Fuel System16419-27 & 16430-36 Sec 2 Vol 2

Index
Instructions for gen-set auxiliaries

Section 2, Volume 2
Plant: Confidence Power Rangpur Ltd. Issued date: 06.09.2018
Order no: 317130 Engine no: 16419-27
16430-36
Engine type: B32:40V16AH Revision: 0
Techn. Part. No. Syst. Doc. No.

Spec. Description of equipment Art. No. Dwg. Instr. No. Chap
Pos.No Dwg. No.
04.00 EXHAUST SYSTEM 4

04.00 Charge air & exhaust system P&ID B 1202/67
Exhaust gas silencer
Expansion bellow
07.00 FUEL OIL/NOZZLE SYSTEM PART 1 5
07.00 Fuel oil system 16419-27 P&ID B 1200/04
07.00 Fuel oil system 16430-36 P&ID B 1202/68
07.07 Fuel inj. pumps cleaning equipment, drawing B00403375 L 740/32
Part list for Fuel inj. pumps cleaning equipment B00403375
07.08 DO/HFO Change over unit 16419-27 B00709148 F 164/06
07.09 HFO Duplex filte 16419-27 B00709152 F 164/11
07.19 Mechanical limit switch, DN40 B00709241 F 170/83
07.50 Pressure control valve, DN50 16430-36 B01002782 F 180/55
HFO Feeder module (Aura Marine)
LFO Feeder module (Aura Marine)
Floating ball valve Rotex
08.00 Nozzle oil temp. control system, drawing P&ID B 1203/25
08.05 Nozzle oil temp. control module B00708805 F 162/16
Sec 2 Vol 2 Confidence Power Rangpur Ltd. 1

[ BLANK ]
[ BLANK ]
D
I – Installation documentation D – Operation/maintenance documentation S – Service documentation
Component: Exhaust gas silencer
Type : BBM Acoustic
Engines : 16419-27 & 16430-36
BEAS Project no: 317130
Date/Sign/rev.: 30.08.18/IvGu/0
BERGEN ENGINES AS
A Rolls-Royce Power System Company
P.Box. 3, 5109 Hylkje, Norway, Switchboard + 47 55536000, Telefax + 47 55 53 61 04
[ BLANK ]
Exhaust Gas Silencer
[ BLANK ]
1 2 3 4 5 6 7 8 9 10 11 12
112 111
90° 6
THK
5
THK
A TYP 5 113 103 Address: Gat No. 266, A
BBM Acoustic
6
40
R60 India Pvt. Ltd. Village Bhare
Ph : 009120-66732400 E-mail: sales@bbmindia.com Pirangut, Tal Mulshi
50
115 www.bbm-akustik.de Pune-412108
45°
87 : CONFIDENCE POWER
200
PROJECT
120
5
350
470
5 TYP CUSTOMER : BERGEN ENGINES INDIA PVT. LTD.
101
n36
OUT TO OUT
(2320 `10.0 )
P.O. NO. : 11091-201 to 207

2100±5.0
0° 90 6
BCD
TAG NO. : **
180° THK
TYP DESIGNATION : EXHAUST GAS SILENCER (B32:40V16AH)
5
20
THK
56
OPERATING TEMP. : 310 ~C
DETAIL D
45 °
B 101 MAX. ALLOWABLE TEMP. : 340 ~ C B
TYP 5 OPERATING PRESSURE : Atm
5
110 DETAIL C 2 MAX. ALLOWABLE PRESSURE : Atm

DESIGNED & ENGINEERED BY : BBM Akustik Technologie GmbH
270° 117
105 106 107 108 109
244 `5.0
Ø1220 ` 5.0 QTY REQUIRED: 07 NOS.

118
5 THK APPROX WEIGHT: 4640 Kg/Silencer Approx. 2
C 104 C
D
NOTES:
FOR 7 ENGINE NO:- (16430-16436) 1. ALL DIMENSIONS ARE IN mm.
6
THK
2. SURFACE PREPARATION : GRIT BLASTING TO SA 2 1/2.

3. PAINTING:
a) PRIMER COAT : INORGANIC ZINC SILICATE: 75µm
115 b) FINAL COAT : HR ALUMINIUM: 25µm
C) TOTAL DFT : 100µm
MAKE:- AKZO NOBEL / JOTUN / CARBOLINE / HEMPEL.
D OPERATING DATA D
Engine No. B32:40V16AH
1900 `5.0 Medium EXHAUST GAS
5 THK CASING OD Design Mass Flow rate 53020 Kg/hr
3250
2 Max. operating pressure ATM

Working temperature 310 deg C
117 Pressure drop 5.0 mbar
Attenuation 35 dB
NDT as per QAP
E C 1000 1 GLASS NEEDLE FELT AS REQUIRED ISO GLASS

E
900 1 MINERAL WOOL AS REQUIRED IS 8183
6800 `5.0 CASING LENGTH
500 1 CAPSULE ABS UNIT AS REQUIRED SS 409 1.5 THK

400 1 CASING ABS UNIT AS REQUIRED SS 409 1.5 THK
OUT TO OUT
(7300 `15.0)
118 12 RIB-01 Plate 6 IS 2062

114
117 1 NAME PLATE BRACKET Plate 5 IS 2062
116 1 SPARK ARRESTOR Plate 5 IS 2062
115 4 LIFTING LUG Plate 20 IS 2062
114 4 MOUNTING BRACKET Plate 20 IS 2062
2 113 1 BRACKET RF PAD Plate 6 x OD1912...470 Lg IS 2062
112 1 PLUG 1 1/2"-IS 1239 Part 2 IS 1239
111 1 DRAIN COUPLING 1 1/2"-IS 1239 Part 2 IS 1239
101
F 110 1 SPARK COLLECTING CHAMBER Plate5 IS 2062 F
109 144 WASHER for M20 Std Galv.
108 144 HEX NUT M20 Gr.10
107 72 STUD M20 x 90Lg. Gr.10.9
106 2 GASKET 3 Thk GE1520 (Teadit)
2 n1366
5° 105 4 INLET OUTLET FLANGE Plate 16 IS 2062
10° OD
n22
104 2 INLET OUTLET PIPE Plate 5 x OD1220...255 Lg IS 2062
4500
3650 `5.0
n1310
2 103 1 OUTLET END PLATE Plate 6 x OD1920 x ID1226 IS 2062
(36x) PCD
102 1 INLET END PLATE Plate 6 IS 2062
n1226 101 1 CASING Plate 5 x OD1900...6800 Lg IS 2062
110 ID ITEM QTY DESCRIPTION DIMENSION MATERIAL
PARTS LIST
G G
2 12.09.2017 REVISED AS MARKED. GRJ GRJ
100
116 1 11.09.2017 REVISED AS MARKED. GRJ GRJ
0 08.09.2017 FIRST ISSUE SRM GRJ
Rev. Date: Description By Chk
80
APPROVED BY:
Maße nicht abgreifbar / not to scale

BBM Acoustic BBM Akustik
THK
6
TECHNOLOGIE
11091-A02-100.idw
INDIA Pvt. LTD.
60
266, VILLAGE BHAR E, POST GHOTAWADE, P IRANGUT, PUNE: 412 108. 82152 Planegg / 45472 Mülheim a.d. Ruhr - Germany
Customer: P. No.: Format:
A1 Date: Name:
104 BERGEN ENGINES INDIA PVT. LTD. BBMP11091 Drawn: 08.09.2017 GRJ
40
H ISO VIEW H
244 `5.0
Projection:
A/C: CONFIDENCE POWER, RANGPURA PH-1. Checked: 08.09.2017 GRJ
Ø1220 ` 5.0 105 106 107 108 109
ITEM NO. 105 Title: Approved: 08.09.2017 RP
5 THK 16 THK
Data/File
GENERAL ARRANGMENT DRAWING FOR Drg.-No.:
20
Sheet: Scale: Rev.:
EXHAUST GAS SILENCER 11091-A02-100 1/1 NTS 2
1 2 3 4 5 6 7 8 9 10 11 12
[ BLANK ]
Exhaust Gas Silencer
(9 X B32:40 V16AH)
(Engine No: 16419 – 27)
[ BLANK ]
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
NOTE:
1.) ALL DIMENSIONS AR IN MM
A 2.) SURFACE PREPERATION: A
Section A-A a) EXTERNAL SURFACE: SA 2 21 SHOT BLASTED
MATING FLANGES b) INTERNAL SURFACE: MECHANICALLY CLEANED
1 3.) PAINTING SPECIFICATION:
& BOLTS, NUTS, WASHER
17 18 19 20 a) FIRST COAT: 70 µm ETHYL ZINC SILIKATE (INTERZINC 22)
WITH GASKET b) FINAL COAT: 30 µm SILIKON ALUMINIUM (INTERTHERM 50)
OD. 2200 CASING ISOMETRIC VIEW c) TOTAL DFT: 100 ±20 µm
A OD. 1220 OUTLET
OUTLET NOZZLE
9
250
RIB FLANGE TABLE
10
FLANGE AS PER DIN 86044-600
B B
TOP END PLATE SR.NO. FLANGE FLANGE PCD DIA BOLT HOLES BOLT DIA. NO. OF THICKNESS OFF
8 ID (mm) OD (mm) (mm) (mm) (mm) BOLTS FLANGE (mm)
(350)
1 1226 1366 1310 22 M20 36 20
CHAMBER 4 Matching flanges will be machined and matching surfaces will be applied with
ø45
(HOLE)
rust inhibitor (lacquer paint)
NAME PLATE
12 DESIGN DATA
BRACKET CHAMBER 3
C SR.NO. DESCRIPTION MEASUREMENT C
1 TYPE EXHAUST SILENCER
2 EXHAUST FLOW RATE 53400 kg/h
3 EXHAUST TEMPERATURE 360°C - 410 °C
4 EXHAUST SILENCER PRESSURE DROP 400 Pa (@ 100% LOAD)
INTERNAL CHAMBER 5 EXHAUST GAS VELOCITY 45 m/sec.
OD. 2200 CASING 7
ASSEMBLY 6 SOUND ATTENUATION 35 dB (A)
6000 5 (FLANGE FACE TO FACE)

7 WEIGHT OF SILENCER 3500 kg
1988
B B CHAMBER 2
5500 CASING (LENGTH)

D D
4800
5500
SUPPORT BRACKET
11
20
MINERAL WOOL WITH
5
E GLAS NEEDLE FELT E
6
EARTHING
14
BOSS
SILENCER CASING
4
2250
2250
LIFTING
2500 5
13 CHAMBER 1
LUG
F F
ø45
(HOLE)
BOTTOM END PLATE

350
3
RIB
10
INLET NOZZLE
2
250
G SPARK TRAP G
15 OD. 1220 INLET
A DRAIN PIPE+CAP MATING FLANGES
1 QTY. REQ.: 09 Nos.
16 & BOLTS, NUTS, WASHER
WITH GASKET 17 18 19 20 22 2 WASHER for M10 BOLT A2
21 2 HEXAGON BOLT ISO 4017 - M10 x 25 A2
20 144 WASHER for M20 BOLT STD.
TOP VIEW Sektion B-B 19 144 NUT M20 A194 GR. 2H
18 72 STUD BOLT M20 x 100 A193 GR. B7
180° 180°
H NAME PLATE 17 2 GASKET AS REQUIRED ASBESTOSE FREE H
12
BRACKET 16 1 SPARK TRAP DRAIN PIPE CAP 2" CAP P 235 GH
00
22 15 1 SPARK TRAP DRAIN PIPE 2" PIPE x 150 LG: P 235 GH
225° 
135° 14 2 EARTHING BOSS AS REQUIRED 1.4301
LIFTING SUPPORT BRACKET 13 2 LIFTING LUG PL. 15 x 131 x 142 LG. S 235 JR
13 220 11
LUG 2 EARTHING 12 1 NAME PLATE BRACKET PL. 4 x 120 x 384 LG. S 235 JR
14 11 4 SUPPORT BRACKET PL. 20 x 226 x 330 LG. S 235 JR
BOSS
10 12 RIB PL. 6 x 224 x 450 LG. S 235 JR
9 1 OUTLET NOZZLE PL. 5 x OD 1220 x 260 LG. S 235 JR
I I
330
8 1 TOP END PLATE PL. 6 x OD 2220 x ID 1220 S 235 JR

270° 90° 270° 90° EARTHING
14 7 1 INTERNAL CHAMBER ASSEMBLY AS REQUIRED 1.4512
BOSS
6 LOT NEEDEL FELT AS REQUIRED -
5 LOT MINERAL WOOL 100 kg/m³ MiWo
4 1 SILENCER CASING PL. 5 x OD 2200 x 5000 LG. S 235 JR
750
3 1 BOTTOM END PLATE PL. 6 x OD 2220 x ID 1220 S 235 JR

2 1 INLET NOZZLE PL. 5 x OD 1220 x 260 LG. S 235 JR
15°
1 4 FLANGE REF. TABLE S 235 JR
J HEXAGON BOLT ITEM QTY. DESCRIPTION DIMENSION MATERIAL
J
SPARK TRAP 21
15 WASHER
0° DRAIN PIPE+CAP 0°
BILL OF MATERIAL
16 22
2425 3
100
2640
DETAIL NAMEPLATE ( 1 : 3 )
80
gezeichnet geprüft
K Rev. Änderung / Revision Datum/Date drawn by checked by K
Maße nicht abgreifbar / not to scale

BBM Akustik
BBM Akustik Datum/Date Unterschrift/signature Format
TECHNOLOGIE
Gezeichnet format
82152 Planegg / 45472 Mülheim a.d. Ruhr - Germany
www.bbm-akustik.de
drawn by 08.02.2017 rgl
TECHNOLOGIE
60
Bezeichnung / Designation
Geprüft
checked by 08.02.2017 utz A1
KKS - Nr. / Tag - No.
Projektleiter 82152 Planegg / 45472 Mülheim a.d. Ruhr - Germany

Proj.Engineer 08.02.2017 am www.bbm-akustik.de
Kom.-Nr.: Maßstab/Scale Benennung/Designation Datei/File
17448-DRW-A01_00.dwg
FLOW L17448 1:33 GENERAL ARRANGEMENT DRAWING
40
Kennwort/Code word Projection EXHAUST GAS SILENCER 17448 A 1/0 0
‐
RANGPUR 09 PIECE Zeichnungs-Nr./Drawing-no. Rev.
L Schweißnahtberwertung für drucktr. Bauteile nach EN ISO 5817 B Allgemeintoleranzen für Behälter Schutzvermerk nach L
Schweißnahtberwertung für nicht drucktr. Bauteile nach EN ISO 5817 C
20
nach DIN 28005 T1, AD 2000 HP 1. DIN ISO 16016 beachten
Welding evaluation for pressure parts acc. EN ISO 5817 B General tolerances for vessels Consider note of safe-conduct
Welding evaluation for non pressure parts acc. EN ISO 5817 C acc. DIN 28005 T1, AD 2000 HP 1. acc. to DIN ISO 16016
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
[ BLANK ]
[ BLANK ]
D
Component: Expansion Bellow
Type : Beloflex Single
Engines : 16419-27 & 16430-36
BERGEN ENGINES AS
[ BLANK ]
Expansion Bellows
(9 X B32:40 V16AH)
(Engine No: 16419 - 27)
Expansion Bellows
(7 X B32:40 V16AH)
(Engine No: 16430 - 36)
[ BLANK ]
[ BLANK ]
[ BLANK ]
[ BLANK ]
[ BLANK ]
[ BLANK ]
20/03/2018 10:34 ItemName Size Draw ID/Doc ID/rev
Pipe Injection Pump Room Arr. Clean.W/Tank.Inj.Pump B00403375/!# L740_32/!#OR
POS Item ID Name Size Draw ID/Doc ID/rev Qty ERP UOM
1 B00403091 Injection Pump Cleaning Pipe Arr. Mount. L737_69/!C 1 pcs
2 B00403357 Reservoir Tank, Cleaning.Fuel Oil L739_86/!B 1 pcs
3 B00017621 Plug 1" BSP-Brass B00017621/# 2 pcs
4 B00011206 Male Stud Coupling P-GEV 8LR F160_18/# 2 pcs
5 B00021244 Adjustable Male Stud Elbow P-EWV 8L Adj. B00021244/# 1 pcs
6 B00020870 Pipe Seamless Ø8 X1 Stainless B00020870/# 280 mm
7 B00020870 Pipe Seamless Ø8 X1 Stainless B00020870/# 125 mm
8 B00703641 Level Sensor Lub.O, Gauge 1"Light Met. F117_46/!# 2 pcs
9 B00010953 Screw Hexagon Head Fully Threaded M10 X25 B00010953/# 4 pcs
10 B00016591 Nut Hexagon High M10-8.8 B00016591/# 4 pcs
11 B00016902 Washer Spring Ø10 B00016902/# 4 pcs
12 B00017630 Gasket Copper Ø33,5 X39 X2 B00017630/# 2 pcs
1
[ BLANK ]
F 164/06 D
Component: DO/HFO Change over unit
Type : Aura Marine
Engines : 16419-27
BEAS Part no: B00709148
BERGEN ENGINES AS
[ BLANK ]
23.03.2017
AMFI 515121
Unit, fuel change

PCO-M-38/38-MDO/HFO
14225
Contact details 2(102)
Document ID: AMFI 515121
Auramarine LTD
Street address:
Keskiläntie 1, 20660 Littoinen
P.O. Box 849, FI-20101 Turku
Postal address:
P.O. BOX 849
FIN-20101 TURKU
FINLAND
Tel. +358 204 860 5030

Fax +358 204 860 5031
www.auramarine.com
Business ID: 0684696-3

Domicile: Turku
Spare parts and service

after.sales@auramarine.com
Document ID: AMFI 515121 3(102)
Table of Contents
Section Document ID Page
1 Data sheet, general arrangement

Technical specification D10160, - 5
General arrangement 310009, - 10
2 PI Diagram, part list

PI Diagram P13014, - 13
Part list 0014225 14
3 Electric drawings, part list

Electric drawing 410299, A 17
4 Instruction Manual
Instruction Manual D03554, B 23
5 Attachments
Factory certificate 14225 - 101
Document ID AMFI 515121 4(102)
Section 1
Data sheet, general arrangement
7.12.2016 1(5)

Technical specification Doc no.: D10160

DFO/HFO change‐over unit
PCO‐M‐38/38‐MDO/HFO

Bergen Engines AS
Part no.: 709148

Auramarine Ltd
Unit Nos.: 14225

AURAMARINE LTD.
P.O. Box 849, FI‐20101 Turku
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Business ID: 0684696‐3
Domicile: Turku
7.12.2016 2(5)


1. Design Basis

Engine type: 16B32/40L
Main voltage: 415 V / 50 Hz
Control voltage: 110 VAC
Instrumentation voltage: 24 VDC
Fuel working / test pressure: 8 / 15 bar
Min pressure into the unit: 4 bar
Control air: dry, oil free, 5‐8 bar, est. consumption 25 Ndm3/h

HFO pump capacity 6,05 m3/h, 5/8 bar, 12 cSt
Electric motor IEC90, 2,2 kW, 2900 rpm, IP55, Ins. F, Temp F

DFO pump capacity 7,41 m3/h, 5/8 bar, 7 cSt
Electric motor IEC90, 2,2 kW, 2900 rpm, IP55, Ins. F, Temp F

7.12.2016 3(5)


2. Main Components

Pos. Denomination

D005 HFO pump
IMO ACE 038K NTBP
‐ Rotary self‐ priming displacement screw pump
‐ Equipped with mechanical shaft seal
‐ Driven by electric motor (pos.M005)
‐ Starter not included

D006 DFO pump
IMO ACE 038N NVBP
‐Rotary self‐ priming displacement screw pump
‐ Driven by electric motor (pos.M006)
‐ Starter not included

V001 3‐way valve
Starline 285, DN32/PN40
‐ Equipped with a double action actuator, limit switches
and a solenoid valve

V002 2 x 4‐way valve
Starline DN32/PN40, X‐ 90
‐ Two pcs 4‐way valves connected to one common double acting
actuator with limit switches and a solenoid valve

B001 Compensating tank
Auramarine
‐ Volume 50 liter, pressure class 20 bar.
‐ Isolated with mineral wool and covered with galvanized
steel plate

V007 Pressure keeping valve
Kracht SPVF40
‐ Pressure regulating overflow valve
‐ Setting range 0.5 – 2.5 bar, set point 8 bar g

V030 Regulating valve
‐ Globe valve

7.12.2016 4(5)


3. Instruments

Ind. Denomination

PT Pressure transmitters at pump outlet, range 4‐20 mA = 0‐16 bar
PI Manometers at pump inlet & outlet, glycerine filled, range 0‐16 bar

4. Electrical equipment

Terminal box for instruments, limit switches and pilot solenoid valves
Emergency stop buttons for each pump
Junction box for trace heating

5. Materials, miscellaneous

Frame ‐ Welded of profile steel bars
‐ Equipped with bottom for leakage oil
‐ Painting system ISO 12944‐5:2007 A2.06 (EP 120/2 FeSa 2½)
‐ Color RAL 5019

Oil pipes ‐ Seamless carbon steel St 37.4 DIN 2391
‐ Welding according to ISO 3834‐2:2005
‐ Painting system: SFS‐EN ISO 12944‐5; 2007 A2.06 EP120/2
‐ Color RAL 5019
‐ HFO lines electrically trace heated and insulated with mineral
wool covered with galvanized steel sheet

Compensating tank ‐ Insulated with mineral wool and covered with galvanized steel
sheet.

Connection flanges ‐ EN 1092‐1, counter flanges, gaskets bolts and nuts are included

Instrument pipes ‐ Oil lines: Hydraulic pipe St 35.4 DIN 2445.2.2
‐ Air lines: Copper pipe

Valves ‐ Ball valves, nominal pressure class 40 bar, uninsulated

Name plates ‐ Material of stainless steel for process components and connection flanges
according to PI diagram
‐ Engraved plastic name plates on terminal box and emergency stop buttons

7.12.2016 5(5)


6. Operation

Reference is made to P&I diagram P13014

DFO running ‐‐ > Changing over ‐‐ > HFO running

V001 open channels 1‐2 1‐3; Duration 300 sec. 1‐2

V002 open channels 1‐4 1‐2 1‐2
2‐3 3‐4 3‐4

HFO running ‐‐ > Changing over ‐‐ > DFO running

V001 open channels 1‐2 1‐3; Duration 300 sec. 1‐2

V002 open channels 1‐2 1‐4 1‐4
3‐4 2‐3 2‐3

7. Revision list

‐
1 2 3 4 5 6 7 8
A A
1547
1500 B
1441 R
B B
240 A,F,E,E1,H
45 C
0
C C
1344
960
1790 H 300 300

890 E1
980 R
500 F
300
0
70
D 1250 40 D
X 25
50
S=10
18
660
DETAIL X
600
SCALE 1 : 10
E
RECOMMENDED
SERVICE SPACE
0
Units Sheet Description

mm kg 1 / 1 GENERAL ARRANGEMENT
0
A 500
E 890
B 1105
1920
General tolerances: SFS-EN ISO 13920B PCO-M-38/38-MDO/HFO

Designed Date Dwg.No. Rev
F SSo 27.10.2016
Checked Date
JSa 27.10.2016
310009
- 27.10.2016 SSo
Rev Change Date Designed www.auramarine.com
Approved
TLe
Date
27.10.2016 -
1 2 3 4
Section 2
PI Diagram, part list
Part list
0014225_PI structure
Structure 0014225 Desc 1 Unit, fuel change Status Main information created
Modified 2017-03-15 Desc 2 PCO-M-38/38-MDO/HFO
Item code Rev Position Desc 1 Desc 2 Qty Pcs
S005437 0 PI structure PCO-M-38/38-MDO/HFO 1 1
AM04743 0 B001 Vessel, Compensation 50 l, PN 20 1 1
M000029 0 D005 Pump, screw ACE038K3_NTBP, DN40 1 1
M000062 0 D005A Connecting frame ACE038, IEC90, F165, Al 1 1
M000075 0 D005B Angle bracket IEC80-90, 025-052, F165, Al 1 1
M000515 0 D005C Coupling A24A, 64 Sh D, d19/d24 1 1
M000023 0 D006 Pump, screw ACE038N3_NVBP, DN40 1 1
M000062 0 D006A Connecting frame ACE038, IEC90, F165, Al 1 1
M000075 0 D006B Angle bracket IEC80-90, 025-052, F165, Al 1 1
M000515 0 D006C Coupling A24A, 64 Sh D, d19/d24 1 1
M000034 0 M005 El. motor, induction+ptc HMA2 90L-2, 2.2kW,400Y,3000r,IE2 1 1
M000034 0 M006 El. motor, induction+ptc HMA2 90L-2, 2.2kW,400Y,3000r,IE2 1 1
M021621 0 P001 Indicator, pressure 213,0-16,bar,d63,R1/4",S1 1 1
M021727 0 P013 Transmitter, Pressure MBS3350,0-16,bar,R1/4",4-20mA,32V 1 1
AM05508 0 V001/V001A Valve, 3-way, Actuator, Lim. 285SGT/BW,DN32,L2/90,AT201D-24DC,PC
1 1
switch
S005379 0 V002/V002A Valve, 4/2, actu, switch, solen 193SGT/X-90,AT450D,XCK,DN32,24V 1 1
M021073 0 V003 Valve, ball 225 SGS/BW SCH 40, DN40, PN100 1 1
M021526 0 V007 Valve, pressure relief SPVF 40 C2F1A02, DN40 1 1
M021085 0 V010 Valve, ball 1720, Rp1/4", PN64 1 1
Part list
M021103 0 V030 Valve, globe 228, DN32, thro, cast steel, str 1 1
M020269 0 Tracing Cable, heating HTSX-12-2-FOJ, 37 W/m, 230 V 1 15
M020556 0 Tracing Junction box 311020 2xPg16, 89x89x42, ZnAl 1 1
M020268 0 Tracing Accessories Install kit PETK-2 for HTXS cable 1 1
M020959 0 Tracing Cable gland Pg16, brass, 161/MS 1 1
M020878 0 Tracing Cable gland M20, polyamide, inner D 7.0-13.0mm 1 1
M003125 0 X001 Seal guard 12SL00-125, grease dispenser (Ex) 1 1
M003847 0 X002 Hose with fittings 301-04-04/EZ-04/302-02-04, L800 1 1
S003558 0 X003 Machining, part Test flange, D40x5, Rs1/4", Brass 1 2
Section 3
Electric drawings, part list
Part list
0014225_El. structure
S005438 0 El. structure PCO-M-38/38-MDO/HFO 1 1
S005374 0 Junction box PCO-M-38/38-MDO/HFO 1 1
M020549 0 Accessories Door stay, SZ 2519.000, AE 1 1
M020603 0 Rail DIN, 35x7.5mm, 2933/2 SL .6 1
M002195 0 Cable conduit GF-DIN-SH-A7/5, 37.5x37.5 1.2 1
M021763 0 Accessories Holder, PMR 1427 1 2
M021766 0 Busbar PSK 152, L=1000 mm .2 1
M021764 0 Terminal, ground KJ 18, 1,5-16 mm2 1 15
M020555 0 Accessories Moisture inhibit tape,VCI-170 .03 1
M020878 0 Cable gland M20, polyamide, inner D 7.0-13.0mm 1 14
M020879 0 Lock nut M20, polyamide 1 14
M020486 0 Terminal block, spring D2.5/5.I.3L,2.5mm2,grey,24A,single 1 29
M020494 0 End section FED5.I.3L,grey,spring,single 1 2
M020488 0 Terminal block, spring D2.5/5.I.P.3L,2.5mm2,ye/gr,single 1 4
M020474 0 End stop BAM2,grey 1 4
M021022 0 Button, E-stop box MEPY1-1024, 1NO, 1NC 1 2
M020861 0 Sign, emergency stop MA6-1101, plastic 1 2
M021023 0 Shroud MA1-8053, e-stop 1 2
S005375 0 Unit components PCO-M-38/38-MDO/HFO 1 1
M020193 0 Cable, power LKM-HF, 3G1.5mm2, 0.6/1kV 10 1
M020242 0 Cable, Control RFE-HF, 2x2x0.5mm2, 0.15/0.25kV 25 1
S005376 0 Nameplate set PCO-M-38/38-MDO/HFO 1 1
Section 4
Instruction Manual
Instruction Manual 23(102)
Contents
1 STORAGE, HANDLING AND INSTALLATION..................................................................................................2
1.1 Storage.....................................................................................................................................................2
1.2 Handling ...................................................................................................................................................2
1.3 Installation ...............................................................................................................................................3
2 SAFETY INSTRUCTIONS ................................................................................................................................3
3 WARNINGS AND INSTRUCTIONS .................................................................................................................4
4 START-UP .....................................................................................................................................................5
5 GENERAL TROUBLE SHOOTING ...................................................................................................................5
6 MAINTENANCE ............................................................................................................................................6
6.1 Parts subject to wear ...........................................................................................................................6
6.2 Periodic maintenance ..........................................................................................................................6
6.2.1 Function tests ..................................................................................................................................6
7 HOW TO ORDER SPARE PARTS ....................................................................................................................7
8 COMPONENT MANUALS..............................................................................................................................8
Components ....................................................................................................................................................8
1 STORAGE, HANDLING AND INSTALLATION

1.1 Storage
The unit is to be protected from rain, snow and dirt. In order to avoid
condensation, it is recommended to avoid temperature variation.
Storage temperature: -10 to +60 ºC
Ambient humidity: max. 85 %
Storage time is one year for a constant container, in case of longer
storage time please contact Auramarine.
1.2 Handling
Figure a) packed unit b) unpacked unit
Unit is handled with lift hangers or with forklift truck.

Used lifting device is to have adequate lifting capacity and break resistance, and it is
prohibited to be under lifted load.
1.3 Installation
Package material is wood and plastic. Package materials are to be disposed or recycled according to
local law.
Before final installation and fastening of the unit, the following is to be taken into account:
- Visual inspection is recommended in order to see possible damages caused by transport or
moving to the installation place.
- Installation place is to be as vibration free as possible.
- Installation place must have adequate ventilation in order to prevent explosion danger.
- The unit must be fastened with bolts or by welding, see general arrangement drawing.
Additional bracing of booster unit must be done if vibration is detected.
- Plugs of pipe connections are to be removed before installing pipes to fuel oil unit.
- Pipe ends of the pipes to be attached need to be clean from the inside.
- It is recommended that all HFO pipelines connected to fuel oil units are insulated and trace
heated.
- Pipeline connections can be seen in the general arrangement drawing.
- Needed service space can be seen in the general arrangement drawing.
- Electrical connections can be seen in the interconnection pages of the electric drawings.
- Protective binding to be executed according to the standards of the installation place.
2 SAFETY INSTRUCTIONS
BEFORE COMMENCING ANY WORK, READ THIS MANUAL CAREFULLY!
1. Only trained personnel familiar with standards should handle this type of apparatus.
2. Wear protective clothing, ear defenders and eye protection. Danger of burning lesion. Beware of
hot surfaces, hot oil and noise.
3. Switch voltage off before maintenance occurs.
4. Electrical work must be carried out according to the standards by authorized persons.
5. Close shut off valves from both sides and depressurize the equipment and pipes before any
maintenance action. To prevent danger of hot liquid/steam spray.
6. Use crane to lift heavy parts during maintenance and ensure that parts removed come off in a
controlled manner.
7. After maintenance, ensure that all parts are assembled correctly.
8. Ensure that the safety instructions for all cleaners, oils and paints are available.
9. Keep the environment of the unit clean.
10. Smoking and open fire is not allowed in the immediate surroundings of fuel oil units.
11. Unwanted equipment and chemicals should be disposed of in a safe manner and according to
local laws and regulations.
3 WARNINGS AND INSTRUCTIONS

1. Pumps start automatically after power failure if auto reset is in use.
2. Run only one pump and heater simultaneously. Switch the other pump to stand-by.
3. Ensure fuel oil flow through intended heater if heater is installed.
4. Turn trace heating on if unit is stopped during HFO running, if trace heating is installed. Sludge
and vent lines in HFO use always need to be on trace.
5. Do not heat DFO.
6. Do not adjust pressure from pumps.
7. Do not run pumps dry.
8. The air pressure for the unit needs to be in the limits mentioned in the technical specification.
9. It is recommended that all HFO pipelines connected to fuel oil units are insulated and trace
heated.
10. Make sure that the operating pressure of the system as well as air pressure for the system does
not exceed the design pressure, that the temperature of the system does not exceed the
maximum allowed operating temperature (found from technical specification) and that- the
connections do not leak.
11. If the unit is suitable also for low level sulphur DFO-oils (defined in ISO8217:2005). According to
these regulations, DFO-oil viscosity should be in the range of 1,4-6,0 cSt at 40 °C. However note
that fuel viscosity must not be lower than 1,4 cSt under no circumstances. Too low viscosity
does not ensure sufficient lubrication of pump and will cause serious pump damage.
12. The limit values of technical specification need to be followed for fuel viscosity and
temperature.
13. Ensure that enough fuel consumption is present during fuel change over to consume the mixed
fuel from the system
4 START-UP
1. Switch main switches and all control switches of the unit to off position.
- Door of the control panel can be opened with main switch on by

pressing with a pin to hole shown below.
2. Switch instrument air on to fuel oil units.

3. Ensure that all miniature circuit breakers are switched on in local control
panel(s) of the fuel oil unit(s).
4. Switch main switch to on position.
5. Check all pipe connections, and in case of leakage, tighten the pipe connection.
5 GENERAL TROUBLE SHOOTING

Problem Check points / actions
3-way valve does not Solenoid valve does not work.
work Air pressure is insufficient.
Changeover process Ensure that there is enough consumption to remove the mixed fuel from the
takes too long system (See below).
Consumption
Consumption
HFO
Changeover time Changeover time
HFO fraction at feeding system decreases linearly HFO concentration at supply system decreases non-
linearly due to constant blending in the system
Check the function description from the component manuals section for more information.
6 MAINTENANCE
6.1 Parts subject to wear
Although all Auramarine fuel unit contracts offer a guarantee of quality, normal wear and tear parts are
not included in the guarantee. The following are considered wear parts:
 All gaskets, rubber pistons and O-rings
6.2 Periodic maintenance

6.2.1 Function tests
Function of all valves and actuators should be tested regularly to ensure component function. Testing
is recommended to be done every 6 months (open, close).
7 HOW TO ORDER SPARE PARTS

Identification of needed part
When ordering spare parts, please mention the following:
1. Serial number of the unit
o mentioned on the unit’s serial plate located on the unit’s upper beam
o welded on the bottom beam of the unit frame
2. Part number from the part list
3. Serial number of the part to be replaced (mentioned in the rating plate of the part)
Ordering address:
Auramarine Ltd., After Sales Dept., P.O. Box 849, FIN-20101 TURKU
Fax +358 204 86 5031
Tel +358 204 86 5030
http://www.auramarine.com/
In case of guarantee part(s), please return the damaged part(s) to the above mentioned address.
8 COMPONENT MANUALS
Components
Position Part code Description Page
8.1 D005, D006 M000029, M000023 Pump, screw - ACE3 32
8.2 M005, M006 M000034 El. motor, induction - HMA, HMC, HMD, HMT, MS, 58
Y2E1, Y2E2, YDT
8.3 V001/V001A AM05508 Valve, 3/2, actu, switch, solen - 285/283, AT, PCR 62
8.4 V003, V004, V005, V006 M021073 Valve, ball - 225 SGS, Standard 78
8.5 V007 M021526 Valve, Pressure relief - SPV / F 80
8.6 V010, V011, V012, V013, M021085 Valve, ball - 1700 series 86
V014, V015, V016, V017
8.7 X001 M003125 Seal guard - Simalube 88
Position: D005, D006

Part code: M000029, M000023
8.1 Pump, screw - ACE3
Screw pump 1
ACE3
Contents
Screw pump ACE3.............................................................................................................................................. 2
1 Installation ............................................................................................................................................. 3
1.1 Transport and storage ................................................................................................................... 3
1.2 Lifting of pump .............................................................................................................................. 3
1.3 Mounting ....................................................................................................................................... 3
1.4 Alignment and shaft couplings ...................................................................................................... 3
1.5 Pipe connections ........................................................................................................................... 5
1.6 Suction line .................................................................................................................................... 5
1.7 Discharge line ................................................................................................................................ 5
1.8 Deaeration ..................................................................................................................................... 5
1.9 Strainer .......................................................................................................................................... 6
1.10 Shaft seal drain .............................................................................................................................. 6
1.11 Liquid trap...................................................................................................................................... 6
1.12 Gauges ........................................................................................................................................... 7
1.13 Pressure relief valve ...................................................................................................................... 7
1.14 Pressure testing and flushing ........................................................................................................ 7
2 Start-up .................................................................................................................................................. 8
2.1 Before starting ............................................................................................................................... 8
2.2 Direction of rotation ...................................................................................................................... 9
2.3 Starting .......................................................................................................................................... 9
2.4 Setting the pressure relief valve .................................................................................................... 9
2.5 Adjusting the tuning ...................................................................................................................... 9
3 Exploded view...................................................................................................................................... 11
3.1 List of components ...................................................................................................................... 12
3.2 Ordering spare parts .................................................................................................................... 13
4 Maintenance........................................................................................................................................ 14
4.1 Service intervals ........................................................................................................................... 14
4.2 Inspection of shaft seal ................................................................................................................ 14
4.3 Inspection of rotors ..................................................................................................................... 14
4.4 Sectional view .............................................................................................................................. 15
4.5 Useful tools .................................................................................................................................. 16
4.6 Shaft seal - assembly drawing ..................................................................................................... 16
Screw pump 2
ACE3
4.7 Dismantling .................................................................................................................................. 17

4.8 Reassembly .................................................................................................................................. 20
4.9 Pressure relief valve .................................................................................................................... 23
5 Trouble shooting.................................................................................................................................. 24
Screw pump ACE3
This instruction is valid for all following ACE pump models

- Sizes ACE 025/032/038 Rotor diameter and Generation: D3/K3/L3/N3
- With version codes N, V, T, B, P
o Also valid for pump options: A101
o The version code is composed of the letters in the 4 columns.
o Example of pump designations std: ACE 025L3 NTBP;
o option: ACE 038N3 NVBP A101
Before commencing any work, read this instruction carefully! Failure to comply with these
instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we
refer to the ACE Product description.
Screw pump 3
ACE3
1 Installation
1.1 Transport and storage
Always protect the pump against ingress of water and other impurities. Store the pump in a clean,
dry and warm environment. The pump is delivered with the internals oiled and with protective
covers over the pipe connections and drain openings. These covers should remain in place for as
long as possible during the mounting and installation procedure but must be removed before
start up.
1.2 Lifting of pump

All pumps should be lifted with straps securely attached
to the pump or pump unit, so that the center of gravity
is located between the straps in order to avoid tipping of
the pump.
Use two eye bolts (M 20) securely fastened to the front
cover for pump LPQ. Pump and connecting frame are
lifted together using two eye bolts securely fastened to
the top of the connecting frame. (Thread dimension is M
16, except for frame size 600, where it is M 20).
Lifting of the complete pump unit with the lifting
device attached to the motor, should be avoided as the
motor’s lifting provisions may not be able to carry the
combined weight of the pump and motor.
1.3 Mounting
The pump must be securely mounted on a firm stable
foundation and positioned so that it is easily accessible
for inspection and servicing. Provisions for collecting oil
spillage when servicing the pump should be considered.
The installation must always be designed to minimize
damage. Should an operational or functional failure
occur. E.g. precautions should be considered to collect
oil spillage due to a broken pipe or pump housing, to
stop pump operation if overheating should occur or if
the oil volume is below a minimum tank level.
1.4 Alignment and shaft couplings

The pump shall be connected to its driver via a flexible
shaft coupling. Pumps of type ACG/UCG and ACF/UCF
may also be driven via gears or pulleys as specified in the
Product Description, provided the radial forces are kept
within the specified range.
Screw pump 4
ACE3
An angular misalignment of 0.1° corresponds to approx. 0.2 mm deviation/100 mm. The coupling
and alignment shall be selected not to transmit any axial or radial loads on the shaft ends. IMO AB
standard couplings shall have a distance between the coupling halves as per table (see table
below) the coupling halves shall be secured by lock screws. For other types of couplings, please
refer to respective maker’s manual.
When fitting the shaft coupling, do not use a hammer or similar as this may damage the ball
bearing and shaft seal. Use some kind of press tool.
When handling liquids that may harm skin use gloves and/or protective clothing.
When handling liquids which may involve fire hazards appropriate precautions to avoid danger
are to be taken.
Distance between coupling halves
Outer diameter Distance between Outer diameter Distance between

of coupling coupling halves of coupling coupling halves
(D mm) (t mm) (D mm) (t mm)
A B A B
50 26 2.0 8 148 3.5
67 40 2.5 16 168 3.5
82 55 3.0 18 194 3.5
97 65 3.0 20 214 4.0
112 80 3.5 24 240 4.0
128 95 3.5 26
Measures shall be provided to avoid accidental contact with the rotating shaft coupling. Any
installed coupling guard shall permit easy access to the pump shaft for maintenance and
inspection of the pump bearing and seal housing.
For direct driven pumps the alignment between pump and

motor shafts must be kept within the following limits:
Max angular
Max run-out misalignment
(mm) (degrees)
Type LPD and
ACD (n/a short coupled)
Other types 0.3 0.1
Screw pump 5
ACE3
1.5 Pipe connections

The pipe work shall be installed and
supported so that no pipe stresses
are transfered to the pump body.
The pipe work should be tight in
order to avoid leakage and
infiltration of foreign particles
and/or air.
Shut off valves should be installed
in both suction and discharge pipes,
so that the pump can be
hydraulically isolated. Pipe connections
1.6 Suction line

The suction pipe should be designed so
that the total pressure drop, measured at
the pump inlet flange, does not exceed
the suction capability of the pump.
Make a proper calculation of the suction
line including components such as valves,
strainer, pipe bends etc. Generally, the
pressure drop in the suction line
Suction line
should be as low as possible, which
is achieved if the suction pipe is short, straight and has a suitable diameter.
The velocity in the suction line should be kept in the range 0.5 - 1.2 m/s. For L.O. circulating
systems, we recommend to keep it as low as possible. The suction line must be equipped with a
port that allows filling the pump before start.
1.7 Discharge line

The discharge line should be dimensioned to keep
the velocity in the range 1 - 3 m/s.
1.8 Deaeration
In installations with negative suction head, where
the pump might be started against a pressurized
system, a deaeration pipe with an orifice (2-3 mm
recommended) has to be installed. The deaeration
pipe should be connected to the outlet pipe’s
highest point.
This must also be installed when the pump is used as Dearation
a stand-by pump
Screw pump 6
ACE3
1.9 Strainer
The pump has to be protected from foreign matter, such as
weld slag, pipe scale, etc., that could enter the pump via the
suction line. If the cleanliness of the system cannot be
guaranteed, a strainer must be installed in the inlet pipe near
the pump. For practical reasons a suction strainer with 0.6
mm mesh openings is recommended:
The size of the strainer should be selected so that it is large
enough to allow adequate pressure at the pump inlet. The
pressure drop across the strainer should preferably not
exceed 0.1 bar at max. flow rate and normal operating Strainer
viscosity. A vacuum gauge between the strainer and the pump
inlet is recommended to indicate when the strainer needs cleaning.
Note: The service life of the pump is decisively influenced by the degree of contamination of the
fluid being conveyed, that means, by the number, size and hardness of the abrasive components.
1.10 Shaft seal drain

The pump should be installed so that any leakage
from the shaft seal does not become a hazard. As
the shaft seal has to be lubricated a small amount
of oil dripping cannot be avoided. Provisions to
collect the leakage from the shaft seal must be
made.
A drain pipe can be connected to the drain
connection on the pump, (not applicable to pump
series LPD). However, when pumping heavy fuel oil
or any other liquid that is likely to become very Shaft seal drain
viscous at ambient temperature, we recommend
that the liquid is allowed to drop freely from the drain
opening.
1.11 Liquid trap

In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations the
suction pipe should be arranged so it forms a liquid
trap together with the pump, keeping the pump half
filled with liquid. See Liquid trap figure.
Liquid trap
Screw pump 7
ACE3
1.12 Gauges
Gauges for monitoring the pump’s working conditions are recommended.
These gauges should be placed readable as close to the pump’s in- and
outlet flanges as possible. On standard pumps, series ACE, LPE, ACG/UCG,
ACF/UCF and LPQ, there are gauge connections for both in- and outlet.
1.13 Pressure relief valve

All systems with screw pumps should be equipped with a pressure relief
valve installed immediately adjacent to the pump. In the standard versions
of IMO AB low pressure pumps, this pressure relief valve is an integral part Gauges
of the pump to protect the pump against excess pressure.
This relief valve is intended for momentary protection of the pump
against overpressure. It is neither intended to be a system pressure
control device, nor used as a flow regulation device.
When liquid is circulated through the valve it is heated up in
proportion to the set pressure level and the percentage of by-
Pressure relief valve
passed liquid.
Up to 50 % by-pass can generally pass for unlimited periods of
time without harming the pump except when pumping low
viscosity media.
If more than 50% recirculation is anticipated, a value specific to
each application should be determined by closely monitoring the
pump body temperature.
For flow less than ~50 m3/h
 100% by-pass can only be tolerated for less than about 3
minutes, provided the viscosity & temperature is within
the limit of the pump type.
For flow higher than ~50 m3/h
External control with pressure relief
 100% by-pass is tolerated less than 30 seconds. valve
Note that an open valve can cause noise.

If the pump is operating in line with a separate pressure control valve (see fig. 14), the setting of
the relief valve should be high enough to not to interfere with the control valve.
Likewise, if two pumps are operating in parallel, the setting should be such that interference
between the two valves is avoided.
1.14 Pressure testing and flushing

The system must be flushed and pressure tested before connecting the pump. If corrosive liquid,
such as water is used, the system must be thoroughly drained, dried and protected against
corrosion after having been flushed.
Oil leakage may make the floor slippery and cause personal injury.
Screw pump 8
ACE3
2 Start-up
2.1 Before starting
After installation and whenever it can be
assumed that the pump has been emptied, the
pump must be thoroughly filled with liquid. See
figure Filling the pump.
For ACE Generation 3, LPE Generation 3, ACG
Generation 7 and ACF Generation 4 delivered
after 1997, ACF Generation 5 and LPQ the
Filling the pump
pumps have been fitted with deaeration plugs
making venting of the shaft seal compartment easy
before start-up.
In installations with positive suction pressure: After
opening the inlet and outlet valves, simply open the
deaeration plug a few turns until oil sips out. Tighten
the plug. In installation with negative suction
pressure: After opening the inlet and outlet valves,
remove the deaeration plug and fill the shaft seal
compartment with oil. Fit and tighten the plug. See
fig. 16.
Note: for LPQ the amount of oil is appr 50 liter.
Make sure the prime mover is locked out and can
not be started accidentally.
Rotate the shaft by hand while filling the pump, to
ensure that the rotor bores and the shaft seal cavity
is filled. On the smaller pumps: (LPD, ACD, ACE, LPE, Dearation plugs
ACG/UCG), this is done by rotating the fan on the
electric motor after removing the fan cover.
Do not forget to fit the motor fan cover again before making start of motor possible.
On the ACF/UCF and LPQ pumps, the pump can be turned using the shaft coupling. If the suction
pipe cannot be completely filled, it is important to ensure that the trapped air is evacuated
without any pressure build up. (See fig. Deaeration).
ATTENTION
Starting a dry pump is likely to cause damage, especially to the shaft seal.
Screw pump 9
ACE3
2.2 Direction of rotation

When the pump is ready to be started, switch the motor briefly on
and off and check that the drive motor rotates in the correct direction
as indicated by the rotation arrow.
The arrow is placed on different spots depending on the pump series.
ATTENTION
Don’t mix up with arrow for inlet and outlet!
Direction of rotatio
2.3 Starting
Check that all valves necessary for the operation are fully opened in both discharge and suction
lines.
The first time, the pump should be started with the adjusting spindle of the pressure relief valve
tightened to half of the available turns (the valve setting is increased when the spindle is turned
clockwise).
By monitoring the pressure gauge it can be determined when the suction line is primed and the
pump begins to work. Should the pump not operate normally soon after start, stop the pump
within half a minute. Start again after about 3-5 minutes (the shaft seal must have time to cool
off) and run for half a minute. This procedure may need to be repeated a couple of times if the
suction line is extremely long. Should the pump still not work, it must be assumed there is a
problem in the system that needs to be remedied. Check the suction line calculation and/or see
”Trouble shooting”.
Pumps with external ball bearing including grease nipple, must be regreased after one hour of
running, while the pump is operating
2.4 Setting the pressure relief valve

To set the opening pressure; Tighten the valve spindle by rotating clockwise to the maximum
extent. The system pressure is regulated by throttling an external valve to required value. The
pressure relief valve is eased until the pressure is just beginning to decrease by turning the
spindle CCW. The internal relief valve is now preset for desired opening pressure. Open the
throttling external valve entirely.
As standard, the recommended valve setting is 1 bar above system pressure.
NOTE: The set screw on LPD is hidden behind a plate.
2.5 Adjusting the tuning

The tuning adjustment, which is a standard feature on ACF/UCF and LPQ
(option on ACG/UCG pumps, is a device for minimizing the effects of
dissolved and free air in lube oil systems. The tuning principle is
described in the Product Description. The tuning should be adjusted
while the pump is working under normal operating conditions. This is
done by turning the tuning spindle with an Allen key (size 8 mm for Adjusting the tuning1
ACG/UCG , 12 mm for ACF/UCF and LPQ ) to a position where the
Screw pump 10
ACE3
noise level comes to a minimum. On a double acting pump like the LPQ pump, there are two
tuning valves, which must be adjusted individually.
Setting of tuning of the LPQ:
1. Before starting the setting check that both setting screws (8 mm socket head cap screw
on the discharge side) are closed.
2. Turn the lower screw until the noise level obtains a minimum.(If turned too much the
noise will increase again).
3. Turn the upper screw and continue to reduce the noise level. (If turned too much the
4. Repeat item 2. and 3. in order to achieve the lowest possible noise level.
Setting of tuning of the ACG/UCG and ACF/UCF:
1. Before starting the setting, check that the setting screw (8 mm: ACG/UCG, 12 mm:
ACF/UCF, socket head cap screw on the discharge side) are closed.
2. Turn the screw CCW until the noise level becomes the lowest (if turned too much the
noise will increase again). Once set, the tuning needs no further adjustment, providing the
operating conditions stay the same.
NOTE: It´ s not possible to accidentally turn the tuning spindle too far.
If operating temperature exceeds 60°C (149°F), appropriate measures to avoid skin contact shall
be provided.
Use hearing protections whenever high noise can be expected from pump, motor and/or
environment.
Screw pump 11
ACE3
3 Exploded view
Figure 2
Screw pump 12
ACE3
3.1 List of components

Components included in spare parts sets:
Pos. no Denomination Q-ty Notes G011 G012 G050 G053 G054 G057 G070
1010 Power rotor 1 x (x)
1020 Power rotor 1 x x
113 Key 1 x x x
122 Ball bearing 1 x x x
125 Secondary seal 1 1 x x x x
201 Idler rotor 2 x (x)
202 Idler rotor 2 x x
351 Balancing bush 1 x x x
401 Pump body 1
416 Suction flange 1
417 Screw 8
418 Gasket to suction flange 1 x x x
423 Gasket to discharge flange 1 x x x
427 Discharge flange 1
440 Return valve 1 2
451 Screw 4
453 Screw 4
462 Plug 1
462A Sealing washer 1 x x x
463 Plug 1
501 Front cover 1
506 Gasket 1 x x x
509 Shaft seal 1 x x x
537 Deaeration plug 2
537A Washer 2 x x x
551 Rear cover 1
556 Gasket 1 x x x
557 Plug 1
557A Washer 1 x x x
605 O-ring 1 x x x x
608 Valve spindle 1 x x
608A Tension pin 1 x x
6120 Set screw 1 x x
613 Pin 1 x x
614 Valve piston 1 x x
615 Valve spring 1 x x
Notes 1. Version NTBP
2. Removed from August 2011
Screw pump 13
ACE3
3.2 Ordering spare parts

Part numbers for pump size
Item Spare parts set 025 032 038
G012 Rotor set CW-rotation (std)
Low lead-L3 AG01614 AG01613 -
Low lead-K3 - - AG00085
Normal lead-N3 AG01615 AG01589 AG01529
High lead-D3 - - AG01612
G050 Shaft seal-xVxx AM07199 AM07199 AM07199
Shaft seal-xTxx AG00883 AG00883 AG00884
G053 Minor kit-xVxx AG00869 AG00870 AG00871
Minor kit-xTxx AG00872 AG00873 AG00874
G054 Major kit=G012(G011)+G053+G070
G057 Joint kit-xVxx AG00875 AG00876 AG00877
Joint kit-xTxx AG00878 AG00879 AG00880
G070 Valve element AG00889 AG00889 AG00889
125 Secondary seal xTxx AG00886 AG00886 AG00885
G011 is in reserve
Recommendation:
For maintenance the following spare part sets are recommended:

Set: To be used:
G057 Joint kit
For dismantling the pump.
G053 Minor kit
For service.
G054 Major kit
For repair after damage or greater wear.
Ordering example:
For Auramarine feeder 13154 IMO-pump ACE 032N3 NVBP, serial number 456789:
Shaft seal pos G050 p/n AM07199
Valve element pos G070 p/n AG00889
Screw pump 14
ACE3
4 Maintenance
All work carried out on the pump has to be performed in such a manner that risks for personal
injury are observed!
are to be taken.
In case of failure for a system with elevating pressure fluid jets may cause injury and/or
damage.
Connecting and disconnecting of electric cables must be done only by personnel authorized to
do such work.
Before any maintenance work, ensure that the driver is deenergized and the pump hydraulically
isolated.
4.1 Service intervals

The intervals for inspection and replacement of wear parts vary greatly with the properties of the
pumped liquid and can only be determined by experience.
Pumping liquid which contains abrasive materials, or liquid that is corrosive, will significantly
reduce service life and call for shorter service intervals.
Wear will normally show as unnormal:
- Vibration
- Noise
• Loss of capacity
• Reduction in flow/pressure
• Leakage
If the pumps operating temperature exceeds 60°C let the pump cool off before any service,
maintenance or dismantling work is commenced to avoid burn injury.
4.2 Inspection of shaft seal

Excessively leaking shaft seals (more than 10 drops per hour) should be changed without delay, as
the leakage normally will grow worse and cause additional damage.
In installations where unplanned shut downs must be avoided, it is advisable to dismantle the
pump for a thorough inspection and thereby change out shaft seal and ball bearing, every three
years as a max period.
It is recommended always to have the spares included in minor spare part kit available.
4.3 Inspection of rotors

A quick inspection of the idler rotors can be made simply by removing the rear cover. Note that
the driver must be deenergized and the pump hydraulically isolated before the rear cover is
removed.
Screw pump 15
ACE3
If a more thorough investigation is needed, proceed as under ”Dismantling/Reassembly.
4.4 Sectional view

Screw pump 16
ACE3
4.5 Useful tools
4.6 Shaft seal - assembly drawing

Screw pump 17
ACE3
4.7 Dismantling
Turn the electricity OFF. Close the valves and
remove the pump from the system.
Attention! Use appropriate vessels to collect oil
spillage when removing and opening the pump!
Note the position of the shaft coupling.

