only control. i p# vnn, 1,10 d]. 28 Velocity,'Temperature/Mapping (VTM) with four calibration data 0 sets over process temperature range of 0'C up to 500`C. 2 Accuracy:±(3% reading + 30 SFPM), Specify Process Temperature Range, Air, 02 and N2 only. HHT models only. 0 No Solid -State Relay or Pulsed outputs, alarm functions dis- played on LCD. I Two Optically Isolated Solid -State Alarm Relays 2 Two Optically Isolated Solid -State pulsed outputs for remote flow totalizers. 3 One Optically Isolated Solid -State Alarm Relay and one pulsed output for a remote flow totalizer. RS -232C or RS -48S Qumper Selected) serial port; echoes the display and permits remote keypad entry for use with a PC running a terminal emulator program, supports configuration Upload/Download. 2 Option I plus a read-only command set for all METERS, including the log (L) or summary command. 30 ption I with RS -485 Multi -Point ModbusASClI or RTU protocol with read-only control. „'.. }}pcioir ales crypt n� ,, .... 0 No 4-20 mA Outputs. 2 Two 4-20 mA outputs, loop -powered, optically isolated. ATEX: 0113 GD, EEx nA II TS * a 12 p#�on ', l.�escmptennM� 115/230VAC, IS W, 50!60 Hz PH I,.20`C to 60'C ambient, 0 No LCD'Keypad and enclosure lid without window. I Includes back -lit LCD with 20 -button keypad and CSA: Class I, Div. 2, GPS. ABCD,T4 enclosure lid with window. 0 No Solid -State Relay or Pulsed outputs, alarm functions dis- played on LCD. I Two Optically Isolated Solid -State Alarm Relays 2 Two Optically Isolated Solid -State pulsed outputs for remote flow totalizers. 3 One Optically Isolated Solid -State Alarm Relay and one pulsed output for a remote flow totalizer. RS -232C or RS -48S Qumper Selected) serial port; echoes the display and permits remote keypad entry for use with a PC running a terminal emulator program, supports configuration Upload/Download. 2 Option I plus a read-only command set for all METERS, including the log (L) or summary command. 30 ption I with RS -485 Multi -Point ModbusASClI or RTU protocol with read-only control. CRN not available for Model 454PFT nor any Model for use with Chlorine. Kurz Instruments, Inc. ■ 241E Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax 831-646-8901 r www urzinctrumantg rnm ■ e-mgil• sales n7y 1, —instruments co Opeiut% ` x. � t3es� ,Mian �� Non-Intendive (NI), MT and HHT Models: 24VDC 0.6 A, -20`C to WC ambient,IP66!NEMA4Xi7: ATEX: 0113 GD, EEx nA II TS CSA: Class I, Div. 2, GPS. ABCD,TS 12 115/230VAC, IS W, 50!60 Hz PH I,.20`C to 60'C ambient, IP66!NEMA4Xl7: ATEX: D II 3 GD, EEx nA tI T4 CSA: Class I, Div. 2, GPS. ABCD,T4 Flame -Proof (FP)/Explosion-Proof (XP) MT Models only: 24VDC 0.6 A or 115!230! VAC; 15 W, 50160 Hz PH I, -20'C to 24 60'C ambient.TI95'C.IP66!NEMA4X!7: ATEX: (9 II 2 GD, EEx d IIB + H2 T3 CSA: Class L Div. I, GPS, ABCD T3, Class II, Div. I, GPS. EF&G 32* Non-Intendive (NI), MT and HHT Models: Includes CRN otherwise same as Option 12 44* Flame -Proof (FP) Explosion -Proof (XP) MT Models only: Includes CRN otherwise same as Option 24 CRN not available for Model 454PFT nor any Model for use with Chlorine. Kurz Instruments, Inc. ■ 241E Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax 831-646-8901 r www urzinctrumantg rnm ■ e-mgil• sales n7y 1, —instruments co iii 4�34icT`OUTLINE DRAWINGS 5.44 0.64 [I38.'mm]-+- + [ 16.3mm] L2 Flow(See note 2) 3/4" FNPT Typ. direction 2.50.E rrow a Display maybe rotated at A [63.Smm] 90° increments for [►- proper viewing direction -- Dual chamber electronics enclosure Caution label -�`---'[External Gnd 1 r_ screw#10.32 Power, ground, outputs,� I j shielded cable, seals, fittings Kurz Model No., & conduit by customer 1:' Serial No., Item No., & Safety Approval Tag Electronics Enclosure Directly Attached First Digit of Feature 5, Option 1 FL�W I.D. Tag Electronics Enclosure Remotely Attached First Digit of Feature 5, Option 2 3/4" FNPT Typ. 4 1.06 -►i [26.9mm] 2.82 [71.6mm] 4.75 _5.50 _ [139.7mm] 6.13 . [155.7mm] Junction Box L (See Feature 2. See Note 2.0 [50.8mm] U (See Feature 4. See note I) 45, --►i 0.78 CL [I9.8mm] 1 Sensor support I Sensor support "a - I - - - - - ---_ D fitting -I -- _ o Sensor material FL�W 4 see Feature 1 Sensor Flange VIEW A -A see Feature 3 1/2" FNPT air purge sensor cleaning inlet fitting, I.D. Tag Model 454PFTonly. No CRN Registration Note 1: L = U + L2 - 2.00", (min) U=4" Note 2: L2 (min) = 4" for MT Models and 8" for HHT Models Caution Yes 3.50" (88.9mm) 6.60" [167.6mm] label 3/4" MNPT plug 2.82" [71.6mm) 6.60" [167.6mm] ® 3 plcs.- 3.50" [88.9mm) 2.82" [71.6mm] 24VDC No 2.82" [71.6mm] Power, ground, ground, _ Sensor support outputs, shielded junction box cable, seals fittings B O & conduit by ct customer p Conduit seals r by customer 3/4" nipple External 3 plcs. mounting location ground .t ] t I.D. Tag screw5 #8-32 conductor shielded j=� cable in rigid conduit Sensor wire terminal or cable with junction box Kurz model no., perimeter bonded serial no., item & seal by customer safety approval tag tag o.25 thru [6 35mm] 2 pits. �5.25 (t133.3m 4.60 [I 1b.8mm] 1 2.81 AC Yes 3.50" (88.9mm) 6.60" [167.6mm] AC No 2.82" [71.6mm) 6.60" [167.6mm] 24VDC Yes 3.50" [88.9mm) 2.82" [71.6mm] 24VDC No 2.82" [71.6mm] 2.82" [71.6mm] x-3/4" FNPT_ 4.75 Typ. (I20.6mm]� 5.25 [133.3mm] I 4.60 [I 16.8mm] -WIA Dual Chamber Electronics Enclosure 454FT-08 ( 1h" [12.7mm] 454FT-12 4S4FT-I6 1" [2.S4mm] Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 RAGE 8 Fax 831-646-8901 11 ,..:.kurz;nstr..ments.com ® e=ma:l: sales@ku .--lnstruments.co, IES (Note f ) Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax 831-644-8901 rw—s o=ai.l.l: sulesnl ..:,+.mencom — ._r srafNN�G 7 MOUNTING FLANGE ASSEMBLIES x x Class 150 and 300 ANSI B16.5 flanges with 3" overall length, V2", %4", 1 ", 111/4", 1 W" sizes, threaded or unthreaded pipe sleeves, + - carbon steel, 316 SS, Alloy C276. Refer to Part No. 759032. BRANCH FITTINGS (Thredolets-ID and Sockolets@) Convenient for attaching mounting hardware to process piping. Sizes W', 3/4", 1 ", 1/`4", 1 %z" for pipe sizes above 2'/z". Carbon Steel, 316 SS,AIIoyC-276. Refer to Part No. 759033 for Thredolets. Refer to Part No. 759034 for Sockolets, flimdolec and Sockolet are registered tadanarks of Bonney Forge. BALL VALVES Sizes of %4", I ", I %", IW' are available in 316SS, Alloy C-276 and Monel. Refer to Part No. 754060. PACKING GLANDS Models PG -08, PG 12 and PG -16 fit the %i',;4", and I" sensor supports respectively. Optional body materials are 316SS, Alloy C-276 and Monel.The standard packing material is Gortex Expanded PTFE. Refer to Part No. 759050. RETRACTO RIRE STRAI NTS Model RR -08, RR -12 and RR -16 clamp to the packing gland and sensor support. it has a worm -gear crank mechanism and adjustable stops. Refer to Part No. 759040. PIPE NIPPLES These schedule 40 pipe nipples are used with ball valves, retractor/restraints, packing glands and pipe mounting fittings. Pipe sizes of li', %4', I", I'r4", 1 W" in length from 2" to 12" are available in Carbon Steel, 316SS,AIIoy C-276 and Monel. Refer to Part No. 759070. MALE COMPRESSION FITTINGS Bored-thru %z'', -YV and I" tube fittings for use with Thredolets or customer's fittings with �", 3/4', 1 ", I''/4' and IA" male IPS threads, O 316 SS Body, 316 SS, Nylon or Teflon ferrules. Refer to Part No. 759031. DUCT MOUNTING BRACKETS These convenient brackets are used to mount the ”, or / /4„ "diameter sensor support on flat or curved ducts. 316 Stainless O— O ( i ; — — Steel bracket and compression fitting,Teflon, Nylon or 316 SS ferrules. Refer to Part No. 759030. IDENTIFICATION TAGS Part Number 170098, 1,25" x 3", 316 SS, maximum of 4 lines, 32 characters per line. HOT-AIR PURGE SENSOR CLEANNG SYSTEMS Models 146 or 148 includes timer, flash air heater, valves and continuous air bleed system, Consult Kurz for details. Note I: Series 454FT Accessories do not have CRN. Kurz Instruments, Inc. ■ 2411 Garden Road, Monterey, CA 93940 ■ Tel 800-424-7356 Fax 831-644-8901 rw—s o=ai.l.l: sulesnl ..:,+.mencom — ._r srafNN�G 7 UNISTRUT° P2860 Plastic White End Caps (25.4) P2860-33 Use with P3300 channel. WU100 pcs 2.5 Lbs (1.1 kg) MATERIAL Unistrut channels are accurately and carefully cold formed to size from low -carbon strip steel. All spot-welded combination members, except P1001 T, are welded 3" (76 mm) maximum on center. STEEL: PLAIN 12 Ga. (2.7 mm), 14 Ga.(1.9 mm) and 16 Ga. (1.5 mm) ASTM A1011 GR33 STEEL: PRE -GALVANIZED 12 Ga. (2.7 mm), 14 Ga. (1.9 mm) and 16 Ga. (1.5mm) ASTM A653 GR 33 For other materials, see Special Metals or Fiberglass sections. (25.4) P2860-50 Use with P5000 & P1001 channels. Wt/100 pcs 5 Lbs (2.3 kg) FINISHES (25.4) P2860-55 Use with P5500 channel. Wt/100 pcs 4.7 Lbs (2.1 kg) All channels are available in: • Parma Green If (GR) • Pre -galvanized (PG), conforming to ASTM A653 G90 • Hot -dipped galvanized (HG), conforming to ASTM A123 • Plain (PL) Project: Approval Stamp: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: UNISTRUT® P1000 Wt/100 Ft: 190 Lbs (283 kg/100 m) Allowable Moment 5,080 In -Lbs (570 N -m) e 12 Gauge Nominal Thickness.105° (2.7mm) 9.5 222 95 N, Channel Finishes:" 'w Standard x r i• COLUMN LOADING - P1000 MATERIAL Unistrut channels are accurately and carefully cold formed to size from low -carbon strip steel. All spot-welded combination members, except P1001 T, are welded 3" (76 mm) maximum on center. STEEL: PLAIN BEAM LOADING - P1000 Maximum Unhrac0 -Allowable Load 'Maximum Column Loatl Apolietl at C.G.' Heigot- at Slot Face:: Load': Span(180..Span/240.;Span%360; :, 1n=.; Lbs 24 24 3,450 10,750 9,900 8,770 7,730 36 3,050 8,910 7,730 6,370 5,280 48 2,660 7,250 5,980 4,660 3,770 60 2,290 5,890 4,660 3,600 2,940 72 2,000 4,800 3,770 2,940 2,380 84 1,760 4,010 3,170 2,460 1,970 96 1,570 3,450 2,730 2,090 1,650 108 1,410 3,020 2,380 1,800 120 120 1,270 2,680 2,090 80 144 MATERIAL Unistrut channels are accurately and carefully cold formed to size from low -carbon strip steel. All spot-welded combination members, except P1001 T, are welded 3" (76 mm) maximum on center. STEEL: PLAIN BEAM LOADING - P1000 12 Ga. (2.7 mm), 14 Ga.(1.9 mm) and 16 Ga. (1.5 mm) FINISHES ASTM A1011 GR33 All channels are available in: ----tP STEEL: PRE -GALVANIZED -Pe rma Green II (GR) 12 Ga. (2.7 mm), 14 Ga. (1.9 mm) and 16 Ga. (1.5mm) -Pre -galvanized (PG), conforming to ASTM A653 G90 ASTM A653 GR 33 --* -Ho t -dipped galvanized (HG), conforming to ASTM A123 For other materials, see Special Metals or Fiberglass sections. •Pla in (PL) Project: Approval Stamp: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: AIIoWable Uniform Uniform Loading at.Deflection, ; .; ' ,Span Uniform Load Load': Span(180..Span/240.;Span%360; :, 24 1,690 0.06 1,690 1,690 1,690 36 1,130 0.13 1,130 1,130 900 48 850 0.22 850 760 510 60 680 0.35 650 490 320 72 560 0.50 450 340 220 84 480 0.68 330 250 170 96 420 0.89 250 190 130 108 380 1.13 200 150 100 120 340 1.40 160 120 80 144 280 2.01 110 80 60 168 240 2.74 80 60 40 192 210 3.57 60 50 NR 216 190 4.52 50 40 NR 240 170 5.58 40 NR NR 12 Ga. (2.7 mm), 14 Ga.(1.9 mm) and 16 Ga. (1.5 mm) FINISHES ASTM A1011 GR33 All channels are available in: ----tP STEEL: PRE -GALVANIZED -Pe rma Green II (GR) 12 Ga. (2.7 mm), 14 Ga. (1.9 mm) and 16 Ga. (1.5mm) -Pre -galvanized (PG), conforming to ASTM A653 G90 ASTM A653 GR 33 --* -Ho t -dipped galvanized (HG), conforming to ASTM A123 For other materials, see Special Metals or Fiberglass sections. •Pla in (PL) Project: Approval Stamp: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: UNISTRUT° P1 109 thru P1126 Pipe Clamps for Rigid Steel Conduit Slotted hex head screw and nut included. Finish: Electro -galvanized. MATERIAL Unistrut pipe clamps, unless noted, are punch -press made from hot -rolled, pickled FINISHES and oiled steel plates, strip or coil, and conform to ASTM specifications A1008, A575, A576, A635, or A36. The fitting steel also meets the physical requirements of Pipe supports are available in: ASTM A1011 SS GR 33. The pickling of the steel produces a smooth surface free • Electro -galvanized (EG), conforming to ASTM 8633 Type III SC1 from scale. --* ° Hot -dipped galvanized (HG), conforming to ASTM A123 or A153 (hardware) Many items are also available in stainless steel. Consult factory for ordering information. ° Perma-Green II (GR), and plain (PL). Project: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: Approval Stamp: O D Vlltl100 ;Design: _t Size "- Thickness. pcs L`oazi Number , , In ,In (mm)" Gauge, (mm) Lbs (kg)" "Lbs (kg) -,i P1109 3/a 0.675 16 10 400 17.1 1.5 4.5 181 P1111 1/2 0.840 16 11 400 21.3 1.5 5.0 181 P1112 3/4 1.050 14 15 600 26.7 1.9 6.8 272 P1113 1 1.315 14 17 600 33.4 1.9 7.7 272 P1114 11/4 1.660 14 19 600 42.2 1.9 8.6 272 P1115 11/2 1.900 12 29 800 48.3 2.7 13.2 363 P1117 2 2.375 12 34 800 60.3 2.7 15.4 363 P1118 21/2 2.875 12 40 800 73.0 2.7 18.1 363 P1119 3 3.500 12 47 800 88.9 2.7 21.3 363 P1120 31/2 4.000 11 62 1,000 101.6 3.0 28.1 454 P1121 4 4.500 11 67 1,000 114.3 3.0 30.4 454 P1123 5 5.563 11 80 1,000 141.3 3.0 36.3 454 P1124 6 6.625 10 102 1,000 168.3 3.4 46.3 454 P1126 8 8.625 10 130 1,000 219.1 3.4 59.0 454 MATERIAL Unistrut pipe clamps, unless noted, are punch -press made from hot -rolled, pickled FINISHES and oiled steel plates, strip or coil, and conform to ASTM specifications A1008, A575, A576, A635, or A36. The fitting steel also meets the physical requirements of Pipe supports are available in: ASTM A1011 SS GR 33. The pickling of the steel produces a smooth surface free • Electro -galvanized (EG), conforming to ASTM 8633 Type III SC1 from scale. --* ° Hot -dipped galvanized (HG), conforming to ASTM A123 or A153 (hardware) Many items are also available in stainless steel. Consult factory for ordering information. ° Perma-Green II (GR), and plain (PL). Project: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: Approval Stamp: UNISTRUT® P2072A, P2072A SQ Wt/100 pcs: 373 Lbs (169.2 kg) W. 3/s" 4 Holes (22.2) (22.2 %a" (19.1) Dia. 4 Holes 4)Y""%a" (19.1) Dia. 3" (22.2) O Q 3" (76.2) 6"(76.2) 6" 3„ (152.4) U 3„ (152.4) (76.2) /8, Q 0 (76.2) 2) (22. 3" 3" 3" 3" (76.2) (76.2) (76.2) (76.2) 6" '— (152.4) 6" (152.4) P2072A P2072A SQ (6.4) MATERIAL Fittings, unless noted, are made from hot -rolled, pickled and oiled steel plates, strip or coil, and conform to ASTM specifications A575, A576, A635, or A36. The fitting steel also meets the physical requirements of ASTM A1011 SS GR 33. The pickling of the steel produces a smooth surface free from scale. Many fittings are also available in stainless steel, aluminum and fiberglass. Consult factory for ordering information. FINISHES Fittings are available in: Perma-Green II (GR), electro -galvanized (EG), conforming to ASTM B633 Type III SC1; Hot -dipped galvanized (HG), conforming to ASTM A123 or A153 and plain (PL). Standard DInn nsiow or15/a" (41;mn*'widkh seri1*6han6el..fittings (Unless Otherwise Shown qn Drawing) Hole Diameter: 9/16" (14.3mm); Hole Spacing -From End: "/1a" (20.6 mm); Hole Spacing -On Center: i'/a' (47.6 mm); Width:11/i'(41mm); Thickness: 1/4" (6.4mm) Project: Approval Stamp: Architect / Engineer: Date: Phone: Contractor: Address: Notes 1: Notes 2: Standard Features (Sizes 1-1 /2" - 14") • Standard model (1-1/2" - 14") has PVC Body and PP Disc for superior chemical resistance and elevated temperature capabilities • 316/403 stainless steel shaft has full engagement over the entire length of the disc and is a non -wetted part. • Only solid and abrasion -resistant plastic disc and elastomeric liner are wetted parts. • ISO bolt circle on top flange -no body or stem modifications required for accessories. • Stem retainer -PP retainer to prevent stem removal. • Seat over tightening protection -Molded body stops and seat stress relief area. • Sperical disc design offers increased Cv, ultimate sealing and high cycle life. Options • Pneumatically and electrically actuated with accessories • Alternate discs: ^---� (1) PVC : 1-1/2" - 14" (111) PVDF : 1-1/2" - 14" • PlasgearTM gear operators for 1-1/2"- 6" • Lug style (Stainless Steel 304 or 316) for blocking and end -of -line applications • Stems in 316 stainless steel, titanium, Hastelloy CO. • 2" square nut on stem • 2" square nut on gear operator • Stem extensions (Single stem and two-piece stem) • Locking devices (Gear Type - Standard on Lever) • Chain operators • Manual limit switch • Tandem arrangements (Patented by A/A, Inc.) S 8 ' "PARTS• " PP NO. DESCRIPTION PCS. MATERIAL 16a Metal Insert in Handle 1 PUC, PP, PVDF 2 Disc 1 PVC, PP, PVDF 3 _ Seat" 1 EPDM, FKM, NBR 6 O -Ring (C) 1 EPDM, FKM, NBR 8 Stem Retainer 1 PP 16 Handle 1 PP 16a Metal Insert in Handle 1 Stainless Steel 316L 17 Handle Lever 1 .PPG 18 Pin 1 PPG 19 Spring 1 Stainless, Steel 304 20 Washer (A) 1 Stainless Steel 304 i21 Bolt (B) ; :�1 Stainless,Steel 304,,:,' 22 Locking Plate 1 PPG 23 Screw, (B) 4 Stainless Steel 304 24 Cap (A) 1 PP 156 Liner Stabilization .Ring 2 Stainless Steel ,(SCS13) " 157 Screw (F) 4 Stainless Steel 304 ASAHI/AMERICA Rev. D 06-06 BODY PVC PP DISC PP PP ;"PUDE" NOMINAL _ NOMINAL i VACUUM NOMINALSIZE SIZE 30° F 121* F 141* F -5° F .� 141' F -5° F 141* F176* F211* F PVC I "' Pp,- PVDF SIZE SERVICE ,(INCHES' OF 120° F 140° F 175° F�140° F 175° F 140° F 175° F2110* F250* F ___ MERCURY) INCHES mm i INCHES mm INCHES mm 11/2, 40 i " 150 70 30 150 100 150 100 $5 75 1 1/2 40 j 3 3 3 1 1/2 40 -29.92 t 2 ` 50 150 70 30 i 150 100 150 100 85 75 2 50 4 3 4 2 50 1 -29.92 2,11/2 I 65 150 70 30 i 150 i00 150 100 $5 75 2 t/2 65 ; 4 3 4 2 1/2 65 -29.92 4 (50 45 30' j 150 100 150 100 _ 85 75 4:' <t00 6 5 7 5 125 150 45 30 , 150 100 150 100 85 75 5 11251 11 9 13 5 125- -29.92 6 I" 150 150 45 30 j 150 100 150 .100 85- 6 150 13 10 15 6 15Q-29.92 ' 20 5f) 40 20 150 85 150 85 75 ` 60 8 1"2 21"' 16' 25 * For lug style data consult factory 35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618.781-321-5409 • Fax: 800-426-7058 • E-mail: asahi®asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com Dimensions (Sizes 1-1/2"- 14") (NOTE: GEAR OPERATED VALVE IS STANDARD 8" - 14"; SIZES 1-1 /2 " - b" ARE OPTIONS) NOMINAL ANSI CLASS Gear SIZE 150 Box INCHES mm d C n h D D1 D2 D3 L H H1 H2 H3 L Al A2 Wheel Cycles Model No. 1,1/2 40 i ` 1.77 3.88 4 0.62 ' 5.91 2.83 4:80 6.30 1.54 ". 5.12 2.95. 3.74 3.54 8.2746.57-2;52 9. 2 50 2.20 4.75 4 0.75 6.50 3.23 4.80 6.30 1.65 15.51 3.25 4.13 13.64 8.66 6.57 2.52 19.5 21/2 65 12.72 5.50 4 %0.75 7.28 3.781,4.80 J, 6.30 1.81 5.91 3.64 4.53 3.54 :9.06:11'.6.57 2.52 95 3 80 3.03 6.00 4 0.75 8.31 4.17 4.80 6.30 1.81 6.50 4.15 ` 5.12 3.54 9.65 6.57 2.52 9.5 4 100 1 4.02 7.50 8 0.75 '9.37 5.31 4:80 6.30 2.20 7.09 4.fi9 5.71 3.54 10.24 6.57 2.52 9.5 241 ' 5 125 15.08 8.50 8 0.88 10.39 6.69 4.80 6.30 2.60 7.68 5.20 6.30 3.54 10.83 6.57 2.52 9.5 6` 150 d 5.91 9.50; 8 0.88 .1 1.22 7.52 4.80 6.30 2.80:; 827 5:61 ' 6.89 3.54 11.42 .6.57 2.52 9.5 8 2001 7.68 11.75 8 0.88 13.39 9.53 4.80 6.30 3.43 9.49 6.69 8.11 3.54 12.64 6.57 2.52 9.5 10:',250:19.84 14.25 12' 1.00 16.57 11.80:14-8p 6.30 4.33` 1b.81% 8.31 9.49 3:62 14.02 6.57 2.52 9.5 12 300111.9317.00 12 1.00 19.21 14.17 7.40 11.81 5.08 13.39 9.61 11.73 4.25 19.29 9.53 3.90 9.5 14 350 13.82 18.75 12 ! 1.12 21.22 15.47 7.40 11.81 5.08 `, 14.45 10:63 12.80 4.25 20.35 9.53 3:90 9.5 243 ®i ASAHI/AMERICA Rev. D 05-06 Standard Features • Pressure rated at 150 psi at 120° F (water) • Precise fingertip control • Calibrated flow indicator • Rugged unibody construction, sturdy stem • Full vacuum rated, 29.9" Hg • 90° turn operation with lever handle • Cv = 1.6 • Optional FKM seats and stem 0 -ring Sample Specification All LABCOCK® valves shall be of compact, unibody construction having a lever handle, calibrated flow indicator and male threads, female threads, hose ends or elbow as part of the valves' integral construction. Valves shall be constructed of PVC conforming to ASTM D1784 Cell Classification 12454- A. All &rings shall be EPDM or FKM. LABCOCK® valves are rated to 150 psi at 70° F, as manufactured by AsahVAmerica, Inc. Parts List (Size 1/4") 35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618 . 781-321-5409 • Fax: 800-426-7058 • E-mail: asahi@asahi-amedca.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com PARTS NO. DESCRIPTION PCS. MATERIAL i Botly 1 PVG 2 Ball and Stem 1 PVC 3 End Connector 2 PVC 4 Gland 1 PVC 5 Seat 2' EPDM;,Others 6 O -Ring 1 EPDM, Others _7 , ; Handle 1 ABS 35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618 . 781-321-5409 • Fax: 800-426-7058 • E-mail: asahi@asahi-amedca.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com Product Specifications HARVEV CPVC Industrial Pipe: Schedule 40 & 80 Application: Corrosion resistant pressure pipe, IPS sizes 1/8" through 24", for use at temperatures up to and including 2007. Pressure rating (130 psi to 1130 psi) varies with schedule, pipe size, and temperature as shown on page 2 of this specification, and as stated in Harvel Plastics, Inc. engineering bulletin (Product Bulletin 112/401). Generally resistant to most acids, bases, salts, aliphatic solutions, oxidants, and halogens. Chemical resistance data is available and should be referenced for proper material selection. Pipe exhibits excellent flammability characteristics (ULC Listed for Surface Burning Characteristics) and other physical properties. Typical applications include: chemical processing, plating, high purity applications, hot and cold potable water systems, water and wastewater treatment, and other industrial applications involving hot corrosive fluid transfer. Scope: This specification outlines minimum manufacturing requirements for Chlorinated Polyvinyl Chloride (CPVC) schedule 40 and 80 iron pipe size (IPS) pressure pipe. This pipe is intended for use in industrial systems where the fluid conveyed does not exceed 200°F. This pipe meets and or exceeds the industry standards and requirements as set forth by the American Society for Tbsting and Materials (ASTM) and the National Sanitation Foundation (NSF). CPVC Materials: The material used in the manufacture of the pipe shall be a rigid chlorinated polyvinyl chloride (CPVC) compound, Type IV Grade I, with a Cell Classification of 23447 as defined in ASTM D1784. This compound shall be light gray in color, and shall be approved by NSF for use with potable water. Dimensions: CPVC Schedule 40 and Schedule 80 pipe shall be manufactured in accordance to the requirements of ASTM F441 for physical dimensions and tolerances. Each production run of pipe manufactured in compliance to this standard, shall also meet the test requirements for materials, workmanship, burst pressure, flattening, and extrusion quality defined in ASTM F441. All belled -end pipe shall have tapered sockets to create an interference -type fit, which meet or exceed the dimensional requirements, and the minimum socket length for pressure-type sockets, as defined in ASTM D2672. Marking: Product marking shall meet the requirements of ASTM F 441 and shall include: the manufacturers name (or the manufacturers trade- mark when privately labeled); the nominal pipe size; the material designation code; the pipe schedule and pressure rating in psi for water @ 737; F; the ASTM designation F 441; and the independent laboratory's seal of approval for potable water usage. Marking shall also include the flame spread rating and smoke development rating when tested and listed for surface burning characteristics per CAN/ULC S102.2 (Flame Spread (F.S.) of <25 and Smoke Development (S.D.) of <50). Sample Specification: All CPVC Schedule 40 and schedule 80 pipe shall be manufactured from a Type IV, Grade I Chlorinated Polyvinyl Chloride (CPVC) compound with a minimum Cell Classification of 23447 per ASTM D1784. The pipe shall be manufactured in strict compliance to ASTM F441, consistently meeting the Quality Assurance test requirements of this standard with regard to material, workmanship, burst pressure, flattening, and extrusion quality. The pipe shall be produced in the USA using domestic materials, by an ISO 9001 certified manufacturer, and shall be stored indoors after production, at the manufacturing site, until shipped from factory. This pipe shall carry the National Sanitation Foundation (NSF) seal of approval for potable water applications. The pipe shall have a Flame Spread rating < 25 and a Smoke Development rating < 50 when tested and listed for Surface Burning Characteristics in accordance with CAN/ULC-S102-2-M88 or equivalent. All pipe shall be manufactured by HARVEL PLASTICS, INC. Harvel Plastics, Inc. • 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 • Fax: 610.253.4436 • www.harve1.com MARVEL° Schedule 40 Dimensions Nom. Pipe Size (in.) O.D. Average I.D. Min. Wall Nom. Wt./Ft. Max. W.P 1/4 0.540 0.344 0.088 0.096 780 318 0.675 0.473 0.091 0.128 620 112 0.840 0.602 0.109 0.190 600 314 1.050 0.804 0.113 0.253 480 1 1.315 1.029 0.133 0.371 450 1-1/4 1.660 1.360 0.140 0.502 370 1-1/2 1.900 1.590 0.145 0.599 330 2 2.375 2.047 0.154 0.803 280 2-1/2 2.875 2.445 0.203 1.267 300 3 3.500 3.042 0.216 1.660 260 3-1/2 4.000 3.521 0.226 1.996 240 4 4.500 3.998 0.237 2.363 220 5 5.563 5.016 0.258 2.874 190 6 6.625 6.031 0.280 4.164 180 8 8.625 7.942 0.322 6.268 160 10 10.750 9.976 0.365 8.886 140 12 12.750 11.889 0.406 11.751 130 14 14.000 13.073 0.437 13.916 130 16 16.000 14.940 0.500 18.167 130 18 18.000 16.809 0.562 22.965 130 20 20.000 18.743 0.593 29.976 120 24 24.000 22.544 0.687 37.539 120 Schedule 80 Dimensions Nom. Pipe Size (in.) O.D. Average I.D. Min. Wall Nom. Wt./Ft. Max. W.P. 1/4 0.540 0.282 0.119 0.117 1130 3/8 0.675 0.403 0.126 0.162 920 1/2 0.840 0.526 0.147 0.238 850 3/4 1.050 0.722 0.154 0.322 690 1 1.315 0.936 0.179 0.473 630 1-1/4 1.660 1.255 0.191 0.654 520 1-1/2 1.900 1.476 0.200 0.793 470 2 2.375 1.913 0.218 1.097 400 2-1/2 2.875 2.290 0.276 1.674 420 3 3.500 2.864 0.300 2.242 370 3-1/2 4.000 3.326 0.318 2.735 350 4 4.500 3.786 0.337 3.277 320 5 5.563 4.768 0.375 4.078 290 6 6.625 5.709 0.432 6.258 280 8 8.625 7.565 0.500 9.506 250 10 10.750 9.493 0.593 14.095 230 12 12.750 11.294 0.687 19.392 230 14 14.000 12.410 0.750 23.261 220 16 16.000 14.213 0.843 29.891 220 18 18.000 16.014 0.937 37.419 220 20 20.000 17.814 1.031 45.789 220 24 24.000 21.418 1.218 64.959 210 ASTM STANDARD D1784 MATERIAL EQUIVALENTS: Cell Classification 23447 = CPVC Type IV Grade I = CPVC 4120 PIPE SIZES SHOWN ARE MANUFACTURED IN STRICT COMPLIANCE WITH ASTM F441 Product Specifications CPVC Industrial Pipe: Schedule 40 & 80 The pressure ratings given are for water, non -shock, @ 73'E The following temperature de -rating factors are to be applied to the working pressure ratings listed when operating at elevated temperatures. De -Rating Factor Multiply the working pressure Operating De -Rating rating of the selected pipe Temp (°F) Factor at 73'F, by the appropriate 73-80 1.00 de -rating factor to determine 90 0.91 the maximum working 100 0.82 pressure rating of the pipe 110 0.72 at the elevated temperature 120 0.65 chosen. 130 0.57 140 0.50 EX: 10" CPVC SCH 80 150 0.42 @ 120-F = ? 160 170 0.40 0.29 230 psi x 0.65 = p 180 0.25 149.5 psi max. @ 120-F 200 0.20 THE MAXIMUM SERVICE TEMPERATURE FOR CPVC IS 2007.. Solvent -cemented joints should be utilized when working at or near maximum temperatures. Harvel Plastics does not recommend the use of CPVC for threaded connections at temperatures above 150°F; use flanged joints, unions, or roll grooved couplings where disassembly is necessary at elevated temperatures. Threading of Sch 40 CPVC pipe is not a recommended practice due to insufficient wall thickness. Thread only Sch 80 or heavier walls. Threading requires a 50% reduction in pressure rating stated for plain end pipe @73'E Chemical resistance data should be referenced for proper material selection and possible de -rating when working with fluids other than water. Refer to Harvel Plastics 112/401 Product Bulletin for chemical resistance and installation data, Harvel Plastics, Inc. • 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 • Fax: 610.253.4436 • www.harvel.com Product Specifications PVC Industrial Pipe: Schedule 80 Application: MILII-\wl\l.lml Corrosion resistant pressure pipe, IPS sizes 1/8" through 24', for use at temperatures up to and including 1407.. Pressure rating (210 psi to 1230 psi) varies with schedule, pipe size, and temperature as stated in Harvel Plastics, Inc. engineering bulletin (Product Bulletin 112/401). Generally resistant to most acids, bases, salts, aliphatic solutions, oxidants, and halogens. Chemical resistance data is available and should be referenced for proper material selection. Pipe exhibits excellent physical properties and flammability characteristics (independently tested flame and smoke characteristics -ULC). Typical applications include: chemical processing, plating, high purity applications, potable water systems, water and wastewater treatment, irrigation, agricultural, and other industrial applications involving corrosive fluid transfer. Scope: This specification outlines minimum manufacturing requirements for Polyvinyl Chloride (PVC) Schedule 80 iron pipe size (IPS) pressure pipe. This pipe is intended for use in applications where the fluid conveyed does not exceed 1407 F. This pipe meets and or exceeds the industry standards and requirements as set forth by the American Society for Tbsting and Materials (ASTM) and the National Sanitation Foundation (NSF International). PVC Materials: The material used in the manufacture of the pipe shall be domestically produced rigid polyvinyl chloride (PVC) compound, Type I Grade I, with a Cell Classification of 12454 as defined in ASTM D1784, trade name designation H707 PVC. This compound shall be gray in color as specified, and shall be approved by NSF International for use with potable water (NSF Std 61). Dimensions: PVC Schedule 80 pipe shall be manufactured in strict accordance to the requirements of ASTM D1785 for physical dimensions and tolerances. Each production run of pipe manufactured in compliance to this standard, shall also meet or exceed the test requirements for materials, workmanship, burst pressure, flattening, and extrusion quality defined in ASTM D1785. All belled -end pipe shall have tapered sockets to create an interference -type fit, which meet or exceed the dimensional requirements and the minimum socket length for pressure-type sockets as defined in ASTM D2672. All PVC Schedule 80 pipe must also meet the requirements of NSF Standard 14 and CSA Standard B137.3 rigid PVC pipe for pressure applications, and shall bear the mark of these Listing agencies. This pipe shall have a flame spread rating of 0-25 when tested for surface burning characteristics in accordance with CAN/ULC-S102-2-M88 or equivalent. Marking: Product marking shall meet the requirements of ASTM D1785 and shall include: the manufacturer's name (or the manufacturer's trademark when privately labeled); the nominal pipe size; the material designation code; the pipe schedule and pressure rating in psi for water @ 73'F; the ASTM designation D1785; the independent laboratory's seal of approval for potable water usage; and the date and time of manufacture. Sample Specification: All PVC Schedule 80 pipe shall be manufactured from a Type I, Grade I Polyvinyl Chloride (PVC) compound with a Cell Classification of 12454 per ASTM D1784. The pipe shall be manufactured in strict compliance to ASTM D1785, consistently meeting and/or exceeding the Quality Assurance test requirements of this standard with regard to material, workmanship, burst pressure, flattening, and extrusion quality. The pipe shall be manufactured in the USA, using domestic materials, by an ISO 9001 certified manufacturer. Standard lengths of pipe sizes 6" and larger shall be beveled each end by the pipe manufacturer. All pipe shall be stored indoors after production at the manufacturing site until shipped from factory. This pipe shall carry the National Sanitation Foundation (NSF) seal of approval for potable water applications. All pipe shall be manufactured by HARVEL PLASTICS, INC. Harvel Plastics, Inc. • 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 • Fax: 610.253.4436 • www. h a rve 1. c o m HARVEL Schedule 80 Dimensions Nom. Pipe Size (in.) O.D. Average I.D. Min. Wall Nom. Wt./Ft. Max. W.P. 1/8 0.405 0.195 0.095 0.063 1230 1/4 0.540 0.282 0.119 0.105 1 130 3/8 0.675 0.403 0.126 0.146 920 1/2 0.840 0.526 0.147 0.213 850 3/4 1.050 0.722 0.154 0.289 690 1 1.315 0.936 0.179 0.424 630 1-1/4 1.660 1.255 0.191 0.586 520 1-112 1.900 1.476 0.200 0.711 470 2 2.375 1.913 0.218 0.984 400 2-112 2.875 2.290 0.276 1.500 420 3 3.500 2.864 0.300 2.010 370 3-1/2 4.000 3.326 0.318 2.452 350 4 4.500 3.786 0.337 2.938 320 5 5.563 4.768 0.375 4.078 290 6 6.625 5.709 0.432 5.610 280 8 8.625 7.565 0.500 8.522 250 10 10.750 9.493 0.593 12.635 230 12 12.750 11.294 0.687 17.384 230 14 14.000 12.410 0.750 20.852 220 16 16.000 14.213 0.843 26.810 220 18 18.000 16.014 0.937 33.544 220 20 20.000 17.814 1.031 41.047 220 24 24.000 21.418 1.218 58.233 210 Product Specifications PVC Industrial Pipe: Schedule 80 The pressure ratings given are for water, non -shock, @ 73 ° F. The following temperature de -rating factors are to be applied to the working pressure ratings (WP) listed when operating at elevated temperatures. Multiply the working pressure rating of the selected pipe at 73'F by the appropriate de -rating factor to determine the maximum working pressure rating of the pipe at the elevated temperature chosen. EX: 10" PVC SCH 80 @ 120"F = ? 230 psi x 0.40 = 92 psi max. @ 120°F De -Rating Factor Operating De -Rating Temp (°F) Factor 73 1.00 80 0.88 90 0.75 100 0.62 110 0.51 120 0.40 130 0.31 140 0.22 THE MAXIMUM SERVICE TEMPERATURE FOR PVC IS 140'F. Solvent -cemented joints should be utilized when working at or near maximum temperatures. Harvel Plastics does not recommend the use of PVC for threaded connections at temperatures above 110 ° F; use flanged joints, unions, or roll grooved couplings where disassembly is necessary at elevated temperatures. Thread only Schedule 80 or heavier walls. Threading requires a 50% reduction in pressure rating stated for plain end pipe @73 °F. Threading of Schedule 40 PVC pipe is not a recommended practice due to insufficient wall thickness. Chemical resistance data should be referenced for proper material selection and possible de -rating when working with fluids other than water. Refer to Harvel Plastics 112/401 Product Bulletin for chemical resistance, installation data, and additional information. ASTM STANDARD D1784 MATERIAL EQUIVALENTS: Cell Classification 12454 = PVC ape I Grade I = PVC1120 Pipe sizes shown are manufactured in strict compliance with ASTM D1785. Harvel Plastics, Inc. - 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 -Fax: 610.253.4436 - www.harvel.com TRUE UNION 2000 INDUSTRIAL BALL VALVES Features — PVC, CPVC This multi -featured, space saving quarter -turn shutoff valve is designed to meet the demands of today's industrial and chemical processing applications. PVC and CPVC valves are available in IPS sizes 1/2" through 6" with socket/regular thread, SR (Special Reinforced) thread, flanged or spigot end connectors and 8" Venturied valve with socket or flanged ends. Also available in metric socket and BSP thread sizes 1/2" through 2". Sample Engineering Specification All thermoplastic ball valves shall be True Union 2000 Industrial type manufactured to ASTM F 1970 and constructed from PVC Type I, ASTM D 1784 Cell Classification 12454 or CPVC Type IV, ASTM D1784 Cell Classification 23447. All 0 -rings shall be EPDM or Viton®. All valves shall have Safe -T Shear® stem with double O-ring stem seals. All valve handles shall be polypropylene with built-in lockout mechanism. All valve union nuts shall have Buttress threads. All seal carriers shall be Safe -T Blocked®. All valve components shall be replaceable. All valves shall be certified by NSF International for use in potable water service. All 1/2" through 2" valves shall be pressure rated to 235 psi, all 2-1/2" through 6", 8" Venturied and all flanged valves shall be pressure rated to 150 psi for water at 73°F. Quick -View Valve Selection Chart Valve O-ring PVC Part Number t Pressure Size Material Socket Threaded SR Threaded I Flanged Spigot Rating EPDM 1829-005 included 1821-005SR 1823-005 1827-005 1/2 VitonO 1839-005 included 1831-005SR 1833-005 1837-005 EPDM 1829-007 included 1821-007SR 1823-007 1827-007 235 psi 3/4 Non -Shock VitonO 1839-007 included 1831-007SR 1833-007 1837-007 1 EPDM 1829-010 included 1821-010SR 1823-010 1827-010 Water @ 73°F Vi )4n 1839Oi0, included 1831-010SR 1833-010 1837-010 1-1/4 EPDM 1829-012 included 1821-012SR 1823-012 1827-012 (Flanged Vitone 1839-012 included 1831-012SR 1833-012 1837-012 150 psi Non 1-1/2 EPDM 1829-015 included 1821-015SR 1823-015 1827-015 -Shock) Water Uton 9839-Of5 included 1831-015SR 1833-015 1837-015 G73°F EPDM 1829-020 included 1821-020SR 1823-020 1827-020 2 VitonO 1839-020 included 1831-020SR 1833-020 1837-020 EPDM 1822-025 1821-025 1821-025SR 1823-025 1827-025 2-1/2 ton 183206; 1831-025 1831-025SR 1833-025 1837-025 EPDM 1822-030 1821-030 1821-030SR 1823-030 1827-030 3 ')v! 1832 030 1831-030 1831-030SR 1833-030 1837-030 150 psi EPDM 1822-040 1821-040 1821-040SR 1823-040 1827-040 Non -Shock 4 meter V�ton 1832-U4U" 1831-040 1831-040SR 1833-040 1837-040 73°F EPDM 1822-060 1821-060 1821-060SR 1823-060 1827-060 6 Vaion 18360 1831-060 1831-060SR 1833-060 1837-060 83 EPDM 1822-080 — — 1823-080 — Viton® 1832-080 — — 1833-080 — • Chemical & Corrosion Resistant PVC or CPVC Construction • Also Available in Spears® LXT"m High Purity, Low Extractable PVC Material • Interchangeable with all True Union 2000 Valves Mates with Union 2000 Pipe Unions • High Impact Polypropylene Handle • Built-in Handle Lockout • Schedule 80 Full -Bore Design • Strong, Buttress Thread Union Nuts • Spears® Double O-ring Safe -T -Shear' Stem Design • EPDM or VitonO 0 -rings • Spears® Safe -T Blocked® Seal Carrier • Self Adjusting PTFE Floating Seat Design • Fully Serviceable, Replaceable Components • Sizes 1/2" - 2" pressure rated to 235 psi @ 73°F. Sizes 2-1/2" - 6", 8" Venturied and all Flanged to 150 psi @ 73°F. • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Manufactured to ASTM F 1970 Optional Vented Ball Valves Same valve with special ball vent design for sodium hypochlorite (bleach) and other chemical applications where entrapped fluids may form caustic crystalline residues and pressure build up from gases developed. Valve has a 1/8" vent hole in ball to equalize internal fluid pressures. Install valve with ball vent on the pressure (upstream) side when in closed position. Optional Accessories* • Retro -Fit End Connector Sets for Valve Replacement • Split -Nut Repair Kits for Union Nut Replacement • Supplemental End Connectors • Round Safety Handles • Handle Lockout Ring • Stem Extension Kits • Square Operator Nuts • Multi Mount Valve/Actuation Mounting Kits 1) (o'.r C,PUC a1d tt ieer=C', fo{lowug the si�eepde of partT�umber.listedi(e.g.,1829-005C, 1821 005CSR) •See `BALL VALVEACCESSOR/ES" section for details of 2) For Special Ball Vent Design, add the letter' V' before the dash separafor (e.g.,1829V-005, 1821 V-005CSR) individual products. 3) 8" Venturied Valves are 5' ball valves fitted with 6x8 end connector adapters. 10 TRUE UNION 2000 INDUSTRIAL BALL VALVES Replacement Parts 1:1 No. Component Qty. Material 1 Seal Carrier 1 PVC/CPVC 2 Seat 2 PTFE 3 Body 1 PVC/CPVC 4 Carrier 0 -ring 1 EPDMNiton® 5 Stem 1 PVC/CPVC 6 Stem Bearing 1 PP 7 Handle 1 PP 8 Stem 0 -ring 2 EPDMNiton® 9 Handle Lock 1 PP 10 Ball 1 PVC/CPVC 11 Union Nut 2 PVC/CPVC 12 End Connector 0 -ring 2 EPDMNiton® 13 End Connector 2 PVC/CPVC Dimensions, Weights, Operating Torque & Cv Values Nominal Size A B1 Soc/Thd Dimensions Reference (inches, ± 1/16) C Spigot Socket Thread Spigot D E F G Approx. M. (Lbs.) PVC CPVC Oper.2 Cv3 Values Torque (in. lbs.) Socrrhd Flanged Spigot 112 1-7/8 2-3/8 2-7/8 4-3116 3-3/16 4-5/8 2-9116 2-13/16 3-1/2 2-31/32 .36 .38 16 29 18 27 3/4 2-1/4 2-314 3-1/4 4-3/4 4-1/4 5-1/4 2-7/8 3-3/8 3-7/8 3-5/16 .56 .58 17 63 39 57 1 2-1/2 2-7/8 3-1/2 5-1/8 4-11/16 5-3/4 3-1/8 3-7/16 4-1/2 3-5/8 .74 .77 22 120 73 108 1-1/4 3-1/16 3-1/4 3-13/16 5-3/4 5-3/16 6-5/16 3-5/8 3-7/8 4-5/8 3-31/32 1.13 1.19 28 243 151 223 1-1/2 3-1/2 3-1/2 4 6-1/4 5-7/16 6-3/4 4 4-3/16 5 4-3/8 1.54 1.60 61 357 223 333 2 4-1/4 4-3/4 5-3/16 7-3/4 6-314 8-1/4 4-1/2 5-1/8 6 5-1/4 2.72 2.85 77 599 395. 571 2-1/2 5-3/8 6-7/8 7-13/16 10-7/16 9-11/16 11-3/8 5-1/8 6-1/4 7-1/2 6 7.42 7.70 132 856 579 734 3 6-3/16 7 7-13/16 10-11/16 9-7/8 11-9/16 5-7/8 7-5/8 7-1/2 6-13116 7.46 7.81 132 1416 974 1322 4 7-5/8 7-5/16 8-1/4 11-7/8 10-1/4 12-3/4 6-3/4 9-3/16 9 7-1/2 12.35 12.48 396 2865 1952 2672 6 11-5/8 11-1/16 13 17-1/16 15-3/4 18-1/2 8-1/8 14-5/16 11-1/4 10-3116 37.53 40.55 732 6638 4824 6149 84 11-5/8 23-3/16 -- 31-7/8 — -- 8-1/8 14-5116 13-1/2 17-13/16 50.84 55.92 732 NIA N/A N/A 1: Valve Lay Length 2: Torque required at valve maximum internal pressure rating, 5ft/sec. Flow velocity; due to adjustment differences during installation, actual valves may vary. 3: Gallons per minute at 1 psi pressure drop. Valves calculated from laying length, based on derivative of Hazen-Wlliams equation with surface roughness factor of C=150. 4: 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters. Temperature Pressure Rating System Operating 100 110 120 130 140 150 160 170 180 190 200 210 Temperature T (°C) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) PVC 235 211 150 75 50 -0- -0- -0- -0- -0- -0- -0- 1/2" 2" (1.62) (1.45) (1.03) (.52) (34) (-0-) (-0-) (-0-) (-0-) (-o-) (-0-) (-0-) Valve Pressure - CPVC 235 219 170 145 130 110 90 80 70 60 50 -0- Rating (1.62) (1.51) (1.17) (1.00) (.90) (.76) (62) (55) (.48) (41) (.34) (-0-) psi PVC 150 135 110 75 50 -0- -0- -0- -0- -0- -0- -o- (MPa) 2-1/2" 8" (1.03) (.93) (.76) (.52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) - CPVC 150 140 130 120 110 100 90 80 70 60 50 0- (1.03) (.97) (.90) (.83) (.76) (.70) (.62) (.55) (.48) (.41) (.34) (-0-) NOTE: Flanged Valves have a base pressure rating of 150 psi. NOT FOR USE WITH COMPRESSED AIR OR GASES 11 Mi care VaLVEs Features —. PVC; CPVC This solid, proven designs well'suifed for a variety of chemical, industrial and irrigation applications. Spears® Gate Valves are feature -packed with a variety of end connector options. Individual special features are found in each size range 1/2" through 2", 2-1/2" & 3", and in the full featured Heavy Industrial 4" valve. See Spears® Plug Gate Valves for 6" size. • Heavy Bodied PVC & CPVC Construction • Tapered Wedge with Specially Designed Sealing Surface • Non -Rising Stem Design • Patented Strain -Equalizing Stem/Wedge Thread • 0 -ring Stem Seals Instead of Packing - No Retightening Required • Buna-N, EPDM, or Viton® O-ring Seals 1/2" - 2" PVC & CPVC Heavy Duty Gate Valves • Available with socket, threaded or flanged end connectors. • Pressure rated to 200 psi @ 73°F. Flanged Valve Pressure Rated to 150 psi @ 73°F • Positive Grip, High Impact Polypropylene Handwheel Operator • Fully Serviceable, Replaceable Components -Accessible Without Valve Removal • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Metric Socket and BSP Thread Available, 1/2" - 2" Note: 2-1/2" size is a bushed down 3" valve. Sample Engineering Specification 4" PVC & CPVC Heavy Industrial Gate Valves • Available with socket, SR (Special Reinforced) threaded or flanged end connectors. • Pressure rated to 235 psi @ 73°F. Flanged Valve Pressure Rated to 150 psi @ 73°F • SS 316 Exterior Bonnet & Hardware • Built-in Quick -View Position Indicator • Optional 2" Squarefr Style Operator Nut available. All thermoplastic Gate Valves shall be constructed from PVC Type I Cell Classification 12454 or CPVC Type IV Cell Classification 23447. All 0 -rings shall be Buna-N, EPDM or Viton®. All valves shall have non -rising stem and Polypropylene handwheel. All valve gate wedges shall have Strain -Equalizing threads. PVC valves shall have Polypropylene wedge and CPVC valves shall have CPVC wedge. All valve components shall be replaceable. All 1/2" through 2" valves shall be pressure rated at 200 psi, all 2-1/2" through 3" valves shall be pressure rated at 150 psi, and all 4" valves shall be pressure rated at 235 psi for water at 73°F, as manufactured by Spears® Manufacturing Company. CA JT GATE VALVES Quick -View Valve Selection Chart Valve Size O-ring Material PVC Part Numbersl Socket Threaded Flanged Pressure Rating 15 Buna-N 2012-005 2011-005 2013-005 44 1/2 EPDM 2022-005 2021-005 2023-005 144 127 Vitons 2032-007 2031-005 2033-005 (77) See Note 2 Buna-N 2012-007 2011-007 2013-007 1 583 3/4 EPDM 2022-007 2021-007 2023-007 50 -0- Vton® 2032-007 2031-007 2033-007 200 psi -0- Buna-N 2012-010 2011-010 2013-010 Non -Shock Water 1 EPDM 2022-010 2021-010 2023-010 @ 73°F (-0-) Viton® 2032-010 2031-010 2033-010 Buna-N 2012-012 2011-012 2013-012 (Flanged 1-1/4 EPDM 2022-012 2021-012 2023-012 150 psi Vton® 2032-012 2031-012 2033-012 Non -Shock 140 Buna-N 2012-015 2011-015 2013-015 Water @ 73°F) 1-1/2 EPDM 2022-015 2021-015 2023-015 Udon® 2032-015 2031-015 2033-015 (.76) (.69) Buna-N 2012-020 2011-020 2013-020 (.34) 2 EPDM 2022-020 2021-020 2023-020 130 110 Viton® 2032-020 2031-020 2033-020 -0- -0- Buna-N 2012-0253 2011-0253 2013-0253 2-1/2"-3" 2-1/2 EPDM 2022-0253 2021-0253 2023-0253 150 (-0-) Viton® 2032-0253 2031-0253 2033-0253 psi Non -Shock (-0-) Buna-N 2012-030 2011-030SR 2013-030 Water 3 EI?DM 2422 430' 2027: 030SR 2023-03b 73°F Viton® 2032-030 2031-030SR 2033-030 4 Buna-N 2012-040 2011-040SR 2013-040 2352 psi Non -Shock Water EPDM 2022-040 2021-040SR 2023-040 90 Vitons 2032-040 1 2031-040SR 2033-040 @ 73°F 1: For CPVC valves, add the letter "C" to the part numbers (e.g., 2031-005C). 2: Flanged end connectors have a Maximum Internal Pressure Rating of 150 psi @ 73°F. 3: Outlet sized with bushing. Temperature Pressure Rating Cv Values Nominal Size CV1 Gallons/Minute SocketlThreaded Flanged 1/2 19 15 3/4 37 29 1 44 39 1-1/4 128 105 1-1/2 144 127 2 333 279 2-1/2 (77) See Note 2 '�� 33a 323 4 1 583 1 566 Flanged valves calculated for additional laying length of flanged valve. 1: Gallons per minute at 1 psi pressure drop. 2: Size 2-1/2" is a reducer bushed down 3" valve, Cv not available. System Operating 100 110 120 130 140 150 160 170 180 190 200 210 Temperature °F(°C) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) PVC 200 135 120 75 50 -0- -0- -0- -0- -0- -0- -0- 1/2'!-2" (1.38) (.93) (.83) (.52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) CPVC 200 155 140 125 110 100 90 80 70 60 50 -0- (1.38) (1.07) (.97) (.86) (.76) (.69) (.62) (.55) (.48) (.41) (.34) (-0-) Valve PVC 150 130 110 60 50 -0- -0- -0- -0- -0- -0- -0- Pressure Rating 2-1/2"-3" (1.03) (.90) (.76) (.41) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) psi CPVC 150 140 130 120 110 100 90 80 70 60 50 -0- (MPa) (1.03) (.97) (.90) (.83) (.76) (.69) (.62) (.55) (.48) (.41) (.34) (-0-) PVC 235 140 130 90 50 -0- -0- -0- -0- -0- -0- -0- 4 (1.62) (.97) (.90) (.62) (•34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) CPVC 235 219 170 145 130 110 95 80 70 60 50 0- (1.62) (1.51) (1.17) (1.00) (.90) (.76) (.66) (.55) (.48) (.41) (.34) (-0-) NOT FOR USE WITH COMPRESSED AIR OR GASES 1/2" - 2" Replacement Parts GATE VALVES No. Component Qty. Material 1 Handle 1 PP 2 Stem 1 PVC/CPVC 3 Stem 0 -ring 1 Buna-N/EPDMMtion® 4 Stem Bushing 1 PP 5 Stem Nut 1 PVC/CPVC 6 Stem Washer 1 1 PP 7 Wedge Washer/0-ring 1 Buna-N/EPDM/Vition® 8 1 Wedge 1 PP/CPVC 9 Body (Socket/Threaded) 1 PVC/CPVC 10 Bonnet O-ring 1 Buna-N/EPDM/Vition® 11 Bonnet 1 PVC/CPVC 12 Bonnet Nut 1 PVC/CPVC 56 2-1/2" & 3" Replacement Parts No. Component Qty. Material 1 Handle 1 PP 2 Stem 1 PVC/CPVC 3 Stem Bearing 1 PP 4 Stem O-ring 1 Buna-N/EPDMMtion® 5 1 Stem Nut 1 PVC 6 Stem Retaining Ring 1 SS 316 7 Split Washer 1 PP 8 Stem Bushing 1 PP 9 Bonnet Retainer 1 PVC/CPVC 10 Bonnet Half 2 PVC/CPVC 11 1 Seal Carrier 1 PVC/CPVC 12 Carrier O-ring 1 Buna-N/EPDM/Vition® 13 Wedge 1 PP/CPVC 14 Body 1 PVC/CPVC TRUE UNION 2000 INDUSTRIAL BALL CHECK VALVES Sample Engineering Specification Features — PVC, CPVC Flow tested design provides quick response with positive seal for prevention of system back flow in industrial and chemical processing applications. Valves are available in IPS sizes 1/2" through 6" with socket/regular thread, SR threaded (Special Reinforced), flanged or spigot end connectors and 8" venturied valve with socket or flanged ends.. Also available in metric socket and BSP thread sizes 1/2" through 2". All thermoplastic check valves shall be True Union 2000 Industrial Ball Check type manufactured to ASTM F 1970 and constructed from PVC Type I, ASTM D 1784, Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell Classification 23447. All 0 -rings shall be EPDM or Viton®. All valve union nuts shall have Buttress threads. All valve seats shall be a standard O-ring type. All seal carriers shall be Safe -T Blocked®. All valve components shall be replaceable. All valves shall be listed by NSF for use in potable water service. All valves shall be certified by NSF International for use in potable water service. All PVC and CPVC 1/2" through 2" valves shall be pressure rated to 235 psi, all 2-1/2" through 6", 8" Venturied and all flanged valves shall be pressure rated to 150 psi for water at 73°F as manufactured by Spears® Manufacturing Company. Quick -View Valve Selection Chart Valve 0 -ring Y�. PVC Part Number' Pressure Size Material Socket Threaded SR Threaded Flanged Spigot Rating 1/2 EPDM 4529-005 included 4521-005SR 4523-005 4527-005 Viton® 4539-005 included 4531-005SR 4533-005 4537-005 235 psi Non -Shock Water F 3/4 EPDM 4529-007 included 4521-007SR 4523-007 4527-007 Vitort® 4539-007 included 4531-007SR 4533-007 4537-007 1 EPDM 4529-010 included 4521-010SR 4523-010 4527-010 Vton® 4539-010 included 4531-010SR 4533-010 4537-010 (Flanged 1-1/4 EPDM 4529-012 included 4521-012SR 4523-012 4527-012 Viton® 4539-012 included 4531-012SR 4533-012 4537-012 150 psi Non -Shock) Water 1-1/2 EPDM 4529-015 included 4521-015SR 4523-015 4527-015 WW 4539It5i included 4531-015SR 4533-015 4537-015 @ 73°F 2 EPDM 4529-020 included 4521-020SR 4523-020 4527-020 Viton® 4539-020 included 4531-020SR 4533-020 4537-020 2-1/2 EPDM 4522-025 4521-025 4521-025SR 4523-025 4527-025 V#otic 43 U25 4531-025 4531-025SR 4533-025 4537-025 3 EPDM 4522-030 4521-030 4521-030SR 4523-030 4527-030 150 psi Non-Shock Vton® 4532-030 4531-030 4531-030SR 4533-030 4537-030 4 EPDM 4522-040 4521-040 4521-040SR 1 4523-040 4527-040 Viton® 4532-040 4531-040 4531-040SR 4533-040 4537-040 6 EPDM 4522-060 4521-060 4521-060SR 4523-060 4527-060 @ 73°F Viton® 4532-060 4531-060 4531-060SR 4533-060 4537-060 82 EPDM 4522-080 — — 4523-080 — Vdon®4532-080 — — 4533-080 — 1 For CPUC 4al a add the IGtfar C"` to ttte part numb®r(e.g., 4529-005C, 4521-005CSR) 2: &' Venturied Valves are 5' ban valves fitted with 6x8 end connector adapters 20 • Chemical & Corrosion Resistant PVC or CPVC Construction • Also Available in Spears® LXTT- High Purity,Low Extractable PVC Material • Strong, Buttress Thread Union Nuts • Spears® Safe -T Blocked® Seal Carrier • Uses Standard O-ring Seat • EPDM or Viton® 0 -rings • Fully Serviceable, Replaceable Components • Sizes 1/2" - 2" Pressure Rated to 235 psi @ 73°F, Sizes 2-1/2" - 6", 8" Venturied and all Flanged Pressure Rated to 150 psi @ 73°F • Suitable for Either Horizontal or Vertical Installations • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Manufactured to ASTM F 1970 Optional Accessories* • Retro -Fit End Connector Sets for Valve Replacement • Split -Nut Repair Kits for Union Nut Replacement • Supplemental End Connectors ' See "BALL VALVE ACCESSORIES" section for details of individual products. Ball Check Foot Valves Spears® Ball Check Valves easily convert to foot valves utilizing optional Foot Valve Screen adapters found in Ball Valve Accessories section. Y�. � s Spears® Ball Check Valves easily convert to foot valves utilizing optional Foot Valve Screen adapters found in Ball Valve Accessories section. TRUE UNION 2000 INDUSTRIAL BALL CHECK VALVES Dimensions, Weights, & Cv Values Replacement Parts SPEARS , No. Component Qty. Material 1 Seal Carrier 1 PVC/CPVC 2 Seal Carrier Nut 1 PVC/CPVC 3 Carrier O-ring 1 EPDM/VtonO 4 Seat Plate 1 PVC/CPVC 5 Seat O-ring 1 EPDMNiton® 6 Body 1 PVC/CPVC 7 Ball 1 PVC/CPVC 8 Union Nut 2 PVC/CPVC 9 End Connector O-ring 2 EPDM/Vitono 10 End Connector 2 PVC/CPVC Nominal 100 110 Dimensions Reference (inches, t 1116) 130 140 Approx. Wt. (Lbs.) 160 Cv2 Values 180 Horizontal Closing Size AF B1 SodThd Spigot Socket C Thread Spigot (60) G PVC CPVC Soc/Thd Flange Spigot Feet of Head (Wats) GPM (minimum) 1/2 1-7/8 2-7/16 2-7/8 4-3/16 3-13/16 4-5/8 3-1/2 2-31/32 .30 .33 1 6.3 6 6.3 1.6 .10 314 2-1/4 2-3/4 3-1/4 4-3/4 4-1/4 5-114 3-7/8 3.5116 .46 .50 17 16 17 1.6 .10 1 2-1/2 2-7/8 3-112 5-1/8 4-11/16 5-3/4 4-1/4 3.5/8 .70 .74 25 24 25 1.6 1 .25 1-1/4 3-1/16 3-1/4 3-3116 5-3/4 1 5-3116 6.5/16 1 4-5/8 3-31/32 1.04 1.09 65 61 65 1.6 .40 1-1/2 3-1/2 3.1/2 4 6-1/4 5-7/16 6-3/4 5 4-3/8 1.37 1.45 86 82 86 1.6 .75 2 4.1/4 4-3/4 5.3/16 7-3/4 6-3/4 8-1/4 6 5-1/4 2.47 2.62 130 125 130 1.6 .75 2-1/2 6.3116 5-718 7-13/16 9-5/16 8-1/2 11-3/8 7-1/2 6 6.80 7.25 200 193 200 1.0 1.50 3 6-3/16 6-7/8 7-13/16 10-11/16 9-3/4 11-9/16 7-1/2 6-13/16 6.98 7.35 275 268 275 1.0 4.00 4 7-112 7-1/4 8.1/4 11-13/16 10-1/4 12-3/4 9 7-1/2 12.13 12.96 500 489 500 1.0 5.50 6 11-5/8 11-1/6 13 17-1/16 15-3/4 18.1/2 11-1/4 10.3116 37.07 39.98 800 794 800 N/A WA 83 115/8 1 23-3/16 -- 31-7/8 - 13-1/2 17-13/16 50.84 55.92 N/A N/A N/A N/A N/A 1: Valve Lay Length 2: Gallons per minute at 1 psi pressure drop. Valves calculated from laying length, based on derivative of Hazen -Williams equation with surface roughness factor of C=150. 3: 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters Temperature Pressure Rating System Operating 100 110 120 130 140 150 160 170 180 190 200 210 Temperature T (°C) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) PVC 235 211 150 75 50 -0- -0- -0- -0- -0- -0- -0- 1/2" 2" (1.62) (1.45) (1.03) (.52) (34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) Valve Pressure - CPVC 235 219 170 145 130 110 90 80 70 60 50 -0- Rating (1.62) (1.51) (1.17) (1.00) (.90) (.76) (.62) (.55) (.48) (.41) (34) (-0-) psi(MPa) PVC 150 135 110 75 50 -0- -0- -0- -0- -0- -0- -0- 2-1/2" - g (1.03) (.93) (.76) (.52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) CPVC 150 140 130 120 110 100 90 80 70 60 50 -0- (1.03) (.97) (.90) (.83) (.76) (.70) (.62) {.55) (.48) (.41) (.34) (-0-) NOTE: Flanged valves have abase pressure rating of 150 psi General Installation Information: Ball check valves may be installed in either horizontal or vertical position. A minimum of ten (10) pipe diameters distance maintained from any pump or other source of turbulence. Check valves MUST be installed with the valves FLOW arrow pointing in the direction of flow. NOT FOR USE WITH COMPRESSED AIR OR GASES 21 ��t CP 404M Sealed Regenerative Blower w/Explosion-Proof Motor 60 2.0- 50 1.5 w 40 U y p 30 a 1.0 0 s Z 20 0.5 10 U IrUw 100 Uzm 75 FCR 50 Oza 25 0 1500 w 1000 nz 3 500 0 BLOWER PERFORMANCE AT STANDARD CONDITIONS AIR FLOW RATE (M3/MIN) AIR FLOW RATE (M3/MIN) 0.5 1.0 1.5 2.0 2.5 3.0 0.5 1.0 1.5 2.0 2.5 -60 4 -50 3 F -40 U W m a O -30 E O 2 y W z U z -20 z 1 -10 ISHEEM" C'"■M■M■ 1\'IMMMON IMMUMMM I..,... �aa�aai 3.0 125 100 0 20 40 60 60 100 • 75 ap E AMETEK Technical and Industrial Products, Kent, OH 44240 • e mail: rotronindustrial@ametek.com • internet: www.ametektmd.com 1� AMETEK Technical and Industrial Products, Kent, OH 44240 • e mail: rotronindustrial@ametek.com • internet: www.ametektmd.com Sealed Regenerative Blower w/Fxplosion-Proof Motor 7.18 12.10:t.19 182.00 307 1 1- DIA. 6.17 157.00 Scale CAD drawing available upon request 11A4 291 oc700.rl9.7REF i 3_0 3.75 76.295.25512 _ 130.00 M-111% NPSC 11.11 *0.19 8.93 THREAD 282 t 5.0 .47 226.6 11.90 DIA 10.12 (4) MTG HOLES 257.00 DIMENSIONS: MM IN 8 MODEL L (IN) x .30 L (MM) x 8 2.XXX -030 t .800 (UNLESS OTHERWISE NOTED) !EN1C!P4G!4AR58ML_ 15.58 398 0.75" NPT CONDUIT CONNECTION AT 12 O'CLOCK POSITION SPECIFICATIONS MODEL EN404AR58ML EN404AR72ML CP404FQ58MLR CP404FQ72MLR Part No. 038173 038174 080075 038958 Motor Enclosure - Shaft Material Explosion -proof - CS E osion- roof -,IS Chem XP - SS Vhern XP - S Horsepower 1.0 X 1.0 Same as EN404AR58ML - 038173 except add Chemical Processing (CP) features from catalog inside front cover Same as EN AR7 L - 4 exc add Chemic cessing (CP) features from catalog inside front cover Phase - Frequency Sin le - 60 Hz T e - 60 z Volta e 1 115 230 208-23 460 Motor Nameplate Ams 11.4 5.69 3.5-3.2 1.6 Max. Blower Amps 3 14.4 7.2 4.2 2.1 Inrush Ams 72 36 20.2 10.1 Starter Size 0 00 0 0 Service Factor 1.0 1.0 Thermal Protection 2 Class B - Automatic As B - Pilot D XP Motor Class - GroupI-D II-F&G I -D, II-F&G Shipping Weight 72 Ib (33 kg) 65 Ib (30 kg) Rotron motors are designed to handle a broad range of world voltages and power supply variations. Our dual voltage 3 phase motors are factory tested and certified to operate on both: 208-230/415-460 VAC -3 ph -60 Hz and 190-208/380-415 VAC -3 ph -50 Hz. Our dual voltage 1 phase motors are factory tested and certified to operate on both: 104-115/208-230 VAC -1 ph -60 Hz and 100-110/200-220 VAC -1 ph -50 Hz. All voltages above can handle a:00% voltage fluctuation. Special wound motors can be ordered for voltages outside our certified range. Maximum operating temperature: Motor winding temperature (winding rise plus ambient) should not exceed 140°C for Class F rated motors or 120°C for Class B rated motors. Blower outlet air temperature should not exceed 140°C (air temperature rise plus inlet temperature). Performance curve maximum pressure and suction points are based on a 40°C inlet and ambient temperature. Consult factory for inlet or ambient temperatures above 40°C. Maximum blower amps corresponds to the performance point at which the motor or blower temperature rise with a 40°C inlet and/or ambient temperature reaches the maximum operating temperature. Specifications subject to change without notice. Please consult your Local Field Sales Engineer for specification updates. Rev: 2/04 AMETEK Technical and Industrial Products, Kent, OH 44240 • e mail: rotronindustrial@ametek.com • internet: www.ametektmd.com LEAALII; =86 79 JEAJA4 808 Single -Phase and CP Options Sealed Regenerative Blower w/Fxplosion Proof Motor 5.0 1`W 120 4.0- 100 W 3.0 3 80 LL a O M 60 2.0 UJ= U Z 40 1.0 150 O R E 100 0 a 50 w 0 10,000 U1 7,500 az 3 5,000 2,500 BLOWER PERFORMANCE -AT STANDARD CONDITIONS AIR FLOW RATE (M3/MIN) AIR FLOW RATE (M3/MIN) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 200 Q m 150 10 ]-140 -120 8 -100 O W U, 6 i -80 i a U- O O 0 -60 W W 4 x = U z -40 2 9.0 10.0 350 SUCTION A -MAX SUCTION 300 POINT 0 50 100 150 200 250 300 350 AIR FLOW RATE (SCFM) 150 Oz N 100 Cza 50 2NE o 10,000 W7,500 0. a z 9 5,000 2,500 a v 150 Mo. 150 3 2 100 3 w W 100 1 � 50 ~ �¢F 50 Q 0 mQ 0 Rev. 2/04 AMETEK Technical and Industrial Products, Kent, OH 44240 9 e mail: rotronindustrial@ametek.com • internet: www.ametektmd.com 250 200 2 m 150 E 100 50 �s, jr-=N' � 808 Single Phase and CP Options Sealed Regenerative Blower w/Explosion-Proof Motor A G 16.52 /1 0 t 6.37 419.6 ' I 161.8 B _ _ _ _ _ 10.18 258.6 Wd 10.25 260.4 5.00 127 C 9.50 .75 2.00 8.42 241.3 19 X 50.8 SLOT 213.9 5.61 13.00 (4) PLACES 142.5 330.2 DIMENSIONS: AAM TOLERANCES: XX x '1 2.5 (UNLESS OTHERWISE NOTED) A� 0.75" NPT CONDUIT CONNECTION AT 12 O'CLOCK POSITION SPECIFICATIONS Scale CAD drawing available upon request 6.82 4.00 173.2 -r-102///-2 1/2 - 8 NPSC FEMALETHIREAD BOTH PORTS E ROTATION Y, DIRECTION 4.25 8 10 !J 8.50 215.9 10.00 MODEL EWCP707 ENWP608 CP707FX5MWLR IN MM A 2. 4 23.0 562 B 19A 494 19.5 494 C 7.4 187 7.4 187 D 6. 164 7.1 180 E Service Factor 1.0 1.0 Thermal Protection ss B - Pilot D Class B - Pilot Du 3.4 86 F .5 4 16.5 419 G 2023 514 20.7 526 MODEL EN707FL5MWL EN808FL5MWL CP707FX5MWLR CP808FX5MWLR Part No. 038712 038732 080616 - Motor Enclosure - Shaft Material E osion- roof - S Explosion -proof - CS hem XP - S Chem XP - SS Horsepower 5.5 5.5 Same as EN FI -5 L- 7 exc add Chemic cessing (CP) features from catalog inside front cover Same as EN808FL5MWL- 038732 except add Chemical Processing (CP) features from catalog inside front cover Phase - Frequency SI le - 6 z Single - 60 Hz Voltage 30 230 Motor Nameplate Ams 21.7 Max. Blower Amps 2 29.9 Inrush Ams 155 155 Starter Size 1 1 Service Factor 1.0 1.0 Thermal Protection ss B - Pilot D Class B - Pilot Du XP Motor Class - GroupI-D I -D Shipping Weight 244 Ib (111 kg) 378 Ib (172 kg) 1 Maximum operating temperature: Motor winding temperature (winding rise plus ambient) should not exceed 140°C for Class F rated motors or 120°C for Class B rated motors. Blower outlet air temperature should not exceed 140°C (air temperature rise plus inlet temperature). Performance curve maximum pressure and suction points are based on a 40°C inlet and ambient temperature. Consult factory for inlet or ambient temperatures above 40°C. 2 Maximum blower amps corresponds to the performance point at which the motor or blower temperature rise with a 40°C inlet and/or ambient temperature reaches the maximum operating temperature. Specifications subject to change without notice. Please consult your Local Field Sales Engineer for specification updates. Rev, 2,104 AMETEK Technical and Industrial Products, Kent, OH 44240 9 e mail: rotronindustrial@ametek.com • internet: www.ametektmd.com Regenerative Blower Noise Chart* in dBA * Average at 1 meter, 4 places around the blower «Contents>> <<Index>> General DAIDSTATION Specifications Dx1 000 GS 04L41 B01-01 E OVERVIEW The DX1000 is a DAQSTAT/ON that displays real-time measured data on a color LCD and saves data on a CompactFlash memory card (CF card). It can be hooked up to network via Ethernet, which enables to inform by E- mail and to monitor on Web site as well as to transfer files by using FTP. Also, it can communicate with Modbus/RTU or ModbUS/TCP. It comes with a two, four, six -channel or twelve -channel model. As the input signal, a DC voltage, thermocouple, resistance temperature detector, or contact signal can be set to each channel. The data saved on a CF card can be converted by data conversion software to Lotus 1-2-3, Excel, or ASCII format file, facilitating processing on a PC. Not only this, the Viewer software allows a PC to display waveforms on its screen and to print out wave- forms. STANDARD SPECIFICATIONS General Specifications Construction Mounting: Flush panel mounting (on a vertical plane) Mounting may be inclined downward up to 30 degrees from a horizontal plane. Allowable panel thickness: 2to26mm Material: Case: drawn steel Bezel: polycarbonate Display filter: polycarbonate Case color: Case: Grayish blue green (Munsell 2.06 5.0/1.7 or equivalent) Bezel: Charcoal grey light (Munsell 10B 3.6/0.3 or equivalent) Front panel: Water and dust -proof (based on IEC529-IP65) Dimensions: 144(W) x 144(H) x 229(D)* mm *Maximum Weight: approx. 2.9 kg* *without optional features YOKOGAWA mm", e =091nced Input Number of inputs: DX1002: two channels DX1004: four channels DX1006: six channels DX1012: twelve channels Measurement interval: DX1002, DX1004: 125 ms, 250 ms, 25 ms (fast sampling mode*) DX1006, DX1012: 1 s (Not available when A/D integration time is set to 100 ms), 2 s, 5 s, 125 ms (fast sampling mode*) * A/D integration time is fixed to 1.67 ms in case of fast sampling mode. Inputs: DCV (DC voltage), TC (thermocouple), RTD (resistance temperature detector), DI (digital input for event recording), DCA (DC current with external shunt resistor attached) GS 041-411301-011H ©Copyright November. 2005 1st Edition Nov. 2005(KP) <<Contents>> <<Index» Input type Range Measuring range 20 mV -20.000 to 20.000 mV 60 mV -60.00 to 60.00 mV DCV 200 mV -200.00 to 200.00 mV 2 V -2.0000 to 2.0000 V 6 v -6.000 to 6.000 V 1-5v -0.800 to 5.200 V 20V -20.000 to 20.000 V 50V -50.00 to 50.00 V R'1 0.0 to 1760.0*C 32 to 3200*F S'1 0.0 to 1760.0°C 32 to 3200*F TC B-' 0.0 to 1820.0*C 32 to 3308T K'1 -200.0 to 1370.0*C -028 to 2498*F E-1 -200.0 to 800.0*C -328.0 to 1472.0°F J'1 -200.0 to 1100.0*C -328.0 to 2012.0*F T-1 -200.0 to 400.0°C -328.0 to 752.0°F N.1 0.0 to 1300.0*C 32 to 2372°F W2 0.0 to 2315.0°C 32 to 4199°F L-3 -200.0 to 900.0°C -328.0 to 1652.0'F U-3 -200.0 to 400.0°C -328.0 to 752.0°F WRe 4 0.0 to 2400.0°C 32 to 4352*F RTD Pt100' 0.0°C -328.0 to 1112.0°F 5.0JPt1005 2000650°C 128.0 to 1022.0°F DI DCV input (TTL) OFF: less than 2.4 V ON : more than 2.4 V Contact input Contact ON/OFF *1 R, S, B, K, E, J, T, N: IEC584-1 (1995), DIN IEC584,JIS C 1602-1995 *2 W: W-5% RdNV--26% Rd (Hoskins Mfg. Co.), ASTM E988 *3 L: Fe-CuNi, DIN43710, U: Cu-CuNi, DIN43710 *4 WRe: W-3%ReM-25%Re (Hoskins Mfg. Co.) *5 PH 00: JIS C 1604-1997, IEC 751-1995, DIN IEC751-1996 JPt100: JIS C 1604-1989,JIS C 1606-1989 Measuring current: i = 1 mA A/D integration time: 20 ms (50 Hz), 16.7 ms (60 Hz), 100ms (50/ 601-lz for DX1006/1012), or AUTO selectable (automatic selection by detection of power supply frequency) A/D integration time is fixed to 1.67 ms (6001-1z) in case of fast sampling mode. Thermocouple burnout: Burnout upscale/downscale function can be switched on/off (for each channel). Burnout upscale/downscale selectable Normal: Less than 2 k12, Bum out: More than 100 kil Detection current: approx. 10 µ A 1-5V range burnout: Burnout upscale/downscale function can be switched on/off (for each channel). Burnout upscale/downscale selectable Upscale burnout: More than +10% of configured span Downscale burnout: Less than -5% of configured span Moving average: Moving average on/off selectable for each channel Moving average cycles 2 to 400 selectable Calculation: Differential computation: Between any two channels Available for DCV, TC, RTD and DI ranges. Linear scaling: Available for DCV, TC, RTD and DI ranges. Scaling limits: -30000 to 30000 Decimhal point: user -selectable Engineering unit: user -definable, up to 6 characters Overvalue: Exceeds ± 5% of scaling limits (on/off selectable) Square root: Available for DCV range. Scaling limits: -30000 to 30000 Decimal point: user -selectable Engineering unit: user -definable, up to 6 characters Low level cut off: 0.0 to 5.0% of display span Over value: Exceeds :t 5% of scaling limits (on/off selectable) 1-5VDC scaling: Available for 1-5VDC range. Scaling limits: -30000 to 30000 Display span limit: 0.800 to 5.200 Decimal point: user -selectable Engineering unit: user -definable, up to 6 characters Low level cut off: Fixed to lower span limit Overvalue: Exceeds ± 5% of scaling limits (on/off selectable) Display Display unit: 5.5 -inch TFT color LCD (VGA, 320 x 240 pixels) Note) In the part of crystal display, there are some pixels that can't always turn on or off. Please understand that the brightness of screen looks uneven because of characteristics of crystal display, but it is not out of order. Display group: Each measurement channel and computation channel can be assigned to display group of the trend, digital and bargraph display. Number of display: 10 groups Number of assignable channels for one group: 6 channels Display color: Trend/Bargraph: Selectable from 24 colors Background: White or black selectable Trend display: Trend display type: Vertical, horizontal, landscape, horizontal or split selectable Number of indication channels: 6 channels per display (maximum) Number of display: 10 displays (10 groups) Line width: 1, 2, and 3 pixels selectable Scales: Maximum 6 scales. Bargraph, green band area and alarm mark can be displayed on scale display. Number of divisions: Selectable from 4 to 12 or C10 (10 divisions by main scale mark and scale values are displayed on 0, 30, 50, 70 and 100% position). All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS O4L41 BO1-01 E 1st Edition Nov. 09,2005-00 «Contents>> <<Index>> Waveform span rate: 15, 30 sec.,1, 2, 5, 10, 15, 20, 30 min., 1, 2, 4, 10 hours/div selectable (15 sec/div is available for only DX1002 and DX1004) Bargraph display: Direction: Vertical or horizontal selectable Number of indication channels: 6 channels per display Number of display: 10 displays (10 groups) Scales: Green band area and alarm mark can be displayed on scale display. Number of divisions: Selectable from 4 to 12 Reference position: Left, right or center Display renewal rate: 1 s Digital indication: Number of indication channels: 6 channels per display Number of display: 10 displays (10 groups) Display renewal rate: 1 s Overview display: Number of indication channels: Measuring values and alarm status of all channels Information display: Alarm summary display: Display the list of latest 1000 alarms summary. Jump to historical trend display by cursor pointing. Message summary display: Display the list of latest 500 messages and time. Jump to historical trend display by cursor pointing. Memory information: Display the file list in internal memory. Jump to historical trend display by cursor pointing. Report information: Display the report data in internal memory. Modbus status: Display the Modbus status. Relay status: Display the on/off status of internal switch and relay output. Log display: Log display types: Login log, error log, communication log, FTP log, Web log, E-mail log, SNTP log, DHCP log, Modbus log Tags: Number of characters: 16 characters maximum Messages: Number of characters: 32 characters maximum Number of messaged: 100 messages (including 10 free mes- sages) Message adding function: Message can be added on historical display. 3 Other display contents: Status display area: Date & time (year/month/day, hour:minute:second), batch name (batch number + lot number), login user name, display name, internal memory status, status indication icon Trend display area: Grid lines (number of divisions selectable from 4 to 12), hour: minutes on grid, trip levels (line widths are selectable from 1, 2 and 3 pixels) Data referencing function: Display the retrieved data (display data or event data) from internal or external memory. Display format: Whole display or divided to 2 areas Time axis operation: Display magnification or reduction, scroll by key operation Display auto scroll function: Display group of monitor display (trend display, bargraph display and digital display) automatically changes in a preset interval (5, 10, 20, 30 s and 1 min). LCD saver function: The LCD backlight automatically dims or off (selectable) if no key is touched for a certain preset time (can be set from 1, 2, 5, 10, 30, and 60 min). Display register function: Up to 8 display types can be registered with display name. Display auto return function: The display type automatically returns to registerd display type if no key is touched for a certain preset time (can be set from 1, 2, 5, 10, 20, 30 and 60 min) Temperature unit: °C or OF selectable Data Saving Function External storage medium: Medium: CompactFlash memory card (CF card) Format: FAT16 or FAT32 Internal memory: Medium: Flash memory Capacity: Selectable from 80MB or 200MB Maximum number of files can be saved: 400 files (total number of display data file and event data file) Manual saving: Data files in internal memory can be saved manually. Selectable form all data saving or selected data saving. Drive: CF card or USB flash drive (only for USB option) Automatic saving: Display data: Periodic saving to CF card Event data: In case of trigger free... Periodic saving to CF card In case of using trigger ... Save the data when sampling is finished Data Saving Period: Display data file: Linked with the waveform span rate Event file: Linked with the specified sampling period All Rights Reserved. Copyright© 2005, Yokogawa Electric Corporation GS 041 -41B01 -01E 1st Edition Nov. 09,2005-00 «Contents» —Index— Event File Sampling Period: DX1002, DX1004: Selectable from 25,125, 250, 500 ms, and 1, 2, 5, 10, 30, 60, 120, 300, and 600 s* DX1006, DX1012: Selectable from 125, 250, 500 ms, and 1, 2, 5, 10, 30, 60, 120, 300, and 600 s* *Sampling period faster than measurement interval can not be selected. Measurement data File: The following two file types can be created. Event file (stores instantaneous values sampled periodically at a specified sampling rate) Display data file (stores the maximum and minimum values for each waveform span rate from among measured data sampled at measurement intervals) Files can be created in the following combinations. (a) Event file + display data file (b) Display data file only (c) Event file only Data format: YOKOGAWA private format (Binary) Maximum data size per file: 8,000,000 byte (8MB) Data per channel: Display data file: Measurement data ...... 4 byte/data Mathematical data ...... 8 byte/data Event data file: Measurement data ...... 2 byte/data Mathematical data ...... 4 byte/data Sampling time: The sampling time per file (8MB) during manual data saving can be determined by the formula "number of data items per channel x interval of data saving." This logic is explained in more detail below: 1) When handling display data files only If we assume that the number of measuring channels is 12, the number of computing channels is 24, and the display update interval is 30 min/div (60 sec waveform span rate), then: Number of data items per channel = 8,000,000 bytes/(8 bytes(time stamp) + 12 x 4 bytes + 24 x 8 bytes) = 32,258 data items Sampling time per file = 32,258 x 60 sec = 1,935,480 sec = approx. 22 days 2) When handling event files only If we assume that the number of measuring channels is 12, the number of computing channels is 24, and the data saving interval is 1 sec, then : Number of data items per channel = 8,000,000 bytes/(8 bytes(time stamp) + 12 x 2 bytes + 24 x 4 bytes) = 62,500 data items Sampling time per file = 62,500 x 1 sec = 62,500 sec = approx. 17 hours 3) When handling both display data files and event files The sampling time is calculated by defining the size of data items in a display data file as 8,000,000 bytes and the size of data items in an event data file as 8,000,000 bytes. The method of calculation is the same as shown above. Examples of Sampling Time for 1 file (8MB)*: *If sampling time exceeds 31 days, data file is divided. In case measurement ch = 4 ch, mathematical ch = 0 ch Display data file (approx.) Waveform span rate (time/div) 15S 30s 1 min 2 min 5 min 10 min 1 h Data saving period 0.5s Is 2s 4s los 20s 2 min Sampling time 1 46.3 h 3 days 7 days 15 days 38 days 77 days 44 days Event data file (approx.) Data saving period 25 ms 125 ms 0.5s 1 s 2s 5s I los Sampling time 3.5 h 17.4 h 2 days 5 days 11 days 28 days 157 days In case measurement ch = 12 ch, mathematical ch = 24 ch Display data file (approx.) Waveform span rate (timeldiv) 15s 1 min 5 min 10 min 20 min 30 min 1 h Data saving period NA 2s 10s 20s 40s 1 min 2 min Sampling time NA 17.9 h 3 days 7 days 14 days 22 days 44 days Event data file (approx.) Data saving period 25 ms 125 ms 0.5s 1 s 10s 30 s 1 min Sampling time NA 2.2 h 8.7 h 17.4 h 7.2 days 21 days 143 days All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS O41-41 B01-01 E list Edition Nov. 09,2005-00 «Contents» <<Index>> 5 Manual sample data: The measuring and computing data can be saved manually to the internal memory and CF card. Trigger: Key operation, communication command or event action function Data format: ASCII Max. number of data: 400 data (if exceeds 400 data, oldest data is overwritten) Report data (only for MATH option): Types: Hourly, daily, hourly + daily, daily + weekly, and daily + monthly Data format: ASCII Drive: CF card Trigger function: Selectable from FREE or TRIG for event data saving. Trigger mode: Selectable from free, single or repeat trigger Data length: Selectable from 10, 20, 30 min, 1, 2, 3, 4, 6, 8, 12 hour, 1, 2, 3, 5, 7, 10, 14, 31 day Pre trigger: Selectable from 0, 5, 25, 50, 75, 95, 100% Trigger source: Key or event action function Display hard copy: Trigger: Key operation, communication command or event action function Data format: prig format Drive/output: CF card or communication interface Data file retrieving function: Data file in CF card or USB flash drive (only for USB option) can be retrieved and displayed. Retrieved data file: Display data file or event data file Saving and retrieving of configuration data: Configuration information can be saved and retrieved as ASCII data. Drive: CF card or USB flash drive (only for USB option) Alarm Function Number of alarm levels: Up to four levels for each channel Alarm types: High and low limits, differential high and low limits, high and low rate -of -change limits and delay high and low Alarm delay time: 1 to 3600 s Interval time of rate -of -change alarms: The measurement interval times 1 to 32 Display: The alarm status (type) is displayed in the digital value display area upon occurrence of an alarm. A common alarm indication is also displayed. Alarming behavior: non -hold or hold -type can be selectable for common to all channels. Hysteresis: On/off selectable (common to measurement channels, mathematical channels or external channels) 0.0 to 5.0% of display span (or scaling span) Outputs: Output: Internal switch or relay output (optional) Number of internal switch: 30 points Internal switch action: AND/OR Number of relay output points: 2, 4 or 6 points (optional) Relay action: Energized/deenergized, hold/non-hold, AND/OR, alarm reflash selectable. Alarm no logging function: When alarm occurs, only internal switch or relay output is activated. There are no alarm display on screen and no record on alarm summary. On/off selectable for each channel and alarm level. Memory: The times of alarm occurrences/recoveries, alarm types, etc. are stored in the memory. Up to 1000 latest alarm events are stored. Event action function General: Particular action can be executed by particular event. Number of event action: 40 actions can be set Event list: Event Level/Edge Description Remote Level/Edge Action by remote control signal Relay Level/Edge Action by relay operation Internal switch Level/Edge Action by internal switch operation Alarm Level/Edge Action by any alarm Timer Edge Action by timer time up Match time lEdge Action by time up of match time timer USER key JEdge Action by USER key operation Action list: Action Level/Edge Description Memory starv,to Level Memory start and stop Memory start Edge Memory start Memory stop Edge Memory stop Event trigger Edge Event data sampling start Alarm ACK Edge Alarm ACK Math start/stop Level Computation start and stop Math start Edge Computation start Math stop Edge Computation stop Math reset Edge Computation reset Manual sample Edge Manual sample Snapshot Edge Save display image to external media Message input Edge Message writing Waveform span rate change Level Change waveform span rate Display data save Edge Save currently sampled display data to internal memory as a file Event data save Edge Save currently sampled event data to internal memory as a file Relative time timer reset Edge Reset relative time timer Display group change Edge Change to specified display group Time adjustment Edge Adjust internal clock to the nearest hour Flag I Level Normal: "0", Event: "1" Setting file load Edge Load setting file from CF card (up to 3 setting files). All Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation GS 041 -41B01 -01E 1st Edition Nov. 09,2005-00 <<Contents>> <<Index>> Security functions General: Login function or key lock function can be set for each key operation or communication operation. Key lock function: On/off and password can be set for each operation key and FUNC operation. Login function: User name and password to login can be set. User level and number of users: System administrator: 5 users General users: 30 users 10 kinds of login mode can be set for general users. Clock Clock: With calendar function (year of grace) Clock accuracy: 10 ppm, excluding a delay (of 1 second, maximum) caused each time the power is turned on. Time setting method: Key operation, communication command, event action function or SNTP client function Time adjustment method: During memory sample: Adjust 40 ms per second (No influence for measurement period) During memory stop: Adjust at a time Time zone: Time difference from GMT: Settable from -1300 to 1300 Date display format: Selectable from YYYY/MM/DD, MM/DD/ YYYY, DD/MM/YYYY or DD.MM.YYYY DST function (summer/winter time): The time at which the daylight savings time adjustment is automatically calculated and configured. Communication Functions Electrical specifications: Confirms to IEEE802.3 (DIX specification for Ethernet frames) Connection: Ethernet (10BASE-T) Protocols: TCP, UDP, IP, ICMP, ARP, DHCP, HTTP, FTP, SMTP, SNTP, Modbus, DX private E-mail inform function: E-mail is sent by events as below. - Alarm occurring/alarm canceling - Recover from power failure - Memory end - Storage medium error, FTP client function error - Specified time period - Report data time up (only for mathematical option) FTP client function: Data file auto -transfer from DX Transferred data file: Display data file, event data file, report data file and display image file FTP server function: File transfer from DX, file elimination, directory operation and file list output are available by request from host computer. Web server function: Display image of DX and alarm information can be displayed on web browser software SNTP client function: The time on DX can be synchronized to the time of a SNTP server. SNTP server function: The DX can operate as a SNTP server. DHCP client function: Network address configuration can be obtained automatically from DHCP server. Obtained information: IP address, subnet mask, default gateway and DNS information Modbus client function: Reading or writing of measurement data on other instruments are available by Modbus protocol. Mathematical option is required to read the data from other instruments. Modbus server function: Output of measurement data from DX is available by Modbus protocol. Setting/measurement server function: Operation, setting or output of measurement data are available by DX private protocol. Maintenance/test server function: Output connection information or network information of the Ethernet communication. Instrument information server function: Output instrument information such as serial number or model name of DX. Batch function General: Data display and data management with batch name, text field function and batch comment function are available. Batch name: Batch name can be used as file name of display data, event data and report data. Batch name format: Batch number (max. 32 characters) + lot number (max. 8 characters) Use/not use selectable for lot number, on/ off selectable for auto increment function Text field function: Field number: 1 to 8 Field title: Max. 20 characters Field text: Max. 30 characters Batch comment function: Batch comment is added to display data and event data. Batch comment information: 3 comments (max. 50 characters) are available. All Rights Reserved. Copyright 0 2005. Yokogawa Electric Corporation GS 04L411301 -01E 1st Edition Nov. 09,2005-00 «Contents>> <<Index>> Power Supply Rated power supply: 100 to 240 VAC (automatic switching) Allowable power supply voltage range: 90 to 132 or 180 to 264 VAC Rated power supply frequency: 50/60 Hz (automatic switching) Power consumption: Supply voltage LCD off Normal �V�A 100VAC 15 VA 24 VA 45240 VAC 25 VA 32 VA 60 Allowable interruption time: Less than 1 cycle of power supply frequency Other Specifications Memory backup: A built-in lithium battery backs up the setup parameters and latest measurement data in SRAM (battery life: approximately 10 years at room temperature). Insulation resistance: Each terminal to ground terminal: 20 Mfl or greater (at 500 VDC) Dielectric strength: Power supply to ground terminal: 2300 VAC (50/60 Hz), 1 min Contact output terminal to ground terminal: 1600 VAC (50/60 Hz), 1 min Measuring input terminal to ground terminal: 1500 VAC (50/60 Hz), 1 min Between measuring input terminals: 1000 VAC (50/60 Hz), 1 min (except for b - terminal of RTD input of DX1006 and DX1012) Between remote control terminal to ground terminal: 1000 VDC, 1 min Safety and EMC Standards CSA: CSA22.2 No1010.1 Installation category ll`', pollution degree 2`2 UL: UL61010B-1 (CSA NRTUC) CE: EMC directive: EN61326 compliance (Emission: Class A, Immunity: Annex A) EN61000-3-2 compliant EN61000-3-3 compliant EN55011 compliant, Class A Group 1 Low voltage directive: EN61010-1 compliant, measurement category II*3, pollution degree 2`2 C -Tick: AS/NZS CISPR11 compliant, Class A Group 1 *1: Installation Category (Overvoltage Category) II Describes a number which defines a transient overvoltage condition. It implies the regulation for impulse withstand voltage. "Il" applies to electrical equipment which is supplied from fixed installations like distribution boards. *2: Pollution Degree Describes the degree to which a solid, liquid, or gas which deteriorates dielectric strength or surface resistivity is adhering. "2" applies to normal indoor atmosphere. Normally, only non-conductive pollution occurs. *3: Measurement Category II Applies to measuring circuits connected to low voltage installation, and electrical instruments supplied with power from fixed equipment such as electric switchboards. Normal Operating Conditions Power voltage: 90 to 132 or 180 to 250 VAC Power supply frequency: 50 Hz ±2%, 60 Hz ±2% Ambient temperature: 0to50°C Ambient humidity: 20% to 80% RH (at 5 to 40 °C) Vibration: 10 to 60 Hz, 0.2 m/sz or less Shock: Not acceptable Magnetic field: 400 AT/m or less (DC and 50/60 Hz) Noise: Normal mode (50/60 Hz): DCV: The peak value including the signal must be less than 1.2 times the measuring range. TC: The peak value including the signal must be less than 1.2 times the measuring thermal electromotive force. RTD: 50 mV or less Common mode noise voltage (50/60 Hz): 250 Vrms AC or less for all ranges Maximum noise voltage between channels (50/60 Hz): 250 Vrms AC or less Mounting position: Can be inclined up to 30 deg backward. Mounting at an angle away from the perpendicular is not acceptable. Warm-up time: At least 30 min after power on Installation location: In -room Altitude: Less than 2000 m All Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation GS 041 -41B01 -01E 1st Edition Nov. 09,2005-00 «Contents>> «Index» Standard Performance Measuring and Recording Accuracy: The following specifications apply to operation of the recorder under standard operation conditions. Temperature: 23±2°C Humidity: 55%.t 10% RH Power supply voltage: 90 to 132 or 180 to 250 VAC Power supply frequency: 50/60 Hz ± 1% Warm-up time: At least 30 min. Other ambient conditions such as vibration should not adversely affect recorder operation. Input Range Measurement accuracy (digital display) Max. resolution of digital display A/D integration time: 16.7ms or more A/D integration time: 1.67ms fast sampling mode 20 mV ±(0.05% of rdg + 12 digits) ±(0.1 % of rdg + 40 digits) 1 µV DCV 60 mv ±(0.05% of rdg + 3 digits) ±(0.1 % of rdg + 15 digits) 10 gv _200 mV 10 gv 2 V ±(0.05% of rdg + 12 digits) ±(0.1 % of rdg + 40 digits) 100 µv 6 V 1 mV ±(0.05% of rdg + 3 digits) ±(0.1 % of rdg + 15 digits) 1-5 V 1 mV 20 V 1 mV 50V 10 mV R ±(0.15% of rdg + 1 IC) However, ±(0.2% of rdg + 4oC) However, R, S: R, S: ±3.71C at 0 to 100°C ±10oC at 0 to 1001C S ±1.5°C at 100 to 300oC ±5*C at 100 to 300°C B: B: ±21C at 400 to 600oC ±71C at 400 to 600oC B Accuracy at less than 400oC Accuracy at less than is not guaranteed. 4000C is not guaranteed. ±(0.15% of rdg + 0.7oC) ±(0.2% of rdg + 3.5°C) TC (Excluding K However, ±(0.15% of rdg + 1 °C) at However, ±(0.15% of rdg + 6oC) at RJC -200 to -1 001C -200 to -100oC accuracy) 0.1oC E ±(0.15% of rdg + 0.50C) However, ±(0.1596of rdg + 0.7oC) at -200 to -100oC ±(0.2% of rdg + 2.5°C) However, ±(0.2% of rdg + SIC) at -200 to -100oC J T U N ±(0.15% of rdg + 0.7oC) ±(0.3% of rdg + 3.5oC) W ±(0.15% of rdg + 1oC) ±(0.3% of rdg + 71C) ±(0.2% of rdg + 2.50C) ±(0.3% of rdg + 10oC) WRe However, However, ±41C at 0 to 200oC ±1 BIC at 0 to 2001C RTD P 0 ± (0.15% of rdg + 0.WC) ±(0.3% of rdg + 1.5oc) t1 JPtI00 All Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation GS 041-41601-01 E 1 st Edition Nov. 09,2005-00 «Contents» «Index» Measurement accuracy in case of scaling (digits): = measurement accuracy (digits) x scaling span (digits)/measurement span (digits) + 2 digits Decimals are rounded off to the next highest number. Reference junction compensation: INT (intemal)/EXT (external) selectable (common for all channels) Reference junction compensation accuracy: Types R, S, B, W, WRe: ± 1 °C Types K, J, E, T, N, L, U: ± 0.5 °C (Above 0 °C, input terminal temperature is balanced) Maximum allowable input voltage: ± 60 VDC (continuous) for all input ranges Input resistance: Approx. 10 M12 or more for DCV ranges of 200 mVDC or less and TC Approx. 1 MSZ for more than 2 VDC ranges Input source resistance: DCV, TC: 2 kd2 or less RTD: 10 d2 or less per wire (The resis- tance of all three wires must be equal.) Input bias current: 10 nA or less (approx. 