Model SD Scale Diverter Valve
Installation, Operation
& Maintenance Manual
Revision Date September 14, 2000
© MAC Equipment, Inc., 1997
PO. Box 205
Sabetha, KS, 66534
Sales & Parts
888-821-2476 (U.S.A. & Canada)
816-891-9300 (International)
SD Scale Diverter Valve Operator Manual
Do not attempt to operate or maintain this piece of equipment until
you have read and thoroughly understand all of the safety
information contained in this manual. All such information must be
taken seriously. This airlock contains moving parts and potential
pinch points which can cause serious injury or death. If you do not
understand any part of this manual, seek assistance from your
supervisor or call MAC Equipment Inc. before operating this
equipment.
NO haga funcionar este equipo hasta haber leido y comprehendido
el contenido de este manual. Si aiguna partre del contenido del
manual queda sin comprehender, notifiqueselo a su supervisor.
Este manual contiene instrucciones importantes en cuanto al
anterimiento, uso, y funcionamiento sequros de este producto. El
no seguir las instrucciones contenidas en este manual podria
ocasionar lesiones graves.
Revision May 15, 1998
I-a
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Table of Contents
LIST of FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - c
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document Scope & Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer/Owner Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling and Storage of Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-2
1-3
1-3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Signal Words and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Lockout-Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Hazard Review & Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Crush/Pinch Point Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Compressed Air Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Automatic Start Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Warning Decals & Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
PRODUCT FEATURES & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Scale Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Scale Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-1
5-1
5-2
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-1
6-2
Revision May 13, 1998
I-a
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Normal Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Position Proof Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeve, O-Ring and Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling the Scale Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-assembling the SD Scale Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-1
7-1
7-1
7-2
7-4
7-4
7-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requesting Service Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-1
8-2
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...........................................................
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-2
9-3
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
Supporting Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
MicroSwitch Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Skinner Solenoid Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
Operator Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
Revision May 13, 1998
I-b
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
LIST of FIGURES
Figure 1-1 Scale Valve Lifting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Figure 2-1 Air Line Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Figure 2-2 Electrical Power Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Figure 2-3 SD Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Figure 4-1 SD Process Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Figure 5-1 Mounting a SD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Figure 5-2 Flex Hose Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Figure 7-1 SD Valve Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Figure 7-2 SD Exploded Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Figure 7-3 Transition Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-4 Trim SD Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-5 Lubricating Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-6 Installing O-Ring Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-7 Insert Shaft into Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-8 Protect O-Ring Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-9 Silicone Blade Shaft Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-10 Seat SD Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-11 Insert Groove Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-12 Silicone Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-13 Position Polyurethane Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-14 Lubricate Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-15 Tighten Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
Figure 7-16 Attach Adapter Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
Figure 9-1 SD Exploded Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2
Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Revision May 13, 1998
I-c
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
INTRODUCTION
Chapter 1
GENERAL
INTRODUCTION
Document
Scope &
Purpose
Congratulations on your selection of a MAC SD Scale Diverter Valve.
We know you had a choice when making this purchase and
appreciate your confidence in MAC Equipment, Inc.
This document describes the installation, operation and maintenance of
the MAC SD Scale Diverter Valve. It is part of a larger information
packet that includes the following:
z This manual (printed version)
z Manufacturer’s documentation for accessories and options
This manual is not intended to provide instruction on specific
applications nor on the safety practices common to your industry.
CUSTOMER/OWNER
RESPONSIBILITY
Revision May 13, 1998
This SD Scale Diverter Valve is a component in a process stream that
works together with other components to form a complete system. It is
not intended to operate as a stand-alone device. SD Scale Diverter
Valves have been used for some applications that may not be familiar to
the MAC representative who designed or sold this component.
Therefore it is critical that the owner of this scale diverter valve:
z Has a clear and documented understanding of the process
this scale valve is being used in and of any resulting hazards
or special requirements arising from this specific application.
z Allow only properly trained and instructed personnel to install,
operate or service this equipment.
z Maintain a comprehensive safety program involving all who
work with this valve and other associated process equipment.
z Establish clear areas of staff responsibility, e.g. operation,
set-up, sanitation, maintenance and repairs.
z Provide all personnel with the necessary safety equipment.
z Periodically inspect the equipment to insure that the safety
devices are in place and functioning, that all safety
instructions & warning labels are intact and legible and that
the equipment is in good working order.
z In addition to the operating instructions, observe and enforce
the applicable legal and other binding regulations, national
and local codes.
z Install the scale diverter valve in the process stream in
accordance with the guidelines outlined in the chapter titled
“Installation”.
1-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
INTRODUCTION
Chapter 1
OPERATOR
RESPONSIBILITIES
As the person with the most to gain or lose from working safely, it is
important that you work responsibly and stay alert. By following a few
simple rules, you can prevent an accident that could injure or kill you or a
co-worker.
z
z
z
z
Disconnect, lockout and tagout electrical and compressed air
sources and bleed off residual air before inspecting, cleaning,
servicing or repairing the scale valve.
Do not operate, clean or service this valve until you have read
and understood the contents of this manual. If you do not
understand the information in this manual, bring it to the
attention of your supervisor or call MAC Equipment for
assistance.
Understand and follow the safety practices required by your
employer and this manual.
PAY ATTENTION to what you and other personnel are doing
and to how these activities may affect your safety.
Failure to follow these instructions may result in serious personal injury
or death.
Revision May 13, 1998
1-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
INTRODUCTION
Chapter 1
RECEIVING YOUR
EQUIPMENT
As soon as the SD Scale Diverter Valve is received, it should be
carefully inspected to make certain the unit sustained no damage during
shipment and that all items on the packing list are accounted for. All
damage or shortages should be noted on the Bill of Lading. The
purchaser must take immediate steps to file reports and damage claims
with the carrier. All damages incurred during transit are the responsibility
of the common carrier if the equipment was shipped FOB. Ownership
passes to purchaser when the unit is loaded and accepted by carrier.
By law, any claims for in-transit damage or shortage must be brought
against the carrier by the purchaser.
HANDLING AND
STORAGE OF YOUR
EQUIPMENT
If the valve is not going to be installed soon after arrival, it should be
stored in a dry location to protect against rust and corrosion.
The SD Scale Diverter Valve is shipped from the factory mounted on a
heavy shipping skid and with the inlet and outlet ports covered to prevent
foreign materials from entering the scale valve during shipping. It is
recommended that the valve remain bolted to the skid with the inlet and
outlet ports covers in place until just prior to installation.
