operators manual farval cs2000 stations - bijur … · cs2000 stations consist of sub-assemblies...

Operators Manual

FARVAL® CS2000 STATIONS Description & Installation Instructions

2011F r#3

Farval®series - CS2000 Central Stations

2

Features

• Dual piston pump with working pressure rating

of 3500 psi (240 bar).

• Life rating of pump more than 2 million cycles

at 3500 psi.

• Steel reservoir supplied with visual indicator

and low level warning switch standard.

• Simplified construction - internal porting elim-

inated tubing and fittings.

• Air bleed in reservoirs to eliminate air pock-

ets.

• Adjustable relief valve - readily accessible on

the outside.

• Functional interchangeable with older stations

such as DJ10 and DJ25.

DJ2000 Pump

CS2212 Pump


3

Table of Contents

Illustrations and specifications are not binding in detail.Designs are subject to modification and improvement without notice.

INTRODUCTIONCS2000 stations store, control and supply the lubricant to systems. Depending on reservoir size, they can be used in systems that service anything from small machine tools to large machinery in steel mills, or from small to large off road machinery such as power drills, power shovels and drag lines. A. Standard Items Standard items on these stations include a switch arrange-ment for automatic level warning systems, visual level indi-cation, an adjustable pressure relief valve and a n electri-cally driven pump. B. Options A variety of reservoir sizes, a reversing valve for DUALINE systems, and a high level warning switch are offered. C. Kits Kits are available for mounting controls and NEMA 4 appli-cations. D. General Specifications

Contents

INTRODUCTION ...............................................3

Standard Items ..............................................3

Options .............................................................3

Kits ...................................................................3

General Specifications ..................................3

DESCRIPTION .................................................4

INSTALLATION SPECIFICATIONS Small Capacity DUALINE Stations ...............5

Medium Capacity DUALINE Stations ..........6

Large Capacity DUALINE Stations ..............7

PARTS DESCRIPTION

Pump.................................................................8

Reservoir Modules .................................. 9-11

Reversing Valve ........................................... 12

Reversing Valve Conversion Loop ............ 13

Pump type Dual piston

Pump output 6.0 in3/min @ 175 strokes/min @ 1000 psi (70 bar)

Maximum operating pressure *For higher pressures, consult engineering

3500 psi * (240 bar)

Gear ratio Note: Other ratios are available at extra cost.

10:1 standard

Lubricants Oil and Grease

Reservoirs - Oil 6 Gallon Steel 15 Gallon Steel 30 Gallon Steel

Reservoirs - Grease 10 Pound Plastic 10 Pound Steel 24 Pound Steel

100 Pound Steel

Motor Note: Other motors are available at extra cost.

1/3HP, 230/440V, 3 Phase,NEMA 48 Frame

& TEFC

Reversing Valve DR45 Standard on DUALINE stations

Factory set @ 1500 psi (103 bar)

Relief Valve All Stations Factory set @ 3000 psi (206 bar)


4

Figure 1

Part Number Reservoir Size & Material Type High Level

Warning Switch Part Number Reservoir Size & Material Type High Level

Warning Switch

CS2210 10 lb. Plastic Dualine/Grease No CS2225 24 lb. Steel Dualine/Grease Yes

CS2211 10 lb. Plastic Dualine/Grease Yes CS2206 6 gal. Steel Dualine/Oil No

CS2212 10 lb. Steel Dualine/Grease No CS2207 6 gal. Steel Dualine/Oil Yes

CS2224 24 lb. Steel Dualine/Grease No CS22101 100 lb. Steel Dualine/Grease Yes

Central Stations consist of a pump, reservoir and motor. Devices associated with particular types of systems are included with some stations. Optional equipment such as control mounts, are offered as kits. There are eight standard CS2000 Central Stations. With some basic features being made standard, this lineup should meet the needs of most applications. The eight standard units are shown in Figure 1.

Description

10 LB. STEELGREASERESERVOIR

10 LB. PLASTICGREASERESERVOIR


6 GALLON STEELOILRESERVOIR


FIGURE 2

II. DESCRIPTION

CS2000 Stations consist of sub-assemblies that aredesigned as modular kits. These kits may be combinedto form the variety of stations shown in Figure 1.Figure 2 illustrates how the modules are combined.

