Part Number 80-01

Revision A

INSTALLATION, OPERATION, MAINTENANCE

AND ILLUSTRATED PARTS BREAKDOWN

AUDIO AND VISUAL (A/V) PURGE ALARM

SYSTEM
P/N 220600 SERIES

Manufacturers of Precision Instruments

Printed in U.S.A. November 14, 1995

 List of Effective Pages

Manual 80-01 contains 69 pages as follows:

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . November 1995

i through iii . . . . . . . . . . . . . . . . . . . . . . . November 1995
TOC-1 through TOC-2 . . . . . . . . . . . . . . November 1995
LOF-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . November 1995
LOT-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . November 1995
1-1 through 1-2 . . . . . . . . . . . . . . . . . . . . November 1995
2-1 through 2-10 . . . . . . . . . . . . . . . . . . . November 1995
3-1 through 3-12 . . . . . . . . . . . . . . . . . . . November 1995
4-1 through 4-2 . . . . . . . . . . . . . . . . . . . . November 1995
5-1 through 5-6 . . . . . . . . . . . . . . . . . . . . November 1995
6-1 through 6-18 . . . . . . . . . . . . . . . . . . . November 1995
A-1 through A-4 . . . . . . . . . . . . . . . . . . . November 1995
B-1 through B-2 . . . . . . . . . . . . . . . . . . . November 1995
Drawings 1 through 5 . . . . . . . . . . . . . . . November 1995

All product, brand, or trade names used in this publication are the trademarks or
registered trademarks of their respective owners.

Information in this manual is subject to change without notice.

i November 14, 1995

M/D TOTCO
 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

November 14, 1995 ii

M/D TOTCO
LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iii November 14, 1995

M/D TOTCO
 TABLE OF CONTENTS
Paragraph/Title Page

CHAPTER 1 - INTRODUCTION

1-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 SCOPE OF MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 INTENDED AUDIENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 PERSONNEL QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 NOTES, CAUTIONS AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

CHAPTER 2 - OVERVIEW

2-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3-1 Air Filter and Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3-2 Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3-3 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3-3-1 "Main Power On/Off" Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3-3-2 "Purge Air/Push to Test" Indicator Light and Pushbutton . . . . . . . . . . . . . . . . . . . 2-5
2-3-3-3 "No Purge Air/Push to Silence" Indicator Light and Pushbutton . . . . . . . . . . . . . . 2-5
2-3-4 Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3-5 Alarm Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-4 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-5 SYSTEM CONFIGURATIONS AND DASH NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

CHAPTER 3 - INSTALLATION AND SET UP

3-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3-1 Component Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3-1-1 Air Filter and Regulator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3-1-2 Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-3-1-3 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3-1-4 Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3-1-5 Alarm Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3-2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-3-3 Putty Application to Cable Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-3-4 Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4 SET-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4-1 Installing Enclosures Certified for Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4-2 Pressure Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4-3 Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4-4 Purge Timer Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

January 10, 1995 TOC–1

M/D TOTCO
 AUDIO AND VISUAL PURGE ALARM SYSTEM
Table Of Contents Manual 80-01

CHAPTER 4 - OPERATION

4-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3 PURGE COMPLETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-4 PURGE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-5 POWER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-6 POWER DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-7 INDICATOR AND ALARM HORN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-7-1 "Purge Air/Push to Test" Indicator Light and Pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-7-2 "No Purge Air/Push to Silence" Indicator Light and Pushbutton . . . . . . . . . . . . . . . . . . . . 4-2

CHAPTER 5 - MAINTENANCE

5-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2-1 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2-2 Pressure Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2-3 Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2-4 Verification Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

CHAPTER 6 - ILLUSTRATED PARTS BREAKDOWN

6-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3-1 Figure and Index Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3-2 Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3-4 Units Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3-5 Use On Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3-6 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

APPENDIX A - CONVERSION DATA

A-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-2 TEMPERATURE CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A-3 CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B - ENGINEERING DRAWINGS

B-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

TOC–2 January 10, 1995

M/D TOTCO
 LIST OF FIGURES

Figure/Title Page

Figure 2-1 AV Purge Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure 2-2 Air Filter and Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Figure 2-3 Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-4 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-5 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-6 Alarm Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 3-1 Dimensions for Junction Box, 218092-001 & 218092-002. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2 Dimensions for Control Box, 216273-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-3 Dimensions for Pressure Switches, 218937 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-4 Hole Pattern for Pressure Switch, 218937 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Figure 3-5 Dimensions for Alarm Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-6 Armored Cable and Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-7 Step 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-8 Step 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-9 Step 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-10Step 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-11Step 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 6-1 A/V Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 6-2 A/V Purge Air Filter and Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-3 A/V Purge Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Figure 6-4 A/V Purge Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-4 A/V Purge Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Figure 6-5 A/V Purge Alarm Horn Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Figure 6-6 A/V Purge Alarm Horn Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

January 10, 1995 LOF–3

M/D TOTCO
LIST OF TABLES

Table/Title Page

Table 2-1 System Options and Dash Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table 2-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table 5-1 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 6-1 Parts List Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Table A-1 Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Table B-1 Engineering Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

LOT–4 January 10, 1995

M/D TOTCO
 CHAPTER 1
INTRODUCTION

1-1 INTRODUCTION
The purpose of this manual is to provide a description of M/D TOTCO’s Audio and Visual (A/V)
Purge Alarm System. Information in this manual should enable qualified personnel to install, oper-
ate, maintain and replace parts in that system.

1-2 SCOPE OF MANUAL

This manual is divided into the following chapters:
q Chapter 1 - Introduction to manual
q Chapter 2 - System overview and specifications
q Chapter 3 - Installation and set-up
q Chapter 4 - Operation
q Chapter 5 - Maintenance and troubleshooting
q Chapter 6 - Illustrated parts breakdown and recommended spare parts inventory
q Appendix A - Conversion Data
q Appendix B - Engineering Drawings

1-3 INTENDED AUDIENCE

This manual is intended for use by field engineering, maintenance, operation and repair personnel.

1-4 PERSONNEL QUALIFICATIONS

Installation and maintenance of the A/V Purge Alarm system components should be attempted
only by personnel who are fully qualified and trained to perform the procedures in this manual and
who have read the Safety Notice on Page B.

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Chapter 1 AUDIO AND VISUAL PURGE ALARM SYSTEM
Introduction Manual 80-01

1-5 NOTES, CAUTIONS AND WARNINGS

Notes, cautions and warnings are presented to aid in understanding and operating the equipment
or to protect personnel and equipment. Examples and explanations for each are presented below.

NOTE

Provides additional information about the current topic.

CAUTION
Provides information to prevent equipment malfunction or damage that
could result in interruption of service.

