Installation Guide for FW MURPHY models including: LM500 Lube Level Maintainer, LM500, LM500-TF, Lube Level Maintainer, Level Maintainer, Maintainer
10 mag 2022 — Before installation of this product: • It is your responsibility to ensure that qualified mechanical and electrical technicians install this product.
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sect. 15 00-02-0729 rev. 2022/06/30 Installation of Lube Level Maintainer Models LM500 / LM500-TF Please read the following instructions and warnings before installation. Visually inspect the product for any damage that may have occurred during shipping. WARNINGS Before installation of this product: · It is your responsibility to ensure that qualified mechanical and electrical technicians install this product. · Disconnect all electrical power to the machine. · Make sure the machine cannot operate during installation. · Follow all safety warnings of the machine manufacturer. · Read and follow all installation instructions. · Please contact FW Murphy Production Controls immediately if you have any questions. The FW Murphy LM500 model maintains the crankcase oil level of an engine, pump or compressor. Adjusted to the correct running oil level, the LM500 will replenish oil as it is used. The low level switch will alarm and/or shut down the equipment if the supply oil is lost and the equipment continues to use oil. The LM500-TF model includes a test feature that confirms both the float and switch are operating correctly with a single press of the test button. Range of the Snap-Switch This illustration shows the LM500 dial and the operating range of the switch. If level is within the designated zones, the switch will activate. The switch activates approximately 1/4 in. (6 mm) from the bottom of the low zone. If the level continues to drop into the lowlow zone, a shutdown will occur. NOTE: Color zones on dial face show approximate normal operating zones. Actual conditions may vary depending upon operating characteristics of the engine. Placement of the LM500 according to these instructions will compensate for these conditions. Test Feature The form C (3-wire) contact allows a controller/annunciator to be wired as a closed loop system, resulting in a reliable fault-sensitive circuit. NOTE: Holding test button for a prolonged period of time could cause crank case to overfill. LM500 Series Flow Rates GPH 4.000 LM500 Series Flow Rates The LM500 Series Flow 3.500 Rates are 3.000 based on SAE 2.500 40 motor oil 2.000 @2 ft. head 1.500 pressure. 1.000 Friction 0.500 losses due to 0.000 piping are not 0 10 20 30 40 50 60 70 80 90 100 110 120 130 considered. Temperature (°F) 1 Operation As the equipment uses oil, the float falls, providing immediate level compensation. At the FULL position, the float holds the valve closed. If the clean oil supply is depleted and oil level continues to fall, the low level switch will operate an alarm or equipment shutdown. NOTE: Holding test button for a prolonged period of time could cause crank case to overfill. Dimensions, Mounting Brackets (Optional) Pipe Mount Bracket Universal Mount Bracket 2 Dimensions, LM500 Series LM500 Vent 1/2-14 NPT Electrical Conduit Connection 4-1/8 in. (104 mm) Viewing Lens 1/2-14 NPT Oil Inlet 3/4-14 NPT Outlet (3 places) 5-29/32 in. (149 mm) 4-29/32 in. (124 mm) 6-7/32 in. (157 mm) 3-35/64 in. (89 mm) LM500-TF Test Button Vent 1/2-14 NPT Electrical Test Button Conduit Connection Vent 6-35/64 in. (166 mm) 4-1/8 in. (104 mm) Viewing Lens 1/2-14 NPT Oil Inlet 3/4-14 NPT Outlet (3 places) 4-29/32 in. (124 mm) 6-7/32 in. (157 mm) 3-35/64 in. (89 mm) 3 Typical Installation WARNING Perform this installation using appropriate protection. Trapped air and hot oil may cause burns. Attach the mounting bracket to the backside of the LM500. If using the Universal bracket, this may be done now or after the bracket is attached to the base or the oil pan. 4X 1/4-20 UNC Supplied in bracket kit; Mounting bolts 1/4-20 UNC x 3/4 long and washers. The Pipe bracket uses 4 screws with a lock washer on each. The Universal bracket uses 4 screws with a lock washer and flat washer on each. Follow instructions for Pipe Bracket Kit (15000518) or Universal Flange kit (15000519). See LM500 Series Kits. CAUTION Excessive vibration can cause overfill. Be sure mounting brackets are supported. IMPORTANT Mount the LM500 as close as possible to the crankcase. Pipe Bracket Mount (PM) (P/N 15000518) 1. Mount a nominal 1/2 inch (13 mm) diameter pipe to the base of the skid or fixture. 