PUMP ANDBASE ASSEMBLY

DR45REVERSING VALVEMODULE


5


Warning Switch

CS2210 10 lb. Plastic Grease No

CS2211 10 lb. Plastic Grease Yes

CS2212 10 lb. Steel Grease No

D. SMALL CAPACITY DUALINE STATIONS OUTLINE AND MOUNTING DIMENSIONS Figure 6

Installation Specifications

SEE VIEW A-A FORHIGH LEVEL SWITCH

VIEW A-A FOR HIGH LEVEL SWITCH



6


Warning Switch

CS2224 24 lb. Steel Grease No

CS2225 24 lb. Steel Grease Yes

CS2206 6 gal. Steel Oil No

CS2207 6 gal. Steel Oil Yes

E. MEDIUM CAPACITY DUALINE STATIONS OUTLINE AND MOUNTING DIMENSIONS Figure 7



VIEW A-A FOR HIGH LEVEL SWITCH



7

G. LARGE CAPACITY DUALINE STATIONS OUTLINE AND MOUNTING DIMENSIONS Figure 9



Warning Switch

CS22101 100 lb. Steel Grease Yes

REVERSING VALVE


8

A. PUMP CS2000 stations have dual piston pumps.

The two pistons are driven by eccentrics,

a worm gear, and an electric motor.

The drive shaft rotation must be in the

direction of the arrow shown by item

51 of Figure 9. All station assemblies

include one-way couplings to prevent

damage to the pump.

The crankcase of the pump should be

filled with a 140SAE grade gear oil.

Parts Description - Pump

DJ2000 PUMP

No. Req'd

Item No.

DescriptionPart

NumberNo.

Req'dItem No.

