SY-100 FUEL FLOW SENSOR USER`S MANUAL Description
Contents
1. 101 9 21 mw wus TERIS MUI M313AMO13 00148 6564 11 1 021 0 2 1 1XZ 1 ONIMVYG 1031NO9 60622 ON ALIO H138vzri3 Bm S OMINOO MOTI M33JOH zum 0 2 OON ma HIM 3nddns 8108 2 1 1d 59 7501 401 55012035809 6 AKINIAI INVISNOO HLM NOLY NE 1531 UNNIN 0 AAO XO Z3 ALVY 80713 CGY nes SF 30 2025 UVY MOL SIGNIS ANYIN NUSAS 8 SSAI 30 SHNOH 2 1 SONVAGLNWN JALIROD 40 6 5531 30 SHOH Z LIN 5300 Hd 002 7081 1531 009 OQLZ OOS 006 OSF 1531 SUCSt I Hid INSIGHTS 193 79 SNY L LL OLS UN SU 4 08 2 1 3 30 J5VSSVd MOT 01 dii DOAS 611 2 1 Wd 309 IDOI SMIHSTIE AGS 30V NOISONQI NAYI WOUOfRISWOO 30 SRGIYN 7 XDAYSONG 0 341 92051 4 20 BIW d NOLL VOLU NOI 90207 1 11 NOULOSUSNI 4 05 74 30 014 ONY 7 0 5 01 UON INTIM 114 015 1 SHN SWA 50 331 018 ALRIENTUSI 1 SSY D 8 106 5 300065 1 ONY 91 015 1 SNOUVOOSES ANVIDIN Ed 05 23955384 HY X08 519030 091 01 OF 3 lv Od SZ 5531 0308 E0001 080 py 0 022. an Hd 001 PNRA 19 09 009 NANCY on 5 RON 7 SHL 30 NOLO 221 DON 303 3501 38 01 51 SNMYHO SHL i SSHOU YOLID3dS
3. KOK MINNY dS VL OL NOUVUSIT D HLM 3137900 ONY LIVHS S380 80104 30 SISISNOO 005 51 1 09 10 N d WIBIGSSY 57 TSLUVd 3uYdS C3ONJPPIOOIE G BAZ QS A 02907130 SONY ONV A008 331388011 8 HOV O3nidans SI0G 2 WI 58 7501 3901 5 580123400 5571 YO SHNOH 2 1 1 3AUD3HNOD JO 8 1005 901 954 OSL 4001 303 OBd GLC 9NUS3I DU VISDNOAH 031530034 ALISOOSA 33810 SSTIND 531521 NOLVBOITY2 1 01 SLNGRGUINOSY 1531 5 55 Hd P LE 30108 SH3HSVM 2 TWNUNO BATTS NOISONDL SONRIVGG 30 5 X 4008 NO CHAG NOUVOLLN3OI 80209 1 18 45 22 415 788 9 Old ONY 812 015 708 B 3108 11 015 SINY SWA 30 3471 018 ALTRBVTES 1 SSY TO 8 3441 H 106 01S YN 6 ONY L 91 01S UN NOLLVWBIA 009 0005 SY NOUJDHISNOO AAYN TUIS IWYS 1338 OL INNA SNOLLVOLID3dS AYLIN 2 SONY FOOD 04 954 OSZ S39N 4 FOSI 954 SLE 38056384 00d HY 01 1 9N YH3dO Hdd 00 054 SZ 5531 HOLOS C301 30 UinviVad3 0096 OL 092 JO XO ZT OFZ IONYY MO 002 0 99888 4 18 7304 9 4 TUND 1
4. 100 2 00 214 Flow Sensor Model No Fuel System Interface Installation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench 2 00 HP214 SY100 Flowmeter Technical Manual HO 3 8 SY100 Flow Sensor 3 8 5 100 150 300 1 2 ANSI Raised Face Flange 5 0 1 16 face to face Monolithic Fail safe Construction MIL E 16884G 375 750 PSIG 45 to 360 Gallons per Hour 18 to 540 Gallons per Hour 2 of Reading 45 to 360 GPH 0 5 of Reading 45 to 360 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1350 ohms 10 MS 3106F 10SL 4S Designed to meet Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N HO 3 8 112 S Y 100 5 SY100 Flowmeter Technical Manual Flow Sensor Model No Fuel System Interface Installation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench A 6 HO 1 4 SY100 Flow Sensor HO 1 4 SY
5. 214 SY100 Flowmeter Technical Manual 3 INSTALLATION 3 1 Introduction This chapter provides instructions for installing the SY 100 Fuel Flow Sensor The SY 100 Fuel Flow Sensor is composed of the following parts e Appropriately sized SY 100 Flow Sensor e Mating Connector e User Supplied Signal Cabling Planning for the installation site selection unpacking special tools installation and installation checkout are described 3 2 Installation Drawings Refer to APPENDIX A for the outline drawing of the SY 100 Flow Sensors Refer to Figure 2 for the installation piping requirements SHIPS PIPING UPSTREAM DOWNSTREAM 0 PIPE DIAMETE MINIMUM PIPE DIAMETE MINIMUM Figure 2 Flow Sensor Installation Piping Requirements 2 00 HP214 5 SY100 Flowmeter Technical Manual 3 3 Flow Sensor Site Selection The following provides a summary of the site selection criteria for successful installation and operation of the SY 100 Fuel Flow Sensor Note A fuel flow strainer is required to be installed in the fuel system upstream of the flowmeter The SY 100 Fuel Flow Sensor relies on the strainer to capture large foreign matter which could otherwise foul the turbine rotor The flow sensor shall be installed in the fuel flow line A horizontal orientation is suggested but not required The site chosen for installation of the flow sensor shall maintain adequate access for
6. AND THERE ARE NO AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THE AGREEMENT PURCHASER S SOLE AND EXCLUSIVE REMEDY IS THE REPAIR AND OR REPLACEMENT OF NONCONFORMING GOODS AS PROVIDED IN THE PRECEDING PARAGRAPHS HFC SHALL NOT BE LIABLE FOR ANY OTHER DAMAGES WHATSOEVER INCLUDING INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES HFC 9708 5 100 Flowmeter Technical Manual FORWARD The manual contains the information required to install operate maintain and repair a SY 100 Fuel Flow Sensor The SY 100 Fuel Flow Sensor is intended to be used with the SY 100 Naval Fuel Flowmeter System which is used to provide ships personnel with the ability to monitor fuel oil consumption at selected points on the vessel The SY 100 Fuel Flow Sensor is of a fail safe construction where a failure of the flow sensor will not result in a blockage of fuel flow nor will a portion of the Flow Sensor come adrift This manual is organized to permit ease of use Individual sections are provided to cover General Information Operation Functional Description Preventative Maintenance Troubleshooting Installation and Corrective Maintenance A parts list section is also provided Illustrations are used to improve the clarity of the information presented 2 00 HP214 SY100 Flowmeter Technical Manual TABLE OF CONTENTS SY 100 TECHNICAL NEAINUIAL ee dede eb a e drin erue 1 FABLE OF CONTEN Ges Ree
