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Starter Relay Valve
SRV Series
User Manual
Form P6513
CCN 03530515
Edition 9
December 2006
Save These Instructions
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Product Description
WARNING
WARNING
DO NOT USE WITH
NATURAL GAS OR OTHER
FLAMMABLE GASES
DANGER
WARNING
CAUTION
NOTICE
This product is a non-regulating, pneumatically-operated, relay valve designed to provide control over uid ow to the starter motor in an air
starter-based, internal combustion engine starting system.
General Product Safety Information
Read and understand this manual before operating this product.
•
It is your responsibility to make this safety information available to others that will operate this product.
•
Failure to observe the following warnings could result in injury.
•
Always install, operate, inspect and maintain this product in accordance with all applicable standards and regulations (local, state,
•
country, federal, etc.).
Product Safety Information
This Starter Relay Valve is designed by Ingersoll Rand specically for use on Air Starter installations. Any other use may result in injury or
•
equipment damage.
Only use this Starter Relay Valve at or below 225 psig (15.5 bar/1550 kPa) maximum pressure, unless otherwise labeled. Higher pressure
•
may result in hazardous situations including rupture of the Starter Relay Valve and associated hardware.
To use this Starter Relay Valve at a pressure of 225 psig (15.5 bar/1550 kPa), all associated pipe, hose and ttings must be rated at 225 psig
•
or more. Some IR models are sold with lower pressure ratings due to associated piping.
Do not use this Starter Relay Valve with any corrosive gas or with any liquid.
•
Except for SRV100, SRV125, SRV150 and SRV150SS, the Starter Relay Valve was designed for use with compressed air only. Only those
•
models may be used with natural gas.
Always shut-o the air supply to the Starter Relay Valve, and bleed o any residual pressure, before performing any maintence on the
•
Starter Relay Valve.
Never remove the Retaining Ring from the Starter Relay Valve unless all pressure has been bled o. Internal parts will be forcefully ejected
•
if Retaining Ring is removed while pressurized.
Always wear eye protection when performing any maintenance on this Starter Relay Valve.
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Do not remove any labels. Replace any damaged label.
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Never use a damaged or malfunctioning Starter Relay Valve.
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Do not modify the Starter Relay Valve.
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Do not use this Starter Relay Valve for purposes other than those recommended.
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Be sure all hoses & ttings are the correct size & are tightly secured.
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Do not use damaged, frayed or deteriorated air hoses & ttings.
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Safety Symbol Identication
Read Manuals Before Operating Product This warning applies to all Starter Relay Valves except SRV100,
SRV125, SRV150 and SRV150SS.
Safety Information - Explanation of Safety Signal Words
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or
property damage.
Indicates information or a company policy that relates directly or indirectly to the safety of personnel or
protection of property.
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Product Parts Information
CAUTION
NOTICE
PILOT (ACTIVATION) OPERATION PORT
AIR SUPPLY
TO AIR STARTER MOTOR
TO AIR STARTER CONTROL
VALVE (IF APPLICABLE)
TYPICAL INSTALLATION
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased Starter Relay Valve
performance, and increased maintenance, and may invalidate all warranties.
Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll Rand Authorized Service Center.
Placing the Starter Relay Valve in Service
(Dwg. 45508561)
This Starter Relay Valve is specially designed and manufactured by Ingersoll Rand for use on Starter installations. Install it in
accordance with the following instructions.
Pre-Installation
Clean the air line, O-ring groove and sealing surfaces to be sure they are free of foreign material.
1.
Ensure that enough space is left for removal and service of this valve.
2.
Ensure that the air line is suitably aligned and supported to avoid strained joints.
3.
Do not over tighten the air line connections.
4.
Starter Relay Valves that have a small drain hole above the “OUT” connection (including SRV125T, SRV150T, SRV150T-LT and SRV150SST-LT)
5.
are to be installed with the drain hole down.
Installation of the Starter Relay Valve (threaded connections)
Use a short pipe nipple between the supply line and the Starter Relay Valve. The nipple should be the same size as the inlet of the Starter
1.