Release the stop screw.
Remove the shaft coupling.
Remove the key 113.

Screw pump 18
ACE3
Remove the screws 451.
Remove the front cover 501 and power rotor 1020.
Separate the front cover 501 and the power rotor

1020.
xTxx
Remove the secondary seal 125 with a suitable
screw driver.
Screw pump 19
ACE3
Place the front cover 501 on a pair of wood-en

pieces.
Press out the shaft seal, stationary member with a
suitable tool.
xVxx
Loosen the shaft seal rotating member.
xTxx
Insert two suitable screw drivers in the carrier S5
slots and gently push the rotating member S4, S7
off the rotor shaft.
Loosen the two stop screws S8 (3 mm Allen key) on
the carrier S5 and pull it off.
Remove and inspect the idler rotors 202.

Screw pump 20
ACE3
4.8 Reassembly
Lubricate the idler rotors 202 and fit them
into the pump body 401 Lubrication groves
turning downwards.
Un-pack a new shaft seal 509.

Check that the O-ring S6 is in place.
xVxx
Polish the power rotor shaft 1020 with a
fine emery and oil
Fit the rotating member above the ball
bearing 122 and lock it with its stop screws
S8.
xTxx
Polish the power rotor shaft 1020 with a
fine emery and oil
Fit the carrier S5 tight against the ball
bearing. Make sure the carrier is not fitted
upside down
Firmly tight the two stop screws S8.
Lubricate the O-ring S6 in the rotating
member with oil.
Press the rotating member S4, S7 gently on
to the rotor shaft and make sure the driving
lugs enters the slots in the carrier S5.
Screw pump 21
ACE3
Insert the Power rotor 1020 into the pump

body 401.
xTxx: Press the Secondary seal 125 in place

with a suitable tool in two steps as shown.
Use a column drill machine as a press tool.
xVxx: Pos 125 should not be replaced.
NOTE! Tool 2 has one end for sizes 025, 032
and one end for size 038
xVxx
Fit the spring unit S7 in place. Note the
position for the Seat slots and lugs. (See
Shaft seal - assembly drawing.)
Lubricate the O-ring S2 and put it on the
seat S1. Fit the seat S1 on top of the spring
unit. Watch position of the Seat slots and
lugs. (See Shaft seal - assembly drawing.)
Press the seat gently into the recess in the
front cover 501 with a suitable tool as
shown.
Turn the front cover 501 up-side down. The
seat shall now remain in the cover.
Screw pump 22
ACE3
xTxx
Fit the retainer S3 in place. Note the
position for the retainer lugs and cover
slots. (See Shaft seal - assembly drawing.)
Lubricate the O-ring S2 and put it on the
seat S1. Fit the seat S1 on top of the
retainer. Watch the position of the seat
slots and lugs. (See Shaft seal - assembly
drawing.)
Press the seat gently into the recess in the
front cover 501 with a suitable tool as
shown.
Turn the front cover 501 up-side down. The
seat shall now remain in the cover.
Replace the gasket 506.
Carefully fit the Front cover 501 on the
pump.
Fit the screws 451.

Tight them crosswise, step by step to avoid
deformation on bearing outer ring and seal
dam-ages.
Turn the shaft to check that it moves
without too much force.
Screw pump 23
ACE3
Fit the key 113 back in place.
Press on the shaft coupling to its original

position.
Tighten the stop screw.
Install the pump back into the system and
proceed according to instructions under
”Start-up” in the Installation manual.

Attention! Spring tension!
Release spring tension by turning set screw 6120 CCW as much
as possible.
Loosen and remove the screws 453.
Separate the valve element from the rear cover 551.
If necessary, replace the gasket 556 and the O-ring 605.
Reassemble the parts in reverse order. Be careful to tighten
the screws 453 crosswise.
Readjust the valve pressure according to the ”Installation and
Start-up Instruction for IMO Low pressure pumps”.
Screw pump 24
ACE3
5 Trouble shooting
Problem Cause What to do
Wrong direction of Electric cables to motor wrongly connected. Reverse the terminal connection on electric motor.
rotation
Connecting and disconnecting of electric cables
must be done only by personnel authorized to do
such work.
The pump cannot be Wrong direction of rotation. See above.

primed
Suction line is not open or pressure drop in Check all components in suction line. The inlet
the suction line is too high. condition should be checked with a vacuum gauge
at the pump inlet.
Major air leakage into the suction line. Check the suction line.
The pump cannot evacuate the air through See the chapter on Deaeration
the discharge line due to excessive counter
pressure.
No flow The pump is not primed. See above.
The pressure relief valve is set below the Readjust the pressure relief valve to a value above
counter pressure. counter pressure.
Flow too low The pressure relief valve is set too low Readjust the pressure relief valve.
(Discharge pressure also low).
Something is restricting the flow in the Check all components in the suction line (strainers,
suction line. (This would usually cause noise). valves etc.).
The pumped liquid contains a significant See the chapter on Noise and Vibration.
amount of com- pressible gas, such as free
air. (This would usually cause noise).
Pressure too low The pressure relief valve is set too low. Readjust the pressure relief valve.
Counter pressure in the discharge line is too Check the components in the discharge line
low due to a major leakage. inclusive the recipients.
The valve piston is stuck in open position. Check the valve. See Maintenance and Service
instruction for respective pump.
suction line. (This would usually cause valves etc.).
noise).
A too small pump has been chosen. Contact Auramarine

Screw pump 25
ACE3
Pressure too high The pressure relief valve is set too high. Readjust the pressure relief valve.
The oil is too cold (or has higher viscosity Reduce the pressure setting until operational
than anticipated). temperature has been reached.
Counter pressure in the discharge line is too Check the discharge line.
high.
Drive motor difficult Counter pressure too high. See above: Pressure too high.
to start or tends to
stop by tripping the
motor overload relay
Liquid too cold Readjust the pressure relief valve to a lower value.
Thus the power consumption for the pumping is
relieved and overloading due to the high viscosity
may be avoided. When the liquid has reached
normal temperature and thus flows easily, the relief
valve is reset to normal pressure.
Motor is undersized for the prevailing Check the motor.

conditions.
Electrical power supply faulty. Check the motor and motor connection.
Motor overload relay set too low or is faulty. Readjust or replace the relay.
Incorrect setting of Y/D starter. Readjust the setting of the starting sequence. The
time before the motor overload relay is tripped
should not exceed 10-15 seconds.
Noise and vibrations The flow to the pump is insufficient. See chapter: The flow is too low.
Monitor the pump Insufficient support of pipe work. Check for pipe vibrations in the pump connections.
function and shut Check that the pipes are sufficiently clamped.
down if any sign of
malfunction is
noticed.
Bad alignment Check alignment.
Air leakage into the suction line. Check the suction line for air leakage.
Free air in the liquid or gas cavitation. For pumps with Tuning: Adjust the Tuning. If this
does not help or for pumps without Tuning: Contact
Auramarine.
Faulty electrical supply. Check all three phases of the supply.

Position: M005, M006

Part code: M000034
8.2 El. motor, induction - HMA,
HMC, HMD, HMT, MS, Y2E1,
Y2E2, YDT
Electric Motors
Motor Manual
hoyermotors.com
Manual
Motor
Manual
General with a hammer as this will cause damage to the bearing.

The motor are balancing with half key, ensure that the drive
This manual concerns the following types of standard
components are also the same.
induction motors from Hoyer:
Correct alignment is essential to avoid bearing, vibration and
HMA3, HMC3, HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT
shaft failure.
These motors are manufactured in accordance with IEC/EN
Use appropriate methods for alignment.
60034-4 and IEC/EN 60072.
Re-check the alignment after the final tightening of the bolts
Motors are rated for the ambient temperature range -20°C to
or studs.
+40°C and site altitudes ≤1000 m above sea level.
Check that drain holes and plugs face downwards. We
Low-voltage motors are components for installation in
recommend opening the drain hole for motors placed
machinery. They are CE marked according to the Low Voltage
outdoors and not running 24 hours / day, so that the motor
Directive 2006/95/EC
can breathe, thus ensuring a dry motor.
Transport and storage

Electrical connection
Check the motor for external damage immediately upon
Work is only permitted to be carried out by qualified
receipt and, if found, inform the forwarding agent right away.
specialists and must to be carried out in accordance with
Check all rating plate data, and compare it with the
local regulations.
requirement of the motor.
Before work commences, ensure that all power is switched
Turn the shaft by hand to check free rotation, remove
off and cannot be switched on again. This also applies to the
transport locking if used.
auxiliary power circuits, e.g. anti-condense heaters.
Transport locking must be used again for internal transport
Check that supply voltage and frequency are the same as
also. It is also important that transport locking is used when
rated data.
motors are transported mounted on equipment.
Motors can be used with a supply deviation of ± 5% voltage
All motors should be stored indoors, in dry, vibration- and
and ± 2% frequency, according to IEC60034-1
dust-free conditions.
Connection diagrams for main supply and accessory as PTC

Lifting eyebolts must be tightened before use. Damaged
or heater are located inside the terminal box.
eyebolts must not be used, check before use. Lifting eyes at
motor must not be used to lift the motor when it is attached
Connections must be made in such a way as to ensure that
to other equipment.
a permanently safe electrical connection is maintained, both
for the main supply and the earth connection.
Before commissioning, measure the insulation impedance. If
We recommend that crimped connections are made in
values are ≤ 10MΩ at 25°C, the winding must be oven dried.
accordance with IEC 60352-2.
The insulation resistance reference is halved for each 20°C
rise in motor temperature.
Tightening torques for terminal board screws:
It is recommended that shafts are rotated periodically by
hand to prevent grease migration. Thread M5 M6 M8 M10 M12 M16 M20 M24
T.(Nm) 2.5 3.5 7 12 18 35 55 80
Installation
The motor must be fixed on a stable, clear and flat foundation. Ensure that the terminal box is clean and dry.
It must be sufficiently rigid to withstand possible short Unused glands must be closed with blind caps.
circuit forces. Check the terminal box gasket before it is remounted.
It is important to ensure that the mounting conditions do
not cause resonance with the rotational frequency and the Maintenance
doubled supply frequency. Inspect the motor at regular intervals, keep it clean and
Only mount or remove drive components (pulley, coupling, ensure free ventilation air flow, check the condition of shaft
etc.) using suitable tools, never hit the drive components seals and replace if necessary. Both electrical and mechanical
2
Motor
Manual
connections must be checked and tightened if necessary. The table values are based on an ambient temperature of
Bearing size and type are specified on the rating plate. Motor 25°C. The values must be halved for every 15K increase in
types HMA3 and HMC3 is as standard with lifetime greased bearing temperature.
bearings in motors size ≤180 for cast iron and size ≤132 for Higher speed operations, e.g. frequency converter drive will
aluminium. Motor types HMA2 and HMC2 is as standard require shorter greasing intervals. Typically, doubling the
with lifetime greased bearing in motors size ≤225. speed will reduce the values by 50%.
Motor types MS and Y2E is as standard with lifetime greased
bearing in motors size ≤160. Special note for Atex Zone 22 and nA motors
Designation of motor according to IEC standard:
Typical duty hours for lifetime lubricated bearings. II 3D Ex tc IIIB T120°C
Frame size Poles Typical lifetime II 3G Ex nA IIC T3
56 - 160 2-8 40,000h
The hazardous 3-phase asynchronous motors are in
180 2 35,000h
accordance with International standard IEC 60079-31 and
200 2 27,000h
IEC 60079-15.
225 2 23,000h Only one electrical installation may be installed in one
180 - 225 4-8 40,000h specified area (zone).
Motors with a re-greasing system must be lubricated with
Only certificated cable glands may be used. Unused glands
high quality lithium complex grease, NLGI grade 2 or 3, with
must be closed.
a temperature range of between -40°C to +150°C.
Motors are normal fitted with a data plate with greasing
information; if it is missing use the following re-greasing
for the main supply and earth connection.
intervals.
Installations must be in accordance with actual standards
for installation in hazardours area.
Frame Grease (g) 2 pole 4 pole 6 pole (h) 8 pole (h)
size (h) (h)
It is recommended that the IEC standard is followed according
160 20 4200 7000 8500 8500
to temperature and dust on the motor surface.
180 20 4200 7000 8500 8500 The use of motors with so much surface dust that the motor
200 25 3100 6500 8500 8500 temperature increases is not permitted.
225 25 3100 6500 8500 8500 Regularly cleaning is recommended.
250 35 2000 6000 7000 7000 The radial shaft sealing ring is part of the ATEX certification.
280 35 2000 6000 7000 7000 It is important that the ring is always intact.
315 50 1500 5500 6500 6500
The shaft sealing must be regularly checked, and if dry it
must be lubricated. It is recommended that the seal is re-
355 60 1000 4000 5000 6000
lubricated regularly.
400 80 800 3000 4000 6000
Always use the original seal ring when replaced.
Grease the motor while running, open the grease outlet plug Replacing bearings also means replacing the seals.
and let the motor run 1-2 hours before the outlet grease plug
is closed again. All machines must be inspected regularly for mechanical
Grease the motor for the first time during commissioning. damage.
The user is responsible for changing parts in accordance
The following applies in general for both lifetime lubricated with the lifetime of parts, in particular:
and re-lubricated bearings: bearings, grease and lubrication of shaft sealing.
At 60Hz the time will be reduced by app. 20%.
Data for vertically mounted motors are half of the above Maintenance, repairs and replacement on this type of motors
values. must only be carried out by qualified specialists.
3
Position: V001/V001A
Part code: AM05508
8.3 Valve, 3/2, actu, switch, solen -
285/283, AT, PCR
Three and four way valve 1
Three and four way valve
ITEM QTY PART ITEM QTY PART

NO NAME NO NAME
1 1 Handle *11 2 Body seals * Start-up: 5% of ordered quantity
Suggested materials after 2 years
**2 a b 2 Handle nut 12 1 Body seals *
service
Suggested materials after 5 years
*3 1 Packing ring 13 2 End connection **
service
**4 2 Spring washer 14 1 Step-pin Note 1 for DN08 to DN40 n4 bolts for size
**5 1 Antistatic stem 16 Note 1 Bolts for DN50 n6 bolts for size
6 1 Gland packing **17 1 Step washer for DN65 n8 bolts for size
*7 1 Thrust washer *18 2 Ring seal
*8 1 "O" ring stem 19 2 Seat retainer
**9 1 Ball 20 1 Name plate
*10 2 Seats
Table with tightness values for handle nut 2A-2B and body bolts 16
Valve Handle nut 2 A and lock nut 2 B Body bolts part No.16
size Dimensions Nm Inch lbs Dimensions Nm Inch lbs
DN 08-
10 M10x1 8 70 M8x17 35 310
DN 15 M12x1.25 15 130 M8x17 35 440
DN 20 M12x1.25 15 130 M10x22 50 440
DN 25 M15x1.25 25 220 M10x22 50 440
DN 32-
40 M15x1.5 25 220 M12x30 70 620
DN 50 M22x1.5 40 335 M12x35 70 620
DN 65 M24x2 50 440 M12x35 70 620
Air torque 1
AT045U→AT801U
Contents
AT045U→AT801U.............................................................................................................................................. 1
1 GENERAL ................................................................................................................................................ 1
2 WARNING .............................................................................................................................................. 1
3 WORKING CONDITIONS AND TECHNICAL DATA.................................................................................... 2
4 OPERATING FUNCTION AND DIRECTION OF ROTATION ....................................................................... 3
5 ACTUATOR INSTALLATION INSTRUCTIONS............................................................................................ 4
5.1 Important safety notice!................................................................................................................ 4
5.2 Interfaces for actuator control and connections, figure A: ........................................................... 5
5.3 Assembly of accessories: solenoid valves and switchboxes, figure B: .......................................... 5
5.4 Assembly of valve figure C: ............................................................................................................ 5
6 MAINTENANCE INSTRUCTION ............................................................................................................... 7
6.1 DRAWING WITH ITEMIZED COMPONENTS AND RECOMMENDED SPARE PARTS ......................... 7
6.2 DISASSEMBLY ................................................................................................................................. 7
6.3 ASSEMBLY: ..................................................................................................................................... 9
7 STORAGE INSTRUCTIONS..................................................................................................................... 10
8 LIFTING and HANDLING ....................................................................................................................... 10
1 GENERAL
This instruction manual contains important information regarding the installation, operation,
maintenance and storage for AIR TORQUE rack and pinion pneumatic actuators. Please read these
instructions carefully and keep them for future reference. It is important that the use and
maintenance of the actuator is made only by properly trained personnel.
2 WARNING
 Do not operate the actuator using inflammable, oxidizing, corrosive, explosive or unstable
gases or liquids (use only not dangerous fluids – group 2 according to 97/23/EC directive).
Moreover, for actuators installed in potentially explosive zones, make sure that the
internal parts of the actuator do not come into contact with the external atmosphere.
 Referring to the Machinery Directive 2006/42/EC, the actuators can be classified as
“PARTLY COMPLETED MACHINERY” (see the DECLARATION OF INCORPORATION).
Therefore the actuator can not put into service until the machinery and/or the system,
where the actuator is incorporated, will be declared in compliance with the requirements
of the Directive 2006/42/EC.
 Air Torque actuators are designed, produced and classified according to the ATEX
Directive 94/9/EC (see actuator label and safety instructions). The use of the actuators in
Air torque 2
potential explosive atmosphere zones has to comply with the ATEX classification indicated
on the actuator label and according to the ATEX safety instructions.
 The use, the installation and the maintenance of the Air Torque actuators must be made
by adequately trained personnel. For the use, installation and maintenance of Air Torque
actuators it is recommended to comply to the safety notice and to use proper equipment
to protect health and prevent accidents.
 It is important that the actuator is used only within the working limits indicated in the
technical specifications.
 Do not operate the actuator over temperature limits: this could damage internal and
external components (disassembly of spring return actuator may become dangerous).
 Do not operate the actuator over pressure limits: this could damage internal parts as well
as cause damage to the housing and end-caps.
 Do not use the actuator in corrosive environments with incorrect protection: this could
damage the internal and external parts.
 Do not disassemble individual spring cartridges, this may result in personal injury. If
maintenance to springs is necessary, send them to AIR TORQUE.
 Close and disconnect all air supply lines and make sure that air connections are vented
during maintenance and installation on valve.
 Do not disassemble the actuator or remove end caps while the actuator is pressurized.
 The 4TH GENERATION Upgrade Series actuators are designed to be used only on valves.
 Before installing the actuator onto the valve make sure that the rotation direction and the
position indicator are in the correct position.
 If the actuator is incorporated in a system or used within safety devices or circuits, the
customer shall ensure that the national and local safety laws and regulations are
observed.
 In case the actuator is installed on a valve with a gearbox for emergency manual
operation, make sure that the stroke of the gearbox does not exceed the stroke allowed
by the actuator. Caution: make sure that the gearbox stroke, both in closed and in opened
position, is properly adjusted. If you exceed the stroke allowed by the actuator with the
manual operation of the gearbox, you can cause severe damage to the adjustment
screws, to the pistons and to the actuator itself.
3 WORKING CONDITIONS AND TECHNICAL DATA

 Operating media:
Dry or lubricated air or inert gases, provided that they are compatible with the actuator
internal parts and lubricant.
The operating media must have a dew point equal to –20°C (-4°F) or at least 10°C below
the ambient temperature. The maximum particle size contained into the operating media
must not exceed 30 μm.
 Supply pressure:
 The maximum supply pressure is 8 bar (116 Psi). For double acting and spring return
actuators the working pressure is from 2.5 bar (36 Psi) to 8 bar (116 Psi).
 Operating temperature:
==> “Standard” actuators from -40°C (-40°F) to +80°C (+176°F)
Air torque 3
==> Actuators for high temperature “HT” from -15°C (+5°F) to +150°C (+300°F)
==> Actuators for extreme low temperature “LLT” from -55°C (-67°F) to + 80°C (+176°F)
Caution: for low and high temperature service, special grease and special components are
required. Please contact
AIR TORQUE. Working at high or low temperature can affect the life and the output
torque of the actuator.
 Operating time (see technical data sheet):
Caution: the operating time depends on several factors such as supply pressure, supply
system capacity (pipe diameter, flow capacity of pneumatic accessories), valve type, valve
torque and figures, applied safety factor, cycle frequency, temperature, etc.
 Rotation and stroke adjustment (see technical data sheet):
For standard actuators (90° rotation), 120° actuators (120° rotation), 135° actuators (135°
rotation) and 180° actuators (180° rotation).
Stroke adjustment at 0°(closed pistons): +15°max/ - 5°. Stroke adjustment at 90°, 120°,
135° and 180°(open pistons): +5°/-15°max. For actuator AT045U the stroke adjustment at
90° (open pistons) is available only on request.
 Lubrication:
The actuators are factory lubricated for the life of the actuator in normal working
conditions. The standard lubricant type GSTD is suitable for use from -40°C (-40°F) to
+80°C (+176°F). For extreme low temperature (LLT) and high temperature (HT) service,
special grease is required: please contact Air Torque.
 Construction: rack and pinion actuator design suitable for both indoor or outdoor
installations.
 Protection and corrosion resistance:
All the actuators are supplied with corrosion protection for normal environments. For
corrosion resistance of the different types of protection see technical data sheet. Before
installing the actuator in aggressive environment, ensure that the selected protection
level is suitable.
 Actuator designation and marking (see technical data sheets):
The actuator type, size, operating pressure, output torque, direction of rotation, spring
action, operating temperature and type of connections/interfaces are determined by
designation.
 All AIR TORQUE actuators are supplied with an identification label showing the serial
number and all necessary information on use, service, operation and product designation.
Where applicable, the label indicates the classification according to ATEX Directive
94/9/EC.
4 OPERATING FUNCTION AND DIRECTION OF ROTATION

The actuator is a pneumatic device for remote operation of industrial valves. The operation
(90°,120°,135° or 180° rotation) may be activated by different methods:
 Direct mounting of solenoid valve (5/2 for double acting, 3/2 for spring return) to
pressure connections 2 and 4, connected to supply and control lines.
Air torque 4
 Screwed connection (to pressure connections 2 and 4) with air lines from separate control
cabinet. The standard rotation (when port 4 is pressurized or for spring action) is
clockwise to close. When port 2 is pressurized, counter-clockwise rotation is obtained.
Air Torque actuators can be supplied with different types of assembly/rotation direction
depending on the type of required operation and/or installation, see technical data
sheets.
5 ACTUATOR INSTALLATION INSTRUCTIONS

The Air Torque actuator is a pneumatic device for the remote operation of industrial valves. The
actuator will operate through 90°,120°,135° and 180° rotation permitting the opening and closing
of many types of valves up to 180° rotation.
All the necessary technical information to install the actuator correctly and safely onto a valve i.e.:
Dimensions, Output torque, Supply pressure, Air volume, Stroke adjustment, Operating time,
Operating temperature, Direction of rotation and Weight is stated clearly on the Actuator label, in
the catalogue and technical data sheets. Please read all technical information before proceeding
with the actuator installation.
5.1 Important safety notice!

 For safety reasons, the actuator must not be pressurized at any time during installation as
injury may result.
 The utmost cleanliness is required during air supply connection to the actuator i.e. the
connecting pipe thread, fittings and seals must be clean and dirt-free.
Air torque 5
 When fitting accessories onto the actuators, assemble them in such a way that the
emergency control of the solenoid valve and the top of the drive shaft are easily
accessible, should emergency manual operations be required.
 Before fitting onto the valve, make sure that the actuator/valve are correctly orientated,
depending upon which direction of rotation is required.
 For spring return actuators, avoid that dangerous and/or corrosive substances in the
working environment enter into the external chambers by using adequate filters and/or
solenoid valves.
 Remove plugs from actuator air connections during installation and operation. Protect the
air connections of actuators not being used immediately.
5.2 Interfaces for actuator control and connections, figure A:
5.3 Assembly of accessories: solenoid valves and switchboxes, figure B:

 Solenoid valve mounting:
Before mounting a solenoid valve, ensure that the actuator is in its normal position
(closed position) with pistons inwards.
For standard rotation type “ST” (clockwise to close) assembly: the groove on the drive
shaft or on the position indicator 2 must be horizontal to the longitudinal axis of the
actuator in closed position.
Fit the solenoid valve 4 onto the actuator 3 using the provided screws (max. tightening
torque see table).
 Switchbox mounting:
Fit the switchbox and bracket 1 onto the actuator 3 using four provided screws (max.
tightening torque see table).
5.4 Assembly of valve figure C:

Before installing the actuator onto a valve, verify that the maximum transmissible torque for
available ISO Flange and drive shaft connection is not exceeded according to ISO 5211
considering: the maximum actuator output torque, the maximum air supply pressure and the
maximum valve torque.
Before proceeding with the assembly of the actuator onto the valve, be sure that the actuator
operates in the desired direction of rotation when pressurised and both actuator / valve are in the
correct position.
Important: when using a spring return actuator for a fail safe operation, ensure that when air or
electricity failure occurs the direction of rotation is correct for your application.
Fit the actuator 3 onto the valve 5. It is possible to assemble the valve onto the actuator in two
ways:
 Direct-mount: fit the stem of the valve 5 directly into the female connection of the
actuator 3 and bolt together through the valve ISO pad (max. tightening torque see table).
 Bracket-mount: mounting with a bracket 6 and coupling 7, the bracket is bolted to the
actuator / valve to join them together and the coupling is used to connect the actuator
output drive to the valve stem (max. tightening torque see table).
Air torque 6
Air torque 7
6 MAINTENANCE INSTRUCTION
With the information given below, AIR TORQUE provides the end user with all the required
information necessary for maintenance. Under normal conditions, the actuator requires only
periodic observation to ensure proper operation.
Maintenance (disassembly, maintenance and rebuilding) of AIR TORQUE actuators is allowed only
to AIR TORQUE personnel or properly instructed personnel. In case of controversy the product
guarantee will expire!
Spare kits for maintenance are available to replace all seals and bearings (soft parts indicated into
the table), that may be necessary between 300.000 and 1.000.000 cycles depending on operating
and environmental conditions and actuator size.
6.1 DRAWING WITH ITEMIZED COMPONENTS AND RECOMMENDED SPARE

PARTS
6.2 DISASSEMBLY
When disassembly of actuator is required for maintenance, firstly remove the actuator from the
valve. Before performing any disassembly operations it is important to verify that the actuator is
not pressurised.
Always use caution and double check that the ports 2 and 4 are vented and are free from any
accessory and/or device. When the actuator is a spring return unit, make sure that the actuator is
in the failed position and with pistons completely inwards before disassembling.
A) Removal of position indicator and graduated ring (Part N° 19,19.0,19.1), figure 01:
 Remove cap screw (39) if fitted.
Air torque 8
 Lift position indicator (19 or 19.1) off shaft, it may be necessary to pry gently with a
screwdriver.
 Lift, if necessary, the graduated ring (19.0) off the body, it may be necessary to pry gently
with a screwdriver.
B) Removal of stop cap screws (Part N° 02), figure 02:
 Remove both stop cap screws together with nut (04) and washer (03).
 Remove stop screw o-rings (11) and discard if replacing all soft parts.
C) End caps disassembly (Part N° 30), figure 03:
 End caps disassembly for spring return actuators (disassemble one end cap at a time).
Unscrew the end cap bolts (13) in the sequence shown in figure 03, until the end-caps are
free from springs force (for AT045U and AT051U 20-23 turns of the screws, for AT101U to
AT801U 4-5 turns of the screws).
Then completely unscrew the screws and remove the end-cap and the springs.
If there is still force on the end-caps after unscrewing as indicated above, this may
indicate that spring cartridge is damaged or that the pistons are not completely closed, so
any further disassembly should be discontinued.
Further disassembly of the end caps may result in injury.
 End caps disassembly for double acting actuators (disassemble one end cap at a time)
Unscrew the end cap bolts (13) in the sequence shown in figure 03, until the screws are
completely unscrewed and the end caps are free.
 Remove the o-rings (14) using a screwdriver. Discard soft parts if replacing.
 Only for actuators with adjustment 50% or 100%, remove the nut 04R, the washers 03R
and o-rings 11R and discard soft parts if replacing.
D) Pistons disassembly (Part N° 40), figure 04:
 Holding the body (50) in a vice or similar device, rotate the drive shaft (60) until the
pistons (40) are released. Caution: air pressure should not be used to remove the pistons
from the body.
 Remove o-rings (16) using a screwdriver. Remove the piston back (05) and piston head
(15) bearings.
 Discard bearings when replacing all soft components.
E) Drive shaft disassembly (Part N° 60), figure 05:
 If necessary, remove the graduated ring (19.0) with a screwdriver, remove the spring clip
(18) using snap-ring pliers or screwdriver for spiral rings, remove the thrust washer (10)
and the external thrust bearing (08). Apply downward force to top of drive shaft (60),
until it is partially out of the bottom of the body when it is possible to remove the internal
thrust bearing (08) and the octi-cam (01), then push the pinion (60) completely out of the
body. If pinion is not easily removed, gently tap the top of the shaft with a plastic
hammer.
 Remove top (06) and bottom (07) pinion bearings and top (20) and bottom (21) pinion o-
rings.
 Discard bearings (06) and (07), internal and external thrust washer (08) and o-rings (20)
and (21) if replacing the soft components.
All the components disassembled and not replaced will have to be cleaned and inspected
for wear and before reassembly, if necessary, also replace the plugs (09).
Air torque 9
6.3 ASSEMBLY:
Prior to assembly, ensure that:
 all the components are perfectly clean and in good condition.

 the spare parts and the lubricant used are suitable for the operating temperature of the
actuator (see Air Torque technical data sheets).
 Note: The lubricants suitable for the various operating temperatures (Standard, HT and
LLT actuators) are available in Air Torque.
Only for “standard” actuators, for temperature from -40°C (-40°F) to +80°C (+176°F), it is
possible to use lubricant
Dow Corning type Molykote® G-2003.
A) Drive shaft assembly (Part N° 60), figures 06, 07 and 07A:
 Install top (06) and bottom (07) bearings, grease and insert the bottom (20) and top (21)
pinion o-rings onto the shaft.
 Grease the outside surface of the drive shaft as shown in figure 06.
 Insert partially the drive shaft (60) in the body (50), install octi-cam (01) in the correct
position (for standard assembly or for lock-out) as shown in figures 07 and 07A, related to
the bottom and top of the drive shaft and the rotation of the actuator when energised.
Install the internal thrust bearing (08). Insert completely the drive shaft in the body.
 Fit external thrust bearing (08), thrust washer (10) and then external spring clip (18) using
snap ring pliers or screwdriver for spiral rings.
B) Pistons assembly (Part N° 40), figures 08, 09, 10 and 11:
 Grease and install o-rings (16), piston back (05) and piston head (15) bearings.
 Grease the internal surface of the body (50) and the piston (40) rack teeth.
 Insert the female connection of the drive shaft (60) in a properly fixed coupling.
 Ensure that the octi-cam is in the right position as shown in figure 09.
 For standard rotation assembly type “ST” (clockwise to close), rotate the body (50) about
40-45° clockwise from top view, as shown in figure 10.
 Insert and press the two pistons (40) simultaneously inside the body (50) until the pistons
are engaged, then rotate the body anticlockwise from top view until the stroke is
completed.
 Ensure that with pistons completely closed, the rotation obtained referred to the axis of
the body is about over 0° for models AT051U→AT801U (0,5° over 0° for AT045U) and that
the dimension “A” on both sides is the same as shown in figure 11.
C) End cap (Part N° 30) assembly, figures 12, 13 and 14:
 Assemble one end cap at a time.
 Lubricate the body.
 For spring return actuators, insert the springs in each end cap according to the desired
configuration, as shown in figure 12 and related tables. For models AT101U→AT801U
insert spring cartridges as shown in figure 13.
 Fit end cap o-ring seal (14) into the groove on both end caps.
 Fit end caps onto the body (50), verifying that the o-ring remains in the groove.
 Only for actuators with 50% or 100% stroke adjustment, ensure that the adjustment
screws 221G/222G are completely screwed into the end-cap.
Air torque 10
Insert the cap screws (13) and tighten each only partially. Complete tightening by making
1-2 turns for each screw in the sequence shown in figure 14 until tightening is completed.
See the table for screw tightening torque.
D) Assembly of stop cap screws (Part 02) and stroke adjustment for models AT051U→AT801U,
figures 15 and 16:
 Insert on both stop screws (02) the nut (04), the washer (03) and the o-ring (11).
 Fit the stop cap screws (02) in the body.
 Stroke adjustment for actuators with standard type “ST” rotation / assembly (clockwise to
close).
Stroke adjustment in close position: with the actuator in close position 0°, screw or
unscrew the right (from top view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to lock it in place.
Stroke adjustment in open position: with the actuator in open position 90°, screw or
unscrew the left (from top view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to lock it in place.
For spring return actuators, it could be necessary to make rotation tests to verify the
correct stroke adjustment in open position.
 Only for actuators with adjustment 50% or 100%, fit on end-cap adjustment screws
221G/222G the o-rings 11R, the washers 03R and the nuts 04R. To adjust the stroke in
open position: with the actuator in partially or totally open position, screw or unscrew the
end-cap adjustment screw 221G/222G until the desired position is achieved. It is
important that the two end-cap adjustment screws are both in contact with the pistons.
Then lock the nuts 04R.
E) Assembly of graduated ring and position indicator (Part N° 19,19.0,19.1), figures 17,18 and 19:
 Fix the graduated ring (19.0) to the body.
 If necessary, correctly position the “Top Adaptor” (19.5) and lock it with the proper
screws (19.6).
 Insert the indicator (19 or 19.1) making sure that it indicates the correct actuator position.
 Screw the indicator screw (39) if assembled.
7 STORAGE INSTRUCTIONS
If the actuator is not for immediate use, the following precaution must be taken for storage:
 Store the actuator in a clean and dry environment and at temperature between –20°C (-
4°F) and +40°C (+104°F).
 It is recommended that the actuator be stored in its original box.
 Do not remove the plastic plugs on air supply ports.
8 LIFTING and HANDLING

It is recommended to lift the actuators with proper, adequate and permitted systems in relation
to the actuator weight and by following the ruling laws in terms of safety and health protection.
The weight of the actuators is indicated on the Air Torque catalogue and on the related technical
data-sheets. During the lifting and the handling of the actuators, it is recommended to avoid
clashes and/or accidental falls in order to avoid irreparable damages to the actuators and to
compromise the functionality. Contact Air Torque for any information and technical data-sheets.
Air torque 11
Air torque 12
Microswitch PCR 1
Microswitch PCR
1 Description
Signal devices are used to report and control the position of valves which are operated by
pneumatic actuators. Depending on their design the signal boxes type PCR3… and PCR8… are
equipped with up to four micro-switches. With the enclosed mounting parts the boxes can be
easily and quickly mounted on actuators or valves.
2 Assembling
1. Bring the actuator to a completely “Open” or “Close” position.
 Closed: Valve is closed, Channel position is abreast the actuators longitudinal axis.
 Open: Valve is open, Channel position towards actuator axis.
2. Equate the modules axis with the actuator.
3. Attach the box with bracket on the actuator or valve and fix it.
4. Adapt the control unit by leading the system cable through the cable gland and wiring the
single conductors with the terminal block.
Please note the wiring diagram. The wiring diagram can also be
found in the box.
3 Adjusting switch-points
Ex factory the modules are adjusted in the following way:
 Switch-point close: Position Valve/Actuator at 0° to 3°
 Switch-point open: Position Valve/Actuator at 87° to 90°
(Switch-points of other switches optionally)
If readjustment should be necessary proceed as following:
1. Remove the housing cover.
2. Push down the switch cams exterior ring of the switch, which has to be readjusted (1). Turn
the switch cam until the wanted position has been reached. (2)
3. Proceed similarly with other switch-points.
4. Refasten housing cover.
4 Maintenance
Long time outdoor usage can cause gaskets to become brittle after some time. Safe operation can
only be guaranteed with leak-proof boxes.
Seals should be exchanged immediately if they are damaged, or at least after five years.
Seals and other parts can be ordered at all times.
Microswitch PCR 2
5 Explosion view
Pos Pcs Description

1 1 housing (base)
2 1 O-Ring-sealing
3 1 housing (cover)
4 1 TCR-axis
5a 1 Switch cam system adjustable
6 2 Microswitch
7 1 Bracket, size 1-4
Position: V003, V004, V005, V006

Part code: M021073
8.4 Valve, ball - 225 SGS, Standard
Standard valve 1
Standard valve

NO NAME NO NAME
1 1 Handle *11 2 Body seals
**2 a b 2 Handle nut 12 1 Body
*3 1 Packing ring 13 2 End connection
**4 2 Spring washer 14 1 Step-pin
**5 1 Antistatic stem 16 Note 1 Bolts
6 1 Gland packing **17 1 Step washer
*10 2 Seats
* Start-up: 5% of ordered quantity
* Suggested materials after 2 years service
** Suggested materials after 5 years service
DN 08-
10 M10x1 8 70 M8x47 35 310
DN 15 M10x1 8 70 M8x51 35 440
DN 20 M12x1.25 15 130 M10x64 50 440
DN 25 M12x1.25 15 130 M10x75 50 440
DN 32 M15x1.5 25 220 M12x88 70 620
DN 40 M15x1.5 25 220 M12x95 70 620
Position: V007
Part code: M021526
8.5 Valve, Pressure relief - SPV / F
Pressure Relief Valves SPV, SPVF directly-operated
Construction
1
d
T c
3
1 Housing
b 2 Sliding piston
3 Compression spring
4 Set screw
5 5 Bleeding screw
6 Protective cap
4
Description Valve Construction
The pressure relief valve SPV/SPVF is a direct spring The sIiding piston 2 is pressed against the annuIated
sliding piston valve. It is intended for mounting in area a by the compression spring 3. Thus the pump
pipelines and is suitable to safeguard low pressure connection P is separated from the reservoir connection
hydraulic circuits up to pmax bar 20 (30) bars. T by sealing the diameter d. As soon as the operating
The pipe connection is to be effected either by pressure p is achieved, adjusted by the set screw 4,
SAE-mounting surfaces (3000 psi) or by Whitworth the sIiding piston 2 releases the oil flow to the reservoir.
pipe threads ”G“. The spring chamber b is pressure compensated by the
bore c. When starting-up the valve the spring chamber
b must be bleeded by the bleeding screw 5,
(hex. socket width: 4). The valve should preferably be
installed in vertical fitting position with the pressure
setting arrangement down.
The pressure relief valves are available in four different
pressure setting ranges because, due to their springrates,
each of the compression springs can only cover a limited
pressure setting range.
2 KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu
ATEX
Explosion protection – The qualification for the surface temperature is T4;

Field of application for the pressure relief valves. for all gases, vapours, mists with an ignition
The valve is used to secure low pressure hydraulic temperature > 135 °C, the operating materials are not an
circuits with various flammable and non-flammable ignition source.
fluids. In the Dust-Ex area, 135 °C is the reference temperature
for further considerations regarding the safety margin to
They can be used: the glow temperature, etc. (can only be decided by the
a In Zone 2 (Gas-Ex, Category 3 G) operating company).
in the explosion groups IIA, IIB and IIC The permissible ambient temperature ranges from
b In Zone 22 (Dust-Ex, Category 3 D) -- 20 °C ≤ Ta ≤ + 60 °C.
in dusts with a minimum ignition energy > 3 mJ
Marking according to the EU Machine Directive
c In Zone 1 (Gas-Ex, Category 2 G) RL 94 / 9 / EU
in explosion groups IIA, IIB and IIC
Manufacturer KRACHT GmbH
d In Zone 21 (Dust-Ex, Category 2 D) D-58791 Werdohl
in dusts with a minimum ignition energy > 3 mJ Type designation SPV...
Consignment no.,
Year of manufacture xxxxxx/xx-xxx xx.xx
Tech. File Ref. TRR: 04.02X
Protection type marking II 2 GD EEx c IIC (T4) or
II 2 GD EEx c (T4)
KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu 3
Characteristics
Product name / Nominal size SPVF = NG 10
SPVF = NG 20 ... 80
Construction Sliding piston relief valve – directly-operated

(Seat on request)
Mounting In pipeline
Pipe connection SAE-flange (3000 psi)

Whitworth pipe thread G
Dimensions Pages 7, 9, 10, 11
Weight Pages 7, 9, 10, 11
Fitting position Set screw down (preferred)
Housing material EN-GJL-300 (EN-GJS-400-15)
Type setting Mechanical Set screw

Knob
Accessories Welding flange SAE (3000 psi)

Page 11
Δp-Q-Characteristics Page 5
Hydraulic fluids Hydraulic oils acc. to DIN 51 524 / 25

(other fluids on request)
Hydraulic Characteristics
Nominal size 10 20 / 25 32 / 40 50 80
Max. flow capacity l/min 40 90 450 550 800
Nom. working pressure bar 30 30 25 25 20
Pressure setting ranges p v min bar 0.5 0.5 0.5 0.5 0.5
pv max bar 30 40 25 25 20
Fluid temperature range ϑm min °C -- 20 -- 20 -- 20 -- 20 -- 20

ϑm max °C 80 (220) 80 (220) 80 (220) 80 (220) 80 (220)
Ambient temperature ϑu min °C -- 20 -- 20 -- 20 -- 20 -- 20

ϑu max °C 60 60 60 60 60
Viscosity range νmin mm2/s 6

νmax mm2/s 600 (standard)
νmax mm2/s 1500 (possible)
at Qmax 50 % Q N and
at pmax 75 % pN
Explosion proof design (ATEX) Note:

The devices comply with these protective classes: Metallic protective cap (cap nut) in ATEX version
II 2 GD EEx c IIC (T4) or
II 2 GD EEx C (T4
4 KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu
Characteristic Curves pE – Q Viscosity = 34 mm2/s
20 40
16
30
12 30
pE in bar
pE in bar
SPV 10 12 20
8
10
4 02
05
0 10 20 30 40 50 0 10 20 30 40 50
Q in l/min. Q in l/min.
50
20 30 30
40
16
20 20 30 25
12 12
pE in bar
pE in bar
SPVF 20/25
pE in bar
8 20
10
4 02 05 10
0 20 40 60 80 100 0 20 40 60 80 100 0 20 40 60 80 100

Q in l/min. Q in l/min. Q in l/min.
20 30 35
16 25
20 20 25
12 12
pE in bar
pE in bar
pE in bar
SPVF 32/40
8
10 15
4 02 05
5
0 100 200 300 400 500 0 100 200 300 400 500 100 200 300 400 500
20 30 35
16 25
20 25
12 12 20
pE in bar
pE in bar
pE in bar
SPVF 50
8
10 15
4 02 05
5
0 100 200 300 400 500 600 0 100 200 300 400 500 600 100 200 300 400 500 600
20 30
16
20 20
12
pE in bar
pE in bar
12
SPVF 80
8
10
4 05
02
0 100 200 300 400 500 600 700 800 0 100 200 300 400 500 600 700 800
KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu 5
Position: V010, V011, V012, V013, V014, V015,

V016, V017
Part code: M021085
8.6 Valve, ball - 1700 series
Ball valve 1
Ball valve 1700

Position: X001
Part code: M003125
8.7 Seal guard - Simalube
EN
Product Specification
Product automatic long-term grease and oil dispenser
Power generation hydrogen gas producing drycells
Working pressure max. 5 bar
Adjustment stepless 1–12 months (for standard conditions)
Dispensing rate see table on page 15 –17
Operating –20°C to +55°C (–4°F to +131°F) ambient temperature
temperature (Note: grease consistency changes with temperature)
Operation/Usage Grease dispenser can be installed in any position, even under
water. Attention: do not expose to direct heat.
Certifications/ II 1G Ex ia IIC T6
Approvals II 1D Ex iaD 20T 80°C
I M1 Ex ia I
Ingress protection IP68 (dustproof and waterproof)

Usage period within 2 years of production date
Stock temperature recommended at 20°C ± 5°C (65°F ± 5°F)
30 ml 60 ml 125 ml 250 ml
Weight full ~ 82 g ~ 115g ~ 190 g ~ 335 g
Weight empty ~ 55 g ~ 60 g ~ 75 g ~ 111 g
simalube 250
Ø 52 mm (2.05 in.)
simalube 125
186 mm (7.3 in.)
Ø 52 mm (2.05 in.)
simalube 60
simalube 30 Ø 52 mm (2.05 in.)

100 mm (3.9 in.)
Ø 52 mm (2.05 in.)
62 mm (2.4 in.)
43 mm (1.7 in.)
(0.55 in.)
(0.55 in.)
(0.55 in.)
(0.55 in.)
mm
mm
mm
mm
14
14
14
14
R 1/4“ R 1/4“ R 1/4“ R 1/4“
14
Assembly and Installation
1) Open the lubricator outlet by cutting off seal or removing plug.
Do not remove plug from oil filled units! Cut off the

protruding nipple with a knife; a small black point becomes
visible (opening now guaranteed).
2) To start the simalube lubricator, set the gas generator to the
required dispensing time (stepless in months, 1–12) using a
3 mm Allen key. The lubricator is activated once the dispensing
time has been set. Take the required dispensing quantity from
the tables on page 16.
3) Note the starting date on the label using a waterproof pen.
4) Clear grease lines and fill them with the appropriate grease.
Screw simalube onto the greasing point. If necessary, use acces
sories shown on page 20–22. Apply safety rules.
5) Once the set dispensing time has expired, replace empty lubri-
cator with the same type or refill. Before restarting, clear grease
lines and fill them with the appropriate grease.
6) The gas generator is sufficient to empty the unit once,

irrespective of the dispensing time set.
Security note: If the lubricator is started without opening the outlet or in case of
blocked grease lines within the installation, the pressure in the lubricator can build up
approx. 5 bar. At an overpressure of approx. 6 bar the lubricator breaks at the defined
breaking point between housing and bottom. The pressure behind the piston releases
and oil or grease can come out at the breaking point.
The correct functioning of the lubricator can only be assured if recommended lubricants
(see table on page 19) and original simalube accessories are used, and if the installa-
tion, operating and maintenance instructions are closely followed. The manufacturer
cannot accept any responsibility for damages as a result of ignoring the instructions
mentioned above. Important: Before putting simalube into operation fill extensions and
the lubrication lines with the appropriate simalube greases (cartouches KA0 ...KA25)
using a grease gun. Use only original accessories.
Temperature / Output rate
The output rate can be adjusted as required, depending on the ambient temperature
(see table).
Example: You want to set the dispensing time for a 125 ml simalube for 180 days.
Ambient temperature: 20°C Ambient temperature: 55°C
Setting: 6 Setting: 7
15
EN
simalube 30
Dispensing
30 90 180 270 360
time (days)
ml/day 1.00 0.33 0.17 0.11 0.08
Temperature Setting Setting Setting Setting Setting
–20°C + 2 3.5 5.5 7.5
4°C + 2.5 5 7.5 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10.5 –
+ use larger dispenser with longer dispensing time
– smallest possible output rate reached
simalube 60
Dispensing
30 90 180 270 360
time (days)
ml/day 2.00 0.67 0.33 0.22 0.17
–20°C + 2 4 6.5 8
4°C + 2.5 5.5 9 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10.5 –
simalube 125
Dispensing
30 90 180 270 360
time (days)
ml/day 4.17 1.39 0.69 0.46 0.35
–20°C + 2 4 6.5 8.5
4°C + 2.5 5.5 8 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10 –
simalube 250
Dispensing
30 90 180 270 360
time (days)
ml/day 8.33 2.78 1.39 0.93 0.69
–20°C ++ 2 4.5 7.5 9.5
4°C ++ 2.5 5.5 8 10.5
20°C 1 3 6 9 12
40°C 1 3 6 9 –
55°C 1 3.5 6.5 9.5 –
++ use 2-fold adapter
– use smaller dispenser with shorter dispensing time
16
The values relate to laboratory conditions, SL01 with no counterpressure. At low tempe
ratures in particular, the values may vary between one grease type and another. The
dispensers must be replaced once the dispensing time set has expired, even if they are
not completely empty.
The grease quantity dispensed – counter pressure/resistance from

per day is influenced by: the grease lines
– ambient temperature
– viscosity of the grease
Start-up time:
The lubricator requires a certain start-up time until the lubricant is first dispensed.
The start-up time varies in line with the volume dispensed, dispenser size and operating
temperature selected. At 20°C ambient temperature and a dispensing time setting of
12 months, the dispenser outputs the lubricant within one week. The start-up time dou-
bles at low temperatures (–20°C) or with small dispensers (30 ml).
You can reduce the start-up time in such a case by setting a dispensing time on the
lubricator of one month for one to two days and then changing to the desired dispens
ing time.
Calculation pro:
An online calculation program is available at www.simatec.com (simalube/calculation
pro). This tool calculates the right setting for the simalube lubricator if you enter the
precise operating parameters.
Notes:
In order for the unit to function reliably, it is important to have clear, filled grease lines.
It must be ensured that the grease lines are not blocked. Consequently, the grease lines
should always be cleared with a grease gun before starting.
The simalube can be re-adjusted or switched off during operation.
The values on the gas generator relate to laboratory conditions (see page 15). Depend
ing on the temperature and setting, it may take several hours (or several days in the
case of long-term settings) until the lubricant is first dispensed.
The user must check the operation of the simalube regularly.
Grease lines should be no longer than 0.5 m. Recommended bore diameter: 6 – 8 mm
Resistance in grease lines has to be minimized, narrow passages and right angles
should be avoided.
Use a mounting support in the event of strong vibrations or high accelerations (for
accessories, see page 21).
The simalube may only be used to supply a single grease point. No branches may be
made.
Once the lubricator is installed and activated, it must not be removed and mounted
onto another lubrication point.
17
EN
Filling and Refilling (for small quantities)
Filling with grease

1a. 2a.
1a. Push piston all the way forward by blowing
gently with compressed air or with the aid
of a plastic rod (7 mm diameter), towards
the bottom or opening.
2a. Screw on refill nipple (article no. 3012)
and connect grease gun, or screw
connector nipple (3013 or 3014) onto
3a. 4. grease gun. Keep the dispenser pressed
to the adapter during the filling process
so that you do not have to screw on the
refill nipple again. Press grease into the
dispenser. Avoid air bubbles when filling
the unit. Continue the filling process until
the piston has been pushed all the way
5. 6. back. Do not overfill! Caution: Lever
presses can create pressure of up to
80 bar, which is enough to destroy
the dispenser.
3a. Use closing nipple (green) if the dispenser
is to be stored.
4. Position gas generator (make sure the O-ring is positioned correctly)

and attach firmly with a 1.5 – 2.0 Nm torque key.
5. Clip in cover disk.
6. Note grease type and filling date on the label.
Filling with oil

1b. 2b.
1b. Push the piston all the way back
(towards the gas generator).
2b. Pour in oil through the opening
at the bottom.
3b. Position non-return valve
(yellow, article no. 5060).
3b. 4–6 Continue as above.
Refilling with grease or oil

1. Remove cover disk.
2. Unscrew gas generator (SW 21) and
recycle with other batteries. Never remove
near an open flame! Then continue as
above for filling with grease or oil.
Note
1.
To ensure that the simalube lubricator operates
reliably, only greases that have been tested
and approved for use with the simalube
should be used. In particular, it is important to
ensure the good stability of the grease against
bleeding of the base oil and a low consistency
2. class (max. NLGI 2). No guarantee claims will
be accepted when dispensers are filled by the
user or not explicitly approved lubricants are
used. If in doubt, please contact our Technical
Department or your local distributor.
18
Lubricants
The standard lubricant range suitable for simalube includes modern high quality lubri-
cants tested and modified for the special requirements of grease and oil dispensers.
Datasheets are available online for all lubricants (www.simatec.com). Please refer to these
datasheets for the instructions/safety regulations of the grease/oil manufacturers.
No. Application Temperature range

(in the area of lubrication)
SL01 Multipurpose grease –30 / +120°C

SL02 Multipurpose grease with MoS2 –25 / +130°C
SL04 High temperature grease –20 / +160°C
SL06 Fluid grease –20 / +120°C
SL09 Biodegradable grease –20 / +80 / 100°C
SL10 Food industry grease (NSF H1) –30 / +140°C
SL14 Chain oil –10 / +90°C
SL15 High temperature chain oil 0 / +250°C
SL18 Food industry oil (NSF H1) –15 / +150°C
SL24 Grease for a wide temperature range –30 / +150°C
simalube can also be delivered filled with other lubricants or as an empty unit.
Ask for advice. The operation of simalube with oils of different viscosities is also possible.
Troubleshooting
Fault Possible cause Remedy

– no grease output – seal not cut off/closing nipple – open/remove
still in place
– not switched on – switch on
– grease lines blocked – clear lines with grease gun
– gas generator loose – tighten with 2 Nm
– insufficient output – dispensing time too long – set to lower number
– ambient temperature too low – c orrect setting according to
table, page 16
– grease lines blocked/too – clean, allow for free flow of
narrow grease
– short-term extreme low – none
temperatures, piston moves
backwards
– high counter pressure – clear grease lines, check
installation
– excessive output – dispensing time too short – set to higher number
For other malfunctions contact simatec engineering or your local distributor.

