for official use only s9515-as-mmm-010 - navy tribe · 2015. 11. 4. · s9515-as-mmm-010...

S9515-AS-MMM-0100910-LP-107-2816 REVISION 1

TECHNICAL MANUAL

MAINTENANCE MANUAL

CO AND H2 BURNERMARK IV-E, SIZE 500 CFM

THIS MANUAL SUPERSEDES NAVSEA S9515-AS-MMM-010, DATED 1 JUNE 1989.

DISTRIBUTION STATEMENT D - DISTRIBUTION AUTHORIZED TO THE DEPARTMENT OF DEFENSE AND U.S. DODCONTRACTORS ONLY; CRITICAL TECHNOLOGY; (7 JANUARY 2008). OTHER REQUESTS SHALL BE REFERRED TOCOMNAVSEASYSCOM(07L).

DESTRUCTION NOTICE - FOR CLASSIFIED DOCUMENTS, FOLLOW THE PROCEDURES IN DOD 5220.22-M, INDUSTRIALSECURITY MANUAL, CHAPTER 5, SECTION 7, OR OPNAVINST 5510.1G, CHAPTER 17. FOR UNCLASSIFIED LIMITEDDISTRIBUTION DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS ORRECONSTRUCTION OF THE DOCUMENT.

WARNING - THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORTCONTROL ACT (TITLE 22, U.S.C., SEC 2751, ET SEQ). OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED,TITLE 50, U.S.C., APP 2401 ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINALPENALTIES.

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

7 JANUARY 2008

FOR OFFICIAL USE ONLY


RECORD OF CHANGES

Change NoDate ofChange Title or Brief Description Date Entered

Entered By(Signature)

Original 01 Jun 1989 Initial issue. N/A N/A

Original 07 Jan 2008 Revision 1. Manual converted intoelectronic format.

N/A N/A

THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONICSOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NOLOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOTMATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS EXACTLYTHE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT IN THISPAGINATED VERSION.

FOR OFFICIAL USE ONLYS9515-AS-MMM-010

Original Change Record-1/(Change Record-2 blank)


NOTICE TO USERS OF THIS MANUALThis manual is intended to clearly and accurately reflect the actual configuration of the installed equipment andcomponents described. Users are urged to report instances wherein the manual does not achieve this objective.Additionally, recommendations to correct errors, deficiencies, or omissions are invited.

Users of this manual may provide feedback to the Los Angeles Class Technical Manual Maintaining Activity (TMMA) bythe method described in detail in the Procedures for Maintaining Non-Reactor Plant Systems Manuals and Equipment/Component Technical Manuals (‘‘010 Manual’’), T0005-AA-GYD-010, which has been provided separately to allauthorized manual holders. All recommendations of a routine nature are to be made using the Technical ManualDeficiency Evaluation Report (TMDER) form found at the end of this manual. The TMDER form should be reproducedlocally for this purpose. All completed TMDER forms should be submitted per instructions at the top of the form.

TMDERs which recommend issuance of an Advance Change Notice (ACN) should be submitted by Naval message or insome cases via the TMDER form. Refer to the manual maintenance instructions noted above for prescribed formats andprocedures for submission to the TMMA. Telephone inquiries to resolve questions concerning TMDER preparation orsubmittal procedures may be made to the TMMA at (757) 896-5457.

Replacement or additional copies of manuals may be obtained directly from the stocking activity. Please consult theTechnical Data Management Information System (TDMIS) for correct stocking activity for this manual. Assistance orinformation to resolve problems associated with manuals listed in the TDMIS may be obtained by calling Fleet Support at(757) 896-5440.


Original NTU-1/(NTU-2 blank)


MANUAL CHANGE FORM (MCF)

PROJECT OR SHIP: SSN688 Class Submarines

TITLE OF MANUAL: CO and H2 Burner, Mark IV-E, Size 500 CFM

NAVSEA NO.: S9515-AS-MMM-010

MODIFICATION: Original DATE: 07 Jan 2008

APPLICABILITY: See TDMIS.

SUBJECT OF MODIFICATION: Revision 1. Manual converted into electronic format.

SUPERSEDES ACN NO.(S): None.

CHANGE DOCUMENTS INCLUDED IN THIS CHANGE: None

TECHNICAL APPROVAL LTR.: See Synopsis of Modification Content. DATE: 07 Jan 2008

SYNOPSIS OF MODIFICATION CONTENT

The following information is included in this revision:

a. This Technical Manual (TM) has been developed from an intelligent electronic source known as standardgeneralized markup language (SGML). There is no LOEP. All changes, if applicable, are included. Thepagination in this TM will not match the pagination of the original paper TM; however, the content isexactly the same. Any changes received after receipt of this TM will only fit in this paginated version.

INSTRUCTIONS TO MANUAL HOLDERS

a. This MCF promulgates the revision of S9515-AS-MMM-010.

b. The content of this manual modification does not affect SUBSAFE/Hull Integrity Certification.

c. This revision supersedes all previously issued copies of S9515-AS-MMM-010. Destroy all previouslyissued copies of S9515-AS-MMM-010 in accordance with applicable security regulations.


Original I/(II blank)


1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-1.1 WARNING/CAUTION/NOTE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-1.2 SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-1.3 ADDITIONAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2.2 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2.3 SUPERSEDURE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2.4 APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2.5 MAINTENANCE PHILOSOPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-3 CO AND H2BURNER, MARK IV-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41-3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41-3.2 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41-3.3 ALARM RELAY CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.4 THERMOCOUPLE PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.5 TEMPERATURE INDICATING CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.6 AIR FILTER HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.7 AC MOTOR AND FAN WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.8 BYPASS DUCT AND PUSH-PULL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.9 HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.10 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-3.11 CATALYST SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-3.12 AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-3.13 AIRFLOW AND PRESSURE MEASURING COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 1-61-3.14 COMPOUND MASS BARS AND RESILIENT MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-3.15 LITHIUM CARBONATE FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-4 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-4.1 REFERENCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-4.2 REFERENCE PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1.2 OPERATOR-EQUIPMENT RELATIONSHIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1.3 REFRIGERANT-EQUIPMENT RELATIONSHIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1.4 SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-2.1 CONTROL STATION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-2.2 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-2.3 INSTRUMENT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-2.4 PUSH-PULL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-3 OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-3.1 PREOPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-3.2 NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82-3.3 NORMAL SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112-3.4 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112-3.5 EMERGENCY SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-1.2 GENERAL FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-2 CO AND H2BURNER, MARK IV-E, COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . 3-4


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3-2.1 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43-2.2 THERMOCOUPLE PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63-2.3 TEMPERATURE INDICATING CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63-2.4 AIR FILTER HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.5 AC MOTOR AND FAN WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.6 BYPASS DUCT AND PUSH-PULL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.7 HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.8 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.9 CATALYST SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-2.10 AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93-2.11 AIRFLOW AND PRESSURE MEASURING COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 3-93-2.12 COMPOUND MASS BARS AND RESILIENT MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113-3 SYSTEM FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113-3.1 AIRFLOW THROUGH BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113-3.2 ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-1.1 PLANNED MAINTENANCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-1.2 EXTENT OF COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-2 PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-1.1 PURPOSE AND SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-1.2 SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-2 PRELIMINARY TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-3 SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25-3.1 TROUBLESHOOTING OBSERVATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25-3.2 TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35-4 COMPONENT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75-4.1 AC MOTOR AND FAN WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75-4.2 FUSES AND TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75-4.3 HEATER, OVERRIDE, AND AUDIBLE ALARM SWITCHES . . . . . . . . . . . . . . . . . . . . . . . 5-85-4.4 TEMPERATURE INDICATING CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95-4.5 ALARM RELAY CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-1.2 SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-1.3 TOOLS, EQUIPMENT, AND MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION I ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-2.1 ADJUSTMENT COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-3 ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-3.1 THERMAL OVERLOAD RELAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-3.2 ALARM RELAY CONTROLLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-3.3 TEMPERATURE INDICATING CONTROLLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 6-76-3.4 TEMPERATURE INDICATING CONTROLLER, MODEL 1612-4, CALIBRATION . . . . . . . . . 6-116-3.5 TEMPERATURE INDICATING CONTROLLER, CEPEDA SERIES 988. . . . . . . . . . . . . . . . 6-136-3.6 TEMPERATURE INDICATING CONTROLLER, WEST MODEL 2075 . . . . . . . . . . . . . . . . . 6-13


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6-3.7 DIFFERENTIAL PRESSURE GAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

SECTION II REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-176-4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-176-4.1 REPAIR COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-176-4.2 PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-176-5 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-176-5.1 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-176-5.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186-6 REPAIR AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-196-6.1 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-196-6.2 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-196-7 CO AND H2BURNER, MARK IV-E, REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 6-206-7.1 CO AND H2BURNER, MARK IV-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-206-7.2 CATALYST SECTION REPLENISHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-326-7.3 THERMOCOUPLE PROBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-336-7.4 DISPOSABLE AIR FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-7.5 AC MOTOR AND FAN WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-7.6 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-416-7.7 INSTRUMENT MOUNTING BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-546-7.8 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-586-7.9 HEAT EXCHANGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

7 ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17-1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17-1.1 PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17-1.2 REPAIR PARTS IDENTIFICATION AND PROCUREMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-17-1.3 MANUFACTURERS’ CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37-1.4 ABBREVIATIONS AND ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57-1.5 CROSS-REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

SECTION II ILLUSTRATIONS AND GROUP ASSEMBLY PARTS LISTS . . . . . . . . . . . . . . . . . . . . . 7-117-2 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117-2.1 EQUIPMENT BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117-2.2 GROUP ASSEMBLY PARTS LIST DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

SECTION III NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-577-3 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-577-3.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-577-3.2 BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

SECTION IV REFERENCE DESIGNATION INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-657-4 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-657-4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-657-4.2 BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

SECTION V FASTENER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-677-5 FASTENER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67

8 ENGINEERING DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1



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8-1.1 DRAWING INCLUSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18-1.2 DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Appendix A CEPEDA SERIES 988 TEMPERATURE INDICATING CONTROLLER (PART NUMBER1048Y-B255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-2.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-2.2 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-3 REMOVAL OF EXISTING TEMPERATURE INDICATING CONTROLLER (TIC) . . . . . . . . . A-2A-4 INSTALLING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER . . . . . . . . . A-2A-4.1 WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2A-4.2 INSTALLATION KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A-4.3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A-5 PRESTART-UP VERIFICATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A-6 PROGRAMMING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER. . . . . . . A-3A-6.1 INPUT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A-6.2 OUTPUT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A-6.3 SYSTEM SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A-7 INPUT CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A-7.1 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A-7.2 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A-8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6A-8.1 TROUBLESHOOTING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER . . . A-6A-8.2 SERIES 988 TEMPERATURE INDICATING CONTROLLER TROUBLESHOOTING

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Appendix B WEST MODEL 2075 TEMPERATURE INDICATING CONTROLLER . . . . . . . . . . . . . B-1B-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-2.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-2.2 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.1 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.2 MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.3 AUTOMATIC/SELF-TUNE DISABLED MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.4 AUTOMATIC/PRE-TUNE/SELF-TUNE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.5 AUTOMATIC/SELF-TUNE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1B-3.6 INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2B-4 REMOVAL OF EXISTING TEMPERATURE INDICATING CONTROLLER . . . . . . . . . . . . . B-2B-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3B-6 PRESTARTUP VERIFICATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4B-7 PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7B-7.1 R-12 SYSTEM PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7B-7.2 R-134a SYSTEM PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8



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LIST OF ILLUSTRATIONSFigure Title Page

1-1 CO and H2 Burner, Mark IV-E, General Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12-1 Control and Indicator Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32-2 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52-3 Instrument Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62-4 Airflow Pressure Differential Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-5 Normal Warmup Temperature Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102-6 Normal Cooldown Temperature Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123-1 CO and H2 Burner, Mark IV-E (2 Sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23-2 CO and H2 Burner Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43-3 Alarm Relay Controller Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53-4 Temperature Indicating Controller, Model 1612-4, Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 3-73-5 Airflow and Pressure Measuring Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103-6 Airflow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123-7 Air Filter Housing Assembly and Fan Configuration for SSN21 Class. . . . . . . . . . . . . . . . . . . 3-135-1 Preliminary Troubleshooting Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26-1 Thermal Overload Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-2 Alarm Relay Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-3 Temperature Indicating Controller, Model 1612-4 (Standard), Adjustment. . . . . . . . . . . . . . . . . 6-86-4 Temperature Indicating Controller, Model 102 (Standard), Adjustment. . . . . . . . . . . . . . . . . . . 6-96-5 Temperature Indicating Controller, Model-1600 Series (SSN21 Class), Adjustment. . . . . . . . . . 6-106-6 Differential Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-146-7 AC Motor Shaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-396-8 AC Contactor, N850, Wear Allowance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-446-9 Contact Spring Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-456-10 AC Contactor, N850, Wear Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-466-11 Magnet Frame Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-486-12 AC Contactor, N894, Wear Allowance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-506-13 Temperature Indicating Controller Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-567-1 Allowance Parts List Sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27-2 Part Identification, Research, and Procurement Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37-3 How To Use the Illustrated Parts Breakdown When the Part Number or Reference Designation Is

Known . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97-4 How To Use the Illustrated Parts Breakdown When the Part Number or Reference Designation Is

Not Known . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107-5 Top-Down Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127-6 CO and H2 Burner, Mark IV-E, General Arrangement (4 Sheets). . . . . . . . . . . . . . . . . . . . . . 7-167-7 AC Motor and Fan Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-307-8 Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-347-9 AC Contactor, N850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-397-10 AC Contactor, N894 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-427-11 Thermal Overload Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-457-12 Instrument Mounting Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-487-13 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-517-14 Heat Exchanger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54A-1 Series 988 Temperature Indicating Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-2 Electrical Assembly Wiring & Schematic Diagrams Mark IV-E Burner (2 Sheets). . . . . . . . . . . A-9A-3 Temperature Indicating Controller Installation Kit, Mark IV-E Burner (3 Sheets). . . . . . . . . . . . A-13A-4 Troubleshooting Diagram, Series 988 Temperature Indicating Controller. . . . . . . . . . . . . . . . . A-19B-1 Front and Exploded Views of the M2075 Temperature Indicating Controller. . . . . . . . . . . . . . . B-2B-2 M2075 Temperature Indicating Controller Terminal Connections. . . . . . . . . . . . . . . . . . . . . . . B-5B-3 M2075 Temperature Indicating Controller Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . B-6B-4 M2075 Temperature Indicating Controller Replacement Installation Diagram. . . . . . . . . . . . . . B-7FO-1 Electrical Schematic (Simplified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1FO-2 Alarm Relay Controller Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3



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FO-3 CO and H2 Burner, Mark IV-E, Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-5FO-4 Temperature Indicating Controller Schematic (3 Sheets). . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-7FO-5 CO and H2 Burner, Mark IV-E, General Arrangement (8 Sheets). . . . . . . . . . . . . . . . . . . . . . FP-13FO-6 CO and H2 Burner, Mark IV-E, General Arrangement (8 Sheets). . . . . . . . . . . . . . . . . . . . . . FP-29FO-7 CO and H2 Burner, Mark IV-E, SSN21 Class General Arrangement (8 Sheets). . . . . . . . . . . . . FP-45FO-8 CO and H2 Burner, Mark IV-E, SSN21 Class Reliance 2 HP Motor (3 Sheets). . . . . . . . . . . . . FP-61


LIST OF ILLUSTRATIONS – ContinuedFigure Title Page

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LIST OF TABLESTable Title Page

1-1 U.S.-to-Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41-2 CO and H2 Burner Reference Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-3 Electrical and Heat Load Apportionments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81-4 Burning Efficiency (Fresh Catalyst) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81-5 Reference Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92-1 Approximate Air Temperatures Through CO and H2 Burner with R-12 or R-134a . . . . . . . . . . . 2-12-2 Required CO and H2 Catalyst Temperature Alarm Setpoints for Ships with R-12 or R-134a. . . . 2-22-3 Control and Indicator Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44-1 Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15-1 System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35-2 Airflow Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35-3 Temperature Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55-4 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56-1 Stator Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-387-1 Manufacturers’ Codes, Names, and Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47-2 Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57-3 Illustrated Parts Breakdown Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137-4 Drawing Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147-5 Fastener List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67


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SAFETY SUMMARY

GENERAL SAFETY NOTICE

The following general safety notices supplement specific warnings and cautions appearing elsewhere in this manual. Theyare recommended precautions that must be understood and applied during operation and maintenance of the equipmentcovered herein. If situations arise that are not covered in the general or specific safety precautions, the commandingofficer or other authority will issue orders as deemed necessary to cover the situation.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances should repair or adjustment of energized equipment be attempted alone. The immediate presenceof someone capable of rendering aid is required. Before making adjustments, be sure to protect against grounding. Ifpossible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when powerhas been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors.Circuits must be grounded and all capacitors discharged prior to attempting repairs.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a test meter must be held, ground the case of the meter beforestarting measurement; do not touch live equipment or personnel working on live equipment while holding a test meter.Some types of measuring devices should not be grounded; such devices should not be held when taking measurements.

INTERLOCKS

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. Theyshould not be battle-shorted or otherwise modified except by authorized maintenance personnel. Do not depend solelyupon interlocks for protection. Whenever possible, disconnect power at power distribution source.

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shallbe posted. The safety watch shall have a full view of the operations being performed, and immediate access to controlscapable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation. If someone isinjured and stops breathing, initiate resuscitation immediately. A delay could cost the victim’s life.

GENERAL PRECAUTIONS

The following general precautions are to be observed at all times:

a. Install and ground all electrical components associated with this system/equipment in accordance with applicableNavy regulations and approved shipboard practices.

b. Ensure that all maintenance operations comply with Navy Safety Precautions, OPNAVINST 5100 series.


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c. Observe precautions set forth in Naval Ships’ Technical Manual (NSTM), Chapter 300, Chapter 302, Chapter 310and Chapter 320 with respect to electrical equipment and circuits.

d. Ensure that protective guards and shutdown devices are properly installed and maintained around rotating parts ofmachinery and high voltage sources.

e. Do not wear loose clothing while working around rotating parts of machinery.

f. Ensure that special precautionary measures are employed to prevent applying power to the system/equipment anytime maintenance work is in progress.

g. Do not make any unauthorized alterations to equipment or components.

h. Before working on electrical system/equipment, check with voltmeter to ensure that system is not energized.

i. Consider all circuits, not known to be ‘‘dead’’, ‘‘live’’ and dangerous at all times.

j. When working near electricity, do not use metal rules, flashlights, metallic pencils or any other objects havingexposed conducting material.

k. Deenergize all equipment before connecting or disconnecting meters or test leads.

l. When connecting a meter to terminals for measurement, use range higher than expected voltage.

m. Before operating equipment or performing any tests or measurements, ensure that frames of all motors and starterpanels are securely grounded.

n. Ensure that area is well-ventilated when using cleaning solvent/compound. Avoid prolonged breathing of fumesand solvent/compound contact with skin or eyes. For approved cleaning solvents/compounds for use onboardsubmarines refer to S9510-AB-ATM-010, Nuclear Submarine Atmosphere Control Manual.

WARNINGS AND CAUTIONS

Specific warnings and cautions applying to the system/equipment covered by this manual are summarized below. Thesewarnings and cautions appear elsewhere in the manual following paragraph headings and immediately preceding the textto which they apply. They are repeated here for emphasis.

WARNING

If an obvious leak or spillage of refrigerant occurs on board the ship, or if theconcentration exceeds the specified 90-day limit, the CO and H2 burner must besecured. This action minimizes the decomposition of the refrigerant into toxic andcorrosive hydrochloric (HCI) and hydrofluoric (HF) acids for R-12 and R-114.R-134a decomposes to HF only. Refer to the SSM, OI 635-5, for further appropriateaction. (Page 1-3, page 2-13)

WARNING

To prevent injury or death from contaminants absorbed by catalyst due to backflow,ensure that inlet and outlet dampers on idle burner are closed. (Page 2-7)


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WARNING

To prevent injury or death, exercise extreme caution when working with or aroundrotating parts of machinery or operating equipment. (Page 2-8)

WARNING

To prevent injury or death, ensure that burner is completely deenergized and taggedout of service. (Page 5-7, page 5-8, page 5-8, page 5-9, page 5-10, page 6-3, page6-4, page 6-5, page 6-5, page 6-11, page 6-13, page 6-20, page 6-32, page 6-33,page 6-34, page 6-34, page 6-41, page 6-42, page 6-43, page 6-43, page 6-48, page6-49, page 6-53, page 6-53, page 6-55, page 6-57, page 6-58, page 6-58, page A-2,page A-2, page B-3, page B-4)

WARNING

High voltages are present in this equipment. To prevent injury or death, extremecaution shall be exercised when working with energized equipment. (Page 5-9, page5-10, page 6-6, page 6-12, page 6-12)

WARNING

Do not use solvents on air stream components unless complete solvent removal canbe ensured. Toxic reactions between solvents and catalyst in catalyst bed may occur.(Page 6-17, page 6-59)

WARNING

Pressurized air can drive particles into eyes and skin if handled improperly. Toprevent personnel injury or equipment damage, wear face shield and appropriateclothing and exercise extreme caution. (Page 6-18, page 6-37)

WARNING

To prevent injury, allow 4 hours for catalyst to cool prior to disassembly of burner.(Page 6-20)

WARNING

Air filter housing weighs 30 pounds. Ensure that extreme care is used duringhandling. (Page 6-21, page 6-31)

WARNING

The standard motor weighs 70 pounds, the SSN21 Class motor weighs 88 pounds.To prevent injury or death, ensure that extreme care and proper lifting devices areused during handling. (Page 6-22, page 6-30, page 6-35)

WARNING

Fan wheel housing and motor mounting bracket and fan wheel weigh 40 pounds.Ensure that extreme care is used during handling. (Page 6-22, page 6-30)


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WARNING

Control box weighs 50 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling. (Page 6-23, page 6-29)

WARNING

Heater weighs 70 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling. (Page 6-23, page 6-28, page 6-59,page 6-60)

WARNING

To prevent injury, ensure that emergency air breathing mask is worn when handlingcatalyst. (Page 6-23, page 6-29, page 6-32)

WARNING

Compound mass bar is heavy. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling. (Page 6-24, page 6-26, page6-26)

WARNING

Aftercooler weighs 90 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling. (Page 6-24, page 6-27)

WARNING

Heat exchanger weighs 690 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling. (Page 6-25, page 6-27)

WARNING

Mounting bracket weighs 35 pounds. Ensure that extreme care is used duringhandling. (Page 6-25, page 6-26)

WARNING

Catalyst section weighs 240 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling. (Page 6-26, page 6-26)

WARNING

Compound mass tie bar is heavy. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling. (Page 6-28)

WARNING

To prevent injury, allow 4 hours for spent catalyst to cool prior to removal. (Page6-32)


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WARNING

Solvent is flammable and toxic. To prevent injury or death, use solvent inwell-ventilated area. Wear appropriate protective covering and avoid prolongedbreathing of fumes or solvent contact with skin. (Page 6-37, page 6-41)

WARNING

Heated ball bearings reach temperatures as high as 212 °F (100 °C). To preventinjury, exercise extreme care and wear insulated gloves when handling heated ballbearings. (Page 6-40)

WARNING

Cleaning compound is flammable and toxic. To prevent injury or death, use cleaningcompound in well-ventilated area. Wear appropriate protective covering and avoidprolonged breathing of fumes or compound contact with skin. (Page 6-59)

WARNING

Casing weighs 260 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling. (Page 6-61, page 6-62)

WARNING

Core weighs 430 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling. (Page 6-62, page 6-62)

WARNING

Prior to removing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual. (Page A-2, page B-3)

WARNING

To avoid personnel injury, follow normal shutdown and cool down procedurescontained in Chapter2 of this manual. (Page A-2, page B-3)

WARNING

Prior to installing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual. (Page A-2, page B-4)

WARNING

Prior to programming the temperature indicating controller, all personnel shall readand be familiar with the Warnings and Cautions contained in theSafety Summaryinthe front of this manual. (Page A-3)


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CAUTION

Operating with cooling valves fully open will cause excessive acidic condensationin the aftercooler with the possibility of corrosive damage. (Page 2-10)

CAUTION

To prevent corrosive damage to components or poisoning of catalyst, ensure thatcooling water to aftercooler is secured when burner is not operating. (Page 2-11)

CAUTION

To prevent equipment damage from boiling water in aftercooler, do not securecooling water to aftercooler until burner cools to below 200 °F (93.3 °C). (Page2-11)

CAUTION

To prevent serious equipment damage, cause of any overload shall be determinedand corrected before burner is returned to normal operation. (Page 2-13)

CAUTION

To prevent equipment damage from boiling water in aftercooler, do not securecooling water to aftercooler until burner cools to below 200 °F (93.3 °C). In case ofpower loss however, the cooling water should be turned off to prevent the formationof corrosive condensate in the interior of the burner. (Page 2-13)

CAUTION

To prevent equipment damage, ensure that thermal overload relay is not adjusted tosetting higher than necessary. (Page 6-4)

CAUTION

To prevent damage to alarm relay controller, ensure that input millivoltage neverexceeds 25 mV. (Page 6-5)

CAUTION

Meter movement is very delicate and easily broken. To prevent meter damage,apply very gentle pressure while turning meter adjustment slot. (Page 6-11)

CAUTION

To prevent equipment damage, do not use harsh abrasives that might scratch, score,or otherwise mar surface finishes. (Page 6-17)

CAUTION

Do not agitate parts in ultrasonic equipment longer than 5 minutes at any one time.Serious damage to parts may result. (Page 6-18)


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CAUTION

Do not alter concentricity of any part. Do not attempt minor repair to stripped orcrossed threads of fittings or bosses of components operating under high pressure.Leakage around loosely threaded parts, or movement between bolted parts, cancause failure and damage to equipment. (Page 6-19)

CAUTION

To prevent equipment damage, do not allow machined or lapped mating surfaces tocontact any surface without protection against nicks, scratches, and burrs. (Page6-19)

CAUTION

Proper seating of heat exchanger corner seals is extremely difficult. Removal andreinstallation of heat exchanger should not be attempted without factory support andtraining. (Page 6-25)

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed underheat exchanger and catalyst section before removing either component. (Page 6-25)

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed undercatalyst section before reinstallation. (Page 6-27)

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed underheat exchanger before reinstallation. (Page 6-27)

CAUTION

To prevent equipment damage, extreme care is required when handling bearings.Surfaces of shaft/bearing fit and bearings shall be protected during handling. (Page6-35, page 6-36, page 6-39)

CAUTION

To prevent equipment damage, use appropriate bearing puller to remove ballbearings, applying force evenly to inner race and outer race. (Page 6-35, page 6-36)

CAUTION

To prevent equipment damage, remove rotor and shaft very carefully without slidingrotor across stator windings. (Page 6-36)

CAUTION

To prevent equipment damage, do not use harsh abrasives that might scratch, scoreor otherwise mar surface finishes. (Page 6-37)


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CAUTION

To prevent equipment damage, do not lubricate main contacts. Lubrication defeatsdesign function. (Page 6-43, page 6-45, page 6-49, page 6-51)

CAUTION

To prevent equipment damage, ensure that movable and stationary contacts areinstalled so that contact surfaces mate properly. (Page 6-45)

CAUTION

To prevent equipment damage, ensure that movable and stationary main contacts areinstalled so that contact surfaces will mate properly. (Page 6-51)

CAUTION

To prevent equipment damage, do not force lever handle beyond 90 degrees or camlatch may shear off. (Page 6-56)

CAUTION

Proper seating of heat exchanger corner seals is extremely difficult. Disassemblyand reassembly should not be attempted without factory support and training. (Page6-61)

CAUTION

Do not start burner blower or the heaters until after the newly installed temperatureindicating controller has been programmed for the first time. Turning on the bloweror the heaters before the controller has been programmed will cause the controllerto operate improperly. (Page A-3, page A-4, page B-4)


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CHAPTER 1GENERAL INFORMATION AND SAFETY PRECAUTIONS

Figure 1-1. CO and H2 Burner, Mark IV-E, General Arrangement


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1-1 SAFETY PRECAUTIONS

1-1.1 WARNING/CAUTION/NOTE USAGE Warnings and cautions appearing throughout this technical manual are ofparamount importance to personnel and equipment safety. Prior to any attempt to operate, maintain, troubleshoot, or repairany part of the Mark IV-E CO and H2 burner, all warnings and cautions shall be thoroughly reviewed and understood.Refer to theSafety Summarywhich appears in the front matter of this manual. The following paragraphs define warnings,cautions, and notes as they are used in the manual.

WARNINGIdentifies an operating or maintenance procedure, practice, condition orstatement, which if not strictly followed could result in death or seriousinjury to personnel.

CAUTIONIdentifies an operating or maintenance procedure, practice, condition orstatement, which if not strictly followed could result in equipment damage orserious impairment of system operation.

NOTEHighlights certain operating or maintenance condition or statement which isessential but not of known hazardous nature as indicated by warnings andcautions.

1-1.2 SAFETY REQUIREMENTS During normal operation, various contaminants which may form corrosive and/ortoxic products are passed through the burner. Hydrocarbons that have been heated but not purified may produce a toxicgas. This may be caused by using an improper catalyst, such as charcoal, or by not completely filling the catalyst section.The proper catalyst is called hopcalite, which may be confused with charcoal. To distinguish hopcalite from charcoal, afew granules of the questionable substance are placed in a small amount of clean monoethanolamine(MEA)(MIL-M-23573) which is used in the CO2 scrubbers. Hopcalite reacts with the MEA and causes a definite blue colorationof the solution in approximately 10 minutes. If the substance is charcoal, no blue color appears. A partial bypass in thecatalyst section resulting from an underfilled or loosely packed catalyst section may cause incomplete burning ofhydrocarbons resulting in toxic gas generation but is more a function of low and out-of-SPEC catalyst bed operatingtemperature. For this reason, it is important that the catalyst level be checked frequently. The catalyst level can also bechecked by measuring the differential pressure across the catalyst section as described in paragraph2-3.2.i. The catalystlevel can also be checked by visual inspection. The life of the catalyst is not known but is poisoned by halogencontaining compounds (refrigerants), chlorinated solvents and sulfurous compounds. If the catalyst is replaced, the usedcatalyst should be disposed of in accordance with ship procedures. If two burners are installed but only one is operated,the inlet and outlet dampers to the idle burner must be closed to prevent contamination of its catalyst due to backflow. Ata low or ambient temperature, the catalyst is capable of absorbing various contaminants from the atmosphere, causingundesirable reactions when the burner is heated to normal operating temperature. On startup of the idle burner, theabsorbed contaminants may be given off. For more complete information on possible shipboard contaminants, refer toNAVSEA S9510-AB-ATM-010, Nuclear Submarine Atmosphere Control Manual. When the burner is running or after theburner is shut down, some areas may still be hot. Therefore, insulated gloves should be worn during repairs.


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WARNING

If an obvious leak or spillage of refrigerant occurs on board the ship, or if theconcentration exceeds the specified 90-day limit, the CO and H2 burner must besecured. This action minimizes the decomposition of the refrigerant into toxic andcorrosive hydrochloric (HCI) and hydrofluoric (HF) acids for R-12 and R-114.R-134a decomposes to HF only. Refer to the SSM, OI 635-5, for further appropriateaction.

1-1.3 ADDITIONAL PRECAUTIONS Personnel responsible for the burner shall become thoroughly familiar with andfrequently review the following specific safety precautions. These precautions apply to both personnel and equipment andare supplemental to the general precautions and specific warnings and cautions listed in theSafety Summary.

a. Ensure that inlet and outlet dampers to idle burner are closed.

b. Do not attempt to start, operate, or make repairs to burner without first reading and understanding appropriatesections of this manual.

c. Wear appropriate protective clothing and use extreme caution when working with cleaning solvents andcompounds. Ensure that area is well-ventilated. For additional information refer to NAVSEA S9510-AB-ATM-010.

d. Ensure that catalyst level is checked frequently.

1-2 INTRODUCTION

1-2.1 PURPOSE This manual provides the necessary information required for the operation, maintenance, and repairof the burner (Figure1-1). A further intent is to provide a basic manual requiring minimum update for possible futureprocurement of units of a similar design. This manual may also be used in whole or in part as a training document.

1-2.2 SCOPE This manual has been developed in accordance with the content requirements of MIL-M-15071 for aType I Technical Manual and with the style and format requirements of MIL-M-38784. Detailed physical and functionaldescriptions of the equipment are presented. In addition to the physical and functional descriptions, sufficient informationis presented to enable personnel to operate, maintain, troubleshoot, and repair the burner. The Illustrated Parts Breakdownin Chapter7 contains illustrations, parts lists, and cross-reference information for all components. A list of allabbreviations and acronyms appearing in this manual is also presented in Chapter7. Engineering drawings in Chapter8provide additional information required to repair, replace, or manufacture components not covered in detail in Chapter6.Measurement conversion information for units of measure appearing throughout all chapters is presented in Talbe1-1.

1-2.3 SUPERSEDURE DATA This manual supersedes NAVSEA 0388-LP-051-9000, dated March 1965; NAVSEA0938-LP-048-4010, dated 6 May 1972; NAVSEA 0938-LP-055-1010, dated April 1975;NAVSEA S9550-BG-MMA-010,dated June 1986; and NAVSEA S9515-AS-MMA-010; and all changes thereto.

1-2.4 APPLICABILITY The information contained in this manual is applicable to the standard and the Seawolf(SSN21) 500-cfm Mark IV-E CO and H2 burners.

1-2.5 MAINTENANCE PHILOSOPHY This manual provides complete coverage for two levels ofmaintenance(organizational and intermediate). There are three levels at which maintenance is normally performed,depending upon the complexity of the work and availability of support equipment. The first is the organizational level,where the work is accomplished by the ship’s force with no outside assistance other than routine supply services. Thesecond is the intermediate level, which refers to maintenance and repairs accomplished by a repair ship, tender, repairfacility, or shore intermediate maintenance activity. The third, which this manual does not include, is the depot level, suchas a naval or private shipyard where the more difficult and complex maintenance and repairs are accomplished. Thismanual does not designate or determine which maintenance level (organizational or intermediate) should accomplish


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preventive and corrective maintenance, that being the prerogative of the forces afloat. All components designated asrepairable items have been addressed in corrective maintenance. Sufficient coverage has been given to nonrepairable itemsto provide an understanding of item purposes and functions. Adequate information available in other official publicationshas been referenced rather than duplicated in this manual.

Table 1-1. U.S.-to-Metric Conversion Factors

When You Know Multiply by To DetermineLength

inches 2.540 centimetersfeet 30.480 centimetersyards 0.914 metersmiles (survey) 1.609 kilometers

Areasquare inches 6.452 square centimeterssquare feet 0.093 square meterssquare yards 0.836 square meterssquare miles(survey)

2.590 square kilometers

Volumefluid ounces 29.574 milliliterspints 0.473 litersquarts 0.946 litersgallons 3.785 literscubic feet 0.028 cubic meterscubic yards 0.765 cubic meters

Weightounces 28.350 gramspounds 0.454 kilogramstons - short 0.907 metric tons

1-3 CO AND H2BURNER, MARK IV-E

1-3.1 GENERAL DESCRIPTION The burner purifies air by means of a catalytic reaction which burns carbonmonoxide to carbon dioxide, hydrogen to water vapor and hydrocarbons to carbon dioxide and water vapor. The burnerconsists of a control box, a thermocouple probe, a temperature indicating controller, an air filter housing assembly, an acmotor, a fan wheel, a bypass duct, a push-pull control, a heat exchanger, a heater, a catalyst section, an aftercooler,airflow and pressure measuring components, compound mass bars, and resilient mounts.

NOTE

The type of refrigerant used in the ship stores refrigeration plant dictates thetemperature of the burners catalytic reaction. Ships with R-12(CFC-12) operate thecatalyst bed at 600 °F (316 °C) and those converted to R-134a (HFC-134a) byShipAlt SSN688-03983 operate at 500 °F (260 °C). Normal burner airflow is 500cfm regardless of catalyst bed temperature.

1-3.2 CONTROL BOX The control box contains the electrical components which control electrical power to themotor, the heater, and the control circuitry. It provides a safety enclosure for the ac contactors, thermal overload relays, analarm relay controller, a transformer, an elapsed time meter, and fuses. The ac contactors connect and disconnect electrical


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power to the motor and the heater. The thermal overload relays provide overload protection for the motor and the heater.The alarm relay controller provides excessive temperature indication at 650 °F (343.3 °C)and shutdown protection at 675°F (357.2 °C). The transformer steps down 440-Vac power to 115-Vac power for use in the burner control circuits. Theelapsed time meter records the actual running time of the motor. The fuses protect the 115-Vac circuits from overloads. Inaddition, the control box houses controls and indicators for burner control during normal or emergency operations.

1-3.3 ALARM RELAY CONTROLLER The alarm relay controller provides excessive temperature indication andprotection. The controller is a fully adjustable, solid-state electronic relay controller. The controller has a thermocouplereference, two set point potentiometers, a reference supply, two trip amplifiers and two output relays. The controllerreceives inputs from the thermocouple.

1-3.4 THERMOCOUPLE PROBE The thermocouple probe provides the temperature indicating and alarm relaycontrollers with voltages equivalent to the temperature of the catalyst section. The thermocouple is a temperaturetransducer comprising a closed circuit made of iron and constantan. These dissimilar metals develop a voltage that isproportional to the temperature in the catalyst section. The thermocouple is located on the front of the catalyst section.

1-3.5 TEMPERATURE INDICATING CONTROLLER The temperature indicating controller is a fully adjustable,solid-state electronic device which controls the catalyst bed operating temperature and the temperature of the air in thecatalyst section. The controller has a full scale analog set point and indication, a time proportioning relay primary output,and a process alarm output. The controller receives inputs from the thermocouple. The controller has four functionalareas: power supply, input, process, and output. There are several types of controllers currently in use. The model 1612–4is installed on new and refurbished burners and the model 102 is installed on the older burners in the SSN688 Class, andthe model 1600 series is installed in the SSN21 Class. ShipAlt SSN4108 installs the Cepeda series 988 controller toeventually replace existing controllers. The West model 2075 controller has, through the years, been installed as a sparepart replacement in some burners.

1-3.6 AIR FILTER HOUSING ASSEMBLY The air filter housing assembly cleans air drawn into the burner. The airfilter housing assembly consists of an air inlet silencer (SSN21 Class only), air filter housing, a disposable air filter, an airinlet, an air filter housing cover, and air filter retaining springs. Air enters the burner through the ship’s duct system,which is located on top of the air filter housing. The air filter housing cover is used to gain access to the filter. The airfilter retaining springs hold the filter firmly against the air filter housing. The filter is a disposable cartridge-type filtercontaining over 70 square feet of filter paper.

1-3.7 AC MOTOR AND FAN WHEEL The fan wheel, driven by the motor, pushes air through the burner. The motorprovides the mechanical force to turn the fan wheel. The fan wheel draws air into the air filter housing assembly andpushes the air through the burner at a rate of 500 cfm. The SSN21 Class fan wheel has a split vane impellerconfiguration.The standard motor is a 2-hp, 3,485-rpm, induction motor which draws approximately 2.9 amperes ofelectric current at full load. The SSN21 Class motor is a 2-hp, 3,250-rpm induction motor which draws approximately 2.6amperes of electric current at full load.

1-3.8 BYPASS DUCT AND PUSH-PULL CONTROL The bypass duct and the push-pull control are used to controlthe temperature in the catalyst section when a high concentration of hydrogen is burned. The bypass duct diverts a portionof the cool inlet air from the fan wheel housing and routes this air directly into the heater. Thus the heat exchanger ispartially bypassed and the cooler air reduces the temperature of the catalyst section. The push-pull control varies theamount of cool air that passes through the bypass duct. The push-pull control is a lock-T handle that travels 1-3/8 inches.

1-3.9 HEAT EXCHANGER The heat exchanger preheats air entering the burner and cools the air leaving the catalystsection of the burner. Air is passed over the inlet side of the heat exchanger where it is preheated by air leaving thecatalyst section. This cools the air leaving the outlet side of the heat exchanger by transferring heat to the incoming air.