7. IROUBLESHOOTINGI itis ade Mace aq cape 15 5 1 Introductionis ere Ure 15 5 2 Flow Sensor Troubleshooting Procedures eese entente nete 15 6 CORRECTIVE MAINTENANCE ep 17 17 6 2 Flow Sensor Removal isinen eres eatre aee EENE ETS aE t eoon EAER E en E EA eaS RE Aar 17 0 3 Flow Sensor Cleaning eodera ertet ene pep een eret uen eb ene 17 6 4 Flow Sensor Reinstallation eder etre rne retraite tte teer t PRENNE dp tuner e eeu e evo 19 PARTS DAS T 21 7 1 Introduction intr eem Renee nei TEES 21 7 2 Listof Attaching eee 21 7 3 Recommend 5 5 5 2 e a ated eu ie 22 7 4 Listof Manufactuters rrt rh etr PR Re TR REA IR PERSE 22 7 5 Parts Location 11115 ete eI tnr ie ree 23 PRP PES DIG INA eere eie d etx uel 1 SY100 Flow Sensor Specification Summary esee 1 SY100 Flow Sensor Outline Drawings w Specifications eerte A 7 2 00 HP214 i SY100 Flowmeter Technical Manual Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 LIST OF FIGURES BIOW Sensor ERREUR D Flow Sensor Installation Pi
8. 100 150 300 1 2 ANSI Raised Face Flange 5 0 1 16 face to face Monolithic Fail safe Construction MIL E 16884G 375 750 PSIG 21 to 210 Gallons per Hour 15 to 270 Gallons per Hour 2 of Reading 21 to 210 GPH 0 5 of Reading 21 to 210 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1350 ohms 10 MS 3106F 10SL 4S Designed to meet Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N HO 1 4 112 S Y 100 2 00 HP214 SY100 Flowmeter Technical Manual SY100 Flow Sensor Outline Drawings w Specifications List of Control Drawings 2 00 HP214 Drawing Description Number SY 100 402 HO 1 2X1 1 2 3 120 T 1M F3SS SY 100 FLOWMETER HO1 2204 17 X 17 SY100 FLOWMETER HO3 4 2204 3 4 X 3 4 SY100 FLOWMETER HO1 2 2204 1 2 X 1 2 SY100 FLOWMETER HO3 8 2204 1 2 X 3 8 SY100 FLOWMETER 1 4 2204 1 2 X 1 4 SY100 FLOWMETER 7 3AMO13 OOLAS 1 X 7 1 ONIMVHO 10MLNOO 60642 ON ALID HL38VZIT13 S IOHINOO 3440 3lvd NOW 5532 3837 SNOBAdN 000 HONI 834 08 01 OF 530089 HLM 39v4 SIVA 00145 95224 N d QILNDYN HONIM 5 WL X
9. Spanner Wrench The information will be presented by listing the observed condition followed by the required action to be taken 6 2 Flow Sensor Removal Note The recommended spanner wrench or equal is required to disassemble and remove the internals kit from the flow sensor housing Isolate and drain the fuel system prior to removal of internals kit Disconnect the signal cable from the flow sensor pickup Remove the flange mounting bolts Remove the flow sensor from the line 6 3 Flow Sensor Cleaning The recommended cleaning procedure applicable to the fuel sensor is presented in the following steps Note that this operation requires interruption of the fuel service line and as such should be scheduled in advance Note The calibration of the SY 100 Fuel Flow Sensor will be impaired is any of the rotor blades are lost or bent Observe special handling to avoid damage to this assembly during cleaning operations 2 00 HP214 17 SY100 Flowmeter Technical Manual 1 Study Figure 6 prior to disassembling the flow sensor Use the spanner wrench to remove the retaining nut on the flowmeter inlet The internals kit may now be removed from the flowmeter housing PICKUP COIL gt WITH LOCKNUT HOUSING INTERNALS KIT 227 FLOW gt lt 1 a RETAINING NUT 1 SPACER FLOW FLOW STRAIGHTNER STRAIGHTNER UPSTREAM DOWNSTREAM IDENTIFICA
10. and welding slag Position the flow sensor into the ship s piping observing that the flow direction marking on the flow sensor body matches the direction of fuel flow in the installation Position gaskets and align the flange bolts in such a position that the pickup coil shall be positioned to permit ease of assembly of the interconnecting cabling and is clear of obstructions Place nuts on all flange bolts and tighten securely Place the prepared interconnecting cables on the pickup and tighten 2 00 HP214 19 SY100 Flowmeter Technical Manual 20 2 00 HP214 SY100 Flowmeter Technical Manual 7 PARTS LIST 7 1 Introduction This section provides a summary of the parts lists for the SY 100 Fuel Flow Sensor Provisioned parts recommended for the system are also presented Parts location illustrations are shown on the assembly drawings 7 2 List of Attaching Hardware The following table lists the required attaching hardware for the installation of the flow sensor The required mating electrical connector is supplied with each sensor Manufacturer and Description Quantity Part Number Flange Mounting Bolts 8 Flange Mounting Washers 16 Flange Mounting Nuts 8 Alpha PN 3241 Signal Cable NSN 6145 00 056 8184 TBD MS3106F 10SL 4S Flow Pickup Coil Mating Connector 1 Cannon Notes 1 Mating connector is supplied with each sensor 2 Cable types were chosen to achieve the desired electromagnetic attenuation Armored cable