DescriptionPart

Number1 1 MAIN SPRING 200870 2 25 COTTER PIN U201A4

2 2 BEARING, SINGLE ROW AF1001 4 26 HEX HD BOLT U204A3

1 3 BEARING CONE, SINGLE ROW AF10041 4 27 HEX HD BOLT U204B5

1 4 PLUG, MAIN PISTON BORE PLU10758B 3 28 HEX HD BOLT U204C12

1 5 BEARING CONE AF10141 4 29 LOCK WASHER U213E

2 6 WRIST PIN DC2512 4 30 LOCK WASHER U213F

2 7 ECCENTRIC DJ1010101 3 31 COPPER WASHER U1305F

2 8 CONNECTING ROD DJ1010111 2 32 3/8" BALL U230E

1 9 PUMP HOUSING HSG10737D 2 33 WOODRUFF 505 U233E

1 10 SPUR GEAR, DJ2000 PUMP GEA10724B 2 34 5/8-18 RETAINER SCREW, SLOTTED U1204G

1 11 WORM GEAR, DJ2000 WOR10723B 1 35 1/4 X 15/16 L STRAIGHT KEY U1215C6

1 12 SHIM, PUMP CYLINDER SHM10726B 1 36 SPRING U1304J

1 13 PISTON AND CYLINDER ASSEMBLY LB10546 1 37 COPPER WASHER U1305L

1 14 PLATE, OPEN END WORM PLA10739B 1 38 CLOSURE PLUG U1501J

1 15 PLATE CLAMPING GEAR, MACHINED PLA10720B 1 39 SHAFT SEAL, .375 OIL U1738B

1 16 FLAT POINT SET SCREW U250G8 1 40 O-RING BUNA U1720009

1 17 SHAFT - GEAR AND ECCENTRIC SHA10735B 1 41 NAMEPLATE, ARROW U1312BL

1 18 GEAR SPACER SPA10718A 1 42 NAMEPLATE, ALUMINUM U1312C

1 19 TAG, LUBRICANT FILL NOTE(NOT SHOWN) TAG11750A 1 43 CHECK VALVE ASSEMBLY, 1/8 NPT B4942

1 20 ELBOW, 1/4 MPT X 3/8 FPT U1023 1 44 NAMEPLATE, SHAFT ROTATION U1312W

3 21 1/4-18 NPTF PLUG, PLATED U119BC 1 45 SPRING RETAINER RET10925B

1 22 3/8-18 NPTF, PLUG PLATED U119CC 1 46 BEARING CUP, SINGLE ROW AF10042

3 23 1/8-27 NPTF PLUG U1351 1 47 BEARING CUP AF10142

1 24 COPPER WASHER, U1305AB 2 48 COPPER WASHER U1305E

15

264 PL

294 PL

44

23

23

42

51

35

6 2 PL

7

810

12

17

18

24

25 2 PL

33 2 PL7

10

43

4746

SECTION B-B

21

21

37

38

23AA

B

B

1

9

13

14

16

27 4 PL

32

45

30 4 PL

48

48

NOTE 2

SET RELIEF AT 3000+/-100 PSI. THIS IS APPROXIMATELY 1.5 TURNS OF SCREW ADJUSTMENT WHEN SPRING COMPRESSION STARTS.

NOTE 2FIGURE 9

SECTION A-A

2 2

11

39

NOTE: STANDARD COUPLINGS:U109011 ONE WAY CLUTCH (MOTOR)U968B FLEX COUPLING (PUMP)UX968 SPIDER ONLY

FILLER CONNECTION(SEE FIGURE 10)

DRIVESHAFTROTATION

C

C

4

20

22

21 28 3 PL

32

342X

36

41

31 3 PL

SECTION C-C

40


9

Parts Description - ReservoirsT2002 - 10 LB. GREASE - STEEL

No. Req'd

Item No.

DescriptionPart

Number1 1 Kit - Switch & Indicator (Low-Level) LB105781 2 Follower Assembly LB105831 3 Body - Reservoir (Steel) BOD10905B1 4 Spring - Reservoir SPR11114B1 5 Cover - Reservoir COV10796C3 6 Rod - Tie ROD10797B1 7 Retainer - Rod RET10799B3 8 Washer - Lock - 5/16" U213F3 9 Nut - Hex - 5/16" U219B1 10 Plug - Hole 7/8" PLU11106A1 11 Filler Screen Assembly T30S10151A1 12 Nipple - Pipe - 1/4" x 2" U101B51 13 Bushing - Reducing - 1/4" - 3/8" U104C21 14 Coupling - Pipe - Straight - 1/4" U112B1 15 Plug - Quick Disconnect - 1/4" MP U421BC1 16 Coupling - Quick Disconnect - 3/8" FP U422C1 17 Elbow - Steel Street - 1/4" U1104B1 18 Washer - Copper - 1" I.D. U1305AA1 19 Nameplate - Farval U1312BT1 20 Gasket GAS10873B2 21 Nameplate - Hazard Warning U1312R1 22 Nameplate - Model U1312C3 23 Washer - Flat - 5/16" U241C

T2000 - 10 LB. GREASE - PLASTICNo.

Req'dItem No.

DescriptionPart

Number1 1 Kit - Switch & Indicator (Low-Level) LB105781 2 Follower Assembly LB105821 3 Body - Reservoir (Plastic) BOD10793B1 4 Spring - Reservoir SPR11114B1 5 Cover - Reservoir COV10796C3 6 Rod - Tie ROD10797B1 7 Plug - Closure U1522H3 8 Washer - Lock - 5/16" U213F3 9 Nut - Hex - 5/16" U219B1 10 Plug - Hole 7/8" PLU11106A1 11 Filler Screen Assembly T30S10151A1 12 Nipple - Pipe - 1/4" x 2" U101B51 13 Bushing - Reducing - 1/4" - 3/8" U104C21 14 Coupling - Pipe - Straight - 1/4" U112B1 15 Plug - Quick Disconnect - 1/4" MP U421BC1 16 Coupling - Quick Disconnect - 3/8" FP U422C1 17 Elbow - Steel Street - 1/4" U1104B1 18 Washer - Copper - 1" I.D. U1305AA1 19 Nameplate - Farval U1312BT1 20 Gasket GAS10873B2 21 Nameplate - Hazard Warning U1312R1 22 Nameplate - Model U1312C3 23 Washer - Flat - 5/16" U241C

BB

22

21

10

16

15

14

12

13 111817

7

8

19

20

4

3

6

5

23

9

2

1

21

FIGURE 10

FILLER CONNECTION(SEE FUIGURE 9 FOR LOCATION)

BB

22

21

10

16

15

14

12

13 111817

7

8

19

20

4

3

6

5

23

9

2

1

21

FIGURE 12


10

Parts Description - Reservoirs

T2005 - 24 LB. GREASE - STEELNo.

