Tech_Manaul_167-00_Part_1.pdf

WATERTIGHT DOOR SYSTEM

INSTRUCTIONS AND RENEWAL PARTS SHEETS

AS SUPPLIED FOR

AGOR-24

CUSTOMER: HALTER MARINE, INC.

MOSS POINT, MISSISSIPPI

PURCHASE ORDER NUMBER: M014199

DESIGN & SALES OFFICE:

WALZ & KRENZER, INC.

. 90 FOREST A VENUE

LOCUST VALLEY, NEW YORK 11560

TELEPHONE: (516) 671-2063 FAX NO. : (516) 759-9405

SALES & MANUFACTURING OFFICE:

WALZ & KRENZER, INC.

1390 Mr. READ BOULEY ARD

ROCHESTER, NEW YORK 14606

TELEPHONE: (716) 254-6670 FAX NO.: (716) 254-6178

OCTOBER 25, 1994

WK JOB NO. 8581

15'

HYDRAULIC DOOR

TABLE OF CONTENTS

, ...-.... SECTION TITLE PAGE NO.

I GENERAL INFORMATION 4

II DESCRIPTION AND PRINCIPLES OF OPERATION 5-6

m INSTALLATION PROCEDURE 7-14

IV TEST PROCEDURE 15

v OPERA TING INSTRUCTIONS - POWER OPERA TED DOOR 16-17

VI OPERA TING INSTRUCTIONS - HAND OPERA TED DOOR 18

VII MAINTENANCE 19 - 22

VIII TROUBLE SHOOTING GUIDE 23

IX DRAWINGS - POWER OPERATED DOOR 24-32

x DRAWINGS - POWER OPERATED & HAND OPERATED 33-36

XI DRAWINGS - HAND OPERATED DOOR 37

LIST OF DRAWINGS

SECTION IX - DRAWINGS - POWER OPERATED DOOR

DRAWING NO. TITLE

D-WK-492-A81 HORIZONTAL ELECTRO-HYDRAULIC WATERTIGHT DOOR

C-WK-437-57 MOTOR PUMP

C-WK-471-44 PRESSURE SWITCH

D-WK-756-35 ELECTRICAL WIRING DIAGRAM

B-WK-723-88 WARNING HORN

B-WK-488-24 MOTOR OUTLINE DATA AND PUMP ADAPTOR

B-WK-756-23 LOCAL CONTROL SWITCH

C-WK-723-94 LIMIT SWITCH

D-WK-756-22 PILOT HOUSE STATION (2) DOOR

SECTION IX - DRAWINGS - POWER OPERATED DOOR

PAGE NO.

D-WK-492-A71

C-WK-364-4

A-WK-672-131

HYDRAULIC COMPONENTS FOR SLIDING WATERTIGHT DOOR 33

MECHANICAL INDICATOR 34

SPARE PARTS LIST, PAGES 1 & 2 OF 2 35 &36

SECTION IX- DRAWINGS - POWER OPERATED DOOR

D-WK-492-A69 HAND HYDRAULIC HORIZONTAL WATERTIGHT DOOR 37

-~ SECTION I

GENERAL INFORMATION

A. THE BASIC USE OF THIS TYPE OF DOOR IS TO SEAL OFF BULKHEADS IN CASE OF

EMERGENCY. IT HAS THE FOLLOWING CHARACTERISTICS:

POWER OPERATED DOOR

1. IT IS FLAMETIGHT AND WATERTIGHT.

2. IT CAN BE OPERATED FROM A REMOTE POSITION AND FROM LOCAL POSITIONS EACH

SIDE OF THE BULKHEAD.

3. IN CASE OF POWER FAILURE, IT CAN BE OPERATED MANUALLY FROM LOCAL POSITIONS

EACH SIDE OF THE BULKHEAD AND FROM A REMOTE POSITION ABOVE THE DOOR

4. IT CONFORMS WITH U. S. COAST GUARD REGULATIONS FOR CLASS III DOORS.

HAND OPERATED DOOR

1. IT IS FLAMETIGHT AND WA TERTIGIIT.

2. IT CAN BE OPERATED MANUALLY FROM LOCAL POSITIONS EACH SIDE OF THE

BULKHEAD AND FROM A REMOTE POSITION ABOVE THE MARGIN LINE.

3. IT CONFORMS WITH U.S. COAST GUARD REGULATIONS FOR CLASS II DOORS.

SECTION II

DESCRIPTION AND PRINCIPLES OF OPERATION

A. MECHANICAL EQUIPMENT

1. THE POWER OPERATED DOOR, PAGE 24, AND THE HAND OPERATED DOOR, PAGE 37, MOVE

IN A HORIZONTAL DIRECTION AND ARE GUIDED BY GUIDE RAIL ASSEMBLIES. THE TOP

AND BOTTOM EDGES OF THE DOOR AND FRAME ARE MACHINED TO A MATCHING TAPER

WHICH ALLOWS AUTOMATIC "SEALING OFF" OF THE CLEAR OPENING WHEN DOOR IS

CLOSED.

2. A MECHANICAL INDICATOR, PAGE 34, INDICATES THE POSITION OF THE DOOR AT THE

REMOTE MANUAL CONTROL STATION. THIS CONSISTS OF A TRANSMITTER MOUNTED AT

THE DOOR, CONNECTED TO A FLEXIBLE CABLE WIDCH IS RUN TO A RECEIVER

INDICATOR AT THE REMOTE STATION.

B. HYDRAULIC EQUIPMENT - POWER OPERA TED DOOR - REFER TO DETAIL "B" PAGE 24.

1. THE DOOR IS ACTUATED BY A HYDRAULIC CYLINDER, PRESSURE BEING SUPPLIED BY A

MOTOR DRIVEN PUMP AND, IN THE ABSENCE OF ELECTRIC POWER OR IN CASE OF

EMERGENCY, BY ROTARY HAND PUMPS.

2. THE LOCAL HAND PUMP, LOCATED BESIDE THE DOOR, IS REVERSIBLE TO PERMIT

OPENING OR CLOSING THE DOOR. IF CONDITIONS PERMIT, A SINGLE PUMP WITH DUAL

SHAFT EXIENSIONS MAY BE USED TO ALLOW OPERATION FROM EITHER SIDE OF THE

BULKHEAD.