1-3.10 HEATER The heater heats the incoming air from the heat exchanger to approximately 600 °F625 ° (315.5 °C613.9°). The heater consists of 18 finned hairpin-shaped heating elements. The finned design provides a large surfacearea for maximum heat transfer. Each heating element has a rating of 1,450 watts at 254 volts. The total rating for the


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heater is 26,100 watts. This rating provides rapid heatup to operating temperature without causing equipment damage dueto excessively rapid thermal expansion. The heater is located below the catalyst section.

1-3.11 CATALYST SECTION The catalyst section purifies air containing carbon monoxide, hydrogen, andhydrocarbons by means of a catalytic reaction and heat. The catalyst in the catalyst section greatly speeds up theoxidation reaction by which carbon monoxide, hydrogen, and hydrocarbons are burned. At temperatures of 200 °F (93.3°C) and above, carbon monoxide and hydrogen combine with oxygen on the surface of the catalyst to produce carbondioxide (CO2) and water vapor (H2O). Transitioning between ambient temperature and 450 °F (232.2 °C) and vice versamay result in the formation of an insignificant amount of partial decomposition products. Temperatures of 450 °F (232.2°C) or greater will convert hydrocarbons to CO2 and H2O. When refrigerants experience temperatures greater than 550 °F(287.8 °C)for R-134a, a hydrofluorocarbon (HFC) and 650 °F (343.3 °C) for R-12 and R-114, chlorofluorocarbons (CFC),excessive amounts of acid gases (hydrogen fluoride (HF) for R-134a and HF and hydrogen chloride (HCl) for R-12 andR-114)are produced. Therefore, the catalyst bed operating temperature excessive temperature alarm and high temperatureshutdown alarm are set at 600625 °F(316613.9 °C), 650610 °F (34365.6 °C), and 675610 °F (35765.6 °C),respectively for ships with R-12 installed in the Ship Stores Refrigeration plant; and 500625 °F(260613.9 °C), 550610 °F (287.865.6 °C), and 575610 °F (301.765.6 °C), respectively, when R-134a is installed (ShipAltSSN-688-03983). The catalyst chemically speeds these oxidation reactions but is not consumed itself as the reactions takeplace. Because the catalyst is not chemically consumed, it may remain active indefinitely if not exposed to and poisonedby halogen containing compounds (refrigerants), chlorinated solvents and sulfurous compounds. A chemical substancecalled Hopcalite, which contains 10% by volume lithium hydroxide, is used as the catalyst in the burner.The lithiumhydroxide is converted to lithium carbonate and removes acids during the oxidation reaction. It is efficient and does notabsorb hydrocarbons at normal burner operating temperatures. The catalyst is located in the catalyst section above theheater assembly. Assuming proper burner operation, catalyst is located in the catalyst section above the heater assembly.Assuming proper burner operation, catalyst replacement is based on the burners inability to control carbon monoxide andhydrogen levels which is affected by extensive catalsyt poisoning.

1-3.12 AFTERCOOLER The aftercooler cools air being discharged from the heat exchanger and controls thetemperature of the outlet air to prevent condensation. The aftercooler has no moving parts. Chilled water moves throughthe tube side of the aftercooler to cool the air. The maximum chilled water flow through the aftercooler is 15 gpm. Theaftercooler maintains the required outlet temperature of 100 to 110 °F (317 to 43.3 °C), using 45 °F (7.2 °C) water at aflow rate of approximately 2 gpm with the burner operating at 600 °F (316 °C) for ships with R-12 ship storesrefrigeration plants, or approximately 1.5 gpm with the burner at 500 °F (260 °C) for ships with R-134a.

1-3.13 AIRFLOW AND PRESSURE MEASURING COMPONENTS The airflow and pressure measuringcomponents give a visual measurement of airflow and differential pressure in the burner. The airflow and pressuremeasuring components consist of a differential pressure gage, a manifold valve assembly, and a pitot tube. The gageindicates the pressure selected by any pair of flip toggle valves on the manifold valve assembly. The flip toggle valvesselect the points in the burner that are to be measured. Differential pressure can be measured across the filter, the heatexchanger inlet, the catalyst section, and the heat exchanger outlet. Compression fittings connect the tubes from the fliptoggle valves at these sampling points on the burner. Air flow through the burner is measured by the pitot tube. The gageand manifold valve assembly are connected to each other and are mounted on the instrument mounting bracket.

1-3.14 COMPOUND MASS BARS AND RESILIENT MOUNTS To minimize structure-born noise transmitted fromthe burner to the submarine’s hull, the burner is resiliently mounted. Two compound mass bars are supported from thesubmarine base by six resilient mounts, except for SSN21 Class ships, where the compound mass bars are hard-mounted.The burner is supported on the compound mass bars by four resilient mounts.

1-3.15 LITHIUM CARBONATE FILTERS Lithium carbonate (LiCO3) filters are located in the ventilation ductworkdownstream of the burner. They remove harmful acids which may be produced by refrigerant and chlorinated solventdecomposition in the burner. NAVSEA S9510-AB-ATM-010 discusses lithium carbonate filters, and should be referred tofor further information.


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1-4 REFERENCE INFORMATION

1-4.1 REFERENCE DATA Reference data for the burner is provided in Table1-2. Electrical and heat loadapportionments are listed in Table1-3 and burner efficiency data is listed in Table1-4.

1-4.2 REFERENCE PUBLICATIONS Reference publications for the burner are listed in Table1-5.

Table 1-2. CO and H2 Burner Reference Data

Equipment DescriptionGeneral Data

Burner CO and H2 Burner, Mark IV-E, 500 cfmManufacturer Atlantic Research Corporation or

Cepeda Associates, Inc.Power Supply 440 Vac, 3 ph, 60 HzCurrent Rating 41 ampHeight 67 in.Width 39 in.Depth 39 in.Weight (with catalyst) 2,320 lbs (Standard)

2,340 lbs (SSN21 Class)AC Motor (standard)

Manufacturer Reliance Electric CompanyType Totally enclosed, fan cooled, squirrel cage, single speed,

inductionPower Supply 440 Vac, 3 ph, 60 HzCurrent Rating 2.9 ampSpeed 3,600 rpm (syn)

3,485 rpm (flld)Maximum Ambient Temperature 122 °F (50 °C)Duty Type ContinuousHorsepower 2Weight 70 lbs

AC Motor (SSN21 class)Manufacturer Reliance Electric CompanyType Totally enclosed, fan cooled, squirrel cage, single speed,

inductionPower Supply 440 Vac, 3 ph, 60 HzCurrent Rating 2.6 ampSpeed 3,600 rpm (syn)

3,520 rpm (flld)Maximum Ambient Temperature 122 °F (50 °C)Duty Type ContinuousHorsepower 2Weight 88 lbs

Heating ElementQuantity 18Operating Voltage 254 Vac (Y-connection of 440 Vac)Wattage, Each Element 1,450 W

Alarm Relay Controller


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Table 1-2. CO and H2 Burner Reference Data – Continued

Equipment DescriptionManufacturer Acromag, IncorporatedPower 115 VacAccuracy Rating 61 percent of input span at 77 °F (25 °C)Operating Ambient Temperature Range 32 ° to 158 °F (0 ° to 70 °C)

Temperature Indicating ControllerManufacturer West-Gulton Industries, IncorportedPower Supply 115 VacAccuracy Rating 61 percent of span over middle

80 percent of span at 46 °F (7.8 °C)Operating Ambient Temperature Range 0 ° to 131 °F (−17.8 ° to 55 °C)

Differential Pressure GageManufacturer Dwyer Instruments, IncorporatedRange 0 to 5 in. of waterAccuracy 62 percent of full scale at 70 °F (21.1 °C)Operating Ambient Temperature Range 20 ° to 140 °F (–6.7 ° to 60 °C)

Table 1-3. Electrical and Heat Load Apportionments

H2Concentration

(Percent byVolume

Heat Added Heat RemovedElectrical(Btu/hr)

H2Burned(Btu/hr)

Water(Btu/hr) a

Air(Btu/hr) b

Radiant Loss(Btu/hr) c

600 °F 500 °F 600 °F 500 °F 600 °F 500 °F0 75,000 57,600 0 54,400 43,600 0 0 21,400 14,000

0.5 39,700 21,200 37,500 55,200 44,200 0 0 22,000 14,5001.0 3,500 0 74,900 55,800 59,900 0 0 22,600 15,0001.5 0 0 112,400 86,000 91,900 3,200 5,200 23,200 15,3001.8 0 0 134,900 102,000 107,700 9,300 11,500 23,600 15,700

aAssuming chilled water temperature of 45 °F and adjusting flow to attempt to maintain 100 °F air outlet temperature.b If the air outlet will be above 100 °F, the excess heat energy of the stream is calculated using degrees above 100 °Fassuming 500 scfm flow, 70 °F standard temperature and specific heat of 0.259 Btu/lbm.c Heat loss from burner to compartment. (Primary mode of transfer is radiant)

Table 1-4. Burning Efficiency (Fresh Catalyst)

Gas BurnedInlet

ConcentrationOutlet

ConcentrationEfficiency a

(Percent Burned)Hydrogen 0.50 percent 0.05 percent 90 percent

1.00 percent 0.05 percent 95 percent1.50 percent 0.07 percent 95 percent1.80 percent 0.10 percent 95 percent

Carbon Monoxide 50 percent less than 5 ppm greater than 90 percentHydrogen and Carbon Monoxide 100 ppm 5 ppm 95 percent

1.80 percent 0.09 percent 95 percent100 ppm 5 ppm 95 percent

aEfficiency is the same with the catalyst bed operating temperature at 500 °F (260 °C) or 600 °F(316 °C).


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Table 1-5. Reference Publications

Title NumberNaval Ships’ Technical Manual

Chapters074 (Welding and Allied Processes) S9086-CH-STM-010244 (Bearings) S9086-HN-STM-000300 (Electric Plant General) S9086-KC-STM-000302 (Electric Motors and Controllers) S9086-KE-STM-000310 (Electric Power and Generators and Conversion Equipment) S9086-KN-STM-000320 (Electric Power Distribution Systems) S9086-KY-STM-000504 (Pressure, Temperature, and Other Mechanical and Electromechanical

Measuring Instruments)S9086-RJ-STM-000

COSAL Use and Maintenance Manual SPCCINST 4441.170Navy Safety Precautions OPNAVINST 5100 (Series)Planned Maintenance System OPNAVINST 4790.4Nuclear Submarine Atmosphere Control Manual S9510-AB-ATM-010Electronics Installation and Maintenance Book, Test Methods and Practices 0967-LP-000-0130Electronics Installation and Maintenance Book, General Maintenance SE000-00-EIM-160


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CHAPTER 2OPERATION

2-1 INTRODUCTION

2-1.1 SCOPE Proper operation of the Mark IV-E CO and H2 burner extends the service life of the equipment. Thischapter provides procedures to check, prepare, operate, and shut down the burner. Although these burners are alwaysinstalled in pairs, they may be operated either singly or simultaneously. The procedures given in this chapter apply only toa single burner unless otherwise specifically stated. These procedures are sufficient to enable assigned personnel to operatethe burner safely and efficiently. Measurement conversion information for units of measure appearing throughout allchapters is presented in Table1-1.

2-1.2 OPERATOR-EQUIPMENT RELATIONSHIP The burner operates continuously and automatically with onlyperiodic checks of airflow, differential pressure, and temperature required by the operator. Operation is carried out byactuating electrical switches, flip toggle valves, ship’s ventilation dampers, and ship’s chilled water supply valve, and bymanually opening and closing the push-pull control in the bypass duct. Airflow readings are taken, using the pitot tube,appropriate flip toggle valves, and the differential pressure gage, as the air leaves the fan wheel housing. Differentialpressure readings are taken across the disposable air filter, the inlet side of the heat exchanger, the catalyst section, andthe outlet side of the heat exchanger. Flip toggle valves and the differential pressure gage are used for differential pressuremeasurements. Temperature readings are taken in the top part of the catalyst section and are read on the temperatureindicating controller and the aftercooler outlet by a temperature gage.

2-1.3 REFRIGERANT-EQUIPMENT RELATIONSHIP The type of refrigerant used iin the ship stores refrigerationplant determines the burner’s catalyst bed operating temperature. Ships with R-12 operate at 600 °F (316 °C) to safelycontrol the levels of HF and HCl formed in the event that R-12 is processed by the burner. Ships with R-134a operate theburner at 500 °F (260 °C) to safely control the level of HF formed in the event that R-134a is processed by the burner.Table2-1 shows how the air temperatures in the burner differ when controlling the catalyst bed temperature to 600 °F(316 °C) for R-12 and 500 °F (260 °C) for R-134a. Table2-2 shows the required burner catalyst bed operatingtemperature and associated excessive temperature and high temperature shutdown alarm setpoints when either R-12 orR-134 is installed on the ship.

2-1.4 SAFETY REQUIREMENTS Prior to burner operation, personnel shall review and become thoroughly familiarwith the general safety notices and precautions listed in theSafety Summary. Additional safety requirements, presented inparagraph1-1.2of this manual, also shall be reviewed before operating the burner. In addition, all warnings and cautionsprovided in this chapter and throughout the manual shall be observed.

2-2 CONTROLS AND INDICATORS

2-2.1 CONTROL STATION LOCATIONS The burner is located in middle level auxiliary machinery room 1(AMR1)on SSBN submarines and/or in the lower level operation compartment on various classes of SSN submarines. Thecontrol station, which consists of the control box and the instrument mounting bracket, is located on the front of theburner. Controls and indicators enable operators to control and monitor all burner operations. Controls and indicators andtheir locations are shown in Figure2-1 and listed in Table2-3. Words printed entirely in capital letters in Table2-3represent placards or nameplates appearing on the controls or indicators.

Table 2-1. Approximate Air Temperatures Through CO and H2 Burner with R-12 or R-134a

Location in BurnerRefrigerant

R-12 R-134aAir Into Inlet Side of Heat Exchanger 100 °F (37.8 °C) 100 °F (37.8 °C)Air From Inlet Side of Heat Exchanger 500 °F (260 °C) 420 °F (215.6 °C)Air From Heater Assembly 600 °F (316 °C) 500 °F (260 °C)


Original 2-1


Table 2-1. Approximate Air Temperatures Through CO and H2 Burner with R-12 orR-134a – Continued

Location in BurnerRefrigerant

R-12 R-134aAir Across Catalyst Bed 600 °F (316 °C) 500 °F (260 °C)Air From Discharge Side of Heat Exchanger 200 °F (93.3 °C) 180 °F (82.2 °C)Air From Cooling Coil (Aftercooler) 100 °F (37.8 °C) 100 °F (37.8 °C)

Table 2-2. Required CO and H2 Catalyst Temperature Alarm Setpoints for Ships with R-12 or R-134a

Location In BurnerRefrigerant

R-12 R-134aCatalyst Bed 600625 °F (316613.9 °C) 500625 °F (260613.9 °C)Excessive Temperature Alarm 650610 °F (343.365.6 °C) 550610 °F (287.865.6 °C)High Temperature Shutdown Alarm 675610 °F (357.265.6 °C) 575610 °F (301.765.6 °C)

2-2.2 CONTROL BOX The control box (Figure2-2) provides controls and indicators to operate the burner. The startswitch and stop/reset switch energize and deenergize the control circuit, starting and stopping the ac motor. The stop/resetswitch also resets the thermal overload relay for the motor. A heater reset switch resets the thermal overload relay for theheater. A heater switch operates the heater once the control circuit has been energized. The excessive temperature lampindicates that air temperature in the catalyst section has reached 50 °F (10 °C) above the catalyst bed setpointtemperature. (See Table2-2 to determine excessive temperature alarm setpoint.) The override switch allows restarting ofthe burner after burner high temperature shutdown due to burner temperature in excess of 75 °F (23.9 °C) above thecatalyst bed setpoint temperature. (See Table2-2 to determine high temperature shutdown alarm setpoint.) When theburner shuts down, the alarm buzzer sounds. The alarm buzzer can be silenced with the audible alarm switch. The controlbox has three lamps. The control circuit lamp indicates that the control circuit is energized. The heater lamp indicates thatthe heater is energized. The control box has an elapsed time meter which records the running time of the motor.

2-2.3 INSTRUMENT MOUNTING BRACKET The instrument mounting bracket (Figure2-3) provides controls andindicators to monitor burner operation. It includes a differential pressure gage, flip toggle valves, and a temperatureindicating controller.

2-2.3.1 Differential Pressure Gage and Flip Toggle Valves The differential pressure gage provides a visualindication of inlet airflow and differential pressure across various burner components. A differential pressure or airflowmeasurement is selected by opening the appropriate pair of flip toggle valves. All other flip toggle valves remain closed.The flip toggle valves select sampling tubes from the filter, the pitot tube, the catalyst section, the heat exchanger inletand the heat exchanger outlet. The differential pressure in inches of water shown on the differential pressure gagecorresponds approximately to the airflow (Figure2-4).

• Acceptable differential pressure ranges at 500 cfm and 600625 °F(316613.9 °C)

1. Air Filter 0.3 to 2.0 inches of water2. Heat Exchanger Inlet 1.2 to 2.0 inches of water3. Catalyst Bed 2.3 to 4.5 inches of water4. Heat Exchange Outlet 0.7 to 1.8 inches of water

Pitot tube reading is stamped on operating instructions plate foreither 500 °F (260 °C) or 600 °F (316 °C), as applicable.


2-2 Original


• Catalyst bed, heat exchanger inlet, and heat exchanger outlet readings at the minimum value of the acceptabledifferential pressure range may be as much as 0.2 inches of water lower when operating at 500625 °F(260613.9°C).

Figure 2-1. Control and Indicator Locations


Original 2-3


Table 2-3. Control and Indicator Locations

Location Control IndicatorControl Box Start Switch Control Circuit Lamp

START CONTROL ON/OFFStop/Reset Switch

STOP/RESET —Heater Reset Switch

RESET —Heater Switch Heater Lamp

ON HEATER ON/OFFOFF —

Override SwitchOVERRIDE —NORMAL —

Audible Alarm SwitchON —OFF —

— Excessive Temperature LampEXCESSIVE TEMP

Elapsed Time MeterInstrumentMounting Bracket

Filter Flip Toggle Valves —Pitot Tube Flip Toggle Valves —Heat Exchanger Inlet Flip Toggle Valves —Catalyst Bed Flip Toggle Valves —Heat Exchanger Outlet Flip Toggle Valves —

— Differential Pressure Gage (0 to 5 in.water)

— Meter (0 to 800 °F)— Heater On Lamp— Heater Off Lamp— Alarm Lamp

Primary Set Point Knob —Bypass Duct Push-Pull Control —


2-4 Original


Figure 2-2. Control Box


Original 2-5


2-2.3.2 Temperature Indicating Controller The temperature indicating controller controls the temperature of the airentering the catalyst section by automatically cycling the heater to maintain the desired temperature. The desiredtemperature, is selected by the primary set point knob on the front of the temperature indicating controller. See Table2-2to determine catalyst bed operating temperature. The temperature of the catalyst is indicated on the meter. Themodel-1612-4 (standard) temperature indicating controller has a heater on lamp, a heater off lamp, an excessivetemperature alarm lamp, and one lamp that is not used. The model-102(standard) temperature indicating controller has aheater on lamp and heater off lamp. The model-1600 series (SSN21 Class) temperature controller has a power on lampand an excessive temperature lamp (refer to Figure6-5 ). The above controllers function in a similar manner.ShipAltSSN4108 will eventually replace existing controllers with the Cepeda series 988 controller; it is covered in AppendixAof this manual. The West model 2075 controller has, through the years, been installed as a spare part replacement in someburners; it is covered in AppendixB of this manual.

Figure 2-3. Instrument Mounting Bracket


2-6 Original


2-2.4 PUSH-PULL CONTROL The push-pull control (shown in Figure2-1) diverts some of the airflow from the heatexchanger directly to the heater to reduce burner operating temperature. This is usually necessary only if hydrogenconcentration in the air exceeds 1 percent. The push-pull control must be pushed in to its open position to divert airflowthrough the bypass duct.

2-3 OPERATING PROCEDURES

2-3.1 PREOPERATIONAL CHECKS The following procedure shall be used before burner startup.

a. Ensure that burner is energized at power panel.

b. Ensure that both inlet and outlet dampers for burner to be used are open.

WARNING

To prevent injury or death from contaminants absorbed by catalyst due to backflow,ensure that inlet and outlet dampers on idle burner are closed.

c. If only one burner is to be operated, inlet damper of idle burner shall be closed to prevent backflow through idleburner. Chilled water shall be secured on idle burner.

d. Ensure that drain line is connected to bottom of aftercooler.

e. Ensure that no noise shorts exist between burner, each compound mass bar, and foundation.

f. Ensure that burner is grounded.

g. Ensure that ship’s chilled water is available to aftercooler.

Figure 2-4. Airflow Pressure Differential Curve


Original 2-7


h. Ensure that primary set point pointer on temperature indicating controller is set at 600 °F (315.5 °C) when R-12 isinstalled in ship stores refrigeration plant or 500 °F (260 °C) when R-134a is installed.

i. Ensure that push-pull control is pulled out as far as possible to close off bypass duct.

j. Ensure that override switch is at NORMAL.

k. Ensure that heater has been checked in accordance with Planned Maintenance System (PMS) MaintenanceRequirement Cards (MRC’s).

2-3.2 NORMAL OPERATION After startup, the burner operates continuously and automatically. Only periodic checksof airflow, differential pressure, and temperature are required. The following procedure shall be used to start up the burnerand to check burner operation.

a. On control box, place heater switch at OFF.

b. Momentarily press start switch and ensure that control circuit lamp comes on.

WARNING

To prevent injury or death, exercise extreme caution when working with or aroundrotating parts of machinery or operating equipment.

c. Check for correct fan wheel rotation as indicated by rotation arrow at end of motor. This check shall be made firsttime burner is started and whenever any work is done on motor or control circuit wiring.

d. On control box, place audible alarm switch and heater switch at ON and ensure that heater lamp comes on.

e. Check and adjust burner airflow.

(1) Place two pitot tube flip toggle valves at ON position.

NOTE

Air flow is set at 500 cfm when R-12 or R-134a is installed in the ship storesrefrigeration plant.

(2) Verify that differential pressure gage reading is within limits set for 500 cfm, noted on instruction plate ofindividual burner.

(3) If airflow reading is not 500 cfm, adjust, using inlet damper in ship’s air inlet duct.

(4) Place two pitot tube flip toggle valves at OFF position.

f. Burner willl warm up to normal operating temperature in approximately 45 minutes. Normal operating temperatureis 600625 °F (316613.9 °C) when R-12 is installed in the ship stores refirgeration plant or 500625 °F (260613.9 °C) when R-134a is installed. Use Figure2-5 to estimate burner warmup time. When hydrogenconcentration is high, warmup time is appreciably shorter.

g. Check differential pressure across filter.

(1) Place two filter flip toggle valves at ON position.


2-8 Original


(2) Verify that differential pressure gage reads 0.3 to 2.0 inches of water.

(3) Place two filter flip toggle valves at OFF position.

NOTE

Opearion at 500 °F (316 °C) may lower the minimum values of the acceptabledifferential pressure ranges in steps2-3.2.hthrough2-3.2.j by as much as 0.2 inchesof water.

h. Check differential pressure across heat exchanger inlet.

(1) Place two heat exchanger inlet flip toggle valves at ON position.

(2) Verify that differential pressure gage reads 2.3 to 4.5 inches of water for the standard burner and 2.0 to 4.5 forthe SSN21 burner.

(3) Place two heat exchanger inlet flip toggle valves at OFF position.

i. Check differential pressure across catalyst section.

(1) Place two catalyst bed flip toggle valves at ON position.


(3) Place two catalyst bed flip toggle valves at OFF position.

j. Check differential pressure across heat exchanger outlet.

(1) Place two heat exchanger outlet flip toggle valves at ON position.


(3) Place two heat exchanger outlet flip toggle valves at OFF position.


Original 2-9


k. Maintain temperature of air leaving aftercooler at 100 to 110 °F (37.8 to 43.3 °C) when either R-12 or R-134a isinstalled in the ship stores refrigeration plant.

(1) At dial thermometer in ship’s air outlet duct, read air temperature.

CAUTION

Operating with cooling valves fully open will cause excessive acidic condensationin the aftercooler with the possibility of corrosive damage.

(2) Throttle cooling water to aftercooler as required to maintain correct air temperature.

l. Periodically repeat steps2-3.2.eand2-3.2.gthrough2-3.2.k to ensure proper burner operation.

NOTE

Temperatures listed in steps2-3.2.m.(1)through2-3.2.m.(4)are dependent uponwhether R-12 or R-134a is installed in the ship stores refrigeration plant

m. If hydrogen concentration exceeds 1 percent, use push-pull control to control temperature.

(1) If temperature increases to 650 °F (343.3 °C) for ships with R-12 or to 550 °F (287.8 °C) for ships withR-134a, or if excessive temperature lamp on control box and alarm lamp on temperature indicating controllercome on, turn and push in on push-pull control to fully open bypass duct.

Figure 2-5. Normal Warmup Temperature Curves


2-10 Original


(2) When temperature drops below 650 °F (343.3 °C) for ships with R-12 or below 550 °F (287.8 °C) for shipswith R-134a, adjust push-pull control to maintain temperature above 600 °F (315.5 °C) for ships with R-12 orabove 500 °F (260 °C) for ships with R-134a. Temperature change due to opening or closing of push-pullcontrol lags behind any adjustment.

(3) If hydrogen concentration increases, adjust push-pull control so that temperature is close to 600 °F (315.5 °C)for ships with R-12 or close to 500 °F (260 °C)for ships with R-134a without turning on heater.

(4) As hydrogen concentration decreases, adjust push-pull control so that temperature is closer to 650 °F (343.3°C) for ships with R-12 or closer to 550 °F (287.8 °C) for ships with R-134a.

2-3.3 NORMAL SHUTDOWN The following procedure shall be used to shut down the burner.

a. Place heater switch at OFF and ensure that heater lamp goes off.

b. Allow burner to cool for 40 to 50 minutes to below 200 °F (93.3 °C). Use Figure2-6 to estimate cooldown time.

c. If rapid cooling is required, push in push-pull control to open bypass duct.

d. Press stop/reset switch and ensure that control circuit lamp goes off.

CAUTION

To prevent corrosive damage to components or poisoning of catalyst, ensure thatcooling water to aftercooler is secured when burner is not operating.

CAUTION

To prevent equipment damage from boiling water in aftercooler, do not securecooling water to aftercooler until burner cools to below 200 °F (93.3 °C).

e. When burner has cooled to below 200 °F (93.3 °C), secure chilled water to aftercooler.

f. Close inlet damper in ship’s air inlet duct.

2-3.4 EMERGENCY OPERATION Under emergency conditions, the burner is capable of operating indefinitelywithout cooling water. In case of power loss, however, the cooling water should be turned off to prevent the formation ofcorrosive condensate in the interior of the burner.

The following procedures shall be used to operate the burner when it has shut down due to excessive temperature oroverload.

2-3.4.1 Recovery After Excessive Temperature Shutdown

a. Turn and push in push-pull control as far as possible to open bypass duct.

b. Place override switch at OVERRIDE. This prevents heaters from coming on.

c. Press start switch.


Original 2-11


NOTE

Temperature listed in steps2-3.4.1.dand2-3.4.1.gare dependent upon whetherR-12 or R-134a is installed in the ship stores refrigeration plant.

d. Verify that alarm buzzer, alarm lamp on temperature indicating controller, and excessive temperature lamp oncontrol box go off when temperature drops below 675 °F (357.2 °C) for ships with R-12, or below 575 °F (301.7°C) for ships with R-134a.

e. When temperature drops below 650 °F (343.3 °C), adjust push-pull control to maintain temperature between 600°F (315.5 °C) and 650 °F (343.3 °C) for ships with R-12, and between 500 °F (260 °C) and 550 °F (287.8 °C)forships with R-134a.

f. Place override switch at NORMAL.

g. If hydrogen concentration increases, adjust push-pull control so that temperature is closer to 600 °F (315.5 °C) forships with R-12 and closer to 500 °F(260 °C) for ships with R-134a, without turning on heater. Temperaturechange due to opening or closing of bypass duct lags behind any adjustment.

h. When hydrogen concentration decreases to below 1 percent, return burner to normal operation.

2-3.4.2 Recovery After Overload Shutdown

a. Press stop/reset switch for motor or heater reset switch for heater to reset thermal overload relay.

Figure 2-6. Normal Cooldown Temperature Curves


2-12 Original


CAUTION

To prevent serious equipment damage, cause of any overload shall be determinedand corrected before burner is returned to normal operation.

b. Determine and correct cause of overload.

Perform preoperational checks (paragraph2-3.1).

c. Start burner (paragraph2-3.2).

WARNING

If an obvious leak or spillage of refrigerant occurs on board the ship, or if theconcentration exceeds the specified 90-day limit, the CO and H2 burner must besecured. This action minimizes the decomposition of the refrigerant into toxic andcorrosive hydrochloric (HCI) and hydrofluoric (HF) acids for R-12 and R-114.R-134a decomposes to HF only. Refer to the SSM, OI 635-5, for further appropriateaction.

2-3.5 EMERGENCY SHUTDOWN The following procedure shall be used to shut down the burner duringemergencies.

a. Deenergize motor and control circuit by pressing stop/reset switch on control box.

b. If unable to shut down burner from control box, deenergize burner at power panel.

c. Close both inlet and outlet dampers to burner.

CAUTION

To prevent equipment damage from boiling water in aftercooler, do not securecooling water to aftercooler until burner cools to below 200 °F (93.3 °C). In case ofpower loss however, the cooling water should be turned off to prevent the formationof corrosive condensate in the interior of the burner.

d. Secure chilled water only after electrical system is restored and monitored temperature is below 200 °F (93.3 °C).




CHAPTER 3FUNCTIONAL DESCRIPTION

3-1 INTRODUCTION

3-1.1 SCOPE This chapter provides a functional description of the 500-cfm Mark IV-E CO and H2 burner.Measurement conversion information for units of measure appearing throughout all chapters is presented in Table1-1.

3-1.2 GENERAL FUNCTIONAL DESCRIPTION The Mark IV-E CO and H2 burner (Figure3-1) purifies air bymeans of a catalytic reaction which burns carbon monoxide to carbon dioxide, hydrogen to water vapor, and hydrocarbonsto carbon dioxide and water vapor. The burner consists of a control box, a thermocouple probe (thermocouple), atemperature indicating controller, an air filter housing assembly, an ac motor, a fan wheel, a bypass duct, a push-pullcontrol, a heat exchanger, a heater, a catalyst section, an aftercooler, airflow and pressure measuring components,compound mass bars, and resilient mounts. A functional block diagram of the burner is shown in Figure3-2. The controlbox contains electrical components used to control operation of the burner. The thermocouple generates voltagesproportional to the temperature in the catalyst section. The temperature indicating controller uses the voltage from thethermocouple to control the temperature of the air entering the catalyst section by turning the heater on and off. Air entersthe burner through the air filter housing assembly, where it is cleaned. The fan wheel, driven by the motor, pushes airthrough the burner. The bypass duct and the push-pull control are used to control the temperature in the catalyst sectionwhen a high concentration of hydrogen is burned. The heat exchanger preheats air entering the burner and cools airleaving the catalyst section. The heater heats the incoming air to maintain the catalyst at the proper operating temperature.

NOTE

The type of refrigerant used in the ship stores refrigeration plant dictates thetemperature of the burners catalytic reaction. Ships with R-12 (CFC-12) operate thecatalyst bed at 600 °F (316 °C) and those converted to R-134a (HFC-134a) byShipAlt SSN688-03983 operate at 500 °F (260 °C). Normal burner airflow is 500cfm regardless of catalyst bed temperature.

The catalyst section purifies air containing carbon monoxide, hydrogen, and hydrocarbons by means of a catalytic reactionand heat. The aftercooler cools the air being discharged from the heat exchanger. Airflow and pressure measuringcomponents give a visual measurement of airflow and differential pressure in the burner. The compound mass bars andthe resilient mounts minimize the structure-borne noise transmitted from the burner to the submarine’s hull.


Original 3-1


Figure 3-1. CO and H2 Burner, Mark IV-E (Sheet 1 of 2)


3-2 Original


Figure 3-1. CO and H2 Burner, Mark IV-E (Sheet 2 of 2)


Original 3-3


3-2 CO AND H2BURNER, MARK IV-E, COMPONENT DESCRIPTION

3-2.1 CONTROL BOX The control box contains the electrical components which control electrical power to themotor, the heater, and the control circuitry. It provides a safety enclosure for the ac contactors, thermal overload relays, analarm relay controller, a transformer, an elapsed time meter, and fuses. The ac contactors connect and disconnect electricalpower to the motor and the heater. The thermal overload relays provide overload protection for the motor and the heater.The alarm relay controller provides excessive temperature indication and protection. The transformer steps down 440-Vacpower to 115-Vac power for use in the control circuits. The elapsed time meter records the actual running time of themotor. The fuses protect the 115-Vac circuits from overloads. In addition, the control box houses controls and indicators

Figure 3-2. CO and H2 Burner Functional Block Diagram


3-4 Original


for burner control during normal or emergency operations.

3-2.1.1 AC Contactors The ac contactors connect and disconnect the ac power to the motor and the heater withrelatively low input power. Energizing the shunt coil causes a magnetic pull on the movable armatures, closing the maincontacts and establishing the circuit which provides 440-Vac power to the motor and the heater. Deenergizing the shuntcoil eliminates the magnetic pull, releasing the magnet frame spring which then opens the main contacts, interruptingpower. This deenergizes the motor and the heater. The ac contactors also energize and deenergize the control circuits.

3-2.1.2 Thermal Overload Relays Thermal overload relays monitor current to the motor and the heater. A thin film ofsolder holds internal parts of two heater coils and a thermal element together. When the current through either heater coilbecomes great enough, the solder film melts. This releases internal parts of the thermal element which rotate and release aratchet mechanism. This opens the control circuit and breaks the circuit to the shunt coil of the ac contactors,disconnecting power to the motor and the heater. With no load and an open circuit, the heater coils and solder film cool.When the solder film cools and hardens, the relay can be reset with the stop/reset switch or the reset switch. The motorthermal overload relay also has a start switch and a stop/reset switch. When the start switch is pressed, contacts in thethermal overload relay momentarily close, energizing the motor. When the stop/reset switch is pressed, contacts in thethermal overload relay momentarily open, deenergizing the motor and the control circuit.

3-2.1.3 Alarm Relay Controller The alarm relay controller (Figure3-3) provides excessive temperature indication andshutdown protection. The alarm relay controller is a fully adjustable, solid-state electronic relay controller. The alarmrelay controller contains a thermocouple reference, two set point potentiometers, a reference supply, two trip amplifiers,and two output relays. The thermocouple reference receives the signal from the thermocouple and makes up the inputsignal. The two set point potentiometers are used to adjust the reference signal from the reference supply to the requiredset points of 650 °610 °F (343.3 °65.6 °C) and 675 °610 °F (357.2 °65.6 °C) for ships using R-12 in the shipstores refrigeration plant, or 550610 °F (287.865.6 °C) and 575610 °F(301.765.6 °C) for ships with R-134a. Thereference supply makes up the reference signal. The two trip amplifiers compare the input signal from the thermocouplereference to the reference signal, and operate the output relays if the input signal exceeds the reference signal. The outputrelays are the high-temperature relay and the shutdown alarm relay. The high-temperature relay turns on the excessivetemperature lamp when the temperature in the catalyst section rises above 650 °610 °F (343.3 °65.6 °C) for shipsusing R-12 in the ship stores refrigeration plant, or 550610 °F (287.865.6 °C) for ships with R-134a. The shutdownalarm relay opens the motor controller contactor, shutting down the burner, and triggering the alarm buzzer.

3-2.1.4 Transformer The control box transformer converts incoming 440-Vac main power, needed for burneroperation, to outgoing 115-Vac power, needed for lamps, switch operation, and the control circuit.

Figure 3-3. Alarm Relay Controller Block Diagram


Original 3-5


3-2.1.5 Controls and Indicators The control box houses controls and indicators to operate the burner. The control boxhas three toggle switches, three lamps, and three thermal overload relay switches. The toggle switches control operationof the heater, and override operation of the motor and the alarm buzzer. The lamps indicate whether the control circuit orheater is energized or whether the catalyst section temperature is excessive. The thermal overload relay switches start andstop the motor, and reset the thermal overload relays.

3-2.2 THERMOCOUPLE PROBE The thermocouple probe provides the temperature indicating and alarm relaycontrollers with voltages equivalent to the temperature of the catalyst section. The thermocouple is a temperaturetransducer comprising a closed circuit made of iron and constantan. These dissimilar metals develop a voltage that isproportional to the temperature in the catalyst section. The thermocouple is located on the front of the catalyst section.

3-2.3 TEMPERATURE INDICATING CONTROLLER The temperature indicating controller is a fully adjustable,solid-state electronic device, which controls the temperature of the air entering the catalyst section. The controller has afull scale analog set point and indication, a time proportioning relay primary output, and a process alarm output. Thecontroller receives inputs from the thermocouple. The controller has four functional areas: power supply, input, process,and output. The interaction of these areas is shown in Figure3-4. Two types of temperature indicating controllers arecurrently in use on various installations. The model 1612-4 is installed on new and refurbished burners, and the model102 is installed on old burners. Both types function in basically the same way.

3-2.3.1 Power Supply The 115-Vac input to the power supply is stepped down by a transformer, rectified, and filteredto approximately positive and negative 16 Vdc. This unregulated voltage goes through a voltage regulator that developsthe positive and negative regulated voltages of the power supply. These regulated voltages power the remaining controlcircuit functions of the temperature indicating controller.

3-2.3.2 Input The input signal from the thermocouple goes through the filter and the input amplifier where it istransformed to an equivalent process variable signal. This process variable signal then drives the analog deviationamplifier, the rate amplifier, the meter amplifier, and the process alarm output.


3-6 Original


3-2.3.3 Process The analog deviation amplifier compares the process variable signal to the primary set point signal.The primary set point is adjustable and is set at 600 °F (315.5 °C) for ships with R-12 in the ship stores refrigerationplant, or at 500 °F (260 °C) for ships with R-134a. When the process variable signal differs from the set point signal, theanalog deviation amplifier generates an error signal. This error signal is one input to the adjustable gain proportional bandamplifier. The second input is from the rate amplifier which applies a corrective signal determined by the rate of changeof the process variable signal. The output of the adjustable gain proportional band amplifier is the input signal for theautomatic reset and fixed gain proportional band amplifier. When it is enabled by the reset windup inhibit amplifier, theautomatic reset and fixed gain proportional band amplifier produces a corrective signal to reduce the error signal to zero.The automatic reset and fixed gain proportional band amplifier is one input to the heating on/off comparator amplifier.

Figure 3-4. Temperature Indicating Controller, Model 1612-4, Diagram


Original 3-7


The second input is the ramp signal from the cycle time generator. From these two inputs, the heating on/off comparatoramplifier generates an on/off periodic signal. The ratio of on to off is determined by the magnitude of the signal from theautomatic reset and fixed proportional band amplifier. The meter amplifier amplifies the process variable signal for use bythe analog process indicator.

3-2.3.4 Output The on/off periodic signal drives a time proportioning relay that turns the heater on and off. The analogprocess indicator receives an input from the meter amplifier. The analog process indicator gives an output in the form of afull-scale analog meter indication. The process alarm output accepts the process variable signal as an input. This inputsignal may not be used in all installations.

3-2.4 AIR FILTER HOUSING ASSEMBLY The air filter housing assembly cleans air drawn into the burner. The airfilter housing assembly consists of an air filter housing, a disposable air filter, an air inlet, an air filter housing cover, andair filter retaining springs. Air enters the burner through the ship’s duct system, which is located on top of the air filterhousing. The air filter housing cover is used to gain access to the filter. The air filter retaining springs hold the filterfirmly against the air filter housing. The filter, which is capable of removing particles of approximately 50-microns andlarger, is a disposable cartridge-type filter containing over 70 square feet of filter paper.

