Ruelco Self-Contained Product Manual Rev 4

Function
The Ruelco Self-Contained System is designed for the automatic closing of hydraulic actuators operating
in various conditions, when external power sources are unavailable. The system allows the operator to
easily and reliably open the well control actuator, and ensure that the system is functioning properly.
The low and high pressure accumulators will maintain system pressure through temperature
fluctuations. The integrated pressure switches allow for precise high and low pressure control of the
flow line, and will automatically act to shut down the actuator.

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Ruelco Self-Contained Product Manual Rev 4

Design Features
- Manifold design with no external tubing on the unit reduces leak points as well as
reduces likelihood of damage at jobsite.

- All material is NACE rated using anodized 6061-T6 aluminum and 316 stainless steel.

- Low and high pressure relief valves preset to desired pressure to prevent damage to
actuator or low pressure equipment.

- Quick Exhaust for fast response time

- Solenoid operated control (50 psi Max)

- 40 micron suction filter and magnetic drain plug to prevent contamination of the
system.

- Stainless steel gauges with dual scales.

- Integrated pressure switches allow for flow line control without additional components
and reduce the tubing required for install.

- Seal material used allows full functionality from -50° F to 180° F (Optional seal materials
available upon request).

- High and low pressure accumulator accommodates for thermal expansion volume
changes.

- System is easily charged with use of red anodized latch.

- Sight glass on tank allows for visual level indication of system.

- Check valve in suction tube ensures a constant prime of the pump.

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Ruelco Self-Contained Product Manual Rev 4

1 High Pressure Hand Pump 11 Sight Glass

2 1.6 Gallon Aluminum Reservoir 12 Low Pressure Switch

3 High Pressure Relief Valve 13 High Pressure Switch

4 Low Pressure Relief Valve 14 HP Gas Charge Accumulator

5 Manual Reset Relay 15 Fuse Plug

6 Regulator 16 40 Micron Filter

7 4.8 cu in LP Spring Accumulator 17 Suction Check Valve

8 0 - 5,000 psi Gage 18 Magnetic Drain Plug

9 0 - 60 psi Gage (Standard) 19 Quick Exhaust

10 Vent/ Fill Cap 20 Solenoid Operator (12VDC or 24 VDC)

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Ruelco Self-Contained Product Manual Rev 4

Specifications
Temperature Range -50 F to 180 F
HP Circuit Max Pressure 5,000 psi
LP Circuit Max Pressure 120 psi
Min Pressure 30 psi
LP Relief Valve Range 50-150 psi
HP Relief Valve Range 2,000 - 6,000 psi
Range (Optional) 250 - 3,000 psi
Reservoir Capacity 1.6 gallons
Capacity (Optional) 2.5 gallons
LP Accumulator Capacity 4.8 cu in
HP Accumulator Capacity 6 cu in
Capacity (Optional) 16 cu in
Solenoid Voltage 12VDC or 24 VDC
Normally Open Wattage 1.8 watts
Rating Class 1 Div 1 A,B,C,D
NEMA 4
Max Pressure 50 psi
Pump Displacement .39 cu in/ stroke
Fuse Plug Temperature Range 158°F to 283°F
Pressure Switch Repeatability 1%
Deadband 8%
Cv .13
Max Process WP 5,000 psi
Max Process WP (Optional) 10,000 psi (316 Only)
Burst Pressure 5,000 psi
Burst Pressure (Optional) 10,000 psi (316 Only)
Standard Ranges 1G ( 50 - 200 psi)
1Y ( 175 - 450 psi)
2G ( 450 - 1,750 psi)
2Y ( 1,500 - 3,000 psi)
High Pressure 2P ( 2,000 - 5,000 psi)
2S (4,500 - 10,000 psi)

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Ruelco Self-Contained Product Manual Rev 4
Installation
Every Ruelco Self-Contained unit is 100% function tested using a fully charged gas accumulator. After
testing, the gas accumulator is fully discharged and the each unit is shipped with a clean and empty
tank.