100nA for TC range with burnout function) Maximum common mode noise voltage: 250 Vrms AC (50/60 Hz) Maximum noise voltage between channels: 250 Vrms AC (50/60 Hz) Interference between channels: 120 dB (when the input source resistance is 50011 and the inputs to other channels are 60 V) Common mode rejection ratio: A/D integration time 20 ms: More than 120 dB (50 Hz ± 0.1 %, 500 d2 imbalance between the minus terminal and ground) A/D integration time 16.7 ms: More than 120 dB (60 Hz ± 0.1 %, 500 Sb imbalance between the minus terminal and ground) A/D integration time 1.67 ms: More than 80 dB (50/60 Hz ± 0.1%, 500 n imbalance between the minus terminal and ground) Normal mode rejection ratio: A/D integration time 20 ms: More than 40 dB (50 Hz ± 0.1 %) A/D integration time 16.7 ms: More than 40 dB (60 Hz ± 0.1 %) A/D integration time 1.67 ms: 50/60Hz is not rejected. Effects of Operating Conditions Ambient temperature: (Only for 16.7 ms A/D integration time or more) With temperature variation of 10 °C DCV, TC: ± (0.1% of rdg + 0.05% of range) orless Excluding the error of reference junction compensation RTD: ± (0.1 % of rdg + 2 digits) or less Power supply: With variation within 90 to 132 V and 180 to 250 VAC (50/60 Hz): Within measurement accuracy With variation of ± 2 Hz from rated power frequency (at 100 VAC): Within measurement accuracy Magnetic field: AC (50/60 Hz) and DC 400 A/m fields: ± (0.1 % of rdg + 10 digits) or less Input source resistance: (1) DCV range (with variation of +1 kd2) 200 mVDC range or less: ± 10 RV or less 2 VDC range or greater: ± 0.15% of rdg or less (2) TC range (with variation of +1 kfl) ±10µV (3) RTD range (Pt100) With variation of 10 fl per wire (resistance of all three wires must be equal): ± (0.1 % of rdg + 1 digit) or less With maximum difference of 40 mfl between wires: approx. ± 0.1 °C Transport and Storage Conditions The following specifies the environmental conditions required during transportation from shipment to the start of service and during storage as well as during transpor- tation and storage if this instrument is temporarily taken out of service. No malfunction will occur under these conditions without serious damage, which is absolutely impossible to repair; however, calibration may be necessary to recover normal operation performance. Ambient temperature: -25 °C to 60 °C Humidity: 5% to 95% RH (No condensation is allowed.) Vibration: 10 to 60 Hz, 4.9 m/s2 maximum Shock: 392 m/s2 maximum (while being packed) AM Rights Reserved. Copyright© 2005, Yokogawa Electric Corporation GS 04L41B01-01E 1st Edition Nov. 09,2005-00 <<Contents>> <<Index>> SPECIFICATIONS OF OPTIONAL FUNC- TIONS Alarm Output Relays (/A1, /A2, /A3) An alarm signal is output from the rear panel as a relay contact signal. Number or output: Select from 2, 4 and 6 points Relay contact rating: 250 VDC/0.1 A (for resistance load), 250 VAC (50/60 Hz)/3 A Terminal configuration: SPDT (NO -C -NC). Energized -at -alarm/ deenergized-at-alarm, AND/OR, and hold/non-hold actions are selectable. Serial Communication Interface (/C2, /C3) Connection: EIA RS -232 (/C2) or RS -422A/485 (/C3) Protocols: DX private protocol, Modbus(master/slave) protocol Synchronization method: Start -stop asynchronous transmission Connection method (RS -422A/485): 4 -wire half -duplex multi -drop connection (1:N,N=1 to 31) Transmission speed: 1200, 2400, 4800, 9600, 19200 or 38400 bps Data length: 7 or 8 bits Stop bit: 1 bit Parity: Odd, even, or none Communication distance (RS -422A/485): Up to 1.2 km Communication mode: ASCII for input/output for control and setting ASCII or binary for output of measured data Setting/measurement server function: Operation, setting or output of measurement data are available by DX private protocol. Modbus communication: Reading or writing of measurement data on other instruments are available by Modbus protocol. Mathematical function option is needed to read measurement data from other instru- ments. Operation mode: RTU MASTER or RTU SLAVE Modbus master command number: 1to16 Fail/Status Output (/F1) The relay contact output on the rear panel indicates the occurrence of CPU failure or selected status. FAIL output relay: The relay contact output on the rear panel indicates the occurrence of CPU failure. Relay operation: CPU normal: Energized, CPU failure: Deenergized lU Status output relay: The relay contact output on the rear panel indicates the occurrence of selected status Relay operation: Status detection: Energized Status Description Memory status Relay is energized when inrenal memory or external storage media is in the following conditions: Abnormality in the inteernal memory When automatic saving of settings to the external storage media is ON • When the remaining space on the external storage medium reaches 10%. • When an abnormality occurs with the external storage medium, and auto save fails • When the external storage medium is not inserted, operation is same as when automatic saving of settings to the external storage media is Off When automatic saving of settings to the external storage media is Off • When the remaining space on the internal memory reaches 10% • When the number of data file which is not saved to external storage media exceeds 390 'Not including USB memory connected to the instrument Measurement Relay energized upon A!D converter abnormality or Failure burnout detection Comm. failure Relay energized when communication error occurs in the Modbus master Memory stop Relay energized upon memory stop Relay contact rating: 250 VDC/0.1 A (for resistance load), 250 VAC (50/60 Hz)/3A Clamped Input Terminal (/H2) Clamped input terminal (detachable type) is used for input terminal. Available wire size: 0.08 to 1.5 mm2 (AWG28 to16) Desk Top Type (/H5[ ]) Provides carrying handle and power cord. Mathematical Functions (/M1) Used for calculating data, displaying trends and digital values, and recording calculated data assigned to channels. Channel assignable to calculated data: DX1002, DX1004: Up to 12 channels (101 to 112) DX1006, DX1012: Up to 24 channels (101 to 124) Max. character length of expression: 120 characters Operation: General arithmetic operations: Four arithmetic operations, square root, absolute, common logarithm, natural logarithm, exponential, power, relational operations (>, >_, <, <_ =, *), logic operations (AND, OR, NOT, XOR) Statistical operations: TLOG (Average, maximum, minimum, summation and P -P value of time series data) CLOG (Average, maximum, minimum, summation and P -P value of channel series data) All Rights Reserved. Copyright© 2005, Yokogawa Electric Corporation GS O41 -41B01 -01E 1st Edition Nov. 09,2005.00 <<Contents>> «Index>> Special operations: PRE (Previous data) HOLD(a):b (Hold data of "b" in case of "a" is not "0") RESET(a):b (Reset data of "b" and restart in case of "a" is not "0") CARRY(a):b (If "b" exceeds "a", 'b -a" becomes computation results) Conditional operation: [a?b:c] (Execute "b" in case of "a" is not "0", or execute "c" in case of "a" is "0") Constant: Up to 60 constants (K01 to K60) Digital data input via communication: Up to 60 data (C01 to C60) External input: Up to 240 data (201 to 440) (only for external input option) Remote status input: Remote input status (0/1) can be used in mathematical expression Up to 8 inputs (D01 to D08) Pulse input: Up to 8 pulse count input (P01 to P08, Q01 to Q08) (only for pulse input option) Status input: Internal switch status (S01 to S30), relay status (101 to 106) and flag status (F01 to F08) can be used in mathematical expression Cu10, Cu25 RTD Input /3 leg isolated RTD Input (/N1) This option allows Cu10 and Cu25 inputs to be added to the standard input types. A, B, b legs are of isolated input type for DX1006, and DX1012. Input type Measuring range: The following specifications apply to operation of the recorder under standard operation conditions. Temperature: 23±2°C Humidity: 55% t 10% RH 11 Report functions: Number of report channels: DX1002, DX1004: up to 12 channels DX1006, DX1012: up to 24 channels Report type: Hourly, daily, hourly + daily, daily +weekly and daily + monthly Operation: Max. 4 types are selectable from average, maximum, minimum, instantaneous and summation Data format: ASCII Long term rolling average: Computation interval: 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30 sec., 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, 60 min Number of sampling: 1 to 1500 Power supply voltage: 90 to 132 or 180 to 250 VAC Power supply frequency: 50/60 Hz ± 1 % Warm-up time: At least 30 min. Other ambient conditions such as vibration should not adversely affect recorder operation. Input p TY� Measurement range Accuracy guarantee d range Measurement accuracy Max. resoluta on of digital display AID integration time: 16.7 ms or more AID integration time: 1.67ms (Fast sampling mode) Cu10 (GE) -70 to 170°C Cu10 (L&N) -75 to 150°C RTD -200 to ±(0.4% of rdg + 1.0°C) ±(0.8% of rdg + 5.0°C) RTD Cu10 (WEED) -200 to '1 300°C 260°C 0.1°C Cu10 BAILEY Cu10:a =0.00392 at 20°C -200 to 300°C CU10:a =0.00393 at 20°C Cu25:a =0.00425 at 0°C ±(0.3% of rdg + 0.8°C) ±(0.5% of rdg + 2.0°C) '1 Measuring current: i =I mA Input source resistance: 1 fl or less per wire (The resistance of all three wires must be equal.) Ambient temperature: (Only for 16.7 ms A/D integration time or more) With temperature variation of 10 °C ± (0.2% of rdg + 2 digits) or less Input source resistance: With variation of 1 fl per wire (resistance of all three wires must be equal): ± (0.1 % of rdg + 1 digit) or less With maximum difference of 40 ma between wires: approx. ± 1 °C All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 041-41 B01-01 E 1st Edition Nov. 09,2005-00 «Contents>> <<Index>> 3 legs Isolated RTD Input (/N2) A, B, b legs are of isolated input type. * Can be specified only for DX1006 and DX1012. A, B, b legs of DX1002 and DX1004 are isolated as standard. Extended Input Types (/N3) This option allows extra inputs types to be added to the standard input types. Input type Measuring range: The following specifications apply to operation of the recorder under standard operation conditions. 12 Temperature: 23±2°C Humidity: 55% +- 10% RH Power supply voltage: 90 to 132 or 180 to 250 VAC Power supply frequency: 50/60 Hz ± I% Warm-up time: At least 30 min. Other ambient conditions such as vibration should not adversely affect recorder operation. 1 Measuring current: i = 1 mA Input source resistance: TC: 2 kfl or less RTD: 1 f2 or less per wire (The resistance of all three wires must be equal.) Ambient temperature: (Only for 16.7 ms A/D integration time or more) With temperature variation of 10 °C TC: ± (0.1 % of rdg + 0.05% of range) or less Excluding the error of reference junction compensation. RTD: ± (0.2% of rdg + 2 digits) or less Input source resistance: (1) TC range (with variation of+ 1 kfb) ±10 µV (2) RTD range With variation of 1 fl per wire (resistance of all three wires must be equal): :t (0.1 % of rdg + 1 digit) or less With maximum difference of 100 mn between wires: approx. ± 1 OC Remote Control (/R1) This option allows eight functions to be controlled remotely by a contact input. Please refer the part of "Event action function" for functions to be controlled. 24 VDC transmitter power supply (/TPS2, /TPS4) Output voltage: 22.8 to 25.2 VDC (rated load current) Rated output current: 4 to 20 mADC Max. output current: 25 mADC (current to guard operation against overcurrent: approx. 68 mADC) Allowable conductor resistance: RL s (17.8 - transmitter minimum operation voltage)/0.02 A (not include drop voltage with load shunt resistance) Max. length of wiring: 2 km (CEV cable) Insulation resistance: output terminal to grand terminal more than 20 Mft (500 VDC) Dielectric strength: output terminal to grand terminal: 500 VAC (50/60 Hz, I = 10 mA), 1 min Between output terminal: 500 VAC (50/60 Hz, I = 10 mA), 1 min Easy text entry (/KB1, /KB2) Normal operating conditions: Ambient temperature for usage: 0 to 40 °C All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 041-411301-01E 1st Edition Nov. 09,2005-00 Measurement accuracy Max. resoluta Input Type Mearangent on of digital AID integration time: AID integration time: 16.7 ms or more 1.67ms (Fast sampling mode) display Kp vs Au7Fe 0.0 to 300.OK Within ±4.5K at 0 to 20K Within ±13.5K at 0 to 20K 0.1 K Within ±2.5K at 20 to 300K Within ±7.5K at 20 to 300K PLATINEL 0.0 to 1400.0°C t(0.25% of rdg+2.3°C) ±(0.25% of rdg+8.0°C) Accuracy is not guaranteed Accuracy is not guaranteed at 0 to 450°C at 0 to 450°C ±(0.9% of rdg+3.2°C) at ±(0.9% of rdg+15.0°C) at 450 to 750°C 450 to 750°C PR40-20 0.0 to 1900.0°C ±(0.9% of rdg+1.3°C) at ±(0.9% of rdg+6.0°C) at TC 750 to 1100°C 750 to 1100°C ±(0.9% of rdg+0.4°C) at ±(0.9% of rdg+3.0°C) at 1100 to 1900°C 1100 to 1900°C 0.11C NiNiMo 0.0 to 1310.0°C ±(0.25% of rd +0.7°C) ±(0.5% of rd +3.5°C ±15.0°C at 0 to 400°C ±30.0°C at 0 to 400°C W/WRe 0.0 to 2400.0°C ±(0.2%of rdg+2.0°C) at 400 ±(0.4%of rdg+4.0°C) at 400 to 2400°C to 2400°C TypeN(AWG14) 0.0 to 1300.0°C ±(0.2% of rdg+1.3°C) ±(0.5% of rdg+7.0°C) Pt50 -200.0 to 550.0°C ±(0.3% of rd +0.6°C ±(0.6% of rd+3.0°C Ni100 SAMA -200.0 to 250.0°C ±(O. 15% of rd +0.4°C ±(0.3% of rd +2.0°C Ni100 DIN -60.0 to 180.0°C ±(O. 15% of rd +0.4°C ± 0.3%of rd +2.0°C Ni120 -70.0 to 200.0°C ±(O. 15% of rd +0.4°C ±(0.3% of rd +2.0°C RTD 1 J263*B 0.0 to 300.0 K Within ±3.OK at 0 to 40K Within ±9.OK at 0 to 40K 0.1 K Within ±1.0K at 40 to 300K Within ±3.OK at 40 to 300K Cu53 50.0 to 150.0°C 0.15% of rd +0.8°C ± 0.3% of rd +4.0°C Cu100 50.0 to 150.0°C ± 0.2% of rd +1.0°C 0.4% of rd +5.0°CL 0.1 °C Pt25 -200.0 to 550.0°C 1±(0.15% of rd +0.6°C 0.3% of rd +3.0°C 1 Measuring current: i = 1 mA Input source resistance: TC: 2 kfl or less RTD: 1 f2 or less per wire (The resistance of all three wires must be equal.) Ambient temperature: (Only for 16.7 ms A/D integration time or more) With temperature variation of 10 °C TC: ± (0.1 % of rdg + 0.05% of range) or less Excluding the error of reference junction compensation. RTD: ± (0.2% of rdg + 2 digits) or less Input source resistance: (1) TC range (with variation of+ 1 kfb) ±10 µV (2) RTD range With variation of 1 fl per wire (resistance of all three wires must be equal): :t (0.1 % of rdg + 1 digit) or less With maximum difference of 100 mn between wires: approx. ± 1 OC Remote Control (/R1) This option allows eight functions to be controlled remotely by a contact input. Please refer the part of "Event action function" for functions to be controlled. 24 VDC transmitter power supply (/TPS2, /TPS4) Output voltage: 22.8 to 25.2 VDC (rated load current) Rated output current: 4 to 20 mADC Max. output current: 25 mADC (current to guard operation against overcurrent: approx. 68 mADC) Allowable conductor resistance: RL s (17.8 - transmitter minimum operation voltage)/0.02 A (not include drop voltage with load shunt resistance) Max. length of wiring: 2 km (CEV cable) Insulation resistance: output terminal to grand terminal more than 20 Mft (500 VDC) Dielectric strength: output terminal to grand terminal: 500 VAC (50/60 Hz, I = 10 mA), 1 min Between output terminal: 500 VAC (50/60 Hz, I = 10 mA), 1 min Easy text entry (/KB1, /KB2) Normal operating conditions: Ambient temperature for usage: 0 to 40 °C All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 041-411301-01E 1st Edition Nov. 09,2005-00 «Contents» <<Index>> 13 Ambient humidity for usage: 20 to 80% RH (When to 40 °C, no condensation) Ambient temperature for storage: -10 to 60 'C Power supply: AA dry battery x 2 Weight: Approx. 60 g (excluding dry battery) Dimensions: 170 (W) x 50 (H) x 23.7 (D) mm Number of units that can be controlled: Max. 32 units by ID setting Communication distance: Max. 8 m (depending on battery strength and usage area) Orientation specifications: Depends on battery strength & usage area USB interface (/USB1) USB interface specification: Based on Rev1.1, host function Number of ports: 2 ports (Front and rear panel) Power supply: 5V, 500mA (for each port)*1 Available USB devices: Keyboard: 104/89 keyboard (US) based on USB HID Class Ver. 1.1 External medium: USB flash drive (some of USB flash drives may not be supported by DXAdvanced) *1: For low powered devices (bus power < 100 mA): 5V:t: 5% For high powered devices (bus power < 500 mA): 5V ± 10% Devices which need more than 500 mA total bus power for 2 ports can not be connected at the same time. Pulse input (/PM1) Pulse input option includes mathematical functions option (/M1) and remote control option (/R1). Number of inputs: 3 points (8 points are available in case of using remote inputs) Input format: Photocoupler isolation (shared common) Isolated power supply for input terminal (approx. 5 V) Input type: Non -voltage contact: Close: 200 dZ or less, Open: 100 kfl or more Open collector: ON: 0.5 V or less (30 mADC), Leakage current of OFF: 0.25 mA or less Counting: Counts rising edges of pulses Allowable input voltage: 30 VDC Max. sampling pulse period: Max. 100 Hz Minimum pulse length: 5 ms Pulse detection period: Approx. 3.9 ms (256Hz) Pulse measuring accuracy: ±1 pulse (for instantaneous mode) Pulse count period: Counts the number of pulse per measure- ment period (P01 to P08) or per second (Q01 to Q08). Calibration correction function (/CC1) Corrects the measurement value of each channel using segment linearizer approximation. Number of segment points - 2 to 16 APPLICATION SOFTWARE DAQSTANDARD for DXAdvanced Operating environment OS: Microsoft Windows 2000/XP Processor: Pentium 11 333 MHz or higher (Pentium III 600 MHz or higher recommended) Memory: Free area of 32 MB or more (128 MB or more recommended) Disk device: CD-ROM drive that is applied to Windows 2000/XP Hard disk: Free area of at least 100 MB Display card: Compatible with Windows 2000/XP Can display 32,000 colors or higher (64,000 colors or higher recommended) Printer: A printer and printer driver compatible with Windows 2000/XP Basic function (packages) Configuration software: External memory medium: configuration of setting and basic setting mode Configuration via communication: configuration of setting and basic setting mode without communication configuration (ex. IP address) Data viewer software: Numbers of display channels: 32 channels for each group, at most 50 groups Display function: Waveform display, digital display, circular display, list display, report display etc. File connection display: Connect data files that are divided because of auto -save during continuous data collecting or power failure, and then display (can connect up to total 5 million) Section computation: Maximum, minimum, average, effective and P -P value Data conversion: Print out: File conversion to ASCII, Lotus 1-2-3 or MS -Excel format Print out displayed data All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 041 -41B01 -01E 1st Edition Nov. 09,2005-00 «Contents>> <<Index>> MODEL AND SUFFIX CODES Model code Suffix code Optional code Description DX1002 2ch, 125ms (Fast sampling mode: 25ms DX1004 4ch, 125ms Fast sampling mode: 25ms DX1006 6ch, 1s Fast sampling mode:125ms DX1012 12ch, 1s Fast sampling mode: 125ms Internal memory —1 Standard memory (80MB —2 Large memory (200MB) External media T-4 CF card (with media) Display language —2 English, degF, DST(summedwinter time) Options /A1 Alarm output 2 points *1 /A2 Alarm output 4 points *1 /A3 Alarm output 6 points *1 *2 /C2 RS -232 interface *3 /C3 RS-422AI485 interface *3 /F1 FAIUStatus output *2 /1-12 Clamped input terminal (detachable) /H5[] Desktop type *4 /M1 Mathematical functions /N1 Cu10,Cu25 RTD input/3 leg isolated RTD /N2 3 leg isolated RTD *5 /N3 Extended input type (PR40-20, Pt50, etc.) /R1 Remote control /TPS2 24VDC transmitter power supply (2 loops) *6 /TPS4 24VDC transmitter power supply (4 loops) *7 /KB1 Easy text entry (with input terminal) *8 *9 1KB2 Easy text entry (without input terminal) *8 /USBt I USB interface /PM1 I Pulse input (including remote control and mathematical functions) *10 /CC1 I Calibration correction function *1 /A1, /A2, /A3 cannot be specked together. *2 /A3 and /F1 cannot be specified together. *3 /C2 and /C3 cannot be specified together. *4/H5[ ] D: Power cord UL, CSA st'd F: Power cord VDE st'd R: Power cord SAA st'd J: Power cord BS st'd H: Power cord GB std *5 /N2 can be specified for only DX1006 and DX1012. *6 In case that /TPS2 is specked, /iPS4, /A2, /A3 or /F1 cannot be specified together. *7 In case that /TPS4 is specified, /TPS2, /A1, /A2, /A3 or /F1 cannot be specked together. *8 /KB1 and /KB2 cannot be specified together. *9 In case that /KB1 is specified, remote input terminal (438227) is included. *10 In case that /PM1 is specified, /A3, /M1, /R1, /TPS2 or /TPS4 cannot be specked. And combination of /A2/F1 cannot be specified together. Application Software Model code I Description CIS DXA120 I DAQSTANDARD for DXAdvanced Windows 2000/XP 14 All Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation GS 041 -41B011 -01E 1st Edition Nov. 09,2005-00 <<Contents» <<Index>> STANDARD ACCESSORIES Product oty Mounting brackets 2 Terminal screws 5 Door lock key 2 Operation guide 1 Instruction manual (CD-ROM) 1 DAOSTANDARD software (CD-ROM) 1 CF card (32MB) 1 Power cable '1 1 `1 For /H5(] option For/ KB1 option Product Qty Remote control terminal (438227) 1 AA alkali dry battery 2 Labels for remote control terminal 2 OPTIONAL ACCESSORIES Product Model code (part number) Specification Shunt resister (for screw input terminal) 415920 250 Q±0.1 % 415921 100 SZt0.1% 415922 10 Q±0.1% Shunt resister (for clamped input terminal) 438920 250 n±0.1% 438921 100 Q40.1% 438922 10 00.1 % CF card adapter 772090 CF card 772091 128MB 772092 256MB 772093 512MB 772094 11GB Mounting bracket r B9900BX — Door lock key B8706FX I — Remote control terminal 438227 1 For /KB1, /KB2 option 15 All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 04L.4111301 -01E list Edition Nov. 09,2005-00 «Contents>> <<Index» 16 DIMENSIONS Dimentions Unit: mm (approx.inch) M N Option Terminal t4.Ur) Tarminal Arrangement Power Supply Terminal Input Terminal 1-12ch MAX 228.5 (9.0) (/H2 or /PM1) I 224.1(8.82) I) 170.5 (6.71) (min. space for v of Note: If not specified, the tolerance is ±3%. However, for dimentions less than 10mm, the tolerance is ±0.3mm. a M O after All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS O4L41B01-01E 1st Edition Nov. 09,2005-00 <<Contents>> <<Index>> Panel cutout Single -unit Mounting Side-by-side Mounting (horizontally) 137"o Ern U� :� rn M M t(j r r0 L Units L +0 (mm) 2 282 3 426 4 570 5 1 714 6 858 7 1002 8 1146 9 1290 10 1434 n (144 x n) — 6 17 Unit: mm (approx.inch) Side-by-side Mounting (vertically, max. 3 units) 175 min (6.89) 1370 (5.39) Note: If not specified, the tolerance is ±3%. However, for dimensions less than 10 mm, the tolerance is ±0.3 mm. +3 J All Rights Reserved. Copyright© 2005, Yokogawa Electric Corporation GS 041-41 B01-01 E 1st Edition Nov. 09,2005-00 <<Contents>> «Index>> Dimentions 138.8 (5.46) 144.14 Unit: mm (approx.inch) Tarminal Arrangement USB (/USB1) RS -422A/485 (/C3) fYA o 0 0 Ethernet Power Supply Terminal FRS -232 (/C2) MAX 252.5 (9.94)(/H2 or /PM1) If not specified, the tolerance is ±3%. However, for dimentions less than 10mm, the tolerance is ±0.3mm. All Rights Reserved. Copyright 0 2005, Yokogawa Electric Corporation GS 041-411301-01E 1st Edition Nov. 09,2005-00 «Contents>> <<Index» Power Supply Terminal RS -422-A/485 Terminal QOQQOQ Input Terminals Screw Terminals •...O...M �,.. �....O■.E �, •. ■OMM■MM■M M�� MOMMEME M M E■E MOOMM■M M E MEMI ONOMMOMMEMEM CH6 CH4 CH2 CH5 CH3 CH1 M 0 • 19 RS -232 Terminal 12345 1 N.C. 6789 2 RD 3 SD O aooa .a.� W 5 SG 6 N.C. 7 RS 8 C5 9 N.C. Clamped Terminals (/H2) ..o CH H1 i� • ►■511 t 11 lel �I�� �■�'� /b o o � CH5 CH3 CH1 1b +/A a s +/A -/B • -/B CH6 CH4 CH2 /b o o CH11 CH9 CH7 CH5 CH3 CH1 /b +/A • +/A -/B[------/B CH12 CH10 CH8 CH6 CH4 CH2 All Rights Reserved. Copyright 0 2005. Yokogawa Electric Corporation GS 041-411301-01E 1st Edition Nov. 09,2005-00 <<Contents>> <<Index>> Option Terminals /A1/F1/PM1 Combination NC C NO Mosomommma � 1 1 _o w� CO 0 J T Q o. 0 LL MOMMOMMOMB E > LL 1 O E>, 0 UFT (/F1) a� (/A2) MEBMEMMMMM (/R1) /A1/R1/TPS2 C 2 Combination ©MMEM®MmOO � 1 1 _o w� CO 0 J T Q o. 0 LL O E > LL 1 O E>, 0 UFT (/F1) a� (/A2) (/A1) /A1/R1/TPS2 C 2 Combination ©MMEM®MmOO 3 2 a o w O CO 0 E T o U N Q� E 00000©ODOO (/R1) LL 1 O E>, 0 UFT a � (/A2) ...O.m.mOO (/R1) � Y � N E C T O Q F N U N � 3 N d (/TPS2) 2 1 3 2 a o w O CO 0 E T o U N Q� E (/AS) (/R1) /A2/F1/R1 Combination NC 0 .mm■mm.00© 3 2 1 o w �—� o >1 75 2 J Ea 0©HE©©0000 LL 1 O E>, 0 UFT a � (/A2) MEEMEEMEMB (/R1) a 4 3 2 1 o w �—� o >1 75 2 J Ea LL 1 O E>, 0 UFT a � (/A2) (/R1) /A3/R1 Combination NN C NOEssonsoman ■m®o®m■®MOMMEMEMBE v© 6 5 4 3 2 a 75O E> b 0 Q9 (/A3) C 1 2 1 The TCP/IP software used in this product and the document for that TCP/IP software are based in part on BSD networking software, Release 1 licensed from The Regents of the University of California. • DAQSTATION is a registered trademark of Yokogawa Electric Corporation. • Microsoft, MS and Windows are registered trademarks of Microsoft Corporation USA. • Lotus and 1-2-3 are registered trademark of Lotus Development Corporation. • Pentium are registered trademarks of Intel Corporation. • Ethernet is a registered trademark of XEROX Corporation. • Modbus is a registered trademark of AEG Schneider. • Other company and/or product names are registered trade mark of their manufactures. O 0 U N E (/R1) 20 All Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation GS 041-411301-01E 1st Edition Nov. 09,2005-00 Subject to change without notice The 418XA has a cast iron lid and rim, replaceable Buna-N gasket, galvanized sheet metal skirt and stainless steel bolts. Lugs on the inside of the body rim are threaded for bolts to draw lid down tight. Bolted cover provides weathertight seal and "limited access" feature. The 418XAH has a 14 -gauge heavy skirt WELL PIPE u CAP and nylon washers, available in 9"x7" and 9"x12" sizes. Meets H-20 Load Requirements. Each manhole is individually boxed. I.D. NUMBER A B C D E F BOLT HEIGHT WIDTH WEIGHT 418XA-0500 AM 7" x 10" CI GS Buna SS N 5/16" 10" 6.75" 8 418XA-0850 AM 8" x 8' CI GS Buna SS N 3/8" 8.125" 9" 13.5 418XA-0900 AM 8" x 12" CI GS Buna IS N 3/8" 13" 9" 15 418XA-0100 AM 9" x T' CI GS Buna SS N 1/2" 7.0625" 9" 17 418XA-0200 AM 12" x 7" CI GS Buna SS N 1/2" 7" 12" 20 41BXA-0300 AM 2" CI GS Buna SS N 1/2" 13.0625" 9" 27 418XA-0400 AM 12" CI GS Buna SS N 1/2" 13" 13.25" 30 418XA-1000 AM 12" CI GS Buna SS N 1/2" 13.25" 18.75" 75 418XA-1100 AM 18' CI GS Buna SS N 1/2" 19.25" 18.75" 78 418XAH0300 AM 2" CI 14G Buna SS N 1/2" 13.0625" 10.25" 22 418XAP0500 AM 0" dxl CI GS Buna SS Y 5/16" 10"6.75" 8 418XAP0850 AM 8' CI GS Buna SS Y 3/8" 8.125" 9" 13.5 418XAP0900 AM 2" CI GS Buna SS Y 3/8" 13" 9"17 41BXAP0300 AM 2" CI GS Buna SS Y 1/2" 13.0625" 9"20 418XAP0200 AM 7" CI GS Buna SS Y 1/2" 7" 12" 27 418XAP0400 AM 12" CI GS Buna SS Y 1/2" 13" 13.25" 29 418XAP1200 AM 18" x 12" CI GS Buna SS Y 1/2" 13.25" 18.75" 75 418XAP1300 AM 18" x 18' U-17TS-1 Buna I SS Y 1/2" 1 19.25" 1 18.75" 1 86 418XAS0400 AM 12" x 12" ST I GS I Buna I SS N 1/2" 1 13" 1 13.25" 1 27 OALVAN¢ED STEEL SKIRT CHART KEY: A—Size B—Cover Material: Cl (Cast Iron); ST (Steel) C—Skirt Material: GS (Galvanized Sheet Metal); 14G (14 -Gauge) D—Gasket Material: Buna E—Bolt Material: SS (Stainless Steel) F—Painted Cover: Y (Yes) or N (No) Bolt—Bolt Size Height Width Weight—Shipping Weight P.O. Box 238 • Dubuque, Iowa 52004-0238 UMorrison BCo. 563.583.5701 (tel) • 800.553.4840.563.583.5028 (fax) Established 1855 www . m o r b r o s. c o m Morrison Steel Manholes Highway Specification Standards Description Manholes: 1. Figure 318, 318TM, 318XA and 318VR Series (9",12", 18", and 24" sizes) 2. Figure 418, 418TM, 418 XA , 418XAH, 418XAP, 418XAS and 418XAW Series (7, 899, 9",12", 18" and 24" sizes) 3. Figure 524 Series (20" and 24" sizes) 4. Figure 519 Series (9" and 12" sizes) The above listed manholes have been tested by an official testing laboratory and results confirm their use and performance to meet the following: 1. Federal SpecificationAA60005 2. ASTM A48 3. AASHTO standard for "H-20" truck loadings .v LAMorrison Bros., CO. P.O. Box 238 • Dubuque, Iowa 52004-0238 563.583.5701 (tel) • 800.553.4840 563.583.5028 (fax) �tht�leslr�a"I 1�i :": o . b r .^. 3 L. J Flow tested design provides quick response with positive seal for prevention of system back flow in industrial and chemical processing applications. Valves are available in IPS sizes 1/2" through 6" with socket/regularthread, SR threaded (Special Reinforced), flanged or spigot end connectors and 8" venturied valve with socket or flanged ends.. Also available in metric socket and BSP thread sizes 1/2" through 2". All thermoplastic check valves shall be True Union 2000 Industrial Ball Check type manufactured to ASTM F 1970 and constructed from PVC Type I, ASTM D 1784, Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell Classification 23447. All 0 -rings shall be EPDM or Viton�z". All valve union nuts shall have Buttress threads. All valve seats shall be a standard O-ring type. All seal carriers shall be Safe -T -Blocked All valve components shall be replaceable. All valves shall be listed by NSF for use in potable water service. All valves shall be certified by NSF International for use in potable water service. All PVC and CPVC 1/2" through 2" valves shall be pressure rated to 235 psi; all 2-1/2" through 6", 8" Venturied and all flanged valves shall be pressure rated to 150 psi for water at 73F as manufactured by Spears`!" Manufacturing Company. Quick -View Valve Selection Chari Valve 0 -ring PVC Part Numberl Pressure Size Material Socket Threaded SR Threaded Flanged Spigot Rating 1/2 EPDM 4529-005 included 4521-005SR 4523-005 4527-005 Viton® 4539-005 included 4531-005SR 4533-005 4537-005 3/4 EPDM 4529-007 included 4521-007SR 4523-007 4527-007 235 psi Viton@ 4539-007 included 4531-007SR 4533-007 14537-007 Non -Shock 1 EPDM 4529-010 included 4521-010SR 4523-010 4527-010 Nater Viton® 4539-010 included 4531-010SR 4533-010 4537-010 1-1/4 EPDM 4529-012 included 4521-012SR 4523-012 4527-012 (Flanged Vton® 4539-012 included 4531-012SR 4533-012 4537-012 150 psi 1-1/2 EPDM 4529-015 included 4521-015SR 4523-015 4527-015 Non-Shock) Water Uton® 4539-015 included 4531-015SR 4533-015 4537-015 @ 73-F 2 EPDM 4529-020 included 4521-020SR 4523-020 4527-020 Viton@ 4539-020 included 4531-020SR 4533-020 4537-020 2-1(2 EPDM 4522-025 4521-025 4521-025SR 4523-025 4527-025 Uton' 4532-025 4531-025 4531-025SR 4533-025 4537-025 EPDM 4522-030 4521-030 4521-030SR 4523-030 4527-030 3 Viton@ 4532-030 4531-030 4531-030SR 4533-030 4537-030 4 EPDM 4522-040 4521-040 4521-040SR 4523-040 4527-040 150 psi VtonO 4532-040 4531-040 4531-040SR 4533-040 4537-040 NOShock "later EPDM 4522-060 4521-060 4521-060SR 4523-060 4527-060 @ 73-F 6 Viton' 4532-060 4531-060 4531-060SR 4533-060 4537-060 82 EPDM 4522-080 — — 4523-080 — VitonO 4532-080 — — 4531080 — 1: For CPVC valve, add the letter "C' to the part number (e.g., 4529-005C, 4521-005CSR) 2: 8" Venturied Valves are o" ball valves fitted with 6x8 end connector adapters 20 • Chemical & Corrosion Resistant PVC or CPVC Construction • Also Available in Spears"' LXTTm High Purity,Low Extractable PVC Material • Strong, Buttress Thread Union Nuts • Spears` Safe -T -Blocked Seal Carrier • Uses Standard 0 -ring Seat • EPDM or Vitona.0-rings Fully Serviceable, Replaceable Components • Sizes 1/2" - 2" Pressure Rated to 235 psi @ 73°F, Sizes 2-1/2" - 6", 8" Venturied and all Flanged Pressure Rated to 150 psi @ 73°F • Suitable for Either Horizontal or Vertical Installations • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Manufactured to ASTM F 1970 Optional Accessories* • Retro -Fit End Connector Sets for Valve Replacement • Split -Nut Repair Kits for Union Nut Replacement •, Supplemental End. Connectors See `BALL VALVE ACCESSORIES" section for details of individual products. Ball Check Foot Valves z Spear89 Ball Check Valves easily convert to foot valves utilizing optional Foot Valve Screen adapters found in Ball Valve Accessories section. TRUE UNION 2000 INDUSTRIAL BALL CHECK VALVES, J Dimensions,Weights,&,Cv Values • r r F No. Component Qty. Material 1 Seal Carrier 1 PVC/CPVC 2 Seal Carrier Nut 1 PVC/CPVC 3 Carrier O-ring 1 EPDMNiton"" 4 Seat Plate 1 PVC/CPVC 5 Seat O-ring 1 EPDMNitonG 6 Body 1 PVC/'CPVC 7 Ball 1 PVC/CPVC 8 Union Nut 2 PVC/CPVC 9 End Connector O-ring 2 EPDMNitonO 10 1 End Connector 2 1 PVC/CPVC Nominal 100110 Dimensions Reference Inches, t 11%) 130 140 Approx. Wt (Lbs.) 160 Cv2 Values 180 Horizontal Closing Size A B1 SociThd Spigot Socket C Thread Spigot F G PVC CPVC Soc/Thd Flange Spigot Feet of Head (water) GPM (minimum) 1/2 1-7/8 2-7./16 2-7,8 4-3/16 3.13116 4-518 3-112 2-31/32 .30 .33 6.3 6 6.3 1.6 .10 314 2-1/4 2-34 3-1/4 4-314 4-114 5.1!4 3-7!8 3-5/16 .46 .50 17 16 17 1.6 .10 1 2-1/2 2-718 3-112 5-118 4-11/16 5-3/4 4-1A 3-5/8 .70 I .74 25 24 25 1.6 .25 1-114 1 3-116 3-1A 3-3;16 1 5-314 53116 6-5116 4-5/8 331/32 1.04 1.09 65 61 65 1.6 .40 1-1/2 3.1/2 3-1/2 4 6-114 5-7116 63,4 5 4-38 1.37 1.45 86 82 86 1.6 .75 2 4-1A 4-3/4 5-316 7-314 63/4 8-1,4 6 5.1A 2.47 2.62 130 125 130 1.6 .75 2-112 63116 5-7/8 7-13116 9-5/16 8-1/2 11-38 7-112 1 6 6.80 7.25 200 193 200 1.0 1,50 3 6-3/16 6-7/8 7-13116 10-11/16 9-314 11-9/16 7-112 613/16 6.98 7.35 275 268 275 1.0 4.00 4 7-112 7-1/4 8-1/4 11-13116 10-1/4 12-314 9 7-112 12.13 12.96 500 489 500 1.0 5.50 6 11-518 11-1/6 13 17-1/16 15-3./4 18.1/2 11-114 10-3116 37.07 39.98 800 794 800 N/A N/A 83 11-518 23-3/16 --- 31-7/8 -- --- 13-1/2 17-13116 50.84 55.92 N/A N/A N/A N/A N/A 1: Valve Lay Length 2: Gallons per minute at 1 psi pressure drop. Valves calculated from laying length; based on derivative of Hazen `vvilliams equation with surface roughness factor of C=150. 3: 8" Ventu(ed Valves are 6" ball valves fitted with 6x8 end connector adapters System Operating 100110 120 130 140 150 160 170 180 190 200 210 Temperature °F (°C) {38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) PVC 235 211 150 75 50 -0- -0- -0- -0- -0- -0- -0- (1.62) (1.45) (1.03) (52) (.34) (-0-) (-0-) (-07) (-0-) (-0-) (-0-) (-0-) Valve 112"- 2" CPVC 235 219 170 145 130 110 90 80 70 60 50 -0- Pressure (162) (1.51) (1.17) (1.00) (90) (.76) (.62) (.55) (48) (.41) (.34) (-0-) Rating psi PVC 150 135 110 75 50 0- -0- -0- -0- -0- -0- -0- (M") 2-1/2"- 8" (1.03) (.93) (.76) (.52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) CPVC 150 140 130 120110 100 90 80 70 60 50 -0- (1.03) (.97) (.90) (.83) {.76) (.70) (.62) (.55) (.48) (.41) (.34) (-0-) NOTE:. Flanged valves have a base pressure rating of 150 psi General Installation Information: Ball check valves may be installed in either horizontal or vertical position. A minimum of ten (10) pipe diameters distance maintained from any pump or other source of turbulence. Check valves MUST be installed with the valves FLOW avow pointing in the direction of flow. 21 Standard Features (Sizes 1-1/2" - 14") • Standard model (1-1/2" - 14") has PVC Body and PP Disc for superior chemical resistance and elevated temperature capabilities • 316/403 stainless steel shaft has full engagement over the entire length of the disc and is a non -wetted part. • Only solid and abrasion -resistant plastic disc and elastomeric liner are wetted parts. • ISO bolt circle on top flange -no body or stem modifications required for accessories. • Stem retainer -PP retainer to prevent stem removal. • Seat over tightening protection -Molded body stops and seat stress relief area. • Sperical disc design offers increased Cv, ultimate sealing and high cycle life. Options • Pneumatically and electrically actuated with accessories • Alternate discs: (1) PVC : 1-1/2" - 14"" [III) PVDF : 1-1/2" - 14" PlasgearTM gear operators for 1-1/2"- 6" • Lug style (Stainless Steel 304 or 316) for blocking and end -of -line applications • Stems in 316 stainless steel, titanium, Hastelloy G". • 2" square nut on stem • 2" square nut on gear operator Stem extensions (Single stem and two-piece stem) • Locking devices (Gear Type - Standard on Lever) • Chain operators • Manual limit switch • Tandem arrangements (Patented by A/A, Inc.) ASAHI/AMERICA Rev. D 06-06 Dimensions (Lever: Sizes 1-1/2" - 8") Cv Values 77 NOMINAL NOMINAL Glu SIZE ANSI CLASS _.. - 150 SIZE (at uanot,�s �p �Fl aegeees ); ....... . .,.. :. NCHes mm d C n h D D1 L H H1 H2 H3 A INCHES mm 30 60 90 1 "O P 7�3 88 4 0 62 5.91 2 83 1 54 614 ; 2 95 3 94 2 20 1 8.66 1 ill 40 4 43 711 �. ......... . 2 50 2.20 4.75. 4 0.75 ` 6.50 3.23 1.65 6.54 3.25 4.33 1 2.20 8.66 i 2 50 7 73 120 2 11215 72 547 4 0 75 7 28 3 78 E 1 81 6 93 .8 64 4 72 1 2.20' 8.66 2 112 65 15 153 X25{} ...: ..: .= -. .� :_.. .._ } 3 80 3.03 6.00 4 0.75 -' 8.31 4.17 1.81 -' 7.52 4.15 5.31 2.20 1 9,84: 3 80 18 183 300 c ¢4�10q 4 027�0 8: 1 017;6 9.37 5 31 = 2.20 ; , 811 ; 4 69 5 91 x.20 £ ,9.84 4 100 28 87� 40 or 5 ° 125. 5.08 8.50: 8 0.88 10.39: 6.69 2.60 9.33 5.20 6.61 2.72 12,60 5' 125 49 506 830 L. 8 200 7.68 11.75 8 0 88 13 39 9 53 3.43 11.14 8.43 2.72 1.._...-.--.--.--_._..._.__.__......___.___.._.____...__......____.._.._...._.. Pressure vs. Temperature (PSI, WATER, NON -SHOCK)* Wt, { 2 50 150 70 30 ;150 100 150 100 85' 75 2 50 . 4 'Vacuum Service 1 y. i y NOMINAL r UAp"yoM , SR ;:`:€7U�1F_ SIZE SERVICE•„ * For lug style data consult factory 35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618 • 781-321-5409 • Fax: 800-426-7058 • E-mail: asahi@asahi-america.com Register at our interactive web Site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.coYii Dimensions (Sizes 1-1 /211- 1411) (NOTE: GEAR OPERATED VALVE IS STANDARD 8" - 14"; SIZES 1-1/2 " - 6° ARE OPTIONS.) ASAHI/AMERICA Rev, u 0e-06 Standard Features • Pressure rated at 150 psi at 120° F (water) • Precise fingertip control • Calibrated flow indicator • Rugged unibody construction, sturdy stem • Full vacuum rated, 29.9° Hg = 90° turn operation with lever handle Cv = 1.6 s Optional FKM seats and stem O-ring All LABCOCK�' valves shall be of compact, unibody construction having a lever handle, calibrated flow indicator and male threads, female threads, hose ends or elbow as part of the valves' integral construction. Valves shall be constructed of PVC conforming to ASTM D1784 Cell Classification 12454- A. All wrings shall be EPDM or FKM. LABCOCK valves are rated to 150 psi at 70° F, as manufactured by Asahi/America, Inc. Parts List (Size 1/4") 35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618 • 781-321-5409 • Fax: 800-426-7058 • E-mail: asahi@asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com Product Specifications ILARYEE CPVC Industrial Pipe: Schedule 40 & 80 Application: Corrosion resistant pressure pipe, IPS sizes 1/8" through 24", for use at temperatures up to and including 200°E Pressure rating (130 psi to 1130 psi) varies with schedule, pipe size, and temperature as shown on page 2 of this specification, and as stated in Harvel Plastics, Inc. engineering bulletin (Product Bulletin 112/401). Generally resistant to most acids, bases, salts, aliphatic solutions, oxidants, and halogens. Chemical resistance data is available and should be referenced for proper material selection. Pipe exhibits excellent flammability characteristics (ULC Listed for Surface Burning Characteristics) and other physical properties. Typical applications include: chemical processing, plating, high purity applications, hot and cold potable water systems, water and wastewater treatment, and other industrial applications involving hot corrosive fluid transfer. Scope: This specification outlines minimum manufacturing requirements for Chlorinated Polyvinyl Chloride (CPVC) schedule 40 and 80 iron pipe size (IPS) pressure pipe. This pipe is intended for use in industrial systems where the fluid conveyed does not exceed 2007 F This pipe meets and or exceeds the industry standards and requirements as set forth by the American Society for `I;sting and Materials (ASTM) and the National Sanitation Foundation (NSF). CPVC Materials: The material used in the manufacture of the pipe shall be a rigid chlorinated polyvinyl chloride (CPVC) compound, Type IV Grade I, with a Cell Classification of 23447 as defined in ASTM D1784. This compound shall be light gray in color, and shall be approved by NSF for use with potable water. Dimensions: CPVC Schedule 40 and Schedule 80 pipe shall be manufactured in accordance to the requirements of ASTM F441 for physical dimensions and tolerances. Each production run of pipe manufactured in compliance to this standard, shall also meet the test requirements for materials, workmanship, burst pressure, flattening, and extrusion quality defined in ASTM F441. All belled -end pipe shall have tapered sockets to create an interference -type fit, which meet or exceed the dimensional requirements, and the minimum socket length for pressure-type sockets, as defined in ASTM D2672. Marking: Product marking shall meet the requirements of ASTM F 441 and shall include: the manufacturers name (or the manufacturers trade- . mark when privately labeled); the nominal pipe size; the material designation code; the pipe schedule and pressure rating in psi for water @ 737; F; the ASTM designation F 441; and the independent laboratory's seal of approval for potable water usage. Marking shall also include the flame spread rating and smoke development rating when tested and listed for surface burning characteristics per CAN/ULC S102.2 (Flame Spread (ES.) of <25 and Smoke Development (S.D.) of <50). Sample Specification: All CPVC Schedule 40 and schedule 80 pipe shall be manufactured from a Type IV, Grade I Chlorinated Polyvinyl Chloride (CPVC) compound with a minimum Cell Classification of 23447 per ASTM D1784. The pipe shall be manufactured in strict compliance to ASTM F441, consistently meeting the Quality Assurance test requirements of this standard with regard to material, workmanship, burst pressure, flattening, and extrusion quality. The pipe shall be produced in the USA using domestic materials, by an ISO 9001 certified manufacturer, and shall be stored indoors after production, at the manufacturing site, until shipped from factory. This pipe shall carry the National Sanitation Foundation (NSF) seal of approval for potable water applications. The pipe shall have a Flame Spread rating < 25 and a Smoke Development rating < 50 when tested and listed for Surface Burning Characteristics in accordance with CAN/ULC-S102-2-M88 or equivalent. All pipe shall be manufactured by HARVEL PLASTICS, INC. Harvel Plastics, Inc. • 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 • Fax: 610.253.4436 • www.harvel.com Schedule 40 Dimensions Product Specifications CPVC Industrial Pipe: Schedule 40 & 80 ASTM STANDARD D1784 MATERIAL EQUIVALENTS: Cell Classification 23447 = CPVC 1Ype IV Grade I = CPVC 4120 PIPE SIZES SHOWN ARE MANUFACTURED IN STRICT COMPLIANCE WITH ASTM F441 Harvel Plastics, Inc. - 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 -Fax: 610.253.4436 - www.harvel.com The pressure ratings given are for water, non -shock, @ 73 ° F. The Nom. Pipe Average Min. Nom. Max. following temperature de -rating factors are to be applied to the Size (in.) O.D. I.D. Wall Wt./Ft. W.P working pressure ratings listed when operating at elevated 114 0.540 0.344 0.088 0.096 780 temperatures. 318 0.675 0.473 0.091 0.128 620 De -Rating Factor 112 0.840 0.602 0.109 0.190 600 Multiply the working pressure 3/4 1.050 0.804 0.113 0.253 480Operating De -Rating rating of the selected pipe 1 1.315 1.029 0.133 0.371 450 at 73'F, by the appropriate Temp (°F) Factor 1-114 1.660 1.360 0.140 0.502 370 73-80 1.00 de -rating factor to determine 1-112 1.900 1.590 0.145 0.599 330 90 0.91 the maximum working 100 0.82 2 2.375 2.047 0.154 0.803 280 pressure rating of the pipe 110 0.72 2-1/2 2.875 2.445 0.203 1.267 300 at the elevated temperature 120 0.65 3 3.500 3.042 0.216 1.660 260 3-112 4.000 3.521 0.226 1.996 240 chosen. 130 0.57 140 0.50 4 4.500 3.998 0.237 2.363 220 EX: 10" CPVC SCH 80 150 0.42 5 5.563 5.016 0.258 2.874 190 160 0.40 6 6.625 6.031 0.280 4.164 180 @ 120-F = ? 170 0.29 8 8.625 7.942 0.322 6.268 160 230 psi x 0.65 = 180 0.25 10 10.750 9.976 0.365 8.886 140 149.5 psi max. @ 1207 F 200 0.20 12 12.750 11.889 0.406 11.751 130 14 14.000 13.073 0.437 13.916 130 16 16.000 14.940 0.500 18.167 130 THE MAXIMUM SERVICE TEMPERATURE FOR CPVC IS 200°E 18 18.000 16.809 0.562 22.965 130 Solvent -cemented joints should be utilized when working at 20 20.000 18.743 0.593 29.976 120 or near maximum temperatures. Harvel Plastics does not 24 24.000 22.544 0.687 37.539 120 recommend the use of CPVC for threaded connections at temperatures above 1507; F; use flanged joints, unions, or roll Schedule 80 Dimensions grooved couplings where disassembly is necessary at elevated temperatures. Nam. Pipe Average Min. Nom. Max. Size (in.) O.D. I.D. Wall Wt./Ft. WR Threading of Sch 40 CPVC pipe is not a recommended practice 114 0.540 0.282 0.119 0.117 1 130 due to insufficient wall thickness. Thread only Sch 80 or heavier 3/8 0.675 0.403 0.126 0.162 920 walls. Threading requires a 50% reduction in pressure 1/2 0.840 0.526 0.147 0.238 850 rating stated for plain end pipe @73°E 3/4 1.050 0.722 0.154 0.322 690 1 1.315 0.936 0.179 0.473 630 Chemical resistance data should be referenced for proper 1-1/4 1.660 1.255 0.191 0.654 520 material selection and possible de -rating when working with 1-1/2 1.900 1.476 0.200 0.793 470 fluids other than water. Refer to Harvel Plastics 112/401 2 2.375 1.913 0.218 1.097 400 Product Bulletin for chemical resistance and installation data. 2-1/2 2.875 2.290 0.276 1.674 420 3 3.500 2.864 0.300 2.242 370 3-1/2 4.000 3.326 0.318 2.735 350 4 4.500 3.786 0.337 3.277 320 5 5.563 4.768 0.375 4.078 290 6 6.625 5.709 0.432 6.258 280 8 8.625 7.565 0.500 9.506 250 10 10.750 9.493 0.593 14.095 230 12 12.750 11.294 0.687 19.392 230 14 14.000 12.410 0.750 23.261 220 16 16.000 14.213 0.843 29.891 220 18 18.000 16.014 0.937 37.419 220 20 20.000 17.814 1.031 45.789 220 24 24.000 21.418 1.218 64.959 210 ASTM STANDARD D1784 MATERIAL EQUIVALENTS: Cell Classification 23447 = CPVC 1Ype IV Grade I = CPVC 4120 PIPE SIZES SHOWN ARE MANUFACTURED IN STRICT COMPLIANCE WITH ASTM F441 Harvel Plastics, Inc. - 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 -Fax: 610.253.4436 - www.harvel.com Product Specifications PVC Industrial Pipe: Schedule 80 Application: Corrosion resistant pressure pipe, IPS sizes 1/8" through 241, for use at temperatures up to and including 140°E Pressure rating (210 psi to 1230 psi) varies with schedule, pipe size, and temperature as stated in Harvel Plastics, Inc. engineering bulletin (Product Bulletin 112/401). Generally resistant to most acids, bases, salts, aliphatic solutions, oxidants, and halogens. Chemical resistance data is available and should be referenced for proper material selection. Pipe exhibits excellent physical properties and flammability characteristics (independently tested flame and smoke characteristics -ULC). Typical applications include: chemical processing, plating, high purity applications, potable water systems, water and wastewater treatment, irrigation, agricultural, and other industrial applications involving corrosive fluid transfer. Scope: This specification outlines minimum manufacturing requirements for Polyvinyl Chloride (PVC) Schedule 80 iron pipe size (IPS) pressure pipe. This pipe is intended for use in applications where the fluid conveyed does not exceed 140 ° F. This pipe meets and or exceeds the industry standards and requirements as set forth by the American Society for Rsting and Materials (ASTM) and the National Sanitation Foundation (NSF International). PVC Materials: The material used in the manufacture of the pipe shall be domestically produced rigid polyvinyl chloride (PVC) compound, Type I Grade I, with a Cell Classification of 12454 as defined in ASTM D1784, trade name designation H707 PVC. This compound shall be gray in color as specified, and shall be approved by NSF International for use with potable water (NSF Std 61). Dimensions: PVC Schedule 80 pipe shall be manufactured in strict accordance to the requirements of ASTM D1785 for physical dimensions and tolerances. Each production run of pipe manufactured in compliance to this standard, shall also meet or exceed the test requirements for materials, workmanship, burst pressure, flattening, and extrusion quality defined in ASTM D1785. All belled -end pipe shall have tapered sockets to create an interference -type fit, which meet or exceed the dimensional requirements and the minimum socket length for pressure-type sockets as defined in ASTM D2672. All PVC Schedule 80 pipe must also meet the requirements of NSF Standard 14 and CSA Standard B137.3 rigid PVC pipe for pressure applications, and shall bear the mark of these Listing agencies. This pipe shall have a flame spread rating of 0-25 when tested for surface burning characteristics in accordance with CAN/ULC-S102-2-M88 or equivalent. Marking: Product marking shall meet the requirements of ASTM D1785 and shall include: the manufacturer's name (or the manufacturer's trademark when privately labeled); the nominal pipe size; the material designation code; the pipe schedule and pressure rating in psi for water @ 737; the ASTM designation D1785; the independent laboratory's seal of approval for potable water usage; and the date and time of manufacture. Sample Specification: All PVC Schedule 80 pipe shall be manufactured from a Type I, Grade I Polyvinyl Chloride (PVC) compound with a Cell Classification of 12454 per ASTM D1784. The pipe shall be manufactured in strict compliance to ASTM D1785, consistently meeting and/or exceeding the Quality Assurance test requirements of this standard with regard to material, workmanship, burst pressure, flattening, and extrusion quality. The pipe shall be manufactured in the USA, using domestic materials, by an ISO 9001 certified manufacturer. Standard lengths of pipe sizes 6" and larger shall be beveled each end by the pipe manufacturer. All pipe shall be stored indoors after production at the manufacturing site until shipped from factory. This pipe shall carry the National Sanitation Foundation (NSF) seal of approval for potable water applications. All pipe shall be manufactured by HARVEL PLASTICS, INC. Harvel Plastics, Inc. • 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 • Fax: 610.253.4436 • www.harvel.com Product Specifications PVC Industrial Pipe: Schedule 80 Schedule 80 Dimensions The pressure ratings given are for water, non -shock, @ 73' E The Nom. Pipe Average Min. Nom. Max. following temperature de -rating factors are to be applied to the Size (in.) O.D. I.D. Wall Wt./Ft. W.P. working pressure ratings (WP) listed when operating at elevated 1/8 0.405 0.195 0.095 0.063 1230 temperatures. 1/4 0.540 0.282 0.119 0.105 1130 De -Rating Factor 3/8 0.675 0.403 0.126 0.146 920 Multiply the working pressure 1/2 0.840 0.526 0.147 0.213 850 rating of the selected pipe at Operating De -Rating 3/4 1.050 0.722 0.154 0.289 690 73 ° F, by the appropriate Temp (°F) Factor 1 1.315 0.936 0.179 0.424 630 de -rating factor to determine 73 1.00 1-1/4 1.660 1.255 0.191 0.586 520 the maximum working pressure 80 0.88 1-1/2 1.900 1.476 0.200 0.711 470 rating" of the pipe at the 90 0.75 2 2.375 1.913 0.218 0.984 400 elevated temperature chosen. 100 0.62 2-1/2 2.875 2.290 0.276 1.500 420 -110 0.51 3 3.500 2.864 0.300 2.010 370 EX: 120 0.40 3-1/2 4.000 3.326 0.318 2.452 350 10" PVC SCH 80 @ 120°F = 9 130 0.31 4 4.500 3.786 0.337 2.938 320 230 psi x 0.40 = 92 psi max. 140 0.22 5 5.563 4.768 0.375 4.078 290 6 6.625 5.709 0.432 5.610 280 @ 120-F 8 8.625 7.565 0.500 8.522 250 THE MAXIMUM SERVICE TEMPERATURE FOR PVC IS 140°F 10 10.750 9.493 0.593 12.635 230 12 12.750 11.294 0.687 17.384 230 Solvent -cemented joints should be utilized when working at 14 14.000 12.410 0.750 20.852 220 or near maximum temperatures. Harvel Plastics does not 16 16.000 14.213 0.843 26.810 220 recommend the use of PVC for threaded connections at 18 18.000 16.014 0.937 33.544 220 temperatures above 1107; F; use flanged joints, unions, or roll 20 20.000 17.814 1.031 41.047 220 grooved couplings where disassembly is necessary at elevated 24 24.000 21.418 1.218 58.233 210 temperatures. Thread only Schedule 80 or heavier walls. Threading requires a 50% reduction in pressure rating stated for plain end pipe @73 °E Threading of Schedule 40 PVC pipe is not a recommended practice due to insufficient wall thickness. Chemical resistance data should be referenced for proper material selection and possible de -rating when working with fluids other than water. Refer to Harvel Plastics 112/401 Product Bulletin for chemical resistance, installation data, and additional information. ASTM STANDARD D1784 MATERIAL EQUIVALENTS: Cell Classification 12454 = PVC Type I Grade I = PVC1120 Pipe sizes shown are manufactured in strict compliance with ASTM D1785. Harvel Plastics, Inc. - 300 Kuebler Rd., Easton, PA 18040-9290 Tel: 610.252.7355 -Fax: 610.253.4436 - www.harvel.com ri 1 UNIONTRUE a/i INDUSTRIAL � J r r « This multi -featured, space saving quarter -turn shutoff valve is designed to meet the demands of today's industrial and chemical processing applications. PVC and CPVC valves are available. in IPS sizes 1/2" through 6" with socket/regular thread, SR (Special Reinforced) thread, flanged or spigot end connectors and 8" Venturied valve with socket or flanged ends. Also available in metric socket and BSP thread sizes 1/2" through 2". All thermoplastic ball valves shall be True Union 2000 Industrial type manufactured to ASTM F 1970 and constructed from PVC Type 1, ASTM D 1754 Cell Classification 12454 or CPVC Type IV, ASTM D1784 Cell Classification 23447. All 0 -rings shall be EPDM or Vitod�. All valves shall have Safe -T -Shear' stem with double O-ring stem seals. All valve handles shall be polypropylene with built-in lockout mechanism. All valve union nuts shall have Buttress threads. All seal carriers shall be Safe -T -Blocked*. All valve components shall be replaceable. All valves shall be certified. by NSF International for use in potable water service. All 1/2" through 2" valves shall be pressure rated to 235 psi, all 2-1/2" through 6", 5" Venturied and all flanged valves shall be pressure rated to 150 psi for water at 737. Quick -View Valve Selection Chart Valve O-ring PVC Part Number I Pressure Size Material Socket Threaded SR Threaded Flanged Spigot Rating EPDM 1829-005 included 1821-005SR 1823-005 1827-005 1/2 VitonO 1839-005 included 1831-005SR 1633-005 1837-005 EPDM 1829-007 included 1821-007SR 1823-007 1827-007 235 psi 3(4 Vitoni') 1839-007 included 1831-007SR 1833-007 1837-007 Non -Shock EPDM 1829-010 included 1821-010SR 1823-010 1827-010 Water @F 73` 1 VitonO 1839-010 included 1831-010SR 1833-010 1837-010 1-114 EPDM 1829-012 included 1821-012SR 1823-012 1827-012 (Flanged Viton") 1839-012 included 1831-012SR 1833-012 1837-012 150 si p Non EPDM 1829-015 included 1821-015SR 1823-015 1827-015 -Shock) Water 1-1/2 VitonO 1839-015 included 1831-015SR 1833-015 1837-015 @ 73°1` EPDM 1829-020 included 1821-020SR 1823-020 1827-020 2 Viton- 1839-020 included 1831-020SR 1833-020 1837-020 EPDM 1822-025 1821-025 1821-025SR 1823-025 1827-025 2-1/2 VitonO 1832-025 1831-025 1831-025SR 1833-025 1837-025 EPDM 1822-030 1821-030 1821-030SR 1823-030 1827-030 3 Viton(O 1832-030 1831-030 1831-030SR 1833-030 1837-030 EPDM 1822-040 1821-040 1821-040SR 1823-040 1827-040 150 psi Non -Shock 4 Vitono 1832-040 1831-040 1831-040SR 1833-040 1837-040 Water 73`F EPDM 1822-060 1821-060 1821-060SR 1823-060 1827-060 6 Viton© 1832-060 1831-060 1831-060SR 1833-060 1837-060 83 EPDM 1822-080 — — 1823-080 — VitonO 1 1832-080 1 -- 1833-080 --- 1) For CPVC, add [tie letter "C" following the size code of part number listed (e.g.,1829-005C, 1821-005CSR) 2) For Special Bell Vent Design, add the letter "1P' before the dash. separator-(e.g.,1829V-005, 1821 V-005CSR) 3) 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters. 10 • Chemical & Corrosion Resistant PVC or CPVC Construction • Also Available in Spears' LXTT11 High Purity, Low Extractable PVC Material • Interchangeable with all True Union 2000 Valves Mates with Union 2000 Pipe Unions • High Impact Polypropylene Handle • Built-in Handle Lockout • Schedule 80 Full -Bore Design • Strong, Buttress Thread Union Nuts • Spears' Double O-ring Safe -T -Shears Stem Design • EPDM or Viton- 0 -rings • Spears'' Safe -T -Blocked' Seal Carrier • Self Adjusting PTFE Floating Seat Design • Fully Serviceable, Replaceable Components • Sizes 1/2" - 2" pressure rated to 235 psi @ 73°F. Sizes 2-1/2" - 6". 8" Venturied and all Flanged to 150 psi @ 73°F. • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Manufactured to ASTM F 1970 Same valve with special ball vent design for sodium hypochlorite (bleach) and other chemical applications where entrapped fluids may form caustic crystalline residues and pressure build up from gases developed. Valve has a 1/8" vent hole in ball to equalize internal fluid pressures. Install valve with ball vent on the pressure (upstream) side when in closed position. Optional Accessories* • Retro -Fit End Connector Sets for Valve Replacement • Split -Nut Repair Kits for Union Nut Replacement • Supplemental End Connectors • Round Safety Handles • Handle Lockout Ring • Stem Extension Kits • Square Operator Nuts • Multi Mount Valve/Actuation Mounting Kits *See "BALL VALVE ACCESSORIES" section for details of individual products. I� TRUE UNION01/ INDUSTRIALt Replacement Parts No. Component Qty. Material 1 Seal Carrier 1 PVC/CPUC 2 Seat 2 PTFE 3 Body 1 PVC/CPVC 4 Carrier 0 -ring 1 EPDM/VitonO 5 Stem 1 PVC/CPVC 6 Stem Bearing 1 PP 7 Handle 1 PP 8 Stem 0 -ring 2 EPDMNitonc 9 Handle Lock 1 PP 10 Ball 1 PVC/CPVC, 11 Union Nut 2 PVC/CPVC 12 End Connector 0 -ring 2 EPDMNiton° 13 End Connector 2 PVC/CPVC Nominal Size A g1 Socrrhd Dimensions Reference (inches, ± 1/16) C Spigot Socket Thread Spigot D E F G Approx. Wt. (Lbs.) PVC CPVC Oper.2 Cv3 Values Torque (in.lbs. Socfrhd Flanged Spigot ) 112 1-7/8 2-3/8 2-7/8 4-3/16 3-3116 4-5/8 2-9/'16 2-13/16 3-1/2 2-31132 .36 .38 16 29 18 27 314 2-114 2-3/4 3-1/4 4-314 4-1,14 5-1/4 2-7/8 3-3/8 3-7!8 3-5/16 .56 .58 17 63 39 57 1 2-112 2-7/8 3-1/2 5-1/8 4-11/16 5-3/4 3-118 3-7/16 4-112 3-5/8 .74 - .77 22 120 73 108 1-1/4 3-1/16 3-1/4 3-13/16 5-3314 5-3/16 6-5/16 3-5,8 3-718 4-5/8 3-31/32 1.13 1.19 28 243 151 223 1-112 3.1/2 3-112 4 6-1/4 5-7116 6-3/4 4 4-3/16 5 4-3/8 1.54 1.60 61 357 223 333 2 4-1/4 4-3/4 5-3/16 7-3/4 6-3/4 8-114 4-1/2 5-118 6 5-114 2.72 2.85 77 599 395 571 2-1/2 5-318 6-7/8 7-13116 10-7116 9-11%16 11-3/8 5-118 6-1/4 7-112 6 7.42 7.70 132 856 579 734 3 6-3/16 7 7-13/16 10-11/16 9-718 11-91,16 5-718 7-5/8 7-1/2 6-13il6 7.46 7.81 132 1416 974 1322 4 7-5/8 7-5/16 8-1/4 11-7/8 10-1/4 12-3/4 6-314 9-3/16 9 7-1/2 12.35 12.48 396 2865 1952 2672 6 11-5/8 11-1116 13 17-1/16 15-3/'4 18-112 8-118 14-5/16 11-114 10-3/16 37.53 40.55 732 6638 4824 6149 84 11-5/8 23-3/16 -- 31-7/8 — -- 8-118 14-5/16 13-1/2 17-13.-16 F50.84 55.92 732 NIA 1: Valve Lay Length 2: Torque required at valve maximum internal pressure rating, 5ft/sec. Flow velocity; due to adjustment differences during installation, actual valves may vary. 3: Gallons per minute at 1 psi pressure drop. Valves calculated from laying length, based on derivative of Hazen -Williams equation with surface roughness factor of C=150. 4: 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters. Temperature Pressure Rating System Operating 100 110 120 130 140 150 160 170 180 190 200 210 Temperature °F (°C) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99). PVC 235 211 150 75 50 -0- -0- -0- -0- -0- -0- -0- (1.62) (1.45) (1.03) (52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) Valve Pressure 1/2" - 2" CPVC 235 219 170 145 130 110 90 80 70 60 50 -0- Rating (1.62) (1.51) (1.17) (1.00) (.90) (.76) (.62) (.55) (.48) (-41) (.34) (-0-) psi PVC 150 135 110 75 50 -0- -0- 0- -0- -0- -0- -0- (MPa) (1,03) (.93) (.76) (.52) (.34) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) (-0-) 2-1/2" - 8" CPVC 150 140 130 120 110 100 90 80 70 60 50 -0- (1.03) (.97) (.90) (.83) (.76) (.70) (.62) (.55) (.48) (.41) (.34) (-0-) NOTE: Flanged Valves have a base pressure rating of 150 psi - 1E Q GATE VALVES Features — PVC, CPVC This solid, proven design is well suited for a variety of chemical, industrial and irrigation applications. Spears® Gate Valves are feature -packed with a variety of end connector options. Individual special features are found in each size range 1/2" through 2", 2-1/2" & 3", and in the full featured Heavy Industrial 4" valve. See Spears® Plug Gate Valves for 6" size. • Heavy Bodied PVC & CPVC Construction • Tapered Wedge with Specially Designed Sealing Surface • Non -Rising Stem Design • Patented Strain -Equalizing Stem/Wedge Thread • O-ring Stem Seals Instead of Packing - No Retightening, Required • Buna-N, EPDM, or Viton® O-ring Seals 1/2" - 2" PVC & CPVC Heavy Duty Gate Valves • Available with socket, threaded or flanged end connectors. • Pressure rated to 200 psi @ 73°F. Flanged Valve Pressure Rated to 150 psi @ 73°F • : Positive Grip, High Impact Polypropylene Handwheel Operator • Fully Serviceable, Replaceable Components -Accessible Without Valve Removal • NSF Certified for Potable Water use • Suitable for Vacuum Service • Assembled with Silicone -Free, Water Soluble Lubricants • Metric Socket and BSP Thread Available, 1/2" - 2" 2-1/2" & 3" PVC & CPVC Heavy Duty Gate Valves • Available with socket, SR (Special Reinforced) threaded or flanged end connectors. • .Pressure rated to 150 psi @.73°F. • Optional 2" Square/T-Style Operator Nut available. Note: 2-1/2" size is a bushed down 3" valve. Sample Engineering Specification 4" PVC & CPVC Heavy Industrial Gate Valves • Available with socket, SR (Special Reinforced) threaded or flanged end connectors. • Pressure rated to 235 psi @ 73°F. Flanged Valve Pressure Rated to 150 psi @ 73°F • SS 316 Exterior Bonnet & Hardware • Built-in Quick -View Position Indicator • Optional 2" Square/T-Style Operator Nut available. All thermoplastic Gate Valves shall be constructed from PVC Type I Cell Classification 12454 or CPVC Type IV Cell Classification 23447. All O -rings shall be Buna-N, EPDM or Viton®. All valves shall have non -rising stern and Polypropylene handwheel. All valve gate wedges shall have Strain -Equalizing threads. PVC valves shall have Polypropylene wedge and CPVC valves shall have CPVC wedge. All valve components shall be replaceable. All 1/2" through 2" valves shall be pressure rated at 200 psi, all 2-1/2" through 3" valves shall be pressure rated at 150 psi, and all 4" valves shall be pressure rated at 235 psi for water at 73°F, as manufactured by Spears® Manufacturing Company. 54 GATE VALVES Quick -View Valve Selection Chart Valve Size O-ring Material PVC Part Numbersi Socket Threaded Flanged Pressure Rating 15 Buna-N 2012-005 2011-005 2013-005 44 1/2 EPDM 2022-005 2021-005 2023-005 144 127 Vitono 2032-007 2031-005 2033-005 (77) See Note 2 Buna-N 2012-007 2011-007 2013-007 583 3/4 EPDM 2022-007 2021-007 2023-007 50 -0- Viton® 2032-007 2031-007 2033-007 200 psi -0- Buna-N 2012-010 2011-010 2013-010 Non -Shock Water 1 EPDM 2022-010 2021-010 2023-010 @ 73-F 0-) Viton® 2032-010 2031-010 2033-010 Buna-N 2012-012 2011-012 2013-012 (Flanged 1-1/4 EPDM 2022-012 2021-012 2023-012 150 psi Viton® 2032-012 2031-012 2033-012 Non -Shock Water 140 Buna-N 2012-015 2011-015 2013-015 @ 73°F) 1-1/2 EPDM 2022-015 2021-015 2023-015 Viton® 2032-015 2031-015 2033-015 (.76) (.69) Buna-N 1 2012-020 2011-020 2013-020 (.34) 2 EPDM 2022-020 2021-020 2023-020 130 110 Viton® 2032-020 2031-020 2033-020 -0- -0- Buna-N 2012-0253 2011-0253 2013-0253 2-1/2 EPDM 2022-0253 2021-0253 2023-0253 150 (-0-) Viton® 2032-0253 1 2031-0253 2033-0253 psi Non -Shock (-0-) Buna-N 2012-030 2011-030SR 2013-030 Water 3 EPDM 2022-030 2021-030SR 2023-030 @0 73-F Viton® 2032-030 2031-030SR 2033-030 CPVC Buna-N 2012-040 2011-040SR 2013-040 2352 psi 4EPDM 90 2022-040 2021-040SR 2023-040 Non -Shock Water -0- Viton® 1 2032-040 1 2031-040SR 2033-040 @ 73°F 1: For CPVC valves, add the letter "C" to the part numbers (e.g., 2031-005C). 2: Flanged end connectors have a Maximum Internal Pressure Rating of 150 psi @ 73T. 3: Outlet sized with bushing. Temperature Pressure Rating Cv Values Nominal Size Cv, Gallons/Minute SocketlThreaded Flanged 1/2 19 15 3/4 37 29 1 44 39 1-1/4 128 105 1-1/2 144 127 2 333 279 2-1/2 (77) See Note 2 3 335 323 4 583 566 Flanged valves calculated for additional laying length of flanged valve. 1: Gallons per minute at 1 psi pressure drop. 2: Size 2-1/2" is a reducer bushed down 3" valve, C„ not available. System Operating 100 110 120 130 140 150 160 170 180 190 200 210 Temperature °F(°C) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) PVC 200 135 120 75 50 -0- -0- -0- -0- -0- -0- -0- (1.38) (.93) (.83) (.52) (.34) (-0-) (-0-) (-0-) 0-) (-0-) (-0-) 0-) CPVC 200 155 140 125 110 100 90 80 70 60 50 -0- (1.38) (1.07) (.97) (.86) (.76) (.69) (.62) (.55) (.48) (.41) (.34) (-0-) Valve PVC 150 130 110 60 50 -0- -0- -0- -0- -0- -0- -0- Pressure Rating (1.03) (.90) (.76) (.41) (.34) (-0-) 0-) 0-) (-0-) 0-) 0-) (-0-) 2-1/2"-3" psi CPVC 150 140 130 120 110 100 90 80 70 60 50 -0- (MPa) (1.03) (.97) (.90) (.83) (.76) (.69) (.62) (.55) (.48) (.41) (.34) (-0-) PVC 235 140 130 90 50 -0- -0- -0- -0- -0- -0- -0- (1.62) (.97) (.90) (.62) (.34) (-0-) (-0-) 0-) 0-) (-0-) (-0-) (-0-) 4" CPVC 235 219 170 145 130 110 95 80 70 60 50 -0- (1.62) (1.51) (1.17) (1.00) (.90) (.76) (.66) (.55) (.48) (.41) (.34) (-0-) NOT FOR USE WITH COMPRESSED AIR OR GASES 55 SPEARS 1/2" - 2" Replacement Parts GATE VALVES No. Component Qty. Material 1 Handle 1 PP 2 Stem 1 PVC/CPVC 3 Stem O-ring 1 Buna-N/EPDM/ ition@ 4 Stem Bushing 1 PP 5 Stem Nut 1 PVC/CPVC 6 1 Stem Washer 1 PP 7 Wedge Washer/O-ring 1 Buna-N/EPDM/Vition® 8 Wedge 1 PP/CPVC 9 Body (Socket/Threaded) 1 PVC/CPVC 10 Bonnet O-ring 1 Buna-N/EPDMNitionO 11 Bonnet 1 PVC/CPVC 12 1 Bonnet Nut F 1 PVC/CPVC 56 2-1/2" & 3" Replacement Parts No. Component Qty. Material 1 Handle 1 PP 2 Stem 1 PVC/CPVC 3 Stem Bearing 1 PP 4 Stem O-ring 1 Buna-N/EPDMNition® 5 1 Stem Nut 1 PVC 6 Stem Retaining Ring 1 SS 316 7 Split Washer 1 PP 8 Stem Bushing 1 PP 9 Bonnet Retainer 1 PVC/CPVC 10 Bonnet Half 2 PVC/CPVC 11 Seal Carrier 1 PVC/CPVC 12 Carrier O-ring 1 Buna-N/EPDM/ ition® 13 Wedge 1 PP/CPVC 14 Body 1 1 1 PVC/CPVC YOKOGAWA ELECTRIC CORPORATION Headquarters 2-9-32, Nakacho; Musashino-shi, Tokyo, 180-8750 JAPAN Branch Sales Offices Nagoya, Osaka, Hiroshima, Fukuoka, Sapporo, Sendai, Ichihara, Toyoda, Kanazawa, Takamatsu, Okayama, and Kitakyusyu. 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Yokogawa Electric Corporation 11111111111116111PIIII!IIIIIIIIIII IIIIIIIIIIII IIII IM 041_411301-03E 1st Edition Coontents Overviewof the Functional Changes.........................................................................................................................4 Checking the Style Number and Release Number on the Name Plate.....................................................................4 Operations on the DX1000/DX1000N/DX2000.............................................................................................................5 Improvement to the Operability on the Historical Trend Display................................................................................5 Displaying the Data in the Grid Time of the Trend Display........................................................................................5 Improvement to the Display Group Setup Operation.,......._...................................................................... ...........6 Specifying the Base Position of the Bar Graph..........................................................................................................6 Alarm Output Relay Action When the Alarm ACK Operation Is Executed.................................................................9 Resetting the Computed Value during Computation (/M1 and /PM1 Options)........................................................10 Changes to How the Data Files Are Named............................................................................................................10 Sorting the Files by the Update Date/Time..............................................................................................................11 Storage Method for Constantly Retaining the Most Recent Data Files in the CF Card (Media FIFO).....................12 Progress Display When Saving All Data of the Internal Memory .............................................................................14 Changing the Initial Display Selection Menu...........................................................................................................14 Improvement to the Data Save Operation to the USB Flash Memory .....................................................................14 Retaining the State of the CapsLock and NumLock Keys on the USB Keyboard...................................................14 Function for Automatically Assigning MW100s to the Modbus Client (DX2000 Only).............................................15 Changing of the Default Setting of the Web Server Function..................................................................................18 AList of Added Messages.......................................................................................................................................18 CommunicationCommands.......................................................................................................................................19 Specifying the Base Position of the Bar Graph........................................................................................................19 Storage Method for Constantly Retaining the Most Recent Data Files in the CF Card (Media FIFO).....................19 Format of the File List Output Using the ME Command..........................................................................................19 Alarm Output Relay Action When the Alarm ACK Operation Is Executed...............................................................20 DAQSTANDARDfor DXAdvanced..............................................................................................................................21 HardwareConfigurator............................................................................................................................................21 Viewer......................................................................................................................................................................23 2 IM 04L41 B01 -03E Viewer IM 04L41B01-03E DAQSTANDARD for DXAdvanced Linking the Previous and Subsequent Files Collectively You can collectively link previous and subsequent files to the working file. Up to now, the previous or subsequent file could be linked sepaparately. Carry out the following procedure with the file opened. • Operation on the Toolbar All linkable files are linked and displayed. TL.. IJ.. ....i.......:..... :.. �.�._�.�J_J L_ aLe • Operation from the Menu Bar On the [File] menu, click [Link All Files]. All linkable files are linked and displayed. • Operation on the Link File Dialog Box On the [Window] menu, click [Link]. The [Link File] dialog box opens. Click [All]. All linkable files are linked and displayed 10- Section 4.5, "Linking Files and Saving the Link Settings File" in the DAQSTANDARD for DXAdvanced User's Manual 23 DAQSTANDARD for DXAdvanced 22 Dialog Box for Setting the Display Type for Each View Group Select [View group] on the [General Setting] tab screen. Double-click the view group number to display a dialog box for setting each group View group number Enter the view group name Select the type of views to be displayed or drag and drop the view icons Select the group to be displayed 1 Selectable view types 10- Section 3.5, "Entering General Settings" in the DAQSTANDARD for DXAdvanced User's Manual Setting the Expression This applies to the operation for setting the expression on the setup screen of each computation channel. You can display a list of variables and constants and click the desired variables or constants to create the expression. Click the tab to display a list of that item Section 3.4, "Setting the Computation Channels" in the DAQSTANDARD for DXAdvanced User's Manual IM 041-41601-03E Thank you for purchasing the Daqstation DX1000/DX1000N/DX2000 (DX). This manual covers functions that has been changed in hardware style 2 and firmware release 2 or later. It also covers functions that have been changed on DAQSTANDARD version 7.21 or later. Change the contents of the following manuals with the contents of this manual. Manuals Provided on the CD-ROM Manual Title Manual No. Description Daqstation DX1000/DX1000N IM 041-411301-01E See this manual for the descriptions of the User's Manual DX1000/DX1000N operations. Daqstation DX2000 IM 041-421301-01E See this manual for the descriptions of the User's Manual DX2000 operations. Daqstation IM 041-411301-17E See this manual for the descriptions of DX1000/DX1000N/DX2000 communication commands. Communication Interface User's Manual DXA120 IM 041-41 B01-61 E See this manual for the descriptions of the DAQSTANDARD for DAQSTANDARD operations. DXAdvanced User's Manual Paper Manuals Manual Title Manual No. Description Daqstation DX1000/DX1000N IM 041-41 B01 -02E Explains the basic operations of the Operation Guide DX1000/DX1000N. Daqstation DX2000 IM 041-42601-02E Explains the basic operations of the Operation Guide DX2000. 1st Edition : February 2007 (YK) All Right Reserved, Copyright © 2007, Yokogawa Electric Corporation IM 04L411301 -03E 3 Overview of the Functional Changes Below is an overview of the main functional changes. • Improvement to the Operability on the Historical Trend Display When changing to the all data display, the DX loads as much of the continuous data as the display memory can hold and shows the data. • Alarm Output Relay Action When the Alarm ACK Operation Is Executed You can select the mode in which the alarm output relay is turned OFF when alarm ACK is executed and remains OFF until the next alarm occurs. • Addition of the Media FIFO Function If not enough free space is available when saving a new data file to the CF card, files are deleted in order from the oldest data update date/time to save the new file. • Function That Automatically Assigns MW100s to Modbus Clients When connecting MW100s to the DX using the Modbus/TCP communications, the MW100 channels can be assigned automatically to the DX external input channels. * Only on DX2000s with the external input channels (/MC1 option). • NEMA4 Compliance (Only the Waterproof Construction) The waterproof construction of the DX front panel complies with the NEMA4 standard. Checking the Style Number and Release Number on the Name Plate As shown below, the style number and release number are marked on the name plate attached to the DX. Firmware release number Hardware style number 4 IM 04L41 601.03E ' The functions below have been added or changed since DAQSTANDARD revision 7.21. Hardware Configurator Setup Menu Corresponding to the DX Functions of Firmware Version 2.Ox • Specifying the Base Position of the Bar Graph Applies to the operations on the [Measure channel], [Math channel], or [Ext channel] tab screen. IM 04L41B01.03E Bar Display Position Set the base position of the bar graphs to [Normal], [Center], [Lower], or [Upper]. Operations on the DX1000/DX1000N/DX2000: Page 6 • Alarm Output Relay Action When the Alarm ACK Operation Is Executed Select [Alarm] on the [Basic Setting] tab screen. Relay Action on ACK Normal The relay output is deactivated when the alarm ACK operation is executed. If the condition for activating the alarm output relay is met in the next scan interval, the relay output is activated. This operation is valid only when the alarm output relay is set to [Hold]. Reset The relay output is deactivated when the alarm ACK operation is executed. If a new condition for activating the alarm output relay, the relay is activated. Operations on the DX1000/DX1000N/DX2000: Page 9 Storage Method for Constantly Retaining the Most Recent Data Files in the CF Card (Media FIFO) Select [Environment] > [Detail Setting] on the [Basic Setting] tab screen. Media 1-11-v: This is valid only when [Auto Save] is [ON]. ON If there is no more free space on the CF card, the oldest file is deleted, and the newest file is saved. OFF If there is no more free space on the CF card, the measured data is not saved to the CF card. Operations on the DX1000/DX1000N/DX2000: Page 12 21 Communication Commands 20 Alarm Output Relay Action When the Alarm ACK Operation Is Executed WO Set alarm and DO settings Set the Output Relay Syntax WO p1,p2,p3,p4,p5<terminator> pi DO type (RLY) p2 Relay number NONE No AND setting 101 Specify only 101 101-lxx Specify 101 to Ixx xx={02 to 361 p3 Energize/De-energize the relay DE—ENERGIZE ENERGIZE P4 Hold/Not hold the relay NONHOLD HOLD P5 Relay action on ACK NORMAL RESET Example No AND operation of the output relay, relay action is energize, and release the relay output when the alarm ACK operation is performed regardless of the alarm status. WORLY,NONE,ENERGIZE,HOLD,RESET Section 3.6, "Basic Setting Commands" in the communication interface user's manual Settings on the DX: Page 9 IM 04L41B01-03E Below are the operational changes as a result of the functional changes. This section mainly uses the DX1000 display in the explanations. Improvement to the Operability on the Historical Trend Display Loading Operation of Continuous Data to the Display Memory All Data Display When all data display is enabled, as much of the past measured data that are continuous to the measured data shown on the screen at that point as the display memory can hold are loaded. This allows you to view the past measured data without having to load the data for each screen. • Conventional Display Method • New Display Method Shows only the display data that was showing before the change when switching to the all data display. Loads as much of the continuous data as the display memory can hold and shows the data when switching to the all data display. Section 4.3, "Displaying Past Measured Data (Historical Trend Display)" in the user's manual Displaying the Data in the Grid Time of the Trend Display If the trend update interval is set to 1 h/div or higher, the month, day, and hour at the grid position are displayed on the screen. The display format can be changed by setting the date format. IM 04L41B01.03E Date Format Display Format of the Grid Time Display Example Year/Month/Day MM/DD hh 12/31 08 Month/Day/Year MM/DD hh 12/31 08 Day/Month/Year DD/MM hh 31/1208 Day.Month.Year DD.MM hh 31.1208 10- Section 2.4, "Setting the Date Format" in the user's manual 5 ODerations on the DX1000/DX1000N/DX2000 Improvement to the Display Group Setup Operation The channel settings of a display group can be copied to another group. Setup Screen Press MENU (switch to the setting mode) and select Group set, Trip line Procedure 1. Select the copy source channel settings. 2. Press the Copy soft key. 3. Select the copy destination channel settings. 4. Press the Paste soft key. The channel settings are copied. 10- Section 5.1, "Setting Display Groups' in the user's manual Specifying the Base Position of the Bar Graph The base position of the bar graph can be set to span lower limit (scale lower limit) or span upper limit (scale upper limit). The setting is applied when displaying the bar graph and when displaying the current value on the scale using the bar graph. Setup Screen N and select Meas channel > Bar Graph IM 04L41B01-03E Communication commands are described in chapter 3, "Commands" in the DX1000/ DX1000NIDX2000 Communication Interface User's Manual (IM 04L41B01-17E). Specifying the Base Position of the Bar Graph S® Sets the bar graph for each channel Syntax SB p1,p2,p3<terminator> pl Measurement/computation/external input channel number P2 Base position of the bar graph display NORMAL Normal (lower limit) CENTER Center LOWER Lower limit UPPER Upper limit P3 Number of scale divisions (4 to 12) Section 3.4, "Setting Commands (Setting)" in the communication interface user's manual 01- Settings on the DX: Page 6 Storage Method for Constantly Retaining the Most Recent Data Files in the CF Card (Media FIFO) WWU Sets the environment Set the media Syntax WU p1, p2, p3<terminator> pl Setting type (MEDIA) p2 Auto save function (OFF or ON) p3 Media FIFO (OFF or ON) Example Use media FIFO. WUMEDIA,ON,ON 11110- Section 3.6, "Basic Setting Commands" in the communication interface user's manual Settings on the DX: Page 12 Format of the File List Output Using the ME Command Because the method of assigning the file name has been changed, the output format has also changed. The number of output file name characters is 51. • Syntax EACRLF yy/mo/dd hh:mm:ss ssssssss fff••• 0 XXX •••CRLF .............................................. ENCRLF IM 04L41B01-03E fff • • • name (51 characters including the extension. If it is less than 48, spaces are entered. If this is a directory, the characters <DIR> are shown at the position displaying the file data size. Section 4.2, "Output Format of ASCII Data" in the communication interface user's manual 19 Operations on the DX1000/DX1000N/DX2000 Changing of the Default Setting of the Web Server Function The default setting of the Web server function has been changed to Use. You can use the Web server function by setting the monitor page or operator page to On. 00Section 1.5, "Monitoring the DX on a PC Browser" in the communication interface user's manual A List of Added Messages The following error messages have been added. Code Message Explanation/Countermeasures/Ref, section 129 IP address is not set. Set the IP address of the DX. 131 You have exceeded the available You cannot connect more than 240 channels. Value at the bottom of the bar graph: channel capacity. 132 You have exceeded the available The maximum number of commands that can Value at the top of the bar graph: number of commands. be sent is 16. The modules that can be set with lower Limit or scale upper limit), whichever is a single command are consecutive modules that Starting point of the bar: Bottom edge can be automatically set. Change the MW100 Value at the bottom of the bar graph: module configuration so that there are no empty Value at the top of the bar graph: Same as with Normal. slots. 133 External 1/0 auto setting information Below are the possible causes. Check them. is not available. • The MW100 is in calibration mode. Change to the setting mode or measurement mode. • The measurement module may not have been detected. Perform system reconfiguration. • There are no modules that can be automatically set. Check the modules. • An IP address has not been assigned to the MW100. Set the IP address. • The Modbus server of the MW100 is turned OFF. Turn ON the server. 134 Auto setting has already been You cannot set an MW100 that has been executed. automatically set. 135 External 1/0 cannot be found. Check the Ethernet connection. 136 External 1/0 start cannot be executed. The current MW100 settings do not allow the measurement to be started. Check the settings. 137 DNS for this device is not set. Set the DNS of the DX. In addition, the following status messages have been added. These messages appear when the respective processing operation takes a long time. Code 513 Post process in progress. 514 Now loading historical data. 515 Data save is completed. 516 Files are now beino sorted. 1110- Section 10. 1, "A List of Messages" in the user's manual (section 11.1 for the DX2000) Operations on the DX1000/DX1000N/DX2000 Setup Items Span upper limit (or scale upper limit) • Bar graph > Base position Span lower limit (or scale lower limit) Set the base position of the bar graphs to Normal, Center, Lower, or Upper. The bar I graphs for the different settings are shown below. When the Display Direction of the Bar Graph Is Vertical • Normal Starting point of the bar Value at the bottom of the bar graph: Span lower limit or span upper limit (or scale lower limit or scale upper limit), whichever is less Value at the top of the bar graph: Span lower limit or span upper limit (or scale lower Limit or scale upper limit), whichever is greater Starting point of the bar: Bottom edge • Center Value at the bottom of the bar graph: Same as with Normal. Value at the top of the bar graph: Same as with Normal. Starting point of the bar: Center • Lower Value at the bottom of the bar graph: Span lower limit (or scale lower limit) Value at the top of the bar graph: Span upper limit (or scale upper limit) Starting point of the bar: Bottom edge • Upper Value at the bottom of the bar graph: Same as with Lower. Value at the top of the bar graph: Same as with Lower. Starting point of the bar: Top edge _.... Normal Center Lower Upper VL VL Vupper Vupper VS 14 VS Li Vlower14 Vlower 18 IM 04L41B01-03E IM 04L41B01-03E Vupper: Span upper limit (or scale upper limit) Vlower: Span lower limit (or scale lower limit) VL: Vlower or Vupper, whichever is greater VS: Vlower or Vupper, whichever is less Starting point of the bar Operations on the DX1000/DX1000N/DX2000 When the Display Direction of the Bar Graph Is Horizontal The span lower limit (or scale lower limit) becomes the left edge of the bar graph, and the span upper limit (or scale upper limit) becomes the right edge of the bar graph. • Starting point of the bar Normal: Left edge or right edge, whichever is less Center: Center Lower: Left edge Upper: Right edge Lower Vlower Vupper When Displaying the Current Value on the Scale Using the Bar Graph Normal Center Lower Upper 10- Section 5.11, "Changing the Bar Graph Display Method" in the user's manual Operation using communication commands: Page 19 IM 04L41B01-03E Operations on the DX1000/DX1000N/DX2000 Note About the MW100 • MW100s that support auto setting are those with firmware version R2.22 or later. fi MW100 modules that can be automatically set are the following input modules. 4 -CH, High -Speed Universal Input Module 10 -CH, Medium -Speed Universal Input Module 6 -CH, Medium -Speed Four -Wire RTD Resistance Input Module 10 -CH, High-speed Input Module • If there are no channels to be assigned or the Modbus server setting is OFF, auto setting fails with an error. Check the settings. • MW100s that are connected through auto setting automatically switches to the measurement mode. • Port number 34324 of the MW100 is used to perform auto setting. • For details on the MW100 settings, see the user's manual of the MW100. The first channel information of the MW100 that is automatically set to the external input channel can be displayed when the cursor is on the first or last channel. IM 041 -41B01 -03E In addition, the status of the connected MW100 can be confirmed on the Modbus status display screen. Read cycle is Connect.retry : 2min Comm. Data No. Status First Last Server name Resisters 1 READ 0 Cnct 201 - 220 192.168.1.101 30001 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 16 on the DX1000/DX1000N/DX2000 Setup Items The MW100 channels are assigned to the external input channels of the DX as follows: • Channel Number The channels of the MW100 selected first are assigned consecutively from external input channel 201. The channels of the MW100 selected next are assigned to the available external input channels from the smallest number. You cannot select the external input channels to be assigned. DX DX external input channels channels MW100 CH2O1 ---------------------------- ' CH001 CH220 CH221 CH240 CH241 Meas. channels , 1 CH270 • Range Settings MW100 meas. Order of automatic channels MW100 assignment ---------------------------- ' CH001 ' Meas. channels , 1 CH001 to CH020i CH-------------------� -------- ----------------------- CH001 _. Meas. channels E CH001 to CH004: 2 CH014 ora CH011 to CH0141 --------------------------9 ----------- ' CH001 1' ME Meas. channels 3 CH001 to CH030i The range settings of the MW100 (including the span and unit) are set automatically to the external input channels. If the span setting of the MW100 range exceeds the span setting range of the DX external input channel (-30000 to 30000), it is set to the span upper limit (30000) or lower limit (-30000). Specify the settings such as the alarm, tag, and the area display of the color scale band of each channel after the auto setting is complete. Note Precautions When Assigning Channels to the External Input Channels • The MW100 channels are assigned in unit of 10 channels to the external input channels. If the MW100 measurement module consists of less than 10 channels, "OFF" is assigned to the external input channels for the section without channels. • An error occurs if the number of MW100 channels to be automatically set is greater than the number of available external input channels. • If the range setting of a MW100 channel is set to "SKIP," the external input channel of the DX is set to "OFF." • If a MW100 unit contains a module that cannot be set automatically, only the channels that can be assigned are assigned to the external input channels of the DX. • If a new MW100 is added, auto setting is executed again. At this point, all the settings are cleared. Therefore, you must execute the auto setting again for all MW100s. • If you are connecting MW100s that can be automatically set and MW100s that cannot be automatically set or other Modbus devices, automatically set the MW100s that can be automatically set first and then manually set the connection of the remaining devices. IM 041-411301-03E ns on the DX1000/DX1000N/DX2000 Alarm Output Relay Action When the Alarm ACK Operation Is Executed You can select the relay output status that is enabled after the alarm ACK operation from IM 04L41601 -03E the following two settings. • Normal: The relay output is deactivated when the alarm ACK operation is executed. If the condition for activating the alarm output relay is met in the next scan interval, the relay output is activated. This operation is valid only when the alarm output relay is set to Hold. • Reset: The relay output is deactivated when the alarm ACK operation is executed. If a new condition for activating the alarm output relay is met, the relay is activated. An example of the relay action when alarm ACK is executed is shown below. This example is for the case when the output relay AND item is set to OR and the Hold item is set to Hold. • Normal Alarm 1 Alarm 2 ON Alarm output relay OFI • Reset Alarm 1 Alarm 2 ON Alarm output relay_ Alarm ACK V is activated in the next scan interval Alarm ACK V is activated on the next alarm occurrence Setup Screen Press MENU (switch to the setting mode), hold down FUNC for 3 s (switch to the basic setting mode), select Alarm > Switch, Relay Setup Items Relay > Relay Action on Ack Select Normal or Reset. 110- Section 3.5, "Setting the Auxiliary Alarm Function" in the user's manual 00- Section 3.8, "Releasing the Alarm Output (Alarm ACK Operation)" in the user's manual Operation using communication commands: Page 20 10 ons on the DX1000/DX1000N/DX2000 Resetting the Computed Value during Computation (/M1 and /PM1 Options) You can reset the computed value not only when the computation is stopped but also when the computation is in progress. Section 9.4, "Starting/Stopping Computation, Resetting Computation, and Releasing Computation Data Dropout Display" in the user's manual Changes to How the Data Files Are Named The table below shows the file name that is assigned when the measured data is saved to the CF card. Differences from the File Names up to Now • The "ID" item at the end of the file name is deleted and its functionality is included in the "Separator" of the 7 -digit sequence. • The sequence section of the display data and event data file names is changed to 7 digits, and the "ID" function is included in the "Separator" when using the "Batch name." Structure Description Date Display data Consists of a 6 -digit number and a separator. The number is Event data 7 d it -' ....3. pecified strin Date - -, r ', , Extension Manual sampled data Ex.: 000123_AAAAAAAAAAA050928_174633.DAD Snapshot data The separator starts with an underscore followed by a character Report data Specitie�050928D17463i; T _e .Extension Date YYMMDD_HHMiSS Ex.tl000123 3HD.DAR Sequence Display data HH: Hour, Mi: Minute, SS: Second Specified string Event data 7 di it :'.E1 Specified strinq Extension Batch name Manual sampled data Ex.: 000123 AAAAAAAAAAA.DAD Type Snapshot data Report data type Report data d. d ;iIMJLSpecified strinq T e Extension Ex.:000123 AAAAAAAAAAAOHD.DAR Batch name Display data DM: Daily and monthly - di it_llills= Batch name Extension Display data :DAD Event data Ex.: 000123 BBBBBBBBBBBBBBBBBBBBB.DAD Event data :DAE Report data Manual sampled data :DAM Setup data :PDL Ex.:000123 050928 174633HD.DAR Manual sampled data Snapshot data p Ex.:000123 050928 174633.DAM _ _ Item Description 7 -digit sequence 000001-999999 Consists of a 6 -digit number and a separator. The number is assigned in order of occurrence. When the 6 -digit number reaches 999999, it returns to 000000. The separator starts with an underscore followed by a character that changes in the following order: A to Z and then 0 to 9. Date YYMMDD_HHMiSS YY: Year (lower two digits), MM: Month, DD: Day HH: Hour, Mi: Minute, SS: Second Specified string AAAAAAAAA•••A Up to 16 alphanumeric characters can be used Batch name BBBBBBBBBBB•••B Up to 40 alphanumeric characters can be used Type H_, D_, W_, M_, Report data type HD, DW, DM H_: Hourly, D_: Daily, W_: Weekly, M_: Monthly, HD: Hourly and daily, DW: Daily and weekly, DM: Daily and monthly Extension Display data :DAD Report data :DAR Event data :DAE Snapshot data :PNG Manual sampled data :DAM Setup data :PDL IM 04L41B01-03E on the DX1000/DX1000N/DX2000 Function for Automatically Assigning MW100s to the Modbus Client (DX2000 Only) IM 04L41B01-03E If the DX2000 is a Modbus client, MW100s, Modbus servers on the network, can be automatically assigned to the DX2000. This function can be used only on DX2000s with the external input channel function (/MC1 option). Setup Preparation Set the MW100s so that measurements can be started (IP address, system construction, range setting, and the like of the MW100s to be automatically assigned). For details, see the user's manual of the MW100. Setup Procedure If the IP address of the DX is not set, set it before carrying out the procedure below. 1. Press MENU (switch to the setting mode), hold down the FUNC key for 3 s (switch to the basic setting mode), and select Communication (Ethernet) > Modbus client > Auto setting 2. Carefully read the displayed precautions. Select Yes to execute the auto setting. Select No to return to the screen operation. 3. From the list of MW100s that is displayed, select the MW100s to be connected using the up and down arrow keys, and press DISP/ENTER. The selected MW100s are assigned to the external input channel of the DX. Displays the IP address or host name. Displays the MW100 unit number. The list displays up 'nallest unit number. status of the external input channel assignments. igs: Status in which the MW100 is not assigned automatically dy: Status in which the MW100 cannot be connected* display: Displays the number of the assigned external input channels Example: If a MW100 is assigned to external input channels 201 to 220, the status displays 201/220. For the corrective action, see "A List of Added Messages" on page 18. Pressing the Call soft key causes "—" to blink on the 7 -segment LED display of the selected MW100 for 2 seconds. This allows you to check which MW100 is selected if multiple MW100s are connected. 15 on the DX1000/DX1000N/DX2000 Progress Display When Saving All Data of the Internal Memory If you carry out All Save* on the memory summary screen, a pop-up window appears showing the progress of the save operation. * Function for saving all data in the internal memory to a CF card or USB flash memory. Note • The pop-up window appears only when the memory summary display is showing. • If you press the ESC key, the pop-up window clears temporarily and reappears approximately 10 seconds later. • The time estimate for saving all data is indicated in the table below (when the memory is full of data). It may take longer depending on the operating conditions of the DX. ns on the DX1000/DX1000N/DX2000 Sorting the Files by the Update Date/Time The files can be sorted in order by the update date/time in the screens below. This - function allows you to easily locate the files you need. /V File list/delete • Load display data • Load event data • Load settings (setting mode) • Load settings (basic setting mode) Time to Save All Data (Estimate) Save Destination CF Card USB Flash Memory Standard memory (internal memory size suffix code -1) 4 minutes 16 minutes Expansion memory (internal memory size suffix code -2) 10 minutes 40 minutes 10- Section 4.8, "Using the Memory Summary" in the user's manual Changing the Initial Display Selection Menu -, SELECT SAVE and ALL SAVE are shown in the initial display menu. Section 4.8, "Using the Memory Summary" in the user's manual Section 5.17, "Changing the FUNC Key Menu and Display Selection Menu" in the user's manual (section 5.18 for the DX2000) Improvement to the Data Save Operation to the USB Flash Memory Save data is displayed only when a flash memory is connected to the USB port and is usable* in the operation mode. * If DX is configured so that any of the items below is shown in the display menu, Save data can be executed. You can change the items shown in the display menu using the menu customize function. SELECT SAVE, M.SAMPLE SAVE, REPORT SAVE, or ALL SAVE Section 2.12, "Using the USB Flash Memory (/USB1 Option)" in the user's manual 1110- Section 5.17, "Changing the FUNC Key Menu and Display Selection Menu" in the user's manual (section 5.18 for the DX2000) Retaining the State of the CapsLock and NumLock Keys on the USB Keyboard The state of the CapsLock and NumLock keys is retained even if you disconnect the USB keyboard. Section 2.11, "Controlling the DX with a Keyboard (/USB1 Option)" in the user's manual 3 14 IM 04L41B01-03E IM 04L41B01-03E Procedure The procedure is explained using the "File list/delete" screen of the CF card as an example. 