Transport the valve from the unloading site to the installation or storage
site by using a forklift or hand-truck to pick it up by the skid. After the
valve is removed from the skid, it should be lifted using two heavy lifting
straps securely fastened and tied off around the valve body. See Figure
1-1 below for position of the lifting straps.
Lifting Strap Locations
Figure 1-1 Scale Valve Lifting Locations
Revision May 13, 1998
1-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
SAFETY INFORMATION
Do not attempt to operate or maintain this piece of equipment until
you have read and thoroughly understand all of the safety
information contained in this manual. All such information must be
taken seriously. If you do not understand any part of this manual,
seek assistance from your supervisor or call MAC Equipment Inc.
before operating this equipment.
NO haga funcionar este equipo hasta haber leido y comprehendido
el contenido de este manual. Si aiguna partre del contenido del
manual queda sin comprehender, notifiqueselo a su supervisor.
Este manual contiene instrucciones importantes en cuanto al
anterimiento, uso, y funcionamiento sequros de este producto. El
no seguir las instrucciones contenidas en este manual podria
ocasionar lesiones graves.
Introduction
Every year, accidents in the work place injure or kill people. Although it
may be impossible to prevent all accidents, those involving SD Scale
Diverter Valves are completely preventable with the right combination of
training, operating practices, safety devices and operator vigilance. The
purpose of this safety section is to educate valve users about hazards
and unsafe practices, and to recommend hazard avoidance techniques.
Signal Words and
Symbols
It is very important that operators and maintenance personnel
understand the words and symbols that are used to communicate safety
information. Signal words, their meaning and format have been
standardized for U.S. manufacturers and published by ANSI. The
European Community (E.C.) has adopted a different format based on
the International Standards Organization ( I.S.O.) and applicable
machinery directives. Both formats are presented below. Graphic
symbols are not standardized, but most manufacturers will use some
variation of the ones seen in this manual. The signal words and symbols
used in this manual or on the scale valve are described below.
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury and/or property damage.
Revision May 13, 1998
2-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
Provides additional information that the operator needs to be aware of to
avoid a potentially hazardous situation.
Mandatory Lockout Power Symbol. Disconnect, lockout and tagout
electrical and compressed air sources and bleed off all residual air
before inspecting, cleaning or performing maintenance on this scale
valve.
Mandatory Lockout Tagout Action Symbol (I.S.O. format). This symbol
instructs the operator to disconnect, lockout and tagout all electrical
power and compressed air sources and bleed off all residual air before
inspecting, servicing or cleaning a scale valve.
International Safety Alert Symbol. The exclamation point (!)
surrounded by a yellow triangle indicates that an injury hazard exists.
However, it does not indicate the seriousness of the potential injury. An
exclamation point (!) is used with the DANGER, WARNING and
CAUTION warnings. When used in conjunction with these symbols, the
potential injury is indicated.
Compressed Air Hazard Symbol. This symbol indicates that a
compressed air hazard exists and injury could result from contacting an
exposed air stream and flying projectiles. The potential injuries include
puncture wounds to the eyes, face and other body parts, and could
result in blindness.
Electrocution Hazard Symbol. This symbol indicates that an
electrocution hazard exists. Serious injury or death could result from
contacting high voltage.
International Electrocution Hazard Symbol. This symbol indicates that
an electrocution hazard exists. Serious injury or death could result from
contacting high voltage points.
Mandatory Read Manual Action Symbol (I.S.O. format). This symbol
instructs personnel to read the Operator Manual before servicing or
operating this scale valve.
Revision May 13, 1998
2-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
Mandatory Read Manual Action Symbol. This symbol instructs
personnel to read the Operators Manual before servicing or operating
this scale valve.
This symbol indicates that an important maintenance or installation detail
is being described. Special notice should be taken to heed the
instructions to prevent damage to the equipment.
Revision May 13, 1998
2-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
LOCKOUT-TAGOUT
REQUIREMENTS
Disconnect, lockout and tagout electrical and compressed air
sources and bleed off residual air before inspecting, cleaning or
performing maintenance on this valve.
Figure 2-1 Air Line Lockout
Figure 2-2 Electrical Power
Lockout
Control of this equipment must be in accordance with OSHA Standard
1910.147 "The control of hazardous energy (lockout-tagout)". This
standard "requires employers to establish a program and utilize
procedures for affixing appropriate lockout or tagout devices to energy
isolating devices, and to otherwise disable machines or equipment to
prevent unexpected energizing, start-up or release of stored energy in
order to prevent injury to employees".
For further information on lockout-tagout requirements, see your
company's Safety Director or refer to OSHA Standard 1910.147.
Revision May 13, 1998
2-4
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
HAZARD REVIEW &
SAFETY
INSTRUCTIONS
SAFETY
The most common scale valve hazards and their potential injuries are
described below. Although this is not an exhaustive list, it does cover
those hazards which are most likely to be encountered.
Crush/Pinch
Point Hazard
SD Scale Diverter Valves contain moving parts that could crush or
pinch body parts and shear them off. Contact with a moving blade
could amputate fingers, hands, arms or legs.
Crush and pinch point hazards are dangerous. The pinch point hazard
is located inside the SD Scale Diverter Valve and is not exposed during
normal operation.
Crush or pinch accidents can occur when operators reach into a valve
inlet or outlet port and inadvertently contact a moving blade. These
accidents can be prevented by locking out the air supply and bleeding
off residual air in the air cylinder and connected air lines prior to servicing
or inspecting the valve.
Compressed Air
Hazard
Scale valve actuators store compressed air that, if released
uncontrollably, could eject small particles and cause puncture
wounds to the eyes, face or other body parts.
A compressed air hazard is created when compressed air stored in the
actuator or plant air system is released in an uncontrolled manner such
as when disconnecting or cutting an air line. The escaping gas can pick
up and hurl small particles at high velocities. These flying particles can
puncture eyes or skin, causing severe injury. This hazard can be
avoided by locking out the air supply and bleeding the residual air off
slowly prior to servicing or inspecting the scale valve. Always wear
safety glasses, gloves and long sleeve shirts when working on a scale
valve to provide additional personal protection.
Revision May 13, 1998
2-5
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
Electrocution
Hazard
Severe burns or death may result from contact with exposed high
voltage sources.
Electrocution accidents are most likely to occur during maintenance of
the electrical system or when working on or near exposed high voltage
wiring. Solenoids and position proof switches are typically the only
devices found on an SD Scale Diverter Valve that may use high voltage
power sources. This hazard does not exist when the electrical power
has been disconnected, properly locked and tagged out.