TWO PUMPS WITH SINGLE SHAFT EXIENSION MAY BE PROVIDED IF NECESSARY. HAND

CRANKS, MOUNTED ON THE SHAFT, ALLOW THE OPERATOR TO ROTATE THE PUMP.

REVERSAL OF ROTATION REVERSES THE DIRECTION OF TRAVEL OF THE DOOR.

3. THE REMOTE HAND PUMP, LOCATED AT THE REMOTE, MANUAL CONTROL STATION, IS

UNI-DIRECTIONAL AND, IN ACCORDANCE WITH U.S.C.G. REGULATIONS, ALLOWS FOR

CLOSING OF THE DOOR ONLY.

4. THE MOTOR, PUMP AND HYDRAULIC CONTROL VALVES ARE MOUNTED ON A COMMON

BASE TO BE MOUNTED BESIDE THE DOOR.

5. A TWO GALLON OIL EXPANSION TANK IS MOUNTED ABOVE AND ADJACENT TO THE

REMOTE MANUAL PUMP. THIS MAKES UP THE DIFFERENCE IN DEMAND OF OIL WHEN

OPENING OR CLOSING THE DOOR DUE TO THE DIFFERENCE IN AREA OF THE TWO SIDES

OF THE PISTON.

6. THE AUXILIARY OIL TANK IS USED TO INSURE DOOR OPERATION IN THE EVENT OF

RUPTURE OF HYDRAULIC TANK LINE MORE THAN 10' FROM DOOR.

SECTION 11-(Continued)

DESCRIPTION AND PRINCIPLES OF OPERATION (Continued)

C. HYDRAULIC EQUIPMENT- HAND OPERATED DOOR-REFER TO DETAIL "B" PAGE 37

1. OPERATION AND ACTUATION OF THIS DOOR IS IDENTICAL TO THE POWER OP.ERATED

DOOR, PARAGRAPH B, EXCEPT THAT IT DOES NOT HA VE THE "POWER OPERA TED"

FEATURE.

D. ELEC1RIC EQUIPMENT - REFER TO DRAWING PAGE 27.

1. A REVERSING CONTROLLER ST ARTS AND STOPS THE MOTOR - PUMP UNIT, ALLOWING

ROTATION OF THE PUMP IN EITHER DIRECTION.

2. THE CONTROLLER IS ENERGIZED BY TWO LOCAL CONTROL SWITCHES MOUNTED ONE

ON EACH SIDE OF THE BULKHEAD IN CLOSE PROXIMITY TO THE DOOR.

3. RED AND GREEN LIGHTS LOCATED AT THE REMOTE STATION, AND ENERGIZED BY LIMIT

SWITCHES MOUNTED AT EACH END OF THE DOOR TRAVEL, INDICATE DOOR POSITION AS

FOLLOWS:

REDLIGHT

GREEN LIGHT

FLASHING RED LIGHT -

DOOR OPEN

DOOR CLOSED

DOOR INTERMEDIATE

4. THE DOOR MAY BE OPENED OR CLOSED FROM THE LOCAL STATION, BUT CLOSED

ONLY FROM THE REMOTE STATION.

SECTION III

INSTALLATION PROCEDURE

A. HYDRAULIC BOLTED TYPE OF DOOR

THE WALZ & KRENZER SLIDING WATERTIGHT DOOR AND FRAME IS A PRECISION PIECE OF

MACHINERY. EACH DOOR AND FRAME ASSEMBLY IS STRESS RELIEVED PRIOR TO

MACHINING AND, AFTER ASSEMBLY, IS HYDRO-ST A TI CALLY TESTED TO FULL DESIGN HEAD

PRESSURE PRIOR TO LEA YING OUR WORKS.

THESE DOORS HA VE A SEALING GASKET, CONSEQUENTLY, WHEN THE DOOR IS WEDGED

INTO THE CLOSED POSITION THERE IS FULL MET AL TO MET AL CONT ACT BETWEEN THE

BRASS FACE 0 F THE DOOR AND STEEL SEAT OF THE FRAME. THE DOOR ASSEMBLY IS

ESSENTIALLY THE EQUIVALENT OF A LARGE GATE VALVE. ANY DISTORTION AFFECTS THE

WATERTIGHT INTEGRITY. (SEE U.S.C.G. TEST FOR TIGHTNESS, PAR. NO. 163.001-6 (b)(5) :

"The degree of contact between door and frame shall be such as to exclude a .003" feeler gauge or its clear passage through and between the sealing surfaces at any point around the sealing perimeter."

THE FOLLOWING PRECAUTIONS SHOULD BE NOTED:

1. NEVER COMPLETELY WELD MOUNTING ANGLE INTO POSITION UNTIL MOST OF THE

HEAVY SHIP' S STRUCTURE IN THE VICINITY OF THE BULKHEAD, OVERHEAD DECKS AND

SUPERSTRUCTURE ARE WELDED IN PLACE. ADDITIONAL WELDING IN THE AREA AND

ADDITIONAL WEIGHT OF SUPERSTRUCTURE COULD CAUSE DISTORTION OF THE DOOR

FRAME MAKING IT NECESSARY TO CUT THE LINER FREE AND REWELD AND RETRUE

THE SURF ACE IN ORDER TO COMPLY WITH THE CLEARANCES REQUIRED BY THE U.S.

COAST GUARD. r ·

2. IT IS WISE TO LEA VE THE DOOR FRAME AND MOUNTING ANGLE TACKED IN PLACE

UNTIL MOST OF THE WORK IN THE AREA IS COMPLETED. THESE TACKS CAN BE EASILY

BROKEN PERMITTING THE DOOR, FRAME AND LINER TO ALIGN ITSELF FREELY BEFORE

FINAL WELDING.

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SECTION III (Continued)

INSTALLATION PROCEDURE (Continued)

B. REMOVE DOOR FROM FRAME PROPER. LAY OUT OPENING IN BULKHEAD TO FIT MOUNTING

ANGLE AS CLOSE AS POSSIBLE.. CUT OPENING WITH ACETYLENE TORCH. WARPING MAY BE

PREVENTED BY FOLLOWING FLAME WITH A SMALL STREAM OF WATER, APPROXIMATELY 6"

(l5CM) BACK OF TORCH. MOUNTING ANGLE SHOULD BE CUT AND FIITED TO THE FRAME.