WARNING

Provides information to prevent equipment malfunction or damage that

could result in serious or fatal injury to personnel or major property
loss.

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M/D TOTCO
 CHAPTER 2
OVERVIEW

2-1 INTRODUCTION
This chapter contains the following:
• A description of the A/V Purge Alarm system and its main
components
• An explanation of how part numbers relate to configuration
• System specifications

2-2 FUNCTION
The A/V Purge Alarm system performs the following functions:
• Filters incoming air and regulates purge air pressure so that a con-
stant 4 psig of filtered air is provided to an electronic enclosure to
allow use in Class I, Division 1, Groups C and D hazardous locations.
• Shuts off AC power to the purged enclosure and activates audio and
visual alarms if purge fails due to loss of purge pressure or overpres-
sure.
• Controls when AC power can be safely restored to the enclosure after
purge is restored.

2-3 MAIN COMPONENTS

The A/V Purge Alarm system is shown in Figure 2-1. Its main components are listed below and
described in the paragraphs that follow.
• Filter and regulator assembly
• Junction box
• Control box
• Pressure switches
• Alarm horn

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Chapter 2 AUDIO AND VISUAL PURGE ALARM SYSTEM
Overview Manual 80-01

FIGURE 2

Figure 2-1. A/V Purge Alarm System

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Manual 80-01 Overview

2-3-1 Air Filter and Regulator Assembly

The filter and regulator assembly consists of a filter and two-stage regulator. It performs the follow-
ing functions:
• Filters incoming air by removing particles and moisture. Incoming air
must be a non-flammable gas, such as instrument-quality com-
pressed air or compressed inert gases (for example, dry nitrogen).
• Uses a two-stage regulator to supply a constant 4 psi of filtered air to
the purged enclosure. The first stage regulates incoming air pressure
(typically 90 psig) down to a constant 20 psig. The second stage reg-
ulates 20 psig down to a constant 4 psig for the purged enclosure.

Figure 2-2. Air Filter and Regulator, 216742-003

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Overview Manual 80-01

2-3-2 Junction Box

The junction box contains a transformer, timer, relays and a 5-amp power fuse.
The timer is controlled by the pressure switch (Section 2-3-4 on page 6) and performs the following
functions:
• Shuts off AC power to the purged enclosure if purge fails.
• Activates audio and visual alarms if purge fails.
• Controls when AC power can be safely restored to the enclosure after
purge is restored.
The relays enable the operator to test the alarm horn and the red and green indicator lights on the
control box (Section 2-3-3 on page 5). The relays also enable the alarm horn to be silenced during
a purge failure while the visual alarm (red "No Purge Air" light on the control box) stays on until AC
power is restored to the purged enclosure.

Figure 2-3. Junction Box, 218092-002

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Manual 80-01 Overview

2-3-3 Control Box

The control box contains a "Main Power On/Off" switch, a green "Purge Air/Push to Test" indicator
light and pushbutton and a red "No Purge Air/Push to Silence" indicator light and pushbutton. The
function of each is summarized below.

2-3-3-1 "Main Power On/Off" Switch

The "Main Power On/Off" switch controls AC power to the A/V Purge Alarm system and to the
purged enclosure.

2-3-3-2 "Purge Air/Push to Test" Indicator Light and Pushbutton

The "Purge Air/Push to Test" indicator light and pushbutton consist of a green "Purge Air" indicator
light and a green pushbutton. The green indicator light comes on when power is applied to the
purged enclosure. The green pushbutton is used to test operation of the alarm horn, green indica-
tor light and red indicator light.

2-3-3-3 "No Purge Air/Push to Silence" Indicator Light and Pushbutton

The "No Purge Air/Push to Silence" indicator light and pushbutton consist of a red "No Purge Air"
indicator light and a red pushbutton. The red indicator light comes on when the purge has failed
and stays on until AC power is restored to the purged enclosure. The red pushbutton is used to
silence the alarm horn during an alarm condition.

Figure 2-4. Control Box, 216 273-001

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2-3-4 Pressure Switches

The A/V Purge Alarm system contains two pressure switches. One is set to sense loss of purge
pressure. The other is set to sense an over-pressure condition. When either condition exists, the
reaction of the pressure switch causes the timer in the junction box to shut off AC power to the
purged enclosure and activate the audio and visual alarms.

Figure 2-5. Pressure Switch, 218937

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2-3-5 Alarm Horn

The alarm horn sounds when loss of purge pressure or over-pressure conditions occur.
Alarm horn P/N 218947-005 is a 120 VAC, explosion-proof, audible-signal horn for use in a haz-
ardous location.
Alarm horn P/N 218947-006 is a 240 VAC, explosion-proof, audible-signal horn for use in a haz-
ardous situation.

Figure 2-6. Alarm Horn

2-4 THEORY OF OPERATION

The control box "Main Power On/Off" switch turns on the A/V Purge Alarm system. Instru-
ment-quality air enters the regulator assembly, is filtered and regulated to 4 psig. The regulated air
flows through the enclosure to be purged until such time that AC power can be safely applied to
the enclosure. The time must be determined which will be required to adequately purge any flam-
mable gases that may have accumulated in the enclosure. The standards requires that purge gas
be circulated through the enclosure until such time that five times the combined volume of the
enclosure and the purge air lines has passed through the system. The determined time is used as
the setting of the timer in the Junction box. The time is calculated as shown in Chapter 3. When
AC power can be safely applied to the enclosure, the junction box timer allows AC power to be
applied to the enclosure and the green indicator light on the control box comes on.

During system operation, the pressure switches continuously sense purge air pressure. If the
purge fails, the pressure switches cause the junction box timer to shut off AC power to the purged
enclosure, the alarm horn sounds and the red indicator light on the control box comes on.

2-5 SYSTEM CONFIGURATIONS AND DASH NUMBERS

The following options are available when ordering an A/V Purge Alarm system:
• Input voltage
• Control box mounting orientation
• Cable type
These options are specified with a three-digit extension (dash number) that follows the part num-
ber (220600). Table 2-1 shows how to use dash numbers when ordering an A/V Purge Alarm

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Chapter 2 AUDIO AND VISUAL PURGE ALARM SYSTEM
Overview Manual 80-01

system. For example, 220600-111 would have 120 Vac input, a vertically mounted control box,
armored cable and barrier glands.