Automatic Start
Hazard
This valve may actuate without warning, causing serious injury.
STAY CLEAR.
SD Scale Diverter Valves are usually controlled by an automated system
and may start without warning. However, automatic startup by itself is
not a hazard. Failure to properly disconnect, lockout and tagout all
electrical energy and compressed air sources while inspecting, servicing
or attempting to dislodge material creates this very hazardous situation.
Serious personal injury may result.
Revision May 13, 1998
2-6
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
Safety
Precautions
Do not operate, inspect or service this valve unless the following
safety precautions are in effect:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Disconnect, lockout and tagout electrical and compressed air
sources and bleed off residual air before inspecting, cleaning
or performing maintenance on a valve.
SD Scale Diverter Valves should be operated only by properly
qualified and trained personnel who have read and fully
understand the Operator and Safety Manuals.
All covers must be securely in place.
All warning labels must be in place, visible and legible.
Never reach into a scale valve port while the valve is in operation.
Never reach around a scale valve blade shaft or air cylinder while
it is in operation.
The characteristics of the material being processed must be
known, and appropriate safety measures must be taken to
protect personnel and property. Possible hazards include (but are
not position proofed to): toxicity, high temperatures, explosive
potential, chemical hazard, abrasion hazard, etc. Refer to
applicable Material Safety Data Sheets (MSDS’s) or consult your
supplier for the properties of the material being processed.
Electrical system maintenance should be performed only by
qualified electricians who have specialized training.
Never touch exposed electrical wires without first verifying with a
voltage meter that they are not energized, even after power has
been disconnected, locked and tagged out.
Keep work areas clean and orderly, free of debris, tools, etc.
Operating personnel should wear proper ear and eye protection,
and have secured loose hair, clothing, jewelry, etc.
Be sure that the equipment has been wired and grounded in
accordance with all applicable national and local codes.
Do not operate or perform maintenance on a scale valve while
under the influence of alcohol or drugs.
Failure to follow these safety instructions may result in death,
personal injury, and/or property damage!
Revision May 13, 1998
2-7
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
WARNING DECALS &
GUARDS
SAFETY
This valve has several warning decals in different locations. It is the
owner/operator’s responsibility to maintain the integrity of these decals
and to ensure that all operators of the equipment are aware of the
warnings and understand their meaning. Replacement decals are
available free of charge from your MAC Equipment Service
Representative, or by calling MAC Equipment Inc. at 888-821-2476 (USA
& Canada) or 816-891-9300 (International).
DO NOT attempt to operate this equipment with a warning label that
has been damaged or removed.
Decal Locations
The figure below shows typical locations for safety and other decals on
an SD Scale Diverter Valve. The location of decals on your particular
valve may vary from those indicated. Inspect your valve for locations of
all decals. The decals in the figure are described in the table on the
following page.
Figure 2-3 SD Decal Locations
Revision May 13, 1998
2-8
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
Safety Decals
SAFETY
Examples of the decals provided on the scale valve pictured in Figure 23 are shown below. Locate all the safety decals on your equipment and
know their meaning prior to operating this scale valve. Free replacement
decals are available on request. Ask for Decal Kit P/N 416406.
A
This valve may be remotely
controlled. It can start without
warning unless it is properly
locked out. Do not rely on the
control system for safe lockout.
Properly lockout and tagout all
power sources prior to
servicing or inspecting the
valve!
B
MAC Logo.
Located on
the back side
of the valve
body. Not
shown in
figure 2-3.
Valve actuators store
compressed air. Uncontrolled
release of this air could eject
small particles that cause
puncture wounds to the eyes,
face or other body parts.
Slowly bleed all residual air
prior to servicing or inspecting
the scale valve.
C
Revision September 14, 2000
2-9
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 2
SAFETY
Do not attempt to operate or
maintain this piece of
equipment until you have read
and thoroughly understand all
of the safety information
contained in this manual. All
such information must be taken
seriously. This manual
identifies and suggests actions
that enhance safety. If you do
not understand any part of this
manual, seek assistance from
your supervisor or call MAC
Equipment Inc. before
operating or servicing this
equipment.
D
E
Typical MAC Equipment
nameplate.
Safety Summary
Review this safety section periodically to remind yourself of these
important safety issues. Be aware and do your part to prevent SD Scale
Diverter Valve accidents.
If you remember nothing else, remember this:
Disconnect, lockout and tagout all electrical power and compressed
air sources and bleed off residual air before inspecting, cleaning,
servicing or performing maintenance on a valve.
Following this simple rule every time virtually eliminates all possibilities of
serious injury as a result of a SD Scale Diverter Valve accident.
Revision May 13, 1998
2 - 10
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 3
PRODUCT FEATURES
Scale Valve
Specifications
PRODUCT FEATURES & SPECIFICATIONS
The SD Scale Diverter Valve is designed to provide years of trouble
free service. Key features are:
z Polyurethane liner
z Rugged construction
z Standard plain end connections in pipe or tubing sizes,
optional flanged connections available
z Stainless steel blade & shaft
Minimum
Maximum
-15 “ Hg
15 PSI
Operating Temperature
Range Standard Valve
-40 (F
180 (F
Standard Sleeve
White Cast Urethane
-40 (F
180 (F
Standard O-Rings
Nitrile Rubber (Buna-N)
-40 (F
225 (F
Optional High
Temperature Sleeve
Nitrile Buna-N
-30 (F
250 (F
Optional High
Temperature O-Rings
Red Silicone
-65 (F
400 (F
80 PSI
(60 PSI with
optional oversized
air cylinder)
100 PSI
Differential Pressure
Compressed Air
Requirements
Electrical Requirements
Instrument Air Usage
@ 90 PSIG
Revision May 13, 1998
3-1
Refer to Nameplate Voltage
Less than 1 cubic foot of air per stroke
of the air cylinder
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 3
PRODUCT FEATURES & SPECIFICATIONS
Approximate Weight (lbs)
Model
Cast Iron
Revision May 13, 1998
Stainless
Steel
Port O.D.
Aluminum
inches
SD-25
101
101
54
2-3/8
SD-30
98
98
53
3
SD-35
166
166
97
3-1/2
SD-40
171
171
99
4
SD-45
171
171
99
4-1/2
SD-50
171
171
99
5
SD-55
282
282
204
5-9/16
SD-60
284
284
206
6-5/8
3-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 4
PRINCIPLES OF OPERATION
FUNCTIONAL
DESCRIPTION
SD Scale Diverter Valves are specialized switching devices used in a
pneumatic conveying line. Normally it is used to divert material from a
pneumatic conveying line into a scale hopper.