MOUNTING ANGLE, OF COURSE, SHOULD BE FLAT AND TRUE.

CLAMP MOUNTING ANGLE TO FRAME AND AVOIDING EXCESSIVE HEAT, TACK WELD AT 12"

INTERVALS.

PLACE ENTIRE UNIT AGAINST BULKHEAD AND TACK WELD FRAME ANGLE ONLY AT

CONTACT POINTS. DO NOT ATTEMPT TO DRAW BULKHEAD INTO ALIGNMENT WITH LINER.

CAREFULLY PACK SHIMS INTO ALL OPEN SPACES BETWEEN THE BULKHEAD AND ANGLE.

LEAVING FRAME ATTACHED, WELD ANGLE TO BULKHEAD AS FOLLOWS:

1. WELD ONE BEAD UPWARDS APPROXIMATELY 12" (30CM) LONG ON THE OPERATOR'S

LEFT FROM THE DOOR SIDE OF BULKHEAD.

2. CHANGE TO OPPOSITE SIDE OF BULKHEAD, WELDING ONE BEAD UPWARDS

APPROXIMATELY 12" (30CM) FROM THE BOTTOM OF THE OPERATOR'S LEFT.

3. ON THE SAME SIDE OF THE BULKHEAD, WELD ONE BEAD UPWARDS APPROXIMATELY 12"

(30CM) LONG ON THE OPERATOR'S RIGHT.

4. CHANGE TO DOOR SIDE OF BULKHEAD, WELD ONE BEAD APPROXIMATELY 12" (30CM).

PROCEED, BEGINNING WITH OPERATION 1, UNTIL ANGLE IS COMPLETELY WELDED ON BOTH

SIDES, BOTH FORWARD AND AFT SIDES OF BULKHEAD.

FOLLOW A SIMILAR PROCEDURE IN WELDING TOP AND BOTTOM.

REMOVE FRAME FROM ANGLE. CHECK ANGLE FOR FLATNESS. NOTE THAT ANY DEVIATION

IN FLATNESS WILL BE CARRIED THROUGH TO THE FRAME WHEN IT IS SECURELY BOLTED TO

THE BULKHEAD WHICH WOULD, IN TURN, DISTORT THE FRAME SEAT AND RESULT IN A

POORLY FITTED DOOR.

THE ABOVE SHOULD NOT BE INTERPRETED AS A DEFINITE REQUIREMENT, BUT AS A

PROCEDURE THAT HAS BEEN TRIED AND FOUND TO WORK SATISFACTORILY. IN ANY CASE,

EVERY EFFORT SHOULD BE MADE TO KEEP THE HEAT AT A MINIMUM AND DISTRIBUTED AS

EVENLY AS POSSIBLE.

CHECK DOOR SEAT AND FRAME SEAT TO SEE THAT THEY ARE FREE FROM DAMAGE. A

REASONABLE AMOUNT OF GREASE SHOULD BE APPLIED TO THE SEAT OF THE FRAME AND

THE SEAT AND WEDGING SURF ACE OF THE DOOR.

LOCATE DOOR IN FRAME AND REPLACE WEDGE PLATES. BOLT GUIDE RAILS TO FRAME,

INST ALL AND WELD SUPPORT BRACKET (FURNISHED BY SHIPYARD) AS SHOWN ON

ASSEMBLY DRAWING. INSURE THAT GUIDE RAILS ARE PROPERLY ALIGNED WITH FRAME

BEFORE WELDING. LOCATE CYLINDER MOUNTING BRACKET, AS SHOWN ON DOOR

ASSEMBLY DRAWING, AND SECURE ACCORDINGLY. REINFORCE BULKHEAD IN WAY OF

CYLINDER MOUNTING BRACKET TO INSURE SUFFICIENT RIGIDITY. INSTALL CYLINDER.

THESE INSTRUCTIONS ARE BASED ON THE INSTALLATION OF A HORIZONTAL DOOR SIMILAR

PROCEDURE WILL APPLY TO VERTICAL DOOR INSTALLATION.

INSTALLATION PROCEDURE (Continued)

C. HYDRAULIC EQUIPMENT

WE WILL NOT ATTEMPT TO MAKE FITTING RECOMMENDATIONS EXCEPT THAT THEY SHOULD

BE OF A CLASS SATISFACTORY FOR THE PRESSURE SHOWN AND ACCEPTABLE TO

REGULATORY AGENCIES. ALL LINES ARE SUBJECT TO HIGH PRESSURE EXCEPT THE 3/4"

(l.88CM) LINE BETWEEN THE SUPPLY TANK AND THE VALVE BLOCK, AND ALL DRAIN LINES.

THE TUBING SIZES SPECIFIED ON DRAWING, PAGE 23, ALLOW FOR A REASONABLE NUMBER

OF BENDS AND FITTINGS AND IN NO CASE SHOULD A SMALLER SIZE BE USED:

NOTE: IN THE EVENT THAT TUBE RUNS EXCEED 60 FEET (1800CM) OR EXCESSIVE BENDS

ARE USED, TUBING SIZE MUST BE INCREASED ACCORDINGLY.

IT IS MOST IMPORTANT THAT ALL HYDRAULIC LINES BE CLEANED AND FLUSHED BEFORE

CONNECTING TO ANY OF THE PUMPS, VAL YES OR CYLINDERS. DUE TO THE NATURE OF THE

HYDRAULIC CIRCUIT IT MAY BE NECESSARY TO DISASSEMBLE ALL COMPONENTS IN THE

SYSTEM IF THE SYSTEM BECOMES CONTAMINATED. USE A BENDING TOOL TO MAINTAIN

MAXIMUM AREA. TUBING SHOULD BE CAREFULLY AND PROPERLY FITTED, MAKING SURE

THAT NO BURRS, CHIPS OR OTHER FOREIGN MATTER ARE ALLOWED IN THE SYSTEM.