11. calibration of the SY 100 Fuel Flow Sensor will be impaired if any of the rotor blades are lost or bent Observe special handling to avoid damage to this assembly during cleaning operations 1 Isolate and drain the fuel system prior to removal of the internals kit 2 Disconnect the signal cable from the flow sensor pickup coil 3 Remove the eight flange mounting bolts and remove the flow sensor from the line 4 Study Figure 3 prior to disassembling the flow sensor Use the appropriately sized spanner wrench to remove the retaining nut on the flowmeter inlet The internals kit may now be removed from the flowmeter housing PICKUP COIL amp WITH LOCKNUT RETAINING NUT BOUSING FLOW gt 1 P FLOW FLOW STRAIGHTNER STRAIGHTNER UPSTREAM DOWNSTREAM IDENTIFICATION PLATES Figure 3 Flow Sensor Disassembly 5 The upstream flow straightener and spacer are a slip fit on the shaft and may now be removed from the internals kit 6 Remove any fibrous matter which may be attaching itself on the rotor blades or wrapped about the shaft on either side of the rotor 7 The internals kit may be cleaned in a turbine oil solvent PT 37 alcohol or other approved cleaning solvent to remove any sticky residue 12 2 00 4 SY100 Flowmeter Technical Manual 4 3 Flow Sensor Inspection The following is a summary procedure for inspection of the flow se
12. d Ad es 1 1 SAFETY SUMMARY idee e di lii 1 GENERAL INFORMATION 5 5 3 otio aaa 1 1 1 122 0 1 153 Reference Data eite ten piede tenet et e e e eee 1 2 FUNCTIONAL DESCRIPTION 3 2T MAO UCONN uis Mee eter 3 272 Principle Operation 1 Cei dett IE 3 3 AINS TATE ALON 5 3 1 Introduction 5 3 2 Installation Drawings cette eee 5 3 3 Flow Sensor 5 6 5616 222 eerte 3 4 Unpacking and Packing ete 7 3 5 Blow Sensor Installatioh 8 326 Installation Checkout en 9 4 PREVENTATIVE MAINTENANCE Se es 11 4 1 Introduction ete RR Ge eet ri te E RERO eU 11 4 2 Flow Sensor Cleaning e rece Re e RE E RERO AL 11 4 5 Flow Sensor 066110 e 13 274 LUT CALI OM dre tede 14 4 5 Flow Sensor iB testes peu ERR LEO HR 14 5
13. maintenance and shall include provisions for safe drainage of fuel oil which is required during maintenance operations In addition the location shall be chosen to maximize the distance from any nearby sources of electrical interference Such sources include motors transformers fans pumps electric valves ignition controls and power wiring The flow sensor shall be at least two feet away from any such source of interference The flow line upstream of the flowmeter shall be modified to provide a minimum of 10 pipe diameters of pipe of the meter size The mating connection on the piping shall consist of an appropriately sized flange of the required pipe size to MIL STD 777 The flow line downstream of the flowmeter shall be modified to provide at least 5 pipe diameters of pipe of the meter size The mating connection on the piping shall consist of an appropriately sized flange of the required pipe size to MIL STD 777 A user supplied interconnecting cable is required to run from the flow sensor to the electronics unit The cable run shall provide for adequate support and mechanical protection to strain relieve the cable 2 00 214 SY100 Flowmeter Technical Manual 3 4 Unpacking and Packing Caution When unpacking or packing the flow sensor assembly care must be taken to see that no foreign matter is permitted to enter the flowmeter housing If packing is required protect the flanges with protective material Cardboard wi
14. s sole and exclusive remedy is the repair and or replacement of nonconforming goods as provided in the following paragraphs In the event Purchaser believes the goods are defective the goods must be returned to HFC transportation prepaid by Purchaser within twelve 12 months after delivery of goods or eighteen 18 months for goods delivered outside the continental United States for inspection by HFC If HFC s inspection determines that the workmanship or materials are defective the goods will be either repaired or replaced at HFC s sole determination free of additional charge and the goods will be returned transportation paid by HFC using the lowest cost transportation available Prior to returning the goods to HFC Purchaser must obtain a Returned Material Authorization RMA Number from HFC s Customer Service Department within 30 days after discovery of a purported breach of warranty but no later than the warranty period otherwise such claims shall be deemed waived See the Return Requests Inquiries Section of this manual If HFC s inspection reveals the goods are free of defects in material and workmanship or such inspection reveals the goods were improperly used improperly installed and or improperly selected for service intended HFC will notify the purchaser in writing and will deliver the goods back to purchaser upon i receipt of Purchaser s written instructions and ii the cost of transportation If Purchaser does no
