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~ ConservAIR®<br />

.".."." Technologies<br />

.. INTERMEDIATE CONTROL®<br />

E-SERIES (I/C)®<br />

OM-CA-2<br />

INSTALLATION,<br />

OPERATION,<br />

START-UP, &<br />

MAINTENANCE<br />

MANUAL<br />

Record above information from name plate.<br />

Retain this information for future reference.<br />

Replacement Price $25.00<br />

r<br />

CONSERVAIR<br />

Compressed Air<br />

MANAGEMENT<br />

SYSTEMS<br />

_


1<br />

CONSERVAIR TECHNOLOGIES<br />

TABLE OF CONTENTS<br />

I. GENERAL INFORMATION 1<br />

II. INSPECTION 1<br />

III. SAFETY INSTRUCTIONS 1<br />

IV. INSTAl.l.ATION ~<br />

V. RECOMMENDED INSTALLATION DIAGRAM 3<br />

VI. START-UP & OPERATION 4<br />

VII. GENERAL ARRANGEMENT DRAWiNG 5<br />

VIII. CONTROL VALVE ASSEMBLY DRAWINGS 6, 7<br />

IX. SERVMATIC CONTROL DIAGRAM<br />

X. DIGITAL ADJUSTMENT CHART<br />

XI. OPTION DETAILS<br />

W XII. TROUBLE-SHOOTING GUiDE<br />

)(111. \nIARRANlr"<br />

8<br />

9<br />

10<br />

11, 12<br />

1~<br />

RECEIVING - INSPECTION<br />

Inspect equipment. Any concealed shipping damage must be<br />

reported to the carrier immediately. Damage claims should be<br />

filed by the consignee with the carrier.<br />

SAFETY INSTRUCTIONS<br />

When using air compressors and compressed air accessories,<br />

basic safety rules, and precautions must always be followed,<br />

including the following:<br />

1. READ ALL INSTRUCTIONS FULLY<br />

., ..... WARNING<br />

Air from compressor, Pneumatech Air Drying System, and<br />

ConservAir Intermediate Control as equipped, is NOT for human<br />

respiration (breathing).<br />

2. WIRING & BREAKERS<br />

Wiring, breakers, and other electrical equipment must<br />

conform to local and national electric codes. Do not<br />

operate this unit with damaged wiring after the unit or air<br />

handling parts have been dropped or damaged in any<br />

manner. Notify authorized service facility for examination,<br />

repair or other adjustments.


2<br />

I. INSTALLATION<br />

Your E-Series Intermediate Control Unit (I/C) has<br />

been air tested for functions and leaks and is ready<br />

for installation. ConservAIR suggests that a temporary<br />

or in-line strainer be installed on the inlet side<br />

of the I/C to guard against contaminants and insure<br />

proper operation.<br />

1) Inspect unit upon receipt. Immediately<br />

report any damage to the shipping<br />

carrier.<br />

2) The ConservAIR IIC Unit has an "IN"<br />

and "OUT" with directional flow arrows<br />

cast right into the Control Element.<br />

Orient the I/C unit in accordance with<br />

compressed air system flow.<br />

3) The ConservAIR IIC Unit can be<br />

installed in any plane. The headers are<br />

capable of supporting the weight of the<br />

unit for either vertical or horizontal<br />

mounting. DO NOT SUPPORT THE<br />

UNIT FROM THE CONTROL ELE­<br />

MENTS OR THE ASSOCIATED<br />

CONTROL PIPING.<br />

7) Connect 115 VAC/Single Phase to the<br />

labeled terminal block. A lug is provided<br />

for grounding the control panel enclosure.<br />

The grounding lug is located next<br />

to the terminal block. Note for (I/C)<br />

units with the manual bypass<br />

option: Open the bypass located on<br />

the I/C header before applying<br />

power.<br />

8) Grounding: It is mandatory that the I/C<br />

control panel be grounded. Use an<br />

adequate ground with the conductor<br />

sized to NEC specifications.<br />

9) During shipments, wire connections<br />

may become loose. As recommended<br />

by U.L. specification, torque terminal<br />

screws inside enclosure to 20 in. Ibs.<br />

4) Mount the control panel where most<br />

convenient. The panel is designed for<br />

top connections. Do not exceed 150<br />

feet from the I/C header to the control<br />

panel.<br />

5) Pilot air tubing between the I/C header<br />

and the control panel is 1/4" 00. See<br />

the general arrangement drawing for<br />

control panel pneumatic connections.<br />

Install the CP-5, 40 micron filter, on the<br />

inlet control piping feeding the control<br />

panel.<br />

6) LEAK TEST: An air leak may develop<br />

during transportation or installation.<br />

Pressurize system and check for any<br />

leaks. The servo control line is<br />

extremely sensitive to leakage. This<br />

line must be bubble tight!