Table 2-1. System Options and Dash Numbers

Part Number Dash Number Input Voltage Control Box Mtg Cable Type

220600 -1XX 120 Vac

220600 -2XX 240 Vac

220600 -X0X Horizontal

220600 -X1X Vertical

220600 -XX0 *None

220600 -XX1 **Armored

220600 -XX2 ***Conduit Sealing

* None = No cable or cable connectors

** Armored = Armored cable, P/N H10910-4AJ, 12AJ, & barrier glands, P/N H10909A-1NPT-
3NPT
*** Conduit Sealing = Conduit sealing fittings provided, but no cable

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2-6 SPECIFICATIONS
The M/D TOTCO A/V Purge Alarm system is Underwriters Laboratories certified as compliant with
the National Fire Protection Association standard NFPA 496, Type X purge control and IEC 79-10
First Case requirements.

The system components are approved as explosion-proof for use in Class I, Division 1, Groups C
and D hazardous locations as described in National Electrical Code (NEC) Article 500. The sys-
tem also complies with Zone 1, Group IIB hazardous locations as described in IEC 79-10 when
installed and operated as instructed in M/D TOTCO Drawing 220296 (Appendix B) of this manual.
The maximum purged enclosure volume for which the system has been approved is 2.5 cubic feet.
The system uses both audio and visual alarms in the form of a horn and illuminated indicators.

The system is intended for use with an enclosure that has an integral purge pressure indicator, a
pressure relief valve rated for opening at 0.5 psig for protection of the enclosure, and a flow meter
for verification of purge air flow rate.

The system requires a source of instrument-quality air with a minimum pressure of 20 psig and a
maximum pressure of 150 psig.

Additional specifications are listed in Table 2-2 below.

Table 2-2. Specifications

Parameter Requirements and LImits

Electrical

Primary Power:

220600-1xx * 120 Vac

220600-2xx * 240 Vac

Frequency:

220600-1xx * 50-60 Hz, single phase

220600-2xx * 50-60 Hz, single phase

Current Requirements

220600-1xx * 5 amp max.

220600-2xx * 5 amp max.

Primary Power Fuse 5 amp, 3AG

Purged Apparatus Current 4 amp max.

Environmental

Operating Temperature -40oC - 60oC (-40oF - 140oF)

* See Table 2-1 for system options.

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M/D TOTCO
 CHAPTER 3
INSTALLATION AND SET UP

3-1 INTRODUCTION

This chapter contains the following:

• Main components and mounting dimensions
• Descriptions of the installation procedures
• Descriptions of the set-up procedures

3-2 MAIN COMPONENTS

The following are the main components of the A/V Purge Alarm system:
• Air filter and regulator
• Junction box
• Control box
• Pressure switches
• Alarm horn

3-3 INSTALLATION PROCEDURES

The following paragraphs describe the procedures for the component, electrical and pneumatic
installations.

3-3-1 Component Mounting

The main components of the A/V Purge Alarm system are the air filter and regulator assembly,
pressure switches, alarm horn, and control box. Component-specific installation requirements are
identified in the following paragraphs.

3-3-1-1 Air Filter and Regulator Assembly

The air filter and regulator assembly can be mounted in any convenient location. The air supply
must be of instrument quality (instrument quality compressed air or a compressed inert gas such
as dry nitrogen) with the intake to the compressor located in a non-hazardous area.
CAUTION
The compressor intake line must not pass through any hazardous
areas.

WARNING

Do not open the purge system component enclosures unless you

know the area does not to contain flammable gases or that all power
has been removed from the enclosure.

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3-3-1-2 Junction Box

The junction box should be mounted in a location that allows removal of the cover for installation
adjustments. Dimensions are shown in Figure 3-1.

Figure 3-1. Dimensions and Hole Pattern for Junction Box, 218092-001, -002

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Manual 80-01 Installation and Set Up

3-3-1-3 Control Box

The control box must be located where the operator of the purged apparatus can readily see the
indicators and reach the pushbuttons. The control box may be mounted vertically as shown or
horizontally. Dimensions are in Figure 3-2.
Apply thread lubricant to all male threads of cable glands and conduit fittings to prevent seizing.

Figure 3-2. Dimensions and Hole Pattern for Control Box, 216273-001

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3-3-1-4 Pressure Switches

To insure proper pressure sensing, the pressure switches must be mounted with the pressure
switch faces in a vertical position such that the manufacturer’s nameplate reads correctly. The
location should be free from excessive vibration and corrosive atmosphere. Dimensions and hole
pattern are shown in Figure 3-3 and in Figure 3-4.

NOTE

The pressure sensing line must not exceed a length of 25 ft. from the
purged enclosure to the pressure switches.

Figure 3-3. Dimensions for Pressure Switches, 218937

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Manual 80-01 Installation and Set Up

Figure 3-4. Hole Pattern for Pressure Switches, 218937

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3-3-1-5 Alarm Horn

The alarm horn must be mounted close enough to the operator to be heard over the ambient noise
level. Dimensions are shown in Figure 3-5

218947-005 218947-006
MOUNTING MOUNTING

Figure 3-5. Dimensions and Hole Patterns for Alarm Horns

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Manual 80-01 Installation and Set Up

3-3-2 Electrical Installation

Electrical connections must be made by licensed personnel trained in the installation of hazardous
area equipment. The electrical installation must comply with the Drawing 220296, sheet 2, con-
tained in Appendix B and be in accordance with the NEC Article 501 or the regulations of the
appropriate local regulatory authority.
The schematic diagram of the system wiring is provided in Appendix B to aid with installation and
troubleshooting.

3-3-3 Putty Application to Cable Glands

Refer to Figure 3-6 and follow the steps below to apply putty to the cable glands:

Figure 3-6. Armored Cable and Connector

1. Remove loose particles, grease and so forth from the conductors.

2. Mix the two packages of putty compound completely by rolling
between hands until color becomes uniform. The putty is good for 45
to 60 minutes at 59° to 68° F (15° to 20° C).

CAUTION
The putty will not harden below 32° F (0° C). Apply gentle external
heat in freezing temperatures.

3. Spread the conductors slightly and apply a portion of mixed putty to

the center of the conductors as shown in Figure 3-7.

Figure 3-7. Step 3

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Chapter 3 AUDIO AND VISUAL PURGE ALARM SYSTEM
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4. Bring the conductors back together and pack the putty into the cham-
ber of the armored cone as shown in Figure 3-8.

Figure 3-8. Step 4

5. Pack putty around the conductors to the approximate size of the

inside of the ferrule as shown in Figure 3-9.

Figure 3-9. Step 5

6. With the remainder of the putty, form a ring and feed it into the ferrule
as shown in Figure 3-10.

Figure 3-10. Step 6

7. Slide the ferrule over the conductors and push it over the armored
cable up to the groove X as shown in Figure 3-11.

Figure 3-11. Step 7

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AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 3
Manual 80-01 Installation and Set Up

8. Screw and then tighten the coupler barrel to the hub body. This
forces the putty out both ends of the ferrule.
9. Remove the coupler barrel and wipe away excess putty, especially
from tapered surfaces of the body and ferrule, to allow removal of the
cable at some later time.
10. Tighten the coupler barrel to the hub body, and then tighten the jacket
seal assembly to the coupler barrel.