TUBING SHOULD BE INSTALLED AT A SLIGHT PITCH WITH VENT VALVES PLACED AT THE

HIGHPOINT.

IN THE FOLLOWING PARA GRAPHS, ALL ITEMS IDENTIFIED BY # REFER TO DETAIL "C", PAGE

24. MAKE CONNECTIONS AS SHOWN ON DETAIL "B''. WHEN INSTALLATION IS COMPLETE,

FILL TANK WITH A GOOD GRADE OF PETROLEUM BASE HYDRAULIC FLUID HAVING A

VISCOSITY OF 250-325 SSU AT 100 degrees F. OPEN VALVES #19 AND1f20.

CAUTION: DO NOT OPERATE DOOR WITH VALVES #19 AND #20 CLOSED AS THIS WILL

BACK-PRESSURE THELOCAL HAND PUMP AND CAUSE THE SHAFT SEALS TO

BLOW.

INSTALLATION PROCEDURE (Continued)

IT IS ASSUMED THAT THE DOOR IS IN AN OPEN POSITION. OPEN VENT ON MOUNTING END

OF CYLINDER, ROTATE CRANK IN CLOSING DIRECTION AT REMOTE STATION UNTIL OIL

FLOWS FREELY FROM VENT. CLOSE VENT AND CONTINUE TO ROTATE CRANK UNTIL DOOR

CLOSES.

REMOVE 1/4" (.375CM) SOCKET HEAD PIPE PLUG FROM DRAIN LINE IN QUAD CHECK VAL VE,

ITEM H7 PAGE 24, UNTIL OIL FLOWS. OPEN VENT AT ROD END OF CYLINDER. ROTATE

CRANK ON LOCAL PUMP IN OPENING DIRECTION UNTIL ALL AIR IS EMITIED. CLOSE VENT

AND ROTATE CRANK UNTIL DOOR IS OPENED. IT MAY BE NECESSARY TO VENT MOUNTING

END OF CYLINDER AND ROTATE LOCAL PUMP EMITTING AIR AND CLOSING DOOR; THEN

REVERSE OPERATION UNTIL SYSTEM IS FREE FROM AIR. IT IS IMPERATIVE THAT ALL AIR IS

OUT OF THE SYSTEM TO INSURE PROPER OPERATION.

IF THE DOOR DOES NOT CLOSE PROPERLY, FOREIGN MATIER WILL UNDOUBTEDLY BE

FOUND UNDER ONE OF THE CHECKS OR CHECK MAY BE STICKING DUE TO CONTAMINATION

OF OIL, ALLOWING OIL TO ESCAPE FROM THE CLOSING SIDE OF THE CIRCUIT. A SIMILAR

CONDITION IN THE OPENING SIDE OF 1HE LINE WOULD AFFECT THE OPENING OF THE DOOR.

REFER TO DRAWING PAGE 33, ITEMS #9 AND #12.

THE CLOSING CIRCUIT IS A DUPLICATE OF THE OPENING CIRCUIT EXCEPT THAT, FROM THE

REMOTE STATION, THE DOOR MAY BE CLOSED ONLY. A SHUTfLE VALVE IS USED TO

CONTROL THE FLOW OF OIL, ITEM 10 OF PAGE 33. THIS VALVE IS AUTOMATICALLY

OPERATED BY A PILOT PRESSURE CREATED BY THE PUMPS AS ROTATION IS CHANGED. THE

CIRCUIT IS SO ARRANGED THAT A FEW SECONDS ARE REQUIRED TO ALLOW THE SHUTfLE

VAL VE TO SHIFT FROM ONE POSITION TO ANOTHER. THEREFORE, ·IT IS DESIRABLE TO

DELAY REVERSING ROTATION OF LOCAL PUMPS FOR A FEW SECONDS AS AN IMMEDIATE

CHANGE OF ROTATION TENDS TO INCREASE DELAY IN MOVEMENT OF DOOR RATHER THAN

DECREASE IT.

INSTALLATION PROCEDURE (Continued)

THE LOCAL PUMP, #5, DRAWING PAGE 33, IS A HIGH CAPACITY, LOW SPEED, GEAR TYPE

POSITIVE DISPLACEMENT, REVERSIBLE PUMP. IN THE EVENT THAT THE SHIP STRUCTURE IS

SUCH THAT IT IS NOT POSSIBLE OR PRACTICAL TO EXTEND THE CRANK THROUGH THE

BULKHEAD FOR OPERATION ON THE OPPOSITE SIDE, TWO PUMPS MAY BE SUPPLIED IN LIEU

OF ONE, BOTH OF WHICH WOULD HA VE SINGLE SHAFT EXTENSIONS AND COULD BE

LOCATED IN ANY CONVENIENT LOCATION NEAR THE DOOR APPROVED BY THE U.S. COAST

GUARD. WHERE TWO LOCAL PUMPS ARE USED, INCREASE TUBING SIZE TO 3/4" (1.88CM) O.D.

BETWEEN VAL VE BLOCK AND PUMPS. A HINGED TYPE HANDLE MAY BE FURNISHED IN

LIEU OF THE RIGID HANDLE IN THE EVENT THAT SPACE IN THE PASSAGEWAY IS LIMITED.

THIS DESIGN HAS ALSO BEEN APPROVED BY THE U.S. COAST GUARD.

THE REMOTE PUMP, #6, . DRAWING PAGE 33, IS A DUPLICATE IN CONSTRUCTION AND

CAPACITY OF PUMP #5, EXCEPT THAT IT IS NON-REVERSIBLE INASMUCH AS IT IS ONLY

NECESSARY TO CLOSE THE DOOR FROM THE REMOTE STATION. A SURGE TANK, #1

DRAWING PAGE 33, 2 GALLON (7.6 LITERS) CAPACITY, IS PROVIDED TO BE INSTALLED NEAR

THE REMOTE PUMP TO ALLOW FOR A SLIGHT SURPLUS OF OIL AND ALSO THE EXPANSION

AND CONTRACTION RESULTING FROM THE UNEQUAL ENDS OF THE CYLINDER DUE TO

PISTON DISPLACEMENT. SHUT-OFF VALVE H-19 AND H-20, PAGE 24, ARE RECOMMENDED SO

THAT OIL IN THE TANK MAY BE SHUT OFF IN THE EVENT OF LEAKAGE IN THE JOINTS OR IF

REPAIRS MAY BE NECESSARY. AN AUXILIARY TANK IS MOUNTED WITHIN 10' OF DOOR TO

INSURE DOOR OPERATION EVEN IN THE EVENT OF RUPTURED HYDRAULIC TANK LINE

BEYOND 10' OF DOOR.