i\lI!!,fp'H $<br />

e<br />

--<br />

e<br />

T - TEMPERATURE GAUGE<br />

P - PRESSURE GAUGE<br />

R - RELIEF VALVE<br />

®<br />

AIR COOLED<br />

SEPARATOR<br />

~LE~ (R~,.)','ij'R'i;%<br />

..... Technologies<br />

ConservAIR® '<br />

~~ ~=-M<br />

"'2a..r~<br />

~aw<br />

COMPRESSED AIR SYSTEMS<br />

RECOMMENDED INSTALLATION<br />

FLOW DIAGRAM ~<br />

T<br />

RECEIVER<br />

DIFFERENTIAL<br />

PRESSURE GAUGE<br />

OPTIONAL 3 VALVE<br />

SYSTEM BYPASS<br />

REFRIGERATED<br />

AIR DRYER<br />

- ~·O<br />

DIFFERENTIAL<br />

PRESSURE GAUGE<br />

---., ConservAIR -=­<br />

TflchnologOl;J5<br />

INTERMEDIATE<br />

CONTROL<br />

AIR<br />

COMPRESSOR<br />

II<br />

11- ,,~n ~" I I<br />

.. - _..<br />

u<br />

WATER COOLED<br />

AFTERCOOLER<br />

COALESCING<br />

II<br />

AFTERFILTER<br />

4477<br />

II<br />

II<br />

AUTO<br />

II<br />

@<br />

DRAIN<br />

II<br />

DRAIN<br />

II<br />

II<br />

®<br />

4477<br />

AUTO<br />

DRAIN<br />


4<br />

II. START liP & OPERATION (See Control Panel Layout<br />

& General Arrangement Drawing)<br />

Prior to start up, check for unusual pressure drops<br />

between the compressor and the I/C unit. Ball<br />

valves located on the I/C should be open if option<br />

included. During start up, relief valves in the<br />

storage portion of the system may open. The air<br />

compressor system characteristics change after<br />

the I/C unit is put on line.<br />

The automatic bypass located on the I/C header is<br />

a fail safe open valve (spring openlair to close). If<br />

control air is disconnected from the automatic<br />

bypass or there is a power failure the automatic<br />

bypass will open. Important: Cycle the automatic<br />

bypass every three (3) months to insure proper<br />

operation.<br />

The control modules on the I/C header are fail<br />

closed valves. If control air (servo) is disconnected<br />

the valves will close. However, the control panel<br />

provides a servo signal to fully open the control<br />

valves in the event of a power failure. Isolation<br />

valves are provided to isolate each control module<br />

for maintenance.<br />

1) Turn the control panel power switch to<br />

the "off" position. Turning the control<br />

power off will insure that the automatic<br />

bypass opens. (For manual bypass<br />

option open the manual bypass located<br />

on the header.)<br />

2) Open the control panel door and turn<br />

the digital adjustment knob to a setting<br />

that is higher than the target discharge<br />

pressure. (This will insure that the<br />

control modules remain open when<br />

power is applied.) The digital adjustment<br />

knob comes equipped with a<br />

locking lever. Push the lever to the left<br />

to adjust the setting. A digital adjustment<br />

chart is located in the appendix<br />

and on the inside of the control panel<br />

door.<br />

3) Turn the control panel power switch to<br />

the "on" position. This will engage the<br />

ServMatic controller and close the<br />

automatic bypass. (For manual bypass<br />

option close the manual bypass located<br />

on the header.)<br />

4) Turn the digital adjustment knob<br />

counter clockwise to the desired discharge<br />

pressure. Turn the digital<br />