3-3-4 Pneumatic Installation

Pneumatic installation must be made by personnel trained in the installation of hazardous area
equipment.
The supply line from the air filter and regulator assembly to the purged enclosure must be a mini-
mum of 1/4 inch diameter. The pressure sense line from the purged enclosure to the pressure
switches assembly must be 1/4 inch diameter and less than 25 ft. long.

CAUTION
The supply line from the regulators must not be connected to the rest
of the system unless you know that the pressure regulators are prop-
erly adjusted.

CAUTION
The air supply must be of instrument quality with the intake to the com-
pressor located in a non-hazardous area. The compressor intake line
must not pass through any hazardous areas.

3-4 SET-UP PROCEDURES

Additional information for enclosures separately certified for purging are in Paragraph 3-4-1.

3-4-1 Installing Enclosures Certified for Purging

When installing enclosures specifically certified for purging, refer to the enclosure manufacturer’s
labeling and installation procedures.

3-4-2 Pressure Regulator Adjustment

The pressure regulators are factory adjusted to the required settings and should not require
adjustment at installation. If adjustment is believed to be required, refer to the chapter on mainte-
nance for the pressure regulator adjustment procedure.

3-4-3 Pressure Switch Adjustment

The pressure switches are factory adjusted to the required settings and should not require adjust-
ment at installation.
The pressure switches must be properly adjusted to provide the limits at which the "No Purge Air"
indicator and alarm horn will be activated. If adjustment is believed to be required, refer to the
chapter on maintenance for the pressure switch adjustment procedure.

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3-4-4 Purge Timer Setting

WARNING

Do not open the junction box unless you know the area does not con-
tain flammable gases or know that all power has been removed from
the enclosure.

Before setting the purge timer, first determine the time required to adequately purge any flamma-
ble gases that may have accumulated in the enclosure. The standards require that purge gas be
circulated through the enclosure until five times the combined volume of the enclosure and the
purge air lines has passed through the system. The determined time is used as the setting of the
timer in the junction box. Calculate the time as follows:
1. The length and diameter of the air line from the air filter and regulator
to the enclosure affects the maximum flow rate that can be devel-
oped. This may require a flow meter with a larger full scale capability
for shorter or larger diameter air lines.
If provided, a flow meter integral to the enclosure to be purged can be used to mea-
sure and adjust the flow rate. Adjust the flow contained within the installation instruc-
tions for the specific enclosure. Record the flow rate in the space provided below.
Connect a flow meter with a full scale of at least 30 SCFH in line with the purged
enclosure to the Air Filter and Regulator line. The flow meter should be connected to
the enclosure to be purged by a short length of tubing. Measure the flow rate in cubic
feet per hour and record below.

Flow Rate: ________________ cubic feet per hour

2. Measure the maximum outside dimensions (in inches) of the enclo-
sure to be purged and record below.

Height (H): ________________ in.

Width (W): ________________ in.
Depth (D): ________________ in.
3. Calculate the enclosure volume by multiplying the height, width, and
depth dimensions and record below.

Enclosure Volume = H X W X D = ________________ cubic inches

4. Calculate the volume of the purge supply lines that connect the air fil-
ter and regulator to the purged enclosure as shown below.

Supply Line Volume = 3.14 X (D/2)2 X Length (inches) =

________________ cubic inches

Where D is the internal diameter of the supply line in inches and L is

the length of the supply line in inches.

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5. Add the results from Steps 3 and 4 together to find the total volume in
cubic inches and record below.

Total Volume = Enclosure Volume + Supply Line Volume =

________________ cubic inches
6. Convert the total volume in cubic inches found in Step 5 to cubic feet
and record the results below.

Total Volume in cubic feet = Total Volume in cubic inches X .0005787

= ________________ cubic feet
7. Multiply the total volume in cubic feet from Step 6 by five and record
below.

Total Volume in cubic feet X 5 = ________________

8. Convert the flow rate determined in Step 1 to cubic feet per minute by
dividing by 60 minutes per hour.
(Flow Rate) / 60 = ________________ cubic feet per minute
9. Calculate the minimum purge timer setting required to allow five times
the enclosure volume to pass by dividing the total volume from Step 7
by the Flow Rate from Step 8.

Minimum Purge Timer Setting = (Total Volume) / (Flow Rate) =

________________ minutes
10. Remove the junction box cover and set the timer relay for not less
than the minimum purge timer setting from Step 9.
11. Close the junction box enclosure and tighten all bolts securely.

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Chapter 3 AUDIO AND VISUAL PURGE ALARM SYSTEM
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M/D TOTCO
 CHAPTER 4
OPERATION

4-1 INTRODUCTION
This chapter contains the following:
• Start-up procedure
• Purge complete
• Purge failure
• Power failure
• Power-down procedure
• Indicator and alarm horn test

4-2 START-UP PROCEDURE

Apply purge air then verify that the flow rate is the same as determined during installation and that
the purge pressure indicator on the enclosure indicates purge pressure or flow is present.
Set the "Main Power On/Off" switch on the control box to "ON". The red "No Purge Air" indicator
will illuminate and the alarm horn will sound, indicating that the power is being withheld until the
timer has timed out. The operator can depress the "Push To Silence" pushbutton to shut off the
horn. The alarm horn will be automatically enabled again when the timer reaches time out.

4-3 PURGE COMPLETE

When the preset time has elapsed, the green "Purge Air" indicator will illuminate and the red "No
Purge Air" indicator will extinguish. Power will then be available to the purged apparatus and the
purged apparatus can be operated.

4-4 PURGE FAILURE

If purge pressure exceeds the preset range of 0.5 PSIG to 2.0 PSIG, the red "No Purge Air" indica-
tor will illuminate and the horn will sound. The operator should turn off the "Main Power On/Off"
switch on the control box and then shut off the purge air supply. Purge air is removed to prevent
possible damage to the enclosure if over pressure caused the failure condition to exist. The power
and purge air supply should remain off until the cause of the purge pressure error is determined
and corrected.

4-5 POWER FAILURE

When power is lost and restored, a red "No Purge Air" indicator will illuminate and the alarm horn
will sound. The "No Purge Air" indicator will remain illuminated and the alarm horn will continue to
sound until the timer reaches time out again. The operator can depress the "Push To Silence"
pushbutton to turn off the alarm horn as described in Section 4-4.

4-6 POWER DOWN

When it is desired to cease operation of the purged apparatus, set the "Main On/Off" switch to
"OFF". The purge air supply can then be shut off. Do not shut off the purge air unless power has
been removed from the purged apparatus.