Req'dItem No.

DescriptionPart

Number1 1 Retainer - Follower Rod RET10929B1 2 Kit Switch & Indicator Res. Level LB105781 3 Follower Assembly LB106091 4 Cover - Reservoir COV10839C4 5 Rod - Tie ROD10840B1 6 Spring - Reservoir SPR10841B1 7 Body - Reservoir BOD10842B4 8 Washer - Lock - 5/16" U213F4 9 Nut - Hex 5/16" - 18 U219B1 10 Nameplate U1312BT1 11 Plate - Base Reservoir PLA10850C1 12 Gasket GAS10843A1 13 Filler Screen Assembly T30S10151A1 14 Plug - Quick Disconnect - 3/8" FP U421CC1 15 Coupling - Quick Disconnect - 3/8" FP U422C1 16 Washer - Copper - 1" I.D. U1305AA2 17 Nameplate - Hazard Warning U1312R6 18 Screw - Soc. HD Cap. - 5/16" - 18 x 1" U225B56 19 Washer - Copper - 21/64" I.D. U1305E1 20 Gasket GAS10873B1 21 Nameplate - Model U1312C1 22 Tubing - Spring Guide TUB11128B1 23 Nut - Jam - Hex 3/4" - 16 U239J1 24 Washer - Copper U1305S

T2004 - 6 GAL. OIL - STEELNo.

Req'dItem No.

DescriptionPart

Number1 1 Retainer - Float Rod RET10799B1 2 Float Switch Assembly LB105841 3 Float Assembly LB106101 4 Body - Reservoir BOD10906B1 5 Cover - Reservoir COV10839C4 6 Rod - Tie ROD10840B4 7 Washer - Lock - 5/16" U213F4 8 Nut - Hex - 5/16" - 18 U219B1 9 Nameplate U1312BT1 10 Plate - Base Reservoir PLA10850C1 11 Gasket GAS10843A1 12 Gasket GAS10873B6 13 Screw - Soc. HD Cap. - 5/16" - 18 x 1" U225B26 14 Washer - Copper 21/64" I.D. U1305E1 15 Filler Screen Assembly T30S10151A1 16 Nipple Pipe - 1/4" x 2" U101B51 17 Bushing - Reducing - 1/4" - 3/8" U104C21 18 Coupling - Pipe Straight - 1/4" U112B1 19 Plug - Quick Disconnect - 1/4" MP U421BC1 20 Coupling - Quick Disconnect U422C1 21 Elbow - Steel Street - 1/4" U1104B1 22 Washer - Copper 1" I.D. U1305AA1 23 Nameplate - Model U1312C

AA

23

1522 17

21

16

18

19

20

SECTION A-A

5

1

8

4

10

11

2

13

14

12

3

7

6

9

AA

21

16 1513 14

17

4

1

9

11

12

2

18

19

20

6

8

5

3

22

23 24

7


11

Parts Description - Reservoirs

AA

SECTION A-A

4

6

7

8

2

9

18

20

1117

15

5

14

21

10

3

13

12

1

24

19

23 22

24BB

SECTION B-BSCALE 1 : 1

NOTE: SOME ITEMS HAVE BEEN ROTATEDIN THE SECTION VIEW FOR CLARITY

5

T40D1C1 - 100 LB. GREASE - STEELItem No.

No. Req.

Part No. Description

T40D

1C1

RESE

RVOI

R AS

SEM

BLY

1 1 T4010051 RESERVOIR BODY, 100LB

2 1 T4010071 COVER, 100LB RES.