1. Press MENU (switch to the setting mode) and select Save/Load > File list/delete > CF soft key* > DISP/ENTER * When a CF card and a USB flash memory (/USB1 option) are being used 2. Press the Sort soft key to sort the files by the update date/time. F:/DATAO/ 1 Pressing the Sort key sorts the file list in order from M.9TFLE DATA (00314000) the oldest to newest update date/time, or vice versa. FEFiRT CATH (020/100) 06/11/29 19:44 Each time the key is pressed thereafter, the sort STELE pTrA• 0 DISFLAJ Ef M(. CCD) 06/11/29 20:14 order reverses. The arrow next to the Date/Time Stat Ti- Erd Tire Data Fa_tm y lYY 10:22:52 12/26 11:07:28 1133 : Sorts from oldest update date/time (ascending) 12610:26:53 12/1610:27:24 14 SKr 12/2- 10:21:10 12126 10: 35: 18 5 - 12/v 10:25:16 12/2, 10:25:18 12/610:6:12 1211610:6:14 2 2 St - - 12 dL 10: 6:03 1218610:25:10 2 Sux 12/E- 10:7-:16 121,5 10:39:10 03 =..o Note • The pop-up window appears only when the memory summary display is showing. • If you press the ESC key, the pop-up window clears temporarily and reappears approximately 10 seconds later. • The time estimate for saving all data is indicated in the table below (when the memory is full of data). It may take longer depending on the operating conditions of the DX. ns on the DX1000/DX1000N/DX2000 Sorting the Files by the Update Date/Time The files can be sorted in order by the update date/time in the screens below. This - function allows you to easily locate the files you need. /V File list/delete • Load display data • Load event data • Load settings (setting mode) • Load settings (basic setting mode) Time to Save All Data (Estimate) Save Destination CF Card USB Flash Memory Standard memory (internal memory size suffix code -1) 4 minutes 16 minutes Expansion memory (internal memory size suffix code -2) 10 minutes 40 minutes 10- Section 4.8, "Using the Memory Summary" in the user's manual Changing the Initial Display Selection Menu -, SELECT SAVE and ALL SAVE are shown in the initial display menu. Section 4.8, "Using the Memory Summary" in the user's manual Section 5.17, "Changing the FUNC Key Menu and Display Selection Menu" in the user's manual (section 5.18 for the DX2000) Improvement to the Data Save Operation to the USB Flash Memory Save data is displayed only when a flash memory is connected to the USB port and is usable* in the operation mode. * If DX is configured so that any of the items below is shown in the display menu, Save data can be executed. You can change the items shown in the display menu using the menu customize function. SELECT SAVE, M.SAMPLE SAVE, REPORT SAVE, or ALL SAVE Section 2.12, "Using the USB Flash Memory (/USB1 Option)" in the user's manual 1110- Section 5.17, "Changing the FUNC Key Menu and Display Selection Menu" in the user's manual (section 5.18 for the DX2000) Retaining the State of the CapsLock and NumLock Keys on the USB Keyboard The state of the CapsLock and NumLock keys is retained even if you disconnect the USB keyboard. Section 2.11, "Controlling the DX with a Keyboard (/USB1 Option)" in the user's manual 3 14 IM 04L41B01-03E IM 04L41B01-03E Procedure The procedure is explained using the "File list/delete" screen of the CF card as an example. 1. Press MENU (switch to the setting mode) and select Save/Load > File list/delete > CF soft key* > DISP/ENTER * When a CF card and a USB flash memory (/USB1 option) are being used 2. Press the Sort soft key to sort the files by the update date/time. F:/DATAO/ Pressing the Sort key sorts the file list in order from the oldest to newest update date/time, or vice versa. 30119-061129_191428,DAD 06/11/29 19:44 Each time the key is pressed thereafter, the sort 30120-061129_194428.DAD 06/11/29 20:14 order reverses. The arrow next to the Date/Time ,30121-061129201428.DAD 06/11/29 20:: column title Indicates ascending or descending order. ,30123-061129211428.DAD 06/11/2921:4144 06/11/29 21:44 : Sorts from oldest update date/time (ascending) 30124_061129214428.DAD 06/11/29 22:14:'' : Sorts from newest update date/time 30125_061129221428.DAD 06/11/29 22:44+. Fr_e05 0'4'V /= 1/622317 Kbytes -- !' (descending) 11 ns on the DX1000/DX1000N/DX2000 Storage Method for Constantly Retaining the Most Recent Data Files in the CF Card (Media FIFO) When saving the data files automatically, you can save the data so that the most recent data files are constantly retained in the CF card. This method allow you to use the DX continuously without having to replace the CF card. Operation Old Update date New Deleted File 1 h File 2 File 3 Saved: File 4 74 a q K :-;:,r�<: .row, 4' ,_. •9:o.�u'm;.e.'+rs//..� 3 �j .-...,.,,/.. Medium If not enough free space is available when saving a new data file to the CF card, files are deleted in order from the oldest data update date/time to save the new file. This operation is referred to as FIFO (First In First Out). • The FIFO operation is carried out only when saving the following files automatically. It is not carried out when saving files to the save destination directory using another method. Display data files, event data files, report data files, manual sample data files, and snapshot files • Files that are deleted All the files in the save destination directory are applicable to be deleted. However, the following files are excluded. Hidden files, read-only files, files in the subdirectory within the save destination directory • The most recent 1000 files are retained. If the number of files in the save destination directory exceeds 1000, the number of files is held at 1000 by deleting old files even if there is enough free space. If there are more than 1000 files already in the save destination directory, one or more files are always deleted before saving the new file. Setup Screen Press MENU (switch to the setting mode), hold down the FUNC key for 3 s (switch to the basic setting mode), and select Environment > Security, Media save Setup Items Save > Auto save Select On. Save > Media FIFO Select On. 10- Section 6.2, "Setting the Method for Saving the Data" in the user's manual Operation using communication commands: Page 19 12 IM 041-41601-03E Operations on the DX10001DX1000N/DX2000 Status Display of the CF Card • If an error occurs on the CF card, the CF card icon in the status display section changes to an error display. , An error occurred while accessing the CF card. (White) Detected an error when the CF card was inserted or performed a key operation to eject the CF card when an error was occurring (Light blue) while the CF card was being accessed. • If the media FIFO is turned ON, the icon does not turn red even when the free space on the CF card falls below 10% of the total CF card size. Section 1.3, "Display" in the user's manual E-mail Transmission of CF Card Errors • An e-mail message can be sent when an error occurs on the CF card. • If the media FIFO is turned ON, an e-mail message is not sent even when the free space on the CF card falls below 10% of the total CF card size. To send e-mail message of CF card errors, set the DX to send a system mail. Setup Screen Press MENU (switch to the setting mode), hold down the FUNC key for 3 s (switch to the basic setting mode), and select Communication (Ethernet) > E-mail 110- Section 1.4, "Sending E-mail Messages" in the communication interface user's manual Relay Contact Output When a CF Card Error Occurs (/F1 and /F2 Options) A relay contact output can be activated when an error occurs on the CF card. Setup Screen MENU key (switch to the setting mode) > Hold down the FUNC key for 3 s (switch to the basic setting mode), and select Status Relay Setup Items Memory/Media status Select On. Section 2.9, "Outputting the DX Status via the Relay Contact" in the user's manual Operation When a CF Card Error Occurs Carry out the procedure below to reset the CF card icon to normal and release the relay output. • Replace the CF card with a normal one. • Format the CF card on the DX. IM 041-41 B01 -03E 13 0 MLaC�Q9 �5u7 Operating and Maintenance Instructions 3BA Regenerative Blowers INSTALLATION & OPERATING MANUAL 3BA REGENERATIVE BLOWERS Table of Contents Section: Page Number: 1. Pump Ranges 3 Table 1: 3 Phase, Single Stage, 50 Hertz 5 Table 2: 3 Phase, Single Stage, 60 Hertz 6 Table 3: 3 Phase, Two/Three Stage, 50 Hertz 7 Table 4: 3 Phase, Two/Three Stage, 60 Hertz 8 Single Stage — Approx. Temperature Rise 10 Two/Three Stage — Approx. Temperature Rise 11 Tightening Torque Specifications 12 2. Installation 14 Installation Procedure 15 3. Start-up 17 4. Maintenance and Servicing 18 Troubleshooting Chart 19 Lifting 21 Storage 22 Disposal 22 5. Exploded -View Drawings 23 3BA1 Single -Stage 23 3BA1 Two -Stage 24 3BA7 Single -Stage 25 3BA7 Two -Stage 26 Warranty Statement 27 2 1. Pump Ranges These operating instructions cover the Airtech 3BA side channel vacuum pumps and compressors supplied with standard TEFC motors. Other configurations are available including V -belt driven units, units with explosion proof motors, mechanical seals, magnetic drives, coatings and modifications for high pressure service. Airtech can provide any combination of modifications to meet your application requirements. Such blowers, however, are outside the scope of this manual. Description All regenerative blowers are dynamic compression devices and utilize a non - contacting impeller to accelerate the gas and a specially designed housing to compress the gas. Cooling is accomplished by using the motor fan to blow air over the housing. In larger models, the housing is specially designed with cooling fins to allow a wider range of operation. Both the inlet and outlet ports have built-in silencers and mesh screens. Both the inlet and outlet have an inside connection thread corresponding to DIN ISO 228. On larger units, multiple suction and discharge connection configurations may be available. The wetted parts are constructed of Aluminum on all models. The blower shares a bearing with the motor. The seal between the bearing and the motor is not gas tight in most models, therefore these blowers are not recommended for handling of toxic or explosive gases. (Contact Airtech Vacuum, Inc. for additional options if explosive or toxic gases will be handled.) A full range of accessory items are available, including vacuum or pressure relief valves, check valves, suction filters, motor starters, vacuum/pressure cross-over valves, and in-line filters. Application/Installation Environment CAUTION! These blowers are designed for use in general industry. Suitable personnel protection according to OSHA requirements is provided, but the equipment should not be operated in residential settings. Airtech blowers can be operated as either vacuum pumps or compressors. They are suitable for use with air having a relative humidity up to 90 percent, but not generally suitable for handling corrosive or erosive gases. Special versions for toxic or aggressive gases may be available. Use of the standard blower in aggressive environments may cause damage to the blower or exposure to gases being handled in the local environment. CAUTION! Dangerous (flammable or explosive) or aggressive (corrosive) gases should not be handled by the standard blower. 3 Handling of flammable or aggressive gases and vapors may be possible by using a specially configured or modified blower. Contact factory for additional information. The standard blower is not suitable for operation in explosive environments as defined by NFPA 70. Contact factory for assistance. CAUTION! The ambient and suction temperatures should be between 40 and 105 F. For temperatures outside this region, please contact the factory. The maximum permissible pressure difference for vacuum or pressure is dependant on the motor rating (See Tables 1 to 4 for detailed information by model number.) and power supply frequency. The figures in Tables 1 to 4 are computed assuming an ambient temperature of 77 F (25 C) and a local barometric pressure of 1013 mbar (sea level). Operation at an ambient temperature of 104 F (40C) is the maximum permissible, and will result in a reduction of 10 percent on maximum vacuum or pressure attainable by the unit. For temperatures between 77 F and 104 F, reduce the maximum pressure reduction is a linear function of temperature. M Table 1. Three-phase, Single Stage, 50 Hertz Model Rated Power HP/kW Voltage Motor Current (Amps) Open Flow Capacity CFM/m3/hr Maximum Pressure (mbar) Sound Pressure Level (dBA) 3BA1300-7AT06 .33/.25 200-240/345-415 2.1/1.2 48/82 -100/100 53 2BA1300-7AT16 .54/.4 200-240/345-415 2.6/1.5 1 48/82 -120/130 53 3BA1400-7AT06 .94/.7 200-240/345-415 3.8/2.2 84/142 -120/120 63 2BA1400-7AT16 1.15/.85 200-240/345-415 4.2/2.4 84/142 63 3BA1400-7AT26 1.75/1.3 200-240/345-415 5.7/3.3 84/142 -170/200 63 3BA1500-7AT06 1.15/.85 200-240/345-415 4.2/2.4 120/204 -100/100 64 3BA1500-7AT16 1.75/1.3 200-240/345-415 5.7/3.3 120/204 -170/170 64 3BA1500-7AT26 2.15/1.6 200-240/345-415 7.5/4.3 120/204 -200/190 64 3BA1500-7AT36 2.96/2.2 200-240/345-415 9.7/5.6 120/204 -220/270 64 3BA1600-7AT06 2.15/1.6 200-240/345-415 8.5/4.9 188/320 -160/150 69 3BA1600-7AT16 2.96/2.2 200-240/345-415 9.7/5.6 188/320 -190/190 69 3BA1600-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 188/320 -260/270 69 3BA1600-7AT36 5.4/4.0 200-240/345-415 13.0/7.5 188/320 -290/360 69 3BA1630-7AT06 2.15/1.6 200-240/345-415 8.5/4.9 240/408 -160/150 69 3BA1630-7AT16 2.96/2.2 200-240/345-415 9.7/5.6 240/408 -190/190 69 3BA1630-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 240/408 -260/270 69 3BA1630-7AT36 5.4/4.0 200-240/345-415 15.6/9.0 240/408 -260/290 69 3BA1800-7AT06 5.4/4.0 200-240/345-415 15.6/9.0 280/476 -200/200 70 3BA1800-7AT16 7.4/5.5 200-240/345-415 23/13.3 280/476 -300/300 70 3BA1800-7AT26 10/7.5 200-240/345-415 29/16.7 280/476 -320/430 70 3BA1830-7AT06 5.4/4 200-240/345-415 15.6/9 400/680 -200/200 76 3BA1830-7AT16 7.4/5.5 200-240/345-415 23/13.3 400/680 -320/430 76 3BA1830-7AT26 10/7.5 200-240/345-415 29/16.7 400/680 -320/430 76 3BA1900-7AT06 10.8/8 200-240/345-415 568/965 74 3BA1900-7AT16 16.8/12.5 200-240/345-415 48.5/28 568/965 -290/280 74 3BA1900-7AT36 25/18.5 200-240/345-415 64.5/37 568/965 74 3BA1930-7AT16 16.8/12.5 200-240/345-415 48.5/28 744/1264 -290/280 71 3BA1930-7AT36 25/18.5 200-240/345-415 64.5/37 744/1264 -310/310 71 3BA7210-OAT167 .75/.55 200-240/345-415 2.8/1.6 28/48 -230/290 57 3BA7310-OAT167 .75/.55 200-240/345-415 2.8/1.6 40/68 -250/250 57 3BA7410-OAT167 1.5/1.1 200-240/345-415 5.4/3.1 50/84 -300/380 58 3BA7510-OAT168 2/1.5 200-240/345-415 7.5/4.3 70/120 -370/650 64 3BA7510-OAT268 3/2.2 200-240/345-415 9.7/5.6 70/120 -310/430 64 3BA7610-OAT168 3/2.2 200-240/345-415 9.7/5.6 1 96/163 1 -310/430 65 3BA7610-OAT368 4.4/3.3 200-240/345-415 13/7.5 1 96/163 1 -500/750 65 Table 2. Three-phase, Single -stage, 60 Hz Model Rated Power HP/kW Voltage Motor Current (Amps) Open Flow Capacity CFM/m3/hr Maximum Pressure (mbar) Sound Pressure Level (dBA) 3BA1300-7AT06 .39/.29 220-250/415-460 1.74/1.0 60/102 -100/100 56 2BA1300-7AT16 .67/.5 220-250/415-460 2.6/1.5 60/102 -150/160 56 3BA1400-7AT06 1.12/.83 220-250/415-460 3.75/2.15 105/179 -130/130 64 3BA1400-7AT16 1.28/.95 220-250/415-460 4.35/2.5 105/179 64 3BA1400-7AT26 2/1.5 220-250/415-460 5.5/3.2 105/179 -210/200 64 3BA1500-7AT06 1.28/.95 220-250/415-460 4.35/2.5 150/255 -80/70 70 3BA1500-7AT16 2/1.5 220-250/415-460 5.5/3.2 150/255 -150/140 70 3BA1500-7AT26 2.7/2.05 220-250/415-460 7.5/4.4 150/255 -220/210 70 3BA1500-7AT36 3.4/2.55 220-250/415-460 9.0/5.3 150/255 -260/290 70 3BA1600-7AT06 2.7/2.05 220-250/415-460 7.5/4.4 235/400 -160/150 72 3BA1600-7AT16 3.4/2.55 220-250/415-460 9.0/5.3 235/400 -190/190 72 3BA1600-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 235/400 -240/230 72 3BA1600-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 235/400 -320/310 72 3BA1630-7AT06 2.7/2.05 220-250/415-460 7.5/4.4 300/510 -160/150 72 3BA1630-7AT16 3.4/2.55 220-250/415-460 9.0/5.3 300/510 -190/190 72 3BA1630-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 300/510 -240/230 72 3BA1630-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 300/510 -260/260 72 3BA1800-7AT06 6.1/4.6 220-250/415-460 15.2/8.5 350/595 -160/160 74 3BA1800-7AT16 8.4/6.3 220-250/415-460 20/11.2 350/595 -300/280 74 3BA1800-7AT26 11.5/8.6 220-250/415-460 27.5/15 350/595 -350/400 74 3BA1830-7AT06 6.4/4.6 220-250/415-460 15.2/8.5 500/850 -160/160 79 3BA1830-7AT16 8.4/6.3 220-250/415-460 20/11.2 500/850 -300/280 79 3BA1830-7AT26 11.5/8.6 220-250/415-460 27.5/15 500/850 -350/400 79 3BA1900-7AT06 12.1/9 220-250/415-460 710/1207 79 3BA1900-7AT16 19.5/14.5 220-250/415-460 50/29 710/1207 -270/260 79 3BA1900-7AT36 28.7/21.3 220-250/415-460 68/39 710/1207 79 3BA1930-7AT16 19.5/14.5 220-250/415-460 50/29 930/1581 -270/260 75 3BA1930-7AT36 28.7/21.3 220-250/415-460 68/39 930/1581 -300/280 75 3BA7210-OAT167 1.1/.83 220-250/415-460 3.75/2.15 35/60 -270/320 62 3BA7310-OAT167 1.1/.83 220-250/415-460 3.75/2.15 1 48/82 -260/250 62 3BA7410-OAT167 2/1.5 220-250/415-460 5.5/3.2 1 60/102 -340/370 62 When operating at altitudes above 3280 feet (1000 m) above mean sea level, contact Airtech Inc. CAUTION! Operation of the unit outside the recommended range of pressures and ambient conditions will result in shorted operating life. Table 3. 3 Phase, Two/Three Stage, 50 Hertz Model Rated Power HP/kW Voltage Motor Current (Amps) Open Flow Capacity CFM/m3/hr Maximum Pressure (mbar) Sound Pressure Level (dBA) 3BA1310-7AT26 .94/.7 200-240/345-415 3.8/2.2 48/81.6 -120/120 55 3BA1410-7AT36 2.15/1.6 200-240/345-415 7.5/4.3 84/142.8 -200/190 66 3BA1410-7AT46 2.96/2.2 200-240/345-415 9.7/5.6 84/142.8 -320/420 66 3BA1510-7AT46 4.04/3.0 200-240/345-415 12.5/7.2 121.6/206.7 -340/410 72 3BA1510-7AT56 5.39/4.0 200-240/345-415 17.4/10 121.6/206.7 -390/440 72 3BA1610-7AT36 2.9/2.2 200-240/345-415 9.7/5.6 188/319.6 -190/190 73 3BA1610-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 188/319.6 -260/270 73 3BA1610-7AT36 5.39/4.0 200-240/345-415 13.0/7.5 188/319.6 -290/360 73 3BA1610-7AT46 7.41/5.5 200-240/345-415 23/13.3 188/319.6 -420/500 73 3BA1610-7AT56 10.1/7.5 200-240/345-415 29/16.7 188/319.6 -420/610 73 3BA1640-7AT36 5.39/4.0 200-240/345-415 13.0/7.5 280/476 -290/360 74 3BA1640-7AT46 7.41/5.5 200-240/345-415 23/13.3 280/476 -420/500 74 3BA1640-7AT56 10.1/7.5 200-240/345-415 29/16.7 280/476 -420/610 74 3BA1810-7AT16 7.4/5.5 200-240/345-415 23/13.3 280/476 -420/500 74 3BA1810-7AT26 10.1/7.5 200-240/345-415 29/16.7 280/476 -320/430 74 3BA1810-7AT36 14.8/11 200-240/345-415 29/16.7 280/476 -430/600 74 3BA1810-7AT46 20.2/15 200-240/345-415 56.5/32.5 280/476 -460/670 74 3BA1840-7AT26 10.1/7.5 200-240/345-415 29.0/16.7 280/476 -320/430 74 3BA1840-7AT36 14.8/11.0 200-240/345-415 48.5/28.0 280/476 -430/600 74 3BA1910-7AT16 16.8/12.5 200-240/345-415 48.5/28 624/1061 -290/280 74 3BA1910-7AT36 26.95/20. 200-240/345-415 - 624/1061 - 74 3BA7220-OAT567 2/1.5 200-240/345-415 7.5/4.3 28/48 -370/650 58 3BA7320-OAT467 1.5/1.1 200-240/345-415 5.4/3.1 40/68 -300/380 58 3BA7320-OAT567 2/1.5 200-240/345-415 7.5/4.3 40/68 -480/450 59 3BA7420-OAT267 2/1.5 200-240/345-415 7.5/4.3 50/84 -480/450 61 3BA7420-OAT567 4.4/3.3 200-240/345-415 13/7.5 50/84 -500/750 61 3BA7520-OAT268 3/2.2 200-240/345-415 9.7/5.6 70/120 -470/460 64 3BA7620-OAT368 4.4/3.3 200-240/345-415 13/7.5 96/163 -500/750 68 3BA7620-OAT468 5.4/4 200-240/345-415 14/8.1 96/163 -370/650 67 3BA7620-OAT568 7.5/5.5 200-240/345-415 19.9/11.5 1 96/163 1 -520/750 68 3BA7630-OAT668 10.1/7.5 200-240/345-415 29/16.7 1 96/163 1 -420/610 77 Table 4. 3 Phase, Two/Three Stage, 60 Hertz Model Rated Power HP/kW Voltage Motor Current (Amps) Open Flow Capacity CFM/m3/hr Maximum Pressure (mbar) Sound Pressure Level (dBA) 3BA1310-7AT26 1.11/.83 220-250/415-460 3.75/2.15 60/102 -130/130 61 3BA1410-7AT36 2.7/2.05 220-250/415-460 7.5/4.4 105/179 -220/210 69 3BA1410-7AT46 3.4/2.55 220-250/415-460 9.0/5.3 105/179 -350/440 69 3BA1510-7AT46 4.6/3.45 220-250/415-460 12.0/6.5 152/258 -380/360 74 3BA1510-7AT56 6.1/4.6 220-250/415-460 15.2/8.5 152/258 -410/480 74 3BA1610-7AT36 3.4/2.55 220-250/415-460 9.0/5.3 235/400 -190/190 76 3BA1610-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 235/400 -240/230 76 3BA1610-7AT36 6.4/4.8 220-250/415-460 16.5/9.8 235/400 -320/310 76 3BA1610-7AT46 8.4/6.3 220-250/415-460 20/11.2 235/400 -440/440 76 3BA1610-7AT56 11.5/8.6 220-250/415-460 27.5/15.0 235/400 -440/670 76 3BA1640-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 350/595 -320/310 78 3BA1640-7AT46 8.4/6.3 220-250/415-460 20.0/11.2 350/595 -440/440 78 3BA1640-7AT56 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -440/670 78 3BA1810-7AT16 8.4/6.3 220-250/415-460 20.0/11.2 350/595 -440/440 78 3BA1810-7AT26 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -350/400 78 3BA1810-7AT36 17/12.6 220-250/415-460 50.2/29.0 350/595 -460/600 78 3BA1810-7AT46 23.3/17.3 220-250/415-460 60.0/34.5 350/595 -490/750 78 3BA1840-7AT26 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -350/400 78 3BA1840-7AT36 17/12.6 220-250/415-460 50.2/29.0 350/595 -460/600 78 3BA1910-7AT16 19.5/14.5 220-250/415-460 50.0/29.0 780/1326 -270/260 84 3BA1910-7AT36 31/23 220-250/415-460 --- / --- 780/1326 --- / --- 84 3BA7220-OAT567 2.7/2.05 220-250/415-460 7.5/4.4 35/60 -500/740 62 3BA7320-OAT467 2/1.5 220-250/415-460 5.5/3.2 48/82 -340/370 63 3BA7320-OAT567 2.7/2.05 220-250/415-460 7.5/4.4 48/82 -430/410 63 3BA7420-OAT267 2.7/2.05 220-250/415-460 7.5/4.4 60/102 -430/410 66 3BA7420-OAT567 5.1/3.8 220-250/415-460 13.5/7.8 60/102 -510/850 66 3BA7520-OAT268 3.4/2.55 220-250/415-460 9/5.3 84/143 -500/450 70 3BA7620-OAT368 5.1/3.8 220-250/415-460 13.5/7.8 115/196 -510/850 71 3BA7620-OAT468 6.1/4.6 220-250/415-460 15.2/8.5 115/196 -480/500 71 3BA7620-OAT568 8.4/6.6 220-250/415-460 22.5/12.6 1 115/196 -520/820 72 3BA7630-OAT668 11.5/8.6 220-250/415-460 27.5/15 1 115/196 -440/670 80 Operation of any blower is possible at 87 Hertz without modification. When using a VFD to operate the blower at this frequency, refer to the nameplate for limits on vacuum and pressure, current draw and motor performance. If your specific model number is not listed above, please consult the nameplate on the unit for electrical data. If the model you are installing is listed above, please confirm the data on the nameplate. Data in Tables 1 through 4 is subject to change and is approximate. Be sure to confirm necessary operating data what that on the nameplate before commissioning the unit. CAUTION! Do not operate any 3113A blower above 87 Hz without consultation with the factory. Failure of the blower motor is possible when operating out of range. Consult with the factory for assistance. 9 Expected temperature rise of the handled gas at maximum allowable pressure differential and when operating at sea level is indicated below: Single Stage — Approximate Temperature Rise Blower Model Maximum Rise at 50 Hz speed Degrees F Degrees K Maximum Rise at 60 Hz speed Degrees F Degrees K 3BA1100-7..0. 115 46 136 58 3BA1200-7..0. 65 18 101 38 3BA1300-7..0. 90 32 77 25 3BA1300-7..1. 90 32 140 60 3BA1300-7..2. 90 32 158 70 3BA1400-7..0. 99 37 86 30 3BA1400-7..1. 129 54 122 50 3BA1400-7..2. 149 65 167 75 3BA1500-7..0. 86 30 72 22 3BA1500-7..1. 115 46 97 36 3BA1500-7..2. 138 59 122 50 3BA1500-7..3. 203 95 180 82 3BA1500-7..6. 248 120 248 120 3BA1600-7..0. 81 27 68 20 3BA1600-7..1. 145 63 104 40 3BA1600-7..2. 171 77 176 80 3BA1600-7..3. 225 107 185 85 3BA1600-7..6. 248 120 194 90 3BA1600-7..7. 248 120 248 120 3BA1800-7..0. 104 40 104 40 3BA1800-7..1. 153 67 185 85 3BA1800-7..2. 248 120 221 105 3BA1900-7..0. 97 36 95 35 3BA1900-7..0. 182 83 155 68 3BA1900-7..0. 230 110 212 100 3BA7210-0..1.. 126 52 142 61 3BA7310-0..1.. 142 61 142 61 3BA7310-0..2.. 178 81 187 86 3BA7410-0..1.. 194 90 214 101 3BA7510-0..1.. 199 93 232 111 3BA7510-0..2.. 248 120 234 112 3BA7610-0..1.. 244 118 255 124 3BA7610-0..3.. 244 118 255 124 10 Two/Three Stage — Approximate Temperature Rise Blower Model Maximum Rise at 50 Hz speed Degrees F Degrees K Maximum Rise at 60 Hz speed Degrees F Degrees K 3BA1310-7..2. 127 53 165 74 3BA1410-7..3. 154 68 149 65 3BA1410-7..4. 181 83 180 82 3BA1510-7..4. 190 88 176 80 3BA1510-7..5. 194 90 201 94 3BA1610-7..1. 92 33 86 30 3BA1610-7..2. 129 54 118 48 3BA1610-7..3. 176 80 167 75 3BA1610-7..4. 221 105 190 88 3BA1610-7..5. 246 120 266 130 3BA1610-7..7. 176 80 167 75 3BA1610-7..8. 176 80 248 120 3BA1810-7..1. 113 45 - - 3BA1810-7..2. 185 85 140 60 3BA1810-7..3. 248 120 248 120 3BA1910-7..1. 119 48 115 46 3BA1910-7..2. 203 95 169 76 3BA1910-7..3. 248 12 274 134 3BA7220-0..2.. 131 55 171 77 3BA7220-0..5.. 165 74 230 110 3BA7320-0..5.. 178 81 255 124 3BA7420-0..2.. 192 89 176 80 3BA7420-0..5.. 250 121 243 117 3BA7520-0..2.. 192 89 216 102 3BA7520-0..7.. 257 125 230 110 3BA7620-0..3.. 255 124 259 126 3BA7620-0..5.. 255 124 262 128 3BA7630-0..6.. 248 120 248 120 11 Tightening Torque Specifications For non -electrical connections Thread Ft -lbs maximum torque Nm maximum torque M42.43 0.6 to 0.9 3.3 M5 3.25 4.4 M6 6.49 8.8 M8 19.47 26.4 M10 34.10 46.2 M12 56.76 77 For electrical connections Thread Ft -lbs torque Nm torque M4 0.6 to 0.9 0.8 to 1.2 M5 1.3 to 1.8 1.3 to 1.8 For metal threaded glands/unions Thread Ft -lbs maximum torque Nm maximum torque M12x1.5 3to4.5 4to6 M16x1.5 3.7 to 5.5 5to7.5 M20x1.5 4.4 to 6.6 6 to 9 M32x1.5 5.9 to 8.9 8 to 12 M40x1.5 5.9 to 8.9 8 to 12 For plastic threaded qlands/unions Thread Ft -lbs maximum torque Nm maximum torque M12x1.5 1.5 to 2.6 2to3.5 M16x1.5 2.2to3 3to4 M20x1.5 3to3.7 4to5 M32x1.5 3.7 to 5.2 5 to 7 M40x1.5 3.7 to 5.2 5 to 7 12 Operating above the indicated maximum pressure or vacuum would overload the motor and/or overheat the unit. In addition to the maximum allowable pressure difference, careful consideration should be given to matching the motor protection devices (provided by others) to the expected current draw. In no case should the blower be operated with inadequate motor overload protection. Since regenerative blowers are dynamic compression devices, the performance limits shown in Tables 1 to 4 are applicable only for a gas with the same specific gravity, dynamic viscosity and chemical characteristics as air. For gases with different physical properties than air, the limits will be different from those shown in the tables. Please contact Airtech for assistance in determining the proper blower size and configuration if handling gases other than air. A vacuum relief valve or pressure relief valve should always be installed at the suction or discharge of the regenerative blower. This will prevent operation outside the applicable ranges shown in Tables 1 to 4. If the relief valves were not specified in the ordering process, please contact Airtech for details, price and availability of the needed valves before commissioning the unit. Failure to use the proper relief valve may result in failure of the blower due to operation outside the applicable limits; any such failure is outside the scope of Airtech's standard warranty. WARNING! Be sure to install the necessary personnel protection devices if unexpected shut -down of the unit presents danger of death or injury. 13 2. Installation As illustrated in Figure 1, the Airtech 313A blower can be installed in any physical configuration. CAUTION! Regenerative blowers can have surface temperatures in excess of 120 F. To avoid burns or other physical injury, take care to avoid contact with the surfaces of the blower during and immediately after operation. To ensure adequate cooling of the blower during operation, install the blower with the minimum clearance as indicated in the table below. Minimum installation clearances, 313A blowers Range Distance from fan guard to closest obstruction. (inches/mm) Distance from cover (opposite of fan) to closest obstruction. (inches/mm) 3BA11 through 3BA14 1.4/34 0.79/20 3BA15 through 3BA19 2.1/53 1.57/40 3BA72 and 3BA73 1.3/34 1.18/30 3BA74 through 3BA76 2.1/54 1.18/30 Please note that it may be desirable, where possible, to allow for larger clearances to allow access for maintenance or repair personnel. The noted clearances are to ensure adequate air flow for cooling only and are a minimum requirement. Failure to allow for the noted clearances may result in premature failure of the blower due to lack of cooling, even if all other precautions are taken as recommended. For specific advice about installations requiring closer clearances, please contact Airtech, Inc. for recommendations. Airtech regenerative blowers can be mounted in any configuration, either horizontally or vertically mounted. It is not usually necessary to bolt the smaller blowers to a rigid surface during operation, though this may be desirable to reduce pipe vibration, movement and noise. Larger models should be bolted in place, especially when installed vertically, to prevent possible rotation, damage or injury due to start-up torque. CAUTION! For installations at altitudes greater than 3250 Feet above sea level there will be a loss in capacity. Please contact your factory representative for assistance in determining the extent of the loss of capacity likely at your specific location. WARNING! Be sure to follow all local codes and regulations with respect to installation and operation of the blower. The blower motor should be wired to a branch circuit disconnect and all other safety devices recommended by the relevant sections of NFPA 70, National Electrical Code, and in accordance with all applicable state and local regulations and requirements. Installation Procedure Perform the installation exactly in accordance with the following steps: 1. For vacuum operation, connect the suction pipe to connection A, and for pressure operation connect the pressure pipe to connection B (See Figure 1). Install startup screens before startup to protect pump from debris. Compressor Vacuum Connection Connection (pump inM - A) (pump outlet - B) Pump Cutaway CAUTION! Design your piping system to avoid unnecessary pressure loss, which may significantly affect the operation of any regenerative blower. Contact your Airtech representative for assistance in designing and configuring an appropriate piping system for your application. Figure i For alternation between vacuum and pressure in any application, changeover valves are available. Use of the changeover valve allows the same connection to be used for both vacuum and pressure. 2. The electrical data shown in Tables 1 to 4 should be confirmed by examination of the motor data plate on your 3BA blower. The motors feature Class F insulation as a standard and are UL recognized for applications in both Canada and the United States (CUL). Motors are IEC design IP55, equal to a NEMA TEFC motor design. The connection diagram for the motors can be found in the inside of the terminal box cover. Be sure to confirm that your electrical supply has sufficient capacity to operate the blower according to the nameplate requirements. 3. A magnetic motor starter should always be used to connect the motor to the power supply. It is advisable to use thermal overload motor starters to provide 15 maximum protection for the motor and wiring. All cabling used on starters should be secured with good quality cable clamps. We recommend that the motor starters used feature a time delay trip on high amperage to avoid nuisance trips on start-up. When the unit is started cold, over amperage may be experienced for a short time due to the higher resistance of the windings at lower temperatures. If using a change over or solenoid valve, ensure that the voltage connected to the valve matches that shown on the valve instructions or nameplate. Most valves are rated for 110 Volts 60Hz or 220 Volts 50 Hz. Connection of these valves to higher voltages may result in immediate valve failure. WARNING! The electrical installation should be made by a qualified electrician and in complete compliance with all NFPA 70 (National Electrical Code) requirements along with all state and local code requirements. The main disconnect and motors starters are assumed to be provided by others. 4. Install the necessary relief valves and confirm their proper operation. 16 3. Start-up CAUTION! Do not start the blower motor more than 10 times in one hour. If multiple and frequent start-ups are required by your application, install a minimum run timer in the motor control circuit to avoid decreased motor life and possible fire due to over -starting of the motor. 1. Before operation, confirm the correct direction of rotation by jogging (switching rapidly on and off) the motor and observing the motor fan rotation in the same direction as the arrow. If the direction of rotation is incorrect, lock out the power and switch two leads (three phase) or rewire (single phase) to effect the opposite rotation direction. Recheck the direction of rotation before proceeding. 2. Do not operate the blower at pressure or vacuum ranges that exceed those shown in Tables one through four for the model being installed. This can be achieved by use of the recommended relief valve shown in Table 5. Note: Relief valves that have been factory pre-set have a label indicating the set pressure and an arrow indicating the direction of flow. The arrow will point into the pipe when installed in vacuum applications and out of the pipe when installed in pressure applications. Do not re -set the relief valve if it has been pre-set from the factory. In the event the relief valve setting needs to be reset, adjust the set screw to increase or decrease the tension on the spring. Place the blower in operation and note the current draw of the motor. When the current draw of the motor is near the maximum noted on the motor nameplate, tighten the locking nut on the valve and proceed. 3. When checking the current draw of the motor with an ammeter, be sure to confirm the voltage at the motor junction box. Low voltage conditions may result in difficulty starting or in unexpected motor failure or motor starter trips. Potential Risks for Operators Noise emission: Free field noise limits are indicated in Tables one through four. Hearing protection is not normally required at the expected noise generation levels in the table; however, local conditions may result in higher ambient noise. If this is the case and local noise exceeds OSHA recommended levels for expected exposure time (typically 85 dBA for eight hours), hearing protection should be used. 17 4. Maintenance and Servicing WARNING! Be sure the power supply is disconnected and locked out before attempting to do any maintenance on the unit. It is critical that the unit be locked out from starting during maintenance as severe injury or death could result from exposure to high voltage or rotating parts. CAUTION! Allow the blower to cool to a surface temperature of lees than 100 F before attempting maintenance. Prolonged exposure to temperatures above 120F can cause severe burns. Clean the blower surfaces periodically to avoid build up of dust or other debris. Build up of debris can cause overheating and premature failure of the blower. If an inlet filter is being use, ensure that it remains clean during operation by examining the filter cartridge for debris build up. Replace dirty or clogged filter cartridges. On pressure units, periodically clean the inlet mesh screen to avoid loss of capacity. If an external inlet filter is used, All INLET OUTLET Figure 2 the filter element should be cleaned monthly or as frequently as required by local conditions. Excessive pressure drop will develop from use of clogged or dirty filters. This pressure drop will degrade blower performance and increase operating temperatures, leading possibly to premature pump failure. To replace the filter, remove the wing nut and cover. Remove the element and either clean with compressed air or replace. Reassemble in reverse order. For vacuum applications, the optional in-line vacuum filter must be cleaned regularly, depending on local conditions. Cleaning can be achieved by blowing out with compressed air. If cleaning is not possible, replace the cartridge. Access the cartridge by unhooking the relevant clips and removing the cover. CAUTION! Do not attempt to check the filter cartridge during operation of the blower. Only check the cartridge after disconnecting the power from the blower and locking out the power to prevent an unexpected start. 011 Inline F ler for Vacuum Se mice Figure 3 Bearings require regreasing with Exxon/Esso UNIREX N3 or equal grease after approximately 20,000 operating hours (normal conditions) or between 2 and 3 years after installation and commissioning. Do not mix grease types. Troubleshooting Chart Fault Cause Remedy Responsible Party Motor does Two or more Check fuses, terminals, etc.. for Electrician not start, no power legs source of interruption and noise. interrupted correct. Motor does One power Check fuses, terminals, etc.. for Electrician not start, supply lead source of interruption and humming interrupted correct. noise. Impeller is Open blower cover, remove Service jammed. debris, clean. Technician Check impeller clearance and reset if necessary. Defective Replace impeller. Service Impeller Technician Defective Replace defective bearing. Service Bearing Technician Trip of motor Incorrect Ensure starter setting is correct Electrician starter at starter setting (check current on nameplate) start-up Winding short- Megger motor Electrician circuit Motor Inspect filters, mufflers and Operator overloaded connection pipes and clean as due to required. operation of pump at Check relief valve operation. excessive Reset or replace as necessary. differential pressures. Impeller See above fault Motor does not Operator Jammed start, humming noise, cause jammed impeller. Excessive Lime or other Decalcify or clean unit as Operator Power deposits required (see Maintenance Consumption Chart) No Vacuum Severe leak in Close off pump and run Operator or Pressure. system deadheaded to confirm pump is operating properly. If so, find and fix leak in the system. Wrong Check air flow direction and Operator direction of change direction of rotation if Electrician rotation necessary. 19 Insufficient System too Use larger system Operator Vacuum small Inlet piping too Increase pipe diameter to Operator long or too reduce pressure loss in inlet small. piping. Contact Airtech for assistance in determining correct pipe size. Leak at Check for leaks and repair if Operator connection to necessary. vacuum system. Density of gas Consider increased limits on Airtech handles operation due to density Engineering different from differences. Consult Airtech, air. Inc. for assistance. Change in Clean impeller and examine for Service impeller wear. Replace if necessary. Technician geometry due to erosion Inlet filter Change filter element; remove Operator clogged. clog. Vacuum relief Reset or replace vacuum relief Operator valve valve. Contact Airtech for incorrectly set. assistance. Seal defective. Replace seal. Service Technician Abnormal Flow speed Clean pipes or use larger pipes Operator flow noises. too high. to connect unit to process. Muffler soiled. Clean muffler inserts, replace if Operator necessary. Abnormal Ball bearing Re -grease or replace bearing Service running noise defective or as required. Technician insufficient lubrication on bearing. Compressor Seals on Tighten muffler connection. Operator leaky muffler Replace gasket if necessary. defective. Seals in motor Replace as necessary. Service area defective Technician Repair on-site WARNING! Before attempting an on-site repair, ensure that a qualified electrician has disconnected the motor from the power supply so that accidental starting of the motor is impossible. After a repair and before re -installation be sure to follow the instructions noted in this manual under "Installation and Operation." Lifting For smaller units (less than 65 lbs/ 30 kgs), it may be possible to lift the units manually. When doing so, be sure to understand the weight of the unit being lifted and to follow good lifting safety procedures. Model weight Lbs/kgs Model weight Lbs/kgs 3BA1300-7AT06 20/9 3BA1310-7AT26 33/15 2BA1300-7AT16 22/10 3BA1410-7AT36 55/25 3BA1400-7AT06 29/13 3BA1410-7AT46 59.5/29 3BA1400-7AT26 37.5/17 3BA1510-7AT46 86/39 3BA1500-7AT06 40/18 3BA1510-7AT56 97/44 3BA1500-7AT16 46.5/21 3BA1610-7AT26 104/47 3BA1500-7AT26 51/23 3BA1610-7AT36 119/54 3BA1500-7AT36 55/25 3BA1610-7AT46 163/74 3BA1600-7AT06 57.5/26 3BA1610-7AT56 172/78 3BA1600-7AT16 64/29 3BA1640-7AT36 128/58 3BA1600-7AT26 75/34 3BA1640-7AT46 172/78 3BA1600-7AT36 90.5/41 3BA1640-7AT56 181/82 3BA1800-7AT06 128/58 3BA1810-7AT16 250/113 3BA1800-7AT16 143/65 3BA1810-7AT26 260/118 3BA1800-7AT26 150/68 3BA1810-7AT36 316/143 3BA1900-7AT06 265/120 3BA1810-7AT46 341/155 3BA1900-7AT16 314/142 3BA1840-7AT26 260/118 3BA1840-7AT36 316/143 3BA1910-7AT16 409/186 3BA1910-7AT36 455/206 3BA7210-OAT167 35.3/16 3BA7220-OAT567 61.7/28 3BA7310-OAT167 35.3/16 3BA7320-OAT567 66.1/30 3BA7410-OAT167 50.7/23 3BA7420-OAT267 72.7/33 3BA7510-OAT168 57.3/26 3BA7420-OAT567 86/39 3BA7510-OAT268 63.9/29 3BA7520-OAT268 88.2/40 3BA7610-OAT168 70.5/32 3BA7620-OAT368 106/48 3BA7610-OAT368 77.2/35 3BA7620-OAT568 143/65 3BA7630-OAT668 207/94 21 When lifting 3BA15 through 3BA19 (but not 3BA1943 units) or the 3BA75 through the 3BA76, use the eye bolt provided (eye bolts are not included on smaller units). One attachment point should be sufficient. Ensure that the crane is rated for the weight being lifted. For the 3BA1943, use the eye bolt and the holes in the feet of the blower to lift and maintain a balanced load. Storage The 3BA units should be stored in a clean, dry environment. If stored in an area with a humidity of greater than 80 percent, store in a closed container with desiccant drying agents to avoid damage. Disposal Dispose in accordance with all local health and safety regulations. Spare parts list are available from your local Airtech service center. Please contact your local Airtech representative for assistance. For additional assistance, please contact: Airtech, Inc., 150 South Van Brunt Street Englewood, NJ, 07631 Phone: 1-201-569-1173 Fax: 201-569-1696. 22 2.08 2.07 1.04 2.06- 2.05 2.04 2.03 2.02 2.01 M � 0 1.02 3BA1 SINGLE STAGE EXPLODED VIEW 3.1 311 -3.15 3.07 3.10 -� 3.16 3.06- 3.05 3.08-- -. 3.04 3.13 3.03 b 3.18 3.01 4.05 - 3.1 7 .14.04 3.19 : 017 1.12 4.03 -1.10r • -4.02 x1.09 } -4.01 1.08 1.03 1.07 1.06 -1.05 23 4.07 4.06 36A1 TWO STAGE 4.12 -Vf EXPLODED VIEW 4.09 4.11 4.10 3.15 4A8 4.06 3.16 3.17 4.07 4.05 3.12 3.D9 d 3.08 3.13' 4.01 3.07 4.12 18 f 4.04 3.06 3.�- 4.11 4.13 % 3.05` 3.19' -4.10 3.02 3.10. � ��. 3.01- v 3.04 3.14 - 4.49 1.17 3.20 4.08 1.03 r 4.03 4.07 2.aa3 04 r )- 4.06 2.07 1.1 fi- 2.06 2.09 3.03 1.15 4.01 2 4.05 2.04 4.04 2.03 1'p2 _ 1.10 4.01 r 2.02 i 1.09 4.02 2.D1 4.01 1.01 1.08 1.13 2.0706 1.04 1.12 1.07 1..0 1.11 � 1.d5 T.14 t 24 -4.13 -4.11 X4.12 O�' .-4.01 4.02 - - ------- 4.10 3BA7 SINGLE STAGE EXPLODED VIEW 3.08 3.07 105- -3.09 3.06- 0 3.05 -3.12 3.13 3.04 103- 3.14 3.02 404 1.14 O� i 2.08- 1.02 403 2.09 k 402 2.10 ;% ) 4.05 ' 4.05 2.10--4D1 2 08 109 3.15 - k� � t;�o -4.04 �,, 2.04-- r�15 w 1-7�0 2.03 2.02 1.01- 2.01 1.13 1.12 1,11 1,10 4.06 9 4V 4.07 4.08 +r ri --4.03 3.01 -1.09 -4.02 1.08 4,01 1.06 4.09 2,07 --1.07 2.06 2.05 -1,03 --1,05 1.04 25 1.01 1.15 1.14 1.13 M2 4,02 4.03 4.04 ya ti :. 4.09 4.01 4.06 4.07 4.05 4.08 3BA7 TWO STAGE EXPLODED VIEW 3.06 3.05 3.09 3.03 3.10 3.06 3.11 3.04 3.08 3.13 3.03 3.07 3.14 3.02 3.0 T 1.19 7.}6 1.20 2.12 i.l$ 8 b L 3.12 1.17- 4.01 2.13- 1.03 ' 4,0$ 1.2] 2.11 T 2.14 4.07 4.06 2.10 3.16 2.09 i 2.07 4.09 1.02 2.08 ti -+' 7.10 ` 2.14 4.02 2.14 }}} 2,13 1 1.09 -4.01 2.12 1.D8 -4.09 ` 2.12 1.04 7.06 2 D7 2.13 1.05 2.14 2.13 2.12 M6 2.05 2.04 2.03 2.02 2.01 26 3,15 4.05 4.04 4.03 Airtech, Inc. ("Company") Warranty Statement Company warrants that on the date of shipment to Purchaser the goods will be of the kind and quality described herein, merchantable, and free of all defects in workmanship and materials. If within one year from the date of initial operation, but not more than eighteen months from date of shipment by the Company, of any item of the goods, Purchaser discovers that such item was not as warranted above and promptly notifies Company in writing thereof, Company shall remedy such defect by, at the Company's option, adjustment, repair or replacement of the item and any affected part of the good. Purchaser shall assume all responsibility and expense for removal, reinstallation and freight in connection with the foregoing remedy. The same obligations and conditions shall extend to replacement items furnished by the Company hereunder. Company shall have the right of disposal of items replaced by it. Purchaser shall grant Company access to the goods at all reasonable times in order for Company to determine any defect in the goods. In the event that adjustment, repair or replacement does not remedy the defect, the Company and Purchaser shall negotiate in good faith an equitable adjustment in the contract price. The Company's responsibility does not extend to any item of the goods which has not been manufactured and sold by the Company. Such item shall be covered only by the express warranty, if any, by the manufacturer thereof. The Company and its suppliers shall also have no responsibility if the goods have been improperly stored, handled or installed, or if the goods have not been operated or maintained according to their ratings or according to the instructions in Company or supplier furnished manuals, or if unauthorized repairs or modifications have been made to the goods. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES (EXCEPT TITLE) INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS, AND CONSTITUTES THE ONLY WARRANTY OF COMPANY WITH RESPECT TO THE GOODS. The forgoing states Purchaser's exclusive remedy against Company and its suppliers for any defect in the good or for failure of the goods to be as warranted, whether Purchaser's remedy is based on contract, warranty, failure of such remedy to achieve its essential purpose, tort (including negligence), strict liability, indemnity, or any other legal theory, and whether arising out of warranties, representations, instructions, installations, or defects from any cause. Neither Company nor its suppliers shall be liable, whether in contract, warranty, failure of a remedy to meet its essential purpose, tort (including negligence), strict liability, indemnity or any other legal theory, for loss of use, revenue or profit or for cost of capital or of substitute use or performance or for indirect, liquidated, incidental or consequential damages or for any other loss or cost of a similar type, or for claims by Purchaser for damages of Purchaser's customers. 27 For Further Information Please contact: AIRT=CH° 150 South Van Brunt St. Englewood, NJ 07631 Tel: 1-888-222-9940 Fax: 201-569-1696 airtech@airtechusa.com AIRT=CK SOUTH 2211 Newmarket Parkway Marietta, GA 30067 Tel: 770-690-0700 Fax: 770-690-0709 airtechsouth@airtechusa.com www.airtechusa.com AIRT=CHOWEST 7�Z777775oo 42 Digital Drive #9 Novato, CA 94949 Tel: 415-382-9000 Fax: 415-382-9700 airtechwest@airtechusa.com docs\Literature\Manuals\3BA Manual\3BA OAM 02-09 HITACHI Inspire the Next SJ200 Series Inverter Instruction Manual • Single-phase Input 200V Class • Three-phase Input 200V Class • Three-phase Input 400V Class Manual Number: NB650XA March 2004 After reading this manual, keep it handy for future reference. Hitachi Industrial Equipment Systems Co., Ltd. SJ200 Inverter Safety Messages For the best results with the SJ200 Series inverter, carefully read this manual and all of the warning labels attached to the inverter before installing and operating it, and follow the instructions exactly. Keep this manual handy for quick reference. Definitions and Symbols A safety instruction (message) includes a "Safety Alert Symbol" and a signal word or phrase such as WARNING or CAUTION. Each signal word has the following meaning: AHIGH VOLTAGE: This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operation this equipment. Read the message and follow the instructions carefully. AWARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious injury or death. ICAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor to moderate injury, or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as WARNING), so be sure to observe them. 4[ -Step 1: Indicates a step in a series of action steps required to accomplish a goal. The number of the step will be contained in the step symbol. NOTE: Notes indicate an area or subject of special merit, emphasizing either the product's capabilities or common errors in operation or maintenance. TIP: Tips give a special instruction that can save time or provide other benefits while installing or using the product. The tip calls attention to an idea that may not be obvious to first-time users of the product. Hazardous High Voltage A HIGH VOLTAGE: Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing drives and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking com- ponents. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery. General Precautions - Read These First! !WARNING: This equipment should be installed, adjusted, and serviced by qualified electrical maintenance personnel familiar with the construction and operation of the equipment and the hazards involved. Failure to observe this precaution could result in bodily injury. AeWARNING: The user is responsible for ensuring that all driven machinery, drive train mechanism not supplied by Hitachi Industrial Equipment Systems Co., Ltd., and process line material are capable of safe operation at an applied frequency of 150% of the maximum selected frequency range to the AC motor. Failure to do so can result in destruction of equipment and injury to personnel should a single -point failure occur. WARNING: For equipment protection, install a ground leakage type breaker with a fast A!* response circuit capable of handling large currents. The ground fault protection circuit is not designed to protect against personal injury. AiWARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING POWER BEFORE WORKING ON THIS CONTROL. WARNING: Wait at least five (5) minutes after turning OFF the input power supply A!* y before performing maintenance or an inspection. Otherwise, there is the danger of electric shock. CAUTION: These instructions should be read and clearly understood before working A!* g on SJ200 series equipment. CAUTION: Proper grounds, disconnecting devices and other safety devices and their A!e r location are the responsibility of the user and are not provided by Hitachi Industrial Equipment Systems Co., Ltd. CAUTION: Be sure to connect a motor thermal disconnect switch or overload device to A the SJ200 series controller to assure that the inverter will shut down in the event of an overload or an overheated motor. AiHIGH VOLTAGE: Dangerous voltage exists until power light is OFF. Wait at least five (5) minutes after input power is disconnected before performing maintenance. WARNING: This equipment has high leakage current and must be permanently (fixed) A!hard-wired ) to earth ground via two independent cables. SJ200 Inverter IWARNING: Rotating shafts and above -ground electrical potentials can be hazardous. Therefore, it is strongly recommended that all electrical work conform to the National Electrical Codes and local regulations. Installation, alignment and maintenance should be performed only by qualified personnel. Factory -recommended test procedures included in the instruction manual should be followed. Always disconnect electrical power before working on the unit. CAUTION: ! a) Class I motor must be connected to earth ground via low resistive path (< O.1Q) b) Any motor used must be of a suitable rating. c) Motors may have hazardous moving parts. In this event suitable protection must be provided. ICAUTION: Alarm connection may contain hazardous live voltage even when inverter is disconnected. When removing the front cover for maintenance or inspection, confirm that incoming power for alarm connection is completely disconnected. ICAUTION: Hazardous (main) terminals for any interconnection (motor, contact breaker, filter, etc.) must be inaccessible in the final installation. f CAUTION: This equipment should be installed in IP54 or equivalent (see EN60529) enclosure. The end application must be in accordance with BS EN60204-1. Refer to the section "Choosing a Mounting Location" on page 2-10. The diagram dimensions are to be suitably amended for your application. CAUTION: Connection to field wiring terminals must be reliably fixed having two ! independent means of mechanical support. Use a termination with cable support (figure below), or strain relief, cable clamp, etc. O Terminal (ring lug) �wLM ZS• Cable CAUTION: A double -pole disconnection device must be fitted to the incoming main power supply close to the inverter. Additionally, a protection device meeting IEC947-1/ IEC947-3 must be fitted at this point (protection device data shown in "Determining Wire and Fuse Sizes" on page 2-18). NOTE: The above instructions, together with any other requirements highlighted in this manual, must be followed for continued LVD (European Low Voltage Directive) compliance. Index to Warnings and Cautions in This Manual Cautions and Warnings for Orientation and Mounting Procedures Ai CAUTION: Hazard of electrical shock. Disconnect incoming power ....... 2-4 before working on this control. Wait five (5) minutes before removing the front cover. CAUTION: Be sure to install the unit on flame -resistant material such as ..... 2-10 AGO! a steel plate. Otherwise, there is the danger of fire. A*! CAUTION: Be sure not to place any flammable materials near the ..... 2-10 inverter. Otherwise, there is the danger of fire. I CAUTION: Be sure not to let the foreign matter enter vent openings in ..... 2-10 the inverter housing, such as wire clippings, spatter from welding, metal shavings, dust, etc. Otherwise, there is the danger of fire. A*weight CAUTION: Be sure to install the inverter in a place that can bear the ..... 2-10 according to the specifications in the text (Chapter 1, Specifica- tions Tables). Otherwise, it may fall and cause injury to personnel. AS! CAUTION: Be sure to install the unit on a perpendicular wall that is not ..... 2-10 subject to vibration. Otherwise, it may fall and cause injury to personnel. AS! CAUTION: Be sure not to install or operate an inverter that is damaged ..... 2-10 or has missing parts. Otherwise, it may cause injury to personnel. A! CAUTION: Be sure to install the inverter in a well -ventilated room that ..... 2-10 does not have direct exposure to sunlight, a tendency for high tempera- ture,, high humidity or dew condensation, high levels of dust, corrosive gas, explosive gas, inflammable gas, grinding -fluid mist, salt damage, etc. Otherwise, there is the danger of fire. A! CAUTION: Be sure to maintain the specified clearance area around the ..... 2-11 inverter and to provide adequate ventilation. Otherwise, the inverter may overheat and cause equipment damage or fire. Wiring - Warnings for Electrical Practices and Wire Specifications I WARNING: "Use 60/75°C Cu wire only" or equivalent. 217 WARNING: "Open Type Equipment." ..... 217 IN7 WARNING: "Suitable for use on a circuit capable of delivering not more ..... 2-17 than 5,000 rms symmetrical amperes, 240 V maximum." For models with A!eh suffix N or L. SJ200 Inverter Wiring - Cautions for Electrical Practices A! ' CAUTION: Fasten the screws with the specified fastening torque in the .... 2-19 table below. Check for any loosening of screws. Otherwise, there is the danger of fire. CAUTION: Be sure that the input voltage matches the inverter specifica- .... 2-20 ! tions: • Single/Three phase 200 to 240 V 50/60 Hz (up to 2.2kW) for NFEF/NFU models • Three phase 200 to 240V 50/60Hz (above 2.2kW) for LFU models • Three phase 380 to 480 V 50/60Hz for HFEF models A! CAUTION: Be sure not to power a three -phase -only inverter with single .... 2-20 A! phase power. Otherwise, there is the possibility of damage to the inverter and the danger of fire. CAUTION: Be sure not to connect an AC power supply to the output .... 2-21 A! terminals. Otherwise, there is the possibility of damage to the inverter and the danger of injury and/or fire. SJ200 Inverter Power Input Output to Motor � I F_ I MMM H D41 14 11 ��_A WARNING: "Suitable for use on a circuit capable of delivering not more .... 2-17 A! I than 5,000 rms symmetrical amperes, 480 V maximum." For models with suffix H. Ai HIGH VOLTAGE: Be sure to ground the unit. Otherwise, there is a .... 2-17 danger of electric shock and/or fire. HIGH VOLTAGE: Wiring work shall be carried out only by qualified .... 2-17 A personnel. Otherwise, there is a danger of electric shock and/or fire. Ai HIGH VOLTAGE: Implement wiring after checking that the power .... 2-17 supply is OFF. Otherwise, you may incur electric shock and/or fire. Ai HIGH VOLTAGE: Do not connect wiring to an inverter or operate an .... 2-17 inverter that is not mounted according the instructions given in this manual. Otherwise, there is a danger of electric shock and/or injury to personnel. A! WARNING: Make sure the input power to the inverter is OFF. If the drive .... 2-23 has been powered, leave it OFF for five minutes before continuing. Wiring - Cautions for Electrical Practices A! ' CAUTION: Fasten the screws with the specified fastening torque in the .... 2-19 table below. Check for any loosening of screws. Otherwise, there is the danger of fire. CAUTION: Be sure that the input voltage matches the inverter specifica- .... 2-20 ! tions: • Single/Three phase 200 to 240 V 50/60 Hz (up to 2.2kW) for NFEF/NFU models • Three phase 200 to 240V 50/60Hz (above 2.2kW) for LFU models • Three phase 380 to 480 V 50/60Hz for HFEF models A! CAUTION: Be sure not to power a three -phase -only inverter with single .... 2-20 A! phase power. Otherwise, there is the possibility of damage to the inverter and the danger of fire. CAUTION: Be sure not to connect an AC power supply to the output .... 2-21 A! terminals. Otherwise, there is the possibility of damage to the inverter and the danger of injury and/or fire. SJ200 Inverter Power Input Output to Motor � I F_ I MMM H D41 14 11 ��_A Ae! CAUTION: Remarks for using ground fault interrupter breakers in the ..... 2-21 main power supply: Adjustable frequency inverters with CE -filters (RFI - filter) and shielded (screened) motor cables have a higher leakage current toward Earth GND. Especially at the moment of switching ON this can cause an inadvertent trip of ground fault interrupters. Because of the rectifier on the input side of the inverter there is the possibility to stall the switch -off function through small amounts of DC current. Please observe the following: • Use only short time -invariant and pulse current -sensitive ground fault interrupters with higher trigger current. • Other components should be secured with separate ground fault interrupters. • Ground fault interrupters in the power input wiring of an inverter are not an absolute protection against electric shock. A! ' CAUTION: Be sure to install a fuse in each phase of the main power ..... 2-21 supply to the inverter. Otherwise, there is the danger of fire. CAUTION: For motor leads, ground fault interrupter breakers and ..... 2-21 ! electromagnetic contactors, be sure to size these components properly (each must have the capacity for rated current and voltage). Otherwise, there is the danger of fire. Powerup Test Caution Messages A0S! CAUTION: The heat sink fins will have a high temperature. Be careful ..... 2-24 not to touch them. Otherwise, there is the danger of getting burned. I CAUTION: The operation of the inverter can be easily changed from low ..... 2-24 speed to high speed. Be sure to check the capability and limitations of the motor and machine before operating the inverter. Otherwise, there is the danger of injury. A' CAUTION: If you operate a motor at a frequency higher than the inverter .... 2-24, A standard default setting (50Hz/60Hz), be sure to check the motor and ..... 2-30 machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage and/or injury. AeOtherwise, CAUTION: Check the following before and during the powerup test. ..... 2-24 there is the danger of equipment damage. • Is the shorting bar between the [+1] and [+] terminals installed? DO NOT power or operate the inverter if the jumper is removed. • Is the direction of the motor rotation correct? • Did the inverter trip during acceleration or decelera- tion? • Were the rpm and frequency meter readings as expected? • Were there any abnormal motor vibrations or noise? SJ200 Inverter Warnings for Configuring Drive Parameters At WARNING: When parameter BO 12, level of electronic thermal setting, is .... 3-32 set to motor FLA rating (Full Load Ampere nameplate rating), the inverter provides solid state motor overload protection at 115% of motor FLA or equivalent. If parameter BO 12 exceeds the motor FLA rating, the motor may overheat and be damaged. Parameter BO 12, level of electronic thermal setting, is a variable parameter. Cautions for Configuring Drive Parameters I CAUTION: Be careful to avoid specifying a braking time that is long .... 3-19 enough to cause motor overheating. If you use DC braking, we recom- mend using a motor with a built-in thermistor, and wiring it to the inverter's thermistor input (see "Thermistor Thermal Protection" on page 4-25). Also refer to the motor manufacturer's specifications for duty -cycle recommendations during DC braking. Warnings for Operations and Monitoring WARNING: Be sure to turn ON the input power supply only after closing ...... 4=3 ! the front case. While the inverter is energized, be sure not to open the front case. Otherwise, there is the danger of electric shock. A!Otherwise, WARNING: Be sure not to operate electrical equipment with wet hands. ...... 4=3 there is the danger of electric shock. WARNING: While the inverter is energized, be sure not to touch the ...... 4-3 ! inverter terminals even when the motor is stopped. Otherwise, there is the danger of electric shock. WARNING: If the Retry Mode is selected, the motor may suddenly ...... 4=3 i restart after a trip stop. Be sure to stop the inverter before approaching the machine (be sure to design the machine so that safety for personnel is secure even if it restarts.) Otherwise, it may cause injury to personnel. I WARNING: If the power supply is cut OFF for a short period of time, the ...... 4=3 inverter may restart operation after the power supply recovers if the Run command is active. If a restart may pose danger to personnel, so be sure to use a lock -out circuit so that it will not restart after power recovery. Otherwise, it may cause injury to personnel. A! ' WARNING: The Stop Key is effective only when the Stop function is ...... 4=3 enabled. Be sure to enable the Stop Key separately from the emergency stop. Otherwise, it may cause injury to personnel. A! WARNING: During a trip event, if the alarm reset is applied and the Run ...... 4=3 command is present, the inverter will automatically restart. Be sure to apply the alarm reset only after verifying the Run command is OFF. Otherwise, it may cause injury to personnel. Cautions for Operations and Monitoring CAUTION: The heat sink fins will have a high temperature. Be careful ....... 44=2 ! not to touch them. Otherwise, there is the danger of getting burned. ACAUTION: The operation of the inverter can be easily changed from low ....... 44=2 e speed to high speed. Be sure check the capability and limitations of the motor and machine before operating the inverter. Otherwise, it may cause injury to personnel. CAUTION: If you operate a motor at a frequency higher than the inverter ....... 44=2 A standard default setting (50Hz/6OHz), be sure to check the motor and machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage. CAUTION: It is possible to damage the inverter or other devices if your ....... 4-4 application exceeds the maximum current or voltage characteristics of a A! connection point. CAUTION: Be sure to turn OFF power to the inverter before changing ....... 44=9 Ase! the SR/SK switch position. Otherwise, damage to the inverter circuitry may occur. CAUTION: Be careful not to turn PID Clear ON and reset the integrator ..... 4-28 sum when the inverter is in Run Mode (output to motor is ON). Other- wise, this could cause the motor to decelerate rapidly, resulting in a trip. WARNING: Be sure not to touch the inside of the energized inverter or to ....... 4-3 A! ' put any conductive object into it. Otherwise, there is a danger of electric shock and/or fire. Ae WARNING: If power is turned ON when the Run command is already ....... 44=3 active, the motor will automatically start and injury may result. Before turning ON the power, confirm that the RUN command is not present. When the Stop key function is disabled, pressing the Stop ....... 44=3 !WARNING: key does not stop the inverter, nor will it reset a trip alarm. A! I WARNING: Be sure to provide a separate, hard -wired emergency stop ....... 44=3 switch when the application warrants it. A WARNING: If the power is turned ON and the Run command is already ..... 4-12 active, the motor starts rotation and is dangerous! Before turning power ON, confirm that the Run command is not active. Ae WARNING: After the Reset command is given and the alarm reset ..... 4-24 occurs, the motor will restart suddenly if the Run command is already active. Be sure to set the alarm reset after verifying that the Run command is OFF to prevent injury to personnel. Cautions for Operations and Monitoring CAUTION: The heat sink fins will have a high temperature. Be careful ....... 44=2 ! not to touch them. Otherwise, there is the danger of getting burned. ACAUTION: The operation of the inverter can be easily changed from low ....... 44=2 e speed to high speed. Be sure check the capability and limitations of the motor and machine before operating the inverter. Otherwise, it may cause injury to personnel. CAUTION: If you operate a motor at a frequency higher than the inverter ....... 44=2 A standard default setting (50Hz/6OHz), be sure to check the motor and machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage. CAUTION: It is possible to damage the inverter or other devices if your ....... 4-4 application exceeds the maximum current or voltage characteristics of a A! connection point. CAUTION: Be sure to turn OFF power to the inverter before changing ....... 44=9 Ase! the SR/SK switch position. Otherwise, damage to the inverter circuitry may occur. CAUTION: Be careful not to turn PID Clear ON and reset the integrator ..... 4-28 sum when the inverter is in Run Mode (output to motor is ON). Other- wise, this could cause the motor to decelerate rapidly, resulting in a trip. SJ200 Inverter Warnings and Cautions for Troubleshooting and Maintenance A! WARNING: Wait at least five (5) minutes after turning OFF the input ...... 66=2 power supply before performing maintenance or an inspection. Other- wise, there is the danger of electric shock. WARNING: Make sure that only .qualified personnel will perform ...... 66=2 maintenance, inspection, and part replacement. Before starting to work, A!remove any metallic objects from your person (wristwatch, bracelet, etc.). Be sure to use tools with insulated handles. Otherwise, there is a danger of electric shock and/or injury to personnel. A! WARNING: Never remove connectors by pulling on its wire leads (wires ...... 66=2 � for cooling fan and logic P.AC.board). Otherwise, there is a danger of fire due to wire breakage and/or injury to personnel. CAUTION: Do not connect the megger to any control circuit terminals .... 6-10 I such as intelligent I/O, anaAlog terminals, etc. Doing so could cause damage to the inverter. A! CAUTION: Never test the withstand voltage (HIPOT) on the inverter. .... 6-10 � The inverter has a surge proAi Atector between the main circuit terminals above and the chassis ground. HIGH VOLTAGE: Be careful not to touch wiring or connector terminals .... 6-14 when working with the inverters and taking measurements. Be sure to place the measurement circuitry components above in an insulated housing before using them. General Warnings and Cautions AWARNING: Never modify the unit. Otherwise, there is a danger of electric shock and/ or injury. CAUTION: Withstand voltage tests and insulation resistance tests (HIPOT) are executed before the units are shipped, so there is no need to conduct these tests before operation. CAUTION: Do not attach or remove wiring or connectors when power is applied. Also, A do not check signals during operation. Ae!CAUTION: Be sure to connect the grounding terminal to earth ground. CAUTION: When inspecting the unit, be sure to wait five minutes after tuning OFF the ! power supply before opening the cover. AWARNING: Never modify the unit. Otherwise, there is a danger of electric shock and/ or injury. CAUTION: Withstand voltage tests and insulation resistance tests (HIPOT) are executed before the units are shipped, so there is no need to conduct these tests before operation. CAUTION: Do not attach or remove wiring or connectors when power is applied. Also, A do not check signals during operation. Ae!CAUTION: Be sure to connect the grounding terminal to earth ground. CAUTION: When inspecting the unit, be sure to wait five minutes after tuning OFF the ! power supply before opening the cover. ' CAUTION: Do not stop operation by switching OFF electromagnetic contactors on the primary or secondary sides of the inverter. Ground fault interrupter Power _ Input When there has been a sudden power failure while an operation instruction is active, then the unit may restart operation automatically after the power failure has ended. If there is a possibility that such an occurrence may harm humans, then install an electromagnetic contactor (Mgo) on the power supply side, so that the circuit does not allow automatic restarting after the power supply recovers. If the optional remote operator is used and the retry function has been selected, this will also cause automatic restarting when a Run command is active. So, please be careful. ' CAUTION: Do not insert leading power factor capacitors or surge absorbers between the output terminals of the inverter and motor. Ground fault interrupter Surge absorber Power Ind L1, L2, L3 U, V, W (motor, Inverter I Leading power GND lug T factor capacitor 1111 I CAUTION: MOTOR TERMINAL SURGE VOLTAGE SUPPRESSION FILTER (For the 400 V CLASS) In a system using an inverter with the voltage control PWM system, a voltage surge caused by the cable constants such as the cable length (especially when the distance between the motor and inverter is 10 in or more) and cabling method may occur at the motor terminals. A dedicated filter of the 400 V class for suppressing this voltage surge is available. Be sure to install a filter in this situation. SJ200 Inverter ICAUTION: EFFECTS OF POWER DISTRIBUTION SYSTEM ON INVERTER In the cases below involving a general-purpose inverter, a large peak current can flow on the power supply side, sometimes destroying the converter module: 1. The unbalance factor of the power supply is 3% or higher. 2. The power supply capacity is at least 10 times greater than the inverter capacity (or the power supply capacity is 500 kVA or more). 3. Abrupt power supply changes are expected, due to conditions such as: a. Several inverters are interconnected with a short bus. b. A thyristor converter and an inverter are interconnected with a short bus. c. An installed phase advance capacitor opens and closes. Where these conditions exist or when the connected equipment must be highly reliable, you MUST install an input -side AC reactor of 3% (at a voltage drop at rated current) with respect to the supply voltage on the power supply side. Also, where the effects of an indirect lightning strike are possible, install a lightning conductor. AA CAUTION: SUPPRESSION FOR NOISE INTERFERENCE FROM INVERTER The inverter uses many semiconductor switching elements such as transistors and IGBTs. Thus, a radio receiver or measuring instrument located near the inverter is susceptible to noise interference. To protect the instruments from erroneous operation due to noise interference, they should be used well away from the inverter. It is also effective to shield the whole inverter structure. The addition of an EMI filter on the input side of the inverter also reduces the effect of noise from the commercial power line on external devices. Note that the external dispersion of noise from the power line can be minimized by connecting an EMI filter on the primary side of inverter. EMI FilterInverter R1 R2 L1 U S1 S2 L2 V Motor T1 T2 L3 W LE ------------------ noise ' EMI Filter Inverter - - - - - - - - Motor Completely ground the enclosed panel, metal Remote screen, etc. with asOperator short a wire as possible.�� _ _ _ Grounded frame - J Conduit or shielded cable—to be grounded ACAUTION: When the EEPROM error E08 occurs, be sure to confirm the setting values again. CAUTION: When using normally closed active state settings (COI I to C016) for exter- !* nally commanded Forward or Reverse terminals [FW] or [RV], the inverter may start automatically when the external system is powered OFF or disconnected from the inverter! So, do not use normally closed active state settings for Forward or Reverse terminals [FW] or [RV] unless your system design protects against unintended motor operation. ACAUTION: In all the illustrations in this manual, covers and safety devices are e! occasionally removed to describe the details. While operating the product, make sure that the covers and safety devices are placed as they were specified originally and operate it according to the instruction manual. UL® Cautions, Warnings, and Instructions Wiring Warnings for Electrical Practices and Wire Sizes The Warnings and instructions in this section summarize the procedures necessary to ensure an inverter installation complies with Underwriters Laboratories® guidelines. A!*WARNING: "Use 60/75°C Cu wire only" or equivalent. WARNING: "Open Type Equipment." • WARNING: "Suitable for use on a circuit capable of delivering not more than 5,000 A!* 0 rms symmetrical amperes, 240 V maximum." For models with suffix N or L. A!rms WARNING: "Suitable for use on a circuit capable of delivering not more than 5,000 symmetrical amperes, 480 V maximum." For models with suffix H. AWARNING: "Hot surface—risk of burn." ! WARNING: "Install device in pollution degree 2 environment." A!6 WARNING: "Risk of electric shockcapacitor discharge time is at least 5 minutes." ! WARNING: "Solid state motor overload protection is provided in each model." SJ200 Inverter Terminal Tightening Torque and Wire Size The wire size range and tightening torque for field wiring terminals are presented in the tables below. Input Voltage Motor Output Inverter Model Power Terminal Wiring Size Range (AWG) Torque kW HP ft -lbs (N -m) 0.2 1/4 SJ200-002NFEF/NFU 16 0.6 0.8 0.4 1/2 SJ200-004NFEF/NFU 0.55 3/4 SJ200-005NFEF 200V 0.75 1 SJ200-007NFEF/NFU 14 0.9 1.2 1.1 11/2 SJ200-01INFEF 1.5 2 SJ200-015NFEF/NFU 12 2.2 3 SJ200-022NFEF/NFU 10 3.7 5 SJ200-037LFU 12 5.5 71/2 SJ200-055LFU 10 1.5 2.0 7.5 10 SJ200-075LFU 8 400V 0.4 1/2 SJ200-004HFEF/HFU 16 0.9 1.2 0.75 1 SJ200-007HFEF/HFU 1.5 2 SJ200-015HFEF/HFU 2.2 3 SJ200-022HFEF/HFU 3.0 4 SJ200-030HFEF 14 4.0 5 SJ200-040HFEF/HFU 5.5 71/2 SJ200-055HFEF/HFU 12 1.5 2.0 7.5 10 SJ200-075HFEF/HFU Wiring Size Torque Terminal Connector Range (AWG) ft -lbs (N -m) Logic and Analog connectors 30-16 0.16-0.19 0.22-0.25 Relay connector 30-14 0.37-0.44 0.5-0.6 Wire Connectors O WARNING: Field wiring connections must be made by a UL Listed and CSA Certified ring lug terminal connector sized for the wire gauge being used. The connector must be fixed using the crimping tool specified by the connector manufacturer. Terminal (ring lug) \ Cable support U0 Cable Circuit Breaker and Fuse Sizes The inverter's connections to input power must include UL Listed inverse time circuit breakers with 600V rating, or UL Listed fuses as shown in the table below. Input Voltage Motor Output Inverter Model Fuse (A) (UL -rated, class J, 600V) kW HP 0.2 1/4 SJ200-002NFEF/NFU 10 0.4 1/2 SJ200-004NFEF/NFU 10 0.55 3/4 SJ200-005NFEF 10 0.75 1 SJ200-007NFEF/NFU 15 1.1 11/2 SJ200-01INFEF 15 200V 1.5 2 SJ200-015NFEF/NFU 20 (single ph.) 15 (three ph.) 2.2 3 SJ200-022NFEF/NFU 30 (single ph.) 20 (three ph.) 3.7 5 SJ200-037LFU 30 5.5 71/2 SJ200-055LFU 40 7.5 10 SJ200-075LFU 50 0.4 1/2 SJ200-004HFEF/HFU 3 0.75 1 SJ200-007HFEF/HFU 6 1.5 2 SJ200-015HFEF/HFU 10 400V 2.2 3 SJ200-022HFEF/HFU 10 3.0 4 SJ200-030HFEF 15 4.0 5 SJ200-040HFEF/HFU 15 5.5 71/2 SJ200-055HFEF/HFU 20 7.5 10 SJ200-075HFEF/HFU 25 Motor Overload Protection Hitachi SJ200 inverters provide solid state motor overload protection, which depends on the proper setting of the following parameters: • B012 "electronic overload protection" • B212 "electronic overload protection, 2nd motor" Set the rated current [Amperes] of the motor(s) with the above parameters. The setting range is 0.2 * rated current to 1.2 * rated current. !WARNING: When two or more motors are connected to the inverter, they cannot be protected by the electronic overload protection. Install an external thermal relay on each motor. SJ200 Inverter Table of Contents Safety Messages Hazardous High Voltage i General Precautions - Read These First! ii Index to Warnings and Cautions in This Manual iv General Warnings and Cautions ix UL® Cautions. Warnings. and Instructions xii Table of Contents Revisions xvii Contact Information xviii Chapter 1: Getting Started Introduction SJ200 Inverter Specifications 11=5 Introduction to Variable -Frequency Drives 1-12 Frequently Asked Questions 1-17 Chapter 2: Inverter Mounting and Installation Orientation to Inverter Features Basic System Description 22=8 Step -by -Step Basic Installation 22=9 Powerup Test 2-23 Using the Front Panel Kead 2-25 Chapter 3: Configuring Drive Parameters Choosing a Programming Device 33=2 Using Keypad Devices 33=3 "D" Group: Monitoring Functions 33=6 "F" Group: Main Profile Parameters 33=8 "A" Group: Standard Functions 33=9 "B" Group: Fine Tuning Functions 3-30 "C" Group: Intelligent Terminal Functions 3-41 "H" Group: Motor Constants Functions 3-55 Chapter 4: Operations and Monitoring Introduction 4-2 Connecting to PLCs and Other Devices 4-4 Control Logic Signal Specifications 44=6 Intelligent Terminal Listing_ 44=7 Using Intelligent Input Terminals 44=9 Using Intelligent Output Terminals 4-34 Analog Input Operation 4-51 Analog Output Operation 4-53 PID Loop Operation 4-54 Configuring the Inverter for Multiple Motors 4-56 Chapter 5: Inverter System Accessories Component Descriptions 55=3 Dynamic Braking 5-5 Chapter 6: Troubleshooting and Maintenance Troubleshooting 6-2 Monitoring Trip Events. History. & Conditions 66=5 Restoring Factory Default Settings 66=8 Maintenance and Inspection 66=9 Warranty 6-16 Appendix A: Glossary and Bibliography Glossary Bibliography Appendix B: ModBus Network Communications Introduction B-2 Connecting the Inverter to ModBus BB3 Network Protocol Reference B-6 ModBus Data Listing B-19 Appendix C: Drive Parameter Settings Tables Introduction C-2 Parameter Settings for Keypad Entry C-2 Appendix D: CE—EMC Installation Guidelines CE—EMC Installation Guidelines D-2 Hitachi EMC Recommendations D-6 Index Revisions Revision History Table SJ200 Inverter No. Revision Comments Date of Issue Operation Manual No. Initial release of manual NB650X Feb. 2004 NB650X 1 Revision A March 2004 NB650XA Page 4-35 — Added page on internal relay operation Pages 4-37 to 4-50 — Added relay drawing for outputs Index 1-6 — Revised entire Index, added page I-6 Other minor corrections throughout Contact Information Hitachi America, Ltd. Power and Industrial Division 50 Prospect Avenue Tarrytown, NY 10591 U.S.A. Phone: +1-914-631-0600 Fax: +1-914-631-3672 Hitachi Europe GmbH Am Seestern 18 D-40547 Dusseldorf Germany Phone: +49-211-5283-0 Fax: +49-211-5283-649 Hitachi Asia Ltd. 16 Collyer Quay #20-00 Hitachi Tower, Singapore 049318 Singapore Phone: +65-538-6511 Fax: +65-538-9011 Hitachi Asia (Hong Kong) Ltd. 7th Floor, North Tower World Finance Centre, Harbour City Canton Road, Tsimshatsui, Kowloon Hong Kong Phone: +852-2735-9218 Fax: +852-2735-6793 Hitachi Australia Ltd. Level 3, 82 Waterloo Road North Ryde, N.S.W. 2113 Australia Phone: +61-2-9888-4100 Fax: +61-2-9888-4188 Hitachi Industrial Equipment Systems Co, Ltd. International Sales Department WBG MARIVE WEST 16F 6, Nakase 2-chome Mihama-ku, Chiba-shi, Chiba 261-7116 Japan Phone: +81-43-390-3516 Fax: +81-43-390-3810 Hitachi Industrial Equipment Systems Co, Ltd. Narashino Division 1-1, Higashi-Narashino 7-chome Narashino-shi, Chiba 275-8611 Japan Phone: +81-47-474-9921 Fax: +81-47-476-9517 NOTE: To receive technical support for the Hitachi inverter you purchased, contact the Hitachi inverter dealer from whom you purchased the unit, or the sales office or factory contact listed above. Please be prepared to provide the following inverter nameplate information: 1. Model 2. Date of purchase 3. Manufacturing number (MFG No.) 4. Symptoms of any inverter problem If any inverter nameplate information is illegible, please provide your Hitachi contact with any other legible nameplate items. To reduce unpredictable downtime, we recom- mend that you stock a spare inverter. Getting Started In This Chapter... — Introduction..................................................... 2 — SJ200 Inverter Specifications .......................... 5 — Introduction to Variable -Frequency Drives .... 12 — Frequently Asked Questions ......................... 17 Introduction Introduction Main Features Congratulations on your purchase of an SJ200 Series Hitachi inverter! This inverter drive features state-of- the-art circuitry and components to provide high performance. The housing footprint is exceptionally small, given the size of the corre- sponding motor. The Hitachi SJ200 product line includes more than a dozen inverter models to cover motor sizes from 1/4 horsepower to 10 horsepower, in either 240 VAC or 480 VAC power input versions. The main features are: • 200V and 400V Class inverters STR FUN< a T. SJ200-004LFU SJ200-037LFU • US or EU versions available (country -specific input voltage range and default values) • New intelligent sensorless vector control (iSLV)—auto-tuning no longer necessary • Dynamic braking with external resistor • Convenient, removable keypad for parameter settings, can be mounted on panel door • Built-in RS -485 MODBUS RTU as standard • New current limit function • Sixteen programmable speed levels • PID control adjusts motor speed automatically to maintain a process variable value The design in Hitachi inverters overcomes many of the traditional trade-offs between speed, torque and efficiency. The performance characteristics are: • High starting torque of 200% at 1Hz • Continuous operation at 100% torque within a 1:10 speed range (6/60 Hz / 5/50 Hz) without motor derating • Fan has ON/OFF selection to provide longer life for cooling fan (on models with fan) A full line of accessories from Hitachi is available to complete your motor application: • Digital remote operator keypad • Panel -mount keypad bezel kit and DIN rail mounting adapter (35mm rail size) • Dynamic braking unit with resistors • Radio noise filters • CE compliance filters Operator Interface Options The SJ200 inverter has a removable keypad, as shown to the right (part no. OPE—SRmini). This allows the keypad to operate the inverter remotely, as shown (below, left). A cable (part no. ICS -1 or ICS -3, Im or 3m) connects the modular connectors of the keypad and inverter. SJ200 Inverter Hitachi provides a panel mount keypad kit (below, right). It includes the mounting flange, gasket, keypad, and other hardware. You can OPE—SRmini mount the keypad with the potentiometer for a NEMA1 rated installation. The kit also provides for removing the potentiometer knob to meet NEMA 4X requirements, as shown (part no. 4X—KITmini). Digital Operator Copy Unit - The optional digital operator / copy unit (part no. SRW-OEX) is shown to the right. It has a 2 -line display that shows parameters by function code and by name. It has the additional capability of reading (uploading) the parameter settings in the inverter into its memory. Then you can connect the copy unit on another inverter and write (download) the parameter settings into that inverter. OEMs will find this unit particularly useful, as one can use a single copy unit to transfer parameter settings from one inverter to many. Other digital operator interfaces may be available from your Hitachi distributor for particular indus- tries or international markets. Contact your Hitachi distributor for further details. MON FUN STR aJ*©v SRW—OEX Introduction Inverter Specifications Label The Hitachi SJ200 inverters have product labels located on the right side of the housing, as pictured below. Be sure to verify that the specifications on the labels match your power source, motor, and application safety requirements. Specifications label Regulatory agency approval labels (opposite side) — Inverter model number Motor capacity for this mode Power Input Rating: frequency, voltage, phase, cu Output Rating: Frequency, voltage, current Manufacturing codes: Lot number, date, etc. Model Number Convention •.nniiiiiiio�o s� �� ®= l ss� ® assss csss. � ss as as asss L•. • .m. HITACHI ModeI:SJ200—037LFR kw/ (HP) : 3.7/ (5 ) Input/Entree: 50Hz,6OHz V 1Ph A 50Hz, 60Hz 200-240 V Ph 22.0 A Output/Sort i e:0. 5-40OHz 200-240 V Ph 17.5 A MFG No. 30A T15882 B 008 Date: 0310 Hitachi Industrial Equipment MADE IN JAPAN NEI 7668 —6 A Systems Co., Ltd. — The model number for a specific inverter contains useful information about its operating characteristics. Refer to the model number legend below: SJ200 — 037 H TF TE F EMC filter Restricted distribution: Series name E=Europe, U=USA, R=Japan Configuration type F = with digital operator (keypad) Input voltage: N = single or three-phase 200V class H = three-phase 400V class L = three phase only, 200V class Applicable motor capacity in kW 002=0.2kW 022=2.2kW 004=0.4kW 030=3.0kW 005 = 0.55 kW 037 = 3.7 kW 007 = 0.75 kW 040 = 4.0 kW 011 = 1.1 kW 055 = 5.5 kW 015=1.5kW 075=7.5kW SJ200 Inverter SJ200 Inverter Specifications Model -specific tables for 200V and 400V class inverters The following tables are specific to SJ200 inverters for the 200V and 400V class model groups. Note that "General Specifications" on page 1-10 apply to both voltage class groups. Footnotes for all specifications tables follow the table below. Item 200V Class Specifications SJ200 inverters, EU version 002NFEF 004NFEF 005NFEF 007NFEF 01 INFEF 200V models USA version 002NFU 004NFU - 007NFU - Applicable motor size *2 kW 0.2 0.4 0.55 0.75 1.1 HP 1/4 1/2 3/4 1 1.5 Rated capacity 230V 0.6 1.0 1.1 1.5 1.9 (kVA) 240V 0.6 1.0 1.2 1.6 2.0 Rated input voltage 1 -phase: 200 to 240V ±10%, 50/60 Hz f5%, 3-phase: 200 to 240V ±10%, 50/60 Hz f5%, (037LFU, 055LFU, and 075LFU 3-phase only) Integrated EMC EU version Single phase filter, Category C3 *5 filter USA version - Rated input 1 -phase 3.5 5.8 6.7 9.0 11.2 current (A) 3-phase 2.0 3.4 3.9 5.2 6.5 Rated output voltage *3 3-phase: 200 to 240V (proportional to input voltage) Rated output current (A) 1.6 2.6 3.0 4.0 5.0 Starting torque *7 200% or more Dynamic braking approx. % without resistor, from 50 / 60 Hz 100%:<_ 50Hz 50%:<_ 60Hz torque, short time stop *8 with resistor 150% DC braking Variable operating frequency, time, and braking force Weight EU version (-NFEF kg 0.8 0.95 0.95 1.4 1.4 lb 1.75 2.09 2.09 3.09 3.09 US version (-NFU) kg 0.7 0.85 - 1.8 lb 1.54 1.87 - 3.97 SJ200 Inverter Specifications Footnotes for the preceding table and the tables that follow: Note 1: The protection method conforms to JEM 1030. Note 2: The applicable motor refers to Hitachi standard 3-phase motor (4 -pole). When using other motors, care must be taken to prevent the rated motor current (50/ 60 Hz) from exceeding the rated output current of the inverter. Note 3: The output voltage decreases as the main supply voltage decreases (except when using the AVR function). In any case, the output voltage cannot exceed the input power supply voltage. Note 4: To operate the motor beyond 50/60 Hz, consult the motor manufacturer for the maximum allowable rotation speed. Note 5: When using the inverter with 3-phase power input, remove the single phase filter and install a 3-phase filter with the appropriate ratings. Note 6: For achieving approved input voltage rating categories: • 460 to 480 VAC — Over -voltage Category 2 • 380 to 460 VAC— Over -voltage Category 3 To meet the Over -voltage Category 3, insert an EN or IEC standard compliant isolation transformer that is earth grounded and star connected (for Low Voltage Directive). Note 7: At the rated voltage when using a Hitachi standard 3-phase, 4 -pole motor (when selecting intelligent sensorless vector controliSLV). Note 8: The braking torque via capacitive feedback is the average deceleration torque at the shortest deceleration (stopping from 50/60 Hz as indicated). It is not continuous regenerative braking torque. The average deceleration torque varies with motor loss. This value decreases when operating beyond 50 Hz. If a large regenerative torque is required, the optional regenerative braking resistor should be used. Note 9: The frequency command is the maximum frequency at 9.8V for input voltage 0 to 10 VDC, or at 19.6 mA for input current 4 to 20 mA. If this characteristic is not satisfactory for your application, contact your Hitachi sales representa- tive. Note 10: If the inverter is operated outside the region shown in the graph below, the inverter may be damaged or its service life may be shortened. Set B083 Carrier Frequency Adjustment in accordance with the expected output current level. Derating Curve Rated 100% Curve at 40°C current 70% ------------- Operating region 01 i kHz 5.0 14.0 Carrier frequency Note 11: The storage temperature refers to the short-term temperature during transport. Note 12: Conforms to the test method specified in JIS C0040 (1999). For the model types excluded in the standard specifications, contact your Hitachi sales representative. SJ200 Inverter SJ200 Inverter Specifications, continued... Item 200V Class Specifications, continued SJ200 inverters, EU version 015NFEF 022NFEF - 200V models USA version 015NFU 022NFU 037LFU 055LFU 075LFU Applicable motor size *2 kW 1.5 2.2 3.7 5.5 7.5 HP 2 3 5 7.5 10 Rated capacity 230V 3.1 4.3 6.9 9.5 12.7 (kVA) 240V 3.3 4.5 7.2 9.9 13.3 Rated input voltage 1 -phase: 200 to 240V ±10%, 50/60 Hz f5%, 3-phase: 200 to 240V ±10%, 50/60 Hz f5%, (037LFU, 055LFU, 075LFU 3-phase only) Integrated EMC filter EU version Single phase filter, Category C3 *5 - USA version - Rated input 1 -phase 17.5 24.0 current (A) 3-phase 10.0 14.0 22.0 30.0 40.0 Rated output voltage *3 3-phase: 200 to 240V (proportional to input voltage) Rated output current (A) 8.0 11.0 17.5 1 24 1 32 Starting torque *7 200% or more 180% or more Dynamic braking approx. % without resistor, from 50 / 60 Hz 70%: <_ 50Hz 50%:<_ 60Hz 20%:<_ 50Hz 20%:<_ 60Hz torque, short time stop *8 with resistor 150% 100% 80% DC braking Variable operating frequency, time, and braking force Weight EU version (-NFEF kg 1.9 1.9 lb 4.2 4.2 US version (-NFU) kg 1.8 1.8 1.9 5.5 5.7 lb 3.97 3.97 4.2 12.13 12.57 SJ200 Inverter Specifications Item 400V Class Specifications SJ200 inverters, EU version 004HFEF 007HFEF 015HFEF 022HFEF 400V models USA version 004HFU 007HFU 015HFU 022HFU Applicable motor size *2 kW 0.4 0.75 1.5 2.2 HP 1/2 1 2 3 Rated capacity (460V) kVA 1.1 1.9 2.9 4.2 Rated input voltage *6 3-phase: 380 to 480V ±10%, 50/60 Hz f5% Integrated EMC EU version Three phase filter, Category C3 *5 filter USA version - Rated input current (A) 2.0 3.3 5.0 7.0 Rated output voltage *3 3-phase: 380 to 480V (proportional to input voltage) Rated output current (A) 1.5 2.5 3.8 5.5 Starting torque *7 200% or more Dynamic braking approx. % without resistor, from 50/60 Hz 100%:<_ 50Hz 50%:<_ 60Hz 70%:<_ 50Hz 20%:<_ 60Hz torque, short time stop * 8 with resistor 150% 100% DC braking Variable operating frequency, time, and braking force Weight EU version (-HFEF kg 1.4 1.8 1.9 1.9 lb 3.09 3.97 4.19 4.19 US version (-HFU) kg 1.3 1.7 1.8 1.8 lb 2.87 3.75 3.97 3.97 SJ200 Inverter Item 400V Class Specifications, continued SJ200 inverters, EU version 030HFEF 040HFEF 055HFEF 075HFEF 400V models USA version — 040HFU 055HFU 075HFU Applicable motor size *2 kW 3.0 4.0 5.5 7.5 HP 4 5 7.5 10 Rated capacity (460V) kVA 6.2 6.6 10.3 12.7 Rated input voltage *6 3-phase: 380 to 480V ±10%, 50/60 Hz f5% Integrated EMC EU version Three phase filter, Category C3 — filter USA version — Rated input current (A) 10.0 11.0 16.5 20.0 Rated output voltage *3 3-phase: 380 to 480V (proportional to input voltage) Rated output current (A) 7.8 8.6 13 16 Starting torque *7 180% or more Dynamic braking approx. % without resistor, from 50/60 Hz 20%:<_ 50Hz 20%:<_ 60Hz torque, short time stop *8 with resistor 100% 80% DC braking Variable operating frequency, time, and braking force Weight EU version (-HFEF kg 1.9 1.9 5.5 5.7 lb 4.19 4.19 12.13 12.57 US version (-HFU) kg — 1.8 5.4 5.6 lb — 3.97 11.91 12.35 SJ200 Inverter Specifications General Specifications The following table applies to all SJ200 inverters. Item General Specifications Protective housing *I IP20 Control method Sinusoidal Pulse Width Modulation (PWM) control Carrier frequency 2kHz to 14kHz (default setting: 5kHz) Output frequency range *4 0.5 to 400 Hz Frequency accuracy Digital command: 0.01% of the maximum frequency Analog command: 0.1% of the maximum frequency (25°C f 10°C) Frequency setting resolution Digital: 0.1 Hz; Analog: max. frequency/ 1000 Volt./Freq. characteristic V/f optionally variable, V/f control (constant torque, reduced torque), intelligent sensorless vector control (iSLV) Overload capacity 150% of rated current for 1 minute Acceleration/deceleration time 0.01 to 3000 seconds, linear and S-curve accel/decel, second accel/decel setting available Input Freq. Operator panel Up and Down keys / Value settings signal setting potentiometer Analog setting External signal 0 to 10 VDC (input impedance 10k Ohms), 4 to 20 mA (input *9 impedance 250 Ohms), Potentiometer (lk to 2k Ohms, 2W) FWD/ Operator panel Run/Stop (Forward/Reverse run change by command) REV Run External signal Forward run/stop, Reverse run/stop Intelligent input FW (forward run command), RV (reverse run command), CF1—CF4 terminal (multi -stage speed setting), JG (jog command), DB (external braking), SET (set second motor), 2CH (2 -stage accel./decel. command), FRS (free run stop command), EXT (external trip), USP (startup function), SFT (soft lock), AT (analog current input select signal), RS (reset), TH (thermistor thermal protection), STA (start), STP (stop), F/R (forward/reverse), PID (PID disable), PIDC (PID reset), UP (remote control up function), DWN (remote control down function), UDC (remote control data clearing), OPE (operator control), ADD (ADD frequency enable), F -TM (force terminal mode) Output Intelligent output RUN (run status signal), FA1,2 (frequency arrival signal), OL signal terminal (overload advance notice signal), OD (PID error deviation signal), AL (alarm signal), Dc (analog input disconnect detect), FBV (PID two-stage control output), NDc (network detection signal), LOG (logic output) Frequency monitor PWM output; Select analog output frequency monitor, analog output current monitor or digital output frequency monitor Alarm output contact ON for inverter alarm (1C contacts, both normally open or closed avail.) SJ200 Inverter Item General Specifications Other functions AVR function, curved accel/decel profile, upper and lower limiters, Discrete logic inputs 16 -stage speed profile, fine adjustment of start frequency, carrier Discrete logic outputs frequency change (2 to 14 kHz), frequency jump, gain and bias Analog output setting, process jogging, electronic thermal level adjustment, retry Analog input, current function, trip history monitor, 2nd setting selection, fan ON/OFF Analog input, voltage selection Protective function Over -current, over -voltage, under -voltage, overload, extreme high/ Alarm relay contacts low temperature, CPU error, memory error, ground fault detection at startup, internal communication error, electronic thermal Operat- Temperature Operating (ambient): -10 to 40°C (*10) / Storage: -25 to 70°C (*11) E g iron Humidity 20 to 90% humidity (non -condensing) ment Vibration *12 5.9 m/s2 (0.6G), 10 to 55 Hz Location Altitude 1,000 in or less, indoors (no corrosive gasses or dust) Coating color Munsell 8.5YR6.2/0/2 Options Remote operator unit, copy unit, cables for the units, braking unit, braking resistor, AC reactor, DC reactor, noise filter, DIN rail mounting Signal Ratings Detailed ratings are in "Control Logic Signal Specifications" on page 4-6. Signal / Contact Ratings Built-in power for inputs 24VDC, 30 mA maximum Discrete logic inputs 27VDC maximum Discrete logic outputs 50mA maximum ON state current, 27 VDC maximum OFF state voltage Analog output 0 to l OVDC, 1 mA Analog input, current 4 to 19.6 mA range, 20 mA nominal Analog input, voltage 0 to 9.6 VDC range, l OVDC nominal, input impedance 10 M +1 OV analog reference 1OVDC nominal, 10 mA maximum Alarm relay contacts 250 VAC, 2.5A (R load) max., 0.2A (I load, P.F.