The information provided reflects the manufacturer’s current level of development and
understanding. Subject to change. The products are subject to strict manufacturing con-
trols and meet internal works specifications. As a result of the wide range of conditions
and areas of application possible in each case, no guarantee can be provided for effec-
tiveness or success in each individual instance. No responsibility is accepted for damage
or malfunctions caused by incorrect use or improper work on or with the lubricator.
19
EN
Accessories
Note: Use only original accessories. If you have technically demanding or unusual
applications, please contact our Technical Department or your local distributor.
Bent connection 45°
D R 1/4
Nr. 1001
D R 1/4
Nr. 1002
90° connection with thread (only for oil)

70 mm incl. 2 nuts
L 70 [ mm ]
Nr. 1005
Connecting nipple
D R 3/8 R 1/2
Nr. 1010 1011
Reducing nipple
D R 1/8 R 1/4 M6 M8 M8x1 M10 M10x1 M12 M12x1.5 UNF 1/4
Nr. 1020 1021 1022 1023 1024 1025 1026 1027 1028 1121
Extension
L 10 35 50 [ mm ]
Nr. 1021 1040 1041
Screwed connection with hole

25 mm incl. 1 nut
L 25 60 [ mm ]
Nr. 1045 1046
Y-manifold
Contains reduction 1021
D R 1/4
Nr. 1050
Quick connection
For hose ø 8 mm
D R 1/4
Nr. 1060
Quick connection
For hose ø 8 mm
D R 1/8 R 1/4 R 3/8
Nr. 1070 1071 1072
Hose
Maximum length to greasing point: 0.5 m /available by the metre
L per meter
Nr. 2000/...m
20
Clamp for simalube/round brush
Plastic
D 50 28 [ mm ]
Nr. 2010 2013
Adapter for Perma clamp

Plastic
D 50 [ mm ]
Nr. 2012
Distance holder to clamp for round brush (2013)
H 15 [ mm ]
Nr. 2014
Non-return valve
D R 1/8 R 1/4
Nr. 2020 2021
Round brush
Plastic bristles
DxL ø 25x45 [ mm ]
Nr. 2034
Brush
Horse bristles
L 40 70 100 25 [ mm ]
Nr. 2035 2036 2037 2038
Brush, lateral connection

Horse bristles
L 40 70 100 [ mm ]
Nr. 2035-S 2036-S 2037-S
Elevator brush
High 32 mm
Nr. 2039
Elevator brush small

High 32 mm
Nr. 2042
113 Round brush

Horse bristles
DxL ø 25x15 [ mm ]
84
Nr. 2041
Mounting support for all simalube sizes
Nr. 2080
Protective cover to mounting support 2080 (steel)

(for simalube 125 ml or smaller)
Nr. 2081
21
EN
Bracket to mounting support
1-fold length 75 mm 3-fold length 240 mm 5-fold length 390 mm
Nr. 2082 2083 2084
Bracket, universally adjustable
Nr. 2800
Connector nipple
For cleaning and filling of grease lines
D R 1/4
Nr. 3011
Refill nipple
For refilling of simalube
D R 1/4
Nr. 3012
Connecting nipple
To grease gun filler for filling simalube
D R 1/4 R 3/8
Nr. 3013 3014
4-fold adapter
D R 1/2 R 1/4
Nr. 4100 4101
2-fold adapter
D R 1/2 R 1/4
Nr. 4102 4103
Gas generator
For refilling
30 ml 60 ml 125 ml 250 ml
Nr. 5004 5006 5008 5010
Closing nipple
Plastic
Nr. 5050
Non-return valve plug

Plastic
Nr. 5060
Gasket ring
Nr. 5080
Grease cartridge
400 ml
Grease SL01 SL02 SL04 SL06 SL09 SL10 SL24 SL25
Nr. KA01 KA02 KA04 KA06 KA09 KA10 KA24 KA25
22
Oil bottle, 0.5 l
Chain oil OF14

High temperaure chain oil OF15
Food industry oil OF18
Recycling Instructions
1) Unscrew gas generator and dispose of
complete unit for battery recycling
(see above). Note: Do not detach lubrica-
tor near an open flame.
2) Dispose of empty housing for PET recyc
ling. If the lubricator still contains lubricant
after use, please dispose of it in accord
ance with local regulations.
simalube has been safety inspected and approved by the following institutions:
• Physikalisch Technische Bundesanstalt, Brunswick, Germany, Nr. 3.42-16990/94
• FM Approvals, USA, Project Identification Number: 3013825
• Technischer Überwachungsverein (TÜV) Rheinland, Cologne, Germany, 12.05.95
• DMT Gesellschaft für Forschung und Prüfung GmbH, Germany Nr. 16420/344/96
• LOBA NRW, Dortmund, Germany, Nr. 12.22.63-4-2
• INERIS, France, Nr. 96.Y.300 X, CROSS ia I
• EECS / BASEEFA, United Kingdom, No. 95 (A) 0692, 1997-04-10
• TÜV Product Service GmbH, Germany, Nr. Z1 08 02 29499 015
• TÜV Product Service GmbH, Germany, Nr. EX3 10 04 29499 016
• KEMA Quality B.V., Netherland Nr. KEMA 09ATEX0098
II 1 G Ex ia IIC T6
• II 1 D Ex iaD 20 T 80°C
I M1 Ex ia I
EU Declaration of Conformity
simatec ag
Stadthof 2 in CH-3380 Wangen a. Aare
declares that the
single point lubricators
simalube & simalube multipoint
are designed and manufactured in
accordance with
Directive 94/9/EC of the European
Parliament and the Council for equipment
and protective systems intended for use in
potentially explosive atmospheres.
The following standards have been applied:
EN 60079-0:2006
EN 60079-11:2007
EN 60079-26:2004
EN 61241-0:2006
EN 61241-11:2006
EN 50303:2000
Manufactured by:
Notified Body:
TÜV Product Service GmbH simatec ag
D-80339 Munich Stadthof 2
KEMA Quality B.V., NL-6812 AR Arnhem CH-3380 Wangen a. Aare
Certificate No. www.simalube.com
KEMA 09ATEX0098
Wangen a. Aare, 20.09.10
Mischa Wyssmann, Managing Director CEO
23
Section 5
Attachments
~ .=:=::. AURA Document id rev
~t='~MARINE I FC14225 I
Manufacturing no: 14225
page :1/2
FACTORYCERTIFICA TE
This is to certify that AURAMARINE LTD, FINLAND
did inspection and testing of:
Unit type: PCO-M-38/38-MDO/H FO

Intended Service
Orderer Rolls-Royce Power Systems - Bergen Engines AS
Order no 262559
DRAWINGS:
Flow chart P13014
General arrangement 310009
Electric diagrams 410299
VOLTAGE: 415V 50Hz I 24 VDC
PROOF PRESSURE TEST: DP/bar WP/bar TP/bar MEDIA
HFO side 10 8 15 Oil
DFO side 10 8 15 Oil
The unit is surveyed in finished condition and tested min

to 1,5 * DP and found tight and in satisfactory condition.
GENERAL INSPECTION: The installation of mechanical/electrical

equipment was considered satisfactory.
Place: Littoinen
Date: ~ 1.03.2017
Surveyor:--,-~
-----
Ake Puisto
Distribution Made:RTu
Original: Project file Appr:HSa
Copy:Technical manual Date: 14.02.2002
AURAMARINE LTD.
Street address : Postal address : Tel +358 ( 0 )2 414 2200 Reg office Lie to
Kukkosenapaja 1 P.O.BOX 849 Fax +358 ( 0 )2 414 2250 Trade reg. no: 402 .012
FIN-20660 LITTOINEN FIN-201 01 TURKU Telex 62595 AUMA Fl ALV rek I VAT reg : F106846963
FINLAND FINLAND
~ .:::::=.. AURA Document id rev
.,a"t;;'-:=... MARINE I FC14225 I
Manufacturing n.o: 14225
page :2/2
FACTORY TEST CERTIFICATE FOR UNIT
FUNCTIONING TEST RESULTS AND SET POINTS
Proof pressure test:
HFO side 15 bar
DFO side 15 bar
DENOMINATION FUNCTIO- SETTING SET POINT

NING RANGE
1. INSPECTION OF COMPONENT ok
SUPPORT
2. MOTOR PROTECTION ok 4,55A
3. SAFETY VALVES INSIDE PUMPS ok 10 bar

4. VALVE CONTROLS AND INDICATIONS ok
. CONTINUITY OF PROTECTIVE ok Tested according

BONDING CIRCUIT to IEC-204-1
. INSULATION RESISTANCE TEST ok "

. VOLTAGE TEST ok "
. MOTOR-& EL.HEATER CURRENTS DO NOT ok
EXCEED NOMINAL VALUES
Distribution
Original: Project file Made: RTu
Copy: Technical manual Appr: HSa
Date: 14.02.2002
AURAMARINE LTD.
Street address: Postal address: Tel +358 ( 0 )2 414 2200 Reg office Lie to
Kukkosenapaja 1 P.O.BOX 849 Fax +358 ( 0 )2 414 2250 Trade reg. no: 402.012
FIN-20660 LITIOINEN FIN-20101TURKU Telex 62595 AUMA Fl ALV rek I VAT reg : F106846963
FINLAND FINLAND
F 164/11 D
Component: HFO Duplex filter
Type : Aura Marine
Engines : 16419-27
BEAS Part no: B00709152
BERGEN ENGINES AS
[ BLANK ]
22.03.2017
AMFI 514897
Unit, fine filter

AFF-M-10-MDO/HFO
14224
Auramarine LTD
Street address:
P.O. Box 849, FI-20101 Turku
Postal address:
P.O. BOX 849
FIN-20101 TURKU
FINLAND
Tel. +358 204 860 5030

Fax +358 204 860 5031
www.auramarine.com
Business ID: 0684696-3

Domicile: Turku
Spare parts and service

Table of Contents

General arrangement 310011, - 8

PI Diagram P13016, - 11

Electric drawing 410298, - 15
Instruction Manual D03556, A 19
5 Attachments
Factory certificate 14224 - 57
Section 1
7.12.2016 1(3)


HFO duplex filter 10 m3/h
AFF‐L‐10‐HFO/MDO

Bergen Engines AS
Part no.: 709152

Auramarine Ltd
Unit Nos.: 14224

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku
7.12.2016 2(3)


1. Design Basis

Engine type: 16B32/40L
Trace heating voltage 1 ~230 V+N (Available at site)
Fuel working / test pressure: 8 / 15 bar

2. Main Components

Pos. Denomination

B012A, B012B Fine filter
‐ Replaceable filter elements (1 pc / each housing)
‐ Filtration degree 5µm nom. / 10µm abs.
‐ Equipped with safety valves
‐ Vent and drain valves
‐ Diff. press. indication switch (P012)


‐ Equipped with bottom for leakage oil
‐ Color RAL 5019

Oil pipes ‐ Seamless carbon steel St 37.4 DIN 2391
‐ Painting system: SFS‐EN ISO 12944‐5; 2007 A2.06 EP120/2
‐ Color RAL 5019
‐ HFO lines electrically trace heated and insulated with mineral
wool covered with galvanized steel sheet

Filter housings ‐ Seamless carbon steel St 35 DIN 2448
‐ Welded construction
‐ Equipped with connecting legs
‐ Colour RAL 5019.
‐ Isolated with mineral wool and covered with galvanized steel sheet
‐ Electric trace heating in two circuits, one for each chamber

Connection flanges ‐ EN 1092‐1, counter flanges, gaskets bolts and nuts are included

7.12.2016 3(3)


Instrument pipes ‐ Oil lines: Hydraulic pipe St 35.4 DIN 2445.2.2
‐ Air lines: Copper pipe

Valves ‐ Ball valves, nominal pressure class 40 bar, uninsulated

Name plates ‐ Material of stainless steel for process components and connection flanges
according to PI diagram

Junction box ‐ Junction box for each trace heating circuit.
‐ Engraved plastic name plates on junction boxes

4. Revision list

‐
1 2 3 4 5 6 7 8
2425
A DN65 FUEL OIL INLET
A B DN65 FUEL OIL OUTLET A
C R2" DRAIN FROM UNIT
1755
DIMENSION TOLERANCES FOR LOCATION
OF CONNECTIONS ±5mm.
PIPE CONNECTION FLANGES: EN1092‐1 PN16/40.
PIPE CONNECTIONS WITH COUNTER FLANGES.
PIPE CONNECTIONS A AND B ON FRONT SIDE OF UNIT.
B B
CONNECTION C ON BOTH SIDES OF UNIT.
A 1066
FRAME SUPERSTRUCTURE TO BE SUPPORTED ON BOARD.
FASTENING FRAME ONTO FOUNDATION BY WELDING
IS RECOMMENDED.
WEIGHT ~800kg
B 265
C C
C 45
0
1150
0
750
1500
500 500
RECOMMENDED SERVICE SPACE
40
D D
S=10
200
250
18
DETAIL A
E A
SCALE 1 : 10
100
600
OPERATION SIDE Units Sheet Description

mm kg 1 / 1 AFF-M-10-MDO/HFO
General tolerances: SFS-EN ISO 13920B

F JSa 26.10.2016
Checked Date
- 26.10.2016 JSa SSo 26.10.2016
Rev Change Date Designed www.auramarine.com
Approved
TLe
Date
26.10.2016
310011 -
1 2 3 4
Section 2
Part list
Structure 0014224 Desc 1 Unit, fine filter Status Main information created
Modified 2016-12-07 Desc 2 AFF-M-10-MDO/HFO
S005432 0 PI structure AFF-M-10-MDO/HFO 1 1
AM05989 0 B012A Casing, Filter Ø508x1131mm + cover 1 1
AM05989 0 B012B Casing, Filter Ø508x1131mm + cover 1 1
AM01297 0 B012AB Filter insert 1 2
M002233 0 P012 Indicator, pressure difference 700.01,0-2,bar+psi,Rp1/4",S5,switch 1 1
M021501 0 V109 Valve, safety 851 BF-12, Rp1/2", 12bar 1 1
M021501 0 V110 Valve, safety 851 BF-12, Rp1/2", 12bar 1 1
M020269 0 Tracing 1 Cable, heating HTSX-12-2-FOJ, 37 W/m, 230 V 1 12
M020556 0 Tracing 1 Junction box 311020 2xPg16, 89x89x42, ZnAl 1 1
M020268 0 Tracing 1 Accessories Install kit PETK-2 for HTXS cable 1 1
M020959 0 Tracing 1 Cable gland Pg16, brass, 161/MS 1 1
M020878 0 Tracing 1 Cable gland M20, polyamide, inner D 7.0-13.0mm 1 1
M020269 0 Tracing 2 Cable, heating HTSX-12-2-FOJ, 37 W/m, 230 V 1 12
M020556 0 Tracing 2 Junction box 311020 2xPg16, 89x89x42, ZnAl 1 1
M020268 0 Tracing 2 Accessories Install kit PETK-2 for HTXS cable 1 1
M020959 0 Tracing 2 Cable gland Pg16, brass, 161/MS 1 1
M020878 0 Tracing 2 Cable gland M20, polyamide, inner D 7.0-13.0mm 1 1
M003125 0 X001 Seal guard 12SL00-125, grease dispenser (Ex) 1 1
Part list
M003847 0 X002 Hose with fittings 301-04-04/EZ-04/302-02-04, L800 1 1
Section 3
Part list
S005433 0 El. structure AFF-M-10-MDO/HFO 1 1
Section 4
Instruction Manual
Contents
1.1 Storage.................................................................................................................................................2
1.2 Handling ...............................................................................................................................................2
1.3 Installation ...........................................................................................................................................3
4 START-UP .....................................................................................................................................................4
6 MAINTENANCE ............................................................................................................................................5
7 HOW TO ORDER SPARE PARTS ....................................................................................................................6
8 COMPONENT MANUALS..............................................................................................................................7
Components ....................................................................................................................................................7

1.1 Storage
storage time please contact Auramarine.
1.2 Handling
Figure a) packed unit, b) unpacked unit
Unit is lifted with lift hangers or with forklift truck.

Used lifting device must have adequate lifting capacity and break resistance
it is prohibited to be under lifted load.
1.3 Installation
Package material is wood and plastic. Materials are to be disposed or recycled according to local law.
heated.
2. Wear protective clothing, ear defenders and eye protection. Danger of burning lesion. Beware
of hot surfaces, hot oil and noise.
controlled manner.

2. Do not heat DFO.
3. It is recommended that all HFO pipelines connected to unit are insulated and trace heated.
maximum allowed operating temperature (found from technical specification) and that the
4 START-UP
1. Ensure fuel flow to unit.
2. Fill fuel oil unit and pipelines to and from engine(s).
3. The pressure in the unit and engine(s) should rise to range stated in the technical specification. If
not, check positions of valves.

Problem Check points / actions
Filter alarm clogged Change to bypass filter and clean the filter.
6 MAINTENANCE
Although all Auramarine fuel supply unit contracts offer a guarantee of quality, normal wear and tear
parts are not included in the guarantee. The following are considered wear parts:
 Mechanical shaft seals of the pumps
 Filter candles and elements
 Couplings and coupling elements
 Ball bearings for pumps and electric motors


Ordering address:
Fax +358 204 86 5031
Tel +358 204 86 5030
8 COMPONENT MANUALS
Components
8.1 P012 M002233 Indicator, diff. pressure gauge - 700.01, 700.02 26
8.2 V100, V101, V102, V103 M021074 Valve, ball - 225 SGS, Standard 34
8.3 V106, V107, V112, V113, M021084, M021085 Valve, ball - 1700 series 36
V115, V116, V120, V121,
V122, V123
8.4 V109, V110 M021501 Valve, safety - 851, 852, 652 861 38
8.5 X001 M003125 Seal guard - Simalube 44
Position: P012
Part code: M002233
8.1 Indicator, diff. pressure gauge -
700.01, 700.02
3. Specifications / 4. Design and function
3. Specifications
Specifications Model 700.01 Model 700.02

Nominal size 80 GB
Accuracy class ± 3 % of full scale value with ± 5 % of full scale value with
increasing differential pressure increasing differential pressure
Scale ranges 0 … 400 mbar to 0 … 10 bar 0 … 160 mbar to 0 … 2.5 bar
Max. working optionally 100, 250 or 400 bar 100 bar
pressure (scale ranges 0 ... 160 mbar and
(static pressure) 0 ... 250 mbar: 50 bar)
Overpressure safety either side to maximum working pressure
(exception for model 700.02, scale ranges 0 ... 160 mbar and
0 ... 250 mbar: Overpressure safety up to 50 bar)
Ingress protection lP 54 (EN 60529 / lEC 529)
Measuring chamber Stainless steel 1.4571, 2 x G ¼ female, on the right and left side,
with pressure in-line (EN 837-1 /7.3)
connection (wetted)
For further specifications see WIKA data sheet PM 07.14 and the order
documentation.
4. Design and function

Description
Pressures p1 and p2 are given in the ⊕ and ⊖ measuring chambers, separated
by the magnetic piston under pressure(or magnetic piston and separating
diaphragm for model 700.02).
The difference in pressure causes an axial movement (deflection) of the piston

supported by the compression spring.
The deflection resulting from this is taken up by a ring magnet found on the
instrument pointer and appropriately displayed. This design combines the
advantages of complete separation of the measuring system and the indication
while eliminating any leakage to the exterior.
For model 700.01 the volume flow from the ⊕ measuring chamber to the ⊖
2103869.04 12/2012 GB/D/F/E
measuring chamber is minimised by the constructive design and will not interfere
with standard processes.
These instruments are mainly intended for gas/air supply and preparation appli-
cations where no magnetic particles are involved.
WIKA operating instructions differential pressure gauge with piston 7

5. Options and accessories
In processes with floating particles model 700.02 should be used.
Scope of delivery
Cross-check the scope of delivery with the delivery note.
GB
5. Options and accessories
5.1 Mounting flange (only for model 700.01, see left illustration)
May be retrofitted on site as required.
Alignment of the front bezel (A) by means of the stamped cams to the grooves
found on the case circumference. Push front bezel on the case until it snaps into
position.
5.2 Minimum or maximum drag pointer (see illustrations)

The drag pointer (B) serves to monitor and control the miniumum or maximum
occurring differential pressure.
5.3 Reed contact model 851.3 and 851.3.3 (see illustrations)

May be retrofitted and adjusted on site as required.
Fastening is by means of two screws (D) integrated in the reed case (C) on the
display case with the pertinent female thread.
C D
A
C D
B
2103869.04 12/2012 GB/D/F/E
8 WIKA operating instructions differential pressure gauge with piston

6. Transport, packaging and storage / 7. Commissioning ...
6. Transport, packaging and storage

5.1 Transport
Check pressure gauge for any damage that may have been caused by transport.
Obvious damage must be reported immediately. GB
6.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g.
change in installation site, sending for repair).
6.3 Storage
Permissible conditions at the place of storage:
Storage temperature: -20 ... +70 °C (optional: -40 … +70 °C)
7. Commissioning, operation
Mechanical connection
The installation of the differential pressure gauge is made following the installation
recommendations for pressure gauges in accordance with EN 837-2 /7.
Mounting of the process connection according to affixed symbols ⊕ and ⊖

⊕ high pressure, ⊖ low pressure
■■ Hold against the connection pieces in the case of installation by means of

17 mm screw spanner (installation without holding against the connection
pieces may cause thet measuring system to get loose).
■■ The maximum permissible medium/ambient temperature must not be

exceeded
■■ Prior to the installation of the pressure gauge, clean the measuring lines
thoroughly by tapping and blowing or rinsing
■■ Mount and operate the measuring instruments free from vibration
■■ Protect measuring instruments from contamination and high temperature

2103869.04 12/2012 GB/D/F/E
changes
To avoid foreign matter in the measuring system and the resulting damage to the
system, the pressure gauge must be mounted above the connector. For measuring
media containing suspended particles model 700.02 should be used.

If the line to the gauge is not rigid enough for a vibration-free installation, the gauge
should be mounted by means of appropriate fastening elements for wall mounting,
or, if necessary, with a capillary.
GB
Wall mounting (see drawing)
Installation / fastening by means of mounting brackets
Hexagon bolt
without reed contact M8 x 50 (M8 x 100)
with reed contact
Slotted screw M4 x 10
Drag pointer
Plug
1581007.02
Reed case
Electrical connection (for instruments with electrical accessories)

Electrical connection of the pressure gauge is by means of terminal box and
cable. Precise wiring schemes can be seen in the following connection diagram.
In addition both the pin assignment and the required power supply are stated on
the product label of the reed case.
Electrical connection diagram
Reed contact model 851.3 and 851.3.3

(change-over contact)
The instruments do not

provide for incorporated
2103869.04 12/2012 GB/D/F/E
overcurrent protectors. If
851.3. 3
2nd contact overcurrent protectors are
requested, these have to
851. 3 1nd contact be provided for externally.
Terminal box

Switch point adjustment

Preference should be given to setting the switch point before installing the
measuring instrument. The necessary test path is generated manually (e.g. by
means of an antimagnetic screwdriver).
GB
Manual test path generation
Plus media chamber
antimagnetic
The switch point can also be set in a pressurised condition after installation. The
switch points are set at the factory when the set points are given.
The switch point is adjusted by turning the contact adjustment screws on the
outside of the reed case.
Anticlockwise rotation:
Switch point can be moved in the direction of the
start of the measuring range
Clockwise rotation:
Switch point can be moved in the direction of the
end of the measuring range
Zero point check

In general, the zero point should only be checked and adjusted at zero pressure.
The system fastening lug on the back of the case can be easily slackened off for
zero point correction of the pressure gauge. Now the zero point can be readjusted
by moving the measuring system to the right or left. After this has been done the
measuring system is to be secured again with the mounting screw (recommended
tightening torque of the mounting screw 1.3 Nm).
2103869.04 12/2012 GB/D/F/E

8. Maintenance and cleaning / 9. Dismounting and disposal
8. Maintenance and cleaning
8.1 Maintenance
The instruments are maintenance-free.
GB
The differential pressure gauges with piston offer long service life provided they
are handled and operated properly.
Checks should be carried out on a regular basis to ensure the measuring

accuracy of the pressure gauge.
Repairs must only be carried out by the manufacturer or appropriately qualified
skilled personnel.
8.2 Cleaning
CAUTION!
■■ Clean the pressure gauge with a moist cloth.
■■ Wash or clean the dismounted pressure gauge before retur-

ning it, in order to protect persons and the environment from
exposure to residual media.
9. Dismounting and disposal
WARNING!
Residual media in dismounted pressure gauges can result in a
risk to persons, the environment and equipment. Take sufficient
precautionary measures.
9.1 Dismounting
Only disconnect the pressure gauge once the system has been depressurised!
9.2 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an

environmentally compatible way and in accordance with the country-specific
waste disposal regulations.
2103869.04 12/2012 GB/D/F/E

Position: V100, V101, V102, V103

Part code: M021074
8.2 Valve, ball - 225 SGS, Standard
Standard valve 1
Standard valve

NO NAME NO NAME
1 1 Handle *11 2 Body seals
**2 a b 2 Handle nut 12 1 Body
*3 1 Packing ring 13 2 End connection
**4 2 Spring washer 14 1 Step-pin
**5 1 Antistatic stem 16 Note 1 Bolts
6 1 Gland packing **17 1 Step washer
*10 2 Seats
* Start-up: 5% of ordered quantity
* Suggested materials after 2 years service
** Suggested materials after 5 years service
DN 08-
10 M10x1 8 70 M8x47 35 310
DN 15 M10x1 8 70 M8x51 35 440
DN 20 M12x1.25 15 130 M10x64 50 440
DN 25 M12x1.25 15 130 M10x75 50 440
DN 32 M15x1.5 25 220 M12x88 70 620
DN 40 M15x1.5 25 220 M12x95 70 620
Position: V106, V107, V112, V113, V115, V116,

V120, V121, V122, V123
Part code: M021084, M021085
Ball valve 1
Ball valve 1700

Position: V109, V110

Part code: M021501
8.4 Valve, safety - 851, 852, 652
861
Safety valve 1
851 / 451, 852 / 452 / 352, 652 mFK, 652 sGK, 861 / 461, 420, 460
A B
C D
Safety valve 2
E F
1 Assembly and maintenance instructions

1.1 General Notes of Safety
 Only use the valve:
- for the specified purpose
- in satisfactory condition
- with respect for safety and potential hazards
 Always observe the installation instructions.
 Faults that may impair safety must be addressed immediately.
 The valves are exclusively intended for the application area stated in these installation
instructions. Any other or further use is not valid as the intended use.
 The manufacturer´s warranty shall be null and void if the sealed cover is removed.
 All assembly work is to be carried out by authorized specialist staff.
Safety valve 3
1.2 General Notes

Safety valves are high-quality fittings which require a particularly careful handling. The sealing
surfaces are precision-machined at the seat and cone to attain the required tightness. Always
avoid the penetration of foreign particles into the valve during assembly and during the
operation. The tightness of a safety valve can be impaired when using hemp, Teflon tape, as well
as through welding beads, among other things. Also rough handling of the finished valve during
storage, transport and assembly can result in a safety valve leaking. If the safety valves are
painted, make sure that the sliding parts do not come into contact with the paint.
1.3 Installation and Assembly

Spring-loaded safety valves are to be installed with the spring bonnet pointing vertically upward.
To ensure a satisfactory operation of the safety valves they must be installed in such a way that
the safety valve is not exposed to any impermissible static, dynamic or thermal loads. Appropriate
protection devices must be applied if the medium that discharges upon actuation of the valve can
lead to direct or indirect hazards to people or the environment. Always pay attention to possible
fumes discharging from the relief bores in the spring bonnet.
Supply
Supply connection pieces for safety valves are to be kept as short as possible and are to be
designed in such a way that there can be no pressure loss greater than max. 3% of the response
pressure.
Removal of condensate discharge
In the event of possible condensate formation the pipes or the valves themselves (in flanged
version) must be fitted at their lowest point with a continuously operating condensate discharge
device. Hazard-free removal of the condensate or medium discharge must be ensured. The body,
pipes and silencers must be protected against freezing.
Blowing-off pipe / backpressure
The blow-off pipe of the safety valves must be designed to ensure that the required mass flow can
be discharged pressure-free during the blowing-off process. In safety valves with metal bellows a
backpressure of up to max. 4 bar has no impact on the response pressure of the safety valve.
1.4 Operation/maintenance
The operating pressure of the plant is to be least 5% lower than the closing pressure of the safety
valve. In this way, the valve can satisfactorily close again after blowing off. In the event of minor
leaks, which may be caused by contamination between the sealing surfaces, the valve can be
made to blow off through lifting, for cleaning purposes. If this does not remove the leak, the
sealing surface is probably damaged and this can only be repaired at our factory or by authorized
specialists. Depending on the version, lifting is either carried out by means of a knurled nut above
the spring bonnet (Fig. a) which is turned counterclockwise (afterwards the knurled nut has to be
turned back to the stop) or by actuating the lifting lever on the upper part of the valve (Fig. b). For
delivery purposes the lifting lever is blocked by means of strap which has to be removed for
actuating the lifting device.
Safety valve 4
Safety valves without bellows and without gastight cap ( Fig. c)

In addition, in the case of safety valves without bellows and without gastight cap, the entire upper
part can be unscrewed from the housing using appropriate tools and any residue removed from
the seat and the seat sealing.
Prior to removal make sure that the safety valve is not under pressure.
The response pressure of the safety valve is not altered through the reassembly of the upper part
in the housing.
Safety valve with metal bellows (Fig. d)
In the case safety valves with metal bellows the upper part is not to be separated from the
housing, because otherwise tightness is no longer guaranteed in the event of backpressure
occurring.
Safety valves with gas-tight cap ( Fig. f) or gastight lifting ( Fig. g)
On safety valves with gas-tight cap or gastight lifting lever, the top part may not be separated
from the housing as this compromises gas tightness. However, if the top part does have to be
unscrewed for a repair, it should be ensured that the tension on the spring is released before
dismantling. You should also check before dismantling the valve whether there is any medium in
the cap and if so, what it is. Potential risk of chemical burns or poisoning.
Lifting for maintenance purposes
In the case of safety valves with a lifting device it is recommended, and in certain plant-specific
cases even stipulated that the valves from time to time must be made to blow-off by lifting the
seal off the seat, in order to assure the correct functioning of the safety valve. This ist why they
can be made to open at the latest as from an
pressure. The lifting device is not to be operated when in a pressure-free state. In steam
generating equipment, testing the ease of movement of safety valves must be carried at least
every 4 weeks in compliance with TRD 601. Safety valves are the ultimate safety device for the
tank or system. They must be able to prevent impermissible overpressure even when all other
upstream control and monitoring equipment fail. To ensure these functional characteristics safety
valves require regular and recurring maintenance. The maintenance intervals are determined be
the operator in dependence of the operating conditions.
1.5 Dismantling the fitting

In addition to the general installation instructions it must be ensured that the system is made
pressure free prior to disassembly of the safety valve.
1.6 Repairs
Please contact Auramarine in case of any repair work.
Position: X001
Part code: M003125
8.5 Seal guard - Simalube
EN
Product Specification
Product automatic long-term grease and oil dispenser
Power generation hydrogen gas producing drycells
Working pressure max. 5 bar
Adjustment stepless 1–12 months (for standard conditions)
Dispensing rate see table on page 15 –17
Operating –20°C to +55°C (–4°F to +131°F) ambient temperature
temperature (Note: grease consistency changes with temperature)
Operation/Usage Grease dispenser can be installed in any position, even under
water. Attention: do not expose to direct heat.
Certifications/ II 1G Ex ia IIC T6
Approvals II 1D Ex iaD 20T 80°C
I M1 Ex ia I
Ingress protection IP68 (dustproof and waterproof)

Usage period within 2 years of production date
Stock temperature recommended at 20°C ± 5°C (65°F ± 5°F)
30 ml 60 ml 125 ml 250 ml
Weight full ~ 82 g ~ 115g ~ 190 g ~ 335 g
Weight empty ~ 55 g ~ 60 g ~ 75 g ~ 111 g
simalube 250
Ø 52 mm (2.05 in.)
simalube 125
186 mm (7.3 in.)
Ø 52 mm (2.05 in.)
simalube 60
simalube 30 Ø 52 mm (2.05 in.)

100 mm (3.9 in.)
Ø 52 mm (2.05 in.)
62 mm (2.4 in.)
43 mm (1.7 in.)
(0.55 in.)
(0.55 in.)
(0.55 in.)
(0.55 in.)
mm
mm
mm
mm
14
14
14
14
R 1/4“ R 1/4“ R 1/4“ R 1/4“
14
Assembly and Installation
1) Open the lubricator outlet by cutting off seal or removing plug.
Do not remove plug from oil filled units! Cut off the

protruding nipple with a knife; a small black point becomes
visible (opening now guaranteed).
2) To start the simalube lubricator, set the gas generator to the
required dispensing time (stepless in months, 1–12) using a
3 mm Allen key. The lubricator is activated once the dispensing
time has been set. Take the required dispensing quantity from
the tables on page 16.
3) Note the starting date on the label using a waterproof pen.
4) Clear grease lines and fill them with the appropriate grease.
Screw simalube onto the greasing point. If necessary, use acces
sories shown on page 20–22. Apply safety rules.
5) Once the set dispensing time has expired, replace empty lubri-
cator with the same type or refill. Before restarting, clear grease
lines and fill them with the appropriate grease.
6) The gas generator is sufficient to empty the unit once,

irrespective of the dispensing time set.
Security note: If the lubricator is started without opening the outlet or in case of
blocked grease lines within the installation, the pressure in the lubricator can build up
approx. 5 bar. At an overpressure of approx. 6 bar the lubricator breaks at the defined
breaking point between housing and bottom. The pressure behind the piston releases
and oil or grease can come out at the breaking point.
The correct functioning of the lubricator can only be assured if recommended lubricants
(see table on page 19) and original simalube accessories are used, and if the installa-
tion, operating and maintenance instructions are closely followed. The manufacturer
cannot accept any responsibility for damages as a result of ignoring the instructions
mentioned above. Important: Before putting simalube into operation fill extensions and
the lubrication lines with the appropriate simalube greases (cartouches KA0 ...KA25)
using a grease gun. Use only original accessories.
Temperature / Output rate
The output rate can be adjusted as required, depending on the ambient temperature
(see table).
Example: You want to set the dispensing time for a 125 ml simalube for 180 days.
Ambient temperature: 20°C Ambient temperature: 55°C
Setting: 6 Setting: 7
15
EN
simalube 30
Dispensing
30 90 180 270 360
time (days)
ml/day 1.00 0.33 0.17 0.11 0.08
–20°C + 2 3.5 5.5 7.5
4°C + 2.5 5 7.5 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10.5 –
simalube 60
Dispensing
30 90 180 270 360
time (days)
ml/day 2.00 0.67 0.33 0.22 0.17
–20°C + 2 4 6.5 8
4°C + 2.5 5.5 9 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10.5 –
simalube 125
Dispensing
30 90 180 270 360
time (days)
ml/day 4.17 1.39 0.69 0.46 0.35
–20°C + 2 4 6.5 8.5
4°C + 2.5 5.5 8 10.5
20°C 1 3 6 9 12
40°C 1 3 6.5 9.5 –
55°C 1 3.5 7 10 –
simalube 250
Dispensing
30 90 180 270 360
time (days)
ml/day 8.33 2.78 1.39 0.93 0.69
–20°C ++ 2 4.5 7.5 9.5
4°C ++ 2.5 5.5 8 10.5
20°C 1 3 6 9 12
40°C 1 3 6 9 –
55°C 1 3.5 6.5 9.5 –
++ use 2-fold adapter
– use smaller dispenser with shorter dispensing time
16
The values relate to laboratory conditions, SL01 with no counterpressure. At low tempe
ratures in particular, the values may vary between one grease type and another. The
dispensers must be replaced once the dispensing time set has expired, even if they are
not completely empty.
The grease quantity dispensed – counter pressure/resistance from

per day is influenced by: the grease lines
– ambient temperature
– viscosity of the grease
Start-up time:
The lubricator requires a certain start-up time until the lubricant is first dispensed.
The start-up time varies in line with the volume dispensed, dispenser size and operating
temperature selected. At 20°C ambient temperature and a dispensing time setting of
12 months, the dispenser outputs the lubricant within one week. The start-up time dou-
bles at low temperatures (–20°C) or with small dispensers (30 ml).
You can reduce the start-up time in such a case by setting a dispensing time on the
lubricator of one month for one to two days and then changing to the desired dispens
ing time.
Calculation pro:
An online calculation program is available at www.simatec.com (simalube/calculation
pro). This tool calculates the right setting for the simalube lubricator if you enter the
precise operating parameters.
Notes:
In order for the unit to function reliably, it is important to have clear, filled grease lines.
It must be ensured that the grease lines are not blocked. Consequently, the grease lines
should always be cleared with a grease gun before starting.
The simalube can be re-adjusted or switched off during operation.
The values on the gas generator relate to laboratory conditions (see page 15). Depend
ing on the temperature and setting, it may take several hours (or several days in the
case of long-term settings) until the lubricant is first dispensed.
The user must check the operation of the simalube regularly.
Grease lines should be no longer than 0.5 m. Recommended bore diameter: 6 – 8 mm
Resistance in grease lines has to be minimized, narrow passages and right angles
should be avoided.
Use a mounting support in the event of strong vibrations or high accelerations (for
accessories, see page 21).
The simalube may only be used to supply a single grease point. No branches may be
made.
Once the lubricator is installed and activated, it must not be removed and mounted
onto another lubrication point.
17
EN
Filling and Refilling (for small quantities)
Filling with grease

1a. 2a.
1a. Push piston all the way forward by blowing
gently with compressed air or with the aid
of a plastic rod (7 mm diameter), towards
the bottom or opening.
2a. Screw on refill nipple (article no. 3012)
and connect grease gun, or screw
connector nipple (3013 or 3014) onto
3a. 4. grease gun. Keep the dispenser pressed
to the adapter during the filling process
so that you do not have to screw on the
refill nipple again. Press grease into the
dispenser. Avoid air bubbles when filling
the unit. Continue the filling process until
the piston has been pushed all the way
5. 6. back. Do not overfill! Caution: Lever
presses can create pressure of up to
80 bar, which is enough to destroy
the dispenser.
3a. Use closing nipple (green) if the dispenser
is to be stored.
4. Position gas generator (make sure the O-ring is positioned correctly)

and attach firmly with a 1.5 – 2.0 Nm torque key.
5. Clip in cover disk.
6. Note grease type and filling date on the label.
Filling with oil

1b. 2b.
1b. Push the piston all the way back
(towards the gas generator).
2b. Pour in oil through the opening
at the bottom.
3b. Position non-return valve
(yellow, article no. 5060).
3b. 4–6 Continue as above.
Refilling with grease or oil

1. Remove cover disk.
2. Unscrew gas generator (SW 21) and
recycle with other batteries. Never remove
near an open flame! Then continue as
above for filling with grease or oil.
Note
1.
To ensure that the simalube lubricator operates
reliably, only greases that have been tested
and approved for use with the simalube
should be used. In particular, it is important to
ensure the good stability of the grease against
bleeding of the base oil and a low consistency
2. class (max. NLGI 2). No guarantee claims will
be accepted when dispensers are filled by the
user or not explicitly approved lubricants are
used. If in doubt, please contact our Technical
Department or your local distributor.
18
Lubricants
The standard lubricant range suitable for simalube includes modern high quality lubri-
cants tested and modified for the special requirements of grease and oil dispensers.
Datasheets are available online for all lubricants (www.simatec.com). Please refer to these
datasheets for the instructions/safety regulations of the grease/oil manufacturers.
No. Application Temperature range

(in the area of lubrication)
SL01 Multipurpose grease –30 / +120°C

SL02 Multipurpose grease with MoS2 –25 / +130°C
SL06 Fluid grease –20 / +120°C
SL09 Biodegradable grease –20 / +80 / 100°C
SL10 Food industry grease (NSF H1) –30 / +140°C
SL14 Chain oil –10 / +90°C
SL15 High temperature chain oil 0 / +250°C
SL18 Food industry oil (NSF H1) –15 / +150°C
SL24 Grease for a wide temperature range –30 / +150°C
simalube can also be delivered filled with other lubricants or as an empty unit.
Ask for advice. The operation of simalube with oils of different viscosities is also possible.
Troubleshooting
Fault Possible cause Remedy

– no grease output – seal not cut off/closing nipple – open/remove
still in place
– not switched on – switch on
– grease lines blocked – clear lines with grease gun
– gas generator loose – tighten with 2 Nm
– insufficient output – dispensing time too long – set to lower number
– ambient temperature too low – c orrect setting according to
table, page 16
– grease lines blocked/too – clean, allow for free flow of
narrow grease
– short-term extreme low – none
temperatures, piston moves
backwards
– high counter pressure – clear grease lines, check
installation
– excessive output – dispensing time too short – set to higher number
For other malfunctions contact simatec engineering or your local distributor.

The information provided reflects the manufacturer’s current level of development and
understanding. Subject to change. The products are subject to strict manufacturing con-
trols and meet internal works specifications. As a result of the wide range of conditions
and areas of application possible in each case, no guarantee can be provided for effec-
tiveness or success in each individual instance. No responsibility is accepted for damage
or malfunctions caused by incorrect use or improper work on or with the lubricator.
19
EN
Accessories
Note: Use only original accessories. If you have technically demanding or unusual
applications, please contact our Technical Department or your local distributor.
D R 1/4
Nr. 1001
D R 1/4
Nr. 1002
90° connection with thread (only for oil)

70 mm incl. 2 nuts
L 70 [ mm ]
Nr. 1005
Connecting nipple
D R 3/8 R 1/2
Nr. 1010 1011
Reducing nipple
D R 1/8 R 1/4 M6 M8 M8x1 M10 M10x1 M12 M12x1.5 UNF 1/4
Nr. 1020 1021 1022 1023 1024 1025 1026 1027 1028 1121
Extension
L 10 35 50 [ mm ]
Nr. 1021 1040 1041
Screwed connection with hole

25 mm incl. 1 nut
L 25 60 [ mm ]
Nr. 1045 1046
Y-manifold
Contains reduction 1021
D R 1/4
Nr. 1050
Quick connection
For hose ø 8 mm
D R 1/4
Nr. 1060
Quick connection
For hose ø 8 mm
D R 1/8 R 1/4 R 3/8
Nr. 1070 1071 1072
Hose
Maximum length to greasing point: 0.5 m /available by the metre
L per meter
Nr. 2000/...m
20
Clamp for simalube/round brush
Plastic
D 50 28 [ mm ]
Nr. 2010 2013
Adapter for Perma clamp

Plastic
D 50 [ mm ]
Nr. 2012
Distance holder to clamp for round brush (2013)
H 15 [ mm ]
Nr. 2014
Non-return valve
D R 1/8 R 1/4
Nr. 2020 2021
Round brush
Plastic bristles
DxL ø 25x45 [ mm ]
Nr. 2034
Brush
Horse bristles
L 40 70 100 25 [ mm ]
Nr. 2035 2036 2037 2038
Brush, lateral connection

Horse bristles
L 40 70 100 [ mm ]
Nr. 2035-S 2036-S 2037-S
Elevator brush
High 32 mm
Nr. 2039
Elevator brush small

High 32 mm
Nr. 2042
113 Round brush

Horse bristles
DxL ø 25x15 [ mm ]
84
Nr. 2041
Mounting support for all simalube sizes
Nr. 2080
Protective cover to mounting support 2080 (steel)

(for simalube 125 ml or smaller)
Nr. 2081
21
EN
Bracket to mounting support
1-fold length 75 mm 3-fold length 240 mm 5-fold length 390 mm
Nr. 2082 2083 2084
Bracket, universally adjustable
Nr. 2800
Connector nipple
For cleaning and filling of grease lines
D R 1/4
Nr. 3011
Refill nipple
For refilling of simalube
D R 1/4
Nr. 3012
Connecting nipple
To grease gun filler for filling simalube
D R 1/4 R 3/8
Nr. 3013 3014
4-fold adapter
D R 1/2 R 1/4
Nr. 4100 4101
2-fold adapter
D R 1/2 R 1/4
Nr. 4102 4103
Gas generator
For refilling
30 ml 60 ml 125 ml 250 ml
Nr. 5004 5006 5008 5010
Closing nipple
Plastic
Nr. 5050
Non-return valve plug

Plastic
Nr. 5060
Gasket ring
Nr. 5080
Grease cartridge
400 ml
Grease SL01 SL02 SL04 SL06 SL09 SL10 SL24 SL25
Nr. KA01 KA02 KA04 KA06 KA09 KA10 KA24 KA25
22
Oil bottle, 0.5 l
Chain oil OF14

High temperaure chain oil OF15
Food industry oil OF18
Recycling Instructions
1) Unscrew gas generator and dispose of
complete unit for battery recycling
(see above). Note: Do not detach lubrica-
tor near an open flame.
2) Dispose of empty housing for PET recyc
ling. If the lubricator still contains lubricant
after use, please dispose of it in accord
ance with local regulations.
simalube has been safety inspected and approved by the following institutions:
• Physikalisch Technische Bundesanstalt, Brunswick, Germany, Nr. 3.42-16990/94
• FM Approvals, USA, Project Identification Number: 3013825
• Technischer Überwachungsverein (TÜV) Rheinland, Cologne, Germany, 12.05.95
• DMT Gesellschaft für Forschung und Prüfung GmbH, Germany Nr. 16420/344/96
• LOBA NRW, Dortmund, Germany, Nr. 12.22.63-4-2
• INERIS, France, Nr. 96.Y.300 X, CROSS ia I
• EECS / BASEEFA, United Kingdom, No. 95 (A) 0692, 1997-04-10
• TÜV Product Service GmbH, Germany, Nr. Z1 08 02 29499 015
• TÜV Product Service GmbH, Germany, Nr. EX3 10 04 29499 016
• KEMA Quality B.V., Netherland Nr. KEMA 09ATEX0098
II 1 G Ex ia IIC T6
• II 1 D Ex iaD 20 T 80°C
I M1 Ex ia I
EU Declaration of Conformity
simatec ag
Stadthof 2 in CH-3380 Wangen a. Aare
declares that the
single point lubricators
simalube & simalube multipoint
are designed and manufactured in
accordance with
Directive 94/9/EC of the European
Parliament and the Council for equipment
and protective systems intended for use in
potentially explosive atmospheres.
The following standards have been applied:
EN 60079-0:2006
EN 60079-11:2007
EN 60079-26:2004
EN 61241-0:2006
EN 61241-11:2006
EN 50303:2000
Manufactured by:
Notified Body:
TÜV Product Service GmbH simatec ag
D-80339 Munich Stadthof 2
KEMA Quality B.V., NL-6812 AR Arnhem CH-3380 Wangen a. Aare
Certificate No. www.simalube.com
KEMA 09ATEX0098
Wangen a. Aare, 20.09.10
Mischa Wyssmann, Managing Director CEO
23
Section 5
Attachments
Document id rev
~.=:.AURA I FC1422 4
.-~-=:.MARINE Manufacturing no: 14224
Page :1/2
FACTORY C E R T IF II C A T E
This is to certify that AURAMARINE LTO, FINLAND
did inspection and testing of:
Unit type: AFF-M-10-MDO/HFO

Orderer: Rolls-Royce Power Systems - Bergen Engines AS
Order no: 262559
Intended Service
Ship
Classification
DRAWINGS:
Flow chart DRG No: P13016
General arrangement DRG No: 310011
Electric diagrams DRG No: 410298
PROOF PRESSURE TEST: DPbar WP/bar TP/bar MEDIA
Suction side 16 8 24 oil
Pressure side 16 8 24 oil
The unit is surveyed in finished condition and tested min

to 1,5 * DP and found tight and in satisfactory condition.
GENERAL INSPECT~ON: The installation of mechanical/electrical

equipment was considered satisfactory.
Place: Littoinen Date: 16.3.2017

p
Surveyor: ~~
Ake Puisto
Distribution Made:RTu
Original: Project file Appr:HSa
Copy:Technical manual Date:26.1 0.2000
AURAMARINE LTD.
Kukkosenapaja 1 P.O.BOX 849 Fax +358 ( 0 )204 86 5031 Trade reg. no: 402 .012
FIN-20660 LITTOINEN FIN-201 01TURKU ALV rek I VAT reg: F106846963
FINLAND FINLAND
Document id rev
11:§..=:. AURA I FC14224
.-.~-=.MARINE Manufacturing no: 14224
Page :2/2
FACTORY TEST CERTIFICATE FOR MODULE
FUNCTIONING TEST RESULTS AND SET POINTS
Oil quality Neste LO
Proof pressure test:

Suction side 24 bar
Pressure side 24 bar
DENOMINATION FUNCTIO- SETTING SET POINT

NING RANGE
1. INSPECTION OF COMPONENT ok
SUPPORT
2. FINE FIL TRS
Diff. Pressure for alarm ok 0-2,0 bar 1,0 bar
Safety valves ok 12 bar
Distribution
Original: Project file
Copy: Technical manual
Date: 27.10.2000
Made: RTu
Appr: HSa
AURAMARINE LTO.
Kukkosenapaja 1 P.O.BOX 849 Fax +358 ( 0 )204 86 5031 Trade reg. no: 402.012
FIN-20660 LITTOINEN FIN-201 01 TURKU ALV rek I VAT reg : F106846963
FINLAND FINLAND
F 170/83 I
I – Installation documentation D – Operation/maintenance documentation S – Service (Internal use only)
Component: Mechanical Limit Switch

Type: 5310
BEAS part no.: 709241
Date/Sign/rev.: 19.10.2016/TKv/A
Bergen Engines AS, A Rolls-Royce Power Systems Company

P.O.Box. 329 Sentrum, N-5804 Bergen, Norway, Switchboard +47 55 53 60 00, E-mail: engines.bergen@rolls-royce.com
[ BLANK ]
[ BLANK ]
F180/55 I/D
I – Installation documentation D – Operation/maintenance documentation S – Service (Internal use only)
Component:
PRESSURE CONTROL VALVE
Size Range BEAS Part no

DN25 0,5 - 2,5 bar B00712013
DN40 0,5 - 2,5 bar B00809801
DN40 4 - 12 bar B01003108
DN50 2 - 5 bar B00809799
DN50 4 - 12 bar B00809800
DN50 0,5 - 2,5 bar B01002782
Date/Sign/rev.: 17.10.16/OH/Rev.B
Bergen Engines AS, A Rolls-Royce Power Systems Company

P.O.Box. 329 Sentrum, N-5804 Bergen, Norway, Switchboard +47 55 53 60 00, E-mail: engines.bergen@rolls-royce.com
[ BLANK ]
Construction
Ød 1
T c
3
1 Housing
b 2 Sliding piston
3 Compression spring
4 Set screw
5 5 Bleeding screw
6 Protective cap
4
Valve Construction
The sIiding piston 2 is pressed against the annuIated

area a by the compression spring 3. Thus the pump
connection P is separated from the reservoir connection
T by sealing the diameter d. As soon as the operating
pressure p is achieved, adjusted by the set screw 4, the
sIiding piston 2 releases the oil flow to the reservoir. The
spring chamber b is pressure compensated by the bore c.
When starting-up the valve the spring chamber b must be
bleeded by the bleeding screw 5, (hex. socket width: 4).
The pressure relief valves are available in four different
pressure setting ranges because, due to their springrates,
each of the compression springs can only cover a limited
pressure setting range.
Note
When using strongly aerated media, the valve should
preferably be mounted vertical with the setscrew facing
down.
SOURCE: KRACHT data sheet: SPV, SPVF directly-operated/ GB/08.14

Characteristics
Pipe connection SAE-flange (3000 PSI)

Delivered with counter flanges
Housing material EN-GJL-300 : DN 25 & DN 40
(EN-GJS-400-15: DN50)
Hydraulic Characteristics
Nominal size 25 40 50
Max. flow capacity l/min 90 450 550
Max. working pressure bar 120 120 100
Fluid temperature range FKM ϑm = -- 15 °C... 150 °C (Design C + K)
Ambient temperature ϑu = -- 20 °C... 60 °C
Viscosity range νmin mm2/s 1.2

νmax mm2/s 1000 (standard)

Characteristic Curves pE – Q Viscosity = 34 mm2/s
= possible setting range of the

respective pressure stage
20 30
16
20
12 20
DN 25 12
pE in bar
pE in bar
8
10
4
02 05
0 20 40 60 80 100 0 20 40 60 80 100
20 30
16
20
12 20
DN 40
pE in bar
12
pE in bar
8
10
4
02 05
0 100 200 300 400 500 0 100 200 300 400 500
20 30
16
20
12
20
DN 50
pE in bar
pE in bar
12
8
10
4
02 05
0 100 200 300 400 500 600 0 100 200 300 400 500 600
SOURCE: KRACHT data sheet: SPV,SPVFdirectly-operated/

GB/08.14
Dimensions (in mm)
Nom. SAE Weight

size flange A B C D E F G H K1 L1 L2 SW1 SW2 kg
25 1˝ 52.4 26.2 M 10 59 70 24 20 50 160 210 217 17 5 3.0
40 1 1⁄ 2 ˝ 69.9 35.7 M 12 83 94 38 20 65 170 235 237 17 5 6.0
50 * 2˝ 77.8 42.9 M 12 97 102 50.5 20 75 192 267 284 287 75 19 6 8.2
* Housing material spheroidal cast iron

D
Component: HFO Feeder Module
Type : Aura Marine
Engines : 16419-27 & 16430-36
BERGEN ENGINES AS
[ BLANK ]
Fuel supply systems
Release Date: 19.12.2017
Language version: EN
Installation, Operating and Maintenance

Manual
Unit type: Unit, feeder

Technical name: AMF-L-50-HFO
Serial Number: 14502
Customer reference: Bangladesh Project
Get an electronic copy here:

AuraMarineManuals
http://bit.ly/AuraMarineManuals
Contact us
Spare parts:
email: spares@auramarine.com
Tel: +358 20 486 6003
Service and maintenance:
email: service@auramarine.com
Tel: +358 20 486 6003
Fuel system sales:
email: sales@auramarine.com
Tel. +358 20 486 5030
www.auramarine.com
Auramarine LTD, Finland

Tel. + 358 20 486 5030
Street address: Postal address:

Keskiläntie 1 P.O. BOX 849
FI-20660 Littoinen FI-20101 Turku
Finland Finland
Auramarine Asia LTD, China

Tel. +86 21 67104305
13 Long Yang Industrial Park

1515 Yuandong Road
Fengpu Industrial Development Zone
Fengxian 201401
Shanghai, P.R.C.
Auramarine Hong Kong LTD

Unit 702, 7/F Bangkok Bank Bldg No. 18
Bonham Strand West
Hong Kong
Table of Contents

General arrangement P14628, - 10

PI Diagram 310058, - 13

Electric drawing 410377, D 17
4 Auramarine customized spare part selection

Auramarine customized spare part selection Spare 39
6 Attachments
14502 Factory certificate - 159
Section 1
Technical Specification 1(5)

11.9.2017 D11343

HFO FEEDER UNIT
TECHNICAL SPECIFICATION

Type: AMF‐L‐50‐HFO
Manufacturer: Auramarine Ltd.