PROCESS
DESCRIPTION
When actuated, the two separate blades rotate from a horizontal
position to an inclined position. As they do, the direct path through the
valve is closed off and the alternate path through the outlet at the bottom
of the valve opens. Material and air are directed into the scale hopper.
At the same time, convey air is allowed to escape through a second port
on the bottom of the valve and down the conveying line. The figure
below shows the two positions of the blades and the flow lines.
Flow
Direction
Thru Position
Flow
Direction
Divert Position
Figure 4-1 SD Process Illustration
Revision May 13, 1998
4-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 5
INSTALLATION
Inspecting the
Scale Valve
Support
INSTALLATION
This SD Scale Diverter Valve is shipped with internal components
pre-assembled at the factory. However, installation of the valve in the
system is the responsibility of the owner and consists of:
z Inspecting the valve
z Installing the valve on the scale hopper or other hopper
z Connecting the upstream and downstream conveying lines
z Plumbing plant air to the control valves
z Wiring the solenoid and position proof switches
Make an inspection of the SD Scale Diverter Valve before proceeding
with the installation:
1. Remove the packing material. If the valve is mounted on a shipping
skid, leave the skid in place temporarily.
2. Be sure there is no foreign material lodged inside the valve.
3. Be sure the solenoid valve and position proof switches have not
been damaged.
The SD Scale Diverter Valve is supported by the scale hopper. This
hopper and associated support structure must be designed and supplied
by the owner. It must be designed to carry the weight of the valve.
Figure 5-1 Mounting a SD Valve
Revision May 13, 1998
5-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 5
Grounding
INSTALLATION
It is important to provide a ground path from the convey line to the SD
Scale Diverter Valve. One way this can be done is to wrap a ground
wire around the flex hose. The distance between the coils should not
exceed 6 inches. If this is not done, a static charge can build up and
discharge periodically. These sparks could ignite an explosion if the
right conditions are present.
Figure 5-2 Flex Hose Connection
1.
2.
3.
4.
Installation
Steps
Convey Line
Hose Clamp
Ground Wire
Flexible Hose
Only trained and authorized persons should be permitted to install,
service, or maintain electrical components. It is the
buyer’s/installer’s responsibility to ensure that all applicable
electrical codes are met.
Care must be taken when interlocking any type of motion or position
sensing device to the control circuits of upstream and downstream
systems. Failure to fully understand and account for the
requirements of the entire system can create hazardous conditions
resulting in personal injury and/or property damage.
Revision May 13, 1998
5-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 5
INSTALLATION
Disconnect, lockout and tagout electrical power and compressed air
sources and bleed off residual air before installing and wiring this
scale diverter valve.
Procedure
Revision May 13, 1998
The installation steps below assume that the SD Scale Diverter Valve is
being installed on a scale hopper. The procedure is virtually identical
when connecting to other types of hoppers. Connect the valve as
follows:
1. Clean the surface of the mounting flange on the scale hopper.
2. Install the flange gasket on the scale hopper mounting flange. If a
flange gasket is not available, a bead of silicone caulk placed on the
flange surface can be used as a substitute.
3. Lift the valve into the proper position on top of the scale hopper.
4. Insert and alternately tighten the flange bolts until they are secure.
5. Connect the valve to the conveying lines with an intervening flexible
hose. Care must be taken to ensure that there are no loads
transmitted from the convey line to the valve. If there are, these
loads will adversely affect the accuracy of the associated scale
system. All connected convey lines must have rigid structural
supports located within 24" of the flexible hose connection.
6. Connect a bare grounding wire to the convey line and valve.
7. Connect a compressed air supply to the 1/4" NPT port of the
solenoid valve.
8. The compressed air supply should have a lockout compatible valve,
pressure regulator and filter just ahead of the solenoid connection.
9. Connect control wiring to the solenoid valve. Ensure the control
power is of the proper voltage. Refer to the label on the solenoid for
power requirements.
10. Connect control power to the position proof switches.
11. Connect either the N.O. or N.C. contact terminal to the control
system depending on the logic requirements.
12. Energize the solenoid.
13. Confirm that the valve actuates and is in the proper position.
14. Verify that the position proof switch is made and that the proper
signal is being relayed to the control system.
15. De-energize the solenoid.
16. Confirm the valve actuates and is in the proper position.
17. Verify that the position proof switch is made and that the proper
signal is being relayed to the control system.
5-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 6
OPERATIONS
OPERATION
Disconnect, lockout and tagout electrical and compressed air
sources and bleed off residual air before inspecting, cleaning or
performing maintenance on this valve.
Pre-Startup
Checklist
1. Check to ensure that the plant air pressure is between 80 and 100
psi.
2. Verify that the position proof switch position signals correspond with
the actual valve position.
3. Check to ensure that all pneumatic conveying line connections are
tight.
4. Be sure all the warning decals are in place, visible and legible.
Start-up
During the startup phase, process equipment such as SD Scale Diverter
Valves are “dry run” without material to ensure the proper operation and
interaction of the components. Prior to startup, check the following:
1. Energize the compressed air service.
2. Actuate the valve several times to ensure proper operation. If it does
not actuate, refer to the section titled “Trouble Shooting” for
instructions on how to identify and correct any problems.
3. While the system is in operation, locate any apparent air leaks. If
any leaks are detected:
a. Lockout all compressed air sources
b. Fix all of the leaks
c. Re-energize the compressed air sources
Revision May 13, 1998
6-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 6
OPERATIONS
NORMAL OPERATION
Normal Operating
Checklist
Operating Parameter Form
Revision May 13, 1998
Do not operate the SD Scale Diverter Valve unless the following
items have been checked and found to be satisfactory.
1. The valve is properly supported and securely fastened in place.
2. Convey line connections are secure and airtight.
3. The plant air supply at the valve is between 80 psi and 100 psi.
4. All warnings are properly in place, secure and visible.
Use the form on the following page to record system information and
operating conditions once start-up has been completed and the
system is operating normally. Record changes in this information as
they occur. This information will be useful to you and service
personnel when troubleshooting the system or monitoring its
performance.