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Operation Manual 80-01

4-7 INDICATOR AND ALARM HORN TEST

Depressing the "Purge Air/Push to Test" pushbutton will cause both indicators to illuminate and the
alarm horn to sound momentarily.

4-7-1 "Purge Air/Push to Test" Indicator Light and Pushbutton

The "Purge Air/Push to Test" indicator light and pushbutton consist of a green "Purge Air" indicator
light and a green pushbutton. The green indicator light comes on when power is applied to the
purged enclosure. The green pushbutton is used to test operation of the alarm horn, green indica-
tor light and red indicator light. Under normal operating conditions, the green indicator light should
be illuminated. When the test pushbutton is pressed, the alarm should sound and both lights
should illuminate. When the pushbutton is released, the alarm horn should silence and the red
indicator light should go off.

4-7-2 "No Purge Air/Push to Silence" Indicator Light and Pushbutton

The "No Purge Air/Push to Silence" indicator light and pushbutton consist of a red "No Purge Air"
indicator light and a red pushbutton. The red indicator light comes on when the purge pressure is
out of the preset range or when AC power has failed and stays on until the purge pressure has
returned to an acceptable value or until AC power is restored to the purged enclosure. The red
pushbutton is used to silence the alarm horn during an alarm condition as follows: when the push-
button is pressed, the alarm horn stops sounding.

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M/D TOTCO
 CHAPTER 5
MAINTENANCE

5-1 INTRODUCTION

The pressure regulator settings, the pressure switch settings, and the operation of the purge sys-
tem should be verified on a periodic basis to prevent problems that could lead to potentially unsafe
operation or damage to the purged enclosure and apparatus. This chapter describes the follow-
ing:
• General checks
• Routine maintenance:
Air filter
Filter regulator
Pressure switches
Alarm horn
Control box
• Troubleshooting guide

5-2 ROUTINE MAINTENANCE

Field experience indicates that minor repairs can correct 90 percent of all electronic equipment fail-
ures, avoiding replacement of major assemblies. Before performing more extensive troubleshoot-
ing procedures, complete the following checks:
• Verify that the required primary power is supplied to the system.
• Check for loose, crushed, frayed, cut or otherwise damaged cables,
or damaged pneumatic lines.
• Verify that all system components are properly connected and seated
in their mating connector or socket (Chapter 3).
• Verify that purge air is available at the specified pressure.

5-2-1 Air Filter

The filter on the filter and regulator assembly should be inspected regularly. The condensation
drain should be checked for any obstructions and the filter element should be inspected and
replaced when necessary.

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Maintenance Manual 80-01

5-2-2 Pressure Regulator Adjustment

Perform the following procedure with the air line to the enclosure to be purged disconnected from
the enclosure.
1. Remove the plug from the side port of the pressure regulator to be
adjusted.

2. Connect a suitable pressure gauge to the port.

3. If adjusting the first pressure regulator, adjust for 20 ± 2 PSIG. If

adjusting the second pressure regulator, adjust for 4 ± 0.5 PSIG.

4. Remove the pressure gauge and re-install the plug.

5-2-3 Pressure Switch Adjustment

The following procedure may be used to adjust the pressure switch settings.

WARNING

This procedure must be performed with all power removed from the
system and while the location is known to not contain any flammable
gases.

1. Connect a supply of Instrument quality air to the filter and regulator

assembly. The inlet pressure to the filter and regulator assembly
should be approximately 90 PSIG.

2. Adjust the first pressure regulator to 20 psig. Refer to the section on

pressure regulator adjustment for detailed instructions.

3. Adjust the second pressure regulator to 0.5 psig. Refer to the sec-
tion on pressure regulator adjustment for detailed instructions.

4. Disconnect the tubing which connects the Pressure Switch to the filter
and regulator.

5. Temporarily install a tee fitting and suitable lengths of tubing between

the filter and regulator assembly and the Pressure Switch assembly.

6. Connect a pressure test gauge, with a full scale not more than 5 PSI,
to the tee fitting.

7. Remove the cover of the conduit outlet box on the Pressure Switch
assembly.

8. Set a multi-meter to the lowest resistance range or to measure conti-

nuity.

9. Connect the multimeter to terminals 1 and 4 of the terminal block in

the conduit outlet box.

10. Remove the plastic cap from the range adjustment screw on the low
pressure switch.

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Manual 80-01 Maintenance

11. Adjust the screw very slowly and carefully to obtain switch closure at
0.5 ± 0.25 PSI, using the multimeter to indicate when contact is
made.

NOTE

Turn the adjustment screw slowly clockwise to raise the set point and
slowly counterclockwise to lower the set point.

12. Replace the plastic cap on the adjustment screw.

13. Move the multi-meter lead connected to terminal 1 to terminal 2 of the

terminal block, leaving the other lead connected to terminal 4.

14. Re-adjust the second regulator on the filter and regulator assembly to
provide 2.0 ± 0.25 PSI as measured by the test gauge.

15. Remove the plastic cap from the range adjustment screw on the high
pressure switch.

16. Adjust the screw very slowly and carefully to obtain opening of the
switch at 2.0 PSI, using the multimeter to indicate when contact is
lost.

NOTE

Turn the adjustment screw slowly clockwise to raise the set point and
slowly counterclockwise to lower the set point.

17. Replace the plastic cap on the adjustment screw.

18. Remove the multimeter and close the cover on the conduit outlet box
on the Pressure Switch assembly.

19. Re-adjust the second regulator on the filter and regulator assembly to
4.0 ± 0.25 psig using the test gauge.

20. Remove the pressure test gauge and tee fitting, and reconnect sys-
tem.

November 14, 1995 Page 5-3

M/D TOTCO
Chapter 5 AUDIO AND VISUAL PURGE ALARM SYSTEM
Maintenance Manual 80-01

5-2-4 Verification Of Operation

The proper operation of the A/V Purge Alarm system may be verified by performing the procedures
below.
1. Verification of Indicator and Alarm Operation

a. Set the "Main Power On/Off" switch to "Off". Both indica-

tors should not be illuminated.

b. Set the "Main Power On/Off" switch to "On" and start a

stopwatch to begin the measurement of the power appli-
cation delay time. The red "No Purge Air" indicator
should illuminate and the alarm horn should sound.

c. Press the red "No Purge Air" indicator to silence the horn.

d. The green "Purge Air" indicator should illuminate after the

previously set time delay has elapsed.

e. Compare the time delay observed with the Junction box

timer setting determined by the installation procedure.

f. Operation is acceptable if the observed time is the same

as or greater than the time determined by the installation
procedure.