15. types offering improved physical protection with the required braided shield may be substituted 3 Alternate sources for MIL C 5015 connectors may be used 2 00 HP214 21 SY100 Flowmeter Technical Manual 7 3 Recommend Spare Parts The following table lists the recommended spare parts Meter Internals Kit peces 1 1 2 100 1 1 2 3 120 T INTERNALS SY 100 PC24 45G SY 100 1 5 100 HO1 4 60 T INTERNALS SY 100 PC13 75G SY 100 HO3 4 SY 100 HO3 4 2 5 29 T INTERNALS SY 100 PC24 45G SY 100 HO1 2 SY100 HO1 2 1 10 T INTERNALS SY 100 PC24 45G SY 100 HO3 8 S Y 100 HO3 8 75 6 T INTERNALS SY 100 PC24 45G SY 100 HO1 4 SY100 HO1 4 35 3 5 T INTERNALS SY 100 PC24 45G SY 100 If specific meter not found in the above list check the specification drawings in APPENDIX A for the meter in question 7 4 List of Manufacturers The following table lists the manufacturers of subassembly components utilized in the sensor and their identifying CAGE code numbers CAGE Code Name and Address Hoffer Flow Controls Inc 33321 107 Kitty Hawk Lane P O Box 2145 Elizabeth City NC 27909 Alpha Wire Corp 711 Lidgerwood Avenue Elizabeth NJ 07207 92194 ITT Cannon 666 East Dyer Road Santa Ana CA 92702 Internals Kit consists of rotor cones shaft hangers sleeve and complete calibration w tag 22 2 00 HP214 SY100 Flowmeter Technical Manual 7 5 Parts Location Illustration Refer to Figure 7 for the
16. 5 100 FUEL FLOW SENSOR USER S MANUAL Description Operation Installation And Maintenance Instructions HP 214 March 1998 H HOFFER FLOW CONTROLS INC Perfecting Measurement 107 Kitty Hawk Lane P O 2145 Elizabeth City North Carolina 27906 2145 1 800 628 4584 252 331 1997 FAX 252 331 2886 www hofferflow com Email info hofferflow com SY100 Flowmeter Technical Manual Notice HOFFER FLOW CONTROLS INC MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE This manual has been provided as an aid in installing connecting calibrating operating and servicing this unit Every precaution for accuracy has been taken in the preparation of this manual however HOFFER FLOW CONTROLS INC neither assumes responsibility for any omissions or errors that may appear nor assumes liability for any damages that may result from the use of the products in accordance with information contained in the manual HOFFER FLOW CONTROLS policy is to provide a user manual for each item supplied Therefore all applicable user manuals should be examined before attempting to install or otherwise connect a number of related subsystems During installation care must be taken to select the correct interconnecting wiring drawing The choice of an incorrect connection drawing may result in damage to the system an
17. Flowmeter Technical Manual 10 2 00 HP214 SY100 Flowmeter Technical Manual 4 PREVENTATIVE MAINTENANCE 4 1 Introduction This section provides a description of the cleaning and inspection procedure applicable to the SY 100 Fuel Flow Sensors The SY 100 Fuel Flow Sensor does not require regularly scheduled preventative maintenance Observe any scheduled organizational level maintenance instructions dictated by the requirements of the Planned Maintenance System PMS established by the Naval Sea System Command for fuel system components Caution Do not allow fuel spills when servicing the flow sensor Isolate and drain the fuel line prior to starting work Observe all safety practices during performance of the cleaning and maintenance operations 4 2 Flow Sensor Cleaning Fibrous debris in the fuel system which is passed by the fuel strainer over a period of time may accumulate in the fuel flow sensor Such an accumulation of matter may result in a deterioration in performance or a stalled rotor condition if not cleaned periodically Note The recommended spanner wrench or equal is required to disassemble and remove the internals kit from the flow sensor housing The recommended cleaning procedure applicable to the fuel sensor is presented in the following steps This operation requires interruption of the service line and should be scheduled in advance 2 00 HP214 11 SY100 Flowmeter Technical Manual Note The
18. HLM 311402 3A3TIS ONY SUJONVH LIVHS SINOD 580108 0 SISISNOD 00 45 51 41 1 01 427 4 N d WIEKGSSY STWNUGLNI 6 34 06 3822 15 11 53 S39NVi A008 HALIN HOVE C3nadns 5106 2 78 59 1501 3901 0103800 5531 80 5 2 1 32NVINIVIE 02 30 6 5531 0 SHNOH Z YUN 4005 03 064 OSL 4001 404 954 ONUSIL 218150 031530038 415005 AGHLO SSTINN 53153 0 MALYM INOJ Di 153 SH3N3LHOIYMIS MOT ON INON NOILVINGIUO 2 1 30 5 1HOIVHIS MY3HISNAOO Jdid 2 1 30 01 LHOWALS SIN3KGHInO38 SNLNDON Y 55 817 539NVJ 55 91 55 91 SH3N31HDIVMIS MOL 55 Hd WLI NOLLOMRUSNOD 30 STVRGLYR 4008 NO MHAI OxIO3U NOLLVOLIULN3CH 80259 1 1 NOLLOSdSNI 24 4015 71 JO 014 8 2 015 1 B 310N ONITTM LLL QLS UN SINY SAYR 30 340 018 CALEY V 55810 B H 108 Q1S A 252086 H 1 015 9 1 0 00145 SY NOWINULSNOD AAYN TULS IWYS L33N OL 1708 5 0345 Z 530 14 FOOF 03 954 OSL S39NY M FOGI 801 954 SLE chifSS3Hd X08 OL 209 SNUYN3dO 012 9 064 SZ NYHL 5531 50109 133001 5354 30 X
19. N3ICPATO3H 9 55 980 SINY 55 BIE 55 BIC 5 55 7 1 SH3HSYM Z ONY ONIHSNG SATIS 30088VO NOLSONNL NOLLOMMLSNOD 30 SIWRELYA E 008 NO KALI ONLD3T3 NOLLYOULLNGG 80507 NOLLOdSNI 24 015 7 8 JO Old ONY 8 2 015 3108 1 018 30 5 V SSY 8 H 105 01S IN 6 ONY 1 3441 L 91 0 5 f 001 0045 Sv NOUOfRHLSNOO AAYN TULS LIIR OL 17108 SNOUVOHID3dS Z 5 4006 03 954 OSL S39NY U FOSI 01 954 38055184 30084 3091 01 10 09 054 SZ 5531 035001 JOYO 0 MSOF ALMEVLIY3JJ Hd9 096 01 Sy 3O XOT ALRN3N 14041 Gr ANININ 39NYH 2 02 or8891 1 1 Gnd 9 1 VEI 1 HOFFER FLOW CONTROLS INC ELIZABETH CITY NC 27909 CONTROL DRAWING 3 4 X 3 4 SY100 FLANGES WELDED CONSISTS OF ROTOR CONES SHAFT HANGERS AMD SLEEVE COMPLETE WIH CALIBRATION AND COL MAGNETIC P N 24 400 5 100 4 8 i 83 1 LET Ta ipu Y ONIMVHO IOMINOO 60622 ALIO HI38VZI13 STOHLNOO 3440 SOSA 9022 10 00145 091 0124 N d