6-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 6
OPERATIONS
Job Information
Comments
MAC Equipment Job No.:
Customer Purchase Order
No.:
Purchase Date:
Customer Drawing No.:
SD Scale Diverter Valve
Information
Model No.:
Plant Air Pressure:
PSI
Serial No.:
Tag No.:
Operating Parameters
Material Conveyed:
Conveying Line Size:
Line Pressure/Vacuum:
PSIG
HG
User Notes
Revision May 13, 1998
6-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
MAINTENANCE
MAINTENANCE AND
ADJUSTMENT
The SD Scale Diverter Valve is designed to require minimal
maintenance, but regular maintenance intervals are recommended.
However, the ideal interval periods must take into account the
conveyed material properties, air flows and hours in service. Below are
minimum maintenance recommendations.
Monthly
Maintenance
Every 700 operating hours or one month of service, check the
compressed air supply filter and service according to the manufacturer’s
recommendations.
Annual
Maintenance
Every 8600 operating hours or 1 year of service:
1. Check all functions of the SD Scale Diverter Valve.
2. Replace all O-Ring, shaft seals, and Elastomer Sleeve.
3. Rebuild solenoids with the appropriate repair kit.
4. Re-lubricate or replace any worn or non-functional part as necessary.
Revision May 13, 1998
7-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
Adjusting the
Position Proof
Switch
MAINTENANCE
Position proof switches are included on some models. These switches
provide a signal to the control system when the valve is in the through
and diverted position. The signals must be synchronized with the blade
position. To synchronize the signals, the position proof switch arm must
be properly positioned.
Figure 7-1 SD Valve Limit Switch Adjustment
1.
2.
3.
4.
Position proof Switch
Adjustment Screw
Adjustment Arm
Lever Arm
Refer to the following steps to adjust the switch. Each switch must be
adjusted individually.
1. Actuate the valve and verify that it is in the proper position.
2. Loosen the adjustment screw #2 until the adjustment arm #3 turns
freely on the shaft.
3. Move the adjustment arm #3 against the lever arm # 4 as shown.
4. Turn the shaft while holding the adjustment arm against the shaft
until the switch actuates.
5. Tighten the adjustment screw.
6. Actuate the valve several times and verify that the control signal
properly indicates valve position.
7. Repeat the above steps for the other position proof switch.
Revision May 13, 1998
7-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
Air Actuator
MAINTENANCE
The SD Scale Diverter Valve is typically equipped with an air cylinder
actuator. The air cylinder is a critical part of the mechanism that
actuates the internal blades.
The air actuated valves are typically controlled by an automatic control
system. For complete instructions on how to disassemble and
reassemble the air cylinder, refer to the section titled “Disassembling the
Scale Valve” and “Assembling the Scale Valve”.
Revision May 13, 1998
7-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
Sleeve, O-Ring
and Shaft Seal
Replacement
Disassembling
the Scale Valve
MAINTENANCE
The scale valve sleeve, O-Ring and shaft seal components wear out with
use. As a result, these parts must be replaced periodically. The ORings and Shaft Seal should be replaced every time the valve is
disassembled.
Disassembling the SD Scale Diverter Valve is a simple exercise. The
procedure is described below:
Figure 7-2 SD Exploded Assembly
Disconnect, lockout and tagout electrical power and compressed air
sources, and bleed off residual air before working on this valve.
1.
2.
3.
4.
5.
6.
7.
8.
Revision May 13, 1998
Mark the compressed air lines so that they can re-attached to the
same ports.
Disconnect the compressed air lines connecting the cylinder to
the solenoid.
Remove the convey line.
Remove the flange bolts.
Move the valve to a suitable work table.
Remove the retaining clips (11) on the pin (14)
Remove pin (14).
Remove the air cylinder (13).
7-4
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
MAINTENANCE
9.
10.
11.
12.
13.
Revision May 13, 1998
Remove the flange bolts from the adapter section (1) and cone
section (3).
Remove the lever arm (12) from the blade shaft #8.
Remove the two groove pins (9)
Remove the blade (6) from the shaft. Use a rubber mallet to jar
the blade loose from the shaft if necessary.
Drive the shaft (8) out of the body housing (4).
7-5
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
Re-assembling
the SD Scale
Diverter Valve
MAINTENANCE
In order to ensure proper operation of the SD Scale Diverter Valve, the
following procedure must be followed to re-assemble the valve. Refer to
figure 7-2 for valve parts diagram and referencing part numbers.
1. Place the body shaft seal (2) in the groove in
the body. The body shaft seal prevents air from
leaking between the two ports on the transition
body.
Figure 7-3
Transition Shaft
Seal
2. Trim the seal (2) so that the seal
ends are flush with the end of the
groove.
Figure 7-4 Trim SD Shaft
Seal
3. Lubricate the shaft (8) with a thin
film of food grade fluid film.
Figure 7-5 Lubricating Shaft
4. Slide an O-Ring seal (7) over
each end of the shaft.
Position it in the groove near
the end of the shaft (8).
Figure 7-6 Installing O-Ring Seal
Revision May 13, 1998
7-6
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
MAINTENANCE
5. Insert the shaft (8) with blade
groove facing out. Use a screw
driver to gently compress the
body shaft seal (2) so the shaft
will slide over it without
dislodging it.
Figure 7-7 Insert Shaft into Body
6. Use C clamp to guide the shaft (8) into the body hole.
7. Use a screw driver to gently
compress the O-Ring Seal (7) as
it enters the transition housing.
Failure to do this could damage
the O-Ring and cause the scale
valve to leak.
Figure 7-8 Protect O-Ring Seal
8. Place a 1/4" bead of silicone caulk in
the blade groove.
Figure 7-9 Silicone Blade
Shaft Connection
9. Insert the blade (6) into the groove. Seat the
blade by driving a punch into the groove pin
holes.
Figure 7-10 Seat SD
Blade
Revision May 13, 1998
7-7
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
MAINTENANCE
10.
Insert the groove pins (9) in the groove pin
holes. Drive the pins into the shaft until
the ends are flush.
Figure 7-11 Insert
Groove Pin
11.
Place a small bead of silicone over
the shaft (8) as shown at left.
Figure 7-12 Silicone Shaft
12.
Position the sleeve (5) so that the curved
tabs are aligned over the shaft.
13.
Seat the polyurethane sleeve securely on
the body section (4).
Figure 7-13 Position
Polyurethane Sleeve
14.
Lubricate the cone section (3)
so that it will slide easily over
the sleeve (5).