Relay Valve.
Apply No. SMB-441 Ingersoll Rand Sealant to the male thread on the nipple, and install the nipple on the supply line. Tighten the
2.
connection so that it is airtight.
Note that one of the tapped inlets on the Starter Relay Valve is marked “IN”. Thread this inlet onto the nipple and tighten the connection so
3.
that it is airtight.
Apply Ingersoll Rand Sealant to the male threads on the air line that goes to the Starter, and thread this line into the tapped outlet on the
4.
Starter Relay Valve that is marked “OUT”. Make certain the connection is airtight.
Attach the hose from the outlet side of a 3-way normally vented Control Valve to the small tapped hole in the top of the Starter Relay Valve.
5.
Use Ingersoll Rand Sealant on the male thread.
Installation of the Starter Relay Valve (ange connections)
Place the O-ring supplied with the ange tting into the groove on the Starter Relay Valve.
1.
Mount the Starter Relay Valve to the tank using ST500-K166 Flange Assembly. The air ow arrow must point toward the starter.
2.
Check the O-ring to see that it properly seated in the groove to prevent cutting.
3.
Push the two clamp halves inward as far as they will go.
4.
Tighten the four ange bolts in an alternating pattern to 35-45 ft-lbs (47-61Nm) torque.
5.
Attach the air hose from the outlet side of a 3-way normally vented Control Valve to the small tapped hole in the top of the Starter Relay
6.
Valve. Use SMB-441 Ingersoll Rand Sealant on the male thread.
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Starter Relay Valve Exploded View
1
2
3
4
5
6
7
8
9
10
11
12
13
(Dwg. TPD1731)
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Starter Relay Valve Parts List
NOTICE
Part Number
Item Part Description
1 Valve Housing SRV150SS-40 45504404 45504362
2 Pipe Plug HSPPS-2 HSPPS-2 HSPPS-2 HSPPS-2
3 Upper Piston O-ring * SRV150-210 * SRV150-210 ** 45504305 ** 45504305
4 Piston SRV150-246 04555900 45504388 45504289
5 Bumper * SRV150-339 * SRV150-339 ** 45504321 ** 45504321
6 Piston O-ring * SRV150-211 * SRV150-211 ** 45504313 ** 45504313
7 O-ring Retainer * SRV150-33 * SRV150-33 ** SRV150-33 ** SRV150-33
8 Spring SRV150-250 SRV150-250 SRV150-250 SRV150-250
9 End Plug O-ring * SRV150-67 * SRV150-67 ** 45504347 ** 45504347
10 End Plug SRV150-338 SRV150SS-338 45504396 45504354
11 End Plug Seal O-ring * SRV150-604 * SRV150-604 ** 45504339 ** 45504339
12 Retaining Ring * SRV150-340 * SRV150-340 ** SRV150-340 ** SRV150-340
13 Pipe Plug - SRV150-368 - SRV150-368
14 Warning Label “not for natural gas”
Aluminum Models
for SRV100 SRV100-40 - - -
for SRV125 SRV125-40 - - -
for SRV125F SRV125F-40 - - -
for SRV125T 04333639 - - -
for SRV150 SRV150-40 - - -
for SRV150T SRV150T-40 - - -
-
for SRV125F 04333274 - - -
for SRV125T 04333274 - - -
for SRV150T 04333274 - - -
SRV150SS
(Stainless Steel)
- 04333274 04333274
SRV150T-LT
(Low Temperature
Aluminum)
SRV150SST-LT
(Low Temperature
Stainless Steel)
* Indicates part in Tune-Up Kit SRV150-TK3
** Indicates part in Tune-Up Kit SRV150-LT-TK1
Tune-up Kits are available for maintaining the Starter Relay Valve. Those Tune-up Kits include all O-rings (3, 6, 9, 11), Bumper (5),
O-ring Retainer (7), End Plug Retaining Ring (12) and SRV-GR55 Grease.