2. If not already done, install the pipe bracket to the LM500 using the supplied fasteners, four 1/4-20 UNC x 3/4 inch bolts with lock washers on each. 3. Slip the LM500 onto the pipe and install the two adjustment bolts (nuts threaded close to bolt head), 1/4-20 UNC x 1-1/2 inch bolt. a. DO NOT tighten the adjustment bolts too tight, as you will need to adjust the LM500 later in the installation process. a. Refer to Connect Fittings and Hoses for more information regarding height adjustment of the LM500 in alignment with the oil level in the crankcase. 4 Universal Flange Mount (UB) (P/N 15000519) The Universal Flange bracket has two mounting methods: base mounting or oil pan mounting. Base Mounting 1. Install the universal bracket to the base as shown using a 5/16 inch diameter bolt and lock washer, customer supplied. 2. If not already done, mount the LM500 to the universal bracket using the supplied fasteners, four 1/4-20 UNC x 3/4 inch bolts with lock and flat washers. a. DO NOT tighten the bolts too tight, as you will need to adjust the LM500 later in the installation process. b. Refer to Connect Fittings and Hoses, for more information regarding height adjustment of the LM500 in alignment with the oil level in the crankcase. Crankcase (Oil Pan) Mounting 1. Install the universal bracket to the crankcase using an existing crankcase bolt, washer and nut. Crankcase bolt diameter must be no larger than 7/16 inch (11 mm). NOTE: Check clearance between crankcase and mounting bracket before installing the mounting bracket. If space between the crankcase and mounting bracket is narrow, attach LM500 to mounting bracket prior to installation on crankcase. 2. If not already done, mount the LM500 to the universal bracket using the supplied fasteners, four 1/4-20 UNC x 3/4 inch bolts with lock and flat washers. a. DO NOT tighten the bolts too tight, as you will need to adjust the LM500 later in the installation process. b. Refer to Connect Fittings and Hoses, for more information regarding height adjustment of the LM500 in alignment with the oil level in the crankcase. 5 Connect Fittings and Hoses The following instructions start after LM500 is mounted, using Hose Kit (15000355) and Fitting Kit (15000943). IMPORTANT If connecting to the drain plug on the crankcase, we recommend adding a T-fitting to allow draining of the oil for service. IMPORTANT Apply a sealant such as Teflon® to all threaded connections. Perform the Operation Test after the unit is installed and wired appropriately. 1. Ensure the crankcase oil level is below the connections needed for this procedure. a. Start the engine or power up the monitor. 2. Using the barb fittings as needed, attach the 1 inch (25 mm) diameter flexible oil hose to the crankcase and to one of the (3) oil outlet locations on the LM500. Secure with hose clamps. a. The hose must slope slightly downward from the LM500 and without any droops or low spots. b. If crankcase drain plug is used, we recommend installing a T-fitting at the crankcase to assist with routine oil changes. 3. Apply Teflon to threads of the ¾-14 NPT pipe plug fitting. Install pipe plug fittings to the remaining (2) oil outlets. Plugs supplied in LM500's shipping box. 5. For vented crankcase, you may use the plastic vent Vented System, Vent Options plug that came installed in the LM500 or install the vent tube (candy cane). a. To install the vent tube, remove the plastic vent plug. Install and tighten the compression fitting connector with the vent tube. Plastic Vent Plug Copper Vent Tube 2. For sealed systems, remove the plastic vent plug. Use the barb fittings to install the 1/2 inch (13 mm) I.D. x 3 ft. (914 mm) hose to the vent connection on the LM500 and to the vent connection on the crankcase. Cut hose as needed and secure with hose clamps. a. The vent connection on the crankcase must be well above the regulated oil level. b. The hose must be clear of obstructions, valleys or dips that could create liquid traps or gas/air pockets. The connections should be as straight as possible. Sealed System and Alignment Illustration 5. Before continuing, verify that all hose clamps are tight. 6. Fill the crankcase to the proper oil level. 7. With the engine running and warm, loosen the mounting bracket adjustment bolts and adjust the LM500 so that the oil level in the viewing lens aligns with the middle of the green bar on the dial. 8. Holding the LM500 in alignment, tighten the adjustment bolts on the mounting bracket. Green Bar 6 Connect LM500 to Oil Supply Tank Perform the Operation Test after the unit is installed and wired appropriately. 