=0.4) max. 100 VAC, l OmA min. 30 VDC, 3.OA (R load) max., 0.7A (I load, P.F.=0.4) max. 5 VDC, 100mA min. Introduction to Variable -Frequency Drives Introduction to Variable -Frequency Drives The Purpose of Motor Speed Control for Industry Hitachi inverters provide speed control for 3-phase AC induction motors. You connect AC power to the inverter, and connect the inverter to the motor. Many applications benefit from a motor with variable speed, in several ways: • Energy savings - HVAC • Need to coordinate speed with an adjacent process—textiles and printing presses • Need to control acceleration and deceleration (torque) • Sensitive loads - elevators, food processing, pharmaceuticals What is an Inverter? The term inverter and variable frequency drive are related and somewhat interchange- able. An electronic motor drive for an AC motor can control the motor's speed by varying the frequency of the power sent to the motor. An inverter, in general, is a device that converts DC power to AC power. The figure below shows how the variable -frequency drive employs an internal inverter. The drive first converts incoming AC power to DC through a rectifier bridge, creating an internal DC bus voltage. Then the inverter circuit converts the DC back to AC again to power the motor. The special inverter can vary its output frequency and voltage according to the desired motor speed. Power Variable -frequency Drive Input Converter Internal Inverter Motor L1 I F-----1 DC Bus + U'T' L2 Rectifier � L3 V/T2 W/T3 The simplified drawing of the inverter shows three double -throw switches. In Hitachi inverters, the switches are actually IGBTs (insulated gate bipolar transistors). Using a commutation algorithm, the microprocessor in the drive switches the IGBTs on and off at a very high speed to create the desired output waveforms. The inductance of the motor windings helps smooth out the pulses. SJ200 Inverter Torque and Constant Volts/Hertz Operation In the past, AC variable speed drives used an Output open loop (scalar) technique to control speed. voltage The constant -volts -per -hertz operation V maintains a constant ratio between the applied - - - - - - - - - - - - - voltage and the applied frequency. With these Constant torque conditions, AC induction motors inherently delivered constant torque across the operating speed range. For some applications, this scalar f technique was adequate. 0 100% Today, with the advent of sophisticated micro- Output frequency processors and digital signal processors (DSPs), it is possible to control the speed and torque of AC induction motors with unprecedented accuracy. The SJ200 utilizes these devices to perform complex mathematical calcula- tions required to achieve superior performance. The technique is referred to as intelligent sensorless vector control (iSLV). It allows the drive to continuously monitor its output voltage and current, and their relationship to each other. From this it mathematically calculates two vector currents. One vector is related to motor flux current, and the other to motor torque current. The ability to separately control these two vectors is what allows the SJ200 to deliver extraordinary low -speed performance and speed control accuracy. Inverter Input and Three -Phase Power The Hitachi SJ200 Series of inverters includes two sub -groups: the 200V class and the 400V class inverters. The drives described in this manual may be used in either the United States or Europe, although the exact voltage level for commercial power may be slightly different from country to country. Accordingly, a 200V class inverter requires (nominal) 200 to 240VAC, and a 400V class inverter requires from 380 to 480VAC. Some 200V class inverters will accept single-phase or three-phase power, but all 400V class inverters require a three-phase power supply. fTIP: If your application only has single phase power available, refer to SJ200 inverters of 3HP or less; they can accept single phase input power. The common terminology for single phase power is Line (L) and Neutral (N). Three- phase power connections are usually labeled Line 1 [R/L I], Line 2 [S/L2] and Line 3 [T/L3]. In any case, the power source should include an earth ground connection. That ground connection will need to connect to the inverter chassis and to the motor frame (see "Wire the Inverter Output to Motor" on page 2-22). Introduction to Variable -Frequency Drives Inverter Output to the Motor The AC motor must be connected only to the inverter's output terminals. The output terminals are uniquely labeled (to differentiate them from the input terminals) with the designations U/T1, V/T2, and W/T3. This corresponds to typical motor lead connection designa- tions T1, T2, and T3. It is often not necessary to connect a particular inverter output to a particular motor lead for a new application. The consequence of swapping any two of the three connections is the reversal of the motor direction. In applications where reversed rotation could 3 -Phase AC Motor U/T1 V/T2 Earth GND W/T3 cause equipment damage or personnel injury, be sure to verify direction of rotation before attempting full -speed operation. For safety to personnel, you must connect the motor chassis ground to the ground connection at the bottom of the inverter housing. Notice the three connections to the motor do not include one marked "Neutral" or "Return." The motor represents a balanced "Y" impedance to the inverter, so there is no need for a separate return. In other words, each of the three "Hot" connections serves also as a return for the other connections, because of their phase relationship. The Hitachi inverter is a rugged and reliable device. The intention is for the inverter to assume the role of controlling power to the motor during all normal operations. There- fore, this manual instructs you not to switch off power to the inverter while the motor is running (unless it is an emergency stop). Also, do not install or use disconnect switches in the wiring from the inverter to the motor (except thermal disconnect). Of course, safety-related devices such as fuses must be in the design to break power during a malfunction, as required by NEC and local codes. Intelligent Functions and Parameters Much of this manual is devoted to describing how to use inverter functions and how to config- ure inverter parameters. The inverter is micro- processor -controlled, and has many independent functions. The microprocessor has an on -board EEPROM for parameter storage. The inverter's front panel keypad provides access to all functions and parameters, which you can access through other devices as well. The general name for all these devices is the digital operator, or digital operator panel. Chapter 2 will show you how to get a motor running, using a minimal set of function commands or configuring parame- ters. The optional read/write programmer will let you read and write inverter EEPROM contents from the programmer. This feature is particularly useful for OEMs who need to duplicate a particu- lar inverter's settings in many other inverters in assembly -line fashion. Braking SJ200 Inverter In general, braking is a force that attempts to slow or stop motor rotation. So it is associ- ated with motor deceleration, but may also occur even when the load attempts to drive the motor faster than the desired speed (overhauling). If you need the motor and load to decelerate quicker than their natural deceleration during coasting, we recommend installing a braking resistor. The dynamic braking unit (built into the SJ200) sends excess motor energy into a resistor to slow the motor and load (see "Introduction" on page 5-2 and "Dynamic Braking" on page 5-5 for more information). For loads that continuously overhaul the motor for extended periods of time, the SJ200 may not be suitable (contact your Hitachi distributor). The inverter parameters include acceleration and deceleration, which you can set to match the needs of the application. For a particular inverter, motor, and load, there will be a range of practically achievable accelerations and decelerations. Introduction to Variable -Frequency Drives Velocity Profiles The SJ200 inverter is capable of sophisticated speed control. A graphical representation of that capability will help you understand and configure the associated parameters. This manual makes use of the velocity profile graph used in industry (shown at right). In the example, acceleration is a ramp to a set speed, and deceleration is a decline to a stop. Speed Set speed Accel Decel 0 t Velocity Profile Maximum speed Acceleration and deceleration settings specify the time required to go from a stop to Speed maximum frequency (or visa versa). The resulting slope (speed change divided by time) is the acceleration or deceleration. An increase in output frequency uses the acceleration 0 slope, while a decrease uses the deceleration slope. The accel or decel time a particular speed change depends on the starting and Acceleration --o-I (time setting) ending frequencies. However, the slope is constant, corresponding to the full-scale accel or decel time setting. For example, the full-scale acceleration setting (time) may be 10 seconds—the time required to go from 0 to 60 Hz. The SJ200 inverter can store up to 16 preset speeds. And, it can apply separate acceleration and deceleration transitions from any preset to any other preset speed. A multi -speed profile (shown at right) uses two or more preset speeds, which you can select via intelligent input terminals. This external control can Speed Speed 2 Speed 1 0 t Multi -speed Profile apply any preset speed at any time. Alterna- tively, the selected speed is infinitely variable across the speed range. You can use the potentiometer control on the keypad for manual control. The drive accepts analog 0-1OV signals and 4-20 mA control signals as well. The inverter can drive the motor in either direction. Separate FW and RV commands Speed select the direction of rotation. The motion profile example shows a forward motion 0 followed by a reverse motion of shorter duration. The speed presets and analog signals control the magnitude of the speed, while the FWD and REV commands determine the direction before the motion starts. Forward move Reverse move Bi-directional Profile NOTE: The SJ200 can move loads in both directions. However, it is not designed for use in servo -type applications that use a bipolar velocity signal that determines direction. SJ200 Inverter Frequently Asked Questions Q. What is the main advantage in using an inverter to drive a motor, compared to alternative solutions? A. An inverter can vary the motor speed with very little loss of efficiency, unlike mechanical or hydraulic speed control solutions. The resulting energy savings usually pays for the inverter in a relatively short time. Q. The term "inverter" is a little confusing, since we also use "drive" and "amplifier" to describe the electronic unit that controls a motor. What does "inverter" mean? A. The terms inverter, drive, and amplifier are used somewhat interchangeably in industry. Nowadays, the terms drive, variable frequency drive, variable - speed drive, and inverter are generally used to describe electronic, micropro- cessor -based motor speed controllers. In the past, variable -speed drive also referred to various mechanical means to vary speed. Amplifier is a term almost exclusively used to describe drives for servo or stepper motors. Q. What is the "Intelligent Sensorless Vector Control" feature? A. Intelligent Sensorless Vector Control (iSLV) is Hitachi's newest variable speed control technology. The original sensorless vector control (SLV) did not require motor shaft position sensors (thus "sensorless)", but still required setting several motor parameters (either manually or through an auto -tuning procedure). Now, iSLV uses proprietary Hitachi algorithms and high-speed processing to provide smooth control that adapts to motor characteristics in real time. Even the need to do auto -tuning procedures has been eliminated. Q. Although the SJ200 inverter is a variable speed drive, can I use it in a fixed -speed application? A. Yes, sometimes an inverter can be used simply as a "soft -start" device, providing controlled acceleration and deceleration to a fixed speed. Other functions of the SJ200 may be useful in such applications, as well. However, using a variable speed drive can benefit many types of industrial and commercial motor applications, by providing controlled acceleration and deceleration, high torque at low speeds, and energy savings over alternative solutions. Q. Can I use an inverter and AC induction motor in a positioning application? A. That depends on the required precision, and the slowest speed the motor will must turn and still deliver torque. The SJ200 inverter will deliver full torque while turning the motor at only 0.5 Hz (15 RPM). DO NOT use an inverter if you need the motor to stop and hold the load position without the aid of a mechanical brake (use a servo or stepper motion control system). Q. Can the inverter be controlled and monitored via a network? A. Yes. SJ200 inverters have built-in ModBus communications. See Appendix B for more information on network communications. Frequently Asked Questions Q. Why does the manual or other documentation use terminology such as "200V class" instead of naming the actual voltage, such as "230 VAC?" A. A specific inverter model is set at the factory to work across a voltage range particular to the destination country for that model. The model specifications are on the label on the side of the inverter. A European 200V class inverter (`BU" marking) has different parameter settings than a USA 200V class inverter ("US" marking). The initialization procedure (see "Restoring Factory Default Settings" on page 6-8) can set up the inverter for European or US commercial voltage ranges. Q. Why doesn't the motor have a neutral connection as a return to the inverter? A. The motor theoretically represents a "balanced Y" load if all three stator windings have the same impedance. The Y connection allows each of the three wires to alternately serve as input or return on alternate half -cycles. Q. Does the motor need a chassis ground connection? A. Yes, for several reasons. Most importantly, this provides protection in the event of a short in the motor that puts a hazardous voltage on its housing. Secondly, motors exhibit leakage currents that increase with aging. Lastly, a grounded chassis generally emits less electrical noise than an ungrounded one. Q. What type of motor is compatible with the Hitachi inverters? A. Motor type — It must be a three-phase AC induction motor. Use an inverter - grade motor that has 800V insulation for 200V class inverters, or 1600V insulation for 400V class. Motor size — In practice, it's better to find the right size motor for your application; then look for the inverter to match the motor. NOTE: There may be other factors that will affect motor selection, including heat dissi- pation, motor operating speed profile, enclosure type, and cooling method. Q. How many poles should the motor have? A. Hitachi inverters can be configured to operate motors with 2, 4, 6, or 8 poles. The greater the number of poles, the slower the top motor speed will be, but it will have higher torque at the base speed. Q. Will I be able to add dynamic (resistive) braking to my Hitachi SJ200 drive after the initial installation? A. Yes. The SJ200 inverter already has a dynamic braking circuit built in. Just add the resistor sized to meet the braking requirements. For more informa- tion, contact your nearest Hitachi representative. SJ200 Inverter Q. How will I know if my application will require resistive braking? A. For new applications, it may be difficult to tell before you actually test a motor/drive solution. In general, some applications can rely on system losses such as friction to serve as the decelerating force, or otherwise can tolerate a long decel time. These applications will not need dynamic braking. However, applications with a combination of a high -inertia load and a required short decel time will need dynamic braking. This is a physics question that may be answered either empirically or through extensive calcu- lations. Q. Several options related to electrical noise suppression are available for the Hitachi inverters. How can I know if my application will require any of these options? A. The purpose of these noise filters is to reduce the inverter electrical noise so the operation of nearby electrical devices is not affected. Some applications are governed by particular regulatory agencies, and noise suppression is mandatory. In those cases, the inverter must have the corresponding noise filter installed. Other applications may not need noise suppression, unless you notice electrical interference with the operation of other devices. Q. The SJ200 features a PID loop feature. PID loops are usually associated with chemical processes, heating, or process industries in general. How could the PID loop feature be useful in my application? A. You will need to determine the particular main variable in your application the motor affects. That is the process variable (PV) for the motor. Over time, a faster motor speed will cause a faster change in the PV than a slow motor speed will. By using the PID loop feature, the inverter commands the motor to run at the optimal speed required to maintain the PV at the desired value for current conditions. Using the PID loop feature will require an additional sensor and other wiring, and is considered an advanced application. Inverter Mounting and Installation In This Chapter.... — Orientation to Inverter Features ...................... 2 — Basic System Description ............................... 8 — Step -by -Step Basic Installation ........................ 9 — Powerup Test ................................................ 23 — Using the Front Panel Keypad ...................... 25 Orientation to Inverter Features Orientation to Inverter Features Unpacking and Inspection Please take a few moments to unpack your new SJ200 inverter and perform these steps: 1. Look for any damage that may have occurred during shipping. 2. Verify the contents of the box include: a. One SJ200 inverter b. One Instruction Manual c. One SJ200 Quick Reference Guide 3. Inspect the specifications label on the side of the inverter. Make sure it matches the product part number you ordered. Main Physical Features The SJ200 Series inverters vary in size accord- ing to the current output rating and motor size for each model number. All feature the same basic keypad and connector interface for consis- tent ease of use. The inverter construction has a heat sink at the back of the housing. The larger models include a fan(s) to enhance heat sink performance. The mounting holes are pre- drilled in the heat sink for your convenience. Smaller models have two mounting holes, while larger ones have four. Be sure to use all the mounting holes provided. Two chassis GND screws are located on the metal tab on the heat sink at the bottom of the inverter. Never touch the heat sink during or just after operation; it can be very hot. The electronics housing and front panel are built onto the front of the heat sink. Inverter Keypad - The inverter uses a digital operator interface, or keypad. The four -digit display can show a variety of performance parameters. LEDs indicate whether the display units are Hertz or Amperes. Other LEDs indicate Power (external), and Run/Stop Mode and Program/Monitor Mode status. Membrane keys Run and Stop/Reset, and an output frequency potentiometer (speed setting knob) control motor operation. The FUNC.,1 , and keys allow an operator to navigate to the inverter's functions and parameter values. The Store key is used when changing a setting. Inverter Keypad Removal and Installation Keypad Removal - The SJ200 has a removable keypad. To remove the keypad, locate the retention latch as shown to the right. Press downward on the latch, while gently pulling toward you. The keypad will tilt forward, as two retaining tabs at the bottom edge of the keypad also hold it in place. Then remove the keypad from the keypad bay. SJ200 Inverter Internal LED Indicators / Communications Connector - Refer to the keypad bay in the illustration below. After removing the keypad, the internal LED viewing window will be visible. These LEDs indicate status for your convenience when the keypad is remotely mounted and you are nearer to the inverter location. The RJ45 connection consists of two parts. The clear plastic RJ45 modular interconnect makes the connection between the inverter and the keypad. It is easily removed to allow you to plug a communications cable into the modular connector. =eeeeeeem Internal LED indicators: r Power POW AlarmALM p Run Mode RUN 0 RJ45 modular interconnect / communications connector Keypad bay 0 A WARNING 1011 HAZARD OF PERSONAL INJURY OR ELECTRIC SHOCK Oism.b.P Lg r'a.ntl w�� lD. no,,,, f.'"' IY1J. 9i�fi£riS h. 1SI]Ifdkmgl.9®CIWtiAH�. imlfiaCC' dt4HUi8�tl�5511lO11JJOi FnIhtIWIY44 k 57�t. �I.WPI]IYdt- Installing the Keypad - Follow these steps: 1. Remember to install the RJ45 modular interconnect. Otherwise, there will be no connection to the keypad. 2. Set the bottom edge of the keypad into the inverter keypad bay. 3. Tilt the top edge of the keypad forward. If it stops before seating firmly, DO NOT force the keypad. You may need to adjust the end RJ45 modular connector slightly (upward or downward). Then seat the keypad. 4. Make sure the retention latch clicks into place on the inverter housing top edge. Otherwise, vibration may cause the keypad to loosen in the future. Orientation to Inverter Features Front Housing Cover AiHIGH VOLTAGE: Hazard of electrical shock. Disconnect incoming power before working on this control. Wait five (5) minutes before removing the front cover. Housing Cover Removal - The front housing cover is held in place by two pairs of tabs. Since these are hidden from view, it is good to become familiar with their locations before attempting to remove the cover. The figure below shows a typical housing cover in an upside-down position to reveal the tabs. The two locking tabs are the ones which you will need to press to remove the cover. The two hinging tabs will allow the cover to tilt open after the locking tabs are released. PRESS Locking tabs Hinging tabs J ESS The figure below shows the procedure for removing the housing cover. While pressing inward on the housing, it is helpful to wiggle the cover side-to-side in order to release the locking tabs. DO NOT force the cover open; it is possible to break a tab in this way. 1. Press inward on both sides. 2. Tilt upward after both locking tabs are free. V 1 10 I I` i SJ200 Inverter Logic Connector Introduction After removing the front housing cover, take a moment to become familiar with the connectors, as shown below. Relay output \ contacts PPPPPPirrr1 f; r Jul" Logic inputs Analog input/ output and logic outputs Logic Connector Removal/Replacement - The two 8 -position main logic connectors are removable from the circuit board to make testing or service more convenient. Note that the relay output connector is not removable, as it must carry higher currents and provide high integrity for alarm conditions. The alarm circuit may carry hazardous live voltages (from external wiring) even when the main power to the inverter is OFF. So, never directly touch any terminal or circuit component. The logic input connector (top connector) can be removed by pulling gently upward as shown (below left). DO NOT force the connector, as damage to the circuit board may occur. Try gently shifting the connector side-to-side while pulling, if having difficulty. The analog input/output and logic output connector (bottom connector) has retention screws. DO NOT attempt to remove the connector before loosening the screws. As the figure shows (below right), use a small Phillips screwdriver to loosen the screw at each end. The connector can be pulled forward easily after the screws are removed. Orientation to Inverter Features DIP Switch Introduction The inverter has three (3) internal DIP switches, located to the right of the logic connec- tors as shown below. This section provides an introduction, and refers you to other chapters that discuss each DIP switch in depth. ��777 7 71 73 72 7 1 w rrrrrr SR F485 FTW I h�2'I1LI �I f� OPE PRG SK .. OPE I PRG SR The SR/SK (Source/Sink) DIP switch configures the inverter's intelligent inputs for sinking or sourcing type circuit. Note that the installation and IM Powerup Test steps in this chapter do not require wiring the input terminals. FS_K1 The SR/SK switch configuration is covered in detail in "Using Intelligent Input Terminals" on page 4-9. 485 The 485/OPE (RS-485/Operator) DIP switch configures the inverter's RS - 485 serial port. You can use the inverter's keypad (OPE-SRmini) either on the inverter, or connected via a cable to the serial port. For the keypad, either ■ position of the 485/OPE DIP switch will work. However, communication OPE With "smart" operator devices requires the proper setting. Using digital operators (such as OPE—SR or OPE—OEX requires the "OPE" setting. Inverter control via a ModBus network communication requires the "485" setting. See "Connecting the Inverter to ModBus" on page B-3 for more details. TM The TM/PRG (Terminal/Program) DIP switch affects the inverter's setting for control sources. Parameter A001 sets the source selection for the inverter's output frequency (motor speed). Parameter A002 selects the Run ■ command source (for FW and RV). These independently select among PRG sources such as input terminals, inverter keypad keys and potentiometer, internal register settings, ModBus network, etc. When the TM/PRG switch is set to PRG, parameter settings A001 and A002 are in effect. However, when the switch is in the TM (terminal) position, the inverter uses the analog input terminals for the motor speed setting, and uses the [FW] and/or [REV] terminals for the Run command. More information is in "Control Source Settings" on page 3-93-9. Power Wiring Access - First, ensure no power source of any kind is connected to the inverter. If power has been connected, wait five minutes after powerdown and verify the Power LED is OFF to proceed. After removing the front housing cover, the housing partition that covers the power wiring exit will be able to slide upward as shown to the right. Notice the four wire exit slots (on larger model inverters) in the housing partition. This helps keep the power wiring (to the left) separate from signal -level logic or analog wiring (to the right). Remove the housing partition and as shown as set it aside in a secure place while wiring. Never operate the inverter drive with the parti- tion removed or the front housing cover removed. The power input and motor 3-phase wiring connect to the lower row of terminals. The upper row of power terminals connect to optional dynamic braking components. The following sections in this chapter will describe the system design and guide you through a step-by-step installation process. After the section on wiring, this chapter will show how to use the front panel keys to access functions and edit parameters. SJ200 Inverter Power and motor connection terminals Basic System Description Basic System Description A motor control system will obviously include a motor and inverter, as well as a breaker or fuses for safety. If you are connecting a motor to the inverter on a test bench just to get started, that's all you may need for now. But a system can also have a variety of additional components. Some can be for noise suppression, while others may enhance the inverter's braking performance. The figure and table below show a system with all the optional components you may need in your finished application. From power supply ' V,���Brealer, MCCB or GFI 7�� L1 L2 L3 +1 Inverter Name Function Breaker / discon- A molded -case circuit breaker (MCCB), ground fault nect interrupter (GFI), or a fused disconnect device. NOTE: The installer must refer to the NEC and local codes to ensure safety and compliance. Input -side This is useful in suppressing harmonics induced on the AC Reactor power supply lines and for improving the power factor. WARNING: Some applications must use an input - side AC reactor to prevent inverter damage. See Warning on next page. Radio noise filter Electrical noise interference may occur on nearby equipment such as a radio receiver. This magnetic choke filter helps reduce radiated noise (can also be used on output). EMI filter (for Reduces the conducted noise on the power supply CE applications, wiring between the inverter and the power distribution see Appendix D) system. Connect to the inverter primary (input side). Radio noise filter This capacitive filter reduces radiated noise from the (use in non -CE main power wires in the inverter input side. applications) DC link choke Suppresses harmonics generated by the inverter. However, it will not protect the input diode bridge rectifier. Braking resistor This is useful for increasing the inverter's control torque for high duty -cycle (ON-OFF) applications, and improving the decelerating capability. Radio noise filter Electrical noise interference may occur on nearby equipment such as a radio receiver. This magnetic choke filter helps reduce radiated noise (can also be used on input). Output -side This reactor reduces the vibrations in the motor caused AC reactor by the inverter's switching waveforms, by smoothing the waveform to approximate commercial power quality. It is also useful to reduce harmonics when wiring from the inverter to the motor is more than l Om in length. LCR filter Sine wave shaping filter for output side. NOTE: Note that some components are required for regulatory agency compliance (see Chapter 5 and Appendix D). SJ200 Inverter I WARNING: In the cases below involving a general-purpose inverter, a large peak current can flow on the power supply side, sometimes destroying the converter module: 1.The unbalance factor of the power supply is 3% or higher. 2. The power supply capacity is at least 10 times greater than the inverter capacity (or the power supply capacity is 500 kVA or more). 3.Abrupt power supply changes are expected, due to conditions such as: a. Several inverters are interconnected with a short bus. b. A thyristor converter and an inverter are interconnected with a short bus. c. An installed phase advance capacitor opens and closes. Where these conditions exist or when the connected equipment must be highly reliable, you MUST install an input -side AC reactor of 3% (at a voltage drop at rated current) with respect to the supply voltage on the power supply side. Also, where the effects of an indirect lightning strike are possible, install a lightning conductor. Step -by -Step Basic Installation This section will guide you through the following basic steps of installation: Step Activity Page 1 Choose a mounting location in compliance with the Warnings and Cautions. See NOTE below. 2-10 2 Check the mounting location for adequate ventilation. 2-11 3 Cover the inverter's ventilation openings to prevent debris from entering. 2-11 4 Check the inverter dimensions for footprint and mounting hole locations. 2-12 5 Study the Cautions, Warnings, wire and fuse sizes, and terminal torque specifications before wiring the inverter. 2-17 6 Connect wiring for the inverter power input. 2-19 7 Wire the inverter output to the motor. 2-22 g Uncover the inverter's ventilation openings applied in Step 3. 2-23 9 Perform the Powerup Test. (This step includes several substeps.) 2-23 10 Make observations and check your installation. 2-34 NOTE: If the installation is in an EU country, study the EMC installation guidelines in Appendix D. Step -by -Step Basic Installation Choosing a Mounting Location Step 1: Study the following caution messages associated with mounting the inverter. This is the time when mistakes are most likely to occur that will result in expensive rework, equipment damage, or personal injury. ICAUTION: Be sure to install the unit on flame -resistant material such as a steel plate. Otherwise, there is the danger of fire. AI CAUTION: Be sure not to place any flammable materials near the inverter. Otherwise, there is the danger of fire. A!CAUTION: Be sure not to let the foreign matter enter vent openings in the inverter * housing, such as wire clippings, spatter from welding, metal shavings, dust, etc. Other- wise, there is the danger of fire. CAUTION: Be sure to install the inverter in a place that can bear the weight according A to the specifications in the text (Chapter 1, Specifications Tables). Otherwise, it may fall and cause injury to personnel. A!CAUTION: Be sure to install the unit on a perpendicular wall that is not subject to * vibration. Otherwise, it may fall and cause injury to personnel. CAUTION: Be sure not to install or operate an inverter that is damaged or has missing A!* g parts. Otherwise, it may cause injury to personnel. CAUTION: Be sure to install the inverter in a well -ventilated room that does not have A!* e direct exposure to sunlight, a tendency for high temperature, high humidity or dew condensation, high levels of dust, corrosive gas, explosive gas, inflammable gas, grinding -fluid mist, salt damage, etc. Otherwise, there is the danger of fire. Ensure Adequate Ventilation D SJ200 Inverter Step 2: To summarize the caution messages—you will need to find a solid, non-flamma- ble, vertical surface that is in a relatively clean and dry environment. In order to ensure enough room for air circulation around the inverter to aid in cooling, maintain the speci- fied clearance around the inverter specified in the diagram. Clear area 10 cm (3.94") minimum D SJ200 5 cm (1.97") 5 cm (1.97") minimum minimum 10 cm (3.94") minimum Air flow CAUTION: Be sure to maintain the specified clearance area around the inverter and to provide adequate ventilation. Otherwise, the inverter may overheat and cause equipment damage or fire. Keep Debris Out of Inverter Vents Step 3: Before proceeding to the wiring section, it's 4EjD a good time to temporarily cover the inverter's ventilation openings. Paper and masking tape are all that is needed. This will prevent harmful debris such as wire clippings and metal shavings from entering the inverter during installation. Please observe this checklist while mounting the inverter: Ventilation holes (top) 1. The ambient temperature must be in the range of \ –10 to 40°C. Ventilation holes (both sides) 2. Keep any other heat -producing equipment as far away from the inverter as possible. 3. When installing the inverter in an enclosure, maintain the clearance around the inverter and verify that its ambient temperature is within specification when the enclosure door is closed. 4. Do not remove the front housing cover at any time during operation. Step -by -Step Basic Installation Check Inverter Dimensions Step 4: Locate the applicable drawing on the following pages for your inverter. a� Dimensions are given in millimeters (inches) format. SJ200-002NFEF,—002NFU 5(0.20) N • �� iiivn�«iii • i it ri ri r © O O 67(2.64 80(3.15 ■ P) CV r C!� � Alarm Terminal 000 N � T T T win, ansuran 5 (0 11, cY) _ o Earth 0 r T ty 00000 OOOQ 000 000 000 000 0000 000 000 00000 F=-�- - -1 L� NOTE: Some inverter housings require two mounting screws, while others require four. Be sure to use lock washers or other means to ensure screws do not loosen due to vibration. Dimensional drawings, continued... SJ200-004NFEF,—004NFU,—005NFEF 5 (0.20) N o r o -mm M olh �0 �0 �0 oxui O ® oPRO O O O O YJ CV r � �? Lq Alarm Terminal It le LO 0 0 0 r N It T T T rwnrnw.rr M. 1 SJ200 Inverter I LL I ff�� ��� M Step -by -Step Basic Installation Dimensional drawings, continued... SJ200-007NFEF,—007NFU, —011 NFEF,—004HFEF,—004HFU WW" irMo 00, R OA LL 00000® z '0C", O (O r r �mLO T T T 5(0.20) 98 (3.86) - 110 (4.33) N 0 Alarm Terminal 0 O 000 O O OO 00 O 00 0 00 0 00 0 m�� o 00 0 00 0 00 0 0000 0 f= --� J m L L7 � o tCw,,71Tv.in1 Maio Terminal 0000000000000 000 O r Earth Dimensional drawings, continued... SJ200-007HFEF,-007HFU 2 - � 5 +O��N PMO 0000 O O O OD 00 0 00 0 00 0 00 0 �o0 0 00 0 00 0 ��® AMO ® OA m L L - �I 7 ,-� LL LLLL �OOO® Z z U') N O LO CO M T T LO T UJ 5(0.20) 98 (3ez-.86) N 110 (4.33) o ME O CO SJ200 Inverter Alarm Terminal I Control Terminal Mai rminal 0000 O O O OD 00 0 00 0 00 0 00 0 �o0 0 00 0 00 0 0000 0 m L L - �I 7 Control Terminal Mai rminal Step -by -Step Basic Installation Dimensional drawings, continued... SJ200-015NFEF,—015NFU,—022NFEF,—022NFU,—037LFU,—015HFEF,—015HFU, —022HFEF,—022HFU,--030HFEF,—040HFEF,—040HFU �98 (3.86)(3.86)) 110(4.33) — T J Alarm Terminal Exhaust 4 LL LL z � N O It Lf) 00 0 Ln 'T^ T T W T 5(0.20) 00 N 0 1 Control Terminal Main�Terminal 00 0� E=IJ L11 00 O 00 O 00 O 00 O �00 O 00 O 00 0 0 0 o L L7- -1 p Control Terminal Main�Terminal SJ200 Inverter Prepare for Wiring Step 5: It is very important to perform the wiring steps carefully and correctly. Before proceeding, please study the caution and warning messages below. ! WARNING: "Use 60/75°C Cu wire only" or equivalent. ! WARNING: "Open Type Equipment." IWARNING: "Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240 V maximum." For models with suffix N or L. AA WARNING: "Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 480 V maximum." For models with suffix H. AiHIGH VOLTAGE: Be sure to ground the unit. Otherwise, there is a danger of electric shock and/or fire. AiHIGH VOLTAGE: Wiring work shall be carried out only by qualified personnel. Other - wise, there is a danger of electric shock and/or fire. AiHIGH VOLTAGE: Implement wiring after checking that the power supply is OFF. Oth- erwise, you may incur electric shock and/or fire. AiHIGH VOLTAGE: Do not connect wiring to an inverter or operate an inverter that is not mounted according the instructions given in this manual. Otherwise, there is a danger of electric shock and/or injury to personnel. Step -by -Step Basic Installation Determining Wire and Fuse Sizes The maximum motor currents in your application determines the recommended wire size. The following table gives the wire size in AWG. The "Power Lines" column applies to the inverter input power, output wires to the motor, the earth ground connection, and any other component shown in the "Basic System Description" on page 2-8. The "Signal Lines" column applies to any wire connecting to the two green 8 -position connectors just inside the front panel half -door. Motor Output (kW/HP) Inverter Model Wiring Applicable equipment kW HP Power Lines Signal Lines Fuse (UL -rated, class J, 600V) 0.2 1/4 SJ200-002NFEF/NFU AWG16 / 1.3 mm2 18 to 28 AWG / shm2 0.to 0.75 mm2 shielded wire (see Note 4) 10A 0.4 1/2 SJ200-004NFEF/NFU 0.55 3/4 SJ200-005NFEF 0.75 1 SJ200-007NFEF/NFU AWG14 / 2.1 mm2 15A 1.1 11/2 SJ200-01INFEF 1.5 2 SJ200-015NFEF/NFU AWG12 / 3.3 mm2 20A (single ph.) 15A (three ph.) 2.2 3 SJ200-022NFEF/NFU AWG10 / 5.3 mm2 30A (single ph.) 20A (three ph.) 3.7 5 SJ200-037LFU AWG12 / 3.3 mm2 30A 5.5 7 1/2 SJ200-055LFU AWG10 / 5.3 m 40A 7.5 10 SJ200-075LFU AWG8 / 8.4 mm2 50A 0.4 1/2 SJ200-004HFEF/HFU AWG 16 / 1.3 mm2 3A 0.75 1 SJ200-007HFEF/HFU 6A 1.5 2 SJ200-015HFEF/HFU 10A 2.2 3 SJ200-022HFEF/HFU 3.0 4 SJ200-030HFEF AWG14 / 2.1 mm2 15A 4.0 5 SJ200-040HFEF/HFU 5.5 71/2 SJ200-055HFEF/HFU AWG12 / 3.3 mm2 20A 7.5 10 SJ200-075HFEF/HFU 25A Note 1: Field wiring must be made by a UL -listed and CSA -certified closed-loop terminal connector sized for the wire gauge involved. Connector must be fixed by using the crimping tool specified by the connector manufacturer. Note 2: Be sure to consider the capacity of the circuit breaker to be used. Note 3: Be sure to use a larger wire gauge if power line length exceeds 66 ft. (20m). Note 4: Use 18 AWG / 0.75 mm2 wire for the alarm signal wire ([ALO], [AL 1 ], [AL2] terminals). Terminal Dimensions and Torque Specs O SJ200 Inverter The terminal screw dimensions for all SJ200 inverters are listed in table below. This information is useful in sizing spade lug or ring lug connectors for wire terminations. CAUTION: Fasten the screws with the specified fastening torque in the table below. Check for any loosening of screws. Otherwise, there is the danger of fire. When connecting wiring, use the tightening torque listed in the following table to safely attach wiring to the connectors. Screw Tightening Torque Screw Tightening Torque Screw Tightening Torque M2 0.2 N•m (max. 0.25 N -m) M3.5 0.8 N•m (max. 0.9 N -m) M5 2.0 N•m (max. 2.2 N -m) M3 0.5 N•m (max. 0.6 N -m) M4 1.2 N•m (max. 1.3 N -m) Wire the Inverter Input to a Supply Step 6: In this step, you will connect wiring to the a[:�D input of the inverter. First, you must determine whether the inverter model you have requires three-phase power only, or if it can accept either single-phase or three-phase power. All models have the same power connector terminals [R/L1], [S/L2], and [T/L3]. So, you must refer to the specifications label (on the side of the inverter) for the acceptable power source types! For inverters that can accept single-phase power and are connected that way, terminal [S/L2] will remain unconnected. The wiring example to the right shows an SJ200 inverter wired for 3-phase input. Note the use of ring lug connectors for a secure connection. Models 002NF, Models 007NF- Models 055LF, Number 004NF, 005NF 022NF, 037LF, 075LF, 05511F, Connector of Screw 004HF - 040HF 075HF Terminals Screw Width Screw Width Screw Width Diameter (mm) Diameter (mm) Diameter (mm) Power Terminals 12 M3.5 7.1 M4 9 M5 13 Control Signal 16 M2 — M2 — M2 — Alarm Signal 3 M3 M3 — M3 — Ground Terminals 2 M4 — M4 — M5 — When connecting wiring, use the tightening torque listed in the following table to safely attach wiring to the connectors. Screw Tightening Torque Screw Tightening Torque Screw Tightening Torque M2 0.2 N•m (max. 0.25 N -m) M3.5 0.8 N•m (max. 0.9 N -m) M5 2.0 N•m (max. 2.2 N -m) M3 0.5 N•m (max. 0.6 N -m) M4 1.2 N•m (max. 1.3 N -m) Wire the Inverter Input to a Supply Step 6: In this step, you will connect wiring to the a[:�D input of the inverter. First, you must determine whether the inverter model you have requires three-phase power only, or if it can accept either single-phase or three-phase power. All models have the same power connector terminals [R/L1], [S/L2], and [T/L3]. So, you must refer to the specifications label (on the side of the inverter) for the acceptable power source types! For inverters that can accept single-phase power and are connected that way, terminal [S/L2] will remain unconnected. The wiring example to the right shows an SJ200 inverter wired for 3-phase input. Note the use of ring lug connectors for a secure connection. Step -by -Step Basic Installation Please use the terminal arrangement below corresponding to your inverter model. Inverter models SJ200-002NFEF/NFU to—005NFEF/NFU Jumper MMMMMM L1 L2 N/L3 U/T1 V/T2 W/T3 Chassis Ground ig� Inverter models SJ200-007NFEF to—022NFEF, —007NFU to—037LFU,—004HFEF/HFU to—040HFEF/HFU Jumper MMM M Chassis NFEF, NFU L1 L2 N/L3 U/T1 V/T2 W/T3 Ground LFU, HFEF, HFU L1 L2 L3 U/T1 V/T2 W/T3 �OD Inverter models SJ200-055HFEF/HFU,—075HFEF/HFU L1 L2 L3 U/T1 V/T2 W/T3 6i ff_' 00 96 Jumper Chassis Ground NOTE: An inverter powered by a portable power generator may receive a distorted power waveform, overheating the generator. In general, the generator capacity should be five times that of the inverter (kVA). AeCAUTION: Be sure that the input voltage matches the inverter specifications: • Single/Three phase 200 to 240 V 50/60 Hz (up to 2.2kW) for NFEF/NFU models • Three phase 200 to 240V 50/601-lz (above 2.2kW) for LFU models • Three phase 380 to 480 V 50/601-lz for HFEF models ICAUTION: Be sure not to power a three -phase -only inverter with single phase power. Otherwise, there is the possibility of damage to the inverter and the danger of fire. SJ200 Inverter ICAUTION: Be sure not to connect an AC power supply to the output terminals. Other- , wise, there is the possibility of damage to the inverter and the danger of injury and/or fire. SJ200 Inverter Power Input Output to Motor ACAUTION: Remarks for using ground fault interrupter breakers in the main power supply: Adjustable frequency inverters with CE -filters (RFI -filter) and shielded (screened) motor cables have a higher leakage current toward Earth GND. Especially at the moment of switching ON this can cause an inadvertent trip of ground fault interrupters. Because of the rectifier on the input side of the inverter there is the possibility to stall the switch -off function through small amounts of DC current. Please observe the following: • Use only short time -invariant and pulse current -sensitive ground fault interrupters with higher trigger current. • Other components should be secured with separate ground fault interrupters. • Ground fault interrupters in the power input wiring of an inverter are not an absolute protection against electric shock. A!CAUTION: Be sure to install a fuse in each phase of the main power supply to the inverter. Otherwise, there is the danger of fire. !CAUTION: For motor leads, ground fault interrupter breakers and electromagnetic contactors, be sure to size these components properly (each must have the capacity for rated current and voltage). Otherwise, there is the danger of fire. Step -by -Step Basic Installation Wire the Inverter Output to Motor Step 7: The process of motor selection is beyond the scope of this manual. However, it must be an AC induction motor with three phases. It should also come with a chassis ground lug. If the motor does not have three power input leads, stop the installation and verify the motor type. Other guidelines for wiring the motor include: • Use an inverter -grade motor for maximum motor life (1600V insulation). • For standard motors, use the AC reactor accessory if the wiring between the inverter and motor exceeds 10 meters in length. Simply connect the motor to the terminals [U/T1], [V/T2], and [W/T3] as shown to the right. This is a good time to connect the chassis ground lug on the drive as well. The motor chassis ground must also connect to the same point. Use a star ground (single - point) arrangement, and never daisy -chain the grounds (point-to-point). Use the same wire gauge on the motor and chassis ground wiring as you used on the power input wiring in the previous step. After completing the wiring: Check the mechanical integrity of each wire crimp and terminal connection. Replace the housing partition that covers access to the power connections. Replace the front housing cover. First, align the two hinging tabs. Then press the cover onto the inverter until the locking tabs click into place. Logic Control Wiring SJ200-037HFEF/LFU Wiring Example To Power To Chassis To Motor Supply Ground After completing the initial installation and powerup test in this chapter, you may need to wire the logic signal connector for your application. For new inverter users/applications, we highly recommend that you first complete the powerup test in this chapter without adding any logic control wiring. Then you will be ready to set the required parameters for logic control as covered in Chapter 4, Operations and Monitoring. Uncover the Inverter Vents Step 8: After mounting and wiring the inverter, remove any covers from the inverter housing. This includes material over the side ventilation ports. AWARNING: Make sure the input power to the inverter is OFF. If the drive has been powered, leave it OFF for five minutes before continuing. Powe ru p Test SJ200Inverter � Ventilation holes (top) OD DO O� Ventilation holes (both sides) Step 9: After wiring the inverter and motor, you're ready to do a powerup test. The procedure that follows is designed for the first-time use of the drive. Please verify the following conditions before conducting the powerup test: • You have followed all the steps in this chapter up to this step. • The inverter is new, and is securely mounted to a non-flammable vertical surface • The inverter is connected to a power source and motor. • No additional wiring of inverter connectors or terminals has been done. • The power supply is reliable, and the motor is a known working unit, and the motor nameplate ratings match the inverter ratings. • The motor is securely mounted, and is not connected to any load. Goals for the Powerup Test If there are any exceptions to the above conditions at this step, please take a moment to take any measures necessary to reach this basic starting point. The specific goals of this powerup test are: 1. Verify that the wiring to the power supply and motor is correct. 2. Demonstrate that the inverter and motor are generally compatible. 3. Get an introduction to the use of the built-in operator keypad. The powerup test gives you an important starting point to ensure a safe and successful application of the Hitachi inverter. We highly recommend performing this test before proceeding to the other chapters in this manual. Powerup Test Pre-test and Operational Precautions The following instructions apply to the powerup test, or to any time the inverter is powered and operating. Please study the following instructions and messages before proceeding with the powerup test. 1. The power supply must have fusing suitable for the load. Check the fuse size chart presented in Step 5, if necessary. 2. Be sure you have access to a disconnect switch for the drive input power if necessary. However, do not turn OFF power during inverter operation unless it is an emergency. 3. Turn the keypad potentiometer to the minimum position (fully counter -clockwise). ACAUTION: The heat sink fins will have a high temperature. Be careful not to touch them. Otherwise, there is the danger of getting burned. A! CAUTION: The operation of the inverter can be easily changed from low speed to high speed. Be sure to check the capability and limitations of the motor and machine before operating the inverter. Otherwise, there is the danger of injury. CAUTION: If you operate a motor at a frequency higher than the inverter standard default setting (50Hz/60Hz), be sure to check the motor and machine specifications with A! h the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage and/or injury. ACAUTION: Check the following before and during the powerup test. Otherwise, there is the danger of equipment damage. • Is the shorting bar between the [+1] and [+] terminals installed? DO NOT power or operate the inverter if the jumper is removed. • Is the direction of the motor rotation correct? • Did the inverter trip during acceleration or deceleration? • Were the rpm and frequency meter readings as expected? • Were there any abnormal motor vibrations or noise? Powering the Inverter If you have followed all the steps, cautions and warnings up to this point, you're ready to apply power. After doing so, the following events should occur: • The POWER LED will illuminate. • The numeric (7 -segment) LEDs will display a test pattern, then stop at D.O. • The Hz LED will be ON. If the motor starts running unexpectedly or any other problem occurs, press the STOP key. Only if necessary should you remove power to the inverter as a remedy. NOTE: If the inverter has been previously powered and programmed, the LEDs (other than the POWER LED) may illuminate differently than as indicated above. If necessary, you can initialize all parameters to the factory default settings. See "Restoring Factory Default Settings" on page 6-8. SJ200 Inverter Using the Front Panel Keypad Please take a moment to familiarize yourself with the keypad layout shown in the figure below. The display is used in programming the inverter's parameters, as well as monitor- ing specific parameter values during operation. Display Units (Hertz / Amperes) LEDs; Power LED Parameter Display HIT `�HI ALARMO so. OA Run Key Enable LED ® ORUN�O i O PRG. Run Key FUN ®®STR Stop/Reset Key Function key Up/Down keys Key and Indicator Legend Alarm LED Run/Stop LED Program/Monitor LED Potentiometer Enable LED Potentiometer Store key • Run/Stop LED - ON when the inverter output is ON and the motor is developing torque (Run Mode), and OFF when the inverter output is OFF (Stop Mode). • Program/Monitor LED - This LED is ON when the inverter is ready for parameter editing (Program Mode). It is OFF when the parameter display is monitoring data (Monitor Mode). • Run Key Enable LED - is ON when the inverter is ready to respond to the Run key, OFF when the Run key is disabled. • Run Key - Press this key to run the motor (the Run Enable LED must be ON first). Parameter F004, Keypad Run Key Routing, determines whether the Run key generates a Run FWD or Run REV command. • Stop/Reset Key - Press this key to stop the motor when it is running (uses the programmed deceleration rate). This key will also reset an alarm that has tripped. • Potentiometer - Allows an operator to directly set the motor speed when the potenti- ometer is enabled for output frequency control. • Potentiometer Enable LED - ON when the potentiometer is enabled for value entry. • Parameter Display - A 4 -digit, 7 -segment display for parameters and function codes. • Display Units, Hertz/Amperes - One of these LEDs will be ON to indicate the units associated with the parameter display. • Power LED - This LED is ON when the power input to the inverter is ON. • Alarm LED - ON when an inverter trip is active (alarm relay contacts will be closed). • Function Key - This key is used to navigate through the lists of parameters and functions for setting and monitoring parameter values. • Up/Down ( Q,'W) Keys -Use these keys alternately to move up or down the lists of parameter and functions shown in the display, and increment/decrement values. • Store ( srR ) Key - When the unit is in Program Mode and you have edited a parameter value, press the Store key to write the new value to the EEPROM. Using the Front Panel Keypad Keys, Modes, and Parameters The purpose of the keypad is to provide a way to change modes and parameters. The term function applies to both monitoring modes and parameters. These are all accessible through function codes that are primarily 4 -character codes. The various functions are separated into related groups identifiable by the left-most character, as the table shows. HITACHI POWER O d L•' 1 AZ ALARM O O O RUN O PRG •: • FUN ® ® STR Monitor Function Group Type (Category) of Function Mode to Access PRG LED Indicator "D" Monitoring functions Monitor O "F" Main profile parameters Program O "A" Standard functions Program O "B" Fine tuning functions Program O "C" Intelligent terminal functions Program 0 "H" Motor constant functions Program O "E" Error codes For example, function "A004" is the base frequency setting for the motor, typically 50 Hz or 60 Hz. To edit the parameter, the inverter must be in Program Mode (PRG LED will be ON). You use the front panel keys to first select the function code "A004." After displaying the value for "A004," use the Up/Down (l or 'W ) keys to edit it. HITACHI ALARM; O Hz OA O O RUN ® ®O PRG ..O • • FUN ® ® STR HITACHI POWER ALARM O R�j �� O Hz �L� 01 O A FUNC O ; RUN O• FUNC O PRG • • FUN ®®STR HITACHI A LARM; M;. L' OAz O O RUN ® ®1 PRG .� • • FUN ®®STR NOTE: The inverter 7 -segment display shows lower case "b" and "d," meaning the same as the upper case letters "B" and "D" used in this manual (for uniformity "A to F"). The inverter automatically switches into Monitor Mode when you access "D" Group functions. It switches into Program Mode when you access any other group, because they all have editable parameters. Error codes use the "E" Group, and appear automatically when a fault event occurs. Refer to "Monitoring Trip Events, History. & Conditions" on page 6-5 for error code details. MONITOR PROGRAM "A" Group "D" Group «B" Group "C" Group "F" Group "H" Group SJ200 Inverter Keypad Navigational Map The SJ200 Series inverter drives have many programmable functions and parameters. Chapter 3 will cover these in detail, but you need to access just a few items to perform the powerup test. The menu structure makes use of function codes and parameter codes to allow programming and monitoring with only a 4 -digit display and a few keys and LEDs. So, it is important to become familiar with the basic navigational map of parame- ters and functions in the diagram below. You may later use this map as a reference. Monitor Mode Program Mode O PRG LED=OFF PRGLED=ON Display Data Select Parameter Edit Parameter (000.01 powerdown ® FDNC Select ti�Function 833or Group ®It [loot, H--- r R--- -� FOOq UNC 1 2 The navigational map shows the relationship of all resources of the inverter in one view. In general, use the E) key to move left and right, and the Al W (arrow) keys to move up and down. as powerup tHOStore 0 07 default ® ® Increment/ decrement value ®' Edit FUNCFUNC 2 3. l F12-3. STR ® L®7 b 1 S O O ' O [] 101, 101, 1 Write 010 data to EEPROM Return to parameter ® — 0\list The navigational map shows the relationship of all resources of the inverter in one view. In general, use the E) key to move left and right, and the Al W (arrow) keys to move up and down. Using the Front Panel Keypad Selecting Functions and Editing Parameters To prepare to run the motor in the powerup test, this section will show how to configure the necessary parameters: 1. Confirm the TM/PRG DIP switch setting. 2. Select the keypad potentiometer as the source of motor speed command (A001) 3. Select the keypad as the source of the RUN command (AO02) 4. Set the inverter's maximum output frequency to the motor (A003) 5. Set the motor current for proper thermal protection (13012) 6. Set the inverter's Automatic Voltage Regulation for the motor (AO82) 7. Set the number of poles for the motor (HO04) The following series of programming tables are designed for successive use. Each table uses the previous table's final state as the starting point. Therefore, start with the first and continue programming until the last one. If you get lost or concerned that some of the other parameters settings may be incorrect, refer to "Restoring Factory Default Settings" on page 6-8. TM TM/PRG DIP Switch Setting - This switch must be in the "PRG" position (factory default) in order for A001 and A002 settings to be active. Other- wise, the keypad will be unable to accept a Run command or set the motor speed with the potentiometer. If the switch setting has been changed, see the PRG "DIP Switch Introduction" on page 2-6. Prepare to Edit Parameters - This sequence begins with powering ON the inverter; then it shows how to navigate to the "A" Group parameters for subsequent settings. You can also refer to the "Keypad Navigational Map" on page 2-27 for orientation through- out the steps. Action Display Func./Parameter Turn ON the inverter.Inverter O O RUN O PRG ,,O output frequency displayed (OHz in Stop Mode). Press the FDNC key. �� "D" Group selected Press the ® key four times. "A" Group selected Select the Potentiometer for Speed Command - The inverter output frequency can be set from several sources, including an analog input, memory setting, or the network, for example. The powerup test uses the keypad potentiometer as the speed control source for your convenience. In the figure to the right, notice the Potentiometer Enable LED, just above the knob. If the LED is ON, the potentiometer is already selected as the source, and you may skip this step. Note that the default setting depends on the country. Potentiometer Enable LED HITACHI '" ` 1 • Hz _I LI, L/ O A ALAR O O RUN O PRG ,,O 0. FUN ®®STR SJ200 Inverter If the Potentiometer Enable LED is OFF, follow the steps below. Action Display Func./Parameter (Starting point) AM] "A" Group selected Press theuNc key. i Speed command source setting Press the uNc key again. 00 = Keypad potentiometer 01 =Control terminals 02 =Function F001 setting 03 = ModBus network 10 = Calculate function output Press the ® key. L i� 00 = potentiometer (selected) Press the sTR key.3 Stores parameter, returns to "A" Group list Select the Keypad for the RUN Command - The RUN command causes the inverter to accelerate the motor to the selected speed. The Run command can arrive from various sources, including the control terminals, the Run key on the keypad, or the network. In the figure to the right, notice the Run Key Enable LED, just above the Run key. If the LED is ON, the Run key is already selected as the source, and you may skip this step. Note that the default setting depends on the country. Run Key Enable LED HITACHI POWER ALARM O 0.0 oAZ O O RUN O PRG .-0. FUN ® ® STR If the Potentiometer Enable LED is OFF, follow the steps below (the table resumes action from the end of the previous table). Action Display Func./Parameter (Starting point) AM] Speed command source setting Press the ® key once. A� � � i Run command source setting Press theuNc key. 01 = control terminals 02 = Run key on keypad 03 = ModBus network input Press the ® key. W 02 = keypad (selected) Press the sTR key.W Stores parameter, returns to "A" Group list NOTE: After completing the steps above, the Run Key Enable LED will be ON. This does not mean the motor is trying to run; it means that the RUN key is now enabled. DO NOT press the RUN key at this time—complete the parameter setup first. Using the Front Panel Keypad Set the Motor Base Frequency - The motor is designed to operate at a specific AC frequency. Most commercial motors are designed for 50/60 Hz operation. First, check the motor specifications. Then follow the steps below to verify the setting or correct it for your motor. DO NOT set it greater than 50/60 Hz unless the motor manufacturer specifically approves operation at the higher frequency. Action Display Func./Parameter (Starting point) AW Run command source setting Press the ® key once. AM Base frequency setting Press the uNc key. or 9 Default value for base frequency. US = 60 Hz, Europe = 50 Hz. Press the ® or ® key as needed. Set to your motor specs (your display may be different) Press the sTR key.'�i Stores parameter, returns to "A" Group list CAUTION: If you operate a motor at a frequency higher than the inverter standard default setting (50Hz/6OHz), be sure to check the motor and machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage. Set the AVR Voltage Setting - The inverter has an Automatic Voltage Regulation (AVR) function. It adjusts the output voltage to match the motor's nameplate voltage rating. The AVR smooths out fluctuations in the input power source, but note that it does not boost the voltage in the event of a brown -out. Use the AVR setting (A082) that most closely matches the one for your motor. • 200V Class: 200 / 215 / 220 / 230 / 240 VAC • 400V Class: 380 / 400 / 415 / 440 / 460 / 480 VAC TIP: If you need to scroll through a function or parameter list, press and hold thel or key to auto -increment through the list. To set the motor voltage, follow the steps on the following page. SJ200 Inverter Action Display Func./Parameter (Starting point) 3 Base frequency setting Press the ® key and hold until--> AVR voltage select Press the FUNC key. ] or EW400V Default values for AVR voltage: 200V class = 230VAC 400V class = 400VAC (—xxxFEF) class = 460VAC (—xxxFU) Press the ® or ® key as needed.j j Set to your motor specs (your display may be different) Press the sTR key. �i , �- Level of electronic thermal setting Stores parameter, returns to "A" Group list Set the Motor Current - The inverter has thermal overload protection that is designed to protect the inverter and motor from overheating due to an excessive load. The inverter's uses the motor's current rating to calculate the time -based heating effect. This protection depends on using the correct current rating for your motor. The level of electronic thermal setting, parameter B012, is adjustable from 20% to 120% of the inverter's rated current. A proper configuration will also help prevent unnecessary inverter trip events. Read the motor's current rating on its manufacturer's nameplate. Then follow the steps below to configure the inverter's thermal overload protection setting. Action Display Func./Parameter (Starting point) ' , Base frequency setting Press the uNc key. 'A" Group selected Press the ® key. "B" Group selected Press the uNc key. j First `B" Group parameter selected Press the ® key and hold until--> �� �� Level of electronic thermal setting Press the FDNC key. 1 Default value will be 100% of inverter rated current. Press the or ®key as needed. y I.Ou Set to your motor specs (your display may be different) Press the sTR key.�i Stores parameter, returns to `B" Group list Using the Front Panel Keypad Set the Number of Motor Poles - The motor's internal winding arrangement deter- mines its number of magnetic poles. The specifications label on the motor usually indicates the number of poles. For proper operation, verify the parameter setting matches the motor poles. Many industrial motors have four poles, corresponding to the default setting in the inverter (H004). Follow the steps in the table below to verify the motor poles setting and change it if necessary (the table resumes action from the end of the previous table.) Action Display Func./Parameter (Starting point) E] j Level of electronic thermal setting Press the FDNC key. `B" Group selected Press the ® key two times. "H" Group selected Press the FUNc key. First "H" parameter Press the ® key once. Motor poles parameter Press the FUNc key. 2 = 2 poles 4 = 4 poles (default) 6 = 6 poles 8 = 8 poles Press the ® or ® key as needed. Set to match your motor (your display may be different) Press the sTR key. Stores parameter, returns to "H" Group list This step concludes the parameter setups for the inverter. You are almost ready to run the motor for the first time! TIP: If you became lost during any of these steps, first observe the state of the PRG LED. Then study the "Keypad Navigational Map" on page 2-27 to determine the current state of the keypad controls and display. As long as you do not press the STR key, no parameters will be changed by keypad entry errors. Note that power cycling the inverter causes it to power up Monitor Mode, displaying the value for D001 (output frequency). The next section will show you how to monitor a particular parameter from the display. Then you will be ready to run the motor. Monitoring Parameters with the Display After using the keypad for parameter editing, it's a good idea to switch the inverter from Program Mode to Monitor Mode. The PRG LED will be OFF, and the Hertz or Ampere LED indicates the display units. For the powerup test, monitor the motor speed indirectly by viewing the inverter's SJ200 Inverter HITACHI POWER ALARM O �� *HZ S 0 1. U 0 O ORUN O PRG .: • • • FUN ® ® STR output frequency. The output frequency must not be confused with base frequency (501 60 Hz) of the motor, or the carrier frequency (switching frequency of the inverter, in the kHz range). The monitoring functions are in the "D" list, located near the top left of the "Keypad Navigational Map" on page 2-27. Output frequency (speed) monitor - Resuming keypad operation from the previous table, follow the steps below. Or instead, you can simply power cycle the inverter, which automatically sets the display to D001 (output frequency value). Action Display Func./Parameter Press the uNc key. "H" Group selected Press the ® key. d 7 Output frequency selected Press theuNc key. Output frequency displayed When the inverter displays a monitor value, the PRG LED is OFF. This confirms the inverter is not in programming mode, even while you are selecting the particular monitoring parameter. The display shows the current speed (is zero at this point). The Hz LED will be ON, indicating the display units. For current, the Amperes LED will be ON. Running the Motor If you have programmed all the parameters up to this point, you're ready to run the motor! First, review this checklist: 1. Verify the Power LED is ON. If not, check the power connections. 2. Verify the Potentiometer Enable LED is ON. If it is OFF, check the A001 setting. 3. Verify the Run Key Enable LED is ON. If it is OFF, check the A002 setting. 4. Verify the PRG LED is OFF. If it is ON, review the instructions above. 5. Make sure the motor is disconnected from any mechanical load. 6. Turn the potentiometer to the minimum position (completely counter clock -wise). 7. Now, press the RUN key on the keypad. The RUN LED will turn ON. 8. Slowly increase the potentiometer setting in clockwise fashion. The motor should start turning. 9. Press the STOP key to stop the motor rotation. Using the Front Panel Keypad Powerup Test Observations and Summary Step 10: Reading this section will help you make some useful observations when first 10 running the motor. Error Codes - If the inverter displays an error code (format is "E X X'), see "Monitoring Trip Events. History, & Conditions" on page 6-5 to interpret and clear the error. Acceleration and Deceleration - The SJ200 inverter has programmable acceleration and deceleration values. The test procedure left these at the default value, 10 seconds. You can observe this by setting the potentiometer at about half speed before running the motor. Then press RUN, and the motor will take 5 seconds to reach a steady speed. Press the STOP key to see a 5 second deceleration to a stop. State of Inverter at Stop - If you adjust the motor's speed to zero, the motor will slow to a near stop, and the inverter turns the outputs OFF. The high-performance SJ200 can rotate at a very slow speed with high torque output, but not zero (must use servo systems with position feedback for that feature). This characteristic means you must use a mechanical brake for some applications. Interpreting the Display - First, refer to the output frequency display readout. The maximum frequency setting (parameter A004) defaults to 50 Hz or 60 Hz (Europe and United States, respectively) for your application. Example: Suppose a 4 -pole motor is rated for 60 Hz operation, so the inverter is config- ured to output 60 Hz at full scale. Use the following formula to calculate the RPM. Frequency x 60 _ Frequency x 120 60 x 120 Speed in RPM = – _ = 1800RPM Pairs of poles # of poles 4 The theoretical speed for the motor is 1800 RPM (speed of torque vector rotation). However, the motor cannot generate torque unless its shaft turns at a slightly different speed. This difference is called slip. So it's common to see a rated speed of approxi- mately 1750 RPM on a 60 Hz, 4 -pole motor. Using a tachometer to measure shaft speed, you can see the difference between the inverter output frequency and the actual motor speed. The slip increases slightly as the motor's load increases. This is why the inverter output value is called "frequency," since it is not exactly equal to motor speed. You can program the inverter to display output frequency in units more directly related to the load speed by entering a constant (discussed more in depth on page 3-36). Run/Stop Versus Monitor/Program Modes – The Run LED on the inverter is ON in Run Mode, and OFF in Stop Mode. The Program LED is ON Run Stop when the inverter is in Program Mode, and OFF for Monitor Mode. All four mode combinations are possible. The diagram to the right depicts the FDNC modes and the mode transitions via keypad. Monitor Program NOTE: Some factory automation devices such as PLCs have alternate Run/Program modes; the device is in either one mode or the other. In the Hitachi inverter, however, Run Mode alternates with Stop Mode, and Program Mode alternates with Monitor Mode. This arrangement lets you program some values while the inverter is operating— providing flexibility for maintenance personnel. Configuring Drive Parameters AIEPF In This Chapter.... page — Choosing a Programming Device ................... 2 Using Keypad Devices .................................... 3 — "D" Group: Monitoring Functions ..................... 6 — "F" Group: Main Profile Parameters ................ 8 — "A" Group: Standard Functions ....................... 9 — "B" Group: Fine Tuning Functions ................. 30 — — "C" Group: Intelligent Terminal Functions...... 41 "H" Group: Motor Constants Functions ......... 55 Choosing a Programming Device Choosing a Programming Device Introduction Hitachi variable frequency drives (inverters) use the latest electronics technology for getting the right AC waveform to the motor at the right time. The benefits are many, including energy savings and higher machine output or productivity. The flexibility required to handle a broad range of applications has required ever more configurable options and parameters—inverters are now a complex industrial automation component. And this can make a product seem difficult to use, but the goal of this chapter is to make this easier for you. As the powerup test in Chapter 2 demonstrated, you do not have to program very many parameters to run the motor. In fact, most applications would benefit only from program- ming just a few, specific parameters. This chapter will explain the purpose of each set of parameters, and help you choose the ones that are important to your application. If you are developing a new application for the inverter and a motor, finding the right parameters to change is mostly an exercise in optimization. Therefore, it is okay to begin running the motor with a loosely tuned system. By making specific, individual changes and observing their effects, you can achieve a finely tuned system. And, the SJ200 Series inverters feature intelligent sensorless vector control (iSLU) to eliminate the need for manually setting motor parameters, or even to do an auto -tuning procedure. Introduction to Inverter Programming The front panel keypad is the first and best way to get to know the inverter's capabilities. Every function or programmable parameter is accessible from the keypad. The other devices simply imitate the keypad's layout and inverter access, while adding another valuable aspect to the system. For example, the Digital Operator/Copy Unit can transfer one inverter's parameter settings to another inverter, while still providing standard operator keypad control. In this way, you can use a variety of programming devices with basically the same keypad skills. The following table shows various programming options, the features unique to each device, and the cables required. NOTE: When an external digital operator device such as an OPE–SRmini or SRW–OEX is connected to the inverter, the inverter's keypad is automatically disabled (except for the Stop Key). Parameter Cables (choose one) Device Part Parameter setting Number Access storage Part number Length Inverter keypad, OPE–SRmini Monitor and EEPROM in ICS -1 1 meter removable program inverter ICS -3 3 meters Digital Operator/ SRW–OEX Monitor and EEPROM in ICS -1 1 meter Copy Unit program operator panel ICS -3 3 meters NOTE: When an external digital operator device such as an OPE–SRmini or SRW–OEX is connected to the inverter, the inverter's keypad is automatically disabled (except for the Stop Key). SJ200 Inverter Using Keypad Devices The SJ200 Series inverter front keypad contains all the elements for both monitoring and programming parameters. The keypad layout is pictured below. All other programming devices for the inverter have a similar key arrangement and function. Display Units (Hertz / Amperes) LEDq Power LED Parameter Display HIT `�HI ALARMO so. OA Run Key Enable LED ® ORUN�O i O PRG. Run Key FUN �® STR Stop/Reset Key Function key Up/Down keys Key and Indicator Legend Alarm LED Run/Stop LED Program/Monitor LED Potentiometer Enable LED Potentiometer Store key • Run/Stop LED - ON when the inverter output is ON and the motor is developing torque (Run Mode), and OFF when the inverter output is OFF (Stop Mode). • Program/Monitor LED - This LED is ON when the inverter is ready for parameter editing (Program Mode). It is OFF when the parameter display is monitoring data (Monitor Mode). • Run Key Enable LED - is ON when the inverter is ready to respond to the Run key, OFF when the Run key is disabled. • Run Key - Press this key to run the motor (the Run Enable LED must be ON first). Parameter F004, Keypad Run Key Routing, determines whether the Run key generates a Run FWD or Run REV command. • Stop/Reset Key - Press this key to stop the motor when it is running (uses the programmed deceleration rate). This key will also reset an alarm that has tripped. • Potentiometer - Allows an operator to directly set the motor speed when the potenti- ometer is enabled for output frequency control. • Potentiometer Enable LED - ON when the potentiometer is enabled for value entry. • Parameter Display - A 4 -digit, 7 -segment display for parameters and function codes. • Display Units, Hertz/Amperes - One of these LEDs will be ON to indicate the units associated with the parameter display. • Power LED - This LED is ON when the power input to the inverter is ON. • Alarm LED - ON when an inverter trip is active (alarm relay contacts will be closed). • Function Key - This key is used to navigate through the lists of parameters and functions for setting and monitoring parameter values. • Up/Down ( Q, 'W ) Keys - Use these keys alternately to move up or down the lists of parameter and functions shown in the display, and increment/decrement values. • Store ( STR ) Key - When the unit is in Program Mode and you have edited a parameter value, press the Store key to write the new value to the EEPROM. Using Keypad Devices Keypad Navigational Map You can use the inverter's front panel keypad to navigate to any parameter or function. The diagram below shows the basic navigational map to access these items. Monitor Mode 0 PRG LED=OFF Display Data � 0 1 11117 1 L1 LI 1 Program Mode • PRG LED=ON Select Parameter Edit Parameter Store as Select © powerup Function default or Group H f j 0 ' ® ® Increment/ 3 decrement value LI' 00 0.0 IF 1007Edit FUNC. 0 FUNC FUNC 7►11 L® ' 0 ST ® ® Write data to 1� 3 EEPROM Pool Return to parameter list NOTE: The inverter 7 -segment display shows lower case "b" and "d," meaning the same as the upper case letters `B" and "D" used in this manual (for uniformity "A to F"). NOTE: The Store Key saves the edited parameter (shown in the display) to the inverter's EEPROM. Upload or download of parameters to/from external devices is accomplished through a different command—do not confuse Store with Download or Upload. Operational Modes The RUN and PRG LEDs tell just part of the story; Run Mode and Program Modes are independent modes, not opposite modes. In the state diagram to the right, Run alternates with Stop, and Program Mode alternates with Monitor Mode. This is a very important ability, for it shows that a technician can approach a running machine and change some parameters without shutting down the machine. The occurrence of a fault during operation will cause the inverter to enter the Trip Mode as shown. An event such as an output overload will cause the inverter to exit the Run Mode and turn OFF its output to the motor. In the Trip Mode, any request to run the motor is ignored. You must clear the error by pressing the Stop/Reset switch. See "Monitoring Trip Events, History, & Conditions" on page 6-5. Run Mode Edits SJ200 Inverter STOP RESET RUN FUNC Monitor Program The inverter can be in Run Mode (inverter output is controlling motor) and still allow you to edit certain parameters. This is useful in applications that must run continuously, yet need some inverter parameter adjustment. The parameter tables in this chapter have a column titled "Run Mode Edit." An Ex mark means the parameter cannot be Run Mode edited; a Check mark means the parameter can be edited. Edit The Software Lock Setting (parameter B031) determines when the Run Mode access permission is in effect and access permission in other conditions, as well. It is the responsibility of the user to choose a useful and safe software lock setting for the inverter operating conditions and personnel. Please refer to "Software Lock Mode" on page 3-34 for more information. Control Algorithms The motor control program in the SJ200 inverter has three sinusoidal PWM switch- ing algorithms. The intent is that you select the best algorithm for the motor characteris- tics in your application. Each algorithm generates the frequency output in a unique way. Once configured, the algorithm is the basis for other parameter settings as well (see "Torque Control Algorithms" on page 3-16). Therefore, choose the best algorithm early in your application design process. Inverter Control Algorithms Variable freq. control, constant torque Variable freq. control, Output reduced torque Intelligent sensorless vector control (iSLV) "D" Group: Monitoring Functions "D" Group: Monitoring Functions You can access important system parameter values with the "D" Group monitoring functions, whether the inverter is in Run Mode or Stop Mode. After selecting the function code number for the parameter you want to monitor, press the Function key once to show the value on the display. In functions D005 and D006, the intelligent termi- nals use individual segments of the display to show ON/OFF status. If the inverter display is set to monitor a parameter and powerdown occurs, the inverter stores the present monitor function setting. For your convenience, the display automati- cally returns to the previously monitored parameter upon the next powerup. "D" Function Run Mode Units Func. Name / Code SRW Display Description Edit D001 Output frequency Real-time display of output — Hz monitor frequency to motor, from 0.0 to 400.0 Hz Frl f ;_ -.: _ D002 Output current monitor Filtered display of output current — A to motor (100 ms internal filter Iaut time constant), range is 0 to 200% of inverter rated current D003 Rotation direction Three different indications: — — monitor "F"..... Forward "o" .. Stop Dir STEP "r"..... Reverse D004 Process variable (PV), Displays the scaled PID process — % times PID feedback monitor variable (feedback) value (A075 is constant scale factor), FD`"i`-i `��i�° 0.00 to 99.99, 100.0 to 999.9, 1000. to 9999., 1000 to 999, and 10000 to 99900 D005 Intelligent input Displays the state of the intelligent — — terminal status input terminals: IN -TIS LL._. -LL ��� lo� Do� Do� ON �00 Do0 Io0 Io0 OFF 6 5 4 3 2 1 Terminal numbers D006 Intelligent output Displays the state of the intelligent terminal status output terminals: OUT-Thl LLL �o� �o� ��� ��� ON OFF AL 12 11 Terminal numbers SJ200 Inverter "D" Function Run Mode Units Func. Name / Code SRW Display Description Edit D007 Scaled output frequency Displays the output frequency — Hz times monitor scaled by the constant in B086. constant Decimal point indicates range: D081 F_Cnv ,.,,,.,ii.,ii711.4 0101 XXXX 0.00 to 99.99 — — tion: XXXX 100.0 to 999.9 ERR 1 UUUUUUUU XXXX. 1000. to 9999. XXXX 1000 to 9999 (x10= D082 Trip monitor 2 • Output freq. at trip point 10000 to 99999) ERR 2 ?' 14 441 14 441 D013 Output voltage monitor Voltage of output to motor, — V Trip monitor 3 range is 0.0 to 600.OV — • Cumulative inverter opera- Vout 00000V ERR 3 ttuu:l::i:i:i#t D016 Cumulative operation Displays total time the inverter has — hours • Cumulative power -ON time RUN time monitor been in RUN mode in hours. at trip point Range is 0 to 9999 / RUN``4'F 1000 to 9999 / I'100 to x999 (10,000 to 99,900) D017 Cumulative power -on Displays total time the inverter has — hours time monitor been in RUN mode in hours. Range is 0 to 9999 / ON 171 _i i„4 i.ii.ii_ii••. c•• 1000 to 9999 / 17100 to F999 (10,000 to 99,900) Trip Event and History Monitoring The trip event and history monitoring feature lets you cycle through related information using the keypad. See "Monitoring Trip Events, History, & Conditions” on page 6-5 for more details. "D" Function Run Mode Units Func. Name / Code SRW Display Description Edit D080 Trip counter Number of trip events, — events range is 0. to 9999 ERR CNT 00000 D081 Trip monitor 1 Displays trip event informa- — — tion: ERR 1 UUUUUUUU • Error code D082 Trip monitor 2 • Output freq. at trip point ERR 2 ?' 14 441 14 441 • Motor current at trip point • DC bus voltage at trip point D083 Trip monitor 3 — — • Cumulative inverter opera- ERR 3 ttuu:l::i:i:i#t tion time at trip point • Cumulative power -ON time at trip point "F" Group: Main Profile Parameters "F" Group: Main Profile Parameters The basic frequency (speed) profile is defined by parameters contained in the Output frequency 17002 170 31 "F" Group as shown to the right. The set running frequency is in Hz, but accelera- tion and deceleration are specified in the F001 - - - - - time duration of the ramp (from zero to maximum frequency, or from maximum 0 frequency to zero). The motor direction t parameter determines whether the keypad Run key produces a FWD or REV command. This parameter does not affect the intelli- gent terminal [FWD] and [REV] functions, which you configure separately. Acceleration 1 and Deceleration 1 are the standard default accel and decel values for the main profile. Accel and decel values for an alternative profile are specified by using parameters Ax92 through Ax93. The motor direction selection (17004) determines the direction of rotation as commanded only from the keypad. This setting applies to any motor profile (1 st or 2nd) in use at a particular time "F" Function Run Mode Edit Defaults Func. Code Name / SRW Display Description –FEF (EU) –FU (USA) Units 17001 Output frequency Standard default target 0.0 0.0 Hz setting frequency that determines constant motor speed, is 0.0 / start frequency R _ _ _ _ _ iiiArange to 400 Hz F002 Acceleration (1) time Standard default acceleration, 10.0 10.0 sec. setting range is 0.01 to 3000 sec. ACC 1 010.00s F202 Acceleration (1) time Standard default acceleration, 10.0 10.0 sec. setting, 2nd motor 2nd motor, range is 0.01 to 3000 sec. 2ACC1 010.00s F003 Deceleration (1) time Standard default deceleration, 10.0 10.0 sec. setting range is 0.01 to 3000 sec. DEC 1 010.00s F203 Deceleration (1) time Standard default deceleration, 10.0 10.0 sec. setting, 2nd motor 2nd motor, range is 0.01 to 3000 sec. 2DEC1 010.00s F004 Keypad Run key routing Two options; select codes: 00 00 — 00 ... Forward 01 ... Reverse D ': -'..':._':'l FWD SJ200 Inverter "A" Group: Standard Functions Control Source Settings The inverter provides flexibility in how you control Run/Stop operation and set the output frequency (motor speed). It has other control sources that can override the A001/ A002 settings. Parameter A001 sets the source selection for the inverter's output frequency. Parameter A002 selects the Run command source (for FW or RV Run commands). The default settings use the input terminals for –FEF (European) models, and the keypad for –FU (USA) models. "A" Function Run Mode Edit Defaults Func. Name / Description –FEF –FU Units Code SRW Display 01 (EU) (USA) A001 Frequency source Five options; select codes: Function F001 setting - The value in F001 is a constant, used 01 00 — setting 00... Keypad potentiometer B-19 register for inverter output frequency 10 01... Control terminal 3-28 selectable analog input sources (A and B). The output can be the sum, difference, or product (+, –, x) of the two outputs. F -COM VR 02... Function F001 setting 03... ModBus network input 10... Calculate function output A002 Run command source Three options; select codes: 01 02 setting 01... Control terminal 02... Run key on keypad, or r,'`°` °' EE' 1 ��'-r° " RE'ldigital operator 03... ModBus network input Frequency Source Setting - For parameter A001, the following table provides a further description of each option, and a reference to other page(s) for more information. Code Frequency Source Refer to page(s)... 