20. SOF ALTIBVLV3dOH 012 01 12 30 XOT 042 30 14051 OIZ ANAKYN 140507 iz WANNI MOH 2 0 99888 1 108 1304 9 4 VAM ONN TWIN 1 X 2 1 8 00145 IONLNOD 60645 ON ALIO H138VZI13 S IOMLNOO 3440 alts 6 0008 022 8 ow ono 08 01 6 53130089 HLM 30y3 35 LLL QLS WN 00155 96 4224 N d QU3NDVM 109 HINI 1GNNYdS OWL NOLVUSII HLM 3LT3dNOO BATTS SH39NYH LIVHS SINOD HOLOM 30 SISISNOD 00145 51 4114 1 9 417 8 N d 55 S TYNHSLNI Sid 3uvdS 023876 3812 15 10 OOA S3ONY4 ONV A008 83138014 8 HOVI HLA G3ndans 5106 2 10 5 1501 3901 SUQLOSNNOD 1 SS31 SUNOH 2 1 1 40 8 553 0 Z HLN 9 1006 OBd 1 4031 954 6 5 ONS 2 VLSONOAH 13153038 218005 H3HLO SSTINN 531521 2 1 01 38 1531 5 SHIN3LHDIYMIS MOLY SLNN NOLLYINGRO 3did 2 1 30 5 346 LHOWMLS MYRUISNMOG 2 1 JO DL NAN 344 1 15 SE
21. TION PLATES Figure 6 Flow Sensor Disassembly 2 The upstream flow straightener and spacer are a slip fit on the shaft and may now be removed from the internals kit 3 Remove any fibrous matter which may be attaching itself on the rotor blades or wrapped about the shaft on either side of the rotor 4 The internals kit may be cleaned in a turbine oil solvent alcohol or other approved cleaning solvent to remove sticky residue 5 Reinstall the spacer and flow straightener on the shaft and insert the internals into the flowmeter housing 6 Apply thread locking Adhesive 242 blue to the retaining nut and threads into housing 18 2 00 HP214 SY100 Flowmeter Technical Manual 6 4 Flow Sensor Reinstallation Caution Do not allow fuel spills when installing the flow sensor Drain the fuel line prior to starting any work Observe all safety practices during performance of the installation Do not use the flow sensor body as a Spool Piece during any welding operations while installing Suitable fasteners for the flange ratings shall be obtained from ship s stores in advance of starting the work Suitable gaskets two required shall be prepared to match the bolt pattern and meter inlet bore The mating flange and piping segments shall be free of weld protrusions into the piping Such obstructions may create turbulence and result in flow measurement errors The ship s fuel piping shall be cleaned of all loose foreign material
22. anual 2 00 HP214 SY100 Flowmeter Technical Manual 1 GENERAL INFORMATION 1 1 Introduction The SY 100 Fuel Flow Sensor is part of a general purpose fuel oil flow metering system for use on shipboard installations The system provides a number of display indications of fuel usage and has an auxiliary output for optional connection to remote data acquisition system This technical manual provides descriptive data operation maintenance installation instructions and repair parts lists for the SY 100 Fuel Flow Sensor 1 2 Equipment Description The SY 100 Fuel Flow Sensor is a rugged turbine flowmeter that when used with an appropriate electronics unit provides a rugged fuel flow measurement system The intended use of this flow sensor is to aid in providing accurate fuel measurements associated with the operations of shipboard power and propulsion plant boilers The SY 100 Fuel Flow Sensor is capable of accurately sensing the flow of MIL F 16884G Marine Diesel Fuel and similar low viscosity fuels The flow sensor has a fail safe construction and minimal pressure drop in the event of fouling This adds to the ease of installation for shipboard service A meter fuel bypass line is not required 1 3 Reference Data APPENDIX A details the flow measurement range capabilities and lists the reference data for the SY 100 Fuel Flow Sensors 2 00 HP214 1 SY100 Flowmeter Technical Manual 2 2 00 214 SY100 Flowmeter Technica
23. ction MIL E 16884G 375 750 PSIG 150 to 1740 Gallons per Hour 90 to 2100 Gallons per Hour 2 of Reading 150 to 1740 GPH 0 5 of Reading 150 to 1740 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1350 ohms 10 MS 3106F 10SL 4S Designed to meet Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N HO 3 4 112 S Y 100 a ee SY100 Flowmeter Technical Manual Flow Sensor Model No Fuel System Interface Installation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench A 4 HO 1 2 SY100 Flow Sensor HO 1 2 SY100 150 300 1 2 ANSI Raised Face Flange 5 0 1 16 face to face Monolithic Fail safe Construction MIL E 16884G 375 750 PSIG 60 to 600 Gallons per Hour 36 to 720 Gallons per Hour 2 of Reading 60 to 600 GPH 0 5 of Reading 60 to 600 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1350 ohms 10 MS 3106F 10SL 4S Designed to meet Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N 1 2 112 5