1. Remove the plug from the oil inlet connection. Be sure the removable screen inside the connection is clear of debris. Install the oil inlet connection. 2. Connect a 1/2 inch I.D. (13 mm) or larger hose to the oil inlet fitting on the LM500 and to the shut-off valve on the oil supply tank. a. Recommended minimum height above the LM500 is 2 feet. (0.6 m); maximum 25 feet (7.7 m). b. The hose must maintain a downward slope and not have low spots or droops. c. Maximum head pressure rating is 9.50 psi or 25-foot oil (head pressure). 3. Before filling the supply tank with oil, be sure the tank is clean and dry and the shut-off valve is closed. Also, be sure all hoses and clamps are tight. Fill the tank with CLEAN oil. WARNING Overfill condition can be caused by excessive inlet pressure and/or improper vent-to-crankcase installation. 4. After oil supply tank is full, open the shut-off valve. 5. Make the proper electrical connections for the application. LM500 Typical Installation Diagram With Supply Tank WARNING Perform this installation using appropriate protection. Trapped air and hot oil may cause burns. For vented crankcase, use the plastic vent plug or optional vent tube kit (15000954). Test Button LM500 Oil Outlet For sealed systems, vent must be piped back to crankcase, above oil level. Electrical Conduit wire to switch circuits Oil Inlet CRANKCASE Clean Oil Supply Tank, height above LM500 2 ft. (0.6 m) minimum recommended. 25 ft. (7.7 m) maximum. Shutoff Valve Typical Pipe Mount Installation In this example, the oil outlet hose is connected to the bottom oil outlet, the (2) side oil outlets are plugged. Typical Universal Mount Installation In this example, the oil outlet hose is connected to the bottom oil outlet, the (2) side oil outlets are plugged. Test Button Oil Inlet Hose Viewing Lens Oil Supply Tank Running Engine Crankcase Oil Level Crankcase Hose 7 LM500 Series Kits Pipe Bracket Kit (P/N 15000518) Qty Description 1 Bracket, Mtg, Back Housing, LM500 4 Screw, Hex Head 1/4-20x3/4 Zinc 2 Screw, Set, 1/4-20x1-1/2 4 Washer, Split Lock 1/4 Med 2 Nut, Hex, 1/4-20x7/16 Steel Universal Bracket Kit (P/N 15000519) Qty Description 1 Bracket, Universal Tall 4 Screw, Hex Head 1/4-20x3/4 Zinc 4 Washer, Split Lock 1/4 Med 4 Washer, 1/4, Flat, SS Bubble Lens Kit (P/N 15000532) Qty Description 1 Dial 1 O-ring, 0.139 C/S, 4.359 ID 6 Shoulder screw, #8-32 x 0.3125 1 Bubble lens Specifications Crankcase Balance Vent Connection: 1/2 NPTF (top) Inlet Connection: 1/2 NPTF removable screen (side) Outlet Connection: 2 x 3/4 NPTF (side) 1 x 3/4 NPTF (bottom) Thumb-Valve Material: Viton Snap-switch: SPDT rating 10 A, 125 VAC; 0.5 A, 125 VDC; 10 A, 30 VDC Wire leads: 18 AWG x 14 in. +/- 2 in. (355 mm) length Conduit Connection: 1/2 inch conduit (female, top) (Refer to 00-02-0735 Teflon Tape Wrapping Technique) Fittings Kit (P/N 15000943) Qty Description 1 Tubing vent, soft copper, candy cane 1 Hose barb, 1/2 NPT to 1/2 Hose 1 Hose barb, 1in. I.D. Hose X 3/4 NPT 1 Connector, 1/4 x 1/2 NPT compression fitting Hose Kit (P/N 15000355) Qty Description 1 Hose, 1/2 in. (13 mm) I.D. x 3 ft. (914 mm) long 1 Hose1 in. (25 mm) I.D. x 3 ft. (914 mm) long 2 Clamp, 1/2 in. (13 mm) worm gear 2 Clamp, 1 in. (25 mm) worm gear 2 Barbed fitting, 1/2 NPT x 1/2 in. (13 mm) Vent Fittings Kit (P/N 15000954) Qty Description 1 Tubing vent, soft copper, candy cane 1 Connector, 1/4 x 1/2 NPT compression fitting Case: Die-cast aluminum Lens: Clear frog eye non-staining, high impact, high temperature polycarbonate; UV and heat stabilized Dial: High visibility white background with solid green band for normal level indication Maximum Inlet Pressure: 9.50 psi/25 ft. oil (head pressure) Maximum Differential: 2 in. (51 mm) between running and stopped Maximum Ambient Temperature: 250o F (121o C) Float: 304 Stainless Steel Flow Rates: Refer to Flow Rate Chart In order to consistently bring you the highest quality, full-featured products, we reserve the right to change our specifications and designs at any time. FW MURPHY product names and the FW MURPHY logo are proprietary trademarks. This document, including textual matter and illustrations, is copyright protected with all rights reserved. (c) 2022 FW MURPHY. A copy of our typical warranty may be viewed or printed by going to www.fwmurphy.com/warranty. 8Adobe InDesign 17.3 (Windows) Adobe PDF Library 16.0.7