3-2.5 AC MOTOR AND FAN WHEEL The fan wheel, driven by the motor, pushes air through the burner. The motorprovides the mechanical force to turn the fan wheel. The fan wheel draws air into the air filter housing assembly andpushes the air through the burner at a rate of 500 cfm. The motor consists of a stator coil wound inside the stator frame,a squirrel cage rotor, and an inner fan mounted on the shaft. To help meet very low structure-borne noise limits, the rotorand the inner fan are precision-balanced as an assembly and the shaft rides in two noise tested ball bearings. The innerfan cools the motor. Alternating current in the stator coil creates a rotating magnetic field which induces another magneticfield in the rotor. The interaction of these magnetic fields rotates the shaft. The motor standard is a 2-hp, 3,485-rpm,induction motor which draws approximately 2.9 amperes of electric current at full load. The SSN21 Class motor is a2-hp, 3,520-rpm induction motor which draws approximately 2.6 amperes of electric current at full load. The motor ismounted on the motor mounting bracket. The fan wheel is attached to the motor shaft within the fan wheel housing.

3-2.6 BYPASS DUCT AND PUSH-PULL CONTROL The bypass duct and the push-pull control are used to controlthe temperature in the catalyst section when a high concentration of hydrogen is burned. The bypass duct diverts a portionof the cool inlet air from the fan wheel housing and motor mounting bracket and routes this air directly to the heater.Thus the heat exchanger is partially bypassed and the cooler air reduces the temperature of the catalyst. The push-pullcontrol varies the amount of cool air that passes through the bypass duct. The push-pull control is a lock-T handle thattravels 1-3/8 inches, opening or closing the flapper valve in the bypass duct.

3-2.7 HEAT EXCHANGER The heat exchanger preheats air entering the burner and cools air leaving the catalystsection and the burner. Air is passed over the inlet side of the heat exchanger where it is preheated by air leaving thecatalyst section. This cools the air leaving the outlet side of the heat exchanger by transferring heat to the incoming air.The heat exchanger consists of a core and a casing. The casing has a lower and an upper half. The incoming andoutgoing air streams are separated in the heat exchanger by four wedge seals located at each corner of the heat exchanger.The heat exchanger core is a series of dimpled sheets with alternating air passages. The heat exchanger sheet bundle iswelded at the seams to seal the air passages.

3-2.8 HEATER The heater heats the incoming air from the heat exchanger to approximately 600 °F (315.5 °C) forships with R-12 in the ship stores refrigeration plant, or 500 °F (260 °C) for ships with R-134a. The heater consists of 18finned hairpin-shaped heating elements. The finned design provides a large surface area for maximum heat transfer. Eachheating element has a rating of 1,450 watts at 254 volts. The total rating for the heater is 26,100 watts. This ratingprovides a rapid heatup to operating temperature without causing equipment damage due to excessively rapid thermalexpansion. The heater is located below the catalyst section.

3-2.9 CATALYST SECTION The catalyst section purifies air containing carbon monoxide, hydrogen, andhydrocarbons by means of a catalytic reaction and heat. The catalyst is maintained at a temperature of 600625 °F(316613.9 °C) for ships with R-12 in the ship stores refrigeration plant or 500625 °F (260613.9 °C) for ships with R-134a


3-8 Original


(refer to paragraph1-3.11for further discussion). The catalyst in the catalyst section speeds up the oxidation reaction bywhich the carbon monoxide, hydrogen, and hydrocarbons are burned. These toxic or explosive substances combine withoxygen on the surface of the catalyst, under heat, to produce carbon dioxide and water vapor. As they pass through thecatalyst, carbon monoxide is converted to carbon dioxide, hydrogen is converted to water vapor, and hydrocarbons areconverted to both carbon dioxide and water vapor. The catalyst chemically speeds these oxidation reactions but is notconsumed itself as the reactions take place. Because the catalyst is not chemically consumed, it may remain activeindefinitely if not exposed to and poisoned by halogen containing compounds(refrigerants), chlorinated solvents, andsulfurous compounds. A chemical substance called Hopcalite is used as the catalyst in the burner. It is efficient and doesnot absorb hydrocarbons at normal burner operating temperatures. The catalyst is located in the catalyst section above theheater assembly. Assuming proper burner operation, catalyst replacement is based on the burners inability to controlcarbon monoxide and hydrogen levels which is affected by extensive catalyst poisoning.

3-2.10 AFTERCOOLER The aftercooler cools air being discharged from the heat exchanger and controls thetemperature of the outlet air to prevent condensation.. The aftercooler has no moving parts. Chilled water moves throughthe tube side of the aftercooler to cool the air. The maximum chilled air water flow through the aftercooler is 15 gpm.The aftercooler maintains the required outlet temperature of 100 to 110 °F (37.7 to 43.3 °C), using 45 °F (7.2 °C) waterat a flowrate of approximately 2 gpm with the burner operating at 600 °F (316 °C) on ships with R-12 in the ship storesrefrigeration plant, or approximately 1.5 gpm with the burner at 500 °F (260 °C) on ships with R-134a installed.

3-2.11 AIRFLOW AND PRESSURE MEASURING COMPONENTS The airflow and pressure measuringcomponents (Figure3-5) give a visual measurement of airflow and differential pressure in the burner. The airflow andpressure measuring components consist of a differential pressure gage, a manifold valve assembly, and a pitot tube. Thegage indicates the pressure selected by any pair of flip toggle valves on the manifold valve assembly. The flip togglevalves select the points in the burner that are to be measured. Differential pressure can be measured across the filter, theheat exchanger inlet, the catalyst section, and the heat exchanger outlet. Compression fittings connect the 1/8-inch ODtubes from the flip toggle valves at these sampling points on the burner. Airflow through the burner is measured by thepitot tube. The gage and manifold valve assembly are connected to each other and are mounted on the instrumentmounting bracket.

3-2.11.1 Differential Pressure Gage The gage indicates airflow and differential pressure measurements in the burner.Measurements are indicated when the diaphragm in the gage is actuated by air pressure differences between two inputs.The gage displays measurements in inches of water and has a 0- to 5-inch water range.


Original 3-9


3-2.11.2 Flip Toggle Valves The flip toggle valves are used to select the points in the burner where the differentialpressure or the airflow is to be measured. Each flip toggle valve is a manual-release valve. When the toggle is moved tothe deflected(on) position, it pushes down on the toggle plunger, moving the spool plunger downward. The spool plungerthen allows the air at the inlet to travel to the outlet. When the toggle is moved back to the neutral (off) position, a springpushes up on the spool plunger and toggle plunger, stopping airflow to the gage.

3-2.11.3 Pitot Tube Airflow through the burner is measured by the pitot tube. The pitot tube is an airflow samplingtube assembly extending into the inlet air stream at the fan wheel housing and motor mounting bracket. The pitot tubeconsists of two tubes. One tube extends straight into the air stream with its opening parallel to the airflow. The second

Figure 3-5. Airflow and Pressure Measuring Components


3-10 Original


tube is bent at a right angle to the air stream and its opening faces the airflow. The difference in airflow velocitymeasured by each tube is displayed on the differential pressure gage as the actual velocity of the airflow into the burner.

3-2.12 COMPOUND MASS BARS AND RESILIENT MOUNTS To minimize structure-borne noise transmitted fromthe burner to the submarine’s hull, the burner is resiliently mounted. Two compound mass bars are supported from thesubmarine base by six resilient mounts, except on SSN21 Class ships, where the compound mass bars are hard mounted.The burner is supported on the compound mass bars by four resilient mounts (shown in Figure3-1).

3-3 SYSTEM FUNCTIONAL DESCRIPTION

3-3.1 AIRFLOW THROUGH BURNER Air is drawn into the burner (Figure3-6) by the fan wheel. Air enters at thetop of the air filter housing assembly, and through the inlet silencer (SSN21 Class only), where it is cleaned by the filter.The motor-driven fan wheel pushes the air through the inlet side of the heat exchanger where it is preheated by theheated air leaving the catalyst section. The air then passes over the heater where it is heated to approximately 600 °F(315.5 °C) for ships with R-12 in the ship stores refrigeration plant or 500 °F (260 °C) for ships with R-134a. The air ispurified by means of a catalytic reaction which burns carbon monoxide to carbon dioxide, hydrogen to water vapor, andhydrocarbons to carbon dioxide and water vapor. From the catalyst section, heated air is directed through the heatexchanger. Most of the heat is removed by the heat exchanger and is used to heat incoming air. The air then passesthrough the aftercooler. The aftercooler further cools the air to 100 ° to 110 °F (37.7 ° to 43.3 °C) before it is dischargedfrom the burner whether R-12 or R-134a is used in the ship stores refrigeration plant. When a high concentration ofhydrogen, above 1 percent, is burned, the temperature of the air leaving the catalyst section increases appreciably. Whenthis happens, the bypass duct and the push-pull control must be used to control burner temperature. The bypass duct andthe push-pull control divert cool inlet air and route it directly to the catalyst section. Thus the heat exchanger is partiallybypassed and cool inlet air reduces burner temperature.


Original 3-11


Figure 3-6. Airflow Diagram


3-12 Original


3-3.2 ELECTRICAL OPERATION The electrical components on the burner provide controls and indications to startand stop the motor and the heater, and to regulate and protect burner temperature. A simplified electrical schematic isshown inFO-1. This discussion applies specifically to burners equipped with the model-1612-4 temperature indicatingcontroller. All other burners operate similarly.

3-3.2.1 Starting The 440-Vac, 3-ph, 60-Hz power is directed to the transformer (TR) and to the main contacts of themotor contactor (MC) and the heater contactor(HC). The TR converts 440-Vac to 115-Vac control circuit voltage throughfuses F1 and F2. When the start switch is momentarily pressed, the MC shunt coil is energized. The main contacts of MCclose, directing 440 Vac to the motor through the heater coil of the motor overload relay (MOL). An interlock contact ofMC also closes, maintaining the 115-Vac power around the released start switch. Power to the motor is indicated bycontrol circuit lamp L1. The heater is energized by placing heater switch SW1 at the on position. The main contacts ofHC close, directing 440-Vac power to the heater through the heater coils of the heater overload relay (HOL). Power to theheater is indicated by heater lamp L2.

3-3.2.2 Stopping The burner shuts down when the stop/reset switch is momentarily pressed. This deenergizes motorcontactor MC and heater contactor HC shunt coils, allowing all main contacts to open, and deenergizing the motor andthe heater.

3-3.2.3 Overload Protection The motor and the heater are protected from excessive current by their respectivethermal overload relays. The motor overload relay (MOL) contacts open to deenergize motor contactor MC whenexcessive current passes through the MOL heater coils. The heater is protected in a similar way by the heater overloadrelay (HOL). In the event that the MOL opens, the heater will also be deenergized because its contactor coil is wired inseries with the MOL. The stop/reset switch resets MOL. The HOL is reset by the heater reset switch(not shown).

3-3.2.4 Overtemperature Protection Thermocouple (TC1) and the alarm relay controller shut down the burner whenthe temperature exceeds 675 °F (357.2 °C) for ships with R-12 in the ship stores refrigeration plant or 575 °F (301.7 °C)for ships with R-134a. When an alarm relay (RY2) normally closed (NC) contact opens, the motor contactor (MC) shuntcoil is deenergized, opening its contacts to deenergize the control circuit. Loss of the control circuit shuts off the motorand the heater. The RY2 normally open (NO) contact closes, sounding the alarm buzzer through audible alarm switch

Figure 3-7. Air Filter Housing Assembly and Fan Configuration for SSN21 Class


Original 3-13


SW3. The override switch (SW2) is used to bypass RY2 and restart the burner. When SW2 is placed in the overrideposition preventing heater operation, the MC circuit is reestablished around RY2. The start switch is then momentarilypressed to start the motor.

3-3.2.5 Temperature Control The temperature indicating controller (TIC) controls the temperature of the air enteringthe catalyst section by automatically cycling the heater on and off. The TIC does this by opening or closing timeproportioning relay TS1 contact that controls the power to heater contactor HC. The controller determines the length ofthe on and off cycle by measuring the difference between the primary set point and the input from thermocouple TC1 andTC2. If the temperature exceeds 650 °F (343.3 °C) for ships with R-12 in the ship stores refrigeration plant or 550 °F(287.8 °C) for ships with R-134a, high-temperature relay RY1 contact closes, turning on excessive temperature lamp L3.On some ships, this system also triggers alarm relay RY2. Light-emitting diodes indicate whether the heater is on or offand whether there is a process alarm.


3-14 Original


CHAPTER 4SCHEDULED MAINTENANCE

4-1 INTRODUCTION

4-1.1 PLANNED MAINTENANCE SYSTEM Preventive maintenance procedures to be performed on a scheduledbasis are provided in Planned Maintenance System (PMS) documentation. This system is described in OPNAVINST4790.4, which also covers departmental and work center recordkeeping, as well as the Maintenance Index Page (MIP) andMaintenance Requirement Cards (MRC’s). Scheduled maintenance procedures for the Mark IV-E CO and H2 burner arecovered by the MCR’s.

4-1.2 EXTENT OF COVERAGE The extensive and comprehensive scheduled preventive maintenance provided byMRC’s eliminates the need for specific coverage within this chapter. Specific corrective maintenance (adjustment,alinement, and repair) is covered in Chapter6 of this manual.

4-2 PREVENTIVE MAINTENANCE SCHEDULE

Table 4-1 provides the recommended schedule (from the MIP) for preventive maintenance of the Mark IV-E CO and H2

Burner. The table contains three columns; Periodicity Code, Maintenance Requirement Description, and MRC (SYSCOMMRC Control Number). The periodicity codes are as follows:

M = Monthly Q = Quarterly A = AnnuallyR = Requirement LU = Lay-Up PM = Periodic MaintenanceSU = Start-Up ** = for scheduling purposes; no MRC is provided

Table 4-1. Preventive Maintenance Schedule

PeriodicityCode Maintenance Requirement Description MRC

In-Service Equipment MaintenanceM-2R a Inspect lithium carbonate. 4DRY

Q-1 Inspect catalyst bed level. 2HQWQ-3 Conduct short term monitoring of CO-H2 baseline operating parameters. 7CFXA-1 Test thermal switch. 2TGAA-2 Clean and inspect control panel. 6MDQ

A-3 b Test thermal shutdown function. 8UERA-2R c Inspect CO-H2 burner components with fiber optic equipment. 7BWVA-3R d Inspect after cooler coil for damage and deterioration. 3KQC

Inspect aftercooler coil drain.R-3e Replace air inlet filter element. 3WGJR-7f Renew lithium carbonate. 3XWT

Inactive Equipment MaintenanceThe following requirements will be scheduled when equipment is inactivated for periodsof prolonged ideleness.Lay-Up Maintenance:

LU-1 g Remove lithium carbonate. 3RNURemove catalyst.

LU-2 h

**Install protective covers over gageboard and motor.


Original 4-1


Table 4-1. Preventive Maintenance Schedule – Continued

PeriodicityCode Maintenance Requirement Description MRC

Periodic Maintenance:PM-1i

**Inspect protective covers for damage or deterioration.

PM-2j

**Rotate blower shaft 1-1/4 turns by hand.

Start-Up Maintenance:SU-1k Install lithium carbonate. 3RNV

Install catalyst.SU-2l

**Remove protective covering.

aAccomplish monthly or when atmosphere has become contaminated by a refrigerant leak.b MRC A-3 applies to ships with SHIPALT SSBN 1987 or SSN 2873 for MKIV and MKIV-E burners.c Accomplish annually or when CO-H2 burner degradation is suspectedd Accomplish annually and following prolonged (more than 4 days) high levels of refrigerant in atmosphere.eAccomplish when rated air flow through filter cannot be maintained.f Accomplish prior to deployment or patrol.g Accomplish if ship is to be inactive longer than 60 days.h Accomplish in an industrial environment when equipment will be subjected to welding, chipping, sandblasting, orpainting dust.i Accomplish weekly when equipment is covered.j Accomplish weekly.k Accomplish if lithium carbonate has been removed.l Accomplish when equipment has been covered for protection


4-2 Original


CHAPTER 5TROUBLESHOOTING

5-1 INTRODUCTION

5-1.1 PURPOSE AND SCOPE This chapter provides information to aid qualified personnel in troubleshooting theMark IV-E CO and H2 . The most common burner malfunctions, their causes, and appropriate corrective actions areidentified in a fault logic diagram and troubleshooting tables. Information necessary for the use of fault logic diagramsand the tables appears in text. This information includes safety requirements, preliminary troubleshooting, systemtroubleshooting, and component troubleshooting. The troubleshooting information in this chapter applies only tomalfunctions of single components. Compound malfunctions involving the simultaneous failure of two or morecomponents are not covered in the chapter. Measurement conversion information for units of measure appearingthroughout all chapters is presented in Table1-1.

5-1.2 SAFETY REQUIREMENTS Prior to performing any troubleshooting procedures on the burner, maintenancepersonnel shall review and become thoroughly familiar with the general safety notices and precautions listed in theSafetySummary. Additional safety requirements, presented in paragraph1-1.2of this manual, also shall be reviewed beforetroubleshooting burner malfunctions. Specific troubleshooting procedures, along with their individual warnings andcautions, shall be read in full prior to beginning troubleshooting.

5-2 PRELIMINARY TROUBLESHOOTING

At first sign of a malfunction, stop the burner in accordance with ship procedures. Check the procedures forpreoperational checks and normal operation (paragraphs2-3.1and2-3.2) to verify that all procedures have beenperformed correctly. If this does not correct the malfunction, the fault logic diagram in Figure5-1 shall be used toperform a preliminary troubleshooting check. In the fault logic diagram, the top of the diagram (at START) begins aseries of tests or observations. A test in a shaded block is one that can be performed without special test equipment orprocedures. Double-lined blocks enclose conclusions about identified faults and/or reference further action.


Original 5-1


5-3 SYSTEM TROUBLESHOOTING

5-3.1 TROUBLESHOOTING OBSERVATIONS The following questions shall be answered to determine the natureof the malfunction.

a. Did the malfunction first become evident during preoperational checks or normal operation?

b. Are there unusual noises, odors, or vibrations?

c. Are LED lamps on temperature indicating controller on or off?

Figure 5-1. Preliminary Troubleshooting Checks


5-2 Original


d. Did the excessive temperature lamp on the control box come on?

e. What temperature is indicated on the temperature indicating controller?

f. What measurements, if any, does the differential pressure gage show?

5-3.2 TROUBLESHOOTING TABLES To use the troubleshooting tables, first identify the symptom/malfunction inthe left-hand column of the system troubleshooting table (Table5-1) that best describes the problem with the burner. Oncea symptom/malfunction has been identified, proceed to probable causes listed in the middle column of the systemtroubleshooting table. Probable causes are listed in the approximate order in which they should be checked, although theydo not necessarily have to be checked in this order. Certain sounds, vibrations, or odors may indicate specific probablecauses and eliminate others. Knowledge of the maintenance history of the burner also aids in identifying probable causes.Tests or observations in the tables shall be performed only by qualified maintenance personnel. To check a probablecause, proceed to either the airflow, temperature, or electrical troubleshooting table (Tables5-2, 5-3, or 5-4) or to theprocedure referenced in the right-hand column of the system troubleshooting table. Locate the proper symptom/malfunction and probable cause in the referenced troubleshooting table and perform the specific corrective action listed inthe right-hand column of this table. An alarm relay controller schematic (FO-2) and burner electrical schematic (FO-3) arealso provided to aid in troubleshooting.FO-2 andFO-3 are located at the end of the chapter.

Table 5-1. System Troubleshooting

Symptom/Malfunction Probable Cause Table/Procedure1. Burner does not operate No power to control circuit Table5-42. Motor does not turn 1. Electrical malfunction Table5-4

2. Motor defective paragraph5-4.13. Burner does not heat up properly 1. Improper airflow Table5-2

2. Temperature increase is too slow Table5-33. Temperature does not increase to normal

catalyst bed operating temperature.aTable5-3

4. Temperature does not increase afterburner is started.

Table5-4

4. Burner overheats Electrical malfunction Table5-45. Improper differential pressure

measurementsImproper airflow Table5-2

6. Excessive noise or vibration Motor and fan wheel assembly defective paragraph5-4.17. Burner operates but does not lower

CO and H2 concentrationsIneffective catalyst reaction Table5-2

aShips with R-12 installed in the ship stores refrigeration plant operate at 600 °F (316 °C) and those with R-134ainstalled operate at 500 °F (260 °C).

Table 5-2. Airflow Troubleshooting

Symptom/Malfunction Probable Cause Corrective Action1. High differential pressure

measurements across disposable airfilter (filter) and low burner airflowmeasurements

1. Clogged filter Replace filter orfilter gasket(paragraph6-7.4)

2. Clogged pressure port Clean pressure portat filter housin

2. Correct burner airflow measurementcannot be obtained

Pitot tube assembly leaking Tighten pitot tubeconnections


Original 5-3


Table 5-2. Airflow Troubleshooting – Continued

Symptom/Malfunction Probable Cause Corrective Action3. Low differential pressure

measurements across filter and highburner airflow measurements

Air leaking around filter Replace filter orfilter gasket(paragraph6-7.4)

2. Ship’s ventilation duct restricted Ensure that damperis open and thatthere is properairflow throughlithium carbonatefilters

3. Pressure gage indicator incorrect Check pressuregage (paragraph6-3.7)

4. Motor rotates backwards Reverse motor leads4. Low differential pressure

measurement across catalyst section1. Low catalyst level allows air to leak

around catalystFill catalyst section(paragraph6-7.2)

2. Low temperature Ensure that catalystbed temperature isgreater than 550 °F(288 °C) for shipswith R-12 in theship storesrefrigeration plantor 450 °F (232 °C)for those withR-134a.

5. Low differential measurement acrossheat exchanger inlet or outlet

a N/A

6. High differential pressuremeasurement across catalyst section

Catalyst is old and has settled Replace catalyst(paragraph6-7.2)

7. High differential pressure across heatexchanger inlet or outlet

Clogged, dirty, or defective heat exchanger Clean/repair/replaceheat exchanger(paragraph6-7.9)

8. Burner operates but ineffectivecatalyst reaction prevents lowering ofCO and H2 concentration

1. Low catalyst level allows air to leakaround catalyst

Fill catalyst section(paragraph6-7.2)

2. Effective life of catalyst exceeded Replace catalyst(paragraph6-7.2)

9. Airflow and/or pressures cannot bemeasured

1. Gage not functioning properly Check accuracy ofgage (paragraph6-3.7)

2. Manifold valve assembly blocked Replace manifoldvalve assembly(paragraph6-7.7)

3. Flip toggle valve defective or blocked Replace flip togglevalve (paragraph6-7.7)

aShips using R-134a in ship stores refrigeration plant require the burner to be operated at 500°F (260°C), and may havereadings at the minimum value of the acceptable differential pressure range that are as much as 0.2 inches of water lower.


5-4 Original


Table 5-3. Temperature Troubleshooting

Symptom/Malfunction Probable Cause Corrective Action1. Temperature does not increase to

normal catalyst bed operatingtemperaturea or rises too slowly

1. Heating element shorted to ground Check resistancefrom phase toground (2 megohmsminimum). Replaceheater if defective(paragraph6-7.8)

2. Door gasket on bypass duct damaged Repair/replace doorgasket on bypassduct (paragraph6-7.1)

3. Burned-out heating element in heater Replace defectiveheating element(s)of heater (paragraph6-7.8)

4. Thermocouple probe not at correct depthin catalyst bed

Ensure that probe isinserted as deeplyas possible intocatalyst bed

2. Excessive temperature cycling 1. Input voltage or current incorrect Check voltage andcurrent to burner

2. Airflow in burner low Adjust airflow3. Temperature indicating controller

malfunctionAdjust temperatureindicating controller(paragraph6-3.3)

4. Current exceeds 36 amps at 440 volts Replace heater(paragraph6-7.8)

aShips with R-12 in the ship stores refrigeration plant operate at 600 °F (316 °C) and those with R-134a operate at 500°F (260 °C).

Table 5-4. Electrical Troubleshooting

Symptom/Malfunction Probable Cause Corrective Action1. Burner does not operate when start

switch is pressedNo power to control circuit Check fuses and

transformer (paragraph5-4.2).

2. Motor does not run with controlcircuit lamp on

1. Defective ac contactor Repair/replace accontactor (paragraph6-7.6.3)

2. Defective motor thermal overloadrelay heater coil

Replace heater coil(paragraph6-7.6.5.1)

3. Defective motor thermal overloadrelay

Repair/replace thermaloverload relay(paragraph6-7.6.5)


Original 5-5


Table 5-4. Electrical Troubleshooting – Continued

Symptom/Malfunction Probable Cause Corrective Action3. Burner temperature does not increase

with heater lamp on1. Defective ac contactor Repair/replace ac

contactor (paragraph6-7.6.4)

2. Defective heater thermal overloadrelay heater coil

Replace heater coil(paragraph6-7.6.5.1)

3. Defective heaters Replace heaters(paragraph6-7.8)

4. Burner temperature increases withheater lamp off

1. Temperature indicating controllermalfunction

Adjust temperatureindicating controller(paragraph6-3.3)

2. Defective heater switch Check heater switch(paragraph5-4.3)

3. Defective override switch Check override switch(paragraph5-4.3)

4. Defective heater thermal overloadrelay

Repair/replace thermaloverload relay(paragraph6-7.6.5)

5. Burner shuts down when temperatureis less than the minimum temperatureshutdown setpoint.a

1. Alarm relay controller malfunction Adjust alarm relaycontroller (paragraph6-3.2)

2. Motor thermal overload relay trips Determine cause ofmotor overload andcorrect.

3. Defective thermocouple probe Replace thermocoupleprobe (paragraph6-7.3)

6. Burner does not shut down whentemperature is more than themaximum high temperature shutdownsetpoint.a

1. Alarm relay controller malfunction Adjust alarm relaycontroller (paragraph6-3.2)

2. Defective thermocouple probe Replace thermocoupleprobe (paragraph6-7.3)

7. Meter indicator remains at or nearzero

1. Defective temperature indicatorcontroller

Replace temperatureindicating controller(paragraph6-7.7.1)

2. Shorted thermocouple probe Check thermocouplewires

3. Temperature indicating controllermalfunction

Adjust temperatureindicating controller(paragraph6-3.3)

8. Temperature indicating controllermaintains high reading (800 °F(426.7 °C))

Open input circuit from thermocoupleprobe

1. Replacethermocouple probe(paragraph6-7.3)

2. Check for brokenlead wires

9. Heater on lamp on, with temperatureindicator needle indicating decreasingtemperature

Thermocouple probe malfunction Reverse thermocouplewire polarity

aShips with R-12 in the ship stores refrigeration plant have a high temperature shutdown setpoint of 675610 °F (357.265.6 °C) and those with R-134a have a setpoint of 575610 °F (301.765.6 °C).


5-6 Original


5-4 COMPONENT TROUBLESHOOTING

5-4.1 AC MOTOR AND FAN WHEEL ASSEMBLY The following procedure andFO-3 shall be used to troubleshootthe motor and fan wheel assembly. Common problems include bearing damage, insulation breakdown, and excessivevibration. If any check indicates defective equipment, refer to paragraph6-7.5 for repair procedures.

a. Ensure that motor shaft rotates freely and in direction of rotation arrow.

b. Check that all bolts and nuts are securely tightened.

c. Using thermometer, ensure that temperature of casing near bearings and any exposed surface of motor has notexceeded 60.8° to 78.5°F (16° to 26 °C) above ambient temperature of 122 °F (50 °C).

d. Listen for noise and feel for vibration during operation. Excessive noise or vibration may indicate worn bearingsor defective fan wheel.

e. Check insulation resistance.

WARNING

To prevent injury or death, ensure that burner is completely deenergized and taggedout of service.

(1) Deenergize burner at power panel and tag out of service in accordance with ship procedures.

(2) In control box, tag and disconnect leads to motor at terminal blocks (TB2-1, TB2-2, and TB2-3).

(3) Attach one lead of megger to one disconnected motor lead and attach second megger lead to any accessibleground point.

(4) Measure insulation resistance. Minimum insulation resistance is 1.0 megohm.

(5) Disconnect megger lead from motor lead.

(6) Repeat steps5-4.1.e.(3)through5-4.1.e.(5)for two remaining motor leads.

(7) Disconnect megger and reconnect motor leads to TB2-1, TB2-2, and TB2-3.

(8) If any insulation resistance is below 1.0 megohm, clean windings or rewind motor (paragraph6-7.5.2or6-7.5.3).

(9) Remove out of service, tag in accordance with ship procedures, and energize burner at power panel.

f. Ensure proper motor rotation. Motor should rotate in direction of arrow on motor.

5-4.2 FUSES AND TRANSFORMER The following procedure andFO-3 shall be used to troubleshoot the controlcircuit.


Original 5-7


WARNING


a. Deenergize burner at power panel and tag out of service in accordance with ship procedures.

b. Remove fuses F1 and F2 and check for continuity, using multimeter. Replace any blown fuse.

c. Identify and tag wires to terminals (H1 and H4)of transformer TR.

d. Disconnect wires from H1 and H4.

e. Using multimeter set to read continuity, check continuity at H1 and H4. If reading is infinite, replace transformer(paragraph6-7.6.1).

f. Repeat step5-4.2.eat terminals X1 and X2 of transformer. If reading is infinite, replace transformer.

g. Reconnect wires to H1 and H4.

h. Reinstall fuses.

i. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

5-4.3 HEATER, OVERRIDE, AND AUDIBLE ALARM SWITCHES The following procedure shall be used to checkthe heater, override, and audible alarm switches, SW1, SW2, and SW3.

WARNING



b. Identify and tag wire to one terminal of each set of contacts.

c. Disconnect wires from contact terminals.

d. Using multimeter set to read continuity, check continuity of contacts.

(1) Check continuity of all contacts. Open contacts should indicate infinity, and closed contacts should indicatecontinuity. Indication for operated contacts should be reversed.

(2) Operate switch and repeat step5-4.3.d.(1).

(3) If any continuity readings are not correct, replace switch (paragraph6-7.6.1).

e. Reconnect wires to contact terminals.

f. Remove out of service tag in accordance with ship procedures and reenergize burner at power panel.


5-8 Original


5-4.4 TEMPERATURE INDICATING CONTROLLER Troubleshooting the temperature indicating controller is not anormal shipboard maintenance action. However, if a replacement temperature indicating controller is not available, thetemperature indicating controller schematic(FO-4); NAVSEA 0967-LP-000-0130, Electronics Installation and MaintenanceBook, Test Methods and Practices; and paragraphs5-4.4.1and5-4.4.2can be used to troubleshoot the temperatureindicating controller.FO-4 is located at the end of the chapter. Suggested methods for repair and replacement of thetemperature indicating controller are explained in SE000-00-EIM-160, Electronics Installation and Maintenance Book,General Maintenance.

5-4.4.1 Temperature Indicating Controller, Model 1612-4, Calibration Check To ensure accuracy, perform thisprocedure when ambient temperature of temperature indicating controller is 75 °65 °F (23.9 °62.8 °C).

WARNING



b. Gain access to control box.

c. Identify, tag, and disconnect thermocouple wires from terminal boards (TB3-9 and -10).

NOTE

Ships with R-12 installed in the ship stores refrigeration plant operate at 600625°F (316613.9 °C) and ships with R-134a operate at 500625 °F (260613.9 °C).

d. Connect power supply and voltage divider to TB3-9 and -10 and set as follows:

(1) 16.0 mVdc when operating at 600 °F (316 °C)

(2) 12.9 mVdc when operating at 500 °F (260 °C)

WARNING

High voltages are present in this equipment. To prevent injury or death, extremecaution shall be exercised when working with energized equipment.

e. Remove out of service tag in accordance with ship procedures and reenergize burner at power supply.

f. Temperature indicating controller should read 600 °625 °F (315.6 °613.9 °C) if R-12 is installed in ship storesrefrigeration plant or 500625 °F (260613.9 °C) if R-134a is used. If it does not, adjust controller (paragraph6-3.3.1).

g. Deenergize burner at power panel and tag out of service in accordance with ship procedures.

h. Remove power supply and voltage divider from control box and reconnect thermocouple wires to TB3-9 and -10.

i. Remove out of service tag in accordance with ship procedures and reenergize burner at power supply.

5-4.4.2 Temperature Indicating Controller, Model 1612-4, Primary Control Circuit and Alarm Circuit Check Toensure accuracy, perform this procedure when ambient temperature of temperature indicating controller is 75°65 °F(23.9°62.8 °C).


Original 5-9


WARNING



b. Remove temperature indicating controller from instrument mounting bracket (paragraph6-7.7).

c. Connect power supply and voltage divider to terminals labeled T/C located on rear of temperature indicatingcontroller.

d. To ensure that proper input voltage is obtained, connect multimeter to terminals labeled T/C.

WARNING


e. At rear of controller, connect 115-Vac power source to terminals labeled 120 and LN. Allow 20 minutes warmuptime.

f. Check primary control circuit.

(1) Record position of proportional band, rate, and reset adjustment potentiometers.

(2) Turn proportional band and rate potentiometers counterclockwise to their minimum positions.

(3) Turn reset potentiometer clockwise to its maximum position.

NOTE

Ships with R-12 installed in the ship stores refrigeration plant operate at 600625°F (316613.9 °C) and those with R-134a operate at 500625 °F (260613.9 °C).

(4) Turn primary set point knob until set point indicator indicates as follows:

(a) 600 °F if R-12 is installed

(b) 500 °F if R-134a is installed

(5) At rear of controller, connect ohmmeter to terminals labeled C and L.

(6) Adjust voltage divider for 15.2 mV output if R-12 is installed or 12.2 mV if R-134a is installed and wait 15seconds. Ohmmeter should read 1 megohm (open circuit).

(7) Adjust voltage divider for 16.8 millivolts output if R-12 is installed or 13.7 mV if R-134a is installed and wait15 seconds. Ohmmeter should read 0.1 ohms (short circuit).

(8) If controller meets conditions described in step5-4.4.2.f.(6)and5-4.4.2.f.(7), primary control circuit isfunctioning properly. If not, replace controller (paragraph6-7.7).

(9) Readjust proportional band, rate, and reset potentiometers to positions noted in step5-4.4.2.f.(1).


5-10 Original


g. Check high temperature alarm circuit.

NOTE

Ships with R-12 installed in the ship stores refrigeration plant set the hightemperature alarm at 650610 °F (34365.6 °C) and those with R-134a set it at550 610 °F (287.865.6 °C).

(1) Adjust voltage divider for 17.530 mV output if R-12 is used or 14.5 mV if R-134a is used.

(2) Turn process alarm set point potentiometer on controller until alarm lamp just comes on.

(3) Adjust millivolt source above and below setting of step5-4.4.2.g.(1)to verify that alarm is triggered astemperature reading rises to 650 °F (343.3 °C) if R-12 is installed or 550 °F (287.8 °C) if R-134a is installed.

h. Disconnect 115-Vac power source from controller terminals.

i. Disconnect power supply, voltage divider, multimeter, and ohmmeter from controller terminals.

j. Reinstall temperature indicating controller in instrument mounting bracket (paragraph6-7.7).

5-4.4.3 Temperature Indicating Controller, Cepeda Series 988 Refer to AppendixA of this manual for informationon the Cepeda Series 988 temperature indicating controller.

5-4.4.4 Temperature Indicating Controller, West Model 2075 Refer to AppendixB of this manual for informationon the West Model 2075 temperature indicating controller.

5-4.5 ALARM RELAY CONTROLLER The following procedure shall be used to verify the proper operation of thealarm relay controller.

a. Perform preoperational check (paragraph2-3.1).

b. Start burner (paragraph2-3.2).

NOTE

Ships with R-12 installed in the ship stores refrigeration plant operate at 600625°F (316613.9 °C) and those with R-134a operate at 500625 °F (260613.9 °C).

c. Operate burner normally until operating temperature of 600 °F (316.6 °C) is reached if R-12 is installed or 500 °F(260 °C) if R-134a is installed.

d. Set primary set point pointer on temperature indicating controller to 700 °F (371.1 °C) if R-12 is installed or 600°F (316.6 °C) if R-134a is installed.

e. Adjust pitot tube for minimum (400 cfm) airflow through burner.

NOTE

Ships with R-12 installed in the ship stores refrigeration plant set the shutdownalarm relay at 675610 °F (357.265.6 °C) and for those with R-134a set it at 575610 °F (301.765.6 °C).


Original 5-11


f. Observe temperature at which burner shuts down. If alarm relay controller is functioning properly, burner hightemperature lamp should illuminate at 650610 °F (343.365.6 °C) if R-12 is installed or at 550610 °F (287.865.6 °C) when R-134a is installed and burner should shut down at 675 °610 °F (357.2 °6 5.6 °C) if R-12 isinstalled or 575610 °F (301.765.6 °C) if R-134a is installed.

g. If burner does not shut down, adjust alarm relay controller (paragraph6-3.2).

h. Set primary set point pointer on temperature indicating controller to 600 °F (316.6 °C) if R-12 is installed or 500°F (260 °C) if R-134a is installed.

i. Readjust airflow to 500 cfm.

j. Shut down burner (paragraph2-3.3).


5-12 Original


CHAPTER 6CORRECTIVE MAINTENANCE

6-1 INTRODUCTION

6-1.1 SCOPE This chapter provides specific corrective action for organizational and intermediate level maintenancefor the Mark IV-E CO and H2burner. Corrective action consists of procedures to adjust, aline, repair, or replacecomponents. Adjustment and alinement procedures are presented in SectionI. Repair procedures, detailing removal,disassembly, repair, reassembly, and reinstallation, are presented in SectionII . Measurement conversion information forunits of measure appearing throughout all chapters is presented in Table1-1. Applicable technical manual numbers forNaval Ships’ Technical Manual (NSTM) chapters and titles for other referenced technical manuals are presented in Table1-5.

6-1.2 SAFETY REQUIREMENTS Prior to performing any corrective maintenance on the burner, maintenancepersonnel shall review and become thoroughly familiar with the general safety notices and precautions listed in theSafetySummary. Additional safety requirements, presented in paragraph1-1.2of this manual, also shall be reviewed beforeperforming any maintenance on the burner. Specific adjustment/alignment and repair procedures, along with theirindividual warnings and cautions, shall be read in full prior to beginning corrective maintenance.

6-1.3 TOOLS, EQUIPMENT, AND MATERIALS Maintenance procedures contained in this chapter require the use ofstandard tools and equipment. The following standard tools, equipment, and materials are recommended for maintenance.

1. Abrasive stick, rubberized (NSN 5350-01-012-8454) For breaking sharp edges after lapping2. Air hose3. Ammeter, clamp on, ac/dc (SCAT 4228) For thermal overload relay adjustment4. Arbor press For ac motor repair5. Bag, plastic (NSN 8105-00-579-8451)6. Brush, soft bristled7. Brush, stiff bristled8. Calibration set (King Nutronics model 3460, APL 546479001

or 464790002; or model 3461, APL 464790013)For differential pressure gage adjustment

9. Cardboard10. Catalyst, carbon monoxide and hydrocarbon oxidizing

(MIL-C-21665) (Hopcalite)11. Cleaning compound For intermediate-level maintenance

activity use only12. Cloth, lint free (NSN 7920-00-044-9281)13. Container For collecting and discarding fluids14. Crocus cloth, 400 grit15. Convection oven For heating ball bearings16. Detergent, general purpose, (liquid, nonionic) Type I

(MIL-D-16791)17. Digital voltmeter (NSN 6625-00-032-5862) For measuring millivoltages18. Divider, voltage (SCAT 4678) For dividing voltage into millivolts19. Face shield20. Flashlight21. Floor matting, gray safety rubber, 36 in.22. Foil, aluminum23. Gage, 12-in. feeler, 14 blade, 1/4-in. tip, size 0.0015 to

0.125-in. T


Original 6-1


24. Gloves, insulated25. Gloves electrical worker, natural rubber, 5,000 V26. Goggles, industrial27. Hammer, plastic tipped28. India stone, fine For breaking sharp edges of ferrous

metals29. Lapping compound 400 grit30. Lapping plate For truing flat surfaces, using lapping

compound31. Lubricating oil, general purpose, light, NATO Code 0-196

(VV-L-820, sym LO)32. Magnifying glass33. Mask, emergency air breathing For use during catalyst replacement34. Mirror inspection, 2-1/4-in. diameter, telescoping35. Manometer For intermediate maintenance activity

gage adjustment/calibration36. Monoethanolamine (chelating agent solution) (MIL-M-23573,

sym MEA)For testing catalyst

37. Multimeter, ac/dc, 20 kVdc (SCAT 4245) For indicating voltage, resistance, andcontinuity

38. Paintbrush39. Pencil, general writing40. Pliers, long nosed, 6 in.41. Polish, liquid metal (MIL-P-15422) For removing corrosion42. Precision power supply For calibrating43. Puller kit, mechanical (25-piece, complete set) (NSN

5120-00-033-5606)44. Sandpaper, fine (no. 00)45. Screwdrivers, flat tip, 4, 6, and 8 in.46. Scriber, machinist, 9 in.47. Socket set48. Stopwatch (NSN 6645-00-250-4680) For timing component operation49. Solder, silver50. Solvent drycleaning, Type III (P-D-680)(NSN

6850-00-274-5421)51. Tag, safety52. Tag, shipping, string53. Tape, Teflon (MIL-T-27730)54. Tee For gage accuracy check55. Torch56. Tubing, rubber or vinyl For gage accuracy check57. Vacuum cleaner, portable, nonmetallic nozzle58. Wooden blocks59. Wrench, strap60. Wrench set, combination, box and open end, 5/16 to 1 in.61. Wrench set, socket, 3/8 and 1/2 in. drive


6-2 Original


SECTION IADJUSTMENT

6-2 INTRODUCTION

6-2.1 ADJUSTMENT COVERAGE This section provides procedures for adjustment of the following components.