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Optional Equipment for SRV125F
M
L
U
J
A
B
C
G
F
E
H
I
S
T
N
O
P
R
Q
Q
P
U
D
K
WARNING
(Dwg. TP2212)
Item Part Description Part Number Item Part Description Part Number
Solenoid and Mounting Hardware - Position 1 Pilot Port Hardware - Position 2
A Solenoid L 90° Elbow with Push to Lock EL90-4M4DOT
12 Volt Pioneer Connections 150BMP-A1051C M 90° Elbow with JIC 37° EL90-4M437M
12 Volt, Wire Leads 150BMP-1051B Left and Right Live Air Port hardware - Position 3 and 4
12 Volt, Wire Leads 150BMP-2451B N 90° Elbow with Push to Lock EL90-4M4D0T
B 900 Elbow with Push to Lock EL90-4M4DOT O T Connection with Push to Lock 150TMP-MRT4M4
C Solenoid Mounting Bracket 150TMP-2451 P Schrader Valve 04333654
D Solenoid Mounting Screw (2) Y133-105C Q 1/4” Pipe Plug HSPPS-2
E Solenoid Mounting Screw Washer (2) Y117-110 R T Fitting with 1/4” NPT SRV125F-188
F Solenoid Mounting Bracket Screw (2) 150TMP-128 + Pressure Gauge SRV125F-1064
G Solenoid Mounting Bracket Washer (2) Y14-516C Secondary Inlet Port Hardware - Position 5
H 90° Elbow with Push to Lock EL90-4M4DOT S Check Valve ST400-1056
I Connection Hose 150 TMP-125 T Plug SRVI25F-34
J 90° Elbow with Push to Lock EL90-4M4DOT U 1-1/4” Flange Kit ST500-K166
K Connection Hose 150TMP-125
(+) Items Not Shown
For Position Coding information refer to Drawing 10554749
Always wear eye protection when performing maintenance on the Starter Relay Valve. Always bleed o the pressure before
performing any maintenance on the Starter Relay Valve.
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Installation of the Tune-up Kit
NOTICE
Disassembly of the Starter Relay Valve
Bleed o the pressure.
1.
Clamp the Relay Valve in a vise with the Retaining Ring (12) up.
2.
Carefully remove the Retaining Ring. The End Plug (10) should spring out. If it does not, tap the Valve Housing (1) lightly with a soft hammer
3.
until the End Plug springs out.
Remove the End Plug, Spring (8), and Piston Assembly (4).
4.
Remove and discard all used O-rings and Bumper (5).
5.
Clean all other parts in a clean, suitable cleaning solution in a well ventilated area.
6.
Assembly of the Starter Relay Valve
Using O-ring lubricant, lubricate and install the new Piston O-ring (6) and the new Upper Piston O-ring (3) on the Piston.
1.
The Upper Piston O-ring (3) is slightly larger in diameter than the End Plug O-ring (9).
2. Turn the Piston over and insert the new Bumper (5).
3. Using O-ring lubricant, lubricate and install the new End Plug Seal O-ring (11) and the new End Plug O-ring (9) on the End Plug (10).
4. Lubricate the lower small bore of the Valve Housing (1) with O-ring lubricant.
5. Insert the Piston Assembly into the Valve Housing. Push on the Piston until the Piston O-ring (6) seats against the beveled face.
6. Install the O-ring Retainer (7) with the large opening over the Piston O-ring.
7. Place the Piston Spring (8) on the Piston.
8. Place the End Plug Assembly on the Piston Spring.
9. Using a press to hold down the End Plug Assembly, install the End Plug Retaining Ring (12).
General Information
When the life of the Starter Relay Valve has expired, it is recommended that the Starter Relay Valve be disassembled, degreased and parts be
separated by material so that they can be recycled.
The original language of this manual is English.
Manuals can be downloaded from www.irtools.com.
Refer all communications to the nearest Ingersoll Rand oce or distributor.
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www.irtools.com
© 2006 Ingersoll Rand Company
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