adjustment knob in small increments<br />

allowing the system to stabilize<br />

between adjustments. CAUTION!<br />

Failure to adjust the I/C in this manner<br />

may result in a system drawdown. The<br />

"AIR OUT" gauge displays discharge<br />

pressure of the I/C unit.<br />

5, 6, and 7 are Start up instructions for the AUTO­<br />

BYPASS ONLY.<br />

5) The low pressure alarm is factory set at<br />

70 psig. If the discharge air pressure<br />

falls below 70 psig the auto bypass<br />

opens, the low pressure light illuminates,<br />

the bypass ready light turns off,<br />

and the buzzer resonates. The low<br />

pressure alarm is a latching alarm. To<br />

restore normal I/C operation the discharge<br />

pressure must rise above 78<br />

psig and an operator must press the<br />

low pressure reset button.<br />

6) The low pressure alarm is activated by<br />

a pressure switch located in the control<br />

panel. The pressure switch setting is<br />

adjustable from 10-100 psig. To change<br />

the low pressure alarm setting the I/C's<br />

discharge pressure must be lowered to<br />

the desired alarm set point. Then, the<br />

thumb wheel on the pressure switch is<br />

turned until the alarm activates. The<br />

thumb wheel is turned clockwise to<br />

increase the setting and counter-clockwise<br />

to decrease the setting.<br />

7) The automatic bypass has an<br />

adjustable travel stop to limit the valves<br />

opening when engaged. Set the<br />

opening for a fixed pressure drop of<br />

approximately 5 psig when the valve is<br />

open. This will provide a smoother transition<br />

if a low pressure alarm occurs<br />

and help prevent a possible compressed<br />

air drawdown situation. To set<br />

the opening position the bypass valve<br />

must be closed. An indicator is<br />

mounted on the actuator. When the<br />

indicator is perpendicular to the pipe<br />

run it is closed. Turn the bolt on the<br />

actuator clockwise to limit opening.<br />

When the bolt is full clockwise the valve<br />

is limited 100% and will not open. Full<br />

adjustable range is approximately 8<br />

turns.<br />

Maximum inlet pressure is 150 PSIG. Maximum<br />

regulating pressure is 145 PSIG.


INTERMEDIATE CONTROL<br />

W/AUTO BYPASS<br />

INTERMEOIA TE CONTROL<br />

W/MANUAL BYPASS<br />

5<br />

IILET<br />

AlR AIR AIR<br />

----7- ~ ~<br />

CJJTlET<br />

]ILET<br />

CUTLET<br />

FlLTEl<br />

Cf'-5<br />

Fll...lER<br />

CP-S<br />

All II<br />

TO I>JIt II ClUE<br />

ElCWUST<br />

~[]]]<br />

~<br />

iiS-i-60<br />

115-1-00<br />

ALL PNELMATIC CONTROL LINES ARE 1/4' 0.0.<br />

f---"-,---::=O:...:,,O-..:..;N-=...;OT,-S=C'"'-"AL=E'----=:-t----.---<br />

---i_J:l_B..,IO_---I GENERAL AR RA NGEMENT<br />

ALL lJn-elSI()G JJ1E IN IhO-ES<br />

ORA WING<br />

-$- -E}- f--+<br />

REy ---OESCRI--PTl-OH----t-­ t--'''-T-E---i~ Conserv AIR~T"""'rol""'~<br />

rRtU:CTI()I THlI\O #0.£ BY '-"" ",~'~ ~...... VV'v~<br />

UUSS Onel\ilSC 5I'£CIFlEl THIS [RA1JlI(; IJIO Sf'ECIFIC",T1GlS ME HE I'R(l'ERTI IF I'lEU1ATECH SCALE, _ DRA'vIING NO. REV.<br />

TCl..£IW(:ES<br />

DC. .I.I(J IIAY lOT IE CXJ'IH) te'RCDJCED, eft BE U5HJ IN IoIl-U.E CR<br />

ClIK3ffi()G +/- V~tl ((l.'\1wnl IN rMT. loS " &SIS Fal iE;IGN. w.K..FACTUlE. eft SALE \IllIOJT MC- 1()95 00<br />