2. Verification of Pressure Switch Operation

The operation of the Pressure Switch assembly may be verified by

performing the procedure for adjustment in section 2 above.

Page 5-4 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 5
Manual 80-01 Maintenance

5-3 TROUBLESHOOTING GUIDE

The following table summarizes the steps to take to if there is trouble with the A/V Purge Alarm
system.

Table 5-1. Troubleshooting Guide

Symptoms Possible Causes Recommended Corrective Action

Alarm horn sounds during 1. High or low purge pressure 1. Check the following:
normal operation. a. pressure at inlet to purged enclo-
sure
b. enclosure leaks
c. pressure relief valve on purged
enclosure stuck closed
d. pressure regulator for proper
operation.

2. Power outage has 2. Depress the "Push to Silence Horn"

occurred button and wait for timer relay to
timeout.

Green "Push to Test Horn" 1. Low or high purge pressure 1. Check pressure at inlet to purged
indicator fails to illuminate enclosure.
after time-out.
2. Failed timer relay 2. Test and replace timer relay in
junction box if needed.

3. Failed pressure switch 3. Test and adjust or replace high and

low pressure switches.

4. Failed relay 1 (K1) or 4. Test and replace relay 1 or relay 2 if

relay 2 (K2) needed.

Alarm horn fails to sound 1. Failed alarm horn 1. Test and replace alarm horn if
when "Push to Test Horn" needed.
indicator is depressed.
2. Failed relay 1 (K1) or relay 2. Test and replace relay 1 or relay 2 if
2 (K2) needed.

Neither indicator is illumi- 1. Line-voltage supply failure 1. Check source of power.

nated.
2. Junction box fuse blown 2. Replace blown fuse.

3. Faulty master power switch 3. Test and replace power switch in

control box if needed.

4. Failed lamps in both indica- 4. Test and replace lamps if needed.

tors

November 14, 1995 Page 5-5

M/D TOTCO
Chapter 5 AUDIO AND VISUAL PURGE ALARM SYSTEM
Maintenance Manual 80-01

Page 5-6 November 14, 1995

M/D TOTCO
 CHAPTER 6
ILLUSTRATED PARTS BREAKDOWN

6-1 INTRODUCTION

This chapter contains an illustrated parts breakdown (IPB) and recommended spare parts
inventory for the A/V Purge Alarm system. The IPB consists of component illustrations and
accompanying parts lists. Features of the IPB are described below.

6-2 ILLUSTRATIONS

Stand-alone parts and assemblies are assigned index numbers on the illustrations. If an assembly
is detailed in a separate figure, its index number is circled.

6-3 PARTS LIST

The parts list headings are described in the following paragraphs.

6-3-1 Figure and Index Number

This column lists the figure number and index number of each illustrated item.

6-3-2 Part Number

This column lists the M/D TOTCO part number of each item.

November 14, 1995 Page 6-1

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

6-3-3 Description

This column contains the name and description of each item. If an assembly can be disassembled
in the field, its component part descriptions are indented to the right one period ( . ) from its
description.

6-3-4 Units Per Assembly

This column lists the number of units required for one next higher assembly (NHA).

6-3-5 Use On Code

This column is used when the illustrated assembly has more than one configuration. Since there
is only one configuration, this column is blank.
FIGURE 6
TABLE 6

Page 6-2 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

6-3-6 Abbreviations

Table 6-1 contains standard abbreviations used in parts lists.

Table 6-1. Parts List Abbreviations

Abbreviation Explanation Abbreviation Explanation

AL Aluminum MTG Mounting
AP Attaching Parts NHA Next Higher Assembly
AR As Required NPT National Pipe Thread
ASSY Assembly NYL Nylon
AWG American Wire Gauge OD Outer Diameter
BDGH Binding Head PCB Printed Circuit Board
BRS Brass PN Part Number
BRZ Bronze PNHD Pan Head
CND Conduit POS Position
CSK Countersunk PT Point
CT Count RD Root Diameter
CTN Carton RDHD Round Head
EXT External REF Reference
FLHD Flat Head SHLD Shield
GA Gauge SHLDR Shoulder
HD Head SLFLKG Self-Locking
HDW Hardware SLTD Slotted
HLDG Holding SST Stainless Steel
HX Hexagonal ST Self-Tapping
ID Inner Diameter STD Standard
INTL Internal THD Thread
IS Intrinsically Safe UNC Unified Coarse Thread
LCD Liquid Crystal Display UNF Unified Fine Thread
LED Light-Emitting Diode UNS Unified Straight
Thread
LG Length UL Underwriters Labora-
tories
M/F Male/Female

November 14, 1995 Page 6-3

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-1. A/V Purge System

Page 6-4 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

6-1 220600 A/V Purge System N/A N/A

1 216742-003 Filter-Regulator Assembly 1
2 218947-005 Alarm Horn Assembly, 120 volt 1
3 218092-002 Purge Junction Box 1
4 216273-001 Control Box 1
5 218937 Purge Alarm Pressure Switches 1
6 218947-006 Alarm Horn Assembly, 220 volt 1
7 XXXX Typical Purge Device (Reference only) 1

November 14, 1995 Page 6-5

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-2. A/V Purge Air Filter and Regulator

Page 6-6 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

6-1 216742-003 Filter/Regulator Assy, A/V Purge Alarm N/A N/A

1 971156-002 CONNECTOR, male, brass, 1/4 NPTx1/4 tube 2
2 971100-002 FITTING, bulkhead, brass, 1/4 NPT 1
3 968631-013 ELBOW, male, SST, 1/4 NPT 1
4 968144-003 NIPPLE, close, brass, 1/4 NPT 2
5 972300-002 FILTER 1
6 968705-003 TEE, street, brass, 1/4 NPT 1
7 968104-002 UNION, female, steel, 1/4 NPT 1
8 968638-002 ELBOW, male, brass, 1/4 NPTx1/4 tube 2
9 968139-014 NIPPLE, steel, 1/4 NPTx3.0 1
10 974511-002 REGULATOR, 0-30 psig 2
* 991201-023 SEALANT, pipe AR