Paragraph1. Thermal Overload Relay 6-3.12. Alarm Relay Controller 6-3.23. Temperature Indicating Controller 6-3.34. Differential Pressure Gage 6-3.7

6-3 ADJUSTMENT PROCEDURES

6-3.1 THERMAL OVERLOAD RELAY ADJUSTMENT Each thermal overload relay is adjustable to between 90 and110 percent of rated heater coil current. The following procedure shall be used to adjust the ac motor overload relay andthe heater overload relay.

WARNING



b. In interior of enclosure (22, Figure7-8, sheet 2) of control box, gain access to thermal overload relay (18 or 19) tobe adjusted.

c. Loosen binding screws (shown in Figure6-1) of each heater coil.

d. For thermal overload relay being adjusted, position one heater coil at 90-percent setting and other heater coil at110-percent setting.

e. Tighten binding screws of each heater coil.

f. Connect one clamp-on ammeter to each output of motor or heater.

g. Remove out of service tag and energize burner at power panel.

h. Check amperage of thermal overload relay.

(1) Ensure that motor clamp-on ammeter indicates 2.9 amps or less for standard motor and 2.6 amps or less forSSN21 Class motor.

(2) Ensure that heater clamp-on ammeter indicates 38.5 amps or less.

i. If thermal overload relay does not trip, proceed to step6-3.1.l.

j. If thermal overload relay trips and current is greater than 2.9 amps for standard motor or greater than 2.6 amps forSSN21 Class motor, or greater than 38.5 amps for heater, isolate cause of overload and correct.


Original 6-3


k. If thermal overload relay trips and current is 2.9 amps or less for standard motor, and 2.6 amps or less for SSN21Class motor, or 38.5 amps or less for heater, current is too low. Adjust thermal overload relay.

(1) Shut down burner (paragraph2-3.3).

WARNING


(2) Deenergize burner at power panel and tag out of service.

(3) Reset thermal overload relay by pressing reset switch.

CAUTION

To prevent equipment damage, ensure that thermal overload relay is not adjusted tosetting higher than necessary.

(4) Loosen binding screws of heater coil set at 90 percent.

(5) Increase heater coil setting by 10 percent.

(6) Tighten binding screws.

(7) Repeat steps6-3.1.gand6-3.1.h.

(8) If thermal overload relay trips again, repeat steps6-3.1.k.(1)through6-3.1.k.(7).

(9) If thermal overload relay trips at 110-percent setting, replace heater coils (paragraph6-7.6.5.1).

l. Shut down burner (paragraph2-3.3).

Figure 6-1. Thermal Overload Relay Adjustment


6-4 Original


WARNING


m. Deenergize burner at power panel and tag out of service.

n. Loosen binding screws of heater coil set at 110-percent and position heater coil to 90 percent. Tighten bindingscrews.

o. Repeat steps6-3.1.gand6-3.1.h.

p. If thermal overload relay trips, perform steps6-3.1.j or 6-3.1.kas required. If correct setting cannot be obtained,replace thermal overload relay (paragraph6-7.6.5).

q. If thermal overload relay does not trip, deenergize burner at power panel and tag out of service.

r. Remove clamp-on ammeters.

s. Ensure that binding screws are tight.

t. Secure control box.

u. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

v. Return burner to normal operating condition in accordance with ship procedures.

6-3.2 ALARM RELAY CONTROLLER ADJUSTMENT The following procedure shall be used to adjust the alarmrelay controller.

WARNING



b. Gain access to alarm relay controller (20, Figure7-8, sheet 2) in control box.

c. Remove cover of alarm relay controller.

d. Identify and tag thermocouple wires to input terminals of alarm relay controller (Figure6-2).

e. Disconnect wires from input terminals.

CAUTION

To prevent damage to alarm relay controller, ensure that input millivoltage neverexceeds 25 mV.

f. Connect dc millivolt supply to input terminals.

g. Turn deadband adjustment potentiometers located on side of circuit boards fully counterclockwise.


Original 6-5


WARNING


h. Using safety precautions described in NSTM chapter 300, remove out of service tag and energize burner at powerpanel.

i. Perform preoperational checks (paragraph2-3.1) and momentarily press start switch and ensure that control circuitlamp comes on.

NOTE

Ships with R-12 in the ship stores refrigeration plant set the high temperature alarmat 650610 °F (343.365.6 °C) and ships with R-134a set it at 550610 °F (287.865.6 °C).

j. Slowly increase output of dc millivolt supply until excessive temperature lamp comes on but do not exceed 25millivolts to prevent damage to controller. The dc millivolt supply output should be between 17.2 and 17.8 mV at75 °F (23.8 °C) ambient temperature which represents 650 °610 °F (343.3 °65.6 °C) for ships with R-12, or14.1 and 14.8 mV representing 550610 °F (287.865.6 °C) for ships with R-134a.

k. If lamp does not come on within proper millivolt range, correct high-temperature relay (RY1) set point.

(1) Turn RY1 set point potentiometer as required to increase or decrease set point until light just comes on.

(2) Decrease dc millivolt supply output to 0 volts.

Figure 6-2. Alarm Relay Controller


6-6 Original


(3) Repeat steps6-3.2.j, 6-3.2.k.(1), and6-3.2.k.(2)until set point is properly set.

(4) If RY1 chatters and/or gives false alarms, increase deadband adjustment potentiometer located on side of alarmrelay controller and repeat step6-3.2.j.

(5) If RY1 cannot be properly set, replace alarm relay controller (paragraph6-7.6.2).

NOTE

Ships with R-12 in the ship stores refrigeration plant set the shutdown alarm relayat 675610 °F (357.265.6 °C) and ships with R-134a set it at 575610 °F (301.765.6 °C).

l. Slowly increase output of dc millivolt supply until burner shuts down. The dc millivolt supply output should bebetween 18.0 and 18.6 mV at 75 °F (23.8 °C) ambient temperature which represents 675 °610 °F (357.2 °65.6°C) with R-12 installed or 14.9 and 15.5 mV representing 575610 °F(301.765.6 °C) with R-134a installed.

m. If burner does not shut down within proper millivolt range, correct alarm relay(RY2) set point.

(1) Turn RY2 set point potentiometer as required to increase or decrease set point until burner shuts down.

(2) Decrease dc power supply to 0 volts.

(3) Momentarily press start switch and ensure that control circuit lamp comes on.

(4) Repeat steps6-3.2.l through6-3.2.m.(2)until set point is properly set.

(5) If RY2 chatters and/or gives false alarms, increase deadband adjustment potentiometer located on side of alarmrelay controller and repeat step6-3.2.l.

(6) If RY2 cannot be properly set, replace alarm relay controller (paragraph6-7.6.2).

n. Decrease dc millivolt supply output to 0 volts.

o. Deenergize burner at power panel and tag out of service.

p. Disconnect dc millivolt supply from input terminals.

q. Reconnect thermocouple wires to input terminals.

r. Reinstall cover of alarm relay controller.

s. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

t. Return burner to normal operating condition in accordance with ship procedures.

6-3.3 TEMPERATURE INDICATING CONTROLLER ADJUSTMENT The following procedures shall be used totime and adjust the temperature indicating controller, model-1612-4 (standard), model-102 (standard), and the model-1600series (SSN21 Class).


Original 6-7


NOTE

Ships with R-12 in the ship stores refrigeration plant operate at 600625 °F(316613.9 °C) and ships with R-134a operate at 500625 °F (260613.9 °C).

6-3.3.1 Temperature Indicating Controller, Model 1612-4 (Standard), Adjustment

a. Ensure that burner is energized at power panel and control circuit lamp is on.

b. Open access door on front of temperature indicating controller (2, Figure7-12).

c. Turn reset, cycle time, proportional band, and process alarm set point potentiometers counterclockwise until stophas been reached for maximum setting as shown in Figure6-3.

d. Turn primary set point knob until set point indicator indicates 600 °F (315.6 °C) if R-12 is installed or 500 °F(260 °C) if R-134a is installed.

e. Slowly turn cycle time potentiometer fully clockwise. This sets heater cycle time at maximum (60 seconds).

f. Slowly turn proportional band potentiometer fully clockwise. This sets proportional band at 40.

g. Slowly turn reset potentiometer clockwise to 1.248 reset rate reading.

h. Energize burner (paragraphs2-3.1and2-3.2).

i. After burner reaches operational equilibrium, verify that meter indicator is in the range of 600 °F625 °F (315.6°C 613.9 °C) when R-12 is installed or 500625 °F (260613.9 °C) when R-134a is installed. If below requiredrange, turn reset potentiometer clockwise one minor division on scale. If above required range, turn resetpotentiometer counterclockwise one minor division on scale. After each adjustment, allow 1/2 hour for controllerto respond. Repeat this step until meter indicator indicates required range.

Figure 6-3. Temperature Indicating Controller, Model 1612-4 (Standard), Adjustment


6-8 Original


j. Close access door.

k. Operate burner (paragraphs2-3.1and2-3.2) as required to test controller completely.

l. Return burner to normal operating condition in accordance with ship procedures.

6-3.3.2 Temperature Indicating Controller, Model 102 (Standard), Adjustment

a. Open access door on front of temperature indicating controller (3, Figure7-12).

b. Turn primary set point adjustment (shown in Figure6-4) until red heater set point indicator needle indicates 600°F (315.6 °C) when R-12 is installed or 500 °F (260 °C) when R-134a is installed.

c. Turn alarm set point adjustment until green alarm set point indicator needle indicates 650 °F (343.3 °C) whenR-12 is installed or 550 °F (287.8 °C) when R-134a is installed.

d. Operate burner (paragraphs2-3.1and2-3.2). Ensure that burner is warmed up.

e. Note temperature indicator needle fluctuation. Needle should fluctuate slowly between 590 °F (310 °C) and 610 °F(321.1 °C) when R-12 is installed or 490 °F (254.4 °C) and 510 °F (265.6 °C) when R-134a is installed.Fluctuation of625 °F (613.9 °C) around the set point in paragraph6-3.3.2.bis acceptable.

f. If needle fluctuation is incorrect, turn proportional band adjustment in 1/8-turn increments to correct needlefluctuation. Wait 15 to 20 minutes between adjustments to allow burner and controller to react.

g. If burner temperature cannot be maintained at 600 °625 °F (315.6 °613.9 °C) when R-12 is installed or500625 °F (260613.9 °C)when R-134a is installed, with proper needle fluctuation, replace controller withproperly calibrated unit (paragraph). 6-7.7

h. Turn alarm set point adjustment until alarm set point indicator needle reads 600 °F (315.6 °C) when R-12 isinstalled or 500 °F (260 °C) when R-134a is installed. Verify that alarm lamp on controller and excessivetemperature lamp on control box come on.

Figure 6-4. Temperature Indicating Controller, Model 102 (Standard), Adjustment


Original 6-9


i. If lamps do not come on, replace controller with properly calibrated unit (paragraph6-7.7).

j. Turn alarm set point adjustment until alarm set point indicator needle reads 650 °F (343.3 °C) when R-12 isinstalled or 550 °F (287.8 °C) when R-134a is installed.

k. Close access door.


6-3.3.3 Temperature Indicating Controller, Model-1600 Series (SSN21 Class), Adjustment

a. Ensure the burner is energized at power panel and green power light is illuminated.

b. Open access door on front of temperature indicating controller (2, Figure7-12).

c. Turn process alarm, proportional band (gain), cycle time, and reset potentiometers counterclockwise until stop hasbeen reached, refer to Figure6-5.

d. Turn the control set point adjustment knob counterclockwise until the ‘‘red’’ control set point indicator pointerindicates 600 °F (315.6 °C) when R-12 is installed or 500 °F (260 °C) when R-134a is installed.

e. Slowly turn cycle time potentiometer fully clockwise. This sets heater cycle time at maximum (60 seconds).

f. Slowly turn proportional band potentiometer fully clockwise. This sets the proportional band at 40.

g. Slowly turn reset potentiometer clockwise to 1.248 reset rate reading.

h. Energize the burner (paragraphs2-3.1and2-3.2).

Figure 6-5. Temperature Indicating Controller, Model-1600 Series (SSN21 Class),Adjustment


6-10 Original


i. After the burner reaches operational equilibrium, observe the ‘‘green’’process temperature indicator pointer. If thepointer indicates a temperature below 600 °F (315.6 °C) when R-12 is installed or 500 °F (260 °C) when R-134ais installed, turn the reset potentiometer clockwise one minor division on the scale. Allow 1/2 hour for thecontroller to respond to equilibrium conditions. Repeat this step until the ‘‘green’’ pointer indicates 600 °625 °F(315.6 °613.9 °C) when R-12 is installed or 500625 °F (260613.9 °C) when R-134a is installed.

j. If, after the burner reaches operational equilibrium, the ‘‘green’’process temperature indicator pointer indicates atemperature above 600 °F (315.6 °C) when R-12 is installed or 500 °F (260 °C) when R-134a is installed, turn thereset potentiometer counter clockwise one minor division on the scale. Allow 1/2 hour for the controller to respondto equilibrium conditions. Repeat this step until the ‘‘green’’ pointer indicates 600 °625 °F (315.6 °613.9 °C)when R-12 is installed or 500625 °F (260613.9 °C) when R-134a is installed.

k. Close access door.


6-3.4 TEMPERATURE INDICATING CONTROLLER, MODEL 1612-4, CALIBRATION The following proceduresshall be used for calibration of the model 1612-4 temperature indicating controller. To ensure accuracy of calibration,perform this procedure only when ambient temperature of the temperature indicating controller is at 75 °65 °F (23.9 °62.8 °C).

WARNING


NOTE

Ships with R-12 in the ship stores refrigeration plant operate at 600625 °F(316613.9 °C) and ships with R-134a operate at 500625 °F (260613.9 °C).


b. Remove temperature indicating controller from instrument mounting bracket (paragraph6-7.7.1).

c. Check meter indicator to ensure that it is zeroed. If meter indicator is not at zero, use following procedure.

(1) Remove primary set point knob from unit by pulling it outward.

(2) Open access door and remove two screws holding plastic front plate. Remove plastic front plate.

(3) Locate zero adjustment slot for meter indicator.

CAUTION

Meter movement is very delicate and easily broken. To prevent meter damage,apply very gentle pressure while turning meter adjustment slot.

(4) Carefully turn adjustment slot in direction meter indicator should go, until meter indicator is zeroed. If meterindicator cannot be zeroed, replace it (paragraph6-7.7.1).

(5) Reinstall plastic front plate and secure, using two screws.


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(6) Reinstall primary set point knob on unit.

d. At rear of unit, connect source of millivolts(power supply and voltage divider) to terminal labeled T/C.

e. To ensure proper input voltage, connect digital voltmeter to terminal labeled T/C. Monitor digital voltmeter whenadjusting millivolt source.

WARNING


f. Connect 115-Vac power source to terminals labeled 120 and LN. Allow at least 20 minutes warmup time.

g. Adjust millivolt source to 16.0 mV which corresponds to 600 °F (315.6 °C) when R-12 is installed or 12.9 mVcorresponding to 500 °F (260 °C) when R-134a is installed.

h. Temperature indicating controller should indicate 600625 °F (315.6613.9 °C) when R-12 is installed or 500625 °F (260613.9 °C) when R-134a is installed. Record reading.

i. Adjust millivolt source to .72 mV. This corresponds to 100 °F (37.8 °C).

j. Temperature indicating controller should indicate 100 °F610 °F (37.8 °C65.6 °C). Record reading.

k. Compare readings recorded in steps6-3.4.hand6-3.4.j. If there is linear temperature discrepancy, for example 110°F and 660 °F (43.3 °C and 348.9 °C) when R-12 is installed or 560 °F (43.3 °C and 293.3 °C) when R-134a isinstalled, consider this to be gain error and proceed to step6-3.4.l. If there is constant temperature discrepancy, forexample 115 °F to 615 °F (46.1 °C and 323.8 °C) when R-12 is installed or 515 °F (46.1 °C and 268.3 °C) whenR-134a is installed, consider this to be offset error and proceed to step6-3.4.m.

WARNING


l. Correct gain error.

(1) Remove controller from case (paragraph6-7.7.1).

(2) Adjust R13 potentiometer (shown inFO-4) on side of controller.

(3) Repeat steps6-3.4.gand6-3.4.l. If controller gain error cannot be corrected, replace controller (paragraph6-7.7.1).

m. Correct offset error.

(1) Remove controller from case (paragraph6-7.7.1).

(2) Adjust R9 potentiometer (shown inFO-4) on side of controller.

(3) Repeat steps6-3.4.gthrough6-3.4.kand6-3.4.m. If controller offset error cannot be corrected, replacecontroller (paragraph6-7.7.1).


6-12 Original


n. Remove millivolt and 115-Vac power sources from terminals.

o. Reinstall temperature indicating controller in instrument mounting bracket (paragraph6-7.7).

p. Check calibration of temperature indicating controller (paragraph5-4.4).

q. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

r. Return burner to normal operating condition in accordance with ship procedures.

6-3.5 TEMPERATURE INDICATING CONTROLLER, CEPEDA SERIES 988 Refer to AppendixA of this manualfor all information concerning the Cepeda series 988 controller.

6-3.6 TEMPERATURE INDICATING CONTROLLER, WEST MODEL 2075 Refer to AppendixB of this manualfor all information concerning the West model 2075 controller.

6-3.7 DIFFERENTIAL PRESSURE GAGE ADJUSTMENT The following procedures shall be used to adjust thedifferential pressure gage.

6-3.7.1 Zero Adjustment

a. At instrument mounting bracket, place filter flip toggle valve (5, Figure7-12) at on position to vent gage (4).

b. Turn zero adjust setscrew (shown in Figure6-6) until pointer is at zero. If pointer cannot be set to zero, replacegage (paragraph6-7.7.2).

c. Place filter flip toggle valves at off position.

6-3.7.2 Accuracy Check Gage calibration, when required, shall be performed by a gage calibration lab. If inplacecalibration must be performed, the following procedure may be used.

WARNING


a. Deenergize burner at power panel and tag out of service.

b. Tag and disconnect tubes from back of gage (4, Figure7-12).

c. Turn zero adjust setscrew (shown in Figure6-6) until pointer is at zero. If pointer cannot be set to zero, replacegage (paragraph6-7.7.2).

d. Using rubber or vinyl tubing connected to tee, connect one tube to high-pressure side of gage.

e. Connect second tube to manometer or high-pressure side of second gage.

f. Connect third tube to calibration set to supply pressure for test. Refer to NSTM chapter 504 for operation ofcalibration set.

g. Apply pressure to full scale of gage being tested and allow 3 seconds for pressure to equalize.


Original 6-13


h. Compare reading of gage to manometer or second gage. If gage is within6 2 percent of manometer or matchessecond gage, accuracy of gage is acceptable.

i. Vent pressure slowly. Repeat steps6-3.7.2.gand6-3.7.2.h. If gage fails, replace gage (paragraph6-7.7.2).

j. In emergency situation only, use following steps to adjust accuracy of gage. Replace gage at first availableopportunity (paragraph6-7.7.2).

(1) Remove tubing, tee, manometer, and calibration set from gage.

(2) Remove screws securing gage to instrument mounting bracket and remove gage.

(3) With gage case (shown in Figure6-6) held firmly, loosen bezel by turning counterclockwise with strap wrenchor similar tool.

(4) Remove bezel and lift out plastic cover and O-ring.

(5) Remove scale screws securing scale assembly.

(6) Remove scale assembly by lifting it up and away from pointer. Ensure that pointer is not damaged.

(7) Loosen clamp screw and move clamp slightly forward if gage is reading high or slightly backward if gage isreading low. Tighten clamp screw.

(8) Reinstall scale assembly and secure, using scale screws. Ensure that pointer is not damaged.

(9) Place O-ring and plastic cover on case. Ensure that zero adjust setscrew on plastic cover is alined properly ingage.

Figure 6-6. Differential Pressure Gage


6-14 Original


(10) Secure plastic cover by screwing bezel down snugly. Area under plastic cover is pressurized during operation.Gage leaks if not properly tightened.

(11) Position gage on instrument mounting bracket and secure, using screws.

(12) Repeat steps6-3.7.2.cthru 6-3.7.2.i.

k. Remove tubing, tee, manometer or second gage, and calibration set from gage.

l. Reconnect tubes to back of gage.

m. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

n. Test-operate burner (paragraphs2-3.1and2-3.2) as required to completely test gage.

o. Return burner to normal operating condition in accordance with ship procedures.




SECTION IIREPAIR

6-4 INTRODUCTION

6-4.1 REPAIR COVERAGE This section provides procedures for repair and/or replacement of the following:

paragraph1. CO and H2 Burner 6-72. Catalyst Section 6-7.23. Thermocouple Probe 6-7.34. Disposable Air Filter 6-7.45. AC Motor and Fan Wheel Assembly 6-7.56. Control Box Assembly 6-7.67. Instrument Mounting Bracket Assembly 6-7.78. Heater 6-7.89. Heat Exchanger Assembly 6-7.9

6-4.2 PRESENTATION The section provides procedures for complete disassembly of the burner and its assemblies,subassemblies, and components. Disassembly shall be only to the extent necessary to perform required repair and/orreplacement. Procedures shall be read in full before starting repairs. When required, illustrations are provided in thissection to assist in repair of components. Chapter7 illustrations are referenced to assist in removal, disassembly,reassembly, and parts identification.

6-5 CLEANING AND INSPECTION

6-5.1 CLEANING The following general cleaning procedure shall be used during repairs. Additional cleaninginformation applicable to electrical components is provided in NSTM Chapter 300 and Chapter 302. Specific cleaningprocedures may be provided for a particular item in the individual repair procedures. Applicable warnings and cautionsshall be carefully observed.

WARNING

Do not use solvents on air stream components unless complete solvent removal canbe ensured. Toxic reactions between solvents and catalyst in catalyst bed may occur.

CAUTION

To prevent equipment damage, do not use harsh abrasives that might scratch, score,or otherwise mar surface finishes.

a. Wash all metal parts in general purpose detergent(MIL-D-16791) and water solution.

b. Use stiff-bristled brush to remove hardened deposits of dirt and other contaminants on noncritical surfaces.

c. Clean mating surfaces with cleaning compound approved for submarine use and clean, lint-free cloth. Ensure thatseating surfaces are not damaged.


Original 6-17


CAUTION

Do not agitate parts in ultrasonic equipment longer than 5 minutes at any one time.Serious damage to parts may result.

d. If available, ultrasonic cleaning may be used on some parts.

e. Refer to NSTM Chapter 244 for cleaning procedures for new and used bearings.

f. Allow bearings to air-dry after cleaning.

g. After drying, rinse bearings in lubricating oil(VV-L-820) and wrap individually in protective wrap such as plasticbag or aluminum foil.

WARNING

Pressurized air can drive particles into eyes and skin if handled improperly. Toprevent personnel injury or equipment damage, wear face shield and appropriateclothing and exercise extreme caution.

h. After cleaning, dry parts thoroughly with clean, dry, low-pressure air or with clean, lint-free cloth.

6-5.2 INSPECTION The following procedure shall be used for inspection of components during repair. Wheneverpossible, all parts shall be visually inspected under strong light and magnification.

a. Check all parts for discoloration (caused by overheating), fractures, and corrosion.

b. Examine all parts for deformities, pitting, scoring, scratches, nicks, and accumulation of hardened dirt deposits andother contaminants.

c. Inspect all seating surfaces for cracks, pits, scoring, scratches, uneven wear, and failure of parts to seat evenly.

d. Inspect all threaded areas for stripped threads and evidence of cross-threading; examine areas adjacent to threadsfor cracks.

e. Inspect bearings for flat spots and corrosion. Verify smooth operation.

f. Inspect retainers and seals for nicks, scratches, and burrs.

g. Check drive shafts for flat spots and uneven wear.

h. Check all springs for cracks and bends; verify uniform expansion and retraction capability.

i. Inspect passages for corrosion and blockages.

j. Inspect keyways for galling, corrosion, rounded edges, and nicks.

k. Check stainless steel tubing and connections for leaks.

l. Inspect gaskets for cuts, tears, and distortion.


6-18 Original


6-6 REPAIR AND REPLACEMENT

6-6.1 REPAIR Repair parts as indicated by inspection in accordance with standard shop practices, using standard shoptools along with those listed in paragraph6-1.3, as required. Minor repair to precision-machined parts may be performedif fits and clearances are maintained and if part reliability is not impaired. The following procedure shall be used to repairparts.

CAUTION

Do not alter concentricity of any part. Do not attempt minor repair to stripped orcrossed threads of fittings or bosses of components operating under high pressure.Leakage around loosely threaded parts, or movement between bolted parts, cancause failure and damage to equipment.

a. Remove light surface discoloration from bare metal surfaces, using cloth saturated with liquid metal polish.Remove discoloration by rubbing briskly; then polish with clean, dry, lint-free cloth.

b. Remove corrosion from metal surfaces by polishing with crocus cloth, grit 400, and polish as indicated in step6-6.1.a.

c. Remove minor nicks and scratches from metal surfaces by polishing with crocus cloth, 400 grit. Blend out edgesof reworked area and polish as indicated in step6-6.1.a.

CAUTION

To prevent equipment damage, do not allow machined or lapped mating surfaces tocontact any surface without protection against nicks, scratches, and burrs.

d. If rework is required on mating surface, finish lap, using lapping plate.

e. Small scratches and pitting may be removed from mating surfaces by lapping with lapping compound, 400 grit.

f. Break all sharp edges after lapping, using rubberized abrasive stick for nonferrous metal parts and fine India stonefor ferrous metal parts.

6-6.2 REPLACEMENT Parts not meeting inspection requirements, or not within allowable wear limits after repairshave been made, shall be replaced. Replace parts in accordance with standard shop practices, using standard shop toolsalong with those listed in paragraph6-1.3, as required. The following procedure shall be used to replace parts.

a. Replace any parts that show severe discoloration from overheating.

b. When serviceability of any part is questionable, replace part.

c. Replace all O-rings, seals, gaskets, and packing during reassembly.

d. Do not discard used parts until availability of replacement parts is determined.

e. If replacement parts are not available and equipment must be reassembled due to emergency, used O-rings, seals,gaskets, and packing may be reused.

f. If used parts are reused, equipment shall be closely monitored for performance and leakage.


Original 6-19


6-7 CO AND H2BURNER, MARK IV-E, REPAIR PROCEDURES

6-7.1 CO AND H2BURNER, MARK IV-E Complete disassembly and reassembly of the Mark IV-E CO and H2 burner(Figure7-6) is provided in the following procedures. Also the following procedures shall be used to repair or replacegeneral components of the burner.

6-7.1.1 Removal

WARNING


WARNING

To prevent injury, allow 4 hours for catalyst to cool prior to disassembly of burner.

a. Deenergize burner at power panel and secure ship’s chilled water to burner. Tag out of service in accordance withship procedures.

b. Remove tubing (2, sheet 1) with compression fittings(1, sheet 1, and 3 and 4, sheet 2) and tube clamps.

(1) Identify and tag tubing, with compression fittings attached, and tube clamps.

(2) Disconnect tubing from pitot tube assembly (items 6 through 9, sheet 1), air filter housing assembly (A),transition duct (50, sheet 2), after-cooler (70), heat exchanger (79), and catalyst section (99).

(3) Disconnect tubing from manifold valve assembly (items 5 through 10, Figure7-12).

(4) Remove tubing from burner.

c. Remove and disassemble pitot tube assembly.

(1) Remove bolts and lockwashers securing pitot tube assembly to fan wheel housing and motor mounting bracket(38, Figure7-6, sheet 1).

(2) Remove pitot tube assembly and gasket (10).

(3) Remove union elbows (6) from tubing (7 and 8).

(4) Tubing is not normally removed from plate (9). If tubing removal is necessary for repair, unbraze tubing inaccordance with NSTM Chapter 074 and remove from plate.

d. Remove and disassemble air filter housing assembly.

(1) Unscrew screws (11, bubble A) securing air filter housing cover (12) to air filter housing (28).

(2) Remove air filter housing cover from air filter housing.

(3) Unhook and remove air filter retaining springs(13) from right-hand side of air filter housing.

(4) Pull disposable air filter (14) and disposable air filter gasket (15) out of air filter housing.


6-20 Original


(5) If installed, remove nuts (16), lockwashers (17), bolts (18), and washers (19) securing air inlet duct and airinlet gasket(20) to air filter housing.

(6) Separate air inlet duct and air filter housing and remove air inlet gasket.

(7) Gain access to interior of control box (45, sheet 1), and remove nuts (21, bubble A), lockwashers (22), bolts(23), and washers(24) securing air filter housing to control box.

(8) Remove bolts (25), lockwashers (26), and washers(27) securing air filter housing assembly to fan wheelhousing and motor mounting bracket.

WARNING

Air filter housing weighs 30 pounds. Ensure that extreme care is used duringhandling.

(9) Support weight of air filter housing and carefully remove nuts, lockwashers, bolts, and washers securing airfilter housing to transition duct.

(10) Remove air filter housing with air filter box gasket (29).

e. Remove fan motor conduit (30, sheet 1) from motor and fan wheel assembly (31) and control box.

(1) Remove capscrews (1, Figure7-7), lockwashers (2), conduit box cover (3), and conduit box cover gasket (4)from conduit box (20).

(2) Identify, tag, and disconnect wires from terminal lugs (14).

(3) Remove fan motor conduit (30, Figure7-6, sheet 1) from conduit box.

(4) Gain access to interior of control box.

(5) Identify, tag, and disconnect wires from control box.

(6) Remove fan motor conduit.

(7) Remove fan motor conduit from burner.

f. Remove motor and fan wheel assembly from fan wheel housing and motor mounting bracket.

NOTE

For SSN21 model, remove spacer (56, Figure7-7) part number 1072-B1100 fromshaft after removing washer (7) from shaft.

(1) Reach inside fan wheel housing and motor mounting bracket and remove cotter pin (5, Figure7-7), nut (6),and washer (7) from shaft (50).

(2) Secure fan wheel (8) with temporary fastenings so that it will not fall from fan wheel housing when motor(items 9 through 55) is removed.

(3) Remove nuts, lockwashers, bolts, and washers securing motor to fan wheel housing and motor mountingbracket.


Original 6-21


WARNING

The standard motor weighs 70 pounds, the SSN21 Class motor weighs 88 pounds.To prevent injury or death, ensure that extreme care and proper lifting devices areused during handling.

(4) Using proper lifting devices, remove motor and motor hub seal (32, Figure7-6) from fan wheel housing andmotor mounting bracket. Remove seal.

g. Remove and disassemble bypass duct assembly (items 33 through 37).

(1) Remove bolts, lockwashers, and washers securing bypass duct assembly to fan wheel housing and motormounting bracket.

(2) Remove nuts, lockwashers, bolts, and washers securing bypass duct assembly to catalyst section.

(3) Remove bypass duct assembly and gaskets (36 and 37).

(4) Remove push-pull control (33) from bypass duct assembly.

(5) Remove door gasket (34) from bypass duct (35).

h. Remove fan wheel housing and motor mounting bracket from transition duct.

(1) At countersunk holes, remove nuts, lockwashers, and capscrews securing fan wheel housing and motormounting bracket to transition duct.

(2) From remaining holes, remove nuts, lockwashers, bolts, and washers.

WARNING

Fan wheel housing and motor mounting bracket and fan wheel weigh 40 pounds.Ensure that extreme care is used during handling.

(3) Lift fan wheel housing and motor mounting bracket with fan wheel (8, Figure7-7) inside from transition duct.

(4) Remove fan wheel housing gasket (39, Figure7-6, sheet 1).

(5) Remove fan wheel from fan wheel housing and motor mounting bracket.

i. Remove thermocouple probe (40).

(1) Gain access to interior of control box.

(2) Identify, tag, and disconnect wires to thermocouple probe from control box.

(3) Remove thermocouple probe wires.

(4) Remove thermocouple probe from catalyst section.

j. Remove control box from burner.


6-22 Original


(1) Identify, tag, and disconnect wires of 440-Vac electrical cable, heater conduit (9, Figure7-13), and temperatureindicating controller conduit (1, Figure7-12) from control box.

(2) Remove electrical cable from control box.

(3) Remove temperature indicating controller conduit and heater conduit from control box.

(4) Remove nuts (41, Figure7-6, sheet 1), lockwashers (42), bolts (43), and washers (44) securing control box toinstrument mounting bracket.

(5) Remove nuts, lockwashers, bolts, and washers securing control box to transition duct.

WARNING

Control box weighs 50 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling.

(6) Using proper lifting device, remove control box from burner.

k. Remove nuts, lockwashers, bolts, washers, and instrument mounting bracket from transition duct.

l. Remove 10 bolts (1, Figure7-13), 10 seal washers (2), cover (3), and one heater gasket (4) from heatexchanger(79, Figure7-6, sheet 2).

m. Remove remaining bolts (1, Figure7-13) and remaining seal washers from heater housing (19) and heatexchanger.

n. Remove bolts (5), lockwashers (6), and heater cover (7) from heater housing.

o. Identify and tag wires to heater housing.

p. Remove nuts (8) from heating elements (17) and disconnect wires from heater housing.

q. Remove heater conduit (9) with wires.

WARNING

Heater weighs 70 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling.

r. Using proper rigging and lifting devices, remove heater housing assembly (items 10 through 19) with remainingheater gasket from catalyst section. Remove heater gasket from heater housing assembly.

s. Remove bolts, lockwashers, seal washers, catalyst cover add plates (48, Figure7-6, sheet 1), and two catalystcover gaskets (49) from catalyst section.

WARNING

To prevent injury, ensure that emergency air breathing mask is worn when handlingcatalyst.

t. Remove bolts, lockwashers, seal washers, catalyst cover removal plate (48), and one catalyst cover gasket, andremove catalyst from catalyst section.


Original 6-23


(1) Vacuum cleaner may be used through catalyst fill port to remove catalyst granules.

(2) When cleaning and inspecting catalyst bed, remove loose catalyst from catalyst bed screens by vacuumingscreens. Replace screens if punctured or corroded.

u. Remove transition duct from heat exchanger.

(1) Remove two bolts and lockwashers securing transition duct to heat exchanger.

(2) Remove four capscrews and lockwashers securing transition duct to heat exchanger at corner holes.

(3) Lift transition duct and transition duct gasket(51) from heat exchanger.

WARNING

Compound mass bar is heavy. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling.

v. Remove nuts, lockwashers, and bolts, and, using proper lifting devices with minimum capacity of 200 pounds,remove one compound mass tie bar (52) from compound mass bar (98). Repeat for second compound mass tie bar.

w. Remove aftercooler from heat exchanger.

(1) Ensuring that chilled water to aftercooler is secured, disconnect chilled water piping to aftercooler.

(2) Remove nuts (53), lockwashers (54), bolts (55), and washers (56) from air outlet duct and aftercooler.

(3) Remove bolts (57), lockwashers (58), and washers(59) from air outlet duct and aftercooler.

(4) Separate air outlet duct and aftercooler and remove air outlet gasket (60).

(5) Remove bolts (61), lockwashers (62), access cover(63), and access cover gasket (64) from aftercooler.

WARNING

Aftercooler weighs 90 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling.

(6) Using proper lifting devices, support weight of aftercooler.

(7) Remove jamnuts (65), lockwashers (66), and capscrews(67) securing aftercooler to heat exchanger.

(8) Remove bolts (68) and lockwashers (69).

(9) Using proper lifting devices, remove aftercooler and aftercooler gasket (71).

x. Remove heat exchanger from catalyst section. Knowledge of internal arrangement of heat exchanger is required toremove heat exchanger from catalyst section.


6-24 Original


CAUTION

Proper seating of heat exchanger corner seals is extremely difficult. Removal andreinstallation of heat exchanger should not be attempted without factory support andtraining.

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed underheat exchanger and catalyst section before removing either component.

(1) Place wooden blocks under heat exchanger and catalyst section.

WARNING

Heat exchanger weighs 690 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling.

(2) Using proper lifting devices, support weight of heat exchanger.

(3) Remove bolts (72) and lockwashers (73) from heater section mounting brackets (91 and 92) and heatexchanger.

(4) Remove capscrews (74) and lockwashers (75) securing heat exchanger to catalyst section at side holes.

(5) Remove nuts (76), lockwashers (77), and bolts(78) securing heat exchanger to catalyst section from bottomthrough-holes.

(6) Remove heat exchanger and heat exchanger gasket(80) from catalyst section.

y. Remove resilient mounts (89), heater section mounting brackets, and catalyst section mounting brackets (95 and96) from compound mass bars and catalyst section.

WARNING

Mounting bracket weighs 35 pounds. Ensure that extreme care is used duringhandling.

(1) Remove bolts (81) and mounting bracket covers(82) from catalyst section.

(2) Remove nuts (83 and 86), lockwashers (84 and 87), rods (85), and bolts (88) securing catalyst sectionmounting brackets and heater section mounting brackets to compound mass bars.

(3) Remove resilient mounts, mount gaskets (90), and heater section mounting brackets from compound mass barsand catalyst section mounting brackets.

(4) Remove bolts (93) and lockwashers (94) securing catalyst section mounting brackets to catalyst section.

(5) Remove catalyst section mounting brackets and spacer (97) from burner.


Original 6-25


WARNING


z. Using proper lifting devices with minimum capacity of 300 pounds, remove each compound mass bar from basesupport and from ship’s resilient mounts.

WARNING

Catalyst section weighs 240 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling.

aa. Using proper lifting devices, remove catalyst section.

6-7.1.2 Cleaning and Inspection Clean and inspect all parts (paragraphs6-5.1and6-5.2).

6-7.1.3 Repair and Replacement Repair or replace any worn or defective parts (paragraph6-6.1or 6-6.2).

6-7.1.4 Reinstallation

WARNING


a. Using proper lifting devices with minimum capacity of 300 pounds, reinstall each compound mass bar (98, Figure7-6, sheet 2) on base support and ship’s resilient mounts.

b. Reinstall heater mounting brackets (92 and 91), resilient mounts (89), and catalyst section mounting brackets (96and 95)on compound mass bars.

WARNING

Mounting bracket weighs 35 pounds. Ensure that extreme care is used duringhandling.

(1) Position heater mounting brackets, two resilient mounts, and two mount gaskets (90) on compound mass barsand secure, using two rods (85), four lockwashers (84), and four nuts (83).

(2) Secure resilient mounts to heater mounting brackets, using bolts (88), lockwashers (87), and nuts (86).

(3) Position catalyst section mounting brackets, spacer(97), two resilient mounts, and two mount gaskets oncompound mass bars and secure, using two rods, four lockwashers (84), and four nuts (83).

(4) Secure resilient mounts to catalyst section mounting brackets, using bolts (88), lockwashers (87), and nuts (86).

c. Reinstall catalyst section (99) on compound mass bars.

WARNING

Catalyst section weighs 240 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling.


6-26 Original


(1) Using proper lifting devices, position catalyst section between compound mass bars and catalyst sectionmounting brackets.

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed undercatalyst section before reinstallation.

(2) Place wooden blocks under catalyst section.

(3) Secure catalyst section to catalyst section mounting brackets, using lockwashers (94) and bolts (93).

(4) Secure mounting bracket cover (82) to catalyst section, using bolts (81).

d. Reinstall heat exchanger (79).