Customer: Bergen Engines India Private Limited.
Project: Bangladesh project

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11343

1. Design Basis

Engine type: 7 x B32:40V16AH
Total power max.: 7 x 7015 kW = 49 105 kW
Fuel consumption max.: 7 x 1.6 m3/h = 11.2 m3/h
HFO viscosity max.: 180 cSt / 50°C
HFO day tank temp.: 65°C
Main voltage: 3x415 V / 50 Hz + neutral
Pressurized air supply: 5‐10 bar, dry, oil free
Trace heating: Steam
Required HFO inlet pressure: +0.2 bar (at unit inlet flange)
Design / test pressure: 10 / 15 bar

2. Technical data

HFO feeder pump capacity: 17.8 m³/h, 0/5 bar, 86 cSt (1285 r/min@44 Hz)
Electric motor: IEC160, 11 kW, 1460 r/min (nominal), IE2, IP55, F, B
External cooling fan included

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11343

3. Main Components

Pos. Denomination

B001, B002. Suction strainer
‐ Filtration 400 µm

D001, D002. HFO Feeder pump
‐ One is stand‐by pump while the others are working

V017. Emergency shut off valve
‐ Actuator operated and spring returned (N.C.) ball valve
‐ Valve opens by air when voltage to pilot solenoid valve is
switched on and closes by spring force when voltage is switched off
‐ Equipped with limit switches
‐ Closing the valve stops the pumps

B030. Instrument air filter/regulator
‐ Setting range 0.5 – 10 bar, set point 6 bar (max. 8 bar)
‐ 5 µ filter with manual, self‐relieving drain

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11343

4. Control Automation and Starters

Equipment

Control cabinet
‐ Feeder pump VFCs with stand‐by automatic.
‐ All alarms via profibus interface
‐ On / Off / Remote switches for each emergency shut off valve via profibus
‐ On / Off / Standby / Remote switches for each electric motor of feeder pump via profibus
‐ Control signals to feeder unit
- Opening and closing of each emergency shut off valve
- Starting and stopping of pumps
- Pump preset speed control (1 = 100% speed, 2 = 50% speed, 3 = 30% speed)
‐ Control signals from feeder unit
- Stand‐by pump started
- Analog signal for FO outlet pressure; 0‐10 bar = 4‐ 20 mA
‐ Emergency stop buttons for each pump

‐ Lights at control cabinet
‐ Motor circuit breaker tripped
‐ Pump running
‐ Emergency shut off valve open/ close

5. Instruments

Ind. Denomination
TI Thermometers, liquid pillar type (scale in °C)
PI Manometers, Ø 63 mm, glycerine filled (scale in bar)
PS Pressure switch for local stand‐by automatic
PT Pressure transmitter for FO outlet pressure
GS Limit switches for emergency shut off valve.
Note! These switches interlocked with feeder pumps

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11343


‐ Equipped with a bottom for leakage oil
‐ Grease gun
‐ Painting system 12944‐5:2007 A2.06 (EP 120/2 FeSa 2½)
‐ Color RAL 5019

Components ‐ Original painting color from manufacturer, i.e. no additional
painting by Auramarine

Piping ‐ Seamless carbon steel St 37.4 DIN 2391
‐ Painting system 12944‐5:2007 A2.06 (EP 120/2)
‐ Color RAL 5019
‐ Steam trace heating for HFO pipes
‐ HFO pipes Insulated with mineral wool covered by metal sheet

External connections ‐ EN1092‐1, counter flanges, gaskets, bolts and nuts are included.
‐ Drain connections in the frame are of size R2” (internal thread
connection) as per EN ISO 228‐1. No flanges or pipe adapters at
these connections.

Instrument pipes ‐ Hydraulic pipe St 35.4 DIN 2445.2.2
‐ Copper pipe for instrument air

Valves ‐ Ball, Gate and Globe valves
‐ Nominal pressure class min. 10 bar

7. Revision list

‐
AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku

1 2 3 4 5 6 7 8
FC
2050
A A
R 1800
CONTROL PANEL
B B
~80
640 640
C 45 45 C
0 0 0
0
R 50
K,L ~170
A 350
C 500
0
C 500
B 650
1000
0
A,K 100
B,L 2800
2900
40
D D
400 18
400
200
250
S=10
E X DETAIL X
600
SCALE 1 : 10
Units Sheet Description

RECOMMENDED SERVICE SPACE mm kg 1 / 1 GENERAL ARRANGEMENT
General tolerances: SFS-EN ISO 13920B AMF-L-50~120-HFO
F SSo 25.08.2017
Checked Date
-
Rev Change
25.8.2017
Date
SSo
Designed www.auramarine.com
Approved
JSa
KSi
Date
25.08.2017
25.08.2017
P14628 -
1 2 3 4
Section 2
Part list
Structure 0014502 Desc 1 Unit, feeder
Modified 2017-12-19 Desc 2 AMF-L-50-HFO
S005969 0 PI structure AMF-L-50-HFO 1 1
M002558 0 B001 Strainer 821 A 150 C 46, 400um, DN150 1 1
M003765 0 B030 Filter regulator, air MC104-D10, 5um, Rp1/4" 1 1
M021598 0 B030A Indicator, pressure P1415,0-10,bar,d40,R1/8",B5 1 1
M000056 0 D001 Pump, screw ACG070K7_NTBP, DN100 1 1
M000072 0 D001A Connecting frame ACG060-070,IEC160, F300, Al 1 1
M000524 0 D001B Coupling A38A+B, 64 Sh D, d28/d42 1 1
M003401 0 M001/M001A El. motor, induction+heat+fan+ptc HMC2 160M-4,11kW,400D,1500r,IE2 1 1
M021626 0 P001 Indicator, pressure 213,-1-3,bar,d63,R1/4",S1 1 1
M021751 0 P004 Switch, Pressure MBC5100,1-10,bar,Rp1/4",CO,250V 1 1
CM001215 0 T001 Indicator, temperature JWV-C,0-160,C,L150,R1/2",S1,gold 1 1
M021511 0 V002 Valve, gate 125, DN150, PN10 1 1
M021039 0 V008 Valve, globe 215A31,DN100,non-ret,GG,str 1 1
S004468 0 V017/E017 Valve, 2/2, actu, switch, solen 720185,SR200,XSWM,NA34,DN150,110V1 1
Section 3
Part list
S005970 3 El. structure AMF-L-50-HFO 1 1
S006142 3 Control panel AMF-L-50-HFO 1 1
M020537 0 Enclosure AE 1100.500, 1000x760x210, ST 1 1
M020603 0 Rail DIN, 35x7.5mm, 2933/2 SL 2.9 1
M002196 0 Cable conduit GF-DIN-SH-A7/5, 50x25 1 1
M002203 0 Cable conduit GF-DIN-SH-A7/5, 75x37.5 .95 1
M002204 0 Cable conduit GF-DIN-SH-A7/5, 75x50 2.5 1
M002205 0 Cable conduit GF-DIN-SH-A7/5, 75x75 .95 1
M003834 0 Cable hose SPZ-20, HF .75 1
M021766 0 Busbar PSK 152, L=1000 mm .5 1
M020692 0 A0Q1 Switch, main OT125F3, 125A, 50kA, 0.75kV 1 1
M020706 0 A0Q1 Handle, padlockable OHYS2AJ, OT16-125, rd/ye 1 1
M020699 0 A0Q1 Accessories Shaft, OXS6x160, OT16-125 1 1
M020502 0 N Terminal block, Screw KE61.2, 50mm2, blue,145A,single 1 1
M020503 0 PE Terminal block, Screw KE61.3, 50mm2,Ye/Gr,145A,single 1 1
M021021 0 A0S1 Button, E-stop MPMT3-10R, 40mm,Twist release 1 1
M020860 0 A0S1 Sign, emergency stop SK615546-2, 70mm, aluminum 1 1
M021018 0 A0S1 Contact holder MCBH-00, 3 contacts 1 1
M021017 0 A0S1 Auxiliary contact MCB-01, 1NC 1 1
M020414 0 A0Q3 Manual motor starter MS132-1,6, 1-1.6A, 690V 1 1
M021139 0 A0T1 Transformer PE400, 380-440/110-230V,1ph 1 1
M020382 0 A0F1,A0F2,A0F3 Circuit breaker, miniature S202-C4, 4A, 400V 1 3
M001997 0 A0A1 Alarm panel LLC-10, DI10DO2R, 24V 1 1
M004147 0 A0K4,A0K5 Relay, miniature 55.34.8.110.0040, 110V, 4CO 1 2
M004101 0 A0K4,A0K5 Relay interface module 94.54.SPA, screwless,4CO 1 2
M004102 0 A0K4,A0K5 Accessories 094.91,3, relay clip, plastic,4CO 1 2
M021889 0 A0S9 Switch, rotary cam OC25G06PNBN00NU3, 1-0-2, 25A, 690V 1 1
M003888 0 A0H5,A0H6 Indicating light LED CL2-513C, 110V, clear 1 2
M004141 0 A0A2 CPU 750-343, Profibus DP coupler, 24VDC 1 1
M004150 0 A0A2 Cable, fieldbus DEL-37,Serial extension cable, 2m 1 1
Part list
M004143 0 A0A2.0 Power supply module 750-602, 24VDC 1 1
M002560 0 A0A2.1 DI Module 750-1405, 16 DI, 24VDC 1 1
M004144 0 A0A2.2 DO Module 750-1504, 16 DO, 24VDC 1 1
M004145 0 A0A2.5 AI Module 750-455, 4 AI, 24VDC 1 1
M004146 0 A0A2.6 AO Module 750-555, 4 AO, 24VDC 1 1
M002562 0 A0A2.7 Accessories 750-600, end module 1 1
M020346 0 A0K10-A0K20 Relay, miniature 46.52.9.024.0074, 24DC, 2CO 1 10
M020343 0 A0K10-A0K20 Relay interface module 97.52SPA, screwless 1 10
M004149 0 A0K10-A0K20 Accessories Diode, 99.02.3.000.00, 6-220DC 1 10
M021897 0 A1S1,A2S1 Switch, rotary cam OC25G06PNBN00S031F, 1-0-2-3, 25A, 1 2
690V
M002182 0 A1K1 Relay, time CT-MBS.22P, 24-240V, 2CO 1 1
M020330 0 A1K2,A2K2 Relay, control NF22E-13, 100-250V, 2NO 2NC 1 2
M020335 0 A1K2,A2K2 Auxiliary contact CA4-01-T, 1NC 1 2
M020328 0 A1K4,A2K4 Relay, control NF40E-13, 100-250V, 4NO 1 2
M020321 0 A1Q2,A2Q2 Contactor AF09-30-10-13, 100-250V 1 2
M002263 0 A1Q1,A2Q1 Accessories Fuse holder, 22x58mm, 3 poles 1 2
M002258 0 A1Q1,A2Q1 Fuse Ceramic tube, 22x58mm, 32A, 690V 1 6
M020448 0 A0Q3,A1Q1.1,A2Q1.1 Accessories Power infeed block, S1-M1-25 1 3
M020412 0 A1Q1.1,A2Q1.1 Manual motor starter MS132-0.63, 0.4-0.63A, 690V 1 2
M020427 0 A1Q1.1,A2Q1.1 Auxiliary contact HKF1-11, 1xNO 1xNC 1 2
M020428 0 A1Q1.1,A2Q1.1 Auxiliary contact HK1-20, 2xNO 1 2
M020431 0 A1Q1.1,A2Q1.1 Auxiliary contact SK1-11, 1xNO 1xNC 1 2
Part list
M020508 0 A1X1,A2X1 U,V,W Terminal block, Screw M10/10, 10mm2,grey,57A,single 1 6
M020498 0 End section FEM6, grey, screw, single 1 2
M020552 0 Accessories Wiring plan pocket, SZ 2515.000, A5 1 1
S006143 0 Unit components AMF-L-50-HFO 1 1
M004140 0 FC001, FC002 Frequency converter FC-202,18.5kW,380-480V,37.5A,DIO3,S 1 2
M020878 0 FC001, FC002 Cable gland M20, polyamide, inner D 7.0-13.0mm 1 6
M020962 0 FC001, FC002 Cable gland M25, brass, inn. D 11-17mm, EMC 1 2
M020197 0 Cable, power LKM-HF, 4G10mm2, 0.6/1kV 14 1
M020222 0 Cable, power LKSM-HF, 4G10mm2, 0.6/1kV 14 1
M020246 0 Cable, Control RFE-HF,4x2x0.5mm2, 0.15/0.25kV 14 1
S006144 0 Nameplate set AMF-L-50-HFO 1 1
Section 4
Auramarine customized spare part
selection

selection
Proper function of the fuel supply system is crucial for the ship’s operational efficiency and
for its combustion system health. We recommend maintaining at least the below listed
selected spares inventory on board to avoid fuel supply disturbances, costly fuel system
downtime or ad hoc deliveries. The below items have been selected for this particular unit
and their selection method is based on Auramarine’s experience of over 14,000 installed fuel
supply units. Planning ahead will also make your spares administration easier.
In case of component failure, please see the exact code of the component in question in the
specific component manual in Section 'Instruction manual'.
Please contact spares@auramarine.com for further information and delivery details.
Part code Position Ordering code Part Description Qty Maintenance rate
M000056 D001, D002 no Pump, screw
AFS000434 G053 Minor kit 1 1 year
Section 5
Instruction Manual
Contents
1.1 Storage.................................................................................................................................................2
1.2 Handling ...............................................................................................................................................2
1.3 Installation ...........................................................................................................................................3
4 START-UP .....................................................................................................................................................5
4.1 Initial start-up ......................................................................................................................................5
4.2 Normal start-up ...................................................................................................................................6
5 SHUTDOWN .................................................................................................................................................6
7 MAINTENANCE ............................................................................................................................................8
7.3 Lubrication recommendations ............................................................................................................8
8 HOW TO ORDER SPARE PARTS ..................................................................................................................10
9 COMPONENT MANUALS............................................................................................................................11
Components ..................................................................................................................................................11

1.1 Storage
storage time please contact Auramarine ltd.
1.2 Handling

1.3 Installation
local law.
heated.
1. Read the instruction manual for the unit.
controlled manner.

5. Do not heat DFO.
9. If the unit is suitable also for low level sulphur DFO -oils (defined in ISO8217:2005). According to
these regulations, DFO -oil viscosity should be in the range of 1,4-6,0 cSt at 40 °C. However note
temperature.
4 START-UP
4.1 Initial start-up
IMPORTANT POINTS TO REMEMBER
Pumps with mechanical shaft seal

The mechanical seals leak to operate properly. The mechanical seals consist of two highly polished,
very flat surfaces. The surfaces may not run dry, as they will otherwise fail very quickly. Therefore,
they are designed to allow a very thin film of liquid to exist between them. Some of the liquid will
leak out of the seal. When pumping HFO, the leaking HFO will visibly accumulate on the pump. This is
normal and does not indicate a manufacturing defect. It is not a guarantee issue.
A leakage rate of 10 drops of oil per hour or less is considered normal. Please note that seals will
sometimes require a “run in” period, with leakage gradually diminishing over several hours of
operation after the initial start-up. Start-ups can be particularly hard on mechanical seals. Never start
a pump without priming. Always make sure that the Seal Guard lubricator is activated, if the pump is
equipped with one.
Automatic filter
During the initial start-up of the fuel system, the automatic filter may get clogged. This does not
indicate a defect in the automatic filter. Normally during the first start-up of a new built vessels fuel
oil system the tanks and pipes of the vessel contain some debris from welding etc. The automatic
filter will catch the dirt, but there may be so much of it that the filter cannot clean itself anymore.
The clogging of the filter will also depend on the quality of the oil and amount of dirt deposited inside
the piping. Poor quality oil containing particles, tar, paraffin and other impurities, tends to clog the
filter elements. As a result, the automatic filter will need to be stripped and the filter elements
cleaned, in some cases repeatedly. When the dirt has been flushed from the system, the automatic
filter will operate normally. This is all normal and not a guarantee issue.
Viscometer
During the initial start-up of the fuel oil unit, the viscometer may indicate an unexpected viscosity.
Should this happen, the value will tend to be too high. This is typically caused by a dirty sensor, i.e.
the pendulum. Poor quality oil will worsen this, thus requiring a cleaning of the pendulum. Flush the
pendulum with diesel oil or a mild detergent. Be extremely careful when handling the pendulum, as
it is a sophisticated instrument.
4.2 Normal start-up

Before start-up, activate the gas generator of the pump shaft seal lubrication device, if
the pump is equipped with one.


3. Check that electric heaters and steam/thermal oil control valve are
interlocked with booster pumps viscometer and HFO/ DFO three way valve.
4. Ensure DFO flow to feeder unit. Suction pressure gauge of the unit should indicate pressure
(> 0 bar). Open the equipment valves of feeder unit and close by-pass valves.
5. Ensure that all miniature circuit breakers, motor circuit breakers and molded case circuit
breakers are switched on in local control panel(s) of the fuel oil unit(s).
7. After resetting the alarm panel, the following alarms should be on. Low outlet pressure (if
installed).
8. Start feeder pump and check rotation direction.
9. To fill fuel oil unit and pipelines to and from engine(s) with DFO will take from 2-10 minutes.
10. Pressure in fuel oil unit and engine(s) should rise to range from three to five bar. If not, check
positions of valves.
11. Change running feeder pump. Check rotation direction. Use always one pump as running and
one pump as stand-by. Change running pump periodically in order to run pumps equally.
12. If viscometer is installed start the viscometer. Viscosity of DFO is in range from approximately
3-8 cSt.
13. If auto filter is installed start auto filter. If bypass is installed check that automatic filter has
been chosen.
14. Ensure that needed trace heating is on.
15. After engine has run from 1,5 to 2 hours with HFO, check all pipe connections, and in case of
leakage, tighten the pipe connection.
5 SHUTDOWN
1. Circulate the fuel oil through heater at least ten minutes after turning heating off in order to
cool the heater down.
2. Turn the trace heating on if there is HFO in pipe system of the fuel oil unit.

Problem Check points/actions
Stand-by pump Open suction valves if they are closed.
starts. (low Suction pressure should be above -0,5 bar, if below clean the suction strainers.
pressure) Check if pressure relief valve is operational and the set point of pressure relief
valve should be 4-5 bar.
The by-pass valve of the pressure control valve should be closed.
Check rotation direction of pumps.
Check pressure control valve setting at engine(s) equipment.
Ensure that fuel oil from engine(s) flows to booster unit’s mixing tank.
Check the motor circuit breaker.
The shut-off valve of the pressure switch should be open.
Check the operation of the automatic filter and by-pass filter.
Check the operation of the pressure switch and the alarm panel
Check the settings and cleanliness of the internal over flow valves of the pumps.
Check that the delay of the stand-by pump start is sufficient.
Pressure too high at Check settings of valves
pump outlet. Run only one feeder pump simultaneously.
Set point of pressure control valve equipment may be too high.
Viscometer is not Check positions of control switches at local control panel.
working. Viscometer should be on and viscosity control should be selected.
Check wiring of the controller and viscosity measuring loop.
By-pass valve of the viscometer should be closed.
Viscometer sensor might be dirty.
Flow meter is not Check the cleanness of the flow meter filter and rotor.
working. The valves of the flow meter may be closed.
The by-pass valve of the flow meter is dirty.
Check wiring and settings if there are out going signals.
Safety valve is open. Working pressure is above the set points of the safety valves.
Safety valve is damaged.
7 MAINTENANCE
Although all Auramarine fuel feeder unit contracts offer a guarantee of quality, normal wear and tear

7.3 Lubrication recommendations

7.3.1 ACG series pump, type xTxx
Name of device Application Interval (hours) Remark

Feeder/Supply Pump External grease lubricated ball Depending on pump On horizontal mounted pumps the
(pos. D00x, refer to technical bearing (pump type xTxx) size, rotation speed and greasing intervals are doubled
specification) mounting position. referred to table below.
Installation in dusty or dirty premises
or in a corrosive environment reduces
lubrication intervals.
Lubrication grease specification for ACG series pumps

Mobilith SHC 460 or similar that meets or exceeds the requirements of:
Standard: DIN 51825: (2004-06)
Approval: KPHC 1-2N-40
7.3.2 Lubricating intervals in working hours
Pump sizes 045 and 052 Pump sizes 060 and 070
Temp max
Speed, r/min Speed, r/min
[°C]
3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
155 325 375 525 575 625 750 300 325 475 500 575 650
*) at rotation speed > 3 500 r/min special instructions are given by manufacturer.
7.3.3 ACE series pump with Seal Guard lubrication device

Filling quantity
per pump
Feeder/Supply Pump Rechargeable shaft seal Depending on the gas generator 125 ml Initially filled by
(pos. D00x, refer to technical lubrication device ‘Seal setting, (1-12) from 700 to 8700 manufacturer
specification) Guard’
Lubrication oil with high temperature resistance and low viscosity characteristics is required.
Lubrication oil recommendations for ACE series pumps

Viscocity at 40°C/flash Viscocity at 40°C/flash Other oils visc. at
Manuf. Hydraulic oils Aut. transmission oils
point point 40°C/flash point
AGIP Agip Arnica 32 32.0 cSt at 40°C/202°C Agip Dexron III 35.8 cSt at 40°C/200°C
Agip OSO 32 30.8 cSt at 40°C/214°C Agip Dexron II D (2D) 34.0 cSt at 40°C/200°C
Agip ATF 33 F/G 35.9 cSt at 40°C/206°C
BP BP Bartran HV 32 31.8 cSt at 40°C/200°C BP Autran DX III 33.5 cSt at 40°C/202°C
BP Energol SHV-HV 32 32.0 cSt at 40°C/200°C BP Autran GM-MP 34.3 cSt at 40°C/210°C
BP Energol GHL 32 31.0 cSt at 40°C/196°C BP Autran LTF 32.5 cSt at 40°C/240°C
BP Energol HLP-D/DH/HM 32 32.0 cSt at 40°C/216°C BP Autran MBX 39.0 cSt at 40°C/196°C
BP Energol HL-XP 32 33.0 cSt at 40°C/230°C
CALTEX Rando HD 30.5 cSt at 40°C/210°C Texamatic 1888 35.8 cSt at 40°C/190°C
CASTROL Castrol Hyspin AWS 32 32.0 cSt at 40°C/200°C Castrol ATF TQ DIII 35.0 cSt at 40°C/216°C
Castrol Hyspin AWH-M 32 32.0 cSt at 40°C/186°C Castrol TQ 37.7 cSt at 40°C/210°C
Castrol Hyspin VG 32 32.0 cSt at 40°C/200°C
Castrol Hyspin ZZ 32 32.0 cSt at 40°C/218°C
Castrol Tribol 943 AW-32
CHEVRON
Rando HDZ 32 32.0 cSt at 40°C/200°C
/ FAMM
EXXON Mobil Delvac Hydraulic 10W 39.2 cSt at 40°C/226°C Esso ATF D/D2/D3 35-37 cSt at 40°C/200°C Mobil Mobilfluid 125
MOBIL Mobil DTE 13M 32.0 cSt at 40°C/210°C Mobil ATF 220 37.0 cSt at 40 °C/200°C 30.0 cSt at 40°C/225°C
Mobil DTE 24 32.0 cSt at 40°C/220°C Mobil ATF 320 35.0 cSt at 40 °C/182°C Mobil Rarus 424
Mobil EAL Hydraulic Oil 32 32.0 cSt at 40°C/248°C Mobil Multipurpose ATF 32.0 cSt at 40 °C/182°C 32.0 cSt at 40°C/236°C
GULF Gulf Harmony 32 31.2 cSt at 40°C/210°C Gulf ATF III 30.0 cSt at 40 °C/176°C
Gulf Harmony AW 32 31.2 cSt at 40°C/202°C Gulf Gulfpride III H ATF 37.1 cSt at 40 °C/186°C
Gulf Harmony AW Plus 32 31.0 cSt at 40°C/206°C
Gulf Harmony HVI 32 32.1 cSt at 40°C/218°C
Gulf Harmony HVI Plus 32 32.2 cSt at 40°C/219°C
GulfSea Hydraulic HVI Plus 32 32.2 cSt at 40°C/219°C
LUKOIL Renolin B32 HVI 32.0 cSt at 40°C/178°C Titan ATF 4000 38.0 cSt at 40 °C/190°C
Renolin MR 520 32.0 cSt at 40°C/170°C
SHELL Shell Hydrau Oils HM 32 32.0 cSt at 40°C/215°C Shell Donax TF 39.9 cSt at 40 °C/180°C
Shell Tellus Oil 32 32.0 cSt at 40°C/209°C Shell Donax TM 40.0 cSt at 40 °C/170°C
Shell Tellus Oil S 32 32.0 cSt at 40°C/207°C Shell Donax TX 33.7 cSt at 40 °C/185°C
Shell Tellus Oil 37 37.0 cSt at 40°C/212°C Shell Tellus Oil S2 V 32 32.0 cSt at 40 °C/210°C
SK ZIC SUPERWIS AW 32 32.1 cSt at 40°C/230°C ZIC ATF III 37.9 cSt at 40 °C/220°C
ZIC VEGA 32 33.3 cSt at 40°C/230°C ZIC DEXRON 28.8 cSt at 40 °C/208°C
ZIC XP III 35.7 cSt at 40 °C/224°C
TEBOIL Larita Oil 32 32.0 cSt at 40°C/200°C Teboil Fluid D 38.0 cSt at 40 °C/190°C
TOTAL Azolla AF 32 32.1 cSt at 40°C/227°C Total ATF 33 39.0 cSt at 40 °C/190°C
Azolla DZF 32 32.7 cSt at 40°C/210°C Total Fluide AT 42 34.0 cSt at 40 °C/196°C
Azolla VTR 32 32.0 cSt at 40°C/207°C Total Fluide ATX 40.0 cSt at 40 °C/190°C
Azolla ZS 32 32.0 cSt at 40°C/227°C Total Fluide CC 40.5 cSt at 40 °C/190°C
Equivis 32 32.3 cSt at 40°C/208°C Total Fluide II D 36.8 cSt at 40 °C/210°C
Visga 32 32.0 cSt at 40°C/>200°C

Ordering address:
Fax +358 204 86 5031
Tel +358 204 86 5030
9 COMPONENT MANUALS
Components
9.1 B001, B002 M002558 Strainer - Fig 821, 823 52
9.2 B030 M003765 Filter regulator, air - MC series 60
9.3 D001, D002 M000056 Pump, screw - ACG/UCG 7 64
9.4 M001/M001A, M003401 El. motor, induction - HMA, HMC, HMD, HMT, MS, 94
M002/M002A Y2E1, Y2E2, YDT
9.5 V008, V009 M021039 Valve, Globe - Fig 215, Fig 216 98
V505, V506, V507
9.7 A0A1 M001997 Alarm panel - LLC-10 108
9.8 A1K1 M002182 Relay, time - CT-MXS, CT-WBS 112
9.9 FC001,FC002 M004140 Frequency converter - FC-202 126
Position: B001, B002

Part code: M002558
9.1 Strainer - Fig 821, 823
Strainer 1
Fig 821, 823
Strainer – Filter Fig. 821, 823

1 PRODUCT DESCRIPTION
Y strainers - filters are provided with casted marking according to requirements of PN-EN19
standard. The marking facilitates technical identification and contains:
· diameter nominal DN (mm),
· pressure nominal PN (bar),
· body and cover material marking,
· arrow indicating medium flow direction,
· manufacturer marking,
· heat number,
· CE marking, for valves subjected 97/23/EC directive. CE marking starts from DN32
2 REQUIREMENTS FOR MAINTENANCE STAFF

The staff assigned to assembly, operating and maintenance tasks should be qualified to carry out
such jobs. If during strainer operation heat parts of the strainer, for example cover or body could
cause burn, user is obliged to protect them against touch.
3 TRANSPORT AND STORAGE

Transport and storage should be carried out at temperature from –200 to 650C, and strainers
should be protected against external forces influence and destruction of painting layer as well.
The aim of painting layer is to protect the strainers against rust during transport and storage.
Strainers should be kept at unpolluted rooms and they should be also protected against influence
Strainer 2
Fig 821, 823
of atmospheric conditions. There should be applied drying agent or heating at damp rooms in
order to prevent condensate formation. Strainer weights are given at catalogue card.
It is not allowed to fit lifting devices to connecting holes
4 FUNCTION
Strainers – wire mesh filters are designed for cleaning flowing medium. Their task is to protect
against pollutions the most sensitive plant components such as pumps, control valves, flow and
heat meters. Strainer holds solid particles which dimensions exceeds screen mesh. In order to
remove magnetic pollutions from the medium it is recommended to use magnetic cartridge
located in the centre of filter screen.
Application range was mentioned at catalogue card. The kind of working medium makes some
materials to be use or to be prohibited for use. Strainers were designed for normal working
conditions. In the case that working conditions exceed these requirements (for example for
aggressive or abrasive medium) user should ask manufacturer before placing an order.
When selecting the strainer for specific medium,”List of Chemical Resistance” can be helpful. It
can be found at manufacturer website near catalogue cards.
Working pressure should be adapted to maximum medium temperature according to the table as
below :
Strainer 3
Fig 821, 823
Plant designer is responsible for strainer selection suitable for working conditions.
5 APPLICATION
· hot and cold water plants , steam, air, glycol.
· industrial technologies, power industry, heat industry, HVAC plants
6 ASSEMBLY
During the assembly of strainers following rules should be observed:
· to evaluate before an assembly if the strainers were not damaged during the transport or
storage
· to make sure that applied strainers are suitable for working conditions and medium used in
the plant
· to take off dust caps if the strainers are provided with them
· check if strainer body is free of solid particles

· steam pipelines should be fitted in such a way to avoid condensate collection
Strainer 4
Fig 821, 823
· to protect the strainers during welding jobs against splinters and used plastics against
excessive temperature
Pipeline where the strainers are fitted should be conducted and assembled in such a way that
the strainer body is not subjected to bending moment and stretching forces. Bolted joints on
the pipeline must not cause additional stress resulted from excessive tightening, and fastener
materials must comply with working conditions of the plant.
To assembly the strainer in such a way that flow direction comply with an arrow placed on the
body.
· strainer body throat with a screen must be put downwards in order to prevent pollution
return to the pipeline,
· in the case of water hammer risk caused by condensate formation, strainer body throat
should be assembled in horizontal position,
· plant designer should ensure enough space to take screen out of strainer body for cleaning,
· use expansion pipe joints in order to reduce influence of pipeline thermal expansion,
· before plant startup, especially after repairs carried out, flash out the pipeline
7 MAINTENANCE
During maintenance following rules should be observed:
· startup process – sudden changes of pressure and temperature should be avoided when
starting the plant,
Strainer 5
Fig 821, 823
· strainers – wire mesh filters do not contain moving parts and do not require any maintenance
jobs with exception of screen cleaning,
· strainer screens require regular cleaning – screen cleaning intervals should be established by
user depending on the pollution grade of the medium,
Before taking up any service jobs make sure that medium supply to the pipeline was cut off,
pressure was decreased to ambient pressure, medium was removed from the pipeline and
plant was cooled down.
· cleaning or replacement the screen is possible when body – cover bolt nuts are unscrewed
and screen is taken out of the strainer – remove screen impurities by strong water stream
without using metal tools,
· some part of impurities can be removed by unscrewing the plug from the cover if strainer is
provided with plug
· before strainer reassembly remember to replace body – cover gasket.
Precautions should be taken when touching gasket between body and strainer cover. The
gasket contains stainless steel stripe that may cause injury,
· tighten hexagon nuts of cover bolts evenly and crosswise by torque wrench.
In order to assure safety performance, each strainer (especially rarely used) should be
surveyed on regular basis. Inspection frequency should be laid down by user, but not less
than one time per month.
8 SERVICE AND REPAIR

All service and repair jobs should be carried out by authorized staff using suitable tools and
original spare parts. Before disassembly of complete strainer from the pipeline or before service,
the pipeline should be out of operation. During service and repair jobs:
- the pressure should be decreased to zero degrees and valve temperature to ambient
temperature,
- personal health protectives in pursuance of existing threat should be used,
- after strainer disassembly it is necessary to replace flange connection gaskets between
strainer and pipeline,
- tighten torques for body – cover bolts
Strainer 6
Fig 821, 823
- before strainer re-assembly in the pipeline it is necessary to check strainer operation and
tightness of all connections. Tightness test should be carried out with water pressure of 1,5
nominal pressure of the valve.
9 REASONS OF OPERATING DISTURBANCES AND REMEDY

When seeking of strainer malfunction reasons safety rules should be strictly obeyed
Fault Possible reason Remedy

No flow Flange dust caps were not removed Remove dust caps on the flanges
Poor flow Dirty screen Clean or repair the screen
Clogged pipeline Check the pipeline
Broken connecting flange Bolts tighten unevenly Replace the strainer with new one
Position: B030
Part code: M003765
9.2 Filter regulator, air - MC series
COMPONENT MANUAL Page 1/3
Filter regulator, MC series ID: D07981
Filter regulator, air – MC series

1 Technical characteristics
Construction compact modular with filtering element in HDPE - diaphragm type
Materials zama, NBR, technopolymer
Ports G1/4 G3/8 G1/2
Condensate capacity / cm³ 28 72 72
Weight 0,443 0,948 0,928
Pressure gauge ports G1/8
Operating temperature -5°C to 50 °C at 10 bar (with the dew point of the fluid lower than 2 °C
at the min. working temperature)
Porocity of filtering element 25 μm standard - 5 μm upon request
Draining of condensate manual - semi-automatic standard
Finishing enamelled
Inlet pressure with standard drain and protected depressurisation 0,3 to 16 bar
with depressurisation 0,3 to 10 bar
with automatic drain 1,5 to 12 bar for G3/8 and G1/2
2 Important information for the use of pneumatic components
2.1 General
Respecting the limit values for:
 Pressure
 Speed
 Mass
 Voltage
 Actuating force
 Temperature
The pneumatic have to be used with properly prepared compressed air. The type of preparation
depends on the environmental characteristics and the sector of industry in which they will be used.
Except for different information shown on the technical data sheet for the single products, in general
the air characteristics should be:
Fluid temperature: -10 to + 60 °C
Environmental temperature: -20 to + 80 °C
Air filtering: According to DIN ISO 8573-1: not superior to the class 5/5/4
(see table)
Lubrication: Not necessary, if used then use ISOVG32 oil and do not
interrupt once applied
Oil contents: From 1 to 5 drops every 100 litres of air
2.2 Air treatment
2.2.1 Filtering
The temperature affects the capacity of air to maintain water particles (relative humidity). Warm air
contains a larger quantity of water than the same volume filled with cold air. An excess of humidity
causes the formation of condensate. Cooling of the air modifies the structure of the water it
contains, by turning it from a gaseous to a liquid state. Specific apparatus can be used to cool
(refrigerator) and heat (drier) the air and are, as a rule, assembled on the outlet of the compressor.
The filtering elements mounted inside the filters for compressed air, are only partly able to separate
the condensate from the air, in fact, their main function is to eliminate any solid particles. During the
production of compressed air, compressors can introduce oil into the distribution network. The
characteristics of this oil are not compatible with the seals of pneumatic components and with the
market trend towards miniaturized products imposes the requirement to use coalescing filters. It is
advisable to provide for automatic drains on the filters.
2.2.2 Lubrication
This is not necessary as the components are already greased with special products. Only use oils with
a viscosity of 32 cSt at 40 °C. The oil quantity has to be a maximum of 1 drop per minute, this
regulation has to be made with the machine in normal operation. The lubrication, once applied, must
never be interrupted. If not, the seals of the components could degenerate, compromising their
function.
For a correct use of our products, refer to the values shown in the table of the Air Quality classes,
according to the Standard DIN ISO 8573-1.
Class Solid bodies Air contents Oil quantity

Max dimension of the particles dew-point Max concentration
1 0.1 µm -70 °C 0.01 mg/m3
2 1 µm -40 °C 0.1 mg/m3
3 5 µm -20 °C 1 mg/m3
4 15 µm +3 °C 5 mg/m3
5 40 µm +7 °C 25 mg/m3
3 Spare parts
Pos. Description Pos. Description

1 Complete bowl with semiautomatic- 6 Bell fixing screw
manual drain
Complete bowl with depressure drain 7 Panel nut
Complete bowl with protected 8 Spring, 1 / 2 / 4 / 7 / 10 bar
depressuration drain
Complete bowl with port 1/8 (without 9 Complete standard diaphragm / without
drain) bleeder / with controlled leak
2 Complete filtering element 25 / 5 µm 10 Complete standard poppet valve
3 Filtering element 25 / 5 µm 11 Rear screw for pressure gauge
connection
4 Standard bowl O-ring 12 Special O-ring seal
5 Complete bell with regulation screw 13 Protection body with holes

Part code: M000056
9.3 Pump, screw - ACG/UCG 7
Screw pump 1
ACG/UCG 7
Contents
Screw pump ACG/UCG 7 ................................................................................................................................... 2
1 Installation ............................................................................................................................................. 3
1.2 Lifting of pump .............................................................................................................................. 3
1.3 Mounting ....................................................................................................................................... 3
1.6 Suction line .................................................................................................................................... 5
1.7 Discharge line ................................................................................................................................ 5
1.8 Deaeration ..................................................................................................................................... 5
1.9 Strainer .......................................................................................................................................... 6
1.10 Shaft seal drain .............................................................................................................................. 6
1.11 Liquid trap...................................................................................................................................... 6
1.12 Gauges ........................................................................................................................................... 7
2 Start-up .................................................................................................................................................. 8
2.1 Before starting ............................................................................................................................... 8
2.3 Starting .......................................................................................................................................... 9
3 Explosion view ..................................................................................................................................... 11
4 Maintenace .......................................................................................................................................... 14
4.2 Service for ball bearing ................................................................................................................ 14
4.4 Shaft seal-assembly drawing ....................................................................................................... 15
4.5 Lubricating intervals in working hours ........................................................................................ 15
4.6 Useful tools .................................................................................................................................. 16
Screw pump 2
ACG/UCG 7

4.8 Sectional view .............................................................................................................................. 18
4.9 Dismantling .................................................................................................................................. 19
4.10 Reassembly .................................................................................................................................. 23
Screw pump ACG/UCG 7
Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K7/N7
- With version codes N, V, T, B, F, E, P, G
o Also valid for pump options: A101, A327, A385
o Example of pump designations std: ACG 045N7 NVPB
o option: ACG 070N7 NVBP A101
refer to the ACG/UCG Product description.
Screw pump 3
ACG/UCG 7
1 Installation
start up.
1.2 Lifting of pump

the pump.
1.3 Mounting

Screw pump 4
ACG/UCG 7
are to be taken.

A B A B
50 26 2.0 8 148 3.5
67 40 2.5 16 168 3.5
82 55 3.0 18 194 3.5
97 65 3.0 20 214 4.0
112 80 3.5 24 240 4.0
128 95 3.5 26

Max angular
(mm) (degrees)
Type LPD and
Other types 0.3 0.1
Screw pump 5
ACG/UCG 7

and/or air.
1.6 Suction line

Suction line
1.7 Discharge line

1.8 Deaeration
highest point.
a stand-by pump
Screw pump 6
ACG/UCG 7
1.9 Strainer

made.
opening.
1.11 Liquid trap

Liquid trap
Screw pump 7
ACG/UCG 7
1.12 Gauges

passed liquid.
viscosity media.


Screw pump 8
ACG/UCG 7
2 Start-up
2.1 Before starting
Filling the pump
before start-up.
fig. 16.
ATTENTION
Screw pump 9
ACG/UCG 7

ATTENTION
2.3 Starting
lines.
clockwise).


Screw pump 10
ACG/UCG 7
be provided.
environment.
Screw pump 11
ACG/UCG 7
3 Explosion view
Screw pump 12
ACG/UCG 7

Qty Components included in Spare parts sets:
PosNo Denomination G011 G012 G050 G053 G054 G057 G070 Note
1010 Power rotor CCW-rot. 1 x (x)
1020 Power rotor CW-rot. 1 x x
106 Balancing piston 1 x x x 5
113 Shaft key 1 x x x
120 Distance sleeve 1
122 Ball bearing 1 x x
124 Retaining ring 1 x x x
124A Support ring 1 x x x
201 Idler rotor CCW-rot. 2 x (x)
202 Idler rotor CW-rot. 2 x x
359 Distance washer 1
401 Pump body 1
424 Sleeve 1 4
424A Washer 1 4
429 Spindle 1 4
437 O-ring 1 4
451 Screw 4/6
453 Screw 4
462 Plug 2 1
462A Sealing washer 2 x x x 1
473 Grease nipple 1
473A Grease nipple cover 1
480 Valve housing 1 2
5010 Front cover 1
502 Tension pin 1 6
502A Plug 1 6
506 Gasket 1 x x x
537 Plug 2
551 Rear cover 1 3
556 Gasket 1 x x x
601 Valve cover 1 x 2,7
602 Sealing washer 1 x x x x 2
605 O-ring 1 x x x x 2
608 Valve spindle 1 x 2,7
608A Retaining ring 1 x x x x 2
612 Set screw 1 x 2,7
614 Valve piston 1 x 2,7
615 Valve spring 1 x 2
Notes:
1) Excluded in xxxG 5) Included in item 1020 or 1010
2) Excluded in xxxE 6) Included in item 5010
3) Valid for xxxE 7) Only sold as G070
4) Valid for pump option A327 8) Removed from August 2011
Screw pump 13
ACG/UCG 7

Pos
no. Spare parts set
Rotor set CW-rotation (std):

G012 Normal lead - pump version N7
Low lead - pump version K7
Complete shaft seal - version code xVxx
G050
” - version code xTxx
Minor kit - version code xVxx
G053
G054 Major kit=G012(G011)+G053
G057 Joint kit
G070 Valve element - version code xxxP/G
122 Ballbearing
G011 is in reserve
Recommendation:
Set: To be used:
G057 Joint kit For dismantling of the pump
G053 Minor kit For service
G054 Major kit For repair after damage or greater wear.

Ordering example:
For Auramarine feeder 13152 IMO-pump ACG 045N7 NVBP, serial number 456789
Shaft seal pos G050 p/n AFS000662
Ballbearing pos 122 p/n AFM000300
Screw pump 14
ACG/UCG 7
4 Maintenace
pumped liquid and can only be determined by experience. All internal parts of the ACG-pump are
lubricated by the pumped liquid. Pumping liquid which contains abrasive materials, or liquid that
is corrosive, will significantly reduce service life and call for shorter service intervals.
Wear in the pump may be indicated by:
 Vibration
 Noise
 Loss of capacity
 Reduction in flow/pressure
 Leakage
In installations where unplanned shut downs must be avoided, it is advisable to have a complete
pump available for replacement, should any malfunction occur. Furthermore we recommend
planned inspection and overhaul at regular intervals, not exceeding 3 years.
4.2 Service for ball bearing

The ACG-pump is fitted with an external grease lubricated ball bearing. When delivered from IMO
AB, the ball bearings in pump version xVxx are filled with grease of type B. For version xTxx, type C
is used. Whenever the ball bearing is removed, it is recommended to exchange it for a new one.
Fit the new ball bearing properly greased and regrease it after one hour of running, while the
pump is operating.

As the seal faces of a mechanical shaft seal are lubricated by the fluid a certain leakage will always
be present. Ten drops per hour can be considered as acceptable.
An external visual inspection of the pump is advisable at least every two days to assure that the
shaft seal is not leaking too much.
Excessively leaking shaft seals should be changed without delay, as the leakage normally will grow
worse and cause additional damage.
Follow the instructions in the dismantling/reassembly session.
When working with a shaft seal, cleanliness is of utmost importance. Avoid touching the seal
faces. If necessary, the seal faces should be cleaned immediately prior to assembly, using a dust
free cloth and clean solvent.
Never use grease on the seal faces. Connecting and disconnecting of electric cables must be
done only by personnel authorized to do such work.
Screw pump 15
ACG/UCG 7
4.4 Shaft seal-assembly drawing
Use an appropriate type of grease, as per table and a grease gun suitable for grease nipple (pos
473) according to DIN 71 412 (ISO 6392).
On vertical mounted units the greasing intervals are reduced to half. Installed in dusty or dirty
premises or in a corrosive environment it should be lubricated at more frequent intervals.
If using others than these recommended greases check if it is possible to mix them with each
other, otherwise clean before using a new grease.
4.5 Lubricating intervals in working hours

Temp Pump sizes 045 and 052 Pump sizes 060 and 070
max Grease
type
o
C 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 10000
90 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750
110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350
130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100
155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1400
*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.
Recommended greases (the availability of the greases can differ locally):
Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak
EP2, SKF LGMT2, Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3,
FINA MARSON L3.
Screw pump 16
ACG/UCG 7
Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL
RETINAX LX, SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS,
CASTROL LMX, INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.
Type C: Mobilith SHC 460
Pump size 045 052 060 070

Grease amount (g) 4 6 7 9
isolated.
are to be taken.
In case of failure for a system with elevated pressure, fluid jets may cause injury and/or
damage.
4.6 Useful tools

Screw pump 17
ACG/UCG 7

If an indication of a worn pump is noticed (see service intervals above), a brief inspection of the
idler rotors is recommended.
A quick inspection of the idler rotors can be made simply by removing the rear cover or valve
cover. Note that the driver must be deenergized and the pump hydraulically isolated before the
rear cover is removed. Provisions to handle the fluid are to be made. If a more thorough
investigation is needed, proceed as under ”Dismantling”.
Internal clearances in the pump, which are vital for its proper function, may have been affected by
wear. Acceptable wear can be determined only by experience of the actual application. As a rule
of thumb the following max clearance values may apply:
 Between rotor and bores or bushings: 0.2 mm
 Between rotor flanks: 0.4 mm
For light duties (low pressure, medium viscosity) even bigger clearances may be acceptable but
for low visc./high pressure duties the limit will be lower. Also check if there are major scratches
on these parts.
Screw pump 18
ACG/UCG 7
4.8 Sectional view

Screw pump 19
ACG/UCG 7
4.9 Dismantling
Turn the electricity OFF.
Close the valves.
Remove the pump from the system.
ATTENTION
Use appropriate vessels to collect oil spillage
when removing and opening the pump.
Note the axial position of the shaft coupling.


Screw pump 20
ACG/UCG 7
Remove the key 113.
Remove the retaining rings 124 and 514.

Remove the support ring 124A.
Screw pump 21
ACG/UCG 7
Remove the front cover 5010 with a puller.
Push out the ball bearing 122 together with the

distance sleeve 120. If there is tight fit use a
mounting sleeve and a mallet.
Remove the distance washer 359 and the support
ring 359A.
The sealing surfaces of the shaft seat should not

be touched with the fingers.
Turn the front cover 5010 upside down.
Push out the seat from the front cover 5010.
Remove the o-ring S2.
Remove the gasket 506.
Screw pump 22
ACG/UCG 7
Pull the power rotor 1020 out of the pump body

and place it into the jaws of a jaw vice with soft
jaws or a column drilling machine.
Push with two drivers as shown on the sketch, to
remove the shaft seal.
Unscrew the seal ring carrier S5 screws and take

off the seal ring carrier S5 together with the seal
ring S4 and the o-ring S6.
Take out the idler rotors.

Clean all parts that are going to be used again.
Screw pump 23
ACG/UCG 7
4.10 Reassembly
Lubricate the idler rotors and fit them into the
pump.
Lubrication groove turned downwards.
Carefully place the power rotor 1020 into the jaw

vice with soft jaws.
Lubricate all surfaces of the power rotor 1020.
Open a package with a new sealing 509, version
xVxx.
Place the bellows unit S5 on the shaft of the
power rotor and press it down against the
balance piston (106) (See Sectional view).
Open a package with a new shaft seal 509

version xTxx.
Place the seal ring carrier S5 on the shaft of the
power rotor 1020 flush against the balance
piston and lock it with its stop screws. Fit the o-
ring S6 and the seal ring S4.
Screw pump 24
ACG/UCG 7
Lubricate the O-ring S2 and the recess of the

front cover 5010.
Clean the sealing faces and fit the seat S1 into
the front cover 5010. Mind the position of the
retaining pin if applicable.
Lubricate the balance piston 106 with a thick oil

(ISO VG 460).
Fit the front cover onto the power rotor 1020
untill it rests on the bellows unit S5.
Fit the support ring 359A and the distance
washer 359 into the front cover. Mind the
position of the distance washer 359.
Fit the distance sleeve 120 into the front cover
5010.
Fill the ball bearing with appropriate grease. See
page 5 for grease selection.
Fit the ball bearing 122 onto the shaft.
ATTENTION
The open side of the bearing towards the cover.
Fit the mounting sleeve and push the bearing to
its final position in the front cover. To do this
some force is required. Use Your column drilling
machine or mounting kit (see fig 4).
Do not use a hammer etc. as this might damage
the shaft seal and ball bearing.
Fit the support ring 124A and the retaining ring
124 on the shaft.
Fit the retaining ring 514 back in place.
Screw pump 25
ACG/UCG 7
Fit the key back in position, see fig. Remove the Do not use a hammer etc. as this might
key 113. damage the shaft seal and ball bearing.
Fit the shaft coupling back into place (see fig.
Axial position and Remove shaft coupling) with
the same methode used when fitting the ball
bearing.
Remove the plug 537 and washer 537A.
Hold the rotor unit horizontally with the bore for
537 upwards. Carefully fill the space completely
with thin oil (f. ex. ISO VG 46).
When the oil is flooding, reassemble the above
parts in reverse order.
Slowly turn the shaft a few turns to make sure it
moves freely (a certain resistance from the shaft
seal is normal but it must be the same during the
turns).
Place the gasket 506 on the pump body 401.
Lubricate the power rotor 1020 and fit the front
cover 5010 together with the rotor set into the
pump body. Mind the position of the tension pin
545.
Fit the screws 451 and tighten them crosswise.
Put the pump back into the system and proceed

according to instructions under ”Startup” in the
installation manual.
Screw pump 26
ACG/UCG 7

Replacement of O-ring 605
 To avoid changing the setting of the valve, use an Allen key to prevent spindle 608 to turn.
Unscrew cover 601 and pull up unit 601/608.
 Remove retaining ring 608A and pull the spindle 608 out of cover 601. Replace O-ring 605
and assemble the unit 601/608 in reverse order. Replace retaining ring 608A if necessary
and washer 602.
 Fit the unit 601/608 in the valve. Make sure the
608 enters the set screw 612 and use the Allen
key to prevent 608 to turn when cover 601 is
tightened.
Replacement of Valve Element G070
 Release the spring tension by turning the spindle
608 CCW with an Allen key. Use the Allen key to
prevent spindle 608 to turn and unscrew cover
601 but do not remove it yet.
 Remove the set screw 612 by turning the spindle
608 CCW. Pull out the valve piston/spring unit
614/615.
 Fit the valve element in reverse order with a new
washer 602. Turn the spindle 608 CW until the set
screw leave enough room for cover 601. Use the
Allen key to prevent 608 to turn further when
cover 601 is tightened.
 Adjust the valve setting according to the "Installation and Start-up Instruction".
Screw pump 27
ACG/UCG 7
5 Trouble shooting
rotation
such work.

primed
at the pump inlet.
pressure.
noise).