3 1 T4010101 FOLLOWER PLATE, MACHINED

4 1 T4010111A INDICATOR ROD

5 2 U220J HEX NUT, 1-14

6 1 U232F EYEBOLT, SHOULDERED

7 1 U127B DRAIN COCK, 1/4NPT

8 3 U204F2 HEX HD BOLT

9 1 T4010272 FOLLOWER SEAL

10 1 T4010302 BAND CLAMP

11 1 T4010241 RESERVOIR GASKET

12 1 U1025 STREET ELBOW 3/4 NPT X 3/4 NPT

13 1 U101E18 PIPE NIPPLE, 3/4 X 6

18 8 U204E7 HEX HD BOLT

20 8 U213J 1/2 LOCK WASHER

21 8 U219E 1/2-13 HEX NUT

22 2 U213E 1/4 LOCK WASHER

23 2 U204A2 HEX HD BOLT

T40D

1A21

RESE

RVOI

R AD

APTE

R AS

SEM

BLY

14 1 T4010061 RES.ADPT 100LB & 200LB

15 2 T4010141 CLOSED END COVER

17 8 U204B10 HEX HD BOLT

19 8 U213F LOCK WASHER

24 1 T4010202 HI-LO LEVEL SWITCH ASSY


12

C. REVERSING VALVE MODULE (MODULE KIT DR45K)

Parts Description Reversing Valve

SWITCH ~ S.P.D.T.

CONDUIT CONNECTION1/2” N.P.S.M.

TORQUE TO BE 150+/-10 LB./IN. PRESSURE GAUGE 0-5000 P.S.I. (2 PLACES)

3/8” N.P.S.F.(2 PLACES)

OPTIONAL RETURN1/4” N.P.S.F. PLUGGED(2 PLACES)

FIGURE 17

RETURN LINES ~ 3/8” N.P.S.F. PLUGGED

RELIEF ~ 1/2”N.P.S.F.(PLUGGED) REF.

5.75”(3.5”)

REAR VIEW

SUPPLY1/4”N.P.S.F.

ALTERNATERELIEF1/8”N.P.S.F.

4.3”

3.12”

0.69”

3.0”

3.40” MAX.3.12” MIN.

0.62”

NON-RETURN SYSTEMARRANGEMENT #1STANDARD FROM FACTORY

LOOP SYSTEMARRANGEMENT #2

NO. 1 RETURN LINE1/4” N.P.T


2.31”2.19”

1.50” 1.62”

2.19”2.31”

1

1b1a

1c

9

8

6

5

2

4

3

ARRANGEMENT #3



4

No. Required Arrangements Item

# Description Part Number#3 #2 #11 1 1 1 Switch and Adapter Assembly FT15801C8

1a Switch U10623

1b Switch Adapter 37041

1c Set Screw 37037

2 2 Bushing - Face - 3/8" x 1/4" P. U148C2

2 3 Elbow - Street - 1/4" P. Brass U152B

2 2 4 Tee - Street - 1/4" P. U156B

2 5 Elbow - Street - 1/4" P. 45 Deg. U1103B

1 1 1 6 Nameplate - Model U1312C

1 1 1 7 Nameplate-PR-Set(not shown) NAM10431A

1 1 1 8 Reversing Valve Assembly DR4-5

2 2 2 9 Gauge-Pressure 0-5,000 P.S.I. U902F


13

Reversing Valve Loop Conversion

INSTALL 1/8”PIPE PLUGFOR LOOPSYSTEM.(TWO PLACES)

FIGURE 18

INSTALL 1/8”PIPE PLUGFOR LOOPSYSTEM.

RETURN LINE #2

RETURN LINE #1

RELIEFLINE

SUPPLYLINE

OPTIONALRELIEF

BOTTOM VIEW REAR VIEW

FRONTVIEW

CONVERSION OF DR45 REVERSING VALVE TO LOOP SYSTEM Valves are shipped for non-return systems, without the 1/8" pipe plug installed. All that is required to make the discharge connec-tions on the front face of the valve. For loop systems, install the 1/8" pipe plugs as shown and make the return connections to either the return ports on the front face, or the two return ports located on the bot-tom of the valve.


14

Notes


15

Notes

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operators manual farval cs2000 stations - bijur … · cs2000 stations consist of sub-assemblies...

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