Nn..E _ +/ - \. f'8MSSUJII FIDl f'1€U1,', TECH DC. t:J


6<br />

---<br />

I:EY<br />

PART NO.<br />

1. 37-199<br />

2. 37-197<br />

3. 37-202<br />

4. 37-205<br />

s. 37-73M-SRI95<br />

6.. 37-218<br />

7. 37-2 19M5 19S<br />

a 37-151<br />

9. 37-241<br />

Ie. 37-233<br />

11. 37-231<br />

12. 37-237<br />

13. 37-28<br />

14. 37-223<br />

IS. 37-221<br />

16. 37-208A<br />

17. 37-201M<br />

18.<br />

19.<br />

6eL.-esM<br />

37-1988<br />

01986<br />

L-1l49<br />

DESCRIPTION<br />

CAP<br />

VALVE SPRING<br />

VALVE a-RING<br />

CAP a-RING<br />

.-EAO<br />

RETAINING RING<br />

DOME<br />

SPRING<br />

PUSHUT FASTEJI::R<br />

Slft'ORT<br />

DIAPl-RAGM<br />

HOUER<br />

O-RING<br />

STEM O-RING<br />

RETAINERO x VI6W<br />

PILOT ~<br />

STEM<br />

SCREW<br />

VALVE<br />

ALLEN PLUG<br />

LABEL<br />

SW-ASSEMBLY on<br />

I<br />

I<br />

I<br />

I<br />

I<br />

1<br />

1<br />

1<br />

I<br />

1.37-237<br />

DIAPI-RAGM I<br />

ASSEMBLY I<br />

1<br />

1<br />

1<br />

I<br />

1<br />

A37-198BM 1<br />

VALVE 1<br />

ASSEMBLY<br />

1<br />

4<br />

4<br />

E£JEiJ------0<br />

NOTES,<br />

l. LUBRICATE DOME \.11TH PARKER<br />

a-LUBE PRIOR TO AN[) AFTER<br />

INSTALLAnON OF PISTON.<br />

2. ALL DIMENSIONS ARE IN INCHES<br />

DO NOT SCALE<br />

+ -E3­<br />

rRO..ECTlOI ~ NQ.£<br />

INLET<br />

1-1/2' NPTCF) 1--_-1<br />

1@ @jS.00<br />

II<br />

~r_0 ~.-------rr-----..---r' __,<br />

~<br />

SERVO SIGNAL<br />

1/4" NPTCF)<br />

OUTLET<br />

1-1/2' NPT(Fl<br />

CF1200 ASSEMBLY ORAWlNG<br />

f------t------------+---+----j~\Conserv AIR~T<br />

rol",.,,~<br />

RE DESClUPTIOH BY DATE / --.,,'~ ~ , VV'V~


Ci37 [ 3.<br />

~<br />

7<br />

KEY PART NO. DESCRIPTlON SUB-ASSEMBLY OTY<br />

l. 37-93 O-RING 2-[/8 ID x 1/81,.1 I<br />

2. 37-92 a-RING 1-1/4 10 x 1/8\.1 1<br />

-<br />

37-84 VALVE. A37-84<br />

~<br />

4. 37-87 VALVE SEAT I<br />

17 5. 37-81-2 HEAD 1<br />

6. 37-90 a-RING 5 IO x l/8W I<br />

2<br />

7. 37-91 a-RING 3-7/8 10 x 3/161,..1 2<br />

8. 37-82t'F DOME (TEFLON eOA TEDJ 1<br />

9. 37-8311 PISTON<br />

~ I<br />

3<br />

la. 37-191 BIAS SPRING I<br />

11. 37-98 O-RING 1/4 ID x 1/81,../ 1<br />

4<br />

r"I<br />

12. 456-11 BREATHER ELEMENT 2<br />

L-'<br />

13. --­ ----­ -­<br />

16 14. 37-99 RETAINING RING<br />

1<br />

~ 15. 130-21 O-RING 1/1 10 x 1/161,.1 1<br />

16. 37-89 VALVE STEM I<br />

17. 37-198 VALVE SPRING I<br />

18. 37-85F CAP (TEFLON COATEDJ I<br />

19<br />

19. L-1148 LABEL<br />

I<br />

2a. a 1986 ALLEN PLUG 4<br />

~<br />

\J<br />

~~I<br />

I<br />

@<br />

IN<br />

:~<br />

~/<br />

v-®<br />

if~v® /' ~<br />

~<br />

I<br />

"....<br />

~t-"<br />

~<br />

c::::c:::::J<br />

t<br />

SERVO SIGNAL<br />

114' NPTlF)<br />

NOTES,<br />