NOTE: The gas charge accumulator must be pre-charged at the time of commissioning at the operating
temperature for proper function of the unit. Ruelco can recommend a pre-charge and operating
pressure based upon the actuator minimum hold open pressure, maximum actuator pressure, and the
environmental conditions. For actuator volumes/ systems over 150 cu in, Ruelco recommends using the
16 cu in option in order to optimize the functional temperature range of the unit. Charge kits are
available P/N: 20-205-000.

Ruelco recommends using Shell Aero 41 or equivalent.

Connections

Only two connection lines are necessary to install and operate the unit.

1. Connect the actuator to one of the three high pressure outlet ports on the manifold or if installed, the
“To Actuator” port of the quick exhaust.

2. Connect the process flow line to the back of the pressure switch manifold.

Gas Charge Accumulator Charging Procedure

1. Remove Gas Valve Guard from top of the Accumulator then remove the yellow gas valve stem cap.

2. Using the two ¾” open-ended wrenches, open the accumulator gas valve by turning the top hex
clockwise.

3. Connect charging gooseneck fitting to a nitrogen tank with a pressure gauge in line.

4. Connect the swivel nut on the gooseneck fitting to the gas valve.

5. Slowly open nitrogen supply valves until in line pressure gauge reads required pressure.

6. Using the two ¾” open-ended wrenches, completely close the accumulator gas valve by turning the
bottom hex counterclockwise.

7. Close all valves leading to the nitrogen supply tank. Vent any nitrogen that remains in the lines.

8. Remove the accumulator from the swivel nut on gooseneck fitting.

9. Install the yellow gas valve stem cap, and then reinstall the gas valve guard.

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Ruelco Self-Contained Product Manual Rev 4

Operation
For maximum performance and system life, prior to connecting the system to the actuator, ensure that
the actuator and connecting tubing is fully flushed and cleaned. This will prevent debris from entering
the system through the actuator when draining as well as prevent mixing hydraulic oils or other fluids
within the system. The unit is shipped dry and is tested using clean and filtered hydraulic oil.

Prior to operating the system, ensure that the low pressure and high pressure relief valves are set to the
needs of the actuator.

Flowline pressure should be connected to the ¼” npt port on the pressure switch base.

Ruelco recommends that prior to ordering the unit; the information on page 10 “Self-Contained
Parameters” is completed. This will allow Ruelco to recommend set points for the relief valves and
operating conditions for the unit. Proper set points will allow the unit to better function in the desired
environment for extended periods of time.

Start-up Manual Mode

1. Lift the latch handle into the horizontal position.

2. Stroke the pump until the desired low pressure output is obtained. The low pressure circuit is preset
to 30 psi via the regulator.

Note: If the flow line pressure is between the high and low set points of the pressure switches, the latch
will fall into an armed position. If the flow line pressure is out of the pressure switch set points, the latch
will remain in the “Manual” position. If this occurs, the system is not in “Automatic mode” and can only
be shutdown manually.

3. Continue to stroke the pump until the actuator is fully opened.

4. The latch should be in the armed hanging position indicating that the system is in the “Set” state.

5. Ruelco recommends that the pump handle be left in the upward position to prevent any high
pressure leakage, causing slow bleed down of the system.

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Ruelco Self-Contained Product Manual Rev 4

Shutdown

High or Low Pressure

The system will automatically shut down if the flowline pressure deviates outside of the pressure switch
set points. The pressure switches are independently adjustable for both high and low pressure control,
by screwing in or out the adjustment plug. The ranges can also be easily changed by changing the

springs or piston seals. Once the flow line pressure rises or falls outside the parameters set by the
pressure switches, the pilot signal holding the latch handle will vent and shut down the system. The
latch handle will return to the downward locked state.

Fuse Plug

A fuse plug comes installed in the low pressure outlet port of the regulator and will vent the low
pressure hydraulic signal, if fire activated. The fuse plug can be set to a variety of temperatures ranging
from 158° F to 350° F. The fuse plug will have to be replaced after use.

Manual Push Relay

The relay latch can be pushed inward, manually venting the pilot control signal. This will shut down the
low pressure and high pressure circuit, closing the connected actuator.

Solenoid

An integrated manifold mounted solenoid valve can be used as a remote operated shutdown. The
normally open solenoid is mounted to the relay and will vent the pilot signal upon loss of an electric
signal. This will shift the relay and shut down the system. The solenoid is available in a 12VDC or 24VDC
option.