Screw pump 28
ACG/UCG 7
high.

conditions.
down if any sign of
malfunction is
noticed.
Auramarine.

Position: M001/M001A, M002/M002A

Part code: M003401
Y2E2, YDT
Electric Motors
Motor Manual
hoyermotors.com
Manual
Motor
Manual

shaft failure.
60034-4 and IEC/EN 60072.
or studs.

local regulations.
rated data.

to other equipment.
T.(Nm) 2.5 3.5 7 12 18 35 55 80
Installation
2
Motor
Manual
56 - 160 2-8 40,000h
180 2 35,000h
200 2 27,000h
IEC 60079-15.
must be closed.
intervals.
size (h) (h)
160 20 4200 7000 8500 8500
315 50 1500 5500 6500 6500
355 60 1000 4000 5000 6000
400 80 800 3000 4000 6000
3

Part code: M021039
9.5 Valve, Globe - Fig 215, Fig 216
COMPONENT MANUAL Page 1 (6)
Valve, Globe ID: D04278A
Globe valve
Fig.215 straight form
Fig.216 angle form
1 Product description
Globe valves are manufactured at different executions, they are used as stop valves, throttling valves, SDNR valves. Stop valves
are designed only for shut off and open the flow, throttling valves are designed for flow control and SDNR valves are used as n on
return valves protecting the plant against back flow of medium and additionally they can shut off the flow. SDNR valves visually
differ from stop valves having cylinder stem extension on the upper end of the stem.
Globe valves are provided with casted marking according to requirements of PN-EN19 standard. The marking facilitates technical
identification and contains:
 diameter nominal DN (mm),
 pressure nominal PN (bar),
 body and bonnet material marking,
 arrow indicating medium flow direction,
 manufacturer marking,
 heat number,
 CE marking, for valves subjected 2014/68/UE directive. CE marking starts from DN32
AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
2 Function
Valves with stop disc are designed for shut off medium flow, valves with throttling disc enable to control the flow and SDNR valves
are designed to work as non-return valves and enable to shut off the valve at any time as well. Application range was mentioned at
catalogue card. The kind of working medium makes some materials to be use or to be prohibited for use. Valves were designed for
normal working conditions. In the case that working conditions exceed these requirements (for example for aggressive or abrasive
medium) user should ask manufacturer before placing an order. When selecting the valve for specific medium,”List of Chemical
Resistance” can be helpful. It can be found at manufacturer website near catalogue cards. Working pressure should be adapted to
maximum medium temperature according to the table as below.
3 Assembly
During the assembly of balancing valves following rules should be observed:
 to evaluate before an assembly if the valves were not damaged during the transport or storage,
 to make sure that applied valves are suitable for working conditions and medium used in the plant,
 to take off dust caps if the valves are provided with them,
 to protect the valves during welding jobs against splinters and used plastics against excessive temperature,
 steam pipelines should be fitted in such a way to avoid condensate collection; in order to avoid water hammer steam trap
should be applied

FIN-20101 TURKU Fax + 358 204 86 5031
 during pipeline painting valve stem should be protected,

 stop valves can be assembled in any position, however it is recommended to install the valve with hand wheel upwards,
 screw down and non-return valves (version with spring) can be assembled in any position, screw down and non-return
valves (version without spring) should be assembled only on the horizontal pipelines with hand wheel upwards
 before plant startup, especially after repairs carried out, flash out the pipeline through entirely open valve, in order to avoid
solid particles or welding splinters which may be harmful for sealing surfaces,
 strainer (wire mesh filter) installed before the valve increases certainty of its correct action.
4 Maintenance
 startup process – sudden changes of pressure and temperature should be avoided when starting the plant,
 valve is closed by turning the hand wheel clockwise when looking from above the hand wheel (according to arrow
direction marked on the hand wheel),
 valve is opened by turning the hand wheel counter-clockwise,

 performance of fitted valves can be checked by multiple closing and opening,

FIN-20101 TURKU Fax + 358 204 86 5031
 if leakage on stem occurs for valves Fig.215, 216 (PN6 – PN25) it is necessary to tighten with moderate force two T-bolt
nuts pressing the packing gland untill the leakage disappear, for SDNR valves Fig.215, Fig.216 (PN40) similar nuts on
eye bolts, whereas for stop valves Fig.215 (PN40) packing rings are pressed by tightening threaded gland nut screwed in
the bonnet, the nut press the rings by gland,
 in the case of necessity to replace packing rings, it should be done without overpressure inside the valve, when the valve
is completely open. In this position inner space of the valve is entirely shut off : stop valves are provided with back seat on
the upper part of disc which adheres to bonnet seat, SDNR valves are provided with flange on the stem which adheres to
bonnet seat,
 in order to refill packing rings of valves Fig.215, 216 (PN6 – PN25) unscrew the nuts on T-bolts, move the gland into hand
wheel direction, working under lifted gland refill cut - packing rings in the stuffing box, then press again these cut packing
rings. There are similar procedures for SDNR valves Fig.215, Fig.216 (PN40) but there are eye bolts instead of T-bolts
that can be swing aside. For stop valves Fig.215 (PN40) packing can be refilled when gland nut is unscrewed.

FIN-20101 TURKU Fax + 358 204 86 5031
5 Service and repair

All service and repair jobs should be carried out by authorized staff using suitable tools and original spare parts. Before
disassembly of complete valve from the pipeline or before service, the pipeline should be out of operation. During service and repair
jobs it is necessary to decrease pressure to 0 bars, valve temperature to ambient temperature and to use personal health
protectives in pursuance of existing threat. After valve disassembly it is necessary to replace flange connection gaskets between
valve and pipeline.
Every time when valve bonnet was disassembled sealing surface should be cleaned. During assembly it should be applied new
gasket of the same type as previously used. Body-bonnet bolt connections should be tighten when the valve is at open position.
The bolts should be tighten evenly and crosswise by torque wrench.

FIN-20101 TURKU Fax + 358 204 86 5031
Tighten torques
before valves re-assembly in the pipeline it is necessary to check valve operation and tightness of all connections. Tightness test
should be carried out with water pressure of 1,5 nominal pressure of the valve.
6 Reasons of operating disturbances and remedy

When seeking of valve malfunction reasons safety rules should be strictly obeyed

FIN-20101 TURKU Fax + 358 204 86 5031
Position: V501, V502, V503, V504, V505, V506,

V507
Part code: M021085
Ball valve 1
Ball valve 1700

Position: A0A1
Part code: M001997
9.7 Alarm panel - LLC-10
ALARM DISPLAY UNIT LLC–10 LRS
UNIVERSAL PANEL IN THE ”DIN” SERIES, FOR USE BY POCESS
INDUSTRIES AND MACHINE MANUFACTURERS
Advantages and Operation
LLC-10 LRS is a compact alarm display unit in the ”DIN”-series. It
is designed for exacting applications. The unit is programmable for
use with either normally open or closed sensor contacts, with adjus-
table time delay. The alarm display unit has two output relays (A and
B alarms). All channels shall be connected to A-alarm.
When a sensor flashing after the pre-set time delay has elapsed.
At the same time the both output relays are activated (the B relay
is delayed 5 sec in relation to the A relay). If a new sensor will be
activated the B relay will do a quick status change. The signal is
acknowledged by pressing the RESET button. This releases the out-
put A relay and the flashing light becomes steady. The B relay will
be in alarm mode as long as any channel is in alarm state.
When the fault has been corrected and the sensor contact has retur-
ned to its normal state, the indicator lamp goes out. If the fault self-
corrects and the sensor contact returns before acknowledgement,
the fault remains in the unit memory, the light flashes and the output
relays remain activated, until the RESET button is pressed.
LLC-10 is equipped with a channel memory. The unit is always
ready to receive new alarm signals, independent of system status.
The panel can be provided with legends for each alarm channel or
with a common 10 points legend.
SECURITY
LLC-10 LRS is designed for severe mechanical and electrical envi-
ronmental conditions. It is provided with special protection against
polarity reversal and accidental connection of voltage, interruptions
etc. The unit is designed to indicate voltage failures, each group
relay is normally activated. In the alarm state the relay is deactivated
and a signal can be given with a horn, for example. The same hap-
pens with interruption in supply voltage.
Its limited size and depth and depth allow it to be easily mounted in
panels, walls and similar spaces.
Normal function testing is carried out by pressing a test button
which simulates faults on the alarm channels in the system.
• 10 channel unit for both normally open and
INSTALLATION
closed sensor contacts (No/Nc). LLC-10 LRS is designed for panel, wall or cabinet mounting, and is
supplied only in the master form. Systems with more than 10 alarm
channels require, demand additional panels. Connection is made to
• Alarm grouping in 2 categories (A-B alarms) the unit by an easily accessible screw terminal block,which can be
fitted with a corresponding terminal strip. The use of this system
• Memory and flasher means that cable connections need not be disturbed once the instal-
lation is complete, and the unit can be disconnected very quickly.
• Time delay for each alarm channel SPECIFICATIONS

Supply voltage: 24V AC/DC ± 20%
• Running light indicator Supply current: Normal condition 0,1A
Alarm condition 0,2A
Time delay: Individually adjustable time 0,5-20 sec. each chan-
• Group indication nel.
Output contacts: One change-over contact per alarm group (A and
• Voltage failure indication B alarms). Selection device on each alarm point
contact rated max 100V 2A resistive load.
Front: Dull black aluminium with plastic cover IP44 and
• Prepared for datatransfer together with gasket IP65
Main dimension: DIN 144x144x35 mm
Panel recess: 125x125 mm
Legends: Space for individual channel legends or common 5
channel legends
Indicators: Red LED for unacknowledged alarm
––
––
Position: A1K1
Part code: M002182
9.8 Relay, time - CT-MXS, CT-WBS
CT-MXS
CT-WBS
(D) Betriebs- und Montageanleitung (E) Instrucciones de servicio y de montaje

Elektronische Zeitrelais, CT-S Reihe Temporizadores electrónicos, serie CT-S
Hinweis: Diese Betriebs- und Montageanleitung enthält nicht Nota: Estas instrucciones no contienen todas las
sämtliche Detailinformationen zu allen Typen der Produktreihe informaciones detalladas relativas a todos los tipos del
und kann auch nicht jeden Einsatzfall der Produkte berück- producto ni pueden considerar todos los casos de operación.
sichtigen. Alle Angaben dienen ausschließlich der Produkt- Todas las indicaciones son a título descriptivo del producto
beschreibung und sind nicht als zugesicherte Eigenschaften y no constituyen obligaciones legales. Para más información,
im Rechtssinne aufzufassen. Weiterführende Informationen consulte los catálogos, las hojas de características, la
und Daten erhalten Sie in den Katalogen und Datenblättern sucursal local de ABB o la Web http://www.abb.com. Sujeto
der Produkte, über die örtliche ABB-Niederlassung sowie auf a cambios técnicos sin previo aviso. En caso de duda,
der ABB Homepage unter http://www.abb.com. Technische prevalece el texto alemán.
Änderungen jederzeit vorbehalten. In Zweifelsfällen gilt der La instalación debe llevarse a cabo sólo por personal
deutsche Text. especializado. Es necesario respetar las normas
Nur von einer entsprechend qualifizierten Fachkraft zu especificas del país (p.ej. VDE, etc.). Antes de la
installieren. Dabei landesspezifische Vorschriften (z.B. instalación lea completamente estas instrucciones.
VDE, etc.) beachten. Vor der Installation diese Be- Estos aparatos son equipos para su montaje en
triebs- und Montageanleitung sorgfältig lesen und be- conjuntos y son de libre mantenimiento.
achten. Die Geräte sind wartungsfreie Einbaugeräte.
(GB) Operating and installation instructions (I) Istruzioni per l’uso ed il montaggio
Electronic time relays, CT-S range Relè temporizzatori elettronici, serie CT-S
Note: These operating and installation instructions cannot Nota: Le presenti istruzioni per l’uso ed il montaggio non
claim to contain all detailed information of all types of this contengono tutte le informazioni dettagliate su tutta la gamma
product range and can even not consider every possible di prodotti e non possono trattare tutti i casi applicativi. Tutte
application of the products. All statements serve exclusively le indicazioni servono esclusivamente a descrivere il prodotto
to describe the product and have not to be understood as e non sono da interpretare come caratteristiche garantite
assured characteristics with legal force. Further information con valore di legge. Per ulteriori informazioni consultare i
and data is obtainable from the catalogues and data sheets cataloghi ed i data sheet dei prodotti, o la nostra homepage
of this product, from the local ABB sales organisations as http://www.abb.com, oppure rivolgersi alla locale filiale ABB.
well as on the ABB homepage http://www.abb.com. Subject Ci riserviamo di eventuali modifiche tecniche. In caso di
to change without prior notice. The German text applies in differenze o problemi è valido il testo tedesco.
cases of doubt. Installazione solo a cura di personale specializzato.
The device must be installed by qualified persons Bisogna osservare le specifiche norme nazionali
only and in accordance with the specific national (p.e. VDE, etc.). Prima dell’installazione leggere
regulations (e.g., VDE, etc.). Before installing attentamente le seguenti istruzioni. Questi prodotti
this unit, read these operating and installation sono apparecchi ad incasso, che non hanno bisogno
instructions carefully and completely. The devices are di manutenzione.
maintenance-free chassis-mounted units.
(F) Instructions de service et de montage (CN) ֡ፕᇑҾጎኸళ

Relais électroniques temporisés, gamme CT-S ‫ۉ‬ጱ้क़ी‫ۉ‬ഗ CT-S ဣଚ
Note: Ces instructions de service et de montage ne ጀᅪǖԨ֡ፕኸళփԈࡤरຍຕ਍ࢅඇևׂ೗ᆌᆩຫ௽ǈ໯ᆶ
contiennent pas toutes les informations relatives à tous les ຕ਍ኻ๟ਏᆶ‫ׂܔ‬೗༬Ⴀ৊ႜຫ௽‫ڦ‬ፕᆩǈᅺُփਏԢ݆ୱၳ
types de cette gamme de produits et ne peuvent pas non ᆌăၘဦຫ௽൩֖ለरຍᄣԨई૴ஏABB‫ںړ‬Ӹ๚‫ت‬ई៓બ
plus tenir compte de tous les cas d’application. Toutes les BCCྪበǄhttp://www.abb.comǅăසᆶ߸߀ǈທփཚኪăժ
indications ne sont données qu’à titre de description du ᅜ‫ڤ‬࿔ྺՔጚă
produit et ne constituent aucunes obligations légales. Pour ഗॲՂႷᆯጆᄽටᇵӀቷࡔाጆᄽࡀቤҾጎǄස
de plus amples informations, veuillez-vous référer aux VDEǅăҾጎമǈ൩ံၘဦለ‫܁‬ԨҾጎኸళă
catalogues et aux fiches techniques des produits, à votre ׂ೗‫ڹ‬ಎփࡤඪࢆႴᄲҾጎ‫ڦ‬և‫ݴ‬ǈ൩փᄲ‫ٶ‬ਸ‫ڹ‬
Printed in the Fed. Rep. of Germany
agence ABB ou à notre site http://www.abb.com. Sous ಎăׂُ೗ྺ௨ྼࢺ‫ڹ‬ӱҾጎഗॲă

1SVC 630 030 M0000 A2 (01/10)
réserve de modifications techniques. En cas de divergences,

le texte allemand fait foi.
L’installation de ces produits doit être réalisée
uniquement par une personne compétente et en con-
formité avec les prescriptions nationales (p.e. VDE,
etc.). Avant l’installation de cet appareil veuillez lire
l’intégralité de ces instructions. Ces produits sont
des appareils encliquetables qui ne nécessitent pas
d’entretien.
ABB Stotz-Kontakt GmbH

Hauptstr. 14-16
78132 Hornberg / Germany
www.abb.com/lowvoltage -> Control Products -> Electronic Relays and Controls
(D) Produkt anbringen
(GB) Fix product
(F) Monter le produit
(E) Fijar el producto
(I) Montare il prodotto
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2CDC 252 282 F0005

(D) Plombierbare Klarsichtabdeckung anbringen
(GB) Fix sealable transparent cover
(F) Fixation du capot transparent condamnable
(E) Fijar cubierta transparente sellable
(I) Fissare
ssa e la copertura
a cope u a trasparente sigillabile
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g
2CDC 252 047 F0b09
0.6...0.8 Nm
5.31...7.08 lb.in
Ø 4.5 mm / 0.177 in / PH 1
7 mm
0.28 in
2 x 0.5...4 mm²
2 x 20...12 AWG
7 mm
2CDC 252 146 F0006
0.28 in
2 x 0.75...2.5 mm²
2 x 18...14 AWG
7 mm
0.28 in
2 x 0.75...2.5 mm²
2 x 18...14 AWG
2
I I Frontansichten mit Bedienelementen Deutsch
Einstellung des Zeitbereiches durch Wahl des

Endwertes
Bereich Endwert
0,15 - 3 s >> 3 s gelbe
1,5 - 30 s >> 30 s Skala
15 - 300 s >> 300 s
1,5 - 30 min >> 30 min
15 - 300 min >> 300 min
2 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h
1 1 0,05 - 1 s >> 1 s weiße
0,5 - 10 s >> 10 s Skala
2 4 2 4 5 - 100 s >> 100 s
Absolutskala zur Einstellung des Zeitwertes

1 3 innerhalb des gewählten Bereiches
Auswahl der Funktion bei CT-WBS
5 Funktionen siehe IV
2CDC 252 143 F0006
2CDC 252 144 F0006

Betriebszustandsanzeige mit LEDs
U/T: LED grün - Anzeige Steuerspeise-
spannung und Zeitablauf
V Steuerspeise-
spannung liegt an
W Verzögerungszeit
läuft
R: LED gelb - Anzeige der Schaltstellung
des Ausgangsrelais
V angezogen
II II DIP Schalter
฀ Auswahl der Funktion bei CT-MXS

1 ON = Einzeltaktgeber, pausebeginnend
2 ON = Ansprech- und Rückfallverzögerung,
asymmetrisch
3 ON = Ein- und Ausschaltwischer
4 ON = keine Funktion
2CDC 252 284 F0005
All ON = ON/OFF-Funktion
All OFF = Taktgeber, impuls- oder
pausebeginnend
Auslieferungszustand:
Alle DIP-Schalter in Position OFF
III III Elektrischer Anschluss
Bemessungssteuerspeisespannung
und Schaltbild dem seitlichen
Typenschild am Gerät entnehmen
A1-A2 Steuerspeisespannung Us
A1-Y1/B1 Steuereingang für Zeitstart
Z2-Z3/Z1 1./2. Fernpotentiometeranschluss zur
Zeitfeineinstellung.
Bei Anschluss eines externen Potentio-
meters wird das entsprechende
interne, frontseitige Potentiometer
automatisch abgeschaltet.
15-16/18 1. Wechsler
3
I Front view with operating controls English I Face avant et dispositifs de Français
commande
Adjustment of the time range by selecting the Réglage de la plage de temporisation par
max. value sélection de la valeur maximale
Range Max. value Plage Valeur maximale
0.15 - 3 s >> 3 s yellow 0,15 - 3 s >> 3 s échelle
1.5 - 30 s >> 30 s dial 1,5 - 30 s >> 30 s jaune
15 - 300 s >> 300 s 15 - 300 s >> 300 s
1.5 - 30 min >> 30 min 1,5 - 30 min >> 30 min
15 - 300 min >> 300 min 15 - 300 min >> 300 min
1.5 - 30 h >> 30 h 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h 15 - 300 h >> 300 h
0.05 - 1 s >> 1 s white 0,05 - 1 s >> 1 s échelle
0.5 - 10 s >> 10 s dial 0,5 - 10 s >> 10 s blanche
5 - 100 s >> 100 s 5 - 100 s >> 100 s
Direct reading scale to set the time value within Valeur absolue pour le réglage de la
the chosen range temporisation à l’intérieur de la plage choisie.
Selection of the function on CT-WBS Sélection de la fonction pour CT-WBS
Functions: see IV Pour les fonctions, voir IV
Status display with LEDs Indication de fonctionnement par LED
U/T: green LED - Status indication of control U/T: LED verte - Indication de la tension
supply voltage and timing d’alimentation de
V Control supply commande et temporisation
voltage applied V Tension
W Time delay is d’alimentation de
running commande appliquée
W Temporisation en
R: yellow LED - Status indication of output
cours
relay
R: LED jaune - Indication de l’état du relais
V energized
de sortie
V activé
II DIP switches II Micro-interrupteurs
฀ Selection of the function on CT-MXS ฀ Sélection de la fonction pour CT-MXS

1 ON = Single pulse generator, starting with OFF 1 ON = Générateur d’impulsion unique,
2 ON = ON-delay and OFF-delay, asymmetrical démarrant par arrêt
3 ON = Impulse-ON and impulse-OFF 2 ON = Temporisation Travail et Repos,
4 ON = no function asymétrique
All ON = ON/OFF-Function 3 ON = Contact de passage à l’activation et
All OFF = Pulse generator, starting with ON or OFF à la désactivation
State of delivery: 4 ON = pas de fonction
All DIP switches in position OFF Tous ON = Fonction ON/OFF
Tous OFF = Générateur d’impulsion, démarrant
par marche ou par arrêt
Etat de livraison:
Tous les micro-interrupteurs en position OFF
III Electrical connection III Raccordement électrique

For the rated control supply voltage Pour la tension assignée
and the circuit diagram, see label at d’alimentation de commande et pour
the side of the unit le schéma des connexions voir
l’étiquette placée sur le côté du relais.
A1-A2 Control supply voltage Us
A1-Y1/B1 Control input to start timing A1-A2 Tension d’alimentation de commande Us
Z2-Z3/Z1 1st/2nd remote potentiometer A1-Y1/B1 Entrée de commande pour le
connection for the fine adjustment of démarrage de la temporisation
the time delay. Z2-Z3/Z1 1er/2ème raccordement pour
When an external potentiometer is potentiomètre déporté pour le réglage
connected, the corresponding internal, fin de la temporisation.
front-face potentiometer is disabled. Quand un potentiomètre externe est
15-16/18 1st c/o contact raccordé, le potentiomètre interne
25-26/28 2nd c/o contact correspondant, sur la face avant, est
automatiquement désactivé.
15-16/18 1er inverseur
25-26/28 2ème inverseur
4
I Vistas frontales con elementos de Español I Vista frontale con gli elementi di Italiano
mando comando
Ajuste del margen de tiempo para selección Impostazione del campo di temporizzazione
del valor fondo escala mediante selezione del valore massimo
del campo
Margen Fondo escala
0,15 - 3 s >> 3 s escala Campo Valore massimo
1,5 - 30 s >> 30 s amarilla 0,15 - 3 s >> 3 s scala
15 - 300 s >> 300 s 1,5 - 30 s >> 30 s gialla
1,5 - 30 min >> 30 min 15 - 300 s >> 300 s
15 - 300 min >> 300 min 1,5 - 30 min >> 30 min
1,5 - 30 h >> 30 h 15 - 300 min >> 300 min
15 - 300 h >> 300 h 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h
0,05 - 1 s >> 1 s escala
0,5 - 10 s >> 10 s blanca 0,05 - 1 s >> 1 s scala
5 - 100 s >> 100 s 0,5 - 10 s >> 10 s bianca
5 - 100 s >> 100 s
Escala absoluta para el ajuste del valor de
temporización dentro de margen seleccionado Scala a lettura diretta per l’impostazione del
tempo all’interno del campo selezionato
Selección de la función para CT-WBS
Funciones: vease IV Selezione della funzione per CT-WBS
Funzioni: vedi IV
Indicador de servicio con LEDs
U/T: LED verde - Indicación tensión de LED di visualizzazione dello stato di funzionamento
alimentación y U/T: LED verde - Indicazione tensione
temporización d’alimentazione e stato
V Tensión de della temporizzazione
alimentación aplicada V Tensione
W Temporización en d’alimentazione applicata
curso W Temporizzazione in
R: LED amarillo - Indicación del estado del corso
relé de salida R: LED giallo - Indicazione dello stato del
V energizado relè d’uscita
V eccitato
II Interruptores DIP II Interruttori DIP

฀ Selección de la función para CT-MXS ฀ Selezione della funzione per CT-MXS
1 ON = Generador de un único impulso, 1 ON = Generatore di singolo impulso,
inicio en OFF inizio con OFF
2 ON = Retardo a la conexión y a la 2 ON = Ritardo all’eccitazione ed alla
desconexión, asimétrico diseccitazione, asimmetrico
3 ON = Pulso a la conexión y a la 3 ON = Impulso all’eccitazione ed alla
desconexión diseccitazione
4 ON = ninguna función 4 ON = senza funzione
Todos ON = Función ON/OFF Tutti ON = Funzione ON/OFF
Todos OFF = Generador de pulsos, arranque en Tutti OFF = Generatore di impulsi, inizio con
ON ó en OFF ON o OFF
Entrega de fábrica: Impostazione di fabbrica:
Todos los interruptores DIP en posición OFF Tutti interruttori DIP in posizione OFF
III Conexión eléctrica III Collegamento elettrico

Véase la etiqueta lateral de Per la tensione nominale
características para la tensión nominal d’alimentazione e per lo schema
de alimentación y para el esquema elettrico, vedi la targhetta laterale del
contactos relè.
A1-A2 Tensión de alimentación Us A1-A2 Tensione d’alimentazione Us
A1-Y1/B1 Entrada de mando para el inicio de la A1-Y1/B1 Ingresso di comando per lo start della
temporización temporizzazione
Z2-Z3/Z1 1era/2da conexión del potenciometro Z2-Z3/Z1 1°/2° connessione per il potenziometro
remoto para el ajuste fino del tiempo de a distanza per la regolazione di
retardo. precisione del tempo.
Cuando un potenciometro externo se Il corrispondente potenziometro interno,
conecta, el correspondiente potencio- sul lato frontale, si disattiva auto-
metro interno del frontal se desactiva. maticamente al collegamento del
15-16/18 1er. contacto conmutado potenziometro esterno.
25-26/28 2do. contacto conmutado 15-16/18 1° contatto di scambio
25-26/28 2° contatto di scambio
5
I മ௬ӱ֡ፕ CN &$% " 0 !"'. >YWWPNO
($% "2
ۙব้क़‫ྷݔ‬ፌ‫ٷ‬ኵ >KIYQNVTHPF HVKRKSSTIT JNFUFMTSF UYXKR

‫ྷݔ‬ ፌ‫ٷ‬ኵ YWXFSTHPN RFPW MSF]KSNd
0.15 - 3 s >> 3 s ࣜ෥ਗ਼‫܈‬ 6NFUFMTS ;FPW MSF]KSNK
1.5 - 30 s >> 30 s W W LKQXFd
15 - 300 s >> 300 s W W ^PFQF
1.5 - 30 min >> 30 min W W
15 - 300 min >> 300 min RNS RNS
1.5 - 30 h >> 30 h RNS RNS
15 - 300 h >> 300 h ] ]
] ]
0.05 - 1 s >> 1 s ӣ෥ਗ਼‫܈‬
0.5 - 10 s >> 10 s W W GKQFd
5 - 100 s >> 100 s W W ^PFQF
W W
CPFQF H FGWTQcXS`[ MSF]KSNd[ JQd

ሞ჋ስ‫้ڦ‬क़‫ాྷݔ‬ǈ኱‫܁‬ਗ਼‫܈‬ಎย้ۨक़ኵ YWXFSTHPN XT]STIT MSF]KSNd HVKRKSN
H UVKJKQF[ H`GVFSSTIT JNFUFMTSF
CT-WBSࠀీ჋ስ
! ! ࠀీ;֖ੂJW 4`GTV ZYSP\NN SF "%!
BYSP\NN WR IQFHY $
LEDs!ጒༀኸ๖
6NWUQKO WTWXTdSNd WT WHKXTJNTJFRN
U/T:෥!LED - ࠃ‫ۉۉ‬უࢅऺ้ጒༀኸ๖! #" MKQKSÒ ?86 8SJNPF\Nd WTWXTdSNd
V!ࠃ‫ۉۉ‬უฉ‫ۉ‬ SFUVdLKSNd UNXFSNd
N TXW]KXF HVKRKSN
W!ၚᆌჽ้Tvᆶၳ V =TJFST
SFUVdLKSNK UNXFSNd
W 8JKX TXW]KX HVKRK
R:ࣜ෥LED - ๼‫؜‬ी‫ۉ‬ഗ‫ۯ‬ፕጒༀኸ๖!
SN WVFGFX`HFSNd VKQK
V ‫ۯ‬ፕ
LKQXÒ ?86 8SJNPF\Nd WTWXTdSNd
H`[TJSTIT VKQK
V FPXNHNVTHFST
II DIP ਸ࠲
$% 1,'
჋ስCT-MXSࠀీ 4`GTV ZYSP\NN SF "&!
1 ON = ‫ڇ‬ஞ؋݀ิഗǈᅜOFFਸ๔ 5KSKVFXTV TJNST]S`[ NRUYQaWTH
2 ON = ཚ/܏‫ۉ‬ჽ้ǈჽ้้क़փ၎‫ڪ‬ SF]FQT TXW]KXF W HVKRKSN UFYM`
3 ON = ཚ‫ۉ‬ஞ؋ჽ้ࢅ܏‫ۉ‬ஞ؋ჽ้
4`JKVLPF UVN WVFGFX`HFSNN N
4 ON = ࿮ᆖၚ H`JKVLPF UVN TXUYWPFSNN
໯ᆶ ON = ON/OFF֪๬ࠀీ FWWNRKXVN]SFd
໯ᆶ!OFF = ஞ؋݀ิഗǈᅜONईOFFਸ๔ 8RUYQaW UVN WVFGFX`HFFSNN N
‫׍؜‬ఐණ࿋ዃ: NRUYQaW UVN TXUYWPFSNN
໯ᆶਸ࠲‫ت‬ᇀOFFጒༀ SKX ZYSP\NN
4WK ZYSP\Nd 49:4D9:
4WK 5KSKVFXTV NRUYQaWTH SF]FQT
TXW]KXF W HVKRKSN NRUYQaWF
NQN HVKRKSN UYFM`
?TWXTdSNK UTWXFHPN
4WK UKVKPQc]FXKQN H UTQTLKSNN 4D9:
III ‫ۉ‬ഘ૶থ '%,&# $# 1,"

၎࠲‫ۉۉࠃڦ‬უࢅথ၍࣮ୟǈ <TRNSFQaSTK SFUVdLKSNK UNXFSNd
! ! ൩֖ੂ้क़ी‫ۉ‬ഗ֨௬‫ڦ‬Քധ! N W[KRY WTKJNSKSNO WR SF bXNPKXPK
SF GTPY UVNGTVF

<FUVdLKSNK UNXFSNd #0
A1-A2 Usࠃ‫ۉۉ‬უ
' AUVFHQdc_NO H[TJ JQd MFUYWPF
A1-Y1/B1 ऺ้ਸ๔੦዆๼෇
HVKRKSS`[ ZYSP\NO
Z2-Z3/Z1 ‫ڼ‬ᅃĂ‫ܾڼ‬ᇺ‫ۉײ‬࿋ऺۙবჽ‫้׿‬क़
(
(( =TJWTKJNSKSNK IT
IT H`STWSTIT
! ! ‫ྔړ‬থᇺ‫ۉײ‬࿋ऺࢫǈी‫ۉ‬ഗമ௬ӱ้ۨ‫!ۉ‬
UTXKS\NTRKXVF JQd XTSPTO SFWXVTOPN
! ! ࿋ऺ฿ၳ
HVKRKSN MFJKVLPN =VN UTJPQc]KSNN
15-16/18 ‫ڼ‬ᅃ๼‫ۅة؜‬
HSK^SKIT UTXKS\NTRKXVF HWXVTKSSÒ
25-26/28 ‫ܾڼ‬๼‫ۅة؜‬
UTXKS\NTRKXV SF QN\KHTO UFSKQN
FHXTRFXN]KWPN TXPQc]FXKWd
Ò UP

TO UP
6
IV Function diagrams
1 DE 6 DB
A1-A2
2CDC 252 075 F0207

A1-Y1/B1
15-18, 25-28
15-16, 25-26
green LED
t1 t2 t2 t1
t1 = adjusted OFF time

t2 = adjusted ON time
2 EC 7 CA
3 AB 8 AC
4 CE 9 BC
5 DA 10 A
A1-A2
2CDC 252 013 F0207
15-18, 25-28
15-16, 25-26
green LED
t <t
t = adjusted time delay
11 G
7
8
IV Funktionen Deutsch
CT-MXS
1 DE Taktgeber, impuls- oder pausebeginnend
t1 eingestellte Pausenzeit
t2 eingestellte Impulszeit
2 EC Einzeltaktgeber, pausebeginnend
3 AB Ansprech- und Rückfallverzögerung,
asymmetrisch
t1 eingestellte Ansprechverzögerungszeit
t2 eingestellte Rückfallverzögerungszeit
4 CE Ein- und Ausschaltwischer
t1 eingestellte Wischzeit 1
t1 und t2 sind unabhängig voneinander einstellbar
CT-WBS
5 DA Blinker, impulsbeginnend
t eingestellte Blinkzeit
6 DB Blinker, pausebeginnend
7 CA Einschaltwischer
t eingestellte Wischzeit
8 AC Verzögerter fester Impuls
t1 eingestellte Verzögerungszeit
t2 Impulszeit fix 500 ms
9 BC Einstellbarer Impuls, fest verzögert
t2 Verzögerungszeit fix 500 ms
10 A Ansprechverzögerung
t eingestellte Verzögerungszeit
11 G ON/OFF-Funktion
ON-Funktion - Zeitbereich ≠ 300 h
OFF-Funktion - Zeitbereich = 300 h
Legende:
LED grüne LED blinkt während Zeitfablauf
A1-A2 Steuerspeisespannung
A1-Y1/B1 Steuereingang (potentialbehaftete Ansteuerung)
G Steuerspeisespannung liegt nicht an /
Ausgangskontakt geöffnet
B Steuerspeisespannung liegt an /
Ausgangskontakt geschlossen
Weitere Details zu den Funktionen und den

technischen Daten entnehmen Sie bitte dem Katalog.
9
IV Functions English IV Fonctions Français
CT-MXS CT-MXS
1 DE Pulse generator, starting with ON or OFF 1 DE Générateur d’impulsion, démarrant par
t1 adjusted OFF time marche ou par arrêt
t2 adjusted ON time t1 temps d’arrêt affiché
2 EC Single pulse generator, starting with OFF t2 temps de marche affiché
t1 adjusted OFF time 2 EC Générateur d’impulsion unique,
t2 adjusted ON time démarrant par arrêt
3 AB ON-delay and OFF-delay, asymmetrical t1 temps d’arrêt affiché
t1 adjusted ON-delay t2 temps de marche affiché
t2 adjusted OFF-delay 3 AB Temporisation au travail et Repos, asymétrique
4 CE Impulse-ON and impulse-OFF t1 temporisation au travail affichée
t1 adjusted pulse time 1 t2 temporisation au repos affichée
t2 adjusted pulse time 2 4 CE Contact de passage à l’activation et à la
t1 are t2 independently adjustable désactivation
t1 temps d’impulsion 1 affiché
CT-WBS t2 temps d’impulsion 2 affiché
5 DA Flasher, starting with ON t1 et t2 sont affichables indépendamment un de l’autre
t adjusted flashing time
6 DB Flasher, starting with OFF CT-WBS
t adjusted flashing time 5 DA Clignotant, démarrant par marche
7 CA Impulse-ON t temps de clignotement affiché
t adjusted pulse time 6 DB Clignotant, démarrant par arrêt
8 AC Fixed impulse with adjustable time delay t temps de clignotement affiché
t1 adjusted time delay 7 CA Contact de passage à l’activation
t2 fixed pulse time of 500 ms t temps d’impulsion affiché
9 BC Adjustable impulse with fixed time delay 8 AC Impulsion fixe avec temporisation affichable
t1 adjusted pulse time t1 temporisation affichée
t2 fixed time delay of 500 ms t2 temps d’impulsion fixe 500 ms
10 A ON-delay 9 BC Impulsion affichable avec temporisation fixe
t adjusted time delay t1 temps d’impulsion affiché
11 G ON/OFF-Function t2 temporisation fixe 500 ms
ON-Function - time sector ≠ 300 h 10 A Temporisation au travail
OFF-Function - time sector = 300 h t temporisation affichée
11 G Fonction ON/OFF
Fonction ON - plage de temporisation ≠ 300 h
Fonction OFF - plage de temporisation = 300 h
Legend: Légende:
LED Green LED flashes whilst timing LED La LED verte clignote pendant la temporisation
A1-A2 Control supply voltage A1-A2 Tension d’alimentation de commande
A1-Y1/B1 Control input (voltage-related triggering) A1-Y1/B1 Entrée de commande (activation par tension)
15-16/18 1st c/o contact 15-16/18 1er inverseur
25-26/28 2nd c/o contact 25-26/28 2ème inverseur
G Control supply voltage not applied / G Tension d’alimentation de commande non
output contact open appliquée / contact de sortie ouvert
B Control supply voltage applied / B Tension d’alimentation de commande
output contact closed appliquée / contact de sortie fermé
Pour de plus amples détails sur les fonctions et les

For further details on functions and technical data, données techniques, consultez s’il vous plaît, notre
please see our catalog. catalogue.
10
IV Funciones Español IV Funzioni Italiano
CT-MXS CT-MXS
1 DE Generador de impulso, inicio en ON ó en OFF 1 DE Generatore di impulsi, inizio con ON o OFF
t1 tiempo en OFF ajustado t1 tempo OFF impostato
t2 tiempo en ON ajustado t2 tempo ON impostato
2 EC Generador de un único pulso, inicio en OFF 2 EC Generatore di singolo impulso, inizio con OFF
3 AB Retardo a la conexión y a la desconexión, 3 AB Ritardo all’eccitazione ed alla diseccitazione,
asimétrico asimmetrico
t1 retardo a la connexion ajustado t1 ritardo all’eccitazione impostato
t2 retardo a la desconnexion ajustado t2 ritardo alla diseccitazione impostato
4 CE Pulso a la conexión y a la desconexión 4 CE Impulso all’eccitazione ed alla diseccitazione
t1 tiempo de pulso 1 ajustado t1 tempo d’impulso 1 impostato
t1 y t2 pueden ajustarse por separado t1 e t2 sono impostabile indipendentemente uno dell’altro
CT-WBS CT-WBS
5 DA Intermitencia, inicio en ON 5 DA Lampeggiatore, inizio con ON
t tiempo de intermitencia ajustado t tempo di lampeggiamento impostato
6 DB Intermitencia, inicio en OFF 6 DB Lampeggiatore, inizio con OFF
7 CA Pulso a la conexión 7 CA Impulso all’eccitazione
t tiempo de pulso ajustado t tempo d’impulso impostato
8 AC Pulso fijo con tiempo de retardo ajustable 8 AC Impulso fisso con tempo di ritardo impostabile
t1 tiempo de retardo ajustado t1 tempo di ritardo impostato
t2 tiempo de pulso fijo de 500 ms t2 tempo d’impulso fisso 500 ms
9 BC Pulso ajustable con tiempo de retardo fijo 9 BC Impulso impostabile con tempo di ritardo fisso
t1 tiempo de pulso ajustado t1 tempo d’impulso impostato
t2 tiempo de retardo fijo de 500 ms t2 tempo di ritardo fisso 500 ms
10 A Retardo a la conexión 10 A Ritardo all’eccitazione
t tiempo de retardo ajustado t tempo di ritardo impostato
11 G Función ON/OFF 11 G Funzione ON/OFF
Función ON - margen de temporización ≠ 300 h Funzione ON -
Función OFF - margen de temporización = 300 h campo di temporizzazione ≠ 300 h
Funzione OFF -
campo di temporizzazione = 300 h
Leyenda: Leggenda:
LED El LED verde parpadea durante la LED Il LED verde lampeggia durante il trascorrere
temporización del tempo
A1-A2 Tensión de alimentación A1-A2 Tensione d’alimentazione
A1-Y1/B1 Entrada de mando A1-Y1/B1 Ingresso di comando (pilotaggio con tensione
(disparo con potencial) di riferimento )
15-16/18 1er. contacto conmutado 15-16/18 1° contatto di scambio
G Tensión de alimentación no aplicada / G Tensione d’alimentazione non applicata /
contacto de salida abierto contatto d’uscita aperto
B Tensión de alimentación aplicada / B Tensione d’alimentazione applicata /
contacto de salida cerrado contatto d’uscita chiuso
Per ulteriori informazioni su dettagli tecnici e

Para más información en funciones y datos técnicos, funzionalità dei prodotti Vi preghiamo di consultare
por favor consulte nuestro catálogo. il nostro catalogo tecnico.
11
>YWWPNO
IV ࠀీ!!!!! DO! ("+

CT-MXS DE 5KSKVFXTV NRUYQaWTH SF]FQT TXW]KXF
1 DE ஞ؋݀ิഗǈᅜpoईpgg!ਸ๔ W HVKRKSN NRUYQaWF NQN UFYM`
t1 off ้क़ۙব 1 VKIYQNVYKRTK HVKRd UFYM`
t2 on ้क़ۙব 1
VKIYQNVYKRTK HVKRd NRUYQaWF
2 EC ‫ڇ‬ஞ؋݀ิഗǈᅜOFFਸ๔
EC 5KSKVFXTV TJNST]S`[ NRUYQaWTH
t1 off ้क़ۙব SF]FQT TXW]KXF W HVKRKSN UFYM`
t2 on ้क़ۙব 1 VKIYQNVYKRTK HVKRd UFYM`
3 AB ཚ/܏‫ۉ‬უჽ้ǈჽ้้क़փ၎‫ڪ‬ 1
t1 on ้क़ۙব AB 4`JKVLPF UVN WVFGFX`HFSNN
t2 off ้क़ۙব N H`JKVLPF UVN TXUYWPFSNN
4 CE ཚ‫ۉ‬ஞ؋ჽ้ࢅ܏‫ۉ‬ஞ؋ჽ้ FWWNRKXVN]SFd
t1 ஞ؋้क़2ۙব 1 VKIYQNVYKRFd H`JKVLPF UVN
t2 ஞ؋้क़3ۙব WVFGFX`HFSNN
t1 ๟ t2 ‫܀‬૬‫ۙڦ‬ব 1
VKIYQNVYKRFd H`JKVLPF UVN
TXUYWPFSNN
CT-WBS CE 8RUYQaW UVN WVFGFX`HFSNN
5 DA ཚ‫ۉ‬෻ຮǈᅜଋༀONਸ๔ N NRUYQaW UVN TXUYWPFSNN
t ෻ຮ้क़ۙব 1 VKIYQNVYKRTK HVKRd NRUYQaWF
6 DB ཚ‫ۉ‬෻ຮǈᅜӁༀOFFਸ๔ 1
t ෻ຮ้क़ۙব 1 N 1
VKIYQNVYcXWd TXJKQaST
7 CA ཚ‫ۉ‬ஞ؋ჽ้
t ஞ؋้क़ۙব
8 AC ჽ้้क़੗ۙǈࠦۨஞ؋้क़ DA ;NIFSNK W SF]FQTR NRUYQaWF
t1 ჽ้้क़ۙব 1 VKIYQNVYKRTK HVKRd RNIFSNd
! ! t2 ࠦۨஞ؋้क़611!nt DB ;NIFSNK W SF]FQTR UFYM`
9 BC ੗ۙஞ؋้क़ǈࠦۨჽ้้क़ 1 VKIYQNVYKRTK HVKRd RNIFSNd
t1 ஞ؋้क़ۙব CA 8RUYQaW UVN WVFGFX`HFSNN 49:
! ! t2 ࠦۨჽ้้क़611!nt 1 VKIYQNVYKRTK HVKRd NRUYQaWF
10 A ཚ‫ۉ‬ჽ้ AC BNPWNVYKRÒ NRUYQaW W
t ჽ‫้׿‬क़ۙব VKIYQNVYKR`R HVKRKSKR MFJKVLPN
11 G ON/OFF֪๬ࠀీ 1 VKIYQNVYKRTK HVKRd MFJKVLPN
ON -ࠀీ-้क़ਗ਼‫ ܈‬300ၭ้ 1
HVKRd ZNPWNVTHFSSTIT NRUYQaWF
OFF-ࠀీ-้क़ਗ਼‫ =܈‬300ၭ้ RW
BC >KIYQNVYKRÒ NRUYQaW W ZNPWNVTHFS
S`R HVKRKSKR MFJKVLPN
1 VKIYQNVYKRTK HVKRd NRUYQaWF
1
ZNPWNVTHFSSTK HVKRd MFJKVLPN
RW
A 7FJKVLPF UVN WVFGFX`HFSNN
1 VKIYQNVYKRTK HVKRd MFJKVLPN
G BYSP\Nd 49:4D9:
཮๖: BYSP\Nd 49: HVKR WKPXTV ]
LED ऺ้ዐ୴෥LED෻ຮ BYSP\Nd 4D9: HVKR WKPXTV ]
A1-A2 ࠃ‫ۉۉ‬უ
A1-Y1/B1 ੦዆๼෇Ǆ߅থ‫ۅ‬ǅ
15-16/18 ‫ڼ‬ᅃ‫ۅة‬ #","2
25-26/28 ‫ۅةܾڼ‬ ?86 7KQKSÒ ?86 RNIFKX UVN TXW]KXK
G ࠃ‫ۉۉ‬უ࿄ฉ‫ ۉ‬/ ๼‫܏ۅة؜‬ਸ HVKRKSN
B ࠃ‫ۉۉ‬უฉ‫ ۉ‬/ ๼‫ۅة؜‬Կࢇ
<FUVdLKSNK UNXFSNd
' AUVFHQdc_NO H[TJ W MFUYWPTR
HVKRKSS`[ ZYSP\NO UTJF]KO
SFUVdLKSNd UNXFSNd SF H[TJ YUVFHQKSNd
Ò UP

TO UP
G <FUVdLKSNK UNXFSNd TXWYXWXHYKX
H`[TJSTO PTSXFPX VFMTRPSYX
B <FUVdLKSNK UNXFSNd UTJFST
H`[TJSTO PTSXFPX MFRPSYX
#$# "' /"(1")#%!+1#)("+2*

߸‫ీࠀܠ‬႑တतरຍጨଙǈ൩֖ੂᄣԨă '*",&*$%!'%* &!"-!
' #
12
Position: FC001,FC002
Part code: M004140
9.9 Frequency converter - FC-202
ID: D11592
VLT AQUA Drive FC202 Frequency converter

1 Connection
1.1 Power and supply terminals
Mains DC link circuit Motor
Terminal no. Description Remarks
91 (L1), 92 (L2), 93 Three-phase connection for mains supply

(L3)
95 PE conductor connection Use minimum 10 mm2. See note below.
96 (W), 97 (V), 98 Three-phase motor connection See nameplate for nominal data
(W)
99 PE conductor connection Equipotential bonding for motor
88 (-), 89 (+) Capacitor-backed DC link circuit intended Note: maximum voltage 850–1000 V DC.
for coupling several drive axes
81 (-), 82 (+) Optional brake resistor connection for Note: maximum voltage 850–1000 V DC.
increased dynamic braking
35 (-), 36 (+) MCB 107 D option: connection for optional Max. 24 V DC +/- 15%
external 24 V power supply for control Max. Input current 2.2 A
electronics (plug-and-socket connector).
As frequency converters can produce earth leakage currents greater than 3.5
mA due to their mode of operation, in accordance with EN 50178 an earth
conductor with a cross-section of at least 10 mm2 must be used or two
separately installed earth conductors must be connected.

FIN-20101 TURKU Fax + 358 204 86 5031
ID: D11592
1.2 Control terminals in basic unit (without A, B or C options)
See Section 1.3 for a description of switches S201, S202 and S801. The maximum rated
voltage on analogue inputs 53 and 54 is 20 V.

FIN-20101 TURKU Fax + 358 204 86 5031
ID: D11592
Term Description Remarks

inal
12, 13 Internal +24 V DC source for powering digital inputs. Maximum load 200 mA
no.
18 Digital input (see parameter 5-10 for function) 0–24 V DC, Ri = 4 kΩ
19 Digital input (see parameter 5-11 for function) < 5 V = logic “0” (PNP logic)
> 10 V = logic “1” (PNP logic)
20 Reference potential (0 V) for external digital input/output Frame potential for terminals 12, 13
configuration
27 Digital input/output (see parameters 5-01, 5-12 & 5-30 for Input: see terminals 18 and 19
29 function)
Digital input/output (see parameters 5-02, 5-13 & 5-31 for Output: 0/24 V DC, max. 40 mA Pulse
function) output: see product manual
32 Digital input (see parameter 5-14 for function) Input: see terminals 18 and 19 Pulse
33 Digital input (see parameter 5-15 for function) input: see product guide
Only for FC 200 with optional safe stop To achieve the safety function, the
37 Digital input for safe stop compliant with EN 954-1 Cat. 3 or information in the design guide must
EN 13849-1 SIL 2 (see parameter 5-19 for function) be observed.
39 Ground potential for analogue output 42
42 Scalable analogue output 0/4–20 mA (see parameter 6.5* for 0/4–20 mA, 500 Ω max.
function)
50 Internal +10 V DC power source, for example, for supplying 10 V DC, max. 15 mA
potentiometer or motor thermistor
Analogue inputs 0–10 V DC or 0/4–20 mA, selectable for 0 to +10 V, scalable, Ri approx. 10 kΩ;
reference/feedback or motor thermistor 0 to 20 mA, scalable, Ri approx. 200
53, 54 (function: terminal 53, see parameter 6-1*; terminal 54, see Ω V/mA selection; see S201/S202
parameter 6-2*; Note: maximum voltage on analogue
reference, see parameters 3-15, 3-16 & 3-17; feedback, see inputs
parameter 20-0*; motor thermistor, see parameters 1-93 & 1- 20 V.
90)
55 Ground potential for analogue inputs 53 and 54
61 Integrated RC decoupling Do not use
68 (+), RS 485 serial interface (see parameter 8-3* for function) Max. 115 kbit/s
69 (-)
01, 02, Relay output 1 (see parameter 5-40 [0] for function) Max. 240 V AC, 2 A (resistive load)
03 See the design guide for further
information.
04, 05, 06 Relay output 2 (see parameter 5-40 [1] for function)

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1.3 Function of DIP switches in basic unit (without A, B or C

options)
Changes to DIP switch settings become effective only after switching off and then on
again.
1.4 Digital input programming options

Terminal no. Index 18 19 27 29 32 33
Parameter 5-10 5-11 5-12 5-13 5-14 5-15
Not used [0] x x
Alarm reset [1]
Coast (inverse) [2] x
Coast/Reset (inverse) [3]
Quick stop ramp (inverse) [4]
DC brake (inverse) [5]
Stop (inverse) [6]

Ext. interlock [7]
Start [8] x
Latched start pulse [9]
Reversing [10]
x
Start + reversing [11]
Fixed speed (jog) [14]
Fixed reference enabled [15]

Fixed reference bit 0 [16]

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Parameter 5-10 5-11 5-12 5-13 5-14 5-15
Store reference [19]
Store speed [20]
Speed up [21]
Speed down [22]
Set-up select bit 0 [23]
Counter input [30] - - - -

Pulse input [32] - - - -
Ramp bit 0 [34]
Mains failure (inverse) [36]
Run Permissive [52]
Manual Start [53]
Auto start [54]
DigiPot Increase [55]
DigiPot Decrease [56]
DigiPot Clear [57]
Counter A (+1) [60] - - - -

Counter A (-1) [61] - - - -
Reset Counter A [62]
Counter B (+1) [63] - - - -

Counter B (-1) [64] - - - -
Reset Counter B [65]
Sleep Mode [66]
Reset Maintenance Word [78]
Lead Pump Start [120]
Lead Pump Alternation [121]
Pump 1 Interlock [130]
[ ] = selectable; [-] not selectable; [x] = factory setup. See programming manual for details.