I. LUBRICATE DOME \.lITH PARKER<br />

a-LUBE PRIOR TO AND AFTER<br />

INSTALLATION OF FIST ON.<br />

2. ALL DIMENSIONS ARE IN INCHES<br />

DO NOT SCALE<br />

AI...J.. D~~~~~l!l1lOES<br />

0<br />

It-LET<br />

OUTLET<br />

2" NFTCF) 2' NFTlFJ<br />

e:t><br />

ct><br />

5.75<br />

, /'<br />

I<br />

t<br />

11<br />

~ /<br />

7<br />

rJ;638<br />

9<br />

~I<br />

II)<br />

I<br />

lel<br />

""-­=:>/1<br />

INLET<br />

r<br />

OUTLET<br />

2' NFTIF) 2' NFTIFJ<br />

@<br />

@<br />

8<br />

1<br />

8.00<br />

IN<br />

OUT<br />

5.00 I I 5.00<br />

J<br />

LL~<br />

.KlB to.<br />

~ -dal<br />

ADDEO DE~lPTlONS TO ITEMS 8. 18 DJH 4-14-94<br />

t<br />

SERVO SIGNAL<br />

1/4' NFTIFJ<br />

CF 1600RS ASSEt"IBL Y ORA WING<br />

~\ConservAIR~<br />

PRlA.ECTIOli THIRD NQE<br />

REV DESCRIPTION B1 DATE TecIloologles<br />

\JlESS OTl£R'WISE SI'ECIFIEO HilS ou.loIlI«' AND SPEClFICHI()15 ME lIE I'Ra'ERlY IF f'NEU1AlECH SCALf, -<br />

TCl...El\AlCES<br />

lJC. All) !\AT t()T EE CO"IEO. REf'ROCUE), (»{ BE USEll IN \l1O..E III<br />

IAPRVU B1, (J;;1 !DRA\.IING NO. REV.<br />

-/- v~'" (d_ IN PART. 1>5 A BASIS FOR CESIGN. IoWLFAClUIE. ()l SALE 'w'IIH:XJT<br />

OJ/EIlSIOIlS _<br />

NlCLE -/-1' I'SlMISSION F!IO'i f'IEUo1ATECH INC.<br />

DAlE" 1-2'HH IDRAW'N BY, B.JS IHOA - 1161 0 1


8,---- -----,<br />

SERVO<br />

(MUST BE BUBBLE TIGHT<br />

TO CONTROL VALVE)<br />

r----;GAUGE<br />

3 6 G<br />

F<br />

S<br />

3<br />

0,0-5,0<br />

G<br />

0,0-5,0 VDC<br />

INPUT SIGNAL<br />

VDC<br />

SERVO SIGNAL<br />

EXHAUST<br />

AIR IN<br />

6<br />

I<br />

I<br />

(+ )S • (- )G •<br />

(+ )F<br />

•<br />

DIGITAL ADJUSTMENT<br />

INPUT SIGNAL<br />

r--<br />

~<br />

IN­<br />

IN+ ~<br />

~<br />

2 V+<br />

15 VDC<br />

1 GND ~<br />

00,0-99,9% 4 0-15 VDC<br />

0-150 PSrG<br />

~<br />

3<br />

~<br />

I--­<br />

~<br />

The ServMat1c poppet valves maid require cleaning if residue accumulates in<br />

the valves, Before cleaning the ServMatic circuit board, disconnect the power<br />

source and remove from the electrical enclosure, Cleaning of the poppet<br />

valves should be done on a clean dr\:J surface using a clean cloth,<br />

CAUTION: Each poppet valve is frequenc!,j tuned, If the diaphragm or metal<br />

O-ring is damaged, or lost, the valve will need to be rep laced,<br />

r--::-:---::::O:::::O=N=OT~SC:_:_;;AL:;:_:;E~:_t____,__---------+_-KJ-B___,NO___" ------j SERV MATIC CCiNT RCiL [lIAGRAM<br />

ALL Dil'E~lCJNSrME~~iN<br />

INCfi::S<br />

-$- --E3­ 01 ADDED CLEANING NOTE DJt1 9 17-96 ~\ConservAIR\~<br />

PR~cmlM TH~NoIGLE REV DESCRIPTION BY DA TE ./ -~_.'/~ J Tochnotogles<br />

lM..ESS OT~ISE SPEClFlEO THIS DRA.....ING AND SPECIFICATWNS ARE THE PROPERTY OF PNElA'4ATECH SCALE - I APRVD BY, .' ~. lORA WING NO, IREV,<br />