00 Keypad potentiometer - The range of rotation of the knob 2-25 matches the range defined by B082 (Start frequency adjust- ment) to A004 (Maximum frequency setting) 01 Control terminal - The active analog input signal on analog 4-51,3-13,3-51 terminals [O] or [OI] sets the output frequency 02 Function F001 setting - The value in F001 is a constant, used 33=8 for the output frequency 03 ModBus network input - The network has a dedicated B-19 register for inverter output frequency 10 Calculate function output - The Calculate function has user- 3-28 selectable analog input sources (A and B). The output can be the sum, difference, or product (+, –, x) of the two outputs. "A" Group: Standard Functions Run Command Source Setting - For parameter A002, the following table provides a further description of each option, and a reference to other page(s) for more information Code Run Command Source Refer to page(s)... 01 Control terminal - The [FW] or [RV] input terminals control Run/Stop operation 4-12,3-42 02 Keypad Run key - The Run and Stop keys provide control 2-25 03 ModBus network input - The network has a dedicated coil for Run/ Stop command and a coil for FW/RV B-19 A001/A002 Override Sources - The inverter allows some sources to override the settings for output frequency and the Run command in A001 and A002. This provides flexibility for applications that occasionally need to use a different source, leaving the standard settings in A001/A002. In particular, note the TM/PRG (Terminal/Program) DIP switch behind the front panel cover shown below. It is the switch to the right. The TM/PRG switch setting forces terminal operation, according to the table below: TM/PRG Switch Position Item Source PRG (Program) Output frequency source Specified by A001 setting Run command source Specified by A002 setting TM (Terminal) Output frequency source [O] or [OI] analog input terminal Run command source [FW] and/or [RV] input terminals When A001 = 01 and A002 = 01, the inverter control source is the terminals, regardless of the TM/PRG switch position. When A001 and A002 setting is not 01, then the TM/PRG switch can force terminal input control. SJ200 Inverter The inverter has other control sources that can temporarily override the parameter A001 setting, forcing a different output frequency source. The following table lists all frequency source setting methods and their relative priority ("1" is the highest priority). Priority A001 Frequency Source Setting Method Refer to page... 1 [CFI] to [CF4] Multi -speed terminals 4-13 2 [OPE] Operator Control intelligent input 4-31 3 [F -TM] intelligent input 4-33 4 [AT] terminal 4-23 5 TM/PRG DIP Switch - (if switch is in "TM" position) 3-10 6 A001 Frequency source setting 33=9 The inverter also has other control sources that can temporarily override the parameter A002 setting, forcing a different Run command source. The following table lists all Run command setting methods and their relative priority ("1" is the highest priority). Priority A002 Run Command Setting Method Refer to page... 1 [OPE] Operator Control intelligent input 4-31 2 [F -TM] intelligent input 4-33 3 TM/PRG DIP Switch - (if switch is in "TM" position) 3-10 4 A002 Run command source setting 33=9 "A" Group: Standard Functions Basic Parameter Settings These settings affect the most fundamental behavior of the inverter—the outputs to the motor. The frequency of the inverter's AC output determines the motor speed. You may select from three different sources for the reference speed. During application develop- ment you may prefer using the potentiometer, but you may switch to an external source (control terminal setting) in the finished application, for example. The base frequency and maximum frequency settings interact according to the graph below (left). The inverter output operation follows the constant V/f curve until it reaches the full-scale output voltage at the base frequency. This initial straight line is the constant -torque part of the operating characteristic. The horizontal line over to the maximum frequency serves to let the motor run faster, but at a reduced torque. This is the constant -power operating range. If you want the motor to output constant torque over its entire operating range (limited to the motor nameplate voltage and frequency rating), then set the base frequency and maximum frequency equal as shown (below right). A003 V A003 A004 V A004 °------' 100% 100% ______________ Base Maximum Frequency Frequency 0 Constant torque Base frequency = maximum frequency NOTE: The "2nd motor" settings in the tables in this chapter store an alternate set of parameters for a second motor. The inverter can use the 1 st set or 2nd set of parameters to generate the output frequency to the motor. See "Configuring the Inverter for Multiple Motors" on page 4-56. "A" Function Run Mode Defaults Func. Name / -FEF -FU Code SRW Display Description Edit (EU) (USA) Units A003 Base frequency setting Settable from 30 Hz to the 50.0 60.0 Hz maximum frequency F- SE-.' ��1�� 0E--OHz A203 Base frequency setting, Settable from 30 Hz to the 2nd 50.0 60.0 Hz 2nd motor maximum frequency 2F -BASE 0006OHz A004 Maximum frequency Settable from the base 50.0 60.0 Hz setting frequency up to 400 Hz F-r-1f)X 00060Hz A204 Maximum frequency Settable from the 2nd base 50.0 60.0 Hz setting, 2nd motor frequency up to 400 Hz 2F-rIAX 0006OHz SJ200 Inverter Analog Input Settings The inverter has the capability to accept an external analog input that can command the output frequency to the motor. Voltage input (0 —1 OV) and current input (4-20mA) are available on separate terminals ([O] and [OI], respectively). Terminal [L] serves as signal ground for the two analog inputs. The analog input settings adjust the curve characteristics between the analog input and the frequency output. Adjusting [0—LI characteristics — In the graph to the right, A013 and A014 select the active portion of the input voltage range. Parameters A011 and A012 select the start and end frequency of the converted output frequency range, respectively. Together, these four parameters define the major line segment as shown. When the line does not begin at the origin (A011 and A013 > 0), then A015 defines whether the inverter outputs OHz or the A011 -specified frequency when the analog input value is less than the A013 setting. When the input voltage is greater than the A014 ending value, the inverter outputs the ending frequency specified by A012. Adjusting [OI—L] characteristics — In the graph to the right, A103 and A104 select the active portion of the input current range. Parameters A 10 1 and A102 select the start and end frequency of the converted output frequency range, respectively. Together, these four parameters define the major line segment as shown. When the line does not begin at the origin (A101 and A103 > 0), then A105 defines whether the inverter outputs OHz or the A101 -specified frequency when the analog input value is less than the A103 setting. When the input voltage is greater than the A104 ending value, the inverter outputs the ending frequency specified by A102. f max frequency A012[---------- A015=00 11 1 i A015=01 0% A013 A014 100% OV 10V Input scale f max frequency ---------------a A10J[---------- ' Al 05=00 i A 001 0 ' A105=01 0% A103 A 004 04mA Input scale 100% 20mA "A" Group: Standard Functions "A" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units A005 [AT] selection Four options, select codes: 00 00 Hz 00... Select between [O] and AT -Slot. 0101 [OI] at [AT] 01... [O] + [OI] ([AT] input is ignored) 02... Select between [O] and keypad potentiometer 03 ... Select between [OI] and keypad potentiometer A011 Pot./O—L input active The output frequency corre- 0.0 0.0 Hz range start frequency sponding to the analog input range starting point, L1-E?S�'= = -' range is 0.0 to 400.0 A012 Pot./O—L input active The output frequency corre- 0.0 0.0 Hz range end frequency sponding to the analog input range ending point, O -EXE 0000.0Hi range is 0.0 to 400.0 A013 Pot./O—L input active The starting point (offset) for 0. 0. % range start voltage the active analog input range, range is 0. to 100. 0-EX%S 00000% A014 Pot./O—L input active The ending point (offset) for 100. 100. % range end voltage the active analog input range, range is 0. to 100. Q-EX%E 00100': A015 Pot./O—L input start Two options; select codes: 01 01 frequency enable 00... Use offset (A011 value) 01... Use 0 Hz 0 -LVL 0Hz A016 External frequency Range n = 1 to 8, where n = 2. 8. Sam - filter time constant number of samples for avg. pies F-:-:: s= 00008 Multi -speed and Jog Frequency Setting The SJ200 inverter has the capability to store and output up to 16 preset frequencies to the motor (A020 to A035). As in traditional motion terminology, we call this multi -speed profile capability. These preset frequencies are selected by means of digital inputs to the inverter. The inverter applies the current acceleration or deceleration setting to change from the current output frequency to the new one. The first multi -speed setting is dupli- cated for the second motor settings (the remaining 15 multi -speeds apply only to the first motor). SJ200 Inverter The jog speed setting is used whenever the Jog command is active. The jog speed setting range is arbitrarily limited to 10 Hz, to provide safety during manual operation. The acceleration to the jog frequency is instantaneous, but you can choose from three modes for the best method for stopping the jog operation. "A" Function Run Mode Defaults Func. Name / -FEF -FU Code SRW Display Description Edit (EU) (USA) Units A020 Multi -speed frequency Defines the first speed of a 0.0 0.0 Hz setting multi -speed profile, range is 0.0 / start frequency to 400 Hz SFD "-� - �'' �'... � . �;... __ A020 = Speed 0 (1 st motor) A220 Multi -speed frequency Defines the first speed of a 0.0 0.0 Hz setting, 2nd motor multi -speed profile for 2nd motor, range is 0.0 / start 2 S P D 0 0 s ...:..:�::=::iHz frequency to 400 Hz A220 = Speed 0 (2nd motor) A021 Multi -speed frequency Defines 15 more speeds, see see Hz to settings range is 0.0 / start frequency next next A035 (for both motors) to 400 Hz. row row A021= Speed 1... A035 = Speed 15 ::J 3 H z A021 0.0 0.0 �::......... .....'_'..''Hz A022 0.0 0.0 ':'.. .......... .....'"' ..' i� �:_� A023 0.0 0.0 ':'._' ........ _' .. 1a�..�:_� A024 0.0 0.0 ::::::: _'..1aL..I:_. A025 0.0 0.0 .. °....... ...... A026 0.0 0.0 .::.!:DTI ''.' :.... _' .. �a�..�:_. A027 0.0 0.0 D Or .......... ...... -'.:: � F..�:= A029 0.0 0.0 ..� .... ... ... ... _ �..,:. A030 0.0 0.0 �.:...... ........:: ; .�;...;::�: A031 0.0 0.0 '_::;:- : ;1.._:. ... ... ...:'...; A032 0.0 0.0 A033 0.0 0.0 SF°: 1:::� _. �:;;� � 1-:14:�� A034 0.0 0.0 SPE.1 1 ..;:z A035 0.0 0.0 A038 Jog frequency setting Defines limited speed for jog, 1.00 1.00 Hz range is 0.00 / start frequency Tai -F 001_ F:� '.�i-Iz to 9.99 Hz A039 Jog stop mode Define how end of jog stops 00 00 - the motor; three options: _ tire:= 00... Free -run stop 01... Controlled deceleration 02... DC braking to stop "A" Group: Standard Functions Torque Control Algorithms The inverter generates the motor output according to the V/f algorithm or the intelli- gent sensorless vector control algorithm. Parameter A044 selects the inverter algorithm for generating the frequency output, as shown in the diagram to the right (A244 for 2nd motor). The factory default is 02 (intelligent sensorless vector control). Review the following descriptions to help you choose the best torque control algorithm for your application. Inverter Torque Control Algorithms V/f control, 00 A044 constant torque V/f control, 01 Output variable torque Intelligent sensor- 02 less vector control (iav) • The built-in V/f curves are oriented toward developing constant torque or variable torque characteristics (see graphs below). • Intelligent sensorless vector control (iSLV) calculates an ideal torque vector based on current motor position, winding currents, and so on. It is a more robust and precise control method than the V/f control methods. Using the iSLV mode, the inverter automatically adapts to the electrical characteristics of your motor. Constant and Variable (Reduced) Torque — The graph below (left) shows the constant torque characteristic from OHz to the base frequency A003. The voltage remains constant for output frequencies higher than the base frequency. The graph below (right) shows the general variable (reduced) torque curve. The range from OHz to the base frequency is the variable characteristic. V 100% W A044 = 00 Constant torque Base Max. freq. freq. Hz Manual Torque Boost — The Constant and Variable Torque algorithms feature an adjustable torque boost curve. When the motor load has a lot of inertia or starting friction, you may need to increase the low frequency starting torque characteristics by boosting the voltage above the normal V/f ratio (shown at right). The function attempts to compensate for voltage drop in the motor primary winding in the low speed range. The boost is applied from zero to 1/2 the base frequency. You set the V 100% I A044 = 01 Variable torque Base Max. freq. freq. V A042 = 5 (%) 100%- - ------------- Torque boost 01/ 5% - A 0 ' 1.8Hz 30.OHz f base = T 60Hz A043 = 3 (%) Hz Hz SJ200 Inverter breakpoint of the boost (point A on the graph) by using parameters A042 and A043. The manual boost is calculated as an addition to the standard V/f curve. NOTE: Manual torque boost is not operational when intelligent sensorless vector control is in use. Be aware that running the motor at a low speed for a long time can cause motor overheating. This is particularly true when manual torque boost is ON, or if the motor relies on a built-in fan for cooling. NOTE: Manual torque boost applies only to constant torque (A044=00) and variable torque (A044=01) V/f control. Voltage Gain – Using parameter A045 you can modify the voltage gain of the inverter (see V graph at right). This is specified as a percent- 100% age of the full scale output voltage. The gain can be set from 20% to 100%. It should be adjusted in accordance with the motor specifi- 20% cations. 0 Voltage Gain A045 IF Hz Intelligent Sensorless Vector Control (iSLV) – This advanced torque control algorithm improves torque performance at very low speeds—down to 0.5 Hz, as well as improve regulation across the speed range. Set parameter A044=02 to select iSLV operation. The iSLV algorithm automatically matches the characteristics of the particular motor connected to your inverter. Auto -tuning is not required. The iSLV control includes voltage compensation (A046) and slip compensation (A047). NOTE: You must disable intelligent sensorless vector operation when two or more motors are connected (parallel operation) to the inverter. NOTE: If the inverter experiences over -current trips during deceleration, set AVR Function Select (parameter A081) to "AVR enabled" (A081 = 00). The following table shows the methods of torque control selection. "A" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units A042 Manual torque boost Can boost starting torque 5.0 5.0 % value between 0 and 20% above normal V/f curve, 5, -Bt '" "' "'...." range is 0.0 to 20.0% "A" Group: Standard Functions "A" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units A242 Manual torque boost Can boost starting torque 0.0 0.0 % value, 2nd motor between 0 and 20% above normal V/f curve, ,� st ����. range is 0.0 to 20.0% A043 Manual torque boost Sets the frequency of the V/f 3.0 3.0 % frequency adjustment breakpoint A in graph (top of previous page) for torque -� st F ���.�� boost, range is 0.0 to 50.0% A243 Manual torque boost Sets the frequency of the V/f 0.0 0.0 % frequency adjustment, breakpoint A in graph (top of 2nd motor previous page) for torque boost, range is 0.0 to 50.0% 2MBst F 0000.0,, A044 V/f characteristic curve Two available V/f curves; 02 02 — selection three select codes: 00... Constant torque CTRL I-SLV 01... Reduced torque 02 ... Intelligent sensorless vector control (iSLV) A244 V/f characteristic curve Two available V/f curves; 02 02 — selection, 2nd motor three select codes: 00... Constant torque 2C:TRL I-SLV 01... Reduced torque 02... Intelligent sensorless vector control (iSLV) A045 V/f gain setting Sets voltage gain of the 100. 100. % inverter, range is 20. to 100.% V -Gain 00100% A046 Automatic torque boost Sets torque boost voltage gain 100 100 — voltage gain of the inverter, range is 0 to 255 A A246 Automatic torque boost Sets torque boost voltage gain 100 100 — voltage gain, 2nd motor of the inverter, range is 0 to 255 .SAB_ t 1, L.1100% A047 Automatic torque boost Sets torque boost slip gain of 100 100 slip gain the inverter, is 0 to 255 A-Bst. S1 00,00%range A247 Automatic torque boost Sets torque boost slip gain of 100 100 — slip gain, 2nd motor the inverter, range is 0 to 255 2ABst S1 00100% SJ200 Inverter DC Braking Settings The DC braking feature can provide additional stopping torque when + I Running Free run DC braking compared to a normal deceleration to a stop. DC braking is particularly useful 0 at low speeds when normal decelera- t tion torque is minimal. When you – enable DC braking, the inverter injects A053 A 555 a DC voltage into the motor windings during deceleration below a frequency you can specify (A052). The braking power (A054) and duration (A055) can both be set. You can optionally specify a wait time before DC braking (A053), during which the motor will free run (coast). ACAUTION: Be careful to avoid specifying a braking time that is long enough to cause motor overheating. If you use DC braking, we recommend using a motor with a built-in thermistor, and wiring it to the inverter's thermistor input (see "Thermistor Thermal Protection" on page 4-25). Also refer to the motor manufacturer's specifications for duty -cycle recommendations during DC braking. "A" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units A051 DC braking enable Two options; select codes: 00 00 — 00... Disable DCB r -lode CUFF 01... Enable A052 DC braking frequency The frequency at which DC 0.5 0.5 Hz setting braking begins, range is from the start _ _ DC"` frequency (13082) to 60 Hz A053 DC braking wait time The delay from the end of 0.0 0.0 sec. controlled deceleration to start DCB Wait OOOO.Os of DC braking (motor free runs until DC braking begins), range is 0.0 to 5.0 sec. A054 DC braking force for Level of DC braking force, 0. 0. % deceleration settable from 0 to 100% DCB V A055 DC braking time for Sets the duration for DC 0.0 0.0 sec. deceleration braking, range is 0.0 to 60.0 seconds DCB T OOOO.Os A056 DC braking / edge or Two options; select codes: 01 01 — level detection for [DB] 00... Edge detection input 01... Level detection DCB LEVEL "A" Group: Standard Functions Frequency -related Functions Frequency Limits — Upper and lower Run Mode Edit limits can be imposed on the inverter Output frequency output frequency. These limits will apply Description regardless of the source of the speed refer- A061 Upper ence. You can configure the lower limit frequency limit to be greater than zero as shown in the graph. The upper limit must (EU) not exceed the rating of the motor or Ao62 Lower capability of the machinery. The limit maximum frequency setting (A004/A204) 0 takes precedence over frequency upper limit (A061/A261). Frequency command "A" Function Run Mode Edit Defaults Func. Name / Description —FEF —FU Units Code SRW Display (EU) (USA) A061 Frequency upper limit Sets a limit on output 0.0 0.0 Hz setting frequency less than the maximum frequency (A004). Liri7 H 004 0.OHz Range is from frequency lower limit (A062) to maximum frequency (A004). 0.0.. setting is disabled >0.1 setting is enabled A261 Frequency upper limit Sets a limit on output 0.0 0.0 Hz setting, 2nd motor frequency less than the maximum frequency (A004). 2Lim H'_"-'"'' Range is from frequency lower limit (A262) to maximum frequency (A204). 0.0.. setting is disabled >0.1 setting is enabled A062 Frequency lower limit Sets a limit on output 0.0 0.0 Hz setting frequency greater than zero. Range is start frequency Lie.. kc_ '"" "' "' " .... "'' (13082) to frequency upper limit (A061). 0.0.. setting is disabled >0.1 setting is enabled A262 Frequency lower limit Sets a limit on output 0.0 0.0 Hz setting, 2nd motor frequency greater than zero. Range is start frequency 2Lim L :?::�,�,..�a!-!:-. - (13082) to frequency upper limit (A261). 0.0.. setting is disabled >0.1 setting is enabled SJ200 Inverter Jump Frequencies - Some motors or machines exhibit resonances at particular speed(s), which can be destructive for prolonged running at those speeds. The inverter has up to three jump frequencies as shown in the graph. The hysteresis around the jump frequencies causes the inverter output to skip around the sensitive frequency values. Output frequency I T t ] FA 0-6 71 - - - - - - - - - - - - - - - - - - - - - - - _IF_ --AV- - - FAQ -6-8 FA 0-6 81 --- Jump frequencies IF- - - I ALJA066 Hysteresis values FA_0__6,4 A70673 -AV-/' - - I I FA064] Frequency command "A" Function Run Mode Defaults Func. Name / -FEF -FU Code SRW Display Description Edit (EU) (USA) Units A063, Jump (center) frequency Up to 3 output frequencies can 0.0 0.0 Hz A065, setting be defined for the output to 0.0 0.0 A067 jump past to avoid motor0.0 0.0 resonances (center frequency) 7. C-2: Range is 0.0 to 400.0 Hz ... ... ... .. 1:% z A064, Jump (hysteresis) Defines the distance from the 0.5 0.5 Hz A066, frequency width setting center frequency at which the 0.5 0.5 A068 jump around occurs 0.5 0.5 JUMPJUMP W1W2 OOOf-1 5H- Range is 0.0 to 10.0 Hz Ir.,1 IJ JUMP W3 Of-."' "A" Group: Standard Functions PID Control When enabled, the built-in PID loop calculates an ideal inverter output value to cause a loop feedback process variable (PV) to move closer in value to the setpoint (SP). The frequency command serves as the SP. The PID loop algorithm will read the analog input for the process variable (you specify the current or voltage input) and calculate the output. A scale factor in A075 lets you multiply the PV by a factor, converting it into engineering units for the process. • Proportional, integral, and derivative gains are all adjustable. • See "PID Loop Operation" on page 4-54 for more information. "A" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units A071 PID Enable Enables PID function, 00 00 — two option codes: PI="! OFF 00... PID Disable 01... PID Enable A072 PID proportional gain Proportional gain has a range 1.0 1.0 — of 0.2 to 5.0 PID P 0001.0 A073 PID integral time Integral time constant has a 1.0 1.0 sec. constant range of 0.0 to 150 seconds PID I 0001.Os A074 PID derivative time Derivative time constant has a 0.0 0.0 sec. constant range of 0.0 to 100 seconds PID D 000.00s A075 PV scale conversion Process Variable (PV) scale 1.00 1.00 — factor (multiplier), range of PID Cnu 001.00% 0.01 to 99.99 A076 PV source setting Selects source of Process 00 00 — Variable (PV), option codes: PID INP OI 00... [OI] terminal (current in) 01... [O] terminal (voltage in) 02 ... ModBus network 03 ... Calculate function output A077 Reverse PID action Two option codes: 00 00 00... PID input = SP – PV PID MINUS i IFF 01... PID input = –(SP – PV) A078 PID output limit Sets the limit of PID output as 0.0 0.0 % percent of full scale, PI'.' . "' _ "'....- ..0� range is 0.0 to 100.0% NOTE: The setting A073 for the integrator is the integrator's time constant Ti, not the gain. The integrator gain Ki = 1/Ti. When you set A073 = 0, the integrator is disabled. SJ200 Inverter Automatic Voltage Regulation (AVR) Function The automatic voltage regulation (AVR) feature keeps the inverter output waveform at a relatively constant amplitude during power input fluctuations. This can be useful if the installation is subject to input voltage fluctuations. However, the inverter cannot boost its motor output to a voltage higher than the power input voltage. If you enable this feature, be sure to select the proper voltage class setting for your motor. "A" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units A081 AVR function select Automatic (output) voltage 00 00 — regulation, selects from three AVRON r,�, ,, "` type of AVR functions, three option codes: 00... AVR enabled 01... AVR disabled 02... AVR enabled except during deceleration A082 AVR voltage select 200V class inverter settings: 230/ 230/ V ....... 200/215/220/230/240 400 460 _ AVR AC L-1_ _ : _�, ' 400V class inverter settings: ....... 380/400/415/440/460/480 "A" Group: Standard Functions Second Acceleration and Deceleration Functions The SJ200 inverter features two-stage acceleration and deceleration ramps. This gives flexibility in the profile shape. You can specify the frequency transition point, the point at which the standard acceleration (F002) or deceleration (FO03) changes to the second acceleration (A092) or deceleration (A093). Or, you can use intelligent input [2CH] to trigger this transition. These profile options are also available for the second motor settings. Select a transition method via A094 as depicted below. Be careful not to confuse the second acceleration/deceleration settings with settings for the second motor! A094 = 00 Transition via 2CH input Output frequency �Acce12 Accel 1 0 2CH 1 t input 0 t A094 = 01 Transition via freq. level Output frequency Accel2 A 95- 7Ac Frequency cel 1 transition point 0 t "A" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units A092 Acceleration (2) time Duration of 2nd segment of 15.00 15.00 sec. setting acceleration, range is: 0.01 to 3000 sec. ACC _ _ y_ .OG�s A292 Acceleration (2) time Duration of 2nd segment of 15.00 15.00 sec. setting, (2nd motor) acceleration, 2nd motor, range is: 0.01 to 3000 sec. ��}}//��j� +.}} _ L I'7ls L E'�i U102 A093 Deceleration (2) time Duration of 2nd segment of 15.00 15.00 sec. setting deceleration, range is: 0.01 to 3000 sec. DEC 2 kij5,kikl= A293 Deceleration (2) time Duration of 2nd segment of 15.00 15.00 sec. setting, (2nd motor) deceleration, 2nd motor, range is: 0.01 to 3000 sec. 2pEC2 P M Mi.. Apia. A094 Select method to switch Two options for switching 00 00 to Acc2/Dec2 profile from 1 st to 2nd accel/decel: 00 ... 2CH input from terminal ACC i2Hia Tr1 01 ... transition frequency A294 Select method to switch Two options for switching 00 00 — to Acc2/Dec2 profile, from 1 st to 2nd accel/decel: 2nd motor 00... 2CH input from terminal 01... transition frequency 2ACCCHG TM (2nd motor) SJ200 Inverter "A" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units A095 Acc 1 to Acct frequency Output frequency at which 0.0 0.0 Hz transition point Accel l switches to Acce12, range is 0.0 to 400.0 Hz ACC CHfrO000.OHz A295 Acc 1 to Acc2 frequency Output frequency at which 0.0 0.0 Hz transition point, 2nd Accell switches to Accel2, motor range is 0.0 to 400.0 Hz A096 Dec 1 to Dec2 frequency Output frequency at which 0.0 0.0 Hz transition point Decel l switches to Decel2, range is 0.0 to 400.0 Hz u� j_! -j! !r,! ,, _,u-. DEC C'r- A296 Dec 1 to Dec2 frequency Output frequency at which 0.0 0.0 Hz transition point, 2nd Decell switches to Decel2, motor range is 0.0 to 400.0 Hz 2DECCHf'r-0000.OHz NOTE: For A095 and A096 (and for 2nd motor settings), if you set a very rapid Acc 1 or Dec 1 time (less than 1.0 second), the inverter may not be able to change rates to Acc2 or Dec2 before reaching the target frequency. In that case, the inverter decreases the rate of Acc 1 or Dec 1 in order to achieve the second ramp to the target frequency. "A" Group: Standard Functions Accel/Decel Standard acceleration and deceleration is linear. The inverter CPU can also calculate Output frequency Accel. curve selection an S-curve acceleration or deceleration curve as shown. This profile is useful for Target favoring the load characteristics in particu- freq. lar applications. Curve settings for acceleration and decel- eration are independently selected. To enable the S-curve, use function A097 (acceleration) and A098 (deceleration). -------------- Linear IA097 = 00 S-curve IA097 = 01 Acceleration period "A" Function Run Mode Defaults Func. Name / –FEF –FU Description Edit Units Code SRW Display (EU) (USA) A097 Acceleration curve Set the characteristic curve of 00 00 — selection Acc 1 and Acc2, two options: 00 ... linear iCC L?:111=: L 01... S-curve A098 Deceleration curve Set the characteristic curve of 00 00 — selection Acc 1 and Acc2, two options: 00 ... linear DEC LINE L 01... S-curve SJ200 Inverter Additional Analog Input Settings Input Range Settings — The parameters in the following table adjust the input charac- teristics of the analog current input. When using the inputs to command the inverter output frequency, these parameters adjust the starting and ending ranges for the current, as well as the output frequency range. Related characteristic diagrams are located in "Analog Input Settings" on l2aae 3-13. "A" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units A101 [OI]—[L] input active The output frequency corre- 0.0 0.0 Hz range start frequency sponding to the current input range starting point. Range is 0.00 to 400.0 Hz �y A102 [OI]—[L] input active The output frequency corre- 0.0 0.0 Hz range end frequency sponding to the current input range ending point. 0I -EXE 0000.OHz Range is 0.00 to 400.0 Hz A103 [OI]—[L] input active The starting point for the 0.0 0.0 % range start current current input range. Range is 0. to 100.% OI-EX%S 00000: A104 [OI]—[L] input active The ending point for the 100. 100. % range end current current input range. Range is 0. to 100.% 0I-EX%E 00100% A105 [OI]—[L] input start Two options: 01 01 frequency enable 00... Use A 10 1 start value 01... Use OHz OI -L'% -'L OHz "A" Group: Standard Functions Analog Input Calculate Function – The inverter can mathematically combine two input sources into one value. The Calculate function can either add, subtract, or multiply the two selected sources. This provides the flexibility needed by various applica- tions.You can use the result for the output frequency setting (use A001=10) or for the PID Process Variable (PV) input (use A075=03). Digital operator A141 Func. Name / Potentiometer —FEF —FU A input select [O] input SRW Display A143 [OI] input (USA) A141 Network variable A • 00 A + B "CAL" result 02 02 B • 01 A — B calculate function Digital operator • 02 A x B Potentiometer 01... Keypad potentiometer B input select [O] input _0 [OI] input = CAL= Sl-:. ,l C 02... [O] input Network variable A142 "A" Function Run Mode Edit Defaults Func. Name / Description —FEF —FU Units Code SRW Display (EU) (USA) A141 A input select for Five options: 02 02 — calculate function 00 ... Digital operator 01... Keypad potentiometer CAL= Sl-:. ,l C 02... [O] input 03 ... [OI] input 04 ... Network variable A142 B input select for Five options: 03 03 calculate function 00... Digital operator 01... Keypad potentiometer 02 ... [O] input 03 ... [OI] input 04 ... Network variable A143 Calculation symbol Calculates a value based on the 00 00 — A input source (A141 selects) CALC Sl1BL ADD and the B input source (A142 selects). Three options: 00 ... ADD (A input + B input) 01... SUB (A input — B input) 02 ... MUL (A input x B input) SJ200 Inverter ADD Frequency – The inverter can add or subtract an offset value to the output frequency setting which is specified by A001 (will work with any of the five possible sources). The ADD Frequency is a value you can store in parameter A145. The ADD Frequency is summed with or subtracted from the output frequency setting only when the [ADD] terminal is ON. Function A146 selects whether to add or subtract. By config- uring an intelligent input as the [ADD] terminal, your application can selectively apply the fixed value in A145 to offset (positively or negatively) the inverter output frequency in real time. Keypad potentiometer A001 Frequency source setting Control terminal Function F001 setting + Output frequency setting ��N ModBus network input +/– Calculate function output A146 ADD direction select A145 ADD frequency --o , Intelligent input [ADD] "A" Function Run Mode Edit Defaults Func. Name / Description –FEF –FU Units Code SRW Display (EU) (USA) A145 ADD frequency An offset value that is applied 0.0 0.0 Hz to the output frequency when ST-PNT 0000.0Hz the [ADD] terminal is ON. Range is 0.0 to 400.0 Hz A146 ADD direction select Two options: 00 00 — 00... Plus (adds A145 value to ADD DIP, PLUS the output frequency setting) 01... Minus (subtracts A145 value from the output frequency setting) "B" Group: Fine Tuning Functions "B" Group: Fine Tuning Functions The `B" Group of functions and parameters adjust some of the more subtle but useful aspects of motor control and system configuration. Automatic Restart Mode The restart mode determines how the inverter will resume operation after a fault causes a trip event. The four options provide advantages for various situations. Frequency matching allows the inverter to read the motor speed by virtue of its residual magnetic flux and restart the output at the corresponding frequency. The inverter can attempt a restart a certain number of times depending on the particular trip event: • Over -current trip, restart up to 3 times • Over -voltage trip, restart up to 3 times • Under -voltage trip, restart up to 16 times When the inverter reaches the maximum number of restarts (3 or 16), you must power cycle the inverter to reset its operation. Other parameters specify the allowable under -voltage level and the delay time before restarting. The proper settings depend on the typical fault conditions for your applica- tion, the necessity of restarting the process in unattended situations, and whether restart- ing is always safe. Power failure < allowable power fail time (6002), inverter resumes Input power 0 Inverter output 0 ' Motor free -running speed 0 Power fail t Allowable �� 6002 power fail time; Retry wait time B003 Power failure > allowable power fail time (13002), inverter trips Input power 0 Inverter output 0 Motor ' free -running speed 0 —P�, Power fail ;4— t B002 ;� Allowable power fail time SJ200 Inverter "B" Function Run Mode Defaults Func. Name / 80% - - Reduced —FEF —FU teristic that matches your load. This allows Code SRW Display Description Edit (EU) (USA) Units 13001 Selection of automatic Select inverter restart method, 00 00 restart mode four option codes: 00. Alarm output after trip, ALMno automatic restart 01 ... Restart at OHz 02... Resume operation after frequency matching 03... Resume previous freq. after freq. matching, then decelerate to stop and display trip info. B002 Allowable under- The amount of time a power 1.0 1.0 sec. voltage power failure input under -voltage can occur time without tripping the power failure alarm. Range is 0.3 to IPS Time 0001.Os 25 sec. If under -voltage exists longer than this time, the inverter trips, even if the restart mode is selected. B003 Retry wait time before Time delay after under -voltage 1.0 1.0 sec. motor restart condition goes away, before the inverter runs motor again. -i�� ti '., { IP._; :..:..+1.0s Range is 0.3 to 100 seconds. B004 Instantaneous power Two option codes: 00 00 sec. failure / under -voltage 00... Disable trip alarm enable 01... Enable IPU TRIP OFF B005 Number of restarts on Two option codes: 00 00 sec. power failure / under- 00... Restart 16 times voltage trip events 01... Always restart IPS RETRY 16 Electronic Thermal Overload Alarm Setting The thermal overload detection protects the Torque inverter and motor from overheating due to Constant torque 13013 = 01 an excessive load. It uses a current/inverse 100% time curve to determine the trip point. 80% - - Reduced First, use B013 to select the torque charac- 60% torque teristic that matches your load. This allows ; 13013 =00 the inverter to utilize the best thermal overload characteristic for your application. 0 5 20 60 120 Hz The torque developed in a motor is directly Output frequency proportional to the current in the windings, which is also proportional to the heat generated (and temperature, over time). Therefore, "B" Group: Fine Tuning Functions you must set the thermal overload threshold in terms of current (amperes) for parameter B012. The range is 20% to 120% of the rated current for each inverter model. If the current exceeds the level you specify, the inverter will trip and log an event (error E05) in the history table. The inverter turns the motor output OFF when tripped. Separate settings are available for the second motor (if applicable) as shown in the following table. "B" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units B012 Level of electronic Set a level between 20% and Rated current A thermal setting 120% for the rated inverter for each current. inverter model _ _ _ C. H11i i 2Y1 L_ ri B212 Level of electronic Set a level between 20% and Rated current A thermal setting, 2nd 120% for the rated inverter for each motor current. inverter model B013 Electronic thermal Select from two curves, option 01 01 — characteristic codes: 00 ... Reduced torque 1 _ _...._ 01... Constant torque 02 ... Reduced torque 2 B213 Electronic thermal Select from two curves, option 01 01 — characteristic, 2nd codes: motor 00 ... Reduced torque 1 01... Constant torque 2ETHr'-..-:-. `.SRT 02 ... Reduced torque 2 Note 1: For inverter models 005NFEF, 01 INFEF, and 030HFEF, the thermal value is less than the rated amperes (is the same as models 004NFEF, 007NFEF, and 040HFEF respectively). Therefore, be sure to set the electronic thermal overload according to the actual motor driven by the particular inverter. i WARNING: When parameter B012, level of electronic thermal setting, is set to motor FLA rating (Full Load Ampere nameplate rating), the inverter provides solid state motor overload protection at 115% of motor FLA or equivalent. If parameter B012 exceeds the motor FLA rating, the motor may overheat and be damaged. Parameter B012, level of electronic thermal setting, is a variable parameter. Overload Restriction If the inverter's output current exceeds a preset current level you specify during acceleration or constant speed, the overload restriction feature automatically reduces the output frequency to restrict the overload. This feature does not generate an alarm or trip event. You can instruct the inverter to apply overload restriction only during constant speed, thus allowing higher currents for acceleration. Or, you may use the same threshold for both acceleration and constant speed. When the inverter detects an overload, it must decelerate the motor to reduce the current until it is less than the threshold. You can choose the rate of deceleration that the inverter uses to lower the output current. SJ200 Inverter Motor Current B022 Restriction area --- - --- - ---- 0 t Output frequency 0 B023 t "B" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units B021 Overload restriction Select the operating mode 01 01 — operation mode during overload conditions, three options, option codes: OL Mode ON 00... Disabled 01... Enabled for acceleration and constant speed 02... Enabled for constant speed only B022 Overload restriction Sets the level for overload Rated current x A setting restriction, between 20% and 1.5 150% of the rated current of OL LVL 002, 0 the inverter, setting resolution is 1% of rated current B023 Deceleration rate at Sets the deceleration rate when 1.0 30.0 sec. overload restriction inverter detects overload, range is 0.1 to 30.0, resolution is 0.1. OL Cns+, 0001,g "B" Group: Fine Tuning Functions Software Lock Mode The software lock function keeps personnel from accidentally changing parameters in the inverter memory. Use B031 to select from various protection levels. The table below lists all combinations of B031 option codes and the ON/OFF state of the [SFT] input. Each Check or Ex Run Mode indicates whether the corresponding parameter(s) can be edited. Edit The Standard Parameters column below shows access is permit- ted for some lock modes. These refer to the parameter tables throughout this chapter, each of which includes a column titled Run Mode Edit as shown to the right. The marks (Check or Ex ) under the "Run Mode Edit" column title indicate whether access applies to each parameter as defined in the table below. In some lock modes, you can edit only F001 and the Multi -speed parameter group that includes A020, A220, A021—A035, and A038 (Jog). However, it does not include A019, Multi -speed operation selection. The editing access to B031 itself is unique, and is specified in the right -most two columns below. B031 Lock Mode [SFT] Intelligent Input Standard Parameters F001 and Multi -Speed B031 Stop Run Stop & Run Stop Run 00 OFF Run mode edit access ON 01 OFF Run mode edit access ON 02 (ignored) 03 (ignored) NOTE: Since the software lock function B031 is always accessible, this feature is not the same as password protection used in other industrial control devices. SJ200 Inverter "B" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units B031 Software lock mode Prevents parameter changes, in 01 01 selection four options, option codes: 00... all parameters except S -Lock MD1 B031 are locked when [SFT] terminal is ON 01... all parameters except B031 and output frequency F001 when [SFT] terminal is ON 02... all parameters except B031 are locked 03... all parameters except B031 and output frequency F001 setting are locked NOTE: To disable parameter editing when using B031 lock modes 00 and 01, assign the [SFT] function to one of the intelligent input terminals. See "Software Lock" on page 4-22. "B" Group: Fine Tuning Functions Miscellaneous Settings The miscellaneous settings include scaling factors, initialization modes, and others. This section covers some of the most important settings you may need to configure. B080: [AM] analog signal gain — This parameter allows you to scale the analog output [AM] relative to the monitored variable. B082: Start frequency adjustment — When the inverter starts to run, the output frequency does not ramp from OHz. Instead, it steps directly to the start frequency (13082), and the ramp proceeds from upward there. B083: Carrier frequency adjustment — The internal switching frequency of the inverter circuitry (also called the chopper frequency). It is called the carrier frequency because the lower AC output frequency of the inverter "rides" the carrier. The faint, high-pitched sound you hear when the inverter is in Run Mode is characteristic of switching power supplies in general. The carrier frequency is adjustable from 2.0 kHz to 14 kHz. The audible sound decreases at the higher frequencies, but RFI noise and leakage current may be increased. Refer to the specification derating curves in Chapter 1 to determine the maximum allowable carrier frequency setting for your particular inverter and environmental conditions. NOTE: The carrier frequency setting must stay within specified limits for inverter -motor applications that must comply with particular regulatory agencies. For example, a European CE -approved application requires the inverter carrier to be less than 5 kHz. B084, B085: Initialization codes — These functions allow you to restore the factory default settings. Please refer to "Restoring Factory Default Settings" on page 6-8. B086: Frequency display scaling — You can convert the output frequency monitor on D001 to a scaled number (engineering units) monitored at function D007. For example, the motor may run a conveyor that is monitored in feet per minute. Use this formula: Scaled output frequency (D_07) = Output frequency (D_01) x Factor (B_86) SJ200 Inverter "B" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units B080 [AM] analog signal Adjust of analog output at 100. 100. gain terminal [AM], range is 0 to 255 AM_Ad i 00100 B082 Start frequency adjust- Sets the starting frequency for 0.5 0.5 Hz ment the inverter output, range is 0.5 to 9.9 Hz B083 Carrier frequency Sets the PWM carrier (internal 5.0 5.0 kHz setting switching frequency), range is 2.0 to 14.0 kHz Carrier 0005.0 B084 Initialization mode Select the type of initialization 00 00 — (parameters or trip to occur, two option codes: history) 00... Trip history clear 01 ... Parameter initialization IhaI!.:TRP T 02... Trip history clear and parameter initialization B085 Country code for initial- Select default parameter values 01 02 ization for country on initialization, four options, option codes: I N T T _ _ USA 00... Japan version 01... Europe version 02... US version B086 Frequency scaling Specify a constant to scale the 1.0 1.0 — conversion factor displayed frequency for D007 monitor, range is 0.1 to 99.9 Cnu fain 0001.0 B087 STOP key enable Select whether the STOP key 00 00 — on the keypad is enabled, two TP Ke-=; ON option codes: 00... enabled 01... disabled "B" Group: Fine Tuning Functions B091/B088: Stop Mode / Restart Mode Configuration — You can configure how the inverter performs a standard stop (each time Run FWD and REV signals turn OFF). Setting B091 determines whether the inverter will control the deceleration, or whether it will perform a free -run stop (coast to a stop). When using the free -run stop selection, it is imperative to also configure how you want the inverter to resume control of motor speed. Setting B088 determines whether the inverter will ensure the motor always resumes at 0 Hz, or whether the motor resumes from its current coasting speed (also called frequency matching). The Run command may turn OFF briefly, allowing the motor to coast to a slower speed from which normal operation can resume. In most applications a controlled deceleration is desirable, corresponding to B091=00. However, applications such as HVAC fan control will often use a free -run stop (13091=01). This practice decreases dynamic stress on system components, prolonging system life. In this case, you will typically set B088=01 in order to resume from the current speed after a free -run stop (see diagram below, right). Note that using the default setting, B088=00, can cause trip events when the inverter attempts to force the load quickly to zero speed. NOTE: Other events can cause (or be configured to cause) a free -run stop, such as power loss (see "Automatic Restart Mode" on page 3-30), or an intelligent input terminal [FRS] signal. If all free -run stop behavior is important to your application (such as HVAC), be sure to configure each event accordingly. An additional parameter further configures all instances of a free -run stop. Parameter B003, Retry Wait Time Before Motor Restart, sets the minimum time the inverter will free -run. For example, if B003 = 4 seconds (and B091=01) and the cause of the free -run - stop lasts 10 seconds, the inverter will free -run (coast) for a total of 14 seconds before driving the motor again. 13091 = 01 Stop Mode = free -run stop 13091 = 01 Stop Mode = free -run stop 13088 = 00 Resume from OHz 13088 = 01 Resume from current speed Motor speed [FW, RV] Motor speed B003 Wait time B090: Dynamic braking usage ratio — This parameter limits the amount of time the inverter can use the dynamic braking accessory device without entering the Trip Mode. Please refer to "Dynamic Braking" on page 5-5 for more information on dynamic braking accessories. SJ200 Inverter "B" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units B088 Restart mode after FRS Selects how the inverter 00 00 resumes operation when the RUN FP{, ZST free -run stop (FRS) is cancelled, two options: 00... Restart from OHz 01 ... Restart from frequency detected from real speed of motor (frequency matching) B090 Dynamic braking usage Selects the rate of use (in %) of 0.0 0.0 % ratio the regenerative braking resistor per 100 sec. intervals, BR, ,_F_r. 0000.0% range is 0.0 to 100.0% 0%. Dynamic braking disabled >0% Enabled, per value B091 Stop mode selection Selects how the inverter stops 00 00 — the motor, two option codes: STP Slot DEC 00... DEC (decelerate and stop) 01 ... FRS (free run to stop) B092 Cooling fan control Selects when the fan is ON per 00 00 — inverter operation, two options: �� T� i OFF 00... Fan is always ON 01... Fan is ON during run, OFF during stop (5 min. delay from ON to OFF) 02... Fan is temperature - controlled B095 Dynamic braking Three option codes: 00 00 — control 00... Disable 01... Enable during RUN only BPTI t..., c * OFF 02... Enable always B096 Dynamic braking Range is: 360/ 360/ activation level 330 to 380V (200V class), 720 720 660 to 760V (400V class) BIND LVL 00360V B130 Over -voltage Pauses deceleration ramp when 00 00 LADSTOP enable DC bus voltage rises above threshold level, in order to OVLHDSTi iP OFF avoid over -voltage trip. Two option codes: 00... Disable 01... Enable B140 Over -current trip Two option codes: 00 00 — suppression 00... Disable 01... Enable I -SUP Mode OFF "B" Group: Fine Tuning Functions "B" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units B150 Carrier mode Automatically reduces the 00 00 — carrier frequency as the Cr -ITEC OFF ambient temperature increases. Two option codes: 00... Disable 01... Enable SJ200 Inverter "C" Group: Intelligent Terminal Functions The six input terminals [1], [2], [3], [4], [5], and [6] can be configured for any of 19 different functions. The next two tables show how to configure the six terminals. The inputs are logical, in that they are either OFF or ON. We define these states as OFF=O, and ON= 1. The inverter comes with default options for the six terminals. These default settings are initially unique, each one having its own setting. Note that European and US versions have different default settings. You can use any option on any terminal, and even use the same option twice to create a logical OR (though usually not required). NOTE: Terminal [6] has the ability to be a logical input, and to be an analog input for a thermistor device when the PTC function (option code 19) is assigned to that terminal. Input Terminal Configuration Functions and Options –The function codes in the following table let you assign one of nineteen options to any of the six logic inputs for the SJ200 inverters. The functions COO lthrough C006 configure the terminals [ 1 ] through [6] respectively. The "value" of these particular parameters is not a scalar value, but it is a discrete number that selects one option from many available options. For example, if you set function COO I=00, you have assigned option 00 (Forward Run) to terminal [1]. The option codes and the specifics of how each one works are in Chapter 4. "C" Function Run Mode Edit Defaults Func. Code Name / SRW Display Description –FEF (EU) –FU (USA) Units C001 Terminal [ 1 ] function Select terminal [ 1 ] function, 24 options (see next section) 00 [FW] 00 [FW] — IN -TM 1 FW C002 Terminal [2] function Select terminal [2] function, 24 options (see next section) 01 [RV] 01 [RV] — IN -TM 2 RV C003 Terminal [3] function Select terminal [3] function, 24 options (see next section) 02 [CF1] 16 [AT] — IN -TM 3 AT C004 Terminal [4] function Select terminal [4] function, 24 options (see next section) 03 [CF2] 13 [USP] — IN -TM 4 USP C005 Terminal [5] function Select terminal [5] function, 24 options (see next section) 18 [RS] 09 [2CH] — IN -TM 5 2CH C006 Terminal [6] function Select terminal [6] function, 24 options (see next section) 09 [2CH] 18 [RS] — IN-Th1 E. P:_; "C" Group: Intelligent Terminal Functions The input logic convention is programmable for each of the six inputs. Most inputs default to normally open (active high), but you can select normally closed (active low) in order to invert the sense of the logic. "C" Function Run Mode Edit Defaults Func. Name / Description –FEF –FU Units Code SRW Display (EU) (USA) C01 Terminal [1] active state Select logic convention, two 00 00 — option codes: 0/C-1 NO 00 ... normally open [NO] 01... normally closed [NC] C012 Terminal [2] active state Select logic convention, two 00 00 — option codes: OIC -2 NO 00 ... normally open [NO] 01... normally closed [NC] C013 Terminal [3] active state Select logic convention, two 00 00 — option codes: OIC. -3 NO 00 ... normally open [NO] 01... normally closed [NC] C014 Terminal [4] active state Select logic convention, two 00 01 — option codes: OIC -4 NC 00 ... normally open [NO] 01... normally closed [NC] C015 Terminal [5] active state Select logic convention, two 00 00 — option codes: 0/C_5 NO 00 ... normally open [NO] 01... normally closed [NC] C016 Terminal [6] active state Select logic convention, two 00 00 — option codes: 0!C_6 NO 00 ... normally open [NO] 01... normally closed [NC] NOTE: An input terminal configured for option code 18 ([RS] Reset command) cannot be configured for normally closed operation. Intelligent Input Terminal Overview Each of the six intelligent terminals may be assigned any of the options in the following table. When you program one of the option codes for terminal assignments C001 to C006, the respective terminal assumes the function role of that option code. The terminal functions have a symbol or abbreviation that we use to label a terminal using that function. For example the "Forward Run" command is [FW]. The physical label on the terminal block connector is simply 1, 2, 3, 4, 5, or 6. However, schematic examples in this manual also use the terminal symbol (such as [FW]) to show the assigned option. The option codes for CO 11 to C016 determines the active state of the logical input (active high or active low). SJ200 Inverter Input Function Summary Table — This table shows all twenty-four intelligent input functions at a glance. Detailed descriptions of these functions, related parameters and settings, and example wiring diagrams are in "Using Intelligent Input Terminals" on page 4-9. Input Function Summary Table Option Code Terminal Symbol Function Name Description 00 FW Forward Run/Stop ON Inverter is in Run Mode, motor runs forward OFF Inverter is in Stop Mode, motor stops 01 RV Reverse Run/Stop ON Inverter is in Run Mode, motor runs reverse OFF Inverter is in Stop Mode, motor stops 02 CF1 *1 Multi -speed Select, Bit 0 (LSB) ON Binary encoded speed select, Bit 0, logical 1 OFF Binary encoded speed select, Bit 0, logical 0 03 CF2 Multi -speed Select, Bit 1 ON Binary encoded speed select, Bit 1, logical 1 OFF Binary encoded speed select, Bit 1, logical 0 04 CF3 Multi -speed Select, Bit 2 ON Binary encoded speed select, Bit 2, logical 1 OFF Binary encoded speed select, Bit 2, logical 0 05 CF4 Multi -speed Select, Bit 3 (MSB) ON Binary encoded speed select, Bit 3, logical 1 OFF Binary encoded speed select, Bit 3, logical 0 06 JG Jogging ON Inverter is in Run Mode, output to motor runs at jog parameter frequency OFF Inverter is in Stop Mode 07 DB External DC Braking ON DC braking will be applied during deceleration OFF DC braking will not be applied 08 SET Set (select) 2nd Motor Data ON The inverter uses 2nd motor parameters for generating frequency output to motor OFF The inverter uses 1 st (main) motor parameters for generating frequency output to motor 09 2CH 2 -stage Acceleration and Deceleration ON Frequency output uses 2nd -stage acceleration and deceleration values OFF Frequency output uses standard acceleration and deceleration values 1 I FRS Free -run Stop ON Causes output to turn OFF, allowing motor to free run (coast) to stop OFF Output operates normally, so controlled deceler- ation stops motor 12 EXT External Trip ON When assigned input transitions OFF to ON, inverter latches trip event and displays E12 OFF No trip event for ON to OFF, any recorded trip events remain in history until Reset "C" Group: Intelligent Terminal Functions Input Function Summary Table Option Code Terminal Symbol Function Name Description 13 USP Unattended Start ON On powerup, the inverter will not resume a Run Protection command (mostly used in the US) OFF On powerup, the inverter will resume a Run command that was active before power loss 15 SFT Software Lock ON The keypad and remote programming devices are prevented from changing parameters OFF The parameters may be edited and stored 16 AT Analog Input ON Terminal [OI] is enabled for current input (uses Voltage/current terminal [L] for power supply return) Select OFF Terminal [O] is enabled for voltage input (uses terminal [L] for power supply return) 18 RS Reset Inverter ON The trip condition is reset, the motor output is turned OFF, and powerup reset is asserted OFF Normal power -ON operation 19 PTC PTC Thermistor ANLG When a thermistor is connected to terminals [6] Thermal Protection and [L], the inverter checks for over- temperature and will cause trip event and turn OFF output to motor OPEN A disconnect of the thermistor causes a trip event, and the inverter turns OFF the motor 20 STA Start ON Starts the motor rotation (3 -wire interface) OFF No change to present motor status 21 STP Stop ON Stops the motor rotation (3 -wire interface) OFF No change to present motor status 22 F/R FWD, REV ON Selects the direction of motor rotation: ON = (3 -wire interface) FWD. While the motor is rotating, a change of F/R will start a deceleration, followed by a change in direction. OFF Selects the direction of motor rotation: OFF = REV. While the motor is rotating, a change of F/ R will start a deceleration, followed by a change in direction. 23 PID PID Disable ON Temporarily disables PID loop control. Inverter output turns OFF as long as PID Enable is active (A071=01). OFF Has no effect on PID loop operation, which operates normally if PID Enable is active (A071=01). SJ200 Inverter Input Function Summary Table Option Code Terminal Symbol Function Name Description 24 PIDC PID Reset ON Resets the PID loop controller. The main conse- quence is that the integrator sum is forced to zero. OFF No effect on PID loop controller 27 UP Remote Control ON Accelerates (increases output frequency) motor UP Function (motor- from current frequency ized speed pot.) OFF Output to motor operates normally 28 DWN Remote Control ON Decelerates (decreases output frequency) motor DOWN Function from current frequency (motorized speed pot.) OFF Output to motor operates normally 29 UDC Remote Control Data ON Clears the UP/DVN frequency memory by Clearing forcing it to equal the set frequency parameter F001. Setting C 10 1 must be set --00 to enable this function to work. OFF UP/DVN frequency memory is not changed 31 OPE Operator Control ON Forces the source of the output frequency setting (A001) and the source of the RUN command (A002) to be from the digital operator OFF Source of output frequency set by (A001) and source of run command set by (A002) is used 50 ADD ADD frequency ON Adds the A145 value (Add Frequency) to the enable output frequency OFF Does not add the A145 value to the output frequency 51 F -TM Force Terminal ON Force inverter to use input terminals for output Mode frequency and Run command sources OFF Source of output frequency set by (A001) and source of Run command set by (A002) is used 255 — Not selected ON (input ignored) OFF (input ignored) Note 1: When using the Multi -speed Select settings CFI to CF4, do not display parameter F001 or change the value of F001 while the inverter is in Run Mode (motor running). If it is necessary to check the value of F001 during Run Mode, please monitor D001 instead of F001. "C" Group: Intelligent Terminal Functions Output Terminal Configuration The inverter provides configuration for logic (discrete) and analog outputs, shown in the table below. "C" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units CO21 Terminal [I I ] function Select logic convention, two 01 01 — state option codes: [FA1] [FA1] 00... normally open (NO) OUT -TM 11 FAi 10 programmable functions CO22 Terminal [12] function 00 00 — C032 (discrete) available for to g ( ) Select logic convention, two [RUN] [RUN] 00 OUT -TM 1:� FUN state outputs (see next section) 00... normally open (NO) CO26 Alarm relay terminal 01... normally closed (NC) 05 05 — function Alarm relay active state Select logic convention, two [AL] [AL] 01 — option codes: OUT -T I' _.' AL CO28 [AM] signal selection Two available functions: 00 ... normally open (NO) 00 00 — OO ... Actual motor speed output output AM-KINI F O 1... Motor current freq. freq. (see after next section) The output logic convention is programmable for terminals [11], [ 12], and the alarm relay terminals. The open -collector output terminals [ 111 and [ 12] default to normally open (active low), but you can select normally closed (active high) for these terminals in order to invert the sense of the logic. You can invert the logical sense of the alarm relay output as well. "C" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units C031 Terminal [11] active Select logic convention, two 00 00 — state option codes: 00... normally open (NO) O!C-11 NO 01... normally closed (NC) C032 Terminal [12] active Select logic convention, two 00 00 — state option codes: 00... normally open (NO) OIC -12 NO 01... normally closed (NC) C036 Alarm relay active state Select logic convention, two 01 01 — option codes: OIC-RY NC 00 ... normally open (NO) 01... normally closed (NC) SJ200 Inverter Output Function Summary Table — This table shows all ten functions for the logical outputs (terminals [ 111, [ 12]) at a glance. Detailed descriptions of these functions, related parameters and settings, and example wiring diagrams are in "Using Intelligent Output Terminals" on page 4-34. Output Function Summary Table Option Code Terminal Symbol Function Name Description 00 RUN Run Signal ON when inverter is in Run Mode OFF when inverter is in Stop Mode 01 FA1 Frequency Arrival ON when output to motor is at the set frequency Type 1 — Constant Speed OFF when output to motor is OFF, or in any accelera- tion or deceleration ramp 02 FA2 Frequency Arrival ON when output to motor is at or above the set Type 2 — Over- frequency, even if in accel. or decel. ramps frequency OFF when output to motor is OFF, or at a level below the set frequency 03 OL Overload Advance ON when output current is more than the set thresh - Notice Signal old for the overload signal OFF when output current is less than the set threshold for the overload signal 04 OD Output Deviation for ON when PID error is more than the set threshold for PID Control the deviation signal OFF when PID error is less than the set threshold for the deviation signal 05 AL Alarm Signal ON when an alarm signal has occurred and has not been cleared OFF when no alarm has occurred since the last clearing of alarm(s) 06 Dc Analog Input ON when the [O] input value < B082 setting (signal Disconnect Detect loss detected), or the [OI] input current < 4mA OFF when no signal loss is detected 07 FBV PID Second Stage ON Transitions to ON when the inverter is in RUN Output Mode and the PID Process Variable (PV) is less than the Feedback Low Limit (C053) OFF Transitions to OFF the PID Feedback Value (PV) exceeds the PID High Limit (C052), and transi- tions to OFF when the inverter goes from Run Mode to Stop Mode. 08 NDc Network Detection ON when the communications watchdog timer Signal (period specified by C077) has timed out OFF when the communications watchdog timer is satisfied by regular communications activity "C" Group: Intelligent Terminal Functions Output Function Summary Table Option Terminal Function Name Description Code Symbol Analog Frequency 09 LOG Logic Output ON when the Boolean operation specified by C143 Function 01 has a logical "1" result Motor current (% of maximum rated 0 to 200% OFF when the Boolean operation specified by C143 output current) has a logical "0" result Analog Function Summary Table — This table shows both functions for the analog voltage output [AM] terminal, configured by CO28. More information on using and calibrating the [AM] output terminal is in "Analog Output Operation" on page 4-53. Analog Function Summary Table Option Code Function Name Description Range 00 Analog Frequency Actual motor speed 0 to max. Monitor frequency in Hz 01 Analog Current Output Motor current (% of maximum rated 0 to 200% Monitor output current) Output Function Adjustment Parameters The following parameters work in conjunction with the intelligent output function, when configured. The overload level parameter (C041) sets the motor current level at which the overload signal [OL] turns ON. The range of settings is from 0% to 200% of the rated current for signal Motor current C041 0 Overload the inverter. This function is for generating an early warning logic output, without causing either a trip event or a restriction of the motor current (those effects are available on other functions). The frequency arrival signal, [FA1] or [FA2], is intended to indicate when the inverter output has reached (arrived at) the target frequency. You can adjust the timing of the leading and trailing edges of the signal via two parameters specific to accel- eration and deceleration ramps, C042 and C043. 0 t t Output frequency C 442 C043 0 t Arrival signal 1 0 T_ SJ200 Inverter The Error for the PID loop is the magni- PID Error (PV—SP) deviation threshold tude (absolute value) of the difference PV between the Setpoint (desired value) and Output SP Process Variable (actual value). The PID - - - output deviation signal [OD] (output 0 C044 terminal function option code 04) ; t indicates when the error magnitude has Deviation exceeded a magnitude you define. signal 1 0 t "C" Function Run Mode Defaults Func. Name / _FEF —FU Code SRW Display Description Edit (EU) (USA) Units C041 Overload level setting Sets the overload signal level Rated current A between 0% and 200% (from 0 for each OL LCL 00; _-:Ap - to two times the rated current inverter model of the inverter) C042 Frequency arrival Sets the frequency arrival 0.0 0.0 Hz setting for acceleration setting threshold for the output frequency during acceleration, Afti1 "`'` "''" ' range is 0.0 to 400.0 Hz C043 Arrival frequency Sets the frequency arrival 0.0 0.0 Hz setting for deceleration setting threshold for the output frequency during deceleration, ARV DEC 0000:: 0Hz range is 0.0 to 400.0 Hz C044 PID deviation level Sets the allowable PID loop 3.0 3.0 % setting error magnitude (absolute value), SP - PV, range is 0.0 to _ 100%, resolution is 0.1% C052 PID FBV function When the PV exceeds this 100.0 100.0 % high limit value, the PID loop turns OFF the PID Second Stage Output, PID Lt�J �10�, range is 0.0 to 100.0% C053 PID FBV function When the PV goes below this 0.0 0.0 % variable low limit value, the PID loop turns ON the PID Second Stage Output, PID LtL 0000.0 range is 0.0 to 100.0% "C" Group: Intelligent Terminal Functions Network Communication Settings The following table lists parameters that configure the inverter's serial communications port. The settings affect how the inverter communicates with a digital operator (such as SRW—OEX), as well as a ModBus network (for networked inverter applications). The settings cannot be edited via the network, in order to ensure network reliability. Refer to "ModBus Network Communications" on page B -1B-1 for more information on controlling and monitoring your inverter from a network. "C" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units C071 Communication speed Three option codes: 06 04 baud selection 04...4800 bps bps COM BAI..I 480005...9600 06...19200 bps C072 Node allocation Set the address of the inverter 1. 1 — on the network. Range is 1 to n , _ r� r, CO:': ..nF, E :.... 32. C074 Communication parity Three option codes: 00 00 — selection 00... No parity 01 ... Even parity CCM FRTY NON 02... Odd parity C075 Communication stop bit Range is 1 to 2 1 1 — selection COr9 STP IBIT C076 Communication error Selects inverter response to 02 02 — select communications error. Five options: tNone 00... Trip (error code E60) 01... Decelerate to a stop and trip (error code E60) 02... Disable 03 ... Free run stop (coasting) 04 ... Decelerate to a stop C077 Communication error Sets the communications 0.00 0.00 sec. time-out watchdog timer period. Range is 0.00 to 99.99 sec. COM ETIM 000.00_ C078 Communication wait Time the inverter waits after 0. 0. msec. time receiving a message before it transmits. Range is 0. to 1000. ms COM l:1,,;+ ��C�r�r��"_ CO:': ' ""`" ' SJ200 Inverter Analog Signal Calibration Settings The functions in the following table configure the signals for the analog output termi- nals. Note that these settings do not change the current/voltage or sink/source character- istics—only the zero and span (scaling) of the signals. "C" Function Run Mode Defaults Func. Name / –FEF –FU Code SRW Display Description Edit (EU) (USA) Units C081 O input span calibration Scale factor between the 100.0 100.0 % external frequency command i rArA -DJ 4'`'"" on terminals L – O (voltage input) and the frequency output, range is 0.0 to 200.0% C082 OI input span calibra- Scale factor between the 100.0 100.0 % tion external frequency command on terminals L – OI (current OI-ADJ tai AID:: 0,a -input) and the frequency output, range is 0.0 to 200.0% C085 Thermistor input tuning Range is 0.0 to 200.0% 100.0 100.0 % PTC Acl 9 0:::: C086 [AM] terminal offset Range is 0.0 to l0.OV 0.0 0.0 V tuning C1 V NOTE: When you restore factory default settings, the values will change to those listed above. Be sure to manually reconfigure the values for your application, if needed, after restoring factory defaults. "C" Group: Intelligent Terminal Functions Miscellaneous Functions The following table contains miscellaneous functions not in other function groups. "C" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units C091 Debug mode enable Displays debug parameters. 00 00 — Two option codes: DEG Slot OFF 00... Disable 01... Enable C101 Up/Down memory Controls speed setpoint for the 00 00 — mode selection inverter after power cycle. Two option codes: UPA.— 1 C. 'TR 00... Clear last frequency (return to default frequency F001) 01... Keep last frequency adjusted by UP/DWN C102 Reset selection Determines response to Reset 00 00 — input [RST]. RS Slot ON Three option codes: 00... Cancel trip state at input signal ON transition, stops inverter if in Run Mode 01... Cancel trip state at signal OFF transition, stops inverter if in Run Mode 02... Cancel trip state at input signal ON transition, no effect if in Run Mode SJ200 Inverter Output Logic and Timing Logic Output Function — The inverter has a built-in logic output feature. You can select any two of the other nine intelligent output options for internal inputs. Then, configure the logic function to apply the logical AND, OR, or XOR (exclusive OR) operator as desired to the two inputs. The terminal symbol for the new output is [LOG]. Use CO21, CO22, or CO26 to route the logical result to terminal [11], [ 12], or the relay terminals. Intelligent out- puts used as internal inputs: C141 RUN, FA1, FA2, OL, Input A OD, AL, Dc, FBV, NDc RUN, FA1, FA2, OL, 10 OD, AL, Dc, FBV, NDc C142 Input B C143 Logic function [LOG AND, OR, XOR CO21 11 CO22 - - 12 CO26 - - AL1 ALO AL2 The following table shows all four possible logic input combinations with each of the three available logical operations. Input States [LOG] Output State A B AND OR XOR 0 0 0 0 0 0 1 0 1 1 1 0 0 1 1 1 1 1 1 0 "C" Function Run Mode Defaults Func. Name / —FEF —FU Code SRW Display Description Edit (EU) (USA) Units C141 Input A select for logic 00 00 output programmable functions L,_._,,.:..,„.. RUN9 available for logic (discrete) C 142 Input B select for logic outputs 01 01 — output "C" Group: Intelligent Terminal Functions "C" Function Run Mode Defaults Func. Name / Name / SRW Display —FEF —FU Code SRW Display Description Edit (EU) (USA) Units C143 Logic function select Applies a logic function to 00 00 — 0.0 calculate [LOG] output state, DLAY 11 OOOO.Os C 145 Losic.OPE AND three options: 0.0 0.0 00... [LOG] = A AND B HOLD 11 C 146 Terminal [ 12] ON delay 01... [LOG] = A OR B 0.0 0.0 02... [LOG] = A XOR B DLAY 12 OOOO.Os C 147 Output Signal ON/OFF Delay Function - Intelligent outputs including terminals [111, [12], and the output relay, have configurable signal transition delays. Each output can delay either the OFF -to -ON or ON -to -OFF transitions, or both. Signal transition delays are variable from 0.1 to 100.0 seconds. This feature is useful in applications that must tailor inverter output signals to meet timing requirements of certain external devices. "C" Function Run Mode Edit Defaults Func. Code Name / SRW Display Description —FEF (EU) —FU (USA) Units C 144 Terminal [ 11 ] ON delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. DLAY 11 OOOO.Os C 145 Terminal [ 11 ] OFF delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. HOLD 11 C 146 Terminal [ 12] ON delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. DLAY 12 OOOO.Os C 147 Terminal [ 12] OFF delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. HOLD 12 E.;,_.„7;111_'.'_: C 148 Output relay ON delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. DLF- Y RY 0000.0s C 149 Output relay OFF delay Range is 0.0 to 100.0 sec. 0.0 0.0 sec. HOLD RY OOOO.Os NOTE: If you are using the output terminal OFF delay feature (any of C 145, C 147, C149 > 0.0 sec.), the [RS] (Reset) terminal affects the ON -to -OFF transition slightly. Normally (without using OFF delays), the [RS] input causes the motor output and the logic outputs to turn OFF together, immediately. However, when any output uses an OFF delay, then after the [RS] input turns ON, that output will remain ON for an additional 1 sec. period (approximate) before turning OFF. SJ200 Inverter "H" Group: Motor Constants Functions The "H" Group parameters configure the inverter for the motor characteristics. You must manually set H003 and H004 values to match the motor. Parameters H006 and H007 are factory -set. If you want to reset the parameters to the factory default settings, use the procedure in "Restoring Factory Default Settings" on page 6-8. Other motor parameters are automatically calculated and used when the inverter is in Inverter Torque Control Algorithms V/f control, 00 A044 constant torque Output V/f control, 01 variable torque Intelligent sensor- 02 less vector control (iSLV) intelligent sensorless vector control (iSLV) mode. Use A044 to select the torque control algorithm as shown in the diagram. The Sj200 inverter's iSLV mode eliminates the need for manual entry of additional motor parameters, or even for doing an auto -tuning procedure. "H" Function Run Mode Edit Defaults Func. Code Name / SRW Display Description _FEF (EU) –FU (USA) Units H003 Motor capacity Nine selections: Specified by kW 0.2/0.4/0.75/1.5/2.2/3.7 5.5/7.5/11 the capacity of each inverter AUX K -i ° 4 1'll model H2O3 Motor capacity, 2nd Nine selections: kW setting 0.2/0.4/0.75/1.5/2.2/3.7 5.5/7.5/11 2AU,'K 0.4 kW H004 Motor poles setting Four selections: 4 4 poles 2/4/6/8 AUX P 4P H2O4 Motor poles setting, 2nd Four selections: 4 4 poles motor 2/4/6/8 21il-. ;. INF"R H006 Motor stabilization Motor constant (factory set), 100 100 — constant range is 0 to 255 AUX KCD I P H206 Motor stabilization Motor constant (factory set), 100 100 — constant, 2nd motor range is 0 to 255 2AUXKCD 100 H007 Motor voltage select Two selections, option codes: Factory set V 00... 200V 01... 400V according to inverter model AUS dolt 2001x' H2O7 Motor voltage select, Two selections, option codes: V 2nd motor 00... 200V 01...400V 2AUX olt 200V Operations and Monitoring In This Chapter.... page — Introduction..................................................... 2 — Connecting to PLCs and Other Devices ......... 4 — Control Logic Signal Specifications ................. 6 — Intelligent Terminal Listing ............................... 7 — Using Intelligent Input Terminals ..................... 9 — Using Intelligent ntelligent Output Terminals ................ 34 —Analog Input Operation ................................. 51 Analog Output Operation .............................. 53 — PID Loop Operation ...................................... 54 — Configuring the Inverter for Multiple Motors.. 56 Introduction Introduction The previous material in Chapter 3 gave a reference listing of all the programmable functions of the inverter. We suggest that you first scan through the listing of inverter functions to gain a general familiarity. This chapter will build on that knowledge in the following ways: 1. Related functions — Some parameters interact with or depend on the settings in other functions. This chapter lists "required settings" for a programmable function to serve as a cross-reference and an aid in showing how functions interact. 2. Intelligent terminals — Some functions rely on an input signal on a control logic connector terminal, or generate output signals in other cases. 3. Electrical interfaces — This chapter shows how to make connections between the inverter and other electrical devices. 4. PID Loop Operation — The SJ200 has a built-in PID loop that calculates the optimal inverter output frequency to control an external process. This chapter shows the parameters and input/output terminals associated with PID loop operation. 5. Multiple motors — A single SJ200 inverter may be used with two or more motors in some types of applications. This chapter shows the electrical connections and inverter parameters involved in multiple -motor applications. The topics in this chapter can help you decide the features that are important to your application, and how to use them. The basic installation covered in Chapter 2 concluded with the powerup test and running the motor. Now, this chapter starts from that point and shows how to make the inverter part of a larger control or automation system. Caution Messages for Operating Procedures Before continuing, please read the following Caution messages. I CAUTION: The heat sink fins will have a high temperature. Be careful not to touch them. Otherwise, there is the danger of getting burned. AI CAUTION: The operation of the inverter can be easily changed from low speed to high speed. Be sure check the capability and limitations of the motor and machine before operating the inverter. Otherwise, it may cause injury to personnel. CAUTION: If you operate a motor at a frequency higher than the inverter standard ! default setting (50Hz/6OHz), be sure to check the motor and machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage. SJ200 Inverter Warning Messages for Operating Procedures Before continuing, please read the following Warning messages. WARNING: Be sure to turn ON the input power supply only after closing the front case. While the inverter is energized, be sure not to open the front case. Otherwise, there is the danger of electric shock. A! WARNING: Be sure not to operate electrical equipment with wet hands. Otherwise, there is the danger of electric shock. WARNING: While the inverter is energized, be sure not to touch the inverter terminals A even when the motor is stopped. Otherwise, there is the danger of electric shock. AWARNING: If the Retry Mode is selected, the motor may suddenly restart after a trip e! stop. Be sure to stop the inverter before approaching the machine (be sure to design the machine so that safety for personnel is secure even if it restarts.) Otherwise, it may cause injury to personnel. WARNING: If the power supply is cut OFF for a short period of time, the inverter may ! restart operation after the power supply recovers if the Run command is active. If a restart may pose danger to personnel, so be sure to use a lock -out circuit so that it will not restart after power recovery. Otherwise, it may cause injury to personnel. AWARNING: The Stop Key is effective only when the Stop function is enabled. Be sure to enable the Stop Key separately from the emergency stop. Otherwise, it may cause injury to personnel. A!WARNING: During a trip event, if the alarm reset is applied and the Run command is * present, the inverter will automatically restart. Be sure to apply the alarm reset only after verifying the Run command is OFF. Otherwise, it may cause injury to personnel. WARNING: Be sure not to touch the inside of the energized inverter or to put any A!conductive y object into it. Otherwise, there is a danger of electric shock and/or fire. WARNING: If power is turned ON when the Run command is already active, the motor ! will automatically start and injury may result. Before turning ON the power, confirm that the RUN command is not present. A! WARNING: When the Stop key function is disabled, pressing the Stop key does not stop the inverter, nor will it reset a trip alarm. WARNING: Be sure to provide a separate, hard -wired emergency stop switch when the A application warrants it. Connecting to PLCs and Other Devices Connecting to PLCs and Other Devices AG! Hitachi inverters (drives) are useful in many types of applications. During installation, the inverter keypad (or other programming device) will facilitate the initial configura- tion. After installation, the inverter will generally receive its control commands through the control logic connector or serial interface from another controlling device. In a simple application such as single -conveyor speed control, a Run/Stop switch and poten- tiometer will give the operator all the required control. In a sophisticated application, you may have a programmable logic controller (PLC) as the system controller, with several connections to the inverter. It is not possible to cover all the possible types of application in this manual. It will be necessary for you to know the electrical characteristics of the devices you want to connect to the inverter. Then, this section and the following sections on I/O terminal functions can help you quickly and safely connect those devices to the inverter. CAUTION: It is possible to damage the inverter or other devices if your application exceeds the maximum current or voltage characteristics of a connection point. The connections between the inverter and other devices rely on the electrical input/ output characteristics at both ends of each connection, shown in the diagram to the right. The inverter's configurable inputs accept either a sourcing or sinking output from an external device (such as a PLC). This chapter shows the inverter's internal electrical component(s) at each I/O termi- nal. In some cases, you will need to insert a power source in the interface wiring. In order to avoid equipment damage and get your application running smoothly, we recommend drawing a schematic of each connection between the inverter and the other device. Include the internal compo- nents of each device in the schematic, so that it makes a complete circuit loop. After making the schematic, then: 1. Verify that the current and voltage for each connection is within the operating limits of each device. L. Make sure that the logic sense (active high or active low) of any ON/OFF connection is correct. Other device SJ200 Inv Input signal Output circuit return circuit Output signal Input circuit return circuit 3. Check the zero and span (curve end points) for analog connections, and be sure the scale factor from input to output is correct. 4. Understand what will happen at the system level if any particular device suddenly loses power, or powers up after other devices. SJ200 Inverter Example Wiring Diagram The schematic diagram below provides a general example of logic connector wiring, in addition to basic power and motor wiring covered in Chapter 2. The goal of this chapter is to help you determine the proper connections for the various terminals shown below for your specific application needs. Breaker, MCCB or GFI R SJ200 U (L1) (T1) Power source, 3-phase or S V Motor 1 -phase, per (L2) (T2) inverter model ---o T W I N(L3) (T3) Intelligent inputs, PD/+1 6 terminals DC reactor PCS (optional) Forward F24V+ PDI+ NOTE: For the wir- 1 In — ing of intelligent 1/O Reverse circus Braking and analog inputs, be 2 unit sure to use twisted RB (optional) pair / shielded cable. Braking Attach the shield wire 3 resistor (optional) for each signal to its respective common N/— terminal at the 4 [6] configurable as inverter end only. discrete input or 5 thermistor input AU Thermistor 6 IF Relay contacts, ALO type 1 Form C GND for logic inputs * L Meter AL2 AM Open collector outputs Output Ou t Analogreference piut cir12 Run signal H Load 0-10VDC Freq. arrival signal O 11 Load 4-20mA 01 + GND for logic outputs L CM2 GND for analog signals Control Logic Signal Specifications Control Logic Signal Specifications The control logic connectors are located just behind the front housing cover. The relay contacts are just to the left of the logic connectors. Connector labeling is shown below. AL2 AU ALO -I I Relay contacts �!I%-.q 101 CiIg9B9 rVQ`MMi Logic inputs 0000000 Analog Analog Logic inputs output outputs H 10 01 LAM CM2 12 11 Specifications for the logic connection terminals are in the following table: Terminal Name Description Ratings [PCS] +24V for logic inputs 24VDC, 30 mA max. (do not short to terminal L) [1], [2], [3], [4],[5], [6] Discrete logic inputs 27VDC max. (use PCS or an external supply refer - enced to terminal L) [L] (top row) *I GND for logic inputs sum of input [ 1 ]—[6] currents (return) [11], [ 12] Discrete logic outputs 50mA maximum ON state current, 27 VDC maximum OFF state voltage [CM2] GND for logic outputs 100 mA: sum of 11 and 12 currents (return) [AM] Analog voltage output 0 to IOVDC, 1mA maximum [L] (bottom row) *2 GND for analog signals sum of OI, O, H, and AM currents (return) [OI] Analog input, current 4 to 19.6 mA range, 20 mA nominal, input impedance 250 Q [O] Analog input, voltage 0 to 9.8 VDC range, l OVDC nominal, input impedance 10 M [H] +10V analog reference IOVDC nominal, 10 mA max [ALO] Relay common contact 250 VAC, 2.5A (R load) max., 250 VAC, 0.2A (I load, P.F.=0.4) max. 100 VAC, l OmA min. 30 VDC, 3.OA (R load) max. 30 VDC, 0.7A (I load, P.F.=0.4) max. 5 VDC, l OOmA min. [ AL1] *3 Relay contact normally open [AL2] *3 Relay contact, normally closed Note 1: The two terminals [L] are electrically connected together inside the inverter. Note 2: We recommend using the top row [L] logic GND for logic input circuits and the [L] GND on the bottom row of terminals for analog I/O circuits. Note 3: Default relay N.O./N.C. configuration is reversed. See page 4-35. SJ200 Inverter Intelligent Terminal Listing Intelligent Inputs Use the following table to locate pages for intelligent input material in this chapter. Intelligent INPUTS Symbol Code Name Page FW 00 Forward Run/Stop 4-12 RV O1 Reverse Run/Stop 4-12 CH 02 Multi -speed Select, Bit 0 (LSB) 4-13 CF2 03 Multi -speed Select, Bit 1 4-13 CF3 04 Multi -speed Select, Bit 2 4-13 CF4 05 Multi -speed Select, Bit 3 4-13 JG 06 Jogging 4-15 DB 07 External DC Braking 4-16 SET 08 Set Second Motor 4-17 2CH 09 2 -stage Acceleration and Deceleration 4-18 FRS 11 Free -run Stop 4-19 EXT 12 External Trip 4-20 USP 13 Unattended Start Protection 4-21 SFT 15 Software Lock 4-22 AT 16 Analog Input Voltage/current Select 4-23 RS 18 Reset Inverter 4-24 TH 19 Thermistor Thermal Protection 4-25 STA 20 Start (3 -wire interface) 4-26 STP 21 Stop (3 -wire interface) 4-26 F/R 22 FWD, REV (3 -wire interface) 4-26 PID 23 PID Disable 4-28 PIDC 24 PID Reset 4-28 UP 27 Remote Control UP Function 4-29 DWN 28 Remote Control DOWN Function 4-29 UDC 29 Remote Control Data Clearing 4-29 OPE 31 Operator Control 4-31 ADD 50 ADD Frequency Enable 4-32 F -TM 51 Force Terminal Mode 4-33 Intelligent Terminal Listing Intelligent Outputs Use the following table to locate pages for intelligent output material in this chapter. Intelligent OUTPUTS Symbol Code Name Page RUN 00 Run Signal 4-37 FA1 01 Frequency Arrival Type 1 — Constant Speed 4-38 FA2 02 Frequency Arrival Type 2 — Over -frequency 4-38 OL 03 Overload Advance Notice Signal 4-40 OD 04 Output Deviation for PID Control 4-41 AL 05 Alarm Signal 4-42 Dc 06 Analog Input Disconnect Detect 4-44 FBV 07 Feedback Value Check 4-45 NDc 08 Network Detection Signal 4-48 LOG 09 Logic Output 4-49 Using Intelligent Input Terminals D SJ200 Inverter Terminals [1], [2], [3], [4], [5], and [6] are identical, programmable inputs for general use. The input circuits can use the inverter's internal (isolated) +24V field supply or an external power supply. This section describes input circuits operation and how to connect them properly to switches or transistor outputs on field devices. The SJ200 inverter features selectable sinking or sourcing inputs. These terms refer to the connection to the external switching device—it either sinks current (from the input to GND) or sources current (from a power source) into the input. Note that the sink/source naming convention may be different in your particular country or industry. In any case, the just follow the wiring diagrams in this section for your application. The inverter has a DIP switch for config- uring the choice of sinking or sourcing inputs. To access it, you must remove the front cover of the inverter housing. In the figure to the right, the SR/SK switch ("source/sink switch") is shown as located on the circuit board, at the right end of the logic signal connector. DO NOT confuse it with the two, larger configuration switches nearby. The circuit board has the SR and SK markings above and below the switch as shown. Logic inputs I SR L 6 5 4 3 2 1 PCS ❑❑ SK Legend: SR M 1 Sink SK SR ? Source I (default) SR CAUTION: Be sure to turn OFF power to the inverter before changing the SR/SK switch position. Otherwise, damage to the inverter circuitry may occur. [PCS] Terminal Wiring - The [PCS] terminal (Programmable Control System terminal) is named to include various devices that can connect to the inverter's logic inputs. In the figure to the right, note the [PCS] terminal and the nearby diodes and DPDT switch. The upper part of the SR/SK switch selects between connecting the inverter's +24V internal supply to [PCS] or allowing an external supply power to connect. The lower part of the SR/SK switch selects between connecting the input circuit common node to either Logic GND or the +24V supply. The wiring diagrams on the following pages show the four combinations of using sourcing or sinking inputs, and using the internal or an external DC supply. Using Intelligent Input Terminals The two diagrams below show input wiring circuits using the inverter's internal +24V supply. Each diagram shows the connection for simple switches, or for a field device with transistor outputs. Note that in the lower diagram, it is necessary to connect terminal [L] only when using the field device with transistors. Be sure to use the correct SR/SK switch position shown for each wiring diagram. Sinking Inputs, Internal Supply SJ200 SR/SK switch = SK position PCs"—T /—� SR 24V Open collector outputs, SK NPN transistors SR Input Field device switches Input circuits 6 6 PtEL—i ]GNID Logic GND L 7 Sourcing Inputs, Internal Supply SR/SK switch = SR position PNP transistor sourcing outputs Field device Common, to [PC,9] 1 i6 to PNP bias circuits IGNID PCS Input switches 6 --off Logic GND L SJ200 K 24V SR + SK P-- S R Input circuits SJ200 Inverter The two diagrams below show input wiring circuits using an external supply. If using the upper wiring diagram, be sure to use a diode with the external supply. This will prevent a power supply contention in case the SR/SK switch is accidentally placed in the incorrect position. Be sure to use the correct SR/SK switch position shown for each wiring diagram. Sinking Inputs, External Supply SR/SK switch = SK positionSJ200 1 0 PCS * * Open collector outputs, L—p�� SK 24V NPN transistors SR + Field device + 24V SK SR Input + +V switches Input circuits 6 GND ♦ Logic GND L V * Note: If the external power supply GND is (optionally) connected to [L], then install the above diode. Sourcing Inputs, External Su SR/SK switch = SR position PNP transistor sourcing outputs Field device 2L �6 — 24V GND Using Intelligent Input Terminals Forward Run/Stop and Reverse Run/Stop Commands: When you input the Run command via the terminal [FW], the inverter executes the Forward Run command (high) or Stop command (low). When you input the Run command via the terminal [RV], the inverter executes the Reverse Run command (high) or Stop command (low). Option Terminal Function Name State Description Code Symbol 00 FW Forward Run/Stop ON Inverter is in Run Mode, motor runs forward OFF Inverter is in Stop Mode, motor stops 01 RV Reverse Run/Stop ON Inverter is in Run Mode, motor runs reverse OFF Inverter is in Stop Mode, motor stops Valid for inputs: C001, C002, C003, C004, Example (default input configuration shown— 0005, C006 see page 3-41): Required settings: A002 = 01 RV FW Notes: L 16 15 14 3 2 1 PCS • When the Forward Run and Reverse Run commands are active at the same time, the inverter enters the Stop Mode. • When a terminal associated with either [FW] or [RV] function is configured for normally closed, the motor starts rotation when that terminal is See I/O specs on page 4-6. disconnected or otherwise has no input voltage. NOTE: The parameter F004, Keypad Run Key Routing, determines whether the single Run key issues a Run FWD command or Run REV command. However, it has no effect on the [FW] and [RV] input terminal operation. AWARNING: If the power is turned ON and the Run command is already active, the motor starts rotation and is dangerous! Before turning power ON, confirm that the Run command is not active. Multi -Speed Select The inverter can store up to 16 different target frequencies (speeds) that the motor output uses for steady-state run condition. These speeds are acces- sible through programming four of the intelligent terminals as binary -encoded inputs CF 1 to CF4 per the table to the right. These can be any of the six inputs, and in any order. You can use fewer inputs if you need eight or fewer speeds. Note: When choosing a subset of speeds to use, always start at the top of the table, and with the least -significant bit: CF1, CF2, etc. The example with eight speeds in the figure below shows how input switches configured for CF 1—CF3 functions can change the motor speed in real time. 3rd 7th 5th 2nd 1 st 6th 4th 0th 1 [CF1] 0 1 [CF2] 0 1 [CF3] 0 1 [FWD] 0 Sneed SJ200 Inverter Multi- speed Input Function CF4 CF3 CF2 CF1 Speed 0 0 0 0 0 Speed 1 0 0 0 1 Speed 2 0 0 1 0 Speed 3 0 0 1 1 Speed 4 0 1 0 0 Speed 5 0 1 0 1 Speed 6 0 1 1 0 Speed 7 0 1 1 1 Speed 8 1 0 0 0 Speed 9 1 0 0 1 Speed 10 1 0 1 0 Speed 11 1 0 1 1 Speed 12 1 1 0 0 Speed 13 1 1 0 1 Speed 14 1 1 1 0 Speed 15 1 1 1 1 NOTE: Speed 0 is set by the A020 parameter value. Option Terminal Function Name Input Description Code Symbol State 02 CF1 Multi -speed Select, ON Binary encoded speed select, Bit 0, logical 1 Bit 0 (LSB) OFF Binary encoded speed select, Bit 0, logical 0 03 CF2 Multi -speed Select, ON Binary encoded speed select, Bit 1, logical 1 Bit 1 OFF Binary encoded speed select, Bit 1, logical 0 04 CF3 Multi -speed Select, ON Binary encoded speed select, Bit 2, logical 1 Bit 2 OFF Binary encoded speed select, Bit 2, logical 0 05 CF4 Multi -speed Select, ON Binary encoded speed select, Bit 3, logical 1 Bit 3 (MSB) OFF Binary encoded speed select, Bit 3, logical 0 Using Intelligent Input Terminals Option Terminal Function Name Input Description Code Symbol State Valid for inputs: C001, C002, C003, C004, Example (some CF inputs require input C005, C006 configuration; some are default inputs—see page 3-41): F001, A001 = 02, Required settings: A020 to A035 (MSB) (LSB) CF4CF3CF2CF1 Notes: L 6 5 4 3 2 1 PCS • When programming the multi -speed settings, be sure to press the Store key each time and then set the next multi -speed setting. Note that when the key is not pressed, no data will be set. • When a multi -speed setting more than 50Hz(6OHz) is to be set, it is necessary to program the maximum frequency A004 high enough to allow that speed. See 1/0 specs on page 4-6. While using the multi -speed capability, you can monitor the present frequency with monitor function D001 during each segment of a multi -speed operation. NOTE: When using the Multi -speed Select settings CFI to CF4, do not display parame- ter F001 or change the value of F001 while the inverter is in Run Mode (motor running). If it is necessary to check the value of F001 during Run Mode, please monitor D001 instead of F001. There are two ways to program the speeds into the registers A020 to A035: 1. Standard keypad programming: a. Select each parameter A020 to A035. b. Press the FONc key to view the parameter value. c. Use the Al and 'T keys to edit the value. d. Use the s� key to save the data to memory. 