November 14, 1995 Page 6-7

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

* Not shown

Figure 6-3. A/V Purge Junction Box

Page 6-8 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

6-2 218092-002 Purge Junction Box, A/V Purge Alarm N/A N/A
1 220008 J-BOX & MTG PLT, A/V Purge Alarm 1
2 989515-031 CAPLUG #13 1
3 989515-023 CAPLUG #9-X 4
4 944222-006 TRANSFORMER, auto, 230V/115V 1
5 999334-515 SCREW, 8-32x.50 rdhd sltd sst 10
6 938701-001 FUSEBLOCK, 3AG, 1 pole, sldr term 1
7 999334-536 SCREW, 6-32x.50 rdhd sltd sst 1
8 938200-024 FUSE, 3AG, 5 Amp 1
9 220307-002 LABEL, term blk, TB2 A/V Purge 1
10 951508-010 TERM, blk, 10 ckt/dbl (5.12") 1
11 999334-385 SCREW, 3/8-16X.50 rdhd sltd plt 0
12 930317-002 RELAY, 8 pin, gen purpose 2
13 999334-380 SCREW, rdhd, sltd, 4-40x.50, pltd 6
14 929108-001 SOCKET, Screw scrw term 12-20 AWG 3
15 950801-013 TERMINAL, ring .38x #22-16 red 1
16 930318-002 RELAY, time delay 1
17 220307-001 LABEL, term blk, TB1 A/V Purge 1
18 951508-012 TERM, blk, 12 ckt/dbl (6.0") 1
19 969143-001 PLUG, cnd, sq soc, .50" NPT stl 1
20 957000-001 DRAIN/BREATHER, 1/2"NPT sst 1
21 992419-002 LUBRICANT, thd, "stl2" (1.75 oz) N/A
* 218235-001 LABEL, wiring diag-A/V Purge JBX 1
* H10406A-000019 TERMINAL, flg spd #6X #18-14 blu 15
* 950814-004 TERMINAL, flg spd #6X #22-16 red 32
* 946613-082 WIRE IPVC 18AWG white 3 ft
* 946613-078 WIRE IPVC 18AWG green 3 ft
* 946613-073 WIRE IPPVC 18AWG black 3 ft
* 946613-081 WIRE IPPVC 18AWG gray 5 ft
* 946613-075 WIRE IPPVC 18AWG red 1 ft
* 996870-010 TUBING, ht.shrink .142" (#10) 1 ft
* 996857-027 TUBING, ht.shrink .37" black 1 ft

* Not shown

November 14, 1995 Page 6-9

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-4. A/V Purge Control Box

Page 6-10 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

6-3 216273-001 Control Box, A/V Purge Alarm N/A N/A

1 955219-004 . CONTROL BOX 1
2 969134-035 . PLUG, Pipe, .75 NPT 1
3 955219-006 . PUSHBUTTON, Red 1
4 955219-008 . CONTACT BLOCK 3
5 957507-007 . BOOT, Pushbutton 2
6 955219-007 . PUSHBUTTON, Green 1
7 955219-009 . SELECTOR SWITCH, 2 Position 1
8 957507-004 . BOOT, Selector switch 1
* 992419-002 . LUBRICANT, Thread, anti-seize AR
* Not shown

November 14, 1995 Page 6-11

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-5. A/V Purge Alarm Pressure Switches

Page 6-12 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

6-4 218937 Pressure Switches, A/V Purge Alarm N/A N/A

1 932901-003 . SWITCH, High Pressure, explosion proof 1
2 218938 . OUTLET BODY, Modified 1
3 956203-001 . ELBOW, 90°, Male/female, 1/2 NPT 3
4 956283-002 . NIPPLE, Steel, 1/2 NPT X 1.50 L 2
5 951330-007 . TERMINAL BLOCK, 4 position 1
6 999334-514 . SCREW, Round head, SST, 8-32 UNC X .25 L 2
7 968754-005 . CONNECTOR, Elbow swivel, 1/8 NPT X 1/4 tube 1
8 932901-9001 . PLUG, Filter, nylon, 1/8 NPT 2
9 999393-226 . SCREW, Hex head, SST, 1/4-20 UNC X 1.00 L 4
10 999279-005 . NUT, Hex, SLFLKG, SST, 1/4-20 UNC 4
12 946613-082 . WIRE, White, IPVC, 18 AWG 18
13 946613-078 . WIRE, Green, IPVC, 18 AWG 18
14 946613-073 . WIRE, Black, IPVC, 18 AWG 18
15 970615-003 . TUBING, Black nylon, 1/4 OD X .035 wall 12
16 991201-023 . SEALANT, Pipe AR
17 992419-002 . LUBRICANT, Thread, anti-seize AR
18 956288-001 . FITTING, Sealing, vert/horiz, 1/2 NPT 2
19 932901-006 . SWITCH, Low Pressure, explosion proof 1
20 968758-002 . TEE, Run, male, swivel, 1/8 NPT X 1/4 tube, brs 1
21 989515-023 . CAPLUG, #9X, 1/2 NPT 1
22 950801-008 . LUG, Terminal, ring, NO 6 6
23 991915-002 . SEALING COMPOUND AR

November 14, 1995 Page 6-13

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-6. Alarm Horn Assembly - 218947-005

Page 6-14 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

(Figure 6-5) 218947-005 Alarm Horn Assembly N/A N/A

1 937502-001 Horn, Elec. 120VAC SST 1
2 956221-004 Bushing, CND, 0.75 X 0.5 1
3 956203-001 Elbow, Conduit M/F 1/2" 1
4 999393-250 Screw, 5/16-18 X 1.25 2
5 999279-006 Nut, Hex 5/16 X 1.25 2
18 989515-023 Caplug #9-X 1

November 14, 1995 Page 6-15

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Figure 6-7. Alarm Horn Assembly - 218947-006

Page 6-16 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Chapter 6
Manual 80-01 Illustrated Parts Breakdown

FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE

(Figure 6-6) 218947-006 Alarm Horn Assembly N/A N/A

1 956221-004 Bushing, DNG, 0.75 X 0.5 1
4 999393-250 Screw, 5/16 - 18 X 1.25 2
5 999279-006 Nut, Hex, 5/16 -18 X 1.25 2
9 956283-002 Nipple, CND, GLV, 1/2 - 14 1
16 H10524A Horn, 240 VAC Explosion Proof 1
17 955220-022 Conduit outlet, ELL, 1/2 1
18 989515-023 Caplug #9-X 1
20 220493-003 ID Plate, Horn, AV Purge 1

November 14, 1995 Page 6-17

M/D TOTCO
Chapter 6 AUDIO AND VISUAL PURGE ALARM SYSTEM
Illustrated Parts Breakdown Manual 80-01

Page 6-18 November 14, 1995

M/D TOTCO
 APPENDIX A
CONVERSION DATA

A-1 INTRODUCTION

This chapter contains the following conversion information:

• Methods for converting temperature from degrees Fahrenheit (oF) to
degrees Centigrade (oC) and vice versa
• Conversion factors for commonly used units

A-2 TEMPERATURE CONVERSIONS

To convert from degrees Fahrenheit (oF) to degrees Centigrade (oC), subtract 32 from the degrees
Fahrenheit, then multiply by 0.556, as shown below:

o
C = [ oF - 32 ] x 0.556

To convert from degrees Centigrade (oC) to degrees Fahrenheit (oF), multiply the degrees Centi-
grade by 1.7985, then add 32, as shown below:

oF = [ oC x 1.8 ] + 32

A-3 CONVERSION FACTORS

Conversion factors for commonly used units are presented in Table A-1.