WARNING

Heat exchanger weighs 690 pounds. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling.

(1) Using proper lifting device, position heat exchanger next to catalyst section.

CAUTION

To prevent equipment damage, ensure that wooden blocks have been placed underheat exchanger before reinstallation.

(2) Place wooden blocks under heat exchanger.

(3) Insert heat exchanger gasket (80) between heater exchanger and catalyst section.

(4) Secure heat exchanger and heat exchanger gasket to catalyst section, using lockwashers (75) and capscrews(74) at side holes.

(5) Secure heat exchanger to heater section mounting brackets, using lockwashers (73) and bolts (72).

(6) Secure heat exchanger to catalyst section, using bolts (78), lockwashers (77), and nuts (76) throughbottom-through holes.

e. Reinstall aftercooler (70) on heat exchanger.

WARNING

Aftercooler weighs 90 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling.

(1) Using proper lifting devices, position aftercooler and aftercooler gasket (71) on heat exchanger and secure,using capscrews(67), lockwashers (66), and jamnuts (65).

(2) Secure aftercooler to heat exchanger, using lockwashers(69) and bolts (68).


Original 6-27


(3) Position air outlet duct and air outlet gasket(60) on aftercooler and secure, using washers (56), bolts (55),lockwashers(54), and nuts (53).

(4) Secure air outlet gasket and air outlet duct to aftercooler, using washers (59), lockwashers (58), and bolts (57).

(5) Secure access cover (63) and access cover gasket(64) to aftercooler, using lockwashers (62) and bolts (61).

(6) Reconnect chilled water piping to aftercooler.

WARNING

Compound mass tie bar is heavy. To prevent injury or death, ensure that extremecare and proper lifting devices are used during handling.

f. Using proper lifting devices with minimum capacity of 200 pounds, position one compound mass tie bar (52) oncompound mass bar and secure, using nuts, lockwashers, and bolts. Repeat for second compound mass tie bar.

g. Reinstall transition duct (50) on heat exchanger.

(1) Position transition duct and transition duct gasket(51) on heat exchanger.

(2) Reinsert capscrews and lockwashers into corner holes of transition duct.

(3) Reinsert bolts and lockwashers into remaining holes.

h. Position one heater gasket (4, Figure7-13) on heater housing (19).

WARNING


i. Using-proper rigging and lifting device, position heater housing assembly (items 10 through 19) with heater gasketon catalyst section and secure, using 10 seal washers (2) and 10 bolts (1).

j. Reinstall heater conduit (9) with wires into heater housing.

k. Reconnect wires.

(1) Reconnect wires to heating elements (17) and secure, using nuts (8). Remove identification tags attachedduring disassembly.

(2) Ensure that heater wire connections at both ends and at buss bars are tight.

(3) Using multimeter, ensure that resistance across heater phases is 15 ohms.

(4) Ensure that heater resistance from phase to ground is 2 megohms minimum.

(5) If resistance measured in step 6-7.1.4.k.(2) and/or step 6-7.1.4.k.(3) is unacceptable, check for shorts caused byheater terminal contact with heater housing, or loose buss bars acting as a bridge across ceramic part of one ormore heater elements. If no shorts are located, then buss bars should be removed from heater elements andindividual elements checked for resistance of 45 ohms. Replace faulty heater elements.


6-28 Original


l. Position heater cover (7) on heater housing and secure, using lockwashers (6) and bolts (5).

m. Position remaining heater gasket and cover (3)on heat exchanger and secure, using remaining seal washers (2) andremaining bolts (1).

WARNING


n. Fill catalyst section with new catalyst.

(1) Test catalyst to ensure that it is hopcalite and not charcoal. To distinguish hopcalite from charcoal, a fewgranules of questionable substance are placed in small amount of clean monoethanolamine (MEA)(MIL-M-23573)which is used in CO2 scrubbers. Hopcalite reacts with MEA and causes definite blue colorationof solution in approximately 10 minutes. If substance is charcoal, no blue color appears.

(2) Position catalyst removal cover plate (48, sheet 1) and one catalyst cover gasket (49) on catalyst section andsecure, using bolts, lockwashers, and seal washers.

(3) Add hopcalite to catalyst section through catalyst add door. Fill catalyst section to not less than 1-1/2 inchesbelow catalyst add door. Tamp down to ensure dense catalyst packing.

o. Reinstall thermocouple probe (40) in catalyst section. Ensure that probe is inserted as deeply as possible intocatalyst bed.

p. Position catalyst add cover plates (48) and two catalyst cover gaskets on catalyst section and secure, using bolts,lockwashers, and seal washers.

q. Position instrument mounting bracket (46) on transition duct and secure, using nuts, lockwashers, bolts, andwashers.

r. Reinstall control box (45) on burner.

WARNING

Control box weighs 50 pounds. To prevent injury or death, ensure that extreme careand proper lifting devices are used during handling.

(1) Using proper lifting devices, position control box on transition duct and secure, using nuts, lockwashers, bolts,and washers.

(2) Reinstall washers (44), bolts (43), lockwashers(42), and nuts (41) to secure control box to instrument mountingbracket.

(3) Push wires from heater conduit (9, Figure7-13) and temperature indicating controller conduit (1, Figure7-12)into holes of control box.

(4) Reinsert 440-Vac electrical cable and reconnect all wires in control box. Remove identification tags attachedduring disassembly.

s. Reinsert thermocouple probe wires into control box.


Original 6-29


(1) Push wires from thermocouple probe into hole of control box.

(2) Reconnect thermocouple probe wires. Remove identification tags attached during disassembly.

t. Reinstall fan wheel housing and motor mounting bracket (38) on transition duct.

(1) Position fan wheel (8, Figure7-7) in fan wheel housing and motor mounting bracket. Secure fan wheel so thatit does not fall out.

WARNING

Fan wheel housing and motor mounting bracket and fan wheel weigh 40 pounds.Ensure that extreme care is used during handling.

(2) Position fan wheel housing and motor mounting bracket with fan wheel inside and fan wheel housing gasket(39, Figure7-6, sheet 1) on transition duct. Secure, using nuts, lockwashers, and capscrews at countersunkholes.

(3) Reinstall nuts, lockwashers, bolts, and washers in remaining holes.

(4) Reinstall nuts, lockwashers, bolts, and washers.

u. Reassemble and reinstall bypass duct assembly(items 33 through 37).

(1) Reinstall door gasket (34) and push-pull control(33) on bypass duct (35).

(2) Position gasket (36) on fan wheel housing and motor mounting bracket and gasket (37) on catalyst section.

(3) Position bypass duct assembly on gaskets.

(4) Reinstall bolts, lockwashers, and washers to secure bypass duct assembly to fan wheel housing and motormounting bracket.

(5) Reinstall nuts, lockwashers, bolts, and washers to secure bypass duct assembly to catalyst section.

v. Reinstall motor and fan wheel assembly (31) on fan wheel housing and motor mounting bracket.

(1) Position motor hub seal (32) on motor (items 9 through 55, Figure7-7).

WARNING


(2) Using proper lifting devices, position motor to align shaft (50) with fan wheel in fan wheel housing.

(3) Reach inside fan wheel housing and secure fan wheel to shaft, using washer (7), nut (6), and cotter pin (5).Remove temporary fastenings from fan wheel.


6-30 Original


NOTE

For SSN21 model, install spacer (56, Figure7-7) part number 1072–B1100 on shaft(50) before washer (7).

(4) Reinstall nuts, lockwashers, bolts, and washers to secure motor and fan wheel assembly to fan wheel housingand motor mounting bracket.

w. Reinstall fan motor conduit (30) on motor and fan wheel assembly and control box.

(1) Position fan motor conduit on burner and reinstall fan motor conduit on control box.

(2) Push wires from fan motor conduit into hole of control box and reconnect wires. Remove identification tagsattached during disassembly.

(3) Push wires from fan motor conduit into hole of conduit box (20, Figure7-7) and reconnect fan motor conduitto conduit box.

(4) Reconnect wires of fan motor conduit to terminal lugs (14). Remove identification tags attached duringdisassembly.

(5) Position conduit box cover gasket (4) and conduit box cover (3) on conduit box and secure, using lockwashers(2) and capscrews(1).

x. Reassemble air filter housing assembly (A, Figure7-6, sheet 1) on burner.

WARNING

Air filter housing weighs 30 pounds. Ensure that extreme care is used duringhandling.

(1) Position air filter housing (28, bubble A) with air filter box gasket (29) on fan wheel housing and motormounting bracket and secure, using washers (27), lockwashers (26), and bolts (25).

(2) Reinstall nuts, lockwashers, and washers to secure air filter housing to transition duct.

(3) Reinstall washers (24), bolts (23), lockwashers(22), and nuts (21) to secure air filter housing to control box.

(4) Position air inlet gasket (20) between air filter housing and air inlet duct and secure, using washers (19), bolts(18), lockwashers(17), and nuts (16).

(5) Reinstall air filter retaining springs (13) in air filter housing. Hook one and of each spring to left side of airfilter housing.

(6) Insert replacement filter (14) with disposable air filter gasket (15) into right side of air filter housing. Ensurethat airflow arrow on filter points in proper direction toward motor and that gasket seats firmly against sealplate in air filter housing. Tension from springs will be felt as filter is inserted.

(7) Secure filter by hooking other end of each spring to right side of air filter housing. Ensure that springs drawfilter firmly against seal plate and that disposable air filter gasket is slightly compressed.

(8) Position air filter housing cover (12) on air filter housing and secure, using screws (11).


Original 6-31


y. Reassemble and reinstall pitot tube assembly (items 6 through 10, sheet 1).

(1) If removed, position tubing (7 and 8) in plate(9) and braze in accordance with NSTM Chapter 074.

(2) Reinstall union elbows (6) on tubing.

(3) Position pitot tube assembly and gasket (10) on fan wheel housing and motor mounting bracket and secure,using bolts and lockwashers.

z. Reinstall tubing (2, sheet 1) and compression fittings (1, sheet 1, and 3, 4, and 5, sheet 2).

(1) Reinstall compression fittings and tubing on burner.

(2) Reinstall tubing into manifold valve assembly (items 5 through 10, Figure7-12).

aa. Repair or replace damaged insulation.

ab. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

ac. Adjust temperature indicating controller (paragraph6-3.3), as required.

ad. Operate burner (paragraphs2-3.1and2-3.2) as required to test burner for proper operation. Check for leaks.

ae. Return burner to normal operating condition in accordance with ship procedures.

6-7.2 CATALYST SECTION REPLENISHMENT The following procedure shall be used to replace the catalyst in thecatalyst section (Figure7-6).

WARNING


WARNING

To prevent injury, allow 4 hours for spent catalyst to cool prior to removal.


b. Remove bolts, lockwashers, seal washers, catalyst add cover plates (48, sheet 1), and two catalyst cover gaskets(49) from catalyst section (99, sheet 2).

c. Remove bolts, lockwashers, seal washers, catalyst removal cover plate (48, sheet 1), and one catalyst cover gasketfrom catalyst section.

WARNING


d. Remove catalyst from catalyst section through catalyst cover plate access.

(1) Vacuum cleaner may be used through catalyst fill port to remove catalyst granules.


6-32 Original


(2) When cleaning and inspecting catalyst bed, remove loose catalyst from catalyst bed screens by vacuumingscreens. Replace screens if punctured or corroded.

e. Fill catalyst section with new catalyst.

(1) Test catalyst to ensure that it is hopcalite and not charcoal. To distinguish hopcalite from charcoal, fewgranules of questionable substance are placed in small amount of clean monoethanolamine (MEA)(MIL-M-23573)which is used in CO2 scrubbers. Hopcalite reacts with MEA and causes definite blue colorationof solution in approximately 10 minutes. If substance is charcoal, no blue color appears.

(2) Position catalyst removal cover plate and one catalyst cover gasket on catalyst section and secure, using sealwashers, lockwashers, and bolts.

(3) Put hopcalite into catalyst section through catalyst add cover plates. Fill catalyst section to no less than 1-1/2inches below catalyst add cover plates. Tamp down catalyst to ensure uniform packing.

f. Position catalyst add cover plates and two catalyst cover gaskets on catalyst section and secure, using sealwashers, lockwashers, and bolts.

g. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

h. Operate burner (paragraphs2-3.1and2-3.2) as required to test catalyst section.

i. Return burner to normal operating condition in accordance with ship procedures.

6-7.3 THERMOCOUPLE PROBE REPLACEMENT The following procedure shall be used to replace thethermocouple probe (Figure7-6, sheet 1).

WARNING



b. Remove thermocouple probe (40) from catalyst section(99, sheet 2).

c. Gain access to interior of control box (45, sheet 1).

d. Identify, tag, and disconnect wires to thermocouple probe from control box.

e. Remove thermocouple probe.

f. Install replacement thermocouple probe in catalyst section. Ensure that probe is inserted as deeply as possible incatalyst bed.

g. Reconnect wires to control box. Ensure that leads are not reversed. Remove identification tags.

h. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

i. Operate burner (paragraphs2-3.1and2-3.2) as required to test thermocouple probe completely.

j. Return burner to normal operation in accordance with ship procedures.


Original 6-33


6-7.4 DISPOSABLE AIR FILTER REPLACEMENT The following procedure shall be used to replace the disposableair filter (Figure7-6, bubble A).

WARNING



b. Remove screws (11) securing air filter housing cover (12) to air filter housing (28). Remove air filter housingcover.

c. Unhook air filter retaining springs (13) from right side of air filter housing. Hook springs to left side of air filterhousing.

d. Pull filter (14) and disposable air filter gasket(15) out of air filter housing.

e. Clean air filter housing and air filter housing cover with general purpose detergent (MIL-D-16791) and watersolution.

f. Inspect base of air filter housing for obstructions.

g. Insert replacement filter with disposable air filter gasket to right side of air filter housing. Ensure that airflowarrow on filter points in proper direction toward motor and that gasket seats firmly against seal plate in air filterhousing. Tension from springs will be felt as filter is inserted.

h. Unhook springs from left side of air filter housing and secure filter by hooking springs to right side of air filterhousing. Ensure that springs draw filter firmly against seal plate and that disposable air filter gasket is slightlycompressed.

i. Position air filter housing cover on air filter housing assembly and secure, using screws.

j. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

k. Return burner to normal operating condition in accordance with ship procedures.

6-7.5 AC MOTOR AND FAN WHEEL ASSEMBLY The following procedures shall be used to repair or replace theac motor(motor) and fan wheel assembly (Figure7-7).

6-7.5.1 Removal and Disassembly

WARNING



NOTE

If more information is required for removal of interference refer to paragraph6-7.1.1.


6-34 Original


b. Remove air filter (14, Figure7-6, sheet 3).

c. Remove the orifice plate (28A, Figure7-6, sheet 3) attached to the air filter housing (28, Figure7-6, sheet 3) airoutlet.

d. Secure fan wheel (31B, Figure7-6, sheet 3) with temporary fastener device(s) to impede rotation of the fan andmotor shaft (31B and 31A, Figure7-6, sheet 3). Remove the cotter key (31C, Figure7-6, sheet 3), castellated nut(31E, Figure7-6, sheet 3), and washer (31D, Figure7-6, sheet 3) that secure the fan wheel to the motor shaft.

e. Use an appropiate size wheel puller to remove the fan wheel from the motor shaft.

f. Remove the conduit box cover (3, Figure7-7) from motor, then disconnect the electrical leads which come fromthe control box and disconnect its conduit from the conduit box.

WARNING


g. Remove nuts, and washers and bolts that secure the motor to the fan wheel housing and motor mounting bracket.Using proper lifting devices, remove motor from burner.

NOTE

For SSN21 Class motors useFO-8 when performing motor maintenance. Althoughparts and sequences of removal are similar to the maintenance actions for thestandard motor listed below through paragraph6-7.5.4, there are significantdifferences, such as the SSN21 Class motor having two balance rings vice one.

h. Remove screws (9, Figure7-7), lockwashers (10), washers (11), and lead clamps (12 and 13) from lead clampsupport (17).

i. Remove terminal lugs (14).

j. Remove screws (15), lockwashers (16), and lead clamp support from conduit box (20).

k. Remove screws (18), locwashers (19), conduit box and conduit box gasket (21), from stator frame(55).

l. Remove key(22), from shaft (50).

m. Remove capscrews (23), lockwashers(24), and back-end bracket (25), from stator frame.

CAUTION

To prevent equipment damage, extreme care is required when handling bearings.Surfaces of shaft/bearing fit and bearings shall be protected during handling.

CAUTION

To prevent equipment damage, use appropriate bearing puller to remove ballbearings, applying force evenly to inner race and outer race.


Original 6-35


n. Using bearing puller and puller attachment , remove back-end ball bearing (26) from shaft.

o. Remove capscrews (27), lockwashers (28), wahsers (29) and balance ring cover (30) from front-end bracket (38).

p. Remove screws (31) from balance ring (34).

q. Remove setscrews (32 and 33).

r. Remove balance ring from shaft.

s. Remove balance ring key (35).

t. Remove capscrews(36), lockwashers (37), and front-end bracket from stator frame.

u. Remove front-end spring washer(39) and front-end thrust washer (40) from shaft.

CAUTION


CAUTION

To prevent equipment damage, use appropriate bearing puller to remove ballbearings, applying force evenly to inner race and outer race.

v. Using bearing puller and puller attachment, remove front-end ball bearing (41).

w. Remove nut (42), lockwasher (43), setscrew (44), and insert (45) from inner fan (46).

x. Pull inner fan from shaft and remove key (47).

CAUTION

To prevent equipment damage, remove rotor and shaft very carefully without slidingrotor across stator windings.

y. Slowly and carefully move rotor and shaft subassembly (items 48, 49, and 50) through stator core (54)horizontally. Ensure that rotor (48) does not slide across stator windings.

z. Carefully lower rotor and shaft subassembly onto large sheet of thick cardboard or equivalent. Block rotor inplace.

aa. Remove rotor and key (49) from motor shaft only if parts must be replaced. Rotor is welded onto shaft and 7- to20-ton force using arbor press, is required to press rotor from shaft after weld is cut. Rotor is welded inaccordance with NSTM Chapter 074 and requires a torch to break weld.

ab. Remove screws and identifications plate (51) and then remove retaining pin (52) from stator frame.

ac. Remove stator coils (53) and stator core from stator frame only if parts must be replaced. Stator core removalrequires 5- to 7-ton force, using arbor press, to press stator core from frame.


6-36 Original


6-7.5.2 Cleaning and Inspection

CAUTION

To prevent equipment damage, do not use harsh abrasives that might scratch, scoreor otherwise mar surface finishes.

a. Use clean, dry cloth to remove old lubricant from outer surface of motor.

b. Use vacuum cleaner or soft-bristled brush to remove accumulation of dust and dirt from stator frame and inner fanwheel blades.

c. Use stiff-bristled brush to remove hardened deposits of dirt and other contaminants.

WARNING

Solvent is flammable and toxic. To prevent injury or death, use solvent inwell-ventilated area. Wear appropriate protective covering and avoid prolongedbreathing of fumes or solvent contact with skin.

d. Clean metal parts in solvent (P-D-680).

e. Clean all motor parts. Inspect all motor parts for nicks, scratches, burrs, discoloration, (caused by overheating),deterioration of bearings, burned stator insulation, and splattered solder.

WARNING

Pressurized air can drive particles into eyes and skin if handled improperly. Toprevent personnel injury or equipment damage, wear face shield and appropriateclothing and exercise extreme caution.

f. After cleaning, dry parts thoroughly with low-pressure air or with clean, dry, lint-free cloth.

g. When possible, inspect all parts visually under strong light and magnification.

h. Inspect all threaded areas for stripped or crossed threads. All threads shall be sharp and unmarked.

i. Check motor shaft for flat spots and uneven wear.

6-7.5.3 Repair and Replacement

a. Repair or replace any worn or defective parts (paragraph6-6.1or 6-6.2).

b. Rewind motor in accordance with NAVSEA 0900-LP-060-2010;NSTM Chapter 300, Appendix A; and Table6-1.

c. Machine shaft for proper rotor or bearing fit. This procedure shall be performed only by qualified personnel inproperly equipped facilities. Shaft dimensions are shown in Figure6-7.

d. Motor and fan wheel are precision-balanced as an assembly. If motor is replaced, replace fan wheel also.

6-7.5.4 Reassembly and Reinstallation


Original 6-37


a. If removed, insert stator coils (53) into stator core (54) and press into stator frame (55), using arbor press withforce of 5 to 7 tons.

b. Reinstall retaining pin (52) and identification plate (51) on stator frame and secure, using screws.

c. If removed, insert key (49) into rotor (48) and press rotor onto shaft (50), using arbor press with force of 7 to 20tons. Welds cut for disassembly must be restored in accordance with NSTM Chapter 074.

d. Carefully slide rotor and shaft subassembly (items 50, 49, and 48) into stator core.

Table 6-1. Stator Winding Data

Characteristic RequirementNumber of Poles 2Type of Connection WYE-single circuitNumber of Slots 24Number of Coils 24Winding Pitch in Slots 1-8Turns in Series per Coil 40Conductor Diameter (Bare) 20 AWGConductor/Insulation J-W-1177/15 Type MConductor in Parallel 1 of 20 AWGResistance Between Terminals 9.4 ohms at 77 °F (25 °C)Weight of Copper 5 lbs


6-38 Original


e. Reinstall key (47) and inner fan (46) on shaft.

f. Reinstall insert (45), setscrew (44), lockwasher(43), and nut (42) on inner fan.

CAUTION


Figure 6-7. AC Motor Shaft Dimensions


Original 6-39


g. Reinstall front-end ball bearing (41) and back-end ball bearing (26) on shaft. Instructions for other methods ofbearing installation and other heat sources are given in NSTM Chapter 244.

(1) Heat ball bearings in thermostatically controlled convection oven to 203 °610 °F (95.6 °65.6 °C). In mostcases, bearing temperature, if measured using Fahrenheit scale, should be 100 ° higher than shaft temperature.If measured using Celsius scale, bearing temperature should be 55.6 ° higher than shaft temperature.

WARNING

Heated ball bearings reach temperatures as high as 212 °F (100 °C). To preventinjury, exercise extreme care and wear insulated gloves when handling heated ballbearings.

(2) Push heated ball bearings on shaft and seat firmly against shoulder of shaft.

(3) Allow bearings to cool. To protect from contamination, cover bearings and shaft.

h. Slide front-end thrust washer (40) and front-end spring washer (39) onto shaft.

i. Slide front-end bracket (38) over shaft, position at stator frame and secure, using lockwashers (37) and capscrews(36).

j. Reinstall balance ring key (35) on shaft.

k. Slide balance ring (34) over balance ring key and shaft, and secure, using setscrews (33 and 32).

l. Reinstall screws (31) in balance ring.

m. Slide balance ring cover (30) over shaft, position on front-end bracket, and secure, using washers (29),lockwashers (28), and capscrews (27).

n. Slide back-end bracket (25) over shaft, position at stator frame, and secure, using lockwashers (24) and capscrews(23).

o. Position key (22) in shaft.

p. Position conduit box gasket (21) and conduit box(20) on stator frame and secure, using lockwashers (19) andscrews (18).

q. Position lead clamp support (17) in conduit box and secure, using lockwashers (16) and screws (15).

r. Reinstall terminal lugs (14).

s. Clamp leads of motor, using lead clamps (13 and 12), washers (11), lockwashers (10), and screws (9).

t. Reinstall motor and fan wheel assembly (31, Figure7-6, sheet 1) and air filter housing assembly (A) (paragraph6-7.1.4).

u. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

v. Operate burner (paragraphs2-3.1and2-3.2) as required to test ac motor and fan wheel assembly completely.

w. Return burner to normal operating condition in accordance with ship procedures.


6-40 Original


6-7.6 CONTROL BOX ASSEMBLY The following procedures shall be used to repair or replace components of thecontrol box (Figure7-8).

6-7.6.1 General Electrical Component Replacement The following procedures shall be used to replace generalelectrical components (Figure7-8) that are not repairable.

6-7.6.1.1 Removal

WARNING



b. Remove cover of enclosure (22, sheet 2) containing components to be replaced.

c. Identify, tag, and disconnect wires from components(items 1 through 15, sheets 1 and 2).

d. Remove mounting screws or bolts of components.

e. Remove components from enclosure.

6-7.6.1.2 Cleaning and Inspection

a. Wipe off hardened deposits of dirt with clean, lint-free cloth.

WARNING

Solvent is flammable and toxic. To prevent injury or death, use solvent inwell-ventilated area. Wear appropriate protective covering and avoid prolongedbreathing of fumes or solvent contact with skin.

b. Remove surface dirt, dust, or grease from parts with clean cloth lightly moistened with solvent (P-D-680). Browndiscoloration on contacts is normal and need not be removed.

c. Check all parts for discoloration (caused by overheating), fractures, and corrosion.

d. Examine all parts for deformities, pitting, scoring, scatches, nicks, and accumulation of hardened dirt deposits andother contaminants.

e. Inspect all threaded areas for stripped threads and evidence of crossthreading and examine area adjacent to threadsfor cracks.

f. Check all springs for cracks and bends and verify uniform expansion and retraction capability.

g. Inspect all contacts for pitting, burning, and sharp projections. Remove small projections with fine sandpaper (No.00). Replace contacts which cannot be properly sanded.

6-7.6.1.3 Replacement

a. Replace any parts that show severe discoloration from overheating.


Original 6-41


b. If serviceability of any part is questionable, replace part.

c. Do not discard used items until availability of replacement parts is determined.

d. If replacements are not available and equipment must be reassembled, due to ship’s mission or other emergency,used parts may be reused. If used parts are reused, equipment should be closely monitored for proper operation.

6-7.6.1.4 Reinstallation

a. Position components (items 1 through 15, sheets 1 and 2) in enclosure (22) and secure, using mounting screws orbolts.

b. Reconnect wires to components and remove identification tags attached during disassembly.

c. Ensure that all electrical connections and mechanical fastenings are tight.

d. Reinstall cover of enclosure.

e. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

f. Operate burner (paragraphs2-3.1and2-3.2) as required to test components completely.

g. Return burner to normal operating condition in accordance with ship procedures.

6-7.6.2 Alarm Relay Controller The following procedure shall be used to replace the alarm relay controller (20,Figure7-8, sheet 2).

WARNING



b. Gain access to alarm relay controller in enclosure(22).

c. Identify, tag, and disconnect wires to alarm relay controller.

d. Remove screws, lockwashers, and alarm relay controller from enclosure.

e. Clean and inspect all parts (paragraph6-7.6.1.2).

f. Repair or replace any worn or defective parts (paragraph6-7.6.1.3).

g. Reinstall alarm relay controller (20) in enclosure(22) and secure, using lockwashers and screws.

h. Reconnect wires to alarm relay controller.

i. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

j. Operate burner (paragraphs2-3.1and2-3.2) as required to test components completely.

k. Return burner to normal operating condition in accordance with ship procedures.


6-42 Original


6-7.6.3 AC Contactor, N850 The following procedures shall be used to repair the N850 ac contactor (Figure7-9).

6-7.6.3.1 Preliminary inspection

WARNING



b. Using multimeter, test all main power and coil terminals to ensure that power is off.

c. Manually move armatures (17) of contactor to check for binding or dragging of parts.

CAUTION

To prevent equipment damage, do not lubricate main contacts. Lubrication defeatsdesign function.

d. If binding occurs, check for dirt or foreign matter in mechanical linkage. Remove and clean as needed. Lubricatelinkage, but do not lubricate contacts.

e. Ensure that all electrical connections and mechanical fastenings are clean and tight.

f. Using multimeter, ensure that shunt coil (18)resistance is 53.4 ohms. Replace shunt coil (paragraph6-7.6.3.5) ifdifferent resistance is measured.

g. If no other procedures are to be performed, remove out of service tag in accordance with ship procedures andenergize burner at power panel.

h. Return burner to normal operating condition in accordance with ship procedures.

6-7.6.3.2 Removal

WARNING



b. Identify and tag wires of contactor (16, Figure7-8, sheet 2).

c. Disconnect wires from contactor.

d. Remove screws and lockwashers securing contactor to control mounting plate (21).

e. Carefully remove contactor from plate and enclosure(22).

6-7.6.3.3 Main Contact Wear Check


Original 6-43


a. Manually bring both armatures (17, Figure7-9) together uniformly until stationary main contacts (5 and 6) andmovable main contacts (9) just touch. To determine when main contacts touch, check continuity of main contacts,using multimeter.

b. Hold armatures in this position. Measure distance from surface of contact case (Figure6-8) to top of metal knob.Record measurement.

c. Push armatures in uniformly to fully seated position and again measure and record distance as in step6-7.6.3.3.b.

d. Compute difference between measurements recorded in steps6-7.6.3.3.band6-7.6.3.3.c. Difference representsremaining wear allowance. Wear allowance in excess of 0.0156 inch is acceptable.

e. Repeat steps6-7.6.3.3.athrough6-7.6.3.3.dfor each remaining set of main contacts.

f. If remaining wear allowance of any main contact is 0.0156 inch or less, replace all main contacts. Do not adjustworn contacts.

6-7.6.3.4 Contact Inspection, Removal, and Replacement

a. Disconnect leads of shunt coil (18) from coil lead terminals (12).

b. Remove four contact case mounting screws (1), lockwashers (2), and washers (3) from one contact case assembly(items 4 through 14) and mounting brackets (16).

c. Move one contact case assembly away from mounting brackets vertically in straight line.

d. Lay contact case assembly on clean surface with contact case cover (4) up.

e. Remove contact case cover from contact case (14)with interlock terminals (13) attached.

f. Inspect stationary main contacts (5 and 6), stationary interlock contacts (7), movable interlock contacts (8), andmovable main contacts(9) for wear, burning, pitting, or deformation.

g. If any contact is worn, burnt, pitted, or deformed, clean and smooth surface with emery cloth or fine file. If anymain contact has remaining wear allowance of less than 0.0156 inch, replace all contacts.

(1) Remove two movable contact assemblies (items 8 through 11) from contact case. Do not allow movablecontact assemblies to become interchanged in contact case.

Figure 6-8. AC Contactor, N850, Wear Allowance Measurement


6-44 Original


(2) Remove contact spring (10) from contact bar (11) (shown in Figure6-9).

(3) Slide movable main contact out of contact bar.

(4) Remove contact mounting screws and movable interlock contacts (8) from contact bars.

(5) Repeat steps6-7.6.3.4.g.(2)through6-7.6.3.4.g.(4)for remaining movable contact assembly.

(6) Remove contact mounting screws and stationary interlock contacts from contact case.

(7) Remove capscrews, nuts, lockwashers, washers, and stationary main contacts from contact case.

(8) Wipe interior of contact case and contact bars with clean, dry cloth.

CAUTION

To prevent equipment damage, ensure that movable and stationary contacts areinstalled so that contact surfaces mate properly.

(9) Position stationary main contacts in contact case and secure, using washers, capscrews, lockwashers, and nuts.

(10) Position stationary interlock contacts in contact case and secure, using contact mounting screws.

(11) Position movable interlock contacts on contact bars and secure, using contact mounting screws.

(12) Insert movable main contact into contact bar (shown in Figure6-9).

(13) Reinstall contact spring into contact bar.

(14) Position one movable contact assembly (items 8 through 11) in contact case.


CAUTION


(16) Lubricate interlock contacts with thin film of lubricating oil (VV-L-820). Do not lubricate main contacts.

Figure 6-9. Contact Spring Removal and Installation


Original 6-45


h. Position contact case cover on contact case. Contact case cover fits properly on contact case in only one position.

i. Position one contact case assembly on mounting brackets and secure, using four washers, lockwashers, and contactcase mounting screws. Ensure that drive link (shown in Figure6-10) of armature (17) engages contact bar.

j. Reconnect shunt coil leads to coil lead terminals.

k. Repeat steps6-7.6.3.4.athrough6-7.6.3.4.jfor second contact case assembly.

l. Contact replacement usually, but not always, ensures adequate wear adjustment. Ensure adequate wear adjustmentby performing main contact wear check (paragraph6-7.6.3.3).

(1) If travel is less than 0.062 inch, remove two screws (shown in Figure6-10) securing nameplate and drive linkto base of each armature. Remove nameplate and drive link. Add shims to base. Then reinstall nameplate anddrive link to base and secure, using two screws.

(2) If travel is greater than 0.082 inch, remove two screws securing nameplate and drive link to base of eacharmature. Remove nameplate, drive link, and shims, an required. Then reinstall nameplate and drive link, andsecure, using two screws.

m. Ensure that all screws are tight.

6-7.6.3.5 Shunt Coil Replacement



Figure 6-10. AC Contactor, N850, Wear Adjustment


6-46 Original


c. Move one contact case assembly away from mounting brackets vertically in straight line. Tag contact caseassembly as to relative position (top or bottom).


e. Remove second contact case assembly. When second contact case assembly is removed, internal mechanism,consisting of two magnet frame spring assemblies (items 15 and 16), two armatures (17), and shunt coil, becomesunsupported group of five parts.

f. Carefully separate five parts and remove shunt coil.

g. Wipe off any accumulation of dirt and old lubricant on magnet frame spring assemblies and armatures. Ifadditional cleaning is necessary, clean in accordance with paragraph6-7.6.1.2.

h. Inspect surfaces of case and armature. These components seal when contactor is closed. Clean with emery cloth ifthere are any signs of corrosion. Rusted surfaces cause contactor to operate irregularly and are usuallyaccompanied by hum or buzz.

i. Replace magnet frame springs (15).

(1) Remove magnet frame springs (Figure6-11) from mounting brackets.

(2) Apply very small amount of lubricating oil (VV-L-820) to spring seat groove of end support.

(3) Hook spring on one end support.

(4) With long-nosed pliers, slip unhooked end of spring on other end support, stretching only as necessary to seatspring.

j. Lubricate mechanical linkage points on mounting brackets with one drop of lubricating oil. Wipe off excess.

k. Position shunt coil with leads extending toward front (nameplate) of armature.

l. Reassemble armatures, mounting bracket assemblies, and shunt coil. Ensure that armatures engage sliders onmounting brackets.

m. Position bottom contact case assembly on mounting brackets and secure, using four washers, lockwashers, andcontact case mounting screws. Ensure that contact bars (11) engage drive links (shown in Figure6-10) ofarmatures.

n. Position top contact case assembly on mounting brackets and secure, using four washers, lockwashers, and contactcase mounting screws. Ensure that contact bars engage drive links of armatures.


Original 6-47


o. Manually operate armatures and ensure that all parts are properly engaged and that contactor operates freely.

p. Reconnect shunt coil leads to coil lead terminals.

q. Ensure that all screws are tight.

r. To ensure proper operation, connect shunt coil to power source and electrically operate contactor. Disconnectpower source.


a. Position contactor (16, Figure7-8, sheet 2) on control mounting plate (21) in enclosure (22)and secure, usinglockwashers and screws.

b. Reconnect wires to contactor. Remove identification tags attached during disassembly.

c. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

d. Operate burner (paragraphs2-3.1and2-3.2) as required to test contactor completely.

e. Return burner to normal operating condition in accordance with ship procedures.

6-7.6.4 AC Contactor, N894 The following procedures shall be used to repair the N894 ac contactor (Figure7-10).

6-7.6.4.1 Preliminary Inspection

WARNING



Figure 6-11. Magnet Frame Spring Assembly


6-48 Original


b. Using multimeter, test all main power and coil terminals to ensure that power is off.

c. Manually move armatures (18) of contactor to check for binding or dragging of parts.

CAUTION


d. If binding occurs, check for dirt or foreign matter in mechanical linkage. Remove and clean as needed. Lubricatelinkage, but not contacts.

e. Ensure that all electrical connections and mechanical fastenings are clean and tight.

f. Using multimeter, ensure that shunt coil (19)resistance is 38.4 ohms. Replace shunt coil (paragraph6-7.6.3.5) ifdifferent resistance is measured.

g. If no other procedures are to be performed, remove out of service tag in accordance with ship procedures andenergize burner at power panel.

h. Return burner to normal operating condition in accordance with ship procedures.

6-7.6.4.2 Removal

WARNING



b. Identify and tag wires of contactor (17, Figure7-8, sheet 2).

c. Disconnect wires from contactor.

d. Remove screws and lockwashers securing contactor to control mounting plate (21).

e. Carefully remove contactor from plate and enclosure(22).

6-7.6.4.3 Main Contact Wear Check

a. Manually bring both armatures (18, Figure7-10) together uniformly until stationary main contacts (5) and movablemain contacts (8) just touch. To determine when main contacts touch, check continuity of main contacts, usingmultimeter.

b. Hold armatures in this position. Measure distance from surface of contact case (shown in Figure6-12) to outeredge of metal engaging plate (10). Record measurement.

c. Push armatures in uniformly to fully seated position and again measure and record distance as in steps6-7.6.4.3.b.

d. Compute difference between measurements recorded in steps6-7.6.4.3.band6-7.6.4.3.c. Difference representsremaining wear allowance. Wear allowance in excess of 0.0156 inch is acceptable.


Original 6-49


e. Repeat steps6-7.6.4.3.athrough6-7.6.4.3.dfor each remaining set of main contacts.

f. If remaining wear allowance of any main contact is 0.0156 inch or less, replace all main contacts. Do not adjustworn contacts.

6-7.6.4.4 Contact Inspection, Removal, and Replacement



c. Move contact case assembly away from mounting brackets vertically in straight line.


e. Remove contact case cover from contact case (15)with interlock terminals (14) attached.

f. Inspect stationary main contacts (5), stationary interlock contacts (6), movable interlock contacts (7), and movablemain contacts(8) for wear, burning, pitting, or deformation.

g. If any contact is worn, burned, pitted, or deformed, clean and smooth surface with emery cloth or fine file. If anymain contact has remaining wear allowance of less than 0.0156 inch, replace all contacts.

(1) Remove two movable contact assemblies (items 7 through 11) from contact case. Do not allow movablecontact assemblies to become interchanged in contact cases.

(2) Remove contact spring (9) from contact bar (11) (shown in Figure6-9).

(3) Slide movable main contact out of contact bar.

(4) Remove contact mounting screws and movable interlock contacts (7) from contact bars.


(6) Remove contact screws, lockwashers, and stationary interlock contact from contact case.

(7) Remove capscrews and stationary main contacts from contact case.

Figure 6-12. AC Contactor, N894, Wear Allowance Measurement


6-50 Original


(8) Wipe interior of contact case and contact bars with clean, dry cloth.

CAUTION

To prevent equipment damage, ensure that movable and stationary main contacts areinstalled so that contact surfaces will mate properly.

(9) Position stationary main contacts in contact case and secure, using capscrews.

(10) Position stationary interlock contacts in contact case and secure, using lockwashers and contact screws.

(11) Position movable interlock contacts in contact bars with metal engaging plates (10) attached, and secure, usingcontact mounting screws.

(12) Insert movable main contact (shown in Figure6-9) into contact bar.

(13) Reinstall contact spring into contact bar.

(14) Position one movable contact assembly (items 7 through 11) in contact case.


CAUTION


(16) Lubricate interlock contacts with thin film of lubricating oil (VV-L-820). Do not lubricate main contacts.

h. Position contact case cover on contact case. Contact cover fits properly on contact case in only one position.

i. Position one contact case assembly on mounting bracket and secure, using four washers, lockwashers, and contactcase mounting screws. Ensure that metal engaging plates of contact bars engage armatures.

j. Reconnect leads of shunt coil to coil lead terminals.

k. Repeat steps6-7.6.4.4.athrough6-7.6.4.4.jfor second contact case assembly.

l. Contact replacement usually, but not always, ensures adequate wear adjustment. Ensure adequate wear adjustmentby performing main contact wear check (paragraph6-7.6.3.3).

(1) If travel is less than 0.066 inch, remove two screws (shown in Figure6-12) securing metal engaging plate toeach contact bar. Remove metal engaging plate and add shims. Then reinstall metal engaging plate and secure,using two screws.

(2) If travel is greater than 0.086 inch, remove two screws securing metal engaging plate to each contact bar.Remove metal engaging plate and shims as required. Then reinstall metal engaging plate and secure, using twoscrews.

m. Ensure that all screws are tight.