ESD Valve (Not Included)

An optional external ESD valve can be connected to the low pressure output on the manifold. If this
valve is activated manually, the low pressure signal will be lost and the shut down the system.

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Ruelco Self-Contained Product Manual Rev 4

Spare Parts/ Repair List

Description Part Number Qty Required
Regulator 5001-05000 1
LP Spring Accumulator 5002-05000 1
Relay 5003-05000 1
Pressure Switch 5004-XXXX0 1
Quick Exhaust 5005-05000 1
Solenoid Valve 5003-S5000 1
Fuse Plug 2102-25XXX 1
HP Gas Charge Accumulator 2400-L5000 1
HP Relief Valve 7500-2R000 1
LP Relief Valve SC-055-000 1
Magnetic Drain Plug SC-070-000 1
Pump w/ SS Shaft SC-071-00S 1
40 Micron Filter SC-024-040 1
Suction Check Valve SC-023-000 1
Reservoir 50-003-000 1
Sight Glass SC-077-000 1
0-60 psi Gauge SC-075-060 1
0-5000 psi Gauge SC-076-000 1
Handle SC-072-000 1
Mounting Bracket 50-100-000 1

Repair Kit f/ Regulator SC-044-000 1

Repair Kit f/ LP Spring Accumulator SC-013-000 1
Repair Kit f/ Relay SC-016-000 1
Repair Kit f/ Pressure Switches 50-015-000 1
Repair Kit f/ HP Gas Charge
Accumulator 20-204-000 1
Repair Kit f/ HP Relief Valve 75-015-000 1
Repair Kit f/ Quick Exhaust 50-047-000 1
Repair Kit f/ Solenoid Valve 50-064-000 1
Repair Kit f/ LP Relief Valve SC-054-000 1
Repair Kit f/ Pump SC-021-000 1
Repair Kit f/ Sight Glass SC-065-000 1
Tank Gasket SC-022-000 1
Gas Charge Kit 20-205-000 1

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Ruelco Self-Contained Product Manual Rev 4

Side View of Bracket

Back View of 3” -7” Square Mounting Slots

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Ruelco Self-Contained Product Manual Rev 4

Title: Author:
Griff Poindexter
Ruelco Self-Contained Parameters Date:

Customer Name:
Inquiry Date:

Actuator Information

Actuator Volume= cu.in.

Max Actuator Pressure= psi

Minimum Actuator Hold Open Pressure= psi

Ruelco Self-Contained Operating Parameters

Accumulator Size= 6 cu.in. Standard

Ruelco Recommended Based Upon

High Pressure Relief Valve Set Point= psi Actuator Data

Low Pressure Relief Valve Set Point= 50 psi Standard

Regulator Set Point= 30 psi Standard

Calculation based on temperature

High Pressure Accumulator Pre-charge= psi performance

High Pressure Switch Set Point= psi Customer Provided (if applicable)

Low Pressure Switch Set Point= psi Customer Provided (if applicable)

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Ruelco Self-Contained Product Manual Rev 4
TROUBLESHOOTING
Trouble Possible Causes Corrective Repair Instructions

Cannot Charge System 1. Low Oil Level - Fill with oil until above
minimum level

2. No Power to Solenoid - Check solenoid connections

3. Clogged Filter - Remove Tank and clean filter

4. Process Pressure out of Range - Check that process pressure is

in between Pressure switch Set
Points

5. Stuck Check Valve - Remove Pump and lightly

depress suction check ball

Losing System Pressure 1. Hydraulic leak in external lines - Check all fitting connections

2. Pressure Switch tripped High or - Check sense pressure gauge

Low and adjust set points if needed

3. Thermal expansion - Check HP accumulator pre-

charge is set correctly
- Check HP relief valve is set
sufficiently above the max
anticipated control pressure

4. Low Pressure Leaks - Check that low set pressure is

above 25 psi (minimum to hold
relay open)
- Check LP relief valve is set
sufficiently above the low
pressure control circuit

5. Low Pressure Rises - Clean Regulator /Change Seat

6. High Pressure Leaks - Make sure pump handle is in

the upward position
- Ensure proper torque on Pump
45 ft*lbs

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