24. d or one of the components Please review the complete model number of each item to be connected and locate the appropriate manual s and or drawing s Identify all model numbers exactly before making any connections A number of options and accessories may be added to the main instrument which are not shown on the basic user wiring Consult the appropriate option or accessory user manual before connecting it to the system In many cases a system wiring drawing is available and may be requested from HOFFER FLOW CONTROLS This document contains proprietary information which is protected by copyright AII rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of HOFFER FLOW CONTROLS INC HOFFER FLOW CONTROLS policy is to make running changes not model changes whenever an improvement is possible This affords our customers the latest in technology and engineering The information contained in this document is subject to change without notice RETURN REQUESTS INQUIRIES Direct all warranty and repair requests inquiries to the Hoffer Flow Controls Customer Service Department telephone number 252 331 1997 or 1 800 628 4584 BEFORE RETURNING ANY PRODUCT S TO HOFFER FLOW CONTROLS PURCHASER MUST OBTAIN A RETURNED MATERIAL AUTHORIZATION RMA NUMBER FROM HOFFER FLOW CONTROLS CUSTOMER SERVICE DEPARTMENT IN ORDER TO AVOID PROCESSING DELAYS The ass
25. ents shall be free of weld protrusions into the piping Such obstructions may create turbulence and result in flow measurement errors The ships fuel piping shall be free of all loose foreign material and welding slag Orient the flow sensor into the piping observing that the flow direction markings on the flow sensor body matches the direction of fuel flow in the installation Position gaskets and align the flange bolts in such a position that the pickup coil shall be oriented to permit ease of assembly of the interconnecting cabling and is clear of obstructions Place nuts on all flange bolts and tighten securely Place the prepared interconnecting cable on the pickup coil and tighten 8 2 00 214 SY100 Flowmeter Technical Manual 3 6 Installation Checkout Caution Fuel leaks may occur if improper gaskets are used or flange bolts are not secure Check bolt tightness prior to pressurizing the fuel line Check the workmanship on all modifications to the ship s piping prior to pressurizing the fuel line Note It is recommended that the fuel lines be cleaned of any debris prior to installing the flowmeter Large pieces of debris may result in a Stalled Turbine Rotor which may cause damage to the Turbine Rotor resulting in loss of calibration for the flow sensor Verify that the flowmeter has been installed with the flowmeter housing orientation and flow arrow marking in the direction of fuel flow 2 00 HP214 SY100
26. igned RMA number should then be marked on the outside of the return package and on any correspondence FOR WARRANTY RETURNS please have the FOR NON WARRANTY REPAIRS OR following information available BEFORE contacting CALIBRATIONS consult HOFFER FLOW HOFFER FLOW CONTROLS CONTROLS for current repair calibration charges Have 1 P O number under which the product was the following information available BEFORE contacting PURCHASED HOFFER FLOW CONTROLS 2 Model and serial number of the product under 1 P O number to cover the COST of the warranty and repair calibration 3 Repair instructions and or specific problems relative 2 Model and serial number of the product and to the product HFC 9708 3 Repair instructions and or specific problems relative to the product LIMITED WARRANTY HOFFER FLOW CONTROLS INC HFC warrants HFC s products goods described in the specifications incorporated in this manual to be free from defects in material and workmanship under normal use and service but only if such goods have been properly selected for the service intended properly installed and properly operated and maintained This warranty shall extend for a period of 1 year from the date of delivery to the original purchaser or eighteen 18 months if the delivery to the original purchaser occurred outside the continental United States This warranty is extended only to the original purchaser Purchaser Purchaser
27. l Manual 2 FUNCTIONAL DESCRIPTION 2 1 Introduction The SY 100 Fuel Flow Sensor is an appropriately sized specially constructed turbine flowmeter which when used with an appropriate electronics unit is intended to provide ships company with fuel flow and consumption information 2 2 Principle of Operation The turbine flow sensor consists of a vaned rotor assembly which is supported on a shaft held in place by rotor supports within the flowmeter housing The rotor is free to spin on a carbide sleeve bearing A magnetic pickup coil is positioned on the exterior of the flowmeter housing above the rotor These components are shown in the following figure Pickup Coil 277722 12222222 Rotor Support Rotor Figure 1 Flow Sensor Cut away 2 00 HP214 ES SY100 Flowmeter Technical Manual As the fuel oil passes through the flowmeter it causes the vaned rotor assembly to spin at a rate proportional to the fuel oil flow rate The pickup coil generates a pulsing signal as the rotor spins The frequency of this signal is proportional to flow rate while summation of this signal is proportional to flow total The number of pulses produced per gallon by the flow sensor is termed the calibration factor or K Factor This calibration factor is marked on the equipment label for each flow sensor and is unique to that particular flow sensor 4 2 00