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2 Operation via LCP 102

2.1 Graphical control unit LCP 102
2.2 Explanation of LCP 102 status display

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3 Easy commissioning
3.1 Commissioning menu (submenu Q2 of Quick Menu)
The commissioning menu has a set of 11 parameters that are necessary during
typical commissioning. These parameters are arranged logically instead of by
number. Note: always enter the parameters in the order shown. To access the
commissioning menu, press the [Quick Menu] button, select „Q2 commissioning
menu“, and confirm with [OK]. Press the [Status] button to return to normal view.
Par. Description Setting

0-01 Language English [0] or set to local language
1-20 Motor power [kW] According to motor nameplate data
1-22 Motor voltage [V] According to motor nameplate data
1-23 Motor frequency [Hz] According to motor nameplate data
1-24 Motor current [A] According to motor nameplate data
1-25 Rated motor speed [rpm] According to motor nameplate data
3-41 Ramp-up time 1 Set ramp-up time (acceleration time up to rated motor speed)
3-42 Ramp-down time 1 Set ramp-down time (deceleration time from rated speed to zero RPM)
4-12 Min. speed [RPM] Set desired minimum speed
4-14 Max. speed [RPM] Set desired maximum speed
1-29 Automatic Motor Adaptation (AMA) AMA is worthwhile if motor operation is unsatisfactory or
additional optimisation is desired.
See the description of AMA in the product guide.

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3.2 Other commonly used parameters in the main menu

The following table lists other parameters in the main menu that are often
necessary in addition to the commissioning parameters. The parameters in the
main menu can be accessed by pressing the [Main Menu] button and selecting the
subgroups.

1-00 Control response Speed control or PID control
[0] compressor torque, [1] square-law torque, [2] automatic energy
1-03 Load torque characteristics optimisation CT, [3] automatic energy optimisation VT
1-9* Thermal motor protection Motor temperature monitoring, see description under 6. Application
examples:
3-10 Fixed references (0–7) Use digital fixed references
3-15 Variable reference 1
3-16 Variable reference 2 Select an analogue input, digital input or bus port as the
3-17 Variable reference 3 reference signal. See also description under 6. Application
examples:
6-1* Analogue input, terminal 53 Input signal scaling (current/voltage) and the associated reference and
feedback values.
6-2* Analogue input, terminal 54 Input signal scaling (current/voltage) and associated reference and
feedback values.
20-0* Feedback Specify feedback inputs and signal characteristic
Specify signal conditioning here when using several feedback values

20-2* Feedback/reference and/or additional reference values.
15-0* Operating data Display of current operating data
15-3* Fault log Read out fault log data and values
15-43/-45/-51: frequency converter identification. This information is

15-4* Type data necessary for service queries.
14-50 RFI filter Must be disabled if the unit is used in an IT network.
of all current frequency converter and system data (such as reference,

16-** Data display feedback, bus, motor, and FC data)

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3.3 Using the LCP copy function (parameter 0 -50) to transfer device
parameters
The copy function can be used to store all unit parameters in the LCP 102 control
panel. The stored parameters can be transferred to the same unit of other units if
necessary. The data is permanently stored (in EEPROM) in the LCP and can only
be changed or deleted by overwriting with new data. The parameters in the LCP
memory can only be accessed by loading them back from the unit. Parameter 0-50
can be accessed by pressing the [Main Menu] button and selecting menu „0-**
Operation/Display“ or „0-5* Copy/Store“.
No motor data is transferred if „Load from LCP, only Fct.“ is selected.
3.4 Parameter setting with MCT 10 software

Source and system requirements
Download the software from the Software/MCT 10 Software page at
www.danfoss.com/drives
The free basic version of the MCT 10 software can be used to archive data from
and document all current Danfoss frequency converter series. The CD key
required for installation is 12314500.
Minimum system requirements: Pentium III 350 MHz (or compatible), 128 MB
RAM, 200 MB free hard drive space.

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Data exchange with the converter
Converter -> PC:

1. Connect the converter to the PC
2. Select the converter in the network
3. Select „Copy“
4. Click the project and select „Add“
5. Save the project in the File menu
PC -> Converter:
1. Open the saved file
3. Select the converter in the project
4. Select „Write to frequency converter“
Access via USB port
The connection between the converter and PC is detected automatically. Configuration

of the parameters in the converter or the PC software is not necessary

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Access via RS-232, Ethernet, or USB Converter
Every Danfoss converter has a bus-capable RS-485 interface. It supports up to 32

network nodes (127 with repeaters).
For access to the interface, a suitable converter (RS-232 to RS-485, USB to RS-485, or
Ethernet TCP/IP to RS-485) is necessary.
Connection
How to connect
In order to use the connection and configure the converter, the interface
settings of the MCT 10 software (Communication -> Driver menu) must be
compatible (address range, COM port and baud rate). You can use the
Communication -> Network Search menu item to look for connected
converters.
4 Profibus DP interface
4.1 General settings
Parameter Description Setting
8 - 10 Control Word Profile See PLC
9 - 18 Profibus node address (set all address DIP 0–125

switches to „ON“)
9 - 22 PPO type Automatic
9 - 63 Baud rate Automatic
The settings do not take effect until the Profibus interface has been initialised
(use parameter 9-72 to reset the interface or switch the external 24 V supply
off and back on).

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4.2 Further settings

8 - 01 Control Site Activate control word
8 - 02 Active control word Option A
8 - 50 … 8 - 56 Priorities between bus/terminal operation (observe parameter 8-01) Application dependent
8 - 03 … 8 - 05 Control word timeout (defined response to bus failure) Application dependent
8 - 07 Diagnosis Trigger (disable in case of doubt) See PLC
9 - 15 … 9 - 16 PCD Configuration See PLC
9 - 27 … 9 - 28 PCW/PCD enabled/disabled Enabled
5 Fault analysis
5.1 Warnings, alarms, and alarm resetting
Warning (yellow Warning LED on)
A warning is an indication of a defined state. Warning indications
can occur during normal operation; they may be purely informative
(uncritical) or indicate a potential problem. Analyse the warning
based on the displayed warning number [Wxxx].
Alarm (red Alarm LED blinks)

Alarm indications occur when motor operation has been inhibited
by the FC 200 for safety reasons. Analyse the alarm based on the
displayed alarm number [Axxx]. There are several ways to reset
alarms that are „trip- locked“ after the cause has been remedied:
- [Reset] button on LCP

- Programmed digital input (see parameter settings in group 5-1*)
- Automatic reset function (see parameter settings in group 14-2*)
- Reset signal via bus interface (such as RS-485 or Profibus)
The reset signal resets the frequency converter after an alarm (trip). The button can be
enabled [1] or disabled [0] with parameter 0-43, “LCP Reset button”.
Warning
Before resetting an alarm, always determine and remedy the cause. Resetting an alarm
without adequately determining the cause can lead to damage to the frequency converter
or system as well as serious accidents.

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Trip-locked alarm (red Alarm LED blinks, alarm cannot be reset, and „Trip-lock“ is
displayed on the control panel (if present))
Trip-lock is an additional protective function of the VLT AQUA Drive

and can only be cancelled by disconnecting mains power to the unit.
If the unit has an external 24 V DC supply (D option), it is only
necessary to disconnect the unit from the mains supply voltage. In
this case, the control card remains active (for example, to support
fieldbus communication).
The alarm can be reset again as previously described after the VLT
AQUA Drive FC 200 has been switched off and on.
If the display still shows a trip-lock after the unit has been switched
off (before the alarm is reset), the unit may have an internal fault.
Contact your Danfoss Service provider in this case.
5.2 If the drive does not restart after an alarm reset

An alarm is still displayed Setting
1. Is the alarm trip-locked? See description in Section 5.1.
2. Has the cause of the alarm been remedied, or is the
alarm displayed again immediately after it is reset?
View the alarm numbers in the fault/alarm log and
use them to determine the cause of the alarm.
3. Is the LCP [Reset] button enabled? See parameter 0-43
An alarm is no longer displayed Setting

1. Is the LCP [Off] button enabled? Press the [Auto-On] button to restart.
2. Is a start signal present on the digital input or bus Check whether a start signal is present on the digital
interface? input or the bus.
3. Is a reference value available on an analogue or digital Check the reference value.
input or the bus interface?
4. Is there an open circuit between the frequency Check the motor wiring. Is a contactor or motor switch
converter output and the motor? present?

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5.3 Warning and alarm indications

No. Description Warning Alarm / trip Alarm / Trip-lock See parameter
1 10 V low X
2 Signal fault (X) (X) 6-01
3 No motor (X) 1-80
4 Mains phase imbalance (X) (X) (X) 14-12
5 DC link voltage high X
6 DC link voltage low X
7 DC overvoltage X X
8 DC undervoltage X X
9 Inverter overloaded X X
10 Motor ETR overtemperature (X) (X) 1-90
11 Motor thermistor (X) (X) 1-90
12 Torque limit X (X) 14-25
13 Overcurrent X X X
14 Earth fault X X X
15 Hardware mismatch X X
16 Short circuit X X
17 Control word time-out (X) (X) 8-04
23 Internal fan fault (X) (X) 14-53
24 External fan fault (X) (X) 14-53
25 Brake resistor shorted X
26 Brake resistor power limit (X) (X) 2-13
27 Brake chopper shorted X X
28 Brake resistor test (X) (X) 2-15
29 Inverter overtemperature X X X
30 Motor phase U dropout (X) (X) (X) 4-58
31 Motor phase V dropout (X) (X) (X) 4-58
32 Motor phase W dropout (X) (X) (X) 4-58
33 Inrush fault X X
34 Fieldbus fault X (X)
36 Mains failure X X
38 Internal fault X X
40 Overload digital output 27 X 5-00, 5-01
42 Overload on digital output X
47 30-6/30-7
24 V supply low X X X
48 1.8 V supply low X X
49 Speed limit X
50 AMA calibration fault X
51 AMA check Unom and Inom X
52 AMA low Inom X
53 AMA motor too big X
54 AMA motor too small X
55 AMA parameter out of range X
56 AMA interrupted by user X
57 AMA timeout X
58 AMA internal fault X X
59 Current limit X
60 Ext. interlock (X) 5-1*
62 Output frequency limit X 4-19
64 Motor voltage X
65 Control board X X X
66 overtemperature
Temperature low X
67 New options X
68 Safe stop X
69 Inverter overtemperature X X
70 Invalid FC configuration X X
79 Invalid PS configuration X X
80 Unit initialised X
92 K. flow X X 22-23
93 Dry pump X X 22-26
94 End of curve X X 22-50
95 Broken belt X X 22-60
96 Start delay X 22-75, 22-76
97 Stop delay X 22-75, 22-77
98 Clock fault X 0-7*
250 New spare part
251 New type code

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6 Application examples
6.1 Start/stop, four pole motor, motor thermistor
Reference 0 –50 Hz via terminal 53; motor thermistor
monitoring on terminal 19.
Visual alarm indication.
Relevant parameters
Par. Function Setting
0-02 Hz/rpm selection [1] Hz
1-25 Rated motor speed see motor nameplate
5-10 Terminal 18: digital input [8] Start*

5-11 Terminal 19: digital input [0] Not used
1-90 Motor thermal protection [2] Thermistor trip

1-93 Thermistor connection [4] Digital input 19
3-15 Variable reference 1 [1] Analogue input 53*

4-53 High speed warning 1500 rpm
5-40[0] Relay 1 function [9] Alarm
5-40[1] Relay 2 function [5] Motor running
*Factory setting
This example constitutes a non-binding recommendation with regard to the General

Delivery and Warranty Conditions. It is based on the factory setup and presumes that the
motor data has been configured correctly. This recommendation must be verified by the
user.

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6.2 Start/stop, four-pole motor, oversynchronous, motor

thermistor
0–72 Hz reference value via terminal 53.
Motor thermistor monitoring on terminal 19.
Visual alarm indication
Relevant parameters


3-03 Max. reference 72 Hz

4-14 Max. frequency [Hz] 72 Hz
6-15 Ter. 53 scale max. ref/feedback 72 Hz
*Factory setting

user.

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6.3 Start/stop, two-pole motor, motor thermistor

Reference 0–50 Hz via potentiometer on terminal 53.
Relevant parameters



*Factory setting

user.

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6.4 Start/stop, two-pole motor, oversynchronous, motor

thermistor
Relevant parameters



*Factory setting

user.

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6.5 Start/stop, motor thermistor

Reference 0 –50 Hz terminal 53;
Relevant parameters


5-02 Terminal 29 Mode [1] Output
5-31 Terminal 29: digital output [60] Comparator 0

Interrogation Alarm 11 (motor thermistor)

13-10[0] Comparator operand [20] Alarm number
13-11[0] Comparator function [1] !(equal)*
13-12[0] Comparator value 11,000
*Factory setting

user.

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6.6 Fixed speeds

Three different speeds (preset references) can be selected
via floating contacts.
Relevant parameters

5-11 Terminal 19: digital input [6] Stop (inverse)
5-30 Terminal 27: digital input [70] Logic rule 0
5-13 Terminal 29: digital input [16] Preset ref. bit 0
Internal logic rule

13-40[0] Boolean 1 [36] Digital input 29
13-41[0] Logic operation 1 [2] OR
References
3-10[1] Preset ref.1 Desired Speed 1
*Factory setting

user.

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6.7 Automatic fast ramp

The starts up with fast acceleration and then runs with slow
acceleration. Reference 0–1500 rpm via potentiometer.
Relevant parameters

5-12 Terminal 27: digital input [2] Coast (inverse)*

5-31 Terminal 29: digital output [16] Under min. speed
5-15 Terminal 33: digital input [34] Ramp bit 0
3-41 Ramp Up 1 „Slow“

3-42 Ramp Down 1 „Slow“
3-51 Ramp Up 2 „Fast“
3-42 Ramp Down 2 „Fast“
4-11 Motor speed low limit 900 rpm

4-52 Motor speed low limit warning 900 rpm
*Factory setting

user.

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6.8 Manual/Off/Automatic selection with reference value input via

keypad
In the switch position „Auto“, the reference is active via potentiometer.
In the switch position „Manual“, the reference can be set using the „Up“ and „Down“
buttons.
In the switch position „Off“, the motor is stopped.
Relevant parameters

5-11 Terminal 19: digital input [8] Start

5-13 Terminal 29: digital input [20] Freeze output
5-14 Terminal 32: digital input [21] Speed up
5-15 Terminal 33: digital input [22] Speed down
*Factory setting

user.

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potentiometer
In switch position „Auto“, the reference is active via potentiometer.
In switch position „Manual“, the unit can only be operated via the display.
In switch position „Off“, the motor is stopped.
Relevant parameters

5-11 Terminal 19: digital input [54] Auto start
5-12 Terminal 27: digital input [53] Manual start
*Factory setting

user.

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potentiometer
With Profibus control, the converter does not accept any commands via the terminals.
If Profibus control is interrupted, the converter automatically switches to manual mode
(reference setting via buttons). Manual mode can also be selected via terminal 18.
Relevant parameters
1-1* Motor data see motor nameplate
8-03 Ctrl. param. for timeout time 1 sec

8-04 Timeout function ctrl. param. [8] Select Setup 2
8-05 Timeout End ctrl. param. [1] Resume setup*
9-18 Node address As required
5-10 Terminal 18: digital input [23] Setup select bit 0

5-40[0] Relay function [9] Alarm
5-40[1] Relay function [23] Bus OK
0-51 Setup copy [2] Copy to Setup 2

0-10 Active setup [9] Multi Setup
0-12 Link setup to [2] Setup 2
Settings only for Setup 1

8-01 Control Site Digital only
8-02 Active control parameter Disabled

*Factory setting

user.

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6.11 Pressure control in %

Pressure control with integrated process controller.
Internal reference, feedback 0–100% on terminal 54.
Relevant parameters
Start/Stop
Pressure control
1-00 Control mode [3] PID closed loop
20-12 Reference/feedback unit [1] %*
20-21 Reference 1 50%
20-94 PID integration time 0.8
Feedback signal
20-00 Feedback terminal 1 [2] Analogue input 54*
6-24 Ter. 54 scale min. ref/feedback 0%*
6-25 Ter. 54 scale max. ref/feedback 100%*
Display indication (optional)

0-20 Display line 1.1 [1601] Reference [unit]
0-22 Display line 1.3 [1652] Feedback [unit]
*Factory setting

user.

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6.12 Pressure control in Pa

Internal reference, feedback 0–2000 Pa on terminal 54.
Relevant parameters
Start/Stop
Pressure control
Scaling in Pa
3-02 Min. reference 0 Pa*
3-03 Max. reference 2000 Pa
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 Pa*
6-25 Ter. 54 scale max. ref/feedback 2000 Pa

*Factory setting

user.

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6.13 Pressure control in bar with pipe compensation

Pressure control using integrated process controller with pipe
pressure drop compensation. Internal reference, feedback 0–10 bar
on terminal 54.
Relevant parameters
0-02 Hz/rpm selection [1] Hz*
Start/Stop
Pressure control
20-12 Reference/feedback unit [71] bar
20-21 Reference 1 5 bar
20-93 PID proportional guide 0.5
Scaling in bar
3-02 Min. reference 0 bar*
3-03 Max. reference 10 bar
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 bar*
6-25 Ter. 54 scale max. ref/feedback 10 bar
Pipe compensation
22-80 Flow compensation [1] Enabled
22-81 Quad./lin. curve calculation 100
22-84 Speed at no flow [Hz] 25 Hz
22-86 Freq. design point [Hz] 50 Hz
22-87 Pressure at no-flow speed 3 bar

0-24 Display line 3 [1665] Analogue output 42
*Factory setting

user.

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6.14 Volume flow control in m³/h, feedback signal output 0–20 mA

Volume flow control with integrated process controller.
Internal reference, feedback 0–5000 m3/h on terminal 54.
Feedback output 0–5000 m3/h as 0–20 mA signal on terminal 42.
Relevant parameters
Start/Stop
Volume flow control

20-01 Feedback conversion 1 [1] Square root
20-12 Reference/feedback unit [25] m3/h
20-21 Reference 1 2500 m3/h
20-94 PID integration time 2
Scaling in m3/h
3-02 Min. reference 0 m3/h
3-03 Max. reference 5000 m3/h
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 m3/h *
6-25 Ter. 54 scale max. ref/feedback 5000 m3/h
Analogue output
6-50 Terminal 42: analogue output [102] Feedback 0–20 mA
6-51 Ter. 54 min. scaling 50%
6-52 Ter. 54 max. scaling 75%

*Factory setting

user.

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6.15 Volumetric flow control in m³/h, oversynchronous, feedback

signal output 0–20 mA
Relevant parameters
4-14 Max. frequency [Hz] 72Hz
Start/Stop
Volume flow control

Scaling in m3/h
Feedback signal
Analogue output

*Factory setting

user.

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6.16 Pressure control in bar, basic cascade controller

The VLT® AQUA Drive cascade controller can switch on additional
pumps via the relays if necessary.
Controlled variable 0–10 bar on terminal 54.
Relevant parameters
3-10 Preset ref. [0]
Start/Stop
5-12 Terminal 27: digital input [2] Coast (inverse) *
Pressure control
Scaling in bar
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 bar
20-73 Min. feedback level 0 bar
20-74 Max. feedback level 10 bar
Cascade control
25-00 Cascade controller [1] Enabled
25-05 Preset control group [1] Yes *
25-06 Number of pumps [1] 3 pumps
25-45 Switch-on threshold [Hz] 45 Hz *
Relay
5-40[0] Relay 1 function [212] Casc pump 2 **
*Factory setting
user.

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Section 6
Attachments
D
Component: LFO Feeder Module
Type : Aura Marine
Engines : 16419-27 & 16430-36
BERGEN ENGINES AS
[ BLANK ]
Fuel supply systems
Release Date: 19.12.2017
Language version: EN
Installation, Operating and Maintenance

Manual
Unit type: Unit, feeder

Technical name: AMF-L-50-LFO
Serial Number: 14503
Customer reference: Bangladesh Project
Get an electronic copy here:

AuraMarineManuals
http://bit.ly/AuraMarineManuals
Contact us
Spare parts:
email: spares@auramarine.com
Tel: +358 20 486 6003
Service and maintenance:
email: service@auramarine.com
Tel: +358 20 486 6003
Fuel system sales:
email: sales@auramarine.com
Tel. +358 20 486 5030
www.auramarine.com
Auramarine LTD, Finland

Tel. + 358 20 486 5030
Street address: Postal address:

Keskiläntie 1 P.O. BOX 849
FI-20660 Littoinen FI-20101 Turku
Finland Finland
Auramarine Asia LTD, China

Tel. +86 21 67104305
13 Long Yang Industrial Park

1515 Yuandong Road
Fengpu Industrial Development Zone
Fengxian 201401
Shanghai, P.R.C.
Auramarine Hong Kong LTD

Unit 702, 7/F Bangkok Bank Bldg No. 18
Bonham Strand West
Hong Kong
Table of Contents

General arrangement P14646, - 10

PI Diagram 310059, - 13

Electric drawing 410378, D 17
4 Auramarine customized spare part selection

Auramarine customized spare part selection Spare 39
6 Attachments
14503 Factory certificate - 159
Section 1

11.9.2017 D11344

LFO FEEDER UNIT
TECHNICAL SPECIFICATION

Type: AMF‐L‐50‐LFO
Manufacturer: Auramarine Ltd.

Customer: Bergen Engines India Private Limited.
Project: Bangladesh project

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11344

1. Design Basis

Engine type: 7 x B32:40V16AH
Total power max.: 7 x 7015 kW = 49 105 kW
Fuel consumption max.: 7 x 1.6 m3/h = 11.2 m3/h
LFO viscosity max.: 9 cSt / 38°C
LFO day tank temp.: 40°C
Main voltage: 3x415 V / 50 Hz + neutral
Pressurized air supply: 5‐10 bar, dry, oil free
Required LFO inlet pressure: +0.1 bar (at unit inlet flange)
Design / test pressure: 10 / 15 bar

2. Technical data

LFO feeder pump capacity: 17.5 m³/h, 0/5 bar, 6 cSt (1460 r/min@50 Hz)
Electric motor: IEC160, 11 kW, 1460 r/min (nominal), IE2, IP55, F, B
External cooling fan included

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11344

3. Main Components

Pos. Denomination

B005, B006. Suction strainer
‐ Filtration 400 µm

D005, D006. LFO Feeder pump
‐ One is stand‐by pump while the others are working

V015. Emergency shut off valve
‐ Actuator operated and spring returned (N.C.) ball valve
‐ Valve opens by air when voltage to pilot solenoid valve is
switched on and closes by spring force when voltage is switched off
‐ Equipped with limit switches
‐ Closing the valve stops the pumps

B030. Instrument air filter/regulator
‐ Setting range 0.5 – 10 bar, set point 6 bar (max. 8 bar)
‐ 5 µ filter with manual, self‐relieving drain

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11344

4. Control Automation and Starters

Equipment

Control cabinet
‐ Feeder pump VFCs with stand‐by automatic.
‐ All alarms via profibus interface
‐ On / Off / Remote switches for each emergency shut off valve via profibus
‐ On / Off / Standby / Remote switches for each electric motor of feeder pump via profibus
‐ Control signals to feeder unit
- Opening and closing of each emergency shut off valve
- Starting and stopping of pumps
- Pump preset speed control (1 = 100% speed, 2 = 50% speed, 3 = 30% speed)
‐ Control signals from feeder unit
- Stand‐by pump started
- Analog signal for FO outlet pressure; 0‐10 bar = 4‐ 20 mA
‐ Emergency stop buttons for each pump

‐ Lights at control cabinet
‐ Motor circuit breaker tripped
‐ Pump running
‐ Emergency shut off valve open/ close

5. Instruments

Ind. Denomination
TI Thermometers, liquid pillar type (scale in °C)
PI Manometers, Ø 63 mm, glycerine filled (scale in bar)
PS Pressure switch for local stand‐by automatic
PT Pressure transmitter for FO outlet pressure
GS Limit switches for emergency shut off valve.
Note! These switches interlocked with feeder pumps

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku


11.9.2017 D11344


‐ Equipped with a bottom for leakage oil
‐ Grease gun
‐ Painting system 12944‐5:2007 A2.06 (EP 120/2 FeSa 2½)
‐ Color RAL 5019

Components ‐ Original painting color from manufacturer, i.e. no additional
painting by Auramarine

Piping ‐ Seamless carbon steel St 37.4 DIN 2391
‐ Painting system 12944‐5:2007 A2.06 (EP 120/2)
‐ Color RAL 5019

External connections ‐ EN1092‐1, counter flanges, gaskets, bolts and nuts are included.
‐ Drain connections in the frame are of size R2” (internal thread
connection) as per EN ISO 228‐1. No flanges or pipe adapters at
these connections.

Instrument pipes ‐ Hydraulic pipe St 35.4 DIN 2445.2.2
‐ Copper pipe for instrument air

Valves ‐ Ball, Gate and Globe valves
‐ Nominal pressure class min. 10 bar

7. Revision list

‐

AURAMARINE LTD.
Tel. +358 204 86 5030
Fax +358 204 86 5031
www.auramarine.com

Domicile: Turku

1 2 3 4 5 6 7 8
FC
A A
2050
R 1800
CONTROL PANEL
B B
~80
640 640
C C
45 45
0 0 0
0
R 50
A 350
C 500
0
C 500
B 650
1000
0
A 100
B 2800
2900
400 40
D D
400
18
200
250
S=10
X
DETAIL X
600
E
SCALE 1 : 10
RECOMMENDED SERVICE SPACE Units Sheet Description

mm kg 1 / 1 GENERAL ARRANGEMENT
General tolerances: SFS-EN ISO 13920B AMF-L-50~120-LFO
F SSo 25.08.2017
Checked Date
-
Rev Change
25.8.2017
Date
SSo
Designed www.auramarine.com
Approved
JSa
KSi
Date
25.08.2017
25.08.2017
P14646 -
1 2 3 4
Section 2
Part list
Modified 2017-12-19 Desc 2 AMF-L-50-LFO
S005975 0 PI structure AMF-L-50-LFO 1 1
M003765 0 B030 Filter regulator, air MC104-D10, 5um, Rp1/4" 1 1
M021598 0 B030A Indicator, pressure P1415,0-10,bar,d40,R1/8",B5 1 1
M021751 0 P008 Switch, Pressure MBC5100,1-10,bar,Rp1/4",CO,250V 1 1
CM001215 0 T002 Indicator, temperature JWV-C,0-160,C,L150,R1/2",S1,gold 1 1
S004468 0 V015/E015 Valve, 2/2, actu, switch, solen 720185,SR200,XSWM,NA34,DN150,110V1 1
Section 3
Part list
S005976 3 El. structure AMF-L-50-LFO 1 1
S006145 3 Control panel AMF-L-50-LFO 1 1
M020537 0 Enclosure AE 1100.500, 1000x760x210, ST 1 1
M020603 0 Rail DIN, 35x7.5mm, 2933/2 SL 2.9 1
M002196 0 Cable conduit GF-DIN-SH-A7/5, 50x25 1 1
M002203 0 Cable conduit GF-DIN-SH-A7/5, 75x37.5 .95 1
M002204 0 Cable conduit GF-DIN-SH-A7/5, 75x50 2.5 1
M002205 0 Cable conduit GF-DIN-SH-A7/5, 75x75 .95 1
M003834 0 Cable hose SPZ-20, HF .75 1
M021766 0 Busbar PSK 152, L=1000 mm .5 1
M020692 0 A0Q1 Switch, main OT125F3, 125A, 50kA, 0.75kV 1 1
M020706 0 A0Q1 Handle, padlockable OHYS2AJ, OT16-125, rd/ye 1 1
M020699 0 A0Q1 Accessories Shaft, OXS6x160, OT16-125 1 1
M020502 0 N Terminal block, Screw KE61.2, 50mm2, blue,145A,single 1 1
M020503 0 PE Terminal block, Screw KE61.3, 50mm2,Ye/Gr,145A,single 1 1
M021021 0 A0S1 Button, E-stop MPMT3-10R, 40mm,Twist release 1 1
M020860 0 A0S1 Sign, emergency stop SK615546-2, 70mm, aluminum 1 1
M021018 0 A0S1 Contact holder MCBH-00, 3 contacts 1 1
M021017 0 A0S1 Auxiliary contact MCB-01, 1NC 1 1
M020414 0 A0Q3 Manual motor starter MS132-1,6, 1-1.6A, 690V 1 1
M021139 0 A0T1 Transformer PE400, 380-440/110-230V,1ph 1 1
M020382 0 A0F1,A0F2,A0F3 Circuit breaker, miniature S202-C4, 4A, 400V 1 3
M001997 0 A0A1 Alarm panel LLC-10, DI10DO2R, 24V 1 1
M021889 0 A0S9 Switch, rotary cam OC25G06PNBN00NU3, 1-0-2, 25A, 690V 1 1
M004141 0 A0A2 CPU 750-343, Profibus DP coupler, 24VDC 1 1
M004150 0 A0A2 Cable, fieldbus DEL-37,Serial extension cable, 2m 1 1
Part list
M004143 0 A0A2.0 Power supply module 750-602, 24VDC 1 1
M002560 0 A0A2.1 DI Module 750-1405, 16 DI, 24VDC 1 1
M004144 0 A0A2.2 DO Module 750-1504, 16 DO, 24VDC 1 1
M004145 0 A0A2.5 AI Module 750-455, 4 AI, 24VDC 1 1
M004146 0 A0A2.6 AO Module 750-555, 4 AO, 24VDC 1 1
M002562 0 A0A2.7 Accessories 750-600, end module 1 1
M020346 0 A0K10-A0K20 Relay, miniature 46.52.9.024.0074, 24DC, 2CO 1 10
M020343 0 A0K10-A0K20 Relay interface module 97.52SPA, screwless 1 10
M004149 0 A0K10-A0K20 Accessories Diode, 99.02.3.000.00, 6-220DC 1 10
M021897 0 A1S1,A2S1 Switch, rotary cam OC25G06PNBN00S031F, 1-0-2-3, 25A, 1 2
690V
M002182 0 A5K1 Relay, time CT-MBS.22P, 24-240V, 2CO 1 1
M020335 0 A5K2,A6K2 Auxiliary contact CA4-01-T, 1NC 1 2
M020328 0 A5K4,A6K4 Relay, control NF40E-13, 100-250V, 4NO 1 2
M020321 0 A5Q2,A6Q2 Contactor AF09-30-10-13, 100-250V 1 2
M002263 0 A5Q1,A6Q1 Accessories Fuse holder, 22x58mm, 3 poles 1 2
M002258 0 A5Q1,A6Q1 Fuse Ceramic tube, 22x58mm, 32A, 690V 1 6
M020448 0 A0Q3,A5Q1.1,A6Q1.1 Accessories Power infeed block, S1-M1-25 1 3
M020412 0 A5Q1.1,A6Q1.1 Manual motor starter MS132-0.63, 0.4-0.63A, 690V 1 2
M020427 0 A5Q1.1,A6Q1.1 Auxiliary contact HKF1-11, 1xNO 1xNC 1 2
M020428 0 A5Q1.1,A6Q1.1 Auxiliary contact HK1-20, 2xNO 1 2
M020431 0 A5Q1.1,A6Q1.1 Auxiliary contact SK1-11, 1xNO 1xNC 1 2
Part list
M020508 0 A5X1,A6X1 U,V,W Terminal block, Screw M10/10, 10mm2,grey,57A,single 1 6
M020498 0 End section FEM6, grey, screw, single 1 2
M020552 0 Accessories Wiring plan pocket, SZ 2515.000, A5 1 1
S006146 0 Unit components AMF-L-50-LFO 1 1
M004140 0 FC001, FC002 Frequency converter FC-202,18.5kW,380-480V,37.5A,DIO3,S 1 2
M020962 0 FC001, FC002 Cable gland M25, brass, inn. D 11-17mm, EMC 1 2
M020197 0 Cable, power LKM-HF, 4G10mm2, 0.6/1kV 14 1
M020222 0 Cable, power LKSM-HF, 4G10mm2, 0.6/1kV 14 1
M020246 0 Cable, Control RFE-HF,4x2x0.5mm2, 0.15/0.25kV 14 1
S006147 0 Nameplate set AMF-L-50-LFO 1 1
Section 4
selection

selection
Proper function of the fuel supply system is crucial for the ship’s operational efficiency and
for its combustion system health. We recommend maintaining at least the below listed
selected spares inventory on board to avoid fuel supply disturbances, costly fuel system
downtime or ad hoc deliveries. The below items have been selected for this particular unit
and their selection method is based on Auramarine’s experience of over 14,000 installed fuel
supply units. Planning ahead will also make your spares administration easier.
In case of component failure, please see the exact code of the component in question in the
specific component manual in Section 'Instruction manual'.
Please contact spares@auramarine.com for further information and delivery details.
Part code Position Ordering code Part Description Qty Maintenance rate
M000056 D005, D006 no Pump, screw
AFS000434 G053 Minor kit 1 1 year
Section 5
Instruction Manual
Contents
1.1 Storage.................................................................................................................................................2
1.2 Handling ...............................................................................................................................................2
1.3 Installation ...........................................................................................................................................3
4 START-UP .....................................................................................................................................................5
4.1 Initial start-up ......................................................................................................................................5
4.2 Normal start-up ...................................................................................................................................6
5 SHUTDOWN .................................................................................................................................................6
7 MAINTENANCE ............................................................................................................................................8
7.3 Lubrication recommendations ............................................................................................................8
8 HOW TO ORDER SPARE PARTS ..................................................................................................................10
9 COMPONENT MANUALS............................................................................................................................11
Components ..................................................................................................................................................11

1.1 Storage
storage time please contact Auramarine ltd.
1.2 Handling

1.3 Installation
local law.
heated.
1. Read the instruction manual for the unit.
controlled manner.

5. Do not heat DFO.
9. If the unit is suitable also for low level sulphur DFO -oils (defined in ISO8217:2005). According to
these regulations, DFO -oil viscosity should be in the range of 1,4-6,0 cSt at 40 °C. However note
temperature.
4 START-UP
4.1 Initial start-up
IMPORTANT POINTS TO REMEMBER
Pumps with mechanical shaft seal

The mechanical seals leak to operate properly. The mechanical seals consist of two highly polished,
very flat surfaces. The surfaces may not run dry, as they will otherwise fail very quickly. Therefore,
they are designed to allow a very thin film of liquid to exist between them. Some of the liquid will
leak out of the seal. When pumping HFO, the leaking HFO will visibly accumulate on the pump. This is
normal and does not indicate a manufacturing defect. It is not a guarantee issue.
A leakage rate of 10 drops of oil per hour or less is considered normal. Please note that seals will
sometimes require a “run in” period, with leakage gradually diminishing over several hours of
operation after the initial start-up. Start-ups can be particularly hard on mechanical seals. Never start
a pump without priming. Always make sure that the Seal Guard lubricator is activated, if the pump is
equipped with one.
Automatic filter
During the initial start-up of the fuel system, the automatic filter may get clogged. This does not
indicate a defect in the automatic filter. Normally during the first start-up of a new built vessels fuel
oil system the tanks and pipes of the vessel contain some debris from welding etc. The automatic
filter will catch the dirt, but there may be so much of it that the filter cannot clean itself anymore.
The clogging of the filter will also depend on the quality of the oil and amount of dirt deposited inside
the piping. Poor quality oil containing particles, tar, paraffin and other impurities, tends to clog the
filter elements. As a result, the automatic filter will need to be stripped and the filter elements
cleaned, in some cases repeatedly. When the dirt has been flushed from the system, the automatic
filter will operate normally. This is all normal and not a guarantee issue.
Viscometer
During the initial start-up of the fuel oil unit, the viscometer may indicate an unexpected viscosity.
Should this happen, the value will tend to be too high. This is typically caused by a dirty sensor, i.e.
the pendulum. Poor quality oil will worsen this, thus requiring a cleaning of the pendulum. Flush the
pendulum with diesel oil or a mild detergent. Be extremely careful when handling the pendulum, as
it is a sophisticated instrument.
4.2 Normal start-up

Before start-up, activate the gas generator of the pump shaft seal lubrication device, if
the pump is equipped with one.


3. Check that electric heaters and steam/thermal oil control valve are
interlocked with booster pumps viscometer and HFO/ DFO three way valve.
4. Ensure DFO flow to feeder unit. Suction pressure gauge of the unit should indicate pressure
(> 0 bar). Open the equipment valves of feeder unit and close by-pass valves.
5. Ensure that all miniature circuit breakers, motor circuit breakers and molded case circuit
breakers are switched on in local control panel(s) of the fuel oil unit(s).
7. After resetting the alarm panel, the following alarms should be on. Low outlet pressure (if
installed).
8. Start feeder pump and check rotation direction.
9. To fill fuel oil unit and pipelines to and from engine(s) with DFO will take from 2-10 minutes.
10. Pressure in fuel oil unit and engine(s) should rise to range from three to five bar. If not, check
positions of valves.
11. Change running feeder pump. Check rotation direction. Use always one pump as running and
one pump as stand-by. Change running pump periodically in order to run pumps equally.
12. If viscometer is installed start the viscometer. Viscosity of DFO is in range from approximately
3-8 cSt.
13. If auto filter is installed start auto filter. If bypass is installed check that automatic filter has
been chosen.
14. Ensure that needed trace heating is on.
15. After engine has run from 1,5 to 2 hours with HFO, check all pipe connections, and in case of
leakage, tighten the pipe connection.
5 SHUTDOWN
1. Circulate the fuel oil through heater at least ten minutes after turning heating off in order to
cool the heater down.
2. Turn the trace heating on if there is HFO in pipe system of the fuel oil unit.

Problem Check points/actions
Stand-by pump Open suction valves if they are closed.
starts. (low Suction pressure should be above -0,5 bar, if below clean the suction strainers.
pressure) Check if pressure relief valve is operational and the set point of pressure relief
valve should be 4-5 bar.
The by-pass valve of the pressure control valve should be closed.
Check rotation direction of pumps.
Check pressure control valve setting at engine(s) equipment.
Ensure that fuel oil from engine(s) flows to booster unit’s mixing tank.
Check the motor circuit breaker.
The shut-off valve of the pressure switch should be open.
Check the operation of the pressure switch and the alarm panel
Check the settings and cleanliness of the internal over flow valves of the pumps.
Check that the delay of the stand-by pump start is sufficient.
Pressure too high at Check settings of valves
pump outlet. Run only one feeder pump simultaneously.
Set point of pressure control valve equipment may be too high.
Viscometer is not Check positions of control switches at local control panel.
working. Viscometer should be on and viscosity control should be selected.
Check wiring of the controller and viscosity measuring loop.
By-pass valve of the viscometer should be closed.
Viscometer sensor might be dirty.
Flow meter is not Check the cleanness of the flow meter filter and rotor.
working. The valves of the flow meter may be closed.
The by-pass valve of the flow meter is dirty.
Check wiring and settings if there are out going signals.
Safety valve is open. Working pressure is above the set points of the safety valves.
Safety valve is damaged.
7 MAINTENANCE
Although all Auramarine fuel feeder unit contracts offer a guarantee of quality, normal wear and tear

7.3 Lubrication recommendations

7.3.1 ACG series pump, type xTxx

Feeder/Supply Pump External grease lubricated ball Depending on pump On horizontal mounted pumps the
(pos. D00x, refer to technical bearing (pump type xTxx) size, rotation speed and greasing intervals are doubled
specification) mounting position. referred to table below.
Installation in dusty or dirty premises
or in a corrosive environment reduces
lubrication intervals.
Lubrication grease specification for ACG series pumps

Mobilith SHC 460 or similar that meets or exceeds the requirements of:
Standard: DIN 51825: (2004-06)
Approval: KPHC 1-2N-40
7.3.2 Lubricating intervals in working hours
Pump sizes 045 and 052 Pump sizes 060 and 070
Temp max
[°C]
3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
155 325 375 525 575 625 750 300 325 475 500 575 650
*) at rotation speed > 3 500 r/min special instructions are given by manufacturer.
7.3.3 ACE series pump with Seal Guard lubrication device

Filling quantity
per pump
Feeder/Supply Pump Rechargeable shaft seal Depending on the gas generator 125 ml Initially filled by
(pos. D00x, refer to technical lubrication device ‘Seal setting, (1-12) from 700 to 8700 manufacturer
specification) Guard’
Lubrication oil with high temperature resistance and low viscosity characteristics is required.
Lubrication oil recommendations for ACE series pumps

Viscocity at 40°C/flash Viscocity at 40°C/flash Other oils visc. at
Manuf. Hydraulic oils Aut. transmission oils
point point 40°C/flash point
AGIP Agip Arnica 32 32.0 cSt at 40°C/202°C Agip Dexron III 35.8 cSt at 40°C/200°C
Agip OSO 32 30.8 cSt at 40°C/214°C Agip Dexron II D (2D) 34.0 cSt at 40°C/200°C
Agip ATF 33 F/G 35.9 cSt at 40°C/206°C
BP BP Bartran HV 32 31.8 cSt at 40°C/200°C BP Autran DX III 33.5 cSt at 40°C/202°C
BP Energol SHV-HV 32 32.0 cSt at 40°C/200°C BP Autran GM-MP 34.3 cSt at 40°C/210°C
BP Energol GHL 32 31.0 cSt at 40°C/196°C BP Autran LTF 32.5 cSt at 40°C/240°C
BP Energol HLP-D/DH/HM 32 32.0 cSt at 40°C/216°C BP Autran MBX 39.0 cSt at 40°C/196°C
BP Energol HL-XP 32 33.0 cSt at 40°C/230°C
CALTEX Rando HD 30.5 cSt at 40°C/210°C Texamatic 1888 35.8 cSt at 40°C/190°C
CASTROL Castrol Hyspin AWS 32 32.0 cSt at 40°C/200°C Castrol ATF TQ DIII 35.0 cSt at 40°C/216°C
Castrol Hyspin AWH-M 32 32.0 cSt at 40°C/186°C Castrol TQ 37.7 cSt at 40°C/210°C
Castrol Hyspin VG 32 32.0 cSt at 40°C/200°C
Castrol Hyspin ZZ 32 32.0 cSt at 40°C/218°C
Castrol Tribol 943 AW-32
CHEVRON
Rando HDZ 32 32.0 cSt at 40°C/200°C
/ FAMM
EXXON Mobil Delvac Hydraulic 10W 39.2 cSt at 40°C/226°C Esso ATF D/D2/D3 35-37 cSt at 40°C/200°C Mobil Mobilfluid 125
MOBIL Mobil DTE 13M 32.0 cSt at 40°C/210°C Mobil ATF 220 37.0 cSt at 40 °C/200°C 30.0 cSt at 40°C/225°C
Mobil DTE 24 32.0 cSt at 40°C/220°C Mobil ATF 320 35.0 cSt at 40 °C/182°C Mobil Rarus 424
Mobil EAL Hydraulic Oil 32 32.0 cSt at 40°C/248°C Mobil Multipurpose ATF 32.0 cSt at 40 °C/182°C 32.0 cSt at 40°C/236°C
GULF Gulf Harmony 32 31.2 cSt at 40°C/210°C Gulf ATF III 30.0 cSt at 40 °C/176°C
Gulf Harmony AW 32 31.2 cSt at 40°C/202°C Gulf Gulfpride III H ATF 37.1 cSt at 40 °C/186°C
Gulf Harmony AW Plus 32 31.0 cSt at 40°C/206°C
Gulf Harmony HVI 32 32.1 cSt at 40°C/218°C
Gulf Harmony HVI Plus 32 32.2 cSt at 40°C/219°C
GulfSea Hydraulic HVI Plus 32 32.2 cSt at 40°C/219°C
LUKOIL Renolin B32 HVI 32.0 cSt at 40°C/178°C Titan ATF 4000 38.0 cSt at 40 °C/190°C
Renolin MR 520 32.0 cSt at 40°C/170°C
SHELL Shell Hydrau Oils HM 32 32.0 cSt at 40°C/215°C Shell Donax TF 39.9 cSt at 40 °C/180°C
Shell Tellus Oil 32 32.0 cSt at 40°C/209°C Shell Donax TM 40.0 cSt at 40 °C/170°C
Shell Tellus Oil S 32 32.0 cSt at 40°C/207°C Shell Donax TX 33.7 cSt at 40 °C/185°C
Shell Tellus Oil 37 37.0 cSt at 40°C/212°C Shell Tellus Oil S2 V 32 32.0 cSt at 40 °C/210°C
SK ZIC SUPERWIS AW 32 32.1 cSt at 40°C/230°C ZIC ATF III 37.9 cSt at 40 °C/220°C
ZIC VEGA 32 33.3 cSt at 40°C/230°C ZIC DEXRON 28.8 cSt at 40 °C/208°C
ZIC XP III 35.7 cSt at 40 °C/224°C
TEBOIL Larita Oil 32 32.0 cSt at 40°C/200°C Teboil Fluid D 38.0 cSt at 40 °C/190°C
TOTAL Azolla AF 32 32.1 cSt at 40°C/227°C Total ATF 33 39.0 cSt at 40 °C/190°C
Azolla DZF 32 32.7 cSt at 40°C/210°C Total Fluide AT 42 34.0 cSt at 40 °C/196°C
Azolla VTR 32 32.0 cSt at 40°C/207°C Total Fluide ATX 40.0 cSt at 40 °C/190°C
Azolla ZS 32 32.0 cSt at 40°C/227°C Total Fluide CC 40.5 cSt at 40 °C/190°C
Equivis 32 32.3 cSt at 40°C/208°C Total Fluide II D 36.8 cSt at 40 °C/210°C
Visga 32 32.0 cSt at 40°C/>200°C

Ordering address:
Fax +358 204 86 5031
Tel +358 204 86 5030
9 COMPONENT MANUALS
Components
9.1 B005, B006 M002558 Strainer - Fig 821, 823 52
9.2 B030 M003765 Filter regulator, air - MC series 60
9.3 D005, D006 M000056 Pump, screw - ACG/UCG 7 64
9.4 M005/M005A, M003401 El. motor, induction - HMA, HMC, HMD, HMT, MS, 94
M006/M006A Y2E1, Y2E2, YDT
9.5 V013, V014 M021039 Valve, Globe - Fig 215, Fig 216 98
V505, V506, V507
9.7 A0A1 M001997 Alarm panel - LLC-10 108
9.8 A5K1 M002182 Relay, time - CT-MXS, CT-WBS 112
9.9 FC001,FC002 M004140 Frequency converter - FC-202 126
Position: B005, B006

Part code: M002558
9.1 Strainer - Fig 821, 823
Strainer 1
Fig 821, 823
Strainer – Filter Fig. 821, 823

1 PRODUCT DESCRIPTION
Y strainers - filters are provided with casted marking according to requirements of PN-EN19
standard. The marking facilitates technical identification and contains:
· diameter nominal DN (mm),
· pressure nominal PN (bar),
· body and cover material marking,
· arrow indicating medium flow direction,
· manufacturer marking,
· heat number,
· CE marking, for valves subjected 97/23/EC directive. CE marking starts from DN32
2 REQUIREMENTS FOR MAINTENANCE STAFF

The staff assigned to assembly, operating and maintenance tasks should be qualified to carry out
such jobs. If during strainer operation heat parts of the strainer, for example cover or body could
cause burn, user is obliged to protect them against touch.
3 TRANSPORT AND STORAGE

Transport and storage should be carried out at temperature from –200 to 650C, and strainers
should be protected against external forces influence and destruction of painting layer as well.
The aim of painting layer is to protect the strainers against rust during transport and storage.
Strainers should be kept at unpolluted rooms and they should be also protected against influence
Strainer 2
Fig 821, 823
of atmospheric conditions. There should be applied drying agent or heating at damp rooms in
order to prevent condensate formation. Strainer weights are given at catalogue card.
It is not allowed to fit lifting devices to connecting holes
4 FUNCTION
Strainers – wire mesh filters are designed for cleaning flowing medium. Their task is to protect
against pollutions the most sensitive plant components such as pumps, control valves, flow and
heat meters. Strainer holds solid particles which dimensions exceeds screen mesh. In order to
remove magnetic pollutions from the medium it is recommended to use magnetic cartridge
located in the centre of filter screen.
Application range was mentioned at catalogue card. The kind of working medium makes some
materials to be use or to be prohibited for use. Strainers were designed for normal working
conditions. In the case that working conditions exceed these requirements (for example for
aggressive or abrasive medium) user should ask manufacturer before placing an order.
When selecting the strainer for specific medium,”List of Chemical Resistance” can be helpful. It
can be found at manufacturer website near catalogue cards.
Working pressure should be adapted to maximum medium temperature according to the table as
below :
Strainer 3
Fig 821, 823
Plant designer is responsible for strainer selection suitable for working conditions.
5 APPLICATION
· hot and cold water plants , steam, air, glycol.
· industrial technologies, power industry, heat industry, HVAC plants
6 ASSEMBLY
During the assembly of strainers following rules should be observed:
· to evaluate before an assembly if the strainers were not damaged during the transport or
storage
· to make sure that applied strainers are suitable for working conditions and medium used in
the plant
· to take off dust caps if the strainers are provided with them
· check if strainer body is free of solid particles

· steam pipelines should be fitted in such a way to avoid condensate collection
Strainer 4
Fig 821, 823
· to protect the strainers during welding jobs against splinters and used plastics against
excessive temperature
Pipeline where the strainers are fitted should be conducted and assembled in such a way that
the strainer body is not subjected to bending moment and stretching forces. Bolted joints on
the pipeline must not cause additional stress resulted from excessive tightening, and fastener
materials must comply with working conditions of the plant.
To assembly the strainer in such a way that flow direction comply with an arrow placed on the
body.
· strainer body throat with a screen must be put downwards in order to prevent pollution
return to the pipeline,
· in the case of water hammer risk caused by condensate formation, strainer body throat
should be assembled in horizontal position,
· plant designer should ensure enough space to take screen out of strainer body for cleaning,
· use expansion pipe joints in order to reduce influence of pipeline thermal expansion,
· before plant startup, especially after repairs carried out, flash out the pipeline
7 MAINTENANCE
· startup process – sudden changes of pressure and temperature should be avoided when
starting the plant,
Strainer 5
Fig 821, 823
· strainers – wire mesh filters do not contain moving parts and do not require any maintenance
jobs with exception of screen cleaning,
· strainer screens require regular cleaning – screen cleaning intervals should be established by
user depending on the pollution grade of the medium,
Before taking up any service jobs make sure that medium supply to the pipeline was cut off,
pressure was decreased to ambient pressure, medium was removed from the pipeline and
plant was cooled down.
· cleaning or replacement the screen is possible when body – cover bolt nuts are unscrewed
and screen is taken out of the strainer – remove screen impurities by strong water stream
without using metal tools,
· some part of impurities can be removed by unscrewing the plug from the cover if strainer is
provided with plug
· before strainer reassembly remember to replace body – cover gasket.
Precautions should be taken when touching gasket between body and strainer cover. The
gasket contains stainless steel stripe that may cause injury,
· tighten hexagon nuts of cover bolts evenly and crosswise by torque wrench.
In order to assure safety performance, each strainer (especially rarely used) should be
surveyed on regular basis. Inspection frequency should be laid down by user, but not less
than one time per month.
8 SERVICE AND REPAIR

All service and repair jobs should be carried out by authorized staff using suitable tools and
original spare parts. Before disassembly of complete strainer from the pipeline or before service,
the pipeline should be out of operation. During service and repair jobs:
- the pressure should be decreased to zero degrees and valve temperature to ambient
temperature,
- personal health protectives in pursuance of existing threat should be used,
- after strainer disassembly it is necessary to replace flange connection gaskets between
strainer and pipeline,
- tighten torques for body – cover bolts
Strainer 6
Fig 821, 823
- before strainer re-assembly in the pipeline it is necessary to check strainer operation and
tightness of all connections. Tightness test should be carried out with water pressure of 1,5
nominal pressure of the valve.
9 REASONS OF OPERATING DISTURBANCES AND REMEDY

When seeking of strainer malfunction reasons safety rules should be strictly obeyed
Fault Possible reason Remedy

No flow Flange dust caps were not removed Remove dust caps on the flanges
Poor flow Dirty screen Clean or repair the screen
Clogged pipeline Check the pipeline
Broken connecting flange Bolts tighten unevenly Replace the strainer with new one
Position: B030
Part code: M003765
9.2 Filter regulator, air - MC series
Filter regulator, air – MC series

1 Technical characteristics
Construction compact modular with filtering element in HDPE - diaphragm type
Materials zama, NBR, technopolymer
Ports G1/4 G3/8 G1/2
Condensate capacity / cm³ 28 72 72
Weight 0,443 0,948 0,928
Pressure gauge ports G1/8
Operating temperature -5°C to 50 °C at 10 bar (with the dew point of the fluid lower than 2 °C
at the min. working temperature)
Porocity of filtering element 25 μm standard - 5 μm upon request
Draining of condensate manual - semi-automatic standard
Finishing enamelled
Inlet pressure with standard drain and protected depressurisation 0,3 to 16 bar
with depressurisation 0,3 to 10 bar
with automatic drain 1,5 to 12 bar for G3/8 and G1/2
2 Important information for the use of pneumatic components
2.1 General
Respecting the limit values for:
 Pressure
 Speed
 Mass
 Voltage
 Actuating force
 Temperature
The pneumatic have to be used with properly prepared compressed air. The type of preparation
depends on the environmental characteristics and the sector of industry in which they will be used.
Except for different information shown on the technical data sheet for the single products, in general
the air characteristics should be:
Fluid temperature: -10 to + 60 °C
Environmental temperature: -20 to + 80 °C
Air filtering: According to DIN ISO 8573-1: not superior to the class 5/5/4
(see table)
Lubrication: Not necessary, if used then use ISOVG32 oil and do not
interrupt once applied
Oil contents: From 1 to 5 drops every 100 litres of air
2.2 Air treatment
2.2.1 Filtering
The temperature affects the capacity of air to maintain water particles (relative humidity). Warm air
contains a larger quantity of water than the same volume filled with cold air. An excess of humidity
causes the formation of condensate. Cooling of the air modifies the structure of the water it
contains, by turning it from a gaseous to a liquid state. Specific apparatus can be used to cool
(refrigerator) and heat (drier) the air and are, as a rule, assembled on the outlet of the compressor.
The filtering elements mounted inside the filters for compressed air, are only partly able to separate
the condensate from the air, in fact, their main function is to eliminate any solid particles. During the
production of compressed air, compressors can introduce oil into the distribution network. The
characteristics of this oil are not compatible with the seals of pneumatic components and with the
market trend towards miniaturized products imposes the requirement to use coalescing filters. It is
advisable to provide for automatic drains on the filters.
2.2.2 Lubrication
This is not necessary as the components are already greased with special products. Only use oils with
a viscosity of 32 cSt at 40 °C. The oil quantity has to be a maximum of 1 drop per minute, this
regulation has to be made with the machine in normal operation. The lubrication, once applied, must
never be interrupted. If not, the seals of the components could degenerate, compromising their
function.
For a correct use of our products, refer to the values shown in the table of the Air Quality classes,
according to the Standard DIN ISO 8573-1.
Class Solid bodies Air contents Oil quantity

Max dimension of the particles dew-point Max concentration
1 0.1 µm -70 °C 0.01 mg/m3
2 1 µm -40 °C 0.1 mg/m3
3 5 µm -20 °C 1 mg/m3
4 15 µm +3 °C 5 mg/m3
5 40 µm +7 °C 25 mg/m3
3 Spare parts
Pos. Description Pos. Description

1 Complete bowl with semiautomatic- 6 Bell fixing screw
manual drain
Complete bowl with depressure drain 7 Panel nut
Complete bowl with protected 8 Spring, 1 / 2 / 4 / 7 / 10 bar
depressuration drain
Complete bowl with port 1/8 (without 9 Complete standard diaphragm / without
drain) bleeder / with controlled leak
2 Complete filtering element 25 / 5 µm 10 Complete standard poppet valve
3 Filtering element 25 / 5 µm 11 Rear screw for pressure gauge
connection
4 Standard bowl O-ring 12 Special O-ring seal
5 Complete bell with regulation screw 13 Protection body with holes

Part code: M000056
9.3 Pump, screw - ACG/UCG 7
Screw pump 1
ACG/UCG 7
Contents
Screw pump ACG/UCG 7 ................................................................................................................................... 2
1 Installation ............................................................................................................................................. 3
1.2 Lifting of pump .............................................................................................................................. 3
1.3 Mounting ....................................................................................................................................... 3
1.6 Suction line .................................................................................................................................... 5
1.7 Discharge line ................................................................................................................................ 5
1.8 Deaeration ..................................................................................................................................... 5
1.9 Strainer .......................................................................................................................................... 6
1.10 Shaft seal drain .............................................................................................................................. 6
1.11 Liquid trap...................................................................................................................................... 6
1.12 Gauges ........................................................................................................................................... 7
2 Start-up .................................................................................................................................................. 8
2.1 Before starting ............................................................................................................................... 8
2.3 Starting .......................................................................................................................................... 9
3 Explosion view ..................................................................................................................................... 11
4 Maintenace .......................................................................................................................................... 14
4.2 Service for ball bearing ................................................................................................................ 14
4.4 Shaft seal-assembly drawing ....................................................................................................... 15
4.5 Lubricating intervals in working hours ........................................................................................ 15
4.6 Useful tools .................................................................................................................................. 16
Screw pump 2
ACG/UCG 7

4.8 Sectional view .............................................................................................................................. 18
4.9 Dismantling .................................................................................................................................. 19
4.10 Reassembly .................................................................................................................................. 23
Screw pump ACG/UCG 7
Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K7/N7
- With version codes N, V, T, B, F, E, P, G
o Also valid for pump options: A101, A327, A385
o Example of pump designations std: ACG 045N7 NVPB
o option: ACG 070N7 NVBP A101
refer to the ACG/UCG Product description.
Screw pump 3
ACG/UCG 7
1 Installation
start up.
1.2 Lifting of pump

the pump.
1.3 Mounting

Screw pump 4
ACG/UCG 7
are to be taken.