6-7.6.4.5 Shunt Coil Replacement


Original 6-51



b. Remove four contact case mounting screws (1), lockwashers (2), and washers (3) from contact case assembly(items 4 through 15) and mounting brackets (17).

c. Move one contact case assembly away from mounting brackets vertically in straight line. Tag contact caseassembly as to relative position (top or bottom).


e. Remove second contact case assembly, using steps6-7.6.4.5.bthrough6-7.6.4.5.d. When second contact caseassembly is removed, internal mechanism consisting of two magnet fram spring assemblies (items 16 and 17), twoarmatures (18), and shunt coil, becomes unsupported group of five parts.

f. Carefully separate five parts and remove shunt coil. Do not remove screws holding metal engaging plates (10) onends of contact bars (11).

g. Wipe off any accumulation of dirt and old lubricant on mounting bracket assemblies and armatures. If additionalcleaning is necessary, clean in accordance with paragraph6-7.6.1.2.

h. Inspect surfaces of case and armature. These components seal when contactor is closed. Clean with emery cloth ifthere are any signs of corrosion. Rusted surfaces will cause contactor to operate irregularly and are usuallyaccompanied by hum or buzz.

i. Replace magnet frame springs (16).

(1) Remove magnet frame springs (shown in Figure6-11) from mounting brackets.

(2) Apply very small amount of lubricating oil (VV-L-820)to spring seat groove of end support.

(3) Hook spring on one end support.

(4) With long-nosed pliers, slip unhooked end of spring on other end of support, stretching only as necessary toseat spring.

j. Lubricate mechanical linkage points on mounting brackets (17) with one drop of lubricating oil. Wipe off excess.

k. Position shunt coil with leads extending toward front (nameplate) of armature.

l. Reassemble armatures, mounting bracket assemblies, and shunt coil. Ensure that armatures engage rectangular slotsof mounting brackets.

m. Position bottom contact case assembly on mounting brackets and secure, using four washers, lockwashers, andcontact case mounting screws. Ensure that metal engaging plates of contact bars engage amatures.

n. Position top contact case assembly on mounting brackets and secure, using four washers, lockwashers, and contactcase mounting screws. Ensure that metal engaging plates of contact bars engage armatures.

o. Manually operate armatures and ensure that all parts are properly engaged and that contactor operates freely.

p. Reconnect shunt coil leads to coil lead terminals.

q. Ensure that all screws are tight.


6-52 Original


r. To ensure proper operation, connect shunt coil to power source and electrically operate contactor. Disconnectpower source.


a. Carefully position contactor (17, Figure7-8, sheet 2) on control mounting plate (21) in enclosure (22)and secure,using lockwashers and screws.

b. Reconnect wires to contactor. Remove identification tags attached during disassembly (paragraph6-7.6.4.2.b).

c. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

d. Operate burner (paragraphs2-3.1and2-3.2) as required to test contactor completely.

e. Return burner to normal operating condition in accordance with ship procedures.

6-7.6.5 Thermal Overload Relay The following procedures shall be used to repair or replace the thermal overloadrelays (Figure7-11).

6-7.6.5.1 Heater Coil Replacement

WARNING



b. Remove screws (1) and washers (2) that secure each heater coil (3).

c. Slide each heater coil out of thermal elements(10).

d. Slide each replacement heater coil over solder tubes (9) and into thermal elements with heater coil mountingbrackets on top of terminal plates (8).

e. Reinstall screws and washers through heater coil mounting into terminal plate.

f. Adjust thermal overload relay (paragraph6-3.1).

6-7.6.5.2 Removal

WARNING



b. Identify and tag wires to thermal overload relay(18 or 19, Figure7-8, sheet 2).

c. Disconnect wires from thermal overload relay.

d. Remove screws (1, Figure7-11) and washers (2) that secure each heater coil (3).


Original 6-53


e. Slide each heater coil out of thermal elements(10).

f. Remove screws and lockwashers securing thermal overload relay.

g. Carefully remove thermal overload relay from plate and enclosure (22, Figure7-8).

6-7.6.5.3 Contact Structure Replacement

a. Remove contact structure mounting screws (4, Figure7-11) from contact structure (14) and thermal elements (10).

b. Remove nut (5), screw (6), and base mounting brackets(7) from thermal elements.

c. Remove thermal elements.

(1) With one hand, grasp contact structure and one thermal element assembly (items 8, 9, and 10).

(2) With other hand, grasp second thermal element and pull down approximately 0.25 inch; then move secondthermal element away from first.

(3) Remove remaining thermal element with terminal plate (8) and solder tube (9) from contact structure in similarmanner.

d. Grasp replacement contact structure in one hand and use thumb of same hand to move splitter arms (11) out ofcontacts (13).

e. Assemble thermal elements with terminal plates and solder tubes on contact structure. Operating arms (12) mustbe in front and should be inclined upward in reset position. Each operating arm must rest on top of splitter arm.

f. Reinstall contact structure mounting screws through contact structure in thermal elements.

g. Position base mounting brackets on thermal elements.

h. Slide screw through base mounting brackets and thermal elements. Then reinstall nut on screw.


a. Position thermal overload relay (18 or 19, Figure7-8, sheet 2) on control mounting plate (21)in enclosure (22) andsecure, using lockwashers and screws.

b. Slide heater coils (3, Figure7-11) over solder tubes (9) and into thermal elements (10) with heater coil mountingbrackets on top of terminal plates (8).

c. Reinstall washers (2) and screws (1) through heater coil mounting brackets and into terminal plates.

d. Reconnect wires to thermal overload relay. Remove identification tags attached during disassembly.

e. Ensure that all electrical connections and mechanical fastenings are tight.

f. Adjust thermal overload relay (paragraph6-3.1).

6-7.7 INSTRUMENT MOUNTING BRACKET ASSEMBLY The following procedures shall be used to replacecomponents of the instrument mounting bracket (Figure7-12).


6-54 Original


6-7.7.1 Temperature Indicating Controller, Model 1612-4, Replacement

WARNING



b. Remove mounting bracket bolts (Figure6-13, view A) securing mounting bracket to instrument mounting bracket.

c. Pull mounting bracket out of instrument mounting bracket as far as possible.

d. Identify, tag, and disconnect wires from temperature indicating controller case.

e. Loosen nuts securing vertical retaining bracket and slide vertical retaining bracket off temperature indicatingcontroller case.

f. Remove mounting bracket from instrument mounting bracket.

g. Remove front bracket bolts and front bracket from mounting bracket.


Original 6-55


h. Remove screw and horizontal retainer bracket from mounting bracket.

i. Remove temperature indicating controller case.

CAUTION

To prevent equipment damage, do not force lever handle beyond 90 degrees or camlatch may shear off.

Figure 6-13. Temperature Indicating Controller Replacement


6-56 Original


j. Remove model-1612-4 temperature indicating controller(2) by depressing lever handle (Figure6-13, view B) inlower right hand corner to unlatch. Swing lever handle outward 90 degrees. Lever cam action will move controllerout about 1/4 inch.

k. Pull controller from temperature indicating controller case.

l. Clean and inspect all parts (paragraph6-7.6.1.2).

m. Replace defective temperature indicating controller (paragraph6-7.6.1.3).

n. Reinstall controller into temperature indicating controller case and push lever handle into controller.

o. Insert temperature indicating controller case into mounting bracket.

p. Reinstall front bracket on mounting bracket and secure, using front bracket bolts.

q. Reinstall horizontal retainer bracket on mounting bracket and secure, using screw.

r. Reinstall mounting bracket in instrument mounting bracket.

s. Reinstall vertical retaining bracket on temperature indicating controller case and tighten nuts.

t. Reconnect wires to temperature indicating controller.

u. Secure mounting bracket to instrument mounting bracket, using mounting bracket bolts.

v. Adjust controller (paragraph6-3.3).

6-7.7.2 Differential Pressure Gage Replacement

WARNING



b. Identify and tag tubes to gage (4, Figure7-12).

c. Disconnect tubes from gage.

d. Remove screws securing gage to instrument mounting bracket (11) and remove gage.

e. Install replacement gage in instrument mounting bracket.

f. Reconnect tubes to gage and remove identification tags.

g. Secure gage to instrument mounting bracket, using screws.

h. Adjust gage (paragraph6-3.7).


Original 6-57


6-7.7.3 Manifold Valve Assembly Replacement

WARNING


a. Deenergize burner at power panel and tag out of service-in accordance with ship procedures.

b. Identify and tag tubing (2, Figure7-6, sheet 1) to flip toggle valves (5 through 9, Figure7-12) at back of themanifold valve assembly (items 5 through 10).

c. Disconnect tubing from manifold valve assembly.

d. Remove nuts, lockwashers, bolts, and washers securing manifold valve assembly to instrument mounting bracket(11).

e. Remove manifold valve assembly from instrument mounting bracket.

f. Remove flip toggle valves from valve mounting plate (10) by removing nuts on front of flip toggle valves.

g. Clean and inspect all parts (paragraphs6-5.1and6-5.2).

h. Repair or replace any worn or defective parts (paragraph6-6.1or 6-6.2).

i. Reinstall flip toggle valves on valve mounting plate and secure, using nuts.

j. Position manifold valve assembly in instrument mounting bracket.

k. Reconnect tubing to manifold valve assembly. Remove identification tags.

l. Secure manifold valve assembly on instrument mounting bracket, using washers, bolts, lockwashers, and nuts.

m. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

n. Operate burner (paragraphs2-3.1and2-3.2) as required to test manifold valve assembly completely.

o. Return burner to normal operating condition in accordance with ship procedures.

6-7.8 HEATER The following procedures shall be used to repair or replace the heater (Figure7-13).

6-7.8.1 Removal and Disassembly

WARNING



b. Remove 10 bolts (1, Figure7-13), 10 seal washers (2), cover (3), and one heater gasket (4) from heat exchanger(79, Figure7-6, sheet 2).


6-58 Original


c. Remove remaining bolts (1, Figure7-13) and remaining seal washers (2) from heater housing (19)and heatexchanger.

d. Remove bolts (5), lockwashers (6), and heater cover (7) from heater housing.

e. Identify and tag wires to heater housing.

f. Remove nuts (8) from heating elements (17) and disconnect wires from heater housing.

g. Remove heater conduit (9) with wires.

WARNING


h. Using proper rigging and lifting device, remove heater housing assembly (items 10 through 19) with one heatergasket from heat exchanger. Remove heater gasket from heater housing assembly.

i. Remove remaining nuts (8) and bus bars (10 through 13) from heating elements and end housing (18).

j. Remove nuts (14) and washers (15) from one heating element.

k. Pull one heating element with gaskets (16) from heater housing.

l. Remove gaskets from heating element.

m. Repeat steps6-7.8.1.jthrough6-7.8.1.lfor remaining heating elements.

6-7.8.2 Cleaning and Inspection

a. Wipe off hardened deposits of dirt with clean, lint-free cloth.

WARNING

Cleaning compound is flammable and toxic. To prevent injury or death, use cleaningcompound in well-ventilated area. Wear appropriate protective covering and avoidprolonged breathing of fumes or compound contact with skin.

WARNING

Do not use solvents on air stream components unless complete solvent removal canbe ensured. Toxic reactions between solvents and catalyst in catalyst bed may occur.

b. Remove surface dirt, dust, or grease with clean cloth lightly moistened with cleaning compound (MIL-STD-1428).

c. Refer to NSTM Chapter 300 and Chapter 302 for cleaning procedures for electrical components.

d. Check all parts for discoloration (caused by overheating), fractures, and corrosion.

e. Examine all parts for deformities, pitting, scoring, scratches, nicks, and accumulation of hardened dirt deposits andother contaminants.


Original 6-59


f. Inspect all threaded areas for stripped threads and evidence of crossthreading; examine area adjacent to threads forcracks.

g. Look for any signs of electrical arcing on wire terminals. This condition indicates that terminal nut is not tightenough.

h. Look for any signs of corrosion of wires, terminals, nuts, bus bars, or terminal studs. Corrosion indicates externalcontamination of heater installation.

i. Inspect gaskets for cuts, tears, and distortion.

j. Inspect teflon tape on heater housing. If it is damaged, replace teflon tape.

(1) Remove old teflon tape from heater housing.

(2) Wipe off hardened dirt deposits with clean, lint-free cloth.

(3) Use clean cloth lightly soaked with solvent approved for submarine service to remove dirt and grease fromwalls of heater housing. Sector to be cleaned shall be minimum of 3 inches wide, measured from edge ofheater housing. Cleaned strip must cover entire perimeter formed by four inner walls of housing. Allowcleaned surfaces to dry.

(4) Cut teflon tape to length of 9 inches.

(5) Working at bottom of inner heater housing, place teflon tape with adhesive side toward housing 3 inches fromedge of housing.

(6) Use ruler to apply pressure to tape and ensure adhesive contact with wall of housing.

(7) Repeat this procedure for other 9-inch wall and two 6-5/8-inch walls.

(8) Use knife to trim away any tape covering electrical conduit hole.

6-7.8.3 Repair and Replacement Repair or replace any worn or defective parts (paragraph6-6.1or 6-6.2).

6-7.8.4 Reassembly and Reinstallation

a. Reinstall gaskets (16) on heating elements (17).

b. Slide each heating element into heater housing(19) and secure, using washers (15) and nuts (14).

c. Position bus bars (10 through 13) over heating elements and end housing (18). Secure, using two nuts (8).

d. Position one heater gasket (4) on heater housing.

WARNING


e. Using proper rigging and lifting device, position heater housing assembly (items 10 through 19) with heater gasketon heater housing and secure, using 10 seal washers (2) and 10 bolts (1).


6-60 Original


f. Reinstall heater conduit (9) with wires.

g. Reconnect wires.

(1) Reconnect wires to heating elements and secure, using remaining nuts (8). Remove identification tags attachedduring disassembly.

(2) Ensure that heater wire connections at both ends and buss bars are tight.

(3) Using multimeter, ensure that resistance across heater phases is 15 ohms.

(4) Ensure that heater resistance from phase to ground is 2 megohms minimum.

(5) If resistance measured in step6-7.8.4.cand/or6-7.8.4.dis unacceptable, check for shorts caused by heaterterminal contact with heater housing, or loose buss bars acting as bridge across ceramic part of one or moreheater elements. If no shorts are located, then buss bars should be removed from heater elements andindividual elements checked for resistance of 45 ohms. Replace faulty heater elements.

h. Position heater cover (7) on heater housing and secure, using lockwashers (6) and bolts (5).

i. Position remaining heater gasket and cover (3)on heat exchanger and secure, using remaining seal washers (2) andremaining bolts (1).

j. Remove out of service tag in accordance with ship procedures and energize burner at power panel.

k. Operate burner (paragraphs2-3.1and2-3.2) as required to test heater completely.


6-7.9 HEAT EXCHANGER ASSEMBLY The following procedure shall be used to repair or replace the heatexchanger (Figure7-14).

CAUTION

Proper seating of heat exchanger corner seals is extremely difficult. Disassemblyand reassembly should not be attempted without factory support and training.

a. Remove heat exchanger from burner (paragraph6-7.1.1).

b. Remove bolts (1), lockwashers (2), cover plate(3), and gasket (4) from lower casing (17).

c. Remove capscrews (5) and lockwashers (6) securing lower casing (17) to upper casing (13).

WARNING

Casing weighs 260 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling.

d. Using proper lifting devices, remove upper casing subassembly (items 7 through 13) from lower casing.

e. Remove bolts (7), seal washers (8), upper seal spacer (9), and upper seal gasket (10) from upper casing.

f. Remove corner seals (11 and 12).


Original 6-61


g. Remove heat exchanger gaskets (14) from lower casing.

WARNING

Core weighs 430 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling.

h. Using proper lifting device, remove core (15).

i. Remove corner seals.

j. Remove spring pins (16).

k. Clean and inspect all parts (paragraphs6-5.1and6-5.2). Ensure that catalyst dust is completely removed frombetween plates of heat exchanger.

l. Repair or replace any worn or defective parts (paragraphs6-6.1or 6-6.2).

m. Reinstall spring pins in lower casing.

n. Sparingly apply approved high-temperature sealant to corner seals and reinstall them.

WARNING

Core weighs 430 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling.

o. Using proper lifting device, reinstall core.

p. Position heat exchanger gaskets.

q. Sparingly apply approved high-temperature sealant to corner seals and reinstall them on upper casing.

r. Apply approved high-temperature sealant to upper seal gasket and upper seal spacer. Position gasket and spacer onupper casing and secure, using seal washers and bolts.

WARNING

Casing weighs 260 pounds. To prevent injury or death, ensure that extreme care andproper lifting devices are used during handling.

s. Using proper lifting device, position upper casing subassembly on lower casing and secure, using lockwashers (6)and capscrews.

t. Position gasket and cover plate on lower casing and secure, using lockwashers (2) and bolts.

u. Reinstall heat exchanger on burner (paragraph6-7.1.4).


6-62 Original


CHAPTER 7ILLUSTRATED PARTS BREAKDOWN

SECTION IINTRODUCTION

7-1 SCOPE

7-1.1 PRESENTATION This chapter provides the Illustrated Parts Breakdown (IPB) for the Mark IV-E CO and H2

burner. The chapter is divided into four sections. SectionI, Introduction, outlines the scope and content of this chapter. Italso provides general procedures for using the data in the IPB and Group Assembly Parts Lists (GAPL’s) to identify andrequisition repair parts. Supportive information, such as manufacturers’codes/Commercial and Government Entity(CAGE), abbreviations, and acronyms, and IPB cross-referencing, is also provided. SectionII , Illustrations and GroupAssembly Parts Lists, details how the equipment is broken down/disassembled and how the GAPL is arranged. It includesillustrations and parts lists for the equipment. SectionIII , Numerical Index, tells how the numerical index is arranged andlists cross-references between part numbers and figure and index numbers of the GAPL. SectionIV, ReferenceDesignation Index, tells how the reference designation index is arranged and lists cross-references between establishedelectrical reference designations and figure and index numbers of the GAPL. SectionV, Fastner List, provides a list of allbolts, nuts and washers used to assemble the unit. Measurement conversion information for units of measure appearingthroughout all chapters is presented in Table1-1.

7-1.2 REPAIR PARTS IDENTIFICATION AND PROCUREMENT The information contained in this chapter,combined with the Coordinated Shipboard Allowance List (COSAL) and related Allowance Parts Lists (APL’s)for theequipment, will assist in identifying and procuring repair parts needed for maintenance/repair.

7-1.2.1 Group Assembly Parts Lists The primary purpose of the IPB and related GAPL’s is to help identify theneeded repair parts and to provide a part number for procurement if at all possible. The IPB also shows the equipment/assembly/ subassembly breakdown in disassembly order. When the needed part has been identified in the individualillustration of the IPB, the information provided in the related GAPL can be used to requisition the needed part. SuchGAPL information may include:APL number, National Stock Number (NSN), manufacturer part or drawing number, andany additional detailed description which would help to further identify the part. (Specific details of the informationprovided in the GAPL are presented in SectionII of this chapter.)

7-1.2.2 Coordinated Shipboard Allowance List In addition to the GAPL, another important document relative torepair parts support aboard ship is the COSAL. A ship is provisioned with repair parts based on the COSAL prepared forthat specific ship. The COSAL is generated from APL’s, which are equipment/system configuration oriented. Foradditional information regarding the COSAL, refer to SPCCINST 4441.170, COSAL Use and Maintenance Manual.

7-1.2.2.1 Allowance Parts List/National Stock Number Equipment APL’s describe the equipment and list those partsconsidered necessary for its support. System and complex-equipment APL’s may list other applicable APL’s, as well asparts that apply to the overall system/equipment. The APL’s list the corresponding NSN for the applicable part listed asshown in Figure7-1. If the information has been obtainable, the applicable APL’s and NSN’s for the respective partsshown in the illustration are presented in the GAPL description column. However, the APL may be checked to verify partnumber accuracy and/or to detect recent changes in repair part support. It can also be determined if the part identified bythe NSN is stocked aboard ship by checking either the COSAL, Part III, Stock Number Sequence List (SNSL) or theIntegrated Stock List (ISL). The ISL in a summary of SNSL’s/APL’s that is prepared upon completion of a ship overhaul.

7-1.2.2.2 Group Assembly Parts List Versus Allowance Parts List Not all of the parts listed in the GAPL are listedin the APL or carried aboard ship as repair parts. A typical step-by-step procedure for obtaining a repair part is shown inFigure7-2. A part number listed in the GAPL that does not have an APL part number or NSN in the description columnmay be checked against the COSAL, Part III, Section D, which is a cross-reference listing. If a needed part listed in the


Original 7-1


GAPL is not listed in the COSAL or the APL’s, it is not likely to be carried aboard ship. It must be obtained fromanother source, usually a Navy supply depot. Procedures for obtaining repair parts from the supply department will varyslightly from ship to ship. A requisition containing a part number (if available, CAGE, and all of the information listed inthe GAPL description column is required by the supply department).

Figure 7-1. Allowance Parts List Sample


7-2 Original


7-1.3 MANUFACTURERS’ CODES Manufacturers’ and suppliers of the equipment/components used in the GAPLare listed in Table7-1 in numerical order by CAGE number. Corresponding names and addresses are provided for CAGE.

Figure 7-2. Part Identification, Research, and Procurement Flow Chart


Original 7-3


Table 7-1. Manufacturers’ Codes, Names, and Addresses

Code Name Address03688 Conax Corporation 2300 Walden Ave.

Buffalo, NY 1422505918 Acromag, Incorporated 30765 Wixom Road

Wixom, MI 4809614907 Cramer Co. Milrock Rd.

Old Saybrook CT 1647527191 Cutler Hammer, Inc.

(Formerly CAGEs 15605 & 27192)4201 N. 27th StreetMilwaukee, WI 53216

39481 Mead Fluid Dynamics, Division ofStanray Corporation

4114 North Knox AvenueChicago, IL 60641

45681 Parker Hannifin Corporation 17325 Euclid AvenueCleveland, Ohio 44112

50380 Reliance Electric Company 24701 Euclid AvenueCleveland, Ohio 44117

60756 Cepeda Associates, Incorporated 11100 Decimal DriveLouisville, KY 40299

65586 Edwin L.Wiegand DivisionEmerson Electric Company

7500 Thomas Blvd.Pittsburgh, PA 15208

71400 Bussman Mfg. DivisionMc Graw-Edison Co.

2538 W. University StreetSt. Louis, MO 63107

72619 Dialight Division, Amperex ElectronicsCorporation

203 Harrison PlaceBrooklyn, NY 11237

72962 Elastic Stopnut Corp. of AmericaEsna DivisionAmerica Corporation

2330 Vauxhall RoadUnion, NJ 07803

74459 Industrial Service Centers, Inc. 255 Bent StreetCambridge, MA 02141

75138 Jefferson Electric Division ofLitton Systems, Inc.

Bellwood,IL

76005 Lord Corporation, Aerospace Products Division 1635 West 12th StreetP.O. Box 10039Erie, PA 16514

80097 American Chain and Cable Co., Inc.Cable Controls Division

Suite 307, 24800 Northwestern Hwy.Southfield, MI 48075

85274 Dwyer Instruments, Incorporated Junction 211 and U.S. 12P.O. Box 373Michigan City, IN 46360

88223 General Products Corporation,A Gulf and Western Systems Company

107 Salem StreetUnion Springs, NY 13160

8R870 Accutherm, Inc. 821 Lyon StreenHannibal, MO 63401

91929 Honeywell, Incorporated, Microswitch Division 11 West Spring StreetFreeport, IL 61032

9C599 Mallory Distributor Products 3029 E. Washington St.P.O. Box 1558Indianapolis, IN 46207


7-4 Original


7-1.4 ABBREVIATIONS AND ACRONYMS The abbreviations and acronyms listed in Table7-2 appear in the GAPLand in the text of this manual. Abbreviations used in the text of this manual may be in lowercase letters, initial capitalswith lowercase letters, or all capitals. Abbreviations used in the GAPL are in all capitals. Acronyms used, both in the textand in the GAPL, are in all capitals. The abbreviations and acronyms listed in Table7-2are capitalized for consistencyand presented in alphabetical order.

NOTE

Certain manufacturer or design abbreviations and acronyms appearing in Chapter8cannot be defined and therefore are not included in this table.

Table 7-2. Abbreviations and Acronyms

Abbreviation/Acronym/Symbol Definition

A Ampere(s)AC Alternating CurrentAMP Ampere(s)AMR Auxiliary Machinery RoomAP Attaching PartAPL Allowance Parts ListAR As RequiredASSY AssemblyASTM American Society for Testing and MaterialsAWG American Wire GageBE Back EndBLK BlackBLU BlueBRN BrownBTU British Thermal Unit(s)°C Degrees CelsiusCAGE Commercial and Government EntityCERMET Ceramic Metal ElementCFM Cubic-Feet Per MinuteCL Centerline/ClassCO Carbon MonoxideCO2 Carbon DioxideCO3 CarbonateCOM CommonCOML CommercialCON ConcessionCONT ContinuousCOSAL Coordinated Shipboard Allowance ListCTR CenterDC Direct CurrentDEG DegreeDES DesignationDIA Diameter


Original 7-5


Table 7-2. Abbreviations and Acronyms – Continued


DIM DimensionDWG DrawingENCL EnclosureEXCH Exchanger°F Degrees FahrenheitF FaradFIG. FigureFLH Flat HeadFLLD Full LoadFNSH Finish(ed)FRTN Front EndGAPL Group Assembly Parts ListGPM Gallons Per MinuteGRN GreenH2 HydrogenHD HeadHEX HexagonalHP HorsepowerHR HourHZ HertzIN. InchINCL IncludeINTLK InterlockIPB Illustrated Parts BreakdownISL Integrated Stock ListJMPR JumperKV Kilovolt(s)KVDC Kilovolts, Direct CurrentKWY KeywayLB Pound(s)LCTN LocationLED Light Emitting DiodeLG LengthLI LithiumMACH MachineMDM MediumMEA MonoethanolamineµF MicrofaradMFD ManufacturedMFR ManufacturerMIP Maintenance Index PageMOD Modification/ModifiedMPT Male Pipe ThreadMRC Maintenance Requirement CardMTG Mounting


7-6 Original




NATO North Atlantic Treaty OrganizationNAVSEA Naval Sea Systems CommandNC National Coarse (Thread)/Normally ClosedNF National Fine (Thread)NHA Next Higher AssemblyNORM Normal/NormallyNO Normally OpenNO. NumberNPFC Naval Publications and Form CenterNPN Negative Positive NegativeNSN National Stock NumberNSTM Naval Ships’ Technical ManualOD Outside DiameterOPNAVINST Office of the Chief of Naval Operations InstructionORN OrangePARA paragraphPF PicofaradPH PhasePMS Planned Maintenance SystemPN Part NumberPNP Positive Negative PositivePPM Parts Per MillionPUBN PublicationR RadiusRDH Round HeadREF ReferenceRPM Revolutions Per MinuteSCAT Sequential Component Automatic TestingSCH Socket HeadSF SemifinishedSLTD SlottedSNSL Stock Number Sequence ListSPCCINST Ship’s Parts Control Center InstructionSST Stainless SteelSTD StandardSTL SteelSYM SymbolSYN SynchronousTDBD Top-Down BreakdownTEMP TemperatureTHD Thread(s)THRU ThroughTIR Total Indicator ReadingTPI Threads Per InchUNC Unified National Coarse (Thread)


Original 7-7




V Volts/VoltageVAC Volts, Alternating CurrentVDC Volts, Direct CurrentW WattW/ WithWHT WhiteWW Wire WoundX ByYEL Yellow

7-1.5 CROSS-REFERENCE The IPB is arranged so that maximum cross-referencing of the table of contents, GAPL,numerical index, and reference designation index is possible for easier location of part numbers. The cross-referenceprocedures for locating a part number when the part number or reference designation is known and when the part numberor reference designation is not known are explained and illustrated in Figures7-3 and7-4. (Refer to paragraph7-2.2.2foradditional information on reference designations.)


7-8 Original


Figure 7-3. How To Use the Illustrated Parts Breakdown When the Part Number orReference Designation Is Known


Original 7-9


Figure 7-4. How To Use the Illustrated Parts Breakdown When the Part Number orReference Designation Is Not Known


7-10 Original


SECTION IIILLUSTRATIONS AND GROUP ASSEMBLY PARTS LISTS

7-2 SCOPE

7-2.1 EQUIPMENT BREAKDOWN This section provides illustrations and related parts lists for the burner intop-down breakdown/disassembly sequence. Each illustration is assigned a figure number based on the chapter numberand number of illustrations required in the chapter. For example, Figure7-1 is the first figure in Chapter7. A top-downbreakdown (TDBD) in block diagram form is shown in Figure7-5. This breakdown shows how the major equipment/installation and its related assemblies, subassemblies, and component parts are organized and broken down in disassemblysequence. Applicable APL’s and drawing/part numbers are shown in the individual figure blocks if available. This TDBDis the basis of the individual illustrations and GAPL’s presented herein.

7-2.1.1 Major Equipment/Installation The top or primary block of the diagram represents the major equipment/installation covered in the manual. It is shown as the first illustration in the IPB. The first block (Figure7-6) contains thetop drawing or part number and applicable APL’s for the equipment identified within that block.

7-2.1.2 Major Assemblies/Components The major assemblies are shown as blocks flowing directly from the majorequipment/installation block. These blocks list applicable drawing numbers and accessory APL’s. On the major equipmentillustration these are shown assembled(not broken down/exploded within that figure). Each of these major assemblies isalso illustrated in its own exploded-view figure as indicated in Figure7-5. Some individual components/parts that areremoved directly from the major equipment during removal of assemblies appear in the detailed exploded view of themajor equipment illustration itself and do not appear in the block diagram.

7-2.1.3 Subassemblies/Components Subassemblies of the major assemblies are shown as blocks flowing directlyfrom the major assembly block(s). These are presented individually as exploded-view figures, with applicable drawing/part numbers and APL’s also provided when available.

7-2.1.4 Bubble Presentation Subassemblies that are too complex or detailed to be shown on the first sheet of the IPBillustration are shown on following sheets. These are identified by an arc ‘‘bubble’’. The bubbled areas are identified byalpha characters, such as A, B, or C on the TDBD.


Original 7-11


7-2.2 GROUP ASSEMBLY PARTS LIST DESCRIPTION A GAPL is provided for each figure identified in theTDBD and illustrated in the IPB. Each component shown disassembled in the IPB is assigned an index number. Indexnumbers indicate the disassembly sequence for the illustrated assembly or subassembly. Index numbers on the illustrationalso correspond to numbers in the GAPL. For example, the component with index number 20 in Figure7-7 (Chapter7,second figure) is listed as 7-7-20 in the corresponding GAPL. Some assemblies that are too complex to be shown in onefigure are indexed and listed in the GAPL with reference to another figure where that assembly is shown disassembled.The GAPL’s for each of these figures cross-reference each other (refer to paragraph7-2.2.5). The following paragraphsfurther describe the information contained in each column of the GAPL. A list of all illustrations in the IPB is presentedin Table7-3.

Figure 7-5. Top-Down Breakdown


7-12 Original


Table 7-3. Illustrated Parts Breakdown Illustrations

Figure TitleFigure7-6 CO and H2 Burner, Mark IV-E, General Arrangement (3 Sheets)Figure7-7 AC Motor and Fan Wheel AssemblyFigure7-8 Control Box Assembly (2 Sheets)Figure7-9 AC Contactor, N850Figure7-10 AC Contactor, N894Figure7-11 Thermal Overload RelayFigure7-12 Instrument Mounting Bracket AssemblyFigure7-13 HeaterFigure7-14 Heat Exchanger Assembly

7-2.2.1 Figure and Index Number Column The figure and index number column lists, in numerical order, the figureand index number of each part shown on the corresponding illustration.

7-2.2.2 Reference Designation Column The reference designation column lists the established reference designationfor each electrical or electronic part. If there are no such parts in this equipment, there will be no entry in this column.Only those parts assigned reference designations in the original engineering drawings, electrical schematics, or othersource material are listed. A reference designation is usually a group of two or more alpha or alpha-numeric combinationsused instead of lengthy nomenclature to identify components.

Examples: MC AC Contactor, 850HC AC Contactor, N894SW1 Toggle Switch (ON/OFF) (w/panel seal)

7-2.2.3 Part Number Column The part number column lists the part identification for all parts shown on theapplicable disassembly drawing. Numbers listed in this column are obtained from engineering design drawings/drawingparts lists, manufacturer assembly drawings, vendor parts lists, shipcheck verification, photographs, previous manuals, andother source material. Entries include some or all of the following:

Shipcheck Part Number IdentificationNAVSEA Drawing NumberNAVSEA Drawing and Item/Piece NumberManufacturer Drawing NumberManufacturer Drawing and Item/PieceNumberManufacturer Part or Identification NumberCommercial (COML)NO NUMBER

In every case, the number listed identifies the part in some way. When ordering or requesting replacement parts, eachnumber must be written as listed, including dashes, slashes, periods, and spaces, in order for the supply department toidentify, and procure the part.

7-2.2.3.1 Commercial and No Number Entries The entry COML indicates that the item is a common hardware item(such as nut, screw/bolt, or washer). It may be carried as consumable stock in general stores aboard ship or is availablethrough a variety of commercial sources, and is identified by the data in the description column. The entry NO NUMBER


Original 7-13


indicates that the item is a general arrangement or grouping/installation of equipment assemblies, or that the assembly/parthas no identified applicable part number. Should such a part have to be ordered, the order/request shall include all thedata in the description column.

7-2.2.3.2 Drawing Number Entries A drawing number entry consists of a number or number/alpha set followed by(DWG), such as 4497172 (DWG). Drawing numbers are listed when no other part identification is available; however,sometimes the drawing number and part number are considered the same by the manufacturer of the part. The drawingpermits further research of the equipment being maintained, if required. It can assist the supply office in identifying andprocuring parts not normally stocked or identifiable as repair/replacement parts. After initial introduction of an assembly/component drawing number followed by (DWG), subsequent entries of the same drawing plus dash number for pieceparts will not repeat the (DWG).

Example:PART

NUMBER INDENT DESCRIPTIOND5000-535-02 (DWG) 1 CO AND H2 BURNER, MARK IV-E, GENERAL

ARRANGEMENT (SIZE 500 CFM)D5501-535-02-3 2 TUBINGD5501-535-02-8 2 FITTING, COMPRESSION, 1/8 IN. TUBE (CAP)

7-2.2.3.3 Drawing Number Table Engineering/manufacturer drawings used to develop the IPB/GAPL, and identifiedas such in the GAPL, are presented in alphanumerical order in Table7-4. Some of these drawings may be found in theengineering drawing chapter of this manual or may be obtained from the ship’s department technical library.

Table 7-4. Drawing Numbers

Drawing Number Title CAGEB-1045-70 Flip Toggle Valves 39481D5000-535-02 Mark IV-E CO and H2Burner, General Arrangement (Size 500 cfm) 95335WI-102-2 (DWG) Schematic - 102 Model Temperature Indicating Controller 987871027-D100 CO/H2 Burner Assembly, Mark IV-E Burner, Size 500 CFM 607561053-D100 CO/H2 Burner Assembly, Size 500 CFM, Mark IV-E Burner - SEAWOLF 60756801624-535 Motor, Alternating Current 50380

7-2.2.4 Indent Column The numbers 1 through 4 in the indent column show the relationship of subassemblies andparts to major assemblies. The indent system lists the principal(or top) item (equipment installation/general arrangement/assembly) in a particular figure as indent 1. The detail parts and subassemblies which make up the top item are indent 2.If an indent-2 subassembly is further broken down in the same figure, its detail parts are indent 3. Further breakdown ofsubassemblies into sub-subassemblies and/or parts is indicated by the next higher number, as required. Generally, indentnumbers will not exceed 5.

7-2.2.5 Description Column The description column contains descriptions of all parts as illustrated in the applicabledisassembly drawings. Modifiers are included to identify the characteristics of a particular item. When a separateillustration is used to show the detail parts of an assembly/subassembly, the description column contains the appropriatefigure cross-reference (FOR DETAILS SEE FIG._____). This cross-reference appears in the listing where the assembly isfirst described, and a corresponding reverse cross-reference for the next higher assembly (NHA)appears in the listing inwhich the assembly is broken down (FOR NHA SEE FIG._____). For every cross-reference entry, the abbreviation REFappears in the quantity per assembly column (paragraph7-2.2.7). If a component/part is listed in the APL, the APLnumber is provided in parentheses (example 1). If the number in the part number column is the same as the APL part


7-14 Original


number, the NSN is shown in parentheses (NSN_____) (example 2). The NSN can be used to obtain the repair part. If thenumber in the part number column is different from the part number in the APL, the APL part number and NSN areshown in parentheses (APL PN_____/NSN_____) (example 3). The NSN can be used to obtain a repair part anddetermine whether or not it is a good replacement part. If not, all information provided in the GAPL should be used toobtain an exact replacement part.

PART NUMBER INDENT DESCRIPTIONEXAMPLE 1: D5000-535-02 (DWG) 1 CO AND H2 BURNER, MARK IV-E, GENERAL

ARRANGEMENT (SIZE 500 CFM) (APL 303000009)EXAMPLE 2: C5515-535-07 2 GASKET (NSN 533-00-876-2493)EXAMPLE 3: D5160-535-01 2 PITOT TUBE ASSY (APL PN B20693/NSN

4460-00-923-2260)

The description column may also contain the entry (AP), which means that the item is an attaching part for the previouslylisted item having a figure and index number. Abbreviations and acronyms used in the description column are discussed indetail in paragraph7-1.4.

7-2.2.6 Manufacturer’s Code Column The manufacturer’s code column lists the Commercial and Government Entity(CAGE), a number that identifies the manufacturer(supplier) of the part. Table7-1 lists manufacturers’codes, names, andaddresses, which are also available in the Commercial and Government Entity (CAGE), Cataloging Handbook H4/H8.

7-2.2.7 Quantity Per Assembly Column The quantity per assembly column contains one of the following entries:anumber, indicating the quantity of the item at the indicated location only;the abbreviation REF, indicating that therequired quantity is listed with the figure referenced as the NHA in the description column; or the abbreviation AR,indicating that the item is used in quantity, size, or length, as required.


Original 7-15


Figure 7-6. CO and H2 Burner, Mark IV-E, General Arrangement (Sheet 1 of 4)


7-16 Original




Original 7-17




7-18 Original




Original 7-19


Fig. &Index No.