28. ll suffice for this purpose Place protective covers over electrical connectors and pack into a strong carton with shock absorbing material 2 inches deep on all surfaces Remove the flow sensor from the carton Remove the end covers from the flanges Remove the protective cover from the pickup coil connector only after the sensor is mounted in its final location A mating electrical connector has been supplied with each sensor as well as calibration records Locate these records in the shipping container and keep them with the equipment for reference until the installation has been completed 2 00 HP214 7 SY100 Flowmeter Technical Manual 3 5 Flow Sensor Installation Caution Do not allow fuel spills when installing the flow sensor Drain the fuel line prior to starting any work Observe all safe practices during performance of the installation Do not use the flow sensor body as a Spool Piece during welding operations during installation of the SY 100 Fuel Flow Sensor Suitable fasteners for the flange ratings shall be obtained from ship s stores in advance of starting the work Suitable gaskets two required are required to match the bolt pattern and meter inlet bore Prepare the ship s piping for the installation of the flow sensor as shown in Figure 2 Provide adequate support for this new piping to restrict travel during high shock conditions Maintain adequate access for maintenance The mating flange and piping segm
29. low rate configure the digital multimeter to measure AC volts using the two volt scale Connect the positive lead to pin A of pickup coil And the negative lead to pin B of pickup coil Depending on the flow rate an approximate voltage reading of 10 millivolts to 1 volt should be measured If zero volts are measured a stalled rotor condition is indicated Remove the flow sensor from the piping as discussed in the previous chapter 2 00 HP214 15 SY100 Flowmeter Technical Manual No flow indication on electronics unit isi YES Is there any visible damage to the Repair as required signal interconnecting cable NO TP YES Is cable open or short circuited Repair as required NO With no flow amp pick up coil disconnected from electronics unit Repair as required does pick up coil read proper resistance YES With flow does pick up coil generate Examine flowmeter internals a signal Clean Replace as required YES Difficulty is in the electronics unit Figure 5 Flow Sensor Fault Logic Diagram 16 2 00 214 SY100 Flowmeter Technical Manual 6 CORRECTIVE MAINTENANCE 6 1 Introduction The corrective maintenance procedures are intended to provide the user with the necessary procedures to adjust repair and reinstall the SY 100 Fuel Flow Sensor The required tools and test equipment necessary to perform corrective maintenance are as follows Digital Multimeter Fluke model 8060A or equal
30. nsor internals kit The procedure is intended to assist in the assessment of the state of wear of the internals kit The accumulative effects of mechanical wear and chemical attack may result in a deterioration of the flow sensor bearing surfaces over a period of years This bearing deterioration may manifest itself in a flow measurement inaccuracy or in a stalled rotor condition Examine the flowmeter kit after performing the preceding cleaning procedure Perform the following examination steps to determine if the internals kit is operating satisfactory or should be replaced at this time 1 Lubricate the flowmeter kit with clean turbine oil 2 The rotor should freely spin on the shaft for several seconds when spun 3 Examine the internals kit for signs of excessive bearing wear using the criteria shown in the following figure Rotor should slide freely along shaft There should no ROCKING of the rotor on the shaft Figure 4 Inspection of Internals Kit If replacement is suggested follow the procedure outlined in the Corrective Maintenance section of this document 2 00 HP214 13 SY100 Flowmeter Technical Manual 4 4 Lubrication There are no lubrication requirements applicable to SY 100 Fuel Flow Sensors 4 5 Flow Sensor Assembly Slip the spacer onto the downstream flow straightener Align the upstream flow straightener with the notches on the spacer and slip o
31. nto shaft Insert the assembled internal kit see Figure 3 into the flowmeter housing Apply thread locking adhesive 242 blue to the retaining nut and thread the retaining nut into the housing 14 2 00 214 SY100 Flowmeter Technical Manual 5 TROUBLESHOOTING 5 1 Introduction The troubleshooting techniques in this chapter are designed to isolate and locate the area of failure and to present the procedures for the replacement of subassemblies to make the system operational 5 2 Flow Sensor Troubleshooting Procedures The required test equipment for troubleshooting the flow sensor is as follows Digital Multimeter Fluke Model 8060A or equal 1 In the event of signal failure no flow indication the following procedure should be followed In each case proceed to the next instruction only if the defect is not found Refer to the fault logic diagram Figure 5 for the flow sensor 2 Visually examine the interconnecting signal cable for broken or shorted leads 3 Disconnect the signal cable from the electronics unit and from the flow sensor Check the continuity of each lead of the cable If defective replace or repair 4 With the signal cable disconnected from the flow sensor measure the DC resistance of the pickup coil The resistance should read between 1150 and 1550 ohms between pin A and pin B A short or an open indicates a defective pickup coil and the pickup coil must be replaced 5 With an established f