2. Programming using the CF switches. Set the speed by following these steps: a. Turn the Run command OFF (Stop Mode). b. Turn inputs ON to select desired Multi -speed. Display the value of F001 on the digital operator. c. Set the desired output frequency by pressing thel and 'T keys. d. Press the s� key once to store the set frequency. When this occurs, F001 indicates the output frequency of Multi -speed n. e. Press the & key once to confirm that the indication is the same as the set frequency. L Repeat operations in 2. a) to 2. e) to set the frequency of other Multi -speeds. It can be set also by parameters A020 to A035 in the first procedure 1. a) to 1. d). SJ200 Inverter Jogging Command The Jog input [JG] is used to command the 1 motor to rotate slowly in small increments for [�Gl 0 Description Code manual operation. The speed is limited to [FW], 1 State 06 JG 10 Hz. The frequency for the jogging opera- [RV] 0 Inverter is in Run Mode, output to motor runs at tion is set by parameter A038. Jogging does Jog OFF not use an acceleration ramp, so we recom- speed - mend setting the jogging frequency A038 to A038 ' ' 5 Hz or less to prevent tripping. C005, C006 When the terminal [JG] is turned ON and the A039 t Run command is issued, the inverter outputs Jog decel type the programmed jog frequency to the motor. JG To enable the Run key on the digital operator for jog input, set the value 01(terminal mode) 161514 in A002 (Run command source). The type of deceleration used to end a motor jog operation is selectable by programming function A039. The options are: PCS • 00 Free -run stop (coasting) • No jogging operation is performed when the set • 01 Deceleration (normal level) and stop value of jogging frequency A038 is smaller than the • 02 Use DC braking and stop start frequency B082, or the value is 0 Hz. Option Terminal Function Name Input Description Code Symbol State 06 JG Jogging ON Inverter is in Run Mode, output to motor runs at jog parameter frequency OFF Inverter is in Stop Mode Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): Required settings: A002= 01, A038 > B082, A038 > 0, A039 JG Notes: L 161514 3 2 1 PCS • No jogging operation is performed when the set value of jogging frequency A038 is smaller than the start frequency B082, or the value is 0 Hz. • Be sure to stop the motor when switching the function [JG] ON or OFF. See 1/0 specs on page 4-6. Using Intelligent Input Terminals External Signal for DC Braking When the terminal [DB] is turned ON, the DC braking feature is enabled. Set the follow- ing parameters when the external DC braking terminal [DB] is to be used: • A053 - DC braking delay time setting. The range is 0.1 to 5.0 seconds. • A054 - DC braking force setting. The range is 0 to 100%. The scenarios to the right help show how DC braking works in various situations. 1. Scenario 1 - The [FW] or [RV] terminal is ON. When [DB] is ON, DC braking is applied. When [DB] is OFF again, the output frequency ramps to the prior level. 2. Scenario 2 - The Run command is applied from the operator keypad. When the [DB] terminal is ON, DC braking is applied. When the [DB] terminal is OFF again, the inverter output remains OFF. 3. Scenario 3 - The Run command is applied from the operator keypad. When the [DB] terminal is ON, DC braking is applied after the delay time set by A053 expires. The motor is in a free -running (coasting) condition. When the [DB] terminal is OFF again, the inverter output remains OFF. Scenario 1 [FW, RV] 0 [DB] 0 Output frequency t Scenario 2 Run command 1 from operator 0 1 [DB] 0 Output frequency t Scenario 3 Run command 1 (from operator) 0 1 [DB] 0 delay '4-- A053 Output frequency Option Terminal Function Name Input Description Code Symbol State 07 DB External DC Braking ON applies DC injection braking during deceleration OFF does not apply DC injection braking during deceleration Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): DB Required settings: A053, A054 Notes: L 16 15 4 3 2 1 PCS • Do not use the [DB] input continuously or for a long time when the DC braking force setting A054 is high (depends on the motor application). • Do not use the [DB] feature for continuous or high duty cycle as a holding brake. The [DB] input is designed to improve stopping performance. Use a mechanical brake for holding a stop position. See 1/0 specs on page 4-6. SJ200 Inverter Set Second Motor If you assign the [SET] function to an intelligent input terminal, you can select between two sets of motor parameters. The second parameters store an alternate set of motor characteristics. When the terminal [SET] is turned ON, the inverter will use the second set of parameters to generate the frequency output to the motor. When changing the state of the [SET] input terminal, the change will not take effect until the inverter is stopped. When you turn ON the [SET] input, the inverter operates per the second set of parame- ters. When the terminal is turned OFF, the output function returns to the original settings (first set of motor parameters). Refer to "Configuring the Inverter for Multiple Motors" on page 4-56 for details. Option Terminal Function Name Input Description Code Symbol State 08 SET Set (select) 2nd ON causes the inverter to use the 2nd set of motor Motor Data parameters for generating the frequency output to motor OFF causes the inverter to use the 1 st (main) set of motor parameters for generating the frequency output to motor Valid for inputs•' C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): SET L 16 15 14 3 2 1 PCS Required settings: (none) Notes: • If the terminal state is changed while the inverter is running, the inverter continues using the current set of parameters until the inverter is stopped. See 1/0 specs on page 4-6. Using Intelligent Input Terminals Two-stage Acceleration and Deceleration When terminal [2CH] is turned ON, the inverter changes the rate of acceleration and deceleration from the initial settings (F002 and F003) to use the second set of accelera- tion/deceleration values. When the terminal is turned OFF, the inverter is returned to the original acceleration and deceleration time (F002 acceleration time 1, and F003 decelera- tion time 1). Use A092 (acceleration time 2) and A0093 (deceleration time 2) to set the second stage acceleration and deceleration times. Output target frequency frequency second initial [2CH] [FW], 1 [RV] 0 t In the graph shown above, the [2CH] becomes active during the initial acceleration. This causes the inverter to switch from using acceleration 1 (F002) to acceleration 2 (A092). Option Terminal Function Name Input Description Code Symbol State 09 2CH Two-stage Accelera- ON Frequency output uses 2nd -stage acceleration tion and Deceleration and deceleration values OFF Frequency output uses the initial acceleration 1 and deceleration 1 values Valid for inputs: C001 C002, C003 C004 Exam default in configurations Example � put C005 C006 shown—see page 3-41): Required settings: A092, A093, A094=00 2CH Notes: L 6 5 4 13 12 11 PCS • Function A094 selects the method for second stage acceleration. It must be set = 00 to select the input –FU and FR terminal method in order for the [2CH] terminal –FE 10 4 models assignment to operate. models See 1/0 specs on page 4-6. SJ200 Inverter Free -run Stop When the terminal [FRS] is turned ON, the inverter stops the output and the motor enters the free -run state (coasting). If terminal [FRS] is turned OFF, the output resumes sending power to the motor if the Run command is still active. The free -run stop feature works with other parameters to provide flexibility in stopping and starting motor rotation. In the figure below, parameter B088 selects whether the inverter resumes operation from 0 Hz (left graph) or the current motor rotation speed (right graph) when the [FRS] terminal turns OFF. The application determines the best setting. Parameter B003 specifies a delay time before resuming operation from a free -run stop. To disable this feature, use a zero delay time. B088 = 00 Zero -frequency start MF,\ otor speed Resume from motor speed B088 = 01 — I* -- B003 wait time Motor speed FRS 0 FRS [FW], 1 [FW], [RV] 0 t [RV] t Option Terminal Function Name Input Description Code Symbol State 11 FRS Free -run Stop ON Causes output to turn OFF, allowing motor to free run (coast) to stop OFF Output operates normally, so controlled deceler- ation stops motor Valid for inputs•' C001, C002, C003, C004, Example (requires input configuration— 0005, C006 see page 3-41): FRS Required settings: B003, B088, CO 11 to C016 I L 16 15 14 3 2 1 PCS Notes: • When you want the [FRS] terminal to be active low (normally closed logic), change the setting (CO 11 to C016) that corresponds to the input (C001 to C006) that is assigned the [FRS] function. See 1/0 specs on page 4-6. Using Intelligent Input Terminals External Trip When the terminal [EXT] is turned ON, the inverter enters the trip state, indicates error code E12, and stops the output. This is a general purpose interrupt type feature, and the meaning of the error depends on what you connect to the [EXT] terminal. Even if the [EXT] input is turned OFF, the inverter remains in the trip state. You must reset the inverter or cycle power to clear the error, returning the inverter to the Stop Mode. In the graph below, the [EXT] input turns ON during normal Run Mode operation. The inverter lets the motor free -run to a stop, and the alarm output turns ON immediately. When the operator initiates a Reset command, the alarm and error are cleared. When the Reset is turned OFF, the motor begins rotation since the Run command is already active. [EXT] terminal Motor revolution speed [RS] terminal Alarm output terminal RUN command [FW, RV] Option Terminal Function Name Input Description Code Symbol State 12 EXT External Trip ON When assigned input transitions OFF to ON, inverter latches trip event and displays E12 OFF No trip event for ON to OFF, any recorded trip events remain in history until Reset Valid for inputs: C001, C002, C003, C004, Example (requires input configuration— 0005, C006 see page 3-41): EXT Required settings: (none) L 16 15 14 3 2 1 PCS Notes: • If the USP (Unattended Start Protection) feature is in use, the inverter will not automatically restart after cancelling the EXT trip event. In that case, it must receive either another Run command (OFF -to - ON transition), a keypad Reset command, or an [RS] intelligent terminal input signal. See 1/0 specs on page 4-6. SJ200 Inverter Unattended Start Protection If the Run command is already set when power is turned ON, the inverter starts running immediately after powerup. The Unattended Start Protection (USP) function prevents that automatic startup, so that the inverter will not run without outside intervention. When USP is active and you need to reset an alarm and resume running, either turn the Run command OFF, or perform a reset operation by the terminal [RS] input or the keypad Stop/reset key. In the figure below, the [UPS] feature is enabled. When the inverter power turns ON, the motor does not start, even though the Run command is already active. Instead, it enters the USP trip state, and displays E 13 error code. This requires outside intervention to reset the alarm by turning OFF the Run command per this example (or applying a reset). Then the Run command can turn ON again and start the inverter output. 1 RUN command [FW, RV] 0 1 [USP] terminal 0 1 Alarm output terminal 0 1 Inverter output frequency 0 Inverter power supply 0 Events: i .._.... I C 10 , „u, display cleared command Option Terminal Function Name Input Description Code Symbol State 13 USP Unattended Start ON On powerup, the inverter will not resume a Run Protection command (mostly used in the US) OFF On powerup, the inverter will resume a Run command that was active before power loss Valid for inputs: C001, C002, C003, C004, Example (default input configuration shown for C005, C006 —FU models; —FE and —FR models require input configuration—see page 3-41): Required settings: (none) Notes: • Note that when a USP error occurs and it is USP canceled by a reset from a [RS] terminal input, the L 16 15 14 3 2 1 PCS inverter restarts running immediately. • Even when the trip state is canceled by turning the terminal [RS] ON and OFF after an under voltage protection E09 occurs, the USP function will be performed. • When the running command is active immediately after the power is turned ON, a USP error will See I/O specs on page 4-6. occur. When this function is used, wait for at least three (3) seconds after the powerup to generate a Run command. Using Intelligent Input Terminals Software Lock When the terminal [SFT] is turned ON, the data of all the parameters and functions (except the output frequency, depending on the setting of B031) is locked (prohibited from editing). When the data is locked, the keypad keys cannot edit inverter parameters. To edit parameters again, turn OFF the [SFT] terminal input. Use parameter B031 to select whether the output frequency is excluded from the lock state or is locked as well. Option Terminal Function Name Input Description Code Symbol State 15 SFT Software Lock ON The keypad and remote programming devices are prevented from changing parameters OFF The parameters may be edited and stored Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): Required settings: B031 (excluded from lock) SFT L 16 15 14 3 2 1 PCS Notes: • When the [SFT] terminal is turned ON, only the output frequency can be changed. • Software lock can include the output frequency by setting B031. • Software lock by the operator is also possible without the [SFT] terminal being used (B031). See 1/0 specs on page 4-6. SJ200 Inverter Analog Input Current/Voltage Select The [AT] terminal selects whether the inverter uses the voltage [O] or current [OI] input terminals for external frequency control. When intelligent input [AT] is ON, you can set the output frequency by applying a current input signal at [OI] -[L]. When the [AT] input is OFF, you can apply a voltage input signal at [O] -[L] to set the output frequency. Note that you must also set parameter A001 = 01 to enable the analog terminal set for control- ling the inverter frequency. Option Terminal Function Name Input Description Code Symbol State 16 AT Analog Input ON Terminal OI is enabled for current input (uses Voltage/current terminal L for power supply return) Select OFF Terminal O is enabled for voltage input (uses terminal L for power supply return) Valid for inputs: C001, C002, C003, C004, Example (default input configuration shown C005, C006 for–FU models; –FE and –FR models require input configuration—see page 3-41): Required settings: A001 = 01 Notes: • If the [AT] option is not assigned to any intelligent AT input terminal, then inverter uses the algebraic sum L 6 5 4 3 2 1 PCS of both the voltage and current inputs for the frequency command (and A001=01). • When using either the analog current and voltage input terminal, make sure that the [AT] function is allocated to an intelligent input terminal. • Be sure to set the frequency source setting A001=01 to select the analog input terminals. H O 01 L FM CM2 12 11 ♦ 4-20 mA when AT= ON + 0-10 V when AT= OFF See 1/0 specs on page 4-6. Using Intelligent Input Terminals Reset Inverter The [RS] terminal causes the inverter to execute the reset operation. If the inverter is in Trip Mode, the reset cancels the Trip state. When the signal [RS] is turned ON and OFF, the inverter executes the reset operation. The minimum pulse width for [RS] must be 12 ms 12 ms 1 minimum [RS] 0 approx. 30 ms Alarm 1 signal 0 or greater. The alarm output will be cleared within 30 ms after the onset of the Reset command. AWARNING: After the Reset command is given and the alarm reset occurs, the motor will restart suddenly if the Run command is already active. Be sure to set the alarm reset after verifying that the Run command is OFF to prevent injury to personnel. Option Terminal Function Name Input Description Code Symbol State 18 RS Reset Inverter ON The motor output is turned OFF, the Trip Mode is cleared (if it exists), and powerup reset is applied Valid for inputs: Required settings: Notes: OFF C001, C002, C003, C004, C005, C006 (none) When the control terminal [RS] input is already ON at powerup for more than 4 seconds, the remote operator display is "R -ERROR COMM<2>" (the display of the digital operator is – – –. However, the inverter has no error. To clear the digital operator error, turn OFF the terminal [RS] input and press one of the operator keys. Normal power -ON operation Example (default input configurations shown—see page 3-41): –FU and F models RS See 1/0 specs on page 4-6. • Pressing the Stop/Reset key of the digital operator can generate a reset operation only when an alarm occurs. • A terminal configured with the [RS] function can only be configured for normally open operation. The terminal cannot be used in the normally closed contact state. • When input power is turned ON, the inverter performs the same reset operation as it does when a pulse on the [RS] terminal occurs. • The Stop/Reset key on the inverter is only operational for a few seconds after inverter powerup when a hand-held remote operator is connected to the inverter. • If the [RS] terminal is turned ON while the motor is running, the motor will be free running (coasting). • If you are using the output terminal OFF delay feature (any of C145, C147, C149 > 0.0 sec.), the [RS] terminal affects the ON -to -OFF transition slightly. Normally (without using OFF delays), the [RS] input causes the motor output and the logic outputs to turn OFF together, immediately. However, when any output uses an OFF delay, then after the [RS] input turns ON, that output will remain ON for an additional 1 sec. period (approximate) before turning OFF. SJ200 Inverter Thermistor Thermal Protection Motors that are equipped with a thermistor can be protected from overheating. Input terminal [6] has the unique ability to sense a thermistor resistance. When the resistance value of the thermistor connected to terminal [TH] (6) and [L] is more than 3 k Q ±10%, the inverter enters the Trip Mode, turns OFF the output to the motor, and indicates the trip status E35. Use this function to protect the motor from overheating Option Code Terminal Symbol Function Name Input State Description 19 TH Thermistor Thermal Sensor When a thermistor is connected to terminals [6] Protection and [L], the inverter checks for over -temperature and will cause trip (E35) and turn OFF the output to the motor Open An open circuit in the thermistor causes a trip, and the inverter turns OFF the output Valid for inputs: C006 only Example (requires input configuration— see page 3-41): TH Required settings: C085 Notes: L 6 5 4 3 2 1 PCS • Be sure the thermistor is connected to terminals [6] and [L]. If the resistance is above the threshold the inverter will trip. When the motor cools down enough, the thermistor resistance will change enough to permit you to clear the error. Press the STOP/Reset key to clear the error. thermistor MOTOR Using Intelligent Input Terminals Three -wire Interface Operation The 3 -wire interface is an industry standard motor control interface. This function uses two inputs for momentary contact start/stop control, and a third for selecting forward or reverse direction. To implement the 3 -wire interface, assign 20 [STA] (Start), 21 [STP] (Stop), and 22 [F/R] (Forward/Reverse) to three of the intelligent input terminals. Use a momentary contact for Start and Stop. Use a selector switch, such as SPST for the Forward/Reverse input. Be sure to set the operation command selection A002=01 for input terminal control of motor. If you have a motor control interface that needs logic -level control (rather than momen- tary pulse control), use the [FW] and [RV] inputs instead. Option Terminal Function Name Input Description Code Symbol State 20 STA Start Motor ON Start motor rotation on momentary contact (uses acceleration profile) OFF No change to motor operation 21 STP Stop Motor ON No change to motor operation OFF Stop motor rotation on momentary contact (uses deceleration profile) 22 F/R Forward/Reverse ON Select reverse direction of rotation OFF Select forward direction of rotation Valid for inputs: C001, C002, C003, C004, Example (requires input configuration— 0005, C006 see page 3-41): STP F/R STA Required settings: A002 = 01 Notes: L 6 5 4 3 2 1 PCS • The STP logic is inverted. Normally the switch will be closed, so you open the switch to stop. In this way, a broken wire causes the motor to stop automatically (safe design). • When you configure the inverter for 3 -wire inter- face control, the dedicated [FW] terminal is automatically disabled. The [RV] intelligent See 1/0 specs on page 4-6. terminal assignment is also disabled. SJ200 Inverter The diagram below shows the use of 3 -wire control. STA (Start Motor) is an edge -sensi- tive input; an OFF -to -ON transition gives the Start command. The control of direction is level -sensitive, and the direction may be changed at any time. STP (Stop Motor) is also a level -sensitive input. 1 [STA] terminal 0 1 [STP terminal] 0 1 [F/R] terminal 0 Motor revolu- tion speed Using Intelligent Input Terminals PID ON/OFF and PID Clear The PID loop function is useful for controlling motor speed to achieve constant flow, pressure, temperature, etc. in many process applications. The PID Disable function temporarily suspends PID loop execution via an intelligent input terminal. It overrides the parameter A071 (PID Enable) to stop PID execution and return to normal motor frequency output characteristics. the use of PID Disable on an intelligent input terminal is optional. Of course, any use of the PID loop control requires setting PID Enable function A071=01. The PID Clear function forces the PID loop integrator sum = 0. So, when you turn ON an intelligent input configured as [PIDC], the integrator sum is reset to zero. This is useful when switching from manual control to PID loop control and the motor is stopped. ACAUTION: Be careful not to turn PID Clear ON and reset the integrator sum when the inverter is in Run Mode (output to motor is ON). Otherwise, this could cause the motor to decelerate rapidly, resulting in a trip. Option Terminal Function Name Input Description Code Symbol State 23 PID PID Disable ON Disables PID loop execution OFF Allows PID loop execution if A71=01 24 PIDC PID Clear ON Force the value of the integrator to zero OFF No change to PID loop execution Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): PIDC Required settings: A071 PID Notes: L 16 15 4 3 2 1 PCS • The use of [PID] and [PIDC] terminals are optional. Use A071=01 if you want PID loop control enabled all the time. • Do not enable/disable PID control while the motor is running (inverter is in Run Mode). • Do not turn ON the [PIDC] input while the motor is See I/O specs on page 4-6. running (inverter is in Run Mode). SJ200 Inverter Remote Control Up and Down Functions The [UP] [DWN] terminal functions can adjust the output frequency for remote control while the motor is running. The acceleration time and deceleration time of this function is same as normal operation ACC 1 and DEC 1 (2ACC 1,2DEC 1). The input terminals operate according to these principles: • Acceleration - When the [UP] contact is turned ON, the output frequency accelerates from the current value. When it is turned OFF, the output frequency maintains its current value at that moment. • Deceleration - When the [DWN] contact is turned ON, the output frequency deceler- ates from the current value. When it is turned OFF, the output frequency maintains its current value at that moment. In the graph below, the [UP] and [DWN] terminals activate while the Run command remains ON. The output frequency responds to the [UP] and [DWN] commands. Output frequency 1 [UP] 0 1 [DWN] 0 [FW], [RV] 0 Using Intelligent Input Terminals It is possible for the inverter to retain the frequency set from the [UP] and [DWN] termi- nals through a power loss. Parameter C 101 enables/disables the memory. If disabled, the inverter retains the last frequency before an UP/DWN adjustment. Use the [UDC] terminal to clear the memory and return to the original set output frequency. Option Terminal Function Name Input Description Code Symbol State 27 UP Remote Control ON Accelerates (increases output frequency) motor UP Function (motor- from current frequency ized speed pot.) OFF Output to motor operates normally 28 DWN Remote Control ON Decelerates (decreases output frequency) motor DOWN Function from current frequency (motorized speed pot.) OFF Output to motor operates normally 29 UDC Remote Control Data ON Clears the Up/down frequency memory Clear OFF No effect on Up/down memory Valid for inputs: C001, C002, C003, C004, Example (requires input configuration— 0005, C006 see page 3-41): DWN UP Required settings: A001 = 02 Notes: L16 15 4 3 2 1 PCS • This feature is available only when the frequency command source is programmed for operator control. Confirm A001 is set to 02. • This function is not available when [JG] is in use. • The range of output frequency is 0 Hz to the value in A004 (maximum frequency setting). See 1/0 specs on page 4-6. • The minimum ON time of [UP] and [DWN] is 50 ms. • This setting modifies the inverter speed from using F001 output frequency setting as a starting point. SJ200 Inverter Force Operation from Digital Operator This function permits a digital operator interface to override the following two settings in the inverter: • A001 - Frequency source setting • A002 - Run command source setting When using the [OPE] terminal input, typically A001 and A002 are configured for sources other than the digital operator interface for the output frequency and Run command sources, respectively. When the [OPE] input is ON, then user has immediate command of the inverter, to start or stop the motor and to set the speed. Option Terminal Function Name Input Description Code Symbol State 31 OPE Force Operation ON Forces the operator interface to override: from Digital A001 - Frequency Source Setting, and Operator A002 - Run Command Source Setting OFF Parameters A001 and A002 are in effect again, for the frequency source and the Run command source, respectively Valid for inputs•' C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): OPE Required settings: A001 (set not equal to 00) A002 (set not equal to 02) L 16 15 14 3 2 1 PCS Notes: • When changing the [OPE] state during Run Mode (inverter is driving the motor), the inverter will stop the motor before the new [OPE] state takes effect. • If the [OPE] input turns ON and the digital operator gives a Run command while the inverter is already running, the inverter stops the motor. Then the See 1/0 specs on page 4-6. digital operator can control the motor. Using Intelligent Input Terminals ADD Frequency Enable The inverter can add or subtract an offset value to the output frequency setting which is specified by A001 (will work with any of the five possible sources). The ADD Frequency is a value you can store in parameter A145. The ADD Frequency is summed with or subtracted from the output frequency setting only when the [ADD] terminal is ON. Function A146 selects whether to add or subtract. By configuring an intelligent input as the [ADD] terminal, your application can selectively apply the fixed value in A145 to offset (positively or negatively) the inverter output frequency in real time. Keypad potentiometer Control terminal Function F001 setting -0 `c ModBus network input ---�° Calculate function output A145 ADD frequency --0) Intelligent input [ADD] A001 Frequency source setting +,r� Output frequency setting A146 ADD direction select Option Terminal Function Name Input Description Code Symbol State 50 ADD ADD Frequency ON Applies the A145 Add Frequency value to the Enable output frequency. OFF Does not apply the Add Frequency. The output frequency retains its normal value. Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): Required settings: A001, A145, A146 ADD L 16 15 4 3 2 1 PCS Notes: • A001 may specify any source; the Add Frequency will be added to or subtracted from that value to yield the output frequency value. See 1/0 specs on page 4-6. SJ200 Inverter Force Terminal Mode The purpose of this intelligent input is to allow a device to force the inverter to allow control of the following two parameters via the control terminals: • A001 - Frequency source setting (01 = control terminals [FW] and [RV] • A002 - Run command source setting (01 = control terminals [O] or [OI] Some applications will require one or both settings above to use a source other than the terminals. You may prefer to normally use the inverter's keypad and potentiometer, or to use the ModBus network for control, for example. However, an external device can turn ON the [F -TM] input to force the inverter to (temporarily) allow control (frequency source and Run command) via control terminals. When the [F -TM] input is OFF, then the inverter uses the regular sources specified by A001 and A002 again. Option Terminal Function Name Input Description Code Symbol State 51 F -TM Force Terminal ON Forces A001=01 (frequency source setting = Mode control terminal), and A002=01(Run command source setting = control terminal) OFF Inverter applies the user setting for A001 and A002 normally Valid for inputs: C001, C002, C003, C004, Example (requires input configuration—see C005, C006 page 3-41): F -TM L 16 15 14 3 2 1 PCS Required settings: A001, A002 Notes: • When changing the [F -TM] state during Run Mode (inverter is driving the motor), the inverter will stop the motor before the new [F -TM] state takes effect. See 1/0 specs on page 4-6. Using Intelligent Output Terminals Using Intelligent Output Terminals The intelligent output terminals are programmable in a similar way to the intelligent input terminals. The inverter has several output functions that you can assign individu- ally to three physical logic outputs. Two of the outputs are open -collector transistors, and the third output is the alarm relay (form C — normally open and normally closed contacts). The relay is assigned the alarm function by default, but you can assign it to any of the functions that the open -collector outputs use. Sinking Outputs, Open Collector The open -collector transistor outputs can handle up to 50mA each. We highly recom- mend that you use an external power source as shown. It must be capable of providing at least 100mA to drive both outputs at full load. To drive loads that require more than 50mA, use external relay circuits as shown to the right. Sinking Outputs, Open Collector with External Relays If you need output current greater than 50mA, use the inverter output to drive a small relay. Be sure to use a diode across the coil of the relay as shown (reverse -biased) in order to suppress the turn-off spike, or use a solid-state relay. Internal Relay Output The inverter has an internal relay output with normally open and normally closed contacts (Type 1 form Q. The output signal that controls the relay is configurable; the Alarm Signal is the default setting. Thus, the terminals are labeled [ALO], [AL1], [AL2], as shown to the right. However, you can assign any one of the nine intelligent outputs to the relay. For wiring purposes, the general terminal function are: • [ALO] —Common contact • [AL 1 ] —Normally open contact • [AL2] — Normally closed contact SJ200 Inverter ------------------- Inverter logic circuit board F F"', , ALO AL1 AL2 ------------------ The relay itself can be configured as "normally open or closed." Parameter C036, Alarm Relay Active State, is the setting. This setting determines whether or not the relay coil is energized when its output signal is OFF: • C036=00 — "Normally open" (relay coil is de -energized when output signal is OFF) • C036=01 — "Normally closed" (relay coil is energized when the output signal is OFF) Since the relay already has normally open [AL1] and normally closed [AL2] contacts, the purpose of the ability to invert the relay coil's active state may not be obvious. It allows you to determine whether or not an inverter power loss causes the relay to change state. The default relay configuration is the Alarm Signal (CO26=05), as shown to the right. And, C036=01 sets the relay to "normally closed" -------------- - - - - -, Inverter logic circuit board AL CO26=05 C036=01 ALO AL1 AL2 ------------------- (relay coil normally energized). The reason for this is that a typical system design will require an Relay shown with inverter power ON, Alarm Signal OFF inverter power loss to assert an alarm signal to external devices. The relay can be used for other intelligent output signals, such as the Run Signal (set CO26=00). For these remaining output signal types, the relay coil typically must NOT change state upon inverter power loss (set C036=00). The figure to the right shows the relay settings for the Run Signal output. If you assign the relay an output signal other than the Alarm Signal, the inverter can still have an Alarm Signal output. In this case, you can assign it to either terminal [ 111 or [ 12], providing an open collector output. ------------------- Inverter logic circuit board RUN CO26=00 C036=00 ALO AL1 AL2 ------------------- Relay shown with inverter power ON, Run Signal OFF Using Intelligent Output Terminals Output Signal ON/OFF Delay Function Intelligent outputs including terminals [11], [ 12], and the output relay, have configurable signal transition delays. Each output can delay either the OFF -to -ON or ON -to -OFF transitions, or both. Signal transition delays are variable from 0.1 to 100.0 seconds. This feature is useful in applications that must tailor inverter output signals to meet timing requirements of certain external devices. The timing diagram below shows a sample output signal (top line) and the results of various ON/OFF delay configurations. • Original signal - This example signal waveform consists of three separate pulses named "A," `B," and "C." • ...with ON delay - Pulse A is delayed by the duration of the ON delay time. Pulses B and C do not appear at the output, because they are shorter than the ON delay. • ...with OFF delay - Pulse A is lengthened by the amount of the OFF delay time. The separation between pulses B and C does not appear at the output, because it is shorter than the OFF delay time. • ...with ON/OFF delays - Pulse A is delayed on both leading and trailing edges by the amounts of the ON and OFF delay times, respectively. Pulses B and C do not appear at the output, because they are shorter than the ON delay time. OFF ON delay delays B C R OFF FT-] delays To configure ON and OFF delays, use the following table to set the desired delay times. Func. ON Range delay Output Signals: ;~ 0.0 to 100.0 sec. A C145 1 0.0 to 100.0 sec. 0.0 original (no delays) 0 0.0 to 100.0 sec. 0.0 ...with ON delay Terminal [12] OFF delay 0.0 to 100.0 sec. 0.0 C148 1 0.0 to 100.0 sec. ...with OFF delay 0 Output relay OFF delay 0.0 to 100.0 sec. with ON/OFF delays 0. F OFF ON delay delays B C R OFF FT-] delays To configure ON and OFF delays, use the following table to set the desired delay times. Func. Description Range Default C 144 Terminal [ 11 ] ON delay 0.0 to 100.0 sec. 0.0 C145 Terminal [11] OFF delay 0.0 to 100.0 sec. 0.0 C 146 Terminal [ 12] ON delay 0.0 to 100.0 sec. 0.0 C147 Terminal [12] OFF delay 0.0 to 100.0 sec. 0.0 C148 Output relay ON delay 0.0 to 100.0 sec. 0.0 C 149 Output relay OFF delay 0.0 to 100.0 sec. 0.0 Use of the ON/OFF signal delay functions are optional. Note that any of the intelligent output assignments in this section can be combined with ON/OFF signal timing delay configurations. SJ200 Inverter Run Signal When the [RUN] signal is selected as an intelligent output terminal, the inverter [FW], 1 outputs a signal on that terminal when it is in [RV] 0 Run Mode. The output logic is active low, and B082 is the open collector type (switch to ground). Output1 start freq __ freq. ------ Run 1 Signal 01 ON Option Terminal Output Code Symbol Function Name State 00 RUN Run Signal ON OFF Valid for outputs: 11, 12, ALO - AL2 Required settings: I (none) Notes: • The inverter outputs the [RUN] signal whenever the inverter output exceeds the start frequency specified by parameter B082. The start frequency is the initial inverter output frequency when it turns ON. • The example circuit for terminal [12] drives a relay coil. Note the use of a diode to prevent the negative - going turn-off spike generated by the coil from damaging the inverter's output transistor. t Description when inverter is in Run Mode when inverter is in Stop Mode Example for terminals [11] and 12 (default output configuration shown—see page 3-46): ---------------- Inverter output RUN- - terminal circuit H 10 1011 L I FM ICM2112111 Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3 -46): ------------------------ Inverter logic RUN circuit board ALO AU AL2 ---------------- ------ Power Load See 1/0 specs supply on page 44=6. Using Intelligent Output Terminals Frequency Arrival Signals The Frequency Arrival group of outputs help coordinate external systems with the current velocity profile of the inverter. As the name implies, output [FA I] turns ON when the output frequency arrives at the standard set frequency (parameter FOOD. Output [FA2] relies on programmable accel/ decel thresholds for increased flexibility. For example, you can have an output turn ON at one frequency during acceleration, and have it turn OFF at a different frequency during deceleration. All transitions have hyster- esis to avoid output chatter if the output frequency is near one of the thresholds. Option Terminal Function Name Output Description Code Symbol State O1 FA1 Frequency Arrival ON when output to motor is at the set frequency Type 1 - Constant Speed OFF when output to motor is OFF, or in any accelera- tion or deceleration ramp 02 FA2 Frequency Arrival ON when output to motor is at or above the set Type 2 - Over- frequency thresholds for, even if in acceleration frequency or deceleration ramps OFF when output to motor is OFF, or during accelera- tion or deceleration before the respective thresh- olds are crossed Valid for outputs: 11, 12, ALO - AL2 Example (default output configuration shown—see page 3-46): Required settings: (none) " Inv---erter ----output --------F-A1 ---, � Notes: • For most applications you will need to use only one :terminal circuit type of frequency arrival outputs (see examples). However, it is possible assign both output terminals FHTOT01 L I FM ICM2112 11 to output functions [FA I] and [FA2]. • For each frequency arrival threshold, the output anticipates the threshold (turns ON early) by 1.5Hz. • The output turns OFF as the output frequency + moves away from the threshold, delayed by 0.5Hz. - H • The delay time of the output signal is 60 ms (nominal). Example for terminals [ALO], [AL1], [AL2] • The example circuit for terminal [12] drives a relay (requires output configuration— coil. Note the use of a diode to prevent the negative- see pages 4-35 and 3-46): going turn-off spike generated by the coil from damaging the inverter's output transistor. Inverter logic FA1 circuit board ALO AL1 AL2 ---------------- ------ Power Load See 1/0 specs supply on page 4-6. Frequency arrival output [FA I] uses the standard output frequency (parameter F001) as the threshold for switching. In the figure to the right, Frequency Arrival [FA I] turns ON when the output frequency gets within 0.5 Hz below or 1.5 Hz above the target constant frequency. This provides hysteresis that prevents output chatter near the threshold value.The hysteresis effect causes the output to turn ON slightly early as the speed approaches the threshold. Then the turn -OFF point is slightly delayed. The timing is further modified by a small 60 ms delay. Note the active low nature of the signal, due to the open collector output. Frequency arrival output [FA2] works the same way; it just uses two separate thresholds as shown in the figure to the right. These provide for separate acceler- ation and deceleration thresholds to provide more flexibility than for [FAI]. [FA2] uses C042 during acceleration for the ON threshold, and C0043 during deceleration for the OFF threshold. This signal also is active low and has a 60 ms delay after the frequency thresholds are crossed. Having different accel and decel thresholds provides an asymmetrical output function. However, you can use equal ON and OFF thresholds, if desired. SJ200 Inverter Output freq.0.5 Hz 1.5 Hz F001 - F001 - - / 1.5 Hz f ---i 0.5 Hz�1; T _ t t 0 signal ON ! ON —1" A_ t 60 ms 60 ms Output freq. Thresholds C042 accel. 0.5 Hz 1.5 Hz C043decel. ------------- ---� ' � T 0 t FA2 ' signal � ON ' 60 ms 60 ms Using Intelligent Output Terminals Overload Advance Notice Signal When the output current exceeds a preset value, the [OL] terminal signal turns ON. Current threshold - - - - - - 1 tt - - - - - - - - The parameter C041 sets the overload C041 ; power running threshold. The overload detection circuit operates during powered motor opera- tion and during regenerative braking. The C041 - regeneration - - -� - `threshold output circuits use open -collector OL [ ] 1 when output current is more than the set thresh - transistors, and are active low. Signal 0 1 ON ON t OFF Option Terminal Function Name Output Description Code Symbol State 03 OL Overload Advance ON when output current is more than the set thresh - Notice Signal old for the overload signal OFF when output current is less than the set threshold for the overload signal Valid for outputs: 11, 12, ALO - AL2 Example (requires output configuration— see page 3-46):Required settings: C041 --------------------, , Inverter output OL i Notes• • The default value is 100%. To change the level � terminal circuit i from the default, set C041 (overload level). FH70 01 L FM CM2 12 11 • The accuracy of this function is the same as the function of the output current monitor on the [FM] terminal (see "Analog Output Operation" on page 4-53). • The example circuit for terminal [12] drives a relay + RY coil. Note the use of a diode to prevent the negative - going turn-off spike generated by the coil from damaging the inverter's output transistor. Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3 -46): ------------------------ Inverter logic OL circuit board ALO AU AL2 Power Load See 1/0 specs supply on page 4-6. Output Deviation for PID Control The PID loop error is defined as the magnitude (absolute value) of the differ- ence between the Setpoint (target value) and the Process Variable (actual value). When the error magnitude exceeds the preset value for C044, the [OD] terminal signal turns ON. Refer to "PID Loop Operation" on page 4-54. SJ200 Inverter SP, PV Ae- Process variable C044�Setpoint -I-- i -- 0044 [OD] 1 Signal 0 ON ON t Option Terminal Function Name Output Description Code Symbol State 04 OD Output Deviation for ON when PID error is more than the set threshold for PID Control the deviation signal OFF when PID error is less than the set threshold for the deviation signal Valid for outputs: 11, 12, ALO - AL2 Example (requires output configuration— see page 3-46): Required settings: C044 Inverter output OD Notes: terminal circuit • The default difference value is set to 3%. To change this value, change parameter C044 (deviation level). I H 011 L FM CM2 12 11 • The example circuit for terminal [12] drives a relay coil. Note the use of a diode to prevent the negative - going turn-off spike generated by the coil from + RY damaging the inverter's output transistor. Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3 -46): ----------------------- Inverter logic OD circuit board ALO AL1 AL2 ----------- --- ------ Power Load See 1/0 specs supply on page 4-6. Using Intelligent Output Terminals Alarm Signal The inverter alarm signal is active when a fault has occurred and it is in the Trip Mode (refer to the diagram at right). When the fault is cleared the alarm signal becomes inactive. We must make a distinction between the alarm signal AL and the alarm relay contacts [AL0], Trip `Fault [AL1] and [AL2]. The signal AL is a logic function, which you can assign to the open collec- Alarm signal active for output terminals [ 11 ] or [ 12] or the relay outputs. The most common (and default) use of the relay is for AL, thus the labeling of its terminals. Use an open collector output (terminal [ 11 ] or [ 12]) for a low -current logic signal interface or to energize a small relay (50 mA maximum). Use the relay output to interface to higher voltage and current devices (10 mA minimum). Option Terminal Function Name Output Description Code Symbol State 05 AL Alarm Signal ON when an alarm signal has occurred and has not been cleared OFF when no alarm has occurred since the last clearing of alarm(s) Valid for outputs: 11, 12, ALO - AL2 Example for terminal [11 ] or [12] (requires output configuration—see page 3-46): Required settings: CO26 CO36 --------------------- Inverter output AL Notes: i terminal circuit • By default, the relay is configured as normally closed (C036=01). Refer to the next page for an FHTOT01 L FM CM2 12 11 explanation. • In the default relay configuration, an inverter power loss turns ON the alarm output. the alarm signal remains ON as long as the external control circuit §�R has power. • When the relay output is set to normally closed, a time delay of less than 2 seconds occurs after Example for terminals [AL0], [AL1], [AL2] powerup before the contact is closed. (default output configuration shown— • Terminals [ 11 ] and [ 12] are open collector outputs, see page 3-46): so the electric specifications of [AL] are different - - - - - - - - - - - - - - - - - - - - - - - ' Inverter logic AL from the contact output terminals [ALO], [AL1], [AL2]. circuit board • This signal output has the delay time (300 ms Relay position nominal) from the fault alarm output. shown is for • The relay contact specifications are in "Control normal opera - tion (no alarm). ALO AL1 AL2 Logic Signal Specifications" on page 4-6. The - - - - - - - - - - - - - - - - - - - - - , contact diagrams for different conditions are on the next page. Power Load See I/O specs supply on page 4-6. SJ200 Inverter The alarm relay output can be configured in two main ways: Trip/Power Loss Alarm – The alarm relay is configured as normally closed (C036=1) by default, shown below (left). An external alarm circuit that detects broken wiring also as an alarm connects to [ALO] and [AL 1 ]. After powerup and short delay (< 2 seconds), the relay energizes and the alarm circuit is OFF. Then, either an inverter trip event or an inverter power loss will de -energize the relay and open the alarm circuit. • Trip Alarm – Alternatively, you can configure the relay as normally open (C036=0), shown below (right). An external alarm circuit that detects broken wiring also as an alarm connects to [ALO] and [AL2]. After powerup, the relay energizes only when an inverter trip event occurs, opening the alarm circuit. However, in this configuration, an inverter power loss does not open the alarm circuit. Be sure to use the relay configuration that is appropriate for your system design. Note that the external circuits shown assume that a closed circuit = no alarm condition (so that a broken wire also causes an alarm). However, some systems may require a closed circuit = alarm condition. In that case, then use the opposite terminal [AL 1 ] or [AL2] from the ones shown. N.C. contacts (C036=01) N.O. contact (C036=00) During normal operation When an alarm occurs During normal operation When an alarm occurs or when power is OFF or when power is OFF ALO AL1 AL2 Power Alarm supply device ALO AL1 AL2 ALO AL1 AL2 PowerAlarm Power Alarm supply device supply device Power Run Mode ALO– AL1 ALO– AL2 ON Normal Closed Open ON Trip Open Closed OFF — Open Closed 1 ALO AL1 AL2 Power I I Alarm supply device Power Run Mode ALO— AL1 ALO— AL2 ON Normal Open Closed ON Trip Closed Open OFF — Open Closed Using Intelligent Output Terminals Analog Input Disconnect Detect This feature is useful when the inverter receives a speed reference from an external device. Upon input signal loss at either the [O] or [OI] terminal, the inverter normally just decelerates the motor to a stop. However, the inverter can use the intelligent output terminal [Dc] to signal other machinery that a signal loss has occurred. Voltage signal loss at [O] terminal - Parameter B082 is the Start Frequency Adjust- ment. It sets the beginning (minimum) output frequency when the speed reference source is greater than zero. If the analog input at terminal [O] is less than the Start Frequency, the inverter turns ON the [Dc] output to indicate a signal loss condition. Current signal loss at [OI] terminal - The [OI] terminal accepts a 4mA to 20mA signal, with 4mA representing the beginning of the input range. If the input current falls below 4mA, the inverter applies a threshold to detect signal loss. Note that a signal loss is not an inverter trip event. When the analog input value is again above the B082 value, the [Dc] output turns OFF. There is no error condition to clear. Option Terminal Function Name Output Description Code Symbol State 06 Dc Analog Input ON when the [O] input value < B082 Start Disconnect Detect Frequency Adjustment (signal loss detected), or when the [OI input current is less than 4mA OFF when no signal loss is detected Valid for outputs: 11, 12, ALO - AL2 Example (requires output configuration— see page 3-46): Required settings: A001=01, B082 --------------------, Inverter output Dc ' terminal circuit ' Notes: • The [Dc] output can indicate an analog signal' disconnect when the inverter is in Stop Mode, as H 0 0I I L I FM ICM2112111 well as Run Mode. • The example circuit for terminal [12] drives a relay coil. Note the use of a diode to prevent the negative- + going turn-off spike generated by the coil from _ RY damaging the inverter's output transistor. Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3 -46): ------------------------ Inverter logic Dc circuit board ALO AL1 AL2 Power Load See 1/0 specs supply on page 4-6. SJ200 Inverter PID Second Stage Output The inverter has a built-in PID loop feature for two-stage control, useful for certain applications such as building ventilation or heating and cooling (HVAC). In an ideal control environment, a single PID loop controller (stage) would be adequate. However, in certain conditions, the maximum output energy from the first stage is not enough to maintain the Process Variable (PV) at or near the Setpoint (SP). And, the output of the first stage is in saturation. A simple solution is to add a second stage, which puts an additional and constant amount of energy into the system under control. When sized properly, the boost from the second stage brings the PV toward the desired range, allowing the first stage PID control to return to its linear range of operation. The two-stage method of control has some advantages for particular applications. • The second stage is only ON in adverse conditions, so there is an energy savings during normal conditions. • Since the second stage is simple ON/OFF control, it is less expensive to add than just duplicating the first stage. • At powerup, the boost provided by the second stage helps the process variable reach the desired setpoint sooner than it would if the first stage acted alone. • Even though the second stage is simple ON/OFF control, when it is an inverter you can still adjust the output frequency to vary the boost it provides. Refer to the example diagram below. Its two stages of control are defined as follows: • Stage 1 - Inverter #1 operating in PID loop mode, with motor driving a fan • Stage 2 - Inverter #2 operating as an ON/OFF controller, with motor driving a fan Stage #1 provides the ventilation needs in a building most of the time. On some days, there is a change in the building's air volume because large warehouse doors are open. In that situation, Stage #1 alone cannot maintain the desired air flow (PV sags under SP). Inverter #1 senses the low PV and its PID Second Stage Output at [FBV] terminal turns ON. This gives a Run FWD command to Inverter #2 to provide the additional air flow. Fan#1 k1 Air flow Sensor Fan#2 Stage #1 FqX Stage #2 Inverter #1 1 1 1 Inverter#2 [U, V, W] �J I [U, V, W] PV [0 or [OI]] 1 PID Second F`lf [FBV] Stage Output [FW] Process Variable Using Intelligent Output Terminals To use the PID Second Stage Output feature, you will need to choose upper and lower limits for the PV, via C053 and C052 respectively. As the timing diagram below shows, these are the thresholds Stage #1 inverter uses to turn ON or OFF Stage #2 inverter via the [FBV] output. The vertical axis units are percent (%) for the PID setpoint, and for the upper and lower limits. The output frequency, in Hz, is superimposed onto the same diagram. When the system control begins, the following events occur (in sequence in the timing diagram): 1. Stage #1 inverter turns ON via the [FW] Run command. 2. Stage #1 inverter turns ON the [FBV] output, because the PV is below the PV low limit C053. So, Stage #2 is assisting in loop error correction from the beginning. 3. The PV rises and eventually exceeds the PV high limit C052. Stage #1 inverter then turns OFF the [FBV] output to Stage #2, since the boost is no longer needed. 4. When the PV begins decreasing, only Stage #1 is operating, and it is in the linear control range. This region is where a properly configured system will operate most often. 5. The PV continues to decrease until it crosses under the PV low limit (apparent external process disturbance). Stage #1 inverter turns ON the [FBV] output, and Stage #2 inverter is assisting again. 6. After the PV rises above the PV low limit, the [FW] Run command to Stage #1 inverter turns OFF (as in a system shutdown). 7. Stage #1 inverter enters Stop Mode and automatically turns OFF the [FBV] output, which causes Stage #2 inverter to also stop. %/Hz PV high limit C052 PV low limit C053 1 Stage #1 [FW] 0 [FBV] to Stage #2 [FW] 1 0 Events PID feedback (PV) PID setpoint (SP) Output frequency - - - - - - - I' - - - - - - - �- - - - - - - - - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ I I I I I I I I I I I I t 1,2 3 4 5 6 7 The terminal [FBV] configuration table is on the following page. Option Terminal Code Symbol 07 FBV Function Name Output State Feedback Value ON Check OFF Valid for outputs: 111, 12, ALO - AL2 Required settings: A076, C052, C053 Notes: • The [FBV] is designed for implementing two-stage control. The PV high limit and PV low limit param- eters, C052 and C053, do not function as process alarm thresholds. Terminal [FBV] does not provide a PID alarm function. • The example circuit for terminal [12] drives a relay coil. Note the use of a diode to prevent the negative - going turn-off spike generated by the coil from damaging the inverter's output transistor. SJ200 Inverter Description • Transitions to ON when the inverter is in RUN Mode and the PID Process Variable (PV) is less than the Feedback Low Limit (C053) • Transitions to OFF when the PID Feedback Value (PV) exceeds the PID High Limit (C052) • Transitions to OFF when the inverter goes from Run Mode to Stop Mode Example (requires output configuration— see page 3-46): 1-------------------, Inverter output FBV ' terminal circuit ' Example for terminals [AL0], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3-46): ---------------------- Inverter logic FBV circuit board ALO AU AL2 ----------- --- ---- Power Load See 1/0 specs supply on page 4-6. Using Intelligent Output Terminals Network Detection Signal The Network Detection Signal output indicates the general status of network communi- cations. The inverter has a programmable watchdog timer to monitor network activity. Parameter C077 sets the time-out period. If communications stop or pause longer than the specified time-out period, the Ndc output turns ON. Option Terminal Function Name Output Description Code Symbol State 08 NDc Network Detection ON when the communications watchdog timer Signal (period specified by C077) has timed out OFF when the communications watchdog timer is satisfied by regular communications activity Valid for outputs: 11, 12, ALO - AL2 Example (requires output configuration— see page 3-46): Required settings: C076, C077 Inverter output NDc Notes: I terminal circuit • To disable the communications watchdog timer, set C077=00.00 sec. FHTOT01 L FM CM2 12 11 • If you set Communications Error Select to "Disable" (C076=02), you still have the option of using the Network Detection Signal and setting the watchdog time-out period with C077. + RY Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3-46): ----------------------- Inverter logic NDc circuit board ALO AL1 AL2 ---------------- ------ Power Load See 1/0 specs supply on page 4-6. Additionally, the inverter can respond to a communications time-out in various ways. Refer to the following diagram (top of next page). You configure the desired response via function C076, Communications Error Select. This selects whether or not you want the inverter to trip (alarm with error code E60) and whether to stop the motor or just let it coast. Together, parameters C076 and C077 set the network detection watchdog time-out and the inverter's response. Master Slave Watchdog timer 0077 =xx.xx sec. [NDc] Alarm C076 =00 or 01 Logic Output Function SJ200 Inverter The Logic Output Function uses the inverter's built-in logic feature. You can select any two of the other nine intelligent output options for internal inputs (use C 141 and C 142). Then, use C 143 to configure the logic function to apply the logical AND, OR, or XOR (exclusive OR) operator as desired to the two inputs. Intelligent outputs used C141 as internal inputs: , RUN, FA1, FA2, OL, OD, Input A C143 AL, Dc, FBV, NDc 0 0 Logic function 0 KIN AND, OR, XOR RUN, FA1, FA2, OL, OD, Input B AL, Dc, FBV, NDc 1 Input States [LOG] Output State A Input (C141 select) B Input (C142 select) AND OR XOR (C143=00) (C143=01) (C143=02) 0 0 0 0 0 0 1 0 1 1 1 0 0 1 1 1 1 1 1 0 Using Intelligent Output Terminals Option Code Terminal Symbol Function Name Output State Description 09 LOG Logic Output ON when the Boolean operation specified by C143 Function has a logical "1" result OFF when the Boolean operation specified by C143 has a logical "0" result Valid for outputs: 11, 12, ALO - AL2 Example (requires output configuration— see page 3-46): Required settings: C141, C142, C143 Inverter output LOG Notes: terminal circuit FHT0701 L FM CM2 12 11 Example for terminals [ALO], [AL1], [AL2] (requires output configuration— see pages 4-35 and 3 -46): ----------------------- Inverter logic LOG circuit board ALO AL1 AL2 ------------------------ ---------------------,Power Power Load See 1/0 specs supply on page 4-6. Analog Input Operation The SJ200 inverters provide for analog input to command the inverter frequency output value. The analog input terminal group includes the [L], [OI], [O], and [H] terminals on the control connector, which provide for Voltage [O] or Current [OI] input. All analog input signals must use the analog ground [L]. If you use either the voltage or current analog input, you must select one of them using the logic input terminal function [AT] analog type. If terminal [AT] is OFF, the voltage input [O] can command the inverter output frequency. If terminal [AT] is ON, the current input [OI] can command the inverter output frequency. The [AT] terminal function is covered in"Analog Input CurrentNoltage Select" on page 4-23. Remember that you must also set A001 = 01 to select analog input as the frequency source. SJ200 Inverter H 10 1011 L IAMICM2112111 +V Ref. 1 Voltage input Current input 10 A GND V/1 input select [AT]■------, A001 Frequency setting = ON OFF NOTE: If no logic input terminal is configured for the [AT] function, then inverter sums the voltage and current input to determine the desired input value. Using an external potentiometer is a common H O 01 L AM CM2 12 11 way to control the inverter output frequency (and a good way to learn how to use the analog inputs). The potentiometer uses the built-in IOV reference [H] and the analog La ground [L] for excitation, and the voltage 1 to 2kQ, 2W input [O] for the signal. By default, the [AT] terminal selects the voltage input when it is OFF. Take care to use the proper resistance for the potentiometer, which is 1 to 2 k Ohms, 2 Watts. Voltage Input - The voltage input circuit uses terminals [L] and [O]. Attach the signal H O 01 L AM CM2 12 11 cable's shield wire only to terminal [L] on the - - - - - 0 to 9.6 VDC, inverter. Maintain the voltage within specifi- - - - - 0 to 10V nominal cations (do not apply negative voltage). + - Current Input - The current input circuit uses terminals [OI] and [L]. The current H O 01 L AMC 12 11 comes from a sourcing type transmitter; a , - - - - - sinking type will not work! This means the _ _ _ _ - 4 to 19.6 n 4 to 20 mA nomminal current must flow into terminal [OI], and ♦ terminal [L] is the return back to the transmit - See I/O specs on page 4-6. ter. The input impedance from [OI] to [L] is 250 Ohms. Attach the cable shield wire only to terminal [L] on the inverter. Analog Input Operation The following table shows the available analog input settings. Parameter A005 and the input terminal [AT] determine the External Frequency Command input terminals that are available, and how they function. The analog inputs [O] and [OI] use terminal [L] as the reference (signal return). A005 [AT] Input Analog Input Configuration 00 OFF [O] ON [OI] of (ignored) Sum ([O] + 1011) 02 OFF [O] ON Keypad potentiometer 03 OFF [OI] ON Keypad potentiometer Other Analog Input -related topics: • "Analn" T"",,+ Qaffi""c" nn "n"n 111 • "Additional Analog Input Settings" on page 3-27 • "Analog Signal Calibration Settings" on page 3-51 • "Analog Input CurrentNoltage Select" on page 4-23 • "ADD Frequency Enable" on page 4-32 • "Analog Input Disconnect Detect" on page 4-44 SJ200 Inverter Analog Output Operation In inverter applications it is useful to monitor H 101011 L AM CM2 12 11 the inverter operation from a remote location or from the front panel of an inverter enclosure. In + Analog some cases, this requires only a panel -mounted A GND Voltage Output volt meter. In other cases, a controller such as a PLC may provide the inverter's frequency 10VDC command, and require inverter feedback data full scale, (such as output frequency or output current) to 1 mA max confirm actual operation. The analog output terminal [AM] serves these purposes. See I/O specs on page 4-6. The inverter provides an analog voltage output on terminal [AM] with terminal [L] as analog GND reference. The [AM] can output inverter frequency or current output value. Note that the voltage range is 0 to +10V (positive -going only), regardless of forward or reverse motor rotation. Use CO28 to configure terminal [FM] as indicated below. Func. Code Description Range CO28 00 Output frequency 0 — Max. frequency (Hz) 0 to 255 01 Output current 0-200% The [AM] signal offset and gain are adjustable, as indicated below. Func. Description Range Default B080 [AM] analog signal gain 0 to 255 100 C086 [AM] terminal offset tuning 0 — l OV 0.0 The graph to the right shows the effect of the [AM] gain setting. To calibrate the [AM] output for 10V - - - - - _ 6080=200% your application, follow the steps below: ' 1. Verify that the inverter is in Stop Mode. B080=1 2. Use C086 to adjust the offset voltage. The 5V - - - - - - - - - - - - factory default (OV) is the correct value for B080=5 most cases. Otherwise, you can have a positive voltage at zero speed or current. 3. Run the motor at the full scale speed. 0 1/2full Full a. If [AM] represents output frequency, use scale scale B080 to set the voltage for full scale output output (up to IOV). b. If [AM] represents motor current, use B080 to set the voltage for full scale output. Remember to leave room at the upper end of the range for increased current when the motor is under heavier loads. nc or A PID Loop Operation PID Loop Operation In standard operation, the inverter uses a reference source selected by parameter A001 for the output frequency, which may be a fixed value (F001), a variable set by the front panel potentiometer, or value from an analog input (voltage or current). To enable PID operation, set A071 = 01. This causes the inverter to calculate the target frequency, or setpoint. A calculated target frequency can have a lot of advantages. It lets the inverter adjust the motor speed to optimize some other process of interest, potentially saving energy as well. Refer to the figure below. The motor acts upon the external process. To control that external process, the inverter must monitor the process variable. This requires wiring a sensor to either the analog input terminal [O] (voltage) or terminal [OI] (current). Setpoint Erro PID Freq. SP � Calculation Inverter flr Motor Process Variable External Process Sensor When enabled, the PID loop calculates the ideal output frequency to minimize the loop error. This means we no longer command the inverter to run at a particular frequency, but we specify the ideal value for the process variable. That ideal value is called the setpoint, and is specified in the units of the external process variable. For a pump application it may be gallons/minute, or it could be air velocity or temperature for an HVAC unit. Parameter A075 is a scale factor that relates the external process variable units to motor frequency. The figure below is a more detailed diagram of the PID function. Setpoint Scale factor St d d (Target) an ar setting A075 F001 F001 Scale factor reciprocal Frequency Multi -speed 1 source select A001 settings A075 P gain A020 to FA 335 A072 Potentiometer Error Frequency on keypad SP I gain setting V/1 input A073 ly select , PV [AT] M - - - - - - - - Process Variable D gain Voltage (Feedback) 0074 O Analog input scaling A GND A012 Scale factor Monitor A011 PV A075 D004 i � A015 A013 A014 OI Current A076 PID V/1 input select SJ200 Inverter PID Loop Configuration The inverter's PID loop algorithm is configurable for various applications. PID Output Limit - The PID loop controller has a built-in output limit function. This function monitors the difference between the PID setpoint and the loop output (inverter output frequency), measured as a percentage of the full scale range of each. The limit is specified by parameter A078. • When the difference I(Setpoint – loop output)) is smaller than or equal to the A078 limit value, the loop controller operates in its normal linear range. • When the difference I(Setpoint – loop output)) is larger than the A078 limit value, the loop controller changes the output frequency as needed so that the difference does not exceed the limit. The diagram below shows PID setpoint changes and the related output frequency behavior when a limit value in A078 exists. Output limit PID Setpoint Output frequency Output limit A078 Limit value I- - - Limit imposed on output i A078 — — -- — -- Limit value — - - — - - 1 Limit imposed on output t Error Inversion - In typical heating loops or ventilation loops, an increase in energy into the process results in an increasing PV. In this case, the Loop Error = (SP – PV). For cooling loops, an increase in energy into the process results in a decreasing PV. In this case, the Loop Error = –(SP – PV). Use A077 to configure the error term. A077 = 00 SP + Erro PID Freq Calculation PV PV from process with positive correlation Other PID -related topics: • "PID Control" on page 3-22 • "PTT) !)N/CRR nnrl PTT) 1-1l nr" nn narra d -7R A077 = 01 SP – I Erro PID Freq Calculation PV + PV from process with negative correlation • "Output Deviation for PID Control" on page 4-41 • "PID Second Stage Output" on page 4-45 Configuring the Inverter for Multiple Motors Configuring the Inverter for Multiple Motors Simultaneous Connections For some applications, you may need to connect two or more motors (wired in parallel) to a single inverter's output. For example, this is common in conveyor applications where two separate conveyors need to have approximately the same speed. The use of two motors may be less expensive than making the mechanical link for one motor to drive multiple conveyors. Some of the characteristics of using multiple motors with one drive are: • Use only V/f (voltage -frequency) control; do not use iSLV (intelligent sensorless vector control). • The inverter output must be rated to handle the sum of the currents from the motors. • You must use separate thermal protection switches or devices to protect each motor. Locate the device D ••• SJ200 U/T1 V/T2 Motor 1 W/T3 U/T1 V/T2 Motor 2 W/T3 to Nth motor for each motor inside the motor housing or as close to it as possible. • The wiring for the motors must be permanently connected in parallel (do not remove one motor from the circuit during operation). NOTE: The motor speeds are identical only in theory. That is because slight differences in their loads will cause one motor to slip a little more than another, even if the motors are identical. Therefore, do not use this technique for multi -axis machinery that must maintain a fixed position reference between its axes. Inverter Configuration for Two Motor Types Some equipment manufacturers may have a single type of machine that has to support two different motor types—and only one motor will be connected at a time. For example, an OEM may sell basically the same machine to the US market and the European market. Some reasons why the OEM needs two motor profiles are: • The inverter power input voltage is different for these markets. • The required motor type is also different for each destination. In other cases, the inverter needs two profiles because the machine characteristics vary according to these situations: • Sometimes the motor load is very light and can move fast. Other times the motor load is heavy and must move slower. Using two profiles allows the motor speed, accelera- tion and deceleration to be optimal for the load and avoid inverter trip (fault) events. • Sometimes the slower version of the machine does not have special braking options, but a higher performance version does have braking features. SJ200 Inverter Having two motor profiles lets you store two "personalities" for motors in one inverter's memory. The inverter allows the final selection between the two motor types to be made in the field through the use of an intelligent input terminal function [SET]. This provides an extra level of flexibility needed in particular situations. See the following table. Parameters for the second motor have a function code of the form x2xx. They appear immediately after the first motor's parameter in the menu listing order. The following table lists the parameters that have the second parameter register for programming. Function Name Parameter Codes 1st motor 2nd motor Multi -speed frequency setting A020 A220 Acceleration (1) time setting F002 F202 Deceleration (1) time setting F003 F203 Acceleration (2) time setting A092 A292 Deceleration (2) time setting A093 A293 Select method to use Acc2/Dec2 A094 A294 Acc 1 to Acc2 frequency transition point A095 A295 Dec 1 to Dec2 frequency transition point A096 A296 Level of electronic thermal setting BO 12 B212 Electronic thermal characteristic B013 B213 Manual torque boost value A042 A242 Manual torque boost frequency adjustment A043 A243 V/f characteristic curve selection A044 A244 iSLV voltage gain A046 A246 iSLV slip compensation A047 A247 Base frequency setting A003 A203 Maximum frequency setting A004 A204 Frequency upper limit setting A061 A261 Frequency lower limit setting A062 A262 Motor capacity H003 H2O3 Motor poles setting H004 H2O4 Motor stabilization constant H006 H2O6 Motor voltage select H007 H2O7 Inverter System Accessories In This Chapter.... — Introduction..................................................... 2 — Component Descriptions ................................. 3 — Dynamic Braking ............................................. 5 Introduction Introduction A motor control system will obviously include a motor and inverter, as well as fuses for safety. If you are connecting a motor to the inverter on a test bench just to get started, that's all you may need for now. But a fully developed system can also have a variety of additional components. Some can be for noise suppression, while others may enhance the inverter's braking performance. The figure below shows a system with several possible optional components, and the table gives part number information. From power supply Veaker, CCBor �A---I-- q-� GFI AC reactor RF noise filter EMI filter Capacitive filter L1 L2 L3 +1 DC link choke + Braking Inverter resistor RBI Braking IBJ unit GND T1 T2 T3 Name Part No. Series See page Europe, Japan USA AC reactor, input side ALI–xxx2 HRL–x 55=3 RF noise filter, input side ZCL–xxx ZCL–xxx 5-4 EMI filter (for CE) FFL100–xxx FFL100–xxx 5-4 Capacitive filter CFI–x CFI–x 5-4 DC link choke DCL–x–xx HDC–xxx 5-4 Braking resistor JRB–xxx–x SRB–xxx–x JRB–xxx–x SRB–xxx–x 5-5 Braking resistor, NEMA -rated — HRB-x, NSRBx00–x NJRB–xxx 55=5 Resistance braking unit BRD–xxx BRD–xxx 55=5 RF noise filter, output side ZCL–xxx ZCLrxxx 5-4 AC reactor, output side ALI–x2–xxx HRL–xxx 55=3 LCR filter Combination: ALI–x2–xxx LPF–xxx R-2–xxx HRL–xxC 5-3 RF noise Note: The Hitachi part number series for accesso- filter ries includes different sizes of each part type, AC reactor, or specified by the —x suffix. Hitachi product litera- LCR filter ture can help match size and rating of your inverter to the proper accessory size. Motor Each inverter accessory comes with its own printed instruction manual. Please refer to those manuals for Thermal complete installation details. This chapter gives only an switch overview of these optional system devices. SJ200 Inverter Component Descriptions AC Reactors, Input Side This is useful in suppressing harmonics induced on the power supply lines, or when the main power voltage imbalance exceeds 3% (and power source capacity is more than 500 kVA), or to smooth out line fluctuations. It also improves the power factor. In the following cases for a general-purpose inverter, a large peak current flows on the main power supply side, and is able to destroy the inverter module: • If the unbalanced factor of the power supply is 3% or higher • If the power supply capacity is at least 10 times greater than the inverter capacity (the power supply capacity is 500 kVA or more) • If abrupt power supply changes are expected Examples of these situations include: 1. Several inverters are connected in parallel, sharing the same power bus 2. A thyristor converter and an inverter are connected in parallel, sharing the same power bus 3. An installed phase -advance (power factor correction) capacitor opens and closes Where these conditions exist or when the connected equipment must be highly reliable, you MUST install an input -side AC reactor of 3% (at a voltage drop at rated current) with respect to the supply voltage on the power supply side. Also, where the effects of an indirect lightning strike are possible, install a lightning conductor. Example calculation: VRS = 205V, VST = 203V, VTR = 197V, where VRS is R -S line voltage, VST is S -T line voltage, VTR is T R line voltage Unbalance factor of voltage —_ Max. line voltage (min.) — Mean line voltage x 100 Meanline voltage VRS — ( VRS + VST + VTR) /3 ( VRS + VST + VTR) //3 X 100 = 205 02 02 x 100 = 1.5% Please refer to the documentation that comes with the AC reactor for installation instruc- tions. AC Reactors, Output Side This reactor reduces the vibrations in the motor caused by the inverter's switching waveforms, by smoothing the waveforms to approximate commercial power quality. It is also useful to reduce the reflected voltage wave phenomenon when wiring from the inverter to the motor is more than l Om in length. Please refer to the documentation that comes with the AC reactor for installation instructions. Component Descriptions Zero -phase Reactor (RF Noise Filter) The zero -phase reactor helps reduce radiated noise from the inverter wiring. It can be used on the input or output side of the inverter. The example zero -phase reactor shown to the right comes with a mounting bracket. The wiring must go through the opening to reduce the RF component of the electrical noise. Loop the wires three times (four turns) to attain the full RF filtering effect. For larger wire sizes, place multiple zero -phase reactors (up to four) side-by-side for a greater filtering effect. EMI Filter D ZCL–xxx The EMI filter reduces the conducted noise on the power supply wiring generated by the inverter. Connect the EMI filter to the inverter primary (input side). The FFL 100 series filter is required for compliance to the EMC Class A directive (Europe) and C -TICK (Australia). See "CE–EMC Installation Guidelines" on page D-2. WARNING: The EMI filter has high internal leakage current from power wiring to the chassis. Therefore, connect the chassis ground of the EMI filter before making the power connections to avoid danger of shock or injury. �r, IIIIIIIIIIIIIIIIIIIIIIIIIl IIIIIllI1 Jl�II `'`~"��: I FFL100–xxx RF Noise Filter (Capacitive) This capacitive filter reduces radiated noise from the main power wires in the inverter input side. This filter is not for achieving CE compliance and is applicable to the input side only of the inverter. It comes in two versions—for 200V class inverters or 400V class inverters. Please refer to the documentation that comes with the radio noise filter for installation instructions. DC Link Choke The DC choke (reactor) suppresses harmonics generated by the inverter. It attenuates the high -frequency components on the inverter's internal DC bus (link). However, note that it does not protect the diode rectifiers in the inverter input circuit. SJ200 Inverter Dynamic Braking Introduction The purpose of dynamic braking is to improve the ability of the inverter to stop (decelerate) the motor and load. This becomes neces- sary when an application has some or all of the following characteris- tics: • High load inertia compared to the available motor torque • The application requires frequent or sudden changes in speed • System losses are not great enough to slow the motor as needed When the inverter reduces its output frequency to decelerate the load, the motor can temporarily become a generator. This occurs when the motor rotation frequency is higher than the inverter output frequency. This condition can cause the inverter DC bus voltage to rise, resulting in an over -voltage trip. In many applications, the over -voltage condi- tion serves as a warning signal that we have exceeded the deceleration capabilities of the system. SJ200 inverters have a built-in braking unit, which sends the regenerative energy from the motor during deceleration to the optional braking resistor(s). External braking units may also be used if higher braking torques and/or duty cycles are required. The dynamic braking resistor serves as a load, developing heat to stop the motor just as brakes on an automobile develop heat during braking. The braking resistor is the main component of a braking resistor assembly that includes a fuse and thermally activated alarm relay for Braking Resistor safety. However, be careful to avoid overheating its resistor. The fuse and thermal relay are safeguards for extreme conditions, but the inverter can maintain braking usage in a safe zone. Dynamic Braking Dynamic Braking Usage Ratio The inverter controls braking via a duty cycle BRD method (percent of the time braking is ON t1 t2 t3 versus total time). Parameter B090 sets the ' dynamic braking usage ratio. In the graph to ON the right, the example shows three uses of dynamic braking in a 100 -second period. The OFF inverter calculates the average percentage t usage in that time (T%). The percentage ofo (tl + t2 + t3) FB -9 0 T/o = x 100 usage is proportional to the heat dissipated. If 100 seconds T% is greater than the B090 parameter setting, the inverter enters the Trip Mode and turns OFF the frequency output. Please note the following: • When B090 is set for 0%, dynamic braking is not performed. • When the T% value exceeds the limit set by 13090, dynamic braking ends. • When mounting an external dynamic braking unit, set the usage ratio (B090) to 0.0 and remove the external resistors. • The cable from the external resistor to the inverter must not exceed 5 m (16 ft.) length. • The individual wires from the resistor to the inverter must not be bundled together. Troubleshooting and Maintenance In This Chapter.... Troubleshooting............................................... 2 Monitorina Tria Events. Historv. & Conditions. 5 — Restoring Factory Default Settings ................. 8 — Maintenance and Inspection ........................... 9 — Warranty........................................................ 16 Troubleshooting Troubleshooting Safety Messages Please read the following safety messages before troubleshooting or performing mainte- nance on the inverter and motor system. I WARNING: Wait at least five (5) minutes after turning OFF the input power supply before performing maintenance or an inspection. Otherwise, there is the danger of electric shock. AWARNING: Make sure that only qualified personnel will perform maintenance, inspec- tion, and part replacement. Before starting to work, remove any metallic objects from your person (wristwatch, bracelet, etc.). Be sure to use tools with insulated handles. Otherwise, there is a danger of electric shock and/or injury to personnel. A!WARNING: Never remove connectors by pulling on its wire leads (wires for cooling * fan and logic P.C.board). Otherwise, there is a danger of fire due to wire breakage and/or injury to personnel. General Precautions and Notes • Always keep the unit clean so that dust or other foreign matter does not enter the inverter. • Take special care in regard to breaking wires or making connection mistakes. • Firmly connect terminals and connectors. • Keep electronic equipment away from moisture and oil. Dust, steel filings and other foreign matter can damage insulation, causing unexpected accidents, so take special care. Inspection Items This chapter provides instructions or checklists for these inspection items: • Daily inspection • Periodic inspection (approximately once a year) • Insulation resistance test SJ200 Inverter Troubleshooting Tips The table below lists typical symptoms and the corresponding solution(s). Symptom/condition I Probable Cause Solution The motor will not run. The inverter outputs [U], [V], [W] are not supplying voltage. Inverter outputs [U], [v], IWl are supplying voltage. The optional remote operator is used (SRW). The direction of the motor is reversed. • Is the frequency command source A001 parameter setting correct? • Is the Run command source A002 parameter setting correct? • Make sure the parameter setting A001 is correct. • Make sure the parameter setting A002 is correct. • Is power being supplied to termi- • Check terminals [L1], [L2], nals [L1], [L2], and [L3/N]? If so, and [L3/N], then [U/T1], the POWER lamp should be ON. [V/T2], and [W/T3]. • Turn ON the power supply or check fuses. • Is there an error code E:l Av displayed? • Are the signals to the intelligent input terminals correct? • Is the Run Command active? • Is the [FW] terminal (or [RV]) connected to [PCS] (via switch, etc.) • Press the Func. key and determine the error type. Eliminate the error cause, then clear the error (Reset). • Verify the terminal functions for C001 — C006 are correct. • Turn ON Run Command enable. • Supply 24V to [FW] or [RV] terminal, if configured. • Has the frequency setting for F001 • Set the parameter for F001 been set greater than zero? to a safe, non -zero value. • Are the control circuit terminals • If the potentiometer is the [H], [O], and [L] connected to the frequency setting source, potentiometer? verify voltage at [O] > OV. • Is the RS (reset) function or FRS (free -run stop) function ON? • Is the motor load too heavy? • Are the operational settings between the remote operator and the inverter unit correct? • Are the connections of output terminals [U/T1], [V/T2], and [W/T3] correct? • Is the phase sequence of the motor forward or reverse with respect to [U/T1], [V/T2], and [W/T3]? • Are the control terminals [FW] and [RV] wired correctly? • Is parameter F004 properly set? • Turn OFF the command(s). • Reduce load, and test the motor independently. • Check the operator type setting. • Make connections according to the phase sequence of the motor. In general: FWD = U -V -W, and REV=U-W-V. • Use terminal [FW] for forward, and [RV] for reverse. • Set motor direction in F004. Troubleshooting Symptom/condition Probable Cause Solution • If using the analog input, is the • Check the wiring. current or voltage at [O] or [OI]? . Check the potentiometer or signal generating device. • Is the load too heavy? • Reduce the load. The motor speed will not reach • Heavy loads activate the the target frequency (desired overload restriction feature speed). (reduces output as needed). • Is the inverter internally limiting • Check max frequency the output frequency? setting (A004) • Check frequency upper limit setting (A061) • Is the load fluctuation too great? • Increase the motor capacity (both inverter and motor). • Is the supply voltage unstable? • Fix power supply problem. The rotation is unstable. . Is the problem occurring at a partic- • Change the output frequency ular frequency? slightly, or use the jump frequency setting to skip the problem frequency. The RPM of the motor does not • Is the maximum frequency setting • Verify the V/f settings match match the inverter output A004 correct? motor specifications. frequency setting. • Does the monitor function D001 • Make sure all scaling (such display the expected output as A011 to A014) is frequency? properly set. • Was power turned OFF after a • Edit the data and press the parameter edit but before pressing Store key once. the Store key? No downloads • Edits to data are permanently • Wait six seconds or more have occurred. Inverter data stored at power down. Was the time before turning power OFF is not from power OFF to power ON less after editing data. correct. than six seconds? A download to • Was the power turned OFF within • Copy the data to the inverter the inverter was six seconds after the display again, and keep power ON attempted. changed from REMT to INV? for six seconds or more after copying. A parameter True for certain • Is the inverter in Run Mode? Some • Put inverter in Stop Mode will not parameters parameters cannot be edited during (press the Stop/reset key). change after Run Mode. Then edit the parameter. an edit True for all • If you're using the [SFT] intelligent • Change the state of the SFT (reverts to parameters input (software lock function)—is input, and check the B031 old setting). the [SFT] input ON? parameter (SFT mode). SJ200 Inverter Monitoring Trip Events, History, & Conditions Fault Detection and Clearing The microprocessor in the inverter detects a variety of fault conditions and captures the event, record- ing it in a history table. The inverter output turns Run ® Stop OFF, or "trips" similar to the way a circuit breaker trips due to an over -current condition. Most faults Fault in occur when the motor is running (refer to the Trip Fault diagram to the right). However, the inverter could have an internal fault and trip in Stop Mode. In either case, you can clear the fault by pressing the Stop/Reset key. Additionally, you can clear the inverter's cumulative trip history by performing the procedure "Restoring Factory Default Settings" on page 6-8 (setting B084=00 will clear the trip history but leave inverter settings intact). Error Codes An error code will appear on the display automatically when a fault causes the inverter to trip. The following table lists the cause associated with the error. Error Code Name Cause(s) C 0 1 Over -current event while The inverter output was short-circuited, or the motor at constant speed shaft is locked or has a heavy load. These conditions cause excessive current for the inverter, so the inverter E Ls L Over -current event during deceleration output is turned OFF. The dual -voltage motor is wired incorrectly. C 0 3 Over -current event during acceleration E 0 q Over -current event during other conditions ►' D C Overload protection When a motor overload is detected by the electronic thermal function, the inverter trips and turns OFF its output. E 0 6 Braking resistor overload When the regenerative braking resistor exceeds the usage time allowance or usage ratio, the inverter trips and turns OFF its output to the motor. E L-11 l Over -voltage protection When the DC bus voltage exceeds a threshold, due to regenerative energy from the motor. C 0 8 EEPROM error When the built-in EEPROM memory has problems due to noise or excessive temperature, the inverter trips and turns OFF its output to the motor. C L_17 13 Under -voltage error A decrease of internal DC bus voltage below a thresh- old results in a control circuit fault. This condition can also generate excessive motor heat or cause low torque. The inverter trips and turns OFF its output. Monitoring Trip Events, History, & Conditions Error Code Name Cause(s) C I I CPU error A malfunction in the built-in CPU has occurred, so the inverter trips and turns OFF its output to the E 2 LF motor. Ell L7 External trip A signal on an intelligent input terminal configured as EXT has occurred. The inverter trips and turns OFF the output to the motor. C 13 USP When the Unattended Start Protection (USP) is enabled, an error occurred when power is applied while a Run signal is present. The inverter trips and does not go into Run Mode until the error is cleared. Ell 11 Ground fault The inverter is protected by the detection of ground faults between the inverter output and the motor upon during powerup tests. This feature protects the inverter, and does not protect humans. E 1 5 Input over -voltage The inverter tests for input over -voltage after the inverter has been in Stop Mode for 100 seconds. If an over -voltage condition exists, the inverter enters a fault state. After the fault is cleared, the inverter can enter Run Mode again. E2 1 Inverter thermal trip When the inverter internal temperature is above the threshold, the thermal sensor in the inverter module detects the excessive temperature of the power devices and trips, turning the inverter output OFF. E 2 i Gate array error An internal inverter error has occurred in communica- tions between the CPU and gate array IC. 3 j Thermistor When a thermistor is connected to terminals [6] and [L] and the inverter has sensed the temperature is too high, the inverter trips and turns OFF the output. 