TOLERANCES INC, AND 'lAY NOT BE C


Cl'l<br />

DIGITAL ADJUSTMENT CHART<br />

160<br />

140<br />

120<br />

-G'<br />

CI) 100<br />

e:,<br />

~<br />

;::,<br />

en<br />

en<br />

....<br />

ll..<br />

4)<br />

4) 80<br />

~<br />

.c<br />

en<br />

is<br />

(,) 60<br />

40<br />

20<br />

o<br />

V<br />

/<br />

/<br />

/' /<br />

/<br />

V<br />

/<br />

/<br />

./'/<br />

/<br />

00.0 10.0 20.0 30.0 40.0 ~o.o 60.0 70.0 80.0 90.0 99.9<br />

Digital Adjustment<br />

• t. .." 0 d- .. -p.<br />

/<br />

V<br />

/


10<br />

PRESSURE RESET OPTION for Manual Bypass VC's<br />

The Pressure Reset option allows the operator to<br />

change the I/C discharge setting via a local or<br />

remote switch.<br />

When the Pressure Reset switch is in the "on" position<br />

the Pressure Reset digital adjustment provides<br />

the control signal. In the "auto" position a remote<br />

switch must be used to activate the Pressure Reset<br />

option. The main digital adjustment and Pressure<br />

Reset digital adjustment are set the same way as<br />

described in the Start Up & Operation section.<br />

PRESSURE RESET OPTION for Auto Bypass IIC's<br />

The Pressure Reset option allows the operator to<br />

change the I/C discharge setting via a local or<br />

remote switch.<br />

REMOTE I LOCAL CONTROL OPTION for E Series<br />

Intermediate Control<br />

When the control panel selector switch is in the<br />

local position, use the digital adjustment to set the<br />

desired I/C discharge pressure.<br />

PRESSURE RANGE 0-150 psi<br />

When the control panel selector switch is in the<br />

remote position, a customer supplied 4-20 mA<br />

signal sets the desired I/C discharge pressure. A<br />

pressure transmitter may be installed on the I/C's<br />

outlet header to provide the process variable for a<br />

PID type control algorithm.<br />

INPUT SIGNAL 4-20 rna<br />

INPUT IMPEDANCE 625 ohm<br />

INPUT CURRENT LOOP POWER 15 vdc min.<br />

PRESSURE RANGE 25-125 psi<br />

When the Pressure Reset switch is in the "on" position<br />

the Pressure Reset digital adjustment provides<br />

the control signal. In the "auto" position a remote<br />

switch must be used to activate the Pressure Reset<br />

option. The main digital adjustment and Pressure<br />

Reset digital adjustment are set the same way as<br />

described in the Start Up & Operation section.<br />

A time delay relay is used to delay the pressure<br />

switch from triggering a low pressure alarm when<br />

switching from Pressure Reset mode to normal<br />

mode. <strong>Inc</strong>rease the delay time if the low pressure<br />

alarm activates prematurely.<br />

The Pressure Reset low pressure alarm is factory<br />

set at 50 psig. See Start Up & Operation section 5<br />

and 6 for procedure to change the Pressure Reset<br />

alarm setting. Note: the Pressure Reset option<br />

must be engaged to change the alarm setting.


~ .. ;~ .. 'i ..<br />

IV. TROUBLE-SHOOTING GUIDE<br />

SYMPTOMS<br />

A. Low IIC discharge pressure.<br />

SeNo gauge reads zero.<br />

CAUSE<br />

Pneumatic control tubing is leaking or<br />

damaged. (SeNo line is extremely sensitive to<br />

leaks.)<br />

REMEDY<br />

.:....::..====-.::..._---------­<br />

Check for leak and repair as needed.<br />

B. High IIC discharge pressure.<br />

Control modules on header are stuck closed,<br />

internally leaking.<br />

SeNMatic is defective (see ServMatlc drawing).<br />

Auto bypass valve is open.<br />

Manual bypass valve is open.<br />

SeNMatic is defective. (see ServMatic drawing).<br />

Remove auto bypass valve control line to<br />

open bypass (caution: line is pressurized and<br />

will continuously vent air). Close control<br />

module isolation ball valves. SeNo gauge<br />

should increase in pressure. Check for leak<br />

and repair as needed. Open isolation ball<br />

valves. Reattach auto bypass control line.<br />

Open the manual bypass located on the IIC<br />

header. Close control module isolation ball<br />

valves. SeNo gauge should increase in pressure.<br />

Check for leak and repair as needed.<br />

Open isolation ball valves. Close the manual<br />

bypass.<br />

ServMatic test points F, G should read<br />

0-5 VDC for Digital Adjustment setting<br />

00.0-99.9%. Test points S, G should read the<br />

same as F, G. Clean, repair or replace.<br />

Inlet and outlet gauges read the same pressure.<br />

Check if bypass solenoid is closed<br />

andlor deenergized. Repair or replace the<br />

bypass solenoid. Check if there is sufficient<br />

pressure to close the auto bypass valve.<br />

Repair or replace the bypass actuator.<br />

Inlet and outlet gauges read the same pressure.<br />

Close the manual bypass.<br />

ServMatic test points F, G should read<br />

0-5 VDC for Digital Adjustment setting<br />

00.0-99.9%. Test points S, G should read the<br />

same as F, G. Clean, repair or replace.<br />

Control modules are stuck open, relieving<br />

excessive air.<br />

Check modules for contamination. Clean,<br />

repair, or replace.<br />

.....<br />

.....