ReferenceDesignation

PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-6 -0 D5000-535-02(DWG)

1 CO AND H2 BURNER.MARK IV-E, GENERALARRANGEMENT(SIZE 500 CFM)SSN 688 (APL 30320001)(NSN 4446-01-214-8352)

NOTE

Unit may have beenrefurbished by 60756

95335 1

NOTE

Refer to Applicable Drawing(s) foradditional parts information

95335

FO-6FO-7

1053-D100 (DWG) SSN21 (APL 303200002)(NSN 4460-01-395-4726)

60756

NOTE

All SSN21 Class fasteners shall be Mil-S-1222

7-6 -1 D5501-535-02-8 2 FITTING, COMPRESSION,1/8 IN. TUBE (CAP)

95335 17

7-6 -2 1016-B951-8/6881053-B951-8/SSN21

2 TUBING 74459 AR

7-6 -3 1016- B951-2/6881053-B951-2/SSN21

2 FITTING, COMPRESSION1/8 TUBE X 1/8 IN. MPT(90 DEG MALE ELBOW)

45681 17

7-6 -4 D5501-535-02-5 2 FITTING, COMPRESSION,1/8 IN TUBE (UNION TEE)

95335 1

7-6 -5 1016-B951-5/6881053-B951-2/SSN21

2 FITTING, COMPRESSION,1/8 TUBE X 1/8 IN. MPT(MALE RUN TEE)

39481 8

1016-B320/6881053-B320/SSN21

2 PITOT TUBE ASSY 60756 1

COML 2 BOLT, HEX HD, 1/4-20UNC X 3/4 IN. (SF) (SST)(AP)

4

COML 2 LOCKWASHER,INTERNAL TOOTH, 1/4IN. (SST) (AP)

4

7-6 -6 D5160-535-01 3 ELBOW, UNION, 90 DEG 95335 27-6 -7 D5160-535-01-3 3 TUBING 95335 17-6 -8 D5160-535-01-2 3 TUBING 95335 17-6 -9 D5160-535-01-1 3 PLATE 95335 1


7-20 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-6 -10 1016-D802-4/6881053-D802-4/SSN21

2 GASKET, PILOT TUBEASSY

60756 1

NO NUMBER 2 AIR FILTER HOUSINGASSY

95335 1

COML 2 NUT, HEAVY HEX, 3/8-16UNC (SF) (SST) (AP)

4

COML 2 LOCKWASHER, STDHEAVY, 3/8 IN. (SST) (AP)

4

COML 2 BOLT, HEX HD, 3/8-16UNC X 1-1/4 IN. (SF)(SST) (AP)

4

COML 2 WASHER, STD FLAT, 3/8IN, (SST) (AP)

4

7-6 -11 NO NUMBER 3 SCREW 95335 67-6 -12 D5531-535-03 3 COVER, AIR FILTER

HOUSING95335 1

7-6 -13 1016-B960/688 3 FASTENER, AIR FILTER 60756 31053-B960/SSN21 RETAINING SPRING

7-6 -14 1020-B310/6881020-B310/SSN2

3 FILTER, AIR 60756 1

7-6 -15 NO NUMBER 3 GASKET, DISPOSABLEAIR FILTER

95335 1

7-6 -16 COML 3 NUT, HEAVY HEX, 5/16-18UNC (SF) (SST)

18

7-6 -17 COML 3 LOCKWASHER,INTERNAL TOOTH, 5/16IN. (SST)

18

7-6 -18 COML 3 BOLT, HEX HD, 5/16-18UNC X 1 IN. (SF) (SST)

18

7-6 -19 COML 3 WASHER, STD FLAT, 5/16IN. (SST)

18

7-6 -20 1016-D804-4/6881053-D804-4/SSN21

3 GASKET, AIR INLET 60756 1


2


2

7-6 -23 COML 3 BOLT, HEX HD, 5/16-18UNC X 7/8 IN. (SF) (SST)

2

7-6 -24 COML 3 WASHER, STD FLAT 5/16IN. (SST)

2


Original 7-21


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-6 -25 COML/SSN688 3 BOLT, HEX HD. 5/16-18UNC X 3/4 IN. (SF) (SST)

12

COML/SSN21 3 BOLT, HEX HD. 5/16-18UNC X 3/4 IN. (SF) (SST)

6

7-6 -25A 1053-D100-87/SSN21 3 BOLT, HEX HD. 5/16-18UNC X 1-1/4 IN. (SST)

6


12

7-6 -27 COML 3 WASHER STD FLAT, 5/16IN. (SST)

12

7-6 -28 D5529-535-17 3 HOUSING, AIR FILTER 95335 17-6 -28A 1016-D270-19/688

1072-D720-2/SSN212 PLATE, ORIFICE (Piece

7-6-28B IS GLUED TOTHIS PIECE)

60756 1

7-6 -28B 1053-D802-5/SSN21 3 GASKET, ORIFICE PLATE 60756 17-6 -28C 1072-B100/SSN21 2 SILENCER, AIR INLET 60756 17-6 -29 1016-D801-1/688

1053-D801-1/SSN213 GASKET, AIR FILTER

BOX TO FAN HOUSING60756 1

7-6 -30 1016-D20C/6881053-D720C/SSN21

3 CONDUIT, FAN MOTOR 60756 1

7-6 -31 NO NUMBER 2 AC MOTOR & FANWHEEL ASSY (FOR 688DETAILS SEE FIGURE7-7) (FOR SSN21 DETAILSSEEFO-8)

50380 1

COML 2 NUT, HEAVY HEX, 1/2-13UNC (SF) (SST (AP)

4


4


4

COML 2 WASHER, STD FLAT, 1/2IN. (SST) (AP)

4

7-6 -31A NO NUMBER 2 REFER TO ITEM7-6-31 50380 17-6 -31B 1016-D250/688

1072-B230/SSN212 WHEEL, FAN 60756 1

7-6 -31C COML/688 3 PIN, COTTER, SHAFT, 1/8DIA X 1-1/4 IN (STL)

1

COML/SSN21 3 PIN, COTTER, SHAFT,3/16 DIA X 1-1/4 IN (STL)

1

7-6 -31D 406882-7A/688 2 WASHER, FLAT 50380 1


7-22 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

COML/SSN21 2 WASHER, FLAT, SHAFT,5/8 IN (STL)

1

7-6 -31E COML/688 3 NUT, HEX, 5/8-11 UNC(STL)

1

COML/SSN21 3 CASTLE NUT, HEX, 5/8-11(SAEJ104)

1

7-6 -31F 1072-B1100/SSN21 2 SPACER FAN WHEEL 60756 17-6 -32 1016-D805-1/688

1053-D805-1/SSN212 GASKET, FAN MOTOR

HUB SEAL60756 1

1016-B230/6881053-B230/SSN21

2 BYPASS DUCTASSEMBLY

60756 1

COML 2 BOLT, HEX HD 5/16-18UNC X 7/8 IN. (SF) (SST)(AP)

9


9


9


6

COML 2 LOCKWASHER,INTERNAL TOOTH, 5/16 I.(SST) (AP)

6


6


6

7-6 -33 1016-B230-2/6881053-B230-2/SSN21

3 CONTROL, PUSH-PULL 60756 1

7-6 -34 1016-D801-3/6881053-D801-3/SSN21

3 GASKET, VALVE DOOR/BYPASS

60756 1

7-6 -35 1016-B230/6881053-B230/SSN21

3 DUCT, BYPASS TO FANHOUSING

60756 1

7-6 -36 1016-D801-2/6881053-D801-2/SSN21

2 GASKET, BYPASS TO FANHOUSING

60756 1

7-6 -37 1016-D802-3/6881053-D802-3/SSN21

2 GASKET, BYPASS TOCATALYST

60756 1

7-6 -38 D5090-535-01 2 FAN WHEEL HOUSING &MOTOR MOUNTINGBRACKET

95335 1


Original 7-23


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


4


4

COML 2 CAP SCREW, FLAT SCH,5/16-18 UNC X 1-1/4 IN.(SST) (AP)

4


6


6

COML 2 BOLT, HEX HD, 5/16-18UNC X 1-1/8 IN. (SF)(SST)(AP)

6


6


3


3

COML 2 BOLT, HEX HD, 1/2-13UNC X 1-1/2 IN. (SF)(SST)(AP)

3


3

7-6 -39 1016-D805-4/6881053-D805-4/SSN21

2 GASKET, FAN WHEELHOUSING

1

7-6 -40 1016-B730/6881053-B730/SSN21

2 PROBE, THERMOCOUPLE 03688 1


2


2


2

7-6 -44 COML 2 WASHER, STD FLAT, 5/16IN. (SF) (SST)

2

7-6 -45 D5100-535-02 (MOD) 2 CONTROL BOX ASSY(FOR DETAILS SEEFIGURE 7-8)

95335 1


7-24 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


3


3


3


3

7-6 -46 NO NUMBER 2 INSTRUMENTMOUNTING BRACKETASSY (FOR DETAILS SEEFIGURE 7-12)

95335 1


4


4


4


4

7-6 -47 1016-D710/6881053-D710/SSN21

2 HEATER ASSEMBLY (FORDETAILS SEE FIGURE7-13)

60756 1

7-6 -48 1016-D802-5/6881053-B234/SSN21

2 COVERPLATE,CATALYST,ADD/REMOVAL

60756 3


12


12

USCA-56312-SS-3 2 WASHER, SEAL (AP) 93484 127-6 -49 1016-D805-2/688

1053-D805-2/SSN212 GASKET, CATALYST

ADD/REMOVAL60756 3

7-6 -50 D5110-535-02 2 DUCT, TRANSITION 95335 1COML 2 BOLT, HEX HD, 5/16-18

UNC X 3/4 IN. (SF) (SST)(AP)

18


Original 7-25


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


18

COML 2 CAPSCREW, SCH, 5/16-18UNC X 3/4 IN. (FNSH)(SST) (AP)

8


8

7-6 -51 1016-D804-3/6881053-D804-3/SSN21

2 GASKET, TRANSITIONDUCT

60756 1

7-6 -52 C5535-535-02 2 TIE BAR, COMPOUNDMASS

95335 2


8


8

COML 2 BOLT, HEX HD, 5/8-11UNC X 6 IN. (SF) (SST)(AP)

8


11


11

7-6 -55 COML 2 BOLT, HEX HD, 5/16-18UNC X 1-1/2 IN. (SF)(SST)

11


11


7


7


7

7-6 -60 1016-D804-5/6881053-D804-5/SSN21

2 GASKET, AIR OUTLET 60756 1


10


7-26 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


10

7-6 -63 NO NUMBER 2 COVER, ACCESS 95335 17-6 -64 B5515-535-21 2 GASKET, ACCESS COVER 95335 17-6 -65 COML 2 JAMNUT, HEX, 5/16-18

UNC (SF) (SST)20


20

7-6 -67 COML 2 CAPSCREW, SCH, 5/16-18UNC X 1-1/4 IN. (SF)(SST)

20


10

7-6 -69 COML 2 LOCKWASHERINTERNAL TOOTH, 5/16IN. (SST)

10

7-6 -70 1016-D280/6881053-D280/SSN21

2 AFTERCOOLER 60756 1

7-6 -71 1016-D804-2/6881053-D804-2/SSN21

2 GASKET, AFTERCOOLER/HEAT EXCHANGER

60756 1


24


24

7-6 -74 COML 2 CAPSCREW, SCH, 3/8-16UNC X 1 IN. (SF) (SST)

22


22


7


7


7


Original 7-27


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-6 -79 1016-D210/6881053-D210/SSN21

2 HEAT EXCHANGER ASSY(FOR DETAILS SEEFIGURE 7-14)

60756 1

7-6 -80 1016-D804-1/6881053-D804-1/SSN21

2 GASKET, HEATEXCHANGER/ CATALYSTSECTION

60756 1

7-6 -81 COML 2 SCREW, PAN HD, 1/4-20UNC X 1-1/2 IN

12

7-6 -82 D5531-535-09 2 COVER, MTG BRACKET 95335 27-6 -83 COML 2 NUT, HEAVY HEX, 3/4-10

UNC (SF) (SST)8

7-6 -84 COML 2 LOCKWASHER, STDHEAVY, 3/4 IN. (SST)

8

7-6 -85 COML 2 ROD, THD, 3/4-10 UNC X11-1/4 IN. (SST)

4


8

7-6 -87 COML 2 LOCKWASHER, STDHEAVY, 5/8 IN. (SST)

8


8

7-6 -89 J-6744-1/688J-6744-1/SSN21

2 MOUNT, RESILIENT(TYPE 7E450)

76005 4

7-6 -90 1016-D801-4/6881053-D801-4/SSN21

2 GASKET, MOUNT 60756 4

7-6 -91 D5515-535-03-2 2 BRACKET, HEATERSECTION MTG

95335 1

7-6 -92 D5515-535-03-1 2 BRACKET, HEATERSECTION MTG

95335 1


24


24

7-6 -95 D5515-535-04-3 2 BRACKET, CATALYSTSECTION MTG

95335 1

7-6 -96 D5515-535-04-1 2 BRACKET, CATALYSTSECTION MTG

95335 1

7-6 -97 B5534-535-03 2 SPACER 95335 17-6 -98 D5535-535-02 2 BAR, COMPOUND MASS 95335 2


7-28 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-6 -99 1016-D220/6881053-D220/SSN21

2 CATALYST & HEATERSECTION

60756 1


Original 7-29


Figure 7-7. AC Motor and Fan Wheel Assembly


7-30 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-7 -0 NO NUMBER 1 AC MOTOR & FANWHEEL ASSY (FOR NHASEE FIGURE7-6-31)

95335 REF

85608-51 (688 DWG)REFER TO FIGURE7-7 FOR SSN688PARTS INFORMATION

2 AC MOTOR (2 HP, 440 V,3 PH, 60 HZ, 3,485 RPM,2.9 AMP) (APL 174753142)

50380 1

801624–535 (SSN21DWG) REFER TOFO-8 FOR SSN21PARTS INFORMATION

1 AC MOTOR (2 HP, 440 V,3 PH, 60 HZ, 3,520 RPM,2.6 AMP)

50380

7-7 -1 COML 3 CAPSCREW, HEX HD,1/4-20 UNC X 1/2 IN.(STL, FF-S-85)

2

7-7 -2 COML 3 LOCKWASHER, 1/4 IN.(MDM STL, FF-W-84)

2

7-7 -3 75451-B 3 COVER, CONDUIT BOX 50380 17-7 -4 65630-B 3 GASKET, CONDUIT BOX

COVER50380 1

7-7 -5 COML 3 PIN, COTTER, 1/8 DIA X1-1/4 IN. (STL)

1

7-7 -6 COML 3 NUT, HEX, 5/8-11 UNC(STL)

1

7-7 -7 406882-7A 2 WASHER, FLAT 50380 17-7 -8 D5140-535-01/688

1072-830/SSN212 WHEEL, FAN 95335 1

7-7 -9 COML 3 SCREW, RDH MACH,1/4-20 UNC X 1-1/4 IN.(STL, FF-S-92)

2


2

7-7 -11 COML 3 WASHER, STD FLAT, 1/4IN. (STL, FF-W-92)

2

7-7 -12 404666-C 3 CLAMP, LEAD 50380 17-7 -13 404666-M 3 CLAMP, LEAD 50380 17-7 -14 47024-3-A 3 LUG, TERMINAL 50380 37-7 -15 COML 3 SCREW, RDH MACH,

1/4-20 UNC X 1 IN. (STL,FF-S-92)

2


2


Original 7-31


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-7 -17 48487-A 3 SUPPORT, LEAD CLAMP 50380 17-7 -18 COML 3 SCREW, RDH MACH,

1/4-20 UNC X 5/8 IN.(STL, FF-S-92)

2


2

7-7 -20 75450-4A 3 BOX, CONDUIT 50380 17-7 -21 43202-AE 3 GASKET, CONDUIT BOX 50380 17-7 -22 COML 3 KEY, 3/16 X 3/16 X 1-3/8

IN. (STL, ASTM A108)1

7-7 -23 COML 2 CAPSCREW, SCH, 5/16-18UNC X 1-1/4 IN. (STL,FF-S-86)

4

7-7 -24 COML 2 LOCKWASHER, 5/16 IN.(STL)

4

7-7 -25 88245-7R 3 BRACKET, (BE) 50380 17-7 -26 405850-59-B/688

416821-69-FG/SSN213 BEARING, BALL (BE)

FAN MOTOR50380 1

7-7 -27 COML 3 CAPSCREW, HEX HD,1/4-20 UNC X 3/4 IN.(STL, FF-S-85)

4

7-7 -28 COML 3 LOCKWASHER, 1/4 IN.(STL, FF-W-84)

4

7-7 -29 COML 3 WASHER, STD FLAT, 1/4IN. (STL, FF-W-92)

4

7-7 -30 77284-AB 3 COVER, BALANCE RING 50380 17-7 -31 COML 3 SCREW, FLH, 1/4-20 UNC

X LG TO SUIT (SST)12

7-7 -32 COML 3 SETSCREW, SCH, NO.10-24 UNC X 5/8 IN. (STL,FF-S-200)

2

7-7 -33 COML 3 SETSCREW, SCH, NO.10-24 UNC X 9/16 IN.(STL, FF-S-200)

2

7-7 -34 601527-18-A 3 RING, BALANCE 50380 17-7 -35 COML 3 KEY, BALANCE RING,

0.19 X 0.19 X 0.88IN.(SST)

1

7-7 -36 COML 3 CAPSCREW, SCH, 5/16-18UNC X 1-1/4 IN. (STL,FF-S-86)

4

7-7 -37 COML 3 LOCKWASHER, 5/16 IN.(STL, FF-W-84)

4


7-32 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-7 -38 601566-R 3 BRACKET, (FRTN) 50380 17-7 -39 400638-1C 3 WASHER, SPRING (FRTN) 50380 17-7 -40 08373-11-X 3 WASHER, THRUST

(FRTN)50380 1

7-7 -41 405850-59-A/688416821-69-FF/SSN21

3 BEARING, BALL (FRTN) 50380 1

7-7 -42 COML 3 NUT, STD HEX, NO. 10-24UNC (STL, FF-N-836)

1

7-7 -43 COML 3 LOCKWASHER, NO. 10(MDM STL, FF-W-84)

1

7-7 -44 COML 3 SETSCREW, SCH, NO.10-24 UNC X 5/8 IN. (STL,FF-S-200)

1

7-7 -45 402580-K 3 INSERT 50380 17-7 -46 75435-5-A 3 FAN, INNER 50380 17-7 -47 COML 3 KEY, 3/16 X 3/16 X 1/2 IN.

(STL, ASTM A108)1

7-7 -48 403750-ER 3 ROTOR 50380 17-7 -49 COML 3 KEY, 3/16 X 3/16 X 2-1/2

IN. (STL, ASTM A108)50380 1

7-7 -50 601588-70-A 3 SHAFT 50380 17-7 -51 613RP 3 PLATE, IDENTIFICATION 50380 1

NO NUMBER 3 SCREW (AP) 50380 47-7 -52 403783G 3 PIN, RETAINING 50380 17-7 -53 E/5503881 3 COIL, STATOR 50380 247-7 -54 65480-R 3 CORE, STATOR 50380 17-7 -55 81630-C 3 FRAME, STATOR 50380 17-7 -56 1072-B1100/SSN21 3 SPACER, FAN WHEEL

(SSN 21 CLASS ONLY)60756 1


Original 7-33


Figure 7-8. Control Box Assembly


7-34 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-8 -0 D5100-535-02 (MOD) 1 CONTROL BOX ASSY(FOR NHA SEE FIGURE7-6-45)

95335 REF

7-8 -1 L1 181-8836-935(688 & SSN21)

2 LIGHT, INDICATING(WHITE) (W/NEON BULBPN NE-2D)

72619 1

7-8 -2 L2 181-8836-933(688 & SSN21)

2 LIGHT, INDICATING(AMBER) (W/NEON BULBPN NE-2D)

72619 1

7-8 -3 L3 181-8836-931(688 & SSN21)

2 LIGHT, INDICATING(RED) (W/NEON BULB PNNE-2D)

72619 1

7-8 -4 F1, F2 F03B(688 & SSN21)

2 FUSE (2 AMP) 71400 2

7-8 -5 HGA-C(688 & SSN21)

2 HOLDER, FUSE 71400 1

7-8 -6 SW1 511-TS1-2(688 & SSN21)

2 HEATER SWITCH,TOGGLE (ON/OFF)(W/PANEL SEAL) (NSN5930-00-655-1514)

91929 1

7-8 -7 SW2 511-TS1-3(688 & SSN21)

2 SWITCH, TOGGLE(OVERRIDE/NORMAL)(W/PANEL SEAL) (NSN5930-00-655-1515)

91929 1

7-8 -8 SC-110-M(688 & SSN21)

2 ALARM, AUDIO(EXCESSIVE TEMPSHUTDOWN)

9C599 1

7-8 -9 SW3 511–TS1–2(688 & SSN21)

2 SWITCH, TOGGLE(ALARM) (ON/OFF)

91929 1

7-8 -10 ETM 620H(688 & SSN21)

2 METER, ELAPSED TIME 14907 1

7-8 -11 NO NUMBER 2 PLATE, MTG 95335 1NO NUMBER 2 SCREW (AP) 95335 4

7-8 -12 53-646-3 2 PUSHBUTTON ASSY(START/STOP-RESET)(NSN 5930-00-132-0122)

15605 1

NO NUMBER 2 SCREW (AP) 95335 67-8 -13 53-647 2 PUSHBUTTON ASSY

(RESET)(NSN 5930-00-132-0123)

15605 1

NO NUMBER 2 SCREW (AP) 95335 4


Original 7-35


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-8 -14 TB1, TB2,TB3

17-TB10(688 & SSN21)

2 TERMINAL BLOCK(NSN 5940-00-955-7710)

88223 3

COML 2 SCREW, SLTD RDHMACH, NO. 10-24 NC X7/8 IN. (FNSH) (SST) (AP)

6

COML 2 LOCKWASHER,INTERNAL TOOTH, NO.10 (SST) (AP)

6

COML 2 WASHER, STD FLAT, NO.10 (SST) (AP)

6

7-8 -15 TR 637-571(688 & SSN21)

2 TRANSFORMER 75138 1

COML 2 BOLT, HEX HD, 1/4-20 NCX 5/8 IN. (SF) (SST) (AP)

4


4

7-8 -16 MC 6957ED25-1CQ(688 & SSN21)

2 MOTOR CONTACTOR,N850(FOR DETAILS SEEFIGURE 7-9)

27192 1


4


4

7-8 -17 HC 6957ED29-2C1(688 & SSN21)

2 HEATER CONTACTOR,N894 (FOR DETAILS SEEFIGURE 7-10)

27192 1


4


4

7-8 -18 MOL 6957ED14-2A(688 & SSN21)

2 THERMAL OVERLOADRELAY (FOR DETAILSSEE FIGURE7-11)

27192 1


4


7-36 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


4

7-8 -19 HOL 6957ED14-1A 2 THERMAL OVERLOADRELAY (FOR DETAILSSEE FIGURE7-11)

27192 1


4

COML 2 LOCKWASHER,INTERNAL TOOTH, NO10. (SST) (AP)

4

7-8 -20 RY 160A0-J-DN-NP-1-C(688 & SSN21)

2 CONTROLLER, ALARMRELAY (MODIFIED)

09518 1


4


4

7-8 -21 NO NUMBER 2 PLATE, CONTROL MTG 95335 1COML 2 NUT, HEX, 3/8-16 NC (SF)

(SST) (AP)6


6

7-8 -22 NO NUMBER 2 ENCLOSURE 95335 17-8 -23 1053-D810-2

(Replaces 1016-D810-2& C5516-535-12)

2 LABEL PLATE,OPERATINGINSTRUCTIONS, 600 °FCATALYST BEDTEMPERATURE

60756 1

7-8 -23A 1053-D810-2Aa 2 LABEL PLATE,OPERATINGINSTRUCTIONS, 500 °FCATALYST BEDTEMPERATURE, SHIPALTSSN 688-03983

60756 1

7-8 -24 1027-D100-110 2 SCREW, SLOTTED HEAD,4-40 UNF-2A x 1/4 IN LG.

60756 12

7-8 -24A 1053-D100-111 2 RIVET, BLIND, 3/321 x3/81 LG.

60756 12


Original 7-37


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-8 -25 1016-D810-15(ReplacesC5516-535-09)

2 LABEL PLATE, NORMALTEMP. & PRESS., 600 °FCATALYST BEDTEMPERATURE

60756 1

7-8 -25A 1016-D810-15Aa 2 LABEL PLATE, NORMALTEMP. & PRESS., 500 °FCATALYST BEDTEMPERATURE, SHIPALTSSN 688-03983

60756 1

aShips receiving ShipAlt SSN 688-03983 (Conversion of R-12 Plant to Non-CFC R-134a) will use7-8-24A, blind rivets,to attach plates P/N7-8-23A and7-8-25A to the control box.


7-38 Original


Figure 7-9. AC Contactor, N850


Original 7-39


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-9 -0 MC 6957ED25-1C1 1 AC CONTACTOR, N850(SIZE 1, 18 AMP ENCL,440 V, CONT DUTY, 4POLE: 4 NORM OPENMAIN CONTACTS, 2NORM OPEN/ 2 NORMCLOSED INTLKCONTACTS)(MIL-C-2212)(APL 198301003)(NSN 5945-00-850-0867)(FOR NHA SEE FIGURE7-8-16)

27192 REF

NOTE

FOR REPLACEMENTPARTS ON FOLLOWINGITEMS, PROVIDECONTACTOR PN ANDPUBN ITEM NO. WHENGIVEN IN PN COLUMN.EXAMPLE: ACCONTACTOR6957ED25-1C1, PUBN NO.10971, ITEM 4

7-9 -1 10971-5 2 SCREW, RDH (CONTACTCASE MTG)

27192 8

7-9 -2 NO NUMBER 2 LOCKWASHER 27192 87-9 -3 NO NUMBER 2 WASHER 27192 87-9 -4 10971-8 2 COVER, CONTACT CASE 27192 27-9 -5 23-2871 2 CONTACT, MAIN

(STATIONARY)(NSN 5999-00-773-2784)

27192 4

NO NUMBER 2 NUT (AP) 27192 4NO NUMBER 2 LOCKWASHER (AP) 27192 4NO NUMBER 2 CAPSCREW (AP) 27192 4NO NUMBER 2 WASHER, FLAT (AP) 27192 4

7-9 -6 23-2871-2 2 CONTACT, MAIN(STATIONARY)(NSN 5999-00-773-2783)

27192 4

NO NUMBER 2 NUT (AP) 27192 4


7-40 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

NO NUMBER 2 LOCKWASHER (AP) 27192 4NO NUMBER 2 CAPSCREW (AP) 27192 4NO NUMBER 2 WASHER, FLAT (AP) 27192 4

7-9 -7 23-2912 2 CONTACT, INTLK(STATIONARY)(NSN 5999-00-262-0828)

27192 8

NO NUMBER 2 SCREW, CONTACT MTG(AP)

27192 8

7-9 -8 23-1595 2 CONTACT, INTLK(MOVABLE)(NSN 5999-00-877-0260)

27192 4


27192 4

7-9 -9 23-2129 2 CONTACT, MAIN(MOVABLE)(NSN 5999-00-696-4981)

27192 4

7-9 -10 69-1406 2 SPRING, CONTACT(NSN 5999-00-1547-1127)

27192 4

7-9 -11 10971-7 2 BAR, CONTACT 27192 47-9 -12 10971-4 2 TERMINAL, COIL LEAD 27192 27-9 -13 10971-9 2 TERMINAL, INTLK 27192 AR7-9 -14 NO NUMBER 2 CASE, CONTACT 27192 27-9 -15 69-2022 2 SPRING, MAGNET

FRAME(NSN 5360-00-690-5474)

27192 2

7-9 -16 10971-1 2 BRACKET, MTG 27192 27-9 -17 10971-3 2 ARMATURE 27192 27-9 -18 9-1545-1 2 COIL, SHUNT

(NSN 5950-00-773-2786)27192 1


Original 7-41


Figure 7-10. AC Contactor, N894


7-42 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-10 -0 HC 6957ED29-2C1 1 AC CONTACTOR, N894(SIZE 2, 45 AMP ENCL,440 V, CONT DUTY, 4POLE: 4 NORM OPENMAIN CONTACTS, 2NORM OPEN/2 NORMCLOSED INTLKCONTACTS)(MIL-C-2212)(APL198301033)(NSN 000-LL-CG5-5847)(FOR NHA SEE FIGURE7-8-17)

27192 REF

NOTE

FOR REPLACEMENTPARTS ON FOLLOWINGITEMS, PROVIDECONTACTOR PN ANDPUBN ITEM NO. WHENGIVEN IN PN COLUMN.EXAMPLE: ACCONTACTOR6957ED29-2C1, PUBN NO.11281, ITEM 4

7-10 -1 11281-5 2 SCREW, RDH (CONTACTCASE MTG)

27192 8

7-10 -2 NO NUMBER 2 LOCKWASHER 27192 87-10 -3 NO NUMBER 2 WASHER 27192 87-10 -4 11281-8 2 COVER, CONTACT CASE 27192 27-10 -5 23-3054 2 CONTACT, MAIN

(STATIONARY)(NSN 5999-00-839-6478)

27192 8

NO NUMBER 2 CAPSCREW (AP) 27192 87-10 -6 23-2912 2 CONTACT, INTLK

(STATIONARY)(NSN 5999-00-262-0828)

27192 8

NO NUMBER 2 SCREW, CONTACT (AP) 27192 8NO NUMBER 2 LOCKWASHER (AP) 27192 8

7-10 -7 23-3004 2 CONTACT, INTLK(MOVABLE)(NSN 5999-00-817-7864)

27192 4


Original 7-43


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode


27192 8

7-10 -8 23-3081 2 CONTACT, MAIN(MOVABLE)(NSN 5999-00-839-6477)

27192 4

7-10 -9 69-2291 2 SPRING, CONTACT(NSN 5360-00-894-4489)

27192 4

7-10 -10 NO NUMBER 2 PLATE, METALENGAGING

27192 4

NO NUMBER 2 SCREW (AP) 27192 87-10 -11 11281-7 2 BAR, CONTACT 27192 47-10 -12 11281-12 2 PLATE, TERMINAL 27192 4

NO NUMBER 2 SCREW (AP) 27192 47-10 -13 11281-4 2 TERMINAL, COIL

LEAD27192 2

NO NUMBER 2 SCREW (AP) 27192 2NO NUMBER 2 LOCKWASHER (AP) 27192 2

7-10 -14 11281-16 2 TERMINAL, INTLK 27192 ARNO NUMBER 2 SCREW (AP) 27192 AR

7-10 -15 NO NUMBER 2 CASE, CONTACT 27192 27-10 -16 69-2240 2 SPRING, MAGNET

FRAME(NSN 5360-00-839-4368)

27192 2

7-10 -17 11281-1 2 BRACKET, MTG 27192 27-10 -18 11281-3 2 ARMATURE 27192 27-10 -19 9-1620-1 2 COIL, SHUNT

(NSN 5950-00-086-8858)27192 1


7-44 Original


Figure 7-11. Thermal Overload Relay


Original 7-45


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-11 -0 MOL 6957ED14-2A/6886957ED14-2A/SSN21

1 THERMAL OVERLOADRELAY (N750, 10 AMPENCL, 440 V, 1 NORMOPEN/2 NORM CLOSEDCONTACTS, 50 AMPTERMINAL RATING)(START/STOP-RESET)(MIL-C-2212)(NSN 5945-00-567-6264)(FOR NHA SEE FIGURE7-8-18)

27192 REF

HOL 6957ED14-1A/6886957ED14–1A/SSN21

1 THERMAL OVERLOADRELAY (N750, 10 AMPENCL, 440 V, 1 NORMCLOSED CONTACT, 50AMP TERMINAL RATING)(MIL-C-2212)(NSN 5945-00-666-0964)(FOR NHA SEE FIGURE7-8-19) (NOTE:

27192 REF

NOTE

FOR REPLACEMENTPARTS ON FOLLOWINGITEMS, PROVIDE RELAYAND PUBN ITEM NO.WHEN GIVEN IN PNCOLUMN.EXAMPLE: RELAY6957ED14-1A, PUBN 7583,ITEM 4

7-11 -1 NO NUMBER 2 SCREW, BINDING 27192 87-11 -2 NO NUMBER 2 WASHER 27192 87-11 -3 9104H3932A/688

9104H930A/SSN212 MOTOR OVERLOAD

RELAY HEATER(USE ON 6957ED14-2A)

27191 2

9104H3964A/6889104H3964A/SSN21

2 HEATER OVERLOADRELAY HEATER(USE ON 6957ED14-1A)

27191 2

7-11 -4 7583-2 2 SCREW, CONTACTSTRUCTURE MTG

27192 2

7-11 -5 NO NUMBER 2 NUT 27192 1


7-46 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-11 -6 7583-6 2 SCREW 27192 17-11 -7 NO NUMBER 2 BRACKET, BASE MTG 27192 27-11 -8 NO NUMBER 2 PLATE, TERMINAL (50

AMP)27192 2

NO NUMBER 2 PLATE, TERMINAL (100AMP) (W/ 1/4-20 STUD)

27192 2

7-11 -9 NO NUMBER 2 TUBE, SOLDER 27192 27-11 -10 7583-5 2 ELEMENT, THERMAL 27192 27-11 -11 7583-7 2 ARM, SPLITTER 27192 27-11 -12 7583-3 2 ARM, OPERATING 27192 27-11 -13 NO NUMBER 2 CONTACT 27192 27-11 -14 10-1544-10 2 STRUCTURE, CONTACT

(USE ON 6975ED14-2A)27192 1

7583-1 2 STRUCTURE, CONTACT(USE ON 6957ED14-1A)

27192 1


Original 7-47


Figure 7-12. Instrument Mounting Bracket Assembly


7-48 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-12 -0 NO NUMBER 1 INSTRUMENTMOUNTING BRACKETASSY (FOR NHA SEEFIGURE 7-6-46)

95335 REF

7-12 -1 1016–D720B/6881053–D720B/SSN21

2 CONDUIT ASSY,TEMPERATUREINDICATINGCONTROLLER

60756 1

7-12 -2 TIC 1612-4-9508/6881612-4-9508/SSN21

2 CONTROLLER,TEMPERATUREINDICATING (MODEL1612-4)

60756 1

NO NUMBER 2 SCREW (AP) 95335 4NO NUMBER 2 LOCKWASHER (AP) 95335 4

7-12 -3 TIC WI-102-2 (DWG) 2 CONTROLLER,TEMPERATUREINDICATING (MODEL102)

98787 1

7-12 -4 MODEL 2005/688MODEL 2005/SSN21

2 GAGE, DIFFERENTIALPRESSURE, 0–5’ WATER

85274 1

NO NUMBER 2 SCREW (AP) 95335 31016-B951/6881053-B951/SSN21

2 MANIFOLD VALVE ASSY 60756 1


4


4


4


8

7-12 -5 MV-35P 3 VALVE, FLIP TOGGLE(FILTER)(MFR DWG B-1045-70)(NSN 4530-00-115-2711)

39481 2

7-12 -6 MV-35P 3 VALVE, FLIP TOGGLE(PITOT TUBE)(MFR DWG B-1045-70)(NSN 4530-00-115-2711)

39481 2


Original 7-49


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-12 -7 MV-35P 3 VALVE, FLIP TOGGLE(HEAT EXCH INLET SIDE)(MFR DWG B-1045-70)(NSN 4530-00-115-2711)

39481 2

7-12 -8 MV-35P 3 VALVE, FLIP TOGGLE(CATALYST BED)(MFR DWG B-1045-70)(NSN 4530-00-115-2711)

39481 2

7-12 -9 MV-35P 3 VALVE, FLIP TOGGLE(HEAT EXCH OUTLETSIDE)(MFG DWG B-1045-70)(NSN 4530-00-115-2711)

39481 2

7-12 -10 NO NUMBER 3 PLATE, VALVE MTG 95335 17-12 -11 D5518-535-09 2 BRACKET, INSTRUMENT

MTG95335 1


7-50 Original


Figure 7-13. Heater


Original 7-51


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-13 -0 1016-D710/6881053-D710/SSN21

1 HEATER ASSEMBLY (FORNHA SEE FIGURE7-6-47)

60756 REF


20

7-13 -2 USCA-56312-SS-3 2 WASHER, SEAL 93484 207-13 -3 1016-D931/688

1053-D931/SSN212 COVER, HEATER, REAR 60756 1

7-13 -4 1016-D805-3/6881053-D805-3/SSN21

2 GASKET, HEATER 60756 2


2


2

7-13 -7 1016-D930/6881053-D930/SSN21

2 COVER, HEATER 60756 1

1016-D710/6881053-D710/SSN21

2 HEATER ASSY(NSN 0000-LL-CJ5-2188)

60756 1

1016-B740/6881053-B740/SSN21

3 HEATING ELEMENTASSY(NSN 4540-00-009-7334)

65586 18

7-13 -8 40518 4 LOCK NUT, HIGH TEMP,1/4-28-NF-3 (HEATERTERMINAL)

72962 2

7-13 -9 1016-D720A/6881053-D720A/SSN21

2 CONDUIT ASSY, HEATER 60756 1

7-13 -10 1016-D710-4/6881053-B745-4/SSN21

3 BUS BAR (PART OFHEATER ASSY)

60756 3

7-13 -11 1016-D710-7/6881053-B745-3/SSN21


60756 6

7-13 -12 1016-D710-6/6881053-D745-2/SSN21


60756 6

7-13 -13 1016-D710-5/6881053-B745-1/SSN21


60756 12

7-13 -14 NO NUMBER 4 NUT (PART OF HEATINGELEMENT ASSY)

95335 2

7-13 -15 NO NUMBER 4 WASHER (PART OFHEATING ELEMENTASSY)

95335 2


7-52 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-13 -16 NO NUMBER 4 GASKET (PART OFHEATING ELEMENTASSY)

95335 2

7-13 -17 118-116306-001 OR422-40-3-MO-1

4 ELEMENT, HEATING 655868R870

2

7-13 -18 D5529-535-04 3 HOUSING, END (PART OFHEATER ASSY)

95335

7-13 -19 D5529-535-02 3 HOUSING, HEATER (PARTOF HEATER ASSY)

95335


Original 7-53


Figure 7-14. Heat Exchanger Assembly


7-54 Original


Fig. &Index No.


PartNumber

Indent Description

Mfr’sCode

Qty

perAssy

UsedonCode

7-14 -0 1016-D210/6881053-D210/SSN21

1 HEAT EXCHANGER ASSY(FOR NHA SEE FIGURE7-6-79)

60756 REF

7-14 -1 MS 35307-332 2 BOLT, 5/16-18 UNC X 3/4IN. (SST)

96906 4

7-14 -2 MS 35333-75 2 LOCKWASHER, 5/16 IN.(SST)

96906 4

7-14 -3 C5520-535-02 2 PLATE, COVER 95335 17-14 -4 C5515-535-04 2 GASKET 95335 17-14 -5 MS 16005-83 2 CAPSCREW, SCH, 3/8-16

UNC X 1-1/2 IN. (SST)96906 10

7-14 -6 COML 2 LOCKWASHER, 3/8 IN.(SST)

10

7-14 -7 MS 35307-329 2 BOLT, 5/16-18 UNC X1-1/2 IN. (SST)

96906 10

7-14 -8 USCA-56312-SS-3 2 WASHER, SEAL, 5/16 IN. 93484 107-14 -9 C5534-535-02 2 SPACER, UPPER SEAL 95335 27-14 -10 C5515-535-06 2 GASKET, UPPER SEAL 95335 27-14 -11 C5020-535-02-3 2 SEAL, CORNER 95335 27-14 -12 C5020-535-02-1 2 SEAL, CORNER 95335 27-14 -13 D5501-535-03 2 CASING, UPPER 95335 17-14 -14 C5515-535-05 2 GASKET, HEAT

EXCHANGER95335 4

7-14 -15 D5030-535-02 2 CORE ASSY 95335 17-14 -16 COML 2 PIN, SPRING, 1/4 DIA X

1-1/4 IN. (SST) (MS171656)

4

7-14 -17 D5501-535-03 2 CASING, LOWER 95335 1




SECTION IIINUMERICAL INDEX

7-3 SCOPE

7-3.1 DESCRIPTION The numerical index is an alphanumeric listing of the part numbers included in the GAPL.Figure and index numbers are given for reference to the GAPL.

7-3.2 BREAKDOWN The following paragraphs describe the information contained in the three columns of thenumerical index.

7-3.2.1 Part Number Column The part number column lists in alphanumeric order all part numbers appearing in theGAPL. The alphanumeric arrangement of part numbers starts with the extreme left character of the part number andcontinues from left to right, one character at a time, until part number alphanumeric arrangement is determined. The orderof precedence in the alphanumeric arrangement is as follows:

First Position (Extreme Left) Second (and Succeeding Positions)Letters A through Z Space (blank)

Numerals 0 through 9 Diagonal (/)Point (.)Dash (-)

Letters A through ZNumerals 0 through 9

7-3.2.2 Figure and Index Number Column The figure and index number column lists the figure and index number ofeach illustrated item for which a listed part number appears,

7-3.2.3 Reference Designation Column The reference designation column lists the established reference designationfor each electrical/electronic part identified in the numerical index.

