THE CYCLONE 4400 INSTRUCTION & OPERATING MANUAL Version: 05012002 Rev.1

SECTION 1: FIRST THINGS TO KNOW ABOUT THE MLS Operation Specifications Injection Pump Operating Pressure: Actuation Pressure: Displacement: Operating System Temperature: Service Connections: Actuation Gas Inlet: Lubricant Discharge: 1/4” NPT Female 1/8” S/ST tube, Ferrule Oil Reservoir Material: Capacity: Compatible Lubricants: Polycarbonate & Anodized Aluminum 6 oz. (175 cc) (1250 injections) Chemlube, Anderol, 5w or equivalent Controller Power Supply: Battery Reserve: Timer Accuracy: Display: Flow input: Continuous: Minimum Pulse Width: Pulse Type: Lithium battery pack 2 years (1 stroke/hr)...

SECTION 1: FIRST THINGS TO KNOW ABOUT THE MLS Theory of Operation The Cyclone 4400 MLS is a pipeline mounted system which uses the pneumatically operated, positive displacement Cyclone 4400 pump, the Z-65/6.1H timer/controller, the YZ filter/regulator and a low power solenoid valve to deliver injections. The 4400 provides three modes of operation: A. Time-based injection: In this mode of operation, the 4400 injects lubricant into the meter at regular time intervals. The volume of injection is preset at .140 cc/stroke. The Z-65/6.1H controller operates as a recycling timer, periodically energizing...

SECTION 1: FIRST THINGS TO KNOW ABOUT THE MLS Application One of the difficulties in maintaining turbine meters in the field is that they require lubricant for the unrestricted movement of the turbine, and for measurement accuracy. Maintaining the lubricant level in meters is a problem that has existed for a very long time. Today, at YZ Systems, we have the solution in the Cyclone — Meter Lubrication System 4400. Capable of accepting pulses directly from a meter, index pulser, electronic corrector, or flow computer, the Cyclone can operate in Proportional-to-flow or time-based injection modes....

NSTALLA ALLATION SECTION 2: SYSTEM INSTALLATION System Components The primary components of the Cyclone 4400 MLS (Meter Lubrication System) are illustrated below. Solenoid Valve Lubricant Reservoir Factory Mutual System Approved Serial Number Plate Filter Regulator Actuation Gas Manifold (1/4" NPT Inlet) Mounting Plate Lubricant Discharge Cyclone Protector

SECTION 2: SYSTEM INSTALLATION NSTALLA ALLATION Injector Location 1. The injector unit should be located as close to meter as possible. In addition, discharge tubing should be kept as short as possible. 2. The injector unit is designed to mount to a 2" pole. The recommend mounting configuration is shown below. Lubricant Discharge Pipline Flow Turbine Meter (By Customer)

NSTALLA ALLATION SECTION 2: SYSTEM INSTALLATION Injector Installation 1. The Cyclone 4400 should be mounted in a vertical position. 2. The Cyclone 4400 requires a 1/4" NPT pipeline gas connection. 3. The 1/8" discharge tubing should connect to the meter injection port. An in-line check valve should be installed at the injection port. Actuation Gas Lubricant Discharge (1/8" Tubing) In-Line Check (By Customer) Isolation Valve (By Customer) Isolation Valve (By Customer) Turbine Meter (By Customer)

NSTALLA ALLATION SECTION 2: SYSTEM INSTALLATION (Optional) DPS-2 Installation 1. With the low pressure supply valve and the high pressure supply valve closed, connect the DPS-2 to the orifice connection tubing. 2. Open the equalization valve. Black 3. Open the low pressure supply valve or the high pressure supply valve. IMPORTANT NOTE: Factory Mutual System Approved Do not open either the low pressure supply valve or the high pressure supply valve without ensuring that the equalization valve is open. Failure to do so may damage the DPS-2's internal components. 4. Open the other supply valve....

ONTROL SECTION 3: SYSTEM CONTROL LECTRONICS ELECTRONICS Solenoid Valve Lubricant Reservoir Factory Mutual System Approved Serial Number Plate Filter Regulator Actuation Gas Manifold (1/4" NPT Inlet) Mounting Plate Lubricant Discharge Cyclone Protector Actuation Gas Lubricant Discharge (1/8" Tubing) In-Line Check (By Customer) Isolation Valve (By Customer) Isolation Valve (By Customer) Turbine Meter (By Customer)

ONTROL SECTION 3: SYSTEM CONTROL LECTRONICS ELECTRONICS Setting Input Parameters Z-65 Set-Up Proportional-To-Flow In this mode of operation, the Z-65 controller is used as a dividing counter to control the rate at which the pump is actuated. The desired time between pump strokes is controlled by the host computer or output device that will give an input pulse to the Z-65 controller. 1. Determine if the incoming input is either a dry contact or voltage pulse. Factory Mutual System Approved 2. If the input is a dry contact: a. Terminate the incoming connections to the Z-65/6.1H terminal strip (see...

ONTROL SECTION 3: SYSTEM CONTROL LECTRONICS ELECTRONICS Calculate the counter setting using the following chart: 2. Desired injections lubricant per volume of flow (cc/MMCF or cc/MCM) 3. pulses/volume metered (pulses/MMCF or pulses/MCM) Example #1: English Gas Flow Units pump displacement injection rate pulses per volume metered Example #2: Metric Gas Flow Units Example #1 counter setting Example #2 counter setting If the calculated counter setting is less than 10 or greater than 9900, the pulses per volume metered will need to be adjusted. This can be programmed in most flow meters to the desired...

ONTROL SECTION 3: SYSTEM CONTROL LECTRONICS ELECTRONICS 2. Set the timer dials on the Z-65/6.1H to the injection rate from step 8.1. TIME XX, X.X (HR.) COUNT x100, x10 18 hours IMPORTANT NOTE: The time (18 hours) above corresponds to the dial setting shown for the Z-65/6.1H model with the timer range setting in the factory position (jumper on the two left pins). See page 21 Timer Range Setting. 3. Turn mode switch 1 to on. 4. Turn mode switch 2 to on. 5. Turn mode switch 3 to on. 6 .Turn mode switch 4 to off. 7. Press the test button once to initiate the timer sequence. YZ

SECTION 3: SYSTEM CONTROL ONTROL ELECTRONICS LECTRONICS Setting Input Parameters Z-65 Set-Up Proportional-To-Time w/DPS-2 Option 1. Calculate the injection rate using the following 30 day chart: 2. Set the timer dials on the Z-65 to the determined time from step 1 above. TIME XX, X.X (HR.) COUNT x100, x10 18 hours 3. Turn mode switch 1 to on. IMPORTANT NOTE: 4. Turn mode switch 2 to on. The time (18 hours) above corresponds to the dial setting shown for the Z-65/6.1H model with the timer range setting in the factory position (jumper on the two left pins). See page 21 Timer Range Setting. 5. Turn...