"'""<br />

IV. TROUBLE-SHOOTING GUIDE (Cont.)<br />

....<br />

IV<br />

SYMPTOMS<br />

..=.C.:....:A=U.=S=E<br />

_<br />

REMEDY<br />

C. Low I/C discharge pressure in alarm<br />

mode.<br />

Auto bypass valve is closed.<br />

Check if bypass solenoid is open and/or energized.<br />

Repair or replace bypass solenoid.<br />

Bypass valve is sticking to its seat. Clean,<br />

repair, or replace bypass valve. Bypass actuator<br />

is defective. Repair or replace bypass<br />

actuator.<br />

D. Control modules exhaust excessive air<br />

while IIC in the alarm mode.<br />

Check valves are leaking.<br />

Check valves for contamination. Clean, repair,<br />

or replace.<br />

Control modules are stuck open.<br />

Check modules for contamination. Clean,<br />

repair, or replace.<br />

E. No I/C control panel power.<br />

Fuse is blown.<br />

Replace<br />

Disconnect is defective (if option included).<br />

Repair or replace<br />

F. Unstable discharge pressure.<br />

Inlet air pressure is within 4 psig of discharge<br />

air pressure set point.<br />

Pneumatic "servo" control line and/or fittings<br />

are leaking. This line should be bubble tight.<br />

ServMatic is defective. (see ServMatic drawing).<br />

Control modules are contaminated and/or<br />

have torn or cracked o-rings.<br />

<strong>Inc</strong>rease inlet air pressure and/or decrease<br />

discharge air pressure set point.<br />

Check for leak from ServMatic circuit board to<br />

each control module. Repair leak.<br />

ServMatic test points F, G should read 0-5<br />

VDC for Digital Adjustment setting 00.0­<br />

99.9%. Test points S, G should read the same<br />

as F, G. Clean, repair or replace.<br />

Clean, repair, or replace (Note: for CF1600<br />

control module, replace o-ring 130-21.)<br />

e ~


I<br />

~E------41.5"------­<br />

EJ<br />

23,0"<br />

AIR<br />

------<br />

IN<br />

AIR<br />

--<br />

OUT<br />

®<br />

1. 2" Control Module<br />

2, 2" Ball Valve<br />

3. 2" Union<br />

4, 2" Check Valve<br />

5, 3" Header<br />

6, 1/4" NPT Cou ling<br />

7, 2" Butterfl~ Valve<br />

8, 2" Half Coupling<br />

9, 3" 150# R.Ft Flange<br />

Note:<br />

1. Depth: 15"<br />

2. Approximate Weight: 170 LBS.<br />

3, A11 Dimensions Are In <strong>Inc</strong>hes<br />

\<br />

~N:~Do:rut~I~EE~~-----------I-.XJ-B-.IO---1E3-2C2A2 WELDED<br />

IMENSICtlS .... +/: 1/11n 01 AIUJ5TED D1I'ENSJIJIS AS BULT lUI 3-2-95 Intermedl te Control<br />

.•. +/ 4mm ~Xl \/'::::'--/<br />

HOLE ~. +/-1" REV DESCRIPTION BY DATE ~\Conserv AIR~~


~================:;==r==========::::::;::======:::;=:::::;::;l<br />

KEY DESCRIPTION SUB-ASSEMBL Y QTY<br />

1. O-RING 2-lIS ID x liS'" 1<br />

r-=2 ::c..'-+-=O:..--.:....:R;::c:.1N.:.::G:........::.,l--=1:..-/.....;.4.....;.I:..=D,---,-,x......:...1/....;;S.....;."'..--.., C-116 1<br />

3. O-RING 5 In x liS'" VAL VE 1<br />

4 :"-.--+-=O'---R':""IN-G-3--7-/-S-I-D-x-3-/-16-",---I 0 -RING 2<br />

5. O-RING 114 In x liS'" KIT I JA~~E 1<br />

r-=6:..:...-+-=O:..--.:....:R::..:.IN.:.::G:..-:..:1I_4~I=-D -=x-,----"l,;..../::..:16:....:."'=-----+__--1 REPAIR 1<br />