A SINGLE DOUBLE-ACTING CYLINDER, #4, DRAWING PAGE 33, IS 2-3/4" (6.88CM) BORE WITH A

STROKE SUIT ABLE FOR THE OPENING OF THE DOOR SHOWN. THIS CYLINDER IS EQUIPPED

WITH A NON-ADJUSTABLE PACKING GLAND AND WIPER WHICH PREVENTS LEAKAGE AT

EITHER THE OPERATING PRESSURE WHICH IS A MAXIMUM OF 800 P.S.I. (56KG/SQ.CM) OR THE

STATIC HEAD WHICH MAYBE AS LOW AS 3 P.S.I. (.21KG/SQ.CM)

INSTALLATION PROCEDURE (Continued)

DEPENDING ON THE LOCATION OF REMOTE STATION. REMOVAL OF CYLINDER ROD NUT

WILL ALLOW FOR OPENING AND CLOSING THE DOOR IN THE EVENT OF MECHANICAL

FAILURE. MOTOR PUMP, #H-9, DRAWING PAGE 24, IS AN INTERNAL AND EXTERNAL PUMP

DRIVEN BY A TORQUE TYPE MOTOR VAL VE ASSEMBLY, PUMP AND MOTOR ARE MOUNTED

ON A COMMON BASE, DETAIL "B" PAGE 24. HYDRAULIC CONNECTIONS HAVE BEEN MADE

AT THE FACTORY AND ENTIRE ARRANGEMENT HAS BEEN TESTED AS A COMPLETE UNIT.

PRESSURE SWITCH, DRAWING PAGE 26, HAS BEEN SET AT APPROXIMATELY 750 P.S.I.

IMPORTANT NOTES:

1. WHERE POSSIBLE WE SUGGEST THAT HYDRAULIC LINES TO THE CYLINDER BE RUN

UNDER THE DOOR TO MINIMIZE THE POSSIBILITY OF TRAPPING AIR. BLEED VALVES

SHOULD BE INSTALLED WHERE HIGH POINTS OCCUR IN THE PIPING.

2. IT IS MOST IMPORTANT THAT ALL HYDRAULIC LINES BE CLEANED AND FLUSHED

BEFORE CONNECTING TO ANY OF THE PUMPS, VAL VE BLOCKS, CYLINDERS, ETC.

3. DO NOT REMOVE THE PLUGS FROM ANY OF THE COMPONENTS UNTIL READY TO MAKE

CONNECTIONS.

4. DUE TO THE NATURE OF THE HYDRAULIC CIRCUIT, IF THE ABOVE PROCEDURE IS NOT

FOLLOWED IT MAY REQUIRE COMPLETE DISASSEMBLY OF ALL COMPONENTS TO

REMOVE ANY ENTRAINED FOREIGN PARTICLES.

5. THE OIL IN THIS CIRCUIT DOES NOT HA VE UNI-DIRECTIONAL FLOW AND FOR THIS

REASON CANNOT BE FLUSHED AFTER COMPONENTS ARE CONNECTED.

D. HYDRAULIC EQUIPMENT- HAND OPERATED DOOR ONLY - REFER TO PAGE 37.

THE SAME PROCEDURE APPLIES TO THIS DOOR AS THAT OF THE POWER OPERATED DOOR

REFER TO PARAGRAPH "B'' AND DISREGARD ALL DATA PERTAINING TO POWER EQUIPMENT.

INSTALLATION PROCEDURE (Continued)

E. REMOTE INDICATOR, PAGE 34.

1. LOCATE AND SECURE·TRANSMITTING UNIT ON TOP GUIDE RAIL ASSEMBLY AS SHOWN ON

DRAWING. DO NOT ATTACH LEVER TO DOOR YET.

2. LOCATE AND SECURE INDICATING UNIT WHEREVER DESIRED.

3. INSTALL CONDUIT BETWEEN INDICATOR AND TRANSMITTER USING THE CONNECTORS

SUPPLIED. KEEP THE NUMBER OF BENDS IN THE CONDUIT TO A MINIMUM. RADIUS OF

EACH BEND TO BE A MINIMUM OF 5,, (12.5 CM). A BEND BLOCK FOR THIS PURPOSE IS

F1JRNISHED FOR THIS INSTALLATION. BE SURE TO REMOVE BURRS FROM END OF

CONDUIT. CONNECTORS ARE F1JRNISHED TO BE USED BETWEEN LENGTHS.

4. SUPPORT CONDUIT AT A MAXIMUM OF 4 FOOT (120CM) INTERVALS, CLIPS FOR WHICH

ARE F1JRNISHED FOR THIS INSTALLATION.

5. IN THE EVENT THAT CONDUIT IS TO PASS THROUGH WATERTIGHT BULKHEAD OR DECK,

STUFFING GLANDS ARE SUPPLIED IF ORDERED

6. REMOVE SPENT TUBE FROM TRANSMITTER, AND REMOVE POINTER AND NYLON GUIDE

FROM INDICATOR PASS CABLE THROUGH CONDUIT TO BE SURE THAT ALL BURRS AND

FOREIGN MATTER ARE REMOVED. WIPE CABLE CLEAN AND LUBRICATE WITH A LIGHT

GREASE, KEYSTONE #44 OR EQUIVALENT. REINSERT UNTIL IT PROTRUDES THROUGH TOP

OF INDICATOR

7. WITH INDICATOR ATTACHED TO TRANSMITTER ARM AND IN VERTICAL POSITION

WITH RESPECT TO GUIDE RAIL ASSEMBLIES ADJUST INDICATOR GUIDE SO

POINTER HOLE IS CENTERED BETWEEN "CLOSE" AND "OPEN,,. MARK CABLE AT

TOP OF GUIDE. REMOVE INDICATOR HOUSING AND CUT CABLE AT MARK.