Figure 7-14 Lubricate Sleeve
Revision May 13, 1998
7-8
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 7
MAINTENANCE
15.
Slide the cone (3) over the sleeve. Position the cone so that the
mount brackets are over the shaft.
16.
Insert the bolts in the flanges and
tighten them in pairs, 180( apart.
Figure 7-15 Tighten Bolts
17.
Figure 7-16 Attach
Adapter Section
Revision May 13, 1998
7-9
Position the adapter (1) on the cone (3)
with the mount bracket aligned with the
cone as shown. Bolt these sections
together.
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 8
TROUBLESHOOTING
TROUBLESHOOTING
Requesting
Service Help
If a problem arises, it is recommended that the customer first
troubleshoot the system using the guide in this chapter.
Under some circumstances, service assistance may be required. If it
becomes necessary to request service help, call the MAC Equipment
Service Manager at 877-821-7378 (877-821-SERV) (U.S. & Canada) or
816-891-9300 (International). These numbers are for service help
only. To order spare parts, refer to Chapter 9. If service personnel are
not available to take your call, it will be forwarded to the Engineering
Department.
When calling to request service help, please have the following
information ready:
Essential Information:
MAC Equipment job number (located on the Order Acknowledgment)
Equipment model number(s)
Equipment serial number(s)
Operating temperature
Type of material being conveyed
Occasionally, a service trip may be necessary. There will be a charge
for such a trip unless the problem is under warranty or covered by a prepaid start-up agreement. The Service Department can provide
information on service trip rates and billing procedures.
Revision May 13, 1998
8-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 8
TROUBLESHOOTING
Troubleshooting
Guide
Before inspecting or servicing the SD Scale Diverter Valve, perform
an approved lockout-tagout procedure on the electrical service and
the compressed air sources. Bleed off all residual air.
The following trouble shooting steps should be followed in the order
listed. This systematic approach normally results in the quickest
identification and resolution to the most common problems.
PROBLEM and
SOLUTION
POSSIBLE CAUSE
SCALE VALVE WILL NOT
ACTUATE
Plant air pressure too low
A. Plant air is turned off or locked out at the valve.
B. Plant air pressure at the scale diverter valve must be
at least 80 PSI. Increase the pressure if it is too low.
No control power to the
solenoid
A. Check for proper control voltage at the control panel.
B. If the voltage is OK, check the field wiring.
C. If the voltage is wrong, check the control system and
verify that the logic is correct.
Solenoid valve failed
A. Internal parts of the solenoid are stuck. Check for
debris or water in the valve mechanism and remove
debris.
B. Check the coil for proper operation. Replace if it has
failed.
C. Check for further instructions in the solenoid
maintenance and operating instructions.
Revision May 13, 1998
8-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 8
TROUBLESHOOTING
PROBLEM and
POSSIBLE CAUSE
The valve blade is stuck.
THE SD SCALE DIVERTER
VALVE ACTUATES BUT THE
BLADE POSITION IS NOT
PROPERLY INDICATED TO THE
CONTROLS
The control signal indicates an
incorrect valve position
There is no signal from one or
both of the position proof
switches
Revision May 13, 1998
SOLUTION
A. If the valve has not been actuated recently, the blade
may be stuck in its current position. Tap on the
actuator arm with a rubber mallet to break the blade
loose.
B. Check condition of Elastomer Sleeve. Replace if
worn or torn.
C. Check for material buildup between the shaft and
housing.
A. The position proof switches are wired backward.
Switch the control wiring between the position proof
switches. This is often easier to do at the control
panel.
B. The control logic is incorrect. Reverse the input logic.
A. Check the control power to the position proof
switches. Correct if there is no control power.
B. Check the position of the position proof switch arms.
Adjust the arms to actuate the position proof switch
when the valve is fully actuated.
C. If position proof switch fails to indicate a change of
state even when the position proof switch arm is
manually actuated, the switch has failed. Replace
the switch.
8-3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 9
ORDERING SPARE
PARTS
SPARE PARTS
To order spare parts by phone, dial 888-821-2476 (U.S. & Canada) or
816-891-9300 (International). The following information is necessary
when placing an order for spare parts to help ensure prompt service:
A. Model Number
B. MAC Job Number (or Sales Order Number)
This can be found on the Order Acknowledgment or drawings.
C. Serial Number
This can be found on the serial # plate located on the side of the
SD Scale Diverter Valve.
D. Part Description
E. Part Number
F. Quantity Required
Revision May 13, 1998
9-1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 9
SPARE PARTS
SD Scale Diverter Valve
Parts List
Figure 9-1 SD Exploded Assembly
ITEM
Revision May 13, 1998
DESCRIPTION
1
Adapter Section
2
Shaft Seal
3
Cone Section
4
Body Section
5
Sleeve
6
Blade
7
O-Ring
8
Shaft
9
Groove Pin
10
Position proof Switch Actuator
11
Pin Lock
12
Lever Arm
13
Air Cylinder
14
Clevis Pin
15
Solenoid Valve
16
Position proof Switch
9-2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 9
SPARE PARTS
ITEM
Recommended
Spare Parts List
Revision September 14, 2000
DESCRIPTION
17
Nylon Tubing
18
Position proof Switch Mount Bracket
I
t
e
m
#
Description
15
Solenoid
Nema 4
13
Q
T
Y
SD Scale Diverter Valve
Model
SD-25
& 30
SD-35,
40, 45,
50
SD-55 &
60
1
100533
100533
100533
Air Cylinder
1
100540
100539
351989
6
SS Blade
1
407809
407811
407812
8
SS Shaft
1
308037
308038
308039
7
O-Ring
2
324426
324426
100739
9
Groove Pin
2
304927
304927
390828
5
Sleeve
1
100639
100638
100637
2
(15") Shaft
Seal
1
101641
101641
101641
22
12 “ Nylon
Tubing
1
301131
301131
301131
9-3
Customer
Specified
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
SUPPORTING
DOCUMENTATION
Revision May 13, 1998
REFERENCE
Additional information may be required occasionally for components
such as solenoids, switches etc. Copies of the original manufacturers
manuals are included as part of this manual.
10 - 1
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
MicroSwitch Manual
Installation Instructions for Heavy
Duty Position proof Switches
MOUNTING
All Heavy Duty Limit Switches (HDLS) have exactly
the same mounting dimensions. Mount by either
of two methods: (a) use two #10 screws from the
front, or (b) use two #10-32 UNF screws from the
back. HDLS offers the advantage of front mount
construction. The electrician will find a complete
switch, with no parts missing and ample wiring
space.