7. VALVE KIT 1<br />

S. VALVE SEAT 1<br />

9. RETAINING RING 1<br />

10. VALVE STEM 1<br />

11. VAL VE SPRING 1<br />

12. HEAD<br />

13. DOME (TEFLON COATED)<br />

14. PISTON<br />

15. BIAS SPRING<br />

16. CAP <br />

17. ALLEN PLUG 4<br />

_IN__~<br />

INLET<br />

2' NPT<br />

r 6.13<br />

1156]I<br />

[ I ] 1<br />

~=<br />

I<br />

,.....,<br />

OUTLET lJ)<br />

2' NPT '-'<br />

r<br />

INLET OUTLET<br />

2' NPT(D<br />

r<br />

2' NPT


7,0<br />

NOTES:<br />

AIR IN AIR OUT 1. DEPTH 8,0"<br />

2. ALL Dlt'IENSIONS ARE<br />

IN INCHES<br />

~\C_on5ervAIR\~<br />

, ,,,,\.., ----"-----J,..,} Technologies<br />

20.0<br />

Power Bypass Low Pressure<br />

· I On I I Ready Alarm/Reset<br />

"" /<br />

0 "- }tJ" ©<br />

/<br />

Power<br />

I Off On<br />

@<br />

Hasp<br />

16,0 ---------=;>~I<br />

NEMA 12 ENCLOSURE WITH HINGED DOOR<br />

AND LOCKABLE HASP<br />

mN:~DOt~~~IijEEs 02 flEHO't13) NOTE FROM PANa :..':+-97 LOW PRESSURE CONTROL PANEL<br />

IMENSIOOS .... +/-I/1ln<br />

ARRANGEMENT<br />

... +/-4mm 01 CHANJ8) f"O'WER C»I / CFF LAllEl D-H 11-29-93 r:::---/<br />

HOLE .... +/_1° REV DESCRlPTION BY DIITE ~\COn5erV AIR\~<br />

_r---l<br />

IS ORAWOO A/() SPECIFICATIONS ARE nE P~TY IF<br />

+ ---c.::::.::r- TECH ItC ANO ~y NOT BE OO'IBl. REPROOlX::Bl. ~ BE SCALE. - APRIIO BY, ORA'WING NO. REV.<br />

-$ _<br />

aJ IN WHOLE O~ IN f'A~T. /IS A BASlS Fe« DESIGN, M~AC- PA 10018 02<br />

PIlOJECTIC»II THIRD AN3LE • CR SALE WITI-D.JT PRICR PERMISSION FROM f'IIELHATECH INC. DATE. 8-21-92 DRAWN BY, B.L. - tJ


AIR IN BYPASS SERVD AIR OUT<br />

~<br />

2 PORT<br />

20,0<br />

...<br />

EXHAUST<br />

PRESSURE<br />

I -----+------+---J'<br />

SIJITCH<br />

~:=:=:=:±==~--­<br />

ServHotlc<br />

I'<br />

I'<br />

I I<br />

I'<br />

I' ,I<br />

,I CONTACT. CONTACT [R]<br />

BlOCK<br />

BlOCK<br />

,I ITDJITDJ 0<br />

Ii<br />

_-J.j<br />

DIGITAL<br />

ADJUSTMENT<br />

i----------------l<br />

CONTROL<br />

RELAY<br />

FUSE-O.5A<br />

DGROUND 1<br />

TERMINAL BLOCK<br />

I.<br />

"<br />

16,0<br />

sou - SERVO SOLENOID VALVE<br />

SOL2 - BYPASS SOLENOID VALVE<br />

, NEMA 12 ENCLOSURE VITH HINGED DOOR<br />

AND LOCKABLE HASP


115V-IPH-60HZ<br />

L1<br />

I<br />

I<br />

I<br />

GND<br />

i<br />

I<br />

I<br />

/ '\.<br />

POler On Light<br />

RtA-fIJ<br />

Servo Solenoid Vo.lve<br />

LOl Pressure Light<br />

2<br />

Bypo.ss Solenoid Vo.lve<br />

BypllsS Reo.dy Light<br />

RIB-fIJ<br />

EXHAUST<br />

SERVO<br />

AIR IN<br />

. 12<br />

+<br />

PO'w'ER<br />

SOURCE<br />

15VDC<br />

13<br />

CIRCUIT<br />

BOARD<br />

4<br />

G)<br />

®<br />

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