8. REINSTALL HOUSING. POSITION GUIDE ON CABLE. INSTALL SET SCREWS AND POINTER.

9. ATTACHINDICATORARMTODOORUSINGINDICATORSTUD. OPENDOOR. CUTCABLETO

LENGTH LEAVING 3-1/2" (8. 75CM) EXTENDING THROUGH THE TRANSMITTER SPENT TUBE

OPENING.

10. CHECK INSTALLATION TO SEE THAT ALL CONNECTIONS ARE TIGHT.

INSTALLATION PROCEDURE (Continued)

F. ELECTRICALEQUIPMENT

ELECTRICAL EQUIPMENT IS TO BE INSTALLED AND WIRED IN ACCORDANCE WITHDRAWING

PAGE 27. LIMIT SWITCHES ARE TO BE INSTALLED AS SHOWN ON ASSEMBLY DRAWING.

ADJUST CLOSING LIMIT SWITCH TO OPEN CIRCillT 1/8" (.313CM) BEFORE DOOR REACHES

CLOSED POSITION. THE PRESSURE SWITCH STOPS 1RA VEL OF THE DOOR; THE LIMIT SWITCH

PREVENTS HUNTING AND ACTUATES SIGNAL LIGHTS. WHEN THE ABOVE IS COMPLETE,

ACTUATE MOTOR WITII POWER AND CHECK ROTATION WITH LOCAL CONTROL. IF

REQillRED, REVERSE ARMATURE LEADS AT REVERSING CONTROLLER. CLOSE DOOR FROM

THE LOCAL STATION CHECKING PRESSURE. PRESSURE SWITCH SHOULD OPEN CIRCUIT AT

APPROXIMATELY 750 (53KG/SQ.CM) P.S.I. ADJUST ONLY IF NECESSARY. ADJUST STOP BOLTS

TO DOOR AND TIGHTEN JAM NUTS. CHECK CLOSING LIMIT SWITCH FOR PROPER

ADJUSTMENT. OPEN DOOR AND CHECK ADJUSTMENT OF OPEN LIMIT SWITCH. IT MAY NOW

BE NECESSARY TO BLEED ADDITIONAL AIR FROM CYLINDER. AS PREVIOUSLY STATED,

DOOR WILL NOT OPERATE PROPERLY WITH AIR IN THE SYSTEM. AFTER THIS OPERATION IS

COMPLETE, CHECK OPERATION AND SIGNAL LIGHTS FROM THE REMOTE STATIONS. LEAVE

SWITCH IN CLOSED POSITION AND CHECK LOCAL OPERATION. IF WIRING IS CORRECT, DOOR

WILL OPERATE ACCORDING TO REGULATIONS.

THE ELECTRICAL EQUIPMENT DOES NOT REQUIRE ANY SPECIAL ATTENTION, THEREFORE,

NORMAL PROCEDURE SHOULD BE FOLLOWED.

SECTION IV

TEST PROCEDURE

A. FOR TESTING PROCEDURE, OPERA TE DOOR IN ACCORDANCE WITII SECTION V, OPERA TING

INSTRUCTIONS.

B. 1. ALL HYDRAULIC COMPONENTS HA VE BEEN FACTORY TESTED.

2. WORKING PRESSURE FOR THIS SYSTEM IS 750 (53KG/SQ.CM) P:S.I. RELIEF VALVES FOR

THIS SYSTEM ARE SET AT SLIGHTLY ABOVE THIS.

3. DUE TO CIRCUIT DESIGN IT IS NECESSARY TO DISCONNECT ALL COMPONENTS AND PLUG

ENDS OF PIPING IF TEST PRESSURE FROM AN EXTERIOR SOURCE IS USED. IF THIS IS NOT

DONE, DAMAGE CAN RESULT TO THE RELIEF VALVE, PRESSURE SWITCH, VALVE SPRINGS

AND SEALS, AND TO THE PUMP SEALS.

SECTIONV

OPERATING INSTRUCTIONS

ELECTRO-HYDRAULIC SLIDING WATERTIGHT DOORS

A. LOCAL POWER OPERATION

1. ENGAGE EXTERNAL DISCONNECT ON MOTOR CONTROLLER, PAGE 27.

2. TO OPEN - MOVE LOCAL CONTROL SWITCH HANDLE TO "OPEN" POSITION AND HOLD

UNTIL DOOR IS OPEN AND MOTOR STOPS. UPON RELEASING, HANDLE WILL RETURN

TO NEUTRAL.

3. TO CLOSE - MOVE LOCAL CONTROL SWITCH HANDLE TO "CLOSE" POSITION. HANDLE

WILL ST A Y IN THIS POSITION. WARNING HORN WILL SOUND FOR 5-10 SECONDS AND

THEN DOOR WILL AUTOMATICALLY CLOSE AND MOTOR WILL SHUT OFF. HANDLE

MUST BE RETURNED TO NEUTRAL MANUALLY.

NOTE: IF HANDLE IS LEFT IN CLOSE POSITION, DOOR MAY BE OPENED FROM OPPOSITE

SIDE OF BULKHEAD BUT WILL AUTOMA TI CALLY CLOSE AFTER WARNING HORN

SOUNDS FOR 5-10 SECONDS.

B. REMOTE POWER OPERATION

TO CLOSE - MOVE DOOR CONTROL SWITCH TO "CLOSE". DOOR WILL AUTOMATICALLY

CLOSE AND GREEN INDICATOR LIGHT WILL REMAIN LIGHTED AT END OF CYCLE.

NOTE: (a) IF SWITCH IS LEFT IN "CLOSE" POSITION, DOOR MAY BE OPENED LOCALLY

BUT WILL AUTOMATICALLY CLOSE WHEN CONTROL SWITCH RETURNS TO

NEUTRAL.

(b) DOOR MAY NOT BE OPENED FROM THE REMOTE POSITION.

SECTION V -(Continued)

OPERATING INSTRUCTIONS

ELECTRO-HYDRAULIC SLIDING WATERTIGHT DOORS

C. REMOTE HAND PUMP

1. ROTA TE HAND PUMP AS SHOWN ON ROTATION PLATE MOUNTED THEREON. THIS

ROTATION PLATE INDICATES THE DIRECTION THE PUMP MUST ROTATE TO EITHER

"OPEN" OR "CLOSE".