1_5 1081 Communications error The inverter's watchdog timer for the communica- tions network has timed out. _ _ _ Under -voltage (brown- Due to low input voltage, the inverter turns its output out) with output shutoff OFF and tries to restart. If it fails to restart, then the alarm trips to record the under -voltage error event. NOTE: If an EEPROM error (E08) occurs, be sure to confirm the parameter data values are still correct. If the power is turned OFF while the [RS] (Reset) intelligent input terminal is ON, an EEPROM error will occur when power is restored. SJ200 Inverter Trip History and Inverter Status We recommend that you first find the cause of the fault before clearing it. When a fault occurs, the inverter stores important performance data at the moment of the fault. To access the data, use the monitor functions (Dxxx) and select D081 for details about the present fault (En). The previous two faults are stored in D082 and D083, with D(Ei_1 and En_2). Each error shifts D081 -D082 to D082 -D083, and writes the new error to D081. The following Monitor Menu map shows how to access the error codes. When fault(s) exist, you can review their details by first selecting the proper function: D081 is the most recent, and D083 is the oldest. Monitor Menu FUNC No error Error Ng_' � FUNC exists? Yes Tri p OConditions E 0 S' Error Code 7 0.0 Output frequency ® ® at trip point 2 S Motor current ® ® at trip point DC bus voltage ® ® at trip point - - Cumulative inverter -' ® ® operation time at trip point Cumulative power - ON time at trip point FUNC Restoring Factory Default Settings Restoring Factory Default Settings You can restore all inverter parameters to the original factory (default) settings for the intended country of use. After initializing the inverter, use the powerup test in Chapter 2 to get the motor running again. To initialize the inverter, follow the steps below. No. Action Display Func./Parameter I Use the el ®, and ® keys to navigate to the `B" Group. �� _ _ _ "B" Group selected 2 Press the FUNC key. C] First `B" parameter selected 3 Press and hold the ® key until i Country code for initialization selected 4 Press the FUNC key.�� 00 = Japan, 01 = Europe, 02 = USA 5 Confirm the country code is correct. Do not change it unless you are absolutely sure the power input voltage range and frequency match the country code setting. To change the country code, press ® or ® to set, s to store. 6 Press the FDNC key. C] 5 Country code for initialization selected 7 Press the ® key. �� �i Initialization function selected 8 Press the FDNC key. 00 = initialization disabled, clear trip history only 9 Press the ® key. 1 01 = initialization enabled 10 press the sTR key. �� Initialization now enabled to restore all defaults 11press and hold the FUNC , ®, ®, and keys. Do not release yet. �� S First part of special key sequence 12 When your country code appears in the display, release all the keys. Default parameter country code shown during initialization process (left-most char displays alternating pattern) 13 Initialization is complete. Function code for output frequency monitor shown NOTE: Initialization cannot be performed with a remote operator panel. Disconnect the device and use the inverter's front panel keypad. SJ200 Inverter Maintenance and Inspection Monthly and Yearly Inspection Chart Note 1: The life of a capacitor is affected by the ambient temperature. See "Capacitor Life Curve" on page 6-11. Note 2: The inverter must be cleaned periodically. If dust accumulates on the fan and heat sink, it can cause overheating of the inverter. Inspection Cycle Inspection Item Inspected Check for... Method Criteria Month Year Ambient Extreme Thermometer, Ambient temperature environment temperatures hygrometer between -10 to 40°C, & humidity non -condensing Major devices Abnormal Visual and aural Stable environment for Overall noise & vib. electronic controls Power supply Voltage Digital volt meter, 200V class: voltage tolerance measure between 200 to 240V 50/60 Hz inverter terminals 400V class: [L1], [L2], [L3] 380 to 460V 50/60 Hz Ground Adequate Digital volt meter, 5 Meg. Ohms or greater Insulation resistance GND to terminals Mounting No loose Torque wrench M3: 0.5 — 0.6 Nm screws M4: 0.98 — 1.3 Nm M5:1.5 — 2.0 Nm Components Overheating Thermal trip events No trip events Housing Dirt, dust Visual Vacuum dust and dirt Terminal block Secure Visual No abnormalities Main connections circuit Smoothing Leaking, Visual No abnormalities capacitor swelling Relay(s) Chattering Aural Single click when switching ON or OFF Resistors Cracks or Visual Use Ohm meter to discoloring check braking resistors Cooling fan Noise Power down, Rotation must be manually rotate smooth Dust Visual Vacuum to clean Overall No odor, Visual No abnormalities discoloring, Control corrosion circuit Capacitor No leaks or Visual Undistorted appearance deformation Display LEDs Legibility Visual All LED segments work Note 1: The life of a capacitor is affected by the ambient temperature. See "Capacitor Life Curve" on page 6-11. Note 2: The inverter must be cleaned periodically. If dust accumulates on the fan and heat sink, it can cause overheating of the inverter. Maintenance and Inspection Megger Test D The megger is a piece of test equipment that uses a high voltage to determine if an insulation degradation has occurred. For inverters, it is important that the power termi- nals be isolated from the Earth GND terminal via the proper amount of insulation. The circuit diagram below shows the inverter wiring for performing the megger test. Just follow the steps to perform the test: 1. Remove power from the inverter and wait at least 5 minutes before proceeding. 2. Open the front housing panel to access the power wiring. 3. Remove all wires to terminals [R, S, T, RB, PD/+1, PD/+, N/—, U, V, and W]. Most importantly, the input power and motor wires will be disconnected from the inverter. 4. Use a bare wire and short terminals [R, S, T, RB, PD/+1, PD/+, N/—, U, V, and W] together as shown in the diagram. 5. Connect the megger to the inverter Earth GND and to the shorted power terminals as shown. Then perform the megger test at 500 VDC and verify 5MQ or greater resis- tance. Add test jumper wire DisconnectnSJ200 Disconnect power sourcemotor wires Motor Megger, 50OVDC Earth GND 6. After completing the test, disconnect the megger from the inverter. 7. Reconnect the original wires to terminals [R, S, T, RB, PD/+1, PD/+, N/—, U, V, and W]. CAUTION: Do not connect the megger to any control circuit terminals such as intelli- gent I/O, analog terminals, etc. Doing so could cause damage to the inverter. CAUTION: Never test the withstand voltage (HIPOT) on the inverter. The inverter has a surge protector between the main circuit terminals above and the chassis ground. SJ200 Inverter Spare parts We recommend that you stock spare parts to reduce down time, including these parts: Capacitor Life Curve The DC bus inside the inverter uses a large capacitor as shown in the diagram below. The capacitor handles high voltage and current as it smooths the power for use by the inverter. So, any degradation of the capacitor will affect the performance of the inverter. Power Variable -frequency Drive Input Converter Internal Inverter Motor L1 DC Bus + L2 + U/T1 Rectifier L3 V/T2 W/T3 J� Cap/acitor — Q Capacitor life is reduced in higher ambient temperatures, as the graph below demon- strates. Be sure to keep the ambient temperature at acceptable levels, and perform maintenance inspections on the fan, heat sink, and other components. If the inverter is installed on a cabinet, the ambient temperature is the temperature inside the cabinet. 50 - - Capacitor Life Curve Ambient temperature, °C 40 - - ; - - - - - - .Operation for 12 hours/day 30 --'-------------- 20 -- ' - - - - -- '-------- - - - - - J 10 ' 0 -10 Years 1 2 3 4 5 6 7 8 9 10 Quantity Part description Symbol Notes Used Spare Cooling fan FAN 1 1 015NF, 022NF, 030LF, 015HF to 075HF Case Cv 1 1 • Front case • Key cover • Case • Bottom cover Capacitor Life Curve The DC bus inside the inverter uses a large capacitor as shown in the diagram below. The capacitor handles high voltage and current as it smooths the power for use by the inverter. So, any degradation of the capacitor will affect the performance of the inverter. Power Variable -frequency Drive Input Converter Internal Inverter Motor L1 DC Bus + L2 + U/T1 Rectifier L3 V/T2 W/T3 J� Cap/acitor — Q Capacitor life is reduced in higher ambient temperatures, as the graph below demon- strates. Be sure to keep the ambient temperature at acceptable levels, and perform maintenance inspections on the fan, heat sink, and other components. If the inverter is installed on a cabinet, the ambient temperature is the temperature inside the cabinet. 50 - - Capacitor Life Curve Ambient temperature, °C 40 - - ; - - - - - - .Operation for 12 hours/day 30 --'-------------- 20 -- ' - - - - -- '-------- - - - - - J 10 ' 0 -10 Years 1 2 3 4 5 6 7 8 9 10 Maintenance and Inspection General Inverter Electrical Measurements The following table specifies how to measure key system electrical parameters. The diagrams on the next page show inverter -motor systems and the location of measurement points for these parameters. Parameter Circuit location Measuring Notes Reference Value of measurement instrument Supply voltage ER – across L 1 and L2 Moving -coil Fundamental Commercial E1 Es – across L2 and L3 type voltmeter or wave effective supply voltage ET – across L3 and L1 rectifier type value (200V class) 200– voltmeter 240V, 50/60 Hz 400V class 380- 460V, 50/60 Hz Supply current Ir – L1, IS – L2, It – L3 Total effective — I1 value Supply power W11 – across L1 and L2 Total effective — W1 W12 – across L2 and L3 value Supply power W 1 — factor Pfl Pf1 = x 100% F3xE1xI1 Output voltage EU – across U and V Rectifier type Total effective — E0 EV – across V and W voltmeter value EW – across W and U Output current IU – U Moving -coil Total effective — 1° Iv – V ammeter value 1w – W Output power W01 – across U and V Electronic type Total effective — Wo W02 – across V and W wattmeter value Output power Calculate the output power factor from the output voltage E, — factor Pfo output current I, and output power W. Wo Pf0 = x 100% ,F3xE0xI0 Note 1: Use a meter indicating a fundamental wave effective value for voltage, and meters indicating total effective values for current and power. Note 2: The inverter output has a distorted waveform, and low frequencies may cause erroneous readings. However, the measuring instruments and methods listed above provide comparably accurate results. Note 3: A general-purpose digital volt meter (DVM) is not usually suitable to measure a distorted waveform (not pure sinusoid). SJ200 Inverter The figures below show measurement locations for voltage, current, and power measure- ments listed in the table on the previous page. The voltage to be measured is the funda- mental wave effective voltage. The power to be measured is the total effective power. Single-phase Measurement Diagram L1 W Three-phase Measurement Diagram Inverter L1 I1 R U I1 T1 E1 Wog Eu v Woi L2 12 S V I1 T2 Motor E1 Woz EU -V Woz L313 T W I T3 E 1 Eu -v Maintenance and Inspection Inverter Output Voltage Measurement Techniques Taking voltage measurements around drives equipment requires the right equipment and a safe approach. You are working with high voltages and high -frequency switching waveforms that are not pure sinusoids. Digital voltmeters will not usually produce reliable readings for these waveforms. And, it is usually risky to connect high voltage signals to oscilloscopes. The inverter output semiconductors have some leakage, and no-load measurements produce misleading results. So, we highly recommend using the following circuits to measure voltage for performing the equipment inspections. Voltage measurement with load Voltage measurement without load V Class Diode Bridge Voltmeter 200V Class 600V O.OIA min. 300V range 400V Class 100V O.IA min. 600V range L1/R U/T1 L2/S Inverter V/T2 L3/T W/T3 5 kQ Additional resistor 30W 220 kQ 1 2W V Class Diode Bridge Voltmeter 200V Class 600V O.OIA min. 300V range 400V Class 100V O.IA min. 600V range AHIGH VOLTAGE: Be careful not to touch wiring or connector terminals when working with the inverters and taking measurements. Be sure to place the measurement circuitry components above in an insulated housing before using them. SJ200 Inverter IGBT Test Method The following procedure will check the inverter transistors (IGBTs) and diodes: 1. Disconnect input power to terminals [R, S, and T] and motor terminals [U, V, and W]. 2. Disconnect any wires from terminals [+] and [RB] for regenerative braking. 3. Use a Digital Volt Meter (DVM) and set it for IQ resistance range. You can check the status of the charging state of terminals [R, S, T, U, V, W, RB, +, and —] of the inverter and the probe of the DVM by measuring the charging state. [R] IS] [T] [+11 [+] [RB] Table Legend — Almost infinite resistance: - oo Q Almost zero resistance: - 0 Q Part DVM Measured Value Part DVM Measured Value Part DVM Measured Value + — + — + — D1 [R] +1 = oo Q D5 [S] [N] = 0 92 TR4 [U] [—] = 0 S2 +1 [R] = 0 S2 [N] [S] = - S2 [-] [U] = - S2 D2 [S] +1 = oo 92 D6 [T] [N] = 0 92 TR5 [V] [—] = 0 Q +1 [S] = 0 S2 [N] [T] = - S2 [-] [V] = - S2 D3 [T] +1 = oo 92 TRI [U] [+] = oo f2 TR6 [W] [—] = 0 Q +1 [T] = 0 S2 [+] [U] = 0 Q [-] [W] = - S2 D4 [R] [N] = 0 92 TR2 [V] [+] = oo S2 TR7 [RB] [+] = 0 Q [N] [R] = oo S2 [+] [V] = 0 S2 [+] [RB] = ao S2 ANTR3 [W] [+] = co Q [RB] [—] = 0 S2 [+] [W] = 0 S2 [—] [RB] --092 NOTE: The resistance values for the diodes or the transistors will not be exactly the same, but they will be close. If you find a significance difference, a problem may exist. NOTE: Before measuring the voltage between [+] and [—] with the DC current range, confirm that the smoothing capacitor is discharged fully, then execute the tests. Warranty Warranty Warranty Terms The warranty period under normal installation and handling conditions shall be eighteen (18) months from the date of purchase, or twelve (12) months from the date of installation, whichever occurs first. The warranty shall cover the repair or replacement, at Hitachi's sole discretion, of ONLY the inverter that was installed. 1. Service in the following cases, even within the warranty period, shall be charged to the purchaser: a. Malfunction or damage caused by mis-operation or modification or improper repair b. Malfunction or damage caused by a drop after purchase and transportation c. Malfunction or damage caused by fire, earthquake, flood, lightening, abnormal input voltage, contamination, or other natural disasters 2. When service is required for the product at your work site, all expenses associated with field repair shall be charged to the purchaser. 3. Always keep this manual handy; please do not lose it. Please contact your Hitachi distributor to purchase replacement or additional manuals. Glossary and Bibliography In This Appendix.... — Glossary.......................................................... 2 — Bibliography.................................................... 8 Glossary Glossary Ambient Temperature The air temperature in the chamber containing a powered electronic unit. A unit's heat sinks rely on a lower ambient temperature in order to dissipate heat away from sensitive electronics. Arrival Frequency The arrival frequency refers to the set output frequency of the inverter for the constant speed setting. The arrival frequency feature turns on an output when the inverter reaches the set constant speed. The inverter has various arrival frequencies and pulsed or latched logic options. Auto -tuning The ability of a controller to execute a procedure that interacts with a load to determine the proper coefficients to use in the control algorithm. Auto -tuning is a common feature of process controllers with PID loops. Hitachi inverters feature auto tuning to determine motor parameters for optimal commutation. Auto -tuning is avail- able as a special command from a digital operator panel. See also Digital Operator Panel. Base Frequency The power input frequency for which an AC induction motor is designed to operate. Most motors will specify a 50 to 60 Hz value. The Hitachi inverters have a programmable base frequency, so you must ensure that parameter matches the attached motor. The term base frequency helps differentiate it from the carrier frequency. See also Carrier Frequency and Frequency Setting. Braking Resistor An energy -absorbing resistor that dissipates energy from a deceler- ating load. Load inertia causes the motor to act as a generator during deceleration. See also Four -quadrant Operation and Dynamic Braking. Break -away Torque The torque a motor must produce to overcome the static friction of a load, in order to start the load moving. Carrier Frequency The frequency of the constant, periodic, switching waveform that the inverter modulates to generate the AC output to the motor. See also PWM. CE A regulatory agency for governing the performance of electronic products in Europe. Drive installations designed to have CE approval must have particular filter(s) installed in the application. Choke An inductor that is tuned to react at radio frequencies is called a "choke," since it attenuates (chokes) frequencies above a particular threshold. Tuning is often accomplished by using a movable magnetic core. In variable -frequency drive systems, a choke positioned around high -current wiring can help attenuate harmful harmonics and protect equipment. See also Harmonics. SJ200 Inverter DC Braking The inverter DC braking feature stops the AC commutation to the motor, and sends a DC current through the motor windings in order to stop the motor. Also called "DC injection braking," it has little effect at high speed, and is used as the motor is nearing a stop. Deadband In a control system, the range of input change for which there is no perceptible change in the output. In PID loops, the error term may have a dead band associated with it. Deadband may or may not be desirable; it depends on the needs of the application. Digital Operator Panel For Hitachi inverters, "digital operator panel" (DOP) refers first to Four -quadrant Referring to a graph of torque versus direction, a four -quadrant operation drive can turn the motor either forward or reverse, as well as decel- erate in either direction (see also reverse torque). A load that has a relatively high inertia and must move in both directions and change directions rapidly requires four -quadrant capability from its drive. Free -run Stop A method of stopping a motor, caused when the inverter simply turns OFF its motor output connections. This may allow the motor and load to coast to a stop, or a mechanical brake may intervene and shorten the deceleration time. the operator keypad on the front panel of the inverter. It also includes hand-held remote keypads, which connect to the inverter via a cable. Finally, the DOP Professional is a PC-based software simulation of the keypad devices. Diode A semiconductor device that has a voltage -current characteristic that allows current to flow only in one direction, with negligible leakage current in the reverse direction. See also Rectifier. Duty Cycle 1. The percent of time a square wave of fixed frequency is ON (high) versus OFF (low). 2. The ratio of operating time of a motor, braking resistor, etc. to its resting time. This parameter usually is specified in association with the allowable thermal rise for the device. Dynamic Braking The inverter dynamic braking feature shunts the motor -generated EMF energy into a special braking resistor. The added dissipation (braking torque) is effective at higher speeds, having a reduced effect as the motor nears a stop. Error In process control, the error is the difference between the desired value or setpoint (SP) and the actual value of a the process variable (PV). See also Process Variable and PID Loop. EMI Electromagnetic Interference - In motor/drive systems, the switch- ing of high currents and voltages creates the possibility of generat- ing radiated electrical noise that may interfere with the operation of nearby sensitive electrical instruments or devices. Certain aspects of an installation, such as long motor lead wire lengths, tend to increase the chance of EMI. Hitachi provides accessory filter components you can install to decrease the level of EMI. Four -quadrant Referring to a graph of torque versus direction, a four -quadrant operation drive can turn the motor either forward or reverse, as well as decel- erate in either direction (see also reverse torque). A load that has a relatively high inertia and must move in both directions and change directions rapidly requires four -quadrant capability from its drive. Free -run Stop A method of stopping a motor, caused when the inverter simply turns OFF its motor output connections. This may allow the motor and load to coast to a stop, or a mechanical brake may intervene and shorten the deceleration time. Glossary Frequency Setting While frequency has a broad meaning in electronics, it typically refers to motor speed for variable -frequency drives (inverters). This is because the output frequency of the inverter is variable, and is proportional to the attained motor speed. For example, a motor with a base frequency of 60 Hz can be speed controlled with an inverter output varying form 0 to 60 Hz. See also Base Frequency, Carrier Frequency, and Slip. Harmonics A harmonic is a whole number multiple of a base of fundamental frequency. The square waves used in inverters produce high - frequency harmonics, even though the main goal is to produce lower -frequency sine waves. These harmonics can be harmful to electronics (including motor windings) and cause radiated energy that interferes with nearby electronic devices. Chokes, line reactors, and filters are sometimes used to suppress the transmission of harmonics in an electrical system. See also Choke. Horsepower A unit of physical measure to quantify the amount of work done per unit of time. You can directly convert between horsepower and Watts as measurements of power. IGBT Insulated Gate Bipolar Transistor (IGBT) — A semiconductor transistor capable of conducting very large currents when in satura- tion and capable of withstanding very high voltages when it is OFF. This high-power bipolar transistor is the type used in Hitachi invert- ers. Inertia The natural resistance a stationary object to being moved by an external force. See also Momentum. Intelligent Terminal A configurable input or output logic function on the Hitachi invert- ers. Each terminal may be assigned one of several functions. Intelligent Sensorless Intelligent Sensorless Vector Control (iSLV) is Hitachi's newest Vector Control (iSLV) variable speed control technology. The original sensorless vector control (SLV) did not require motor shaft position sensors (thus "sensorless)", but still required setting several motor parameters (either manually or through an auto -tuning procedure). Now, iSLV uses proprietary Hitachi algorithms and high-speed processing to provide smooth control that adapts to motor characteristics in real time. Even the need to do auto -tuning procedures has been elimi- nated. Inverter A device that electronically changes DC to AC current through an alternating process of switching the input to the output, inverted and non -inverted. A variable speed drive such as the Hitachi SJ200 is also called an inverter, since it contains three inverter circuits to generate 3-phase output to the motor. SJ200 Inverter Isolation Transformer A transformer with 1:1 voltage ratio that provides electrical isola- Open -collector Outputs A common logic -type discrete output that uses an NPN transistor that acts as a switch to a power supply common, usually ground. The transistor's collector is open for external connection (not connected internally). Thus, the output sinks external load current to ground. Power Factor A ratio that expresses a phase difference (timing offset) between current and voltage supplied by a power source to a load. A perfect power factor = 1.0 (no phase offset). Power factors less than one cause some energy loss in power transmission wiring (source to load). tion between its primary and secondary windings. These are typically used on the power input side of the device to be protected. An isolation transformer can protect equipment from a ground fault or other malfunction of nearby equipment, as well as attenuate harmful harmonics and transients on the input power. Jogging Operation Usually done manually, a jog command from an operator's panel requests the motor/drive system to run indefinitely in a particular direction, until the machine operator ends the jog operation. Jump Frequency A jump frequency is a point on the inverter output frequency range that you want the inverter to skip around. This feature may be used to avoid a resonant frequency, and you can program up to three jump frequencies in the inverter. Line Reactor A three-phase inductor generally installed in the AC input circuit of an inverter to minimize harmonics and to limit short-circuit current. Momentum The physical property of a body in motion that causes it to remain in motion. In the case of motors, the rotor and attached load are rotating and possesses angular momentum. Multi -speed Operation The ability of a motor drive to store preset discrete speed levels for the motor, and control motor speed according to the currently selected speed preset. The Hitachi inverters have 16 preset speeds. Motor Load In motor terminology, motor load consists of the inertia of the physical mass that is moved by the motor and the related friction from guiding mechanisms. See also Inertia. NEC The National Electric Code is a regulatory document that governs electrical power and device wiring and installation in the United States. NEMA The National Electric Manufacturer's Association. NEMA Codes are a published series of device ratings standards. Industry uses these to evaluate or compare the performance of devices made by various manufacturers to a known standard. Open -collector Outputs A common logic -type discrete output that uses an NPN transistor that acts as a switch to a power supply common, usually ground. The transistor's collector is open for external connection (not connected internally). Thus, the output sinks external load current to ground. Power Factor A ratio that expresses a phase difference (timing offset) between current and voltage supplied by a power source to a load. A perfect power factor = 1.0 (no phase offset). Power factors less than one cause some energy loss in power transmission wiring (source to load). Glossary PID Loop Proportional - Integral -Derivative - A mathematical model used for process control. A process controller maintains a process variable (PV) at a setpoint (SP) by using its PID algorithm to compensate for dynamic conditions and vary its output to drive the PV toward the desired value. For variable -frequency drives, the process variable is the motor speed. See also Error. Process Variable A physical property of a process that is of interest because it affects the quality of the primary task accomplished by the process. For an industrial oven, temperature is the process variable. See also PID Loop and Error. PWM Pulse -width modulation: A type of AC adjustable frequency drive that accomplishes frequency and voltage control at the output section (inverter) of the drive. The drive output voltage waveform is at a constant amplitude, and by "chopping" the waveform (pulse - width -modulating), the average voltage is controlled. The chopping frequency is sometimes called the Carrier Frequency. Reactance The impedance of inductors and capacitors has two components. The resistive part is constant, while the reactive part changes with applied frequency. These devices have a complex impedance (complex number), where the resistance is the real part and the reactance is the imaginary part. Rectifier An electronic device made of one or more diodes that converts AC power into DC power. Rectifiers are usually used in combination with capacitors to filter (smooth) the rectified waveform to closely approximate a pure DC voltage source. Regenerative Braking A particular method of generating reverse torque to a motor, an inverter will switch internally to allow the motor to become a gener- ator and will either store the energy internally, deliver the braking energy back to the main power input, or dissipate it with a resistor. Regulation The quality of control applied to maintain a parameter of interest at a desired value. Usually expressed as a percent (f) from the nominal, motor regulation usually refers to its shaft speed. Reverse Torque The torque applied in the direction opposite to motor shaft rotation. As such, reverse torque is a decelerating force on the motor and its external load. Rotor The windings of a motor that rotate, being physically coupled to the motor shaft. See also Stator Saturation Voltage For a transistor semiconductor device, it is in saturation when an increase in input current no longer results in an increase in the output current. The saturation voltage is the voltage drop across the device. The ideal saturation voltage is zero. SJ200 Inverter Sensorless Vector A technique used in variable -frequency drives to rotate the force Control vector in the motor without the use of a shaft position sensor (angular). Benefits include an increase in torque at the lowest speed and the cost savings from the lack of a shaft position sensor. See also Intelligent Sensorless Vector Control. Setpoint (SP) The setpoint is the desired value of a process variable of interest. See also Process Variable (PV) and PID Loop. Single-phase power An AC power source consisting of Hot and Neutral wires. An Earth Ground connection usually accompanies them. In theory, the voltage potential on Neutral stays at or near Earth Ground, while Hot varies sinusoidally above and below Neutral. This power source is named Single Phase to differentiate it from three-phase power sources. Some Hitachi inverters can accept single phase input power, but they all output three-phase power to the motor. See also Three-phase. Slip The difference between the theoretical speed of a motor at no load (determined by its inverter output waveforms) and the actual speed. Some slip is essential in order to develop torque to the load, but too much will cause excessive heat in the motor windings and/or cause the motor to stall. Squirrel Cage A "nick -name" for the appearance of the rotor frame assembly for an AC induction motor. Stator The windings in a motor that are stationary and coupled to the power input of the motor. See also Rotor. Tachometer 1. A signal generator usually attached to the motor shaft for the purpose of providing feedback to the speed controlling device of the motor. 2. A speed -monitoring test meter that may optically sense shaft rotation speed and display it on a readout. Thermal Switch An electromechanical safety device that opens to stop current flow when the temperature at the device reaches a specific temperature threshold. Thermal switches are sometimes installed in the motor in order to protect the windings from heat damage. The inverter can use thermal switch signals to trip (shut down) if the motor overheats. See also Trip. Thermistor A type of temperature sensor that changes its resistance according to its temperature. The sensing range of thermistors and their ruggedness make them ideal for motor overheating detection. Hitachi inverters have built-in thermistor input circuits, which can detect an overheated motor and shut off (trip) the inverter output. Bibliography Three-phase power An AC power source with three Hot connections that have phase offsets of 120 degrees is a 3-phase power source. Usually, Neutral and Earth Ground wires accompany the three Hot connections. Loads may be configured in a delta or Y configuration. A Y - connected load such as an AC induction motor will be a balanced load; the currents in all the Hot connections are the same. There- fore, the Neutral connection is theoretically zero. This is why inverters that generate 3-phase power for motors do not generally have a Neutral connection to the motor. However, the Earth Ground connection is important for safety reasons, and is provided. Torque The rotational force exerted by a motor shaft. The units of measure- Variable Speed Drive Fundamentals, 2nd Ed. ment consist of the distance (radius from shaft center axis) and force (weight) applied at that distance. Units are usually given as pound -feet, ounce -inches, or Newton-meters. Transistor A solid state, three -terminal device that provides amplification of signals and can be used for switching and control. While transistors have a linear operating range, inverters use them as high-powered Hitachi Inverter Technical Guide Book switches. Recent developments in power semiconductors have produced transistors capable of handling high voltages and currents, all with high reliability. The saturation voltage has been decreasing, resulting in less heat dissipation. Hitachi inverters use state-of-the- art semiconductors to provide high performance and reliability in a compact package. See also IGBT and Saturation Voltage. Trip Event An event that causes the inverter to stop operation is called a "trip" event (as in tripping a circuit breaker). The inverter keeps a history log of trip events. They also require an action to clear. Watt Loss A measure of the internal power loss of a component, the difference between the power it consumes and what its output delivers. An inverter's watt loss is the input power minus the power delivered to the motor. The watt loss is typically highest when an inverter is delivering its maximum output. Therefore, watt loss is usually specified for a particular output level. Inverter watt loss specifica- tions are important when designing enclosures. Bibliography Title Author and Publisher Variable Speed Drive Fundamentals, 2nd Ed. Phipps, Clarence A. The Fairmont Press, Inc. / Prentice -Hall, Inc. 1997 ISBN 0-13-636390-3 Electronic Variable Speed Drives Brumbach, Michael E. Delmar Publishers 1997 ISBN 0-8273-6937-9 Hitachi Inverter Technical Guide Book Published by Hitachi, Ltd. Japan 1995 Publication SIG-EO02 ModBus Network Communications Alar In This Appendix.... — Introduction..................................................... 2 — Connecting the Inverter to ModBus................. 3 — Network Protocol Reference ........................... 6 — ModBus Data Listing .................................... 19 Introduction Introduction SJ200 Series inverters have built-in RS -485 serial communications, featuring the ModBus RTU protocol. The inverters can connect directly to existing factory networks or work with new networked applications, without any extra interface equipment. The specifications for SJ200 serial communications are in the following table. Item Specifications User -selectable Transmission speed 4800 / 9600 / 19200 bps Communication mode Asynchronous Character code Binary LSB placement Transmits LSB first Electrical interface RS -485 differential transceiver Data bits 8-bit (ModBus RTU mode) (ASCII mode not available) Parity None / even / odd Stop bits 1 or 2 bits Startup convention One-way start from host device Wait time for response 0 to 1000 msec. Connections Station address numbers from 1 to 32 Connector RJ45 modular jack — Error check Overrun, Fleming block check code, CRC -16, or horizontal parity — The network diagram below shows a series of inverters communicating with a host computer. each inverter must have a unique address, from 1 to 32, on the network. In a typical application, a host computer or controller is the master and each of the inverter(s) or other devices is a slave. Host computer ModBus Network SJ200 Inverter Connecting the Inverter to ModBus Follow the steps in this section to connect the inverter to the ModBus network. 1. Keypad Removal - The inverter keypad uses the serial communications interface connector on the front of the inverter. To access the RJ45 modular connector, you will need to remove the keypad. Refer to "Inverter Keypad Removal and Installation" on nage 2-3 for detailed instructions. 2. Modular Interconnect Removal - With the keypad removed, locate the RJ45 modular interconnect, the clear plastic connector in the opening as shown below. Press downward on the locking tab at the top of the connector, releasing it for removal. Be sure to keep it in a secure place; you may need it in the future for placing the keypad on the inverter again. The RJ45 modular jack that remains will new accept the serial communication cable. RJ45 modular • interconnect / 7 communications connector -- \ Keypad bay '�'"' 1 �WAFNING ®Rid Olsc.n Sn8 N.- antivWon 5 minule. Uelol. ap.nip Iro 3. Cable Wiring - The inverter communications port uses RS485 differential transceiver. The pinout is shown to the right and listed below. Be sure the cable connection you make matches the diagram. Pin Symbol Description 1 Not used. Do not connect 2 — Not used. Do not connect 3 — Not used. Do not connect 4 Not used. Do not connect 5 SP Send/Receive data Positive 6 SN Send/Receive data Negative 7 — Not used. Do not connect 8 — Not used. Do not connect 87654321 LJ S S I� Not used N P Not used Connecting the Inverter to ModBus 4. Terminate Network Wiring - The RS -485 wiring must be terminated at each physical end to suppress electrical reflections and help decrease transmission errors. The SJ200 communications port does not include a termination resistor. Therefore, you will need to add termination to the inverter if it is at the end of the network wiring. Select termination resistors that match the characteristic impedance of the network cable. The diagram below shows a network with the needed termination resistor at each end. 5. Set Inverter OPE/485 Switch - The inverter serial port accepts a connection to either the inverter keypad or the network. After removing the keypad, you will need to set a DIP switch on the inverter to configure the port for ModBus communications. Setting the switch will require removing the front housing cover. Remember to power OFF the inverter before removing the cover or changing the DIP switch setting. Refer to "Front Housing Cover" on page 2-4 for detailed instructions. Locate the OPE/485 DIP switch as shown in the figure below. Carefully move the switch to the upper position labeled "485" (slide in direction of arrow). Then replace the front housing cover. L G `�rrrrrrrr` SR 485 TM �-- _, SK � OPE PRG At this point the electrical network connection is complete. The next step will show how to configure parameters and settings related to ModBus communications. SJ200 Inverter 6. Inverter Parameter Setup - The inverter has several settings related to ModBus communications. The table below lists them together. The Required column indicates which parameters must be set properly to allow communications. You may need to refer to the host computer documentation in order to match some of its settings. Func. Code Name Required Settings A001 Frequency source setting 00.. Keypad potentiometer 01 .. Control terminal 02.. Function F001 setting 03.. ModBus network input 10 .. Calculate function output A002 Run command source setting 01 .. Control terminal 02 .. Run key on keypad, or digital operator 03.. ModBus network input C071 Communication speed selection 04.. 4800 bps 05.. 9600 bps 06.. 19200 bps C072 Node allocation Network address, range is 1 to 32 C074 Communication parity selection 00.. No parity 01 .. Even parity 02 .. Odd parity C075 Communication stop bit selection Range is 1 to 2 C076 Communication error select — 00.. Trip (error code E60) 01 .. Decelerate to a stop and trip (error code E60) 02.. Disable 03 .. Free run stop (coasting) 04 .. Decelerate to a stop C077 Communication error time-out — Comm. watchdog timer period, range is 0.00 to 99.99 sec. C078 Communication wait time Time the inverter waits after receiv- ing a message before it transmits. Range is 0. to 1000. ms NOTE: When you edit and store any of the parameters above, the inverter causes it to take effect immediately. ModBus transmission occurs only after you set the OPE/485 DIP switch to the "485" position and turn on the inverter. Note that parameters C071 to C078 cannot be changed via the network. To edit them, reconnect the inverter keypad (or other digital operator) and edit the parameters. Network Protocol Reference Network Protocol Reference Transmission procedure The transmission between the external control equipment and the inverter takes the procedure below External control equipment Inverter Query Latency time (silent interval plus C078 setting) • Query - A frame sent from the external control equipment to the inverter • Response - A frame returned from inverter to the external control equipment The inverter returns the response only after the inverter receives a query from the external control equipment and does not output the response positively. Each frame is formatted (with commands) as follows: Frame Format Header (silent interval) Slave address Function code Data Error check trailer (silent interval) Message Configuration: Query Slave address: • This is a number of 1 to 32 assigned to each inverter (slave). (Only the inverter having the address given as a slave address in the query can receive the query.) • When slave address "0" is specified, the query can be addressed to all inverters simul- taneously. (Broadcasting) • In broadcasting, you cannot call and loop back data. SJ200 Inverter Data: • A function command is set here. • The data format used in the SJ200 series is corresponding to the Modbus data format below. Name of Data Description Coil Binary data that can be referenced and changed (1 bit long) Holding Register 16-bit data that can be referenced and changed Function code: Specify a function you want to make the inverter execute. Function codes available to the SJ200 series are listed below. Function Code Function Maximum data size (bytes available per message) Maximum number of data elements available per message 0 1 h Read Coil Status 4 32 coils (in bits) 0 3 h Read Holding Register 4 4 registers (in bytes) 0 5 h Write in Coil 1 1 coil (in bits) 0 6 h Write in Holding Register 1 lregisters (in bytes) 0 8 h Loopback Test — — 0 F h Write in Coils 4 32 coils (in bits) 10 h Write in Registers 4 4 registers (in bytes) Error check: Modbus-RTU uses CRC (Cyclic Redundancy Check) for error checking. • The CRC code is 16-bit data that is generated for 8-bit blocks of arbitrary length. • The CRC code is generated by a generator polynomial CRC -16 (X16+ X15+ X2+ 1). Header and trailer (silent interval): Latency is the time between the reception of a query from the master and transmission of a response from the inverter. • 3.5 characters (24 bits) are always required for latency time. If the latency time shorter than 3.5 characters, the inverter returns no response. • The actual transmission latency time is the sum of silent interval (3.5 characters long) + C078 (transmission latency time). Network Protocol Reference Message Configuration: Response Transmission time required: • A time period between reception of a query from the master and transmission of a response from the inverter is the sum of the silent interval (3.5 characters long) + C078 (transmission latency time). • The master must provide a time period of the silent interval (3.5 characters long or longer) before sending another query to an inverter after receiving a response from the inverter. Normal response: • When receiving a query that contains a function code of Loopback (08h), the inverter returns a response of the same content of the query. • When receiving a query that contains a function code of Write in Register or Coil (05h, 06h, OFh, or l Oh), the inverter directly returns the query as a response. • When receiving a query that contains a function code of Read Register or Coil (01h or 03h), the inverter returns, as a response, the read data together with the same slave address and function code as those of the query. Response when an error occurs: • When finding any error in a query (except for a transmission error), the inverter returns an exception response without executing anything. • You can check the error by the function code in the response. The function code of the exception response is the sum of the function code of the query and 80h. • The content of the error is known from the exception code. Field Configuration Slave address Function code Exception code CRC -16 Exception Description Code 0 1 h The specified function is not supported 0 2 h The specified address is not found. 0 3 h The format of the specified data is not acceptable. 2 1 h The data to be written in a holding register is outside the inverter. 2 2 h The specified functions are not available to the inverter. • Function to change the content of a register that cannot be changed while the inverter is in service • Function to submit an ENTER command during running (UV) • Function to write in a register during tripping (UV) • Function to write in a read-only register (or coil) SJ200 Inverter No response occurs: In the cases below, the inverter ignores a query and returns no response. • When receiving a broadcasting query • When detecting a transmission error in reception of a query • When the slave address set in the query is not equal to the slave address of the inverter • When a time interval between data elements constituting a message is shorter than 3.5 characters • When the data length of the query is invalid NOTE: Provide a timer in the master and make the master retransmit the same query when no response is made within a preset time period after the preceding query was sent. Network Protocol Reference Explanation of function codes Read Coil Status [01h]: This function reads the status (ON/OFF) of selected coils. An example follows below. • Read intelligent input terminals [1] to [6] of an inverter having a slave address "8." • This example assumes the intelligent input terminals have terminal states listed below. Item Data Intelligent input terminal [1] [2] [3] [4] [5] [6] Coil Status ON ON ON OFF ON OFF Query: No. Field Name Example 1 Slave address (Hex) 1 Slave address *1 08 2 Function code 01 3 Coil start number 00 5 (high order) 12 4 Coil start number 07 (low order) 5 Number of coils 00 (high order) *2 6 Number of coils (low 06 order) *2 7 CRC -16 (high order) OD 8 CRC -16 (low order) 50 Note 1: Broadcasting is disabled. Note 2: When 0 or more than 32 is specified as a number of coils, error code "03h" is returned. Response: No. Field Name Example (Hex) 1 Slave address 08 2 Function code 01 3 Data size (in bytes) 01 4 Coil data *3 17 5 CRC -16 (high order) 12 6 CRC -16 (low order) 1A Note 3: Data is transferred by the specified number of data bytes (data size). • The data set in the response shows terminal states of coils 7 to 14. • Data "17h= 00010111b" indicates the following assuming coil 7 is the LSB. Item Data Coil Number 14 13 12 11 10 9 8 7 Coil Status OFF OFF OFF ON OFF ON ON ON SJ200 Inverter • When a read coil is outside the defined coils, the final coil data to be transmitted contains "0"as the status of the coil outside the range. • When the Read Coil Status command cannot be executed normally, see the exception response. Read Holding Register [03h]: This function reads the contents of the specified number of consecutive holding registers (of specified register addresses). An example follows below. • Reading previous three trip factors from an inverter having a slave address "5" • This example assumes the previous three trip factors are as follows: SJ200 Command D081 (N) D082 (N-1) D083 (N-2) Coil Number 0019h 001Ah 0018h Trip factor Over -voltage (E07) Under -voltage (E09) No trip Query: No. Field Name Example (Hex) 1 Slave address *1 05 2 Function code 03 3 Register start number 00 4 (high order) 00 4 Register start number 19 5 (low order) 07 5 Number of holding 00 6 registers (high order) 00 6 Number of holding 03 7 registers (low order) 09 7 CRC -16 (high order) D5 8 CRC -16 (low order) 88 Note 1: Broadcasting is disabled. Response: No. Field Name Example (Hex) 1 Slave address 05 2 Function code 03 3 Data size (in bytes) *2 06 4 Register start number 00 (high order) 5 Register start number 07 (low order) 6 Register start number + 1 00 (high order) 7 Register start number +1 09 (low order) 8 Register start number + 2 00 (high order) 9 Register start number +2 FF (low order) 10 CRC -16 (high order) 36 11 CRC -16 (low order) 37 Note 2: Data is transferred by the specified number of data bytes (data size). In this case, 6 bytes are used to return the content of three holding registers. Network Protocol Reference The data set in the response is as follows: Response Buffer 4 5 6 7 8 9 Coil Number + 0 (high order) + 0 (low order) + 1 (high order) + 1 (low order) + 2 (high order) + 2 (low order) Coil Status OOh 07h OOh 09h OOh FFh Trip data Over -voltage trip Under -voltage trip No trip When the Read Coil Status command cannot be executed normally, refer to the exception response. Write in Coil [05h]: This function writes data in a single coil. Coil status changes are as follows: Coil Status Data OFF to ON ON to OFF Change data (high order) FFh OOh Change data (low order) OOh OOh An example follows (note that to command the inverter, set A002=03): • Sending a RUN command to an inverter having slave address "10" • This example writes in coil number "1." Query: No. Field Name Example (Hex) 1 Slave address *1 OA 2 Function code 05 3 Coil start number 00 (high order) 4 Coil start number 01 (low order) 5 Change data FF (high order) 6 Change data 00 (low order) 7 CRC -16 (high order) DC 8 CRC -16 (low order) 81 Note 1: No response is made for a broadcasting query. Response: No. Field Name Example (Hex) 1 Slave address OA 2 Function code 05 3 Coil start number 00 (high order) 4 Coil start number 01 (low order) 5 Change data FF (high order) 6 Change data 00 (low order) 7 CRC -16 (high order) DC 8 CRC -16 (low order) 81 SJ200 Inverter When writing in a selected coil fails, see the exception response. Write in Holding Register [06h]: This function writes data in a specified holding register. An example follows: • Write "50Hz" as the first Multi -speed 0 (A020) in an inverter having slave address 665.19 • This example uses change data "500(lF4h)" to set "50Hz" as the data resolution of the register "003Ah" holding the first Multi -speed 0 (A020) is 0.1Hz Query: No. Field Name Example (Hex) 1 Slave address * 1 05 2 Function code 06 3 Register start number 00 (high order) 4 Register start number 3A (low order) 5 Change data 01 (high order) 6 Change data F4 (low order) 7 CRC -16 (high order) A8 8 CRC -16 (low order) 54 Note 1: No response is made for a broadcasting query. Response: No. Field Name Example (Hex) 1 Slave address 05 2 Function code 06 3 Register start 00 number (high order) 4 Register start 3A number (low order) 5 Change data 01 (high order) 6 Change data F4 (low order) 7 CRC -16 (high order) A8 8 CRC -16 (low order) 54 When writing in a selected holding register fails, see the exception response. Network Protocol Reference Loopback Test [08h]: This function checks a master -slave transmission using any test data. An example follows: Send test data to an inverter having slave address "1" and receiving the test data from the inverter (as a loopback test). Query: No. Field Name Example (Hex) 1 Slave address *1 01 2 Function code 08 3 Test subcode 00 (high order) 4 Test subcode 00 (low order) 5 Data Any (high order) 6 Data Any (low order) 7 CRC -16 (high order) CRC 8 CRC -16 (low order) CRC Note 1: Broadcasting is disabled. Response: No. Field Name Example (Hex) 1 Slave address 01 2 Function code 08 3 Test subcode 00 (high order) 4 Test subcode 00 (low order) 5 Data Any (high order) 6 Data Any (low order) 7 CRC -16 (high order) CRC 8 CRC -16 (low order) CRC The test subcode is for echo (00h,00h) only and not available to the other commands. SJ200 Inverter Write in Coils [0Fh]: This function writes data in consecutive coils. An example follows: Change the state of intelligent input terminal [1] to [6] of an inverter having a slave address "5." • This example assumes the intelligent input terminals have terminal states listed below. Item Data Intelligent input terminal [1] [2] [3] [4] [5] [6] Coil number 7 8 9 10 11 12 Terminal status ON ON ON OFF ON OFF Query: No. Field Name Example 1 Slave address (Hex) 1 Slave address * 1 05 2 Function code OF 3 Coil start number 00 5 (high order) 00 4 Coil start number 07 7 (low order) 65 5 Number of coils 00 (high order) 6 Number of coils (low 06 order) 7 Byte number *2 02 8 Change data 17 (high order) *2 9 Change data 00 (low order) *2 10 CRC -16 (high order) DA 11 CRC -16 (low order) EF Note 1: Broadcasting is disabled. Note 2: The change data is a set of high -order data and low -order data. So when the size (in bytes) of data to be changed is an odd number, add "1" to the data size (in bytes) to make it an even number. Response: No. Field Name Example (Hex) 1 Slave address 05 2 Function code OF 3 Data size (in bytes) 00 4 Coil data *3 07 5 Number of coils (high order) 00 6 Number of coils (low order) 06 7 CRC -16 (high order) 65 8 CRC -16 (low order) 8C Network Protocol Reference Writing in Holding Registers [10h]: This function writes data in consecutive holding registers. An example follows: • Write "3000 seconds" as the first acceleration time 1 (17002) in an inverter having a slave address "l." This example uses change data "300000(493EOh)" to set "3000 seconds" as the data resolution of the registers "0024h" and "0025h" holding the first acceleration time 1 (FO02) is 0.01 second. Query: No. Field Name Example (Hex) 1 Slave address *1 01 2 Function code 10 3 Start address (high 00 order) 4 Start address (low 24 order) 5 Number of holding 00 registers (high order) 6 Number of holding 02 registers (low order) 7 Byte number *2 04 8 Change data 1 00 (high order) 9 Change data 1 04 (low order) 10 Change data 2 93 (high order) 11 Change data 2 EO (low order) 12 CRC -16 (high order) DC 13 CRC -16 (low order) FD Note 1: Broadcasting is disabled. Note 2: This is not the number of holding registers. Specify the number of bytes of data to be changed. Response: No. Field Name Example (Hex) 1 Slave address 01 2 Function code 10 3 Start address (high 00 order) 4 Start address (low 24 order) 5 Number of holding 00 registers (high order) 6 Number of holding 02 registers (low order) 7 CRC -16 (high order) 01 8 CRC -16 (low order) C3 When writing in selected holding registers fails, see the exception response. SJ200 Inverter Exception Response: When sending a query (excluding a broadcasting query) to an inverter, the master always requests a response from the inverter. Usually, the inverter returns a response according to the query. However, when finding an error in the query, the inverter returns an excep- tion response. The exception response consists of the fields shown below. Field Configuration Slave address Function code Exception code CRC -16 The content of each field is explained below. The function code of the exception response is the sum of the function code of the query and 80h. The exception code indicates the factor of the exception response. Function Code Query Exception Response 0 1 h 8 1 h 0 3 h 8 3 h 0 5 h 8 5 h 0 6 h 8 6 h OFh 8Fh 10h 9 0 h Exception Code Code Description 0 1 h The specified function is not supported. 0 2 h The specified address is not found. 0 3 h The format of the specified data is not acceptable. 2 1 h The data to be written in a holding register is outside the inverter 2 2 h These specified functions are not available to the inverter: • Function to change the content of a register that cannot be changed while the inverter is in service • Function to submit an ENTER command during running (UV) • Function to write in a register during tripping (UV) • Function to write in a read-only register (or coil) Network Protocol Reference Store New Register Data (ENTER command) C After being written in a selected holding register by the Write in Holding Register command (06h) or in selected holding registers by the Write in Holding Registers command (10h), new data is temporary and still outside the storage element of the inverter. If power to the inverter is shut off, this new data is lost and the previous data returns. The ENTER command is used to store this new data in the storage element of the inverter. Follow the instructions below to submit the ENTER command. Submitting an ENTER Command: Write any data in all memory (of a holding register at 0900h) by the Write in Holding Register command [06h]. NOTE: The ENTER command takes much time to run. You can check its progress by monitoring the Data Writing signal (of a coil at 001Ah). NOTE: The service life of the storage element of the inverter is limited (to about 100,000 write operations). Frequent use of the ENTER command may shorten its service life. SJ200 Inverter ModBus Data Listing ModBus Coil List The following tables list the primary coils for the inverter interface to the network. The table legend is given below. • Coil Number - The network address to the coil, which is a single bit (binary) value • Name - The functional name of the coil • R/W - The read-only (R) or read-write (R/W) access permitted to the inverter data • Description - The meaning of each of the states of the coils List of Coil Numbers Coil Number Name R/W Description OOOOh (Reserved) R OOOlh Run command R/W 0..... Stop 1..... Run (enabled when A003=03) 0002h FW/REV command R/W 0..... REV 1..... FW (enabled when A003=03) 0003h External trip (EXT) R/W 0..... No trip event 1..... Trip occurred 0004h Trip reset (RS) R/W 0..... No reset condition 1..... Reset 0005h (Reserved) R — 0006h (Reserved) R — 0007h Intelligent input terminal 1 R/W 0..... OFF * 1 1..... ON 0008h Intelligent input terminal 2 R/W 0009h Intelligent input terminal 3 R/W OOOAh Intelligent input terminal 4 R/W 00013h Intelligent input terminal 5 R/W OOOCh Intelligent input terminal 6 R/W OOODh (Not used) OOOEh Run/Stop status R 0..... Stop (corresponds to D003 monitor) 1..... Run OOOFh FW/REV status R 0..... FW 1..... RV OO 1 Oh Inverter ready R 0..... Not ready 1..... Ready O011h (Reserved) R — 0012h (Reserved) R — 0013h (Reserved) R — ModBus Data Listing List of Coil Numbers Coil Number Name R/W Description 0014h Alarm signal R 0 ..... Normal 1..... Trip 0015h PID deviation signal R 0 ..... OFF I .....ON 0016h Overload signal R 0017h Frequency arrival signal (set frequency or above) R 0018h Frequency arrival signal (at constant speed) R 0019h Run Mode signal R 001Ah Data writing R 0 ..... Normal status 1..... Writing 001Bh CRC error R 0 ..... No error *2 1..... Error 00l Ch Overrun error R 001 Dh Framing error R 001 Eh Parity error R 00117h Check sum error R Note 1: ON usually when either the control circuit terminal board or a coil is ON. Among intelligent input terminals, the control circuit terminal board is a high- priority terminal. If the master cannot reset the coil ON status due to a trans- mission line break, turn ON and OFF the control circuit terminal board to make the coil OFF status. Note 2: The content of a transmission error is held until the error is reset. (The error can be reset while the inverter is running.) SJ200 Inverter ModBus Holding Registers The following tables list the holding registers for the inverter interface to the network. The table legend is given below. • Function Code - The inverter's reference code for the parameter or function (same as inverter keypad display) • Name - The standard functional name of the parameter or function for the inverter • R/W - The read-only or read-write access permitted to the data in the inverter • Description - How the parameter or setting works (same as Chapter 3 description). • Reg. - The network register address to the value (some values have a high -byte and low -byte address) • Range - The numerical range for the network value that is sent and/or received TIP: The network values are binary integers. Since these values cannot have an embedded decimal point, for many parameters it represents the actual value (in engineer- ing units) multiplied by a factor of 10 or 100. Network communications must use the listed range for network data. The inverter automatically divides received values by the appropriate factor in order to establish the decimal point for internal use. Likewise, the network host computer must apply the same factor when it needs to work in engineering units. However, when sending data to the inverter, the network host computer must scale values to the integer range listed for network communications. • Resolution - This is the quantity represented by the LSB of the network value, in engineering units. When the network data range is greater than the inverter's internal data range, this 1 -bit resolution will be fractional. List of Holding Registers Func. Network Data Code Name R/W Description Reg. Range Res. — Output frequency Inverter output frequency (set 001h 0 to 0.1 Hz command A001=03 to enable this 4000 network register), range is 0.0 to 400.0 Hz Inverter status R/W 00... Initial status 002h 0 to 9 01... (Reserved) 02... Stop Mode 03... Run Mode 04... Free -run stop (FRS) 05... Jogging 06... DC braking 07... Retry 08... Trip alarm 09... Under -voltage — Process Variable (PV) PID loop PV value from the 003h 0 to 0.1% network (set A076=02 to 1000 enable this setting), range is 0.0 to 100.0% ModBus Data Listing List of Holding Registers Func. Network Data Code Name R/W Description Reg. Range Res. D001 Output frequency R Real-time display of output OOAh 0 to 0.1 Hz monitor frequency to motor, from 4000 0.0 to 400.0 Hz D002 Output current monitor R Filtered display of output OOBh 0 to 0.1% *1 current to motor (100 ms 2000 internal filter time constant), range is 0 to 200% of inverter rated current D003 Rotation direction R Three different indications: OOCh 0, 1, 2 — monitor 00... Stop 01 ... Forward 02... Reverse D004 Process variable (PV), R Displays the scaled PID OODh 0 to 0.00% (high) PID feedback monitor process variable (feedback) 999900 times value (A075 is scale factor), const. R range is 0.00 to 99900 OOEh (low) D005 Intelligent input R Displays the state of the intelli- OOFh 0 to 63 — terminal status gent input terminals [x], Bit 0 = [1] to Bit 7 = [6] D006 Intelligent output R Displays the state of the intelli- 0010h 0 to 7 — terminal status gent output terminals [x], Bit 0 = [11], Bit 1 = [ 12], Bit 2 = [AL] D007 Scaled output frequency R Displays the output frequency 0011h 0 to 0.01 Hz (high) monitor scaled by the constant in B086. 999999 times Decimal point indicates range: const. R 0012h 0.00 to 99999 (low) D013 Output voltage monitor R Voltage of output to motor, 0013h 0 to 0.01% range is 0.00 to 200.00% 20000 D016 Cumulative operation R Displays total time the inverter 0014h 0 to 1 hour (high) RUN time monitor has been in RUN mode in 999999 hours. 6 D1 w) R Range is 0 to 999000 0015h R D017 Cumulative power -on R Displays total time the inverter 0016h 0 to 1 hour (high) time monitor has been in RUN mode in 999999 hours. R Range is 0 to 999000 0017h (low) D080 Trip counter R Number of trip events, 0018h 0 to 1 trip range is 0 to 65535 65535 event D081 Trip monitor 1 R Displays trip data 0019h D082 Trip monitor 2 R Displays trip data 001Ah D083 Trip monitor 3 R Displays trip data OO1Bh SJ200 Inverter Note 1: Assume that the inverter current rating is 1000 (for D002). The following table lists holding registers for the "D" Group Monitor Functions. Holding Registers, "D" Group Monitor Functions Func. Code Name R/W Description Network Data Reg. Res. D081 Trip monitor 1 R Trip monitor 1: factor code 0100h — R Frequency 0101h 0.1 Hz R Current 0102h 0.1% R Voltage 0103h 0.1 V R Run time (high) 0104h 1. h R Run time (low) 0105h R ON time (high) 0106h 1. h R ON time (low) 0107h D082 Trip monitor 2 R Trip monitor 1: factor code 0108h — R Frequency 0109h 0.1 Hz R Current 01OAh 0.1% R Voltage OlOBh 0.1 V R Run time (high) 01OCh 1. h R Run time (low) 0101)h R ON time (high) O1 OEh 1. h R ON time (low) 01017h D083 Trip monitor 3 R Trip monitor 1: factor code 0110h — R Frequency Ol llh 0.1 Hz R Current 0112h 0.1% R Voltage 0113h 0.1 V R Run time (high) 0114h 1. h R Run time (low) 0115h R ON time (high) 0116h 1. h R ON time (low) 0117h — Write all memory W Infinite * 1 0900h — Note 1: Stores new data made by transmission (for Write all memory). For more information, refer to the Store New Register Data (ENTER command). ModBus Data Listing The table below lists the holding registers for the "F" Group Main Profile Parameters. Holding Registers, "F" Group Main Profile Parameters Func. Network Data Code Name R/W Description Reg. Range Res. F001 Output frequency R/W Standard default target 0023h 0 / (start 0.1 Hz setting frequency that determines freq. x 10) constant motor speed, to 4000 range is 0.0 / start frequency to 400 Hz F002 Acceleration (1) time R/W Standard default acceleration, 0024h 1 to 0.01 (high) setting *I range is 0.01 to 3000 sec. 300000 sec F002 R/W 0025h (low) F202 Acceleration (1) time R/W Standard default acceleration, 0026h 1 to 0.01 (high) setting, 2nd motor * 1 2nd motor, 300000 sec range is 0.01 to 3000 sec. F202 RNV 0027h (low) F003 Deceleration (1) time R/W Standard default deceleration, 0028h 1 to 0.01 (high) setting *I range is 300000 sec 0.01 to 3000 sec. F003 RNV 0029h (low) F203 Deceleration (1) time R/W Standard default deceleration, 002Ah 1 to 0.01 (high) setting, 2nd motor * 1 2nd motor, 300000 sec range is 0.01 to 3000 sec. F203 R/W 00213h (low) F004 Keypad Run key routing R/W Two options; select codes: 002Ch 0, 1 00... Forward 01... Reverse Note 1: When the value is 10000 (100.0 seconds), a value in the second decimal place is ignored. SJ200 Inverter The following table lists the holding registers for the "A" Group Standard Functions. Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A001 Frequency source R/W Five options; select codes: 002Dh 0 to 3, 10 — setting 00... Keypad potentiometer 01... Control terminal 02... Function F001 setting 03... ModBus network input 10... Calculate function output A002 Run command source R/W Three options; select codes: 002Eh 1, 2, 3 — setting 01... Control terminal 02... Run key on keypad, or digital operator 03... ModBus network input A003 Base frequency setting R/W Settable from 30 Hz to the 002Fh 30 to 1 Hz maximum frequency max. freq. A203 Base frequency setting, R/W Settable from 30 Hz to the 2nd 0030h 30 to 1 Hz 2nd motor maximum frequency max. freq. 2 A004 Maximum frequency R/W Settable from the base 0031h 30 to 400 1 Hz setting frequency up to 400 Hz A204 Maximum frequency R/W Settable from the 2nd base 0032h 30 to 400 1 Hz setting, 2nd motor frequency up to 400 Hz A005 [AT] selection R/W Four options, select codes: 0033h 0, 1, 2, 3 — 00... Select between [O] and [OI] at [AT] 01... [O] + [OI] ([AT] input is ignored) 02... Select between [O] and keypad potentiometer 03... Select between [OI] and keypad potentiometer A011 Pot./O–L input active R/W The output frequency corre- 0034h 0 to 4000 0.1 Hz range start frequency sponding to the analog input range starting point, range is 0.0 to 400.0 A012 Pot./O–L input active R/W The output frequency corre- 0035h 0 to 4000 0.1 Hz range end frequency sponding to the analog input range ending point, range is 0.0 to 400.0 A013 Pot./O–L input active R/W The starting point (offset) for 0036h 0 to 100 1 % range start voltage the active analog input range, range is 0. to 100 A014 Pot./O–L input active R/W The ending point (offset) for 0037h 0 to 100 1 % range end voltage the active analog input range, range is 0. to 100. ModBus Data Listing Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A015 Pot./O–L input start R/W Two options; select codes: 0038h 0, 1 — frequency enable 00... Use offset (A011 value) 01... Use 0 Hz A016 External frequency R/W Range n = 1 to 8, where n = 0039h 1 to 8 1 filter time constant number of samples for avg. sample A020 Multi -speed 0 setting R/W Defines the first speed of a 003Ah 0 / start 0.1 Hz multi -speed profile, range is freq. to 0.0 / start frequency to 400 Hz 4000 A020 = Speed 0 (1st motor) A220 Multi -speed 0 setting, R/W Defines the first speed of a 00313h 0 / start 0.1 Hz 2nd motor multi -speed profile, range is freq. to 0.0 / start frequency to 400 Hz 4000 A220 = Speed 0 (2nd motor) A021 Multi -speed 1 setting R/W 003Ch 0 / start 0.1 Hz freq. to A022 Multi -speed 2 setting R/W Defines 15 more speeds, 003Dh 4000 A023 Multi -speed 3 setting R/W 003Eh A024 Multi -speed 4 setting R/W 003Fh A025 Multi -speed 5 setting R/W 0040h A026 Multi -speed 6 setting R/W 0041h A027 Multi -speed 7 setting R/W 0042h range is 0.0 / start frequency to A028 Multi -speed 8 setting R/W 400 Hz. 0043h A021= Speed 1... A029 Multi -speed 9 setting RNV A035 = Speed 15 0044h A030 Multi -speed 10 setting R/W 0045h A031 Multi -speed 11 setting R/W 0046h A032 Multi -speed 12 setting R/W 0047h A033 Multi -speed 13 setting R/W 0048h A034 Multi -speed 14 setting R/W 0049h A035 Multi -speed 15 setting R/W 004Ah A038 Jog frequency setting R/W Defines limited speed for jog, 00413h 0 / start 0.01 Hz range is 0.00 / start frequency freq. to to 9.99 Hz 999 A039 Jog stop mode R/W Define how end of jog stops 004Ch 0, 1, 2 — the motor; three options: 00... Free -run stop 01... Controlled deceleration 02... DC braking to stop SJ200 Inverter Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A042 Manual torque boost R/W Can boost starting torque 00417h 0 to 200 0.1% value between 0 and 20% above normal V/f curve, range is 0.0 to 20.0% A242 Manual torque boost R/W 0050h value, 2nd motor A043 Manual torque boost R/W Sets the frequency of the V/f 0051h 0 to 500 0.1% frequency adjustment breakpoint A in graph (top of previous page) for torque boost, range is 0.0 to 50.0% A243 Manual torque boost R/W 0052h frequency adjustment, 2nd motor A044 V/f characteristic curve R/W Two available V/f curves; 0053h 0, 1, 2 — selection three select codes: 00... Constant torque 01... Reduced torque A244 V/f characteristic curve R/W 0054h selection, 2nd motor 02... Intelligent sensorless vector control A045 V/f gain setting R/W Sets voltage gain of the 0055h 20 to 100 1 % inverter, range is 20. to 100.% A046 Automatic torque boost R/W Sets torque boost voltage gain 0056h 0 to 255 — voltage gain of the inverter, range is 0 to 255 A246 Automatic torque boost R/W 0057h voltage gain, 2nd motor A047 Automatic torque boost R/W Sets torque boost slip gain of 0058h 0 to 255 — slip gain the inverter, range is 0 to 255 A247 Automatic torque boost R/W 0059h slip gain, 2nd motor A051 DC braking enable R/W Two options; select codes: 005Ch 0, 1 — 00... Disable 01... Enable A052 DC braking frequency R/W The frequency at which DC 005Dh (13082 x 0.1 Hz setting braking begins, 10) to 600 range is from the start frequency (13082) to 60 Hz A053 DC braking wait time R/W The delay from the end of 005Eh 0, 1 — controlled deceleration to start of DC braking (motor free runs until DC braking begins), range is 0.0 to 5.0 sec. A054 DC braking force for R/W Level of DC braking force, 00517h 0 to 100 1 % deceleration settable from 0 to 100% A055 DC braking time for R/W Sets the duration for DC 0060h 0 to 600 0.1 sec deceleration braking, range is 0.0 to 60.0 seconds ModBus Data Listing Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A056 DC braking / edge or R/W Two options; select codes: 0061h 0, 1 — level detection for [DB] 00... Edge detection input 01... Level detection A061 Frequency upper limit R/W Sets a limit on output 0062h (A062 x 0.1 Hz setting frequency less than the maximum frequency (A004).(A004 10) to x A261 Frequency upper limit R/W Range is from frequency lower 0063h 10), setting, 2nd motor limit (A062) to maximum 0=disable frequency (A004). >1=enabl 0.0.. setting is disabled e >0.1 setting is enabled A062 Frequency lower limit R/W Sets a limit on output 0064h (13082 x 0.1 Hz setting frequency greater than zero. Range is start frequency 10) to (A061 x A262 Frequency lower limit R/W 0065h setting, 2nd motor (13082) to frequency upper 10), limit (A061). 0=disable 0.0.. setting is disabled >1=enabl >0.1 setting is enabled e A063, Jump (center) frequency R/W Up to 3 output frequencies can 0066h, 0 to 4000 0.1 Hz A065, setting be defined for the output to 0068h A067 jump past to avoid motor 006Ah resonances (center frequency) Range is 0.0 to 400.0 Hz A064, Jump (hysteresis) R/W Defines the distance from the 0067h 0 to 100 0.1 Hz A066, frequency width setting center frequency at which the 0069h A068 jump around occurs 00613h Range is 0.0 to 10.0 Hz A071 PID Enable R/W Enables PID function, 006Ch 0, 1 two option codes: 00... PID Disable 01... PID Enable A072 PID proportional gain R/W Proportional gain has a range 006Dh 2 to 50 0.1 of 0.2 to 5.0 A073 PID integral time R/W Integral time constant has a 006Eh 0 to 1500 0.1 sec constant range of 0.0 to 150 seconds A074 PID derivative time R/W Derivative time constant has a 00617h 0 to 1000 0.1 sec constant range of 0.0 to 100 seconds A075 PV scale conversion R/W Process Variable (PV) scale 0070h 1 to 9999 0.01 factor (multiplier), range of 0.01 to 99.99 A076 PV source setting R/W Selects source of Process 0071h 0, 1, 2, 3 — Variable (PV), option codes: 00... [OI] terminal (current in) 01... [O] terminal (voltage in) 02 ... Network 03 ... Calculate function output SJ200 Inverter Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A077 Reverse PID action R/W Two option codes: OOElh 0, 1 — 00... PID input = SP — PV 01... PID input = —(SP — PV) A078 PID output limit R/W Sets the limit of PID output as OOE2h 0 to 1000 0.1% percent of full scale, range is 0.0 to 100.0% A081 AVR function select R/W Automatic (output) voltage 0072h 0, 1, 2 regulation, selects from three type of AVR functions, three option codes: 00... AVR enabled 01 ... AVR disabled 02... AVR enabled except during deceleration A082 AVR voltage select R/W 200V class inverter settings: 0073h 0 to 5 — 00... 200 01...215 02... 220 03... 230 04... 240 400V class inverter settings: 00... 380 01 ... 400 02... 415 03... 440 04... 460 05... 480 A092 Acceleration (2) time R/W Duration of 2nd segment of 0074h 1 to 0.1 sec (high) setting acceleration, range is: 0.01 to 3000 sec. 300000 *1 A092 R/W 0075h (low) A292 Acceleration (2) time R/W Duration of 2nd segment of 0076h 1 to 0.1 sec (high) setting, (2nd motor) acceleration, 2nd motor, 300000 range is: 0.01 to 3000 sec * I A292 R/W 0077h (low) A093 Deceleration (2) time R/W Duration of 2nd segment of 0078h 1 to 0.1 sec (high) setting deceleration, range is: 0.01 to 3000 sec. 300000 *1 A093 R/W 0079h (low) A293 Deceleration (2) time R/W Duration of 2nd segment of 007Ah 1 to 0.1 sec (high) setting, (2nd motor) deceleration, range is: 300000 0.01 to 3000 sec. *1 A293 R/W 00713h (low) ModBus Data Listing Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A094 Select method to switch R/W Two options for switching 007Ch 0, 1 to Acc2/Dec2 profile from 1 st to 2nd accel/decel: 00... 2CH input from terminal 01... transition frequency A294 Select method to switch R/W 0071)hto Acc2/Dec2 profile, 2nd motor A095 Accl to Acct frequency R/W Output frequency at which 007Eh 0 to 4000 0.1 Hz transition point Accell switches to Accel2, range is 0.0 to 400.0 Hz A295 Accl to Acc2 frequency R/W 007Fh transition point, 2nd motor A096 Decl to Dec2 frequency R/W Output frequency at which 0080h 0 to 4000 0.1 Hz transition point Decell switches to Decel2, range is 0.0 to 400.0 Hz A296 Dec1 to Dec2 frequency R/W 0081h transition point, 2nd motor A097 Acceleration curve R/W Set the characteristic curve of 0082h 0, 1 — selection Acc 1 and Acc2, two options: 00... linear 01... S-curve A098 Deceleration curve R/W Set the characteristic curve of 0083h 0, 1 selection Acc 1 and Acc2, two options: 00... linear 01... S-curve A101 [OI]–[L] input active R/W The output frequency corre- 0084h 0 to 4000 0.1 Hz range start frequency sponding to the current input range starting point. Range is 0.00 to 400.0 Hz A102 [OI]–[L] input active R/W The output frequency corre- 0085h 0 to 4000 0.1 Hz range end frequency sponding to the current input range ending point. Range is 0.00 to 400.0 Hz A103 [OI]–[L] input active R/W The starting point for the 0086h 0 to 100 1 % range start current current input range. Range is 0. to 100.% A104 [OI]–[L] input active R/W The ending point for the 0087h 0 to 100 1 % range end current current input range. Range is 0. to 100.% A105 [OI]–[L] input start R/W Two options: 0088h 0, 1 — frequency enable 00... Use A 10 1 start value 01... Use OHz SJ200 Inverter Holding Registers for "A" Group Standard Functions Func. Network Data Code Name R/W Description Reg. Range Res. A141 A input select for calcu- R/W Five options: OOE3h 0 to 4 — late function 00... Digital operator 01... Keypad potentiometer 02... [O] input 03... [OI] input 04... Network variable A142 B input select for calcu- R/W Five options: OOE4h 0 to 4 — late function 00... Digital operator 01 ... Keypad potentiometer 02... [O] input 03... [OI] input 04... Network variable A143 Calculation symbol R/W Calculates a value based on the OOE5h 0 1, 2 A input source (A141 selects) and the B input source (A142 selects). Three options: 00... ADD (A input + B input) 01 ... SUB (A input – B input) 02... MUL (A input x B input) A145 ADD frequency R/W An offset value that is applied OOE6h 0 to 4000 0.1 Hz to the output frequency when the [ADD] terminal is ON. Range is 0.0 to 400.0 Hz A146 ADD direction select R/W Two options: OOE7h 0, 1 — 00... Plus (adds A145 value to the output frequency setting) 01... Minus (subtracts A145 value from the output frequency setting) Note 1: When the value is 10000 (100.0 seconds), a value in the second decimal place is ignored (for A092/A292 and A093/A293). ModBus Data Listing The following table lists the holding registers for the `B" Group Fine Tuning Functions. "B" Group Fine Tuning Functions Func. Network Data Code Name R/W Description Reg. Range Res. 13001 Selection of automatic R/W Select inverter restart method, 0089h 0, 1, 2, 3 restart mode four option codes: 00... Alarm output after trip, no automatic restart 01 ... Restart at OHz 02... Resume operation after frequency matching 03 ... Resume previous freq. after freq. matching, then decelerate to stop and display trip info. B002 Allowable under- R/W The amount of time a power 008Ah 3 to 250 0.1 sec voltage power failure input under -voltage can occur time without tripping the power failure alarm. Range is 0.3 to 25 sec. If under -voltage exists longer than this time, the inverter trips, even if the restart mode is selected. B003 Retry wait time before R/W Time delay after under -voltage 00813h 3 to 0.1 sec motor restart condition goes away, before 1000 the inverter runs motor again. Range is 0.3 to 100 seconds. B004 Instantaneous power R/W Two option codes: 008Ch 0,1 — failure / under -voltage 00... Disable trip alarm enable 01... Enable B005 Number of restarts on R/W Two option codes: 0081)h 0, 1 — power failure / under- 00... Restart 16 times voltage trip events 01 ... Always restart B012 Level of electronic R/W Set a level between 20% and 008Eh 2000 to 0.01% thermal setting 120% for the rated inverter 12000 current B212 Level of electronic R/W 008Fh thermal setting, 2nd motor B013 Electronic thermal R/W Select from two curves, option 0090h 0, 1, 2 characteristic codes: *1 00... Reduced torque 1 B213 Electronic thermal RNV 01... Constant torque 0091h characteristic, 2nd 02... Reduced torque 2 motor SJ200 Inverter "B" Group Fine Tuning Functions Func. Network Data Code Name R/W Description Reg. Range Res. B021 Overload restriction R/W Select the operating mode 0092h 0, 1, 2 — operation mode during overload conditions, three options, option codes: 00... Disabled 01... Enabled for acceleration and constant speed 02... Enabled for constant speed only B022 Overload restriction R/W Sets the level for overload 0093h 2000 to 0.01% setting restriction, between 20% and 15000 150% of the rated current of the inverter, setting resolution is 1% of rated current B023 Deceleration rate at R/W Sets the deceleration rate when 0094h 1 to 300 0.1 sec overload restriction inverter detects overload, range is 0.1 to 30.0, resolution is 0.1 B031 Software lock mode R/W Prevents parameter changes, in 0095h 0, 1, 2, 3 — selection four options, option codes: 00... all parameters except B031 are locked when [SFT] terminal is ON 01... all parameters except B031 and output frequency F001 when [SFT] terminal is ON 02... all parameters except B031 are locked 03... all parameters except B031 and output frequency F001 setting are locked B080 [AM] analog signal R/W Adjust of analog output at 0096h 0 to 255 — gain terminal [AM], range is 0 to 255 B082 Start frequency adjust- R/W Sets the starting frequency for 0098h 5 to 99 0.1 Hz ment the inverter output, range is 0.5 to 9.9 Hz B083 Carrier frequency R/W Sets the PWM carrier (internal 0099h 20 to 0.1 Hz setting switching frequency), range is 140 2.0 to 14.0 kHz B084 Initialization mode R/W Select the type of initialization 009Ah 0, 1, 2 — (parameters or trip to occur, two option codes: history) 00... Trip history clear 01... Parameter initialization 02... Trip history clear and parameter initialization ModBus Data Listing "B" Group Fine Tuning Functions Func. Network Data Code Name R/W Description Reg. Range Res. B085 Country code for initial- — Select default parameter values 009Bh — — ization (not accessible for country on initialization. to ModBus) Note: Write not allowed from network. B086 Frequency scaling R/W Specify a constant to scale the 009Ch 1 to 999 0.1 conversion factor displayed frequency for D007 monitor, range is 0.1 to 99.9 B087 STOP key enable R/W Select whether the STOP key 009Dh 0, 1 on the keypad is enabled, two option codes: 00... enabled 01 ... disabled B088 Restart mode after FRS R/W Selects how the inverter 009Eh 0, 1 — resumes operation when the free -run stop (FRS) is cancelled, two options: 00... Restart from OHz 01 ... Restart from frequency detected from real speed of motor (frequency matching) B090 Dynamic braking usage R/W Selects the rate of use (in %) of 009Fh 0 = 0.1% ratio the regenerative braking disabled resistor per 100 sec. intervals, , 1 to range is 0.0 to 100.0% 1000 0% . Dynamic braking disabled enabled >0% Enabled, per value B091 Stop mode selection R/W Selects how the inverter stops OOAOh 0, 1 the motor, two option codes: 00... DEC (decelerate and stop) 01 ... FRS (free run to stop) B092 Cooling fan control R/W Selects when the fan is ON per OOAlh 0, 1, 2 — inverter operation, two options: 00... Fan is always ON 01 ... Fan is ON during run, OFF during stop (5 min. delay from ON to OFF) 02... Fan is temperature controlled B095 Dynamic braking R/W Three option codes: OOA2h 0, 1, 2 control 00... Disable 01 ... Enable during RUN only 02... Enable always B096 Dynamic braking R/W Range is: OOA3h 330 to 1 V activation level 330 to 380V (200V class), 380,660 660 to 760V (400V class) to 760 SJ200 Inverter "B" Group Fine Tuning Functions Func. Network Data Code Name R/W Description Reg. Range Res. B130 Over -voltage R/W Pauses deceleration ramp when OOA4h 0, 1 — LADSTOP enable DC bus voltage rises above threshold level, in order to avoid over -voltage trip. Two option codes: 00... Disable 01 ... Enable B140 Over -current trip R/W Two option codes: OOA5h 0,1 — suppression 00... Disable 01 ... Enable B150 Carrier mode (not Automatically reduces the OOA6h 0,1 — accessible to ModBus) carrier frequency as the ambient temperature increases. Two option codes: 00... Disable 01... Enable Note 1: Assume that the inverter current rating is 10000 (for B013/B213). ModBus Data Listing The following table lists the holding registers for the "C" Group Intelligent Input Functions. "C" Group Intelligent Terminal Functions Func. Network Data Code Name R/W Description Reg. Range Res. C001 Terminal [ 1 ] function R/W OOA7h 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 11, 12, 13, - 0002 Terminal [2] function WW OOA8h C003 Terminal [3] function R/W OOA9h 15, 16, C004 Terminal [4] function R/W See "Input Terminal Config- OOAAh 18, 19, 20, 21, C005 Terminal [5] function R/W uration" on page 3-41 OOABh 22, 23, 24, 27, C006 Terminal [6] function R/W OOACh 28, 29, 31, 50, 511255 CO11 Terminal [1] active state R/W Select logic convention, two option codes: 00... normally open [NO] 01... normally closed [NC] OOADh 0, 1 - 0012 Terminal [2] active state R/W OOAEh 0, 1 - C013 Terminal [3] active state R/W OOAFh 0,1 C014 Terminal [4] active state R/W OOBOh 0, 1 - 0015 Terminal [5] active state R/W OOBlh 0, 1 - 0016 Terminal [6] active state R/W OO132h 0, 1 - 0O21 Terminal [I I] function R/W 00133h- See "Output Terminal 0, 1, 2, 3, CO22 Terminal [ 12] function lUWOOB4h Configuration" on page 33- 4, 5, 6, 7, 8,9 CO26 Alarm relay terminal R/W 46 OOBSh function CO28 [AM] signal selection R/W Two available functions: OO137h 0,1 - 00... Actual motor speed 01 ... Motor current C031 Terminal [11] active R/W Select logic convention, two OOBBh 0, 1 - state option codes: 00... normally open (NO) 01... normally closed (NC) C032 Terminal [12] active R/W Select logic convention, two OO139h 0, 1 - state option codes: 00... normally open (NO) 01... normally closed (NC) C036 Alarm relay active state WW Select logic convention, two OOBAh 0, 1 - option codes: 00... normally open (NO) 01... normally closed (NC) SJ200 Inverter "C" Group Intelligent Terminal Functions Func. Network Data Code Name R/W Description Reg. Range Res. C041 Overload level setting R/W Sets the overload signal level OOBBh 0 to 0.01% between 0% and 200% (from 0 20000 to two times the rated current of the inverter) C042 Frequency arrival R/W Sets the frequency arrival OOBCh 0 to 4000 0.1 Hz setting for acceleration setting threshold for the output * 1 frequency during acceleration, range is 0.0 to 400.0 Hz C043 Arrival frequency R/W Sets the frequency arrival OOBDh 0 to 4000 0.1 Hz setting for deceleration setting threshold for the output frequency during deceleration, range is 0.0 to 400.0 Hz C044 PID deviation level R/W Sets the allowable PID loop OOBEh 0 to 1000 0.1% setting error magnitude (absolute value), SP - PV, range is 0.0 to 100%, resolution is 0.1% C052 PID FBV function high R/W When the PV exceeds this OOEAh 0 to 1000 0.1% limit value, the PID loop turns OFF the PID Second Stage Output, range is 0.0 to 100.0% C053 PID FBV function low R/W When the PV goes below this OOEBh 0 to 1000 0.1% limit value, the PID loop turns ON the PID Second Stage Output, range is 0.0 to 100.0% C071 Communication speed — OOCOh — — selection C072 Node allocation — OOClh — 0074 Communication parity — OOC3h — — selection NOTE: These network settings are not accessible to ModBus. C075 Communication stop bit Use the inverter keypad or OOC4h selection digital operator to edit. Refer to "Network Communication C076 Communication error — OOECh — — Settings" on page 3-50. select C077 Communication error — OOEDh — — time-out C078 Communication wait — O005h — — time C081 O input span calibration R/W Scale factor between the OOC7h 0 to 2000 0.1% external frequency command on terminals L – O (voltage input) and the frequency output, range is 0.0 to 200.0% ModBus Data Listing "C" Group Intelligent Terminal Functions Func. Network Data Code Name R/W Description Reg. Range Res. C082 OI input span calibra- R/W Scale factor between the 0OC8h 0 to 2000 0.1% tion external frequency command on terminals L – OI (current input) and the frequency output, range is 0.0 to 200.0% C085 Thermistor input tuning R/W Range is 0.0 to 200.0% OOEEh 0 to 2000 0.1 % C086 [AM] terminal offset R/W Range is 0.0 to 10.OV 0OC9h 0 to 100 0.1 V tuning C091 Debug mode enable — Displays debug parameters. — — — Two option codes: 00... Disable 01... Enable C101 Up/Down memory R/W Controls speed setpoint for the OOCFh 0,1 — mode inverter after power cycle. Two selection option codes: 00... Clear last frequency (return to default frequency F001) 01 ... Keep last frequency adjusted by UP/DWN C102 Reset selection R/W Determines response to Reset OODOh 0, 1, 2 — input [RST]. Three option codes: 00... Cancel trip state at input signal ON transition, stops inverter if in Run Mode 01... Cancel trip state at signal OFF transition, stops inverter if in Run Mode 02... Cancel trip state at input signal ON transition, no effect if in Run Mode C 141 Input A select for logic R/W OOEFh 0, 1, 2, 3, — output See "Output Logic and Timing" on page 3-53 4, 5, 6, 7, 8,9 C142 Input B select for logic R/W OOFOh output C143 Logic function select R/W Applies a logic function to OOFlh 0, 1, 2 — calculate [LOG] output state, three options: 00... [LOG] = A AND B 01... [LOG] = A OR B 02... [LOG] = A XOR B C144 Terminal [11] ON delay R/W Range is 0.0 to 100.0 sec. 00172h 0 to 1000 0.1 sec C145 Terminal [11] OFF R/W Range is 0.0 to 100.0 sec. 00173h 0 to 1000 0.1 sec delay SJ200 Inverter "C" Group Intelligent Terminal Functions Func. Code Name R/W Description Network Data Reg. Range Res. C146 Terminal [12] ON delay R/W Range is 0.0 to 100.0 sec. OO174h 0 to 1000 0.1 sec C147 Terminal [12] OFF delay R/W Range is 0.0 to 100.0 sec. OOF5h 0 to 1000 0.1 sec C148 Output relay ON delay R/W Range is 0.0 to 100.0 sec. OO176h 0 to 1000 0.1 sec C149 Output relay OFF delay R/W Range is 0.0 to 100.0 sec. OOF7h 0 to 1000 0.1 sec Note 1: Assume that the inverter current rating is 10000 (for C041). The following table lists the holding registers for the "H" Group Motor Constants. "H" Group Motor Constants Func. Network Data Name R/W Description Reg. Range Res. Code H003 Motor capacity R/W Thirteen selections: OOD9h 0 to 12 0..... 0.20 kW H203 Motor capacity, 2nd R/W 1..... 0.37 kW OODAh 0 to 12 — setting 2..... 0.40 kW 3..... 0.55 kW 4..... 0.75 kW 5.....1.10 kW 6.....1.50 kW 7..... 2.2 kW 8..... 3.0 kW 9..... 3.7 kW 10...4.0 kW 11... 5.5 kW 12... 7.5 kW H004 Motor poles setting R/W Four selections: OODBh 2, 4, 6, 1 pole 2/4/6/8 8 H204 Motor poles setting, 2nd R/W OODCh 2, 4, 6, 1 pole motor 8 H006 Motor stabilization R/W Motor constant (factory set), OODDh 0 to 255 1 constant range is 0 to 255 H206 Motor stabilization R/W OODEh 0 to 255 1 constant, 2nd motor H007 Motor voltage select R/W Two selections, option codes: OODFh 0,1 — 00... 200V H2O7 Motor voltage select g R/W 01... 400V OOEOh 0,1 — 2nd motor Drive Parameter Settings Tables In This Appendix.... — Introduction..................................................... 2 — Parameter Settings for Keypad Entry .............. 2 Introduction Introduction This appendix lists the user -programmable parameters for the SJ200 series inverters and the default values for European and U.S. product types. The right -most column of the tables is blank, so you can record values you have changed from the default. This involves just a few parameters for most applications. This appendix presents the parame- ters in a format oriented toward the keypad on the inverter. Parameter Settings for Keypad Entry SJ200 series inverters provide many functions and parameters that can be configured by the user. We recommend that you record all parameters that have been edited, in order to help in troubleshooting or recovery from a loss of parameter data. Inverter model SJ200 MFG. No. Main Profile Parameters This information is printed on the specification label located on the right side of the inverter. "F" Group Parameters Default Setting User Func. Code Name —FE (Europe) —FU (USA) Setting F001 Output frequency setting 0.0 0.0 F002 Acceleration (1) time setting 10.0 10.0 F202 Acceleration (1) time setting, 2nd motor 10.0 10.0 F003 Deceleration (1) time setting 10.0 10.0 F203 Deceleration (1) time setting, 2nd motor 10.0 10.0 F004 Keypad Run key routing 00 00 SJ200 Inverter Standard Functions "A" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting A001 Frequency source setting 01 00 A002 Run command source setting 01 02 A003 Base frequency setting 50.0 60.0 A203 Base frequency setting, 2nd motor 50.0 60.0 A004 Maximum frequency setting 50.0 60.0 A204 Maximum frequency setting, 2nd motor 50.0 60.0 A005 [AT] selection 00 00 A011 Pot./O-L input active range start frequency 0.0 0.0 A012 Pot./O-L input active range end frequency 0.0 0.0 A013 Pot./O-L input active range start voltage 0.0 0.0 A014 Pot./O-L input active range end voltage 100. 