A B A B
50 26 2.0 8 148 3.5
67 40 2.5 16 168 3.5
82 55 3.0 18 194 3.5
97 65 3.0 20 214 4.0
112 80 3.5 24 240 4.0
128 95 3.5 26

Max angular
(mm) (degrees)
Type LPD and
Other types 0.3 0.1
Screw pump 5
ACG/UCG 7

and/or air.
1.6 Suction line

Suction line
1.7 Discharge line

1.8 Deaeration
highest point.
a stand-by pump
Screw pump 6
ACG/UCG 7
1.9 Strainer

made.
opening.
1.11 Liquid trap

Liquid trap
Screw pump 7
ACG/UCG 7
1.12 Gauges

passed liquid.
viscosity media.


Screw pump 8
ACG/UCG 7
2 Start-up
2.1 Before starting
Filling the pump
before start-up.
fig. 16.
ATTENTION
Screw pump 9
ACG/UCG 7

ATTENTION
2.3 Starting
lines.
clockwise).


Screw pump 10
ACG/UCG 7
be provided.
environment.
Screw pump 11
ACG/UCG 7
3 Explosion view
Screw pump 12
ACG/UCG 7

Qty Components included in Spare parts sets:
PosNo Denomination G011 G012 G050 G053 G054 G057 G070 Note
1010 Power rotor CCW-rot. 1 x (x)
1020 Power rotor CW-rot. 1 x x
106 Balancing piston 1 x x x 5
113 Shaft key 1 x x x
120 Distance sleeve 1
122 Ball bearing 1 x x
201 Idler rotor CCW-rot. 2 x (x)
202 Idler rotor CW-rot. 2 x x
359 Distance washer 1
401 Pump body 1
424 Sleeve 1 4
424A Washer 1 4
429 Spindle 1 4
437 O-ring 1 4
451 Screw 4/6
453 Screw 4
462 Plug 2 1
462A Sealing washer 2 x x x 1
473 Grease nipple 1
473A Grease nipple cover 1
480 Valve housing 1 2
5010 Front cover 1
502 Tension pin 1 6
502A Plug 1 6
506 Gasket 1 x x x
537 Plug 2
551 Rear cover 1 3
556 Gasket 1 x x x
601 Valve cover 1 x 2,7
602 Sealing washer 1 x x x x 2
605 O-ring 1 x x x x 2
608 Valve spindle 1 x 2,7
608A Retaining ring 1 x x x x 2
612 Set screw 1 x 2,7
614 Valve piston 1 x 2,7
615 Valve spring 1 x 2
Notes:
1) Excluded in xxxG 5) Included in item 1020 or 1010
2) Excluded in xxxE 6) Included in item 5010
3) Valid for xxxE 7) Only sold as G070
4) Valid for pump option A327 8) Removed from August 2011
Screw pump 13
ACG/UCG 7

Pos
no. Spare parts set
Rotor set CW-rotation (std):

G012 Normal lead - pump version N7
Low lead - pump version K7
Complete shaft seal - version code xVxx
G050
Minor kit - version code xVxx
G053
G054 Major kit=G012(G011)+G053
G057 Joint kit
G070 Valve element - version code xxxP/G
122 Ballbearing
G011 is in reserve
Recommendation:
Set: To be used:
G057 Joint kit For dismantling of the pump
G053 Minor kit For service
G054 Major kit For repair after damage or greater wear.

Ordering example:
For Auramarine feeder 13152 IMO-pump ACG 045N7 NVBP, serial number 456789
Shaft seal pos G050 p/n AFS000662
Ballbearing pos 122 p/n AFM000300
Screw pump 14
ACG/UCG 7
4 Maintenace
pumped liquid and can only be determined by experience. All internal parts of the ACG-pump are
lubricated by the pumped liquid. Pumping liquid which contains abrasive materials, or liquid that
is corrosive, will significantly reduce service life and call for shorter service intervals.
Wear in the pump may be indicated by:
 Vibration
 Noise
 Loss of capacity
 Reduction in flow/pressure
 Leakage
In installations where unplanned shut downs must be avoided, it is advisable to have a complete
pump available for replacement, should any malfunction occur. Furthermore we recommend
planned inspection and overhaul at regular intervals, not exceeding 3 years.
4.2 Service for ball bearing

The ACG-pump is fitted with an external grease lubricated ball bearing. When delivered from IMO
AB, the ball bearings in pump version xVxx are filled with grease of type B. For version xTxx, type C
is used. Whenever the ball bearing is removed, it is recommended to exchange it for a new one.
Fit the new ball bearing properly greased and regrease it after one hour of running, while the
pump is operating.

As the seal faces of a mechanical shaft seal are lubricated by the fluid a certain leakage will always
be present. Ten drops per hour can be considered as acceptable.
An external visual inspection of the pump is advisable at least every two days to assure that the
shaft seal is not leaking too much.
Excessively leaking shaft seals should be changed without delay, as the leakage normally will grow
worse and cause additional damage.
Follow the instructions in the dismantling/reassembly session.
When working with a shaft seal, cleanliness is of utmost importance. Avoid touching the seal
faces. If necessary, the seal faces should be cleaned immediately prior to assembly, using a dust
free cloth and clean solvent.
Never use grease on the seal faces. Connecting and disconnecting of electric cables must be
done only by personnel authorized to do such work.
Screw pump 15
ACG/UCG 7
4.4 Shaft seal-assembly drawing
Use an appropriate type of grease, as per table and a grease gun suitable for grease nipple (pos
473) according to DIN 71 412 (ISO 6392).
On vertical mounted units the greasing intervals are reduced to half. Installed in dusty or dirty
premises or in a corrosive environment it should be lubricated at more frequent intervals.
If using others than these recommended greases check if it is possible to mix them with each
other, otherwise clean before using a new grease.
4.5 Lubricating intervals in working hours

Temp Pump sizes 045 and 052 Pump sizes 060 and 070
max Grease
type
o
C 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 10000
90 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750
110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350
130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100
155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1400
*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.
Recommended greases (the availability of the greases can differ locally):
Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak
EP2, SKF LGMT2, Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3,
FINA MARSON L3.
Screw pump 16
ACG/UCG 7
Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL
RETINAX LX, SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS,
CASTROL LMX, INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.
Type C: Mobilith SHC 460
Pump size 045 052 060 070

Grease amount (g) 4 6 7 9
isolated.
are to be taken.
In case of failure for a system with elevated pressure, fluid jets may cause injury and/or
damage.
4.6 Useful tools

Screw pump 17
ACG/UCG 7

If an indication of a worn pump is noticed (see service intervals above), a brief inspection of the
idler rotors is recommended.
A quick inspection of the idler rotors can be made simply by removing the rear cover or valve
cover. Note that the driver must be deenergized and the pump hydraulically isolated before the
rear cover is removed. Provisions to handle the fluid are to be made. If a more thorough
investigation is needed, proceed as under ”Dismantling”.
Internal clearances in the pump, which are vital for its proper function, may have been affected by
wear. Acceptable wear can be determined only by experience of the actual application. As a rule
of thumb the following max clearance values may apply:
 Between rotor and bores or bushings: 0.2 mm
 Between rotor flanks: 0.4 mm
For light duties (low pressure, medium viscosity) even bigger clearances may be acceptable but
for low visc./high pressure duties the limit will be lower. Also check if there are major scratches
on these parts.
Screw pump 18
ACG/UCG 7
4.8 Sectional view

Screw pump 19
ACG/UCG 7
4.9 Dismantling
Turn the electricity OFF.
Close the valves.
Remove the pump from the system.
ATTENTION
Use appropriate vessels to collect oil spillage
when removing and opening the pump.
Note the axial position of the shaft coupling.


Screw pump 20
ACG/UCG 7
Remove the key 113.
Remove the retaining rings 124 and 514.

Remove the support ring 124A.
Screw pump 21
ACG/UCG 7
Remove the front cover 5010 with a puller.
Push out the ball bearing 122 together with the

distance sleeve 120. If there is tight fit use a
mounting sleeve and a mallet.
Remove the distance washer 359 and the support
ring 359A.
The sealing surfaces of the shaft seat should not

be touched with the fingers.
Turn the front cover 5010 upside down.
Push out the seat from the front cover 5010.
Remove the o-ring S2.
Remove the gasket 506.
Screw pump 22
ACG/UCG 7
Pull the power rotor 1020 out of the pump body

and place it into the jaws of a jaw vice with soft
jaws or a column drilling machine.
Push with two drivers as shown on the sketch, to
remove the shaft seal.
Unscrew the seal ring carrier S5 screws and take

off the seal ring carrier S5 together with the seal
ring S4 and the o-ring S6.
Take out the idler rotors.

Clean all parts that are going to be used again.
Screw pump 23
ACG/UCG 7
4.10 Reassembly
Lubricate the idler rotors and fit them into the
pump.
Lubrication groove turned downwards.
Carefully place the power rotor 1020 into the jaw

vice with soft jaws.
Lubricate all surfaces of the power rotor 1020.
Open a package with a new sealing 509, version
xVxx.
Place the bellows unit S5 on the shaft of the
power rotor and press it down against the
balance piston (106) (See Sectional view).
Open a package with a new shaft seal 509

version xTxx.
Place the seal ring carrier S5 on the shaft of the
power rotor 1020 flush against the balance
piston and lock it with its stop screws. Fit the o-
ring S6 and the seal ring S4.
Screw pump 24
ACG/UCG 7
Lubricate the O-ring S2 and the recess of the

front cover 5010.
Clean the sealing faces and fit the seat S1 into
the front cover 5010. Mind the position of the
retaining pin if applicable.
Lubricate the balance piston 106 with a thick oil

(ISO VG 460).
Fit the front cover onto the power rotor 1020
untill it rests on the bellows unit S5.
Fit the support ring 359A and the distance
washer 359 into the front cover. Mind the
position of the distance washer 359.
Fit the distance sleeve 120 into the front cover
5010.
Fill the ball bearing with appropriate grease. See
page 5 for grease selection.
Fit the ball bearing 122 onto the shaft.
ATTENTION
The open side of the bearing towards the cover.
Fit the mounting sleeve and push the bearing to
its final position in the front cover. To do this
some force is required. Use Your column drilling
machine or mounting kit (see fig 4).
Do not use a hammer etc. as this might damage
the shaft seal and ball bearing.
Fit the support ring 124A and the retaining ring
124 on the shaft.
Fit the retaining ring 514 back in place.
Screw pump 25
ACG/UCG 7
Fit the key back in position, see fig. Remove the Do not use a hammer etc. as this might
key 113. damage the shaft seal and ball bearing.
Fit the shaft coupling back into place (see fig.
Axial position and Remove shaft coupling) with
the same methode used when fitting the ball
bearing.
Remove the plug 537 and washer 537A.
Hold the rotor unit horizontally with the bore for
537 upwards. Carefully fill the space completely
with thin oil (f. ex. ISO VG 46).
When the oil is flooding, reassemble the above
parts in reverse order.
Slowly turn the shaft a few turns to make sure it
moves freely (a certain resistance from the shaft
seal is normal but it must be the same during the
turns).
Place the gasket 506 on the pump body 401.
Lubricate the power rotor 1020 and fit the front
cover 5010 together with the rotor set into the
pump body. Mind the position of the tension pin
545.
Fit the screws 451 and tighten them crosswise.
Put the pump back into the system and proceed

according to instructions under ”Startup” in the
installation manual.
Screw pump 26
ACG/UCG 7

Replacement of O-ring 605
 To avoid changing the setting of the valve, use an Allen key to prevent spindle 608 to turn.
Unscrew cover 601 and pull up unit 601/608.
 Remove retaining ring 608A and pull the spindle 608 out of cover 601. Replace O-ring 605
and assemble the unit 601/608 in reverse order. Replace retaining ring 608A if necessary
and washer 602.
 Fit the unit 601/608 in the valve. Make sure the
608 enters the set screw 612 and use the Allen
key to prevent 608 to turn when cover 601 is
tightened.
Replacement of Valve Element G070
 Release the spring tension by turning the spindle
608 CCW with an Allen key. Use the Allen key to
prevent spindle 608 to turn and unscrew cover
601 but do not remove it yet.
 Remove the set screw 612 by turning the spindle
608 CCW. Pull out the valve piston/spring unit
614/615.
 Fit the valve element in reverse order with a new
washer 602. Turn the spindle 608 CW until the set
screw leave enough room for cover 601. Use the
Allen key to prevent 608 to turn further when
cover 601 is tightened.
 Adjust the valve setting according to the "Installation and Start-up Instruction".
Screw pump 27
ACG/UCG 7
5 Trouble shooting
rotation
such work.

primed
at the pump inlet.
pressure.
noise).

Screw pump 28
ACG/UCG 7
high.

conditions.
down if any sign of
malfunction is
noticed.
Auramarine.

Position: M005/M005A, M006/M006A

Part code: M003401
Y2E2, YDT
Electric Motors
Motor Manual
hoyermotors.com
Manual
Motor
Manual

shaft failure.
60034-4 and IEC/EN 60072.
or studs.

local regulations.
rated data.

to other equipment.
T.(Nm) 2.5 3.5 7 12 18 35 55 80
Installation
2
Motor
Manual
56 - 160 2-8 40,000h
180 2 35,000h
200 2 27,000h
IEC 60079-15.
must be closed.
intervals.
size (h) (h)
160 20 4200 7000 8500 8500
315 50 1500 5500 6500 6500
355 60 1000 4000 5000 6000
400 80 800 3000 4000 6000
3

Part code: M021039
9.5 Valve, Globe - Fig 215, Fig 216
Globe valve
Fig.215 straight form
Fig.216 angle form
1 Product description
Globe valves are manufactured at different executions, they are used as stop valves, throttling valves, SDNR valves. Stop valves
are designed only for shut off and open the flow, throttling valves are designed for flow control and SDNR valves are used as n on
return valves protecting the plant against back flow of medium and additionally they can shut off the flow. SDNR valves visually
differ from stop valves having cylinder stem extension on the upper end of the stem.
Globe valves are provided with casted marking according to requirements of PN-EN19 standard. The marking facilitates technical
identification and contains:
 diameter nominal DN (mm),
 pressure nominal PN (bar),
 body and bonnet material marking,
 arrow indicating medium flow direction,
 manufacturer marking,
 heat number,
 CE marking, for valves subjected 2014/68/UE directive. CE marking starts from DN32

FIN-20101 TURKU Fax + 358 204 86 5031
2 Function
Valves with stop disc are designed for shut off medium flow, valves with throttling disc enable to control the flow and SDNR valves
are designed to work as non-return valves and enable to shut off the valve at any time as well. Application range was mentioned at
catalogue card. The kind of working medium makes some materials to be use or to be prohibited for use. Valves were designed for
normal working conditions. In the case that working conditions exceed these requirements (for example for aggressive or abrasive
medium) user should ask manufacturer before placing an order. When selecting the valve for specific medium,”List of Chemical
Resistance” can be helpful. It can be found at manufacturer website near catalogue cards. Working pressure should be adapted to
maximum medium temperature according to the table as below.
3 Assembly
During the assembly of balancing valves following rules should be observed:
 to evaluate before an assembly if the valves were not damaged during the transport or storage,
 to make sure that applied valves are suitable for working conditions and medium used in the plant,
 to take off dust caps if the valves are provided with them,
 to protect the valves during welding jobs against splinters and used plastics against excessive temperature,
 steam pipelines should be fitted in such a way to avoid condensate collection; in order to avoid water hammer steam trap
should be applied

FIN-20101 TURKU Fax + 358 204 86 5031
 during pipeline painting valve stem should be protected,

 stop valves can be assembled in any position, however it is recommended to install the valve with hand wheel upwards,
 screw down and non-return valves (version with spring) can be assembled in any position, screw down and non-return
valves (version without spring) should be assembled only on the horizontal pipelines with hand wheel upwards
 before plant startup, especially after repairs carried out, flash out the pipeline through entirely open valve, in order to avoid
solid particles or welding splinters which may be harmful for sealing surfaces,
 strainer (wire mesh filter) installed before the valve increases certainty of its correct action.
4 Maintenance
 startup process – sudden changes of pressure and temperature should be avoided when starting the plant,
 valve is closed by turning the hand wheel clockwise when looking from above the hand wheel (according to arrow
direction marked on the hand wheel),
 valve is opened by turning the hand wheel counter-clockwise,

 performance of fitted valves can be checked by multiple closing and opening,

FIN-20101 TURKU Fax + 358 204 86 5031
 if leakage on stem occurs for valves Fig.215, 216 (PN6 – PN25) it is necessary to tighten with moderate force two T-bolt
nuts pressing the packing gland untill the leakage disappear, for SDNR valves Fig.215, Fig.216 (PN40) similar nuts on
eye bolts, whereas for stop valves Fig.215 (PN40) packing rings are pressed by tightening threaded gland nut screwed in
the bonnet, the nut press the rings by gland,
 in the case of necessity to replace packing rings, it should be done without overpressure inside the valve, when the valve
is completely open. In this position inner space of the valve is entirely shut off : stop valves are provided with back seat on
the upper part of disc which adheres to bonnet seat, SDNR valves are provided with flange on the stem which adheres to
bonnet seat,
 in order to refill packing rings of valves Fig.215, 216 (PN6 – PN25) unscrew the nuts on T-bolts, move the gland into hand
wheel direction, working under lifted gland refill cut - packing rings in the stuffing box, then press again these cut packing
rings. There are similar procedures for SDNR valves Fig.215, Fig.216 (PN40) but there are eye bolts instead of T-bolts
that can be swing aside. For stop valves Fig.215 (PN40) packing can be refilled when gland nut is unscrewed.

FIN-20101 TURKU Fax + 358 204 86 5031
5 Service and repair

All service and repair jobs should be carried out by authorized staff using suitable tools and original spare parts. Before
disassembly of complete valve from the pipeline or before service, the pipeline should be out of operation. During service and repair
jobs it is necessary to decrease pressure to 0 bars, valve temperature to ambient temperature and to use personal health
protectives in pursuance of existing threat. After valve disassembly it is necessary to replace flange connection gaskets between
valve and pipeline.
Every time when valve bonnet was disassembled sealing surface should be cleaned. During assembly it should be applied new
gasket of the same type as previously used. Body-bonnet bolt connections should be tighten when the valve is at open position.
The bolts should be tighten evenly and crosswise by torque wrench.

FIN-20101 TURKU Fax + 358 204 86 5031
Tighten torques
before valves re-assembly in the pipeline it is necessary to check valve operation and tightness of all connections. Tightness test
should be carried out with water pressure of 1,5 nominal pressure of the valve.
6 Reasons of operating disturbances and remedy

When seeking of valve malfunction reasons safety rules should be strictly obeyed

FIN-20101 TURKU Fax + 358 204 86 5031
Position: V501, V502, V503, V504, V505, V506,

V507
Part code: M021085
Ball valve 1
Ball valve 1700

Position: A0A1
Part code: M001997
9.7 Alarm panel - LLC-10
ALARM DISPLAY UNIT LLC–10 LRS
UNIVERSAL PANEL IN THE ”DIN” SERIES, FOR USE BY POCESS
INDUSTRIES AND MACHINE MANUFACTURERS
Advantages and Operation
LLC-10 LRS is a compact alarm display unit in the ”DIN”-series. It
is designed for exacting applications. The unit is programmable for
use with either normally open or closed sensor contacts, with adjus-
table time delay. The alarm display unit has two output relays (A and
B alarms). All channels shall be connected to A-alarm.
When a sensor flashing after the pre-set time delay has elapsed.
At the same time the both output relays are activated (the B relay
is delayed 5 sec in relation to the A relay). If a new sensor will be
activated the B relay will do a quick status change. The signal is
acknowledged by pressing the RESET button. This releases the out-
put A relay and the flashing light becomes steady. The B relay will
be in alarm mode as long as any channel is in alarm state.
When the fault has been corrected and the sensor contact has retur-
ned to its normal state, the indicator lamp goes out. If the fault self-
corrects and the sensor contact returns before acknowledgement,
the fault remains in the unit memory, the light flashes and the output
relays remain activated, until the RESET button is pressed.
LLC-10 is equipped with a channel memory. The unit is always
ready to receive new alarm signals, independent of system status.
The panel can be provided with legends for each alarm channel or
with a common 10 points legend.
SECURITY
LLC-10 LRS is designed for severe mechanical and electrical envi-
ronmental conditions. It is provided with special protection against
polarity reversal and accidental connection of voltage, interruptions
etc. The unit is designed to indicate voltage failures, each group
relay is normally activated. In the alarm state the relay is deactivated
and a signal can be given with a horn, for example. The same hap-
pens with interruption in supply voltage.
Its limited size and depth and depth allow it to be easily mounted in
panels, walls and similar spaces.
Normal function testing is carried out by pressing a test button
which simulates faults on the alarm channels in the system.
• 10 channel unit for both normally open and
INSTALLATION
closed sensor contacts (No/Nc). LLC-10 LRS is designed for panel, wall or cabinet mounting, and is
supplied only in the master form. Systems with more than 10 alarm
channels require, demand additional panels. Connection is made to
• Alarm grouping in 2 categories (A-B alarms) the unit by an easily accessible screw terminal block,which can be
fitted with a corresponding terminal strip. The use of this system
• Memory and flasher means that cable connections need not be disturbed once the instal-
lation is complete, and the unit can be disconnected very quickly.
• Time delay for each alarm channel SPECIFICATIONS

Supply voltage: 24V AC/DC ± 20%
• Running light indicator Supply current: Normal condition 0,1A
Alarm condition 0,2A
Time delay: Individually adjustable time 0,5-20 sec. each chan-
• Group indication nel.
Output contacts: One change-over contact per alarm group (A and
• Voltage failure indication B alarms). Selection device on each alarm point
contact rated max 100V 2A resistive load.
Front: Dull black aluminium with plastic cover IP44 and
• Prepared for datatransfer together with gasket IP65
Main dimension: DIN 144x144x35 mm
Panel recess: 125x125 mm
Legends: Space for individual channel legends or common 5
channel legends
Indicators: Red LED for unacknowledged alarm
––
––
Position: A5K1
Part code: M002182
9.8 Relay, time - CT-MXS, CT-WBS
CT-MXS
CT-WBS
(D) Betriebs- und Montageanleitung (E) Instrucciones de servicio y de montaje

Elektronische Zeitrelais, CT-S Reihe Temporizadores electrónicos, serie CT-S
Hinweis: Diese Betriebs- und Montageanleitung enthält nicht Nota: Estas instrucciones no contienen todas las
sämtliche Detailinformationen zu allen Typen der Produktreihe informaciones detalladas relativas a todos los tipos del
und kann auch nicht jeden Einsatzfall der Produkte berück- producto ni pueden considerar todos los casos de operación.
sichtigen. Alle Angaben dienen ausschließlich der Produkt- Todas las indicaciones son a título descriptivo del producto
beschreibung und sind nicht als zugesicherte Eigenschaften y no constituyen obligaciones legales. Para más información,
im Rechtssinne aufzufassen. Weiterführende Informationen consulte los catálogos, las hojas de características, la
und Daten erhalten Sie in den Katalogen und Datenblättern sucursal local de ABB o la Web http://www.abb.com. Sujeto
der Produkte, über die örtliche ABB-Niederlassung sowie auf a cambios técnicos sin previo aviso. En caso de duda,
der ABB Homepage unter http://www.abb.com. Technische prevalece el texto alemán.
Änderungen jederzeit vorbehalten. In Zweifelsfällen gilt der La instalación debe llevarse a cabo sólo por personal
deutsche Text. especializado. Es necesario respetar las normas
Nur von einer entsprechend qualifizierten Fachkraft zu especificas del país (p.ej. VDE, etc.). Antes de la
installieren. Dabei landesspezifische Vorschriften (z.B. instalación lea completamente estas instrucciones.
VDE, etc.) beachten. Vor der Installation diese Be- Estos aparatos son equipos para su montaje en
triebs- und Montageanleitung sorgfältig lesen und be- conjuntos y son de libre mantenimiento.
achten. Die Geräte sind wartungsfreie Einbaugeräte.
(GB) Operating and installation instructions (I) Istruzioni per l’uso ed il montaggio
Electronic time relays, CT-S range Relè temporizzatori elettronici, serie CT-S
Note: These operating and installation instructions cannot Nota: Le presenti istruzioni per l’uso ed il montaggio non
claim to contain all detailed information of all types of this contengono tutte le informazioni dettagliate su tutta la gamma
product range and can even not consider every possible di prodotti e non possono trattare tutti i casi applicativi. Tutte
application of the products. All statements serve exclusively le indicazioni servono esclusivamente a descrivere il prodotto
to describe the product and have not to be understood as e non sono da interpretare come caratteristiche garantite
assured characteristics with legal force. Further information con valore di legge. Per ulteriori informazioni consultare i
and data is obtainable from the catalogues and data sheets cataloghi ed i data sheet dei prodotti, o la nostra homepage
of this product, from the local ABB sales organisations as http://www.abb.com, oppure rivolgersi alla locale filiale ABB.
well as on the ABB homepage http://www.abb.com. Subject Ci riserviamo di eventuali modifiche tecniche. In caso di
to change without prior notice. The German text applies in differenze o problemi è valido il testo tedesco.
cases of doubt. Installazione solo a cura di personale specializzato.
The device must be installed by qualified persons Bisogna osservare le specifiche norme nazionali
only and in accordance with the specific national (p.e. VDE, etc.). Prima dell’installazione leggere
regulations (e.g., VDE, etc.). Before installing attentamente le seguenti istruzioni. Questi prodotti
this unit, read these operating and installation sono apparecchi ad incasso, che non hanno bisogno
instructions carefully and completely. The devices are di manutenzione.
maintenance-free chassis-mounted units.
(F) Instructions de service et de montage (CN) ֡ፕᇑҾጎኸళ

Relais électroniques temporisés, gamme CT-S ‫ۉ‬ጱ้क़ी‫ۉ‬ഗ CT-S ဣଚ
Note: Ces instructions de service et de montage ne ጀᅪǖԨ֡ፕኸళփԈࡤरຍຕ਍ࢅඇևׂ೗ᆌᆩຫ௽ǈ໯ᆶ
contiennent pas toutes les informations relatives à tous les ຕ਍ኻ๟ਏᆶ‫ׂܔ‬೗༬Ⴀ৊ႜຫ௽‫ڦ‬ፕᆩǈᅺُփਏԢ݆ୱၳ
types de cette gamme de produits et ne peuvent pas non ᆌăၘဦຫ௽൩֖ለरຍᄣԨई૴ஏABB‫ںړ‬Ӹ๚‫ت‬ई៓બ
plus tenir compte de tous les cas d’application. Toutes les BCCྪበǄhttp://www.abb.comǅăසᆶ߸߀ǈທփཚኪăժ
indications ne sont données qu’à titre de description du ᅜ‫ڤ‬࿔ྺՔጚă
produit et ne constituent aucunes obligations légales. Pour ഗॲՂႷᆯጆᄽටᇵӀቷࡔाጆᄽࡀቤҾጎǄස
de plus amples informations, veuillez-vous référer aux VDEǅăҾጎമǈ൩ံၘဦለ‫܁‬ԨҾጎኸళă
catalogues et aux fiches techniques des produits, à votre ׂ೗‫ڹ‬ಎփࡤඪࢆႴᄲҾጎ‫ڦ‬և‫ݴ‬ǈ൩փᄲ‫ٶ‬ਸ‫ڹ‬
Printed in the Fed. Rep. of Germany
agence ABB ou à notre site http://www.abb.com. Sous ಎăׂُ೗ྺ௨ྼࢺ‫ڹ‬ӱҾጎഗॲă

1SVC 630 030 M0000 A2 (01/10)
réserve de modifications techniques. En cas de divergences,

le texte allemand fait foi.
L’installation de ces produits doit être réalisée
uniquement par une personne compétente et en con-
formité avec les prescriptions nationales (p.e. VDE,
etc.). Avant l’installation de cet appareil veuillez lire
l’intégralité de ces instructions. Ces produits sont
des appareils encliquetables qui ne nécessitent pas
d’entretien.
ABB Stotz-Kontakt GmbH

Hauptstr. 14-16
78132 Hornberg / Germany
www.abb.com/lowvoltage -> Control Products -> Electronic Relays and Controls
(D) Produkt anbringen
(GB) Fix product
(F) Monter le produit
(E) Fijar el producto
(I) Montare il prodotto
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2CDC 252 282 F0005

(D) Plombierbare Klarsichtabdeckung anbringen
(GB) Fix sealable transparent cover
(F) Fixation du capot transparent condamnable
(E) Fijar cubierta transparente sellable
(I) Fissare
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2CDC 252 047 F0b09
0.6...0.8 Nm
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Ø 4.5 mm / 0.177 in / PH 1
7 mm
0.28 in
2 x 0.5...4 mm²
2 x 20...12 AWG
7 mm
2CDC 252 146 F0006
0.28 in
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2 x 18...14 AWG
7 mm
0.28 in
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2 x 18...14 AWG
2
I I Frontansichten mit Bedienelementen Deutsch
Einstellung des Zeitbereiches durch Wahl des

Endwertes
Bereich Endwert
0,15 - 3 s >> 3 s gelbe
1,5 - 30 s >> 30 s Skala
15 - 300 s >> 300 s
1,5 - 30 min >> 30 min
15 - 300 min >> 300 min
2 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h
1 1 0,05 - 1 s >> 1 s weiße
0,5 - 10 s >> 10 s Skala
2 4 2 4 5 - 100 s >> 100 s
Absolutskala zur Einstellung des Zeitwertes

1 3 innerhalb des gewählten Bereiches
Auswahl der Funktion bei CT-WBS
5 Funktionen siehe IV
2CDC 252 143 F0006
2CDC 252 144 F0006

Betriebszustandsanzeige mit LEDs
U/T: LED grün - Anzeige Steuerspeise-
spannung und Zeitablauf
V Steuerspeise-
spannung liegt an
W Verzögerungszeit
läuft
R: LED gelb - Anzeige der Schaltstellung
des Ausgangsrelais
V angezogen
II II DIP Schalter
฀ Auswahl der Funktion bei CT-MXS

1 ON = Einzeltaktgeber, pausebeginnend
2 ON = Ansprech- und Rückfallverzögerung,
asymmetrisch
3 ON = Ein- und Ausschaltwischer
4 ON = keine Funktion
2CDC 252 284 F0005
All ON = ON/OFF-Funktion
All OFF = Taktgeber, impuls- oder
pausebeginnend
Auslieferungszustand:
Alle DIP-Schalter in Position OFF
III III Elektrischer Anschluss
Bemessungssteuerspeisespannung
und Schaltbild dem seitlichen
Typenschild am Gerät entnehmen
A1-A2 Steuerspeisespannung Us
A1-Y1/B1 Steuereingang für Zeitstart
Z2-Z3/Z1 1./2. Fernpotentiometeranschluss zur
Zeitfeineinstellung.
Bei Anschluss eines externen Potentio-
meters wird das entsprechende
interne, frontseitige Potentiometer
automatisch abgeschaltet.
3
I Front view with operating controls English I Face avant et dispositifs de Français
commande
Adjustment of the time range by selecting the Réglage de la plage de temporisation par
max. value sélection de la valeur maximale
Range Max. value Plage Valeur maximale
0.15 - 3 s >> 3 s yellow 0,15 - 3 s >> 3 s échelle
1.5 - 30 s >> 30 s dial 1,5 - 30 s >> 30 s jaune
15 - 300 s >> 300 s 15 - 300 s >> 300 s
1.5 - 30 min >> 30 min 1,5 - 30 min >> 30 min
15 - 300 min >> 300 min 15 - 300 min >> 300 min
1.5 - 30 h >> 30 h 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h 15 - 300 h >> 300 h
0.05 - 1 s >> 1 s white 0,05 - 1 s >> 1 s échelle
0.5 - 10 s >> 10 s dial 0,5 - 10 s >> 10 s blanche
5 - 100 s >> 100 s 5 - 100 s >> 100 s
Direct reading scale to set the time value within Valeur absolue pour le réglage de la
the chosen range temporisation à l’intérieur de la plage choisie.
Selection of the function on CT-WBS Sélection de la fonction pour CT-WBS
Functions: see IV Pour les fonctions, voir IV
Status display with LEDs Indication de fonctionnement par LED
U/T: green LED - Status indication of control U/T: LED verte - Indication de la tension
supply voltage and timing d’alimentation de
V Control supply commande et temporisation
voltage applied V Tension
W Time delay is d’alimentation de
running commande appliquée
W Temporisation en
R: yellow LED - Status indication of output
cours
relay
R: LED jaune - Indication de l’état du relais
V energized
de sortie
V activé
II DIP switches II Micro-interrupteurs
฀ Selection of the function on CT-MXS ฀ Sélection de la fonction pour CT-MXS

1 ON = Single pulse generator, starting with OFF 1 ON = Générateur d’impulsion unique,
2 ON = ON-delay and OFF-delay, asymmetrical démarrant par arrêt
3 ON = Impulse-ON and impulse-OFF 2 ON = Temporisation Travail et Repos,
4 ON = no function asymétrique
All ON = ON/OFF-Function 3 ON = Contact de passage à l’activation et
All OFF = Pulse generator, starting with ON or OFF à la désactivation
State of delivery: 4 ON = pas de fonction
All DIP switches in position OFF Tous ON = Fonction ON/OFF
Tous OFF = Générateur d’impulsion, démarrant
par marche ou par arrêt
Etat de livraison:
Tous les micro-interrupteurs en position OFF
III Electrical connection III Raccordement électrique

For the rated control supply voltage Pour la tension assignée
and the circuit diagram, see label at d’alimentation de commande et pour
the side of the unit le schéma des connexions voir
l’étiquette placée sur le côté du relais.
A1-A2 Control supply voltage Us
A1-Y1/B1 Control input to start timing A1-A2 Tension d’alimentation de commande Us
Z2-Z3/Z1 1st/2nd remote potentiometer A1-Y1/B1 Entrée de commande pour le
connection for the fine adjustment of démarrage de la temporisation
the time delay. Z2-Z3/Z1 1er/2ème raccordement pour
When an external potentiometer is potentiomètre déporté pour le réglage
connected, the corresponding internal, fin de la temporisation.
front-face potentiometer is disabled. Quand un potentiomètre externe est
15-16/18 1st c/o contact raccordé, le potentiomètre interne
25-26/28 2nd c/o contact correspondant, sur la face avant, est
automatiquement désactivé.
15-16/18 1er inverseur
25-26/28 2ème inverseur
4
I Vistas frontales con elementos de Español I Vista frontale con gli elementi di Italiano
mando comando
Ajuste del margen de tiempo para selección Impostazione del campo di temporizzazione
del valor fondo escala mediante selezione del valore massimo
del campo
Margen Fondo escala
0,15 - 3 s >> 3 s escala Campo Valore massimo
1,5 - 30 s >> 30 s amarilla 0,15 - 3 s >> 3 s scala
15 - 300 s >> 300 s 1,5 - 30 s >> 30 s gialla
1,5 - 30 min >> 30 min 15 - 300 s >> 300 s
15 - 300 min >> 300 min 1,5 - 30 min >> 30 min
1,5 - 30 h >> 30 h 15 - 300 min >> 300 min
15 - 300 h >> 300 h 1,5 - 30 h >> 30 h
15 - 300 h >> 300 h
0,05 - 1 s >> 1 s escala
0,5 - 10 s >> 10 s blanca 0,05 - 1 s >> 1 s scala
5 - 100 s >> 100 s 0,5 - 10 s >> 10 s bianca
5 - 100 s >> 100 s
Escala absoluta para el ajuste del valor de
temporización dentro de margen seleccionado Scala a lettura diretta per l’impostazione del
tempo all’interno del campo selezionato
Selección de la función para CT-WBS
Funciones: vease IV Selezione della funzione per CT-WBS
Funzioni: vedi IV
Indicador de servicio con LEDs
U/T: LED verde - Indicación tensión de LED di visualizzazione dello stato di funzionamento
alimentación y U/T: LED verde - Indicazione tensione
temporización d’alimentazione e stato
V Tensión de della temporizzazione
alimentación aplicada V Tensione
W Temporización en d’alimentazione applicata
curso W Temporizzazione in
R: LED amarillo - Indicación del estado del corso
relé de salida R: LED giallo - Indicazione dello stato del
V energizado relè d’uscita
V eccitato
II Interruptores DIP II Interruttori DIP

฀ Selección de la función para CT-MXS ฀ Selezione della funzione per CT-MXS
1 ON = Generador de un único impulso, 1 ON = Generatore di singolo impulso,
inicio en OFF inizio con OFF
2 ON = Retardo a la conexión y a la 2 ON = Ritardo all’eccitazione ed alla
desconexión, asimétrico diseccitazione, asimmetrico
3 ON = Pulso a la conexión y a la 3 ON = Impulso all’eccitazione ed alla
desconexión diseccitazione
4 ON = ninguna función 4 ON = senza funzione
Todos ON = Función ON/OFF Tutti ON = Funzione ON/OFF
Todos OFF = Generador de pulsos, arranque en Tutti OFF = Generatore di impulsi, inizio con
ON ó en OFF ON o OFF
Entrega de fábrica: Impostazione di fabbrica:
Todos los interruptores DIP en posición OFF Tutti interruttori DIP in posizione OFF
III Conexión eléctrica III Collegamento elettrico

Véase la etiqueta lateral de Per la tensione nominale
características para la tensión nominal d’alimentazione e per lo schema
de alimentación y para el esquema elettrico, vedi la targhetta laterale del
contactos relè.
A1-A2 Tensión de alimentación Us A1-A2 Tensione d’alimentazione Us
A1-Y1/B1 Entrada de mando para el inicio de la A1-Y1/B1 Ingresso di comando per lo start della
temporización temporizzazione
Z2-Z3/Z1 1era/2da conexión del potenciometro Z2-Z3/Z1 1°/2° connessione per il potenziometro
remoto para el ajuste fino del tiempo de a distanza per la regolazione di
retardo. precisione del tempo.
Cuando un potenciometro externo se Il corrispondente potenziometro interno,
conecta, el correspondiente potencio- sul lato frontale, si disattiva auto-
metro interno del frontal se desactiva. maticamente al collegamento del
15-16/18 1er. contacto conmutado potenziometro esterno.
25-26/28 2° contatto di scambio
5
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1.5 - 30 min >> 30 min W W
15 - 300 min >> 300 min RNS RNS
1.5 - 30 h >> 30 h RNS RNS
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W W
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H UVKJKQF[ H`GVFSSTIT JNFUFMTSF
CT-WBSࠀీ჋ስ
! ! ࠀీ;֖ੂJW 4`GTV ZYSP\NN SF "%!
BYSP\NN WR IQFHY $
LEDs!ጒༀኸ๖
6NWUQKO WTWXTdSNd WT WHKXTJNTJFRN
U/T:෥!LED - ࠃ‫ۉۉ‬უࢅऺ้ጒༀኸ๖! #" MKQKSÒ ?86 8SJNPF\Nd WTWXTdSNd
V!ࠃ‫ۉۉ‬უฉ‫ۉ‬ SFUVdLKSNd UNXFSNd
N TXW]KXF HVKRKSN
W!ၚᆌჽ้Tvᆶၳ V =TJFST
SFUVdLKSNK UNXFSNd
W 8JKX TXW]KX HVKRK
R:ࣜ෥LED - ๼‫؜‬ी‫ۉ‬ഗ‫ۯ‬ፕጒༀኸ๖!
SN WVFGFX`HFSNd VKQK
V ‫ۯ‬ፕ
LKQXÒ ?86 8SJNPF\Nd WTWXTdSNd
H`[TJSTIT VKQK
V FPXNHNVTHFST
II DIP ਸ࠲
$% 1,'
჋ስCT-MXSࠀీ 4`GTV ZYSP\NN SF "&!
1 ON = ‫ڇ‬ஞ؋݀ิഗǈᅜOFFਸ๔ 5KSKVFXTV TJNST]S`[ NRUYQaWTH
2 ON = ཚ/܏‫ۉ‬ჽ้ǈჽ้้क़փ၎‫ڪ‬ SF]FQT TXW]KXF W HVKRKSN UFYM`
3 ON = ཚ‫ۉ‬ஞ؋ჽ้ࢅ܏‫ۉ‬ஞ؋ჽ้
4`JKVLPF UVN WVFGFX`HFSNN N
4 ON = ࿮ᆖၚ H`JKVLPF UVN TXUYWPFSNN
໯ᆶ ON = ON/OFF֪๬ࠀీ FWWNRKXVN]SFd
໯ᆶ!OFF = ஞ؋݀ิഗǈᅜONईOFFਸ๔ 8RUYQaW UVN WVFGFX`HFFSNN N
‫׍؜‬ఐණ࿋ዃ: NRUYQaW UVN TXUYWPFSNN
໯ᆶਸ࠲‫ت‬ᇀOFFጒༀ SKX ZYSP\NN
4WK ZYSP\Nd 49:4D9:
4WK 5KSKVFXTV NRUYQaWTH SF]FQT
TXW]KXF W HVKRKSN NRUYQaWF
NQN HVKRKSN UYFM`
?TWXTdSNK UTWXFHPN
4WK UKVKPQc]FXKQN H UTQTLKSNN 4D9:
III ‫ۉ‬ഘ૶থ '%,&# $# 1,"

၎࠲‫ۉۉࠃڦ‬უࢅথ၍࣮ୟǈ <TRNSFQaSTK SFUVdLKSNK UNXFSNd
! ! ൩֖ੂ้क़ी‫ۉ‬ഗ֨௬‫ڦ‬Քധ! N W[KRY WTKJNSKSNO WR SF bXNPKXPK
SF GTPY UVNGTVF

<FUVdLKSNK UNXFSNd #0
A1-A2 Usࠃ‫ۉۉ‬უ
' AUVFHQdc_NO H[TJ JQd MFUYWPF
A1-Y1/B1 ऺ้ਸ๔੦዆๼෇
HVKRKSS`[ ZYSP\NO
Z2-Z3/Z1 ‫ڼ‬ᅃĂ‫ܾڼ‬ᇺ‫ۉײ‬࿋ऺۙবჽ‫้׿‬क़
(
(( =TJWTKJNSKSNK IT
IT H`STWSTIT
! ! ‫ྔړ‬থᇺ‫ۉײ‬࿋ऺࢫǈी‫ۉ‬ഗമ௬ӱ้ۨ‫!ۉ‬
UTXKS\NTRKXVF JQd XTSPTO SFWXVTOPN
! ! ࿋ऺ฿ၳ
HVKRKSN MFJKVLPN =VN UTJPQc]KSNN
15-16/18 ‫ڼ‬ᅃ๼‫ۅة؜‬
HSK^SKIT UTXKS\NTRKXVF HWXVTKSSÒ
25-26/28 ‫ܾڼ‬๼‫ۅة؜‬
UTXKS\NTRKXV SF QN\KHTO UFSKQN
FHXTRFXN]KWPN TXPQc]FXKWd
Ò UP

TO UP
6
IV Function diagrams
1 DE 6 DB
A1-A2
2CDC 252 075 F0207

A1-Y1/B1
15-18, 25-28
15-16, 25-26
green LED
t1 t2 t2 t1
t1 = adjusted OFF time

t2 = adjusted ON time
2 EC 7 CA
3 AB 8 AC
4 CE 9 BC
5 DA 10 A
A1-A2
2CDC 252 013 F0207
15-18, 25-28
15-16, 25-26
green LED
t <t
t = adjusted time delay
11 G
7
8
IV Funktionen Deutsch
CT-MXS
1 DE Taktgeber, impuls- oder pausebeginnend
2 EC Einzeltaktgeber, pausebeginnend
3 AB Ansprech- und Rückfallverzögerung,
asymmetrisch
t1 eingestellte Ansprechverzögerungszeit
t2 eingestellte Rückfallverzögerungszeit
4 CE Ein- und Ausschaltwischer
t1 und t2 sind unabhängig voneinander einstellbar
CT-WBS
5 DA Blinker, impulsbeginnend
6 DB Blinker, pausebeginnend
7 CA Einschaltwischer
t eingestellte Wischzeit
8 AC Verzögerter fester Impuls
t1 eingestellte Verzögerungszeit
t2 Impulszeit fix 500 ms
9 BC Einstellbarer Impuls, fest verzögert
t2 Verzögerungszeit fix 500 ms
10 A Ansprechverzögerung
t eingestellte Verzögerungszeit
11 G ON/OFF-Funktion
ON-Funktion - Zeitbereich ≠ 300 h
OFF-Funktion - Zeitbereich = 300 h
Legende:
LED grüne LED blinkt während Zeitfablauf
A1-A2 Steuerspeisespannung
A1-Y1/B1 Steuereingang (potentialbehaftete Ansteuerung)
G Steuerspeisespannung liegt nicht an /
Ausgangskontakt geöffnet
B Steuerspeisespannung liegt an /
Ausgangskontakt geschlossen
Weitere Details zu den Funktionen und den

technischen Daten entnehmen Sie bitte dem Katalog.
9
IV Functions English IV Fonctions Français
CT-MXS CT-MXS
1 DE Pulse generator, starting with ON or OFF 1 DE Générateur d’impulsion, démarrant par
t1 adjusted OFF time marche ou par arrêt
t2 adjusted ON time t1 temps d’arrêt affiché
2 EC Single pulse generator, starting with OFF t2 temps de marche affiché
t1 adjusted OFF time 2 EC Générateur d’impulsion unique,
t2 adjusted ON time démarrant par arrêt
3 AB ON-delay and OFF-delay, asymmetrical t1 temps d’arrêt affiché
t1 adjusted ON-delay t2 temps de marche affiché
t2 adjusted OFF-delay 3 AB Temporisation au travail et Repos, asymétrique
4 CE Impulse-ON and impulse-OFF t1 temporisation au travail affichée
t1 adjusted pulse time 1 t2 temporisation au repos affichée
t2 adjusted pulse time 2 4 CE Contact de passage à l’activation et à la
t1 are t2 independently adjustable désactivation
t1 temps d’impulsion 1 affiché
CT-WBS t2 temps d’impulsion 2 affiché
5 DA Flasher, starting with ON t1 et t2 sont affichables indépendamment un de l’autre
t adjusted flashing time
6 DB Flasher, starting with OFF CT-WBS
t adjusted flashing time 5 DA Clignotant, démarrant par marche
7 CA Impulse-ON t temps de clignotement affiché
t adjusted pulse time 6 DB Clignotant, démarrant par arrêt
8 AC Fixed impulse with adjustable time delay t temps de clignotement affiché
t1 adjusted time delay 7 CA Contact de passage à l’activation
t2 fixed pulse time of 500 ms t temps d’impulsion affiché
9 BC Adjustable impulse with fixed time delay 8 AC Impulsion fixe avec temporisation affichable
t1 adjusted pulse time t1 temporisation affichée
t2 fixed time delay of 500 ms t2 temps d’impulsion fixe 500 ms
10 A ON-delay 9 BC Impulsion affichable avec temporisation fixe
t adjusted time delay t1 temps d’impulsion affiché
11 G ON/OFF-Function t2 temporisation fixe 500 ms
ON-Function - time sector ≠ 300 h 10 A Temporisation au travail
OFF-Function - time sector = 300 h t temporisation affichée
11 G Fonction ON/OFF
Fonction ON - plage de temporisation ≠ 300 h
Fonction OFF - plage de temporisation = 300 h
Legend: Légende:
LED Green LED flashes whilst timing LED La LED verte clignote pendant la temporisation
A1-A2 Control supply voltage A1-A2 Tension d’alimentation de commande
A1-Y1/B1 Control input (voltage-related triggering) A1-Y1/B1 Entrée de commande (activation par tension)
15-16/18 1st c/o contact 15-16/18 1er inverseur
25-26/28 2nd c/o contact 25-26/28 2ème inverseur
G Control supply voltage not applied / G Tension d’alimentation de commande non
output contact open appliquée / contact de sortie ouvert
B Control supply voltage applied / B Tension d’alimentation de commande
output contact closed appliquée / contact de sortie fermé
Pour de plus amples détails sur les fonctions et les