NOTE: IT MAY BE NECESSARY TO ROTATE HAND CRANK VERY FAST TO BREAK DOOR

LOOSE WHEN INITIALLY OPENING.

D. REMOTE HAND PUMP

ROTATE HAND PUMP IN "CLOSE" DIRECTION AS SHOWN ON ROTATION PLATE. DOOR

POSITION WILL SHOW ON MECHANICAL INDICATOR MOUNTED ABOVE PUMP.

NOTE: DOOR MAY BE CLOSED ONLY FROM THIS REMOTE LOCATION.

CAUTION: DO NOT OPERATE DOOR WITH SHUT-OFF VALVES, ITEMS H-19 AND H-20,

CLOSED AS THIS WILL BACK-PRESSURE THE LOCAL HAND PUMP AND CAUSE

THE SHAFT SEALS TO BLOW.

SECTION VI

OPERATING INSTRUCTIONS

HAND HYDRAULIC SLIDING WATERTIGHT DOORS

A. LOCAL HAND OPERATION

l. ROTATE HAND PUMP AS SHOWN ON ROTATION PLATE MOUNTED THEREON. THIS

ROTATION PLATE INDICATES THE DIRECTION THE PUMP MUST ROTATE TO EITHER

"OPEN" OR "CLOSE".

NOTE: IT MAY BE NECESSARY TO ROTATE HAND CRANK VERY FAST TO BREAK DOOR

LOOSE WHEN INITIALLY OPENING.

B. REMOTEHANDPUMP

1. ROTATE HAND PUMP IN "CLOSE" DIRECTION AS SHOWN ON ROTATION PLATE. DOOR

POSITION WILL SHOW ON MECHANICAL INDICATOR MOUNTED ABOVE PUMP.

NOTE: DOOR MAY BE CLOSED ONLY FROM THIS REMOTE LOCATION.

SECTION VJJ

A. MECHANICAL

MAINTENANCE

SEE LUBRICATION CHART, PAGE 22, FOR TYPE AND FREQUENCY OF LUBRICATION FOR

MECHANICAL PARTS.

1. OPEN-CLOSE CYLINDER, NO. 4 DRAWING PAGE 33.

MAINTENANCE IS VERY SELDOM NECESSARY ON THIS ITEM, BUT IN CASE OF SEVERE

LEAKAGE, REPAIR SHOULD BE UNDERTAKEN BY A TECHNICIAN UNDER SHOP

CONDITIONS AS FOLLOWS:

a) REMOVE TRU-ARC RETAINER, ITEM 4-9, USING TRU-ARC PLIERS SUPPLIED IN SPARE

PARTS.

b) REMOVE GLAND, ITEMS 4-11 AND 4-12, BY APPLYING SMALL AMOUNT OF AIR

PRESSURE TO CYLINDER PORT.

c) IF LEAKAGE WAS OBSERVED AROUND THE ROD, REPLACE ITEMS 4-6, AND KLOZURE, ITEM4-8.

d) IF OIL WAS BY-PASSING AROUND THE PISTON (IT TAKES MANY YEARS TO WEAR OUT

TO THIS POINT) REPLACE CUPS, ITEMS 4-1, AND THE STATIC "O" RING, ITEM 4-2.

e) WHEN REASSEMBLING, EXIREME CARE MUST BE OBSERVED TO AVOID DAMAGE TO

THE "O" RING, ITEM 4-5, AND CUPS, ITEM 4-1, ON TRU-ARC GROOVE AND CYLINDER

PORTS, AND TO AVOID SCRATCHING THE ROD AND CYLINDER BORE.

2. MOTOR PUMP, #5 DRAWING PAGE 33 .

LOCAL HAND PUMP, #6, DRAWING PAGE 33.

IT IS SUGGESTED THAT, IN CASE OF MALFUNCTION, PUMP BE SENT BACK TO WALZ &

KRENZER FOR OVERHAUL. HOWEVER, SEALS MAY BE REPLACED IN CASE OF LEAKAGE

AROUND THE SHAFT. THIS SHOULD BE UNDERTAKEN ONLY BY QUALIFIED TECHNICIANS

UNDER SHOP CONDITIONS.

3. CONTROL VALVES, DRAWING PAGE 33, ITEMS 9, 10, 11, 12 & 13.

THESE VALVES ARE SUPPLIED, BOLTED TOGETHER IN A SANDWICH TYPE OF STACK.

NORMALLY, IF PROPER SYSTEM CLEANLINESS AND INSTALLATION PROCEDURE IS

OBSERVED, THE ONLY MAINTENANCE REQUIRED WOULD BE THE OCCASIONAL

REPLACEMENT OF AN "O" RING BETWEEN THE VALVES OR ALUMINUM GASKET AND "O"

RING UNDER CAPS AND PLUGS. THIS MAY BE ACCOMPLISHED BY DISASSEMBLING

VALVE STACK OR REMOVING CAPS AND PLUGS AND REPLACING "O" RINGS AND GASKET

AS REQUIRED.

SECTION VIJ-(Continued)

B. HYDRAULIC - (Continued)

MAINTENANCE

4. PRESSURE SWITCH, DRAWING PAGE 26.

THIS VAL VE IS ALSO BOLTED TOGETHER WITHIN THE VAL VE BLOCK AND REQUIRES

SYSTEM CLEANLINESS. THE ONLY MAINTENANCE REQUIRED WOULD BE THE "O" RINGS

BETWEEN THE VAL YES, ALUMINUM GASKET AND "O" RING UNDER THE CAPS AND PLUGS

OR REPLACEMENT OF THE MICRO SWITCH.

C. ELECTRICAL EQUIPMENT

1. LOCAL CONTROL SWITCH, DRAWING PAGE 30.

CONT ACT BLOCKS ARE SUPPLIED IN THE SPARE PARTS AND MAY BE REPLACED IF FOUND

NECESSARY.