100. A015 Pot./O-L input start frequency enable 01 01 A016 External frequency filter time constant 2. 8. A020 Multi -speed 0 setting 0.0 0.0 A220 Multi -speed 0 setting, 2nd motor 0.0 0.0 A021 Multi -speed 1 setting 0.0 0.0 A022 Multi -speed 2 setting 0.0 0.0 A023 Multi -speed 3 setting 0.0 0.0 A024 Multi -speed 4 setting 0.0 0.0 A025 Multi -speed 5 setting 0.0 0.0 A026 Multi -speed 6 setting 0.0 0.0 A027 Multi -speed 7 setting 0.0 0.0 A028 Multi -speed 8 setting 0.0 0.0 A029 Multi -speed 9 setting 0.0 0.0 A030 Multi -speed 10 setting 0.0 0.0 Parameter Settings for Keypad Entry "A" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting A031 Multi -speed 11 setting 0.0 0.0 A032 Multi -speed 12 setting 0.0 0.0 A033 Multi -speed 13 setting 0.0 0.0 A034 Multi -speed 14 setting 0.0 0.0 A035 Multi -speed 15 setting 0.0 0.0 A038 Jog frequency setting 1.00 1.00 A039 Jog stop mode 00 00 A042 Manual torque boost value 5.0 5.0 A242 Manual torque boost value, 2nd motor 0.0 0.0 A043 Manual torque boost frequency adjustment 3.0 3.0 A243 Manual torque boost frequency adjustment, 2nd motor 0.0 0.0 A044 V/f characteristic curve selection 02 02 A244 V/f characteristic curve selec- tion, 2nd motor 02 02 A045 V/f gain setting 100. 100. A046 Automatic torque boost voltage gain 100 100 A246 Automatic torque boost voltage gain, 2nd motor 100 100 A047 Automatic torque boost slip gain 100 100 A247 Automatic torque boost slip gain, 2nd motor 100 100 A051 DC braking enable 00 00 A052 DC braking frequency setting 0.5 0.5 A053 DC braking wait time 0.0 0.0 A054 DC braking force for deceleration 0 0 A055 DC braking time for deceleration 0.0 0.0 A056 DC braking / edge or level detec- tion for [DB] input 01 01 A061 Frequency upper limit setting 0.0 0.0 A261 Frequency upper limit setting, 2nd motor 0.0 0.0 SJ200 Inverter "A" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting A062 Frequency lower limit setting 0.0 0.0 A262 Frequency lower limit setting, 2nd motor 0.0 0.0 A063, A065, A067 Jump (center) frequency setting 0.0 0.0 A064, A066, A068 Jump (hysteresis) frequency width setting 0.5 0.5 A071 PID Enable 00 00 A072 PID proportional gain 1.0 1.0 A073 PID integral time constant 1.0 1.0 A074 PID derivative time constant 0.0 0.0 A075 PV scale conversion 1.00 1.00 A076 PV source setting 00 00 A077 Reverse PID action 00 00 A078 PID output limit 0.0 0.0 A081 AVR function select 00 00 A082 AVR voltage select 230/400 230/460 A092 Acceleration (2) time setting 15.00 15.00 A292 Acceleration (2) time setting, (2nd motor) 15.00 15.00 A093 Deceleration (2) time setting 15.00 15.00 A293 Deceleration (2) time setting, (2nd motor) 15.00 15.00 A094 Select method to switch to Acc2/ Dec2 profile 00 00 A294 Select method to switch to Acc2/ Dec2 profile, 2nd motor 00 00 A095 Acc 1 to Acc2 frequency transi- tion point 0.0 0.0 A295 Acc 1 to Acc2 frequency transi- tion point, 2nd motor 0.0 0.0 A096 Dec 1 to Dec2 frequency transi- tion point 0.0 0.0 Parameter Settings for Keypad Entry "A" Group Parameters Default Setting User Func. Name -FEF -FU Setting Code (EU) (USA) A296 Dec 1 to Dec2 frequency transi- 0.0 0.0 tion point, 2nd motor A097 Acceleration curve selection 00 00 A098 Deceleration curve selection 00 00 AIOI [OI]—[L] input active range start 0.0 0.0 frequency A102 [OI]—[L] input active range end 0.0 0.0 frequency A103 [OI]—[L] input active range start 0.0 0.0 current A104 [OI]—[L] input active range end 100. 100. current A105 [OI]—[L] input start frequency 01 01 enable A141 A input select for calculate 02 02 function A142 B input select for calculate 03 03 function A143 Calculation symbol 00 00 A145 ADD frequency 0.0 0.0 A146 ADD direction select 00 00 SJ200 Inverter Fine Tuning Functions "B" Group Parameters Default Setting User Func. Name -FEF -FU Setting Code (EU) (USA) 13001 Selection of automatic restart 00 00 mode B002 Allowable under -voltage power 1.0 1.0 failure time B003 Retry wait time before motor 1.0 1.0 restart B004 Instantaneous power failure / 00 00 under -voltage trip alarm enable B005 Number of restarts on power 00 00 failure / under -voltage trip events B012 Level of electronic thermal Rated Rated setting current for current for each each inverter inverter B212 Level of electronic thermal Rated Rated setting, 2nd motor current for current for each each inverter inverter B013 Electronic thermal characteristic 01 01 B213 Electronic thermal characteristic, 01 01 2nd motor B021 Overload restriction operation 01 01 mode B022 Overload restriction setting Rated Rated current x current x 1.5 1.5 B023 Deceleration rate at overload 1.0 30.0 restriction B031 Software lock mode selection 01 01 B080 [AM] analog signal gain 100. 100. B082 Start frequency adjustment 0.5 0.5 B083 Carrier frequency setting 5.0 5.0 B084 Initialization mode (parameters 00 00 or trip history) B085 Country code for initialization 01 02 B086 Frequency scaling conversion 1.0 1.0 factor Parameter Settings for Keypad Entry "B" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting B087 STOP key enable 00 00 B088 Restart mode after FRS 00 00 B090 Dynamic braking usage ratio 0.0 0.0 B091 Stop mode selection 00 00 B092 Cooling fan control 00 00 B095 Dynamic braking control 00 00 B096 Dynamic braking activation level 360/720 360/720 B130 Over -voltage LADSTOP enable 00 00 B 140 Over -current trip suppression 00 00 B150 Carrier mode 00 00 SJ200 Inverter Intelligent Terminal Functions "C" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting C001 Terminal [ 1 ] function 00 00 C002 Terminal [2] function 01 01 C003 Terminal [3] function 02 16 C004 Terminal [4] function 03 13 C005 Terminal [5] function 18 09 C006 Terminal [6] function 09 18 C011 Terminal [ 1 ] active state 00 00 C012 Terminal [2] active state 00 00 C013 Terminal [3] active state 00 00 C014 Terminal [4] active state 00 01 C015 Terminal [5] active state 00 00 C016 Terminal [6] active state 00 00 CO21 Terminal [I I ] function 01 01 CO22 Terminal [ 12] function 00 00 CO26 Alarm relay terminal function 05 05 CO28 [AM] signal selection 00 00 C031 Terminal [I I ] active state 00 00 C032 Terminal [12] active state 00 00 C036 Alarm relay active state 01 01 C041 Overload level setting Inverter rated current Inverter rated current C042 Frequency arrival setting for acceleration 0.0 0.0 C043 Arrival frequency setting for deceleration 0.0 0.0 C044 j PID deviation level setting 3.0 3.0 C052 PID FBV function high limit 100.0 100.0 C053 PID FBV function low limit 0.0 0.0 C071 Communication speed selection 06 04 C072 Node allocation 1. 1. C074 Communication parity selection 00 00 Parameter Settings for Keypad Entry "C" Group Parameters Default Setting User Func. Code Name -FEF (EU) -FU (USA) Setting C075 Communication stop bit selection 1 1 C076 Communication error select 02 02 C077 Communication erorr time-out 0.00 0.00 C078 Communication wait time 0. 0. C081 O input span calibration 100.0 100.0 C082 OI input span calibration 100.0 100.0 C085 Thermistor input tuning 100.0 100.0 C086 [AM] terminal offset tuning 0.0 0.0 C091 Debug mode enable 00 00 C101 Up/Down memory mode selection 00 00 C102 Reset selection 00 00 C 141 Input A select for logic output 00 00 C142 Input B select for logic output 01 01 C143 Logic function select 00 00 C144 Terminal [I I ] ON delay 0.0 0.0 C145 Terminal [ 11 ] OFF delay 0.0 0.0 C146 Terminal [ 12] ON delay 0.0 0.0 C147 Terminal [ 12] OFF delay 0.0 0.0 C148 Output relay ON delay 0.0 0.0 C149 Output relay OFF delay 0.0 0.0 SJ200 Inverter Motor Constants Functions "H" Group Parameters Default Setting User Func. Name -FEF -FU Setting Code (EU) (USA) H003 Motor capacity Specified Specified by the by the inverter inverter capacity capacity H2O3 Motor capacity, 2nd setting Specified Specified by the by the inverter inverter capacity capacity H004 Motor poles setting 4 4 H2O4 Motor poles setting, 2nd motor 4 4 H006 Motor stabilization constant 100 100 H2O6 Motor stabilization constant, 2nd 100 100 motor H007 Motor voltage select Specified Specified by the by the inverter inverter voltage voltage H2O7 Motor voltage select, 2nd motor Specified Specified by the by the inverter inverter voltage voltage CE—EMC Installation Guidelines In This Appendix.... — CE—EMC Installation Guidelines .................... 2 — Hitachi EMC Recommendations ..................... 6 CE—EMC Installation Guidelines CE -EMC Installation Guidelines You are required to satisfy the EMC directive (89/336/EEC) when using an SJ200 inverter in an EU country. To satisfy the EMC directive and to comply with standard, follow the guidelines in this section. 1. As user you must ensure that the HF (high frequency) impedance between adjustable frequency inverter, filter, and ground is as small as possible. • Ensure that the connections are metallic and have the largest possible contact areas (zinc -plated mounting plates). 2. Avoid conductor loops that act like antennas, especially loops that encompass large areas. • Avoid unnecessary conductor loops. • Avoid parallel arrangement of low-level signal wiring and power -carrying or noise -prone conductors. 3. Use shielded wiring for the motor cable and all analog and digital control lines. • Allow the effective shield area of these lines to remain as large as possible; i.e., do not strip away the shield (screen) further away from the cable end than absolutely necessary. • With integrated systems (for example, when the adjustable frequency inverter is communicating with some type of supervisory controller or host computer in the same control cabinet and they are connected at the same ground + PE -potential), connect the shields of the control lines to ground + PE (protective earth) at both ends. With distributed systems (for example the communicating supervisory controller or host computer is not in the same control cabinet and there is a distance between the systems), we recommend connecting the shield of the control lines only at the end connecting to the adjustable frequency inverter. If possible, route the other end of the control lines directly to the cable entry section of the supervisory controller or host computer. The shield conductor of the motor cables always must connected to ground + PE at both ends. • To achieve a large area contact between shield and ground + PE -potential, use a PG screw with a metallic shell, or use a metallic mounting clip. • Use only cable with braided, tinned copper mesh shield (type "CY") with 85% coverage. • The shielding continuity should not be broken at any point in the cable. If the use of reactors, contactors, terminals, or safety switches in the motor output is neces- sary, the unshielded section should be kept as short as possible. • Some motors have a rubber gasket between terminal box and motor housing. Very often, the terminal boxes, and particularly the threads for the metal PG screw connections, are painted. Make sure there is always a good metallic connection between the shielding of the motor cable, the metal PG screw connection, the terminal box, and the motor housing. If necessary, carefully remove paint between conducting surfaces. SJ200 Inverter 4. Take measures to minimize interference that is frequently coupled in through installa- tion cables. • Separate interfering cables with 0.25m minimum from cables susceptible to inter- ference. A particularly critical point is laying parallel cables over longer distances. If two cables intersect (one crosses over the other), the interference is smallest if they intersect at an angle of 90°. Cables susceptible to interference should there- fore only intersect motor cables, intermediate circuit cables, or the wiring of a rheostat at right angles and never be laid parallel to them over longer distances. 5. Minimize the distance between an interference source and an interference sink (inter- ference -threatened device), thereby decreasing the effect of the emitted interference on the interference sink. • You should use only interference -free devices and maintain a minimum distance of 0.25 in from the adjustable frequency inverter. 6. Follow safety measures in the filter installation. Ensure that the ground terminal (PE) of the filter is properly connected to the ground terminal of the adjustable frequency inverter. An HF ground connection via metal contact between the housings of the filter and the adjustable frequency inverter, or solely via cable shield, is not permitted as a protective conductor connection. The filter must be solidly and permanently connected with the ground potential so as to preclude the danger of electric shock upon touching the filter if a fault occurs. To achieve a protective ground connection for the filter: • Ground the filter with a conductor of at least 10 mm2 cross-sectional area. Connect a second grounding conductor, using a separate grounding terminal parallel to the protective conductor. (The cross section of each single protective conductor terminal must be sized for the required nominal load.) CE—EMC Installation Guidelines SJ200 inverter designed for use in Europe (—xxxLFEF/xxxHFEF models) have built-in line filters. In the event your application needs additional filtering, the following diagrams show control panel mounting and wiring examples for different filter types. SJ200 inverter with footprint -type filter L3 L1 L2 PE 23) SJ200 Inverter SJ200 inverter with book -type filter Hitachi EMC Recommendations Hitachi EMC Recommendations !WARNING: This equipment should be installed, adjusted, and serviced by qualified personal familiar with construction and operation of the equipment and the hazards involved. Failure to observe this precaution could result in bodily injury. Use the following checklist to ensure the inverter is within proper operating ranges and conditions. 1. The power supply to SJ200 inverters must meet these specifications: • Voltage fluctuation ±10% or less • Voltage imbalance f3% or less • Frequency variation f4% or less • Voltage distortion THD = 10% or less 2. Installation measure: • Use a filter designed for SJ200 inverter. 3. Wiring: • Shielded wire (screened cable) is required for motor wiring, and the length must be less than 50 meters. • The carrier frequency setting must be less than 5 kHz to satisfy EMC require- ments. • Separate the power input and motor wiring from the signal/process circuit wiring. 4. Environmental conditions—when using a filter, follow these guidelines: • Ambient temperature: –10 to 40 °C • Humidity: 20 to 90% RH (non -condensing) • Vibration: 5.9 m/sec2 (0.6 G) 10 – 55Hz • Location: 1000 meters or less altitude, indoors (no corrosive gas or dust) Index 0 A Group functions 339 AC reactors 5-3 Acceleration 1-16, 33=8 characteristic curves 3-26 second function 3-24 two-stage 4-18 Access levels 33=5, 3-34, 4-22 Accessories 5-2 ADD frequency 3-29 enable input 4-32 Alarm signal 4-35, 4-42 Algorithms, torque control 33=5, 3-55 Ambient temperature 2-11, A-2 Analog inputs calibration settings 3-51 current/voltage select 4-23 disconnect detect 4-44 operation 4-51 settings 3-13, 3-27 wiring examples 4-51 Analog outputs configuration 3-48 operation 4-53 Arrival frequency A-2 Automatic restart 3-30 Automatic voltage regulation 2-30, 3-23 Auto -tuning A-2 AVR 2-30, 3-23 Ifl B Group functions 3-30 Base frequency 2-30, A-2 setting 3-12 Bibliography A-8 Braking 1-15 dynamic 55=5 resistive 1-18 settings 3-19 Braking resistor 22=8, A-2 Braking unit 22=8 Break -away torque A-2 C Group functions 3-41 Calculate function 3-28 Capacitor life curve 6-11 Carrier frequency 3-36, A-2 Catching a spinning motor 3-38 Cautions general ix index to... iv inverter mounting 2-10 operating procedures 442 CE approval A-2 CE -EMC guidelines D-2 Chassis ground connection 1-18,2-22 error code 6-6 Choke 228, 5=4, A-2 Chopper frequency 3-36 Circuit breaker sizes xiv Clearance for ventilation 2-11 Coasting 3-38 Connectors logic terminals 22=5 removal 2-5 serial port 223, BB3 Constant torque 3-16 Constant volts/hertz operation 1-13 Contact information xviii Control algorithms 3-16 Copy unit 11=3, 33=2 Cover removal 2-4 Current input 3-13 Current overload 2-31, 3-33 Current/voltage analog input select 4-23 131 D Group parameters 33=6 DC braking 3-19, 4-15, 4-16, A-3 Deadband A-3 Deceleration 1-16, 33=8, 4-15 characteristic curves 3-26 second function 3-24 two-stage 4-18 Default settings listing CC2 restoring 66=8 Delay function, output circuits 3-54, 4-36 Derivative gain 3-22 Digital operator 113, 2-25, 33=3, A-3 Dimensions inverter 2-12 terminals 2-19 Diode A-3 DIP switch configuration 2-6, 2-28, 3-10, 4- 9, B4 Disconnect detect, analog input 4-44 Duty cycle A-3 Dynamic braking 1-15,5-5,A-3 error code, usage exceeded 66=5 usage ratio 3-38, 55=6 E Editing parameters 2-25, 2-28 in Run Mode 33=5, 3-34, 4-22 Electromagnetic compatibility D-2 Electronic thermal overload xiv configuration 3-31 error code 6-5 EMC installation guidelines D-2 recommendations D-6 EMI A-3 EMI filter xi, 5-4 Environmental specs 1-10 Error codes, trip events 66=5 Error, PID loop 4-41, A-3 Event clearing 4-24 External trip 4-20 error code 6-6 F F Group functions 33=8 Factory default settings 3-36 restoring 66=8 Fan control 3-39 Fan outlet 2-11, 2-23 FAQ 1-17 Features 11=2, 22=2 Filters, noise suppression 552 Fine-tuning functions 3-30 Force operation from digital operator 4-31 Force terminal mode 4-33 Forward run command 4-12 Four -quadrant operation A-3 Free -run stop 3-38, 4-15, 4-19, A-3 Frequency arrival signals 4-38 Frequency display scaling 3-36 Frequency limits 3-20 Frequency matching 3-38 Frequency setting A-4 Frequency source setting L-99, 4-31, 433 Frequency -related functions 3-20 Frequently asked questions 1-17 Functions 1-15, 2-26 Fuse sizes xiv, 2-18 Glossary of terms A-2 H H Group parameters 3-55 Harmonics A-4 History of trip events 33=7 Horsepower A-4 IGBT 1-12, A-4 test method 6-15 Index of terminal functions 4-7 Inertia A-4 Initialization 6-8 codes 3-36 Input circuits 4-4, 4-9 Inspection electrical measurements 6-12 IGBT test method 6-15 measurement techniques 6-14 procedures 66=9 unpacking 222 Installation instructions 2-9 Insulation test 6-10 Integral gain 3-22 Intelligent input terminals 3-41, 4-9 Intelligent output terminals 3-46, 4-34 Intelligent sensorless vector control 1-17, 33— 17, A-4 Intelligent terminals definition A-4 functions 3-41 index 4-7 Inverter 1-17, A-4 dimensions 2-12 specifications 11=5 iSLV 1-17, 3-16,3-17,A-4 Isolation transformer A-5 J Jog command 4-15 Jog frequency settings 3-14 Jogging operation A-5 Jump frequencies 3-21, A-5 SJ200 Inverter IZI Keypad 1-3,2-2,3-2 features 2-25, 33=3 navigation 2-27, 3-4 navigation, trip events 66=7 removal and installation 22=3 L LEDs 22=3, 2-24, 2-25, 2-33, 333 Line reactor A-5 Linear accel/decel 3-26 Logic output function 3-53, 4-49 Logic terminals 22=5, 3-41, 3-46, 44=6 M Main profile parameters 33=8 Maintenance procedures 66=9 Manual torque boost 3-16 Maximum frequency setting 3-12 Megger test 6-10 ModBus data listing B-19 introduction to network BB2 Model number convention 1-4 on nameplate 1-4 Momentum A-5 Monitor mode 2-27,2-33,2-34,3-4,3-5,6- 5 -27,2-33,2-34,3-4,33=5,6- 5 Monitoring functions 33=6 Motor constants 3-55 load A-5 poles 1-18, 2-32, 3-55 speed 2-34 voltage selection 3-55 wiring 2-22 Mounting clearance for ventilation 2-11 dimensions 2-12 location 2-10 Multiple motors, configuration 4-56 Multi -speed operation 4-13, A-5 profiles 1-16 settings 3-14 Nameplate 1=4 Navigational map 2-27, 3-4 trip events 66=7 NEC A-5 NEMA definition A-5 rated installation 1-3 Network communications 1-17,2-3,B-2 detection signal 4-48 error code 6-6 ModBus data listing B-19 parameter settings BBS protocol reference B-6 termination resistor B-4 Noise filters 5-2 AC reactor 2-8 OPE/485 serial port configuration 22=6, B4 Open -collector outputs 4-34, A-5 Operational modes 33=5 Operator interfaces 11=3 Optional components 11=2, 22=8 Orientation 2-2 Output circuits 4=4, 4-34 delay function 3-54, 4-36 Output deviation for PID control 4-41 Output frequency 2-33 setting 338 Output function adjustment parameters 3-48 Output overload 3-33 Output terminals 2-22 Over -current trip 3-30 Overload advance notice signal 4-40 Overload protection xiv configuration 3-31 error code 6-5 Overload restriction 3-33 Override, source settings 3-11 Over -voltage trip 3-30 error code 66=5, 66=6 Parameter editing 2-25, 2-28 Parameter settings 1-15,2-26 listings CC2 PID loop 1-19 clear input 4-28 configuration 4-55 definition A-6 error 4-41, A-3 error inversion 4-55 ON/OFF input 4-28 operation 4-54 output limit 4-55 process variable, definition A-6 second stage output 4-45 settings 3-22 PLC, connecting to 4=4 Poles of motor 1-18, 2-32, 3-55 Potentiometer 2-28, 33=9, 4-51 Power factor A-5 Power fail 3-30 Powerup Test 2-23 observations 2-34 Powerup, unattended start 4-21 error code 666 Preventative maintenance 6-9 Process variable A-6 Program mode 2-27, 2-34, 3-4, 33=5 Programming device 33=2 Proportional gain 3-22 PV source setting 3-22 PWM A-6 SJ200 Inverter R S Ratings label 1=4 Safety messages i Reactance A-6 Saturation voltage A-6 Read/write copy unit 11=3 Scaling 3-36 Rectifier A-6 S-curve accel/decel 3-26 Reduced torque 3-16 Second accel and decel 3-24 Regenerative braking A-6 Second motor 4-17 Regulation A-6 Second stage output 4-45 Regulatory agency approvals 1-4 Sensorless vector control A-7 Relay Serial port BB3 alarm signal contacts 4-42 Service, warranty 6-16 as intelligent output 4-35 Set 2nd motor 4-17, 4-56 Remote control 4-29 Setpoint A-7 Reset function 3-52, 4-24 Single-phase power A-7 Restart Mode configuration 3-38 Sink/source input configuration 4-9 Reverse run command 4-12 Slip Reverse torque A-6 compensation, iSLV 3-17 Revision history xvii definition A-7 RF noise filter 5=4 Software lock 33=5, 3-34, 4-22 RJ -45 modular connector 2-3, B-3 Source/sink input configuration 2-6 Rotor A-6 Spare parts 6-11 RPM 2-34 Specifications Run command 4-12 control logic signals 1-11, 44=6 Run command source setting 2-29, 33=9, 44— general 1-10 31,4-33 inverter 11=5 Run mode 2-34, 33=5 inverter label 1=4 Run signal 4-37 Speed control 1-12, 1-16, 4-13 Running the motor 2-33 Speed pot 2-28 Run-time edits 33=5, 3-34, 4-22 Squirrel cage A-7 Standard functions 3-9 Start frequency 3-36 Stator A-7 Stop command 4-12 Stop Mode configuration 3-38 Supply wiring 2-19 Switches, configuration 22=6 Switching frequency 3-36 Symbol definitions i System description 228 T Tachometer A-7 Technical support xviii Term definitions A-2 Terminal/program source configuration 226, 2-28,3-10 Terminals arrangement 2-20 listing 44=7 torque specs xiii, 2-19 Termination resistor, network B-4 Thermal protection inverter, error code 666 motor 4-25 Thermal switch A-7 Thermistor definition A-7 error code 66=6 input terminal 4-25 input tuning 3-51 Three-phase power definition A-8 motor phase connections 1-13 wiring precautions 2-20 Three -wire interface operation 4-26 Torque 1-13, A-8 Torque boost 3-16 Torque control algorithms 33=5, 3-16, 3-55 Torque specs, terminals xiii, 2-19 Transistor A-8 Trip events 337, 4-24 clearing 665 definition A-8 error codes 6-5 external input 4-20 history of 66=7 monitoring 66=5 Troubleshooting tips 66=3 Two-stage accel/decel 4-18 A UL instructions xii Unattended start protection 4-21 error code 6-6 Under -voltage trip 3-30 error code 66=5, 66=6 Unpacking 22=2 Up/Down functions 4-29 u V/f control 3-16 Variable torque 3-16 Variable -frequency drives introduction 1-12 Velocity profile 1-16 Ventilation 2-11, 2-23 Voltage gain 3-17 Voltage input 3-13 W Warnings general ix index to... iv operating procedures 44=3 troubleshooting 66=2 Warranty 6-16 Watt loss A-8 Wiring access 2-7 analog inputs 4-51 gauge xiii, 2-18 inverter output 2-22 logic connectors 2-22A-6 power input 2-19 preparation 2-17 relay contacts 4-6 system diagram 4-5 N Zero -phase reactor 5=4 CARBON VESSEL .,1 2 BAKERC� Technical Information !Manual - __ Max. Temp � 150 F _), Types: r» Height: _ IOOOS: 66 -Specialty Media 200052.2j_ Volume"10005: » Diameter •••• 46 2000S: 67 cu. ft. »' Shipping Wt*: .10005: 1800 lbs. - 2800 lbs ( Media dependent) 20005 2000 lbs 4000 lbs _e. (drum + media) 120005: 3050 lbs. - 5050 lbs. �» (* Media dependent) ;» Outler S 4" FNPT FILTER MEDIA _), Types: •••-• Activated Carbon _ -Specialty Media Volume"10005: 34 cu. ft 2000S: 67 cu. ft. » Wei ht*: g i IOOOS: 1000 lbs 2000 lbs ( Media dependent) 20005 2000 lbs 4000 lbs _e. MISCELLAIVEOUSDATA Inlet: . 4 FNPT �» � a , ;» Outler S 4" FNPT � . LL �» 'InteriorN ------- ••• Double -layered epoxy coating Coating: Internals •--•t PVC inlet diffuser » Media Top manway )neoprene gasket) Access. PRESSUREDROPDATA a- 25 O IY p ^ 20 W 15 U7 10 U) W 5 ry 0- EEMAIRA 100 200 300 400 500 600 FLOW (CFM) &NOTES: 1. In the presence of activated carbon, some contaminants may oxidize, polymerize or otherwise react resulting in the release of heat and become a potential fire hazard. Extreme care should be taken in the design and operation of such applications. 2. Wet activated carbon preferentially removes oxygen from air. In closed or partially closed containers and vessels, oxygen depletion may reach hazardous levels. If workers are to enter a vessel containing carbon, appropriate procedures for potentially low oxygen spaces must be followed, including all federal and state requirements. 3020 Old Ranch Parkway 9 Suite 220 • Seal Beach, CA • 562-430-6262 FLAME ARRESTER CERTIFIED TEST REPORT Flame Check, Detonation Arrester, Flame Arrester, Flame Trap Designed and Manufactured under an ISO 9001:2000 Certified Quality System. TUV America Inc. Certificate Registration No: 951 06 3823 ANAB Accredited Dlw Company Model: 7628-04-11-F00 Groth Horizontal Flame Arrester Size: 4" FF Flange Drilling: 150# ANSI Body: Aluminum Element: Aluminum Equipment MAWP: 140 psig Shell Test Pressure: 15 psig Quality Assurance 13650 N. Promenade Blvd. Customer: INNOVATIVE CONTRUCTION SOLUTIO Serial No.: 0710243-01-1 Tag No.: Part Type Body Inlet Base Element Housing Outlet Base Heat Number 092607 091707 Steam Jacket Test Pressure: N/A Stafford, TX 77477 October 23, 2007 Date Tested Office: (281) 295-6800 (800) 354-7684 Fax: (281) 295-6999 www.grothcorp.com T, Installation, Operation and Maintenance Models 7618 / 7628 / 7648 IOM 7618.1 January, 1999 CORPORATION TABLE OF CONTENTS: Description Page Introduction 1 Inspection & Installation 1 Maintenance 3 Replacement Parts 5 Bills of Material & Drawings Model 7618 6 Model 7628 7 Model 7648 8 Model 7618 with Steam Jacket 9 Table 2 - Flange Bolt Torque 2 Table 3 - Housing Bolt Torque 5 Table 4 - Element Housing Weight 5 Table 5 - Flame Arrester Weight 5 Table 6 - Replacement Gaskets 5 INTRODUCTION Groth's flame arresters are designed to inhibit flame propagation in gas piping systems and to protect low pressure tanks containing flammable liquids. They protect low flash point liquids from externally caused sources of heat and ignition, providing increased fire protection and safety. The flame arresters consist of two main components, the arrester bases and the flame element housing. The bases serve as the connecting interface to the piping system. The housing accommodates the flame element and is instrumental in stopping the flame passage. The flame element is comprised of small parallel triangular passageways aligned so that an approaching flame front is slowed down and then quenched before it can propagate to the protected side of the device. All Groth flame elements utilize spiral wound, crimped ribbon constructed of corrosion resistant 1 materials, to insure the best flame quenching performance with minimum pressure drop. Depending on the design of the system in which it is used, the arrester bases can include optional ports for temperature or pressure monitoring devices. These devices can activate warning or shutdown systems if abnormal conditions are detected. A flame arrester should be treated as a safety device and maintained by a knowledgeable repair technician. Carefully read and understand this Manual before installing or servicing this product. Groth Corporation offers repair services for all products manufactured by the Tank Protection Division. For information not contained in this manual, please contact: Groth Corporation Groth Products Group P.O. Box 15293 Houston, Texas, 77220 713-675-6151 713-675-6739(Fax) INSPECTION & INSTALLATION All Groth's flame arresters are bi-directional and the installation on a tank or piping system depends to a great extent on the design of the system. The Model 7618 is recommended for vertical installation in closed piping systems or venting to atmosphere. If a Model 7618 is installed in a horizontal line, it should be equipped with drain ports for removal of condensation from the housing. The Models 7628/7648 are designed for either vertical or horizontal installation. These series of flame arresters have 150# ANSI flange drilling compatibility, [30" & 36" model 7618 & 7628 have API 650 drilling], and are pneumatically tested to 15 PSIG at the factory. Please follow the guidelines listed in Table 2 for flange make-up torque. The arresters are NOT rated for full flange pressure and do not require high bolting torque. Recommended torque values are based on pressures [MAWP] in Table 1. Consult factory for higher pressure applications. -- The following guidelines should be observed at installation: 1. Remove any flange protectors and discard all packing material. Inspect flange faces and flame element for damage or contamination. 2. Inspect the gasket seating surface of the tank nozzle or piping. It must be clean, flat, free of scratches, corrosion and tool marks. 3. Aluminum flame arresters are furnished with flat face flanges; they should only be installed on a mating flat face flange with a full face gasket. WARNING Installation of an aluminum arrester in piping with raised face flanges can cause permanent distortion of the base flanges. This may result in vapor leakage .at the flange connection. Adjacent, piping must have appropriate structural :support to prevent excessive loads on the flame.arrester flanges. 4. Lubricate all studs and nuts with an appropriate thread lubricant. If the arrester will see high temperature service or if stainless steel fasteners are used, select an anti -seize compound such as moly-disulfide. 5. Inspect the gasket; make sure that the material is suitable for the application. Center the gasket within the bolt circle. 6. Set the arrester between its mating flanges or on the nozzle. Position the lifting handles and jacking nuts to facilitate future removal of the flame arrester housing (See Maintenance Instructions). Install the studs and tighten nuts hand tight. 2 Table 1: Flame Arrester MAWP PSIG (kPa) Size Model 7618 Alum Model 7618 CS/SS Model 7628 Alum Model 7628 CS/SS 2 50 100 150 285 3 50 100 140 285 4 50 100 140 285 6 50 100 140 285 8 50 100 90 200 10 50 100 75 150 12 50 100 75 150 All Model 7618A & 7628A: MAWP = 15 PSIG All Model 7648: MAWP = 285 PSIG Table 2: Flange Bolt Torque (*) Lb. Ft. (Nm) Size Raised Face Flat Face Size Raised Face 2 60 (82) 60 (82) 14 240 (326) 3 60 (82) 60 (82) 16 240 (326) 4 60 (82) 60 (82) 18 340 (462) 6 105 (143) 105 (143) 20 340(462) 8 105 (143) 105 (143) 24 460 (626) 10 140 (190) 170 (231) 30 105 (143) 12 140 (190) —170(231) 1 36 1 105 (143) * Torque values are for reference only and based on a nitrile binder synthetic gasket, 1/16" thick and unlubricated threads Notes: • When installing Model 7628 in the horizontal position, the eccentric portion of the housing must be positioned upward (See Page 8). In this position condensation will tend to move in the direction of flow and not collect in the element. • Leave space behind mating pipe flange for insertion of studs, as there may not be sufficient space to insert studs from the flame arrester side. (Models 7618 & 7628). 8. Torque all fasteners to half the value listed in Table 1 in a staggered, alternating pattern to provide an evenly compressed gasket joint. FLAME STUDS WITHOUT SPREADER NUTS E 9. Make up the final torque and check that no further nut rotation occurs at the specified torque value. L LL�'ILIV I 1 IU V.�IIVU LIFTING HANDLE(S) MAINTENANCE BA Fig. 1- Typical Model 7618 Flame Arrester For maximum operating efficiency the element of a flame arrester must be inspected for clogging at regular intervals. Frequency of inspection and maintenance should be based on the experience gained in each application. For ease of service, the flame element housing can be easily removed for inspection and maintenance without removing the arrester from the line. It is recommended that the arrester be removed for inspection of the element at least once per year or any time that one of the following conditions occurs: 3 HOUSING NUTS SPREADER NUTS RAIN OR STRUMENT JNECTIONS 1 4 supporting grids for damage or corrosion build- up from both sides. If the flame element appears to be damaged, it should be replaced immediately. 11. Make up the final torque and check that no further nut rotation occurs at the specified torque value. The torque values are based on original gaskets supplied by Groth Corporation and unlubricated studs. Table 3: Housing Bolt Torque Chart (*) Ft. Lb. (Nm) Size Model 7618 Model 7628 2 60 (82) 40 (54) 3 1 60 (82) 40 (54) 4 60 (82) 40 (54) 6 105 (143) 105 (143) 8 105(143) 105(143) 10 170 (231) 220 (300) 12 170 (231) 220 (300) 14 40 (54) 40 (54) 16 40 (54) 40 (54) 18 40 (54) 40 (54) 20 40 (54) 40 (54) 24 40 (54) 40 (54) 30 40 (54) 40 (54) 36 60 (82) 60 (82) * Torque values are for reference only and based on a nitrile binder synthetic gasket, 1/16" thick and unlubricated threads Table 4: Element Housing Weight - [Lb. (kg)] Models 7618 / 7628 Size Aluminum Alum/SS (+) Steel 2" 5. (2) 10 (5) 15 (7) 3" 10 (5) 10 (5) 20 (9) 4" 15 (7) 20 (9) 35 (16) 6" 30 (14) 45 (20) 75 (34) 8" 45 (20) 70 (32) 115 (52). 10" 70 (32) 110 (50) 175 (80) 12" 95 (43) 160 (73) 250 (114) 14 Consult Factory 575 (261) 16 745 (339) 18 890 (405) 20 1135 (516) 24 1805 (820) 30 3095(1407) 36 4315(1961) (+) = Aluminum construction with SS flame element. 5 Table 5: Flame Arrester Assembly Weight - [Lb. (kg)] Models 7618 Size Aluminum Alum/SS (+) Steel 2" 15 (7) 20 (9) 45. (70) 3" 25 (11) 30 (14) 75 (34) 4" 40 (18) 45 (20) 105(48) 6" 80 (36) 100 (45) 225 (102) 8" 130 (59) 155 (70) 360 (164) 10" 200 (91) 245 (111) 555 (252) 12" 285 (130) 345 (157) 795 (361) 14 Consult Factory 1110 (505) 16 1535 (698) 18 1765(802)_ 20 2240(1018) 24 3360(1527) 30 5730(2605) 36 9240(4200) Models 7628 Size Aluminum Alum/SS (+) Steel 2" 25 (11) 30 (14) 70(32) 3" 35 (16) 40 (18) 95 (43) 4" 50 (23) 60 (27) 105(48)_ 6" 85 (39) 100 (45) 225.(102) 8" 150 (68) 175 (80) 360 (164) 10" 235 (107) 280 (127) 555 (252) 12" 320 (125) 385 (175) 795 (361) 14 Consult Factory 1110(505)_ 16 1535 (698) 18 1765 (802) 20 2240(1018) 24 3360(1527) 30 5730(2605) 36 9240(4200) To order original Groth general purpose replacement gaskets (#), select the corresponding Part Number for the arrester size from the table below: Table 6: Gasket Part Number Size Part No. 2 80018020 3 80018030 4 80018040 6 80018060 8 80018080 10 80018100 12 80018120 Size Part No. 14 80018123 16 80018126 18 80018127 20 80018135 24 80018136 30 Teadit 24B 36 Teadit 24B (#) = Synthetic Non -Asbestos Fiber sheet material with a nitrile binder. For special applications or chemical compatibility please contact factory. NU ON (UP I1UNAL) Groth Model 7618 Flame Arrester with Steam Jacket Groth Model 7618 Flame Arrester 6 LE USED 2' UNITS TYPICAL :AL :OND HANDLE USED 6' THRU 12' UNITS. 1/2" NPT TYPICAL (OPTIONAL) Groth Model 7628 Flame Arrester ITEM DESCRIPTION CARBON ALUMINUM STAINLESS 1 Base CS Aluminum 316 SS 2 Handle CS Aluminum 316 SS 3 Hex Nut 304 SS 304 SS 304 SS 4 Stud 304 SS 304 SS 304 SS 5 Plug SS SS 316 SS 6 Rod SS SS 316 SS 7 Grid SS Aluminum 316 SS 8 Housing CS Aluminum 316 SS 9 Coupling (optional) CS Aluminum 316 SS 10 Plug (optional) CS Aluminum 316SS 11 Gasket (*) Non -Asbestos Compressed Fiber 12 Flame Element SS Aluminum 1 316 SS (*)= Spare parts (See Table 6). Groth Model 7618A Flame Arrester Groth Model 7628A Flame Arrester l 8 Groth Model 7648 Flame Arrester ITEM DESCRIPTION CARBON ALUMINUM STAINLESS 1 Base CS Aluminum 316 SS 2 Grid SS Aluminum 316 SS 3 Flame Element SS Aluminum 316SS 4 Plug SS SS 316 SS 5 Rod SS SS 316 SS Groth Model 7618 Flame Arrester w/ Weatherhood HANDLE USED HRU 12' UNITS. " NPT TYPICAL 'TIONAL) ITEM DESCRIPTION CARBON ALUMINUM STAINLESS 1 Base CS Aluminum 316 SS 2 Handle CS Aluminum 316 SS 3 Hex Nut 304SS 304 SS 316 SS 4 Stud 304 SS 304 SS 316 SS 5 Plug SS SS 316 SS 6 Rod SS SS 316 SS 7 Grid SS Aluminum 316 SS 8 Housing CS Aluminum 316 SS 9 Coupling (optional) CS Aluminum 316 SS 10 Plug (optional) CS Aluminum 316SS 11 Gasket (*) Non -Asbestos Compressed Fiber 12 Flame Element SS Aluminum 316 SS 13 Weatherhood Post 304 SS 304 SS 316 SS 14 Eye Nut CS CS SS 15 Hex Nut 304 SS 304 SS 316 SS 16 Weatherhood CS Aluminum 316 SS 17 Screen SS PVC SS 18 Adapter Plate Aluminum CS SS (*)= Spare parts (See 'fable 6). 10 The nameplate on the flame arrester contains the Model Number, Serial Number and additional information about materials of construction and options. The following chart will assist in relating the Model Number to the characteristics of your equipment: •t M --M 1 7618 7628 7648 SIZE MATERIAL OPTIONS ------ Co ------------- 02 03 04 06 08 10 12 14 16 18 20 24 30 36 1=A 1=Aluminum Element 5=316 SS Element Z=Special Element , 3=Carbon Steel Body 5=316 SS Body Z=Special Body O = No Specials Z = Special Options O = No Jacket J = Steam Jacket I F = Flanged Outlet I W = Weatherhood EXAMPLE: 7,618 -02 -35 -FOO indicates a 2" Model 7618 with Carbon Steel body, 316SS flame element winding and no special options. PRODUCT LIMITED WARRANTY A. Seller warrants that products which are marketability, merchantability, for a particular manufactured by Seller, are manufactured in purpose or ust;, or against infringement of any accordance with published specifications and free patent of products. In no event shall Seller be from defects in materials and/or workmanship for liable for any direct, incidental or consequential a period of (12) twelve months. Seller, at its damages of any nature, or losses or expenses option, will repair or replace any products resulting from any defective new product or the returned intact to the factory, transportation use of any such product, including any damages charges prepaid, which Seller, upon inspection, for loss of time, inconvenience, or loss of use of shall determine to be defective in material and/or any such product. workmanship. The foregoing shall constitute the sole remedy for any breach of Seller's warranty. C. The original Manufacturer shall be solely responsible for the design, development, supply, B. THERE ARE NO UNDERSTANDINGS, production, and performance of its products AGREEMENTS, REPRESENTATIONS, OR hereunder, and the protection of its trade name or WARRANTIES, EXPRESS OR IMPLIED, names, if any. It assumes no responsibility, for (INCLUDING MERCHANTABILITY OR products modified or changed in any way by its FITNESS FOR A PARTICULAR PURPOSE agent or customer. Any such modifications or REGARDING PRODUCTS) UNLESS changes to products sold by Seller hereunder shall SPECIFIED IN THE SALES CONTRACT. THIS make the product limited warranty null and void. CONTRACT STATES THE ENTIRE OBLIGATION OF SELLER. D. The Manufacturer shall be under no obligation to Seller makes no warranties, either express or manufacture, sell, or supply, or to continue to implied, except as provided herein, including manufacture, sell or supply any of the Products. without limitation thereof, warranties as to 11 INLINE FLOW METER Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com t Monterey, CA 93940 Quick Start Guide Models 155, 452, 454FT, 502, 504FT, and 534FT. October 2003 155 Line and Flow Elements MFT Line 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com Monterey, CA 93940 The following information is an abbreviated list of what you need to do for your flow meter to achieve maximum possible repeatability and accuracy. Most of the steps will be required for all products. Please read this before you start. You will ultimately need to refer to the product manual, which is found on the attached CD. Given the Model number of your product, you can find the manual you require. + Kurz Model # _ Unpacking/Expected Content Your flow meter has been shipped to you with the following items. Please make sure you have them and contact us if this is incomplete. 1. Flow element or Flowmeter, compare the packing list against your order. 2. Calibration certificate of the above 3. Flow Computer Input Configuration Sheet 4. Manual on CD Mounting of the equipment (see guidelines sheet) You will need to remove the protective shipping covers from the sensor or flowbody before installing the unit. A thermal meter must have direct contact with the process fluid to work. The meter will need to be mounted in accordance to safe design practice accounting for the process pressures, corrosion, temperature and any potentially hazardous area requirements. The electronics head needs to be in an accessible area so you can do wiring to it or perhaps use the local keypad LCD. Some models have remote electronics heads, which must be mounted/wired too. Most units can be programmed with a Laptop portable computer or even a PDA using the RS -232 port. For best results, please carefully look over the installation guidelines sheet for more on the sensor placement criteria. Insertion Meters must be mounted with a compression fitting to the duct/pipe or flange mounted then checked for leaks. Make sure the insertion depth is adequate to get into the center 1/3 of the diameter where the flow profiles are the most stable. The distance from profile disruptions needs to be adhered to for the best repeatability/accuracy.(see the guideline sheet) In -Line Meters have similar requirements for undisrupted straight runs except for the 534FT line. 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U te+ cnEn N O �S" �3 cC3 O. sU O4. _� O _ N IR H w M V"1 w d - O H w N O N O kn H w kn d - N tI) cl' kn O 9 i O �I � a� O a o� w I I � U U i v] � o Q M � h N N � O N � � o � r fu U -o w O to N O n O �I d - OC> 0 a, c W Cd on cl Q O � a� O a o� w I I d F� U � � o Q M � h N � O N � � o � r fu U -o w O to O n w � N rf • • • � t b d' U � N d � O N C> N p o U b � u N O M wAll u tk t M 4 er w d - OC> 0 a, c W Cd on cl Q O � a� O a o� w I I d � � U � ME > n u w � � U � � o Q > � M � h N � � N � � o � r fu w -o O O n rf • • • � t b d' C> p o U 0 N O M e N 00 � O U _ U � � U 00 O 'N d O O O (� O 0 P� o � o 00 O a3 U O r3 O O O (� O 0 P� U U�4W Q O � O a o� w I I U O a d d �y O N cF 00 O-� U O N p O i%] U U�4W I 00 Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com Monterey, CA 93940 Wiring, Sensor, Power and Signals The thermal flow meter uses several watts of power to measure flow, so requires more than a simple 4-20 mA loop powered connection for operation. In general our products are know as a "4 -wire" device, power (2) and signal (2). The exact wiring diagram for your meter can be looked up on the provided CD manual using the model number of the meter. Potentially Hazardous Area Use and EMI Compliance Please consult the full manual on the provided CD for safety and EMI related issues. Sensor For "Remote Electronics" you need to run five wire cable for each sensor between the sensor J -box and Flow Computer. The wire gage/length and conduit/shielding requirements are found in the manual and on the field wiring diagrams. The transmitter attached versions have no sensor wiring requirements. 15 5J I/O board photo (155A/B,155C-2/E-2 are not shown). 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 831-646-5911 www.kurz-instruments.com 454FT/504FT/534FT: I/O board major connections. Power Most units are available with either 115/230 VAC or 24 VDC depending on which version you purchased. Both types require a ground wire for product safety compliance. Switching between 115 and 230 VAC requires a solder jumper setting change. Analog Output This is an optional feature which can be wired two ways but you still need the 24 VDC power (or AC power option) to operate the unit as a "4 -wire" connection: 1. The 4-20 mA interface can be optically isolated (also known as loop powered). In this case your 4-20 mA input circuit is providing the excitation voltage. 2. You can self power the 4-20 mA circuit from the flow meter where Kurz provides the 24 VDC excitation voltage. The output is not isolated in this case. Here your 4-20 mA input will need a differential current receiver or other method to accept the current signal which is ground referenced at the flow transmitter. Digital Communications Some of the flow meters support RS -232 point-to-point connections and/or RS -485 multipoint connections. The RS -485 can be full or half duplex (4 wire or 2 wire plus ground). See the Modbus section for multi -point configurations. The 155 flow computers have a fixed 9600 baud rate connection via a straight though DB -9 connector to a PC. The 454FT, 504FT & 534FT have a default 9600 baud but are programmable from 1.2 k baud to 38.4 k baud. They too use a straight though RS -232 connection to the PC on a DB -9 cable. Alarms fl 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 10 Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 831-646-5911 www.kurz-instruments.com Discrete contacts for closure or open on event are optionally available. These are isolated relays or SSRs. The maximum current, voltage and isolation specs are on the brochure/ product manual. Display Orientation The keyboard/display on the 454FT/504FT/534FT may be mounted in any 90 ° orientation for optimum viewing and keyboard access when mounted in the process. Disconnect the power first then open the explosion proof lid. You simply unscrew the cross point screws (2 or 4), move spacers as required then tighten back down (see photo below). The ribbon cable for the display is long enough if not twisted up too much to rotate into any of the four positions. Navigating Menus All flow meters and their optional flow computers (Models 155) use a similar menu system for their operation. The picture below is for the 454FT/504FT/534FT and shows a 2x16 character display and 20 key data entry pad. D = Display Mode P = Program Mode L= Forced Log on the serial port. E = Entry C = Clear H = Hold, HH = help ^ = increment, yes etc. v = decrement, no etc. User access code 123456 in Program Mode When in a menu area, you can advance with D or P and sometimes you need to use E to select the area your want to enter. If typing data on the keypad, you can use D to backup one character or C to clear the whole entry. You can select items in a choice menu with the ^ v keys. You can exit menus or Program Mode by pressing C several times progressively leaving the menu tree you are in. If you are using a laptop with HyperTerminal or PDA (Palm, etc.) with a terminal emulator program you can also enter letters by just typing them (helpful for doing meter tags using the meter ID parameter). Remote Keyboard commands are lower case, d, p, 1, enter(for E), c and h with v and ^ being down and up. When entering meter IDs or tags, use the shift lock so only upper case characters are used (otherwise they are interpreted as commands). 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 11 Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com Monterey, CA 93940 Insertion Meter Programming The insertion meters, 410, 452, 454FT all have a low up -front cost but require more work on the part of the user to achieve an accurate measurement whereas the 502, 504FT and 534FT are already calibrated for flow and need a minimum of field adjustments to read accurately. The in-line meters only need the output range to be specified (see following sections) For all insertion meters do the following: Area. The duct inside flow area must be entered in the meter section of the flow computer. Depending on your units (English or International) this must be entered as ft2 or m2 respectively. D <7_�) Area = D2Tc/4 -------- ---------------------------; W H Area = HW You press the P key to enter Program Mode, then the 123456 access code and E. Now press P to advance to the "Set Meter Data" menu then press E and select which meter (^v on the 155) then using P advance to the screen "Set Meter Area" where you just type the value followed by E. It will say new value accepted if you make a change. Last press the C key a few times to exit Program Mode. More extensive programming instructions and the Menu state diagram are found in the manual. Sensor or Probe Blockage. The duct/pipe area blocked off by the insertion of the sensor/probe, accelerates the flow reading. This can be adjusted using the Sensor Blockage Correction Factor (SBCF) on the 454FT but is not critical as this effect is measured during the field calibration. Other insertion devices (410, 452, 452FT) can skip this step and will make this adjustment during the field calibration. SBCF = (A 1-A2)/A 1 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 12 Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com Monterey, CA 93940 SBCF is performed by simply entering the following data: 1. Insertion depth (L) in ft or meters from the end of the probe window to the duct inside wall. 2. Probe diameter (d) in inches. The 454FT comes in %2, 3/4 and 1 inch versions and the 454PFT or purge version is a 1 inch unit but must be selected as such because of its higher blockage. You press the P key to enter Program Mode, then the 123456 access code and E. Now press P to advance to the "Set Meter #1 Flow" menu then press E then using P advance to the screen "Next Sens Dia ^ v" where the ^ v arrows are used to choose the value followed by E. It will say "new value accepted" if you make a change. Last press the C key a few times to exit Program Mode. More extensive programming instructions and the Menu state diagram are found in the manual. Flow/velocity Units. The engineering units displayed by the unit are extensive and can be programmed for the following partial list (please refer to the appropriate product for more info). Note that actual velocity or flow is not available. 454FT/504FT/534FT you have these options: Velocity SFPM, SMPS (only 454FT) Flow Rate SCFM, SCFH, SCMM, SCMH Mass Rate PPM, PPH, KGM, KGH Temperature DEGF, DEGC 410/452/502/510 with 155 Flow Computer Velocity SFPM, SMPS (only 410/452) Flow Rate SCFM, SCFH, SCMM, SCMH Mass Rate PPH, KGM Temperature DEGF, DEGC (only on T versions or K -BAR -2000 elements) To change the type of units you press the P key to enter Program Mode, then the 123456 access code and E. Now press P to advance to the "SET METER #1 FLOW" menu then press E then using P advance to the screen "DISPLAY NEXT ^v FLOW IS XXXX" where the ^v arrows are used to choose the value XXXX followed by E. It will say new value accepted if you make a change. Last press the C key a few times to exit Program Mode. r-F� o t�ozis ou see for t epe ds on 3. 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 13 Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 831-646-5911 www.kurz-instruments.com Reference Temp and Pressure for Standards. The selected standard flow or velocity is the same as actual at the temperature and pressure known as the "standard." Typical standards are 77 °F, 14.69 PSIA, or 0 °C, 760 mmHg. With the 155 flow computer the reference conditions are determined at the factory and are not field programmable. With the MFT line, 454FT, 504FT, 534FT you can separately set the temperature and pressure of the standard conditions. After you have done so it will compute the new standard density then modify all the calibration data so it reads the same flow rate as before but now referenced to a new standard density. To change the standard conditions, you enter Program Mode and advance to the "SET METER DATA" menu, scroll down to the menu "NEW TEMP REF" or "NEW PRESS REF." After making changes you press E. It will confirm the change and show the new reference density in this menu. Last you press C a few times to exit Program Mode. Field Calibration. This is the most difficult part of setting up an insertion flow meter. On the other hand, an In -Line meter does not needed this step as it is already calibrated to read flow with its area, blockage and correction factors built in already. To perform a Field Calibration, a reference flow method is used to know the true flow while noting the indicated flow from the meter. This is best left to experienced users or professionals who know how to do it. See the manual if you want more information on this. Tag/Labeling of the Meter The best way to change a meter's label is to use the Keyboard on your Laptop or PDA because non -numeric characters are hard to do with the Kurz 4x5 numeric keyboard. (see manual if you are using the local keypad/display). You connect your computer via the RS -232 port to the flow computer's serial port. The default baud rate is 9600 but can be changed on the MFT line via its local keypad. Use HyperTer Serial Ports 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 14 Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 831-646-5911 www.kurz-instruments.com On the PC or PDA you start a terminal emulator program like HyperTerminal, then you can use the lower case c, d, p, enter and other keys to navigate the menus and make changes. You start/stop the communications with the + key and will see a dialog like shown below on a MFT unit. The unit shown below had its Echo turned on where a list of terminal commands was shown then it started scrolling its meter data with their tags. p :program h :hold - :terminal echo d display :up arrow ? :help <BkSpc> :backspace U :down arrow 1 :dump log to terminal <CR> :enter c :clear q :query TERMINAL ECHO IS STARTED KURZ INSTRUMENTS 9:40 6/17/2002 PRESS H FOR HOLD HH FOR HELP METER #1, FLOW ID: FIT89 26.65436 SCFM 12944.61 SCF 26.65436 SCFM 12944.61 SCF METER #2, TEMP ID: METER 00002 587.1 DEGF 587.1 DEGF KURZ INSTRUMENTS 9:40 6/17/2002 PRESS H FOR HOLD HH FOR HELP METER 41, FLOW ID: FIT89 26.35618 SCFM 12951.66 SCF 26.35618 SCFM 12951.66 SCF METER #2, TEMP ID: METER 00002 To change a meter's label, using HyperTerminal you follow the example shown below. 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 15 Kurz Instruments, Inc. 831-646-5911 2411 Garden Road www.kurz-instruments.com Monterey, CA 93940 Pressed p Then the 123456 access code followed by enter. NFttt LM m I lJ i t I Y- u,21,Ur Uf+ll�El �Fi .0 't...... Then you press p several times to PRESS E TO RESET TOTALIZED advance to: PRESS E TO SET TIME & DATES PRESS E TO SET ADO SAMPLE RATE PRESS E TO SET FLOW CAL DATA PRESS E TO SET METER #1, FLOW Set Meter ENTER METER ID METER 01 followed by ENTER METER ID METER 01 '` enter. ENTER METER ID F Then you shift to ENTER METER ID FI caps -lock and ENTER METER ID FIT type the"tag" ENTER METER ID FIT$ and enter. ENTER METER ID FIT89 ENTER METER ID FIT9 NEW VALUE ACCEPTED You should see NEW VALUE ACCEPTED NEXT TYPE —v IN—LINE FLOW � Now turn off PRESS E TO SET METER H2, TEMP 9:44 6/13/2002 caps -lock and KURZ INSTRUMENTS P press c several PRESS H FOR HOLD HH FOR HELP "�' times to exit �, _ �r z A. N_ _. :a ,--�-_ program mode. 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 16 Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 Output Setup 831-646-5911 www.kurz-instruments.com The meter output can be analog via the 4-20 mA or digital via the RS -232 or RS -485. The 4-20 mA hardware is pre -calibrated at the factory so when it thinks 12 mA is being generated that it is. You may optionally re -calibrate with a 4 %2 digit multi -meter. This procedure is described in the manual. The output range of the 4-20 mA needs to be specified. If the Digital output is used you must program the protocol, baud rate, device address and set the proper hardware jumpers. Analog Output Range. The analog output range (4.00 mA = yy flow, 20.00 mA = zz flow), is programmed using the following sequence from the keypad: You will need to program your receiving device for the same range. Enter Program Mode by pressing P then the access code 123456 and E then advance the major menus using the P key till you see the menu "SET ANALOG OUTPUTS" now your press E to enter, then select the output channel to program, by typing the number or use the ^ v keys then press E. Now you assign the meter # you want to this output channel. For the MFT line, #I meter is the flow and #2 is the temperature. In the 155 Flow Computer, you have up to 16 meters that are completely programmable to their output being, velocity, flow, temperature, average of other meters etc. Next you see the menu "OUT # NEXT TYPE ^ v " Flow or VELOCITY on an insertion meter. The screen will show "LOW = 0.000 SCFM AT 4 mA" and you can enter whatever value you like followed by the E key for the low current value which will state new value accepted if you make a change. The next menu will read: "HIGH = YYY.YY SCFM AT 20 mA". Again you enter the new value followed by E to make a change. The next analog output channel will come up and your can select this with the E or escape using the C key multiple times. Summary of Maior Configuration Menus Field Operations in Program MFT Line, 454FT, 504FT, 155 Line Mode 534FT, K -BAR -2000 Enter Data from a Calibration PRESS E TO SET PRESS ENTER TO Certificate (pre done by Kurz) FLOW CAL DATA SET LINEARIZERS Change Range of Analog PRESS E TO SET PRESS ENTER TO Output (page 17) ANALOG OUTPUTS SET ANALOG OUT Change Area or Correction PRESS E TO SET PRESS ENTER TO Factors (page 11) METER #1, FLOW SET METER DATA Change Response Time PRESS E TO SET PRESS ENTER TO METER FILTER TC SET INPUT FILTER 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 17 Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 831-646-5911 www.kurz-instruments.com Digital Output. The most common digital communications protocol used today is Modbus. It has been around for decades and still selling strong, and is well supported with many third party OPC servers that can be configured to read parameters from our flow meters that are then used by client HMI or SCADA programs on the same computer or network like Excel, Lookout, Wonderware and Fix32 to name a few. Please see the manual for more on OPC and the Modbus register assignments to read data out of the MFT product line. The 155 Flow Computer does not have Modbus available. To setup the digital output we need to choose the protocol, baud rate and serial port type. A. Protocols: 1. Remote Terminal Mode is where you talk to the meter from a Laptop using HyperTerminal. Both the MFT line and 155 Flow Computers support this. 2. Plus Logging is the command that provides a meter summary and can be generated from an internal timer or external "1" command. For the 155 Flow Computer this is the "x" command. 3 Modbus, which is a multi -point protocol that can be used on one device via the RS -232 or many devices on the RS -485 port. Both the Modbus ASCII or RTU protocols are supported. The device address may be any number between 1 and 247.: B. Baud Rate: This can be 1.2 k to 38.4 k with the MFT line and is set from the local keypad. This is fixed to 9.6 k baud on the 155 Flow Computers. C. Serial Port Type: This is limited to RS -232 or RS -485. It is jumper selected as there is only one port, which can be either logic level standard. RS -232 is convenient for talking to PCs but the RS -485 is designed for long distances and addressing multiple devices. When using the RS -485 connection there are bus loading resistors and other issues that are needed for reliable operation defined on the field wiring diagrams that need to be consulted. Glossary See CD manual for glossary. 360206C Models 155, 452, 454FT, 502, 502FT, 504FT, 534FT 18 H2S SENSOR LL � esc i t on Features 139nefilts • Solid-state, not wet cell, • Functions in the harshest operation environments • Highly selective to H2S • Low risk of false alarms • Long service life, typically • Maximum reliability and low 3 to 5 years cost of ownership • Not affected by over -range • Durable in all applications exposure or continuous exposure to H2S • Temperature controlled • Copes with low temperatures well above ambient and high humidity • Robust mechanical design • Vibration and shock resistant General Monitors' hydrogen sulfide (H2S) sensor is a solid state semiconductor, diffusion, adsorption device, designed and manufactured to the highest quality standards. It is specifically sensitive to H2S and remains unaffected by high concentrations of other gases such as methane and hydrogen, which are often present in the same areas. A high tolerance to ambi- ent temperature variations (temperature range of -40°F to +195°F (-40°C to +900C)) and extreme humidity conditions is an outstanding feature of this sensor, as is the ability to withstand exposure to extremely high H2S concentrations without any harmful effects. The operating principle is based on the fact that the semiconductor will preferentially adsorb H2S, in which the resistance across its surface is reduced at a rate proportional to the concentration present. This signal is fed to the controller where it is linearized to drive a display and provide alarm outputs. The sensor substrate is maintained at an elevated temperature by means of a thermistor and a potted temperature control circuit, thus negating any effects caused by variations in ambient temperature and humidity. Often called a "MOS" (metal oxide semiconductor) sensor, it is the key part of all General Monitors' smart and control card -based H2S detection systems. With many advantages over the alternative electrochemical cell - based instruments, it is the heart of plant safety systems throughout the world. The sensor is safely and conveniently calibrated using a single ampoule method provided. Disposable canisters of pre -mixed H2S with air are also available. The key design features, with the corresponding benefits, are summarized above. There are small design differences according to the approval type and junction box used, but all General Monitors plants and sales offices can provide all types on demand. All have the same outstanding properties and a typical operational life of 3-5 years. Approvals range from FM to CSA in North America to ATEX and GOST for Europe and Russia, in addition, the MOS sensors meet the stringent performance standards of ISA S92.0.01 Part 1 1998 requirements as verified by FM. Sensor bodies are in corrosion resis- tant aluminum alloy or a 316 grade stainless steel. A wide variety of accessories are available to provide additional protection against airborne contaminants or for mounting in ducts or sample lines. Al;licctions • Oil Refining • Oil and Gas Exploration and Production • Sulfur Recovery Plants • Chemical Plants • Compressor Stations • LNG Plants • Sewage and Water Treatment Plants • Gas Turbines Sensor ° soca"oda,` : There are no standard rules for sensor placement, since the optimum sensor location is different for each application. Evaluation of facility conditions should make this determination. Generally, sensors should be: Sensor Housings: Type: Continuous diffusion, adsorption type Response Time: Wire screen flame arrestor version: T50 < 1 min. of full scale with full scale concentration applied " With sintered stainless steel flame arrestor: T50< 2 min. of full scale with full scale concentration applied Temperature Range: Standard Sensor: -65°F to +167°F (-55°C to +75°C) High Temperature Sensor to +195°F (90°C) FM Approved: -40°F to +140°F (-40°C to +60°C) Life: Three to five years, normal service Electrical Classification: FM and CSA, Class I, Div. 1, Groups B, C and D; or ATEX and GOST Ex ds IIC T6 Warranty: Two years Mikh P/N 10252-1, CSA, FM approved, P/N B14-020 ATEX approved, explosion -proof housing polyester housing MZIIIIMM� 7p -7 T- ME 50445-1 0-100 ppm, aluminum body, CSA, FM 50445-5 0-50 ppm, aluminum body, CSA, FM 50445-9 0-20 ppm, aluminum body, CSA, FM High Temperature 50448-1 HT 0-100 ppm, stainless steel body, CSA, FM High Temperature 50448-5HT 0-50 ppm, stainless steel body, CSA, FM High Temperature 50448-9HT 0-20 ppm, stainless steel body, CSA, FM 51457-1 0-100 ppm, sintered screen, stainless steel body, ATEX, CSA, GOST" 51457-5 0-50 ppm, sintered screen, stainless steel body, ATEX, CSA, COST" 51457-9 0-20 ppm, sintered screen, stainless steel body, ATEX, CSA, GOST" Sensor Housings: Type: Continuous diffusion, adsorption type Response Time: Wire screen flame arrestor version: T50 < 1 min. of full scale with full scale concentration applied " With sintered stainless steel flame arrestor: T50< 2 min. of full scale with full scale concentration applied Temperature Range: Standard Sensor: -65°F to +167°F (-55°C to +75°C) High Temperature Sensor to +195°F (90°C) FM Approved: -40°F to +140°F (-40°C to +60°C) Life: Three to five years, normal service Electrical Classification: FM and CSA, Class I, Div. 1, Groups B, C and D; or ATEX and GOST Ex ds IIC T6 Warranty: Two years Mikh P/N 10252-1, CSA, FM approved, P/N B14-020 ATEX approved, explosion -proof housing polyester housing Splash Guard Dust Guard Splash Guar (Plat 1,0395-1 The Splash Guard prevents water from entering the sensor cavity and affecting the element response and also acts as an effective windscreen. Constructed of rugged ABS plastic and threaded for simple screw -on installation, the Splash Guard has a series of internal baffles to deflect water down and away from the sensor. Dust Guard' (PIN 10110-1) The General Monitors Dust Guard Assembly prevents dust and other particulate matter from reaching the sensor flame arrestor and affecting the sensor response. The Dust Guard is also available in a kit with twelve disposable screens (P/N 10044-1). Ampoules € f H2S These glass ampoules are manufactured under strict quality control for use with the field calibrator and are available in a range of concentrations. Field Calibrator and Ampoules Duct Mounting Plate kit r Sta hose Steel Dust ? ur r (Plies 1800822) The General Monitors Sintered Stainless Steel Dust Guard protects the sensor from fine particulates. It should be used only in dry environments because the sintered disc has a tendency to absorb water and act as a gas diffusion barrier until it dries out. For accurate calibration, the sensor should be calibrated with the guard in position. Sensor Olcna Cl -amber (P/N 1000-) The Sensor Flow Chamber is constructed of aluminum (optional stainless steel) and is designed to be inserted into a sampling system. Duct Moue l Plate (PILI 10041-x) The Duct Mounting Plate is ideally suited to mount sensors for the monitoring of ducted air for living quarters in large offshore modules. Reld Calibrator (PION 00000) The General Monitors Field Calibrator (also referred to as a breaker bottle) provides a simple and efficient means of calibrating H2S in the field. It consists of a plastic jar fitted with a removable lid and a seal which fits over the sensor. After an H2S ampoule is placed in the ampoule holder, the screw assembly acts as a vice and breaks the ampoule releasing the gas for calibration purposes. portabl Frorge Calibrator [PIS! 11400250-x) The H2S Portable Purge Calibrator is a compact, practical, accurate and safe system for field calibration of H2S sensors. The cylinder is filled with an H2S in air mixture in one of seven separate parts per million (ppm) levels of concentration (10, 20, 25, 35, 50, 70 or 100). Using a known air/gas mixture reduces the possibility of error in field calibration. " The Portable Purge Calibrators are light- weight assemblies that are easy to carry. However, an optional carrying case is available for those desiring to carry more than 1 assembly at a time. The case can hold up to 2 complete assemblies and facilitates trans- porting them in the field. Note: General Monitors recommends using ampoules for calibrating H2S gas detection _ instruments. The H2S Portable Purge Calibrator is available for applications where a calibration method of flowing H2S gas to the sensor might provide a better calibration source (e.g. high humidity environments). S ecHic tions Regulator Flow Rate: 200 milliliters per minute Specifications subject to change without notice. Represented by. Publication # DS-h2s_sensors-D0705 (12.2 cubic inches per minute) Temperature Range: -40°F to 130°F (-40°C to 54°C) Storage Humidity Range: 5% to 100% RH non -condensing Weight: Assembly 5lbs. Cylinder 3lbs. Case 4lbs. Cylinder Length: 13.5 inches Cylinder Diameter: 3.5 inches Specifications subject to change without notice. Represented by. Publication # DS-h2s_sensors-D0705 METHANE SENSOR .,.. .. GENERALmom Im Imm am Im UK am MONITORS Protection for life. Des rl tl n F' e wires Benefits • Extra Strong Support Post • Large Active Bead Surface Area • Precious Metals Used for All Components Mounted in Teflon Body • Active and Reference Beads Matched by Size and Resistance • Teflon Barrier Protects Active and Reference Beads • Ultra Poison Resistant Active Bead • Glass Coated Reference Bead General Monitors' electrocatalytic gas sensors are supplied as original equipment on all of our products worldwide. The sensor's sensitivity, reliability and longevity make it the first choice for most users of the catalytic oxidation gas detection principle. The electrocatalytic sensor forms one half of a Wheatstone Bridge circuit where the change in resistance of a platinum coil within a catalyst -impregnated ceramic bead indicates the presence of flammable gas. It achieves the measurement by a proportional change in the resistance of the coil as the coil temperature rises. The other arm of the Bridge circuit is part of the control electronics; (either control card or field transmitter type) so it is important that the two arms be carefully matched. It is therefore our policy to supply our catalytic sensors, and our replacement sensors, only for General Monitors' equipment. Failure to adhere to this policy can lead to incorrect use and could cause devastating equipment malfunctions. Every component of our catalytic sensors is manufactured in-house to ensure optimum performance. Careful matching of the active and reference elements ("beads") result in a sensor that has negligible zero drift with respect to changes in humidity, pressure and temperature. Consequently, we can offer sensors which maintain base -line stability over a temperature range of -65°F to 400°F (-55°C to 200°C) and have negligible zero drift over a 12 -month period. • Protects beads from shock and vibration, avoiding damage • Large signal-to-noise ratio for stable performance and long sensor life • Functions well in corrosive and aggressive environments • Eliminates signal drift due to temperature and humidity changes • Eliminates heat transfer maximizing output signal • Long sensor life in poisonous atmospheres • Eliminates open drift due to reference bead detecting gas The key design features, with the corresponding benefits, are summarized above. There are small design differences according to the approval type and junction box used, but all General Monitors plants and sales offices can provide all types on demand. All have the same outstanding properties and a typical operational life of 3-5 years. Approvals range from FM to CSA in North America to CENELEC/ATEX and Gosstandart for Europe and Russia. Sensor bodies are in corrosion resistant aluminum alloy or a 316 grade stainless steel. A wide variety of accessories are available to provide additional protection against airborne contaminants or for mounting in ducts or sample lines. Applications • Gas Processing Plants • Oil and Gas Exploration and Production • Ethylene Processes • Vinyl Chloride Monomer Processes • Hydrogen Detection • Compressor Stations • LNG Plants • Sewage and Water Treatment Plants • Gas Turbines • Solvent Extraction Plants . • Ammonia Detection T, ie do of Cnrrect Sensor Teciinclogy Measuring range: 0-100% LEL Type: Continuous diffusion, low temperature catalytic bead; hydrocarbon sensors; high temperature hydrocarbon sensors Response Time: Typically 6 -second time constant when exposed to 50% LEL of methane gas. (CSA) T50 < 10 seconds for ATEX & European Flame Arrester type. Zero Drift: Less than 5% per year Temperature: -65°F to +200°F (-55°C to +93°C) High temperature sensor to +400°F (200°C) (CSA) -40°F to + 248°F (-40°C to + 120°C) High temperature sensor up to + 356°F (+180°C). ATEX Sensor Drive: 300mA DC Life: Three to five years, normal service Elechical Classification: NEC and CSA, Class I, Div. 1, Groups B, C and D; or ATEX IIG EEx d IIC Warranty: Two years Sensor Housings: P/N 10252-1, CSA approved, explosion -proof housing �Pw P/N B13-020 polyester housing P/N B13-021 High temperature housing M 10001-1 General Purpose, Aluminum body, CSA, FM approved 10102-1 Sensor Simulator 10001-1 R General Purpose, Poison Resistant, 10164-1 Hydrogen specific, Aluminum body, CSA approved Aluminum body, CSA, FM approved 10014-1 General Purpose, High temperature to 400°F 11159-1 Stainless steel body, (max. 120°C) (200°C), Aluminum body, CSA, FM approved ATEX, GOST, CSA approved. 10014-1 R General Purpose, Poison Resistant, High temper- 11159-2 Stainless steel body, (max. 180°C) High ature to 400°F (200°C), Aluminum body. CSA, FM temperature. ATEX, GOST, CSA approved. 10015-1 Aluminum body, High temperature (max. 120°C) 11159-3 Stainless steel body, (max. 120°C) Super poison CSA approved resistant. ATEX, GOST, CSA approved. 10022-1 Aluminum body, sintered. CSA approved, 11159-1 L Stainless steel body, (max. 120°C) Group A ATEX, COST, CSA approved. (With lugs) 10058-1 Stainless steel body, CSA approved 11159-2L Stainless steel body, (max. 180°C) High temp- erature. ATEX, GOST, CSA approved. (With lugs) 10058-1 R Stainless steel body, Poison Resistant, 11159-3L Stainless steel body, (max. 120°C) super poison CSA approved resistant. ATEX, GOST, CSA approved. (WAugs) Measuring range: 0-100% LEL Type: Continuous diffusion, low temperature catalytic bead; hydrocarbon sensors; high temperature hydrocarbon sensors Response Time: Typically 6 -second time constant when exposed to 50% LEL of methane gas. (CSA) T50 < 10 seconds for ATEX & European Flame Arrester type. Zero Drift: Less than 5% per year Temperature: -65°F to +200°F (-55°C to +93°C) High temperature sensor to +400°F (200°C) (CSA) -40°F to + 248°F (-40°C to + 120°C) High temperature sensor up to + 356°F (+180°C). ATEX Sensor Drive: 300mA DC Life: Three to five years, normal service Elechical Classification: NEC and CSA, Class I, Div. 1, Groups B, C and D; or ATEX IIG EEx d IIC Warranty: Two years Sensor Housings: P/N 10252-1, CSA approved, explosion -proof housing �Pw P/N B13-020 polyester housing P/N B13-021 High temperature housing -ortable Pure t aftrater (2/ '14V_ 150 }) The Portable Purge Calibrator is a compact, accurate and safe system containing no explosive gas. The lecture bottle is filled with a gas/air mixture below the Lower Explosive Limit (Standard mixture is 50% LEL). Using a known gas/air mixture reduces the possibility of error in field calibration, and the hose and cup adapter permits calibration without removing sensors or their attachments. Please refer to the appropriate General Monitors Instruction Manual for calibration procedures. The following pre -mixed calibration gases at approximately 50% LEL are available at 1200 psia, 8.3 MPa maximum pressure. Butadiene (BD) CA Butane (B) CAO Ethane (E) C2H6 Hydrogen (H) H2 Methane (M) CH, Propane (PR) C,H$ Other gases and concentrations are also available. Please consult your local General Monitors representative for further information. Senis r 1�1ow Shan',her (P/N 10088) The Sensor Flow Chamber is constructed of Aluminum (optional stainless steel) and is designed to be inserted into a sampling system. This allows a sample to be drawn to the sensor when it is not possible to mount it directly in the monitored area. Reasons include: high temperature, pressure, fast air flow or inaccessibility. Dust Guard ( 10110-1) The General Monitors Dust Guard Assembly prevents dust and other particulate matter from reaching the sensor flame arrestor and affecting the sensor response. Comprising a simple threaded stainless steel cylinder with a wire screen at one end, the dust guard assembly is easily removed for cleaning or replacement of the disposable screen. The Dust Guard is also available in a kit with twelve disposable screens (P/N 10044-1). It can act as a wind -screen and is recommended for corrosive, windy or high temperature environments, with typical applications being in areas surrounding vinyl chloride plants or drying ovens. Shhere Stainless Steel Dust Guard (PIN 1800522) The General Monitors Sintered Stainless Steel Dust Guard protects the sensor from fine particulates and is designed for use in windy conditions. It should, however, be used only in dry environments because the sintered disc has a tendency to absorb water and act as a gas diffusion barrier until it dries out. For accurate calibration, the sensor should be calibrated with the guard in position. In construction, the sintered stainless steel Dust Guard, is similar to the Dust Guard Assembly, but has a 3mm thick sintered stainless steel disc at one end with the other end threaded for easy installation. Splash Guard (PIN 111205-1) The General Monitors Splash Guard prevents water, in the form of rain or equipment washes, from entering the sensor cavity and affecting the element response and also acts as an effective windscreen. It is recommended for use in any outside environment involving high winds or rain or where frequent hosedowns are practiced, as on offshore platforms. Constructed of rugged ABS plastic and threaded for simple screw -on installation, the Splash Guard has a series of internal baffles to deflect water down and away from the sensor. Duct 10o tip date (PIN 10211-x) The Duct Mounting Plate is ideally suited to mount sensors for the monitoring of ducted air for living quarters in large offshore modules. 411 Dust Guard - Sintered Stainless Steel Dust Guard ot_ Test Gas applicator "'PIN 10460=2 The remote test gas applicator, TGA -1, is designed to be permanently installed on a combustible gas sensor. The TGA -1 provides protection from outside elements, and it allows the user to apply a test gas to the sensor from a remote source. Sensor Housing Sensor' TGA -1 Customer' Supplied Tubing Flow Meter --:0 Needle Valve — 0 w L 50% LEL Gas Supply> Customer Supplied Conduit Smart E Transmitter or Controller ps)itable Callbraflon Cts - iber PIN 10543-1) The Portable Calibration Chamber is a practical and safe instrument for the field calibration of combustible gas monitoring systems. Sensors can be calibrated in place with a known liquid/air mixture, reducing the possibility of calibration error. The Portable Calibration Chamber is a 3 -liter sample chamber with an intrinsically safe battery powered mixing fan. For our catalytic bead sensors, a porthole allows the chamber to be placed on the sensor for calibration. Represented by: Publication #: DS -Sensors -D0306 AUTO - SUMP 7000 F,:?,, t- - AUTON"UMP 7000 0 & M M AkNUAL m sl - COSTS THE KEY TO LOWER O&M iict'l®ns Vault: All operating components of the condensate pump and control assembly are located in a polyethylene vault that is integrally mounted on flop of condensate liquid sump. Service connections, including the liquid discharge, pressure balance line, and high-pressure air inlet are grommet or bulkhead mounted on a common wall of the vault. Connections: The AUTO -SUMP 7000 has the follbvAng sizes and types: Service Size Connections Furnished Compressed Air Inlet Y2- inch Condensate Liquid Discharge -%- inch_ _ __ FNPT Pressure Equalization Line %- inch FNPT , The condensate liquid inlet to the sump is 3 -inch diameter rated for at least 29.8 inches mercury vacuum. No PVC Pipe is used in the Auto -Sump assembly. The compressed air, liquid and equalizing tube inside the sump is constructed of nylon tube. Liquid Pumix A pneumatic, submersible, AP -4 short body pump manufactured by QED is used to transfer liquids from the sump. Pump seals, which contact liquid, shall be Viiton or Teflon - Level Control: Internal switches in the submersible pump accomplish level control. Compressed Air System The .compressed air system includes an inlet block valve, filter with automatic drain valve, and regulator with removable seat. All components are rated for 150 PSIG. Salts: All bolts, nuts, and washers in contact with LFG are stainless steel type 304. .v ca ti d LD 4 �C� 9 o z I I z p Y ^� o U p o z CQ t44 o CIO ra U-1 F- J O N � N O E— Q J D L7 W W H W Q Q O F- W D L3 w 2 U N p q I W D F- 7 Q W n - Z W J Z W U U Z Q Q 1" J a Q a' u N z U Z N W U J d f Q I aai 3 2 z a- 0 W N O U v ti o Z W q J WI - W i Z 0] S v I-- ¢ a Q f W 2 L'i a J uu to a Z II i II itljll II I I III 1111 I III � SII 111 I III III --------- ------ u'rl --1-- i 6 JI I I -I--- --------------------------------- �QJ O O O 711 ---------------yJ O ��� 1. Stainless Steel Ball Valve, Air Inlet. 2. Condensate Discharge Stainless Steel Ball Valve 3. Isolation Well Balance Line Shut off. 4. Sump Balance Line Shut Off. 5. Stainless Steel Locking Latch (Typ.2) 6. Threaded Plug for Sounding. 7. Auto Drain Filter Regulator. �. Air Quick Disconnect. 9. Drain Plug (into surnp). 10. Stainless Steel Hydraulic gdiok disconnect (condensate discharge). F,f FIGURE #1 2. 3. 4 10. eal 15,�nviro=ental J ]Products AUTO SUMP 7000 1 1-----7-6/6/07 1 M. PR Step 1. 9. Turn the Air Shut Off valve to the of position. See # 1 Fig. 1 - - 2. Turn the Condensate Discharge valve to the off position. See # 2 Fig. 1 Step 3. 3. Turn the Isolation Well Balance valve to the off position. See # 3 Fig. 1 4. Turn the Sump Balance valve to the off position. See # 4 Fico. 1 ftftn Turning the Sump Balance Line to the off position may prevent condensate from, draining into the sump from the header and may cause condensate in the sump to be dram back into the header. This condition will occur if the negative pressure of the header is greater than the distance from the flow line of the header to the top of the water level in the sump. This valve can be left open while servicing the pump and not allow oxygen to enter the system if the water level is higher than the drain holes in the isolation vvel.! Step 5. 5. Disconnect the Air Quick Disconnect. See # 8 Fig. I Step 6. 6, Disconnect the Condensate Quick Disconnect. See# 10 F40. I Step 7. 7. Release the stainless steel quick latches. See # 5 Fig. I ME 8. Carefully pull the Well Head off the Isolation well, and pull the pump from the Isolation well. Installation of BacLuLEgM2 Follow Steps 8. —1. ;, 13 gprn (49 Bpm) 3.5 in (8.9 cm) 41 in. (104 cm) 1. The original automatic air - powered well pump, proven worldwide over 18 years 2. The highest flow rates and deepest pumping capabilities in the industry 3. Patented, proven design for superior reliability and durability, even in severe applications 4. Dandles solids, solvents, hydrocarbons corrosive conditions, viscous fluids and high temperatures (beyond the limits of electric pumps 5. five-year warranty "Consult QED for higher fiovd requirements tr,____ ____ _..._.. The AP4 Bottom Inlet Short AutoPump provides maximum: capabilities and flow in a bottom inlet pump for 4!'(100 mm) diameter and larger wells with shorter water columns and/or the need to pump down to lower water levels, compared to full-length pumps. it is offered in optional versions to handle even the most severe remediation and landfill pumping applications, and delivers flow rates up to 13 gpm (49 Ipm)* The AN Short Bottom Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site specific requirements. Call QED for prompt, no -obligation assistance on your pumping project needs. The AM Bottom Inlet Short AutoPump is part of the famous AutoPump family of original automatic air -powered pumps, developed in the mid 1980s specifically to handle unique pumping needs at remediation and landfill sites. Over the years they've proven their durability at thousands of sites worldwide. AutoPumps are designed to handle difficult pumping challenges that other pumps can't, such as hydrocarbons, solvents, suspended solids, corrosives, temperature extremes, viscous fluids and frequent start/ stop cycles. Beyond just the pump, AutoPump systems offer the most complete range of tubing, hose, connectors, wellhead caps and accessories to help your installation go smoothly. This superior pumping heritage, application experience and support back up every AutoPump you put to work on your project. AP4 AutoPumps are designed to handle the application ranges described below. For applications outside these ranges, consult QED about AP4 upgrades. Model 4" - Short AP4 Bottom Inlet Liquid Inlet Location Bottom OD 3.5 in. (8.9 cm! Length Overall (pump & fittings) 41 in. (104 cm) Length Overall, w / Extended Screen 44 in. 1112 cm) Weight 13 lbs. (5.9 kg) Max. Flow Rate 13 gpm (49 Ipm)' _ See flow Rate Chart Pump Volume / Cycle 0.22 - 0.36 gal (.83 -1.36L ) Min. Actuation Level 27 in. (69 cm) Standard Pump Max. Depth 250 ft. (76 m) Air Pressure Range 5 120 psi (0:4 $.4 kg/cm2) Air Usage 0.4-1.5 scf / gal. (1.5 - 5.7 liter of air/ fluid Titer) - See air usage char High Pressure Pump Max. Depth 425 ft. (130 m) Air Pressure Range 5 - 200 psi .(0.4-14.1.kg/cm2) Min. Liquid Density 0.7 SO (0.7 g/cm3) Standard Construction Materials, Pump Body Fiberglass or Stainless Steel Pump Ends Stainless Steel, UHMWPE3, Brass Internal Components Stainless Steel; Viton, Acetal, PVDP' rube &'Hose Fittings Brass or Stainless Steel Fitting Type Barbs or Quick Connects Tube & Hose. Options Tubing Material, Nylon sizes - Liquid Discharge 1 in. (25 mm) or 1-1/4 in. (32 mm) OD Pump Air Supply 1/2 in. (13 mm) OD Air Exhaust 5/8 in. (16 mm) OD Hose Material Sizes - Liquid Discharge Nitrile 3/4 in. (19 mm) or 1 in. (25 mm) ID Pump Air Supply 3/8 in. (9.5 mm) ID Air Exhaust 1/2 in. (13 mm) ID , Material upgrades available 3 UORE - Ultra High Molecular Weight Polyethy)ene 2 Applies to QED supplied tubing; ° PVDF - PoWnylidene.Ruoride other tubing sources may not conform to QED flings. Long and short AP -4 AutoPumps are warranted for five (5) years: 100% materials and workmanship first three (3) years; 50% materials and workmanship for the fourth (4th) and fifth (5th) years. Low -Drawdown for the AutoPumps are warranted for one (1) year. Maximum Temperature: 150°F (65°C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6, #2 heating oils, BTEX, MTBE, landfill liquids *Consu6t QED for higher flow requirements - — P.O. Box 3726 Ann Arbor, MI 48106.3726 USA 1.800.624.2026 F 1.734.995.1170 infoQgedenv.com www.qedenv.com 11 3/4 inch (19 mm) Inside Diameter Discharge Hose (Equivalent to 1 -Inch O.D. Tubing) I inch (25.4 mm'j Inside Diameter Discharge Hose (Equivilant to 1.25 -Inch O.D. Tubing) 68.1 60.6 16 53 14 45.4 12 - iriC 37.9 10 - 30.3 22.7 :j 6 7.6 2 0 20 40 60 Bo ioo 120 140 160 180 200 fT. DEPTH 6j 12.2183 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters IN WELL 18 63.1 16 60.6 14 53 1 MINI A 12 45 0 37.9 6 22.7 4 15.1 2 7.6 13 a -T DEPTH 20 40 60 80 100 120 1 1 11 00 -L F 6.1 12.218,324.430-536.642.748.8 54.9 261 Meters _j IN WELL 18 16 60.6 53 14 12 t7� 4 ;E 45.4 L 37.9 10 1^v- 8 30.3 6 22.7 4 2 7.6 0 0 ji 20 40 6o so 100 120 140 160 180 200 FT. DEPTH 6.1 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54,9 61 Meters IN WELL ,j 68.1 is ■ 60.6 16 53 14 - 12- -:31 i 45.4 37.9 10- 303 8 :6 22.7 4 7.6 2 J,:! J ^D 0 120 140 160 180 200 Fr. DEPTH 20 60 SU t00 6.1 12. 18 24A 3 )_5 36.6 42.7 48.8 54.9 151 Meters IN WELL is - 68.1 16- 60.6 14- 53 i. 12- 45A ji E 10- 37.9 r. 303 nd J 22.7 6 71 77,17- 15.1 4 7.6 2 0 0! 60 B - 140160 180 200 0 FT. DEPTH 6.1 122 183 24A 30-5 36.6 42.748.8 54-9 61 Meters j IN WELL 71 18 68.1 16 60.6 r� V; C.: r 14+ 53 45.4 Orri 12 "ifiM it 10 37.9 I. A-11 : 8 303 ITN' �A!22.7 6 15.1 4 27.6 0. 20 40 6 So 100 120 140 0 160 IPO 2oF r. DE PTH 6.1 12.2180324.430536.642748.8 54.9 61o Meters NEWELL _j I inch (25.4 mm'j Inside Diameter Discharge Hose (Equivilant to 1.25 -Inch O.D. Tubing) 68.1 60.6 16 53 14 45.4 12 - iriC 37.9 10 - 30.3 22.7 :j 6 7.6 2 0 20 40 60 Bo ioo 120 140 160 180 200 fT. DEPTH 6j 12.2183 24.4 30.5 36.6 42.7 48.8 54.9 61 Meters IN WELL 18 63.1 16 60.6 14 53 1 MINI A 12 45 0 37.9 6 22.7 4 15.1 2 7.6 13 a -T DEPTH 20 40 60 80 100 120 1 1 11 00 -L F 6.1 12.218,324.430-536.642.748.8 54.9 261 Meters _j IN WELL 18 16 60.6 53 14 12 t7� 4 ;E 45.4 L 37.9 10 1^v- 8 30.3 6 22.7 4 2 7.6 0 0 ji 20 40 6o so 100 120 140 160 180 200 FT. DEPTH 6.1 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54,9 61 Meters IN WELL ,j ■ 'FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE. pr -p 1.6 12 3/4 inch (19 mm) 11.2 Inside Diameter Discharge Hose 1.5 (Equivalent to 1 -Inch O.D. Tubing) 10.5 1.4 9.7 13 7 9.0 1.2 7 -7 7-5 1.0 6.7 iF... .9 Y '7 - 7- 7 E3-- 7 52 .6 -i 4.5 3.7 .4 3.0 3 2.22 .21.5 20 40 60 so loo 120 140 160 180 200 Fr. DEPTH 6.1 12.2 183 24.4 30-5 36.6 42-7 48,8 54.9 61 Meters IN WELL L !ncn (e -5."t Mro1I Inside Diameter Discharge Hose (Equivalent to 1.25 -Inch O.D. Tubing) 10.5 3,7 3.0 9.2 7.5 6.7 6.0 5.2 4-5 33 3.0 .4 2.2 .3 MtHE[fi 9 1.5 .220 40 60 so loo 120 140 . DEPTH 160 180 200 FT 6.1 121 183 24.4 30.5 36.6 42.7 482 54.9 61 Meters INWELL --- P.O. Box 3726 Ann Arbor, MI 48106-3726 USA 1.800.624.2026 F 1.734.995.1170 info@aedenv.com www.qedenv.COM z: I I N D U S T R I E S L L C 1160 Nicole Cour Glendora. CA 91746 800-735-5566 9 909-592-627_2 Fax. 909-592-7971 wvvw.carsonind.com 23-511 _w -- Optional Water Meter Reader _--1 5-3/8" 24-5/8" 2-1/4" L -Bolt Option 4-1/4" R II MY u 1 if ry Bolt Down Loc-iKffm (Patent Pending) �s 2" Included FLUSH H CCVER A B fl_ F G253/B" Balt Down 1324-3L — 15-15/16 12" 22-518" 35116" 19-12"(645 (8mm) (495 mm)1324-15 Imm), Bolt Down with Plastic Reader mm) (405 mm) (305 mm) (575 mm) Bolt Down with: Cast Iron Reader 25-114" 15.314' 15-114" 23-5116" 351 20-3116" I (641 mm) (400 mm) (387 mm) (592 mm) (8mm) (513 mm) FLUSH H CCVER Models: 1324-313 Balt Down 1324-3L Captive L -Bolt Lock 1324-5B Bolt Down with Plastic Reader 1324-5L L -Bolt with Plastic Reader 1324-6B Bolt Down with: Cast Iron Reader 1324-61- L -Bolt with Cast Iron Reader T -COVER Moellells: 1324-4B Bolt Down 1324-4L Captive L -Bolt Lock GRADE RONG Model: 1324**2RH Green/Gray BODIES Models: 1324-12 1324-15 COLORS AVAILABLE- Green, Gray, Black, Tan or Violet/Levender Note: For use in non -vehicular traffic situations only. We do not recommend installation in concrete or asphalt. Weights and dimensions may vary slightly. All information contained in this brochure was current at the time of printing. Because of Carson Industries' policy of ongoing research and development, the Company reserves the right to discontinue or update product information without notice. RAW MIATEREA . SPIECI)FIICWTEON S SHIIPPoNG ONFO zMATOON All information contained in this brochure was current at the time of printing. Because of Carson Industries' policy of ongoing research and development, the Company reserves the right to discontinue or update product information without notice. Carson 6ndustries7 LLC 1160 Nicole Cour- Glendora. ourGlendora. CA 91740 800-735-5566 ® 909-592-6272 Fax: 909-592-7971 www carsonind.com HDPE Structural Foam ASTM Test Material Property Method Typical Value' Type, Class, Category D 1248 III, A, 3 Density, g/ cm3 D 1505 0.950 min_, not to exceed 0.965 Tensile Strength, at break, psi D 638 3,000 to 4,400 Elongation, at break, % D 638 400 Tensile impact, ft-lbAn2 D 1822 27 Flexural Modulus, psi D 790 120,000 min., not to exceed 240,000 Low Temperature Brittleness. D 746 <-78 F50. at°C Hardness, Shore 'D D 2240 66 Deflection temperature, at D 648 1501, min., not to exceed 2001, 66 psi -_._.-...-..... ._ Electrical Dielectric Strength, D 949 400 min., not to exceed 600 V/mil Molded Product/ Chemical Resistance D 543 Very Resistant Water Absorption D 570 Less than I% weight change 'The values listed for physical property measurements are nominal values only. Certain physical property measurements are subject to variations consistent with the test methods and are wit'nin a generally accepted range for such values. Test reports available on request. 12118102 Weigh 1324 -3B, -3L, -4B, -4L Covers 6 lbs. 1324* 2RH Grade Ring 4 lbs. 1324-12 Body 16 lbs. 1324-15 Body 20 lbs. ShipDing Configuration 1324-12: Unit, 16 assemblies = 42.6 cu. ft.: 413.0 lbs. 1324-15: Unit, 16 assemblies = 49.75 cu. ft.; 430.0 lbs. Rotary Screw Corepressor Daqstation DX1000/DX1000N ! J Flame Arrester