For further details on functions and technical data, données techniques, consultez s’il vous plaît, notre
please see our catalog. catalogue.
10
IV Funciones Español IV Funzioni Italiano
CT-MXS CT-MXS
1 DE Generador de impulso, inicio en ON ó en OFF 1 DE Generatore di impulsi, inizio con ON o OFF
2 EC Generador de un único pulso, inicio en OFF 2 EC Generatore di singolo impulso, inizio con OFF
3 AB Retardo a la conexión y a la desconexión, 3 AB Ritardo all’eccitazione ed alla diseccitazione,
asimétrico asimmetrico
t1 retardo a la connexion ajustado t1 ritardo all’eccitazione impostato
t2 retardo a la desconnexion ajustado t2 ritardo alla diseccitazione impostato
4 CE Pulso a la conexión y a la desconexión 4 CE Impulso all’eccitazione ed alla diseccitazione
t1 y t2 pueden ajustarse por separado t1 e t2 sono impostabile indipendentemente uno dell’altro
CT-WBS CT-WBS
5 DA Intermitencia, inicio en ON 5 DA Lampeggiatore, inizio con ON
6 DB Intermitencia, inicio en OFF 6 DB Lampeggiatore, inizio con OFF
7 CA Pulso a la conexión 7 CA Impulso all’eccitazione
t tiempo de pulso ajustado t tempo d’impulso impostato
8 AC Pulso fijo con tiempo de retardo ajustable 8 AC Impulso fisso con tempo di ritardo impostabile
t1 tiempo de retardo ajustado t1 tempo di ritardo impostato
t2 tiempo de pulso fijo de 500 ms t2 tempo d’impulso fisso 500 ms
9 BC Pulso ajustable con tiempo de retardo fijo 9 BC Impulso impostabile con tempo di ritardo fisso
t1 tiempo de pulso ajustado t1 tempo d’impulso impostato
t2 tiempo de retardo fijo de 500 ms t2 tempo di ritardo fisso 500 ms
10 A Retardo a la conexión 10 A Ritardo all’eccitazione
t tiempo de retardo ajustado t tempo di ritardo impostato
11 G Función ON/OFF 11 G Funzione ON/OFF
Función ON - margen de temporización ≠ 300 h Funzione ON -
Función OFF - margen de temporización = 300 h campo di temporizzazione ≠ 300 h
Funzione OFF -
campo di temporizzazione = 300 h
Leyenda: Leggenda:
LED El LED verde parpadea durante la LED Il LED verde lampeggia durante il trascorrere
temporización del tempo
A1-A2 Tensión de alimentación A1-A2 Tensione d’alimentazione
A1-Y1/B1 Entrada de mando A1-Y1/B1 Ingresso di comando (pilotaggio con tensione
(disparo con potencial) di riferimento )
15-16/18 1er. contacto conmutado 15-16/18 1° contatto di scambio
G Tensión de alimentación no aplicada / G Tensione d’alimentazione non applicata /
contacto de salida abierto contatto d’uscita aperto
B Tensión de alimentación aplicada / B Tensione d’alimentazione applicata /
contacto de salida cerrado contatto d’uscita chiuso
Per ulteriori informazioni su dettagli tecnici e

Para más información en funciones y datos técnicos, funzionalità dei prodotti Vi preghiamo di consultare
por favor consulte nuestro catálogo. il nostro catalogo tecnico.
11
>YWWPNO
IV ࠀీ!!!!! DO! ("+

CT-MXS DE 5KSKVFXTV NRUYQaWTH SF]FQT TXW]KXF
1 DE ஞ؋݀ิഗǈᅜpoईpgg!ਸ๔ W HVKRKSN NRUYQaWF NQN UFYM`
t1 off ้क़ۙব 1 VKIYQNVYKRTK HVKRd UFYM`
t2 on ้क़ۙব 1
2 EC ‫ڇ‬ஞ؋݀ิഗǈᅜOFFਸ๔
EC 5KSKVFXTV TJNST]S`[ NRUYQaWTH
t1 off ้क़ۙব SF]FQT TXW]KXF W HVKRKSN UFYM`
t2 on ้क़ۙব 1 VKIYQNVYKRTK HVKRd UFYM`
3 AB ཚ/܏‫ۉ‬უჽ้ǈჽ้้क़փ၎‫ڪ‬ 1
t1 on ้क़ۙব AB 4`JKVLPF UVN WVFGFX`HFSNN
t2 off ้क़ۙব N H`JKVLPF UVN TXUYWPFSNN
4 CE ཚ‫ۉ‬ஞ؋ჽ้ࢅ܏‫ۉ‬ஞ؋ჽ้ FWWNRKXVN]SFd
t1 ஞ؋้क़2ۙব 1 VKIYQNVYKRFd H`JKVLPF UVN
t2 ஞ؋้क़3ۙব WVFGFX`HFSNN
t1 ๟ t2 ‫܀‬૬‫ۙڦ‬ব 1
VKIYQNVYKRFd H`JKVLPF UVN
TXUYWPFSNN
CT-WBS CE 8RUYQaW UVN WVFGFX`HFSNN
5 DA ཚ‫ۉ‬෻ຮǈᅜଋༀONਸ๔ N NRUYQaW UVN TXUYWPFSNN
t ෻ຮ้क़ۙব 1 VKIYQNVYKRTK HVKRd NRUYQaWF
6 DB ཚ‫ۉ‬෻ຮǈᅜӁༀOFFਸ๔ 1
t ෻ຮ้क़ۙব 1 N 1
VKIYQNVYcXWd TXJKQaST
7 CA ཚ‫ۉ‬ஞ؋ჽ้
t ஞ؋้क़ۙব
8 AC ჽ้้क़੗ۙǈࠦۨஞ؋้क़ DA ;NIFSNK W SF]FQTR NRUYQaWF
t1 ჽ้้क़ۙব 1 VKIYQNVYKRTK HVKRd RNIFSNd
! ! t2 ࠦۨஞ؋้क़611!nt DB ;NIFSNK W SF]FQTR UFYM`
9 BC ੗ۙஞ؋้क़ǈࠦۨჽ้้क़ 1 VKIYQNVYKRTK HVKRd RNIFSNd
t1 ஞ؋้क़ۙব CA 8RUYQaW UVN WVFGFX`HFSNN 49:
! ! t2 ࠦۨჽ้้क़611!nt 1 VKIYQNVYKRTK HVKRd NRUYQaWF
10 A ཚ‫ۉ‬ჽ้ AC BNPWNVYKRÒ NRUYQaW W
t ჽ‫้׿‬क़ۙব VKIYQNVYKR`R HVKRKSKR MFJKVLPN
11 G ON/OFF֪๬ࠀీ 1 VKIYQNVYKRTK HVKRd MFJKVLPN
ON -ࠀీ-้क़ਗ਼‫ ܈‬300ၭ้ 1
HVKRd ZNPWNVTHFSSTIT NRUYQaWF
OFF-ࠀీ-้क़ਗ਼‫ =܈‬300ၭ้ RW
BC >KIYQNVYKRÒ NRUYQaW W ZNPWNVTHFS
S`R HVKRKSKR MFJKVLPN
1 VKIYQNVYKRTK HVKRd NRUYQaWF
1
ZNPWNVTHFSSTK HVKRd MFJKVLPN
RW
A 7FJKVLPF UVN WVFGFX`HFSNN
1 VKIYQNVYKRTK HVKRd MFJKVLPN
G BYSP\Nd 49:4D9:
཮๖: BYSP\Nd 49: HVKR WKPXTV ]
LED ऺ้ዐ୴෥LED෻ຮ BYSP\Nd 4D9: HVKR WKPXTV ]
A1-A2 ࠃ‫ۉۉ‬უ
A1-Y1/B1 ੦዆๼෇Ǆ߅থ‫ۅ‬ǅ
15-16/18 ‫ڼ‬ᅃ‫ۅة‬ #","2
25-26/28 ‫ۅةܾڼ‬ ?86 7KQKSÒ ?86 RNIFKX UVN TXW]KXK
G ࠃ‫ۉۉ‬უ࿄ฉ‫ ۉ‬/ ๼‫܏ۅة؜‬ਸ HVKRKSN
B ࠃ‫ۉۉ‬უฉ‫ ۉ‬/ ๼‫ۅة؜‬Կࢇ
<FUVdLKSNK UNXFSNd
' AUVFHQdc_NO H[TJ W MFUYWPTR
HVKRKSS`[ ZYSP\NO UTJF]KO
SFUVdLKSNd UNXFSNd SF H[TJ YUVFHQKSNd
Ò UP

TO UP
G <FUVdLKSNK UNXFSNd TXWYXWXHYKX
H`[TJSTO PTSXFPX VFMTRPSYX
B <FUVdLKSNK UNXFSNd UTJFST
H`[TJSTO PTSXFPX MFRPSYX
#$# "' /"(1")#%!+1#)("+2*

߸‫ీࠀܠ‬႑တतरຍጨଙǈ൩֖ੂᄣԨă '*",&*$%!'%* &!"-!
' #
12
Position: FC001,FC002
Part code: M004140
9.9 Frequency converter - FC-202
ID: D11592
VLT AQUA Drive FC202 Frequency converter

1 Connection
1.1 Power and supply terminals
Mains DC link circuit Motor
Terminal no. Description Remarks
91 (L1), 92 (L2), 93 Three-phase connection for mains supply

(L3)
95 PE conductor connection Use minimum 10 mm2. See note below.
96 (W), 97 (V), 98 Three-phase motor connection See nameplate for nominal data
(W)
99 PE conductor connection Equipotential bonding for motor
88 (-), 89 (+) Capacitor-backed DC link circuit intended Note: maximum voltage 850–1000 V DC.
for coupling several drive axes
81 (-), 82 (+) Optional brake resistor connection for Note: maximum voltage 850–1000 V DC.
increased dynamic braking
35 (-), 36 (+) MCB 107 D option: connection for optional Max. 24 V DC +/- 15%
external 24 V power supply for control Max. Input current 2.2 A
electronics (plug-and-socket connector).
As frequency converters can produce earth leakage currents greater than 3.5
mA due to their mode of operation, in accordance with EN 50178 an earth
conductor with a cross-section of at least 10 mm2 must be used or two
separately installed earth conductors must be connected.

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ID: D11592
1.2 Control terminals in basic unit (without A, B or C options)
See Section 1.3 for a description of switches S201, S202 and S801. The maximum rated
voltage on analogue inputs 53 and 54 is 20 V.

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ID: D11592
Term Description Remarks

inal
12, 13 Internal +24 V DC source for powering digital inputs. Maximum load 200 mA
no.
18 Digital input (see parameter 5-10 for function) 0–24 V DC, Ri = 4 kΩ
19 Digital input (see parameter 5-11 for function) < 5 V = logic “0” (PNP logic)
> 10 V = logic “1” (PNP logic)
20 Reference potential (0 V) for external digital input/output Frame potential for terminals 12, 13
configuration
27 Digital input/output (see parameters 5-01, 5-12 & 5-30 for Input: see terminals 18 and 19
29 function)
Digital input/output (see parameters 5-02, 5-13 & 5-31 for Output: 0/24 V DC, max. 40 mA Pulse
function) output: see product manual
32 Digital input (see parameter 5-14 for function) Input: see terminals 18 and 19 Pulse
33 Digital input (see parameter 5-15 for function) input: see product guide
Only for FC 200 with optional safe stop To achieve the safety function, the
37 Digital input for safe stop compliant with EN 954-1 Cat. 3 or information in the design guide must
EN 13849-1 SIL 2 (see parameter 5-19 for function) be observed.
39 Ground potential for analogue output 42
42 Scalable analogue output 0/4–20 mA (see parameter 6.5* for 0/4–20 mA, 500 Ω max.
function)
50 Internal +10 V DC power source, for example, for supplying 10 V DC, max. 15 mA
potentiometer or motor thermistor
Analogue inputs 0–10 V DC or 0/4–20 mA, selectable for 0 to +10 V, scalable, Ri approx. 10 kΩ;
reference/feedback or motor thermistor 0 to 20 mA, scalable, Ri approx. 200
53, 54 (function: terminal 53, see parameter 6-1*; terminal 54, see Ω V/mA selection; see S201/S202
parameter 6-2*; Note: maximum voltage on analogue
reference, see parameters 3-15, 3-16 & 3-17; feedback, see inputs
parameter 20-0*; motor thermistor, see parameters 1-93 & 1- 20 V.
90)
55 Ground potential for analogue inputs 53 and 54
61 Integrated RC decoupling Do not use
68 (+), RS 485 serial interface (see parameter 8-3* for function) Max. 115 kbit/s
69 (-)
01, 02, Relay output 1 (see parameter 5-40 [0] for function) Max. 240 V AC, 2 A (resistive load)
03 See the design guide for further
information.
04, 05, 06 Relay output 2 (see parameter 5-40 [1] for function)

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ID: D11592
1.3 Function of DIP switches in basic unit (without A, B or C

options)
Changes to DIP switch settings become effective only after switching off and then on
again.
1.4 Digital input programming options

Parameter 5-10 5-11 5-12 5-13 5-14 5-15
Not used [0] x x
Alarm reset [1]
Coast (inverse) [2] x
Coast/Reset (inverse) [3]
Quick stop ramp (inverse) [4]
DC brake (inverse) [5]
Stop (inverse) [6]

Ext. interlock [7]
Start [8] x
Latched start pulse [9]
Reversing [10]
x
Start + reversing [11]
Fixed speed (jog) [14]
Fixed reference enabled [15]


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ID: D11592

Parameter 5-10 5-11 5-12 5-13 5-14 5-15
Store reference [19]
Store speed [20]
Speed up [21]
Speed down [22]
Counter input [30] - - - -

Pulse input [32] - - - -
Ramp bit 0 [34]
Mains failure (inverse) [36]
Run Permissive [52]
Manual Start [53]
Auto start [54]
DigiPot Increase [55]
DigiPot Decrease [56]
DigiPot Clear [57]
Counter A (+1) [60] - - - -

Counter A (-1) [61] - - - -
Reset Counter A [62]
Counter B (+1) [63] - - - -

Counter B (-1) [64] - - - -
Reset Counter B [65]
Sleep Mode [66]
Reset Maintenance Word [78]
Lead Pump Start [120]
Lead Pump Alternation [121]
[ ] = selectable; [-] not selectable; [x] = factory setup. See programming manual for details.

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ID: D11592
2 Operation via LCP 102

2.1 Graphical control unit LCP 102
2.2 Explanation of LCP 102 status display

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ID: D11592
3 Easy commissioning
3.1 Commissioning menu (submenu Q2 of Quick Menu)
The commissioning menu has a set of 11 parameters that are necessary during
typical commissioning. These parameters are arranged logically instead of by
number. Note: always enter the parameters in the order shown. To access the
commissioning menu, press the [Quick Menu] button, select „Q2 commissioning
menu“, and confirm with [OK]. Press the [Status] button to return to normal view.

0-01 Language English [0] or set to local language
1-20 Motor power [kW] According to motor nameplate data
1-22 Motor voltage [V] According to motor nameplate data
1-23 Motor frequency [Hz] According to motor nameplate data
1-24 Motor current [A] According to motor nameplate data
1-25 Rated motor speed [rpm] According to motor nameplate data
3-41 Ramp-up time 1 Set ramp-up time (acceleration time up to rated motor speed)
3-42 Ramp-down time 1 Set ramp-down time (deceleration time from rated speed to zero RPM)
4-12 Min. speed [RPM] Set desired minimum speed
4-14 Max. speed [RPM] Set desired maximum speed
1-29 Automatic Motor Adaptation (AMA) AMA is worthwhile if motor operation is unsatisfactory or
additional optimisation is desired.
See the description of AMA in the product guide.

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ID: D11592
3.2 Other commonly used parameters in the main menu

The following table lists other parameters in the main menu that are often
necessary in addition to the commissioning parameters. The parameters in the
main menu can be accessed by pressing the [Main Menu] button and selecting the
subgroups.

1-00 Control response Speed control or PID control
[0] compressor torque, [1] square-law torque, [2] automatic energy
1-03 Load torque characteristics optimisation CT, [3] automatic energy optimisation VT
1-9* Thermal motor protection Motor temperature monitoring, see description under 6. Application
examples:
3-10 Fixed references (0–7) Use digital fixed references
3-15 Variable reference 1
3-16 Variable reference 2 Select an analogue input, digital input or bus port as the
3-17 Variable reference 3 reference signal. See also description under 6. Application
examples:
6-1* Analogue input, terminal 53 Input signal scaling (current/voltage) and the associated reference and
feedback values.
6-2* Analogue input, terminal 54 Input signal scaling (current/voltage) and associated reference and
feedback values.
20-0* Feedback Specify feedback inputs and signal characteristic
Specify signal conditioning here when using several feedback values

20-2* Feedback/reference and/or additional reference values.
15-0* Operating data Display of current operating data
15-3* Fault log Read out fault log data and values
15-43/-45/-51: frequency converter identification. This information is

15-4* Type data necessary for service queries.
14-50 RFI filter Must be disabled if the unit is used in an IT network.
of all current frequency converter and system data (such as reference,

16-** Data display feedback, bus, motor, and FC data)

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3.3 Using the LCP copy function (parameter 0 -50) to transfer device
parameters
The copy function can be used to store all unit parameters in the LCP 102 control
panel. The stored parameters can be transferred to the same unit of other units if
necessary. The data is permanently stored (in EEPROM) in the LCP and can only
be changed or deleted by overwriting with new data. The parameters in the LCP
memory can only be accessed by loading them back from the unit. Parameter 0-50
can be accessed by pressing the [Main Menu] button and selecting menu „0-**
Operation/Display“ or „0-5* Copy/Store“.
No motor data is transferred if „Load from LCP, only Fct.“ is selected.
3.4 Parameter setting with MCT 10 software

Source and system requirements
Download the software from the Software/MCT 10 Software page at
www.danfoss.com/drives
The free basic version of the MCT 10 software can be used to archive data from
and document all current Danfoss frequency converter series. The CD key
required for installation is 12314500.
Minimum system requirements: Pentium III 350 MHz (or compatible), 128 MB
RAM, 200 MB free hard drive space.

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ID: D11592
Data exchange with the converter
Converter -> PC:

2. Select the converter in the network
3. Select „Copy“
4. Click the project and select „Add“
5. Save the project in the File menu
PC -> Converter:
1. Open the saved file
3. Select the converter in the project
4. Select „Write to frequency converter“
Access via USB port
The connection between the converter and PC is detected automatically. Configuration

of the parameters in the converter or the PC software is not necessary

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ID: D11592
Access via RS-232, Ethernet, or USB Converter
Every Danfoss converter has a bus-capable RS-485 interface. It supports up to 32

network nodes (127 with repeaters).
For access to the interface, a suitable converter (RS-232 to RS-485, USB to RS-485, or
Ethernet TCP/IP to RS-485) is necessary.
Connection
How to connect
In order to use the connection and configure the converter, the interface
settings of the MCT 10 software (Communication -> Driver menu) must be
compatible (address range, COM port and baud rate). You can use the
Communication -> Network Search menu item to look for connected
converters.
4 Profibus DP interface
4.1 General settings
8 - 10 Control Word Profile See PLC
9 - 18 Profibus node address (set all address DIP 0–125

switches to „ON“)
9 - 22 PPO type Automatic
9 - 63 Baud rate Automatic
The settings do not take effect until the Profibus interface has been initialised
(use parameter 9-72 to reset the interface or switch the external 24 V supply
off and back on).

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4.2 Further settings

8 - 01 Control Site Activate control word
8 - 02 Active control word Option A
8 - 50 … 8 - 56 Priorities between bus/terminal operation (observe parameter 8-01) Application dependent
8 - 03 … 8 - 05 Control word timeout (defined response to bus failure) Application dependent
8 - 07 Diagnosis Trigger (disable in case of doubt) See PLC
9 - 15 … 9 - 16 PCD Configuration See PLC
9 - 27 … 9 - 28 PCW/PCD enabled/disabled Enabled
5 Fault analysis
5.1 Warnings, alarms, and alarm resetting
Warning (yellow Warning LED on)
A warning is an indication of a defined state. Warning indications
can occur during normal operation; they may be purely informative
(uncritical) or indicate a potential problem. Analyse the warning
based on the displayed warning number [Wxxx].
Alarm (red Alarm LED blinks)

Alarm indications occur when motor operation has been inhibited
by the FC 200 for safety reasons. Analyse the alarm based on the
displayed alarm number [Axxx]. There are several ways to reset
alarms that are „trip- locked“ after the cause has been remedied:
- [Reset] button on LCP

- Programmed digital input (see parameter settings in group 5-1*)
- Automatic reset function (see parameter settings in group 14-2*)
- Reset signal via bus interface (such as RS-485 or Profibus)
The reset signal resets the frequency converter after an alarm (trip). The button can be
enabled [1] or disabled [0] with parameter 0-43, “LCP Reset button”.
Warning
Before resetting an alarm, always determine and remedy the cause. Resetting an alarm
without adequately determining the cause can lead to damage to the frequency converter
or system as well as serious accidents.

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Trip-locked alarm (red Alarm LED blinks, alarm cannot be reset, and „Trip-lock“ is
displayed on the control panel (if present))
Trip-lock is an additional protective function of the VLT AQUA Drive

and can only be cancelled by disconnecting mains power to the unit.
If the unit has an external 24 V DC supply (D option), it is only
necessary to disconnect the unit from the mains supply voltage. In
this case, the control card remains active (for example, to support
fieldbus communication).
The alarm can be reset again as previously described after the VLT
AQUA Drive FC 200 has been switched off and on.
If the display still shows a trip-lock after the unit has been switched
off (before the alarm is reset), the unit may have an internal fault.
Contact your Danfoss Service provider in this case.
5.2 If the drive does not restart after an alarm reset

An alarm is still displayed Setting
1. Is the alarm trip-locked? See description in Section 5.1.
2. Has the cause of the alarm been remedied, or is the
alarm displayed again immediately after it is reset?
View the alarm numbers in the fault/alarm log and
use them to determine the cause of the alarm.
3. Is the LCP [Reset] button enabled? See parameter 0-43
An alarm is no longer displayed Setting

1. Is the LCP [Off] button enabled? Press the [Auto-On] button to restart.
2. Is a start signal present on the digital input or bus Check whether a start signal is present on the digital
interface? input or the bus.
3. Is a reference value available on an analogue or digital Check the reference value.
input or the bus interface?
4. Is there an open circuit between the frequency Check the motor wiring. Is a contactor or motor switch
converter output and the motor? present?

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5.3 Warning and alarm indications

No. Description Warning Alarm / trip Alarm / Trip-lock See parameter
1 10 V low X
2 Signal fault (X) (X) 6-01
3 No motor (X) 1-80
4 Mains phase imbalance (X) (X) (X) 14-12
5 DC link voltage high X
6 DC link voltage low X
7 DC overvoltage X X
8 DC undervoltage X X
9 Inverter overloaded X X
10 Motor ETR overtemperature (X) (X) 1-90
11 Motor thermistor (X) (X) 1-90
12 Torque limit X (X) 14-25
13 Overcurrent X X X
14 Earth fault X X X
15 Hardware mismatch X X
16 Short circuit X X
17 Control word time-out (X) (X) 8-04
23 Internal fan fault (X) (X) 14-53
24 External fan fault (X) (X) 14-53
25 Brake resistor shorted X
26 Brake resistor power limit (X) (X) 2-13
27 Brake chopper shorted X X
28 Brake resistor test (X) (X) 2-15
29 Inverter overtemperature X X X
30 Motor phase U dropout (X) (X) (X) 4-58
31 Motor phase V dropout (X) (X) (X) 4-58
32 Motor phase W dropout (X) (X) (X) 4-58
33 Inrush fault X X
34 Fieldbus fault X (X)
36 Mains failure X X
38 Internal fault X X
42 Overload on digital output X
47 30-6/30-7
24 V supply low X X X
48 1.8 V supply low X X
49 Speed limit X
50 AMA calibration fault X
51 AMA check Unom and Inom X
52 AMA low Inom X
53 AMA motor too big X
54 AMA motor too small X
55 AMA parameter out of range X
56 AMA interrupted by user X
57 AMA timeout X
58 AMA internal fault X X
59 Current limit X
60 Ext. interlock (X) 5-1*
62 Output frequency limit X 4-19
64 Motor voltage X
65 Control board X X X
66 overtemperature
Temperature low X
67 New options X
68 Safe stop X
69 Inverter overtemperature X X
70 Invalid FC configuration X X
79 Invalid PS configuration X X
80 Unit initialised X
92 K. flow X X 22-23
93 Dry pump X X 22-26
94 End of curve X X 22-50
95 Broken belt X X 22-60
96 Start delay X 22-75, 22-76
97 Stop delay X 22-75, 22-77
98 Clock fault X 0-7*
250 New spare part
251 New type code

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6 Application examples
6.1 Start/stop, four pole motor, motor thermistor
Reference 0 –50 Hz via terminal 53; motor thermistor
monitoring on terminal 19.
Relevant parameters



*Factory setting

user.

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6.2 Start/stop, four-pole motor, oversynchronous, motor

thermistor
Visual alarm indication
Relevant parameters



*Factory setting

user.

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ID: D11592
6.3 Start/stop, two-pole motor, motor thermistor

Reference 0–50 Hz via potentiometer on terminal 53.
Relevant parameters



*Factory setting

user.

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6.4 Start/stop, two-pole motor, oversynchronous, motor

thermistor
Relevant parameters



*Factory setting

user.

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6.5 Start/stop, motor thermistor

Reference 0 –50 Hz terminal 53;
Relevant parameters


5-31 Terminal 29: digital output [60] Comparator 0

Interrogation Alarm 11 (motor thermistor)

13-10[0] Comparator operand [20] Alarm number
13-11[0] Comparator function [1] !(equal)*
13-12[0] Comparator value 11,000
*Factory setting

user.

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6.6 Fixed speeds

Three different speeds (preset references) can be selected
via floating contacts.
Relevant parameters

5-11 Terminal 19: digital input [6] Stop (inverse)
5-30 Terminal 27: digital input [70] Logic rule 0
Internal logic rule

References
*Factory setting

user.

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6.7 Automatic fast ramp

The starts up with fast acceleration and then runs with slow
acceleration. Reference 0–1500 rpm via potentiometer.
Relevant parameters

5-12 Terminal 27: digital input [2] Coast (inverse)*

5-31 Terminal 29: digital output [16] Under min. speed
5-15 Terminal 33: digital input [34] Ramp bit 0
3-41 Ramp Up 1 „Slow“

3-42 Ramp Down 1 „Slow“
3-51 Ramp Up 2 „Fast“
3-42 Ramp Down 2 „Fast“
4-11 Motor speed low limit 900 rpm

4-52 Motor speed low limit warning 900 rpm
*Factory setting

user.

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ID: D11592

keypad
In the switch position „Auto“, the reference is active via potentiometer.
In the switch position „Manual“, the reference can be set using the „Up“ and „Down“
buttons.
In the switch position „Off“, the motor is stopped.
Relevant parameters


*Factory setting

user.

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ID: D11592

potentiometer
In switch position „Auto“, the reference is active via potentiometer.
In switch position „Manual“, the unit can only be operated via the display.
In switch position „Off“, the motor is stopped.
Relevant parameters

5-11 Terminal 19: digital input [54] Auto start
5-12 Terminal 27: digital input [53] Manual start
*Factory setting

user.

FIN-20101 TURKU Fax + 358 204 86 5031
ID: D11592

potentiometer
With Profibus control, the converter does not accept any commands via the terminals.
If Profibus control is interrupted, the converter automatically switches to manual mode
(reference setting via buttons). Manual mode can also be selected via terminal 18.
Relevant parameters
1-1* Motor data see motor nameplate
8-03 Ctrl. param. for timeout time 1 sec

8-04 Timeout function ctrl. param. [8] Select Setup 2
8-05 Timeout End ctrl. param. [1] Resume setup*
9-18 Node address As required
5-10 Terminal 18: digital input [23] Setup select bit 0

5-40[0] Relay function [9] Alarm
5-40[1] Relay function [23] Bus OK
0-51 Setup copy [2] Copy to Setup 2

0-10 Active setup [9] Multi Setup
0-12 Link setup to [2] Setup 2


*Factory setting

user.

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6.11 Pressure control in %

Internal reference, feedback 0–100% on terminal 54.
Relevant parameters
Start/Stop
Pressure control
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0%*
6-25 Ter. 54 scale max. ref/feedback 100%*

*Factory setting

user.

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6.12 Pressure control in Pa

Internal reference, feedback 0–2000 Pa on terminal 54.
Relevant parameters
Start/Stop
Pressure control
Scaling in Pa
3-02 Min. reference 0 Pa*
3-03 Max. reference 2000 Pa
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 Pa*
6-25 Ter. 54 scale max. ref/feedback 2000 Pa

*Factory setting

user.

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ID: D11592
6.13 Pressure control in bar with pipe compensation

Pressure control using integrated process controller with pipe
pressure drop compensation. Internal reference, feedback 0–10 bar
on terminal 54.
Relevant parameters
Start/Stop
Pressure control
Scaling in bar
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 bar*
Pipe compensation
22-80 Flow compensation [1] Enabled
22-81 Quad./lin. curve calculation 100
22-84 Speed at no flow [Hz] 25 Hz
22-86 Freq. design point [Hz] 50 Hz
22-87 Pressure at no-flow speed 3 bar

*Factory setting

user.

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6.14 Volume flow control in m³/h, feedback signal output 0–20 mA

Relevant parameters
Start/Stop
Volume flow control

Scaling in m3/h
Feedback signal
Analogue output

*Factory setting

user.

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6.15 Volumetric flow control in m³/h, oversynchronous, feedback

signal output 0–20 mA
Relevant parameters
4-14 Max. frequency [Hz] 72Hz
Start/Stop
Volume flow control

Scaling in m3/h
Feedback signal
Analogue output

*Factory setting

user.

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6.16 Pressure control in bar, basic cascade controller

The VLT® AQUA Drive cascade controller can switch on additional
pumps via the relays if necessary.
Controlled variable 0–10 bar on terminal 54.
Relevant parameters
3-10 Preset ref. [0]
Start/Stop
5-12 Terminal 27: digital input [2] Coast (inverse) *
Pressure control
Scaling in bar
Feedback signal
6-24 Ter. 54 scale min. ref/feedback 0 bar
20-73 Min. feedback level 0 bar
20-74 Max. feedback level 10 bar
Cascade control
25-00 Cascade controller [1] Enabled
25-05 Preset control group [1] Yes *
25-06 Number of pumps [1] 3 pumps
25-45 Switch-on threshold [Hz] 45 Hz *
Relay
*Factory setting
user.

FIN-20101 TURKU Fax + 358 204 86 5031
Section 6
Attachments
D
Component: Floating Ball Valve
Type : Rotex
Engines : 16419-27 & 16430-36
BERGEN ENGINES AS
[ BLANK ]
S.NO DESCRIPTION MODEL MAKE
BALL VALVE MOC
274 160-APPROX 96 (62F)
1 BODY- WCB
ROTEX
BALL-SS316 65NB FB 150#
SEAT-TFM1600
5
2 ROTARY ACTUATOR QTF100E-22 ROTEX
3 SOLENOID VALVE 30318-5-2G ROTEX
4 COIL 24V-DC-37 ROTEX
5 LIMIT SWITCH DNLF1A2-4R-M1 ROTEX
2
CABLE ENTRY
1
4 2"NPT(F)
450-APPROX.
139
CONN.-
1/4"NPT(F)
1 3
190 ON PCD 140
CUSTOMER NAME : -- -- -- -- -- --
THIS DRAWING IS THE PROPERTY
OF ROTEX MANUFACTURERS AND BERGEN ENGINES INDIA PVT.LTD. -- -- -- -- -- --
ENGINEERS PRIVATE LIMITED,
DOMBIVLI (E) - 421204, INDIA. S.O. NUMBER : 16204189 S.O. DATE : 28/09/2016 -- -- -- -- -- -- TITLE
This Drawing contains confidential
information of ROTEX Manufacturers
OFFER NUMBER : -- -- -- -- -- -- --
And Engineers Private Limited.It must OFFER DATE : -- 01 1/4"BSP(F)--1/4"NPT(F) SAS SAS SAS 12-09-2017 DWG NO. A3
not be disclosed to a third party,
competitors or copied or lent without the P.O. NUMBER : PO/1115/2016/1006 00 INITIAL RELEASE SAS SAS KMS 03/10/2016
written consent of ROTEX Maufacturers
And Engineers Private Limited.
P.O. DATE : 16/08/2016 REV. NO DESCRIPTION DRAWN CHK'D APPV'D APPV'D DATE DEBUR AND BREAK SHARP EDGES
AC SCALE NTS SHEET 01 OF 01
QTY : 18 NO. DO NOT SCALE DRAWING
[ BLANK ]
[ BLANK ]
[ BLANK ]
[ BLANK ]
F 162/16 D
I – Installation documentation D – Instruction/maintenance documentation S – Service documentation
Component: Nozzle Oil Temp. Control Module

Type: Hotstart, 9 kW, 400V/50Hz
Rolls-Royce Marine part no.: 708805
Date/Sign/rev.: 20.07.11/LOS
Rolls-Royce Marine AS, Dep. Engines - Bergen

P.O.Box. 924 Sentrum, N-5808 Bergen, Norway, Switchboard + 47 55 53 60 00, Telefax + 47 55 53 61 04
[ BLANK ]
Technical data, Item No. 708805 (Drwg. No.F162/16)
Power supply: 400V/50Hz
Pump
Gear type positive displacement pump

Capacity: 1817 l/h
Safety valve, adjustable set point: 5 – 8,5 bar
Motor:
Rated power: 1,5 kW

Starting current: 23A
Normal current: 3,1 A
Electrical hetear
Power: 9 kW
Oil tank:
Carbon steel , powder coated
Volume: 20 liters
Normal filling: 15 liters
Low alarm volume: 13 liters
High alarm volume: 17 liters
Oil type:
Refer to Rolls-Royce Engines Bergen Lubricant Guide

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REVISIONS
REV. ECO DATE DESCRIPTION AUTH. DR.
TRANSFORMER PRIMARY HEATER SECONDARY

D FUSES READY FAULT D
CONTACTOR CONTROL RELAY
CIRCUIT SOLENOID
BREAKER RELAY
CONTROL
RELAY
15.50
393.7 PRIME
RELAY
FAULT
RELAY
LOW OIL
C RELAY
C
1
A
12.44
315.9
B B
MAIN POWER MOTOR

CONNECTION TEMPERATURE TIME DELAY MOTOR PROTECTIVE
CONTROL RELAY CONTACTOR SWITCH
6.47 GROUND LUG RELAY
164.4
HOTSTART, INC. SPOKANE, WA. A

PROPRIETARY INFORMATION
A
NOTES: This drawing and the information shown on it are property of Hotstart, Inc.
and are for the sole purpose of doing business with us. Any copying or transmittal to others
CONTROL
POWER IN
of this information is strictly prohibited without prior written consent Hotstart.

TITLE
1. FOR DETAIL "A", SEE SHEET 2 B-NTCS 400V 3P 9kW 2HP SCR
APPROVALS DATE DWG. NO.
UNLESS OTHERWISE SPECIFIED
2. REFERENCE DRAWING A-7320-3 FOR DRAWN BY
ALS 09-03-10
DIMENSIONS ARE IN INCHES [mm]
A-7370-2S
WIRING SCHEMATIC. APPROVED BY
TOLERANCES
(Except as noted) ORIGIN
SIZE
CM 09-03-10 .XX N/A ANGULAR
CO 7075
THIRD ANGLE
PROJECTION
.XXX N/A
DO NOT SCALE DRAWING
N/A
B SCALE
1:3
SHEET
1 OF 2
REV.
00
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
D D
C C
B B
OIL LEVEL HIGH SIGNAL (N/C)
POWER-IN CONNECTIONS OIL LEVEL LOW SIGNAL (N/C)
FAULT SIGNAL (N/C)

ELEMENT (24VDC+)
ELEMENT (24VDC-)
SOLENOID (24VDC+)
SOLENOID (24VDC-)
SHUT-DOWN (24VDC+)
SHUT-DOWN (24VDC-)

A
DETAIL A PROPRIETARY INFORMATION
This drawing and the information shown on it are property of Hotstart, Inc.
SCALE 1:1 and are for the sole purpose of doing business with us. Any copying or transmittal to others
TITLE
B-NTCS 400V 3P 9kW 2HP SCR
DRAWN BY
ALS 09-03-10
TOLERANCES
A-7370-2S
APPROVED BY (Except as noted)
SIZE ORIGIN
CO 7075
THIRD ANGLE
PROJECTION
.XXX N/A
N/A
B SCALE
1:3
SHEET
2 OF 2
REV.
00
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
USER SUPPLIED
CIRCUIT BREAKER
D L1 D
L2
L3
F1 F2
EQUIPMENT GROUND
MUST BE GROUNDED
X1 X2 K2 K1
MOTOR
C OVERLOAD
TO SHEET 2 MANUAL C
RESET
MPS1
HR1
B M1 B
MOTOR

A This drawing and the information shown on it are property of Hotstart, Inc.
and are for the sole purpose of doing business with us. Any copying or transmittal to others
TITLE
808074 NTCS WIRING SCHEMATIC
DRAWN BY
ALS 08-17-10
TOLERANCES
A-7370-3
APPROVED BY (Except as noted)
SIZE ORIGIN
CO 7075
THIRD ANGLE
PROJECTION
.XXX N/A
N/A
B SCALE
1:2
SHEET
1 OF 2
REV.
00
8 7 6 5 4 3 2 1
[ BLANK ]
Nozzle Temperature Control
System
Installation & Operation Manual
216264-000 REV 0
[ BLANK ]
Identifying Your System
The HOTSTART NTCS is designed for use in marine propulsion, diesel-powered generator sets,
locomotives, gas compression, or any large-engine applications where temperature control of the injection
nozzles is necessary. The system is pre-wired, pre-plumbed, and assembled on a steel plate. Each
heating system has an identification plate which includes the part number and serial number. Please
reference those numbers when ordering replacement parts.
Warranty information can be found at hotstart.com or by contacting our customer service
department at (509)536-8660. Have your model and serial numbers ready when contacting the
warranty department.
NOTE: When ordering replacement parts, be sure to reference your heating system’s
Model and Serial Numbers found on the identification plate and the label above.
Typical label – actual label may vary slightly from model

to model, but the general layout is the same.
i
HOTSTART, Inc.
5723 E. Alki Ave. Phone: (509) 534-6171

Spokane, Washington Fax: (509) 534-4216
99212 USA
Customer Support: (509) 536-8660

www.hotstart.com
Important Safety Information
All electrical work must be done by qualified personnel in accordance with local codes.
WARNING System can start automatically and without warning. Before wiring, servicing, or cleaning
the system turn off the power and install a lockout on the heater circuits at the service panel.
Installers and operators of this equipment must be thoroughly familiar with the instructions
CAUTION in this manual before commencing work.
Use proper lifting equipment and rigging to move this equipment. Create a plan before
attempting to move.
Hot surfaces: avoid contact with the system while it is in service – some surfaces may stay
hot even if the system is not energized. Use common sense when performing any
maintenance on this equipment.
Rotating equipment: system can start automatically and without warning – avoid contact
unless a lockout at the service panel has been installed.

ii
Table of Contents
1 Installation ............................................................................................................................................ 1
1.1 Customer Connections .................................................................................................................. 1
1.2 Mounting ....................................................................................................................................... 2
1.3 Main Power Supply....................................................................................................................... 2
1.4 Customer Interface Connections ................................................................................................... 3
2 Overview of Operation ......................................................................................................................... 4
3 Heating System Start-Up ...................................................................................................................... 5
4 System Components and Operation ..................................................................................................... 6
4.1 Prime/Off/Remote 3-Position Switch ........................................................................................... 7
4.2 Indicator Lights ............................................................................................................................. 7
4.3 Automatic Control Relays ............................................................................................................. 7
4.4 Motor Protective Switch (MPS) .................................................................................................... 8
5 Maintenance and Troubleshooting ....................................................................................................... 9
5.1 System Maintenance ..................................................................................................................... 9
5.1.1 Plumbing Connections .......................................................................................................... 9
5.1.2 Electrical Connections .......................................................................................................... 9
5.1.3 System Mounting .................................................................................................................. 9
5.1.4 Pump Seal ............................................................................................................................. 9
5.1.5 Heating Element Replacement & Element RTD Replacement ........................................... 10
5.1.6 Reassembly of Heating Element and Tank ......................................................................... 11
5.1.7 RTD Replacement ............................................................................................................... 12
5.2 Troubleshooting .......................................................................................................................... 13
iii
1 Installation
1.1 Customer Connections
Control Box
Oil Inlet
Oil Outlet
Gravity
Water Inlet
Water Outlet
Mounting holes
1
1.2 Mounting
This equipment must be mounted in the vertical position (as shown on the previous page) for proper
operation. Mounting holes are provided in the lower and upper flanges. These same holes should be used
for lifting the equipment. Welding of the equipment in place is also acceptable where applicable. For
high vibration installations, the upper flange should be attached to a rigid mount to avoid resonance.
Proper rigging and safety equipment must be used to move this equipment –
CAUTION weight is not centered. Plan ahead before attempting to move this equipment.
1.3 Main Power Supply

Connect the specified power (±10% of the rated voltage) to the terminal blocks located in the main
control box. The supply power terminal blocks are labeled L1, L2, and L3.
The main power ground wire must be connected to the ground lug or ground block on the electrical panel
located inside the electrical box.
The main power supply operates the heating elements and the circulating pumps. A transformer is used to
operate the control circuit. The transformer and control circuits are overload protected with fuses and/or a
circuit breaker.
Hazardous Voltage: A lockout must be used at the service panel

WARNING when work is being done inside the control box to avoid
electrocution.
All wiring shall be done by qualified personnel in accordance with
local codes. Each system shall be grounded in accordance with the
local electrical codes. Failure to properly ground the system may
result in electric shock.
2
1.4 Customer Interface Connections
Reference electrical schematic and control box drawing for proper wiring locations. Shown below are
typical customer interface locations.
Normally closed contacts are provided for feedback of the heating system’s health. The oil level is
monitored for both high and low conditions and a signal is also provided for a fault condition. These
connections are electrically isolated from the rest of the control box and will be closed during normal
operation.
Connection points are provided for direct control of the heating element and solenoid valve. A 24V
signal on the element contacts will turn the element on if no faults are present while a 24V signal closes
the solenoid valve, also if no faults are present.
3
2 Overview of Operation
The purpose of the nozzle is to maintain optimal
temperature of the fuel injection nozzles on the engine.
This is achieved by circulating temperature controlled oil
through channels in the nozzles. When the engine is
running on high load, heat is transported away from the
nozzles and transferred to the high temp cooling water
circuit of the engine. When the engine is running on low
load or stopped and kept in “hot stand-by”, heat is
transferred to the nozzles by means of an electrical pre
heater.
The user has control of both the heating element and the
solenoid valve via connection points in the electrical box.
An interposing relay is used for the solenoid to allow
control of both items by a simple 24V DC PLC output.
The entire system can be placed in standby by providing a

24V DC signal to the “shutdown” contacts. Removing the
voltage will cause the system to resume operation.
Signals inside the control box provide the user with

feedback about the system operation and health. Dry
contacts are provided for these signals (see wiring
schematic for details).
4
3 Heating System Start-Up
Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Ensure isolation valves are open before energizing the system.
Step 3 Check for proper rotation of the motor by placing the switch in the prime position
while watching the motor fan. If the pump is not rotating in the correct direction, switch
any two electrical leads at the main power terminal block. Single-phase systems are
factory wired to rotate in the correct direction.
DO NOT RUN MOTOR/PUMP ASSEMBLY DRY FOR MORE THAN A FEW

NOTICE SECONDS.
Running a pump that is not completely filled with liquid will cause damage to the
pump
Step 4 Bleed all trapped air from the heating system by opening a plug or pipe fitting at or near
the oil outlet. Press and hold the prime button to evacuate any remaining air in the lines.
When all the air is evacuated, the discharge pressure gage should indicate pressure.
Step 5 Energize the heating system by switching the control switch to the Remote position. The
pressure gauge should indicate pressure if working correctly. Adjust the globe valve at
the inlet of the system to affect the pump pressure according to the engine manufacturer’s
recommendations.
Step 6 Verify that the 24 V DC controls operate properly (refer to Section 4.3 for operation).
5
4 System Components and Operation
The control box contains the electrical control components for the heating system. The following is an
overview of operation for the standard parts located on the system, including:
 3-Position Switch (Prime/Off/Remote)
 Indicator lights
o Fault
o Prime
o Remote
 Automatic Control Relays
 Control TCR (Temperature Control Relay)
 Motor Protective Switch
6
4.1 Prime/Off/Remote 3-Position Switch
 Prime - The prime position of the switch is used to purge the air out of the system without
switching the elements on. This position should be used before start-up of the system to verify
that oil is circulating
 Off – The system is shut off.
 Remote – Automatic control: the system turns on and off via the relay control.
4.2 Indicator Lights

 Fault – Illuminated when system has a fault (refer to troubleshooting section for specific faults).
To reset, turn remote switch off and back on again.
 Prime – Illuminated when selector switch is in prime position.
 Remote – Illuminated when selector switch is in remote position.
4.3 Automatic Control Relays

When the switch is in the Remote position, a 24 V DC signal may be applied to the remote on/off
terminal blocks in the control box (see wiring schematic) to turn the entire system off. 24 V DC signals
are also used to turn the heating element on and close the solenoid valve.
Interposing relays are utilized to limit user control of the heating element and solenoid valve during fault
conditions. A fault signal will restrict the user from energizing the heating element or the solenoid valve,
providing a fail-safe condition.
7
4.4 Motor Protective Switch (MPS)
The Motor Protective Switch (MPS) is used to protect the circulating motor from over current in the event
that the impeller or shaft is locked and also protects the wire from a short circuit. If the MPS is tripped,
refer to section 5.2 for troubleshooting. To reset the switch, press the black button down. In the event that
the MPS trips again immediately after reset, refer to the system wiring diagram to check that all wiring
connections are in the proper location.
8
5 Maintenance and Troubleshooting
5.1 System Maintenance
Instructions for the following maintenance procedures are provided to ensure trouble-free operation of
your heating system:
• Plumbing Connections
• Electrical Connections and Contacts
• Heating Tanks/Elements
• System Mounting
• Pump Seal
HAZARDOUS VOLTAGE: BEFORE WIRING, SERVICING OR CLEANING THE

WARNING SYSTEM, TURN OFF THE POWER AND INSTALL A LOCKOUT ON THE
HEATER CIRCUITS AT THE SERVICE PANEL. FAILURE TO DO SO COULD
ALLOW OTHERS TO TURN ON POWER UNEXPECTEDLY, WHICH MAY
CAUSE FATAL ELECTRICAL SHOCK.
5.1.1 Plumbing Connections

Periodically check plumbing connections for leaks and, if necessary, tighten connections. A
loose connection on the suction side will cause a loss of flow and cavitation in the pump. It can
also pull air into the heating tank and cause an element failure.
5.1.2 Electrical Connections

Excessive vibration will eventually cause terminals to loosen. Tighten at start-up and check again
in a week. Tighten all screw-type electrical connections every 3 months.
5.1.3 System Mounting

Excessive vibration may cause mounting bolts to loosen. Periodically check and tighten all
mounting bolts.
5.1.4 Pump Seal

Leakage can occur at any time throughout the life of the seal. Always replace the seal at the first
sign of leakage. If the heating system is installed on an engine that is used for a critical
application, replace the seal annually. Instructions to replace the seal are included with the new
seal.
9
5.1.5 Heating Element Replacement & Element RTD Replacement
To replace the heating element or perform routine maintenance, observe the following procedure. The
wattage and phase of the heating element are listed on the identification label on the outside of the
element. Reference this label for the replacement element part number.
BEFORE WIRING, SERVICING OR CLEANING THE SYSTEM, TURN OFF

WARNING THE POWER AND INSTALL A LOCKOUT ON THE HEATER CIRCUITS AT
THE SERVICE PANEL. FAILURE TO DO SO COULD ALLOW OTHERS TO
TURN ON POWER UNEXPECTEDLY, WHICH MAY CAUSE FATAL
ELECTRICAL SHOCK.
Step 1 Turn the heating system OFF, close isolation valves, and lock out at the service panel.
Step 2 Drain the fluid from the heating tank.
Step 3 Remove the cap from the heating element service

entrance enclosure.
Step 4 The wire connections inside the enclosure
correspond to one of the phase configurations
shown at the bottom of the page.
Note your unit’s phase
configuration.
*Replacement elements can be a different
phase configuration. Wire replacement
elements to the cup washers on the replacement
element studs.
Remove the ground (green) and power electrical
wires from the posts inside the cap.
Step 5 Remove the RTD from the heating element (refer to Section 5.1.8).
Step 6 Remove the conduit connector and electrical wires from the heating element.
Step 7 Remove the V-clamp to detach the heating element from the tank as shown on the next page.
Step 8 Replace the heating element or perform the necessary cleaning procedure. Ensure the O-ring is
in place.
1 Phase Parallel 1 Phase Series 3 Phase Delta 3 Phase Wye
10
5.1.6 Reassembly of Heating Element and Tank
To reassemble the heating element and tank, follow the steps listed on the previous page in reverse order.
Make sure the ground and power electrical wires are properly reconnected using the washers, cup washers
and nuts supplied (please note diagram on previous page).
11
5.1.7 RTD Replacement
The high limit RTD is located inside the element enclosure. To replace this RTD, follow the steps listed
below.
High Limit RTD
BEFORE WIRING, SERVICING OR CLEANING THE SYSTEM,

WARNING TURN OFF THE POWER AND INSTALL A LOCKOUT ON THE
HEATER CIRCUITS AT THE SERVICE PANEL. FAILURE TO DO
SO COULD ALLOW OTHERS TO TURN ON POWER
UNEXPECTEDLY, WHICH MAY CAUSE FATAL ELECTRICAL SHOCK.
Step 1 Remove the cover of the service entrance enclosure.

Step 2 Disconnect the RTD wires in the service entrance taking note of current wiring.
Step 3 Drain the tank and remove the RTD.
Step 4 Reassemble in reverse order.
12
5.2 Troubleshooting
System faults occur from an overheating condition, a tripped motor protective switch, or low oil.
Overheating is typically caused by flow restrictions, tripped motor protectors are typically a symptom of
blocked flow, and low oil indicates a leak. High oil level is an indication that the nozzles are injecting
fluid into the heating system. A signal for high oil level is provided, but it does not cause a fault and the
system will continue to operate normally.
Symptom Possible Causes Solution
Bleed all trapped air from lines, restart

Pump not primed properly
system
Isolation valves may be closed Open valves, restart system
Hose kinked or crushed Remove obstruction, restart system
Leak in suction line Repair leak, restart system
Reverse any two leads on power-in (3

Pump motor turning backwards
phase systems), restart system
System Fault Check and replace if needed, restart
Temperature control relay failed
system
Check and replace if needed, restart
Motor failure
system
Check contacts and coil replace if
Motor contactor failure
needed, restart system
Check and reset, if problem happens
Motor protective switch tripped
again check motor, restart system
Fill tank until oil is at or near the center of

Low oil level
the sight level on the tank
Temperature control relay failed Check and replace if needed
Heater has been turned off, fluid is cold Allow time for heater to heat fluid
Check elements for continuity and
Heating element failed
replace if needed
Low Check all element fuses for continuity and

Element fuses failed or Breaker Tripped
Temperature replace as necessary or reset breaker
Check contacts and coil, replace if
Element contactor failed
needed
Check contacts and coil, replace if
Failed element control relay
needed
Check that the solenoid closes when 24 V
Failed solenoid
DC is applied
13

Fuel System16419-27 & 16430-36 Sec 2 Vol 2

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Index

Instructions for gen-set auxiliaries

Techn. Part. No. Syst. Doc. No.

04.00 EXHAUST SYSTEM 4

Sec 2 Vol 2 Confidence Power Rangpur Ltd. 1

Component: Exhaust gas silencer

Type : BBM Acoustic

Engines : 16419-27 & 16430-36

BEAS Project no: 317130

P.O. NO. : 11091-201 to 207

110 DETAIL C 2 MAX. ALLOWABLE PRESSURE : Atm

Ø1220 ` 5.0 QTY REQUIRED: 07 NOS.

2. SURFACE PREPARATION : GRIT BLASTING TO SA 2 1/2.

2 Max. operating pressure ATM

E C 1000 1 GLASS NEEDLE FELT AS REQUIRED ISO GLASS

500 1 CAPSULE ABS UNIT AS REQUIRED SS 409 1.5 THK

118 12 RIB-01 Plate 6 IS 2062

Rev. Date: Description By Chk

Maße nicht abgreifbar / not to scale

6000 5 (FLANGE FACE TO FACE)

5500 CASING (LENGTH)

BOTTOM END PLATE

8 1 TOP END PLATE PL. 6 x OD 2220 x ID 1220 S 235 JR

3 1 BOTTOM END PLATE PL. 6 x OD 2220 x ID 1220 S 235 JR

Maße nicht abgreifbar / not to scale

Projektleiter 82152 Planegg / 45472 Mülheim a.d. Ruhr - Germany

Component: Expansion Bellow

Type : Beloflex Single

Engines : 16419-27 & 16430-36

BEAS Project no: 317130

Pipe Injection Pump Room Arr. Clean.W/Tank.Inj.Pump B00403375/!# L740_32/!#OR

Component: DO/HFO Change over unit

Type : Aura Marine

BEAS Part no: B00709148

Unit, fuel change

Tel. +358 204 860 5030

Business ID: 0684696-3

Spare parts and service

1 Data sheet, general arrangement

2 PI Diagram, part list

3 Electric drawings, part list

1790 H 300 300

Units Sheet Description

General tolerances: SFS-EN ISO 13920B PCO-M-38/38-MDO/HFO

1 STORAGE, HANDLING AND INSTALLATION

Figure a) packed unit b) unpacked unit

Unit is handled with lift hangers or with forklift truck.

3 WARNINGS AND INSTRUCTIONS

- Door of the control panel can be opened with main switch on by

2. Switch instrument air on to fuel oil units.

5 GENERAL TROUBLE SHOOTING

Changeover time Changeover time

6.2 Periodic maintenance

7 HOW TO ORDER SPARE PARTS

2. Part number from the part list

Position: D005, D006

4.7 Dismantling .................................................................................................................................. 17

Screw pump ACE3

This instruction is valid for all following ACE pump models

1.2 Lifting of pump

1.4 Alignment and shaft couplings

Outer diameter Distance between Outer diameter Distance between

For direct driven pumps the alignment between pump and