WIRING
Use size # 12AWG or smaller
solid or stranded wire to connect
to the pressure type connector
terminals. Spades may be up to
.312" wide, rings up to .312" dia.
With spade or ring type
connections, pre-insulated
connectors or heat-shrinkable
tubing should be used to provide
insulation between terminals.
Circuit diagram is shown on the
nameplate.
Figure 1
It will be easier to wire the
double-pole units by connecting
lead wires to the terminals nearest the conduit
opening first. A grounding screw is located in the
housing near the conduit opening.
With plug-in construction, wiring and conduit
connection is made to the base receptacle. This
feature also reduces downtime, since plug-in unit
can be removed without disconnecting wiring or
conduit.
To mount either switch, merely tighten mounting
screws, tighten plug-in unit or cover screws, and
make sure conduit section is sealed. Use of
sealant (teflon tape, pipe dope, etc.) Is
recommended to seal conduit connection.
Because of moisture condensation problems, it is
not good practice to mount the switch upside down
or at the low point of conduit runs.
Switch units with an indicator light in the cover are
furnished with the lead wires from the light connected
to the normally-open male terminals (#3 and #4)
unless otherwise specified on the order. Wires can
be unsoldered and reconnected to the normallyclosed male terminals or they can be ordered
connected to the normally-closed terminals by using a
modification code (refer to Catalog 40). Always
connect these wires to the same set of terminals
used for the load. Across the normally-open male
terminals (#3 and #4) the light will be On (Fig. 1).
Across the normally-closed terminals (#1 and #2) the
light will be Off.
ADJUSTING INSTRUCTIONS
Actuator head. For application
flexibility, actuator head may be
positioned in any of four
directions. Loosen the four
captive head screws, place head
in the desired position, and then
securely tighten the four screws.
Double Pole
Non Plug-In Type
Revision May 13, 1998
Reversing the roller lever. Except for the offset
roller levers, the roller arm may be reversed to face
the roller to the inside or outside of the arm.
10 - 2
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
3. Referring to Fig. 3, slide cam all the way back so
cam is free to rotate on the shaft.
4. Using a screwdriver or similar tool, rotate cam to
desired actuating position (Fig. 4, 5 and 6).
5. Slide cam all the way forward to its original
position, and close hinged cover.
6. Replace operating head on switch housing and
securely tighten head screws.
Heavy Duty Limit Switches
Positioning Lever. Lever on rotary
actuated units is adjustable through
360( around the shaft. Loosen the
screw with a 9/64 inch hexagon key
wrench, move lever to desired
position and securely tighten the
screw until “teller tab” can no longer
be moved by hand. Then tighten
the screw another to ¼ turn to
assure lever is tight on the shaft.
Hexagon key wrenches are
provided in adjusting tool set
LSZ4005 for this purpose.
F
Adjustable Length
Levers. A hexagon key
wrench is required to
adjust length of adjustable
levers.
Top Roller Plunger.
Position top roller plunger
in desired roller plane by
adjusting the head as
explained under Actuator
Head (see page 1).
Side Roller Plunger. Grasp roller with pliers and
rotate it to desired horizontal or vertical plan.
CHANGING DIRECTION OF ACTUATION
Side Rotary. LSM (center neutral) and LSN
(maintained) listings operate in both directions and
cannot be changed. Listings with the first three
letters LSA, LSH, LSL, LSP, LSU, and LSR may
be changed to operate clockwise, counterclockwise or both. NOTE: Instructions for
adjusting switch operation are cast into the hinged
cover (Fig. 2). To change, follow these steps:
1. Loosen the head screws and remove the
head from the switch housing.
2. On the bottom of the head, insert a
screwdriver in slot provided (Fig. 2) and lift open
hinged cover.
Revision May 13, 1998
10 - 3
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
Top Rotary. Follow these steps to change
operating direction of LSB type switches:
1. Loosen head screws and remove head
from the switch housing.
2. From bottom of head grasp end of pin
plunger and remove pin. It may be necessary to
rotate actuating shaft to expose end of pin
plunger.
3. Refer to Fig. 8 and select correct pin
plunger position for desired direction of actuation.
4. Insert the pin plunger in the position
providing desired direction of actuation.
5. Replace the operating head on switch
housing and securely tighten head screws.
Plug-In Type
Catalog
Listing*
on
Switch
Nameplate
Complet
e Plug-in
Unit Less
Base
Receptacle
Plug-in
Base
Recept.
Only
Operatin
g Head
Only
Contact
Block
(Basic
Switch
Only)
LSA1A
LSZ7A1A
LSZ4001
LSZ1A
LSZ3A
LSA1J
LSZ7A1J
LSZ4001
LSZ1A
LSZ3J
LSA2B
LSZ7A2B
LSZ4002
LSZ1A
LSZ3B
LSB1A
LSZ7B1A
LSZ4001
LSZ1B
LSZ3A
LSC1A
LSZ7C1A
LSZ4001
LSZ1C
LSZ3A
LSC1J
LSZ7C1J
LSZ4001
LSZ1C
LSZ3J
LSD1A
LSZ7D1A
LSZ4001
LSZ1D
LSZ3A
LSD1J
LSZ7D1J
LSZ4001
LSZ1D
LSZ3J
LSD2B
LSZ7D2B
LSZ4002
LSZ1D
LSZ3B
LSE1A
LSZ7E1A
LSZ4001
LSZ1E
LSZ3A
LSE1J
LSZ7E1J
LSZ4001
LSZ1E
LSZ3J
LSE2B
LSZ7E2B
LSZ4002
LSZ1E
LSZ3B
LSF1A
LSZ7F1A
LSZ4001
LSZ1F
LSZ3A
Revision May 13, 1998
LSF1J
LSZ7F1J
LSZ4001
LSZ1F
LSZ3J
LSF2B
LSZ7F2B
LSZ4002
LSZ1F
LSZ3B
LSH1A
LSZ7H1A
LSZ4001
LSZ1H
LSZ3A
LSH1J
LSZ7H1J
LSZ4001
LSZ1H
LSZ3J
LSH2B
LSZ7H2B
LSZ4002
LSZ1H
LSZ3B
LSJ1A-7A
LSZ7J1A-7A
LSZ4001
LSZ1JGA
LSZ3A
LSJ1A-7M
LSZ7J1A-7M
LSZ4001
LSZ1JGM
LSZ3A
LSJ2B-7A
LSZ7J2B-7A
LSZ4002
LSZ1JGA
LSZ3B
LSJ2B-7M
LSZ7J2B-7M
LSZ4002
LSZ1JGM
LSZ3B
LSK1A-8A
LSZ7K1A-8A
LSZ4001
LSZ1KHA
LSZ3A
LSK2B-8A
LSZ7K2B-8A
LSZ4002
LSZ1KHA
LSZ3B
LSL2C
LSZ7L2C
LSZ4002
LSZ1L
LSZ3C
LSM2D
LSZ7M2D
LSZ4002
LSZ1M
LSZ3C
LSN1A
LSZ7N1A
LSZ4001
LSZ1N
**
LSN2B
LSZ7N2B
LSZ4002
LSZ1N
**
LSP1A
LSZ7P1A
LSZ4001
LSZ1P
LSZ3A
LSP1J
LSZ7P1J
LSZ4001
LSZ1P
LSZ3J
LSP2B
LSZ7P2B
LSZ4002
LSZ1P
LSZ3B
LSR1A
LSZ7R1A
LSZ4001
LSZ1R
LSZ3A
LSR1J
LSZ7R1A
LSZ4001
LSZ1R
LSZ3J
LSH2B
LSZ7R2B
LSZ4002
LSZ1R
LSZ3B
LSU1A
LSZ7U1A
LSZ4001
LSZ1U
LSZ3A
LSV1A
LSZ7V1A
LSZ4001
LSZ1V
LSZ3J
LSV1J
LSZ7V1J
LSZ4001
LSZ1V
LSZ3A
LSV5A
LSZ7V5A
LSZ4001
LSZ1V
LSZ3A
LSV8A
LSZ7V8A
LSZ4001
LSZ1V
LSZ3A
* Only the listing portion which determines the replacement part is shown.