Part NumberFig. &

Index NoReference

DesignationB5220-535-02 7-8-20 RYB5220-535-03 7-6-40B5515-535-14 7-6-60B5515-535-18 7-6-34B5515-535-20 7-6-90B5515-535-21 7-6-64B5534-535-03 7-6-97C30542 7-6-14C5020-535-02-1 7-14-12C5020-535-02-3 7-14-11C5240-535-01 7-13-9C5240-535-02 7-12-1C5240-535-03 7-6-30C5515-535-03 7-13-4C5515-535-04 7-6-49C5515-535-04 7-14-4C5515-535-05 7-14-14


Original 7-57


Part NumberFig. &

Index NoReference

DesignationC5515-535-06 7-14-10C5515-535-07 7-6-10C5515-535-08 7-6-71C5515-535-09 7-6-80C5515-535-10 7-6-37C5515-535-11 7-6-36C5515-535-12 7-6-51C5515-535-13 7-6-39C5515-535-15 7-6-20C5515-535-16 7-6-32C5515-535-17 7-6-29C5517-535-03 7-6-13C5520-535-02 7-6-48C5520-535-02 7-14-3C5524-535-02-1 7-13-12C5524-535-02-2 7-13-11C5524-535-02-3 7-13-10C5524-535-02-4 7-13-13C5534-535-02 7-14-9C5535-535-02 7-6-52C5538-535-01 7-8-15 TRD5000-535-02 (DWG) 7-6-0D5030-535-02 7-14-15D5040-535-02 7-6-79D5040-535-02 7-14-0D5080-535-02 7-13-7D5090-535-01 7-6-38D5100-535-02 (MOD) 7-6-45D5100-535-02 (MOD) 7-8-0D5110-535-02 7-6-50D5130-535-01 7-6-70D5140-535-01 7-7-8D5160-535-01 7-6-5D5160-535-01 7-6-6D5160-535-01-1 7-6-9D5160-535-01-2 7-6-8D5160-535-01-3 7-6-7D5170-535-01 7-6-32D5170-535-01-2 7-6-33D5180-535-01 7-12-4D5410-535-01 7-13-D5410-535-01 7-13-17D5501-535-02-3 7-6-2D5501-535-02-4 7-6-3D5501-535-02-5 7-6-4D5501-535-02-7 7-6-5D5501-535-02-8 7-6-1


7-58 Original


Part NumberFig. &

Index NoReference

DesignationD5501-535-03 7-14-13D5501-535-03 7-14-17D5515-535-03-1 7-6-92D5515-535-03-2 7-6-91D5515-535-04-1 7-6-96D5515-535-04-3 7-6-95D5518-535-09 7-12-11D5529-535-02 7-13-19D5529-535-04 7-13-18D5529-535-17 7-6-28D5531-535-01 7-13-7D5531-535-02 7-13-3D5531-535-03 7-6-12D5531-535-09 7-6-82D5535-535-02 7-6-18E/5503881 7-7-53F03B 7-8-4 F1, F2HGA-C 7-8-5J-67441-1 7-6-89MS 16005-83 7-14-5MS 35307-329 7-14-7MS 35307-332 7-14-1MS 35333-75 7-14-2MV-35P 7-12-5MV-35P 7-12-6MV-35P 7-12-7MV-35P 7-12-8MV-35P 7-12-9SC-110-M 7-8-8USCA-56312-SS-3 7-13-2USCA-56312-SS-3 7-14-8WI-102-2 (DWG) 7-12-3 TIC08373-11-X 7-7-4010-1544-10 7-11-141016-B230 7-6-321016-B230 7-6-351016-B230-2 7-6-331016-B320 7-6-51016-B730 7-6-401016-B740 7-13-71016-B951 7-12-41016-B951-2 7-6-31016-B951-5 7-6-51016-B951-8 7-6-21016-B960 7-6-131016-D210 7-14-01016-D210 7-6-79


Original 7-59


Part NumberFig. &

Index NoReference

Designation1016-D220 7-6-991016-D250 7-6-31B1016-D270-19 7-6-28A1016-D280 7-6-701016-D710 7-13-01016-D710 7-13-71016-D710 7-6-471016-D710-4 7-13-101016-D710-5 7-13-131016-D710-6 7-13-121016-D710-7 7-13-111016-D720A 7-13-91016-D720B 7-12-11016-D720C 7-6-301016-D801-1 7-6-291016-D801-2 7-6-361016-D801-3 7-6-341016-D801-4 7-6-901016-D802-5 7-6-481016-D802-3 7-6-371016-D802-4 7-6-101016-D804-1 7-6-801016-D804-2 7-6-711016-D804-3 7-6-511016-D804-4 7-6-201016-D804-5 7-6-601016-D805-1 7-6-321016-D805-2 7-6-491016-D805-3 7-13-41016-D805-4 7-6-391053-D810-2 7-8-231053-D810-2A 7-8-23A1016-D930 7-13-71016-D931 7-13-31020-B310 7-6-141027-D100 (DWG) 7-6-11027-D100-100 7-8-241053-B230 7-6-321053-B230 7-6-351053-B230-2 7-6-331053-B234 7-6-481053-B320 7-6-51053-B730 7-6-401053-B740 7-13-71053-B745-1 7-13-131053-B745-2 7-13-121053-B745-3 7-13-11


7-60 Original


Part NumberFig. &

Index NoReference

Designation1053-B745-4 7-13-101053-B951 7-12-41056-B951-2 7-6-31053-B951-5 7-6-51053-B951-8 7-6-21053-B960 7-6-131053-D100 (DWG) 7-6-01053-D100-111 7-8-24A1053-D210 7-6-791053-D210 7-14-01053-D220 7-6-991053-D250 7-6-31B1053-D270-2 7-6-28A1053-D280 7-6-701053-D710 7-6-471053-D710 7-13-01053-D710 7-13-71053-D720A 7-13-91053-D720B 7-12-11053-D720C 7-6-301053-D801-1 7-6-291053-D801-2 7-6-361053-D801-3 7-6-341053-D801-4 7-6-901053-D802-3 7-6-371053-D802-4 7-6-101053-D804-1 7-6-801053-D804-2 7-6-711053-D804-3 7-6-511053-D804-4 7-6-201053-D804-5 7-6-601053-D805-1 7-6-321053-D805-2 7-6-491053-D805-3 7-13-41053-D805-4 7-6-391053-D810-2 7-8-231053-D810-2A 7-8-23A1053-D930 7-13-71053-D931 7-13-310971-1 7-9-1610971-3 7-9-1710971-4 7-9-1210971-5 7-9-110971-7 7-9-1110971-8 7-9-410971-9 7-9-1311281-1 7-10-17


Original 7-61


Part NumberFig. &

Index NoReference

Designation11281-3 7-10-1811281-4 7-10-1311281-5 7-10-111281-7 7-10-1111281-8 7-10-411281-12 7-10-1211281-16 7-10-14118-116306-001 7-13-17160A-J-DN-NP-1-C 7-8-20 RY1612-4-9508 7-12-217TB10 7-8-14 TB1, TB2, TB31803-048 7-13-8181-8836-931 7-8-3 L3181-8836-933 7-8-2 L2181-8836-935 7-8-1 L12005 7-12-423-1595 7-9-823-2129 7-9-923-2871 7-9-523-2871-2 7-9-623-2912 7-9-723-2912 7-10-623-3004 7-10-723-3054 7-10-523-3081 7-10-8400638-1C 7-7-39402580-K 7-7-45403750-ER 7-7-48403783G 7-7-52404666-C 7-7-12404666-M 7-7-1340518 7-13-8405850-59-A 7-7-41405850-59-B 7-7-26406882-7A 7-7-7406882-7A 7-6-31D416821-69-FF 7-7-41416821-69-FG 7-7-26422-40-3-MO-1 7-13-1743202-AE 7-7-2147024-3-A 7-7-1448487-A 7-7-17511-TS1-2 7-8-6 SW1511-TS1-2 7-8-9 SW3511-TS1-3 7-8-7 SW253-646-3 7-8-1253-647 7-8-13


7-62 Original


Part NumberFig. &

Index NoReference

Designation601527-18-A 7-7-34601566-R 7-7-38601588-70-A 7-7-50613RP 7-7-51620H 7-8-10 ETM637-571 7-8-15 TR65480-R 7-7-5465630-B 7-7-469-1406 7-9-1069-2022 7-9-1569-2240 7-10-1669-2291 7-10-96957ED14-1A 7-8-19 HOL6957ED14-1A 7-11-0 HOL6957ED14-2A 7-8-18 MOL6957ED14-2A 7-11-0 MOL6957ED25-1CQ 7-8-16 MC6957ED25-1C1 7-8-16 MC6957ED25-1C1 7-9-0 MC6957ED29-2C1 7-8-17 HC6957ED29-2C1 7-10-0 HC75435-5-A 7-7-4675450-4A 7-7-2075451-B 7-7-37583-1 7-11-147583-2 7-11-47583-3 7-11-127583-5 7-11-107583-6 7-11-67583-7 7-11-1177284-AB 7-7-30801624-535 (DWG) 7-7-081630-C 7-7-5585608-51 (DWG) 7-7-088245-7R 7-7-259-1545-1 7-9-189-1620-1 7-10-199104H3930A 7-11-39104H3932A 7-11-39104H3964A 7-11-3




SECTION IVREFERENCE DESIGNATION INDEX

7-4 SCOPE

7-4.1 DESCRIPTION The reference designation index is an alphanumeric listing of the reference designationsincluded in the GAPL. Figure and Index numbers are given for reference to the GAPL.

7-4.2 BREAKDOWN The following paragraphs describe the information contained in the three columns of thereference designation index.

7-4.2.1 Reference Designation Column The reference designation column lists all reference designations appearingin the GAPL. The alphanumeric arrangement of reference designation numbers is the same as that described for thenumerical index (paragraph7-3.2.1)

7-4.2.2 Figure and Index Number Column The figure and index number column lists the figure or index number ofeach illustrated item for which a listed reference designation appears.

7-4.2.3 Part Number Column The part number column lists the part number for each reference-designated item.


Fig. &Index No

PartNumber

ETM 7-8-10 620HF1 7-8-4 FO3BF2 7-8-4 FO3BHC 7-8-17 6957ED29-2C1HC 7-10-0 6957ED29-2C1HOL 7-8-19 6957ED14-1AHOL 7-11-0 6957ED14-1AL1 7-8-1 181-8836-935L2 7-8-2 181-8836-933L3 7-8-3 181-8836-931MC 7-8-16 6957ED25-1CQMC 7-9-0 6957ED25-1C1MOL 7-8-18 6957ED14-2AMOL 7-11-0 6957ED14-2ARY 7-8-20 160-A-J-DN-NP-1-CSW1 7-8-6 511-TS1-2SW2 7-8-7 511-TS1-3SW3 7-8-9 511-TS1-2TB1 7-8-14 17TB10TB2 7-8-14 17TB10TB3 7-8-14 17TB10TIC 7-12-2 1612-4-9498 or

1612-4-9508TIC 7-12-3 WI-102-2 (DWG)TR 7-8-15 637-571




SECTION VFASTENER LIST

7-5 FASTENER LIST

Table7-5 is a list of fasteners for the CO and H2 burner, Mark IV-E. All bolts, nuts, and washers used to assemble theunit are listed. Use this list if the unit must be disassembled or reassembled, for installation, or for any time a fastenermust be replaced. Refer to notes at end of table.

Table 7-5. Fastener List

Item Location

BoltNutQty

Washer Quantity

Qty Size Length Splitlock FlatTooth

Lockwasher1 Heat Exchanger to Catalyst

Section (Side tapped holes)22 3/8-16a 1-1/4 22

2 Catalyst Section to HeatExchanger (Top tapped holes)

5 3/8-16 1-1/2 5

3 Catalyst Section to HeatExchanger (Bottom throughholes)

7 3/8-16 1-1/2 7 7

4 Heat Exchanger to Aftercooler(Side through holes)

20 5/16-18a 1-1/2 20b 20c

5 Aftercooler to Heat Exchanger(Top and bottom tapped holes)

10 5/16-18 7/8 10

6 Access Plate to Aftercooler 10 5/16-18 1/2 107 Catalyst Section Mounting

Brackets to Catalyst Section24 5/8-11 1-1/2 24

8 Heat Exchanger MountingBrackets to Heat Exchanger

24 5/8-11 1-3/4 24

9 Cover Plate to Heat Exchanger(Lower Casing)

4 5/16-18 3/4 4d

10 Catalyst Removal Door toCatalyst Section

4 5/16-18 3/4 4d

11 Catalyst add Door to CatalystSection

8 5/16-18 3/4 8

12 Heater Assembly and Rear Coverto Catalyst Section

20 5/16-18 3/4 20d

13 Access Plate to Terminal Box 2 5/16-18 3/4 214 Transition Duct and

Superstructure Support to HeatExchanger (Corner holes)

8 5/16-18a 3/4 8

15 Transition Duct andSuperstructure Support to HeatExchanger (Remaining holes)

18 5/16-18 3/4 18

16 Fan Housing and MotorMounting Bracket to TransitionDuct (Counter- sunk holes)

4 5/16-1/8e 1-1/4 4 4

17 Fan Housing and MotorMounting Bracket to TransitionDuct (Remaining holes)

6 5/16-18 1-18 6b 6


Original 7-67


Table 7-5. Fastener List – Continued

Item Location

BoltNutQty

Washer Quantity


Lockwasher18 Motor Housing Bracket to

Superstructure Support3 1/2-13 1-1/2 3b 3 c 3

19 Fan Motor to Motor MountingBracket

4 1/2-13 2-1/4 4b 4 c 4

20 Bypass Duct Assembly to FanHousing

9 5/16-18 7/8 9

21 Bypass Duct Assembly toCatalyst Section

6 5/16-18 1-1/8 6 6 6

22 Pilot Tube Assembly to FanHousing

4 1/4-20 3/4 4

23 Fan Wheel to Fan Motor 5/8-11 1f 1 f

24 Air Filter Box to Fan Housing 12 5/16-18 7/8 12 1225 Air Filter Box to Superstructure

Support4 3/8-16 1-1/4 4b 4 c 4

26 Control Box to SuperstructureSupport

3 3/8-16 1-1/4 3b 3 c 3

27 Control Box to Air Filter Box 2 5/16-18 1 2b 2 2c

28 Alarm Relay Controller toControl

4 #10-24g 1/2 4

29 Terminal Boards to ControlMounting Plate

6 #10-24g 7/8 6 6

30 Transformer to Control MountingPlate

4 1/4-20 5/8 4

31 Motor Contactor to ControlMounting Plate

4 #10-24g 7/8 4

32 Heater Contactor to ControlMounting Plate

6 #10-24g 7/8 6

33 Overload Relay to ControlMounting Plate

8 #10-24g 1/2 8

34 Control Mounting Plate toControl Box

3/8-16 1-1/4 6 12 6

35 Manifold Valve to InstrumentMounting Bracket

4 1/4-20 3/4 4

36 Temperature IndicatingController Case to InstrumentMounting

4 1/4-20 3/4 4

37 Instrument Bracket toSuperstructure Support

4 3/8-16 1-1/4 4b 4 c 4

38 Instrument Bracket to ControlBox

2 5/16-18 1 2b 2 2c

39 Access Panel to InstrumentMounting Bracket

2 1/4-20 3/4 2

40 Resilient Mounts to CatalystSection

8 5/8-11 2-1/2 8b 8 c

41 Compound Mass to ResilientMounts

4 3/4-10h 11-1/4 8b 8 c


7-68 Original


Table 7-5. Fastener List – Continued

Item Location

BoltNutQty

Washer Quantity


Lockwasher42 Compound Mass Tie Bars to

Compound Mass8 5/8-11 6 8b 8 c

43 Ships Duct or Air Inlet ShippingPlate to Air Filter Box

18 5/16-18 1 18b 18 18c

44 Ships Duct or Air OutletShipping Plate to AfterfilterThrough Air Outlet Plate (Topand side through holes)

11 5/16-18 1-1/4 11b 11 11c

45 Ships Duct or Air OutletShipping Plate to AftercoolerThrough Air Outlet Plate(Bottom tapped holes)

7 5/16-18 3/4 7 7

aSocket Head Cap Screwsb Self-locking (SSN21 only)c Not used on SSN21d Seal WasherseFlat Head Socket Screwf Castle Nut, Washer, and Cotter Pin furnished as part of fan motorg Slotted Round Head Machine Screwh Threaded Rod

UNLESS OTHERWISE NOTED:

a. Bolts are Hex Head, Semi-Finished, Stainless Steel, National Coarse Thread.

b. Cap Screws are Hex, Socket, Finished, Stainless Steel, National Coarse Thread.

c. Nuts are Hex, Semi-Finished, Stainless Steel, National Coarse Thread, ASA Standard heavy.

d. Splitlock Washers are ASA Standard Heavy, Stainless Steel.

e. Flat Washers are Commercial Size, Stainless Steel.

f. Internal Tooth Lock Washers are ASA Standard, Stainless Steel.




CHAPTER 8ENGINEERING DRAWINGS

8-1 INTRODUCTION

8-1.1 DRAWING INCLUSIONS Selected engineering drawings from the superseded technical manual NAVSEA0938-LP-055-1010 and existing manufacturer information have been reproduced in this chapter to augment repairprocedures and facilitate inspection/fabrication of certain components. Only drawings that were reproducible have beenincluded. Measurement conversion information for units of measure appearing throughout the manual is presented inTable1-1.

8-1.2 DRAWING Three drawings, each consisting of eight sheets, depicting the general arrangement of the Mark IV-EBurner (FO-5, FO-6, andFO-7) are included in this chapter. Manufacturer drawing D5000-535-2 (FO-5, sheet 2) showsincorrect data on the temperature indicating controller. The drawing may contain change symbols or references relativeonly to the superceded technical manual. These symbols and references should be disregarded as they have no meaningwithin the context of this manual. Also included is the manufacturing drawing of the Mark IV-E Seawolf motor (FO-8).




APPENDIX ACEPEDA SERIES 988 TEMPERATURE INDICATING CONTROLLER (PART

NUMBER 1048Y-B255)

A-1 INTRODUCTION

The Cepeda Series 988 temperature indicating controller is installed by ShipAlt SSN 4108 and will enentually replaceexisting temperature indicating controllers. This appendix provides the information required for removing the existingcontroller, and to install and set up the Series 988 controller. Removal, installation, and setup must be accomplished onboth burners.

A-2 DESCRIPTION

A-2.1 GENERAL DESCRIPTION The series 988 temperature indicating controller (FigureA-1) controls thetemperature of the air entering the catlayst bed. The controller receives input from the thermocouple probe located in thecatalyst bed. It is a digital process controller with a digital numeric read out. The accuracy of the controller is 0.1% of itsspan, with an operating environment of 32 to 149 °F (0 to 65 °C).

A-2.2 FUNCTIONAL DESCRIPTION The series 988 temperature indicating controller controls the temperature of theair entering the catalyst bed at 600 °F (315.6 °C) with R-12 installed or at 500 °F (260 °C) with R-134a installed. It iscapable of controlling the air temperature at65 °F (62.8 °C). It also indicates high temperature at 650 °F (343.3 °C)with R-12 installed or at 550 °F (287.8 °C) with R-134a installed, along with the Acromag. The Acromag also indicateshigh temperature at 650 °F (343.3 °C) with R-12 installed or at 550 °F (287.8 °C) with R-134a installed and excessivetemperature shutdown at 675 °F (357.2 °C) with R-12 installed or at 575 °F (301.7 °C) with R-134a installed.

NOTE

Ships with R-12 installed in the ship stores refrigeration plant set the catalyst bedtemperature at 600 °F (315.6 °C), the high temperature alarm at 650 °F (343.3 °C),and the excessive temperature shutdown at 675 °F (357.2 °C). Ships with R-134ainstalled set these parameters at 500 °F (260 °C), 550°F (287.8 °C), and 575 °F(301.7 °C) respectively.

Figure A-1. Series 988 Temperature Indicating Controller


Original Appendix A-1


A-3 REMOVAL OF EXISTING TEMPERATURE INDICATING CONTROLLER (TIC)

(FO-3)

WARNING

Prior to removing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual.

WARNING

To avoid personnel injury, follow normal shutdown and cool down procedurescontained in Chapter2 of this manual.

WARNING


a. Disconnect wire #57 from TB2-8 and 120 on TIC.

b. Disconnect wire #58 from TB2-10 and L on TIC.

c. Disconnect wire #59 from TB3-5 and C on TIC.

d. Disconnect wire #60 from TB2-6 and LN on TIC.

e. Disconnect wire #64 from TB3-9 and – on TIC.

f. Disconnect wire #66 from TB3-10 and + on TIC.

g. Remove the temperature indicating controller mounting bracket by removing four cap screws.

h. Remove existing temperature indicating controller assembly and discard.

i. Remove existing temperature indicating controller wiring harness and discard.

A-4 INSTALLING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER

WARNING

Prior to installing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual.

WARNING


A-4.1 WIRING FigureA-2 shows the wiring arrangement for the Series 988 temperature indicating controller.


Appendix A-2 Original


A-4.2 INSTALLATION KIT A-3 shows the installation kit for the Series 988 temperature indicating controller.

A-4.3 INSTALLATION (refer to FigureA-2 for wiring arrangement.)

a. Assemble installation kit in accordance withA-3.

b. Install wires 57, 58, 59, 60, 64, and 66 supplied with the installation kit, in the new flex conduit.

c. Install wiring harness between the instrument bracket and control panel.

d. Install the Series 988 temperature indicating controller assembly with four cap screws (part number1016-B950-11).

e. Connect wire # 57 to TB2-8 and terminal 21 on TIC.

f. Connect wire # 58 to TB3-10 and terminal 15 on TIC.

g. Connect wire # 59 to TB3-5 and terminal 16 on TIC.

h. Connect wire # 60 to TB1-5 and terminal 22 on TIC.

i. Connect wire # 64 (– red) to TB3-9 and terminal 10 on TIC.

j. Connect wire # 66 (+ white) to TB3-10 and terminal 9 on TIC.

k. Connect wire # 74 to ground.

A-5 PRESTART-UP VERIFICATION TEST

CAUTION

Do not start burner blower or the heaters until after the newly installed temperatureindicating controller has been programmed for the first time. Turning on the bloweror the heaters before the controller has been programmed will cause the controllerto operate improperly.

a. Verify all wiring connections to ensure that wiring is in accordance with FigureA-2.

b. Perform standard electrical circuit test.

c. Clear electrical tags and energize the burner. Do not start the blower.

A-6 PROGRAMMING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER

After the temperature indicating controller is installed in the burner, it must be programmed. Energize the burner controlpanel so Input Setup, Output Setup, and System Setup can be performed. After being programmed the temperatureindicating controller must be calibrated.

WARNING

Prior to programming the temperature indicating controller, all personnel shall readand be familiar with the Warnings and Cautions contained in theSafety Summaryinthe front of this manual.




CAUTION


NOTE

Ships with R-12 installed in the ship stores refrigeration plant set the catalyst bedtemperature at 600 °F (315.6 °C). When R-134a is installed it is set at 500 °F (260°C).

A-6.1 INPUT SETUP (FigureA-1)

a. Press the up and down arrow keys at the same time for three seconds. The lower display shows [SEt] and theupper display shows [InPt] (Input Menu).

b. Press the mode key. The lower display shows [In 1] (Input 1). Set on Type [J] using the up or down arrow key.

c. Press the mode key. The lower display shows [rL 1] (Range Low 1). Set on [595 with R-12 installed] or on [495with R-134a installed] by pressing the up or down arrow key.

d. Press the mode key. The lower display shows [rH 1] (Range High 1). Set on [605 with R-12 installed] or on [505with R-134a installed] by pressing the up or down arrow key.

e. Press the mode key. The lower display shows [CAL 1]. The default setting is [0]. Do not change.

f. Press the mode key. The lower display shows [Ftr 1]. The default setting is [0]. Do not change.

g. Press the mode key. The lower display shows [SEt]. Input setup is complete.

h. Press the display key.

A-6.2 OUTPUT SETUP (FigureA-1)

a. Press the up and down arrow key at the same time for three seconds. The lower display shows [SEt] and the upperdisplay shows [InPt]. Press the up arrow key one time to read [OtPt] (Output).

b. Press the mode key. The lower display shows [Ot 1] (Output 1). Set on [CL] (Cool) by pressing the up or downarrow key.

c. Press the mode key. The lower display shows [Prc 1] (Process 1). Not in use.

d. Press the mode key. The lower display shows [Ot 2] (Otput 2). Set on [Ht] (Heat) by pressing the up or downarrow key.

e. Press the mode key. The lower display shows [Hys 2] (Hysteria 2). Default setting is [3].

NOTE

The default setting of 3 indicates 3 degrees below set point to energize the heaters.




f. Press mode key. The lower display shows [Ot3] (Output 2). Set on [no] by pressing the up or down arrow key.

g. Press mode key. The lower display shows [SEt]. Output setup is complete.

h. Press the display key. Adjust the set point to 600 with R-12 installed, or to 500 with 134a installed by pressing theup or down arrow key.

A-6.3 SYSTEM SETUP (FigureA-1)

The system setup can be done only after the initial Input and Output setup is completed.

a. Press the mode key. The lower display shows [OPEr] (Operation). The lower display shows [SyS]. Press the up ordown arrow key to show [Pid A] on the upper display.

NOTE

The settings in the following steps (A-6.3.b.(1)throughA-6.3.b.(8)) apply to theburners operating with the catalyst bed at 500 °F (260 °C) or at 600 °F (315.6 °C).The settings set the proportional, integral, and derivative functions of the controller.

b. Press the mode key and verify the following settings. Change the settings by pressing the up or down arrow key.

(1) [Pb 1A]\t140.0

(2) [rE 1A]\t0.0

(3) [rA 1A]\t0.0

(4) [Pb 2A]\t140.0

(5) [rE 2A]\t0.20

(6) [rA 2A]\t1.00

(7) [ct 2A]\t30.0

(8) [db A] \t0.0

Settings are complete.

c. Press the display key.

A-7 INPUT CALIBRATION

A-7.1 EQUIPMENT REQUIRED

a. A Type J reference compensator with reference junction at 32 °F/0 °C, or a Type J thermocouple calibrator set at32 °F/0 °C.

b. A precision millivolt source, 0-50 mV range, 0.01 mV resolution.

A-7.2 CALIBRATION (FiguresA-1 andA-2)




NOTE

The following calibration procedure applies to burners operating with the catalystbed at 500 °F (260 °C) or at 600 °F (315.6 °C). The procedure performs the spanand zero adjustment on the controller.

NOTE

It is important to allow the temperature indicating controller to stabalize beforegoing to the next calibration step.

NOTE

Always use the same wire for millivolt and thermocouple calibration. This willensure accuracy in calibrating the temperature indicating controller.

a. Install power supply to terminal 21 and 22 and ground to terminal 11.

b. Install millivolt supply to temperature indicating controller terminal 9 (+) to 10 (–). Use 20 or 24 gauge copperwire.

c. Turn power on to temperature indicating controller. Allow unit to warm up for 10 to 15 minutes.

d. Press both arrow keys at the same time. The lower display will read [set] and the upper display will read [inpt].Continue to press both arrow keys at the same time until lower display shows [fcty]. Press Up or Down arrow toadvance upper display to read [cal].

e. Press mode key, A50 prompt will appear on lower display. Adjust millivolt signal to 50.00 millivolt to temperatureindicating controller. Upper display will show [no]. Press arrow key to display [yes] on upper display.

f. Press mode key, lower display will show [A00]. Adjust millivolt signal to 0.00 millivolts to temperature indicatingcontroller. Adjust upper display to read [yes].

g. Press mode key, lower display will show [tc]. Now remove millivolt signal generator, install compensator orThermocouple Calibrator with J type thermocouple wire. Set it to simulate 32°F. Allow 10 to 15 seconds forcontroller to stabilize. Press up arrow key to change the upper display to read [yes]. Press [display] button to endcalibration.

A-8 TROUBLESHOOTING

NOTE

Ships with R-12 installed in the ship stores refrigeration plant shall maintain thecatalyst bed temperature at 600 °F (315.6 °C) and those with R-134a shall maintainit at 500 °F (260 °C).

A-8.1 TROUBLESHOOTING THE SERIES 988 TEMPERATURE INDICATING CONTROLLER Troubleshootingthe Series 988 Temperature Indicating Controller may be necessary from time to time.

When the catalyst bed will not maintain the proper temperature, it may be caused by:

A temperature indicating controller out of calibration




A damaged thermocouple probe in the catalyst bed

Air flow not at 500 scfm

Refer to Chapter5, Troubleshooting, in this manual first if the catalyst bed will not maintain the proper temperature. Itmay be necessary to change the System Setup (paragraphA-6.3), to maintain the proper temperature. All Series 988temperature indicating controllers are set up for the CO and H2 burners to maintain the proper catalyst bed temperaturewith the present settings described inA-6.3.

NOTE

Check out all options before changing the system setup.

A-8.2 SERIES 988 TEMPERATURE INDICATING CONTROLLER TROUBLESHOOTING DIAGRAM Refer toFigureA-4 for instructions on troubleshooting the Series 988 Temperature Indicating Controller.


Original Appendix A-7/(Appendix A-8 blank)


Figure A-2. Electrical Assembly Wiring & Schematic Diagrams Mark IV-E Burner (Sheet 1 of 2)




FOR OFFICIAL USE ONLY FOR OFFICIAL USE ONLY

Figure A-2. Electrical Assembly Wiring & Schematic Diagrams Mark IV-E Burner (Sheet 2 of 2)





Figure A-3. Temperature Indicating Controller Installation Kit, Mark IV-E Burner (Sheet 1 of 3)





Figure A-4. Troubleshooting Diagram, Series 988 Temperature Indicating Controller





APPENDIX BWEST MODEL 2075 TEMPERATURE INDICATING CONTROLLER

B-1 INTRODUCTION

The West Model 2075 temperature indicating controller has been installed as a replacement unit in some CO & H2

burners. Removal, installation, and programming must be accomplished on both burners. This appendix provides technicalcoverage for the subject temperature indicating controller.

B-2 DESCRIPTION

B-2.1 GENERAL DESCRIPTION The M2075 temperature indicating controller offers a microprocessor basedproportional-integral-derivative control, digital readout, plug-in interchangeability and full parameter adjustment viaexternal push button and internal rocker switches. FigureB-1 of this Appendix shows the front panel and an explodedview of the M2075 controller internals. The numeric parameters (identified in the lower digital display) can be viewedsequentially in the upper digital display by repeated pressing of the function select button.

B-2.2 FUNCTIONAL DESCRIPTION The M2075 temperature indicating controller provides heater control powerranging from 0% - 100% unlike previous models that only provide 100%. This allows it to operate the heaters on apercentage of power instead of an on/off principle providing more accurate temperature control. This also extends the lifeof the heaters by eliminating the on/off cycling and limiting the large fluctuation in the heater percentage of ‘‘on’’ timecharacterized by previous controllers. This controller provides a more accurate control of the catalyst bed because it cancompute the long term and short term trends of the catalyst bed temperature. In effect, this controller predicts the futurebehavior of the system and adjusts the heaters accordingly.

B-3 OPERATION

B-3.1 MODES OF OPERATION The Model M2075 temperature indicating controller has two major modes ofoperation: Manual and Automatic. The Automatic mode has Sub-divisions of control within it.

B-3.2 MANUAL MODE In the Manual mode the heaters must be switched on or off by the operator to obtain andmaintain the proper temperature.

B-3.3 AUTOMATIC/SELF-TUNE DISABLED MODE The Automatic/Self-Tune Disabled mode of the control uses afixed set of parameters which is installed by the operator.

B-3.4 AUTOMATIC/PRE-TUNE/SELF-TUNE MODE The Automatic/Pre-Tune/Self-Tune mode is a special modedesigned for first time start-up in a new system. The heaters are energized until the system reaches 1/2 of the differencebetween start-up and set point temperature. At that time, the controller shuts down the heaters; the system temperaturethen peaks and begins to decline. From this behavior, the controller determines a safe set point of control parameters tolimit overshoot of the set point. This is called Pre-Tune. The heaters are re-energized and the system temperature proceedstowards the set point. At the set point, the controller enters the Automatic/Self-Tune mode.

B-3.5 AUTOMATIC/SELF-TUNE MODE The Automatic/Self-Tune mode monitors the temperature cycling behaviorof the heaters and recompiles optimal control parameters for each heating cycle. While this mode will adjust certainaspects of the controller parameters, the controller never alters the cycle time of the heaters. As operating conditionschange, accurate control of the heaters is maintained. Long term changes (e.g., air filter clogging, blower efficiencydecreases) are automatically adjusted for by the controller. This mode is made for coninuous use if desired and allcontroller settings are maintained by an internal lithium battery during any power disruptions. The vendor installs ageneric set of safe control parameters into the controller memory so that the controller may be operated for the first timein lieu of the Pre-Tune mode mentioned above. These parameters are generally not optimized, but instead changed whenthe Self-Tune of this mode activates.


Original Appendix B-1


B-3.6 INITIAL OPERATION The M0275 temperature indicating controller should be operated initially in theAutomatic/Pre-Tune/Self-Tune mode. This allows the burner to start conversely (with no overshoot) and to optimize itscontrol parameters for each burner. After the initial period of operation the Pre-Tune function should be disabled byplacing internal switch 1 in the off position. This will allow subsequent start ups to operate in the Automatic/Self-Tunemode, and to be more rapid with the Pre-Tune feature achieved.

B-4 REMOVAL OF EXISTING TEMPERATURE INDICATING CONTROLLER

(FO-3)

Using the electrical schematic onFO-3 label all of the wires before disconnecting the existing temperature indicatingcontroller. Then perform the following steps.

Figure B-1. Front and Exploded Views of the M2075 Temperature IndicatingController


Appendix B-2 Original


WARNING

Prior to removing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual.

WARNING

To avoid personnel injury, follow normal shutdown and cool down procedurescontained in Chapter2 of this manual.

WARNING


NOTE

Verify the specific model and wiring sequence of the temperature indicatingcontroller since various models are in use and the proper removal procedure maydiffer from the one represented here.

a. Disconnect wire #36 from TIC-1 terminal + on the current output.

b. Disconnect wire #37 form TIC-1 terminal – on the current output.

c. Disconnect wire #10 form TIC-1 terminal L and the 120 connection.

d. Disconnect wire #39 from TIC-1 terminal C.

e. Disconnect wire #38 from TIC-1 terminal H.

f. Disconnect wire #10, 6, and 9 from TIC-1 terminal 120.

g. Disconnect wire #38, 42, and 43 from TIC-1 terminal COM.

h. Disconnect wire #53 and 54 from TIC-1 terminal – ground.

i. Disconnect wire #201 from TIC-1 terminal + (T/C wire, white).

j. Disconnect wire #202 from TIC-1 terminal (T/C wire, red).

k. Remove the controller cover bracket by removing the four hex head bolts.

l. Remove the controller support brackets located inside the control box by removing the hex head bolts and discardthe brackets.

B-5 INSTALLATION

Perform the following steps. Refer to FiguresB-2, B-3, and the electrical schematics in Chapter5 of this manual for theM2075 temperature indicating controller wiring diagram. The mechanical interfaces are shown in FigureB-4.




WARNING

Prior to installing the temperature indicating controller, all personnel shall read andbe familiar with the Warnings and Cautions contained in theSafety Summaryat thefront of this manual.

WARNING


a. Assemble the installation kit in accordance with the kit drawings, FiguresB-2, B-3, and the electrical schematicsin Chapter5of this manual.

b. Replace any short wires with wires supplied as part of the installation kit.

c. Install the M2075 temperature controller assembly with four hex head bolts.

d. Install jumper from TIC-1 #8 to TIC-1 #13.

e. Install jumper from TIC-1 #7 to TIC-1 #15.

f. Install wires #53 and #54 to TIC-#9 (ground).

g. Install existing wires #6 and #9 to TIC-1 terminal #8 (115 volt power).

h. Install existing wires #42 and #43 to TIC-1 terminal #7 (AC power neutral).

i. Install wire #36 to TIC-1 terminal #4 (DC volt +).

j. Install wire #37 to TIC-1 terminal #5 (DC volt –).

k. Install wire #39 to TIC-1 terminal #14 (Alarm Common).

l. Install thermocouple wire #201 + (white) TIC-1 to terminal #1.

m. Install thermocouple wire #202 – (red) to TIC-1 terminal#2.

B-6 PRESTARTUP VERIFICATION TEST

Perform the following steps.

CAUTION


a. Verify all wiring connections to ensure wiring is in accordance with the installation kit drawings, FiguresB-2, B-3,and the electrical schematics in Chapter5of this manual.

b. Perform a standard electrical circuit test.




c. Clear electrical tags, switch burner override switch to normal. Turn power to burner on.

Figure B-2. M2075 Temperature Indicating Controller Terminal Connections




Figure B-3. M2075 Temperature Indicating Controller Wiring Diagram




B-7 PROGRAMMING

NOTE

Ships with R-12 installed in the ship stores refrigeration plant set the catalystoperating temperature (SP 1) at 600 °F (315.6 °C) and the high temperatureshutdown (AL 1) at 650 °F (343.3 °C). Ships with R-134a installed set SP 1 at 500°F (260 °C) and set AL 1 at 550 °F(278 °C).

NOTE

The various settings are viewed by touching the function select (FUNC/SEL)buttonon the bottom center of the controller. The set points (SP’s) are raised and loweredby touching the up and down arrow panels.

B-7.1 R-12 SYSTEM PROGRAMMING When R-12 is installed in the ship stores refrigeration plant perform theinitial setup procedure as follows.

a. Press the function select one time.

b. Set SP MAX to 602 °F (316.7 °C).

c. Set SP 1 to 600 °F (315.6 °C).

Figure B-4. M2075 Temperature Indicating Controller Replacement InstallationDiagram




d. Set SP MIN to 598 °F (314.5 °C).

e. Set AL 1 to 650 °F (343.3 °C).

f. Raise the SP RMP setting one number from 9999. This will eliminate this function. The screen will be blank.

g. Press the up and down arrows at the same time. The self-tuned LED will flash until the controller reaches 75% ofthe set point.

h. Press the reset switch on the controller door and start the burner.

i. When the controller has reached 75% of the set point the unit will shut off the heaters and measure the cool downrate. At this time the controller will self-tune and automatically return to normal mode.

The burner will cycle between 590 °F (310 °C) and 610 °F(321.1 °C) as required.

B-7.2 R-134a SYSTEM PROGRAMMING When R-134a is installed in the ship stores refrigeration plant performthe initial setup procedure as follows:

a. Press the function select one time.

b. Set SP MAX to 520 °F (261.1 °C).

c. Set SP 1 to 500 °F (260 °C).

d. Set SP MIN to 498 °F (258.9 °C).

e. Set AL 1 to 550 °F (287.8 °C).

f. Raise the SP RMP setting one number from 9999. This will eliminate this function. The screen will be blank.

g. Press the up and down arrows at the same time. The self-tune LED will flash until the controller reaches 75% ofthe set point.

h. Press the reset switch on the controller door and start the burner.

i. When the controller has reached 75% of the set point the unit will shut off the heaters and measure the cool downrate. At this time the controller will self-tune and automatically return to normal mode.

The burner will cycle between 490 °F (254.5 °C) and 510 °F (265.5 °C) as required.




FO-1 Electrical Schematic (Simplified)



Original FP-1/(FP-2 blank)


FO-2 Alarm Relay Controller Schematic





FO-3 CO and H2 Burner, Mark IV-E, Electrical Schematic





FO-4 Temperature Indicating Controller Schematic (Sheet 1 of 3)





FO-5 CO and H2 Burner, Mark IV-E, General Arrangement (Sheet 1 of 8)





FO-7 CO and H2 Burner, Mark IV-E, SSN21 Class General Arrangement (Sheet 1 of 8)





FO-8 CO and H2 Burner, Mark IV-E, SSN21 Class Reliance 2 HP Motor (Sheet 1 of 3)





Ref: NAVSEAINST 4160.3A NAVSEA S0005-AA-GYD-030/TMMP

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1. PUBLICATION NUMBER 2. VOL/PART 3. REV/DATE OR CHG/DATE 4. SYSTEM/EQUIPMENT ID

5. TITLE OF PUBLICATION 6. REPORT CONTROL NUMBER (6 digit UIC-YY-any four: xxxxxx-03-xxxx)

7. RECOMMEND CHANGES TO PUBLICATION

7a. Page # 7b. Para # 7c. RECOMMENDED CHANGES AND REASONS

8. ORIGINATOR’S NAME AND WORK CENTER 9. DATE 10. ORIGINATOR’S E-MAIL ADDRESS 11. TMMA of Manual (NSDSA will complete)

12. SHIP OR ACTIVITY Name and Address (Include UIC/CAGE/HULL) 13. Phone Numbers: Commercial ( ) -

DSN - FAX ( ) -

NAVSEA 4160/1 (Rev. 7-2003) S/N 0116-lf-985-4100

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INCLUDE COMPLETE ADDRESS USE PROPER POSTAGE FOR OFFICE USE ONLY

COMMANDER CODE 310 BLDG 1388 NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY PORT HUENEME, CA 93043-4307

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for official use only s9515-as-mmm-010 - navy tribe · 2015. 11. 4. · s9515-as-mmm-010...

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