2. LIMIT SWITCH, NO. 51ML7

THE ONLY MAINTENANCE REQUIRED WOULD BE THE REPLACEMENT OF THE BASIC

MICRO-SWITCH DT-2R711-A7. THIS IS ACCOMPLISHED BY REMOVING THE COVER AND

SWITCH MOUNTING SCREWS AND REPLACING DEFECTIVE BASIC SWITCH.

3. BALDOR ELECTRIC MOTOR

DUE TO THE SHORT OPERATING CYCLE AND THE FACT THAT THE BEARINGS ARE PRE

LUBRICATED, LITTLE OR NO MAINTENANCE SHOULD BE REQUIRED. HOWEVER,

BEARINGS AND SEALS ARE SUPPLIED AS SPARES AND SHOULD BE REPLACED ONLY BY

QUALIFIED TECHNICIANS UNDER SHOP CONDITIONS.

SECTION Vll-(Continued)

MAINTENANCE-( Continued)

4. CONTROLLER, DRAWING PAGE 27.

NORMAL MAINTENANCE TO THE CONTROLLER WOULD BE OCCASIONAL REPLACEMENT

OF A BLOWN CONTROL CIRCUIT FUSE OR A BURNED-OUT HEATER. THE ENCLOSURE MAY

BE OPENED BY DISENGAGING EXTERNAL DISCONNECT, LOOSENING THE HOLD-DOWN

BOLTS AND SWINGING OPEN THE COVER.

CAUTION: DO NOT ATTEMPT TO OPEN ENCLOSURE WITH EXTERNAL DISCONNECT

ENGAGED AS DAMAGE TO THE INTERNAL SWITCH ACTUATOR WILL RESULT.

FUSES ARE REPLACED BY USING FUSE PULLERS. THE HEATER COILS ARE EXTRACTED BY

REMOVING THE SCREW HOLDING THEM IN PLACE. REPLACEMENT OF CONT ACTS, SHUNT

COIL OR TRANSFORMER SHOULD BE UNDERTAKEN ONLY BY A QUALIFIED TECHNICIAN.

SECTION VII (Continued)

LUBRICATION CHART

HYDRAULIC. HORIZONTAL- SLIDING WATERTIGHT DOOR

PART

LUBIUCATED

SEALING SURF ACES

AROUND PERIPHERY

OF DOOR

DOOR ROLLERS

PINS ALEMITE

STD. FITTING

SEALING SURF ACES

AROUND PERIPHERY

OF DOOR

LUBRICANT AMOUNT APPLICATION FREQUENCY

LIGHT PETROLEUM THIN FILM APPLY WITH EVERY TWO

BASE GREASE BRUSH OR RAG WEEKS

GOOD GRADE AS NECESSARY GREASE GUN EVERY TWO

OF GREASE WEEKS

HYDRAULIC, VERTICAL- SLIDING WATERTIGHT DOOR

LIGHT PETROLEUM

BASE GREASE .

THIN FILM

APPLY WITH EVERY TWO

BRUSH OR RAG WEEKS

SECTION VIII

TROUBLE SHOOTING GUIDE

REMEDY

l. MOTOR SHUTflNG OFF

BEFORE DOOR COMPLETELY

CLOSED.

PROBLEM

PRESSURE SWITCH SET TOO LOW.

2. MOTOR WlLL NOT SHUT OFF RELIEF VAL VE SETTING TOO LOW.

AT END OF CYCLE. SHOULD BE HIGHER THAN

PRESSURE SWITCH.

3. MOTOR REPEATEDLY SHUTS "CLOSE" LIMIT SWITCH ARM NOT

OFF & STARTS UP AGAIN AT ADJUSTED PROPERLY.

END OF CLOSE CYCLE.

4. MOTOR WILL NOT SHUT OFF "OPEN" LIMIT SWITCH ARM

AT END OF OPEN CYCLE. NOT ADJUSTED PROPERLY.

5. DOOR WILL NOT OPEN UNDER DOOR CLOSING TOOF AR INTO

FULL POWER. TAPERED SEAT.

6. DOORMOVINGVERYSLOW l. RELIEFVALVESETTOOLOW.

AND WITH JERKY MOTION.

7. EXCESSIVE LENGTH OF TIME

TO REVERSE DIRECTION.

8. POWER UNIT NOT STARTING

2. QUAD CHECK BALLS NOT

SEATING PROPERLY.

3. SHUTfLE UNIT BLEED VAL VE

OPEN TOO FAR. PART OF OIL

PASSING TO TANK.

4. AIR IN HYDRAULIC SYSTEM.

AIR IN SYSTEM.

l. OVERLOADRELAYMAY

PROBABLE CAUSE

SETTING SHOULD BE BETWEEN

720 & 800 P.S.I. (50.6 & 56.2KG/SQ.CM)

SETTING SHOULD BE BETWEEN

900 & 1000 P.S.l. (63.3 & 70.3 KG/SQ.CM)

ABOVE VALVE BLOCK.

SET LIMIT SWITCH ARM SO IT

ACTUATES JUST PRIOR TO PRESSURE

SWITCH SHUTfING OFF MOTOR.

ADJUST LIMIT SWITCH ARM SO IT

WILL ACTUATE AND STOP MOTOR.

SET STOP BOLTS SO BRASS OVERLAPS

STEEL SEAT BY 3/4" (l.875CM) MIN. TO

I" (2.5CM) MAX.

I. SEE REMEDY FOR PROBLEM 2.

2. RESEATSTAINLESSSTEELBALLS

USING HAMMER AND BRASS ROD.

3. CLOSE NEEDLE VALVES UNTIL

THEY BOTTOM COMPLETELY.

BACK OFF 1/8 TO 1/4 TURN.

4a CHECK LEVEL OF OIL IN

EXPANSION TANK

b. BLEED OFF AIR AT ALL HIGH

POINTS.

CHECK LEVEL OF OIL IN EXPANSION

TANK. ADD OIL IFNECESSARY.

l. PRESS RESET BUTfON

2. FUSES IN THE CONTROLLER 2. REPLACE BAD FUSE.

MAY BE BLOWN.

3. CONT ACTS IN LOCAL CONTROL 3. REPLACE CONT ACT BLOCK.

SWITCH MAY BE DEFECTIVE.