November 14, 1995 Page A-1

M/D TOTCO
Appendix A AUDIO AND VISUAL PURGE ALARM SYSTEM
Conversion Data Manual 80-01

Table A-1. Conversion Factors

MULTIPLY BY TO OBTAIN
atmospheres (atm) 101.325 kiloPascal (kPa) absolute
atmospheres (atm) 14.7059 pounds per square inch (psi)
barrels (bbl) of petroleum 5.615 cubic feet (ft 3)
barrels (bbl) of petroleum 0.159 cubic meters (m3)
barrels (bbl) of petroleum 42 gallons, U.S. liquid
barrels of petroleum per inch (bbl/in) 0.626 cubic meters per centimeter (m3/cm)
bars 14.5138 pounds per square inch (psi)
centimeters 0.394 inches (in)
centimeters per second (cm/sec) 0.0328 feet per second (ft/sec)
3)
cubic feet (ft 7.4805 gallons, U.S. liquid
3
cubic feet (ft ) 28.32 liters
cubic feet (ft3) 0.178 barrels (bbl) of petroleum
cubic meters (m3 ) 6.289 barrels (bbl) of petroleum
3
cubic meters (m ) 264.2 gallons, U.S. liquid
cubic meters per centimeter (m3/cm) 1.597 barrels of petroleum per inch (bbl/in)
decaNewtons (daN) 2.248 pounds
feet (ft) 0.3048 meter (m)
feet per hour (ft/hr) 0.3048 meters per hour (m/hr)
feet per minute (ft/min) 0.01829 kilometers per hour (km/hr)
feet per minute (ft/min) 0.3048 meters per minute (m/min)
feet per second (ft/sec) 30.48 centimeters per second (cm/sec)
feet per second (ft/sec) 18.29 meters per minute (m/min)
foot-pound 1.4882 kilogram-meter (kg-m)
foot-pound 1.3558 Newton-meter
gallons, U.S. liquid 0.0238 barrels (bbl) of petroleum
gallons, U.S. liquid 0.13368 cubic feet (ft3)
gallons, U.S. liquid 0.003785 cubic meters (m3)
gallons, U.S. liquid 3.7854 liter
3
grams per cubic centimeter (g/cm ) 8.345 pounds per U.S. liquid gallon (lb/gal)
inch (in) 2.54 centimeter (cm)
inches Hg (Mercury) 0.4912 pounds per square inch (psi)
inches H20 (Water) 0.0361 pounds per square inch (psi)
kilograms (kg) 2.2046 pounds
kilogram-meters (kg-m) 0.67196 foot-pound
3
kilograms per cubic meter (kg/m ) 0.00835 pounds per U.S. liquid gallon (lb/gal)
kilograms per meter (kg/m) 0.672 pounds per foot
kilograms per square centimeter (kg/cm3) 14.2227 pounds per square inch (psi)

(Continued)

Page A-2 November 14, 1995

M/D TOTCO
AUDIO AND VISUAL PURGE ALARM SYSTEM Appendix A
Manual 80-01 Conversion Data

MULTIPLY BY TO OBTAIN
kilometers (km) 0.6215 miles
kilometers per hour (km/hr) 54.6747 feet per minute (ft/min)
kiloPascals (kPa) 0.0099 atmospheres (atm)
kiloPascals (kPa) absolute 0.145 pounds per square inch (psi)
liters (l) 0.0353 cubic feet (ft3)
liters (l) 0.2642 gallon, U.S. liquid
liters per minute (lpm) 2.1186 standard cubic feet per hour (scfh)
meters 3.281 feet (ft)
meters per hour (m/hr) 3.2808 feet per hour (ft/hr)
meters per minute (m/min) 3.2808 feet per minute (ft/min)
meters per minute 0.0547 feet per second (ft/sec)
miles 1.609 kilometers (km)
Newtons 0.2284 pounds
Newton-meters 0.7376 foot-pounds
pounds (lb) 0.4448 decaNewtons (daN)
pounds (lb) 0.4536 kilograms (kg)
pounds (lb) 0.000454 metric tons
pounds (lb) 4.448 Newtons (N)
pounds (lb) 0.0005 U.S. tons
pounds per foot (lb/ft) 1.488 kilograms per meter (kg/m)
pounds per gallon (lb/gal) 0.119826 grams per cubic centimeter (g/cm3)
pounds per gallon (lb/gal) 119.826 kilograms per cubic meter (kg/m3)
pounds per square inch (psi) 0.0680 atmospheres (atm)
pounds per square inch (psi) 0.0689 bars
pounds per square inch (psi) 2.0358 inches of Hg (Mercury)
pounds per square inch (psi) 27.6778 inches of H20 (Water)
pounds per square inch (psi) 0.0703 kilograms per square centimeter (kg/cm2)
pounds per square inch (psi) 6.895 kiloPascals (kPa)
2
square centimeters (cm ) 0.155 square inch (in2)
square feet (ft2) 0.0929 square meter (m2)
square inch (in2) 6.4516 square centimeter (cm2)
square meter (m2) 10.764 square feet (ft2)
standard cubic feet per hour (scfh) 0.472 liters per minute (lpm)
tons, metric 2205 pounds
tons, metric 1.1025 U.S. tons
tons, U.S. 0.907 metric tons
tons, U.S. 2000 pounds
metric ton-kilometers (tonne-km) 0.6853 U.S.ton-miles
U.S.ton-miles 1.4593 metric ton-kilometers (tonne-km)

November 14, 1995 Page A-3

M/D TOTCO
Appendix A AUDIO AND VISUAL PURGE ALARM SYSTEM
Conversion Data Manual 80-01

Page A-4 November 14, 1995

M/D TOTCO
 APPENDIX B
ENGINEERING DRAWINGS

B-1 INTRODUCTION

This appendix contains engineering drawings of the A/V Purge Alarm System. The drawings are
listed in Table B-1.
TABLE B
Table B-1. Engineering Drawings

Drawing Number Description

220600 A/V Purge System

220296 Installation Control Drawing, Type X Purge System

220306 Schematic, A/V Purge System

November 14, 1995 Page B-1

M/D TOTCO
APPENDIX B AUDIO AND VISUAL PURGE ALARM SYSTEM
Engineering Drawings Manual 80-01

Page B-2 November 14, 1995

M/D TOTCO