32. parts locations for the SY 100 Flow Sensor PICKUP COIL WITHLOCKNUT RETAINING NUT HOUSING INTERNALS KIT E SPACER case gt 1 4 FLOW FLOW STRAIGHTNER STRAIGHTNER UPSTREAM DOWNSTREAM IDENTIFICATION PLATES Figure 7 Flow Sensor Exploded View 2 00 HP214 23 SY100 Flowmeter Technical Manual APPENDIX A SY100 Flow Sensor Specification Summary Flow Sensor Model No Fuel System Interface Installation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench 2 00 HP214 HO 1 7 SY100 Flow Sensor 0 3008 12 ANSI Raised Face Flange 6 1 16 face to face Monolithic Fail safe Construction MIL E 16884G 750 PSIG 450 to 3600 Gallons per Hour 180 to 7200 Gallons per Hour 2 of Reading 450 to 3600 GPH 0 5 of Reading 180 to 3600 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1350 ohms 10 MS 3106F 10SL 4S Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N HO 1 112 SY 100 A 1 SY100 Flowmeter Technical Manual Flow Sensor Model No Fuel System Interface Ins
33. ping Requirement 3 Blow Sensor Disassembly 12 Inspection or InterBal S KITE AREAS Ma 13 Flow Sensor Fault Logic Diagram 16 Flow Sensor Disassembly ERE UE EC EHE STA 18 Plow Sensor Exploded View EE IEEE ea ISI 25 1 2 00 4 SY100 Flowmeter Technical Manual SAFETY SUMMARY The SY 100 Fuel Flow Sensor is designed to satisfy the safety requirements for shipboard use The safety precautions and warnings described here are to be observed at all times Additional precautionary messages appear throughout this manual There is a danger associated with fuel oil spillage which may accompany the removal of the flow sensor from the fuel line for maintenance or repair Drain fuel lines completely prior to removing the flow sensor There is danger associated with fuel oil leakage which may accompany the improper installation of the gaskets and or improper tightening of the flange mounting bolts Verify the quality and alignment of the flange gaskets prior to installation Securely tighten the flange bolts during installation of the flow sensor The fuel flow sensor should be installed downstream of a flow strainer Large particles passing through the flow sensor may result in a change in calibration or damage to the flow sensor 2 00 HP214 ii SY100 Flowmeter Technical M
34. t respond within 30 days after notice from HFC the goods will be disposed of in HFC s discretion HFC does not warrant these goods to meet the requirements of any safety code of any state municipality or any other jurisdiction and purchaser assumes all risk and liability whatsoever resulting from the use thereof whether used singly or in combination with other machines or apparatus This warranty shall not apply to any HFC goods or parts thereof which have bee repaired outside HFC s factory or altered in any way or have been subject to misuse negligence or accident or have not been operated in accordance with HFC s printed instructions or have been operated under conditions more severe than or otherwise exceeding those set forth in the specifications for such goods THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTLY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE HFC SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE RESULTING DIRECTLY OR INDIRECTLY FROM THE USE OF LOSS OF USE OF THEGOODS WITHOUT LIMITING THE GENERALITY OF THE FOREGOING THIS EXCLUSION FROM LIABILITY EMBRACES THE PURCHASER S EXPENSES FOR DOWNTIME DAMAGES FOR WHICH THE PURCHASER MAY BE LIABLE TO OTHER PERSONS DAMAGES TO PROPERTY AND INJURY TO OR DEATH OF ANY PERSON HFC NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF HFC S GOODS
35. tallation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench A 2 HO 1 SY100 Flow Sensor HO 1 SY100 150 300 1 ANSI Raised Face Flange 5 5 1 16 face to face Monolithic Fail safe Construction MIL E 16884G 375 750 PSIG 240 to 3600 Gallons per Hour 120 to 4500 Gallons per Hour 2 of Reading 240 to 3600 GPH 0 5 of Reading 240 to 3600 GPH Less than 25 PSID Hermetically Sealed Magnetic Motion Sensor Minimum signal 10 mVrms sinusoidal waveform DC impedance 1800 ohms 10 MS 3106F 10SL 4S Designed to meet Shock Rating MIL STD 901C Type B Class I Group A Flow Sensor Vibration MIL STD 167 1 Type I P N 1 112 5 100 2 00 HP214 Flow Sensor Model No Fuel System Interface Installation Length Construction Service Fuel Oil Type Max Operating Pressure Test Pressure Rate Flow Range Extended Usable Range Rate Accuracy Repeatability Stalled Rotor Pressure Drop Pickup Type Output Signal Characteristics Mating Connector Environmental Spanner Wrench 2 00 HP214 SY100 Flowmeter Technical Manual HO 3 4 SY100 Flow Sensor 3 4 5 100 150 300 3 4 ANSI Raised Face Flange 5 5 1 16 face to face Monolithic Fail safe Constru
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