Listings with -7A, -7M, or -8A are complete listings.
** Not user-replaceable.
10 - 4
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
REPLACEMENT PARTS
Should your specific switch catalog listing not
appear in this parts list, contact nearest MICRO
SWITCH Authorized distributor or MICRO SWITCH
sales office.
For ease of making switch adjustments which may
be necessary on various switch listings, order
LSZ4005 (lever and switch adjusting tool set).
This set consists of a special 3/32" open wrench
and necessary hexagon key wrenches to adjust all
types of levers.
Hex head screws. If you
prefer to loosen and
tighten lever with a pliers
or screwdriver, order
15PA164-LS (packet of 50
hexhead screws with
screwdriver slot) to replace
screws furnished with the
lever.
LSG3K
LSF1G
**
LSH3K
LSZ1H
LSZ3K
LSH4L
LSZ1H
LSZ3L
LSJ3K-7A
LSZ1JGA
LSZ3K
LSJ3K-7M
LSZ1JGM
LSZ3K
LSJ4L-7A
LSZ1JGA
LSZ3L
LSJ4L-7M
LSZ1JGM
LSZ3L
LSK3K-8A
LSZ1KHA
LSZ3K
LSK4L-8A
LSZ1KHA
LSZ3L
LSL4M
LSZ1L
LSZ3M
LSM4N
LSZ1M
LSZ3M
LSN3K
LSZ1N
**
LSN4L
LSZ1N
**
LSP3K
LSZ1P
LSZ3K
LSP4L
LSZ1P
LSZ3L
LSR3K
LSZ1R
LSZ3K
LSR4L
LSZ1R
LSZ3L
LSU3K
LSZ1U
LSZ3K
** Not user-replaceable
Replacement Levers. To order replacement
levers, order the same part number that is metal
stamped on either lever or lever hub. For other
lever variations, refer to HDLS in Catalog 40.
Non Plug-In Type
Catalog Listing on
Switch Nameplate
Operating Head
Only
Contact Block (Basic
Switch Only)
LSA3K
LSZ1A
LSZ3K
LAS4L
LSZ1A
LSZ3L
LSB3K
LSZ1B
LSZ3K
LSB4L
LSZ1B
LSZ3L
LSC3K
LSZ1C
LSZ3K
LSC4L
LSZ1C
LSZ3L
LSD3K
LSZ1D
LSZ3K
LSD4L
LSZ1D
LSZ3L
LSE3K
LSZ1E
LSZ3K
LSE4L
LSZ1E
LSZ3L
LSF3K
LSZ1F
LSZ3K
LSF4L
LSZ1F
LSZ3L
Revision May 13, 1998
Replacement Parts for gravity return LSS1H,
extra/low torque LST1H and two examples of a
standard size rotary LSA1A type (LSYAC1A with
Viton seals and LSYAB1A low temperature version)
are listed below.
10 - 5
Catalog
Listing
Plug-In
Units Only
Base
Receptacle
Operating
Head
Contact
Block
LSS1H
LSZ7S1H
LSZ4001
LSZ1S
LSZ3H
LST1H
LSZ7T1H
LSZ4001
LSZ1T
LSZ3H
LSYAB1A
LSZ7YAB1A
LSZ4001
LSZ1AB
LSZ3A
LSYAC1A
LSZ7YAC1A
LSA4001
LSZ1AC
LSZ3A
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
PROPER APPLICATION OF LIMIT SWITCHES
To achieve greatest reliability and longest life
possible, limit switches should be installed as
outlined in NEMA ICS2-225.
Cam or dog arrangements should be such that the
actuator is not suddenly released to snap back
freely.9
For limit switches with pushrod actuators, apply
actuating force as nearly as possible in line with
pushrod axis.
GRAVITY RETURN HDLS
Listings beginning with LSS are gravity return
devices. During installation and setup, not the
following:
1. Operate and release points exchange
location when shaft is rotated 180( (Fig. 9).
2. Switch is near operate-release points
when shaft slot is parallel to switch’s long axis (Fig.
9).
3. The switch should be installed so gravity
return of the actuator releases the switch.
Revision May 13, 1998
10 - 6
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
Skinner Solenoid Manual
Revision May 13, 1998
10 - 7
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
Revision May 13, 1998
REFERENCE
10 - 8
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
Revision May 13, 1998
REFERENCE
10 - 9
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
REFERENCE
Operator Notes
Revision May 13, 1998
10 - 10
MAC Equipment, Inc.
SD Scale Diverter Valve Operator Manual
Chapter 10
Revision May 13, 1998
REFERENCE
10 - 11
MAC Equipment, Inc.